Bradford White eF Series Troubleshooting Manual And Instructions For Service
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Bradford White eF Series Troubleshooting Manual And Instructions For Service

Ultra high efficiency water heater
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Ultra High Efficiency Water Heater
238-54145-00A 3/21
ICON System
eF Series
ONLY
™
Models
®
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
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  • Page 1 Ultra High Efficiency Water Heater ICON System ONLY ™ eF Series Models ® 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)

  • Page 2: Table Of Contents

    Ultra High Efficiency Water Heater Table of Contents Page Service Procedure Serial Number Breakdown……………………………………… - - - Introduction……………………………………………………….. - - - How to Use this Manual…………………………………………. - - - Tools Required for Service……………………………………..5 - - - Specifications……………………………………………………… - - - Sequence of Operation…………………………………………..
  • Page 3 Determining the Age of Your Water Heater The first two characters of the serial number represent the year and month of manufacture. The remainder of the serial is a sequential production number, seven digits in length before December 2007 (DM), and eight digits in length after. For example: Production Year A = 1984 or 2004...

  • Page 4: Introduction

    Introduction The Ultra High Efficiency Water Heater is designed to deliver a high thermal efficiency rating in a quiet running unit with venting options that allow for installation flexibility. Several technologically advanced design features are incorporated in the design that will require additional knowledge on the part of the qualified service provider.

  • Page 5: Tools Required For Service

    Tools Required for Service Manometer: Two types available, a liquid “U” tube type or a digital (magna-helic) type. This device is used to measure gas and/or air pressures and vacuum. Multi-Meter: A digital type is strongly recommended. This device is used to measure electrical values.

  • Page 6: Specifications

    Specifications Recovery GPH at Degree Rise Input Hr. Del Gal Stg. Capacity Therm. Model No. Rate @ 100 °F 40°F 100°F 140°F US Gal Efficiency % BTU/hr Rise 60T125 125,000 363.6 145.5 103.9 96.0 60T150 150,000 422.7 169.1 120.8 93.0 60T199 199,999 557.6...
  • Page 7 Icon System Features of ICON System Module Water heater digital display on control board for setting and displaying the temperature setpoint. Pressing temperature UP and DOWN buttons changes the temperature setpoint. Temperature format may be displayed in °F or °C. Single control board with plug in wiring controls temperature, ignition, and blower operation.
  • Page 8 Vent Tables Maximum Vent Length Table 3 - Maximum Vent Length (Combined Maximum Length for Intake and Exhaust) 60T-150 60T-199 60T-125 100T-150 100T-199 Power Direct Power Direct Power Direct 2” Vent Pipe Power Vent Power Vent Power Vent Vent Vent Vent Max.
  • Page 9 Venting Tables Cont. Notes: 1) Multiply the total number of 90° elbows (intake and exhaust) by 5 feet. Do NOT include the termination fittings or 3" condensate elbow. 2) Multiply the total number of 45° elbows (intake and exhaust) by 2 ½ feet. 3) Add this to the total length of straight pipe - intake and exhaust.

  • Page 10: Sequence Of Operation

    Sequence of Operation 1. Thermostat calls for heat. 2. Combustion blower starts at a reduced rpm for a “soft” start light off. 3. Blower pre-purge period of approximately 15 seconds. 4. Ignition control board runs an internal verification safety check for approximately 15 seconds. 5.
  • Page 11 Sequence of Operation Lockout Conditions The system will go into lock out mode for the following reasons: 1. ERROR CODE 110 a. Control board will go into soft lockout if the main burner cannot be lit or fails to prove flame after 3 ignition trials. The water heater digital display indicates a lockout condition by showing error code 110 with “Service Needed”...

