SERVICE MANUAL - Bradford White
Contents
1. BRADFORD WHITE Troubleshooting 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 dad Setpoint Flashes 1 Step 3 To raise the temperature setpoint press the Temperature Up button until the desired temperature is shown on the water heater display 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 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 Setpoint Flashes E oF setpoint ILLI idle Status Operational SELECIN SEN Step 4 To lower the temperature setpoint press the Temperature Down button until the desired temperature is shown on the water heater display2. Minimum NPT Schedule 40 black Iron Pipe ren recommended ppy piping Y Inadequately sized regulator N With manometer check inlet Is gas supply pressure gas pressure Is it stable between 7 amp 14 W C static regulator adjustable to Y Adjust gas maintain proper and supply regulator heater not running stable setna l see illustrations at right d Venturi A adjustment Y A WARNING Does inlet gas pressure Removing screw from Inlet gas drop more than 2 W C inlet gas pressure tap will pressure tap during burner ignition 8 immediately allow gas to N flow from pressure tap Voltmeter set heck resistance of high voltage A WARNING cable Resistance should be 0 1 ohms GA 120 volt potential If resistance is high replace spark cable If spark cable is good replace Control Board exposure Use caution making voltage checks to avoid personal injury N v Remove high voltage wire connected at the Shark Bod Can Sparking be seen y spark rod and hold approximately 1 4 from metal pars no heard at the spark rod ground with insulated pliers during the ignition to the burner cycle 3 second spark trial period Is there spark to ground Y Y Re Replace Spark Rod y Check continuity of N see Spark Rod spark rod Is Gap ti d Met b reading 0 1 Ohm app Volt meter set to eter probe Replacement OHM setting y
3. So BRADFORD WHITE Notes NOTES es BRADFORD WHITE ee ba BRADFORD WHITE WATER HEATERS Ambler PA For U S and Canada field service contact your professional installer or local Bradford White sales representative Sales 800 523 2931 Fax 215 641 1670 Parts Fax 215 641 2180 Technical Support 800 334 3393 Fax 269 795 1089 Warranty 800 531 2111 Fax 269 795 1089 International Telephone 215 641 9400 Telefax 215 641 9750 x BRADFORD WHITE CANADA INC Mississauga ON Sales 866 690 0961 905 238 0100 Fax 905 238 0105 Technical Support 800 334 3393 Email parts bradfordwhite com techserv bradfordwhite com www bradfordwhite com
4. Transformer Replacement Procedure A WARNING 120 volt potential exposure Isolate the appliance and reconfirm power is Step 1 Position main power switch to OFF disconnected using a multi meter Step 2 Disconnect unplug water heater from 120 volt power source Step 3 Un latch and remove top surround cover Step 4 from top of water heater Remove wires to transformer Step 4 Disconnect primary leads black amp white and secondary leads blue amp yellow from the transformer leads are different sizes to prevent interchanging Step 5 Remove the 2 screws short Phillips screw driver holding the transformer in place and remove transformer from control panel see photo right Step 6 Install new transformer and secure in place with screws from step 5 Step 8 Reconnect primary and secondary wires to transformer leads are different sizes to prevent Remove transformer interchanging mounting screws 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 Ss 44 Ey BRADFORD WHITE Service Procedure X Anode Inspection and Replacement Anode inspection and replacement A WARNING Heater components and stored water may be HOT when
5. II idle Status Operational SELECTV SE 5 F C Display Change 14 BRADFORD WHITE Troubleshooting 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 see page 22 Water Heater Display will show a if there are no error codes 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 TI so delivered to the faucets It is LI highly recommended that the Status Operational maximum setpoint be adjusted to the lowest temperature Sa LEE 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 es BRADFORD WHITE mnmmmmm Troubleshooting Accessing Se
6. CREE Checking continuity of sensor disconnected at Control Board Se Wo Sensor shown fully inserted into well Sensor clip shown installed properly eee Y A If sensor clip is damaged e N Continued on replace clip Replace t Check sensor Sensor is held in place with a clip fastened to the well sensor if damaged DEN pese see photo Check sensor wire for potential damage or breaks in the wire insulation Is the sensor fully inserted into the well Y Check Sensor Resistance See Sensor Resistance i E Testing following section BRADFORD WHITE WATER HEATERS 21 SERVICE PROCEDURE I Thermostat Circuit Testing and Replacement Condition Water Heater Not Operating B WARNING Display shows error code 65 Do not operate water heater without High Water Temperature over 200 F verifying that the overheating Continued from previous page J condition has been corrected 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 m
7. a Does main burner N Check spark gap to burner Light see Spark Rod Gap di Inspection x nd Proceed to next page d Spark Rod Meter probe CHECK SPARK ROD RESISTANCE BRADFORD WHITE am 31 SERVICE PROCEDURE II Combustion System Testing and Replacement 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 A WARNING Continued from 120 volt potential exposure Isolate the previous page i e i appliance and reconfirm power is disconnected using a multi meter Refer to control board illustration is there 24VAC between P5 5 and P5 8 blue and y Be d d brown wires during the flame establishing period Note Control Display must show Heating for operating status Control Boar Venturi Y adjustment Replace Rectifier harness Inlet gas ressure ta Can you hear or feel N Sege p p gas valve energize gas VANS see Gas Valve Replacement Procedure IN d Turn VENTURI set screw clockwise until its bottomed out Turn screw counter clockwise 7 12 turns from bottom Note Venturi adjustment screw is not on the U
