HEC Series - bockwaterheaters.com · HEC Series High Efficiency Water Heaters Table of Contents...
Transcript of HEC Series - bockwaterheaters.com · HEC Series High Efficiency Water Heaters Table of Contents...
Energy SaverHEC Series
High Efficiency Water Heaters
SERVICEMANUALTroubleshooting Guide
and Instructions for Service(To be performed ONLY byqualified service providers)
For Models60HEC-12560HEC-15060HEC-199
100HEC-150100HEC-199100HEC-250100HEC-300100-HEC399
All are available in LP or Natural GasStandard or ASME Construction
Manual 45817B - Save this manual for future reference
HEC SeriesHigh Efficiency Water Heaters
Table of Contents Page HEC Service Procedure
Introduction 3 - - -
How to use this manual 4 - - -
Tool required for service 4 - - -
Specifications 5 ---
Sequence of Operation 8 - - -
Troubleshooting 12 - - -
Thermostat Circuit, Testing & Replacement 14 I
Combustion System Testing & Replacement 20 II
Burner Tube Inspection & Replacement 24 III
Gas Valve Replacement 26 IV
Blower Testing & Replacement 27 V
Exhaust Pressure Switch Testing & Replacement 29 VI
HotSurfaceIgnitorTesting&Replacement 35 VII
Flame Sensor Testing & Replacement 37 VIII
Ignition Module Replacement 39 IX
Transformer Replacement 40 X
Intake Pressure Testing & Replacement 41 XI
Vent Safety Switch Testing & Replacement 43 XII
Anode&FlueBaffleInspection&Replacement 45 XIII
InstallationCheckList 50 ---
HeaterServiceReport 51 ---
GlossaryofTerms 52 ---
2
3
HEC SeriesIntroduction
TheBockHECSeriesHighEfficiencyWaterHeaterisdesignedtodeliveraremarkablethermalefficiencyratinginaquietrunningunitwithventingoptionsthatallowforinstallationflexibility.Severaltechnologicallyadvanceddesignfeatures are incorporated in the design that will require additional knowledge onthepartofthequalifiedserviceprovider.Theinformationinthismanualwillinstruct service and a maintenance professionals on the function, roper diagnosis andrepairoftheBockHECSeriesHighEfficiencyWaterHeater.
TheBockHECSeriesHighEfficiencyWaterHeaterusesalowNoxpremix power burner located at the top of the water heater to direct a turbulent flamedownintoasubmergedcombustionchamber.Thisturbulencecausesathoroughmixingofgasandairforoptimumcombustion.Thecombustiongasesthentravelthroughathreepassfluesystemkeepingthegasesmovingatahighvelocity.Thecombinationofhighturbulenceandvelocityresultsinanoptimumtransferofheatfromthefluegasesintothewater.
Burneroperationiscontrolledusinganelectronicignitionmodule.Themodulemonitors the status of the electronic thermostat, vent temperature limit switch, ventsystempressureswitchesandaflamesensortocontroloutputvoltagetoblowermotor,hotsurfaceigniterandgasvalve.Themodulecontainsprogramming which determines the sequence of operation and timings for purge periods,trialforignition,flamesensingandlockout.Themodulewillalsoprovidediagnostic information on LEDs to help in determining the cause of system lockouts.
The contents of this manual are detailed informational tools to assist in the properdiagnosisoftheHECSeriesHighEfficiencyWaterHeateroperationalfaults.PleasethisservicemanualcompletelyandprovideasmuchinformationregardingtheHECSeriesHighEfficiencyWaterHeateroperationandinstallationspecificconcerns.
4
HEC Series How to Use this Manual
ItisintendedforthismanualtobeusedbyqualifiedservicepersonnelfortheprimarypurposeoftroubleshootinganalysisandrepairoftheBockHECSeriesHighEfficiencyWaterHeater.Understanding the sequence of operation section of this manual will contribute greatly to troubleshootingthisproduct.
An“InstallationCheckList’isshownonpage50.Comparetheinstallationagainsttheinstallationchecklisttoconfirmallrequirementsaremet.
An“HECServiceReport”isshownonpage51.Completingthisformwillassistinthetroubleshootingefforts.Showyouneedtocallfortechnicalsupport,pleaseprovidetheinformationshownonthisformtothesupporttechniciantoinsureaccuratetroubleshooting.
Troubleshooting begins with “System Observation” to determine failure mode as indicated by the LEDstatusoftheignitionmodule.Troubleshootingcontinueswith“FailureModesandProbablecause” listed on page 11, directing the service provider to a series of test procedures to determine rootcauseoffailure.Componentreplacementproceduresdirectlyfollowthetestproceduresforagivencomponent.
Insomedifficulttodiagnoseconditions,itmaybenecessarytoisolatetheheaterfromtheventsystemtodeterminetherootcause.
Contact Technical Support immediately if diagnosis is not determined using the methods described inthisservicemanual.
Tools Required for ServiceManometer: Twotypesavailable,aliquid“U”tubetypeoradigital(magna-helic)type.
Thisdeviceisusedtomeasuregasand/orairpressuresandvacuum.
Multi-Meter: Adigitaltypeisstronglyrecommended.Thisdeviceisusedtomeasureelectricalvalues.ThemeteryouselectmusthavethecapabilitytomeasurevoltsAC,voltsDC,Amps,micro-ampsandohms.
Thermometer: Usedtomeasurewatertemperature.Anaccuratethermometerisrecommended.
WaterPressureGage: Usedtomeasurewatersupplypressure.Alsousedtodeterminetankpressurebyadaptingtothedrainvalveoftheheater.
JumperLeads: Alengthofwire(12”min.)withalligatorclipsatbothends.
Various Hand Tools: Pipe wrench, channel locks, open end wrench set, 12” crescent wrench, allen wrench set, torx bit set, screw drivers (common & phillips), long reach (12”) magnetic tip phillips head screw driver #2 tip, ¼” nut driver, pliers (common & needle nose), socket set including 1-1/16” deep well socket, wire cutters, wire strippers, wire crimpers, torpedo level, small shopvac,stepladder,andflashlight.
5
HEC Series Specifications
NOTE: Diagrams are for both the 60 and 100 gallon models
¾” NPT Gas Inlet
1" NPT SpaceHeating Outlet
1" NPT SpaceHeating Return
1 ½"NPT Inlet
3" PVC Exhaust
3” PVC Air Inlet
G E
B
D
3" PVC Exhaust
½” NPTCondensateConnection
F
ACH
T & P Valve
Cleanout
Drain
B - 28 ¼
Gas Inlet
Exhaust
Air Intake
2 3⁄8”
8 ¼
8 ¼
T & P Valve
1 ½” NPTOutlet
MODEL NUMBER
DIMENSIONS IN INCHES
A HT.
B DIA.
C HOT OUT
D COLD
IN
E GAS
CONN.
F FL. TO VENT
OUTLET
G FL. TO
AIR INTAKE
H FL. TO
T&P VALVE
WATER CONN.
DIA.
60 Gallon Models 57 28 1/4 42 13 531/2 5 521/2 40 1 1/2
100 Gallon Models 775/8 28 1/4 63 13 74 3/4 5 74.75 60 1.5
MODEL NUMBER
STORAGE (GAL)
RATED INPUT (BTUH)
THERMAL EFF %
1ST HR DEL GAL. @ 100° F
RISE
RECOVERY GPH @ DEGREE RISE
MAX 3” PVC,
ABS & CPVC
MAX 4” PVC,
ABS & CPVC
SHIPPING WT (LBS)40° F 100° F 140° F
60HEC-125 60 125,000 96.0% 187 364 145 104 120 ft 170 ft 570
60HEC-150 60 150,000 93.0% 211 423 169 121 100 ft 150ft 570
60HEC-199 60 199,999 92.0% 265 558 223 159 80 ft 130 ft 900
100HEC-150 100 150,000 99.1% 250 450 180 129 120 ft 170 ft 900
100HEC-199 100 199,999 98.5% 309 597 239 171 100 ft 150ft 900
100HEC-250 100 250,000 97.0% 364 735 294 210 80 ft 130 ft 900
100HEC-300 100 300,000 92.0% 405 836 335 239 60 ft 110 ft 900
100-HEC-399 100 399,999 93.0% 521 1127 451 322 50ft 100 ft 950
6
HEC Series Specifications
Power Supply Dedicated120VAC,60Hz,15A,GFI
Gas Supply Minimum1”NPTforHEC100-399,allothers3/4”NPT(schedule 40 black iron pipe recommended)
Approved Gas Type NaturalorPropane.UnitmustmatchgastypesuppliedGasPressure(Nat.&L.P.)
14.0”W.C.maximumstatic,4.5”W.C.minimumrunning(recommend7.0”W.C.minrunning)
Venting System Powervent,balanceddirectventorunbalanceddirectvent.Seeventtablesonpage7Approved Vent Materials PVC, CPVC or ABS
Minimum Clearance for Servicing 18” from top, 24” from front, 4” sides and rear
MaximumWaterSupply Pressure 150PSI
Thermostat Sensor 11,900 Ohms @ 70°F, ECO opens @ 201°F Maximum, ECO close @ 100°F MinimumTemperature Dial Minimumsetpoint5400-6600Ohms,Maximumsetpoint0-50OhmsThermostat Board Maximum temperature 180°F, minimum temperature 91°F, 24VAC, 60Hz MaximumIgnition Module See page 11Transformer 120VAC primary, 24VAC secondary, 40VAHot Surface Igniter 120VAC, 30-120 Ohms @ room temperatureFlame Sensor Output Minimum 1 micro amp, typical range 4 to 7 micro ampsGas Valve Negativeregulation,24VAC,½“PSImaximum,4.5”W.C.MinimumrunninginletVent Safety Switch Normallyclosed,opens@350°F, manual resetIntake Pressure Switch “CF” serial number or later
NotRequired
Intake Pressure Switch serial numbers prior to “CF”
24VAC,normallyclosed,[email protected].
Blocked Vent Pressure Switch “CF” serial number or later
24VAC,normallyclosed,openswhenpressureincreasesto+2.70W.C.
Exhaust Pressure Switch serial numbers prior to “CF”
24VAC, normally open, closes on pressure increases as follows:Note1: +2.58”W.C.-60HEC-150,100HEC-199+1.50”W.C.-100HEC-150(seenote2)+1.22”W.C.-60HEC-150,100HEC-250+2.08”W.C.-60HEC-125+0.55”W.C.-100HEC-300(seenote3)Note2:+5.6”W.C.onserialspriortoAH5039107Note3:+0.8”W.C.onserialspriortoAK5288269
Blower 120VAC,60Hz,.6-1amps,6400RPMCombustion Levels CO2:10-11%;CO:lessthan0.04percent(400PPM)airfree
7
HEC Series Specifications
Vent TablesBalanced Direct Vent Systems
PVC, CPVC or ABSTotal length of intake piping and exhaust piping added together must not exceed
“Maximum Combined Length” shown below
Maximum Combined Length (feet)Model Number 3” 4”
60HEC-125, 100HEC-150 120’ 170’60HEC-150, 100HEC-199 100’ 150’60HEC-199, 100HEC-250 80’ 130’
100HEC-300 60’ 110’100HEC-399 50’ 100’
Unbalanced Direct Vent SystemsAir intake CANNOT exceed exhaust
by more than 30 feet
Power Vented SystemsPVC, CPVC OR ABS
Total length of exhaust piping must notexceed “Maximum Vent Length”
shown belowMaximum Vent Length (feet)
Model Number 3” 4”60HEC-125, 100HEC-150 120’ 170’60HEC-150, 100HEC-199 100’ 150’60HEC-199, 100HEC-250 80’ 130’
100HEC-300 60’ 110’100HEC-399 50’ 100’
Notes:1) Multiply the total number of 90°elbows(intakeandexhaust)by5feet.Donotincludethe
terminationfittingsor3”condensateelbow.2) Multiplythetotalnumberof45° elbows (intake and exhaust) by 2½feet.3) Addthistothetotallengthofstraightpipe-intakeandexhaust.4) The sum total of all elbows and straight pipe - intake and exhaust must not exceed maximum
lengthsfromtablesabove.
Example: 100HEC-199A 3” Balanced Direct Vent System has 30 feet of straight exhaust pipe and 30 feet of straight intakepipe.Ithasthree90° elbows in the exhaust and three 90°elbowsintheintake.Ithasone45°elbowintheexhaustandone45°elbowintheintake.
Therefore:6 - 90°elbowsx5feet=30feet2-45° elbows x 2½feet=5feet60feetofstraightpipe+30feet+5feet=95feetSystem is within “Maximum Combined Length” from table above
8
HEC Series Sequence of OperationFor models prior to CF serial numbers
1. Thermostatcallsforheat. - Prior to energizing blower, ignition module checks safety circuits for normal switch positions:
a) Vent temp switch normally closed b) Intake pressure switch normally closed c) Exhaust pressure switch normally open If the vent temp switch is open, the control waits indefinitelyfortempswitchtoclose(greenlightstayson).
