Bradford White EF120T4003NA3 User manual

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Manual 238-53597-00D REV 3/21
SERVICE
MANUAL
Troubleshooting Guide
and Instructions for Service
(To be performed ONLY by
qualified service providers)
Models Covered
by This Manual:
EF120T4003(N,X)(A)3
EF120T5003(N,X)(A)3
Commercial Ultra High Efficiency Models
with Direct Spark Ignition and ICON Control System
Effective: March 2021
ECO 8323

2
Ultra High Efficiency Models with Direct Spark Ignition
Table of Contents
Serial Number Breakdown……………………………………………………………………..
Introduction…………………………………………………………………………………...
..
..3
..
4
How to Use This Manual……………………………………………………………………..
..5
Tools Required for Service…………………………………………………………………..
..5
Features………………………………………………………………………………………..
..5
Specifications………………………………………………………………………………….
..6
Sequence of Operations………………………………………………………………………
..9
Building Management System (BMS)……………………………………………………….
.11
Troubleshooting……………………………………………………………………………….
.12
Service Procedure I: Thermostat Circuit Testing and Replacement…………………….
.21
Service Procedure II: Combustion System Testing and Replacement……………….....
.25
Service Procedure III: Burner Tube Inspection and Replacement……………………….
.29
Service Procedure IV: Gas Valve Replacement……………………………………………
.31
Service Procedure V: Blower Testing and Replacement………………………………….
.32
Service Procedure VI: Blocked Vent Pressure Switch Testing and Replacement……..
.34
Service Procedure VII: Flame Sensor Testing and Replacement………………………..
.37
Service Procedure VIII: Spark Rod Gap Adjustment and Replacement…………………
.39
Service Procedure IX: Ignition Control Board Replacement………………………………
.41
Service Procedure X: Transformer Replacement………………………………………….
.42
Service Procedure XI: Vent Safety Switch Testing and Replacement…………………..
.43
Service Procedure XII: Power Anode Inspection and Replacement…………………….
.45
Water Heater Installation Checklist………………………………………………………….
.46
Water Heater Service Report…………………………………………………………………
.47
Glossary of Terms……………………………………………………………………………..
.48
Notes……………………………………………………………………………………………
.48
2
3
4
5
5
5
6
9
11
12
22
26
30
32
33
35
38
40
42
43
44
46
47
48
49
49

3
Determining the Age of Your Water Heater
The first two characters of the serial number represent the year and month of manufacture. The
remainder of the serial is a sequential production number, seven digits in length before December
2007 (DM), and eight digits in length after.
For example:
Production Year
A = 1984 or 2004
L = 1994 or 2014
B = 1985 or 2005
M = 1995 or 2015
C = 1986 or 2006
N = 1996 or 2016
D =1987 or 2007
P = 1997 or 2017
E = 1988 or 2008
S = 1998 or 2018
F = 1989 or 2009
T = 1999 or 2019
G = 1990 or 2010
W = 2000 or 2020
H = 1991 or 2011
X = 2001 or 2021
J = 1992 or 2012
Y =2002 or 2022
K = 1993 or 2013
Z = 2003 or 2023
Production Month
A = January
G = July
B = February
H = August
C = March
J = September
D =April
K = October
E = May
L = November
F = June
M = December
For the year column, we do not use the letters: I, O, Q, R U, V
For the month column we do not use the letters: I & N –Z
Due to a computer error there were some OA serial water heaters manufactured. They were built in
January of 1997.
NOTICE
This Service Manual is ONLY for ICON Control Systems (Serial Numbers XC and later). Please
make sure that your water heater falls within this range.
3

