Thermann 16NG50-6 Service Manual
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Thermann 16NG50-6 Service Manual

Gas continuous flow water heaters
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SERVICE MANUAL
Model:16NG50-6/16LP50-6
16NG60-6/16LP60-6
20NG50-6/20LP50-6
20NG60-6/20LP60-6
26NG50-6/26LP50-6
26NG60-6/26LP60-6
GAS CONTINUOUS FLOW
WATER HEATERS
(Residential Outdoor Unit)
TO BE USED BY A LICENSED
PLUMBER ONLY

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Summary of Contents for Thermann 16NG50-6

  • Page 1 SERVICE MANUAL Model:16NG50-6/16LP50-6 16NG60-6/16LP60-6 20NG50-6/20LP50-6 20NG60-6/20LP60-6 26NG50-6/26LP50-6 26NG60-6/26LP60-6 GAS CONTINUOUS FLOW WATER HEATERS (Residential Outdoor Unit) TO BE USED BY A LICENSED PLUMBER ONLY...

  • Page 2: Table Of Contents

    Table of Contents 1. General Outline of Appliance 1-1 Specifications ..........................3 Performance ..........................4 General Construction (Parts Names) ..................5 Main Component Structures ....................... 6 Main Safety Devices ........................8 2. Installation and Related Work Installation Instructions ........................ 9 Dimensions ..........................

  • Page 3: General Outline Of Appliance

    1. General Outline of Appliance 1-1 Specifications MODEL Nominal hourly gas consumption by MJ/h proportional electronic gas control Minimum gas supply pressure 1.13 1.13 1.13 (Natural Gas) Maximum gas supply pressure (Natural Gas) Test point pressure (Natural Gas) 0.56 0.80 0.80 Minimum gas supply pressure 2.75...

  • Page 4: Performance

    1-2 Performance Performance-Capacity characteristic curves. • Model 16 20.0(Maximum) Inlet water temperature 15 C 25 C 2.2(Minimum) Outlet water temperature [ C] • Model 20 20.0(Maximum) Inlet water temperature 15 C 25 C 2.2(Minimum) Outlet water temperature [ C] • Model 26 22.0(Maximum) Inlet water temperature 15 C 25 C...

  • Page 5: General Construction (Parts Names)

    1-3 General Construction (Parts Names) • Model 16/20 • Model 26 PARTS NAME PARTS NAME PCB(Natural Gas)Model 16 Heat Exchanger Assy(Model 16,20) Heat Exchanger Assy(Model 26) PCB(Natural Gas)Model 20 PCB(Natural Gas)Model 26 Over Heat Thermostat PCB(Propane)Model 16 Fan Motor(Model 16,20) Fan Motor(Model 26) PCB(Propane)Model 20 PCB(Propane)Model 26 Temperature Sensor Manifold Assy(Natural Gas)Model 16,20 10 Anti-Frost Heaters 11 Ignitor Manifold Assy(Natural Gas)Model 26...

  • Page 6: Main Component Structures

    1-4 Main Component Structures 1. Gas Control Valve • 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. Gas Valve 1 OUT1 OUT2 11DC0697 Main Gas Valve LP/NG 4D00001 Gas Control Valve Filter Gas Valve 2 Gas Valve 1 (No.2) (No.1) Main Gas Valve (No.0) 2. Water Flow Control Valve with Sensor * M easures 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.
  • Page 7 3. Combustion Control of Rich and Lean Burners Ignition start After the Main Gas Valve, Gas Valve 1, Gas Valve 2 open respectively as required, the Gas Control Valve, being held at the slow ignition position (with gas supply at a constant rate), operates to ignite Burners. During combustion Depending on the required heating capacity, each Gas Valve opens or closes. The combinations are below, Gas valve 1&2&3 open Higher 1&2 Lower Electrode 2burners 5burners 10burners Flame Sensor Gas Valve 2 Gas Valve 3 Fan Motor Gas Valve 1 Only for Model 26 Gas Control...

  • Page 8: Main Safety Devices

    1-5 Main Safety Devices Water Flow Sensor (Boil-dry protection) When the Water Flow Sensor detects the flow rate is set for starting ignition (ignition water flow) or higher, the water heater starts operation. Ignition water flow: 2.7 L/min. Extinction water flow: 2.2 L/min. Flame Sensor (Flame failure detection) Electric signals are transmitted to the flame detection circuit to confirm the normal combustion when the Flame Sensor detects the rectification of normal combustion flame. Therefore, if the combustion of the Burners is not normal, the signals are not sent via the Flame Sensor. The gas control assemblies are closed without the signals and the error code "111" or "121" is displayed on the remote controllers. Thermal Fuse (Over-temperature protection system) The Thermal Fuse is placed around the Heat Exchanger Assembly.

