Bradford White Everhot IGI-180R10 User manual

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SERVICE
MANUAL
Tankless Gas Water Heater
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-180 -10(N,X) IGI-180C-5(N,X)
Manual 45095A Save this manual for future reference

ey 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.
isconnect power supply to unit when carrying out the following service repairs.
Read Fault iagnosis and Wiring iagram carefully to avoid incorrect wiring.
o 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.
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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 way 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
efer to installation and operation manual for the following reference information:
• General Dimensions
• Piping Recommendations
• Remote Control Features
• Water Flow Rates vs Temperature
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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, “ ” 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.
• 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°F for residential models or 96-180˚F for 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-freeze heaters 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 equired for Troubleshooting
Multifunction Digital Testmeter with needle point test leads.
Long reach (12") Magnetic Phillips screw driver (#2 Tip)
3/16 llen wrench
Small (pocket size) blade screw driver
Monometer or Magnehelic inches water column gage
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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 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.
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I - GENERAL INFORMATION (cont.)
CUT-AWAY ILLUST ATION
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I - GENERAL INFORMATION (cont.)
SCHEMATIC ILLUST ATION
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II - SPECIFICATIONS - GENE AL
Model type ESIDENTIAL COMME CIAL
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
pproved 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 ( )
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
nti-frost protection 100 watts
Water temperature control Simulation feedforward and feedback.
Water flow control Water flow sensor, electronic water control
device, and electronic by-pass control device
Recommended Minimum water
supply pressure 20 PSI (recommend 50-80 PSI for maximum performance)
Maximum water supply pressure 150 PSI

II - SPECIFICATIONS - GENE AL
Safety devices ppliance - C 120 Volts - 60Hz. 15 - 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
utomatic 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 feature.
Remote control cable Non-polarized two 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/ ir Intake 0"
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