INSTANTANEOUS GAS WATER HEATER...

from 63 6 720 814 719 SM FP_Australia 2014/12 EN

INSTANTANEOUS GAS WATER HEATER GWI-N

FAN PRESSURIZED GAS WATER HEATER FOR OUTDOOR INSTALLATION

TRAINING AND SERVICE INFORMATION FOR AFTER SALES

This document is restricted to exclusive use by the official service partners. Each country should adapt the manual and its contents to the available range.

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Contents

1. INTRODUCTION ........................................................................................... 3

2. APPLIANCE DESCRIPTION ......................................................................... 3

2.1 APPLIANCE DESIGNATION ...................................................................................................... 3 2.2 AVAILABLE ACCESSORIES ..................................................................................................... 3

3. INSTALLATION ............................................................................................. 5

3.1 APPLIANCE FIXATION ON THE WALL ........................................................................................ 5

3.2 WATER CONNECTIONS ........................................................................................................... 6 3.3 GAS CONNECTION ................................................................................................................. 6 3.4 APPLIANCE PERFORMANCE .................................................................................................... 7

4. COMPONENTS OVERVIEW ......................................................................... 8

4.1 CONTROL PANEL................................................................................................................... 8 4.2 HEAT CELL WITH BURNER PIPES ........................................................................................... 11

4.3 GAS MANIFOLD ................................................................................................................... 12 4.4 FAN ................................................................................................................................... 14 4.5 GAS VALVE ........................................................................................................................ 15

4.6 HEAT EXCHANGER .............................................................................................................. 16 4.7 WATER INLET ASSY ............................................................................................................ 17

4.8 WATER TEMPERATURE SENSORS ......................................................................................... 17

4.9 BOX TEMPERATURE SENSOR ............................................................................................... 17

4.10 WATER FLOW SENSOR ..................................................................................................... 18 4.11 IGNITION ELECTRODE ....................................................................................................... 19

4.12 IONIZATION ELECTRODE .................................................................................................... 21

5. WORKING PRINCIPLE / ELECTRIC MEASUREMENTS ............................ 21

6. SERVICE ..................................................................................................... 27

7. MAINTENANCE .......................................................................................... 39

8. TROUBLE SHOOTING ................................................................................ 44

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1. Introduction

This manual is a complement to the instruction/operation manual delivered with the appliance, with the main

important technical details that are relevant for the official service partners and trainers in the country. In any

case one of the documents replaces the use of the other.

2. Appliance description

This appliance is a fan pressurized gas water heater, which will replace the actual room sealed range of

appliances offering a wider range of modulation and installation advantages with both indoor and outdoor

models available.

2.1 Appliance Designation

The designation allows the identification of the main characteristics of the units, especially when report is needed

through call centre or after sales technicians.

T 4600 – Instantaneous gas water heater model

T 4600 S – fan pressurized operation

T 4600 S 12 / 15 / 18 – Output (flow rate at 25ºC rise)

T 4600 S 12 / 16 / 20 O – Flue less model for outdoor installation

T 4600 S 12 / 16 / 20 O 23/31 – Gas type (23 = natural gas / 31 = liquefied petroleum gas)

Segment Designation

Outdoor Installation

(temperature setting adjustable degree by degree)

T 4600 S 12 O 23

T 4600 S 12 O 31

T 4600 S 15 O 23

T 4600 S 15 O 31

T 4600 S 18 O 23

T 4600 S 18 O 31

Table 1 – Appliance identification

2.2 Available accessories Remote control Possible wired connection to both indoor (optional accessory) and outdoor versions (included in packaging) allowing direct connection to the outside of the appliance with neither the need of configuration, nor a connection inside of the room sealed box.

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Pict. 1 – Remote control connection to the appliance

Pict. 2 – Remote Control with cable, connectors

and instruction manual

Anti-Freeze kit Allows the protection of the appliance against water freezing inside of its pipes until -20ºC (lower environment temperature acceptable by gas valve), so to be used in cases where ambient temperature can be lower than 5ºC.

Pict. 3 – Anti-Freeze Kit

The kit includes 8 resistances of 16W each, which activate under conditions from table 3.

Activation Deactivation

T in ≤ 2ºC T in ≥ 5ºC

or and

T box ≤ 5ºC T box ≥ 10ºC

Table 2 – Anti-freeze activation conditions

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3. Installation

The installation manual of each product must be checked and used by the installer in order to optimize and

leave the appliance in correct operation conditions.

Check lists for technicians/installers:

4.1 Appliance fixation on the wall

Requisite Confirmation

Appliance is levelled and in the vertical position?

Delivered accessories are used accordingly?

Appliance is supported exclusively by the wall fixation and not by hydraulic and/or gas connections?

Table 3 – Check List for Fixation

Pict.4 – Pre-installation distances

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Pict. 5 – Wall Fixation Preparation

4.2 Water connections

Requisite Observations Confirmation

Water pipes were cleaned before connected to the appliance?

Leakage test was done successfully?

Inlet water filter was checked and is cleaned, ensuring the necessary water flow?

Accessories for water connections are adequate?

Water pressure and flow are according to the appliance specifications?

- Nominal pressure: 1- 4 bar - Minimum pressure: 0,15 bar - Maximum pressure: 12 bar

Table 4 – Check list hydraulic connections

4.3 Gas connection

Requisite Confirmation

The appliance is suitable for the available gas type?

Pressure reducer and gas pipe are adequate for the required pressure and gas flow?

Accessories for gas connection are adequate and according to the country specification/standards?

Table 5 – Check list for gas connections

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Pict. 6 – Manometer pipe connection to measure static/dynamic gas supply pressure

4.4 Appliance performance

Measure water flow and temperature increase to check temperature and instantaneous water flow, assuring

correct operation of the appliance.

Pict. 7 – Use of water flow meter and thermometer

gas manometer

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5. Components Overview

1 – Collector 2 – RSF box 3 – Heat exchanger 4 – Heat cell 5 – Burner 6 – Fan 7 – Gas valve

8 – Flow sensor 9 – Ionization electrode 10 – Ignition electrode 11 – Gas inlet 12 – Water inlet 13 – Water outlet

Pict.8 – Internal view of model

6.1 Control panel in remote control The control panel allows the user, installer or technician, to perform all different operations needed.

1 3

2

4

6

10

9

8

7

5

11 12 13

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Pict.9 – wired remote control

On / Off button

The main switch is assembled on

the PCB and disconnects phase-L

from neutral-N.

No voltage at components if the

main switch is in OFF-position

Note: Errors reset function when

pressed for more than 3 seconds

Program Button

Used to enter in different services:

- Enter in service mode

- Scroll in the service mode menu

- Save value or adjust set values

- Save a temperature set (user)

Selection button

Used to select temperature values,

adjustments and navigation on

parameters inside the visualisation

mode.

