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MWH180 - Monitor Products

1. T Bath remote controller d 2777777 777 Remote controller Cover T P d Cover In case of use of store bought cables The remote controller cable can be extended up to 100 30m by splicing the cable and using 18 gauge wire to extend the cable to the appropriate length Cut the connector of the remote controller lead wire and cut remote controller lead wire and store bought cables coating in 0 2 bmm length Insert the end of remote controller cables to clamping connector and caulk using a caulking tool Caulk the store bought cables inserted in the clamping connector using the caulking tool Caulking cables 45 2 18 TESTING OPERATION Follow the steps below to ensure the MWH 180 has been properly installed Preparation for testing operation 1 Fully open the water supply main valve 2 Flush out the water supply piping to clean out any installation debris clean out filter 3 Turn on power to unit and open gas supply valve Testing operation 1 Operate the unit according to Remote controller operation in the instruction manual 2 Make sure the unit operates normally Does the burner ignite and shut off properly Check the combustion lamp The burner may not ignite at first until the air in the gas supply pipe is driven out Repeat the procedure until it ignites e 15 temperatur
2. Water Flow Sensor detects water flow over approximately 0 7 GPM 2 7 Liter min Fan Motor ON Fan Motor detects revolution Igniter Transformer ON Main Gas Solenoid Valve OPEN Gas Modulating Solenoid Valve In approximately 0 2sec Gas Solenoid Valve 2 OPEN Gas Solenoid Valve 1 OPEN Flame rod detects ignition Flame logo indicator lights 6 Igniter Transformer stops Combustion stabilizes Hot water temperature adjustment become normal Hot water faucet Close Water Flow Sensor detects water flow for stop less approximately 0 58GPM 2 2 Liter min OFF stop of combustion Flame logo indicator OFF 1 In approximately 1min Fan Motor stops 53 3 5 Gas Setting Procedure 1 Preparation 1 2 Make sure the appliance is not in operation Then remove the screw from the pressure check inlet Connect the hose of the manometer to the pressure check hole lt See page 56 gt 2 Adjusting nozzle pressure settings lt Minimum pressure should be set before setting the maximum pressure gt 1 2 3 4 5 6 Make sure that Dip Switch No 1 is set to the position for the appropriate gas type After igniting for combustion by opening the hot water supply valve set Dip Switch No 5 to ON position to set the combustion at a minim
3. Outgoing Thermistor 3 White White ArThemistor 3 Whtewnite Heat Exchanger Thermistor 3 White White AC108 132V 45 55Q AC90 110V 43 53Q Primary Brown Blue Secondary Black Blue Air Supply Duct He at Exchanger Over Heat Switch Heat Exchanger Thermistor Anti Frost Heater Burner 2 Air Thermistor Fan Motor PCB Remote Controller Surge Protector Outgoing Thermistor Water Flow Sensor Lg 7 1 YN O AC120V Hot Water Outlet 2 14 Exhaust Duct Frost Sensing Switch Flame Rod Thermal Fuse Electrode Igniter Solenoid Valve SV2 Solenoid Valve SV1 Water Flow Control Device Modulating Solenoid Valve Main Solenoid Valve Water Filter Gas Drain Plug 2 15 WIRING CONTROLLER The Main remote controller model is CMR 2250 P N 3748 The Bath remote controller model is YST 2250 P N 3749 These controllers are to be fitted in the following locations Main remote controller kitchen or laundry Bath remote controller bathroom Only one of each type of controllers can be connected to one MWH 180 water heater i e Installations with two CMR 2250 or two YST 2250 will not function properly The remote controllers can be wired in pa
4. Na W W WEM ANTI FROST HEATER AC120V IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH A WIRE OF AT LEAST 194 F TEMPARATURE RATING AND NUMBER 18AWG OR ITS EQUIVALENT 39 HOT AC120V NEUTRAL d VARISTOR VARISTOR SIRGE ANTI FROST HEATER I FROST SENSING SWITCH Y TRANSFORMER RELAY1 IGNITER REL AY3 MAIN oO Gun SOLENOID VALVE RELAY4 d SOLENOID VALVE 1 Lee RELAYS SOLENOID 5 2 VALVE 2 THERMAL FUSE oO DCIOV 1 DC140V FAN CONTROL CIRCUIT 0 MOTOR SWITCHING POWER SUPPLY 77 OOO WATER FLOW 2 D SENSOR 9 WATER FLOW MODULATING SOLENOID SENSOR CIRCUIT CONTROL DEVICE SEI VO WATER FLOW CONTROL OVER RELAY2L RELAY CPU DEVICE CIRCUIT SWITCH 77 RELAY3 E D FLAME ROD EAE FLAME SENSOR LA THERMISTOR SE AIR TEMP O D THERMISTOR egy THERMISTOR OUTGOING CIRCUIT m REMOTE CONTROLLER REMOTE TEMP CIRCUIT CONTROLLER THERMISTOR HEAT EXCHANGER TEMP 7 7 40 2 13 DIAGNOSTIC POINTS Measurement Point Component Normal Value Notes Power Supplied to Unit Black White 10 Green White 55 650
5. No less than 2 1 4 in ft Horizontal extended installation without drain tee Male male adapter 5 1 5m Reducer Support strap Straight length 90 elbow 1 Drain tee Straight termination Condensation prevention plate Horizontal extended installation with drain tee 3 Plugs 3 Screws Facing plate lt Fig 6 Detail of horizontal extended installation gt 32 Vertical installation Vertical installation Rain cap T Rain cap T Air intake pipe ES 2 Roof flashing Air intake pipe EM Roof flashing oN 90 elbow 2 wm No less than 2 1 4 in ft upward Straight length E Leg t e N KS lt 2 E gt Maximum height 23 7m Draintee Drain tee le lt Fig 7 Vertical installation gt Vertical installation Vertical installation means installation of vent terminal on flat or angled roofs It consists of rain cap reducer straight lengths adjustable lengths and elbows as shown in Fig 7 install drain tee directly on the appliance flue outlet A continuously UPWARD slope of no less than 2 1 4 in ft should be maintained in the horizon tal portion A typical installation is shown in Fig 7 It shall be limited to the maximum heigh
6. Male end Male end Insert the male end fully into the female end until the stopper bead is seated against the stop end on the Pull up the female end with slide piece kept in the female end stopper cover Connection Disconnection lt Fig 2 Joint connection and detachment method a b gt 25 b Rain cap air intake pipe and roof flashing cap shall be connected by turning the screw at each end of pipes clockwise as far as they will go as shown in Fig 3 When connecting between air intake pipe and roof flashing cap confirm that the end of air intake pipe reaches the outer bead of roof flashing cap because the screw section is hidden in outer pipe When disconnecting them turn counterclockwise 9 Male screw S Turn clockwise Female screw Air intake pipe c Tur Male screw urn clockwise Female screw Roof flashing cap of air intake pipe reaches the outer bead of roof flashing cap clockwise till the end L lt Fig 3 Joint connection and detachment method b gt 26 Adjustable lengths Adjustable lengths are available to allow for installation where fixed length sections do not produce the desired dimensions Also adjustable lengths may be used to compensate for linear thermal expansion contract between two fixed points As shown in Table1 2 types of adjustable
7. 269 2181 1881 168 153 141 132 125 118 94 82 11 4 6141 4181 334 284 251 227 209 194 181 171 1371 116 1 1 2 1261 888 723 625 559 5091 471 440 415 393 3201 277 2 2934 2078 1698 1472 1317 1203 1114 1042 983 9331 7621 661 PipeSize Maximum Capacity of Flex TracPipe in Thousands of Btuh Liquified Petroleum 0 5 WC Pressure Drop Length in Feet 40 20 30 40 50 60 70 80 90 100 150 200 3 4 325 2321 191 166 149 136 126 118 112 106 87 76 1 605 425 344 297 265 241 222 2081 197 186 143 129 11 4 971 661 528 449 397 359 330 307 286 270 217 183 1 1 2 1993 1404 1143 988 884 805 745 696 656 621 506 438 PipeSize 2 4638 3285 2684 2327 2082 1902 1761 1647 1554 1475 1205 1045 For reference only Please consult gas pipe manufacturer for actual pipe capacities TracPipe is a registered trademark of Omega Flex Maximum Capacity of Gas Flex Connectors in Cubic Feet per Hour Maximum Capacity of Gas Flex Connectors in Thousands of Natural Gas 0 60 Specific Gravity 0 5 WC Pressure Drop of Btuh Liquified Petroleum 0 5 WC Pressure Drop PipeSize Length in Inches PipeSize Length in Inches 12 24 36 48 60 72 1 2 1801 150 125 106 93 86 1 2 288 240 200 1
8. Normal with 0 8 uA or higher Thermal fuse Over temperature protection system The thermal fuse is placed around the heat exchanger assembly If the ambient tempera ture inside the water heater becomes extremely high the fuse will melt down to break the power circuit In such a case as no power is supplied to the gas control assemblies the gas supply is stopped and the combustion is stopped The system is activated to blow the fuse at 363 F 184 C Over heat switch residual Even if the heat exchanger assembly is over heated by no water combustion every gas path is closed to avoid risks At this time the error code 141 is displayed on the remote controllers The switch is provided with a auto restoration function and turns OFF at 212 F 100 C Fan revolution detection device Hall IC The device detects the fan revolution speed to control the air supply necessary for normal combustion If the fan revolution is out of the preset standard range the gas control as semblies are closed to stop the combustion before combustion failure occurs In this case the error code 611 is displayed on the remote controllers Anti freeze system Frost sensing switch and heater To prevent freezing in the hot water supply circuit anti frost heaters are provided at major points of water flow paths in the unit The heaters are activated by the thermistors in the unit The 4 heaters one located on the front side of heat exchanger is 4
9. e max 10 5 pounces W C 14 0 pounces W C Or GAS PRESSURE INLET MIN 4 0 inches W C 8 0 inches Pression de gaz entr e min 4 0 pounces W C 8 0 pounces W C ONLY FOR USE WITH GAS PRESSURE MANIFOLD MAX 2 4 inches W C 2 4 inches W C Pression d admission max 2 4 pounces W C 2 4 pounces W C GAS PRESSURE MANIFOLD MIN 0 4 inches W C 0 4 inches W C Pression d admission min 0 4 pounces W C 0 4 pounces W C ELECTRICAL RATING AC 120V 60Hz Regime nominal lectrique REFERTO THE LOCAL GAS AUTHORITY FOR CONFIRMATION ON THE GAS TYPE IF IN DOUBT MAX WATER PRESSURE 50 P51 DO NOT REMOVE THIS LABEL UNTIL THE APPLIANCE HAS BEEN INSTALLED AND TESTED Pression d eau max Si vous ne savez pas le type de gaz contactez le fournisseur de gaz ou les autorit locaux Enlevez pas cette etiquette jusqu l appareil a t installer et verifie Gage Wiring Diagram inside Front Cover Sch ma du c blage derri re le couvercle avant Minimum clearances from combustible of non combustible construction D gagements minimaux assurer entre les parois de l appareil et les constuctions combustibles ou incombustibles Back 0 inch arri re Front 6 inches 6 po devant d appareil Top 12 inches 12 po dessus Side 2 inches 2 po c t s FOR YOUR SAFETY Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance This water heater i
10. to vent system Adjust the angle of roof flashing cap so as to make the pipe of roof flashing cap vertical 10 Seal between the parts of roof flashing and roof The pitch of the roof 209 409 Air intake pipe 1 Rain 13 Roof flashing cap 4 2 Roof flashing adapter The procedure of installation The pitch of the roof 20 or less The pitch of the 409 55 S 99 9595 Air intake pipe Roof flashing cap Air intake pipe 1 Roof flashing LP Roof flashing base The procedure of installation Roof flashing base 0 Roof flashing adapter B The procedure of installation lt Fig 8 Detail of vertical installation gt 2 7 GAS LINE SIZING CHARTS Maximum Natural Gas Delivery Capacity in Cubic Feet per Hour 0 60 Specific Gravity 0 5 WC Pressure Drop Length in Feet 10 20 30 40 50 60 70 100 125 119 96 82 73 el ol 56 531 sol 44 3 4 363 249 200 171 152 138 127 118 111 104 o a 684 470 377 323 286 259 239 222 208 197 174 11 4 1404 965 775 663 588 532 490 456 428 404 358 11 2 2103 1445 1161 993 880 798 734 683 641 605 536 zl 4050 2784 2235 1913 1696 1536 1413 1315 1234 1165 1033 Contact the Gas Supplier for Btu Cubic Ft 24 2 6455 4437 3563 3049 2703 2449 2253 2096 1966 1857 1646 Of the Su
