Troubleshooting
Guide
This guide contains information for
identifying and correcting issues
that may arise.
Applicable Models:
i200
i200P
i250
i250P
i200X
i201X
i250X
i251X
iQ251
iQ251D
iQ751
iQ1001
iQ1501
Product Support / Warranty
If the water heater requires additional service, please use one of the following options
for contacting Intellihot Technical Support:
- Call: 309-473-8040 (toll-free 1-877-835-1705), and press 3
- Email: support@intellihot.com
When you contact Technical Support, please have the following information ready:
- Model Number
- Serial Number
- Date purchase / Date installed
- Installation location & application
- Error code (if any) or other problem with the unit
Table of Contents
Error Code List & Suggested Tool List......................................................................2
E1-Blower Speed Fault...................................................................................................3
E3-Blocked Flue................................................................................................................4
E7-Ignition Failure...........................................................................................................5
E9-Temperature Sensor Shorted................................................................................6
EA-Temperature Sensor Open Circuit......................................................................7
EC-Flue Temperature Exceeded.................................................................................8
Ed-Heat Exchanger Outlet Temperature Exceeded............................................9
Flashing Icon..............................................................................................................10
Icon Flashing......................................................................................................11
Recirculation Icon Flashing................................................................................12
Blank (Blue)/Illegible Display....................................................................................13
Breaker Tripped (Over-Load)....................................................................................14
Dead Unit-No Powerup..............................................................................................15
No Hot Water.................................................................................................................16
Rough Ignition...............................................................................................................17
Rumbling.........................................................................................................................18
Water Leaks.....................................................................................................................19
Appendix
Blower Replacement..............................................................................................20
Gas Valve Replacement.........................................................................................21
Electrode Replacement.........................................................................................23
Controller Pin Layout.............................................................................................24
Wiring Diagram (Wall-Hung)...............................................................................24
Wiring Diagram (Floor-Mount)...........................................................................25
1
Error Code List
Code
E1
E3
E7
E9
EA
EC
Ed
Description
Blower Speed Fault
Blocked Flue
Ignition Failure
Temperature Sensor Shorted
Temperature Sensor Open Circuit
Flue Temperature Exceeded
Heat Exchanger Outlet Temperature Exceeded
Suggested Tool List
- Digital Manometer
- Electrical Multimeter
- Flue Gas Analyzer (for NOx & CO2)
- 7mm Socket & Ratchet
- #1 Phillips Screwdriver
- #2 Phillips Screwdriver
- Instrument Flat Blade Screwdriver
- Pliers
- Adjustable Wrench
2
Page
3
4
5
6
7
8
9
Yes
Replace Fuse
Yes
Replace Blower
Yes
Check blower.
Is there a broken
vane?
Yes
Is
Blower
Noisy?
E1 Blower Speed Fault
E1-Blower
Speed Fault
Does
Blower Run
on Start-up
No
Unplug
blower and
measure 120V at the
3-pin Connector
(J15)?
No
Check
fuse. Is it
blown?
No
Replace controller
No
No
J8
Power cycle unit and at
start up, use a
multimeter to check
PWM at J18.
Remove blower
and inspect inside
for damage.
J14
J15
J23
FUSE
FUSE
Does PWM
read between
10-90%?
No
J11
J9
Replace blower
J12
ON
NG
OFF
LP
E12
GREEN LED
(POWER)
DIP SWITCH SW1
FUEL SELECT
J18
RED LED
(BURNER ON)
J7
Black Red
Yes
J3
Check
J18 & J15.
Are the contacts
loose?
No
J20
J10
J19B
CASCADING
CONNECTIONS
J19A
J5
Yes
Repair/tighten
connectors
DIP SWITCH SW3
ON
OFF
J1
3
No
E3-Blocked Flue
E3-Blocked flue
Check
exhaust
termination. Is it
blocked?
Yes
Remove blockage
and Install screens
if not installed
Turn off
gas and
remove condensate
line. Remove the
condensate tube/input
trap. Is it
blocked?
Yes
Are
the drain
hoses sloped
away from
unit?
Yes
Check for double
loops, air locks or
debris in loop
No
No
Slope drain per
Manual
Is
vent
piping sized
(diameter & total
length and installed
per manual?
No
No
Yes
Correct piping per
manual specs
Check Air
switch wiring
(green/black). Is it
loose
Repair faulty
wiring at air switch
Yes
Contact
Authorized
Service Personnel
4
Yes
Gas
No
Are the
regulators & gas
lines sized for
loads?
