Thermann 16NG50-6 User manual

GAS CONTINUOUS FLOW
WATER HEATERS
(Residential Outdoor Unit)
TO BE USED BY A LICENSED
PLUMBER ONLY
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

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Table of Contents
1. General Outline of Appliance
1-1 Specications .............................................................................................................................. 3
1-2 Performance................................................................................................................................ 4
1-3 General Construction (Parts Names) .......................................................................................... 5
1-4 Main Component Structures ....................................................................................................... 6
1-5 Main Safety Devices ................................................................................................................... 8
2. Installation and Related Work
2-1 Installation Instructions................................................................................................................ 9
2-2 Dimensions ................................................................................................................................. 13
2-3 Gas Piping................................................................................................................................... 14
2-4 Water Piping................................................................................................................................ 14
2-5 Electrical Connection .................................................................................................................. 15
2-6 Wiring Remote Controller............................................................................................................ 16
2-7 Testing Operation ........................................................................................................................ 17
2-8 Cascade Installation (Only For Model 26)................................................................................... 18
3. Service and Maintenance
3-1 Operation Principles.................................................................................................................... 19
3-2 Schematic Diagram..................................................................................................................... 21
3-3 Flow Charts ................................................................................................................................. 22
3-4 Fault Findings and Error Code .................................................................................................... 23
3-5 Wiring Diagram ........................................................................................................................... 26
3-6 Cascade Flow Charts.................................................................................................................. 27
3-7 Gas Setting Procedure................................................................................................................ 28
3-8 CombustionSpecication,VariousCombinationSetting ............................................................ 29
3-9 Disassembling/Assembling Parts................................................................................................ 33
3-10 ExplodedView ............................................................................................................................ 40
3-11 Parts List ..................................................................................................................................... 41

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1-1 Specications
MODEL 16 20 26
Nominal hourly gas consumption by
proportional electronic gas control MJ/h 125 158 200
Minimum gas supply pressure
(Natural Gas) kPa 1.13 1.13 1.13
Maximum gas supply pressure
(Natural Gas) kPa 5.0 5.0 5.0
Test point pressure (Natural Gas) kPa 0.56 0.80 0.80
Minimum gas supply pressure
(Propane) kPa 2.75 2.75 2.75
Maximum gas supply pressure
(Propane) kPa 7.0 7.0 7.0
Test point pressure (Propane) kPa 0.91 1.40 1.50
Water heating capacity raised 40°C L/min 10 12.5 16.25
Minimum working pressure kPa 60 90 110
Maximum working pressure kPa 1200 1200 1200
Gas injectors diameter (Natural Gas) mm 0.95 / 1.45 0.95 / 1.45 1.15 / 1.65
Gas injectors diameter (Propane) mm 0.65 / 0.95 0.65 / 0.95 0.7 / 1.0
Input voltage single phase 50Hz V240 240 240
Maximum output current A0.39 0.45 0.46
Inlet gas connection male thread R3/4” (20mm) R3/4” (20mm) R3/4” (20mm)
Cold water connection male thread R3/4” (20mm) R3/4” (20mm) R3/4” (20mm)
Hot water connection male thread R3/4” (20mm) R3/4” (20mm) R3/4” (20mm)
Relief valve pressure setting kPa 1400 1400 1400
Weight dry kg 15 15 16
Dimensions (DxWxH) mm 200 x 350 x 520 200 x 350 x 520 200 x 350 x 520
SAIGApprovalcerticateno.GSCS20021.WatermarkCerticateofcomplianceWMKA00506
1. General Outline of Appliance

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1-2 Performance
Performance-Capacity characteristic curves.
•Model 16
•Model 20
•Model 26
Inlet water temperature
5C
15 C
25 C
Water flow rate [L/min]
37
0
5
2.2(Minimum)
20.0(Maximum)
10
15
20
25
7550 60
Outlet water temperature [
C]
Inlet water temperature
5C
15 C
25 C
Water flow rate [L/min]
37
0
5
2.2(Minimum)
20.0(Maximum)
10
15
20
25
7550 60
Outlet water temperature [
C]
Inlet water temperature
5C
15 C
25 C
Water flow rate [L/min]
37
0
5
2.2(Minimum)
22.0(Maximum)
10
15
20
25
7550 60
Outlet water temperature [
C]

