A.O. Smith 240 T-H3J Service Manual
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A.O. Smith 240 T-H3J Service Manual

A.O. Smith 240 T-H3J Service Manual

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240 (T-H3J), 340 (T-H3S)
and 540 (T-H3) Models
On-Demand Water Heater
Service Manual
A.O. Smith Water Products
Company
500 Tennessee Waltz Parkway
Ashland City, TN 37015
Toll Free: 1-877-737-2840
TRGSM00713

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Summary of Contents for A.O. Smith 240 T-H3J

  • Page 1 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) Models On-Demand Water Heater Service Manual A.O. Smith Water Products Company 500 Tennessee Waltz Parkway Ashland City, TN 37015 Toll Free: 1-877-737-2840 TRGSM00713...
  • Page 2 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 Table of Contents 6. Wiring diagram......................... 13. Components diagrams...................... 14. Parts list..........................15. Revisions........................... Page...

  • Page 3: Specifications

    CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 1. Specifications Model Indoor Outdoor Indoor Outdoor Indoor Outdoor (T-H3J-DV) (T-H3J-OS) (T-H3S-DV) (T-H3S-OS) (T-H3-DV) (T-H3-OS) inch Dimensions Weight lbs. (kg) 58 (26.3) 58 (26.2) 58 (26.3) 58 (26.2) 58 (26.8) 58 (26.9) 160,000...

  • Page 4: Exterior View

    CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 2. Exterior view Direct Vnet Indoor models Side view Front view 17-3/4" (450 mm) 7" (180 mm) 4" (101 mm) 11-1/4" (285 mm) ∅ ∅ 4" (102 mm) 4"...
  • Page 5 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 Outdoor models Front view Side view 17-3/4" (450 mm) 7" (180 mm) 11-1/4" (285 mm) 4-1/2" (114 mm) 11" (281 mm) 10-3/4" (272 mm) 1/2" (13 mm) HOT 4-3/4"...

  • Page 6: Interior View

    CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 3. Interior view 240 Indoor (T-H3J-DV) 340 Indoor (T-H3S-DV) AC120V Page...
  • Page 7 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 240 Outdoor (T-H3J-OS) 340 Outdoor (T-H3S-OS) AC120V Page...
  • Page 8 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 540 Indoor (T-H3-DV) AC120V Page...
  • Page 9 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 540 Outdoor (T-H3-OS) AC120V Page...
  • Page 10 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 4. List of main components in the interior view Items# in Part # Description components 240, 340 and T-H3J, T-H3S and diagram 540 models T-H3 models models Case assembly Outdoor models...
  • Page 11 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 Items# in Part # Description components 240, 340 and T-H3J, T-H3S and diagram 540 models T-H3 models 319143-443 models Fan motor Outdoor 319143-043 models Freeze 319143-496 models protection Outdoor 319143-497...
  • Page 12 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 Items# in Part # Description components 240, 340 and T-H3J, T-H3S and diagram 540 models T-H3 models Gas inlet port 319143-525 319143-527 models (T-H3 models) (540 models) 319143-526 chamber #401...

  • Page 13: Schematic Diagram

    CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 5. Schematic diagram Direct Vent Indoor models only Hi-limit switch for exhaust Intake port Exhaust Exhaust thermistor Secondary heat exchanger Drain pan Primary heat exchanger Hi-limit switch O.H.C.F 540 (T-H3) models only Heat exchanger thermistor...

  • Page 14: Wiring Diagram

    CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 6. Wiring diagram 240 (T-H3J) models / 340 (T-H3S) models W: WHITE BK: BLACK LB: LIGHT BLUE R: RED BL: BLUE Y: YELLOW G: GREEN O: ORANGE BR: BROWN P: PURPLE 240/340 Outdoor...
  • Page 15 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 540 (T-H3) models W: WHITE BK: BLACK LB: LIGHT BLUE R: RED BL: BLUE Y: YELLOW BR: BROWN G: GREEN O: ORANGE P: PURPLE 540 Outdoor 540 Direct Vent Indoor Heater Heater Heater...
  • Page 16 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 7. Wiring diagram check points for diagnosis Check- Part and Description Color of wires Normal range point 120V Power supply White – Black 108 to 132 VAC A1, A2 120V Power supply Black - White...
  • Page 17 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 Check- Part and Description Color of wires Normal range point Remote controller White – Black 11 to 25 VDC Red - Blue 132 to 192 VDC Fan motor Yellow - Blue 13 to 17 VDC Orange - Blue...
  • Page 18 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 8. (A) Resistance values of the temperature thermistors Resisitance values at different temperatures °F Temperature °C Resistance 23.76 19.08 15.43 12.56 10.28 8.47 7.02 5.85 4.90 4.12 °F Temperature °C...
  • Page 19 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 8. (B) Resistance values of the temperature exhaust thermistor Resisitance values at different temperatures °F Temperature °C Resistance 30.04 24.12 19.50 15.87 13.00 10.71 8.87 7.39 6.19 5.21 °F Temperature...

