Noritz GQ-C3260 Water Heater User Manual

Noritz GQ-C3260 Water Heater

Product Information

The Heat Exchanger Replacement procedure applies to the GQ-C3260, GQ-C2860, and GQ-C2660 series. This instructional manual is intended for use by a qualified service professional or authorized Service Representative. Unauthorized use of this manual may void the warranty. Contact customer care for additional support, with contact details available on the rating plate of the water heater. The procedure involves draining the unit, removing the front cover and ground wires, unplugging all wires that attach to the wiring harness, and removing cable ties.

Product Usage Instructions

Before beginning the Heat Exchanger Replacement procedure, ensure that you have the following items:

• 14 Phillips head screwdriver (magnetic)
• 8 Phillips head screwdriver (magnetic)
• Flat head screwdriver or box wrench (5/16)
• Pliers
• Hand towels
• 1-5 gallon bucket

To begin the procedure, follow these steps:

1. Drain the unit using one of the following procedures:
   • Drainage using the Remote Controller RC-7651M-A: Open the drain plug(1) and drain plug(2) and (3) for GQ-C3260WX-FF / GQ-C2860WX-FF, open drain plug(1) and (2) for GQ-C3260WZ-FF, and open drain plug(1) to (6) for GQ-C3260WXQ-FF / GQ-C2660WXQ-FF. Then, drain the water out of the unit.
   • Manual Draining: Open the drain plug(1) and drain plug(2) and (3) for GQ-C3260WX-FF / GQ-C2860WX-FF, open drain plug(1) and (2) for GQ-C3260WZ-FF, and open drain plug(1) to (6) for GQ-C3260WXQ-FF / GQ-C2660WXQ-FF. Then, drain the water out of the unit.
2. Disconnect electrical power to the unit and remove the front cover.
3. Remove the ground wires. Remove 3 ground wires for GQ-C3260WX-FF / GQ-C2860WX-FF and GQ-C3260WXQ-FF / GQ-C2660WXQ-FF, and remove 2 ground wires for GQ-C3260WZ-FF.
4. Unplug all wires that attach to Wiring Harness. Unplug the Flame Rod, Flame Lifting Detection, and Freeze Prevention Heater. Remove Circuit Board to the outside of the unit. Unplug Water Servo – Bypass, Gas Valve, Thermistor (Blue) – Primary Heat Exchanger Inlet, Thermistor (Yellow) – Primary Heat Exchanger Outlet, High Limit Switch, Igniter, Fan Motor, Thermistor (White) – Exhaust, and Thermistor (Pink) – Hot water.
5. Remove cable ties.

Note: Each drain plug might not be visible if insulation is installed around the piping.

Heat Exchanger Replacement: GQ-C3260 / GQ-C2860 / GQ-C2660 Series

This instructional manual is only intended for use by a qualified service professional or authorized Service Representative. Any unauthorized use of this manual may result in voiding the warranty.
Reach out to our customer care for additional support.
Contact details are available on the rating plate of the water heater.

Items Needed for service (Not Included)

• 14″ Phillips head Screwdriver magnetic
• 8″ Phillips head Screwdriver magnetic
• Flat head Screwdriver or Box（ wrench）5/16″)
• Pliers
• hand towels
• 1-5 gallon bucket

Heat Exchanger Replacement Procedure

Procedure

Drain the unit as shown in following procedure.

Drainage using the Remote Controller

RC-7651M-A

RC-9018M

Manual Draining

GQ-C3260WX-FF / GQ-C2860WX-FF

GQ-C3260WZ-FF

GQ-C3260WXQ-FF / GQ-C2660WXQ-FF

Drain Plugs
Each drain plug might not be visible if insulation is installed around the piping.

Remove Front Cover

1. Disconnect electrical power to the unit.
2. Remove 4 screws w/ washer(M4×12).

Remove ground wires

GQ-C3260WX-FF / GQ-C2860WX-FF
GQ-C3260WXQ-FF / GQ-C2660WXQ-FF

• Remove 3 ground wires.

GQ-C3260WZ-FF

1. Remove 2 ground wires.
2. Remove 2 screws(M4×12) that hold Circuit Board.

Unplug all wires that attach to Wiring Harness

1. Unplug the Flame Rod.
   Unplug the Flame Lifting Detection.
   Hold this part of figures by fingers and remove the plug.

2. Unplug Freeze Prevention Heater

3. Remove Circuit Board to the outside of the unit.

4. Remove Cable Ties,
   Unplug Water Servo – Bypass, Gas Valve,
   Thermistor (Blue) – Primary Heat Exchanger Inlet,
   Thermistor (Yellow) – Primary Heat Exchanger Outlet,
   High Limit Switch.

