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Takagi 540P Indoor, Installation Manual And Owner'S Manual

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Takagi 540P Indoor Installation Manual And Owner'S Manual Download Page 5

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INTRODUCTION

• 

This manual provides information necessary for the installation, operation, and maintenance 

of the water heater.

• 

The model description is listed on the rating plate which is attached to the side panel of the 

water heater.

• 

Please read all installation instructions completely before installing this product.

• 

If you have any problems or questions regarding this equipment, consult the manufacturer or 

its local representative.

• 

This equipment is an on-demand, tankless water heater designed to efficiently supply endless 

hot water when properly sized and installed.

• 

This heater incorporates a recirculation pump for homes with an installed circulation system.

• 

These 

high efficiency models

 have a built-in secondary heat exchanger that absorbs latent 

heat from the exhaust gas.

• 

The 540P Indoor model is only to be installed indoors.  The  540P Outdoor model is only to be 

installed outdoors.

• 

The 540P Indoor model is categorized as Category IV when it isn't  installed in the direct vent 

installation.

• 

The principle behind tankless water heaters is simple:

Recirculation pump

Primary HX

Secondary HX

Exhaust thermistor

Thermistor

Bypass valve

Water control valve

Thermistor

Thermistor

Thermistor

Cold water

Gas

Hot water

Return line

Flow sensor

Burners

Gas valves

Fan motor

Computer board

Condensate drain port

  *This diagram illustrates tankless water heater design concepts only and does not accurately 

       represent the water heater’s physical description.

1.  A hot water tap is turned on.

2.  Water enters the heater.

3.  The water flow sensor detects the water flow.

4.  The computer initiates the fan motor and sends a signal to the igniter to create an ignition spark.

5.  The gas ignites and flames appear within the burner chamber.

6.  Water circulates through the heat exchanger and then gets hot.

7.  Using thermistors to measure temperatures throughout the water heater, the computer modulates 

the gas and water valves to ensure proper output water temperature.

8.  When the tap is turned off, the unit shuts down.

Introduction

Installation Manual

Summary of Contents for 540P Indoor

Page 1: ...J or 20 ppm EASY LINK SYSTEM Keep this manual near the water heater for future reference whenever maintenance adjustment or service is required Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your building Immediate...

Page 2: ... w o dedicated return line 34 Pressure relief valve 34 CONDENSATE DRAIN 35 Condensate drain connections 35 ELECTRICAL CONNECTIONS 37 TEMPERATURE REMOTE CONTROLLER 38 Included accessories 38 Installation 38 EASY LINK SYSTEM 40 Easy link connection procedures 40 APPLICATIONS 42 Combination potable water heating and space heating 42 Recirculation 42 Dual purpose hot water heating 43 INITIAL OPERATION...

Page 3: ... Before use we recommend that you read through this installation manual carefully Keep this manual for future reference If you need an additional manual contact the manufacturer or your local distributor When you call please tell us the product name and the serial number of your unit written on the rating plate of the water heater ...

Page 4: ...nsate production in the vent These are equivalent lengths that include head loss for elbows tees unions etc NOTE Check the rating plate to ensure that this product matches your specifications The manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligation Model 540P Indoor 540P Outdoor Natural Gas Input Operating Ra...

Page 5: ...el is categorized as Category IV when it isn t installed in the direct vent installation The principle behind tankless water heaters is simple Recirculation pump Primary HX Secondary HX Exhaust thermistor Thermistor Bypass valve Water control valve Thermistor Thermistor Thermistor Cold water Gas Hot water Return line Flow sensor Burners Gas valves Fan motor Computer board Condensate drain port Thi...

Page 6: ...or showering always check the water temperature Do not store or use gasoline or other flammables vapors or liquids in the vicinity of this appliance Do not reverse the water and or gas connections as this will damage the gas valves and can cause severe injury or death Follow the diagram on p 33 when installing your water heater Should overheating occur or the gas supply fails to shut off turn off ...

