Bock Water heaters 100-HEC399, Service Manual

Page 1: ... Instructions for Service To be performed ONLY by qualified service providers For Models 60HEC 125 60HEC 150 60HEC 199 100HEC 150 100HEC 199 100HEC 250 100HEC 300 100 HEC399 All are available in LP or Natural Gas Standard or ASME Construction Manual 45817B Save this manual for future reference ...

Page 2: ...r Tube Inspection Replacement 24 III Gas Valve Replacement 26 IV Blower Testing Replacement 27 V Exhaust Pressure Switch Testing Replacement 29 VI Hot Surface Ignitor Testing 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 Flue Baf...

Page 3: ...through a three pass flue system keeping the gases moving at a high velocity The combination of high turbulence and velocity results in an optimum transfer of heat from the flue gases into the water Burner operation is controlled using an electronic ignition module The module monitors the status of the electronic thermostat vent temperature limit switch vent system pressure switches and a flame se...

Page 4: ...r a given component In some difficult to diagnose conditions it may be necessary to isolate the heater from the vent system to determine the root cause Contact Technical Support immediately if diagnosis is not determined using the methods described in this service manual Tools Required for Service Manometer Two types available a liquid U tube type or a digital magna helic type This device is used ...

Page 5: ...1 2 40 1 1 2 100 Gallon Models 77 5 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 150 ft 570 60HEC 199 60 199 999 92 0 265 5...

Page 6: ...age 11 Transformer 120VAC primary 24VAC secondary 40VA Hot Surface Igniter 120VAC 30 120 Ohms room temperature Flame Sensor Output Minimum 1 micro amp typical range 4 to 7 micro amps Gas Valve Negative regulation 24VAC PSI maximum 4 5 W C Minimum running inlet Vent Safety Switch Normally closed opens 350 F manual reset Intake Pressure Switch CF serial number or later Not Required Intake Pressure S...

Page 7: ... 100HEC 250 80 130 100HEC 300 60 110 100HEC 399 50 100 Notes 1 Multiply the total number of 90 elbows intake and exhaust by 5 feet Do not include the termination fittings or 3 condensate elbow 2 Multiply the total number of 45 elbows intake and exhaust by 2 feet 3 Add this to the total length of straight pipe intake and exhaust 4 The sum total of all elbows and straight pipe intake and exhaust mus...

Page 8: ... indicating pressure switch fault 4 Blower pre purge period 5 seconds indicated by the PURGE LED on the module 5 Igniter warm up 18 seconds indicated by the IGNITER LED on the module 6 Trial for ignition 4 seconds three trials a Flame establishing period 2 5 seconds gas valve and igniter on indicated by the IGNITER and VALVE LED on the module b Burner on flame providing period 1 5 seconds looking ...

Page 9: ...ostic indicators to provide information on power to control and control status Non interchangeable polarized plug in connectors for all interconnections 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 ...

Page 10: ...eriod 2 5 seconds gas valve and igniter on indicated by the IGNITER and VALVE LED on the module b Burner on flame providing period 1 5 seconds looking for minimum of 1 micro amps indicated by the FLAME VALVE LED on the module 6 Steady state operation Ignition module monitors Thermostat circuit When thermostat opens gas valve is shut down and post purge begins Safety circuit If vent temp switch ope...

Page 11: ...h 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 Operation For models starting with CF serial numbers and later 11 IGNITION MODULE UT ELECTRONIC CONTROLS P2 P3 P5 P1 P7 P6 HUNTINGTON INDIANA 1013 SERIES INTEGRATED WATER HEATER POWER PURGE IGNITOR VALVE FLAME I...

Page 12: ...next page System is OK Supply voltage polarity is incorrect Y N N Y Refer to ignition module illustration is there 24VAC going to module at locations P2 1 and P2 2 WARNING 120 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 ELECTRONIC CONTROLS P2 P3 P5 P1 P7 P6 HU...

