Bradford White EF-100T-399-3X User Manual

Ultra High Efficiency Water Heaters

SERVICE

MANUAL

Troubleshooting Guide

and Instructions for Service

(To be performed ONLY by

qualified service providers)

Manual 238-45817-00F

Models Covered

by This Manual:

For The Bradford White
eF Series
Models:

EFR160T120*(EN,SX)
EF60T125(E)*(N,X)(A)(2)
EF60T150(E)*(N,X)(A)(2)
EF60T199(E)*(N,X)(A)(2)
EF100T150(E)*(N,X)(A)(2)
EF100T199(E)*(N,X)(A)(2)
EF100T250(E)*(N,X)(A)(2)
EF100T300(E)*(N,X)(A)(2)
EF100T399(E)*(N,X)(A)(2)
(*) Denotes Warranty Years

Save this manual for future reference

®

Ultra High Effeciency

The Bradford White

2

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

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.

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.

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-amps and 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 1-1/16 deep well
socket, wire cutters, wire strippers, wire crimpers, torpedo level, small
shop vac, step ladder, and flashlight.

4

4

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.

5

Serial Numbers including and AFTER GB13006174 and ALL EFR models

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

EFR-1-60T-120

EF60T125
EF60T150

EF60T199
EF100T150
EF100T199
EF100T250
EF100T300
EF100T399

120,000
125,000
150,000
199,999
150,000
199,999
250,000
300,000
399,999

180
187
211
265
250
309
364
405
521

345

363.6

422.7

557.6

450.5
597

734.8

836.4

1,127

138

145.5

169.1
223

180.2

238.8

293.9

334.5
451

99

103.9

120.8
158
129
171
210
239
322

60
60
60

60
100
100
100
100
100

95.0

96.0

93.0

92.0

99.1

98.5

97.0

92.0

93.0

57
57
57

57
77 5/8
77 5/8
77 5/8
77 5/8
77 5/8

28 ¼
28 ¼
28 ¼
28 ¼
28 ¼
28 ¼
28 ¼
28 ¼
28 ¼

5
5
5
5
5
5
5
5
5

13
13
13
13
13
13
13
13
13

40
40
40
40
60
60
60
60
60

42 ¼
42 ¼
42 ¼
42 ¼
62 ¼
62 ¼
62 ¼
62 ¼
62

¼

52 ½
52 ½
52 ½

52 ½
73 1/8
73 1/8
73 1/8
73 1/8
73 1/8

53 ½
53 ½
53 ½
53 ½
74 ¾
74 ¾
74 ¾
74 ¾
73 ¼

1
1 ½
1 ½
1 ½
1 ½
1 ½
1 ½
1 ½
1 ½

1
1
1
1
1
1
1
1
1

¾
¾
¾
¾
¾
¾
¾
¾

1

¾
¾
¾
¾
¾
¾
¾
¾

1

570
570
570
570
900
900
900
900
950

Shpg

Wt

(lbs)

T&P
Valve
Open
(NPT)

Gas

Conn

Dia

(NPT)

Space

Heating

Conn

Dia

Front

Wtr

Conn

Dia

H

Flr to

Gas

Conn

G

Flr. To

Air

Intake

F

Flr To
Outlet

Wtr

Conn

E

Flr to

T&P
Valve
Conn

D

Flr to

Inlet

Wtr

Conn

C

Flr

to

Vent

Outlet

B

Dia

A

Ht

Therm

Eff

%

Stg
Cap
U.S.

Gal

140°F100°F40°F

1st Hr

Del

Gal

@

100°F

Rise

Input
Rate

BTU/h

Model No

R

ecovery GPH

at Degree Rise

DIMENSIONS (INCHES)

6

6

7

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

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

Hot Surface Igniter 120VAC, 30-120 ohms @ room temperature.

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

Temperature Dial Min. set point 5400-6600 ohms, Max set point 0-50 ohms.

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

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

Transformer 120VAC primary, 24VAC secondary, 40VA.

Vent Safety Switch Normally closed, opens @ 350°F, manual reset.

Intake Pressure Switch
“CF” serial number or
later

Not required.

