SERVICE MANUAL Troubleshooting Guide and Instructions for Service (To be performed ONLY by qualified service providers) Ultra Low NOx Atmospheric Vent Water Heaters with ICON and Integrated Control Systems Models Covered: SECTION 1 (PG. 5): SERIAL NUMBERS “XF-” (JUN. 2021 AND LATER) WITH “-NDD” DESIGNATOR UCG80H125*(N,X)(A) UCG(80,100)H199*(N,X)(A) UCG(80,100)H270*(N,X)(A) UCG(80,100)H399*(N,X)(A) SECTION 2 (PG. 44): SERIAL NUMBERS “XL-” (NOV.
Table of Contents Serial Number Breakdown.......................................................................................................................................................................... 3 How to Use this Manual ........................................................................................................................................................................... 4 Tools Required for Service ..........................................................................
Determining the Age of Your Water Heater SERIAL NUMBER SECTION: The first two characters represent the year and month of manufacture. The remainder of the serial is a sequential production number, seven digits in length before December 2007 (DM), and eight digits in length after.
Introduction The Bradford White Ultra Low NOx Atmospheric Vent Water Heater is designed to deliver hot water at up to 82% thermal efficiency in a quiet running unit with a top exhaust vent connection that allows for installation in existing locations. While this unit is vented atmospherically, there is no damper required to maintain heat loss during off cycle.
Tools Required for Service Manometer: Two types available, a liquid “U” tube type or a digital (magna-helic) type. This device is used to measure gas and/or air pressures and vacuum. Multi-Meter: A digital type is strongly recommended. This device is used to measure electrical values. The meter you select must have the capability to measure volts AC, volts DC, Amps, microamps and ohms. Thermometer: Used to measure water temperature. An accurate thermometer is recommended.
Specifications . Model Description Model Number Nominal Gal. Capacity BTU/Hr. Input US Imp. Gal Gal.
Specifications Power Supply Gas Supply Approved Gas Type Gas Pressure (Nat.) Gas Pressure (L.P.) Venting System Minimum Clearance for Servicing Maximum Water Supply Pressure Thermostat Sensor Control Display Control Board Transformer Spark Rod Igniter Flame Sensor Output Gas Valve Blower Dedicated 120 VAC, 60 Hz, 15A Minimum 3/4” NPT (schedule 40 black iron pipe recommended) Natural and L.P. Unit must match gas type supplied. 14.0” W.C. maximum static, 4.5” W.C. minimum running (recommend 7.0” W.C.
Specifications Vent Tables (Intake Only) Model Number UCG80H125 UCG(80,100)H199 UCG(80,100)H270 UCG(80,100)H399 2” Max Intake Vent Length (feet) 20 20 20 N/A 3” Max Intake Vent Length (feet) 50 50 50 75 4” Max Intake Vent Length (feet) 75 75 75 20 WARNING The UCG(80,100)H399 model is not approved for 2 inch diameter inlet vent pipe. Venting with 2 inch pipe may result in damage to the water heater or cause an unsafe condition. DO NOT use 2 inch vent air intake pipe with UCG(80,100)H399.
Sequence of Operation 1. Thermostat calls for heat. 2. Combustion blower starts with a “soft” start light off. 3. Blower pre-purge period of approximately 15 seconds. 4. Ignition control board runs an internal verification safety check for approximately 15 seconds. 5. Trial for ignition (approximately 5 seconds per trial, 3 trials total): a. Flame establishing period (3 seconds), gas valve opens, sparks from spark rod to burner surface to ignite the gas. b. Burner on, flame proving period (2 seconds).
Sequence of Operation Lockout Conditions The system will go into lock out mode for the following reasons: 1. Error Code 110 (Ignition failure occurred) a. Control board will go into “Soft Lockout” if the main burner cannot be lit or fails to prove flame after 3 ignition trials. The water heater display indicates a lockout condition by showing an error code number 110 with “Service Needed” in the control display window. Refer to error codes in the diagnostic section of this Service Manual.
Building Management System (BMS) All water heaters with serial numbers after XA…….. (with ICON Systems) can be equipped with a gateway kit that will facilitate a Building Management System (BMS) connection to Modbus or Bacnet®. This kit is sold separately and is not factory installed. A full installation, operation, and troubleshooting manual is provided with the gateway kit.