Page 13: ...ter see Hot Surface Igniter Testing and Replacement Probable Cause Combustion system see Combustion System Testing and Replacement Probable Cause Intake pressure switch Only for models prior to CF serial number see Intake Pressure Switch Testing and Replacement Probable Cause Blower see Blower Testing and Replacement Probable Cause Exhaust pressure switch see Exhaust Pressure Switch Testing and Re...

Page 14: ...ntinuity Check temperature dial harness continuity Is there continuity Replace harness Y N Replace harness N Y See page 16 IMPORTANT NOTE This procedure assumes a cool tank Rotate temperature dial to highest setting Thermostat not calling WARNING 120 volt potential exposure Use caution making voltage checks to avoid personal injury Thermostat Sensor Temperature Dial Yellow Red wires shown jumpered...

Page 15: ...1856 1820 1786 1753 1720 160 1688 1656 1625 1595 1566 1537 1509 1481 1454 1427 170 1402 1376 1351 1327 1303 1280 1257 1235 1213 1191 180 1170 1150 1129 1110 1090 1071 1053 1035 1017 999 190 982 965 949 933 917 901 886 871 857 842 200 828 814 801 788 775 762 749 737 725 713 In Degrees F APPENDIX A Sensor Resistance at Various Temperatures Example If temperature of sensor is 84 F then the resistance...

Page 16: ... Replacement Y Replace thermostat circuit board see Thermostat Board Replacement Procedure Y N Y Thermostat circuit continued from page 14 WARNING 120 volt potential exposure Use caution making voltage checks to avoid personal injury Red Wires Temperature Sensor IGNITION MODULE UT ELECTRONIC CONTROLS P2 P3 P5 P1 P7 P6 HUNTINGTON INDIANA 1013 SERIES INTEGRATED WATER HEATER POWER PURGE IGNITOR VALVE...

Page 17: ... panel see photo at right WIRING DIAGRAM For models starting with CF serial numbers and later WARNING 120 volt potential exposure Isolate the appliance and reconfirm power is disconnected using a multi meter Thermostat Board Mounting screw locations Y TRANSFORMER 115V AC INPUT 24V AC OUTPUT BL BL Y BK GN W 1 P2 2 P2 1 P1 2 P1 3 P1 W GN Y BK TOGGLE SWITCH Y Y BK 115 VOLTS AC N GND LT POTENTIOMETER ...

Page 18: ...ing 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 following the lighting instructions on the lighting instruction label or the lighting instruction located in the installation and operating instruction...

Page 19: ...ck 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 any leaks found Confirm proper operation following the lighting instructions on the lighting instruction label or the lighting instruction located in the installation and operating instruction manual Step 11 Replace surround cover on top of heater ...

Page 20: ...ith manometer check inlet gas pressure Is it stable between 7 14 W C static heater not running see illustrations at right Is gas supply pressure regulator adjustable to maintain proper and stable setting Y N Volt meter set to OHM setting Meter probe Hot surface igniter CHECK IGNITER RESISTANCE WARNING 120 volt potential exposure Use caution making voltage checks to avoid personal injury WARNING Re...

Page 21: ...or Replacement Procedure Inspect burner tube see Burner Tube Inspection and Replacement N Y N WARNING 120 volt potential exposure Isolate the appliance and reconfirm power is disconnected using a multi meter Y Venturi adjustment Inlet gas pressure tap 100HEC 399 Only Gas valve regulator Observe burner operation through the sight glass located on the combustion insert mounting flange Normal burner ...

Page 22: ... Step 7 Remove the 5 bolts socket holding the burner mounting insert in place Step 8 Carefully remove combustion assembly with gasket from water heater Step 9 See next page for combustion system installation procedure Combustion System Removal Procedure WARNING 120 volt potential exposure Isolate the appliance and reconfirm power is disconnected using a multi meter WARNING Heater components may be...

Page 23: ...tep 6 on 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 gas supply 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 following the lighting instruct...

