Bradford-White Corp Tankless Gas Water Heater manual

1 SERVICE MANU AL T ankless Gas W ater Heater Troubleshooting Guide and Instruction f or Service (T o be performed ONL Y b y qualified service pro viders) F or the Bradford White EverHot ® Interior T ankless Gas W ater Heater Models: IGI- 1 80R- 1 0(N,X) IGI- 1 80C-5(N,X) Manual 45095A Sa ve t his manual for future reference[...]

K ey to W ar ning Symbols Failur e to comply with the following ins tructions may results in serious personal injury or damage to the appliance. Be car eful of possible electric shock. Wiring inside this appliance may potentially be at 1 20 v olts. Disconnect power supply to unit when carrying out the following service r epair s. Read Fault Diagnos[...]

T ABLE OF CONTENTS Section Description P ag e - - - Glossar y of T erms and Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . .4 I. . . . . . . . . . . .General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 a. Ho w to Use This Manual. . . . . . . . . . . . . . . . . . . . . . . . . .6 b. Cut Awa y [...]

GLOSSAR Y OF TERMS AND SYMBOLS This glossary of t er ms and symbols is provided to assist y ou in under standing some of the language used thr oughout t his manual. dB(A) - sound pressure level in decibels, “ A ” range DC - direct current AC - alternating cur rent WFCD - wat er flow control device FB - feedbac k inf ormation Hz - her tz IC - in[...]

I - GENER AL INFORMA TION This tankless water heater is a high output, high ef ficiency appliance, whic h heats the wat er continuously as hot wat er is being drawn f or use. Unlike tank type storag e water heaters, this water heater does not store hot water . The burner operates whenev er there is a demand for hot water and is off when the hot wat[...]

I - GENER AL INFORMA TION (cont.) HOW TO USE THIS MANUAL It is intended for t his manual to be used by qualif ied service personnel for the primary purpose of troubleshooting analysis and repair of this tankless gas fired wat er heat er . Understanding the basic operation of the "Main Components" and t he "Sequence of Operation"[...]

I - GENER AL INFORMA TION (cont.) CUT - A WA Y ILLUSTR A TION 7[...]

I - GENER AL INFORMA TION (cont.) SCHEMA TIC ILLUSTRA TION 8[...]

9 II - SPECIFIC A TIONS - GENER AL Model type RESIDENTIAL COMMER CIAL T ype of appliance T emperature controlled continuous flow g as hot wat er syst em Operation With / without remot e controls, mount ed in kit chen, bat hroom, etc. Exhaust syst em Direct V ent - Forced combustion Maximum/Minimum g as rate 1 80,000 BTU's - 1 5,000 BTU's [...]

II - SPECIFIC A TIONS - GENER AL Safety devices Appliance - AC 1 20 Volts - 60Hz. 1 5A - Dedicated R emote control DC 1 2 Volts (Digital) Flame failure - Flame rod Boiling prot ection - 203°F R emaining flame (OHS) 1 94°F bi-metal switch Thermal fuse 264°F Aut omatic fros t prot ection - Bimetal sensor & anti-frost heaters Combustion fan rpm[...]

II - SPECIFIC A TIONS - COMBUS TION Item Gas type Natur al Propane Gas consumption Minimum Btu’s 1 5,000 1 5,000 Maximum Btu’s 1 80,000 1 80,000 Injector Diameter Upper Ø.037 (.95mm) Ø.029 (.75mm) Inches (mm) Lower Ø.062 (1 .6mm) Ø.045 (1 .1 5mm) Main Burner B3A7- 1(Lean and Rich Bunsen Burner) Main Damper H 7 3 - 1 1 5, Up p er: Ø6, Lo w [...]

II - SPECIFIC A TIONS (cont.) DIP SWIT CH SETTINGS D ANGER Do not attempt to adjust dip switc h settings from there factor y default settings. Doing so will result in damage t o unit, proper ty damage, per sonal injury or death. Contact T ec hnical Suppor t f or information per taining to dip switc h function. F ACT OR Y DEF A UL T SETTING, RESIDEN[...]

