Noritz NRC1111-OD Operating and maintenance manual

NRC1111-OD, NRC1111-DV
NCC1991-OD, NCC1991-DV
NCC1992-DV
NRC111OD(GQ-C3257WX US), NRC111DV(GQ-C3257WX-FF US)
NCC199OD(GQ-C3257WZ US), NCC199DV(GQ-C3257WZ-FF US)
SKJ70RQ
Rev. 05/16 Page 1
Phone [phone] Fax [phone]
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.
This instructional manual is only intended for use by a qualified service professional or authorized Noritz
Model Include :
11160 Grace Avenue, Fountain Valley, CA 92708
Heat Exchanger Replacement
Noritz America Corporation

Heat Exchanger Replacement Procedure
1. Drain the unit as shown in follwing procedure 1. Drain the unit as shown in follwing procedure
Manual Draining
Page 2
Drainage using the Remote Controller
Procedure
* RC-9018M
* RC-7651M
Drain Plugs
Each drain plug might not be
visible if insulation is installed
around the piping.

Heat Exchanger Replacement Procedure
Diagram
(2) Remove additional ground wires
Page 3
Procedure
2. Remove Front Cover
(1)Disconnect electrical power to the unit
(2)Turn off gas and water
(3) Remove 4 screws
3. Remove Lightning Protection
(1) Remove 2 screws that hold the Lightning Protection Plate
(Whichever the unit is in case No.1, 2, 3)
(3) Let Lightning Protection hang outside of the unit
(1)
Case No.1
(2)
Case No.2
(2)
Case No.3
(2)
(1)
(1)
Ex.
)
OD model

Heat Exchanger Replacement Procedure
Diagram
4. Unplug all wires that attach to the wiring harness
and the body of the unit
(1) Loosen the wire anchor from left side of Case,
unplug Freeze Prevention Heaters (2),
remove Cover - Drain
(2) Loosen the wire anchor from Condensate Container,
unplug Freeze Prevention Heaters (2),
Water Servo - Main, Water Level Electrode,
and Thermistor - Heat Exchanger
(3) Remove Cable Tie,
unplug Freeze Prevention Heaters (3),
Water Servo - Bypass, and Thermistor - Hot Water
(4) Remove Cable Tie,
unplug Freeze Prevention Heaters (2),
Wiring for Fan Motor, Water Flow Sensor,
Thermistor - Cold Water, and Wiring for Manifold Plate
Page 4
Procedure
Cover - Drain
(1)
(2)
(3)
(4)
Cable Tie
Cable Tie

Heat Exchanger Replacement Procedure
Diagram
(5) Unplug wiring for Igniter
DV model only ; Unplug Thermistor - Exhaust
(6) Loosen the wire anchor from right side of Case,
unplug Freeze Prevention Heater, High Limit Switch,
Thermal Fuse (2) and Themistor - Scale Detection*
(7) Unplug Flame Rod and Ignition Plug
(8) Let all wires hang outside of the unit
Page 5
Procedure
(5)
Thermistor-Exhaust
(6)
(7)
(8)
Thermistor - Scale Detection
*The following models have "Thermistor
- Scale Detection"
NRC111OD(GQ-C3257WX US)
NRC111DV(GQ-C3257WX-FF US)
NCC199OD(GQ-C3257WZ US)
NCC199DV(GQ-C3257WZ-FF US)
Ex.
)
DV model

Heat Exchanger Replacement Procedure
Diagram
5. DV model only ; Remove Exhaust Flue from top of the unit
(1) Disconnect the venting from the unit
(2) Remove 4 screws and pull Exhaust Flue off of the unit
and set aside
6. Remove Manifold Plate
(1) Remove 4 big silver screws on Manifold Plate
that attach the Manifold Plate to Burner
(2) Remove "C" Clamp
(3) Locate inlet pipe to Manifold Plate and push up,
remove the Manifold Plate
7. Remove Pipe - 1/4" Drain from Copper Heat Exchanger
(CU HE)
(1) Remove 2 "C" Clamps
(2) Remove the pipe
Page 6
Procedure
(2)
(1)
(2)
(1)
(3)
(1)

