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American Water Heater (A)BCG385T500-8N manual Troubleshooting, Ignition Control Board Error Codes

Models: (A)BCG38T500-8P (A)BCG385T500-8N

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TROUBLESHOOTING

TROUBLESHOOTING

TROUBLESHOOTING

IGNITION CONTROL BOARD: ERROR CODES

The White Rodgers ignition control board will display a flashing error code with an LED light located on the upper left corner of the Ignition Control Board (Figure 18) when there is a problem. There is a distinctive pause between a series of on/ off flashes (1 to 8 flashes) when there is a problem. The following information describes the meaning of these error “flash” codes and what should be checked and/or repaired. The 5 flash error code is not used with this application.

NOTE: The Ignition Control Board varies the voltage to the Igniter to decrease wear. Lower voltage results in a longer life for the Igniter. For this reason, voltage to the Igniter may vary from 80 VAC to 120 VAC.

1FLASH

System has locked out after 3 trials for ignition.

1Check voltage (80-120 VAC) to igniter.

2Check flame sense rod alignment.

3Check igniter and flame sense rod wiring.

4Check flame sense rod for corrosion; clean with steel wool.

5Check igniter resistance. It should be 11 - 20 ohms.

6Check ceramic insulator on igniter/flame sensor assembly for cracks. Replace if damaged.

7Check manifold gas pressure.

8Check all molex plug connections; on integrated control, ignition control board, and between the various components. Check the pin-to-pin contact between plugs; gently wiggle suspected plug connections during operation.

2FLASHES

Blower Prover Switch circuit was closed during self-diagnostic check at the beginning of the heat cycle. Contacts should have opened at the end of last heat cycle. Blower (Draft Inducer) will not start; call for heat “Status” LED will be illuminated on integrated control.

1Test continuity of blower prover switch; it should be open in “normal state” (blower not running - wires removed)

2Replace blower prover switch if continuity is present between terminals in normal state.

3Check blower prover switch wiring, making sure that there are no jumpers on blower prover switch.

Servicing should only be performed by a Qualiﬁed Service Agent

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American Water Heater (A)BCG385T500-8N, (A)BCG38T500-8P manual Troubleshooting, Ignition Control Board Error Codes, Flashes

Contents

CHECKS - OPERATION & SERVICE -TROUBLESHOOTING MODELS ABCG385T500-8N ABCG38T500-8PService Handbook INSTALLATION CONSIDERATIONS - PRE SERVICEServicing should only be performed by a Qualiﬁed Service Agent COMMERCIAL GAS WATER HEATER SERVICE MANUAL TABLE OF CONTENTSQUALIFICATIONS SERVICE WARNINGSERVICE REMINDER INTRODUCTIONTOOLS OPTIONAL REQUIREMENTSINSTRUCTION MANUAL TOOLS REQUIREDClosed Water Systems INSTALLATION CONSIDERATIONSWATER PIPING GAS PRESSURE REQUIREMENTSAir Supply AIR REQUIREMENTSInsufficient Make-up Air, Negative Air Pressure, and Downdrafts Make-up Air Direct Communication with Outdoors Contaminated Air CLEARANCES WATER HEATERCLEARANCES EXTERIOR VENTING SEQUENCE OF OPERATION OPERATION AND SERVICEELECTRICAL SEQUENCE WIRING DIAGRAM FOR ABCG385T500-8N/8P WIRING DIAGRAMOPERATION AND SERVICE Servicing should only be performed by a Qualiﬁed Service AgentBelow 0.1 uA DC Flame Sense OPERATING SEQUENCE - FLOW CHARTOPERATION AND SERVICE Servicing should only be performed by a Qualiﬁed Service AgentMeasuring Gas Pressures GAS CONTROL VALVEMain Valve Solenoid Connections Manifold Pressure AdjustmentHoneywell Gas Valve Main Burner Shield GAS CONTROL VALVE/BURNER AREA VIEWOPERATION AND SERVICE Servicing should only be performed by a Qualiﬁed Service AgentBLOWER PROVER SWITCH - SETTINGS Servicing should only be performed by a Qualiﬁed Service Agent THERMOSTAT AND IGNITION CONTROL BOARD VIEWOPERATION AND SERVICE Servicing should only be performed by a Qualiﬁed Service Agent WHITE RODGERS INTEGRATED CONTROL - THERMOSTATWHITE RODGERS IGNITION CONTROL BOARD OPERATION AND SERVICEPRE-SERVICE CHECKLIST 2 FLASHES TROUBLESHOOTINGIGNITION CONTROL BOARD ERROR CODES 1 FLASH System has locked out after 3 trials for ignition7 FLASHES 6 FLASHES Reversed polarity in power supply3 FLASHES 4 FLASHESCONTINUOUS ON Internal control board failure 8 FLASHES Igniter not sensed and/or water heater not groundedCONTINUOUS FLASH STATUS INTEGRATED HEATER CONTROL DISPLAY LIGHTSINDICATION ACTIONthen TEST 1 120 VAC TO HEATER CHECKConditions TESTCheck from on/off switch center and white wire terminals to ground TEST 2 POLARITY CHECKTROUBLESHOOTING Servicing should only be performed by a Qualiﬁed Service AgentTROUBLESHOOTING TEST 3 CONTINUITY CHECK OF HIGH LIMIT ECOThen See Ignition Control Board Error CodesTROUBLESHOOTING TEST 4 UPPER TEMPERATURE PROBE CONTINUITY CHECKOHMS RESISTANCE TABLE OhmsConditions TEST 5 CALLING FOR HEAT - NO BLOWER OPERATIONTROUBLESHOOTING Servicing should only be performed by a Qualiﬁed Service AgentProver Switch TEST 6 BLOWER ON, NO IGNITIONTROUBLESHOOTING Servicing should only be performed by a Qualiﬁed Service AgentContinuity check - Power off- Plug removed from E4 receptacles TEST 7 BLOWER ON, BLOWER PROVER SWITCH CLOSED, NO IGNITER OPERATIONTROUBLESHOOTING Servicing should only be performed by a Qualiﬁed Service AgentTEST TEST 8 IGNITER HEATS, NO MAIN BURNERTROUBLESHOOTING Servicing should only be performed by a Qualiﬁed Service AgentConditions TEST 9 IGNITER HEATS, NO MAIN BURNERTROUBLESHOOTING Servicing should only be performed by a Qualiﬁed Service AgentConditions TEST 10 MAIN BURNER IGNITION FOR LESS THAN FIVE SECONDSTROUBLESHOOTING Servicing should only be performed by a Qualiﬁed Service AgentWATER HEATER SHUTTING OFF BELOW SETTING TEST 11 WATER HEATER SHUTTING OFF BELOW SETTINGTROUBLESHOOTING Servicing should only be performed by a Qualiﬁed Service AgentServicing should only be performed by a Qualiﬁed Service Agent Servicing should only be performed by a Qualiﬁed Service Agent Copyright 2010 American Water Heater Company. All rights reserved P.O. Box 1597, Johnson City, TN Phone 800-456-9805 Fax