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Maintenance sheet 68A166

B. Error codes031: Incorrect DIPswitch setting ・Check the DIPswitch settings on the PCB. Refer to Section D.

101: Warning for the “991” error code ・Check the gas type of the house (and/or the bulding). ・Check if there is any blockage in the intake air and/or exhaust. Refer to the “Vent termination clearances” of the installation manual. ・If the water heater is installed as a direct-vent system, check whether there is enough distance between the intake air terminal and the exhaust terminal. Refer to the “Vent termination clearances” of the installation manual. ・Check if the total vent length. Refer to the "Venting instructions" of the Installation manual. ・Check the altitude/elevation of area of where the water heater installed. Refer to the “High-altitude function” of the Section D. And change the DIPswitch settings. ・Check if there is grease and/or dirt in the burner (Part #101) and the fan motor (Part #103), especially if the water heater has been installed in a contaminated area. ・Check if there is dust and lint in heat exchanger. ・Check the manifold pressure of the water heater. Refer to installation manual.111: Ignition failure 1. Check gas supply and inlet gas pressure. 2. Check if the Hi-limit switch (Part #412) is properly functioning. 3. Check for connection/breakage of wires (Part #413, 708, 709, 710, 712), and/or soot on the flame rod (Part #108). And then if O.H.C.F (Part #413) is breakage, Consult the manufacturer. 4. Check if there is a buzzing spark ignition sound coming from the burner (Part #101) when water heater prepares for combustion. 5. Listen for the double “clunk” sound coming from the gas valve assembly (Part #102) when water heater goes into combustion. 6. (Only no sparking and/or kick sound) Check voltage on each wire to gas valves assembly (Part #102) and/or the igniter (Part #711). Refer to the “Appendix A” in Section C. *No sparking sound >>>>> Refer to the #1 at “Appendix A” in Section C. *No kick sound >>>>> Refer to the #2 at “Appendix A” in Section C. 7. Check if there is leaking from heat exchanger (Part #401) 8. Check if there is dust and lint in nozzles of the manifold (Part #102). 9. Check current on the flame rod (Part #108). Refer to the #3 at “Appendix A” in Section C. 121: Loss of flame 1. Check gas supply and inlet gas pressure. 2. Check if the Hi-limit switch (Part #412) is properly functioning. 3. Check for connection/breakage of wires (Part #413, 708, 709, 712), burn marks on the computer board (Part #701), and/or soot on the flame rod (Part #108). And then if O.H.C.F (Part #413) is breakage, Consult the manufacturer. 4. Check if there is leakage from heat exchanger (Part #401). 5. Check if there is dust and lint in nozzles of the manifold (Part #102). 6. Check current on the flame rod (Part #108). Refer to the #3 at “Appendix A” in Section C.311,321,331,341*: Disconnected/short-circuited thermistor ・Check for connection/breakage of wires and/or debris on thermistor (Part #407, 408, 411, 715, 718). ・Check thermistor resistance. Refer to the “Appendix D” in Section C.391: Air-fuel Ratio Rod failure ・Check for connection/breakage of wires (Part #709) and/or soot on the frame rod (Part #108).441: Flow sensor failure (Only Easy-Link system) ・Check for connection/breakage of wires and/or debris on the flow sensor impeller (Part #402).

510,551: Abnormal Main and Solenoid Gas Valve ・Check for connection/breakage of wires (Part #708) and/or burn marks on the computer board (Part #701). ・Reset power supply of the water heater. ・ Check voltage of each valve on the gas valves assembly (Part #102). Refer to the “Appendix C” in Section C.611: Fan motor fault ・Check for connection/breakage of wires, dust buildup in the fan motor (Part #103) and/or burn marks on the computer board (Part #701). ・Check for frozen/corrosion of connectors of the fan motor (Part #103). ・Check voltage between blue wire and each wire of the fan motor (Part #103). Refer to the “Appendix B” in Section C.651: Flow adjustment valve fault (Only Easy-Link system) ・Inspect the flow adjustment valve (Part #402), for connection/breakage of wires, locked motor drive due to scale buildup, and/or water leakage. ・Check voltage between black wire and red wire. Refer to the “Appendix F” in Section C.661: Bypass valve fault ・Inspect the bypass valve (Part #403), for connection/breakage of wires, locked motor drive due to scale buildup, and/or water leakage. ・Check voltage between brown wire and red wire. Refer to the “Appendix F” in Section C.701,711: Computer board fault ・Check for connection/breakage of wires (Part #714), and check resistance between white wire and red wire. Refer to the “Appendix A” in Section C.721: False flame detection 1. Clean the flame rod (Part #108). 2. Check if there is leaking from heat exchanger (Part #401).741: Miscommunication between water heater and remote controller 1. Check the model type of the remote controller. Model No. 9008172005 (TM-RE40) is the correct one. 2. Inspect the connections between the water heater and remote controller. Refer to the “Remote controller connections” of the Installation manual. 3. Check the power supply of the water heater. 4. If this error code appears only the green LED on the PCB (Part #701), check the voltage on the remote controller terminal on the PCB. Refer to the “Appendix E” in Section C. 5. If this error code appears only remote controller, replace the PCB (Part #701). 6. If this error code appears both the PCB (Part #701) and the remote controller, replace the remote controller.751*: Miscommunication between water heater and temperature controller 1. Check the power supply of the water heater. 2. If this error code appears only the green LED on the PCB (Part #701), check the voltage on the remote controller terminal on the PCB. Refer to the “Appendix E” in Section C. 3. If this error code appears only temperature controller, replace the PCB (Part #701). 4. If this error code appears both the PCB (Part #701) and the temperature controller, replace the temperature controller.761: Miscommunication between Parent unit and Child units for Easy-link system ・Check if the connections between the parent unit and the child units are correct. Refer to “Easy-Link system” section in the Installation manual.941*: Abnormal exhaust temperature (Only 540 (T-H3) Direct Vent Indoor) ・Check for connection/breakage of wires, dust buildup in the fan motor (Part #103) and/or burn marks on the computer board (Part #701). ・Check exhaust thermistor resistance. Refer to the "Appendix D" in Section C.991: Imperfect combustion ・Refer to the “101” error code in this section.

