Takagi 540P Indoor Installation Manual And Owner's Manual
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Takagi 540P Indoor Installation Manual And Owner's Manual

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On-Demand Water Heater
Installation Manual and Owner's Guide
ANSI Z21.10.3 • CSA 4.3
Models
• 540P Indoor • 540P O utdoor
Gas Tankless Water Heater
Suitable for combination potable water heating
and space heating. Please refer to local codes for
space-heating compliance.
FEATURING
•
INTEGRATED RECIRCULATION PUMP
•
ENDLESS HOT WATER
•
ON-DEMAND USAGE
•
COMPACT, SPACE SAVING
•
ENERGY CONSERVATION
•
COMPUTERIZED SAFETY
•
NO PILOT LIGHT
•
Complies with SCAQMD Rule
1146.2 for natural gas NOx
emissions of 14 ng/J or 20 ppm.
•
EASY-LINK SYSTEM
Keep this manual near the water heater for future reference whenever maintenance, adjustment or service is required.
R
D
R
TM
If the information in these
instructions is not followed
exactly, a fire or explosion may
result causing property damage,
WARNING
personal injury or death.
- Do not store or use gasoline or other
flammable vapors and liquids in the vicinity
of this or any other appliance.
- WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electric switch, do not
use any phone in your building.
• Immediately call your gas supplier from
a neighbor's phone. Follow the gas
supplier's instructions.
• If you cannot reach your gas supplier, call
the fire department.
- Installation and service must be performed
by a qualified installer, service agency or the
gas supplier.
If you have any questions,
please call or write to
USA: 500 Tennessee Waltz Parkway
Ashland City, TN 37015
Toll Free: 1-877-737-2840
CANADA: 599 Hill Street West
Fergus, ON N1M 2X1
1-888-479-8324

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Summary of Contents for Takagi 540P Indoor

  • Page 1 On-Demand Water Heater Installation Manual and Owner’s Guide ANSI Z21.10.3 • CSA 4.3 If the information in these Models instructions is not followed exactly, a fire or explosion may • 540P Indoor • 540P O utdoor result causing property damage, WARNING personal injury or death.

  • Page 2: Table Of Contents

    Contents CONTENTS APPLICATIONS ..........42 Combination potable water heating Installation Manual and space heating ........42 Recirculation ..........42 SPECIFICATIONS ..........4 Dual-purpose hot water heating ....43 INTRODUCTION ..........5 INITIAL OPERATION ........44 SAFETY GUIDELINES........6 Initial test run ...........44 SAFETY DEFINITION ........6 GENERAL ............6 INCORPORATED RECIRCULATION PUMP ..7 Owner's Guide INSTALLATION ..........7 GENERAL ............7...

  • Page 3: Installation Manual

    Installation Manual Installation Manual CONGRATULATIONS Congratulations and thank you for choosing our tankless water heater. Before use, we recommend that you read through this installation manual carefully. Keep this manual for future reference. If you need an additional manual, contact the manufacturer or your local distributor.

  • Page 4: Specifications

    Installation Manual Specifications SPECIFICATIONS Model 540P Indoor 540P Outdoor Min: 15,000 Natural Gas Input (Operating Range) BTU/h Max.: 199,000 Min: 13,000 Propane Input (Operating Range) BTU/h Max.: 199,000 Gas Connection 3/4" NPT Water Connections 3/4" NPT Water Pressure* psi (MPa) 15 - 150 (0.1 - 1)

  • Page 5: Introduction

    • These high efficiency models have a built-in secondary heat exchanger that absorbs latent heat from the exhaust gas. • The 540P Indoor model is only to be installed indoors. The 540P Outdoor model is only to be installed outdoors.

  • Page 6: Safety Guidelines

    Installation Manual Safety Guidelines SAFETY GUIDELINES SAFETY DEFINITION Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. DANGER Indicates an imminently hazardous situation which, if not avoided, could result in death or serious injury. WARNING Indicates an imminently hazardous situation which, if not avoided, could result in minor or moderate injury.