II - SPECIFIC A TIONS (cont.) DIP SWIT CH SETTINGS Combustion Blower Dip Switch Settings for V ent Lengt h Compensation Under 22 Feet (6.7 m): T o assure optimum ef ficiency and reduced noise lev els, the combustion blo wer switc h has two dip switch settings. Dip switc h number 1 (top dip switc h) is shipped from the factory set t o the OFF positi[...]

II - SPECIFIC A TIONS (cont.) VENTING T ABLE V enting T able – Examples of Maximum V enting Dis tances wit h V arious Elbow Combinations 35 Ft. (1 0.7 m) 1 4 1 (1 2.5 m) 29 Ft. (8.8 m) 2 4 1 (1 2.5 m) 23 Ft. (7 .0 m) 3 4 1 (1 2.5 m) 1 7 Ft. (5.2 m) 4 4 1 (1 2.5 m) 33.5 Ft. (1 0.2 m) 1 1 4 1 (1 2.5 m) 32 Ft. (9.8 m) 1 2 4 1 (1 2.5 m) 27 .5 Ft. (8.[...]

III - MAIN COMPONENTS 1 . Mechanical Wat er Regulat or The unique water regulator mec hanism ensures the hot wat er is maintained with no noticeable chang e to the desired temperature during use, ev en if wat er pressure drops due to another tap being turned on and increasing the demand. 2. Preset Bypass A preset volume of cold wat er is mixed with[...]

III - MAIN COMPONENTS (cont.) 5. Combustion F an Air f or the combustion is supplied b y a centrifugal fan driven b y a DC motor . Af ter a pre-purge period of 0.2 seconds, t he fan speed is controlled b y the PCB to pro vide t he correct volume of air f or combustion. The calculation f or the fan speed is based upon incoming water temperature, wat[...]

IV - SAFET Y DEVICE FUNCTION Flame F ailure Situated to the right of the burner in the front of the combus tion c hamber , the f lame rod monitors t he combustion process. This sensor monitors the f lame intensity , while the PCB compares this signal to the feed back signal from the combustion fan motor , water f low control, and gas f low through [...]

IV - SAFET Y DEVICE FUNCTION (cont.) Over temper ature Cut-Of f The t emperature of the outgoing hot wat er is constantl y monitored by the water temperature thermist or located near the outlet of the appliance. If the outgoing water temperature reaches 5 °F abov e the preset temperature, the bur ner will automaticall y deactivat e. The burner wil[...]

V - SEQUENCE OF OPER A TION The preset temperature is selected at one of t he remotes controls (where fitted). Where no remote control is f itt ed , the default temperature can be set at 1 08, 1 20, 1 30, 1 40, 1 50, 1 60, 1 70, or 1 80°F . T o select one of the abov e temperatures as y our default setting, y ou MUST obtain written per mission and[...]

V - SEQUENCE OF OPER A TION (cont.) When t he hot wat er tap is turned of f, the wat er flow sensor stops revolving, and the magnetic pulse ceases, indicating to the PCB that t here is no wat er flowing, in turn the PCB closes t he g as valv es. The combustion fan continues t o operate for 65 seconds. This will provide quick er ignition when the ta[...]

V - SEQUENCE OF OPER A TION (cont.) Operation Sequence Flow Char t 21[...]

V - SEQUENCE OF OPER A TION (cont.) Operation Sequence Flow Char t 22[...]

V - SEQUENCE OF OPER A TION (cont.) Sequence Timing Char t 23[...]

V - SEQUENCE OF OPER A TION (cont.) Sequence Timing Char t 24[...]

Error F aulty R emedy 1 0 Air Supply Check all v ent components for proper connections. or Exhaust Check that nothing is blocking the flue inlet or exhaust. Block age Ensure proper venting materials were used. Ensure condensation collar was installed cor rectly . V erify dip switc hes are set properl y . 1 1 No Ignition Ensure you have gas to the a[...]

26 Error Faulty Remedy 32 Outgoing W ater Check sensor wiring for damage. T emperature Check resistance onsensor . Sensor Faulty Check and clean dir t from sensor . Replace sensor . 33 Heat Ex changer Check sensor wiring for damage. Outgoing Check resistance on sensor . T emperature Check and clean dir t from sensor . Sensor Faulty Replace sensor .[...]

