Thermann 16LP50-6 Service Manual Download Page 1

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GAS CONTINUOUS FLOW

WATER HEATERS

(Residential Outdoor Unit)

TO BE USED BY A LICENSED

PLUMBER ONLY

SERVICE MANUAL

Model:16NG50-6/16LP50-6

16NG60-6/16LP60-6

20NG50-6/20LP50-6

20NG60-6/20LP60-6

26NG50-6/26LP50-6

26NG60-6/26LP60-6

Summary of Contents for 16LP50-6

Page 1: ...US FLOW WATER HEATERS Residential Outdoor Unit TO BE USED BY A LICENSED PLUMBER ONLY SERVICE MANUAL Model 16NG50 6 16LP50 6 16NG60 6 16LP60 6 20NG50 6 20LP50 6 20NG60 6 20LP60 6 26NG50 6 26LP50 6 26NG60 6 26LP60 6 ...

Page 2: ...r Piping 14 2 5 Electrical Connection 15 2 6 Wiring Remote Controller 16 2 7 Testing Operation 17 2 8 Cascade Installation Only For Model 26 18 3 Service and Maintenance 3 1 Operation Principles 19 3 2 Schematic Diagram 21 3 3 Flow Charts 22 3 4 Fault Findings and Error Code 23 3 5 Wiring Diagram 26 3 6 Cascade Flow Charts 27 3 7 Gas Setting Procedure 28 3 8 Combustion Specification Various Combin...

Page 3: ...re kPa 60 90 110 Maximum working pressure kPa 1200 1200 1200 Gas injectors diameter Natural Gas mm 0 95 1 45 0 95 1 45 1 15 1 65 Gas injectors diameter Propane mm 0 65 0 95 0 65 0 95 0 7 1 0 Input voltage single phase 50Hz V 240 240 240 Maximum output current A 0 39 0 45 0 46 Inlet gas connection male thread R3 4 20mm R3 4 20mm R3 4 20mm Cold water connection male thread R3 4 20mm R3 4 20mm R3 4 2...

Page 4: ... 5 2 2 Minimum 20 0 Maximum 10 15 20 25 75 50 60 Outlet water temperature C Inlet water temperature 5 C 15 C 25 C Water flow rate L min 37 0 5 2 2 Minimum 20 0 Maximum 10 15 20 25 75 50 60 Outlet water temperature C Inlet water temperature 5 C 15 C 25 C Water flow rate L min 37 0 5 2 2 Minimum 22 0 Maximum 10 15 20 25 75 50 60 Outlet water temperature C ...

Page 5: ... 20 Manifold Assy Propane Model 26 3 Gas Control Valve 4 Electrode 5 Flame Rod 7 10 4 5 6 14 12 10 10 1 9 2 3 15 13 9 8 11 10 7 10 4 5 6 14 12 10 10 1 9 2 13 9 8 11 10 3 15 Model 16 20 Model 26 No PARTS NAME 6 Heat Exchanger Assy Model 16 20 Heat Exchanger Assy Model 26 7 Over Heat Thermostat 8 Fan Motor Model 16 20 Fan Motor Model 26 9 Temperature Sensor 10 Anti Frost Heaters 11 Ignitor 12 Pressu...

Page 6: ... Valve 2 No 2 IN 2 Water Flow Control Valve with Sensor Measures the water flow as its rotor bladed wheel spins with the passing water The rotation of the rotor is detected by the sensor rotor blade equipped with a magnet of the wheel and the Hall element which calculates the water quantity When water flows more than water heater capacity hot water temperature becomes lower than the setting The Wa...

Page 7: ...n Burners 1 Ignition start After the Main Gas Valve Gas Valve 1 Gas Valve 2 open respectively as required the Gas Control Valve being held at the slow ignition position with gas supply at a constant rate operates to ignite Burners 2 During combustion Depending on the required heating capacity each Gas Valve opens or closes The combinations are below Gas valve 1 2 3 open 1 2 2 1 Higher Lower ...

Page 8: ...r circuit In such a case as no power is supplied to the gas control assemblies the gas supply is stopped and the combustion is stopped The system is activated to blow the fuse at 169 C 4 Over Heat Thermostat residual Even if the Heat Exchanger Assembly is over heated by no water combustion every gas path is closed to avoid risks At this time the error code 141 is displayed on the remote controller...