Heat Exchanger Replacement Procedure
Diagram
8. Remove Pipe - Flow Sensor to Stainless Steel
Heat Exchanger (SS HE) and Water Flow Sensor
(1) Remove "C" Clamp on top of the pipe going into SS HE
(2) Remove "C" Clamp on bottom of the pipe
going into Water Flow Sensor
(3) Remove the pipe
(4) Remove "C" Clamp on Water Flow Sensor,
remove Water Flow Sensor
9. Remove Condensate Container
(1) Remove the screw holding the metal clamp on
the top of Condensate Container
(2) Remove 3 Hose Clamps on the hoses of Condensate
Container, 1 will be right below SS HE and other 2
will be on Condensate Container (you will need a
needle nose pliers to open Hose Clamps)
(3) Pull hoses off and lift up Condensate Container,
remove Condensate Container
Page 7
Procedure
(1)
(1)
(4)
(2)
(2)
Pipe - Flow Sensor to SS HE
(2)
(2)
(3)
SS HE

Heat Exchanger Replacement Procedure
Diagram
10. Disconnet a pipe from Water Servo - Main
(1) Remove "C" Clamp,
disconnect a pipe from Water Servo - Main
11. Remove the assembly from Case
(1) Remove 2 set screws on the bottom of Burner
(2) Remove 2 set screws near the top of Case
(Surpport bottom of the assembly)
(3) SS HE, Copper Heat Exchanger(CU HE), Burner, and
Fan Motor will come out in one section, remove from
the unit
Page 8
Procedure
(1)
Water Servo - Bypass
(1)
(2)
Water Servo - Main
Ex.) DV model

Heat Exchanger Replacement Procedure
Diagram
12. Remove Pipe - Heat Exchanger SS to CU
(1) Remove "C" Clamp on top of the pipe going into SS HE
(2) Remove "C" Clamp on the pipe going into CU HE
(3) Remove the pipe
13. Separate SS HE from CU HE
(1) Remove 2 screws on the bracket between SS HE
and CU HE
(2) Remove 7 screws that located on the
back side of SS HE
(3) Separate SS HE from CU HE
Page 9
Procedure
Pipe - Heat Exchanger SS to CU
(
1
)
(
2
)
(2)
(1)
NRC1111-OD/DV
NCC1991-OD/DV
NCC1992-DV
NRC111OD/DV(GQ-C3257WX＊＊)
NCC199OD/DV(GQ-C3257WZ＊＊)
Pipe - Heat Exchanger SS to CU

Heat Exchanger Replacement Procedure
Diagram
14. Replacing SS HE
Note: If you are not replacing SS HE then,
you can skip this step and set SS HE aside.
(1) Remove old Gasket between SS HE and CU HE Exhaust
Box and replace with new one
(2) OD model only ;
Remove Gasket on the front of SS HE and place
on new one
15. Remove CU HE
(1) Remove 12 screws holding Burner to CU HE
(2) Separate Burner from CU HE
16. Remove the heat exchanger components from
old heat exchanger and put on new heat exchanger
(1) Front side: Freeze Prevention Heater
(2) Right side: High Limit Switch and Freeze Prevention
Heater (Secure to put Freeze Prevention Heater on
same position)
(3) Left side: Freeze Prevention Heater
(Secure to put Freeze Prevention Heater on
same position)
(4) Back side: Thermistor - Scale Detection*
Remove Packing on CU HE
Remove the small screw(M3×6) on CU HE
that holding the Thermistor - Scale Detection
Page 10
Procedure
(1)
(
1
)
Front side
(
2
)
Ri
g
ht side
(
3
)
Left Side
(1)
(2)
NRC1111-OD/DV
NCC1991-OD/DV
NCC1992-DV
NRC111OD/DV(GQ-C3257WX＊＊)
NCC199OD/DV(GQ-C3257WZ＊＊)
(
2
)
Ri
g
ht side
(
4
)
Back Side
Thermistor - Scale Detection
NRC111OD/DV(GQ-C3257WX＊＊)
NCC199OD/DV(GQ-C3257WZ＊＊)
Gasket
*The following models have "Thermistor
- Scale Detection"
NRC111OD(GQ-C3257WX US)
NRC111DV(GQ-C3257WX-FF US)
NCC199OD(GQ-C3257WZ US)
NCC199DV
(
GQ-C3257WZ-FF US
)
Gasket
Packing
- for holding Thermistor

