Intellihot iE1 User manual

Maintenance Manual
iE1

Thank you for purchasing this Intellihot unit.
This unit is designed for years of trouble free operation, and I urge you to read and follow the
instructions in this “Operation & Installation Manual.”
Our mission to create a better heating system began back in the winter of 2005 when a tank
water heater broke down and ooded my basement. By combining the principles of a diesel
engine’s robustness, robotics intelligence, and marine environment durability, we set out to
design a unit from the ground up that would outperform and outlast all others.
Quickly, our goal grew from not just making a better water heater, but creating an intelligent
water heating and delivery system. Innovation is our hallmark and simplicity, eciency, and
durability are at the core of every lntellihot product.
Our products are proudly engineered and built in Galesburg, Illinois. lntellihot has helped
commercial customers throughout the nation save thousands of dollars while eliminating
downtime. Our talented team of dedicated professionals is ready to assist you and help your
business succeed.
I thank you for purchasing our lntellihot products.
Sincerely,
Sri Deivasigamani
CEO, lntellihot Inc.

Table of Contents
10. Maintenance
10.1 InletStrainerCleaning . . . . . . . . . . . . . . . . . . 34
10.2 FanGuardCleaning ....................34
10.3 Temperature-PressureReliefValveTest ...35
11. Wiring Diagrams and Troubleshooting
11.1 OperationalFlowChart.................36
11.2 Wiring Diagram........................36
11.3 Troubleshooting Guide..................38
11.3.1 TemperatureSensorOpen-Upper
ThermalBatteryError ..................38
11.3.2TemperatureSensorShorted-Bottom
ThermalBatteryError ..................38
11.3.3TemperatureSensorisOutofRange-
BottomThermalBattery ...............38
11.3.4HeatExchangerValveFault ........39
11.3.5BypassValveFault ...............40
11.3.6 Float Switch Failed ..............40
11.3.7BypassValveFault ...............40
12. Serviceable Parts
12.1 Display .............................. 41
12.2 CTA2045 ............................ 41
12.3 Electronics ........................... 41
12.4 ColdSide ............................ 42
12.5 ColdSide ............................ 42
12.6 ColdSide ............................ 43
12.7 Glycol Side ........................... 43
12.8 Glycol Side ........................... 44
12.9 Tank ................................ 44
12.10 Heat Pump ........................... 44
12.11 Miscellaneous ........................ 44

This product complies with UL 60335-2-40/CSA 22.2 Electric Water Heater. For use as potable water heating
DANGER
To avoid product damage, personal injury, or even
possible death, carefully read, understand, and
follow all the instructions in this Installation &
Operation Manual before installing this product.
Improper installation, adjustment, alteration, or maintenance
can cause injury, loss of life, and/or property damage.
This water heater should be installed and serviced by a
qualified technician. The lack of proper service can result in a
dangerous condition.
This manual must remain with the water heater
Due to Intellihot’s policy of continuous product improvement
and technology, the design, technical specifications, or both
in this manual are subject to change without notice.
This manual contains safety information, installation
instructions, and maintenance procedures. It must be left
with the homeowner or placed near the water heater in a
noncombustible location. The customer should retain this
manual for future reference.
Contact Information
Call us, your dealer, first if you have any questions about this
product. We can help answer questions about installation,
operation, or if there are damaged or missing parts when
unpacking this unit from the shipping box.
Dealer Contact Information.
Electrical Shock Hazard - Do Not Touch
Electrical Shock Hazard
If the water heater becomes immersed in water up to or
above the level of the bottom of the element doors, the
heater should be examined by a qualified service agency
before it is placed in operation.
WARNING