Table 6 – Control Panel Buttons

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Symbol Description Observation

Temperature Unit:

ºC – default value

ºF – alternative value

Selection can be done by changing

default value on service mode (P6)

Power bar indicator:

Indication of the current operation

power

Indicative Value (in %)

Flame indication:

Indication of flame in the burner

Symbol displayed when ionization is

detected - flame presence

Warning symbol:

Combined with an error indication

/ warning code indicates a faulty

performance

Tap symbol:

Indication of not enough power to

reach set point

In case symbol is displayed,

decrease (-) or increase (+) flow

accordingly

Solar application:

Indication that the automatic solar

function is activated, meaning that

the appliance is receiving pre-

heated inlet water, with no need

for burner to start

The symbol is displayed and burner

is shutdown when T in is under

following conditions:

T in ≥ T set – 1K

The symbol is deactivated and

burner restarted when:

T out < 60ºC (if T set ≤ 50ºC)

T out < T set + 10ºC (if T set > 50ºC)

Fan operation:

Indication that the fan is in

operation

Table 7 – Display Symbols

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6.2 Heat cell with burner pipes The heat cell includes the flame visualization window, ignition electrode, ionization electrode and the burner pipes.

Inlet: Primary air from the fan and gas from the gas manifold. Outlet: Hot combustion gases to the heat exchanger

Pict.10 – Heat cell detail with ignition / ionization electrodes

Pict.11 – Burner blade Primary air plate The primary air plate is assembled between the heat cell and the gas manifold in order to ensure the correct mixture of air and gas according to the specific appliance model.

Appliance Stamp

12l/min 12 L

15l/min 15 L

18l/min 18 L

Table 8 – Identification of primary air plates

The plate has indexation pins that ensure the correct assembly on the heat cell and the type gas mark orientation to the front.

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Pict. 12 – Primary air plate

6.3 Gas manifold The gas manifold is a gas distribution pipe with integrated drilled injectors and two pressure measuring points:

- gas valve pressure = Pburner - air fan pressure = Pbox

The manifold cover allows the gas supply to the burner over 2 different segments, in order to assure a wide modulation range according to the capacity of the appliance. The gas manifold for GWH 12 models have in total 9 injectors with following distribution:

- NG Ø 1.7 - LPG Ø 1.3

Pict. 13 – Gas manifold for 12l/min appliance with 9 injectors

Burner segment 1

Burner segment 2

GWH 12

GWH 18

Injectors

GWH 15

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The gas manifold for GWH 15 models have in total 11 injectors with following distribution:

- NG Ø 1.7 - LPG Ø 1.3

Pict.14 – Gas manifold for 15l/min appliance with 11 injectors

The gas manifold for GWH 20 models have in total 15 injectors with following distribution:

- NG Ø 1.7 - LPG Ø 1.3

Pict.15 – Gas manifold for 18l/min appliance with 15 injectors

Burner segment 1

Burner segment 2

Burner segment 1

Burner segment 2

Injectors

Injectors

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Pict.16 – Pressure measuring points

6.4 Fan The control unit monitories the primary air flow to the burner by varying the fan motor power supply voltage (DC), ensuring a correct variable speed during the operation according to the output needed. The fan motor provides an additional control signal to enable/disable operation and the speed of the fan is measured by the feedback signal provided by the fan’s motor. The signal consists on a square wave with a frequency proportional to the speed of the fan.

Pict. 17 – Different fan flanges (12 and 15 and 18l/min models)

Gas Pressure Measurement point

= P burner

Air Pressure Measurement point

= P box

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6.5 Gas Valve Over the control unit it is possible to control the gas flow to the burner by the modulating gas valve (MV1). The gas valve is composed by other three solenoids identified as safety valves (SV1 + SV2 + SV3) releasing the modulated gas to and from the solenoid gas valve. Safety solenoid valve The safety valve 1 (SV1) is the first safety element that releases gas to the burner. Safety valves 2 (SV2) and 3 (SV3) are the second safety level elements, that release gas to the first and second burner segments, respectively, acting as safety and segmentation valves.

Pict. 18 – Gas Valve

Modulating valve Mechanical modulated valve The Gas flow (thermal load) is automatically modulated in order to ensure the correct hot water set temperature, under water flow or temperature variations. Switchover valve The burner is composed by 2 segments which are fed according to the solenoid valves activation (SV1 and/or SV2) which can be switched over according to the different thermal load, in order to obtain a stable combustion. These valves ensure the most suitable condition under the control of microcomputer, based on the values detected by the water flow sensor and hot water thermal fuse.

SV1

SV3

SV2

MV1

2nd Burner Segment

1st Burner Segment

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Pict.19 – Gas valve / burner scheme

6.6 Heat Exchanger The copper heat exchanger has different size and number of fins according to the appliance model (12, 16 and 20l/min). This configuration ensures the sealed heat transfer from the flame heat to the water that flows through the copper pipes.

Pict.01 – Heat exchanger

SV2

SV1

SV3

MV1

Burner segment 1

Burner segment 2

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6.7 Water Inlet Assy

The inlet water valve contains the water connection of 1/2” that integrates also the filter.

Pict.21 – Inlet Water Valve

6.8 Water temperature sensors

The outlet and inlet water temperature is measured by a 10kΩ NTC (See table 15). Both NTC are equal, but connected to different cable colors (blue wires to inlet water / red wires to outlet water).

Pict.22 – Temperature sensor

6.9 Box Temperature sensor The Box air temperature is measured by a 220kΩ NTC (See table 14) and is assembled on the control unit back panel, in order to monitor the temperature inside of the room sealed box.

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Pict.23 – Box air temperature sensor

6.10 Water Flow Sensor Water flow is measured by a turbine flow sensor that is fed by a DC signal, proportional to the measured water flow.

- Flow rate to operate the appliance: 2.2 l/min - Flow rate to shut off the appliance: 1.8 l/min

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Pict.24 – Motorized water valve (water flow sensor + stepper motor)

In case Q > 2 l/min following Pout verification occurs:

- If Pout > Minimum Power, the appliance will run with the calculated minimum water flow, in order to

reach the set point with a temperature stability of + / - 1ºC;

- If P out < Minimum Power, In case expected T out > set point, burner will shut down.

Flow [l/min]

Frequency [Hz]

24 96

18 72

14 56

10 40

8 32

4 16

2 8

Table 9 – Water flow sensor values

6.11 Ignition electrode Spark generation is started immediately before opening the gas valve, and stopped when ionization is sensed.

Pict.25 – Ignition electrode

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In order to prevent harder ignition processes and be sure of conditions of gas supply and burner stability,

following situation is verified during the so called safety time period.

