Bradford White BRADFORD WHITE EVERHOT TG-237I-N(X)A Service manual

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)
Manual 45095A
Save this manual for
future reference
1
IGI-180C-5(N,X)
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)
DC
AC
WFCD
FB
Hz
IC
BTU/H
PSI
LED
GPM
mA
W.C.
mm
NOx
OHS
PCB
CPU
POT
rpm
SV
Ø
∆°F
POV
TE
TH
TIN
Tout
-
sound pressure level in decibels, “A” range
direct current
alternating current
water flow control device
feedback information
hertz
integrated circuit
British thermal units per hour
Pounds per square inch
light emitting diode
gallons per minute
milliamps
inches of water column
millimeters
oxides of nitrogen NO & NO2
overheat switch
printed circuit board
central processing unit
potentiometer
revolutions per minute
solenoid valve
diameter
delta T or temperature rise above ambient
modulating valve
thermal efficiency
thermistor
temperature of incoming water
temperature of outgoing water
4
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°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 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-AWAY ILLUSTRATION
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
(Input BTU's)
180,000 BTU's - 15,000 BTU's Natural Gas
180,000 BTU's - 15,000 BTU's Propane Gas
Hot water capacity,
(50°F rise)
0.5 to 6.5 GPM
Setpoint Temperature
(without remote)
Factory setting - 120°F
Factory setting - 140°F
Temperature range
(with remote)
MC controller : 96 - 160°F
BC controller : 96 - 120°F
BSC controller : 96 - 120°F
MCC controller : 96-180°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-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
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-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 feature.
Remote control cable
Non-polarized two core cable or low voltage thermostat wire
Clearances from combustibles
Top of heater 6"
Front of heater 6"
Sides of heater 2"
Back of heater 0"
Floor 12"
Vent/Air Intake 0"
10
(12" min. recomended for service)
(24" min. recomended for service)
II - SPECIFICATIONS - COMBUSTION
Item
Gas type
Gas consumption
Minimum Btu’s
Maximum Btu’s
Upper
Lower
Injector Diameter
Inches (mm)
Main Burner
Main Damper
Gas Pressure
Supply/Manifold
Minimum supply
Maximum supply
Low Fire manifold
High Fire manifold
Natural
Propane
15,000
15,000
180,000
180,000
Ø.037 (.95mm)
Ø.029 (.75mm)
Ø.062 (1.6mm)
Ø.045 (1.15mm)
B3A7-1(Lean and Rich Bunsen Burner)
H73-115, Upper: Ø6, Lower: (Not used)
6" W.C.
10" W.C.
10.5" W.C.
13.5" W.C.
0.77” W.C
0.93” W.C
3.7” W.C
4.2” W.C
11
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
Dip Switch Settings:
(SW1)
#1 = Off
#2 = On
#3 = Off
#4 = Off
#5 = Off
#6 = Off
#7 = Off
#8 = Off
(SW2)
#1 = On
#2 = Off
#3 = Off
#4 = Off
Propane Gas
Dip Switch Settings:
(SW1)
(SW2)
#1 = Off
#1 = Off
#2 = On
#2 = Off
#3 = Off
#3 = Off
#4 = Off
#4 = Off
#5 = Off
#6 = Off
#7 = Off
#8 = Off
FACTORY DEFAULT SETTING, COMMERCIAL UNITS
Natural Gas
Dip Switch Settings:
(SW1)
(SW2)
#1 = Off
#1 = On
#2 = On
#2 = Off
#3 = Off
#3 = Off
#4 = Off
#4 = On
#5 = Off
#6 = Off
#7 = Off
#8 = Off
Propane Gas
Dip Switch Settings:
(SW1)
(SW2)
#1 = Off
#1 = Off
#2 = On
#2 = Off
#3 = Off
#3 = Off
#4 = Off
#4 = On
#5 = Off
#6 = Off
#7 = Off
#8 = Off
See page 13 for special dip switch settings base on vent length.
12
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 adjusted
to compensate for the venting system distance.
When the Total Equivalent Length of vent pipe is more than 22 feet (6.7 m), leave the Dip Switch Number 1 in
the OFF position. This is the factory Dip Switch setting.
When the Total Equivalent Length of vent pipe is 22 feet (6.7 m) or less, Dip Switch Number 1
must be moved to the ON position.
Dip Switch #1 is located in the top row of dip switches, 1 through 8 on the PC board. See 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 (800-523-2931) or Technical Service
(800-334-3393 x3634) for assistance. Use the following examples and the previous discussion on calculating
the equivalent vent length to determine the correct setting for Dip Switch #1.
Example #1:
Dip Switch Settings (Fig. 8)
You have 6 feet (1.82 m) of vent pipe and two 90˚ elbows.
D = 6 + (2 x 6) + (0 x 1.5)
D = 18 feet (5.49 m) of equivalent vent pipe
Dip Switch #1 should be moved to ON position.
Example #2:
You have 15 feet (4.57 m) of vent pipe, one 90˚ elbow, and two 45˚ elbows.
D = 15 + (1 x 6) + (2 x 1.5)
D = 24 feet (7.3 m) of equivalent vent pipe
Leave Dip Switch #1 in the OFF position (factory setting).
WARNING
Do not alter Dip Switch #1 before using the formula and venting charts to determine the equivalent vent
length. All other dip switches with the exception of Dip Switch #1 shown in the illustration MUST NOT be
altered. Unauthorized adjustments can cause property damage, personal injury, scalding, or death.
13
II - SPECIFICATIONS (cont.)
VENTING TABLE
Venting Table – Examples of Maximum Venting Distances with Various Elbow Combinations
Maximum Straight
Pipe Distance
35 Ft. (10.7 m)
29 Ft. (8.8 m)
23 Ft. (7.0 m)
17 Ft. (5.2 m)
33.5 Ft. (10.2 m)
32 Ft. (9.8 m)
27.5 Ft. (8.4 m)
Number of
90 degree elbows
Number of
45 degree elbows
1
2
3
4
1
1
2
1
2
1
Maximum Total
Equivalent Feet
(meters) of Vent Pipe
41 (12.5 m)
41 (12.5 m)
41 (12.5 m)
41 (12.5 m)
41 (12.5 m)
41 (12.5 m)
41 (12.5 m)
NOTICE
Each 90 degree elbow is equivalent to 6 feet 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 venting distance. The maximum vertical height
for through the roof venting cannot exceed 21 feet (6.4 m). A condensate collector must be used if
the venting system height is more than 5 feet (1.52 m) above the water heater.
14
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 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 assembly.
4. Gas Control Valve
The gas control valve uses four solenoids to fully modulate within four different input ranges to
respond quickly and accurately to changes in water flow rate. The four ranges are as follows: up to
18% of total btu’s (using three burners), up to 33% (using five burners), up to 50% (using eight
burners, and up to 100% (using sixteen burners) This increases the flexibility of the regulator/
modulating valve by supplying gas equally to each burners.
15
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 (4) pulses per rotation of the fan. This is
the fan feedback or confirmation data processed by the PCB.
The fan speed is constantly correcting to provide optimum combustion conditions. In addition, the
fan speed will determine the opening degree of the modulating gas valve. This enables the gas rate to
always match the volume of air for combustion, as well as the input required to heat the 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 the PCB by generating a pre-determined number of
pulses in proportion to the water flow. These pulses are counted by the PCB – no pulse indicates no
water flow. The frequency of the magnetic pulses increases as the water flow increases, this enables
the PCB to calculate the exact water flow, and determine the water flow in gallons per minute. As
soon as the required water flow is detected, the PCB activates the combustion fan. The combustion
fan speed is monitored by a magnetic pulse sensor. The output from this sensor is processed by the
PCB which opens the gas modulating valve to a degree proportional to the fan speed. See above for
further details on the combustion fan.