27 VI - TROUBLESHOOTING (cont.) Quick Ref erence Diagnostic Points IMPORT ANT SAFETY NOTES: There are a number of (live) tests that are required when fault f inding this product. Extreme care should be used at all times t o avoid contact with energized components inside the water heater . Only trained and qualified service ag encies should attempt [...]

28 VI - TROUBLESHOOTING (cont.) Thermal Fuse: Wire color V oltag e R esistance Connector # Pin #’s R ed ~ Red 1 00 V AC Below 1 ohm B ~ C B6 ~ C1 Overheat Switch: R ed ~ Red 1 00 V AC Below 1 ohm B ~ C B6 ~ C1 Flame Rod: Place one lead of y our meter to the flame rod and the other to earth or ground. With the unit running y ou should read between[...]

F uses: This unit has two inline (3) amp glass fuses. Remo ve t he fuse and c heck continuity through it. If y ou hav e Continuity thr ough the fuse, it is good. If y ou can not read continuity , t he fuse is blo wn and must be replaced. Wiring Diagram 29[...]

Wiring Schematic 30[...]

31 Nature of F ault Ex amination Point Diagnostic P oint V alues Y/N Action Service Procedure A. The LED on the remote control does not light up, when the syst em is powered up 1 . Do you have voltag e to the unit? P ower source Do you have 1 20 V AC at the power supply? Ye s No Go t o A – ( 2) Plug in cord 2. Is supply voltage correct? Measure v[...]

32 Nature of F ault Ex amination Point Diagnostic P oint V alues Y/N Action Service Procedure 2. Measure the voltage at connector F with appliance power supply on. F – Black ~ Whit e 1 00 ~ 1 20 VA C F 7 – Blue ~ Brown 1 00 ~ 1 20 VA C Are values within those specif ied at lef t. Ye s No Go t o A – ( 7) Replace transformer IGI – 7 7 . Check[...]

33 Nature of F ault Ex amination Point Diagnostic Point V alues Y/N Action Service Procedure Error code "1 1" display ed on digital monitor . 5. Check ignition module. 1 . Measure voltage between grey ~ grey of connector F 8 (sparker). (See page 39) 2. # Remo ve connect or F 8 and measure the resistance between sparker and terminals. (See[...]

34 Nature of F ault Ex amination Point Diagnostic Point V alues Y/N Action Service Procedure C. Combustion occurs, but f lame fails. Error code "1 2" displa yed on digital monitor . 1 . Chec k f lame rod. 2. Check ground wire. 1 . Measure the voltage between f lame rod terminal C 1 and appliance ground. 2. Check t o ensure flame rod brack[...]

35 Nature of F ault Ex amination Point Diagnos tic Point Values Y/N Action Service Procedure 2. Measure voltag e between orange (+) and grey (-) of the water f lo w servo connector B 2 . 3. Measure voltag e between brown ~ grey of water f low servo connector B 2 (Don not turn wat er on) (See page 44) 4. Measure voltag e between yellow ~ grey of the[...]

VI - TROUBLESHOOTING (cont.) T roubleshooting Procedure Unit’s wiring diagram can be found on page 29. Appliance fails to operate (ev en remote control fails t o operate). 1) Is the fuse blown 2) Is the main transformer normal? Check fuse. a. Disconnect unit from power supply . b. # Measure resistance to check the electric fuse (3 amp) Normal: le[...]

3) Is the remot e control normal ? No combustion (despite remote control indication) 1) Is the w ater flow sensor nor mal ? 37 Check voltag e between the two remote control cable connectors. a. Check the voltage between terminals on the remote control t er minal mount D 1 . Normal: 11 ~ 1 3 VDC If normal, c heck f or an open circuit or short before[...]

2) Is the flame rod nor mal ? Er ror “72” is displa yed 3) Is the wat er tem perature thermist or normal? 38 Checking the f lame rod. a. # Detac h the f lame rod terminal C1 , and re-att empt operation. (“72 is display ed) Proceed to c heck it em 3 below . (no “72” display ed) Inspect flame rod wiring for current leak and inspect flame ro[...]