In each of the attempts, the system monitors the ionisation signal; this signal drives the start of normal

operation, however and, in case the ionization signal is not detected during the ignition sequence, the failure

indication EA will be displayed. In this case a non-volatile lock-out is activated, and only a manual reset can

lead the system back to normal operation. If the ionisation signal is interrupted during normal operation, this

ignition sequence is re-started.

Fan Ignition spark

1st & 2nd Ignition Sequence Safety Time = 29 sec

1st Attempt (5 sec)

Purge Period (3 sec)

2nd Attempt (5 sec)


3rd Attempt (5 sec)

Pos Purge (8 sec)

+

+

+

3rd Ignition Sequence Safety Time of 21 sec + 3 min (ready start state)

1st Attempt (5 sec)


2nd Attempt (5 sec)


3rd Attempt (5 sec)

Pos Purge (3 min)

+

+

+

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1.12 Ionization electrode Flame is sensed through an ionization electrode, and detection is granted for ionization currents [higher than 0.8 µA]

Pict.26 – Ionization electrode

Pict.27 – Ignition / ionization electrodes position on the burner

7. Working Principle / Electric Measurements

Water Flow Detection and solar mode operation

Water Flow Calculation procedure

WF = Power (T set – T in)

WF ≥ 2.0 l/min

Burner ON

WF < 1.6 l/min

Burner OFF

Burner On

Solar mode Operation

Burner Off

T in ≥ T set – 1ºC

T out > T set

T out < T set

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Operation Action Connection to

the control unit Result

Standby

(Inputs Signals must be

within expected limits)

Main Switch in control unit Input ON

Electrical plug connected Input 240 V AC

Thermal fuse with continuity Input

Contact closed

Ionization reading Input 0 µA

Temperature sensors OK Input Ohm Value inside

range

Hot Water Demand

(tap opening)

Turbine detects water flow Input Frequency value to

control unit

Spark to ignition electrodes Output

Gas valve solenoid activation Output V DC

Flame on main burner Ionization detection (spark stops) Input I > 0.8 µA

Hot Water Delivery Safety devices monitor operation Input

Table 10 – Operation conditions

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1 – Ionization electrode

2 – Fan

3 – Ignition electrode

4 – Electrical supply

5 – Anti-Freeze Connection

6 – Remote control connection

7 – Solenoid Valve (MV1 – Modulation)

8 – Solenoid Valve (SV1 – Safety)

9 – Solenoid Valve (SV3 – Burner)

10 – Solenoid Valve (SV2 – Burner)

11 – Thermal fuse

12 – Water flow sensor

13 – Air Box temperature NTC

14 – Outlet water temperature NTC

15 – Inlet water temperature NTC

Pict.28 – Electric Diagram

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ID Component Description

Measuring Wire Colours

Value Remarks

12 Water flow sensor

Red-Black GND

5 VDC Control power

Yellow-Black GND ≈ 2.4 VDC

(pulse frequency ~Hz)

On: ≥ 1.9l/min Off: ≤ 2.2/min

Note: see table 11 to check

correspondence between water flow vs frequency signal

11

Thermal Fuse (actuation

temperature: 114ºC)

Multimeter for resistance measurement R (Ω)

White cable – White cable

Circuit open – Not Ok (infinity – no continuity)

Circuit closed – Ok (0 Ohm – continuity)

13

Air Box

temperature NTC

See corresponded values in table 12

14

Outlet water temperature

NTC See corresponded values in table

13

15

Inlet water

temperature NTC

Table 11 – Electric Values

Operating Temperature (ºC) Resistance (KΩ)

-10 1373

-5 1034

0 784.7

5 600.0

10 462.1

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15 358.4

20 279.9

25 220.0

30 174.0

35 138.5

40 110.9

45 89.24

50 72.24

55 58.78

60 48.08

65 39.51

70 32.63

75 27.07

80 22.56

85 18.88

90 15.87

95 13.39

100 11.34

105 9.642

110 8.228

Table 12 – NTC resistance values for Air Box NTC

Operating Temperature (ºC)

R min (KΩ)

R nominal (KΩ)

R max (KΩ)

0 30.34 30.40 36.47

5 23.674 25.902 28.129

10 18.617 20.247 21.878

15 14.749 15.950 17.151

20 11.768 12.657 13.547

25 9.454 10.115 10.777

30 7.644 8.138 8.632

35 6.218 6.589 6.959

40 5.089 5.367 5.646

45 4.188 4.398 4.608

50 3.466 3.624 3.782

55 2.883 3.002 3.122

60 2.410 2.500 2.590

65 2.009 2.092 2.175

70 1.683 1.759 1.835

75 1.416 1.486 1.555

80 1.197 1.260 1.323

85 1.016 1.074 1.131

90 0.866 0.918 0.970

95 0.741 0.788 0.836

100 0.637 0.680 0.722

105 0.549 0.588 0.627

110 0.475 0.510 0.545

Table 13 – NTC resistance values for water temperature NTC’s

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ID Component Description

Measuring Wire Colours

Value Remarks

1 Ionization Electrode

White wire to ionization electrode

Multimeter in position for current measurement, with

scale for µA range of values

Ionization current > 0.8 µA

Note: Cables connected in serial between ionization cable from control unit and electrode.

2 Combustion fan

Brown-Blue GND

~ 0 – 45 V DC Supply power

Orange-Blue GND

~ 10.8 – 13.2 V DC Controlling power

Yellow-Blue GND DC~V

(pulse frequency ~ Hz) Feedback from hall

sensor

7 Mechanically

modulated valve (MV1)

Red-Red ~ 0 – 12 V DC

Current = 0 – 220 mA Resistance ~ 80 Ω

Modulation Valve

8 Main solenoid valve

(SV1) Blue-Blue

~ 20.4 – 24 V DC (open) 0 – 3.6 V (close)

Resistance ~ 99.7 Ω Inlet Safety Valve

9 Solenoid valve (SV3) Black-Black ~ 20.4 – 24 V DC 0 – 3.6 V (close)

Resistance ~ 100.3 Ω Burner Segment 2

10 Solenoid valve (SV2) White-White ~ 20.4 – 24 V DC

0 – 3.6 V DC (close) Resistance ~ 100.4 Ω

Burner Segment 1

Table 14 – Measurements and values

Pict.29 – Gas Valve Solenoids

SV2 – White Wires

SV3 – Black Wires

SV1 – Blue Wires

MV1 – Red Wires

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In order to ensure a correct start up of the appliance and a correct function after any intervention on the

appliance, the installation manual must be read and instructions and main functions must be explained to the

end user.

Table 16 indicates the method and values for testing the main components function and, consequently,

ensure a correct and safe operation of the appliance.

