tankless gas water heaters -

R

Tankless Gas Water Heaters

High Effi ciency Condensing ModelsPHH-25ROFN & PHH-32ROFN (Outdoor Natural Gas Models)PHH-25ROFP & PHH-32ROFP (Outdoor L.P. Gas Models)PHH-25RDVN & PHH-32RDVN (Indoor Direct Vent Natural Gas Models)PHH-25RDVP & PHH-32RDVP (Indoor Direct Vent L.P. Gas Models)

Engineering Handbook

DESIGN

CERTIFIED ®

CERTIFIED

R

Mid Effi ciency ModelsPH2-20R OFN, PH2-25R OFN & PH2-28R OFN (Outdoor Natural Gas Models)PH2-20R OFP, PH2-25R OFP & PH2-28R OFP (Outdoor L.P. Gas Models)PH2-20R DVSN, PH2-25R DVSN & PH2-28R DVSN(Indoor Direct Vent Natural Gas Models)PH2-20R DVSP, PH2-25R DVSP & PH2-28R DVSP(Indoor Direct Vent L.P. Gas Models)

Outdoor Water HeaterPH2-20, 25 & 28ROF Indoor Direct Vent Water Heater

PH2-20, 25 & 28RDVS

Outdoor Water HeaterPHH-25ROF & PHH-32ROF

Indoor Direct Vent Water HeaterPHH-25RDV & PHH-32RDV

2 | Page SVC 820 Tankless Gas Trouble Shooting Manual

2

TABLE OF CONTENTS

General Information Specifications 4 Sequence of Operations 5

1. Ignition Sequence 6 2. Monitoring Sequence 7 3. Shutdown Sequence 8

Error Code Table 9 Components “Callouts” 15 Maintenance Mode “How To” 16 Control Board “Callouts” 18 Reset Procedure 21 Clearing Fault History 21

Error Code Diagnostics No Error Code & No Hot Water 22 P1 Warning Code 23 1L Warning Code 24 03 Error Code 25 05 Warning Code 26 10 Warning Code 29 11 Error Code 33 Gas Supply & Venting 33 Igniter Rod (Spark is NOT visible) 34

Flame Rod (Flame IS visible) 36

Gas Control Valve (Spark IS visible; Flame is NOT visible) 38

Control Board 40

12 Error Code 43 Gas Supply & Venting 43 Flame Rod(s) 44 13 Error Code 47 Venting 47 Ground 47 Flame Rod(s) 48 14 Error Code 50 15 Error Code 53 16 Error Code 54 24 Error Code 56 29 Error Code 59 31 Error Code 60 32 Error Code 62

SVC 820-Tankless Gas Trouble Shooting Manual Page | 3

3

TABLE OF CONTENTS

33 Error Code 64 34 Error Code 66 35 Error Code 68 51 Error Code 70 52 Error Code 72 61 Error Code 74 65 Error Code 76 66 Error Code 78 71 Error Code 80 72 Error Code 82 76 Error Code 84 79 Error Code 86 80 Error Code 88 82 Error Code 90 90 Error Code 91 92 Warning Code 92 93 Error Code 92 99 Error Code 93


4

Specifications common to all models

Model See specification sheets for current models and specs Purpose Domestic Hot Water (DHW) supply for showers, cleaning, and laundry

Rated Gas Input Btu/Hr.) See specification sheets for current models and specs Dimensions See specification sheets for current models and specs

Installation

Indoor Wall Mounting : Can be vented horizontally or vertically Outdoor Wall Mounting : Venting not required Mid Efficiency : ONLY uses Stainless steel (Category III; 316L Certified) concentric venting for indoor installation High Efficiency: Uses PVC; CPVC; ABS; or Stainless Steel (Category III; 316L Certified) venting for indoor installation

Working Water Pressure 14 PSI minimum; 150 PSI maximum Minimum Water Flow 0.4 GPM to activate burner; can be reduced to .26 GPM once burner is activated Maximum Water Flow Based on 35 degree rise; See specification sheets for current models and specs

Gas Connection 3/4” NPT Male Water Connection 3/4" NPT Male

Vent Size Mid Efficiency: 3”/5” Concentric Vent High Efficiency: 2” or 3” Two Pipe Venting (optional concentric vent termination)

Max Vent Length See Use & Care Manual for each product type Inlet Gas Pressure Natural Gas: Minimum 4.0” w.c. Maximum 10.5” w.c.

L.P. Gas : Minimum 8.0” w.c. Maximum 14.0” w.c. Hot Water Supply

Temperatures Factory Setting: 85F – 140F (Up to 140 with Override Adjustment) Commercial Setting: Up to 185F via program chip

Electrical

Rating: 120 VAC/60Hz, 3 Amps Wire : Indoor Models - 3 Prong (Edison) Power Supply Cord Outdoor Models – require field wiring Fuse : 3A Fuse x 2 (line voltage)

Safety Devices

Flame Rods Overheat Film Wrap for Heat Exchanger Heat Exchanger Thermistor (Boiling Point Safety) Electronic Burner and Combustion Monitoring and Control

Freeze Protection Minus 30F (Without Wind-Chill Factor) with power applied

Remote Control

Standard: Main Remote Control UMC-117 (included) Optional: Bath Remote Control USC1-117 – 120 F Max Limit Optional: Second Bath Remote USC2-117 – 120 F Max Limit Only one of each type remote above can be installed on a single unit Only one of each type remote above can be installed on multiple manifold units


5

Sequence of Operations ACTION EXPLANATION

Hot water faucet is open creating a demand Hot water draw initiates water flow thru the water heater

Water flows thru the Water Flow Sensor Minimum flow rate of .4 GPM to activate @ 35o T Control Board senses the flow rate has reached a minimum demand of .4 GPM@ 35o T

Control Board is the ‘brains’ of the machine and controls all input and actions during sequence of operations

Blower Motor conducts a pre-purge Pre purge is designed to verify we have a clear and clean

vent and supply oxygen to burner for proper ignition The Proportional Gas Flow Regulator allows the gas to flow to the main burner

Proportional Gas Flow Regulator initially opens to 75% of BTU input

Simultaneously, the Igniter Rod sparks and ignites the main burner

The Igniter Rod ignites the fuel in the main burner area. All burners will fire initially

After ignition, the Flame Rods sense and monitor the flame and ensure proper combustion

The purpose of the flame rods is to verify flame and proper combustion. In the event of flame failure or improper combustion, the unit will go into an error code

The “In Use Indicator” on the remote control turns “ON” (Red) and the “Priority Indicator” is Green (multiple remote controls)

Main burner is now lit. The PCB goes thru a series of calculations (input sensing) to balance out the cold-water temperature, the thermostat setting, the hot outlet temperature, and the BTU required to heat the water.

The Proportional Gas Flow Regulator continuously adjusts the gas volume in order to maintain the outlet temperature. The water flow sensor also adjusts the proper amount of cold water mix flow to supply a stable hot water temperature at all times. A signal is also sent to the Blower Motor in order to constantly maintain the correct proportion between gas and air volumes

The PCB is constantly monitoring all of these inputs and actions to ensure the outlet water temperature is within 1-5 degrees of thermostat setting. It also monitors the BTU required to heat the cold water to the thermostat setting and adjusts the gas valve accordingly

(Indoor Models Only) When the air intake is blocked, or oxygen is not sufficient, the output of the Flame Sensor changes

The PCB senses this change and controls the Fan and Gas Valve in order to prevent imperfect combustion. If the PCB cannot correct such condition, the unit will go into an error code

When the hot water tap is closed, the flow rate signal from the water flow sensor stops

Gas valve is closed. Main burner shuts off

The Fan continues to run for a few minutes Purpose is to cool the heat exchanger, exhaust all

combustions gases, and to maintain the burner chamber charged with air for immediate ignition if there is another hot water demand


6

YES

NO

Health Check

82 – Program Chip

79 – Blower Motor

71 – Gas Control Valve

76 – Remote Control

14 – OHL

Open Hot Water Tap

Up & Down

Buttons

24: Activated > 20 Seconds

Thermistors Check

Blower Speed

Flue Blockage

Detect Flame

False Flame

1-2 Ignition Attempt

31 – Inlet Thermistor

33 – Outlet Thermistor

32 – HE Thermistor

34 – Ambient Thermistor

61

90: > 12 seconds

72: > 5 seconds

11: > 2 Ignition Attempts

Igniter Rod Off

Gas Control Valve & Igniter Rod On

Blower On

Next Page

1 – Ignition Sequence

SEQUENCE OF OPERATIONS:

1. Ignition Sequence

2. Monitoring Sequence

3. Shutdown Sequence

Plug In


7

Flow Chart

No

Flame Failure

Ignition Failure

10 Warning Code Flashing 05 Warning Code Flashing

Yes Yes

No No Decrease of Fan Motor Ventilation

Imperfect Combustion

Alarm

Attempt to Re-Ignite

11

12

Yes

1-2 Ignition Attempts

Condensation Not Draining 29: Condensing Only

OHL Activated 14

Outlet water temperature too high 16

Hot Water > 207 Degrees F for more than 15 seconds 15

Heat Exchanger > 207 Degrees F for more than 15

seconds

15

Heat Exchanger Outlet Temp Too

Low

Ambient Thermistor

Outlet Thermistor Heat Exchanger Thermistor

Inlet Thermistor

29 34 33 32 31

Trouble with Thermistor(s)

PGFR – Gas Control Valve

Blower Motor Water Control Body Bypass Assembly

35 52 61 65 66

Gas Control Valve Communication Trouble – Remote

Control

Blower Motor Current Not

Detected

Flame Rod

71 76 79 13

Next Page

2 – Monitoring Sequence: while unit is in operation


8

Close Hot Water Tap

Checking Blower Motor

Detect Flame?

Gas Control Valve Off

Unit in Stand-By mode

80: Gas Control Valve

51: Gas Control Valve

Yes (8 Seconds Later)

99

3 – Shutdown Sequence


9

Error Code

Code Fault Remedy

No Code

Flow Rate/Maintenance:

Nothing Happens When Water Is Flowing Through Unit. (Control Board Displays Water Temp)

1. Increase water flow rate or set higher temperature 2. New Installations: Ensure hot and cold water lines are not crossed 3. Check for plumbing crossover in the home 4. Clean water inlet filter 5. Check water flow sensor (may be jammed)

P1 Maintenance Warning:

Water Flow Too Low (Unit Will Still Be Operable; Minimum Flow 0.40 GPM To Activate @ 35o ) T

1. Check hot water tap flow (clean aerator if necessary) 2. Clean water inlet filter 3. Increase flow rate or set higher temperature

If maintenance requirements are met:

1. Check water flow sensor

1L

Maintenance:

Water Heater Has Buildup Of Lime/Scale Deposits

1. Flush Heat Exchanger 2. High Altitude Installations: ensure proper altitude settings have been made

03 MIC 185, MIC 6, & EZ Link 1. Check communications cable connection 2. Check # 4 dip switch setting is in the ‘ON’ position (Dip Set # 1 (Top), Dip

switch # 4 on the water heaters only)

05

Maintenance Warning:

Air Intake Or Vent Exhaust May Be Blocked (Unit Will Still Be Operable)

1. Remove any vent blockage 2. Make sure venting meets all installation requirements


1. Check fan motor

Installation Warning:

The vent Pipes On The Vent Termination May Not Be Connected (Unit Will Still Be Operable)

Make sure all venting is properly sealed and meets all venting requirements (diameter; vent lengths; venting material; venting obstructions; and all other installation requirements as described in installation manual)

If installation requirements are met:

1. Check Blower Motor


10

10

Maintenance:

Decrease Of Ventilation Amount (Blower Motor)

Clean any blockage in venting, Blower Motor, air intake


1. Check Blower Motor

11

Installation/Gas supply:

Ignition Failure

1. Ensure you have gas to the appliance and valves are turned ‘ON’ 2. Ensure gas type, gas pressure, and gas volume are correct 3. Bleed all air from gas lines 4. Ensure gas line, meter, and regulator are sized properly 5. Ensure appliance is properly grounded

If installation/gas supply requirements are met:

1. Check Gas Control valve for open or short circuits 2. Ensure Igniter Rod is operational 3. Check igniter/Flame Rod(s) and Igniter/Flame Rod(s) wiring harness for

damage 4. Check Control Board 5. Check Flame Rod Status

12

Gas supply/Installation/ Maintenance:

Flame Failure (Had Main Burner, Then Lost It)

1. Ensure gas type and pressure is correct 2. Bleed all air from gas lines 3. Ensure Flame Rod wire(s) is connected 4. Check Flame Rod(s) for carbon build-up 5. Ensure gas line, meter, and regulator are sized properly 6. Ensure appliance is properly grounded 7. Check power supply for proper voltage and voltage drops 8. Disconnect and re-connect all wiring harnesses on Gas Control Valve and

Control Board

If gas supply/installation/maintenance requirements are met:

1. Check gas valves for open or short circuits 2. Check flame rod(s) and flame rod(s) wiring harness for damage 3. Check PCB 4. Check flame rod(s) status


11

13

Indoor ONLY

Venting:

Flame Rod FL-2: Reads Poor Or Improper Combustion

Ensure intake and exhaust venting meet all installation requirements (diameter; vent lengths; venting material; venting obstructions; and all other requirements as described in the Use & Care manual {Make sure exhaust is not recirculating into fresh air intake})

If venting requirements are met:

1. Remove any blockage from venting or from in front of vent termination 2. Verify altitude settings 3. Check Flame Rod FL-2 4. Check Blower Motor

14

Condensing only:

Maintenance:

Flue Temperature Too High

Condensing Only:

1. Clean blockage in heat exchanger 2. Remove any blockage from Blower Motor and exhaust vent

Mid Efficiency & Condensing:

Over Heat Limiter (OHL) Fault


If ‘Condensing’ maintenance requirements are met:

1. Verify “U” connector is connected to Control Board 2. Verify wiring harness is connected to OHL 3. Check heat exchanger for cracks and/or separations 4. Inspect Overheat Wrap (Overheat wrap failure: Replace unit) 5. Check thermal overload sensor (condensing models only)

15

Maintenance:

Boiling Safety Device (Heat Exchanger temperature reached 207 F degrees for more than 15 seconds)

1. Flush Heat Exchanger (lime/scale buildup) 2. Check for closed water heater inlet valve or restrictions in cold water inlet

pipe (must be fully open) 3. On commercial water heater, lower set point temperature below 1800F at

high altitudes


1. Check Heat Exchanger Thermistor

16

Maintenance:

Outlet Water Temperature Is Above Remote Thermostat Setting

1. Check for clogged Heat Exchanger 2. Check for restrictions in airflow around unit and vent terminal


1. Check Outlet Thermistor 2. Check Heat Exchanger Thermistor 3. Check gas valve


12

24 Malfunction Of Operational Switch

1. Turn off water. Disconnect Remote Control and retry 2. Verify unit is electrically grounded 3. Press MIN and MAX button on Control Board to reset

29

Condensing Only:

Maintenance:

Neutralizer Is clogged

Condensing Only:

1. Ensure shipping cap for drain line is removed and drain line is not blocked 2. Clear all neutralizer drainage ports inside of unit 3. Clear neutralizer drainage line outside of unit 4. Clean air inlet screen 5. Clean heat exchanger fins


1. Check neutralizer water level electrode


Maintenance:

Heat Exchanger Temperature Is Too Low


1. Clean air inlet screen 2. Clean heat exchanger fins

31 Inlet Thermistor 1. Check Thermistor wiring for damage 2. Check and clean scale from Thermistor 3. Ohm Thermistor

32 Heat Exchanger Thermistor

1. Check Thermistor wiring for damage 2. Check and clean scale from Thermistor 3. Ohm Thermistor

33

Outgoing Water Temperature Sensor

1. Check Thermistor wiring for damage 2. Check and clean scale from Thermistor 3. Ohm Thermistor


13

34 Ambient Thermistor

1. Check Thermistor wiring for damage 2. Check and clean Ambient Thermistor 3. Ohm Thermistor

If wiring and component readings are normal:

1. Check for restrictions in airflow around unit and vent terminal 2. Ensure fan blade is tight on motor shaft and spins freely

35 Improper Thermistor Connection

1. Check that all Thermistors are secured to proper connections on Control

Board 2. Check that all quick connectors between Control Board and Thermistors

51 Gas Control Valve 1. Check Gas Control Valve wiring harness for loose or damaged terminals 2. Ohm Gas Control Valve

52 PGFR Valve (Modulating Valve)

1. Check PGFR Valve wiring harness for loose or damaged connections 2. Ohm PGFR Valve

61 Installation/Maintenance:

Blower Motor

1. Ensure Blower Motor will turn freely. Motor will operate with a small amount of restriction

2. Check wiring harness to Motor for damaged and/or loose connections 3. Check venting length not to exceed max lengths and bends

65 Water Control Valve 1. Check Water Control Valve wiring harness for loose or damaged terminals 2. Check for proper voltage to Water Control Valve

66 Water Bypass Valve 1. Check Water Bypass Valve wiring harness for loose or damaged terminals 2. Check for proper voltage to water by-pass solenoid

71 Gas Control Valve 1. Check Gas Control Valve wiring harness for loose or damaged terminals 2. Ohm Gas Control Valve

72 Flame Rod (Detected False Flame)

1. Ensure Flame Rod(s) is touching flame when unit fires 2. Check inside burner chamber for any foreign material blocking flame at Flame

Rod(s) 3. Check all wiring to Flame Rod for damage 4. Check Flame Rod for proper voltage 5. Remove Flame Rod and check, clean with steel wool (Do not use sandpaper)


14

76 Communication Fault With Remote Control

1. Check Remote Control wiring for loose or damaged connections 2. Bypass Remote Control: connect Remote Control directly to remote

connection at bottom of the heater. Replace cable if found to be faulty 3. Remove water heater power cord from 3 prong outlet. Disconnect the

Remote Control. Plug heater back into supply and test heater without Remote Control connected

79 Blower Motor Current Fault

1. Ensure Blower Motor will turn freely. Motor will operate with a small amount of restriction

2. Check Fan Motor for proper voltage and for water (condensation) damage

80

&

81

Gas Control Valve 1. Ohm Gas Control Valve 2. Check voltage of all Flame Rods

82

Installation:

Control Board Is Not Programmed.

Verify Program Chip is installed

90 Maintenance/Installation:

Blocked Flue/Air Intake Clean any blockage in Heat Exchanger, Blower Motor, inlet flue and exhaust flue

92

Condensing Only:

Maintenance Warning:

Neutralizer Needs To Be Replaced (Unit Will Still Be Operable)

Replace Neutralizer

93

Condensing Only:

Maintenance:

Neutralizer Must Be Replaced (Unit Will NOT Operate)

Replace Neutralizer

99

Maintenance/Installation:

Blower Motor Cannot Vent

1. Clear vent blockages 2. Check for blocked Heat Exchanger


15

COMPONENTS

B

3

2 4 5

9

10 7

6

11

8

1

D

A

1. Condensing ONLY: Secondary Stainless Steel Heat Exchanger

2. Condensing ONLY: Neutralizer

3. Primary Heat Exchanger

4. Flame Rod(s)

5. Sight Glass

6. Igniter Rod

7. Igniter Coil

8. Gas Control Valve

9. Water Control Valve

10. Water Bypass Valve

11. Control Board

12. Blower Motor (Behind Control Board)

A. Heat Exchanger Thermistor

B. Outlet Thermistor

C. Inlet Thermistor

D. Ambient Thermistor

C


16

Maintenance Mode Panel Display The Rheem Tankless has a Maintenance Mode chart on the Remote Control. To access the Maintenance Mode, turn the unit OFF at Remote Control. Then hold down the UP and DOWN arrow keys at the same time for 5 seconds. You will hear an audible beep and see the display go to 1E. By pressing the UP and DOWN arrow keys on the remote thermostat, you can access a variety of information about the water heater. To activate the unit while displaying the maintenance panel: push the power button once, open a hot water fixture, and the green LED will illuminate. This will allow you to access a variety of real time information while the unit is in operation.

Shortcut: Lift dip switch #1 to the up position to go immediately into maintenance mode. This can be done while the water heater is in operation.

While in Maintenance Mode you want to push the up arrow key to select the table you wish to view. The table is designated by a letter and is always displayed as the second digit. Then push the down arrow key to display the number item in the table you selected. You can select as many as 8 readings for each table.

To perform diagnostics in this service manual, press the up arrow until you get to table1Y.

Now using your down arrow you can change the number in front of Y. As you move through the diagnostic readings, the selected table will flash first and then the diagnostic reading. You will see the

following as you navigate the Y table:

0Y = Flame Rod Status

1Y = Water Flow in gallons per minute

2Y = Ambient air temperature

3Y = Water inlet temperature

4Y = Heat exchanger temperature

5Y = Hot water outlet temperature

6Y = Fan speed (x 100 rpm)

7Y = Power for modulating gas valve

8Y = Null (no reading)

9Y = Null (no reading)

*FULL MAINTENANCE DISPLAY CHART AVAILABLE ON NEXT PAGE*


17

MAINTENANCE INFORMATION TABLE

First Digit – Use DOWN arrow key on Remote Control

Seco

nd D

igit

– U

se U

P ar

row

key

on

Rem

ote

Cont

rol

0* 1* 2* 3* 4* 5* 6* 7* 8* 9*

*E Null Fault Codes of the most recent 8 faults Null

*F Null Sequence Number of the most recent 8 faults Null

*C Total combustion times until recent error fault (** x 10000times) Null

*D Total combustion times until recent error fault (** x 100 times) Null

*H Total combustion period until recent error fault (** x 1000 hours) Null

*J Total combustion period until recent error fault (** x 10 hours) Null

*Y

Flam

e Ro

d

Stat

us

GPM

Flo

w R

ate

(*.*

GPM

)

Am

bien

t A

ir

Tem

pera

ture

Cold

Wat

er In

let

Tem

pera

ture

Hea

t Ex

chan

ger

Tem

pera

ture

Hot

Wat

er

Out

let

Tem

pera

ture

Fan

Spee

d x

100

RPM

Pow

er fo

r

P.G

.F.R

. val

ve

Nul

l

Nul

l

*A

Nul

l

Cont

rol

Line

Fa

n

Det

ectiv

e

Valu

e

Fan

Mot

or

Curr

ent

Nul

l

Nul

l

Nul

l

Nul

l

Nul

l

Sequ

ence

Num

ber


18

CONTROL BOARD – Color Picture • Each letter indicates the connector identifier

es ood. Proceed to your error code to resolve the sue. The error codes are listed in the table of ontents.

M T

MIN MAX ADJ


19

CONTROL BOARD

DIP #1 – Adjust max temperature; EZ Link cable

DIP #2 – Adjust for altitude differential

MIN & MAX (SW1 & SW2) – Adjust water temperature setting; gas pressure; etc.

ADJ (SW3) – Adjust gas pressure etc.

M – Flame Rod for all models (detects flame)

T – Flame Rod for indoor models only (monitors combustion efficiency)

F – Communication port (manifold installations)

A – Fuel type and temperature Program Chip

U – Over Heat Limiter (OHL)

R – Thermistors (Ambient, Inlet, Outlet, Heat Exchanger) & Modulating Gas Valve (PFGR)

S – Water Flow Sensor

C – Water Control Valve

B – Water Bypass Valve

V – Remote Control (Main Bath)

G – Blower Motor

K – Gas Control Valve

H – Igniter Rod


20

NOTES:

________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________


21

RESET PROCEDURE:

1. Turn unit OFF. Remove Front Cover. Locate the Dip Switches on the Control Board.

2. Make sure all the Dip Switches are OFF (down position). 3. Locate the #2 Dip Switch and turn it ON (up position) then

immediately turn it off. 4. Within 5 seconds, press and hold the MIN and MAX button for at

least 2 seconds. 5. The Remote Control will flash briefly. 6. You can operate unit.

CLEARING FAULT HISTORY PROCEDURE:

1. Turn unit OFF. Remove Front Cover. Locate the Dip Switches on the Control Board.

2. Make sure all the Dip Switches are OFF (down position). 3. Locate the #1 Dip Switch and turn it ON (up position) then

immediately turn it off. 4. Within 5 seconds, press and hold the MIN and MAX button for at

least 2 seconds. 5. The Remote Control will flash briefly. This indicated the fault

history has been cleared. 6. You can verify clearing history by entering Maintenance Mode

and check the code at location 1E. Should read NULL.


22

No Error Code & No Hot Water (Remote Control Displays Hot Water Temperature Setting)

Explanation: No hot water is delivered when water is flowing through unit and Remote Control displays the hot water temperature setting.