39 Motor chec k. If error “6 1” is display ed, chec k the combustion fan. a. Measure v oltage at connector A1 . Black and red wires. Normal: 6 ~ 45 VDC (F an on) 0 VDC (Fan of f) If normal, c heck it em b below . F aulty: Replace the PCB unit. (Service Procedure IGI-2, pag e 49) F an revolution sensor c heck. b. Measure voltag e at connect or A[...]

40 If error “1 1” or “7 1” is displa yed, chec k the main gas solenoid val ve. a. # Disconnect the main gas solenoid valv e (SV0) connector and measure the resistance at the solenoid terminals. Normal: 1 .7 ~ 2.1 K Ω If normal, c heck b below . Faulty: R eplace g as v alve. (Service Procedure IGI-9, pag e 52) b. Measure voltag e at the ma[...]

9) Is the chang e ov er solenoid (SV3) operating nor mall y? 41 If error “1 1” or “7 1” is displa yed, chec k the change ov er solenoid (SV3). a. # Disconnect the c hangeov er solenoid (SV3) connector , and measure t he resistance at the solenoid t er minals. Normal: 1 .7 – 2.1 K Ω If normal, c heck b below . Faulty: R eplace the manifo[...]

Combustion stops due to flame failure 1) Is the flame rod functioning normally? 2) Is the earth lead wire connected? 42 a. Measure t he voltag e between the flame rod terminal C 1 and the appliance ear th. Normal: 5 – 1 50 V AC from y ellow t o ground. If normal, c heck b below . Faulty: R eplace the PCB unit. (Service Procedure IGI-2, pag e 49) [...]

Unable to adjust hot wat er temper ature 1) Is the wat er tem perature thermist or operating normally ? 2) Is the chang e ov er solenoid (SV1) normal ? 43 a. # Disconnect the connect or B5, and measure the resistance between the white wires, see below f or resistance readings. Thermistor resistance valves: 59 ºF = 1 1 .4 ~ 1 4 K Ω 86 ºF = 6.4 ~[...]

44 a. # Disconnect the modulating valve fes toon C2 terminals and measure the resistance at the terminals. Normal: 67 ~ 81 Ω If normal, c heck b. F aulty: Replace gas valve. (Service Procedure IGI-9, pag e 52) b. Re-connect terminal C2 and measure voltag e across the pink ~ pink wires when the unit is firing. Normal: 2 ~ 1 5 VDC If normal, c heck[...]

Anti-frost heaters do not operat e 1) Are the ceramic anti-frost heat ers operating normally ? 2) Is the frost sensor switc h operating normally ? a. # Disconnect connector F4, and measure t he resistance of the heater mounted in the wat er flow control valve, these are white wires. Disconnect connect or F5, and measure the resistance of the heater[...]

VII - GAS PRESSURE SETTING PROCEDURE All settings/adjustments must be per formed b y a qualified Service T echnician. 1 . T urn unit of f at power source and tur n of f the gas to the wat er heater . 2. R emov e the front cov er from the wat er heater . 3. R emov e the gas pressure test por t plug. Connect manometer to t his por t. (See Figure #1 f[...]

47 Figure #1 Figure #2 VII - GAS PRESSURE SETTING PROCEDURE W ARNING Dip swit ched #7 and #8 (combustion control swit ches) MUST be returned to the "OFF" position, af t er setting pressures. Dip swit ch #1 MUST be returned to the proper position based upon the lengt h of vent pipe (see pag e 1 3). R ef er t o pag e 1 2 f or fact or y def [...]

VIII - Service Pr ocedure NO TE: Bef ore proceeding with dismantling, be sure to follo w t he C A UTION instructions bef ore each explanation. Alwa ys disconnect the electrical supply , turn of f wat er and gas supply service v a lv es, and drain all water from the unit bef ore proceeding. Only trained and qualified service ag encies should att emp[...]

