Bradford-White Corp D-38T-155 manual

Save this manual for future reference Manual 47985A SERVICE MANUAL Troubleshooting Guide and Instructions for Service (To be performed ONLY by qua lified servi ce 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[...]

Table of Conte nts Page Service Procedure Introduction 4 - - - Tools R e quired f or Service 4 - - - Sequence of Operation 6 - - - Troubleshooting 7 - - - Thermos tat Circuit Tes ting 24 D24-I Pilot Operation Testing 27 D24-II Main Burner Oper ation Tes ting 30 D24-III Main Burner & Pilot Removal & Inspection 32 D24-IV Flue Baffle Removal &[...]

FEATUR ES OF HONEY WELL I NTEGRAT ED CONT ROL S SYST EM Attractive digital water heater displ ay on con trol panel for setting and displaying the temper ature setpo int. Pressing temperatu re up and d own buttons cha nges the temper ature setpo int. Tempe rature format m ay be displ ayed in degr ees F or degrees C. Single contr ol board w ith plug [...]

Too ls Re quir ed for Servi ce It i s intended for this manual to be used by qualified servi ce perso nnel for the p rimary purpose of troublesh ooting analysis and repa ir of th e Bradford White 24 Volt F lue Damp er Series Wa ter Hea ter. Understa nding the sequ ence of oper ation sectio n of this manu al will co ntribute gr eatly to troublesh oo[...]

Power S upply Dedic ated 120 VAC, 60 Hz. , 15 A Curren t Draw Less than 5 Amps. Approv ed Gas Type Natur al or Propane. Gas su pply must matc h the gas type li sted on the water heater r atin g l abel. Gas Suppl y Connecti on 1" NPT connectio n to gas val ve for 370,0 00 Btu/hr . and over for nat ural gas, ¾" NPT for rest. Schedul e 40 b[...]

1 Ther mosta t calls for heat . The cont rol b oard sends 24 v olts f rom damp er ter minal #2 on th e con trol plu g to the f lue dam per. 2 Flue dam per begi ns to rotate open. Once the flue dam per is full y open, the da mper end switc h closes and 24 vol ts is allowed t o cont inue t hroug h da mper t o da mper pi n ter minal #5. 3 4 Once pi lo[...]

CAUTION Use Caution Not to Dam age C onnector s wh en makin g Vol tag e Measur ements or J umping Termi nals Water Heat er Faul t: Water hea ter does not ope rate Disp lay Error Code: Wat er heater di splay does n ot opera te - blank display Che ck main power supply to water heater - fuse, circu i t br eaker, plug rece ptacle, line cord or wiring t[...]

Doe s damp e r blad e mo ve to the f ull open pos iti on? Erro r cod e #55 on displ ay. R emove d amper from he ate r and jump bla ck & yel low wires of heat er h arne ss. Ref er to ph oto on thi s page . Doe s w at er h eat er beg in to ope rat e? Che c k for de bri s li miti ng da m pe r ro tat ion. If no d ebr is , re plac e damp e r. I s th[...]

ACCESSI NG SERVICE MODE ON THE WA TER HEATER DISPL AY (FOR SERVICE PERSO NNEL ONLY) The dis play has a “serv ice mode” for changin g the maximum set point and ac cessin g i nformat ion in ai ding serv icing of the water h eater. This pr ocedure is for servic e and insta llation pers onnel on ly. To enter the Ser vice Mode, fo llow the steps ill[...]

1. Max Setpoint (Di splay/ Change) 2a. Water Temperat ure A verage (Dis plays av erage if ther e are two sensor s - sensor temper ature dis played if single sensor is used). SELECT SET Status °F id le Water Temp Operational 2b. Water Tempe rature - Up per Senso r (Display s if there is an upper sensor - some model s) SEL ECT S ET St atus °F i dl [...]

3. Flame Current of Pilot Flam e Sensor (Di splay s only in the Heat ing Cycle) SELECT SET Stat us Heating Operati onal Flame C urr ent ȝ A 4. Setpoint (Dis play/ Change) SELECT SET S tatus °F i dle s etpoint Operational 5. °F/° C (Displ ay/Change) S ELECT SET St at us ° F/C ° idle Operati onal ° F s etpoi nt 6. Diffe renti al (Display only [...]

