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

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Page 1

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

Page 2

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 - - -

Page 3

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.

Page 4

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.

Page 5

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.

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.

Page 6

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

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

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

570 570 570 570 900 900 900 900 950

Shpg

(lbs)

T&P Valve Open (NPT)

Gas

Conn

Dia

(NPT)

Space

Heating

Conn

Dia

Front

Wtr

Conn

Dia

Flr to

Gas

Conn

Flr. To

Air

Intake

Flr To Outlet

Wtr

Conn

Flr to

T&P Valve Conn

Flr to

Inlet

Wtr

Conn

Flr

Vent

Outlet

Dia

Therm

Eff

Stg Cap U.S.

Gal

140°F100°F40°F

1st Hr

Del

Gal

100°F

Rise

Input Rate

BTU/h

Model No

ecovery GPH

at Degree Rise

DIMENSIONS (INCHES)

Page 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.

Page 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.

Page 9

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'

170'

150'

130'

110'

EF100T399 50' 100'

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

30'

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'

170'

150'

130'

110'

EF100T399 50' 100'

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

30'

N/A

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.

Page 10

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.

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.

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

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

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.

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).

For models prior to CF serial numbers

Page 11

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

Page 12

Thermostat calls for heat.

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.

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.

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

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.

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.

Thermostat satisfied.

Burner off.

Blower post purge (15 seconds).

Page 13

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

Page 14

For models with Honeywell Integrated Control

System w/ Direct Spark Ignition

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.

Serial Numbers including and AFTER GB13006174 and ALL EFR models

(Excluding EF100T399 model series)

Page 15

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

LINE IN

PRIMARY

SECONDARY

CONTROL

E-COM

SENSE

SENSOR 1

987

654

321

120 VOLTS A C

LINE

LOAD

24V

COMBUSTION

BLOWER

PV/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

120 VAC

BLACK

120 VOLTS

120 VOLT S

24 V.

WHITE

GROUND

INDUCER

W R

DISPLAY

HIGH VOLTAGE

SPARK

SENSE

GAS VALVE

BLOWER RELAY COIL

(BOARD CIRCUIT)

P.S.

BLOWER RELAY

BLOWER MOT OR

COLLECTOR

LIMIT

ECOTSTAT

GND

TOGGLE SWITCH

LIGHT

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

P.S. (N.C.)

COLL HIGH -LIMIT LIMIT (N.C.)

CONTROL BOARD

Serial Numbers including and AFTER GB13006174 and ALL EFR models

Page 16

Refer to ignition module

illustration, is there 120VAC

between P1(1) and P1(3)?

Is front panel power

switch light on,

indicating power?

Position front panel

power switch to

“ON” position.

Is there 120VAC

across switch?

(see photo at right)

Light burned out,

replace switch.

Is there 120VAC

cross terminal block?

(see photo at right)

Determine power

source problem and

correct.

Repair/replace wire

harness to switch.

Is ignition module

power light on?

Refer to ignition module

illustration, is there 120VAC

going to module at locations

P7(1) and P7(3)?

Replace ignition module.

(see “Ignition Module Replacement”)

Replace transformer.

(see “Transformer Replacement”)

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.

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.

Power Switch

Terminal Block

Replace ignition module.

(see “Ignition Module Replacement”)

Page 17

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”)

Page 18

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.

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?

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?

865

431

3 2 1

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.

Replace Control

Display.

Display Operates - See next

page

Transformer

Top terminals are 24VAC;

Bottom terminals are 120VAC

Make proper wire

terminations

Replace

Control Board

Check wire harness for

proper continuity

Page 19

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

From previous page

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.

865

431

3 2 1

P2P4P5 P7P3

CONTROL BOARD

P10P9J1

Replace wire harness.Replace blower.

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?

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”)

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.

Page 20

Accessing Service Mode on Control Display

For models with Honeywell Integrated Control

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

perational

Wate

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

ELECT SE

tatus

idle

perational

"Max Setpoint"

ext to Temperature

Setpoint value.

Max

etpoin

Page 21

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

perational

ELECT SET

tatus

°F

dle

perational

Max Setpoint value in

Water Heater Display

Max

etpoin

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

SELECT SET

Status

eating

Operational

Flame Current

Page 22

Accessing Service Mode on Control Display

For models with Honeywell Integrated Control

4. Setpoint (Display/Change)

ELECT SET

Status

dle

setpoint

perational

5. °F/°C (Display/Change)

ELECT SET

tatus

°F/C°

idle

perational

°F

etpoint

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

SELECT SET

Status

°F

idle

Differential

Operational

Page 23

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.

ELECT SET

tatus

dle

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.

SELECT SET

Status

idle

perational

oft

SELECT SET

tatus

°F

idle

Max

Operational

Setpoin

Page 24

Accessing Service Mode on Control Display

For models with Honeywell Integrated Control

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

SELECT SET

Status

idle

Operational

Max

Setpoin

"Max Setpoint" continues to flash

while making adjustments

SELECT SET

Status

°F

idle

Operational

Max

etpoint

"Max Setpoint" Flashes

Page 25

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

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.

SELECT SET

Status

°F

idle

Operational

Lower Senso

Page 26

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

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

dle

setpoint

Operational

Page 27

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

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

Page 28

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.

ELECT SET

Status

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°

Page 29

Accessing Service Mode on Control Display

For models with Honeywell Integrated Control

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

SELECT SET

Status

idle

Operational

°C

°F/C°

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

ELECT SET

Status

dle

Operational

F/C°

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

SELECT SET

Status

°F

idle

Operational

°F °F/C°

Page 30

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

SELECT SET

Status

°F

idle

Operational

Lower Sensor

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.

SELECT SET

idle

Service Needed

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.

Page 31

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 -- .

SELECT SET

Status

°F

dle

Operational

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

SELECT SET

Status

idle

Operational

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.

SELECT SET

Status

idle

Operational

Page 32

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.

SELECT SET

Status

idle

Operational

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

ELECT SET

Status

idle

Operational

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.

