Bradford-White X)(A)(2) User Manual

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U a High Efficiency W r Heaters

S ICE MANUAL

T eshooting Guide a structions for Service

(To be performed ONLY by qua ce providers)

M Covered

by This Manual:

For The Bradford White

eF Series® Ultra High Effeciency

Models:

EFR160

EF60T1

EF60T1

EF60T199(E)*(N,X)(A)(2)

EF100T150(E)*(N,X)(A)(2)

EF100T199(E)*(N,X)(A)(2)

EF100T

EF100T

EF100T

(*) Denotes Warra y Years

M

l 238-45817-00F

Save this manual for future reference

The Bradford White

Page

 

eF Service Procedure

Introduction

 

3

- - -

How to use this manual

4

- - -

Tool required for service

4

- - -

Features

5

- - -

Specifications

6

- - -

Sequence of Operation

10

- - -

Troubleshooting

16

- - -

Thermostat Circuit, Testing & Replacement

35

I

Combustion System Testing and Replacement

43

II

Burner Tube Inspection & Replacement

49

III

Gas Valve Replacement

51

IV

Blower Testing and Replacement

52

V

Exhaust Pressure Switch Testing and Replacement

54

VI

Hot Surface Igniter Testing and Replacement

60

VII

Flame Sensor Testing and Replacement

62

VIII

Spark Rod Gap Adjustment and Replacement

64

IX

Ignition Module/Control Board Replacement

66

X

Transformer Replacement

68

XI

Intake Pressure Testing and Replacement

69

XII

Vent Safety Switch Testing and Replacement

71

XIII

Anode & Flue Baffle Inspection and Replacement

73

XIV

Installation Check List

78

- - -

Heater Service Report

79

- - -

Parts List

80

- - -

Glossary of Terms

89

- - -

2

2

The Bradford White eF Series® Ultra High Efficiency Water Heater is designed to deliver a remarkable 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. The information in this manual will instruct service and maintenance professionals on the function, proper diagnosis and repair of The Bradford White eF Series® Ultra High Efficiency Water Heater.

The Bradford White eF Series® Ultra High Efficiency Water Heater uses a low Nox premix power burner located at the top of the water heater to direct a turbulent flame down into a submerged combustion chamber. This turbulence causes a thorough mixing of gas and air for optimum combustion. The combustion gases then travel through a three pass flue system keeping the gases moving at a high velocity. The combination of high turbulence and velocity results in an optimum transfer of heat from the flue gases into the water.

Burner operation is controlled using an electronic ignition module. The module monitors the status of the electronic thermostat, vent temperature limit switch, vent system pressure switches and a flame sensor to control output voltage to blower motor, hot surface igniter/spark rod and gas valve. The module contains programming which determines the sequence of operation and timings for purge periods, trial for ignition, flame sensing and lockout. The module will also provide diagnostic information to help in determining the cause of system lockouts.

The contents in this manual are detailed informational tools to assist in the proper diagnosis of the eF Series® Ultra High Efficiency Water Heater operational faults. Please read this service manual completely and provide as much information regarding the eF Series® Ultra High Efficiency Water Heater operation and installation specific concerns.

3

3

It is intended for this manual to be used by qualified service personal for the primary purpose of troubleshooting analysis and repair of the Bradford White eF Series® Ultra High Efficiency Water Heater. Understanding the sequence of operation section of this manual will contribute greatly to troubleshooting this product.

An “Installation Check List” is shown towards the end of this manual. Compare the installation against the installation check list to confirm all requirements are met.

An “eF Service Report” is shown towards the end of this manual. Completing this form will assist in the troubleshooting efforts. Should you need to call for technical support, Please provide the information shown on this form to the support technician to insure accurate troubleshooting.

Troubleshooting begins with “System Observation” to determine failure mode as indicated by the LED status of the ignition module. Troubleshooting continues with “Failure Modes and Probable cause” directing the service provider to a series of test procedures to determine root cause of failure. Component replacement procedures directly follow the test procedures for a given component.

In some difficult to diagnose conditions, it may be necessary to isolate the heater from the vent system to determine root cause.

Contact Technical support immediately if diagnosis is not determined using the methods described in this service manual.

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. The meter you select must have the capability to

 

measure volts AC, volts DC, Amps, micro-ampsand ohms.

Thermometer:

Used to measure water temperature. An 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, screw drivers (common & phillips), long

 

reach (12") magnetic tip phillips head screw driver #2 tip, ¼" nut driver,

 

pliers (common & needle nose), socket set including a 1-1/16deep well

 

socket, wire cutters, wire strippers, wire crimpers, torpedo level, small

 

shop vac, step ladder, and flashlight.

 

4

4

Serial Numbers including and AFTER GB13006174 and ALL EFR models

Attractive digital water heater display on control panel for setting and displaying the temperature setpoint. Pressing temperature UP and DOWN buttons changes the temperature setpoint. Same water heater display used on all models. Temperature format may be displayed in °F or °C.

Single control board with plug in wiring controls temperature, ignition, and blower operation.

Reduced number of parts for servicing and wiring. Plug in wiring reduces chance of miswirng.

Burner ignition with direct spark ignition - A high voltage spark jumps from the spark rod to the burner surface to ignite the gas. Eliminates burned out hot surface igniter replacements.

Water heater display will show diagnostic codes in the event the water heater needs servicing. Aids in diagnosing and servicing the water heater.

Water heater display can show previous error code history to further aid in servicing the water heater.

NOTICE:

THE EF100T399 MODEL SERIES DO NOT USE THE HONEYWELL INTEGRATED CONTROL SYSTEM. THESE MODELS USE THE UT ELECTRONICS CONTROL MODULE WITH HOT SURFACE IGNITION.

5

5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Recovery GPH

 

 

 

 

 

 

 

DIMENSIONS (INCHES)

 

 

 

 

 

 

 

 

at Degree Rise

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

A

 

B

C

D

E

F

G

H

 

 

 

 

 

 

 

 

1st Hr

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Input

Del

 

 

 

 

Stg

Therm

Ht

 

Dia

Flr

Flr to

Flr to

Flr To

Flr. To

Flr to

Front

Space

Gas

T&P

Shpg

 

 

Gal

 

 

 

 

 

 

Model No

Rate

40°F

 

100°F

140°F

Cap

Eff

 

 

 

to

Inlet

T&P

Outlet

Air

Gas

Wtr

Heating

Conn

Valve

Wt

 

@

 

 

 

 

 

 

BTU/h

 

 

 

 

U.S.

%

 

 

 

Vent

Wtr

Valve

Wtr

Intake

Conn

Conn

Conn

Dia

Open

(lbs)

 

 

100°F

 

 

 

 

 

 

 

 

 

 

Rise

 

 

 

 

Gal

 

 

 

 

Outlet

Conn

Conn

Conn

 

 

Dia

Dia

(NPT)

(NPT)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

EFR-1-60T-120

120,000

180

345

138

99

60

95.0

57

 

28 ¼

5

13

40

42 ¼

52 ½

53 ½

1

1

¾

¾

570

 

EF60T125

125,000

187

363.6

145.5

103.9

60

96.0

57

 

28 ¼

5

13

40

42 ¼

52 ½

53 ½

1 ½

1

¾

¾

570

 

EF60T150

150,000

211

422.7

169.1

120.8

60

93.0

57

 

28 ¼

5

13

40

42 ¼

52 ½

53 ½

1 ½

1

¾

¾

570

 

EF60T199

199,999

265

557.6

223

158

60

92.0

57

 

28 ¼

5

13

40

42 ¼

52 ½

53 ½

1 ½

1

¾

¾

570

 

EF100T150

150,000

250

450.5

180.2

129

100

99.1

77 5/8

 

28 ¼

5

13

60

62 ¼

73 1/8

74 ¾

1 ½

1

¾

¾

900

 

EF100T199

199,999

309

597

238.8

171

100

98.5

77 5/8

 

28 ¼

5

13

60

62 ¼

73 1/8

74 ¾

1 ½

1

¾

¾

900

 

EF100T250

250,000

364

734.8

293.9

210

100

97.0

77 5/8

 

28 ¼

5

13

60

62 ¼

73 1/8

74 ¾

1 ½

1

¾

¾

900

 

EF100T300

300,000

405

836.4

334.5

239

100

92.0

77 5/8

 

28 ¼

5

13

60

62 ¼

73 1/8

74 ¾

1 ½

1

¾

¾

900

 

EF100T399

399,999

521

1,127

451

322

100

93.0

77 5/8

 

28 ¼

5

13

60

62 ¼

73 1/8

73 ¼

1 ½

1

1

1

950

6

6

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Power supply

Dedicated 120 VAC, 60 Hz, 15A, GFI

 

 

 

 

Minimum 1" NPT for EF100T399, all others ¾" NPT

 

 

 

Gas Supply

 

 

 

(schedule 40 black iron pipe recommended)

 

 

 

 

 

 

 

Approved Gas Type

Natural or Propane. Unit must match gas type supplied.

 

 

 

 

 

 

 

 

 

Gas Pressure (Nat & L.P.)

14.0" W.C. maximum static, 4.5" W.C. minimum running (recommend 7.0" W.C. min running)

 

 

 

 

 

 

 

 

 

Venting System

Power vent, balanced direct vent or unbalanced direct vent. See vent tables on page 7

 

 

 

 

 

 

 

 

 

 

Approved Vent Materials

PVC or CPVC

 

 

 

 

 

 

 

 

 

 

 

Minimum Clearance

18" from top, 24" from front, 4" sides and rear.

 

 

 

for Servicing

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Maximum Water Supply

150 PSI

 

 

 

 

Pressure

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Thermostat Sensor

11,900 Ohms @ 70°F, ECO opens @ 201°F Max., ECO close @ 100°F Min.

 

 

 

 

 

 

 

 

 

Temperature Dial

Min. set point 5400-6600ohms, Max set point0-50ohms.

 

 

 

 

 

 

 

 

 

Thermostat Board

Max temp 180°F, Min temp 91°F, 24VAC, 60Hz max.

 

 

 

 

 

 

 

 

 

Ignition Module

See “Sequence of Operation, for models starting with CF serial and later”

 

 

 

 

 

 

 

 

 

Transformer

120VAC primary, 24VAC secondary, 40VA.

 

 

 

 

 

 

 

 

 

Hot Surface Igniter

120VAC, 30-120ohms @ room temperature.

 

 

 

 

 

 

 

 

 

Flame Sensor Output

Minimum 1 micro amp, Typical range 4 to 7 micro amps.

 

 

 

 

 

 

 

 

 

Gas Valve

Negative regulation, 24 VAC, ½" PSI max., 4.5" W.C. Minimum running inlet.

 

 

 

 

 

 

 

 

 

Vent Safety Switch

Normally closed, opens @ 350°F, manual reset.

 

 

 

 

 

 

 

 

 

 

Intake Pressure Switch

 

 

 

 

 

 

“CF” serial number or

Not required.

 

 

 

 

later

 

 

 

 

 

 

Intake Pressure Switch

 

 

 

 

 

 

serial numbers prior to

24VAC, normally closed, opens on vacuum increase @ -1.20W.C.

 

 

 

“CF”

 

 

 

 

 

 

Blocked Vent Pressure

 

 

 

 

 

 

Switch “CF” serial

24VAC, normally closed, opens when pressure increases to +2.70 W.C.

 

 

 

number or later

 

 

 

 

 

 

 

24VAC, normally open, closes on pressure increase as follows

 

 

 

 

Note 1:

 

 

 

 

 

 

+2.58" W.C.

EF(60,100)T199

 

 

 

Exhaust pressure switch

 

+1.50" W.C.

EF100T150 (see note 2)

 

 

 

serial numbers prior to

 

+1.22" W.C.

EF60T150, EF100T250

 

 

 

“CF”

 

+2.08" W.C.

EF60T125

 

 

 

 

 

+0.55" W.C.

EF100T300 (see note 3)

 

 

 

 

Note 2: +5.6" W.C. on serials prior to AH5039107

 

 

 

 

Note 3: +0.8" W.C. on serials prior to AK5288269

 

 

 

 

 

 

 

 

 

Blower

120VAC, 60Hz, .6-1amps, 6400 RPM.

 

 

 

 

 

 

 

 

 

Combustion Levels

CO2: 10-11%,CO: less then 0.04 percent (400 PPM) air free

 

 

 

 

 

 

 

 

 

 

 

 

 

7

 

7

Serial Numbers including and AFTER GB13006174 and ALL EFR models

Power supply

Dedicated 120 VAC, 60 Hz, 15A

 

Minimum ¾" NPT

Gas Supply

(schedule 40 black iron pipe recommended)

 

Approved Gas Type

Natural or Propane. Unit must match gas type supplied.

 

 

Gas Pressure (Nat & L.P.)

14.0" W.C. maximum static, 4.5" W.C. minimum running (recommend 7.0" W.C. min running)

 

 

Venting System

Power vent, balanced direct vent or unbalanced direct vent. See vent tables on page 7

 

 

Approved Vent Materials

PVC or CPVC

 

 

Minimum Clearance

18" from top, 24" from front, 4" sides and rear.

for Servicing

 

 

 

Maximum Water Supply

150 PSI

Pressure

 

 

11,900 Ohms @ 70°F, ECO opens @ 207°F Max., ECO close @ 120°F Min. Redundant

Thermostat Sensor

sensor for ECO. Sensor inside well for easy replacement of sensor.

 

 

Digital display, 24 volts. Temperature Range: 70-180deg. F. Used to set tank temperature

 

Control Display

(deg. F or deg. C), show operating status, Display error codes, error code history, limit

 

maximum setpoint temperature.

 

Operates from 24 volt from transformer. Controls tank temperature, ignition functions,

Control Board

combustion blower. See ignition timings in sequence of operation for Integrated Control.

 

 

 

Transformer

120VAC primary, 24VAC secondary, 40VA.

 

 

Spark Rod Igniter

0.22" nominal gap to the burner surface.

 

 

Flame Sensor Output

Minimum 1 micro amp, Typical range 5 to 30 micro amps.

 

 

Gas Valve

Negative regulation, 24 VAC, ½" PSI max., 4.5" W.C. Minimum running inlet.

 

 

Vent Safety Switch

Normally closed, opens @ 350°F, manual reset.

 

 

Blocked Vent Pressure

24VAC, normally closed, opens when pressure increases to +2.70 W.C.

Switch

 

 

 

Blower

120VAC, 60Hz, .6-1amps, 6400 RPM.

 

 

Combustion Levels

CO2: 10-11%,CO: less then 0.04 percent (400 PPM) air free

 

 

NOTICE:

THE EF100T399 MODEL SERIES DO NOT USE THE HONEYWELL

INTEGRATED CONTROL SYSTEM. THESE MODELS USE THE UT

ELECTRONICS CONTROL MODULE WITH HOT SURFACE IGNITION.

8

8

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Balanced Direct Vent Systems

 

 

 

 

 

 

 

 

 

 

 

 

Power Vented Systems

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PVC, CPVC

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PVC, CPVC

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Total length of intake piping and exhaust piping

 

 

 

 

 

Total length of exhaust piping must not exceed

 

 

 

 

added together must not exceed “Maximum

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

“Maximum Vent Length”

 

 

 

 

 

 

 

 

 

 

 

Combined Length”

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Shown below

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Shown below

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Maximum Combined Length (feet)

 

 

 

 

 

 

 

 

 

 

 

Maximum Vent Length (feet)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Model Number

 

 

2"

 

3"

 

 

 

4"

 

 

 

 

 

Model Number

 

2"

3"

 

4"

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

EFR-1-60T120

 

 

60'

 

120'

 

 

 

170'

 

 

 

 

 

 

EFR-1-60T120

 

60'

120'

170'

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

EF60T125, EF100T150

 

 

30'

 

120'

 

 

 

170'

 

 

 

 

EF60T125, EF100T150

 

30'

120'

170'

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

EF60T150, EF100T199

 

 

30'

 

100'

 

 

 

150'

 

 

 

 

EF60T150, EF100T199

 

30'

100'

150'

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

EF60T199

 

 

30'

 

80'

 

 

 

130'

 

 

 

 

 

 

 

 

 

EF60T199

 

30'

80'

130'

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

EF100T250

 

 

N/A

 

80'

 

 

 

130'

 

 

 

 

 

 

 

EF100T250

 

N/A

80'

130'

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

EF100T300

 

 

N/A

 

60'

 

 

 

110'

 

 

 

 

 

 

 

EF100T300

 

N/A

60'

110'

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

EF100T399

 

 

N/A

 

50'

 

 

 

100'

 

 

 

 

 

 

 

EF100T399

 

N/A

50'

100'

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Unbalanced Direct Vent Systems

 

 

 

 

WARNING! The EF100T250 and EF100T300 models are not

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Air intake

CAN NOT

exceed exhaust

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

approved for 2 inch diameter vent pipe. Venting with 2 inch

 

 

 

 

 

 

 

 

 

 

by more than 30 feet

 

 

 

 

 

 

pipe on these models may result in damage to the water heater

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

or cause an unsafe condition. DO NOT use 2 inch Vent or Air

 

 

 

 

Notes:

 

 

 

 

 

 

 

 

 

Intake Pipe on EF100T250/300 models.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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.

4)The sum total of all elbows and straight pipe - intake and exhaust must not exceed maximum lengths from tables above.

Example: EF100T199

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 2½ feet = 5 feet.

60 feet of straight pipe + 30 feet + 5 feet = 95 feet.

System is within “Maximum Combined Length” from table above.

9

9

For models prior to CF serial numbers

For models prior to CF serial numbers

1

2

3

Thermostat calls for heat.

-Priorto energizing blower, ignition module checks safety circuits for normal switch positions:

a)Vent temp switch normally closed.

b)Intake pressure switch normally closed.

c)Exhaust pressure switch normally open.

If the vent temp switch is open, the control waits indefinitely for temp switch to close (green light stays on).