7. Software Ve rsion (Di splay only) S ELECT SET Statu s i dle Op erational Soft 8. Error Code Hist ory (Displ ays if there ar e present e rror codes or up to 10 previous error codes) . Water Heat er Display will show a “--“ if t here are no er ror codes. S ELECT SET S ta t us idl e O perational To change the Ma ximum Setpoi nt Limit (Ma x Setp[...]

Step 2: Press “Set” butt on to enter s etting mode. “Max Set poin t” will flas h to indicate se tti ng mode. SELECT SET S tatus ° F i dle O pe rationa l M ax Setp oint Step 3: Press the “UP ” or “DOWN” buttons to change th e maximum setpoi nt value. This will li mit the maximum setpoin t the user can selec t. Not e: The maximum set[...]

Step 5: 30 Seconds aft er the last b utton pres s, the Wate r Heater Display will go ba ck to “User Mode” . It wil l read “Max Setpoi nt” without showing a te mperature v alue if the t emperat ure setpoi nt is at the maxim um sett ing. The Water Heater Disp lay ca n be set b ack to the “Us er Mode” immediat ely by pre ssing b oth t he ?[...]

Step 3: For water hea ters using t wo temperat ure sens ors, press ing the “Sele ct” butt on again dis plays the Low er Sensor tempera ture readi ng. “Lower Se nsor” wil l b e displaye d in the lower lef t side of the stat us window of t he water he ater displa y. SEL ECT SE T S tat us ° F idle Ope rational Lower Se nsor To D isp lay Fla m[...]

Step 2: Press the “Set ” button to ent er the set ting mode . “Set point” w ill flas h in the water heat er display . SELECT SET Status ° F idle s etp oint O per ati o nal Step 3: To raise th e t emperat ure setpo int , press the “Temper atur e Up” button unt il the des ired temperat ure is sho wn on the wat er heat er d isplay . S ELE[...]

Step 5: When the desir ed setpoint is reache d on the water he ater displ ay, press the “ Set” but ton to confirm the new setpoi nt. “S etpoin t” stops fl ashing in th e water heat er display . S ELECT SET S tatus °F i dle se tpo i nt O per ati o nal To D is pla y an d Ch ange T em pe rat ure Fo rma t ( ° F/°C ): To Change Temperatu re F[...]

Step 3a: Press “Temperat ure Up” button to chang e temperat ure format to °C SELECT SET Status idle Ope ratio nal ° C % ° F/C° Step 3b: Pr ess “Te mper ature Down ” but ton t o c hange t emperat ure f ormat t o °F SELECT S ET S tatu s id le Ope rat io na l °F °F/C° Step 4: Press “Set ” button to c onfirm °F or °C f ormat. °F/[...]

Step 5: P ressing “ Select” but ton wi ll return di splay to setpo int in for mat select ed (°F or °C) imm ediately S ELECT SET Status °F idl e Operation al L ower S ens or Error Co des an d Er ror Hi story Di splay : If there is an ope rating pr oblem wit h the water heat er, an err or code numb er will appear on th e water heat er display [...]

To vi ew p revious error codes : Step 1: In “S ervic e Mode press the “S elect” butt on until the ne xt dis play af ter th e “Sof tware Vers ion”. If th ere ar e no cur rent e rror code s, the display wi ll show -- . SELEC T SE T Sta tus °F idle Operat ional Step 2: Press t he “Temperat ure Down” butt on to sele ct the error co de in[...]

Step 4: Press the “Te mperature Down ” butt on to change to the prev iou s code index, code #9. SELECT SET Status idle Op era tio nal % Step 5: Press the “Selec t” butt on for code inde x #9 to view if the re are any code number s. SELECT SET S tatus idle O per at i onal Step 6: Continue pres sing the “Temper ature Down” button to chan [...]

ERROR CODE DEFIN ITIONS If t he wat er h eater has an operat ing probl em, th ere wi ll be a n umber in t he water heate r displ ay w ith “Service Need ed” sho wn below the erro r code number. Not e the error code and the defini ti on in the chart belo w. Thi s labe l appears on the cont rol box under t he water heat er disp lay. The followi ng[...]