BMS Wiring Diagram CAUTION Before beginning any Troubleshooting operations listed below, please note that the gateway kit and BMS may need to be disconnected from the heater. Please ensure this has been completed before proceeding with any troubleshooting operation that may be impacted by settings in the BMS. NOTICE The Building Management System (BMS) is only compatible with units that have ICON controllers.
Troubleshooting System Observations WARNING Water Heater Fault: Water heater does not operate Display Error Code: Water heater display does not operate - blank display 120 volt potential exposure. Use caution making voltage checks to avoid personal injury. Check main power supply to water heater – fuse, circuit breaker, plug receptacle, line cord or wiring to water heater. CAUTION Use caution to not damage connectors when making voltage measurements or jumping terminals.
Troubleshooting WARNING CAUTION 120 volt potential exposure. Use caution making voltage checks to avoid personal injury. Use caution to not damage connectors when making voltage measurements or jumping terminals From previous page. Does combustion blower operate? Measure voltage between black and white wires, of the 3 wire harness, at the blower (make sure the control display shows “heating” in the status mode, if not increase the setpoint).
Display Control Water Heater Display and Control Buttons To Increase Temperature Setpoint Step 1. Press and hold “Temperature Up” button until desired setpoint temperature appears on the display. Step 2. Press “DONE” button for new setting to take effect immediately. If the “DONE” button is not pressed, the new temperature setting will take effect in approximately 10 seconds.
To Decrease Temperature Setpoint Step 1. Press and hold “Temperature Down” button until desired setpoint temperature appears on the display. Step 2. Press “DONE” button for new setting to take effect immediately. If the “DONE” button is not pressed, the new temperature setting will take effect in approximately 10 seconds. To View Combustion Rate Step 1. Select Next while viewing Setpoint in User Mode to access Rate screen. Rate will only be displayed while the burner is operating. Step 2.
To Change Temperature Format in Display from F to C or ˚C to ˚F Step 1. Enter “Set-Up Mode” by pressing both UP/DOWN buttons together for 3 seconds. Step 2. Use the arrows to select between °F and °C Step 3. Press done to return to main screen or timeout/change will occur in one minute. An energy cut out (ECO) is incorporated in the sensor and control board which will shut off all gas supply to the burner if the water heater temperature exceeds 207°F (97.2°C).
Troubleshooting Accessing Diagnostic Mode on the Water Heater Display (FOR SERVICE PERSONNEL ONLY) The display has a Diagnostic Mode to access information in aiding servicing of the water heater. This procedure is for service and installation personnel only. To enter the Diagnostic Mode, follow the steps illustrated below: WARNING The following procedure is for service and installation personnel ONLY. Resetting lockout conditions without correcting the malfunction can result in a hazardous condition.
Step 3. Press the lower right “Next” button. The display will flash and show the number of any alert codes. These are not currently used. Step 4. Press lower right “Next” button. The display will flash and show the number of any Lockout codes. If there are no lockouts, the display will show 00. If there are multiple lockout codes “Next” will scroll through them. Step 5. Press “Next”, the display will show “DHW MAX”.
Step 6. Press Next, display will show “DELTA T DHW”, this is the real time temperature reading of the tank. Step 7. Press “Done” to exit Diagnostic Mode and return to the DHW setpoint in User Mode.
NOTICE The UCG ICON control system can produce soft and hard lockouts. Soft lockouts are displayed if active and are not stored in Diagnostic Mode history. The control will periodically attempt to resume normal operation when in soft lockout conditions. If the system resumes normal operation a soft lockout will clear instantly; hard lockouts will display if active and require manual reset. Up to ten previous Hard lockouts are logged chronologically (newest first) in Diagnostic Mode history.
Error Code Definition of Code Cause of Problem and Actions Taken to Correct • 105 Flame detected out of sequence • • • • • • • • 109, 110 Ignition Failure Occurred. • • • • • • 122,123 172 Light-off Rate Proving Failed Water temperature sensor resistance invalid NOTE 22 • • • Check to see if flame is present inside the combustion chamber before or after the ignition cycle. If so, check to make sure the gas valve is wired correctly. Check for voltage at the gas valve connection.