  • Page 20: Operational Flow Chart

    CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 9. Operational flow chart Power supply ON Remove cause Pre-check NORMAL? Above 0.5GPM? BV modulates   Flow&temp valve FM speed (Below 1,000rpm?) Faucet closes   FM speed (Above 1,000rpm?) B V ;...

  • Page 21: Table Of Contents

    CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 10. Component specifications 10-5. Flame rod........................10-6. AFR rod......................... 10-9. Flow adjustment valve....................10-10. Flow sensor......................... 10-11. Bypass valve......................... 10-12. Thermistors........................10-14. Hi-limit switch......................10-16. 10-18. Computer board......................Page...
  • Page 22 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 10-1. Burners Part # Unit Part# #101 Function combustion reaction. Failure events 3. Cracks on the burners. Effects on the water heater if burners fails Error codes when the burners fails Diagnostic Color / Number of wires...
  • Page 23 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 10-2. Gas manifold Included Part # Unit Part# in #102 Function operation. Failure events Effects on the water heater if the manifold fails measures. Error codes when the manifold fails Diagnostic Color / Number of wires...

  • Page 24: Fan Motor

    CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 10-3. Fan motor Part # Unit Part# #103 Function during operation. Failure events Effects on the water heater 2. Failure to ignite or abnormal ignition. if fan motor fails Error codes when the fan motor fails shortage)

  • Page 25: Gas Valve Assembly

    CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 10-4. Gas valve assembly Included in Part# Unit Part# #102 gas valves) Function Failure events Effects on the water heater if valves fails Error codes when the fvalves fails motor initiates.

  • Page 26: Flame Rod

    CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 10-5. Flame rod Part # Unit Part# #108 Function Failure events will display. Effects on the water heater if flame rod fails code will display. Error codes when the flame rod fails Diagnostic Orange - Flame rod...

  • Page 27: Afr Rod

    CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 10-6. AFR rod Part # Unit Part# #108 Function Failure events will display. Effects on the water heater code will display. if AFR rod fails Error codes when the AFR rod fails Diagnostic Yellow - AFR rod...

  • Page 28: Heat Exchanger

    CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 10-7. Heat exchanger Unit Part# *See the table below #401 Part# Function Failure events Effects on the water heater if the heat exchanger fails 3. Abnormal sounds during combustion . Error codes when the heat exchanger fails Diagnostic...
  • Page 29 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 10-7. Heat exchanger and 540 (T-H3) models have the "P77" mark as shown below. 240, 340 Outdoor (T-H3J, T-H3S-OS) 11" (282 mm) 11" (282 mm) 540 Outdoor (T-H3-OS) 11"...

  • Page 30: Secondary Heat Exchanger

    CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 10-8. Secondary heat exchanger Unit Part# *See the table below #401 Part# Function Failure events Effects on the water heater if the secondary heat 3. Abnormal sounds during combustion exchanger fails Error codes when the secondary heat...
  • Page 31 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 10-8. Secondary heat exchanger and 540 (T-H3) models have the "P77" mark as shown below. 240, 340 Outdoor (T-H3J, T-H3S-OS) 11" (282 mm) 11" (282 mm) 540 Outdoor (T-H3-OS) 11"...

  • Page 32: Flow Adjustment Valve

    CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 10-9. Flow adjustment valve Part# Unit Part# #402 Function Failure events Effects on the water heater components. if flow adjustment valve fails Error codes when flow 651 (only within Easy-Link systems) adjustment valve fails Diagnostic Color / Number of wires...