8. if not increase the for the temperature sensors setpoint Is there 110 120 VAC following sections before replacing control board Check the voltage at the connection to the blower Is 110 120 VAC present Check resistance of high voltage cable Remove high voltage wire connected at the spark rod and Resistance should be 0 1 ohms If Can sparking be seen heard at the hold approximately 4 from metal ground with insulated resistance is high replace spark cable spark rod to the burner pliers during the ignition cycle 3 second spark trial period If spark cable is good replace Control Is there spark to ground Board Check continuity of spark rod to burner Error code 62 on display See see section Spark Rod Replacement main burner lights no flame signal in section Combustion System Testing and Replacement Check to see if control display shows any other error codes Error code 63 on display see 29 flow or damper switch 26 vent safety switch or 65 high Does burner continue until thermostat Combustion System Testing and limit If so refer to the appropriate section for testing and set point is reached See setting Replacement replacement display in Service Mode and displaying temperature sensors CONTROL BOARD Does blower post purge for 30 seconds SECONDARY System okay Ka BRADFORD WHITE WATER HEATERS 11 Troubleshooting Accessing Service Mode o
9. 13 Reconnect wire harnesses to blower assembly and gas valve 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 14 Replace surround cover on top of water heater BRADFORD WHITE mnmmmm 20 WATER HEATERS Service Procedure VI Flame Sensor Testing and Replacement WARNING 120 volt potential exposure Use caution making voltage checks to avoid Flame Sensor Testing Procedure personal injury Flame sensor may be too hot to handle take necessary Refer to illustration below is there Va Refer to ignition module control board illustration 24 volts should maintain beyond the v a minimum of 1 micro amp during 1 5 second flame proving period ln With flame sensor Disconnected D J 1 5 second flame proving period Is there 24VAC between P5 5 and P5 8 N ES Replace flame sensor with precautions lt Flame sensing circuit OK from ignition module check gasket Call for continuity to ground and or wire lead t
10. 53 55 77 742 12 1 U100L399E3N A 100 399 999 477 57 8 11075 5374 5534 77 TA V2 12 1 1 Specifications Honeywell Integrated Control System Power supply Dedicated 120 VAC 60 Hz 15A Gas Supply Minimum NPT for 300 000 BTU s hr and below Minimum 1 NPT for 399 999 BTU s hr schedule 40 black iron pipe recommended Approved Gas Type Natural gas only Gas supply must match the gas type listed on the water heater rating label Gas Pressure Nat 14 0 W C maximum static 4 5 W C minimum running recommend 7 0 W C min running Venting System Atmospherically Vented Type B venting system or approved chimney Follow current National Fuel Gas Code requirements or in Canada the Natural Gas Installation Code Minimum Clearance for Servicing 4 from the top O from the front 4 from the exhaust vent side 12 from the circulation loop side 0 from the rear Maximum Water Supply Pressure 150 PSI Thermostat Sensor 11 900 Ohms 70 F ECO opens 207 F Max Redundant sensor for ECO Sensor inside well for easy replacement of sensor 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 transf
11. Number Venting Vent 6 7 or 8 Horizontal length Vertical length Gas Line Gas Pressure Venturi Size amp material Static Setting from Bottom in Turns Distance from meter to water heater Running Inlet Manifold Electrical Line Voltage Low Voltage Polarity Spark Rod Resistance Flame Sense Micro Amps Flame Sense Resistance Error Codes on Control Display Direct Spark Ignition Combustion SE SS Installation Site Name amp Address Installation Site Contact Name amp Phone Number BRADFORD WHITE ai WATER HEATERS Parts List U Model Water Heater jo NNNM 2 Specify model 5 Vent Vertical Tube 6 Vent Protector Assembly 7 Battle 3 Flue Specify Model 8 Damper Bracket Specify Model 9 Thermostat Sensor 12134 NPT Nipple 18 Cold Water Inlet Hydrojet Assembly 49 Plastic Hole Closure Pr NN 22 Specify Model 26 Service Panel Cover 27 Blocked Vent Switch Customer must specify complete model number and serial number when ordering service parts Qo BRADFORD WHITE Parts List Combustion Assembly n cc NN PN Specify model 14 gniter Direct Spark Ignition n ier Specify model 15 Blower Burner Mounting Plate EX Lt Bore itecto 11 Bene Specify Model REENEN 8 GasketTransiionTube II 9 1 4 20Nut IT 10 Screw 8 32 x 14 BUCH pp 11 Gas
12. normally closed or circulator flow switch and damper contacts normally open 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 e Thermostat circuit opens gas valve closes blower continues to operate for 30 second post purge period e lf the normally closed blocked vent safety switch opens the gas valve closes the blower post purges then shuts off with error code 26 displayed in a lockout condition C Thermostat satisfied Gas valve closes burner extinguished Cs Blower post purge for 30 seconds Sequence of Operation For models with Honeywell Integrated Control System w Direct Spark Ignition k A The system will go into lock out mode for the following reasons 1 ERROR CODE 26 If the blocked vent safety switch mounted on the draft hood 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 2 ERROR CODE 29 If the 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 W
13. performing the following steps in this procedure Take necessary precaution to prevent personal injury Step 1 Position main power switch to OFF Step 2 Disconnect unplug water heater from 120 volt power source Step 3 Turn off water supply and drain water heater Step 4 Locate see photo below and remove anode rods from heater 1 1 16 hex socket U65L has 3 anodes 2 front and 1 side and U100L 5 anodes 3 front and 2 side Step 5 Visually inspect anode rod Anode rod should show signs of depletion this is normal If the depletion is 72 of the original diameter approximately 74 diameter replacement is recommended If any of the steel core of the anode is exposed replacement is recommended Step 6 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 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 Side of water heater Anodes Front of water heater located under plastic covers Anodes located under behind the circulator assembly plastic covers between Circulator will need to be inlet and outlet water disconnected to get to anodes connections locations Refer to ci
