Ultra High Efficiency Water Heaters
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 Warranty Years
Manual 238-45817-00F
Save this manual for future reference
Download from Www.Somanuals.com. All Manuals Search And Download.
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.
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.
3
Download from Www.Somanuals.com. All Manuals Search And Download.
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:
Multi-Meter:
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.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
Serial Numbers including and AFTER GB13006174 and ALL EFR models
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.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
Recovery GPH
at Degree Rise
DIMENSIONS (INCHES)
A
B
C
D
E
F
G
H
1st Hr
Del
Input
Rate
BTU/h
Stg
Cap
U.S.
Gal
Therm
Eff
Ht
Dia
Flr
to
Vent
Flr to
Inlet
Wtr
Flr to
T&P
Valve
Flr To
Outlet
Wtr
Flr. To
Air
Intake
Flr to
Gas
Conn Conn
Dia
Front
Wtr
Space
Heating
Conn
Dia
Gas
Conn
Dia
T&P
Valve
Open
(NPT)
Shpg
Wt
(lbs)
Gal
40°F
345
100°F
138
140°F
Model No
@
100°F
Rise
%
Outlet Conn Conn
Conn
(NPT)
EFR-1-60T-120 120,000
180
187
211
265
250
309
364
405
521
99
60
95.0
96.0
93.0
92.0
57
57
57
57
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
52 ½ 53 ½
1
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
EF60T125
EF60T150
EF60T199
EF100T150
EF100T199
EF100T250
EF100T300
EF100T399
125,000
150,000
199,999
150,000
199,999
250,000
300,000
399,999
363.6 145.5 103.9 60
422.7 169.1 120.8 60
52 ½ 53 ½ 1 ½
52 ½ 53 ½ 1 ½
52 ½ 53 ½ 1 ½
557.6
223
158
129
171
210
239
322
60
450.5 180.2
100 99.1 77 5/8
100 98.5 77 5/8
100 97.0 77 5/8
100 92.0 77 5/8
100 93.0 77 5/8
62 ¼ 73 1/8 74 ¾ 1 ½
62 ¼ 73 1/8 74 ¾ 1 ½
62 ¼ 73 1/8 74 ¾ 1 ½
62 ¼ 73 1/8 74 ¾ 1 ½
62 ¼ 73 1/8 73 ¼ 1 ½
597
238.8
734.8 293.9
836.4 334.5
1,127
451
6
Download from Www.Somanuals.com. All Manuals Search And Download.
Power supply
Dedicated 120 VAC, 60 Hz, 15A, GFI
Minimum 1" NPT for EF100T399, all others ¾" NPT
(schedule 40 black iron pipe recommended)
Gas Supply
Approved Gas Type
Natural or Propane. Unit must match gas type supplied.
Gas Pressure (Nat & L.P.) 14.0" W.C. maximum static, 4.5" W.C. minimum running (recommend 7.0" W.C. min running)
Venting System Power vent, balanced direct vent or unbalanced direct vent. See vent tables on page 7
Approved Vent Materials PVC or CPVC
Minimum Clearance
18" from top, 24" from front, 4" sides and rear.
for Servicing
Maximum Water Supply
Pressure
150 PSI
Thermostat Sensor
Temperature Dial
Thermostat Board
Ignition Module
11,900 Ohms @ 70°F, ECO opens @ 201°F Max., ECO close @ 100°F Min.
Min. set point 5400-6600 ohms, Max set point 0-50 ohms.
Max temp 180°F, Min temp 91°F, 24VAC, 60Hz max.
See “Sequence of Operation, for models starting with CF serial and later”
120VAC primary, 24VAC secondary, 40VA.
Transformer
Hot Surface Igniter
Flame Sensor Output
Gas Valve
120VAC, 30-120 ohms @ room temperature.
Minimum 1 micro amp, Typical range 4 to 7 micro amps.
Negative regulation, 24 VAC, ½" PSI max., 4.5" W.C. Minimum running inlet.
Normally closed, opens @ 350°F, manual reset.
Vent Safety Switch
Intake Pressure Switch
“CF” serial number or
later
Not required.
Intake Pressure Switch
serial numbers prior to
“CF”
Blocked Vent Pressure
Switch “CF” serial
number or later
24VAC, normally closed, opens on vacuum increase @ -1.20 W.C.
24VAC, normally closed, opens when pressure increases to +2.70 W.C.
24VAC, normally open, closes on pressure increase as follows
Note 1:
+2.58" W.C.
+1.50" W.C.
+1.22" W.C.
+2.08" W.C.
+0.55" W.C.
EF(60,100)T199
Exhaust pressure switch
serial numbers prior to
“CF”
EF100T150 (see note 2)
EF60T150, EF100T250
EF60T125
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
Blower
120VAC, 60Hz, .6-1 amps, 6400 RPM.
Combustion Levels
CO2: 10-11%, CO: less then 0.04 percent (400 PPM) air free
7
Download from Www.Somanuals.com. All Manuals Search And Download.
Serial Numbers including and AFTER GB13006174 and ALL EFR models
Power supply
Gas Supply
Dedicated 120 VAC, 60 Hz, 15A
Minimum ¾" NPT
(schedule 40 black iron pipe recommended)
Approved Gas Type
Gas Pressure (Nat & L.P.) 14.0" W.C. maximum static, 4.5" W.C. minimum running (recommend 7.0" W.C. min running)
Venting System Power vent, balanced direct vent or unbalanced direct vent. See vent tables on page 7
Natural or Propane. Unit must match gas type supplied.
Approved Vent Materials PVC or CPVC
Minimum Clearance
18" from top, 24" from front, 4" sides and rear.
for Servicing
Maximum Water Supply
Pressure
150 PSI
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.
Thermostat Sensor
Control Display
Control Board
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.
Operates from 24 volt from transformer. 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
Flame Sensor Output
Gas Valve
0.22" nominal gap to the burner surface.
Minimum 1 micro amp, Typical range 5 to 30 micro amps.
Negative regulation, 24 VAC, ½" PSI max., 4.5" W.C. Minimum running inlet.
Normally closed, opens @ 350°F, manual reset.
Vent Safety Switch
Blocked Vent Pressure
Switch
24VAC, normally closed, opens when pressure increases to +2.70 W.C.
Blower
120VAC, 60Hz, .6-1 amps, 6400 RPM.
Combustion Levels
CO2: 10-11%, CO: less then 0.04 percent (400 PPM) air free
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
Download from Www.Somanuals.com. All Manuals Search And Download.
Balanced Direct Vent Systems
PVC, CPVC
Power Vented Systems
PVC, CPVC
Total length of intake piping and exhaust piping
added together must not exceed “Maximum
Combined Length”
Total length of exhaust piping must not exceed
“Maximum Vent Length”
Shown below
Shown below
Maximum Combined Length (feet)
Maximum Vent Length (feet)
Model Number
EFR-1-60T120
EF60T125, EF100T150
EF60T150, EF100T199
EF60T199
2"
60'
3"
120'
120'
100'
80'
4"
Model Number
EFR-1-60T120
EF60T125, EF100T150
EF60T150, EF100T199
EF60T199
2"
60'
3"
120'
120'
100'
80'
4"
170'
170'
150'
130'
130'
110'
100'
170'
170'
150'
130'
130'
110'
100'
30'
30'
30'
30'
30'
30'
EF100T250
N/A
N/A
N/A
80'
EF100T250
N/A
N/A
N/A
80'
EF100T300
60'
EF100T300
60'
EF100T399
50'
EF100T399
50'
Unbalanced Direct Vent Systems
Air intake CAN NOT exceed exhaust
by more than 30 feet
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.
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
A 3" 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.
9
Download from Www.Somanuals.com. All Manuals Search And Download.
For models prior to CF serial numbers
For models prior to CF serial numbers
1
Thermostat 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.
2
3
Blower energizes.
Pressure 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.
4
5
6
Blower pre-purge period (5 seconds) indicated by the PURGE LED on the module.
Igniter warm up (18 seconds), indicated by the IGNITER LED on the module.
Trial 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.
7
Steady 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.
8
9
Thermostat satisfies.
Burner off.
10
Blower post purge (15 seconds).
10
Download from Www.Somanuals.com. All Manuals Search And Download.
For models prior to CF serial numbers
For models prior to CF serial numbers
Lockout Conditions
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.
Ignition Module Specifications
Control Functions:
- 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 Inputs:
Control Outputs:
- Thermostat call for heat.
- Limit Switch Circuit (normally closed)
- Pressure Switch Circuit (normally open)
- Flame sensing.
- Inducer motor
- Hot surface igniter
- Gas valve
WIRING DIAGRAM
- Status indicator LEDs
Power - Green
Purge - Red
- Low voltage supply.
- Line voltage supply.
Igniter - Red
Valve - Red
Flame - Red
IGNITION MODULE
11
Download from Www.Somanuals.com. All Manuals Search And Download.
For models starting with
CF serial numbers and later.
For models starting with CF serial numbers and later.
1
2
Thermostat calls for heat.
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 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
4
Blower pre-purge period (5 seconds) indicated by PURGE LED on the module
Igniter 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.
5
Trial 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.
Steady state operation.
6
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.
7
8
9
Thermostat satisfied.
Burner off.
Blower post purge (15 seconds).
12
Download from Www.Somanuals.com. All Manuals Search And Download.
For models starting with
CF serial numbers and later.
For models starting with CF serial numbers and later.
Lockout Conditions
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.
Ignition Module Specifications
Control Functions:
- 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 Inputs:
Control Outputs:
- Thermostat call for heat.
- Blocked vent pressure switch
(normally closed)
- Inducer motor
- Hot surface igniter
- Gas valve
- Flame sensing.
- Status indicator LEDs
Power - Green
Purge - Red
- Low voltage supply.
- Line voltage supply.
WIRING DIAGRAM
Igniter - Red
Valve - Red
Flame - Red
IGNITION MODULE
13
Download from Www.Somanuals.com. All Manuals Search And Download.
For models with Honeywell Integrated Control
System w/ Direct Spark Ignition
Serial Numbers including and AFTER GB13006174 and ALL EFR models
(Excluding EF100T399 model series)
1
2
Thermostat calls for heat.
Combustion blower starts.
3
4
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.
5
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.
6
Thermostat satisfied
7
8
Gas valve closes, burner extinguished.
Blower post purge for 30 seconds.
14
Download from Www.Somanuals.com. All Manuals Search And Download.
For models with Honeywell Integrated Control
System w/ Direct Spark Ignition
Serial Numbers including and AFTER GB13006174 and ALL EFR models
Lockout Conditions
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.
3.
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.
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.
CONNECTION/WIRING DIAGRAM
WIRING DIAGRAM
CONNECTION DIAGRAM
GROUND
BLACK
WHITE
MV
BR
120 VOLTS
120 VOLTS
BLOWER MOTOR
CONTROL
LOWER
SENSOR
& ECO
M
7
4
1
8
5
2
9
6
3
24V
PV/MV
BLOWER RELAY
BL
120 VAC
24 V.
BK
Y
Y
W
GAS VALVE
BK
GY
R
1
2
3
P.S. (N.C.)
24V
GY
R
P.S. TSTAT ECO
NC
R
R
COLLECTOR
LIMIT
GY
GY
COLL HIGH-LIMIT
LIMIT (N.C.)
GY
SENSOR 1
E-COM
DISPLAY
6 PIN CONNECTOR
TO PRESSURE
SWITCH HARNESS
GAS VALVE
1
PV
24V
2
5
R
1
2
3
2
3
W
120V
GN
BK
O
R
MV
4
5
6
1
2
3
SENSE
M
M
1
W
W
BLOWER RELAY COIL
CONTROL
DISPLAY
2
R
(BOARD CIRCUIT)
COMBUSTION
HIGH VOLTAGE
3
BK
INDUCER
BLOWER
SENSE
SPARK
E-COM
W
1
2
CONTROL BOARD
LINE IN
TOGGLE SWITCH
O
LIGHT
BK
1
HIGH VOLTAGE
SPARK
G
SECONDARY
W
BK
BL
Y
2
L1
NOTE:
1
2
3
24V
LOAD
IF ANY OF THE ORIGINAL WIRES AS SUPPLIED WITH THE APPLIANCE
MUST BE REPLACED. IT MUST BE REPLACED WITH 18. GA STRANDED
GN
3
4
GN
105°C WIRE OR ITS EQUIVALENT.
W
N
SI UN DES CONDUCTEURS D'ORIGINE FOURNI AVEC L'APPAREIL DOIT
ETRE REMPLACE UTILISER UN CONDUCTEUR 18 GA STRANDED 105°C
LINE
120V
TRANSFORMER
GND
120 VOLTS AC
OU L'EQUIVALENT.
