COMMERCIAL 24 VOLT FLUE DAMPER SERIES WATER HEATER WITH HONEYWELL INTEGRATED CONTROL SYSTEM Gas 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 “D” Series Models: D38T155 D75T(125,160,300) D65T(370,399) D80T(180,199,250) D80T(425,505) D100T(199,250) D80L(399,450,505) D100L(199,250,270,300) D100S(199,250) Manual 47985A REV 08/18 Save this manual for future reference
Table of Contents Page Service Procedure Introduction 4 --- Tools Required for Service 4 --- Sequence of Operation 6 --- Troubleshooting 7 --- Thermostat Circuit Testing 24 D24-I Pilot Operation Testing 27 D24-II Main Burner Operation Testing 30 D24-III Main Burner & Pilot Removal & Inspection 32 D24-IV Flue Baffle Removal & Inspection 35 D24-V Anode Removal & Inspection 36 D24-VI Generic Parts List 38 --- Glossary of Terms 41 --- Notes 41 --- Page 2 2
FEATURES OF HONEYWELL INTEGRATED CONTROLS SYSTEM 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. Temperature format may be displayed in degrees F or degrees C. Single control board with plug in wiring controls temperature, ignition, and flue damper operation. Reduced number of parts for servicing and wiring. Plug in wiring reduces chance of miswiring.
Introduction It is intended for this manual to be used by qualified service personnel for the primary purpose of troubleshooting analysis and repair of the Bradford White 24 Volt Flue Damper Series Water Heater. Understanding the sequence of operation section of this manual will contribute greatly to troubleshooting this product.
Specifications Power Supply Dedicated 120 VAC, 60 Hz., 15 A Current Draw Less than 5 Amps. Gas Supply Connection 1" NPT connection to gas valve for 370,000 Btu/hr. and over for natural gas, ¾" NPT for rest. Schedule 40 black iron pipe recommended. Approved Gas Type Natural or Propane. Gas supply must match the gas type listed on the water heater rating label. Gas Pressure (Nat. & L.P.) Manifold Pressure: 4.5" w.c. natural gas, 10.0" w.c. L.P.
Sequence of Operation 1 2 3 Thermostat calls for heat. The control board sends 24 volts from damper terminal #2 on the control plug to the flue damper. Flue damper begins to rotate open. Once the flue damper is fully open, the damper end switch closes and 24 volts is allowed to continue through damper to damper pin terminal #5. Trial for ignition (three 90 second ignition trials, with 65 second pauses between trials). Control Board simultaneously sends: 1.
Troubleshooting CAUTION Use Caution Not to Damage Connectors when making Voltage Measurements or Jumping Terminals Water Heater Fault: Water heater does not operate Display Error Code: Water heater display does not operate - blank display 1 Check main power supply to water heater - fuse, circuit breaker, plug receptacle, line cord or wiring to water heater. Check to make sure switch on top of control panel is in the ON position 2 Checking line voltage to board. Pins to black and white wires.
Troubleshooting CAUTION Use Caution Not to Damage Connectors when making Voltage Measurements or Jumping Terminals From previous page Does damper blade move to the full open position? N Error code #55 on display. Remove damper from heater and jump black & yellow wires of heater harness. Refer to photo on this page. Does water heater begin to operate? Y Is there pilot flame? Y N Check for debris limiting damper rotation. If no debris, replace damper. Error code #62 on display.
Troubleshooting Using Control Display for Servicing the Water Heater ACCESSING SERVICE MODE ON THE WATER HEATER DISPLAY (FOR SERVICE PERSONNEL ONLY) 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.
Troubleshooting 1. Max Setpoint (Display/Change) Max Setpoint value in Water Heater Display °F Max Setpoint idle Status Operational & SELECT SET 2a. Water Temperature Average (Displays average if there are two sensors - sensor temperature displayed if single sensor is used). °F Water Temp idle Status Operational SELECT SET 2b. Water Temperature - Upper Sensor (Displays if there is an upper sensor - some models) °F idle Status Operational Upper Sensor SELECT SET 2c.
Troubleshooting 3. Flame Current of Pilot Flame Sensor (Displays only in the Heating Cycle) ȝA Heating Status Flame Current Operational SELECT SET 4. Setpoint (Display/Change) °F setpoint idle Status Operational SELECT 5. SET °F/°C (Display/Change) °F °F/C° setpoint idle Status Operational SET SELECT 6.
Troubleshooting 7. Software Version (Display only) Soft idle Status Operational SET SELECT 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. WARNING Setting the water temperature to the maximum set point can result in scalding hot water delivered to the faucets.