Page 7: ... conditions in order to prevent heat damage to ABS PVC CPVC or polypropylene Plastic venting If the exhaust gas temperature exceeds 140 F 60 C these components will enable the appliance to safely stop operation These components are not installed on the outdoor model since the exhaust vent is built in If the water heater is used as a direct vent appliance the unit requires 3 in 76 mm or 4 in 102 mm...

Page 8: ...serve these warnings could result in severe personal injury death and or property damage WARNING Installation Installation Manual The warranty will not cover damage caused by water quality Only potable water can be used with this water heater Do not introduce pool or spa water or any chemically treated water into the water heater Water hardness levels must not exceed 7 grains per gallon 120 ppm fo...

Page 9: ...ller kit Outdoor model only Bird screen Indoor model only Qty 1 100276687 TM RE43 Qty 2 Refer to pp 10 and 38 Back Side Front Side Top Bottom Model Top Bottom Front Back Sides 540P Indoor 12 in 305 mm 12 in 305 mm 4 in 102 mm 0 5 in 13 mm 3 in 76 mm 540P Outdoor 36 in 914 mm 12 in 305 mm 24 in 610 mm 0 5 in 13 mm 3 in 76 mm Standard indoor installations and direct vent indoor installations have th...

Page 10: ...on instructions and any applicable local codes Covering wall thicknesses Part Terminator Hood 100112419 Wall Thimble 4 7 in 102 178 mm 100112732 Wall Thimble 5 10 in 123 254 mm 100112733 Termination Thimble4 7in 102 178mm 100112424 Termination Thimble 5 10 in 123 254 mm 100112425 Wall Thimble Terminator Hood 6 Non return valve for common venting 100113130 It is a must have item for common venting ...

Page 11: ...ree sides Outdoor model only Do not install next to a dryer or any source of airborne debris that can be trapped inside the combustion chamber unless the system is direct vented Prohibited Prohibited 3 ft 914 mm Installation Installation Manual Water heater vent terminator must be at least 2 ft 610 mm away from an inside corner for both outdoor installation and direct vent installation Inside Corn...

Page 12: ...14 m 3 000 to 5 000 ft 915 to 1 524 m 5 000 to 7 500 ft 1 525to2 286m 7 500 to 10 100 ft 2 287to3 078m Middle bank of DIP switches 1 2 3 4 5 6 ON No 2 OFF No 3 OFF No 4 OFF 1 2 3 4 5 6 ON No 2 OFF No 3 ON No 4 OFF 1 2 3 4 5 6 ON No 2 OFF No 3 OFF No 4 ON 1 2 3 4 5 6 ON No 2 OFF No 3 ON No 4 ON 1 2 3 4 5 6 ON No 2 ON No 3 ON No 4 ON Altitude DIP switches Installation altitude The maximum certified ...

Page 13: ...t must not be connected to any other gas appliance or vent stack except an approved common venting system Refer to pp 26 and 27 Avoid using an oversized vent pipe or using extremely long runs of the pipe unless it is part of an approved common vent system Air supply pipe can be made of ABS PVC solid core CPVC solid core polypropylene corrugated stainless steel or Category lll IV stainless steel Re...

Page 14: ...rosive chemicals are not present at the air intake Presence of such chemicals at the air intake could result in death personal injury or property damage Examples of locations that require outside air due to chemicals include Beauty salons Photo processing labs Indoor pools Laundry hobby or craft rooms Chemical storage areas Products such as aerosol sprays detergents bleaches cleaning solvents gaso...

Page 15: ...outside ventila tion if you want to provide combustion air with outside ventilation If the air volume of the room is greater than the required air volume it may be possible to install the water heater without outside ventilation However be sure to consider the effects of exhaust fans Exhaust fans can affect the amount of combustion air that is available in your home Appliances such as furnaces who...

Page 16: ...hese rules to ensure that vents and ducts provide adequate air flow Each vent opening must be no smaller than 100 in2 645 cm2 Ducts must have the same cross sectional area as free area of the opening Rectangular ducts must have a minimum dimension of no less than 3 in 76 mm All screens must have mesh or larger Moveable louvers must be locked open or interconnected with the equipment so that they o...

