Bradford-White IGI-180C-5(N User Manual

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Tankless Gas Water Heater

SERVICE

MANUAL

Troubleshooting Guide and Instruction for Service

(To be performed ONLY by qualified service providers)

For the Bradford White EverHot®

Interior Tankless

Gas Water Heater Models:

IGI-180R-10(N,X)

IGI-180C-5(N,X)

Manual 45095A

Save this manual for future reference

Key to Warning Symbols

Failure to comply with the following instructions may results in serious personal injury or damage to the appliance.

Be careful of possible electric shock. Wiring inside this appliance may potentially be at 120 volts.

Disconnect power supply to unit when carrying out the following service repairs.

Read Fault Diagnosis and Wiring Diagram carefully to avoid incorrect wiring.

Do not disassemble. Parts within can not be exchanged or diagnosed faulty.

Please follow the instructions in the following chapters to ensure safe and appropriate service.

After completing the service and confirming that there are no water or gas leaks or incorrect wiring, test operation of the appliance.

2

TABLE OF CONTENTS

Section

Description

Page

- - -

Glossary of Terms and Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . .4

I. . . . . . . . . . .

.General Information.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

a.How to Use This Manual. . . . . . . . . . . . . . . . . . . . . . . . . .6

b.Cut Away illustration. . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

c.Schematic illustration. . . . . . . . . . . . . . . . . . . . . . . . . . . .8

II. . . . . . . . . . . Specifications (General). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

a.Combustion Specifications. . . . . . . . . . . . . . . . . . . . . . . .11

b.Default Dip Switch Settings. . . . . . . . . . . . . . . . . . . . . . .12

c.Venting Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

III. . . . . . . . . . .Main Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 IV. . . . . . . . . . .Safety Device Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 V. . . . . . . . . . . Sequence of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 a. Operation Sequence Flow Chart. . . . . . . . . . . . . . . . . . . .21 b. Sequence Timing Chart. . . . . . . . . . . . . . . . . . . . . . . . . .23

VI. . . . . . . . . . .Troubleshooting (error messages). . . . . . . . . . . . . . . . . . . . . . . . . .25 a. Quick Reference Diagnostic Points. . . . . . . . . . . . . . . . . .27 b. Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 c. Troubleshooting Flow Chart. . . . . . . . . . . . . . . . . . . . . . .31 d. Trouble Shooting Procedure. . . . . . . . . . . . . . . . . . . . . . .36

VII. . . . . . . . . . Gas Pressure Setting Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . .46 VIII. . . . . . . . . .Service Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 IX. . . . . . . . . . .Flushing Procedure for Lime Scale Removal . . . . . . . . . . . . . . . . . .54 X. . . . . . . . . . . Parts Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

Refer to installation and operation manual for the following reference information:

General Dimensions

Piping Recommendations

Remote Control Features

Water Flow Rates vs Temperature

3

GLOSSARY OF TERMS AND SYMBOLS

This glossary of terms and symbols is provided to assist you in understanding some of the language used throughout this manual.

dB(A)

-

sound pressure level in decibels, “A” range

DC

-

direct current

AC

-

alternating current

WFCD

-

water flow control device

FB

-

feedback information

Hz

-

hertz

IC

-

integrated circuit

BTU/H

-

British thermal units per hour

PSI

-

Pounds per square inch

LED

-

light emitting diode

GPM

-

gallons per minute

mA

-

milliamps

W.C.

-

inches of water column

mm

-

millimeters

NOx

-

oxides of nitrogen NO & NO2

OHS

-

overheat switch

PCB

-

printed circuit board

CPU

-

central processing unit

POT

-

potentiometer

rpm

-

revolutions per minute

SV

-

solenoid valve

Ø

-

diameter

∆°F

-

delta T or temperature rise above ambient

POV

-

modulating valve

TE

-

thermal efficiency

TH

-

thermistor

TIN

-

temperature of incoming water

Tout

-

temperature of outgoing water

4

I - GENERAL INFORMATION

This tankless water heater is a high output, high efficiency appliance, which heats the water continuously as hot water is being drawn for use. Unlike tank type storage water heaters, this water heater does not store hot water. The burner operates whenever there is a demand for hot water and is off when the hot water flow stops. Hot water is continuously supplied for any length of time required as long as the specified flow rates are not exceeded. There is no need to set the temperature higher than required for sufficient capacity. This water heater has sufficient capacity to supply several hot water faucets simultaneously. The hot water flow capability will be dependent upon the temperature of the outlet water selected. Operational feature of this water heater include:

The burners ignite by direct spark ignition within 3 seconds of detecting minimum operational water flow. There is no standing pilot.

A variable speed combustion air blower forces the combustion air supply into the burner compartment.

Direct vent design uses only outside air for combustion. The venting system is a coaxial design requiring a single 5 1/4" (13.3 cm) hole through the outside wall or roof. Vent pipe fittings have internal gaskets for a tight seal to prevent leakage of flue products and combustion air.

The burner flame is continuously monitored and modulated to match the heating requirements of the water flow. Temperature and flow sensors continually monitor the water flow and outlet water temperature and adjust the burner and combustion air blower to maintain temperature.

The Indoor Direct Vent model series have a digital temperature control integrally mounted to the front panel of the water heater. The outlet water temperature is adjustable from 96-160°Ffor residential models or96-180˚Ffor commercial models. The front panel temperature control also displays fault codes if the water heater malfunctions to assist with servicing the water heater. No installation is required for the main temperature control.

In addition to the main temperature controller, up to two optional bathroom temperature controls are available on the residential models for setting the water temperature in the bathroom fixtures up to 120°F.

The heat exchanger coil is provided with anti-freezeheaters for protection in cold climate conditions to ambient temperatures as low as-30°F(-34°C).Drain solenoids should be installed to drain the water heater in the event of a power failure.

(See installation instructions)

Tools Required for Troubleshooting

Multifunction Digital Testmeter with needle point test leads. Long reach (12") Magnetic Phillips screw driver (#2 Tip) 3/16 Allen wrench

Small (pocket size) blade screw driver

Monometer or Magnehelic inches water column gage

5

I - GENERAL INFORMATION (cont.)

HOW TO USE THIS MANUAL

It is intended for this manual to be used by qualified service personnel for the primary purpose of troubleshooting analysis and repair of this tankless gas fired water heater. Understanding the basic operation of the "Main Components" and the "Sequence of Operation" sections of this manual will contribute greatly to your success in the troubleshooting analysis of this product.

Sections of this manual reference general information and specifications. The primary focus is trouble shooting analysis and repair. The trouble shooting section consists of the following:

• Error Message Table.

Table showing Error Message as displayed on remote control indicating likely fault and remedy.

• Quick Reference Diagnostics Points Table.

This guide will identify the specific diagnostic point for each component as well as the correct electrical value for each component.

• Troubleshooting Flow Chart.

The "Trouble Shooting Flow Chart" identifies fault potentials and directs service to the appropriate diagnostic check points. The check points are identified in the troubleshooting procedure and are shown on the wiring diagram by means of an encircled letter with a subscript number.

Example:

This chart will also refer to a page number to reference a pictorial version of the component analysis as outlined in the "Trouble Shooting Procedure" section of this manual.

• Trouble Shooting Procedure.

Pictorial procedure including diagnostic points, electrical values and referral to "Service Procedure" for replacement of faulty components.

• Service Procedure.

Pictorial procedure for removal and replacement of components.

6

I - GENERAL INFORMATION (cont.)

CUT-AWAYILLUSTRATION

7

I - GENERAL INFORMATION (cont.)

SCHEMATIC ILLUSTRATION

8

II - SPECIFICATIONS - GENERAL

Model type

RESIDENTIAL

COMMERCIAL

Type of appliance

Temperature controlled continuous

 

 

flow gas hot water system

 

Operation

With / without remote controls, mounted

 

 

in kitchen, bathroom, etc.

 

Exhaust system

Direct Vent - Forced combustion

 

Maximum/Minimum gas rate

180,000 BTU's - 15,000 BTU's Natural Gas

 

(Input BTU's)

180,000 BTU's - 15,000 BTU's Propane Gas

 

Hot water capacity,

0.5 to 6.5 GPM

 

(50°F rise)

 

 

Setpoint Temperature

Factory setting - 120°F

Factory setting - 140°F

(without remote)

 

 

Temperature range

MC controller : 96 - 160°F

 

(with remote)

BC controller : 96 - 120°F

MCC controller : 96-180°F

 

BSC controller : 96 - 120°F

 

Approved gas type

Natural or Propane - Ensure unit matches

 

 

gas supply type.

 

Installation

Indoor Only

 

Dimensions

Height 23 5/8"

 

 

Width 13 25/32"

 

 

Depth 8 13/16"

 

Weight

49 Lbs.

 

Thermal Efficiency rating

0.87 (Propane) 0.82 (Natural)

 

Noise level

49 dB (A)

 

Connections

Gas supply 3/4" NPT (Male)

 

 

Cold water inlet 3/4" NPT (Male)

 

 

Hot water outlet 3/4" NPT (Male)

 

Ignition system

Direct electronic ignition

 

Electrical consumption

Operating - 75 watts

 

 

Standby - 5.5 watts

 

 

Anti-frostprotection 100 watts

 

Water temperature control

Simulation feedforward and feedback.

 

Water flow control

Water flow sensor, electronic water control

 

 

device, and electronic by-passcontrol device

 

Recommended Minimum water

 

 

supply pressure

20 PSI (recommend 50-80PSI for maximum performance)

Maximum water supply pressure

150 PSI

 

9

II - SPECIFICATIONS - GENERAL

Safety devices

Appliance - AC 120 Volts - 60Hz. 15A - Dedicated

 

Remote control DC 12 Volts (Digital)

 

Flame failure - Flame rod

 

Boiling protection - 203°F

 

Remaining flame (OHS) 194°F bi-metalswitch

 

Thermal fuse 264°F

 

 

Automatic frost protection - Bimetal sensor & anti-frostheaters

 

Combustion fan rpm check - Integrated circuit

 

Over current - Glass fuse (3 amp)

 

If remote fails or becomes disconnected unit defaults to

 

100°F with water flowing, this is an anti-scaldfeature.

Remote control cable

Non-polarizedtwo core cable or low voltage thermostat wire

Clearances from combustibles

Top of heater 6"

(12" min. recomended for service)

 

Front of heater 6"

(24" min. recomended for service)

 

Sides of heater 2"

 

 

Back of heater 0"

 

 

Floor 12"

 

 

Vent/Air Intake 0"

 

10

II - SPECIFICATIONS - COMBUSTION

Item

 

Gas type

 

Natural

 

Propane

 

 

 

Gas consumption

 

Minimum Btu’s

 

15,000

 

15,000

 

 

Maximum Btu’s

 

180,000

 

180,000

Injector Diameter

 

Upper

 

Ø.037 (.95mm)

 

Ø.029 (.75mm)

Inches (mm)

 

Lower

 

Ø.062 (1.6mm)

 

Ø.045 (1.15mm)

Main Burner

 

 

B3A7-1(Leanand Rich Bunsen Burner)

Main Damper

 

 

H73-115,Upper: Ø6, Lower: (Not used)

Gas Pressure

 

Minimum supply

 

6" W.C.

