Intellihot iE1 Maintenance Manual
Thank you for purchasing this Intellihot unit. This unit is designed for years of trouble-free operation. Please read and follow the instructions in this “Operation & Installation Manual.”
Intellihot's mission began in 2005 with the goal of creating a better heating system. By combining the robustness of a diesel engine, robotics intelligence, and marine environment durability, Intellihot set out to design a unit that would outperform and outlast all others. The goal evolved to creating an intelligent water heating and delivery system, with simplicity, efficiency, and durability at the core of every Intellihot product.
Intellihot products are engineered and built in Galesburg, Illinois. The company has helped commercial customers save thousands of dollars by eliminating downtime. The Intellihot team is dedicated to assisting customers and ensuring their business success.
Sincerely,
Sri Deivasigamani
CEO, Intellihot Inc.
10. Maintenance
Regular maintenance is crucial for the longevity and performance of your Intellihot unit. The following procedures should be performed at least once every three months, as failure to do so may affect the product warranty.
10.1 Inlet Strainer Cleaning
- Ensure the water heater is turned OFF at the breaker ON/OFF switch before performing any maintenance.
- Shut off the water inlet valve.
- Open a nearby tap/faucet to drain any remaining water, then close the tap.
- Use a wrench to loosen and remove the water inlet strainer.
- Clean the strainer, reinstall it, and tighten the strainer nut.
- Turn on the power supply.
- Open the water inlet valve.
- Visually inspect all water connections for leaks.
Diagram: A visual representation of the water heater with the inlet strainer highlighted for cleaning.
10.2 Fan Guard Cleaning
- Ensure the water heater is turned OFF at the breaker ON/OFF switch before performing maintenance. Verify that the fan has stopped rotating.
- Use a cleaning brush to clean the fan guard located at the back and on the side of the unit.
- Turn ON the water heater and confirm that the fan operates correctly.
10.3 Temperature-Pressure Relief Valve Test
DANGER: When testing the Temperature-Pressure Relief Valve, ensure no one is standing in front of or near the discharge line's outlet, as the discharged water may be hot and cause injury.
WARNING: Exercise caution when using the valve, as it may be hot and cause injury.
CAUTION: Ensure the surrounding area is clear of any objects. The discharged water may be hot and cause property damage.
- Operate the lever at the relief valve's end several times to ensure proper function.
- If the temperature-pressure relief valve fails to reset completely or continues to release water, it must be replaced.
Diagram: An illustration showing a faucet with hot water being discharged, with a warning label indicating potential burns.
11. Wiring Diagrams and Troubleshooting
11.1 Operational Flow Chart
Diagram: A flowchart illustrating the operational sequence of the Intellihot iE1, including system states like OFF, Initialization, System Ready, and fault processing. Key steps include checking sensors, communication, thermal battery charging, and temperature control module operations. Faults can lead to System Fault Processing.
11.2 Wiring Diagram
Diagram: A detailed wiring diagram of the Intellihot iE1, showing the power distribution block, various components like the compressor, fan, sensors, control boards (UPC3, IOT Board, UCM), and their interconnections. It includes labels for power inputs, outputs, and specific components like temperature sensors and valves.
11.3 Troubleshooting Guide
11.4.1 Temperature Sensor Open - Upper Thermal Battery Error
Possible Causes:
- Temperature Sensor is disconnected
- Nipped or Broken wire
- Faulty temperature sensor
Remedy:
- Ensure temperature sensor connectors are correctly attached.
- Replace nicked or broken wires.
- Replace the temperature sensor.
Diagram: An illustration of the water heater with temperature sensors indicated, specifically highlighting the upper thermal battery sensor.
11.4.2 Temperature Sensor Shorted- Bottom Thermal Battery Error
Possible Causes:
- Temperature Sensor is disconnected
- Nipped or Broken wire
- Faulty temperature sensor
Remedy:
- Ensure temperature sensor connectors are correctly attached.
- Replace nicked or broken wires.
- Replace the temperature sensor.
Diagram: An illustration of the water heater with temperature sensors indicated, specifically highlighting the bottom thermal battery sensor.
