Table of Contents
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High Efficiency Water Heaters
Manual 45817B - Save this manual for future reference
Energy Saver
HEC Series
SERVICE
MANUAL
Troubleshooting Guide
and Instructions for Service
(To be performed ONLY by
qualified service providers)
For Models
60HEC-125
60HEC-150
60HEC-199
100HEC-150
100HEC-199
100HEC-250
100HEC-300
100-HEC399
All are available in LP or Natural Gas
Standard or ASME Construction
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Table of Contents
Related Manuals for Bock Water heaters HEC Series
Summary of Contents for Bock Water heaters HEC Series
- Page 1 Energy Saver HEC Series High Efficiency Water Heaters SERVICE MANUAL Troubleshooting Guide and Instructions for Service (To be performed ONLY by qualified service providers) For Models 60HEC-125 60HEC-150 60HEC-199 100HEC-150 100HEC-199 100HEC-250 100HEC-300 100-HEC399 All are available in LP or Natural Gas...
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Page 2: Table Of Contents
HEC Series High Efficiency Water Heaters Table of Contents Page HEC Service Procedure Introduction - - - How to use this manual - - - Tool required for service - - - Specifications - - - Sequence of Operation - - -... -
Page 3: Introduction
HEC Series Introduction The Bock HEC Series High Efficiency Water Heater is designed to deliver a remarkable thermal efficiency rating in a quiet running unit with venting options that allow for installation flexibility. Several technologically advanced design features are incorporated in the design that will require additional knowledge on the part of the qualified service provider. The information in this manual will instruct service and a maintenance professionals on the function, roper diagnosis and repair of the Bock HEC Series High Efficiency Water Heater. The Bock HEC Series High Efficiency Water Heater uses a low Nox premix power burner located at the top of the water heater to direct a turbulent flame down into a submerged combustion chamber. This turbulence causes a... -
Page 4: How To Use This Manual
HEC Series How to Use this Manual It is intended for this manual to be used by qualified service personnel for the primary purpose of troubleshooting analysis and repair of the Bock HEC Series High Efficiency Water Heater. Understanding the sequence of operation section of this manual will contribute greatly to troubleshooting this product. An “Installation Check List’ is shown on page 50. Compare the installation against the installation check list to confirm all requirements are met. An “HEC Service Report” is shown on page 51. Completing this form will assist in the troubleshooting efforts. Show you need to call for technical support, please provide the information shown on this form to the support technician to insure accurate troubleshooting. Troubleshooting begins with “System Observation” to determine failure mode as indicated by the LED status of the ignition module. Troubleshooting continues with “Failure Modes and Probable... -
Page 5: Specifications
HEC Series Specifications 8 ¼ Exhaust 8 ¼ Air Intake Gas Inlet ¾” NPT Gas Inlet T & P Valve 3” PVC Air Inlet 28 ¼ 1 ½” NPT Outlet T & P Valve 1" NPT Space Heating Outlet Cleanout 1"... - Page 6 HEC Series Specifications Dedicated 120 VAC, 60 Hz, 15A, GFI Power Supply Minimum 1” NPT for HEC100-399, all others 3/4” NPT Gas Supply (schedule 40 black iron pipe recommended) Natural or Propane. Unit must match gas type supplied Approved Gas Type Gas Pressure (Nat. & 14.0” W.C. maximum static, 4.5” W.C. minimum running (recommend 7.0” W.C. min L.P.) running) Power vent, balanced direct vent or unbalanced direct vent. See vent tables on page 7 Venting System Approved Vent PVC, CPVC or ABS Materials Minimum Clearance for 18” from top, 24” from front, 4” sides and rear...
- Page 7 HEC Series Specifications Vent Tables Balanced Direct Vent Systems Power Vented Systems PVC, CPVC or ABS PVC, CPVC OR ABS Total length of intake piping and exhaust Total length of exhaust piping must not piping added together must not exceed exceed “Maximum Vent Length”...