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1-3 GeneralConstruction(PartsNames)
No. PARTS NAME
1
PCB(Natural Gas)Model 16
PCB(Natural Gas)Model 20
PCB(Natural Gas)Model 26
PCB(Propane)Model 16
PCB(Propane)Model 20
PCB(Propane)Model 26
2
ManifoldAssy(NaturalGas)Model16,20
Manifold Assy(Natural Gas)Model 26
ManifoldAssy(Propane)Model16,20
Manifold Assy(Propane)Model 26
3GasControlValve
4 Electrode
5 Flame Rod
7
10
4
5
6
141210 10
1
9
2
3
15
13
9
8
11
10
7
10
4
5
6
141210 10
1
9
2
13
9
8
11
10
3
15
•Model 16/20 •Model 26
No. PARTS NAME
6HeatExchangerAssy(Model16,20)
Heat Exchanger Assy(Model 26)
7Over Heat Thermostat
8FanMotor(Model16,20)
Fan Motor(Model 26)
9 Temperature Sensor
10 Anti-Frost Heaters
11 Ignitor
12 PressureReliefValve
13 WaterFlowControlValve(withSensor)
14 Water Filter
15 Ambient Temperature Sensor

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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owinginthroughtheinletmeasuredbytheWaterFlowSensorand
the water temperature calculation.
UP34-47R
LP/NG
4D00001
11DC0697
0
1
2
OUT2OUT1
Main Gas Valve
Gas Valve 1
Filter
Gas Control Valve
Gas Valve 1
(No.1)
Main Gas Valve
(No.0)
Gas Valve 2
(No.2)
IN
2. WaterFlowControlValvewithSensor
*Measuresthewaterow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.
*Whenwaterowsmorethanwaterheatercapacity,hotwatertemperaturebecomes
lowerthanthesetting.TheWaterFlowControlValveautomaticallyreducesthe
waterowtopreventsuchtemperaturedrops.
Inlet
Main Body
Water Flow Sensor
Hall Element IC
Sealant
Valve Body
Water Flow
Control Valve
Rotor

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Gas
Gas Valve 2
Gas Valve 1
Electrode
2burners 5burners 10burners
Only for Model 26
Flame Sensor
Gas Control
Valve
Main Gas Valve
Gas Valve 3
Fan Motor
3. Combustion Control of Rich and Lean Burners
1) 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.
2) During combustion
Dependingontherequiredheatingcapacity,eachGasValveopensorcloses.
The combinations are below,
Gas valve 1&2&3 open
1&2
2
1
Higher
Lower

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1-5 Main Safety Devices
1. Water Flow Sensor (Boil-dry protection)
WhentheWaterFlowSensordetectstheowrateissetforstartingignition(ignition
waterow)orhigher,thewaterheaterstartsoperation.
 Ignitionwaterow:  2.7L/min.
 Extinctionwaterow:  2.2L/min.
2. Flame Sensor (Flame failure detection)
Electricsignalsaretransmittedtotheamedetectioncircuittoconrmthenormal
combustionwhentheFlameSensordetectstherecticationofnormalcombustion
ame.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.
3. Thermal Fuse (Over-temperature protection system)
The Thermal Fuse is placed around the Heat Exchanger Assembly. If the ambient
temperatureinsidethewaterheaterbecomesextremelyhigh,thefusewillmeltdown
tobreakthepowercircuit.Insuchacase,asnopowerissuppliedtothegascontrol
assemblies,thegassupplyisstoppedandthecombustionisstopped.
(The system is activated to blow the fuse at 169°C.)
4. Over Heat Thermostat (residual)
EveniftheHeatExchangerAssemblyisoverheatedbyno-watercombustion,every
gaspathisclosedtoavoidrisks.Atthistime,theerrorcode"141"isdisplayedonthe
remote controllers.
(The switch is provided with a auto-restoration function and turns OFF at 100°C.)
5. Fan Revolution Detection Device (Hall IC)
The device detects the fan revolution speed to control the air supply necessary for
normalcombustion.Ifthefanrevolutionisoutofthepresetstandardrange,thegas
control assemblies are closed to stop the combustion before combustion failure
occurs.Inthiscase,theerrorcode"611"isdisplayedontheremotecontrollers.
6. Freeze Protection System (Anti-Frost Heaters)
Topreventfreezinginthehotwatersupplycircuit,Anti-FrostHeatersareprovidedat
majorpointsofwaterowpathsintheunit.TheheatersareactivatedbytheAmbient
Temperature Sensor in the unit.
(The system turns ON at 3°C and OFF at 13°C.)

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2. Installation and Related Work
2-1 Installation Instructions
•Thecasesshownbelowareclassiedbythedegreeofriskanddamage.
Be sure to follow the instructions for your safety.
Eachmarkindicates:
TheWaterHeatermustbeinstalledinaccordancewiththefollowing:
1. These instructions.
2. National Construction Code and Local authority regulations.
3. AS/NZS3500.4NationalPlumbingandDrainageCode,Part4HotWaterSupply
Systems.
4. The Australian standard for gas installations AS/NZS 5601.
5. Any other statutory regulation that may apply.
6. A notice of intention to install shall be lodged with the relevant local Gas Authority prior
to installation.
INSTALLAION MUST BE CARRIED OUT ONLY BY AN AUTHORISED AND
APPROPRIATE LICENSED PERSON
Installationrequirements
“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.
“Caution” indicates the possibility that some injuries or material damage
may result from the improper installation due to negligence of following
the instructions.
General prohibited
Never fail to do.
Ground
Never install the unit indoors as it is exclusively for outdoor use.
Do not install it in the bathroom. Electric shock or leakage may result.