Page 24: ... assembly Step 8 Remove the 4 nuts 7 16 wrench holding the burner transition in place Lift the blower gas valve transition assembly from burner mounting insert remove gasket and set aside Step 9 Remove burner tube from burner mounting insert See next page for burner tube inspection procedure Burner Tube Removal Procedure WARNING 120 volt potential exposure Isolate the appliance and reconfirm power...

Page 25: ...orrect replacement burner Step 1 Fully inspect burner flange gaskets igniter and flame sensor gaskets for the following a Tears d Dirt or debris b Missing material e Other imperfections that would inhibit proper seal c Cracks If 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...

Page 26: ...r 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 Turn on 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 following the lighting instructio...

Page 27: ... 7 and ground Y N Thermostat not calling for heat see Thermostat Circuit Testing Correctsafety circuit problem per safety circuit trace section Blocked Vent Pressure Switch Testing Y Y Is there 120VAC acrossthe white and black wires at the terminal block seephoto at right N N Refer toignition module control board illustration Isthere 120VAC between P5 1 and P5 3 Y Replace ignition module control b...

Page 28: ...12 Reconnect intake vent and gas line to gas valve assembly and check for gas leaks repair any leaks found Step 13 Reconnect wire harness to blower assembly restore 120 volt power supply Gas supply to water heater and confirm proper operation following the lighting instructions on the lighting instruction label or the lighting instructions located in the installation and operating instruction manu...

Page 29: ... Check PURGE LED status Y Safety Circuit OK see Blower Testing Replacement Replace exhaust pressure switch see Exhaust Pressure Switch Replacement Procedure Replace vent safety switch see Vent Safety Switch Replacement Procedure Call technical support Y N Depress reset button on vent safety switch Is there continuity across high limit switch see photo below Refer to Check Collector Pressure see ne...

Page 30: ...manual Reconfigure vent system to be compliant with vent tables see Specifications Y N With monometer take a reading at the exhaust tube pressure tap location Is value negative see illustration below Check exhaust collector pressure at the exhaust collector pressure tap location see illustration below Is there positive pressure equal to or greater than pressure switch settings below EXHAUST PRESSU...

Page 31: ...tep 5 Step 7 Reconnect wire leads Note wire leads are interchangeable with either terminal Step 8 Reconnect silicone tubing to pressure switch as follows a Exhaust pipe tubing connects to negative side of switch identified by the symbol located on switch b Exhaust collector tubing connects to positive side of switch identified by the symbol located on the switch Step 10 Reinstall service panel acc...

Page 32: ...tion making voltage checks to avoid personal injury Flashing after 5 minutes Error code 29 again Call for technical support Correct blower problem see Blower Testing and Replacement N Y Note The blocked vent pressure switch must be used with the revised ignition control identified with a yellow label Heater side harness Control side harness Y Is there continuity Through GREY wire leads of heater s...

Page 33: ...truction Determine cause and correct Y Is vent system total length compliant with vent tables in the instruction manual Reconfigure vent system to be compliant with vent tables see Specifications Y N With monometer take a reading at the exhaust tube pressure tap location Is value negative or slightly postitive see illustration below Y N With ohmmeter check pressure switch for continuity Contacts s...

Page 34: ...ssure switch mounting screws 5 16 wrench and remove pressure switch Step 6 Assemble new pressure switch to heater using screws from step 5 Step 7 Reconnect wire leads Note wire leads are interchangeable with either terminal Step 8 Reconnect silicone tubing to pressure switch as follows a Exhaust pipe tubing connects to single tap located on switch Step 10 Reinstall service panel access cover and r...

Page 35: ...Use caution making voltage checks to avoid personal injury Igniter may be too hot to handle take necessary precautions UT ELECTRONIC CONTROLS P2 P3 P5 P1 P7 P6 HUNTINGTON INDIANA 1013 SERIES INTEGRATED WATER HEATER POWER PURGE IGNITOR VALVE FLAME INDICATOR LIGHTS FOR OPERATING SEQUENCE TROUBLESHOOTING SEE INSTALLATION AND OPERATING INSTRUCTION MANUAL ANSI Z21 20 AUTOMATIC IGNITION SYSTEMS CAN CSA ...

