Noritz NRC661 Series Operating and maintenance manual

SKJ70F6‐1
Rev.02/13
NRC661SeriesHeatExchanger
Replacement
ModelInclude:
Page1
NoritzAmericaCorporation
11160GraceAvenue,FountainValley,CA92708
Phone866‐766‐7489Fax714‐241‐1196
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.
NRC661‐DV,NRC661‐OD
ThisinstructionalmanualisonlyintendedforusebyaqualifiedserviceprofessionalorauthorizedNoritz

NRC661SeriesHeatExchangerReplacementProcedure
Diagram
1.
(1) Disconnectelectricalpowertounit
(2) Turnoffgasandwater
(3) Remove4screws
(4) Removedrainvalves(2)anddrainunitcompletely
(5) Removecover‐circuitboard
2.
(1) Disconnecttheconnectorsfromcircuitboard
(2) Removethegroundwire
DVmodel;3groundwires
ODmodel;2groundwires
(3) Removethecircuitboard;thereare2screws,oneon
theright‐sideandmiddle‐upperofthecircuitboard.
Letthecircuitboardhangoutsideoftheunit
3.
(1) Flamerodandignitionplug
(2) Loosenwireanchorfromrightsideofcaseandunplug
freezepreventionheater,thermalfuse(2)
(3) Unplugallwiresthatattachtothewiringharness
exceptwaterservo‐main
(4) *DVmodelonly
Unplugfreeze
preventionheater,
thermistor
‐exhaust.
Releasethewire
clamps
Page2
Unplugallwiresthatattachtothewiringharnessandthe
bodyofthewaterheater
Procedure
Removefrontcover
Disconnecttheconnectorsfromcircuitboardandremovethe
groundwire,circuitboard ODmodelhasonlyascrew
oftheupperside
WaterServo‐Main
(
3
)
(
1
)
(
2
)
Cover‐CircuitBoard
(
4
)
Wireclamp

NRC661SeriesHeatExchangerReplacementProcedure
Diagram
4.
(1) Removethe3bigsilverscrewsonthemanifoldplate
thatattachthemanifoldtotheburner
(2) Removethe2smallersilverscrewsfromthemanifold
platethatattachthemanifoldtothegasvalve
(3) Removemanifoldplateandunplugtheconnectorfrom
gassolenoidvalves(3)
5.
(1) Remove"C"Clamp(3)
(2) Removethewaterflowsensor
(3) Makesuretofeedthewiresfromwaterservo‐main
aroundtheoutletwaterpipeasshowninbottom
diagram
Page3
Procedure
Removemanifoldplate
Disconnectwaterpipesfromwaterflowsensorandwater
servo‐main
(
1
)
(
1
)
(2,3)
WaterFlowSensor
Wiringharness
(
2
)
(
3
)

NRC661SeriesHeatExchangerReplacementProcedure
Diagram
6.
(1) Disconnecttheventingfromtheunit
(2) Removethe4screwsandpulltheflueoffoftheunit
andsetaside
7.
(1) Removethe1springclamp
(2) RemovethedrainhosefromSSHEandpullthehose
outasshownintherightdiagram(2)
8.
(1) Removecover‐waterlevelelectrodefrom
condensatecontainer
(2) Makesuretofeedthewiresfromwaterlevel
electrodewiringharnessoutsidethecaseasshownin
diagram(2)
(3) Makesuretofeedthewiresfromhighlimitswitch
andthermistor‐heatexchangerwiringharnessas
shownindiagram(3)
Page4
Removecoverandroutewires‐waterlevelelectrode
Procedure
Removefluefromtopofunit*DVmodelonly
RemovethedrainhosefromStainlessSteelHeat
Exchanger(SSHE)
(
1
)
(
2
)
(
1
)
(
2
)
(
3
)