SELECT SET

Statu s

°F

idle

setpoint

Operational

Exiting Service Mode

Page 33

Error Code Definitions

For models with Honeywell Integrated Control

ERROR CODE DEFINITIONS

f 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

LOW FLAME SENSE CURRENT

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

FLAME DETECTED BEFORE IGNITION

FLAME DETECTED AFTER A HEATING CYCLE COMPLETES

PRESSURE SWITCH FAILED TO CLOSE OR OPEN (STUCK OPEN)

LOWER SENSOR READINGS FAULTY

FLAME ROD SHORTED TO GROUND

AC LINE FREQUENCY ERROR - SIGNAL TOO NOISY OR FREQUENCY INCORRECT

LINE VOLTAGE TOO LOW OR HIGH

DC OUTPUT VOLTAGE UNSTABLE

MAXIMUM NUMBER OF RETRIES DETECTED

MAXIMUM NUMBER OF IGNITION RECYCLES DETECTED

ELECTRONICS FAILURE

HIGH WATER TEMPERATURE (OVER 200°F)

DEFINITION

ERROR

CODE

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

Page 34

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.

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.

Lockout RESET

SELECT

Status

Service needed

Error Code Shown in Water Heater Display

Press for 2 seconds

SELECT SET

Status

Service Needed

SELECT Lockout RESET

Status

Service Needed

Error Code Shown in

Water Heater Display

Step 1: Press for 3 seconds

to enter service mode.

Step 2: Press for 3 seconds to

reset control in service mode.

Resetting Error Codes in Hard Lockout Condition

Page 35

IMPORTANT NOTE: This procedure assumes a cool tank

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

WARNING

Do not reset the display from the hard lockout

state without correcting the cause of the

overheating condition

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

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”).

Turn power “OFF”.

Draw water to cool tank below 120 °F

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

(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

(See Sensor Resistance

Testing, following section)

Condition: Water Heater Not Operating

Display shows error code “65”

High Water Temperature (over 200 °F)

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.

nplug or disconnect electrical power to the water heater

Condition: Water Heater Not Operating

Display shows error code “32” ( Sensor Reading

aulty)

Continued on

If sensor clip is damaged

replace clip. Replace

sensor if damaged.

Sensor shown fully

inserted into well

Sensor clip shown

installed properly

Checking continuity of

sensor (disconnected

at Control Board)

Serial Numbers including and AFTER

GB13006174 and ALL EFR models

(Excluding EF100T399 model series).

Page 36

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.

Serial Numbers including and AFTER GB13006174 and ALL EFR models

Page 37

Refer to ignition module

llustration, Is there 24VAC

between P3(7) and P3(8)?

OK, thermostat is

calling for heat.

Turn off power to heater.

Disconnect YELLOW and RED wires from the

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

photo at right. Use a jumper to connect these two

wires together as shown in photo at right.

Restore power to heater.

Did heater cycle on?

Check thermostat sensor

for proper resistance

(OHMS) across blue wires.

(See Appendix A, sensor

resistance)

Are readings correct?

(see photo at right)

Check temperature dial for proper resistance (OHMS)

(See Appendix B,

temperature dial resistance)

Are readings correct?

(see photo at right)

Replace

thermostat sensor.

(see Thermostat Sensor

Replacement Procedure)

Replace temperature dial

(potentiometer).

(see Thermostat Potentiometer

Replacement Procedure)

Replace thermostat

circuit board.

(see Thermostat Board

Replacement Procedure)

Check sensor harness

continuity.

Is there continuity?

Check temperature dial

harness continuity. Is there continuity?

Replace harness.

See page 39

IGNITION MODULE

IMPORTANT NOTE: This procedure assumes a cool tank

Rotate temperature

dial to highest setting.

Thermostat

not calling

WARNING

120 volt potential exposure. Use

caution making voltage checks

to avoid personal injury.

For models with Hot Surface Ignition

Thermostat

Sensor

Temperature Dial

Yellow & Red

wires shown

jumpered

Yellow Wire

(COM)

Red Wire

(N.O.)

Page 38

°F012345678 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

In Degrees F

APPENDIX - A

Sensor Resistance at Various Temperatures

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.

Be Careful When Making Voltage Measurements or Jumping Terminals

Not to Damage or Deform Connectors or Connector Pins.

APPENDIX - B

Temperature Dial Resistance

Proper Readings Should Be 5400-6600 Ohms at Minimum

Setting

And 0-50 Ohms at Maximum.

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.

Page 39

Refer to ignition module

illustration, Is there 120VAC

between P1(1) and P1(3)?

Refer to ignition module

illustration, Is there

22 - 27VAC between

P2(1) and P2(2)?

Refer to ignition module

illustration, Is there 120VAC

between P7(3) and P7(1)?

Replace transformer.

(see Transformer

Replacement)

Refer to ignition module

illustration, Is there 24VAC

between P3(9) and P2(1).

Check wire harness

continuity. Replace

thermostat sensor or wire

harness as necessary.

(see “Thermostat Sensor

Replacement Procedure”)

Check AC source to

determine why there is no

power.

Replace

ignition module.

(see “Ignition Module

Replacement”)

Check continuity through

ECO, red wires of thermostat sensor.

Check at temperature

less than 160°F Is there continuity? (see photo at right)

Replace ignition module.

(see “Ignition Module

Replacement”)

Replace thermostat

circuit board.

(see “Thermostat Board

Replacement Procedure”)

IGNITION MODULE

Thermostat circuit.

(continued from page 37)

WARNING

120 volt potential exposure. Use caution

making voltage checks to avoid personal injury.

For models with Hot Surface Ignition

Red Wires

(Temperature Sensor)

Page 40

WIRING DIAGRAM

For models prior to

CF serial number

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.

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-latch and remove top surround cover

from top of heater.

Step 4. Locate thermostat board on control panel.

(see photo at right)

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.

Thermostat

Board

Mounting

screw locations

Page 41

Thermostat Potentiometer Replacement Procedure

Step 4. Loosen set screw of adjusting

knob (small blade screw driver) and remove adjusting knob from potentiometer. (see photos at right)

Step 5. Remove retaining nut (½" wrench)

and washer from potentiometer. (see photos at right)

Step 6. 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)

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.