C. Wiring Diagram and check point of the Water heater

Appendix A (For error code 111)

Check these points during ignition stage. # 1. Refer to check point “B” on the wiring diagram above. Check voltage between purple wires. (Normal: 108 to 132 VAC) This Check point is normal? Yes >> Replace the igniter. (Part #711) No >> Go to Next. # 2. Refer to check point “C” and “H1” on the wiring diagram above. Check the voltages below: C: Between blue wire and light blue wire (#3). (Normal: 93 to 120 VDC) C: Between blue wire and orange wire (#53). (Normal: 93 to 120 VDC) H1: Check the voltage between white wire and red wire. (Normal: 1 to 15 VDC) These check points are normal? Yes >> Replace the gas valves assembly. (Part #102) No >> Replace the PCB. (Part #701) # 3. Check current thought the yellow flame rod wire (Part #709). (Normal: more than 5 μA) This check point is normal during operation? Yes >> Replace the PCB. (Part #701) No >> Replace the flame rod. (Part #108)

Appendix B (For error code 611) Refer to check point “G” in the diagram to the left and the following.　• Check voltage between red wire and blue wire. (Normal: 132 to 192 VDC)　• Check voltage between yellow wire and blue wire. (Normal: 13 to 17 VDC)　• Check voltage between orange wire and blue wire. (Normal: 2.0 to 6.5 VDC) All check points are normal? Yes >> Replace the fan motor. (Part #103) No >> Replace the PCB. (Part #701)

Appendix C (For error code 510 and 551) Refer to check point “C” in the diagram to the left and followings. Check voltage on the each valve on the gas valves assembly.　• Between blue wire and light blue wire (#3). (Normal: 93 to 120 VDC)　• Between blue wire and green wire (#9). (Normal: 93 to 120 VDC)　• Between blue wire and orange wire (#53). (Normal: 93 to 120 VDC)　• Between blue wire and red wire (#73). (Normal: 93 to 120 VDC) All check points are normal? Yes >> Replace the gas valves assembly. (Part #102) No >> Replace the PCB. (Part #701)

Appendix D (For error code 311, 321, 331, 341, and 941)　• Outlet thermistor (Find the marking of No.113 on the connector) Check point “E1”　• Inlet thermistor (Find the marking of No.42 on the connector) Check point “E2”　• Heat exchanger thermistor (Find the marking of No.12 on the connector) Check point “E3”　Check resistance between black wire and black wire.

• Exhaust thermistor Check point “K1”　Check resistance between white wire and white wire.

All check points are normal? Yes >> Replace the PCB. (Part #701) No >> Replace the wrong thermistor. (Part #407, 408, 411, 718)

Appendix E (For error code 741 and 751) Error code 741: Refer to check point “F” on the wiring diagram above. Error code 751 : Refer to check point “L” on the wiring diagram above. Check voltage on the remote controller and/or temperature controller on the PCB. • Between black wire and white wire. (Normal: 11 to 25 VDC) This check point is normal? Yes >> Replace the remote controller and/or temperature controller. No >> Replace the PCB. (Part #701)

If the error code is indicated on green LED (Refer to the Section C) on the PCB (Part #701) of the water heater (and/or the remote controller), refer to Section B.<< It takes long time to get hot water at the fixtures >> ・The time it takes to deliver hot water from the water heater to your fixtures depends on the length of piping between the two. The longer the distance or the bigger the pipes, the longer it will take to get hot water. ・If you would like to receive hot water to your fixtures quicker, you may want to consider a hot water recirculation system.<< The water is not hot enough or turns cold and stays cold >> ・Compare the flow and temperature. Refer to the “Output temperature chart” of the installation manual. ・Check cross plumbing between cold water lines and hot water lines. ・Check if the gas supply valve fully open, the gas line sized properly and the gas supplies pressure enough. Refer to the “Gas supply and gas pipe sizing” of the installation manual. ・Check the set temperature, and change the set temperature with the remote controller or the DIPswitch setting. Refer to Section D. ・Refer to “Water circuit” in this section.<<The water is too hot>> ・Check the set temperature, lower setting temperature.<<The hot water is not available when a fixture is opened>> ・Refer to the “Power supply circuit” and “Water circuit” in this section.<<Fluctuation in hot water temperature>> ・Check if the filter on the cold water inlet cleaned. (Part #406) ・Check if the gas line sized properly and the supply gas pressure sufficient. ・Check for cross connection between cold water lines and hot water lines. ・Refer to “Water circuit” in this section.<<Unit does not ignite when water goes through the water heater>> ・Refer to the “Power supply circuit” and “Water circuit” in this section. ・If you use the remote controller, turn the power button on and then the STAND BY LED will light up. ・Check if the filter on the cold water inlet cleaned. (Part #406) ・Refer to “Water circuit” in this section.

A. Troubleshooting <<The fan motor still spinning after operation has stopped>> ・This is normal. After operation has stopped, the fan motor keeps running from 15 to 70 seconds in order to re-ignite quickly, as well as purge all the exhaust gas out of the flue.<<Abnormal sound from water heater>> ・An abnormal sound from the water heaters is caused by not enough air supply or wrong installations. The water heater needs more combustion air. Refer to the “101” error code in the section B.<<Power supply circuit>> 1. If the remote controller installed, press the “ON/OFF” button of the remote controller, and make sure that the STAND BY LED next to the “ON/OFF” button of the remote controller is lit. Restart the water heater. 2. Check if that the green LED on the PCB (Part #701) of the water heater is lit. If so, the power supply circuit of the water heater is under normal condition. Next, refer to the “Water circuit” in this section. 3. Check the fuse on the surge box (Part #703), and if it has a brown spot, need to replace it. 4. Check the power supply, and make sure that the water heater has 120 VAC. 5. If the green LED on the PCB (Part #701) isn’t lit, some electrical parts can be broken. Consult the manufacturer.<<Water circuit>> 1. If you set the remote controller, turn the power button on and then the STAND BY LED will light up. 2. Open all hot water faucets, and make sure that there is enough water flow. This water heater needs at least 0.5 GPM water flow (at the default set temperature) to operate. 3. Check for reverse connection and cross connection. 4. Check if the filter on the cold water inlet cleaned. (Part #406) 5. Check if there is no debris or obstruction on the fixtures. 6. Check if water ways in the water heater are frozen. If so, unfreeze them. And refer to installation manual to protect your water heater from freezing. 7. Check if the inlet water pressure is higher than 40 psi. And if it’s lower than 40 psi, need to increase the pressure. 8. Check for connections and breakage of wires (Part #402). 9. Check if the motor drive of the flow adjustment valve (Part #402) is locked due to scale buildup, and/or water leakage. Consult the manufacturer.

Temperature°F 50 59 68 77 86 95

°C 10 15 20 25 30 35

Resistance kΩ 15.4 12.6 10.3 8.5 7.0 5.9

ATH3W: WHITER: RED

BK: BLACK

P: PURPLE

LB: LIGHT BLUEBL: BLUE

G: GREENY: YELLOW

O: ORANGE BR: BROWN

Temperature°F 50 59 68 77 86 95

°C 10 15 20 25 30 35

Resistance kΩ 19.5 15.9 13.0 10.7 8.9 7.4

D. DIPswitch Settings on the computer board of the water heater

<Lower bank of DIPswitches>

Temperature set120 °F (49 °C)

DEFAULT

140 °F (60 °C)

OFF

ON 1 2 3 4 5 6

OFF

ON 1 2 3 4 5 62 3 4 5 6

Easy-Link system

Parent Unit

Child Unit(DEFAULT)

OFF

ON 1 2 3 4 5 6

OFF

ON 1 2 3 4 5 6

Single unit is the same as the child unit.

