Troubleshooting Guide This guide contains information for identifying and correcting issues that may arise. Applicable Models: i200 i200p i250 i250p i200x i201x i250x i251x iq251 iq251d iq751 iq1001 iq1501 Product Support / Warranty If the water heater requires additional service, please use one of the following options for contacting Intellihot Technical Support: - Call: 309-473-8040 (toll-free 1-877-835-1705), and press 3 - Email: support@intellihot.com When you contact Technical Support, please have the following information ready: - Model Number - Serial Number - Date purchase / Date installed - Installation location & application - Error code (if any) or other problem with the unit
Table of Contents Error Code List & Suggested Tool List...2 E1-Blower Speed Fault...3 E3-Blocked Flue...4 E7-Ignition Failure...5 E9-Temperature Sensor Shorted...6 EA-Temperature Sensor Open Circuit...7 EC-Flue Temperature Exceeded...8 Ed-Heat Exchanger Outlet Temperature Exceeded...9 Flashing Icon...10 Icon Flashing...11 Recirculation Icon Flashing...12 Blank (Blue)/Illegible Display...13 Breaker Tripped (Over-Load)...14 Dead Unit- Powerup...15 Hot Water...16 Rough Ignition...17 Rumbling...18 Water Leaks...19 Appendix Blower Replacement...20 Gas Valve Replacement...21 Electrode Replacement...23 Controller Pin Layout...24 Wiring Diagram (Wall-Hung)...24 Wiring Diagram (Floor-Mount)...25 1
Error Code List Code Description Page E1 Blower Speed Fault 3 E3 Blocked Flue 4 E7 Ignition Failure 5 E9 Temperature Sensor Shorted 6 EA Temperature Sensor Open Circuit 7 EC Flue Temperature Exceeded 8 Ed Heat Exchanger Outlet Temperature Exceeded 9 Suggested Tool List - Digital Manometer - Electrical Multimeter - Flue Gas Analyzer (for NOx & CO 2 ) - 7mm Socket & Ratchet - #1 Phillips Screwdriver - #2 Phillips Screwdriver - Instrument Flat Blade Screwdriver - Pliers - Adjustable Wrench 2
Check J18 & J15. Are the contacts loose? J10 J19B CASCADING CONNECTIONS J19A J20 DIP SWITCH SW3 ON OFF J5 Repair/tighten connectors 3 E1 Blower Speed Fault E1-Blower Speed Fault Does Blower Run on Start-up Is Blower isy? Power cycle unit and at start up, use a multimeter to check PWM at J18. Does PWM read between 10-90%? Unplug blower and measure 120V at the 3-pin Connector (J15)? Check blower. Is there a broken vane? Remove blower and inspect inside for damage. Replace blower J8 J12 Check fuse. Is it blown? Replace Fuse Replace Blower J14 J15 J23 DIP SWITCH SW1 FUEL SELECT RED LED (BURNER ON) GREEN LED (POWER) ON NG LP OFF J9 Replace controller J7 J18 E12 J11 J3 J1 Black Red
Contact Authorized Service Personnel 4 E3-Blocked Flue E3-Blocked flue Check exhaust termination. Is it blocked? Turn off gas and remove condensate line. Remove the condensate tube/input trap. Is it blocked? Check Air switch wiring (green/black). Is it loose Is vent piping sized (diameter & total length and installed per manual? Remove blockage and Install screens if not installed Are the drain hoses sloped away from unit? Repair faulty wiring at air switch Correct piping per manual specs Check for double loops, air locks or debris in loop Slope drain per Manual
Replace igniter Contact an authorized service technician 5 E7-Ignition Failure E7-Ignition Failure Nat. Gas or Propane? Gas Overheat Hi-limit tripped? Replace switch for wall-hung, for IQ check flow change requirement. Check recirc pump ** Propane Are the regulators & gas lines sized for loads? Check the static gas pressure. Is it within specs? Put unit at maximum firing value. Did pressure drop less than 0.5" W.C.? Is the flame visible through the viewport? Is LP conversions completed per manual? Complete the conversion per the manual Size gas lines and regulators for max BTU/h requirements Gas lines and/or regulators inadequate. Please correct. Is dynamic pressure within spec? Regulator or gas lines inadaquate. Please correct. Remove igniter and inspect. (Gap and cleanliness) Bad Replace the igniter Good Is red LED lit up on controller? Check white wire from electrode to controller (E12) Shut off gas and test fire to see if sparks at the gap Check wiring to gas valve and to DSI (brown/blue). Is it damaged? Check for 120 V at J23 pins during ignition Is flame visible during ignition? J14 J15 J8 DIP SWITCH SW1 FUEL SELECT RED LED (BURNER ON) GREEN LED (POWER) ON NG LP J12 OFF J9 J10 J19B CASCADING CONNECTIONS J19A J20 Repair or replace wiring. Replace controller Replace gas valve Go to ** J23 DIP SWITCH SW3 ON OFF J7 J18 E12 J11 J3 J1 J5