NRC661SeriesHeatExchangerReplacementProcedure
Diagram
9.
(1) Removethe2setscrewsonthebottomoftheburner
(2) Removetheupperleftandrightsetscrewsnearthe
topofthecase(ODModelsthescrewswillbeatthe
topcenterofthecase)
(supportbottomofassembly)
(3) SSHE,CopperHeatExchanger(CUHE),Burner,and
Fanwillcomeoutinonesection.Removefromunit.
10.
(1) Removethe2screwsonthebracketbetweentheSS
HEandCUHE
(2) Removethe3screwsthatlocatedonthebacksideof
theSSHE
(3) Remove"C"clamp
(4) SeparatetheSSHEfromtheCUHE
Page5
Procedure
Removeheatexchangerfromcase
SeparatetheSSHEfromCUHE
(1)
(2)DVmodel
(2)ODmodel
(2)
(3)
(1)

NRC661SeriesHeatExchangerReplacementProcedure
Diagram
11.
(1) RemoveoldgasketbetweenSSHEandCUHEExhaust
Boxandreplacewithnewone
(2) *ODmodelonly
RemovethegasketonthefrontoftheSSHEandplace
onnewSSHE
12.
(1) Remove10screwsholdingburnertoCUHE
(2) SeparateburnerfromCUHE
13.
(1) Frontside:Freezepreventionheater
(2) Leftside:Highlimitswitchandthermistor‐heat
exchanger
*ReplacenewORingfotthethermistor‐heat
exchanger
Page6
Removeheatexchangercomponentsfromoldheat
exchangerandputonnewheatexchanger
Procedure
ReplacingtheCUHE
ReplacingSSHE
Note:IfyouarenotreplacingtheSSHEthenyoucanskipthis
stepandsetSSHEaside.
(
1
)
Forthehighlimitswitchandthermistor‐heatexchanger.
Makesuretoroutethewireasshowninthediagram.
(2)ODmodelonly

NRC661SeriesHeatExchangerReplacementProcedure
Diagram
(3) Thermalfuseandfastenersfrom4sidesofheat
exchanger,Seethe4viewsoftheheatexchangerto
makesurethethermalfuseisroutedcorrectly
Page7
Procedure
Theendofinsulationtube(Black)andthe
frontofheatexchangerarelinedup
Rightside
Installthethermalfuse(White)insideof
thestopper
Stopper
Backside
Keepthethermalfusestraight
Leftside‐1
Leftside‐2
Makesuretoroutethethermal
fuseasshowninthediagramto
theright(Leftside‐1&2)
Frontside

NRC661SeriesHeatExchangerReplacementProcedure
Diagram
(4) *DVmodelonly
Replacefreezepreventionheaterwithonethatwas
shippedintheheatexchangerkit.
Wrapfreezepreventionheateraroundinletpipeto
CUHE.
14.
(1) Removeoldburnergasketandreplacewithnewone
(2) RemoveoldgasketbetweenSSHEandCUHEExhaust
Boxandreplacewithnewone
15.
(1) InlettoCUHE
(2) ExittoCUHE
Page8
Procedure
Replacegaskets
PlacenewORingsonnewCUHE
(
2
)
(2)(1)
(1)
LeftsideofHE

NRC661SeriesHeatExchangerReplacementProcedure
Diagram
16.
(1) AttachinletpipetoCUHEwiththe“C”Clamp.
Makesuretoinsertpipeinallthewaybefore
attaching“C”Clamp.
(2) Attachthe3screwsthatlocatedonthebacksideof
theSSHEtoholdtheSSHEtotheCUHE
(3) Attachthe2screwsonthebracketbetweentheSSHE
andCUHE
(4) Attachthe10screwsaroundperimeterofburnerand
heatexchanger
17.
(1) Securethe2setscrewsonthebottomoftheburner
(2) Securetheupperleftandrightsetscrewsnearthetop
ofthecase(ODModelsthescrewswillbeatthetop
centerofthecase)
Page9
Replaceassemblybackinsidecase
Procedure
Reattachburner,CUHE,andSSHE
(2)
(1)
(4)
(1)
(2)ODmodel
(2)DVmodel
(3)