Page 17: ...Space 12 305mm maximum Gable vent to outdoors Install above insulation Figure 5 SIngle opening Confined Space 1 in2 6 5 cm2 per 3 000 btu h Alternative Opening Location Figure 6 Two permanent openings Two permanent Openings 1 in2 per 1 000 btu h 12 305mm maximum 12 305mm maximum Confined Space Figure 4 Horizontal duct openings 1 in2 6 5 cm2 per 2 000 btu h Confined Space Outlet Inlet Outdoor Air Duct...

Page 18: ...le 40 ABS DWV ANSI ASTM D2661 Polypropylene UL 1738 Pipe Cement Primer PVC ANSI ASTM D2564 CPVC ANSI ASTM F493 ABS ANSI ASTM D2235 Use of cellular core PVC ASTM F891 cellular core CPVC or Radel polyphenylsulfone in non metallic venting systems is prohibited Covering non metallic vent pipe and fittings with thermal insulation is prohibited Diameter Max No of Elbows Max Vertical and Horizontal Total...

Page 19: ... before changing the DIP switch settings Failure to observe these warnings could lead to carbon monoxide poison ing or death PVC concentric termination 100112163 installation is applied to the DIP switch settings of 3 76 mm venting Refer to p 10 Set DIP switches shown in the table below depending on the vent diameter and length DIP switch settings Two pipe Direct vent installations Vent diameter 3...

Page 20: ...nnect 3 x 4 76 mm x 102 mm increasers directly on the exhaust and intake vent collar of the water heater 2 Connect 4 102 mm straight pipes to the increasers 4 102 mm straight pipe Exhaust vent collar Female Intake vent collar Female 4 102 mm straight pipe 3 76 mm x 4 102 mm increaser 4 102 mm vent connection 3 76 mm x 4 102 mm increaser Horizontal Installation Vertical Installation Single pipe wit...

Page 21: ...t a 3 76 mm straight pipe to the coupling 3 76 mm vent connection How to install single vent with the indoor model DIP switch settings Single vent pipe installations Vent diameter 3 76 mm venting 4 102 mm venting 5 to 45 ft 1 5 to 13 7 m DEFAULT 46to70ft 13 8to21 3m 5 to 50 ft 1 5 to 15 2m DEFAULT 51 to 100 ft 15 3to30 5m Lower bank of DIP switches 1 2 3 4 5 6 7 8 ON No 3 O N No 4 OFF 1 2 3 4 5 6 ...

Page 22: ...mm Concentric Adaptor ICTC0446 4 102 mm x 87 Elbow ISEL0487 100 mm to 4 102mm Increaser ISIA10004 4 102 mm x 12 305 mm Vent Length ISVL041 4 102 mm x 24 610 mm Vent Length ISVL042 4 102 mm x 36 914 mm Vent Length ISVL043 4 102 mm x 72 1 829 mm Vent Length ISVL046 4 102 mm Horizontal Drain Tee ISHDT04 3 5 76 mm 127 mm x 13 330 mm Concentric Wall Termination SS ICWS3513 3 76 mm Twin Pipe to 3 5 76 m...

Page 23: ...Special BH type gas vent The manufacturer recommends the NovaVent line However the following are also UL listed manufacturers ProTech Systems Inc FasNSeal Metal Fab Inc and Heat Fab Inc Saf T Vent Follow the vent pipe manufacturer s instructions when installing the vent pipe The maximum length of exhaust vent piping must not exceed 100 ft 30 5 m deducting 5 ft 1 5 m for each elbow used in the vent...

Page 24: ...em manufacturer s instructions and all local codes Use 4 102 mm Category III IV approved or Special BH single or double wall stainless steel vent pipe Do not mix parts or fittings of different material types and do not mix pipe fittings or joining methods from different manufacturers Combustion exhaust can contain carbon monoxide and must be properly vented outside Breathing abnormal amounts of ca...