J10 ON J20 J5 OFF 6 E9 Temperature Sensor Shorted E9-Temp. Sensor Shorted Verify Secondary Sensor code: HE-heat exchanger water outlet temperature sensor (orange wire) FL-flue temperature sensor (gray wire) IN-inlet water temperature sensor (blue wire) re-recirculation temperature sensor (white wire) Ou-Domestic hot water outlet temperature sensor (green wire) J14 J15 J8 J23 RED LED (BURNER ON) J7 DIP SWITCH SW1 FUEL SELECT J18 GREEN LED (POWER) ON NG LP OFF E12 J12 J9 CASCADING CONNECTIONS J11 J3 J1 J19B J19A DIP SWITCH SW3 Is Sensor wiring or pigtails damaged or corroded? Check harness connector J3. Is it damaged? Measure resistance of sensor using multimeter. Is it within spec? Contact Authorized Service Personnel Repair nicked or broken sensor wiring/connectors. Repair or replace connector wire. Replace corresponding sensor Temp of Water ( F) Sensor Resistance (kw) 50 18 77 10 140 3
J10 ON J20 J5 OFF 7 EA Error Code-Temp Sensor Open Circuit J8 EA - Temp Sensor-open circuit Verify Secondary Sensor code: HE-heat exchanger water outlet temperature sensor (orange wire) FL-flue temperature sensor (gray wire) IN-inlet water temperature sensor (blue wire) re-recirculation temperature sensor (white wire) Ou-Domestic hot water outlet temperature sensor (green wire) J14 J15 J23 RED LED (BURNER ON) J7 DIP SWITCH SW1 FUEL SELECT J18 GREEN LED (POWER) ON NG LP OFF E12 J12 J9 CASCADING CONNECTIONS J11 J3 J1 J19B J19A DIP SWITCH SW3 Is Sensor wiring or pigtails damaged or corroded? Check harness connector J3. Is it damaged? Measure resistance of sensor using multimeter. Is it within spec? Contact Authorized Service Personnel Repair nicked or broken sensor wiring/connectors. Repair or replace connector wire. Replace corresponding sensor Temp of Water ( F) Sensor Resistance (kw) 50 18 77 10 140 3
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Contact Authorized Service Personnel 9 Ed-Heat Exchanger Outlet Temperature Exceeded Ed- HEX Oulet Temp Exceeded On a well water system? Is there air in system? Check for faulty HE sensor/wiring (orange) Is the unit a combi or pump model? Does the flow rate change more than 2 GPM in 5 sec.? Is pressure within 30-150psi? Bleed out unit with water when unit is off Follow EA & E9 error code processes (Pages 6 & 7) Remove and inspect check valve on the line and inside pump. Is it normal? Add recirculation pump Correct well water system Remove jammed check valve due to water not flowing through unit. Inspect solenoid valve. Is is damaged/ plugged or installed backwards?? Combi Pump Model Correct direction (arrow pointing right-combi, Left for Pump Model) and replace if damaged
10 Flashing Icon! Flashing Icon - Error has occurred Unit is locked, Error Code has occurred. Refer to applicable error code resolution for the code that is present on the units. To reset the water heater, press and hold the power button on the display or unplug unit and plug back in after 10 seconds
Contact Authorized Service Personnel 11 Cascading Icon Flashing Cascading Icon Flashing Check connection data cables, are they damaged or unplugged? Go to cascading mode in each unit. Does each unit have a unique identifier set? Are the DIP Switches for the end units set properly? Are the DIP Switches for the non-end units set properly? Do any of the units show an error code? Reconnect cables and replace any damaged cables or connectors Set each unit with unique number (1-10) per manual Refer to manual for proper configuration Refer to manual for proper configuration Refer to Guide for that specific error code.