If the exhaust pressure switch contacts are closed (not in normal position), the ignition module will wait 45 seconds for pressure switch contact to open before energizing blower. If after 45 seconds and pressure switch contacts do not open, the ignition module locks out with the PURGE light flashing indicating pressure switch fault.

Blower energizes.

Pressure switch proves blower/vent system operation.

If the N.O. contacts of the exhaust pressure switch do not close within 5 minutes of the blower being on, the control locks out with the PURGE light flashing indicating pressure switch fault.

4Blower pre-purgeperiod (5 seconds) indicated by the PURGE LED on the module.

5Igniter warm up (18 seconds), indicated by the IGNITER LED on the module.

6Trial for ignition (4 seconds, three trials).

a)Flame establishing period (2.5 seconds) gas valve and igniter on, indicated by the IGNITER and VALVE LED on the module.

b)Burner on, flame proving period (1.5 seconds, looking for minimum of 1 micro amps), indicated by the FLAME

&VALVE LED on the module.

7Steady state operation. Ignition module monitors:

-Thermostat circuit.

-When thermostat opens, gas valve is shut down and post purge begins.

-Safety circuit.

-If vent temp switch opens, gas valve is shut down, system will post purge and wait for switch to close before attempting re-ignition.

-If either pressure switch opens, Gas valve is shut down, Blower is shut down for 30 seconds after which blower

is re-energizedand system attemptsre-ignitionstarting at pressure switch proving mode.-Flamesensor circuit.

-If flame is lost, gas valve is shut down, system will post purge and system attempts re-ignitionstarting at pressure switch proving mode.

8

9

Thermostat satisfies.

Burner off.

10 Blower post purge (15 seconds).

10

10

For models prior to CF serial numbers

For models prior to CF serial numbers

Lockout Conditions

If normally closed pressure switch contacts open during burner operation, gas valve closes, burner shuts off. Blower restarts after 30 seconds and runs 5 minutes to wait for pressure switch to close. If not, locks out.

The system will go into lock out mode for the following reasons:

-Pressure switches stuck open or closed.

a)Check for exhaust or intake obstructions.

b)Check for compliance with vent tables.

c)Check for evidence of moisture or condensate present in pressure switch tubing or pressure switch.

-No ignition after 3 attempts.

a)Check gas pressures.

b)Igniter resistance too high (lower resistance preferred <150 Ohms).

c)Check venturi screw adjustment (6 ½ turns from bottom)

d)Flame sense micro amp not present (1 to 5 micro amps required).

Lock out reset is accomplished by shutting OFF the line voltage to the system or opening the 24V thermostat circuit for at least 2 seconds.

System will automatically reset lockout after 1 hour of continuous call for heat from the thermostat. Three ignition trials will be attempted each hour until the thermostat is satisfied.

Ignition Module Specifications

Control Functions:

-Ignition & heating functions in response to thermostat.

-Hot surface ignition using a microprocessor to control timing, flame sensing using flame rectification & ignition retries.

-Monitoring of system pressure switches and limit switches.

-Control of gas valve, inducer motor, and hot surface igniter element based on thermostat demand and status of safety inputs.

-Diagnostic indicators to provide information on power to control and control status.

-Non-interchangeablepolarizedplug-inconnectors for all interconnections.

Control Inputs:

Control Outputs:

- Thermostat call for heat.

- Inducer motor

- Limit Switch Circuit (normally closed)

- Hot surface igniter

- Pressure Switch Circuit (normally open)

- Gas valve

- Flame sensing.

- Status indicator LEDs

- Low voltage supply.

Power - Green

- Line voltage supply.

Purge - Red

 

Igniter - Red

 

Valve - Red

 

Flame - Red

WIRING DIAGRAM

IGNITION MODULE

11

11

For models starting with

CF serial numbers and later.

For models starting with CF serial numbers and later.

1 Thermostat calls for heat.

Prior to energizing blower, ignition module checks to make sure the vent temperature switch is in the normally closed position. If the vent temperature switch is open, the control waits indefinitely for the temperature switch to close.

2Blower energizes, pressure switch contacts are normally closed. If the pressure switch contacts are open, blower operates for up to 5 minutes waiting for contacts to close, then blower stops and flashes red PURGE LED indicating lockout condition.

3Blower pre-purgeperiod (5 seconds) indicated by PURGE LED on the module

4Igniter warm up (18 seconds), indicated by the IGNITER LED on the module. Note: The blocked vent pressure switch must be in the normally closed position for the ignition cycle to start.

5Trial for Ignition (4 seconds, 3 trials).

a)Flame establishing period (2.5 seconds), gas valve and igniter on, indicated by the IGNITER and VALVE LED on the module.

b)Burner on, flame proving period (1.5 seconds, looking for minimum of 1 micro amps), indicated by the FLAME & VALVE LED on the module.

6Steady state operation. Ignition module monitors:

-Thermostat circuit.

-When thermostat opens, gas valve is shut down and post purge begins.

-Safety circuit.

-If vent temperature switch opens, gas valve is shut down, system will post purge and wait for switch to close before attempting re-ignition.

-If the blocked vent pressure switch opens, indicating a blocked exhaust vent condition, the gas valve is shut down, blower shuts down for 30 seconds and is re-energizedand system attemptsre-ignitionif the pressure switch is closed. Blower operates for 5 minutes to wait for pressure switch to close, then shuts off with purge light flashing(lock-out).Will restart in 1 hour to attempt to close the switch and restart ignition sequence.

-Flame sensor circuit.

-If flame is lost, gas valve is shut down, system will post purge and system attempts re-ignition.

7Thermostat satisfied.

8Burner off.

9Blower post purge (15 seconds).

12

12

For models starting with

CF serial numbers and later.

For models starting with CF serial numbers and later. Lockout Conditions

Lockout conditions:

The system will go into lock out mode for the following reasons: Blocked vent pressure switch contacts open:

Check for obstruction in exhaust pipe and vent terminal.

Check for blocked condensate trap or drain line. In cold climates, make sure drain is not frozen. No ignition after 3 attempts:

a)Check inlet and outlet gas pressures (pressure taps located on top of gas valve).

b)Igniter resistance too high (lower resistance preferred < 150 ohms).

c)Misadjusted veturi screw (should be 6.5 turns out from bottom).

d)Flame sense microamp not present (1.0 microamps minimum, should be 5 microamps or more). If burner lit, check flame rod for deposits.

e)Check burner tube condition. Refer to section EF-IIIfor Burner Tube Inspection and Replacement.

Ignition Module Specifications

Control Functions:

-Ignition & heating functions in response to thermostat.

-Hot surface ignition using a microprocessor to control timing, flame sensing using flame rectification & ignition retries.

-Monitoring of system pressure switches and limit switches.

-Control of gas valve, inducer motor, and hot surface igniter element based on thermostat demand and status of safety inputs.

-Diagnostic indicators to provide information on power to control and control status.

-Non-interchangeablepolarizedplug-inconnectors for all interconnections.

Control Inputs:

Control Outputs:

- Thermostat call for heat.

- Inducer motor

- Blocked vent pressure switch

- Hot surface igniter

(normally closed)

- Gas valve

- Flame sensing.

- Status indicator LEDs

- Low voltage supply.

Power - Green

- Line voltage supply.

Purge - Red

 

Igniter - Red

 

Valve - Red

 

Flame - Red

WIRING DIAGRAM

IGNITION MODULE

13

13

For models with Honeywell Integrated Control

System w/ Direct Spark Ignition

Serial Numbers including and AFTER GB13006174 and ALL EFR models (Excluding EF100T399 model series)

1Thermostat calls for heat.

2Combustion blower starts.

3Blower pre-purgeperiod of 30 seconds.

4Trial for Ignition. (5 seconds, 3 trials).

Flame establishing period (3 seconds), gas valve opens, sparks from spark rod to burner surface to ignite the gas.

Burner on, flame proving period (2 seconds). Requires a minimum of 0.8 microamp through flame sense rod to prove flame.

If either blocked vent safety switch contacts (normally closed) or blocked vent pressure switch contacts (normally closed) are open, then the ignition sequence will not start and an error code 29 (Pressure switch failed to close or open) will be shown on the display.

5Steady State Operation: Burner continues to operate until:

Thermostat circuit opens, gas valve closes, blower continues to operate for 30 second post-purgeperiod.

If the normally closed blocked vent pressure switch opens, the gas valve closes, the blower continues to operate indefinitely and error code 29 will be displayed after a couple minutes with “Service Needed”, “Pressure Switch”.

If the normally closed 1st Pass Collector vent safety switch opens, the gas valve closes, the blower postpurges, then shuts off with error code 26 displayed in a lockout condition.

6

Thermostat satisfied

7

Gas valve closes, burner extinguished.

8

Blower post purge for 30 seconds.

14

14

For models with Honeywell Integrated Control

System w/ Direct Spark Ignition

Serial Numbers including and AFTER GB13006174 and ALL EFR models

Lockout Conditions

The system will go into lock out mode for the following reasons:

1.ERROR CODE 62 or 63

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 display indicates a lockout condition by showing an error code number (62 or 63) with “Service Needed” in the control display window. Refer to error codes in the diagnostic section of this Service Manual. In a “Soft Lockout” condition, the control will wait for 60 minutes and then make 3 more attempts to light the main burners. Soft lockout reset is accomplished by depressing the lower right button under “Reset” for 3 seconds.

2.ERROR CODE 65

If the top of the tank should exceed 200°F, then the high limit control will shut off the burner and the water heater will go into a “Hard Lockout”. Error code 65 will be shown in the water heater display. The control can only be reset in the “Service Mode”, which is detailed in the “Troubleshooting” section of this Service Manual.

3.ERROR CODE 29

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 closes, and error code 29 will appear on the control display. When the condition is corrected, the error code will disappear and the water heater will resume normal operation. No resetting of the control display is needed for the pressure switch error code.

4.ERROR CODE 26

If the vent safety switch located near the exhaust pressure switch should open, the gas valve will close, the blower will post-purgeand error code 26 will appear on the display. The lockout condition will reset once the problem is corrected and the switch reset. Refer to “Vent Safety Switch Testing and Replacement” in this Service Manual.

CONNECTION/WIRING DIAGRAM

CONNECTION DIAGRAM

 

 

 

 

 

 

 

 

 

 

 

BR

MV

 

 

LOWER

CONTROL

 

 

 

 

 

 

 

 

 

 

7

8

9

 

 

24V

 

 

 

 

 

 

SENSOR

 

 

 

 

BL

PV/MV

 

 

& ECO

 

 

 

 

 

 

 

 

 

 

 

4

5

6

 

 

 

 

 

 

 

 

 

 

BK

 

 

 

 

 

 

 

 

 

 

 

Y

1

2

3

 

 

 

 

 

 

GAS VALVE

 

 

BK

R GY

 

 

 

 

 

1 2 3

 

R

 

24V

 

 

R

 

P.S. (N.C.)

 

 

 

 

 

 

 

 

 

R

 

 

 

GY

 

 

 

 

 

 

 

 

 

SENSOR 1

 

 

 

GY

 

 

GY GY

COLL HIGH-LIMIT

 

 

 

 

E-COM

 

6 PIN CONNECTOR

 

LIMIT (N.C.)

 

 

 

 

 

1

 

 

TO PRESSURE

 

 

 

 

 

24V

 

 

 

 

SWITCH HARNESS

 

 

 

 

1

 

 

2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

W

 

 

 

2

 

 

 

 

 

 

120V

 

 

O

 

 

 

 

 

 

 

 

 

 

 

3

 

 

 

3

 

4

1

 

GN

 

SENSE

 

 

 

 

 

 

 

BK

 

 

 

 

 

 

W

 

1

 

5

2

M

 

 

 

 

CONTROL

 

 

 

 

W

 

 

 

 

 

 

 

6

3

 

 

 

 

 

 

 

R

 

2

 

 

COMBUSTION HIGH VOLTAGE

 

DISPLAY

 

BK

 

3

INDUCER

 

 

1

 

E-COM

BLOWER

 

SPARK

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CONTROL BOARD

 

 

 

 

 

 

 

 

 

 

 

 

 

TOGGLE SWITCH

 

 

2

 

 

LINE IN

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BK LIGHT

 

 

SECONDARY

 

1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BK

 

 

G

W

BL

Y

 

 

 

2

 

 

 

 

 

 

1

 

 

 

 

 

 

 

 

 

 

L1

 

24V

 

 

3

 

 

GN

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

LOAD

2

 

GN

 

 

 

 

 

 

 

 

 

 

4

 

 

 

 

W

 

 

 

 

 

LINE

3

 

 

 

 

 

 

 

 

 

N

 

 

 

 

 

 

 

 

 

 

 

 

GND

 

120V

 

 

 

 

 

 

 

 

 

 

 

 

 

PRIMARY

 

 

 

 

 

 

 

 

 

120 VOLTS AC

TRANSFORMER

 

 

 

 

 

 

 

 

 

 

 

BLACK GROUND

WIRING DIAGRAM

WHITE

 

 

 

 

120 VOLTS

 

 

BLOWER MOTOR 120 VOLTS

 

 

 

 

M

 

BLOWER RELAY

120 VAC

 

 

 

 

 

 

Y

 

 

 

W

 

 

 

 

24 V.

 

P.S. TSTAT ECO

NC

 

 

 

 

COLLECTOR

 

 

 

 

 

LIMIT

 

 

 

 

 

 

DISPLAY

 

 

 

 

 

GAS VALVE

 

2

 

 

R

PV

 

5

 

 

R

MV

 

 

M

 

 

 

 

BLOWER RELAY COIL (BOARD CIRCUIT)

SENSE

W

O

HIGH VOLTAGE

SPARK

NOTE:

IF ANY OF THE ORIGINAL WIRES AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED. IT MUST BE REPLACED WITH 18. GA STRANDED

105°C WIRE OR ITS EQUIVALENT.

SI UN DES CONDUCTEURS D'ORIGINE FOURNI AVEC L'APPAREIL DOIT

ETRE REMPLACE UTILISER UN CONDUCTEUR 18 GA STRANDED 105°C OU L'EQUIVALENT.

15

15

 

 

 

 

 

System Observation

 

 

 

 

 

For models with Hot Surface Ignition

Is front panel power

 

Position front panel

 

 

WARNING

N

 

 

120 volt potential exposure. Use caution

switch light on,

power switch to

 

 

 

 

 

 

 

 

indicating power?

 

“ON” position.

 

 

making voltage checks to avoid personal injury.

Y

 

 

 

 

 

 

 

 

Is there 120VAC

 

 

 

Power Switch

 

 

Y

Light burned out,

 

 

 

across switch?

 

 

 

 

replace switch.

 

 

 

(see photo at right)

 

 

 

 

 

 

 

 

 

 

N

 

 

 

 

 

 

Is there 120VAC

 

 

Terminal Block

 

 

Y

Repair/replace wire

 

 

 

across terminal block?

 

 

 

(see photo at right)

 

harness to switch.

 

 

 

 

 

 

 

 

 

N

 

 

 

 

 

 

Determine power

 

 

 

 

 

 

source problem and

 

 

 

 

 

 

correct.

 

 

 

 

 

 

Refer to ignition module

Y

Refer to ignition module

Refer to ignition module

Is ignition module

N illustration, is there 120VAC

illustration, is there 24VAC

 

illustration, is there 120VAC Y

power light on?

 

going to module at locations

 

between P1(1) andP1(3)?

going to module at locations

 

 

P7(1) and P7(3)?

 

 

P2(1) and P2(2)?

 

 

 

 

 

Y

 

N

 

 

N

N

 

 

Replace ignition module.

 

Replace ignition module.

Replace transformer.

 

(see “Ignition Module Replacement”)

(see “Ignition Module Replacement”)

(see “Transformer Replacement”)

IGNITION MODULE

Is ignition module

Y

Supply voltage polarity

 

power and flame light

 

 

is incorrect.

 

flashing?

 

 

 

 

 

N

 

 

 

Reset heater by

 

Reestablish power and

Allow heater to run

 

Adjust thermostat to

interrupting power.

 

call for heat,

through heating cycle.

 

 

tank must be cold.

 

Did heater complete

N

See next page

heating cycle and did

 

blower post purge?

 

 

 

Y

 

 

 

 

 

 

 

 

 

System is OK.

16

16

LED status & probable cause

For models with Hot Surface Ignition

Determine failure mode by observing flashing LED status on ignition module. LED status and probable cause shown below.

* Denotes conditions that may require the water heater to be isolated from the vent system to determine root cause.

LED STATUS

Only power light

is on and water heater will not function.

Probable Cause*

 

 

 

Probable Cause

 

 

Exhaust pressure

 

 

 

 

switch. (see “Exhaust

 

 

Thermostat circuit.

 

 

Pressure Switch

 

 

(see “Thermostat Circuit

 

 

 

Testing and

 

Testing and Replacement”)

 

 

Replacement”)

 

 

 

 

 

 

 

 

 

 

LED STATUS

 

 

 

 

 

 

 

 

Purge light flashing.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Probable Cause*

 

 

Probable Cause

 

Exhaust pressure

 

 

 

switch. (see “Exhaust

 

 

 

Blower.

 

 

 

Pressure Switch

 

(see “Blower Testing

 

 

 

 

Testing and

 

and Replacement”)

 

 

Replacement”)

 

 

 

 

 

 

 

 

 

 

LED STATUS

 

 

 

 

 

 

 

 

Valve light flashing.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Probable Cause

 

 

Probable Cause*

 

 

 

 

 

 

 

 

 

 

 

 

Hot surface igniter.

 

Combustion system.

 

(see “Hot Surface

 

 

(see “Combustion

 

 

 

 

Igniter Testing and

 

System Testing and

 

 

Replacement”)

 

 

Replacement”)

 

 

 

LED STATUS

 

 

 

 

 

 

 

 

 

 

Power & flame

 

 

 

 

 

 

 

 

 

 

light flashing.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Probable Cause

 

 

 

 

 

 

 

 

 

 

Supply voltage

 

 

 

 

 

 

 

 

 

 

polarity.