Page 25: ...2NVVD4 2SVEVDP04 4 102 mm wall thimble length 4 7 102 178 mm wall thickness 100112732 2NVWT4 2SVSWTF04 4 102 mm wall thimble length 5 10 127 254 mm wall thickness 100112733 2NVWT4L 2SVSWTEF04 4 102 mm 3 in 1 adaptor F F adaptor condensate drain back flow preventer 100112585 2NVBFA4 2SVBFDPA04 4 102 mm F F adaptor 100112399 2NVAFF4 2SVEEWCF0445 4 102 mm Backflow preventer w F F adaptor 100112416 2N...

Page 26: ...ing pieces and components the manufacturer recommends Centrotherm s vent line Typical common vent installation examples Only the above allowable models can be common vented together Different models cannot be common vented CAUTION Allowable models for common venting 240 Indoor 340 Indoor 540 Indoor 540P Indoor Installation Installation Manual Intake wall Exhaust Roof Condensate drain port Non Retu...

Page 27: ...to 5 ft 1 5 m linear length and the maximum number of elbows is 5 Common venting system Vent Diameter D Max No of water heaters Max Vertical and Horizontal Total Vent Length L DIP switch settings 540P Indoor Lower bank of DIP switches 4 in 110 mm 2 25 ft 7 6 m 1 2 3 4 5 6 7 8 ON No 3 ON No 4 OFF 5 in 125 mm 2 50 ft 15 2 m 3 20 ft 6 1 m 6 in 160 mm 2 100 ft 30 5 m 3 75 ft 22 9 m 4 50 ft 15 2 m 5 25...

Page 28: ...or to side of opening 1 ft 30 cm above opening K Clearance to mechanical air supply inlet 6 ft 183 cm 3 ft 91 cm above if within 10 ft 3 m horizontally L Clearance above paved sidewalk or paved driveway located on public property 7 ft 213 cm 7 ft 213 cm 7 ft 213 cm M Clearance under veranda porch deck or balcony 1 ft 30 cm 1 ft 30 cm 1 ft 30 cm Clearance in accordance with local installation codes...

Page 29: ...cipated Snow level Exhaust Termination 2ft 610mm min 1ft 305mm min 1ft 305mm min Inside corner Inside corner Anticipated Snow level 2ft 610mm min 1ft 305mm min 1ft 305mm min Combined intakeand exhaust termination For direct vent sidewall terminationsthatusetwo separate penetrations for the intake and exhaust keep the termination clearances shown in the diagrams on the right Improper installation c...

Page 30: ...ING 3 ft 914 mm min Exhaust gas Intake air 1ft 305mm min 1 ft 305 mm min Anticipated snowlevel Flat roof termination Exhaust gas 2 ft 610 mm min Intake air 1ft 305mm min 1 ft 305 mm min 1 ft 305 mm min Anticipated snowlevel Angled roof termination Vertical wall Anticipated snow level 1 ft 305 mm min 1 ft 305 mm min 2ft 610mm min 2 ft 610 mm min 1ft 305mm min 1 ft 305 mm min 1 ft 305 mm min 1 ft 30...

Page 31: ...r is greater than the specified maximum a field supplied regulator is required The regulator must lower the gas pressure within the approved range Install the gas regulator according to the manufacturer s instructions The regulator must be sized for the water heater input and provide the specified pressures that are listed on the rating plate In the absence of minimum install distance it is recomm...

Page 32: ...th 3 4 19 mm Pipe size 5 1 5 m Length 1 1 4 32 mm Pipe size Gas sizing example Natural Gas Unit kBTU per hour Pipe Size Length Diameter 10 3 0 m 20 6 1 m 30 9 1 m 40 12 2m 50 15 2m 60 18 3m 70 21 3m 80 24 4m 90 27 4m 100 30 5m 125 38 1m 150 45 7m 200 61 0m 1 2 13 mm 268 184 148 126 112 101 93 87 82 77 68 62 53 3 4 19 mm 567 393 315 267 237 217 196 185 173 162 146 132 112 1 25mm 1 071 732 590 504 4...

