Bradford White EF100T150(E)*(N User manual

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Manual 238-45817-00F
SERVICE
MANUAL
Troubleshooting Guide
and Instructions for Service
(To be performed ONLY by
qualified service providers)
Models Covered
by This Manual:
For The Bradford White
eF Series
®
Ultra High Effeciency
Models:
EFR160T120*(EN,SX)
EF60T125(E)*(N,X)(A)(2)
EF60T150(E)*(N,X)(A)(2)
EF60T199(E)*(N,X)(A)(2)
EF100T150(E)*(N,X)(A)(2)
EF100T199(E)*(N,X)(A)(2)
EF100T250(E)*(N,X)(A)(2)
EF100T300(E)*(N,X)(A)(2)
EF100T399(E)*(N,X)(A)(2)
(*) Denotes WarrantyYears
C
Ultra High Efficiency Water Heaters
®

The Bradford White
2
Page eF Service Procedure
Introduction 3 - - -
How to use this manual 4 - - -
Tool required for service 4 - - -
Features 5 - - -
Specifications 6 - - -
Sequence of Operation 10 - - -
Troubleshooting 16 - - -
Thermostat Circuit, Testing & Replacement 35 I
Combustion System Testing and Replacement 43 II
Burner Tube Inspection & Replacement 49 III
Gas Valve Replacement 51 IV
Blower Testing and Replacement 52 V
Exhaust Pressure Switch Testing and Replacement 54 VI
Hot Surface Igniter Testing and Replacement 60 VII
Flame Sensor Testing and Replacement 62 VIII
Spark Rod Gap Adjustment and Replacement 64 IX
Ignition Module/Control Board Replacement 66 X
Transformer Replacement 68 XI
Intake Pressure Testing and Replacement 69 XII
Vent Safety Switch Testing and Replacement 71 XIII
Anode & Flue Baffle Inspection and Replacement 73 XIV
Installation Check List 78 - - -
Heater Service Report 79 - - -
Parts List 80 - - -
Glossary of Terms 89 - - -
2

The Bradford White eF Series®Ultra High Efficiency Water Heater uses a low
Nox premix power burner located at the top of the water heater to direct a turbulent
flame down into a submerged combustion chamber. This turbulence causes a
thorough mixing of gas and air for optimum combustion. The combustion gases
then travel through a three pass flue system keeping the gases moving at a high
velocity. The combination of high turbulence and velocity results in an optimum
transfer of heat from the flue gases into the water.
Burner operation is controlled using an electronic ignition module. The module
monitors the status of the electronic thermostat, vent temperature limit switch, vent
system pressure switches and a flame sensor to control output voltage to blower
motor, hot surface igniter/spark rod and gas valve. The module contains
programming which determines the sequence of operation and timings for purge
periods, trial for ignition, flame sensing and lockout. The module will also provide
diagnostic information to help in determining the cause of system lockouts.
The contents in this manual are detailed informational tools to assist in the proper
diagnosis of the eF Series®Ultra High Efficiency Water Heater operational faults.
Please read this service manual completely and provide as much information
regarding the eF Series®Ultra High Efficiency Water Heater operation and
installation specific concerns.
The Bradford White eF Series®Ultra High Efficiency Water Heater is designed to
deliver a remarkable thermal efficiency rating in a quiet running unit with venting
options that allow for installation flexibility. Several technologically advanced
design features are incorporated in the design that will require additional
knowledge on the part of the qualified service provider. The information in this
manual will instruct service and maintenance professionals on the function, proper
diagnosis and repair of The Bradford White eF Series®Ultra High Efficiency Water
Heater.
3
3

