Bradford White IGI-180R-10 Service Manual
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Bradford White IGI-180R-10 Service Manual

Tankless gas water heater
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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)
Save this manual for future reference
Manual 45095A
1

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Summary of Contents for Bradford White IGI-180R-10

  • Page 1: Troubleshooting Guide

    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) Save this manual for future reference Manual 45095A...
  • Page 2 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Section Description Page - - - Glossary of Terms and Symbols......4 I.

  • Page 4: Glossary Of Terms And Symbols

    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 direct current alternating current WFCD water flow control device feedback information hertz integrated circuit...

  • Page 5: General Information

    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.

  • Page 6: How To Use This Manual

    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"...

  • Page 7: Cut Away Illustration

    I - GENERAL INFORMATION (cont.) CUT-AWAY ILLUSTRATION...

  • Page 8: Schematic Illustration

    I - GENERAL INFORMATION (cont.) SCHEMATIC ILLUSTRATION...
  • Page 9 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...

  • Page 10: Specifications (General)

    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 &...

  • Page 11: Combustion Specifications

    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...

  • Page 12: Default Dip Switch Settings

    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...
  • Page 13 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.

  • Page 14: Venting Table

    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.

  • Page 15: Main Components

    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.
  • Page 16 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.

  • Page 17: Safety Device Function

    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.
  • Page 18 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.

  • Page 19: Sequence Of Operation

    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).
  • Page 20 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.

  • Page 21: Operation Sequence Flow Chart

    V - SEQUENCE OF OPERATION (cont.) Operation Sequence Flow Chart...
  • Page 22 V - SEQUENCE OF OPERATION (cont.) Operation Sequence Flow Chart...

  • Page 23: Sequence Timing Chart

    V - SEQUENCE OF OPERATION (cont.) Sequence Timing Chart...
  • Page 24 V - SEQUENCE OF OPERATION (cont.) Sequence Timing Chart...

  • Page 25: Troubleshooting (Error Messages)

    VI - TROUBLESHOOTING Error Messages Error Faulty Remedy 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.
  • Page 26 VI - TROUBLESHOOTING (cont.) Error Messages Error Faulty Remedy Outgoing Water Check sensor wiring for damage. Temperature Check resistance onsensor. Sensor Faulty Check and clean dirt from sensor. Replace sensor. Heat Exchanger Check sensor wiring for damage. Outgoing Check resistance on sensor. Temperature Check and clean dirt from sensor.

  • Page 27: Quick Reference Diagnostic Points

    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.
  • Page 28 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.

  • Page 29: Wiring Diagram

    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.
  • Page 30 Wiring Schematic...

  • Page 31: Troubleshooting Flow Chart

    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 Action Procedure A. The LED on 1. Do you have Power source Do you have 120 Go to A –...
  • Page 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 Action Procedure 2. Measure the voltage Are values within Go to A – (7) at connector F with those specified at appliance power supply...
  • Page 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 Action Procedure Error code "11" 5. Check ignition 1. Measure voltage 90 ~ 110 VAC Go to B-5-2 displayed on...
  • Page 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 Action Procedure C. Combustion 1. Check flame rod. 1. Measure the voltage 5 ~ 150 VAC Go to C-1-2 occurs, but flame...
  • Page 35 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 Action Procedure 2. Measure voltage 11 ~ 13 VDC Go to 4-3 between orange (+) and Replace PCB IGI –...

  • Page 36: Troubleshooting Procedure

    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 Check fuse.
  • Page 37 VI - TROUBLESHOOTING (cont.) 3) Is the remote control normal ? Check voltage between the two remote control cable connectors. Check the voltage between terminals on the remote control terminal mount D Normal: 11 ~ 13 VDC If normal, check for an open circuit or short before replacing the remote control.
  • Page 38 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. # Detach the flame rod terminal C1, and re-attempt operation.
  • Page 39 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. 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.
  • Page 40 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.
  • Page 41 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). # Disconnect the changeover solenoid (SV3) connector, and measure the resistance at the solenoid terminals.
  • Page 42 VI - TROUBLESHOOTING (cont.) BEFORE CARRYING OUT CHECKS MARKED WITH A # SIGN, DISCONNECT THE POWER SUPPLY. Error code “14” Check the thermal fuse. # Disconnect connector B3 and C3, measure the resistance between the red – red wires. Normal: Less than 1 Ω If normal, check b below.
  • Page 43 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 ? # Disconnect the connector B5, and measure the resistance between the white wires, see below for resistance readings.
  • Page 44 BEFORE CARRYING OUT CHECKS MARKED WITH A # SIGN, DISCONNECT THE POWER SUPPLY. 3) Is the modulating valve operating normally ? Error code 52 # Disconnect the modulating valve festoon C2 terminals and measure the resistance at the terminals. Normal: 67 ~ 81 Ω If normal, check b.
  • Page 45 BEFORE CARRYING OUT CHECKS MARKED WITH A # SIGN, DISCONNECT THE POWER SUPPLY. Anti-frost heaters do not operate 1) Are the ceramic anti-frost heaters operating normally ? # Disconnect connector F4, and measure the resistance of the heater mounted in the water flow control valve, these are white wires.