The water flow control consists of a plug and barrel valve which is rotated by a motor to increase or
decrease the volume of water passing through the heat exchanger.
Automatic water flow control device.
16
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
Also referred to as an Over Heat Switch. This device is fitted to a bend section at the inlet to the heat
exchanger. If the flame remains on to the burner after the tap is closed and the water temperature
inside the heat exchanger reaches 194 ° F, a 12 volt DC bi-metal cut-off switch will shut off the gas
supply to the solenoids.
No Water
Should the incoming water flow become restricted or stop, the water flow sensor will cease to send a
magnetic pulse signal to the PCB, in turn preventing gas to flow into the combustion chamber. If you
have restricted flow, first check to ensure the inline water filter is not clogged.
Thermal Fuse (Non-Resettable)
Wrapped around the entire surface of the heat exchanger you will find a thermal fuse. This device
activates in the event of excessive heat echanger temperatures, or the temperature 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 Fan Revolution Check
The combustion fan rpm’s are continually monitored by a magnetic pulse generator connected to the
PCB. If the fan revolutions deviate from the speed required for complete combustion, a signal is sent
to the PCB and the revolutions adjust accordingly. (If not the unit deactivates)
Automatic Frost Protection
When the temperature inside the appliance drops below 37°F , the frost sensing device inside the
appliance activates the anti-frost heaters to prevent the water inside the unit from freezing. The antifrost heaters remain ON until the temperature inside the appliance rises to 57°F. There are four (16)
watt anti-frost heaters located at various points throughout the main water flow area of the appliance.
The unit also incorporates the ability to fire for (3) seconds in the event the anti-frost heaters can not
keep the water temperature from dropping below 37°F. This unique feature will heat the water in the
lines inside the appliance back up to 57°F. Both of the above features function as long as the unit
has power and gas. There is an optional freeze protection system that can be added to the unit’s
piping. Refer to the auto drain down diagram in the product installation instructions for instructions
on how to install the optional freeze protection in the event of a power failure.
17
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
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 appliance from starting in “High fire” and producing very hot water the first
time it is used.
The data used to determine the outgoing water temperature, initially, is incoming water flow and the
remote control pre-set temperature.
From the incoming water flow and remote control pre-set temperature data, the CPU is able to
determine a suitable gas rate to initiate appliance operation once a hot water tap opens.
The calculation of temperature rise and water flow is called simulation feed-forward.
The water heater calculates incoming water temperature by subtracting the theoretical temperature
rise from the outgoing hot water temperature to establish the correct gas flow.
When a hot water tap is opened, water begins to flow through the water heater. The turbine in the
water flow sensor begins to revolve. 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 flowing, and also, the volume of water flowing. When a
predetermined water flow is sensed, the ignition sequence begins.
The combustion fan pre-purges the combustion chamber. A rev counter on the combustion fan
indicates the fan rpm to the main PCB. When the pre-purge cycle is completed, the PCB controls the
fan rpm by varying the DC voltage to the fan motor. This maintains the correct air/gas ratio
throughout the time the water heater is in use and ensures proper combustion.
The gas is ignited by direct spark and the flame is sensed by the flame rod. The opening degree of
the modulating valve is determined by the combustion fan speed.
The changeover valve directs gas to one side or both sides of the burner. At the point where the
changeover valve opens or closes the modulating valve is instantly re-adjusted by the PCB to
compensate for the change in the number of burners in use. From the information provided by the
water flow sensor and the water temperature thermistor, the PCB determines how much gas is
required to heat the water to the temperature selected on the remote control.
The PCB is programmed to provide the maximum volume of water possible at a given temperature
rise. As the water flow from the tap is increased, the PCB increases the gas and air flow to the burner.
19
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 again.
20
V - SEQUENCE OF OPERATION (cont.)
Operation Sequence Flow Chart
21
V - SEQUENCE OF OPERATION (cont.)
Operation Sequence Flow Chart
22
V - SEQUENCE OF OPERATION (cont.)
Sequence Timing Chart
23
V - SEQUENCE OF OPERATION (cont.)
Sequence Timing Chart
24
VI - TROUBLESHOOTING
Error Messages
Error
Faulty
Remedy
10
Air Supply
or Exhaust
Blockage
Check all vent components for proper connections.
Check that nothing is blocking the flue inlet or exhaust.
Ensure proper venting materials were used.
Ensure condensation collar was installed correctly.
Verify dip switches are set properly.
11
No Ignition
Ensure you have gas to the appliance.
Ensure gas type and pressure is correct.
Bleed all air from gas lines.
Verify dip switches are set properly.
Disconnect all MSA controls.
Ensure gas line, meter, and/or regulator is sized properly.
Ensure appliance is properly grounded.
Check gas solenoid valves for open or short circuits.
Ensure igniter is operational.
Check igniter wiring harness for damage.
Remove burner cover and ensure all burners are properly seated.
Remove burner plate and inspect burner surface for condensation or debris.
12
Flame Failure
Ensure you have gas to the appliance.
Ensure gas type and pressure is correct.
Bleed all air from gas lines.
Verify dip switches are set properly.
Ensure flame rod wire is connected.
Check flame rod for carbon build-up.
Ensure gas line, meter, and/or regulator is sized properly.
Ensure appliance is properly grounded.
Check gas solenoid valves for open or short circuits.
Check power supply for loose connections.
Check power 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 installed.
Ensure condensation collar was installed properly.
Ensure maximum vertical vent length does not exceed 21 ft. and three 90˚ elbows.
Ensure maximum horizontal vent length does not exceed 41equivalent feet and three
90˚ elbows.
Immediate code 12 is usually a defective gas valve, power supply problem, or defective
fan motor wiring harness.
Remove burner plate and inspect burner surface for condensation or debris.
14
Thermo Fuse
Ensure dip switches are set to the proper position.
Ensure high fire and low fire manifold pressure is correct.
Check gas type of unit and ensure it matches gas type being used.
Check heat exchanger for cracks and/or separations.
Check resistance on safety circuit.
Check for improper conversion of product.
Check for restrictions in air flow around unit and vent terminal.
Check for a low flow circulating system that is causing the unit to short cycle.
Check for foreign materials in combustion chamber and/or exhaust piping.
16
Over
Temperature
Warning
Check for clogged heat exchanger.
Check for restrictions in air flow around unit and vent terminal.
Check for a low flow circulating system that is causing the unit to short cycle.
Check for foreign materials in combustion chamber and/or exhaust piping.
25
VI - TROUBLESHOOTING (cont.)
Error Messages
Error
Faulty
Remedy
32
Outgoing Water
Temperature
Sensor Faulty
Check sensor wiring for damage.
Check resistance onsensor.
Check and clean dirt from sensor.
Replace sensor.
33
Heat Exchanger
Outgoing
Temperature
Sensor Faulty
Check sensor wiring for damage.
Check resistance on sensor.
Check and clean dirt from sensor.
Replace sensor.
34
Combustion Air
Temperature
Sensor Faulty
Check sensor wiring for damage.
Check resistance on sensor.
Check and clean dirt from sensor.
Clean blower blades, if dirty.
Ensure fan blade is tight on motor shaft and it is in good condition.
Check for restrictions in air flow around unit and vent terminal.
Replace sensor.
52
Modulating
Solenoid
Valve Signal
Abnormal
Check modulating gas solenoid valve wiring harness for loose or damage terminals.
Check resistance on solenoid valve.