Possible Causes:

• Water Flow

• DIP 1 Setting On Main Control Board (PCB)

• Water flow sensor

Water Flow:

1. Turn OFF water supply to unit. Turn Remote Control OFF; unplug power cord at wall outlet. Wait 10 seconds; plug power cord back into outlet; wait 20 seconds; turn the Remote Control ON. Turn water supply ON; check the nearest hot water fixture for hot water. If you have hot water, then the unit needed to be reset.

2. Water flow might be too low. Open multiple hot water fixtures. If unit fires then there is not enough water flow to engage the unit at a particular fixture. Check your fixture aerator screen(s) for debris. Clean if necessary.

3. Your water lines might be crossed. Make sure your hot and cold water supply lines are connected to the appropriate hot and cold water assembly connections on the unit.

4. Your water flow may be restricted by a debris in Water Filter. Remove the water filter and inspect. Clean if necessary.

Dip 1 Setting:

All Dip 1 switches must be in the ‘OFF’ position.

Manifold Units ONLY: Go to Error Code 03 to verify proper DIP 1 setting

DIP

#1


23

P1 - Warning Code Explanation: No hot water is delivered when water is flowing through unit and Remote Control displays P1. When water flow does not reach a minimum 0.4 GPM rate @ 35o T, for five seconds, P1 warning code is displayed.

Possible Causes:

• Not Enough Water Flow

Water Flow:

Turn the water supply to the unit off. Turn the remote thermostat off, wait 10 seconds and turn the remote thermostat on. Turn the water supply to the unit on and check the nearest hot water fixture for hot water. If you have hot water, then the unit needed to be reset.

Your water lines might be crossed. Make sure your hot and cold water supply lines are connected to the appropriate hot and cold water connections on the unit.

Water flow might be too low. Open multiple hot water fixtures. If unit fires then there is not enough water flow to engage the unit at a particular fixture. Check your fixture aerator screen(s) for debris. Clean if necessary.

Your water flow may be restricted by a dirty In-Line Water Filter. Remove the water filter and inspect. Clean if necessary.


24

1L - Warning Code Explanation: The Control Board has detected possible lime build-up inside the heat exchanger. To prevent permanent damage to the unit, the unit must be drained and flushed. Flushing procedures may need to be repeated for excessive lime and scale build-up. To reset 1L Code, hold down the MIN and MAX buttons at the same time for 10 seconds.

Lime and scale flushing procedure for tankless water heaters: In areas with hard water conditions the tankless water heater can develop lime and scale deposits in the heat exchanger. These deposits can restrict the water flow and degrade the performance of your water heater. These instructions are to provide a safe and effective means to remove lime and scale build up in the heat exchanger of your tankless water heater. If you are not comfortable with this procedure, then seek the assistance of a plumbing professional. Flushing Procedure with Isolation Valves: If your tankless water heater is not installed with isolation valves, it is recommended that you seek the assistance of a plumbing professional.

1. Turn off the electricity and gas, to the tankless water heater. Do not perform this procedure with power or gas turned on; damage to the water heater can occur.

2. Shut off the main water supply valve to the tankless water heater. Consult the instructions provided by the isolation valve manufacturer for specifics in using their valve assemblies.

3. Attach a small garden hose on each drain valve. Connect the cold water hose to the output of a small circulation pump. A pond pump or similar model can be used for this application.

4. Pour approximately five gallons of virgin food grade white vinegar into a pail.

5. Place the inlet hose of the pump and the drain hose from the hot water heater into the pail.

6. Open the drain valves and turn on the pump. Allow solution to circulate for approximately 45 minutes to an hour.

7. Turn off the pump and drain the vinegar from water heater. Close the cold water drain valve.

8. Open the main cold water supply valve and allow fresh water to flush through the water heater for at least 5 minutes to remove all traces of vinegar from the system.

9. Close the cold water main valve and remove water filter screen located in cold water inlet of water heater. Clean the screen of any sediment or dirt and reinstall the filter. See the Use and Care Manual provided with your tankless water heater for detailed instructions.

10. Turn on the water shutoff valves, run a hot water tap to purge any air from the water lines and check the system for any leaks.

11. Turn on gas, electricity, and remote control thermostat and set the desired temperature.

12. Run hot water from several locations to check the operation and performance of the water heater.


25

03 - Error Code (Only for manifold installations utilizing EZ-Link; MIC-6; or MIC-185) Explanation: Communication failure between water heaters, remote control, and/or manifold controller. Diagnostic Checks:

• DIP1 Setting On Main Control Board (PCB)

DIP 1 SETTING:

Manifold units only: DIP #1, switch #4 must be in the ‘ON’ position for each unit

Check ALL Molex connections on ALL Control Boards


26

05 – Warning Code Explanation: The Flame Rod has detected improper burner combustion. The unit is NOT able to maintain the proper fuel/air mixture for proper combustion. This warning code is commonly caused by VENTING and/or GAS SUPPLY. The unit will continue to operate and attempt to resolve improper combustion, but may eventually shut down with an error code 11, 12, or 13. Diagnostic Checks:

• GAS SUPPLY & VENTING • Dip #2 Setting On Printed Circuit Board (PCB)

GAS SUPPLY & VENTING **REFER TO USE & CARE MANUAL**

Make sure you have sufficient fuel for the unit to operate properly.

1. Gas Type (LP or Natural Gas) 2. Gas Pressure 3. Gas Pipe Size 4. Gas Flex Line Not To Exceed 36” In Length, Has The Proper ID (Inside Diameter), & Correct BTU Rating 5. Gas Regulator 6. Gas Shut Off Valves 7. Air In Gas Line

Visually inspect venting for possible blockage and/or recirculation of exhaust. 1. Approved Venting Materials 2. Approved Vent Terminations 3. Vent Lengths 4. Location Of Vent Termination (Recirculation of exhaust) 5. Blocked Venting 6. Venting Not Sealed Properly


27

DIP #2 SETTING:

Locate the two DIP switches at top right of PCB. Switch labeled DIP #2 is the bottom switch.

DO NOT ALTER ANY OTHER SWITCHES

1

Sea Level to 3,280 Feet

3

2

4


28

NOTES:

________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________


29

10 – Warning Code Explanation: The Blower Motor is not creating enough ventilation. The system passed the pre-purge cycle, but detects vent blockage during normal operation. The unit will continue to operate but may eventually shut down with Error Code 99. First check your GAS SUPPLY & VENTING; the most common causes for Error Code 10. Diagnostic Checks:

• GAS SUPPLY & VENTING • Blower Motor



1. Gas Type (LP or Natural Gas) 2. Gas Pressure 3. Gas Pipe Size 4. Gas Flex Line Not To Exceed 36” In Length, has the proper ID (Inside Diameter), and correct BTU rating 5. Gas Regulator 6. Gas Shut Off Valves 7. Air In Gas Line

Visually inspect venting for possible blockage and/or recirculation of exhaust.

1. Approved Venting Materials 2. Approved Vent Terminations 3. Vent Lengths 4. Location Of Vent Termination (Recirculation of exhaust) 5. Blocked Venting 6. Venting Not Sealed Properly


30

BLOWER MOTOR DIAGNOSTICS:

Turn power OFF. Remove and reinsert connector “G” on Control Board. Attempt to operate unit again. IF 10

Warning Code does NOT display, unit had a loose connection.

1

Remove 3 screws holding Blower Motor in place. Clean Blower Motor and reassemble unit. Attempt to operate

unit again. IF 10 Warning Code does NOT display: Blower Motor needed to be cleaned.

Turn power OFF. Remove 3 screws for Control Board mounting bracket. Remove connectors “M”, “T”, & “G”.

Pull PCB out of way to access Blower Motor.

Locate Min & Max buttons on Control Board. Continue to diagnostic chart on next page.

3

2

4

Bottom of Unit

Control Board

Screws

Blower Motor


31

BLOWER MOTOR Diagnostic Chart

YES NO

NO

YES

YES

NO

Test DC voltage across black and red wires on connector “G”:

144 – 192 DC VOLTS

Is the DC voltage OK?

Remove and reinsert connector “G” at Control Board.

Attempt to operate unit again. IF unit continues to display Error Code 10:

Replace Control Board


Press and hold down “MAX” button on Control Board to activate the Blower Motor. While Blower Motor is running, test DC voltage across black and white wires

on connector “G”:

12 – 18 DC VOLTS

Press and hold down “MAX” button on Control Board to activate the blower motor. While blower is

running, test DC voltage across black and blue wires on connector “G”:

4 – 10 DC VOLTS

Remove and reinsert connector “G” at Control Board.

Attempt to operate unit again. IF unit continues to display Error Code 10:


Is the DC voltage OK? Replace Blower Motor

Attempt to operate unit again. If unit continues to display Warning Code 10:

Control Board and Blower Motor are ‘OK’: CHECK VENTING & GAS SUPPLY


32

NOTES:

________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________


33

11 – Error Code Explanation: This error code is commonly a result of GAS SUPPLY and/or VENTING. Flame Rod(s) does not detect flame. This Is caused by the following: Inadequate GAS SUPPLY; Inadequate VENTING; Igniter Rod NOT sparking; Build-up on Flame Rod(s) caused by inadequate GAS SUPPLY and/or VENTING; Gas Valve. IMPORTANT: If all water heater components test ‘OK’, you must thoroughly inspect your GAS SUPPLY & VENTING. First Check: GAS SUPPLY & VENTING Diagnostic Checks:

• GAS SUPPLY & VENTING • Igniter Rod • Flame Rod(s) • Gas Control Valve






34

IGNITER ROD DIAGNOSTICS: (spark is NOT visible)

Turn power OFF. Remove and reinsert connector “H” on Control Board.

1

Remove and reinsert Igniter Coil cable on Igniter Rod. Turn power ON.

Remove and reinsert white Molex connector at Igniter Coil mounted on right side of unit.

While unit is attempting to ignite, determine IF spark is visible through sight glass. IF YES, unit had a loose

connection. IF NO, continue to diagnostic chart on next page.

3

2

4

Igniter Rod Sight Glass

Igniter Coil


35

IGNITER ROD Diagnostic Chart

YES

NO

NO

Check AC Volts across 2 grey wires on connector “H” while unit is attempting to

ignite:

108 – 132 Volts AC

Attempt to operate unit again. IF Igniter Rod does not spark and unit

malfunctions due to Error Code 11:


Replace Igniter Coil

YES

YES

Is the voltage OK?

Does spark arc across Igniter Coil cable and Igniter

Rod?

Remove Igniter Coil cable from Igniter Rod. While unit is attempting to ignite, hold end of Igniter Coil

cable 1/8” from end of Igniter Rod.

Make sure you hold Igniter Coil cable on the rubber insulation while performing this check

Remove Igniter Rod and clean.

Reconnect Igniter Coil cable and Igniter Rod.

Attempt to operate unit again.

NO Is spark visible through sight

glass?

Replace Igniter Rod

Igniter Rod is ‘OK’

IF unit fails again due to Error Code 11:

IF flame IS visible, diagnose Flame Rods

IF flame is NOT visible, diagnose Gas Control Valve


36

FLAME ROD(S) DIAGNOSTICS: (flame IS visible)

Turn power OFF. Remove and reinsert white connector “M” and blue connector “T” on Control Board.

1

Locate sight glass. While unit is attempting to ignite, determine if flame is touching Flame Rod(s). IF NO,

remove any foreign debris. IF foreign debris NOT present: CHECK GAS SUPPLY & VENTING.

Remove and reinsert terminals on Flame Rods(s)*. Attempt to operate unit again. IF 11 Error Code does NOT

display, unit had a loose connection.

On Remote Control; go to Maintenance Mode 0Y table. For Maintenance Mode instructions go to page 16.

Continue to diagnostic chart on next page.

3

2

4

*Indoor Models ONLY: 2 Flame Rods

Sight Glass

Flame Rod(s)*


37

FLAME ROD(s) Diagnostic Chart

NO

YES

YES

NO

Cycle unit ON and check AC Volts at white “M” & blue “T” connectors:

1 – 100 AC VOLTS

Is the AC voltage OK?


IF unit malfunctions due to Error Code 11:


Is Flame Rod(s) detecting flame?

Cycle unit ON; while in Maintenance Mode check Flame Rod status under table 0Y. IF detecting flame,

Maintenance Mode will display:

Indoor Models: 05 Outdoor Models: 01

Attempt to operate unit again. If the unit malfunctions due to an Error Code 11:

Flame Rod(s) are ‘OK’

*CHECK: GAS, VENTING, & GROUND*

Remove and clean Flame Rod(s). Attempt to operate unit again.

IF Flame Rod(s) still does not detect flame:

Replace Flame Rod(s).


38

GAS CONTROL VALVE DIAGNOSTICS: (Igniter Rod DOES spark & NO flame)

Turn power OFF. Remove and reinsert connector “K” on Control Board.

1

Locate PGFR valve on lower right of unit. Remove and reinsert Molex connector with red wire and Molex

connector with black wire on PGFR. Attempt to operate unit again.

Remove and reinsert connector “R” on Control Board.

IF 11 Error Code does NOT display, unit had a loose connection.

IF 11 Error Code IS displayed, continue to diagnostic chart on next page.

3

2

4

PGFR

Molex Connectors


39

GAS CONTROL VALVE Diagnostic Chart

NO

YES

YES

NO

While unit is attempting to ignite, check DC voltage across red wire #1 and black

wire #2 on connector “R”:

1.5 – 14 DC VOLTS



IF the unit malfunctions due to an Error Code 11:


Is the resistance OK?

Turn unit OFF; remove Molex connector “R”. Measure resistance across red wire #1 and black wire

#2 on Molex connector “R”:

40 – 80 Ohms

PGFR is ‘OK’

Continue to next page

Remove and reconnect terminals on PGFR. Attempt to operate unit again.

IF unit malfunctions due to Error Code 11:

Replace Gas Control Valve


40

GAS CONTROL VALVE Diagnostic Chart

NO Is the

resistance OK?

YES

Measure resistance across black wire #6 and yellow wire #1 on Molex connector

“K”:

0.8k – 2.4k Ohms


Measure resistance across black wire #6 and red wire #5 on connector “K”:

0.8k – 2.4k Ohms

Measure resistance across black wire #6 and blue wire #4 on connector “K”:

0.8k – 2.4k Ohms

Measure resistance across black wire #6 and white wire #2 on connector “K”:

0.8k – 2.4k Ohms

Measure resistance across black wire #6 and grey wire #3 on connector “K”:

0.8k – 2.4k Ohms

Is the resistance

OK?

YES

YES

Is the resistance

OK?

YES

Is the resistance

OK?

YES

Is the resistance

OK?

NO

NO

NO

NO

Gas Control Valve is ‘OK’ Continue to next page

Turn unit OFF and remove Molex connector “K” to measure resistance






41

CONTROL BOARD Diagnostic Chart

NO

NO

NO

NO

NO

YES

Measure DC voltage across black wire #6 and yellow wire #1 on connector “K”:

90 – 120 DC Volts

Is the voltage OK?

Measure DC voltage across black wire #6 and red wire #5 on connector “K”:

90 – 120 DC Volts

Measure DC voltage across black wire #6 and blue wire #4 on connector “K”:

90 – 120 DC Volts

Measure DC voltage across black wire #6 and white wire #2 on connector “K”:

90 – 120 DC Volts

Measure DC voltage across black wire #6 and grey wire #3 on connector “K”:

90 – 120 DC Volts

Is the voltage OK?

YES

YES

Is the voltage OK?

YES

Is the voltage OK?

YES

Is the voltage OK?

Control Board is ‘OK’ IF all components tested ‘OK’:

**CHECK GAS, VENTING, & GROUND**

All voltage checks must be performed while unit is attempting to go to main burner and Molex connector “K” IS connected to Control Board. Restart unit after each voltage check.


Replace PCB





42

NOTES:

________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________


43

12 – Error Code Explanation: Commonly a result of inadequate GAS SUPPLY. Unit detected the presence of flame then Flame Rod lost flame recognition.

First Check: *GAS SUPPLY & VENTING*

Diagnostic Checks:

• GAS SUPPLY & VENTING • Flame Rod(s) • Gas Control Valve






44



1



Remove and reinsert terminals on Flame Rod(s)*. Attempt to operate unit again. IF 11 Error Code does NOT




3

2

4

Flame Rod(s)*


Sight Glass


45


NO

YES

YES

NO


1 – 100 AC VOLTS






Cycle unit ON; while in Maintenance Mode check Flame Rod(s) status under table 0Y. IF detecting

flame, Maintenance Mode will display:


Attempt to operate unit again. IF the unit malfunctions due to an Error Code 12:

Flame Rods(s) are ‘OK’

*CHECK: GAS, VENTING, & GROUND*





46

NOTES:

________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________


47

13 – Error Code Explanation: Indoor units ONLY. Flame Rod 2 (FL #2) is detecting poor combustion. This is commonly caused by inadequate or improperly installed VENTING (venting includes fresh air intake and exhaust). Other possible causes: Poor or NO ground connection; dirty or defective FL #2. *If unit shuts down 5 times within a 4 hour period due to an error code 13, the unit must be reset by performing reset procedure on page 21. First Check: VENTING (Primary cause is blockage of the Fresh Air Intake Vent) Diagnostic Checks:

• VENTING • Ground Connection • Flame Rod FL-2

GROUND CONNECTION DIAGNOSTICS:

VENTING:

**REFER TO USE & CARE MANUAL**


Locate and visually inspect green ground wire connections on lower left side of PCB.

Ensure the wires are connected properly and not damaged.

1

Ensure you have a proper ground at power supply to unit.

2


48



1



Remove and reinsert terminals on Flame Rod(s)*. Attempt to operate unit again. IF 11 Error Code does NOT




3

2

4

Flame Rod(s)*


Sight Glass


49


NO

YES

YES

NO


1 – 100 AC VOLTS






Cycle unit ON; while in Maintenance Mode check Flame Rod(s) status under table 0Y. IF detecting

flame, Maintenance Mode will display:



Flame Rod(s) are ‘OK’ – Unit operation is normal:

CHECK VENTING





50

14 – Error Code Explanation: Mid & High Efficiency: Over Heat Limiter (OHL) malfunction. High Efficiency ONLY: Over heat condition in the venting has triggered the Over Temp Limit Switch

Diagnostic Checks: • Mid & High Efficiency:

OHL • High Efficiency ONLY:

Over Temp Limit Switch

OHL DIAGNOSTICS:

Mid Efficiency ONLY: IF 14 Error Code does NOT display, unit had a loose

connection. IF 14 Error Code IS displayed, continue to diagnostic chart on next page.

Turn power OFF. Remove and reinsert white connector “U” on Control Board (white Molex with 2

white wires). Attempt to operate unit again.

1 2

3

High Efficiency ONLY: IF 14 Error Code does NOT display, unit had

a loose connection. IF 14 Error Code IS displayed, locate the over

temp switch and continue to diagnostic chart on next page.

OHL

Over Temp Switch


51

14 – Error Code Diagnostic Chart

NO

High Efficiency ONLY:

Check for continuity across the Over Temp Switch

Turn power OFF and remove Molex connector “U”. Measure resistance

between both white wires:

50K – 500K Ohms

The OHL has activated due to excessive temperatures. This is normally caused by

inadequate/wrong GAS SUPPLY or inadequate VENTING.

Check GAS SUPPLY & VENTING

Unit had a loose connection, operation appears to be normal.

NO

YES

YES

NO

Is the resistance to the OHL ‘OK’?

Did the unit shut down due to

Error Code 14?

Reconnect the Molex; attempt to operate unit again.


Is this a High Efficiency Unit?

Mid Efficiency Unit ONLY: Replace Unit

NO

YES

Is the continuity ‘OK’?

YES


Replace Over Temp Switch


Replace Unit


52

NOTES:

________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________


53

15 – Error Code Explanation: The hot water temperature and/or heat exchanger temperature reached 207 degrees F for more than 15 seconds. IMPORTANT: Inadequate GAS SUPPLY and/or VENTING will create hot spots in the heat exchanger. Diagnostic Checks:

• GAS SUPPLY & VENTING • Sediment Build-Up in Heat Exchanger • Heat Exchanger Temperature Sensor

SEDIMENT BUILD-UP DIAGNOSTICS: Go to Error Code 1L for flushing instructions

HEAT EXCHANGER TEMPERATURE SENSOR DIAGNOSTICS:

Go to Error Code 32 for Heat Exchanger Temperature Sensor diagnostic instructions.






54

16 – Error Code Explanation: Outlet water temperature is too hot. The water temperature is above the set point on Remote Control. Check the Outlet Thermistor FIRST.

Diagnostic Checks: 1. Outlet Thermistor 2. Water Bypass Valve

OUTLET WATER TEMPERATURE SENSOR DIAGNOSTICS:

Turn power OFF. Remove connector “R” on Control Board. Measure resistance between Black #3 & red #4 wires: 7K – 23K Ohms. IF OK, attempt to operate unit again. IF 16 Error Code does NOT display, unit

had a loose connection.

IF resistance tested OK and 16 Error Code IS displayed, go to Error Code 66 for Water Bypass Valve

diagnostics. IF resistance NOT OK, go to step 2.

Turn power OFF. Remove 3 screws for Control Board mounting bracket. Remove connectors “M”, “T” & “G”. Pull control board out of way to access BLACK

Molex for Outlet Thermistor located near the Blower Motor.

1 2

3

Control Board

Bottom of Unit

Screws

Molex Connectors

Outlet Thermistor

Separate top and bottom of BLACK Molex for Outlet Thermistor. Top of

Molex has 2 black wires and 1 red wire. Bottom of Molex has 2 black wires. Continue to diagnostic chart

on next page.


55


Check the resistance across 2 black wires

on bottom Molex:

7k – 23K Ohms

Clean Outlet Thermistor. Retest Thermistor. IF tests OK, the water heater appears to be normal, attempt to operate

unit again. IF resistance NOT OK:

Replace Outlet Thermistor

Replace wiring harness for connector “R” on Control Board

NO

YES

YES

NO

Is the resistance to the Outlet

Thermistor OK?

Is the continuity across all wires

OK?

Remove Molex from connector “R” at Control Board. Check continuity from black #3 wire at Molex

connector “R” and black wires on black Molex located behind Control Board. Check continuity from red #4 wire at Molex connector “R” and red wire on black

Molex located behind Control Board


If the unit malfunctions due to an Error Code 16:

Go to Error Code 66 for Water Bypass Valve diagnostics


56

24 – Error Code Explanation: Remote Control buttons were depressed for more than 20 seconds. IF you were manually holding down any Remote Control buttons for more than 20 seconds, release the buttons and NO Error Code will be displayed. Unit will operate normally. IF error code 24 is still displayed after releasing Remote Control buttons, continue to Remote Control diagnostics. Diagnostic Checks:

• Remote Control

REMOTE CONTROL DIAGNOSTICS:

Visually inspect Remote Control wiring for damaged or loose terminals.

1

Turn power OFF. Remove and reconnect Remote Control wiring terminals at bottom of unit. Attempt to operate

unit again. IF 24 Error Code does NOT display, unit had a loose connection.


2

Hot Water Outlet

Cold Water Inlet

Remote Control Wiring Terminals


57


YES

NO

Unplug unit and remove Remote Control wires from wiring terminals on bottom of

unit. Use a new short piece of wire to connect the Remote Control directly to the Remote Control Wiring Terminals located at bottom of unit. Plug unit in

and open a hot water source.

Did the unit display Error

Code 24?

The wiring is defective.

Replace Remote Control wiring.

Replace Remote Control


58

NOTES:

________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________


59

29 – Error Code Explanation: High Efficiency Condensing Units ONLY: Condensate Drain is NOT draining.

Diagnostic Checks:

• Plug not removed from condensate drain • Pinch in condensate drain line • Blockage in condensate drain line • Drain line has unnecessary “P” trap

CONDENSATE DRAIN DIAGNOSTICS:

Ensure you removed the condensate protection plug located at bottom of unit.

1

Check your condensate drain line for internal or external blockage. Make sure drain line is NOT pinched.

2

Drain Line


60

31 – Error Code Explanation: Inlet Thermistor malfunction

Diagnostic Checks: • Inlet Thermistor

INLET THERMISTOR DIAGNOSTICS:

Turn power OFF. Remove 3 screws for Control Board mounting bracket. Remove connectors “M”, “T” & “G”. Pull Control Board out of way to access WHITE Molex for Inlet Thermistor located near the Blower

Motor.

Turn power OFF. Remove connector “R” on Control Board. Measure resistance between Black #3 & white #6 wires: 7K – 23K Ohms. IF OK, attempt to operate

unit again. IF 31 Error Code does NOT display, you had a loose connection.

1 2

3

Separate top and bottom of WHITE Molex for the Inlet Thermistor. Top of

Molex has 2 black wires and 1 white wire. Bottom of Molex has 2 white wires. Continue to Diagnostic Chart

on next page.

