Bradford White EF100T150(E)*(N User manual

Save this manual for future reference
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