Bradford White D-38T-155 Service Manual
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Bradford White D-38T-155 Service Manual

Bradford White D-38T-155 Service Manual

Commercial 24 volt flue damper series water heater with honeywell integrated control system
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COMMERCIAL 24 VOLT FLUE DAMPER
SERIES WATER HEATER WITH HONEYWELL
INTEGRATED CONTROL SYSTEM
Manual 47985A
Gas Water Heaters
SERVICE
MANUAL
and Instructions for Service
Troubleshooting Guide
(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)
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Summary of Contents for Bradford White D-38T-155

  • Page 1 COMMERCIAL 24 VOLT FLUE DAMPER SERIES WATER HEATER WITH HONEYWELL INTEGRATED CONTROL SYSTEM Manual 47985A 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”...

  • Page 2: Table Of Contents

    Introduction Tools Required for Service Sequence of Operation Troubleshooting Thermostat Circuit Testing Pilot Operation Testing Main Burner Operation Testing Main Burner & Pilot Removal & Inspection Flue Baffle Removal & Inspection Anode Removal & Inspection Generic Parts List Glossary of Terms Notes Table of Contents Page...
  • Page 3 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 up to 10 previous error codes in the service mode to further aid in servicing the water heater.

  • Page 4: Introduction

    Heater. Understanding the sequence of operation section of this manual will contribute greatly to troubleshooting this product. Troubleshooting begins by noting the error code, if any, on the water heater control display and finding the section in this service manual for diagnosing the problem for this error code. This step by step procedure beginning on page 5 will direct the service provider to a series of test procedures to determine root cause of failure.

  • Page 5: Specifications

    Gas Pressure (Nat. & L.P.) Manifold Pressure: 4.5" w.c. natural gas, 10.0" w.c. L.P. Gas Supply Pressure: At least 1" above manifold pressure with water heater operating, 14" w.c. maximum. Venting System Atmospherically Vented, Type B venting system or approved chimney. Follow current National Fuel Gas Code requirements or in Canada, the Natural Gas and Propane Installation Code.

  • Page 6: Sequence Of Operation

    “Reset” for 3 seconds. If the water heater should reach 200 degrees F, then the high limit control will shut off the burners and the water heater will go into a “Hard Lockout”. Error code 65 will be shown in the water heater display.

  • Page 7: Troubleshooting

    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 Check main power supply to water heater - fuse, circuit breaker, plug receptacle, line cord or wiring to water heater.
  • Page 8 Service Needed SELECT Lockout RESET Example of error code shown on control display. Page 8 Troubleshooting Does water heater begin to operate? Check for debris limiting damper rotation. If no debris, replace damper. Damper vane show in open position. If damper is closed, disconnect from harness and REMOVE damper from water heater.
  • Page 9 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”...
  • Page 10 2b. Water Temperature - Upper Sensor (Displays if there is an upper sensor - some models) 2c. Water Temperature - Lower Sensor (Displays if there are two sensors) Max Setpoint value in Water Heater Display °F Setpoint idle...
  • Page 11 Flame Current of Pilot Flame Sensor (Displays only in the Heating Cycle) 4. Setpoint (Display/Change) °F/°C (Display/Change) Differential (Display only - shows the differential of the thermostat) Heating Flame Current Operational Status SELECT setpoint °F idle Operational Status SELECT setpoint °F °F/C°...
  • Page 12 7. Software Version (Display only) 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...
  • Page 13 Step 2: Press “Set” button to enter setting mode. “Max Setpoint” will flash to indicate setting mode. 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. Step 4: Press “Set”...
  • Page 14 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”...
  • Page 15 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. To Display Flame Sense Current of the Pilot Flame Sensor: The pilot flame sense current is available only when the burners are in operation.
  • Page 16 Step 2: Press the “Set” button to enter the setting mode. “Setpoint” will flash in the water heater display. Step 3: To raise the temperature setpoint, press the “Temperature Up” button until the desired temperature is shown on the water heater display.
  • Page 17 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.
  • Page 18 Step 3a: Press “Temperature Up” button to change temperature format to °C 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 °C °F/C° idle Operational Status...
  • Page 19 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.
  • Page 20 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.