PRIMARY
15
Download from Www.Somanuals.com. All Manuals Search And Download.
System Observation
For models with Hot Surface Ignition
WARNING
Is front panel power
switch light on,
indicating power?
Position front panel
power switch to
“ON” position.
N
120 volt potential exposure. Use caution
making voltage checks to avoid personal injury.
Y
Power Switch
Is there 120VAC
across switch?
Light burned out,
Y
Y
replace switch.
(see photo at right)
N
Terminal Block
Is there 120VAC
across terminal block?
(see photo at right)
Repair/replace wire
harness to switch.
N
Determine power
source problem and
correct.
Refer to ignition module
illustration, is there 120VAC
going to module at locations
P7(1) and P7(3)?
Refer to ignition module
illustration, is there 24VAC
going to module at locations
P2(1) and P2(2)?
Refer to ignition module
Y
Is ignition module
power light on?
N
Y
illustration, is there 120VAC
between P1(1) and P1(3)?
Y
N
N
N
Replace ignition module.
(see “Ignition Module Replacement”)
Replace transformer.
(see “Transformer Replacement”)
Replace ignition module.
(see “Ignition Module Replacement”)
IGNITION MODULE
Is ignition module
power and flame light
flashing?
Y
Supply voltage polarity
is incorrect.
N
Reestablish power and
Adjust thermostat to
call for heat,
Did heater complete
heating cycle and did
blower post purge?
Reset heater by
interrupting power.
Allow heater to run
through heating cycle.
N
See next page
tank must be cold.
Y
System is OK.
16
Download from Www.Somanuals.com. All Manuals Search And Download.
LED status & probable cause
For models with Hot Surface Ignition
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
Only power light
is on and water heater
will not function.
Probable Cause*
Exhaust pressure
switch. (see “Exhaust
Pressure Switch
Testing and
Probable Cause
Thermostat circuit.
(see “Thermostat Circuit
Testing and Replacement”)
Probable Cause
Vent safety switch.
(see “Vent Safety Switch
Testing and Replacement”)
Replacement”)
LED STATUS
Purge light flashing.
Probable Cause*
Exhaust pressure
switch. (see “Exhaust
Pressure Switch
Testing and
Probable Cause*
Probable Cause
Blower.
(see “Blower Testing
and Replacement”)
Intake pressure switch. Only for
models prior to CF serial number
(see “Intake Pressure Switch
Testing and Replacement”)
Replacement”)
LED STATUS
Valve light flashing.
Probable Cause
Hot surface igniter.
(see “Hot Surface
Igniter Testing and
Replacement”)
Probable Cause*
Combustion system.
(see “Combustion
System Testing and
Replacement”)
Probable Cause
Flame sensor.
(see “Flame Sensor
Testing and Replacement”)
LED STATUS
Power & flame
light flashing.
Probable Cause
Supply voltage
polarity.
17
Download from Www.Somanuals.com. All Manuals Search And Download.
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
120 volt potential exposure. Use caution
heater - fuse, circuit breaker, plug
receptacle, line cord or wiring to water
heater.
making voltage checks to avoid personal injury.
CAUTION
Use caution not to damage connectors when
making voltage measurements or jumping terminals
Check to make sure switch on front of
control panel is in the ON position
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.
Verify Primary voltage at the
control board.
Verify Secondary voltage at the control
board.
Refer to Control Board illustration. Voltage at
secondary pins P4(1) & P4(2) will be 24VAC.
If not, check transformer. Replace
Transformer
Top terminals are 24VAC;
Bottom terminals are 120VAC
transformer or wire harness.
CONTROL BOARD
3
1
2
2
1
1
1
6
5
4
3
3
1
8
5
1
2
3
3
1
4
J1
P5
P4
P9
P10
P2
P3
P7
Does water heater display operate?
Does the combustion blower start to
operate? Increase thermostat setting if
tank is warm.
Is 24VAC present between
RED and BLACK wire pin
connections on the back of
Control Display?
Check wires for proper termination
to control display.
Are wire terminations connected
properly to control display?
N
Y
Y
Replace Control
Display.
N
N
Y
Is 24VAC present between E-COM
screw terminals P9(2) & P9(3) on
the Control Board.
Check wire
harness for
proper continuity
Make proper wire
terminations
Y
Display Operates - See next
page
N
Replace
Control Board
18
Download from Www.Somanuals.com. All Manuals Search And Download.
System Observation
For models with Direct Spark Ignition
WARNING
120 volt potential exposure. Use caution
making voltage checks to avoid personal injury.
From previous page
CAUTION
Use caution not to damage connectors when
making voltage measurements or jumping terminals
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.
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?
N
N
Does combustion blower operate?
Y
Y
N
Check the voltage at the connection to the
blower. Is 110-120 VAC present?
Y
Replace blower.
Replace wire harness.
Check resistance of high voltage
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?
cable. Resistance should be 0-1
ohms. If resistance is high, replace
spark cable. If spark cable is good,
replace Control Board.
N
N
Can sparking be seen/heard at the
spark rod to the burner?
Y
Y
Check continuity of spark rod and spark rod
gap to burner.
(see section “Spark Rod Gap Adjustment”)
Error code #62 on display. See
main burner lights, no flame signal
in section “Combustion System
Testing and Replacement”
N
N
Does Main Burner Light?
Y
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.
Error code #63 on display. (see
“Combustion System Testing and
Replacement”)
Does burner continue until
thermostat set point is reached?
See setting display in Service Mode
and displaying temperature
sensors.
Y
CONTROL BOARD
Does blower post-purge for 30
seconds?
3
2
Y
1
2
1
3
1
1
4
6
3
1
3
1
8
5
4
5
1
2
3
System okay
J1
P5
P4
P9
P10
P2
P3
P7
19
Download from Www.Somanuals.com. All Manuals Search And Download.
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.
"Max Setpoint"
next to Temperature
Setpoint value.
Max
Setpoint
idle
Operational
Status
SELECT
SET
ꢀ
ꢁ
Step 2: Pressing “Select” button will change display to next mode
Water
Temp
°F
idle
Status
Operational
SELECT
SET
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”.
Error Code Shown
in Water Heater Display
Status Service Needed
SELECT
Lockout RESET
20
Download from Www.Somanuals.com. All Manuals Search And Download.
Accessing Service Mode on Control Display
For models with Honeywell Integrated Control
1. Max Setpoint (Display/Change)
Max Setpoint value in
Water Heater Display
Max
°F
Setpoint
idle
Operational
Status
SELECT
SET
ꢀ
2. Tank Sensor Temperature Displayed Water Temperature Average.
Water Temp
°F
idle
Status
Operational
SELECT
SET
3. Flame Current of Burner Flame Sensor (Displays only in the Heating Cycle)
µA
Heating
Flame Current
Operational
Status
SELECT
SET
21
Download from Www.Somanuals.com. All Manuals Search And Download.
Accessing Service Mode on Control Display
For models with Honeywell Integrated Control
4. Setpoint (Display/Change)
setpoint
°F
idle
Operational
Status
SELECT
SET
5. °F/°C (Display/Change)
setpoint
°F °F/C°
idle
Operational
Status
SELECT
SET
6. Differential (Display only - shows the differential of the thermostat)
Differential
°F
idle
Status
Operational
SELECT
SET
22
Download from Www.Somanuals.com. All Manuals Search And Download.
Accessing Service Mode on Control Display
For models with Honeywell Integrated Control
7. Software Version (Display only)
Soft
idle
Operational
Status
SELECT
SET
ꢀ
8. Error Code History (Displays if there are present error codes or up to 10 previous error codes). Water Heater
Display will show a “--“ if there are no error codes.
idle
Operational
Status
SELECT
SET
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
Max
°F
Setpoint
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.
idle
Status
Operational
SELECT
SET
ꢀ
23
Download from Www.Somanuals.com. All Manuals Search And Download.
Accessing Service 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
Max
°F
Setpoint
idle
Operational
Status
SELECT
SET
ꢀ
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
Max
°F
Setpoint
idle
Operational
Status
SELECT
SET
ꢀ
Step 4: Press “Set” button to confirm new “Max Setpoint” value and stop setting mode.
"Max Setpoint" stops flashing
Max
°F
Setpoint
idle
Status
Operational
SELECT
SET
ꢀ
24
Download from Www.Somanuals.com. All Manuals Search And Download.
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.
Max
Setpoint
idle
Status
Operational
SELECT
SET
ꢀ
ꢁ
Exiting Service Mode
Display of Water Temperature:
Step 1: In Service Mode, Press the “Select” button until “Water Temp” is displayed in the upper right section of the
water heater display. This is the reading for the sensor.
°F
idle
Operational
Status
Lower Sensor
SELECT
SET
ꢁ
2
25
Download from Www.Somanuals.com. All Manuals Search And Download.
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 (µA).
Flame
Current
µA
Heating
Operational
Status
SELECT
SET
To Display and Change Temperature Setpoint:
Step 1: In “Service Mode” press the “Select” button until “Setpoint” is shown in the water heater display
setpoint
°F
idle
Status
Operational
SELECT
SET
26
Download from Www.Somanuals.com. All Manuals Search And Download.
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.
setpoint
°F
idle
Operational
Status
SELECT
SET
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
setpoint
°F
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.
idle
Status
Operational
SELECT
SET
ꢀ
Step 4: To lower the temperature setpoint, press the “Temperature Down” button until the desired temperature is shown
on the water heater display.
"Setpoint" Flashes
setpoint
°F
idle
Status
Operational
SELECT
SET
27
Download from Www.Somanuals.com. All Manuals Search And Download.
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
°F
idle
Status
Operational
SELECT
SET
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.
°F °F/C°
idle
Operational
Status
SELECT
SET
Step 2: Press “Set” button to change temperature format. “°F/°C” symbol will flash in the water heater display.
°F °F/C°
idle
Operational
Status
SELECT
SET
28
Download from Www.Somanuals.com. All Manuals Search And Download.
Accessing Service Mode on Control Display
For models with Honeywell Integrated Control
Step 3a: Press “Temperature Up” button to change temperature format to °C
°C °F/C°
idle
Status
Operational
SELECT
SET
ꢀ
Step 3b: Press “Temperature Down” button to change temperature format to °F
°F °F/C°
idle
Operational
Status
SELECT
SET
Step 4: Press “Set” button to confirm °F or °C format. °F/°C will stop flashing
°F °F/C°
idle
Operational
Status
SELECT
SET
29
Download from Www.Somanuals.com. All Manuals Search And Download.
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
°F
idle
Operational
Status
Lower Sensor
SELECT
SET
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.
idle
Service Needed
SELECT
SET
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 be stored in code index
#1 and the most recent in code index #10.
30
Download from Www.Somanuals.com. All Manuals Search And Download.
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 -- .
°F
idle
Operational
Status
SELECT
SET
Step 2: Press the “Temperature Down” button to select the error code index, starting with the most recent error
code “10”.
idle
Status
Operational
SELECT
SET
ꢀ
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.
idle
Operational
Status
SELECT
SET
31
Download from Www.Somanuals.com. All Manuals Search And Download.
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.
idle
Status
Operational
SELECT
SET
ꢀ
Step 5: Press the “Select” button for code index #9 to view if there are any code
numbers.
idle
Operational
Status
SELECT
SET
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.
setpoint
°F
idle
Operational
Statu
s
SELECT
SET
ꢀ
ꢁ
Exiting Service Mode
32
Download from Www.Somanuals.com. All Manuals Search And Download.
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 display. The following
sections will provide instructions for servicing each error code.
HONEYWELL INTEGRATED CONTROL ERROR CODE
DISPLAY FOR EF MODEL SERIES
ERROR
CODE
4
DEFINITION
LOW FLAME SENSE CURRENT
6
FLAME SENSED OUT OF NORMAL SEQUENCE (BEFORE OPENING GAS VALVE OR AFTER CLOSING GAS VALVE)
FLAME DETECTED BEFORE IGNITION
FLAME DETECTED AFTER A HEATING CYCLE COMPLETES
PRESSURE SWITCH FAILED TO CLOSE OR OPEN (STUCK OPEN)
LOWER SENSOR READINGS FAULTY
FLAME ROD SHORTED TO GROUND
AC LINE FREQUENCY ERROR - SIGNAL TOO NOISY OR FREQUENCY INCORRECT
LINE VOLTAGE TOO LOW OR HIGH
DC OUTPUT VOLTAGE UNSTABLE
MAXIMUM NUMBER OF RETRIES DETECTED
MAXIMUM NUMBER OF IGNITION RECYCLES DETECTED
ELECTRONICS FAILURE
HIGH WATER TEMPERATURE (OVER 200°F)
23
24
29
32
57
58
59
61
62
63
64
65
IF ANY OF THE ABOVE CODES APPEAR ON THE CONTROL DISPLAY, CONTACT YOUR PLUMBER OR QUALIFIED SERVICE AGENT FOR SERVICE OF THE WATER HEATER.