 

 

 

 

 

 

 

Probable Cause

Vent safety switch. (see “Vent Safety Switch Testing and Replacement”)

Probable Cause*

Intake pressure switch. Only for models prior to CF serial number (see “Intake Pressure Switch Testing and Replacement”)

Probable Cause

Flame sensor. (see “Flame Sensor

Testing and Replacement”)

17

17

System Observation

For models with Direct Spark Ignition

Water Heater Fault: Water heater does not operate

Display Error Code: Water heater display does not operate - blank display

Check main power supply to water heater - fuse, circuit breaker, plug receptacle, line cord or wiring to water heater.

Check to make sure switch on front of control panel is in the ON position

Verify Primary voltage at the control board.

Verify Secondary voltage at the control board.

WARNING

120 volt potential exposure. Use caution making voltage checks to avoid personal injury.

CAUTION

Use caution not to damage connectors when making voltage measurements or jumping terminals

Refer to Control Board illustration. Voltage at primary pins P2(1) &P2(3) will be110-120.If not, check Line In pinsP3(1) &P3(4). Check line cord with volt meter. Replace line cord if defective.

Refer to Control Board illustration. Voltage at secondary pins P4(1) &P4(2) will be 24VAC.

If not, check transformer. Replace transformer or wire harness.

Transformer

Top terminals are 24VAC; Bottom terminals are 120VAC

CONTROL BOARD

3

 

1

2

 

 

 

2

 

 

 

 

1

6

3

 

1

1

3

8

5

 

 

 

 

1

2

3

 

5

 

4

1

 

3

 

1

 

 

 

 

 

 

 

 

 

 

4

 

 

 

 

 

J1

Does water heater display operate?

N

 

Is 24VAC present between

Does the combustion blower start to

 

RED andBLACK wire pin

 

 

operate? Increase thermostat setting if

 

 

connections on the back of

tank is warm.

 

 

Control Display?

Y

 

 

 

N

 

 

 

Is 24VAC present between E-COM

Display Operates - See next

 

screw terminals P9(2) &P9(3) on

page

 

 

 

the Control Board.

 

 

 

 

 

 

 

N

 

 

 

 

 

 

 

Replace

 

 

 

Control Board

P5

P4

P9

P10

P2

P3

P7

Y

Check wires for proper termination

 

 

 

to control display.

 

Y

Replace Control

 

Are wire terminations connected

 

 

Display.

 

 

 

 

properly to control display?

 

 

 

 

 

 

N

 

 

Y

Check wire

 

Make proper wire

 

 

harness for

 

terminations

 

 

 

 

 

proper continuity

 

 

 

 

 

18

18

System Observation

For models with Direct Spark Ignition

From previous page

WARNING

120 volt potential exposure. Use caution making voltage checks to avoid personal injury.

CAUTION

Use caution not to damage connectors when making voltage measurements or jumping terminals

 

 

 

 

 

 

 

 

 

 

 

Replace control board if display

 

 

 

Error code #29 on display. Refer to Control Board

 

 

N

shows “heating” and no voltage is

 

N

 

illustration. Measure voltage between terminals P7(3) &

 

 

present to the blower harness.

Does combustion blower operate?

 

 

 

 

 

P7(5) on the “inducer” output (make sure the control display

 

 

Make sure there are no error

 

 

 

 

 

 

shows “heating” in the status mode, if not increase the

 

 

 

codes for the temperature

 

 

 

 

 

setpoint). Is there 110-120VAC?

 

 

 

sensors (following sections)

Y

 

 

 

 

 

 

 

 

 

before replacing control board.

 

 

 

 

Y

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

N

 

 

 

Replace blower.

 

Y Check the voltage at the connection to the

 

 

Replace wire harness.

 

 

blower. Is 110-120VAC present?

 

 

 

 

 

 

 

 

 

 

 

 

 

Can sparking be seen/heard at the spark rod to the burner?

Y

Does Main Burner Light?

Y

Does burner continue until thermostat set point is reached? See setting display in Service Mode and displaying temperature sensors.

Y

Does blower post-purgefor 30 seconds?

Y

System okay

 

Remove high voltage wire connected at the spark rod and

 

Check resistance of high voltage

N

N

cable. Resistance should be 0-1

 

hold approximately ¼" from metal ground with insulated

 

ohms. If resistance is high, replace

 

pliers during the ignition cycle (3 second spark trial period).

 

spark cable. If spark cable is good,

 

Is there spark to ground?

 

replace Control Board.

N

Error code #62 on display. See

main burner lights, no flame signal

 

 

in section “Combustion System

 

Testing and Replacement”

Error code #63 on display. (see N “Combustion System Testing and

Replacement”)

Y

Check continuity of spark rod and spark rod gap to burner.

(see section “Spark Rod Gap Adjustment”)

Check to see if control display shows any other error codes (29, pressure switch, 26, vent safety switch, or 65, high limit). If so, refer to the appropriate section for testing and replacement.

CONTROL BOARD

3

 

1

2

 

 

 

 

 

2

 

 

 

 

 

 

1

6

3

 

 

1

1

3

 

8

5

 

 

 

 

 

 

1

2

3

 

 

5

 

 

 

3

 

1

 

 

4

1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4

 

 

J1

P5

P4

P9

P10

P2

P3

P7

19

19

Accessing Service Mode on Control Display

For models with Honeywell Integrated Control

The display has a “service mode” for changing the maximum setpoint and accessing information in aiding servicing of the water heater. This procedure is for service and installation personnel only. To enter the Service Mode, follow the steps illustrated below:

Step 1: Press “Select” and “Temperature Up” buttons together and hold for 3 seconds until “Max Setpoint” is shown in the display. "Max Setpoint"

next to Temperature Setpoint value.

Max

 

Setpoint

idle

Status Operational

Step 2: Pressing “Select” button will change displaySELECTto next modeSET

°F Water

Temp

idle

Status Operational

SELECT

SET

The following is the sequence of modes available in “Service Mode” by pressing the “Select” button:

Error Code Number (Display/Reset). This is only shown if there is an operating error in the “User Mode”.

Error Code Shown

in Water Heater Display

Status Service Needed

SELECT Lockout RESET

20

20

Accessing Service Mode on Control Display

For models with Honeywell Integrated Control

1. Max Setpoint (Display/Change)

Max Setpoint value in

Water Heater Display

°F Max

Setpoint

idle

Status Operational

SELECT SET

2. Tank Sensor Temperature Displayed Water Temperature Average.

°F Water Temp

idle

Status Operational

SELECT

SET

3. Flame Current of Burner Flame Sensor (Displays only in the Heating Cycle)

 

µA

Heating

Flame Current

Status Operational

SELECT

SET

21

21

Accessing Service Mode on Control Display

For models with Honeywell Integrated Control

4. Setpoint (Display/Change)

°F setpoint

idle

Status Operational

SELECT

SET

5. °F/°C (Display/Change)

°F °F/C° setpoint

idle

Status Operational

SELECT

SET

6. Differential (Display only - shows the differential of the thermostat)

°F Differential

idle

Status Operational

SELECT

SET

22

22

Accessing Service Mode on Control Display

For models with Honeywell Integrated Control

7. Software Version (Display only)

idle

Soft

 

Status Operational

8. Error Code History (Displays if there are present errorSELECT

codes SETor up to 10 previous error codes). Water Heater

Display will show a “--“if there are no error codes.

 

idle

Status Operational

SELECT

SET

To change the Maximum Setpoint Limit (Max Setpoint) for the temperature setpoint:

Step 1: In service mode press the “Select” button until “Max Setpoint” is displayed.

WARNING

Setting the water temperature to the maximum set point can result in scalding hot water delivered to the faucets. It is highly recommended that the maximum setpoint be adjusted to the lowest temperature possible for the needs of the installation. Make sure the water heater control display is not in a public area that can result in the temperature settings being improperly adjusted.

°F Max

Setpoint

idle

Status Operational

SELECT SET

23

23

Accessing Service Mode on Control Display

For models with Honeywell Integrated Control

Step 2: Press “Set” button to enter setting mode. “Max Setpoint” will flash to indicate setting mode.

"Max Setpoint" Flashes

°F Max

Setpoint

idle

Status Operational

SELECT SET

Step 3: Press the “UP” or “DOWN” buttons to change the maximum setpoint value. This will limit the maximum setpoint the user can select. Note: The maximum setpoint is approximately 180°F.

"Max Setpoint" continues to flash while making adjustments

°F

Max

 

 

Setpoint

 

idle

 

Status Operational

 

SELECT

SET

Step 4: Press “Set” button to confirm new “Max Setpoint” value and stop setting mode.

"Max Setpoint" stops flashing

°F

Max

 

 

Setpoint

 

idle

 

 

Status Operational

 

 

SELECT

24

SET

 

24

Accessing Service Mode on Control Display

For models with Honeywell Integrated Control

Step 5: 30 Seconds after the last button press, the Water Heater Display will go back to “User Mode”. It will read “Max Setpoint” without showing a temperature value if the temperature setpoint is at the maximum setting. The Water Heater Display can be set back to the “User Mode” immediately by pressing both the “Temperature Up” and “Select” buttons together for 3 seconds.

Max

Setpoint

idle

Status Operational

ExitingSELECTServiceSETMode

Display of Water Temperature:

Step 1: In Service Mode, Press the “Select” button until “Water Temp” is displayed in the upper right section of the water heater display. This is the reading for the sensor.

°F

 

idle

 

Status Operational

 

Lower Sensor

 

SELECT

SET

25

25

Accessing Service Mode on Control Display

For models with Honeywell Integrated Control

To Display Flame Sense Current of the Pilot Flame Sensor:

The pilot flame sense current is available only when the burners are in operation. Step 1: Make sure the status displays “Heating” or draw enough hot water to start the burners. Step 2: Enter the “Service Mode” described previously. Step 3: Press the “Select” button until a number value is displayed with “Flame Current” to the right of the number. The value displayed is in microamps (µA).

Flame

Current

µA

Heating

Status Operational

SELECT

SET

To Display and Change Temperature Setpoint:

Step 1: In “Service Mode” press the “Select” button until “Setpoint” is shown in the water heater display

°F setpoint

idle

Status Operational

SELECT

SET

26

26

"Setpoint" Flashes

Accessing Service Mode on Control Display

For models with Honeywell Integrated Control

Step 2: Press the “Set” button to enter the setting mode. “Setpoint” will flash in the water heater display.

°F setpoint

idle

Status Operational

SELECT

SET

Step 3: To raise the temperature setpoint, press the “Temperature Up” button until the desired temperature is shown on the water heater display.

NOTICE

The maximum temperature that can be set in the Water Heater Display is limited to the “Max Setpoint” described previously. To change the “Max Setpoint”, refer to the procedure “To Change the Maximum Setpoint Limit…" described previously under “Accessing the Service Mode on the Water Heater Display”.

WARNING

Setting the water temperature to the maximum set point can result in scalding hot water delivered to the faucets. It is highly recommended that the maximum setpoint be adjusted to the lowest temperature possible for the needs of the installation. Make sure the water heater control display is not in a public area that can result in the temperature settings being improperly adjusted.

°F

setpoint

 

 

idle

 

 

Status Operational

 

 

SELECT

SET

 

Step 4: To lower the temperature setpoint, press the “Temperature Down” button until the desired temperature is shown on the water heater display.

°F setpoint

idle

Status Operational

SELECT

SET

27

27

Accessing Service Mode on Control Display

For models with Honeywell Integrated Control

Step 5: When the desired setpoint is reached on the water heater display, press the “Set” button to confirm the new setpoint. “Setpoint” stops flashing in the water heater display.

°F setpoint

idle

Status Operational

SELECT

SET

To Display and Change Temperature Format (°F/°C):

To Change Temperature Format in Display from °F to °C or °C to °F:

Step 1: While in “Service Mode”, press “Select” button until “°F/°C” is shown in the upper right portion of the water heater display.

°F °F/C°

idle

Status Operational

SELECT

SET

Step 2: Press “Set” button to change temperature format. “°F/°C” symbol will flash in the water heater display.

°F °F/C°

idle

Status Operational

SELECT

SET

28

28

Accessing Service Mode on Control Display

For models with Honeywell Integrated Control

Step 3a: Press “Temperature Up” button to change temperature format to °C

°C

°F/C°

 

 

idle

 

 

Status Operational

 

 

SELECT

SET

 

Step 3b: Press “Temperature Down” button to change temperature format to °F

°F °F/C°

idle

Status Operational

SELECT

SET

Step 4: Press “Set” button to confirm °F or °C format. °F/°C will stop flashing

°F °F/C°

idle

Status Operational

SELECT

SET

29

29

Accessing Service Mode on Control Display

For models with Honeywell Integrated Control

Step 5: Pressing “Select” button will return display to setpoint in format selected (°F or °C) immediately

°F

idle

Status Operational

Lower Sensor

SELECT

SET

Error Codes and Error History Display:

If there is an operating problem with the water heater, an error code number will appear on the water heater display with “Service Needed” to the right of the “Status” indicator. The error code label is located under the Water Heater Display and the following section in this Service Manual explains the error codes with corrective actions to repair the water heater.

idle

Service Needed

SELECT SET

Example of Error Code in the Display

Error Code History:

In “Service Mode” pressing the “Select” button after the “Software Version” (item 8 in the previously described sequence of service modes) will show an error code history, if there have been any previous operating problems with the water heater. If the display shows --,there is not a current error code.

The Water Heater Display will provide up to 10 previous error codes. The oldest error code will be stored in code index #1 and the most recent in code index #10.

30

30

Accessing Service Mode on Control Display

For models with Honeywell Integrated Control

To view previous error codes:

Step 1: In “Service Mode press the “Select” button until the next display after the “Software Version”. If there are no current error codes, the display will show -- .

°F

idle

Status Operational

SELECT

SET

Step 2: Press the “Temperature Down” button to select the error code index, starting with the most recent error code “10”.

idle

 

 

Status Operational

 

SELECT

SET

Step 3: Press the “Select” button to view the error code for “code 10”. If there is a number displayed, note what the number is. The label next to the water heater display will identify the code number. If no number is displayed with only a “--“in the water heater display, then there has not been an error code for error code index 10.

idle

Status Operational

SELECT

SET

31

31

Accessing Service Mode on Control Display

For models with Honeywell Integrated Control

Step 4: Press the “Temperature Down” button to change to the previous code index, code #9.

idle

 

 

Status Operational

 

SELECT

SET

Step 5: Press the “Select” button for code index #9 to view if there are any code numbers.

idle

Status Operational

SELECT

SET

Step 6: Continue pressing the “Temperature Down” button to change to the next error code index and press “Select” to view the error code number, if any, for that index number. Continue on to index #1, the oldest error code index. The water heater display will store up to 10 error codes with the oldest code starting in code index #1 with the most recent code in code index #10.

Step 7: 10 seconds after the last button press, the Water Heater Display will revert back to the current error code display. To exit Service Mode, either wait 30 seconds or press Temperature Up button and Select Button for 3 seconds.

°F setpoint

idle

Statu Operational s

ExitingSELECTServiceSETMode

32

32

Error Code Definitions

For models with Honeywell Integrated Control

ERROR CODE DEFINITIONS

If the water heater has an operating problem, there will be a number in the water heater display with “Service Needed” shown below the error code number. Note the error code and the definition in the chart below. This label appears on the control box under the water heater display. The following sections will provide instructions for servicing each error code.

 

 

HONEYWELL INTEGRATED CONTROL ERROR CODE

 

 

DISPLAY FOR EF MODEL SERIES

 

 

 

 

 

ERROR

DEFINITION

 

 

CODE

 

 

 

 

 

4

LOW FLAME SENSE CURRENT

 

6

FLAME SENSED OUT OF NORMAL SEQUENCE (BEFORE OPENING GAS VALVE OR AFTER CLOSING GAS VALVE)

 

23FLAME DETECTED BEFORE IGNITION

24FLAME DETECTED AFTER A HEATING CYCLE COMPLETES

29 PRESSURE SWITCH FAILED TO CLOSE OR OPEN (STUCK OPEN)

32 LOWER SENSOR READINGS FAULTY

57FLAME ROD SHORTED TO GROUND

58AC LINE FREQUENCY ERROR - SIGNAL TOO NOISY OR FREQUENCY INCORRECT

59LINE VOLTAGE TOO LOW OR HIGH

61DC OUTPUT VOLTAGE UNSTABLE

62MAXIMUM NUMBER OF RETRIES DETECTED

63MAXIMUM NUMBER OF IGNITION RECYCLES DETECTED

64ELECTRONICS FAILURE

65HIGH WATER TEMPERATURE (OVER 200°F)

IF ANY OF THE ABOVE CODES APPEAR ON THE CONTROL DISPLAY, CONTACT YOUR PLUMBER OR QUALIFIED SERVICE AGENT FOR SERVICE OF THE WATER HEATER.

33

33

Resetting Error Codes

For models with Honeywell Integrated Control

WARNING

The following procedure is for service and installation personnel only. Resetting lockout conditions without correcting the malfunction can result in a hazardous condition.

If an error code is displayed (except for #4, low flame sense current), the water heater will be in a “lockout condition” with the water heater display showing the error code number and “Service Needed” in the status section of the display window. Error codes 62 (maximum number of retries detected) and 63 (maximum number if ignition recycles detected) are “Soft Lockouts” in which the control can be reset in the “User Mode” by pressing the lower right button under “Lockout Reset” shown in the lower right portion of the display. The control will also go through 3 attempts to relight the burners every hour in the soft lockout condition.