Screws

Bottom of Unit

Control Board

Blower Motor

Molex Connectors

Inlet Thermistor


61


NO

NO

Check the resistance across 2 white wires on bottom Molex:

7K – 23K Ohms

Clean scale build-up on Inlet Thermistor. Retest Thermistor.

IF tests OK, the water heater appears to be normal. Attempt to operate unit again.

IF resistance NOT OK:

Replace Inlet Thermistor

Replace wiring harness for Connector “R” on Control Board

YES

YES

Is the resistance to the Inlet

Thermistor OK?


OK?


connector “R” and black wires at White Molex located behind Control Board. Check continuity from white #6 wire at Molex connector “R” and white wire at

White Molex located behind Control Board





62

32 – Error Code Explanation: Heat Exchanger Thermistor malfunction

Diagnostic Checks: • Heat Exchanger Thermistor

HEAT EXHCANGER THERMISTOR DIAGNOSTICS:

Turn power OFF. Remove 3 screws for Control Board mounting bracket. Remove connectors “M”, “T” &

“G”. Pull Control Board out of way to access YELLOW* Molex for Heat Exchanger Thermistor located near the

Blower Motor.

Turn power OFF. Remove connector “R” on Control Board. Measure resistance between Black #3 & Yellow

#5 wires: 7K – 23K Ohms. IF OK, attempt to operate unit again. IF 32 Error Code does NOT display, unit


1 2

3

Separate top and bottom of YELLOW* Molex for Heat Exchanger Thermistor. Top of Molex has 2 black wires and 1 yellow* wire. Bottom of Molex has 2 white wires. Continue to Diagnostic

Chart on next page.

Screws

Bottom of Unit

Control Board

Molex Connectors

Blower Motor

*High Efficiency (Condensing) Units ONLY: Green wire & Green Molex


63


Check the resistance across 2 white wires

on bottom Molex:

7k – 23K Ohms


Clean Scale Build-Up on Heat Exchanger Thermistor. Retest Thermistor.

IF test OK, the water heater appears to be normal. Attempt to operate unit again.

IF resistance NOT OK: Replace Heat Exchanger Thermistor

NO

YES

YES

NO

Is the resistance to the Heat Exchanger

Thermistor OK?


OK?


connector “R” and black wire at Yellow* Molex located behind Control Board. Check continuity from Yellow* #5 wire at Molex connector “R” and Yellow* wire at Yellow* Molex located behind Control Board




*High Efficiency (Condensing) Units ONLY: Green wire & Green Molex


64

33 – Error Code Explanation: Outlet Thermistor malfunction

Diagnostic Checks: • Outlet Thermistor

OUTLET THERMISTOR DIAGNOSTICS:

Turn power OFF. Remove 3 screws for Control Board mounting bracket. Remove connectors “M”, “T” & “G”. Pull Control Board out of way to access BLACK

Molex for Outlet Thermistor located near the Blower Motor.

Turn power OFF. Remove connector “R” on Control Board. Measure resistance between Black #3 & Red #4 wires: 7K – 23K Ohms. IF OK, attempt to operate unit again. IF 33 Error Code does NOT display, unit


1 2

3

Separate top and bottom of BLACK Molex for Outlet Thermistor. Top of

Molex has 2 black wires and 1 red wire. Bottom of Molex has 2 black

wires. Continue to Diagnostic Chart on next page.

Screws

Bottom of Unit

Control Board

Blower Motor

Molex Connectors

Outlet Thermistor


65



on bottom Molex:

7k – 23K Ohms

Clean Scale Build-Up on Outlet Thermistor. Retest Thermistor. IF tests OK, the water heater appears to be normal. Attempt to operate unit again. IF resistance NOT OK:

Replace Outlet Thermistor


NO

YES

YES

NO

Is the resistance to the Outlet

Thermistor OK?


OK?

Remove Molex from Connector “R” at Control Board. Check continuity from black #3 wire at Connector “R” Molex and black wires at black Molex located behind Control Board. Check continuity from red #4 wire at

Connector “R” Molex and red wire at Black Molex located behind Control Board





66

34 – Error Code Explanation: Ambient Thermistor malfunction

Diagnostic Checks: • Ambient Thermistor

AMBIENT THERMISTOR DIAGNOSTICS:

Turn power OFF. Remove 3 screws for Control Board mounting bracket. Remove connectors “M”, “T” & “G”. Pull Control Board out of way to access BLUE

Molex for Ambient Thermistor located near the Blower Motor.

Turn power OFF. Remove connector “R” on Control Board. Measure resistance between Black #3 & Blue #7 wires: ‘Refer to Data Table for resistance value’. IF OK, attempt to operate unit again. IF 34 Error Code

does NOT display, unit had a loose connection.

1 2

3

Separate top and bottom of BLUE Molex for Ambient Thermistor. Top of

Molex has 2 black wires and 1 blue wire. Bottom of Molex has 2 black

wires. Continue to Diagnostic Chart on next page.

Screws

Bottom of Unit

Control Board

Blower Motor

Molex Connectors

Ambient Thermistor Data Table

64DV; 84DV; 95DV: 7K – 23K Ohms

64X; 84X; 95X: 2K – 72K Ohms

H95DV; H95X: 2K – 72K Ohms


67



on bottom Molex:

Refer to Data Table below


Clean Ambient Thermistor. Retest Thermistor. IF tests OK, the water heater

appears to be normal. Attempt to operate unit again. IF resistance NOT OK:

Replace Ambient Thermistor

NO

YES

YES

NO

Is the resistance to the Ambient Thermistor OK?


OK?

Remove Molex from Connector “R” at Control Board. Check continuity from black #3 wire at Molex

connector “R” and black wires at Blue Molex located behind Control Board. Check continuity from blue #7

wire at Molex connector “R” and blue wire at Blue Molex located behind Control Board





64DV; 84DV; 95DV: 7K – 23K Ohms

64X; 84X; 95X: 2K – 72K Ohms



68

35 – Error Code Explanation: Improper Thermistor connection. Unit has four Thermistors; one or more possibly has a poor connection or not connected in proper location.

Diagnostic Checks: • Inlet, Heat Exchanger, Outlet, and Ambient

Thermistors.

THERMISTORS DIAGNOSTICS:

Turn power OFF. Remove connector “R” on Control Board. Measure the resistance for all temperature sensors (step 3). IF temperature sensor FAILS the

resistance check, go to the appropriate Error Code for diagnostics. IF sensors test ‘OK’ continue to next page.

Turn power OFF. Remove and reinsert connector “R” on Control Board. Attempt to operate unit again. IF

35 Error Code does NOT display, unit had a loose connection.

1 2

3

Black #3 & Blue #7 Wires: Ambient Thermistor

64DV; 84DV; 95DV: 7K – 23K Ohms

64X; 84X; 95X: 2K – 72K Ohms


Black #3 & White #6 Wires: Inlet Thermistor 7K – 23K Ohms. Error Code 31

Black #3 & Yellow #5 Wires: Heat Exchanger Thermistor 7K – 23K Ohms. Error Code 32

Black #3 & Red #4 Wires: Outlet Thermistor 7K – 23K Ohms. Error Code 33

Black #3 & Blue #7 Wires: Ambient Thermistor Refer to Data Table. Error Code 34


69


Check resistance for all Thermistors at

Molex Connector “R”

NO

YES

YES

NO

Is the resistance for all

Thermistors OK?

Go to appropriate Sensor Error Code to diagnose:

1. Inlet: Error Code 31 2. Heat Exchanger: Error Code 32 3. Outlet: Error Code 33 4. Ambient: Error Code 34

Did the unit lockout on Error

Code 35?

Attempt to operate the unit again


The water heater appears to be operating normally


64DV; 84DV; 95DV: 7K – 23K Ohms

64X; 84X; 95X: 2K – 72K Ohms



70

51 – Error Code Explanation: Gas Control Valve malfunction. The unit detects the presence of flame when the demand for hot water is terminated and burner is OFF. This error code will only occur at time of shut down.

Diagnostic Checks: • Flame Rods(s) • Gas Control Valve

FLAME RODS & GAS VALVE DIAGNOSTICS:

Remove and reinsert terminals on Fame Rod(s)*. Attempt to operate unit again. IF 51 Error Code does

NOT display, unit had a loose connection.

Turn power OFF. Remove and reinsert white connector “M” and blue connector “T” on Control

Board.

1 2

3


Visually inspect Gas Control Valve wiring harnesses for loose

connections or damaged wiring. Gas Control Valve is located on lower

right side of unit. Locate sight glass.

Sight Glass

Gas Control Valve


71


NO

Clean or Replace Flame Rod(s)

Water heater appears to be normal.

Attempt to operate unit again

YES

NO

YES

NO

While viewing burner chamber through sight glass:

In 10 second intervals; cycle the water heater 3 times by turning unit “on – off; on – off; on – off”

Is there a visible flame while unit

is OFF?

Visibly inspect burner chamber through Sight Glass

Is debris visible on burner assembly?

YES

Remove and clean burner assembly

NO

Disconnect Molex Connector from Flame Rods(s). Cycle the water heater 3 times by

turning unit “on – off; on – off; on – off”

Does ‘OY’ Status in Maintenance Mode indicate presence of flame after 5

seconds?


seconds?

YES



On Remote Control, go to Maintenance Mode 0Y table. For Maintenance Mode instructions go to page 16.

All Maintenance Mode ‘0Y’ readings should be done immediately after turning the unit OFF. IF Flame Rod(s) is

detecting flame, Maintenance Mode will display:

Indoor Units: 05 Outdoor Units: 01

Attempt to operate unit again. If the unit displays 51 Error Code and flame IS visible while

unit is OFF:



72

52 – Error Code Explanation: PGFR (Proportional Gas Flow Regulator) malfunction. The PGFR is the only modulating valve in the Gas Control Valve.

Diagnostic Checks: • PGFR

PGFR DIAGNOSTICS:

Locate PGFR valve on lower right of unit. Remove and reinsert Molex connector with red wire and Molex

connector with black wire on PGFR. Attempt to operate unit again.

Turn power OFF. Remove and reinsert connector “R” on Control Board.

1 2

3

IF 52 Error Code does NOT display, unit had a loose connection.

IF 52 Error Code IS displayed, continue to diagnostic chart on next

page.

PGFR

Control Board

PGFR

Molex Connectors


73


NO

YES

YES

NO

While unit is attempting to go to main burner, check DC voltage across red wire #1 and black wire #2 on Connector “R”:

1.5 – 14 DC VOLTS






While unit is attempting to go to main burner, check DC voltage across red and black wires at PGFR:

1.5 – 14 DC VOLTS






74

61 – Error Code Explanation: Blower Motor malfunction. Blower Motor speed was not appropriate to allow proper combustion.

Diagnostic Checks: • Blower Motor




“G”. Pull Control Board out of way to access Blower Motor.

Turn power OFF. Remove and reinsert connector “G” on Control Board. Attempt to operate unit again. IF


Remove 3 screws holding Blower Motor in place. Clean Blower Motor and reassemble unit. Attempt to

operate unit again. IF 61 Error Code does NOT display: Blower Motor needed to be cleaned.

1 2

4 3

Blower Motor

Screws Control Board

Bottom of Unit


75


YES NO

NO

YES

YES

NO

Test DC voltage across black and red wires on Molex connector “G”:

144 – 192 DC VOLTS


Remove and reinsert connector “G”. Attempt to operate unit again.




Press and hold down “MAX” button on Control Board to activate Blower Motor. While Blower is running,

test DC voltage across black and white wires on Molex connector “G”:

12 – 18 DC VOLTS


test DC voltage across black and blue wires on Molex connector “G”:

4 – 10 DC VOLTS





Replace Blower Motor





76

65 – Error Code Explanation: Water Control Valve malfunction

Diagnostic Checks: • Water Control Valve

WATER CONTROL VALVE DIAGNOSTICS:

Turn power OFF. Remove 3 screws for Control Board mounting bracket. Remove connectors “M”; “T” & “G”. Pull Control Board out of way to access Water

Control Valve.

Turn power OFF. Remove and reinsert connector “C” on Control Board. Attempt to operate unit again. IF


1 2

3

Visually inspect Water Control Valve wiring harness for loose or damaged terminals. It is located right of the

Blower Motor; connected directly to the water inlet. Reassemble unit and continue to diagnostic chart on next

page.

Screws

Bottom of Unit

Control Board

Blow

er M

otor

Top

of U

nit

Bott

om o

f Uni

t

Water Control Valve


77


YES

NO

YES

YES

NO

While water is flowing and unit is attempting to ignite; check DC Voltage

across White & Black Wires at connector “C”:

8 – 16 DC VOLTS






Turn power to unit OFF then ON again and turn water flow on. Check DC Voltage across Red & Black Wires

at connector “C”:

8 – 16 DC VOLTS

Turn power to unit OFF then ON again and turn water flow on. Check DC Voltage across Green & Black

Wires at connector “C”:

4 – 6 DC VOLTS




Is the DC voltage OK? NO






Replace Water Control Valve


78

66 – Error Code Explanation: Water Bypass Valve malfunction. Hot outlet water temperature is above or below set point on Remote Control.

Diagnostic Checks: • Water Bypass Valve

WATER BYPASS VALVE DIAGNOSTICS:

•

Turn power OFF. Remove 3 screws for Control Board mounting bracket. Remove connectors “M”; “T”; & “G”. Pull Control Board out of way to access Water

Bypass Valve.

Turn power OFF. Remove and reinsert connector “B” on Control Board. Attempt to operate unit again. IF


1 2

3

Visually inspect Water Bypass Valve wiring harness for loose or damaged terminals. It is located right of the Blower Motor; below two copper

pipes. Reassemble unit and continue to diagnostic chart on next page.

Screws

Blow

er M

otor

Top

of U

nit

Bott

om o

f Uni

t

Water Bypass Valve

Control Board

Bottom of Unit


79


NO

YES

YES

NO

Turn Remote Control OFF; unplug unit and then ON again. Check DC voltage across red and black wires on Molex

connector “B”: 8 – 16 DC VOLTS






While Water Bypass Valve is operating (water is flowing), check DC voltage across red and black wires

at Water Bypass Valve wiring harness:

8 – 16 DC VOLTS


Replace Water Bypass Valve





80

71 – Error Code Explanation: Gas Control Valve malfunction Diagnostic Checks: Gas Control Valve

GAS CONTROL VALVE DIAGNOSTICS:

Turn power OFF. Remove and reinsert connector “K” on Control Board. Attempt to operate unit again. IF 71 Error

Code does NOT display, unit had a loose connection.

1

Visually inspect Gas Control Valve wiring harnesses for loose or damaged terminals. Gas Control Valve is located

on lower right side of unit. Continue to diagnostic chart on next page.

2

Gas Control Valve


81


YES

NO

While unit is attempting to go to ignite, check DC voltage across yellow and black

wires on Molex connector “K”:

75 – 100 DC VOLTS


Attempt to operate again.



Reset the water heater and attempt to operate again. If the unit malfunctions due to an Error Code 71:



82

72 – Error Code Explanation: Flame Rod(s) malfunction. Flame Rod(s) is detecting the presence of flame BEFORE igniter is activated.

Diagnostic Checks: • Flame Rod(s) • Gas Control Valve

FLAME ROD(s) & GAS CONTROL VALVE DIAGNOSTICS:

Remove and reinsert terminals on Flame Rod(s)*. Attempt to operate unit again. IF 72 Error Code does



Board.

1 2

Flame Rod(s)*

*Indoor Units ONLY: 2 Flame Rods

Visually inspect Gas Control Valve wiring harnesses for loose

connections or damaged wiring. Gas Control Valve is located on

lower right side of unit. Locate Sight Glass.

Sight Glass

Gas Control Valve

3


83


NO



Attempt to operate again

YES

NO

YES

NO

Turn power OFF. Unplug unit and plug back in. Turn power ON. While viewing burner chamber through sight glass, turn on water flow to begin ignition sequence

Is there a visible flame before Igniter Rod

sparks?

Visibly inspect burner chamber through sight glass


YES


NO

Turn power OFF. Unplug unit. Disconnect Molex connector(s) from Flame Rod(s).

Plug unit in. Turn power ON. Turn water flow ON to begin ignition sequence

Does ‘OY’ Status in Maintenance Mode indicate presence

of flame?

Does ‘OY’ Status in Maintenance Mode indicate presence

of flame?

YES

Attempt to operate again. If unit displays 72 Error Code:


On Remote Control, go to Maintenance Mode 0Y table. For Maintenance Mode instructions go to page 16.

All Maintenance Mode ‘0Y’ readings should be done immediately after turning the unit ON. IF flame sensor IS detecting flame, Maintenance Mode will display:


Attempt to operate again. If unit displays 72 Error Code and flame IS visible while unit is OFF:



84

76 – Error Code Explanation: Communication Fault with Remote Control. Remote Control is not communicating with Control Board

Diagnostic Checks: • Remote Control • Wiring

REMOTE THERMOSTAT DIAGNOSTICS:

Visually inspect Remote Control wiring for damaged or loose terminals.

1

Turn power OFF. Remove and reconnect Remote Control wiring terminals at bottom of unit. Attempt to operate

unit again. IF 76 Error Code does NOT display, unit had a loose connection.


2

Hot Water Outlet

Cold Water Inlet

Remote Control Wiring Terminals


85


NO

YES

YES

NO

Unplug unit and remove Remote Thermostat wires from wiring terminals on bottom of unit. Plug unit in and open

a hot water source.

Did the unit go to main burner?



Did the unit go to main burner?

Unplug unit. Use a short piece of new thermostat wire to connect the Remote Control directly to

Remote Control wiring terminals at bottom of unit.

Plug unit in and open a hot water source.

The wiring is defective. Replace Remote Control wiring.



86

79 – Error Code Explanation: Blower Motor current fault. The unit detected a fault with the Blower Motor.

Diagnostic Checks: • Blower Motor




“G”. Pull Control Board out of way to access Blower Motor.

Turn power OFF. Remove and reinsert connector “G” on Control Board. Attempt to operate unit again. IF


Remove 3 screws holding Blower Motor in place. Clean Blower Motor and reassemble unit. Attempt to

operate unit again. IF 79 Error Code does NOT display: Blower Motor needed to be cleaned.

1 2

4 3

Screws

Blower Motor

Control Board

Bottom of Unit


87


YES NO

NO

YES

YES

NO

Test DC voltage across black and red wires on Molex connector “G”:

144 – 192 DC VOLTS







test DC voltage across black and white wires on Molex connector “G”:

12 – 18 DC VOLTS


test DC voltage across black and blue wires on Molex connector “G”:

4 – 10 DC VOLTS





Replace Blower Motor





88

80 – Error Code Explanation: Gas Control Valve malfunction. The unit detects the presence of flame when the demand for hot water is terminated and burner is OFF. This error code will only occur at time of shut down.

Diagnostic Checks: • Flame Rod(s) • Gas Control Valve

FLAME ROD(s) & GAS CONTROL VALVE DIAGNOSTICS:

Remove and reinsert terminals on Flame Rod(s)*. Attempt to operate unit again. IF 80 Error Code does



Board.

1 2

3

Sight Glass

Gas Control Valve

Visually inspect Gas Control Valve wiring harnesses for loose connection or

damaged wiring. Gas Control Valve is located on lower right side of unit. Locate

Sight Glass.

Flame Rod(s)*

*Indoor Units ONLY: 2 Flame Rods


89


NO



Attempt to operate again

YES

NO

YES

NO

While viewing burner chamber through sight glass:

In 10 second intervals; cycle the water heater 3 times by turning unit “on – off; on – off; on – off”

Is there a visible flame while unit

is OFF?

Visibly inspect burner chamber through sight glass


YES


NO

Disconnect Molex Connector from Flame Rod(s). Cycle heater 3 times by turning

unit “on – off”; “on – off”; “on – off”


seconds?


seconds?

YES

Attempt to operate unit again. If unit displays 80 Error Code:


On Remote Control, go to Maintenance Mode 0Y table. For Maintenance Mode instructions go to page16.

All Maintenance Mode ‘0Y’ readings should be done immediately after turning the unit OFF. IF Flame Rod(s) is detecting flame, Maintenance Mode

will display:


Attempt to operate again. If unit displays 80 Error Code and flame IS visible while unit is OFF:



90

82 – Error Code Explanation: Control Board Program Chip malfunction

Diagnostic Checks: • Program Chip

PROGRAM CHIP DIAGNOSTICS:

Turn power OFF. Verify you have a Program Chip inserted in connector “A”.

1

Remove and reinsert Program Chip. Attempt to operate unit again.

IF unit does NOT display 82 Error Code, unit had a loose connection.

2


91

90 – Error Code Explanation: The unit detected blockage in the venting during pre-purge cycle. This Error Code will occur BEFORE unit goes to ignition. Possible Causes:

• VENTING

VENTING:

**REFER TO USE & CARE MANUAL** Visually inspect venting for possible blockage and/or recirculation of exhaust.

1. Approved Venting Materials 2. Approved Vent Terminations 3. Vent Lengths 4. Location Of Vent Termination (Recirculation of exhaust) 5. Blocked Venting 6. Venting Not Sealed Properly


92

92 – Error Code Explanation: High Efficiency Condensing Units ONLY. This is a warning code and unit will continue to operate but will eventually shut down due to an error code 93. REPLACE NEUTRALIZER ASAP. *Once Neutralizer is replaced; follow reset procedures on page 21.

93 – Error Code Explanation: High Efficiency Condensing Units ONLY. Unit will NOT operate until the Neutralizer Medium is replaced. REPLACE NEUTRALIZER IMMEDIATELY. Neutralizer rocks made from Calcium Carbonate (CACO3). Neutralizer Kit may be ordered through Rheem Supplier. *Once Neutralizer is replaced; follow reset procedures on page 21.

Neutralizer


93

99 – Error Code Explanation: The unit detected blockage in the venting during post-purge cycle. Blockage was detected when the demand for hot water terminated and burner was OFF. This error code will only occur at time of shut down. *Unit must be reset by performing reset procedure on page 21. Possible Causes:

• Venting

VENTING:

**REFER TO USE & CARE MANUAL**



94

NOTES:

________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________


95

NOTES:

________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

R

Tankless Gas Water Heaters

High Effi ciency Condensing ModelsPHH-25ROFN & PHH-32ROFN (Outdoor Natural Gas Models)PHH-25ROFP & PHH-32ROFP (Outdoor L.P. Gas Models)PHH-25RDVN & PHH-32RDVN (Indoor Direct Vent Natural Gas Models)PHH-25RDVP & PHH-32RDVP (Indoor Direct Vent L.P. Gas Models)

Mid Effi ciency ModelsPH2-20ROFN, PH2-25ROFN & PH2-28ROFN (Outdoor Natural Gas ModelsPH2-20ROFP, PH2-25ROFP & PH2-28ROFP (Outdoor L.P. Gas Models)PH2-20RDVSN, PH2-25RDVSN & PH2-28RDVSN (Indoor Direct Vent Natural Gas Models)PH2-20RDVSP, PH2-25RDVSP & PH2-28RDVSP(Indoor Direct Vent L.P. Gas Models)

Second SectionInformation Guide

- 96 -

- Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. To do so may result in an explosion or fire.

- WHAT TO DO IF YOU SMELL GAS * Do not try to light any appliance. * Do not touch any electrical switch; do not use any phone in your building. * Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions. * If you cannot reach your gas supplier, call the fire department. * Do not return to your home until authorized by the gas supplier or fire department.

- Installation and service must be performed by a qualified installer, service agency or the gas supplier.

WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death.

WARNING: Improper installation, adjustment, alternation, service or maintenance can cause property damage, personal injury, or death. For assistance or additional information, consult with a qualifi ed distributor.

WARNING: The content on this manual is intended for use by qualifi ed service personnel ONLY.

Table of Contents for Second Section

- 97 -

PageSpecifi cations .................................................................. 98 ~ 99External Dimensions ...................................................... 100 ~ 101Schematic Construction ................................................. 102 ~ 105Operational Principle ..................................................... 106 ~ 111Capacity ......................................................................... 112 ~ 120Wiring Diagram ............................................................. 121 ~ 122Thermistor Resistance Chart .......................................... 123Adjustment ..................................................................... 124 ~ 132DUOnex Cable ............................................................... 133 ~ 136MIC-185 ......................................................................... 137 ~ 146MIC-6 ............................................................................. 147 ~ 154Commercial Conversion ................................................ 155 ~ 157Schematic Disassembly and Parts List .......................... 158 ~ 171

SPECIFICATIONS (Approx.)Model PH2-20R OFN, PH2-20R OFP,

PH2-25R OFN, PH2-25R OFPPH2-28R OFN, PH2-28R OFP

PH2-20R DVSN, PH2-20R DVSPPH2-25R DVSN, PH2-25R DVSPPH2-28R DVSN, PH2-28R DVSP

Purpose Domestic Hot Water SupplyRated Gas Input(Btu/Hr.)