  • Page 9: Installation And Related Work

    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 instructions for your safety. “Danger” indicates that serious injuries or even death may result from the improper installation due to negligence of following the instructions. “Warning” indicates the possibility that serious injuries or even death may result from the improper installation due to negligence of following the instructions.
  • Page 10 Before installation. Verification of the unit. • 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. Location of the unit. Decide where to install the unit by considering customer’s request and clearances. Ventilation • Install the unit where there is enough space for ventilation. • Do not install the unit where flammables such as gasoline, benzene, and adhesive are handled.
  • Page 11 Installation. • Reinforce the wall if necessary as this unit weighs about 15/16kg (Model 16,20/26). 1. Fix 1 screw (for wall hanging) into the wall leaving about 4mm length to hook on. 2. Hook the center hole of the wall hanging bracket onto the screw and securely fix the unit with 4 screws. Screw (for wall hanging) Wall hanging bracket Screw (for wall hanging) Screw (for wall hanging) Screw (for wall hanging) Screw...
  • Page 12 • Check if adjacent wall or ceiling is fire resistant and allows safe distance for fire prevention. • This water heater is suitable for residential water (potable) heating only. Do not use this water heater for space heating, combination space heating/domestic water heating, or commercial water heating applications. • The Water Heater 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.

  • Page 13: Dimensions

    2-2 Dimensions 350mm 12mm 200mm 15mm 68mm 68mm 68mm 68mm COLD WATER INLET R3/4 /20 POWER CABLE ENTRY PRESSURE RELIEF VALVE REMOTE CONTROLLER CABLE ENTRY HOT WATER OUTLET R3/4 /20 WATER INLET FILTER GAS SUPPLY INLET R3/4 /20 46mm 174mm 260mm 334mm - 13 -...

  • Page 14: Gas Piping

    2-3 Gas Piping • Install the manual gas valve in the gas inlet connection of the Water Heater. • 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.

  • Page 15: Electrical Connection

    2-5 Electrical Connection • 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.

  • Page 16: Wiring Remote Controller

    2-6 Wiring Remote Controller Number of controllers One, two or three remote controllers can be installed as optional extras. Controller locations The controllers allow the water temperature to be set from the various locations where they are installed at kitchen, laundry, bathroom and ensuite. Connection of wiring to the unit Remove the front cover from the unit. Install the wiring to the unit using conduit or by concealing the wires in the wall cavity. Install the wiring into the cabinet through the conduit.

  • Page 17: Testing Operation

    2-7 Testing Operation • Follow the steps below, to ensure the Water Heater 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. 4. Operate the remote controllers according to “INITIAL SETTING CONTROLLERS” in the installation instructions.

  • Page 18: Cascade Installation (Only For Model 26)

    • Depending on water flow and desired temperature, the system can automatically operate or stop either or both units. • Thermann genuine cascade cable can be used to connected the two units. • The distance between the two units must be in the range of 5 -100 cm. • Water and gas pipe length should be the same to both units. Otherwise the temperature of the hot water at the tap can be unstable.

  • Page 19: Service And Maintenance

    3. Service and Maintenance 3-1 Operation Principles [Before operation] • When ON/OFF Button (Power switch) on the remote controller is turned ON, the ON indicator iluminates (in the case of operation with a remote controller). Gas is supplied to the Gas Valve. [During operation (when hot water is supplied)] • When the hot water supply tap is opened, water flows through the Water Flow Control Valve (with sensor) into the Heat Exchanger Assembly. The water heated by the Heat Exchanger Assembly passes through the Outgoing Water Temperature Sensor to go to a hot water outlet. At this time, the Water Flow Sensor detects water flow. Then the PCB starts the Fan Motor, activating the electrode. The Main Gas Valve, Gas Valve 1 and Gas Valve 2 are opened simultaneously when the spark...
  • Page 20 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 Hot water tap, OPEN Water Flow Sensor detects water flow [over approximately 2.7 Liter/min.] Fan Motor, ON Fan Motor detects revolution Ignitor, ON Main Gas Valve, OPEN...

  • Page 21: Schematic Diagram

    3-2 Schematic Diagram Heat Exchanger Over Heat Thermostat Flame Rod Thermal Fuse Burner Electrode Ignitor ONLY FOR MODEL 26 Gas Valve 1 Gas Valve 3 Gas Valve 2 Fan Motor Water Flow Remote Control Valve Controller Outgoing Gas Control Valve Temperature Sensor Incoming Main Gas Valve Temperature Sensor...