Iftheexhaustpressureswitchcontactsareclosed(notinnormalposition),theignitionmodulewillwait45secondsforpressureswitchcontacttoopenbeforeenergizingblower.Ifafter45secondsandpressureswitchcontactsdonotopen,theignitionmodulelocksoutwiththePURGElightflashingindicatingpressureswitchfault.
2. Blowerenergizes
3. Pressureswitchprovesblower/ventsystemoperation IftheN.O.Contactsoftheexhaustpressureswitchdonotclosewithin5minutesoftheblowerbeingon,the
controllocksoutwiththePURGElightflashingindicatingpressureswitchfault.
4. Blowerpre-purgeperiod(5seconds)indicatedbythePURGELEDonthemodule.
5. Igniterwarmup(18seconds),indicatedbytheIGNITERLEDonthemodule.
6. Trialforignition(4seconds,threetrials).a) Flameestablishingperiod(2.5seconds)gasvalveandigniteron,indicatedbytheIGNITERand
VALVE LED on the moduleb) Burneron,flameprovidingperiod(1.5seconds,lookingforminimumof1microamps),indicatedby
theFLAME&VALVELEDonthemodule.
7. Steadystateoperation.Ignitionmodulemonitors. -Thermostatcircuit. -Whenthermostatopens,gasvalveisshutdownandpostpurgebegins. -Safetycircuit.
- If vent temp switch opens, gas valve is shut down, system will post purge and wait for switch to close beforeattemptingre-ignition.
- Ifeitherpressureswitchopens,gasvalveisshutdown.Blowerisshutdownfor30secondsafterwhich blower is re-energized and system attempts re-ignition starting at pressure switch proving mode.
-Flamesensorcircuit.- Ifflameislost,gasvalveisshutdown,systemwillpostpurgeandsystemattemptsre-ignitionstarting
atpressureswitchprovingmode.
8. Thermostatsatisfied.
9. Burneroff.
10.Blowerpostpurge(15seconds).
9
HEC Series Sequence of OperationFor models prior to CF serial numbers
Lockout Conditions Ifnormallyclosedpressureswitchcontactsopenduringburneroperation,gasvalvecloses,burnershutsoff.
Blowerrestartsafter30secondsandruns5minutestowaitforpressureswitchtoclose.Ifnot,locksout. The system will go into lock out mode for the following reasons: - Pressure switches stuck open or closed
a) Checkforexhaustorintakeobstructions.b) Checkforcompliancewithventtables.c) Check for evidence of moisture or condensate present in pressure switch tubing or pressure
switch.-Noignitionafter3attempts.
a) Checkgaspressures.b) Igniterresistancetoohigh(lowerresistancepreferred<150Ohms).c) Check venturi screw adjustment (6 ½turnsfrombottom).d) Flamesensemicroampnotpresent(1to5microampsrequired).
Lock out reset is accomplished by shutting OFF the line voltage to the system or opening the 24V thermostat circuitforatleast2seconds.
Systemwillautomaticallyresetlockoutafter1hourofcontinuouscallforheatfromthethermostat.Threeignitiontrialswillbeattemptedeachhouruntilthethermostatissatisfied.
IgnitionModuleSpecifications Control Function:
- Ignition & heating functions in response to thermostat-Hotsurfaceignitionusingamicroprocessortocontroltiming,flamesensingusingflamerectification&ignitionretries.
- Monitoring of system pressure switches and limit switches- Control of gas valve, inducer motor, and hot surface igniter element based on thermostat demand and statusofsafetyinputs.
- Diagnosticindicatorstoprovideinformationonpowertocontrolandcontrolstatus.- Non-interchangeablepolarizedplug-inconnectorsforallinterconnections
Control Inputs: Control Outputs:- Thermostat call for heat - Inducer motor- Limit switch circuit (normally closed) - Hot surface igniter- Pressure switch circuit (normally open) - Gas valve- Flame sensing - Status indicator LEDs- Low voltage supply Power - Green- Line voltage supply Purge - Red Igniter - Red Valve - Red Flame - Red
IGNITION MODULE
UT ELECTRONICCONTROLS
P2
P3
P5
P1
P7P6
HUNTINGTON, INDIANA1013 SERIES INTEGRATED WATER HEATER
POWER
PURGE
IGNITOR
VALVE
FLAME
INDICATORLIGHTS
FOR OPERATING SEQUENCE TROUBLESHOOTING SEE INSTALLATIONAND OPERATING INSTRUCTION MANUAL
ANSI Z21.20 AUTOMATIC IGNITION SYSTEMSCAN/CSA-22.2 NO. 199-M89
24 VAC 0.5 AMP 50/60Hz
IF SYSTEM LOCK OUT, REMOVE POWER FOR 45 SECONDS TO RESETSYSTEM WILL AUTOMATICALLY RE-TRY AFTER 1 HOUR
WARNINGEXPLOSION HAZARD, CAN CAUSESERIOUS INJURY OR DEATH
THIS DEVICE CAN MALFUCTION IF IT GETSWET. NEVER TRY TO USE A DEVICE THATHAS BEEN WET - - REPLACE IT.
POWERPURGE
IGNITORVALVEFLAME
FS
BLOWER
PRIMARYHSI
120V AC IN
RED/SOCKET
WHITE/PIN
RED/PIN
CONTROL
RED/
SOCK
ET P6
P7P1
P5
AN1
AN2
AN3
AN4
AN5
SECO
NDAR
Y
WHITE/PIN
WHITE/PIN
P2
P3
Y
TRANSFORMER115V AC INPUT
24V AC OUTPUT
BLBL
YBK
GN
W
1P2
2P2
1P1
2P1
3P1
W
GN/Y
BKTOGGLE SWITCH
Y
Y
BK
115 VOLTS ACN
GND
LT
POTENTIOMETER
UPPERSENSOR
POT.
R-C COM
N.O.
SEN-1 S-1
LOWER S-1
24V T-24
T-24H
RR-N.O.
ELECTRONICTHERMOSTAT
BL
BL
R
R
R R
R
BL
BR
GN
GY
GY
P.S. N.C. P.S. N.O.
N.C. TEMP SWITCH
G
TOGGLE SWITCHLIGHT
MV
GAS VALVE
ELECTRONICCONTROLMODULE
W
W
GN
BK
W
BK
IGNITOR
BLOWERMOTOR
FLAME SENSORFS
3 P7
2 P7
1 P7
7 P3
9 P3
2 P3
3 P3
1 P3
4 P3
6 P3
5 P3
8 P3
P6 1
P6 2
P5 1
P5 2
P5 3
P5 4
WIRING DIAGRAM
10
HEC SeriesSequence of Operation
For models starting with CF serial numbers and later
1. Thermostatcallsforheat. Prior to energizing blower, ignition module checks to make sure the vent temperature switch is in the nor-
mallyclosedposition.Iftheventtemperatureswitchisopen,thecontrolwaitsindefinitelyforthetemperatureswitchtoclose.
2. Blowerenergizes,pressureswitchcontactsarenormallyclosed.Ifthepressureswitchcontactsareopen,bloweroperatesforupto5minuteswaitingforcontactstoclose,thenblowerstopsandflashesredPURGELEDindicatinglockoutcondition.
3. Blowerpre-purgeperiod(5seconds)indicatedbythePURGELEDonthemodule.
4. Igniterwarmup(18seconds),indicatedbytheIGNITERLEDonthemodule.Note:theblockedventpres-sureswitchmustbeinthenormallyclosedpositionfortheignitioncycletostart.
5. Trialforignition(4seconds,threetrials).a) Flameestablishingperiod(2.5seconds)gasvalveandigniteron,indicatedbytheIGNITERand
VALVE LED on the moduleb) Burneron,flameprovidingperiod(1.5seconds,lookingforminimumof1microamps),indicatedby
theFLAME&VALVELEDonthemodule.
6. Steadystateoperation.Ignitionmodulemonitors. -Thermostatcircuit. -Whenthermostatopens,gasvalveisshutdownandpostpurgebegins. -Safetycircuit.
- If vent temp switch opens, gas valve is shut down, system will post purge and wait for switch to close beforeattemptingre-ignition.
- If the blocked vent pressure switch opens, indicating a blocked exhaust vent condition, the gas valve is shut down, blower shuts down for 30 seconds and is re-energized and system attempts re-ignition ifthepressureswitchisclosed.Bloweroperatesfor5minutestowaitforpressureswitchtoclose,thenshutsoffwithpurgelightflashing(lockout).Willrestartin1hourtoattempttoclosetheswitchandrestartignitionsequence.
- Flamesensorcircuit.- Ifflameislost,gasvalveisshutdown,systemwillpostpurgeandsystemattemptsre-ignition.
7. Thermostatsatisfied.
8. Burneroff.
9. Blowerpostpurge(15seconds).
HEC SeriesLockout Conditions The system will go into lock out mode for the following reasons:
Blocked vent pressure switch contacts open - Check for obstruction in exhaust pipe and vent terminal - Checkforblockedcondensatetrapordrainline.Incoldclimates,makesuredrainisnotfrozen. Noignitionafter3attempts - Checkinletandoutletgaspressures(pressuretapslocatedontopofgasvalve). - Igniterresistancetoohigh(lowerresistancepreferred<150Ohms). - Misadjusted venturi screw (should be 6 ½turnsoutfrombottom). - Flamesensemicroampsshouldnotpresent(1to5microampsrequired).Ifburnerlit,checkflamerod
fordeposits. - Checkburnertubeconditions.RefertosectionServiceProcedureIIIforburnertubeinspectionand
replacement.
IgnitionModuleSpecifications Control Function:
- Ignition & heating functions in response to thermostat-Hotsurfaceignitionusingamicroprocessortocontroltiming,flamesensingusingflamerectification&ignitionretries.
- Monitoring of system pressure switches and limit switches- Control of gas valve, inducer motor, and hot surface igniter element based on thermostat demand and statusofsafetyinputs.
- Diagnosticindicatorstoprovideinformationonpowertocontrolandcontrolstatus.- Non-interchangeablepolarizedplug-inconnectorsforallinterconnections
Control Inputs: Control Outputs:- Thermostat call for heat - Inducer motor- Blocked vent pressure switch (normally closed) - Hot surface igniter- Flame sensing - Gas valve- Low voltage supply - Status indicator LEDs- Line voltage supply Power - Green Purge - Red Igniter - Red Valve - Red Flame - Red
Sequence of OperationFor models starting with
CF serial numbers and later
11
IGNITION MODULE
UT ELECTRONICCONTROLS
P2
P3
P5
P1
P7P6
HUNTINGTON, INDIANA1013 SERIES INTEGRATED WATER HEATER
POWER
PURGE
IGNITOR
VALVE
FLAME
INDICATORLIGHTS
FOR OPERATING SEQUENCE TROUBLESHOOTING SEE INSTALLATIONAND OPERATING INSTRUCTION MANUAL
ANSI Z21.20 AUTOMATIC IGNITION SYSTEMSCAN/CSA-22.2 NO. 199-M89
24 VAC 0.5 AMP 50/60Hz
IF SYSTEM LOCK OUT, REMOVE POWER FOR 45 SECONDS TO RESETSYSTEM WILL AUTOMATICALLY RE-TRY AFTER 1 HOUR
WARNINGEXPLOSION HAZARD, CAN CAUSESERIOUS INJURY OR DEATH
THIS DEVICE CAN MALFUCTION IF IT GETSWET. NEVER TRY TO USE A DEVICE THATHAS BEEN WET - - REPLACE IT.
POWERPURGE
IGNITORVALVEFLAME
FS
BLOWER
PRIMARYHSI
120V AC IN
RED/SOCKET
WHITE/PIN
RED/PIN
CONTROL
RED/
SOCK
ET P6
P7P1
P5
AN1
AN2
AN3
AN4
AN5
SECO
NDAR
Y
WHITE/PIN
WHITE/PIN
P2
P3
1P2
2P2
1P1
2P1
3P1
ELECTRONICCONTROLMODULE
FS
3 P7
2 P7
1 P7
7 P3
9 P3
2 P3
3 P3
1 P3
4 P3
6 P3
5 P3
8 P3
P6 1
P6 2
P5 1
P5 2
P5 3
P5 4
W
W
GN
BK
W
BK
IGNITOR
BLOWERMOTOR
FLAME SENSOR
TRANSFORMER115V AC INPUT
24V AC OUTPUT
BL
YBK
GNW
W
GN/Y
BK
TOGGLE SWITCHY
Y
G
TOGGLE SWITCHLIGHT
GY
GY
N.C. TEMP SWITCH
R
R
BL
BR
GN
P.S. N.C.
MV
GAS VALVE
POTENTIOMETER
UPPERSENSOR
POT.
R-C COMN.O.
SEN-1 S-1LOWER S-1
24V T-24
T-24H
RR-N.O.
ELECTRONICTHERMOSTAT
BLBL
R
R
BK
115 VOLTS ACN
GND
LT
GN/Y
WBK
POWERED ANODE ON399,999 BTUH MODELS ONLY
LN
21
WIRING DIAGRAM
12
HEC Series TroubleshootingSystem Observation
Refer to ignition moduleillustration, is there 120VACbetween P1(1) and P1(3)?