Service Procedure I: Thermostat Circuit Testing and Replacement IMPORTANT NOTE: This procedure assumes a cool tank. WARNING 120 volt potential exposure. Use caution making voltage checks to avoid personal injury. Condition: Water heater not operating. Display shows error code “93” (sensor reading faulty) CAUTION Unplug or disconnect electrical power to the water heater. Use caution to not damage connectors when making voltage measurements or jumping terminals.
Service Procedure I: Thermostat Circuit Testing and Replacement (Continued) Condition: Water heater not operating. Display shows error code 80 high water temperature (over 207°F (97.2°C)) (continued from previous page). WARNING 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. 24 • Reconnect and switch on power to the water heater.
Service Procedure I: Thermostat Circuit Testing and Replacement (Continued) Thermostat Sensor (Thermister) Replacement Procedure 1. Position main power switch to OFF. 2. Disconnect (unplug) water heater from 120 volt power source. 3. Unlatch and remove the top surround cover from top of heater. WARNING 120 volt potential exposure. Isolate the appliance and reconfirm power is disconnected using a multi-meter. 4. Disconnect the temperature sensor from control (see images below). 5.
Service Procedure I: Thermostat Circuit Testing and Replacement (Continued) 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 temperature and pressure relief valve. Compare temperature with temperature ohms chart below. Example: If the temperature is 84°F, then the resistance through the sensor would be 8449 (see shaded area).
Service Procedure II: Combustion System Testing and Replacement 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.
Service Procedure II: Combustion System Testing and Replacement (Continued) 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.
Service Procedure II: Combustion System Testing and Replacement (Continued) WARNING WARNING Heater components may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury. 120 volt potential exposure. Isolate the appliance and reconfirm power is disconnected using a multi-meter. Combustion System Removal Procedure 1. Position main power switch to OFF. 2. Disconnect (unplug) water heater from 120 volt power source. 3.
Service Procedure II: Combustion System Testing and Replacement (Continued) Combustion System Replacement Procedure 1. Fully inspect burner mounting insert gasket for the following: a. Tears d. Dirt or debris b. Missing material e. Other imperfections that would inhibit proper seal c. Cracks If gasket is NOT affected by any of the above, gasket replacement is not required. 2. Install the combustion assembly using new gasket or fully inspected gasket from Step 1.
Service Procedure III: Burner Tube Inspection and Replacement WARNING WARNING Heater components may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury. 120 volt potential exposure. Isolate the appliance and reconfirm power is disconnected using a multi-meter. Burner Tube Removal Procedure 1. Position main power switch to OFF. 2. Disconnect (unplug) water heater from 120 volt power source. 3. Turn OFF gas supply to water heater. 4.
Service Procedure III: Burner Tube Inspection and Replacement (Continued) WARNING Heater components may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury. Burner Tube Inspection 1. Inspect burner tube as follows (Acotech metal fiber mesh burner). a. Outer fiber mesh should be uniform with no tears or deterioration. b. Gently squeeze burner tube, Burner tube should feel firm without any soft areas around the sides or at the bottom. c.
Service Procedure IV: Gas Valve Replacement Gas Valve Replacement Procedure WARNING 1. Position main power switch to OFF. 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. 3. Turn OFF gas supply to water heater. 4. Unlatch and remove surround cover from top of heater. 5. From the gas valve, disconnect the gas connection, PVC venting, wire harness, and silicone tubing. 6.
Service Procedure V: Blower Testing and Replacement Does blower energize? Ensure control display shows “heating.” Raise temperature setpoint if necessary. Refer to ignition module/control board illustration. Is there 24VAC between blue and yellow wires at location J8. Y N Replace ignition module/control board. Call Technical Support. Y Is there 120VAC across the white and black wires at the incoming power harness connection? (see image at right). Determine power source problem and correct.
Service Procedure V: Blower Testing and Replacement (Continued) Blower Replacement Procedure WARNING 1. Position main power switch to OFF. 2. Disconnect (unplug) water heater from 120 volt power source. 3. Turn OFF gas supply to water heater. 4. Unlatch and remove surround cover from top of heater. 120 volt potential exposure. Isolate the appliance and reconfirm power is disconnected using a multi-meter. 5. Disconnect the 2 wire harnesses from blower. 6.
