Thermann 26LP50C Service Manual Download Page 2

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Table of Contents

1. General Outline of Appliance

1 - 1 Specifications

.............................................................................................................................. 3

1 - 2 Performance

................................................................................................................................ 4

1 - 3 General Construction (Parts Names)

.......................................................................................... 5

1 - 4 Main Component Structures

....................................................................................................... 6

1 - 5 Main Safety Devices

................................................................................................................... 8

2. Installation and Related Work

2 - 1 Installation Instructions

................................................................................................................ 9

2 - 2 Dimensions

................................................................................................................................. 13

2 - 3 Gas Piping

................................................................................................................................... 14

2 - 4 Water Piping

................................................................................................................................ 14

2 - 5 Condensate Drain Piping

............................................................................................................ 15

2 - 6 Electrical Connection

.................................................................................................................. 17

2 - 7 Wiring Remote Controller

............................................................................................................ 18

2 - 8 Testing Operation

........................................................................................................................

2 - 9 Cascade Installation

....................................................................................................................

3. Service and Maintenance

3 - 1 Operation Principles

....................................................................................................................

3 - 2 Schematic Diagram

.....................................................................................................................

3 - 3 Flow Charts

.................................................................................................................................

3 - 4 Fault Findings and Error Code

....................................................................................................

3 - 5 Replacement of PCB

...................................................................................................................

3 - 6 Replacement of Neutralizer

.........................................................................................................

3 - 7 Wiring Diagram

........................................................................................................................... 31

3 - 8 Cascade Flow Charts

..................................................................................................................

3 - 9 Manifold Gas Setting Procedure

................................................................................................. 33

3 - 10 Combustion Specification, Various Combination Setting

............................................................ 34

3 - 11 Disassembling/Assembling Parts

................................................................................................ 38

3 - 12 Exploded View

............................................................................................................................ 46

3- 13 Parts List

..................................................................................................................................... 47

Summary of Contents for 26LP50C

Page 1: ...GAS CONTINUOUS FLOW WATER HEATERS Residential Outdoor Unit TO BE USED BY A LICENSED PLUMBER ONLY SERVICE MANUAL Model 26NG50C 26LP50C 26NG60C 26LP60C ...

Page 2: ... 2 6 Electrical Connection 17 2 7 Wiring Remote Controller 18 2 8 Testing Operation 20 2 9 Cascade Installation 21 3 Service and Maintenance 3 1 Operation Principles 22 3 2 Schematic Diagram 24 3 3 Flow Charts 25 3 4 Fault Findings and Error Code 26 3 5 Replacement of PCB 29 3 6 Replacement of Neutralizer 30 3 7 Wiring Diagram 31 3 8 Cascade Flow Charts 32 3 9 Manifold Gas Setting Procedure 33 3 1...

Page 3: ...pressure Low Propane kPa 0 21 Water heating capacity raised 40 C L min 16 25 Minimum working pressure kPa 115 Maximum working pressure kPa 1200 Gas injectors diameter Natural Gas mm 1 00 1 50 Gas injectors diameter Propane mm 0 7 1 0 Input voltage single phase 50Hz V 240 Maximum output current A 0 66 Inlet gas connection male thread R3 4 20mm Cold water connection male thread R3 4 20mm Hot water c...

Page 4: ... 4 1 2 Performance Performance Capacity characteristic curves 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: ... a Primary Heat Exchanger Assy b Secondary Heat Exchanger Assy 7 Over Heat Thermostat No PARTS NAME 8 Fan Motor 9 Temperature Sensor 10 Anti Frost Heaters 11 Ignitor 12 Pressure Relief Valve 13 Water Flow Control Valve with Sensor 14 Water Filter 15 Ambient Temperature Sensor 16 Neutralizer Assy c Neutralizer d Anti Frost Heater for Neutralizer a 7 10 5 4 10 b 6 14 d 10 11 1 15 2 10 12 13 c 8 9 9 ...

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: ... 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 Primary 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 co...

Page 9: ...al 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 improper install...

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: ...ving 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 599mm Screw for wall hanging Screw for wall hanging Screw for wall hanging ...

Page 12: ...Burner and the Primary and Secondary 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 ...

Page 13: ...mm 25mm 366mm 599mm 12mm 15mm 205mm 21mm 143mm 103mm 83mm 145mm 72mm 350mm 260mm 208mm 174mm 143mm 46mm POWER CABLE ENTRY DRAIN OUTLET COLD WATER INLET R3 4 20 PRESSURE RELIEF VALVE HOT WATER OUTLET R3 4 20 GAS SUPPLY INLET R3 4 20 WATER INLET FILTER ...