Error Code Shown in

Water Heater Display

Status Service needed

SELECT Lockout RESET

Press for 2 seconds

All other error codes will put the water heater into a “Hard Lockout” condition, in which the water heater will not operate and cannot be reset in the “User Mode”. To reset a hard lockout, first enter the “Service Mode” described earlier by pressing both the “Temperature Up” and “Select Buttons” at the same time for 3 seconds. Then press the lower right button under “Lockout Reset” in the water heater display and hold for 3 seconds.

Resetting Error Codes in Hard Lockout Condition

Error Code Shown in

Water Heater Display

Status Service Needed

 

 

SELECT

SET

Step 1: Press for 3 seconds to enter service mode.

Status Service Needed

SELECT Lockout RESET

Step 2: Press for 3 seconds to reset control in service mode.

34

34

Serial Numbers including and AFTER

 

GB13006174 and ALL EFR models

WARNING

(Excluding EF100T399 model series).

120 volt potential exposure. Use

 

IMPORTANT NOTE: This procedure assumes a cool tank

caution making voltage checks

to avoid personal injury.

 

Condition: Water Heater Not Operating

CAUTION

Display shows error code “32” ( Sensor Reading

Use caution not to damage

Faulty)

 

connectors when making voltage

 

measurements or jumping

Unplug or disconnect electrical power to the water heater

terminals

Check continuity of wire harness to sensor. Resistance of harness should be close to 0 ohms. Replace wire harness if high resistance is measured (over 0.5 ohms) Check wires for intermittent connections, shorts, frayed insulation. Replace if necessary

If wire harness is O.K., check sensor resistance detailed in “Appendix - A: sensor resistance at various temperatures” at the end of the thermostat testing and replacement section. Replace 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 display in “Service Mode”).

Condition: Water Heater Not Operating Display shows error code “65”

High Water Temperature (over 200 °F)

WARNING

Do not reset the display from the hard lockout state without correcting the cause of the overheating condition

Checking continuity of sensor (disconnected at Control Board)

Sensor shown fully inserted into well

Turn power “OFF”.

Draw water to cool tank below 120 °F

N

If sensor clip is damaged

replace clip. Replace

Check sensor. Sensor is held in place with a clip fastened to the well

sensor if damaged.

(see photo). Check sensor wire for potential damage or breaks in the

 

wire insulation. Is the sensor fully inserted into the well?

Check Sensor Resistance

Y

(See Sensor Resistance

 

 

Testing, following section)

Sensor clip shown installed properly

Continued on next page

35

35

Serial Numbers including and AFTER GB13006174 and ALL EFR models

Condition: Water Heater Not Operating

Display shows error code “65”

High Water Temperature (over 200 °F)

(Continued from previous page)

Once cause of overheating condition has been diagnosed and corrected, the control may be reset

Reconnect and switch on power to the water heater.

Enter service mode on the water heater display (see illustration) Press button under “Lockout Reset” and hold for 3 seconds. Set thermostat to the desired setting.

Water heater will start.

Monitor temperatures for one complete heating cycle making sure the maximum tank temperature remains well below 200 °F

WARNING

Do not operate water heater without verifying that the overheating condition has been corrected.

36

36

For models with Hot Surface Ignition

IMPORTANT NOTE: This procedure assumes a cool tank

 

 

WARNING

 

Rotate temperature

120 volt potential exposure. Use

 

dial to highest setting.

caution making voltage checks

 

 

 

 

to avoid personal injury.

 

Refer to ignition module

Y

 

illustration, Is there 24VAC

 

 

 

between P3(7) andP3(8)?

 

 

N

OK, thermostat is

 

 

calling for heat.

IGNITION MODULE

Thermostat

 

 

 

not calling

Red Wire

Yellow Wire

 

 

(N.O.)

(COM)

Turn off power to heater.

 

 

 

 

 

 

 

Disconnect YELLOW and RED wires from the

 

 

 

 

 

thermostat board at location N.O. and COM shown in

N

 

 

photo at right. Use a jumper to connect these two

 

 

See page 39

 

 

 

 

 

 

wires together as shown in photo at right.

 

 

 

 

 

Restore power to heater.

 

 

 

 

 

 

 

Did heater cycle on?

 

 

 

 

 

 

 

 

Y

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Check thermostat sensor

 

 

 

 

 

 

 

for proper resistance

 

 

 

 

 

Replace

(OHMS) across blue wires.

 

 

 

 

 

N

 

thermostat sensor.

(See Appendix A, sensor

 

 

 

(see Thermostat Sensor

resistance)

Replacement Procedure)

Are readings correct?

 

(see photo at right)

 

 

Y

 

 

 

 

 

 

Yellow & Red wires shown jumpered

Check sensor harness

N

 

Thermostat

continuity.

Replace harness.

 

 

Is there continuity?

 

 

 

Sensor

 

Y

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Check temperature dial for

 

 

Replace temperature dial

 

proper resistance (OHMS)

 

 

 

(See Appendix B,

N

(potentiometer).

 

temperature dial resistance)

 

 

(see Thermostat Potentiometer

 

Are readings correct?

 

 

Replacement Procedure)

 

(see photo at right)

 

 

 

Temperature Dial

 

 

 

 

 

 

Y

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Check temperature dial

N

Replace harness.

 

harness continuity.

 

 

 

 

Is there continuity?

 

 

 

 

 

Y

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Replace thermostat circuit board.

(see Thermostat Board 37 Replacement Procedure)

37

APPENDIX - A

Sensor Resistance at Various Temperatures

Be Careful When Making Voltage Measurements or Jumping Terminals

Not to Damage or Deform Connectors or Connector Pins.

Draw Water From The T&P Valve. Compare Temperature With

Temperature Ohms Chart Below.

Example: If temperature of sensor is 84°F, then the resistance through the sensor would be 8449 (see shaded area). NOTE: Sensor resistance increases as the temperature falls.

In Degrees F

°F

0

1

2

3

4

5

6

7

8

9

40

26109

25400

24712

24045

23399

22771

22163

21573

21000

20445

50

19906

19383

18876

18383

17905

17440

16990

16553

16128

15715

60

15314

14925

14548

14180

13823

13477

13140

12812

12494

12185

70

11884

11592

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

2298

2253

2209

2166

2124

2083

150

2043

2004

1966

1928

1891

1856

1820

1786

1753

1720

160

1688

1656

1625

1595

1566

1537

1509

1481

1454

1427

170

1402

1376

1351

1327

1303

1280

1257

1235

1213

1191

180

1170

1150

1129

1110

1090

1071

1053

1035

1017

999

190

982

965

949

933

917

901

886

871

857

842

200

828

814

801

788

775

762

749

737

725

713

APPENDIX - B

Temperature Dial Resistance

Proper Readings Should Be 5400-6600Ohms at Minimum

Setting

And 0-50Ohms at Maximum.

Be Careful When Making Voltage Measurements or Jumping Terminals

Not to Damage or Deform Connectors or Connector Pins.

38

38

Thermostat circuit. (continued from page 37)

For models with Hot Surface Ignition

WARNING

120 volt potential exposure. Use caution making voltage checks to avoid personal injury.

Refer to ignition module illustration, Is there 120VAC between P1(1) andP1(3)?

Y

Refer to ignition module illustration, Is there 22 - 27VAC between

P2(1) and P2(2)? Y

Refer to ignition module illustration, Is there 24VAC between P3(9) andP2(1).

N

Replace ignition module. (see “Ignition Module Replacement”)

 

Check AC source to

 

 

determine why there is no

 

 

power.

 

 

Replace

 

 

ignition module.

 

 

(see “Ignition Module

 

 

Replacement”)

 

 

Y

 

N

Refer to ignition module

N

illustration, Is there 120VAC

 

 

 

between P7(3) andP7(1)?

 

N

Replace transformer.

IGNITION MODULE

(see Transformer

 

 

 

 

Replacement)

 

Red Wires

(Temperature Sensor)

 

Check continuity through

 

 

ECO, red wiresof

 

Y

thermostat sensor.

Y

Check at temperature

 

 

 

less than 160°F

 

 

Is there continuity?

 

 

(see photo at right)

 

 

N

 

 

Check wire harness

 

 

continuity. Replace

 

 

thermostat sensor or wire

 

 

harness as necessary.

 

 

(see “Thermostat Sensor

 

 

Replacement Procedure”)

 

 

Replace thermostat

 

 

circuit board.

 

 

(see “Thermostat Board

 

 

Replacement Procedure”)

 

39

39

Thermostat Board Replacement Procedure (Hot Surface Ignition)

Step 1. Position main power switch to “OFF”

Step 2. Disconnect (unplug) water heater from 120 volt power source.

Step 3. Un-latchand remove top surround cover from top of heater.

Step 4. Locate thermostat board on control panel. (see photo at right)

Thermostat

Board

Step 5. Carefully disconnect all wires from thermostat board.

Note: it may be necessary to identify wires for proper re-connection.

Step 6. Remove the two screws (Phillips head screw driver) that secure thermostat board to control panel.

Step 7. Install new thermostat board to control panel using screws from step 6.

Step 8. Carefully reconnect wiring per the wire diagram below. Reconfirm wire connections are correct prior to putting heater back in service

Step 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 instruction located in the installation and operating instruction manual.

Step 10. Replace surround cover on top of heater.

WIRING DIAGRAM

For models starting with CF serial numbers and later.

WARNING

120 volt potential exposure. Isolate the appliance and reconfirm power is disconnected using a multi-meter.

Mounting screw locations

WIRING DIAGRAM

For models prior to

CF serial number

40

40

Thermostat Potentiometer Replacement Procedure

Step 1.

Step 2.

Step 3.

Step 4.

Step 5.

Step 6.

Position main power switch to “OFF”

 

WARNING

Disconnect (unplug) water heater from

120 volt potential exposure. Isolate the

120 volt power source.

 

appliance and reconfirm power is

Un-latchand remove top surround cover

disconnected using a multi-meter.

from top of heater.

 

 

 

Temperature

Loosen set screw

Loosen set screw of adjusting

Adjusting Knob

with small blade

 

screw driver

knob (small blade screw driver)

 

 

 

and remove adjusting knob

 

Remove

from potentiometer. (see photos at right)

retaining nut

Remove retaining nut (½" wrench)

 

 

 

and washer from potentiometer.

 

 

(see photos at right)

 

 

From inside of surround area, remove potentiometer with gasket from side of surround. Notice how indexing tab on potentiometer assembles into locating hole of surround. (see photos below)

Indexing

Tab

Locating

Hole

Potentiometer

Wire Leads

Step 7. Disconnect potentiometer wire leads. (see photo at right)

Step 8. Install new potentiometer with gasket into side of surround. Be sure to assemble with indexing tab inserted into locating hole on side of surround (see photos above).

Step 9. Reconnect wires to potentiometer. Note: Wire leads are interchangeable with either wire.

Step 10. Restore 120 volt power supply to water heater and confirm proper operation following the lighting instructions on the lighting instruction label or the lighting instruction located in the installation and operating instruction manual.

Step 11. Replace surround cover on top of heater.

41

41

Thermostat Sensor (Thermister) Replacement Procedure

Step 1. Position main power switch to “OFF”

Step 2. Disconnect (unplug) water heater from 120 volt power source.

Step 3. Hot Surface Ignition Models:Drain water heater down to a point below the top of the tank.

Step 4. Un-latchand remove top surround cover from top of heater.

Step 5. Fold back insulation just in front of burner to expose temperature sensor (see photo below).

Step 6. Disconnect temperature sensor from harness (see photos at right).

Insulation folded back to expose temperature sensor

WARNING

120 volt potential exposure. Isolate the appliance and reconfirm power is disconnected using a multi-meter.

Disconnect sensor from harness

Hot Surface Ignition Models

Sensor shown fully inserted into well

Sensor clip shown installed properly

Direct Spark Ignition Models

Step 7. Hot Surface Ignition Models: Remove temperature sensor(1-1/16"hex, deep well socket) from heater.Direct Spark Ignition Models: Unclip sensor from well and pull sensor to remove, do not remove well.

Note: Using a deep well socket will allow room inside socket for sensor connector and wires.

Step 8. Hot Surface Ignition Models: Apply thread sealing tape or applicable thread lubricant to threads of new sensor. Install new thermostat sensor and Connect to wire harness from step 6.

Direct Spark Ignition Models: Install new sensor completely into well and reinstall sensor clip. Step 9. Fold insulation back into place. Be sure there are no wires in contact with burner.

Step 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 lighting instruction located in the installation and operating instruction manual.

Step 11. Replace surround cover on top of heater.

42

42

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. Occasional yellow or white streaks are normal.

For models with Hot Surface Ignition System

Note: On higher input models using metal fiber mesh burner (serial number “CK” and later) a red glow from the burner surface is normal.

Verify Minimum Gas Supply Piping Requirements of:

N

Reconfigure gas

 

Minimum 1" NPT for EF100T399, all others use ¾"

 

 

 

supply piping

 

NPT. (Schedule 40 black Iron Pipe recommended).

 

 

 

 

 

 

 

Y

 

Inadequately

 

 

 

 

 

 

 

 

 

 

sized regulator.

 

 

 

With manometer, check inlet

 

N

 

 

 

 

 

Is gas supply pressure

 

 

 

gas pressure. Is it stable

N

 

 

 

regulator adjustable to

Y

Adjust gas

 

between 7" & 14" W.C. static?

 

 

maintain proper and

 

supply regulator

Venturi

(heater not running)

 

 

 

stable setting?

 

 

(see illustrations at right)

 

 

 

adjustment

 

 

 

 

 

Y

 

 

 

 

 

 

 

 

WARNING

Inlet gas

Does inlet gas pressure

Y

Removing screw from

pressure tap

drop more than 2" W.C.

 

inlet gas pressure tap will

 

during burner ignition?

 

immediately allow gas to

 

N

 

flow from pressure tap.

 

 

WARNING

Replace ignition module.

 

120 volt potential

 

(see “Ignition Module

 

exposure. Use caution

Replacement Procedure”)

 

making voltage checks to

 

 

avoid personal injury.

 

 

 

 

N

 

Do you see the igniter

 

Refer to ignition module illustration below,

 

glowing through burner N

is there 120VAC across terminals

 

site glass during the

 

P6(1) and P6(2)?

 

warm up period?

 

(Note: Igniter LED must be lit during this check).

 

Y

 

Y

IGNITION MODULE

 

 

 

 

Volt meter set to

 

 

 

OHM setting

 

Is igniter resistance

 

Replace

 

less than 150 Ohms

N

 

hot surface igniter.

 

(cold)?

 

 

(see “Hot Surface Igniter

 

(see check igniter

 

Meter probe

 

Replacement Procedure)

illustration)

 

Y

 

 

Hot surface

 

 

 

Proceed to next page

 

 

igniter

CHECK IGNITER

RESISTANCE 43

43

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. Occasional yellow or white streaks are normal.

For models with Hot Surface Ignition System

Continued from previous page

WARNING

120 volt potential exposure. Isolate the appliance and reconfirm power is disconnected using a multi-meter.

Refer to ignition module illustration below,

N

Replace

is there 24VAC between P3(2) andP3(5) (blue and

ignition module.

brown wires) during the flame establishing period?

 

(see “Ignition Module

(Note: Valve LED must be lit during this check)

 

Replacement Procedure”)

 

Y

 

 

 

 

 

 

 

 

 

Can you hear or feel N gas valve energize?

Y

Turn VENTURI set screw clockwise until its bottomed out. Turn screw counter-clockwise6-½turns from bottom (see illustration below). Note: EF100T399 models do not have a venturi screw. The gas regulator setting should be 1 - 1 ¼ turns out from bottom.

Y

Replace Rectifier harness and/or gas valve.

(see “Gas Valve Replacement

Procedure”)

 

 

 

 

IGNITION MODULE

 

 

Clear obstruction

N

Inspect burner tube, (see “Burner

 

 

Tube Inspection and Replacement”)

N

 

 

 

 

 

Does burner light smoothly, without

evidence of coughing N or huffing?

Y

Does flame LED on the module light and stay lit?

N

Check flame sensor, Is there 1 to 5 micro amps (min.) during 1.5 second

flame proving period? (see “Flame Sensor Testing Procedure”)

N

Replace flame sensor (see “Flame Sensor Replacement Procedure”)

 

Check for obstruction

 

 

at inlet of gas valve.

 

 

 

Is inlet free of

 

 

 

obstruction?

Venturi

 

 

Y

adjustment

 

 

 

 

 

Call for technical

Inlet gas

 

 

support

 

 

pressure tap

 

 

 

 

Y

Does burner operate

N

 

normaly until thermostat is

 

 

 

 

 

satisfied?

 

 

 

Y

Gas valve

 

 

 

 

 

 

regulator

Y

 

System OK

 

 

 

 

 

 

 

EF100T399

 

 

 

Only

 

 

 

44

44

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. Occasional yellow or white streaks are normal.

Serial Numbers including and AFTER GB13006174 and ALL EFR models

Note: On higher input models using metal fiber mesh burner a red glow from the burner surface is normal.

Verify Minimum Gas Supply Piping Requirements of:

N

Reconfigure gas

 

Minimum ¾" NPT. (Schedule 40 black Iron Pipe

 

 

 

supply piping

 

recommended).

 

 

 

 

 

 

 

 

 

 

 

Y

 

Inadequately

 

 

 

 

 

 

 

 

 

 

sized regulator.

 

 

 

With manometer, check inlet

 

N

 

 

 

 

 

Is gas supply pressure

 

 

 

gas pressure. Is it stable

N

 

 

 

regulator adjustable to

Y

Adjust gas

 

between 7" & 14" W.C. static?

 

 

maintain proper and

 

supply regulator

 

(heater not running)

 

 

 

 

stable setting?

 

 

Venturi

(see illustrations at right)

 

 

 

Y

 

 

 

 

 

adjustment

 

 

 

 

 

 

 

 

 

 

 

WARNING

Inlet gas

Does inlet gas pressure

Y

 

 

 

Removing screw from

drop more than 2" W.C.

 

 

 

 

inlet gas pressure tap will

pressure tap

during burner ignition?

