Service Manual: Troubleshooting Guide and Instruction For Service
Service Manual: Troubleshooting Guide and Instruction For Service
SERVICE
MANUAL
Troubleshooting Guide
and Instruction for Service
(To be performed ONLY by qualified service providers)
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.
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
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.
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 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. The 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 features of this water heater include:
• This water heaters is designed to be installed outdoors on an outside wall using the
supplied wall bracket. No indoor space is needed and the water heater can be
mounted at a height convenient for servicing.
• 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.
• An optional recess box is available which allows the water heater to be recessed into
an outside wall and conceal the piping behind a cover for a more attractive installation.
The box enclosure dimensions are: 40 12⁄ " H x 14 34⁄ " W x 9 12⁄ " D. Contact your supplier
to order this optional accessory.
• 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 included, remote mount Main Control may be conveniently located near the point
of use and is adjustable from 96-160°F for residential models or 96-180°F for
commercial models. In addition to the Main Control, up to two optional bathroom
controls are available on the residential models for setting the temperature in the
bathroom fixtures up to 120°F.
• The Remote Main Control also displays fault codes if the water heater malfunctions to
assist with servicing the water heater.
• The heat exchanger coil is provided with anti-freeze heaters for cold climate conditions
for protection 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)
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:
Table showing Error Message as displayed on remote control indicating likely fault and
remedy.
This guide will identify the specific diagnostic point for each component as well as the
correct electrical value for each component.
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.
• Service Procedure
CUT-AWAY ILLUSTRATION
7
I - GENERAL INFORMATION (cont.)
SCHEMATIC ILLUSTRATION
8
II - SPECIFICATIONS – GENERAL
Type of appliance Temperature controlled continuous flow gas hot water system
Operation With/without remote controls
Exhaust system Direct Vent - Forced combustion
Model Type Residential Commercial
Maximum/Minimum
gas rate (Input Btu's) 199,000 Btu's – 15,000 Btu's Natural gas
199,000 Btu's – 15,000 Btu's Propane Gas
Thermal Efficiency Natural Gas 84% Propane Gas 85%
Energy Factor (EF) Natural Gas 0.82 Propane Gas 0.84
Capacity (Gallons 1st Natural Gas 218 Propane Gas 227
Hour @ 90°F rise)
NOx Emissions (at 3% 02) Less than 40 ppm
Hot water capacity (50°F rise) 0.5 to 6.5 GPM's
Setpoint Temperature Factory setting - 120°F
(without remote)
Temperature range BC-45-4US 96 - 120°F MCC-45-4US 96 - 160°F
with remote keypads connected BSC-45-4US 96 - 120°F
MC-45-4US 96 - 180°F
Approved gas type Natural or Propane – Ensure unit matches gas supply type.
Installation Outdoor installation ONLY
Dimensions Height 2358⁄ "
Width 1334⁄ "
Depth 878⁄ "
Weight 46 Lbs.
Noise levels 49 dB's
Connections Gas supply 3
⁄ " MNPT
4
9
II - SPECIFICATIONS – GENERAL (cont.)
10
II - SPECIFICATIONS (cont.)
COMBUSTION SPECIFICATIONS
11
II - SPECIFICATIONS (cont.)
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.
12
III - MAIN COMPONENTS
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.
13
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.
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.
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.
14
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.
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.
15
IV - SAFETY DEVICE FUNCTION (cont.)
16
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 the 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.
17
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.
18
V - SEQUENCE OF OPERATION (cont.)
19
V - SEQUENCE OF OPERATION (cont.)
20
V - SEQUENCE OF OPERATION (cont.)
21
V - SEQUENCE OF OPERATION (cont.)
22
VI - TROUBLESHOOTING
ERROR MESSAGES
23
VI - TROUBLESHOOTING (cont.)
ERROR MESSAGES
Error Faulty Remedy
32 Outgoing Water Check sensor wiring for damage.
Temperature Sensor Faulty Check resistance on sensor.
Check and clean scale from sensor.
Replace sensor.
33 Heat Exchanger Outgoing Check sensor wiring for damage.
Temperature Sensor Faulty Check resistance on sensor.
Check and clean scale from sensor.
Replace sensor.
34 Combustion Air Check sensor wiring for damage.
Temperature Sensor Faulty Check resistance on sensor.
