305, 505

305, 505
Remote Controller
(Ensure gas pressure check under Commissioning has been completed
first !)
02
Error Codes
16 Over Temperature Warning
No burner operation during freeze protection mode
• Check for restrictions in air flow around unit and vent terminal.
• Check for low water flow in a circulating system causing short-
• Service Call
03 Power interruption during Bath fill (Water will not flow when
cycling.
power returns)
• Check for foreign materials in combustion chamber and/or
• Turn off all hot water taps. Press ON/OFF twice.
exhaust piping.
• Check for clogged heat exchanger.
10 Air Supply or Exhaust Blockage
Check gas type using data plate on side of unit.
If using spare PC board, check gas type switches (Fig.1) are in the
correct position. (dip switch 1 of SW2 ‘ON’ = NG, ‘OFF’ = LPG)
See Dip Switch Settings section below.
Note: ‘ON’ towards right, ‘OFF’ towards left.
•
•
•
•
•
•
•
32 Outgoing Water Temperature Sensor Fault
Ensure approved venting materials are being used.
Check that nothing is blocking the flue inlet or exhaust.
Check all vent components for proper connections.
Ensure vent length is within limits.
Ensure condensation collar was installed correctly.
Verify dip switches are set properly.
Check fan for blockage.
•
•
•
•
33 Heat Exchanger Outgoing Temperature Sensor Fault
•
•
•
•
11 No Ignition
controller,
Set the Water Heater to ‘Forced Low’ combustion by setting No.7 dip
switch of the (SW1) set of dip switches to ‘ON’. (Fig.3).
Set the Water Heater to ‘Forced High’ combustion by setting both No.7
and No.8 dip switches of the bottom (SW1) set to ‘ON’.
• Check that the gas is turned on at the water heater, gas meter,
or cylinder.
Ensure gas type and pressure is correct.
Ensure gas line, meter, and/or regulator is sized properly.
Bleed all air from gas lines.
Verify dip switches are set properly.
Ensure appliance is properly grounded.
Disconnect EZConnect or MSA controls to isolate the problem.
Ensure igniter is operational.
Check igniter wiring harness for damage.
Check gas solenoid valves for open or short circuits.
Remove burner cover and ensure all burners are properly
seated.
• Remove burner plate and inspect burner surface for
condensation or debris.
•
•
•
•
•
•
•
•
•
•
12 Flame Failure
• Check that the gas is turned on at the water heater and gas
meter. Check for obstructions in the flue outlet.
Ensure gas line, meter, and/or regulator is sized properly.
Ensure gas type and pressure is correct.
Bleed all air from gas lines.
Ensure proper venting material was installed.
Ensure condensation collar was installed properly.
Ensure vent length is within limits.
Verify dip switches are set properly.
Ensure appliance is properly grounded.
Disconnect keypad.
Disconnect EZConnect or MSA controls to isolate the problem.
Check power supply for loose connections.
Check power supply for proper voltage and voltage drops.
Ensure flame rod wire is connected.
Check flame rod for carbon build-up.
Disconnect and re-connect all wiring harnesses on unit and PC
board.
• Check all components for electrical short.
• Check gas solenoid valves for open or short circuits.
• Remove burner plate and inspect burner surface for
condensation or debris.
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Gas Pressure Setting
APPLIANCE OPERATING PRESSURES
Table 1
Water
Inlet Min.
505
305
Gas Inlet
Min./Max
NAT.G
Forced High
Forced Low
LPG
NAT.G
LPG
NAT.G
LPG
5"W.C.
8"W.C.
150 PSI /10.5"W.C. /13.5"W.C. 0.56"W.C. 0.88"W.C. 3.3"W.C. 5.1"W.C.
•
•
•
•
Troubleshooting
•
•
•
(SV1, SV2, SV3 and POV) Gas valve and Modulating solenoids: (Set meter above 2K)
Wire color
Voltage
Resistance
Connector # Pin #'s
(Main) Pink - Black 11 ~ 13 VDC
36.8 ~ 44.8 ohms
H5
6-7
(SV1) Black - Yellow 11 ~ 13 VDC
36.8 ~ 44.8 ohms
H6
5-6
(SV2) Black - Blue
11 ~ 13 VDC
36.8 ~ 44.8 ohms
H7
4-6
(SV3) Black - Brown 11 ~ 13 VDC
36.8 ~ 44.8 ohms
H8
3-6
(POV) Pink - Pink
2 ~ 15 VDC
67 ~ 81 ohms
H3
9 - 10
(M) Water Flow Control Devlce Servo or Geared Motor:
Red - Blue
11 ~ 13 VDC
22 ~ 28 ohms
F7
9 - 10
Grey - Brown
4 ~ 6 VDC
N/A
F7
5-7
Grey - Yellow
N/A
N/A
F7
5-8
NOTE: The grey wire listed above turns to black at B connector on the PCB, the orange wire turns to red.