Troubleshooting Step 2: Press “Set” button to enter setting mode. “Max Setpoint” will flash to indicate setting mode. Max Setpoint °F idle Status Operational 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.
Troubleshooting 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.
Troubleshooting Step 3: For water heaters using two temperature sensors, pressing the “Select” button again displays the Lower Sensor temperature reading. “Lower Sensor” will be displayed in the lower left side of the status window of the water heater display. °F idle Status Operational Lower Sensor SELECT SET To Display Flame Sense Current of the Pilot Flame Sensor: The pilot flame sense current is available only when the burners are in operation.
Troubleshooting Step 2: Press the “Set” button to enter the setting mode. “Setpoint” will flash in the water heater display. setpoint °F idle Status Operational 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.
Troubleshooting 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.
Troubleshooting 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 Status Operational SELECT SET Step 4: Press “Set” button to confirm °F or °C format.
Troubleshooting Step 5: Pressing “Select” button will return display to setpoint in format selected (°F or °C) immediately °F idle Status Operational 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.
Troubleshooting 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 Status Operational 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”.
Troubleshooting 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 Status Operational 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.
Troubleshooting 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.
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.
SERVICE PROCEDURE D24-I Thermostat Circuit Testing CAUTION Be Careful When Making Voltage Measurements or Jumping Terminals Not to Damage or Deform Connectors or Connector Pins. DANGER 120 volt exposure. To avoid personal injury, use caution while performing this procedure. This procedure assumes the flue damper is in working order. Be sure damper opens under its own power when the thermostat circuit is by-passed. Damper must be open or removed during this test.
SERVICE PROCEDURE D24-I Thermostat Circuit Testing WARNING! Do not operate water heater without verifying that the overheating condition has been corrected. Condition: Water Heater Not Operating Display shows error code “65” High Water Temperature (over 200 deg. F) Continued Once cause of overheating condition has been diagnosed and corrected, the control may be reset Reconnect and switch on power to the water heater.
SERVICE PROCEDURE D24-I Thermostat Circuit Testing Conditions: Upper or Lower Sensor Reading Faulty, High Water Temperature, or suspect thermostat is not accurate. Sensor Resistance Testing Upper Sensor 1. Determine resistance value of upper sensor. Test across grey wires. Upper thermister location (applicable models) 2. Draw quart of water off T&P valve. Using a thermometer, determine water temperature. 10 3. Use table below to verify correct resistance per water temperature measured.
SERVICE PROCEDURE D24-II Pilot Operation Testing CAUTION Be Careful When Making Voltage Measurements or Jumping Terminals Not to Damage or Deform Connectors or Connector Pins. DANGER 120 volt exposure. To avoid personal injury, use caution while performing this procedure. Condition: Pilot will not light or stay lit, Error codes 62, or 63 shown on Water Heater Display Reset control by pressing the lower right button under “reset” on the display for 3 seconds.
SERVICE PROCEDURE D24-II Pilot Inspection Condition: Error code 57: Flame Rod Shorted to Ground Disconnect power. Shut off gas supply to water heater. Slide out burner assembly (see section on “removing pilot and main burner assembly”). Check to see if pilot shield is touching pilot flame sensor or flame sensor touching pilot hood. Bend shield to prevent interference or replace pilot shield. Check pilot flame sense wire for broken insulation.
SERVICE PROCEDURE D24-II Pilot Operation Testing DANGER 120 volt exposure. To avoid personal injury, use caution while performing this procedure. CAUTION Be Careful When Making Voltage Measurements or Jumping Terminals Not to Damage or Deform Connectors or Connector Pins. Condition: Pilot lights, no or low flame signal. Control Display shows “4” or “62” for Error Codes (Service Needed). Control continues to spark until system “Lock Out”. Main burner will not light.
SERVICE PROCEDURE D24-III Main Burner Operation Testing CAUTION Be Careful When Making Voltage Measurements or Jumping Terminals Not to Damage or Deform Connectors or Connector Pins. DANGER 120 volt exposure. To avoid personal injury, use caution while performing this procedure. Checking MV & MV/PV control plug pins to gas valve for 24 volts output during heating cycle (pilot must be lit with no sparking). Condition: Main burner will not light, Display shows “Heating” under temperature setpoint.
SERVICE PROCEDURE D24-III Main Burner Operation Testing CAUTION Be Careful When Making Voltage Measurements or Jumping Terminals Not to Damage or Deform Connectors or Connector Pins. DANGER 120 volt exposure. To avoid personal injury, use caution while performing this procedure. Condition: Main burner short cycles. Control Display may show error code “63, 57, or 4” and be in “Soft Lockout” state. Check gas inlet pressure to the water heater gas valve. Line pressure should be: Nat. = Min. 5.5" W.C.: Max.