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

Exhaust pressure switch
serial numbers prior to
“CF”

24VAC, normally open, closes on pressure increase as follows
Note 1:

+2.58" W.C. EF(60,100)T199
+1.50" W.C. EF100T150 (see note 2)
+1.22" W.C. EF60T150, EF100T250
+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

Power supply Dedicated 120 VAC, 60 Hz, 15A, GFI

Approved Gas Type Natural or Propane. Unit must match gas type supplied.

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

Approved Vent Materials PVC or CPVC

Gas Supply

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

schedule 40 black iron pipe recommended)

Minimum Clearance
for Servicing

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

Maximum Water Supply
Pressure

150 PSI

Gas Pressure (Nat & L.P.) 14.0" W.C. maximum static, 4.5" W.C. minimum running (recommend 7.0" W.C. min running)

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

Intake Pressure Switch
serial numbers prior to
“CF”

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

Blocked Vent Pressure
Switch “CF” serial
number or later

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

7

8

Power supply Dedicated 120 VAC, 60 Hz, 15A

Thermostat Sensor

11,900 Ohms @ 70°F, ECO opens @ 207°F Max., ECO close @ 120°F Min. Redundant
sensor for ECO. Sensor inside well for easy replacement of sensor.

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.

Control Display

Digital display, 24 volts. Temperature Range: 70-180 deg. F. Used to set tank temperature
(deg. F or deg. C), show operating status, Display error codes, error code history, limit
maximum setpoint temperature.

Control Board

Operates from 24 volt from transformer. Controls tank temperature, ignition functions,
combustion blower. See ignition timings in sequence of operation for Integrated Control.

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

Transformer 120VAC primary, 24VAC secondary, 40VA.

Vent Safety Switch Normally closed, opens @ 350°F, manual reset.

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

Approved Gas Type Natural or Propane. Unit must match gas type supplied.

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

Approved Vent Materials PVC or CPVC

Gas Supply

Minimum ¾" NPT
(

schedule 40 black iron pipe recommended)

Minimum Clearance
for Servicing

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

Maximum Water Supply
Pressure

150 PSI

Gas Pressure (Nat & L.P.) 14.0" W.C. maximum static, 4.5" W.C. minimum running (recommend 7.0" W.C. min running)

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

Blocked Vent Pressure
Switch

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

Serial Numbers including and AFTER GB13006174 and ALL EFR models

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

Notes:

1) Multiply the total number of 90° elbows (intake and exhaust) by 5 feet. Do not include the
termination fittings or 3" condensate elbow.

2) Multiply the total number of 45° elbows (intake and exhaust) by 2 ½ feet.

3) Add this to the total length of straight pipe - intake and exhaust.

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.

Unbalanced Direct Vent Systems

Air intake CAN NOT exceed exhaust

by more than 30 feet

Power Vented Systems

PVC, CPVC

Total length of exhaust piping must not exceed

“Maximum Vent Length”

Shown below

Maximum Vent Length (feet)

Model Number 3"

EF60T125, EF100T150 120'

EF60T150, EF100T199

EF60T199

EF100T300

100'

80'

60'

4"

170'

150'

130'

110'

EF100T399 50' 100'

EFR-1-60T120 60' 120'2"170'

30'

30'

30'

N/A

N/A

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 3"

EF60T125, EF100T150 120'

EF60T150, EF100T199

EF100T250

EF100T300

100'

80'

60'

4"

170'

150'

130'

110'

EF100T399 50' 100'

EFR-1-60T120 60' 120'2"170'

30'

30'

N/A

N/A

N/A

9

EF60T199 80' 130'30'

EF100T250 80' 130'N/A

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.

9

1

Thermostat calls for heat.

-Prior to 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.

2

Blower energizes.

3

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.

4

Blower pre-purge period (5 seconds) indicated by the PURGE LED on the module.

5

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

6

Trial 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.

7

Steady 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-energized and system attempts re-ignition starting at pressure switch proving mode.

-Flame sensor circuit.

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

Thermostat satisfies.

Burner off.

Blower post purge (15 seconds).

9

8

10

For models prior to CF serial numbers

For models prior to CF serial numbers

10

10

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.

For models prior to CF serial numbers

Ignition Module Specifications

- 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-interchangeable polarized plug-in connectors for all interconnections.

Control Functions:

- Thermostat call for heat.

- Limit Switch Circuit (normally closed)

- Pressure Switch Circuit (normally open)

- Flame sensing.

- Low voltage supply.

- Line voltage supply.