 

 

 

 

immediately allow gas to

 

N

 

 

 

 

flow from pressure tap.

 

WARNING

Check resistance of high voltage

 

cable. Resistance should be 0-1ohms.

 

120 volt potential

If resistance is high, replace spark

Voltmeter set to

exposure. Use caution

cable. If spark cable is good, replace

Control Board.

OHM setting

making voltage checks to

 

 

avoid personal injury.

N

 

 

 

 

 

 

Remove high voltage wire connected at the

Can Sparking be seen/

N

spark rod and hold approximately ¼" from metal

heard at the spark rod

 

ground with insulated pliers during the ignition

to the burner?

 

 

 

cycle (3 second spark trial period).

 

 

 

 

 

Is there spark to ground?

Y

 

 

 

 

Y

 

 

 

 

 

 

 

 

 

 

Replace Spark Rod

 

 

 

Y

 

Check continuity of

N

 

 

 

 

(see “Spark Rod

 

 

 

 

spark rod. Is

 

 

 

 

 

 

Gap Inspection and

 

 

 

 

 

reading 0-1Ohm?

 

 

 

 

 

 

 

Replacement”

 

 

 

 

 

 

 

 

Does main burner

N

Check spark gap to burner

 

 

 

(see “Spark Rod Gap

 

 

Light?

 

 

 

 

 

 

 

Inspection”)

 

 

 

 

 

 

 

 

 

Y

Proceed to next page

 

Spark Rod

Volt meter set to

Meter probe

OHM setting

 

 

Spark Rod

 

Meter probe

CHECK SPARK ROD

RESISTANCE

45

45

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. Occasional yellow or white streaks are normal.

Serial Numbers including and AFTER GB13006174 and ALL EFR models

 

 

 

 

 

 

 

 

 

WARNING

 

 

 

 

Continued from

 

 

 

 

 

120 volt potential exposure. Isolate the

 

previous page

 

 

 

 

 

 

appliance and reconfirm power is

 

 

 

 

 

 

 

 

 

 

 

Refer to control board illustration,

 

 

 

 

 

disconnected using a multi-meter.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

is there 24VAC between P5(5) andP5(8) (blue and

N

Replace

 

 

 

 

 

 

 

 

 

 

 

 

brown wires) during the flame establishing period?

 

 

 

 

 

 

 

 

 

 

 

 

 

Control Board

 

 

 

 

 

 

 

 

 

 

 

 

(Note: Control Display must show “Heating” for

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

operating status)

 

 

 

 

 

 

 

Venturi

 

 

 

 

 

 

 

 

Y

 

 

 

 

 

 

 

adjustment

 

 

 

 

 

 

 

 

 

 

Replace Rectifier harness

 

 

 

 

 

 

 

 

Inlet gas

 

 

 

Can you hear or feel

N

 

 

and/or

 

 

 

 

 

 

 

pressure tap

 

 

 

 

 

gas valve.

 

 

 

 

 

 

 

 

 

 

 

 

gas valve energize?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(see “Gas Valve

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Y

 

 

Replacement Procedure”)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Turn VENTURI set screw clockwise until its

 

 

 

 

 

 

 

 

 

 

 

 

 

 

bottomed out. Turn screw counter-clockwise6-½

 

 

 

 

 

 

 

 

 

 

 

 

 

 

turns from bottom. (Note: Venturi adjustment screw

 

 

 

 

 

 

 

 

 

 

 

 

 

 

is not on the EF100T399 models)

 

 

 

 

 

 

N

Inspect burner tube, (see

 

 

 

 

 

 

 

 

Clear obstruction

 

 

 

 

 

 

 

 

 

“Burner Tube Inspection”)

 

 

 

 

 

 

 

N

 

 

 

 

 

 

 

Y

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Does burner light

 

Check for obstruction

 

 

 

 

 

 

 

 

 

 

 

 

smoothly, without

 

at inlet of gas valve.

 

 

 

 

 

 

 

 

 

 

 

 

evidence of coughing

N

Is inlet free of

 

 

 

 

 

 

 

 

 

 

 

 

or huffing?

 

obstruction?

 

 

 

 

 

 

 

 

 

 

 

 

Y

 

 

 

Y

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CONTROL BOARD

 

 

 

 

 

 

 

 

Call for technical

 

 

 

 

 

 

 

 

 

 

 

support

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Y

 

Does burner operate

 

 

 

3

 

 

1

2

 

 

 

 

 

 

 

 

N

 

2

 

 

 

 

 

 

Does burner stay lit?

 

normaly until thermostat is

 

1

 

6

3

 

 

1

1

3

 

 

 

 

 

8

5

1

 

 

 

 

5

 

 

 

 

satisfied?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4

1

 

 

3

 

1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4

 

N

 

 

 

Y

 

 

 

 

 

 

 

 

 

 

 

 

Check flame sensor,

 

 

 

 

 

 

 

J1

 

P5

P4

P9

P10

P2

P3

P7

 

 

 

 

 

 

 

 

 

 

 

 

 

Flame Sense

Is there 1 to 5 micro amps

 

 

 

 

 

 

 

 

 

 

 

 

(min.) during 1.5 second

 

Y

 

System OK

 

Multimeter set to

 

 

 

 

 

Terminal

flame proving period?

 

 

 

 

 

 

 

 

 

 

 

microamp (µA) setting

CHECK FLAME SENSE

 

 

(Value may be displayed on

 

 

 

 

 

ROD MICROAMPS

 

 

the control display by

 

 

 

 

 

 

 

 

 

 

 

 

accessing “Service Mode”)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

N

 

 

 

 

 

 

 

 

 

 

 

 

 

Flame

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Sense Rod

Replace flame sensor

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(see “Flame Sensor

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Replacement

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Procedure”)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

46

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

46

WARNING

Heater components may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury.

Combustion System Removal Procedure

Step 1. Position main power switch to “OFF”.

Step 2. Disconnect (unplug) water heater from 120 volt power source.

Step 3. Turn off gas supply to water heater.

Step 4. Un-latchand remove surround cover from top of heater.

Step 5. From the gas valve, disconnect the gas connection, PVC venting, Silicone tubing and wire harness.

WARNING

120 volt potential exposure. Isolate the appliance and reconfirm power is disconnected using a multi-meter.

Gas valve wire harness

Step 6. Disconnect wire harnesses flame sensor and blower.

For Hot Surface Ignition models, disconnect wire harness from hot surface igniter.

For Direct Spark Ignition models, disconnect high voltage cable from spark rod connection.

Burner mounting screw

(Total of 5)

Step 7. Remove the 5 bolts (½" socket) holding the burner mounting insert in place.

Gas connection

PVC vent connection

Burner mounting insert

Burner tube

Step 8.

Carefully remove combustion assembly

 

 

with gasket from water heater.

 

Step 9.

See next page for combustion system installation procedure.

Burner mounting

insert gasket

47

47

Combustion System Replacement Procedure

Step 1.

Fully inspect burner mounting insert gasket for the following:

 

a) Tears

d) Dirt or debris

 

b) Missing material

e) Other imperfections that would inhibit proper seal

 

c) Cracks

 

 

If gasket is NOT affected by any of the above, gasket replacement is not required.

Step 2.

Install combustion assembly using new gasket or fully inspected gasket from step 1.

 

Secure combustion assembly at the burner mounting insert using screws from step 6

 

on previous page. Tighten screws evenly.

Step 3.

Reconnect wire harnesses to hot surface igniter or high voltage cable to spark rod, flame sensor, blower

 

and gas valve.

 

Step 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.

Step 5.

Restore 120 volt power supply to water heater and confirm proper operation following

 

the lighting instructions on the lighting instruction label or the lighting instruction located

 

in the installation and operating instruction manual.

Step 6.

Replace surround cover on top of

 

water heater.

 

 

 

Gas valve

 

 

wire harness

 

 

Gas

 

 

connection

 

 

Burner mounting

 

 

screw

 

 

(Total of 5)

 

 

PVC vent

 

 

connection

 

 

Burner mounting

 

 

insert

 

 

Burner tube

 

 

Burner mounting

 

 

insert gasket

 

 

48

48

WARNING

Heater components may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury.

Burner Tube Removal Procedure

Step 1. Position main power switch to “OFF”.

Step 2. Disconnect (unplug) water heater from 120 volt power source.

Step 3. Turn off gas supply to water heater.

Step 4. Un-latch& remove surround cover from top of heater.

Step 5. From the gas valve, disconnect the gas connection, PVC venting, wire harness and silicone tubing.

Step 6. Disconnect wire harness from blower assembly.

Step 7. Remove the two screws holding each the hot surface igniter and flame sensor in place (long reach magnetic Phillips screw driver). Carefully remove hot surface igniter and flame sensor from combustion

assembly. For Direct Spark Ignition models, remove the two screws on the spark rod bracket and remove the spark rod.

Step 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.

Step 9. Remove burner tube from burner mounting insert. See next page for burner tube inspection procedure.

WARNING

120 volt potential exposure. Isolate the appliance and reconfirm power is disconnected using a multi-meter.

HOT

SURFACE

IGNITER/

SPARK ROD

BURNER TRANSITION

MOUNTING NUTS

49

49

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.
Install burner tube with gaskets into burner mounting insert. Be sure gasket surfaces are free of debris.
Reconnect the blower/gas valve/transition assembly to burner mounting insert. Secure using nuts from step 8 on previous page.
Carefully reinstall flame sensor with gasket and hot surface igniter with gasket and secure with screws from step 7 on previous page. Reconnect wire harnesses to sensor and igniter.
Reconnect wire harnesses to blower motor and to gas valve.
Reconnect PVC venting, gas supply and silicone tubing to gas valve. Turn on gas to heater and check for gas leaks, repair any gas leaks found.
Restore 120 volt power supply to water heater and confirm proper operation following the lighting instructions on the lighting instruction label or the lighting instruction located in the installation and operating instruction manual.
Replace surround cover on top of water heater.

WARNING

Heater components may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury.

Burner Tube Inspection

Step 1. Inspect burner tube as follows (BSI ceramic fiber mesh burner, water heaters prior to serial number “CK”) :

a) Visually inspect ceramic fiber mesh, mesh should be uniform in appearance without large gaps, tears or fraying. Mesh should have uniform pattern allowing for unrestricted gas flow.

b) Gently squeeze burner tube, Burner tube should feel firm without any soft areas around the sides or at the bottom.

c) Visually inspect inside burner tube, Burner tube should be intact with no areas of deterioration. Ports should be free of any debris.

Inspect burner tube as follows (Acotech metal fiber mesh burner, water heaters with “CK” serial number or later).

a) Outer fiber mesh should be uniform with no tears or deterioration.

Step 2. If burner tube is affected by any of the above, replacement is required. Refer to burner tube replacement procedure below.

Burner Tube Replacement Procedure

Note: New metal fiber mesh burner (Acotech) is the replacement burner for the BSI ceramic fiber sock burner. The length of burner willnot be the same as the previous BSI burner. Provide the model and serial number for the correct replacement burner.

Step 1.

Step 2.

Step 3.

Step 4.

Step 5.

Step 6.

Step 7.

Step 8.

50

50

Gas Valve Replacement Procedure

Step 1.

Position main power switch to “OFF”.

 

WARNING

 

120 volt potential exposure. Isolate the

Step 2.

Disconnect (unplug) water heater from

 

appliance and reconfirm power is

 

120 volt power source.

 

disconnected using a multi-meter.

Step 3.

Turn off gas supply to water heater.

 

 

Step 4.

Un-latch& remove surround cover from top of

 

 

 

heater.

 

 

Step 5.

From the gas valve, disconnect

 

 

 

the gas connection, PVC venting,

 

 

 

wire harness and silicone tubing.

 

 

Step 6.

Remove the 2 gas valve mounting screws (Torx bit) located at the

 

11:00 O-clock& 5:00O-clockposition on the venturi mounting flange

 

and remove gas valve from water heater.

 

 

Step 7.

Remove any residual gasket material from blower and venturi mounting flange.

 

Blower / gas valve

Gas valve

 

gasket

 

 

 

 

wire harness

 

 

 

Gas valve

 

 

 

assembly

Blower

 

 

Gas valve

 

 

 

mounting screws

 

 

 

(2 places)

 

Venturi

Venturi inlet

 

mounting flange

 

 

 

Step 8. Install new gas valve with new gasketprovided. Secure gas valve in place using screws from step 6.

Step 9. Reconnect PVC venting, gas supply, silicone tubing & wire harness to gas valve. Turn on gas supply to heater and check for gas leaks, repair any gas leaks found.

Step 10. Restore 120 volt power supply to water heater and confirm proper operation following the lighting instructions on the lighting instruction label or the lighting instruction located in the installation and operating instruction manual.

Step 11. Replace surround cover on top of water heater.

51

51

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Does blower

 

 

 

 

 

 

Is there 120VAC

 

 

 

 

 

 

 

Refer to ignition module/control board

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

illustration.

 

 

 

 

 

 

 

energize?

Y

 

 

 

 

across the white and

Y

 

 

 

 

 

Hot Surface Ignition Models:

 

 

N

Replace

 

 

(For Direct Spark

 

 

 

 

 

 

black wires at the

 

 

 

 

 

 

Is there 120VAC between P5(1) andP5(3)?

 

 

 

ignition module/

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

terminal block ?

 

 

 

 

 

 

 

 

 

control board.

 

 

Ignition models,

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Direct Spark Ignition Models:

 

 

 

 

 

 

ensure control display

 

 

 

 

 

(see photo at right)

 

 

 

 

 

 

Is there 120VAC between P7(5) andP7(3)?

 

 

 

 

 

 

 

shows “Heating”, raise

 

 

 

 

 

 

 

 

 

N

 

 

 

 

 

 

 

 

 

 

 

Y

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

temperature setpoint if

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

necessary)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

120VAC check at

 

 

 

 

 

 

 

 

N

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Determine

 

 

 

 

 

 

 

 

 

 

 

 

 

Terminal Block

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

power

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

source

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

problem

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

and

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

correct

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Black wire leading to

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

blower motor looped

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

through amprobe.

 

 

 

 

Is there 120VAC

N

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

across the white and

 

 

 

 

 

Check amp draw through

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

black wires at the

 

 

 

 

 

 

BLACK wire lead of blower

 

 

Y

 

 

Is Blower wheel secured to Y

Call technical

 

 

terminal block ?

 

 

 

 

 

 

motor. Is there .6 to 3.0

 

 

 

 

 

 

blower motor shaft?

 

 

 

support.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

amps?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Y

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

N

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

N

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Replace blower.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(see “Blower Replacement

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Refer to ignition module/

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Procedure”)

 

 

 

 

 

 

 

 

 

 

 

 

 

Hot Surface Ignition

 

 

 

 

 

 

Hot Surface Ignition Models:

 

 

 

 

 

 

 

control board illustration.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Hot Surface Ignition Models:

 

 

N

 

 

 

Models ONLY:

 

 

 

Are safety circuits in normal position?

Y

Replace ignition module/

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Is there 120VAC between

 

 

 

Refer to ignition

 

 

Y

 

 

 

Direct Spark Ignition Models:

 

 

 

P5(1) and P5(3)?

 

 

 

 

 

 

 

 

module, is there 24

 

 

 

 

Is collector high limit switch and

 

 

 

control board.

 

 

Direct Spark Ignition Models:

 

 

 

 

 

 

 

VAC between P3(7)

 

 

 

 

pressure switch in normally closed

 

 

 

 

 

 

 

Is there 120VAC between

 

 

 

 

 

 

 

 

 

and ground?

 

 

 

 

 

 

 

position?

 

 

 

 

 

 

 

P7(5) and P7(3)?

 

 

 

 

 

 

 

 

 

 

 

 

N

 

 

 

 

 

 

 

 

 

 

 

 

 

 

N

 

 

 

Checking for 120VAC

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Y

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(Black & White Wires

 

 

 

 

 

 

 

 

 

 

 

 

 

Thermostat not

 

 

 

 

Correct safety circuit problem per

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

calling for heat.

 

 

 

 

 

 

safety circuit trace

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(see “Thermostat

 

 

 

 

(section “Blocked Vent Pressure

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Circuit Testing”)

 

 

 

 

 

 

Switch Testing”).

 

 

 

 

 

 

 

Is there 120VAC

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

across the white and

N

 

 

 

 

 

Repair/replace

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

black wires at the

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

blower?

wire harness.

 

(see photo at right)

 

Y

 

 

 

 

 

 

 

 

Replace blower.

CONTROL BOARD

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(see “Blower

 

 

 

 

 

 

 

 

Replacement

 

 

 

 

 

 

 

 

Procedure”)

 

 

 

 

 

 

 

 

 

3

 

1

2

 

 

 

 

 

2

 

 

 

 

 

 

1

6

3

 

 

1

1

3

 

8

5

 

 

 

 

 

 

1

2

3

 

 

5

 

 

 

3

 

1

 

 

4

1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4

 

IGNITION MODULE

J1

P5

P4

P9

P10

P2

P3

P7

HOT SURFACE IGNITION MODELS

DIRECT SPARK IGNITION MODELS

52

52

Blower Replacement Procedure

Step 1. Position main power switch to “OFF”.

Step 2. Disconnect (unplug) water heater from 120 volt power source.

Step 3. Turn off gas supply to water heater.

Step 4. Un-latch& remove surround cover from top of heater.

WARNING

120 volt potential exposure. Isolate the appliance and reconfirm power is disconnected using a multi-meter.

Step 5. Disconnect wire harness from blower.

Step 6. Disconnect intake vent and gas supply from gas valve assembly.

Step 7. Remove the 2 gas valve mounting screws (Torx bit) located at the 11:00 O-clock& 5:00O-clockposition on the venturi mounting flange.

Step 8. Remove The 4 blower flange mounting screws (5/32 Allen wrench) and remove blower from transition flange.