Is front panel powerswitch light on,
indicating power?
Y
N Position front panelpower switch to“ON” position.
Is there 120VACacross switch?
(see photo at right)
Light burned out,replace switch.
Y
Is there 120VACacross terminal block?
(see photo at right)
N
Determine powersource problem and
correct.
Repair/replace wireharness to switch.
Y
N
Is ignition modulepower light on?
N
Y
Refer to ignition moduleillustration, is there 120VACgoing to module at locations
P7(1) and P7(3)?
N
Replace ignition module. Replace transformer.
N N
Y Y
Is ignition modulepower and flame light
flashing?
Reset heater byinterrupting power.
Reestablish power andAdjust thermostat to
call for heat,tank must be cold.
Allow heater to runthrough heating cycle.
Did heater completeheating cycle and didblower post purge?
See next page
System is OK.
Supply voltage polarityis incorrect.
Y
N
N
Y
Refer to ignition moduleillustration, is there 24VAC
going to module at locationsP2(1) and P2(2)?
WARNING120 volt potential exposure. Use caution
making voltage checks to avoid personal injury.
Power Switch
Terminal Block
Replace ignition module.(see pg 39) (see pg 39) (see pg 40)
IGNITION MODULE
UT ELECTRONICCONTROLS
P2
P3
P5
P1
P7P6
HUNTINGTON, INDIANA1013 SERIES INTEGRATED WATER HEATER
POWER
PURGE
IGNITOR
VALVE
FLAME
INDICATORLIGHTS
FOR OPERATING SEQUENCE TROUBLESHOOTING SEE INSTALLATIONAND OPERATING INSTRUCTION MANUAL
ANSI Z21.20 AUTOMATIC IGNITION SYSTEMSCAN/CSA-22.2 NO. 199-M89
24 VAC 0.5 AMP 50/60Hz
IF SYSTEM LOCK OUT, REMOVE POWER FOR 45 SECONDS TO RESETSYSTEM WILL AUTOMATICALLY RE-TRY AFTER 1 HOUR
WARNINGEXPLOSION HAZARD, CAN CAUSESERIOUS INJURY OR DEATH
THIS DEVICE CAN MALFUCTION IF IT GETSWET. NEVER TRY TO USE A DEVICE THATHAS BEEN WET - - REPLACE IT.
POWERPURGE
IGNITORVALVEFLAME
FS
BLOWER
PRIMARYHSI
120V AC IN
RED/SOCKET
WHITE/PIN
RED/PIN
CONTROL
RED/
SOCK
ET P6
P7P1
P5
AN1
AN2
AN3
AN4
AN5
SECO
NDAR
Y
WHITE/PIN
WHITE/PIN
P2
P3
HEC Series
13
TroubleshootingSystem Observation
Determine failure mode by observing flashing LED status on ignition module.LED status and probable cause shown below.
* Denotes conditions that may require the water heater to be isolated from the ventsystem to determine root cause.
LED STATUSPower & flamelight flashing.
Probable CauseSupply voltage
polarity.
LED STATUSValve light flashing.
Probable CauseFlame sensor.
(see “Flame SensorTesting and Replacement”)
Probable CauseHot surface igniter.(see “Hot SurfaceIgniter Testing and
Replacement”)
Probable Cause*Combustion system.
(see “CombustionSystem Testing and
Replacement”)
Probable Cause*Intake pressure switch. Only for
models prior to CF serial number(see “Intake Pressure SwitchTesting and Replacement”)
Probable CauseBlower.
(see “Blower Testingand Replacement”)
Probable Cause*Exhaust pressure
switch. (see “ExhaustPressure Switch
Testing andReplacement”)
LED STATUSPurge light flashing.
LED STATUSOnly power light
is on and water heaterwill not function.
Probable CauseThermostat circuit.
(see pg 14)
Probable Cause*Exhaust pressure
switch. (see “ExhaustPressure Switch
Testing andReplacement”)
Probable CauseVent safety switch.
(see pg 43)
14
HEC Series Service Procedure IThermostat Circuit Testing & Replacement
Refer to ignition moduleillustration, Is there 24VACbetween P3(7) and P3(8)?
Y
OK, thermostat iscalling for heat.
Turn off power to heater.Disconnect YELLOW and RED wires from the
thermostat board at location N.O. and COM shown inphoto at right. Use a jumper to connect these two
wires together as shown in photo at right.Restore power to heater.
Did heater cycle on?
N
Check thermostat sensorfor proper resistance
(OHMS) across blue wires.(See Appendix A, sensor
resistance)Are readings correct?
(see photo at right)
Check temperature dial forproper resistance (OHMS)
(See Appendix B,temperature dial resistance)
Are readings correct?(see photo at right)
Y
Y
Replacethermostat sensor.
(see Thermostat SensorReplacement Procedure)
Replace temperature dial(potentiometer).
(see Thermostat PotentiometerReplacement Procedure)
N
N
N
Replace thermostatcircuit board.
(see Thermostat BoardReplacement Procedure)
Y
Check sensor harnesscontinuity.
Is there continuity?
Check temperature dialharness continuity.Is there continuity?
Replace harness.
Y
N
Replace harness.N
Y
See page 16
IMPORTANT NOTE: This procedure assumes a cool tank
Rotate temperaturedial to highest setting.
Thermostatnot calling
WARNING120 volt potential exposure. Usecaution making voltage checks
to avoid personal injury.
ThermostatSensor
Temperature Dial
Yellow & Redwires shown
jumpered
Yellow Wire(COM)
Red Wire(N.O.)
IGNITION MODULE
UT ELECTRONICCONTROLS
P2
P3
P5
P1
P7P6
HUNTINGTON, INDIANA1013 SERIES INTEGRATED WATER HEATER
POWER
PURGE
IGNITOR
VALVE
FLAME
INDICATORLIGHTS
FOR OPERATING SEQUENCE TROUBLESHOOTING SEE INSTALLATIONAND OPERATING INSTRUCTION MANUAL
ANSI Z21.20 AUTOMATIC IGNITION SYSTEMSCAN/CSA-22.2 NO. 199-M89
24 VAC 0.5 AMP 50/60Hz
IF SYSTEM LOCK OUT, REMOVE POWER FOR 45 SECONDS TO RESETSYSTEM WILL AUTOMATICALLY RE-TRY AFTER 1 HOUR
WARNINGEXPLOSION HAZARD, CAN CAUSESERIOUS INJURY OR DEATH
THIS DEVICE CAN MALFUCTION IF IT GETSWET. NEVER TRY TO USE A DEVICE THATHAS BEEN WET - - REPLACE IT.
POWERPURGE
IGNITORVALVEFLAME
FS
BLOWER
PRIMARYHSI
120V AC IN
RED/SOCKET
WHITE/PIN
RED/PIN
CONTROL
RED/
SOCK
ET P6
P7P1
P5
AN1
AN2
AN3
AN4
AN5
SECO
NDAR
Y
WHITE/PIN
WHITE/PIN
P2
P3
HEC Series
15
Service Procedure IThermostat Circuit Testing & Replacement
°F 0 1 2 3 4 5 6 7 8 940 26109 25400 24712 24045 23399 22771 22163 21573 21000 2044550 19906 19383 18876 18383 17905 17440 16990 16553 16128 1571560 15314 14925 14548 14180 13823 13477 13140 12812 12494 1218570 11884 11592 11308 11032 10763 10502 10248 10000 9760 952680 9299 9078 8862 8653 8449 8250 8057 7869 7685 750790 7333 7165 7000 6839 6683 6531 6383 6238 6098 5961100 5827 5697 5570 5446 5326 5208 5094 4982 4873 4767110 4663 4562 4464 4368 4274 4183 4094 4006 3922 3839120 3758 3679 3602 3527 3453 3382 3312 3244 3177 3112130 3048 2986 2925 2866 2808 2752 2697 2643 2590 2538140 2488 2439 2391 2344 2298 2253 2209 2166 2124 2083150 2043 2004 1966 1928 1891 1856 1820 1786 1753 1720160 1688 1656 1625 1595 1566 1537 1509 1481 1454 1427170 1402 1376 1351 1327 1303 1280 1257 1235 1213 1191180 1170 1150 1129 1110 1090 1071 1053 1035 1017 999190 982 965 949 933 917 901 886 871 857 842200 828 814 801 788 775 762 749 737 725 713
In Degrees F
APPENDIX - ASensor Resistance at Various Temperatures
Example: If temperature of sensor is 84°F, then the resistance through the sensor would be 8449 (see shaded area).NOTE: Sensor resistance increases as the temperature falls.
Be Careful When Making Voltage Measurements or Jumping TerminalsNot to Damage or Deform Connectors or Connector Pins.
APPENDIX - BTemperature Dial Resistance
Proper Readings Should Be 5400-6600 Ohms at MinimumSetting
And 0-50 Ohms at Maximum.
Be Careful When Making Voltage Measurements or Jumping TerminalsNot to Damage or Deform Connectors or Connector Pins.
Draw Water From The T&P Valve. Compare Temperature WithTemperature Ohms Chart Below.
16
HEC Series Service Procedure IThermostat Circuit Testing & Replacement
Refer to ignition moduleillustration, Is there 120VACbetween P1(1) and P1(3)?
Refer to ignition moduleillustration, Is there
22 - 27VAC betweenP2(1) and P2(2)?
Refer to ignition moduleillustration, Is there 120VACbetween P7(3) and P7(1)?
Replace transformer.(see Transformer
Replacement)
Refer to ignition moduleillustration, Is there 24VACbetween P3(9) and P2(1).
N
N
Y
Y
Check wire harnesscontinuity. Replace
thermostat sensor or wireharness as necessary.
(see “Thermostat SensorReplacement Procedure”)
Check AC source todetermine why there is no
power.
Replaceignition module.
(see “Ignition ModuleReplacement”)
N
Check continuity throughECO, red wires ofthermostat sensor.
Check at temperatureless than 160°F
Is there continuity?(see photo at right)N
Replace ignition module.(see “Ignition Module
Replacement”)
Y
Replace thermostatcircuit board.
(see “Thermostat BoardReplacement Procedure”)
Y
N
Y
Thermostat circuit.(continued from page 14)
WARNING120 volt potential exposure. Use caution
making voltage checks to avoid personal injury.
Red Wires(Temperature Sensor)
IGNITION MODULE
UT ELECTRONICCONTROLS
P2
P3
P5
P1
P7P6
HUNTINGTON, INDIANA1013 SERIES INTEGRATED WATER HEATER
POWER
PURGE
IGNITOR
VALVE
FLAME
INDICATORLIGHTS
FOR OPERATING SEQUENCE TROUBLESHOOTING SEE INSTALLATIONAND OPERATING INSTRUCTION MANUAL
ANSI Z21.20 AUTOMATIC IGNITION SYSTEMSCAN/CSA-22.2 NO. 199-M89
24 VAC 0.5 AMP 50/60Hz
IF SYSTEM LOCK OUT, REMOVE POWER FOR 45 SECONDS TO RESETSYSTEM WILL AUTOMATICALLY RE-TRY AFTER 1 HOUR
WARNINGEXPLOSION HAZARD, CAN CAUSESERIOUS INJURY OR DEATH
THIS DEVICE CAN MALFUCTION IF IT GETSWET. NEVER TRY TO USE A DEVICE THATHAS BEEN WET - - REPLACE IT.
POWERPURGE
IGNITORVALVEFLAME
FS
BLOWER
PRIMARYHSI
120V AC IN
RED/SOCKET
WHITE/PIN
RED/PIN
CONTROL
RED/
SOCK
ET P6
P7P1
P5
1NA2NA
3NA4NA
5NA
YRADNOCES
WHITE/PIN
WHITE/PIN
P2
P3
HEC Series
17
Service Procedure IThermostat Circuit Testing & Replacement
WIRING DIAGRAMFor models prior toCF serial number
Step 5. Carefully disconnect all wires from thermostatboard.
Note: it may be necessary to identify wires for proper re-connection.
Step 6. Remove the two screws (Phillips head screwdriver) that secure thermostat board tocontrol panel.
Step 7. Install new thermostat board to control panel usingscrews from step 6.
Step 8. Carefully reconnect wiring per the wirediagram below. Reconfirm wireconnections are correct prior to puttingheater back in service
Step 9. Restore 120 volt power supply to waterheater and confirm proper operation followingthe lighting instructions on the lightinginstruction label or the lighting instructionlocated in the installation and operatinginstruction manual.
Step 10. Replace surround cover on top of heater.
Thermostat Board Replacement ProcedureStep 1. Position main power switch to “OFF”
Step 2. Disconnect (unplug) water heater from 120volt power source.
Step 3. Un-latch and remove top surround coverfrom top of heater.
Step 4. Locate thermostat board on control panel.(see photo at right)
WIRING DIAGRAMFor models starting withCF serial numbers and
later.
WARNING120 volt potential exposure. Isolate the
appliance and reconfirm power isdisconnected using a multi-meter.