14. 0248 10000 9760 9526 80 9299 9078 8862 8653 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 4167 110 4663 4562 4464 4368 4214 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 T15 762 749 137 125 713 Be Careful When Making Voltage Measurements or Jumping Terminals Not to Damage or Deform Connectors or Connector Pins es BRADFORD WHITE mnmmmmm ZO SERVICE PROCEDURE I Thermostat Circuit Testing and Replacement Thermostat Sensor Thermister Replacement Procedure Step 1 Position main power switch to OFF WARNING Step 2 Disconnect unplug water heater from 120 volt potential exposure Isolate the 120 volt power source appliance and reconfirm power is disconnected using a multi meter Step 3 Un latch and remove top surround cover from top of heater Step 4 Unclip sensor con
15. 100L 399 models Gisarsbsticien N Inspect burner tube see M Jl Burner Tube Inspection N Y Does burner light Check for obstruction smoothly without at inlet of gas valve evidence of coughing N Is inlet free of or huffing obstruction L 3 Call for technical support y y Does burner operate Does burner stay lit normaly until thermostat is satisfied AN UN Check flame sensor Is there 1 to 5 micro amps Flame Sense min during 1 5 second Y flame proving period gt System OK bebo s Poste FLAME Sense us Value may be displayed on microamp pA setting RODMICROAMPS the control display by accessing Service Mode Replace flame sensor see Flame Sensor Replacement Procedure UO CONTROL BOARD O Oo SECONDARY Sensor 1 Flame Sense nd Rod SERVICE PROCEDURE II Combustion System Testing and Replacement A WARNING Heater components may be HOT when performing the following steps in this procedure Take necessary precaution to prevent personal injury Combustion System Removal Procedure Step 1 Position main power switch to OFF Step 2 Disconnect unplug water heater from AA
16. 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 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 mod
17. J v 2 N Y be cate gm amp draw through dere Hep NIE ue BLACK es lead tes and bottom black wire pene I ODE y Is Blower wheel secured to Y Call technical at the power switch iini Is there 6 to 3 0 blower motor shaft support Se amps Y i p N N Replace blower Y see Blower Replacement Procedure Refer to ignition module N Is the blocked vent y lethe tow switeiin eegener X Replace ignition control board illustration m me ona the closed position the open SE Module camma Is there 120VAC between closed position board P7 5 and P7 3 N N N P y Correct safety circuit Correct safety circuit problem per safety circuit problem per safety Inspect Damper trace circuit trace section Damper section Blocked Vent section Flow Switch Testing r y Lee Switch Testing Testing Is there 120VAC Checking for 120VAC across the white and Black amp White Wires N black wires at the aged Haake blower l see photo at right 1 5 UO CONTROL BOARD B e SECONDARY 8 PRIMARY WOU LINE IN INDUCER IA 0 oa OO DEE t um C3 P4 P10 P2 P3 P7 DIRECT SPARK IGNITION MODELS es BRADFORD WHITE WATER HEATERS Service Procedure V Blower Testing and Replacement Blower Replacement Procedure WARNING Step 1 Position main power swi
18. Replacement Procedure Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Fully inspect burner gasket for the following a 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 Install combustion system using new gasket or fully inspected gasket from step 1 Secure the combustion system to the threaded studs using nuts from step 10 on previous page Tighten the nuts evenly Replace the insulation from step 9 from the previous page If the insulation was damaged in the removal process it needs to be replaced Re install the jacket head and components that were removed in step 8 from the previous page Reconnect wire harnesses to the flame sensor spark rod connection blower damper circulator flow switch blocked vent switch and thermostat sensor Reconnect PVC damper assembly gas supply and silicone tubing to gas valve Turn on gas supply to heater and check for gas leaks repair any gas leaks found 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 Replace surround cover on top of water heater Connect damper assembly after step 5 e m a System S En
19. Setpoint Flashes Honeywell Ir F setpoint Ka BRADFORD WHITE WATER HEATERS 19 Troubleshooting 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 Setpoint Stops Flashing I F setpoint LI idle Status Operational SELECK SEN 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 idle Status Operational Leo ees Step 2 Press Set button to change temperature format F C symbol will flash in the water heater display F C Flashes 20 m BRADFORD WHITE Troubleshooting Accessing Service Mode on Control Display For models with Honeywell Integrated Control Step 3a Press Temperature Up button to change temperature format to C Changes to C F C Flashes Step 3b Press Temperature Down button to change temperature f
20. ULATOR TOGGLE SWITCH LIGHT d l IF ANY OF THE ORIGINAL WIRES AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH 18 GA STRANDED 105 C WIRE OR ITS EQUIVALENT SI UN DES CONDUCTEURS D ORIGINE FOURNI AVEC L APPAREIL DOIT GM D ETRE REMPLACE UTILISER LIN CONDUCTEUR 18 GA STRANDED 105 C GROUND GND OU L EQUIVALENT TRANSFORMER PRIMARY STUD TRANSITION 120 VOLTS AC 238 49929 008 BRADFORD WHITE KE 9 Troubleshooting 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 WARNING Check main power supply to water heater fuse circuit breaker plug 120 volt potential exposure Use caution teh Ced making voltage checks to avoid personal injury A CAUTION Use caution not to damage connectors when ee oe making voltage measurements or jumping terminals control panel is in the ON position Refer to Control Board illustration Voltage at primary pins P2 1 amp P2 3 Y l will be 110 120 If not check Line In Verify Primary voltage at the pins P3 1 amp P3 4 Check line cord with control board volt meter Replace line cord if Y non ee l Y defective Verify Secondary voltage at the control board Refer to Control Board illustration Voltage at secondary pins P4 1 amp P4 2 will be 24VAC Tran