11. variable Gas Modulating Solenoid Valve O P Ignition level Gas Solenoid Valve 1 hot water Gas Solenoid Valve 2 Flame sensor Maximum 5 0 Purge 3 0 sec Post ignition 3 4 sec Soft ignition level 1 0 sec Waiting for Constant Revolution of Start amp Delay for Solenoid Valve ON min 0 2 sec Chart for Ignition Retry Timing revolution revolution for ignition for ignition Stabilizing for ignition 0 1 sec Fan output Higher rev Post purge revolution Higher rev Normal combustion revolution Igniter transformer Main Gas Solenoid Valve Gas Modulating Solenoid Valve O P off Slow ignition level Op Slow ignition level O P b Continue combustion Normal combustion Gas Modulating Solenoid Valve O P Gas Solenoid Valve 1 Gas Solenoid Valve 2 Double safe relay lame sensor 250ms 2 5 0 5 0 1 sec 5 0 2 5 sec 0 5 sec 0 1 sec 5 0 sec Waiting for Constant Revolution of Soft Ignition Start amp Delay for Gas Solenoid Valve ON min 0 2 sec Flow Charts Power supply Initial check all on Push ON OFF button on remote controller SUPPLY indication lights on remote controller PRIORITY indication lights on remote controller Move Water flow control device in place Hot water temperature ind
12. D 0 0x6 0x1 5 0 D 18 2x6 0x1 5 30 234 Note In case D value is longer than 41 the unit shall be relocated with vent length of less than 41 In case vent pipe requires extension use coaxial vent pipe and elbows and start from the vent terminal side Install the vent pipe at slight decline toward the vent terminal Install the vent pipe securely by using sling fittings to support the connected parts Use fittings at 5 1 5m intervals Do not use wire When installing extended vent pipe Take special precaution to stay clear of combustible surfaces In case of horizontal direct vent installation be sure to use recommended vent terminal n case of horizontal direct vent installation with recommended vent terminal connect reducer between water heater and vent terminal In case of other horizontal direct vent installation connect reducer between pipe and vent terminal Warning Failure to follow the installation instructions could cause FIRE CARBON MONOXIDE POISONING or DEATH Never change the position of any dip switch other than No 7 amp No 8 Unauthorized alteration and use of the unit in a wrong setting may cause material damage injury accident scalding or even death Exceeding the maximum vent length is dangerous and may result in bad combustion Be sure to connect the vent pipes in such a way so that no exhaust gas leaks when they are installed i
13. SYMPTOM POSSIBLE CAUSE CHECK METHOD CORRECT VALUE Refer Figure NOT FLASHING NOTHING STARTS AND REMOTE S DISPLAY DOES NOT INDICATE ANY FAULT NOTHING STARTS ONLY REMOTE S DISPLAY INDICATES SWITCH ON FUSE BLOWS CHECK THE CONTINUITY OF FUSE ON PCB 0 ohm Pai 120V 100V STEP DOWN AUTO TRANSFORMER DEFECT WATER INLET FILTER IS BLOCKED CHECK FOR AC100V BETWEEN BLACK AND BLUE AT CONNECTOR 8 VISUAL CHECK AND CLEAN CAREFULLY OR REPLACE WATER FLOW SENSOR DEFECT OR JAMMED VISUAL CHECK AS NEXT STEP PULL OUT CONNECTOR 2 CHECK IGNITION WHEN CONNECTION WITH WHITE PIN OF WATER FLOW SENSOR AND UNUSED PIN NOT FLASHING POWER RECOVERY DETECTION 000 indication can be reffered only in call POWER FAILURE DETECTION COMBUSTION STOPS THEN FLASHING ing mode as the record of power failure POWER FAILURE DURING COMBUSTION CLOSE HOT WATER FAUCET AND AGAIN OPEN FAUCET IGNITION FAILURE NO IGNITION THEN COMBUSTION INDICATOR STARTS FLASHING AFTER 15 SEC IGNITER DEFECT CHECK AC VOLTAGE BETWEEN BLACK AND BLACK AT CONNECTOR 7 IN IGNITION AC100V BROKEN INSULATOR IN IGNITER TERMINAL VISUAL CHECK OF IGNITER TERMINAL THERMAL FUSE IS ACTIVATED FUSE WIRE IS DISCONNECTED GAS SOLENOID VALVE ASSY DEFECT CHECK THE CONTINUITY IN TRANSMISSION CONNECTOR YELLOW FOR FUSE SIDE CHECK FOR DC90V AT CONNECTOR 5 IN IGNITION OR CHECK FOR CONTINUITY IN MAIN SOLENOID VA
14. To fix to the maximum capacity level 872967 lt 601 change prolonged exhaust mode Changing hot water temperature when the remote controller is not connected the hot water temperature setting can be changed by selecting one of these settings Dip SW settings for Setting change after the power is turned on is different temperature Temperature F ineffective No 4 12048 The system recognizes the settings and makes 165 74 them effective before power is turned on 9 When the remote controller is connected the Dip SW settings become ineffective Changing combustion capacity level Dip SW settings for ON settings before the power is turned on is different combustion capacity Capacity Level ineffective By detecting setting changes the system Default 4 Locked St minimum validates the changed settings capacity level f the water is not supplied for 5 minutes Locked at maximum e capacity level continuously the settings become ineffective Not applicable Manifold gas pressure by exhaust mode of vent pipe Exhaust mode Setting change after the power is short 2 Long 1 turned on is effective Dip SW Settings No 7 By detecting setting changes the for different exhaust mode No 8 system validates the changed Minimum in W C settings Maximum in W C Minimum in W C Maximum in W C LPG Na
15. controlled by the Gas Solenoid Valve When the required heating capacity becomes lower than a certain level approximately 110 000 BTU the Gas Solenoid Valve 2 is closed while Gas Solenoid Valve 1 remains open to combust with 12 rich burners with the gas supply controlled by the Gas Modulating Sole noid Valve Electrode Flame rod Main burner J Gas Solenoid Valve 2 Combustion fan Eee n Solenoid Valve 1 Gas Modulating Solenoid Valve Main Gas Solenoid Valve 1 6 Main Safety Devices 1 Water flow sensor Boil dry protection When the water flow sensor detects the flow rate set for starting ignition ignition water flow or higher the water heater starts operation Ignition water flow 0 71 GPM 2 7 L min Extinction water flow 0 58 GPM 2 2 L min Flame rod Flame failure detection Electric signals are transmitted to the flame detection circuit to confirm the normal com bustion when the flame rod detects the rectification of normal combustion flame There fore if the combustion of the burners is not normal the signals are not sent via the flame rod The gas control assemblies are closed without the signals and the error code 111 or 121 is displayed on the remote controllers
16. the covers again You can detach the covers by catching the bottom corner s slot with nail Cover Wood screw 44 2 17 BATH REMOTE CONTROLLER YST 2250 P N 3749 1 Safety precautions on Bath remote controller installation Before remote controller installation check the hole position considering wall stud location Note Do not dismantle the remote controller due to water proof design Do not install remote controller where water will contact the remote controller directly The remote controller cables carry low voltage 12VDC digital 2 Installation of Bath remote controller Drill a hole more than dia about 1 2 12mm in a wall for the remote controller cables After passing the remote controller cables through the hole remove the packing s back paper of remote controller Then attach the remote controller to the wall Detach both end covers of remote controller and fix the remote controller to the wall with wood screws 2 pcs in the screw holes provided You can detach the covers with catching the bottom corner s slot with nail Do not tighten the screws excessively as the screw hole may be damaged In case of mounting the remote controller on tile cement or mortar use an expansion bolt Reattach the cover and caulk with silicone around surrounding of the remote controller Remote controller cables Expansion bolt Wood screw Caulking Remote controller packing
17. the feed forward feedback and water flow control Design to reduce water temperature drops to hold temperature variation upon re feeding Maximum flow rate of 5 8 GPM 22 L min allowing simultaneous hot water supply for the kitchen and shower Environmently conscious and low NOx exhaust The rich lean design of the combustion burners allows the value of NOx to be as lower than 55 ppm or less Self diagnostic function Detects the scale clogging of the heat exchanger assembly warning Detects the blocked exhaust system alarming Improved reliability The potted PCB Printed Circuit Board and connectors equipped with retainers have greatly improved the reliability of the electronic components Easier installation work The slide type wall hanging frame is provided so that the intake pipe and exhaust pipe can be aligned during the installation The PCB has a function to let the LED flash upon heater trouble and the remote controller has an error display function With ultra low power consumption the optional remote controllers have highly visible display equipped with a backlight The main remote controller and the bath remote controller are different in design 1 2 Specifications Type of appliance Gas continuous flow water heater Model number MWH 180 Indoor only Installation Wall hanging Type of Hot water supply End stop system Exhaust system Direct vent forced combustion FF type Power supply A
18. 01 Clause 5 13 6 2 Fig 5 3 Check local codes and ordinances which may require higher clearances 2 Clearance to combustibles and openings Maintain clearances to openings as follows Terminate the system 6 1 8m from the combustion air intake of any appliance Place the system at least 3 0 9m away from any other building opening gas utility meter service regulator or the like or less distance if specified in the appliance s instructions Items of vent system Items shown below in TABLE 1 are used for this vent system The diameters of pipes are 3 1 79mm for inner vent pipe and 5 127mm for outer air intake pipe The length of the items are shown in Fig 1 TABLE 1 Items Connection Model MPI P N and KS Ir Number Length 300 11 8 FFTP300 3801 Fig 2 Straight Length 600 24 01 FFTP600 3802 Length 900 35 4 FFTP900 3803 Vent length Adjustable Length 175 230 6 9 9 1 FFTA200 3804 bd Adjustable Length 215 310 8 5 12 2 FFTA260 3805 45 elbow 90 elbow Fi 2 Male maleAdapter FFTMM 3808 82 FFTRD 3816 Air Intake Pipe FFTAIP Rain Cap FFTRT 3818 2 clearance FFTRFB SE Ca aa Roof Flashing FEIRE Vent termination Straight Termination FFT7U Refer to Fig 2 Horizontal Members Adapter A FFTRFAA 3821 Adapter B FFTRFAB 3822 The values enclosed by are effective length unit mm Effective length mean
19. 15A Igniter Transformer Gas Inlet Fuse 5A Water Inlet Water Flow Sensor Hot Water Outlet Water Flow Control Device 1 5 Main Component Structures 1 Gas flow control device Feeds the necessary amount of gas to heat water to a set temperature based on the amount of water flowing in through the inlet measured by the water flow sensor and the water temperature calculation When the thermistor detects the water temperature at the inlet the temperature is com pared with the setting An electric current representing the temperature difference is transmitted to the PCB where the current is amplified and dispatched to the Modulating Solenoid Valve An electromagnetic force caused by the current from the PCB pushes the plunger up ward Upward force Pressure received at the diaphragm due to internal pressure in the chamber of the Modulating Solenoid Valve pushes the plunger downward Downward force The plunger stops moving and stays at a certain position when the Upward and Down ward force are balanced As the plunger remains at the position the valve position of the Modulating Solenoid Valve linked to the plunger is determined This determines a clearance between the valve body and the Modulating Solenoid Valve establishing a necessary gas quantity The required amount of gas is then supplied to the main burner e If the temperature of the heated water is lower or higher than the setti