4
Introduction
The 120T Ultra High Efficiency Water Heater is designed to deliver a high 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 this water heater.
The 120T 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. The
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 control board. The control board monitors the
status of the electronic thermostat, vent temperature limit switch, vent system pressure switch, a flame
sensor, spark rod, and gas valve. The control board contains programming which determines the
sequence of operation and timings for purge periods, trial for ignition, flame sensing, and lockouts. The
control board modulates the water heater to adjust the firing rate to account for varying hot water
demands. Additionally, the control board will provide diagnostic information both on the control board
and digital display 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 120T
Ultra High Efficiency Water Heater operational faults. Please read the entire Service Manual, which
provides detailed information regarding the 120T Ultra High Efficiency Water Heater operation and
installation specific concerns.
How To Use This Manual
It is intended for this manual to be used by qualified service personnel for troubleshooting analysis and
repair of the 120T400/500 models. Understanding the sequence of operation section of this manual will
contribute greatly to troubleshooting this product.
An Installation Checklist is shown on page 44. Compare the installation against this installation checklist
to confirm all requirements are met.
A Service Report is shown on page 45. Completing this form will assist in the troubleshooting efforts.
Should you need to call for technical support, please provide the information shown on this form to the
support technician to ensure accurate troubleshooting.
Troubleshooting begins with System Observation to determine failure mode as indicated by error codes
on the system display. Troubleshooting continues with Failure Modes and Probable Cause, directing
the service provider to a series of test procedures to determine the 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.
4

5
Tools Required for Service
Manometer: Two types available, a liquid “U” tube type or a digital (magnehelic) 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 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 Gauge: Used to measure water supply pressure, and to determine tank pressure by
adapting to the drain valve of the heater.
Jumper Leads: A length of wire (12 in. minimum) with an alligator clip at both ends.
Various Hand Tools: Pipe wrench, channel locks, open end wrench set, 12 in. crescent wrench, Allen
wrench set, Torx bit set, screwdrivers (common & Phillips), long reach (12 in.) magnetic tip Phillips
head screw driver #2 tip, 1/4 in. 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.
Features
Features of the Resideo Integrated Control System
•Water heater digital display on control board for setting and displaying the temperature setpoint.
Pressing temperature UP and DOWN buttons changes the temperature setpoint. Temperature
format may be displayed in °F or °C.
•Single control board with plug-in wiring controls temperature, ignition, and blower operation.
•Plug-in wiring reduces chance of miswiring.
•Burner ignition with direct spark ignition - A high voltage spark occurs between the spark and ground
rods to ignite the gas.
•Water heater digital display will show diagnostic codes in the event the water heater needs servicing.
Aids in diagnosing and servicing the water heater.
•Water heater digital display can show previous error code history to further aid in servicing the water
heater.
5

6
Specifications
DIMENSIONS (INCHES)
Model No.
Input
Rate
BTU/h
Storage
Capacity
U.S.
Gallons
A
Height
B
Floor to Alt.
Hot Water
Outlet
C
Dia.
D
Floor to
Vent
Outlet
E
Floor to
Inlet
Water Conn.
F
Floor to
T&P
Valve Conn.
G
Floor to
Hot Outlet
Water Conn.
H
Floor to Top
of Heater
120T400
399,999
119
77 1/8
70 3/8
33
6 ¾
12 ¼
58 ½
61 ¼
68 ¼
120T500
499,999
119
77 1/8
70 3/8
33
6 ¾
12 ¼
58 ½
61 ¼
68 ¼
Model No.
Input
Rate
BTU/h
Storage
Capacity
U.S.
Gallons
J
Floor to
Air
Intake
K
Floor to
Gas
Conn.
Front
Water
Conn.
Dia.
Space
Heating
Conn.
Dia.
Gas
Conn.
Dia.
Relief
Valve
Open
Shipping
Wt.
(LBS)
120T400
399,999
119
71
73 ¾
1 ½
1
1
1
1120
120T500
499,999
119
71
74 7/8
1 ½
1
1
1
1135
DIMENSIONS (MILLIMETERS)
Model No.
Input
Rate
KW
Storage
Capacity
Liter
A
Height
B
Floor to Alt.
Hot Water
Outlet
C
Dia.
D
Floor to
Vent
Outlet
E
Floor to
Inlet
Water Conn.
F
Floor to
T&P
Valve Conn.
G
Floor to
Hot Outlet
Water Conn.
H
Floor to Top
of Heater
120T400
117.22
450
1959
1787
838
171
311
1486
1556
1733
120T500
146.54
450
1959
1787
838
171
311
1486
1556
1733
Model No.
Input
Rate
KW
Storage
Capacity
Liter
J
Floor to
Air
Intake
K
Floor to
Gas
Conn.
Front
Water
Conn.
Dia.
Space
Heating
Conn.
Dia.
Gas
Conn.
Dia.
Relief
Valve
Open
Shipping
Wt.
(kgs)
120T400
117.22
450
1803
1873
38
25
25
25
508
120T500
146.54
450
1803
1902
38
25
25
25
515
6