Page 9: ...relevant local Gas Authority prior to installation INSTALLAION MUST BE CARRIED OUT ONLY BY AN AUTHORISED AND APPROPRIATE LICENSED PERSON Installation requirements Danger indicates that serious injuries or even death may result from the improper installation due to negligence of following the instructions Warning indicates the possibility that serious injuries or even death may result from the impr...

Page 10: ...ances Ventilation Install the unit where there is enough space for ventilation Do not install the unit where flammables such as gasoline benzene and adhesive are handled This unit does not allow the use of extended exhaust pipes Install the unit as far as possible away from anything in front or above even if it is non combustible in order to prevent exhaust gas recirculation and staining of surfac...

Page 11: ...wall leaving about 4mm length to hook on 2 Hook the center hole of the wall hanging bracket onto the screw and securely fix the unit with 4 screws Installation Screw for wall hanging Wall hanging bracket Screw for wall hanging Wall hanging bracket 4mm 546mm Screw for wall hanging Screw for wall hanging Screw for wall hanging ...

Page 12: ...ere to the Burner and the Heat Exchanger resulting in deformation loss of efficiency or damage to electronic components Do not install the exhaust outlet near the outlets of the other appliances Install the air inlets away from the wind path as the wind may cause imperfect combustion Do not install the unit where commercial chemicals are used Those chemicals are ammonia sulfur chloride ethylene co...

Page 13: ...546mm 12mm 15mm 200mm 350mm 68mm 68mm 584mm 39mm 520mm 25mm 100mm 80mm 69mm 68mm 68mm REMOTE CONTROLLER CABLE ENTRY HOT WATER OUTLET R3 4 20 POWER CABLE ENTRY WATER INLET FILTER PRESSURE RELIEF VALVE COLD WATER INLET R3 4 20 GAS SUPPLY INLET R3 4 20 ...

Page 14: ... and fasten tightly Make sure to conduct gas leakage test before operating the Water Heater 2 3 Gas Piping 2 4 Water Piping Install a manual water valve in the water inlet connection of the Water Heater A union should be used on both the hot and cold water supply lines for connection Purge the water lines to remove all debris and air Make sure both the hot and cold water supply lines are connected...

Page 15: ...ate resulting in possible freezing damage Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing Field wiring to be performed at time of appliance installation Completely turn off the power before starting the work Do not turn the power on until the electric wiring is finished and all work is c...

Page 16: ...from the unit Install the wiring to the unit using conduit or by concealing the wires in the wall cavity Install the wiring into the cabinet through the conduit Attach the wiring to the plate adjacent to the terminal block using the cable clamp provided Then attach the wires to the terminals for the remote controllers Replace the front cover of the water heater One Cable Two or more Cables CONTROL...

Page 17: ... if the temperature can be adjusted as desired If the residence is not ready for habitation or the unit will not be used for an extended time the residual water in the unit and the pipe may freeze and damage the unit or the residual water in the Heat Exchanger may deteriorate Be sure to remove the water in the unit and the pipe 1 Close the gas supply main valve 2 Close the water supply main valve ...

Page 18: ...range of 5 100 cm Water and gas pipe length should be the same to both units Otherwise the temperature of the hot water at the tap can be unstable In case of connecting the remote controller it must be connected with the MASTER of the two units Otherwise the remote controller will not operate correctly Remote Controller Remote Controller Connection Terminals Thermann genuine cascade cable Gas Supp...

Page 19: ...hen the spark is emitted by the Electrode The gas supply is set at the slow ignition level by the Gas Control Valve and goes to Burners When Burners are ignited the Flame Sensor detects the flame condition the In Use Indicator lights and the sparking is stopped The PCB detects the water flow rate based on the signal from the Water Flow Sensor calculates the energy required to heat the water up to ...

Page 20: ... less approximately 2 2 Liter min Fan Motor ON Fan Motor detects revolution Ignitor ON Main Gas Valve OPEN Gas Control Valve Gas Valve 2 OPEN Gas 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 ...

Page 21: ... Incoming Temperature Sensor Water Flow Sensor Hot Water Outlet Cold Water Inlet Gas Supply Inlet Remote Controller AC240V PCB Gas Valve 3 Water Filter Pressure Relief Valve Gas Valve 1 Electrode Main Gas Valve Gas Control Valve Gas Valve 2 Water Flow Control Valve Ignitor Thermal Fuse Flame Rod Heat Exchanger ...