It is intended for this manual to be used by qualified service personal for the primary purpose
of troubleshooting analysis and repair of the Bradford White eF Series®Ultra High
Efficiency Water Heater. Understanding the sequence of operation section of this manual will
contribute greatly to troubleshooting this product.
An “Installation Check List” is shown towards the end of this manual. Compare the installation
against the installation check list to confirm all requirements are met.
An “eF Service Report” is shown towards the end of this manual. Completing this form will
assist in the troubleshooting efforts. Should you need to call for technical support, Please
provide the information shown on this form to the support technician to insure accurate
troubleshooting.
Troubleshooting begins with “System Observation” to determine failure mode as indicated by
the LED status of the ignition module. Troubleshooting continues with “Failure Modes and
Probable cause” directing the service provider to a series of test procedures to determine
root cause of failure. Component replacement procedures directly follow the test procedures
for a given component.
In some difficult to diagnose conditions, it may be necessary to isolate the heater from the
vent system to determine root cause.
Contact Technical support immediately if diagnosis is not determined using the methods
described in this service manual.
Manometer: Two types available, a liquid “U” tube type or a digital (magna-helic)
type. This device is used to measure gas and/or air pressures and
vacuum.
Multi-Meter: A digital type is strongly recommended. This device is used to measure
electrical values. The meter you select must have the capability to
measure volts AC, volts DC, Amps, micro-amps and ohms.
Thermometer: Used to measure water temperature. An accurate thermometer is
recommended.
Water Pressure Gage: Used to measure water supply pressure. Also used to determine tank
pressure by adapting to the drain valve of the heater.
Jumper Leads: A length of wire (12" min.) with alligator clip at both ends.
Various Hand Tools: Pipe wrench, channel locks, open end wrench set, 12" crescent wrench,
Allen wrench set, torx bit set, screw drivers (common & phillips), long
reach (12") magnetic tip phillips head screw driver #2 tip, ¼" nut driver,
pliers (common & needle nose), socket set including a 1-1/16 deep well
socket, wire cutters, wire strippers, wire crimpers, torpedo level, small
shop vac, step ladder, and flashlight.
4
4

Attractive digital water heater display on control panel for setting and displaying the
temperature setpoint. Pressing temperature UP and DOWN buttons changes the
temperature setpoint. Same water heater display used on all models. Temperature
format may be displayed in °F or °C.
Single control board with plug in wiring controls temperature, ignition, and blower
operation.
Reduced number of parts for servicing and wiring.
Plug in wiring reduces chance of miswirng.
Burner ignition with direct spark ignition - A high voltage spark jumps from the spark rod to
the burner surface to ignite the gas. Eliminates burned out hot surface igniter
replacements.
Water heater display will show diagnostic codes in the event the water heater needs
servicing. Aids in diagnosing and servicing the water heater.
Water heater display can show previous error code history to further aid in servicing the
water heater.
5
Serial Numbers including and AFTER GB13006174 and ALL EFR models
NOTICE:
THE EF100T399 MODEL SERIES DO NOT USE THE HONEYWELL
INTEGRATED CONTROL SYSTEM. THESE MODELS USE THE UT
ELECTRONICS CONTROL MODULE WITH HOT SURFACE IGNITION.
5

EFR-1-60T-120
EF60T125
EF60T150
EF60T199
EF100T150
EF100T199
EF100T250
EF100T300
EF100T399
120,000
125,000
150,000
199,999
150,000
199,999
250,000
300,000
399,999
180
187
211
265
250
309
364
405
521
345
363.6
422.7
557.6
450.5
597
734.8
836.4
1,127
138
145.5
169.1
223
180.2
238.8
293.9
334.5
451
99
103.9
120.8
158
129
171
210
239
322
60
60
60
60
100
100
100
100
100
95.0
96.0
93.0
92.0
99.1
98.5
97.0
92.0
93.0
57
57
57
57
77 5/8
77 5/8
77 5/8
77 5/8
77 5/8
28 ¼
28 ¼
28 ¼
28 ¼
28 ¼
28 ¼
28 ¼
28 ¼
28 ¼
5
5
5
5
5
5
5
5
5
13
13
13
13
13
13
13
13
13
40
40
40
40
60
60
60
60
60
42 ¼
42 ¼
42 ¼
42 ¼
62 ¼
62 ¼
62 ¼
62 ¼
62 ¼
52 ½
52 ½
52 ½
52 ½
73 1/8
73 1/8
73 1/8
73 1/8
73 1/8
53 ½
53 ½
53 ½
53 ½
74 ¾
74 ¾
74 ¾
74 ¾
73 ¼
1
1 ½
1 ½
1 ½
1 ½
1 ½
1 ½
1 ½
1 ½
1
1
1
1
1
1
1
1
1
¾
¾
¾
¾
¾
¾
¾
¾
1
¾
¾
¾
¾
¾
¾
¾
¾
1
570
570
570
570
900
900
900
900
950
Shpg
Wt
(lbs)
T&P
Valve
Open
(NPT)
Gas
Conn
Dia
(NPT)
Space
Heating
Conn
Dia
Front
Wtr
Conn
Dia
H
Flr to
Gas
Conn
G
Flr. To
Air
Intake
F
Flr To
Outlet
Wtr
Conn
E
Flr to
T&P
Valve
Conn
D
Flr to
Inlet
Wtr
Conn
C
Flr
to
Vent
Outlet
B
Dia
A
Ht
Therm
Eff
%
Stg
Cap
U.S.
Gal
140°F100°F40°F
1st Hr
Del
Gal
@
100°F
Rise
Input
Rate
BTU/h
Model No
Recovery GPH
at Degree Rise DIMENSIONS (INCHES)
6
6

