TROUBLESHOOTING GUIDE

(for all Gen II units)

This guide contains information

for identifying and correcting any
issues that may arise.

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), press 1
• Email: support@intellihot.com

When contacting Technical Support, please have the following information ready:
• Model Number
• Serial Number
• Date Purchased/Installed
• Installation location & application

Need Help?
Table of Contents
Air Filter Blocked Alert .......................................................................................................................... 3
Air Filter Service Alert ........................................................................................................................... 4
Air Filter Switch Wiring Alert ................................................................................................................ 5
Blocked Flue Fault ................................................................................................................................. 6
Blower Speed Fault/Blower Fault........................................................................................................ 7
Blower Speed Signal Fault .................................................................................................................... 8
Breaker Tripped (Over-Load) .............................................................................................................. 9
Cascading Alert (Fault)..........................................................................................................................10
Dead Unit – No Power Up ................................................................................................................... 11
Flow Sensor Fault ……………..................................................................................................................... 12
Flue Overheat Fault .............................................................................................................................. 13
Fuel Type Alert ……….............................................................................................................................. 14
Heat Exchanger Overheat ................................................................................................................... 15
Ignition Fault .......................................................................................................................................... 16
Manifold Inlet/Outlet Wiring Alert ...................................................................................................... 17
Pump Fault ............................................................................................................................................ 18
Rough Ignition ....................................................................................................................................... 19
Rumbling ................................................................................................................................................ 20
Sensor Fault (Fault/Open/Shorted) .................................................................................................. 21
Water Valve Opening/Closing/Switch Fault .................................................................................... 22
Water Valve Fault ................................................................................................................................. 23

Appendix
Blower Replacement ............................................................................................................................ 24
Gas Valve Replacement ....................................................................................................................... 24
Electrode Replacement ........................................................................................................................ 27
Controller Pin Layout ............................................................................................................................ 28
Wiring Diagram (Wall-Hung) ............................................................................................................... 28
Wiring Diagram (Floor-Standing) ......................................................................................................... 29
Gas Valve Detail ..................................................................................................................................... 30
Resettable Overheat Switch ................................................................................................................ 32
Suggested Tool List
• Digital Manometer
• Electrical Multimeter
• Flue Gas Analyzer (for NOx & CO2)
• 7mm Socket/Ratchet
• #1 & #2 Phillips Screwdrivers
• Instrument Flat Blade Screwdriver
• Pliers
• Adjustable Wrench

Need Help?
 Air Filter Blocked Alert
Air Filter Blocked

Locate the air switch near the air filter.

Carefully remove the two connections out of
the air switch.

Use multimeter and check the resistance

between the two contacts of the air switch
(where the wires plugged into)

No
Is the resistance
Replace the Air Switch
less than 1 ohm?

Yes

No No
No
Is the air intake Please contact
Is there Is the filter
ducted from the Inspect Air intake filter
debris/dirt? damaged?
intellihot support
outside? team.

Yes Yes Yes

No
Is there a blockage at
Clean filter per the
the inside Replace the filter
termination? manufacturer's manual

Yes

Remove the blockage and

install screens

1
 Air Filter Service Alert
Maintenance Alert
Air Filter Service Alert

This alert applies only to iQ751, iQ1001,

iQ1501, iQ2001 and iQ3001.

Please schedule a
Yes The condensate trap installed externally
outside of the unit. Clean the external
maintenance time to
iQ2001/ iQ3001? condensate trap and make sure to clean perform external wye
the hoses connected to the condensate strainer cleaning.
trap.
No No

Clean the external Wye

Open the left hand side, back
Open the right hand side, back panel. The Yes strainer as per the
panel. Locate the condensate trap Is it possible to perform
behind the pump. Clean the air filter is located at the back bottom. manufacturer's
external Wye strainer
condensate trap(refer to IOM for
Remove and clean the air filter (refer to
maintenance now? recommendation. Please
IOM for procedure). valve off the water outlet first
procedure).
and then water inlet.

Follow the steps below to

reset the error on the display.

Resetting would take

couple of minutes. After
reset complete, please
go back to the main
screen.