61
Combustion
Fan Failure
Ensure fan motor will turn freely. Motor will operate with a small amount of resistance.
Check wiring harness to motor for damaged and/or loose connections.
Check resistance on motor winding.
71
SV0, SV1,
SV2, and SV3
Solenoid Valve
Circuit Faulty
Check wiring harness to all solenoids for damage and/or loose connections.
Check resistance on each solenoid.
72
Flame Sensing
Device Faulty
Check micro amps produced by flame rod.
Remove flame rod and check for carbon build-up, clean with sand paper.
Ensure flame rod is touching flame when unit fires.
Check inside burner chamber for any foreign material blocking flame at flame rod.
Check all wiring to flame rod for damage.
Replace flame rod.
LC
Scale Build-up
in Heat
Exchanger
Turn off power supply, then reapply power;
if code reappear separate control wires from the unit’s power supply.
Flush heat exchanger.
Replace heat exchanger.
No code
Nothing happens Clean inlet water supply filter.
when water flow Ensure you have at least the minimum flow rate required to fire unit.
is activated.
Check for pipe dope inside water flow control turbine.
On new installations ensure hot and cold water lines are not crossed.
Check for bleed over. Isolate unit from building by turning off hot water line to building,
then open your pressure relief valve. If unit fires, there’s a bleed over in your plumbing.
If a circulating system is in use, it must be isolated also.
Remote control does not light up but you have 12 VDC at the terminals for controls.
Disconnect water flow control motor, then turn on hot water, if unit fires replace water
flow control assembly.
Check resistance on the water flow control sensor.
26
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.
Remember, before checking for resistance readings, you should disconnect the power source
(unplug it) to the unit and isolate the item to be checked from the circuit.
(TR) Transformer:
Wire color
Black ~ White
Blue ~ Brown
Voltage
100 ~ 120 VAC
110 ~ 120 VAC
Resistance
51 ~ 63 ohms
51 ~ 63 ohms
Connector #
F9
F7
(SV0, SV1, SV2, SV3 and POV) Gas valve and Modulating solenoids: (Set meter above 2K)
(SV0) Pink ~ Black
80 ~ 100 VDC
1,8K ~ 2K ohms
E1
(SV1) Black ~ Yellow
80 ~ 100 VDC
1,8K ~ 2K ohms
E2
(SV2) Black ~ Blue
80 ~ 100 VDC
1,8K ~ 2K ohms
E3
(SV3) Black ~ Brown
80 ~ 100 VDC
1,8K ~ 2K ohms
E4
(POV) Pink ~ Pink
2 ~ 15 VDC
67 ~ 81 ohms
C2
Pin #’s
1~2
1~3
1~2
2~3
2~4
2~5
3~4
(M) Water Flow Control Device Servo or Geared Motor:
Red ~ Blue
11 ~ 13 VDC
22 ~ 26 ohms
B2
9 ~ 10
Grey ~ Brown
4 ~ 6 VDC
N/A
B2
5~7
Grey ~ Yellow
N/A
N/A
B2
5~8
Grey ~ Orange
11 ~ 14 VDC
N/A
B2
5~6
NOTE: The grey wire listed above turns to black at B connector on the PCB, the orange wire turns to red.
(QS) Water Flow Sensor:
Black ~ Red
Yellow ~ Black
11 ~13 VDC
4 ~ 7 VDC
5.5K ~ 6.2K
1 meg ~ 1.4 meg
B4
B4
5~6
1~5
2 ~ 6 VDC
Unit in operating
mode
15 ~ 35K
G4 ~ G5
G2 ~ G5
G1 ~ G5
G3 ~ G5
4~5
2~5
1~5
3~5
(IG) Ignition System:
Grey ~ Grey
90 ~ 100 VAC
N/A
F8
2~3
(FM) Combustion Fan Motor:
Red ~ Black
White ~ Black
Yellow ~ Black
6 ~ 45 VDC
6 ~ 45 VDC
11 ~ 13 VDC 3
N/A
9.2K ~ 9.4K
.5K ~ 3.9K
A1
A1
A1
1~2
2~4
2~3
By-pass Flow Control:
Brown ~ White
Orange ~ White
Yellow ~ White
Red ~ White Gnd
Set your meter to the Hertz scale. Reading across the red and yellow wires at terminals 2 and 3 you should
read between 60 and 350 Hertz.
27
VI - TROUBLESHOOTING (cont.)
Thermal Fuse:
Wire color
Red ~ Red
Voltage
100 VAC
Resistance
Below 1 ohm
Connector #
B~C
Pin #’s
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. With the unit running
you should read between 5 ~ 150 VAC. Set your meter to the µ amp scale, series your meter in line
with the flame rod. You should read1µ or greater for proper flame circuit. In the event of low flame
circuit remove the flame rod and check for carbon and/or damage.
Heat Exchanger, Air Temperature, and Outgoing Water Temperature Thermistors:
Check all thermistors by inserting meter leads into each end of the thermistor plug. Set your meter to
the 20K scale and read resistance. You should be able to apply heat to the thermistor bulb and see
the resistance decrease. Then apply some ice to the thermistor and the resistance should increase.
See below for examples of temperatures and resistance reading at those temperatures.
Example:
Outgoing Water Thermistor:
White ~ White
59ºF = 11.4 ~ 14K
86ºF = 6.4 ~ 7.8K
113ºF = 3.6 ~ 4.5K
140ºF = 2.2 ~ 2.7K
221ºF = 0.6 ~ 0.8K
N/A
See example above
B4
B3 ~ B4
Heat Exchanger Temperature Thermistor:
White ~ Pink
N/A
See example above
B5
B3 ~ B12
Air Temperature Thermistor:
White ~ Orange
N/A
see example above
B1
B2 ~ B11
Surge Protector:
Black ~ White
Blue ~ Brown
108 ~ 132 VAC
108 ~ 132 VAC
N/A
N/A
Surge Protector D1
Surge Protector D2
1~3
1~2
Remote Controls:
Terminals D1
10 ~ 13 VDC digital
1.5K ~ 1.9K ohms
H
1~3
Frost Protection:
This unit has four frost protection heaters mounted at different points inside the unit to protect the
water heater from freeze ups. There are two heaters located on the outlet hot water line next to the
thermistor. Using a voltage meter set on the 200 ohm scale, you should have a resistance reading of
26 ~ 30 ohms through each of these heaters. The heater located on the heat exchanger piping
should have a resistance reading of 81 ~ 86 ohms and the one located in the water flow sensor valve
has a resistance reading of 16 ~ 19 ohms. Voltage throughout this circuit should be 120 VAC.
28
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.
Wiring Diagram
29
Wiring Schematic
30
VI - TROUBLESHOOTING (cont.)
Troubleshooting Flow Chart
BEFORE CARRYING OUT CHECKS MARKED WITH
A # SIGN, DISCONNECT THE POWER SUPPLY.
Nature of Fault
A. The LED on
the remote
control does not
light up, when
the system is
powered up
Examination
Point
1. Do you have
voltage to the unit?
2. Is supply voltage
correct?
3. Check surge
protector.
4. Check both 3
amp electrical fuses.
5. Check for short
circuits.
6. Check to ensure
you have 120 VAC
across both
terminals feeding
the surge protector.
Diagnostic Point
Values
Power source
Y/N
Action
Do you have 120
VAC at the power
supply?
Yes
Go to A – (2)
No
Plug in cord
120 VAC
Yes
Go to A – (3)
No
Check power
supply circuit.
Check fuses.
Do you have 120
volts AC across the
blue and brown
wires at the surge
protector?
Yes
Go to A – (4)
No
Go to A – (5)
# Disconnect and
measure resistance to
confirm if fuse is blown.
