520 (T‐H2) and 320 (T‐H2S) Installation Manual and Owner’s Guide ANSI Z21.10.3 and CSA 4.3 520 (T‐H2) models only If the information in these instructions is not followed exactly, a fire or explosion WARNING may result causing property damage, 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.
Contents SPECIFICATIONS 520 (T‐H2) and 320 (T‐H2S) models CONTENTS 520 (T‐H2) models Natural 320 (T‐H2S) models Natural Propane Propane Gas Connection Water Connections Condensate Drain Port Connection Water Pressure* Natural Gas Inlet Pressure Propane Inlet Pressure 520 Direct Vent Indoor (T‐H2‐DV) 520 Outdoor (T‐H2‐OS) 320 Direct Vent Indoor (T‐H2S‐DV) 320 Outdoor (T‐H2S‐OS) Manifold Pressure** SPECIFICATIONS………………………………... 2 INTRODUCTION……………………………….… 3 SAFETY GUIDELINES…………….……………..
Introduction INTRODUCTION This manual provides information necessary for the installation, operation, and maintenance of the water heater. The model description is listed on the rating plate which is attached to the side panel of the water heater. Please read all installation instructions completely before installing this product. If you have any problems or questions regarding this equipment, consult with the manufacturer or its local representative.
Safety Guidelines SAFETY GUIDELINES GENERAL 1. 2. 3. 4. 5. Follow all local codes, or in the absence of local codes, follow the most recent edition of the National Fuel Gas Code: ANSI Z223.1/NFPA 54 in the USA or CAN/CSA B149.1 Natural Gas, Propane Installation Code in Canada. Properly ground the unit in accordance with all local codes or in the absence of local codes, with the National Electrical Codes: ANSI/NFPA 70 in the USA or CSA standard C22.1 Canada Electrical Code Part 1 in Canada.
Installation INSTALLATION All gas water heaters require careful and correct installation to ensure safe and efficient operation. This manual must be followed exactly. Read the “Safety Guidelines” section at the beginning of this manual. WARNING Installation and service must be performed by a qualified installer (for example, a licensed plumber or gas fitter), otherwise the warranty will be void.
Installation GENERAL 1. Follow all local codes, or in the absence of local codes, follow the most recent edition of the National Fuel Gas Code: ANSI Z223.1/NFPA 54 in the USA or CAN/CSA B149.1 Natural Gas, Propane Installation Code in Canada. 2. The manifold gas pressure is preset at the factory. It is computer controlled and should not need adjustment. 3. Maintain proper space for servicing. Install the unit so that it can be connected or removed easily. Refer to p. 8, p.9 and p. 10 for proper clearances.
Installation OPTIONAL ITEMS 1. Temperature Remote Controller: 9007603005 (TM‐RE30) The Temperature Remote Controller has two functions. It allows the output temperature from the water heater to be adjusted within the range of 100 °F to 185 °F, and it also works as a diagnostic tool that will give a concise error code whenever there is a problem with the unit.
Installation WARNING FOR INSTALLATIONS FOR YOUR SAFETY, READ BEFORE INSTALLATION: Do not install the heater where water, debris or flammable vapors may get into the flue terminal. This may cause damage to the heater and void the warranty. Do not have the vent terminal pointing toward any opening into a building. Do not locate your heater in a pit or location where gas and water can accumulate.
Installation HIGH‐ALTITUDE INSTALLATIONS Check the elevation where your water heater is installed. Set dipswitches shown in the table below depending on the altitude. These dipswitches (No. 5 and No. 6) are on the computer board on the left bank only. Left bank of dipswitches 2,500 to 4,000 ft 4,000 to 5,000 ft Over 5,000 ft ON OFF OFF ON N O N O Switch No.5 Switch No.
Installation INSTALLATION FOR DIRECT VENT INDOOR MODELS The Direct Vent Indoor models are equipped with a thermistor and hi‐limit switch for the exhaust gas, detecting excess temperatures within the flue and enabling the unit to safely stop operations if needed. These components are always monitoring exhaust gas conditions in order to prevent heat damage to PVC (Plastic) venting if PVC is used. If the exhaust gas temperature exceeds 140°F, these components will enable the unit to safely stop operations.