  • Page 22: Flow Charts

    3-3 Flow Charts Water Flow Control Valve failure Kitchen remote controller failure Bath /Ensuite remote controller failure Move Water Flow Control Valve in place PCB failure 700,731 Hot water temperature is displayed on remote controller Cascade comunication failure Hot water tap Open Incoming Temperature Sensor failure Ambient Temperature...

  • Page 23: Fault Findings And Error Code

    3-4 Fault Findings and Error Code Error code ERROR CODE CONDITION NUMBER CORRECT Refer PHENOMENON SYMPTOM CAUSE CHECK METHOD VALUE Figure REMOTE LED IN PCB FLASHING CONTROL NOTHING STARTS AND REMOTE’S FUSE DEFECT CHECK THE CONTINUITY OF FUSE ON PCB 0Ω...
  • Page 24 ERROR CODE CONDITION NUMBER CORRECT Refer PHENOMENON SYMPTOM CAUSE CHECK METHOD VALUE Figure REMOTE LED IN PCB FLASHING CONTROL LED FLASHES FLASHING PCB FAILURE PCB DEFECT EXCHANGE PCB. IMMEDIATELY CHECK GAS INLET PRESSURE(SUFFICIENT GAS PRESSURE OF GAS SUPPLY Table 2 INLET PRESSURE AT MAX.
  • Page 25 Fault findings < Fig. 1> < Fig. 2> < Fig. 3> Continuity of Fuse Water Flow Sensor Voltage of Ignitor Transformer Connect directly pulling Measure voltage without out connector pulling out connector AC240V unused pin Connect directly After pulling out connector No.4 on PCB, connect two pins of the bottom with flat blade screwdriver directly.

  • Page 26: Wiring Diagram

    (OUTGOING TEMP .) ANTI-FROST HEATERS FLAME ROD COMBUSTION INDICATOR FUSE GAS VOLUME ADJUSTING BUTTON (UP) (250V T5A) AC240V GAS VOLUME ADJUSTING BUTTON(DOWN) MODEL NAME PCB NO. 16NG50-6/16LP50-6 WATER FLOW SENSOR 16NG60-6/16LP60-6 GC-153 FAN MOTOR 20NG50-6/20LP50-6 GAS VALVE (CONTROL) 20NG60-6/20LP60-6 26NG50-6/26LP50-6 GC-162...

  • Page 27: Cascade Flow Charts

    3-6 Cascade Flow Charts Hot water tap Open Cumulative amount of combustion, Master unit < Slave unit ? Master unit ON Slave unit ON Required heat capacity, shortage ? The other unit ON The other unit OFF Hot water tap Close ? All units Stop - 27 -...

  • Page 28: Gas Setting Procedure

    3-7 Gas Setting Procedure Preparation (1) Make sure the appliance is not in operation. Then, remove the screw from the pressure check hole. (2) Connect the hose of the manometer to the pressure check hole. Adjusting nozzle pressure settings <Minimum pressure should be set before setting the maximum pressure.> (1) Make sure that “Dip Switch” No. 1 on PCB is set to the position for the appropriate gas type. If installation is a cascade type, change the dip switch block No.2 to all OFF and remove wires from Remote controller Connection Terminals.

  • Page 29: Combustion Specification, Various Combination Setting

    3-8 Combustion Specification, Various Combination Setting Combustion specifications Gas consumption Manifold Assy [MJ/h] Gas type Dip Switch MODEL Gas type Nozzle diameter (mm) on PCB Gas type Maximum Rich Lean mark [Top side] [Bottom side] Propane Φ0.65×15 pcs Φ0.95×15 pcs DipSw. No.1 : OFF Natural Gas Φ0.95×15 pcs Φ1.45×15 pcs DipSw. No.1 : ON Propane Φ0.65×15 pcs Φ0.95×15 pcs...
  • Page 30 Comfort Dip Switch Setting Pattern(Various Combination Setting) <Dip Switch> (The illustrated switch settings show the factory settings for the Propane and 60°C preset.) To switch gas type (Propane or Natural Gas) To change hot water temperature (without remote controller) To fix to the minimum combustion To fix to the maximum combustion • Switching gas type Dip SW setting for gas type Applicable gas type...
  • Page 31 Delivery Temperature Adjustment for 50°C Preset Model This instruction must be read in conjunction with the Operating & Installation instructions and the caution sheet “Instructions for units supplied set at 50°C to comply with AS 3498” which are supplied with the appliance. Application This instruction applies only to appliances labelled “50°C Preset” on the front cover. Background “50°C preset”...
  • Page 32 Table 1 Dip Switch Setting Temperature adjustment of hot water FACTORY STEP1 STEP2 STEP3 STEP4 supply DEFAULT • Ensure building occupants do not have access to any hot water outlets during this procedure. • If the hot water temperature from ANY outlets used primarily for the purposes of personal hygiene exceed 48°C after temperature adjustment in step has been performed, check your work and repeat the temperature delivery adjustment procedure as required.