Page 36: ...ack into place Be sure no wires are in contact with burner flange Step 8 Install new igniter with new gasket provided using screws 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 the lighting instructions on the lighting instruction label or the lighting instructions located...

Page 37: ...sensing circuit OK Y Refer to ignition module control board illustration 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 for technical support Replace flame sensor with gasket 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 ...

Page 38: ...flame sensor with new gasket provided using screws from step 6 Arrange flame sensor with hook towards burner Step 1 Position main power switch to OFF Step 2 Disconnect unplug water heater from 120 volt power source Step 3 Un latch remove surround cover from top of heater Step 11 Restore 120 volt power supply to water heater and confirm proper operation following the lighting instructions on the li...

Page 39: ... all wire harness connection to ignition module Connection are non interchangeable to insure proper reinstallation Step 6 Remove the 3 screws Phillips screw driver holding the ignition module in place and remove ignition module from control panel Step 9 Restore 120 volt power supply to water heater and confirm proper operation following the lighting instructions on the lighting instruction label o...

Page 40: ...ostat board Note the blue wire must connect to the 24 volt HOT terminal see photo at right Step 1 Position main power switch to OFF Step 2 Disconnect Unplug water heater from 120 Volt power source Step 3 Un latch remove surround cover from top of water heater Step 10 Restore 120 volt power supply to water heater and confirm proper operation following the lighting instructions on the lighting instr...

Page 41: ...ent Safety Switch Testing and Replacement or Exhaust Pressure Switch Tesinting and Replacement or Blower Testing and Replacement Y N Y N N Y Is intake vent system obstructed Y N Call for technical support Clear obstruction See Exhaust Pressure Switch Testing and Replacement or Blower Testing and Replacement Is there continuity through the normally closed intake pressure switch see photo above Y Is...

Page 42: ... 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 interchangeable with either switch terminal Step 11 Restore 120 volt power supply to heater verify proper heater operation following the instructions on the lighting instruction labe...

Page 43: ...50 F Y N Sequence of operation With the thermostat calling for heat prior to energizing blower the ignition module checks the vent safety switch for normal switch position of normally closed If the vent safety switch contacts are open not in normal position the ignition module waits indefinitely for contact to close The vent safety switch must be manually reset to close the switch contacts System ...

Page 44: ...4 Disconnect wire leads from vent safety switch see photo at right Step 5 Remove the 2 switch mounting screws Phillips screw driver and nuts 5 16 wrench and remove switch from heater Step 6 Install new switch using screws from step 5 Step 7 Reconnect wire leads Note wire leads are interchangeable with either switch terminal Step 9 Reinstall service panel access cover and rubber escutcheon Step 8 R...

Page 45: ... cover screws 5 16 socket and remove 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 allowing access 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 fo...

Page 46: ...on of inspection or subsequent replacement apply Teflon tape or other thread compound to threads of anode and reinstall into heater Restore water supply and 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 h...

Page 47: ...cement 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 the instructions on the...

Page 48: ...wer 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 powered anode rods Step 3 Check all electrical connections The powered anode rods are insulated from the water heater tank in the bus hing a With...

Page 49: ...Copper Silicone around entire collector flange surface Allow caulk 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 bead of Ultra Copper Silicone around entire collector flange surface Service Procedure XIII Anode Flue Baffle Inspection Replacement ...

Page 50: ... drain at a minimum of per foot Make sure the condensate line does not have the potential to freeze If using more than one heater 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 the top and bottom pressure switches as well as enough overhead room to remove the anode rods for ...

Page 51: ...d Running Inlet Gas Pressure Size Material Length Condensate Line Igniter Resistance Flame Sense Micro Amps Venturi Exhaust Collector Pressure 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 Provider Phone Number Is trap provided Y or N Installation Site Name Address Length of straight pipe exhau...