20. 32 50mm TABLE Relationship between the range of wall thickness and the diameter of opening on the wall Model Number MPI P N the range of wall thickness the diameter of opening FFT 7U 200 3810 3 9 9 8 100 250 95 7 5 9 0144 150 FFT 7U 300 3811 9 8 17 7 250 450 5 8 5 9 0147 150 450 650mm 26 1 6 9 154 175mm 17 7 25 6 17 7 25 6 450 650mm 96 1 6 9 0154 175 diameter of the wall opening does not need to be increased if the wall opening is pitched DOWNWARD towards the outside at a 2 1 4 in ft pitch 16 2 4 SUGGESTED PIPING BASIC INSTALLATION This drawing is intended only as a guide It does not imply compliance with local building codes Installation must be done in accordance with local building codes and may vary depending on installation location Confer with local building officials before installation 2 lt o 7 Union Union Shut off valve Pressure relief valve Valve 1 Valve 2 Minimum 3 4 Gas supply Valve 3 Valve 4 Minimum 3 4 Hot water supply line Minimum 3 4 Cold water supply line DE br 2 5 SUGGESTED PIPING CIRCULATION SYSTEMS This drawing is intended only as a guide It does not imply compliance with local building codes Installation must be done in accordance with local building codes and may vary depending on installation location Confe
21. 4 3 and Fig 4 4 A continuously DOWNWARD slope of no less than 2 1 4 in ft is maintained in the horizontal portion toward the outside 28 TABLE 2 Relationship between the range of wall thickness and the diameter of opening on the wall Model Number MPI P N the range of wall thickness the diameter of opening FFT 7U 200 3810 3 9 9 8 100 250mm 5 7 5 9 0144 150 FFT 7U 300 3811 9 8 17 7 250 450 5 8 5 9 0147 150 9 8 17 7 250 450 05 8 5 0 0147 150 26 1 6 9 0154 175 diameter of the wall opening does not need to be increased if the wall opening is pitched DOWNWARD towards the outside at a 2 1 4 in ft pitch Horizontal installation See Fig 5 The horizontal termination straight termination and L termination consists of two parts sleeve and termination itself Separate them before installation 1 Check the location of appliance and the path for the vent system 2 Check wall thickness where the vent system passes through and select suitable horizontal termination according to TABLE 2 Cut the opening for the sleeve with the diameter in TABLE 2 Cover the flue outlet to avoid debris from entering the appliance 3 Adjust the length of the sleeve so that the end of the sleeve protrudes about 0 2 5mm from the wall Then fasten the sleeve with the screw provided Remember a stamped letter on the sleeve 4 When the opening is too large twist the packing provide
22. 50 F 10 C at inlet Water flow rate GPM 1 0 0 58 GPM 95 100 110 120 130 140 150 160 165 Hot water temperature With water temperature 68 F 20 C at inlet s 5 60 9 50 E 4 0 4 o 3 0 g 20 1 0 0 58 GPM 051 96 95 100 110 120 130 140 160 165 Hot water temperature F 12 Heat Exchanger Thermistor 1 4 General Construction Parts Names No Description Exhaust Gas Duct 13 Outgoing Water Thermistor Thermal Fuse Device 23 Exhaust Chamber 24 Water Filter Assembly Drain Plug Air Inlet Box Assembly Heat Exchanger Flame Rod Modulation Valve Unit Gas Control Assembly Over Heat Switch bi metal switch Frost Sencing Switch bi metal switch Manifold Assembly Combustion Fan Motor Assembly Electrode PCB Unit Surge Protector Combustion Chamber Assembly Burner Assembly Transformer 100V Fuse 3
23. 52 7kW 20 000Btu h 6 0kW Remote controller option CMR 2250 P N3748 Main control kitchen laundry YST 2250 P N3749 Bathroom control Remote controller cable option Nonpolarized two core cable Top of heater 12 30 5cm Front of heater 6 15 2cm Sides of heater 2 5 1cm Clearance from combustibles Back of heater 0 Floor 12 30 5cm Vent pipe 0 Carton box dimensions Height 31 1 2 800mm Width 15 7 8 403mm Depth 11 1 32 280mm consumption 1 3 Performance Performance Capacity characteristic curves 8 0 Water flow rate GPM 7 6 5 4 3 0 a 0 0 0 95 100 110 120 130 140 Hot water temperature F With water temperature 41 F 5 C at inlet 8 0 Water flow rate GPM 7 0 6 0 5 0 4 0 3 0 2 0 e 58 GPM 120 130 140 160 165 Hot water temperature F With water temperature 59 F 15 C at inlet Water flow rate GPM 8 0 2 0 1 0 0 58 GPM 0 5 95 9 400 110 120 130 140 150 160 165 Hot water temperature F With water temperature 77 F 25 C at inlet Water flow rate GPM 8 0 7 0 6 0 5 0 4 0 3 0 2 0 1 0 051 0 58 GPM 110 120 130 140 150 160 165 Hot water temperature F 150 Inlet water temperature 41 F 5 C 50 F 10 C 59 F 15 C 68 F 20 C 77 F 25 C 160 165 With water temperature
24. 69 149 137 3 4 290 255 215 197 173 3 4 465 409 344 315 278 de 581 512 4421 397 347 1 930 825 7081 638 556 11 4 1470 1200 1130 9601 930 1 1 4 2352 1920 1808 1536 1488 For reference only Please consult gas pipe manufacturer for actual pipe capacities 35 2 8 GAS PIPING Install the manual gas control valve in the gas inlet connection of MWH 180 e A union should be used to connect the unit and the gas pipe Check the gas type and the gas inlet pressure before connecting Remove the screw from the test plug before checking the gas inlet pressure Connect the manometer to the plug with the silicon tube and measure the gas inlet pressure The maximum and minimum gas inlet pressures are as follows lt Natural Gas supply pressure gt Min 4 W C 102mmH20 Max 10 5 WC 267mmH20 lt Propane Gas supply pressure gt Min 8 W C 203mmH20 Max 14 W C 356mmH20 e Put the screw back in the test plug and fasten tightly Make sure to conduct gas leakage test before operating MWH 180 2 9 WATER PIPING e Install a manual water control valve in the water inlet connection of MWH 180 e A union should be used on both the hot and cold water supply lines for connection Use soldering materials or piping that will not cause any deterioration of potable water NO LEAD Purge the water lines to remove all debr
25. 8 7 738mm unit mm Fig 1 The dimensions of items 24 A vent system and components are the only vent system and components that have been approved by CSA to use with this unit U L Listed vent components of similar dimensions may be used All the air used for combustion shall be supplied from the outside and all the exhaust gas shall be discharged to the outside The minimum and maximum wall thickness required for installation Minimum 3 9 10 Maximum 25 6 65cm The procedure of installation 1 Common procedure for vertical and horizontal installation Joint connection and detachment method Items in TABLE 1 shall be connected and detached by one of the following method a b The column Connection and detachment in TABLE 1 indicates which method should be used Vent pieces should not be cut Mainly method a is used for connection and detachment It s for Horizontal terminations straight termination and L termination vent lengths drain tee and reducer Slide piece SM Into cover Stopper bead sng Insert the male end fully into the female end until the stopper bead is seated against the stop end on the female end Confirm female male ends of the lengths Then pull out female end holding the slide piece in until A female end has slide piece the slide piece is clear of the stopper bead Slide piece Stopper bead Female end Female end
26. 8W the water supply pipe is 16W the connection of water inlet is 10W and the connection of hot water outlet is 10W In order to keep the heat is the most vulnerable part of heat exchanger the big capacity 48W heater is mounted The system turns ON at 37 F 3 and OFF at 55 F 13 C E 1 7 Scale Build Up Alarm Summary The temperature of residual hot water becoms higher as scale starts to build up inside the heat exchanger The extent of scale build up is judged by monitoring the temperature of re sidual hot water LC scale build up alarm is indicated on the remote controller Flow chart See page 50 1 The set temperature by remote controller needs to be 120 F and over to activate the alarm 2 The stability of the temperature of outgoing hot water is detected by the thermistor of the can body 3 The temperature of residual hot water is detected by the thermistor of the can body when hot water flow is stopped The criterion for judging scale build up varies depending on combustion capacity 4 LC alarm and set temperature are indicated alternately on the remote controller Alarm specification Hot water supply is available even if LC is indicated on the remote controller LC alarm can be reset by turning the power switch off and on No detection is possible in case remote controller is disconnected LC alarm is not memorized in the alarm history record Conditions for invalid detection The ther
27. ECTION MWH 180 must be electrically grounded in accordance with local codes or in the absence of local codes with the most recent edition of the National Electrical Code ANSI NFPA 70 In Canada all electrical wiring to the MWH 180 should be in accordance with local codes and the Canadian Electrical Codes CSA C22 1 Part 1 Do not rely on the gas or water piping to ground the metal parts of the water heater Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing Field wiring to be performed at time of appliance installation Completely turn off the power before starting the work Do not turn the power on until the electric wiring is finished and all work is completed Otherwise electric shock or personal injury may result uds MWH 180 requires 120V AC at 60Hz Disconnect the power supply if the unit is not in use for a long time Remove residual water in the unit when the power supply is off because the freeze prevention in the unit will not activate resulting in possible freezing damage Do not let the power cord contact the gas piping The grounding screw is located in the junction box attached to the outside of bottom plate prevent electrical shock provide a ground with resistance less than 1000 An electrician should do this work 0 o 2 Surge protecto
28. Fuse Thermal Fuse Fig 5 Voltage or resistance of Gas Solenoid Valve Assembly Resistance Measure voltage without pulling out connector Measure resistance pulling out connector See Table 1 Voltage of modulating Solenoid Valve Measure voltage without pulling out connector lt Table 1 gt Resistance of Gas Solenoid Valve Assembly Y C O Solenoid Valve Approximately 1 6 Y C BL Solenoid Valve Approximately 1 6 Y C Y Main solenoid Valve Approximately 1 5 lt Table 2 gt Gas pressure in W C m Gas supply Manifold pressure pressure Minimum 4 4 10 5 Resistance lt Fig 7 Continuity of Over Heat Switch Over Heat Switch Table 3 gt Resistance of Thermistor Thermistor Measure resistance pulling out connector Resistance of Thermistor Approximately 10 4 Approximately 5 9 Approximately 4 9 Approximately 3 5 BL Blue Abbr of color Y Yellow Orange Black R Red Green W White Operational flow chart Hot water supply normal operation Supply power insert power plug into outlet Push ON OFF button With use of remote controller ON indicator lights 4 Hot water faucet OPEN
29. G DIAGRAM e EL 39 DIAGNOSTIC POINT pm UE 41 SCHEMATIC DIAGRAM ts etre 42 WIRING REMOTE CONTROLLER nto tratar 43 MAIN REMOTE CONTROLLER CMR 2250 P N 3748 44 BATH REMOTE CONTROLLER YST 2250 DIN 3749 45 TESTING OPERATION tact chere e et lenit et 46 Service and Maintenance 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 3 9 3 10 3 11 UEM 47 Time e ET 48 Flow Charts 50 FaultFindings anid Error Code T ebe Ee 51 Gas Setting lee EE 54 Combustion Specification Various Combination Setting 1001 55 Remote Controllers Special Features 4400 57 Disassembling Assembling Parts 59 Procedure for Flushing Water Heater ce tenete nente kp i n ua 69 Exploded VIEW M 72 6 s 74 1 General Outline of Appliance 1 1 Features 1 High performance amp high capacity water heater features e Stable heating and supplying from 0 58 to 5 8 GPM with the proven temperature control method combining