Check and clean dirt from sensor.
Ensure fan blade is tight on motor shaft and it is in good
condition. Clean blower blades if dirty.
Check for restrictions in air flow around unit and vent terminal.
Replace sensor.
52 Modulating Solenoid Valve Check modulating gas solenoid valve wiring harness for loose
Signal Abnormal 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 restriction.
Check wiring harness to motor for damaged and/or loose
connections.
Check resistance on motor winding.
71 SV0, SV1, SV2, and SV3 Check wiring harness to all solenoids for damage and/or loose
Solenoid Valve Circuit Faulty 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 does not
reappear separate control wires from the unit's power supply.
Flush heat exchanger.
Replace heat exchanger.
No Nothing happens when water flow Clean inlet water supply filter.
Code is activated Ensure you have at least the minimum flow rate required to fire
unit.
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 water flow control sensor.
24
VI - TROUBLESHOOTING (cont.)
(TR) Transformer:
Wire color Voltage Resistance Connector # Pin #'s
Black ~ White 100 ~ 120 VAC 51 ~ 63 ohms F9 1~2
Blue ~ Brown 110 ~ 120 VAC 51 ~ 63 ohms F7 1~3
(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 1~2
(SV1) Black ~ Yellow 80 ~ 100 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
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. 25
VI - TROUBLESHOOTING (cont.)
Thermal Fuse:
Red ~ Red 100 VAC Below 1 ohm B~C B6 ~ C1
Overheat Switch:
Red ~ Red 100 VAC Below 1 ohm B~C B6 ~ C1
Flame Rod:
Place one lead of your meter to the flame rod and the other to earth or ground. 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 read 1µ or greater for proper flame circuit. In the event of low flame
circuit remove the flame rod and check for carbon and/or damage.
Surge Protector:
Black ~ White 108 ~ 132 VAC N/A Surge Protector D1 1~3
Blue ~ Brown 108 ~ 132 VAC N/A Surge Protector D2 1~2
With the power off you can check the continuity through the surge protector. Place one meter lead on
the top pin #1 of the surge protector and pin #2 on the bottom of the surge protector. Then check
across top pin #3 and bottom pin #1, if you read continuity across these two points the surge
protector is good. If you do not get continuity, replace the surge protector.
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.
26
VI - TROUBLE SHOOTING (cont.)
Using a voltage meter set to 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.
Fuses:
This unit has 2 in line (3) amp glass fuses. Remove the fuse and check continuity through them. If you
have continuity through the fuse, it is good. If you cannot read continuity, the fuse is blown and must
be replaced.
WIRING DIAGRAM
27
VI - TROUBLE SHOOTING (cont.)
WIRING SCHEMATIC
28
VI - TROUBLESHOOTING (cont.)
Troubleshooting Flow Chart
No Replace PCB
IGE – 2
29
VI - TROUBLESHOOTING (cont.)
Troubleshooting Flow Chart
Examination Service
Nature of Fault Point Diagnostic Point Values Y/N Action Procedure
2. Measure the voltage Are values within Yes Go to A – (7)
at connector F with those specified at
appliance power supply left. No Replace IGE – 7
on. transformer
F – Black ~ White
100 ~ 120 VAC
F7 – Blue ~ Brown
100 ~ 120 VAC
7. Check remotes (s) Measure voltage 11 ~ 13 VDC Digital Yes Check cable
(where connected.) between remote control for shorts or
terminals at D. broken wires.
Replace
remote
control.
No Replace PCB. IGE – 2
B. Digital monitor 1. Check water flow 1. Measure voltage 11 ~ 13 VDC Yes Go to B–1-2
lights up, but sensor. between red ~ black of No Replace PCB. IGE – 2
combustion does connector B4.
not commence. (See page 35)
(when remotes 2. Measure voltage 4 ~ 7 VDC Yes Go to B - 2
are connected). between yellow ~ black No Replace water IGE – 3
at connector B4. flow sensor.
(See page 35)
Error code "72" 2. Check flame rod # Measure resistance Resistance > 1MΩ? Yes Replace PCB IGE – 2
displayed on the between flame rod No Replace flame
digital monitor. terminal C1 and earth. rod
(See page 36)
Error code "32" 3. Check outgoing # Disconnect connector Are values as shown Yes Replace water IGE – 6
displayed on the water temperature B5 and measure at left? temperature
digital monitor. thermistor. resistance. thermistor.
