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GAS CONTINUOUS FLOWWATER HEATERS
(Residential Outdoor Unit) TO BE USED BY A LICENSEDPLUMBER ONLY
SERVICE MANUALModel:26NG50C/26LP50C
26NG60C/26LP60C
- 3 -
Table of Contents
1. General Outline of Appliance1 - 1 Specifications .............................................................................................................................. 31 - 2 Performance ................................................................................................................................ 41 - 3 GeneralConstruction(PartsNames) .......................................................................................... 51 - 4 MainComponentStructures ....................................................................................................... 61 - 5 MainSafetyDevices ................................................................................................................... 8
2. Installation and Related Work2 - 1 InstallationInstructions ................................................................................................................ 92 - 2 Dimensions ................................................................................................................................. 132 - 3 GasPiping ................................................................................................................................... 142 - 4 WaterPiping ................................................................................................................................ 142 - 5 CondensateDrainPiping ............................................................................................................ 152 - 6 ElectricalConnection .................................................................................................................. 172 - 7 WiringRemoteController ............................................................................................................ 182 - 8 TestingOperation ........................................................................................................................ 202 - 9 CascadeInstallation .................................................................................................................... 21
3. Service and Maintenance3 - 1 OperationPrinciples .................................................................................................................... 223 - 2 SchematicDiagram ..................................................................................................................... 243 - 3 FlowCharts ................................................................................................................................. 253 - 4 FaultFindingsandErrorCode .................................................................................................... 263 - 5 ReplacementofPCB ................................................................................................................... 293 - 6 ReplacementofNeutralizer ......................................................................................................... 303 - 7 WiringDiagram ........................................................................................................................... 313 - 8 CascadeFlowCharts .................................................................................................................. 323 - 9 ManifoldGasSettingProcedure ................................................................................................. 333 - 10CombustionSpecification,VariousCombinationSetting ............................................................ 343 - 11 Disassembling/AssemblingParts ................................................................................................ 383 - 12ExplodedView ............................................................................................................................ 463- 13PartsList ..................................................................................................................................... 47
- 3 -
1-1 Specifications
MODEL 26
Nominalhourlygasconsumptionbyproportionalelectronicgascontrol MJ/h 173
Minimumgassupplypressure(NaturalGas) kPa 1.13
Maximumgassupplypressure(NaturalGas) kPa 5.0
Minimumgassupplypressure(Propane) kPa 2.75
Maximumgassupplypressure(Propane) kPa 7.0
TestpointpressureHigh(NaturalGas) kPa 0.84
TestpointpressureLow(NaturalGas) kPa 0.16
TestpointpressureHigh(Propane) kPa 1.27
TestpointpressureLow(Propane) kPa 0.21
Waterheatingcapacityraised40°C L/min 16.25
Minimumworkingpressure kPa 115
Maximumworkingpressure kPa 1200
Gasinjectorsdiameter(NaturalGas) mm 1.00/1.50
Gasinjectorsdiameter(Propane) mm 0.7/1.0
Inputvoltagesinglephase50Hz V 240
Maximumoutputcurrent A 0.66
Inletgasconnectionmalethread R3/4”(20mm)
Coldwaterconnectionmalethread R3/4”(20mm)
Hotwaterconnectionmalethread R3/4”(20mm)
Reliefvalvepressuresetting kPa 1400
Weightdry kg 20.5
Dimensions(DxWxH) mm 205x366x573
IAPMOApprovalcertificateno.GMK10408.WatermarkCertificateofcomplianceWM-000506
1. General Outline of Appliance
- 4 - - 5 -
1-2 PerformancePerformance-Capacitycharacteristiccurves.
Inlet water temperature
5 C
15 C
25 C
Wa
ter
flow
ra
te [L
/min
]
370
52.2(Minimum)
22.0(Maximum)
10
15
20
25
7550 60
Outlet water temperature [ C]
- 4 - - 5 -
1-3 GeneralConstruction(PartsNames)
No. PARTS NAME
1 PCB(Natural Gas)PCB(Propane)
2 ManifoldAssy(NaturalGas)ManifoldAssy(Propane)
3 GasControlValve4 Electrode5 FlameRod6 HeatExchangerAssya PrimaryHeatExchangerAssyb SecondaryHeatExchangerAssy7 OverHeatThermostat
No. PARTS NAME8 Fan Motor9 TemperatureSensor10 Anti-Frost Heaters11 Ignitor12 PressureReliefValve13 WaterFlowControlValve(withSensor)14 Water Filter15 AmbientTemperatureSensor16 NeutralizerAssyc Neutralizerd Anti-FrostHeaterforNeutralizer
a
7
10
5
4
10
b
6
14d 10
11
1
15
2
10 12 13
c
8
9
9 3
- 6 - - 7 -
1-4 MainComponentStructures1. GasControlValve
•Feedsthenecessaryamountofgastoheatwatertoasettemperature,basedontheamountofwaterflowinginthroughtheinletmeasuredbytheWaterFlowSensorandthewatertemperaturecalculation.
UP34-47RLP/NG
4D00001
11DC0697
0
12
OUT2OUT1
Main Gas Valve
Gas Valve 1
Filter
Gas Control Valve
Gas Valve 1(No.1)
Main Gas Valve(No.0)
Gas Valve 2(No.2)
IN
2. WaterFlowControlValvewithSensor*Measuresthewaterflowasitsrotor(bladedwheel)spinswiththepassingwater.Therotationoftherotorisdetectedbythesensorrotor(bladeequippedwithamagnet)ofthewheelandtheHallelementwhichcalculatesthewaterquantity.
*Whenwaterflowsmorethanwaterheatercapacity,hotwatertemperaturebecomeslowerthanthesetting.TheWaterFlowControlValveautomaticallyreducesthewaterflowtopreventsuchtemperaturedrops.
Inlet
Main Body
Water Flow Sensor
Hall Element ICSealant
Valve Body
Water Flow Control Valve
Rotor
- 6 - - 7 -
Gas
Gas Valve 2
Gas Valve 1
Electrode2burners 5burners 10burners
Flame Sensor
Gas ControlValve
Main Gas Valve
Gas Valve 3Fan Motor
3. CombustionControlofRichandLeanBurners
1) IgnitionstartAftertheMainGasValve,GasValve1,GasValve2openrespectivelyasrequired,theGasControlValve,beingheldattheslowignitionposition(withgassupplyataconstantrate),operatestoigniteBurners.
2) DuringcombustionDependingontherequiredheatingcapacity,eachGasValveopensorcloses.The combinations are below,Gas valve 1&2&3 open 1&2 2 1
Higher
Lower
- 8 - - 9 -
1-5 Main Safety Devices
1. WaterFlowSensor(Boil-dryprotection)WhentheWaterFlowSensordetectstheflowrateissetforstartingignition(ignitionwaterflow)orhigher,thewaterheaterstartsoperation. Ignitionwaterflow:2.7L/min. Extinctionwaterflow:2.2L/min.
2. FlameSensor(Flamefailuredetection)ElectricsignalsaretransmittedtotheflamedetectioncircuittoconfirmthenormalcombustionwhentheFlameSensordetectstherectificationofnormalcombustionflame.Therefore,ifthecombustionoftheBurnersisnotnormal,thesignalsarenotsentviatheFlameSensor.Thegascontrolassembliesareclosedwithoutthesignalsandtheerrorcode"111"or"121"isdisplayedontheremotecontrollers.
3. ThermalFuse(Over-temperatureprotectionsystem)TheThermalFuseisplacedaroundthePrimaryHeatExchangerAssembly.Iftheambienttemperatureinsidethewaterheaterbecomesextremelyhigh,thefusewillmeltdowntobreakthepowercircuit.Insuchacase,asnopowerissuppliedtothegascontrolassemblies,thegassupplyisstoppedandthecombustionisstopped.(Thesystemisactivatedtoblowthefuseat169°C.)
4. OverHeatThermostat(residual)EvenifthePrimaryHeatExchangerAssemblyisoverheatedbyno-watercombustion, everygaspathisclosedtoavoidrisks.Atthistime,theerrorcode"141"isdisplayedontheremotecontrollers.(Theswitchisprovidedwithaauto-restorationfunctionandturnsOFFat100°C.)