iE1 Maintenance 34
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10.Maintenance
10.1 Inlet Strainer Cleaning
The following procedures must be performed atleast once
in every three months or it may affect the warranty of the
product.
1. The water heater must be turned OFF at the breaker
ON/OFF switch before maintenance checks can be
performed.
2. Shut off the water inlet valve.
3. Open a nearby tap/faucet and make sure that all the
water is drained then close the tap.
4. Use a wrench to loosen the water inlet strainer and
remove the strainer.
5. Clean the strainer, reinstall it and tighten the strainer nut.
6. Turn on the power supply.
7. Open the water inlet valve.
8. Perform visual inspection of the water connections to
9. Make sure that there are no leaks.
Inlet
Strainer
Cleanout
10.2 Fan Guard Cleaning
The following procedures must be performed atleast once
in every three months or it may affect the warranty of the
product.
1. The water heater must be turned OFF at the breaker
2. ON/OFF switch before maintenance checks can be
performed. Make sure that the fan stops rotating.
3. Use a cleaning brush to clean the fan guard at the back
and on the side.
4. Turn ON the water heater and make sure that the fan
runs properly.

35 iE1 Maintenance
Aug2023-Revision00
10.3 Temperature-Pressure Relief Valve Test
The following procedures must be performed atleast once
in every three months or it may affect the warranty of the
product.
DANGER
WARNING
When testing the Temperature-Pressure Relief Valve’s
functionality, make sure that no one is standing in front of or
near the discharge line’s outlet. The discharged water may be
hot and may cause injury to personnel.
WARNING
When using a valve, exercise caution because it might be hot
and may cause injury to personnel.
CAUTION
Make sure that the surrounding is clear off any objects. The
discharged water may be hot and may cause damage to
property.
1. Operate the lever at the relief valve’s end several times.
Make sure that the valve functions properly.
2. The temperature-pressure relief valve must be replaced if
it fails to completely reset and continues to release water.

iE1 Wiring Diagrams and Troubleshooting 36
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11. Wiring Diagrams and Troubleshooting
11.1 Operational Flow Chart
Temp Control Module
Maintain Temp
Thermal Battery Module
HP ON (based on mode)
Manage Grid Command
Temp Control Module
Maintain Temp
Initialization
(a. Check Sensors
b. Check Communication
c. Check Thermal Battery)
System OFF
Wait Until Thermal Battery
Charging Completes
Power ON
Fault
Fault
Fault
Fault
System Fault Processing Thermal Battery Low
Thermal Battery Full
System Ready
11.2

37 iE1 Wiring Diagrams and Troubleshooting
Aug2023-Revision00
11.3 Wiring Diagram
Stepper Motor
SPI (CTA-2045)
BMS
JTAG
IOT Board
Leak
Snsr
μ
USB
LTE
ANT
BT
ANT
Gylcol
Flow
Flow
Snsr 2
IOT to Main PCB
Lvl Snsr
LTE
BLE
Glycol
Conc
Snsr
+24V
+12V
LKS
GCS
AK2
WV2.1
WV2.2
WV2.3
WV2.4
WVS
FSW
GND
+
-
GND
+
-
Vout
GND
+
-
+Vdc
GND
+5V
B1
B2
B3
B4
B5
B6
B7
GND
+Vdc
DI1
DI2
DI3
DI4
DI5
DI6
DI7
DIC1
GND
Y1
Y2
Y3
Y4
B8
B9
B10
B11
B12
GND
DI8
DI9
DI10
GND
BMS CARD
UPC3
EEV2
EEV1
PT
TAM
C1
NO1
NO2
NO3
C2
NO4
NO5
NO6
NO7
C3
NC7
C4
NO8
NO9
NO10
NO11
NO12
10
1
2
8
6
4
5
Electric Expansion Valve
Fan Control
Compressor
LEVEL
SENSOR
Tank Element
Upper Tank Element
Lower Tank Element
UCM
Compressor Discharge Pressure (Exhaust)
Ambient Temp.
Evaporator Outlet CO2 Temp. (Coil)
Compressor Suction Temp.
Compressor Discharge Temp.(Exhaust)
Evaporator Temp.
Glycol Cooler Inlet Temp.
Compressor Suction Pressure
Temperature Sensors
Sensors
FILL SOLENOID
TEMPERATURE SENSORS
DHW Outlet Temp
(Only one Display per unit)
Upper Tank Temp
Lower Tank Temp
Glycol Cooler Outlet Temp.
Electronic Cooling Fan
Defrost Solenoid
L
N
L
N
N
J10
1
6
5
10
J20
J5
J19B
J19A
J1
J3
J11
J18
J6
J7
J23
J15
J14
J8
J12
J9
1
1
8
1
5
4
8
1
7
6
12
1
4
3
6
1
1
1
1
1
1
1
3
4
6
10
12
1
3
1
3
2
4
J24
POWER
DISTRIBUTION
BLOCK
INDUCTOR
COIL
120VAC To
24/20VAC
208VAC To
120VAC
XFMR
XFMR
UPPER
COIL
RELAY
LOWER
COIL
RELAY
L2
L1
G
L1
L2
G
L
N
I2
I1
G
L1
L2
U
V
W
L
L
L
N
Crankshaft Heat
WATER
PUMP
DRIVE
TB Glycol
PUMP
LEAK
SENSOR
Glycol
Keyence
Flow
Coil Outlet Temp
TB Isolation Valve
COIL ISOLATION VALVE
AND FLOW SENSOR
DHW
INLET TEMP
Glycol Concentration Sensor
Condensate
Block Switch
LINE
NEUTRAL
Thermal Fuse
LINE
NEUTRAL
L
N
L1
L2
L2
L1
Relay Switch
Pressure Switch
B1
B2
B3
B4
B6
B7
B8
B10
B12
IOT Board will plug in on J24 of control PCB
Thermal Fuse
L
N
UF1
BYPASS VALVE
AND FLOW
SENSOR
CONTROL
PCB
IGT-LBL0193
GREEN LED (POWE R)
RED LED (BURNER ON)
ON
OFF
NG
LP
FUSE FUSE

