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

 

1

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

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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"

 

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