EverHot IGE-199R-10N Service Manual
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EverHot IGE-199R-10N Service Manual

Troubleshooting guide and instruction for service exterior tankless gas water heater
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Tankless Gas Water Heater
SERVICE
MANUAL
Troubleshooting Guide
and Instruction for Service
(To be performed ONLY by qualified service providers)
For the LAARS
®
Heating System
®
EverHot
Exterior Tankless
Gas Water Heater Models:
IGE-199R-10(N,X)
IGE-199C-5(N,X)
Save this manual for future reference
Document 11014

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  • Page 1 SERVICE MANUAL Troubleshooting Guide and Instruction for Service (To be performed ONLY by qualified service providers) For the LAARS ® Heating System ® EverHot Exterior Tankless Gas Water Heater Models: IGE-199R-10(N,X) IGE-199C-5(N,X) Save this manual for future reference Document 11014...
  • Page 2 Key to Warning Symbols Failure to comply with the following instructions may results in serious personal injury or damage to the appliance. Be careful of possible electric shock. Wiring inside this appliance may potentially be at 120 volts. Disconnect power supply to unit when carrying out the following service repairs. Read Fault Diagnosis and Wiring Diagram carefully to avoid incorrect wiring.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Section Description Page - - - Glossary of Terms and Symbols............. 4 I ......General Information................ 5 a. How to Use This Manual..........6 b. Cut Away illustration............7 c. Schematic illustration............8 II .....Specifications. (General)..............9 a.

  • Page 4: Glossary Of Terms And Symbols

    GLOSSARY OF TERMS AND SYMBOLS This glossary of terms and symbols is provided to assist you in understanding some of the language used throughout this manual. dB(A) sound pressure level in decibels, "A" range direct current alternating current WFCD water flow control device feedback information hertz integrated circuit...
  • Page 5 I - GENERAL INFORMATION This tankless water heater is a high output, high efficiency appliance, which heats the water continuously as hot water is being drawn for use. Unlike tank type storage water heaters, this water heater does not store hot water. The burner operates whenever there is a demand for hot water and is off when the water flow stops.

  • Page 6: How To Use This Manual

    I - GENERAL INFORMATION (cont.) 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 this tankless gas fired water heater. Understanding the basic operation of the "Main Components"...

  • Page 7: Cut Away Illustration

    I - GENERAL INFORMATION (cont.) CUT-AWAY ILLUSTRATION...

  • Page 8: Schematic Illustration

    I - GENERAL INFORMATION (cont.) SCHEMATIC ILLUSTRATION...

  • Page 9: Specifications. (General)

    II - SPECIFICATIONS – GENERAL Type of appliance Temperature controlled continuous flow gas hot water system Operation With/without remote controls Exhaust system Direct Vent - Forced combustion Model Type Residential Commercial Maximum/Minimum gas rate (Input Btu's) 199,000 Btu's – 15,000 Btu's Natural gas 199,000 Btu's –...
  • Page 10 II - SPECIFICATIONS – GENERAL (cont.) Power Supply Appliance – 120 Volts A.C. – 60 Hz. Remote control 12 volt D.C. (Digital) Safety Devices Flame failure - Flame rod Boiling protection - 203˚F Remaining flame (OHS) 194˚F bi-metal switch Fusible link Automatic frost protection - Bimetal sensor &...

  • Page 11: Combustion Specifications

    II - SPECIFICATIONS (cont.) COMBUSTION SPECIFICATIONS Item Gas Type Natural Propane Gas Consumption Minimum Btu's 15,000 15,000 Maximum Btu's 199,000 199,000 Injector Diameter Upper ø.045 (1.15mm) ø.029 (.75mm) Inches (mm) Lower ø.070 (1.8mm) ø.045 (1.15mm) Main Burner B3A7-1 (Lean and Rich Bunsen Burner) Main Damper H73-115 (Upper: ø6, Lower: Not Used) Gas Pressure...