Lower bank

Upper bank

Appendix F (For error code 651 and 661) Error code 651 : Refer to check point “J” on the wiring diagram above. Check voltage between black wire and red wire. (Normal: 7 to 16 VDC) Error code 661 : Refer to check point “J1” on the wiring diagram above. Check voltage between brown wire and red wire. (Normal: 3 to 11 VDC) This check point is normal? Yes >> Error code 651: Replace the Flow adjustment valve. (Part #402) / Error code 661: Replace the Bypass valve. (Part #403) No >> Replace the PCB. (Part #701)

High-altitude functionIndoor models Outdoor models

DEFAULT DEFAULT

Up to 2,500 ft Up to 2,000 ft



Over 10,100 ft: Over 6,000 ft:Consult themanufacturer

FM speed is increased automatically.

OFF

ON 1 2 3 4 5 6

OFF

ON 1 2 3 4 5 6

OFF

ON 1 2 3 4 5 6

OFF

ON 1 2 3 4 5 6

OFF

ON 1 2 3 4 5 6

OFF

ON 1 2 3 4 5 6

OFF

ON 1 2 3 4 5 6

OFF

ON 1 2 3 4 5 6

OFF

ON 1 2 3 4 5 6

*The 341, 751 and 941 error codes are applied to the 540 (T-H3) Direct Vent Indoor model only.

<Upper bank of DIPswitches>

Locate the bank of DIPswitches at the bottom left of the computer board of the unit.Change the DIPswitch settings when the power supply is turned off.The dark square is the direction the DIPswitch should be set to. DEFAULT is the factory setting.

C

87

65

43

21 ON

65

43

21 ON

RW

G Y

PCB

W

120 VACG

Ground

SWGround

BKWG BK

W

Surge box

7353

93

BLBL

RBKRW BK

BKBK

BKBKBK

WBK

WBK

Hi-limit switch for exhaust

Exhaust thermistorWW W

W

HeaterY

Y

Thermostat

BK

O

Ground

Flame rod

AFR rod

BKWVent Indoor

Only

540 Direct

W BLR BK Temperature controller

BK

BKW

MAX buttonMIN button

Increase buttonDecrease button

Green LED

DIPswitches

Bypass Vavle

R

W

BR

YBL

GasPropor-tional Valve

RY O

BL

WFM

IGIgniter rod PP

exchanger Heatthermistor Inlet thermistorOutlet thermistor

Remote controller

Parent

12

FlowSensor

FlowAdjust- ment

Valve

HeaterHeater

540 Outdoor Only

Heater

Y

YHeater

Y

Y

HeaterHeater

540 Direct Vent Indoor Only

Hi-swichlimit

O.H.C.F

MV

SV1

SV2

SV3

BLBL BL

BL

LBG O

R

BL

Vent Indoor Only

540 Direct

A1A2

B1

GA

B

C2C1

H2

I

F

J

E1E2E3

H1

K1K2

J1D1D2L

Set DIPswitches shown in the table above depending on the vent length.

Vent settings (Direct vent Indoor models only)

3" ventings 5 to 20 ft (DEFAULT) 21 to 40 ft 41 to 70 ft

4" ventings 5 to 50 ft (DEFAULT) 51 to 100 ft N/A

OFF

ON 1 2 3 4 5 6 7 8

OFF

ON 1 2 3 4 5 6 7 8

OFF

ON 1 2 3 4 5 6 7 8

*Factory setting

Gas type*

Propane

Natural Gas

OFF

ON 1 2 3 4 5

OFF

ON 1 2 3 4 5

Model type*Direct ventIndoor model

Outdoor model

OFF

ON 1 2 3 4 5 6

OFF

ON 1 2 3 4 5 6

E. Components Diagram / Parts List

Case assembly

Item # Part # Description540 models T-H3 models

001 N/AN/A

EK159EK164

Case assembly for Indoor modelsCase assembly for Outdoor models

002 319143-507319143-508

EK158EK174

Front cover for Indoor modelsFront cover for Outdoor models

003004005006007

319143-509N/A

319143-510319143-511319143-512

EK170EK162EK190EK171EK161

Intake air port assemblyBracket

Junction boxPower suuply code assembly

Back guard panel008009

319143-513319143-018

EK160EKH23

Chamber fixing plateCondensate drain port

050051052053054

319143-025319143-325319143-026319143-060319143-326

EW000EW001EW002EW003EW004

Screw M4×12 (W/Washer)Screw M4×10 (W/Washer)

Screw M4×10 (Coated)Screw M4x10

Hex head screw M4×12 (W/Washer)055056057058059

319143-063N/A

319143-201319143-087319143-328

EW005EW018EKK31EW00AEW009

Hex head screw M4x8Pan screw M4x20

Tap tight screw M4x12 FEZNScrew M3x6Screw M4x6

060061062063064065

319143-438N/A

319143-059319143-048

N/A319143-330

EKK37EK191

EW00DEM167EK230EW00B

Screw M4x12Screw M3x6Screw M4x8

Wire clamp 60Screw M4x10

Screw M3x6 SUS3101102

319143-514319143-515319143-516

EK192EK181EK182

Burner assemblyManifold with gas valve assembly LP Manifold with gas valve assembly NA

Item # Part # Description540 models T-H3 models

103 319143-443319143-043

EK109EKK25

Fan motor for Indoor modelsFan motor for Outdoor models

104105106107108

319143-031319143-282319143-033319143-034319143-517

EKK2XEM381EKK2VEKK2WEK193

Burner gasketFan damper for Indoor models

Burner windowRod holder gasket

Flame rod109110111112

319143-037319143-036319143-038319143-518319143-519

EKK0FEKK32EKN61EK183EK169

Igniter rodRod holder

Rod capBurner damper LPBurner damper NA

113114115116117

319143-044319143-045319143-032319143-042319143-520

EKK2YEKK2KEKK0GEKK2DEX019

Manifold gasket AManifold gasket B

Burner holder gasketPressure port

Combustion chamber tube118119120121

319143-455319143-342319143-521319143-522

EK117EX00DEK194EK163

Gas inletGas inlet ringIgniter plate

Surge box plate150151152153

319143-350319143-057319143-523319143-524

EZP18EK042EK157EK177

O-ring P18 NBR (Black)O-ring P20 NBR (Black)

Silicon ring for Outdoor modelsExhaust port for Outdoor models

401

402403404

319143-527319143-528319143-463319143-464319143-193

EK200EK206EK129EKD58EKK1U

Heat exchanger assembly for Indoor models Heat exchanger assembly for Outdoor models