30. LVE SOLENOID VALVE 1 amp 2 RESPECTIVELY DC90V Table 1 MODULATING SOLENOID VALVE DEFECT LOSS OF GAS SUPPLY CHECK FOR DC 3 2 9 5 V CONNECTOR 1 WITHOUT PULLING OUT THE PLUG ON CHECK GAS INLET PRESSURE DC 3 2 9 5V IGNITES THEN LED STARTS FLASHING AFTER 15 SECS FLAME ROD INSULATOR FAILURE OR SHORT CIRCUITED VISUAL CHECK OF FLAME ROD INSULATION EARTH CABLE CHECK FOR DISCONNECTION OR LOOSE CONNECTIONS AT TERMINAL NOZZLE OF MANIFOLD VISUAL CHECK OF INJECTOR BLOCKAGE FLAME FAILURE DURING COMBUSTION FLAME FAILURE DURING COMBUSTION INSUFFICIENT GAS PRESSURE SETTING MODULATING SOLENOID VALVE CHECK MANIFOLD PRESSURE Table 2 LOSS OF GAS SUPPLY CHECK GAS INLET PRESSURE Table 2 OVER HEAT SWITCH ON COMBUSTION STOPS AND COMBUSTION INDICATOR STARTS FLASHING OVER HEAT SWITCH DEFECT AND 15 ACTIVATED CHECK THE CONTINUITY BETWEEN THE TERMINALS OF THE SWITCH 0 ohm FLASHING OUTGOING THERMISTOR WIRE BREAKAGE HEAT EX THERMISTOR WIRE BREAKAGE AIR THERMISTOR WIRE BREAKAGE COMBUSTION INDICATOR FLASHES IMMEDIATELY WIRE BREAKAGE CHECK THE RESISTANCE AT CONNECTOR 3 Table 3 FAN MOTOR FAILURE BREAKING NO IGNITION COMBUSTION INDICATOR STARTS FLASHING AFTER 10 SECS FAN MOTOR DETECT REPLACE FAN MOTOR WIRE BREAKAGE FOR FAN MOTOR FUSE 3A REPLACE FAN MOTOR AND FAN MOTOR FUSE AT SAME TIME WATER FLOW CONTROL DEVICE FAIL
31. Purple White 55 650 Orange White 55 65Q Red Black DC11 13V Power Supplied to Unit Water Flow Sensor 2 White Black DC5 7V DCO 1V Power Supplied to Unit DC2 12V Flame Condition Gray Gray 65 77 Black Black DC11 13V Power Supplied to Unit Red Blue DC155 165V Power Supplied to Unit Yellow Blue DC14 16V Revolving Condition Orange Blue DC2 6V Revolving Condition White Blue DC8 12V Revolving Condition White Green AC50 150V After Ignition White Flame Rod DC1 20pA Flame Condition Yellow Yellow Below 1Q Black Black AC90 110V Igniting Condition Yellow Yellow Below 19 DC80 100V Flame Condition Yellow Yellow 1 4 1 6kQ DC80 100V Flame Condition Yellow Orange 1 55 1 75kQ DC80 100V Flame Condition 1 5 1 7kQ White White 40 F 19 21kQ 80 F 7 5 8 5kQ White White 120 3 3 3 9kQ White White 160 1 7 1 9 Transformer Water Flow Control Device Modulating Solenoid Valve 1 Remote Controller Fan Motor Flame Rod Over Heat Switch Igniter Thermal Fuse Main Solenoid Valve Solenoid Valve 1 Solenoid Valve 2 Yellow Blue Outgoing Thermistor Air Thermistor Heat Exchanger Thermistor Black White Green White Purple White Orange White RedBlack White Black Remote Controler 9 White Blue Over Heat Switch 3 YelowYelow 7 Thermal Fuse 5 YelowYelow 17 tin
32. URE COMBUSTION INDICATOR FLASHES IMMEDIATELY WATER FLOW CONTROL DEVICE DEFECT REPLACE WATER FLOW CONTROL DEVICE FALSE FLAME DETECTION COMBUSTION INDICATOR FLASHES IMMEDIATELY FLAME ROD INSULATOR DEFECT VISUAL CHECK OF FLAME ROD INSULATION NOT FLASHING NOTHING OPERATES AND THE ERROR CODE DISPLAYS IN 1 MINUTE PCB DEFECT TURN OFF AND ON IF NOT RECOVERY REPLACE PCB COMMUNICATION FAILURE WITH MAIN REMOTE CONTROLLER COMMUNICATION FAILURE WITH BATHROOM REMOTE CONTROLLER COMMUNICATION FAILURE NO COMBUSTION OR COMBUSTION STOPS COMBUSTION INDICATOR FLASHES IMMEDIATELY WIRE BREAKAGE OF REMOTE CONTROLLER CABLE SHORT CIRCUITED VISUAL CHECK OF WIRE AND REMOTE CONTROL CONNECTIONS REMOTE CONTROLLER FAILURE WHEN OPENING HOT WATER FAUCET WITHOUT CONNECTING REMOTE CONTROLLER IF NORMAL COMBUSTION STARTS REPLACE REMOTE CONTROLLER AIR SUPPLY OR EXHAUST BLOCKAGE FAILURE COMBUSTION STOPS AND COMBUSTION INDICATOR STARTS FLASHING VENT TOP IS BLOCKED VISUAL CHECK OF VENT TOP IF BLOCKAGE TAKE OUT LIGHTING SCAL BUILDUP IN HEAT EXCHANGER FAILURE COMBUSTION CONTINUES HOWEVER LC SHOWS ON REMOTE CONTROLLER SCALE BUILDS UP IN HEAT EXCHANGER REMOVE SCALE BY USING SCALE REMOVER LIGHTING CHECKING METHOD OF FAULTS In case of using circuit tester HOT WATER TEMPERATURE CAN NOT BE REACHED PRESET TEMPERATURE Connector No 1 3 4 5 6 7 8 on PCB c
33. alve 4 and water outlet valve valve 3 Gradually open the relief valve to release the residual pressure inside the unit After the pressure release securely close the relief valve again Connect an appropriate circulation pump in valve 1 and 2 which is located in the upper of valve 3 and 4 See Fig 1 At this time make sure that the pump outlet dischange side is connected to the water inlet side valve 2 of the unit Prepare approximately 2 gallons of cleaning liquid by mixing 1 5 gallons of speci fied cleaning agent such as CLR and 0 5 gallon of water Turn on the power to start the pump and circulate the liquid for 45 minutes For several minutes after the circulation start carbon dioxide gas may come out from the hose connected to the water outlet because of the dissolution of scale con tents Turn off the power of the pump After closing valve 2 disconnect the hose connected to the water inlet Place the end of the hose connected to the water outlet into an empty bucket See Fig 2 Open the valve 4 gradually to flush off the cleaning liquid remaining in the water circuit of the water heater by supplying water at least for 5 minutes At that time be sure to close the valve 3 Shut off the water valve 1 and 4 disconnect the hose connected to the valve 1 Check the water inlet filter Fig 3 for clogging If clogged remove the foreign substance After cleaning the filter install it again Open both water valve 3 and 4 Rest
34. an check fault by measure voltage with tester in inserting connector Water filter There are some symptoms such as ignition failure or firstly smooth ignition and later ignition failure Possible reason are that water filter does not turn off securely after water filer cleaning water filter does not turn off to the end securely and foreign matter passes through without stopping in water filter water flow control device or water flow sensor are blocked with foreign matter 51 THERMISTOR DEFECT CHECK RESISTANCE AT CONNECTOR 3 Table 3 MODULATING SOLENOID VALVE CHECK MANIFOLD PRESSURE Table 2 PRESSURE OF GAS SUPPLY CHECK INLET GAS SUPPLY SUFFICIENT PRESSURE AT MAX COMBUSTION Table 2 REMOTE CONTROLLER DEFECT OPERATE WATER HEATER WITHOUT REMOTE CONTROLLER AND CHECK HOTWATER TEMPERATURE AT 42 60 75 WATER INLET FILTER IS BLOCKED VISUAL CHECK AND CLEAN Fault findings lt Fig 1 Continuity of Fuse lt Fig 2 gt Water Flow Sensor check Pull out Pull out connector and direct coupling R 4 CMS NN Unused pin 1 Connect pin for lead wire white and unused pin Fig 3 Voltage of Igniter Transformer Measure voltage without pulling out connector Fig 4 Continuity of Thermal
35. an stops after running for 65 seconds Post purge 47 3 2 Time Charts Combustion start Timing chart with blockage detection Number of revolution for ignition Normal operation variable Ignition 300 7 Fan output Double safe relay Igniter Transformer Main Gas Solenoid Valve Gas Modulating Solenoid Valve O P off E Normal operation variable Gas Modulating Solenoid Valve Ignition level Gas Solenoid Valve 1 ho water Gas Solenoid Valve 2 Flame Sensor Maximum 5 0 i Post ignition 3 4 sec Stabilizing for ignition 0 1 sec ignition level 1 0 sec Vent block detection Waiting for constant revolution of start amp delay for Gas Solenoid Valve ON 0 2 sec Chart for Stop Combustion Timing Fan output Normal combustion rev Post purge revolution Igniter Transformer Main Gas Solenoid Valve Gas Modulating Solenoid Valve O P off Slow ignition level Gas Modulating Solenoid Valve O P Normal combustion Gas Solenoid Valve 1 Gas Solenoid Valve 2 Double safe relay Combustion start Restart in less than 10 minutes after initial start Normal operation variable Ignition RPM 300rpm Number of revolution for ignition Fan output Double safe relay Igniter transformer Main Gas Solenoid Valve Release Gas Modulating Solenoid Valve O P off Normal operation
36. ater from tea kettle or electrical pot Do not put Main remote controller in direct sunshine It is convenient to install it where it will be used most frequently Do not install Main remote controller at the place where any 00 commercial chemicals like ammonia sulfur chlorine ethylenic compound and acids etc are used The remote controller cables carry low voltage 12VDC digital R emote controller Remote controller fitting bracket 4 2 Installation of Main remote controller e Detach the fitting bracket from Main remote controller by sliding it down e Attach the fitting plate to wall Install conduit inside of wall in advance and secure the wiring box Pass remote controller cables through conduit Then pass the cables through the hole of the fitting bracket and pull them out Attach the fitting bracket with screws adjusting the screw hole to the wiring box Connect the remote controller cables to the terminal for the remote controller of PCB In case of installing of the fitting bracket for remote controller Align the slots of Main remote controller s back to 4 hooks on the fitting bracket Then slide them on from the top Wiring box Remote controller 7 fitting bracket In case you are not using the fitting bracket of the remote controller Detach right and left covers of the remote controller and fix them to the wall directly with wood screws Then attach
37. can be secured This unit is designed to be installed indoors using the proper vent piping to exhaust by products of combustion to the outside environment Contact your dealer or MPI for proper vent kits Do not install the unit over other combustion appliances such as gas cooking stove or a range Oil residue and dust in the air can adhere to the burner and the heat exchanger resulting in deformation loss of efficiency or damage to electronic components Do not install the vent terminal near the outlets of the other appliances Install the air intake terminal away from the wind path as the wind may cause imperfect combustion Keep the vent terminal away from the wall or the overhangs as far as possible even if it is noncombustible in order to prevent discoloration and staining caused by the exhaust gas Do not install the unit where commercial chemicals are used Those chemicals are ammonium sulfur chloride ethylene compound and acids which are used at beauty shop laundry factory and so forth Do not install the unit over food or dishes Installer must install a Pressure relief valve Pipe pressure relief to a drain or outside environment or within 4 of the floor Pipe pressure relief discharge to a drain or outside environment The appliance should be located in an area where leakage from the unit or connections will not result in damage to the area adjacent to the appliance or to lower floors of the structure Whe
38. d around the end of the sleeve after peeling off backing paper from the packing 5 Insert the sleeve to the wall and fasten with 4 screws provided Use plugs provided if needed Ensure the UP label on sleeve plate is at the top If it isn t easy to insert the sleeve because the packing doesn t fit the wall press down the packing during insertion 6 Seal between the end of the sleeve and wall and between the end of inner sleeve pipe and outer pipe 7 Adjust the length of the termination by fastening it at the stamped number same as that in 2 8 Fasten the condensation prevention plate with the screw provided In case of L termination or straight termination with reducer and elbow without additional straight length put this plate without fail 9 Insert the termination into the sleeve from inside wall so that 4 studs on sleeve plate are inserted into each 4 holes on termination plate and fasten the termination to the sleeve with the 4 nuts provided Ensure that the label on the termination is at the top 10 Ensure that the end of air intake pipe protrudes about 0 4 10mm from the sleeve 11 If using straight termination connect reducer on appliance flue outlet and 90 elbow between reducer and termination If using L termination connect reducer on appliance flue outlet and slide the adjustable part or the termination to fit it to the flue outlet Make sure that a continuously DOWNWARD slope of no less than 2 1 4 in ft is