21. WARNING 120 volt power source 120 volt potential exposure Isolate the appliance and reconfirm power is Step 3 Turn off gas supply to water heater disconnected using a multi meter Step 4 Un latch and remove surround cover from top of heater Step 5 From the gas valve disconnect the gas connection PVC damper assembly silicone tubing D 8 ben and wire harness indi REH damper assembly System Step 6 Disconnect wire harnesses to the flame sensor H spark rod connection blower damper circulator T flow switch blocked vent switch and thermostat sensor Step 7 Remove screws that hold jacket head onto the jacket Step 8 Remove jacket head with all control panel and all the wire harnesses attached to it Step 9 Remove the two pieces of insulation that cover access to the burner mounting insert Step 10 Remove the 4 nuts 7 16 socket holding the burner assembly in place eode pd 7 16 socket Step 11 Carefully remove the combustion system components and gaskets from the water heater Step 12 See next page for combustion system installation procedure BRADFORD WHITE mnmmmmm 2j SERVICE PROCEDURE II Combustion System Testing and Replacement Combustion System
22. anual Step 10 Replace surround cover on top of water heater o0 mm m BRADFORD WHITE Service Procedure IV Gas Valve Replacement Gas Valve Replacement Procedure Step 1 Position main power switch to OFF WARNING Step 2 Disconnect unplug water heater from 120 volt potential exposure Isolate the 120 volt power source appliance and reconfirm power is Step 3 Turn off gas supply to water heater disconnected using a multi meter Step 4 Un latch amp remove surround cover from top of heater Step 5 From the gas valve disconnect the gas connection PVC damper assembly silicone tubing and wire harness Step 6 Remove the 2 gas valve mounting screws Torx bit located at the 11 00 O clock amp 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 BEES mounting flange Gas valve assembly Gas valve mounting screws X2 Venturi mounting flange Step 8 Install new gas valve with new gasket provided Secure gas valve in place using screws from step 6 Step 9 Reconnect PVC damper assembly gas supply wire harness and silicone tubing to gas valve Turn on gas supply to heater and ch
23. aximum tank temperature remains well below 200 F s s HEIN This water heater is equipped with a manual reset type gas shutoff device designed to shut off the gas to the burners if excessive water temperature occurs To reset the control first press the temperature up and select buttons on the water heater display for 3 seconds to enter service mode Then press the lower right button under RESET in the display for 3 seconds Error code 65 indicates high limit lockout condition Step 1 Press for 3 seconds Step 2 Press for 3 to enter service mode seconds to reset control WATER HEATERS SERVICE PROCEDURE I Thermostat Circuit Testing and Replacement APPENDIX A Sensor Resistance at Various Temperatures Be Careful When Making Voltage Measurements or Jumping Terminals Not to Damage or Deform Connectors or Connector Pins Draw Water From The T amp P Valve Compare Temperature With Temperature Ohms Chart Below 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 In Degrees F F 0 1 2 3 40 26109 25400 24712 24045 50 19906 19383 18876 18383 60 15314 14925 14548 14180 9 6 T 8 9 22771 22163 21573 21000 20445 17440 16990 16553 16128 19715 13477 13140 12812 12494 12185 70 11884 11592 11308 11032 10502 1
24. ben BRADFORD WHITE WATER HEATERS Ultra Low NOx Atmospheric Vent Gas Water Heaters 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 Manual 238 50129 00A Save this manual for future reference The Bradford White Ultra Low NOx Atmospheric Vent Water Heaters Table of Contents Page Service Procedure Introduction 3 How to use this manual 4 Tool required for service 4 Features J Specifications 6 Sequence of Operation 8 Troubleshooting 10 Thermostat Circuit Testing amp Replacement 27 I Combustion System Testing and Replacement Sch II Burner Tube Inspection amp Replacement 35 IH 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 LB 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 White Ultra Low NOx Atmospheric Vent Water
25. d the insulation back to expose the flame sensor 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 amp gasket from transition base flange Step 7 Remove any residual gasket material from transition base flange Step 8 Install new flame sensor with new gasket provided Es F using screws from step 6 Arrange flame sensor with hook towards burner Ls Step 9 Reconnect flame sensor wire Step 10 Fold insulation back into place Be sure no wires are under the insulation that could come in contact with burner flange 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 Flame sensor screws X2 Flame sensor gasket Flame senor TO BRADFORD WHITE WATER HEATERS 41 SERVICE PROCEDURE VII Spark Rod Replacement Spark Rod Replacement Procedure A WARNING Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 Step 10 Step 11 Position main power switch to OFF 120 volt potential exposure Isolate the appliance and reconfirm power is Disconnect unplug water heater fr
26. e stored in code index 1 and the most recent in code index 10 22 e BRADFORD WHITE WATER HEATERS Troubleshooting 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 No Current Error Code idle Status Operational Step 2 Press the Temperature Down button to select the error code index starting with the most recent error code 10 Error Code Index idle II m O 0 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 No Error Code Shown for Code Index 10 Ka BRADFORD WHITE WATER HEATERS 23 Troubleshooting 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 Error Code Index tional SE Step 5 Press the Select button for code index 9 to view if there are any code numbers Stored Error Code Fo