5. FanRevolutionDetectionDevice(HallIC)Thedevicedetectsthefanrevolutionspeedtocontroltheairsupplynecessaryfornormalcombustion.Ifthefanrevolutionisoutofthepresetstandardrange,thegascontrolassembliesareclosedtostopthecombustionbeforecombustionfailureoccurs.Inthiscase,theerrorcode"611"isdisplayedontheremotecontrollers.
6. FreezeProtectionSystem(Anti-FrostHeaters)Topreventfreezinginthehotwatersupplycircuit,Anti-FrostHeatersareprovidedatmajorpointsofwaterflowpathsintheunit.TheheatersareactivatedbytheAmbientTemperatureSensorintheunit.(ThesystemturnsONat3°CandOFFat13°C.)
- 8 - - 9 -
2. Installation and Related Work
2-1 Installation Instructions•Thecasesshownbelowareclassifiedbythedegreeofriskanddamage. Besuretofollowtheinstructionsforyoursafety.
Eachmarkindicates:
TheWaterHeatermustbeinstalledinaccordancewiththefollowing:
1. Theseinstructions.2.NationalConstructionCodeandLocalauthorityregulations.3. AS/NZS3500.4PlumbingandDrainage-HeatedWaterServices.4. TheAustralianstandardforgasinstallationsAS/NZS5601.5. Anyotherstatutoryregulationthatmayapply.6. AnoticeofintentiontoinstallshallbelodgedwiththerelevantlocalGasAuthorityprior
to installation.
INSTALLAION MUST BE CARRIED OUT ONLY BY AN AUTHORISED AND APPROPRIATE LICENSED PERSON
Installationrequirements
“Danger”indicatesthatseriousinjuriesorevendeathmayresultfromtheimproperinstallationduetonegligenceoffollowingtheinstructions.
“Warning”indicatesthepossibilitythatseriousinjuriesorevendeathmayresultfromtheimproperinstallationduetonegligenceoffollowingtheinstructions.
“Caution”indicatesthepossibilitythatsomeinjuriesormaterialdamagemayresultfromtheimproperinstallationduetonegligenceoffollowingtheinstructions.
Generalprohibited
Neverfailtodo.
Ground
Neverinstalltheunitindoorsasitisexclusivelyforoutdooruse.Donotinstallitinthebathroom.Electricshockorleakagemayresult.
-10- - 11 -
•Makesuretheunittobeinstalledsuitstheintendeduseandapplication.•Donotuseanygasotherthanspecifiedonthesticker.•Donotoperatewithanypowersource(voltage/frequency)otherthanspecifiedonthesticker.
Verificationoftheunit.
Before installation.
Locationoftheunit.Decidewheretoinstalltheunitbyconsideringcustomer’srequestandclearances.
Ventilation•Installtheunitwherethereisenoughspaceforventilation.•Donotinstalltheunitwhereflammablessuchasgasoline,benzene,andadhesivearehandled.
•Thisunitdoesnotallowtheuseofextendedexhaustpipes.•Installtheunitasfaraspossible,awayfromanythinginfrontoraboveevenifitisnon-combustibleinordertopreventexhaustgasrecirculation,andstainingofsurfaces.
•Takepreventivemeasuresagainstsnowdriftsforairinletandexhaustoutlettostayunaffectedincasethereisapossibilitythattheymaybeblockedbysnowfall.
-10- - 11 -
•Reinforcethewallifnecessaryasthisunitweighsabout20.5kg.
1. Fix1screw(forwallhanging)intothewallleavingabout4mmlengthtohookon.
2.Hookthecenterholeofthewallhangingbracketontothescrewandsecurelyfixtheunitwith4screws.
Installation.
Screw(for wall hanging)
Wall hanging bracket
Screw(for wall hanging) Wall hanging bracket
4mm
599m
m
Screw(for wall hanging)
Screw(for wall hanging)
Screw(for wall hanging)
-12- - 13 -
•Checkifadjacentwallorceilingisfireresistantandallowssafedistanceforfire prevention.
•Thiswaterheaterissuitableforresidentialwater(potable)heatingonly.Donotusethiswaterheaterforspaceheating,combinationspaceheating/domesticwaterheating,orcommercialwaterheatingapplications.
•TheWaterHeaterisnotsuitableforuseinpoolorspaapplications.•Maintainproperspacearoundtheunitforproperservicingandoperation.Minimumclearancesfromcombustiblematerialsarelistedbelow.
Topofheater 30cmFrontofheater 60cmSidesofheater 15cmBackofheater 0cmFloor 30cm
•Secureenoughspacesothattheinspectionandrepairscanbedoneeasily.•Securespacenotonlyinfrontbutalsoundertheunit.•Donotinstalltheunitoverothercombustionappliances. OilresidueanddustintheaircanadheretotheBurnerandthePrimaryand SecondaryHeatExchangerresultingindeformation,lossofefficiency,ordamagetoelectroniccomponents.
•Donotinstalltheexhaustoutletneartheoutletsoftheotherappliances. Installtheairinletsawayfromthewindpathasthewindmaycauseimperfect combustion.
•Donotinstalltheunitwherecommercialchemicalsareused. Thosechemicalsareammonia,sulfur,chloride,ethylenecompoundandacidswhichareusedatbeautyshop,laundry,factoryandsoforth.
•Donotinstalltheunitoverfoodordishes.•Pipepressurerelieftoadrainoroutsideenvironment,orwithin100mmofthefloor. Pipepressurereliefdischargetoadrainoroutsideenvironment.
•Theapplianceshouldbelocatedinanareawhereleakagefromtheunitorconnectionswillnotresultindamagetotheareaadjacenttotheapplianceortolowerfloorsofthestructure.Whensuchlocationscannotbeavoided,itisrecommendedthatasuitabledrainpan,adequatelydrained,beinstalledundertheappliance.Thepanmustnot restrictcombustionairflow.
-12- - 13 -
2-2 Dimensions
68mm68mm
68mm68mm
637m
m
573m
m25
mm
366mm
599m
m12
mm
15mm205mm21mm
143m
m
103m
m
83m
m
145m
m
72m
m
350mm
260mm
208mm
174mm
143mm
46mm
POWER CABLE ENTRYDRAIN OUTLET
COLD WATER INLETR3/4 /20
PRESSURE RELIEF VALVE
HOT WATER OUTLETR3/4 /20
GAS SUPPLY INLETR3/4 /20
WATER INLET FILTER
- 14 - - 15 -
•InstallthemanualgasvalveinthegasinletconnectionoftheWaterHeater.
•Aunionshouldbeusedtoconnecttheunitandthegaspipe.
•Checkthegastypeandthegasinletpressurebeforeconnecting.
•Removethescrewfromthetestplugbeforecheckingthegasinletpressure. Connectthemanometertotheplugwiththesilicontubeandmeasurethegasinlet pressureandconfirmfromtheratinglabelontheappliance.
•Putthescrewbackinthetestplugandfastentightly.
•MakesuretoconductgasleakagetestbeforeoperatingtheWater Heater.
2-3 Gas Piping
2-4 WaterPiping
•InstallamanualwatervalveinthewaterinletconnectionoftheWaterHeater.
•Aunionshouldbeusedonboththehotandcoldwatersupplylinesforconnection.
•Purgethewaterlinestoremovealldebrisandair.
•Makesureboththehotandcoldwatersupplylinesareconnectedcorrectly.
•Afilterisplacedatthewatersupplyinlettoremovedebris. Cleanthefilterregularly. Donotoperatetheunitwithoutthefilterinplace. Inareasofheavydebris,suchaswithsomewells,installawholehousewaterfilterinlinebeforetheunit.
- 14 - - 15 -
2-5 Condensate Drain Piping
Thisunitgeneratescondensatecontinuouslyatarateofupto5litresperhourasa by-productofthehighlyefficientgasburnersystem.Thiscondensatemustbedrainedviaapipetoasuitablepointofdischarge.Asthecondensateisaby-productofgascombustion,itismildlyacidic.Forthisreason,coppertubeandfittingsMUSTNOTbeused,astheywillcorrode.Theunithasanin-builtcondensateneutralizertomakethecondensatesafefordischarge.ItisrecommendedtouseDN15highpressurePVCpipeandfittingsforthecondensatedrain line.