39. dr MWH180 Service Manual MWH180 Instantaneous Gas Water Heater Residential Indoor Unit Table of Contents General Outline of Appliance 1 1 1 2 1 3 1 4 1 5 1 6 1 7 sm 1 UEM 2 GELEET ee PUN 3 General Construction Parts Names eerie eee pe temet de eid Eed 4 Main Component Str ct res 5 iiic ee err testes dt apart eau eR du c cua cade 5 Main Satety DeVICBS asesores Pub e pe 9 scale Build Up Alartm SE R EROR SER DER 10 Installation and Related Work 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 2 9 2 10 2 11 2 12 2 13 2 14 2 15 2 16 2 17 2 18 INSTAEE ATION ZINSTRU G TIONS acc Su ci sue rn teen aee 11 DIMENSIONS m HE 15 TEMPLATE OF L TERMINATION INSTALLATION 16 SUGGESTED PIPING BASIC INSTALLATION 17 SUGGESTED PIPING CIRCULATION 5 5 8 18 VENT PIPE INS TAELATIOIN 22 des taste ra dez ee 19 GAS LINE SIZING CHART S EE 35 GAS PIPING E 36 KN IT lr EE 36 PRESSURE RELIEF VALVE a ete Aa 37 ELECTRICAL CONNECTION x icc to ir tate tet emt tae etes n eset Reed dea Eege 37 WIRIN
40. e Gas Solenoid Valve SV2 Close etry ignition once and below 50 Main Gas Solenoid Valve Close Solenoid Valve Gas Modulating Close i Gas Solenoid Valve SV1 Close Gas Solenoid Valve SV2 Close Flame logo indicator OFF detection Over 30 minutes elapses after ignition Flame loss once and below Flame rod detects Cause clearing Turn ON OFF button on remote controller Hot water faucet Close Fan motor OFF in one minute Fan motor post purge 1 Flame logo indicator OFF Gas Solenoid Valve SV2 Close Gas Solenoid Valve SV1 Close Gas Modulating Solenoid Valve Close Main Gas Solenoid Valve Close 121 Over heat switch activates 141 Outgoing thermistor failure 321 Heat exchanger thermistor failure 331 Air thermistor failure 341 Fan motor failure 611 Main remote controller failure 740 Bath remote controller failure 750 Remote controller communication failure 760 Air supply or exhaust blockage failure Ignition failure LITITIIIIIILI 990 3 4 Fault Findings and Error Code ERROR CODE CONDITION OF COMBUSTION INDICATOR ON PCB NUMBER OF FLASHING PHENOMENON
41. e setting workable Check if the temperature can be adjusted as desired Procedure after testing operation If the residence is not ready for habitation or the unit will not be used for an extended time the residual water in the unit and the pipe may freeze and damage the unit or the residual water in the heat exchanger may deteriorate Be sure to remove the water in the unit and the pipe Refer to the instruction manual 1 Close the gas supply main valve 2 Close the water supply main valve 3 Take off the water filter drain stopper drain the valve and remove the water Take this procedure when the unit cools down after the testing operation 4 Disconnect the power or turn off the power supply 5 Open the faucet and shower faucet if any and remove the water 6 Leave the unit in this condition until ready to use Explanation to customers Fill out the warranty form with the customer and send to it 1 Explain the How to use the unit section of this instructional manual to the customer 46 3 Service and Maintenance 3 1 Operation Principles Before operation When ON OFF Button Power switch on the Main remote controller or Bath remote controller is turned ON the ON indicator iluminates in the case of operation with a remote controller Gas is supplied to the Gas Solenoid Valve During operation when hot water is supplied When the hot water supply faucet is opened water flows through th
42. e water flow control device and water flow sensor into the heat exchanger assembly The water heated by the heat exchanger assembly passes through the Outgoing Water Thermistor to go to a hot water outlet At this time the water flow sensor detects water flow Then the PCB starts the combustion fan activating the electrode The Main Gas Solenoid Valve Gas Solenoid Valve 1 and Gas Solenoid Valve 2 are opened simultaneously when the spark is emitted by the electrode The gas supply is set at the slow ignition level by the Gas Modulating Solenoid Valve and goes to main burners When all the main burners are ignited the flame rod detects the flame condition the Flame Logo Indicator lights and the sparking is stopped The PCB detects the water flow rate based on the signal from the water flow sensor calculates the energy required to heat the water up to the set temperature and adjusts the opening position of the gas flow control device and the combustion fan rpm After this PCB maintains the combustion to keep the water at the set temperature by check ing with the Outgoing Water Thermistor While controlling the combustion fan rpm and gas supplied by the Gas Modulating Solenoid Valve Feedforward feedback control Operation stop When the hot water faucet is closed the water flow sensor detects no water flow In response to this PCB closes the Main Gas Solenoid Valve the Gas Solenoid Valve 1 and Gas Solenoid Valve 2 and the combustion f
43. ellings Permitted only if veranda porch deck or balcony is fully open on a minimum of two sides beneath the floor For clearances not specified in ANSI Z223 1 NFPA 54 or CSA B149 1 one of the following shall be indicated a A minimum clearance value determined by testing in accordance with section 2 20 or b A reference to the following footnote Note Check local codes and ordinances 19 Use only designated vent terminal sold separately Install correctly in accordance with the installation manual attached e Select the correct switch position depending on the length of the vent pipe Make sure that the proper distance within the limitations is determined between the unit and the termination of the vent pipe Make sure the terminal of the vent pipe sticks out outdoors Prevent the exhaust gas from flowing back indoors through the gap between the termination and the wall where the vent pipe penetrates Make sure snow drift will not suffocate the vent terminal when it has been piled or fallen Do not place hazardous materials near the end of the vent termination Make sure to install the vent terminal at downward slope to prevent rain from entering inside e Some vapor or condensation may be generated from the vent terminal Place the vent terminal where it is not affected by water splashing or falling off the roof eaves A vent system that exits the structure through a sidewall shall terminate
44. eriod In energy saving mode the display becomes dim 1 Turn off the operation switch 2 Press and hold the adjustment switch 4 for approximately five seconds 2250 enger or bath te ACAUTION 202 Press the operation switch to turn it off The current settings appear 3 Press the adjustment switch Energy saving mode is activated or e deactivated according to the table below If no data are changed within a period of approximately 20 seconds the cur rent settings remain active The settings can also be determined by pressing the operation switch CAUTION th before tsi Meaning If no data are adjusted with a period of Note approximately 25 seconds the display The settings for the main remote controller becomes dim d bath t troll b If no data are adjusted with a period of approximately 25 seconds the display adjusted individually becomes more dim Energy saving mode is set to level 01 by default at the time of shipping The display always remains bright The display always remains dim 58 3 8 Disassembling Assembling Parts Procedure Illustration 1 Removing Water Flow Control Device and Water Flow Sensor 1 Drain water and turn off the power Water Filter 2 Disconnect Water Flow Control Device 8PIN connector on PCB side and Water Flow Senso
45. ication lights on remote controller Hot water faucet Open Water flow sensor ON at 0 7 GPM Fan motor ON Fan motor exceeds 1000rpm Start up initial check all on Igniter Transformer ON Main Gas Solenoid Valve Open Gas Modulating Solenoid Valve Open Fo Gas Solenoid Valve SV1 Open Gas Solenoid Valve SV2 Open Flame detection exceeds 0 8 uA Flame logo indicator lights on remote controller i 39 Igniter Transformer OFF Gas flow air flow hot water t Proportional control operation emperature and water flow Hot water capacity exceeds 95000BTU Gas Solenoid Valve SV2 Open Gas Solenoid Valve SV2 Close Safety devices activates Flame rod detects at 0 6 uA and below Water flow control device failure 51 Main remote controller failure 449 Bath remote controller failure 130 Remote controller communication failure 180 Outgoing thermistor failure Se Heat exchanger thermistor failure 331 Air thermistor failure gt 341 Fan motor failure gt 611 Over heat switch gt activates Igniter Transformer OFF Main Gas Solenoid Valve Close Gas Modulating Solenoid Valve Close Solenoid Valve SV1 Clos
46. ip B Fan Motor Assembly Wall Hanging Bracket Transformer Hexagon Head Screw 0 Water Inlet Quick Fastener 16A Hot Water Outlet Quick Fastener 16C Water Filter Rubber Packing Drain Plug Thermal Fuse Clip Water Flow Sensor Igniter Bracket Surge Protector Pressure Tube Cable Inlet Main Remote Controller CMR 2250 Water Flow Control Device Assembly Bath Remote Controller YST 2250 Igniter Transformer Harness Thermistor Over Heat Switch Power Supply Lead Wire Water Flow Control Device Lead Wire Thermal Fuse Heater Lead Wire PCB Propane Gas Terminal Block Lead Wire PCB Natural Gas O ring P4 Fluorine Manifold Assembly Propane Gas O ring P16 EPDM Manifold Assembly Natural Gas O ring P15 EPDM Burner O ring P4 EPDM Damper Propane Gas O ring P12 EPDM Damper Natural Gas O ring P8 EPDM Anti Frost Heater Assembly O ring P24 NBR Junction Box Cover PCB Fuse Cable Inlet Surge Protector Fuse Electrode Packing Electrode Flame Rod Electrode Holder Frost Sensing Switch
47. is and air Make sure both the hot and cold water supply lines are connected correctly A filter is placed at the water supply inlet to remove debris Clean the filter regularly Do not operate the unit without the filter in place In areas of heavy debris such as with some wells install a whole house water filter in line before the unit 15 PSI or higher water pressure is required to operate MHW 180 36 2 10 PRESSURE RELIEF VALVE Install an approved pressure relief valve with every gas water heater installation The pressure relief valve shall conform to the following requirements Relief Valves and Automatic Gas Shutoff Devices for Hot Water Supply Systems ANSI Z21 22 This pressure relief valve shall activate with the pressure of 150PSI The pressure relief valve shall be installed in the outgoing hot water supply line according to the manufacturer s instruction No valves or shut off device shall be placed between the relief valve and the unit The discharge from the pressure relief valve shall be piped to the ground or into the drain system to prevent possible burns to humans or animals Hot water discharged from the relief valve may cause severe scalding instantly and even death Do not cap the relief valve and do not install any depressurizer or restriction device in the relief line Manually operate the pressure relief valve at least once a year to check if it functions properly 2 11 ELECTRICAL CONN