Contact Authorized Service Personnel J10 J19B CASCADING CONNECTIONS J19A J20 DIP SWITCH SW3 ON OFF J5 12 Recirculation Icon Flashing (Pump Models Only) Recirc Icon Flashing J14 J15 J8 J23 DIP SWITCH SW1 FUEL SELECT RED LED (BURNER ON) GREEN LED (POWER) ON NG LP J12 OFF J9 J7 J18 E12 J11 J3 J1 Check to see if pump is rotating by touching or with pump rotation tester. Contact Authorized Service Personnel Black Red Inspect the pump wiring connections (J7). Are they damaged or unplugged? Check J7 that there is 120V when the recirc icon is on. Replace controller Remove and inspect check valve on the line and inside pump. Is it normal? Remove jammed check valve due to water not flowing through unit. Inspect solenoid valve. Is is damaged/ plugged or installed backwards?? Correct direction (arrow pointing right-combi, Left for Pump Model) and replace if damaged Plug in or repair wiring & connections. Combi Pump Model
13 Blank (Blue) / Illegible Display Blank (Blue) / Illegible Display Power Cycle the Unit. Is Display still blue/illegible? Check the wiring at display end. Is it loose? Replace the Display All OK Plug in securely. Repeat power cycle of the unit.
J10 J19B CASCADING CONNECTIONS J19A ON J20 J5 OFF Contact Authorized Service Personnel 14 Breaker Tripped (Over-Load) J8 Breaker Tripped J12 J14 DIP SWITCH SW1 FUEL SELECT ON NG LP OFF J9 J15 RED LED (BURNER ON) GREEN LED (POWER) Review manual for breaker sizes. Are they size appropriately? Power down the unit. Unplug transformer, pump and blower. (J12, J7, J18) J23 J7 J18 E12 J11 J3 J1 DIP SWITCH SW3 Appropriately size the breakers per the manual Plug in transformer (J12), and power up unit did breaker trip? Replace transformer Plug in Pump Plug in blower. (J18) (if present) (J7). Did Did Breaker trip? breaker trip? Replace pump Replace blower
Replace with appropriate fuse Contact Authorized Service Personnel 15 Dead Unit - Power Up Unit is Dead - Power Up Is Unit plugged in? Is corresponding breaker tripped? Check the power connection to the controller (J14). Is it loose or damaged? Check the fuses on controller. Are they rated at 10A / 250V? Plug in Unit(s) See Breaker tripped page Correct or replace power connection Are the fuses blown or damaged? Replace Fuse and see Breaker Tripped page. J8 J12 J10 Black Red J14 J15 DIP SWITCH SW1 FUEL SELECT RED LED (BURNER ON) GREEN LED (POWER) ON NG LP OFF J9 J19B CASCADING CONNECTIONS J19A J20 J23 DIP SWITCH SW3 ON OFF J7 J18 E12 J11 J3 J1 J5
16 Hot Water Hot Water Open faucet, is the flow icon lit? Open drain on bottom of unit is water flowing? Remove Pump & inspect check valve, is it stuck? (pump & combi models only) Contact Authorized Service Personnel Check inlet strainer, is it plugged? Open and clean out strainer per manual Repair or replace check valve Is the inlet & outlet water connection piped correctly? Remove water inlet valve. Inspect for debris or PTFE paste. Is there debris? Blow on valve to hear for movement of turbine? Repair piping to have proper inlet and outlet. Clear out debris Replace valve
Contact Authorized Service Personnel 17 Rough Ignition Rough Ignition Nat. Gas or LP? NG Check HV cable. Is it unplugged or damaged? Check the static gas pressure. Is it within specs? Check the emissions. Are they within specs? Check with gas company about the caloric value of gas value is within limit (975-1050)? LP Has unit been converted to LP per manual? Replace or plug in HV cable Gas lines and/or regulators inadequate. Please correct. Retune gas valve to set emissions to specs. See manual and convert.