ThermostatBoard
Mountingscrew locations
Y
TRANSFORMER115V AC INPUT
24V AC OUTPUT
BLBL
YBK
GN
W
1P2
2P2
1P1
2P1
3P1
W
GN/Y
BKTOGGLE SWITCH
Y
Y
BK
115 VOLTS ACN
GND
LT
POTENTIOMETER
UPPERSENSOR
POT.
R-C COM
N.O.
SEN-1 S-1
LOWER S-1
24V T-24
T-24H
RR-N.O.
ELECTRONICTHERMOSTAT
BL
BL
R
R
R R
R
BL
BR
GN
GY
GY
P.S. N.C. P.S. N.O.
N.C. TEMP SWITCH
G
TOGGLE SWITCHLIGHT
MV
GAS VALVE
ELECTRONICCONTROLMODULE
W
W
GN
BK
W
BK
IGNITOR
BLOWERMOTOR
FLAME SENSORFS
3 P7
2 P7
1 P7
7 P3
9 P3
2 P3
3 P3
1 P3
4 P3
6 P3
5 P3
8 P3
P6 1
P6 2
P5 1
P5 2
P5 3
P5 4
1P2
2P2
1P1
2P1
3P1
ELECTRONICCONTROLMODULE
FS
3 P7
2 P7
1 P7
7 P3
9 P3
2 P3
3 P3
1 P3
4 P3
6 P3
5 P3
8 P3
P6 1
P6 2
P5 1
P5 2
P5 3
P5 4
W
W
GN
BK
W
BK
IGNITOR
BLOWERMOTOR
FLAME SENSOR
TRANSFORMER115V AC INPUT
24V AC OUTPUT
BL
YBK
GNW
W
GN/Y
BK
TOGGLE SWITCHY
Y
G
TOGGLE SWITCHLIGHT
GY
GY
N.C. TEMP SWITCH
R
R
BL
BR
GN
P.S. N.C.
MV
GAS VALVE
POTENTIOMETER
UPPERSENSOR
POT.
R-C COMN.O.
SEN-1 S-1LOWER S-1
24V T-24
T-24H
RR-N.O.
ELECTRONICTHERMOSTAT
BLBL
R
R
BK
115 VOLTS ACN
GND
LT
GN/Y
WBK
POWERED ANODE ON399,999 BTUH MODELS ONLY
LN
21
18
HEC Series Service Procedure IThermostat Circuit Testing & Replacement
Thermostat Potentiometer Replacement Procedure
Step 4. Loosen set screw of adjustingknob (small blade screw driver)and remove adjusting knobfrom potentiometer. (see photos at right)
Step 5. Remove retaining nut (½" wrench)and washer from potentiometer.(see photos at right)
Step 6. From inside of surround area, remove potentiometerwith gasket from side of surround. Notice how indexingtab on potentiometer assembles into locating hole ofsurround. (see photos below)
Step 7. Disconnect potentiometer wire leads.(see photo at right)
Step 8. Install new potentiometer with gasket into side of surround. Be sure to assemble withindexing tab inserted into locating hole on side of surround (see photos above).
Step 9. Reconnect wires to potentiometer. Note: Wire leads are interchangeable with either wire.
Step 10. Restore 120 volt power supply to water heater and confirm proper operation followingthe lighting instructions on the lighting instruction label or the lighting instruction locatedin the installation and operating instruction manual.
Step 11. Replace surround cover on top of heater.
Step 1. Position main power switch to “OFF”
Step 2. Disconnect (unplug) water heater from120 volt power source.
Step 3. Un-latch and remove top surround coverfrom top of heater.
WARNING120 volt potential exposure. Isolate the
appliance and reconfirm power isdisconnected using a multi-meter.
TemperatureAdjusting Knob
IndexingTab
LocatingHole
Loosen set screwwith small blade
screw driver
Removeretaining nut
PotentiometerWire Leads
HEC Series
19
Service Procedure IThermostat Circuit Testing & Replacement
Thermostat Sensor (Thermister) Replacement Procedure
Step 5. Fold back insulation just in front of burner to expose temperature sensor (see photo below).
Step 6. Disconnect temperature sensor from harness (see photos below).
Step 7. Remove temperature sensor (1-1/16" hex, deep well socket) from heater.
Note: Using a deep well socket will allow room inside socketfor sensor connector and wires.
Step 8. Apply Teflon tape or applicable thread lubricant to threads of new sensor.Install new thermostat sensor and Connect to wire harness from step 6.
Step 9. Fold insulation back into place. Be sure there are no wires in contact with burner.
Step 10. Restore 120 volt power supply and water supply to water heater, check and repair anyleaks found. Confirm proper operation following the lighting instructions on the lightinginstruction label or the lighting instruction located in the installation and operatinginstruction manual.
Step 11. Replace surround cover on top of heater.
Step 1. Position main power switch to “OFF”
Step 2. Disconnect (unplug) water heater from120 volt power source.
Step 3. Drain water down to the point belowthe top of the tank.
Step 4. Un-latch and remove top surround cover from top of heater.
WARNING120 volt potential exposure. Isolate the
appliance and reconfirm power isdisconnected using a multi-meter.
Disconnect sensorfrom harnessInsulation folded
back to exposetemperature sensor
20
HEC Series Service Procedure IICombustion System Testing & Replacement
Does inlet gas pressuredrop more than 2" W.C.during burner ignition?
Adjust gassupply regulator
Inadequatelysized regulator.
Y
N
N
Y
N
Y
N
Verify Minimum Gas Supply Piping Requirements of:Minimum 1" NPT for EF100T399, all others use ¾"NPT. (Schedule 40 black Iron Pipe recommended).
Reconfigure gassupply piping
Y
Observe burner operation through the sight glass located on the combustion insert mounting flange.Normal burner operation should ignite smoothly, without evidence of coughing or huffing uponignition. The burner flame should be a blue flame near the burner surface in a uniform flame pattern.Occasional yellow or white streaks are normal.
Inlet gaspressure tap
Venturiadjustment
Is igniter resistanceless than 150 Ohms
(cold)?(see check igniter
illustration)
Refer to ignition module illustration below,is there 120VAC across terminals
P6(1) and P6(2)?(Note: Igniter LED must be lit during this check).
Y
NReplace
hot surface igniter.(see “Hot Surface IgniterReplacement Procedure)
Replace ignition module.(see “Ignition Module
Replacement Procedure”)
N
Y
Do you see the igniterglowing through burner
site glass during thewarm up period?
Proceed to next page
With manometer, check inletgas pressure. Is it stable
between 7" & 14" W.C. static?(heater not running)
(see illustrations at right)
Is gas supply pressureregulator adjustable tomaintain proper and
stable setting?
Y
N
Volt meter set toOHM setting
Meter probe
Hot surfaceigniter
CHECK IGNITERRESISTANCE
WARNING120 volt potential
exposure. Use cautionmaking voltage checks to
avoid personal injury.
WARNINGRemoving screw from
inlet gas pressure tap willimmediately allow gas toflow from pressure tap.
Note: On higher input models using metal fiber mesh burner (serialnumber “CK” and later) a red glow from the burner surface is normal.
IGNITION MODULE
UT ELECTRONICCONTROLS
P2
P3
P5
P1
P7P6
HUNTINGTON, INDIANA1013 SERIES INTEGRATED WATER HEATER
POWER
PURGE
IGNITOR
VALVE
FLAME
INDICATORLIGHTS
FOR OPERATING SEQUENCE TROUBLESHOOTING SEE INSTALLATIONAND OPERATING INSTRUCTION MANUAL
ANSI Z21.20 AUTOMATIC IGNITION SYSTEMSCAN/CSA-22.2 NO. 199-M89
24 VAC 0.5 AMP 50/60Hz
IF SYSTEM LOCK OUT, REMOVE POWER FOR 45 SECONDS TO RESETSYSTEM WILL AUTOMATICALLY RE-TRY AFTER 1 HOUR
WARNINGEXPLOSION HAZARD, CAN CAUSESERIOUS INJURY OR DEATH
THIS DEVICE CAN MALFUCTION IF IT GETSWET. NEVER TRY TO USE A DEVICE THATHAS BEEN WET - - REPLACE IT.
POWERPURGE
IGNITORVALVEFLAME
FS
BLOWER
PRIMARYHSI
120V AC IN
RED/SOCKET
WHITE/PIN
RED/PIN
CONTROL
RED/
SOCK
ET P6
P7P1
P5
1NA2NA
3 NA4NA
5NA
YRADNOCESWHITE/PIN
WHITE/PIN
P2
P3
SIGHT GLASS
HEC Series
21
Service Procedure IICombustion System Testing & Replacement
Refer to ignition module illustration below,is there 24VAC between P3(2) and P3(5) (blue andbrown wires) during the flame establishing period?
(Note: Valve LED must be lit during this check)
Y
Replaceignition module.
(see “Ignition ModuleReplacement Procedure”)
N
Replace Rectifier harness and/orgas valve.
(see “Gas Valve ReplacementProcedure”)
N
Y
Does flame LED on the modulelight and stay lit?
Can you hear or feelgas valve energize?
Does burner lightsmoothly, without
evidence of coughingor huffing?
Y
N
Check for obstructionat inlet of gas valve.
Is inlet free ofobstruction?
Check flame sensor,Is there 1 to 5 micro amps(min.) during 1.5 second
flame proving period?(see “Flame Sensor Testing
Procedure”)
N
Y
Continued fromprevious page
N
Call for technicalsupport
Clear obstruction
Y
Does burner operatenormaly until thermostat is
satisfied?
N
System OK
Y
Turn VENTURI set screw clockwise until itsbottomed out. Turn screw counter-clockwise 6-½turns from bottom (see illustration below). Note:100HEC-399 models do not have a venturi screw.The gas regulator setting should be 1 - 1 ¼ turns
out from bottom.
Replace flame sensor(see “Flame Sensor
ReplacementProcedure”)
Inspect burner tube, (see “BurnerTube Inspection and Replacement”)
N
Y
N
WARNING120 volt potential exposure. Isolate the
appliance and reconfirm power isdisconnected using a multi-meter.
Y
Venturiadjustment
Inlet gaspressure tap
100HEC-399Only
Gas valveregulator
Observe burner operation through the sight glass located on the combustion insert mounting flange.Normal burner operation should ignite smoothly, without evidence of coughing or huffing uponignition. The burner flame should be a blue flame near the burner surface in a uniform flame pattern.Occasional yellow or white streaks are normal.
IGNITION MODULE
UT ELECTRONICCONTROLS
P2
P3
P5
P1
P7P6
HUNTINGTON, INDIANA1013 SERIES INTEGRATED WATER HEATER
POWER
PURGE
IGNITOR
VALVE
FLAME
INDICATORLIGHTS
FOR OPERATING SEQUENCE TROUBLESHOOTING SEE INSTALLATIONAND OPERATING INSTRUCTION MANUAL
ANSI Z21.20 AUTOMATIC IGNITION SYSTEMSCAN/CSA-22.2 NO. 199-M89
24 VAC 0.5 AMP 50/60Hz
IF SYSTEM LOCK OUT, REMOVE POWER FOR 45 SECONDS TO RESETSYSTEM WILL AUTOMATICALLY RE-TRY AFTER 1 HOUR
WARNINGEXPLOSION HAZARD, CAN CAUSESERIOUS INJURY OR DEATH
THIS DEVICE CAN MALFUCTION IF IT GETSWET. NEVER TRY TO USE A DEVICE THATHAS BEEN WET - - REPLACE IT.
POWERPURGE
IGNITORVALVEFLAME
FS
BLOWER
PRIMARYHSI
120V AC IN
RED/SOCKET
WHITE/PIN
RED/PIN
CONTROL
RED/
SOCK
ET P6
P7P1
P5
AN1
AN2
AN3
AN4
AN5
SECO
NDAR
Y
WHITE/PIN
WHITE/PIN
P2
P3
22
HEC Series Service Procedure IICombustion System Testing & Replacement
Step 1. Position main power switch to “OFF”.
Step 2. Disconnect (unplug) water heater from120 volt power source.
Step 3. Turn off gas supply to water heater.
Step 4. Un-latch and remove surround cover from top ofheater.
Step 5. From the gas valve, disconnect the gasconnection, PVC venting, Silicone tubingand wire harness.
Step 6. Disconnect wire harnesses from hot surface igniter, flame sensor and blower
Step 7. Remove the 5 bolts (½" socket)holding the burner mounting insertin place.
Step 8. Carefully remove combustion assemblywith gasket from water heater.
Step 9. See next page for combustion system installation procedure.
Combustion System Removal Procedure
WARNING120 volt potential exposure. Isolate the
appliance and reconfirm power isdisconnected using a multi-meter.
WARNINGHeater components may be HOT when performing the following steps in this procedure.
Take necessary precaution to prevent personal injury.
Gas valvewire harness
Gasconnection
PVC ventconnection
Burner mountinginsert
Burner mountingscrew
(Total of 5)
Burner tube
Burner mountinginsert gasket
HEC Series
23
Service Procedure IICombustion System Testing & Replacement
Combustion System Replacement ProcedureStep 1 Fully inspect burner mounting insert gasket for the following:
a) Tears d) Dirt or debrisb) Missing material e) Other imperfections that would inhibit proper sealc) Cracks
If gasket is NOT affected by any of the above, gasket replacement is not required.