  • Page 21: Exiting Service Mode

    #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.

  • Page 22: Error Code Definitions

    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.
  • Page 23 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.

  • Page 24: Thermostat Circuit Testing

    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”.
  • Page 25 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.
  • Page 26 The dual thermisters are used to provide high limit protection in case the thermostat circuit fails to shut off the water heater. 2. Draw quart of water off Drain Valve. Using a thermometer, determine water temperature.

  • Page 27: Pilot Operation Testing

    Gas Valve? (see photo 12) Check wire harness for damage or loose connections. Repair or replace as needed. Turn on power to the water heater and verify proper operation SERVICE PROCEDURE D24-II Be Careful When Making Voltage Measurements or Jumping Terminals Not to Damage or Deform Connectors or Connector Pins.

  • Page 28: 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”). Make sure pilot shield clears flame sense rod Flame Sense Rod...
  • Page 29 “Select” until the flame current is shown. The control must be in the heating mode with the pilot lit to display a reading. See section on accessing service mode on the water heater display. Micro-amp readings 0.000 Micro Amp = Replace control board or pilot if wire is damaged.

  • Page 30: Main Burner Operation Testing

    DANGER 120 volt exposure. To avoid personal injury, use caution while performing this procedure. Condition: Main burner will not light, Display shows “Heating” under temperature setpoint. Tank is cold. Is Pilot lit? Does control board continue to spark with pilot lit? Insert meter probes into back of “Control”...
  • Page 31 (see photo below) Check manifold pressure. See photo on lower right section of page for manifold pressure tap location. Refer to water heater rating label for specified manifold pressure. If the manifold pressure is not within 0.3" w.c. of the specified pressure, then remove the regulator cap from the gas valve and turn plastic screw clockwise to increase pressure and counterclockwise to decrease pressure.

  • Page 32: Main Burner & Pilot Removal & Inspection

    Main Burner Removal 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. Disconnect Gas supply line from the gas valve (see photo 17).
  • Page 33 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.
  • Page 34 120 volt exposure. To avoid personal injury, unplug while performing this procedure. Control board replacement Step 1: Disconnect Power Depress plastic tabs Step 3: To remove board, tilt control panel to the right and slide control hook tabs from slots in control panel. Slots in control panel Unhook tabs...

  • Page 35: Flue Baffle Removal, Inspection

    Step 5. Remove screws holding jacket head to top of water heater and remove jacket head from top of water heater. Note, it may be necessary to use a screw driver to pry underneath jacket head (see photo 28).

  • Page 36: Anode Removal & Inspection

    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. Open drain valve and drain a minimum of 5 gallons of water from the water heater.
  • Page 37 SERVICE PROCEDURE D24-VI Anode Removal and Inspection Approximate Anode Rod Locations Page 37...

  • Page 38: Generic Parts List

    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 16/16A 17/17A 11.
  • Page 39 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.
  • Page 40 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 Generic Parts List 11B.

  • Page 41: Glossary Of Terms

    Alternating Current BTU/H British Thermal Units per Hour Carbon Monoxide Carbon Dioxide Direct Current Energy Cut Off Ground fault interrupt Gallons per Minute Hertz Light Emitting Diode Oxides of Nitrogen National Pipe Thread Pounds per Square Inch Volt Amps Volts Alternating Current W.C.
  • Page 42 NOTES Page 34...
  • Page 43 NOTES Page 34...
  • Page 44 Email parts@bradfordwhite.com techserv@bradfordwhite.com www.bradfordwhite.com...

This manual is also suitable for:

D75t125D75t160D75t300D65t370D65t399D80t180 ... Show all

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