IMPORTANT CONSIDERATIONS FOR THE CONDENSATE DRAIN PIPEThecontentofAS/NZS3500‘Temperature/PressureReliefandExpansionControlValveDrainLines’hasbeenusedasaguideinpreparingtheseconsiderations.
Condensatedrainoutletconnection,R1/2"(15mm)BSPmalenylon.Note:thewhiteplasticshippingcapMUSTBEremovedfromthecondensatedrainoutletpriortowaterheateroperation.Inthecasethatwhite-ishstonepieces(calciumcarbonate)comesoutoftheneutralizerwhenthecapisremoved,theyshouldbediscarded.Thecondensatedrainlinemusthaveacontinuousfall(ofatleast2°)fromthewaterheatertothedischargepoint.Lengthsandbendsmustbeinaccordancewith'Lengthandchangesofdirection'diagrambelow.
Drainage of condensate water
Lengths and changes of direction
Maxreliefdrainlength(m) 9 8 7 6
Maxnumbersofchangesofdirection(greaterthan45°) 3 4 5 6
Drain outlet
2° fall
Fix with pipe clip
PVC piping
- 16 - - 17 -
1. ThedrainlineMUSTNOTdischargeontoelectricalconnections,earthstakes,copper pipes,concretepathsorintoapond.
2.Thepointofdischargefromeachdrainlineshallbelocatedsothatthereleaseof condensatedoesnotcauseanuisance,isreadilydiscernableandincursnoriskofdamagetothebuilding.
Condensatedrainlinesfrommultiplewaterheatersmaybejoinedtogetherprovidedtheyconformwiththe'Installationrequirements'onpage9.
Whereindividualwaterheatersareinstalledinamulti-storybuilding,thecondensatedrainlinemaydischargeintoacommonstack,subjecttothefollowing:(a)Thedischargefromthecommonstackistoatundish,havingadischargelinethatis
notlessthanthesizeofthecommonstack,directlyconnectedtoafixturetrap,and installedinconnectionwithanyadjacentsoilorwastestack.
(b)Thedischargepointofthecommonstackissuchthatanydischargeisreadilyvisible andnotcauseanynuisance.
(c)Thecommonstackisventedbyextendingthepipeupwardsabovetherooflevel.
ThedrainlinefromanytundishshallnotbelessthanDN20orlessthanonesizelargerthanthatofthelargestdrainlinedischargingintothetundish.Tundishdrainlinesshallcomplywiththe’Installationrequirements’onpage9.
Inareaswherewaterpipesarepronetofreezing,thedrainpipefromanyvalveshallbeinsulatedandnotexceed300mminlength.Itshalldischargeintoatundishthroughanairgapofnotlessthan75mmandnotmorethan150mmmeasuredfromtheoutletofthedrainpipetotherimofthetundish.
Installation
Interconnection of condensate drain lines
Commonstackdischarge
Tundish drain lines
Areas subject to freezing
Inviewof(1)and(2),suitablepointsofdischargearedeemedtobedrainsorsewers.3. Thereshallbenotap,valve,orotherrestrictionsinanyline.4. Thedrainlineshallfallcontinuouslytotheapprovedpointofdischarge.5. Wheredischargingoveratundishorgullytrap,drainlinesshallhaveanairgapofa
sizeatleasttwicethediameterofthedrainline.
PLEASE NOTEThewarrantywillnotcoveranyfailuresoroperatingdifficultiesduetothefollowing:•improperinstallationandmaintenance(includingbutnotlimitedto):•condensatedamageoranyotherconsequentiallosseitherdirectlyorindirectly•removaloftheneutralizer•notreplacingtheneutralizerattheendofit’slife
- 16 - - 17 -
2-6 Electrical Connection
•TheWaterHeaterrequires240VACat50Hz. Disconnectthepowersupplyiftheunitisnotinuseforalongtime.
•Removeresidualwaterintheunitwhenthepowersupplyisoffbecausethefreeze preventionintheunitwillnotactivate,resultinginpossiblefreezingdamage.
•Labelallwirespriortodisconnectionwhenservicingcontrols.Wiringerrorscancauseimproperanddangerousoperation. Verifyproperoperationafterservicing. Fieldwiringtobeperformedattimeofapplianceinstallation.
•Completelyturnoffthepowerbeforestartingthework. Donotturnthepoweronuntiltheelectricwiringisfinishedandallworkiscompleted. Otherwiseelectricshockorpersonalinjurymayresult.
- 18 - - 19 -
2-7 WiringRemoteController
1. NumberofcontrollersOne,twoorthreeremotecontrollerscanbeinstalledasoptionalextras.
2. RemoteControllerlocationsTheremotecontrollersallowthewatertemperaturetobesetfromthevariouslocationswheretheyareinstalledatkitchen,laundry,bathroomandensuite.
3. Connectionofcabletothethermannunit(1)Removethefrontcoverfromtheunit.(2)InstallthecabletotheThermannmainunitusingconduitorbyconcealingthe
cablesinthewallcavity.(3)Installthecableintothecabinetthroughtheconduitinaccordancewiththetablein
nextpage.(4)Basedon“Howtofixthecables”,attachthecabletotheplateadjacenttothe
terminalblock,usingthecableclampprovided.(5)Attachthecablestotheterminalsfortheremotecontrollers.(6)Replacethefrontcoverofthewaterheater.
- 18 - - 19 -
L SM SMS
180mm
270mm
KNOT
KNOT
180mm
KNOT
180mm
KNOT
KNOT
270mm
KNOT
270mm
KNOT
KNOT
How to fix the cables (Remote controller cable(s) and cascade cable)
Number of cable
How to tie thecable(s) at thepower cableentry
Required cable clamp
How to fix thecable(s)
The lengthbetween the knotand the cable terminal
How to connectthe cable(s) tothe terminal
1 2 3 4*
Make a knot Tie two cablesTie two cables andmake a knot on therest cable
Tie the cablestwo by two
Clamp (small) Clamp (medium) 1 cable:clamp (small) 2 cables:clamp (medium)
1 cable:clamp (small) 3 cables:clamp (large)
180mm 180mm1 cable:270mm2 cables:180mm
2 cables:270mm2 cables:180mm
Attach the cable tounderside of terminal
Attach the cables tounderside of terminal
Attach the cable(180mm) to underside of terminalAttach the cables(270mm) to upperside of terminal
Attach the cables(180mm) to underside of terminalAttach the cables(270mm) to upperside of terminal
* Up to three remote controller can be installed. In this case, three remote controller cables and one cascade cable shall be connected.
-20- -21-
2-8 TestingOperation
•Followthestepsbelow,toensuretheWaterHeaterhasbeenproperlyinstalled.
1. Fullyopenthewatersupplymainvalve.2.Flushoutthewatersupplypipingtocleanoutanyinstallationdebris,cleanoutfilter.3. Turnonpowertounitandopengassupplyvalve.4. Operatetheremotecontrollersaccordingto“INITIAL SETTING REMOTE
CONTROLLERS”intheinstallationinstructions.
1. Operatetheunitaccordingto"OperationofRemoteController”intheoperating instructions.
2.Makesuretheunitoperatesnormally. •DoestheBurnerigniteandshutoffproperly?CheckthecombustionlamponthePCB. TheBurnermaynotigniteatfirstuntiltheairinthegassupplypipeisdrivenout. Repeattheprocedureuntilitignites.
•Istemperaturesettingworkable? Checkifthetemperaturecanbeadjustedasdesired.
•Iftheresidenceisnotreadyforhabitationortheunitwillnotbeusedforanextendedtime,theresidualwaterintheunitandthepipemayfreezeanddamagetheunit,ortheresidualwaterinthePrimaryandSecondaryHeatExchangermaydeteriorate. Besuretoremovethewaterintheunitandthepipe.
1. Closethegassupplymainvalve.2.Closethewatersupplymainvalve3. Takeoffthewaterfilterandpressurereliefvalve(drainstopper),andremovethewater.