Step 2. Install combustion assembly using new gasket or fully inspected gasket from step 1.Secure combustion assembly at the burner mounting insert using screws from step 6on previous page. Tighten screws evenly.
Step 3. Reconnect wire harnesses to hot surface igniter, flame sensor, blower and gas valve.
Step 4. Reconnect PVC venting, gas supply and silicone tubing to gas valve. Turn on gassupply to heater and check for gas leaks, repair any gas leaks found.
Step 5. Restore 120 volt power supply to water heater and confirm proper operation followingthe lighting instructions on the lighting instruction label or the lighting instruction locatedin the installation and operating instruction manual.
Step 6. Replace surround cover on top ofwater heater.
Gas valvewire harness
Gasconnection
PVC ventconnection
Burner mountinginsert
Burner mountingscrew
(Total of 5)
Burner tube
Burner mountinginsert gasket
24
HEC Series Service Procedure IIIBurner Tube Inspection & Replacement
Step 1. Position main power switch to “OFF”.
Step 2. Disconnect (unplug) water heater from120 volt power source.
Step 3. Turn off gas supply to water heater.
Step 4. Un-latch & remove surround cover from top ofheater.
Step 5. From the gas valve, disconnectthe gas connection, PVC venting,wire harness and silicone tubing.
Step 6. Disconnect wire harness fromblower assembly.
Step 7. Remove the two screws holdingeach the hot surface igniter andflame sensor in place (long reachmagnetic Phillips screw driver).Carefully remove hot surface igniterand flame sensor from combustionassembly.
Step 8. Remove the 4 nuts (7/16" wrench) holdingthe burner transition in place. Lift the blower/gasvalve transition assembly from burner mountinginsert, remove gasket and set aside.
Step 9. Remove burner tube from burnermounting insert. See next page forburner tube inspection procedure.
Burner Tube Removal Procedure
WARNING120 volt potential exposure. Isolate the
appliance and reconfirm power isdisconnected using a multi-meter.
WARNINGHeater components may be HOT when performing the following steps in this procedure.
Take necessary precaution to prevent personal injury.
BURNER TRANSITIONMOUNTING NUTS
BLOWER/GAS VALVE/TRANSITION ASSEMBLY
FLAMESENSOR
BURNERFLANGEGASKET
BURNERFLANGEGASKET
GAS VALVEWIRE HARNESS
GAS CONNECTION
BURNERTRANSITION
HOT SURFACEIGNITER
BURNER TUBE
BURNER MOUNTING INSERT
PVC VENTCONNECTION
HEC Series
25
Service Procedure IIIBurner Tube Inspection & Replacement
Burner Tube InspectionStep 1. Inspect burner tube as follows (BSI ceramic fiber mesh burner, water heaters prior to
serial number “CK”) :a) Visually inspect ceramic fiber mesh, mesh should be uniform in appearance without large
gaps, tears or fraying. Mesh should have uniform pattern allowing for unrestricted gas flow.b) Gently squeeze burner tube, Burner tube should feel firm without any soft areas
around the sides or at the bottom.c) Visually inspect inside burner tube, Burner tube should be intact with no areas of
deterioration. Ports should be free of any debris.Inspect burner tube as follows (Acotech metal fiber mesh burner, water heaters with“CK” serial number or later).a) Outer fiber mesh should be uniform with no tears or deterioration.
Step 2. If burner tube is affected by any of the above, replacement is required. Refer to burnertube replacement procedure below.
Burner Tube Replacement ProcedureNote: New metal fiber mesh burner (Acotech) is the replacement burner for the BSI ceramic fiber sock burner. The lengthof burner will not be the same as the previous BSI burner. Provide the model and serial number for the correct replacementburner.
Step 1. Fully inspect burner flange gaskets, igniter and flame sensor gaskets for the following:a) Tears d) Dirt or debrisb) Missing material e) Other imperfections that would inhibit proper sealc) CracksIf gaskets are NOT affected by any of the above, gasket replacement is not required.
Step 2. Install burner tube with gaskets into burner mounting insert. Be sure gasket surfaces are free of debris.
Step 3. Reconnect the blower/gas valve/transition assembly to burner mounting insert. Secure usingnuts from step 8 on previous page.
Step 4. Carefully reinstall flame sensor with gasket and hot surface igniter with gasket and secure withscrews from step 7 on previous page. Reconnect wire harnesses to sensor and igniter.
Step 5. Reconnect wire harnesses to blower motor and to gas valve.
Step 6. Reconnect PVC venting, gas supply and silicone tubing to gas valve. Turn on gas to heaterand check for gas leaks, repair any gas leaks found.
Step 7. Restore 120 volt power supply to water heater and confirm proper operation following thelighting instructions on the lighting instruction label or the lighting instruction located in theinstallation and operating instruction manual.
Step 8. Replace surround cover on top of water heater.
WARNINGHeater components may be HOT when performing the following steps in this procedure.
Take necessary precaution to prevent personal injury.
26
HEC Series Service Procedure IVGas Valve Replacement
Gas Valve Replacement Procedure
Step 6. Remove the 2 gas valve mounting screws (Torx bit) located at the11:00 O-clock & 5:00 O-clock position on the venturi mounting flangeand remove gas valve from water heater.
Step 7. Remove any residual gasket material from blower and venturi mounting flange.
Step 8. Install new gas valve with new gasketprovided. Secure gas valve in place using screws from step 6.
Step 1. Position main power switch to “OFF”.
Step 2. Disconnect (unplug) water heater from120 volt power source.
Step 3. Turn off gas supply to water heater.
Step 4. Un-latch & remove surround cover from top of heater.
Step 5. From the gas valve, disconnect the gas connection, PVC venting, wire harness and silicone tubing.
Step 9. Reconnect PVC venting, gas supply, silicone tubing & wire harness to gas valve. Turnon gas supply to heater and check for gas leaks, repair any gas leaks found.
Step 10. Restore 120 volt power supply to water heater and confirm proper operation followingthe lighting instructions on the lighting instruction label or the lighting instruction locatedin the installation and operating instruction manual.
Step 11. Replace surround cover on top of water heater.
Gas valveassembly
Blower / gas valvegasket
Blower
Venturimounting flange
Gas valvemounting screws
(2 places)
Venturi inlet
Gas valvewire harness
WARNING120 volt potential exposure. Isolate the
appliance and reconfirm power isdisconnected using a multi-meter.
HEC Series
27
Service Procedure VBlower Testing & Replacement
Aresafety circuits in normal position?See Safety Circuit Trade on pg 32
Does blowerenergize?
Is there 120VACacrossthe white and
black wires at theblower?
(see photo at right)
Replace blower.(see “BlowerReplacementProcedure”)
Y
N
Refer to ignition module/control board illustration.Is there 120VACbetween
P5(1) and P5(3)?
Repair/replacewire harness.
Y Replace ignition module(see pg 39)
Y
N
N
Y
N
N
Is there 120VACacrossthe white and
black wires at theterminal block ?
Refer to ignitionmodule, isthere 24VAC between P3(7)
and ground?
Y
N
Thermostat notcalling for heat.
(see “ThermostatCircuit Testing”)
Correctsafety circuit problem persafety circuit trace
(section“Blocked Vent PressureSwitch Testing”).
Y
YIs there 120VAC
acrossthe white andblack wires at theterminal block ?
(seephoto at right)
N
NRefer toignition module/control board
illustration.Isthere 120VAC between P5(1) and P5(3)?
Y
Replaceignition module/control board.
Call technicalsupport
Check amp drawthroughBLACK wirelead of blower
motor. Isthere .6 to 3.0amps?
Replace blower.(see “Blower Replacement
Procedure”)
N
Y Is Blower wheel secured toblower motor shaft?
N
Y
Determinepower
sourceproblem
andcorrect
Black wire leading toblower motor looped
through amprobe.
120VAC check atTerminal Block
Checking for 120VAC(Black & White Wires)
28
HEC Series Service Procedure VBlower Testing & Replacement
Blower Replacement Procedure
Step 5. Disconnect wire harness from blower.
Step 6. Disconnect intake vent and gas supply from gas valve assembly.
Step 7. Remove the 2 gas valve mounting screws (Torx bit) located at the11:00 O-clock & 5:00 O-clock position on the venturi mounting flange.
Step 8. Remove The 4 blower flange mounting screws (5/32 Allen wrench) and remove blowerfrom transition flange.
Step 9. Remove any residual gasket materialfrom venturi mounting flange and transition flange.
Step 10. Install new blower with new gasketprovided. Secure blower in place usingscrews from step 8.
Step 11. Reconnect gas valve assembly to blowerwith new gasket provided. Secure gasvalve in place using screws from step 7.Step 12. Reconnect intake vent and
gas line to gas valve assembly andcheck for gas leaks repair any leaks found.
Step 13. Reconnect wire harness to blower assembly, restore 120 volt power supply & Gas supplyto water heater and confirm proper operation following the lighting instructions on thelighting instruction label or the lighting instructions located in the installation and operatinginstruction manual.
Step 14. Replace surround cover on top of water heater.
Step 1. Position main power switch to “OFF”.
Step 2. Disconnect (unplug) water heater from120 volt power source.
Step 3. Turn off gas supply to water heater.
Step 4. Un-latch & remove surround cover from top of heater.
WARNING120 volt potential exposure. Isolate the
appliance and reconfirm power isdisconnected using a multi-meter.
Gas valveassembly
Blower / gas valvegasket
Blower
Venturimounting flange
Gas valvemounting screws
2 places.
Blower / transitiongasket
Blower flangemounting screws
Transitionflange
Venturi inlet
HEC Series
29
Service Procedure VIExhaust Pressure Switch Testing & Replacement
For serial numbers prior to “CF”
Does blowerenergize?
N Y
Sequence of operation:With the thermostat calling for heat, prior to energizing blower, the ignition module checks the exhaust pressure switch for normalSwitch position of normally open. If the exhaust pressure switch contacts are closed (not in normal position), the ignition modulewaits 45 seconds for the pressure switch contacts to open. If the pressure switch contacts do not open after 45 seconds, theignition module locks out with the PURGE LED flashing indicating a pressure switch fault.
Is there continuityThrough GREY
wire leads of heater sidesafety circuit harness?
(see photo below)
N
Y
Is there continuitythrough RED
wire leads of heater sidesafety circuit harness?
(see photo below)
N
Check PURGE LED status.
Y
Safety Circuit OK,(see “Blower Testing
& Replacement”)
Replace exhaustpressure switch (see“Exhaust Pressure
Switch ReplacementProcedure”)
Replace vent safetyswitch.
(see “Vent SafetySwitch Replacement
Procedure”)
Call technicalsupport.
Y
N
Depress resetbutton on vent
safety switch. Isthere continuityacross high limit
switch?(see photo below)
Refer to“Check Collector Pressure”
(see next page)
Check blower for properoperation (see page 27)
Is blower OK?
N
Check PURGE LED statuson ignition module,
Flashing after 45 seconds?
On within 5 minutes? Pressure switch is OK.
Y
Y
Safety Circuit Trace
Does heaterfunction?
Verify properswitch operation.(see “Vent Safety
Switch Testing andReplacement”)
N
Y
LED StatusOnly power LED is on, or
Purge LED flashing.
N
Flashing after5 minutes?
Call for technicalsupport.
Correct blower problem(see “Blower Testing and
Replacement”)
N
Y
Y
WARNING120 volt potential exposure. Use caution
making voltage checks to avoid personal injury.
Heater sideharness
Control sideharness
Reset button
30
HEC SeriesService Procedure VI
Exhaust Pressure Switch Testing & ReplacementFor serial numbers prior to “CF”
Inspect the area housing the combustionsystem and control panel located at the
top of the heater.Does the area show signs of corrosion
and/or exssesive heat?
Y
N
Call fortechnical support
Remove combustion assembly(see “Combustion System
Removal Procedure”)Inspect combustion chamber
for blockage or debrisaccumulation
N
Replaceexhaust pressure switch.
(see “Exhaust Pressure SwitchReplacement Procedure”)
Is exhaust ventingsystem blocked or
obstructed?
Clear obstruction.Determine cause
Y
Is vent system totallength compliant with
vent tables in theinstruction manual?
Reconfigure ventsystem to be
compliant withvent tables (see“Specifications”).
Y
N
With monometer, take areading at the exhaust
tube pressure tap location.Is value negative (-)?
(see illustration below).
Check exhaust collector pressure at the exhaustcollector pressure tap location (see illustration below). Is
there positive pressure equal to or greater thanpressure switch settings below?
EXHAUST PRESSURE SWITCH SETTINGS60HEC-199,100HEC-199 +2.58" W.C.100HEC-150 +1.50" W.C.(see note 1)60HEC-150,100HEC-250 +1.22" W.C.60HEC-125 +2.08" W.C.100HEC-300 +0.55" W.C.(see note 2)
Note 1: +5.6" W.C. on serials prior to AH5039107Note 2: +0.8" W.C. on serials prior to AK5288269
Y
N
Y
Y
N
N
Clear obstruction.Determine cause
and correct.