  • Page 12: Building Management System (Bms)

    Building Management System (BMS) All water heaters with ICON Systems can be equipped with a gateway kit that will facilitate a Building Management System (BMS) connection to Modbus or Bacnet ® . This kit is sold separately and is not factory installed.
  • Page 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: Troubleshooting

    Troubleshooting System Observation WARNING Water Heater Fault: Water heater does NOT operate. Display Error Code: Water heater digital display does 120 volt potential exposure. Use caution making NOT operate - blank display. voltage checks to avoid personal injury. Check main power supply to water heater. CAUTION Check fuse, circuit breaker, plug receptacle, line cord, and wiring to water heater.
  • Page 15 Troubleshooting CAUTION WARNING Use caution to NOT damage connectors when 120 volt potential exposure. Use caution making making voltage measurements or jumping terminals. voltage checks to avoid personal injury. Continued from Error code 62 on display. Measure voltage previous page. Verify 120V from power switch.
  • Page 16 Display Control Water Heater Display and Control Buttons To Increase Temperature 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 To Decrease Temperature Setpoint Step 1. Press and hold “Temperature Down” 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. To View Combustion Rate Step 1.
  • Page 18 To Change Temperature Format in Display from F to C or C to F Step 1. Enter “Set-Up Mode” by pressing both UP/DOWN buttons together for 3 seconds. Step 2. Use the arrows to select between °F and °C Step 3. Press done to return to main screen or timeout/change will occur in one minute. An energy cut out (ECO) is incorporated in the sensor and control board which will shut off all gas supply to the burner if the water heater temperature exceeds 207°F (93°C).
  • Page 19 Troubleshooting Accessing Diagnostic Mode on the Water Heater Display (FOR SERVICE PERSONNEL ONLY) The display has a Diagnostic Mode to access information in aiding servicing of the water heater. This procedure is for service and installation personnel only. To enter the Diagnostic Mode, follow the steps illustrated below: WARNING The following procedure is for service and installation personnel ONLY.
  • Page 20 Step 3. Press the lower right “Next” button. The display will flash and show the number of any alert codes. These are not currently used. Step 4. Press 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.
  • Page 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 DIAGNOSTIC ERROR CODES AND TROUBLESHOOTING PROCEDURES FOR MODELS WITH ICON SYSTEMS CONTROL NOTICE The ICON control system can produce soft and hard lockouts. Soft lockouts are displayed if active and are not stored in Diagnostic Mode history. The control will periodically attempt to resume normal operation when in soft lockout conditions.
  • Page 23 Definition Error Code Cause of Problem and Actions Taken to Correct LOG? of Code Check the wiring from the sensor to the control module. Measure the resistance of each outside wire to the center wire. High Limit If either outside wire has a much different resistance reading, replace the (Overheat sensor.

  • Page 24: Thermostat Circuit Testing And Replacement

    Service Procedure I Thermostat Circuit Testing and Replacement WARNING IMPORTANT NOTE: This procedure assumes a cool tank. 120 volt potential exposure. Use caution making voltage checks to avoid personal injury. Condition: Water heater not operating. Digital display shows error code 93 (sensor reading faulty). CAUTION Use caution to NOT damage connectors when Unplug or disconnect electrical power to the water heater.
  • Page 25 Service Procedure I Thermostat Circuit Testing and Replacement Continued from previous page. WARNING DO NOT operate the water heater without Condition: Water heater not operating. Digital verifying that the overheating condition has display shows error code 80 high water been corrected. temperature (over 207°F) (continued from previous page).
  • Page 26 Service Procedure I Thermostat Circuit Testing and Replacement Thermostat Sensor (Thermistor) Replacement Procedure WARNING 1. Position main power switch to “OFF.” 120 volt potential exposure. Use 2. Disconnect (unplug) water heater from 120 volt power source. caution making voltage checks to 3.
  • Page 27 Service Procedure I Thermostat Circuit Testing and Replacement Appendix – A Sensor Resistance at a Various Temperatures Be careful when making voltage measurements or jumping terminals NOT to damage or deform connectors or connector pins. Draw water from the Temperature and Pressure Relief Valve. Compare the Temperature with Temperature Ohms Chart below.
  • Page 28 Service Procedure I Thermostat Circuit Testing and Replacement WARNING Thermostat Sensor (Thermister) 120 volt potential exposure. Isolate the appliance and Replacement Procedure reconfirm power is disconnected using a multi-meter. 1. Position main power switch to OFF. 2. Disconnect (unplug) the water heater from 120 volt power source.

