Noritz EZ98 Operating and maintenance manual

FADK109
Rev. 06/17 Page 1
11160 Grace Avenue, Fountain Valley, CA 92708
Phone [phone] Fax [phone]
This instructional manual is only intended for use by a qualified service professional or authorized Noritz
Service Representative. Any unauthorized use of this manual may result in voiding the warranty.
Contact Noritz Technical Support (866-766-7489) for additional support.
Noritz America Corporation
Heat Exchanger Replacement
EZ98 (EZTR50) [GQ-C2859WX-FF US]
EZ111 (EZTR75) [ GQ-C3259WX-FF US]
NCC199CDV [GQ-C3259WZ-FF US]
NRCB180DV [GHQ-C2801WX-FF US]
NRCB199DV [GHQ-C3201WX-FF US]

Heat Exchanger Replacement Procedure
1. Drain the unit as shown in following procedure for EZ111DV/EZ98DV or NCC199CDV
(Refer to page 3 for NRCB199DV/NRCB180DV.)
Manual Draining
Page 2
Procedure
Drainage using the Remote Controller
* RC-9018M
* RC-7651M
Drain Plugs
Each drain plug might not be visible if insulation is
installed around the piping.
EZ111DV / EZ98DV
NCC199CDV
Drain Plug (1)
Drain Plug (2)
Drain Plug (3)
≪Lid - Condansate Container≫
Do not take the lid off.

Heat Exchanger Replacement Procedure
1. Drain the unit as shown in following procedure for NRCB199DV/NRCB180DV
(Refer to page 2 for EZ111DV/EZ98DV or NCC199CDV.)
Manual Draining
Page 3
Procedure
Drainage using the Operation Panel

Heat Exchanger Replacement Procedure
Diagram
* EZ111DV/EZ98DV or NCC199CDV: 3 screws
NRCB199DV/NRCB180DV: 2 screws
Page 4
(2) Remove the screws(M4×12)* that hold Circuit Board.
(1) Remove 2 ground wires.
Procedure
2. Remove Front Cover
(1) Disconnect electrical power to the unit.
(2) Remove 4 screws w/ washer(M4×12).
3. Remove ground wires
NRCB199DV/NRCB180DV
(2)
(1)
e.g. EZ111DV
EZ111DV/EZ98DV or NCC199CDV
(2)
EZ111DV/EZ98DV or NCC199CDV
(2)
NRCB199DV/NRCB180DV
(2)

Heat Exchanger Replacement Procedure
Diagram
4. Unplug all wires that attach to Wiring Harness
(1) Unplug Flame Rod.
Hold this part of the figure by the finger and
remove the plug.
(2) Only EZ111DV/EZ98DV or NCC199CDV
Unplug remote control connector.
(3) Only EZ111DV/EZ98DV or NCC199CDV
Unplug Thermistor.
(4) Remove Circuit Board to the outside of the unit.
Page 5
Procedure
EZ111DV/EZ98DV or NCC199CDV
(4)
NRCB199DV/NRCB180DV
(4)
(1)
e.g. EZ111DV
(2)
e.g. EZ111DV
(3)
e.g. EZ111DV

Heat Exchanger Replacement Procedure
Diagram
(5) Only EZ111DV/EZ98DV or NCC199CDV
Remove Cable Ties,
unplug 6 Freeze Prevention Heaters,
Water Servo - Bypass,
Gas Valve
Thermistor - Primary Heat Exchanger Inlet,
High Limit Switch. (EZ111DV/EZ98DV)
(NCC199CDV：2 High Limit Switches. )
(6) Unplug Igniter.
(7) For EZ111DV/EZ98DV or NCC199CDV
Detach the Wiring Harness from the clips.
Unplug 4 Freeze Prevention Heaters
(NCC199CDV：1 Freeze Prevention Heater. ),
Fan Motor,
Thermistor - Primary Heat Exchanger Outlet,
Thermistor - Exhaust.
For NRCB199DV/NRCB180DV
Detach Wiring Harness from Wire Clamps.
Unplug Fan Motor and Thermistor - Exhaust.
(8) Unplug High Limit Switch.
Page 6
Procedure
EZ111DV/EZ98DV or NCC199CDV
(7)
(8
Overall view
EZ111DV/EZ98DV NRCB199DV/NRCB180DV
(5)
(6)
EZ111DV/EZ98DV or NCC199CDV
NRCB199DV/NRCB180DV
(6)
NRCB199DV/NRCB180DV
(8
(7)
NCC199CDV