7
Specifications
Power Supply Dedicated 120 VAC, 60 Hz, (15A GFI recommended)
Gas Supply Minimum 1 in. NPT
(schedule 40 black iron pipe recommended)
Approved Gas Type Natural and L.P.
Gas Pressure (Nat. and
L.P.)
Natural: 14” W.C. maximum static, 4.5” W.C. minimum
running (recommended 7” W.C. min running)
L.P. (Propane): 14” W.C. maximum static, 8” W.C.
minimum running (recommended 11” W.C. min running)
Venting System Power vent, balanced direct vent or unbalanced direct
vent. See vent tables on page 7.
Approved Venting Materials PVC and CPVC venting
Minimum Clearance for
Servicing 18 in. from top, 24 in. from front, 4 in. sides and rear.
Maximum Water Supply
Pressure
150 PSI
Thermostat Sensor
11,900 Ohms @ 70°F, ECO opens @ 207°F maximum.
Redundant sensor for ECO. Sensor inside well for easy
replacement of sensor.
Control Display
Digital display, 24 volts. Temperature range: 100 to
183°F. Used to set tank temperature (°F or °C), show
operating status, display error codes, error code history,
and limit maximum setpoint temperature.
Control Board
Operates on 24 volt from transformer. Controls tank
temperature, ignition functions, combustion blower. See
ignition timings in sequence of operation for Integrated
Control.
Transformer 120 VAC primary, 24 VAC secondary, 40 VA.
Spark Rod Igniter 3/16” from spark rod to ground rod. 5/16” from spark rod
to burner surface.
Flame Sensor Output Minimum 1 micro amp. Typical range 5 to 30 micro amps.
Gas Valve Negative regulation, 24 VAC, 1/2 in. PSI max., 4.5” W.C.
minimum running inlet.
Vent Safety Switch Normally closed, opens @ 190°F, manual reset.
Blocked Exhaust Vent
Pressure
24 VAC, normally closed, opens when pressure increases
to +2.70”W.C.
Blower 120 VAC, 60 Hz, 2.5-5.5 amps, full blower RPM
Combustion Levels
Nat.: 8-9.5% CO2
L.P.: 9-10.5% CO2. CO: less than 0.04% (400 PPM) air
free
7

8
Specifications
Vent Tables
Power Direct Vent and Power Vent Maximum Vent Length
(Combined Maximum Length for Intake and Exhaust)
Air intake CANNOT exceed exhaust by more than 30 ft
WARNING
Ensure that the elbows are counted when determining total vent length. See below and the Installation and
Operation Manual for more information.
WARNING
The 120T400/500 model is NOT approved for 2 in diameter vent pipe. Venting with 2 in pipe may result in
damage to the water heater or cause an unsafe condition. DO NOT use 2 in vent or air intake pipe.
Notes:
1) Multiply the total number of 90° elbows (intake and exhaust) by 5 ft. DO NOT include the 4 in termination
fittings or 4 in condensate elbow.
2) Multiply the total number of 45° elbows (intake and exhaust) by 2 1/2 ft.
3) Add this to the total length of straight pipe - intake and exhaust.
4) The total of all elbows and straight pipe: intake and exhaust must not exceed maximum lengths from tables
above.
Example:
A 4 in balanced direct vent system has 10 ft of straight exhaust pipe and 10 ft of straight intake pipe. It has 1-
90° elbow in the exhaust and 1- 90° elbow in the intake. It has 1- 45° elbow in the exhaust and 1- 45° elbow in
the intake.
Therefore:
2- 90° elbows x 5 ft = 10 ft.
2- 45° elbows x 21/2 ft = 5 ft.
20 ft of straight pipe + 10 ft + 5 ft = 35 ft.
System is within “Maximum Combined Length” from table above.
120T-400- 399,999 BTU/hr
120T-500- 499,999 BTU/hr
3 in. Vent Pipe
Power Direct Vent
Power Vent
Power Direct Vent
Power Vent
Max. Intake Length 65 ft. N/A 65 ft. N/A
Max. Exhaust Length 65 ft. 65 ft. 65 ft. 65 ft.
4 in. Vent Pipe
Power Direct Vent
Power Vent
Power Direct Vent
Power Vent
Max. Intake Length 100 ft. N/A 100 ft. N/A
Max. Exhaust Length 100 ft. 100 ft. 100 ft. 100 ft.
6 in. Vent Pipe
Power Direct Vent
Power Vent
Power Direct Vent
Power Vent
Max. Intake Length 120 ft. N/A 120 ft. N/A
Max. Exhaust Length 120 ft. 120 ft. 120 ft. 120 ft.
8