  • Page 29: Combustion System Testing And Replacement

    Service Procedure II Combustion System Testing and Replacement Observe burner operation through the sight glass located on the combustion insert mounting flange. Normal burner operation should ignite smoothly, without evidence of coughing or huffing upon ignition. The burner flame should be a blue flame near the burner surface in a uniform flame pattern.
  • Page 30 Service Procedure II Combustion System Testing and Replacement Observe burner operation through the sight glass located on the combustion insert mounting flange. Normal burner operation should ignite smoothly, without evidence of coughing or huffing upon ignition. The burner flame should be a blue flame near the burner surface in a uniform flame pattern.
  • Page 31 Service Procedure II Combustion System Testing and Replacement WARNING Combustion System Removal Procedure 120 volt potential exposure. Isolate the appliance and reconfirm power is disconnected using a multi-meter. 1. Position main power switch to OFF. WARNING 2. Disconnect (unplug) water heater from Heater components may be HOT when performing the 120 volt power source.
  • Page 32 Service Procedure II Combustion System Testing and Replacement Combustion System Removal Procedure 1. Fully inspect burner mounting insert gasket for the following: Tears d) Dirt or debris Missing material e) Other imperfections that would inhibit proper seal Cracks If gasket is NOT affected by any of the above, gasket replacement is not required. 2.

  • Page 33: Burner Tube Inspection And Replacement

    Service Procedure III Burner Tube Inspection and Replacement WARNING Burner Tube Removal Procedure 120 volt potential exposure. Isolate the appliance and 1. Position main power switch to OFF. reconfirm power is disconnected using a multi-meter. 2. Disconnect (unplug) water heater from 120 volt WARNING power source.
  • Page 34 Service Procedure III Burner Tube Inspection and Replacement WARNING Burner Tube Inspection Heater components may be HOT when performing Inspect burner tube as follows (ceramic the following steps in this procedure. Take fiber mesh burner, water heaters prior to necessary precaution to prevent personal injury. serial number “CK”): a) Visually inspect ceramic fiber mesh;...
  • Page 35 Service Procedure IV Gas Valve Replacement WARNING Gas Valve Replacement Procedure 120 volt potential exposure. Isolate the appliance and reconfirm power is disconnected using a multi-meter. Position main power switch to OFF. Disconnect (unplug) water heater from 120 volt power source. Turn OFF gas supply to water heater.

  • Page 36: Blower Testing And Replacement

    Service Procedure V Blower Testing and Replacement Are collector high limit Does blower energize? Refer to ignition switch and pressure control board Ensure digital display Replace ignition switches in normally shows “Heating.” Raise illustration below. Is control board. closed position? temperature setpoint if there 24-28VAC necessary.
  • Page 37 Service Procedure V Blower Testing and Replacement WARNING Blower Replacement Procedure 120 volt potential exposure. Isolate the appliance and reconfirm power is disconnected using a multi-meter. Position main power switch to OFF. 2. Disconnect (unplug) water heater from 120 volt power source. 3.

  • Page 38: Exhaust Pressure Switch Testing And Replacement

    Service Procedure VI Exhaust Pressure Switch Testing and Replacement Exhaust Pressure Switch Replacement Procedure 1. Position main power switch to OFF. 2. Loosen adhesive backed rubber escutcheon from service panel access cover and slide escutcheon back along exhaust pipe to allow for removal of cover. Rubber Remove screws from service panel access cover (¼"...
  • Page 39 Service Procedure VI Blocked Vent Pressure Switch Testing and Replacement WARNING Make sure exhaust collector compartment is not WARNING overheating (350°F) before resetting vent safety switch. If 120 volt potential exposure. Use caution there is evidence the collector compartment is overheating, making voltage checks to avoid personal injury.
  • Page 40 Service Procedure VI Blocked Vent Pressure Switch Testing and Replacement Check Exhaust Tube Pressure With monometer, take a Is exhaust venting system Clear obstruction. reading at the exhaust tube pressure blocked or obstructed? Check Determine cause tap location. Is value negative (-) or condensate elbow and drain.
  • Page 41 Service Procedure VI Blocked Vent Pressure Switch Testing and Replacement Exhaust Pressure Switch Replacement Procedure 1. Position main power switch to “OFF” position. Rubber 2. Loosen adhesive backed rubber escutcheon from escutcheon service panel access cover and slide escutcheon back along exhaust pipe to allow for removal of cover.