Step 1. Position main power switch to “OFF”

Step 2. Disconnect (unplug) water heater from

120 volt power source.

Step 3. Un-latch and remove top surround cover

from top of heater.

WARNING

120 volt potential exposure. Isolate the

appliance and reconfirm power is

disconnected using a multi-meter.

Temperature

Adjusting Knob

Indexing

Tab

Locating

Hole

Loosen set screw

with small blade

screw driver

Remove

retaining nut

Potentiometer

Wire Leads

Page 42

Thermostat Sensor (Thermister) Replacement Procedure

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).

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.

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-latch and remove top surround cover

from top of heater.

WARNING

120 volt potential exposure. Isolate the

appliance and reconfirm power is

disconnected using a multi-meter.

Sensor shown fully

inserted into well

Sensor clip shown

installed properly

Direct Spark Ignition Models

Disconnect sensor

from harness

Hot Surface Ignition Models

Insulation folded

back to expose

temperature sensor

Page 43

Does inlet gas pressure drop more than 2" W.C.

during burner ignition?

Adjust gas

supply regulator

Inadequately

sized regulator.

IGNITION MODULE

Verify Minimum Gas Supply Piping Requirements of: Minimum 1" NPT for EF100T399, all others use ¾" NPT. (Schedule 40 black Iron Pipe recommended).

Reconfigure gas

supply piping

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.

Inlet gas

pressure tap

Venturi

adjustment

Is igniter resistance

less than 150 Ohms

(cold)?

(see check igniter

illustration)

Refer to ignition module illustration below,

is there 120VAC across terminals

P6(1) and P6(2)?

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

Replace

hot surface igniter.

(see “Hot Surface Igniter

Replacement Procedure)

Replace ignition module.

(see “Ignition Module

Replacement Procedure”)

Do you see the igniter

glowing through burner

site glass during the

warm up period?

Proceed to next page

With manometer, check inlet

gas pressure. Is it stable

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

(heater not running)

(see illustrations at right)

Is gas supply pressure

regulator adjustable to

maintain proper and

stable setting?

Volt meter set to

OHM setting

Meter probe

Hot surface

igniter

CHECK IGNITER

RESISTANCE

WARNING

120 volt potential

exposure. Use caution

making voltage checks to

avoid personal injury.

WARNING

Removing screw from

inlet gas pressure tap will

immediately allow gas to

flow from pressure tap.

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

For models with Hot Surface Ignition System

Page 44

Refer to ignition module illustration below,

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

brown wires) during the flame establishing period?

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

Replace

ignition module.

(see “Ignition Module

Replacement Procedure”)

Replace Rectifier harness and/or

gas valve.

(see “Gas Valve Replacement

rocedure”)

Does flame LED on the module

light and stay lit?

Can you hear or feel

gas valve energize?

Does burner light

smoothly, without

evidence of coughing

or huffing?

Check for obstruction

at inlet of gas valve.

Is inlet free of

obstruction?

Check flame sensor,

Is there 1 to 5 micro amps

(min.) during 1.5 second

flame proving period?

(see “Flame Sensor Testing

Procedure”)

IGNITION MODULE

Continued from

Call for technical

support

Clear obstruction

Observe burner operation through the sight glass located on the combustion insert mounting flange. Normal burner o

peration 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.

Does burner operate

normaly until thermostat is

satisfied?

System OK

Turn VENTURI set screw clockwise until its

bottomed out. Turn screw counter-clockwise 6-½

turns 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.

Replace flame sensor

(see “Flame Sensor

Replacement

Procedure”)

Inspect burner tube, (see “Burner

Tube Inspection and Replacement”)

WARNING

120 volt potential exposure. Isolate the

appliance and reconfirm power is

disconnected using a multi-meter.

Venturi

adjustment

Inlet gas

pressure tap

EF100T399

Only

Gas valve

regulator

For models with Hot Surface Ignition System

Page 45

Does inlet gas pressure drop more than 2" W.C.

during burner ignition?

Adjust gas

supply regulator

Inadequately

sized regulator.

Verify Minimum Gas Supply Piping Requirements of: Minimum ¾" NPT. (Schedule 40 black Iron Pipe recommended).

Reconfigure gas

supply piping

Inlet gas

pressure tap

Venturi

adjustment

Does main burner

Light?

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?

Check spark gap to burner

(see “Spark Rod Gap

Inspection”)

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.

Can Sparking be seen/

heard at the spark rod

to the burner?

Proceed to next page

With manometer, check inlet

gas pressure. Is it stable

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

(heater not running)

(see illustrations at right)

Is gas supply pressure

regulator adjustable to

maintain proper and

stable setting?

WARNING

120 volt potential

exposure. Use caution

making voltage checks to

avoid personal injury.

WARNING

Removing screw from

inlet gas pressure tap will

immediately allow gas to

flow from pressure tap.

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

Check continuity of

spark rod. Is

reading 0-1 Ohm?

Replace Spark Rod

(see “Spark Rod

Gap Inspection and

Replacement”

CHECK SPARK ROD

RESISTANCE

Meter probe

Spark Rod

Volt meter set to

OHM setting

Spark Rod

Voltmeter set to

OHM setting

Serial Numbers including and AFTER GB13006174 and ALL EFR models

Page 46

Refer to control board illustration,

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

brown wires) during the flame establishing period?

(Note: Control Display must show “Heating” for

operating status)

Replace

Control Board

Replace Rectifier harness

and/or

gas valve.

(see “Gas Valve

eplacement Procedure”)

Does burner stay lit?

Can you hear or feel

gas valve energize?

Does burner light

smoothly, without

evidence of coughing

or huffing?

Check for obstruction

at inlet of gas valve.

Is inlet free of

obstruction?

Check flame sensor,

Is there 1 to 5 micro amps

(min.) during 1.5 second

flame proving period?