33
Download from Www.Somanuals.com. All Manuals Search And Download.
Resetting Error Codes
For models with Honeywell Integrated Control
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 flame 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
Status Service needed
SELECT
Lockout RESET
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
SELECT
Status Service Needed
SET
SELECT
Lockout RESET
ꢀ
Step 2: Press for 3 seconds to
reset control in service mode.
Step 1: Press for 3 seconds
ꢁ
to enter service mode.
34
Download from Www.Somanuals.com. All Manuals Search And Download.
Serial Numbers including and AFTER
GB13006174 and ALL EFR models
(Excluding EF100T399 model series).
WARNING
120 volt potential exposure. Use
caution making voltage checks
to avoid personal injury.
IMPORTANT NOTE: This procedure assumes a cool tank
Condition: Water Heater Not Operating
Display shows error code “32” ( Sensor Reading
Faulty)
CAUTION
Use caution not to damage
connectors when making voltage
measurements or jumping
terminals
Unplug or disconnect electrical power to the water heater
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
Checking continuity of
sensor (disconnected
at Control Board)
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.
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”).
Sensor shown fully
inserted into well
Condition: Water Heater Not Operating
Display shows error code “65”
High Water Temperature (over 200 °F)
WARNING
Do not reset the display from the hard lockout
state without correcting the cause of the
overheating condition
Sensor clip shown
installed properly
Turn power “OFF”.
Draw water to cool tank below 120 °F
If sensor clip is damaged
Continued on
N
Check sensor. Sensor is held in place with a clip fastened to the well
(see photo). Check sensor wire for potential damage or breaks in the
wire insulation. Is the sensor fully inserted into the well?
Y
replace clip. Replace
next page
sensor if damaged.
Check Sensor Resistance
(See Sensor Resistance
Testing, following section)
35
Download from Www.Somanuals.com. All Manuals Search And Download.
Serial Numbers including and AFTER GB13006174 and ALL EFR models
WARNING
Condition: Water Heater Not Operating
Display shows error code “65”
High Water Temperature (over 200 °F)
(Continued from previous page)
Do not operate water heater without
verifying that the overheating
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 maximum tank temperature remains well below 200 °F
36
Download from Www.Somanuals.com. All Manuals Search And Download.
For models with Hot Surface Ignition
IMPORTANT NOTE: This procedure assumes a cool tank
WARNING
Rotate temperature
dial to highest setting.
120 volt potential exposure. Use
caution making voltage checks
to avoid personal injury.
Refer to ignition module
Y
illustration, Is there 24VAC
between P3(7) and P3(8)?
OK, thermostat is
calling for heat.
N
IGNITION MODULE
Thermostat
not calling
Red Wire
(N.O.)
Yellow Wire
(COM)
Turn off power to heater.
Disconnect YELLOW and RED wires from the
thermostat board at location N.O. and COM shown in
photo at right. Use a jumper to connect these two
wires together as shown in photo at right.
Restore power to heater.
N
See page 39
Did heater cycle on?
Yellow & Red
wires shown
jumpered
Y
Check thermostat sensor
for proper resistance
Replace
thermostat sensor.
(see Thermostat Sensor
Replacement Procedure)
(OHMS) across blue wires.
N
(See Appendix A, sensor
resistance)
Are readings correct?
(see photo at right)
Y
Check sensor harness
continuity.
Is there continuity?
N
Thermostat
Sensor
Replace harness.
Y
Check temperature dial for
proper resistance (OHMS)
(See Appendix B,
temperature dial resistance)
Are readings correct?
(see photo at right)
Replace temperature dial
(potentiometer).
N
N
(see Thermostat Potentiometer
Replacement Procedure)
Temperature Dial
Y
Check temperature dial
harness continuity.
Is there continuity?
Replace harness.
Y
Replace thermostat
circuit board.
(see Thermostat Board
Replacement Procedure)
37
Download from Www.Somanuals.com. All Manuals Search And Download.
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&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
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
0
1
2
3
4
5
6
7
8
9
26109
19906
15314
11884
9299
7333
5827
4663
3758
3048
2488
2043
1688
1402
1170
982
25400
19383
14925
11592
9078
7165
5697
4562
3679
2986
2439
2004
1656
1376
1150
965
24712
18876
14548
11308
8862
7000
5570
4464
3602
2925
2391
1966
1625
1351
1129
949
24045
18383
14180
11032
8653
6839
5446
4368
3527
2866
2344
1928
1595
1327
1110
933
23399
17905
13823
10763
8449
6683
5326
4274
3453
2808
2298
1891
1566
1303
1090
917
22771
17440
13477
10502
8250
6531
5208
4183
3382
2752
2253
1856
1537
1280
1071
901
22163
16990
13140
10248
8057
6383
5094
4094
3312
2697
2209
1820
1509
1257
1053
886
21573
16553
12812
10000
7869
6238
4982
4006
3244
2643
2166
1786
1481
1235
1035
871
21000
16128
12494
9760
7685
6098
4873
3922
3177
2590
2124
1753
1454
1213
1017
857
20445
15715
12185
9526
7507
5961
4767
3839
3112
2538
2083
1720
1427
1191
999
842
713
828
814
801
788
775
762
749
737
725
APPENDIX - B
Temperature Dial Resistance
Proper Readings Should Be 5400-6600 Ohms at Minimum
Setting
And 0-50 Ohms at Maximum.
Be Careful When Making Voltage Measurements or Jumping Terminals
Not to Damage or Deform Connectors or Connector Pins.
38
Download from Www.Somanuals.com. All Manuals Search And Download.
For models with Hot Surface Ignition
WARNING
Thermostat circuit.
(continued from page 37)
120 volt potential exposure. Use caution
making voltage checks to avoid personal injury.
Check AC source to
determine why there is no
power.
Replace
ignition module.
(see “Ignition Module
Replacement”)
Y
Refer to ignition module
illustration, Is there 120VAC
between P1(1) and P1(3)?
Refer to ignition module
illustration, Is there 120VAC
between P7(3) and P7(1)?
N
N
N
Y
Refer to ignition module
illustration, Is there
22 - 27VAC between
P2(1) and P2(2)?
Replace transformer.
(see Transformer
Replacement)
IGNITION MODULE
Y
Red Wires
(Temperature Sensor)
Check continuity through
ECO, red wires of
thermostat sensor.
Check at temperature
less than 160°F
Is there continuity?
(see photo at right)
Refer to ignition module
illustration, Is there 24VAC
between P3(9) and P2(1).
Y
Y
N
N
Replace ignition module.
(see “Ignition Module
Replacement”)
Check wire harness
continuity. Replace
thermostat sensor or wire
harness as necessary.
(see “Thermostat Sensor
Replacement Procedure”)
Replace thermostat
circuit board.
(see “Thermostat Board
Replacement Procedure”)
39
Download from Www.Somanuals.com. All Manuals Search And Download.
Thermostat Board Replacement Procedure (Hot Surface Ignition)
WARNING
Step 1.
Position main power switch to “OFF”
120 volt potential exposure. Isolate the
appliance and reconfirm power is
disconnected using a multi-meter.
Step 2.
Disconnect (unplug) water heater from 120
volt power source.
Step 3.
Step 4.
Un-latch and remove top surround cover
from top of heater.
Locate thermostat board on control panel.
(see photo at right)
Thermostat
Board
Step 5.
Step 6.
Carefully disconnect all wires from thermostat
board.
Note: it may be necessary to identify wires
for proper re-connection.
Mounting
screw locations
Remove the two screws (Phillips head screw
driver) that secure thermostat board to
control panel.
WIRING DIAGRAM
For models prior to
CF serial number
Step 7.
Step 8.
Install new thermostat board to control panel using
screws from step 6.
Carefully reconnect wiring per the wire
diagram below. Reconfirm wire
connections are correct prior to putting
heater back in service
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 heater.
WIRING DIAGRAM
For models starting with
CF serial numbers and
later.
40
Download from Www.Somanuals.com. All Manuals Search And Download.
Thermostat Potentiometer Replacement Procedure
Step 1.
Step 2.
Position main power switch to “OFF”
WARNING
120 volt potential exposure. Isolate the
appliance and reconfirm power is
disconnected using a multi-meter.
Disconnect (unplug) water heater from
120 volt power source.
Step 3.
Step 4.
Un-latch and remove top surround cover
from top of heater.
Temperature
Loosen set screw
with small blade
screw driver
Adjusting Knob
Loosen set screw of adjusting
knob (small blade screw driver)
and remove adjusting knob
Remove
retaining nut
from potentiometer. (see photos at right)
Step 5.
Step 6.
Remove retaining nut (½" wrench)
and washer from potentiometer.
(see photos at right)
From inside of surround area, remove potentiometer
with gasket from side of surround. Notice how indexing
tab on potentiometer assembles into locating hole of
surround. (see photos below)
Indexing
Tab
Locating
Hole
Potentiometer
Wire Leads
Step 7.
Step 8.
Step 9.
Disconnect potentiometer wire leads.
(see photo at right)
Install new potentiometer with gasket into side of surround. Be sure to assemble with
indexing tab inserted into locating hole on side of surround (see photos above).
Reconnect wires to potentiometer. Note: Wire leads are interchangeable with either wire.
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 heater.
41
Download from Www.Somanuals.com. All Manuals Search And Download.
Thermostat Sensor (Thermister) Replacement Procedure
Step 1.
Step 2.
Position main power switch to “OFF”
WARNING
120 volt potential exposure. Isolate the
appliance and reconfirm power is
disconnected using a multi-meter.
Disconnect (unplug) water heater from
120 volt power source.
Step 3.
Step 4.
Hot Surface Ignition Models: Drain water
heater down to a point below the top of the tank.
Un-latch and remove top surround cover
from top of heater.
Step 5.
Step 6.
Fold back insulation just in front of burner to
expose temperature sensor (see photo below).
Disconnect temperature sensor from
harness (see photos at right).
Disconnect sensor
from harness
Hot Surface Ignition Models
Sensor shown fully
inserted into well
Insulation folded
back to expose
temperature sensor
Sensor clip shown
installed properly
Direct Spark Ignition Models
Step 7.
Hot Surface Ignition Models: Remove temperature sensor (1-1/16" hex, deep well socket) from heater.
Direct Spark Ignition Models: Unclip sensor from well and pull sensor to remove, do not remove well.
Note:
Using a deep well socket will allow room inside socket
for sensor connector and wires.
Step 8.
sensor.
Hot Surface Ignition Models: Apply thread sealing tape or applicable thread lubricant to threads of new
Install new thermostat sensor and Connect to wire harness from step 6.
Direct Spark Ignition Models: Install new sensor completely into well and reinstall sensor clip.
Step 9.
Fold insulation back into place. Be sure there are no wires in contact with burner.
Step 10. Restore 120 volt power supply and water supply to water heater, check and repair any
leaks found. 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 heater.
42
Download from Www.Somanuals.com. All Manuals Search And Download.
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.
For models with Hot Surface Ignition System
Note: On higher input models using metal fiber mesh burner (serial
number “CK” and later) a red glow from the burner surface is normal.
Verify Minimum Gas Supply Piping Requirements of:
Minimum 1" NPT for EF100T399, all others use ¾"
NPT. (Schedule 40 black Iron Pipe recommended).
N
Reconfigure gas
supply piping
Y
Inadequately
sized regulator.
N
With manometer, check inlet
gas pressure. Is it stable
between 7" & 14" W.C. static?
(heater not running)
Is gas supply pressure
regulator adjustable to
maintain proper and
stable setting?
N
Adjust gas
supply regulator
Y
Venturi
adjustment
(see illustrations at right)
Y
WARNING
Inlet gas
pressure tap
Does inlet gas pressure
drop more than 2" W.C.
during burner ignition?
Removing screw from
inlet gas pressure tap will
immediately allow gas to
flow from pressure tap.
Y
N
WARNING
120 volt potential
exposure. Use caution
making voltage checks to
avoid personal injury.
Replace ignition module.
(see “Ignition Module
Replacement Procedure”)
N
Do you see the igniter
glowing through burner
site glass during the
warm up period?
Refer to ignition module illustration below,
is there 120VAC across terminals
P6(1) and P6(2)?
N
(Note: Igniter LED must be lit during this check).
Y
IGNITION MODULE
Y
Volt meter set to
OHM setting
Is igniter resistance
less than 150 Ohms
(cold)?
(see check igniter
illustration)
Replace
N
hot surface igniter.
(see “Hot Surface Igniter
Replacement Procedure)
Meter probe
Y
Hot surface
igniter
Proceed to next page
CHECK IGNITER
RESISTANCE
43
Download from Www.Somanuals.com. All Manuals Search And Download.