  • Page 33: Flow Sensor

    CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 10-10. Flow sensor Part# Unit Part# #402 Function magnetic pick-up. Failure events Effects on the water heater operation) if flow sensor fails Error codes when flow 441 (only within Easy-Link systems) sensor fails impeller.

  • Page 34: Bypass Valve

    CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 10-11. Bypass valve (540 (T-H3) models only) Part # Unit Part# #403 540 (T-H3) models only inlet in order to modulate and control the water heater’s outlet water temperature.
  • Page 35 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 10-12. Thermistors #407 (Inlet) Unit Part # *See the table below #408 (Outlet ) Part# #411 (Heat exchanger) Function Failure events Effects on the water heater if thermistor fails Error codes when 311 (Outlet) 321 (Inlet)

  • Page 36: Thermistors

    CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 10-12. Thermistors 240 (T-H3J) and 340 (T-H3S) models (Outlet thermistor) 113 540 (T-H3) models Black Blue (Outlet thermistor) 113 Black thermistor) 12 Resistance values of thermistors as a function of temperature 25.00 20.00 15.00...

  • Page 37: Exhaust Thermistor

    CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 10-13. Exhaust thermistor Part# Unit Part# #718 Function Failure events Effects on the water heater if exhaust thermistor fails Error codes when exhaust 341 (Direct Vent Indoor models only) thermistor fails impeller.

  • Page 38: Hi-Limit Switch

    CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 10-14. Hi-limit switch 240 (T-H3J) /340 (T-H3S) models Part# Unit Part# #412 540 (T-H3) models Function valves are severed, shutting down the water heater instantly. The "111" or "121"...
  • Page 39 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 10-14. Hi-limit switch After the hi-limit switch was working, refer to the following procedure. 1. T 3. Press the button on the hi-limit switch. Page...
  • Page 40 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 10-15. Hi-limit switch for exhaust Part# Unit Part# #472 Function Failure events Effects on the water heater if hi-limit switch for exhaust fails process, and the "941" error code will display. Error codes when hi-limit 941 (Direct Vent Indoor models only) switch for exhaust fails...
  • Page 41 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 10-16. Overheat cut off fuse Part# Unit Part# #413 Function communication between the computer board and gas valves will sever, shutting down the water heater instantly. The "111" or "121" error code will display.

  • Page 42: Freeze Protection Heaters

    CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 10-17. Freeze protection heaters #414 #415 Part# Unit Part# #417 #464 Function devices in the water heater. Failure events heat up. Ceramic heaters do not activate, allowing water contained in the heat Effects on the water heater if heater fails Error codes when heater...
  • Page 43 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 10-18. Computer board 240 (T-H3J) models Part# 340 (T-H3S) models Unit Part# #701 540 (T-H3) models Function Failure events Effects on the water heater if the computer board fails Error codes when the computer board fails Diagnostic...
  • Page 44 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 10-19. Igniter Part # Unit Part# #711 Function Failure events 2. Makes attempts to ignite at all times. Effects on the water heater if the igniter fails wears down.

  • Page 45: Freeze Protection Thermostat

    CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 10-20. Freeze protection thermostat Part# Unit Part# #713 Temperature detecting device which prevents the pipes within the water Function temperature). Failure events Effects on the water heater components inside the water heater.