Takethisprocedurewhentheunitcoolsdownafterthetestingoperation.4. Disconnectthepower,orturnoffthepowersupply.5. Openthetapandshowertap(ifany)andremovethewater.6. Leavetheunitinthisconditionuntilreadytouse.
Filloutthewarrantyformwiththecustomer.Explainthe“RemoteController“sectionoftheoperatinginstructionstothecustomer.
Preparation for testing operation.
Testing operation.
Procedure after testing operation.
Explanationtocustomers.
-20- -21-
2-9 Cascade Installation
•Thistypeofinstallationallowstwounitstooperatetogetherbyconnectingtwounitswitha2-wirecableandsomesimpleprogramming.
•Theunitswilloperateinarangebetween22MJ/hand346MJ/hwhentwounitsareconnectedtogether.
•Dependingonwaterflowanddesiredtemperature,thesystemcanautomatically operateorstopeitherorbothunits.
•Thermanngenuinecascadecablecanbeusedtoconnectedthetwounits.•Thedistancebetweenthetwounitsmustbeintherangeof50-1000mm.•Waterandgaspipelengthshouldbethesametobothunits.Otherwisethetemperatureofthehotwateratthetapcanbeunstable.
•Ifconnectingoptionalremotecontrollers,theymustbeconnectedtooneunitonly. ThatunitwillneedtobesetupastheMASTERunitforthesystemtooperatecorrectly.
•Allfittings,valvesandbranchlinesshouldbematchedsetstoeachofthewaterheaters.
RemoteController
Remote ControllerConnection Terminals
Thermann genuinecascade cable
Gas Supply
Hot Water Supply Line
Cold Water Supply Line
PCB
(50-1000mm)
the MASTER unit the SLAVE unit
PCB
ManifoldDN25
WeatherproofGPO×2
BranchesDN20
•Toconnectthecascadecable,referto“Howtofixthecables’’onpage19.
RecommendationManifoldlinesizeforcold,hotandgaspipesisDN25.Branchlinesizeforcold,hotandgaspipesisDN20.(RefertoAS/NZS5601forgaspipeandAS/NZS3500.4forwaterpiperequirements).
(Maximum Four Cables)
REMOTECONTROLLER CABLE
CABLE CLAMP (Small)
REMOTE CONTROLLER CONNECTION TERMINALS
CABLE CLAMP (Large)
CASCADE CABLE
-22- -23-
3. Service and Maintenance
3-1 Operation Principles
[Beforeoperation]•WhenON/OFFButton(Powerswitch)ontheremotecontrolleristurnedON,theONindicatoriluminates(inthecaseofoperationwitharemotecontroller).Gasis suppliedtotheGasValve.
[Duringoperation(whenhotwaterissupplied)]•Whenthehotwatersupplytapisopened,waterflowsthroughtheWaterFlow ControlValve(withsensor)intothePrimaryandSecondaryHeatExchanger Assembly.ThewaterheatedbytheHeatExchangerAssemblypassesthroughtheOutgoingWaterTemperatureSensortogotoahotwateroutlet.Atthistime, theWaterFlowSensordetectswaterflow.ThenthePCBstartstheFanMotor, activatingtheelectrode.TheMainGasValve,GasValve1andGasValve2areopenedsimultaneouslywhenthesparkisemittedbytheElectrode.
•ThegassupplyissetattheslowignitionlevelbytheGasControlValveandgoestoBurners.WhenBurnersareignited,theFlameSensordetectstheflamecondition,the“In Use”Indicatorlightsandthesparkingisstopped.
•ThePCBdetectsthewaterflowratebasedonthesignalfromtheWaterFlowSensor,calculatestheenergyrequiredtoheatthewateruptothesettemperature,and adjuststheopeningpositionoftheGasControlValveandtheFanMotorrpm. Afterthis,PCBmaintainsthecombustiontokeepthewateratthesettemperaturebycheckingwiththeOutgoingWaterTemperatureSensor,whilecontrollingtheFan MotorrpmandgassuppliedbytheGasControlValve.(Feedforwardfeedback control)
[Operationstop]•Whenthehotwatertapisclosed,theWaterFlowSensordetectsnowaterflow.In responsetothis,PCBclosesalltheGasValvesandtheFanMotorstopsafter runningfor65seconds.(Postpurge)
-22- -23-
In approximately 0.2sec.
In approximately 1min.
Hot water supply normal operation
Supply power (insert power plug into outlet)
Push ON/OFF button
ON indicator lights
Hot water tap, OPEN
Water Flow Sensor detects water flow [over approximately 2.7 Liter/min.]
Water Flow Sensor detects water flow for stop [less approximately 2.2 Liter/min.]
Fan Motor, ON
Fan Motor detects revolution
Ignitor, ONMain Gas Valve, OPEN
Gas Control Valve
Gas Valve 2, OPENGas Valve 1, OPEN
Flame Sensor detects ignition
"In Use” indicator lights
Ignitor stops
Combustion stabilizes.Hot water temperature adjustment become normal.
Each Gas Valve opens or closes, depending on the reguired heating capacity
Hot water tap, Close
Fan Motor stops
OFF (stop of combustion)"In Use” indicator, OFF
With use of remote controller
Operationalflowchart
-24- -25-
3-2 SchematicDiagram
Over Heat Thermostat
SecondaryHeat Exchanger
PrimaryHeat Exchanger
Burner
Gas Valve 3
Flame Rod
Electrode
Fan Motor
Neutralizer
OutgoingTemperature Sensor
IncomingTemperature Sensor
Water Flow Sensor
Water Level Electrode
HotWaterOutlet
DrainOutlet
ColdWaterInlet
GasSupply Inlet
RemoteController
AC240V
PCB
Water Filter
Pressure Relief Valve
Gas Valve 1
Main Gas Valve
Gas Control Valve
Gas Valve 2Water FlowControl Valve
Ignitor
Thermal Fuse
-24- -25-
3-3 Flow Charts
No
No
Yes
No
Yes
Yes
⑥
No
Yes
No
Power supply Cause cleaning
① Initial check all onWater Flow Control
Valve failure651
Turn ON/OFF buttonon remote controller
YesKitchen remotecontroller failure
740
Push ON/OFF buttonon remote controller
Hot waterfaucet Close
Bath/Ensuite remotecontroller failure
750
Remote controllercommunication failure
760
②
PRIORITY' indicationlights on remote controller
PCB failure 700Move Water Flow Control
Value in place Memory PCBunattached
732Hot water temperature is
displayed on remote controller [Alarm] Failure of PCBand Memory PCB
733
Ambient TemperatureSensor failure
341④
Cascade comunicationfailure
735Hot water tap Open
Clogging of Neutralizer 290
Water Flow SensorON at 2.7 L/min
⑤ Integrated heat output58.2 Gcal and over
[Alarm] Replacementof Neutralizer
920
③
Incoming TemperatureSensor failure
311
Outgoing TemperatureSensor failure
321
Initial check all on
Fan Motor ON
⑦ Fan Motor exceeds
1000rpmFan Motor failure 611
False Flame detection 721⑧
Start‐up initialcheck all on Over Heat Thermostat
activates141
Yes
No Yes
No
⑫
NoYes
Yes ⑮
No
No
Yes
⑨ Ignitor ON Fan Motor OFF in
one minuteMain Gas Valve OpenGas Control Valve Open
All Gas Valves CloseFan Motorpost-purge
⑩ Gas Valve 1 Open Gas Control
Valve CloseGas Valve 2 Open"In Use"
indicator OFF Yes "In Use"indicator OFF
⑪ Flame Sensordetects Low Gas Control
Valve CloseFlame loss threetimes and below
All Gas ValvesClose"In Use" indicator lights on
remote controller
Loss of Combustion 121Ignitor OFF
Burner fails to ignite 111
⑬ Proportional control operation(Gas flow, air flow, hot watertemperature and water flow)
Over Heat Thermostatactivates 141
Incoming TemperatureSensor failure 311
Each Gas Valve opens orcloses, depending on therequired heating capacity
Outgoing TemperatureSensor failure 321
Fan Motor failure 611
740
Hot watertap close
Bath/Ensuite remotecontroller failure 750
Remote controllercommunication failure 760
Flame Sensordetects Low
510,511
Yes
Main Gas Valve/Gas Valve 1,2,3
(Alternately) close
PCB failure 700
Cascadecommunication failure 735
No
Flame Sensordetects High
Yes
All Gas Valves CloseGas ControlValve Close
Gas Valve failure
⑭ Safety devices activates
Kitchen remotecontroller failure
-26- -27-
3-4 FaultFindingsandErrorCodeError code
ERRORCODE
ONREMOTECONTROL
CONDITION OF
LED IN PCB
NUMBER OF
FLASHINGPHENOMENON SYMPTOM CAUSE CHECK METHOD CORRECT
VALUEREFERFIGURE
- NOT FLASHING -
NOTHINGSTARTSANDREMOTE’SDISPLAY DOES NOT INDICATE FUSE DEFECT CHECK THE CONTINUITY OF FUSE ON PCB 0Ω Fig.1
NOTHINGSTARTS,ONLYREMOTE’SDISPLAY INDICATES SWITCH ON
WATER INLET FILTER CLOG UP. VISUALCHECKANDCLEANIT.