11,000 (Min.) ~ 150,000 (Max.) (PH2-20R Series) Modulating11,000 (Min.) ~ 180,000 (Max.) (PH2-25R Series) Modulating 11,000 (Min.) ~ 199,900 (Max.) (PH2-28R Series) Modulating

Dimensions (in.) 13 7/8 (W) x 23 5/8 (H) x 8 7/8 (D) 13 7/8 (W) x 25 5/8 (H) x 9 7/8 (D)

Net Weight (lbs.) 60Installation Outdoor Wall Mounting Type Direct Vent Indoor Wall Mounting Type

Can be vented either horizontally or verticallyWorking Water Pressure 14 psi ~ 150 psiMinimum Water Flow 0.40 GPMMaximum Flow Rate 6.4 GPM (PH2-20R); 8.4 GPM (PH2-25R); 9.5 GPM (PH2-28R) at 35ºF Temp. RiseGas Connection 3/4” NPT Female (w/supplied Gas Shutoff Valve)Water Connection 3/4” NPT MaleVent Size N/A (Outdoor Installation) 3”/5” Concentric Special Venting (Category III)Max. Vent Length N/A (Outdoor Installation) 36 Feet with Three 90º ElbowEffi ciency Rating 84% Energy Factor 0.82Inlet Gas Pressurebefore water heater

Natural Gas: Min. 4.0” w.c. Max. 10.5” w.c.L.P. Gas: Min. 8.0” w.c. Max. 13.0” w.c. (Do not exceed maximum pressure.)

Hot Water Supply Adjusting Range 85ºF ~ 120ºF (140ºF) (Residential)Adjusting Range 85ºF ~ 185ºF (Commercial) (By conversion kit)Max. Setting W/ Main Remote Control (UMC-117) & Adjustment

Electrical Portion Electrical Rating 120VAC/60Hz, Less than 2 AmpsPower Supply Cord 3 Pin Power Supply Cord 10 Feet (Direct Vent)

Safety Devices Oxygen Depletion Safety Sensing Burner (Direct Vent)Over Heat Limiter Film Type for Entire Heat ExchangerFlame Failure Safety Flame Rod Type

Freeze Protection Minus 30ºF (Without Wind-Chill Factor)Optional Accessory First Bath Remote Control (USC1-117); Second Bath Remote Control (USC2-117)

DUOnex ™ for 2-Unit ManifoldingMIC-185 for Multi-Unit System Controller (2 to 6 units); MICS-180 for Expansion Board(Up to 20 units); Communication Cables for MIC-185 (16, 32 & 65 feet)MIC-6 for Manifold Controller (2 to 6 units); Manifold Cables for MIC-6 (6 & 18 feet)

High Altitude Setting High Altitude DIP Switch Adjustment

Hot Water Flow Rate and Temperature RiseTemp. Rise (ºF) 35 45 50 60 70 80 90 100Water Flow (GPM) PH2-20R 6.4 5.6 5.1 4.2 3.6 3.2 2.8 2.5Water Flow (GPM) PH2-25R 8.4 6.7 6.1 5.1 4.3 3.8 3.4 3.0Water Flow (GPM) PH2-28R 9.5 7.4 6.6 5.5 4.7 4.1 3.7 3.3

- 98 -

Note: Special Venting: The adapter, vent pipe, elbow, vent terminal, etc. should be UL 1738 Certifi ed Category III Stainless Steel Venting Materials . “B” vent is not permitted.Since we are constantly improving our products, all specifi cations are subject to change without notice.

SPECIFICATIONS (Approx.)Model PHH-25ROFN, PHH-25ROFP

PHH-32ROFN, PHH-32ROFPPHH-25RDVN, PHH-25RDVPPHH-32RDVN, PHH-32RDVP

Purpose Domestic Hot Water SupplyRated Gas Input(Btu/Hr.)

11,000 (Min.) ~ 157,000 (Max.) (PHH-25R Series) Modulating 11,000 (Min.) ~ 199,900 (Max.) (PHH-32R Series) Modulating

Dimensions (in.) 18 1/2 (W) x 27 5/8 (H) x 9 3/4 (D) 18 1/2 (W) x 30 3/8 (H) x 9 3/4 (D)

Net Weight (lbs.) 76Installation Outdoor Wall Mounting Type Direct Vent Indoor Wall Mounting Type

Can be vented either horizontally or verticallyWorking Water Pressure 14 psi ~ 150 psiMinimum Water Flow 0.40 GPMMaximum Flow Rate 8.5 GPM (PHH-25R); 9.5 GPM (PHH-32R) at 35ºF Temp. RiseGas Connection 3/4” NPT Female (w/supplied Gas Shutoff Valve)Water Connection 3/4” NPT MaleVent Size N/A (Outdoor Installation) 2” or 3” PVC or CPVCMax. Vent Length N/A (Outdoor Installation) 35 Feet with Three 90º Elbow (3” PVC)

5 Feet with One 90º Elbow (2” PVC)Effi ciency Rating 93% (PHH-25ROF, PHH-32ROF, PHH-32RDV); 94% (PHH-25RDV) Energy Factor 0.93 (PHH-25ROF); 0.94 (PHH-25RDV, PHH-32ROF, PHH-32RDV)Inlet Gas Pressurebefore water heater

Natural Gas: Min. 4.0” w.c. Max. 10.5” w.c.L.P. Gas: Min. 8.0” w.c. Max. 13.0” w.c. (Do not exceed maximum pressure.)

Hot Water Supply Adjusting Range 85ºF ~ 120ºF (140ºF) (Residential)Adjusting Range 85ºF ~ 185ºF (Commercial) (By conversion kit)Max. Setting W/ Main Remote Control (UMC-117) & Adjustment

Electrical Portion Electrical Rating 120VAC/60Hz, Less than 2 AmpsPower Supply Cord 3 Pin Power Supply Cord 10 Feet (Direct Vent)

Safety Devices Oxygen Depletion Safety Flame Rod (Direct Vent)Over Heat Limiter Film Type for Entire Heat ExchangerFlame Failure Safety Flame Rod Type

Freeze Protection Minus 30ºF (Without Wind-Chill Factor)Optional Accessory First Bath Remote Control (USC1-117); Second Bath Remote Control (USC2-117)

DUOnex ™ for 2-Unit ManifoldingMIC-185 for Multi-Unit System Controller (2 to 6 units); MICS-180 for Expansion Board(Up to 20 units); Communication Cables for MIC-185 (16, 32 & 65 feet)MIC-6 for Manifold Controller (2 to 6 units); Manifold Cables for MIC-6 (6 & 18 feet)

High Altitude Setting High Altitude DIP Switch Adjustment

Hot Water Flow Rate and Temperature RiseTemp. Rise (ºF) 35 45 50 60 70 80 90 100Water Flow (GPM) PHH-25R 8.5 6.6 5.9 4.9 4.2 3.7 3.3 3.0Water Flow (GPM) PHH-32R 9.5 8.4 7.6 6.3 5.4 4.7 4.2 3.8

- 99 -

Note: Venting: Schedule 40 (PVC), Schedule 40 (CPVC) or Category III Stainless Steel . “B” vent is not permitted.Since we are constantly improving our products, all specifi cations are subject to change without notice.

EXTERNAL DIMENSIONS

(Rem

ote

Con

trol)

COM

BUST

ION

IND

ICAT

OR

POW

ER O

N/O

FFIN

DIC

ATO

R

POW

ER O

N/O

FFBU

TTO

N

PRIO

RIT

Y IN

DIC

ATO

R

TEM

PERA

TURE

ADJU

STM

ENT

BUTT

ON

LED

DIS

PLAY

POW

ERO

N/O

FF

PRIO

RITY

°F

7/8”

(21m

m)

4 3/

4” (1

20m

m)

4 3/4” (120mm)

1 7/

8” 4

6mm

)

3 1/4” (83.5mm)

13 7/8” (350 mm) 12 15/16” (328 mm)

3 1/2” (90 mm)

25 3

/16”

(640

mm

)

23 5

/8” (

600

mm

) 22

3/8

” (56

8 m

m)

2 7/8” (72.5 mm)

2 15

/16”

(73

mm

)

5 3/16” (132 mm)

1 1/8” (28 mm)

5” (127 mm)

2 1/

16” (

53 m

m)

2 1/

4” (5

8 m

m)

5 1/

4” (1

34 m

m)

7/16” (10.5 mm) 8 7/16” (215 mm) 3/8” (10 mm)

Hot Water OutletConnection 3/4” NPT (M)

Water Inlet Connection 3/4” NPT (M)

Gas Connection 3/4” NPT (F)(W/Supplied Gas Shutoff Valve)

For Power CordFor Remote ControlConnection

(PH2-20ROF, PH2-25ROF & PH2-28ROF Outdoor Models)

13 7/8” (350 mm) 12 15/16” (328 mm)

5 1/8” (130 mm)

3”/5” Concentric

9 7/16” (240 mm)

5 1/8” (131 mm)

3/8” ~ 1 9/16” (10 ~ 40 mm)

Hot Water OutletConnection 3/4” NPT (M) Water Inlet Connection

3/4” NPT (M)

Gas Connection 3/4” NPT (F)(W/Supplied Gas Shutoff Valve)

3” (100.5 mm)

5 3/16” (132 mm) 5” (127 mm)1 1/8” (28 mm)

7 7/

8” (2

00 m

m)

4 3/

16” (

107

mm

)

3 3/

8” (8

6 m

m)

3 5/

8” (9

2 m

m)

26 7

/16”

(672

mm

)

25 5

/8” (

650

mm

)

24 3

/8” (

618

mm

)

(PH2-20RDVS, PH2-25RDVS & PH2-28RDVS Direct Vent Models)

- 100 -

EXTERNAL DIMENSIONS

(Rem

ote

Con

trol)

COM

BUST

ION

IND

ICAT

OR

POW

ER O

N/O

FFIN

DIC

ATO

R

POW

ER O

N/O

FFBU

TTO

N

PRIO

RIT

Y IN

DIC

ATO

R

TEM

PERA

TURE

ADJU

STM

ENT

BUTT

ON

LED

DIS

PLAY

POW

ERO

N/O

FF

PRIO

RITY

°F

7/8”

(21m

m)

4 3/

4” (1

20m

m)

4 3/4” (120mm)

1 7/

8” 4

6mm

)

3 1/4” (83.5mm)

(PHH-25ROF & PHH-32ROF Outdoor Models)

(PHH-25RDV & PHH-32RDV Direct Vent Models)

- 101 -

18 1/2” (470 mm)

Air Intake Exhaust Outlet

5 1/2” (140 mm)

5 15/16” (152 mm)

3/8

” (10

mm

)

30 1

/2” (

775

mm

)

27 1

/2” (

700

mm

)

26 7

/16”

(672

mm

)

9 7/16” (240 mm)

Hot Water OutletConnection 3/4” NPT (M) Gas Connection 3/4” NPT (F)

(W/Supplied Gas Shutoff Valve)Water Inlet Connection 3/4” NPT (M) For Power Cord

For Remote ControlConnection

2 1/4” (57 mm)

Drain Outlet

7 1/

2” (1

91 m

m)

3 3/

4” (9

6 m

m)

6 11/16” (170 mm)

2 7/

8” (7

3 m

m)

3 7/16” (88 mm) 2 7/8” (72 mm)

9/16” (15 mm)

7 1/2” (190 mm)

2 1/

4” (5

7 m

m)

4 3/

16” (

106

mm

)

2 1/

16” (

52 m

m)

18 1/2” (470 mm) 17 3/4” (451 mm) 9 7/17” (240 mm)

3/8”

(10

mm

)

3/4” (18.5 mm)

26 7

/16”

(672

mm

) 27

1/2

” (70

0 m

m)

30 1

/2” (

775

mm

)

Hot Water OutletConnection 3/4” NPT (M) Water Inlet Connection 3/4” NPT (M)

Gas Connection 3/4” NPT (F)(W/ Supplied Gas Shutoff Valve)

4 3/4” (120 mm)

For Power Cord For Remote Control Connection

3 3/

4” (9

6 m

m)

Drain Outlet 3 7/16” (88 mm) 6 11/16” (170 mm)

2 7/

8” (7

3 m

m)

4 3/

16” (

106

mm

)

6 3/

16” (

156

mm

)

2 1/

4” (5

7 m

m)

2 1/

16” (

52 m

m)

7 1/2” (190 mm)

- 102 -

SCHEMATIC CONSTRUCTION(PH2-20ROF, PH2-25ROF & PH2-28ROF Outdoor Models)

No. Name of Parts No. Name of Parts No. Name of Parts1 Gas Connection 11 Bypass Pipe 21 Film Type OHL2 Gas Control Valve Assy. 12 Heat Exchanger 22 PC Board3 Lower Burner Assy. 13 Heat Transfer Coil 23 Fan Assembly4 Flame Rod 14 Fin 24 Heat Exchanger Thermistor5 Main Burner 15 Turbulence Coil 25 Igniter6 Inner Case 16 U-Pipe 26 Electrode (IG)7 Exhaust Flue Assy. 17 Hot Water Supply Coil 27 Front Cover8 Water Inlet Connection 18 Hot Water Supply Pipe 28 Back Cover9 Water Control Valve Assy. 19 Hot Water Outlet Connection 29 Junction Box10 Water Supply Pipe 20 Drain Valve

- 103 -

SCHEMATIC CONSTRUCTION

No. Name of Parts No. Name of Parts No. Name of Parts1 Gas Connection 11 Bypass Pipe 21 Film Type OHL2 Gas Control Valve Assy. 12 Heat Exchanger 22 Heat Exchanger Thermistor3 Lower Burner Assy. 13 Heat Transfer Coil 23 PC Board4 Flame Rod 14 Fin 24 Fan Assembly5 Main Burner 15 Turbulence Coil 25 Electrode (IG)6 Inner Case 16 U-Pipe 26 Igniter7 Exhaust Flue Assy. 17 Hot Water Supply Coil 27 Back Cover8 Water Inlet Connection 18 Hot Water Supply Pipe 28 Front Cover9 Water Control Valve Assy. 19 Hot Water Outlet Connection10 Water Supply Pipe 20 Drain Valve


- 104 -

SCHEMATIC CONSTRUCTION(PHH-25ROF & PHH-32ROF Outdoor Models)

No. Name of Parts No. Name of Parts No. Name of Parts1 Front Cover 11 Gas Control Valve Assy. 21 Water Control Valve Assy.2 Back Cover 12 Fan Assembly 22 Water Supply Pipe3 Heat Exchanger 13 Film Type OHL 23 Bypass Pipe4 Fin 14 Igniter 24 Turbulence Coil5 Heat Transfer Coil 15 PC Board 25 Hot Water Supply Coil6 Inner Case 16 Electrode (FL 1) 26 Hot Water Supply Pipe7 Exhaust Flue Assy. 17 Electrode (IG) 27 Hot Water Outlet Connection8 Second Heat Exchanger

Top Plate Assy.18 Gas Connection 28 Drain Valve

9 Second Heat Exchanger 19 Lower Burner Assy.10 Main Burner 20 Water Inlet Connection

- 105 -

SCHEMATIC CONSTRUCTION

No. Name of Parts No. Name of Parts No. Name of Parts1 Front Cover 11 Gas Control Valve Assy. 21 Water Control Valve Assy.2 Back Cover 12 Fan Assembly 22 Water Supply Pipe3 Heat Exchanger 13 Film Type OHL 23 Bypass Pipe4 Fin 14 Igniter 24 Turbulence Coil5 Heat Transfer Coil 15 Electrode (FL 2) 25 Hot Water Supply Coil6 Inner Case 16 Electrode (FL 1) 26 Hot Water Supply Pipe7 Exhaust Flue Assy. 17 Electrode (IG) 27 Hot Water Outlet Connection8 Second Heat Exchanger

Top Plate Assy.18 Gas Connection 28 Drain Valve

9 Second Heat Exchanger 19 Lower Burner Assy. 29 PC Board10 Main Burner 20 Water Inlet Connection

(PHH-25RDV & PHH-32RDV Direct Vent Models)

- 106 -

OPERATIONAL PRINCIPLE

No. Name of Parts No. Name of Parts No. Name of Parts1 Hot Water Tap 11 Solenoid Valve 2 21 Film Type OHL2 Water Flow Servo 12 Solenoid Valve 3 22 Fan3 Water Flow Sensor 13 Solenoid Valve 4 23 Fan Motor4 Water Inlet Thermistor 14 Proportional Gas Control Valve 24 Drain Valve5 Heat Exchanger Thermistor 15 Orifi ce 25 Remote Control6 Hot Water Outlet Thermistor 16 Igniter 26 Freeze Protection Heater7 PC Board 17 Electrode 27 Bypass Solenoid Valve8 Water Filter 18 Flame Rod 28 Exhaust Outlet9 Gas Inlet Solenoid Valve 19 Main Burner10 Solenoid Valve 1 20 Heat Exchanger

Hot Water Outlet

Water Inlet

Gas Inlet

Exhaust Gas

(PH2-20ROF, PH2-25ROF & PH2-28ROF Outdoor Models)

- 107 -


Air Intake

ExhaustOutlet

Hot Water Outlet

Water Inlet

Gas Inlet


No. Name of Parts No. Name of Parts No. Name of Parts1 Hot Water Tap 11 Solenoid Valve 2 21 Film Type OHL2 Water Flow Servo 12 Solenoid Valve 3 22 Fan3 Water Flow Sensor 13 Solenoid Valve 4 23 Fan Motor4 Water Inlet Thermistor 14 Proportional Gas Control Valve 24 Drain Valve5 Heat Exchanger Thermistor 15 Orifi ce 25 Remote Control6 Hot Water Outlet Thermistor 16 Igniter 26 Freeze Protection Heater7 PC Board 17 Electrode 1 27 Bypass Solenoid Valve8 Water Filter 18 Flame Rod 28 Exhaust Outlet9 Gas Inlet Solenoid Valve 19 Main Burner 29 Flame Rod 2 (ODS)10 Solenoid Valve 1 20 Heat Exchanger

- 108 -

OPERATIONAL PRINCIPLEWHEN SUPPLYING HOT WATER

1) By opening the Hot Water Top (1), the water fl ows through the Water Flow Sensor (3) to the Heat Heat Exchanger (20).

2) The frequency signal is given from the Water Flow Sensor (3) and when the PC Board (7) senses the signal that reached a certain frequency, the Fan (22) starts to turn round.

3) After the Fan (22) turned round and pre-purged, the Gas Inlet Solenoid Valve (9), Solenoid Valve 1 (10), Solenoid Valve 2 (11), Solenoid Valve 3 (12) and Solenoid Valve 4 (13) open at the same time. Then, the Proportional Gas Control Valve (14) becomes an ignition motion and allows the gas to fl ow to the Main Burner (19).

4) At the same time, the Igniter (16) continuously makes sparks and ignites the Main Burner (19). After ignited, when the Flame Rod (18) senses the fl ame and make sure the combustion, the Proportional Gas Control Valve (14) fi nishes the ignition motion.

5) After fi nished the ignition motion, the proportional gas control is started. When there is a temperature difference between the hot water temperature that is sensed by the Hot Water Outlet Thermistor (6) and the set temperature on the Remote Control, the PC Board (7) judges it and open or close the Solenoid Valve 1 (10), Solenoid Valve 2 (11), Solenoid Valve 3 (12) and Solenoid Valve 4 (13), and also the Proportional Gas Control Valve (14) continuously adjusts the gas volume in order to maintain the outlet temperature from the Heat Exchanger (20). The Water Flow Servo (2) also adjusts the proper amount of water fl ow to supply a stable hot water temperature at all times.

6) According to the adjustment of the gas volume by the Proportional Gas Control Valve (14), a signal from the PC Board (7) is also sent to the Fan Motor (23) in order to maintain the relation between the gas volume and air volume at all times.

7) (For Direct Vent Models only) When the air intake or venting is blocked, or the oxygen of the air intake is not suffi cient, the Flame Rod 2 (29) senses the change. When the PC Board (7) senses this change, it shuts off the Gas Inlet Solenoid Valve (9), Solenoid Valve 1 (10), Solenoid Valve 2 (11), Solenoid Valve 3 (12), Solenoid Valve 4 (13) and Proportional Gas Control Valve (14) in order to stop the operation.

8) When the Hot Water Tap (1) is closed, the frequency signal from the Water Flow Sensor (3) is stopped and the Gas Inlet Solenoid Valve (9), Solenoid Valve 1 (10), Solenoid Valve 2 (11), Solenoid Valve 3 (12), Solenoid Valve 4 (13) and Proportional Gas Control Valve (14) turn off and becomes a post-purge motion.

9) When the time of the post-purge is up, the Fan (22) stops.

- 109 -


No. Name of Parts No. Name of Parts No. Name of Parts1 Hot Water Tap 11 Solenoid Valve 2 21 Film Type OHL2 Water Flow Servo 12 Solenoid Valve 3 22 Fan3 Water Flow Sensor 13 Solenoid Valve 4 23 Fan Motor4 Water Inlet Thermistor 14 Proportional Gas Control Valve 24 Drain Valve5 Heat Exchanger Thermistor 15 Orifi ce 25 Remote Control6 Hot Water Outlet Thermistor 16 Igniter 26 Freeze Protection Heater7 PC Board 17 Electrode 27 Bypass Solenoid Valve8 Water Filter 18 Flame Rod 28 Exhaust Outlet9 Gas Inlet Solenoid Valve 19 Main Burner 29 Second Heat Exchanger10 Solenoid Valve 1 20 Primary Heat Exchanger

(PHH-25ROF & PHH-32ROF Outdoor Models)

Exhaust Gas

Air Intake

Hot Water Outlet

Water InletGas Inlet

- 110 -

OPERATIONAL PRINCIPLE(PHH-25RDV & PHH-32RDV Direct Vent Models)

No. Name of Parts No. Name of Parts No. Name of Parts1 Hot Water Tap 11 Solenoid Valve 2 21 Film Type OHL2 Water Flow Servo 12 Solenoid Valve 3 22 Fan3 Water Flow Sensor 13 Solenoid Valve 4 23 Fan Motor4 Water Inlet Thermistor 14 Proportional Gas Control Valve 24 Drain Valve5 Heat Exchanger Thermistor 15 Orifi ce 25 Remote Control6 Hot Water Outlet Thermistor 16 Igniter 26 Freeze Protection Heater7 PC Board 17 Electrode 27 Bypass Solenoid Valve8 Water Filter 18 Flame Rod 1 28 Exhaust Outlet9 Gas Inlet Solenoid Valve 19 Main Burner 29 Flame Rod 2 (ODS)10 Solenoid Valve 1 20 Primary Heat Exchanger 30 Second Heat Exchanger

Air Inlet Exhaust Gas

Hot Water Outlet

Water Inlet

Gas Inlet

- 111 -

OPERATIONAL PRINCIPLEWHEN SUPPLYING HOT WATER

1) By opening the Hot Water Top (1), the water fl ows through the Water Flow Sensor (3) to the Primary Heat Exchanger (20).

2) The frequency signal is given from the Water Flow Sensor (3) and when the PC Board (7) senses the signal that reached a certain frequency, the Fan (22) starts to turn round.

3) After the Fan (22) turned round and pre-purged, the Gas Inlet Solenoid Valve (9), Solenoid Valve 1 (10), Solenoid Valve 2 (11), Solenoid Valve 3 (12) and Solenoid Valve 4 (13) open at the same time. Then, the Proportional Gas Control Valve (14) becomes an ignition motion and allows the gas to fl ow to the Main Burner (19).

4) At the same time, the Igniter (16) continuously makes sparks and ignites the Main Burner (19). After ignited, when the Flame Rod (18) senses the fl ame and make sure the combustion, the Proportional Gas Control Valve (14) fi nishes the ignition motion.

5) After fi nished the ignition motion, the proportional gas control is started. When there is a temperature difference between the hot water temperature that is sensed by the Hot Water Outlet Thermistor (6) and the set temperature on the Remote Control, the PC Board (7) judges it and open or close the Solenoid Valve 1 (10), Solenoid Valve 2 (11), Solenoid Valve 3 (12) and Solenoid Valve 4 (13), and also the Proportional Gas Control Valve (14) continuously adjusts the gas volume in order to maintain the outlet temperature. The Water Flow Servo (2) also adjusts the proper amount of water fl ow to supply a stable hot water temperature at all times.

