Bradford White D75T125 Bedienungsanleitung

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Manual 47324A

SERVICE

MANUAL

Troubleshooting Guide

and Instructions for Service

(To be performed ONLY by

qualified service providers)

Models Covered

by This Manual:

For The Bradford White

“D” Series Models:

D38T155

D75T(125,160,300)

D65T(370,399)

D80T(180,199,250)

D80T(425,505)

D100T(199,250)

D80L(399,450,505)

D100L(199,250,270,300)

D100S(199,250)

Gas Water Heaters

COMMERCIAL 24 VOLT FLUE DAMPER

SERIES WATER HEATER

Table of Contents

Page eF Service Procedure

Introduction 3 - - -

Tool required for service 3 - - -

Sequence of Operation 4 - - -

Troubleshooting 5 - - -

Thermostat Circuit Testing 6 D24-I

Pilot Operation Testing 8 D24-II

Main Burner Operation testing 10 D24-III

Main Burner & Pilot Removal & Inspection 12 D24-IV

Flue Baffle Removal & Inspection 14 D24-V

Anode Removal & Inspection 15 D24-VI

Generic Parts List 16 - - -

Glossary of Terms 19 - - -

Page 2

Tools Required for Service

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 24 Volt Flue Damper Series Water

Heater. Understanding the sequence of operation section of this manual will contribute greatly to

troubleshooting this product.

Troubleshooting begins simply by resetting the water heater and observing the lighting sequence

to determine failure mode. This step by step procedure beginning on page 5 will direct the service

provider to a series of test procedures to determine root cause of failure.

Contact Technical support immediately if diagnosis is not determined using the methods described

in this service manual.

Page 3

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.

Introduction

1Thermostat calls for heat.

The relay closes on the thermostat board, sending 24 volts from the “COM” terminal of the thermostat board

to the flue damper.

2Flue damper begins to rotate open. Once damper is full open, 24 volts is allowed to continue through damper to the

“TH” terminal of ignition module.

3LED on ignition module illuminates.

5Once pilot flame is proven, sparking will stop.

Page 4

Sequence of Operation

Trial for ignition (90 second trials, 3 trials with 30 second pause between trials).

Ignition module simultaneously sends:

1. 24 volts from “MV/PV” terminal, to “MV/PV”

terminal of gas valve (common terminal).

2. 24 volts from “PV” terminal, through the

ECO located in the lower thermister, to “PV”

terminal of gas valve to establish

gas flow at pilot.

3. Low current high voltage from “spark”

terminal, to generate spark at the pilot and

ignite pilot gas flow.

4. Pilot flame proving signal (measured in

micro-amps). from the “sense” terminal, to

prove pilot flame.

6Once sparking stops, 24 volts is sent from “MV” terminal on

module, to “MV” terminal on gas valve to establish main

burner gas flow. Main burners ignite from the pilot flame.

The ignition module constantly monitors pilot flame. If pilot

flame is lost, pilot and main burner are shut down. After a

30 second purge period, module will attempt to re-light pilot

beginning at sequence 4 above.

7Main burner fires until the thermostat is satisfied. The relay on

the thermostat board opens, interrupting 24 volts through the

damper and ignition module. Pilot and main burner is turned off.

8Flue damper rotates to the closed position.

WIRING DIAGRAM

LOCKOUT CONDITION

Ignition module will “lockout” if the pilot can not be lit after 3

ignition trials. The ignition module indicates a lockout condition

by the continues flash of the LED located on the module.

Lockout reset is accomplished by interrupting 120 VAC to the

unit for at least 5 seconds.

TROUBLESHOOTING

If LED on ignition module is flashing,

reset water heater by turning “OFF”

power. Wait 5 seconds and turn

power back “ON”

Rotate thermostat dial to the

highest setting.

Does damper vane Move to the full

open position?

Does LED light on ignition module

illuminate?

Is there pilot flame?

Does Main burner operate?

Does burner continue until thermostat

set point is reached?

Does flue damper rotate to the closed

position?

System okay.

Remove damper from

heater and

Jump black & yellow wires

ofheater harness

(see photo 2)

Does LED light on

ignition module

illuminate?

Check for debris limiting

damper rotation, if no

debris, replace damper

See pilot will not light

(page 8)

See pilot lights, no flame

signal.

(page 9)

See main burner

short cycle

(page 11).