7
Thermostat Sensor 11,900 Ohms @ 70°F, ECO opens @ 201°F Max., ECO close @ 100°F Min.
Thermostat Board Max temp 180°F, Min temp 91°F, 24VAC, 60Hz max.
Hot Surface Igniter 120VAC, 30-120 ohms @ room temperature.
Flame Sensor Output Minimum 1 micro amp, Typical range 4 to 7 micro amps.
Temperature Dial Min. set point 5400-6600 ohms, Max set point 0-50 ohms.
Ignition Module See “Sequence of Operation, for models starting with CF serial and later”
Gas Valve Negative regulation, 24 VAC, ½" PSI max., 4.5" W.C. Minimum running inlet.
Transformer 120VAC primary, 24VAC secondary, 40VA.
Vent Safety Switch Normally closed, opens @ 350°F, manual reset.
Intake Pressure Switch
“CF” serial number or
later
Not required.
Blower 120VAC, 60Hz, .6-1 amps, 6400 RPM.
Exhaust pressure switch
serial numbers prior to
“CF”
24VAC, normally open, closes on pressure increase as follows
Note 1:
+2.58" W.C. EF(60,100)T199
+1.50" W.C. EF100T150 (see note 2)
+1.22" W.C. EF60T150, EF100T250
+2.08" W.C. EF60T125
+0.55" W.C. EF100T300 (see note 3)
Note 2: +5.6" W.C. on serials prior to AH5039107
Note 3: +0.8" W.C. on serials prior to AK5288269
Power supply Dedicated 120 VAC, 60 Hz, 15A, GFI
Approved Gas Type Natural or Propane. Unit must match gas type supplied.
Venting System Power vent, balanced direct vent or unbalanced direct vent. See vent tables on page 7
Approved Vent Materials PVC or CPVC
Gas Supply Minimum 1" NPT for EF100T399, all others ¾" NPT
(schedule 40 black iron pipe recommended)
Minimum Clearance
for Servicing 18" from top, 24" from front, 4" sides and rear.
Maximum Water Supply
Pressure 150 PSI
Gas Pressure (Nat & L.P.)14.0" W.C. maximum static, 4.5" W.C. minimum running (recommend 7.0" W.C. min running)
Combustion Levels CO2: 10-11%, CO: less then 0.04 percent (400 PPM) air free
Intake Pressure Switch
serial numbers prior to
“CF”
24VAC, normally closed, opens on vacuum increase @ -1.20 W.C.
Blocked Vent Pressure
Switch “CF” serial
number or later
24VAC, normally closed, opens when pressure increases to +2.70 W.C.
7

8
Power supply Dedicated 120 VAC, 60 Hz, 15A
Thermostat Sensor 11,900 Ohms @ 70°F, ECO opens @ 207°F Max., ECO close @ 120°F Min. Redundant
sensor for ECO. Sensor inside well for easy replacement of sensor.
Spark Rod Igniter 0.22" nominal gap to the burner surface.
Flame Sensor Output Minimum 1 micro amp, Typical range 5 to 30 micro amps.
Control Display
Digital display, 24 volts. Temperature Range: 70-180 deg. F. Used to set tank temperature
(deg. F or deg. C), show operating status, Display error codes, error code history, limit
maximum setpoint temperature.
Control Board Operates from 24 volt from transformer. Controls tank temperature, ignition functions,
combustion blower. See ignition timings in sequence of operation for Integrated Control.
Gas Valve Negative regulation, 24 VAC, ½" PSI max., 4.5" W.C. Minimum running inlet.
Transformer 120VAC primary, 24VAC secondary, 40VA.
Vent Safety Switch Normally closed, opens @ 350°F, manual reset.
Blower 120VAC, 60Hz, .6-1 amps, 6400 RPM.
Approved Gas Type Natural or Propane. Unit must match gas type supplied.
Venting System Power vent, balanced direct vent or unbalanced direct vent. See vent tables on page 7
Approved Vent Materials PVC or CPVC
Gas Supply Minimum ¾" NPT
(schedule 40 black iron pipe recommended)
Minimum Clearance
for Servicing 18" from top, 24" from front, 4" sides and rear.
Maximum Water Supply
Pressure 150 PSI
Gas Pressure (Nat & L.P.)14.0" W.C. maximum static, 4.5" W.C. minimum running (recommend 7.0" W.C. min running)
Combustion Levels CO2: 10-11%, CO: less then 0.04 percent (400 PPM) air free
Blocked Vent Pressure
Switch 24VAC, normally closed, opens when pressure increases to +2.70 W.C.
Serial Numbers including and AFTER GB13006174 and ALL EFR models
NOTICE:
THE EF100T399 MODEL SERIES DO NOT USE THE HONEYWELL
INTEGRATED CONTROL SYSTEM. THESE MODELS USE THE UT
ELECTRONICS CONTROL MODULE WITH HOT SURFACE IGNITION.
8