10" W.C.

Supply/Manifold

 

Maximum supply

 

10.5" W.C.

13.5" W.C.

 

 

Low Fire manifold

 

0.77” W.C

0.93” W.C

 

 

High Fire manifold

 

3.7” W.C

4.2” W.C

11

II - SPECIFICATIONS (cont.)

DIP SWITCH SETTINGS

DANGER

Do not attempt to adjust dip switch settings from there factory default settings. Doing so will result in damage to unit, property damage, personal injury or death.

Contact Technical Support for information pertaining to dip switch function.

FACTORY DEFAULT SETTING, RESIDENTIAL UNITS

Natural Gas

 

Propane Gas

 

Dip Switch Settings:

 

Dip Switch Settings:

(SW1)

(SW2)

(SW1)

(SW2)

#1 = Off

#1 = On

#1 = Off

#1 = Off

#2 = On

#2 = Off

#2 = On

#2 = Off

#3 = Off

#3 = Off

#3 = Off

#3 = Off

#4 = Off

#4 = Off

#4 = Off

#4 = Off

#5 = Off

 

#5 = Off

 

#6 = Off

 

#6 = Off

 

#7 = Off

 

#7 = Off

 

#8 = Off

 

#8 = Off

 

FACTORY DEFAULT SETTING, COMMERCIAL UNITS

Natural Gas

Dip Switch Settings:

(SW1)

(SW2)

#1 = Off

#1 = On

#2 = On

#2 = Off

#3 = Off

#3 = Off

#4 = Off

#4 = On

#5 = Off

 

#6 = Off

 

#7 = Off

 

#8 = Off

 

Propane Gas

Dip Switch Settings:

(SW1)

(SW2)

#1 = Off

#1 = Off

#2 = On

#2 = Off

#3 = Off

#3 = Off

#4 = Off

#4 = On

#5 = Off

 

#6 = Off

 

#7 = Off

 

#8 = Off

 

See page 13 for special dip switch settings base on vent length.

12

II - SPECIFICATIONS (cont.)

DIP SWITCH SETTINGS

Combustion Blower Dip Switch Settings for Vent Length Compensation Under 22 Feet (6.7 m):

To assure optimum efficiency and reduced noise levels, the combustion blower switch has two dip switch settings. Dip switch number 1 (top dip switch) is shipped from the factory set to the OFF position to compensate for the maximum vent/air intake length.

Depending upon the vent/air intake length of the installation, Dip Switch Number 1 may need to be adjusted to compensate for the venting system distance.

When the Total Equivalent Length of vent pipe is more than 22 feet (6.7 m), leave the Dip Switch Number 1 in the OFF position. This is the factory Dip Switch setting.

When the Total Equivalent Length of vent pipe is 22 feet (6.7 m) or less, Dip Switch Number 1 must be moved to the ON position.

Dip Switch #1 is located in the top row of dip switches, 1 through 8 on the PC board. See the following diagram to identify the correct switch. If you do not understand the information concerning the Dip Switch settings or the location of the Dip Switch, contact Bradford White Sales (800-523-2931)or Technical Service(800-334-3393x3634) for assistance. Use the following examples and the previous discussion on calculating the equivalent vent length to determine the correct setting for Dip Switch #1.

Example #1:

Dip Switch Settings (Fig. 8)

You have 6 feet (1.82 m) of vent pipe and two 90˚ elbows.

D = 6 + (2 x 6) + (0 x 1.5)

D = 18 feet (5.49 m) of equivalent vent pipe

Dip Switch #1 should be moved to ON position.

Example #2:

You have 15 feet (4.57 m) of vent pipe, one 90˚ elbow, and two 45˚ elbows.

D = 15 + (1 x 6) + (2 x 1.5)

D = 24 feet (7.3 m) of equivalent vent pipe

Leave Dip Switch #1 in the OFF position (factory setting).

WARNING

Do not alter Dip Switch #1 before using the formula and venting charts to determine the equivalent vent

length. All other dip switches with the exception of Dip Switch #1 shown in the illustration MUST NOT be

altered. Unauthorized adjustments can cause property damage, personal injury, scalding, or death.

13

II - SPECIFICATIONS (cont.)

VENTING TABLE

Venting Table – Examples of Maximum Venting Distances with Various Elbow Combinations

Maximum Straight

Number of

Number of

Maximum Total

Pipe Distance

90 degree elbows

45 degree elbows

Equivalent Feet

 

 

 

(meters) of Vent Pipe

35 Ft. (10.7 m)

1

 

41 (12.5 m)

29 Ft. (8.8 m)

2

 

41 (12.5 m)

23 Ft. (7.0 m)

3

 

41 (12.5 m)

17 Ft. (5.2 m)

4

 

41 (12.5 m)

33.5 Ft. (10.2 m)

1

1

41 (12.5 m)

32 Ft. (9.8 m)

1

2

41 (12.5 m)

27.5 Ft. (8.4 m)

2

1

41 (12.5 m)

NOTICE

Each 90 degree elbow is equivalent to 6 feet in straight vent pipe length. Each 45 degree elbow is equivalent to 1.5 feet (0.46 m) in straight pipe length. The total maximum equivalent vent pipe distance cannot exceed 41 feet (12.5 m) for horizontal venting distance. The maximum vertical height for through the roof venting cannot exceed 21 feet (6.4 m). A condensate collector must be used if the venting system height is more than 5 feet (1.52 m) above the water heater.

14

III - MAIN COMPONENTS

1. Mechanical Water Regulator

The unique water regulator mechanism ensures the hot water is maintained with no noticeable change to the desired temperature during use, even if water pressure drops due to another tap being turned on and increasing the demand.

2. Preset Bypass

A preset volume of cold water is mixed with water heated in the heat exchanger.

3. Burner

The burner assembly is made up of 16 identical stainless steel Bunsen burners, secured by an aluminized steel framework. An aluminum manifold with 32 integral injectors supplies gas to the burners, and is attached to the front lower cover of the burner box and gas control assembly.

4. Gas Control Valve

The gas control valve uses four solenoids to fully modulate within four different input ranges to respond quickly and accurately to changes in water flow rate. The four ranges are as follows: up to 18% of total btu’s (using three burners), up to 33% (using five burners), up to 50% (using eight burners, and up to 100% (using sixteen burners) This increases the flexibility of the regulator/ modulating valve by supplying gas equally to each burners.

15

III - MAIN COMPONENTS (cont.)

5. Combustion Fan

Air for the combustion is supplied by a centrifugal fan driven by a DC motor. After a pre-purgeperiod of 0.2 seconds, the fan speed is controlled by the PCB to provide the correct volume of air for combustion. The calculation for the fan speed is based upon incoming water temperature, water flow and the temperature selected on the remote controls.

The actual speed of the motor is continuously monitored by a magnetic pulse sensor.

This sensor emits (4) pulses per rotation of the fan. This is the fan feedback or confirmation data processed by the PCB.

The fan speed is constantly correcting to provide optimum combustion conditions. In addition, the fan speed will determine the opening degree of the modulating gas valve. This enables the gas rate to always match the volume of air for combustion, as well as the input required to heat the water.

6. Water Flow Sensor and Water Flow Control device

Water flow is detected by a turbine/magnetic pulse generating device. Water flows through the turbine/magnetic sensor providing information to the PCB by generating a pre-determinednumber of pulses in proportion to the water flow. These pulses are counted by the PCB – no pulse indicates no water flow. The frequency of the magnetic pulses increases as the water flow increases, this enables the PCB to calculate the exact water flow, and determine the water flow in gallons per minute. As soon as the required water flow is detected, the PCB activates the combustion fan. The combustion fan speed is monitored by a magnetic pulse sensor. The output from this sensor is processed by the PCB which opens the gas modulating valve to a degree proportional to the fan speed. See above for further details on the combustion fan.

The water flow control consists of a plug and barrel valve which is rotated by a motor to increase or decrease the volume of water passing through the heat exchanger.

Automatic water flow control device.

16

IV - SAFETY DEVICE FUNCTION

Flame Failure

Situated to the right of the burner in the front of the combustion chamber, the flame rod monitors the combustion process. This sensor monitors the flame intensity, while the PCB compares this signal to the feed back signal from the combustion fan motor, water flow control, and gas flow through the POV valve. If any one of the feedback signals are incorrect, the unit will shut off, preventing discharge of gas to the burner.

Over Heat Protection Device

Also referred to as an Over Heat Switch. This device is fitted to a bend section at the inlet to the heat exchanger. If the flame remains on to the burner after the tap is closed and the water temperature inside the heat exchanger reaches 194 ° F, a 12 volt DC bi-metalcut-offswitch will shut off the gas supply to the solenoids.

No Water

Should the incoming water flow become restricted or stop, the water flow sensor will cease to send a magnetic pulse signal to the PCB, in turn preventing gas to flow into the combustion chamber. If you have restricted flow, first check to ensure the inline water filter is not clogged.

Thermal Fuse (Non-Resettable)

Wrapped around the entire surface of the heat exchanger you will find a thermal fuse. This device activates in the event of excessive heat echanger temperatures, or the temperature outside the heat exchanger reaches 264 °F. If the thermal fuse melts, it breaks an electronic circuit which in turn shuts off the power supply to the gas solenoids, deactivating the unit.

Combustion Fan Revolution Check

The combustion fan rpm’s are continually monitored by a magnetic pulse generator connected to the PCB. If the fan revolutions deviate from the speed required for complete combustion, a signal is sent to the PCB and the revolutions adjust accordingly. (If not the unit deactivates)

Automatic Frost Protection

When the temperature inside the appliance drops below 37°F , the frost sensing device inside the appliance activates the anti-frostheaters to prevent the water inside the unit from freezing. The antifrost heaters remain ON until the temperature inside the appliance rises to 57°F. There are four (16) wattanti-frostheaters located at various points throughout the main water flow area of the appliance. The unit also incorporates the ability to fire for (3) seconds in the event theanti-frostheaters can not keep the water temperature from dropping below 37°F. This unique feature will heat the water in the lines inside the appliance back up to 57°F.Both of the above features function as long as the unit has power and gas. There is an optional freeze protection system that can be added to the unit’s piping. Refer to the auto drain down diagram in the product installation instructions for instructions on how to install the optional freeze protection in the event of a power failure.

17

IV - SAFETY DEVICE FUNCTION (cont.)

Over temperature Cut-Off

The temperature of the outgoing hot water is constantly monitored by the water temperature thermistor located near the outlet of the appliance. If the outgoing water temperature reaches 5 °F above the preset temperature, the burner will automatically deactivate. The burner will ignite again when the outgoing hot water temperature falls below the preset temperature.

18

V - SEQUENCE OF OPERATION

The preset temperature is selected at one of the remotes controls (where fitted). Where no remote control is fitted , the default temperature can be set at 108, 120, 130, 140, 150, 160, 170, or 180°F. To select one of the above temperatures as your default setting, you MUST obtain written permission and training (Contact your technical service group).

When the unit is first plugged into 120 volts, the PCB assumes an incoming water temperature of 77°F. This prevents the appliance from starting in “High fire” and producing very hot water the first time it is used.