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Page 8: Sequence Of Operation
HEC Series Sequence of Operation For models prior to CF serial numbers 1. Thermostat calls for heat. - Prior to energizing blower, ignition module checks safety circuits for normal switch positions: a) Vent temp switch normally closed b) Intake pressure switch normally closed Exhaust pressure switch normally open If the vent temp switch is open, the control waits indefinitely for temp switch to close (green light stays on). - Page 9 HEC Series Sequence of Operation For models prior to CF serial numbers Lockout Conditions If normally closed pressure switch contacts open during burner operation, gas valve closes, burner shuts off. Blower restarts after 30 seconds and runs 5 minutes to wait for pressure switch to close. If not, locks out. The system will go into lock out mode for the following reasons: - Pressure switches stuck open or closed a) Check for exhaust or intake obstructions. b) Check for compliance with vent tables. c) Check for evidence of moisture or condensate present in pressure switch tubing or pressure switch.
- Page 10 Sequence of Operation HEC Series For models starting with CF serial numbers and later 1. Thermostat calls for heat. Prior to energizing blower, ignition module checks to make sure the vent temperature switch is in the nor- mally closed position. If the vent temperature switch is open, the control waits indefinitely for the temperature switch to close. 2. Blower energizes, pressure switch contacts are normally closed. If the pressure switch contacts are open, blower operates for up to 5 minutes waiting for contacts to close, then blower stops and flashes red PURGE LED indicating lock out condition.
- Page 11 Sequence of Operation HEC Series For models starting with CF serial numbers and later Lockout Conditions The system will go into lock out mode for the following reasons: Blocked vent pressure switch contacts open - Check for obstruction in exhaust pipe and vent terminal - Check for blocked condensate trap or drain line. In cold climates, make sure drain is not frozen.
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Page 12: Troubleshooting
HEC Series Troubleshooting System Observation WARNING Is front panel power Position front panel 120 volt potential exposure. Use caution switch light on, power switch to making voltage checks to avoid personal injury. indicating power? “ON” position. Power Switch Is there 120VAC... - Page 13 HEC Series Troubleshooting System Observation Determine failure mode by observing flashing LED status on ignition module. LED status and probable cause shown below. * Denotes conditions that may require the water heater to be isolated from the vent system to determine root cause.
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Page 14: Thermostat Circuit Testing & Replacement
HEC Series Service Procedure I Thermostat Circuit Testing & Replacement IMPORTANT NOTE: This procedure assumes a cool tank WARNING CONTROL ELECTRONIC 120 volt potential exposure. Use CONTROLS WHITE/PIN WHITE/PIN caution making voltage checks Rotate temperature HUNTINGTON, INDIANA 1013 SERIES INTEGRATED WATER HEATER dial to highest setting. - Page 15 HEC Series Service Procedure I Thermostat Circuit Testing & Replacement APPENDIX - A Sensor Resistance at Various Temperatures Be Careful When Making Voltage Measurements or Jumping Terminals Not to Damage or Deform Connectors or Connector Pins. Draw Water From The T&P Valve. Compare Temperature With Temperature Ohms Chart Below.
- Page 16 HEC Series Service Procedure I Thermostat Circuit Testing & Replacement WARNING Thermostat circuit. (continued from page 14) 120 volt potential exposure. Use caution making voltage checks to avoid personal injury. Check AC source to determine why there is no CONTROL ELECTRONIC power.
- Page 17 HEC Series Service Procedure I Thermostat Circuit Testing & Replacement Thermostat Board Replacement Procedure WARNING Step 1. Position main power switch to “OFF” 120 volt potential exposure. Isolate the Step 2. Disconnect (unplug) water heater from 120 appliance and reconfirm power is volt power source.
- Page 18 HEC Series Service Procedure I Thermostat Circuit Testing & Replacement Thermostat Potentiometer Replacement Procedure WARNING Step 1. Position main power switch to “OFF” 120 volt potential exposure. Isolate the Step 2. Disconnect (unplug) water heater from appliance and reconfirm power is 120 volt power source.
- Page 19 HEC Series Service Procedure I Thermostat Circuit Testing & Replacement Thermostat Sensor (Thermister) Replacement Procedure Step 1. Position main power switch to “OFF” WARNING 120 volt potential exposure. Isolate the Step 2. Disconnect (unplug) water heater from appliance and reconfirm power is 120 volt power source.