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.
For models with Hot Surface Ignition System
WARNING
120 volt potential exposure. Isolate the
Continued from
previous page
appliance and reconfirm power is
disconnected using a multi-meter.
Refer to ignition module illustration below,
is there 24VAC between P3(2) and P3(5) (blue and
brown wires) during the flame establishing period?
(Note: Valve LED must be lit during this check)
Replace
N
ignition module.
(see “Ignition Module
Replacement Procedure”)
Y
Replace Rectifier harness and/or
gas valve.
(see “Gas Valve Replacement
Procedure”)
Can you hear or feel
gas valve energize?
N
Y
Turn VENTURI set screw clockwise until its
bottomed out. Turn screw counter-clockwise 6-½
turns from bottom (see illustration below). Note:
EF100T399 models do not have a venturi screw.
The gas regulator setting should be 1 - 1 ¼ turns
out from bottom.
IGNITION MODULE
N
Inspect burner tube, (see “Burner
Tube Inspection and Replacement”)
Clear obstruction
N
Y
Does burner light
smoothly, without
evidence of coughing
or huffing?
Check for obstruction
at inlet of gas valve.
Is inlet free of
N
obstruction?
Venturi
adjustment
Y
Y
Call for technical
support
Inlet gas
pressure tap
Does burner operate
normaly until thermostat is
satisfied?
Y
Does flame LED on the module
light and stay lit?
N
N
Y
Gas valve
regulator
Check flame sensor,
Is there 1 to 5 micro amps
(min.) during 1.5 second
flame proving period?
(see “Flame Sensor Testing
Procedure”)
System OK
Y
EF100T399
Only
N
Replace flame sensor
(see “Flame Sensor
Replacement
Procedure”)
44
Download from Www.Somanuals.com. All Manuals Search And Download.
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.
Serial Numbers including and AFTER GB13006174 and ALL EFR models
Note: On higher input models using metal fiber mesh burner a red
glow from the burner surface is normal.
Verify Minimum Gas Supply Piping Requirements of:
Minimum ¾" NPT. (Schedule 40 black Iron Pipe
recommended).
N
Reconfigure gas
supply piping
Y
Inadequately
sized regulator.
N
With manometer, check inlet
gas pressure. Is it stable
between 7" & 14" W.C. static?
(heater not running)
Is gas supply pressure
regulator adjustable to
maintain proper and
stable setting?
N
Adjust gas
supply regulator
Y
Venturi
(see illustrations at right)
adjustment
Y
WARNING
Inlet gas
pressure tap
Does inlet gas pressure
drop more than 2" W.C.
during burner ignition?
Removing screw from
inlet gas pressure tap will
immediately allow gas to
flow from pressure tap.
Y
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.
WARNING
120 volt potential
exposure. Use caution
making voltage checks to
avoid personal injury.
Voltmeter set to
OHM setting
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).
Can Sparking be seen/
heard at the spark rod
to the burner?
N
Is there spark to ground?
Y
Y
Spark Rod
Replace Spark Rod
Check continuity of
spark rod. Is
reading 0-1 Ohm?
Y
N
(see “Spark Rod
Gap Inspection and
Replacement”
Meter probe
Volt meter set to
OHM setting
Spark Rod
Check spark gap to burner
(see “Spark Rod Gap
Inspection”)
N
Does main burner
Light?
Meter probe
Y
Proceed to next page
CHECK SPARK ROD
RESISTANCE
45
Download from Www.Somanuals.com. All Manuals Search And Download.
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.
Serial Numbers including and AFTER GB13006174 and ALL EFR models
WARNING
Continued from
120 volt potential exposure. Isolate the
previous page
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
N
Replace
Control Board
brown wires) during the flame establishing period?
(Note: Control Display must show “Heating” for
operating status)
Venturi
adjustment
Y
Inlet gas
pressure tap
Replace Rectifier harness
and/or
Can you hear or feel
gas valve energize?
N
gas valve.
(see “Gas Valve
Replacement Procedure”)
Y
Turn VENTURI set screw clockwise until its
bottomed out. Turn screw counter-clockwise 6-½
turns from bottom. (Note: Venturi adjustment screw
is not on the EF100T399 models)
N
Inspect burner tube, (see
“Burner Tube Inspection”)
Clear obstruction
N
Y
Does burner light
smoothly, without
evidence of coughing
or huffing?
Check for obstruction
at inlet of gas valve.
Is inlet free of
N
obstruction?
Y
Y
CONTROL BOARD
Call for technical
support
3
2
1
2
Does burner operate
normaly until thermostat is
satisfied?
Y
1
3
1
1
4
6
3
1
N
3
1
Does burner stay lit?
N
8
5
4
5
1
2
3
Y
J1
P5
P4
P9
P10
P2
P3
P7
Check flame sensor,
Is there 1 to 5 micro amps
(min.) during 1.5 second
flame proving period?
Flame Sense
Terminal
Y
Multimeter set to
microamp (µA) setting
System OK
CHECK FLAME SENSE
ROD MICROAMPS
(Value may be displayed on
the control display by
accessing “Service Mode”)
Flame
Sense Rod
N
Replace flame sensor
(see “Flame Sensor
Replacement
Procedure”)
46
Download from Www.Somanuals.com. All Manuals Search And Download.
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”.
WARNING
Step 2.
Disconnect (unplug) water heater from
120 volt power source.
120 volt potential exposure. Isolate the
appliance and reconfirm power is
disconnected using a multi-meter.
Step 3.
Step 4.
Turn off gas supply to water heater.
Un-latch and remove surround cover from top of
heater.
Step 5.
From the gas valve, disconnect the gas
connection, PVC venting, Silicone tubing
and wire harness.
Gas valve
wire harness
Step 6.
blower.
Disconnect wire harnesses flame sensor and
Gas
connection
For Hot Surface Ignition models, disconnect wire
harness from hot surface igniter.
For Direct Spark Ignition models, disconnect high
voltage cable from spark rod connection.
Burner mounting
screw
(Total of 5)
PVC vent
connection
Burner mounting
insert
Burner tube
Step 7.
Remove the 5 bolts (½" socket)
holding the burner mounting insert
in place.
Step 8.
Step 9.
Carefully remove combustion assembly
with gasket from water heater.
Burner mounting
insert gasket
See next page for combustion system installation procedure.
47
Download from Www.Somanuals.com. All Manuals Search And Download.
Combustion System Replacement Procedure
Step 1.
Fully inspect burner mounting insert gasket for the following:
a) Tears
d) Dirt or debris
b) Missing material
c) Cracks
e) Other imperfections that would inhibit proper seal
If gasket is NOT affected by any of the above, gasket replacement is not required.
Step 2.
Install combustion assembly using new gasket or fully inspected gasket from step 1.
Secure combustion assembly at the burner mounting insert using screws from step 6
on previous page. Tighten screws evenly.
Step 3.
Step 4.
Step 5.
Reconnect wire harnesses to hot surface igniter or high voltage cable to spark rod, flame sensor, blower
and gas valve.
Reconnect PVC venting, 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.
Step 6.
Replace surround cover on top of
water heater.
Gas valve
wire harness
Gas
connection
Burner mounting
screw
(Total of 5)
PVC vent
connection
Burner mounting
insert
Burner tube
Burner mounting
insert gasket
48
Download from Www.Somanuals.com. All Manuals Search And Download.
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
Step 1.
Step 2.
Position main power switch to “OFF”.
WARNING
120 volt potential exposure. Isolate the
appliance and reconfirm power is
disconnected using a multi-meter.
Disconnect (unplug) water heater from
120 volt power source.
Step 3.
Step 4.
Turn off gas supply to water heater.
Un-latch & remove surround cover from top of
heater.
Step 5.
Step 6.
Step 7.
From the gas valve, disconnect
the gas connection, PVC venting,
wire harness and silicone tubing.
Disconnect wire harness from
blower assembly.
Remove the two screws holding
HOT
SURFACE
IGNITER/
SPARK ROD
each the hot surface igniter and
flame sensor in place (long reach
magnetic Phillips screw driver).
Carefully remove hot surface igniter
and flame sensor from combustion
assembly. For Direct Spark Ignition models,
remove the two screws on the spark rod bracket
and remove the spark rod.
BURNER TRANSITION
MOUNTING NUTS
Step 8.
Step 9.
Remove the 4 nuts (7/16" wrench) holding
the burner transition in place. Lift the blower/gas
valve transition assembly from burner mounting
insert, remove gasket and set aside.
Remove burner tube from burner
mounting insert. See next page for
burner tube inspection procedure.
49
Download from Www.Somanuals.com. All Manuals Search And Download.
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.
Inspect burner tube as follows (BSI ceramic fiber mesh burner, water heaters prior to
serial number “CK”) :
a) Visually inspect ceramic fiber mesh, mesh should be uniform in appearance without large
gaps, tears or fraying. Mesh should have uniform pattern allowing for unrestricted gas
flow.
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.
Inspect burner tube as follows (Acotech metal fiber mesh burner, water heaters with
“CK” serial number or later).
a) Outer fiber mesh should be uniform with no tears or deterioration.
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
Note: New metal fiber mesh burner (Acotech) is the replacement burner for the BSI ceramic fiber sock burner. The length
of burner will not be the same as the previous BSI burner. Provide the model and serial number for the correct replacement
burner.
Step 1.
Fully inspect burner flange gaskets, igniter and flame sensor gaskets for the following:
a) Tears
d) Dirt or debris
b) Missing material
c) Cracks
e) Other imperfections that would inhibit proper seal
If gaskets are NOT affected by any of the above, gasket replacement is not required.
Step 2.
Step 3.
Step 4.
Install burner tube with gaskets into burner mounting insert. Be sure gasket surfaces are free
of debris.
Reconnect the blower/gas valve/transition assembly to burner mounting insert. Secure using
nuts from step 8 on previous page.
Carefully reinstall flame sensor with gasket and hot surface igniter with gasket and secure with
screws from step 7 on previous page. Reconnect wire harnesses to sensor and igniter.
Step 5.
Step 6.
Reconnect wire harnesses to blower motor and to gas valve.
Reconnect PVC venting, gas supply and silicone tubing to gas valve. Turn on gas to heater
and check for gas leaks, repair any gas leaks found.
Step 7.
Step 8.
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.
50
Download from Www.Somanuals.com. All Manuals Search And Download.
Gas Valve Replacement Procedure
WARNING
Step 1.
Step 2.
Position main power switch to “OFF”.
120 volt potential exposure. Isolate the
appliance and reconfirm power is
disconnected using a multi-meter.
Disconnect (unplug) water heater from
120 volt power source.
Step 3.
Step 4.
Turn off gas supply to water heater.
Un-latch & remove surround cover from top of
heater.
Step 5.
From the gas valve, disconnect
the gas connection, PVC venting,
wire harness and silicone tubing.
Step 6.
Step 7.
Remove the 2 gas valve mounting screws (Torx bit) located at the
11:00 O-clock & 5:00 O-clock position on the venturi mounting flange
and remove gas valve from water heater.
Remove any residual gasket material from blower and venturi mounting flange.
Blower / gas valve
Gas valve
wire harness
gasket
Gas valve
assembly
Gas valve
mounting screws
(2 places)
Blower
Venturi
mounting flange
Venturi inlet
Step 8.
Install new gas valve with new gasketprovided. Secure gas valve in place using
screws from step 6.
Step 9.
Reconnect PVC venting, gas supply, silicone tubing & wire harness to gas valve. Turn
on gas supply to heater and check 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.
51
Download from Www.Somanuals.com. All Manuals Search And Download.
Refer to ignition module/control board
illustration.
Is there 120VAC
across the white and
black wires at the
terminal block ?
Does blower
energize?
Replace
ignition module/
control board.
Y
N
Hot Surface Ignition Models:
Y
(For Direct Spark
Ignition models,
ensure control display
shows “Heating”, raise
temperature setpoint if
necessary)
Is there 120VAC between P5(1) and P5(3)?
Direct Spark Ignition Models:
Is there 120VAC between P7(5) and P7(3)?
(see photo at right)
N
Y
120VAC check at
Terminal Block
N
Determine
power
source
problem
and
correct
Black wire leading to
blower motor looped
through amprobe.
Is there 120VAC
across the white and
black wires at the
terminal block ?
N
Check amp draw through
BLACK wire lead of blower
motor. Is there .6 to 3.0
amps?
Is Blower wheel secured to
blower motor shaft?
Call technical
support.
Y
Y
N
Y
N
Replace blower.
(see “Blower Replacement
Procedure”)
Refer to ignition module/
control board illustration.
Hot Surface Ignition Models:
Is there 120VAC between
P5(1) and P5(3)?