8. Service

When replacing the control unit, configurations need to be checked and set accordingly.

Attention:

Control units are supplied as spare part with following default values:

- 20 = Natural Gas (see P7)

- 12 = 12 liters appliance operation (see AP on P4)

Pict.30 – Confirmation of HMI configuration (gas type) (South Africa settings highlighted)

* Not Applicable for ZA models

*

*

*

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Pict.31 – Confirmation of HMI configuration (appliance type)

Note: In case of replacement of control unit, register P1 and P2 values from the existent unit configuration. Procedure to enter in Service Mode:

- Press and hold "Program", “+” and “-“ buttons for more than 3 seconds;

- As soon as '188' is displayed, release buttons, till the display indicates P2.

From this position and using the selection buttons “+” and “-“, different service modes can be assessed.

Pict.32 – Service mode entry procedure

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Table 15 – Service Mode Parameters List (1st level)

P1 Maximum Power

P2 Minimum Power

P3 Remote Control Registration

P4 Diagnostic mode

P5 Ignition Startup delay

P6 Temperature Unit Selection

P7 Gas Type Selection

Set point Normal Mode

P0 Gas valve adjustment

P8 Back light activation

See Combustion - gas power adjustments section for more details

P9 Fan Purge

PA Calibration of components

See table with parameters

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Table 16 – P4 Diagnostic Mode Parameters List (2nd level)

…

P2 Minimum Power

…

P4 Diagnostic mode

…

E Exit

0D Set point

1D Inlet Temperature

2D Outlet Temperature

3D Water Flow

5D Box air temperature

1F – 10F Last recent failures

AL Show All Segments

rP Restore factory default values in P1 / P2

AP Appliance Power

Setpoint Normal Mode

AS Altitude Adjustment

SC Set Point Calibration

Pu Purge selection

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Combustion – Gas Power Adjustment Parameters

The adjustment of the appliance for minimum / maximum power operation can be needed under following

conditions:

- Gas Conversion (see correspondent manual);

- Gas valve replacement;

- Start up of unit when need to operate with Propane (LPG models are adjusted on factory for Butane).

Following image indicates the 2 measurement points to be used:

Pict.33 – P0 / P1 / P2 adjustment measurement points

Pict.34 – Gas Manometer Connection

Gas Pressure Measurement Point Measurable values:

- P burner - P0 - P1 – L1 - P2 – L2

Fan Pressure Measurement Point

Measurable values:

- P box - P1 – A1 - P2 – A2

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Technician Level Comments

The value measured when in

P0 should be 1.2 mbar

Range of value in control unit is from 0

to 40

Spare part default setting is 20

Table 17 – P0

The P1 mode can be accessed in the service mode, depending on the adjustment and/or

confirmation need. Check parameters according gas and model type and check results

according to the manual – ensure constant result (P burner – P box = P L1 – P A1)

To keep the appliance in P1 (maximum power adjustment), is important to assure a minimum

water flow, otherwise the appliance will jump automatically to P2 (minimum power).

GWH 12: Flow > 4 l/min



Table 18 – Minimum water flow needed to keep P1

Maximum Power adjustment


Maximum power burner

adjustment after repairs /

maintenance / gas

conversions

P1 contains the fan speed setting (A1)

and gas power (L1) at maximum power

(depends on gas type / model)

When P1 is visible, press “P” and enter in the 2nd level accessing “E”

for enter and/or exit P1

Maximum Input Power Not Used (by default will display 20)

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Adjustment of air flow without

change gas conditions

Range from 0 to 40


Adjustment of gas flow

without change air conditions

Range from 0 to 40


Table 19 – P1 sub menus

Values in P1 mode are settled according to the appliance selection and gas type from

factory. To check default value or to change parameter, press “Program” button when

inside of P1.

Appliance Natural Gas Butane

P1

ΔP (kPa)

GWH 12 0,48 - 0,56 0,42 - 0,54

GWH 15 0,44 - 0,56 0,44 - 0,56

GWH 18 0,40 - 0,52 0,38 - 0,50

P2

ΔP (kPa)

GWH 12 0,04 - 0,08 0,05 - 0,09

GWH 15 0,04 - 0,08 0,05 - 0,09

GWH 18 0,08 - 0,09 0,04 - 0,08

Table 20 – Values measured on gas manometer

The P2 mode can be accessed in the service mode, depending on adjustment and/or

confirmation need. Check parameters according gas and model type and check results

according to the manual – ensure constant result (Pburner – Pbox = PL2 – PA2)

Minimum Power adjustment

(Minimum gas and water flow)


Minimum power burner

adjustment after repairs /

maintenance / gas

conversions

P2 contains the fan speed setting (A2)

and gas power (L2) at maximum power



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When P2 is visible, press “P” and enter in the 2nd level accessing “E”

for enter and/or exit P1

Minimum Input Power Not Used (by default will display 20)

Adjustment of air flow without

change gas conditions

Range from 0 to 40


Adjustment of gas flow

without change air conditions

Range from 0 to 40


Table 21 – P2 sub menus

Remote control registration Installer Level Technician Level Comments

Not used

Table 22 – P3

The access to the data visualization mode, is made by entering first in the “service mode”

and then, scrolling to the parameter “P4” of the adjustment mode.

Diagnostic mode and visualization mode

Installer Level Technician Level Comments

This mode helps the

installer in the startup

to check parameters

such as water flow

through the appliance

and inlet / outlet

temperatures

This mode helps the

technician to find some

information useful to

adjust and to check

functionality of the

appliance.

Main recommendation is

to perform always a check

on the last 10 failures in

memory in order to

analyze eventual

problems in installation

that might need to be

corrected

Table 23 – P4

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By pressing the “P” button while the display shows “P4”, the LCD will enter into

visualization mode and will show “E”, meaning “Exit” from the visualization mode. By

pressing “P” button again, the LCD will show “P4”, i.e. the visualization mode has been

exited.

After entering into data visualization mode (showing “E”) and then pressing “+” or “-”

button, the parameter and failure visualization fields can be selected as shown in table 5.

Sequence of

Parameters in P4 Comment Value / Unit

Entry / Exit of visualization mode

Possible change of set point

without leave service mode and

perform any needed control

ºC or ºF

(depends on P6 setting)

Temperature indication

Inlet water temperature

Temperature read by inlet sensor

ºC or ºF

Temperature indication

Hot water temperature

Temperature read by outlet sensor

ºC or ºF

Water flow indication

l/min ( ±0.5l/min )

Indicates water flow measured by the

turbine (l/min)

Not existing

Temperature of air in room sealed

box

Temperature read by outlet sensor

ºC or ºF

until

Last 10 Failures for diagnostic

purposes

Failure 1 is last failure occurred

Failure 2 occurred before Failure1









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Test Display Visualization of all segments of text

display (LCD)

Reset to Factory default values

Allows the individual reset of P1 and

P2 for the default values memorized

from factory during appliance

adjustment.

