Bradford White 100T150 Troubleshooting Manual And Instructions For Service Download

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238-54145-00A 3/21

SERVICE

MANUAL

Troubleshooting Guide

and Instructions for Service

(To be performed ONLY by

qualified service providers)

Models Covered

by This Manual:

For Ultra High Efficiency Models:

60T125(E)*(N,X)(A)(2)

60T150(E)*(N,X)(A)(2)

60T199(E)*(N,X)(A)(2)

100T150(E)*(N,X)(A)(2)

100T199(E)*(N,X)(A)(2)

100T250(E)*(N,X)(A)(2)

100T300(E)*(N,X)(A)(2)

(*) Denotes Warranty Years

eF Series

Models

Ultra High Efficiency Water Heater

ICON System

™

ONLY

Summary of Contents for 100T150

Page 1: ... be performed ONLY by qualified service providers Models Covered by This Manual For Ultra High Efficiency Models 60T125 E N X A 2 60T150 E N X A 2 60T199 E N X A 2 100T150 E N X A 2 100T199 E N X A 2 100T250 E N X A 2 100T300 E N X A 2 Denotes Warranty Years eF Series Models Ultra High Efficiency Water Heater ICON System ONLY ...

Page 2: ...Replacement 29 II Burner Tube Inspection and Replacement 33 III Gas Valve Replacement 35 IV Blower Testing and Replacement 36 V Exhaust Pressure Switch Testing and Replacement 38 VI Flame Sensor Testing and Replacement 42 VII Spark Rod Gap Adjustment and Replacement 43 VIII Ignition Module Control Board Replacement 45 IX Transformer Replacement 46 X Vent Safety Switch Testing and Replacement 47 XI...

Page 3: ...18 F 1989 or 2009 T 1999 or 2019 G 1990 or 2010 W 2000 or 2020 H 1991 or 2011 X 2001 or 2021 J 1992 or 2012 Y 2002 or 2022 K 1993 or 2013 Z 2003 or 2023 For the year column we do not use the letters I O Q R U V For the month column we do not use the letters I N Z Due to a computer error there were some OA serial water heaters manufactured They were built in January of 1997 Production Month A Janua...

Page 4: ...ystem lockouts The contents in this manual are detailed informational tools to assist in the proper diagnosis of the Ultra High Efficiency Water Heater operational faults Please read this service manual completely and provide as much information regarding the Ultra High Efficiency Water Heater operation and installation specific concerns How to Use this Manual It is intended for this manual to be ...

Page 5: ...accurate thermometer is recommended Water Pressure Gage Used to measure water supply pressure Also used to determine tank pressure by adapting to the drain valve of the heater Jumper Leads A length of wire 12 min with alligator clip at both ends Various Hand Tools Pipe wrench channel locks open end wrench set 12 crescent wrench Allen wrench set Torx bit set screwdrivers common Phillips long reach ...

Page 6: ...0 000 405 836 4 334 5 239 100 92 0 DIMENSIONS INCHES Model No A Height B Dia C Floor to Vent Outlet D Floor to Inlet Water Conn E Floor to T P Valve Conn F Floor to Outlet Water Conn G Floor to Air Intake H Floor to Gas Conn Front Water Conn Dia Space Heating Conn Dia Gas Conn Dia NPT T P Valve Open NPT Shipping Weight lbs 60T125 57 28 5 13 40 42 52 53 1 1 570 60T150 57 28 5 13 40 42 52 53 1 1 570...

Page 7: ...nd 7 0 W C min running Venting System Power vent balanced direct vent or unbalanced direct vent See vent tables on page 8 Approved Vent Materials PVC CPVC Polypropylene or Stainless Steel Minimum Clearance for Servicing 18 from top 24 from front 4 sides and rear Maximum Water Supply Pressure 150 PSI Thermostat Sensor 11 900 Ohms 70 F ECO opens 207 F Max ECO close 120 F Min Redundant sensor for ECO...