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
A3" Balanced Direct vent system has 30 feet of straight exhaust pipe and 30 feet of straight
intake pipe. It has 3- 90° elbows in the exhaust and 3- 90° elbows in the intake. It has 1- 45°
elbow in the exhaust and 1- 45° elbow in the intake.
Therefore:
6- 90° elbows x 5 feet = 30 feet.
2- 45° elbows x 2½ feet = 5 feet.
60 feet of straight pipe + 30 feet + 5 feet = 95 feet.
System is within “Maximum Combined Length” from table above.
Unbalanced Direct Vent Systems
Air intake CAN NOT exceed exhaust
by more than 30 feet
Power Vented Systems
PVC, CPVC
Total length of exhaust piping must not exceed
“Maximum Vent Length”
Shown below
Maximum Vent Length (feet)
Model Number 3"
EF60T125, EF100T150 120'
EF60T150, EF100T199
EF60T199
EF100T300
100'
80'
60'
4"
170'
150'
130'
110'
EF100T399 50' 100'
EFR-1-60T120 60' 120'
2"
170'
30'
30'
30'
N/A
N/A
Balanced Direct Vent Systems
PVC, CPVC
Total length of intake piping and exhaust piping
added together must not exceed “Maximum
Combined Length”
Shown below
Maximum Combined Length (feet)
Model Number 3"
EF60T125, EF100T150 120'
EF60T150, EF100T199
EF100T250
EF100T300
100'
80'
60'
4"
170'
150'
130'
110'
EF100T399 50' 100'
EFR-1-60T120 60' 120'
2"
170'
30'
30'
N/A
N/A
N/A
9
EF60T199 80' 130'30'
EF100T250 80' 130'N/A
WARNING! The EF100T250 and EF100T300 models are not
approved for 2 inch diameter vent pipe. Venting with 2 inch
pipe on these models may result in damage to the water heater
or cause an unsafe condition. DO NOT use 2 inch Vent or Air
Intake Pipe on EF100T250/300 models.
9

1Thermostat calls for heat.
-Prior to energizing blower, ignition module checks safety circuits for normal switch positions:
a) Vent temp switch normally closed.
b) Intake pressure switch normally closed.
c) Exhaust pressure switch normally open.
If the vent temp switch is open, the control waits indefinitely for temp switch to close (green light stays on).
If the exhaust pressure switch contacts are closed (not in normal position), the ignition module will wait 45 seconds for
pressure switch contact to open before energizing blower. If after 45 seconds and pressure switch contacts do not open,
the ignition module locks out with the PURGE light flashing indicating pressure switch fault.
2Blower energizes.
3Pressure 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.
4Blower pre-purge period (5 seconds) indicated by the PURGE LED on the module.
5Igniter warm up (18 seconds), indicated by the IGNITER LED on the module.
6Trial 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.
7Steady state operation.
Ignition module monitors:
-Thermostat circuit.
-When thermostat opens, gas valve is shut down and post purge begins.
-Safety circuit.
-If vent temp switch opens, gas valve is shut down, system will post purge and wait for switch to close before
attempting re-ignition.
-If either pressure switch opens, Gas valve is shut down, Blower is shut down for 30 seconds after which blower
is re-energized and system attempts re-ignition starting at pressure switch proving mode.
-Flame sensor circuit.
-If flame is lost, gas valve is shut down, system will post purge and system attempts
re-ignition starting at pressure switch proving mode.
Thermostat satisfies.
Burner off.
Blower post purge (15 seconds).
9
8
10
For models prior to CF serial numbers
For models prior to CF serial numbers
10
10