SERVICE PROCEDURE D24-IV Main Burner & Pilot Removal and Inspection WARNING Heater components may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury. Gas Valve Wire Leads Main Burner Removal Gas Valve Control Knob Step 1. Disconnect (un-plug) water heater from electrical supply. Step 2. Turn “OFF” gas supply to water heater. Step 3. Rotate gas valve control knob to the “OFF” position (see photo 17). Step 4.
SERVICE PROCEDURE D24-IV Main Burner & Pilot Removal and Inspection Pilot Shield Pilot Burner Removal Step 1. With burner rack removed from heater, disconnect pilot tube connection from gas valve Step 2. Remove the two pilot burner mounting screws securing the pilot and pilot shield in place. Step 3. Remove pilot shield and pilot from burner rack. Step 4. To install pilot burner and pilot shield, reverse above procedure. Be sure to reconnect green ground wire.
SERVICE PROCEDURE D24-IV Control Board Replacement DANGER 120 volt exposure. To avoid personal injury, unplug while performing this procedure. Control board replacement Step 1: Disconnect Power Step 2: Unplug wire connections from board. 24 23 Depress plastic tabs Wire connections Step 3: To remove board, tilt control panel to the right and slide control hook tabs from slots in control panel. 25 To remove lower sensor Remove clip, pull sensor out.
SERVICE PROCEDURE D24-V Flue Baffle Removal, Inspection WARNING Heater components may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury. 27 Step 1. Disconnect (unplug) water heater from electrical supply. Step 2. Disconnect venting from draft diverter and remove draft diverter from top of water heater. Step 3. Disconnect flue damper from wire harness and remove flue damper from top of water heater (see photo 27). Step 4.
SERVICE PROCEDURE D24-VI Anode Removal and Inspection WARNING Heater components may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury. 36 Step 1. Disconnect (unplug) water heater from electrical supply. Step 2. Turn “OFF” water supply to water heater. Step 3. Open a near by hot water faucet to relieve tank pressure. Step 4. Connect hose to drain valve of water heater and route to an open drain.
SERVICE PROCEDURE D24-VI Anode Removal and Inspection Approximate Anode Rod Locations Page 37 37
Generic Parts List 2 3 1 5 4 11 30 10 8 9 6 28 24 29 7 12 27 13 25 19 23 14 26 22 21 20 15 15A 16/16A 17/17A 18 1. Draft Diverter w/Leg Kit 2. Draft Diverter 3. Draft Diverter Leg 4. Damper Outlet Reducer 5. Flue Damper 6. Hot Outlet Nipple 7. Cold Water Inlet Dip Tube 8. Hex Head Anode 9. Flue Baffle 10. Flue Reducer 11. Flue Core 12. 1" x ¾" Reducer Bushing 13. Nipple T&P Valve 14. T&P Valve 15. Cleanout O-Ring 15A. Cleanout Gasket (ASME) 16. Cleanout Access Cover 16A.
Generic Parts List 13A 1A 2A 4A 3A 14A 16A 7A 8A 5A 17A 9A 6A 11A 18A 10A 12A 15A 19A 20A 1A. Draft Panel 2A. Burner Rack 3A. Burner Tube 4A. Gas Valve 5A. Burner Manifold 6A. Main Burner Orifice 7A. Pilot Shield 8A. Pilot Burner 9A. Pilot Orifice 10A. Pilot Tubing 11A. Pilot Mounting Screw 12A. Burner Tube Support 13A. Manifold Bracket 14A. C-Cane Manifold 15A. Manifold Straight 16A. Manifold Bracket 17A. 90° Street Elbow Black 18A. 1" Down Pipe Nipple Black 19A. 1" 90° Elbow Black 20A.
Generic Parts List 19B 20B 7B 17B 18B 8B 6B 5B 4B 3B 9B 16B 2B 12B 10B 13B 1B 11B 14B 15B 1B. Temperature Display 2B. Control Box Cover 3B. Integrated Control Board 4B. Screw 8-16 X ½ PHCR 5B. Transformer 6B. Ground Lug 7B. On/Off Switch 8B. Control Box Panel 9B. Screw 8/32 X ¼ PHCR 10B. 7/8" Snap Bushing 11B. Power Cord Strain Relief 12B. Pilot Wire Strain Relief 13B. Secondary Transformer Wiring Harness 14B. Primary Transformer Wiring Harness 15B. Screw 8-18 x ¾ PHCR 16B.
Glossary of Terms AC BTU/H CO CO2 DC ECO GFI GPM Hz LED NOx NPT PSI VA VAC W.C.
NOTES Page 34
NOTES Page 34
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