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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


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


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


P2

P3

P5

P1

P7P6


POWER

PURGE

IGNITOR

VALVE

FLAME

INDICATORLIGHTS



24 VAC 0.5 AMP 50/60Hz




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


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


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.


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?


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


P2

P3

P5

P1

P7P6


POWER

PURGE

IGNITOR

VALVE

FLAME

INDICATORLIGHTS



24 VAC 0.5 AMP 50/60Hz




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?


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


P2

P3

P5

P1

P7P6


POWER

PURGE

IGNITOR

VALVE

FLAME

INDICATORLIGHTS



24 VAC 0.5 AMP 50/60Hz




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



Refer to ignition moduleillustration, Is there

22 - 27VAC betweenP2(1) and P2(2)?


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)



Red Wires(Temperature Sensor)

IGNITION MODULE


P2

P3

P5

P1

P7P6


POWER

PURGE

IGNITOR

VALVE

FLAME

INDICATORLIGHTS



24 VAC 0.5 AMP 50/60Hz




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


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


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.


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


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


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


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.


BLBL

R

R

BK

115 VOLTS ACN

GND

LT

GN/Y

WBK

POWERED ANODE ON399,999 BTUH MODELS ONLY

LN

21

18


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 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.



TemperatureAdjusting Knob

IndexingTab

LocatingHole

Loosen set screwwith small blade

screw driver

Removeretaining nut

PotentiometerWire Leads

HEC Series

19


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 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.



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)


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


P2

P3

P5

P1

P7P6


POWER

PURGE

IGNITOR

VALVE

FLAME

INDICATORLIGHTS



24 VAC 0.5 AMP 50/60Hz




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



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


P2

P3

P5

P1

P7P6


POWER

PURGE

IGNITOR

VALVE

FLAME

INDICATORLIGHTS



24 VAC 0.5 AMP 50/60Hz




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 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



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 6. Replace surround cover on top ofwater heater.


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 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





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.



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 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.



Gas valveassembly

Blower / gas valvegasket

Blower

Venturimounting flange

Gas valvemounting screws

(2 places)

Venturi inlet




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?


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.








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”


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


(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



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


and correct.

Check Collector Pressure


Exhaust Tubepressure tap location

Exhaust collectorpressure tap location

Exhaust tubeat bottom of water

heater

HEC Series

31



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



Reset button


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



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



(see photo below)

N

Y

Is there continuitythrough RED


(see photo below)

N

Safety Circuit OK,(see “Blower Testing

& Replacement”)

Replace exhaustpressure switch (see“Exhaust Pressure

Switch ReplacementProcedure”)

Replace vent safetyswitch.


Procedure”)


Y

N

Depress resetbutton on vent

safety switch. Isthere continuityacross high limit


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



Check Exhaust Tube Pressure


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.


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



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.


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”)



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


making voltage checks to avoidpersonal injury. Igniter may be too hotto handle, take necessary precautions


P2

P3

P5

P1

P7P6


POWER

PURGE

IGNITOR

VALVE

FLAME

INDICATORLIGHTS



24 VAC 0.5 AMP 50/60Hz




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 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.


Note:New replacement igniter willnot have a shield over element.Handle carefully to preventbreakage.



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


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


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


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 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.


Transitionbase flange

Flame sensormounting screws

Flame sensor

Flame sensorgasket

Arrange hookof sensor

towards burner

Flamesensor



HEC Series

39

Service Procedure IXIgnition Module Replacement

Ignition Module Replacement Procedure


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.


Note: Replacement hot surfaceignition module works on all models prior to and later than

“CF” serial numbers.

Ignition Modulelocated on control panel



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 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 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.



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 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 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



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.


Y


Lead wires of heater sideharness?


N

Replace ventsafety switch

(see “Vent SafetySwitch



Y N

Depress resetbutton on highlimit switch. Is

there continuityacross high limit


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


Procedure”)

Heater sideharness

Control sideharness



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 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.





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.


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


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.




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



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


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



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



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



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



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


HEC Series

57



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


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

[email protected]

www.bockwaterheaters.com

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