Heat Exchanger Replacement Procedure
Diagram
(4) Attach Thermal Fuse, 4 Clamps, and Harness Clip
on 4 sides of CU HE, see 4 views of CU HE to make
sure Thermal Fuse is routed correctly
Page 11
Procedure
The end of Insulation tube(Black) and the Inlet pipe of CU HE are lined up
Front side
Left side
Keep Thermal Fuse straight
Back side
Clamp
Clamp
NRC1111-OD/DV
NCC1991-OD/DV
NCC1992-DV
NRC111OD/DV(GQ-C3257WX＊＊)
NCC199OD/DV
(
GQ-C3257WZ＊＊
)
Back side Clamp
Right side
Harness Clip
Wiring Harness of Thermistor - Scale Detection Thermal Fuse
Harness Clip
◆Tie the wiring harnesses of "Thermal Fuse" and "High Limit Switch" with
Harness Clip
◆Tie wiring harnesses of "Thermal Fuse", "High Limit Switch" and
"Thermistor - Scale Detection" with Harness Clip
Secure the Thermistor - Scale Detection
with the screw(M3×6) on CU HE
NOTE ; Only tighten by a handscrewdriver (No Drills).
Not need to attach the Packing (for holding
Thermistor - Scale Detection)
when replacement.
To hold Wiring Harness of Thermistor
- Scale Detection, tie the Wiring Harness
with Harness Clip.

Heat Exchanger Replacement Procedure
Diagram
17. Replase Gaskets
(1) Replace new Gasket on CU HE Exhaust Box
(2) Remove old Burner Gasket and replace with new one
18. Place new O - Rings on new CU HE
(1) Inlet to CU HE
(2) Outlet from CU HE
Page 12
Procedure
(
1
)
(
2
)
(1)
(2)
Gasket
Gasket

Heat Exchanger Replacement Procedure
Diagram
19. Replace Burner, CU HE, and SS HE
(1) Attach 7 screws that located on the back side of SS HE
to hold SS HE to CU HE
(2) Attach 2 screws on the bracket between SS HE
and CU HE
(3) Connect Pipe - Heat Exchanger SS to CU
(4) Attach "C" Clamp on top of the pipe going into SS HE
(5) Attach "C" Clamp on the pipe going into CU HE
(6) Attach 12 screws around perimeter of Burner and CU HE
Page 13
Procedure
(
2
)
(1)
Pipe - Heat Exchanger SS to CU
(4)
(5)
(6)
Ex.
)
NRC1111-DV

Heat Exchanger Replacement Procedure
Diagram
20. Replace the assembly back inside the case
(1) Secure 2 set screws near the top of Case
(2) Secure 2 set screws on the bottom of Burner
21. DV model only ; Replace Exhaust Flue on top of the unit
(1) Attach Exhaust Flue to the unit and secure 4 screws
(2) Reconnect the venting to the unit
22. Reconnect a pipe to Water Servo - Main,
(1) Insert a pipe to Water Servo - Main,
and attach "C" Clamp
Page 14
Procedure
(1)
(2)
Water Servo- Bypass
(1)
(1)
Water Servo- Main
Ex.
)
DV model

Heat Exchanger Replacement Procedure
Diagram
23. Reinstall Condensate Container
(1) Locate the 3 key holes inside of Case
(2) Locate the 3 knobs on Condensate Container
(3) Line up the knobs with the key holes and pull
down to secure Condensate Container
(4) Attach with a screw the mounting plate to secure
Condensate Container to bracket on Case
(5) Attach 3 hose with Hose Clamps, you will need
a needle nose pliers for these clamps
Page 15
Procedure
(5)
(4)
(1)
(2)
(5)
(5)

Heat Exchanger Replacement Procedure
Diagram
24. Reconnect Pipe - Water Flow Sensor to SS HE,
and attach Water Flow Sensor
(1) Attach Water Flow Sensor with "C" Clamp
(2) Insert the pipe into Water Flow Sensor and
SS HE
(3) Attach "C" Clamp on top of the pipe
going into SS HE
(4) Attach "C" Clamp on bottom of the pipe
going into Water Flow Sensor
25. Reconnect Pipe - 1/4" Drain from CU HE
(1) Insert the pipe into CU HE and Drain
Connection - 1/4" tube
(2) Attach with 2 "C" Clamps
Page 16
Procedure
(3)
(1)
(
2
)
(4)
Pipe - Flow Sensor to SS HE
(2)
(2)
(2)