Page 33: ... within the cold inlet and return inlet to trap debris from entering your heater This will need to be cleaned periodically to maintain optimum flow Refer to p 63 3 Before installing the water heater flush the water line to remove all debris and after installation is complete purge the air from the line Failure to do so may cause damage to the heater Cold inlet Hot outlet Gas inlet As Close as Poss...

Page 34: ... be rated for a maximum of 150 psi 1 MPa The discharge piping for the pressure relief valve must be directed so that the hot water cannot splash outward and cause damage or personal injury Attach the discharge tube to the pressure relief valve and run the end of the tube to within 6 in 152 mm from the floor This discharge tube must allow free and complete drainage without any restrictions If the p...

Page 35: ... in the secondary heat exchanger can be neutralized by the neutralizer accessory 100112159 TH NT01 Although a neutralizer is not required a condensate drain must be installed as described on the next page Condensate drain connections CONDENSATE DRAIN The water heater does not include a built in condensate neutralizer cartridge for reducing the pH level of condensate water If local codes dictate th...

Page 36: ...c if drained improperly The actual life of the neutralizer may vary depending on the application and usage Replace the cartridge when the condensate pH goes below 6 0 Please ensure that the cartridge is properly replaced before the neutralizer elements have been completely consumed All preventative measures and safety practices must be adhered to when draining condensate Themanufacturerwillnotbere...

Page 37: ...wing procedure is for outdoor model only 1 The water heater must be electrically grounded Do not attach the ground wire to either the gas or the water piping 2 The water heater requires a 120 VAC 60 Hz electrical power supply that is properly grounded A proper disconnect i e on off switch power plug etc controlling the main power to the water heater must be provided for service reasons Must comply...

Page 38: ...ler cable Verify that the items listed below are included with the remote controller Temperature remote controller Screws Fork terminals Manual Remote controller cable Qty 1 Qty 2 Qty 4 Qty 1 Qty 1 The remote control is an optional accessory that can be installed in a hall closet etc to allow for temperature adjustment without having to go to the heater When installed the remote will take priority...

Page 39: ... to the remote controller terminal on the computer board No polarity Do NOT jump or short circuit the cable or the computer will be damaged 7 Replace the front cover securely Inlet for the remote controller cable Cut out Fig D 2 Fig D 1 Installation Installation Manual Connect other end to these terminals Plastic cover Back side of the remote Remotecontrollerterminals Remote controller cable Two f...

Page 40: ...be connected to 540 models when 540P is a PARENT unit in the system A remote controller is not required for an Easy Link System However it does provide for more temperature options and ease of maintenance If a remote controller is used the temperature on all the units in the system will auto matically be set to the same temperature that is set on the remote When a remote is used in an Easy Link Sy...

Page 41: ...is warning could result in carbon monoxide poisoning or death 5 Between the PARENT and the CHILD 1 units Connect the PARENT connector of the PARENT unit to the 1 connector of the CHILD 1 unit using the supplied linking cable 6 Between the CHILD 1 and the CHILD 2 units Connect the 2 connector of the CHILD 1 unit to the 1 connector of the CHILD 2 unit 7 Between the CHILD 2 and the CHILD 3 units Conn...

Page 42: ... flow rate requirements must be followed Toxic chemicals used in boiler treatments such as alcohol glycerol and glycol groups must not be introduced into the system The water heater can be used to supply potable water and space heating and shall not be connected to any heating system or component s previously used with non potable water where any chemicals were added to the water heating appliance...

Page 43: ...tivates every 6 hours for 60 seconds Wire to product approved pump Heating Coil used with air handler Cold water supply 3 inch gas exhaust vent Discharge must comply with local and state codes Cannot be common vented with other appliances in Massachusetts An approved temperature and pressure relief valve Tie to location approved by local codes and must meet BTU rating of water heater model used Ch...