(Value may be displayed on

the control display by

accessing “Service Mode”)

Continued from

Call for technical

support

Clear obstruction

Observe burner operation through the sight glass located on the combustion insert mounting flange. Normal burner o

peration 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.

Does burner operate

normaly until thermostat is

satisfied?

System OK

Turn VENTURI set screw clockwise until its

bottomed out. Turn screw counter-clockwise 6-½

turns from bottom. (Note: Venturi adjustment screw

is not on the EF100T399 models)

Replace flame sensor

(see “Flame Sensor

Replacement

Procedure”)

Inspect burner tube, (see “Burner Tube Inspection”)

WARNING

120 volt potential exposure. Isolate the

appliance and reconfirm power is

disconnected using a multi-meter.

Venturi

adjustment

Inlet gas

pressure tap

123

865

431

3 2 1

P2P4P5 P7P3

CONTROL BOARD

P10P9J1

Flame

Sense Rod

CHECK FLAME SENSE

ROD MICROAMPS

Multimeter set to

microamp (µA) setting

Flame Sense

Terminal

Serial Numbers including and AFTER GB13006174 and ALL EFR models

Page 47

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 and remove surround cover from top of

heater.

Step 5. From the gas valve, disconnect the gas

connection, PVC venting, Silicone tubing and 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.

Step 7. Remove the 5 bolts (½" socket)

holding the burner mounting insert in place.

Step 8. Carefully remove combustion assembly

with gasket from water heater.

Step 9. See next page for combustion system installation procedure.

Combustion System Removal Procedure

WARNING

120 volt potential exposure. Isolate the

appliance and reconfirm power is

disconnected using a multi-meter.

WARNING

Heater components may be HOT when performing the following steps in this procedure.

Take necessary precaution to prevent personal injury.

Gas valve

wire harness

Gas

connection

PVC vent

connection

Burner mounting

insert

Burner mounting

screw

(Total of 5)

Burner tube

Burner mounting

insert gasket

Page 48

Combustion System Replacement Procedure

Step 1. Fully inspect burner mounting insert gasket for the following:

) 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

PVC vent

connection

Burner mounting

insert

Burner mounting

screw

(Total of 5)

Burner tube

Burner mounting

insert gasket

Page 49

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.

Burner Tube Removal Procedure

WARNING

120 volt potential exposure. Isolate the

appliance and reconfirm power is

disconnected using a multi-meter.

WARNING

Heater components may be HOT when performing the following steps in this procedure.

Take necessary precaution to prevent personal injury.

BURNER TRANSITION

MOUNTING NUTS

HOT SURFACE IGNITER/

SPARK ROD

Page 50

Burner Tube Inspection

tep 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 will not be the same as the previous BSI burner. Provide the model and serial number for the correct replacement burner.

Step 1. Fully inspect burner flange gaskets, igniter and flame sensor gaskets for the following:

a) Tears d) Dirt or debris b) Missing material e) Other imperfections that would inhibit proper seal c) Cracks

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

Step 2. Install burner tube with gaskets into burner mounting insert. Be sure gasket surfaces are free

of debris.

Step 3. Reconnect the blower/gas valve/transition assembly to burner mounting insert. Secure using

nuts from step 8 on previous page.

Step 4. 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.

Step 5. Reconnect wire harnesses to blower motor and to gas valve.

Step 6. 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.

Step 7. 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 8. 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.

Page 51

Gas Valve Replacement Procedure

Step 6. Remove the 2 gas valve mounting screws (Torx bit) located at the

11:00 O-clock & 5:00 O-clock position 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.

Step 8. Install new gas valve with new gasketprovided. Secure gas valve in place using

screws from step 6.

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 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.

Gas valve

assembly

Blower / gas valve

gasket

Blower

Venturi

mounting flange

Gas valve

mounting screws

(2 places)

Venturi inlet

Gas valve

wire harness

WARNING

120 volt potential exposure. Isolate the

appliance and reconfirm power is

disconnected using a multi-meter.

Page 52

Hot Surface Ignition Models:

Are safety circuits in normal position?

Direct Spark Ignition Models:

Is collector high limit switch and

pressure switch in normally closed

position?

oes blower

energize?

(For Direct Spark

Ignition models,

ensure control display shows “Heating”, raise temperature setpoint if

necessary)

Is there 120VAC

across the white and

black wires at the

blower?

(see photo at right)

Replace blower.

(see “Blower

Replacement

Procedure”)

Refer to ignition module/

control board illustration.

Hot Surface Ignition Models:

Is there 120VAC between

P5(1) and P5(3)?

Direct Spark Ignition Models:

Is there 120VAC between

P7(5) and P7(3)?

Repair/replace

wire harness.

Replace ignition module/

control board.

Is there 120VAC

across the white and

black wires at the

terminal block ?

Hot Surface Ignition

Models ONLY:

Refer to ignition

module, is there 24

VAC between P3(7)

and ground?

Thermostat not calling for heat.

(see “Thermostat

Circuit Testing”)

Correct safety circuit problem per

safety circuit trace

(section “Blocked Vent Pressure

Switch Testing”).

Is there 120VAC

across the white and

black wires at the

terminal block ?

(see photo at right)

Refer to ignition module/control board

illustration.

Hot Surface Ignition Models:

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

Direct Spark Ignition Models:

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

Replace

ignition module/

control board.

Call technical

support.

Check amp draw through

BLACK wire lead of blower

motor. Is there .6 to 3.0

amps?

Replace blower.

(see “Blower Replacement

Procedure”)

Is Blower wheel secured to

blower motor shaft?

Determine

power

source

problem

and

correct

Black wire leading to blower motor looped

through amprobe.

120VAC check at

Terminal Block

Checking for 120VAC

(Black & White Wires)

IGNITION MODULE

HOT SURFACE IGNITION MODELS

123

865

431

3 2 1

P2P4P5 P7P3

CONTROL BOARD

P10P9J1

DIRECT SPARK IGNITION MODELS

Page 53

Blower Replacement Procedure

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 & 5:00 O-clock position on the venturi mounting flange.

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

from transition flange.

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 11. Reconnect gas valve assembly to blower

with new gasket provided. Secure gas valve in place using screws from step 7.