WARNING The follo wing procedu re is for ser vice and installat ion personne l only. Resetti ng lockout condition s without corre cting the malfu nction can result in a ha zardous cond ition. If an err or code is displ ayed (excep t for #4, low fla me sense cur rent), the water heat er will be in a “lo ckout condit ion ” with th e water heater [...]

SERV ICE PROCEDURE D24- I Thermos tat Circuit Testing CAUTION Be Carefu l When Making Voltage Meas ureme nts or Jum pi ng Ter mina ls Not to D amage or De form C onn ect ors or Co nne ctor P in s. DANGER 120 vo lt exposur e. To avoid personal inju ry, use ca ution while per forming th is procedure . WARNING! Do not rese t the displa y from the hard[...]

SERVICE P ROCEDURE D24-I Thermostat Circuit Testing Condit ion: Water Heat er Not Oper ating Display sho ws error code “65” High Water Temper ature (o ver 200 deg. F) Co ntin ue d WARN ING! Do not oper ate water heat er witho ut verif ying that the over heati ng condit ion has been co rrected . Onc e ca use of ove rhe at in g co nd iti on h as [...]

° F 012345678 9 40 26109 25400 24712 24045 23399 22771 22163 21573 21000 20445 50 19906 19383 18876 18383 17905 17440 16990 16553 16128 15715 60 15314 14925 14548 14180 13823 13477 13140 12812 12494 12185 70 11884 11592 11308 11032 10763 10502 10248 1000 9760 9526 80 9299 907 8 886 2 8653 844 9 8250 805 7 7869 768 5 7507 90 7333 716 5 700 0 6839 6[...]

SERVI CE P RO CEDU RE D24-II Pilot Operation Testing CAUTION Be Carefu l When Making Voltage Meas ureme nts or Jum pi ng Ter mina ls Not to D amage or De form C onn ect ors or Co nne ctor P in s. DANGER 120 vo lt exposur e. To avoid personal inju ry, use ca ution while per forming th is procedure . Cond ition: Pi lot wi ll not lig ht or stay l it, [...]

Cond ition: Error c od e 57: Flam e Rod S hort ed t o Grou nd Di sconn ect p ower. Sh ut of f gas sup p ly t o w at er he ater . Sli de o ut b urne r ass embly (see s ect io n o n “ remo ving pilo t and main bu rner a ss embly ” ). SERVI CE P RO CEDU RE D24-II Pilot Ins pection Ch eck to s ee if pi lo t s hiel d is to uchi ng pil ot fl ame se n[...]

SERVI CE P RO CEDU RE D24-II Pilot Operation Testing CAUTION Be Carefu l When Making Voltage Meas ureme nts or Jum pi ng Ter mina ls Not to D amage or De form C onn ect ors or Co nne ctor P in s. DANGER 120 vo lt exposur e. To avoid personal inju ry, use ca ution while per forming th is procedure . C onditi on: Pil ot ligh ts , n o or low fla me si[...]

SERVICE P ROCEDURE D24-II I Main Burner Operation Tes ting CAUTION Be Carefu l When Making Voltage Meas ureme nts or Jum pi ng Ter mina ls Not to D amage or De form C onn ect ors or Co nne ctor P in s. DANGER 120 vo lt exposur e. To avoid personal inju ry, use ca ution while per forming th is procedure . Cond ition: Ma in burn er w ill n ot li gh t[...]

SERVICE P ROCEDURE D24-II I Main Burner Operation Tes ting CAUTION Be Carefu l When Making Voltage Meas ureme nts or Jum pi ng Ter mina ls Not to D amage or De form C onn ect ors or Co nne ctor P in s. DANGER 120 vo lt exposur e. To avoid personal inju ry, use ca ution while per forming th is procedure . Con dition : Mai n bu rne r sho rt cy cle s.[...]

SERV ICE PROCEDURE D24- IV M ain B urner & P ilot Removal and Inspe cti on WARNING Heater c omponents m ay be HOT when performin g the following st eps in this p rocedure. Take ne cessary precau tion to preve nt person al injury. Main Bu rner Re moval Step 1. Disconne ct (un- plug) wat er heater f rom electr ical suppl y. Step 2. Turn “OFF”[...]