48. lengths are available according to the limits in which its effective length can be made longer and shorter Elbows 45 and 90 elbow are available for changing the direction of the vent system The flexible section of each can be bent by hand for making small angle adjustment Do not bend repeatedly or extremely because it may cause vent gas leaks Drain tee Connect the drain tee directly on to the appliance flue outlet as shown in Fig 4 4 Attach one end of a drain hose to the drain tee outlet and the other end to a condensate drain so that any steam or condensed water will be handled properly The drain hose must be suitable for use with acidic effluent Follow the appliance manufacturer s instructions and all local and national codes for draining the condensate and acidic effluent Caution Periodically check the terminal end to ensure it is not blocked or obstructed Support Support the vent system every 5 1 5m 1 Secure the support to solid material using the screws provided with the support 2 Loosen the nuts of the cylinder After inserting pipes fasten the loosened nuts Use the pairs of nuts and bolts provided with the support eo ae 2 Detail of installation No less than 2 1 4 in ft No less than 2 1 4 in ft Male end L termination E H Jl Reducer X Female end Fig 4 1 Fig 4 3 H
49. maintained in the horizontal portion Refer to Fig 4 1 amp 4 2 12 Attach facing plate for outer wall as required Drill 3 pilot holes in the outer wall first Then insert plugs to the holes and fasten the facing plate to the wall with 3 screws provided Locate the notch of the facing plate at the bottom of the plate Seal between the facing plate and the wall Do not seal the notch 200 Stamped End of air intake pipe letter See 0 2 ni DI 1 A 4 N End of sleeve Sleeve d No less than 2 1 4 in ft L termination 4 Screws SEN Horizontal installation FFT 7U L Seal between inner sleeve pipe and outer pipe Seal between siasva and wal No less than 2 1 4 in ft Straight termination Reducer 90 elbow Horizontal installation FFT 7U 3 Plugs 3 Screws lt Fig 5 Detail of horizontal installation gt 30 Maximum vent length Number of 90 elbow Maximum vent length 3 23 7 0m 2 29 8 8m 1 35 10 7m Unless a drain tee is used the maximum vertical height of the vent system can not exceed 5 1 5m Horizontal extended installation See Fig 6 The straight termination consists of 2 parts sleeve and termination itself Separate them before installation 1 Check the location of appliance and the path for the vent
50. mistor of the can body is broken or short circuited The alarm is in process During forced combustion by the dip switch The set temperature is under 120 F 10 2 Installation and Related Work 2 1 INSTALLATION INSTRUCTIONS The cases shown below are classified by the degree of risk and damage Be sure to follow the instruction for your safety A Danaer Danger indicates that serious injuries or even death may result from the 9 improper installation due to negligence of following the instructions Warning indicates the possibility that serious injuries or even death may A Warning result from the improper installation due to negligence of following the instructions Caution indicates the possibility that some injuries or material damage A Caution may result from the improper installation due to negligence of following the instructions Each mark indicates General prohibited O Never fail to do Never install the unit outdoors as it is exclusively for indoor use Do not install it in the bathroom Electric shock or leakage may result To the installers Z Warning Read and understand the installation manual to carry out the installation as specified for proper and safe usage A competent dealer or plumber should perform the complete installation including placement venting plumbing gas line and electrical connection Consumers should not try to install their own unit Make do
51. n a concealed area such as the attic Caution The edges of sheet metal parts may be sharp Always wear gloves and appropriate eye foot and other protections when handling these products e It is recommended that experienced professionals familiar with the opration and maintenance of heating appliances and vent air intake system install this system These instructions are a guide to assist a professional installer Before commencing installation please read the installation instructions carefully Failure to follow the installation instructions could cause not only the lower performance of appliance but also property damage or personal injury Different manufactures have different joint systems and adhesives Do not mix pipe fitting or joining methods from different manufacturers Examine all components for shipping damage prior to installation DE H General installation requirements 1 Selecting installation site A vent system that exits the structure through a sidewall or the like shall terminate not less than 12 30 5cm above the ground The termination of the vent system shall be located above the snow line in geographical areas where snow accumulates The termination of the vent system shall not be located in public traffic areas such as walkways unless the vent system is at least 7 2 13m above the ground And also ensure that positioning of the vent system complies with the requirements of AS5601 AG6
52. n such locations can not be avoided it is recommended that a suitable drain pan adequately drained be installed under the appliance The pan must not restrict combustion airflow 14 2 2 DIMENSIONS SS 1 3 eeh bE 4 uuo Z SN 26 6 8 m A U ke gt 0 wwo L JAE 9 L EL b uSE EL 9 L S io E eo 5 le 2 Te 20 8i tE Ss I 1 D f eO E 7 oR 1 S NEI m 4 S O te 0 Y Q 2 te 9 Ce 4 1 Sch P i U o lo y KM S i d E le J 1 4 9 6 cell vc 48 68 29 26 11 15 2 3 TEMPLATE L TERMINATION INSTALLATION Thickness refer to TABLE Facing plate refer to TABLE Eu INR fh L termination E Facing plate Reducer 6 5 8 168mm 3 5 16 84mm Moe Mete el ci mx rus Fr NE S 59 Y is of 2 M 4 31
53. ng the resistance of the hot water temperature detecting thermistor changes accordingly to automatically adjust the gas amount by changing greater or lower the current transmitted to the Modu lating Solenoid Valve This stabilizes the heated water temperature When the gas supply pressure is changed the receiving pressure of the diaphragm changes and also changes the clearance between the valve body and the Modulating Solenoid Valve The gas is controlled to remain at a constant level Diaphragm Feed back air connection S Sa lt gt Plunger Lea gt Plunger spring T Feed back air connection Pressure check hole Solenoid Valve Modulating Solenoid Valve 2 Water flow sensor Measures the water flow as its rotor bladed wheel spins with the passing water The rotation of the rotor is detected by the sensor rotor blade equipped with a magnet of the wheel and the Hall element which calculates the water quantity 150 20 3 Water flow control device When water flows more than water 50 heater capacity hot water temperature becomes lower than the setting The water flow control device automatically reduces the water flow to preve
54. not less than 12 30 5cm above the ground Check local codes and ordinances which may require higher clearances The termination of the vent system shall not be located in public traffic areas such as walk ways unless the vent system is at least 7 2 1m above the ground Terminate the system 6 1 8m from the combustion air intake of any appliance Place the system at least 3 0 9m away from any other building opening gas utility meter service regulator or the like or less distance if specified in the appliance s instructions And also ensure that positioning of the vent system complies with the requirements of AS5601 AG601 Clause 5 13 6 2 Fig 5 3 20 n case extension of the vent pipe is required it shall be limited to the maximum of 41 12 5m based on the formula below However the maximum height of the vent pipe is limited to 23 feet Calculate D distance value according to the length of the vent pipe and the number of elbows D L Mso X 6 Mas X 1 5 D Distance L Total extended length of straight vent pipe and adjustable vent pipe Moo Number of 90 elbow Mas Number of 45 elbow Note Maximum number of is 3pcs Maximum number of Mas is 5pcs In case of combination use for Meo and Mas maximum total number is 5pcs To prevent the vent air intake piping from occurring condensation the fan has following 4 type settings with 2 dip swiches No 7 amp No 8 in each D value Bo
55. nt such 1 3 temperature drops If the water flow is S T greater than the heater capacity a signal from the PCB activates the water flow control device s motor stepping motor In response to this operation the valve body of the water flow control Pont ol device motoi device also is operated to reduce the water flow by narrowing the water path Water flow fluctuations are detected and transmitted to the PCB by the water flow sensor When the appropriate level of water flow is reached the PCB signals the motor to stop Thus the water flow ET remains at this level E 29 5 Valve body Valve main body 28 5 Lf 4 Combustion control of rich and lean burners 1 Ignition start After the Main Gas Solenoid Valve Gas Solenoid Valve 1 Gas Solenoid Valve 2 open respectively as required the Gas Modulating Solenoid Valve being held at the slow igni tion position with gas supply at a constant rate operates to ignite rich burners and lean burners 2 During combustion When a heating capacity higher than a certain level approximately 95 000 BTU is re quired both Gas Solenoid Valve 1 and Gas Solenoid Valve 2 are opened to burn with rich and lean burners while the gas supply is
56. ore power to the water heater e Be sure the area is well ventilated as opening windows and doors e Be sure to wear rubber gloves e f the specified cleaning agent comes into contact with skin or eyes flush area with cool water immediately for 15 min Call physician if irritation continues e f swallowed do not induce vomiting drink a glass of water followed with milk Call a physician immediately 69 Fig 1 Minimum 3 4 Gas supply Pressure relief valve Valve 1 Valve 3 Valve 4 Minimum 3 4 Cold water supply line Check valve Bucket Pump 70 Fig 2 Fig 3 Union Union Im 2 Union Shut off valve NANES Minimum 3 4 Gas supply Valve 1 Valve 3 Valve 4 Minimum 3 4 Cold water supply line Check valve Hose end Bucket ST 3 10 Exploded View 2 AZ Saas Se See See ee eee eed 73 3 11 Parts List MPI P N Description Number Front Panel MPI P N Description Heat Exchanger Thermistor Casing Assembly Air Inlet Adapter Heat Exchanger Assembly Thermistor Holder Air Inlet Box Assembly Anti Frost Heater Clip A Gas Connection Gas Control Assembly Thermistor Clip Anti Frost Heater Cl
57. orizontal installation FFT 7U L Horizontal extended installation without drain tee No less than 2 1 4 in ft No less than 2 1 4 in ft Straight termination CAN wt Reducer a adapter 90 elbow Drain tee Fig 4 2 Fig 4 4 Horizontal installation FFT 7U Horizontal extended installation with drain tee Horizontal installation Horizontal installation can consist of only horizontal termination straight termination or L termination reducer and 90 elbow If the distance between an inner wall and the center of the appliance flue outlet is under 5 7 146mm use L termination FFT 7U L and reducer as shown in Fig 4 1 Otherwise use straight termination FFT 7U and reducer as shown in Fig 4 2 A continuously DOWNWARD slope of no less than 2 1 4 in ft is maintained in the horizontal portion Horizontal extended installation Horizontal extended installation means installation on an internal wall apart from the appliance It can consist of straight termination reducer straight lengths adjustable lengths and elbows as shown in Fig 4 3 If vent system has vertically installed lengths longer than 5 1 5m or has 3 elbows install drain tee direct on the appliance flue outlet and male male adapter before horizontal lengths as shown in Fig 4 4 The directions of lengths are different between Fig