Heat Exchanger Replacement Procedure
Diagram
Page 7
(5) Tilt Pipe - Water Servo - Main
to the bottom of the unit.
(4) Remove "C" Clamp,
Pipe - Primary SS HEX Connection.
Pipe - Primary SS HEX to T-Elbow.
(3) Remove 2 "C" Clamps,
○EZ111DV/EZ98DV ＆NCC199CDV
(2) Remove 2 "C" Clamps,
Pipe - T-Elbow to Outlet Water Connection.
○NCC199CDV ONLY
(1) Remove 2 "C" Clamps,
Pipe - Primary SS HEX to Drain Water Connection.
Procedure
5. Remove Pipes for EZ111DV/EZ98DV or NCC199CDV
(Refer to page 8 for NRCB199DV/NRCB180DV.) NCC199CDV ONLY
(1)
(1)
NCC199CDV
EZ111DV / EZ98DV
(2)(2)
(2)
(2)
(3)(3)
EZ111DV / EZ98DV ＆
NCC199CDV
(4)
(5)

Heat Exchanger Replacement Procedure
Diagram
5. Remove Pipes for NRCB199DV/NRCB180DV
(Refer to page 7 for EZ111DV/EZ98DV or NCC199CDV.)
(1) Remove 4 "C" Clamps,
Pipe - T-Elbow to Relief Valve Connection,
Pipe - T-Elbow to Distribution Valve - Heating and
T-Elbow.
(2) Tilt T-Elbow to the bottom of the unit.
(3) Remove 2 "C" Clamps and
Pipe - Pump Outlet - Elbow to Secondary SS HEX.
Page 8
Procedure
(2)
(1) (1)
(1)
(3)
(3)
(1)

Heat Exchanger Replacement Procedure
Diagram
6. Remove Fan Motor and Venturi assembly
(1) Remove "C" Clamp.
Then remove the 4 screws(M5×12) with a Long Philips
screwdriver.
Do not use a power drill.
(2) Pull up Fan Motor and Venturi assembly.
(3) Tilt Fan Motor and Venturi assembly.
(4) Rotate and detach Fan Motor and Venturi assembly.
Page 9
Procedure
EZ111DV/EZ98DV or NCC199CDV
(2)
NRCB199DV/NRCB180DV
(2)
(1)
EZ111DV/EZ98DV or NCC199CDV
(1)
NRCB199DV/NRCB180DV
(1)
e.g. EZ111DV
(3)
e.g. EZ111DV
②
①
(4)
e.g. EZ111DV

Heat Exchanger Replacement Procedure
Diagram
7. Remove the heat exchanger assembly from Case
(1) Remove Hose Clamp,
pull Drain Hose - SS HEX off.
(2) Remove 4 screws(M4×12),
pull Exhaust Flue off.
Discard these screws.
(3) Remove 8 screws(M4×10) fixing heat exchanger assembly.
(4) Lift up and remove the heat exchanger assembly
from the case.
8.Remove parts from the heat exchanger
(1) Remove 2 "C" Clamps,
Pipe - Secondary SS HEX to Primary SS HEX.
(2) Remove 2 screws(M4×8),
unplug Ignition Plug.
(3) Remove Mounting Plate - Igniter
Page 10
Procedure
EZ111DV/EZ98DV or NCC199CDV
(1)
NRCB199DV/NRCB180DV
(1)
(2)
e.g. EZ111DV
(1)
(1)
e.g. EZ111DV
(2)(2)
e.g. EZ111DV
(3)
e.g. EZ111DV