Flow adjustment valve / Flow sensorBypass valveWater inlet

Temperature remote controller

724

Water intlet section

402460456

461

458 404417

407454

405

457

406

D

052059

Water outlet section

410455

408458 454

462

C

052

409 417 Item # Part # Description540 models T-H3 models

405406407408409410

319143-197319143-198319143-465319143-190319143-530319143-199

EKK2BEKK2CEK137EKK1AEK208EKK2E

Inlet drain plugInlet water filterInlet thermistor

Outlet thermistorWater outlet

Outlet drain plug411412413414415

319143-096319143-095319143-149319143-531319143-532319143-533

EKK2TEKN34EK333EK209EK210EK211

Heat exchanger thermistorHi-Limit switch

Overheat-cut-off fusePipe heater

Inlet heater for Indoor modelsInlet heater for Outdoor models

416417

319143-534319143-468

EK231EK105

Drain tubeInlet heater

450451452453454

319143-088319143-125319143-066319143-146319143-082

EKK27EK031EKK26EK029EZM04

Pipe heater fixing plateHeater fixing plate 16Fuse fixing plate 18Fuse fixing plate 14

O-ring P4 FKM455456457458459

319143-080319143-100319143-091319143-083319143-097

EZM06EZM14EZM15EZM16EKH30

O-ring P6 FKMO-ring P14 FKMO-ring P15 FKMO-ring P16 FKMFastener “4-11”

460461462463464

319143-105319143-226319143-205319143-112319143-535

EKK24EM192EKK39EX12KEK217

Fastener “14-22”Fastener “16A”

Fastener “16-25A”Fastener “6-15”

Flat heater465466467468469

319143-536319143-538319143-539319143-540319143-541


Drain pipeCold pipe

Stainless heat exchanger out pipeHeader connection

Drain port470471472473

319143-106319143-111319143-104319143-542

EX13HEX13LEKH6GEK229

Thermistor fixing plateExhaust thermistor gasketHi-limit switch for exhaust

Gasket701702703704

319143-545319143-334320273-128319143-427319143-546

EK176EX00BEK280EK146EK143

Computer board Rubber grommet

Surge box120 VAC wire for Indoor models

120 VAC wire for Outdoor models706707708709710

319143-141319143-491319143-492319143-493319143-494

EKK4VEK165EK168EK166EK172

120 VAC Power ON-OFF switchRemote controller wire

Gas valve wire Flame rod wire

EH-IG wire 711712713

714715

319143-479319143-495319143-496319143-497319143-498319143-499

EK153EK195EK184EK185EK167EK179

IgniterHigh voltage igniter cable

Switch wire with thermostat for Indoor modelsSwitch wire with thermostat for Outdoor models

Proportional gas valve wire 24V cables

716717718719

319143-191319143-500319143-131319143-484

EKK1MEX13CEKH6EEK152

Computer board coverCable clamp for Indoor modelsExhaust thermistor assembly

Remote fixing plate721722723

319143-501319143-502319143-503

EK180EK173EK178

Exhaust Hi-limit switch wireTemperature controller for Indoor models

Fixing plate724 319143-485 ER014 Temperature remote controller

Outdoor modelsIndoor models

052052

003

007

002

050

006

704

005

052

702

704

008

052

050

052

717702

713

004

002

001

001

004

Surge box

703

706063709053

703

121

713Burner assembly

Water way assembly

B

E

E

459454

411

F

412

058

F

413

452

450414

451

414

401

416

009

464C

453

468

468

052

455

463

455

469

052

463

462

467

064462

462

473

473

465

471

064

153

152

053

718470

415

472

A

451

414466

451

D

415

056

723

722

Temperature contoller Indoor models

101104

115

106107

108

110

109 111 712112062

053

053

709

053

401

103

105

065

054

113114

102

708

119

151

118055

051

150

057055

120

711 063

117

053

116

062

121

714719

707

712

117

Burner assembly

Manifold Assembly

Computer board assembly

701

714

403

715

721 707 722715

402

402

103

713

708710

709

716

403

456

460

458

462

B

A

Bypass section

Maintenance sheet 68B166

B. Error codes031: Incorrect DIPswitch setting ・Check the DIPswitch settings on the PCB. Refer to Section D.

101: Warning for the “991” error code ・Check the gas type of the house (and/or the bulding). ・Check if there is any blockage in the intake air and/or exhaust. Refer to the “Vent termination clearances” of the installation manual. ・If the water heater is installed as a direct-vent system, check whether there is enough distance between the intake air terminal and the exhaust terminal. Refer to the “Vent termination clearances” of the installation manual. ・Check if the total vent length. Refer to the "Venting instructions" of the Installation manual. ・Check the altitude/elevation of area of where the water heater installed. Refer to the “High-altitude function” of the Section D. And change the DIPswitch settings. ・Check if there is grease and/or dirt in the burner (Part #101) and the fan motor (Part #103), especially if the water heater has been installed in a contaminated area. ・Check if there is dust and lint in heat exchanger. ・Check the manifold pressure of the water heater. Refer to installation manual.

111: Ignition failure 1. Check gas supply and inlet gas pressure. 2. Check if the Hi-limit switch (Part #412) is properly functioning. 3. Check for connection/breakage of wires (Part #413, 708, 709, 710, 712), and/or soot on the flame rod (Part #108). And then if O.H.C.F (Part #413) is breakage, Consult the manufacturer. 4. Check if there is a buzzing spark ignition sound coming from the burner (Part #101) when water heater prepares for combustion. 5. Listen for the double “clunk” sound coming from the gas valve assembly (Part #102) when water heater goes into combustion. 6. (Only no sparking and/or kick sound) Check voltage on each wire to gas valves assembly (Part #102) and/or the igniter (Part #711). Refer to the “Appendix A” in Section C. *No sparking sound >>>>> Refer to the #1 at “Appendix A” in Section C. *No kick sound >>>>> Refer to the #2 at “Appendix A” in Section C. 7. Check if there is leaking from heat exchanger (Part #401) 8. Check if there is dust and lint in nozzles of the manifold (Part #102). 9. Check current on the flame rod (Part #108). Refer to the #3 at “Appendix A” in Section C.

121: Loss of flame 1. Check gas supply and inlet gas pressure. 2. Check if the Hi-limit switch (Part #412) is properly functioning. 3. Check for connection/breakage of wires (Part #413, 708, 709, 712), burn marks on the computer board (Part #701), and/or soot on the flame rod (Part #108). And then if O.H.C.F (Part #413) is breakage, Consult the manufacturer. 4. Check if there is leakage from heat exchanger (Part #401). 5. Check if there is dust and lint in nozzles of the manifold (Part #102). 6. Check current on the flame rod (Part #108). Refer to the #3 at “Appendix A” in Section C.

311,321,341*: Disconnected/short-circuited thermistor ・Check for connection/breakage of wires and/or debris on thermistor (Part #407, 408, 715, 718). ・Check thermistor resistance. Refer to the “Appendix D” in Section C.