6) According to the adjustment of the gas volume by the Proportional Gas Control Valve (14), a signal from the PC Board (7) is also sent to the Fan Motor (23) in order to maintain the relation between the gas volume and air volume at all times.

7) (For Direct Vent Models only) When the air intake or venting is blocked, or the oxygen of the air intake is not suffi cient, the Flame Rod 2 (29) senses the change. When the PC Board (7) senses this change, it shuts off the Gas Inlet Solenoid Valve (9), Solenoid Valve 1 (10), Solenoid Valve 2 (11), Solenoid Valve 3 (12), Solenoid Valve 4 (13) and Proportional Gas Control Valve (14) in order to stop the operation.

8) When the Hot Water Tap (1) is closed, the frequency signal from the Water Flow Sensor (3) is stopped and the Gas Inlet Solenoid Valve (9), Solenoid Valve 1 (10), Solenoid Valve 2 (11), Solenoid Valve 3 (12), Solenoid Valve 4 (13) and Proportional Gas Control Valve (14) turn off and becomes a post-purge motion.

9) When the time of the post-purge is up, the Fan (22) stops.

- 112 -

CapacityHot Water Capacity Curve: PH2-20R Residential Use

0.5 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0

85

100

120

130

140

Inlet Water Temperature : 40°F (PH2-20R)

Water Flow Rate (GPM)

Out

let T

empe

ratu

re (°

F)

6.4 GPM

When maximum temperature is set at 140°F


90

110

0.40 GPM

0.5 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0

85

100

120

130

140



Out

let T

empe

ratu

re (°

F)

90

110

0.40 GPM

6.4 GPM



0.5 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0

85

100

120

130

140



Out

let T

empe

ratu

re (°

F)

90

110

0.40 GPM



6.4 GPM

0.5 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0

85

100

120

130

140



Out

let T

empe

ratu

re (°

F)

90

110



0.40 GPM

6.4 GPM

°F

°F

Water Pressure & Water Flow Rate:

Wat

er F

low

Rat

e (G

PM

)

Water Pressure (psi)

2.8

3.2

4.0

4.4

4.8

5.1Inlet Water Temperature: 70

Inlet Water Temperature: 40

(5.1)

(3.2)

15 30 45 60 105 120 135

(At The Outlet Hot Water Temperature : 120 )°F

3.6

- 113 -


0.5 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0

85

100

120

130

140



Out

let T

empe

ratu

re (°

F)

8.4 GPM



90

110

0.40 GPM

0.5 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0

85

100

120

130

140



Out

let T

empe

ratu

re (°

F)

90

110

0.40 GPM

8.4 GPM



0.5 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0

85

100

120

130

140



Out

let T

empe

ratu

re (°

F)

90

110

0.40 GPM



8.4 GPM

0.5 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0

85

100

120

130

140



Out

let T

empe

ratu

re (°

F)

90

110



0.40 GPM

8.4 GPM

°F

°F


Wat

er F

low

Rat

e (G

PM

)


3.3

3.8

4.3

4.8

5.3

5.8



(6.1)

(3.8)

22 35 45 60 105 120 135


- 114 -

CapacityHot Water Capacity Curve: PH2-25R Commercial Setting

0.5 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0

100

110

120

130

140

Inlet Water Temperature : 40°F (PH2-25R Commercial Setting)


Out

let T

empe

ratu

re (°

F)

150

160

170

180

185

85

8.4 GPM



0.40 GPM

0.5 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0

100

110

120

130

140



Out

let T

empe

ratu

re (°

F)

150

160

170

180

185

85

0.40 GPM



8.4 GPM

0.5 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0

100

110

120

130

140



Out

let T

empe

ratu

re (°

F)

150

160

170

180

185

85



0.40 GPM

8.4 GPM

0.5 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0

100

110

120

130

140



Out

let T

empe

ratu

re (°

F)

150

160

170

180

185

85

0.40 GPM



8.4 GPM

°F

°F


Wat

er F

low

Rat

e (G

PM

)


3.3

3.8

4.3

4.8

5.3

5.8



(6.1)

(3.8)

22 35 45 60 105 120 135


- 115 -


0.5 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0

85

100

120

130

140



Out

let T

empe

ratu

re (°

F)

9.5 GPM



90

110

0.40 GPM

0.5 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0

85

100

120

130

140



Out

let T

empe

ratu

re (°

F)

9.5 GPM



90

110

0.40 GPM

0.5 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0

85

100

120

130

140



Out

let T

empe

ratu

re (°

F)

90

110

9.5 GPM



0.40 GPM

0.5 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0

85

100

120

130

140



Out

let T

empe

ratu

re (°

F)

90

110

9.5 GPM

0.40 GPM



°F

°F


Wat

er F

low

Rat

e (G

PM

)


3.7

4.2

4.7

5.2

5.7

6.2



(6.7)

(4.2)

29 40 50 60 105 120 135


- 116 -

CapacityHot Water Capacity Curve: PH2-28R Commercial Setting

0.5 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0

100

110

120

130

140



Out

let T

empe

ratu

re (°

F)

150

160

170

180

185

85

9.5 GPM



0.40 GPM

0.5 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0

100

110

120

130

140



Out

let T

empe

ratu

re (°

F)

150

160

170

180

185

85

9.5 GPM

0.40 GPM



0.5 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0

100

110

120

130

140



Out

let T

empe

ratu

re (°

F)

150

160

170

180

185

85

0.40 GPM

9.5 GPM



0.5 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0

100

110

120

130

140



Out

let T

empe

ratu

re (°

F)

150

160

170

180

185

85

9.5 GPM

1.0

0.40 GPM



°F

°F


Wat

er F

low

Rat

e (G

PM

)


3.7

4.2

4.7

5.2

5.7

6.2



(6.7)

(4.2)

29 40 50 60 105 120 135


- 117 -

CapacityHot Water Capacity Curve: PHH-25R Residential Use

°F

°F


Wat

er F

low

Rat

e (G

PM

)


3.3

3.8

4.3

4.8

5.3

5.8



(6.1)

(3.8)

22 35 45 60 105 120 135


0.5 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0

85

100

120

130

140

Inlet Water Temperature : 40°F (PHH-25R)


Out

let T

empe

ratu

re (°

F)

8.5 GPM



90

110

0.40 GPM

0.5 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0

85

100

120

130

140



Out

let T

empe

ratu

re (°

F)

90

110

0.40 GPM

8.5 GPM



0.5 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0

85

100

120

130

140



Out

let T

empe

ratu

re (°

F)

90

110

0.40 GPM

8.5 GPM



0.5 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0

85

100

120

130

140



Out

let T

empe

ratu

re (°

F)

90

110

8.5 GPM

0.40 GPM



- 118 -

CapacityHot Water Capacity Curve: PHH-25R Commercial Setting

°F

°F


Wat

er F

low

Rat

e (G

PM

)


3.3

3.8

4.3

4.8

5.3

5.8



(6.1)

(3.8)

22 35 45 60 105 120 135


0.5 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0

100

110

120

130

140

Inlet Water Temperature : 40°F (PHH-25R Commercial Setting)


Out

let T

empe

ratu

re (°

F)

150

160

170

180

185

85

0.40 GPM

8.5 GPM



0.5 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0

100

110

120

130

140



Out

let T

empe

ratu

re (°

F)

150

160

170

180

185

85

0.40 GPM

8.5 GPM



0.5 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0

100

110

120

130

140



Out

let T

empe

ratu

re (°

F)

150

160

170

180

185

85

0.40 GPM

8.5 GPM



0.5 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0

100

110

120

130

140



Out

let T

empe

ratu

re (°

F)

150

160

170

180

185

85

0.40 GPM

8.5 GPM



- 119 -

CapacityHot Water Capacity Curve: PHH-32R Residential Use

°F

°F


Wat

er F

low

Rat

e (G

PM

)


3.7

4.2

4.7

5.2

5.7

6.2



(6.7)

(4.2)

29 40 50 60 105 120 135


0.5 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0

85

100

120

130

140



Out

let T

empe

ratu

re (°

F)

9.5 GPM

90

110

0.40 GPM



0.5 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0

85

100

120

130

140



Out

let T

empe

ratu

re (°

F)

90

110

0.40 GPM



9.5 GPM

0.5 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0

85

100

120

130

140



Out

let T

empe

ratu

re (°

F)

90

110

0.40 GPM



9.5 GPM

0.5 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0

85

100

120

130

140



Out

let T

empe

ratu

re (°

F)

90

110

0.40 GPM



9.5 GPM

- 120 -

CapacityHot Water Capacity Curve: PHH-32R Commercial Setting

°F

°F


Wat

er F

low

Rat

e (G

PM

)


3.7

4.2

4.7

5.2

5.7

6.2



(6.7)

(4.2)

29 40 50 60 105 120 135


0.5 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0

100

110

120

130

140



Out

let T

empe

ratu

re (°

F)

150

160

170

180

185

85

9.5 GPM

0.40 GPM



0.5 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0

100

110

120

130

140



Out

let T

empe

ratu

re (°

F)

150

160

170

180

185

85

0.40 GPM

9.5 GPM



0.5 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0

100

110

120

130

140



Out

let T

empe

ratu

re (°

F)

150

160

170

180

185

85

0.40 GPM

9.5 GPM



0.5 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0

100

110

120

130

140



Out

let T

empe

ratu

re (°

F)

150

160

170

180

185

85

1.0

0.40 GPM

9.5 GPM



Wiring Diagram for PH2-20R, PH2-25R & PH2-28R

31-9

3618

0

VERT

/JAUN

EG/

Y:GR

EEN/

YELL

OW,

AC 120V

O:O

RANG

E,O

RANG

E

CODE

DE C

OULE

URCO

LOR C

ODE

MIN B

UTTO

NBO

UTON

MIN.

G/Yo

rGW

BOUT

ON M

AX.

BL

BLBL

LED

GG

MAX B

UTTO

NAD

JUSTER

BUTTO

N

BL

BOUT

ON DE

RÉGL

AGE BL

12345A

FOR I

NDOO

R,DIRE

CT-VE

NTMO

DEL O

NLY

POUR

MOD

ÈLE I

NTÉR

IEUR À

ÉVEN

T DIRE

CT SE

ULEM

ENT

43

21

YW

RBK

BLW

BLR

OY

FOR D

IRECT

-VENT

MOD

EL ON

LYPO

UR M

ODÈL

E À ÉV

ENT D

IRECT

SEUL

EMEN

TSW

3SW

2SW

1

U2 1

S13 2

W W

12

34

IJ

H

F

W W

23

41

B

R Y O W BRBK

12345678R Y O W BRBK

12345678

C9

RBR BK

BK WBK W

12

34

YWBK

12

3K

SV0

SV1

SV2

SV3

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- 121-

- 122 -

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Resis-tanceK Ohm

TempºF

Resis-tanceK Ohm

TempºF

Resis-tanceK Ohm

TempºF

Resis-tanceK Ohm

32 23.73 77 8.494 122 3.485 167 1.59833.8 22.706 78.8 8.177 123.8 3.371 168.8 1.55235.6 21.733 80.6 7.873 125.6 3.262 170.6 1.50837.4 20.806 82.4 7.583 127.4 3.156 172.4 1.46539.2 19.925 84.2 7.304 129.2 3.055 174.2 1.424

41 19.085 86 7.037 131 2.957 176 1.38442.8 18.286 87.8 6.781 132.8 2.863 177.8 1.34544.6 17.525 89.6 6.536 134.6 2.773 179.6 1.30746.4 16.799 91.4 6.302 136.4 2.686 181.4 1.27148.2 16.108 93.2 6.076 138.2 2.602 183.2 1.236

50 15.449 95 5.86 140 2.52 185 1.20251.8 14.82 96.8 5.653 141.8 2.442 186.8 1.16953.6 14.221 98.6 5.454 143.6 2.367 188.6 1.13755.4 13.469 100.4 5.264 145.4 2.295 190.4 1.10657.2 13.104 102.2 5.081 147.2 2.225 192.2 1.077

59 12.583 104 4.905 149 2.157 194 1.04860.8 12.086 105.8 4.736 150.8 2.092 195.8 1.0262.6 11.611 107.6 4.574 152.6 2.029 197.6 0.99364.4 11.157 109.4 4.418 154.4 1.968 199.4 0.96666.2 10.723 111.2 4.269 156.2 1.91 201.2 0.941

68 10.309 113 4.125 158 1.853 203 0.91669.8 9.913 114.8 3.987 159.8 1.799 204.8 0.89371.6 9.534 116.6 3.854 161.1 1.746 206.6 0.86973.4 9.172 118.4 3.726 163.4 1.695 208.4 0.84775.2 8.826 120.2 3.603 165.2 1.646 210.2 0.825

- 123 -

- 124 -

AdjustmentAdjustment of Burner Control Assembly (PC Board)

The content on this page is intended for use by qualifi ed service personnel only.

PCB Replacement Procedure

WARNING: You will need to perform this procedure when you replace the PCB.Without this adjustment, the water heater may not function properly.WARNING: Improper adjustment, alteration, service or maintenance can cause property damage, personal injury, or death.Note: During the adjustment procedure if [EE] is displayed on the LED of remote control, adjust again with caution. This means there was an error in the adjustment sequence.NOTE: If the value number for the Maximum, Minimum and Slow Ignition manifold setting (01~39) were written down on the front plate, record these numbers and skip the steps 3 ~ 5.When replacing the printed circuit board (PCB), adjust as follows.1. Find the SW1, SW2, SW3 buttons and DIP1 switch located at the top right hand side of the PCB. (See PCB Figure 1)2. Record any DIP switches setting.3. With old PCB installed verify minimum manifold pressure setting. The setting value will be displayed on the remote control. a. Without any water fl ow, press and hold down the Adjusting Button (SW3) b. Momentarily press the Minimum Button (SW1) c. Record the number that displays on the remote control ________________ d. Release the Adjusting Button (SW3)4. Verify maximum manifold setting. The setting value will be displayed on the remote control. a. Without any water fl ow, press and hold down the Adjusting Button (SW3) b. Momentarily press the Maximum Button (SW2) c. Record the number displayed on the remote control ___________________ d. Release the Adjusting Button (SW3)

ON

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OFF

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IP1

MIN MAX ADJ

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DIP 1

DIP 2AdjustingButton (SW3)

ProgramChip

MaximumButton (SW2)MinimumButton (SW1)

LED

Printed Circuit Board (PCB) - Figure 1 5. Verify slow ignition manifold setting. The setting value will be displayed on the remote control. a. Find DIP1 and change DIP switch #1 setting of DIP1 to ON position. DO NOT alter any other DIP switch. b. Without any water fl ow, press the Maximum Button (SW2), then Minimum Button (SW1) within 2 seconds and hold down both button for more than 5 seconds. The “P” is displayed on the LED of remote control. c. Release the Maximum Button (SW2) and Minimum Button (SW1), then press and hold down the Adjusting Button (SW3) to change “P” to the value. d. Record the number displayed on the remote control __________________ e. Release the Adjusting Button (SW3) f. Change the DIP switch #1 setting of DIP1 to OFF position. DO NOT alter any other DIP switch.6. Turn off power at remote control.7. Disconnect power from water heater. Turn off gas and water supply to water heater.

- 125 -

Adjustment of Burner Manifold settings on the new PCB.

Note: Always start from “Minimum” when adjusting the burner manifold pressure setting. The display is on remote control. Always connect the remote control to monitor this procedure.13. Reconnect power to water heater.14. Adjustment of minimum manifold setting a. Repeat steps 3.a. and 3.b. from the above procedure. If the recorded value does not agree with current value then proceed to next step. If the value does agree then move onto step 14.d. b. Without any water fl ow, press and hold down the Adjusting Button (SW3) c. While holding the Adjusting Button (SW3); momentarily push the Minimum Button (SW1) on the PCB. The current number [01 - 39] is displayed on the LED of remote control. Continue to momentarily press the Minimum Button (SW1) until you get to the value recorded in step 3.c.

Note: Every time you press the MINIMUM (SW1) Button, the display will cycle up to the number 39. Once it reaches 39, it will automatically reverse and cycle back down to 01.

d. Release the Minimum Button (SW1) fi rst, then release the Adjusting Button (SW3).

15. Adjusting of maximum manifold setting a. Repeat steps 4.a. and 4.b. from the above procedure. If recorded value does not agree with the current value then proceed to next step. If the value does agree then move onto step 15.d. b. Without any water fl ow, press and hold down the Adjusting Button (SW3) c. While holding the Adjusting Button (SW3); momentarily push the Maximum Button (SW2) on the PCB. The current number [01 - 39] is displayed on the LED of remote control. Continue to momentarily press the Maximum Button (SW2) until you get to the value recorded in step 4.c.

Note: Every time you press the MAXIMUM (SW2) Button, the display will cycle up to the number 39. Once it reaches 39, it will automatically reverse and cycle back down to 01. d. Release the Maximum Button (SW2) fi rst, then release the Adjusting Button (SW3).

17. Attach the unit’s front cover.18. Turn on gas supply (Note: ensure there are no gas leaks). Turn on water supply (Note: ensure there are no water leaks). 19. Turn on remote control.20. Check and ensure safe operation and performance of the water heater.

8. Carefully remove the existing program chip, see fi gure 1 for location. Lightly grip the edges of the chip, top and bottom, as in fi gure 2, and pull the chip straight out from the PCB and set it aside.9. Remove the old PCB.10. Install the new PCB.11. Gripping the removed program chip, as in fi gure 2, carefully align and insert the chip into the socket on the PCB. Do Not Force.12. Adjust the DIP switch setting, if necessary, for high altitude setting, etc.

Figure 2

16. Adjusting of slow ignition manifold setting a. Repeat steps 5.a., 5.b. and 5.c. from the above procedure. If recorded value does not agree with the current value then proceed to next step. If the value does agree then move onto step 16.c. b. Press and hold down the Adjusting Button (SW3). The current number [01 - 39] is displayed on the LED of remote control. Continue to momentarily press the Maximum Button (SW2) for increasing the number or the Minimum Button (SW1) for decreasing the number on the PCB until you get to the value recorded in step 5.d. c. Release the Adjusting Button (SW3).

- 126 -

Adjusting of Burner Manifold setting on the new PCB if the old PCB was completely broken or you could not get the value number [01 - 39].

Note: During the adjustment procedure if [EE] is displayed on the LED of remote control, adjust again with caution. This means there was an error in the adjustment sequence.

1. Turn off power at remote control. Disconnect power from water heater. Turn off gas and water supply to water heater.2. Record any DIP switches setting.

3. Carefully remove the existing program chip, see fi gure 1 for location. Lightly grip the edges of the chip, top and bottom, as in fi gure 2, and pull the chip straight out from the PCB and set it aside.4. Remove the old PCB.5. Install the new PCB.6. Gripping the removed program chip, as in fi gure 2, carefully align and insert the chip into the socket on the PCB. Do Not Force.7. Adjust the DIP switch setting, if necessary, for high altitude setting, etc.

Figure 2

8. Remove the plug for the manifold pressure and connect the manometer.9. Reconnect power to water heater.10. Do Not turn on remote control.

Note: Always start from “Minimum” when adjusting the burner manifold pressure setting. 11. Adjustment of manifold pressure Measurement of Fan Pressure Measure the fan pressure before adjusting the burner manifold pressure. The fan pressure differs depending on models, types of gas or installation condition. Measure the fan pressure at each installation site. (1) Measurement of minimum capacity. a. At the condition that the remote control is off and with any water fl ow, press and hold down the Minimum Button (SW1) on the PCB. b. Using the manometer, measure and record the minimum fan pressure (within 20 seconds). (2) Measurement of maximum capacity. a. At the condition that the remote control is off and with any water fl ow, press and hold down the Maximum Button (SW2) on the PCB. b. Using the manometer, measure and record the maximum fan pressure (within 20 seconds).

12. Adjustment of minimum manifold setting a. Turn on gas supply (Note: ensure there are no gas leaks). Turn on water supply (Note: ensure there are no water leaks). b. Turn on remote control. c. Open the hot water tap gradually until the water heater ignites at the minimum operating water fl ow. d. Press and hold down the Adjusting Button (SW3). e. While holding the Adjusting Button (SW3); momentarily push the Minimum Button (SW1) on the PCB. (Note: It becomes to the minimum setting forcibly when the water is fl ow.) Using the manometer, adjust the minimum manifold pressure to the standard pressure (see table below) plus the previous recorded minimum fan pressure in step 11. (1) b. f. Every time you press the Minimum Button (SW1), the displayed value is [UP] or [DOWN]. Adjust the value at the manometer. g. After adjusted, release the Minimum Button (SW1) fi rst, then release the Adjusting Button (SW3).

- 127 -

13. Adjustment of maximum manifold setting a. Open the hot water tap fully and make the maximum fl ow. b. Press and hold down the Adjusting Button (SW3). c. While holding the Adjusting Button (SW3); momentarily push the Maximum Button (SW2) on the PCB. (Note: It becomes to the maximum setting forcibly when the water is fl ow.) Using the manometer, adjust the maximum manifold pressure to the standard pressure (see table below) plus the previous recorded maximum fan pressure in step 11. (2) b. d. Every time you press the Maximum Button (SW2), the displayed value is [UP] or [DOWN]. Adjust the value at the manometer. e. After adjusted, release the Maximum Button (SW2) fi rst, then release the Adjusting Button (SW3).

14. Adjustment of slow ignition manifold setting a. Find DIP1 and change DIP switch #1 setting of DIP1 to ON position. DO NOT alter any other DIP switch. b. Press the Maximum Button (SW2), then press the Minimum Button (SW1) within 2 seconds and hold down both for more than 5 seconds. The “P” is displayed on the LED of remote control. c. With the maximum hot water fl ow (open the hot water tap fully), press the Maximum Button (SW2) and measure and record the fan pressure for the slow ignition point. d. Press and hold down the Adjusting Button (SW3) and using the manometer, adjust the slow ignition manifold pressure to the standard pressure (see table below) plus the previous recorded fan pressure for the slow ignition point in step 14.b. above. e. Release the Adjusting Button (SW3). f. Turn off power at remote control. g. Changed the DIP switch #1 setting of DIP1 to OFF position. DO NOT alter any other DIP switch.

15. Attach the unit’s front cover.16. Turn on gas supply (Note: ensure there are no gas leaks). Turn on water supply (Note: ensure there are no water leaks).17. Turn on remote control.18. Check and ensure safe operation and performance of the water heater.Standard Pressure (inch in w.c.)

PH2-28RDVS PH2-25RDVS PH2-20RDVSL.P. NAT L.P. NAT L.P. NAT

Minimum Capacity 0.87/11.0 0.51/7.1 0.87/11.0 0.51/7.1 0.87/11.0 0.51/7.1

Maximum Capacity 3.25/11.0 2.48/7.1 2.80/11.0 2.10/7.1 2.00/11.0 1.50/7.1Slow Ignition Point 1.85/11.0 0.59/7.1 1.85/11.0 0.59/7.1 1.85/11.0 0.59/7.1

PH2-28ROF PH2-25ROF PH2-20ROFL.P. NAT L.P. NAT L.P. NAT

Minimum Capacity 0.91/11.0 0.63/7.1 0.91/11.0 0.63/7.1 0.91/11.0 0.63/7.1Maximum Capacity 3.35/11.0 3.00/7.1 2.72/11.0 2.52/7.1 1.93/11.0 1.73/7.1Slow Ignition Point 2.76/11.0 2.05/7.1 2.76/11.0 2.05/7.1 2.76/11.0 2.05/7.1

[How To Check Test Point Gas Pressure]When press the Maximum Button (SW2) or Minimum Button (SW1), the combustion is fi xed at Maximum or Minimum and then the LED of remote control displays as follows.

1__ L__

Minimum Combustion1st Step Combustion

4__ H__

Maximum Combustion4th Step Combustion

Note: Make sure that you adjusted the DIP switch setting, if necessary, for the high altitude setting, etc.

Standard Pressure (inch in w.c.)

PHH-32RDV PHH-25RDVL.P. NAT L.P. NAT

Minimum Capacity 0.91/11.0 0.71/7.1 0.91/11.0 0.71/7.1

Maximum Capacity 3.64/11.0 3.13/7.1 2.24/11.0 1.97/7.1Slow Ignition Point 2.76/11.0 2.52/7.1 2.76/11.0 2.52/7.1

PHH-32ROF PHH-25ROFL.P. NAT L.P. NAT

Minimum Capacity 0.89/11.0 0.65/7.1 0.89/11.0 0.65/7.1Maximum Capacity 3.46/11.0 3.11/7.1 2.17/11.0 1.97/7.1Slow Ignition Point 2.76/11.0 2.68/7.1 2.76/11.0 2.68/7.1

- 128 -

- 129 -

High Altitude DIP Switch Adjustment For High Altitude Installation Above 3,280 Feet (1,000 M):WARNING: Improper adjustment, alternation, service or maintenance can cause property damage, personal injury, or death.