2
 Air Filter Switch Wiring Alert
Air Filter Switch Wiring Alert

This alert applies only to iQ751, iQ1001,

iQ1501, iQ2001 and iQ3001. The air filter
switch wires are in yellow & black colors, and
connected J10 on the control board.

Yes Check air filter wiring at

iQ3001? HEX9 & HEX12's control
board.

No

Yes
Check air filter wiring at
iQ2001? HEX6 & HEX8's control
board.

No
No
For all other models, No
check the air filter wiring Wires came loose Broken or damaged Please contact
at each Heat exchanger's or not connected? wiring? intellihot support
control board

Yes Yes

Fix the connection Replace the air filter

wiring harness

3
 Blocked Flue Fault
Blocked Flue Fault
Check & Clean the condensate cup.

If wall-hung, remove the condensate hose,

and clean/rinse it. Please perform condensate maintenance
No Yes more frequently, preferrably every 3
Was there a months. For air filter
Model is blockage? models(iQ751/iQ1001
iQ2001/iQ3001? /iQ1501/iQ2001/iQ3001), please clean it
as part of the maintenance.
1. Check & Clean the condensate
connection from the back of the unit to the
No
Yes external Neutralizer/drain.
2. Make sure condensate water is going to
the drain freely. Replace the Air
3. If necessary adjust the piping slope so Switch
that water flows freely to the drain.

No
Carefully remove the two
connections out of the air
No Check Air Switch No switch. Use multimeter check
Check Exhaust
wiring Is the resistance less
termination. Is it the resistance between the
(green/black). Is it than 1 ohm?
blocked? loose or damaged? two contacts of the air switch
(where the wires plugged
into)
Yes Yes Yes

Remove the blockage. If Replace faulty air

bird screes were not switch wiring.
Yesplease
previously installed, Yes Is the vent piping
install bird screens sized (diameter &
total length) as per
the manual?
Adjust the drain hoses. Drain
No Are the drain hoses
hoses from the HEXes are
sloped away from
sloped down to the the unit?
condensate trap. No

Yes
Correct Vent Piping as
Check for double loops, per the manual
air locks or debris in the
loop

4
 Blower Fault / Blower Speed Fault
E1 Blower Speed Fault

Reboot the unit.

Check all harnesses are plugged in and free
of corrosion

Yes No
In Floor models, unplug the 5 pin Shut down the unit and disconnect the J18
Does the blower run connector from the blower. In wall hung Does the blower connector. Power cycle the unit. At startup, use a
on Start-up? models, unplug the J18 connector from speed ramp up? multimeter to measure the voltage at Control
the Control board. board's J18, pin 1 & 5.

No Yes

Measure the AC voltage at the Yes Is the blower noisy

Control board's J15 connector, Replace the blower
or damaged, or
between blue & brown wires. (SPR0008). broken vanes?

No
Yes
Measures 120V Replace the blower
AC? (SPR0008). Yes
Yes Is blower signal (5PIN
Is the voltage reads
Connector) PIN 3 is
connected to PIN 5?
24V DC?

Replace the Control board

(SPR0002). Please check the blower signal No
No No
wiring connections. Please contact
intellihot support team.
Use the multimeter to measure the AC
Unit model is Voltage at the transfomer connector J12,
iQ751/iQ1001/iQ1501? between PIN 7 & 10.

Yes

Please contact intellihot support

team and request ELC0305 Is the voltage
blower signal jumper package. reads 24V AC?
Yes

No

Replace the Control board Replace the

(SPR0002). transformer

5
 Blower Speed Signal Fault

E1.1 Blower Speed

Signal Fault

At the blower, Is
Yes No
blower signal (5 PIN Any of the
Please replace the blower &
connector) PIN 3 is Blower signal
the blower wiring harness.
connected to PIN 5 wires damaged?
(black wire)?

Yes
No

Please contact intellihot

support team and request Replace the Blower signal
ECL0305 blower signal wiring harness
jumper package.

6
 Breaker Tripped
Breaker Tripped

No
Review the manual for breaker Is the breaker sized Please size the breaker as
size properly? per the manual.