The data used to determine the outgoing water temperature, initially, is incoming water flow and the remote control pre-settemperature.

From the incoming water flow and remote control pre-settemperature data, the CPU is able to determine a suitable gas rate to initiate appliance operation once a hot water tap opens.

The calculation of temperature rise and water flow is called simulation feed-forward.

The water heater calculates incoming water temperature by subtracting the theoretical temperature rise from the outgoing hot water temperature to establish the correct gas flow.

When a hot water tap is opened, water begins to flow through the water heater. The turbine in the water flow sensor begins to revolve. The revolution speed is proportional to the water flow. A sensor located inside the device relays information in the form of magnetic pulses to the main PCB to determine whether or not water is flowing, and also, the volume of water flowing. When a predetermined water flow is sensed, the ignition sequence begins.

The combustion fan pre-purgesthe combustion chamber. A rev counter on the combustion fan indicates the fan rpm to the main PCB. When thepre-purgecycle is completed, the PCB controls the fan rpm by varying the DC voltage to the fan motor. This maintains the correct air/gas ratio throughout the time the water heater is in use and ensures proper combustion.

The gas is ignited by direct spark and the flame is sensed by the flame rod. The opening degree of the modulating valve is determined by the combustion fan speed.

The changeover valve directs gas to one side or both sides of the burner. At the point where the changeover valve opens or closes the modulating valve is instantly re-adjustedby the PCB to compensate for the change in the number of burners in use. From the information provided by the water flow sensor and the water temperature thermistor, the PCB determines how much gas is required to heat the water to the temperature selected on the remote control.

The PCB is programmed to provide the maximum volume of water possible at a given temperature rise. As the water flow from the tap is increased, the PCB increases the gas and air flow to the burner.

19

V - SEQUENCE OF OPERATION (cont.)

When the hot water tap is turned off, the water flow sensor stops revolving, and the magnetic pulse ceases, indicating to the PCB that there is no water flowing, in turn the PCB closes the gas valves. The combustion fan continues to operate for 65 seconds. This will provide quicker ignition when the tap is turned on and off in rapid succession, and removes the need for a pre-purgecycle allowing the burner tore-lightimmediately when a hot water tap is opened again.

20

V - SEQUENCE OF OPERATION (cont.)

Operation Sequence Flow Chart

21

V - SEQUENCE OF OPERATION (cont.)

Operation Sequence Flow Chart

22

V - SEQUENCE OF OPERATION (cont.)

Sequence Timing Chart

23

V - SEQUENCE OF OPERATION (cont.)

Sequence Timing Chart

24

VI - TROUBLESHOOTING

Error Messages

Error

Faulty

Remedy

10

Air Supply

Check all vent components for proper connections.

 

or Exhaust

Check that nothing is blocking the flue inlet or exhaust.

 

Blockage

Ensure proper venting materials were used.

 

 

Ensure condensation collar was installed correctly.

 

 

Verify dip switches are set properly.

11

No Ignition

Ensure you have gas to the appliance.

 

 

Ensure gas type and pressure is correct.

 

 

Bleed all air from gas lines.

 

 

Verify dip switches are set properly.

 

 

Disconnect all MSA controls.

 

 

Ensure gas line, meter, and/or regulator is sized properly.

 

 

Ensure appliance is properly grounded.

 

 

Check gas solenoid valves for open or short circuits.

 

 

Ensure igniter is operational.

 

 

Check igniter wiring harness for damage.

 

 

Remove burner cover and ensure all burners are properly seated.

 

 

Remove burner plate and inspect burner surface for condensation or debris.

12

Flame Failure

Ensure you have gas to the appliance.

 

 

Ensure gas type and pressure is correct.

 

 

Bleed all air from gas lines.

 

 

Verify dip switches are set properly.

 

 

Ensure flame rod wire is connected.

 

 

Check flame rod for carbon build-up.

 

 

Ensure gas line, meter, and/or regulator is sized properly.

 

 

Ensure appliance is properly grounded.

 

 

Check gas solenoid valves for open or short circuits.

 

 

Check power supply for loose connections.

 

 

Check power supply for proper voltage and voltage drops.

 

 

Disconnect all MSA controls.

 

 

Disconnect keypad.

 

 

Disconnect and re-connectall wiring harnesses on unit and PC board.

 

 

Ensure proper venting material was installed.

 

 

Ensure condensation collar was installed properly.

 

 

Ensure maximum vertical vent length does not exceed 21 ft. and three 90˚ elbows.

 

 

Ensure maximum horizontal vent length does not exceed 41equivalent feet and three

 

 

90˚ elbows.

 

 

Immediate code 12 is usually a defective gas valve, power supply problem, or defective

 

 

fan motor wiring harness.

 

 

Remove burner plate and inspect burner surface for condensation or debris.

14

Thermo Fuse

Ensure dip switches are set to the proper position.

 

 

Ensure high fire and low fire manifold pressure is correct.

 

 

Check gas type of unit and ensure it matches gas type being used.

 

 

Check heat exchanger for cracks and/or separations.

 

 

Check resistance on safety circuit.

 

 

Check for improper conversion of product.

 

 

Check for restrictions in air flow around unit and vent terminal.

 

 

Check for a low flow circulating system that is causing the unit to short cycle.

 

 

Check for foreign materials in combustion chamber and/or exhaust piping.

16

Over

Check for clogged heat exchanger.

 

Temperature

Check for restrictions in air flow around unit and vent terminal.

 

Warning

Check for a low flow circulating system that is causing the unit to short cycle.

 

 

Check for foreign materials in combustion chamber and/or exhaust piping.

 

 

 

25

VI - TROUBLESHOOTING (cont.)

Error Messages

Error

Faulty

Remedy

32

Outgoing Water

Check sensor wiring for damage.

 

Temperature

Check resistance onsensor.

 

Sensor Faulty

Check and clean dirt from sensor.

 

 

Replace sensor.

33

Heat Exchanger

Check sensor wiring for damage.

 

Outgoing

Check resistance on sensor.

 

Temperature

Check and clean dirt from sensor.

 

Sensor Faulty

Replace sensor.

34

Combustion Air

Check sensor wiring for damage.

 

Temperature

Check resistance on sensor.

 

Sensor Faulty

Check and clean dirt from sensor.

 

 

Clean blower blades, if dirty.

 

 

Ensure fan blade is tight on motor shaft and it is in good condition.

 

 

Check for restrictions in air flow around unit and vent terminal.

 

 

Replace sensor.

52

Modulating

Check modulating gas solenoid valve wiring harness for loose or damage terminals.

 

Solenoid

Check resistance on solenoid valve.

 

Valve Signal

 

 

Abnormal

 

61

Combustion

Ensure fan motor will turn freely. Motor will operate with a small amount of resistance.

 

Fan Failure

Check wiring harness to motor for damaged and/or loose connections.

 

 

Check resistance on motor winding.

71

SV0, SV1,

Check wiring harness to all solenoids for damage and/or loose connections.

 

SV2, and SV3

Check resistance on each solenoid.

 

Solenoid Valve

 

 

Circuit Faulty

 

72

Flame Sensing

Check micro amps produced by flame rod.

 

Device Faulty

Remove flame rod and check for carbon build-up,clean with sand paper.

 

 

Ensure flame rod is touching flame when unit fires.

 

 

Check inside burner chamber for any foreign material blocking flame at flame rod.

 

 

Check all wiring to flame rod for damage.

 

 

Replace flame rod.

LC

Scale Build-up

Turn off power supply, then reapply power;

 

in Heat

if code reappear separate control wires from the unit’s power supply.

 

Exchanger

Flush heat exchanger.

 

 

Replace heat exchanger.

No code

Nothing happens

Clean inlet water supply filter.

 

when water flow

Ensure you have at least the minimum flow rate required to fire unit.

 

is activated.

Check for pipe dope inside water flow control turbine.

 

 

On new installations ensure hot and cold water lines are not crossed.

 

 

Check for bleed over. Isolate unit from building by turning off hot water line to building,

 

 

then open your pressure relief valve. If unit fires, there’s a bleed over in your plumbing.

 

 

If a circulating system is in use, it must be isolated also.

 

 

Remote control does not light up but you have 12 VDC at the terminals for controls.

 

 

Disconnect water flow control motor, then turn on hot water, if unit fires replace water

 

 

flow control assembly.

 

 

Check resistance on the water flow control sensor.

 

 

26

VI - TROUBLESHOOTING (cont.)

Quick Reference Diagnostic Points

IMPORTANT SAFETY NOTES:

There are a number of (live) tests that are required when fault finding this product. Extreme care should be used at all times to avoid contact with energized components inside the water heater.

Only trained and qualified service agencies should attempt to repair this product. Remember, before checking for resistance readings, you should disconnect the power source (unplug it) to the unit and isolate the item to be checked from the circuit.

(TR) Transformer:

 

Wire color

 

Voltage

Resistance

Connector #

Pin #’s

 

 

Black ~ White

100 ~ 120 VAC

51 ~ 63 ohms

F9

1 ~ 2

 

 

 

 

 

Blue ~ Brown

110

~ 120 VAC

51 ~ 63 ohms

F7

1 ~ 3

 

 

(SV0, SV1, SV2, SV3 and POV) Gas valve and Modulating solenoids: (Set meter above 2K)

 

 

 

(SV0) Pink ~ Black

80

~ 100 VDC

1,8K ~ 2K ohms

E1

1 ~ 2

 

 

(SV1) Black ~ Yellow

80

~ 100 VDC

1,8K ~ 2K ohms

E2

2 ~ 3

 

 

(SV2) Black ~ Blue

80

~ 100 VDC

1,8K ~ 2K ohms

E3

2 ~ 4

 

 

 

 

 

 

(SV3) Black ~ Brown

80

~ 100 VDC

1,8K ~ 2K ohms

E4

2 ~ 5

 

 

(POV) Pink ~ Pink

2

~ 15 VDC

67 ~ 81 ohms

C2

3 ~ 4

 

 

(M) Water Flow Control Device Servo or Geared Motor:

 

 

 

 

Red ~ Blue

11

~ 13 VDC

22 ~ 26 ohms

B2

9 ~ 10

 

 

 

 

 

 

 

Grey ~ Brown

4

~ 6 VDC

N/A

B2

5 ~ 7

 

 

Grey ~ Yellow

 

 

N/A

N/A

B2

5 ~ 8

 

 

Grey ~ Orange

11

~ 14 VDC

N/A

B2

5 ~ 6

 

NOTE: The grey wire listed above turns to black at B connector on the PCB, the orange wire turns to red.