Direct Spark Ignition Models:
Is there 120VAC between
P7(5) and P7(3)?
Hot Surface Ignition
Models ONLY:
Hot Surface Ignition Models:
Are safety circuits in normal position?
Direct Spark Ignition Models:
Is collector high limit switch and
pressure switch in normally closed
position?
N
Y
Refer to ignition
Replace ignition module/
control board.
Y
module, is there 24
VAC between P3(7)
and ground?
Checking for 120VAC
(Black & White Wires)
N
N
Y
Thermostat not
calling for heat.
(see “Thermostat
Circuit Testing”)
Correct safety circuit problem per
safety circuit trace
(section “Blocked Vent Pressure
Switch Testing”).
Is there 120VAC
across the white and
Repair/replace
wire harness.
N
black wires at the
blower?
(see photo at right)
Y
CONTROL BOARD
Replace blower.
(see “Blower
Replacement
Procedure”)
3
1
1
2
2
1
1
3
1
6
5
4
3
1
3
5
1
8
2
3
4
J1
P5
P4
P9
P10
P2
P3
P7
IGNITION MODULE
HOT SURFACE IGNITION MODELS
DIRECT SPARK IGNITION MODELS
52
Download from Www.Somanuals.com. All Manuals Search And Download.
Blower Replacement Procedure
WARNING
120 volt potential exposure. Isolate the
appliance and reconfirm power is
disconnected using a multi-meter.
Step 1.
Step 2.
Position main power switch to “OFF”.
Disconnect (unplug) water heater from
120 volt power source.
Step 3.
Step 4.
Turn off gas supply to water heater.
Un-latch & remove surround cover from top of
heater.
Step 5.
Step 6.
Step 7.
Disconnect wire harness from blower.
Disconnect intake vent and gas supply from gas valve assembly.
Remove the 2 gas valve mounting screws (Torx bit) located at the
11:00 O-clock & 5:00 O-clock position on the venturi mounting flange.
Step 8.
Remove The 4 blower flange mounting screws (5/32 Allen wrench) and remove blower
from transition flange.
Blower
Blower / gas valve
gasket
Gas valve
assembly
Gas valve
mounting screws
2 places.
Blower flange
mounting screws
Blower / transition
gasket
Venturi
mounting flange
Venturi inlet
Transition
flange
Step 9.
Remove any residual gasket material
from venturi mounting flange and transition flange.
Step 10. 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 intake vent and
gas line to gas valve assembly and
check for gas leaks repair any leaks found.
Step 13. Reconnect wire harness to blower assembly, restore 120 volt power supply & Gas 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.
53
Download from Www.Somanuals.com. All Manuals Search And Download.
Exhaust Pressure Switch Testing and Replacement
For serial numbers prior to “CF”
Sequence of operation:
With the thermostat calling for heat, prior to energizing blower, the ignition module checks the exhaust pressure switch for normal
switch position of normally open. If the exhaust pressure switch contacts are closed (not in normal position), the ignition module
waits 45 seconds for the pressure switch contacts to open. If the pressure switch contacts do not open after 45 seconds, the
ignition module locks out with the PURGE LED flashing indicating a pressure switch fault.
WARNING
LED Status
Only power LED is on, or
Purge LED flashing.
120 volt potential exposure. Use caution
making voltage checks to avoid personal injury.
Safety Circuit Trace
Is there continuity
Through GREY
wire leads of heater side
safety circuit harness?
(see photo below)
Is there continuity
through RED
Safety Circuit OK,
Y
N
Y
Does blower
energize?
N
wire leads of heater side
safety circuit harness?
(see photo below)
(see “Blower Testing
& Replacement”)
Y
Y
N
Call technical
support.
Replace exhaust
pressure switch (see
“Exhaust Pressure
Switch Replacement
Procedure”)
Check PURGE LED status
on ignition module,
Flashing after 45 seconds?
Depress reset
button on vent
safety switch. Is
there continuity
across high limit
switch?
N
Does heater
function?
Y
Control side
harness
Heater side
harness
Y
(see photo below)
Verify proper
switch operation.
(see “Vent Safety
Switch Testing and
Replacement”)
N
Replace vent safety
switch.
(see “Vent Safety
Switch Replacement
Procedure”)
Check PURGE LED status.
Y
N
On within 5 minutes?
N
Pressure switch is OK.
Flashing after
5 minutes?
Call for technical
support.
Y
Check blower for proper
operation (see page 27)
Is blower OK?
Correct blower problem
(see “Blower Testing and
Replacement”)
N
Y
Reset button
Refer to
“Check Collector Pressure”
(see next page)
54
Download from Www.Somanuals.com. All Manuals Search And Download.
Exhaust Pressure Switch Testing and Replacement
For serial numbers prior to “CF”
Check Collector Pressure
Check exhaust collector pressure at the exhaust
collector pressure tap location (see illustration below). Is
there positive pressure equal to or greater than
pressure switch settings below?
With monometer, take a
reading at the exhaust
tube pressure tap location.
Is value negative (-)?
EXHAUST PRESSURE SWITCH SETTINGS
Is exhaust venting
system blocked or
obstructed?
Clear obstruction.
Determine cause
and correct.
Y
N
Y
N
EF(60,100)T199
EF100T150
+2.58" W.C.
+1.50" W.C.(see note 1)
+1.22" W.C.
(see illustration below).
EF60T150,EF100T250
EF60T125
+2.08" W.C.
+0.55" W.C.(see note 2)
N
EF100T300
Y
Reconfigure vent
system to be
compliant with
vent tables (see
“Specifications”).
Is vent system total
length compliant with
vent tables in the
Note 1: +5.6" W.C. on serials prior to AH5039107
Note 2: +0.8" W.C. on serials prior to AK5288269
instruction manual?
N
Y
Replace
exhaust pressure switch.
(see “Exhaust Pressure Switch
Replacement Procedure”)
Inspect the area housing the combustion
system and control panel located at the
top of the heater.
Does the area show signs of corrosion
and/or exssesive heat?
Y
Call for
technical support
N
Remove combustion assembly
(see “Combustion System
Removal Procedure”)
Inspect combustion chamber
for blockage or debris
accumulation
Clear obstruction.
Determine cause
and correct.
Y
N
Call for
technical support
Exhaust collector
pressure tap location
Exhaust Tube
pressure tap location
Exhaust tube
at bottom of water
heater
55
Download from Www.Somanuals.com. All Manuals Search And Download.
Exhaust Pressure Switch Testing and Replacement
For serial numbers prior to “CF”
Exhaust Pressure Switch Replacement Procedure
Step 1.
Position main power switch to “OFF” position.
Step 2.
Loosen adhesive backed rubber escutcheon from service panel access cover
and slide escutcheon back along exhaust pipe to allow for removal of cover.
Rubber
escutcheon
Step 3.
Step 4.
Remove screws from service panel access cover
(¼" nut driver) and remove cover from heater.
(see photos at right)
Disconnect silicone tubing and wire leads from
pressure switch. (see photos at right)
Step 5.
Step 6.
Remove pressure switch mounting screws
(5/16" wrench) and remove pressure switch.
Pressure switch
mounting screw
5/16 hex head
Assemble new pressure switch to heater using
screws from step 5.
Wire leads
Step 7.
Step 8.
Reconnect wire leads. Note: wire leads are
interchangeable with either terminal.
Reconnect silicone tubing to pressure switch
as follows:
Silicone tubing
a) Exhaust pipe tubing connects to
negative (-) side of switch
identified by the (-) symbol
located on switch.
Exhaust collector
pressure tap location
b) Exhaust collector tubing connects
(serial numbers prior
to positive (+) side of switch
identified by the (+) symbol located
on the switch.
to “CF”)
Exhaust pipe
pressure tap location
Example of switch
showing positive
side identifier
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 instructions located in the installation
and operating instruction manual.
Step 10. Reinstall service panel access cover and
rubber escutcheon.
56
Download from Www.Somanuals.com. All Manuals Search And Download.
Blocked Vent Pressure Switch Testing and
Replacement for serial number “CF” and later
Sequence of operation:
The blocked vent pressure switch monitors the pressure in the exhaust tube. The switch contacts are normally closed and will
not open unless there is a blockage in the exhaust venting or terminal (snow, ice, debris). If the blocked vent pressure switch
contacts open after the thermostat initiates the blower, the blower will remain on for to 5 minutes waiting for the contacts to close.
If the contacts remain open, the blower will stop and the PURGE LED will flash for hot surface ignition models, or error code 29
will display for direct spark ignition models.
LED Status
WARNING
Only power LED is on, or
120 volt potential exposure. Use caution
Purge LED flashing.
Error Code 29 or 26
(Direct Spark Ignition
Models)
making voltage checks to avoid personal injury.
Safety Circuit Trace
Is there continuity
Through GREY
wire leads of heater side
safety circuit harness?
(see photo below)
Is there continuity
through RED
Safety Circuit OK,
Does blower
energize?
Y
N
Y
N
wire leads of heater side
safety circuit harness?
(see photo below)
(see “Blower Testing
& Replacement”)
Y
Y
N
Call technical
support.
Replace exhaust
pressure switch (see
“Exhaust Pressure
Switch Replacement
Procedure”)
Check PURGE LED status
on ignition module,
Flashing after 45 seconds?
Depress reset
button on vent
safety switch. Is
there continuity
across high limit
switch?
N
Does heater
function?
Y
Control side
harness
Heater side
harness
Y
(see photo below)
Verify proper
switch operation.
(see “Vent Safety
Switch Testing and
Replacement”)
N
Replace vent safety
switch.
(see “Vent Safety
Switch Replacement
Procedure”)
Hot Surface Ignition Models:
Check PURGE LED status.
Direct Spark Ignition Models:
Check control display
Y
N
On within 5 minutes?
N
Pressure switch is OK.
Flashing after 5 minutes?
Error code 29 again?
Call for technical
support.
Y
Check blower for proper
operation (see “Blower
Testing and Replacement”)
Is blower OK?
Correct blower problem
(see “Blower Testing and
Replacement”)
N
Reset button
Y
Refer to
“Check Collector Pressure”
(see next page)
WARNING
Note: HOT SURFACE IGNITION MODELS
ONLY - The blocked vent pressure switch
must be used with the revised ignition control,
identified with a yellow label.
Make sure exhaust collector compartment is not
overheating (350°F) before resetting vent safety
switch. If there is evidence the collector compartment
is overheating, CALL TECHNICAL SUPPORT.
57
Download from Www.Somanuals.com. All Manuals Search And Download.
Blocked Vent Pressure Switch Testing and
Replacement for serial number “CF” and later
Check Exhaust Tube Pressure
With monometer, take a
reading at the exhaust
tube pressure tap location.
Is value negative (-) or
slightly postitive
Is exhaust venting
system blocked or
obstructed? Also
check condensate
elbow and drain.
Clear obstruction.
Determine cause
and correct.
N
Y
N
(see illustration below).
N
Y
Reconfigure vent
system to be
compliant with
vent tables (see
“Specifications”).
Is vent system total
length compliant with
vent tables in the
instruction manual?
Y
Replace
blocked vent switch.
(see “Blocked Vent
Switch Testing and
Replacement”)
With ohmmeter check
pressure switch for
continuity. Contacts should
be closed.
Is pressure in exhaust tube near 2.7" w.c. or more? If so, correct
blockage (above). If exhaust pressure is low (0.40" or less),
replace pressure switch.
N
Y
Exhaust Tube
pressure tap location
Pressure switch O.K.
Exhaust tube
at bottom of heater
58
Download from Www.Somanuals.com. All Manuals Search And Download.
Blocked vent Switch Testing and Replacement
For serial number “CF” or later
Exhaust Pressure Switch Replacement Procedure
Step 1.
Position main power switch to “OFF” position.
Step 2.
Loosen adhesive backed rubber escutcheon from service panel access cover
and slide escutcheon back along exhaust pipe to allow for removal of cover.
Rubber
escutcheon
Step 3.
Step 4.
Remove screws from service panel access cover
(¼" nut driver) and remove cover from heater.
(see photos at right)
Disconnect silicone tubing and wire leads from
pressure switch. (see photos at right)
Step 5.
Step 6.
Remove pressure switch mounting screws
(5/16" wrench) and remove pressure switch.
Pressure switch
mounting screw
5/16 hex head
Assemble new pressure switch to heater using
screws from step 5.
Wire leads
Step 7.
Step 8.
Reconnect wire leads. Note: wire leads are
interchangeable with either terminal.
Reconnect silicone tubing to pressure switch
as follows:
Silicone tubing
a) Exhaust pipe tubing connects to
single tap located on switch
Step 9.
Restore 120 volt power supply to water heater
and confirm proper operation following the
lighting instructions on the lighting instruction
Exhaust Tube
pressure tap location
label or the lighting instructions located in the installation
and operating instruction manual.