If normally closed pressure switch contacts open during burner operation, gas valve closes, burner shuts off. Blower
restarts after 30 seconds and runs 5 minutes to wait for pressure switch to close. If not, locks out.
The system will go into lock out mode for the following reasons:
- Pressure switches stuck open or closed.
a) Check for exhaust or intake obstructions.
b) Check for compliance with vent tables.
c) Check for evidence of moisture or condensate present in pressure switch tubing or pressure switch.
- No ignition after 3 attempts.
a) Check gas pressures.
b) Igniter resistance too high (lower resistance preferred <150 Ohms).
c) Check venturi screw adjustment (6 ½ turns from bottom)
d) Flame sense micro amp not present (1 to 5 micro amps required).
Lock out reset is accomplished by shutting OFF the line voltage to the system or opening the 24V thermostat
circuit for at least 2 seconds.
System will automatically reset lockout after 1 hour of continuous call for heat from the thermostat. Three ignition trials will
be attempted each hour until the thermostat is satisfied.
For models prior to CF serial numbers
Ignition Module Specifications
-Ignition & heating functions in response to thermostat.
-Hot surface ignition using a microprocessor to control timing, flame sensing using flame rectification & ignition
retries.
-Monitoring of system pressure switches and limit switches.
-Control of gas valve, inducer motor, and hot surface igniter element based on thermostat demand and status of
safety inputs.
-Diagnostic indicators to provide information on power to control and control status.
-Non-interchangeable polarized plug-in connectors for all interconnections.
Control Functions:
-Thermostat call for heat.
-Limit Switch Circuit (normally closed)
-Pressure Switch Circuit (normally open)
-Flame sensing.
-Low voltage supply.
-Line voltage supply.
Control Inputs: Control Outputs:
Lockout Conditions
-Inducer motor
-Hot surface igniter
-Gas valve
-Status indicator LEDs
Power - Green
Purge - Red
Igniter - Red
Valve - Red
Flame - Red
WIRING DIAGRAM
IGNITION MODULE
For models prior to CF serial numbers
11
11

1Thermostat calls for heat.
2Blower energizes, pressure switch contacts are normally closed. If the pressure switch contacts are open, blower
operates for up to 5 minutes waiting for contacts to close, then blower stops and flashes red PURGE LED indicating lock-
out condition.
3
6Steady state operation.
Ignition module monitors:
-Thermostat circuit.
-When thermostat opens, gas valve is shut down and post purge begins.
-Safety circuit.
- If vent temperature switch opens, gas valve is shut down, system will post purge and wait for switch to close
before attempting re-ignition.
-If the blocked vent pressure switch opens, indicating a blocked exhaust vent condition, the gas valve is shut
down, blower shuts down for 30 seconds and is re-energized and system attempts re-ignition if the pressure
switch is closed. Blower operates for 5 minutes to wait for pressure switch to close, then shuts off with purge
light flashing (lock-out). Will restart in 1 hour to attempt to close the switch and restart ignition sequence.
-Flame sensor circuit.
-If flame is lost, gas valve is shut down, system will post purge and system attempts re-ignition.
For models starting with
CF serial numbers and later.
For models starting with CF serial numbers and later.
Prior to energizing blower, ignition module checks to make sure the vent temperature switch is in the normally closed
position. If the vent temperature switch is open, the control waits indefinitely for the temperature switch to close.
Blower pre-purge period (5 seconds) indicated by PURGE LED on the module
4Igniter warm up (18 seconds), indicated by the IGNITER LED on the module. Note: The blocked vent pressure switch
must be in the normally closed position for the ignition cycle to start.
5Trial for Ignition (4 seconds, 3 trials).
a) Flame establishing period (2.5 seconds), gas valve and igniter on, indicated by the IGNITER and VALVE LED on the
module.
b) Burner on, flame proving period (1.5 seconds, looking for minimum of 1 micro amps), indicated by the FLAME &
VALVE LED on the module.
7Thermostat satisfied.
8Burner off.
9Blower post purge (15 seconds).
12
12