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•Make sure the unit to be installed suits the intended use and application.
•Donotuseanygasotherthanspeciedonthesticker.
•Donotoperatewithanypowersource(voltage/frequency)otherthanspeciedonthe
sticker.
Vericationoftheunit.
Before installation.
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ammablessuchasgasoline,benzene,andadhesiveare
handled.
•This unit does not allow the use of extended exhaust pipes.
•Installtheunitasfaraspossible,awayfromanythinginfrontoraboveevenifitisnon-
combustibleinordertopreventexhaustgasrecirculation,andstainingofsurfaces.
•Take preventive measures against snow drifts for air inlet and exhaust outlet to stay
unaffected in case there is a possibility that they may be blocked by snow fall.

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•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xthe
unit with 4 screws.
Installation.
Screw
(for wall hanging)
Wall hanging bracket
Screw
(for wall hanging) Wall hanging bracket
4mm
546mm
Screw
(for wall hanging)
Screw
(for wall hanging)
Screw
(for wall hanging)

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•Checkifadjacentwallorceilingisreresistantandallowssafedistanceforre
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.
Top of heater 30cm
Front of heater 60cm
Sides of heater 15cm
Back of heater 0cm
Floor 30cm
•Secure enough space so that the inspection and repairs can be done easily.
•Secure space not only in front but also under the unit.
•Do not install the unit over other combustion appliances.
Oil residue and dust in the air can adhere to the Burner and the Heat Exchanger
resultingindeformation,lossofefciency,ordamagetoelectroniccomponents.
•Do not install the exhaust outlet near the outlets of the other appliances.
Install the air inlets away from the wind path as the wind may cause imperfect
combustion.
•Do not install the unit where commercial chemicals are used.
Thosechemicalsareammonia,sulfur,chloride,ethylenecompoundandacidswhich
areusedatbeautyshop,laundry,factoryandsoforth.
•Do not install the unit over food or dishes.
•Pipepressurerelieftoadrainoroutsideenvironment,orwithin100mmoftheoor.
Pipe pressure relief discharge to a drain or outside environment.
•The appliance should be located in an area where leakage from the unit or connections
willnotresultindamagetotheareaadjacenttotheapplianceortoloweroorsofthe
structure.Whensuchlocationscannotbeavoided,itisrecommendedthatasuitable
drainpan,adequatelydrained,beinstalledundertheappliance.Thepanmustnot
restrictcombustionairow.

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2-2 Dimensions
334mm
260mm
174mm
46mm
12mm
546mm 12mm
15mm200mm350mm
68mm68mm
584mm
39mm 520mm 25mm
100mm
80mm
69mm
68mm68mm
REMOTE CONTROLLER
CABLE ENTRY
HOT WATER OUTLET
R3/4 /20
POWER CABLE ENTRY
WATER INLET FILTER
PRESSURE RELIEF VALVE
COLD WATER INLET
R3/4 /20
GAS SUPPLY INLET
R3/4 /20

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•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.
Connect the manometer to the plug with the silicon tube and measure the gas inlet
pressureandconrmfromtheratinglabelontheappliance.
•Put the screw back in the test plug and fasten tightly.
•Make sure to conduct gas leakage test before operating the
Water Heater.
2-3 Gas Piping
2-4 Water Piping
•Install a manual water valve in the water inlet connection of the Water Heater.
•A union should be used on both the hot and cold water supply lines for connection.
•Purge the water lines to remove all debris and air.
•Make sure both the hot and cold water supply lines are connected correctly.
•Alterisplacedatthewatersupplyinlettoremovedebris.
Cleanthelterregularly.
Donotoperatetheunitwithoutthelterinplace.
Inareasofheavydebris,suchaswithsomewells,installawholehousewaterlterinline
before the unit.

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2-5 Electrical Connection
•TheWaterHeaterrequires240VACat50Hz.
Disconnect the power supply if the unit is not in use for a long time.
•Remove residual water in the unit when the power supply is off because the freeze
preventionintheunitwillnotactivate,resultinginpossiblefreezingdamage.
•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nishedandallworkiscompleted.
Otherwise electric shock or personal injury may result.