Yes
Check
the static gas
pressure. Is it
within specs?
Replace switch for
wall-hung, for IQ
check flow change
requirement. Check
recirc pump
Yes
No
J5
Yes
No
Put unit at maximum
firing value. Did pressure
drop less than 0.5" W.C.?
No
Is
dynamic
pressure within
spec?
Yes
Yes
Yes
Is the
flame visible
through the
viewport?
No
Remove
igniter and
inspect. (Gap and
cleanliness)
Bad
Yes
Replace the igniter
Replace gas valve
No
Is flame
visible during
ignition?
Regulator or gas
lines inadaquate.
Please correct.
No
Check for 120 V at J23
pins during ignition
Yes
Replace controller
No
Repair or
replace wiring.
Check wiring
to gas valve and to
DSI (brown/blue). Is it
damaged?
No
J10
J19B
CASCADING
CONNECTIONS
J19A
J1
DIP SWITCH SW3
ON
OFF
J20
Gas lines and/or
regulators
inadequate.
Please correct.
J9
J11
J3
Size gas lines and
regulators for max
BTU/h
requirements
J12
ON
NG
OFF
LP
GREEN LED
(POWER)
E12
Overheat
Hi-limit tripped?
E7-Ignition Failure
E7-Ignition
Failure
Nat.
Gas or
Propane?
Propane
Is LP
conversions
completed per
manual?
No
J8
FUSE
FUSE
J18
RED LED
(BURNER ON)
DIP SWITCH SW1
FUEL SELECT
Complete the
conversion per the
manual
J14
J15
J23
J7
**
Is red
LED lit up on
controller?
No
Check white wire
from electrode to
controller (E12)
Replace igniter
No
Shut off
gas and test fire
to see if sparks at
the gap
Good
Yes
Go to **
Yes
Contact an
authorized service
technician
Yes
5
No
Replace
corresponding
sensor
No
J14
J8
J23
J15
Measure
resistance of sensor
using multimeter. Is it
within spec?
E9 Temperature Sensor Shorted
E9-Temp.
Sensor Shorted
Verify Secondary Sensor code:
HE-heat exchanger water outlet temperature sensor (orange wire)
FL-flue temperature sensor (gray wire)
IN-inlet water temperature sensor (blue wire)
rE-Recirculation temperature sensor (white wire)
Ou-Domestic hot water outlet temperature sensor (green wire)
No
Yes
Check
harness
connector J3. Is it
damaged?
Yes
Repair or replace
connector wire.
Is
Sensor
wiring or pigtails
damaged or
corroded?
Repair nicked or
broken sensor
wiring/connectors.
FUSE
FUSE
DIP SWITCH SW1
FUEL SELECT
J12
ON
NG
OFF
LP
GREEN LED
(POWER)
E12
J9
J11
Contact
Authorized
Service Personnel
J18
RED LED
(BURNER ON)
J7
Yes
J3
18
10
3
J20
J10
J19B
J1
J5
DIP SWITCH SW3
ON
OFF
J19A
CASCADING
CONNECTIONS
Temp of Water Sensor Resistance
(kW)
(°F)
50
77
140
6
No
Replace
corresponding
sensor
No
Measure
resistance of sensor
using multimeter. Is it
within spec?
J8
J23
J15
J14
FUSE
FUSE
Yes
J7
J12
ON
NG
OFF
LP
GREEN LED
(POWER)
E12
J9
J11
Contact
Authorized
Service Personnel
J18
RED LED
(BURNER ON)
DIP SWITCH SW1
FUEL SELECT
EA Error Code-Temp Sensor Open Circuit
EA - Temp
Sensor-open circuit
Verify Secondary Sensor code:
HE-heat exchanger water outlet temperature sensor (orange wire)
FL-flue temperature sensor (gray wire)
IN-inlet water temperature sensor (blue wire)
rE-Recirculation temperature sensor (white wire)
Ou-Domestic hot water outlet temperature sensor (green wire)
Check
harness
connector J3. Is it
damaged?
Yes
No
Yes
Repair or replace
connector wire.
Is
Sensor
wiring or pigtails
damaged or
corroded?
Repair nicked or
broken sensor
wiring/connectors.