11.4.3 Temperature Sensor is Out of Range- Bottom Thermal Battery
Possible Causes:
- Faulty temperature sensor
- Sensor value is outside the range
- Temperature Sensor is disconnected
- Nipped or Broken wire
- Incorrect temperature sensor wiring
- Too much heat in the water outlet or water inlet
- Faulty temperature sensor controller
Remedy:
- Replace the temperature sensor.
- Ensure temperature sensor connectors are correctly attached.
- Make sure the connectors are dry and free of corrosion.
- Replace nicked or broken wires.
- Allow the water outlet temperature to decrease. Verify sensor resistance: 18 kΩ at 50°F, 10 kΩ at 77°F, 3 kΩ at 140°F.
- Replace the Control Board.
Diagram: An illustration of the water heater with temperature sensors indicated, specifically highlighting the bottom thermal battery sensor.
11.4.4 Heat Exchanger Valve Fault
Possible Causes:
- 8 PIN wire disconnected
- Nicked or broken connector
- Faulty temperature sensor wiring
- Water valve clogged or damaged
Remedy:
- Ensure connectors and wiring harness are dry and free of corrosion.
- Replace nicked or broken wires and ensure correct connection.
- Replace the water valve.
Diagram: An illustration showing the heat exchanger valve and bypass valve.
11.4.5 Bypass Valve Fault
Possible Causes:
- 8 PIN wire disconnected
- Incorrect or broken wiring
- Nicked or broken connector
- Faulty temperature sensor wiring
- Water valve clogged or damaged
- Faulty loT interface board
Remedy:
- Ensure connectors and wiring harness are dry and free of corrosion.
- Ensure temperature sensor connectors are correctly attached.
- Replace the water valve.
- Replace loT interface board.
11.4.6 Float Switch Failed
Possible Causes:
- Faulty thermal battery drain port
- Faulty thermal battery inlet port
- Fill solenoid assembly failed or clogged
- Faulty Level sensor
- Faulty Glycol Concentration sensor
Remedy:
- Replace thermal battery drain port.
- Replace thermal battery inlet port.
- Replace fill solenoid assembly.
- Replace level sensor.
- Replace Glycol Concentration sensor.
11.4.7 Bypass Valve Fault
Possible Causes:
- Faulty upper tank temperature sensor
- Faulty lower tank temperature sensor
- Faulty heat pump control board
- Faulty heating element relay
Remedy:
- Replace upper tank temperature sensor.
- Replace lower tank temperature sensor.
- Replace Heat pump control board.
- Replace heating element relay.
12. Serviceable Parts
12.1 Display
Diagram: An illustration of the Intellihot iE1 unit with the display panel highlighted.
| Item | Part Number | Description | Qty |
|---|---|---|---|
| 1 | IGT-ELC0399 | DISPLAY, 7" CAPACITIVE WITH ENCLOSURE | 1 |
12.2 CTA2045
| Item | Part Number | Description | Qty |
|---|---|---|---|
| 2 | IGT-ELC0404 | CTA2045 Interface Board | 1 |
| 3 | IGT-ELC0389 | CTA2045 Interface Module (optional not included) | 1 |
12.3 Electronics
Diagram: An exploded view of the electronic components within the Intellihot iE1 unit, with numbered parts corresponding to the table below.
| Item | Part Number | Description | Qty |
|---|---|---|---|
| 4 | IGT-ELC0414 | HPU, COMPRESSOR/FAN INVERTER DRIVER | 1 |
| 5 | IGT-ELC0363 | TRANSFORMER, 120V, 50/60Hz | 1 |
| 6 | IGT-ELC0391 | Transformer, 208V/240V to 120V | 2 |
| 7 | IGT-ELC0382 | iOT Module | 1 |
| 8 | IGT-ELC0398 | HPU, ELECTRIC HEATER RELAY | 2 |
| 9 | IGT-ELC0383 | CAREL CONTROL (UPC3) BOARD | 1 |
| 10 | IGT-SPR0129 | CONTROLLER BOARD, V9.4 | 1 |
| 11 | IGT-SLS0106 | SEAL, CLOSED CELL, 1/8 THK X 1/2 WIDE | 1 |
12.4 Cold Side
Diagram: A detailed illustration of the cold side components of the Intellihot iE1, with numbered parts corresponding to the table below.