SERV ICE PROCEDURE D24- IV M ain B urner & P ilot Removal and Inspe cti on Pilot Burn er Removal Step 1. With burner rack remov ed from heat er, disconn ect pilot t ube connect ion from gas val ve S tep 2. Remove the two pilot burner mou nting screws securi ng the pilot a nd pilot shield in pla ce . Step 3. Rem ove pilot shield and pi lot f rom[...]

SERV ICE PROCEDURE D24- IV Control Board Re placement Control boar d rep lacement S tep 1: Discon nect Power Depress plastic t abs Slots i n control p anel Unhoo k tabs from control panel slots To r em ove l ower s enso r Remove cli p, pull se nsor out. S tep 2: Unplug wire conne ctions f rom board. Pull out senso r Remo ve clip Wire c onnections D[...]

SERVICE PR OC EDURE D24-V Flue Baff le Removal, I nspection Step 1. Disconne ct (unplug ) water heater fr om electrica l suppl y. Step 2. Disconne ct venti ng from dr aft diver ter and remov e draft divert er f rom t op of wat er heat er. Step 3. Disconne ct flu e damper from wire harness and rem ove flue dam per from top of wa ter heater (see pho [...]

SERV ICE PROCEDURE D24- VI Anode Removal a nd Inspection Step 1. Disconne ct (unplug ) water heater fr om electrica l suppl y. Step 2. Tu rn “ OFF” wat er supp ly t o wate r hea ter. Step 3. Ope n a near by hot water fauce t to reli eve t ank pr essure. Step 4. Connec t hose to drain valv e of water heat er and route t o an open drain. Open dra[...]

Pag e 37 SERV ICE PROCEDURE D24- VI Anode Removal a nd Inspection Ap pr oxim at e A node Ro d Lo ca tio ns 37[...]

G eneric Part s List 1. Dra ft Di ver ter w/L eg Ki t 2. Dra ft Di ver ter 3. Dra ft Di ver ter Leg 4. Da mper Outl et Redu cer 5. F lue Damper 6. Hot Outlet Nippl e 7. Co ld Water I nlet Dip Tub e 8. He x Hea d Anod e 9. F lue Baffle 10. Flue Red ucer 11. F lue Cor e 12. 1" x ¾" Reducer Bushing 13. Ni pple T&P Val ve 14. T&P Val[...]

G eneric Part s List 1A. Dr aft Panel 2A. Burner Rack 3A. B urner Tube 4A. Gas Valve 5A. B urner M anifold 6A. M ain Burner Orifice 7A. P il ot Shiel d 8A. P il ot Bur ner 9A. Pilot Orifice 10A. P ilot T ubing 11A. P ilot Mount ing Screw 12A. B urne r T ube Su pport 13A. Manifold B racket 14A . C- Ca ne Ma nif old 15A . M ani f old S tra ig ht 16A.[...]

G eneric Part s List 1B. Tem peratur e Display 2B. Cont rol Box Cover 3B. Int egrat ed Control Board 4B. Scr ew 8-16 X ½ PHCR 5B. Tran sformer 6B. Gr ound Lug 7B. O n/O ff S witc h 8B. Cont rol Box Panel 9B. Scr ew 8/32 X ¼ PHCR 10B . 7/8" Snap Bushing 11B. Power Cor d Strain Rel ief 12B. Pil ot Wire Strain Relief 13B. S econd ary Tran sform[...]

NOTES AC Altern ating Cur rent BTU/H British Thermal Units per Hour CO Carbon M onoxide CO2 Carbon D ioxide DC Direct Current ECO Energy Cut Off GFI Ground fault inte rrupt GPM Ga l lo ns per Minute Hz Hertz LED Lig ht Emitting Diod e NOx Oxide s of Nitrogen NPT Natio nal Pipe Thread PSI Poun ds per Square Inch VA Volt Am ps VAC Volts A lternating [...]

NOTES Pag e 34[...]

NOTES Pag e 34[...]

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