Page 44: ... to check for the presence of leaking gas toward the bottom of the unit because some gases are heavier than air and may settle towards the floor Check the GAS PRESSURE Refer to p 31 Do not try to light the burner manually It is equipped with an electronic ignition device which automatically lights the burner Check for PROPER VENTING and COMBUSTIBLE AIR to the water heater Purge the GAS and WATER L...

Page 45: ...he loop several times to relieve air in the pipe If air is stuck in the pump it can cause pump failure or decreased water flow 8 Check recirculation water flow Refer to p 60 Make sure the flow rate is approx 2 to 3 GPM If the flow rate is less than 2 GPM there is a possibility that air is stuck in the pump Open and close the faucet again to relieve air Water flow EX 3 0GPM 9 After finishing the pu...

Page 46: ...46 Page This page is intentionally left blank Initial operation Installation Manual ...

Page 47: ...heater Before use we recommend that you read through this owner s guide carefully Keep this manual for future reference If you need an additional manual contact the manufacturer or your local distributor When you call please tell us the product name and the serial number of your unit written on the rating plate of the water heater ...

Page 48: ...empted repair may result in a fire or explosion D Do not use this appliance if any part has been under water Immediately contact a qualified installer or service agency to replace a flooded water heater Do not attempt to repair the unit It must be replaced 1 STOP Read the safety information above on this label 2 Turn off all electric power to the appliance 3 Do not attempt to light the burner by h...

Page 49: ... In approved containers 3 Tightly closed and out of reach of children 4 Water heater has a main burner which may come on at any time and will ignite flammable vapors Vapors 1 Cannot be seen 2 Are heavier than air 3 Go a long way on the floor 4 Can be carried from other rooms to the main burner by air currents Do not install water heater where flammable products will be stored or used unless the ma...

Page 50: ...D Thecurrenttime settemperature error code and other information are displayed 3 COLD Button 7 PUMP Button Press this button to set and con trol the pump operation 4 INFO Button Press the INFO button to dis play the inlet outlet water tem perature and water flow and set the outlet temperature pump choosing and unit conversion 8 IN USE LED The LED lights during combustion 9 STAND BY LED The LED lig...

Page 51: ...the set temperature of output water on its display as shown in the picture on the right EX 120 F 5 Press the HOT button or the COLD button to set the temperature setting of the unit Increasing temperature from 120 F 50 C to 125 F 52 C 1 The water heater must be in Stand By to increase the temperature 2 Press the HOT button to set 120 F 50 C 3 Press and hold the INFO button and the HOT button for a...

Page 52: ... time and set temperature are displayed When the remote is off the display turns off OR SETTING THE TIME PUMP OPERATION TIMERS The built in controller and remote offer two timer settings for the pump operation PUMP TIMER 1 and TIMER 2 The pump will only operate during the times set for TIMER 1 and TIMER 2 There are four options for pump timer operation 1 Both PUMP TIMER 1 and PUMP TIMER 2 are acti...

Page 53: ...time more quickly NOTICE The time is displayed in twenty four hour clock time For example 11 00 is 11 00 a m and 23 00 is 11 00 p m 4 Press the PUMP button when the desired time flashes on the display The OFF time for PUMP TIMER 1 will flash indicating that you can set the end time 5 Press the HOT button or COLD button to select the time Press and hold the HOT or COLD button to adjust the time mor...

Page 54: ...time Press and hold the HOT or COLD button to adjust the time more quickly NOTICE The time is displayed in twenty four hour clock time For example 11 00 is 11 00 a m and 23 00 is 11 00 p m 10 Press the PUMP button when the desired time flashes on the display 11 The following steps will set the temperature drop that must occur before the recirculation pump will activate Temperature drop below set t...

Page 55: ... When the controller is off the display turns off OR Selecting a pump timer Operation Controllers Built in controller Remote controller 1 Press the PUMP button on the controller to set the mode The options are shown in step 3 This operation is available regardless of the ON OFF status of the controller 2 The current status of the PUMP TIMER will flash for 10 seconds During this time you can change...