Lockout conditions:
The system will go into lock out mode for the following reasons:
Blocked vent pressure switch contacts open:
Check for obstruction in exhaust pipe and vent terminal.
Check for blocked condensate trap or drain line. In cold climates, make sure drain is not frozen.
No ignition after 3 attempts:
a) Check inlet and outlet gas pressures (pressure taps located on top of gas valve).
b) Igniter resistance too high (lower resistance preferred < 150 ohms).
c) Misadjusted veturi screw (should be 6.5 turns out from bottom).
d) Flame sense microamp not present (1.0 microamps minimum, should be 5 microamps or more). If burner lit,
check flame rod for deposits.
e) Check burner tube condition. Refer to section EF-III for Burner Tube Inspection and Replacement.
For models starting with
CF serial numbers and later.
Ignition Module Specifications
-Ignition & heating functions in response to thermostat.
-Hot surface ignition using a microprocessor to control timing, flame sensing using flame rectification & ignition
retries.
-Monitoring of system pressure switches and limit switches.
-Control of gas valve, inducer motor, and hot surface igniter element based on thermostat demand and status of
safety inputs.
-Diagnostic indicators to provide information on power to control and control status.
-Non-interchangeable polarized plug-in connectors for all interconnections.
Control Functions:
-Thermostat call for heat.
-Blocked vent pressure switch
(normally closed)
-Flame sensing.
-Low voltage supply.
-Line voltage supply.
Control Inputs: Control Outputs:
Lockout Conditions
-Inducer motor
-Hot surface igniter
- Gas valve
-Status indicator LEDs
Power - Green
Purge - Red
Igniter - Red
Valve - Red
Flame - Red
IGNITION MODULE
For models starting with CF serial numbers and later.
WIRING DIAGRAM
13
13

For models with Honeywell Integrated Control
System w/ Direct Spark Ignition
Thermostat calls for heat.
Combustion blower starts.
Blower pre-purge period of 30 seconds.
Trial for Ignition. (5 seconds, 3 trials).
Flame establishing period (3 seconds), gas valve opens, sparks from spark rod to burner surface to ignite
the gas.
Burner on, flame proving period (2 seconds). Requires a minimum of 0.8 microamp through flame sense
rod to prove flame.
If either blocked vent safety switch contacts (normally closed) or blocked vent pressure switch contacts
(normally closed) are open, then the ignition sequence will not start and an error code 29 (Pressure switch
failed to close or open) will be shown on the display.
Steady State Operation: Burner continues to operate until:
Thermostat circuit opens, gas valve closes, blower continues to operate for 30 second post-purge period.
If the normally closed blocked vent pressure switch opens, the gas valve closes, the blower continues to
operate indefinitely and error code 29 will be displayed after a couple minutes with “Service Needed”,
“Pressure Switch”.
If the normally closed 1st Pass Collector vent safety switch opens, the gas valve closes, the blower post-
purges, then shuts off with error code 26 displayed in a lockout condition.
Thermostat satisfied
Gas valve closes, burner extinguished.
Blower post purge for 30 seconds.
1
2
3
5
6
7
8
4
14
Serial Numbers including and AFTER GB13006174 and ALL EFR models
(Excluding EF100T399 model series)
14