Installation ‐Exhaust vent (PVC and ABS vent) ‐ The Direct Vent Indoor models can be connected with PVC or ABS venting (temperature rated up to 149°F). However, the manufacturer recommends PVC (or ABS) venting certified to ULC S636 standards.
Installation Do not common vent this appliance with any other vented appliance (Do not terminate vent into a chimney. If the vent must go through the chimney, the vent must run all the way through the chimney with Category III / IV approved or Special BH vent pipe). The maximum length of exhaust vent piping must not exceed 50 ft. (deducting 5 ft. for each elbow used in the venting system). Do not use more than 5 elbows. When the horizontal vent run exceeds 5 ft., support the vent run at 3 ft.
Installation ‐PVC Venting Illustrations‐ Horizontal Installation Diagram (With elbow terminations) Vertical Installation Diagram Wall Roof Roof Flashing Fire stop Connection between exhaust vent collar and PVC piping See the next page for instructions. Horizontal Installation Diagram (With 3” PVC Concentric Termination) Concentric Termination Wall 1” minimum clearance Keep a 1” clearance between wall and the intake section of the concentric termination. See the diagram to the left.
Installation (For Intake: 4” only) 1. Connect a 4” PVC Straight pipe directly on the intake vent collar of the water heater. (For Intake: 3” only) 1. Connect a 4” PVC Straight pipe directly on the intake vent collar of the water heater. 2. Connect a 4x3” PVC reducer to the 4” PVC Straight pipe. 3. From the reducer, continue on the rest of the vent run with 3” PVC pipe.
Installation ‐Vent clearances‐ Canada Direct vent and other than Direct Vent U.S.A Direct vent Other than Direct Vent 1 foot A Clearance above grade, veranda, porch, deck, or balcony. 1 foot 1 foot B Clearance to window or door that may be opened. 3 feet 1 foot C 4 feet from below or side opening. 1 foot from above opening.
Installation ‐Additional clearances ‐ Please follow all local and national codes in regards to proper termination clearances. In the absence of such codes, the following clearances can be used as guidelines. Local codes supersede these guidelines. For sidewall terminations 2ft. 3ft. 1ft. 1ft. 2ft. 1ft. 3ft. 1ft. 3ft. Inside corner Exhaust termination For multiple sidewall exhaust terminations (e.g. multi‐unit systems), an exhaust termination must be at least 1 ft.
Installation GAS SUPPLY AND GAS PIPE SIZING TO TURN OFF GAS TO APPLIANCE 1. Turn off all electric power to the water heater if service is to be performed. 2. Turn the manual gas valve located on the outside of the unit clockwise to the off position. WARNING 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.
Installation ‐Natural Gas Supply Piping‐ Maximum Delivery Capacity of Cubic Feet of Gas per Hour of IPS Pipe Carrying Natural Gas of 0.60 Specific Gravity Based on Pressure Drop of 0.5” WC Based on Energy Content of 1,000 BTU/Cubic Ft.: The water heater requires 199 Cubic Ft./hr for the 520 (T‐H2) models, and 180 Cubic Ft./hr for the 320 (T‐H2S) models.
Installation ‐Measuring inlet gas pressure‐ 1. Turn off all electric power to the water heater if service is to be performed. 2. Turn the manual gas valve located on the outside of the unit clockwise to the off position. The water heater cannot perform properly without sufficient inlet gas pressure. Below are instructions on how to check the inlet gas pressure. THIS IS ONLY TO BE DONE BY A LICENSED PROFESSIONAL. 1. 2. 3. 4. 5. Shut off the manual gas valve on the supply gas line.
Installation ‐Pressure relief valve‐ The water heater has a high‐temperature shut off switch built in as a standard safety feature (called a Hi‐Limit switch) therefore a “pressure only” relief valve is required. This unit does not come with an approved pressure relief valve. An approved pressure relief valve must be installed on the hot water outlet. The pressure relief valve must conform to ANSI Z21.22 or CAN 1‐4.4 and installation must follow local code.