When the water heater is installed above 3,280 feet (1,000m) or when the Burner Control Assembly (PCB) was replaced, the adjustment of DIP switch is required for high altitude installation.Without adjusting the DIP switch, the water heater may not function properly.

NOTICE: If the water heater is installed less than 3,280 feet (1,000m), no action is required.

How to adjust the DIP switch on the PCB for high altitude installation:

(1) Check the altitude (above sea level) where the water heater is installed.(2) If the altitude is more than 3,280 feet (1,000m), the adjustment of DIP switch is required.(3) Turn off the gas shutoff valve and water shutoff valve.(4) Remove the front cover.(5) Find the two DIP switches located at the top right hand side of the PCB. The switch labeled “DIP 2” is the bottom switch.(6) Change the DIP switch #3 setting of DIP 2 to “ON” position if the water heater is installed above 3,280 feet (1,000m) below 6,560 feet (2,000m). See the diagram below. DO NOT alter any other DIP Switch.(7) Change the DIP switch #4 setting of DIP 2 to “ON” position if the water heater is installed above 6,560 feet (2,000m) below 9,840 feet (3,000m). See the diagram below. DO NOT alter any other DIP Switch.

NOTICE: Manifold pressure will be reduced by this adjustment.

(8) Attach the unit’s front cover.(9) Turn on the gas shutoff valve and water shutoff valve.(10) Check and ensure safe operation and performance of the water heater.

ON

1 2 3 4

ON

OFF

ON

1 2 3 4

ON

OFF

1 2 3 4

1 2 3 4

DIP2

DIP1

MIN MAX ADJ

LED

DIP 1

DIP 2AdjustingButton (SW3)

ProgramChip

MaximumButton (SW2)MinimumButton (SW1)

LED

Dip switch adjustment3,280 feet (1,000m)

thru6,560 feet (2,000m)

ON

1 2 3 4

As set from factory

ON

1 2 3 4

ON

1 2 3 4

Dip switch adjustment6,560 feet (2,000m)

thru9,840 feet (3,000m)

- 130 -

Instruction for changing the setting to 85ºF (29ºC):WARNING: Improper adjustment, alternation, service or maintenance can cause property damage, personal injury, or death.Minimum Temperature Adjustment by the Remote Control (UMC-117)

Follow the instruction below if it is determined that a setting of 85º (29ºC) is required.

(1) Turn on the remote control (UMC-117). Turn off the gas and water shutoff valves.(2) Press the DOWN arrow temperature adjustment button on the remote control for several times and set the tempera-ture at 100ºF (38ºC).(3) Press the DOWN button on remote control 3 times within 5 seconds. The display of the remote control will show “85”.(4) Push the UP or DOWN button to set desired temperature.(5) Turn on the gas and water shutoff valves.(6) Check and ensure safe operation and performance of the water heater.

NOTICE: The maximum fl ow rate at 85ºF (29ºC) is 1.3 gpm (5.0 l/m).

WARNING: Changing this setting is done at your risk.WARNING: Water Temperature over 125ºF (52ºC) can cause severe burns instantly or death from scalds. Children, disabled and elderly persons are at highest risk of being scalded. See the Instruction Manual before setting the temperature on the remote control. FEEL WATER BEFORE BATHING or SHOWERING. DO NOT leave a child in the bath unsupervised.Danger: Hotter water increases the potential for Hot Water SCALDS.Notice: For safety reasons the BATH Remote Control(s) cannot be adjusted to temperature above 120ºF (49ºC).Note: We recommend that you install the thermostatically controlled tub and shower valve & tempering valve for your safety.

°F

PRIORITY

POWERON/OFF

Higher (Hotter) Lower (Cooler)

In Use Indicator(Lit during operation)

LED Display(Display watertemperature and error code)

PriorityIndicator

TemperatureAdjustmentButtons

ON/OFFIndicator

100 102 104 106 108 110 112 114 116 118 120*

38 39 40 41 42 43 44 46 47 48 49*

85

29

125 130 135 140 150 160 170 185 °F

52 54 57 60 66 71 77 85 °C

Temperature Time to Produce Serious Burn Temperature Time to Produce Serious Burn 120°F (49°C) More than 5 minutes 140°F (60°C) Less than 5 seconds 125°F (52°C) 1-1/2 to 2 minutes 145°F (63°C) Less than 3 seconds 130°F (54°C) About 30 seconds 150°F (66°C) About 1-1/2 seconds 135°F (57°C) About 10 seconds 155°F (68°C) About 1 secondTable courtesy of The Shriners Burn Institute

Time/Temperature Relationship in Scalds

Required adjustment for 85ºF (29ºC) water temperature setting.

- 131 -

Instruction for changing the setting back to 120ºF (49ºC):WARNING: Improper adjustment, alternation, service or maintenance can cause property damage, personal injury, or death.Adjustment to LIMIT maximum water temperature setting to 120ºF (49ºC) by the Main Remote Control (UMC-117)

Follow the instruction below if it is determined that a setting of up to 140º (60ºC) or 185ºF (85ºC) is no longer required.

(1) Turn on the remote control (UMC-117). Turn off the gas and water shutoff valves.(2) Press the DOWN arrow temperature adjustment button on the remote control for several times and set the mini-mum setting temperature at 100ºF (38ºC) or 85ºF (29ºC).(3) Press and hold the DOWN button on remote control for more than 5 seconds. Number on the display of the remote control will begin to blink.(4) While the number is blinking, push the DOWN arrow temperature adjustment button and the UP arrow temperature adjustment button at the same time. Number on the display of the remote control will stop blinking.(5) Push the UP or DOWN button to set desired temperature.(6) Turn on the gas and water shutoff valves.(7) Check and ensure safe operation and performance of the water heater.

WARNING: Changing this setting is done at your risk.WARNING: Water Temperature over 125ºF (52ºC) can cause severe burns instantly or death from scalds. Children, disabled and elderly persons are at highest risk of being scalded. See the Instruction Manual before setting the temperature on the remote control. FEEL WATER BEFORE BATHING or SHOWERING. DO NOT leave a child in the bath unsupervised.Danger: Hotter water increases the potential for Hot Water SCALDS.Notice: For safety reasons the BATH Remote Control(s) cannot be adjusted to temperature above 120ºF (49ºC).Note: We recommend that you install the thermostatically controlled tub and shower valve & tempering valve for your safety.

°F

PRIORITY

POWERON/OFF




PriorityIndicator


ON/OFFIndicator

100 102 104 106 108 110 112 114 116 118 120*

38 39 40 41 42 43 44 46 47 48 49*

85

29

125 130 135 140 150 160 170 185 °F

52 54 57 60 66 71 77 85 °C



- 132 -

Instruction for changing the setting to 140ºF (60ºC) or185ºF (85ºC):WARNING: Improper adjustment, alternation, service or maintenance can cause property damage, personal injury, or death.Maximum Temperature Adjustment by the Main Remote Control (UMC-117)Required adjustment for up to 140ºF (60ºC) water temperature setting for Residential product or 185ºF (85ºC) water temperature setting for Commercial version.

Follow the instruction below if it is determined that a setting of up to 140º (60ºC) or 185ºF (85ºC) is required.

(1) Turn on the remote control (UMC-117). Turn off the gas and water shutoff valves.(2) Press the UP arrow temperature adjustment button on the remote control for several times and set the temperature at 120ºF (49ºC).(3) Press and hold the UP button on remote control for more than 5 seconds. Number (120) on the display of the re-mote control will begin to blink.(4) While the number is blinking, push the UP arrow temperature adjustment button and the DOWN arrow temperature adjustment button at the same time. The display of the remote control will show “140”.(5) Push the UP or DOWN button to set desired temperature.(6) Turn on the gas and water shutoff valves.(7) Check and ensure safe operation and performance of the water heater.

Note: Commercial version requires the adjustment by the commercial conversion kit.WARNING: Changing this setting is done at your risk.WARNING: Water Temperature over 125ºF (52ºC) can cause severe burns instantly or death from scalds. Children, disabled and elderly persons are at highest risk of being scalded. See the Instruction Manual before setting the temperature on the remote control. FEEL WATER BEFORE BATHING or SHOWERING. DO NOT leave a child in the bath unsupervised.Danger: Hotter water increases the potential for Hot Water SCALDS.Notice: For safety reasons the BATH Remote Control(s) cannot be adjusted to temperature above 120ºF (49ºC).Note: We recommend that you install the thermostatically controlled tub and shower valve & tempering valve for your safety.DO NOT execute the following adjustment if the setting of up to 140ºF (60ºC) or 185ºF (85ºC) is not required.

°F

PRIORITY

POWERON/OFF




PriorityIndicator


ON/OFFIndicator

100 102 104 106 108 110 112 114 116 118 120*

38 39 40 41 42 43 44 46 47 48 49*

85

29

125 130 135 140 150 160 170 185 °F

52 54 57 60 66 71 77 85 °C



Tankless Water Heater DUOnex™ 2-Unit SystemInstallation Instructions

It is very important that all persons who are expected to install, operate or adjust this DUOnex™ system and/or water heater read these instructions

along with those instructions provided with the tankless water heater. Recognize this symbol as an indication of Important Safety Information!!

Refer to the Use and Care Manual provided with your tankless water heater for the proper installation procedures.

This kit contains: 1 - DUOnex™ Cable, 2 - Cable Clamps, and 2 - Screws

Install two tankless water heaters of the same model together in a parallel plumbing application (see Figure 2) and in accordance with the instructions in the Use and Care Manual.

NOTICE: A Remote Control Thermostat is included with each water heater. When using the DUOnex™ system, only one (1) Remote Control Thermostat is needed. Connect only one (1) remote control to either water heater following the instructions provided in the Use and Care Manual. This water heater will become the main unit. The installed Remote Control Thermostat will control temperature and functionality of both water heaters. Keep the unused remote control as a spare.

1. Make sure power is disconnected and turn off gas and water to both water heaters, then remove the front cover from each water heater.

2. Feed one end of the DUOnex™ cable through a grommeted hole in the bottom of the fi rst heater.

3. Plug the cable into the connector marked “F” in the upper right-hand corner of the Control Board (see Figure 1). The connector will only fi t one way. Press until the connector snaps into place.

4. Secure the DUOnex™ cable with the clamp and screw provided to the bottom right of the Control Board (see Figure 1).

5. Change the #4 Dip Switch setting to the “ON” position (see Figure 1 inset) on that water heater.

6. Pass the other end of the DUOnex™ cable through a grommeted hole in the bottom of the second water heater.

7. Plug the cable into the connector marked “F” in the upper right-hand corner of the Control Board (see Figure 1). The connector will only fi t one way. Press until the connector snaps into place.

8. Secure the DUOnex™ cable with the clamp and screw provided to the bottom of the Control Board (see Figure 1).

9. Change the # 4 Dip Switch setting to the “ON” position (see Figure 1 inset) on that water heater.

10. Attach the front cover on each unit, and turn on the power, gas, and water.

11. Test the units by turning on a tub or shower fi xture.

Notice: The DUOnex™ System is designed to electronically con-trol two tankless water heaters operating as one. Depending upon the hot water demand, one or both units may be in operation. To test both units, increase the hot water fl ow by turning on more than one hot water appliance or fi xture. - 133 -

Control Board - Figure 1

ON

1 2 3 4DIP

1

ON

OFF

1 2 3 4

SW1 SW2

SW3

ON

1 2 3 4DIP

1D

IP1

ON

ON

OFF

OFF

1 2 3 4

Dip Switch

Connector “F”

DUOnex™ Cable

Cable clamp and screw

LED

Dip Switch Position #4

Figure 1 inset

Type 1DUOnexTM Installation

Typical Two Unit Manifold - Figure 2 Review the Use and Care Manual provided with the water heater for complete information and installation instructions.

Danger - Water Temperature Setting Safety and energy

conservation are factors to be considered when selecting the water temperature setting of a water heater’s Remote Control Thermostat. Water temperatures above 125°F (52°C) can cause severe burns or death from scalding. Be sure to read and follow the warnings outlined on the label pictured to the left and information in the Use and Care Manual provided with your tankless water heater.

D A N G E R!

HOT

Water temperature over 125° can cause severe burns instantly or death from scalds.

Children, disabled and elderly areat highest risk of being scalded.

See instruction manual beforesetting temperature at waterheater.Feel water before bathing orshowering.Temperature limiting valves areavailable, see manual.

BURN

F (52°C)

!

140°F (60°C) Maximum Temperature Adjustment The factory default temperature setting is 120°F (49°C). Follow these instructions to set the system to allow up to 140°F (60°C) operation. Note: Only the UMC-117 Main Remote Control Thermostat can be used for 140°F (60°C) operation. 1. Turn off the system at the Remote Control Thermostat and

remove the front cover from the main water heater.

2. At the main water heater, the one that is wired to the Remote Control Thermostat, change the #4 Dip Switch setting (see Figure 3) to the “OFF” position. Wait two seconds, and change the #4 Dip Switch setting back to the “ON” position. The LED (see Figure 1) on the Control Board and “dashes” on the display of the Remote Control Thermostat (see Figure 4) will begin to blink .

Dip Switches and Buttons - Figure 3

120°F(49°C) Maximum Temperature Reset Follow these instructions to reset the water heater back to the factory 120°F (49°C) maximum temperature setting.

1. Turn off the system at the remote control and remove the front cover from the main water heater.

2. At the main water heater, the one that is wired to the Remote Control Thermostat, change the #4 Dip Switch setting (see Figure 3) to the “OFF” position. Wait two seconds and turn the #4 Dip Switch setting back to the “ON” position. The LED (see Figure 1) on the Control Board and “dashes” on the display of the Remote Control Thermostat (see Figure 4) will begin to blink.

3. Push and hold the “SW1” button for three seconds. The LED on the Control Board and “dashes” on the display on the Remote Control Thermostat will stop blinking and stay lit for about 10 seconds, then go off.

4. Reinstall the front cover on the water heater and turn on the system using the Remote Control Thermostat and adjust to the desired temperature (see Figure 4).

Remote Control Thermostat - Figure 4

°F

PRIORITY

POWERON/OFF

LED DisplayTemperature Adjustment

Buttons

Power Button

ON

1 2 3 4 DIP

1

ON

O

FF

1 2 3 4

SW1 SW2

SW3

ON

1 2 3 4DIP

1D

IP1

ON

ON

OFF

OFF

1 2 3 4

SW 1 SW 2

SW 3

Control Switches and

Buttons

Switch 1

Switch 2

Dip Switch Position #4

Vent Termination

°F

PRIORITY

POWERON/OFF

Venting Follow the instructions

in the Use and Care manual. Units cannot be common vented.

Remote Control

Water Isolation Valves

(optional)

Relief Valve piped to suitable drain. See Use

and Care Manual for detailed instructions. Hot Water

to fi xturesGrounded

Outlet

Cold Water Supply

DUOnex™ Cable

Drip Leg

Gas supply and shut off

Gas SupplyFollow the

instructions in the Use and Care Manual for proper

pipe sizing.

Unit 2Unit 1

3. While the LED on the Control Board and the “dash” on the Remote Control Thermostat are blinking, push and hold the “SW2” button (see Figure 3) for three seconds. The LED on the Control Board and “dashes” on the display on the Remote Control Thermostat will stop blinking and stay lit for about 10 seconds, then go off.

4. Reinstall the front cover on the water heater and turn on the system using the Remote Control Thermostat and adjust to the desired temperature (see Figure 4).

- 134 -

1. Make sure power is disconnected and turn off gas and water to both water heaters, then remove the front cover from each water heater.

2. Feed one end of the DUOnexTM cable through a grommeted hole in the bottom of the fi rst heater.

3. Plug the cable into the connector marked “F” on the right of the Control Board (see Figure 5). The connector will only fi t one way. Press until the connector snaps into place.

4. Find DIP1 Switches in the upper right-hand corner of the Control Board (see Figures 5 and 6).

5. Change the #4 Dip Switch setting on the DIP1 Switches to the “ON” position on the fi rst water heater.

6. Pass the other end of the DUOnexTM cable through a grommeted hole in the bottom of the second water heater.

7. Plug the cable into the connector marked “F” on the right of the Control Board (see Figure 5). The connector will only fi t one way. Press until the connector snaps into place.

8. Find DIP1 Switches in the upper right-hand corner of the Control Board (see Figures 5 and 6).

9. Change the #4 Dip Switch setting on the DIP1 Switches to the “ON” position on the second water heater.

10. Attach the front cover on each unit and turn on the power, gas and water.

11. Test the units by turning on a tub or shower fi xture.

ON

1 2 3 4

ON

OFF

ON

1 2 3 4

ON

OFF

1 2 3 4

1 2 3 4

DIP

2D

IP1

MIN MAX ADJ

LED

ON

1 2 3 4

ON

OFF

ON

1 2 3 4

ON

OFF

1 2 3 4

1 2 3 4

DIP

2D

IP 1

MIN MAX ADJ

Dip Switches and Buttons - Figure 6 Control Board - Figure 5

DIP 1

DIP 2

Type 2DUOnexTM Installation

- 135 -

140°F (60°C) Maximum Temperature Adjustment

The factory default temperature setting is 120°F (49°C). Follow these instructions to set the system to allow up to 140°F (60°C) operation. Note: Only the UMC-117 Main Remote Control Thermostat can be used for 140°F (60°C) operation.

DO NOT execute the following adjustment if the setting of up to 140°F (60°C) is not required.

This adjustment is intended for use by qualifi ed installation/service personnel ONLY. 1. Turn on the remote control. Turn off the gas and water shutoff

valve.

2. Press the UP arrow temperature adjustment button on the remote control (see Figure 4) for several times and set the temperature at 120°F (49°C).

3. Press and hold the UP button on the remote control for more than 5 seconds. Number (120) on the display of the remote control will begin to blink.

4. While the number is blinking, push the UP arrow temperature adjustment button and the DOWN arrow temperature adjustment button at the same time (see Figure 4). The display of the remote control will show “140”.

5. Push the UP or the DOWN button to set desired temperature.

6. Turn on the gas and water shutoff valves

7. Check and ensure safe operation and performance of the water heater.

120°F (49°C) Maximum Temperature Reset

Follow these instructions to reset the water heater back to the factory default 120°F (49°C) maximum temperature setting. 1. Turn on the remote control. Turn off the gas and water shutoff

valve.

2. Press the DOWN arrow temperature adjustment button on the remote control (see Figure 4) for several times and set the minimum setting temperature ((100°F (38°C) or 85°F(29°C)).

3. Press and hold the DOWN button on the remote control for more than 5 seconds. Number on the display of the remote control will begin to blink.

4. While the number is blinking, push the DOWN arrow temperature adjustment button and the UP arrow temperature adjustment button at the same time (see Figure 4). Number of the display of the remote control will stop blinking.

5. Push the UP or the DOWN button to set desired temperature.

6. Turn on the gas and water shutoff valves

7. Check and ensure safe operation and performance of the water heater.

Danger - Water Temperature Setting Safety and energy

conservation are factors to be considered when selecting the water temperature setting of a water heater’s Remote Control Thermostat. Water temperatures above 125°F (52°C) can cause severe burns or death from scalding. Be sure to read and follow the warnings outlined on the label pictured to the left and information in the Use and Care Manual provided with your tankless water heater.

D A N G E R!

HOT




BURN

F (52°C)

!

- 136 -

1

MIC-185 Manifold ControllerOperation and Installation Manual

SAFETY PRECAUTIONS● Read these instructions and the water heater instruction manual entirely before installing or

operating the manifold controller and the water heater.

● Use this manifold controller only for its intended purpose as described in these instructions.

● Be sure your water heater and the manifold controller are properly installed in accordance with

local codes and the provided installation instructions.

● Do not attempt to repair or replace any parts. All servicing should be referred to a qualifi ed

technician.

● Read and follow all instructions. Save this instruction for future reference.

Table of Contents

Safety Information

Operation Instructions

Trouble Shooting and Diagnosis

Instructions for the Installer

Extended Communications Board

High Temperature Operation

- 137 -

2

IMPORTANT SAFETY INFORMATIONREAD ALL INSTRUCTIONS BEFORE USING.

Safety and energy conservation are factors to be considered when selecting the water temperature setting of a water heater. Water temperatures above 125°F (52°C) can cause severe burns or death from scalding. Be sure to read and follow the warning outlined in the label pictured below.

WATER TEMPERATURE SETTING

For your safety, the information in these instructions and the instructions provided with the water heater must be followed to minimize the risk of fire or explosion, electric shock, or to prevent property damage, personal injury, or loss of life.

Improper adjustment, alteration, service or maintenance can cause property damage, personal injury or death. Only qualified service personnel should install or make adjustments.

Water Temperature Time To Produce a Serious Burn

120°F (49°C) More than 5 minutes125°F (52°C) 11/2 to 2 minutes130°F (54°C) About 30 seconds135°F (57°C) About 10 seconds140°F (60°C) Less than 5 seconds145°F (63°C) Less than 3 seconds150°F (66°C) About 11/2 seconds155°F (68°C) About 1 second

Table courtesy of Shriners Burn Institute


D A N G E R!

HOT




BURN

F (52°C)

The time/temperature relationship table shown above may be used as a guide in determining the proper water temperature for your home or any other application. ! DANGER: Hotter water increases the risk of hot water

scalds.! DANGER: Households with small children, disabled,

or elderly persons may require a 120°F (49°C) or lower temperature setting to prevent contact with “HOT” water.

Notice: When this water heater is supplying general purpose hot water requirements for use by individuals, a thermostatically controlled mixing valve for reducing point of use water temperature is recommended to reduce the risk of scald injury. Contact a licensed plumber or the local plumbing authority for further information.

WARNING!!

! DANGER!

This system is designed to operate up to 20 tankless water heaters in a parallel manifold system. All tankless water heaters on a single system and connected to this controller must be a like model. Do not connect water heaters of different sizes, capacities, or types, to this system.

- 138 -

3

Manifold Control System Components

(optional Kit)MICS-180 Expansion Card

For use when more than 6 Tankless Heaters are used in a manifold.

Includes Expansion BoardConnecting Wire Harness

Mounting Hardware

MIC-185 Board(Included with Control System)

The MIC-185 Manifold Control System Contains the following: Weather Resistant Case, (1) Control Board, (1) 10ft Power Cord, (1) Hard Wire Pigtail , Mounting Hardware, and this Instruction.

Electrical Junction Box

10ft Power Cord

Field Connection Pig TailFor use when the controller needs to

be hard wired to a power source

Weather Resistant Cabinet Upper Mounting Bracket

Expansion Card WireHarness

Water Heater Manifold Control Cable Slots 7 - 13



Manifold Cable Support Mounting Holes

4 Digit Diagnostic Display

Service Dip Switches

Service Switches

Remote Control Terminals

Available Accessories

MICS-180 Expansion Card Kit MIC-K-16 16ft Manifold Control Cable MIC-K-32 32ft Manifold Control Cable MIC-K-65 65ft Manifold Control Cable

Lower Mounting Bracket

Remote Control - Required to Run SystemThe remote is included with the tankless water heaters. Connect only one (1) remote of the manifold controller.

REMOTEPRIORITY

BURNERINDICATORShow Status

of the Burners

LED DISPLAY

Shows Temperature Setting and Error Codes

UP BUTTON

DOWN BUTTON

POWER BUTTON

POWER INDICATOR

Tankless Water Heater Communication Status LED

(one at each controlcable connection point)

Power Connection Terminals

Control Board Ground Wire

- 139 -

4

Typical Manifold System

A manifold system consists of the manifold controller referenced by this instruction, and a bank or 3 to 20 tankless water heaters. The tankless heaters are installed in a parallel manifold system where each unit if independently fed with cold water from a common water

main and independently feed a hot water main. See Figure 1.0. This system will not operate if the tankless water heaters are installed in series, one feeding another. All tankless water heaters on this system must be of the same type, do not mix types or capacities.

Section 1.1 - Basic Operation

This section covers the basic operation of the Manifold System by the end user from turning on the system, temperature adjustment, and trouble shooting. This section assumes the system has been installed and is operating normally.

The system is designed to operate with multiple tankless water heat-ers (units), each of which is fi red sequentially depending upon the demand or water fl ow rate. Over time the starting unit will rotate to spread the total operational time out evenly over all the units.

As the hot water demand increase the system will detect this and bring online additional units to meet the increased demand. As the hot water demand decreases the system will reduce the number of operating units. As the water fl ow stops, or units are shut down for reduced demands, the system will go into a stand by ready to fi re mode for a few minutes. It is normal for the fans to run after the wa-ter demand has stopped and the burners have shut off.