| Item | Part Number | Description | Qty |
|---|---|---|---|
| 12 | IGT-CST0062 | CASTING, WATER INLET, COLD SIDE | 1 |
| 13 | IGT-SLS0116 | SEAL, EPDM, 70 DURO, NSF 61 | 3 |
| 14 | IGT-LNE0072 | CORRUGATED LINE, Ø32 | 1 |
| 15 | IGT-SLS0115 | SEAL, WATER INLET, IE1 | 1 |
| 16 | IGT-OR0031 | O-RING, #119, EPDM, NSF 61, 70 DURO | 2 |
| 17 | IGT-FTT0302 | RETAINING RING, G3/4 | 2 |
| 18 | IGT-HRD0020 | CLIP, RETAINING, Ø19mm-Ø20mm | 3 |
| 19 | IGT-FTT0296 | FITTING, ADAPTER, 20mm X G3/4 | 2 |
| 20 | IGT-VL0044-2 | COIL ISOLATION VALVE | 1 |
| 21 | IGT-SPR0003 | FLOW SENSOR SPARE PARTS KIT | 1 |
| 22 | IGT-OR0010 | O-Ring #113 EPDM, FDA, 70 DURO | 1 |
| 23 | IGT-FTT0297 | FITTING, ADAPTER, 19mm X 1-1/4 NPT | 1 |
12.5 Cold Side
| Item | Part Number | Description | Qty |
|---|---|---|---|
| 24 | IGT-VL0045 | VALVE, GLYCOL FILL SOLENOID | 1 |
| 25 | IGT-LNE0073 | LINE, WATER, FILL PORT, 1/4 | 1 |
| 26 | IGT-FTT0303 | FITTING, COMPRESSION, G1/4 BSPP X 1/4 TUBE | 2 |
| 27 | IGT-SLS0110 | SEAL, G1/4 BSPP | 2 |
| 28 | IGT-LNE0074 | LINE, WATER, FILL PORT, 1/4 | 1 |
| 29 | IGT-CST0065 | CASTING, FILL PORT, GLYCOL | 1 |
12.6 Cold Side
Diagram: A detailed illustration of the cold side components of the Intellihot iE1, with numbered parts corresponding to the table below.
| Item | Part Number | Description | Qty |
|---|---|---|---|
| 30 | IGT-LNE0075 | LINE, CORRUGATED, 25" LG | 1 |
| 31 | IGT-FTT0300 | FITTING, ADAPTER, G3/4 TO 3/4 NPT | 1 |
| 32 | IGT-SLS0112 | SEAL, G3/4 BSPP | 1 |
| 33 | IGT-CST0064 | CASTING, WATER OUTLET, HOT SIDE | 1 |
| 34 | IGT-SLS0117 | SEAL, WATER OUTLET, IE1 | 1 |
| 35 | IGT-ELC0062 | SENSOR, THERMISTOR, AIR | 1 |
| 36 | IGT-SPR0003 | FLOW SENSOR SPARE PARTS KIT | 1 |
| 37 | IGT-FTT0295 | FITTING, ADAPTER, 20mm X 1-1/4 NPT | 1 |
12.7 Glycol Side
Diagram: A detailed illustration of the glycol side components of the Intellihot iE1, with numbered parts corresponding to the table below.
| Item | Part Number | Description | Qty |
|---|---|---|---|
| 38 | IGT-FTT0301 | FITTING, ADAPTER, G1/2 TO 1/2 NPT | 1 |
| 39 | IGT-SLS0111 | SEAL, G1/2 BSPP | 1 |
| 40 | IGT-SLS0113 | SEAL, G1 BSPP | 1 |
| 41 | IGT-ELC0396 | SENSOR, GLYCOL, CONCENTRATION | 1 |
| 42 | IGT-FTT0304 | FITTING, PLUG, G1, SST | 2 |
| 43 | IGT-FTT0294 | FITTING, 3/4 FIP TO G3/4 | 1 |
| 44 | IGT-SLS0114 | SEAL, DRAIN PORT, IE1 | 1 |
12.8 Glycol Side
Diagram: A detailed illustration of the glycol side components of the Intellihot iE1, with numbered parts corresponding to the table below.