Installation ‐Condensate Drain Connections‐ Discharge condensate (acidic water) in accordance with all local codes and WARNING common safety practices. The water heater models are high efficiency condensing water heaters that produce condensate (acidic water). The acidic condensate generated in the secondary heat exchanger can be neutralized by the Neutralizer accessory. Case A: If a neutralizer is not required 1.
Installation The condensate drain is at atmospheric pressure (non‐pressurized) and therefore must be allowed to drain freely with gravity only. Please ensure that there are no blockages along the condensate drain tube. All portions of the condensate drain (neutralizer and drain tube) must be at a lower elevation than the water heater to prevent condensate water from building up inside the heat exchanger.
Installation REMOTE CONTROLLER CONNECTION 1. Disconnect power supply from the water heater. 2. Take off the water heater’s front cover. 3. Locate the remote controller terminal, pictured below (located around the upper right‐hand side of the computer board). 4. Open the plastic cover of the remote controller accessory, and then attach the two fork terminals to connector base of the backside the controller with two screws. Make sure the terminals are firmly fixed. 5.
Installation PUMP CONTROL CONNECTIONS The water heater can be used to control a recirculation pump. Proper pump control helps to preserve the life of the system and saves energy as well. The water heater pump control port is a “normally open dry contact”, and therefore needs additional components to properly control a recirculation pump. To control a recirculation pump, connect the pump to the “Pump connector” in the water heater as shown in the diagram below.
Installation PUMP CONTROL MODE The water heater provides the four types of the pump control modes. The pump control modes are selected by changing dipswitch settings. The dipswitches that change the pump control modes are located in the right bank of dipswitches in the upper‐ left quadrant of the computer board in the water heater. (See right.) These 4 modes only affect pumps that are connected to the water heater pump control (p.24) Right bank of dipswitches A) Recirculation Control: No.
Installation D) Normal Control (Default setting): No.5 and No.6 OFF Feature: This mode provides no special pump control. Pump activation can only be turned ON or OFF by the remote controller. Function: The pump will run continually all the time as long as there is a power supply to the water heater. The pump will only stop when the remote is turned off. Water in the loop will be maintained at the set temperature of the water heater.
Installation EASY‐LINK SYSTEM Available on the 520 (T‐H2) models only ‐General‐ The water heater can be connected with other heaters of the same model with communication cables to work as a multiple‐unit manifold system. The Easy‐Link system allows up to 4 units to manifold together. A communication cable (gray color) comes with each unit. You can manifold from 2 to 4 units without the need for a multi‐system controller.
Installation 4. 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. 5. Between the “CHILD‐1” and the “CHILD‐2” units Connect the “[2] connector” of the “CHILD‐1” unit to the “[1] connector” of the “CHILD‐2” unit. 6. Between the “CHILD‐2” and the “CHILD‐3” units Connect the “[2] connector” of the “CHILD‐2” unit to the “[1] connector” of the “CHILD‐3” unit. 7. Make sure the “3‐digit 7‐seg.
Installation (C) Examples of incorrect settings and/or connections CASE 1: Unless you change dipswitch No.10 of the “PARENT” unit to the “ON” position, the system will not work as an Easy‐Link system. The units will operate as individual units.
Installation CASE 3: If you connect the “PARENT connector” of the “CHILD‐1” unit to the “[1] connector” of the “CHILD‐2” unit, the “CHILD‐2” unit will operate as an individual unit, and will not be part of the Easy‐Link system.
Applications APPLICATIONS WARNING‐Space‐Heating Applications In order to purge air in water pipes within a closed‐loop system, an air vent and air separator should be installed in to the system. Required circulation flow rates are labeled next to each application diagram. These flow rate requirements must be followed.
Applications ‐Dual‐purpose hot water heating‐ (Domestic and Space Heating): Diagramatic Layout of Radiant Heating and Domestic Water Heater Per Mass.
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. If the knob will not turn by hand, do not try to force it; call a qualified service technician. Forced repair may result in a fire or explosion due to gas leaks.