391: Air-fuel Ratio Rod failure ・Check for connection/breakage of wires (Part #709) and/or soot on the frame rod (Part #108).510,551: Abnormal Main and Solenoid Gas Valve ・Check for connection/breakage of wires (Part #708) and/or burn marks on the computer board (Part #701). ・Reset power supply of the water heater. ・ Check voltage of each valve on the gas valves assembly (Part #102). Refer to the “Appendix C” in Section C.611: Fan motor fault ・Check for connection/breakage of wires, dust buildup in the fan motor (Part #103) and/or burn marks on the computer board (Part #701). ・Check for frozen/corrosion of connectors of the fan motor (Part #103). ・Check voltage between blue wire and each wire of the fan motor (Part #103). Refer to the “Appendix B” in Section C.701,711: Computer board fault ・Check for connection/breakage of wires (Part #714), and check resistance between white wire and red wire. Refer to the “Appendix A” in Section C.721: False flame detection 1. Clean the flame rod (Part #108). 2. For indoor models, check if condensate drain is installed on the vent collar of the water heater. 3. Check if there is leaking from heat exchanger (Part #401).741: Miscommunication between water heater and remote controller 1. Check the model type of the remote controller. Model No. 9008172005 (TM-RE40) is the correct one. 2. Inspect the connections between the water heater and remote controller. Refer to the “Remote controller connections” of the Installation manual. 3. Check the power supply of the water heater. 4. If this error code appears only the green LED on the PCB (Part #701), check the voltage on the remote controller terminal on the PCB. Refer to the “Appendix E” in Section C. 5. If this error code appears only remote controller, replace the PCB (Part #701). 6. If this error code appears both the PCB (Part #701) and the remote controller, replace the remote controller.751*: Miscommunication between water heater and temperature controller 1. Check the power supply of the water heater. 2. If this error code appears only the green LED on the PCB (Part #701), check the voltage on the remote controller terminal on the PCB. Refer to the “Appendix E” in Section C. 3. If this error code appears only temperature controller, replace the PCB (Part #701). 4. If this error code appears both the PCB (Part #701) and the temperature controller, replace the temperature controller.941*: Abnormal exhaust temperature (Only 240 (T-H3J) and 340 (T-H3S) Direct Vent Indoor) ・Check for connection/breakage of wires, dust buildup in the fan motor (Part #103) and/or burn marks on the computer board (Part #701). ・Check exhaust thermistor resistance. Refer to the "Appendix D" in Section C.991: Imperfect combustion ・Refer to the “101” error code in this section.

C. Wiring Diagram and check point of the Water heater

Appendix A (For error code 111)

Check these points during ignition stage. # 1. Refer to check point “B” on the wiring diagram above. Check voltage between purple wires. (Normal: 108 to 132 VAC) This Check point is normal? Yes >> Replace the igniter. (Part #711) No >> Go to Next. # 2. Refer to check point “C” and “H1” on the wiring diagram above. Check the voltages below: C: Between blue wire and light blue wire (#3). (Normal: 93 to 120 VDC) C: Between blue wire and orange wire (#53). (Normal: 93 to 120 VDC) H1: Check the voltage between white wire and red wire. (Normal: 1 to 15 VDC) These check points are normal? Yes >> Replace the gas valves assembly. (Part #102) No >> Replace the PCB. (Part #701) # 3. Check current thought the yellow flame rod wire (Part #709). (Normal: more than 5 μA) This check point is normal during operation? Yes >> Replace the PCB. (Part #701) No >> Replace the flame rod. (Part #108)

Appendix B (For error code 611)

Refer to check point “G” in the diagram to the left and the following.　• Check voltage between red wire and blue wire. (Normal: 132 to 192 VDC)　• Check voltage between yellow wire and blue wire. (Normal: 13 to 17 VDC)　• Check voltage between orange wire and blue wire. (Normal: 2.0 to 6.5 VDC) All check points are normal? Yes >> Replace the fan motor. (Part #103) No >> Replace the PCB. (Part #701)

Appendix C (For error code 510 and 551)

Refer to check point “C” in the diagram to the left and followings. Check voltage on the each valve on the gas valves assembly.　• Between blue wire and light blue wire (#3). (Normal: 93 to 120 VDC)　• Between blue wire and green wire (#9). (Normal: 93 to 120 VDC)　• Between blue wire and orange wire (#53). (Normal: 93 to 120 VDC)　• Between blue wire and red wire (#73). (Normal: 93 to 120 VDC) All check points are normal? Yes >> Replace the gas valves assembly. (Part #102) No >> Replace the PCB. (Part #701)

Appendix D (For error code 311, 321, 341, and 941)

　• Outlet thermistor (Find the marking of No.113 on the connector) Check point “E1”　• Inlet thermistor (Find the marking of No.42 on the connector) Check point “E2”　Check resistance between black wire and black wire.

• Exhaust thermistor Check point “K1”　Check resistance between white wire and white wire.

All check points are normal? Yes >> Replace the PCB. (Part #701) No >> Replace the wrong thermistor. (Part #407, 408, 718)

If the error code is indicated on green LED (Refer to the Section C) on the PCB (Part #701) of the water heater (and/or the remote controller), refer to Section B.<< It takes long time to get hot water at the fixtures >> ・The time it takes to deliver hot water from the water heater to your fixtures depends on the length of piping between the two. The longer the distance or the bigger the pipes, the longer it will take to get hot water. ・If you would like to receive hot water to your fixtures quicker, you may want to consider a hot water recirculation system.<< The water is not hot enough or turns cold and stays cold >> ・Compare the flow and temperature. Refer to the “Output temperature chart” of the installation manual. ・Check cross plumbing between cold water lines and hot water lines. ・Check if the gas supply valve fully open, the gas line sized properly and the gas supplies pressure enough. Refer to the “Gas supply and gas pipe sizing” of the installation manual. ・Check the set temperature, and change the set temperature with the remote controller or the DIPswitch setting. Refer to Section D. ・Refer to “Water circuit” in this section.<<The water is too hot>> ・Check the set temperature, lower setting temperature.<<The hot water is not available when a fixture is opened>> ・Refer to the “Power supply circuit” and “Water circuit” in this section.<<Fluctuation in hot water temperature>> ・Check if the filter on the cold water inlet cleaned. (Part #406) ・Check if the gas line sized properly and the supply gas pressure sufficient. ・Check for cross connection between cold water lines and hot water lines. ・Refer to “Water circuit” in this section.<<Unit does not ignite when water goes through the water heater>> ・Refer to the “Power supply circuit” and “Water circuit” in this section. ・If you use the remote controller, turn the power button on and then the STAND BY LED will light up. ・Check if the filter on the cold water inlet cleaned. (Part #406) ・Refer to “Water circuit” in this section.