iE1 Wiring Diagrams and Troubleshooting 38
Aug2023-Revision00
11.4 Troubleshooting Guide
Before troubleshooting the water heater for faults please see
Section “2. Safety” on page 6 for safety instructions
Water
Outlet
Sensor
Upper Thermal
Battery Sensor
Heat
Exchanger
Water Sensor
Inlet
Sensor This Sensor Is
Not Used
Bottom Thermal
Battery Sensor
(Connected to
Bypass Valve)
11.4.1 Temperature Sensor Open - Upper Thermal
Battery Error
Possible Causes Remedy
Temperature Sensor is
disconnected
Make sure that the temperature sensor
connectors are correctly attached.
Unplugged connectors Replace the temperature sensor.
Faulty temperature sensor
Nicked or Broken wire.
Replace nicked or broken wires.
Incorrect temperature sensor
wiring
Too much heat in the water
outlet or water inlet
Allow the water outlet temperature to
decrease and make sure the resistance
of the temperature sensor at the
connector is 18 kΩ at 50°F, 10 kΩ at
77°F, 3 kΩ at 140°F.
Faulty temperature sensor
controller Replace the Control Board.
11.4.2 Temperature Sensor Shorted- Bottom
Thermal Battery Error
Possible Causes Remedy
Temperature Sensor is
disconnected
Make sure that the temperature sensor
connectors are correctly attached.
Nipped or Broken wire Replace nicked or broken wires.
Faulty temperature sensor Replace the temperature sensor.
11.4.3 Temperature Sensor is Out of Range-
Bottom Thermal Battery
Possible Causes Remedy
Faulty temperature sensor
Replace the temperature sensor.
Sensor value is outside the
range
Temperature Sensor is
disconnected
Make sure that the temperature sensor
connectors are correctly attached.
Nipped or Broken wire Make sure the connectors are dry and
free of corosion.