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: ...NZS 3500 Temperature Pressure Relief and Expansion Control Valve Drain Lines has been used as a guide in preparing these considerations Condensate drain outlet connection R1 2 15mm BSP male nylon Note the white plastic shipping cap MUST BE removed from the condensate drain outlet prior to water heater operation In the case that white ish stone pieces calcium carbonate comes out of the neutralizer ...

Page 16: ...than DN20 or less than one size larger than that of the largest drain line discharging into the tundish Tundish drain lines shall comply with the Installation requirements on page 9 In areas where water pipes are prone to freezing the drain pipe from any valve shall be insulated and not exceed 300mm in length It shall discharge into a tundish through an air gap of not less than 75mm and not more t...

Page 17: ...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 18: ...nnection of cable to the thermann unit 1 Remove the front cover from the unit 2 Install the cable to the Thermann main unit using conduit or by concealing the cables in the wall cavity 3 Install the cable into the cabinet through the conduit in accordance with the table in next page 4 Based on How to fix the cables attach the cable to the plate adjacent to the terminal block using the cable clamp ...

Page 19: ...the rest cable Tie the cables two by two Clamp small Clamp medium 1 cable clamp small 2 cables clamp medium 1 cable clamp small 3 cables clamp large 180mm 180mm 1 cable 270mm 2 cables 180mm 2 cables 270mm 2 cables 180mm Attach the cable to underside of terminal Attach the cables to underside of terminal Attach the cable 180mm to underside of terminal Attach the cables 270mm to upperside of termina...

Page 20: ...e 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 Primary and Secondary 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 su...

Page 21: ...te controllers they must be connected to one unit only That unit will need to be set up as the MASTER unit for the system to operate correctly All fittings valves and branch lines should be matched sets to each of the water heaters Remote Controller Remote Controller Connection Terminals Thermann genuine cascade cable Gas Supply Hot Water Supply Line Cold Water Supply Line PCB 50 1000mm the MASTER...

Page 22: ...taneously when 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 w...

Page 23: ... 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 24: ...tor Neutralizer Outgoing Temperature Sensor Incoming Temperature Sensor Water Flow Sensor Water Level Electrode Hot Water Outlet Drain Outlet Cold Water Inlet Gas Supply Inlet Remote Controller AC240V PCB Water Filter Pressure Relief Valve Gas Valve 1 Main Gas Valve Gas Control Valve Gas Valve 2 Water Flow Control Valve Ignitor Thermal Fuse ...

Page 25: ...nitial check all on Over Heat Thermostat activates 141 Yes No Yes No No Yes Yes No No Yes Ignitor ON Fan Motor OFF in one minute Main Gas Valve Open Gas Control Valve Open All Gas Valves Close Fan Motor post purge Gas Valve 1 Open Gas Control Valve Close Gas Valve 2 Open In Use indicator OFF Yes In Use indicator OFF Flame Sensor detects Low Gas Control Valve Close Flame loss three times and below ...

Page 26: ...le 2 141 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 8 001 6 POWER FAILURE DETECTION COMBUS...

Page 27: ...T EXCHANGE PCB Page29 732 FLASHING 23 MEMORY PCB UNATTACHED COMBUSTION STOPS AND LED STARTS FLASHING ATTACHMENT FAILURE OF MEMORY PCB VISUAL CHECK 733 FLASHING 24 FAILURE OF PCB AND MEMORY PCB COMBUSTION STOPS AND LED STARTS FLASHING DEFECT OF PCB AND MEMORY PCB REPLACE PCB MEMORY PCB AND NEUTRALIZER AT THE SAME TIME Page30 LIGHTING UP HOT WATER TEMPERATURE CAN NOT BE REACHED PRESET TEMPERA TURE P...

Page 28: ...Y C Y ALL DC12V Fig 4 Continuity of Thermal Fuse Thermal fuse 0 Over Heat Thermostat 0 9 Measure voltage without pulling out connector BK BK AC240V 4 GR GR DC1 8 16 2V Measure voltage without pulling out connector Measure after removing the connector Infinite Neutralizer 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 ...

Page 29: ...PCB should be moved to the new PCB If not the error code 732 Memory PCB unattached is displayed on the remote controller and the unit cannot be operated In case that hot water is not supplied and the error code 732 Memory PCB unattached is displayed check that the Memory PCB is attached correctly Then unplug power supply cable and plug it again Note Make sure to unplug power supply cable when the ...