Enter this mode and select P1 or P2

according need and press P for reset

(+/- 3 sec)

SC = Set Point Calibration

Internal Compensation of set point

defined by user in order to

compensate temperature loss until

last consumption point.

Value can be adjusted from:

set point -5ºC

to

set point +5ºC

(ºC by ºC)

AS = Altitude Adjustment

(combustion optimization)

(default value depends of TTNR

and destination Country –

Australia is set to 1)

1= sea level to 500 m

2= 500 m to 1000 m

3= 1000 m to 1500 m

4= 1500 m to 2000 m

5= 2000 m to 2500 m

6> 2500 m

Purge time definition

Allows the change of time for pos-

purge time between:

- 3 min (at min fan speed)

or

- 30 sec (at normal fan

speed)

Appliance Power definition

Parameter for control unit adaptation

according appliance model

(modulation range)

12 = GWH 12

15 = GWH 15

18 = GWH 18

Table 24 – Visualization mode parameters

Start-up delay Activation

Press the button until P5 appears and press Program button “P” to define a time frame for

the activation of the appliance when the appliance is installed as a backup for a solar

installation. Press and hold Program button until CC blinks on the display.

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Start up delay Default Value Comments

______

(Note: from 0 to 60 sec)

The value defined here is defined in seconds and

will create a delay in the startup sequence since

flow rate is detected in order to allow pre-heated

water to reach appliance without unnecessary

burner activation when water is hot.

Table 25 – P5

Temperature Unit selection

To change the temperature unit, enter first into the service mode and then scroll to the

parameter “P6”. By pressing the “P” button while the display shows “P6”, the LCD will

enter into temperature selection unit mode and show “C” which indicates “Celsius degree”.

Pushing “+” or “-” button, the LCD will show “F” which indicates “Fahrenheit degree”.

Temperature unit selection Default Value Possible

Selection Comments

ºC ºF

To set one of these units it is

necessary to store the value.

For that, press program button

until the desired option flashes

on the display

Table 26 – P6

To change the gas type, enter first into the service mode and then scroll to the parameter

“P7”. This parameter allows the control of the modulation range according to the gas type.

In order to ensure a proper operation of the appliance, this parameter must be checked

when the control unit is replaced.

Appliance Type selection Settings: Comments

20 – Natural Gas G20

(with injectors of 1.7)

30 – Butane G30

31 – Propane G31

25 – Natural Gas G25

28 – natural Gas G20

(with injectors of 1.8)

NG models will have

from factory 20

LPG models will have

from factory 31

Note: spare part pre-set value

is 20

Table 27 – P7

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Backlight activation Default Value Possible

Selection Comments

dE

(deactivated) ON

Allows the activation of the

backlight of the LCD

Table 28 – P8

Purge mode Comments

To set one of these units it is necessary to store the value. For

that, press program button until the desired option flashes on the

display

Table 29 – P9

The following parameter is only applicable when correspondent component is replaced in field.

Components Calibration Technician Task Comments

Only applicable when

components are replaced

Allows the technician to calibrate

components operation range after a

replacement

Entry / Exit parameter

Adjustment of bypass Not Applicable for ZA Model

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Adjustment of motorized

water valve (stepper motor) Not applicable for ZA market

Adjustment of water flow

sensor

Open hot water to start appliance and press

P checking the water flow

(l/s x 10).

Appliance will shut off while calibration is

being done until inlet and outlet NTC

measure same temperature and water flow

start blinking.

Press P to finish.

Table 30 – PA

9. Maintenance

To ensure continued efficient operation of the appliance, it is recommended that it is checked and serviced as necessary at regular intervals. The frequency of servicing will depend on the particular installation conditions and use profile, but in general, once a year should be adequate. Any intervention / service work in the appliance must be carried out by a competent person such as registered and competent technician. Before any service operation, turn off the gas supply at the main gas service cock upstream. Carry out the service operation as described in the manual. The service partners have all necessary accessories and tools for the interventions.

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L641 – O’rings in contact with water HFt1 v5 – Gaskets in contact with gas

Pict.35 – Recommended lubricants for connections

Cleaning the filter For the cleaning of the filter, first loose the clip (2), than remove the cover (3) that is fixed in the body of water valve – see picture 38. Pull the water flow restrictor with integrated filter from the front to the outside of the water assy. Clean the filter with water and / or air pressure and assemble it back on the water.

Pict.36 – Water filter removal

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Inspect and clean the heat exchanger when needed. To remove the heat exchanger, isolate the appliance from incoming cold water supply at the inlet cock. Open the taps to release any remaining water pressure and drain the appliance over the water assy cover -(3) in picture 38.

Pict.37 – Heat exchanger cleaning

Take care not to damage the seals that ensure tightness between the heat exchanger, the heat cell and collector and ensure correct clearing and alignment of the fins. In hard water regions it may be necessary to descale the heat exchanger body, using a proper descaler. Fill the heat exchanger with the descaling solution and let it act until the solution stops bubbling. Drain and thoroughly wash out the exchanger with clean water. Warning: Acid/water solutions must be used with extreme caution. Take care not to splash on to the skin or into the eyes. Wash any affected areas with large amounts of cold water and seek medical advice.

Pict.38 – heat exchanger descaling

Re-assemble the heat exchanger ensuring its correct position on the two support hooks in

the appliance back plate, good conditions of sealings and tightness between heat

exchanger, collector and burner.

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Pict.39 – heat exchanger

Replacement of Parts Any service work must be carried out by a competent person such as the technician indicated by the after sales organization. Before any service operation, turn off the gas supply at the main gas service cock. When replacing components, always use the supplied gaskets / sealings.

