Bradford White U65L155E N Series Bedienungsanleitung

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Manual 238-50129-00A

SERVICE

MANUAL

Troubleshooting Guide

and Instructions for Service

(To be performed ONLY by

qualified service providers)

Models Covered

by This Manual:

U65L155E*N (A)

U65L199E*N (A)

U65L270E*N (A)

U100L199E*N (A)

U100L270E*N (A)

U100L300E*N (A)

U100L399E*N (A)

(*) Denotes Warranty Years

Gas Water Heaters

Ultra Low NOx Atmospheric Vent

Table of Contents

The Bradford White

Page Service Procedure

Introduction 3 - - -

How to use this manual 4 - - -

Tool required for service 4 - - -

Features 5 - - -

Specifications 6 - - -

Sequence of Operation 8 - - -

Troubleshooting 10 - - -

Thermostat Circuit, Testing & Replacement 27 I

Combustion System Testing and Replacement 31 II

Burner Tube Inspection & Replacement 35 III

Gas Valve Replacement 37 IV

Blower Testing and Replacement 38 V

Flame Sensor Testing and Replacement 40 VI

Spark Rod Replacement 42 VII

Ignition Module/Control Board Replacement 43 VIII

Transformer Replacement 44 IX

Anode Inspection and Replacement 45 X

Circulator Assembly Inspection and Replacement 46 XI

Blocked Vent Switch Inspection and Replacement 47 XII

Damper Inspection and Replacement 48 XIII

Heater Service Report 49 - - -

Parts List 50 - - -

Glossary of Terms 53 - - -

Introduction

The Bradford Ultra Low NOx Atmospheric Vent Water Heater uses a ultra low Nox

premix power burner located at the top of the water heater to direct a turbulent

flame down into the combustion chamber. This turbulence causes a thorough

mixing of gas and air for optimum combustion. The combustion gases then travel

through a single 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, blocked vent limit switch,

circulator flow switch, flame sensor to control output voltage to blower motor, 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 Ultra Low NOx Atmospheric Vent Water Heater operational faults.

Please read this service manual completely and record as much information

regarding the Ultra Low NOx Atmospheric Vent Water Heater operation and

installation specifics related to any concerns.

The Bradford White Ultra Low NOx Atmospheric Vent Water Heater is designed to

deliver a remarkable amount of hot water at 84% efficient in a quiet running unit

with a low vent connection that allows for installation existing locations. 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 Ultra Low NOx

Atmospheric Vent Water Heater.

Tools Required for Service

Itis intended for this manual to be used by qualified service personal for the primary purpose

of troubleshooting analysis and repair of the Bradford White Ultra Low NOX Atmospheric

Vent Water Heater. Understanding the sequence of operation section of this manual will

contribute greatlyto troubleshooting this product.

A“Service Report” is shown towards the end of this manual. Completing this form will assist

in the troubleshooting efforts. Shouldyou 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

Probablecause” directing the service provider to aseries of test procedures to determine

root cause of failure. Component replacement procedures directlyfollow the test procedures

for agiven component.

Contact Technical support immediatelyif diagnosis is not determined using the methods

described in this service manual.

Manometer: Twotypes available, aliquid “U” tube typeor adigital (magna-helic)

type. Thisdeviceisused to measuregas and/or air pressures and

vacuum.

Multi-Meter: A digital typeisstrongly recommended. Thisdeviceisused to measure

electrical values. Themeter you selectmust havethecapability to

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

Thermometer: Used to measurewater temperature. Anaccurate thermometer is

recommended.

Water PressureGage:Used to measurewater supply pressure. Also used to determine tank

pressureby adapting to thedrainvalveof theheater.

Jumper Leads:Alength of wire(12" min.) with alligator clip at both ends.

VariousHand Tools: Pipewrench, channel locks, open end wrench set, 12" crescent wrench,

Allen wrench set, torx bitset, screw drivers(common & Phillips), long

reach (12") magnetic tip Phillipshead screw driver #2tip, ¼" nutdriver,

pliers(common & needle nose), socket set including a1-1/16 deep well

socket, wirecutters, wirestrippers, wirecrimpers, torpedolevel, small

shop sac, step ladder, and flashlight.

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.

Singlecontrol board with plug in wiring controlstemperature, 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 - Ahigh 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.

Features of Honeywell Integrated Control System

Model Description

Hour

Delivery at

100°F Rise

(Gal.)

Floor to

Top of

Vent

(in.)

Vent

Dia.

(in)

Floor

Cold

Water

Conn.

(in)

Floor

T& P

(in)

Floor

to Hot

Water

Conn.

(in)

Floor to

Top of

Water

Heater

(in)

Floor

to Gas

Conn.

(in)

Water

Conn.

Dia.

(in.)

Gas

Conn.

Dia.

(in.)

Relief

Valve

(in.)

Model Number Capacity

(GAL)

Input BTU/Hr.

NAT.