Control Inputs: Control Outputs:

Lockout Conditions

- Inducer motor

- Hot surface igniter

- Gas valve

- Status indicator LEDs
Power - Green
Purge - Red
Igniter - Red
Valve - Red
Flame - Red

WIRING DIAGRAM

IGNITION MODULE

For models prior to CF serial numbers

11

11

1

Thermostat calls for heat.

2

Blower 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.

3

6

Steady 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-energized and system attempts re-ignition if 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.

For models starting with

CF serial numbers and later.

For models starting with CF serial numbers and later.

Prior to energizing blower, ignition module checks to make sure the vent temperature switch is in the normally closed
p

osition. If the vent temperature switch is open, the control waits indefinitely for the temperature switch to close.

B

lower pre-purge period (5 seconds) indicated by PURGE LED on the module

4

Igniter 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.

5

Trial 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.

7

Thermostat satisfied.

8

Burner off.

9

Blower post purge (15 seconds).

12

12

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-III for Burner Tube Inspection and Replacement.

For models starting with

CF serial numbers and later.

Ignition Module Specifications

- 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-interchangeable polarized plug-in connectors for all interconnections.

Control Functions:

- Thermostat call for heat.

- Blocked vent pressure switch
(normally closed)

- Flame sensing.

- Low voltage supply.

- Line voltage supply.

Control Inputs: Control Outputs:

Lockout Conditions

- Inducer motor

- Hot surface igniter

- Gas valve

- Status indicator LEDs
Power - Green
Purge - Red
Igniter - Red
Valve - Red
Flame - Red

IGNITION MODULE

For models starting with CF serial numbers and later.

WIRING DIAGRAM

13

13

For models with Honeywell Integrated Control

System w/ Direct Spark Ignition

T

hermostat calls for heat.

Combustion blower starts.

Blower pre-purge period of 30 seconds.

Trial 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.

Steady State Operation: Burner continues to operate until:

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

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.

Thermostat satisfied

Gas valve closes, burner extinguished.

Blower post purge for 30 seconds.

1

2

3

5

6

7

8

4

14

Serial Numbers including and AFTER GB13006174 and ALL EFR models

(Excluding EF100T399 model series)

14

For models with Honeywell Integrated Control

System w/ Direct Spark Ignition

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-purge and 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.

Lockout Conditions

CONNECTION/WIRING DIAGRAM

15

LINE IN

PRIMARY

SECONDARY

CONTROL

E-COM

1

2

3

E-COM

1

3

2

SENSE

SENSOR 1

987

654

321

1

2

1

2

3

4

1

2

3

321

120 VOLTS A C

LINE

LOAD

24V

1

2

3

M

COMBUSTION

BLOWER

PV/MV

MV

GAS VALVE

LOWER

SENSOR

& ECO

6 PIN CONNECTOR

TO PRESSURE

SWITCH HARNESS

IF ANY OF THE ORIGINAL W IRES AS SUPPLIED W ITH THE APPLIANCE

105°C WIRE OR ITS EQUIVALENT.

MUST BE REPLACED. IT MUST BE RE PLACED WITH 18. GA STRANDED

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

NOTE:

CONNECTION DIAGRAM

WIRING DIAGRAM

CONTROL

DISPLAY

TRANSFORMER

120V

HIGH VOLTAGE

SPARK

120V

24V

24V

24V

120 VAC

BLACK

120 VOLTS

120 VOLT S

24 V.

WHITE

GROUND

INDUCER

41

52

63

BK

BK

Y

BK

O

BL

BR

W

BK

W

BL

W

GN

BK

Y

W
R

W

Y

M

DISPLAY

HIGH VOLTAGE

SPARK

SENSE

R

R

MV

GAS VALVE

M

BLOWER RELAY COIL

W

O

PV

(BOARD CIRCUIT)

5

2

P.S.

BLOWER RELAY

BLOWER MOT OR

GN

GN

R

R

GY

GY

NC

COLLECTOR

LIMIT

ECOTSTAT

G

GND

N

L1

TOGGLE SWITCH

LIGHT

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

GY

R

R

GY

GY

P.S. (N.C.)

COLL HIGH -LIMIT
LIMIT (N.C.)

CONTROL BOARD

W

BK

Serial Numbers including and AFTER GB13006174 and ALL EFR models

15

Refer to ignition module

illustration, is there 120VAC

between P1(1) and P1(3)?