For models with Honeywell Integrated Control
System w/ Direct Spark Ignition
The system will go into lock out mode for the following reasons:
1. ERROR CODE 62 or 63
Control board will go into “Soft Lockout” if the main burner cannot be lit or fails to prove flame after 3 ignition trials.
The water heater display indicates a lockout condition by showing an error code number (62 or 63) with “Service
Needed” in the control display window. Refer to error codes in the diagnostic section of this Service Manual. In a
“Soft Lockout” condition, the control will wait for 60 minutes and then make 3 more attempts to light the main
burners. Soft lockout reset is accomplished by depressing the lower right button under “Reset” for 3 seconds.
2. ERROR CODE 65
If the top of the tank should exceed 200°F, then the high limit control will shut off the burner and the water heater
will go into a “Hard Lockout”. Error code 65 will be shown in the water heater display. The control can only be
reset in the “Service Mode”, which is detailed in the “Troubleshooting” section of this Service Manual.
3. ERROR CODE 29
If the exhaust terminal becomes blocked or the condensate elbow fails to drain condensate, the normally closed
exhaust pressure switch will open, the gas valve closes, and error code 29 will appear on the control display.
When the condition is corrected, the error code will disappear and the water heater will resume normal operation.
No resetting of the control display is needed for the pressure switch error code.
4. ERROR CODE 26
If the vent safety switch located near the exhaust pressure switch should open, the gas valve will close, the blower
will post-purge and error code 26 will appear on the display. The lockout condition will reset once the problem is
corrected and the switch reset. Refer to “Vent Safety Switch Testing and Replacement” in this Service Manual.
Lockout Conditions
CONNECTION/WIRING DIAGRAM
15
LINE IN
PRIMARY
SECONDARY
CONTROL
E-COM
1
2
3
E-COM
1
3
2
SENSE
SENSOR 1
987
654
321
1
2
1
2
3
4
1
2
3
321
120 VOLTS AC
LINE
LOAD
24V
1
2
3
M
COMBUSTION
BLOWER
PV/MV
MV
GAS VALVE
LOWER
SENSOR
&ECO
6PIN CONNECTOR
TO PRESSURE
SWITCH HARNESS
IF ANY OF THE ORIGINAL WIRES AS SUPPLIED WITH THE APPLIANCE
105°C WIRE OR ITS EQUIVALENT.
MUST BE REPLACED. IT MUST BE REPLACED WITH 18. GA STRANDED
SI UN DES CONDUCTEURS D'ORIGINE FOURNI AVEC L'APPAREIL DOIT
NOTE:
CONNECTION DIAGRAM WIRING DIAGRAM
CONTROL
DISPLAY
TRANSFORMER
120V
HIGH VOLTAGE
SPARK
120V
24V
24V
24V
120 VAC
BLACK
120 VOLTS 120 VOLTS
24 V.
WHITE
GROUND
INDUCER
41
52
63
BK
BK
Y
BK
O
BL
BR
W
BK
W
BL
W
GN
BK
Y
W
R
W
Y
M
DISPLAY
HIGH VOLTAGE
SPARK
SENSE
R
R
MV
GAS VALVE
M
BLOWER RELAY COIL
W
O
PV
(BOARD CIRCUIT)
5
2
P.S.
BLOWER RELAY
BLOWER MOTOR
GN
GN
RRGY
GY
NC
COLLECTOR
LIMIT
ECOTSTAT
G
GND
N
L1
TOGGLE SW ITCH
LIGHT
ETRE REMPLACE UTILISER UN CONDUCTEUR 18 GA STRANDED 105°C
OU L'EQUIVALENT.
GY
RR
GY GY
P.S. (N.C.)
COLL HIGH-LIMIT
LIMIT (N.C.)
CONTROL BOARD
W
BK
Serial Numbers including and AFTER GB13006174 and ALL EFR models
15

Refer to ignition module
illustration, is there 120VAC
between P1(1) and P1(3)?
Is front panel power
switch light on,
indicating power?
Y
NPosition front panel
power switch to
“ON” position.
Is there 120VAC
across switch?
(see photo at right)
Light burned out,
replace switch.
Y
Is there 120VAC
across terminal block?
(see photo at right)
N
Determine power
source problem and
correct.
Repair/replace wire
harness to switch.
Y
N
Is ignition module
power light on?
N
Y
Refer to ignition module
illustration, is there 120VAC
going to module at locations
P7(1) and P7(3)?
N
Replace ignition module.
(see “Ignition Module Replacement”)
Replace transformer.
(see “Transformer Replacement”)
NN
YY
Is ignition module
power and flame light
flashing?
Reset heater by
interrupting power.
Reestablish power and
Adjust thermostat to
call for heat,
tank must be cold.
Allow heater to run
through heating cycle.
Did heater complete
heating cycle and did
blower post purge?
See next page
System is OK.
Supply voltage polarity
is incorrect.
Y
N
N
Y
Refer to ignition module
illustration, is there 24VAC
going to module at locations
P2(1) and P2(2)?
System Observation
For models with Hot Surface Ignition
IGNITION MODULE
WARNING
120 volt potential exposure. Use caution
making voltage checks to avoid personal injury.
16
Power Switch
Terminal Block
Replace ignition module.
(see “Ignition Module Replacement”)
16

Determine failure mode by observing flashing LED status on ignition module.
LED status and probable cause shown below.
*Denotes conditions that may require the water heater to be isolated from the vent
system to determine root cause.
LED status & probable cause
For models with Hot Surface Ignition
LED STATUS
Power & flame
light flashing.
Probable Cause
Supply voltage
polarity.
LED STATUS
Valve light flashing.
Probable Cause
Flame sensor.
(see “Flame Sensor
Testing and Replacement”)
Probable Cause
Hot surface igniter.
(see “Hot Surface
Igniter Testing and
Replacement”)
Probable Cause*
Combustion system.
(see “Combustion
System Testing and
Replacement”)
Probable Cause*
Intake pressure switch. Only for
models prior to CF serial number
(see “Intake Pressure Switch
Testing and Replacement”)
Probable Cause
Blower.
(see “Blower Testing
and Replacement”)
Probable Cause*
Exhaust pressure
switch. (see “Exhaust
Pressure Switch
Testing and
Replacement”)
LED STATUS
Purge light flashing.
LED STATUS
Only power light
is on and water heater
will not function.
Probable Cause
Thermostat circuit.
(see “Thermostat Circuit
Testing and Replacement”)
Probable Cause*
Exhaust pressure
switch. (see “Exhaust
Pressure Switch
Testing and
Replacement”)
Probable Cause
Vent safety switch.
(see “Vent Safety Switch
Testing and Replacement”)
17
17