Page 56: ...ne of them is in operation In this example PUMP TIMER 1 is running because it is set to activate between 6 00 AM and 9 00 AM See above Current time 7 00 AM 7 00 Set temperature of output water 120 F PUMP TIMER 1 SET PUMP TIMER 2 SET 6 The display shows that PUMP TIMER 1 and PUMP TIMER 2 are set and none of them is in operation The current time falls outside the time ranges that are set for for PUM...

Page 57: ... during Manual pump operation 3 The pump will stop automatically in five minutes and the current set temperature and time will be displayed on the screen Manual pump operation Normal Operation Owner s Guide The following procedure will operate the pump This is useful to verify that the pump is operating prop erly and to check the water flow rate This operation runs the pump and fire the water heat...

Page 58: ... other DIP switches Turn off the power supply to the water heater before changing the DIP switch settings Failure to observe these warnings could lead to carbon monoxide poi soning or death Set DIP switch shown in the table below Manual pump operation Lower bank of DIP switches 1 2 3 4 5 6 7 8 ON No 5 OFF DEFAULT 1 2 3 4 5 6 7 8 ON No 5 ON Lower bank of DIP switches ...

Page 59: ...X 120 F Water flow EX 3 5 GPM NOTICE When installed on an indoor heater the 100276687 TM RE43 has priority for set temperature over the built in controller Unit conversion mode Units of measure can be changed from Imperial to Metric and vice versa For example temperature can be changed from F to C Flow rate will also change from gallons per minute to liters per minute when this setting is changed ...

Page 60: ...adjust the other DIP switches Turn off the power supply to the water heater before changing the DIP switch settings Failure to observe these warnings could lead to carbon monoxide poison ing severe personal injury or death FLOW Appliance Use Flow rate GPM US L min Lavatory Faucet 1 0 3 8 Bath Tub 4 0 10 0 15 2 37 8 Shower 2 0 7 5 Kitchen Sink 1 5 5 6 Dishwasher 1 5 5 6 Washing machine 4 0 15 2 Hou...

Page 61: ...In any areas subject to freezing temperatures the manufacturer highly recommends an indoor installa tion with an indoor model The manufacturer also highly recommends the use of a backflow preventer sold separately to mini mize the amount of cold air entering through the exhaust venting when the water heater is off It is the installer s responsibility to be aware of freezing issues and take all pre...

Page 62: ...ailure to follow these steps could lead to fire or explosion resulting in personal injury or death WARNING The water heater cannot perform properly without sufficient inlet gas pressure Below are instructions on how to check the inlet gas pressure THIS IS ONLY TO BE DONE BY A LICENSED PROFESSIONAL 7 The static and dynamic pressures should be within the ranges specified on the heater s rating plate...

Page 63: ...esidual water flow has ceased close all hot water taps 6 Have a bucket or pan to catch the water from the unit s drain plugs If Isolation valves are installed open the drains to drain the water If isolation valves are not installed unscrew the two drain plugs large and small to drain all the water out of the unit Do not lose the o rings that will be on the two drain plugs 7 Wait a few minutes to e...

Page 64: ...te controller and or temperature controller is the power button turned on Is the gas supply valve open fully p 44 Is the water supply valve open fully p 44 Is the filter on the cold water inlet and return connection clean p 63 Is the hot water fixture sufficiently open to draw at least 0 5 GPM 1 9 L min through the water heater p 50 Is the unit frozen p 61 Is there enough gas in the tank cylinder ...

Page 65: ... the unit is supplied with power Make sure the connection to the unit is correct pp 38 and 39 NOTICE When the unit has not operated for five minutes or more the display of the controllers turns off to conserve energy Although the controller of the parent unit will display the set temperature at the Easy Link System the controller of the child unit will not display the set temperature An ERROR code...

Page 66: ...emote controller 321 will be displayed on the screen in its entirety Green LED on the computer board The green LED on the computer board will indicate this code with two flashes every 1 2 second The pattern will repeat with a three second delay between patterns Error code Green LED on on on on on on off off off off off 321 Error Indication 540P computer board Green LED flashes to indicate error code Er...