Heat Exchanger Replacement Procedure
Diagram
26. Replace Manifold Plate
(1) Secure Manifold Plate to Burner with 4 big
silber screws
(2) Secure gas pipe of Manifold Plate to gas inlet fitting
with "C" Clamp
27. Reconnect all wires that attach to the wiring harness
and the body of the unit
(1) Plug wiring for Igniter
DV model only ; Plug Thermistor - Exhaust
(2) Plug Freeze Prevention Heater, High Limit Switch,
Thermal Fuse (2) and Thermistor - Scale Detection*
Tie all wires with the anchor from right side of Case
(3) Plug Flame Rod and Ignition Plug
Page 17
Procedure
(1)
(2)
(1)
(3)
Thermistor - Exhaust
(2)
Thermistor - Scale Detection
Ex.
)
NRC111DV
(
GQ-C3257WX-FF US
)
*The following models have "Thermistor
- Scale Detection"
NRC111OD/DV(GQ-C3257WX＊＊)
NCC199OD/DV(GQ-C3257WZ＊＊)
Caution!
1. Don't tie Ignition Wire with the anchor.
2.Set Ignition wire behind of other wires.

Heat Exchanger Replacement Procedure
Diagram
(4) Plug Freeze Prevention Heaters (2),
Wiring for Fan Motor, Water Flow Sensor,
Thermistor - Cold Water, and Wiring for Manifold Plate
And then tie wires with Cable Tie
(5) Plug Freeze Prevention Heaters (3),
Water Servo - Bypass, and Thermistor - Hot water
And then tie wires with Cable Tie
(6) Plug Freeze Prevention Heaters (2),
Water Servo - Main, Water Level Electrode,
and Thermistor - Heat Exchanger
Tie wires with the anchor from Condensate Container
(7) Plug Freeze Prevention Heaters (2),
Tie wires with the anchor from left side of Case
And then attach Cover - Drain
Page 18
Procedure
(7)
(6)
(5)
(4)
Cable Tie
Cable Tie
Cover - Drain

Heat Exchanger Replacement Procedure
Diagram
Page 19
28. Replace Lightning Protection
(1) Attach Lightning Protection Plate with 2 screws
(2) Attach additional ground wires
Procedure
(1)
Case No.1
(2)
(
1
)
Case No.2
(2)
(1)
Case No.3
(2)
NRC111OD/DV(GQ-C3257WX＊＊) and
NCC199OD/DV(GQ-C3257WZ＊＊) have "Blue connector"
for Scale Flushing
NOTE ; Don't connect this blue connector when
replacing Heat Exchanger
Disconnected

Heat Exchanger Replacement Procedure
Diagram
29. Check for water leak
(1) Secure 4 drain valves
(2) Turn on water inlet valve slowly (check for
leaks around "C" Clamps)
(3) If you get leaks, close water inlet valve
Re-secure "C" Clamps of leaking points
30. Check for gas leaks and doing trial operation
(1) Turn on gas supply valve
(2) Turn on the unit
Check for leaks around Manifold Plate and joining areas
For example ; Between Burner and CU HE
(3) If you get leaks, Close gas supply valve
Re-secure "C" Clamps of leaking points
31. Replace Front Cover
(1) Secure Front Cover with 4 screws
32. Check for correct operation of the water heater.
The following steps are for "NRC111DV/OD(GQ-C3257WX**)"
and "NCC199DV/OD(GQ-C3257WZ**)"
(1) Turn on the remote controller
The water heater does not need to run now
(Do not open the water outlet valve and faucet)
(2) Press and hold both the "UP(▲)" and "DOWN(▼)" buttons
simultaneously for more than 2 seconds to enter
the Maintenance Monitor mode*
"03" will first appear on the remote controller
*The maintenance monitor data No. will appear on the
display for 2 seconds, and then the data will appear
(Type A remote controller only)
(3) Push the "UP(▲)" button until you see the data No.35**
**The data No.35 shows the "Temperature of Thermistor-
Scale Detection
(4) Turn on the gas supply valve, and then open the water
supply valve and faucet (water outlet valve) to run
the water heater for at least 1 minute.
(5) Check whether the data No.35 rises when the water
heater is running
(The water heater operation is correct if it displays more
than 32°F )
If the temperature does not rise or displays 32°F, then the
connection to the Thermistor-Scale Detection need to be
checked and repeat (1) - (5) in step 32
(6) Press and hold both the "UP(▲)" and "DOWN(▼)" buttons
simultaneously for more than 2 seconds to return
normal mode Page 20
Procedure
(1)
Ex.
)
OD model
Ex.) This shows the data No.35 "75°F"
(Thermistor-ScaleDetection detects "75°F)
Ex.) This shows the data No.35 rises "75°F" to
"125°F" when the water heater is running
Type A
Type B
2 seconds
later