Pict.40 – using supplied sealing’s in burner / collector replacement

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Pict.41 – using supplied sealing’s in heat exchanger replacement

When opening heat cell for cleaning / washing refers to gasket kit if components are not being replaced as example below for 12 / 16 / 20 models (1 kit per capacity)

Pict.42 – using gasket kit when opening heat cell for cleaning / washing

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10. Trouble Shooting

Error Code

Description Type

A0 Both Inlet and outlet NTC temperature sensors are damaged (open / short circuit)

Lockout (self reset when conditions corrected)

A1 High temperature detected by NTC inside the box (T box > 70ºC)

Warning (reset by closing water)

A4 Air Box NTC temperature sensor defected (open or short circuit)

Lockout (self reset when conditions corrected)

A7 Outlet water NTC temperature sensor defected (open or short circuit)

Warning (self reset when conditions corrected)

A9 Output below expected value / Outlet sensor not assembled correctly (safe mode operation)

Warning (reset by closing water)

C1 Insufficient air flow at start up

Lockout (manual reset))

C7 Fan unplugged / no detection of rotation/speed signal from fan

Lockout (reset by closing water)

CA Water flow signal over specified maximum value (flow > 25 l/min)

Warning (self reset by reducing water flow)

CF Blocked exhaustion / Combustion failure Lockout (manual reset)

E0 Control Unit damage: Ionization circuit test fault / Software error

Lockout (manual reset)

E1 Over-temperature detected in hot water outlet sensor (T

out > 85ºC) Warning Lockout (Self-Reset when T < 60ºC)

E2 Inlet water NTC temperature sensor defected (open or short circuit)

Warning (self reset when conditions corrected)

E4 Air Box NTC temperature sensor protection by over temperature detection (T air > 80ºC)


E9 Thermo fuse opened circuit (overheat – T=114ºC)


EA No ionization detected during safety time (safety time with 3 + 3 + 3 trials elapsed)


EC Loss of ionization 5 consecutive times in less than 5 sec Lockout (manual reset)

EE Modulating Solenoid disconnected Self reset when solved

EF High Output (wrong gas type) Lockout (manual reset)

F7 Ionization error (flame sensing during stand-by) Lockout (manual reset)

FA Leakage error on gas valve when ionization is detected after demand finish


FC Buttons pressed more than 30 sec

Self-reset when button released

F9 Safety Solenoid disconnected Lockout (manual reset)

Table 32 – Error code list

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8.1) Problems without error codes

Combustion noise too high

No Convert appliance according IM (check existence of EF codes in

memory)

Gas supply type according appliance gas type ?

Gas supply pressure (static / dynamic) according IM ?

Assure gas supply pressure, testing appliance at

maximum and minimum

In case of need contact gas supplier

Yes

No

Check exhaustion system for eventual recirculation of

combustion products (cross contamination)

Cross contamination persist / Combustion

not ok

Clearances for air admission / flue discharge according IM / Sealing between flue pipes

and appliance

Measure CO2 value (at flue measurement point) in maximum power with /

without front cover

Without Front Cover CO2 (G20) ≈ 5.5% (+/-0.2%) CO2 (G31) ≈ 6.6% (+/-0.2%)

Temp gases máx ≈ 170ºC Temp. gases min ≈ 45ºC

With Front Cover

Máx CO2 = CO2 without front cover + 0.3 %

Yes

Yes

No

No

Adjust appliance by confirming ΔP1 / ΔP2

according IM Note: check air / gas

measurement independently to be sure reading is ≠ 0 and then

check ΔP

Problem solved ?

Emissions according specification ?

End

End

ATTENTION: CO2 > nominal = flue

recirculation CO2 increasing > 0.3%

difference from cover Off to cover On = flue recirculation

ATTENTION: Adjustments of ΔP are done

without front cover

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Strong Ignition Noise

No Startup / Ignition Spark

Noise produced during start up upon a demand.

Noisy Solenoids activation?

Check contact between connector of ignition wires and electrode. Replace it in case of

need and inspect electrode

Yes

No

Front Cover deflection?

Re-check minimum power adjustment.

Intermittent spark generation?

Yes

No

Normal noise (component characteristic)

Appliance remains in standby and without start ignition

sequence even with tap open

Low water flow due dirty outlet in tap?

Yes

Low water flow due to blocked appliance inlet

filter?

Water flow below minimum specified value

(Min. water flow > 2.2 l/min)

)

No

Clean eventual debris / dirtiness in tap

Remove purge cap and disconnect inlet connection to inspect and clean inlet

filter

Yes

Water flow above minimum specified value and confirmed

with water flow meter?

No

Check turbine connections in control unit and in water

flow sensor.

Yes

Remove water flow sensor and check if turbine spins.

Measure signals: Red – Black (input): 5 V dc Yellow – Black (output): 2.4 V dc

Signal from turbine? Refer to spare part list and replace turbine

Yes

Turbine ok but ignition transformer damaged?

Refer to spare part list and replace control unit

No

Yes

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8.2) Problems with Error Codes

A0 Fault in both inlet and outlet NTC sensor

Component Characteristic: NTC temperature sensor (10 kΩ type)

Lock Out Error Burner shutdown and manual reset necessary

The Inlet / Outlet NTC sensor is interrupted

or in short circuit

Ensure NTC wire is attached in NTC sensor

Unplug Wires and measure the NTC electrical resistance [R] (Ω)

[R] > 30 kΩ or < 0.5 kΩ

[R] = ∞ Ω

NTC values out of range

NTC interrupted

Replace NTC

Plug NTC connection wire and turn ON unit

Problem solved?

End

Change wiring

Problem solved?

Replace control unit

See spare part list

See spare part list

Refer to table with values in Service

Manual

Yes

No

No

Yes

No

No

Yes

Yes

ATTENTION: Red wires – outlet NTC Blue wires – inlet NTC

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A1 Temperature inside room sealed box and detected by air flow NTC sensor is > 70ºC

Component Characteristic: NTC temperature sensor (220 kΩ type)

Warning Message Appliance keeps operation and code is flashing until tap is

closed

Temperature inside box is high

Check position of sensor (attached at back cover of control unit)

NTC out of place and touching hot surface ?

Measure the NTC electrical resistance [R] (Ω)

[R] Ω = Current T air (ºC) ?

Correct position and fix NTC in original position

Replace wiring

Check origin of high temperature inside box

Evidences of leakages through sealing’s or HE

overheat?

End

Correct problem by inspecting and/or

replacing gaskets / sealings in Heat Cell

See spare part list

Yes

No

No

Yes

No

Yes


Manual

Power Reduction Procedure

Start condition: T air > 70ºC

Power lower in 5 % / 30 sec Stop Condition:

T air < 70ºC Note: when maximum power

reduction is 20 % or T air > 80ºC E4 is displayed

Heat Cell includes heat exchanger sealing with burner / flue collector

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A4 Fault in the air flow NTC sensor

Component Characteristic: NTC temperature sensor (220 kΩ)

Lock Out Error Burner shutdown

The Air NTC sensor is interrupted or in short

circuit

Assure NTC cable harness is connected in control unit

Unplug the NTC connection and measure the NTC electrical resistance [R] (Ω)

[R] > 1300 kΩ or < 8.2 kΩ

[R] = ∞ Ω


NTC interrupted

Change wiring

Plug connection wire and turn ON unit

Problem solved?

End

Change wiring

Problem solved?


See spare part list

See spare part list


Manual

Yes

No

No

Yes

No

No

Yes

Yes

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A7 Fault in the outlet water temperature sensor

Component Characteristic: NTC contact temperature sensor

Warning Message Appliance keeps operation and code is flashing

The Outlet NTC sensor is interrupted

or in short circuit

[R] > 30 kΩ or < 0.5 kΩ

[R] = ∞ Ω


NTC interrupted

Replace NTC


Problem solved?