J3
18
10
3
J20
J10
J19B
CASCADING
CONNECTIONS
J19A
J5
DIP SWITCH SW3
ON
OFF
J1
Temp of Water Sensor Resistance
(kW)
(°F)
50
77
140
7
8
No
Yes
Check
for faulty HE
sensor/wiring
(orange)
No
Is there air in
system?
Yes
No
Is the unit a combi
or pump model?
Yes
Remove and
inspect check valve
on the line and inside
pump. Is it
normal?
No
Remove jammed
check valve due to
water not flowing
through unit.
Follow EA & E9
error code
processes (Pages
6 & 7)
Yes
Bleed out unit with
water when unit is
off
Pump Model
No
No
No
Contact Authorized
Service Personnel
No
Does
the flow rate
change more than
2 GPM in 5
sec.?
Yes
Add recirculation
pump
Correct direction
(arrow pointing
right-Combi, Left for
Pump Model) and
replace if damaged
Yes
Inspect solenoid
valve. Is is damaged/
plugged or installed
backwards??
Yes
Ed-Heat Exchanger Outlet Temperature Exceeded
Ed- HEX
Oulet Temp
Exceeded
On a
well water
system?
Yes
Is
pressure within
30-150psi?
No
Correct well water
system
Combi
9
Flashing Icon
! Flashing Icon Error has occurred
Unit is locked, Error Code has occurred.
Refer to applicable error code resolution for
the code that is present on the units.
To reset the water heater,
press and hold the power
button on the display or
unplug unit and plug back in
after 10 seconds
10
No
Set each unit with
unique number
(1-10) per manual
No
Go to cascading
mode in each unit. Does
each unit have a unique
identifier set?
Yes
No
Yes
No
Refer to manual
for proper
configuration
Are
the DIP
Switches for the
non-end units set
properly?
Refer to manual
for proper
configuration
Are
the DIP
Switches for the
end units set
properly?
Cascading Icon Flashing
Cascading Icon
Flashing
Check
connection data
cables, are they
damaged or
unplugged?
Yes
Reconnect cables
and replace any
damaged cables
or connectors
Yes
Do any of
the units show an
error code?
Yes
Refer to Guide for
that specific error
code.
No
Contact
Authorized
Service Personnel
11
Yes
No
Contact
Authorized
Service Personnel
Check
J7 that there
is 120V when the
recirc icon is
on.
No
Replace controller
Yes
Pump Model
Remove jammed
check valve due to
water not flowing
through unit.
No
Remove and
inspect check valve
on the line and inside
pump. Is it
normal?
Recirculation Icon Flashing
(Pump Models Only)
Recirc Icon
Flashing
Check
to see if pump
is rotating by
touching or with
pump rotation
tester.
No
Inspect the
pump wiring
connections (J7). Are
they damaged or
unplugged?
Yes
Plug in or repair
wiring &
connections.
Combi
Yes
J14
J15
J8
J23
J7
J12
ON
NG
OFF
LP
E12
GREEN LED
(POWER)
DIP SWITCH SW1
FUEL SELECT
J18
RED LED
(BURNER ON)
FUSE
FUSE
Black Red
Inspect
solenoid valve. Is is
damaged/ plugged or
installed
backwards??
Yes
Correct direction
(arrow pointing
right-Combi, Left for
Pump Model) and
replace if damaged
J9
J11
No
J3
J20
J10
J19B
CASCADING
CONNECTIONS
J19A
J5
DIP SWITCH SW3
ON
OFF
J1
Contact
Authorized
Service Personnel
12
Yes
Plug in securely.
Repeat power cycle of
the unit.
Yes
Check the
wiring at display end.
Is it loose?
Blank (Blue) / Illegible Display
Blank (Blue) /
Illegible Display
Power
Cycle the Unit.
Is Display still
blue/illegible?
No
All OK
No
Replace the
Display
13
Yes
Power down the unit.
Unplug transformer, pump
and blower. (J12, J7, J18)
J14
J15
J8
J23
FUSE
FUSE
DIP SWITCH SW1
FUEL SELECT
J12
ON
NG
OFF
LP
GREEN LED
(POWER)
E12
J9
J11
Plug in blower. (J18)
Did Breaker trip?
J18
RED LED
(BURNER ON)
J7
No
Yes
Plug in Pump
(if present) (J7). Did
breaker trip?
Yes
Replace blower
Plug in
transformer
(J12), and power up
unit did breaker
trip?
Yes
Replace pump
No
Breaker Tripped (Over-Load)
Breaker Tripped
Review manual
for breaker sizes. Are
they size
appropriately?