Operating Safety Ow n er’ s Gu id e 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 water heater does not have a pilot. It is equipped with an ignition device that automatically lights the burner. Do not try to light the burner by hand. B. BEFORE OPERATING smell all around the water heater area for evidence of leaking gas.
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. Keep flammable products: 1. 2. 3. 4. Vapors: Far away from heater. In approved containers. Tightly closed Out of children's reach 1. 2. 3. 4.
Normal Operation NORMAL OPERATION GENERAL 1. Open a hot water tap. 2. Mix cold water with the hot to get the correct temperature water. 3. Close the hot water tap. Flow rate to activate the water heater : 0.5 gallons per minute at the default set temperature Flow rate to keep the water heater running : 0.4 gallon per minute WARNING WARNING Hot Water temperatures over 125F can cause severe burns instantly or death from scalding.
Normal Operation Figure.1 Increase button Decrease button 3‐digit 7‐Seg LED Computer board Temperatures available 100 105 110 115 (unit:°F) 120 125 135 140 145 150 155 160 165 170 175 185 The temperature has been preset at the factory to 120°F (49°C). If temperatures other than the ones listed above are required, the remote controller can provide a couple more temperature options. Refer to p. 7 for a list of available temperatures on the remote controller.
Normal Operation FLOW The flow rate through the water heater is limited to a maximum of 9.0 GPM for the 520 (T‐H2) models, and 8.0 GPM for the 320 (T‐H2S) models. The temperature setting, along with the supply temperature of the water will determine the flow rate output of the unit. Please refer to the temperature vs. gallons per minute chart on p. 50 to determine the likely flow rates based on your local ground water temperature and your desired outlet water temperature combination.
Normal Operation MAINTENANCE AND SERVICE WARNING Turn off the electrical power supply and close the manual gas shutoff valve and the manual water control valve before servicing. Clean the cold‐water inlet filter. (Refer to diagram below) Be sure that all openings for combustion and ventilation air are not blocked. The venting system should be checked annually for any leaks, corrosion, blockages or damage. The burner should be checked annually for dust, lint, grease or dirt.
Troubleshooting TROUBLESHOOTING GENERAL PROBLEM It takes long time to get hot water at the fixtures. SOLUTIONS The time it takes to deliver hot water from the water heater to your fixtures depends on the length of piping between the two. The longer the distance or the bigger the pipes, the longer it will take to get hot water. If you would like to receive hot water to your fixtures quicker, you may want to consider a hot water recirculation system. (p.
Troubleshooting ‐EASY‐LINK SYSTEM‐ ‐Remote controller: 9007606005 (TM‐RE30) (OPTIONAL)‐ ‐ WATER HEATER ‐ PROBLEM Unit does not ignite when water goes through the unit. SOLUTIONS Is the flow rate over 0.5 GPM? (p. 36) Check for the filter on cold water inlet. (p. 39) Check for reverse connection and cross connection. If you use the remote controller, is the power button turned on? The fan motor is still spinning after operation has stopped. This is normal.
Troubleshooting ERROR CODES The units are self diagnostic for safety and convenience when trouble shooting. If there is a problem with the installation or the unit, it will display a numerical error code on the 3‐ digit 7‐Seg. LED on the computer board (visible through a window on the front cover) or remote controller (if installed) to communicate the source of the problem. Consult the table on the following page for the cause of each error code. 3‐digit 7‐Seg.
Troubleshooting ‐FAULT ANALYSIS OF ERROR CODES‐ If there is a problem with the installation of the water heater, it will display a numerical error code on the 3‐digit 7‐Seg. LED of the computer board or the remote controller (if installed) to communicate the source of the problem.