Verify Primary and secondary voltage

at the transformer

(see photo 1)

Ignition Module LED Status

OFF = No power to module

ON = Module has power

Flashing = Module is in lock-out

CAUTION

Use Caution Not to Damage Connectors when making Voltage Measurements or Jumping Terminals

Is there 24 VAC between

terminals “TR” & “TH” of the

ignition module?

(see photo 1A)

Check for debris limiting

damper rotation, if no

debris, replace damper

Damper vane show in open position. If damper

is closed, disconnect from harness and

REMOVE damper from water heater.

Harness shown disconnected from damper

with BLACK and YELLOW wires jumped.

See thermostat testing

(page 6).

DANGER

120 volt exposure. Use Caution

To Avoid Personal Injury.

Rear terminals

primary

(120 VAC)

Forward terminals

secondary

(24 VAC) Ignition module

Page 5

YReplace ignition module

Check damper harness

connection.

Check for 24 VAC

across terminals

“TR” & “TH”

SERVICE PROCEDURE D24-I

Thermostat Circuit Testing

CAUTION

Be Careful When Making Voltage

Measurements or Jumping Terminals

Not to Damage or Deform Connectors or

Connector Pins.

DANGER

120 volt exposure. To avoid personal injury,

use caution while performing this procedure.

THERMOSTAT CIRCUIT BY-PASS

Turn power “OFF” to water heater and

locate thermostat board inside control box

of water heater. Disconnect YELLOW wires

from the thermostat board at location

“N.O.” & “COM”. Use a jumper to connect

these two wires together

(see photos 4 & 5).

Does pilot and main burner operate?

With power on to water heater,

Verify Primary and secondary voltage at

the transformer

(see photo 3)

Turn power on to water heater.

Does LED on ignition module illuminate?

(see photo 6)

This procedure assumes the flue damper is in working order. Be sure damper opens under its own power when the

thermostat circuit is by-passed. Damper must be open or removed during this test. Do not force damper open using your

hands or tools.

Verify transformer voltage

(see photo 3)

See pilot operation testing

(page 8)

Disconnect ORANGE potentiometer (temp

adjustment dial) wires from thermostat

board (see photo 7)

DANGER

Do not leave thermostat jumper in

place for normal operation.

Turn power “OFF”.

Remove jumper and re-connect wires to

thermostat board. Wires are identified for

proper connection to board.

Check potentiometer for proper resistance values of:

Greater then 4800 Ohms with dial at minimum setting.

Less than 50 Ohms with dial at maximum setting.

(see photo 8).

Are readings correct?

Replace potentiometer

Check Thermisters

(see page 7)

Rear terminals

primary

(120 VAC)

Forward terminals

secondary

(24 VAC)

LED Location

Page 6

°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 1000 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

Thermister Resistance at Various Temperatures

Example: If water temperature is 84°F, then the resistance through the sensor would be 8449 (see shaded area).

NOTE: Sensor resistance increases as the temperature falls.

Page 7

SERVICE PROCEDURE D24-I

Thermostat Circuit Testing

Upper thermister location

(applicable models)

Lower thermister

access located inside

control box.

Thermister Resistance Testing

Upper Thermister:

1. Determine resistance value of upper thermister. Test across

grey wires. (see photo 9).

2. Draw quart of water off T&P valve. Using a thermometer,

determine water temperature.

3. Use table below to verify correct resistance per water

temperature measured.

Lower Thermister:

1. Determine resistance value of lower thermister. Test across

blue wires. (see photo 10).

2. Draw quart of water off Drain Valve. Using a thermometer,

determine water temperature.

3. Use table below to verify correct resistance per water

temperature measured.

Are readings

correct?

NReplace

thermister

Check harness

continuity.

Continuity okay?

Replace

thermostat

board

Replace

harness

CAUTION

Be Careful When Making Resistance

Measurements Not to Damage or

Deform Connectors or Connector Pins.

SERVICE PROCEDURE D24-II

Pilot Operation Testing

CAUTION

Be Careful When Making Voltage

Measurements or Jumping Terminals

Not to Damage or Deform Connectors or

Connector Pins.

DANGER

120 volt exposure. To avoid personal injury,

use caution while performing this procedure.

Condition:

Pilot will not light,

Ignition module LED is “ON”

Is there 22-27 volts AC output across

terminals “MV/PV” & “PV” of Ignition

Module?Disconnect wires & check

across terminal of module.

(see photo 11)

Loosen pilot tubing connection at

the gas valve and soap test.

Is there pilot gas flow out of the

gas valve?