39 iE1 Wiring Diagrams and Troubleshooting
Aug2023-Revision00
11.4.4 Heat Exchanger Valve Fault
Heat
Exchange
Valve
Bypass Valve
Possible Causes Remedy
8 PIN wire disconnected Make sure the connectors and wiring harness
are dry and free of corosion.
Nicked or broken connector
Replace nicked or broken wires and make sure
the wire are correctly connected.
Faulty temperature sensor
wiring
Water valve clogged or
damaged Replace the water valve

iE1 Wiring Diagrams and Troubleshooting 40
Aug2023-Revision00
11.4.5 Bypass Valve Fault
Possible Causes Remedy
8 PIN wire disconnected
Make sure the connectors and wiring
harness are dry and free of corosion.
Incorrect or broken wiring
Nicked or broken connector
Faulty temperature sensor
wiring
Make sure that the temperature sensor
connectors are correctly attached.
Water valve clogged or
damaged Replace the water valve
Faulty IoT interface board Replace IoT interface board
11.4.6 Float Switch Failed
Possible Causes Remedy
Faulty thermal battery drain
port Replace thermal battery drain port.
Faulty thermal battery inlet
port Replace thermal battery inlet port.
Fill solenoid assembly failed
or clogged Replace fill solenoid assembly
Faulty Level sensor Replace level sensor
Faulty Glycol Concentration
sensor Replace Glycol Concentration sensor
11.4.7 Bypass Valve Fault
Possible Causes Remedy
Faulty upper tank
temperature sensor Replace upper tank temperature sensor.
Faulty lower tank
temperature sensor Replace lower tank temperature sensor.
Faulty heat pump control
board Replace Heat pump control board
Faulty heating element relay Replace heating element relay

41 iE1 Serviceable Parts
Aug2023-Revision00
12. Serviceable Parts
12.1 Display
Item Part Number Description Qty
1 IGT-ELC0399 DISPLAY, 7" CAPACITIVE
WITH ENCLOSURE 1
12.2 CTA2045
Item Part Number Description Qty
2 IGT-ELC0404 CTA2045 Interface Board 1
3 IGT-ELC0389 CTA2045 Interface Module
(optional not included) 1
12.3 Electronics
Item Part Number Description Qty
4 IGT-ELC0414 HPU, COMPRESSOR/FAN
INVERTER DRIVER 1
5 IGT-ELC0363 TRANSFORMER, 120V,
50/60Hz 1
6 IGT-ELC0391 Transformer, 208V/240V to
120V 2
7 IGT-ELC0382 iOT Module 1
8 IGT-ELC0398 HPU, ELECTRIC HEATER
RELAY 2
9 IGT-ELC0383 CAREL CONTROL (UPC3)
BOARD 1
10 IGT-SPR0129 CONTROLLER BOARD, V9.4 1
11 IGT-SLS0106 SEAL, CLOSED CELL, 1/8
THK X 1/2 WIDE 1

iE1 Serviceable Parts 42
Aug2023-Revision00
12.4 Cold Side
Item Part Number Description Qty
12 IGT-CST0062 CASTING, WATER INLET,
COLD SIDE 1
13 IGT-SLS0116 SEAL, EPDM, 70 DURO,
NSF 61 3
14 IGT-LNE0072 CORRUGATED LINE, Ø32 1
15 IGT-SLS0115 SEAL, WATER INLET, iE1 1
16 IGT-OR0031 O-RING, #119, EPDM, NSF 61,
70 DURO 2
17 IGT-FTT0302 RETAINING RING, G3/4 2
18 IGT-HRD0020 CLIP, RETAINING, Ø19mm-
Ø20mm 3
19 IGT-FTT0296 FITTING, ADAPTER, 20mm
X G3/4 2
20 IGT-VL0044-2 COIL ISOLATION VALVE 1
21 IGT-SPR0003 FLOW SENSOR SPARE
PARTS KIT 1
22 IGT-OR0010 O-Ring #113 EPDM, FDA, 70
DURO 1
23 IGT-FTT0297 FITTING, ADAPTER, 19mm X
1-1/4 NPT 1
12.5 Cold Side
Item Part Number Description Qty
24 IGT-VL0045 VALVE, GLYCOL FILL
SOLENOID 1
25 IGT-LNE0073 LINE, WATER, FILL PORT, 1/4 1
26 IGT-FTT0303 FITTING, COMPRESSION,
G1/4 BSPP X 1/4 TUBE 2
27 IGT-SLS0110 SEAL,G1/4BSPP 2
28 IGT-LNE0074 LINE, WATER, FILL PORT, 1/4 1
29 IGT-CST0065 CASTING, FILL PORT,
GLYCOL 1