IMPORT ANT When dismantling the unit you should alwa ys isolate the follo wing items: • Gas supply • Electrical supply • W ater suppl y • Drain all wat er from the appliance The f ollowing diagram will be of assistance in locating t he abov e. IGI – 1 . Remo val of the F ront Panel CAUTION 1 20 volt potential exposure. Isolate the applian[...]

b. Remo ve t he four (4) Phillips screws that secure the water inlet filter housing to the unit. See picture belo w for location of screws. Once screws are remo ved reac h into the unit and pull up and out on the f low control assembl y to remov e it from the appliance. Inspect o-ring for damage. c. Disconnect wiring har ness from assembl y and rem[...]

IGI – 7 . Remo val of T ransf or mer: CAUTION 1 20 volt potential exposure. Isolate the appliance and reconfirm power has been disconnected using a multi- meter . a. R emov e the combustion fan motor assembly as described in IGI - 5 a,b. b. Remo ve t he two (2) Phillips screws to release the transformer . c. Disconnect wiring har ness connectors [...]

IGI – 9. Remo val of the Gas V alv e Assembly: CAUTION 1 20 volt potential exposure. Isolate the appliance and reconfirm power has been disconnected using a multi- meter . a. R emov e the burner manifold, refer to IGI - 8 a,b,c. b. Remo ve t he four (4) Phillips screws that hold the gas connection and g as control v alve in place at the bottom of[...]

53 IGI – 1 1 . Remo val of Thermal Fuse: CAUTION 1 20 volt potential exposure. Isolate the appliance and reconfirm power has been disconnected using a multi- meter . This pr ocess may invol ve remo ving the heat ex changer if the thermo-fuse on the r ear of the heat exc hanger is blown. (Service Procedure IGI - 1 0, see pag e 52) a. The unit has [...]

IX - FLUSHING PROCEDURE FOR LIME SCALE REMO V AL FROM HEA T EXCHANGER The amount of calcium carbonate (lime) released from water is in direct propor tion t o water temperature and usage. The higher the water temperature or water usage and the harder the water (more dissolved calcium carbonate), the more lime deposits are dropped out of t he wat er [...]

55 X - P ART S BREAKDOWN Disassembled View - Cabinet[...]

X - P ART S BREAKDOWN Disassembled View - Internals 56[...]

X - P ART S BREAKDOWN Disassembled View - Internals 57[...]

X - P ART S BREAKDOWN Disassembled View - Electrical 58[...]

P ARTS LIST Number Description Quantity 00 1 Casing Assembly 1 002 Wall Fitting Brac k et 2 003 Rubber Bushing 1 004 Connection Reinfor cement Panel 1 005 Heat Protection Plate 1 006 Fr ont Panel 1 007 Fr ont Panel Gasket 1 008 Fr ont Panel Gasket – Side 2 1 00 Gas Control Assembly 1 101 S c r e w 2 1 02 Gas Connection (3/4" NPT) 1 1 03 Burn[...]

405 Bypass O-Ring 1 406 Wat er Filter Assembly 1 407 Filter Plug 1 408 Hot Water Outlet – _" NPT 1 409 Sensor Bracket 1 4 1 0 Small Plug Gasket 1 4 1 1 Drain Valv e 1 700 PCB Board Assembly 1 70 1 Surge Protect or 1 702 PCP Cover - Side 1 703 PCB Cover - Fr ont 1 704 T ransformer 1 705 PCB Bracket 1 706 Igniter 1 707 High T ension Lead 1 708[...]

61 OPTIONAL VENTING COMPONENTS Note: When ordering service replacement par ts, the full model and serial number s from the water heater nameplate are required.[...]

62 Notes[...]

63 Notes[...]

Sales/ 800-523-2931 Fax/ 215-641-1670 Technical Support/ 800-334-3393 Fax/ 269-795-1089 W arranty/ 800-531-2111 Fax/ 269-795-1089 International: T elephone/ 215-641-9400 T elefax/ 215-641-9750 Ambler , P A 888-538-7833 Fax on Demand: bradfor dwhite.com www. For U.S. and Canada field service, contact your professional installer or local Bradford Whi[...]