WATER FLOW SENSOR DEFECT
VISUALCHECK.ASNEXTSTEP,PULLOUTCONNECTOR(4),CHECK FAN MOTOR IS ROTATED WHEN CONNEC-TION WITH TWO PINS OF THE BOTTOM.
Fig.2
111
FLASHING
1 GAS BURNER FAILS TO IGNITE
NOIGNITION,THEN LED STARTS FLASHING AFTER 30SECS.
IGNITOR DEFECT CHECKACVOLTAGEBETWEENBLACKANDBLACKAT CONNECTOR (9) IN IGNITION AC240V Fig.3
BROKEN INSULATOR AT IGNITOR TERMINAL VISUALCHECKOFIGNITORTERMINAL
THERMALFUSEACTIVATED.(BREAKING OF THE WIRE)
CHECK THE CONTINUITY IN TRANSMISSION CONNECTOR (YELLOW) FOR FUSE SIDE. 0Ω Fig.4
GASVALVEDEFECTCHECKFORDCVOLTAGEATCONNECTOR(8)IN IGNITION OR CHECK FOR CONTINUITY IN GAS VALVERESPECTIVELY.
Table1 Fig.5
GASCONTROLVALVEDEFECTCHECKFORDCVOLTAGEATCONNECTOR(4) IN IGNITION OR CHECK FOR CONTINUITY IN GAS VALVERESPECTIVELY.
Table1 Fig.6
LOSS OF GAS SUPPLY CHECK GAS INLET PRESSURE Table2
INGNITES,THENLED STARTS FLASHING AFTER 30SECS.
FLAME ROD INSULATOR FAILURE,BREAKINGORSHORTCIRCUIT
VISUALCHECKOFFLAMERODINSULATION
EARTH CABLE CHECK FOR BREAKING OR LOOSE CONNECTIONS AT TERMINAL.
NOZZLEHOLDER VISUALCHECKOFNOZZLEHOLE’SBLOCKAGE.
721 2 FALSE FLAME DETECTION
LED FLASHES IMMEDIATELY PCB FAILURE EXCHANGE PCB
121 3 LOSS OF COMBUSTION
COMBUSTION STOPS AND LED STARTS FLASHING
LOSS OF GAS SUPPLY CHECK GAS INLET PRESSURE Table2INSUFFICIENT PRESSURE ADJUSTMENT AT MANIFOLD PRESSURE
CHECK FOR MANIFOLD PRESSURE Table2
141 4OVERHEATTHERMOSTAT CUT OFF
COMBUSTION STOPS AND LED STARTS FLASHING
OVERHEATTHERMOSTATCUTOFF DEFECT
CHECK THE CONTINUITY BETWEEN THE TERMINALSOFTHEDEVICE. 0Ω Fig.7
321 5
TEMPERATURE SENSOR WIRE BREAKING(OUTGOING)
LED FLASHES IMMEDIATELY
TEMPERATURE SENSOR WIRE BREAKING
CHECK THE RESISTANCE IN TRANSMISSON CONNECTOR FOR SENSOR SIDE. Table3 Fig.8
001 6 POWER FAILURE DETECTION
COMBUSTION STOPS AND LED STARTS FLASHING IMMEDIATELY
POWER FAILURE OR INTERRUP-TION OCCURS DURING COMBUSTION
CLOSE WATER TAP AND OPEN IT AGAIN.
611 7 FAN MOTOR FAILURE
NOIGNITION,LEDSTARTS FLASHING AFTER 10SECS.
FAN MOTOR DEFECT EXCHANGE FAN MOTOR.
740750
NOT FLASHING - NOTHING OPERATES AND THE
ERROR CODE DISPLAYS IN 1 MINUTE. PCB DEFECT TURNOFFANDON.IFNOTRECOVERY,REPLACEPCB.
740
FLASHING
8
COMMUNICATION FAILURE WITH MAIN REMOTE CONTROLLER NO COMBUSTION
OR COMBUSTION STOPS,COMBUSTION INDICATOR FLASHES IMMEDIATELY
REMOTE CONTROLLER FAILURE
WHEN OPENING HOT WATER TAP WITHOUT CONNECTINGREMOTECONTROLLER,IFNORMALCOMBUSTIONSTARTS,REPLACEREMOTECONTROLLER.750
COMMUNICATION FAILURE WITH BATH/ENSUITEREMOTE CONTROLLER
760 COMMUNICATION FAILURE
WIRE BREAKAGE OF REMOTE CONTROLLERCABLE,SHORT-CIRCUITED
VISUALCHECKOFWIREANDREMOTE CONTROLLER CONNECTIONS
651 9WATER FLOW CONTROLVALVEFAILURE
LED FLASHES IMMEDIATELY
WATERFLOWCONTROLVALVEDEFECT EXCHANGEWATERFLOWCONTROLVALVE
341 11
TEMPERATURE SENSOR WIRE BREAKING (AMBIENT)
TEMPERATURE SENSOR WIRE BREAKING
CHECK THE RESISTANCE IN TRANSMISSION CONNECTOR FOR SENSOR SIDE. Table3
735 15CASCADE COMMUNICATION FAILURE
WIRE BREAKAGE OF CASCADE CABLE VISUALCHECKOFWIREANDPCBCONNECTIONS
CASCADE SET UP MISTAKE CHECKTHESETTINGOFDIPSWITCH2ONPCB
Installa-tion
instruc-tions
510 16 MAINGASVALVEFAILURE GASVALVEDEFECT EXCHANGEGASCONTROLVALVE.
511 17 GASVALVEFAIURE(NOT MAIN)
311 18
TEMPERATURE SENSOR WIRE BREAKING(INCOMING)
TEMPERATURE SENSOR WIRE BREAKING
CHECK THE RESISTANCE IN TRANSMISSON CONNECTOR FOR SENSOR SIDE. Table3 Fig.8
-26- -27-
Displaysoneachremotecontrollerincommunicationfailure.