Normal < than 1 MΩ
Is fuse blown?
Yes
Go to A – (5)
replace fuse
Go to A – (6)
1. Measure resistance of
each solenoid valve. #
Remove connector E
from the PCB before
measuring.
Pink ~ Black (SV0)
1.7 ~ 2.1KΩ
Yellow ~ Black (SV1)
1.7 ~ 2.1KΩ
Brown ~ Black (SV2)
1.7 ~ 2.1KΩ
(See page 40)
1. Measure the
resistance.
# Disconnect sparker
connector F8 and
measure the resistance
between both terminals.
(See page 39)
3. Check wiring.
Are valves within
those specified at
left? # Measure
after checking that
there are no broken
wires or shorts.
Measure voltage at
power point.
Inspect visually
1. Measure voltage at
the blue and brown
wires.
No
Go to
A – (6) - 2
No
Replace gas
valve.
Is resistance >1MΩ ? Yes
Are there any
shorts?
100 ~ 120 VAC
31
Yes
Service
Procedure
IGI – 9
Go to
A (5 – 3)
No
Replace
sparker.
Yes
Rectify
/Replace
No
Replace PCB
Yes
Go to A (6 – 2)
No
Check for
proper voltage
to unit.
IGI – 4
IGI – 2
VI - TROUBLESHOOTING (cont.)
Troubleshooting Flow Chart
BEFORE CARRYING OUT CHECKS MARKED WITH
A # SIGN, DISCONNECT THE POWER SUPPLY.
Nature of Fault
Examination
Point
Diagnostic Point
Values
Action
Are values within
those specified at
left.
Yes
Go to A – (7)
No
Replace
transformer
11 ~ 13 VDC Digital
Yes
1. Measure voltage
between red ~ black of
connector B4.
(See page 37)
2. Measure voltage
between yellow ~ black
at connector B4.
(See page 37)
11 ~ 13 VDC
No
Yes
No
Check cable
for shorts or
broken wires.
Replace
remote
control.
Replace PCB.
Go to B–1-2
Replace PCB.
4 ~ 7 VDC
Yes
No
Go to B - 2
Replace water
flow sensor.
2. Measure the voltage
at connector F with
appliance power supply
on.
7. Check remotes (s)
(where connected.)
Y/N
F – Black ~ White
100 ~ 120 VAC
F7 – Blue ~ Brown
100 ~ 120 VAC
Measure voltage
between remote control
terminals at D.
Service
Procedure
IGI – 7
IGI – 2
B. Digital monitor
lights up, but
combustion does
not commence.
(when remotes
are connected).
1. Check water flow
sensor.
Error code "72"
displayed on the
digital monitor.
2. Check flame rod
# Measure resistance
between flame rod
terminal C1 and earth.
(See page 38)
Resistance > 1MΩ?
Yes
No
Replace PCB
Replace flame
rod
IGI – 2
Error code "32"
displayed on the
digital monitor.
3. Check outgoing
water temperature
thermistor.
# Disconnect connector
B5 and measure
resistance.
Open circuit: > 1MΩ
Short circuit: < 1Ω
(See page 38)
Are values as shown
at left?
Yes
IGI – 6
No
Replace water
temperature
thermistor.
Go to B - 4
1. Check motor.
Measure voltage
between black ~ red at
connector A1.
(See page 39)
2. Check fan rotation
sensor. Measure voltage
between black ~ yellow
at connector A1.
(See page 39)
6 ~ 45 VDC (Fan on)
0 VDC (Fan off)
Yes
No
Go to B – 5-2
Replace PCB
IGI – 2
11 ~ 13 VDC
Yes
No
Go to B – 4-3
Replace PCB
IGI – 2
3. Measure voltage
between black ~ white
of connector A1.
(See page 39)
6 ~ 45 VDC
Yes
No
Go to B – 5
Replace fan
IGI – 5
Error code "61"
displayed on the
digital monitor.
4. Check
combustion fan.
32
IGI – 2
IGI – 3
VI - TROUBLESHOOTING (cont.)
Troubleshooting Flow Chart
BEFORE CARRYING OUT CHECKS MARKED WITH
A # SIGN, DISCONNECT THE POWER SUPPLY.
Nature of Fault
Error code "11"
displayed on
digital monitor.
Examination
Point
5. Check ignition
module.
Values
1. Measure voltage
between grey ~ grey of
connector F8 (sparker).
(See page 39)
2. # Remove connector
F8 and measure the
resistance between
sparker and terminals.
(See page 39)
3. Check if unit is
sparking.
6. Check main gas
solenoid valve (SV0)
Error code 71
7. Check solenoid
valve (SV1)
8. Check
changeover solenoid
valve (SV2)
Error code "14"
displayed on
digital monitor
Diagnostic Point
9. Check thermal
fuse
10. Check overheat
(remaining flame) bimetal switch
90 ~ 110 VAC
Y/N
Action
Yes
Go to B-5-2
No
Replace PCB
Is resistance >
1MΩ?
Yes
No
Go to B-5-3
Adjust/
Replace
ignition
module
Is the ignition
module sparking?
Yes
Go to B-6
No
Adjust/
Replace
electrode
Go to B-6-2
1. # Disconnect the main
solenoid valve connector
E from the PCB, and
measure the resistance
between pink ~ black
(SV0)
1.7 ~ 2.1KΩ
2. Measure voltage
between pink ~ black of
SV0 connector.
(See page 40)
Yes
Service
Procedure
IG2 – 2
IGI – 4
No
Replace gas
valve
80 ~ 100 VDC
Yes
No
Go to B-7
Replace PCB
1. # Disconnect
connector E from the
PCB. Measure resistance
between yellow ~ black
of (SV1).
1.7 ~ 2.1KΩ
Yes
Go to B-7-2
No
Replace gas
valve
2. Measure voltage
between yellow ~ black
of SV1 connector.
(See page 40)
80 ~ 100 VDC
Yes
No
Go to B-8
Replace PCB
1. # Disconnect
connector E from the
PCB. And measure
resistance between blue
~ black (SV2)
1.7 ~ 2.1KΩ
Yes
Go to B-8-2
No
Replace gas
valve
2. Measure the voltage
between blue ~ black or
SV2 connector.
(See page 40)
80 ~ 100 VDC
Yes
No
Go to B-9
Replace PCB
IGI – 2
1. # Disconnect
connector B3 and C3
measure resistance
between red ~ red.
2. # Disconnect OHS
(remaining flame) bimetal switch festoon
terminal B3 and C3, and
measure resistance
between terminal on
switch. (See page 42)
Is resistance < 1Ω?
Yes
No
Go to B-10
Replace
thermal fuse
IGI – 11
Yes
Replace PCB
IGI – 2
No
Replace
remaining
flame bi-metal
switch
33
Is resistance < 1Ω?
IGI – 9
IGI – 2
IGI – 9
IGI – 2
IGI – 9
VI - TROUBLESHOOTING (cont.)
Troubleshooting Flow Chart
BEFORE CARRYING OUT CHECKS MARKED WITH
A # SIGN, DISCONNECT THE POWER SUPPLY.
Nature of Fault
C. Combustion
occurs, but flame
fails.
Error code "12"
displayed on
digital monitor.
Examination
Point
1. Check flame rod.
2. Check ground
wire.
Diagnostic Point
Values
Y/N
1. Measure the voltage
between flame rod
terminal C1 and
appliance ground.
2. Check to ensure flame
rod bracket is not loose.
5 ~ 150 VAC
Yes
No
Go to C-1-2
Replace PCB
Is it secure?