U65L155E3N(A) 65 155,000 203 56 ¼ 6 10 ½ 37 39 ½ 61 581 ½ ¾ ¾

U65L199E3N(A)

65 199,999

249 56 ¼ 6 10 ½ 37 39 ½ 61 581 ½ ¾ ¾

U65L270E3N(A)

65 270,000

320 56 ¼ 6 10 ½ 37 39 ½ 61 581 ½ ¾ ¾

U100L199E3N(A)

100 199,999

27456 ¼ 6 10 ½ 53 ¼ 55 ¾ 77 ¼ 74½ 1 ½ ¾ ¾

U100L270E3N(A)

100 270,000

345 56 ¼ 6 10 ½ 53 ¼ 55 ¾ 77 ¼ 74½ 1 ½ ¾ 1

U100L300E3N(A)

100 300,000

375 57 ¼ 7 10 ½ 53 ¼ 55 ¾ 77 ¼ 74½ 1 ½ ¾ 1

U100L399E3N(A)

100 399,999

477 57 ¼ 810 ½ 53 ¼ 55 ¾ 77 ¼ 74½ 1 ½ 1 1

Dimensional Layout

Honeywell Integrated Control System

Power supply Dedicated 120 VAC, 60 Hz,15A

Thermostat Sensor 11,900 Ohms @ 70°F, ECO opens @ 207°FMax. Redundant sensor for ECO.Sensor insidewell for easy

replacement of sensor.

SparkRod Igniter 0.22" nominal gap to the burner surface.

Flame Sensor Output Minimum 1microamp, Typical range 5to 30 microamps.

Control Display

Digital display, 24 volts. TemperatureRange: 70-180 deg. F. Used to set tank temperature(deg. For

deg. C), show operating status, Display error codes, error codehistory, 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.

Transformer120VAC primary, 24VAC secondary, 40VA.

Blocked Vent Safety Switch Normally closed,opens @ 240°F, manual reset.

Blower120VAC, 60Hz,.6-1 amps, 6400 RPM.

Approved Gas Type Natural gas only. Gas supply must match the gas type listed on the water

heater rating label.

Venting System

Atmospherically Vented,Type B venting system or approved chimney. Follow

current National Fuel Gas Coderequirements or in Canada, the Natural Gas

Installation Code.

Gas Supply Minimum ¾”NPT for 300,000 BTU’s/hr.and below. Minimum 1" NPT for 399,999 BTU’s/hr.

(schedule 40 black iron pipe recommended)

Minimum Clearance

for Servicing

4" from the top, 0"from the front, 4" from the exhaust vent side, 12" from the circulation loop side, 0"

from the rear.

Maximum Water Supply

Pressure150 PSI

Gas Pressure (Nat.)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 0.04percent (400 PPM) air free

Circulator Flow Switch 24 VAC, normally open, closes when circulator is operational

Circulator120VAC ,60Hz,.76-1 amps, 3250 PRM

For models with Honeywell Integrated Control

System w/ Direct Spark Ignition

Thermostat callsfor heat.

Combustion blower &circulator start whilethe damper opens.

Blower pre-purge period of 30 seconds.

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

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 aminimum of 0.8microamp through flame sense

rod to prove flame.

Ifeither blocked vent safety switch contacts (normallyclosed) or circulator flow switch and damper contacts

(normallyopen) remain open after being energized, then the ignition sequence will not start and an error

code 29 (Safety switch circuit 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.

Ifthe normallyclosed blocked vent safety switch opens, the gas valve closes, the blower post-purges, then

shuts off with error code 26 displayed in alockout condition.

Thermostat satisfied.

Gas valve closes, burner extinguished.

Blower post purge for 30 seconds.

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 26

Ifthe blocked vent safety switch mounted on the draft hood shouldopen, 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.

2.ERROR CODE 29

Ifthe circulator flow switch or the damper contacts fail to open or close in the normal sequence of operation, 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. Noresetting of the control display is

needed for resetting this error code.

3.ERROR CODE 62 or 63

Control board will go into “Soft Lockout” if the main burner cannot be lit or failsto prove flame after 3ignition trials.

The water heater display indicates alockout 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. Ina

“Soft Lockout” condition, the control will wait for 60 minutes and then make 3more attempts to light the main

burners. Soft lockout reset is accomplished by depressing the lower right button under “Reset” for 3seconds.

4. ERROR CODE 65

Ifthe top of the tank shouldexceed 207°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 onlybe

reset in the “Service Mode”, which is detailed in the “Troubleshooting” section of this Service Manual.

Lockout Conditions (Complete list of error codes is listed on the unit)

CONNECTION/WIRING DIAGRAM

System Observation

For modelswithDirect SparkIgnition

Water Heater Fault: Water heater does not operate

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

Checkmain power supplyto water

heater - fuse, circuit breaker, plug

receptacle, line cord or wiring to water

heater.

Check to make sure switch on front of

control panel is in the ON position

Verify Primary voltage at the

control board.

Verify Secondary voltage at the control

board.

Check wires for proper termination

to control display.

Are wire terminations connected

properlyto 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.

Is24VAC present between

RED and BLACK wire pin

connections on the back of

Control Display?

123

P4P5 P7P3

CONTROL BOARD

P10P9J1

Refer to Control Board illustration.

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

will be 110-120. Ifnot, check Line In

pins P3(1)&P3(4). Check line cord with

voltmeter. Replace line cord if

defective.

Refer to Control Board illustration. Voltage at

secondary pins P4(1)&P4(2)will be 24VAC.

Ifnot, 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.

Is24VAC present between E-COM

screw terminalsP9(2)&P9(3)on

the Control Board.

Replace Control

Display.

Display Operates - See next

page

Make proper wire

terminations

Replace

Control Board

YCheck wire

harness for

proper continuity

Transformer

Top terminalsare 24VAC (Blue and Yellow/Green)

Bottom terminalsare 120VAC (Black and White)

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