Heat Exchanger Replacement Procedure
Diagram
(4) Only NRCB199DV/NRCB180DV
Remove 2 screws(M4×12) and Mounting Plate-Circuit
Board from Exhaust Duct.
(5) Remove 2 screws(M4×12) on the back of Exhaust Duct.
(6) Remove 15 screws(M4×12) on the bottom of
Exhaust Duct.
(7) Remove Exhaust Duct.
(8) Only EZ111DV/EZ98DV and NCC199CDV
Remove "Cover - Exhaust duct", and exchange to new one.
9.Separate Primary SS HEX and Secondary SS HEX
(1) To separate Primary SS HEX and Secondary SS HEX,
remove 16 screws(M4×10) from the bottom of
Secondary SS HEX.
Page 11
Procedure
Mounting Plate
-Cir uit Board
(4)
(5)
e.g. EZ111DV
(6)
e.g. NRCB199DV
(1)
e.g. EZ111DV

Heat Exchanger Replacement Procedure
Diagram
10.Separate Primary SS HEX and Burner Chamber
(1) Remove 6 screws(M4×10) to remove
Mounting Plate - Chamber.
(2) Remove 8 screws(M4×18) to separate
Primary SS HEX and Burner Chamber.
(3) Separate Primary SS HEX and Burner Chamber.
※Put Burner Chamber so that the burner face faces upward.
Page 12
Procedure
(1)
(3)
(2)
Do not remove
Torx s rew

Heat Exchanger Replacement Procedure
Diagram
11.Replace Primary SS HEX
(1) Attach Water Connector - Elbow and "C" Clamp
to new Primary SS HEX.
In that case, exchange O ring - High Temp P16 of
Water Connector - Elbow for a new one.
(NCC199CDV ONLY)
Attach Pipe - Primary SS HEX Connection
with 2 "C" Clamps to new Primary SS HEX.
In that case, exchange O rings - High Temp P16 of
Pipe - Primary SS HEX Connection for new ones.
(2) Only EZ111DV/EZ98DV or NCC199CDV
Attach 2 Freeze Prevention Heaters to new
Primary SS HEX with 2 Clamps.
(3) Exchange 2 Gasket - Primary Heat Exchangers
for new ones.
12.Join Primary SS HEX and Burner Chamber
(1) Peel off old Gasket- Burners and replace it
with new Gasket - Burner.
Page 13
Procedure
(1)
(1)
EZ111DV
(3)
e.g. EZ111DV
(2)
NC199CDV
(1)
Atta h in the enter of the line

Heat Exchanger Replacement Procedure
Diagram
(2) Join Primary SS HEX and Burner Chamber with
8 screws(M4×18).
When tightening is over, please check again
for looseness of screws
(3) Attach Mounting Plate - Chamber to Burner Chamber.
13.Assemble Primary SS HEX and new Secondary SS HEX
(1) Replace new Gasket - Secondary Heat Exchanger
with a new one.
(2) Join Primary SS HEX and new Secondary SS HEX
with 16 screws(M4×10).
Page 14
Procedure
(3)
(2)
Re he k looseness
(1)
e.g. EZ111DV
(2)
e.g. EZ111DV

Heat Exchanger Replacement Procedure
Diagram
14. Exhaust Duct Replacement
(1) Put the heat exchanger assembly upside down on
something with the height of 6 inch (150 mm) or more.
Without support, the chamber and Exhaust Duct
can be damaged.
(2) Set Gasket-Exhaust Duct to match the line inside
the secondary heat exchanger.
At this time, make sure that the black side of
Gasket-Exhaust Duct comes to the top
as shown in the figure.
(3) Attach Exhaust Duct to the secondary heat exchanger and
fix with 15 screws(M4×12).
(4) Only NRCB199DV/NRCB180DV
Attach Mounting Plate-Circuit Board to the new Exhaust
Duct and fix 2 screws(M4×12).
Page 15
Procedure
(1)
(2)
e.g. EZ111DV
6 in h (150 mm)
or more
Atta h Exhaust Du t
e.g. EZ111DV
(3)
e.g. NRCB199DV
Mounting Plate
-Cir uit Board
(4)