Yes

Power down the unit. Remove the

If iQ751, iQ1001, iQ1501, iQ2001 and
blower power harness (3 wire
iQ3001, remove the side panels. All
connector) from all the blowers.
other models, open the front door.
Restart the unit.

One of the blower is seized up.

No Plug in one blower at a time to find
the faulty blower. Replace the faulty
Breaker trips?
Connect power harness to all other blower
blowers. Leave the faulty blower
power harness disconnected.

Single
Yes For single fuse holder pump,
internal Pump model fuse
extreme caution is required. We
(iN401, iN501, iQ751, Locate the fuse holder
Two fuses? recommend an electrician to
iQ1001, iQ1501, of the internal pump.
iQ2001 and iQ3001)? perform the steps. Please wear
electrical safety gloves.
Two fuses

No
Turn OFF the breaker to the unit.
Yes Either remove the two fuses or Remove the fuse out of the fuse
Turn ON the unit. holder.
disconnect the pump pigtail
Still breaker trips? On the pump, remove all 3 wires
connection.
out of the pump and install wire
nuts on the bare wires.
Please make sure no loose bare
No wires.
Turn ON the breakter
Check resettable
Replace the internal
switches for water
pump
damages or corrosion.

Please contact
intellihot support

7
 Cascading Alert (Fault)

Cascading Alert (Fault)

Existing
Install Yes No Please contact intellihot
Brand new install or Any blower Does all all blower
Any cascaded model Yes signals PIN 3 (5 PIN support team and request
This setup working blower faults
is iQ751, iQ1001 , or
without issues for found in the
connector) is ELC0305 blower signal
iQ1501? connected to PIN jumper package.
few weeks? error history? 5?

No New Install
Yes
No

Cables
No errors 1. In each unit, set Cascading ID.
connected
Did you connect 1. Turn OFF each units. 2. Turn OFF all units.
first Any units show cascading
cascading cable first 2. Disconnect all cables. error (standalone, without 3. Set DIP SW3 as per the manual.
prior to changing the 3. Turn ON each unit to make sure cascading cables 4. Connect cascading cables.
cascading ID? no errors. connected)? 5. Turn ON units sequentially from
1,2,etc.

Setup Yes,
Cascading Errors
ID First Please contact intellihot
support team.

Yes

Yes
No In each unit, go to
Does any of the Yes Are the DIP SW3
All units have same settings, and cascading.
units have any setup correctly as
software version? Does each unit has a
other errors? unique cascading ID? per the manual?

Yes No No
No

1. Turn OFF each unit. Disconnect cascading cables.

Resolve the unit's error. Any other Update the units so that all
error would induce cascading error. 2. Turn ON each unit and set unique cascading ID.
units have the same software
2. Turn OFF all units.
version.
3. Set DIP SW3 as per the manual.
4. Connect cascading cables.
5. Turn ON units sequentially from 1,2,etc.

8
Dead Unit - No Power Up
Unit is Dead -
No Power Up

Is Check the Check the

Is Unit corresponding power connection to fuses on controller. Replace with
plugged in? Yes No the controller (J14). Is it No No
breaker Are they rated at 10A appropriate fuse
tripped? loose or / 250V?
damaged?

No
Yes Yes Yes

See Breaker Correct or replace Are the Contact

Plug in Unit(s) fuses blown or
tripped page power connection No Authorized
damaged? Service Personnel

Yes

Replace Fuse and

see Breaker
Tripped page.

9
 Flow Sensor Fault
Replace the Water Valve (SPR0003)
Flow Sensor Fault
Yes

Is the wiring harness Yes

At the water valve, disconnect No
from the control
the 3 pin wire. Check the 3 pin Are the 3 wires connection
board to the water
wire at the water valve for loose damaged, corroded?
valve is damaged or
connection or corrosion.
broken?

Replace
No the wiring
harness

On the Control board, at J20, No Replace the

The Voltage is 12 V DC
measure the DC voltage control board
(+/- 5%)?
between PIN 1 & 3. (SPR0002)

Yes

If Floor models, go to If the measurement

On the Control
settings->cascading, set the stagging Zero flow is 0V DC (+/- 5%),
Display flow rate is board, at J5,
to OFF. Please wait for 3 minutes. then valve is
less than 1 GPM, measure the DC
On the display, go to Flow/Temp currently open. If
but not zero? voltage between PIN
screen. Observe the flow rate of the not, the valve is
6 & 8.
particular HEX. closed.

less than 1 gpm

There is a blockage at the

water valve, water valve is
faulty, or the unit is scaling.