(QS) Water Flow Sensor:

 

Black ~ Red

11 ~13 VDC

5.5K ~ 6.2K

B4

5 ~ 6

 

 

Yellow ~ Black

4 ~ 7 VDC

1 meg ~ 1.4 meg

B4

1 ~ 5

 

 

By-passFlow Control:

 

 

 

 

 

 

Brown ~ White

2 ~ 6 VDC

Unit in operating

G4 ~ G5

4 ~ 5

 

 

Orange ~ White

 

mode

G2 ~ G5

2 ~ 5

 

 

Yellow ~ White

 

15 ~ 35K

G1 ~ G5

1 ~ 5

 

 

Red ~ White Gnd

 

 

G3 ~ G5

3 ~ 5

 

 

(IG) Ignition System:

 

 

 

 

 

 

Grey ~ Grey

90 ~ 100 VAC

N/A

F8

2 ~ 3

 

 

(FM) Combustion Fan Motor:

 

 

 

 

 

 

Red ~ Black

6 ~ 45 VDC

N/A

A1

1 ~ 2

 

 

 

 

 

 

White ~ Black

6 ~ 45 VDC

9.2K ~ 9.4K

A1

2 ~ 4

 

 

Yellow ~ Black

11 ~ 13 VDC 3

.5K ~ 3.9K

A1

2 ~ 3

 

Set your meter to the Hertz scale. Reading across the red and yellow wires at terminals 2 and 3 you should read between 60 and 350 Hertz.

27

VI - TROUBLESHOOTING (cont.)

Thermal Fuse:

 

Wire color

Voltage

Resistance

Connector #

Pin #’s

 

 

Red ~ Red

100 VAC

Below 1 ohm

B ~ C

B6 ~ C1

 

 

Overheat Switch:

 

 

 

 

 

 

Red ~ Red

100 VAC

Below 1 ohm

B ~ C

B6 ~ C1

 

Flame Rod:

Place one lead of your meter to the flame rod and the other to earth or ground. With the unit running you should read between 5 ~ 150 VAC. Set your meter to the µ amp scale, series your meter in line with the flame rod. You should read1µ or greater for proper flame circuit. In the event of low flame circuit remove the flame rod and check for carbon and/or damage.

Heat Exchanger, Air Temperature, and Outgoing Water Temperature Thermistors:

Check all thermistors by inserting meter leads into each end of the thermistor plug. Set your meter to the 20K scale and read resistance. You should be able to apply heat to the thermistor bulb and see the resistance decrease. Then apply some ice to the thermistor and the resistance should increase. See below for examples of temperatures and resistance reading at those temperatures.

 

Example:

59ºF = 11.4 ~ 14K

 

 

 

 

 

 

86ºF = 6.4 ~ 7.8K

 

 

 

 

 

 

113ºF = 3.6 ~ 4.5K

 

 

 

 

 

 

140ºF = 2.2 ~ 2.7K

 

 

 

 

 

 

221ºF = 0.6 ~ 0.8K

 

 

 

 

 

Outgoing Water Thermistor:

 

 

 

 

 

 

White ~ White

N/A

See example above

B4

B3 ~ B4

 

 

Heat Exchanger Temperature Thermistor:

 

 

 

 

 

White ~ Pink

N/A

See example above

B5

B3 ~ B12

 

 

Air Temperature Thermistor:

 

 

 

 

 

 

White ~ Orange

N/A

see example above

B1

B2 ~ B11

 

 

Surge Protector:

 

 

 

 

 

 

Black ~ White

108 ~ 132 VAC

N/A

Surge Protector D1

1 ~ 3

 

 

Blue ~ Brown

108 ~ 132 VAC

N/A

Surge Protector D2

1 ~ 2

 

 

Remote Controls:

 

 

 

 

 

 

Terminals D1

10 ~ 13 VDC digital

1.5K ~ 1.9K ohms

H

1 ~ 3

 

Frost Protection:

This unit has four frost protection heaters mounted at different points inside the unit to protect the water heater from freeze ups. There are two heaters located on the outlet hot water line next to the thermistor. Using a voltage meter set on the 200 ohm scale, you should have a resistance reading of 26 ~ 30 ohms through each of these heaters. The heater located on the heat exchanger piping should have a resistance reading of 81 ~ 86 ohms and the one located in the water flow sensor valve has a resistance reading of 16 ~ 19 ohms. Voltage throughout this circuit should be 120 VAC.

28

Fuses:

This unit has two inline (3) amp glass fuses. Remove the fuse and check continuity through it. If you have Continuity through the fuse, it is good. If you can not read continuity, the fuse is blown and must be replaced.

Wiring Diagram

29

Wiring Schematic

30

VI - TROUBLESHOOTING (cont.)

Troubleshooting Flow Chart

BEFORE CARRYING OUT CHECKS MARKED WITH

A # SIGN, DISCONNECT THE POWER SUPPLY.

 

Examination

 

 

 

 

 

 

Service

Nature of Fault

Point

Diagnostic Point

Values

Y/N

Action

Procedure

 

 

 

 

 

 

 

 

A. The LED on

1. Do you have

Power source

Do you have 120

Yes

Go to A – (2)

 

the remote

voltage to the unit?

 

VAC at the power

 

 

 

 

 

 

 

 

 

 

 

control does not

 

 

supply?

No

Plug in cord

 

light up, when

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

the system is

2. Is supply voltage

Measure voltage at

120 VAC

Yes

Go to A –

(3)

 

powered up

correct?

power point.

 

 

 

 

 

 

 

 

No

Check power

 

 

 

 

 

 

 

 

 

 

 

 

 

supply circuit.

 

 

 

 

 

 

 

Check fuses.

 

 

 

 

 

 

 

 

 

 

3. Check surge

Inspect visually

Do you have 120

Yes

Go to A –

(4)

 

 

protector.

 

volts AC across the

 

 

 

 

 

 

 

 

 

 

 

 

 

blue and brown

No

Go to A – (5)

 

 

 

 

wires at the surge

 

 

 

 

 

 

 

protector?

 

 

 

 

 

 

 

 

 

 

 

 

 

4. Check both 3

# Disconnect and

Is fuse blown?

Yes

Go to A –

(5)

 

 

amp electrical fuses.

measure resistance to

 

 

 

replace fuse

 

 

 

confirm if fuse is blown.

 

 

No

Go to A –

(6)

 

 

 

Normal < than 1 MΩ

 

 

 

 

 

 

 

5. Check for short

1. Measure resistance of

Are valves within

Yes

Go to

 

 

 

circuits.

each solenoid valve. #

those specified at

 

A – (6) - 2

 

 

 

 

Remove connector E

left? # Measure

 

 

 

 

 

 

from the PCB before

after checking that

 

 

 

 

 

 

 

 

 

 

 

 

measuring.

there are no broken

 

 

 

 

 

 

Pink ~ Black (SV0)

wires or shorts.

No

Replace gas

IGI – 9

 

 

1.7 ~ 2.1KΩ

 

 

 

valve.

 

 

 

 

Yellow ~ Black (SV1)

 

 

 

 

 

 

 

 

1.7 ~ 2.1KΩ

 

 

 

 

 

 

 

 

Brown ~ Black (SV2)

 

 

 

 

 

 

 

 

1.7 ~ 2.1KΩ

 

 

 

 

 

 

 

 

(See page 40)

 

 

 

 

 

 

 

 

1. Measure the

Is resistance >1MΩ ?

Yes

Go to

 

 

 

 

resistance.

 

 

 

A (5 – 3)

 

 

 

 

# Disconnect sparker

 

 

No

Replace

 

IGI – 4

 

 

connector F8 and

 

 

 

 

 

 

 

 

 

 

 

 

 

 

sparker.

 

 

 

 

measure the resistance

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

between both terminals.

 

 

 

 

 

 

 

 

(See page 39)

 

 

 

 

 

 

 

 

3. Check wiring.

Are there any

Yes

Rectify

 

 

 

 

 

 

 

 

 

 

shorts?

 

/Replace

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

No

Replace PCB

IGI – 2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

6. Check to ensure

1. Measure voltage at

100 ~ 120 VAC

Yes

Go to A (6 – 2)

 

 

you have 120 VAC

the blue and brown

 

 

 

 

 

 

 

 

 

 

 

 

 

 

across both

wires.

 

 

No

Check for

 

 

 

terminals feeding

 

 

 

 

proper voltage

 

 

the surge protector.

 

 

 

 

to unit.

 

 

 

 

 

 

 

 

 

 

 

31

VI - TROUBLESHOOTING (cont.)

Troubleshooting Flow Chart

BEFORE CARRYING OUT CHECKS MARKED WITH

A # SIGN, DISCONNECT THE POWER SUPPLY.

 

Examination

 

 

 

 

Service

Nature of Fault

Point

Diagnostic Point

Values

Y/N

Action

Procedure

 

 

 

 

 

 

 

 

 

 

 

 

2. Measure the voltage

Are values within

Yes

Go to A – (7)

 

 

 

 

 

 

at connector F with

those specified at

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

appliance power supply

left.

No

Replace

IGI –

7

 

 

 

 

on.

 

 

transformer

 

 

 

 

 

 

F – Black ~ White

 

 

 

 

 

 

 

 

 

100 ~ 120 VAC

 

 

 

 

 

 

 

 

 

F7 – Blue~ Brown

 

 

 

 

 

 

 

 

 

100 ~ 120 VAC

11 ~ 13 VDC Digital

 

 

 

 

 

 

 

7. Check remotes (s)

Measure voltage

Yes

Check cable

 

 

 

 

 

(where connected.)

between remote control

 

 

for shorts or

 

 

 

 

 

 

terminals at D.

 

 

broken wires.

 

 

 

 

 

 

 

 

 

Replace

 

 

 

 

 

 

 

 

 

remote

 

 

 

 

 

 

 

 

 

control.

 

 

 

 

 

 

 

 

No

Replace PCB.

IGI –

2

 

 

B. Digital monitor

1. Check water flow

1. Measure voltage

11 ~ 13 VDC

Yes

Go to B–1-2

 

 

 

 

lights up, but

sensor.

between red ~ black of

No

Replace PCB.

IGI –

2

 

 

 

 

 

combustion does

 

connector B4.

 

 

 

 

 

 

 

not commence.

 

(See page 37)

 

 

 

 

 

 

 

(when remotes

 

2. Measure voltage

4 ~ 7 VDC

Yes

Go to B - 2

 

 

 

 

are connected).

 

between yellow ~ black

No

Replace water

IGI – 3

 

 

 

 

at connector B4.

 

 

flow sensor.

 

 

 

 

 

 

(See page 37)

 

 

 

 

 

 

 

Error code "72"

2. Check flame rod

# Measure resistance

Resistance > 1MΩ?

Yes

Replace PCB

IGI – 2

displayed on the

 

between flame rod

 

No

Replace flame

 

 

 

 

digital monitor.

 

terminal C1 and earth.

 

 

rod

 

 

 

 

 

 

(See page 38)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Error code "32"

3. Check outgoing

# Disconnect connector

Are values as shown

Yes

Replace water

IGI – 6

displayed on the

water temperature

B5 and measure

at left?

 

temperature

 

 

 

 

digital monitor.

thermistor.

resistance.

 

 

thermistor.

 

 

 

 

 

 

Open circuit: > 1MΩ

 

No

Go to B - 4

 

 

 

 

 

 

Short circuit: < 1Ω

 

 

 

 

 

 

 

 

 

(See page 38)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Error code "61"

4. Check

1. Check motor.

6 ~ 45 VDC (Fan on)

Yes

Go to B – 5-2

 

 

 

 

displayed on the

combustion fan.

Measure voltage

0 VDC (Fan off)

No

Replace PCB

IGI – 2

digital monitor.