Service Procedure VI: Flame Sensor Testing and Replacement WARNING Flame Sensor Testing Procedure Refer to illustration below, is there a minimum of 1 µA during 1.5 second flame proving period? Y N With flame sensor disconnected from ignition module, check continuity to ground. Is there continuity to ground? Y N Remove flame sensor from water heater. Check continuity from tip of flame sensor to end of wire lead.
Service Procedure VI: Flame Sensor Testing and Replacement (Continued) Flame Sensor Replacement Procedure WARNING 1. Position main power switch to OFF. 2. Disconnect (unplug) water heater from 120 volt power source. 3. Unlatch and remove surround cover from top of heater. 120 volt potential exposure. Isolate the appliance and reconfirm power is disconnected using a multi-meter. 4. Disconnect the wire lead from flame sensor. 5.
Service Procedure VII: Spark Rod Gap Adjustment and Replacement Spark Rod Gap Inspection and Adjustment 1. Remove combustion system as described Combustion System Removal Procedure, pg 27. in 2. Measure spark gap between the spark rod and burner tube. Acceptable spark gap is from 3/16" to 1/4" (see image below). 3.
Service Procedure VII: Spark Rod Gap Adjustment and Replacement (Continued) Spark Rod Replacement Procedure WARNING 1. Position main power switch to OFF. 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. 3. Unlatch and remove surround cover from the top of the water heater. 4. Disconnect wire lead from spark rod. 5.
Service Procedure VIII: Ignition Module/Control Board Replacement Control Board Replacement WARNING 1. Position main power switch to OFF. 2. Disconnect (unplug) water heater from 120 volt power source. 3. Unlatch and remove top surround cover from the top of the water heater. 120 volt potential exposure. Isolate the appliance and reconfirm power is disconnected using a multi-meter. 4. Locate the control board. 5. Carefully disconnect all wire connections from the control board.
Service Procedure IX: Anode Inspection and Replacement Anode Replacement Procedure WARNING 1. Position main power switch to OFF. Heater components and stored water may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury. 2. Disconnect (unplug) water heater from 120 volt power source. 3. Turn OFF water supply and drain the water heater. 4. Locate (see image below) and remove anode rods from heater (1-1/16 hex socket). 5.
Service Procedure X: Display Module Replacement WARNING Display Module Replacement 1. Position main power switch to OFF. 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. 3. Remove 4 screws that hold the display into the enclosure (see image below). 4. After removing the screws pull the display out of the enclosure. 5. Once the display is removed, disconnect the two mating plugs. 6.
Service Procedure XI: Transformer Replacement Transformer Replacement Procedure WARNING 1. Position main power switch to OFF. 120 volt potential exposure. Isolate the appliance and reconfirm power is disconnected using a multi-meter. 2. Disconnect (unplug) water heater from 120 volt power source. 3. Unlatch and remove surround cover from top of water heater. 4.
SECTION 2: SERIAL NUMBERS “XL-” (NOV. 2021 AND LATER) WITH “-NDD-895” DESIGNATOR Specifications Model Description Model Number Nominal Gal. Capacity BTU/Hr. Input US Imp. Gal Gal. UCG80H125 80 UCG80H199 80 UCG100H199 100 Dimensions (inches) GPH Recovery at Degree Rise 40°F 100°F 140°F 67 125,000 67 199,999 83 199,999 308 493 493 123 88 197 141 197 141 A Floor to Vent Conn. in. 57 57 64 7/8 B C Jacket Vent Dia. Size in. in. 28 28 28 5 6 6 D Floor to T&P Conn. in. E Floor to Gas Conn. In.
Specifications Power Supply Gas Supply Approved Gas Type Gas Pressure (Nat.) Gas Pressure (L.P.) Venting System Minimum Clearance for Servicing Maximum Water Supply Pressure Thermostat Sensor Control Display Control Board Transformer Spark Rod Igniter Flame Sensor Output Gas Valve Blower Dedicated 120 VAC, 60 Hz, 15A Minimum 3/4” NPT (schedule 40 black iron pipe recommended) Natural and L.P. Unit must match gas type supplied. 14.0” W.C. maximum static, 4.5” W.C. minimum running (recommend 7.0” W.C.