Page 22: ... Fan Motor ON 611 Fan Motor failure Fan Motor exceeds 1000rpm Gas Control Valve Close Gas Control Valve Close Fan Motor OFF in one minute Fan Motor post purge In Use indicator OFF 121 111 141 311 321 611 141 721 False Flame detection Over Heat Thermostat activates Flame loss three times and below Bath Ensuite remote controller failure Kitchen remote controller failure Fan Motor failure All Gas Val...

Page 23: ...4 OVER HEAT THERMOSTAT CUT OFF COMBUSTION STOPS AND LED STARTS FLASHING OVER HEAT THERMOSTAT CUT OFF DEFECT CHECK THE CONTINUITY BETWEEN THE TERMINALS OF THE DEVICE 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 Table 3 Fig 8 341 NOT FLASHING TEMPERATURE SENSOR WIRE BREA...

Page 24: ...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 Table 2 WATER INLET FILTER CLOG UP VISUAL CHECK AND CLEAN IT GAS CONTROL VALVE CHECK MANIFOLD PRESSURE Table 2 TEMPERATURE SENSOR DEFECT OUTGOING INCOMING CHECK THE RESISTANCE IN TRANSMISSON CONNECTOR FOR SENSOR SIDE Table 3 Fig 8 REMOTE CO...

Page 25: ...g out connector See Table 1 GR GR DC1 8 16 2V Measure voltage without pulling out connector 9 Measure voltage without pulling out connector BK BK AC240V Y C G Y C O Y C BL Y C Y ALL DC12V Table 1 Resistance of Gas Valve Assembly Lead wire Resistance Ω Yellow C Orange Gas valve 1 Approx 33 Yellow C Blue Gas valve 2 Approx 33 Yellow C Green Gas valve 3 Approx 33 Yellow C Yellow Main gas valve Approx...

Page 26: ...V T5A 2 3 4 6 1 Y Y REMOTE CONTROLLER BL G O Y BK BK BK BK AMBIENT TEMP BL BK P W O G R Y W W W BL BL W W W W OUTGOING TEMP INCOMING TEMP BK GR GR R W BK BK R Y W BL GAS VOLUME ADJUSTING BUTTON DOWN GAS VOLUME ADJUSTING BUTTON UP COMBUSTION INDICATOR BK BK White Black Brown Blue Grey Light Blue Orange Red Green Purple Yellow 10 8 9 W BK BR BL GR LB O R G P Y ONLY FOR 26NG50 6 26LP50 6 26NG60 6 26L...

Page 27: ...Flow Charts 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 ...

Page 28: ...t the steps 2 to check that the settings are correct 4 With the combustion going on set Dip Switch No 6 to ON position to set the combustion at a maximum capacity level At this time a substantial amount of water should be supplied As the maximum capacity is forced if the water inlet temperature is high the heated water may reach boiling point 5 Set the gas amount for the maximum capacity level by ...

Page 29: ... PCB Maximum Gas type mark Nozzle diameter mm Rich Top side Lean Bottom side 16 Propane 125 A Φ0 65 15 pcs Φ0 95 15 pcs DipSw No 1 OFF Natural Gas H Φ0 95 15 pcs Φ1 45 15 pcs DipSw No 1 ON 20 Propane 158 A Φ0 65 15 pcs Φ0 95 15 pcs DipSw No 1 OFF Natural Gas H Φ0 95 15 pcs Φ1 45 15 pcs DipSw No 1 ON 26 Propane 200 A Φ0 70 17 pcs Φ1 00 17 pcs DipSw No 1 OFF Natural Gas H Φ1 15 17 pcs Φ1 65 17 pcs D...

Page 30: ...es them effective before power is turned on When the remote controller is connected the Dip SW settings become ineffective Instructions for delivery temperature adjustment for 50 C preset model are located in the pocket inside the appliance front cover ON settings before the power is turned on is ineffective By detecting setting changes the system validates the changed settings If the water is not...

Page 31: ... losses in the pipework between the water heater and any outlets and achieve the required temperature at the outlet This instruction contains the procedure steps for carrying out such adjustment Measure the maximum hot water temperature from the sanitary ﬁxture used primarily for the purposes of personal hygiene that is closest to the hot water heater for example a shower outlet in the bathroom cl...