27. echnical support Is there continuity to ground see Flame Sensor A Replacement Procedure N Remove flame sensor from water heater Check continuity from tip of flame sensor N to end of wire lead there continuity N f E Replace flame sensor Is flame sensor free Is ceramic of flame Y see Flame Sensor of oxidation sensor cracked Replacement Procedure NM ji Clean or d b D flame sensor see Flame Sensor Replacement Volt meter set to BOARD a Procedure Micro amps setting CONTROL BO Q HA i EM SECONDARY Fl CONTROL Sen Meter probe Lar OO zD 9 elle BOO 4 S cn SIE 9 S s BN DOA SAHE D 5O 24 SS 123 19 n Amm H Uc Ire 7 y Flame sensor J1 P5 P4 9 P10 P2 P3 P7 terminal Flame sensor terminal on M control board SEHR DIRECT SPARK IGNITION MODELS BRADFORD WHITE 40 WATER HEATERS Service Procedure VI Flame Sensor Testing and Replacement Flame Sensor Replacement Procedure WARNING Step 1 Position main power switch to OFF 120 volt potential exposure Isolate the appliance and reconfirm power is disc f ected using a multi meter Step 2 Disconnect unplug water heater from 120 volt power source Step 3 Un latch amp remove surround cover from top of heater Step 4 Carefully cut a path in the insulation from the blower tube towards the flame sensor shown below Pay close attention to not cut any wires Fol
28. eck 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 BRADFORD WHITE mnmmm X O Service Procedure V Blower Testing and Replacement ES Replace blower see Blower Replacement Procedure Isthere 120VAC C b Does blower across the white and energize Y Refer to ignition module control board N Replace i gt ee eae dd gt illustration ignition module For Direct Spark P3 on the control i 5 g Ignition models board Is there 120VAC between P7 5 and P7 3 control board shows Heating raise m P M A temperature setpoint if N Y Se E J Black wire leading to control N board from power switch looped through amprobe Determine power Source problem and correct j
29. ential exposure Use caution making voltage checks to avoid personal injury IMPORTANT NOTE This procedure assumes a cool tank d CAUTION Use caution not to damage connectors when making voltage measurements or jumping terminals Condition Water Heater Not Operating Display shows error code 32 Sensor Reading Faulty Y Unplug or disconnect electrical power to the water heater Y 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 y 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 Y 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 Y Condition Water Heater Not Operating Display shows error code 65 High Water Temperature over 200 F Y WARNING Do not reset the display from the hard lockout state without correcting the cause of the C overheating condition Y Turn power OFP Draw water to cool tank below 120 F Sey Cc db P d ETUR
30. ermination Contact your plumbing professional to correct this issue Blocked Vent Switch should be installed on the lip of the drafthood Step 4 When no blockage or downdraft issues are present check the continuity of the switch see photo below If there is no continuity present even when switch is reset the blocked vent switch assembly needs to be replaced Step 5 If blocked vent switch assembly is functioning correctly check to see if the wire harness has any signs of damage Replace harness if any signs of damage exist Step 6 Restore water heater to use 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 Set voltmeter to B Ohms setting The switch should be very close to 0 ohms M 2 BRADFORD WHITE mnmmmm Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 10 48 Service Procedure XIII Damper Inspection and Replacement Un latch and remove top surround cover from top of water heater Locate the damper at the back of the units If the damper is working properly intake air should be pulling in through the screened elbow see picture right Verify that the damper is in the Open positio
31. ervice Procedure VIII Ignition Module Control Board Replacement Control Board Replacement WARNING Step 1 Position main power switch to OFF 120 volt potential exposure Isolate the appliance and reconfirm power is Step 2 Disconnect unplug water heater from 120 disconnected using a multi meter volt power source Step 3 Un latch and remove top surround cover from top of water heater Step 4 Locate control board Step 5 Remove 4 screws that attach display panel Remove to control panel save screws Screws X4 Ze Step 6 Carefully disconnect all wire connections from E control board Identify all wire connections Step 7 Depress tabs on the top of control first then tilt the control forward Step 8 Unhook the tabs on the control out of the slots on the control panel and remove control Display panel Step 9 Replace control board and all wire connections Step 10 Re attach the display panel from step 5 using the Unclip this same screws side first 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 instruction located in the installation and operating instruction manual Step 12 Replace surround cover on top of water heater CORO BARTA Identify wires for proper re connection BRADFORD WHITE aE Service Procedure IX Transformer Replacement
32. fter repair is made Step 9 Disconnect and replace either the flow switch and or circulator assembly Step 10 During replacement of the components apply thread sealing tape or other thread compound to threads of the flow switch or circulator assembly onto heater Restore water supply and check for and repair any leaks found Check continuity between top and bottom screws Remove cover from flow switch Step 11 Replace pipe insulation from step 8 Step 12 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 Ww a Gently pull the lever up to break continuity or push the lever down to make continuity Ss 40 e BRADFORD WHITE Service Procedure XII i Blocked Vent Switch Inspection and Replacement Step 1 First determine is the Blocked Vent Switch was installed correctly on the drafthood see picture right Step 2 When Error Code 26 is present you first must determine if there is a blocked vent condition present If so clear the obstruction and reset the switch then continue with normal operation Step 3 If the switch is tripped and there is no obstruction in the venting there could have been an extended down draft that tripped the switch The down draft could have been caused by damage vent t
33. hen 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 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 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 4 ERROR CODE 65 If the top of the tank should exceed 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 only be reset in the Service Mode which is detailed in the Troubleshooting section of this Service Manual CONNECTION WIRING DIAGRAM WIRING DIAGRAM 120 VOLTS AC DAMPER FLOW SWITCH N O 24W LY He GY GY ay 9 PIN CON xx O VENT LIMIT N C TO SAFETY HARNESS p SENSE IGNITION SYSTEM VALVE 8 R COM 5 R Ms ttt I BK B o HIGH VOLTAGE DEE J COMBUSTION BLOWER CIRC