| Item | Part Number | Description | Qty |
|---|---|---|---|
| 45 | IGT-FTT0298 | FITTING, ADAPTER, GLYCOL PUMP TO 1/2 NPT | 1 |
| 46 | IGT-HRD0240 | CLIP | 2 |
| 47 | IGT-OR0032 | O-RING, 3.00 CS X Ø12.50mm ID, VITON | 2 |
| 48 | IGT-PMP0010 | PUMP, CIRCULATION, IE1 | 1 |
| 49 | IGT-FTT0299 | FITTING, ADAPTER, GLY PUMP TO G1/2 | 1 |
12.9 Tank
Diagram: An illustration of the Intellihot iE1 tank, highlighting the thermal battery storage.
| Item | Part Number | Description | Qty |
|---|---|---|---|
| 50 | IGT-THBT0001 | THERMAL-BATTERY STORAGE, iE1 | 1 |
12.10 Heat Pump
Diagram: An illustration of the heat pump unit for the Intellihot iE1.
| Item | Part Number | Description | Qty |
|---|---|---|---|
| 51 | IGT-HPU0001 | Heat Pump Deck | 1 |
12.11 Miscellaneous
| Part Number | Description | Qty |
|---|---|---|
| IE1-ELC0367 | IE1-Power Cord Jumper & Upper Coil Relay Harness | 1 |
| IGT-ELC368 | IE1-Display Harness | 1 |
| IGT-ELC0369 | IE1-120VAC Terminal Block to Transformer Harness | 1 |
| IGT-ELC0370 | IE1-120VAC Main Power Harness | 1 |
| IGT-ELC0371 | IE1-TB Valve Harness | 1 |
| IGT-ELC0372 | IE1-Lower Coil Relay Harness | 1 |
| IGT-ELC0373 | IE1-IOT Harness | 1 |
| IGT-ELC0374 | IE1-Fill Solenoid Harness | 1 |
| IGT-ELC0375 | IE1-Temperature Sensors Harness | 1 |
| IGT-ELC0376 | IE1-Hex Valve Harness | 1 |
| IGT-ELC0377 | IE1-HEX Flow Sensor Harness | 1 |
| IGT-ELC0378 | IE1-Bypass Valve Harness | 1 |
| IGT-ELC0379 | IE1-Bypass Flow Sensor Harness | 1 |
| IGT-ELC0380 | iE1-Internal Comms Cable Harness | 1 |
| IGT-ELC0381 | iE1-Glycol Concentration Harness | 1 |
| IGT-ELC0386 | iE1-Glycol Keyence Harness | 1 |
| IGT-ELC0388 | CTA2045 to iOT Board Harness | 1 |
| IGT-ELC0395 | Glycol Level sensor with Harness | 1 |
This product complies with UL 60335-2-40/CSA 22.2 Electric Water Heater. For use as potable water heating.
Logos: ENERGY STAR, NSF Certified, ETL Listed, ECOPORT
Contact Information
Call your dealer first if you have any questions about this product. They can assist with installation, operation, or if there are damaged or missing parts when unpacking the unit.
Dealer Contact Information
DANGER: To avoid product damage, personal injury, or even possible death, carefully read, understand, and follow all instructions in this Installation & Operation Manual before installing this product. Improper installation, adjustment, alteration, or maintenance can cause injury, loss of life, and/or property damage.
This water heater should be installed and serviced by a qualified technician. Lack of proper service can result in a dangerous condition.
This manual must remain with the water heater.
Due to Intellihot's policy of continuous product improvement and technology, the design, technical specifications, or both in this manual are subject to change without notice.
This manual contains safety information, installation instructions, and maintenance procedures. It must be left with the homeowner or placed near the water heater in a noncombustible location. The customer should retain this manual for future reference.
WARNING: Electrical Shock Hazard - Do Not Touch
If the water heater becomes immersed in water up to or above the level of the bottom of the element doors, the heater should be examined by a qualified service agency before it is placed in operation.