Step 12. Reconnect intake vent and

gas line to gas valve assembly and check for gas leaks repair any leaks found.

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.

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.

Gas valve

assembly

Blower / gas valve

gasket

Blower

Venturi

mounting flange

Gas valve

mounting screws

2 places.

Blower / transition

gasket

Blower flange

mounting screws

Transition

flange

Venturi inlet

Page 54

Does blower

energize?

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.

Is there continuity

Through GREY

wire leads of heater side

safety circuit harness?

(see photo below)

Is there continuity

through RED

wire leads of heater side

safety circuit harness?

(see photo below)

Check PURGE LED status.

Safety Circuit OK,

(see “Blower Testing

& Replacement”)

Replace exhaust

pressure switch (see

“Exhaust Pressure

Switch Replacement

Procedure”)

Replace vent safety

switch.

(see “Vent Safety

Switch Replacement

Procedure”)

Call technical

support.

Depress reset button on vent

safety switch. Is

there continuity

across high limit

switch?

(see photo below)

Refer to

“Check Collector Pressure”

(see next page)

Check blower for proper operation (see page 27)

Is blower OK?

Check PURGE LED status

on ignition module,

Flashing after 45 seconds?

On within 5 minutes? Pressure switch is OK.

Safety Circuit Trace

Does heater

function?

Verify proper switch operation. (see “Vent Safety

Switch Testing and

Replacement”)

LED Status

Only power LED is on, or

Purge LED flashing.

Exhaust Pressure Switch Testing and Replacement

For serial numbers prior to “CF”

Flashing after

5 minutes?

Call for technical

support.

Correct blower problem

(see “Blower Testing and

Replacement”)

WARNING

120 volt potential exposure. Use caution

making voltage checks to avoid personal injury.

Heater side

harness

Control side

harness

Reset button

Page 55

Inspect the area housing the combustion

system and control panel located at the

top of the heater.

Does the area show signs of corrosion

and/or exssesive heat?

Call for

technical support

Remove combustion assembly

(see “Combustion System

Removal Procedure”)

Inspect combustion chamber

for blockage or debris

accumulation

Replace

exhaust pressure switch.

(see “Exhaust Pressure Switch

Replacement Procedure”)

Is exhaust venting system blocked or

obstructed?

Clear obstruction. Determine cause

and correct.

Is vent system total

length compliant with

vent tables in the

instruction manual?

Reconfigure vent

system to be

compliant with

vent tables (see

“Specifications”).

With monometer, take a

reading at the exhaust

tube pressure tap location.

Is value negative (-)?

(see illustration below).

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

Clear obstruction.

Determine cause

and correct.

Check Collector Pressure

Call for

technical support

Exhaust Pressure Switch Testing and Replacement

For serial numbers prior to “CF”

Exhaust Tube

pressure tap location

Exhaust collector

pressure tap location

Exhaust tube

at bottom of water

heater

Page 56

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.

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.

Step 6. Assemble new pressure switch to heater using

screws from step 5.

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 on the switch.

Step 10. Reinstall service panel access cover and

rubber escutcheon.

Exhaust Pressure Switch Testing and Replacement

For serial numbers prior to “CF”

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.

Exhaust pipe

pressure tap location

Exhaust collector

pressure tap location

(serial numbers prior

to “CF”)

Example of switch

showing positive

side identifier

Rubber

escutcheon

Pressure switch mounting screw

5/16 hex head

Silicone tubing

Wire leads

Page 57

Reset button

Does blower

energize?

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. I

f 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.

Hot Surface Ignition Models:

Check PURGE LED status.

Direct Spark Ignition Models:

Check control display

Refer to

“Check Collector Pressure”

(see next page)

Check blower for proper

operation (see “Blower

Testing and Replacement”)

Is blower OK?

On within 5 minutes? Pressure switch is OK.

Safety Circuit Trace

LED Status

Only power LED is on, or

Purge LED flashing.

Error Code 29 or 26

(Direct Spark Ignition

Models)

Blocked Vent Pressure Switch Testing and

Replacement for serial number “CF” and later

WARNING

120 volt potential exposure. Use caution

making voltage checks to avoid personal injury.

Flashing after 5 minutes?

Error code 29 again?

Call for technical

support.

Correct blower problem

(see “Blower Testing and

Replacement”)

Note: HOT SURFACE IGNITION MODELS ONLY - The blocked vent pressure switch must be used with the revised ignition control, identified with a yellow label.

Heater side

harness

Control side

harness

Is there continuity

Through GREY

wire leads of heater side

safety circuit harness?

(see photo below)

Is there continuity

through RED

wire leads of heater side

safety circuit harness?

(see photo below)

Safety Circuit OK,

(see “Blower Testing

& Replacement”)

Replace exhaust

pressure switch (see

“Exhaust Pressure

Switch Replacement

Procedure”)

Replace vent safety

switch.

(see “Vent Safety

Switch Replacement

Procedure”)

Call technical

support.

Depress reset button on vent

safety switch. Is

there continuity

across high limit

switch?

(see photo below)

Check PURGE LED status

on ignition module,

Flashing after 45 seconds?

Does heater

function?

Verify proper

switch operation.

(see “Vent Safety

Switch Testing and

Replacement”)

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.

Page 58

Check Exhaust Tube Pressure

Blocked Vent Pressure Switch Testing and

Replacement for serial number “CF” and later

Exhaust Tube

pressure tap location

Exhaust tube

at bottom of heater

Replace

blocked vent switch.

(see “Blocked Vent Switch Testing and

Replacement”)

Is exhaust venting system blocked or

obstructed? Also

check condensate

elbow and drain.

Clear obstruction.

Determine cause

and correct.

Is vent system total

length compliant with

vent tables in the

instruction manual?

Reconfigure vent

system to be

compliant with

ent tables (see

“Specifications”).

With monometer, take a

reading at the exhaust

tube pressure tap location.

Is value negative (-) or

slightly postitive

(see illustration below).

With ohmmeter check

pressure switch for

continuity. Contacts should

be closed.