 

between black ~ red at

 

 

 

 

 

 

 

 

 

connector A1.

 

 

 

 

 

 

 

 

 

(See page 39)

 

 

 

 

 

 

 

 

 

2. Check fan rotation

11 ~ 13 VDC

Yes

Go to B – 4-3

 

 

 

 

 

 

sensor. Measure voltage

 

No

Replace PCB

IGI – 2

 

 

between black ~ yellow

 

 

 

 

 

 

 

 

 

at connector A1.

 

 

 

 

 

 

 

 

 

(See page 39)

 

 

 

 

 

 

 

 

 

3. Measure voltage

6 ~ 45 VDC

Yes

Go to B – 5

 

 

 

 

 

 

between black ~ white

No

Replace fan

IGI – 5

 

 

 

 

 

of connector A1.

 

 

 

 

 

 

 

 

 

(See page 39)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

32

VI - TROUBLESHOOTING (cont.)

Troubleshooting Flow Chart

BEFORE CARRYING OUT CHECKS MARKED WITH

A # SIGN, DISCONNECT THE POWER SUPPLY.

 

Examination

 

 

 

 

Service

Nature of Fault

Point

Diagnostic Point

Values

Y/N

Action

Procedure

 

 

 

 

 

 

 

Error code "11"

5. Check ignition

1. Measure voltage

90 ~ 110 VAC

Yes

Go to B-5-2

 

displayed on

module.

between grey ~ grey of

 

 

 

 

digital monitor.

 

connector F8 (sparker).

 

No

Replace PCB

IG2 – 2

 

 

 

 

 

 

 

 

(See page 39)

 

 

 

 

 

 

2. # Remove connector

Is resistance >

Yes

Go to B-5-3

 

 

 

F8 and measure the

1MΩ?

No

Adjust/

IGI – 4

 

 

resistance between

 

 

Replace

 

 

 

 

 

 

 

sparker and terminals.

 

 

ignition

 

 

 

(See page 39)

 

 

module

 

 

 

3. Check if unit is

Is the ignition

Yes

Go to B-6

 

 

 

sparking.

module sparking?

 

 

 

 

 

No

Adjust/

 

 

 

 

 

 

 

 

 

 

 

Replace

 

 

 

 

 

 

electrode

 

 

6. Check main gas

1. # Disconnect the main

1.7 ~ 2.1KΩ

Yes

Go to B-6-2

 

 

solenoid valve (SV0)

solenoid valve connector

 

 

 

 

 

 

 

 

 

 

Error code 71

E from the PCB, and

 

No

Replace gas

IGI – 9

 

 

measure the resistance

 

 

valve

 

 

 

between pink ~ black

 

 

 

 

 

 

(SV0)

 

 

 

 

 

 

 

 

 

 

 

 

 

2. Measure voltage

80 ~ 100 VDC

Yes

Go to B-7

 

 

 

between pink ~ black of

No

Replace PCB

IGI – 2

 

 

 

 

 

SV0 connector.

 

 

 

 

 

 

(See page 40)

 

 

 

 

 

 

 

 

 

 

 

 

7. Check solenoid

1. # Disconnect

1.7 ~ 2.1KΩ

Yes

Go to B-7-2

 

 

valve (SV1)

connector E from the

 

 

 

 

 

 

 

 

 

 

 

PCB. Measure resistance

 

No

Replace gas

IGI – 9

 

 

between yellow ~ black

 

 

valve

 

 

 

of (SV1).

 

 

 

 

 

 

 

 

 

 

 

 

 

2. Measure voltage

80 ~ 100 VDC

Yes

Go to B-8

 

 

 

between yellow ~ black

No

Replace PCB

IGI – 2

 

 

 

 

 

of SV1 connector.

 

 

 

 

 

 

(See page 40)

 

 

 

 

 

8. Check

1. # Disconnect

1.7 ~ 2.1KΩ

Yes

Go to B-8-2

 

 

changeover solenoid

connector E from the

 

 

 

 

 

 

 

 

 

 

valve (SV2)

PCB. And measure

 

No

Replace gas

IGI – 9

 

 

resistance between blue

 

 

valve

 

 

 

~ black (SV2)

 

 

 

 

 

 

 

 

 

 

 

 

 

2. Measure the voltage

80 ~ 100 VDC

Yes

Go to B-9

 

 

 

between blue ~ black or

 

 

 

 

 

No

Replace PCB

IGI – 2

 

 

SV2 connector.

 

 

 

(See page 40)

 

 

 

 

 

 

 

 

 

 

 

Error code "14"

9. Check thermal

1. # Disconnect

Is resistance < 1Ω?

Yes

Go to B-10

 

displayed on

fuse

connector B3 and C3

 

No

Replace

 

digital monitor

 

measure resistance

 

 

thermal fuse

IGI – 11

 

 

between red ~ red.

 

 

 

 

 

10. Check overheat

2. # Disconnect OHS

Is resistance < 1Ω?

Yes

Replace PCB

IGI – 2

 

(remaining flame) bi-

(remaining flame) bi-

 

 

 

 

 

metal switch

metal switch festoon

 

No

Replace

 

 

 

terminal B3 and C3, and

 

 

remaining

 

 

 

measure resistance

 

 

flame bi-metal

 

 

 

between terminal on

 

 

switch

 

 

 

switch. (See page 42)

 

 

 

 

33

VI - TROUBLESHOOTING (cont.)

Troubleshooting Flow Chart

BEFORE CARRYING OUT CHECKS MARKED WITH

A # SIGN, DISCONNECT THE POWER SUPPLY.

 

Examination

 

 

 

 

Service

Nature of Fault

Point

Diagnostic Point

Values

Y/N

Action

Procedure

 

 

 

 

 

 

 

 

 

C. Combustion

1. Check flame rod.

1. Measure the voltage

5 ~ 150 VAC

Yes

Go to C-1-2

 

 

 

occurs, but flame

 

between flame rod

No

Replace PCB

IGI –

2

 

 

 

 

fails.

 

terminal C1 and

 

 

 

 

 

 

 

 

appliance ground.

 

 

 

 

 

 

Error code "12"

 

2. Check to ensure flame

Is it secure?

Yes

Go to C-2

 

 

 

 

rod bracket is not loose.

 

No

Replace/

 

 

 

displayed on

 

 

 

 

rectify

 

 

 

digital monitor.

2. Check ground

Check for faulty ground

Are connections

 

 

 

 

 

 

wire.

wire connections at unit,

OK?

Yes

Check for

 

 

 

 

 

receptacle, and ground

 

 

other causes

 

 

 

 

 

rod to home, and for

 

 

of flame

 

 

 

 

 

broken or shorted wires.

 

 

failure.

 

 

 

 

 

 

 

No

Replace or

 

 

 

 

 

 

 

 

repair

 

 

 

 

 

 

 

 

grounding

 

 

 

 

 

 

 

 

circuit to unit.

 

 

 

 

 

 

 

 

 

 

 

 

D. Cannot adjust

1. Check hot water

# Disconnect connector

Resistance values

Yes

Go to D – 2

 

 

 

water

thermistor.

B5 and measure the

match table on page

No

Replace water

IGI –

6

 

temperature.

(outgoing

resistance between

#43

 

temperature

 

 

 

 

thermistor)

white ~ white.

 

 

thermistor.

 

 

 

 

 

(See page 43)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2. Check

1. # Disconnect

1.7 ~ 2.1KΩ

Yes

Go to D – 2-2

 

 

 

 

changeover solenoid

connector E from PCB

No

Replace

IGI –

8

 

 

 

 

 

valve (SV3).

and measure the

 

 

manifold

 

 

 

 

 

resistance between

 

 

assembly

 

 

 

 

 

brown ~ black.

 

 

 

 

 

 

 

 

2. Measure the voltage

80 ~ 100 VDC

Yes

Go to D – 3

 

 

 

 

 

No

Replace PCB

 

 

 

 

 

between brown ~ black

 

IGI – 2

 

 

wire of the changeover

 

 

 

 

 

 

 

 

 

 

 

 

 

solenoid valve (SV3) at

 

 

 

 

 

 

 

 

connector E.

 

 

 

 

 

 

 

 

(See page 41)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3. Check

1. # Disconnect

67 ~ 81Ω

Yes

Go to D – 3-2

 

 

 

 

modulating valve.

modulating valve at C2

No

replace gas

IGI –

9

 

 

 

 

 

 

festoon terminal and

 

 

valve

 

 

 

 

 

measure resistance at

 

 

 

 

 

 

 

 

solenoid terminals.

 

 

 

 

 

 

 

 

(See page 44)

 

 

 

 

 

 

 

 

2. Measure the voltage

2 ~ 15 VDC

Yes

Go to D – 3-3

 

 

 

 

 

between two harness

 

No

Replace PCB

IGI – 2

 

 

terminals at C2.

 

 

 

 

 

 

 

 

(See page 44)

 

 

 

 

 

 

 

 

3. Check whether the

Does the manifold

Yes

Go to D – 4

 

 

 

 

 

manifold pressure alters

pressure change?

No

Replace gas

IGI – 9

 

 

when remote control

 

 

valve

 

 

 

 

 

 

 

 

 

temperature is altered

 

 

 

 

 

 

 

4. Check water flow-

between 96° ~ 140°F.

22 ~ 26Ω

Yes

Go to D – 4-2

 

 

 

 

1, # Measure resistance

 

 

 

 

servo.

between red ~ blue

No

Replace water

IGI – 3

 

 

 

 

wires of the water flow

 

 

flow servo

 

 

 

 

 

servo connector B2.

 

 

sensor.

 

 

 

 

 

(See page 44)

 

 

 

 

 

 

34

VI - TROUBLESHOOTING (cont.)

Troubleshooting Flow Chart

BEFORE CARRYING OUT CHECKS MARKED WITH

A # SIGN, DISCONNECT THE POWER SUPPLY.

 

Examination

 

 

 

 

Service

Nature of Fault

Point

Diagnostic Point

Values

Y/N

Action

Procedure

 

 

 

 

 

 

 

 

 

 

2. Measure voltage

11 ~ 13 VDC

Yes

Go to 4-3

 

 

 

 

between orange (+) and

 

No

Replace PCB

IGI –

2

 

 

grey (-)of the water flow

 

 

 

 

 

 

 

servo connector B2.

 

 

 

 

 

 

 

3. Measure voltage

4 ~ 6 VDC

Yes

Go to D-4-4

 

 

 

 

between brown ~ grey

No

Replace water

IGI –

3

 

 

of water flow servo

 

 

flow servo

 

 

 

 

connector B2 (Don not

 

 

sensor.

 

 

 

 

turn water on)

 

 

 

 

 

 

 

(See page 44)

 

 

 

 

 

 

 

4. Measure voltage

4 ~ 6 VDC

Yes

Normal

 

 

 

 

between yellow ~ grey

No

Replace water

IGI –

3

 

 

 

 

 

of the water flow servo

 

 

flow servo

 

 

 

 

connector B2 (Do not

 

 

sensor.