End

Change wiring

Problem solved?


See spare part list

See spare part list


Manual

Yes

No

No

Yes

No

No

Yes

Yes

ATTENTION: Red wires – outlet NTC



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A9 The hot or cold water temperature sensor is not sensing the expected temperature

Component Characteristic: NTC temperature sensor

Warning Message Appliance keeps operation and code is displayed and

keeps flashing until tap is closed for self reset

Safe Mode Procedure Start condition:

1. After 30 sec from start up a misreading temperature is detected 2. After 2 min of output < 30% A9 is displayed (no message if output ok before 2 min)

The Inlet / Outlet NTC sensor is not

measuring the expected temperature

Unplug the NTC connection wire in both inlet / outlet sensors

Measure the NTC electrical resistance [R] (Ω) in both

sensors

[R] Ω = Current Temp. (ºC) ?

Replace Sensor


Manual

Yes

No

Check assembly location on hot water pipe (NTC with red wires) / cold water pipe (NTC with blue wires) and assure sensor tip is in

contact with pipes (straight surface / not in elbows)

Test appliance and water stability. Problem solved? End

Yes

Confirm gas type - Inlet Gas pressure too low ?

No

Measure dynamic gas pressure and check

pressure regulator in bottle

Gas type is LPG (butane) and bottle is

freezing / lower output?

Problem solved? Yes

No

Recommend different gas bottle location / regulator according output power of

appliance

Gas manifold is correct? (check GN / GPL mark in

injectors distribution pipe)

Check also the ΔP1 / ΔP2 values

No

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CF Combustion failure detected

Characteristic: Primary Fan (DC Centrifugal Fan)

Lock Out Error Burner shutdown / manual reset required

Air Flow Estimation Procedure

Start condition: 1. Airflow estimation should be achieved in +/- 20 % in 30 sec 2. Lockout after 1 min of inadequate air flow

High Resistance in flue exhaustion / not enough air

admission

Total vent length according specification?

Flue terminal is within clearances from adjacent walls/ceiling as stated in

manual?

Refer to Installation Manual (only for indoor models)

Concentric: L max = L pipes + L equiv elbows

Parallel: L max = L pipes intake + L equiv elbows + L

pipes exhaust

Yes No

Obstruction in flue path?

Yes

No

Possible mis-adjustment of P1 / P2

With flue gas analyzer check CO2 correcting

A1 / A2

Sealing in flue collector / extension pipes joining are obstructing the air

admission.

See spare part list

In case of need, reset P1 / P2 values and re-adjust appliance with help of flue gas analyzer

and ΔP values

Without Front Cover CO2 (G20 / 25) ≈ 5.5% (+/-0.2%)

CO2 (G30) ≈ 6.8% (+/-0.2%) CO2 (G31) ≈ 6.6% (+/-0.2%)


Correct exhaustion system. Problem

solved?

End

Obstruction in appliance?

Check if air restrictor in fan is correct / ensure sealing

between fan and burner is not creating obstruction

Yes

No

Yes

Problem solved? No

End

No

Yes

Check if parameter AS in P4 is adjusted according altitude

of installation location

For Outdoor versions check air admission grille in back of the unit and free exhaust grille

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C1 Insufficient air flow at start up

Characteristic: Primary Fan (DC Centrifugal Fan)

Lock Out Error Burner shutdown / manual reset

Total vent length according specification?

Flue terminal is within clearances from adjacent walls/ceiling as stated in

manual?

Refer to Installation Manual Concentric: L max = L pipes +

L equiv elbows Parallel: L max = L pipes

intake + L equiv elbows + L pipes exhaust

Yes No

Obstruction in flue path?

Yes

No

Possible mis-adjustment of P1 / P2

With flue gas analyzer check CO2 values correcting A1 / A2

Sealing in flue collector / extension pipes joining are obstructing the air

admission.

See spare part list

In case of need, reset P1 / P2 values and re-adjust appliance with help of flue gas analyzer

and ΔP values

Without Front Cover CO2 (G20 / 25) ≈ 5.5% (+/-0.2%)

CO2 (G30) ≈ 6.8% (+/-0.2%) CO2 (G31) ≈ 6.6% (+/-0.2%)


Correct exhaustion system. Problem

solved?

End

Obstruction in appliance?

Check if air restrictor in fan is correct / ensure sealing

between fan and burner is not creating obstruction

Yes

No

Yes

Problem solved? No

End

Air Flow Estimation Procedure

Start condition: 1. Airflow estimation should be achieved in +/- 20 % in 20 sec

High Resistance in flue exhaustion / not enough air

admission

No

Yes

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C7 No rotational speed sensor signal from primary fan

Characteristic: Primary Fan (DC centrifugal fan)

Lock Out Error appliance enters in lock out immediately

Check bad wire connection in the connector in the back cover of

control unit

Problem solved?

Fan unplugged / cables disconnected or not correctly

attached

Yes

No

Measure output signal from control unit

End

Brown – Blue: 0 – 45 V dc Orange – Blue: 10.8 – 13.2 V dc Yellow – Blue: pulse frequency

Defective Fan

No signal from control unit to fan?

Defective Control Unit

Replace Control Unit

Replace Fan

No Yes

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CA Excessive water flow (over specified value > 25 l/min)

Characteristic: Water flow sensor (turbine)


E0 Software / hardware failure in control unit

Characteristic: Control Unit

Lock Out Error

Excessive water flow through water heater

Water pressure excessive

Water flow signal > 172.5 Hz

Yes No

Refer to table in service manual with color code / flow

per model and correct it.

End

Remove inlet water connection and check existence of water flow

restrictor / filter

Problem solved?

No

Check need for water pressure reducer valve

Defective control unit

No

Wrong connections in cables?


Turn Off and On Unit.

Permanent error code? Yes

Correct Connections Yes

Error code after interface manipulation?

Yes

Problem persist?

Yes

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E1 Over temperature detected by the NTC sensor in the hot water pipe (T out > 85 ºC)

Characteristic: NTC Temperature Sensor

Warning Message Appliance shutdown burner operation but self reset when T

out < 60ºC

Error code self reset when temperature

decrease and appears repetitively?

Yes

No

Problem solved?

Maximum inlet appliance is 60ºC – ensure existence of thermostatic

mixing valve before unit

Clean filter and check if water flow restrictor is according specification

Appliance installed as a solar backup unit?

No

Flow of water is very low Check water flow with a

water flow meter

Yes

Maximum power very high

Unplug the NTC connection wire in outlet sensor


[R] Ω = Current Temp. (ºC) ?