Tighten pilot tube connection at

the gas valve. Check incoming

gas pressure to water heater. if

okay, replace gas valve

Check for clogged or kinked

pilot tube, clogged pilot orifice.

Clean or replace as needed.

(see page 13)

Is there 22-27 volts AC input

across wire leads

“MV/PV” & “PV”

at Gas Valve?

(see photo 12)

Check continuity across ECO

(RED) leads of lower thermister

(see photo 13)

Is continuity okay?

Check wire harness for damage

or loose connections. Repair or

replace as needed.

Reset heater by turning power

“OFF”. Wait 5 seconds and turn

power “ON”. When LED of

ignition module turns “ON” does

ignition module send “spartk”

signal (buzzing or clicking sound)

Replace ignition

module

Check across

“MV/PV” & “PV”

terminals

Check across “MV/PV”

&“PV” Wire leads to

gas valve

Check across RED

wire leads of lower

thermister (ECO).

ECO Specifications

Opens between 181°F/201°F

Closes between 160°F/100°F

Replace ignition

module

Is there spark at the

pilot?

Check for:

Loose or damaged ignition wire

Grounded pilot electrode

Damaged pilot.

Page 8

SERVICE PROCEDURE D24-II

Pilot Operation Testing

CAUTION

Be Careful When Making Voltage

Measurements or Jumping Terminals

Not to Damage or Deform Connectors or

Connector Pins.

DANGER

120 volt exposure. To avoid personal injury,

use caution while performing this procedure.

Condition:

Pilot lights, no flame signal.

Module continues to spark until

system “Lock Out”.

Main burner will not light.

Disconnect white flame sense

lead from ignition module at the

“SENSE” location. Set multi-

meter to the “Micro Amps”

setting (ȝA) (see note). Check

micro amp reading. Be sure

module is sparking during this

test.

(see illustration 2)

Micro-amp readings

0.000 Micro Amp = Replace module.

1.0 micro amp or less = Clean pilot flame rod or replace pilot.

Check for loose or damaged

ground wire(s). Are ground wires

okay?

Check for loose or damaged

flame sense lead from pilot to

module. (see illustration 1).

Is flame sense lead okay?

Repair wire lead

or replace pilot.

White flame

sense lead from

pilot

Illustration 1

White wire lead

from pilot

Illustration 2

Meter

Probe

Meter

Probe

Repair ground

wire(s) or replace

as needed.

NOTE:

If multi meter is not capable of

testing micro amps, check

continuity of sense lead. If no

continuity, clean pilot flame rod

or replace pilot.

(see illustration 3)

Illustration 3

Flame rod

Multi-meter set

to micro-amp

setting (ȝA)

Meter

Probe

Meter

Probe

Multi-meter set

to check

continuity.

Check venting conditions or

negative pressure

Is vent system okay?

Correct improper

venting condition.

Is heater condensing causing

pilot interruption?

Determine cause for

condensing and correct.

Under sized heater or high

demand periods

Page 9

SERVICE PROCEDURE D24-III

Main Burner Operation Testing

CAUTION

Be Careful When Making Voltage

Measurements or Jumping Terminals

Not to Damage or Deform Connectors or

Connector Pins.

DANGER

120 volt exposure. To avoid personal injury,

use caution while performing this procedure.

Condition:

Main burner will not light,

Ignition module LED is “ON”

IsPilot lit? See “pilot will not light”

(page 8).

Does module continue to spark

with pilot lit?

See “Pilot lights, no flame signal”

(Page 9).

Disconnect “brown” wire from

“MV” terminal of ignition module.

Is there 22-27 volts AC across

“MV” terminal of Ignition Module & ground?

(see photo 14)

Disconnect brown wire lead from

“MV” terminal of gas valve.

Is there 22-27 volts AC across

brown wire lead & ground

(see photo 15)

Replace ignition

module

Be sure module LED is “ON”,

pilot is lit and module is not sparking

Recheck voltage across

“MV” terminal of Ignition Module & ground.

Is voltage present?

Check wire harness for damage or

loose connections. Repair or replace

as needed.

Check incoming gas pressure to

gas valve. if okay,

replace gas valve.

Disconnect “brown”

wire from “MV”

location of ignition

module.

Ground

Check voltage from

“MV” Terminal of

Ignition module

&ground.

Reconnect brown wire

to ignition module.

Brown wire disconnected

from “MV” terminal of gas

valve

Ground lug of

gas valve

Page 10

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