Check Collector Pressure
Call fortechnical support
Exhaust Tubepressure tap location
Exhaust collectorpressure tap location
Exhaust tubeat bottom of water
heater
HEC Series
31
Service Procedure VIExhaust Pressure Switch Testing & Replacement
For serial numbers prior to “CF”
Exhaust Pressure Switch Replacement ProcedureStep 1. Position main power switch to “OFF” position.
Step 2. Loosen adhesive backed rubber escutcheon from service panel access coverand slide escutcheon back along exhaust pipe to allow for removal of cover.
Step 3. Remove screws from service panel access cover(¼" nut driver) and remove cover from heater.(see photos at right)
Step 4. Disconnect silicone tubing and wire leads frompressure switch. (see photos at right)
Step 5. Remove pressure switch mounting screws(5/16" wrench) and remove pressure switch.
Step 6. Assemble new pressure switch to heater usingscrews from step 5.
Step 7. Reconnect wire leads. Note: wire leads areinterchangeable with either terminal.
Step 8 Reconnect silicone tubing to pressure switchas follows:
a) Exhaust pipe tubing connects tonegative (-) side of switchidentified by the (-) symbollocated on switch.
b) Exhaust collector tubing connectsto positive (+) side of switchidentified by the (+) symbol locatedon the switch.
Step 10. Reinstall service panel access cover andrubber escutcheon.
Step 9. Restore 120 volt power supply to water heaterand confirm proper operation following thelighting instructions on the lighting instructionlabel or the lighting instructions located in the installationand operating instruction manual.
Exhaust pipepressure tap location
Exhaust collectorpressure tap location(serial numbers prior
to “CF”)
Example of switchshowing positive
side identifier
Rubberescutcheon
Pressure switchmounting screw5/16 hex head
Silicone tubing
Wire leads
32
HEC SeriesService Procedure VI
Exhaust Pressure Switch Testing & ReplacementFor serial numbers prior to “CF”
Reset button
Does blowerenergize?
N
Sequence of operation:The blocked vent pressure switch monitors the pressure in the exhaust tube. The switch contacts are normally closed and willnot open unless there is a blockage in the exhaust venting or terminal (snow, ice, debris). If the blocked vent pressure switchcontacts open after the thermostat initiates the blower, the blower will remain on for to 5 minutes waiting for the contacts to close.If the contacts remain open, the blower will stop and the PURGE LED will flash for hot surface ignition models, or error code 29will display for direct spark ignition models.
Check PURGE LED status.
Y
Refer to“Check Collector Pressure”
(see next page)
Check blower for properoperation (see “Blower
Testing and Replacement”)Is blower OK?
N
On within 5 minutes? Pressure switch is OK.
Y
Y
Safety Circuit Trace
LED StatusOnly power LED is on, or
Purge LED flashing.
N
WARNING120 volt potential exposure. Use caution
making voltage checks to avoid personal injury.
Flashing after 5 minutes?Error code 29 again?
Call for technicalsupport.
Correct blower problem(see “Blower Testing and
Replacement”)
N
Y
Note: The blocked vent pressure switchmust be used with the revised ignition control,identified with a yellow label.
Heater sideharness
Control sideharness
Y
Is there continuityThrough GREY
wire leads of heater sidesafety circuit harness?
(see photo below)
N
Y
Is there continuitythrough RED
wire leads of heater sidesafety circuit harness?
(see photo below)
N
Safety Circuit OK,(see “Blower Testing
& Replacement”)
Replace exhaustpressure switch (see“Exhaust Pressure
Switch ReplacementProcedure”)
Replace vent safetyswitch.
(see “Vent SafetySwitch Replacement
Procedure”)
Call technicalsupport.
Y
N
Depress resetbutton on vent
safety switch. Isthere continuityacross high limit
switch?(see photo below)
Check PURGE LED statuson ignition module,
Flashing after 45 seconds?Does heater
function?
Verify properswitch operation.(see “Vent Safety
Switch Testing andReplacement”)
N
Y
Y
WARNINGMake sure exhaust collector compartment is notoverheating (350°F) before resetting vent safety
switch. If there is evidence the collector compartmentis overheating, CALL TECHNICAL SUPPORT.
HEC Series
33
Service Procedure VIExhaust Pressure Switch Testing & Replacement
For serial numbers prior to “CF”
Check Exhaust Tube Pressure
Exhaust Tubepressure tap location
Exhaust tubeat bottom of heater
N
Replaceblocked vent switch.(see “Blocked VentSwitch Testing and
Replacement”)
Is exhaust ventingsystem blocked orobstructed? Also
check condensateelbow and drain.
Clear obstruction.Determine cause
and correct.
Y
Is vent system totallength compliant with
vent tables in theinstruction manual?
Reconfigure ventsystem to be
compliant withvent tables (see“Specifications”).
Y
N
With monometer, take areading at the exhaust
tube pressure tap location.Is value negative (-) or
slightly postitive(see illustration below).
Y
N
With ohmmeter checkpressure switch for
continuity. Contacts shouldbe closed.
Y
N
Pressure switch O.K.
Is pressure in exhaust tube near 2.7" w.c. or more? If so, correctblockage (above). If exhaust pressure is low (0.40" or less),
replace pressure switch.
34
HEC SeriesService Procedure VI
Exhaust Pressure Switch Testing & ReplacementFor serial numbers prior to “CF”
Exhaust Pressure Switch Replacement Procedure
Step 1. Position main power switch to “OFF” position.
Step 2. Loosen adhesive backed rubber escutcheon from service panel access coverand slide escutcheon back along exhaust pipe to allow for removal of cover.
Step 3. Remove screws from service panel access cover(¼" nut driver) and remove cover from heater.(see photos at right)
Step 4. Disconnect silicone tubing and wire leads frompressure switch. (see photos at right)
Step 5. Remove pressure switch mounting screws(5/16" wrench) and remove pressure switch.
Step 6. Assemble new pressure switch to heater usingscrews from step 5.
Step 7. Reconnect wire leads. Note: wire leads areinterchangeable with either terminal.
Step 8 Reconnect silicone tubing to pressure switchas follows:
a) Exhaust pipe tubing connects tosingle tap located on switch
Step 10. Reinstall service panel access cover andrubber escutcheon.
Step 9. Restore 120 volt power supply to water heaterand confirm proper operation following thelighting instructions on the lighting instructionlabel or the lighting instructions located in the installationand operating instruction manual.
Exhaust Tubepressure tap location
Rubberescutcheon
Pressure switchmounting screw5/16 hex head
Silicone tubing
Wire leads
HEC Series
35
Service Procedure VIIHot Surface Igniter Testing & Replacement
Is igniter resistanceless than 150 Ohms
(cold)?(see “check igniterresistance” below)
Refer to ignition module illustration below,is there 120VAC across terminals
P6(1) and P6(2)?(Check during igniter warm up period,
indicated by the igniter LED glowing on theignition module).
Y
N
Replacehot surface igniter(see “Hot Surface
Igniter ReplacementProcedure”)
Replace ignition module.(see “Ignition Module
ReplacementProcedure”)
N
Check harnessconnection from igniter
to ignition module.
Y
Hot Surface Igniter Testing Procedure
Volt meter set toOHM setting
Meter probe
Hot surfaceigniter
CHECK IGNITERRESISTANCE
WARNING120 volt potential exposure. Use caution
making voltage checks to avoidpersonal injury. Igniter may be too hotto handle, take necessary precautions
UT ELECTRONICCONTROLS
P2
P3
P5
P1
P7P6
HUNTINGTON, INDIANA1013 SERIES INTEGRATED WATER HEATER
POWER
PURGE
IGNITOR
VALVE
FLAME
INDICATORLIGHTS
FOR OPERATING SEQUENCE TROUBLESHOOTING SEE INSTALLATIONAND OPERATING INSTRUCTION MANUAL
ANSI Z21.20 AUTOMATIC IGNITION SYSTEMSCAN/CSA-22.2 NO. 199-M89
24 VAC 0.5 AMP 50/60Hz
IF SYSTEM LOCK OUT, REMOVE POWER FOR 45 SECONDS TO RESETSYSTEM WILL AUTOMATICALLY RE-TRY AFTER 1 HOUR
WARNINGEXPLOSION HAZARD, CAN CAUSESERIOUS INJURY OR DEATH
THIS DEVICE CAN MALFUCTION IF IT GETSWET. NEVER TRY TO USE A DEVICE THATHAS BEEN WET - - REPLACE IT.
POWERPURGE
IGNITORVALVEFLAME
FS
BLOWER
PRIMARYHSI
120V AC IN
RED/SOCKET
WHITE/PIN
RED/PIN
CONTROL
RED/
SOCK
ET P6
P7P1
P5
1NA2NA
3NA4NA
5NA
YRADNOCES
WHITE/PIN
WHITE/PIN
P2
P3
IGNITION MODULE
36
HEC Series Service Procedure VIIHot Surface Ignitor Testing & Replacement
Hot Surface Igniter Replacement Procedure
Step 1. Position main power switch to “OFF”
Step 2. Disconnect (unplug) water heaterfrom 120 volt power source.
Step 3. Un-latch & remove surround coverfrom top of heater.
Step 4. Fold back insulation in front of combustion assembly to expose hot surface igniter.(see photo at right)
Step 5. Disconnect igniter wire leads from ignition module.
Step 6. Remove the 2 igniter mounting screws (magnetictip, long reach Phillips screw driver) and removeigniter and gasket from transition base flange.
Step 7. Remove any residual gasket material fromtransition base flange.
Step 9. Reconnect igniter wire harness.
Step 10. Fold insulation back into place. Be sure no wires are in contact with burner flange.
Step 8. Install new igniter with new gasket provided usingscrews from step 5. Arrange igniter flange with off-center hole towards front of heater.
Step 11. Restore 120 volt power supply to water heater and confirm proper operation following thelighting instructions on the lighting instruction label or the lighting instructions located inthe installation and operating instruction manual.
Step 12. Replace surround cover on top of water heater.
Note:New replacement igniter willnot have a shield over element.Handle carefully to preventbreakage.
WARNING120 volt potential exposure. Isolate the
appliance and reconfirm power isdisconnected using a multi-meter.
Note:Do not handle igniter elementor allow foreign material tocome in contact with element.
Heater front
Off-centermounting hole
Igniter flangeIgniter gasket
Transitionbase flange
Igniter mountingscrews
HEC Series
37
Service Procedure VIIIFlame Sensor Testing & Replacement
With flame sensor Disconnectedfrom ignition module, check
continuity to ground.Is there continuity to ground?
N
Y
Flame Sensor Testing Procedure
Refer to illustration below, is therea minimum of 1 micro amp during1.5 second flame proving period?
Y
N
Is flame sensor freeof oxidation?
Clean or replaceflame sensor.
(see “Flame SensorReplacementProcedure”)
N
Is ceramic of flamesensor cracked?
Replace flame sensor.(see “Flame Sensor
ReplacementProcedure”)
Y
N
Flame sensing circuit OKY
Refer to ignition module/control boardillustration.(24 volts should maintain beyond the
1.5 second flame proving period.)Is there 24 volts AC at locations P3(2) & P3(5)?
Y
N
Call fortechnical support
Replace flame sensor withgasket
and/or wire lead.(see “Flame Sensor
Replacement Procedure”)
Remove flame sensor from water heater.Check continuity from tip of flame sensor
to end of wire lead.Is there continuity?
N
Y
WARNING120 volt potential exposure. Use caution
making voltage checks to avoidpersonal injury. Flame sensor may be
too hot to handle, take necessaryprecautions
Flamesensor
terminal
Volt meter set toMicro amps setting
( A)
Meterprobe
Meterprobe
Flame sensorterminal on
ignition module.
P2
P3
P5P1
P7
38
HEC Series Service Procedure VIIIFlame Sensor Testing & Replacement
Flame Sensor Replacement Procedure
Step 4. Fold back insulation in front of combustion assembly to expose flame sensor.(see photo at right)
Step 5. Disconnect wire lead from flame sensor.
Step 6. Remove the 2 sensor mounting screws (magnetictip, long reach Phillips screw driver) and removeflame sensor & gasket from transition baseflange.
Step 7. Remove any residual gasket material fromtransition base flange.
Step 9. Reconnect flame sensor wire.
Step 10. Fold insulation back into place. Be sure no wires are incontact with burner flange.
Step 8. Install new flame sensor with new gasket providedusing screws from step 6. Arrange flame sensor withhook towards burner.
Step 1. Position main power switch to “OFF”
Step 2. Disconnect (unplug) water heaterfrom 120 volt power source.
Step 3. Un-latch & remove surround coverfrom top of heater.
Step 11. Restore 120 volt power supply to water heater and confirm proper operation following thelighting instructions on the lighting instruction label or the lighting instructions located inthe installation and operating instruction manual.
Step 12. Replace surround cover on top of water heater.
Transitionbase flange
Flame sensormounting screws
Flame sensor
Flame sensorgasket
Arrange hookof sensor
towards burner
Flamesensor
WARNING120 volt potential exposure. Isolate the
appliance and reconfirm power isdisconnected using a multi-meter.