Specifications Vent Tables (Intake Only) Model Number UCG80H125 UCG(80,100)H199 2” Max Intake Vent Length (feet) 20 20 3” Max Intake Vent Length (feet) 50 50 4” Max Intake Vent Length (feet) 75 75 Determining Required Intake Vent Length 5. 6. 7. 8. Determine the total length of straight vent pipe (in feet) required for the intake. Add 5 feet of venting for every 90° elbow. Add 2 ½ feet of venting for every 45° elbow.
Sequence of Operation 1. Thermostat calls for heat. 2. Combustion blower starts. 3. Blower pre-purge period of 30 seconds. 4. Trial for Ignition (5 seconds, 3 trials). a. Flame establishing period (3 seconds), gas valve opens, sparks from spark rod to burner surface to ignite the gas. b. Burner on, flame proving period (2 seconds). Requires a minimum of 1 microamp through flame sense rod to prove flame. 5. Steady State Operation: Burner continues to operate until: a.
Sequence of Operation Lockout Conditions The system will go into lockout mode for the following reasons: 1. Error Code 62 or 63 a. Control board will go into Soft Lockout if the main burner cannot be lit and 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.
Troubleshooting System Observations WARNING Water Heater Fault: Water heater does NOT operate. 120 volt potential exposure. Use caution making voltage checks to avoid personal injury. Display Error Code: Water heater display does NOT operate – blank display. CAUTION Check main power supply to water heater – fuse, circuit breaker, plug receptacle, line cord, or wiring to water heater. Use caution to NOT damage connectors when making voltage measurements or jumping terminals.
Troubleshooting CAUTION WARNING Use caution to NOT damage connectors when making voltage measurements or jumping terminals. 120 volt potential exposure. Use caution making voltage checks to avoid personal injury. From previous page. Does combustion blower operate? Refer to control board illustration. Measure voltage between terminals P7(3) & P7(5) on the “inducer” output. Make sure the control displays shows “heating” in the status mode. If not, increase the setpoint.
Troubleshooting This 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 Service Mode, follow the steps that follow. Step 1. Press “Select” and “Temperature Up” buttons together and hold for 3 seconds until “Max Setpoint” is shown in the display. Step 2. Pressing “Select” button will change display to the next mode.
Troubleshooting Step 1. Max Setpoint (Display/Change). Step 2. Tank Sensor Temperature (displays water temperature average). Step 3. Flame Current of Burner Flame Sensor (displays only in the Heating Cycle). Step 4. Setpoint (Display/Change).
Troubleshooting Step 5. °F/°C (Display/Change). Step 6. Differential (displays only – shows the differential of the thermostat). Step 7. Software Version (display only). Step 8. Error Code History (displays if there are present error codes or up to 10 previous error codes). Water Heater Display will show “--” if there are no error codes.
Troubleshooting 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 setpoint can 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 installation.
Troubleshooting Step 4. Press “Set” button to confirm new “Max Setpoint” value and stop setting mode. Step 5. 30 seconds after the last button press, the water heater display will go back to “User Mode.” If 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 “User Mode” immediately by pressing both the “Temperature Up” and “Select” buttons together for 3 seconds.
Troubleshooting To Display Flame Sense Current of the Flame Sensor: The 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 “Service Mode” described previously. Step 3. Press the “Select” button until a number value is displayed with the “Flame Current” to the right of the number. The value displayed is in microamps (µA). To Display the Current Temperature Setpoint: Step 1.
Troubleshooting Step 3. To raise the temperature setpoint, press the “Temperature Up” button until the desired temperature is shown on the water heater display. Note: The maximum temperature that can be set is limited to the “Max Setpoint” described previously. WARNING Setting the water temperature to the maximum setpoint can result in scalding hot water delivered to the faucets.
Troubleshooting To Display and Change Temperature Format (°F/°C) To change temperature format 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. Step 2. Press “Set” button to change temperature format. “°F/°C” symbol will flash in the water heater display. Step 3a. Press “Temperature Up” button to change temperature format to °C.
Troubleshooting Step 3b. Press “Temperature Down” button to change temperature format to °F. Step 4. Press “Set” button to confirm °F or °C format. °F/°C will stop flashing. Step 5. Pressing “Select” button will return display to setpoint in format selected (°F/°C) immediately.