   • GQ-C3260WX-FF / GQ-C2860WX-FF
     Unplug 4 Freeze Prevention Heaters.

   • GQ-C3260WZ-FF
     GQ-C3260WXQ-FF / GQ-C2660WXQ-FF
     Unplug 3 Freeze Prevention Heaters.

5. Unplug Igniter.

6. Detach the Wiring Harness from the Wire clamps.
   Unplug Fan Motor, Thermistor (White) – Exhaust.
   ONLY GQ-C3260WX-FF / GQ-C2860WX-FF
   Unplug 2 Freeze Prevention Heaters, Thermistor (Pink) – Hot water.

Overall view

Remove Pipes, Elbow and Hose

1. Remove “C” Clamp

   • GQ-C3260WX-FF / GQ-C2860WX-FF
     Remove 2 “C” Clamps, Pipe – Water Connector-T-Elbow to Outlet Water Connection.
     Remove 2 “C” Clamps, Pipe – Heat Exchanger to Water　Connector -T-Elbow

   • GQ-C3260WZ-FF
     GQ-C3260WXQ-FF / GQ-C2660WXQ-FF
     Remove 2 “C” Clamps, Pipe – Heat Exchanger to Water　Connector -T-Elbow.

2. Remove “C” Clamp, Water　Connector-Elbow – Heat Exchanger Connection.

3. Remove Hose Clamp, pull Drain Hose – Exhaust Duct off.

Remove Fan Motor and Venturi assembly

1. Remove the “C” Clamp.
   Then remove the screw (M4×10) with a Phillips screwdriver.

2. Disconnect the Gas Valve SET and push down it.

3. Remove the 4 screws(M5×25) with a Long Phillips screwdriver.
   Do not use a power driver.

4. Detach Fan Motor and Venturi assembly

Remove Heat Exchanger assembly from Case

1. Remove 4 screws(M4×12),
   pull Exhaust Flue off.
   Discard these screws.

2. Remove 8 screws(M4×10) fixing heat exchanger assembly.

3. Lift up and remove the heat exchanger assembly from the case.

Remove parts from Heat Exchanger

1. Remove 2 “C” Clamps, Pipe – Secondary SS HEX to Primary SS HEX.

2. Remove the screw(M4×8), unplug High Voltage Igniter

3. Wires from Ignition Plug.

4. Remove and discard Silicon Sleeve and Plug Cover.

5. Remove and discard Silicon Sleeve.
   ONLY GQ-C3260WZ-FF

6. Remove the screw(M4×8).
   Then remove Mounting Plate – System Controller.

Remove Exhaust Duct

1. Remove 2 screws(M4×12) on the back of Exhaust Duct.
2. Remove 12 screws(M4×12) on the bottom of Exhaust Duct.
3. Remove Exhaust Duct.
   NOTE: Remove Exhaust Duct carefully not to damage Heat Exchanger and Exhaust Duct.
   NOTE: Make sure that the exhaust duct is not deformed by heating. If it’s deformed, replace it.

Remove Burner Chamber SET

1. Remove 6 screws(M4×10) to remove Mounting Plate – Chamber.

2. Remove 6 screws(M4×18) to separate
   Heat Exchanger and Burner Chamber.

3. Detach Burner Chamber SET and Heat Exchanger.
   NOTE: DO NOT place Burner Chamber SET with the burner side downward. If you need to place the Burner Chamber SET on somewhere, put the Burner Chamber SET so that the burner faces upward like as following image.

Replace Heat Exchanger
Attach 2 Freeze Prevention Heaters to the new Heat Exchanger according with the instruction as right figure.

Secure Heat Exchanger to Burner Chamber SET

1. Peel off old Gasket- Burners and replace it with new Gasket – Burner.

2. Secure the new Burner Chamber SET to Heat Exchanger with 6 screws (M4×18).
   When tightening is over, please check again for looseness of screws.

3. Attach Mounting Plate – Chamber to Burner Chamber SET.

Attach Exhaust Duct to Heat Exchanger

1. Put the heat exchanger assembly upside down on something with the height of 6 inch (150 mm) or more.
   Without support, the chamber and Exhaust Duct can be damaged.
   NOTE: DO NOT deform the Flame Lifting Detection when turn the Heat Exchanger upside down.