Open circuit: > 1MΩ No Go to B - 4
Short circuit: < 1Ω
(See page 36)
Error code "61" 4. Check 1. Check motor. 6 ~ 45 VDC (Fan on) Yes Go to B – 5-2
displayed on the combustion fan. Measure voltage 0 VDC (Fan off) No Replace PCB IGE – 2
digital monitor. between black ~ red at
connector A1.
(See page 37)
2. Check fan rotation 11 ~ 13 VDC Yes Go to B – 4-3
sensor. Measure voltage No Replace PCB IGE – 2
between black ~ yellow
at connector A1.
(See page 37)
3. Measure voltage 6 ~ 45 VDC Yes Go to B – 5
between black ~ white No Replace fan IGE – 5
of connector A1.
(See page 37)
30
VI - TROUBLESHOOTING (cont.)
Troubleshooting Flow Chart
Examination Service
Nature of Fault Point Diagnostic Point Values Y/N Action Procedure
Error code "11" 5. Check ignition 1. Measure voltage 90 ~ 110 VAC Yes Go to B-5-2
displayed on module. between grey ~ grey of
digital monitor. connector F8 (ignition No Replace PCB IGE – 2
module).(See page 37)
2. # Remove connector Is resistance >1MΩ? Yes Go to B-5-3
F8 and measure the No Adjust/
IGE – 4
resistance between Replace
ignition module and ignition
terminals. (See page 37) module
3. Check if unit is Is the ignition Yes Go to B-6
sparking. module sparking?
No Adjust/
Replace
electrode
6. Check main gas 1. # Disconnect the main 1.7 ~ 2.1KΩ Yes Go to B-6-2
solenoid valve (SV0) solenoid valve connector
Error code 71 E from the PCB, and No Replace gas IGE – 9
measure the resistance valve
between pink ~ black
(SV0)
31
VI - TROUBLESHOOTING (cont.)
Troubleshooting Flow Chart
Examination Service
Nature of Fault Point Diagnostic Point Values Y/N Action Procedure
C. Combustion 1. Check flame rod. 1. Measure the voltage 5 ~ 150 VAC Yes Go to C-1-2
occurs, but flame between flame rod No Replace PCB IGE – 2
fails. terminal C1 and
appliance ground.
2. Check to ensure flame Is it secure? Yes Go to C-2
Error code "12" rod bracket is not loose. No Replace/
displayed on rectify
digital monitor. 2. Check ground Check for faulty ground Are connections
wire. wire connections at unit, OK? Yes Check for
receptacle, and ground other causes
rod to home, and for of flame
broken or shorted wires. failure.
No Replace or
repair
grounding
circuit to unit.
D. Cannot adjust 1. Check hot water # Disconnect connector Resistance values Yes Go to D – 2
water thermistor. B5 and measure the match table on page No Replace water IGE – 6
temperature. (outgoing resistance between #41 temperature
thermistor) white ~ white. thermistor.
(See page 41)
32
VI - TROUBLESHOOTING (cont.)
Troubleshooting Flow Chart
Examination Service
Nature of Fault Point Diagnostic Point Values Y/N Action Procedure
2. Measure voltage 11 ~ 13 VDC Yes Go to 4-3
between orange (+) and No Replace PCB IGE – 2
grey (-) of the water flow
servo connector B2.
3. Measure voltage Yes Go to D-4-4
between brown ~ grey 4 ~ 6 VDC No Replace water IGE – 3
of water flow servo flow servo
connector B2 (Don not sensor.
turn water on)
(See page 42)
4. Measure voltage 4 ~ 6 VDC Yes Normal
between yellow ~ grey No Replace water IGE – 3
of the water flow servo flow servo
connector B2 (Do not sensor.
turn water on)
(See page 42)
33
VI - TROUBLESHOOTING (cont.)
Troubleshooting Procedure
BEFORE CARRYING OUT CHECKS MARKED WITH A # SIGN, DISCONNECT THE POWER SUPPLY.
Resistance reading 51 ~ 63 Ω
34
VI - TROUBLESHOOTING (cont.)
Normal: 11 ~ 13 VDC
If normal, check for an open circuit or short before
replacing the remote control.
Faulty: Replace PCB.