Pressure switch O.K.

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

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

replace pressure switch.

Page 59

Exhaust Pressure Switch Replacement Procedure

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

tep 2. Loosen adhesive backed rubber escutcheon from service panel access cover

and slide escutcheon back along exhaust pipe to allow for removal of cover.

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.

Step 6. Assemble new pressure switch to heater using

screws from step 5.

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 10. Reinstall service panel access cover and

rubber escutcheon.

Blocked vent Switch Testing and Replacement

For serial number “CF” or later

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.

Exhaust Tube

pressure tap location

Rubber

escutcheon

Pressure switch mounting screw

5/16 hex head

Silicone tubing

Wire leads

Page 60

Is igniter resistance

less than 150 Ohms

(cold)? (see “check igniter resistance” below)

Refer to ignition module illustration below,

is there 120VAC across terminals

P6(1) and P6(2)?

(Check during igniter warm up period,

indicated by the igniter LED glowing on the

ignition module).

Replace hot surface igniter (see “Hot Surface

Igniter Replacement

Procedure”)

Replace ignition module.

(see “Ignition Module

Replacement

Procedure”)

Check harness

connection from igniter

to ignition module.

Hot surface Igniter Testing Procedure

Volt meter set to

OHM setting

Meter probe

Hot surface

igniter

CHECK IGNITER

RESISTANCE

IGNITION MODULE

WARNING

120 volt potential exposure. Use caution

aking voltage checks to avoid

personal injury. Igniter may be too hot

to handle, take necessary precautions

Page 61

Hot surface Igniter 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 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.

Step 9. Reconnect igniter wire harness.

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

Step 8. Install new igniter with new gasket provided using

screws from step 5. Arrange igniter flange with offcenter hole towards front of heater.

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.

Note: New replacement igniter will not have a shield over element. Handle carefully to prevent breakage.

WARNING

120 volt potential exposure. Isolate the

appliance and reconfirm power is

disconnected using a multi-meter.

Hot Surface

Igniter

Note: Do not handle igniter element or allow foreign material to come in contact with element.

Heater front

Off-center

mounting hole

Igniter flange

Igniter gasket

Transition

base flange

Igniter mounting

screws

Igniter filament

Page 62

With flame sensor Disconnected

from ignition module, check

continuity to ground.

Is there continuity to ground?

Flame Sensor Testing Procedure

Refer to illustration below, is there

a minimum of 1 micro amp during

1.5 second flame proving period?

Is flame sensor free

of oxidation?

Clean or replace

flame sensor.

(see “Flame Sensor

Replacement

Procedure”)

Is ceramic of flame

sensor cracked?

Replace flame sensor.

(see “Flame Sensor

Replacement

Procedure”)

Flame sensing circuit OK

Refer to ignition module/control board

illustration.(24 volts should maintain beyond the

1.5 second flame proving period.) Hot Surface Ignition Models:

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

Direct Spark Ignition Models:

s there 24VAC between P5(5) and P5(8)?

Call for

technical support

Replace flame sensor with

gasket

and/or wire lead.

(see “Flame Sensor

Replacement Procedure”)

Remove flame sensor from water heater. Check continuity from tip of flame sensor

to end of wire lead. Is there continuity?

WARNING

120 volt potential exposure. Use caution

making voltage checks to avoid

ersonal injury. Flame sensor may be

too hot to handle, take necessary

precautions

Flame

sensor

terminal

Volt meter set to

Micro amps setting

(µA)

Meter probe

Flame sensor

terminal on

control board.

Flame sensor

terminal

865

431

3 2 1

P2P4P5 P7P3

CONTROL BOARD

P10P9J1

Volt meter set to

Micro amps setting

(µA)

Meter probe

Flame sensor

terminal on

ignition module.

HOT SURFACE IGNITION MODELS

DIRECT SPARK IGNITION MODELS

Page 63

Flame Sensor Replacement Procedure

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.

Step 9. Reconnect flame sensor wire.

Step 10. Fold insulation back into place. Be sure no wires are in

contact with burner flange.

Step 8. Install new flame sensor with new gasket provided

using screws from step 6. Arrange flame sensor with hook towards burner.

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 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.

Transition

base flange

Flame sensor

mounting screws

Flame sensor

gasket

Arrange hook

of sensor

towards burner

Flame

sensor

WARNING

120 volt potential exposure. Isolate the

appliance and reconfirm power is

disconnected using a multi-meter.

Page 64

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).

Step 4. Re-measure and 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

Burner Tube

Spark Rod

Hold spark rod

near ceramic

insulator

Bend spark

rod near

burner tube

CAUTION

Use caution while performing these

steps to prevent stressing or cracking

the ceramic insulator.

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.

Page 65

Spark Rod Replacement Procedure

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.

Step 7. Remove any residual gasket material from

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.

Step 8. Install new spark rod with new gasket provided

using screws from step 6. Arrange spark rod with hook towards burner (off-center mounting hole towards the front of the water heater).

Step 9. Remove combustion system following “Combustion System

Removal Procedure”, and verify spark gap following “Spark Rod Gap Inspection and Adjustment”.

Step 1. Position main power switch to “OFF”

Step 2. Disconnect (unplug) water heater

from 120 volt power source.

tep 3. Un-latch & remove surround cover

from top of heater.

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.

WARNING

120 volt potential exposure. Isolate the

appliance and reconfirm power is

disconnected using a multi-meter.

Heater front

Off-center

mounting hole

Transition

base flange

Spark rod

mounting screws

Spark rod

gasket

Arrange hook

of spark rod

towards burner

Spark Rod

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.

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.

Page 66

Ignition Module 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.

Step 4. Locate Ignition module on control panel inside surround area.

(see photo below)

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-interchangeable to insure proper reinstallation.

Step 5. Carefully disconnect all wire harness connection to ignition module. Connection are

non-interchangeable to 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 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.

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).

Ignition Module

located on control panel

WARNING

120 volt potential exposure. Isolate the

appliance and reconfirm power is

disconnected using a multi-meter.