  • Page 7: Incorporated Recirculation Pump

    9. The 540P Indoor is to be installed indoors only. This water heater is equipped with a thermistor and hi-limit switch for the exhaust gas, detecting excess temperatures within the flue and enabling the appliance to safely stop operation if needed.
  • Page 8 Installation Manual Installation • Installation and service must be performed by a qualified installer (for example, a licensed plumber or gas fitter), otherwise the warranty will be void. • The installer (licensed professional) is responsible for the correct installation of the water heater and for compliance with all national, state/provincial, and local codes.

  • Page 9: Clearances

    Bottom Model Bottom Front Back Sides 12 in 12 in 4 in** 0.5 in 3 in 540P Indoor* (305 mm) (305 mm) (102 mm) (13 mm) (76 mm) 36 in 12 in 24 in 0.5 in 3 in 540P Outdoor...
  • Page 10 Installation Manual Installation 1. Temperature remote controller: 2. Pipe cover: 100112718 (TH-PC03) 100276687 (TM-RE43) pipe cover The temperature remote controller has protects the following features: plumbing pipes to Adjusts set water temperature • the water heater Controls the pump operation •...

  • Page 11: Warning For Installations

    Installation Manual Installation WARNING FOR INSTALLATIONS FOR YOUR SAFETY, READ BEFORE INSTALLATION: Do not install the heater where water, debris or Do not have the vent terminal pointing toward flammable vapors may get into the flue terminal. any opening into a building. Do not locate your This may cause damage to the heater and void the heater in a pit or location where gas and water warranty.

  • Page 12: High-Altitude Installations

    Installation Manual Installation HIGH-ALTITUDE INSTALLATIONS • To adjust high altitude settings, adjust only the No. 2, No. 3, and No. 4 DIP switches in the MIDDLE bank of DIP switches. (See below.) DO NOT adjust the other DIP switches. • Turn off the power supply to the water heater before changing the DIP WARNING switch settings.

  • Page 13: Venting Instructions

    Installation Manual Installation VENTING INSTRUCTIONS 540P Indoor model -General- • Improper venting of this appliance can result in excessive levels of carbon monoxide which can result in severe personal injury or death. • Improper installation can cause nausea or asphyxiation, severe injury or death from carbon monoxide and flue gases poisoning.

  • Page 14: Combustion Air Supply

    Installation Manual Installation -Combustion air supply- This gas water heater requires an adequate source of clean air for combustion and ventilation. Without sufficient air, your water heater may not operate properly and may emit excessive and abnormal amounts of carbon monoxide which may result WARNING in carbon monoxide poisoning or death.
  • Page 15 Installation Manual Installation Your water heater’s BTU/h rating is on the rating plate. The BTU/h ratings should be on the other appliances’ rating plates. If you have trouble determining the BTU/h ratings, contact the manufacturer or have a qualified person determine the ventilation requirements. : If you are replacing your old water heater with one that has a higher BTU/h rating, the amount of NOTICE ventilation required may be greater.
  • Page 16 Installation Manual Installation Determine type of ventilation There are several types of ventilation that can be used. The various options are listed below. See also the illustrations on the next page. 1. Direct to outdoors 2. Vertical ducts 3. Horizontal ducts 4.
  • Page 17 Installation Manual Installation Combustion air supply options Gable vent to outdoors Install above insulation 12” (305 mm) Outlet air to Confined maximum attic 1 in (6.5 cm Space per 4,000 btu/h Two permanent Openings Confined Alternate 1 in (6.5 cm Space Inlet air from Air Inlet per 4,000 btu/h the crawl space...

  • Page 18: Exhaust Vent (Abs,Pvc,Cpvc, Or Polypropylene Vent)

    Installation Manual Installation -Exhaust vent (ABS, PVC, CPVC, or polypropylene vent)- The Indoor model can be vented with ABS, PVC, CPVC, or polypropylene (temperature rated up to 149 °F). Vent material certified to ULC S636 standards is recommended in the USA. In Canada, plastic venting must be certified to ULC S636 standards.