Blower

Blower / gas valve

gasket Gas valve assembly

Blower flange mounting screws

Blower / transition gasket

Transition flange

Gas valve mounting screws 2 places.

Venturi mounting flange

Venturi inlet

Step 9. Remove any residual gasket material

from venturi mounting flange and transition flange.

Step 10. Install new blower with new gasket provided. Secure blower in place using screws from step 8.

Step 12. Reconnect intake vent and

gas line to gas valve assembly and

check for gas leaks repair any leaks found.

Step 11. Reconnect gas valve assembly to blower with new gasket provided. Secure gas valve in place using screws from step 7.

Step 13. Reconnect wire harness to blower assembly, restore 120 volt power supply & Gas supply to water heater and confirm proper operation following the lighting instructions on the lighting instruction label or the lighting instructions located in the installation and operating instruction manual.

Step 14. Replace surround cover on top of water heater.

53

53

Exhaust Pressure Switch Testing and Replacement

For serial numbers prior to “CF”

Sequence of operation:

With the thermostat calling for heat, prior to energizing blower, the ignition module checks the exhaust pressure switch for normal switch position of normally open. If the exhaust pressure switch contacts are closed (not in normal position), the ignition module waits 45 seconds for the pressure switch contacts to open. If the pressure switch contacts do not open after 45 seconds, the ignition module locks out with the PURGE LED flashing indicating a pressure switch fault.

LED Status

Only power LED is on, or

Purge LED flashing.

Safety Circuit Trace

WARNING

120 volt potential exposure. Use caution making voltage checks to avoid personal injury.

Does blower

N

energize?

 

Y

 

Call technical support.

N

Does heater function?

Y

Verify proper switch operation. (see “Vent Safety Switch Testing and Replacement”)

Is there continuity Through GREY Y

wire leads of heater side safety circuit harness?

(see photo below)

N

Depress reset button on vent Y safety switch. Is

there continuity across high limit

switch? (see photo below)

N

Replace vent safety switch.

(see “Vent Safety Switch Replacement Procedure”)

Is there continuity through RED

wire leads of heater side safety circuit harness?

(see photo below)

Y

Check PURGE LED status on ignition module, Flashing after 45 seconds?

N

Safety Circuit OK,

(see “Blower Testing

 

 

& Replacement”)

 

Replace exhaust

Ypressure switch (see

“Exhaust Pressure

Switch Replacement

Procedure”)

Control side

Heater side

harness

harness

Check PURGE LED status.

 

 

 

 

 

Y

 

 

 

 

 

 

 

 

On within 5 minutes?

 

 

Pressure switch is OK.

 

 

 

 

N

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Flashing after

N

 

 

Call for technical

5 minutes?

 

 

 

support.

 

Y

 

 

 

 

Check blower for proper

 

N

 

Correct blower problem

operation (see page 27)

 

 

(see “Blower Testing and

 

 

 

Is blower OK?

 

 

 

Replacement”)

Y

Reset button

Refer to

“Check Collector Pressure” (see next page)

54

54

Exhaust Pressure Switch Testing and Replacement

For serial numbers prior to “CF”

Check Collector Pressure

Check exhaust collector pressure at the exhaust collector pressure tap location (see illustration below). Is there positive pressure equal to or greater than pressure switch settings below?

EXHAUST PRESSURE SWITCH SETTINGS

 

 

 

 

 

EF(60,100)T199

+2.58"

W.C.

EF100T150

+1.50"

W.C.(see note 1)

EF60T150,EF100T250

+1.22"

W.C.

EF60T125

+2.08"

W.C.

EF100T300

+0.55"

W.C.(see note 2)

Note 1: +5.6" W.C. on serials prior to AH5039107 Note 2: +0.8" W.C. on serials prior to AK5288269

N

Inspect the area housing the combustion system and control panel located at the Y

top of the heater. Does the area show signs of corrosion

and/or exssesive heat?

N

 

With monometer, take a

 

 

 

 

 

 

 

 

Y

reading at the exhaust

 

N

 

Is exhaust venting

 

Clear obstruction.

tube pressure tap location.

 

 

Y

 

 

system blocked or

 

Determine cause

 

Is value negative (-)?

 

 

 

 

 

 

 

 

 

obstructed?

 

and correct.

 

(see illustration below).

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Y

 

 

 

 

N

 

Reconfigure vent

 

 

 

 

 

 

 

 

 

 

 

 

Is vent system total

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

system to be

 

 

 

 

 

 

length compliant with

 

N

 

 

 

 

 

 

compliant with

 

 

 

 

 

 

vent tables in the

 

 

 

 

 

 

 

 

vent tables (see

 

 

 

 

 

 

instruction manual?

 

 

 

 

 

 

 

 

“Specifications”).

 

 

 

 

 

 

 

Y

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Replace

 

 

 

 

 

 

 

 

exhaust pressure switch.

 

 

 

 

 

 

 

(see “Exhaust Pressure Switch

 

 

 

 

 

 

 

Replacement Procedure”)

 

 

 

Call for

 

 

 

 

 

 

 

 

technical support

 

 

 

 

 

 

 

 

Remove combustion assembly

 

 

(see “Combustion System

 

Clear obstruction.

Removal Procedure”)

Y

Determine cause

Inspect combustion chamber

 

 

and correct.

for blockage or debris

 

 

 

accumulation

 

 

 

N

 

 

 

 

 

 

 

 

 

Call for

technical support Exhaust collector pressure tap location

Exhaust Tube pressure tap location

Exhaust tube at bottom of water

heater

55

55

Exhaust Pressure Switch Testing and Replacement

For serial numbers prior to “CF”

Exhaust Pressure Switch Replacement Procedure

Step 1. Position main power switch to “OFF” position.

Step 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

escutcheon

Step 3. Remove screws from service panel access cover (¼" nut driver) and remove cover from heater. (see photos at right)

Step 4. Disconnect silicone tubing and wire leads from pressure switch. (see photos at right)

Step 5.

Remove pressure switch mounting screws

 

 

(5/16" wrench) and remove pressure switch.

Pressure switch

Step 6.

Assemble new pressure switch to heater using

mounting screw

5/16 hex head

 

screws from step 5.

Wire leads

 

 

Step 7. Reconnect wire leads. Note: wire leads are interchangeable with either terminal.

Step 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

Example of switch on the switch. showing positive

side identifier

Step 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 installation and operating instruction manual.

Silicone tubing

Exhaust collector pressure tap location (serial numbers prior to “CF”)

Exhaust pipe pressure tap location

Step 10. Reinstall service panel access cover and rubber escutcheon.

56

56

Blocked Vent Pressure Switch Testing and

Replacement for serial number “CF” and later

Sequence of operation:

The blocked vent pressure switch monitors the pressure in the exhaust tube. The switch contacts are normally closed and will not open unless there is a blockage in the exhaust venting or terminal (snow, ice, debris). If the blocked vent pressure switch contacts open after the thermostat initiates the blower, the blower will remain on for to 5 minutes waiting for the contacts to close. If the contacts remain open, the blower will stop and the PURGE LED will flash for hot surface ignition models, or error code 29 will display for direct spark ignition models.

LED Status

 

 

 

 

 

 

WARNING

 

 

Only power LED is on, or

 

 

 

 

 

 

120 volt potential exposure. Use caution

Purge LED flashing.

 

 

 

 

 

 

 

 

 

 

 

 

making voltage checks to avoid personal injury.

Error Code 29 or 26

 

 

 

 

 

 

(Direct Spark Ignition

 

 

Safety Circuit Trace

 

 

 

 

Models)

 

 

 

 

 

 

 

 

 

 

 

Is there continuity

 

Is there continuity

 

Safety Circuit OK,

Does blower

 

N

 

 

Through GREY

Y

through RED

N

 

 

wire leads of heater side

wire leads of heater side

(see “Blower Testing

energize?

 

 

 

safety circuit harness?

 

safety circuit harness?

 

& Replacement”)

 

 

 

 

 

 

Y

 

 

 

 

(see photo below)

 

(see photo below)

 

 

 

Call technical

 

N

 

Y

 

Replace exhaust

 

 

 

 

 

 

 

 

support.

 

Depress reset

 

Check PURGE LED status

Y

pressure switch (see

 

 

 

 

 

 

on ignition module,

 

“Exhaust Pressure

 

 

 

 

 

button on vent

 

 

 

 

 

N

 

 

Flashing after 45 seconds?

 

Switch Replacement

 

 

 

 

safety switch. Is

 

 

 

Does heater

Y

 

 

 

Procedure”)

 

there continuity

 

 

 

 

 

function?

 

 

 

 

 

 

 

 

across high limit

 

 

 

 

 

 

 

 

 

 

Control side

Heater side

 

 

 

Y

 

switch?

 

 

 

 

 

(see photo below)

 

harness

 

harness

 

Verify proper

 

 

 

 

 

 

 

 

 

 

switch operation.

 

N

 

 

 

 

(see “Vent Safety

 

 

 

 

 

 

Replace vent safety

 

 

 

 

Switch Testing and

 

 

 

 

 

 

Replacement”)

 

switch.

 

 

 

 

 

 

 

 

 

(see “Vent Safety

 

 

 

 

Hot Surface Ignition Models:

 

 

 

 

Switch Replacement

 

 

 

 

Check PURGE LED status.

 

 

 

 

Procedure”)

 

 

 

 

Direct Spark Ignition Models:

 

 

 

 

 

 

 

 

Check control display

 

 

 

 

 

 

 

 

 

On within 5 minutes?

Y

 

Pressure switch is OK.

 

 

 

 

 

 

 

 

 

 

N

 

 

 

 

 

 

 

 

 

Flashing after 5 minutes?

N

 

Call for technical

 

 

 

 

Error code 29 again?

 

 

 

support.

 

 

 

 

Y

 

 

 

 

 

 

 

 

 

Check blower for proper

 

 

Correct blower problem

 

 

 

 

operation (see “Blower

 

N

 

 

 

 

 

(see “Blower Testing and

 

 

 

 

Testing and Replacement”)

 

 

 

 

 

 

Replacement”)

 

 

 

 

Is blower OK?

 

 

 

 

 

 

 

 

 

 

Reset button

 

 

Y

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Refer to

 

 

 

 

 

 

 

 

 

“Check Collector Pressure”

 

 

 

 

 

 

 

 

(see next page)

 

 

 

 

 

 

 

 

 

Note: HOT SURFACE IGNITION MODELS

ONLY - The blocked vent pressure switch must be used with the revised ignition control, identified with a yellow label.

WARNING

Make sure exhaust collector compartment is not

overheating (350°F) before resetting vent safety

switch. If there is evidence the collector compartment

is overheating, CALL TECHNICAL SUPPORT.

57

57

Blocked Vent Pressure Switch Testing and

Replacement for serial number “CF” and later

Check Exhaust Tube Pressure

With monometer, take a

 

Is exhaust venting

 

 

 

 

 

reading at the exhaust

 

 

 

Clear obstruction.

N

system blocked or

 

 

tube pressure tap location.

Y

 

obstructed? Also

 

Determine cause

Is value negative (-)or

 

 

 

 

check condensate

 

 

and correct.

slightly postitive

 

 

 

 

elbow and drain.

 

 

 

 

 

(see illustration below).

 

 

 

 

 

 

 

 

 

N

 

 

 

 

 

 

Y

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Reconfigure vent

 

 

 

Is vent system total

 

 

 

 

 

 

 

system to be

 

 

 

length compliant with

N

 

 

 

 

 

compliant with

 

 

 

vent tables in the

 

 

 

 

 

 

 

vent tables (see

 

 

 

instruction manual?

 

 

 

 

 

 

 

“Specifications”).

 

 

 

 

 

Y

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Replace

 

 

 

 

 

 

 

 

blocked vent switch.

 

 

 

 

 

 

 

 

(see “Blocked Vent

 

 

 

 

 

 

 

 

Switch Testing and

 

 

 

 

 

 

 

 

 

Replacement”)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

With ohmmeter check

 

 

 

 

 

 

 

 

 

N

 

Is pressure in exhaust tube near 2.7" w.c. or more? If so, correct

pressure switch for

 

continuity. Contacts should

 

 

blockage (above). If exhaust pressure is low (0.40" or less),

 

 

 

 

 

 

 

replace pressure switch.

be closed.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Y

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Exhaust Tube

Pressure switch O.K.

 

 

 

 

 

 

 

 

 

 

 

 

pressure tap location

 

 

Exhaust tube at bottom of heater

58

58

Blocked vent Switch Testing and Replacement

For serial number “CF” or later

Exhaust Pressure Switch Replacement Procedure

Step 1. Position main power switch to “OFF” position.

Step 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

escutcheon

Step 3. Remove screws from service panel access cover (¼" nut driver) and remove cover from heater. (see photos at right)

Step 4. Disconnect silicone tubing and wire leads from pressure switch. (see photos at right)

Step 5.

Remove pressure switch mounting screws

 

 

(5/16" wrench) and remove pressure switch.

Pressure switch

Step 6.

Assemble new pressure switch to heater using

mounting screw

5/16 hex head

 

screws from step 5.

Wire leads

 

 

Step 7. Reconnect wire leads. Note: wire leads are interchangeable with either terminal.

Step 8. Reconnect silicone tubing to pressure switch as follows:

a)Exhaust pipe tubing connects to single tap located on switch

Step 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 installation and operating instruction manual.

Silicone tubing

Exhaust Tube pressure tap location

Step 10. Reinstall service panel access cover and rubber escutcheon.

59

59

Hot surface Igniter Testing Procedure

Is igniter resistance less than 150 Ohms Y

(cold)? (see “check igniter

resistance” below) N

Replace

hot surface igniter (see “Hot Surface Igniter Replacement Procedure”)

Refer to ignition module illustration below, is there 120VAC across terminals

P6(1) and P6(2)?Y (Check during igniter warm up period,

indicated by the igniter LED glowing on the ignition module).

N

Replace ignition module. (see “Ignition Module Replacement Procedure”)

WARNING

120 volt potential exposure. Use caution making voltage checks to avoid personal injury. Igniter may be too hot to handle, take necessary precautions

Check harness connection from igniter to ignition module.

Volt meter set to

OHM setting

Meter probe

 

Hot surface

 

igniter

 

CHECK IGNITER

IGNITION MODULE

 

RESISTANCE

 

60

60

Hot surface Igniter Replacement Procedure

Step 1.

Position main power switch to “OFF”

WARNING

Step 2.

Disconnect (unplug) water heater

120 volt potential exposure. Isolate the

 

from 120 volt power source.

appliance and reconfirm power is

Step 3.

Un-latch& remove surround cover

disconnected using a multi-meter.

 

from top of heater.

 

Step 4.

Fold back insulation in front of combustion assembly to expose hot surface igniter.

 

(see photo at right)

 

Step 5. Disconnect igniter wire leads from ignition module.

Step 6. Remove the 2 igniter mounting screws (magnetic tip, long reach Phillips screw driver) and remove igniter and gasket from transition base flange.

Step 7. Remove any residual gasket material from transition base flange.

Note:

Note:

New replacement igniter will

Do not handle igniter element

not have a shield over element.

or allow foreign material to

Handle carefully to prevent

come in contact with element.

breakage.

 

Step 8. Install new igniter with new gasket provided using screws from step 5. Arrange igniter flange with offcenter hole towards front of heater.

Hot Surface

Igniter

 

Off-center

Igniter mounting

Igniter flange

 

mounting hole

screws

Igniter gasket

 

 

 

 

Heater front

Transition

Igniter filament

 

 

 

 

 

Step 9.

Reconnect igniter wire harness.

base flange

 

 

 

Step 10. Fold insulation back into place. Be sure no wires are in contact with burner flange.

Step 11. 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 installation and operating instruction manual.

Step 12. Replace surround cover on top of water heater.

61

61

Flame Sensor Testing Procedure

WARNING

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 ignition module/control board

 

 

Refer to illustration below, is there

 

 

illustration.(24 volts should maintain beyond the

 

 

Y

 

1.5 second flame proving period.)

Y

Flame sensing circuit OK

a minimum of 1 micro amp during

 

Hot Surface Ignition Models:

 

 

 

1.5 second flame proving period?

 

 

Is there 24 volts AC at locations P3(2) &P3(5)?

 

 

 

 

 

 

 

Direct Spark Ignition Models:

 

 

N

 

 

 

 

Is there 24VAC between P5(5) andP5(8)?

 

 

 

 

 

 

Replace flame sensor with

N

 

 

With flame sensor Disconnected

 

Call for

 

 

from ignition module, check

 

Y

 

gasket

 

 

 

 

and/or wire lead.

technical support

 

 

continuity to ground.

 

 

 

 

 

Is there continuity to ground?

 

(see “Flame Sensor

 

 

 

N

 

 

 

Replacement Procedure”)

 

 

 

 

 

 

 

 

 

 

 

Remove flame sensor from water heater.

 

 

 

 

 

Check continuity from tip of flame sensor N

 

 

Volt meter set to

 

 

to end of wire lead.

 

 

 

 

Micro amps setting

 

 

Is there continuity?

 

 

 

 

 

 

 

 

 

 

(µA)

 

 

Y

 

 

 

 

 

 

 

 

 

N

 

Meter

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

probe

 

 

 

Is flame sensor free

Y

Is ceramic of flame

 

 

 

 

of oxidation?

 

sensor cracked?

Flame

 

 

 

 

 

 

 

 

 

 

 

N

 

 

Y

 

sensor

 

 

 

 

 

 

terminal

Meter

Flame sensor

 

 

 

 

 

 

 

 

 

 

 

 

probe

Clean or replace

 

 

 

 

 

terminal on

 

Replace flame sensor.

 

 

 

flame sensor.

 

 

 

 

ignition module.