  • Page 12: Default Dip Switch Settings

    II - SPECIFICATIONS (cont.) DIP SWITCH SETTINGS DANGER Do not attempt to adjust dip switch settings from there factory default settings. Doing so will result in damage to unit, property damage, personal injury or death. Contact Technical Support for information pertaining to dip switch function. FACTORY DEFAULT SETTING, RESIDENTIAL UNITS Natural Gas Model Propane Gas Models...

  • Page 13: Main Components

    III - MAIN COMPONENTS 1. Mechanical Water Regulator The unique water regulator mechanism ensures the hot water is maintained with no noticeable change to the desired temperature during use, even if water pressure drops due to another tap being turned on and increasing the demand. 2.
  • Page 14 III - MAIN COMPONENTS (cont.) 5. Combustion Fan Air for the combustion is supplied by a centrifugal fan driven by a DC motor. After a pre-purge period of 0.2 seconds, the fan speed is controlled by the PCB to provide the correct volume of air for combustion. The calculation for the fan speed is based upon incoming water temperature, water flow and the temperature selected on the remote controls.

  • Page 15: Safety Device Function

    IV - SAFETY DEVICE FUNCTION Flame Failure Situated to the right of the burner in the front of the combustion chamber, the flame rod monitors the combustion process. This sensor monitors the flame intensity, while the PCB compares this signal to the feed back signal from the combustion fan motor, water flow control, and gas flow through the POV valve.
  • Page 16 IV - SAFETY DEVICE FUNCTION (cont.) Over temperature Cut-Off The temperature of the outgoing hot water is constantly monitored by the water temperature thermistor located near the outlet of the appliance. If the outgoing water temperature reaches 5 °F above the preset temperature, the burner will automatically deactivate. The burner will ignite again when the outgoing hot water temperature falls below the preset temperature.

  • Page 17: Sequence Of Operation

    V - SEQUENCE OF OPERATION The preset temperature is selected at one of the remotes controls (where fitted). Where no remote control is fitted , the default temperature can be set at 108, 120, 130, 140, 150, 160, 170, or 180 °F. To select one of the above temperatures as your default setting, you MUST obtain written permission and training.
  • Page 18 V - SEQUENCE OF OPERATION (cont.) When the hot water tap is turned off, the water flow sensor stops revolving, and the magnetic pulse ceases, indicating to the PCB that there is no water flowing, in turn the PCB closes the gas valves. The combustion fan continues to operate for 65 seconds.

  • Page 19: Operation Sequence Flow Chart

    V - SEQUENCE OF OPERATION (cont.) OPERATION SEQUENCE FLOW CHART...
  • Page 20 V - SEQUENCE OF OPERATION (cont.) OPERATION SEQUENCE FLOW CHART...

  • Page 21: Sequence Timing Chart

    V - SEQUENCE OF OPERATION (cont.) SEQUENCE TIMING CHART...
  • Page 22 V - SEQUENCE OF OPERATION (cont.) SEQUENCE TIMING CHART...

  • Page 23: Troubleshooting (Error Messages)

    VI - TROUBLESHOOTING ERROR MESSAGES Error Faulty Remedy Air Supply or Exhaust Blockage Check intake and exhaust ports for obstructions. Check that nothing is blocking the flue inlet or exhaust. Did you maintain the proper clearance from combustibles around the unit? No Ignition Ensure you have gas to the appliance.
  • Page 24 VI - TROUBLESHOOTING (cont.) ERROR MESSAGES Error Faulty Remedy Outgoing Water Check sensor wiring for damage. Temperature Sensor Faulty Check resistance on sensor. Check and clean scale from sensor. Replace sensor. Heat Exchanger Outgoing Check sensor wiring for damage. Temperature Sensor Faulty Check resistance on sensor.