(Service Procedure IGE-2, page 47)
35
VI - TROUBLESHOOTING (cont.)
BEFORE CARRYING OUT CHECKS MARKED WITH A # SIGN, DISCONNECT THE POWER SUPPLY.
36
VI - TROUBLESHOOTING (cont.)
BEFORE CARRYING OUT CHECKS MARKED WITH A # SIGN, DISCONNECT THE POWER SUPPLY.
37
VI - TROUBLESHOOTING (cont.)
BEFORE CARRYING OUT CHECKS MARKED WITH A # SIGN, DISCONNECT THE POWER SUPPLY.
39
VI - TROUBLESHOOTING (cont.)
BEFORE CARRYING OUT CHECKS MARKED WITH A # SIGN, DISCONNECT THE POWER SUPPLY.
40
VI - TROUBLESHOOTING (cont.)
BEFORE CARRYING OUT CHECKS MARKED WITH A # SIGN, DISCONNECT THE POWER SUPPLY.
41
BEFORE CARRYING OUT CHECKS MARKED WITH A # SIGN, DISCONNECT THE POWER SUPPLY.
43
VII - GAS PRESSURE SETTING PROCEDURE
1. Turn unit off at power source and turn off the gas to 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, at least three
gallons per minute.
5. To adjust the "Low" fire pressure, use small (pocket) common screwdriver to set combustion
control dip 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 regulator screw to achieve the correct gas pressure.
(See figure #1 for location of the regulator adjustment screw.) Below are the proper pressures
for "Low" fire, per gas type.
Propane 0.88" w.c. @ 10" w.c. supply (Low fire rate of 15,000 BTU's)
Natural 0.56" w.c. @ 6" w.c. supply (Low fire rate of 15,000 BTU's)
6. To adjust the "High" fire pressure, use small (pocket) common screwdriver to set combustion
control dip 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.
Propane 5.1" w.c. @ 10" w.c. supply (High fire rate of 199,000 BTU's)
Natural 3.4" w.c. @ 6" w.c. supply (High fire rate of 199,000 BTU's)
7. 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. Dip switches #7 and #8 (combustion control switches), MUST be returned
to the "Off" position, after setting the pressures.
44
WARNING
Dip switched #7 and #8 (combustion control switches) MUST
be returned to the "OFF" position, after setting pressures.
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 residential models or 140˚ for
commercial models.
Figure #1 Figure #2
45
VIII - SERVICE PROCEDURE
Service Procedure
Re-assembly in all tasks listed above in the reverse order of dismantling (unless stated otherwise.)
46
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).
IMPORTANT IGE - 2. Removal of PC board
When dismantling the unit you should always isolate
the following items: CAUTION
120 volt potential exposure. Isolate the appliance and
• Gas supply reconfirm power has been disconnected using a
• Electrical supply multimeter.
• Water supply
• Drain all water from the appliance a. Remove the two (2) screws holding the
PCB in place with a Phillips screw driver,
The following diagram may be of assistance in locating then pull the PC board out of the
the above. appliance.
Disconnect all connectors.
47
a. Remove the four (4) Phillips screws that IGE - 5. Removal of the Combustion Fan:
secure the water inlet filter housing to the
unit. See picture below for location of CAUTION
screws. Once screws are removed reach 120 volt potential exposure. Isolate the appliance
into the unit and pull up and out on the and reconfirm power has been disconnected
flow control assembly to remove it from using a multimeter.
the appliance. Inspect o-ring for damage.
a. Disconnect wiring harness from fan motor.
48
IGE - 7. Removal of Transformer:
CAUTION
120 volt potential exposure. Isolate the appliance
and reconfirm power has been disconnected
using a multimeter.
CAUTION
120 volt potential exposure. Isolate the appliance
and reconfirm power has been disconnected
using a multimeter.
49
IGE - 9. Removal of the Gas Valve Assembly: b. Remove the heat exchanger water
connection lines, refer to section 3-a.
CAUTION
120 volt potential exposure. Isolate the appliance c. Remove the three (3) Phillip screws
and reconfirm power has been disconnected securing the gas manifold assembly to the
using a multimeter. gas control valve.
a. Remove the burner manifold, refer to d. Remove the six (6) Phillip screws that
section 8-a,b,c. secure the heat exchanger assembly in
place.
b. Remove the four (4) Phillips screws that
hold the gas connection and gas control e. Disconnect connectors B1, B5, B6, C1, C3,
valve in place at the bottom of the unit. F1and F8. These are the igniter, flame rod,
Pull the gas connection down to thermo-fuse, hot water inlet and outlet
disconnect it from the gas valve assembly. thermistor, and the anti-freeze heater
Inspect o-ring for damage and/or defects. connections.