58. oving Gas Control Assembly 1 Remove Manifold Assembly See 5 2 Remove Terminals of Gas Modulating Solenoid Valve 3 Remove the Pressure Tube Remove two set screws one on right side in front and the another on left side at the rear fixing the Gas Control Assembly Remove plug 1 pc from the gas pressure check hole 62 Procedure Illustration 6 Pull the Gas Control Assembly out eas disconnect the terminals 3 pcs 77 of the Gas Solenoid Valves and remove them as one unit als A 7 Removing Fan Motor 1 Remove Water Control Device and Water Flow Sensor See 1 2 Remove Manifold Assembly and Gas Control Assembly See 5 6 3 Remove the set screw 1 pc fixing the fan Thermistor 4 Remove the set screws 5 pcs fixing the Fan Motor to pull it out forward Procedure Illustration 8 Removing Electrode and Flame Rod Electrode 1 Disconnect high voltage cord 2 Remove set screws 2 pcs fixing the Electrode Holder to pull the Holder out Flame rod 1 Disconnect Flame Rod cords 2 Remove set screws 2 pcs fixing the Electrode Holder to pull the Holder out Disconnect Flame Rod cordss Procedure Illustration S 9 Removing Burner 1 Remove Manifold Assembly See 5 2 Disconnect cords from Flame Rod 3 Disconnect high voltage cord f
59. ppliance AC120V 60Hz Remote controller DC 12V digital Ignition system Direct electronic ignition Outer panel material Pre Painted Galvanized Steel Sheet Hot water capacity e water temp 25 rise EM Maximum hot water capacity 54 rise Maximum water supply pressure 150PSI 1 0MPa Recommended minimum water supply pressure 15PSI recommended 25 75 psi for maximum performance Minimum operational water flow 0 58GPM 2 2L min Normal 61W Electrical comsumption Standby Main Bath remote controller on 3 7 W Anti frost heater operation 84W Gas R3 ANPT Connections Water inlet R3 ANPT Hot water outlet R3 ANPT Exhaust temperature below 480 Noise level 49dB NOx 55ppm Max Flame failure Flame rod Over heat switch 212 F Over heat limit 203 F Safety devices Thermal fuse for heat exchanger 363 F Over current fuse 5A Automatic frost protection Combustion fan motor rpm check PCB Dimensions Height 24 1 32 610mm Width 13 25 32 350mm Depth 8 3 8 210mm Weight 43lbs 20kg Main remote controller 96 140 F Temperrature Range Bath remote controller 96 140 F Available Default Temperatures 110 F 120 F 140 F 165 F without remote controller set by Dip switch on PCB Maximum 180 000Btu h Gas Natural Gas 52 7kW Minimum reference 20 000Btu h 6 0kW Maximum 180 000Btu h Minimum reference Propane Gas
60. pplied Gas 3 11 412 7843 6299 5391 4718 4329 3983 3705 3476 3284 2910 1000 Btu Cubic Ft is a Typical Value 31 2 16 709 11 484 9222 7893 6995 6338 5831 5425 5090 4808 4261 4 23 277 15 298 12 847 10 995 9745 8830 8123 7557 7091 6698 5936 5 Maximum Liquified Petroleum Undiluted Delivery Capacity in Thousands of Btuh 0 5 WC Pressure Drop Length in Feet 10 20 30 40 50 60 70 80 90 100 125 150 200 1 2 275 189 152 129 114 103 96 89 83 78 69 63 55 3 4 567 393 315 267 237 217 196 185 173 1621 146 132 112 1 1071 732 590 504 448 409 378 346 322 307 275 252 213 1 1 4 2205 1496 1212 1039 913 834 771 724 677 630 567 511 440 1 1 2 3307 2299 1858 1559 1417 1275 1181 1086 1023 976 866 787 675 2 6221 4331 3465 2992 2646 2394 2205 2047 1921 1811 1606 1496 1260 PipeSize For reference only Please consult gas pipe manufacturer for actual pipe capacities Maximum Capacity of Flex TracPipe in Cubic Feet per Hour of Natural Gas 0 60 Specific Gravity 0 5 WC Pressure Drop Length in Feet 40 20 30 40 50 60 70 80 90 100 150 200 3 4 206 147 121 105 94 86 80 75 71 67 55 48 1 383
61. provided Ensure that the label on the termination is at the top 10 Ensure that the end of air Intake pipe protrudes about 0 4 10mm from the sleeve 11 Install the vent system from the appliance to straight termination with using straight lengths adjustable lengths and elbows If vent system have vertically installed lengths longer than 5 1 5m or have 3 elbows install drain tee directly on the appliance flue outlet and male male adapter before horizontal lengths Make sure that a continuously DOWNWARD slope of no less than 2 1 4 in ft is maintained in the horizontal portion Refer to Fig 4 3 amp 4 4 12 Support the vent system every 5 1 5m with support straps 13 Attach facing plate for outer wall as required Drill 3 pilot holes in the outer wall first Then insert plugs to the holes and fasten the facing plate to the wall with 3 screws provided Locate the notch of the facing plate at the bottom of the plate Seal between the facing plate and the wall Do not seal the notch 31 Stamped letter End of air intake pipe X 0 2 eee i EN 1 End of sleeve Sleeve Packing No less than 2 1 4 in ft 5 1 5m Reducer 90 elbow 4 Screws Support strap m Straight length Straight termination Seal between sleeve and wall Seal between inner sleeve pipe and outer pipe
62. r 22141 IO 7 CXV Py Power supply lead wire Black hot White neutral Nie m supply lead wire Ground terminal Grounding screw 38 2 12 WIRING DIAGRAM OFF d SWITCH Ale w w Oz 0090 5000 MODULATING SOLENOID VALVE W EVICE 2 20 Les Hess On GY W THERMISTOR R HEAT EXCHANGER TEMP BK W THERMISTOR i AIR TEMP WATER FLOW THERMISTOR SENSOR W G OUTGOING TEMP eap OVER HEAT SWITCH FAN MOTOR ra BL SOLENOID 99 VALVE 2 Y REMOTE 0 SOLENOID CONTROLLER SVD VALVE 1 Y Y MAIN SOLENOID E VALVE SPARK ELECTRODE EHE THERMAL FUSE COLOR CODING White BK BLack FROST SENSING BR Brown SWITCH G 11 H 12 GY Grey TRANSFORMER 0 Orange R Red WW BR SURGE G Green BL PROTECTOR P Purple Y Yell a BL W BK W WW
63. r 3PIN relay con nector Remove the two Quick Fasteners and take out Water Flow Control Device and Water Flow Sensor Water Flow Control Device 4 Remove the Quick Fastener WA Quick Fastener Wate FlowsSensor Procedure Illustration 2 Removing PCB 1 Remove the set screw 1 pc fixing the PCB case and pull the case out 2 Disconnect the Connectors 8 pcs from the electrical PCB 3 If remote controllers are connected disconnect the remote controller cables 3 Removing Surge Protector 1 Disconnect Connectors 2 pcs 2 Remove the Fixing screw 1 pc 3 Remove the Surge Protector Procedure Illustration 4 Removing Igniter Transformer and Transformer 1 Remove the set screw 1 pc installing the Igniter Bracket 2 Disconnect the Igniter Transformer 2P Igniter Transformer SOL 92 relay connector relay connector high voltage cord SS Transformer 2P relay connector and Transformer 3P connector on PCB side Pull out the Igniter Transformer and Transformer with the Igniter Bracket as one unit Remove the set screw 1 pc retaining me the Igniter Transformer and set Transformer screws 2 po retaining the Trans W former Procedure Illustration with washern 3 pcs p A 4 5 Removing Manifold Assembly 1 Remove the set screws fixing the Manifold Assembly M4 x 7 pcs M4 w washer x 3 pcs 6 Rem
64. r with local building officials before installation 8 5 C Union I Union Union Shut off valve Valve 1 Valve 2 E Minimum 3 4 Gas supply Pressure relief valve Valve 3 Valve 4 Minimum 3 4 Minimum 3 4 Cold water supply line Hot water supply line Union Check valve Hot water return Storage tank Pump Check valve Fixtures 18 2 6 VENT PIPE INSTALLATION Vent Terminal Clearances INSIDE CORNER DETAIL 2 2 2 222 77 VENT TERMINAL AIR SUPPLY INLET ES AREA WHERE TERMINAL IS NOT PERMITTED Canadian Installations 1 US Installations A Clearance above grade veranda 12 inches 30cm 12 inches 30cm porch deck or balcony B Clearance to window or door that may 6 inches 15cm for appliances lt 6 inches 15cm for appliances lt be opened 10 000 Btuh 3kW 12 inches 30cm 10 000 Btuh 3kW 9 inches 23cm for for appliances gt 10 000 Btuh 3kW and gt appliances gt 10 000 Btuh 3kW lt lt 100 000 Btuh 30kW 36 inches 50 000 Btuh 15kW 12 inches 30cm 91cm for appliances gt 100 000 Btuh for appliances gt 50 000 Btuh 15kW 30kW C Clearance to window or door that may be opened D Clearance
65. rallel only depending on the distance from MWH 180 to the remote controllers Be sure to peel the protective film off the surface of the remote controller after the installation The surface is covered with a film to prevent scratches during installation A Caution The appliance should always be disconnected from the power supply before REMOTE CONTROLLERS are connected Connect the cord to the terminal block of water heater As remote controller cables are nonpolarized they do not have specific plus and minus Be sure not to touch other electronic components with the screwdriver Replace the front panel of MWH 180 Remote controller connection terminals 5 B Remote controller cable 5 TS Cable clamp d 2 16 MAIN REMOTE CONTROLLER CMR 2250 P N 3748 1 Safety precautions on Main remote controller installation Connect remote controller cable after heater is unplugged S e Never install Main remote controller above a combustion Bad examples appliance like hot plate or a kitchen range The heat will cause electrical component problems or deform Q 4 the exterior Install Main remote controller out of the reach of steam Do Not water drop spray of w
66. rom the Electrode 4 Remove set screws 2 pcs fixing the Damper and pull the Damper out downward Remove Electrode and Flame Rod See 8 Remove set screws 7 pcs fixing the Combustion Chamber Front Panel Procedure Illustration 7 Pull out the Burner forward 10 Removing Heat Exchanger Assembly 1 Remove Fan Motor See 7 2 Remove Burner See 9 3 Remove Pressure Tube 4 Remove set screws 2 pcs fixing the Combustion Chamber Procedure Illustration 5 Disconnect the following connectors Thermal Fuse front 2P connector 1 pc Anti frost Heater 2P relay connector 1 pc Heat Exchanger Thermistor 2P relay connector 1 pc High limit terminal 2 pcs and other connected items 6 Remove set screws 2 pcs retaining the Hot Water Outlet Pipe 7 Remove set screws 2 pcs retaining the Heat Exchanger Assembly 8 Pull the Heat Exchanger Assembly downward to take it out Note If any gaskets or seals are damaged or torn during disassembling they must be replaced 67 Thermal Fuse installation condition 68 3 9 Procedure for Flushing Water Heater If LC is displayed on the remote controllers a few times flush the heat exchanger assembly of the water heater following the steps described below 1 2 3 10 11 12 13 Note Disconnect the power supply to the water heater from the electrical outlet Close both the water inlet valve v
67. s required to have with a pressure relief valve For safe operation of the water heater the relief valve must not be removed from its designated point of installation or plugged POUR VOTRE S CURIT Ne pas entreposer ne utiliser d essence ne d autres vapeurs ou liquides inflammables proximit de cet appareil ou de tout autre appareil Ce chauffe eau d it tre installer avec un soupape de d charge Pour assurer le fonctionnement s curitaire du chauffe eau ne pas retirer ni obturer cette soupape de d charge 20457662 Location of the unit Decide where to install the unit by considering customer s request and venting length limitations Z Warning Ventilation Install the unit where there is enough space for ventilation Use the designated vent terminal option Make sure the pipe termination is kept clear of snow In principle at time of replacing the unit do not reuse vent pipe termination or fitting which has been used over one year However if the components are made of SUS304 or a material having equal or better corrosion resistance they can be reused Check for the holes cracks blockage or gap in connections of the piping Reuse the components only after making sure there is no problem Do not install the unit where flammables such as gasoline benzene and adhesive are handled Installation A Caution Reinforce the wall if necessary as this unit weighs abou
68. s the length of pipe when it is connected with other pipes gx Straight Length Adjustable Length Rain Cap MPI P N 3818 201 5 Model Number MPI P N L Model MPI P N L FFTP300 3801 11 8 300mm FFTA200 3804 6 9 9 1 175 230mm FFTP600 3802 23 6 600mm FFTA260 3805 8 5 12 2 215 310mm FFTP900 3803 35 4 900mm 90 elbow MPI P N 3807 45 elbow MPI P N 3806 Male male Adapter MPI P N 3808 125 50 5153 Air Intake Pipe MPI P N 3817 127 0 15 50 140 50 Support Strap MPI P N 3819 e P L Termination Refer to TABLE 2 Straight Termination Refer to TABLE 2 FFT 7U L FFT 7U g 305 or 365 L2 2120 11 Refer to TABLE 2 L1 Refer to TABLE 2 Roof Flashing adapter Roof Flashing base Roof Flashing cap MPI P N 3820 MPI P N 3820 278 d Model Number MPI P N L1 L2 L3 FFTRFAA 3821 17 3 440 8 1 205mm 25 3 643mm FFTRFAB 3822 17 3 440mm 14 5 369mm 2