  • Page 46: Surge Box

    CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 10-21. Surge box Part# Unit Part# #121 (EK163) lightning. Function A is activated by voltage higher than 220 V, the other one is activated by voltage higher than 680 V. Failure events unit.
  • Page 47 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 11. Fault Analysis & Specifications Remarks: Check Natural of Fault Diagnosis point 1 Check the power supply (Refer to section 12-2) [2] Check the power supply line to the water heater Normal: 120 VAC between (white-black) Normal: 120 VAC between (white-black) controller, even when...
  • Page 48 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 Check Natural of Fault Diagnosis point running. recirculation line has enough check valves. cold and stays cold operation has stopped 2 Check how long the water heater has been installed and in use. 3 Check the installation place.
  • Page 49 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 Check Natural of Fault Diagnosis point Normal: 7.0 to 16 VDC between (red-black) water temperature Error Code Malfunction description Cancellation method Diagnosis Check point Error Code Malfunction description Cancellation method Diagnosis Check point...
  • Page 50 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 Error Code Malfunction description Cancellation method Diagnosis Check point 1 Check gas supply and inlet gas pressure (Refer to section 1) 2 Check the igniter (Refer to section 10-19) observed weak spark.
  • Page 51 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 Error Code Malfunction description Cancellation method Diagnosis Check point 1 Check gas supply and pressure (Refer to section 1) Normal: 93 to 120 VDC between COM (blue) & #3 (light blue) (during operation) Normal: 93 to 120 VDC between COM (blue) &...
  • Page 52 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 Error Code Malfunction description Cancellation method Diagnosis Check point (Refer to section 10-12) thermistor. Error Code Malfunction description Cancellation method (Only 540 (T-H3) models) Diagnosis Check point (Refer to section 10-12) thermistor.
  • Page 53 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 Error Code Malfunction description Cancellation method Diagnosis Check point (Refer to section 10-10) impeller. Error Code Malfunction description Cancellation method (MV) Diagnosis Check point (Refer to section 10-4 & 10-18) Normal: 93 to 120 VDC between COM (blue) &...
  • Page 54 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 Error Code Malfunction description Cancellation method Diagnosis Check point (Refer to section 10-3 & 10-18) dust buildup (causing electrical shortage) Normal: 132 to 192 VDC between red & blue (during operation) Normal: 13 to 17 VDC between yellow &...
  • Page 55 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 Error Code Malfunction description Cancellation method (701 error code) operation. (711 error code) Valve(VG Diagnosis Check point (Refer to section 10-4 & 10-18) burn marks on the computer board. Error Code Malfunction description Cancellation method...
  • Page 56 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 Error Code Malfunction description Cancellation method Miscommunication between water heater and When computer detects proper connections between the models only) water heater and the temperature controller, "751" error code will cease to display.
  • Page 57 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 Error Code Malfunction description Cancellation method Diagnosis Check point 1 Check how long the water heater has been installed and in use. 2 Check the vent length. the water heater has been installed in laundry room.

  • Page 58: Controls And Settings

    CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 12. Controls and settings 12-1. Diagnosis using the temperature controller and temperature remote controller..59 12-2...............63 12-3. Displaying error code history, Clearing error code history memory, and Display 12-10.

  • Page 59: Temperature Controller

    CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 12-1. Diagnosis using the temperature controller and temperature remote controller TEMPERATURE CONTROLLER and TEMPERATU REREMOTE CONTROLLER Temperature controller Temperature remote controller Display for Temperature "INFO" Button hot water temperature will be displayed.
  • Page 60 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 1. Press and hold the "HOT" and "COLD" "HOT" or the "COLD" heaters can be linked together. “INFO” “HOT” or “COLD” (Fig.3 shows mode #6 is being selected.) table on p.61-62 for the proper mode #.
  • Page 61 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 Mode # Whole multi-unit system information (#0) Unit information (#1 to #4) 0 to 999 (GPM) Total operation time 0 to 999 0 to 999 ( the multi-system (×...
  • Page 62 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 Mode # Whole multi-unit system information (#0) Unit information (#1 to #4) Bypass valve position** closed position = 0 cold water** 0 to 999 (mA) proportional valve combustion stages (The water heater combustion.)
  • Page 63 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 12-2. Verifying functionality of computer board A. How to check if the computer board works properly Check the power ON-OFF switch AC120V Power ON-OFF switch Temperature remote controller Temperature controller either the temperature controller or the temperature remote controller.
  • Page 64 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 12-3. Displaying error code history, Clearing error code history memory and Display patterns for error codes Displaying error code history Temperature controller Clearing error code history memory Temperature remote controller OFF during stand-by.
  • Page 65 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 12-4. Clearing the “101” and “991” error code “Increase” and “Decrease” 240 (T-H3J) / 340 (T-H3S) models computer board Green LED 540 (T-H3) models Increase computer board Decrease Green LED Increase...

  • Page 66: Afr Rod Function

    CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 12-5. AFR rod function 240 (T-H3J) models Installation type Direct vent Outdoor Gas type Propane Natural gas Propane Natural gas 12.0 to 35.0 23.6 to 58.0 6.0 to 41.0 17.1 to 55.0 Combustion mode...