Please make sure the internal pump is

running. No Yes Valve off the water outlet &
water inlet. Check & Clean the
i200/i250/iQ251?
If necessary, follow the release water inlet strainer (located near
procedure to release the seized up the water inlet connection)
pump.

If fault returns, valve off the water

outlet & water inlet.
If all the HEXes reporting no flow (or
less than 1 gpm flow), valve off the Power down the unit and then drain
water outlet & water inlet. the unit.

Power down the unit. 1. Check and clean the water valves.
Apply molykote on the O-rings before
Check and clean the external wye installing the water valve back.
strainer.
2. Check for blockage or scale buildup
at the hot water outlet fitting

If further assistance needed,

please contact intellihot support
team

10
 Flue Overheat Fault

Flue Overheat Fault

No
Is the inlet return
temp greater than Resistance depends on
157 deg F? Sensor
temperature of
Flue (gray wires) Flue gas

Yes

Temperature Sensor Resistance

No ( ◦ F) KΩ
Is the venting 50 18
Install proper approved 77 10
material CPVC, PP
venting material
or SS? 140 3

Yes

Yes Check and clean the condensate

No
On the display, advanced Check resistance of the Is the flue assembly.
settings, Is the venting
material set to CPVC, PP or
flue sensor. Refer to sensor Check the bottom of the sidecast
SS? the above table. faulty? where the condensate connects
for any blockage or build up.
Yes

No

Change Flue material

setting on the display Replace the flue
sensor Please contact intellihot support
(settings->advanced
team for further assistance.
settings)

If CPVC or , make sure

If PVC, make sure that
that the inlet
the inlet temperature is
temperature is less than
less than 150 deg F
190 deg F

11
 Fuel Type Alert
Fuel Type Mismatch
Fuel type alert/mismatch

This alert applies only to iN401, iN501, iQ751,

iQ1001, iQ1501, iQ2001 and iQ3001.

If NG unit, all control board's DIP SW1(FUEL SEL)

Yes
should be to the right (ON).
iN401, iN501,
iQ2001, or iQ3001?
If LP unit, all control board's DIP SW1(FUEL
SEL) should be to the left (OFF).

No

For iQ751/iQ1001/iQ1501:

If NG unit, all control board's DIP SW1(FUEL No

Please contact
SEL) should be to the top (ON). DIP SW1 mismatch?
intellihot support
If LP unit, all control board's DIP SW1(FUEL
SEL) should be to the bottom (OFF).
Yes

Turn OFF the unit, fix the

DIPSW and then reboot the
unit.

12
 Heat Exchanger Overheat
Heat Exchanger
Overheat

Floor model

No Is the pump working? No

Check the internal and external
Wallhung model or Temperature is same
On a well water system? pumps. Check the temperature Replace the pump.
floor model? before and after the
before and after the pumps.
pump?

Yes Wallhung
Yes

Yes Yes Yes

Check the temperature before Turn off the unit. By
Is pressure within 30 - Is there an external Is there air in the
and after the external using T&P valve, bleed
150 psi? recirculation pump? system?
recirculation pump. out the air in the unit.

No No
No
In the control board, disconnect the J3
Correct well water Install external connector. Check the orange wires for
system recirculation pump damage, corrosion and perform
continuity from the orange wire to
sensor.

Disconnect the harness at J3 No Yes

No Wires damaged /
Replace the Overheat Resistancea is as per connector from the control board. Replace the wiring
sensor. corroded or no
the table? Check resistance between the two harness
continuity?
orange wires

Outlet water
Sensor Resistance
Temperature Yes
KΩ
( ◦ F)
50 18
77 10 Check for scale buildup.
Contact authorized service
140 3 personnel

13
 Ignition Fault
E7 Ignition Failure Page 1 of 3 Ignition Fault

If wall-hung model, turn off the unit and

reset the overheat limit switch. If floor
model, press the overheat limit switch to
reset it.