  • Page 42: Flame Sensor Testing And Replacement

    Service Procedure VII Flame Sensor Testing and Replacement WARNING Flame Sensor Testing Procedure 120 volt potential exposure. Use caution making voltage checks to avoid personal injury. Flame sensor may be too hot to handle, take necessary precautions. Refer to image below. Is there a minimum of 1 μA during 2 second flame proving period? (may be...
  • Page 43 Service Procedure VIII Spark Rod Gap Adjustment and Replacement WARNING Spark Rod Gap Inspection and Adjustment Spark gap must be set to 3/16” to 1/4”. Failure to set and verify proper spark gap may result in a delayed 1. Remove combustion system as described ignition resulting in damage to the water heater.
  • Page 44 Service Procedure VIII Spark Rod Gap Adjustment and Replacement WARNING Spark Rod Replacement Procedure 120 volt potential exposure. Isolate the appliance and reconfirm power is disconnected using a multimeter. 1. Position main power switch to OFF. CAUTION 2. Disconnect (unplug) water heater from 120 volt power source.
  • Page 45 Service Procedure IX Ignition Module/Control Board Replacement Control Board Replacement WARNING 120 volt potential exposure. Isolate the 1. Position main power switch to OFF. appliance and reconfirm power is 2. Disconnect (unplug) water heater from 120 volt disconnected using a multimeter. power source.

  • Page 46: Transformer Replacement

    Service Procedure X Transformer Replacement WARNING Transformer Replacement Procedure 120 volt potential exposure. Isolate the appliance and reconfirm power is 1. Position main power switch to OFF. disconnected using a multimeter. 2. Disconnect (unplug) water heater from 120 volt power source. 3.

  • Page 47: Vent Safety Switch Testing And Replacement

    Service Procedure XI Vent Safety Switch Testing and Replacement WARNING WARNING Make sure the exhaust collector compartment is not 120 volt potential exposure. Isolate the overheating (350°F) before resetting vent safety switch. If appliance and reconfirm power is there is evidence the collector compartment is disconnected using a multimeter.
  • Page 48 Service Procedure XI Vent Safety Switch Testing and Replacement WARNING Vent Safety Switch Replacement Procedure 120 volt potential exposure. Isolate the appliance and reconfirm power is disconnected using a multimeter. 1. Position main power switch to OFF. 2. Loosen the adhesive backed rubber escutcheon from the service panel access cover and slide the escutcheon back along the exhaust pipe to allow for removal of cover (see photos below).

  • Page 49: Anode/Flue Baffle Inspection And Replacement

    Service Procedure XII Flue Baffle Inspection and Replacement WARNING Heater components may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury. Flue Baffle Inspection and Replacement 1. Disassemble heater per Disassembly Procedure for Access to Anodes and Flue Baffles, page 49. 2.
  • Page 50 Service Procedure XIII Powered Anode Replacement WARNING! Water heater components may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury. The powered anode control module is located on the vertical side of the control panel inside the surround panel.
  • Page 51 Water Heater Installation Checklist Product Handling - Carefully uncrate the heater. Move in place with a hand truck (Do not use the venting pipes for handles). Electrical Requirements - Make sure there is 120 volts line voltage. Line voltage must be properly polarized. Adequate ground supplied to the heater.

  • Page 52: Water Heater Service Report

    Water Heater Service Report Date _________________ Service Provider _______________________ Model Number ___________________________ Phone Number _________________________ Serial Number ___________________________ Venting: Vent size ___________ Vent material _____________________ Length of straight pipe Intake _____________ Intake 45’s (qty) ___________ (intake) ___________ Length of straight pipe Exhaust ___________ Exhaust 45’s (qty) __________ (exhaust) __________...

  • Page 53: Glossary Of Terms

    Glossary of Terms Alternating Current Light Emitting Diode BTU/H British Thermal Units Oxides of Nitrogen Carbon Monoxide National Pipe Thread Carbon Dioxide Pounds per Square Inch Direct Current Revolutions per Minute Direct Spark Ignition Volt Amps Energy Cut Off Volts Alternating Current Ground Fault Interrupt W.C.

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