43 iE1 Serviceable Parts
Aug2023-Revision00
12.6 Cold Side Item Part Number Description Qty
30 IGT-LNE0075 LINE, CORRUGATED, 25" LG 1
31 IGT-FTT0300 FITTING, ADAPTER, G3/4 TO
3/4 NPT 1
32 IGT-SLS0112 SEAL, G3/4 BSPP 1
33 IGT-CST0064 CASTING, WATER OUTLET,
HOT SIDE 1
34 IGT-SLS0117 SEAL, WATER OUTLET, iE1 1
35 IGT-ELC0062 SENSOR, THERMISTOR, AIR 1
36 IGT-SPR0003 FLOW SENSOR SPARE
PARTS KIT 1
37 IGT-FTT0295 FITTING, ADAPTER, 20mm X
1-1/4 NPT 1
12.7 Glycol Side
Item Part Number Description Qty
38 IGT-FTT0301 FITTING, ADAPTER, G1/2 TO
1/2 NPT 1
39 IGT-SLS0111 SEAL, G1/2 BSPP 1
40 IGT-SLS0113 SEAL, G1 BSPP 1
41 IGT-ELC0396 SENSOR, GLYCOL,
CONCENTRATION 1
42 IGT-FTT0304 FITTING, PLUG, G1, SST 2
43 IGT-FTT0294 FITTING, 3/4 FIP TO G3/4 1
44 IGT-SLS0114 SEAL, DRAIN PORT, iE1 1

iE1 Serviceable Parts 44
Aug2023-Revision00
12.8 Glycol Side
Item Part Number Description Qty
45 IGT-FTT0298 FITTING, ADAPTER, GLYCOL
PUMP TO 1/2 NPT 1
46 IGT-HRD0240 CLIP 2
47 IGT-OR0032 O-RING, 3.00 CS X
Ø12.50mm ID, VITON 2
48 IGT-PMP0010 PUMP, CIRCULATION, iE1 1
49 IGT-FTT0299 FITTING, ADAPTER, GLY
PUMP TO G1/2 1
12.9 Tank
Item Part Number Description Qty
50 IGT-THBT0001 THERMAL-BATTERY
STORAGE, iE1 1
12.10 Heat Pump
Item Part Number Description Qty
51 IGT-HPU0001 Heat Pump Deck 1
12.11 Miscellaneous
Part Number Description Qty
IGT-ELC0367 IE1-Power Cord Jumper & Upper Coil
Relay Harness 1
IGT-ELC368 IE1-Display Harness 1
IGT-ELC0369 iE1-120VAC Terminal Block to
Transformer Harness 1
IGT-ELC0370 IE1-120VAC Main Power Harness 1
IGT-ELC0371 iE1-TB Valve Harness 1
IGT-ELC0372 IE1-Lower Coil Relay Harness 1
IGT-ELC0373 iE1-IOT Harness 1
IGT-ELC0374 IE1-Fill Solenoid Harness 1
IGT-ELC0375 iE1-Temperature Sensors Harness 1
IGT-ELC0376 iE1-Hex Valve Harness 1
IGT-ELC0377 iE1-HEX Flow Sensor Harness 1
IGT-ELC0378 iE1-Bypass Valve Harness 1
IGT-ELC0379 iE1-Bypass Flow Sensor Harness 1
IGT-ELC0380 iE1-Internal Comms Cable Harness 1
IGT-ELC0381 iE1-Glycol Concentration Harness 1
IGT-ELC0386 iE1-Glycol Keyence Harness 1
IGT-ELC0388 CTA2045 to iOT Board Harness 1
IGT-ELC0395 Glycol Level sensor with Harness 1

Intellihot Inc. | www.intellihot.com | 2900 W. Main Street, Galesburg, IL 61401 | 877.835.1705 | [email protected]
IGT-MNL0067
08-2023
iE1