 

 

 

 

turn water on)

 

 

 

 

 

 

 

(See page 44)

 

 

 

 

 

 

 

 

 

 

 

 

 

E. Anti-frost

1. check anti-frost

1. # Disconnect

348 ~ 375Ω

Yes

Go to E-1-2

 

 

heater does not

heater.

connector F4 and F5

No

Replace Anti-

 

 

 

 

 

work.

 

measure resistance

 

 

frost sensing

 

 

 

 

across each of the

 

 

switch.

 

 

 

 

heating elements. (white

 

 

 

 

 

 

 

wires)

 

 

 

 

 

 

 

(See page 45)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2. # Read resistance of

100 ~ 110Ω

Yes

Go to E-2

 

 

 

 

the heating element that

 

No

Replace Anti-

 

 

 

 

is mounted on the front

 

 

frost heater

 

 

 

 

of the heat exchanger.

 

 

that is

 

 

 

 

(white wires)

 

 

defective.

 

 

 

 

(See page 45)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3. Read resistance of

33 ~ 39Ω

Yes

Go to E-2

 

 

 

 

heating elements on the

 

No

Replace Anti-

 

 

 

 

heat exchanger outlet

 

 

frost heater

 

 

 

 

hot water line.

 

 

that is

 

 

 

 

(See page 45)

 

 

defective.

 

 

 

2. Check frost

# Disconnect connector

Is resistance <1Ω

Yes

Check wiring

 

 

 

sensing switch

F2 and measure across

after applying ice to

No

Replace Anti-

 

 

 

 

the bi-metalsensing

this switch for five

 

frost sensing

 

 

 

 

switch located on the

minutes?

 

switch.

 

 

 

 

upper right hand of the

 

 

 

 

 

 

 

heat exchanger. check

 

 

 

 

 

 

 

this switch at

 

 

 

 

 

 

 

temperatures below 37

 

 

 

 

 

 

 

°F. You can place an ice

 

 

 

 

 

 

 

cube against the switch

 

 

 

 

 

 

 

to activate it.

 

 

 

 

 

 

 

(See page 45)

 

 

 

 

 

 

 

 

 

 

 

 

35

VI - TROUBLESHOOTING (cont.)

Troubleshooting Procedure

BEFORE CARRYING OUT CHECKS MARKED WITH A # SIGN, DISCONNECT THE POWER SUPPLY.

Unit’s wiring diagram can be found on page 29.

Appliance fails to operate (even remote control fails to operate).

1) Is the fuse blown

Fuses are located in plastic holders in the main harness, on the lower right hand side of the appliance.

Check fuse.

a.Disconnect unit from power supply.

b.# Measure resistance to check the electric fuse (3 amp)

Normal: less than 1Ω

If normal, proceed to check item 2 below. Faulty: Replace 3 amp glass fuse. If the fuse blows again, investigate cause of short circuit.

2) Is the main transformer normal?

Check the transformer.

a.Measure the voltage and/or resistance at connector F, black ~ white wires.

Normal: 100 ~ 120 VAC

51 ~ 63 Ω resistance

Faulty: Check for 120~ 125 VAC at the surge protector, blue~ brown wires, connector F7.

Resistance reading 51 ~ 63 Ω

If normal, check item 3 on next page. Faulty: Replace the transformer.

(Service Procedure IGI-7,page 51)

36

VI - TROUBLESHOOTING (cont.)

3) Is the remote control normal ?

Check voltage between the two remote control cable connectors.

a.Check the voltage between terminals on the remote control terminal mount D1.

Normal: 11~ 13 VDC

If normal, check for an open circuit or short before

replacing the remote control. Faulty: Replace PCB.

(Service Procedure IGI-2,page 49)

No combustion (despite remote control indication)

1) Is the water flow sensor normal ?

Check the water flow sensor.

a.Check the voltage at PCB connector B4 , red and black wires.

Normal: 11 ~ 13 VDC or 5.8 ~ 6.4K Ω If normal, check (b) below.

Faulty: Replace the PCB.

(Service Procedure IGI-2,page 49)

b.Check the voltage at PCB connector B4, yellow and black wires.

Normal: 4 ~ 7 VDC or 1M ~ 1.2M Ω.

If normal, proceed to check item 2 on next page. Faulty: Replace the water flow sensor.

(Service Procedure IGI-2,page 49)

37

VI - TROUBLESHOOTING (cont.)

BEFORE CARRYING OUT CHECKS MARKED WITH A # SIGN, DISCONNECT THE POWER SUPPLY.

2) Is the flame rod normal ? Error “72” is displayed

Checking the flame rod.

a.# Detach the flame rod terminal C1, and re-attemptoperation.

(“72 is displayed)

Proceed to check item 3 below. (no “72” displayed)

Inspect flame rod wiring for current leak and inspect flame rod for carbon build-up.

Measure resistance between the flame rod Terminal C1 and the appliance earth. Normal: 1 M Ω or more.

If normal, replace the PCB unit. Faulty: Replace the flame rod.

(Service Procedure IGI-2,page 49)

See page 42 for additional information and resistance values pertaining to the flame rod.

3) Is the water temperature thermistor normal?

If error “32” is displayed, check the water temperature thermistor.

a.# Disconnect connector B5, and measure resistance of the white ~ white wires.

Resistance > 1 M Ω = open circuit. Resistance < 1 Ω = short circuit.

Normal: Proceed to check item 4 on the next page.Faulty: Replace the water temperature thermistor.

(Service Procedure IGI-6,page 50)

See page 43 for additional information and resistance readings pertaining to the temperature themistor.

38

VI - TROUBLESHOOTING (cont.)

BEFORE CARRYING OUT CHECKS MARKED WITH A # SIGN, DISCONNECT THE POWER SUPPLY.

4) Is the combustion fan motor normal ?

Motor check.

If error “61” is displayed, check the combustion fan.

a.Measure voltage at connector A1. Black and red wires. Normal: 6 ~ 45 VDC (Fan on)

0 VDC (Fan off)

If normal, check item b below. Faulty: Replace the PCB unit.

(Service Procedure IGI-2,page 49)

Fan revolution sensor check.

b.Measure voltage at connector A1, black and yellow wires. Normal: 11 ~ 13 VDC or 3.1 ~ 3.7 K Ω

If normal, check item c below. Faulty: Replace the PCB unit.

(Service Procedure IGI-2,page 49)

c.Measure voltage at connector A1, black and white wires. Normal: 6 ~ 45 VDC or 9 ~ 9.4 K Ω

(33 ~ 400 Hz.)

If normal, proceed to check item 5 below. Faulty: Replace the combustion fan motor.

(Service Procedure IGI-5,page 50)

5)Is the ignition module operating normally ?

Check the sparker module.

a.Measure voltage at connector F8, grey and grey wires. Normal: 90 ~ 110 VAC

0 VDC (when fan is off) If normal, check b below.

Faulty: Replace the PCB unit.

(Service Procedure IGI-2,page 49)

b.# Disconnect connector F8, and measure the resistance between the two sparker terminals.

Normal: > 1 M Ω

Faulty: Replace the igniter module.

(Service Procedure IGI-5,page 50)

Electrode gap should be 3/16” to 1/4" .

39

VI - TROUBLESHOOTING (cont.)

BEFORE CARRYING OUT CHECKS MARKED WITH A # SIGN, DISCONNECT THE POWER SUPPLY.

6) Is the main gas solenoid valve (SV0) operating normally ?

If error “11” or “71” is displayed, check the main gas solenoid valve.

a.# Disconnect the main gas solenoid valve (SV0) connector and measure the resistance at the solenoid terminals.

Normal: 1.7 ~ 2.1 K Ω If normal, check b below.

Faulty: Replace gas valve.

(Service Procedure IGI-9,page 52)

b.Measure voltage at the main gas solenoid (SV0) Pink and black wires.

Normal: 80 ~ 100 VDC

If normal, proceed to check item 7 below. Faulty: Replace PCB unit.

(Service Procedure IGI-2,page 49)

7)Is the change over solenoid (SV1) operating normally ?

If error “11” or “71” is displayed, check the change over solenoid (SV1).

a.# Disconnect the change over solenoid (SV1) connector, and measure resistance at the solenoid terminals.

Normal: 1.7 ~ 2.1 K Ω If normal, check b below.

Faulty: Replace the gas valve.

(Service Procedure IGI-9,page 52)

b.Measure voltage at the change over solenoid (SV1) yellow ~ black wires.

Normal: 80 ~ 100 VDC If normal, check 8 below.Faulty: Replace PCB unit.

(Service Procedure IGI-2,page 49)

8)Is the change over solenoid (SV2) operating normally?

If error “11” or “71” is displayed, check the change over solenoid (SV2).

a.# Disconnect the changeover solenoid (SV2) connector, and measure the resistance at the solenoid terminals. Normal: 1.7 – 2.1 K Ω

If normal, check b below. Faulty: Replace the gas valve.

(Service Procedure IGI-9,page 52)

b.Measure the voltage at the changeover solenoid (SV2), blue – black wires.

Normal: 80 – 100 VDC

If normal, check 9, on next page. Faulty: Replace the PCB unit.

(Service Procedure IGI-2,page 49)

40

VI - TROUBLESHOOTING (cont.)

BEFORE CARRYING OUT CHECKS MARKED WITH A # SIGN, DISCONNECT THE POWER SUPPLY.

9) Is the change over solenoid (SV3) operating normally?

If error “11” or “71” is displayed, check the change over solenoid (SV3).

a.# Disconnect the changeover solenoid (SV3) connector, and measure the resistance at the solenoid terminals.

Normal: 1.7 – 2.1 K Ω If normal, check b below.

Faulty: Replace the manifold assembly.

(Service Procedure IGI-8,page 51)

b.Measure the voltage at the changeover solenoid (SV3), brown – black wires.

Normal: 80 – 100 VDC

If normal, reconfirm gas pressures are correct. Faulty: Replace the PCB unit.

(Service Procedure IGI-2,page 49)

41

VI - TROUBLESHOOTING (cont.)

BEFORE CARRYING OUT CHECKS MARKED WITH A # SIGN, DISCONNECT THE POWER SUPPLY.

Error code “14” Check the thermal fuse.

a.# Disconnect connector B3 and C3, measure the resistance between the red – red wires. Normal: Less than 1 Ω

If normal, check b below.

Faulty: Check manifold gas pressure. Check heat exchanger for cracks and/or separations. If there is nothing abnormal, replace the thermal fuse.

(Service Procedure IGI-11,page 53)

b.Check bi-metalswitch, (remaining flame safety device). Measure resistance between the two terminals at B3 and C3.

Normal: Less than 1 Ω

If normal, process to item a below. Faulty: Replace thebi-metalswitch.

Combustion stops due to flame failure

1) Is the flame rod functioning normally?

a.Measure the voltage between the flame rod terminal C1 and the appliance earth.Normal: 5 – 150 VAC from yellow to ground. If normal, check b below.

Faulty: Replace the PCB unit.

(Service Procedure IGI-2,page 49)

b.Check that the flame rod attachment is not loose. Normal: Replace the PCB unit.

(Service Procedure IGI-2,page 49)

Faulty: Secure the flame rod bracket.

2) Is the earth lead wire connected?

a.Check for defective earth terminal, or an open circuit or short. If normal, investigate other possible causes for the flame failure.