18 Rumbling Unit is Rumbling Verify the intake & exhaust is installed per specification? Is the vent length less than 5 ft? Check the CO 2, is within specs. Contact Authorized Service Personnel Install according to manual instructions Add an elbow or reducer to bring effective length to over 10 ft. Set the CO 2 level within table below CO 2 and CO Standards Description CO 2 Range (%) Max. CO Level (ppm) Natural Gas High Fire 9.1% to 9.3% < 200 ppm Low Fire 9.0% to 9.2% < 60 ppm LP Gas High Fire 9.0% to 9.8% < 200 ppm Low Fire 8.6% to 8.9% < 60 ppm
Contact Authorized Service Personnel 19 Water Leaks Water Leak (internal) Remove cover and inspect to locate leak. Is the leak spotty and located under the casting? Contact Authorized Service Personnel Shut off the inlet & outlet and open an fixture to release pressure in system. Check the internal water lines. Identify location of leaks. Refer to Serviceable parts diagrams in manual, Remove and disassemble leaking/damaged part. Inspect part and O-ring for damage. Repair or replace as needed.
Appendix BLOWER REPLACEMENT (See Diagram, page 22) The blower is located on the top of the heat exchanger Shut off the gas to the heater Shut off power to the heater by unplugging the unit from the 120 VAC outlet remove the front panel (three screws at top and three at bottom) Unplug the display cable from the pcb (press plastic tab and pull) lift up and remove the front display bracket Unplug all the wiring connections from the blower (press the tabs and pull) remove the gas valve wiring located behind the blower Unplug the HV cable from the DSI Remove the gas connection at the top isolating the unit's gas supply from the building remove phillips screws to remove the aluminum gas fitting at the top the unit remove 4 allen screws to remove the aluminum gas adapter fitting remove two plastic taps on top of the cabinet to access the screws securing the blower remove 4 screws securing the blower from the top using a long screwdriver remove the entire blower gas valve assembly from the unit remove the gas valve 3 torx screws install the gas valve on the new blower reverse process to assemble the blower back to the heater ensure the gasket is installed between the blower and the top housing Install the blower gas valve using 4 screws and a long screw driver Install the aluminum gas adapter on top of the gas valve Install the gas fitting and secure it using 4 screws to the cabinet Install the building gas supply Install the blower wiring, HV cable and gas valve wiring turn gas supply back on and check for any gas leaks turn water on and plug the heater to the outlet 20
GAS VALVE REPLACEMENT (See Diagram, page 22) The blower gas valve assembly is located on the top of the heat exchanger Shut off the gas to the heater Shut off power to the heater by unplugging the unit from the 120 VAC outlet remove the front panel (three screws at top and three at bottom) Unplug the display cable from the pcb (press plastic tab and pull) lift up and remove the front display bracket Unplug all the wiring connections from the blower (press the tabs and pull) remove the gas valve wiring located behind the blower Unplug the HV cable from the DSI Remove the gas connection at the top isolating the unit's gas supply from the building remove phillips screws to remove the aluminum gas fitting at the top the unit remove 4 allen screws to remove the aluminum gas adapter fitting remove two plastic taps on top of the cabinet to access the screws securing the blower remove 4 screws securing the blower from the top using a long screwdriver remove the entire blower gas valve assembly from the unit remove the gas valve 3 torx