  • Page 33: Disassembling/Assembling Parts

    3-9 Disassembling/Assembling Parts Procedure Illustration When the unit is disassembled or assembled, turn off the power and drain water. Pressure Relief Valve Water Filter Removing PCB (1)Remove the setscrew fixing the PCB case and lead wires from the PCB claw. PCB case setscrew To remove the hook part of the PCB case from the bottom panel, lift the case PCB claw up slightly and pull it out.
  • Page 34 Procedure Illustration Removing Water Flow Contorol Valve. (1)Remove the setscrew fixing the PCB case. Lift the case up and pull it out. Water Flow Contorol Valve connector (2)Disconnect Water Flow Contorol Valve Incomming Temperature Sensor connector 8P connector(on PCB side), Water Flow Sensor 3P relay connector and Incoming Temperature Sensor connector. Water Flow Sensor relay connector (3)Remove the 2 quick-fasteners and take out Water Flow Contorol Valve.
  • Page 35 Procedure Illustration Removing Ignitor (1)Disconnect the high-voltage cord. Remove the setscrew to the plate retaining the Ignitor. (Screw with steel washer is used for Ignitor earthing.) High-voltage cord (2)Pull out the Ignitor. Ignitor connector (3)Disconnect the Ignitor 2P connector. (4)Remove the setscrews (2 pcs) retaining the Ignitor.
  • Page 36 Procedure Illustration Flame Rod connector Removing Manifold Assy (1)Disconnect Flame Rod connector. (2)Remove Ignitor. (see previous step) (3)Remove the setscrew fixing the PCB case. Lift the case up and pull it out. (4)Remove the setscrews fixing the Setscrews M4 x 7 pcs Manifold Assy (M4 x 7 pcs, M4 with washer x 3 pcs). Setscrews M4 with washer x 3 pcs (5)Pull the connector of the Gas Valve 3 (Model 26 only) Connector of the Gas Valve 3...
  • Page 37 Procedure Illustration (3)Pull the Gas Control Valve out and disconnect from the Gas Valves (4 pcs) and remove them as one unit. (Attention) When connecting, the number of connectors should match with the one of valves marked on Manifold Assy. Gas Valve connectors Model 26 Only Number of Valves Number of Connectors Removing Fan Motor (1)Remove Ignitor. (see previous step) (2)Remove the setscrew fixing the PCB case.
  • Page 38 Procedure Illustration Removing Electrode and Flame Rod Electrode holder setscrews(2 pcs) (1)Disconnect high-voltage cord and Flame Flame Rod connector Rod connector. (2)Remove setscrews (2 pcs) fixing the Electrode holder to pull the holder out. Electrode High-voltage cord Removing Heat Exchanger Assy. (1)Remove Manifold Assy. (see previous step) (2)Remove setscrews (2 pcs) fixing the combustion chamber.
  • Page 39 Procedure Illustration (4)Remove setscrews (2 pcs) retaining the hot water outlet pipe. Hot water outlet pipe setscrews(2 pcs) (5)Remove the quick-fastener and setscrew fixing the Anti-Frost Heater. quick-fastener Anti-Frost Heater setscrew (6)Remove setscrew retaining the Heat Heat Exchanger Assy setscrew Exchanger Assy. (7)Pull the Heat Exchanger Assy forward to take it out.

  • Page 40: Exploded View

    3-10 Exploded View Model 16 Model 26 Model 20 1 Screw with steel washer 2 Special earth Screw with projections - 40 -...

  • Page 41: Parts List

    3-11 Parts List PARTS NAME PARTS NAME PCB(Natural Gas)Model 16 Heat Exchanger Assy(Model 16,20) PCB(Natural Gas)Model 20 Heat Exchanger Assy(Model 26) PCB(Natural Gas)Model 26 Over Heat Thermostat PCB(Propane)Model 16 Fan Motor(Model 16,20) PCB(Propane)Model 20 Fan Motor(Model 26) PCB(Propane)Model 26 Temperature Sensor Manifold Assy(Natural Gas)Model 16,20 Anti-Frost Heaters Manifold Assy(Natural Gas)Model 26...

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