The system will sacrifi ce water fl ow rate to maintain water tempera-ture. If the water fl ow rate exceeds the systems capability the sys-tem will automatically restrict water fl ow to keep it at the thermostat setting. When this occurs there might be a slight or noticeable drop in the hot water pressure at the plumbing fi xtures. This is normal, if it occurs frequently the system may be undersized for the demand.

Section 1.0 - System Description

Figure 1.0

HOT WATERCOLD WATER

GAS

CONTROL CABLES

MANIFOLD CONTROLLER

REMOTE CONTROL

TANKLESS WATER HEATER

UNIT #1


UNIT #2


UNIT #3+

Manifold System OperationTo turn on the system, stop any hot water fl ow, and press the Power Button on the Remote Control Thermostat. See Figure 1.1. A Green indicator in the power button will light, and the display will show the current temperature setting.

Figure 1.1 - Press Power Button

- 140 -

5

Section 1.2 - Adjusting the Temperature

To adjust the system temperature higher, stop any hot water fl ow, and press the Up Button until you reach the desired temperature setting. See Figure 1.2.a.

NOTE: The temperature can only be raised above 112ºF if the water fl ow has been stopped, this is a safety feature of the system.

For temperature settings above 120ºF see the instructions in Sec-tion 1.5 to increase the max temperature range.

Manifold System Operation

To adjust the system temperature lower, press the Down Button to lower the temperature until you reach the desired temperature set-ting. See Figure 1.2.b.

NOTE: You may lower the temperature while water is fl owing and the heaters are in operation.

Figure 1.2.a - Raise Temperature

Figure 1.2.b - Lower Temperature

STANDARD TEMPERATURE SET POINTS in ºF100 102 104 106 108 110112 114 116 118 120

HIGH TEMPERATURE SET POINTS in ºF125 130 135** 140 150 160170 185*

*Max Temperature depends upon water heater model. ** Not available on some models.

Section 1.3 - Status Lights

The status lights on the remote consist of a “Burner On” indicator, see Figure 1.3, and a Priority light.

The “Burner On” indicator will come on to show when only when the system is heating water. This is regardless of the number of units operating in the system.

The “Priority” light tells which remote control has priority over the system in applications with multiple remote controls. This feature is only available on single installation residential units.Figure 1.3 - Raise Temperature


of the Burners

Section 1.4 - System RestartTo restart the system, stop any hot water fl ow, and press the Power Button on the Remote Control Thermostat. See Figure 1.1. A Green indicator in the power button will go out and the display will show blank.

Disconnect the power from the MIC-185 and tankless water heaters. Wait 30 seconds and apply power to all the tankless water heaters fi rst, then apply power to the MIC-185, the display will being to blink dashes. Once the display has stopped blinking dashes, proceed back to Section 1.1 to turn on the system.

- 141 -

6

The Manifold control system is designed with system redundancy in mind. If a failure were to occur within a tankless water heater, the system will shut that unit down, bypass it, and display an error notifi cation on the remote control display.

When an error occurs the remote will fl ash the error code, unit number or temperature. This shows that the system has taken that heater out of service and is continuing operation with the remaining units.

To review the heater trouble codes, open cover on the MIC-185 , on the main control board, the LED display will show the error code on the right, and the unit on the left.

Some errors can be corrected by power cycling the system, turn off the power at the remote control, disconnect power to the MIC-185 and all water heaters. Reconnect power to all water heaters fi rst, then the MIC-185, wait for the start up cycle to complete and power on the system, If failure still occurs contact Technical Service.

Section 2.1 COMMON ERROR CODESCode Description/Resolution

82 EEPROM Error / Contact Technical Services76 Remote Control Communication Error / Contact

Technical Services1L Lime Condition / Follow Flush Procedure in Water

Heater Use and Care Manual

Manifold System Operation / Installation

Section 2.0 - When Trouble Occurs

NOTICE: Follow instructions provided with the water heater for installing the water heater and main remote control. The main remote control is provided with the water heater.

Section 3.0 - Location

The MIC-185 Manifold Control System can be installed indoors or outdoors. The cabinet is designed to be weather resistant.

The system requires the use of a Main Remote Control (UMC-117), one is included with each water heater, that must be installed in-doors and per instructions provided with the water heater. Only in-stall one Remote Control with this manifold system.

Section 3.1 - Mounting the Manifold Controller Cabinet

Make sure the location of the manifold controller allows easy access for service and operation.

Wall studs should be utilized when mounting the manifold control-ler to the wall. Alternately, a suitable piece of wood may be placed inside or outside of the wall to span the distance between the wall studs. Fasten the manifold controller cabinet mounting brackets to the wood. In case of dry wall or concrete wall use appropriate dry wall anchors or lag bolts.

Install a wood screw to hang the cabinet by the upper bracket, leave the head of the screw out with a clearance of 1/8” (3 mm) from the wall. Hang the cabinet by center slot of the upper bracket on the screw. Use a level to square the cabinet and using a wood screw and washer, affi x the lower bracket to the wall (Left and right). Re-peat to affi x the top bracket. See Figure 3.1.a for typical mounting of the manifold controller.

Figure 3.1.a - Mounting Controller Cabinet

Screw for Installation Hanging, leave head

sticking out 1/8”

Wood Screw or Appropriate Fastener

with Washer

Upper Mounting Bracket

Lower Mounting Bracket

(Underneath)

Section 1.5 - Maximum Temperature AdjustmentThe factory default temperature setting is 120°F. Follow these in-structions to set the system to allow Higher Temperature operation.

Follow the instructions below if it is determined that a setting of up to 140°F (185°F with a Commercial Conversion Kit) is required.

Turn on the remote control. Turn off the gas and water shutoff valves.

Press the UP arrow temperature adjustment button on the remote control for several times and set the temperature at 120°F (49°C).

Press and hold the UP button on remote control for more than 5 sec-onds. Number (120) on the display of the remote control will begin to blink.

While the number is blinking, push the UP arrow temperature adjust-ment button and the Down arrow temperature adjustment button at the same time. The display of the remote control will show “140”.

Push the UP or Down button to set desired temperature.

Turn on the gas and water shut off valves.

Check and ensure safe operation and performance of the water heater.

For temperatures with a max of 185°F, each Tankless water heater is required to have a Commercial Conversion kit installed.

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7

WARNING: Field wiring connections and electrical grounding must comply with local codes, or in the absence of local codes, with the latest edition of the National Electrical Code, ANSI/NFPA 70, or in Canada, Canadian Electrical code, CSA C22.1 Part 1.

Manifold System InstallationSection 3.2 - Electrical ConnectionThe manifold controller requires 120VAC/60Hz. Have a receptacle with the ground terminal near the manifold controller. The length of the power supply cord is 10 feet (3.05 m). If local codes require, or if installed outdoors, the manifold controller should be hard wired.

● The electrical power supply requirement for this manifold controller is 120VAC/60Hz, 3 Amps.

● The manifold controller comes with a standard three (3) prong plug power supply cord.

● Use only a power outlet with a ground terminal. See Figure 3.2.a

● Keep any excess length of the power supply cord on the outside of the manifold controller.

● Wiring should be carried out by a qualified electrician in accordance with local codes.

● The electrical power supply requirement for this manifold controller is 120VAC/60Hz, 3 Amps.

● The manifold controller must be grounded.

● A green screw is provided in the junction box for grounding connection.

● Remove the power supply cord and install the connector for the hardwiring (supplied) to allow hardwiring at the junction box.

● DO NOT connect grounding wire to water pipes, gas pipes, telephone cables, lighting conductor circuits and to grounding circuit of other equipment that carry a ground-fault interrupter.

● An ON/OFF disconnect switch must be provided and installed for power supply the controller. The disconnect should be with in reach of the controller. A circuit breaker in/at an electrical panel is not acceptable as a service disconnect switch.

● Connect the live wire to black leg wire and neutral wire to the white neutral wire.

Section 3.2.a - POWER CORD (INDOOR Installation Only)

Section 3.2.b - HARDWIRING THE ELECTRICAL CONNECTIONS (OUTDOOR or INDOOR Installation / Local Codes)

Figure 3.2.a - Power Connection Method

Standard Grounded 3-prong Outlet

3-Prong Power CordSupplied with Unit

Junction Box Inside Controller Cabinet

Code Approved Conduit

Field Connection Hardwire Pigtail

Ground Screw

Properly Sized Field Wiring

Wire Nuts

Section 3.3 - Manifold Control Cable InstallationThe manifold controller communicates with each tankless water heater in the system through a communication cable. Each end of the cable connects to the control board and tankless water heater control board using a molex connector. The cable can only be con-nected one way, do not force the connections as damage to both the cable and control boards can occur.

NOTICE: The tankless water heaters connected to this system must be of the same type and model, do not connect heaters of different types or capacities to this system.

This instructions assumes the tankless water heaters have been installed according to their respective instructions in a parallel mani-fold installation.

Disconnect the power from both the Manifold Controller and the tankless water heater. Leave the power disconnected until all the tankless water heaters in the system have been connected to the manifold controller.

The communication cable is a specialized cable designed specifi -cally to connect to the tankless water heater and manifold controller. The communication cable has two Molex plugs, one at either end. One plug, the end marked “water heater side” and having the three wires, red, black, and white, will connect only the water heater ter-minal. The other end, not marked but having two red wires, a white, and black wire, will only connect to the manifold controller. Do not attempt to use any other cable or wire than a manufacture approved communication cable. Do not install the cable backwards or force the connectors in to the sockets, damage to the water heater and or manifold controller can occur.

Remove the front cover from the tankless water heater; there are 4 (four) screws holding the front cover on to the unit.

Route the water heater end of the communication cable through one of the holes with a grommet at the bottom of the water heater.

Connect the communication cable to the connector marked “F” on of the water heater control board. See fi gure 3.3.a for location of con-nector “F” on either the fi rst and second or third generation models.

Secure the cable with the wire clamp and screw included with the cable to the edge of the control board as illustrated in fi gure 3.3.a.

NOTICE: The DIP switch settings on the water heaters must be changed for the water heaters to be controlled by the manifold controller.

Change the DIP switch #4 setting on the control board of the water heater to “ON” position (UP) in order to switch the water heater to the manifold installation mode. DO NOT alter any other DIP switch. See fi gure 3.3.a for DIP switch location on water heater PCB.

Attach front cover of water heater.

Repeat these steps for each of the water heaters in the manifold system.

DO NOT turn on the power to the water heaters until all communication cables are connected to the water heaters and the manifold controller.

Section 3.3.a - Control Cable Installation at tankless heater.

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8

Manifold System InstallationFigure 3.3.a - Control Cable Installation at Water Heater

Number 4 Dip Switch in the “ON” Position

Control Board Layout for fi rst and second generation models

Control Board Layout for third generation models

Dip SwitchAdjustment

Connector“F”

Wire Clamp

Number 4 Dip Switch in the “ON” Position


Top Set

Connector“F”

Wire Clamp

Disconnect the power from both the Manifold Controller and the tankless water heater. Leave the power disconnected until all the tankless water heaters in the system have been connected to the manifold controller system.

The communication cable is a specialized cable designed specifi -cally to connect to the tankless water heater and manifold controller. The communication cable has two Molex plugs, one at either end. One plug, the end marked “water heater side” and having the three wires, red, black, and white, will connect only the water heater ter-minal. The other end, not marked but having two red wires, a white, and black wire, will only connect to the manifold controller. Do not attempt to use any other cable or wire than a manufacture approved communication cable. Do not install the cable backwards or force the connectors in to the sockets, damage to the water heater and or manifold controller can occur.

Remove the front cover from the manifold controller; there are 4 (four) screws holding the front cover on to the unit.

Route the manifold controller end of the communication cable through one of the holes with a grommet at the bottom of the con-troller cabinet.

Connect the communication cable to one of the six (6) connectors on the right had side of the manifold control board. See fi gure 3.3.b for location of the connections.

Section 3.3.b - Control Cable Installation at the controller

Figure 3.3.b - Control Cable Installation at Controller

Control CableConnectors

DO NOT turn on the power to the water heaters or controller until all communication cables are connected to the water heaters and the manifold controller.

Wire Clamp

Cable ThroughGrommeted

Hole

Section 3.4 - Expansion Card Installation (optional)When more than six (6) water heaters are needed in a manifold, an optional manifold controller expansion card is available for installa-tion in the cabinet. This expansion card will allow for the connection of an additional fourteen (14) tankless water heaters to the system.

Disconnect the power from both the manifold controller and the tankless water heaters. Leave the power disconnected until all the tankless water heaters in the system have been connected to the manifold controller system.


Mount the manifold controller expansion card in the top of the con-troller cabinet, the two legs of the expansion card sit on the tabs, and the card is secured with a single screw at the top. See fi gure 3.4.a.

With the card securely mounted attach the wiring harness to the card. There are 6 small molex connectors, each one of a difference size, to each respective socket at the top middle of the expansion card. Do not attempt to use any other cable or wire than the wiring harness provided with the expansion card. Do not install the wires backwards or force the connectors in to the sockets, damage to the manifold controller can occur.

Main Control Board

Secure the cable in the cabinet with one of the wire straps and screws as illustrated in fi gure 3.3.b. Excess cable may be bundled inside the controller cabinet.

Repeat these steps for each of the water heater control cables in the manifold system.

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9

Manifold System Installation

Figure 3.4.a - Control Cable Installation at Controller


7 - 13

Wire Clamp


14 - 20

ControlCable

Expansion Card

WiringHarness

MainControlBoard

MountingScrew

SupportTab

Connect the other end of the wiring harness with the two large molex connectors to the respective sockets at the top of the main manifold controller card.

Follow the steps in section 3.3.b for connecting the manifold control cables to the expansion card.

Section 3.5 - Installing the Remote ControlWhen using the manifold controller only one (1) remote control can be connected to the system. Do not connect more than one remote control to the system and there is no need to connect a remote con-trol to any of the tankless water heaters.

Notice: Use only 2 conductor 18 AWG thermostat wire, up to 192 ft of wire may be used. Do not use any other wire such telephone or network cable as it can interfere with proper operation of the remote.

Disconnect the power from both the manifold controller and the tan-kless water heaters. Leave the power disconnected until the remote control has been connected to the manifold controller system.

Find a suitable location for the remote control, a preferable location would be somewhere that could be observed easily.

Run the wire to the remote control location, it may be run inside a wall or junction box or surface mounted. Pass the wire through the center hole in the wall plate if the wire is in a junction box or wall.

Mount the remote wall plate to the wall or junction box using suitable fasteners. The remote plate will fi t a single or double gang box or can be mounted directly to the wall surface with suitable anchors.

Connect the two conductor wire to the two screw terminals on the back of the remote control. Secure the wire under the hold down tabs and route the wire towards the center of the remote control. If the wire is surface mounted, route the wire towards the bottom of the remote and carefully remote the knockout at the bottom of the remote. See fi gure 3.5.a

Route the excess wire into the opening on the wall or junction box.

Figure 3.5.a - Remote Control Cable Installation

ConnectionTerminals

Remote Mounting Screw

Wall Plate2 - Conductor

18 AWG T-stat wire

Wall Mounting Screws

Wall Penetration

WallAnchors

Hang the remote on the wall plate and secure the bottom of the remote with the supplied screw.

Section 3.6 - Connecting the Remote Control to ControllerDisconnect the power from both the manifold controller and the tan-kless water heaters. Leave the power disconnected until the remote control has been connected to the manifold controller system.


Run the remote control thermostat wire through one of the grommet-ed holes on the bottom of the controller cabinet. See fi gure 3.6.a.

Secure the wire with a wire clamp and screw to the back of the cabi-net as in fi gure 3.6.a.

Connect the two conductor wire from the remote control to the screw terminals at the bottom right hand side of the manifold controller board as shown in fi gure 3.6.a

Do not connect the two conductor wire from the remote control to the power connection terminals, damage to the remote will occur.

Figure 3.6.a - Remote Control Cable Connection

2 - Conductor18 AWG T-stat wire

Wire Clamp

Cable ThroughGrommeted

Hole

Main Control Board

Remote ControlScrew Terminals

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10

Manifold System InstallationSection 4 - System Start UpOnce the tankless water heaters have been setup and remote con-trol has been installed as instructed in Section 3, you may begin the startup process.

If the manifold control system has been previously powered up, turn off the power at the remote control fi rst, then unplug or disconnect the power supply from the manifold controller. If power is discon-nected before the remote is turned off the system will retain any previous errors and system status. Turning the remote off prior to disconnecting the power supply will reset the system status.


Shutoff all water fl ow from the system.

Turn on the gas supply to the tankless water heaters.

Plug in or turn on the power supply to all the tankless water heaters.

Wait 30 seconds after the last unit has had the power turned on.

Plug in or turn on the power supply to the Manifold Controller

The remote control and diagnostic display on the main control board inside the manifold control cabinet unit will begin to blink “dashes”, see fi gure on page 3. The dashes will appear while the system is synchronizing with the tankless water heaters. Depending upon the number of tankless water heaters connected to the system, this synchronization can take up to 3 minutes. Once the system has syn-chronized the remote control and diagnostic display will go blank.

An LED indicator will light up “solid” next to each connector where a control cable is plugged in to the main control board and/or expan-sion card. If the LED indicator next to a connector begins to blink or does not light then an error has occurred with the communication to the water heater. Check the diagnostic display for an error code and recheck all connections. If an error occurs then the entire start up process will need to be repeated.

Press the power button on the remote control, it should now display the water temperature.

Turn on or start with a low hot water demand or fl ow. The burner on indicator light on the remote should come on once the system has started to fi re and the diagnostic display on the control board will show “on”.

Increase the hot water demand or fl ow to turn on additional units in the system. Continue to increase the fl ow rate until all the units in the system are running.

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1

MIC-6 Manifold ControllerOperation and Installation Manual

SAFETY PRECAUTIONS● Read these instructions and the water heater instruction manual entirely before installing or

operating the manifold controller and the water heater.

● Use this manifold controller only for its intended purpose as described in these instructions.

● Be sure your water heater and the manifold controller are properly installed in accordance with

local codes and the provided installation instructions.

● Do not attempt to repair or replace any parts. All servicing should be referred to a qualifi ed

technician.

● Read and follow all instructions. Save this instruction for future reference.

Table of Contents

Safety Information

Operation Instructions

Instructions for the Installer

High Temperature Operation

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Do not attempt to install this controller in a model other than what is listed on the cover of this instruction.

2

IMPORTANT SAFETY INFORMATIONREAD ALL INSTRUCTIONS BEFORE USING.

Safety and energy conservation are factors to be considered when selecting the water temperature setting of a water heater. Water temperatures above 125°F (52°C) can cause severe burns or death from scalding. Be sure to read and follow the warning outlined in the label pictured below.

WATER TEMPERATURE SETTING

For your safety, the information in these instructions and the instructions provided with the water heater must be followed to minimize the risk of fire or explosion, electric shock, or to prevent property damage, personal injury, or loss of life.

Improper adjustment, alteration, service or maintenance can cause property damage, personal injury or death. Only qualified service personnel should install or make adjustments.

Water Temperature Time To Produce a Serious Burn

120°F (49°C) More than 5 minutes125°F (52°C) 11/2 to 2 minutes130°F (54°C) About 30 seconds135°F (57°C) About 10 seconds140°F (60°C) Less than 5 seconds145°F (63°C) Less than 3 seconds150°F (66°C) About 11/2 seconds155°F (68°C) About 1 second

Table courtesy of Shriners Burn Institute


D A N G E R!

HOT




BURN

F (52°C)

The time/temperature relationship table shown above may be used as a guide in determining the proper water temperature for your home or any other application. ! DANGER: Hotter water increases the risk of hot water

scalds.! DANGER: Households with small children, disabled,

or elderly persons may require a 120°F (49°C) or lower temperature setting to prevent contact with “HOT” water.

Notice: When this water heater is supplying general purpose hot water requirements for use by individuals, a thermostatically controlled mixing valve for reducing point of use water temperature is recommended to reduce the risk of scald injury. Contact a licensed plumber or the local plumbing authority for further information.

WARNING!!

! DANGER!


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3

Manifold Control System Components

Controller Mounts InsideTankless Water Heater

Cabinet, at the Bottom Right

The MIC-6 Manifold Control System Contains the following: MIC-6 Controller Card, (1) 1-feet MIC-Q-1 Type Q Master Control Cable, (1) 10” Ground Wire, Installation Hardware, and this Instruction.

TanklessWater Heater Cabinet

Master Control Cable


Manifold Cable Support Mounting Holes

Service Switches

Remote Control Terminals

Available Accessories MIC-Q-1 - 1ft Manifold Control Cable MIC-Q-6 - 6ft Manifold Control Cable MIC-Q18 - 18ft Manifold Control Cable

These are Type “Q” Cables and will only operate with the MIC-6 Controller, Do not attempt to Use any other type of cable with this controller.

Mounting Bracket

Remote Control - Required to Run SystemThe remote is included with the tankless water heaters. Connect only one (1) remote to the main water heater.

REMOTEPRIORITY


of the Burners

LED DISPLAY

Shows Temperature Setting and Error Codes

UP BUTTON

DOWN BUTTON

POWER BUTTON

POWER INDICATOR

Control BoardGround Wire

Water HeaterControl Board

Connector “F”on Water Heater

Control Board

For operation in a commercial installation or application that requires water temperatures greater than 140°F, a commercial conversion kit is required to be purchased and installed in each tankless water heater in the manifold system.

Only the PH2-25, PH2-28, PHH-32 and PHH-25 Series products may be converted for commercial operation using the MIC-6 Con-troller.

Available Accessories

System GroundScrew

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4

Typical Manifold System

A manifold system consists of the manifold controller referenced by this instruction, and a bank or 3 to 6 tankless water heaters. The tankless heaters are installed in a parallel manifold system where each unit is independently fed with cold water from a common water

main and each feeds a hot water main. See Figure 1.0. This system will not operate if the tankless water heaters are installed in series, one feeding another. All tankless water heaters on this system must be of the same type, do not mix types or capacities.

Section 1.1 - Basic Operation

This section covers the basic operation of the Manifold System by the end user from turning on the system, temperature adjustment, and trouble shooting. This section assumes the system has been installed and is operating normally.

The system is designed to operate with multiple tankless water heat-ers (units), each of which is fi red sequentially depending upon the demand or water fl ow rate. Over time the starting unit will rotate to spread the total operational time out evenly over all the units.

As the hot water demand increase the system will detect this and bring online additional units to meet the increased demand. As the hot water demand decreases the system will reduce the number of operating units. As the water fl ow stops, or units are shut down for reduced demands, the system will go into a stand by ready to fi re mode for a few minutes. It is normal for the fans to run after the wa-ter demand has stopped and the burners have shut off.

The system will sacrifi ce water fl ow rate to maintain water tempera-ture. If the water fl ow rate exceeds the systems capability the sys-tem will automatically restrict water fl ow to keep it at the thermostat setting. When this occurs there might be a slight or noticeable drop in the hot water pressure at the plumbing fi xtures. This is normal, if it occurs frequently the system may be undersized for the demand.

Section 1.0 - System Description

Figure 1.0

HOT WATERCOLD WATER

GAS

CONTROL CABLES

REMOTE CONTROL


UNIT #1


UNIT #2


UNIT #3+

Manifold System OperationTo turn on the system, stop any hot water fl ow, and press the Power Button on the Remote Control Thermostat. See Figure 1.1. A Green indicator in the power button will light, and the display will show the current temperature setting.

Figure 1.1 - Press Power Button

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5

Section 1.2 - Adjusting the Temperature

To adjust the system temperature higher, stop any hot water fl ow, and press the Up Button until you reach the desired temperature setting. See Figure 1.2.a.

NOTE: The temperature can only be raised above 112ºF if the water fl ow has been stopped, this is a safety feature of the system.

For temperature settings above 120ºF see the instructions in Sec-tion 1.5 to increase the max temperature range.

Manifold System Operation

To adjust the system temperature lower, press the Down Button to lower the temperature until you reach the desired temperature set-ting. See Figure 1.2.b.

NOTE: You may lower the temperature while water is fl owing and the heaters are in operation.

Figure 1.2.a - Raise Temperature

Figure 1.2.b - Lower Temperature

Section 1.3 - Status Lights

The status lights on the remote consist of a “Burner On” indicator, see Figure 1.3, and a Priority light.

The “Burner On” indicator will come on to show when only when the system is heating water. This is regardless of the number of units operating in the system.

The “Priority” light tells which remote control has priority over the system in applications with multiple remote controls. This feature is only available on single installation residential units.Figure 1.3 - Raise Temperature


of the Burners

Section 1.4 - System RestartTo restart the system, stop any hot water fl ow, and press the Power Button on the Remote Control Thermostat. See Figure 1.1. A Green indicator in the power button will go out and the display will show blank.