Yes
No
Go to C-2
Replace/
rectify
Check for faulty ground
wire connections at unit,
receptacle, and ground
rod to home, and for
broken or shorted wires.
Are connections
OK?
Yes
Check for
other causes
of flame
failure.
Replace or
repair
grounding
circuit to unit.
No
D. Cannot adjust
water
temperature.
Action
1. Check hot water
thermistor.
(outgoing
thermistor)
# Disconnect connector
B5 and measure the
resistance between
white ~ white.
(See page 43)
Resistance values
match table on page
#43
Yes
No
Go to D – 2
Replace water
temperature
thermistor.
2. Check
changeover solenoid
valve (SV3).
1. # Disconnect
connector E from PCB
and measure the
resistance between
brown ~ black.
1.7 ~ 2.1KΩ
Yes
No
Go to D – 2-2
Replace
manifold
assembly
2. Measure the voltage
between brown ~ black
wire of the changeover
solenoid valve (SV3) at
connector E.
(See page 41)
80 ~ 100 VDC
Yes
No
Go to D – 3
Replace PCB
1. # Disconnect
modulating valve at C2
festoon terminal and
measure resistance at
solenoid terminals.
(See page 44)
2. Measure the voltage
between two harness
terminals at C2.
(See page 44)
3. Check whether the
manifold pressure alters
when remote control
temperature is altered
between 96° ~ 140°F.
1, # Measure resistance
between red ~ blue
wires of the water flow
servo connector B2.
(See page 44)
67 ~ 81Ω
Yes
No
Go to D – 3-2
replace gas
valve
2 ~ 15 VDC
Yes
No
Go to D – 3-3
Replace PCB
Does the manifold
pressure change?
Yes
No
Go to D – 4
Replace gas
valve
22 ~ 26Ω
Yes
No
Go to D – 4-2
Replace water
flow servo
sensor.
3. Check
modulating valve.
4. Check water flowservo.
34
Service
Procedure
IGI – 2
IGI – 6
IGI – 8
IGI – 2
IGI – 9
IGI – 2
IGI – 9
IGI – 3
VI - TROUBLESHOOTING (cont.)
Troubleshooting Flow Chart
BEFORE CARRYING OUT CHECKS MARKED WITH
A # SIGN, DISCONNECT THE POWER SUPPLY.
Nature of Fault
Examination
Point
Diagnostic Point
Values
2. Measure voltage
between orange (+) and
grey (-) of the water flow
servo connector B2.
3. Measure voltage
between brown ~ grey
of water flow servo
connector B2 (Don not
turn water on)
(See page 44)
4. Measure voltage
between yellow ~ grey
of the water flow servo
connector B2 (Do not
turn water on)
(See page 44)
E. Anti-frost
heater does not
work.
1. check anti-frost
heater.
2. Check frost
sensing switch
Y/N
Action
Yes
No
Go to 4-3
Replace PCB
Yes
No
Go to D-4-4
Replace water
flow servo
sensor.
4 ~ 6 VDC
Yes
No
Normal
Replace water
flow servo
sensor.
1. # Disconnect
connector F4 and F5
measure resistance
across each of the
heating elements. (white
wires)
(See page 45)
348 ~ 375Ω
Yes
No
Go to E-1-2
Replace Antifrost sensing
switch.
2. # Read resistance of
the heating element that
is mounted on the front
of the heat exchanger.
(white wires)
(See page 45)
100 ~ 110Ω
Yes
No
Go to E-2
Replace Antifrost heater
that is
defective.
3. Read resistance of
heating elements on the
heat exchanger outlet
hot water line.
(See page 45)
33 ~ 39Ω
Yes
No
Go to E-2
Replace Antifrost heater
that is
defective.
# Disconnect connector
F2 and measure across
the bi-metal sensing
switch located on the
upper right hand of the
heat exchanger. check
this switch at
temperatures below 37
°F. You can place an ice
cube against the switch
to activate it.
(See page 45)
Is resistance <1Ω
after applying ice to
this switch for five
minutes?
Yes
No
Check wiring
Replace Antifrost sensing
switch.
35
11 ~ 13 VDC
4 ~ 6 VDC
Service
Procedure
IGI – 2
IGI – 3
IGI – 3
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.
a.
Disconnect unit from power supply.
b.
# Measure resistance to check the electric fuse
(3 amp)
Fuses are located in plastic
holders in the main harness,
Normal: less than 1Ω
on the lower right hand side
If normal, proceed to check item 2 below.
of the appliance.
Faulty: Replace 3 amp glass fuse. If the fuse
blows again, investigate cause of short circuit.
2) Is the main transformer normal?
Check the transformer.
a.
Measure the voltage and/or resistance at
connector F, black ~ white wires.
Normal: 100 ~ 120 VAC
51 ~ 63 Ω resistance
Faulty: Check for 120 ~ 125 VAC at the surge
protector, blue ~ brown wires, connector
F7.
Resistance reading 51 ~ 63 Ω
If normal, check item 3 on next page.
Faulty: Replace the transformer.
(Service Procedure IGI-7, page 51)
36
VI - TROUBLESHOOTING (cont.)
3) Is the remote control normal ?
Check voltage between the two remote control cable
connectors.
a.
Check the voltage between terminals on the
remote control terminal mount D1.
Normal: 11 ~ 13 VDC
If normal, check for an open circuit or short before
replacing the remote control.
Faulty: Replace PCB.
(Service Procedure IGI-2, page 49)
No combustion (despite remote control indication)
1) Is the water flow sensor normal ?
Check the water flow sensor.
a.
Check the voltage at PCB connector B4 , red and
black wires.
Normal: 11 ~ 13 VDC or 5.8 ~ 6.4K Ω
If normal, check (b) below.
Faulty: Replace the PCB.
(Service Procedure IGI-2, page 49)
b.
Check the voltage at PCB connector B4, yellow and
black wires.
Normal: 4 ~ 7 VDC or 1M ~ 1.2M Ω.
If normal, proceed to check item 2 on next page.
Faulty: Replace the water flow sensor.
(Service Procedure IGI-2, page 49)
37
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.
a.
# Detach the flame rod terminal C1, and re-attempt
operation.
(“72 is displayed)
Proceed to check item 3 below.
(no “72” displayed)
Inspect flame rod wiring for current leak and inspect
flame rod for carbon build-up.
Measure resistance between the flame rod
Terminal C1 and the appliance earth.
Normal: 1 M Ω or more.
If normal, replace the PCB unit.
Faulty: Replace the flame rod.
(Service Procedure IGI-2, page 49)
See page 42 for additional information and resistance values
pertaining to the flame rod.
3) Is the water temperature thermistor normal?
If error “32” is displayed, check the water
temperature thermistor.
a.
# Disconnect connector B5, and measure resistance of
the white ~ white wires.
Resistance > 1 M Ω = open circuit.
Resistance < 1 Ω = short circuit.
Normal: Proceed to check item 4 on the next page.
Faulty: Replace the water temperature thermistor.
(Service Procedure IGI-6, page 50)
See page 43 for additional information and
resistance readings pertaining to the
temperature themistor.
38
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.
a.
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.
Faulty: Replace the PCB unit.
(Service Procedure IGI-2, page 49)
Fan revolution sensor check.
b.
Measure voltage at connector A1, black and yellow wires.
Normal: 11 ~ 13 VDC or 3.1 ~ 3.7 K Ω
If normal, check item c below.
Faulty: Replace the PCB unit.
(Service Procedure IGI-2, page 49)
c.
Measure voltage at connector A1, black and white wires.
Normal: 6 ~ 45 VDC or 9 ~ 9.4 K Ω
(33 ~ 400 Hz.)