A. Troubleshooting <<The fan motor still spinning after operation has stopped>> ・This is normal. After operation has stopped, the fan motor keeps running from 15 to 70 seconds in order to re-ignite quickly, as well as purge all the exhaust gas out of the flue.<<Abnormal sound from water heater>> ・An abnormal sound from the water heaters is caused by not enough air supply or wrong installations. The water heater needs more combustion air. Refer to the “101” error code in the section B.<<Power supply circuit>> 1. If the remote controller installed, press the “ON/OFF” button of the remote controller, and make sure that the STAND BY LED next to the “ON/OFF” button of the remote controller is lit. Restart the water heater. 2. Check if that the green LED on the PCB (Part #701) of the water heater is lit. If so, the power supply circuit of the water heater is under normal condition. Next, refer to the “Water circuit” in this section. 3. Check the fuse on the surge box (Part #703), and if it has a brown spot, need to replace it. 4. Check the power supply, and make sure that the water heater has 120 VAC. 5. If the green LED on the PCB (Part #701) isn’t lit, some electrical parts can be broken. Consult the manufacturer.<<Water circuit>> 1. If you set the remote controller, turn the power button on and then the STAND BY LED will light up. 2. Open all hot water faucets, and make sure that there is enough water flow. This water heater needs at least 0.5 GPM water flow (at the default set temperature) to operate. 3. Check for reverse connection and cross connection. 4. Check if the filter on the cold water inlet cleaned. (Part #406) 5. Check if there is no debris or obstruction on the fixtures. 6. Check if water ways in the water heater are frozen. If so, unfreeze them. And refer to installation manual to protect your water heater from freezing. 7. Check if the inlet water pressure is higher than 40 psi. And if it’s lower than 40 psi, need to increase the pressure. 8. Check for connections and breakage of wires (Part #402). 9. Check if the motor drive of the flow adjustment valve (Part #402) is locked due to scale buildup, and/or water leakage. Consult the manufacturer.

Temperature°F 50 59 68 77 86 95

°C 10 15 20 25 30 35

Resistance kΩ 15.4 12.6 10.3 8.5 7.0 5.9

ATH3J, ATH3S

Model type*

OFF

ON 1 2 3 4 5 6 7 8 9 10

OFF

ON 1 2 3 4 5 6 7 8 9 10Outdoor models

Direct ventIndoor models

D. DIPswitch Settings on the computer board of the water heaterLocate the bank of DIPswitches at the bottom left of the computer board of the unit.Change the DIPswitch settings when the power supply is turned off.The dark square is the direction the DIPswitch should be set to. DEFAULT is the factory setting.

Temperature set

120 °F (49 °C)DEFAULT

140 °F (60 °C)

OFF

ON 1 2 3 4 5 6 7 8 9 10

OFF

ON 1 2 3 4 5 6 7 8 9 10

W: WHITER: RED

BK: BLACK

P: PURPLE

LB: LIGHT BLUEBL: BLUE

G: GREENY: YELLOW

O: ORANGE BR: BROWN

DIPswitches

987654321 10

OFF

Remote controller

RBK

R WBK

Ground

GO

WY BL

O

R

PCB

W

120 VACG

Ground

SWGround

W BKG

Igniter rodP

7353

93

OR

GLBBL

O.H.C.FBL

Hi-limit

SwitchBL

GasPropor-tional Valve

WR

BL

BLBLBL

P

BK

BKW

BKBK

Outlet thermistorInlet thermistor

Surge box

Hi-limit switch for exhaust

Exhaust thermistor

WW

W

W BK

WBL RBKTemperature controller

Heater

HeaterHeater

240/340 Outdoor Only

Heater

BK

DIPswitches

Y

Y

YY

YY

WWW

Y

Flame rod

AFR rod

BKW

Thermostat

HeaterHeater

Heater

240/340 Direct Vent Indoor Only

Decrease buttonIncrease button

MIN buttonMAX button

Green LED

SV3

SV2

SV1

MV

IG

FlowAdjust-ment Valve

FlowSensor

FM

Indoor Only

240/340 Direct Vent

Vent Indoor Only

240/340 Direct

B

CC2C1

GA

A1A2

B1

F

JH2

E1H1

E2

IK2K1

Temperature°F 50 59 68 77 86 95

°C 10 15 20 25 30 35

Resistance kΩ 19.5 15.9 13.0 10.7 8.9 7.4

Gas type*

PropaneOFF

ON1 2 3 4 5 6 7 8 9 10

Natural Gas OFF

ON1 2 3 4 5 6 7 8 9 10

*Factory setting

*The 341, 751 and 941 error codes are applied to the 240 (T-H3J) and 340 (T-H3S) Direct Vent Indoor model only.

L

Set DIPswitches shown in the table above depending on the vent length.

Vent settings (Direct vent Indoor models only)

3" ventings 5 to 20 ft (DEFAULT) 21 to 40 ft 41 to 70 ft

4" ventings 5 to 50 ft (DEFAULT) 51 to 100 ft N/A

OFF

ON 1 2 3 4 5 6 7 8 9 10

OFF

ON 1 2 3 4 5 6 7 8 9 10

OFF

ON 1 2 3 4 5 6 7 8 9 10

High-altitude functionIndoor models Outdoor models

DEFAULT DEFAULT




Up to 10,100 ft Over 6,000 ft: Consult the manufacturer

FM speed is increased automatically.

OFF

ON1 2 3 4 5 6 7

OFF

ON1 2 3 4 5 6 7

OFF

ON1 2 3 4 5 6 7

OFF

ON1 2 3 4 5 6 7

OFF

ON1 2 3 4 5 6 7

OFF

ON1 2 3 4 5 6 7

OFF

ON1 2 3 4 5 6 7

OFF

ON1 2 3 4 5 6 7

OFF

ON1 2 3 4 5 6 7

Appendix E (For error code 741 and 751) Error code 741: Refer to check point “F” on the wiring diagram above. Error code 751 : Refer to check point “L” on the wiring diagram above. Check voltage on the remote controller and/or temperature controller on the PCB. • Between black wire and white wire. (Normal: 11 to 25 VDC) This check point is normal? Yes >> Replace the remote controller and/or temperature controller. No >> Replace the PCB. (Part #701)

E. Components Diagram / Parts List

Case assembly

Item #Part #

Description240 / 340 models

T-H3J / T-H3S models

001 N/AN/A

EK159EK164

Case assembly for Indoor modelsCase assembly for Outdoor models

002 319143-505319143-506

EK187EK188

Front cover for Indoor modelsFront cover for Outdoor models

003004005006007

319143-509N/A

319143-510319143-511319143-512


Intake air port assemblyBracket

Junction boxPower suuply code assembly

Back guard panel008009

319143-513319143-018

EK160EKH23

Chamber fixing plateCondensate drain port

050051052053054

319143-025319143-325319143-026319143-060319143-326

EW000EW001EW002EW003EW004

Screw M4×12 (W/Washer)Screw M4×10 (W/Washer)