(Eg. Is the gas valve open ? Is the filter mesh blocked ?) Was proper venting material used? Did you regulate your gas supply pressure to the proper gas pressure for gas type being used?

Faulty: Ensure unit is properly grounded. Check ground circuit outside home at service pole. There should be an eight foot ground rod driven in the earth and a copper lead tied to the service meter. Ensure connection on ground rod is tight.

42

VI - TROUBLESHOOTING (cont.)

BEFORE CARRYING OUT CHECKS MARKED WITH A # SIGN, DISCONNECT THE POWER SUPPLY.

Unable to adjust hot water temperature

1)Is the water temperature thermistor operating normally ?

a.# Disconnect the connector B5, and measure the resistance between the white wires, see below for resistance readings.

Thermistor resistance valves: 59 ºF = 11.4 ~ 14 K Ω

86 ºF = 6.4 ~ 7.8 K Ω

113 ºF = 3.6 ~ 4.5 K Ω

140 ºF = 2.2 ~ 2.7 K Ω

221 ºF = 0.6 ~ 0.8 Ω

Normal: Proceed to check item 2 below.Faulty: Replace the water temperature thermistor.

(Service Procedure IGI-6,page 50)

2)Is the change over solenoid (SV1) normal ?

a.# Disconnect the changeover solenoid (SV1) connector, and measure resistance at the solenoid terminals.

Normal: 1.7~ 2.1 K Ω If normal, proceed to b.

Faulty: Replace the gas valve.

(Service Procedure IGI-9,page 52)

b.Measure the voltage at the changeover solenoid

(SV1) yellow ~ black wires.Normal: 80~ 100 VDC

If normal, proceed to check item 3, on next page.

Faulty: Replace the PCB unit.

(Service Procedure IGI-2,page 49)

43

BEFORE CARRYING OUT CHECKS MARKED WITH A # SIGN, DISCONNECT THE POWER SUPPLY.

3)Is the modulating valve operating normally ? Error code 52

a.# Disconnect the modulating valve festoon C2 terminals and measure the resistance at the terminals.

Normal: 67 ~ 81 Ω If normal, check b.

Faulty: Replace gas valve.

(Service Procedure IGI-9,page 52)

b.Re-connectterminal C2 and measure voltage

across the pink ~ pink wires when the unit is firing.

Normal: 2 ~ 15 VDC

If normal, check c below. Faulty: Replace the PCB unit.

(Service Procedure IGI-2,page 49)

c.Investigate the change in the manifold gas

pressure, when the remote control pre-settemperature is altered from 96~ 140 ºF. Normal: If the manifold pressure changes, proceed to check item 4 below. DO NOT adjust manifold pressures.

Faulty: Replace gas valve.

(Service Procedure IGI-9,page 52)

4) Is the water flow servo normal ?

a.# Disconnect connector B2 and measure the resistance of the water flow servo, red ~ blue wires.

Normal: 22 ~ 26 Ω

If normal, proceed to b.

Faulty: Replace the water flow servo and sensor.

(Service Procedure IGI-2,page 49)

b.Disconnect connector B2 , and measure the voltage on the PCB unit side, were the orange (+), and/or grey or black (-)wires connect to the board.

Normal: 3.3~ 4.5 VDC If normal, proceed to c.

Faulty: Replace the PCB unit.

(Service Procedure IGI-2,page 49)

c.With connector B2 , connected (do not turn water ON … wait for the water flow servo to return to

fully open), measure the voltage at the brown ~ grey wires.

Normal: 4~ 6 VDC vent limiter OFFFaulty: Replace the water flow servo and sensor. (Service ProcedureIGI-2,page 49)

d.With connector B2 , connected (do not turn water ON… wait for the water flow servo to return to fully open), measure the voltage at the

yellow ~ grey wires.

Normal: Less than 0.5 VDC when unit is set at

120 °F and there is no water flowing through the unit. Faulty: Replace water flow servo and sensor.

(Service Procedure IGI-2,page 49)

44

BEFORE CARRYING OUT CHECKS MARKED WITH A # SIGN, DISCONNECT THE POWER SUPPLY.

Anti-frostheaters do not operate

1)Are the ceramic anti-frostheaters operating normally ?

a.# Disconnect connector F4, and measure the resistance of the heater mounted in the water flow control valve, these are white wires.

Disconnect connector F5, and measure the resistance of the heater in the outlet line connector See connectors in the first and second picture t o the left.

Normal: 348~ 375 Ω If normal, proceed to b.

Faulty: Replace defective element.

b.# Take an ohm meter and read resistance across the heater on the face of the heat exchanger. The resistance across this element is listed below. See third picture to the left for location of this element. These are white wires.

Normal: 100~ 110 Ω

If normal, proceed to check item 2 below. Faulty: Replace defective anti frost heater assembly.

c.Check resistance of the two heat exchanger outlet line heater elements, as shown in the

third picture to the left. Check across each heater independently.

Normal: 33 ~ 39 Ω

Faulty: Replace defective anti frost heater assembly.

2)Is the frost sensor switch operating normally ?

a.# Disconnect connector F2, and measure the resistance through this switch, measure when atmospheric temperature is 37°F + or – 3°F. (See Note) See drawing to left for location of this bimetal

switch. These are white wires to this switch. Normal: Less than 1 Ω

If normal, check wiring harness for defects. (100 volts AC)

Faulty: Replace the frost sensing bimetal switch.

Note: If the atmospheric temperature is too high, cool the switch with ice.

45

VII - GAS PRESSURE SETTING PROCEDURE

All settings/adjustments must be performed by a qualified Service Technician.

1.Turn unit off at power source and turn off the gas to the water heater.

2.Remove the front cover from the water heater.

3.Remove the gas pressure test port plug. Connect manometer to this port. (See Figure #1 for location of the test port plug.) Turn on the gas and power to the water heater.

4.Flow water through the water heater at the maximum flow rate obtainable.

5.To adjust the “Low” fire pressure, use small (pocket) common screwdriver to set combustion control dip switch #1 to the “OFF” position, switch # 7 to the “ON” position, and switch #8 to the “OFF” position (see figure #2 for location of combustion control switches.) This will put the unit into forced low fire. Check the pressure reading on your manometer. If the pressure needs adjusting, remove the rubber plug from the bottom of the water heater casing (located beneath the regulator), to access the regulator adjustment screw. Adjust the pressure to the correct setting (See figure #1 for location of the regulator adjustment screw.) Below are the proper pressures for “Low” fire, per gas type being used.

Propane

0.93” w.c. @ 11” w.c. supply

Natural

0.77” w.c. @ 7” w.c. supply

(Low fire rate of 15,000 BTU’s) (Low fire rate of 15,000 BTU’s)

6.To adjust the “High” fire pressure, use small (pocket) common screwdriver to set combustion control dip switch #1 to the “ON” position, switch # 7 to the “ON” position, and switch #8 to the “ON” position (see figure #2 for location of the combustion control switches), this will put the unit into forced high fire. Check the pressure reading on your manometer. If the pressure needs adjusting, use small (pocket) common screwdriver to adjust the high pressure “Pot”.

(See figure #2 for location of “high pressure setting pot”.)

Below are the proper pressures for “High” fire, per gas type being used.

Propane

4.2” w.c. @ 11” w.c. supply

Natural

3.7” w.c. @ 7” w.c. supply

(High fire rate of 180,000 BTU’s) (High fire rate of 180,000 BTU’s)

7.Verify both low and high fire pressures by placing the water heater into “Forced Low Fire” and “Forced High Fire” as described in steps 5 and 6 above. This completes the gas pressure setting procedure.

46

VII - GAS PRESSURE SETTING PROCEDURE

WARNING

Dip switched #7 and #8 (combustion control switches) MUST be returned to the "OFF" position, after setting pressures.

Dip switch #1 MUST be returned to the proper position based upon the length of vent pipe (see page 13).

Refer to page 12 for factory default dip switch settings.

8.Turn off the gas to the water heater. Remove the manometer connection. Reinstall the pressure port plug.

Turn on the gas to the water heater and check for gas leaks around test port with a leak solution.

9.Reinstall the front cover and place the unit back into operation.

10.Verify the proper water temperature, as set on the controller at your outlets.

If controllers are not being used the output temperature should be 120°F for residnetial models or 140˚ for commercial models.

Figure #1

Figure #2

47

VIII - Service Procedure

NOTE: Before proceeding with dismantling, be sure to follow the CAUTION instructions before each explanation. Always disconnect the electrical supply, turn off water and gas supply service valves, and drain all water from the unit before proceeding. Only trained and qualified service agencies should attempt to repair this product.

Service Procedure

IGI – 1. Removal of the Front Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 IGI – 2. Removal of the PC Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 IGI – 3. Removal of the Water Flow Control and Sensor . . . . . . . . . . . . . . . . . . . 49 IGI – 4. Removal of the Ignition Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 IGI – 5. Removal of the Combustion Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 IGI – 6. Removal of the Water Temperature Thermistor . . . . . . . . . . . . . . . . . . . 50 IGI – 7. Removal of the Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 IGI – 8. Removal of the Burner and Burner Manifold . . . . . . . . . . . . . . . . . . . . . 51 IGI – 9. Removal of the Gas Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 IGI – !0. Removal of the Heat Exchanger Assembly. . . . . . . . . . . . . . . . . . . . . . . 52 IGI – 11. Removal of the Thermal Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Re-assemblyin all tasks listed above in the reverse order of dismantling (unless stated otherwise).

48

IMPORTANT

When dismantling the unit you should always isolate the following items:

Gas supply

Electrical supply

Water supply

Drain all water from the appliance

The following diagram will be of assistance in locating the above.

IGI – 1. Removal of the Front Panel

CAUTION

120 volt potential exposure. Isolate the appliance and reconfirm power has been disconnected using a multimeter.

a.Remove the four (4) screws holding the panel in place with a Phillips driver.

IGI – 2. Removal of PC board

CAUTION

120 volt potential exposure. Isolate the appliance and reconfirm power has been disconnected using a multimeter.

a.Remove the two (2) screws holding the PCB in place with a Phillips screw driver, then pull the PC board out of the appliance.

Disconnect all connectors.

IGI – 3. Removal of the Water Flow Sensor and Water Flow Control Valve Assembly

CAUTION

120 volt potential exposure. Isolate the appliance and reconfirm power has been disconnected using a multimeter.

a.Remove one (1) Phillips screw from the heat exchanger water supply line and (1) screw from the bypass valve assembly. Lift the water line retainer up and over the housing it attaches to, pull water line towards yourself to disconnect water lines from the assembly. Inspect o-ringsfor damage, replace if defective.

49

b.Remove the four (4) Phillips screws that secure IGI – 5. Removal of the Combustion Fan: the water inlet filter housing to the unit. See

picture below for location of screws. Once

 

CAUTION

screws are removed reach into the unit and

120 volt potential exposure. Isolate the appliance and

pull up and out on the flow control assembly

reconfirm power has been disconnected using a multi-

to remove it from the appliance. Inspect o-ring

meter.

 

for damage.

 

 

 

a.

Disconnect wiring harness from fan motor.

 

b.

