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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)
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Manual 45095A
1
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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 instruct
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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.
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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
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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
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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 speci
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I - GENERAL INFORMATION (cont.) CUT-AWAY ILLUSTRATION 7
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I - GENERAL INFORMATION (cont.) SCHEMATIC ILLUSTRATION 8
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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
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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-metal switch Thermal fuse 264°F Automatic frost protection - Bimetal sensor & anti-frost heaters 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-scald fe
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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(Lean and 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.
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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 #
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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 adjuste
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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 degre
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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 fr
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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-purge period 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
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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 Al
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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
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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
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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-purge cycle allowing the burner to re-light immediately when a hot water tap is opened a