2. Replace Gasket-Exhaust Duct with new one. Set Gasket-Exhaust Duct to match the line inside the Heat Exchanger.

3. Attach Exhaust Duct to Heat Exchanger and fix with 12 screws(M4×12).

4. Attach the Heat Exchanger to Exhaust Duct with 2 screws(M4×12) from the backside

Attach parts to Heat Exchanger

1. Attach Pipe – Secondary SS HEX to Primary SS HEX with 2 “C” Clamps.
   In that case, exchange O ring – High Temp P16 of Pipe – Secondary SS HEX to Primary SS HEX for a new one.

2. Attach Mounting Plate – Igniter with the screw(M4×8).

3. Install a new Silicon Sleeve of Ignition Plug on the left side only.
   Then plug High Voltage Igniter Wires to Ignition Plug.
   ONLY GQ-C3260WZ-FF

4. Attach Mounting Plate – System Controller with the screw(M4×8).

Secure Heat Exchanger assembly in the case

1. Secure Heat Exchanger assembly in the case with 8 screws(M4×10).
2. Replace the O-Ring of Exhaust Flue with new one.
3. Attach Exhaust Flue to the case with 4 new screws (M4×12).

Attach Fan Motor and Venturi assembly

1. Make sure that the Gasket is secured properly in place.
   NOTE: Failure to do so will cause gas leaks, possibly resulting in severe personal injury or death.

2. Attach the Fan Motor and Venturi assembly. Secure the Fan Motor and Venturi assembly to the Burner by tightening the 4 screws(M5×25) removed in Step 6. The screws need only to be hand tightened and should not be tightened using a drill. First, insert and tighten 4 screws, but do not fully tighten
   these screws. Once all screws are inserted, proceed to completely tighten 4 screws.
   NOTE: When tightening the screws, be certain to not apply excess force. Excess force can strip out the original holes and screws. Keep the Fan motor in
   horizontal. It makes easier to tighten the screws correctly.

3. Attach the Gas Valve SET to Venturi assembly. Attach the “C” Clamps. Then attach the screw (M4×10) with a Phillips screwdriver.

Attach Pipes, Elbow and Hose.

1. Attach Drain Hose – Heat Exchanger into the drain outlet of Exhaust Duct and fix it with Hose Clamp.
2. Attach “C” Clamp, Elbow – Heat Exchanger Connection.
3. Attach “C” Clamp.
   GQ-C3260WX-FF / GQ-C2860WX-FF
   Attach 2 “C” Clamps, Pipe -Heat Exchanger to Water Connector T-Elbow
   Remove 2 “C” Clamps Pipe – Water　Connector-T-Elbow to Outlet Water Connection. GQ-C3260WZ-FF
   GQ-C3260WXQ-FF / GQ-C2660WXQ-FF
   Attach 2 “C” Clamps, Pipe – Heat Exchanger to Water Connector -T-Elbow

Plug all wires that attach to Wiring Harness

1. Attach the Wiring Harness to the Wire clamps.

   • GQ-C3260WX-FF / GQ-C2860WX-FF
     Plug Fan Motor, Thermistor (White) – Exhaust. Plug 2 Freeze Prevention Heaters, Thermistor (Pink) – Hot water.

   • GQ-C3260WZ-FF
     GQ-C3260WXQ-FF / GQ-C2660WXQ-FF
     Plug Fan Motor, Thermistor (White) – Exhaust.

2. Hook Wiring Harness by using Wire Clamps

3. Plug Water Servo – Bypass, Gas Valve, Thermistor (Blue) – Primary Heat Exchanger Inlet, Thermistor (Yellow) – Primary Heat Exchanger Outlet, High Limit Switch.

   • GQ-C3260WX-FF / GQ-C2860WX-FF
     Plug 4 Freeze Prevention Heaters, and bundle Wiring Harness with 2 Cable Ties.

   • GQ-C3260WZ-FF
     GQ-C3260WXQ-FF / GQ-C2660WXQ-FF
     Plug 3 Freeze Prevention Heaters, and bundle Wiring Harness with 2 Cable Ties.

4. Plug Igniter

5. Plug the Flame Rod.

6. Plug the Flame Lifting Detection

7. Plug Heater connector.

Attach ground wires

GQ-C3260WX-FF / GQ-C2860WX-FF
GQ-C3260WXQ-FF / GQ-C2660WXQ-FF

Attach 3 ground wires.

GQ-C3260WZ-FF
Attach 2 ground wires

Attach Circuit Board

1. Attach Circuit Board with 2 screws(M4×12).

Attach Front Cover
Attach Front Cover with 4 screws w/ washer(M4×12).

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