Screw M4×10 (Coated)Screw M4x10

Hex head screw M4×12 (W/Washer)055056057058059

319143-063N/A

319143-201319143-087319143-328

EW005EW018EKK31EW00AEW009

Hex head screw M4x8Pan screw M4x20

Tap tight screw M4x12 FEZNScrew M3x6Screw M4x6

060061062063064065

319143-438N/A

319143-059319143-048

N/A319143-330

EKK37EK191

EW00DEM167EK230EW00B

Screw M4x12Screw M3x6Screw M4x8

Wire clamp 60Screw M4x10

Screw M3x6 SUS3

Item #Part #



101102

103

319143-514319143-515319143-516319143-443319143-043

EK192EK181EK182EK109EKK25

Burner assemblyManifold with gas valve assembly LP Manifold with gas valve assembly NA

Fan motor for Indoor modelsFan motor for Outdoor models

104105106107108

319143-031319143-282319143-033319143-034319143-157

EKK2XEM381EKK2VEKK2WEK193

Burner gasketFan damper for Indoor models

Burner windowRod holder gasket

Flame rod109110111112

319143-037319143-036319143-038319143-518319143-519

EKK0FEKK32EKN61EK183EK169

Igniter rodRod holder

Rod capBurner damper LPBurner damper NA

113114115116117

319143-044319143-045319143-032319143-042319143-520

EKK2YEKK2KEKK0GEKK2DEX019

Manifold gasket AManifold gasket B

Burner holder gasketPressure port

Combustion chamber tube118119120121

319143-455319143-342319143-521319143-522

EK117EX00DEK194EK163

Gas inletGas inlet ringIgniter plate

Surge box plate150151152153

319143-350319143-057319143-523319143-524

EZP18EK042EK157EK177

O-ring P18 NBR (Black)O-ring P20 NBR (Black)

Silicon ring for Outdoor modelsExhaust port for Outdoor models

Water intlet section

402460456

461

458 404417

407454

405

457

406

D

052059

Water outlet section

410455

408458 454

462

C

052

409 417

Item #Part #



401

402404405

319143-525319143-526319143-463319143-193319143-197

EK198EK199EK129EKK1UEKK2B

Heat exchanger assembly for Indoor models Heat exchanger assembly for Outdoor models

Flow adjustment valve / Flow sensorWater inlet

Inlet drain plug406407408409410

319143-198319143-214319143-529319143-530319143-199

EKK2CEKK4JEK207EK208EKK2E

Inlet water filterInlet thermistor

Outlet thermistorWater outlet

Outlet drain plug412413414415

319143-228319143-149319143-531319143-532319143-533

EM212EK333EK209EK210EK211

Hi-Limit switchOverheat-cut-off fuse

Pipe heaterInlet heater for Indoor models

Inlet heater for Outdoor models416417

319143-534319143-468

EK231EK105

Drain tubeInlet heater

450451452453454

319143-088319143-125319143-066319143-146319143-082

EKK27EK031EKK26EK029EZM04

Pipe heater fixing plateHeater fixing plate 16Fuse fixing plate 18Fuse fixing plate 14

O-ring P4 FKM455456457458459

319143-080319143-100319143-091319143-083319143-097

EZM06EZM14EZM15EZM16EKH30

O-ring P6 FKMO-ring P14 FKMO-ring P15 FKMO-ring P16 FKMFastener “4-11”

460461462463464

319143-105319143-226319143-205319143-112319143-535

EKK24EM192EKK39EX12KEK217

Fastener “14-22”Fastener “16A”

Fastener “16-25A”Fastener “6-15”

Flat heater465466467468469

319143-536319143-537319143-539319143-540319143-541


Drain pipeCold pipe

Stainless heat exchanger out pipeHeader connection

Drain port470471472473

319143-106319143-111319143-104319143-542

EX13HEX13LEKH6GEK229

Thermistor fixing plateExhaust thermistor gasketHi-limit switch for exhaust

Gasket701

702703704

319143-543319143-544319143-334320273-128319143-427319143-546

EK186EK175EX00BEK280EK146EK143

Computer board for 240 (T-H3J) models Computer board for 340 (T-H3S) models

Rubber grommetSurge box

120 VAC wire for Indoor models120 VAC wire for Outdoor models

706707708709710

319143-141319143-490319143-492319143-493319143-494

EKK4VEK189EK168EK166EK172

120 VAC Power ON-OFF switchRemote controller wire

Gas valve wire Flame rod wire

EH-IG wire 711712713

714

319143-479319143-495319143-496319143-497319143-498


IgniterHigh voltage igniter cable

Switch wire with thermostat for Indoor modelsSwitch wire with thermostat for Outdoor models

Proportional gas valve wire 716717718721

319143-191319143-500319143-131319143-501

EKK1MEX13CEKH6EEK180

Computer board coverCable clamp for Indoor modelsExhaust thermistor assemblyExhaust Hi-limit switch wire

722723

319143-502319143-503

EK173EK178

Temperature controller for Indoor modelsFixing plate

724 319143-485 ER014 Temperature remote controller

Outdoor modelsIndoor models

052052

003

007

002

050

006

704

005

052

702

704

008

052

050

052

717702

713

004

002

001

001

004

Computer board assembly701

713

103

709

402

708

714

721

407

408

716

722 402707

710

061

Burner assembly

Water way assembly

E

E

F

412

058

F

413

452

450414

451

414

451

414

401

416

009

464C

453

468

468

052

455

463

455

469

052

463

462

467

064462

462

473

473

466

451

471

064

D

153

152

053

718470

415

472

415

465

101104

115

106107

108

110

109 111 712112062

053

053

709

053

401

103

105

065

054

113114

102

708

119

151

118055

051

150

057055

120

711 063

117

053

116

062

121

714712

117

Burner assembly

Manifold Assembly

056

723

722

Temperature contoller Indoor models

Temperature remote controller

724

Surge box

703

706063709053

703

121

713

Maintenance sheet MC02

C. Maintenance informationHow to check the maintenance information 1. Press the “MODE” button on the computer board of the multi- unit controller. And then the first 2-digit number “_0” displayed on 7-seg LED that indicates the multi-unit controller. The first 2-digit number means unit number. Press the “MODE” button to select the unit number. The unit number changes at ”0→1→2→3→・・・→20→0→1→2 ・・・”. (In this case, the multi-unit controller is connected to 20 units). 2. Press the “SET” button to fix the unit number. 3. Press the “MODE” button to select the mode number. The mode number changes at “1→2→3→・・・→9→10→11→ ・・・→32→1→2→・・・" 4. Press the “SET” button to fix the maintenance number and then the Maintenance number and then the maintenance data will be displayed on 7-segLED.

NOTE Refer to the installation manual of the water heater for error codes. The and means the multi-unit controller and water heater in the text.