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Page 20: Combustion System Testing & Replacement
HEC Series Service Procedure II Combustion System Testing & Replacement Observe burner operation through the sight glass located on the combustion insert mounting flange. Normal burner operation should ignite smoothly, without evidence of coughing or huffing upon ignition. The burner flame should be a blue flame near the burner surface in a uniform flame pattern. - Page 21 HEC Series Service Procedure II Combustion System Testing & Replacement Observe burner operation through the sight glass located on the combustion insert mounting flange. Normal burner operation should ignite smoothly, without evidence of coughing or huffing upon ignition. The burner flame should be a blue flame near the burner surface in a uniform flame pattern.
- Page 22 HEC Series Service Procedure II Combustion System Testing & Replacement WARNING Heater components may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury. Combustion System Removal Procedure Step 1. Position main power switch to “OFF”.
- Page 23 HEC Series Service Procedure II Combustion System Testing & Replacement Combustion System Replacement Procedure Step 1 Fully inspect burner mounting insert gasket for the following: a) Tears d) Dirt or debris b) Missing material e) Other imperfections that would inhibit proper seal c) Cracks If gasket is NOT affected by any of the above, gasket replacement is not required.
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Page 24: Burner Tube Inspection & Replacement
HEC Series Service Procedure III Burner Tube Inspection & Replacement WARNING Heater components may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury. Burner Tube Removal Procedure Step 1. Position main power switch to “OFF”. - Page 25 HEC Series Service Procedure III Burner Tube Inspection & Replacement WARNING Heater components may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury. Burner Tube Inspection Step 1. Inspect burner tube as follows (BSI ceramic fiber mesh burner, water heaters prior to serial number “CK”) :...
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Page 26: Gas Valve Replacement
HEC Series Service Procedure IV Gas Valve Replacement Gas Valve Replacement Procedure WARNING Step 1. Position main power switch to “OFF”. 120 volt potential exposure. Isolate the appliance and reconfirm power is Step 2. Disconnect (unplug) water heater from disconnected using a multi-meter. -
Page 27: Blower Testing & Replacement
HEC Series Service Procedure V Blower Testing & Replacement Is there 120VAC Refer toignition module/control board acrossthe white and Replace Does blower illustration. black wires at the ignition module/ energize? Isthere 120VAC between P5(1) and P5(3)? terminal block ? control board. - Page 28 HEC Series Service Procedure V Blower Testing & Replacement Blower Replacement Procedure WARNING 120 volt potential exposure. Isolate the Step 1. Position main power switch to “OFF”. appliance and reconfirm power is disconnected using a multi-meter. Step 2. Disconnect (unplug) water heater from 120 volt power source.
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Page 29: Exhaust Pressure Switch Testing & Replacement
Service Procedure VI HEC Series Exhaust Pressure Switch Testing & Replacement For serial numbers prior to “CF” Sequence of operation: With the thermostat calling for heat, prior to energizing blower, the ignition module checks the exhaust pressure switch for normal Switch position of normally open. - Page 30 Service Procedure VI HEC Series Exhaust Pressure Switch Testing & Replacement For serial numbers prior to “CF” Check Collector Pressure Check exhaust collector pressure at the exhaust collector pressure tap location (see illustration below). Is there positive pressure equal to or greater than...
- Page 31 Service Procedure VI HEC Series Exhaust Pressure Switch Testing & Replacement For serial numbers prior to “CF” Exhaust Pressure Switch Replacement Procedure Step 1. Position main power switch to “OFF” position. Step 2. Loosen adhesive backed rubber escutcheon from service panel access cover and slide escutcheon back along exhaust pipe to allow for removal of cover.
- Page 32 Service Procedure VI HEC Series Exhaust Pressure Switch Testing & Replacement For serial numbers prior to “CF” Sequence of operation: The blocked vent pressure switch monitors the pressure in the exhaust tube. The switch contacts are normally closed and will not open unless there is a blockage in the exhaust venting or terminal (snow, ice, debris).
- Page 33 Service Procedure VI HEC Series Exhaust Pressure Switch Testing & Replacement For serial numbers prior to “CF” Check Exhaust Tube Pressure With monometer, take a Is exhaust venting reading at the exhaust system blocked or Clear obstruction. tube pressure tap location.