Troubleshooting 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.
Troubleshooting 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 near the water heater display can be used to identify the code number. If no number is displayed on a “--“, then there has not been an error code for index 10. Step 4. Press the “Temperature Down” button to change the previous code index, Code #9. Step 5. Press the “Select” button for code index #9 to view if there are any code numbers.
Troubleshooting Step 6. Continue pressing the “Temperature Down” button to change to the next code error index and press “Select” to view the error code number, if any, for that index number. Continue on index #1 and the most recent 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” and “Select” buttons together for 3 seconds.
Troubleshooting All other error codes will put the water heater into “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 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. Step 2. Press for 3 seconds to reset the control in Service Mode.
Service Procedure I: Thermostat Circuit Testing and Replacement IMPORTANT NOTE: This procedure assumes a cool tank. WARNING 120 volt potential exposure. Use caution making voltage checks to avoid personal injury. Condition: Water heater not operating. Display shows error code 32 (sensor reading faulty). CAUTION Use caution to NOT damage connectors when making voltage measurements or jumping terminals. Unplug or disconnect electrical power to water heater. Check continuity of wire harness to sensor.
Service Procedure I: Thermostat Circuit Testing and Replacement (Continued) WARNING Continued from previous page. DO NOT operate the 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°F). 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 I: Thermostat Circuit Testing and Replacement (Continued) WARNING Thermostat Sensor (Thermistor) Replacement Procedure 120 volt potential exposure. Use caution making voltage checks to avoid personal injury. 1. Position main power switch to OFF. 2. Disconnect (unplug) water heater from 120 volt power source. 3. Unlatch and remove the top surround cover from the top of the water heater. 4.
Service Procedure I: Thermostat Circuit Testing and Replacement (Continued) 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 temperature and pressure relief valve. Compare temperature with temperature ohms chart below. Example: If the temperature is 84°F, then the resistance through the sensor would be 8449 (see shaded area).
Service Procedure II: Combustion System Testing and Replacement 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.
Service Procedure II: Combustion System Testing and Replacement (Continued) 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.
Service Procedure II: Combustion System Testing and Replacement (Continued) WARNING WARNING Heater components may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury. 120 volt potential exposure. Isolate the appliance and reconfirm power is disconnected using a multi-meter. Combustion System Removal Procedure 1. Position main power switch to OFF. 2. Disconnect (unplug) water heater from 120 volt power source. 3.
Service Procedure II: Combustion System Testing and Replacement (Continued) Combustion System Replacement Procedure 1. Fully inspect burner mounting insert gasket for the following: a. Tears d. Dirt or debris b. Missing material e. Other imperfections that would inhibit proper seal c. Cracks If gasket is NOT affected by any of the above, gasket replacement is not required. 2. Install the combustion assembly using new gasket or fully inspected gasket from Step 1.
Service Procedure III: Burner Tube Inspection and Replacement WARNING WARNING Heater components may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury. 120 volt potential exposure. Isolate the appliance and reconfirm power is disconnected using a multi-meter. Burner Tube Removal Procedure 1. Position main power switch to OFF. 2. Disconnect (unplug) water heater from 120 volt power source. 3. Turn OFF gas supply to water heater. 4.
Service Procedure III: Burner Tube Inspection and Replacement (Continued) WARNING Heater components may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury. Burner Tube Inspection 1. Inspect burner tube as follows (Acotech metal fiber mesh burner). d. Outer fiber mesh should be uniform with no tears or deterioration. e. Gently squeeze burner tube, Burner tube should feel firm without any soft areas around the sides or at the bottom. f.
Service Procedure IV: Gas Valve Replacement Gas Valve Replacement Procedure WARNING 1. Position main power switch to OFF. 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. 3. Turn OFF gas supply to water heater. 4. Unlatch and remove surround cover from top of heater. 5. From the gas valve, disconnect the gas connection, PVC venting, wire harness, and silicone tubing. 6.
Service Procedure V: Blower Testing and Replacement Does the blower energize? Ensure control display shows “Heating.” Raise temperature setpoint if necessary. Y Is there 120 VAC across the white and black wires at location P3 on the control board? Y N N Is there 120 VAC across the white and black wires at location P2 the transformer? Y Refer to ignition module/control board illustration. Is there 120 VAC between P7(5) and P7(3)? Call Technical Support.