Page 8: ...ake Length 85 ft 25 9 m N A 75 ft 22 8 m N A 65 19 8 m N A 55 16 7 m N A Max Exhaust Length 85 ft 25 9 m 170 ft 51 8 m 75 ft 22 8 m 150 ft 45 7 m 65 19 8 m 130 39 6 m 55 16 7 m 110 33 5 m 60T 125 60T 150 60T 199 100T 150 6 Vent Pipe Power Direct Vent Power Vent Power Direct Vent Power Vent Power Direct Vent Power Vent Power Direct Vent Power Vent Max Intake Length 85 25 9 m N A 75 22 8 m N A 65 19...

Page 9: ... all elbows and straight pipe intake and exhaust must not exceed maximum lengths from tables above Example 100T199 A 3 balanced direct vent system has 30 feet of straight exhaust pipe and 30 feet of straight intake pipe It has 3 90 elbows in the exhaust and 3 90 elbows in the intake It has 1 45 elbow in the exhaust and 1 45 elbow in the intake Therefore 6 90 elbows x 5 feet 30 feet 2 45 elbows x 2...

Page 10: ...e open will flash once on the digital display The unit will then go into pre purge Hold while the unit is waiting for the issue to be corrected If the issue continues to occur the digital display with flash error code 137 pressure switch is open or vent safety switch is open while the unit is waiting to restart 5 minutes the normal sequence of operation 6 Once the flame signal is verified the blow...

Page 11: ...ard s digital display The control board can only be reset in the Service Mode which is detailed in the ICON System Troubleshooting section of this Service Manual pg 14 3 ERROR CODE 67 a If the exhaust terminal becomes blocked or the condensate elbow fails to drain condensate the normally closed exhaust pressure switch will open the gas valve will close and error code 67 will appear on the digital ...

Page 12: ...rotection 8 No demand due to burner switch register 199 turned off 9 DHW storage 10 Reserved 11 Warm weather shutdown 12 Hot standby Firing rate 00008 Read 002 Actual firing rate or RPM Fan speed 00009 Read 003 RPM Flame signal 00010 Read 004 0 01V or 0 01 μA precision 0 00 50 00V Tank temperature sensor 00012 Read 005 40 130 0 1 C precision Appliance setpoint 00017 Read 006 40 130 0 1 C precision...

Page 13: ...13 13 BMS Wiring Diagram NOTICE The Building Management System BMS is only compatible with units that have SOLA controllers Part Bradford White Part Number BMS Gateway Installation Kit 415 53943 00 ...

Page 14: ...k main power supply to water heater Check fuse circuit breaker plug receptacle line cord and wiring to water heater Check to make sure switch on front of control board is in the ON position Replace digital display Replace control board Check wire harness for proper continuity Check wires for proper termination to control board Are wire terminations connected properly to digital display N Y N Y Y R...

Page 15: ...playing temperature sensors Does blower post purge for 30 seconds System O K Check to see if digital display shows any other error codes 67 pressure switch 67 vent safety switch or 80 high limit If so refer to the appropriate section s for testing and replacement Remove high voltage wire connected at the spark rod and hold approximately 1 4 from metal ground with insulated pliers during the igniti...

Page 16: ...e Setpoint Step 1 Press and hold Temperature Up button until desired setpoint temperature appears on the display Step 2 Press DONE button for new setting to take effect immediately If the DONE button is not pressed the new temperature setting will take effect in approximately 10 seconds ...

Page 17: ...for new setting to take effect immediately If the DONE button is not pressed the new temperature setting will take effect in approximately 10 seconds To View Combustion Rate Step 1 Select Next while viewing DHW Setpoint in User Mode to access Rate screen Rate will only be displayed while the burner is operating Step 2 Select Next to go back to the DHW Setpoint screen ...

Page 18: ...rvice work be performed by a qualified service agency If the water heater is to remain idle for 30 days or more or is subjected to freezing temperatures while shut off the water heater and piping should be fully drained See To Drain the Water Heater and the drain valve should be left fully open WARNING Hydrogen gas can be produced in an operating water heater that has not had water drawn from the ...