34. ket Flame Sense 12 Gasketlgnter IT 13 Sensor Flame Senge II Customer must specify complete model number and serial number when ordering service parts BRADFORD WHITE mmm 51 Parts List Ignition Control Assembly and Harnesses 6 Switch Main Power 116 BlowerHarness 120V 8 Screw 18 BVS Damper Flow Harness 24V 6 Blower Circ Damper Harness 24V Ignition Harness Direct Spark Ignition Damper Harness 120V Flame Sense Harness Customer must specify complete model number and serial number when ordering service parts Ss D2 emm BRADFORD WHITE Glossary of Terms 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 UA Micro Amp NOTES BRADFORD WHITE mnmmmmm X O Notes NOTES
35. me 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 Error Code Shown in Water Heater Display Press for 2 seconds 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 Resetting Error Codes in Hard Lockout Condition Error Code Shown in Water Heater Display Status Service Needed E X Step 1 Press for 3 seconds Step 2 Press for 3 seconds to to enter service mode reset control in service mode WATER HEATERS SERVICE PROCEDURE I Thermostat Circuit Testing and Replacement WARNING 120 volt pot
36. n Control Display For models with Honeywell Integrated Control The 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 Max Setpoint next to Temperature Setpoint value IK 5 CL X i Status Operational SELECTN Step 2 Pressing Select button will change display to next mode 1 E Temp LI idle Status Operational JSELECH SEN 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 opera n E in the User Mode rror Code Shown in Water Heater Display Status Service Needed SELECT Lockout RESET es BRADFORD WHITE WATER HEATERS 12 Troubleshooting Accessing Service Mode on Control Display For models with Honeywell Integrated Control 1 Max Setpoint Display Change Max Setpoint value in Water Heater Display es BRADFORD WHITE KS Troubleshooting Accessing Service Mode on Control Display For models with Honeywell Integrated Control 4 Setpoint Display Change
37. n when there is a call for heat see picture below If you hear the blower on but damper is not open turn the power switch off for 30 seconds and recheck to see if damper opens If the damper doesn t open replace it Check for voltage at the damper harness connection Use a volt meter set to read line voltage see picture below There should always be 102 to 132 volts between black and white wires There should also be 102 to 132 volts between blue and white wires when there is a call for heat If 120 volts is not present from either two inspection points check the harnesses for damage and replace if needed Restore water heater to use 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 Replace surround cover on top of water heater 120 Volt Intake Damper A WARNING 120 volt potential exposure Isolate the appliance and reconfirm power is disconnected using a multi meter eu Remove screw for elbow removal open Damper in Voltmeter set to voltage control board Check for voltage at damper harness from position Screened elbow removed to see damper position iem BRADFORD WHITE WATER HEATERS U65L and U100L Heater Service Report Date Service Provider Model Number Phone Number Serial
38. nector from control board and remove harness from control panel see picture Step 5 Unclip sensor from well and pull sensor to remove do not remove well see picture Step 6 Install new sensor assembly into well and reinstall senor clip Step 7 Reconnect the sensor connector to the control board and route the wire harness through the same path that it was removed Step 8 Restore 120 volt power supply 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 9 Replace surround cover on top of heater Sensor shown fully inserted into well E Sian XONMO7 o L00Lg0ecec Remove sensor connector from control board Sensor clip shown installed properly SERVICE PROCEDURE II Combustion System Testing and Replacement 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 Note Models using metal fiber mesh burner a red glow from the burner surface is normal 5 ght Glass Verify Minimum Gas Supply Piping Requirements of N
39. ocedures directly follow the test procedures for a given component Contact Technical support immediately if diagnosis is not determined using the methods described in this service manual Tools Required for Service 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 amp Phillips long reach 12 magnetic tip Phillips head screw driver 2 tip nut driver pliers Common amp needle nose socket set including a 1 1 16 deep well socket wire cutters wire strippers wire crimpers torpedo level small shop sac step ladder and flashlight 4 KE BRADFORD WHITE Features Features of Honeywell Integrated Control System e Attractive digital water heater di
40. om 120 volt power 1 disconnected using a multi meter source Un latch amp remove surround cover from top of heater Carefully cut a path in the insulation from the blower tube towards the flame sensor shown below Pay close attention to not cut any wires Fold the insulation back to expose the spark rod Disconnect wire lead from spark rod wi Remove the 2 mounting screws magnetic tip long reach Phillips screw driver and remove spark rod amp gasket from transition base flange Remove any residual gasket material from transition base flange Install new spark rod with new gasket provided using screws from step 6 Arrange spark rod with hook towards burner Off center mounting hole only allow installation one way Spark Rod Check distance between spark rod and blower transition tube shown below Fold insulation back into place Be sure no wires are under the insulation that could come in contact with burner flange 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 Replace surround cover on top of water heater Distance of 2 to 2 1 16 for 199 999 input and below Distance of 4 1 8 to 4 3 16 for 270 000 input and above Blower transition tube e Center of spark rod S