System Observation
For models with Direct Spark Ignition
Water Heater Fault: Water heater does not operate
Display Error Code: Water heater display does not operate - blank display
Check main power supply to water
heater - fuse, circuit breaker, plug
receptacle, line cord or wiring to water
heater.
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
properly to control display?
N
Y
CAUTION
Use caution not to damage connectors when
making voltage measurements or jumping terminals
WARNING
120 volt potential exposure. Use caution
making voltage checks to avoid personal injury.
Is 24VAC present between
RED and BLACK wire pin
connections on the back of
Control Display?
123
8
6
5
4
3
1
12
1
4
1
3
3
2
1
1
5
3
P2P4P5 P7P3
CONTROL BOARD
P10P9J1
Refer to Control Board illustration.
Voltage at primary pins P2(1) & P2(3)
will be 110-120. If not, check Line In
pins P3(1) & P3(4).Check line cord with
volt meter. Replace line cord if
defective.
Refer to Control Board illustration. Voltage at
secondary pins P4(1) & P4(2) will be 24VAC.
If not, check transformer. Replace
transformer or wire harness.
Does water heater display operate?
Does the combustion blower start to
operate? Increase thermostat setting if
tank is warm.
Is 24VAC present between E-COM
screw terminals P9(2) & P9(3) on
the Control Board.
Y
N
Replace Control
Display.
N
Display Operates - See next
page
Transformer
Top terminals are 24VAC;
Bottom terminals are 120VAC
18
Y
Make proper wire
terminations
N
Replace
Control Board
YCheck wire
harness for
proper continuity
18

System Observation
For models with Direct Spark Ignition
Does combustion blower operate?
Error code #29 on display. Refer to Control Board
illustration. Measure voltage between terminals P7(3) &
P7(5) on the “inducer” output (make sure the control display
shows “heating” in the status mode, if not increase the
setpoint). Is there 110-120 VAC?
Replace control board if display
shows “heating” and no voltage is
present to the blower harness.
Make sure there are no error
codes for the temperature
sensors (following sections)
before replacing control board.
Check the voltage at the connection to the
blower. Is 110-120 VAC present?
Can sparking be seen/heard at the
spark rod to the burner?
Does Main Burner Light?
Error code #62 on display. See
main burner lights, no flame signal
in section “Combustion System
Testing and Replacement”
Does burner continue until
thermostat set point is reached?
See setting display in Service Mode
and displaying temperature
sensors.
Error code #63 on display. (see
“Combustion System Testing and
Replacement”)
Does blower post-purge for 30
seconds?
System okay
N
Y
N
N
N
Y
Y
Y
Y
From previous page
N
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.
123
8
6
5
4
3
1
12
1
4
1
3
3
2
1
1
5
3
P2P4P5 P7P3
CONTROL BOARD
P10P9J1
Y
Replace wire harness.Replace blower. N
Remove high voltage wire connected at the spark rod and
hold approximately ¼" from metal ground with insulated
pliers during the ignition cycle (3 second spark trial period).
Is there spark to ground?
N
Check resistance of high voltage
cable. Resistance should be 0-1
ohms. If resistance is high, replace
spark cable. If spark cable is good,
replace Control Board.
Check continuity of spark rod and spark rod
gap to burner.
(see section “Spark Rod Gap Adjustment”)
Y
Y
19
Check to see if control display shows any other error
codes (29, pressure switch, 26, vent safety switch, or 65,
high limit). If so, refer to the appropriate section for
testing and replacement.
19

Accessing Service Mode on 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.
Step 2: Pressing “Select” button will change display to next mode
SELECT SET
Status
°F
idle
Operational
Wate
r
Temp
The following is the sequence of modes available in “Service Mode” by pressing the “Select” button:
Error Code Number (Display/Reset). This is only shown if there is an operating error in the “User Mode”.
SELECT Lockout RESET
Status Service Needed
Error Code Shown
in Water Heater Display
20
SELECT SE
T
Status
idle
Operational
%
"Max Setpoint"
next to Temperature
Setpoint value.
&
Max
Setpoin
t
20