Page 19: ...itions without correcting the malfunction can result in a hazardous condition Step 1 Press and hold the lower right button under Next in the lower right display for at least 3 seconds You must be in user mode on the DHW temp screen to access diagnostic mode If in user mode on the view rate screen you cannot access diagnostic mode Step 2 In the first screen of diagnostic mode the display will show ...

Page 20: ...ress lower right Next button The display will flash and show the number of any Lockout codes If there are no lockouts the display will show 00 If there are multiple lockout codes Next will scroll through them Step 5 Press Next the display will show DHW MAX This is the maximum allowable temperature that the unit can get to before a lockout occurs ...

Page 21: ...21 21 Step 6 Press Next display will show DELTA T DHW this is the real time temperature reading of the tank Step 7 Press Done to exit Diagnostic Mode and return to the DHW setpoint in User Mode ...

Page 22: ...s x Check the module power supply and make sure that frequency voltage and VA capacity of the transformer meet specifications x Check to make sure the wiring connections on the control module from terminals J4 10 and J8 2 are connected together YES 62 Fan speed not proved x Check the PWM wire harness connection from the blower to the control module x Make sure the pin terminals make solid contact ...

Page 23: ...e is visible outside of the ignition sequence run cycle then make sure the flame sensor is wired to the correct terminal x Make sure the ignition cable is not crossing the flame sensor wire or ignition ground wires x If problem persists and all other checks have been verified replace the control module YES 110 Ignition Failure Occurred x Burner failed to light or stay lit after 3 retries x Hold co...

Page 24: ...ce sensor if needed Turn power ON to water heater Run water heater through heating cycle and verify proper operation Sensor temperature can be viewed when burner shuts off see section on viewing the digital display in Service Mode Condition Water heater not operating Digital display shows error code 80 high water temperature over 207 F Continued on next page WARNING DO NOT reset the digital displa...

Page 25: ...rd may be reset x Reconnect and switch on power to the water heater x Press button under Reset and hold for 3 seconds x Set thermostat to the desired setting x Water heater will start x Monitor temperatures for one complete heating cycle making sure the maximum tank temperature remains below 207 F Condition Water heater not operating Digital display shows error code 80 high water temperature over ...

Page 26: ...7 Install new sensor completely into well and reinstall sensor clip 8 Connect temperature sensor to control 9 Fold insulation back into place Be sure there are NO wires in contact with burner 10 Restore 120 volt power supply and water supply to water heater check and repair any leaks found Confirm proper operation following the lighting instructions on the lighting instruction label or the lightin...

Page 27: ...1592 11308 11032 10763 10502 10248 10000 9760 9526 80 9299 9078 8862 8653 8449 8250 8057 7869 7685 7507 90 7333 7165 7000 6839 6683 6531 6383 6238 6098 5961 100 5827 5697 5570 5446 5326 5208 5094 4982 4873 4767 110 4663 4562 4464 4368 4274 4183 4094 4006 3922 3839 120 3758 3679 3602 3527 3453 3382 3312 3244 3177 3112 130 3048 2986 2925 2866 2808 2752 2697 2643 2590 2538 140 2488 2439 2391 2344 229...

Page 28: ...Ignition Models Apply thread sealing tape or applicable thread lubricant to threads of new sensor Install new thermostat sensor and connect to the wire harness from step 6 Direct Spark Ignition Models Install the new sensor completely into the well and reinstall the sensor clip 8 Fold the insulation back into place Be sure there are no wires in contact with the burner 9 Restore 120 volt power supp...

Page 29: ...let gas pressure Is it stable between 7 14 W C static heater not running see images at right Is gas supply pressure regulator adjustable to maintain a proper and stable setting Does the inlet gas pressuredrop more than 2 W C during burner ignition Inadequately sized regulator Adjust gas supply regulator Can sparking be seen heard at the spark rod to the burner Remove high voltage wire connected at...

Page 30: ... display must show Heating for operating status Venturi adjustment Inlet gas pressure tap Replace control board Can you hear or feel the gas valve energize Replace the rectifier harness and or gas valve see Gas Valve Replacement Procedure pg 35 Turn venturi set screw clockwise until its bottomed out Turn screw counter clockwise 6 turns from bottom Does burner light smoothly without evidence of cou...