Replace Sensor


Manual

No

Problem solved?

No

Yes

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E2 Failure in the inlet water temperature sensor

Component Characteristic: NTC Temperature sensor


The inlet NTC sensor is interrupted or in

short circuit

[R] > 30 kΩ or < 0.5 kΩ

[R] = ∞ Ω


NTC interrupted

Replace NTC


Problem solved?

End

Change wiring

Problem solved?


See spare part list

See spare part list


Manual

Yes

No

No

Yes

No

No

Yes

Yes

ATTENTION: Blue wires – inlet NTC



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E4 Air box NTC sensor detect high temperature inside room sealed box (Tbox > 80ºC)

Characteristic: NTC Temperature sensor

Lock Out Error Burner shutdown but self reset by closing water

Temperature inside box reach high limit

(Tbox > 80ºC)

Check position of sensor (attached at back cover of control unit)

NTC out of place and touching hot surface ?


[R] Ω = Current T air (ºC) ?

Correct position and fix NTC in original position

Replace wiring

Check origin of high temperature inside box

Evidences of leakages through sealing’s or HE

overheat?

End

Correct problem by inspecting and/or

replacing gaskets / sealings in Heat Cell

See spare part list

Yes

No

No

Yes

No

Yes


Manual

Heat Cell includes heat exchanger sealing with burner / flue collector

Problem solved?

Yes

No

Excessive burner power

Check CO2 emissions and reduce

power in L1 / A1 to correct ΔP1

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E9 Failure in the thermal fuse that opens circuit (Temp = 114 ºC)

Characteristic: Thermal fuse (located at control unit back cover)

Lock Out Error Burner shutdown and manual reset needed after repair

EE Modulating solenoid (MV1) disconnected

Characteristic: electro-valve


Permanent open circuit due to over

temperature

Thermal fuse damaged (melts at 114ºC)

Measure continuity: R = ∞?

Check origin for high temperature occurrence

Replace sensor (see spare part list)

Yes

Inspect main heat exchanger – fins

obstructed?

Yes Remove part and clean external fins

Problem solved?

Minimum Power too low (ΔP of P2)

End

Yes

No current for modulation solenoid

Check cables connection to MV1 (red cables)

No

Adjust P2 (increase L2 value and A2 proportionally). In

case problem persists, leave ΔP2 higher than value in IM.

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EA No ionization signal detected in the burner

Characteristic: Gas Valve + Electrodes

Lock Out Error Burner shutdown after safety time elapsed (3 + 3 + 3 tentative)

Information about ionization

Ionization current at standby = 0 µA (initial condition for startup ignition sequence)

With the appliance working, the normal value is ≈ 6 µA (condition for detection by control unit > 0,8 µA)

Sequence is identified below:

P – Purge / I – Ignition

Startup -> I (5s) -> P (3s) -> I (5s) -> P (3s) -> I (5s) -> P (8s) -> Total time of 29 sec I (5s) -> P (3s) -> I (5s) -> P (3s) -> I (5s) -> P (8s) -> Total time of 29 sec I (5s) -> P (3s) -> I (5s) -> P (3s) -> I (5s) -> P (10s) -> Total time of 31 sec

Lock Out indication “EA”

No flame in the

burner?

Spark is visible? Gas supply closed? Open gas cock to the appliance

Yes

No

Contact gas supplier or check gas meter and safety shut off valve

No gas at apartment?

Yes Yes

Yes

No

Problem solved? Measure static inlet gas pressure

Gas valve not releasing gas to burner

Safety Gas valve connections

disconnected?

Assure Connection and measure resistance

SV1 – Blue Wires (≈ 100Ω) SV2 – White Wires (≈ 100Ω) SV3 – Black Wires (≈ 100Ω)

No

Yes

Solenoid signal to open is not ok?

No

Measure Voltage signal (Between 20 – 24 V dc)

Replace control Unit

No

Ensure gas flow according model power

In case of defective solenoid, refer to spare

part list and replace gas valve

Yes

Failure in spark due to a defective / damaged

electrode

Ensure the 2 red ignition wires are in contact and connected to

control unit / electrode

Problem solved?

Replace ignition wires / electrode

Yes End

No

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EF Output of appliance is too high


Flame presence not

detected

NG (G20) appliance connected to LPG

(G30/31)

Check Gas type of appliance and gas

supply

Gas supply different from gas type on

appliance ?

Convert appliance – refer to spare part list and use defined kit

Yes

No

Appliance in Overload - P1 / P2 too high

Correct adjustments of ΔP for P1 / P2 adjusting L1/L2/A1/A2

proportionally

Appliance power defined in P4 – AP is not

according capacity ?

Enter service mode and check / correct

adjustment.

Yes

Note: all control unit as spare parts are supplied as NG (G20 in P7) and

12 in AP

No

Appliance gas type defined in P7 is not according model ?

Enter service mode and check / correct adjustment.

Yes

No

Spark is ok and flame is visible, but appliance shut off

and tries to re-ignite?

Ionization sensor touching burner / metal

part?

Verify the correct assembly of electrode

Yes

Ionization cable is disconnected /

damaged?

Verify and assure cable is connected and in contact with electrode (black wire). In case

of need replace wiring.

No

Yes

Yes

No

Incorrect adjustment in speed of the fan for

minimum power (check P0 / P2

Flame is not a blue steady one and is lifting? Ensure P7 / P4-AP is

correctly defined

Lean flame – decrease A2 value and increase L2

Yes

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F7 Ionization detected with appliance in standby

Characteristic: Ionization system


F9 Safety solenoid valve disconnected

Characteristic: electro valve


Loose or bad connection between cable and

electrode

Assure black wire is securely connected to

the set of electrode

Ionization cable damaged / defective

isolation ?

Replace wiring and assure connection in

electrode

Yes

No

Ionization electrode damaged?

Replace electrode Yes

Verify wires connection: SV1 – blue wires SV2 – white wires SV3 – black wires

Measure resistance of SV ≈ 99.7 Ω

No

Loose connection in safety solenoid (SV1 /

SV2 / SV3)

Problem solved?

Replace gas valve


No

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FA Gas leakage error due to failure in gas valve that is not closing properly

Characteristic: Gas Valve + Ionization system


Bosch, Termotecnologia S.A

TT-DW/PRM-STI – International Training and Technical Support

Aveiro Plant - Portugal

At end of a demand, ionization is detected at

burner

Replace gas valve

No

Gas leakage caused by internal defect

Problem solved?

Gas leakage caused by

wrong signal

Measure feed signal to SV valves (≈20 – 24 V dc)

Signal is continuous even without demand?

Yes

Replace control unit Yes

INSTANTANEOUS GAS WATER HEATER...

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