Heat Exchanger Replacement Procedure
Diagram
(5) Fix the secondary heat exchanger and Exhaust Duct
with 2 screws(M4×12) from the backside.
15.Attach parts to heat exchanger
(1) Attach Mounting Plate - Igniter with 2 screws(M4×8).
(2) Plug Ignition Plug.
In that case, replace new Plug Cover of
Ignition Plug with a new one.
(3) Attach Pipe - Secondary SS HEX to Primary SS HEX
with 2 "C" Clamps.
Page 16
Procedure
(1)
(2)
Plug Cover
e.g. EZ111DV
(3)
e.g. EZ111DV
e.g. NRCB199DV
(5)

Heat Exchanger Replacement Procedure
Diagram
16. Fix the heat exchanger assembly in the case
(1) Fix the heat exchanger assembly in the case
with 8 screws(M4×10).
(2) Put Drain Hose - SS HEX into the drain outlet
of Exhaust Duct and fix it with Hose Clamp.
Page 17
Procedure
EZ111DV/EZ98DV or NCC199CDV
(2)
Heat ex hanger assembly onne tion
enlarged view
Put into the ase
NRCB199DV/NRCB180DV
(2)
(1)
e.g. EZ111DV

Heat Exchanger Replacement Procedure
Diagram
(3) Replace the O-Ring of Exhaust Flue with new one.
(4) Attach Exhaust Flue to the case
with 4 new screws(M4×12).
17. Attach Fan Motor and Venturi assembly
(1) Attach the Fan Motor and Venturi assembly.
Attach "C" Clamp at the bottom of Venturi.
(2) Secure the Venturi to the Burner Chamber by tightening
the 4 screws(M5×12) removed in Step 6.
The screws need only to be hand tightened and
should not be tightened using a drill.
First, insert and tighten 4 screws, but do not
fully tighten these screws.
Once all screws are inserted, proceed to
completely tighten 4 screws.
NOTE: When tightening the screws, be certain to not
apply excess force. Excess force can strip out the original
holes and screws. Keep the Fan motor in horizontal.
It makes easier to tighten the screws correctly.
Page 18
Procedure
(3)
(2)
(1)
EZ111DV/EZ98DV or NCC199CDV
(1)
NRCB199DV/NRCB180DV
(4)
e.g. EZ111DV

Heat Exchanger Replacement Procedure
Diagram
Page 19
Water Connection with 2 "C" Clamps.
○NCC199CDV ONLY
(4) Attach Pipe - Primary SS HEX to Drain
(3) Attach Pipe - T-Elbow to Outlet Water Connection
with 2 "C" Clamps.
(1) Put Pipe - Water Servo - Main in Secondary SS HEX
and fix it with "C" Clamp.
○EZ111DV/EZ98DV ＆NCC199CDV
(2) Attach Pipe - Primary SS HEX to T-Elbow
with 2 "C" Clamps.
Procedure
18. Attach Pipes for EZ111DV/EZ98DV or NCC199CDV
(Refer to page 17 for NRCB199DV/NRCB180DV.)
○EZ111DV/EZ98DV ＆NCC199CDV
(1)
(4)
(4)
(3)(3)
(3)
(3)
(2)(2)
(1)
EZ111DV / EZ98DV ＆
NCC199CDV
NCC199CDV
EZ111DV / EZ98DV
NCC199CDV ONLY

Heat Exchanger Replacement Procedure
Diagram
18. Attach Pipes for NRCB199DV/NRCB180DV
(Refer to page 19 for EZ111DV/EZ98DV or NCC199CDV.)
(1) Put Pipe - Pump Outlet - Elbow to Secondary SS HEX
and fix it with 2 "C" Clamps.
(2) Attach Pipe - T-Elbow to Relief Valve Connection, T-Elbow
and Pipe - T-Elbow to Distribution Valve - Heating
with 4 "C" Clamps.
Page 20
Procedure
(2) (2)
(2)
(1)
(1)
(2)