Page 31: ... surface igniter For Direct Spark Ignition models disconnect high voltage cable from the spark rod connection 7 Remove the 5 bolts 1 2 socket holding the burner mounting insert in place 8 Carefully remove combustion assembly with gasket from the water heater 9 See next page for combustion system installation procedure WARNING 120 volt potential exposure Isolate the appliance and reconfirm power is...

Page 32: ... Tighten screws evenly 3 Reconnect wire harnesses to hot surface igniter or high voltage cable to spark rod flame sensor blower and gas valve 4 Reconnect PVC venting gas supply and silicone tubing to gas valve Turn on gas supply to heater and check for gas leaks repair any gas leaks found 5 Restore 120 volt power supply to water heater and confirm proper operation following the lighting instructio...

Page 33: ...he hot surface igniter and flame sensor in place long reach magnetic Phillips screwdriver Carefully remove hot surface igniter and flame sensor from combustion assembly 8 Remove the 4 nuts 7 16 wrench holding the burner transition in place Lift the blower gas valve transition assembly from burner mounting insert remove gasket and set aside 9 Remove burner tube from burner mounting insert See next ...

Page 34: ...ct replacement burner 1 Fully inspect burner flange gaskets igniter and flame sensor gaskets for the following a Tears d Dirt or debris b Missing material e Other imperfections that would inhibit proper seal c Cracks If gaskets are NOT affected by any of the above gasket replacement is not required 2 Install burner tube with gaskets into burner mounting insert Be sure gasket surfaces are free of d...

Page 35: ...gas valve with new gasket provided Secure gas valve in place using screws from step 6 9 Reconnect PVC venting gas supply silicone tubing and wire harness to the gas valve Turn ON gas supply to heater and check for gas leaks repair any gas leaks found 10 Restore 120 volt power supply to water heater and confirm proper operation following the lighting instructions on the lighting instruction label o...

Page 36: ...see Blower Replacement Procedure pg 36 Are collector high limit switch and pressure switches in normally closed Correct safety circuit problem per safety circuit trace see Blocked Vent Pressure Switch Testing pg 38 Replace ignition control board Is there 120VAC across white and black wires at the blower see image above Repair replace wire harness Replace blower see Blower Replacement Procedure pg ...

Page 37: ...in place using screws from step 8 11 Reconnect gas valve assembly to blower with new gasket provided Secure gas valve in place using screws from step 7 11 Reconnect intake vent and gas line to gas valve assembly and check for gas leaks repair any leaks found 13 Reconnect wire harness to blower assembly Restore 120 volt power supply and gas supply to water heater and confirm proper operation follow...

Page 38: ...ater using screws from Step 5 7 Reconnect wire leads Note Wire leads are interchangeable with either terminal 8 Reconnect silicone tubing to pressure switch as follows a Exhaust pipe tubing connects to negative side of switch identified by the symbol located on switch b Exhaust collector tubing connects to positive side of switch identified by the symbol located on the switch Example of switch sho...

Page 39: ... continuity through gray wire leads of heater side safety circuit harness see image below Is there continuity through red wire leads of heater side safety circuit harness see image below Safety circuit O K see Blower Testing and Replacement pg 36 Check Purge LED status on ignition module Is it flashing after 45 seconds Replace exhaust pressure switch see Exhaust Pressure Switch Replacement Procedu...

Page 40: ...ust Tube Pressure With monometer take a reading at the exhaust tube pressure tap location Is value negative or slightly positive see image below Is exhaust venting system blocked or obstructed Check condensate elbow and drain Clear obstruction Determine cause and correct Is vent system total length compliant with vent tables in the instruction manual Replace blocked vent switch see Blocked Vent Sw...

Page 41: ...t right 5 Remove pressure switch mounting screws 5 16 wrench and remove pressure switch 6 Assemble new pressure switch to heater using screws from Step 5 7 Reconnect wire leads Note Wire leads are interchangeable with either terminal 8 Reconnect silicone tubing to pressure switch as follows a Exhaust pipe tubing connects to single tap located on switch 9 Restore 120 volt power supply to water heat...