Service Procedure V: Blower Testing and Replacement (Continued) Blower Replacement Procedure WARNING 1. Position main power switch to OFF. 2. Disconnect (unplug) water heater from 120 volt power source. 3. Turn OFF gas supply to water heater. 4. Unlatch and remove surround cover from top of heater. 120 volt potential exposure. Isolate the appliance and reconfirm power is disconnected using a multi-meter. 5. Disconnect the 2 wire harnesses from blower. 6.
Service Procedure VI: Flame Sensor Testing and Replacement WARNING Flame Sensor Testing Procedure Refer to the illustration below. Is there a minimum of 1 µA during 1.5 second flame proving period? Y N 120 volt potential exposure. Use caution making voltage checks to avoid personal injury. Refer to the ignition module/control board illustration. 24 volts should maintain beyond the 1.5 second flame proving period. Is there 24 VAC between P5(5) and P5(8)? Y Flame sensing circuit O.K.
Service Procedure VI: Flame Sensor Testing and Replacement (Continued) Flame Sensor Replacement Procedure WARNING 1. Position main power switch to OFF. 2. Disconnect (unplug) water heater from 120 volt power source. 3. Unlatch and remove surround cover from top of heater. 120 volt potential exposure. Isolate the appliance and reconfirm power is disconnected using a multi-meter. 4. Disconnect the wire lead from flame sensor. 5.
Service Procedure VII: Spark Rod Gap Adjustment and Replacement Spark Rod Gap Inspection and Adjustment WARNING 1. Remove combustion system as described in Combustion System Removal Procedure, pg 68. 2. Measure spark gap between the spark rod and burner tube. Acceptable spark gap is from 3/16" to 1/4" (see image below). 3.
Service Procedure VII: Spark Rod Gap Adjustment and Replacement (Continued) Spark Rod Replacement Procedure WARNING 1. Position main power switch to OFF. 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. 3. Unlatch and remove surround cover from the top of the water heater. 4. Disconnect wire lead from spark rod. 5.
Service Procedure VIII: Ignition Module/Control Board Replacement Control Board Replacement WARNING 120 volt potential exposure. Use caution making voltage checks to avoid personal injury. 1. Position main power switch to OFF. 2. Disconnect (unplug) the water heater from the 120 volt power source. 3. Unlatch and remove the surround cover from the top of the water heater. 4. Locate the control board. 5. Carefully disconnect all wire connections from the control board.
Service Procedure IX: Anode Inspection and Replacement Anode Replacement Procedure WARNING 1. Position main power switch to OFF. Heater components and stored water may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury. 2. Disconnect (unplug) water heater from 120 volt power source. 3. Turn OFF water supply and drain the water heater. 4. Locate (see image below) and remove anode rods from heater (1-1/16 hex socket). 5.
Service Procedure X: Display Module Replacement WARNING Display Module Replacement 1. Position main power switch to OFF. 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. 3. Remove 4 screws that hold the display into the enclosure (see image below). 4. After removing the screws pull the display out of the enclosure. 5. Once the display is removed, disconnect the two mating plugs. 6.
Service Procedure XI: Transformer Replacement Transformer Replacement Procedure WARNING 1. Position main power switch to OFF. 120 volt potential exposure. Isolate the appliance and reconfirm power is disconnected using a multi-meter. 2. Disconnect (unplug) water heater from 120 volt power source. 3. Unlatch and remove surround cover from top of water heater. 4.
Water Heater Installation Checklist 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 5 ft (1.5 m) vertical and 3 ft (.
Water Heater Service Report Date: _______________ Service Provider: _____________________________ Model Number: _______________________________ Phone Number: _______________________________ Serial Number: _____________________________ Intake Venting: Intake Vent size 3”, 4” ______ Intake 45° Elbows (qty) Intake 90° Elbows (qty) ______ Exhaust Vent Size 6”,7”,8” ______ Length of Straight Pipe (Intake) ________ Gas Line: Gas Pressure: Venturi: Size & Material ______________ Static ___________
Notes ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ __________________
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