No
Appropriately size
the breakers per
the manual
Replace
transformer
J3
No
J20
J10
J19B
CASCADING
CONNECTIONS
J19A
J5
DIP SWITCH SW3
ON
OFF
J1
Contact
Authorized
Service Personnel
14
Yes
J14
J8
No
J9
J11
J3
Correct or replace
power connection
Yes
Check the
power connection to
the controller (J14). Is it
loose or
damaged?
J12
ON
NG
OFF
LP
E12
GREEN LED
(POWER)
DIP SWITCH SW1
FUEL SELECT
J18
RED LED
(BURNER ON)
FUSE
FUSE
See Breaker
tripped page
Yes
Is
corresponding
breaker
tripped?
Dead Unit - No Power Up
Unit is Dead No Power Up
Is Unit
plugged in?
No
Plug in Unit(s)
Black
Red
J15
J23
J7
No
J20
J10
J19B
CASCADING
CONNECTIONS
J19A
J5
DIP SWITCH SW3
ON
OFF
J1
Check the
fuses on controller.
Are they rated at 10A
/ 250V?
Yes
Are the
fuses blown or
damaged?
Yes
Replace Fuse and
see Breaker
Tripped page.
No
No
Replace with
appropriate fuse
Contact
Authorized
Service Personnel
15
Clear out debris
Yes
Is
there
debris?
Repair or replace
check valve
Yes
Remove
Pump & inspect
check valve, is it stuck?
(pump & combi
models
only)
Remove water
inlet valve. Inspect
for debris or PTFE
paste.
Open and clean
out strainer per
manual
Yes
Yes
Yes
No Hot Water
No Hot Water
Open
faucet, is the flow
icon lit?
No
Open drain on
bottom of unit is
water flowing?
No
Check
inlet strainer, is it
plugged?
No
Is
the inlet
& outlet water
connection piped
correctly?
No
Repair piping to
have proper inlet
and outlet.
No
No
Blow on
valve to hear for
movement of
turbine?
No
Replace valve
Contact
Authorized
Service Personnel
No
16
NG
Yes
Check
the static gas
pressure. Is it
within specs?
No
Check
HV cable. Is
it unplugged or
damaged?
Gas lines and/or
regulators
inadequate.
Please correct.
No
Replace or plug in
HV cable
Yes
Rough Ignition
Rough Ignition
Nat. Gas or
LP?
LP
Has unit
been converted
to LP per
manual?
No
See manual and
convert.
Yes
Check the
emissions. Are they
within specs?
No
Yes
No
Check
with gas
company about the
caloric value of gas
value is within limit
(975-1050)?
Retune gas valve
to set emissions to
specs.
Yes
Contact
Authorized
Service Personnel
17
Rumbling
Unit is Rumbling
Verify the
intake & exhaust is
installed per
specification?
No
Install according to
manual
instructions
Yes
Is
the vent
length less than
5 ft?
Yes
Add an elbow or
reducer to bring
effective length to
over 10 ft.
Check the CO2, is
within specs.
No
9.1% to 9.3%
< 200 ppm
< 60 ppm
< 200 ppm
Contact
Authorized
Service Personnel
Max. CO Level (ppm)
9.0% to 9.2%
< 60 ppm
No
Yes
Set the CO2 level
within table below
CO2 and CO Standards
CO2 Range (%)
High Fire
9.0% to 9.8%
Description
Low Fire
8.6% to 8.9%
Natural Gas
High Fire
LP Gas
Low Fire
18
Yes
Water Leaks
Water Leak
(internal)
Remove cover and
inspect to locate leak.
Is the
leak spotty and
located under the
casting?
No
Shut off the inlet &
outlet and open an
fixture to release
pressure in
system.
Contact
Authorized Service
Personnel
Check the internal water
lines. Identify location of
leaks.
Refer to Serviceable
parts diagrams in
manual,
Remove and
disassemble
leaking/damaged
part.
Inspect part and
O-ring for damage.
Repair or replace
as needed.