69. system And calculate the required number and combination of items see the dimensions of items in Fig 1 2 Check wall thickness where the vent system passes through and select suitable horizontal termination according to TABLE 2 Cut the opening for the sleeve with the diameter in TABLE 2 Cover the flue outlet to avoid debris from entering the appliance 3 Adjust the length of the sleeve so that the end of the sleeve protrudes about 0 2 5mm from the wall Then fasten the sleeve with the screw provided Remember a stamped letter on the sleeve 4 When the opening is too large twist the packing provided around the end of the sleeve after peeling off backing paper from the packing 5 Insert the sleeve to the wall and fasten with 4 screws provided Use plugs provided if needed Ensure the UP label on sleeve plate is at the top If it isn t easy to insert the sleeve because the packing doesn t fit the wall press down the packing during insertion 6 Seal between the end of the sleeve and wall and between the end of inner sleeve pipe and outer pipe T Adjust the length of the termination by fastening it at the stamped number same as that in 2 8 Fasten the condensation prevention plate with the screw provided if this plate is needed 9 Insert the termination into the sleeve from inside wall so that 4 studs on sleeve plate are inserted into each 4 holes on termination plate and fasten the termination to the sleeve with the 4 nuts
70. t 23 7m Refer to Vent Pipe Installation for maximum total length of vent pipe 485 Vertical installation See Fig 7 1 Check the location of appliance and the path for the vent system And calculate the required number and combination of items see the dimensions of items in Fig 1 of the vent system Check the pitch of roof where the vent system passes through 2 Cut 5 3 135mm diameter openings or suitable oval for pitched roof in each floor ceiling and the roof where the vent system passes through 3 Connect drain tee to the appliance flue outlet 4 Install the vent system from the appliance to roof by using straight lengths adjustable lengths and elbows Make sure that a continuously UPWARD slope of no less than 2 1 4 in ft is maintained in the horizontal portion Refer to Fig 7 5 Support the vent system every 5 1 5m with support straps 6 Once the vent system reaches under the roof set the parts of roof flashing The parts required and the connecting order of them depend on the pitch of the roof shown in Fig 8 7 Fasten the bottom part of roof flashing cap or adapter to roof with screws nails or so on If the 4 holes at the 4 corners of the part is larger than screws or nails insert the 4 washers provided with the part 8 If roof flashing adapter is used connect roof flashing base to roof flashing adapter with the bolts provided with the part 9 Connect the pipe of roof flashing cap
71. t 43lbs Make sure that there is adequate floor drainage to prevent flooding the floor 1 Twist 1 screw for wall hanging into the wall leaving about 1 8 4mm length to hook on 2 Hook the center hole of the wall hanging bracket onto the screw and securely fix the unit with 4 screws 3 Adjust the clearance between the unit and the wall by loosening 8 hexagon head screws upper and lower and then securely fix the unit so it is level About 1 8 for wall hanging Wall hanging bracket Screw for wall hanging Hexagon head screw Screw for wall hanging Screw for wall hanging 24 11 32 618mm 20 for wall hanging Wall hanging bracket s43 Check if adjacent wall or ceiling is fire resistant and allows safe distance for fire prevention This water heater is suitable for residential water portable heating only Do not use this water heater for space heating combination space heating domestic water heating or commercial water heating applications MWH 180 is not suitable for use in pool or spa applications Maintain proper space around the unit for proper servicing and operation Minimum clearances from combustible materials are listed below 12 30 5cm Secure enough space so that the inspection and repairs can be done easily e Secure space not only in front but also under the unit Install the vent terminal in a place where sufficient ventilation
72. th dip switch No 7 amp No 8 ON is factory setting this is suitable for over 30 in D value Depending upon the vent length dip switch No 7 amp No 8 on PCB may need to be adjusted to compensate fan speed Read the following instructions to determine which position this switch should be placed in n case D value is 30 and above leave dip switch No 7 amp No 8 ON In case D value is 21 and above but less than 30 set dip switch No 7 OFF and leave dip switch No 8 ON In case D value is 15 and above but less than 21 leave dip switch No 7 ON and set dip switch No 8 OFF In case D value is less than 15 set both dip switch No 7 amp No 8 OFF Factory setting No 7 amp No 8 ON Example 2 lt Dip switch on PCB Rain 9 Air intake pipe m ES EZ J tasting No 1 dip switch is ON with Natural Gas OFF with Propane Gas 2210 E EI N 90 elbow Br Example 1 Hi L termination E Urt i upwart 2 Reducer lt Dip switch on PCB gt lt Dip switch on PCB gt tJ Draintee E In case of L termination and reducer In case of 6 straight vents and 2 90 elbows Refer to Fig 4 1 Refer to Fig 7 right drawing
73. tion Specification Various Combination Setting COMBUSTION SPECIFICATIONS Gas type LPG Gas consumption Btu h Nozzle diameter of manifold mm Minimum Maximum reference 180 000 Rich Top side 01 00 x19 pcs Lean bottom side 01 20 x18 pcs Gas type dip c o switch DipSw No 1 OFF Natural Gas 180 000 01 35 x19 pcs 01 65 x18 pcs DipSw No 1 ON Damper o o o o o o JUUDUDUUUDUUUDUUUUU LPG Initial setting of Dip Switch No 1 Factory setting for shipping Gas type engraved mark Sm scm Iri Io gt _ o o o o o o o o e DI o o LI Ln x o Lo JUDUUDDUUDUUUDO NAT LPG Natural Gas Gas type engraved mark Switching gas type Dip SW settingf t 5 Tr gas type Applicable gas type Moi Setting change be done with power ON or OFF OFF ON LPG Natural Gas 55 Comfort Dip Switch Setting Pattern Various Combination Setting Dip Switch The illustrated switch settings show the factory settings for the LPG as the gas type To switch gas type LPG or natural gas 340 Exhaust blockage detection To change hot water temperature without remote controller PES To fix to the minimum capacity level
74. to permanently closed i 7 window E Clearance to unventilated soffit F Clearance to outside corner G Clearance to inside corner 5 E H Clearance to each side of center line 3 feet 91cm within a height 15 feet 5 extended above meter regulator above the meter regulator assembly assembly Iz Clearance to service regulator vent 3 feet 1 83m S outlet J Clearance to nonmechanical air supply 6 inches 15cm for appliances 10 000 6 inches 15cm for appliances lt inlet to building or the combustion air Btuh 3kW 12 inches 30cm for 10 000 Btuh 3kW 9 inches 23cm for inlet to any other appliance appliances gt 10 000 Btuh 3kW and lt appliances gt 10 000 Btuh 3kW lt 100 000 Btuh 30kW 36 inches 91cm 50 000 Btuh 15kW 12 inches 30cm for appliances gt 100 000 Btuh 30kW for appliances gt 50 000 Btuh 15kW K Clearance to a mechanical air supply 6 feet 1 83m 3 feet 91cm above if within 10 feet inlet 3m horizontally L Clearance above paved sidewalk or Tfeet 2 13m paved driveway located on public property M Clearance under veranda porch deck 12 inches 30cm 4 5 or balcony 1 In accordance with the current CSA B149 1 Natural Gas and Propane Installation Code 2 n accordance with the current ANSI 2223 1 NFPA 54 National Fuel Gas Code vent shall not terminate directly above a sidewalk or paved driveway that is located brtween two single family dwellings and serves both dw
75. tural Gas Refer to page 21 Installation and Operating instruction for setting of exhaust mode of vent pipe 56 3 7 Remote Controllers Special Features How to adjust the brightness of the remote controller display The brightness of each of the main remote controller CMR 2250 bathroom remote control ler YST 2250 can be adjusted 1 Turn off the operation switch 2 Press and hold the adjustment switch v for approximately five seconds 4 e CAUTION perat heck the watar tom bain te taeng a sho A CAUTION austro e lembar d shower ran O prevent scar A CAUTION Sek Press the operation switch to turn it off The current settings appear 3 Press the adjustment switch The brightness can be adjusted to any of seven levels The higher the number the brighter the display If no data are changed within a period mo of approximately 20 seconds the EECH current settings remain active The settings can also be determined by pressing the operation switch Note The settings for the main remote controller and bath remote controller can be adjusted individually The brightness of the remote controller display is set to level 4 by default at the time of shipping 57 How to set energy saving mode The main remote controller CMR 2250 bathroom remote controller YST 2250 can be set energy saving mode if no operation is carried out within a specified p
76. uble sure that the unit runs in accordance with the check items of trial run standard after it is installed refer to Testing operation When installation of water heater and vent pipes be sure to wear protective equipment to prevent injuries and burns Before installation Verification of the unit Z Warning Make sure the unit to be installed suits the intended use and application Do not use any gas other than specified on the sticker Do not operate with any power source voltage frequency other than specified on the sticker N DIRECT VENT AUTOMATIC INSTANTANEOUS GAS WATER HEATER ONLY FOR USE WITH N GS FOR INDOOR INSTALLATION NATURAL GAS PROPANE GAS Ka Lo CHAUFFE EAU INSTANTAN AUTOMATIQUE VENT DIRECT POUR ANSI Z21 10 3 2004 INSTALLATION INT RIEUR NAT GPL CSA 4 32004 MODEL MWH 180 NATURAL GAS Gaz Naturel PROPANE GAS GPL REFER TO THE LOCAL GAS AUTHORITY FOR CONFIRMATION ON THE GAS TYPE IF IN DOUBT Kee 180 000 180 000 DO NOT REMOVE THIS LABEL UNTIL THE APPLIANCE HAS BEEN INSTALLED AND TESTED Debit calorifique max Si vous ne savez pas le type de gaz contactez le fournisseur de gaz ou les autorit locaux Enlevez pas cette etiquette jusqu l appareil a t installer et verifie 20457650 MIN INPUT 20 000 Btu h 20 000 Btu h Debit calorifique min GAS PRESSURE INLET MAX 10 5 inches W C 14 0 inches W C Pression de gaz entr
77. um capacity level By turning the Minimum gas adjusting control knob under the Dip Switch set the gas amount for the minimum capacity level Then set the Dip Switch No 5 to OFF With the combustion going on set Dip Switch No 6 to ON position to set the combustion at a maximum capacity level At this time a substantial amount of water should be supplied To prevent water from boiling as the maximum capacity is forced if the water temperature is high the heated water may reach boiling point Set the gas amount for the maximum capacity level by turning the Maximum gas adjusting control knob under the Minimum gas adjusting control knob Then set Dip Switch No 6 to OFF Shut the hot water supply valve Open the valve again for combustion Repeat the steps 2 to 4 to check that the settings are correct Shut the hot water supply valve to stop combustion Disconnect the rubber hose of the manometer from the pressure check hole Seal the hole by installing and tight ening the screw After tightening the screw make sure there is no gas leak 9 UUUUUUUU Dip Switch 7 Min Max 16 LEE ar uS Maximum gas adjusting control knob ot 1 T ues e a Minimum gas adjusting control knob e SC Threaded Hose Fitting Rubber Tubing 54 Nozzle pressure 3 6 Combus

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