Page 67

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-latch and remove top surround cover

from top of water heater.

Step 4. Locate control board.

WARNING

120 volt potential exposure. Isolate the

appliance and reconfirm power is

disconnected using a multi-meter.

Step 5. Carefully disconnect all wire

connections from control board.

Note: It may be necessary to

identify wires for 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.

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

Blower

Unclip blower

side first

Unclip this

side second

Control Board

Page 68

Transformer Replacement Procedure

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 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 1. Position main power switch to “OFF”.

Step 2. Disconnect (Unplug) water heater

rom 120 Volt power source.

Step 3. Un-latch & remove surround cover from

top of water heater.

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.

WARNING

120 volt potential exposure. Isolate the

appliance and reconfirm power is

disconnected using a multi-meter.

Step 3

Disconnect harness

“P1” & “P2”

from ignition module

Ignition module

Step 5 Disconnect blue & yellow wire from thermostat board. Note blue wire is

connected to 24 volt “HOT” terminal.

Thermostat

board

Step 6

Remove transformer

mounting screws

24 volt common,

yellow wire connection

24 volt Hot,

blue wire connection

Thermostat

board

Page 69

Is there continuity

through the normally

closed intake pressure

switch?

(see photo at right)

Replace

intake pressure switch.

(see “Intake Pressure Switch

Replacement Procedure”)

Switch OK.

Does Blower Energize?

Does purge LED

illuminate on the ignition

module?

Remove hose from intake

pressure switch and

Restart heater.

Does purge LED illuminate?

With manometer, take a

reading from the inlet tube

pressure tap. Is reading

negative (-)1.2" W.C.

or more?

(see illustration below)

See “Vent Safety Switch Testing

and Replacement”

Exhaust Pressure Switch Tesinting

and Replacement”

“Blower Testing and Replacement”

Is intake vent system

obstructed?

Call for technical support.

Clear obstruction.

See “Exhaust Pressure Switch Testing

and Replacement”)

“Blower Testing and Replacement”

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

Is there continuity

through the normally

closed intake pressure

switch?

(see photo above)

Isolate (disconnect) heater from

intake vent system and

Restart heater.

Does purge LED illuminate?

Disconnect red wire leads from

pressure switch and check

continuity through switch.

WARNING

120 volt potential exposure. Use caution

making voltage checks to avoid personal injury.

Notice:

The intake pressure switch is not used

on serial number “CF” and later.

Inlet Tube

pressure tap

Page 70

Intake Pressure Switch 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.

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

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 5. Disconnect red wire leads from pressure switch

(see photo at right).

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

Intake pressure switch

located on side of

control panel

Step 6

Disconnect tubing from

pressure switch

Step 7

Remove 2

mounting screws

Step 5

Disconnect red wires

WARNING

120 volt potential exposure. Isolate the

appliance and reconfirm power is

disconnected using a multi-meter.

Page 71

Reset heater, observe

heating cycle. Does

switch open?

Does switch open prior

to 350°F?

DO NOT OPERATE

HEATER

System over heating,

immediately contact

technical support.

Locate harness

connection.

(see photo at right)

Is there continuity

Through GREY

Lead wires of heater side

harness?

(see photo at right)

Replace vent safety switch

(see “Vent Safety

Switch

Replacement

Procedure”)

Call technical

support.

Depress reset button on high limit switch. Is

there continuity

across high limit

switch?

(see photo below)

Does heater

function?

Is temp over 350°F?

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. F

or 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.

System OK

Replace vent safety

switch

(see “Vent Safety

Switch Replacement

Procedure”)

Heater side

arness

Control side

arness

WARNING

120 volt potential exposure. Use caution

aking voltage checks to avoid personal injury.

Reset button

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.

Page 72

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.

Step 9. Reinstall service panel access cover and

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.

Rubber

escutcheon

Vent safety

switch

Page 73

Disassembly Procedure for Access to Anodes & Flue Baffles

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. 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).

Step 7. Remove all collector cover

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

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

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

access to anode rods and flue baffles.

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”

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

WARNING

Heater components may be HOT when performing the following steps in this procedure.

Take necessary precaution to prevent personal injury.

WARNING

120 volt potential exposure. Isolate the

appliance and reconfirm power is

disconnected using a multi-meter.

Collector

cover

Anode

locations

Flue

baffles

Control Panel

Mounting Screw

Remove Control

Panel

Page 74

Anode inspection and replacement

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 (1-1/16 hex 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.

WARNING

Heater components and stored water may be HOT when performing the following steps in

this procedure. Take necessary precaution to prevent personal injury.

Page 75

Flue baffle inspection and replacement

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.

WARNING

Heater components may be HOT when performing the following steps in this procedure.

Take necessary precaution to prevent personal injury.

Page 76

Powered Anode Replacement EF100T399 models only

Powered Anode Replacement for EF100T399 only

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

WARNING

Heater components may be HOT when performing the following steps in this procedure.

Take necessary precaution to prevent personal injury.

Page 77

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

Page 78

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 prevent re-circulation of 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

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.

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'

170'

150'

130'

110'

EF100T399 50' 100'

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

30'

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'

170'

150'

130'

110'

EF100T399 50' 100'

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

30'

N/A

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.

Page 79

Date

Model Number

Serial Number

Venting (PVC, CPVC):

Intake 90's (qty)

Vent size 3" or 4"

Exhaust 90's (qty)

Length of straight pipe (intake)

Intake 45's (qty)

Exhaust 45's (qty)

Line Voltage

Polarity

Low Voltage

Electrical:

Size & material

Distance from meter to water heater

Gas Line:

Static

Manifold

Running Inlet

Gas Pressure:

Size & Material

Length

Condensate Line:

Igniter Resistance:

Flame Sense Micro -Amps:

Venturi:

Exhaust Collector Pressure:

Setting from Bottom in Turns

Positive Inches W.C.

LED Flashing Y or N Which One(s)

Combustion:

CO2 CO

Installation Site Contact Name & Phone Number

Service Provider

Phone Number

Is trap provided Y or N

Installation Site Name & Address:

Length of straight pipe (exhaust)

Spark Gap: ___________

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

Page 80

Models prior to “CF” serial number

Customer must specify complete

model number and serial number

when ordering service parts.