If normal, proceed to check item 5 below.
Faulty: Replace the combustion fan motor.
(Service Procedure IGI-5, page 50)
5) Is the ignition module operating normally ?
.
Check the sparker module.
a.
Measure voltage at connector F8, grey and grey wires.
Normal: 90 ~ 110 VAC
0 VDC (when fan is off)
If normal, check b below.
Faulty: Replace the PCB unit.
(Service Procedure IGI-2, page 49)
b.
# Disconnect connector F8, and measure the
resistance between the two sparker terminals.
Normal: > 1 M Ω
Faulty: Replace the igniter module.
(Service Procedure IGI-5, page 50)
Electrode gap should be 3/16” to 1/4" .
39
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.
a.
# Disconnect the main gas solenoid valve (SV0)
connector and measure the resistance at the solenoid
terminals.
Normal: 1.7 ~ 2.1 K Ω
If normal, check b below.
Faulty: Replace gas valve.
(Service Procedure IGI-9, page 52)
b.
Measure voltage at the main gas solenoid (SV0)
Pink and black wires.
Normal: 80 ~ 100 VDC
If normal, proceed to check item 7 below.
Faulty: Replace PCB unit.
(Service Procedure IGI-2, page 49)
7) Is the change over solenoid (SV1) operating normally ?
If error “11” or “71” is displayed, check the change over
solenoid (SV1).
a.
# Disconnect the change over solenoid (SV1)
connector, and measure resistance at the solenoid
terminals.
Normal: 1.7 ~ 2.1 K Ω
If normal, check b below.
Faulty: Replace the gas valve.
(Service 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)
8) Is the change over solenoid (SV2) operating normally?
If error “11” or “71” is displayed, check the change over
solenoid (SV2).
a.
# Disconnect the changeover solenoid (SV2) connector,
and measure the resistance at the solenoid terminals.
Normal: 1.7 – 2.1 K Ω
If normal, check b below.
Faulty: Replace the gas valve.
(Service Procedure IGI-9, page 52)
b.
Measure the voltage at the changeover solenoid (SV2),
blue – black wires.
Normal: 80 – 100 VDC
If normal, check 9, on next page.
Faulty: Replace the PCB unit.
(Service Procedure IGI-2, page 49)
40
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).
a.
# Disconnect the changeover solenoid (SV3)
connector, and measure the resistance at the
solenoid terminals.
Normal: 1.7 – 2.1 K Ω
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: 80 – 100 VDC
If normal, reconfirm gas pressures are correct.
Faulty: Replace the PCB unit.
(Service Procedure IGI-2, page 49)
41
VI - TROUBLESHOOTING (cont.)
BEFORE CARRYING OUT CHECKS MARKED WITH A # SIGN, DISCONNECT THE POWER SUPPLY.
Error code “14” Check the thermal fuse.
a.
# Disconnect connector B3 and C3, measure the
resistance between the red – red wires.
Normal: Less than 1 Ω
If normal, check b below.
Faulty: Check manifold gas pressure. Check heat
exchanger for cracks and/or separations. If there is
nothing abnormal, replace the thermal fuse.
(Service Procedure IGI-11, page 53)
b.
Check bi-metal switch, (remaining flame safety
device). Measure resistance between the two
terminals at B3 and C3.
Normal: Less than 1 Ω
If normal, process to item a below.
Faulty: Replace the bi-metal switch.
Combustion stops due to flame failure
1) Is the flame rod functioning normally?
a.
Measure the voltage between the flame rod
terminal C1 and the appliance earth.
Normal: 5 – 150 VAC from yellow to ground.
If normal, check b below.
Faulty: Replace the PCB unit.
(Service Procedure IGI-2, page 49)
Check that the flame rod attachment is not loose.
Normal: Replace the PCB unit.
(Service Procedure IGI-2, page 49)
Faulty: Secure the flame rod bracket.
b.
2) Is the earth lead wire connected?
a.
Check for defective earth terminal, or an open
circuit or short. If normal, investigate other
possible causes for the flame failure.
(Eg. Is the gas valve open ? Is the filter mesh
blocked ?) Was proper venting material used?
Did you regulate your gas supply pressure 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 earth and a copper lead tied to the service
meter. Ensure connection on ground rod is tight.
42
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 ?
a.
# Disconnect the connector B5, and measure the
resistance between the white wires, see below
for resistance readings.
Thermistor resistance valves:
59 ºF = 11.4 ~ 14 K Ω
86 ºF = 6.4 ~ 7.8 K Ω
113 ºF = 3.6 ~ 4.5 K Ω
140 ºF = 2.2 ~ 2.7 K Ω
221 ºF = 0.6 ~ 0.8 Ω
Normal: Proceed to check item 2 below.
Faulty: Replace the water temperature
thermistor.
(Service Procedure IGI-6, page 50)
2) Is the change over solenoid (SV1) normal ?
a.
# Disconnect the changeover solenoid (SV1)
connector, and measure resistance at the
solenoid terminals.
Normal: 1.7 ~ 2.1 K Ω
If normal, proceed to b.
Faulty: Replace the gas valve.
(Service Procedure IGI-9, page 52)
b.
Measure the voltage at the changeover solenoid
(SV1) yellow ~ black wires.
Normal: 80 ~ 100 VDC
If normal, proceed to check item 3, on next
page.
Faulty: Replace the PCB unit.
(Service Procedure IGI-2, page 49)
43
BEFORE CARRYING OUT CHECKS MARKED WITH A # SIGN, DISCONNECT THE POWER SUPPLY.
3) Is the modulating valve operating normally ? Error code 52
a.
# Disconnect the modulating valve festoon C2
terminals and measure the resistance at the terminals.
Normal: 67 ~ 81 Ω
If normal, check b.
Faulty: Replace gas valve.
(Service Procedure IGI-9, page 52)
b.
Re-connect terminal C2 and measure voltage
across the pink ~ pink wires when the unit is
firing.
Normal: 2 ~ 15 VDC
If normal, check c below.
Faulty: Replace the PCB unit.
(Service Procedure IGI-2, page 49)
c.
Investigate the change in the manifold gas
pressure, when the remote control pre-set
temperature is altered from 96 ~ 140 ºF.
Normal: If the manifold pressure changes,
proceed to check item 4 below. DO NOT
adjust manifold pressures.
Faulty: Replace gas valve.
(Service Procedure IGI-9, page 52)
4) Is the water flow servo normal ?
a.
# Disconnect connector B2 and measure the
resistance of the water flow servo, red ~ blue wires.
b.
c.
d.
Normal: 22 ~ 26 Ω
If normal, proceed to b.
Faulty: Replace the water flow servo and sensor.
(Service Procedure IGI-2, page 49)
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
If normal, proceed to c.
Faulty: Replace the PCB unit.
(Service Procedure IGI-2, page 49)
With connector B2 , connected (do not turn water
ON … wait for the water flow servo to return to
fully open), measure the voltage at the brown ~
grey wires.
Normal: 4 ~ 6 VDC vent limiter OFF
Faulty: Replace the water flow servo and
sensor. (Service Procedure IGI-2, page 49)
With connector B2 , connected (do not turn
water ON… wait for the water flow servo to
return to fully open), measure the voltage at the
yellow ~ grey wires.
Normal: Less than 0.5 VDC when unit is set at
120 °F and there is no water flowing through the unit.
Faulty: Replace water flow servo and sensor.
(Service Procedure IGI-2, page 49)
44
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 ?
a.
# Disconnect connector F4, and measure the
resistance of the heater mounted in the water
flow control valve, these are white wires.