Page 32: ...contravene local regulations For a given installation temperature loss is typically greatest in winter when ambient air and water temperatures are lowest Conversely temperature loss is typically lowest in summer when these ambient temperatures are highest It follows that the delivery temperature of water ﬂowing through outlets is typically higher in summer than it is in winter The installer is to ...

Page 33: ...f Valve 2 Disconnect the connectors 8 pcs from the PCB 3 If remote controllers are connected disconnect the remote controller cables Removing PCB 1 Remove the setscrew fixing the PCB case and lead wires from the PCB claw To remove the hook part of the PCB case from the bottom panel lift the case up slightly and pull it out Connectors PCB case setscrew Hook part PCB claw ...

Page 34: ...PCB case Lift the case up and pull it out 2 Disconnect Water Flow Contorol Valve 8P connector on PCB side Water Flow Sensor 3P relay connector and Incoming Temperature Sensor connector Water Flow Sensor relay connector Incomming Temperature Sensor connector Quick fasteners Water Flow Control Valve Over Heat Thermostat Water Flow Contorol Valve connector 3 Remove the 2 quick fasteners and take out ...

Page 35: ...2 Pull out the Ignitor 3 Disconnect the Ignitor 2P connector 4 Remove the setscrews 2 pcs retaining the Ignitor Attention When inserting the connector to the Ignitor marking should face outward like the illustration If reverse side it can be disconnected High voltage cord Screw with steel washer Ignitor setscrews Screw with steel washer earthing plate side Ignitor connector marking outward ...

Page 36: ...and pull it out 4 Remove the setscrews fixing the Manifold Assy M4 x 7 pcs M4 with washer x 3 pcs 5 Pull the connector of the Gas Valve 3 Model 26 only Removing Gas Control Valve 1 Remove Manifold Assy see previous step 2 Remove setscrews 4 pcs Gas Control Valve setscrews 4 pcs Setscrews M4 with washer x 3 pcs Setscrews M4 x 7 pcs Connector of the Gas Valve 3 Flame Rod connector ...

Page 37: ... Assy Gas Valve connectors Removing Fan Motor 1 Remove Ignitor see previous step 2 Remove the setscrew fixing the PCB case Lift the case up and pull it out 3 Disconnect the connector for Fan Motor from the PCB 4 Remove Anti Frost Heater from the pipe 5 Remove the setscrews 3 pcs fixing the Fan Motor to pull it out forward Fan Motor setscrews 3 pcs Fan Motor connector Anti Frost Heater Number of Va...

Page 38: ...ltage cord Removing Heat Exchanger Assy 1 Remove Manifold Assy see previous step 2 Remove setscrews 2 pcs fixing the combustion chamber 3 Disconnect the following connectors 1 Thermal Fuse front 2P relay connector 2 Anti Frost Heaters 2P connector from the PCB 3 Fan Motor 4P connector from the PCB 4 Over Heat Thermostat connectors 2 pcs and other connected items Combustion chamber setscrews 2 pcs ...

Page 39: ...ixing the Anti Frost Heater 6 Remove setscrew retaining the Heat Exchanger Assy 7 Pull the Heat Exchanger Assy forward to take it out Note If any gaskets or seals are damaged or torn during disassembling they must be replaced Heat Exchanger Assy setscrew Anti Frost Heater setscrew Hot water outlet pipe setscrews 2 pcs quick fastener ...

Page 40: ... 40 3 10 Exploded View A A B B Model 16 Model 20 Model 26 8 8 1 10 7 14 10 3 4 5 11 2 6 12 9 10 9 13 B C 4 7 15 1 5 C 1 2 1 1 1 Screw with steel washer 2 Special earth Screw with projections ...

Page 41: ... Propane Model 26 2 Anti Frost Heaters 10 Gas Control Valve 3 Manifold Assy Natural Gas Model 26 Manifold Assy Propane Model 16 20 Electrode 4 Ignitor 11 Flame Rod 5 Pressure Relief Valve 12 Water Flow Control Valve with Sensor 13 Over Heat Thermostat 7 Heat Exchanger Assy Model 16 20 6 Heat Exchanger Assy Model 26 Fan Motor Model 26 Fan Motor Model 16 20 8 Water Filter 14 Ambient Temperature Sens...

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