  • Page 67: Dipswitch Settings

    CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 12-6. DIPswitch settings 240 (T-H3J) and 340 (T-H3S) models Computer board 240 (T-H3J) / 340 (T-H3S) models Functions ON position OFF position Gas type Propane Disable Natural gas Disable DEFAULT (FM speed is increased automatically.
  • Page 68 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 computer board with the 540 Outdoor 540 (T-H3) models computer board (upper and lower bank) on the computer board. 540 (T-H3) models The upper bank of DIPswitches Functions ON position OFF position...
  • Page 69 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 The lower bank of DIPswitches Functions ON position OFF position Parent Child (FM speed is increased automatically. See section 12-13) ON 1 2 3 4 5 6 No.2: OFF NO.3: OFF No.4: OFF...
  • Page 70 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 12-7. Assigning unit numbers in the Easy-link system Only 540 (T-H3) models 540 (T-H3) models computer board A. How to display the unit number Press the “Increase” child unit.
  • Page 71 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 12-8. (A) ON/OFF conditions: Overview ON / OFF Conditions Conditions needed to turn ON. °C)) the set temperature. Conditions needed to turn OFF. °C)) Page...
  • Page 72 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 12-8. (B) ON/OFF conditions: BTU requirements A. Calculating the ON/OFF conditions of the water heater – T "Condition needed to turn the water heater OFF" – T ) ×...
  • Page 73 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 12-9. Multi-unit system ON/OFF conditions Only 540 (T-H3) models FLOW RATE and the SET TEMPERATURE. Flow rate required to activate additional 540 (T-H3) models = A × n Where n and A is dependent on the set temperature.

  • Page 74: Operation Time For Unit Rotation

    CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 12-10. Operation time for unit rotation Only 540 (T-H3) models A rotation occurs when: Unit No.1 Unit No.2 Unit No.3 Unit No.4 Priorty unit Next step Priorty unit Next step Priorty unit Page...
  • Page 75 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 12-11. Individual unit operation in easy-link system while parent unit is under abnormal conditions (Individual operation mode) Only 540 (T-H3) models link system. happened between child unit and parent unit. Page...
  • Page 76 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 12-12. Easy-Link connections with previous models A. DIPswitch setting on the computer board of the 540 (T-H3) If a Easy-link system contains a 520 (T-H2), change DIPswitch No.6 on the lower bank all of the 540 (T-H3) computer board to the “ON”...
  • Page 77 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 C-1. Temperature settings °F to 175 °F °F as shown below). Although 540 (T-H3) can be connected with the temperasture temperature remote controller 9008172005 (TM-RE40), it cannot be connected with the temperature remote controller 9007603005 (TM-RE30).
  • Page 78 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 HIGH TEMPERATURE MODE The following procedure apply only to case 1 of B. (Refer to P.76) CAUTION Operation Screen Turn on the 120 VAC power supply to the unit. Press the "ON/OFF"...
  • Page 79 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 12-13. High-Altitude Region Support Functions 240 (T-H3J) and 340 (T-H3S) models Computer board operation levels, with the appropriate level being set up by the installer until the abnormal sound problem is solved. (No.3 , No.4 and No.5) on the computer board.
  • Page 80 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 DIPswitch settings Output Fan motor Level Elevation reduction speed change No.3 No.4 No.5 Consult our Technical Services Department DIPswitch settings Output Fan motor Level Elevation reduction speed change No.3 No.4 No.5...
  • Page 81 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 540 (T-H3) models computer board See the table below. DIPswitch settings Output Fan motor Level Elevation reduction speed change No.2 No.3 No.4 DIPswitch settings Output Fan motor Level Elevation reduction...
  • Page 82 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 DIPswitch settings Output Fan motor Level Elevation reduction speed change No.2 No.3 No.4 Consult our Technical Services Department DIPswitch settings Output Fan motor Level Elevation reduction speed change No.2 No.3 No.4...

  • Page 83: Adjusting Manifold Gas Pressure

    CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 12-14. Adjusting manifold gas pressure during operation, which can cause a health hazard, damage the water heater, WARNING recommended unless there are very strong reasons to do so (e.g. high elevation Adjusting maximum manifold pressure secure enough to prevent gas leak.
  • Page 84 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 Fig. 2 Fig. 1 Tube Computer board To manometer Fig. 3 Decrease button Decrease button 240 (T-H3J) / 340 (T-H3S) models 540 (T-H3) models computer board computer board Page...