- Page 34 Service Procedure VI HEC Series Exhaust Pressure Switch Testing & Replacement For serial numbers prior to “CF” Exhaust Pressure Switch Replacement Procedure Step 1. Position main power switch to “OFF” position. Step 2. Loosen adhesive backed rubber escutcheon from service panel access cover and slide escutcheon back along exhaust pipe to allow for removal of cover.
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Page 35: Hot Surface Ignitor Testing & Replacement
HEC Series Service Procedure VII Hot Surface Igniter Testing & Replacement Hot Surface Igniter Testing Procedure WARNING 120 volt potential exposure. Use caution making voltage checks to avoid personal injury. Igniter may be too hot to handle, take necessary precautions... - Page 36 HEC Series Service Procedure VII Hot Surface Ignitor Testing & Replacement Hot Surface Igniter Replacement Procedure Step 1. Position main power switch to “OFF” WARNING 120 volt potential exposure. Isolate the Step 2. Disconnect (unplug) water heater from 120 volt power source.
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Page 37: Flame Sensor Testing & Replacement
HEC Series Service Procedure VIII Flame Sensor Testing & Replacement WARNING Flame Sensor Testing Procedure 1 2 0 volt potential exposure. Use caution m aking voltage checks to avoid personal injury. Flame sensor may be too hot to handle, take necessary... - Page 38 HEC Series Service Procedure VIII Flame Sensor Testing & Replacement Flame Sensor Replacement Procedure Step 1. Position main power switch to “OFF” WARNING 120 volt potential exposure. Isolate the Step 2. Disconnect (unplug) water heater from 120 volt power source.
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Page 39: Ignition Module Replacement
HEC Series Service Procedure IX Ignition Module Replacement Ignition Module Replacement Procedure WARNING Step 1. Position main power switch to “OFF”. 120 volt potential exposure. Isolate the appliance and reconfirm power is Step 2. Disconnect (Unplug) water heater disconnected using a multi-meter. -
Page 40: Transformer Replacement
HEC Series Service Procedure X Transformer Replacement Transformer Replacement Procedure Step 1. Position main power switch to “OFF”. WARNING 120 volt potential exposure. Isolate the Step 2. Disconnect (Unplug) water heater appliance and reconfirm power is from 120 Volt power source. -
Page 41: Intake Pressure Testing & Replacement
Service Procedure XI HEC Series Intake Pressure Switch Testing & Replacement Prior to “CF” serial number Notice: WARNING The intake pressure switch is not used 120 volt potential exposure. Use caution on serial number “CF” and later. making voltage checks to avoid personal injury. - Page 42 Service Procedure XI HEC Series Intake Pressure Switch Testing & Replacement Prior to “CF” serial number Intake Pressure Switch Replacement Procedure WARNING 120 volt potential exposure. Isolate the Step 1. Position main power switch to “OFF”. appliance and reconfirm power is disconnected using a multi-meter.
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Page 43: Vent Safety Switch Testing & Replacement
HEC Series Service Procedure XII Vent Safety Switch Testing & Replacement Sequence of operation: With the thermostat calling for heat, prior to energizing blower, the ignition module checks the vent safety switch for normal switch position of normally closed. If the vent safety switch contacts are open, (not in normal position), the ignition module waits indefinitely for contact to close, The vent safety switch must be manually reset to close the switch contacts. - Page 44 Service Procedure XII HEC Series Vent Safety Switch Testing & Replacement Vent Safety Switch Replacement Procedure Step 1. Position main power switch to “OFF”. Step 2. Loosen adhesive backed rubber escutcheon from service panel access cover and slide escutcheon back along exhaust pipe to allow for removal of cover (see photos at right).
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Page 45: Anode/Flue Baffle Inspection & Replacement
HEC Series Service Procedure XIII Anode/Flue Baffle Inspection & Replacement Disassembly Procedure for Access to Anodes & Flue Baffles WARNING Heater components may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury. -
Page 46: Anode Inspection And Replacement
HEC Series Service Procedure XIII Anode/Flue Baffle Inspection & Replacement Anode Inspection and Replacement WARNING Heater components and stored water may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury. Step 1. - Page 47 HEC Series Service Procedure XIII Anode/Flue Baffle Inspection & Replacement Flue Baffle Inspection and Replacement WARNING Heater components may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury. Step 1. Disassemble heater per “Disassembly Procedure for Access to Anodes & Flue Baffles”.