screws install the new gas valve on the blower 3 torx screws reverse process to assemble the blower back to the heater ensure the gasket is installed between the blower and the top housing Install the blower gas valve using 4 screws and a long screw driver Install the aluminum gas adapter on top of the gas valve (ensure the o-ring is in place) Install the gas fitting and secure it using 4 screws to the cabinet Install the building gas supply Install the blower wiring, HV cable and gas valve wiring turn gas supply back on and check for any gas leaks turn water on and plug the heater to the outlet 21
Blower/Gas Valve Exploded View Gas Valve Blower 22
ELECTRODE REPLACEMENT The electrode is located on the top of the heat exchanger Shut off the gas to the heater Shut off power to the heater by unplugging the unit from the 120 VAC outlet remove the front panel (three screws at top and three at bottom) Unplug the display cable from the pcb (press plastic tab and pull) lift up and remove the front display bracket Unplug the HV cable from the electrode Unplug the electrode connection from the controller at connection E12 Remove the 2 screws & washers securing the electrode Remove electrode from HEX assembly. Insert new electrode into the HEX assembly, careful to use new probe hole seal Fasten the electrode with the 2 screws with washers. Verify that the yellow/green wire is attached beneath the right hand screw. Connect the electrode to the controller at connection E12 Connect the HV cable to the electrode turn gas supply back on turn water on and plug the heater to the outlet 23
Controller Pin Layout J8 J12 J10 J14 J15 DIP SWITCH SW1 FUEL SELECT RED LED (BURNER ON) GREEN LED (POWER) ON NG LP OFF J9 J19B CASCADING CONNECTIONS J19A J20 J23 DIP SWITCH SW3 ON OFF J7 J18 E12 J11 J3 J1 J5 Wiring Diagram (all wall-hung units) 3-cord cable BK WT TRANSFORMER J8 BK WT BOILER TT MODELS i200x, i250x ONLY LEAK SENSOR BN BN RD RD BK BK J12 J10 BN BK AIR SWITCH GN GN-GROUND WT-NEUTRAL BK-LINE BN-LINE BL-NEUTRAL GN/YL-GROUND J14 J15 DIP SWITCH SW1 FUEL SELECT RED LED (BURNER ON) GREEN LED (POWER) ON NG LP OFF J9 J19B CASCADING CONNECTIONS J19A J20 RD RD YL BL BK BLOWER PUMP HEATING SYSTEM PUMP TERMINAL MODELS i200x ADN i250x ONLY MODELS i200p, i250p, i200x, i250x ONLY GROUND NEUTRAL LINE RD WT BL BK BL-NEUTRAL BN-LINE GN/YL-GROUND BL-NEUTRAL BN-LINE GN/YL-GROUND GN/YL BN RD 10A J23 J7 J18 12 BYBASS SOLENOID VALVE TEMPERATURE SENSORS FLUE TEMP J11 J3 J1 GY DIP SWITCH SW3 ON OFF WT J5 BL GY OR GN BK RD GN YL BL OR WT BN *RECIRCULATION TEMP WT BK RD BL BN BN BN BN BL OR 194 F THERMAL 390 F THERMAL HEAT EXCHANGER OUTLET TEMP GN OUTDOOR TEMPERATURE SENSOR MODELS i200x, i250x ONLY (REPLACES COLD WATER INLET TEMP) DIRECT SPARK IGNITION BL GN/YL-GROUND GAS VALVE HIGH VOLTAGE CABLE *HOT WATER OUTLET TEMP *MODELS i200p, i250p, i250p, i200x, i250x ONLY WT IGNTER AND FLAME PROBE WIRE COLOR CODE BK BLACK BL BLUE BN BROWN GN GREEN GY GRAY OR ORANGE RD RED WT WHITE YL YELLOW GN/YL GREEN/YELLOW COLD WATER INLET TEMP WATER CONTROL VALVE AND FLOW SENSOR IGT-LBL0014 REV 02 24
6 Wiring Diagram (all floor-mount units) 25
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Product Support / Warranty If the water heater requires additional service, please use one of the following options for contacting Intellihot Technical Support: - Call: 309-473-8040 (or 1-877-835-1705), and press 3 - Email: support@intellihot.com When you contact Technical Support, please have the following information ready: - Model Number - Serial Number - Date purchase / Date installed - Installation location & application - Error code (if any) or other problem with the unit Revised 9-2015 v1.1