Disconnect connector F5, and measure the
resistance of the heater in the outlet line
connector See connectors in the first and second
picture t o the left.
Normal: 348 ~ 375 Ω
If normal, proceed to b.
Faulty: Replace defective element.
b.
# Take an ohm meter and read resistance across
the heater on the face of the heat exchanger. The
resistance across this element is listed below. See
third picture to the left for location of this element.
These are white wires.
Normal: 100 ~ 110 Ω
If normal, proceed to check item 2 below.
Faulty: Replace defective anti frost heater
assembly.
Check resistance of the two heat exchanger
outlet line heater elements, as shown in the
third picture to the left. Check across each heater
independently.
Normal: 33 ~ 39 Ω
Faulty: Replace defective anti frost heater
assembly.
c.
2) Is the frost sensor switch operating normally ?
a.
# Disconnect connector F2, and measure the
resistance through this switch, measure when
atmospheric temperature is 37°F + or – 3°F. (See Note)
See drawing to left for location of this bimetal
switch. These are white wires to this switch.
Normal: Less than 1 Ω
If normal, check wiring harness for defects.
(100 volts AC)
Faulty: Replace the frost sensing bimetal switch.
Note: If the atmospheric temperature is too high,
cool the switch with ice.
45
VII - GAS PRESSURE SETTING PROCEDURE
All settings/adjustments must be performed
by a qualified Service Technician.
1.
Turn unit off at power source and turn off the gas to the water heater.
2.
Remove the front cover from the water heater.
3.
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.
4.
Flow water through the water heater at the maximum flow rate obtainable.
5.
To adjust the “Low” fire pressure, use small (pocket) common screwdriver to set combustion
control dip switch #1 to the “OFF” position, switch # 7 to the “ON” position, and switch #8 to
the “OFF” position (see figure #2 for location of combustion control switches.) This will put the
unit into forced low fire. Check the pressure reading on your manometer. If the pressure needs
adjusting, remove the rubber plug from the bottom of the water heater casing (located beneath
the regulator), to access the regulator adjustment screw. Adjust 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
Natural
6.
(Low fire rate of 15,000 BTU’s)
(Low fire rate of 15,000 BTU’s)
To adjust the “High” fire pressure, use small (pocket) common screwdriver to set combustion
control dip switch #1 to the “ON” position, switch # 7 to the “ON” position, and switch #8 to
the “ON” position (see figure #2 for location of the combustion control switches), this will put
the unit into forced high fire. Check the pressure reading on your manometer. If the pressure
needs adjusting, use small (pocket) common screwdriver to adjust the high pressure “Pot”.
(See figure #2 for location of “high pressure setting pot”.)
Below are the proper pressures for “High” fire, per gas type being used.
Propane
Natural
7.
0.93” w.c. @ 11” w.c. supply
0.77” w.c. @ 7” w.c. supply
4.2” w.c. @ 11” w.c. supply
3.7” w.c. @ 7” w.c. supply
(High fire rate of 180,000 BTU’s)
(High fire rate of 180,000 BTU’s)
Verify both low and high fire pressures by placing the water heater into “Forced Low Fire” and
“Forced High Fire” as described in steps 5 and 6 above. This completes the gas pressure
setting procedure.
46
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.
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 test port with a leak
solution.
9.
Reinstall the front cover and place the unit back into operation.
10.
Verify the proper water temperature, as set on the controller at your outlets.
If controllers are not being used the output temperature should be 120°F for residnetial
models or 140˚ for commercial models.
Figure #1
Figure #2
47
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.
Service Procedure
IGI – 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
IGI – 6. Removal of the Water Temperature Thermistor . . . . . . . . . . . . . . . . . . . 50
IGI – 7. Removal of the Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
IGI – 8. Removal of the Burner and Burner Manifold . . . . . . . . . . . . . . . . . . . . . 51
IGI – 9. Removal of the Gas Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
IGI – !0. Removal of the Heat Exchanger Assembly. . . . . . . . . . . . . . . . . . . . . . . 52
IGI – 11. Removal of the Thermal Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Re-assembly in all tasks listed above in the reverse order of dismantling (unless stated otherwise).
48
IMPORTANT
IGI – 2. Removal of PC board
When dismantling the unit you should always isolate
the following items:
• Gas supply
• Electrical supply
• Water supply
• Drain all water from the appliance
CAUTION
120 volt potential exposure. Isolate the appliance and
reconfirm power has been disconnected using a multimeter.
a.
The following diagram will be of assistance in
locating the above.
IGI – 1. Removal of the Front Panel
Remove the two (2) screws holding the PCB in
place with a Phillips screw driver, then pull the
PC board out of the appliance.
Disconnect all connectors.
IGI – 3. Removal of the Water Flow Sensor and
Water Flow Control Valve Assembly
CAUTION
CAUTION
120
volt
potential
exposure.
Isolate the appliance and
120 volt potential exposure. Isolate the appliance and
reconfirm
power
has
been
disconnected
using a multireconfirm power has been disconnected using a multimeter.
meter.
a.
Remove the four (4) screws holding the
panel in place with a Phillips driver.
a.
49
Remove one (1) Phillips screw from the heat
exchanger water supply line and (1) screw from
the bypass valve assembly. Lift the water line
retainer up and over the housing it attaches
to, pull water line towards yourself to
disconnect water lines from the assembly.
Inspect o-rings for damage, replace if
defective.
b.
c.
Remove the four (4) Phillips screws that secure
the water inlet filter housing to the unit. See
picture below for location of screws. Once
screws are removed reach into the unit and
pull up and out on the flow control assembly
to remove it from the appliance. Inspect o-ring
for damage.
IGI – 5. Removal of the Combustion Fan:
CAUTION
120 volt potential exposure. Isolate the appliance and
reconfirm power has been disconnected using a multimeter.
a.
Disconnect wiring harness from fan motor.
b.
Remove the (2) Phillips screws that secure the
combustion fan motor to the fan housing. Pull
the fan motor assembly towards yourself to
remove it.
Disconnect wiring harness from assembly and
remove the water flow control assembly from
the unit.
IGI – 4. Removal of Ignition Module:
CAUTION
120 volt potential exposure. Isolate the appliance and
reconfirm power has been disconnected using a multi- IGI – 6. Removal of the Water Temperature
meter.
Thermistor:
a.
b.
Remove one (1) Phillips screw that secures the
CAUTION
sparker module to the unit casing.
120 volt potential exposure. Isolate the appliance and
reconfirm power has been disconnected using a multiDisconnect high tension lead and connector.
meter.
a.
50
Remove the two (2) Phillips screws that secure
the thermistor in place to remove the water
outlet temperature thermistor.
IGI – 7. Removal of Transformer:
CAUTION
120 volt potential exposure. Isolate the appliance and
reconfirm power has been disconnected using a multimeter.
a.
b.
c.
Remove the combustion fan motor assembly
as described in IGI - 5 a,b.
Remove the two (2) Phillips screws to release
the transformer.
Disconnect wiring harness connectors to
transformer and pull out towards you.
d.
e.
To remove the burner assembly remove
(8) Phillip screws around the sight glass
panel. Remove this panel.
Locate the (2) Phillip screws inside the
burner chamber that hold the burner
assembly in place. Remove these two
screws, grip the burner assembly and
slide it out of the combustion housing.
IGI – 8. Removal of Burner Manifold and the Burner:
CAUTION
120 volt potential exposure. Isolate the appliance and
reconfirm power has been disconnected using a multimeter.
a.
b.
c.
To remove the burner manifold, remove (6)
Phillip screws around the burner plate as
shown in the upper right picture.
Remove the (3) Phillip screws at the gas valve
assembly.