- Page 48 Service Procedure XIII HEC Series Powered Anode Replacement for 100HEC-399 Only Powered Anode Replacement 100HEC-399 models only WARNING Heater components may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury. The powered anode control module is located on the right vertical side of the control panel inside the surround panel.
- Page 49 HEC Series Service Procedure XIII Anode/Flue Baffle Inspection & Replacement Collector Cover Installation Procedure Step 1. Remove old silicone from top surface of collector flange and collector cover. Step 2. Apply ¼" bead of Ultra Copper Silicone around entire collector flange surface. Allow caulk to “cure”...
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Page 50: Installation Check List
HEC Series Water Heater Installation Check List Product Handling - Carefully uncrate the heater. Move in place with a hand truck (Do not use the venting pipes for handles). Electrical Requirements - Make sure there is 120 volts line voltage. Line voltage must be properly polarized. -
Page 51: Heater Service Report
HEC Series Water Heater Service Report Date Service Provider Model Number Phone Number Serial Number Venting (PVC, CPVC): Vent size 3" or 4" Length of straight pipe (intake) Intake 90's (qty) Intake 45's (qty) Length of straight pipe Exhaust 90's (qty) -
Page 52: Glossary Of Terms
HEC Series Parts List Models prior to “CF” serial number Ultra High Efficiency Water Heater 1 Combustion Surround Ass'y 2 Burner Ass'y (Specify Model) 3 2nd Pass Top Collector Cover 4 Screw 10-16 x 3/4 5 Vent Termination Elbow 6 Thermostat Sensor Probe 7 Baffle 4”... - Page 53 HEC Series Parts List Models prior to “CF” serial number Latch Assy Screw 8-32 x ½ RHCR Ignition Control Assy Jacket Head Main Power Switch Potentiometer Combustion Surround Surround Base Customer must specify complete model number and serial number when ordering service parts.
- Page 54 HEC Series Parts List Models prior to “CF” serial number Electronic Control Module Screw 8-32 x 1/2 Intake Pressure Switch Control Mounting Panel Thermostat PC Board Transformer 120VAC x 24VAC x 40VA Terminal Terminal Strip Power Cord 10C Control Wire Harness...
- Page 55 HEC Series Parts List Models with “CF” serial or later Combustion Surround Assy. Burner Assy (specify model) Pass Top Collector Cover Screw 10-16 x 3/4 Vent Termination Elbow Thermostat Sensor Probe Baffle 4" Flue (specify model) Anode Rod Assy Powered Anode (for EF100T399) Baffle 2"...
- Page 56 HEC Series Parts List Models with “CF” serial or later Latch Assy Screw 8-32 x ½ RHCR Ignition Control Assy Jacket Head Main Power Switch Potentiometer Combustion Surround Surround Base Customer must specify complete model number and serial number when ordering service parts.
- Page 57 HEC Series Parts List Models with “CF” serial or later Electronic Control Module Screw 8-32 x 1/2 Control Mounting Panel Thermostat PC Board Transformer 120VAC x 24VAC x 40VA Terminal Terminal Strip Power Cord Control Wire Harness Thermostat Wire Harness...
- Page 58 HEC Series Glossary of Terms Alternating Current BTU/H British Thermal Units Carbon Monoxide Carbon Dioxide Direct Current Direct Spark Ignition Energy Cut Off Ground fault interrupt Gallons per Minute Hot Surface Igniter Hertz Light Emitting Diode Oxides of Nitrogen National Pipe Thread...
- Page 59 HEC Series Notes NOTES...
- Page 60 Madison, Wisconsin For U.S. and Canada field service, contact your professional installer or local Bock Water Heaters sales representative Sales/608-227-3311 Fax/608-327-3311 Application & Sizing/608-227-3311 Fax/608-327-3311 Technical Support/888-784-8322 Fax/610-683-9208 Warranty/608-227-3319 Fax/608-327-3300 Email sales@bockwaterheaters.com www.bockwaterheaters.com...
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The automation, specifically the powered anode control module, is located on the right vertical side of the control panel inside the surround panel of the Bock Water Heaters HEC Series.
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