Noritz N-0841MC User manual

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N‐0841MC,N‐0842MC,NRC111andNCC199Series
HeatExchangerReplacement
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ModelsInclude:N‐0841MC,N‐0841MC‐DV
N‐0842MC,N‐0842MC‐DV
NRC111‐SV,NRC111‐DV
NCC199‐SV,NCC199‐DV
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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.
PleasecontactNoritzTechnicalSupport(866‐766‐7489)foradditionalsupport.
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NoritzAmericaCorporation
11160GraceAvenue,FountainValley,CA92708
Phone866‐766‐7489Fax714‐241‐1196
Page 1

NRC111andNCC199(N‐0841MC,N0842MCSeries)HeatExchangerReplacementProcedure
ProcedureDiagram
1. Removefrontcover

(1) Disconnectelectricalpowertounit
(2) Remove4screws
(3) Turnoffgasandwater
(4) Removefilteranddrainunit
completely
(5) Opendrainportsonthebottomofthe
unit
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2. RemoveGFCIandcircuitboard
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(1) RemovetwoscrewsthatholdtheGFCI
Plate,onescrewwillhaveaground
wireattached),LetGFCIhangoutside
oftheunit
(2) Removethegroundwirethatistothe
leftofthecircuitboard
(3) Loosenwireanchorfromrightsideof
case
(4) Removethecircuitboard;thereare
twoscrews,oneontopandbottomof
thecircuitboard.Letthecircuitboard
hangoutsideoftheunit
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 
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Page 2

ProcedureDiagram
3. Removegasvalveassembly
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(1) Locate“C”clamponthebottomright
handcorneroftheunitthatattaches
thegasconnectiontothemanifold
plateandremove.
(2) Locateinletgaspipetomanifoldand
pushup.
(3) Locatethelargewiringconnection,
thatattachesthewiresfromthe
manifoldplatetothewiringharness,
anddisconnecttheplug.
(4) Nextlocatethefourbigsilverscrews
holdingthemanifoldplatetothe
burner,therewillbetwoontheright
andleftsideofthemanifoldplate.
Removethosefourscrewsandthe
manifoldplateandpipecanbe
removedandsetaside.
 
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4. Unplugallwiresthatattachtothewiring
harnessandthebodyofthewaterheater

(1) Wiringforthefan
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Page 3

ProcedureDiagram
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(2) LeftSideWiringHarness:Thermalfuse
(2),Freezepreventionheaters(2),
Neutralizersensorplug
(3) RightSideWiringHarness:Highlimit
switch(2),Freezeprevention
heater(2),Freezepreventionsensor
(4) Flamerods(2),ignitionbox
(5) LeftSideOnStainlessSteelHeat
Exchanger(akaSSHE):Freeze
preventionsensor(takeoffwholeclip)
(6) RightSideOnSSHE:Freezeprevention
sensorplugs(2)
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 
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Page 4

ProcedureDiagram
5. RemovingtheNeutralizer
(1) Removethescrewholdingthemetal
clamponthetopofneutralizer
(2) Removethe3springclampsonthe
hosesoftheneutralizer.1willberight
belowtheSSHEand2willbeonthe
neutralizer(youwillneedaneedle
noseplierstoopenspringclamps)
(3) Pullhosesoffwhereclampswere
removed
(4) Liftuponneutralizerandpulloutand
setaside
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
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6. RemoveWaterPipesInsideUnit
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(1) Remove“C”Clampontopoffoam
coveredpipegoingintoSSHE
(2) Remove“C”Clamponbottomof
foamcoveredpipegoingintoFlow
Sensor
(3) RemovePipeandsetaside
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Page 5

ProcedureDiagram
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(4) Locate¼”drainpipeonrighthandside
ofunitanddisconnectbothsmall“C”
Clampsontopandbottomofpipe
(5) DisconnectFreezepreventionheater
on¼”drainpipe
(6) Remove¼”DrainPipeandsetaside
(7) LeftSide:Disconnect“C”Clampfrom
CopperHeatExchanger(akaCUHE)
andMainWaterControlValve
(8) Pulloutpipe
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7. RemoveFluefromTopofUnit

(1) Disconnecttheventingfromtheunit
(2) Removethe4screwsandpulltheFlue
offoftheunitandsetaside




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Page 6


ProcedureDiagram
8. Removeheatexchangerfromcase

(1) Removethe2setscrewsonthe
bottomoftheburner
(2) Removetheupperleftandrightset
screwsnearthetopcenterofthecase
(supportbottomofassembly)
(3) SSHE,CUHE,Burner,andFanwill
comeoutinonesection.Remove
fromunit.
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9. SeparatetheSSHEfromCUHE

(1) Removethe2screwonthebracket
betweentheSSHEandCUHE
(2) FliptheAssemblyoverandlocatethe
foamcoveredpipeconnectingthetwo
heatexchangers
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


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
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Page 7

ProcedureDiagram
(3) Removethe2“C”Clampsonthe
endofeachpipeandremovepipe
andsetaside
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(4) Removethe9screwsthatlocated
onthebacksideoftheSSHE
(5) SeparatetheSSHEfromtheCUHE

 

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10. ReplacingStainlessSteelHeat
Exchanger
Note:IfyouarenotreplacingtheSSHE
thenyoucanskipthisstepandsetSSHE
side.
shippedintheheatexchanger
theSSHEand
LimitSwitchandplaceonnewSSHE
a