Page 30: ...t 3 Remove the Memory PCB from the PCB and attach the new Memory PCB MC 31 on the PCB 4 Put the PCB back into place Fix the PCB case with setscrew and hang the lead wires on the claw 5 Plug power supply cable 6 Run water to the unit and check the normal combustion Note Make sure to unplug power supply cable when the Memory PCB is removed from the PCB and is attached on the PCB It can cause the dam...

Page 31: ... BK BK BK BK AMBIENT TEMP BL BK P W O G R Y W BL BL W W TEMPERATURE SENSOR 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 GC 172 5 W MEMORY PCB 7 W W W W G LB BR G Y GAS VALVE 3 GAS VALVE ...

Page 32: ...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 33: ...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 pressing the Gas Volume Adjusting Button 6 Shut the hot water supply valve Open the valve again for combustion...

Page 34: ...d Assy Gas type mark A Propane G Natural Gas Gas type Gas consumption MJ h Manifold Assy Gas type Dip Switch on PCB Maximum Gas type mark Nozzle diameter mm Rich Top side Lean Bottom side Propane 173 A Φ0 70 17 pcs Φ1 00 17 pcs DipSw No 1 OFF Natural Gas G Φ1 00 17 pcs Φ1 50 17 pcs DipSw No 1 ON ...

Page 35: ...troller To fix to the maximum combustion To fix to the minimum combustion Setting change after the power is turned on is ineffective The system recognizes the settings and makes 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 insid...

Page 36: ...ork 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 closest to the water ...

Page 37: ...ontravene 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 38: ...f Valve 2 Disconnect the connectors 9 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 39: ...hook the lead wires 3 Disconnect Water Level Electrode 2P connector Anti Frost Heater 2P relay connector and Outgoing Temperature Sensor connector 4 Pull out the rubber hose from the Neutralizer removing the band 5 Remove the setscrew of Manifold Assy 6 Pull up and remove the Neutralizer Band Hook Setscrew Connectors ...

Page 40: ...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 41: ...thing 2 Pull out the Ignitor 3 Disconnect the Ignitor 2P connector 4 Remove the setscrew retaining the Ignitor Attention When inserting the connector to the Ignitor marking should face downward like the illustration If reverse side it can be disconnected High voltage cord Screw with steel washer Ignitor setscrew Screw with steel washer earthing plate side Ignitor connector marking downward ...

Page 42: ...ews fixing the Manifold Assy M4 x 7 pcs M4 with washer x 3 pcs 5 Pull the connector of the Gas Valve 3 Removing Gas Control Valve 1 Remove Manifold Assy see previous step 2 Remove setscrew of Power cable clamp 3 Remove setscrews 4 pcs Setscrews M4 with washer x 3 pcs Remove the setscrews of Manifold Assy M4 x 7 pcs Connector of the Gas Valve 3 Flame Rod connector Gas Control Valve setscrews 4 pcs ...

Page 43: ...e one of valves marked on Manifold Assy Gas Valve connectors Removing Fan Motor 1 Remove Neutralizer 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 the setscrews 3 pcs fixing the Fan Motor to pull it out forward Fan Motor setscrews 3 pcs Fan Motor connector Number of Valves Number of Connec...

Page 44: ...ve Neutralizer and Manifold Assy see previous step 2 Remove setscrews 2 pcs fixing the combustion chamber 3 Remove the setscrew fixing the PCB case Lift the case up and pull it out 4 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 connec...

Page 45: ...the Anti Frost Heater 7 Remove setscrews 2 pcs retaining the Heat Exchanger Assy 8 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 setscrews 2 pcs Anti Frost Heater setscrew Hot water outlet pipe setscrews 2 pcs quick fasteners ...

Page 46: ...6 3 12 Exploded View B E D E B A G F 8 10 11 7 14 10 10 3 5 4 2 16 17 6 12 9 10 9 13 1 F C 5 7 15 1 4 16 G 1 2 1 1 1 Screw with steel washer 2 Special earth Screw with projections 3 Memory PCB D 10 3 A C ...

Page 47: ...me Rod 6 Heat Exchanger Assy 7 Over Heat Thermostat 8 Fan Motor No PARTS NAME 9 Temperature Sensor 10 Anti Frost Heaters 11 Ignitor 12 Pressure Relief Valve 13 Water Flow Control Valve with Sensor 14 Water Filter 15 Ambient Temperature Sensor 16 Neutralizer Assy 17 Anti Frost Heater for Neutralizer For spare parts the Neutralizer Assy includes the Memory PCB ...

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