Case Kitchen Bath EnsuiteKitchenfailure 740 760 760Bathfailure 760 750 760Ensuitefailure 760 760 750PCBfailure 740 750 750
ERRORCODE
ONREMOTECONTROL
CONDITION OF
LED IN PCB
NUMBER OF
FLASHINGPHENOMENON SYMPTOM CAUSE CHECK METHOD CORRECT
VALUEREFERFIGURE
920 FLASHING 20
NEUTRALIZERNEED TO BE REPLACED (WARNING)
- CLOSE TO END-OF-LIFE NEUTRALIZER
REPLACEMEMORYPCBANDNEUTRALIZERATTHESAME TIME Page30
290 FLASHING 21ABNORMAL WATERLEVELINNEUTRALIZER
COMBUSTION STOPS AND LED STARTS FLASHING
CLOGGINGOFNEUTRALIZERREMOVECLOGGINGOFDRAINPIPINGORNEUTRALIZERANDDIRTOFWATERLEVELELECTRODE
InfiniteΩ Fig.9
700 FLASHING 22 PCB FAILURE LED FLASHES IMMEDIATELY PCB DEFECT EXCHANGE PCB. Page29
732 FLASHING 23 MEMORY PCB UNATTACHED
COMBUSTION STOPS AND LED STARTS FLASHING
ATTACHMENT FAILURE OF MEMORY PCB VISUALCHECK
733 FLASHING 24FAILURE OF PCB AND MEMORY PCB
COMBUSTION STOPS AND LED STARTS FLASHING
DEFECT OF PCB AND MEMORY PCB
REPLACEPCB,MEMORYPCBANDNEUTRALIZERAT THE SAME TIME Page30
- LIGHTING UP -
HOT WATER TEMPERATURE CAN NOT BE REACHED PRESET TEMPERA-TURE
PRESSURE OF GAS SUPPLY CHECK GAS INLET PRESSURE(SUFFICIENT GAS INLET PRESSURE AT MAX. COMBUSTION). Table2
WATER INLET FILTER CLOG UP. VISUALCHECKANDCLEANIT.GASCONTROLVALVE CHECK MANIFOLD PRESSURE. Table2TEMPERATURE SENSOR DEFECT(OUTGOING/INCOMING)
CHECK THE RESISTANCE IN TRANSMISSON CONNECTOR FOR SENSOR SIDE. Table3 Fig.8
REMOTE CONTROLLER DEFECT OPERATE WATER HEATER WITHOUT REMOTE CON-TROLLERANDCHECKHOTWATER48°C/60°C/70°C
*ABOVECHECKMETHODISJUSTONLYFORCHECKINGPURPOSE.DONOTUSEJUSTASABOVECHECKINGMETHODINTACTISINNORMALOPERATION.
-28- -29-
Faultfindings
PCB
2
3
4
6
1
10
89
5
PCB
2
6
10
89
5
PCB
2
6
10
89
5
< Fig. 1>Continuity of Fuse
< Fig. 2>Water Flow Sensor
< Fig. 3>Voltage of Ignitor Transformer
< Fig. 5>Voltage or Resistance of Gas Valve Assembly
< Fig. 7>Continuity of Over Heat Thermostat
< Fig. 8>Resistance ofTemperature Sensor
< Fig. 9>Continuity of water level electrode
After pulling out connector No.4 on PCB,connect two pins of the bottom with flat blade screwdriver directly.
5A
OR
Voltage Resistance
Temperature Sensor
SeeTable 3
4unused pin
Connect directly pulling out connector
Connectdirectly
0
BLO
YY(C)
BLG
Y(C)Y
OG
88Pull out
Measure registance with pulling out connector
Measure voltage without pulling out connector
SeeTable 1
PCB
2
3
4
6
1
10
89
5
< Fig. 6>Voltage of Gas Control Valve
Y(C)-GY(C)-OY(C)-BLY(C)-Y
ALLDC12V
< Fig. 4>Continuity of Thermal Fuse
Thermal fuse
0
Over Heat Thermostat
0
9
Measure voltage without pulling out connector
BKBK
AC240V
4GR
GR
DC1.8-16.2V
Measure voltage without pulling out connector
Measure after removing the connector
Infinite
Neutralizer
<Table1>ResistanceofGasValveAssembly
Leadwire Resistance(Ω)Yellow(C)-OrangeGasvalve1 Approx.33Yellow(C)-BlueGasvalve2 Approx.33Yellow(C)-GreenGasvalve3 Approx.33Yellow(C)-YellowMaingasvalve Approx.26Grey-GreyGascontrolvalve Approx.65
<Table3>ResistanceofTemperaturerSensorTemperature
(°C)Resistance(kΩ)(Incoming,Outgoing)
Resistance(kΩ)(Ambient)
10 Approx.15.8 Approx.20.520 Approx.10.4 Approx.12.635 Approx. 5.9 Approx. 8.040 Approx. 4.9 Approx. 5.250 Approx. 3.5 Approx. 3.5
<Table2>Gas Pressure (kPa)
Gastype Gassupplypressure
ManifoldpressureMaximum Minimum
Propane 2.75-7.0 1.20 0.210Natural Gas 1.13-5.0 0.84 0.160
Abbr.ofcolor:Y :Yellow R :Red G :GreenO :Orange BK :Black GR :GreyBL :Blue W :White
-28- -29-
3-5 ReplacementofPCB
Procedure
CAUTION
1. Unplugpowersupplycable.2.RemovethePCB.
(See“RemovingPCB”inpage38)3. RemovetheMemoryPCBfromthe
MemoryPCBconnector.4. TheMemoryPCBinstep3shouldbe
attachedontheMemoryPCBconnectorofthenewPCB.
5. ReplacethenewPCBandinserttheeachconnectortothenewPCB.
6. Plugpowersupplycable.7. Runwatertotheunitandcheckthe
normalcombustion.Then,adjusttheGas.secondarypressure.
ThenewPCBdoesnothavetheMemoryPCB. TheMemoryPCBhasthelife-recordofNeutralizer.TheMemoryPCBmountedontheoriginalPCBshouldbemovedtothenewPCB.Ifnot,theerrorcode“732”(MemoryPCBunattached)isdisplayedontheremotecontrollerandtheunitcannotbeoperated.
Incasethathotwaterisnotsuppliedandtheerrorcode“732”(MemoryPCB unattached)isdisplayed,checkthattheMemoryPCBisattachedcorrectly.Then,unplugpowersupplycableandplugitagain.
Note:-MakesuretounplugpowersupplycablewhentheMemoryPCBisremovedfromthePCBandisattachedonthePCB.ItcancausethedamageofthedataintheMemoryPCB.-ThedataforsettingoftheunitisstoredintheMemoryPCB.Becarefultokeepitfrombeingaffectedbyhumidity,impactorstaticelectricity.
ON
57
61
42
12
83
OFF
ONOFF
PCB
2
11
3
4
6
1
10
89
5
7
Memory PCB connector
New PCB
Attachment
Removed Memory PCB
-30- - 31 -
3-6 ReplacementofNeutralizer
[Replacementofneutralizer]
[ReplacementofMemoryPCB]
1.Unplugpowersupplycable.2.Disconnectthedrainpipeatthebottomofthe
Water Heater.3.Unhooktheleadwires.4.DisconnecttheWaterlevelelectrode2P connector,theAnti-Frostheater2Prelay connectorandtheoutgoingtemperature sensorconnector.
5.PullouttherubberhosefromtheNeutralizerremovingthehoseband.
6.RemovethesetscrewofManifoldAssy.7.PullupandremovetheNeutralizer.8.AttachthenewNeutralizer.9.PutthesetscrewofManifoldAssyandtherubberhosebackintoplace.
1. UnhooktheleadwiresfromthePCBclawandthen,removethesetscrewfixingthePCBcase.2.PullthePCBforward.(It’snotnecessarytoremoveit.)3. RemovetheMemoryPCBfromthePCBandattachthenewMemoryPCB(MC-31)onthePCB.4. PutthePCBbackintoplace.FixthePCBcasewithsetscrewandhangtheleadwires
ontheclaw.5. Plugpowersupplycable.6. Runwatertotheunitandcheckthenormalcombustion.
Note:-MakesuretounplugpowersupplycablewhentheMemoryPCBisremovedfromthePCBandisattachedonthePCB.ItcancausethedamageofthedataintheMemoryPCB.-ThedataforsettingoftheunitisstoredontheMemoryPCB.Becarefultokeepitfrombeingaffectedbyhumidity,impactorstaticelectricity.
Rubber hose
Anti-Frost heater 2P relay connector
Water level electrode 2P connector
Setscrew of Manifold Assy
Procedure
CAUTION
InreplacingtheNeutralizer,theMemoryPCBmustbereplacedatthesametime.TheMemoryPCBhasthelife-recordofNeutralizer.
10.Reconnecttheconnectorsdisconnectedat“Step4’’andhangtheleadwiresonthehookofNeutralizer.
-30- - 31 -
3-7 WiringDiagram
GAS VALVE
TEMPERATURE SENSOR
WATER FLOW CONTROL VALVE
TEMPERATURE SENSOR
FLAME ROD
WATER FLOW SENSOR
FAN MOTOR
(CONTROL)
Y
Y
Y
Y
YY Y
GG G
DIP SWITCH 1
DIP SWITCH 2
ON
57
61
42
12
83
OFF
ONOFF
ANTI-FROST HEATERS
AC240V
PCB
FUSE(250V T5A)
2
11
3
4
6
1
YY
REMOTECONTROLLER
BL
G
O
Y
BKBKBK
BK
(AMBIENT TEMP.)