Step 10. Reinstall service panel access cover and
rubber escutcheon.
59
Download from Www.Somanuals.com. All Manuals Search And Download.
Hot surface Igniter Testing Procedure
WARNING
120 volt potential exposure. Use caution
making voltage checks to avoid
personal injury. Igniter may be too hot
to handle, take necessary precautions
Refer to ignition module illustration below,
Is igniter resistance
is there 120VAC across terminals
less than 150 Ohms
Check harness
connection from igniter
to ignition module.
P6(1) and P6(2)?
(Check during igniter warm up period,
indicated by the igniter LED glowing on the
ignition module).
Y
Y
(cold)?
(see “check igniter
resistance” below)
N
N
Replace ignition module.
(see “Ignition Module
Replacement
Replace
hot surface igniter
(see “Hot Surface
Igniter Replacement
Procedure”)
Procedure”)
Volt meter set to
OHM setting
Meter probe
Hot surface
igniter
IGNITION MODULE
CHECK IGNITER
RESISTANCE
60
Download from Www.Somanuals.com. All Manuals Search And Download.
Hot surface Igniter Replacement Procedure
Step 1.
Step 2.
Position main power switch to “OFF”
WARNING
120 volt potential exposure. Isolate the
appliance and reconfirm power is
disconnected using a multi-meter.
Disconnect (unplug) water heater
from 120 volt power source.
Step 3.
Un-latch & remove surround cover
from top of heater.
Step 4.
Step 5.
Fold back insulation in front of combustion assembly to expose hot surface igniter.
(see photo at right)
Disconnect igniter wire leads from ignition module.
Step 6.
Step 7.
Remove the 2 igniter mounting screws (magnetic
tip, long reach Phillips screw driver) and remove
igniter and gasket from transition base flange.
Remove any residual gasket material from
transition base flange.
Note:
Note:
New replacement igniter will
not have a shield over element.
Handle carefully to prevent
breakage.
Hot Surface
Igniter
Do not handle igniter element
or allow foreign material to
come in contact with element.
Step 8.
Install new igniter with new gasket provided using
screws from step 5. Arrange igniter flange with off-
center hole towards front of heater.
Off-center
Igniter mounting
screws
Igniter flange
Igniter gasket
Igniter filament
mounting hole
Heater front
Transition
base flange
Step 9.
Reconnect igniter wire harness.
Step 10. Fold insulation back into place. Be sure no wires are 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.
61
Download from Www.Somanuals.com. All Manuals Search And Download.
WARNING
120 volt potential exposure. Use caution
making voltage checks to avoid
personal injury. Flame sensor may be
too hot to handle, take necessary
precautions
Flame Sensor Testing Procedure
Refer to ignition module/control board
illustration.(24 volts should maintain beyond the
1.5 second flame proving period.)
Refer to illustration below, is there
a minimum of 1 micro amp during
1.5 second flame proving period?
Y
Y
Y
Hot Surface Ignition Models:
Flame sensing circuit OK
Is there 24 volts AC at locations P3(2) & P3(5)?
Direct Spark Ignition Models:
Is there 24VAC between P5(5) and P5(8)?
N
N
Replace flame sensor with
With flame sensor Disconnected
from ignition module, check
continuity to ground.
Call for
technical support
gasket
and/or wire lead.
(see “Flame Sensor
Replacement Procedure”)
Is there continuity to ground?
N
Remove flame sensor from water heater.
Check continuity from tip of flame sensor
to end of wire lead.
N
Volt meter set to
Micro amps setting
(µA)
Is there continuity?
Y
N
Meter
probe
Is flame sensor free
of oxidation?
Is ceramic of flame
sensor cracked?
Y
Flame
sensor
terminal
N
Y
Meter
probe
Flame sensor
terminal on
Clean or replace
flame sensor.
Replace flame sensor.
(see “Flame Sensor
Replacement
ignition module.
(see “Flame Sensor
Replacement
HOT SURFACE IGNITION MODELS
Procedure”)
Procedure”)
Volt meter set to
Micro amps setting
(µA)
CONTROL BOARD
3
2
1
1
2
1
3
1
4
6
5
4
3
1
3
1
Meter probe
8
5
1
2
3
J1
P5
P4
P9
P10
P2
P3
P7
Flame sensor
terminal
Flame sensor
terminal on
control board.
Meter probe
DIRECT SPARK IGNITION MODELS
62
Download from Www.Somanuals.com. All Manuals Search And Download.
Flame Sensor Replacement Procedure
Step 1.
Position main power switch to “OFF”
WARNING
120 volt potential exposure. Isolate the
appliance and reconfirm power is
disconnected using a multi-meter.
Step 2.
Disconnect (unplug) water heater
from 120 volt power source.
Step 3.
Un-latch & remove surround cover
from top of heater.
Step 4.
Step 5.
Fold back insulation in front of combustion assembly to expose flame sensor.
(see photo at right)
Disconnect wire lead from flame sensor.
Step 6.
Step 7.
Step 8.
Remove the 2 sensor mounting screws (magnetic
tip, long reach Phillips screw driver) and remove
flame sensor & gasket from transition base
flange.
Remove any residual gasket material from
transition base flange.
Flame
sensor
Install new flame sensor with new gasket provided
using screws from step 6. Arrange flame sensor with
hook towards burner.
Flame sensor
mounting screws
Flame sensor
Flame sensor
gasket
Arrange hook
of sensor
towards burner
Transition
base flange
Step 9.
Reconnect flame sensor wire.
Step 10. Fold insulation back into place. Be sure no wires are 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.
63
Download from Www.Somanuals.com. All Manuals Search And Download.
Spark Rod Gap Inspection and Adjustment
WARNING
Spark gap must be set to 3/16" to 1/4".
Failure to set and verify proper spark
gap may result in a delayed ignition
resulting in damage to the water heater.
Step 1.
Step 2.
Remove combustion system as described in
“Combustion System Removal Procedure”.
Measure spark gap between the spark rod
and burner tube. Acceptable spark gap is
between 3/16" - 1/4" (see photo below).
CAUTION
Step 3.
If spark gap is not between 3/16" - 1/4“, the
spark rod may be carefully bent by supporting
the end near the ceramic insulator with pliers
and bending the end near the burner tube
with needle nose pliers (see photo below).
Use caution while performing these
steps to prevent stressing or cracking
the ceramic insulator.
Step 4.
Step 5.
Re-measure and verify spark gap is between 3/16" - 1/4“ after bending.
Reinstall the combustion system per “Combustion System Replacement Procedure” and check several
ignitions to ensure the burner lights smoothly.
Spark Rod
Hold spark rod
near ceramic
insulator
Bend spark
rod near
burner tube
Burner Tube
Spark Rod
64
Download from Www.Somanuals.com. All Manuals Search And Download.
WARNING
Spark Rod Replacement Procedure
120 volt potential exposure. Isolate the
appliance and reconfirm power is
disconnected using a multi-meter.
Step 1.
Step 2.
Position main power switch to “OFF”
Disconnect (unplug) water heater
from 120 volt power source.
Step 3.
Step 4.
Un-latch & remove surround cover
from top of heater.
WARNING
If spark rod is replaced for any reason,
the combustion system MUST be
removed and the spark gap to the burner
measured and adjusted properly.
Fold back insulation in front of combustion assembly
to expose spark rod. (see photo at right)
Step 5.
Step 6.
Disconnect wire lead from spark rod.
Remove the 2 mounting screws (magnetic
tip, long reach Phillips screw driver) and remove
spark rod & gasket from transition base
flange.
Step 7.
Step 8.
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 towards
the front of the water heater).
Spark Rod
Step 9.
Remove combustion system following “Combustion System
Removal Procedure”, and verify spark gap following “Spark
Rod Gap Inspection and Adjustment”.
WARNING
Off-center
Spark gap must be set to 3/16" to 1/4".
Failure to set and verify proper spark
gap may result in a delayed ignition
resulting in damage to the water heater.
mounting hole
Heater front
Transition
base flange
Spark rod
mounting screws
Step 9.
Reassemble combustion system following “Combustion System
Replacement Procedure”.
Spark rod
Spark rod
gasket
Arrange hook
of spark rod
towards burner
Step 10. Fold insulation back into place. Be sure no wires are 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.
65
Download from Www.Somanuals.com. All Manuals Search And Download.
Ignition Module Replacement Procedure
WARNING
Step 1.
Step 2.
Position main power switch to “OFF”.
120 volt potential exposure. Isolate the
appliance and reconfirm power is
disconnected using a multi-meter.
Disconnect (Unplug) water heater
from 120 Volt power source.
Step 3.
Step 4.
Un-latch & remove surround cover from top of water heater.
Locate Ignition module on control panel inside surround area.
(see photo below)
Ignition Module
located on control panel
Note: Replacement hot surface
ignition module works on all EF
models prior to and later than “CF”
serial numbers. Direct spark ignition
models use a different control board
(detailed in following section).
Step 5.
Step 6.
Carefully disconnect all wire harness connection to ignition module. Connection are
non-interchangeable to insure proper reinstallation.
Remove the 3 screws (Phillips screw driver) holding the ignition module in place and
remove ignition module from control panel.
Step 7.
Step 8.
Install new ignition module and secure in place with screws from step 6.
Carefully reconnect all wire harness connection to ignition module. Connection are
non-interchangeable to insure proper reinstallation.
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.
66
Download from Www.Somanuals.com. All Manuals Search And Download.
Control Board Replacement (Honeywell Integrated Control w/ Direct Spark Ignition)
Step 1.
Step 2.
Position main power switch to “OFF”
WARNING
Disconnect (unplug) water heater from 120
volt power source.
120 volt potential exposure. Isolate the
appliance and reconfirm power is
disconnected using a multi-meter.
Step 3.
Step 4.
Un-latch and remove top surround cover
from top of water heater.
Locate control board.
Control Board
Blower
Step 5.
Carefully disconnect all wire
connections from control board.
Unclip this
side second
Note: It may be necessary to
identify wires for
Unclip blower
side first
proper re-connection.
Step 6.
Step 7.
Depress the plastic tabs on the blower side of the
control board first.
Tilt the control panel and slide control hook tabs from
slots in the control panel (see photo at right).
Step 8.
Step 9.
Replace control board and all wire connections.
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.
67
Download from Www.Somanuals.com. All Manuals Search And Download.
Transformer Replacement Procedure
Step 1.
Step 2.
Position main power switch to “OFF”.
WARNING
120 volt potential exposure. Isolate the
appliance and reconfirm power is
disconnected using a multi-meter.
Disconnect (Unplug) water heater
from 120 Volt power source.
Step 3.
Un-latch & remove surround cover from
top of water heater.
Step 4.
Step 5.
For Hot Surface Ignition models, refer to ignition module illustration below, Disconnect wire harness
P1 labeled “PRIMARY” and P2 labeled “SECONDARY” from ignition module.
For Hot Surface Ignition models,
Step 3
Disconnect harness
“P1” & “P2”
Disconnect secondary leads (blue &
yellow wire) from thermostat board.
Note the blue wire is connected to
24 volt “HOT” terminal. (see photo below)
For Direct Spark Ignition models,
Disconnect primary leads (black & white) and
secondary leads (blue & yellow) from the
transformer. (leads are different sizes to
prevent interchanging)
from ignition module
Step 5
Disconnect blue & yellow wire from
thermostat board. Note blue wire is
connected to 24 volt “HOT” terminal.
Ignition module
Thermostat
board
Step 6.
Remove the 2 screws ( short Phillips screw driver) holding the transformer in place and
remove transformer from control panel. (see photo below)
Step 7.
Step 8.
Install new transformer and secure in
place with screws from step 6.
Step 6
Remove transformer
mounting screws
For Hot Surface Ignition models,
Reconnect wire harness P1 & P2,
connections are non-interchangeable
to insure proper reconnection.
For Direct Spark Ignition models,
Reconnect primary and secondary wires to transformer.
(leads are different sizes to prevent interchanging)
Step 9.
For Hot Surface Ignition models,
Reconnect blue & yellow wire leading from the
P2 connection on ignition module to
Thermostat
board
thermostat board. Note the blue wire must connect to the 24
volt “HOT” terminal. (see photo at right)
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.
24 volt common,
yellow wire connection
24 volt Hot,
blue wire connection
Step 11. Replace surround cover on top of water heater.
68
Download from Www.Somanuals.com. All Manuals Search And Download.
Used on EF water heaters prior to “CF” serial number.
Notice:
WARNING
The intake pressure switch is not used
on serial number “CF” and later.
120 volt potential exposure. Use caution
making voltage checks to avoid personal injury.
Is there continuity
Replace
through the normally
N
intake pressure switch.
N
Does Blower Energize?