Page 52: ...for 399 9 Baffle 2 Flue 10 Wire Harness Service Panel 11 Plastisert Nipple 1 NPT 12 Plug 13 Nipple 14 T P Relief Valve 15 Exhaust Pipe PVC w Barb Tap 16 Condensate Trap Elbow 17 Silicone hose 18 Outer Door Service Panel Specify Model 19 Vent Pipe Support Bracket except 399 20 NSF Escutcheon 21 Exhaust Pressure Switch 22 Nuts 23 Collector Limit Switch 24 Screw 6 32 x 3 8 25 Cleanout Access Cover 26...

Page 53: ...et Screw 9A Gas Valve 10A Nipple NPT X3 11A Reducer x NPT 12A Nipple NPT x 6 13A 2 dia Flex Reducer 14A Inlet PVC 15A Gasket Blower Transition 16A Screw 8 32 x RHCR 17A Gasket Flame Sensor 18A Flame Sensor 19A Transition Tube 20A Nut Hex Washer 21A Gasket Hot Surface Igniter 22A Hot Surface Igniter 23A Burner Mounting Gasket 24A Burner Tube 25A Burner Mounting Gasket 26A Burner Mounting Insert 27A...

Page 54: ...ng Panel 5C Thermostat PC Board 6C Transformer 120VAC x 24VAC x 40VA 7C Terminal 8C Terminal Strip 9C Power Cord 10C Control Wire Harness 11C Thermostat Wire Harness 12C Igniter Extension Wire 13C Blower Wire Harness 14C Power Switch Wire Harness 15C Flame Sensor Wire Harness 16C Rectifier Harness 8C 7C 6C 1C 2C 3C 4C 5C 12C 9C 10C 11C 13C 14C 15C 16C Parts List Models prior to CF serial number ...

Page 55: ...specify model 17 Silicone Hose 18 Outer Door Service Panel specify model 19 Vent Pipe Support Bracket except 100HEC 399 20 NSF Escutcheon 21 Exhaust Pressure Switch 22 Nuts 23 Collector Temperature Limit Switch 24 Screw 6 32x 3 8 25 Cleanout Access Cover 26 Cleanout Gasket 27 Screw 5 16 18 x HH Grade 5 28 Cleanout Cover 29 Cold Water Inlet Hydrojet Assy 30 No Handle Brass Drain Valve 31 Concentric...

Page 56: ... 10 32 x3 4 8A Gasket Screw 9A Gas Valve specify model 10A Nipple specify model 11A Reducer specify model 12A Nipple specify model 13A 2 dia Flex Reducer or PVC reducer for 399 14A Inlet PVC 15A Gasket Blower Transition specify model 16A Screw 8 32 x RHCR 17A Gasket Flame Sensor 18A Flame Sensor 19A Transition Tube 20A Nut Hex Washer 21A Gasket Hot Surface Igniter 22A Hot Surface Igniter 23A Burne...

Page 57: ...l Strip Power Cord Control Wire Harness Thermostat 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 Harness Flame Sensor Wire Harness 1C 2C 3C 4C 5C 6C 7C 8C 9C 10C 11C 12C 13C 14C 15C 16C 17C 1C 8C 10C 12C 17C 3C 4C 7C 6C 5C 2C 15C 16C 9C 13C 14C 11C...

Page 58: ... Ignition ECO Energy Cut Off GFI Ground fault interrupt GPM Gallons per Minute HSI Hot Surface Igniter Hz Hertz LED Light Emitting Diode NOx Oxides of Nitrogen NPT National Pipe Thread PSI Pounds per Square Inch RPM Revolutions per Minute VA Volt Amps VAC Volts Alternating Current W C Inches of Water Column C Degrees Centigrade F Degrees Fahrenheit A Micro Amp ...

Page 59: ...HEC Series 59 Notes NOTES ...

Page 60: ...ller or local Bock Water Heaters sales representative Sales 608 227 3311 Fax 608 327 3311 Application Sizing 608 227 3311 Fax 608 327 3311 Technical Support 888 784 8322 Fax 610 683 9208 Warranty 608 227 3319 Fax 608 327 3300 Email sales bockwaterheaters com www bockwaterheaters com ...