Remove the (2) Phillips screws that secure the

 

 

combustion fan motor to the fan housing. Pull

 

 

the fan motor assembly towards yourself to

 

 

remove it.

c.Disconnect wiring harness from assembly and remove the water flow control assembly from the unit.

IGI – 4. Removal of Ignition Module:

 

 

 

CAUTION

 

 

120 volt potential exposure. Isolate the appliance and

 

 

IGI – 6. Removal of the Water Temperature

reconfirm power has been disconnected using a multi-

meter.

 

Thermistor:

a.

Remove one (1) Phillips screw that secures the

 

CAUTION

 

sparker module to the unit casing.

120 volt potential exposure. Isolate the appliance and

 

 

reconfirm power has been disconnected using a multi-

b.

Disconnect high tension lead and connector.

meter.

 

 

 

a.

Remove the two (2) Phillips screws that secure

 

 

 

the thermistor in place to remove the water

 

 

 

outlet temperature thermistor.

50

IGI – 7. Removal of Transformer:

CAUTION

120 volt potential exposure. Isolate the appliance and reconfirm power has been disconnected using a multimeter.

a.Remove the combustion fan motor assembly as described in IGI - 5 a,b.

b.Remove the two (2) Phillips screws to release the transformer.

c.Disconnect wiring harness connectors to transformer and pull out towards you.

IGI – 8. Removal of Burner Manifold and the Burner:

CAUTION

120 volt potential exposure. Isolate the appliance and reconfirm power has been disconnected using a multimeter.

a.To remove the burner manifold, remove (6) Phillip screws around the burner plate as shown in the upper right picture.

b.Remove the (3) Phillip screws at the gas valve assembly.

c.Grip the burner manifold and remove it from the unit.

d.To remove the burner assembly remove

(8) Phillip screws around the sight glass panel. Remove this panel.

e.Locate the (2) Phillip screws inside the burner chamber that hold the burner assembly in place. Remove these two screws, grip the burner assembly and slide it out of the combustion housing.

f.If you need to remove each burner from this housing remove the (2) Phillip screws on each side of the burner, as shown below.

51

IGI – 9. Removal of the Gas Valve Assembly:

CAUTION

120 volt potential exposure. Isolate the appliance and reconfirm power has been disconnected using a multimeter.

a.Remove the burner manifold, refer to IGI - 8 a,b,c.

b.Remove the four (4) Phillips screws that hold the gas connection and gas control valve in place at the bottom of the unit. Pull the gas connection down to disconnect it from the gas valve assembly. Inspect o-ringfor damage and/or defects. Ensureo-ringis in place whenre-assemblingthis connection.

c.Disconnect connectors from solenoids, note which connector goes to each solenoid, alone with the proper wire colors. Pull gas valve assembly out of unit.

IGI – 10. Removal of Heat Exchanger:

CAUTION

120 volt potential exposure. Isolate the appliance and reconfirm power has been disconnected using a multimeter.

a.Remove PCB unit, refer to IGI - 2 a.

b.Remove the heat exchanger water connection lines, refer to IGI - 3 a.

c.Remove the three (3) Phillip screws securing the gas manifold assembly to the gas control valve.

d.Remove the six (6) Phillip screws that secure the heat exchanger assembly in place.

e.Disconnect connectors B1, B5, B6, C1, C3, F1and F8. These are the igniter, flame rod, thermo-fuse,hot water inlet and outlet thermistor, and theanti-freezeheater connections.

f.Pull the heat exchanger out of the heater.

g.Transfer all components found on the old heat exchanger over to the new exchanger.

52

IGI – 11. Removal of Thermal Fuse:

CAUTION

120 volt potential exposure. Isolate the appliance and reconfirm power has been disconnected using a multimeter.

This process may involve removing the heat exchanger if the thermo-fuseon the rear of the heat exchanger is blown.(Service Procedure IGI - 10, see page 52)

a.The unit has four thermal fuses, see picture below for location.

b.Disconnect and remove the thermal fuse. Re-installnew thermo fuse using the existing thermo fuse clips. Reconfirm inlet and manifold gas pressures are set to the proper setting. Ensure unit matches gas type being supplied to the heater.

53

IX - FLUSHING PROCEDURE FOR LIME

SCALE REMOVAL FROM HEAT EXCHANGER

The amount of calcium carbonate (lime) released from water is in direct proportion to 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 the water. This is the lime scale that forms in pipes, water heaters and on cooking utensils.

Lime accumulation reduces the efficiency and longevity of the heat exchanger coil and will cause the water heater to malfunction. The lime scale may need to be periodically removed from the heat exchanger (indicated by the "LC" code on the remote display). The usage of water softening equipment greatly reduces the hardness of the water. However, this equipment does not always remove all of the hardness (lime). The heat exchanger may occasionally need to be flushed to clear out the lime deposits. Use the following procedure and diagram to flush the heat exchanger and remove the lime scale.

1.Disconnect power to the water heater.

2.Close valves in the cold water inlet and outlet supply.

3.Connect PVC hoses (may use garden hose to the drain valve outlet fittings). Connect a circulator pump to the hose connected to the cold water inlet. See figure 11 for hose and circulator connections.

4.Pour 4 gallons of fresh vinegar into a 5 gallon bucket.

5.Place the ends of the hose into the bucket.

6.Open the drain valves to the hose fittings.

7.Turn on power to the circulating pump and allow the vinegar to circulate through the heat exchanger coil for at least 45 minutes. Heavily limed heat exchangers may require several hours.

8.Turn off power to the circulating pump.

9.Run hose from hot water outlet to a drain.

10.Close the drain valve on the cold water inlet. Leave hot

water drain valve open. Open cold water inlet to flush with fresh water.

11. Allow water to flow out of the hose for 5 minutes to flush vinegar from the water heater.

12.Shut off cold water inlet valve. Remove filter screen and clean out any sediment. Reinstall.

13.Close the hot water drain valve. Open the cold water inlet and hot water supply valves.

14.Disconnect the hoses from the drain valve connections.

15.Restore power to the water heater and check operation.

54

X - PARTS BREAKDOWN

Disassembled View - Cabinet

55

X - PARTS BREAKDOWN

Disassembled View - Internals

56

X - PARTS BREAKDOWN

Disassembled View - Internals

57

X - PARTS BREAKDOWN

Disassembled View - Electrical

58

PARTS LIST

Number

Description

Quantity

001

Casing Assembly

1

002

Wall Fitting Bracket

2

003

Rubber Bushing

1

004

Connection Reinforcement Panel

1

005

Heat Protection Plate

1

006

Front Panel

1

007

Front Panel Gasket

1

008

Front Panel Gasket – Side

2

100

Gas Control Assembly

1

101

Screw

2

102

Gas Connection (3/4" NPT)

1

103

Burner Unit Assembly

1

104

Burner Case Front

1

105

Burner Case Bottom Panel

1

106

Burner Air Orifice Plate

1

107

Bunsen Burners

16

108

Burner Case Back Panel

1

109

Damper Plate

1

110

Manifold Assembly – Natural Gas

1

110

Manifold Assembly – L.P. Gas

1

111

Upper Burner Manifold Gasket

1

112

Lower Burner Manifold Gasket

1

113

Combustion Chamber Pressure Tap Screw

1

114

Combustion Chamber Front Plate Assembly

1

115

Combustion Chamber Front Plate

1

116

Spark Ignition Electrode

1

117

Flame Sense Rod

1

118

Electrode Gasket

1

119

Electrode Holder

1

120

Upper Combustion Chamber Gasket

1

121

Combustion Chamber Pressure Tap

1

122

Pressure Tube

1

125

Combustion Blower Assembly

1

126

Blower Housing Assembly

1

127

Blower Mounting Bracket

1

128

Blower Gasket

1

129

Blower Motor

1

130

Blower Venturi Inlet Plate

1

131

Bellow Connecting Bracket/Intake Duct

1

132

Combustion Chamber Bracket

1

135

Side Air Inlet Box Assembly

1

136

Bellows Connecting Bracket/Blower

1

137

Bellows

1

138

Bellows Clamping Ring

1

139

Top Air Inlet Box Assembly

1

140

Exhaust Bracket

1

141

Exhaust Bracket Holder

2

142

Air Inlet Box Cover

1

145

Heat Exchanger – Complete Assembly

1

400

Water Inlet – _" NPT

1

401

Water Flow Servo and Sensor Assembly

1

402

Rectifier

1

403

By-passServo Assembly

1

404

Sensor Bracket

2

59

405

Bypass O-Ring

1

406

Water Filter Assembly

1

407

Filter Plug

1

408

Hot Water Outlet – _" NPT

1

409

Sensor Bracket

1

410

Small Plug Gasket

1

411

Drain Valve

1

700

PCB Board Assembly

1

701

Surge Protector

1

702

PCP Cover - Side

1

703

PCB Cover - Front

1

704

Transformer

1

705

PCB Bracket

1

706

Igniter

1

707

High Tension Lead

1

708

Spark Electrode Boot

1

709

Thermistor

2

710

Thermistor Clip - Large

1

711

Thermal Fuse Clip

5

712

Frost Sensing Switch

1

713

120v Anti-FrostHeater Assembly

1

714

Heater Connecting Harness

1

715

120v Valve Heater Assembly

1

716

Anti-FrostHeater Clip

2

717

Anti-FrostHeater Clip A

1

718

Anti-FrostHeater Clip

1

719

Inlet Air Thermistor

1

720

Power Supply Harness

1

721

Fuse Harness

1

722

100v Harness

1

723

Solenoid Valve Harness

1

724

Sensor Harness

1

725

Thermal Fuse Harness

1

726

Mold-typeLimit Switch

1

800

Screw

8

801

Screw

4

802

Washer

4

803

Screw

3

804

Screw

1

805

Screw

3

810

O-Ring

2

811

O-Ring

1

812

O-Ring

1

813

O-Ring

2

814

O-Ring

2

815

O-Ring

2

816

O-Ring

1

817

O-Ring

1

818

Gasket

2

238-44958-00

Installation and Operating Instructions

1

239-44509-00

Main Control - Residential

1

239-44510-00

Main Control - Commercial

1

239-44507-00

Bathroom Remote Temperature Control

1

239-44508-00

2nd Bathroom Remote Temperature Control

1

238-44957-00

Venting System Installation Instruction

1

Note: When ordering service replacement parts, the full model and serial numbers from the water heater nameplate are required.

60

OPTIONAL VENTING COMPONENTS

Note: When ordering service replacement parts, the full model and serial numbers from the water heater nameplate are required.

61

Notes

62

Notes

63

Ambler, PA

For U.S. and Canada field service, contact your professional installer or local Bradford White sales representative.

Sales/800-523-2931

Fax/215-641-1670

Technical Support/800-334-3393

Fax/269-795-1089

Warranty/800-531-2111

Fax/269-795-1089

International:

Telephone/215-641-9400

Telefax/215-641-9750

Fax on Demand:

888-538-7833www.bradfordwhite.com

Mississauga, ON

Sales/866-690-0961

905-238-0100

Fax/905-238-0105

Technical Support/800-334-3393

Email parts@bradfordwhite.com techserv@bradfordwhite.com

www.bradfordwhite.com

www.bradfordwhitecanada.com