  • Page 19: Dip Switch Settings For Vent Length (Abs,Pvc,Cpvc, Or Polypropylene Vent)

    Installation Manual Installation -DIP switch settings for vent length- PVC, CPVC, ABS, or polypropylene vent Typical installations using • To adjust vent length, adjust only the No. 3 and No. 4 DIP switches in the LOWER bank of DIP switches. (See below.) DO NOT adjust the other DIP switches.
  • Page 20 Installation Manual Installation <How to install intake and exhaust venting (two-pipe, direct-vent) with the indoor model> 3" (76 mm) vent connection 1. Connect 3" (76 mm) couplings directly on 3” (76 mm) 3” (76 mm) straight pipe straight pipe the exhaust and intake vent collar of the water heater. 3” (76 mm) 2. Connect 3" (76 mm) straight pipes to the coupling 3”...
  • Page 21 Installation Manual Installation • To adjust vent length, adjust only the No. 3 and No. 4 DIP switches in the LOWER bank of DIP switches. (See below.) DO NOT adjust the other DIP switches. • Turn off the power supply to the water heater before changing the DIP WARNING switch settings.
  • Page 22 Installation Manual Installation CENTROTHERM PP VENTING (Polypropylene) WARNING! Do not mix parts or fittings of different material types, and do not mix pipe, fittings, or joining methods from different manufacturers. Combustion exhaust can contain carbon monoxide and must be properly vented outside. Breathing abnormal amounts of carbon monoxide can result in seri- ous injury or death.

  • Page 23: Exhaust Vent (Stainless Steel Vent)

    Installation Manual Installation -Exhaust vent (Stainless steel vent)- This is a Category IV appliance and must be vented accordingly. The vent system must be sealed airtight. All seams and joints without gaskets must be sealed with high heat resistant silicone sealant or UL listed aluminum adhesive tape having a minimum temperature rating of 160 °F (71 °C).
  • Page 24 Installation Manual Installation • To adjust vent length, adjust only the No. 3 and No. 4 DIP switches in the LOWER bank of DIP switches. (See below.) DO NOT adjust the other DIP switches. • Turn off the power supply to the water heater before changing the DIP WARNING switch settings.
  • Page 25 Installation Manual Installation Approved Category IV, Single Wall, Venting Suppliers and Part Numbers WARNING! Do not mix parts or fittings of different material types, and do not mix pipe, fittings, or joining methods from different manufacturers. Combustion exhaust can contain carbon monoxide and must be properly vented outside.

  • Page 26: Common Venting System

    (Current Editions), local codes, and the following manufacturer’s instructions. • For common-venting pieces and components, the manufacturer recommends Centrotherm's vent line. Allowable models for common-venting 240 Indoor, 340 Indoor, 540 Indoor, 540P Indoor Only the above allowable models can be common-vented together. Different models cannot be common-vented. CAUTION...
  • Page 27 • For detailed instructions on the common-venting system, refer to the WARNING instructions that are packaged with the vent parts or web site. Common-venting system DIP switch settings Max. Vent Max. Vertical and No.of 540P Indoor Diameter* Horizontal water (Lower bank of (Total) Vent Length** (L) heaters DIP switches) WARNING 4 in 25 ft (7.6 m)

  • Page 28: Vent Termination Clearances

    Installation Manual Installation -Vent termination clearances- Inside corner = Vent terminal detail = Air supply inlet = Area where the terminal is not permitted Fixed Operable Fixed closed closed Operable Regulator/Gas meter vent outlet Canada Installations US Installations Direct vent and other than Other than Direct vent direct vent...

  • Page 29: Clearances For Sidewall Terminations

    Installation Manual Installation -Clearances for sidewall terminations- Improper installation can result in carbon monoxide poisoning or death. Follow all local and national codes in regards to proper termination clearances. In the absence of such codes, the clearances below can be used as guidelines. Local codes supersede these WARNING guidelines.