NRC661SeriesHeatExchangerReplacementProcedure
Diagram
18.
(1) Attachthefluetotheunitandsecurethe4screws
(2) Reconnecttheventingtotheunit
19.
(1) Maintainhighlimitswitch,thermistor‐heat
exchangerandwaterlevelelectrodewiringharnessas
shownindiagram(1)
(2) *DVmodelonly
Maintainfreezepreventionheaterandthermistor‐
exhaustwiringharnessasshownindiagram(2)
(3) Maintainwiringharnessasshownindiagram(3)
(4) InsertpipefromCUHEtowaterservo‐mainand
attach"C"clamp
(5) Insertwaterflowsensortoinletwaterconnectionand
attach"C"clamp.
Andtheninsertwaterinletpipetowaterflowsensor
andattach"C"clamp.
20.
(1) ReplacethedrainhosetoSSHEandreattachthe1
springclampasrightdiagram
Page10
Procedure
Reconnectwaterconnections
ReplacethedrainhosetoSSHE
Replacefluefromtopofunit*DVmodelonly
(1)
(2)
(5)
(4)
(3)

NRC661SeriesHeatExchangerReplacementProcedure
Diagram
21.
(1) Plugtheconnectortogassolenoidvalves(3)asright
diagram
(2) Confirmthatthereiso‐ringbeforereplacemanifold
plate
(3) Replacethe2smallersilverscrewsfromthemanifold
platethatattachthemanifoldtothegasvalve
(4) Replacethe3bigsilverscrewsonthemanifoldplate
thatattachthemanifoldtotheburner
(5) Handtightenall5screwsequally
22.
(1) Replacedrainvalves(2)
(2) Turnoncoldwatershutoffvalveslowly(checkfor
leaksaround“C”clamps)
(3) Ifyougetleaksshutoffwaterandre‐secure“C”
Clamps
Page11
Procedure
Checkforwaterleaks
Replacemanifoldplate
(
4
)
(
2
)
(
1
)
BK&BL
wire
O&BL
wire
GY&BL
wire
(
3
)

NRC661SeriesHeatExchangerReplacementProcedure
Diagram
23.
(1) Plugallwiresthatattachtothewiringharness
(2) Tiewiresbycabletieasrightdiagram
(3) Tiewiresbycabletieasrightdiagram
(4) Puttheallwiresinthepositionasshownindiagram
(4)
*ODmodelonly
Puttheyellowconnectorinthepositionasshownin
diagram(4)ODmodelonly
(5) Securethegroundwire
Page12
Procedure
Plugallwiresthatattachtothewiringharnessandthebody
ofthewaterheater
(5)
(4)
(4)ODmodelonly
YellowConnector
(
2
)
CableTie
WaterFlowSensor
Thermistor‐Air
Thermistor‐
ColdWater
Thermistor‐HotWater
(
3
)
CableTie

NRC661SeriesHeatExchangerReplacementProcedure
Diagram
(6) Replacethecircuitboard;secure2screws,oneonthe
right‐sideandmiddle‐upperofthecircuitboard.
Securethegroundwire.
DVmodel;2groundwires
ODmodel;1groundwires
(7) Reconnecttheconnectorstocircuitboard
(8) Plugfreezepreventionheater,thermalfuse(2)andtie
itbywireanchortorightsideofcaseasrightdiagram
(9) Plugflamerodandignitionplug
(10) *DVmodelonly
Plugfreezepreventionheater,thermistor‐exhaust.
Securethewirebyclamps(2)asshownindiagram(10)
Page13
Procedure
Takeoutallwiresfromtheleft
sideoftheline
(7)
ODmodelhasonlyascrew
oftheupperside
(6)
Wireclamp
(10)
(
9
)
(
8
)

NRC661SeriesHeatExchangerReplacementProcedure
Diagram
(11) Replacecover‐waterlevelelectrodetocondensate
container
(12) *DVmodelonly
Reinstallpowersupplycordasrightdiagram
(13) Putallwiresasrightdiagram
Page14
Procedure
(12)
(13)
(11)

NRC661SeriesHeatExchangerReplacementProcedure
Diagram
(14) Replacecover‐circuitboard
24.
(1) Turnongas
(2) Turnontheunit.
Checkforleaksaroundmanifoldplateandjoining
areas.Forexample‐BetweenBurerandCUHE
(3) Ifyougetleaksshutoffgas,waterandre‐secure
leakingpoints
25.
(1) Securefrontcoverwith4screws
Page15
Replacefrontcover
Procedure
Checkforgasleaksanddoingtrialoperation
Cover‐CircuitBoard