Yes
Check internal &
Is the overheat
external re-circulation
switch tripped?
pump.

No

Yes
New install or Natural Gas Are the Yes Check the static gas
existing install for New Install Natural Gas
regulators & gas pressure at the gas
more than 6 (NG) or Liquid
lines sized for valve. Is it within
months? Propane (LP)?
loads? specs?

Existing Liquid
No No
Install Propane

No Size gas lines Size gas lines

Check & clean the LP Conversion
Complete the
and regulators
conversion as and regulators
condensate hose (wall- completed? for max BTU/h
per the manual for max BTU/h
hung) or condensate requirements requirements
trap (all other models)
Yes
By using the display,
restart the unit.

14
 Page 2 of 3 Ignition Fault

No Yes
Check wiring DSI No Do you get 120 V AC at Check for AC voltage
No flame
Do you see flame in (brown/blue) to the wire going from the at the J23 of the
the glass window? gas valve. Is it DSI (brown/blue) to gas control board. Do you
damaged? Valve? get 120V AC?

Yes, flame visible

Yes No
Yes
Replace the Replace the control
wiring. board

Yes, 120 V AC at
the Gas Valve

Check the static Create hot water demand to No

Yes Remove Electrode
gas pressure at the cause ignition at the unit.
and inspect. (Gap
gas valve. Is it Check the dynamic pressure.
Is it changing from negative to
and cleanliness). Is it
within specs as per
+ve? Good?
manual?
Good

Not
No Yes o
good
Clean the air filter, swirl plate and gas
Size gas lines valve. Replace electrode
and regulators Remover burner, inspect and clean it. If
for max BTU/h burner damaged, replace it.
requirements No Spark

Replace the gas valve

Check the gas

regulator size or
Leave the electrode
gas line is
outside and try to
inadequate.
spark by firing the
unit. Do you see a
Yes, 120V AC At the spark?
control board Yes, sparking

By using multimeter, do
Yes By using multimeter, do
you see continuity Yes Replace DSI &
you see continuity between
between the two high voltage
the two connections at the
connections at the High cable
over heat limit switch?
limit switch?

No
No
If wall-hung model, turn off the unit and
reset the overheat limit switch. If floor
Replace the high
model, press the overheat limit switch to
limit switch
reset it.

After resetting, still no continuity replace the

overheat limit switch

15
 Page 3 of 3 Ignition Fault

Yes, flame visible

Yes, RED LED on

the Control
Board
Is the RED LED on Do you hear or see spark at Yes
the control board the DSI connector where
ON? wires plugged in?

Check the Wiring harness

connection for damages. If no
No issues found, replace the wiring
No, RED LED on the harness.
Control Board

By using the high fire adjustment (flat

screw), richen the gas until the color
For floor models, perform continuity test changes to orange 80% & blue 20%.
on the (white color) flame sensor wire 1/8th of a turn at a time, but please
(that goes between the electrode and the do not go more than 3 turns.
control board). For wall hung, check the
continuity and damages on the electrode
white wire.

Yes
Does the flame Perform combustion as per
For wall hung, iN401, iN501, iQ2001 stay lit? IOM.
Yes
and iQ3001, replace the electrode.
Damaged flame
sensor wire?
For floor model, replace the flame
sensor wiring harness.
No
No Yes

Open the Burner champer.

No
Is the AC Voltage Yes 1. Check for broken flappers. Please contact
Does the flame
measurement at Please contact intellihot 2. Check the burner. If burner OK, intellihot support
stay lit?
J21 is 15V AC or support team. rinse/clean the burner with cold team.
higher? water.

No

Replace the control board

16
 Manifold Inlet/Outlet Wiring Alert

Resistance depends on
Wiring Alert Sensor
temperature of Wire color table:
Manifold Inlet (Black & White) Unit's cold water Inlet Manifold Inlet - Manifold Inlet sensor (Black & White)
Manifold Outlet (Orange & Black) Unit's hot water outlet Manifold Outlet - Manifold Outlet sensor (Orange & Black)
This alert applies only to iN401, iN501, iQ751,
iQ1001, iQ1501, iQ2001 and iQ3001. Refer to The manifold wires are connected J3 on the control board.
the table for the wiring color. The manifold
sensor wires are connected to J3 on the
control board.