  • Page 30: Clearances For Rooftop Terminations

    Installation Manual Installation -Clearances for rooftop terminations- Follow all local and national codes in regards to proper termination clearances. In the absence of such codes, the clearances below must be met. Local codes supersede these clearances. Failure to observe this warning may result in severe personal injury or death. WARNING Canadian requirements differ from the guidelines in this section.

  • Page 31: Gas Supply And Gas Pipe Sizing

    Installation Manual Installation GAS SUPPLY AND GAS PIPE SIZING -General- • Check that the type of gas matches the rating plate first. • Ensure that any and all gas regulators used are operating properly and providing gas pressures within the specified range shown below. Excess gas inlet pressure may cause serious accidents.

  • Page 32: Natural Gas Supply Piping

    Installation Manual Installation -Natural gas supply piping- Maximum delivery Capacity in Cubic Feet of Gas per Hour (based on IPS Pipe carrying Natural Gas with 0.60 Specific Gravity with a Pressure Drop of 0.5" W.C.). Based on Energy Content of 1,000 BTU/Cubic ft: The water heater requires 199 Cubic ft/hr for the 540P model. The following tables are from NFPA 54.

  • Page 33: Water Connections

    4. There is a wire mesh filter within the cold inlet and return inlet to trap debris from entering your heater. This will need to be cleaned periodically to maintain optimum flow. (Refer to p. 63.) -Installation with dedicated return line- Model 540P Indoor 540P Outdoor 3/4" Maximum Pipe length* 500 ft (152.4 m)

  • Page 34: Installation W/O Dedicated Return Line

    Installation Manual Installation -Installation without dedicated return line- • Cold water supply line must be connected to the "Return inlet". NOTICE • The "Cold water inlet" must be capped. This piping installation is used when the heater is installed in a system without a dedicated return line.

  • Page 35: Condensate Drain

    Installation Manual Installation CONDENSATE DRAIN • The water heater does not include a built-in condensate neutralizer cartridge for reducing the pH level of condensate water. If local codes dictate that condensate must be neutralized prior to drainage, a condensate neutralizer must be installed. An accessory Neutralizer assembly (100112159/TH-NT01) is sold separately.
  • Page 36 Installation Manual Installation Installation Installation without neutralizer with neutralizer 3/8" MPT x 3/8" 3/8" MPT x 3/8" (or 1/2") HB (or 1/2") HB 1/2" Condensate 1/2" Condensate drain tube* drain tube* 1/2" MPT x 3/8" FPT (Included with Neutralizer accessory) 1/2"...

  • Page 37: Electrical Connections

    Installation Manual Installation ELECTRICAL CONNECTIONS • Follow the electrical code requirements of the local authority having jurisdiction. In the absence of such requirements, follow the current edition of the National Electrical Code ANSI/NFPA 70 in the U.S. or the current edition of CSA C22.1 Canadian Electrical Code Part 1 in Canada.

  • Page 38: Temperature Remote Controller

    Installation Manual Installation TEMPERATURE REMOTE CONTROLLER -Included accessories - Outdoor model only • The remote control is an optional accessory that can be installed in a hall, closet, etc., to allow for temperature adjustment without having to go to the heater. •...
  • Page 39 Installation Manual Installation Open the Plastic cover and tighten the two Fork terminals beneath the two Remote controller terminal screws on the back of the Main unit (Fig. D-1). Cut out the inlet for the cable from the bottom of the main unit (Fig. D-2). Insert the cable through the inlet. Close the Plastic cover and then hook the Main unit to the Fixing bracket on the Metal plate.

  • Page 40: Easy-Link System

    Installation Manual Installation EASY-LINK SYSTEM The 540P model water heater can be connected to 540 models as only a PARENT unit in an Easy- Link System. • The built-in Easy-Link System allows up to 4 units to manifold together. • Only one 540P can be installed in an Easy-Link System. •...
  • Page 41 Installation Manual Installation 5. Between the “PARENT” and the “CHILD-1” units: Connect the “PARENT” connector of the “PARENT” unit to the “1” connector of the “CHILD-1” unit using the supplied linking cable. 6. Between the “CHILD-1” and the “CHILD-2” units: Connect the “2”...

