Bradford White Everhot IGI-180C-5N Service Manual Download Page 1

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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-180R-10(N,X)

IGI-180C-5(N,X)

Manual 45095A

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Summary of Contents for Everhot IGI-180C-5N

Page 1: ...shooting 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 M...

Page 2: ...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...

Page 3: ...f 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 Char...

Page 4: ...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...

Page 5: ...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 flo...

Page 6: ...d 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 F...

Page 7: ...I GENERAL INFORMATION cont CUT AWAY ILLUSTRATION 7...

Page 8: ...I GENERAL INFORMATION cont SCHEMATIC ILLUSTRATION 8...

Page 9: ...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 E...

Page 10: ...ti 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 featu...

Page 11: ...Injector Diameter Upper 037 95mm 029 75mm Inches mm Lower 062 1 6mm 045 1 15mm Main Burner B3A7 1 Lean and Rich Bunsen Burner Main Damper H73 115 Upper 6 Lower Not used Gas Pressure Minimum supply 6 W...

Page 12: ...as 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...

Page 13: ...e 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 52...

Page 14: ...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 v...

Page 15: ...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 assembl...

Page 16: ...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 t...

Page 17: ...ure 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 Fa...

Page 18: ...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 deactiv...

Page 19: ...ve 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 flow...

Page 20: ...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...

Page 21: ...V SEQUENCE OF OPERATION cont Operation Sequence Flow Chart 21...

Page 22: ...V SEQUENCE OF OPERATION cont Operation Sequence Flow Chart 22...

Page 23: ...V SEQUENCE OF OPERATION cont Sequence Timing Chart 23...

Page 24: ...V SEQUENCE OF OPERATION cont Sequence Timing Chart 24...

Page 25: ...wer supply for proper voltage and voltage drops Disconnect all MSA controls Disconnect keypad Disconnect and re connect all wiring harnesses on unit and PC board Ensure proper venting material was ins...

Page 26: ...d 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...

Page 27: ...0 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 Gea...

Page 28: ...temperatures and resistance reading at those temperatures Example 59 F 11 4 14K 86 F 6 4 7 8K 113 F 3 6 4 5K 140 F 2 2 2 7K 221 F 0 6 0 8K Outgoing Water Thermistor White White N A See example above B...

Page 29: ...s 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 30...

Page 31: ...Check for short circuits 1 Measure resistance of each solenoid valve Remove connector E from the PCB before measuring Pink Black SV0 1 7 2 1K Yellow Black SV1 1 7 2 1K Brown Black SV2 1 7 2 1K See pag...

Page 32: ...de 72 displayed on the digital monitor 2 Check flame rod Measure resistance between flame rod terminal C1 and earth See page 38 Resistance 1M Yes No Replace PCB Replace flame rod IGI 2 Error code 32 d...

Page 33: ...nector E from the PCB Measure resistance between yellow black of SV1 2 Measure voltage between yellow black of SV1 connector See page 40 1 7 2 1K 80 100 VDC Yes No Yes No Go to B 7 2 Replace gas valve...

Page 34: ...eck changeover solenoid valve SV3 1 Disconnect connector E from PCB and measure the resistance between brown black 2 Measure the voltage between brown black wire of the changeover solenoid valve SV3 a...

Page 35: ...2 Read resistance of the heating element that is mounted on the front of the heat exchanger white wires See page 45 3 Read resistance of heating elements on the heat exchanger outlet hot water line Se...

Page 36: ...amp glass fuse If the fuse blows again investigate cause of short circuit Check the transformer a Measure the voltage and or resistance at connector F black white wires Normal 100 120 VAC 51 63 resist...

Page 37: ...rt before replacing the remote control Faulty Replace PCB Service Procedure IGI 2 page 49 Check the water flow sensor a Check the voltage at PCB connector B4 red and black wires Normal 11 13 VDC or 5...

Page 38: ...lace the flame rod Service Procedure IGI 2 page 49 See page 42 for additional information and resistance values pertaining to the flame rod If error 32 is displayed check the water temperature thermis...

Page 39: ...DC or 9 9 4 K 33 400 Hz If normal proceed to check item 5 below Faulty Replace the combustion fan motor Service Procedure IGI 5 page 50 4 Is the combustion fan motor normal 5 Is the ignition module op...

Page 40: ...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 If error...

Page 41: ...d terminals Normal 1 7 2 1 K 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...

Page 42: ...e 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 ea...

Page 43: ...em 2 below Faulty Replace the water temperature thermistor Service Procedure IGI 6 page 50 a Disconnect the changeover solenoid SV1 connector and measure resistance at the solenoid terminals Normal 1...

Page 44: ...o 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 I...

Page 45: ...cation of this element These are white wires Normal 100 110 If normal proceed to check item 2 below Faulty Replace defective anti frost heater assembly c Check resistance of the two heat exchanger out...

Page 46: ...djust 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...

Page 47: ...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...

Page 48: ...I 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...

Page 49: ...appliance and reconfirm power has been disconnected using a multi meter 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 Disc...

Page 50: ...Phillips screw that secures the sparker module to the unit casing b Disconnect high tension lead and connector IGI 5 Removal of the Combustion Fan CAUTION 120 volt potential exposure Isolate the appl...

Page 51: ...has been disconnected using a multi meter 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 v...

Page 52: ...ith 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 usin...

Page 53: ...ger if the thermo fuse on 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 ther...

Page 54: ...r 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 connecte...

Page 55: ...55 X PARTS BREAKDOWN Disassembled View Cabinet...

Page 56: ...X PARTS BREAKDOWN Disassembled View Internals 56...

Page 57: ...X PARTS BREAKDOWN Disassembled View Internals 57...

Page 58: ...X PARTS BREAKDOWN Disassembled View Electrical 58...

Page 59: ...er 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...

Page 60: ...Heater 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 type Lim...

Page 61: ...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: ...62 Notes...

Page 63: ...63 Notes...

Page 64: ...50 Ambler PA 888 538 7833 Fax on Demand bradfordwhite com www For U S and Canada field service contact your professional installer or local Bradford White sales representative Sales 866 690 0961 905 2...

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