Components Diagram COMPONENTS DIAGRAM Case assembly Direct Vent Indoor models 152 014 0 52 004 003 012 052 011 704 152 156 001 013 152 051 052 702 124 152 002 005 004 009 008 703 007 152 010 006 052 054 004 052 Outdoor models 015 052 702 152 016 005 004 051 009 008 703 007 152 010 006 054 44│Page 052
Components Diagram 719 Computer board assembly 055 715 715 712 714 716 053 711 713 053 053 713 055 001 152 701 708 707 717 721 709 705 704 719 423 711 114 710 720 Burner assembly 101 102 103 152 152 104 105 106 113 710 114 152 107 151 108 111 109 110 112 152 116 117 125 710 152 119 712 152 122 705 152 123 118 155 120 708 128 053 154 155 121 054 45│Page 153
Components Diagram Water way assembly Direct Vent Indoor models 445 441 440 402 152 442 401 449 404 444 126 706 403 446 152 152 443 437 C C 127 424 437 432 443 425 455 462 431 426 405 452 150 450 419 420 417 433 434 430 462 414 420 447 423 419 406 450 454 457 A 435 451 418 458 417 455 B 427 452 414 416 052 422 420 150 A 414 429 417 415 436 414 419 438 448 453 414 421 443 428 437 427 454 420 B 463 454 462 413 412 414 405 010 411 052 410 4
Parts List PARTS LIST Item# Description 001 002 003 004 005 006 007 008 009 010 011 012 013 014 015 016 051 052 053 054 055 101 102 103 104 105 106 107 108 109 110 111 112 113 114 116 117 118 Case assembly for Direct Vent Indoor models Front cover for Direct Vent Indoor models Intake air port assembly Bracket Back guard panel Junction box Rubber bush Overheat‐cut off‐fuse for combustion chamber Fastener Condensate drain port Duct Duct gasket A Duct gasket B Duct cover plate Case assembly for Outdoor mod
Parts List Item# Description 127 128 150 151 152 153 154 155 156 157 401 402 403 404 405 406 407 408 409 410 411 412 413 414 415 416 417 418 419 420 421 422 423 424 425 426 427 428 429 430 431 432 433 434 435 436 437 438 440 441 Heat exchanger O‐ring P20 NBR Screw M4×8 Pan screw M4×8 Screw M4×10 Pan screw M4×12 (W/Washer) Pan screw M4×10 Hex head screw M4×8 Flange gasket for fan motor Silicon ring Heat exchanger assembly for Direct Vent Indoor models Silicon ring Fuse fixing plate 18 Overheat‐cut‐off f
Parts List Item# Description 442 443 444 445 446 447 448 449 450 451 452 453 454 455 456 457 458 459 460 461 462 463 701 Hi‐limit switch for exhaust Fastener “14‐22” Thermistor fixing plate Secondary heat exchanger plate Secondary heat exchanger Drain pipe Secondary heat exchanger inlet pipe Exhaust thermistor gasket Fastener “6‐15” Band B Header Flat heater 3 array heater O‐ring P12 FKM Heat exchanger assembly for Outdoor models O‐ring P3 EPDM Secondary heat exchanger drain plug Exhaust port Exhaust ch
Output Temperature Chart OUTPUT TEMPERATURE CHART Output Temperature vs. GPM (Max. 9.0 GPM) with Various Ground Water Temperature Chart is based on properly sized gas line 10.0 9.0 Out Put Hot Water GPM Output Hot Water GPM 8.0 7.0 6.0 5.0 4.0 3.0 2.0 1.0 0.0 100 105 110 115 120 125 130 135 140 150 160 165 170 175 180 185 40 F 6.1 5.6 5.2 4.9 4.6 4.3 4.1 3.8 3.7 3.3 3.0 2.9 2.8 2.7 2.6 2.5 50 F 7.3 6.6 6.1 5.6 5.2 4.9 4.6 4.3 4.1 3.7 3.3 3.2 3.0 2.9 2.
Warranty LIMITED WARRANTY 1. General terms of limited warranty: This limited warranty gives you specific legal rights, and you may also have other rights which vary from State to State. The manufacturer, will honor the warranty to the original retail buyer at the original location only, and it is not transferable.
Warranty 3. Repair, Replacement or Refund: The manufacturer or its authorized Service Representative will, at its sole discretion, repair or replace any failed or defective mechanical or electrical parts, or components thereof, or, if the manufacturer or its authorized Service Representative cannot replace said parts, and repair is not commercially practicable, the manufacturer or its authorized Service Representative will refund the purchase price.