Is front panel power

switch light on,

indicating power?

Y

N

Position front panel

power switch to

“ON” position.

Is there 120VAC

across switch?

(see photo at right)

Light burned out,

replace switch.

Y

Is there 120VAC

a

cross terminal block?

(see photo at right)

N

Determine power

source problem and

correct.

Repair/replace wire

harness to switch.

Y

N

Is ignition module

power light on?

N

Y

Refer to ignition module

illustration, is there 120VAC

going to module at locations

P7(1) and P7(3)?

N

Replace ignition module.

(see “Ignition Module Replacement”)

Replace transformer.

(see “Transformer Replacement”)

N

N

Y

Y

Is ignition module

power and flame light

flashing?

Reset heater by

interrupting power.

Reestablish power and

Adjust thermostat to

call for heat,

tank must be cold.

Allow heater to run

through heating cycle.

Did heater complete

heating cycle and did

blower post purge?

See next page

System is OK.

Supply voltage polarity

is incorrect.

Y

N

N

Y

Refer to ignition module

illustration, is there 24VAC

going to module at locations

P2(1) and P2(2)?

System Observation

For models with Hot Surface Ignition

IGNITION MODULE

WARNING

120 volt potential exposure. Use caution

making voltage checks to avoid personal injury.

16

Power Switch

Terminal Block

Replace ignition module.

(see “Ignition Module Replacement”)

16

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 & probable cause

For models with Hot Surface Ignition

LED STATUS

Power & flame

light flashing.

Probable Cause

Supply voltage

polarity.

LED STATUS

Valve light flashing.

Probable Cause

Flame sensor.

(see “Flame Sensor

Testing and Replacement”)

Probable Cause

Hot surface igniter.

(see “Hot Surface

Igniter Testing and

Replacement”)

Probable Cause*

Combustion system.

(see “Combustion

System 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

Blower.

(see “Blower Testing

and Replacement”)

Probable Cause*

Exhaust pressure

switch. (see “Exhaust

Pressure Switch

Testing and

Replacement”)

LED STATUS

Purge light flashing.

LED STATUS

Only power light

is on and water heater

will not function.

Probable Cause

Thermostat circuit.

(see “Thermostat Circuit

Testing and Replacement”)

Probable Cause*

Exhaust pressure

switch. (see “Exhaust

Pressure Switch

Testing and

Replacement”)

Probable Cause

Vent safety switch.

(see “Vent Safety Switch

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.

C

heck 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.

Check wires for proper termination

to control display.

Are wire terminations connected

properly to control display?

N

Y

CAUTION

Use caution not to damage connectors when

making voltage measurements or jumping terminals

WARNING

120 volt potential exposure. Use caution

making voltage checks to avoid personal injury.

Is 24VAC present between

RED and BLACK wire pin

connections on the back of

Control Display?

12

3

865

431

12

1

4

1

3

3
2
1

1

5

3

P2P4P5 P7P3

CONTROL BOARD

P10P9J1

Refer to Control Board illustration.

Voltage at primary pins P2(1) & P2(3)

will be 110-120. If not, check Line In

pins P3(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.

Does water heater display operate?

Does the combustion blower start to

operate? Increase thermostat setting if

tank is warm.

Is 24VAC present between E-COM

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

the Control Board.

Y

N

Replace Control

Display.

N

Display Operates - See next

page

Transformer

Top terminals are 24VAC;

Bottom terminals are 120VAC

18

Y

Make proper wire

terminations

N

Replace

Control Board

Y

Check wire
harness for

proper continuity

18

System Observation

For models with Direct Spark Ignition

Does combustion blower operate?

Error code #29 on display. Refer to Control Board

illustration. Measure voltage between terminals P7(3) &

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

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

setpoint). Is there 110-120 VAC?

Replace control board if display

shows “heating” and no voltage is

present to the blower harness.

Make sure there are no error

codes for the temperature

sensors (following sections)

before replacing control board.

Check the voltage at the connection to the

blower. Is 110-120 VAC present?

Can sparking be seen/heard at the

spark rod to the burner?

Does Main Burner Light?

Error code #62 on display. See

main burner lights, no flame signal

in section “Combustion System

Testing and Replacement”

Does burner continue until

thermostat set point is reached?

See setting display in Service Mode

and displaying temperature

sensors.