Disconnect the power from the tankless water heaters. Wait 30 sec-onds and apply power to all the tankless water heaters. Wait 30 seconds and proceed back to Section 1.1 to turn on the system.

STANDARD TEMPERATURE SET POINTS in ºF100 102 104 106 108 110112 114 116 118 120

HIGH TEMPERATURE SET POINTS in ºF125 130 135** 140* 150 160170 185*

*Max Temperature depends upon water heater model. ** Not available on some models.

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6

The Manifold control system is designed with system redundancy in mind. If a failure were to occur within a tankless water heater, the system will shut that unit down, bypass it, and display an error notifi cation on the remote control display.

When an error occurs the remote will fl ash the heater number, error code, and the temperature. This shows that the system has taken that heater out of service and is continuing operation with the sys-tem.

To review the heater trouble codes follow the maintenance instruc-tions in the Use and Care Manual for the Tankless Water Heater.

Some errors can be corrected by power cycling the system, turn off the power at the remote control, disconnect power to all water heaters. Reconnect power to all water heaters and wait for the start up cycle to complete and power on the system, If failure still occurs contact Technical Service.

Section 2.1 COMMON ERROR CODESCode Description/Resolution

82 EEPROM Error / Contact Technical Services76 Remote Control or PCB Communication Error /

Contact Technical Services65 Water Valve Open Error / Contact Technical Services1L Lime Condition / Follow Flush Procedure in the Use

and Care Manual for the tankless water heater.03 Dip Switch in Wrong Position for Operation

Manifold System Operation / Installation

Section 2.0 - When Trouble Occurs

NOTICE: Follow instructions provided with the water heater for installing the water heater and main remote control. The main remote control is provided with the water heater.

Section 3.0 - Location

The MIC-6 Manifold Control System is designed specifi cally to mount inside a tankless water heater. This controller will only mount inside and work with the tankless models listed on the cover of this instruction.

The system requires the use a Main Remote Control (UMC-117), one is included with each water heater, that must be installed in-doors and per instructions provided with the water heater. Only in-stall one Remote Control with this manifold system.

Section 3.1 - Mounting the Manifold Controller

After all the tankless water heaters are installed in accordance with the instructions in the Use and Care Manual, select one unit to be the master.

Disconnect the power from the tankless water heater, and remove the front cover.

The Manifold Control Unit will mount to the inside bottom right hand side of the tankless water heater, in front of the gas valve.

Set the controller, face out, into the water heater, and align the mounting bracket with the holes in the bottom of the tankless wa-ter heater. Insert a screw, through each of the two the holes, and tighten. Take care to ensure no wires are pinched under the bracket.

Figure 3.1 - Mounting the Controller

Control BoardGround Wire

System GroundScrew Mounting Screws

From Underneath

Take the green and yellow control board ground wire, and secure the ring terminal under the system ground screw, remove the screw, insert it through the ring terminal with the other wires, and secure back to the water heater chassis. Plug the molex connector into the socket on the manifold control board.

The factory default temperature setting is 120°F. Follow these in-structions to set the system to allow Higher Temperature operation.

Follow the instructions below if it is determined that a setting of up to 140°F (185°F with a Commercial Conversion Kit) is required.

Turn on the remote control. Turn off the gas and water shutoff valves.

Press the UP arrow temperature adjustment button on the remote control for several times and set the temperature at 120°F (49°C).

Press and hold the UP button on remote control for more than 5 sec-onds. Number (120) on the display of the remote control will begin to blink.

While the number is blinking, push the UP arrow temperature adjust-ment button and the Down arrow temperature adjustment button at the same time. The display of the remote control will show “140”.

Push the UP or Down button to set desired temperature.

Turn on the gas and water shut off valves.

Check and ensure safe operation and performance of the water heater.

To increase to 185°F Max temperature each Tankless water heater is required to have a Commercial Conversion kit installed.

Section 1.5 - Maximum Temperature Adjustment

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7

Section 3.2 - Manifold Control Cable InstallationThe manifold controller communicated with each tankless water heater in the system through a communication cable. Each end of the cable connects to the control board and tankless water heater control board using a molex connector. The cable can only be con-nected one way, do not force the connections as damage to both the cable and control boards can occur.

NOTICE: The tankless water heaters connected to this system must be of the same type and model, do not connect heaters of different types or capacities to this system.

This instructions assumes the tankless water heaters have been installed according to their respective instructions in a parallel mani-fold installation.

Section 3.2.a - Control Cable Installation at tankless heater.

Remove the front cover from the tankless water heater; there are 4 (four) screws holding the front cover on to the unit.

Route the water heater end of the communication cable through one of the holes with a grommet at the bottom of the water heater.

Connect the communication cable to the connector marked “F” on of the water heater control board. See fi gure 3.2.a for location of con-nector “F” on either the fi rst and second or third generation models.


ManifoldControl Cable


Connector “F”on Water Heater

Control Board

Figure 3.2 - Manifold Control Cable Installation - Master

Connect the small molex connector of the short manifold control cable, provided with the controller, to the Number 1 position on the manifold controller board.

Connect the large molex connector of the short manifold control ca-ble to the Connector “F” on the tankless water heater control board.

Change the DIP1 switch #4 setting on the control board of the water heater to “ON” position (UP) in order to switch the water heater to the manifold installation mode. DO NOT alter any other DIP switch. See fi gure 3.2.a for DIP switch location on water heater PCB.

Disconnect the power from all tankless water heaters. Leave the power disconnected until all the tankless water heaters in the sys-tem have been connected to the manifold controller.

The communication cable is a specialized cable designed specifi -cally to connect to the tankless water heater and manifold controller. The communication cable has two Molex plugs, one at either end. One plug, the end marked “water heater side” and having the larger connector, will connect only the water heater terminal. The other end, with the smaller connector, will only connect to the manifold controller. Do not attempt to use any other cable or wire than a man-ufacture approved communication cable. Do not install the cable backwards or force the connectors in to the sockets, damage to the water heater and/or manifold controller can occur.

Secure the cable with the wire clamp and screw included with the cable to the edge of the control board as illustrated in fi gure 3.2.a.

NOTICE: The DIP switch settings on the water heaters must be changed for the water heaters to be controlled by the manifold controller.

Change the DIP1 switch #4 setting on the control board of the water heater to “ON” position (UP) in order to switch the water heater to the manifold installation mode. DO NOT alter any other DIP switch. See fi gure 3.2.a for DIP switch location on water heater PCB.

Attach front cover of water heater.

Repeat these steps for each of the water heaters in the manifold system.

DO NOT turn on the power to the water heaters until all communication cables are connected to the water heaters and the manifold controller.

Figure 3.2.a - Control Cable Installation at Water Heater

Control Board Layout for third generation models

DIP 1 Number 4 Switch in the “ON”

Position


Top Set

Connector“F”

Wire Clamp

- 153 -

8


Disconnect the power from all tankless water heaters. Leave the power disconnected until all the tankless water heaters in the sys-tem have been connected to the manifold controller system.

Route the manifold controller end of the communication cable , the one with the small molex connector, through one of the holes with a grommet at the bottom of the main tankless water heater cabinet. Only three cables will fi t through a single opening, there are two opening for cables.

Connect the communication cable to one of the six (6) connectors across the bottom of the manifold control board. See fi gure 3.2.b for location of the connections.

Secure the cable in the cabinet with one of the wire straps and screws as illustrated in fi gure 3.2.b. Excess cable may be bundled under the water heater.

Repeat these steps for each of the water heater control cables in the manifold system.

Section 3.2.b - Control Cable Installation at the controller

Figure 3.2.b - Control Cable Installation at Controller


DO NOT turn on the power to the water heaters or controller until all communication cables are connected to the water heaters and the manifold controller.

Wire ClampCable ThroughGrommeted Hole

Main Control Board

Section 4 - System Start UpOnce the tankless water heaters have been setup and remote con-trol has been installed as instructed in Section 3, you may begin the startup process.

Remove the front cover from the main tankless water heater with the manifold controller; there are 4 (four) screws holding the front cover on to the unit.

Shutoff all water fl ow from the system.

Turn on the gas supply to the tankless water heaters.

Plug in or turn on the power supply to all the tankless water heaters.

Wait 30 seconds after the last unit has had the power turned on.

An LED indicator will light up “solid” above each connector were a control cable is plugged in to the manifold control board. If the LED indicator next to a connector begins to blink or does not light then an error has occurred with the communication to the water heater. Check the diagnostic display for an error code and recheck all con-nections. Make sure the #4 Dip switch is in the “ON” Position at each water heater. If an error occurs then the entire start up process will need to be repeated.

Press the power button on the remote control, it should now display the water temperature.

Turn on or start a low hot water demand or fl ow. The burner on indicator light on the remote should come on once the system has started to fi re.

Increase the hot water demand or fl ow to turn on additional units in the system. Continue to increase the fl ow rate until all the units in the system are running.

Once the system is running, stop the water fl ow, disconnect power to all the tankless water heaters, and reinstall the covers. Reconnect power and verify operation.

Status LED

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Tankless Water Heater Commercial ConversionInstallation Instructions

Refer to the Use and Care Manual provided with your tankless water heater for the proper installation procedures. It is very important that all persons who are expected to install, operate or adjust this commercial conversion and/or water heater read these instructions along with those instructions provided with the tankless water heater.! Recognize this symbol as an indication of Important Safety

Information!! DANGER: Water Temperature Setting Safety and energy conservation

are factors to be considered when selecting the water temperature setting of a water heater’s Remote Control Thermostat. Water temperatures above 125°F (52°C) can cause severe burns or death from scalding. Be sure to read and follow the warnings outlined on the label pictured to the left and information in the Use and Care Manual provided with your tankless water heater.

Commercial Conversion Procedure This conversion kit is designed to upgrade select tankless water heaters to operate at higher water temperatures for commercial applications. Only the selected models can be converted, make no attempt to convert any other tankless model.

Commercial Conversion Program ChipEach program chip is designed for a specifi c model tankless water heater and fuel type, Natural or LP. Please confi rm that this conversion kit is for your specifi c model water heater

D A N G E R!

HOT

Water temperature

death from scalds.



BURN

over 52°C (125°F)can cause severe burns instantly or

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This kit contains: Commercial Conversion Program ChipConversion Notifi cation LabelCommercial WarrantyInstructions for Chip Installation.

NOTICE: Tankless water heaters installed in a commercial application are not Energy Star qualifi ed. Remove the Energy Star label from the front of the tankless water heater.

Chip Installation and InitiationChip Installation 1. Make sure electrical power is disconnected and turn off

gas and water to the water heater, then remove the front cover from the water heater.

2. Carefully remove the existing program chip, see Figure 1 for location. Lightly grip the edges of the chip, top and bottom, as in Figure 2, and pull the chip straight out from

the Control Board and set it aside.3. Remove the replacement chip from the packaging.

Gripping the chip, as in fi gure 2, carefully align and insert the chip into the socket on the control board. Do Not Force

4. Restore power to the unit.

ON

1 2 3 4

ON

OFF

ON

1 2 3 4

ON

OFF

1 2 3 4

1 2 3 4

DIP

2D

IP1

MIN MAX ADJ

LED

Control Board - Figure 1

Dip Switches

Program Chip

LED

Program Chip Initiation

Figure 2

°F

PRIORITY

POWERON/OFF

°F

PRIORITY

POWERON/OFF

Figure 4Figure 3

5. Find the two DIP switches located at the top right hand side of the PCB. The switch labeled “DIP1” in the top switch.

6. Change the DIP Switch #4 setting to the “ON” position. DO NOT alter any other DIP Switch. The LED on the PCB is fl ashing. At the same time, the display of the Main Remote Control starts to fl ash.

7. Press the “Max” button located at the top right hand side of the PCB for more than 1 second. The LED on the PCB

starts illuminating continuously. At the same time, the display of the Main Remote Control is on continuously.

8. Change the DIP Switch #4 setting back to the “OFF” position. DO NOT alter any other DIP Switch. The LED on the PCB will stop illuminating. At the same time, the display of the Main Remote Control will turn off.

9. Turn on the water heater at the remote control by pressing the power button, see Figure 3.

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10. Press the UP arrow temperature adjustment button several times to increase the temperature to a maximum of 185*, see Figure 4. This will verify the unit has been successfully converted. If the temperature does not increase past 120 or 140, then the conversion failed, disconnect and restore power and restart the procedure at step 5.

11. Set the remote control to the desired operating temperature, and restore the gas and water service to the water heater.

12. Place/Stick Conversion Label to the front of the tankless water heater and remove the Energy Star label. Leave the new warranty certifi cate for the customer and discard the original warranty certifi cate.

Available Thermostat Settings - Factory Confi gurationF 85 100 102 104 106 108 110 112 114 116 118 120

C 29 38 39 40 41 42 43 44 46 47 48 49

Residential High Temperature

Settings

Commercial High Temperature Settings

F 125 130 135 140 F 150 160 170 180* 185*

C 52 54 57 60 C 66 71 77 82* 85*

With this Commercial Conversion the temperature ranges available through the thermostat control are as follows:

* Some models may be able to reach up to 180°F (82°C)

! DANGER: Hotter water increases the potential for Hot Water SCALDS.

Commercial Conversion in a Multi-Unit Manifold or DUOnex™ Installation

Commercial Conversion of water heaters in a Multi-Unit Manifold or DUOnex™ Installation requires that each tankless water heater in the installation gets a conversion chip installed on the Control Board, as in steps 1 through 4. After the chip installation the Program Chip Initiation is slightly different from a single unit conversion since in a Multi-Unit installation there is only one remote control. Complete the entire manifold installation before continuing with the Commercial Conversion procedure.A. Complete the chip installation on each water heater as in

steps 1 through 4 on the front side of this document.B. Find the two DIP switches located at the top right hand

side of the PCB. The switch labeled “DIP1” in the top switch.

C. Change the DIP Switch #4 setting to the “ON” position. DO NOT alter any other DIP Switch. The LED on the PCB is fl ashing. At the same time, the display of the Main Remote Control starts to fl ash.

D. Press the “Max” button located at the top right hand side of the PCB for more than 1 second. The LED on the PCB starts illuminating continuously. At the same time, the display of the Main Remote Control is on continuously.

E. Change the DIP Switch #4 setting back to the “OFF” position. DO NOT alter any other DIP Switch. The LED on the PCB will stop illuminating. At the same time, the display of the Main Remote Control will turn off.

F. Turn on the water heater at the remote control by pressing the power button, see fi gure 3.

G. Press the UP arrow temperature adjustment button several times to increase the temperature to a maximum of 185*, see fi gure 4. This will verify the system has been successfully converted. If the temperature does not increase past 120 or 140, then the conversion failed, restart the procedure at step A.

H. Set the remote control to the desired operating temperature, and restore the gas and water service to the manifold system.

I. Place/Stick Conversion Label to the front of the tankless water heater and remove the Energy Star label. Leave the new warranty certifi cate for the customer and discard the original warranty certifi cate.

Commercial Conversion in a Multi-Unit Manifold or DUOnex™ Installation

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Schematic Disassembly (PH2-20RDVS, PH2-25RDVS &PH2-28RDVS)

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- 160 -


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Parts List for PH2-20,25,28RDVSNo. Name of Parts No. Name of Parts No. Name of Parts1 Front Cover Assembly 402 Quick Fastener 751** Program Chip

410 Water Control Assy.10 Upper Block Plate 411 Drain Valve A 756 120V Cord Assembly

412 Bypass Assembly 757 Wiring Assembly26 F Label Packing 415 Heat Exchanger Kit

421 Quick Fastener 759 Relay Cord Assembly422 Quick Fastener 760 Terminal Assembly425 “O” Ring P-14 EPT 778 Remote Control Terminal

40 Slide Bracket A 429 Rubber Bush 792 Gas Shutoff Valve41 Slide Bracket B 445 Flange50 PCB Plate 450 Flange 806 Pan FT 4 x 12103 Gas Control Valve Assy. 451 “O” Ring P-16104 “O” Ring P-26 460 Thermistor Holder106 Pressure Adjustment Tube 512 Drain Valve Assembly 815 Pan Head SW 4 x 10108 Packing 816 Screw SW M4 x L12112 Upper Burner Assy. 701 Film Type OHL113* Lower Burner Assy. 706 Heater Holder C 826 Truss FT 4 x 12114* Burner Block Plate 708 Holder 828 Truss Packing 115 Electrode Cover 709 Resistance 842 Truss Packing117 SD 710 Heater Holder 850 Pan Head FT M4 x 12130 Air Intake Assembly 713 Heat Exchanger Thermistor 858 Screw FT M4 x 10131 Vent Assembly 714 Hot Water Outlet Thermistor

132 Intake Hood E 715 Ambient Temp Thermistor 874 Enplatight Screw 4 x 12133 Electrode (Flame Rod) 716 Water Inlet Thermistor134 Electrode S (ODS) 728 Fan Set135 Electrode Packing 729 Fan Case Assembly 896 Plug

137 Hot Water Outlet Connector 732 Freeze Protection Assy.138 Electrode Holder S 735 Igniter Assembly139 Electrode Holder 736 Electrode (Spark)142 Water Inlet Connector Assy. 736 FR Connection Cord Assy. No.S

144 Gas Inlet Connector Assy. 737 FR Connection Cord Assy.

745 Burner Control Assy. (PCB)

747 Power Cord Assembly152 Packing153 Plate154 Rubber Bush S * Specify NAT or LP Gas ** Specify Model No.

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Schematic Disassembly (PH2-20ROF, PH2-25ROF &PH2-28ROF)

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- 164 -


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Parts List for PH2-20,25,28ROFNo. Name of Parts No. Name of Parts No. Name of Parts1 Front Cover Assembly 402 Quick Fastener 751** Program Chip

410 Water Control Assy. 755 Power Cord Connector Assy.

25 Exhaust Top Assy. 411 Drain Valve A 756 120V Cord Assembly412 Bypass Assembly 757 Wiring Assembly

26 F Label Packing 415 Heat Exchanger Kit28 Top Adapter Assembly 421 Quick Fastener 759 Relay Cord Assembly29 Packing 422 Quick Fastener 760 Terminal Assembly

425 “O” Ring P-14 EPT 778 Remote Control Terminal40 Bracket A 792 Gas Shutoff Valve

445 Flange50 PCB Plate 450 Flange 806 Pan FT 4 x 12103 Gas Control Valve Assy. 451 “O” Ring P-16104 “O” Ring P-26

512 Drain Valve Assembly 815 Pan Head SW 4 x 10108 Packing 816 Screw SW M4 x L12112 Upper Burner Assy. 701 Film Type OHL113* Lower Burner Assy. 706 Heater Holder C 826 Truss FT 4 x 12

708 Holder 828 Truss Packing 115 Electrode Cover 709 Resistance 842 Truss Packing

710 Heater Holder 850 Pan Head FT M4 x 12713 Heat Exchanger Thermistor 858 Screw FT M4 x 10714 Hot Water Outlet Thermistor

715 Ambient Temp Thermistor 874 Enplatight Screw 4 x 12133 Electrode (Flame Rod) 716 Water Inlet Thermistor

728 Fan Set135 Electrode Packing 729 Fan Case Assembly 896 Plug

137 Hot Water Outlet Connector 732 Freeze Protection Assy.735 Igniter Assembly

139 Electrode Holder 736 Electrode (Spark)142 Water Inlet Connector Assy. 737 FR Connection Cord Assy.

144 Gas Inlet Connector Assy. 740 Junction Box745 Burner Control Assy. (PCB)

748 Junction Box Plate

154 Rubber Bush S * Specify NAT or LP Gas ** Specify Model No.

Schematic Disassembly (PHH-32RDV & PHH-25RDV)

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Schematic Disassembly (PHH-32RDV & PHH-25RDV)

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Parts List for PHH-25, 32RDVNo. Name of Parts No. Name of Parts No. Name of Parts1 Front Cover Assembly 402 Quick Fastener 751** Program Chip

410 Water Control Assy.5 Back Cover Support Plate 411 Drain Valve A 756 120V Cord Assembly6 Front Cover Support Plate 412 Bypass Assembly 757 Wiring Assembly

415 Heat Exchanger Kit421 Quick Fastener 760 Terminal Assembly425 “O” Ring P-14 EPT 761 Neutralization Air Outlet

50 PCB Plate 429 Rubber Bush 778 Remote Control Terminal445 Flange 792 Gas Shutoff Valve

103 Gas Control Valve Assy. 450 Flange104 “O” Ring P-26 451 “O” Ring P-16 804 Screw FT 4 x 8

485 Water Outlet Assembly 806 Pan FT 4 x 12108 Packing 512 Drain Valve Assembly

559 Neutralization Kit 815 Pan Head SW 4 x 10112 Upper Burner Assy. 561 Neutralization Plate A 816 Screw SW M4 x L12113* Lower Burner Assy. 701 Film Type OHL 824 Pan Head SW 4 x 8114* Burner Block Plate 706 Heater Holder C 826 Truss FT 4 x 12

708 Holder 828 Truss Packing 117* SD 710 Heater Holder 842 Truss Packing

850 Pan Head FT M4 x 12129 Air Intake Assembly 713 Heat Exchanger Thermistor 858 Screw FT M4 x 10131 Vent Assembly 714 Hot Water Outlet Thermistor

716 Ambient Temp Thermistor 874 Enplatight Screw 4 x 12133 Electrode (Flame Rod) 728 Fan Set134 Electrode S (ODS) 729 Fan Case Assembly135 Electrode Packing 732 Freeze Protection Assy. 896 Plug

733 Freeze Protection Assy.137 Hot Water Outlet Connector 734 Thermostat Assembly138 Electrode Holder S 735 Igniter Assembly139 Electrode Holder 736 Electrode (Spark)142 Water Inlet Connector Assy. 737 FR Connection Cord Assy.

144 Gas Inlet Connector Assy. 738 FR Connection Cord Assy. No.S

154 Rubber Bush S 745 Burner Control Assy. (PCB)

747 Power Line Cord Assy.400 Water Inlet Thermistor

* Specify NAT or LP Gas ** Specify Model No.- 168 -

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Schematic Disassembly (PHH-32ROF & PHH-25ROF)

- 170 -

matic Disassembly (PHH-32ROF & PHH-25ROF)

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Parts List for PHH-25, 32ROFNo. Name of Parts No. Name of Parts No. Name of Parts1 Front Cover Assembly 402 Quick Fastener 751** Program Chip

410 Water Control Assy.5 Back Cover Support Plate 411 Drain Valve A 756 120V Cord Assembly

412 Bypass Assembly 757 Wiring Assembly26 F Label packing 415 Heat Exchanger Kit

421 Quick Fastener 760 Terminal Assembly425 “O” Ring P-14 EPT 761 Neutralization Air Outlet

50 PCB Plate 429 Rubber Bush 778 Remote Control Terminal445 Flange 792 Gas Shutoff Valve

103 Gas Control Valve Assy. 450 Flange104 “O” Ring P-26 451 “O” Ring P-16 804 Screw FT 4 x 8

485 Water Outlet Assembly 806 Pan FT 4 x 12108 Packing 512 Drain Valve Assembly

559 Neutralization Kit 815 Pan Head SW 4 x 10112 Upper Burner Assy. 561 Neutralization Plate A 816 Screw SW M4 x L12113* Lower Burner Assy. 701 Film Type OHL

706 Heater Holder C 826 Truss FT 4 x 12708 Holder 828 Truss Packing

117* SD 710 Heater Holder 842 Truss Packing850 Pan Head FT M4 x 12

713 Heat Exchanger Thermistor 858 Screw FT M4 x 10714 Hot Water Outlet Thermistor

716 Ambient Temp Thermistor 874 Enplatight Screw 4 x 12133 Electrode (Flame Rod) 728 Fan Set

729 Fan Case Assembly135 Electrode Packing 732 Freeze Protection Assy. 896 Plug

733 Freeze Protection Assy.137 Hot Water Outlet Connector

735 Igniter Assembly139 Electrode Holder 736 Electrode (Spark)142 Water Inlet Connector Assy. 737 FR Connection Cord Assy.

144 Gas Inlet Connector Assy.740 Junction Box745 Burner Control Assy. (PCB)

747 Power Line Cord Assy.400 Water Inlet Thermistor 748 Junction Box Plate

* Specify NAT or LP Gas ** Specify Model No.

Paloma Industries, Inc.2151 Eastman AvenueOxnard, CA 93030Phone: (805) 278-5499Fax: (805) 278-5468

Tech Support Center: (800) 432-8373

Printed in USA

2011-08

tankless gas water heaters -

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