SERVICE MANUAL - Reece Group

GAS CONTINUOUS FLOWWATER HEATERS

(Residential Outdoor Unit) TO BE USED BY A LICENSEDPLUMBER ONLY

SERVICE MANUALModel:26NG50C/26LP50C

26NG60C/26LP60C

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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

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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

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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

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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

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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.)

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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.

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•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




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•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

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•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.

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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.

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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


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)


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)



-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


CLOGGINGOFNEUTRALIZERREMOVECLOGGINGOFDRAINPIPINGORNEUTRALIZERANDDIRTOFWATERLEVELELECTRODE

InfiniteΩ Fig.9

700 FLASHING 22 PCB FAILURE LED FLASHES IMMEDIATELY PCB DEFECT EXCHANGE PCB. Page29

732 FLASHING 23 MEMORY PCB UNATTACHED


ATTACHMENT FAILURE OF MEMORY PCB VISUALCHECK

733 FLASHING 24FAILURE OF PCB AND MEMORY PCB


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)


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


BKBK

AC240V

4GR

GR

DC1.8-16.2V


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 -


- 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 -


-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 -


- 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 -


-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 -


- 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 -


- 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 -


- 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.

Documents

SERVICE MANUAL - Reece Group