(see “Flame Sensor

 

(see “Flame Sensor

 

 

 

 

 

 

Replacement

 

 

HOT SURFACE IGNITION MODELS

Replacement

 

 

 

 

 

 

Procedure”)

 

 

Procedure”)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Volt meter set to

CONTROL BOARD

 

 

 

 

 

 

 

Micro amps setting

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(µA)

 

 

 

 

 

 

 

 

 

 

3

 

1

2

 

 

 

 

Meter probe

 

2

 

 

 

 

 

 

1

6

3

 

 

1

1

3

 

 

8

5

 

 

 

 

 

 

 

1

2

3

 

 

5

 

 

 

4

1

 

 

3

 

1

 

 

 

 

 

 

 

 

4

 

Flame sensor

 

J1

P5

P4

P9

P10

P2

P3

P7

terminal

 

 

 

 

 

 

 

 

 

 

 

Flame sensor

 

 

 

 

 

 

 

 

 

terminal on

 

 

 

Meter probe

 

 

 

control board.

 

 

 

 

 

 

 

 

 

 

 

 

 

DIRECT SPARK IGNITION MODELS

62

 

62

Flame Sensor Replacement Procedure

Step 1. Position main power switch to “OFF”

Step 2. Disconnect (unplug) water heater from 120 volt power source.

Step 3. Un-latch& remove surround cover from top of heater.

WARNING

120 volt potential exposure. Isolate the appliance and reconfirm power is disconnected using a multi-meter.

Step 4. Fold back insulation in front of combustion assembly to expose flame sensor. (see photo at right)

Step 5. Disconnect wire lead from flame sensor.

Step 6. Remove the 2 sensor mounting screws (magnetic tip, long reach Phillips screw driver) and remove flame sensor & gasket from transition base flange.

Step 7. Remove any residual gasket material from transition base flange.

Flame sensor

Step 8. Install new flame sensor with new gasket provided using screws from step 6. Arrange flame sensor with hook towards burner.

Flame sensor mounting screws

Flame sensor

Flame sensor gasket

Arrange hook of sensor towards burner

Step 9. Reconnect flame sensor wire.

Step 10. Fold insulation back into place. Be sure no wires are in contact with burner flange.

Transition

base flange

Step 11. 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 installation and operating instruction manual.

Step 12. Replace surround cover on top of water heater.

63

63

Spark Rod Gap Inspection and Adjustment

Step 1. Remove combustion system as described in “Combustion System Removal Procedure”.

Step 2. Measure spark gap between the spark rod and burner tube. Acceptable spark gap is between 3/16" - 1/4" (see photo below).

Step 3. If spark gap is not between 3/16" - 1/4“, the spark rod may be carefully bent by supporting the end near the ceramic insulator with pliers and bending the end near the burner tube with needle nose pliers (see photo below).

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 ignition resulting in damage to the water heater.

CAUTION

Use caution while performing these steps to prevent stressing or cracking the ceramic insulator.

Step 4. Re-measureand verify spark gap is between 3/16" - 1/4“ after bending.

Step 5. Reinstall the combustion system per “Combustion System Replacement Procedure” and check several ignitions to ensure the burner lights smoothly.

Spark Rod

Hold spark rod near ceramic insulator

Bend spark rod near

burner tube

Burner Tube

Spark Rod

64

64

Spark Rod Replacement Procedure

Step 1. Position main power switch to “OFF”

Step 2. Disconnect (unplug) water heater from 120 volt power source.

Step 3. Un-latch& remove surround cover from top of heater.

Step 4. Fold back insulation in front of combustion assembly to expose spark rod. (see photo at right)

Step 5. Disconnect wire lead from spark rod.

Step 6. Remove the 2 mounting screws (magnetic

tip, long reach Phillips screw driver) and remove spark rod & gasket from transition base

flange.

WARNING

120 volt potential exposure. Isolate the appliance and reconfirm power is disconnected using a multi-meter.

WARNING

If spark rod is replaced for any reason,

the combustion system MUST be

removed and the spark gap to the burner

measured and adjusted properly.

Step 7. Remove any residual gasket material from

transition base flange.

Step 8. Install new spark rod with new gasket provided using screws from step 6. Arrange spark rod with

hook towards burner (off-centermounting hole towards the front of the water heater).

Spark Rod

Step 9. Remove combustion system following “Combustion System Removal Procedure”, and verify spark gap following “Spark Rod Gap Inspection and Adjustment”.

WARNING

Off-center

Spark gap must be set to 3/16" to 1/4".

mounting hole

Failure to set and verify proper spark

 

gap may result in a delayed ignition

Heater front

resulting in damage to the water heater.

 

 

Transition

 

base flange

Step 9. Reassemble combustion system following “Combustion System Replacement Procedure”.

Step 10. Fold insulation back into place. Be sure no wires are in contact with burner flange.

Arrange hook of spark rod towards burner

Step 11. 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 installation and operating instruction manual.

Spark rod mounting screws

Spark rod

Spark rod gasket

Step 12. Replace surround cover on top of

water heater.

65

 

65

Ignition Module Replacement Procedure

Step 1.

Step 2.

Step 3.

Step 4.

Position main power switch to “OFF”.

WARNING

120 volt potential exposure. Isolate the

 

Disconnect (Unplug) water heater

appliance and reconfirm power is

from 120 Volt power source.

disconnected using a multi-meter.

Un-latch& remove surround cover from top of water heater.

Locate Ignition module on control panel inside surround area. (see photo below)

Ignition Module located on control panel

Note: Replacement hot surface ignition module works on all EF models prior to and later than “CF” serial numbers. Direct spark ignition models use a different control board (detailed in following section).

Step 5. Carefully disconnect all wire harness connection to ignition module. Connection are non-interchangeableto insure proper reinstallation.

Step 6. Remove the 3 screws (Phillips screw driver) holding the ignition module in place and remove ignition module from control panel.

Step 7. Install new ignition module and secure in place with screws from step 6.

Step 8. Carefully reconnect all wire harness connection to ignition module. Connection are non-interchangeableto insure proper reinstallation.

Step 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 instruction located in the installation and operating instruction manual.

Step 10. Replace surround cover on top of water heater.

66

66

Control Board Replacement (Honeywell Integrated Control w/ Direct Spark Ignition)

Step 1. Position main power switch to “OFF”

Step 2. Disconnect (unplug) water heater from 120 volt power source.

Step 3. Un-latchand remove top surround cover from top of water heater.

Step 4. Locate control board.

Control Board

Step 5.

Carefully disconnect all wire

 

 

connections from control board.

 

 

Note: It may be necessary to

Unclip this

 

identify wires for

side second

 

proper re-connection.

 

Step 6. Depress the plastic tabs on the blower side of the control board first.

Step 7. Tilt the control panel and slide control hook tabs from slots in the control panel (see photo at right).

Step 8. Replace control board and all wire connections.

Step 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 instruction located in the installation and operating instruction manual.

WARNING

120 volt potential exposure. Isolate the appliance and reconfirm power is disconnected using a multi-meter.

Blower

Unclip blower side first

Step 10. Replace surround cover on top of water heater.

67

67

Step 6 Remove transformer
mounting screws

Transformer Replacement Procedure

Step 1. Position main power switch to “OFF”.

Step 2. Disconnect (Unplug) water heater from 120 Volt power source.

Step 3. Un-latch& remove surround cover from top of water heater.

WARNING

120 volt potential exposure. Isolate the appliance and reconfirm power is disconnected using a multi-meter.

Step 4. For Hot Surface Ignition models, refer to ignition module illustration below, Disconnect wire harness P1 labeled “PRIMARY” and P2 labeled “SECONDARY” from ignition module.

Step 5. For Hot Surface Ignition models, Disconnect secondary leads (blue & yellow wire) from thermostat board. Note the blue wire is connected to

24 volt “HOT” terminal. (see photo below)

For Direct Spark Ignition models, Disconnect primary leads (black & white) and secondary leads (blue & yellow) from the transformer. (leads are different sizes to prevent interchanging)

Step 5

Disconnect blue & yellow wire from thermostat board. Note blue wire is connected to 24 volt “HOT” terminal.

Thermostat

board

Step 3 Disconnect harness “P1” & “P2”

from ignition module

Ignition module

Step 6. Remove the 2 screws ( short Phillips screw driver) holding the transformer in place and remove transformer from control panel. (see photo below)

Step 7. Install new transformer and secure in place with screws from step 6.

Step 8. For Hot Surface Ignition models, Reconnect wire harness P1 & P2, connections are non-interchangeable to insure proper reconnection.

For Direct Spark Ignition models,

Reconnect primary and secondary wires to transformer. (leads are different sizes to prevent interchanging)

Step 9. For Hot Surface Ignition models, Reconnect blue & yellow wire leading from the P2 connection on ignition module to

thermostat board. Note the blue wire must connect to the 24 volt “HOT” terminal. (see photo at right)

Step 10. Restore 120 volt power supply to water heater and confirm proper operation following the lighting instructions on the lighting instruction label or the lighting instruction located in the installation and operating instruction manual.

Step 11. Replace surround cover on top of water heater.

Thermostat

board

24 volt common, yellow wire connection

24 volt Hot, blue wire connection

68

68

Used on EF water heaters prior to “CF” serial number.

Notice:

The intake pressure switch is not used on serial number “CF” and later.

 

 

Is there continuity

 

Does Blower Energize?

N

through the normally

N

closed intake pressure

 

 

 

 

switch?

 

 

 

(see photo at right)

 

 

 

 

Y

 

 

 

 

 

 

 

 

 

 

See “Vent Safety Switch Testing

and Replacement”

or

Exhaust Pressure Switch Tesinting

and Replacement”

or

“Blower Testing and Replacement”

Does purge LED

illuminate on the ignition Y Switch OK. module?

 

N

 

 

 

 

 

 

 

 

 

 

 

With manometer, take a

 

Is there continuity

 

reading from the inlet tube

 

 

N

through the normally

 

pressure tap. Is reading

Y

closed intake pressure

 

negative (-)1.2"W.C.

 

switch?

 

or more?

 

 

 

(see photo above)

 

(see illustration below)

 

 

 

 

 

 

 

Y

 

 

N

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

WARNING

120 volt potential exposure. Use caution making voltage checks to avoid personal injury.

Replace

intake pressure switch. (see “Intake Pressure Switch Replacement Procedure”)

Disconnect red wire leads from pressure switch and check continuity through switch.

Remove hose from intake

Y

See “Exhaust Pressure Switch Testing

 

pressure switch and

and Replacement”)

 

Restart heater.

 

or

 

Does purge LED illuminate?

 

“Blower Testing and Replacement”

 

N

 

 

 

Isolate (disconnect) heater from

 

 

intake vent system and

N

 

 

Restart heater.

 

 

 

Does purge LED illuminate?

 

 

 

Y

 

 

 

Is intake vent system

Y

Clear obstruction.

 

obstructed?

 

Inlet Tube

 

 

pressure tap

N

Call for technical support.

69

69

Used on EF water heaters prior to “CF” serial number.

Intake Pressure Switch Replacement Procedure

 

 

WARNING

Step 1.

Position main power switch to “OFF”.

120 volt potential exposure. Isolate the

appliance and reconfirm power is

 

 

Step 2.

Disconnect (Unplug) water heater

disconnected using a multi-meter.

 

from 120 Volt power source.

 

Step 3. Un-latch& remove surround cover from top of water heater.

Step 4. Locate intake pressure switch on control panel inside surround area (see photos below).

Intake pressure switch located on side of control panel

Step 6 Disconnect tubing from

pressure switch

Step 5. Disconnect red wire leads from pressure switch (see photo at right).

Step 5 Disconnect red wires

Step 6. Disconnect silicone tubing from pressure switch (see photos above).

Step 7. Remove the two screws (Phillips screw driver) holding the intake pressure switch in place and remove pressure switch from control panel (see photos above).

Step 8. Install new pressure switch and secure in place with screws from step 7.

Step 9.

Reconnect silicone tubing (from step 6) to pressure switch.

Step 10. Reconnect red wires (from step 5) to pressure switch. Note: wires are interchangeable with either switch terminal.

Step 11. Restore 120 volt power supply to heater & verify proper heater operation following the instructions on the lighting instruction label or the lighting instructions located in the installation & operation manual.

Step 12. Replace surround cover on top of heater.

Step 7

Remove 2 mounting screws

70

70

Sequence of operation:

For Hot Surface Ignition models, with the thermostat calling for heat, prior to energizing blower, the ignition module checks the vent safety switch for normal switch position of normally closed. If the vent safety switch contacts are open, (not in normal position), the ignition module waits indefinitely for contact to close, The vent safety switch must be manually reset to close the switch contacts.

For Direct Spark Ignition models, error code 26 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

120 volt potential exposure. Use caution making voltage checks to avoid personal injury.

Locate harness connection.

(see photo at right)

Call technical support.

N

Does heater function?

Y

 

Is there continuity

 

 

 

 

Through GREY

 

Y

Lead wires of heater side

 

 

 

harness?

 

 

 

 

(see photo at right)

 

 

 

 

 

N

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Depress reset

 

 

Replace vent

 

button on high

 

 

 

 

 

safety switch

Y

limit switch. Is

N

 

 

(see “Vent Safety

 

there continuity

 

 

 

across high limit

Switch

Replacement

switch?

Procedure”)

(see photo below)

 

Control side

Heater side

harness

harness

System OK

N

Reset heater, observe

N

Is temp over 350°F?

Y

heating cycle. Does

 

 

switch open?

 

 

 

Y

 

 

 

 

 

DO NOT OPERATE

 

Does switch open prior

N

HEATER

 

System over heating,

 

to 350°F?

 

 

 

immediately contact

 

 

 

 

Y

 

technical support.

 

 

 

 

Replace vent safety switch

(see “Vent Safety

Reset button Switch Replacement Procedure”)

WARNING

Make sure exhaust collector compartment is not

overheating (350°F) before resetting vent safety

switch. If there is evidence the collector compartment

is overheating, CALL TECHNICAL SUPPORT.

71

71

Vent Safety Switch Replacement Procedure

Step 1. Position main power switch to “OFF”.

Step 2. Loosen adhesive backed rubber escutcheon from service panel access cover and slide escutcheon back along exhaust pipe to allow for removal of cover (see photos at right).

Step 3. Remove screws from service panel access cover (¼" nut driver) and remove cover from heater (see photos at right)

Step 4. Disconnect wire leads from vent safety switch (see photo at right).

Step 5. Remove the 2 switch mounting screws (Phillips screw driver) and nuts (5/16 wrench) and remove switch from heater.

Step 6. Install new switch using screws from step 5.

Step 7. Reconnect wire leads. Note: wire leads are interchangeable with either switch terminal.

Vent safety switch

Rubber escutcheon

Step 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 instruction located in the installation and operating instruction manual.

Step 9. Reinstall service panel access cover and rubber escutcheon.

72

72

Disassembly Procedure for Access to Anodes & Flue Baffles

WARNING

Heater components may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury.

Step 1. Position main power switch to “OFF”.

Step 2. Disconnect (Unplug) water heater from 120 Volt power source.

WARNING

120 volt potential exposure. Isolate the appliance and reconfirm power is disconnected using a multi-meter.

Step 3. Un-latch& remove surround cover from top of heater.

Step 4. Disconnect wire harnesses to allow for removal of control panel.

Note: Where ever possible, rather than disconnecting at the control panel, follow wire harness away from control panel and disconnect at control component location.

Step 5. Remove the three control panel mounting screws (¼” nut driver) and remove control panel from the water heater (see photos below).

Remove Control

Panel

Control Panel

Mounting Screw

Step 6. Completely remove insulation (two pieces) from top of heater to expose collector cover

Step 7. Remove all collector cover screws (5/16" socket) and remove collector cover (see photos at right).

Collector

cover

Step 8. Photo 44 shows heater with collector cover removed allowing

access to anode rods and flue baffles. Anode

locations

a) for anode service, see “Anode Inspection and Replacement”

b) for flue baffle service, see “Flue Baffle Inspection and Replacement” c) for powered anode service, see “Powered Anode Replacement”

Flue

Note: EF100T399 models have only 1 anode baffles rod under the 2nd pass collector cover.

73

73

Anode inspection and replacement

WARNING

Heater components and stored water may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury.

Step 1. Turn off water supply and drain water heater.

Step 2. Disassemble water heater per “Disassembly Procedure for Access to Andoes & Flue Baffles”. Step 3. Locate and remove anode rods from heater (1-1/16hex socket).

Step 4. Visually inspect anode rod. Anode rod should show signs of depletion, this is normal. If the depletion is ½ of the original diameter (approximately ¾" diameter), replacement is recommended. If any of the steel core of the anode is exposed, replacement is recommended.

Step 5. Upon completion of inspection or subsequent replacement, apply thread sealing tape or other thread compound to threads of anode and reinstall into heater. Restore water supply

and check for and repair any leaks found.

Step 6. Reinstall collector cover per “Collector Cover Installation Procedure”.

Step 7. Reinstall collector insulation and control panel, reconnect control panel wire harnesses.

Step 8. 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.

Step 9. Replace surround cover on top of water heater.

74

74

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.

Step 1. Disassemble heater per “Disassembly Procedure for Access to Anodes & Flue Baffles”. Step 2. Remove flue baffles from heater (pliers) (8 two inch baffles & 2 four inch baffles).

Step 3. Visually inspect flue baffles. Flue baffles should show signs of oxidation, this is normal. If the oxidation has deteriorated any portion of the flue baffle, replacement is recommended. If any restrictors are missing, replacement is recommended.

Step 4. Upon completion of inspection or subsequent replacement, reinstall flue baffles into heater.

Step 5. Reinstall collector cover per “Collector Cover Installation Procedure”.

Step 6. Reinstall collector insulation and control panel, reconnect control panel wire harnesses.

Step 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.

Step 8. Replace surround cover on top of water heater.