Grip the burner manifold and remove it from
the unit.
f.
51
If you need to remove each burner from
this housing remove the (2) Phillip screws
on each side of the burner, as shown
below.
IGI – 9. Removal of the Gas Valve Assembly:
b.
CAUTION
c.
120 volt potential exposure. Isolate the appliance and
reconfirm power has been disconnected using a multimeter.
d.
a.
b.
Remove the burner manifold, refer to
e.
IGI - 8 a,b,c.
Remove the four (4) Phillips screws that hold
the gas connection and gas control valve in
place at the bottom of the unit. Pull the gas
connection down to disconnect it from the gas
valve assembly. Inspect o-ring for damage
and/or defects. Ensure o-ring is in place when
re-assembling this connection.
f.
g.
c.
Disconnect connectors from solenoids, note
which connector goes to each solenoid, alone
with 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 using a multimeter.
a.
Remove PCB unit, refer to IGI - 2 a.
52
Remove the heat exchanger water connection
lines, refer to IGI - 3 a.
Remove the three (3) Phillip screws securing
the gas manifold assembly to the gas control
valve.
Remove the six (6) Phillip screws that secure
the heat exchanger assembly in place.
Disconnect connectors B1, B5, B6, C1, C3,
F1and F8. These are the igniter, flame rod,
thermo-fuse, hot water inlet and outlet
thermistor, and the anti-freeze heater
connections.
Pull the heat exchanger out of the heater.
Transfer all components found on the old heat
exchanger over to the new exchanger.
IGI – 11. Removal of Thermal Fuse:
a.
CAUTION
b.
120 volt potential exposure. Isolate the appliance and
reconfirm power has been disconnected using a multimeter.
This process may involve removing the heat exchanger
if the thermo-fuse on the rear of the heat exchanger is
blown. (Service Procedure IGI - 10, see page 52)
53
The unit has four thermal fuses, see picture
below for location.
Disconnect and remove the thermal fuse.
Re-install new thermo fuse using the existing
thermo fuse clips. Reconfirm inlet and
manifold gas pressures are set to the proper
setting. Ensure unit matches gas type being
supplied to the heater.
IX - 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. This is the lime scale that forms in pipes,
water heaters and on cooking utensils.
Lime accumulation reduces the efficiency and longevity of the heat exchanger coil and will cause the water
heater to malfunction. The lime scale may need to be periodically removed from the heat exchanger (indicated
by the "LC" code on the remote display). The usage of water softening equipment greatly reduces the
hardness of the water. However, this equipment does not always remove all of the hardness (lime). The heat
exchanger may occasionally need to be flushed to clear out the lime deposits. Use the following procedure
and diagram to flush the heat exchanger and remove the lime scale.
1. Disconnect power 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 connected to the cold water inlet. See figure 11 for hose and circulator connections.
4. Pour 4 gallons of fresh vinegar into a 5 gallon bucket.
5. Place the ends of the hose into the bucket.
6. Open the drain valves to the hose fittings.
7. Turn on power to the circulating pump and allow the vinegar to circulate through the heat exchanger coil for
at least 45 minutes. Heavily limed heat exchangers may require several hours.
8. Turn off power to the circulating pump.
9. Run hose from hot water outlet to a drain.
10. Close the drain valve on the cold water inlet. Leave hot
water drain valve open. Open cold water inlet to flush with
fresh water.
11. Allow water to flow out of the hose for 5 minutes to flush
vinegar from the water heater.
12. Shut off cold water inlet valve. Remove filter screen and
clean out any sediment. Reinstall.
13. Close the hot water drain valve. Open the cold water inlet
and hot water supply valves.
14. Disconnect the hoses from the drain valve connections.
15. Restore power to the water heater and check operation.
54
X - PARTS BREAKDOWN
Disassembled View - Cabinet
55
X - PARTS BREAKDOWN
Disassembled View - Internals
56
X - PARTS BREAKDOWN
Disassembled View - Internals
57
X - PARTS BREAKDOWN
Disassembled View - Electrical
58
PARTS LIST
Number
001
002
003
004
005
006
007
008
100
101
102
103
104
105
106
107
108
109
110
110
111
112
113
114
115
116
117
118
119
120
121
122
125
126
127
128
129
130
131
132
135
136
137
138
139
140
141
142
145
400
401
402
403
404
Description
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
Burner Case Back Panel
Damper Plate
Manifold Assembly – Natural Gas
Manifold Assembly – L.P. Gas
Upper Burner Manifold Gasket
Lower Burner Manifold Gasket
Combustion Chamber Pressure Tap Screw
Combustion Chamber Front Plate Assembly
Combustion Chamber Front Plate
Spark Ignition Electrode
Flame Sense Rod
Electrode Gasket
Electrode Holder
Upper Combustion Chamber Gasket
Combustion Chamber Pressure Tap
Pressure Tube
Combustion Blower Assembly
Blower Housing Assembly
Blower Mounting Bracket
Blower Gasket
Blower Motor
Blower Venturi Inlet Plate
Bellow Connecting Bracket/Intake Duct
Combustion Chamber Bracket
Side Air Inlet Box Assembly
Bellows Connecting Bracket/Blower
Bellows
Bellows Clamping Ring
Top Air Inlet Box Assembly
Exhaust Bracket
Exhaust Bracket Holder
Air Inlet Box Cover
Heat Exchanger – Complete Assembly
Water Inlet – _" NPT
Water Flow Servo and Sensor Assembly
Rectifier
By-pass Servo Assembly
Sensor Bracket
59
Quantity
1
2
1
1
1
1
1
2
1
2
1
1
1
1
1
16
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
2
405
Bypass O-Ring
406
Water Filter Assembly
407
Filter Plug
408
Hot Water Outlet – _" NPT
409
Sensor Bracket
410
Small Plug Gasket
411
Drain Valve
700
PCB Board Assembly
701
Surge Protector
702
PCP Cover - Side
703
PCB Cover - Front
704
Transformer
705
PCB Bracket
706
Igniter
707
High Tension Lead
708
Spark Electrode Boot
709
Thermistor
710
Thermistor Clip - Large
711
Thermal Fuse Clip
712
Frost Sensing Switch
713
120v Anti-Frost Heater Assembly
714
Heater Connecting Harness
715
120v Valve Heater Assembly
716
Anti-Frost Heater Clip
717
Anti-Frost Heater Clip A
718
Anti-Frost Heater Clip
719
Inlet Air Thermistor
720
Power Supply Harness
721
Fuse Harness
722
100v Harness
723
Solenoid Valve Harness
724
Sensor Harness
725
Thermal Fuse Harness
726
Mold-type Limit Switch
800
Screw
801
Screw
802
Washer
803
Screw
804
Screw
805
Screw
810
O-Ring
811
O-Ring
812
O-Ring
813
O-Ring
814
O-Ring
815
O-Ring
816
O-Ring
817
O-Ring
818
Gasket
238-44958-00
Installation and Operating Instructions
239-44509-00
Main Control - Residential
239-44510-00
Main Control - Commercial
239-44507-00
Bathroom Remote Temperature Control
239-44508-00
2nd Bathroom Remote Temperature Control
238-44957-00
Venting System Installation Instruction
Note: When ordering service replacement parts, the full model and
serial numbers from the water heater nameplate are required.
60
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
5
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
8
4
4
3
1
3
2
1
1
2
2
2
1
1
2
1
1
1
1
1
1
OPTIONAL VENTING COMPONENTS
Note: When ordering service replacement parts, the full model and serial numbers from the water
heater nameplate are required.
61
Notes
62
Notes
63
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
www.bradfordwhite.com
www.bradfordwhitecanada.com