031 : Incorrect DIPswitch setting ・Check the DIPswitch settings on the computer board.101 : Warning for the “991” error code111 : Ignition failure121 : Loss of flame311,321,331,341 : Disconnected/short-circuited thermistor391 : Air-fuel ratio rod failure441 : Flow sensor failure ・Check the flow sensor in the water heaters. Check the water supply for the water heaters.510 : Abnormal main gas valve551 : Abnormal gas solenoid valve

A. Troubleshooting 611 : Fan motor fault631 : Abnormal external pump ・Check the recirculation pump.651 : Flow adjustment valve fault661 : Bypass valve fault681 : Abnormal external fan motor ・Check the external fan motor.701 : Computer board fault721 : False flame detection741 : Miscommunication between multi-unit controller and temperature remote controller ・Check the communication cable between the multi-unit controller and the remote controller.751 : Miscommunication between multi-unit controller and temperature controller of the water heater ・Check the communication cable between the multi-unit controller and the temperature controller of the water heater.761 : Miscommunication in multi unit system ・Check the communication cable between the multi-unit controller and the water heaters.991 : Imperfect combustion

81A005

D. Wiring Diagram and check point of the multi-unit controller

B. DIPswitch Settings on the computer board of the multi-unit controller• Change the DIPswitch settings when

the power supply is turning off.• The dark square is the direction the

DIPswitch should be set to.• DO NOT adjust the right bank of

DIPswitches.

E. Components diagram / parts list

Item # DescriptionPart #

9008300005 model

TM-MC02 model

001002003

BracketJunction boxRubber bush

319143-184N/A

319143-334

EKJ09EM430EX00B

050051052

Screw M4×12 (W/Washer)Screw M4×10 (Coated)Screw M4x10

319143-025319143-026319143-060

EW000EW002EW003

701702703704705

Computer boardSurge box120 VAC wirePCB fixing plateCable strap

320273-550320273-128320273-551320273-552

N/A

EK232EK280EK235EK238EW022

A: Temperature remote controller terminals. Check voltage on the remote controller terminals. (Normal range: 14 to 16 VDC)

B: Water heater terminals. Check voltage on the terminals for water heaters. (Normal range: 14 to 16 VDC)

Freeze protection for re-circulation system

3 4 5 6ON 21

Factory setting

ON 3 4 5 621

001

050

050051

052

051

701

703

704

705

702

052051

051

051

051

003052

002

051

NOTE: *These components are NOT included with the multi-unit controller and are external to the unit. They must be acquired separately.

6ON

1 2 3 4 5 6

In each port510U (T-D2U) : Max 5 units540 (T-H3) : Max 5 units

Lamp buzzer

Power supplyfor Relay andLamp buzzer24 VDC or 24 VAC

BL:Black G:Green

W:White

"SET" button"ERROR CALL" button

"ALARM RESET" button

7-Seg LED

Unit# LED

Timer controlterminals

"MODE" button

"PRIORITY SET"button

"PUMP TEST" button"BYPASS REMOTECONTROL" button

Bank of DIPswitches

"MULTI SYSTEM ALARM"lamp

Re-circulation pump

Power supply forrelays 120 VAC

pump120VAC240VAC

Fan motorcontrol terminals

Pump controlterminals

To 9008172005 (TM-RE40)

Temperature remotecontroller terminals

1 2 3 4 5 6

Alarm terminals

120 VAC

Surge box

WBL

WBL

G

Ground

120 VAC

Externalfan motor

Power supply forrelays 120 VAC

external fan moter120 VAC240 VAC

To Water heaters

Draft switch terminals

MNCNO5432 654321 1O

N

*

*

*

*

Timer Switch

Draft switch

Terminals forwater heaters

*

Power supply forprogram timer120 VAC240 VAC

Power supply for

Power supply for

A

BCD

E

Mode number Whole multi-unit system information (#0) Information for water heaters (#1 to #20)

1 Total system flow rate 0 to 9999 (x 0.1 GPM) Total operation time 0 to 9,999 (× 10 hours)

2 BTU requirement for the multi-system 0 to 9999 (×kBTU/h) The number of operation

cycle0 to 9,999 (× 100 times)

3The number of water heaters connected with multi-unit controller

0 to 20 (units) Fan motor speed 0 to 9,999 rpm

4 Priority water heater 0 to 20 (unit #) Inlet temperature32 to 212 (°F).Over 212 °F = E5,Under 32 °F = E0

5 Quantity of operational water heaters 0 to 20 (units) Heat exchanger temperature

6 Set temperature 100 to 185 °F Outlet temperature

7 Operation time during current rotation 0 to 999 (minutes) Air-Fuel ratio rod current 0 to 9,999 (× 0.1 μA)

8 ON/OFF cycles during current rotation 0 to 999 (times) Flow rate 0 to 999 (× 0.1 GPM)

9 N/A Energization time of the water heater

0 to 9,999 (× 10 hours)

10 Delete units number - Integrating flow of the water heater

0 to 9,999 (× 1,000 gallons)

11 N/A Error code history: displays most recent error code

12 Inlet temperature of the priority water heater 0 to 999 °F Error code history: displays 2nd most recent

error code

13 Outlet temperature of the priority water heater 0 to 999 °F Error code history: displays 3rd most recent error code

14 N/A Clears memory in error code history*

15 Integrating flow of the multi unit system

0 to 9999 (× 100,000 gallons)

Integrating output of the water heater 0 to 999 MBTU/h

16 Energization time of multi-unit controller

0 to 9,999 (× 10 hours) Air-fuel ratio stage 0 to 16,

normal condition=6

17 to 19 N/A Refer to the installation manual of the water heater

20 Operation time of the recirculation pump

0 to 9,999 (× 10 hours)

Ratio of hot water and cold water 0 to 999 (%)

21 to 32 N/A Refer to the installation manual of the water heater

Description of mode numbers in “Diagnostic Mode”

1 2 3 4 5 6ON

1 2 3 4 5 6ON

1 2 3 4 5

6 7 8 9 10

11 12 13 14 15

16 17 18 19 20

UNIT No.

7-Seg LEDs “MODE” button

“SET” button

D: External fan motor control terminals. When the error code appears, the terminals get 0 Ω. When the no error code appears, the terminals get Ω.8

E: Alarm terminals. When the error code appears, the terminals get 0 Ω. When the no error code appears, the terminals get Ω.8

1 2 3 4 5 6

↑

1 2 3 4 5 6

↑

ON

ON

Left bank of DIPswitchesWHWHWH

MC

MC

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WH

WH

MC

MCWH

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WH

MC

MC

WH

Pump control mode

Re-circulation controlNormal control (DEFAULT)

Type A Type BON 3 4 5 621ON 3 4 5 6213 4 5 6ON 21

C: Pump control terminals. When the re-circulation pump needs to be work, the terminals get 0 Ω. When the re-circulation pump needs not to be work, the terminals get Ω.8

MC WH

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