41. ormat to sp Changes to F FC Flashes idle Status Operational SELEGIN SEN Step 4 Press Set button to confirm F or C format F C will stop flashing F C Symbol Stops Flashing BRADFORD WHITE WATER HEATERS 21 Troubleshooting 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 Setpoint shown in F 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 ra id Serv SELECN mag at n Needed CO 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 b
42. ormer Controls tank temperature ignition functions combustion blower See ignition timings in sequence of operation for Integrated Control Transformer 120VAC primary 24VAC secondary 40VA 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 Gas Valve Negative regulation 24 VAC 72 PSI max 4 5 W C Minimum running inlet Blocked Vent Safety Switch Normally closed opens 9 240 F manual reset Circulator Flow Switch 24 VAC normally open closes when circulator is operational Blower 120VAC 60Hz 6 1 amps 6400 RPM Combustion Levels CO2 10 1196 CO less then 0 04 percent 400 PPM air free Circulator 120VAC 60Hz 76 1 amps 3250 PRM BRADFORD WHITE KE WATER HEATERS Sequence of Operation For models with Honeywell Integrated Control System w Direct Spark Ignition s A G Thermostat calls for heat Combustion blower amp circulator start while the damper opens G Blower pre purge period of 30 seconds o9 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 e Burner on flame proving period 2 seconds Requires a minimum of 0 8 microamp through flame sense rod to prove flame e f either blocked vent safety switch contacts
43. play The following sections will provide instructions for servicing each error code HONEYWELL INTERGRATED CONTROL ERROR CODES ERROR CODE DEFINITION 4 LOW FLAME SENSE CURRENT 6 FLAME SENSED OUT OF NORMAL SEQUENCE BEFORE OPENING GAS VALVE OR AFTER CLOSING GAS VALVE 23 FLAME DETECTED BEFORE IGNITION 24 FLAME DETECTED AFTER A HEATING CYCLE COMPLETES 26 BLOCKED VENT SWITCH OVER 240 F 29 FLOW SWITCH OR DAMPER FAILED TO CLOSE OR OPEN 32 LOWER SENSOR READINGS FAULTY 57 FLAME ROD SHORTED TO GROUND 58 AC LINE FREQUENCY ERROR SIGNAL TOO NOISY OR FREQUENCY INCORRECT 59 LINE VOLTAGE TOO LOW OR HIGH 61 DC OUTPUT VOLTAGE UNSTABLE 62 MAXIMUM NUMBER OF RETRIES DETECTED 63 MAXIMUM NUMBER OF IGNITION RECYCLES DETECTED 64 ELECTRONICS FAILURE 65 HIGH WATER TEMPERATURE OVER 200 F IF ANY OF THE ABOVE CODES APPEAR ON THE CONTROL DISPLAY CONTACT YOUR PLUMBER OR QUALIFIED SERVICE AGENT FOR SERVICE OF THE WATER HEATER BRADFORD WHITE mnmmmm O Troubleshooting Resetting Error Codes For models with Honeywell Integrated Control A 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 fla
44. r Code Index 9 idle Status Operational SELECT SEN 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 oneal H1 oF setpoint LI idle Statu Operational S KH Exiting Service Mode 24 smm BRADFORD WHITE Troubleshooting Error Code Definitions For models with Honeywell Integrated Control ERROR CODE DEFINITIONS If 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 dis
45. rculator assembly replacement procedure BRADFORD WHITE WATER HEATERS 45 Service Procedure XI g Circulator Assembly Inspection and Replacement Step 1 When Error Code 29 is present you first must determine if the circulator or flow switch is bad z SS j y k h Circulator 120V Step 2 Check if there is 120V to the circulator harness see picture below If voltage is not present trace wire harness for any sign of damage Replace harness if damaged If voltage is present replace circulator see step 5 Step 3 Check if the flow switch is working properly see picture below Using a volt meter check the continuity between top and bottom screw terminals on the flow switch If the circulator is flowing water there will be continuity Step 4 If there in no continuity present gently push down the flow switch lever down to make continuity If continuity is made recheck to see if the circulator is bad If continuity is not made replace the flow switch see step 5 Flow Switch Step 5 Position main power switch to OFF l Check voltage of Step 6 Disconnect unplug water heater from 120 bottom to volt power source connections with volt meter Step 7 Turn off water supply and drain water heater Step 8 Once the water heater is drained remove the cable ties holding on the pipe insulation Save the pipe insulation to replace a
46. rvice Mode on Control Display For models with Honeywell Integrated Control Step 2 Press Set button to enter setting mode Max Setpoint will flash to indicate setting mode Max Setpoint Flashes IY 17 d idle CL O Q0 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 Max Setpoint continues to flash while making adjustments TTT setpoint idle NN o gt Step 4 Press Set button to confirm new Max Setpoint value and stop setting mode Max Setpoint stops flashing TTT setpoint idle LI Status Operational es BRADFORD WHITE WATER HEATERS 16 Troubleshooting 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 Setpoint 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 idle Status Operational CO Exiting Service Mode Display of Water Temperature Step 1 In Service Mode Press the Select button until Water Temp is displayed in the
47. screws philips head that hold the Spark Rod and Flame Sensor Step 11 Remove the Spark Rod and Flame Sensor The gaskets will need to be replace when reinstalled Remove 6 nuts 7 16 socket Step 12 Remove the 6 nuts 7 16 socket holding the burner plate and combustion system in place Mounting Assemb Step 13 Remover combustion system and burner plate from the mounting assembly See next page for burner tube installation procedure BRADFORD WHITE mnmmmm O SERVICE PROCEDURE III Burner Tube Inspection and Replacement AX WARNING Heater components may be HOT when performing the following steps in this procedure Take necessary precaution to prevent personal injury Burner Tube Inspection Step 1 a Outer fiber mesh should be uniform with no tears or deterioration 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 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 Step 1 Fully inspect burner flange gaskets igni