HEC Series
39
Service Procedure IXIgnition Module Replacement
Ignition Module Replacement Procedure
Step 1. Position main power switch to “OFF”.
Step 2. Disconnect (Unplug) water heaterfrom 120 Volt power source.
Step 3. Un-latch & remove surround cover from top of water heater.
Step 4. Locate Ignition module on control panel inside surround area.(see photo below)
Step 7. Install new ignition module and secure in place with screws from step 6.
Step 8. Carefully reconnect all wire harness connection to ignition module. Connection arenon-interchangeable to insure proper reinstallation.
Step 5. Carefully disconnect all wire harness connection to ignition module. Connection arenon-interchangeable to insure proper reinstallation.
Step 6. Remove the 3 screws (Phillips screw driver) holding the ignition module in place andremove ignition module from control panel.
Step 9. Restore 120 volt power supply to water heater and confirm proper operation following thelighting instructions on the lighting instruction label or the lighting instruction located inthe installation and operating instruction manual.
Step 10. Replace surround cover on top of water heater.
Note: Replacement hot surfaceignition module works on all models prior to and later than
“CF” serial numbers.
Ignition Modulelocated on control panel
WARNING120 volt potential exposure. Isolate the
appliance and reconfirm power isdisconnected using a multi-meter.
40
HEC Series Service Procedure XTransformer Replacement
Transformer Replacement Procedure
Step 4. Refer to ignition module illustration below, Disconnect wire harnessP1 labeled “PRIMARY” and P2 labeled “SECONDARY” from ignition module.
Step 5. Disconnect secondary leads (blue &yellow wire) from thermostat board.Note the blue wire is connected to24 volt “HOT” terminal. (see photo below)
Step 6. Remove the 2 screws ( short Phillips screw driver) holding the transformer in place andremove transformer from control panel. (see photo below)
Step 7. Install new transformer and secure inplace with screws from step 6.
Step 8. Reconnect wire harness P1 & P2,connections are non-interchangeableto insure proper reconnection.
Step 9. Reconnect blue & yellow wire leading from theP2 connection on ignition module tothermostat board. Note the blue wire must connect to the 24volt “HOT” terminal. (see photo at right)
Step 1. Position main power switch to “OFF”.
Step 2. Disconnect (Unplug) water heaterfrom 120 Volt power source.
Step 3. Un-latch & remove surround cover fromtop of water heater.
Step 10. Restore 120 volt power supply to water heater andconfirm proper operation following the lightinginstructions on the lighting instruction label or thelighting instruction located in the installation andoperating instruction manual.
Step 11. Replace surround cover on top of water heater.
WARNING120 volt potential exposure. Isolate the
appliance and reconfirm power isdisconnected using a multi-meter.
Step 3Disconnect harness
“P1” & “P2”from ignition module
Ignition module
Step 5Disconnect blue & yellow wire fromthermostat board. Note blue wire is
connected to 24 volt “HOT” terminal.
Thermostatboard
Step 6Remove transformer
mounting screws
24 volt common,yellow wire connection
24 volt Hot,blue wire connection
Thermostatboard
HEC Series
41
Service Procedure XIIntake Pressure Switch Testing & Replacement
Prior to “CF” serial number
Is there continuitythrough the normally
closed intake pressureswitch?
(see photo at right)Y
Replaceintake pressure switch.
(see “Intake Pressure SwitchReplacement Procedure”)
Switch OK.
Does Blower Energize?
Does purge LEDilluminate on the ignition
module?
Remove hose from intakepressure switch and
Restart heater.Does purge LED illuminate?
N
Y
With manometer, take areading from the inlet tube
pressure tap. Is readingnegative (-)1.2" W.C.
or more?(see illustration below)
N
See “Vent Safety Switch Testingand Replacement”
orExhaust Pressure Switch Tesinting
and Replacement”or
“Blower Testing and Replacement”
Y
N
Y
N
N
Y
Is intake vent systemobstructed?
Y
N
Call for technical support.
Clear obstruction.
See “Exhaust Pressure Switch Testingand Replacement”)
or“Blower Testing and Replacement”
Is there continuitythrough the normally
closed intake pressureswitch?
(see photo above)
Y
Isolate (disconnect) heater fromintake vent system and
Restart heater.Does purge LED illuminate?
N
Y
N
Disconnect red wire leads frompressure switch and checkcontinuity through switch.
WARNING120 volt potential exposure. Use caution
making voltage checks to avoid personal injury.
Notice:The intake pressure switch is not used
on serial number “CF” and later.
Inlet Tubepressure tap
42
HEC SeriesService Procedure XI
Intake Pressure Switch Testing & ReplacementPrior to “CF” serial number
Intake Pressure Switch Replacement Procedure
Step 1. Position main power switch to “OFF”.
Step 2. Disconnect (Unplug) water heaterfrom 120 Volt power source.
Step 3. Un-latch & remove surround cover from top of water heater.
Step 4. Locate intake pressure switch on control panel inside surround area (see photos below).
Step 6. Disconnect silicone tubing from pressure switch (see photos above).
Step 7. Remove the two screws (Phillips screw driver) holding the intake pressure switch inplace and remove pressure switch from control panel (see photos above).
Step 8. Install new pressure switch and secure in place with screws from step 7.
Step 9. Reconnect silicone tubing (from step 6) to pressure switch.
Step 10. Reconnect red wires (from step 5) to pressure switch. Note: wires are interchangeablewith either switch terminal.
Step 11. Restore 120 volt power supply to heater & verify proper heater operation following theinstructions on the lighting instruction label or the lighting instructions located in theinstallation & operation manual.
Step 12. Replace surround cover on top of heater.
Step 5. Disconnect red wire leads from pressure switch(see photo at right).
Intake pressure switchlocated on side of
control panelStep 6
Disconnect tubing frompressure switch
Step 5Disconnect red wires
WARNING120 volt potential exposure. Isolate the
appliance and reconfirm power isdisconnected using a multi-meter.
HEC Series
43
Service Procedure XIIVent Safety Switch Testing & Replacement
Reset heater, observeheating cycle. Does
switch open?
Y
Does switch open priorto 350°F?
DO NOT OPERATEHEATER
System over heating,immediately contacttechnical support.
N
Locate harnessconnection.
(see photo at right)
Y
Is there continuityThrough GREY
Lead wires of heater sideharness?
(see photo at right)
N
Replace ventsafety switch
(see “Vent SafetySwitch
ReplacementProcedure”)
Call technicalsupport.
Y N
Depress resetbutton on highlimit switch. Is
there continuityacross high limit
switch?(see photo below)
Does heaterfunction?
N
Y
Is temp over 350°F?
Y
N
Sequence of operation:With the thermostat calling for heat, prior to energizing blower, the ignition module checks thevent safety switch for normal switch position of normally closed. If the vent safety switch contacts are open, (not in normalposition), the ignition module waits indefinitely for contact to close, The vent safety switch must be manually reset to close theswitch contacts.
System OK
N
Y
Replace vent safetyswitch
(see “Vent SafetySwitch Replacement
Procedure”)
Heater sideharness
Control sideharness
WARNING120 volt potential exposure. Use caution
making voltage checks to avoid personal injury.
Reset button
WARNINGMake sure exhaust collector compartment is notoverheating (350°F) before resetting vent safety
switch. If there is evidence the collector compartmentis overheating, CALL TECHNICAL SUPPORT.
44
HEC Series Service Procedure XIIVent Safety Switch Testing & Replacement
Vent Safety Switch Replacement ProcedureStep 1. Position main power switch to “OFF”.
Step 2. Loosen adhesive backed rubber escutcheon from service panel access coverand slide escutcheon back along exhaust pipe to allow for removal of cover(see photos at right).
Step 3. Remove screws from service panel access cover(¼" nut driver) and remove cover from heater(see photos at right)
Step 4. Disconnect wire leads from ventsafety switch (see photo at right).
Step 5. Remove the 2 switch mountingscrews (Phillips screw driver)and nuts (5/16 wrench) andremove switch from heater.
Step 6. Install new switch using screwsfrom step 5.
Step 7. Reconnect wire leads.Note: wire leads areinterchangeable with eitherswitch terminal.
Step 9. Reinstall service panel access cover and rubber escutcheon.
Step 8. Restore 120 volt power supply to water heater and confirm proper operation following the lighting
instructions on the lighting instruction label or the lighting instruction located in the installation and operating instruction manual
Vent safetyswitch
HEC Series
45
Service Procedure XIIIAnode/Flue Baffle Inspection & Replacement
Disassembly Procedure for Access to Anodes & Flue Baffles
Step 1. Position main power switch to “OFF”.
Step 2. Disconnect (Unplug) water heaterfrom 120 Volt power source.
Step 3. Un-latch & remove surround cover from top of heater.
Step 4. Disconnect wire harnesses to allow for removal of control panel.Note: Where ever possible, rather than disconnecting at the control panel, follow wireharness away from control panel and disconnect at control component location.
Step 5. Remove the three control panel mounting screws (¼” nut driver) and remove controlpanel from the water heater (see photos below).
Step 7. Remove all collector coverscrews (5/16" socket) andremove collector cover(see photos at right).
Step 6. Completely remove insulation (two pieces) from top of heater to expose collector cover
Step 8. Photo 44 shows heater with collector cover removed allowingaccess to anode rods and flue baffles.
a) for anode service, see “Anode Inspection and Replacement”b) for flue baffle service, see “Flue Baffle Inspection and Replacement”c) for powered anode service, see “Powered Anode Replacement”
Note: 100HEC-399 models have only 1 anoderod under the 2nd pass collector cover.
WARNINGHeater components may be HOT when performing the following steps in this procedure.
Take necessary precaution to prevent personal injury.
WARNING120 volt potential exposure. Isolate the
appliance and reconfirm power isdisconnected using a multi-meter.
Collectorcover
Anodelocations
Fluebaffles
Control PanelMounting Screw
Remove ControlPanel
46
HEC Series Service Procedure XIIIAnode/Flue Baffle Inspection & Replacement
Anode Inspection and Replacement
Step 1. Turn off water supply and drain water heater.
Step 2. Disassemble water heater per “Disassembly Procedure for Access to Andoes & Flue Baffles”.
Step 3. Locate and remove anode rods from heater (1-1/16 hex socket).
Step 4. Visually inspect anode rod. Anode rod should show signs of depletion, this is normal. Ifthe depletion is ½ of the original diameter (approximately ¾" diameter), replacement isrecommended. If any of the steel core of the anode is exposed, replacement is recommended.
Step 5. Upon completion of inspection or subsequent replacement, apply Teflon tape or otherthread compound to threads of anode and reinstall into heater. Restore water supplyand check for and repair any leaks found.
Step 6. Reinstall collector cover per “Collector Cover Installation Procedure”.
Step 7. Reinstall collector insulation and control panel, reconnect control panel wire harnesses.
Step 8. Restore 120 volts to water heater and verify proper heater operation following theinstructions on the lighting instruction label or the lighting instruction located in theinstallation and operating instruction manual.
Step 9. Replace surround cover on top of water heater.
WARNINGHeater components and stored water may be HOT when performing the following steps in
this procedure. Take necessary precaution to prevent personal injury.
HEC Series
47
Service Procedure XIIIAnode/Flue Baffle Inspection & Replacement
Flue Baffle Inspection and Replacement
Step 1. Disassemble heater per “Disassembly Procedure for Access to Anodes & Flue Baffles”.
Step 2. Remove flue baffles from heater (pliers) (8 two inch baffles & 2 four inch baffles).
Step 3. Visually inspect flue baffles. Flue baffles should show signs of oxidation, this is normal.If the oxidation has deteriorated any portion of the flue baffle, replacement isrecommended. If any restrictors are missing, replacement is recommended.
Step 4. Upon completion of inspection or subsequent replacement, reinstall flue baffles into heater.
Step 5. Reinstall collector cover per “Collector Cover Installation Procedure”.
Step 6. Reinstall collector insulation and control panel, reconnect control panel wire harnesses.
Step 7. Restore 120 volts to water heater and verify proper heater operation following theinstructions on the lighting instruction label or the lighting instruction located in theinstallation and operating instruction manual.
Step 8. Replace surround cover on top of water heater.
WARNINGHeater components may be HOT when performing the following steps in this procedure.
Take necessary precaution to prevent personal injury.
48
HEC SeriesService Procedure XIII
Powered Anode Replacement for 100HEC-399 Only
Powered Anode Replacement 100HEC-399 models only
The powered anode control module is located on the right vertical side of the control panel inside the surround panel.The control has a LED indicator light to show the status of operation. When the tank is filled with water and the powersupply is on to the water heater, the light should have a steady green glow to indicate that protection current is flowingand operating normally. If the indicator light is not glowing, the power supply to the water heater or powered anodesystem is disconnected.
Step 1. Check the power supply or wire connections to the powered anode control.
Step 2. Indicator light diagnostic codes:a) If the control is flashing red, then there is a malfunction with the powered anode system.
Make sure there are no bare spots in the wire insulation to the poweredanode rods.