Error code #63 on display. (see

“Combustion System Testing and

Replacement”)

Does blower post-purge for 30

seconds?

System okay

N

Y

N

N

N

Y

Y

Y

Y

From previous page

N

CAUTION

Use caution not to damage connectors when

making voltage measurements or jumping terminals

WARNING

120 volt potential exposure. Use caution

making voltage checks to avoid personal injury.

12

3

865

431

12

1

4

1

3

3
2
1

1

5

3

P2P4P5 P7P3

CONTROL BOARD

P10P9J1

Y

Replace wire harness.Replace blower.

N

Remove high voltage wire connected at the spark rod and

hold approximately ¼" from metal ground with insulated

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

Is there spark to ground?

N

Check resistance of high voltage

cable. Resistance should be 0-1
ohms. If resistance is high, replace
spark cable. If spark cable is good,

replace Control Board.

Check continuity of spark rod and spark rod

gap to burner.

(see section “Spark Rod Gap Adjustment”)

Y

Y

19

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.

19

Accessing Service Mode on Control Display

For models with Honeywell Integrated Control

T

he 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.

Step 2: Pressing “Select” button will change display to next mode

SELECT SET

Status

°F

idle

O

perational

Wate

r

T

emp

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”.

SELECT Lockout RESET

Status

Service Needed

Error Code Shown
in Water Heater Display

20

S

ELECT SE

T

S

tatus

idle

O

perational

%

"Max Setpoint"

n

ext to Temperature

Setpoint value.

&

Max

S

etpoin

t

20

Accessing Service Mode on Control Display

For models with Honeywell Integrated Control

1. Max Setpoint (Display/Change)

2. Tank Sensor Temperature Displayed Water Temperature Average.

SELECT SET

Status

°F

idle

Water Temp

O

perational

21

S

ELECT SET

S

tatus

°F

i

dle

O

perational

Max Setpoint value in

Water Heater Display

Max

S

etpoin

t

&

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

SELECT SET

Status

H

eating

Operational

Flame Current

µ

A

21

Accessing Service Mode on Control Display

For models with Honeywell Integrated Control

4. Setpoint (Display/Change)

S

ELECT SET

Status

°

F

i

dle

setpoint

O

perational

5. °F/°C (Display/Change)

S

ELECT SET

S

tatus

°F/C°

idle

O

perational

°F

s

etpoint

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

SELECT SET

Status

°F

idle

Differential

Operational

22

22

Accessing Service Mode on Control Display

For models with Honeywell Integrated Control

7. Software Version (Display only)

8. Error Code History (Displays if there are present error codes or up to 10 previous error codes). Water Heater
Display will show a “--“ if there are no error codes.

S

ELECT SET

S

tatus

i

dle

O

perational

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.

23

SELECT SET

Status

idle

O

perational

S

oft

&

SELECT SET

S

tatus

°F

idle

Max

Operational

Setpoin

t

&

23

Accessing Service Mode on Control Display

For models with Honeywell Integrated Control

S

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

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.

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

"Max Setpoint" stops flashing

SELECT SET

Status

°F

idle

Operational

Max

Setpoin

t

%

SELECT SET

Status

°

F

idle

Operational

Max

Setpoin

t

%

"Max Setpoint" continues to flash

while making adjustments

24

SELECT SET

Status

°F

idle

Operational

Max

S

etpoint

%

"Max Setpoint" Flashes

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
S

etpoint” 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.

SELECT SET

Status

idle

Operational

M

ax

Setpoint

%

&

Exiting Service Mode

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.

25

SELECT SET

Status

°F

idle

Operational

Lower Senso

r

&

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).

SELECT SET

S

tatus

Operational

Flame

Current

Heating

µA

To Display and Change Temperature Setpoint:

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

SELECT SET

Status

°

F

i

dle

setpoint

Operational

26

26

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.

SELECT SET

Status

°F

idle

setpoint

Operational

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

SELECT SET

Status

°F

idle

setpoint

Operational

%

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

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”.

SELECT SET

Status

°F

idle

setpoint

Operational

"Setpoint" Flashes

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.

SELECT SET

Status

°F

idle

setpoint

Operational

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.

S

ELECT SET

Status

i

dle

Operational

°F °F/C°

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

SELECT SET

Status

idle

Operational

°F °F/C°

28

28