Check corresponding
Yes
Manifold wiring at
iQ3001?
HEX9 & HEX12's control
board.

No

Yes Check corresponding

Manifold wiring at
iQ2001?
HEX6 & HEX8's control
board.

No

For all other models, No No

check the corresponding
Wires came loose Broken or damaged Please contact
Manifold wiring at each
Heat exchanger's control
or not connected? wiring? intellihot support
board.
Yes
Yes

Replace the
Fix the connection corresponding manifold
wiring harness

17
 Pump Alert
Pump Alert

Fix wiring or
Is there a GREEN No
replace the
LED on the
fuse.

Check to see if the pump is rotating by

using Grundfos pump checker or by

Yes
Bad pump? Replace the pump.

No

Is there air in Yes Bleed the air by using

the system? the Pump Bleed Screw

No

Check the flow rate at the unit. Open

faucets & showers to increase the flow.

Is the flow rate less No Contact Authorized

than 2 gpm? Service Personnel

Set staging OFF

(Settings->cascading)

Close the hot water outlet to the

unit. Wait for 2 minutes. Check
Flow rate at each HEX. Normally,
the flow rate is more than 4
gpm. Blockage inside the Heat
exchanger such as scale
buildup.

Any HEX with less Yes For each HEX, connect a garden hose to
than 3 GPM flow the cold water connection at the bottom
and make sure the other end of the hose
goes to drain.
No

Contact Authorized
Service Personnel No
3 GPM or more
Blockage in the Silver cold
flow going through
water pipe. Drain the unit
the hose?

Yes

Close the drain ball valve. Remove

the garden hose. Close the hot water
outlet ball valve at the top of the
HEX. Open the T&P valve.

Yes

No Yes 3 GPM or more No

Any more HEX Blockage or scale buildup in
End flow going
with low flow the heat exchanger.
through?

18
Rough Ignition
Rough Ignition

Check
Check Check with gas
HV cable. Is the static gas Check the company about the Contact
Nat. Gas or caloric value of gas
NG it unplugged or No pressure. Is it Yes emissions. Are they Yes Yes Authorized
LP? value is within limit
damaged? within specs? within specs? Service Personnel
(975-1050)?

LP Yes
Yes No

Has unit No No
been converted Gas lines and/or
Retune gas valve
to LP per Replace or plug in regulators
to set emissions to
manual? HV cable inadequate.
specs.
Please correct.

No

See manual and

convert.

19
Rumbling
Unit is Rumbling

Verify the Is
the vent Contact
intake & exhaust is Check the CO2, is
Yes length less than No No Authorized
installed per within specs.
5 ft? Service Personnel
specification?

Yes
No Yes

Add an elbow or
Install according to
reducer to bring Set the CO2 level
manual
effective length to within table below
instructions
over 10 ft.

20
 Inlet/Outlet/Heat Exchanger/Manifold Inlet/Manifold Outlet/Flue Sensor Open/Fault/Shorted

Temperature Sensor
Open/Fault/Shorted Wire color table:
Heat Exchanger - Heat exchanger water outlet temperature sensor (orange wire)
Flue Sensor - Flue temperature sensor (gray wire)
Inlet Sensor - Inlet water temperature sensor (blue wire)
Outlet Sensor - Hot water outlet temperature sensor (green wire)
Manifold Inlet - Manifold Inlet sensor (Black & White)
In the control board, disconnect the J3 Manifold Outlet - Manifold OUtlet sensor (Orange & Black)
connector. Check the corresponding
color wire for damage, corrosion and
perform continuity from the Resistance depends on
corresponding color wires to sensor. Sensor
temperature of Temperature Sensor Resistance
Overheat (orange wires) hot water at the outlet ( ◦ F) KΩ
Flue (gray wires) Flue gas 50 18
Inlet (blue wires) Inlet cold water 77 10
Outlet (green wire) Hot water outlet 140 3
Manifold Inlet (Black & White) Unit's cold water Inlet
Manifold Outlet (Orange & Black) Unit's hot water outlet

Disconnect the harness at J3 No

Wires damaged / No
connector from the control board. Resistance as per the
corroded or no Replace the sensor.
Check resistance between the two table?
continuity?
respective color wires.