  • Page 42: Applications

    Installation Manual Applications APPLICATIONS -Combination potable water heating and space heating- • This water heater is suitable for combination water (potable) heating and space heating and not suitable for space heating applications only. • In order to purge air in water pipes within a closed-loop system, an air vent and air separator should be installed in the system.

  • Page 43: Dual-Purpose Hot Water Heating

    Installation Manual Applications -Dual-purpose hot water heating- (Domestic and Space Heating): Diagrammatic layout of radiant heating and domestic water heater. All water piping should be insulated in accordance with 780 CMR (Massachusetts energy code) 3-inch gas exhaust vent (Discharge must Cold water supply Automatic tempering device comply with local and...

  • Page 44: Initial Operation

    Installation Manual Initial operation INITIAL OPERATION FOR YOUR SAFETY, READ BEFORE OPERATING • Check the GAS and WATER CONNECTIONS for leaks before firing unit for the first time. • Open the main gas supply valve to the unit using only your hand to avoid any spark. Never use tools.
  • Page 45 Installation Manual Initial operation Initial Test Run Start pump operation test by built-in controller or remote con- troller. Press the ON/OFF button on the controller so the STAND BY LED turns off. Press and hold "INFO." and "PUMP" simultaneously for at least three seconds, then the integrated pump starts operation for five minutes.
  • Page 46 Installation Manual Initial operation This page is intentionally left blank. Page...

  • Page 47: Owner's Guide

    Owner's Guide Operating Safety Owner's Guide CONGRATULATIONS Congratulations and thank you for choosing our tankless water heater. Before use, we recommend that you read through this owner's guide carefully. Keep this manual for future reference. If you need an additional manual, contact the manufacturer or your local distributor.

  • Page 48: Operating Safety

    Owner's Guide Operating Safety OPERATING SAFETY FOR YOUR SAFETY READ BEFORE OPERATING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand. B. BEFORE OPERATING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor. WHAT TO DO IF YOU SMELL GAS • Do not try to light any appliance. • Do not touch any electric switch; do not use any phone in your building. • Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions. • If you cannot reach your gas supplier, call the fire department. C. Use only your hand to turn the gas shutoff valve. Never use tools. If the valve will not turn by hand, don’t try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion. D. Do not use this appliance if any part has been under water. Immediately contact a qualified installer or service agency to replace a flooded water heater. Do not attempt to repair the unit! It must be replaced! OPERATING INSTRUCTIONS 1. STOP! Read the safety information above on this label. 2. Turn off all electric power to the appliance. 3. Do not attempt to light the burner by hand. 4. Turn the gas shutoff valve located on the outside of the unit to the closed position. 5. Wait five (5) minutes to clear out any gas. If you then smell gas, STOP! Follow “B” in the safety information above on this label. If you don’t smell gas, go to the next step.
  • Page 49 Owner's Guide Operating Safety DANGER Vapors from flammable liquids will explode and catch fire causing death or severe burns. Do not use or store flammable products such as gasoline, solvents or adhesives in the same room or area near the water heater. Do not install water heater where flammable products will be stored or used unless the main burner is at least 18” above the floor. This will reduce, but not eliminate the risk of vapors being ignited by the main burner. Flammable Vapors FLAMMABLES Read and follow water heater warnings and instructions. If the owner’s manual is missing, contact the retailer or manufacturer. Keep flammable products: Vapors: 1. Far away from heater. 1. Cannot be seen. 2. In approved containers. 2. Are heavier than air. 3. Tightly closed and out of reach of children. 3. Go a long way on the floor. 4. Water heater has a main burner, which may 4. Can be carried from other rooms to the main come on at any time and will ignite flammable...