  • Page 46: Gas Pressure Setting Procedure

    VII - GAS PRESSURE SETTING PROCEDURE All settings/adjustments must be performed by a qualified Service Technician. Turn unit off at power source and turn off the gas to the water heater. Remove the front cover from the water heater. 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.
  • Page 47 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.

  • Page 48: Service Procedures

    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.

  • Page 49: Igi - 1. Removal Of The Front Panel

    IGI – 2. Removal of PC board IMPORTANT CAUTION When dismantling the unit you should always isolate 120 volt potential exposure. Isolate the appliance and the following items: reconfirm power has been disconnected using a multi- • Gas supply meter. •...

  • Page 50: Igi - 4. Removal Of The Ignition Module

    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.

  • Page 51: Igi - 7. Removal Of The Transformer

    IGI – 7. Removal of Transformer: CAUTION 120 volt potential exposure. Isolate the appliance and reconfirm power has been disconnected using a multi- meter. Remove the combustion fan motor assembly as described in IGI - 5 a,b. Remove the two (2) Phillips screws to release the transformer.

  • Page 52: Igi - 9. Removal Of The Gas Valve Assembly

    IGI – 9. Removal of the Gas Valve Assembly: Remove the heat exchanger water connection lines, refer to IGI - 3 a. CAUTION Remove the three (3) Phillip screws securing 120 volt potential exposure. Isolate the appliance and the gas manifold assembly to the gas control reconfirm power has been disconnected using a multi- valve.

  • Page 53: Igi - 11. Removal Of The Thermal Fuse

    IGI – 11. Removal of Thermal Fuse: The unit has four thermal fuses, see picture below for location. CAUTION Disconnect and remove the thermal fuse. 120 volt potential exposure. Isolate the appliance and Re-install new thermo fuse using the existing reconfirm power has been disconnected using a multi- thermo fuse clips.

  • Page 54: Flushing Procedure For Lime Scale Removal

    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.

  • Page 55: Parts Breakdown

    X - PARTS BREAKDOWN Disassembled View - Cabinet...
  • Page 56 X - PARTS BREAKDOWN Disassembled View - Internals...
  • Page 57 X - PARTS BREAKDOWN Disassembled View - Internals...
  • Page 58 X - PARTS BREAKDOWN Disassembled View - Electrical...

  • Page 59: Parts List

    PARTS LIST Number Description Quantity Casing Assembly Wall Fitting Bracket Rubber Bushing Connection Reinforcement Panel Heat Protection Plate Front Panel Front Panel Gasket Front Panel Gasket – Side Gas Control Assembly Screw Gas Connection (3/4" NPT) Burner Unit Assembly Burner Case Front Burner Case Bottom Panel Burner Air Orifice Plate Bunsen Burners...
  • Page 60 Bypass O-Ring Water Filter Assembly Filter Plug Hot Water Outlet – _" NPT Sensor Bracket Small Plug Gasket Drain Valve PCB Board Assembly Surge Protector PCP Cover - Side PCB Cover - Front Transformer PCB Bracket Igniter High Tension Lead Spark Electrode Boot Thermistor Thermistor Clip - Large...
  • Page 61 OPTIONAL VENTING COMPONENTS Note: When ordering service replacement parts, the full model and serial numbers from the water heater nameplate are required.
  • Page 62 Notes...
  • Page 63 Notes...
  • Page 64 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: 888-538-7833 www. 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...

This manual is also suitable for:

Igi-180c-5Everhot igi-180r-10nEverhot igi-180c-5nEverhot igi-180r-10xEverhot igi-180c-5x

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