BLBKP
WOG
RY
W
BLBL W
W
TEMPERATURE SENSORWW W
W(OUTGOING TEMP.)
(INCOMING TEMP.)
BK
GRGR
R
W
BKBK
RY
WBL
GAS VOLUME ADJUSTING BUTTON(DOWN) GAS VOLUME ADJUSTING BUTTON (UP)
COMBUSTION INDICATOR
BKBK
: White: Black: Brown: Blue: Grey: Light Blue: Orange: Red: Green: Purple: Yellow
10
89
WBKBRBLGRLBORGPY
GC-172
5W
MEMORY PCB
7
W
WW
W
G
LBBR
G/Y
GAS VALVE 3
GAS VALVE 2
GAS VALVE 1
GAS VALVE
THERMAL FUSE
THERMOSTAT
WATER LEVEL ELECTRODE
(OVER HEAT)
(MAIN)
ANTI-FROST HEATER
IGNITOR
-32- - 33 -
3-8 CascadeFlowCharts
Master unit ON
The other unit ON
All units Stop
The other unit OFF
Slave unit ON
Hot water tap Open
Cumulative amount of combustion,Master unit < Slave unit ?
Required heat capacity,shortage ?
Hot water tap Close ?
-32- - 33 -
3-9 Manifold Gas Setting Procedure1. Preparation
(1)Makesuretheapplianceisnotinoperation.Then,removethescrewfromthepressurecheckhole.
(2)Connectthehoseofthemanometertothepressurecheckhole.2. Adjustingnozzlepressuresettings<Minimumpressureshouldbeset
beforesettingthemaximumpressure.>(1)Makesurethat“DipSwitch”No.1onPCBissettothepositionfortheappropriate
gastype.Ifinstallationisacascadetype,changethedipswitchblockNo.2toallOFFandremovewiresfromRemotecontrollerConnectionTerminals.
(2) Afterignitingforcombustionbyopeningthehotwatersupplyvalve,set“DipSwitch”No.5toONpositiontosetthecombustionataminimumcapacitylevel.BypressingtheGasVolumeAdjustingButtonunderthe“RemoteController ConnectionTerminals”,setthegasamountfortheminimumcapacitylevel.
(3) Shutthehotwatersupplyvalve.Openthevalveagainforcombustion.Repeatthesteps(2)tocheckthatthesettingsarecorrect.
(4)Withthecombustiongoingon,set“DipSwitch”No.6toONpositiontosetthecombustionatamaximumcapacitylevel.Atthistime,asubstantialamountofwatershouldbesupplied.(Asthemaximumcapacityisforced,ifthewaterinlet temperatureishigh,theheatedwatermayreachboilingpoint.)
(5) SetthegasamountforthemaximumcapacitylevelbypressingtheGasVolumeAdjustingButton.
(6) Shutthehotwatersupplyvalve.Openthevalveagainforcombustion.Repeatthesteps(5)tocheckthatthesettingsarecorrect.
(7) Set“DipSwitch”No.5and6toOFF.(8) Shutthehotwatersupplyvalvetostopcombustion.Disconnecttherubberhose
ofthemanometerfromthepressurecheckhole.Sealtheholebyinstallingandtighteningthescrew.Aftertighteningthescrew,makesurethereisnogasleak.
(9) Intheeventthatisconnectedtocascadetype,followthe“CASCADESETUP”intheinstallationinstructions.(page21)
(10)ForminimumandmaximummanifoldpressurespleaserefertoGasPressureTable.
Nozzle pressure
Rubber TubingThreaded Hose Fitting
Dip Switch
Gas Volume Adjusting Button (UP)
Remote ControllerConnection Terminals
Gas Volume Adjusting Button (DOWN)
Gas Pressure (kPa)
Gastype Gassupplypressure
ManifoldpressureMaximum Minimum
Propane 2.75-7.0 1.20 0.210Natural Gas 1.13-5.0 0.84 0.160
- 34 - - 35 -
3-10CombustionSpecification,VariousCombinationSetting
Combustionspecifications
Manifold Assy
Gas type mark”A” = Propane”G” = Natural Gas
Gastype
Gasconsumption[MJ/h] ManifoldAssy
GastypeDipSwitchon PCB
Maximum Gastypemark
Nozzlediameter(mm)
Rich[Topside]
Lean[Bottomside]
Propane173
A Φ0.70×17pcs Φ1.00×17pcs DipSw.No.1:OFF
Natural Gas G Φ1.00×17pcs Φ1.50×17pcs DipSw.No.1:ON
- 34 - - 35 -
ComfortDipSwitchSettingPattern(VariousCombinationSetting)<DipSwitch>(TheillustratedswitchsettingsshowthefactorysettingsforthePropaneand60°Cpreset.)
•Changinghotwatertemperature(whentheremotecontrollerisnotconnected,thehotwatertemperaturesettingcanbechangedbyselectingoneofthesesettings.)
32
14
OFF
76
58
To switch gas type (Propane or Natural Gas)
To change hot water temperature (without remote controller)
To fix to the maximum combustion
To fix to the minimum combustion
*Settingchangeafterthepoweristurnedonisineffective.*Thesystemrecognizesthesettingsandmakesthemeffectivebeforepoweristurned
on.*Whentheremotecontrollerisconnected,theDipSWsettingsbecomeineffective.*Instructionsfordeliverytemperatureadjustmentfor50°Cpresetmodelarelocatedin thepocketinsidetheappliancefrontcover.
•SwitchinggastypeDipSWsettingforgastype
ApplicablegastypeNo. 1 OFF PropaneON Natural Gas
DipSWsettingsfordifferenttemperatureTemperature(°C)
No.2 No. 3 No. 4OFF ON OFF 48OFF OFF OFF 60OFF OFF ON 70
- 36 - - 37 -
DeliveryTemperatureAdjustmentfor50°CPresetModel
ThisinstructionmustbereadinconjunctionwiththeOperating&Installationinstructionsandthecautionsheet“Instructionsforunitssuppliedsetat50°CtocomplywithAS3498”whicharesuppliedwiththeappliance.
Thisinstructionappliesonlytoapplianceslabelled“50°CPreset”onthefrontcover.
“50°Cpreset”appliancesare“FactorySet”todeliveramaximumtemperaturenot exceeding50°C.However,theyhaveanincrementaladjustmentmechanismthatallowstheinstallertoincreasetheappliancedeliverytemperatureincrementallyfromthe“FactorySet”valuetotemperaturesexceeding50°C.Thisisintendedtoenablecompensationfortemperaturelossesinthepipeworkbetweenthewaterheaterandanyoutletsandachievetherequiredtemperatureattheoutlet.Thisinstructioncontainstheprocedurestepsforcarryingoutsuchadjustment.
Measurethemaximumhotwatertemperaturefromthesanitaryfixtureusedprimarilyforthepurposesofpersonalhygienethatisclosesttothehotwaterheater(forexample,ashoweroutletinthebathroomclosesttothewaterheater)asfollows.1. Unplugpowersupplycabletotheunit.2.Moveuponenotchondipswitchfromtheexistingstep.(Factorypresetmodeis
“FACTORYDEFAULT”.SeeTable1DipSwitchsetting(page37))3. Plugpowersupplycabletotheunit.4. Openthetap.Whenflowrateandtemperaturebecomestable,measurethestabilised
hotwatertemperature.(Itshouldbe48°C)5. Ifthetemperatureislessthantheappropriatetemperature(referto4),returnto1and
adjustagain.
Application
Background
ProcedureSteps-DeliveryTemperatureAdjustment
- 36 - - 37 -
Table 1 Dip Switch Setting
•Ensurebuildingoccupantsdonothaveaccesstoanyhotwateroutletsduringthis procedure.
•IfthehotwatertemperaturefromANYoutletsusedprimarilyforthepurposesofpersonalhygieneexceed48°Caftertemperatureadjustmentinstephasbeenperformed,checkyourworkandrepeatthetemperaturedeliveryadjustmentprocedureasrequired. Temperaturesexceeding48°Cfromanyoutletsprimarilyusedforthepurposesof personalhygienedonotcomplywithAS3500andmaycontravenelocalregulations.