Y
closed intake pressure
switch?
(see photo at right)
(see “Intake Pressure Switch
Replacement Procedure”)
Y
See “Vent Safety Switch Testing
and Replacement”
or
Exhaust Pressure Switch Tesinting
and Replacement”
or
“Blower Testing and Replacement”
Does purge LED
illuminate on the ignition
module?
Y
Switch OK.
Disconnect red wire leads from
pressure switch and check
continuity through switch.
N
With manometer, take a
reading from the inlet tube
pressure tap. Is reading
negative (-)1.2" W.C.
or more?
Is there continuity
through the normally
N
Y
closed intake pressure
switch?
(see photo above)
(see illustration below)
N
Y
Remove hose from intake
pressure switch and
See “Exhaust Pressure Switch Testing
and Replacement”)
Y
N
Restart heater.
or
Does purge LED illuminate?
“Blower Testing and Replacement”
N
Isolate (disconnect) heater from
intake vent system and
Restart heater.
Does purge LED illuminate?
Y
Is intake vent system
obstructed?
Y
Clear obstruction.
Inlet Tube
pressure tap
N
Call for technical support.
69
Download from Www.Somanuals.com. All Manuals Search And Download.
Used on EF water heaters prior to “CF” serial number.
Intake Pressure Switch Replacement Procedure
WARNING
120 volt potential exposure. Isolate the
appliance and reconfirm power is
disconnected using a multi-meter.
Step 1.
Step 2.
Position main power switch to “OFF”.
Disconnect (Unplug) water heater
from 120 Volt power source.
Step 3.
Step 4.
Un-latch & remove surround cover from top of water heater.
Locate intake pressure switch on control panel inside surround area (see photos below).
Intake pressure switch
located on side of
control panel
Step 6
Disconnect tubing from
pressure switch
Step 7
Remove 2
mounting screws
Step 5.
Disconnect red wire leads from pressure switch
(see photo at right).
Step 5
Disconnect red wires
Step 6.
Step 7.
Disconnect silicone tubing from pressure switch (see photos above).
Remove the two screws (Phillips screw driver) holding the intake pressure switch in
place and remove pressure switch from control panel (see photos above).
Step 8.
Step 9.
Install new pressure switch and secure in place with screws from step 7.
Reconnect silicone tubing (from step 6) to pressure switch.
Step 10. Reconnect red wires (from step 5) to pressure switch. Note: wires are interchangeable
with either switch terminal.
Step 11. Restore 120 volt power supply to heater & verify proper heater operation following the
instructions on the lighting instruction label or the lighting instructions located in the
installation & operation manual.
Step 12. Replace surround cover on top of heater.
70
Download from Www.Somanuals.com. All Manuals Search And Download.
Sequence of operation:
For Hot Surface Ignition models, with the thermostat calling for heat, prior to energizing blower, the ignition module checks the
vent safety switch for normal switch position of normally closed. If the vent safety switch contacts are open, (not in normal
position), the ignition module waits indefinitely for contact to close, The vent safety switch must be manually reset to close the
switch contacts.
For Direct Spark Ignition models, error code 26 will display indicating an open circuit for the vent safety switch. Determine if
temperature has reached 350°F before resetting switch and restoring operation. If evidence of extreme temperature is present,
call technical support.
WARNING
120 volt potential exposure. Use caution
making voltage checks to avoid personal injury.
Control side
harness
Heater side
harness
Is there continuity
Through GREY
Locate harness
connection.
(see photo at right)
Y
Lead wires of heater side
harness?
(see photo at right)
N
Call technical
support.
Depress reset
button on high
Replace vent
safety switch
(see “Vent Safety
Switch
Replacement
Procedure”)
N
limit switch. Is
there continuity
across high limit
switch?
Y
N
Does heater
function?
Y
System OK
N
(see photo below)
Reset heater, observe
heating cycle. Does
switch open?
N
Y
Is temp over 350°F?
Y
DO NOT OPERATE
HEATER
System over heating,
immediately contact
technical support.
N
Does switch open prior
to 350°F?
Y
Replace vent safety
switch
(see “Vent Safety
Switch Replacement
Procedure”)
Reset button
WARNING
Make sure exhaust collector compartment is not
overheating (350°F) before resetting vent safety
switch. If there is evidence the collector compartment
is overheating, CALL TECHNICAL SUPPORT.
71
Download from Www.Somanuals.com. All Manuals Search And Download.
Vent Safety Switch Replacement Procedure
Step 1.
Step 2.
Position main power switch to “OFF”.
Loosen adhesive backed rubber escutcheon from service panel access cover
and slide escutcheon back along exhaust pipe to allow for removal of cover
(see photos at right).
Rubber
escutcheon
Step 3.
Remove screws from service panel access cover
(¼" nut driver) and remove cover from heater
(see photos at right)
Step 4.
Step 5.
Disconnect wire leads from vent
safety switch (see photo at right).
Remove the 2 switch mounting
screws (Phillips screw driver)
and nuts (5/16 wrench) and
remove switch from heater.
Step 6.
Step 7.
Install new switch using screws
from step 5.
Reconnect wire leads.
Note: wire leads are
interchangeable with either
switch terminal.
Vent safety
switch
Step 8.
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.
Reinstall service panel access cover and
rubber escutcheon.
72
Download from Www.Somanuals.com. All Manuals Search And Download.
Disassembly Procedure for Access to Anodes & Flue Baffles
WARNING
Heater components may be HOT when performing the following steps in this procedure.
Take necessary precaution to prevent personal injury.
WARNING
Step 1.
Step 2.
Position main power switch to “OFF”.
120 volt potential exposure. Isolate the
appliance and reconfirm power is
disconnected using a multi-meter.
Disconnect (Unplug) water heater
from 120 Volt power source.
Step 3.
Step 4.
Un-latch & remove surround cover from top of heater.
Disconnect wire harnesses to allow for removal of control panel.
Note: Where ever possible, rather than disconnecting at the control panel, follow wire
harness away from control panel and disconnect at control component location.
Step 5.
Remove the three control panel mounting screws (¼” nut driver) and remove control
panel from the water heater (see photos below).
Remove Control
Panel
Control Panel
Mounting Screw
Step 6.
Step 7.
Completely remove insulation (two pieces) from top of heater to expose collector cover
Remove all collector cover
screws (5/16" socket) and
remove collector cover
(see photos at right).
Collector
cover
Step 8.
Photo 44 shows heater with collector cover removed allowing
access to anode rods and flue baffles.
Anode
locations
a) for anode service, see “Anode Inspection and Replacement”
b) for flue baffle service, see “Flue Baffle Inspection and Replacement”
c) for powered anode service, see “Powered Anode Replacement”
Flue
baffles
Note: EF100T399 models have only 1 anode
rod under the 2nd pass collector cover.
73
Download from Www.Somanuals.com. All Manuals Search And Download.
Anode inspection and replacement
WARNING
Heater components and stored water may be HOT when performing the following steps in
this procedure. Take necessary precaution to prevent personal injury.
Step 1.
Step 2.
Step 3.
Step 4.
Turn off water supply and drain water heater.
Disassemble water heater per “Disassembly Procedure for Access to Andoes & Flue Baffles”.
Locate and remove anode rods from heater (1-1/16 hex socket).
Visually inspect anode rod. Anode rod should show signs of depletion, this is normal. If
the depletion is ½ of the original diameter (approximately ¾" diameter), replacement is
recommended. If any of the steel core of the anode is exposed, replacement is
recommended.
Step 5.
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 6.
Step 7.
Step 8.
Reinstall collector cover per “Collector Cover Installation Procedure”.
Reinstall collector insulation and control panel, reconnect control panel wire harnesses.
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.
Step 9.
Replace surround cover on top of water heater.
74
Download from Www.Somanuals.com. All Manuals Search And Download.
Flue baffle inspection and replacement
WARNING
Heater components may be HOT when performing the following steps in this procedure.
Take necessary precaution to prevent personal injury.
Step 1.
Step 2.
Step 3.
Disassemble heater per “Disassembly Procedure for Access to Anodes & Flue Baffles”.
Remove flue baffles from heater (pliers) (8 two inch baffles & 2 four inch baffles).
Visually inspect flue baffles. Flue baffles should show signs of oxidation, this is normal.
If the oxidation has deteriorated any portion of the flue baffle, replacement is
recommended. If any restrictors are missing, replacement is recommended.
Step 4.
Upon completion of inspection or subsequent replacement, reinstall flue baffles into
heater.
Step 5.
Step 6.
Step 7.
Reinstall collector cover per “Collector Cover Installation Procedure”.
Reinstall collector insulation and control panel, reconnect control panel wire harnesses.
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.
Step 8.
Replace surround cover on top of water heater.
75
Download from Www.Somanuals.com. All Manuals Search And Download.
Powered Anode Replacement for EF100T399 only
Powered Anode Replacement EF100T399 models only
WARNING
Heater components may be HOT when performing the following steps in this procedure.
Take necessary precaution to prevent personal injury.
The powered anode control module is located on the right vertical side of the control panel inside the surround panel.
The control has a LED indicator light to show the status of operation. When the tank is filled with water and the power
supply is on to the water heater, the light should have a steady green glow to indicate that protection current is flowing
and operating normally. If the indicator light is not glowing, the power supply to the water heater or powered anode
system is disconnected.
Step 1. Check the power supply or wire connections to the powered anode control.
Step 2. Indicator light diagnostic codes:
a) If the control is flashing red, then there is a malfunction with the powered anode system.
Make sure there are no bare spots in the wire insulation to the powered
anode rods.
Step 3. Check all electrical connections. The powered anode rods are insulated from the
water heater tank in the bushing.
a) With an ohmeter, check continuity between the powered anode terminal and the
bushing. There should not be continuity. If there is continuity, replace the powered
anode assembly.
Volt meter set
to OHM setting
76
Download from Www.Somanuals.com. All Manuals Search And Download.
Collector Cover Installation Procedure
Step 1.
Step 2.
Remove old silicone from top surface of collector flange and collector cover.
Apply ¼" bead of Ultra Copper Silicone around entire collector flange surface. Allow
caulk to “cure” for 10 minutes.
Step 3.
Step 4.
Carefully reinstall collector cover, tighten screws evenly.
Allow a minimum of 6 hours before putting heater back in service.
Apply ¼" bead of Ultra
Copper Silicone around entire
collector flange surface
77
Download from Www.Somanuals.com. All Manuals Search And Download.
Product Handling - Carefully uncrate the heater. Move in place with a hand truck (Do not use the
venting pipes for handles).
Electrical Requirements - Make sure there is 120 volts line voltage. Line voltage must be properly
polarized. Adequate ground supplied to the heater.
Venting Requirements - All venting must stay within the required lengths and diameter (see table
below). Proper support of the venting pipe is a MUST (every 5ft vertical and 3ft horizontal).
Termination must be located to prevent re-circulation of flue gases. Medium to long sweep 90°
elbows or straight exhaust terminal coupling recommended.
Gas Requirements - Gas piping sized adequately, ¾" or larger to heater or 1" or larger for
EF100T399 models. Install a properly sized regulator (if unknown, assure an adequate volume of
gas is available). 7" W.C. is required when the unit is running. Gas pressure must stay below 14"
W.C. static pressure. Pressure drops between static pressure and operating flow should be less
than 3" W.C.
Condensate Requirements - Condensate line needs to slope to a drain at a minimum of ¼" per
foot. Make sure the condensate line does not have the potential to freeze. If using more than one
heater and using a common condensate line, make sure the condensate line is properly sized.
Service/Mechanical Room - Provide adequate space for servicing heater. Leave room to get to the
top and bottom pressure switches as well as enough overhead room to remove the anode rods for
servicing (18" min.).
Vent tables
Balanced Direct Vent Systems
PVC, CPVC
Power Vented Systems
PVC, CPVC
Total length of exhaust piping must not exceed
“Maximum Vent Length”
Total length of intake piping and exhaust piping
added together must not exceed “Maximum
Combined Length” Shown below
Shown below
Maximum Vent Length (feet)
Maximum Combined Length (feet)
Model Number
EFR-1-60T120
EF60T125, EF100T150
EF60T150, EF100T199
EF60T199
2"
60'
3"
120'
120'
100'
80'
4"
Model Number
EFR-1-60T120
EF60T125, EF100T150
EF60T150, EF100T199
EF60T199
2"
60'
3"
120'
120'
100'
80'
4"
170'
170'
150'
130'
130'
110'
100'
170'
170'
150'
130'
130'
110'
100'
30'
30'
30'
30'
30'
30'
EF100T250
N/A
N/A
N/A
80'
EF100T250
N/A
N/A
N/A
80'
EF100T300
60'
EF100T300
60'
EF100T399
50'
EF100T399
50'
Unbalanced Direct Vent Systems
Air intake CAN NOT exceed exhaust
by more than 30 feet
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.