  • Page 85: Manually Adjusting The Fan Motor Speed

    CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 12-15. Manually adjusting the fan motor speed Only 540 (T-H3)models While the FM+ DIPswitch will automatically increase the fan speed by 6%, the fan motor speed on the 540 (T-H3) models can also be manually adjusted.

  • Page 86: Freeze Protection System

    CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 12-16. Freeze protection system Automatic firing system 540 Direct Vent Indoor (T-H3-DV) minutes have elapsed. < 32 °F To sum it up in a chart: 5 minutes have elapsed Will automatic firing Case Exhaust thermistor temperature...
  • Page 87 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 Ceramic heating blocks below 36.5 °F. above 46.4 °F. Page...
  • Page 88 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 12-17. Draining and cleaning the inlet water filter Drain plug 5. Open all hot water taps in the house. When the all valve Drain plug Water valve (Small) Unscrew the drain plugs to 9.

  • Page 89: Components Diagrams

    CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 13. Components diagram Case assembly Outdoor models Indoor models Temperature controller Temperature Indoor models remote controller Page...
  • Page 90 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 Computer board assembly 240 (T-H3J) and 540 (T-H3) models 340 (T-H3S) models 707 722 Surge box assembly Page...
  • Page 91 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 Burner assembly Burner assembly 109 111 Assembly Page...
  • Page 92 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 Water Way assembly 540 (T-H3) models Bypass section Water outlet section (540 (T-H3) models) Water inlet section Page...

  • Page 93: Parts List

    CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 14. Parts list Common parts for Part # other models T-H3J, T-H3S Item # Description 240, 340 T-H3J, T-H3S 240, 340 and and T-H3 and 540 and T-H3 540 models models models...
  • Page 94 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 Common parts for Part # other models T-H3J, T-H3S Item # Description 240, 340 T-H3J, T-H3S 240, 340 and and T-H3 and 540 and T-H3 540 models models models models...
  • Page 95 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 Common parts for Part # other models T-H3J, Item # Description 240, 340 T-H3J, T-H3S 240, 340 and T-H3S and and 540 and T-H3 540 models T-H3models models models 910,...
  • Page 96 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 Common parts for Part # other models T-H3J, T-H3S Item # Description 240, 340 T-H3J, T-H3S 240, 340 and and T-H3 and 540 and T-H3 540 models models models models...
  • Page 97 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 Common parts for Part # other models T-H3J, T-H3S Item # Description 240, 340 T-H3J, T-H3S 240, 340 and and T-H3 and 540 and T-H3 540 models models models models...
  • Page 98 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 Common parts for Part # other models T-H3J, T-H3S Item # Description 240, 340 T-H3J, T-H3S 240, 340 and and T-H3 and 540 and T-H3 540 models models models models...
  • Page 99 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 Common parts for Part # other models T-H3J, T-H3S Item # Description 240, 340 T-H3J, T-H3S 240, 340 and and T-H3 and 540 and T-H3 540 models models models models...
  • Page 100 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 Common parts for Part # other models T-H3J, T-H3S Item # Description 240, 340 T-H3J, T-H3S 240, 340 and and T-H3 and 540 and T-H3 540 models models models models...
  • Page 101 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 Common parts for Part # other models T-H3J, T-H3S Item # Description 240, 340 T-H3J, T-H3S 240, 340 and and T-H3 and 540 and T-H3 540 models models models models...
  • Page 102 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 Common parts for Part # other models T-H3J, T-H3S Item # Description 240, 340 T-H3J, T-H3S 240, 340 and and T-H3 and 540 and T-H3 540 models models models models...
  • Page 103 CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 Common parts for Part # other models T-H3J, T-H3S Item # Description 240, 340 T-H3J, T-H3S 240, 340 and and T-H3 and 540 and T-H3 540 models models models models...

  • Page 104: Revisions

    CONFIDENTIAL 240 (T-H3J), 340 (T-H3S) and 540 (T-H3) models Service Manial Ver. 1.00 15. Revisions Version Date 1.00 First edition Page...

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