Yes
Yes

Replace the wiring

harness Contact authorized service
personnel

21
 Water Valve Opening Fault
Water Valve Closing Fault
Water Valve Switch Fault
Open/Close/Switch Fault

Is the wiring harness Yes

At the water valve, disconnect No
the 3 pin wire. Check the 3 pin from the control
Are the 3 wires connection
wire at the water valve for loose board to the water
damaged, corroded?
connection or corrosion. valve is damaged or
broken?

Yes Replace
Replace the Water Valve (SPR0003) No the wiring
harness

No Yes

Yes

At the water valve, disconnect No Is the wiring harness from the

Are the 8 wires
the 8 pin wire. Check the 8 pin control board to the water
connection damaged,
connection at the water valve valve is damaged, corroded
corroded?
for corrosion or damages. or broken?

No

On the Control board, at J20, No Replace the

The Voltage is 12 V DC
measure the DC voltage control board
(+/- 5%)?
between PIN 1 & 3. (SPR0002)
Replace the
transformer
(SPR0065)

Yes
No

On the Control board, at J5, No On the Control board, at J12,

Measures as 24 V The Voltage is 24
measure the DC voltage measure the AC voltage
DC (+/- 5%)? V AC (+/- 5%)?
between PIN 2 & 8. between PIN 7 & 8

Yes
Yes
Replace the
control board
(SPR0002) On the Control board, at J5, No Replace the
Measures as 5 V
measure the DC voltage control board
DC (+/- 5%)?
between PIN 7 & 8. (SPR0002)
No

Are all
On the Control board, at J5, Yes
measurements
measure the DC voltage
(1&8, 3&8, 4&8,
between PIN 1&8, 3&8, 4&8,
and 5&8) reads as
and 5&8.
24 V DC (+/- 5%)?

Yes

Please contact intellihot

support team

22
 Water Valve Fault
Water Valve Fault

Check blockages at the Y-

If floor model, are Yes strainer and at each water
all HEXes giving valve. Check internal and
water valve alert? external recirculation pumps
are working.

No

Set staging OFF

(Settings->cascading)

Shut down the unit by using

touch screen. Power down
the unit using the power
switch (or unplug power
cable), wait for 15 seconds
and reboot again.

Power down the unit by using

Wall the power switch or
Remove the water valve.
Is the water valve Yes unplugging the power cable
Floor Model Inspect for debris or PTFE
alert back within 15 (this will ensure the water
or Wall- paste. Make sure the water
minutes of reboot? valve open). Close the outlet
hung? valve is in open position (the
& inlet water to the unit. Drain
pin is all the way inside).
the water out of the unit.
Check and Clean the Y-strainer
Floor
No,
error Same
Different
is HEX
HEX
random Error on the
same HEX? Blow on the water
No valve inlet side. Do
Replace the
Check the total flow rate to the you to hear the
water valve
HEX (floor mount) or to the unit movement of the
(wall-hung). Increase the flow by turbine?
opening showers, faucets etc.

Yes
No
Is flow less Contact Authorized
than 1 gpm? Service Personnel Inspect wiring for valve and
flow sensor.

Yes

Check the silver cold water No Is wiring

inlet pipe for blockage or ice
damaged or
buildup.
loose?

Yes

Found issues with Yes Replace or reconnect

Clear the silver cold
Silver cold water appropriate wiring
water pipe blockage.
inlet pipe? harness

No

For wall-hung, close the hot

No
water ball-valve outside the Open the T&P valve. Check the Do you see flow Blockage inside the Heat
unit. For floor units, close the flow rate at the drain outlet as of more than 3 exchanger such as scale
hot water outlet valve at the well as on the display screen. gpm steadily? buildup.
HEX.

Yes

Contact Authorized
Service Personnel

23
Appendix
BLOWER REPLACEMENT (See Diagram, page 26)

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

Need Help?