Ensure o-ring is in place when
re-assembling this connection.
c. Disconnect connectors from solenoids, g. Transfer all components found on the old
note which connector goes to each heat exchanger over to the new exchanger.
solenoid, along with the proper wire
colors. Pull gas valve assembly out of unit.
CAUTION
120 volt potential exposure. Isolate the appliance
and reconfirm power has been disconnected
using a multimeter.
51
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.
52
X - PARTS BREAKDOWN
53
X - PARTS BREAKDOWN
54
X - PARTS BREAKDOWN
55
X - PARTS BREAKDOWN
56
PARTS LIST
Number Description Quantity
001 Front Panel Assembly 1
002 Casing Assembly 1
003 Wall Installation Bracket 1
004 Connection Reinforcement Panel 1
005 Heat Protection Plate 1
006 Rubber Bushing 1
007 Front Panel Gasket 1
008 Front Panel Gasket - Side 1
009 Front Air Inlet Grill 1
011 Rubber Bushing 1
102 Gas Connection (3/4" NPT) 1
103 Burner Unit Assembly 1
104 Burner Case Front 1
105 Burner Case Bottom Panel 1
106 Burner Air Orifice Plate 1
107 Bunsen Burners 16
108 Burner Case Back Panel 1
109 Damper Plate 1
110 Manifold Assembly – Natural Gas 1
110 Manifold Assembly – L.P. Gas 1
111 Gasket – Combustion Chamber 1
112 Lower Gasket – Combustion Chamber 1
113 Combustion Chamber Pressure Tap Screw 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
122 Combustion Blower Assembly 1
123 Blower Motor 1
127 Blower Mounting Bracket 1
128 Blower Gasket 1
132 Combustion Chamber Bracket 1
136 Flue Outlet 1
137 Flue Outlet Gasket 1
138 Flue Outlet Gasket - 6 1
140 Heat Exchanger – Complete Assembly 1
400 Water Inlet – _" NPT 1
401 Water Flow Servo and Sensor Assembly 1
402 Rectifier 1
403 By-pass Servo Assembly 1
404 Stop Bracket 2
405 Plug Band 1
406 Water Filter Assembly 1
407 Filter Plug 1
408 Hot Water Outlet – _" NPT 1
409 Stop Bracket 1
410 Plug Band - Small 1
411 Drain Valve 1
702 PCB Cover - Side 1
703 PCB Cover - Front 1
704 Transformer Assembly 1
705 Ignitor Bracket 1
706 Ignitor 1
707 High Tension Lead 1
708 Spark Electrode Boot 1
709 Thermistor 2
710 Thermistor Clip - Large 1
711 Thermal Fuse Clip 5
57
715 120v Valve Heater Assembly 1
716 Anti-Frost Heater Clip 2
717 Anti-Frost Heater Clip A 1
718 Anti-Frost Heater Clip 1
720 Power Supply Harness 1
721 Fuse Harness 1
722 100v Harness 1
723 Solenoid Valve Harness 1
725 Thermal Fuse Harness 1
726 Mold-type Limit Switch 1
730 PCB Assembly 1
731 Surge Protector 1
732 Frost Sensing Switch 1
733 120V Anti-Frost Heater Assembly 1
734 Sensor Harness - 2 1
800 Screw 8
801 Screw 4
802 Washer 4
803 Screw 3
804 Screw 1
805 Screw 3
806 Screw 4
807 Washer 4
808 Screw 4
809 Screw 4
810 O-Ring 3
813 O-Ring 2
814 O-Ring 2
815 O-Ring 2
817 O-Ring 1
818 Gasket 2
238-44959-00 Installation and Operating Instructions 1
239-44509-00 Main Remote Temperature Control - Residential 1
239-44510-00 Main Remote Temperature Control - Commercial 1
239-44507-00 Bathroom Remote Temperature Control 1
239-44508-00 2nd Bathroom Remote Temperature Control 1
58
Notes
59
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