9
Sequence of Operations
1. Thermostat calls for heat.
2. Combustion blower starts at a reduced rpm for a “soft” start light off.
3. Blower pre-purge period of approximately 15 seconds.
4. Ignition control board runs an internal verification safety check for approximately 15 seconds.
5. Trial for ignition (approximately 5 seconds per trial, 3 trials total):
a. Spark establishing period (3 seconds), gas valve opens, sparks from spark rod to ground rod, igniting
the fuel air mixture at the burner surface.
b. Burner on, flame proving period (2 seconds). Requires a minimum of 1 microamp through the flame
sense rod to prove flame.
c. If the blocked vent pressure switch contacts (normally closed) are open, then the ignition sequence
will not start and error code “67” (pressure switch failed to close/open or vent safety switch failed to
close/open) will flash once on the digital display. The unit will then go into pre-purge/“Hold” while the
unit is waiting for the issue to be corrected. If the issue continues to occur, the digital display with flash
error code “137” (pressure switch is open, or vent safety switch is open) while the unit is waiting to
restart the normal sequence of operation.
6. Once the flame signal is verified, the blower will remain at the “soft” start RPM for 5 seconds to stabilize
the flame.
7. Steady state operation –Burner continues to operate until:
a. The thermostat circuit opens, gas valve closes, and blower continues to operate for 30 second post-
purge period.
b. If the blocked vent pressure switch contacts open (normally closed) while the burner is on, then the
gas valve closes, and the unit will retry a normal sequence of operation. If issue remains on restart,
the unit will go into recycle as described in 5c.
8. The RPM of the blower will modulate depending on the heater demand. The control allows for a turn down
ratio (TDR) of approximately 3:1. Generally, the blower will operate at higher speeds if the thermostat
remains far from the setpoint and at lower speeds as the thermostat approaches the setpoint.
9. Thermostat is satisfied.
10. Gas valve closes and burner is extinguished.
11. Blower post purge for 30 seconds at maximum RPM.
9

10
Sequence of Operations
Lockout Conditions
The system will go into lock out mode for the following reasons:
1. ERROR CODE 110
a. 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 digital display indicates a lockout condition by showing error code 110 with “Service
Needed” on the control board’s digital display. Refer to error codes in the diagnostic section of this Service
Manual. In a soft lockout condition, the control will wait for 15 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 80
a. If the temperature at 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 80 will be shown on the control board’s
digital display. The control board can only be reset in the Service Mode, which is detailed in the
Troubleshooting section of this Service Manual (pg 11).
3. ERROR CODE 67
a. 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 will close, and error code 67 will appear on the
digital display. When the condition is corrected, the error code will disappear, and the water heater will
resume normal operation. No resetting of the control board is needed for the pressure switch error code.
b. 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 67 will appear on the control board’s digital display. The lockout
condition will reset once the problem is corrected and the switch is reset. Refer to Vent Safety Switch
Testing and Replacement in this Service Manual (pg 42).
c. The pressure switch and temperature switch are wired in series. As a result, the water heater will not
function unless both switches are operational.
Connection/Wiring Diagram
10