24
GAS VALVE REPLACEMENT (See Diagram, page 26)

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

Need Help?

25
Blower/Gas Valve Exploded View

Gas Valve

Blower

26
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

27
Controller Pin Layout

J8
FUSE
FUSE J10
J12

ON
J14 DIP SWITCH SW1 NG J19B
FUEL SELECT LP
J9
CASCADING
OFF CONNECTIONS

J15 RED LED GREEN LED

J19A J20
(BURNER ON) (POWER)

DIP SWITCH SW3

ON OFF
J23

J7 E12 J11 J3 J1 J5
J18

Wiring Diagram (all wall-hung units)

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75$16)250(5
FRUGFDEOH

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5'
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5'

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&$6&$',1*
2)) &211(&7,216
%1/,1(
%/1(875$/
',36:,7&+6:
5'
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*1</*5281' %851(521 32:(5 )8(/6(/(&7 %/

',36:,7&+
21 2)) 6:
%/2:(5 %/1(875$/
%1/,1( %.
5'
*1
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%/
25
:7
%1
*1</*5281'

BK
YL
%/
RD

5'
:7
*<
%/
%. )/8(7(03

:7
%/
NOT USED

%1 %1 %1 %1 25
%/

 ) +($7(;&+$1*(5
 ) 287/(77(03
7+(50$/ 7+(50$/
)86( )86( *1

%/ NOT USED

:,5(&2/25&2'(
%. %/$&.
%/ %/8(
%1 %52:1
*$6
9$/9( *1 *5((1 &2/':$7(5
*< *5$< ,1/(77(03
:7
25 25$1*(
*1</*5281' 5' 5('
+,*+92/7$*(&$%/( :7 :+,7( :$7(5&21752/9$/9(
$1')/2:6(1625
,*17(5$1')/$0(352%( </ <(//2:
',5(&763$5.,*1,7,21 *1</ *5((1<(//2:
IGT-LBL0107

28
Wiring Diagram (all floor-standing units)
%. :7
75$16)250(5

%. )86(

5'
)86(

%1
$,56:,7&+

5'
%.

%1
32:(5
',6752%87,21 *1
%/2&.
*1*5281' 21 %.
:71(875$/ 5'
1*
%./,1( /3
&$6&$',1*
2)) &211(&7,216
',36:,7&+6:
%1/,1(
%/1(875$/ )8(/6(/(&7 5'
5('/(' *5((1/(' </
*1</*5281' %851(521 32:(5 ',36:,7&+ %/
6:
21 2))
%/2:(5 %/1(875$/
%1/,1( %.
5'
*1
</
%/
25
*1</*5281' :7
%1

BK
*< YL
5' BL
:7
%/ RD
%.
21/<21(',63/$<3(581,7
7(03(5$785(
6(16256

)/8(7(03

+27:$7(5 *1
287/(77(03
%1 %1 %1 %1
%/

 )
7+(50$/
 )
7+(50$/
,17(//,+2T &21752/ 02'8/(:,5,1*',$*5$0
)86( )86( 02'(/
%/
L4,GEN II: 1 OF 3 SHOWN
L4,GEN II: 1 OF 4 SHOWN
L4,GEN II: 1 OF 6 SHOWN
:,5(&2/25&2'(
%. %/$&.
%/ %/8(
%1 %52:1
*$6
9$/9( *1 *5((1 &2/':$7(5
*< *5$< ,1/(77(03
:7 25 25$1*(
*1</*5281'
5' 5('
:$7(5&21752/9$/9(
:7 :+,7( $1')/2:6(1625
+,*+92/7$*(&$%/( </ <(//2:
',5(&763$5.,*1,7,21 ,*17(5$1')/$0(352%( *1</ *5((1<(//2:
,*7/%/108

29
 Gas Valve

Gas Valve Blue Gray 120V AC

30
 Gas Valve

Hi-Fire uses flat screwdriver. Low-fire uses T20 Torx screwdriver.

31
Resettable overheat switch

32
Resettable overheat switch

Need Help?

33
www.intellihot.com | 2900 W. Main Street, Galesburg IL 61401 | 309.473.8040 main | 309.296.8984 fax