  • Page 25: Quick Reference Diagnostic Points

    VI - TROUBLESHOOTING (cont.) QUICK REFERENCE DIAGNOSTIC POINTS IMPORTANT SAFETY NOTES: There are a number of (live) tests that are required when fault finding this product. Extreme care should be used at all times to avoid contact with energized components inside the water heater. Only trained and qualified service agencies should attempt to repair this product.
  • Page 26 VI - TROUBLESHOOTING (cont.) Thermal Fuse: Red ~ Red 100 VAC Below 1 ohm B ~ C B6 ~ C1 Overheat Switch: Red ~ Red 100 VAC Below 1 ohm B ~ C B6 ~ C1 Flame Rod: Place one lead of your meter to the flame rod and the other to earth or ground. With the unit running you should read between 5 ~ 150 VAC.

  • Page 27: Wiring Diagram

    VI - TROUBLE SHOOTING (cont.) Using a voltage meter set to the 200 ohm scale, you should have a resistance reading of 26 - 30 ohms through each of these heaters. The heater located on the heat exchanger piping should have a resistance reading of 81 –...
  • Page 28 VI - TROUBLE SHOOTING (cont.) WIRING SCHEMATIC...

  • Page 29: Troubleshooting Flow Chart

    VI - TROUBLESHOOTING (cont.) Troubleshooting Flow Chart BEFORE CARRYING OUT CHECKS MARKED WITH A # SIGN, DISCONNECT THE POWER SUPPLY. Examination Service Nature of Fault Point Diagnostic Point Values Action Procedure A. The LED on 1. Do you have Power source Do you have 120 Go to A –...
  • Page 30 VI - TROUBLESHOOTING (cont.) Troubleshooting Flow Chart BEFORE CARRYING OUT CHECKS MARKED WITH A # SIGN, DISCONNECT THE POWER SUPPLY. Examination Service Nature of Fault Point Diagnostic Point Values Action Procedure 2. Measure the voltage Are values within Go to A – (7) at connector F with those specified at appliance power supply...
  • Page 31 VI - TROUBLESHOOTING (cont.) Troubleshooting Flow Chart BEFORE CARRYING OUT CHECKS MARKED WITH A # SIGN, DISCONNECT THE POWER SUPPLY. Examination Service Nature of Fault Point Diagnostic Point Values Action Procedure Error code "11" 5. Check ignition 1. Measure voltage 90 ~ 110 VAC Go to B-5-2 displayed on...
  • Page 32 VI - TROUBLESHOOTING (cont.) Troubleshooting Flow Chart BEFORE CARRYING OUT CHECKS MARKED WITH A # SIGN, DISCONNECT THE POWER SUPPLY. Examination Service Nature of Fault Point Diagnostic Point Values Action Procedure C. Combustion 1. Check flame rod. 1. Measure the voltage 5 ~ 150 VAC Go to C-1-2 occurs, but flame...
  • Page 33 VI - TROUBLESHOOTING (cont.) Troubleshooting Flow Chart BEFORE CARRYING OUT CHECKS MARKED WITH A # SIGN, DISCONNECT THE POWER SUPPLY. Examination Service Nature of Fault Point Diagnostic Point Values Action Procedure 2. Measure voltage 11 ~ 13 VDC Go to 4-3 between orange (+) and Replace PCB IGE –...