Contact
Authorized Service
Personnel
19
Appendix
BLOWER REPLACEMENT (See Diagram, page 22)
The blower is located on the top of the heat exchanger
− Shut off the gas to the heater
− Shut off power to the heater by unplugging the unit from the 120 VAC outlet
− remove the front panel (three screws at top and three at bottom)
− Unplug the display cable from the pcb (press plastic tab and pull)
− lift up and remove the front display bracket
− Unplug all the wiring connections from the blower (press the tabs and pull)
− remove the gas valve wiring located behind the blower
− Unplug the HV cable from the DSI
− Remove the gas connection at the top isolating the unit's gas supply from the building
− remove phillips screws to remove the aluminum gas fitting at the top the unit
− remove 4 allen screws to remove the aluminum gas adapter fitting
− remove two plastic taps on top of the cabinet to access the screws securing the
blower
− remove 4 screws securing the blower from the top using a long screwdriver
− remove the entire blower gas valve assembly from the unit
− remove the gas valve 3 torx screws
− install the gas valve on the new blower
− reverse process to assemble the blower back to the heater
− ensure the gasket is installed between the blower and the top housing
− Install the blower gas valve using 4 screws and a long screw driver
− Install the aluminum gas adapter on top of the gas valve
− Install the gas fitting and secure it using 4 screws to the cabinet
− Install the building gas supply
− Install the blower wiring, HV cable and gas valve wiring
− turn gas supply back on and check for any gas leaks
− turn water on and plug the heater to the outlet
20
GAS VALVE REPLACEMENT (See Diagram, page 22)
The blower gas valve assembly is located on the top of the heat exchanger
− Shut off the gas to the heater
− Shut off power to the heater by unplugging the unit from the 120 VAC outlet
− remove the front panel (three screws at top and three at bottom)
− Unplug the display cable from the pcb (press plastic tab and pull)
− lift up and remove the front display bracket
− Unplug all the wiring connections from the blower (press the tabs and pull)
− remove the gas valve wiring located behind the blower
− Unplug the HV cable from the DSI
− Remove the gas connection at the top isolating the unit's gas supply from the building
− remove phillips screws to remove the aluminum gas fitting at the top the unit
− remove 4 allen screws to remove the aluminum gas adapter fitting
− remove two plastic taps on top of the cabinet to access the screws securing the
blower
− remove 4 screws securing the blower from the top using a long screwdriver
− remove the entire blower gas valve assembly from the unit
− remove the gas valve 3 torx screws
− install the new gas valve on the blower 3 torx screws
− reverse process to assemble the blower back to the heater
− ensure the gasket is installed between the blower and the top housing
− Install the blower gas valve using 4 screws and a long screw driver
− Install the aluminum gas adapter on top of the gas valve (ensure the o-ring is in place)
− Install the gas fitting and secure it using 4 screws to the cabinet
− Install the building gas supply
− Install the blower wiring, HV cable and gas valve wiring
− turn gas supply back on and check for any gas leaks
− turn water on and plug the heater to the outlet
21
Blower/Gas Valve Exploded View
Gas Valve
Blower
22
ELECTRODE REPLACEMENT
The electrode is located on the top of the heat exchanger
− Shut off the gas to the heater
− Shut off power to the heater by unplugging the unit from the 120 VAC outlet
− remove the front panel (three screws at top and three at bottom)
− Unplug the display cable from the pcb (press plastic tab and pull)
− lift up and remove the front display bracket
− Unplug the HV cable from the electrode
− Unplug the electrode connection from the controller at connection E12
− Remove the 2 screws & washers securing the electrode
− Remove electrode from HEX assembly.
− Insert new electrode into the HEX assembly, careful to use new probe hole seal
− Fasten the electrode with the 2 screws with washers. Verify that the yellow/green
wire is attached beneath the right hand screw.
− Connect the electrode to the controller at connection E12
− Connect the HV cable to the electrode
− turn gas supply back on
− turn water on and plug the heater to the outlet
23
Controller Pin Layout
J8
FUSE
FUSE
J10
J12
ON
J14
NG
DIP SWITCH SW1
FUEL SELECT
J19B
J9
LP
CASCADING
CONNECTIONS
OFF
J15
RED LED
(BURNER ON)
J19A
GREEN LED
(POWER)
J20
DIP SWITCH SW3
ON
OFF
J23
J7
J18
J3
J11
E12
J1
J5
Wiring Diagram (all wall-hung units)
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26
27
Product Support / Warranty
If the water heater requires additional service, please use one of the following options
for contacting Intellihot Technical Support:
- Call: 309-473-8040 (or 1-877-835-1705), and press 3
- Email: support@intellihot.com
When you contact Technical Support, please have the following information ready:
- Model Number
- Serial Number
- Date purchase / Date installed
- Installation location & application
- Error code (if any) or other problem with the unit
Revised 9-2015
v1.1