Page 67: ... and 2 will alternately flash on the display Unit Error code Outdoor model installation Unit 2 The green LED on the computer board will flash twice just like in the single unit example Unit 3 and 4 The green LED on the computer board will stay off Indoor model installation Unit 2 321 will flash on the display The green LED on the computer board will be flashing twice just like in the single unit e...

Page 68: ... ignition sound coming from the burner Part 101 when water heater prepares for combustion Listen for the double clunk sound coming from gas valve assembly Part 102 when water heater goes into combustion Check if there is leaking from heat exchanger Part 401 121 Three Times Loss of flame Check if the Hi limit switch Part 412 is functioning properly Check for connection breakage of wires Part 413 70...

Page 69: ...ote controller Check the model type of the remote controller Inspect the connections between the water heater and remote controller Check the power supply of the water heater 751 N A Miscommunication betweenwater heaterand built in controller Indoor model only Inspect the connections between the water heater and built in controller Check the power supply of the water heater 761 N A Miscommunicatio...

Page 70: ...utdoor model Case assembly Temperature remote controller 723 722 056 002 050 050 717 052 008 052 704 702 001 004 002 717 004 052 052 003 007 713 052 725 001 702 006 005 052 Built in controller Indoor model Components Diagram Owner s Guide 724 ...

Page 71: ...71 Page Computer board assembly Surge box assembly Components Diagram Owner s Guide 708 713 711 709 103 707 722 715 402 714 402 715 721 715 726 701 716 121 713 706 703 ...

Page 72: ...de Burner assembly 101 104 115 106 107 108 110 109 111 711 112 062 053 053 709 053 053 401 103 105 065 054 113 102 708 119 151 118 055 051 150 057 055 711 063 121 707 714 719 117 062 709 730 117 053 116 114 Manifold assembly Burner assembly ...

Page 73: ... 458 462 052 409 408 454 417 410 455 451 415 451 415 052 469 455 464 416 450 414 459 454 411 401 718 053 413 453 452 418 152 153 472 418 415 009 052 471 470 402 460 456 461 404 733 460 456 458 729 458 462 417 059 454 732 457 406 052 405 728 451 734 456 460 456 735 451 734 727 726 461 404 458 052 405 457 406 059 454 731 G G H Water inlet section Pump section Water outlet section Bypass section ...

Page 74: ...K191 062 063 064 065 Pan screw M4x8 MFZN Wire clamp 60 Screw M4x10 Screw M3x6 SUS3 Binding head 100074526 100074233 N A 100074514 EW00D EM167 EK230 EW00B 101 102 Burner assembly Manifold with gas valve assembly LP Manifold with gas valve assembly NA 100074670 100074671 100074672 EK192 EK181 EK182 103 Fan motor for Indoor model Fan motor for Outdoor model 100074606 100074228 EK109 EKK25 104 105 106...

Page 75: ...te 16 Fuse fixing plate 18 Fuse fixing plate 14 100074273 100074310 100074251 100074331 EKK27 EK031 EKK26 EK029 454 455 456 457 O ring P4 FKM O ring P6 FKM O ring P14 FKM O ring P15 FKM 100076303 100076305 100076306 100076307 EZM04 EZM06 EZM14 EZM15 458 459 460 461 O ring P16 FKM Fastener 4 11 Fastener 14 22 Fastener 16A 100076308 100074282 100074290 100074410 EZM16 EKH30 EKK24 EM192 462 463 464 4...

Page 76: ...ide 5M2051 1 2000536265 REV B Item Description Part 540P AT H3P 713 Switch wire with thermostat for Indoor model for Outdoor model N A N A EK631 EK636 714 715 716 717 Proportional gas valve wire 24V cables for Indoor model for Outdoor model Computer board cover Cable clamp 100074657 N A N A 100074375 N A EK167 EK632 EK638 EKK1M EX13C 718 719 721 722 723 Exhaust thermistor for Indoor model Remote f...

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