Bradford White EF Series Bedienungsanleitung

The Bradford White

Ultra High Efficiency Water Heaters

SERVICE

MANUAL

Troubleshooting Guide

and Instructions for Service

(To be performed ONLY by

qualified service providers)

For the Bradford White

eF Series®Ultra High

Efficiency Models:

EF60T125E*(NA,XA)(2)

EF60T150E*(NA,XA)(2)

EF60T199E*(NA,XA)(2)

EF100T150E*(NA,XA)(2)

EF100T199E*(NA,XA)(2)

EF100T250E*(NA,XA)(2)

EF100T300E*(NA,XA)(2)

(*) Denotes Warranty Years

Manual 45817A Save this manual for future reference

Page 2

Table of Contents

Page eF Service Procedure

Introduction 3 - - -

How to use this manual 4 - - -

Tool required for service 4 - - -

Specifications 5 - - -

Sequence of Operation 8 - - -

Troubleshooting 10 - - -

Thermostat Circuit, Testing & Replacement 12 I

Combustion System Testing and Replacement 18 II

Burner Tube Inspection & Replacement 22 III

Gas Valve Replacement 24 IV

Blower Testing and Replacement 25 V

Exhaust Pressure Switch Testing and Replacement 27 VI

Hot Surface Igniter Testing and Replacement 30 VII

Flame Sensor Testing and Replacement 32 VIII

Ignition Module Replacement 34 IX

Transformer Replacement 35 X

Intake Pressure Testing and Replacement 36 XI

Vent Safety Switch Testing and Replacement 38 XII

Anode & Flue Baffle Inspection and Replacement 40 XIII

Installation Check List 44 - - -

Heater Service Report 45 - - -

Parts List 46 - - -

Glossary of Terms 49 - - -

The Bradford White

Ultra High Efficiency Water Heaters

Page 2

The Bradford White

Ultra High Efficiency Water Heaters

Introduction

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 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 on LEDs 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 3

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 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 on page 44. Compare the installation against the installation

check list to confirm all requirements are met.

An “eF Service Report” is shown on page 45. 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” listed on page 11 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.

Page 4

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 or 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.

How to Use This Manual

Page 4

Specifications

Page 5

EF60T125

EF60T150

EF60T199

EF100T150

EF100T199

EF100T250

EF100T300

125,000

150,000

199,999

150,000

199,999

250,000

300,000

187

211

265

250

309

364

405

363.6

422.7

557.6

450.5

597

734.8

836.4

145.5

169.1

223

180.2

238.8

293.9

334.5

103.9

120.8

158

129

171

210

239

100

96.0

93.0

92.0

99.1

98.5

97.0

92.0

77 5/8

28 3/8

42 ¼

62 ¼

52 ½

73 1/8

53 ½

74 ¾

1 ½

570

900

Shpg

(lbs)

T&P

Valve

Open

Gas

Conn

Dia

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

Del

Gal

100°F

Rise

Input

Rate

BTU/h

Model No

Recovery GPH

at Degree Rise

DIMENSIONS (INCHES)

Page 5

EF60T125

EF60T150

EF60T199

EF100T150

EF100T199

EF100T250

EF100T300

125,000

150,000

199,999

150,000

199,999

250,000

300,000

187

211

265

250

309

364

405

363.6

422.7

557.6

450.5

597

734.8

836.4

145.5

169.1

223

180.2

238.8

293.9

334.5

103.9

120.8

158

129

171

210

239

100

96.0

93.0

92.0

99.1

98.5

97.0

92.0

77 5/8

28 3/8

73 1/8

1/2

73 1/8

1/4

1/2

3/4

1/2

3/4

570

900

Shpg

(lbs)

T&P

Valve

Open

Gas

Conn

Dia

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

Del

Gal

100°F

Rise

Input

Rate

BTU/h

M od el No

Recovery GPH

at Degree Rise

DIMENSIONS (INCHES)

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 page 9.

Specifications

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

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

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

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

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

Exhaust pressure switch

24VAC, normally open, closes on Pressure increase @:

+2.58" W.C. EF(60,100)T199

+1.50" W.C. EF100T150 (see note 1)

+1.22" W.C. EF60T150, EF100T250

+2.08" W.C. EF60T125

+0.55" W.C. EF100T100 (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

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, CPVC or ABS

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: 10-10.5%, CO: less then 0.04 percent (400 PPM) air free

Page 6

Specifications

Vent Tables

Balanced Direct Vent Systems

PVC, CPVC or ABS

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

EF60T199, EF100T250

EF100T300

Unbalanced Direct Vent Systems

Air intake CAN NOT exceed exhaust by

more than 30 feet

100'

80'

60'

170'

150'

130'

110'

Power Vented Systems

PVC, CPVC or ABS

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, EF100T250

EF100T300

100'

80'

60'

170'

150'

130'

110'

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.

Page 7

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.

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 reignition.

-If either pressure switch opens, Gas valve is shut down, Blower is shut down for 30

seconds after which blower is reenergized and system attempts reignition 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

reignition starting at pressure switch proving mode.

Thermostat satisfies.

Burner off.

Blower post purge (15 seconds).

Page 8

Sequence of Operation

Page 8

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.

Page 9

Sequence of Operation

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

Page 9

Refer to ignition module

illustration, is there 120VAC

between P1(1) and P1(3)?

Is front panel power

switch light on,

indicating power?

NPosition front panel

power switch to

“ON” position.

Is there 120VAC

across switch?

(see photo 1)

Light burned out,

replace switch.

Is there 120VAC

across terminal block?

(see photo 2)

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 pg 34)

Replace ignition module.

(see pg 34)

Replace transformer.

(see pg 35)

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 page 11.

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)?

IGNITION MODULE

Page 10

Troubleshooting

System Observation

WARNING

120 volt potential exposure. Use caution

making voltage checks to avoid personal injury.

Page 10

Refer to ignition module

illustration, is there 120VAC

between P1(1) and P1(3)?

Is front panel power

switch light on,

indicating power?

NPosition front panel

power switch to

“ON” position.

Is there 120VAC

across switch?

(see photo 1)

Light burned out,

replace switch.

Is there 120VAC

across terminal block?

(see photo 2)

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 pg 34)

Replace ignition module.

(see pg 34)

Replace transformer.

(see pg 35)

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 page 11.

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)?

IGNITION MODULE

Page 10

Troubleshooting

System Observation

WARNING

120 volt potential exposure. Use caution

making voltage checks to avoid personal injury.

Refer to ignition module

illustration, is there 120VAC

between P1(1) and P1(3)?

Is front panel power

switch light on,

indicating power?

NPosition front panel

power switch to

“ON” position.

Is there 120VAC

across switch?

(see photo 1)

Light burned out,

replace switch.

Is there 120VAC

across terminal block?

(see photo 2)

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 pg 34)

Replace ignition module.

(see pg 34)

Replace transformer.

(see pg 35)

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 page 11.

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)?

IGNITION MODULE

Page 10

Troubleshooting

System Observation

WARNING

120 volt potential exposure. Use caution

making voltage checks to avoid personal injury.

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