Note: each 3" & 4" 90° Elbow is equivalent to 5 feet of
straight pipe.
Note: each 3" & 4" 45° Elbow is equivalent to 2.5 feet of
straight pipe.
78
78
Download from Www.Somanuals.com. All Manuals Search And Download.
R
Date
Service Provider
Phone Number
Model Number
Serial Number
Venting (PVC, CPVC):
Vent size 3" or 4"
Length of straight pipe
(intake)
Intake 90's (qty)
Intake 45's (qty)
Length of straight pipe
(exhaust)
Exhaust 90's (qty)
Exhaust 45's (qty)
Gas Line:
Gas Pressure:
Venturi:
Size & material
Setting from Bottom in Turns
Static
Distance from meter
to water heater
Running Inlet
Manifold
Electrical:
Line Voltage
Low Voltage
Polarity
Igniter Resistance:
Flame Sense Micro -Amps:
Spark Gap: ___________
LED Flashing Y or N
Which One(s)
Error Codes on Control Display (Direct Spark Ignition System Only): __________________________________
Exhaust Collector
Pressure:
Condensate Line:
Size & Material
Length
Positive Inches W.C.
Is trap provided Y or N
CO2
CO
Combustion:
Installation Site Name & Address:
Installation Site Contact Name &
Phone Number
79
Download from Www.Somanuals.com. All Manuals Search And Download.
Models prior to “CF” serial number
1
2
3
4
5
6
7
8
9
Combustion Surround Assy.
Burner Assy
2nd Pass Top Collector Cover
Screw 10-16 x 3/4
Vent Termination Elbow
Thermostat Sensor Probe
Baffle 4" Flue
Anode
Baffle 2" Flue
10 Wire Harness Service Panel
11 Plastisert Nipple 1-½" NPT
12 Plug
13 Nipple
14 T&P Relief Valve
15 Exhaust Pipe (PVC) w/Hose Barb
16 Condensate Trap Elbow
17 Silicone Hose
18 Outer Door Service Panel
19 Vent Pipe Support Bracket
20 NSF Escutcheon
21 Exhaust Pressure Switch
22 Nut
23 Vent Safety Switch
24 Screw 6-32x 3/8
25 Cleanout Access Cover
26 Cleanout Gasket
27 Screw 5/16-18 x ¾ HH Grade 5
28 Cleanout Cover
29 Cold Water Inlet
30 No Handle Brass Drain Valve
31 Coaxial Vent System
32 ASSE Approved Mixing Valve
Customer must specify complete
model number and serial number
when ordering service parts.
80
Download from Www.Somanuals.com. All Manuals Search And Download.
Models prior to “CF” serial number
AA Latch Assy
BB Screw 8-32 x ½ RHCR
CC Ignition Control Assy
DD Jacket Head
EE Main Power Switch
FF Potentiometer
GG Combustion Surround
JJ Surround Base
Customer must specify complete
model number and serial number
when ordering service parts.
1A Combustion Surround Assy.
2A Blower Gas Valve Assy
3A Burner Assy
4A Blower EBM
5A Silicone Hose
6A Hose Tee Fitting
7A Screw 10-32 x3/4
8A Gasket & Screw
9A Gas Valve
10A Nipple ½" NPT X3"
11A Reducer ¾ x ½ NPT
12A Nipple ¾ NPT x 6"
13A 2" dia. Flex Reducer
14A Inlet (PVC)
15A Gasket Blower Transition
16A Screw 8-32 x ¼ RHCR
17A Gasket Flame Sensor
18A Flame Sensor
19A Transition Tube
20A Nut Hex Washer
21A Gasket Hot Surface Igniter
22A Hot Surface Igniter
23A Burner Mounting Gasket
24A Burner Tube
25A Burner Mounting Gasket
26A Burner Mounting Insert
27A Burner Mounting Insert Gasket
81
Download from Www.Somanuals.com. All Manuals Search And Download.
Models prior to “CF” serial number
1C Electronic Control Module
2C Screw 8-32 x 1/2
3C Intake Pressure Switch
4C Control Mounting Panel
5C Thermostat PC Board
6C Transformer 120VAC x 24VAC x 40VA
7C Terminal
8C Terminal Strip
9C Power Cord
10C Control Wire Harness
11C Thermostat Wire Harness
12C Igniter Extension Wire
13C Blower Wire Harness
14C Power Switch Wire Harness
15C Flame Sensor Wire Harness
16C Rectifier Harness
Customer must specify complete
model number and serial number
when ordering service parts.
82
Download from Www.Somanuals.com. All Manuals Search And Download.
For models with “CF” serial or later.
1
2
3
4
5
6
7
Combustion Surround Assy.
Burner Assy (specify model)
2nd Pass Top Collector Cover
Screw 10-16 x 3/4
Vent Termination Elbow
Thermostat Sensor Probe
Baffle 4" Flue (specify model)
8a Anode Rod Assy
8b Powered Anode (for EF100T399)
9
Baffle 2" Flue
10 Wire Harness Service Panel
11 Plastisert Nipple 1-½" NPT
12 Plug
13 Nipple
14 T&P Relief Valve
Exhaust Pipe (PVC) w/Hose Barb
(except EF100T399)
15
16 Condensate Trap Elbow (specify model)
17 Silicone Hose
18 Outer Door Service Panel (specify model)
Vent Pipe Support Bracket (except
EF100T399)
19
20 NSF Escutcheon
21 Exhaust Pressure Switch
22 Nuts
23 Collector Temperature Limit Switch
24 Screw 6-32x 3/8
25 Cleanout Access Cover
26 Cleanout Gasket
27 Screw 5/16-18 x ¾ HH Grade 5
28 Cleanout Cover
29 Cold Water Inlet (Hydrojet) Assy.
30 No Handle Brass Drain Valve
31 Concentric Vent System (optional)
32 ASSE Approved Mixing Valve (optional)
Customer must specify complete
model number and serial number
when ordering service parts.
83
Download from Www.Somanuals.com. All Manuals Search And Download.
For models with “CF” serial or later.
AA Latch Assy
BB Screw 8-32 x ½ RHCR
CC Ignition Control Assy
DD Jacket Head
EE Main Power Switch
FF Potentiometer
GG Combustion Surround
JJ Surround Base
Customer must specify complete
model number and serial number
when ordering service parts.
Combustion Surround Assy. (specify
model)
1A
2A Blower Gas Valve Assy (specify model)
3A Burner Assy (specify model)
4A Blower EBM (specify model)
5A Silicone Hose
6A Burner Mounting Insert Gasket
7A Screw 10-32 x3/4
8A Gasket & Screw
9A Gas Valve (specify model)
10A Nipple (specify model)
11A Reducer (specify model)
12A Nipple (specify model)
2" dia. Flex Reducer (or PVC reducer for
399)
13A
14A Inlet (PVC)
15A Gasket Blower Transition (specify model)
16A Screw 8-32 x ¼ RHCR
17A Gasket Flame Sensor
18A Flame Sensor
19A Transition Tube
20A Nut Hex Washer
21A Gasket Hot Surface Igniter
22A Hot Surface Igniter
23A Burner Mounting Gasket
24A Burner Tube
25A Burner Mounting Gasket
26A Burner Mounting Insert
84
Download from Www.Somanuals.com. All Manuals Search And Download.
For models with “CF” serial or later.
1C Electronic Control Module
2C Screw 8-32 x 1/2
3C Control Mounting Panel
4C Thermostat PC Board
5C Transformer 120VAC x 24VAC x 40VA
6C Terminal
7C Terminal Strip
8C Power Cord
9C Control Wire Harness
10C Thermostat Wire Harness
11C Rectifier Harness (specify model)
12C Blower Wire Harness (specify model)
13C Power Switch Wire Harness
14C Flame Sensor Wire Harness
15C Powered Anode Control Harness (399 only)
16C Powered Anode Harness (399 only)
17C Powered Anode Control (399 only)
Customer must specify complete
model number and serial number
when ordering service parts.
85
Download from Www.Somanuals.com. All Manuals Search And Download.
For models with Direct Spark Ignition
1
2
3
4
5
6
7
8
9
Combustion Surround Assembly
Burner Assembly (specify model)
2nd Pass Top Collector Cover
Screw 10-16 x 3/4
Vent Termination Elbow
Thermostat Sensor Probe
Baffle 4" Flue (specify model)
Anode Rod Assembly
Baffle 2" flue
10 Wire Harness Service Panel
11 Plastisert Nipple 1-½" NPT
12 Plug
13 Nipple
14 T&P Relief Valve
15 Exhaust Pipe (PVC) w/Hose Barb
16 Condensate Trap Elbow (specify model)
17 Silicone Hose
18 Outer Door Service Panel (specify model)
19 Vent Pipe Support Bracket
20 NSF Escutcheon
21 Exhaust Pressure Switch
22 Nuts
23 Collector Temperature Limit Switch
24 Screw 6-32x 3/8
25 Cleanout Access Cover
26 Cleanout Gasket
27 Screw 5/16-18 x ¾ HH Grade 5
28 Cleanout Cover
29 Cold Water Inlet (Hydrojet) Assembly
30 No Handle Brass Drain Valve
31 Concentric Vent System (optional)
32 ASSE Approved Mixing Valve (optional)
33 Thermal Well
34 Clip
35 Hole Closure
36 Reducer
Customer must specify complete
model number and serial number
when ordering service parts.
86
Download from Www.Somanuals.com. All Manuals Search And Download.
For models with Direct Spark Ignition
1B Latch Assy
4B
1B
2B Screw 8-32 x ½ RHCR
3B Ignition Control Assy
4B Jacket Head
5B Main power switch
6B Honeywell Control Display
7B Combustion Surround
8B Surround Base
3B
7B
5B
6B
Customer must specify complete
model number and serial number
when ordering service parts.
1B
8B
2B
5A
2A
4A
Combustion Surround Assembly
(specify model)
1A
8A
9A
1A
2A Blower Gas Valve Assy. (specify model)
3A Burner Assy. (specify model)
4A Blower EBM (specify model)
5A Silicone Hose
7A
6A Burner Mounting Insert Gasket
7A Screw 10-32 x3/4
15A
8A Gasket
9A Gas Valve (specify model)
10A Nipple (specify model)
11A Reducer (specify model)
12A Nipple (specify model)
13A 2" dia. Flex Reducer
14A Inlet (PVC)
15A Gasket Blower Transition (specify model)
16A Screw 8-32 x ¼ RHCR
17A Gasket Flame Sensor
18A Flame Sensor
16A
16A
20A
17A
18A
21A
22A
3A
23A
24A
25A
26A
19A Transition Tube
20A Nut Hex Washer
21A Spark Rod
22A Spark Rod Gasket
28A
6A
23A Burner Mounting Gasket
24A Burner Tube
25A Burner Mounting Gasket
26A Burner Mounting Insert
27A Ground Wire
28A Gas Regulator Kit (Optional)
87
Download from Www.Somanuals.com. All Manuals Search And Download.
For models with Direct Spark Ignition
2C
8C
3C
4C
5C
9C
10C
1C
11C
12C
6C
13C
7C
1C Control Panel
2C Control Board
3C Transformer 120VAC x 24VAC x 40VA
4C Terminal
5C Terminal Strip
6C Power Cord
7C Controller Wire Harness
8C Transformer Primary Wire Harness
9C Transformer Secondary Wire Harness
10C Blower Wire Harness
11C Power Switch Wire Harness
12C Sensor Wire Harness
13C High Voltage Spark Cable
Customer must specify complete
model number and serial number
when ordering service parts.
88
Download from Www.Somanuals.com. All Manuals Search And Download.
AC
Alternating Current
British Thermal Units
Carbon Monoxide
Carbon Dioxide
BTU/H
CO
CO2
DC
Direct Current
DSI
ECO
GFI
GPM
HSI
Hz
Direct Spark Ignition
Energy Cut Off
Ground fault interrupt
Gallons per Minute
Hot Surface Igniter
Hertz
LED
NOx
NPT
PSI
RPM
VA
VAC
W.C.
°C
°F
µA
Light Emitting Diode
Oxides of Nitrogen
National Pipe Thread
Pounds per Square Inch
Revolutions per Minute
Volt Amps
Volts Alternating Current
Inches of Water Column
Degrees Centigrade
Degrees Fahrenheit
Micro Amp
NOTES
89
Download from Www.Somanuals.com. All Manuals Search And Download.
NOTES
90
Download from Www.Somanuals.com. All Manuals Search And Download.
NOTES
91
Download from Www.Somanuals.com. All Manuals Search And Download.
Email
Download from Www.Somanuals.com. All Manuals Search And Download.
|