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2-6 WiringRemoteController
1. Number of controllers
One,twoorthreeremotecontrollerscanbeinstalledasoptionalextras.
2. 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.
3. 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.
Attachthewiringtotheplateadjacenttotheterminalblock,usingthecableclamp
provided. Then attach the wires to the terminals for the remote controllers. Replace
the front cover of the water heater.
(One Cable) (Two or more Cables)
CONTROLLER CABLE
CABLE CLAMP
CONTROLLER CABLE
CABLE CLAMP
(Small) (Medium or Large)
REMOTE CONTROLLER
CONNECTION TERMINALS
REMOTE CONTROLLER
CONNECTION TERMINALS
Conduit

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2-7 Testing Operation
•Followthestepsbelow,toensuretheWaterHeaterhasbeenproperlyinstalled.
1. Fully open the water supply main valve.
2. Flushoutthewatersupplypipingtocleanoutanyinstallationdebris,cleanoutlter.
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.
1. Operate the unit according to "Operation of Controller ” in the operating instructions.
2. Make sure the unit operates normally.
•Does the Burner ignite and shut off properly? Check the combustion lamp on the PCB.
TheBurnermaynotigniteatrstuntiltheairinthegassupplypipeisdrivenout.
Repeat the procedure until it ignites.
•Is temperature setting workable?
Check if the temperature can be adjusted as desired.
•If the residence is not ready for habitation or the unit will not be used for an extended
time,theresidualwaterintheunitandthepipemayfreezeanddamagetheunit,orthe
residual water in the Heat Exchanger may deteriorate.
Be sure to remove the water in the unit and the pipe.
1. Close the gas supply main valve.
2. Close the water supply main valve
3. Takeoffthewaterlterandpressurereliefvalve(drainstopper),andremovethewater.
Take this procedure when the unit cools down after the testing operation.
4. Disconnectthepower,orturnoffthepowersupply.
5. Open the tap and shower tap (if any) and remove the water.
6. Leave the unit in this condition until ready to use.
Fill out the warranty form with the customer.
Explain the “ RemoteControl “ section of the operating instructions to the customer.
Preparation for testing operation.
Testing operation.
Procedure after testing operation.
Explanationtocustomers.

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2-8 CascadeInstallation(OnlyForModel26)
•This type of installation allows two units to operate together by connecting two units with
a 2-wire cable and some simple programming.
•The units will operate in a range between 25 MJ/h and 400 MJ/h when two units are
connected together.
•Dependingonwaterow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.
•Incaseofconnectingtheremotecontroller,itmustbeconnectedwiththeMASTERof
the two units. Otherwise the remote controller will not operate correctly.
Remote
Controller
Remote Controller
Connection Terminals
Thermann genuine
cascade cable
Gas Supply
Hot Water Supply Line
Cold Water Supply Line
PCB
(5-100cm)
the MASTER unit the SLAVE unit
PCB
•Incasethatthreeremotecontrollersareconnected,
two (small and large) cable clamps shall be used.
CONTROLLER CABLE
CABLE CLAMP (Small)
REMOTE CONTROLLER
CONNECTION TERMINALS
CABLE CLAMP (Large)
CASCADE CABLE
(Maximum Four Cables)

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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ows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ow.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
is emitted by the Electrode.
•ThegassupplyissetattheslowignitionlevelbytheGasControlValveandgoesto
Burners.WhenBurnersareignited,theFlameSensordetectstheamecondition,
the “In Use” Indicator lights and the sparking is stopped.
•ThePCBdetectsthewaterowratebasedonthesignalfromtheWaterFlowSensor,
calculatestheenergyrequiredtoheatthewateruptothesettemperature,and
adjuststheopeningpositionoftheGasControlValveandtheFanMotorrpm.
Afterthis,PCBmaintainsthecombustiontokeepthewateratthesettemperatureby
checkingwiththeOutgoingWaterTemperatureSensor,whilecontrollingtheFan
MotorrpmandgassuppliedbytheGasControlValve.(Feedforwardfeedback
control)
[Operation stop]
•Whenthehotwatertapisclosed,theWaterFlowSensordetectsnowaterow.In
responsetothis,PCBclosesalltheGasValvesandtheFanMotorstopsafter
running for 65 seconds. (Post purge)

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In approximately 0.2sec.
In approximately 1min.
Hot water supply normal operation
Supply power (insert power plug into outlet)
Push ON/OFF button
ON indicator lights
Hot water tap, OPEN
Water Flow Sensor detects water flow [over approximately 2.7 Liter/min.]
Water Flow Sensor detects water flow for stop [less approximately 2.2 Liter/min.]
Fan Motor, ON
Fan Motor detects revolution
Ignitor, ON
Main Gas Valve, OPEN
Gas Control Valve
Gas Valve 2, OPEN
Gas Valve 1, OPEN
Flame Sensor detects ignition
"In Use” indicator lights
Ignitor stops
Combustion stabilizes.
Hot water temperature adjustment become normal.
Each Gas Valve opens or closes,
depending on the reguired heating capacity
Hot water tap, Close
Fan Motor stops
OFF (stop of combustion)
"In Use” indicator, OFF
With use of remote controller
Operationalowchart