1 Combustion Surround Assy.

2 Burner Assy

3 2ndPass Top Collector Cover

4 Screw 10-16 x 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

22 Nut

23 Vent Safety Switch

24 Screw 6-32x 3/8

25 Cleanout Access Cover

26 Cleanout Gasket

27 Screw 5/16-18 x 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

Page 81

Customer must specify complete

model number and serial number

when ordering service parts.

Models prior to “CF” serial number

AA Latch Assy

BB Screw 8-32 x ½ RHCR

CC Ignition Control Assy

DD Jacket Head

EE Main Power Switch

FF Potentiometer

GG Combustion Surround

JJ Surround Base

1A Combustion Surround Assy.

2A Blower Gas Valve Assy

3A Burner Assy

4A Blower EBM

5A Silicone Hose

6A Hose Tee Fitting

7A Screw 10-32 x3/4

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 8-32 x 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

Page 82

Customer must specify complete

model number and serial number

when ordering service parts.

Models prior to “CF” serial number

1C Electronic Control Module

2C Screw 8-32 x 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

Page 83

For models with “CF” serial or later.

Customer must specify complete

model number and serial number

when ordering service parts.

1 Combustion Surround Assy.

2 Burner Assy (specify model)

3 2ndPass Top Collector Cover

4 Screw 10-16 x 3/4

5 Vent Termination Elbow

6 Thermostat Sensor Probe

7 Baffle 4" Flue (specify model)

8a Anode Rod Assy

9 Baffle 2" Flue

10 Wire Harness Service Panel

11 Plastisert Nipple 1-½" NPT

12 Plug

13 Nipple

14 T&P Relief Valve

Exhaust Pipe (PVC) w/Hose Barb

(except EF100T399) 16 Condensate Trap Elbow (specify model)

17 Silicone Hose

18 Outer Door Service Panel (specify model)

Vent Pipe Support Bracket (except

EF100T399) 20 NSF Escutcheon

21 Exhaust Pressure Switch

22 Nuts

23 Collector Temperature Limit Switch

24 Screw 6-32x 3/8

25 Cleanout Access Cover

26 Cleanout Gasket

27 Screw 5/16-18 x 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)

8b Powered Anode (for EF100T399)

Page 84

For models with “CF” serial or later.

Customer must specify complete

model number and serial number

when ordering service parts.

AA Latch Assy

BB Screw 8-32 x ½ RHCR

CC Ignition Control Assy

DD Jacket Head

EE Main Power Switch

FF Potentiometer

GG Combustion Surround

JJ Surround Base

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 10-32 x3/4

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 8-32 x 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

Page 85

For models with “CF” serial or later.

Customer must specify complete

model number and serial number

when ordering service parts.

Electronic Control Module

Screw 8-32 x 1/2

Control Mounting Panel

Thermostat PC Board

Transformer 120VAC x 24VAC x 40VA

Terminal

Terminal Strip

Power Cord

Control Wire Harness

Thermostat Wire Harness

Powered Anode Control Harness (399 only)

Powered Anode Harness (399 only)

Powered Anode Control (399 only)

Rectifier Harness (specify model)

Blower Wire Harness (specify model)

Power Switch Wire Harness

Flame Sensor Wire Harness

10C

11C

12C

13C

14C

15C

16C

17C

Page 86

For models with Direct Spark Ignition

Customer must specify complete

model number and serial number

when ordering service parts.

1 Combustion Surround Assembly

2 Burner Assembly (specify model)

3 2ndPass Top Collector Cover

4 Screw 10-16 x 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

16 Condensate Trap Elbow (specify model)

17 Silicone Hose

18 Outer Door Service Panel (specify model)

20 NSF Escutcheon

21 Exhaust Pressure Switch

22 Nuts

23 Collector Temperature Limit Switch

24 Screw 6-32x 3/8

25 Cleanout Access Cover

26 Cleanout Gasket

27 Screw 5/16-18 x 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

15 Exhaust Pipe (PVC) w/Hose Barb

19 Vent Pipe Support Bracket

35 Hole Closure

36 Reducer

Page 87

For models with Direct Spark Ignition

Customer must specify complete model number and serial number

when ordering service parts.

Combustion Surround Assembly

(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 10-32 x3/4

8A Gasket

9A Gas Valve (specify model)

10A Nipple (specify model)

11A Reducer (specify model)

12A Nipple (specify model)

14A Inlet (PVC)

15A Gasket Blower Transition (specify model)

16A Screw 8-32 x ¼ RHCR

17A Gasket Flame Sensor

18A Flame Sensor

19A Transition Tube

20A Nut Hex Washer

21A Spark Rod

22A Spark Rod Gasket

23A Burner Mounting Gasket

24A Burner Tube

25A Burner Mounting Gasket

26A Burner Mounting Insert

1B Latch Assy

2B Screw 8-32 x ½ RHCR

3B Ignition Control Assy

4B Jacket Head

5B Main power switch

6B Honeywell Control Display

7B Combustion Surround

8B Surround Base

A2A6A16A24A25A26A23A18A17A20A22A21A16A7A15A4A

A1A28A

13A 2" dia. Flex Reducer

27A Ground Wire

28A Gas Regulator Kit (Optional)

Page 88

For models with Direct Spark Ignition

Customer must specify complete

model number and serial number

when ordering service parts.

1C Control Panel

2C Control Board

3C4CTransformer 120VAC x 24VAC x 40VA

Terminal

Terminal Strip

Power Cord

Controller Wire Harness

Transformer Primary Wire Harness

10C

Transformer Secondary Wire Harness

11C

Blower Wire Harness

12C

Power Switch Wire Harness

Sensor Wire Harness

11C

12C

10C

13C

13C High Voltage Spark Cable

Page 89

NOTES

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

Page 90

NOTES

Page 91

NOTES

Page 92

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

Specifications and Main Features

Frequently Asked Questions

User Manual