  • Page 50: Normal Operation

    Owner's Guide Normal Operation NORMAL OPERATION BUILT-IN CONTROLLER and REMOTE CONTROLLER The illustration below shows an example of the controllers. The exact display may differ from examples. Built-in controller Remote controller Description Note Description Note "ON/OFF" "TIME" Press this button to start or stop Press this button to set the Button operation.

  • Page 51: Outlet Water Temperature Setting

    Owner's Guide Normal Operation OUTLET WATER TEMPERATURE SETTING -Set temperature- Controllers Operation Built-in controller Remote controller Turn on the 120 VAC power supply to the unit. Press the "ON/OFF" button on the controller in order to turn the controller on. When ON, the STAND BY LED is lit.

  • Page 52: Setting The Time

    Owner's Guide Normal Operation SETTING THE TIME Controllers Operation Built-in controller Remote controller Turn on the 120 VAC power supply to the unit. Press the "TIME" button on the controller in order to set the time. This operation is available regardless of ON/ OFF of the controller.

  • Page 53: Setting Pump Timers

    Owner's Guide Normal Operation - Setting pump timers - Controllers Operation Built-in controller Remote controller Turn on the 120 VAC power supply to the unit. Press and hold the "PUMP" button on the controller for at least 3 seconds to enter the pump timer setting mode. This operation is available regardless of ON/OFF of the controller.
  • Page 54 Owner's Guide Normal Operation Controllers Operation Built-in controller Remote controller Press the "HOT" button or "COLD" button to select the time. Press and hold the "HOT" or "COLD" button to adjust the time more quickly. NOTICE: The time is displayed in twenty-four hour clock time. For example, 11:00 is 11:00 a.m.

  • Page 55: Selecting A Pump Timer

    Owner's Guide Normal Operation Controllers Operation Built-in controller Remote controller The following steps will set the temperature drop that must occur before the recirculation pump will turn off. °F Temperature drop below set temp. at which pump turns off °C *Preset at the factory.

  • Page 56: Display Example

    Owner's Guide Normal Operation -Display example- The display on the controller indicates which PUMP TIMER is set by displaying a number below the time: 1, 2, or 12. (12 indicates PUMP TIMER 1 and PUMP TIMER 2.) The arrow to the right of ON or OFF indicates the current status of the PUMP TIMER(s). If the current time falls within the time range set for a PUMP TIMER, the arrow will point toward ON.

  • Page 57: Manual Pump Activation

    Owner's Guide Normal Operation -Pump operation test- The following procedure will operate the pump. This is useful to verify that the pump is operating prop- erly and to check the water flow rate. Controllers Operation Built-in controller Remote controller Press the ON/OFF button on the controller so the STAND BY LED turns off.
  • Page 58 Owner's Guide Normal Operation • For manual pump operation, adjust only the No. 5 DIP switch in the LOWER bank of DIP switches. (See below.) DO NOT adjust the other DIP switches. • Turn off the power supply to the water heater before changing the DIP switch settings.

  • Page 59: Additional Features

    Owner's Guide Normal Operation ADDITIONAL FEATURES -Information mode- You can get some information about the water heater condition by pressing the "INFO" button. For more information, follow the procedures below: Controllers Operation Built-in controller Remote controller Press the "INFO" button on the controller to enter the information mode.

  • Page 60: Temperature Settings On The Pcb

    Owner's Guide Normal Operation SETTING THE TEMPERATURE ON THE PCB (WITHOUT BUILT-IN CONTROLLER or REMOTE CONTROLLER) • To set the temperature, adjust only the No. 5 DIP switch in the MIDDLE bank of DIP switches. (See below.) DO NOT adjust the other DIP switches. • Turn off the power supply to the water heater before changing the DIP switch settings.

  • Page 61: Freeze Protection System

    Owner's Guide Normal Operation FREEZE PROTECTION SYSTEM • To set pump operation for freeze protection, adjust only the No. 4 DIP switch in the UPPER bank of DIP switches. (See below.) DO NOT adjust the other DIP switches. • Turn off the power supply to the water heater before changing the DIP switch settings.