Step 3. Check all electrical connections. The powered anode rods are insulated from thewater heater tank in the bushing.
a) With an ohmeter, check continuity between the powered anode terminal and the bushing. There should not be continuity. If there is continuity, replace the poweredanode assembly.
Volt meter setto OHM setting
WARNINGHeater components may be HOT when performing the following steps in this procedure.
Take necessary precaution to prevent personal injury.
LED INDICATOR LIGHT(POWERED ANODE)
POWERED ANODECONTROL MODULE
POWERED ANODE
THERMOSTAT BULB
POWERED ANODE
HEC Series
49
Collector Cover Installation Procedure
Step 1. Remove old silicone from top surface of collector flange and collector cover.
Step 2. Apply ¼" bead of Ultra Copper Silicone around entire collector flange surface. Allowcaulk to “cure” for 10 minutes.
Step 3. Carefully reinstall collector cover, tighten screws evenly.
Step 4. Allow a minimum of 6 hours before putting heater back in service.
Apply ¼" bead of UltraCopper Silicone around entire
collector flange surface
Service Procedure XIIIAnode/Flue Baffle Inspection & Replacement
50
HEC Series Water HeaterInstallation Check List
Product Handling - Carefully uncrate the heater. Move in place with a hand truck (Do not use theventing pipes for handles).
Electrical Requirements - Make sure there is 120 volts line voltage. Line voltage must be properlypolarized. Adequate ground supplied to the heater.
Venting Requirements - All venting must stay within the required lengths and diameter (see tablebelow). Proper support of the venting pipe is a MUST (every 5ft vertical and 3ft horizontal).Termination must be located to prevent re-circulation of flue gases. Medium to long sweep 90°elbows or straight exhaust terminal coupling recommended.
Gas Requirements - Gas piping sized adequately, ¾" or larger to heater or 1" or larger forHEC100-399 models. Install a properly sized regulator (if unknown, assure an adequate volume ofgas is available). 7" W.C. is required when the unit is running. Gas pressure must stay below 14"W.C. static pressure. Pressure drops between static pressure and operating flow should be lessthan 3" W.C.
Condensate Requirements - Condensate line needs to slope to a drain at a minimum of ¼" perfoot. Make sure the condensate line does not have the potential to freeze. If using more than oneheater and using a common condensate line, make sure the condensate line is properly sized.
Service/Mechanical Room - Provide adequate space for servicing heater. Leave room to get to thetop and bottom pressure switches as well as enough overhead room to remove the anode rods forservicing (18" min.).
Vent Tables
Note: each 3" & 4" 90° Elbow is equivalent to 5 feet of straight pipe.Note: each 3" & 4" 45° Elbow is equivalent to 2.5 feet of straight pipe.
Unbalanced Direct Vent SystemsAir intake CAN NOT exceed exhaust
by more than 30 feet
Power Vented SystemsPVC, CPVC
Total length of exhaust piping must not exceed“Maximum Vent Length”
Shown below
Maximum Vent Length (feet)
Model Number 3"
120'
100'
80'
60'
4"
170'
150'
130'
110'
50' 100'
2"
N/A
N/A
N/A
N/A
N/A
Balanced Direct Vent SystemsPVC, CPVC
Total length of intake piping and exhaust pipingadded together must not exceed “Maximum
Combined Length”Shown below
Maximum Combined Length (feet)
Model Number 3"
60HEC-125, 60HEC-150 120'
60HEC-150, 100HEC-199
60HEC-199, 100HEC-250
100HEC-300
100'
80'
60'
4"
170'
150'
130'
110'
100HEC-399 50' 100'
2"
N/A
N/A
N/A
N/A
N/A
60HEC-125, 60HEC-150
60HEC-150, 100HEC-199
60HEC-199, 100HEC-250
100HEC-300
100HEC-399
HEC Series
51
Water HeaterService Report
Date
Model Number
Serial Number
Venting (PVC, CPVC):
Intake 90's (qty)
Vent size 3" or 4"
Exhaust 90's (qty)
Length of straight pipe(intake)Intake 45's (qty)
Exhaust 45's (qty)
Line Voltage PolarityLow Voltage
Electrical:
Size & material
Distance from meterto water heater
Gas Line:
Static
Manifold
Running Inlet
Gas Pressure:
Size & Material
Length
Condensate Line:
Igniter Resistance: Flame Sense Micro -Amps:
Venturi:
Exhaust CollectorPressure:
Setting from Bottom in Turns
Positive Inches W.C.
LED Flashing Y or N Which One(s)
Combustion: CO2 CO
Installation Site Contact Name &Phone Number
Service ProviderPhone Number
Is trap provided Y or N
Installation Site Name & Address:
Length of straight pipe(exhaust)
Spark Gap: ___________
Error Codes on Control Display (Direct Spark Ignition System Only): __________________________________
52
HEC Series Parts ListModels prior to “CF” serial number
Customer must specify completemodel number and serial number
when ordering service parts.
1 Combustion Surround Assy.2 Burner Assy3 2nd Pass Top Collector Cover4 Screw 10-16 x 3/45 Vent Termination Elbow6 Thermostat Sensor Probe7 Baffle 4" Flue8 Anode9 Baffle 2" Flue10 Wire Harness Service Panel11 Plastisert Nipple 1-½" NPT12 Plug13 Nipple14 T&P Relief Valve15 Exhaust Pipe (PVC) w/Hose Barb16 Condensate Trap Elbow17 Silicone Hose18 Outer Door Service Panel19 Vent Pipe Support Bracket20 NSF Escutcheon21 Exhaust Pressure Switch22 Nut23 Vent Safety Switch24 Screw 6-32x 3/825 Cleanout Access Cover26 Cleanout Gasket27 Screw 5/16-18 x ¾ HH Grade 528 Cleanout Cover29 Cold Water Inlet30 No Handle Brass Drain Valve31 Coaxial Vent System32 ASSE Approved Mixing Valve
1
2
34
6
7
8 9
11
30
29
26A
25A
27A
28 27
25
26
2223
24214
17
18
1620
15
19
14
13
12
10
5 31
32
4 17
19
23
21
EXPLODED VIEW
EXHAUST SERVICE AREA DETAIL(ASSEMBLED)
HEC Series
53
Customer must specify completemodel number and serial number
when ordering service parts.
AA Latch AssyBB Screw 8-32 x ½ RHCRCC Ignition Control AssyDD Jacket HeadEE Main Power SwitchFF PotentiometerGG Combustion SurroundJJ Surround Base
1A Combustion Surround Assy.2A Blower Gas Valve Assy3A Burner Assy4A Blower EBM5A Silicone Hose6A Hose Tee Fitting7A Screw 10-32 x3/48A Gasket & Screw9A Gas Valve
10A Nipple ½" NPT X3"11A Reducer ¾ x ½ NPT12A Nipple ¾ NPT x 6"13A 2" dia. Flex Reducer14A Inlet (PVC)15A Gasket Blower Transition16A Screw 8-32 x ¼ RHCR17A Gasket Flame Sensor18A Flame Sensor19A Transition Tube20A Nut Hex Washer21A Gasket Hot Surface Igniter22A Hot Surface Igniter23A Burner Mounting Gasket24A Burner Tube25A Burner Mounting Gasket26A Burner Mounting Insert27A Burner Mounting Insert Gasket
DD
AA
CC
GG
AA
BB
FFEE
JJ
1A
13A
14A
4A
7A
6A
5A
8A9A
10A11A
12A
15A
16A
17A
18A
19A
20A 16A21A
22A
23A
24A
25A
26A
27A
2A
3A
Parts ListModels prior to “CF” serial number
54
HEC Series
Customer must specify completemodel number and serial number
when ordering service parts.
1C Electronic Control Module2C Screw 8-32 x 1/23C Intake Pressure Switch4C Control Mounting Panel5C Thermostat PC Board6C Transformer 120VAC x 24VAC x 40VA7C Terminal8C Terminal Strip9C Power Cord10C Control Wire Harness11C Thermostat Wire Harness12C Igniter Extension Wire13C Blower Wire Harness14C Power Switch Wire Harness15C Flame Sensor Wire Harness16C Rectifier Harness
8C
7C
6C
1C
2C
3C
4C
5C
12C
9C
10C 11C
13C
14C
15C
16C
Parts ListModels prior to “CF” serial number
HEC Series
55
Customer must specify completemodel number and serial number
when ordering service parts.
1 Combustion Surround Assy.2 Burner Assy (specify model)3 2nd Pass Top Collector Cover4 Screw 10-16 x 3/45 Vent Termination Elbow6 Thermostat Sensor Probe7 Baffle 4" Flue (specify model)8a Anode Rod Assy
9 Baffle 2" Flue10 Wire Harness Service Panel11 Plastisert Nipple 1-½" NPT12 Plug13 Nipple14 T&P Relief Valve
15 Exhaust Pipe (PVC) w/Hose Barb(except 100HEC-399)
16 Condensate Trap Elbow (specify model)17 Silicone Hose18 Outer Door Service Panel (specify model)
19 Vent Pipe Support Bracket(except 100HEC-399)
20 NSF Escutcheon21 Exhaust Pressure Switch22 Nuts23 Collector Temperature Limit Switch24 Screw 6-32x 3/825 Cleanout Access Cover26 Cleanout Gasket27 Screw 5/16-18 x ¾ HH Grade 528 Cleanout Cover29 Cold Water Inlet (Hydrojet) Assy.30 No Handle Brass Drain Valve31 Concentric Vent System (optional)32 ASSE Approved Mixing Valve (optional)
8b Powered Anode (for EF100T399)
EXPLODED VIEW
EXHAUST SERVICE AREA DETAIL(ASSEMBLED)
21 4 17
19
23
29
26A
25A
27A
28
22
26
25
27
2324214
17
18
16
2015
19
14
13
30
6
7
8 9
5 31
2
4
3
1
11
32
12
Parts ListModels with “CF” serial or later
56
HEC Series
Customer must specify completemodel number and serial number
when ordering service parts.
AA Latch AssyBB Screw 8-32 x ½ RHCRCC Ignition Control AssyDD Jacket HeadEE Main Power SwitchFF PotentiometerGG Combustion SurroundJJ Surround Base
1A Combustion Surround Assy. (specifymodel)
2A Blower Gas Valve Assy (specify model)3A Burner Assy (specify model)4A Blower EBM (specify model)5A Silicone Hose6A Burner Mounting Insert Gasket7A Screw 10-32 x3/48A Gasket & Screw9A Gas Valve (specify model)
10A Nipple (specify model)11A Reducer (specify model)12A Nipple (specify model)
13A 2" dia. Flex Reducer (or PVC reducer for399)
14A Inlet (PVC)15A Gasket Blower Transition (specify model)16A Screw 8-32 x ¼ RHCR17A Gasket Flame Sensor18A Flame Sensor19A Transition Tube20A Nut Hex Washer21A Gasket Hot Surface Igniter22A Hot Surface Igniter23A Burner Mounting Gasket24A Burner Tube25A Burner Mounting Gasket26A Burner Mounting Insert
DD
AA
CC
AA
BB
EEFF
GG
JJ
5A
8A9A
10A11A
12A
1A
19A
20A16A21A
22A
23A
24A
25A
26A
7A
6A
4A2A
3A
15A
16A
17A
18A13A
14A
Parts ListModels with “CF” serial or later
HEC Series
57
Customer must specify completemodel number and serial number
when ordering service parts.
Electronic Control ModuleScrew 8-32 x 1/2Control Mounting PanelThermostat PC BoardTransformer 120VAC x 24VAC x 40VATerminalTerminal StripPower CordControl Wire HarnessThermostat Wire Harness
Powered Anode Control Harness (399 only)Powered Anode Harness (399 only)Powered Anode Control (399 only)
Rectifier Harness (specify model)Blower Wire Harness (specify model)Power Switch Wire HarnessFlame Sensor Wire Harness
1C2C3C4C5C6C7C8C9C10C11C12C13C14C15C16C17C
1C 8C
10C
12C
17C
3C
4C
7C
6C
5C
2C
15C
16C
9C
13C
14C
11C
Parts ListModels with “CF” serial or later
58
HEC Series Glossary of Terms
NOTES
AC Alternating CurrentBTU/H British Thermal UnitsCO Carbon MonoxideCO2 Carbon DioxideDC Direct CurrentDSI Direct Spark IgnitionECO Energy Cut OffGFI Ground fault interruptGPM Gallons per MinuteHSI Hot Surface IgniterHz HertzLED Light Emitting DiodeNOx Oxides of NitrogenNPT National Pipe ThreadPSI Pounds per Square InchRPM Revolutions per MinuteVA Volt AmpsVAC Volts Alternating CurrentW.C. Inches of Water Column°C Degrees Centigrade°F Degrees Fahrenheit
A Micro Amp
HEC Series
59
Notes
NOTES
Madison, Wisconsin
For U.S. and Canada field service, contact your professional installer or
local Bock Water Heaters sales representative
Sales/608-227-3311Fax/608-327-3311
Application & Sizing/608-227-3311Fax/608-327-3311
Technical Support/888-784-8322Fax/610-683-9208
Warranty/608-227-3319Fax/608-327-3300
www.bockwaterheaters.com