(1) CheckthegasketontheCUHE,ifit
isdamagedreplaceitwithonethat
was
kit
(2) Removethe2FreezePrevention
Heateronthefrontof
placeonnewSSHE
(3) OnRightSideofSSHE,remove
FreezePreventionSensorandHigh







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Page 8

ProcedureDiagram
11. ReplacingtheCopperHeatExchanger

(1) Remove12screwsholdingburner
toheatexchanger
(2) SeparateburnerfromCUHE



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12. Removeheatexchangercomponents
andputonnewheatexchanger

(1) LeftSide:FreezePreventionHeater
(2) RightSide:HighLimitSwitch
(3) Thermalfuseandfastenersfrom
foursidesofheatexchanger

 









LEFTSIDE
BACK
RIGHTSIDE
FRONT
Page 9

ProcedureDiagram
13. Replacegaskets

(1) Removeoldburnergasketand
replacewithnewone
(2) InspectgasketbetweenSSHEand
CUHEExhaustBox,ifthegasketis
damaged,replaceit.




14. PlacenewO‐RingsonnewCUHEand
PipebetweenCUHEandSSHE

(1) InlettoCUHE
(2) ExittoCUHE
(3) FoamPipethatconnectsSSHEand
CUHE






Page 10

ProcedureDiagram
15. Reattachburner,CUHE,andSSHE

(1) 12screwsaroundperimeterof
burnerandheatexchanger
(2) TurnAssemblyaroundexposing
backsideoftheassembly
(3) Attach9screwstoholdtheSSHEto
theCUHE
(4) AttachtheFoamCoveredPipewith
the2“C”Clamp.Makesureto
insertpipeinallthewaybefore
attaching“C”Clamp.
(5) FlipAssemblyaroundexposing
Frontsideofassembly
(6) Attach2screwstoholdSSHEto
bracketonCUHE
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





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 
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Page 11

ProcedureDiagram
16. Replaceassemblybackinsidecase

(1) LocatehooksontopofSSHE(See
BlownUpView)
(2) Locatenotchesontopofwater
heatercase.
(3) Thehooksfromtheheatexchanger
willhelpalignandholdassemblyin
place
(4) Securebottomburnerscrews
(5) Securetopleftandrightscrews











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Page 12

ProcedureDiagram
17. Reconnectwaterconnections

(1) InsertPipefromCUHEintoMain
WaterControlValveandattach“C”
Clamp
(2) InsertFoamCoveredPipeintothe
flowsensorandSSHEandattachwith
“C”Clamps
(3) Insert¼”DrainPipeintoCUHEand
DrainPortandattachwithsmall“C”
Clamps
(4) ReconnectFreezePreventionHeater
on¼”DrainPipeintothewiring
harness


  

18. Reinstallneutralizer

(1) Locatethe3keyholesinsidecase
(2) Locatethe3knobsontheneutralizer
(3) Lineuptheknobswiththekeyholes
andpulldowntosecureneutralizer

 









Page 13

ProcedureDiagram
(4) Attachwithascrewthemounting
platetosecuretheneutralizerto
bracketoncase
(5) Reattach3hoseswithclamps,youwill
needaneedlenosepeelersforthese
clamps






19. Replacegasvalveassembly

(1) Securegasvalveassemblytoburner
with4silverscrews
(2) Securemanifoldpipetogasinlet
fittingwith“C”clamp.
(3) Reconnectlargewiringconnection,
thatattachesthewiresfromthe
manifoldplatetothewiringharness















Page 14

ProcedureDiagram

20. Reconnectallwiresthatattachtothe
wiringharnessandthebodyofthewater
heater

(1) Wiringforthefan
(2) LeftSideWiringHarness:Thermalfuse
(2),Freezepreventionheaters(2),
Neutralizersensorplug
(3) RightSideWiringHarness:Highlimit
switch(2),Freezeprevention
heater(2),Freezepreventionsensor
(4) Flamerods(2),ignitionbox
(5) LeftSideOnSSHE:Freezeprevention
sensor(replaceclipwithwires
attached)
(6) RightSideOnSSHE:Freezeprevention
sensorplugs(2)



 




 




Page 15

ProcedureDiagram
21. ReplacecircuitboardandGFCI

(1) Slidecircuitboardbackintooriginal
position
(2) Securetopofcircuitboardscrew
(3) Securebottomofcircuitboardscrew
andgroundwiretotheleft
(4) SecureWireAnchorabovecircuit
board
(5) SecureGFCIplatetocasewith2
screws(groundwireonrightside)


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ProcedureDiagram
22. ReplaceFluefromTopofUnit

(1) Insetflueintopofunitandsecurethe
4screws
(2) Reconnecttheventingtotheunit
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23. ReplaceFrontCover
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(1) Replacewaterinletfilter
(2) CloseDrainPorts
(3) Turnoncoldwatershutoffvalve
slowly(checkforleaksaround“C”
clamps)
(4) Ifyougetleaksshutoffwaterandre‐
secure“C”Clamps.
(5) Turnongas(check“C”clampsfor
leaks)
(6) Securefrontcoverwith4screws
(7) Returnelectricalpowertotheunit
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