Page 42: ... With flame sensor disconnected from ignition control board check continuity to ground Is there continuity to ground Replace flame sensor with gasket and or wire lead see Flame Sensor Replacement Procedure pg 42 Remove flame sensor from water heater Check continuity from tip of flame sensor to end of wire lead Is there continuity Is flame sensor free of oxidation Clean or replace flame sensor see ...

Page 43: ...nding the end near the burner tube with needle nose pliers see image below 4 Ensure and verify spark gap is between 3 16 1 4 after bending 5 Reinstall the combustion system per Combustion System Replacement Procedure pg 29 and check several ignitions to ensure the burner lights smoothly WARNING Spark gap must be set to 3 16 to 1 4 Failure to set and verify proper spark gap may result in a delayed ...

Page 44: ... Spark Rod Gap Adjustment and Replacement pg 43 10 Reassemble combustion system following Combustion System Replacement Procedure pg 29 11 Fold insulation back into place Be sure no wires are in contact with burner flange 12 Restore 120 volt power supply to water heater and confirm proper operation following the lighting instructions on the lighting instruction label or the lighting instructions l...

Page 45: ...the top back side of the control board first 7 Tilt the control board and slide control board hook tabs from slots in the metal panel see images below 8 Replace the control board and all wire connections 9 Restore 120 volt power supply to water heater and confirm proper operation following the lighting instructions on the lighting instruction label or the lighting instructions located in the Insta...

Page 46: ...nd remove transformer from control board see image below 6 Install new transformer and secure in place with screws from step 6 7 Reconnect primary and secondary wires to the transformer leads are different sizes to prevent interchanging 8 Restore 120 volt power supply to water heater and confirm proper operation following the lighting instructions on the lighting instruction label or the lighting ...

Page 47: ... code 67 will display indicating an open circuit for the vent safety switch Determine if temperature has reached 350 F before resetting switch and restoring operation If evidence of extreme temperature is present call Technical Support WARNING Make sure the exhaust collector compartment is not overheating 350 F before resetting vent safety switch If there is evidence the collector compartment is o...

Page 48: ...witch see image below 5 Remove the 2 switch mounting screws Phillips screwdriver and nuts 5 16 wrench and remove the switch from the water heater 6 Install new switch using the screws from step 5 7 Reconnect the wire leads Note Wire leads are interchangeable with either switch terminal 8 Restore 120 volt power supply to water heater and confirm proper operation following the lighting instructions ...

Page 49: ...er Installation Procedure 6 Reinstall collector insulation and control panel reconnect control panel wire harnesses 7 Restore 120 volts to water heater and verify proper heater operation following the instructions on the lighting instruction label or the lighting instruction located in the Installation and Operating Instruction Manual 8 Replace the surround cover on the top of the water heater Col...

Page 50: ... is not glowing the power supply to the water heater or powered anode system is disconnected 1 Check the power supply or wire connections to the powered anode control 2 Indicator light diagnostic codes a If the control is flashing red then there is a malfunction with the powered anode system Make sure there are no bare spots in the wire insulation to the powered anode rods 3 Check all electrical c...

Page 51: ...recommended Gas Requirements Gas piping sized adequately or larger to heater Install a properly sized regulator if unknown assure an adequate volume of gas is available 7 W C is required when the unit is running Gas pressure must stay below 14 W C static pressure Pressure drops between static pressure and operating flow should be less than 3 W C Condensate Requirements Condensate line needs to slo...

Page 52: ...__________ Igniter Resistance__________ Flame Sense MicroAmps _________ Spark Gap___________ LED Flashing Y or N Which Ones ____________________________ Error Codes on Control Display Direct Spark Ignition System Only ________________________________________________________________________________ Condensate Line Exhaust Collector Pressure Size material ___________ Positive Inches W C ____________...

Page 53: ...ertz A Micro Amp Refer to the parts list on www bradfordwhite com for a complete parts listing and expanded views of the models covered in this manual Notes ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ _______________________________________________...

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