  • Page 34: Troubleshooting Procedure

    VI - TROUBLESHOOTING (cont.) Troubleshooting Procedure BEFORE CARRYING OUT CHECKS MARKED WITH A # SIGN, DISCONNECT THE POWER SUPPLY. Unit’s wiring diagram can be found on page 27. Appliance fails to operate (even remote control fails to operate). 1) Is the fuse blown? Check fuse.
  • Page 35 VI - TROUBLESHOOTING (cont.) 3) Is the remote control normal? Check voltage between the two remote control cable connectors. Check the voltage between terminals on the remote control terminal mount D Normal: 11 ~ 13 VDC If normal, check for an open circuit or short before replacing the remote control.
  • Page 36 VI - TROUBLESHOOTING (cont.) BEFORE CARRYING OUT CHECKS MARKED WITH A # SIGN, DISCONNECT THE POWER SUPPLY. 2) Is the flame rod normal? Error “72” is displayed Checking the flame rod. # Detach the flame rod terminal C1, and re-attempt operation.
  • Page 37 VI - TROUBLESHOOTING (cont.) BEFORE CARRYING OUT CHECKS MARKED WITH A # SIGN, DISCONNECT THE POWER SUPPLY. 4) Is the combustion fan motor normal? Motor check. If error “61” is displayed, check the combustion fan. Measure voltage at connector A1. Black and red wires. Normal: 6 ~ 45 VDC (Fan on) 0 VDC (Fan off) If normal, check item b below.
  • Page 38 VI - TROUBLESHOOTING (cont.) BEFORE CARRYING OUT CHECKS MARKED WITH A # SIGN, DISCONNECT THE POWER SUPPLY. 6) Is the main gas solenoid valve (SV0) operating normally? If error “11” or “71” is displayed, check the main gas solenoid valve. # Disconnect the main gas solenoid valve (SV0) connector and measure the resistance at the solenoid terminals.
  • Page 39 VI - TROUBLESHOOTING (cont.) BEFORE CARRYING OUT CHECKS MARKED WITH A # SIGN, DISCONNECT THE POWER SUPPLY. 9) Is the change over solenoid (SV3) operating normally? If error “11” or “71” is displayed, check the change over solenoid (SV3). # Disconnect the changeover solenoid (SV3) connector, and measure the resistance at the solenoid terminals.
  • Page 40 VI - TROUBLESHOOTING (cont.) BEFORE CARRYING OUT CHECKS MARKED WITH A # SIGN, DISCONNECT THE POWER SUPPLY. Error code “14” Check the thermal fuse. # Disconnect connector B3 and C3, measure the resistance between the red – red wires. Normal: Less than 1 Ω If normal, check b below.
  • Page 41 VI - TROUBLESHOOTING (cont.) BEFORE CARRYING OUT CHECKS MARKED WITH A # SIGN, DISCONNECT THE POWER SUPPLY. Unable to adjust hot water temperature 1) Is the water temperature thermistor operating normally? # Disconnect the connector B5, and measure the resistance between the white wires, see below for resistance readings.
  • Page 42 BEFORE CARRYING OUT CHECKS MARKED WITH A # SIGN, DISCONNECT THE POWER SUPPLY. 3) Is the modulating valve operating normally? Error code 52 # Disconnect the modulating valve festoon C2 terminals and measure the resistance at the terminals. Normal: 67 ~ 81 Ω If normal, check b.
  • Page 43 BEFORE CARRYING OUT CHECKS MARKED WITH A # SIGN, DISCONNECT THE POWER SUPPLY. Anti-frost heaters do not operate 1) Are the ceramic anti-frost heaters operating normally? # Disconnect connector F4, and measure the resistance of the heater mounted in the water flow control valve, these are white wires.

  • Page 44: Gas Pressure Setting Procedure

    VII - GAS PRESSURE SETTING PROCEDURE All settings/adjustments must be performed by a qualified Service Technician. Turn unit off at power source and turn off the gas to the water heater. Remove the front cover from the water heater. Remove the gas pressure test port plug. Connect manometer to this port. (See Figure #1 for location of the test port plug.) Turn on the gas and power to the water heater.
  • Page 45 WARNING Dip switched #7 and #8 (combustion control switches) MUST be returned to the "OFF" position, after setting pressures. Turn off the gas to the water heater. Remove the manometer connection. Reinstall the pressure port plug. Turn on the gas to the water heater and check for gas leaks around test port with a leak solution.

  • Page 46: Service Procedures

    VIII - SERVICE PROCEDURE NOTE: Before proceeding with dismantling, be sure to follow the CAUTION instructions before each explanation. Always disconnect the electrical supply, turn off water and gas supply service valves, and drain all water from the unit before proceeding. Only trained and qualified service agencies should attempt to repair this product.