  • Page 62: Maintenance And Service

    Owner's Guide Normal Operation MAINTENANCE AND SERVICE • Turn off the electrical power supply and close the manual gas shutoff valve and the manual water control valve before servicing. • Failure to do so could result in severe personal injury, or death. WARNING •...

  • Page 63: Unit Draining And Filter Cleaning

    Owner's Guide Normal Operation UNIT DRAINING and FILTER CLEANING 1. Close the manual gas shutoff valve. 2. Turn off power to the unit and wait a couple of seconds. Turn on again. Drain plug 3. Wait 30 seconds, and then turn off power to the unit. with Filter (Large) 4.

  • Page 64: Troubleshooting

    Owner's Guide Troubleshooting TROUBLESHOOTING GENERAL PROBLEM SOLUTIONS It takes a long time to • Check to see if a recirculation timer is active. If not, it will take time for get hot water at the the hot water to get from the heater to the fixture. fixtures.
  • Page 65 Owner's Guide Troubleshooting PROBLEM SOLUTIONS Unit does not ignite • Is the flow rate over 0.5 GPM (1.9 L/min)? (p. 50) when water goes • Is the filter on cold water inlet and return connection clean? (p. 63) through the unit. •...

  • Page 66: Error Codes

    Owner's Guide Troubleshooting ERROR CODES -General- • The units have self-diagnostic functions for safety and convenience when troubleshooting. • If there is a problem with the installation or the unit, the error code will be displayed on the built-in controller or remote controller. •...
  • Page 67 Unit #3 Unit #4 PARENT CHILD CHILD CHILD Error code Green LED *If the 540P Indoor model is the PARENT unit and the remote controller off off off off off is connected to the unit, the remote controller has priority over the built-in Green LED on controller.
  • Page 68 Owner's Guide Troubleshooting -Fault analysis- If the error code is displayed on the computer board of the water heater or remote controller and/or temperature controller, please check the following. After checking, consult with the manufacturer. Green Malfunction Remote Diagnosis description Incorrect DIP •...
  • Page 69 Owner's Guide Troubleshooting Green Malfunction Remote Diagnosis description Four Fan motor fault • Check for connection/breakage of wires, dust buildup in the fan motor (Part #103) and/or burn marks on the computer board Times (Part #701). • Check for frozen/corrosion of connectors (Part #103). Four Pump fault •...

  • Page 70: Components Diagram

    Owner's Guide Components Diagram COMPONENTS DIAGRAM Case assembly Outdoor model Indoor model 008 052 Built-in controller Temperature Indoor model remote controller Page...
  • Page 71 Owner's Guide Components Diagram Computer board assembly Surge box assembly Page...
  • Page 72 Owner's Guide Components Diagram Burner assembly Burner assembly 111 711 Manifold assembly Page...
  • Page 73 Owner's Guide Components Diagram Water way assembly Bypass section Water outlet section Water inlet section Pump section Page...

  • Page 74: Parts List

    Parts List PARTS LIST Part # Item # Description 540P (AT-H3P) Case assembly for Indoor model EK617 for Outdoor model EK635 Front cover for 540P Indoor 100074665 EK158 for 540P Outdoor 100074666 EK174 Intake air port assembly 100074667 EK170 Bracket EK162...
  • Page 75 Owner's Guide Parts List Part # Item # Description 540P (AT-H3P) Primary heat exchanger assembly for 540P model 100276637 EK621 Flow adjustment valve / Flow sensor 100074624 EK129 Bypass valve 100074625 EKD58 Water inlet 100074377 EKK1U Inlet drain plug 100074381 EKK2B Inlet water filter 100074382...

  • Page 76: Output Temperature Chart

    Owner's Guide Parts List Part # Item # Description 540P (AT-H3P) Switch wire with thermostat for Indoor model EK631 for Outdoor model EK636 Proportional gas valve wire 100074657 EK167 24V cables for Indoor model EK632 for Outdoor model EK638 Computer board cover 100074375 EKK1M Cable clamp...

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