48. sformer If not check transformer Replace Top terminals are 24VAC Blue and Yellow Green transformer or wire harness Bottom terminals are 120VAC Black and White Does water heater display operate Is 24VAC present between Check wires for proper termination N e RED and BLACK wire pin to control display connections on the back of Are wire terminations connected Does the combustion blower start to operate Increase thermostat setting if tank is warm Control Display properly to control display Make proper wire terminations Y BREVES pe Is 24VAC present between E COM Check wire screw terminals P9 2 amp P9 3 on harness for pag the Control Board proper continuity Replace N Control Board es BRADFORD WHITE WATER HEATERS 10 Troubleshooting system Observation For models with Direct Spark Ignition WARNING 120 volt potential exposure Use caution making voltage checks to avoid personal injury A CAUTION Use caution not to damage connectors when making voltage measurements or jumping terminals Replace control board if display Error code 29 on display Refer to Control Board shows heating and no voltage is illustration Measure voltage between terminals P7 3 amp present to the blower harness Does combustion blower operate P7 5 on the inducer output make sure the control display Make sure there are no error codes shows heating in the status mode
49. splay 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 e Single control board with plug in wiring controls temperature ignition and blower operation e Reduced number of parts for servicing and wiring e Plug in wiring reduces chance of miswirng e 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 e Water heater display will show diagnostic codes in the event the water heater needs servicing Aids in diagnosing and servicing the water heater e Water heater display can show previous error code history to further aid in servicing the water heater es BRADFORD WHITE KE 5 Specifications m 37 11 16 Model Description 1 Hour Input BTU Hr Delivery at Model Number 100 F Rise Gal NAT in U65L155kE3N A 65 155000 203 56 6 10 37 39 4 61 58 14 U65L199E3N A 65 199999 249 56 6 1074 37 39 61 58 174 U65L270E3N A 65 270000 320 56 6 11074 37 39 61 58 174 U100L199E3N A 100 199999 274 56 6 1074 5374 5534 77 TA 5 12 _ U100L270E3N A 100 270000 345 56 6 10
50. sure gasket is in good condition Evenly tighten 4 nuts 7 16 socket e WATER HEATERS SERVICE PROCEDURE III Burner Tube Inspection and Replacement A WARNING Heater components may be HOT when performing the following steps in this procedure Take necessary precaution to prevent personal injury Burner Tube Removal Procedure MEN NEN A WARNING Step 1 Position main power switch to OFF 120 volt potential exposure Isolate the appliance and reconfirm power is 120 volt power source disconnected using a multi meter Step 2 Disconnect unplug water heater from Step 3 Turn off gas supply to water heater Combustion system Step 4 Un latch amp remove surround cover from top of Spark Rod and Flame and burner plate heater Sense and wire harness Step 6 Disconnect wire harnesses to the flame sensor spark rod connection blower damper circulator flow switch blocked vent switch and thermostat sensor Step 5 From the gas valve disconnect the gas Fe A connection PVC damper assembly silicone tubing k il E Step 7 Remove screws that hold jacket head onto the jacket Burner Step 8 Remove jacket head with all control panel and all fm the wire harnesses attached to it Burner Gasket em E gd Step 9 Remove the two pieces of insulation that cover i b access to the burner mounting insert Sy Step 10 Remove the 4
51. tch to OFF 120 volt potential exposure Isolate the Step 2 Disconnect unplug water heater from appliance and reconfirm power is 120 volt power source disconnected using a multi meter Step 3 Turn off gas supply to water heater Step 4 Un latch amp remove surround cover from top of heater Step 5 From the gas valve disconnect the gas connection PVC damper assembly silicone tubing and wire harness Step 6 Disconnect wire harness from blower Step 7 Remove the 2 gas valve mounting screws Torx bit T 25 or 5 32 Allen wrench located at the 11 00 O clock amp 5 00 O clock position on the venturi mounting flange Step 8 Remove 4 blower flange mounting screws 5 32 Allen wrench and remove blower from transition flange Blower gas valve Blower d gasket Blower transition gasket Blower transition Remove any residual gasket material from venturi mounting flange and transition flange Blower mounting m screws X4 Gas valve mounting screws X2 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 PVC damper assembly 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
52. ter 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 mounting assembly Be sure gasket surfaces are free of debris Step 3 Reinstall the burner plate with combustion assembly with the nuts that were removed from step 12 on previous page Tighten the nuts evenly Step 4 Carefully reinstall flame sensor with gasket and direct spark igniter DSI with gasket and secure with screws from step 11 on previous page Step 5 Replace the insulation from step 9 form the previous page If the insulation was damaged in the removal process it needs to be replaced Step 6 Re install the jacket head and components that were removed in step 8 from the previous page Step 7 Reconnect wire harnesses to the flame sensor spark rod connection blower damper circulator flow switch blocked vent switch and thermostat sensor Step 8 Reconnect PVC damper assembly 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 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 m
53. ule 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 es BRADFORD WHITE KH 3 How to Use This Manual s 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 Ultra Low NOX Atmospheric Vent Water Heater Understanding the sequence of operation section of this manual will contribute greatly to troubleshooting this product A 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 pr
54. upper right section of the water heater display This is the reading for the sensor IT1 CL Status Operational Lower Sensor SEEN N BRADFORD WHITE mn WATER HEATERS Troubleshooting 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 pA i dmm ILL o Heating Status Operational SELECT SET O To Display and Change Temperature Setpoint Step 1 In Service Mode press the Select button until Setpoint is shown in the water heater display II F setpoint ILLI idle Status Operational SELECIN SE 18 m
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