  • Page 47: Ige - 1. Removal Of The Front Panel

    WARNING Dip switched #7 and #8 (combustion control switches) MUST be returned to the "OFF" position, after setting pressures. Dip switch #1 MUST be returned to the proper position based upon the length of vent pipe (see page 13). IMPORTANT IGE - 2.

  • Page 48: Ige - 4. Removal Of The Ignition Module

    Remove the four (4) Phillips screws that IGE - 5. Removal of the Combustion Fan: secure the water inlet filter housing to the unit. See picture below for location of CAUTION screws. Once screws are removed reach 120 volt potential exposure. Isolate the appliance into the unit and pull up and out on the and reconfirm power has been disconnected flow control assembly to remove it from...

  • Page 49: Ige - 7. Removal Of The Transformer

    IGE - 7. Removal of Transformer: CAUTION 120 volt potential exposure. Isolate the appliance and reconfirm power has been disconnected using a multimeter. Remove the combustion fan motor assembly as described in section 5-a,b. Remove the two (2) Phillips screws to release the transformer.

  • Page 50: Ige - 9. Removal Of The Gas Valve Assembly

    IGE - 9. Removal of the Gas Valve Assembly: Remove the heat exchanger water connection lines, refer to section 3-a. CAUTION 120 volt potential exposure. Isolate the appliance Remove the three (3) Phillip screws and reconfirm power has been disconnected securing the gas manifold assembly to the using a multimeter.

  • Page 51: Ige - 11. Removal Of The Thermal Fuse

    IGE - 11. Removal of Thermal Fuse: The unit has four thermal fuses, see picture below for location. CAUTION 120 volt potential exposure. Isolate the appliance Disconnect and remove the thermal fuse. and reconfirm power has been disconnected Re-install new thermo fuse using the using a multimeter.

  • Page 52: Flushing Procedure For Lime Scale Removal

    IX - FLUSHING PROCEDURE FOR LIME SCALE REMOVAL FROM HEAT EXCHANGER The amount of calcium carbonate (lime) released from water is in direct proportion to water temperature and usage. The higher the water temperature or water usage and the harder the water (more dissolved calcium carbonate), the more lime deposits are dropped out of the water.

  • Page 53: Parts Breakdown

    X - PARTS BREAKDOWN DISASSEMBLED VIEW - CABINET...
  • Page 54 X - PARTS BREAKDOWN DISASSEMBLED VIEW - INTERNALS...
  • Page 55 X - PARTS BREAKDOWN DISASSEMBLED VIEW - INTERNALS...
  • Page 56 X - PARTS BREAKDOWN DISASSEMBLED VIEW - ELECTRICAL...
  • Page 57 PARTS LIST Number Description Quantity Front Panel Assembly Casing Assembly Wall Installation Bracket Connection Reinforcement Panel Heat Protection Plate Rubber Bushing Front Panel Gasket Front Panel Gasket - Side Front Air Inlet Grill Rubber Bushing Gas Connection (3/4" NPT) Burner Unit Assembly Burner Case Front Burner Case Bottom Panel Burner Air Orifice Plate...
  • Page 58 120v Valve Heater Assembly Anti-Frost Heater Clip Anti-Frost Heater Clip A Anti-Frost Heater Clip Power Supply Harness Fuse Harness 100v Harness Solenoid Valve Harness Thermal Fuse Harness Mold-type Limit Switch PCB Assembly Surge Protector Frost Sensing Switch 120V Anti-Frost Heater Assembly Sensor Harness - 2 Screw Screw...
  • Page 59 Notes...
  • Page 60 800.900.9276 • Fax 800.559.1583 (Customer Service, Service Advisors) 20 Industrial Way, Rochester, NH 03867 • 603.335.6300 • Fax 603.335.3355 1869 Sismet Road, Mississauga, Ontario, Canada L4W 1W8 • 905.238.0100 • Fax 905.366.0130 www.Laars.com Litho in U.S.A. © Laars Heating Systems 0806 Document 11014...

This manual is also suitable for:

Ige-199c-5nIge-199c-5xIge-199r-10x

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