75

75

Powered Anode Replacement for EF100T399 only

Powered Anode Replacement EF100T399 models only

WARNING

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 right vertical side of the control panel inside the surround panel. The control has a LED indicator light to show the status of operation. When the tank is filled with water and the power supply is on to the water heater, the light should have a steady green glow to indicate that protection current is flowing and operating normally. If the indicator light is not glowing, the power supply to the water heater or powered anode system is disconnected.

Step 1. Check the power supply or wire connections to the powered anode control.

Step 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.

Step 3. Check all electrical connections. The powered anode rods are insulated from the water heater tank in the bushing.

a)With an ohmeter, check continuity between the powered anode terminal and the bushing. There should not be continuity. If there is continuity, replace the powered anode assembly.

Volt meter set to OHM setting

76

76

Collector Cover Installation Procedure

Step 1. Remove old silicone from top surface of collector flange and collector cover.

Step 2. Apply ¼" bead of Ultra Copper Silicone around entire collector flange surface. Allow caulk to “cure” for 10 minutes.

Step 3. Carefully reinstall collector cover, tighten screws evenly.

Step 4. Allow a minimum of 6 hours before putting heater back in service.

Apply ¼" bead of Ultra Copper Silicone around entire collector flange surface

77

77

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.

Venting Requirements - All venting must stay within the required lengths and diameter (see table below). Proper support of the venting pipe is a MUST (every 5ft vertical and 3ft horizontal). Termination must be located to preventre-circulationof flue gases. Medium to long sweep 90° elbows or straight exhaust terminal coupling recommended.

Gas Requirements - Gas piping sized adequately, ¾" or larger to heater or 1" or larger for EF100T399 models. 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 slope to a drain at a minimum of ¼" per foot. Make sure the condensate line does not have the potential to freeze. If using more than one heater and using a common condensate line, make sure the condensate line is properly sized.

Service/Mechanical Room - Provide adequate space for servicing heater. Leave room to get to the

top and bottom pressure switches as well as enough overhead room to remove the anode rods for

servicing (18" min.).

Vent tables

 

Balanced Direct Vent Systems

PVC, CPVC

Total length of intake piping and exhaust piping added together must not exceed “Maximum Combined Length” Shown below

Maximum Combined Length (feet)

 

 

 

Model Number

 

2"

 

3"

 

 

4"

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

EFR-1-60T120

 

60'

 

120'

 

 

170'

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

EF60T125, EF100T150

 

30'

 

120'

 

 

170'

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

EF60T150, EF100T199

 

30'

 

100'

 

 

150'

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

EF60T199

 

30'

 

80'

 

 

130'

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

EF100T250

 

N/A

 

80'

 

 

130'

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

EF100T300

 

N/A

 

60'

 

 

110'

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

EF100T399

 

N/A

 

50'

 

 

100'

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Unbalanced Direct Vent Systems

 

 

 

 

 

 

 

 

Air intake CAN NOT exceed exhaust

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

by more than 30 feet

 

 

 

 

 

Note: each 3" & 4" 90° Elbow is equivalent to 5 feet of straight pipe.

Note: each 3" & 4" 45° Elbow is equivalent to 2.5 feet of straight pipe.

Power Vented Systems

PVC, CPVC

Total length of exhaust piping must not exceed “Maximum Vent Length”

Shown below

Maximum Vent Length (feet)

 

Model Number

2"

3"

4"

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

EFR-1-60T120

60'

120'

170'

 

 

 

 

 

 

 

 

 

 

 

 

EF60T125, EF100T150

30'

120'

170'

 

 

 

 

 

 

 

 

 

 

 

 

 

 

EF60T150, EF100T199

30'

100'

150'

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

EF60T199

30'

80'

130'

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

EF100T250

N/A

80'

130'

 

 

 

 

 

 

 

 

 

 

 

 

 

EF100T300

N/A

60'

110'

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

EF100T399

N/A

50'

100'

 

 

 

 

 

 

 

 

 

 

 

 

 

 

WARNING! The EF100T250 and EF100T300 models are not approved for 2 inch diameter vent pipe. Venting with 2 inch pipe on these models may result in damage to the water heater or cause an unsafe condition. DO NOT use 2 inch Vent or Air Intake Pipe on EF100T250/300 models.

78

78

R

Date

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Service Provider

 

 

 

Model Number

 

 

Phone Number

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Serial Number

 

 

 

 

Venting (PVC, CPVC):

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Vent size 3" or 4"

 

 

 

 

 

 

 

 

 

Length of straight pipe

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Intake 90's (qty)

 

 

Intake 45's (qty)

 

 

 

 

 

 

(intake)

 

 

Exhaust 90's (qty)

Exhaust 45's (qty)

 

 

 

 

 

 

Length of straight pipe

 

 

 

 

 

 

(exhaust)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Gas Line:

 

 

 

Gas Pressure:

 

Venturi:

 

 

 

Size & material

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Static

 

Setting from Bottom in Turns

 

 

 

Distance from meter

 

Running Inlet

 

 

 

 

 

 

to water heater

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Manifold

 

 

 

 

Electrical:

Line Voltage

 

 

 

Low Voltage

 

 

 

Polarity

Igniter Resistance:

 

Flame Sense Micro -Amps:

 

 

 

 

 

 

 

Spark Gap: ___________

 

 

 

 

 

LED Flashing Y or N

Which One(s)

 

 

 

 

 

Error Codes on Control Display (Direct Spark Ignition System Only): __________________________________

Condensate Line:

 

 

 

Exhaust Collector

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Size & Material

 

 

 

 

 

 

Pressure:

 

 

 

 

 

 

 

 

 

 

 

 

Length

 

 

 

 

 

 

Positive Inches W.C.

 

Is trap provided Y or N

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Combustion:

 

CO2

 

CO

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Installation Site Name & Address:

Installation Site Contact Name &

Phone Number

79

79

Models prior to “CF” serial number

1

Combustion Surround Assy.

2

Burner Assy

3

2nd Pass Top Collector Cover

4

Screw 10-16x 3/4

5

Vent Termination Elbow

6

Thermostat Sensor Probe

7

Baffle 4" Flue

8

Anode

9

Baffle 2" Flue

10

Wire Harness Service Panel

11

Plastisert Nipple 1-½"NPT

12

Plug

13

Nipple

14

T&P Relief Valve

15

Exhaust Pipe (PVC) w/Hose Barb

16

Condensate Trap Elbow

17

Silicone Hose

18

Outer Door Service Panel

19

Vent Pipe Support Bracket

20

NSF Escutcheon

 

 

21

Exhaust Pressure Switch

 

C

22

Nut

23

Vent Safety Switch

24

Screw 6-32x3/8

25

Cleanout Access Cover

26

Cleanout Gasket

27

Screw 5/16-18x ¾ HH Grade 5

28

Cleanout Cover

29

Cold Water Inlet

30

No Handle Brass Drain Valve

31

Coaxial Vent System

32

ASSE Approved Mixing Valve

Customer must specify complete model number and serial number when ordering service parts.

80

80

Models prior to “CF” serial number

AA

Latch Assy

BB

Screw 8-32x ½ RHCR

CC

Ignition Control Assy

DD

Jacket Head

EE

Main Power Switch

FF

Potentiometer

GG

Combustion Surround

JJ

Surround Base

 

 

Customer must specify complete model number and serial number when ordering service parts.

1A

Combustion Surround Assy.

2A

Blower Gas Valve Assy

3A

Burner Assy

4A

Blower EBM

5A

Silicone Hose

6A

Hose Tee Fitting

7A

Screw 10-32x3/4

8A

Gasket & Screw

9A

Gas Valve

10A

Nipple ½" NPT X3"

11A

Reducer ¾ x ½ NPT

12A

Nipple ¾ NPT x 6"

13A

2" dia. Flex Reducer

14A

Inlet (PVC)

15A

Gasket Blower Transition

16A

Screw 8-32x ¼ RHCR

17A

Gasket Flame Sensor

18A

Flame Sensor

19A

Transition Tube

20A

Nut Hex Washer

21A

Gasket Hot Surface Igniter

22A

Hot Surface Igniter

23A

Burner Mounting Gasket

24A

Burner Tube

25A

Burner Mounting Gasket

26A

Burner Mounting Insert

27A

Burner Mounting Insert Gasket

81

81

Models prior to “CF” serial number

1C

Electronic Control Module

2C

Screw 8-32x 1/2

3C

Intake Pressure Switch

4C

Control Mounting Panel

5C

Thermostat PC Board

6C

Transformer 120VAC x 24VAC x 40VA

7C

Terminal

8C

Terminal Strip

9C

Power Cord

10C

Control Wire Harness

11C

Thermostat Wire Harness

12C

Igniter Extension Wire

13C

Blower Wire Harness

14C

Power Switch Wire Harness

15C

Flame Sensor Wire Harness

16C

Rectifier Harness

Customer must specify complete model number and serial number when ordering service parts.

82

82

For models with “CF” serial or later.

1

Combustion Surround Assy.

2

Burner Assy (specify model)

3

2nd Pass Top Collector Cover

4

Screw 10-16x 3/4

5

Vent Termination Elbow

6

Thermostat Sensor Probe

7

Baffle 4" Flue (specify model)

8a

Anode Rod Assy

8b

Powered Anode (for EF100T399)

9

Baffle 2" Flue

10

Wire Harness Service Panel

11

Plastisert Nipple 1-½"NPT

 

 

12

Plug

13

Nipple

14

T&P Relief Valve

15

Exhaust Pipe (PVC) w/Hose Barb

(except EF100T399)

 

16

Condensate Trap Elbow (specify model)

17

Silicone Hose

18

Outer Door Service Panel (specify model)

19

Vent Pipe Support Bracket (except

EF100T399)

 

20

NSF Escutcheon

21

Exhaust Pressure Switch

22

Nuts

23

Collector Temperature Limit Switch

24

Screw 6-32x3/8

25

Cleanout Access Cover

26

Cleanout Gasket

27

Screw 5/16-18x ¾ HH Grade 5

28

Cleanout Cover

29

Cold Water Inlet (Hydrojet) Assy.

30

No Handle Brass Drain Valve

31

Concentric Vent System (optional)

32

ASSE Approved Mixing Valve (optional)

Customer must specify complete model number and serial number when ordering service parts.

83

83

For models with “CF” serial or later.

AA

Latch Assy

BB

Screw 8-32x ½ RHCR

CC

Ignition Control Assy

DD

Jacket Head

 

 

EE

Main Power Switch

FF

Potentiometer

GG

Combustion Surround

JJ

Surround Base

Customer must specify complete model number and serial number when ordering service parts.

1A

Combustion Surround Assy. (specify

model)

 

2A

Blower Gas Valve Assy (specify model)

3A

Burner Assy (specify model)

4A

Blower EBM (specify model)

5A

Silicone Hose

6A

Burner Mounting Insert Gasket

7A

Screw 10-32x3/4

8A

Gasket & Screw

9A

Gas Valve (specify model)

10A

Nipple (specify model)

11A

Reducer (specify model)

12A

Nipple (specify model)

13A

2" dia. Flex Reducer (or PVC reducer for

 

399)

14A

Inlet (PVC)

15A

Gasket Blower Transition (specify model)

16A

Screw 8-32x ¼ RHCR

17A

Gasket Flame Sensor

18A

Flame Sensor

19A

Transition Tube

20A

Nut Hex Washer

21A

Gasket Hot Surface Igniter

22A

Hot Surface Igniter

23A

Burner Mounting Gasket

24A

Burner Tube

25A

Burner Mounting Gasket

26A

Burner Mounting Insert

 

 

 

84

84

For models with “CF” serial or later.

1C

Electronic Control Module

2C

Screw 8-32x 1/2

3C

Control Mounting Panel

4C

Thermostat PC Board

5C

Transformer 120VAC x 24VAC x 40VA

6C

Terminal

7C

Terminal Strip

8C

Power Cord

9C

Control Wire Harness

10C

Thermostat Wire Harness

11C

Rectifier Harness (specify model)

12C

Blower Wire Harness (specify model)

13C

Power Switch Wire Harness

14C

Flame Sensor Wire Harness

15C

Powered Anode Control Harness (399 only)

16C

Powered Anode Harness (399 only)

17C

Powered Anode Control (399 only)

 

 

Customer must specify complete model number and serial number when ordering service parts.

85

85

For models with Direct Spark Ignition

1

Combustion Surround Assembly

2

Burner Assembly (specify model)

3

2nd Pass Top Collector Cover

4

Screw 10-16x 3/4

5

Vent Termination Elbow

6

Thermostat Sensor Probe

7

Baffle 4" Flue (specify model)

8

Anode Rod Assembly

9

Baffle 2" flue

10

Wire Harness Service Panel

11

Plastisert Nipple 1-½"NPT

12

Plug

13

Nipple

14

T&P Relief Valve

15

Exhaust Pipe (PVC) w/Hose Barb

 

Condensate Trap Elbow (specify model)

16

 

 

17

Silicone Hose

18

Outer Door Service Panel (specify model)

19

Vent Pipe Support Bracket

20

NSF Escutcheon

21

Exhaust Pressure Switch

22

Nuts

23

Collector Temperature Limit Switch

24

Screw 6-32x3/8

25

Cleanout Access Cover

26

Cleanout Gasket

27

Screw 5/16-18x ¾ HH Grade 5

28

Cleanout Cover

29

Cold Water Inlet (Hydrojet) Assembly

30

No Handle Brass Drain Valve

31

Concentric Vent System (optional)

32

ASSE Approved Mixing Valve (optional)

33

Thermal Well

34

Clip

35

Hole Closure

36

Reducer

 

 

Customer must specify complete model number and serial number when ordering service parts.

86

86

For models with Direct Spark Ignition

1B

Latch Assy

2B

Screw 8-32x ½ RHCR

3B

Ignition Control Assy

4B

Jacket Head

 

 

5B

Main power switch

6B

Honeywell Control Display

7B

Combustion Surround

8B

Surround Base

Customer must specify complete model number and serial number when ordering service parts.

4B

1B

3B

7B

5B

6B

1B

2B

8B

2A

4A

5A

 

 

 

 

 

 

 

1A

Combustion Surround Assembly

 

 

8A

9A

 

1A

(specify model)

 

 

 

 

 

 

 

 

 

 

 

2A

Blower Gas Valve Assy. (specify model)

 

 

 

 

 

 

3A

Burner Assy. (specify model)

 

7A

 

 

 

 

4A

Blower EBM (specify model)

 

 

 

 

 

 

5A

Silicone Hose

 

15A

 

 

 

 

6A

Burner Mounting Insert Gasket

 

 

 

 

 

7A

Screw 10-32x3/4

 

 

 

 

 

 

 

 

 

 

 

 

8A

Gasket

16A

 

 

 

 

 

9A

Gas Valve (specify model)

20A

16A

 

 

 

10A

Nipple (specify model)

17A

 

 

 

 

 

 

 

 

 

 

21A

 

 

 

11A

Reducer (specify model)

18A

 

22A

 

 

 

3A

 

 

 

 

 

12A

Nipple (specify model)

 

 

 

 

 

13A

2" dia. Flex Reducer

 

 

 

 

 

 

 

23A

 

 

 

 

14A

Inlet (PVC)

 

24A

 

 

 

 

15A

Gasket Blower Transition (specify model)

 

25A

 

 

 

 

16A

Screw 8-32x ¼ RHCR

 

 

 

 

 

17A

Gasket Flame Sensor

 

 

 

 

 

 

 

 

26A

 

 

 

18A

Flame Sensor

 

 

 

 

 

 

 

 

 

 

 

 

19A

Transition Tube

 

 

 

 

 

 

20A

Nut Hex Washer

 

 

 

 

 

 

21A

Spark Rod

 

 

6A

 

28A

 

22A

Spark Rod Gasket

 

 

 

 

23A

Burner Mounting Gasket

 

 

 

 

 

 

 

 

 

 

 

 

24A

Burner Tube

 

 

 

 

 

 

25A

Burner Mounting Gasket

 

 

 

 

 

 

26A

Burner Mounting Insert

 

 

 

 

 

 

27A

Ground Wire

 

 

 

 

 

 

28A

Gas Regulator Kit (Optional)

 

 

 

 

 

 

 

87

87

For models with Direct Spark Ignition

2C

8C

3C

4C

5C

9C

10C

1C

11C

12C

6C

13C

7C

1C

Control Panel

2C

Control Board

3C

Transformer 120VAC x 24VAC x 40VA

4C

Terminal

5C

Terminal Strip

6C

Power Cord

7C

Controller Wire Harness

8C

Transformer Primary Wire Harness

9C

Transformer Secondary Wire Harness

10C

Blower Wire Harness

11C

Power Switch Wire Harness

12C

Sensor Wire Harness

13C

High Voltage Spark Cable

Customer must specify complete model number and serial number when ordering service parts.

88

88

 

 

 

 

 

 

 

 

 

 

 

 

 

 

AC

Alternating Current

 

 

 

BTU/H

British Thermal Units

 

 

 

CO

Carbon Monoxide

 

 

 

CO2

Carbon Dioxide

 

 

 

DC

Direct Current

 

 

 

DSI

Direct Spark Ignition

 

 

 

ECO

Energy Cut Off

 

 

 

GFI

Ground fault interrupt

 

 

 

GPM

Gallons per Minute

 

 

 

HSI

Hot Surface Igniter

 

 

 

Hz

Hertz

 

 

 

LED

Light Emitting Diode

 

 

 

NOx

Oxides of Nitrogen

 

 

 

NPT

National Pipe Thread

 

 

 

PSI

Pounds per Square Inch

 

 

 

RPM

Revolutions per Minute

 

 

 

VA

Volt Amps

 

 

 

VAC

Volts Alternating Current

 

 

 

W.C.

Inches of Water Column

 

 

 

°C

Degrees Centigrade

 

 

 

°F

Degrees Fahrenheit

 

 

 

µA

Micro Amp

 

 

 

NOTES

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

89

89

NOTES

90

90

NOTES

91

91

Email parts@bradfordwhite.com techserv@bradfordwhite.com

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