Foragiveninstallation,temperaturelossistypicallygreatestinwinterwhenambientairandwatertemperaturesarelowest.Conversely,temperaturelossistypicallylowestinsummerwhentheseambienttemperaturesarehighest.Itfollowsthatthedelivery temperatureofwaterflowingthroughoutletsistypicallyhigherinsummerthanitisinwinter.Theinstalleristotakeintoconsiderationtheeffectsoftheseseasonalvariationsinambienttemperatureswhencarryingouttemperatureadjustments.
Guidance Note for Table 1 “Dip Switch Setting”
FACTORYDEFAULT STEP1
Lo Hi
12345678
OFF ON
STEP2 STEP3 STEP4
Temperatureadjustmentof hot watersupply
5
76
1
4
2
8
3
PCB
- 38 - - 39 -
Procedure Illustration
- 38 -
3-11Disassembling/AssemblingParts
Whentheunitisdisassembledor assembled,turnoffthepoweranddrainwater.
Water FilterPressureReliefValve
(2)Disconnecttheconnectors(9pcs)fromthePCB.
(3)Ifremotecontrollersareconnected, disconnecttheremotecontrollercables.
RemovingPCB(1)RemovethesetscrewfixingthePCB
caseandleadwiresfromthePCBclaw. ToremovethehookpartofthePCBcasefromthebottompanel,liftthecaseupslightlyandpullitout.
Connectors
PCBcasesetscrew
Hookpart
PCBclaw
- 38 - - 39 -
Procedure Illustration
- 39 -
RemovingNeutralizer.(1)Disconnectthedrainpipeatthebottom
oftheWaterHeater.
(2)Unhooktheleadwires.
(3)DisconnectWaterLevelElectrode2P connector,Anti-FrostHeater2Prelay connectorandOutgoingTemperatureSensorconnector.
(4)Pullouttherubberhosefromthe Neutralizerremovingtheband.
(5)RemovethesetscrewofManifoldAssy.
(6)PullupandremovetheNeutralizer.
Band
Hook
Setscrew
Connectors
-40- - 41 -
Procedure Illustration
-40-
RemovingOverHeatThermostat(1)DisconnecttheOverHeatThermostat
connectors(2pcs).
(2)PulltheOverHeatThermostatforward.
RemovingWaterFlowContorolValve.(1)RemovethesetscrewfixingthePCB
case.Liftthecaseupandpullitout.
(2)DisconnectWaterFlowContorolValve8Pconnector(onPCBside),WaterFlowSensor3PrelayconnectorandIncomingTemperatureSensorconnector. WaterFlowSensor
relayconnector
IncommingTemperatureSensorconnector
Quick-fasteners
WaterFlowControlValve
OverHeatThermostat
WaterFlowContorolValveconnector
(3)Removethe2quick-fastenersandtakeoutWaterFlowContorolValve.
-40- - 41 -
Procedure Illustration
- 41 -
RemovingIgnitor(1)Disconnectthehigh-voltagecord.
RemovethesetscrewretainingtheIgnitorfromManifoldAssy. (ScrewwithsteelwasherisusedforIgnitorearthing.)
(2)PullouttheIgnitor.
(3)DisconnecttheIgnitor2Pconnector.
(4)RemovethesetscrewretainingtheIgnitor.
(Attention) WheninsertingtheconnectortotheIgnitor, markingshouldfacedownwardliketheillustration. Ifreverseside,itcanbedisconnected.
High-voltagecord
Screwwithsteelwasher
Ignitorsetscrew
Screwwithsteelwasher(earthingplateside)
Ignitorconnector
marking( downward)
-42- - 43 -
Procedure Illustration
-42-
RemovingManifoldAssy(1)DisconnectFlameRodconnector.
(2)RemoveIgnitor. (seepreviousstep)
(3)RemovethesetscrewfixingthePCBcase.Liftthecaseupandpullitout.
(4)Removethesetscrewsfixingthe ManifoldAssy(M4x7pcs,M4withwasherx3pcs).
(5)PulltheconnectoroftheGasValve3.
RemovingGasControlValve(1)RemoveManifoldAssy.
(seepreviousstep)
(2)RemovesetscrewofPowercableclamp.
(3)Removesetscrews(4pcs).
SetscrewsM4withwasherx3pcs
RemovethesetscrewsofManifoldAssy
M4x7pcs
ConnectoroftheGasValve3
FlameRodconnector
GasControlValvesetscrews(4pcs)
Powercableclamp
-42- - 43 -
Procedure Illustration
- 43 -
(4)PulltheGasControlValveoutand disconnectfromtheGasValves(4pcs)andremovethemasoneunit.
(Attention) Whenconnecting,thenumberof connectorsshouldmatchwiththeoneofvalvesmarkedonManifoldAssy.
GasValveconnectors
RemovingFanMotor(1)RemoveNeutralizer.
(seepreviousstep)
(2)RemovethesetscrewfixingthePCBcase.Liftthecaseupandpullitout.
(3)DisconnecttheconnectorforFanMotorfromthePCB.
(4)Removethesetscrews(3pcs)fixingtheFanMotortopullitoutforward.
FanMotorsetscrews(3pcs)
FanMotorconnector
NumberofValves
NumberofConnectors
- 44 - - 45 -
Procedure Illustration
- 44 -
RemovingElectrodeandFlameRod(1)Disconnecthigh-voltagecordandFlame
Rodconnector.
(2)Removesetscrews(2pcs)fixingtheElectrodeholdertopulltheholderout.
Electrodeholdersetscrews(2pcs)
FlameRodconnector
Electrode
High-voltagecord
RemovingHeatExchangerAssy.(1)RemoveNeutralizerandManifoldAssy.
(seepreviousstep)(2)Removesetscrews(2pcs)fixingthe
combustionchamber.(3)RemovethesetscrewfixingthePCB
case.Liftthecaseupandpullitout.
(4)Disconnectthefollowingconnectors:1. ThermalFuse(front)2Prelay
connector.2.Anti-FrostHeaters2Pconnectorfrom
thePCB.3. FanMotor4Pconnectorfromthe
PCB.4. OverHeatThermostatconnectors(2
pcs)andotherconnecteditems.
Combustionchambersetscrews(2pcs)
OverHeatThermostatconnectors(2pcs)
ThermalFuserelayconnector
- 44 - - 45 -
Procedure Illustration
- 45 -
(5)Removesetscrews(2pcs)retainingthehotwateroutletpipe.
(6)Removethe2quick-fastenersand setscrewfixingtheAnti-FrostHeater.
(7)Removesetscrews(2pcs)retainingtheHeatExchangerAssy.
(8)PulltheHeatExchangerAssyforwardtotake it out.
Note:Ifanygasketsorsealsaredamagedortornduringdisassembling,theymustbereplaced.
HeatExchangerAssysetscrews(2pcs)
Anti-FrostHeatersetscrew
Hotwateroutletpipesetscrews(2pcs)
quick-fasteners
- 46 - - 47 -
3-12 Exploded View
B
ED
E
B
A
G
F
810
11
7
14
10
10
3
5
4
216
17
6
12
9
10
9
13
1
F
C
5
7
15
1
4
16
G
*1
*2
*1
*1
*1 Screw with steel washer
*2 Special earth Screw with projections
*3 Memory PCB
D
10
*3
A
C
- 46 - - 47 -
3-13 Parts List
GA-16(1)
No. PARTS NAME
1 PCB(Natural Gas)PCB(Propane)
2 ManifoldAssy(NaturalGas)ManifoldAssy(Propane)
3 GasControlValve4 Electrode5 FlameRod6 HeatExchangerAssy7 OverHeatThermostat8 Fan Motor
No. PARTS NAME9 TemperatureSensor10 Anti-Frost Heaters11 Ignitor12 PressureReliefValve13 WaterFlowControlValve(withSensor)14 Water Filter15 AmbientTemperatureSensor16 NeutralizerAssy*17 Anti-FrostHeaterforNeutralizer
*Forspareparts,theNeutralizerAssyincludestheMemoryPCB.