(QS) Water Flow Sensor:
Black - Red
11 ~ 13 VDC
Yellow - Black
4 ~ 7 VDC
5.5 ~ 6.2 K ohms
F2
1 ~ 1.4 Mega ohms F2
By-pass Flow Control (By-pass servo model ONLY):
Brown - White
Orange - White
2 ~ 6 VDC
15 ~ 35 ohms
Yellow - White
(Unit in operating mode)
Red-White - Ground
(IG) Ignition System:
Grey - Grey
90 ~ 110 VAC
N/A
G1
G1
G1
G1
C1
1-3
2-3
1-5
2-5
3-5
4-5
1-2
(FM) Combustion Fan Motor:
Red - Black
6 ~ 45 VDC
N/A
E1
1-2
White - Black
5 ~ 10 VDC
9.2 ~ 9.4 K ohms
E1
2-4
Yellow - Black
11 ~ 13 VDC
3.5 ~ 3.9 K ohms
E1
3-4
Set your meter to the hertz scale. Reading across the white and black wires at terminals 2 and 3
you should read between 60 and 420 hertz.
Thermal Fuse / Overheat Switch:
Check for restrictions in air flow around unit and vent terminal.
Check sensor wiring for damage.
Measure resistance of sensor.
Clean sensor of scale build up.
Ensure fan blade is tight on motor shaft and is in good
condition.
• Replace sensor.
52 Modulating Solenoid Valve Signal Abnormal
• Check modulating gas solenoid valve wiring harness for loose
or damage terminals.
• Measure resistance of valve coil.
61 Combustion Fan Failure
• Ensure fan will turn freely.
• Check wiring harness to motor for damaged and/or loose
connections.
• Measure resistance of motor winding.
65 Water Flow Servo Faulty (does not stop flow properly)
If blank screen is present on remote control then the flow control
has shorted out. Unplug flow control. If remote lights up and unit
starts operating then replace flow control assembly.
71 SV0, SV1, SV2, and SV3 Solenoid Valve Circuit Fault
• Check wiring harness to all solenoids for damage and/or loose
connections.
• Measure resistance of each solenoid valve coil.
72 Flame Sensing Device Fault
• Ensure flame rod is touching flame when unit fires.
• Check all wiring to flame rod for damage.
• Remove flame rod and check for carbon build-up; clean with
sand paper.
• Check inside burner chamber for any foreign material blocking
flame at flame rod.
• Measure micro amp output of sensor circuit with flame present.
• Replace flame rod.
11 ~ 13 VDC
Below 1 ohms
F6
H1
F6 - H12
59°F = 11.4 ~ 14KΩ
86°F = 6.4 ~ 7.8KΩ
113°F = 3.6 ~ 4.5KΩ
LC Scale Build-up in Heat Exchanger (when checking
used.
maintenance code history “00” is substituted for “LC”)
Check for restrictions in air flow around unit and vent terminal.
• Flush heat exchanger. Refer to instructions in manual.
Check for low water flow in a circulating system causing shortcycling.
• Replace heat exchanger.
Ensure dip switches are set to the proper position.
No Code (Nothing happens when water flow is activated.)
Check for foreign materials in combustion chamber and/or
• Clean inlet water supply filter.
exhaust piping.
• On new installations ensure hot and cold water lines are not
Check heat exchanger for cracks and/or separations.
reversed.
Check heat exchanger surface for hot spots which indicate
•
Check for bleed over. Isolate unit from building by turning off
blockage due to scale build up. Refer to instructions in manual
hot water line to building. Isolate the circulating system if
for flushing heat exchanger.
present. Open your pressure relief valve; if unit fires, there is
Measure resistance of safety circuit.
bleed over in your plumbing.
Ensure high fire and low fire manifold pressure is correct.
•
Ensure you have at least the minimum flow rate required to fire
Check for improper conversion of product.
unit.
• Ensure turbine spins freely.
• Measure the resistance of the water flow control sensor.
• Remote control does not light up but you have 12 VDC at the
terminals for controls.
140°F = 2.2 ~ 2.7KΩ
221°F = 0.6 ~ 0.8KΩ
Outgoing Water Thermistor:
White - White
N/A
See example above
Heat Exchanger Temperature Thermistor:
Pink - White
N/A
See example above
Intake Air Thermistor (Indoor model ONLY)
Orange - White
N/A
See example above
Surge Protector:
Black - White
108 ~ 132 VAC
N/A
Blue - Brown
108 ~ 132 VAC
N/A
Wiring Diagram
F5
3-4
F4
3 - 11
F3
3 - 12
D2
D1
1-3
1-3
Remote Controls:
Terminals B1
BR
O
Y
R
W
BY-PASS FLOW
CONTROL DEVICE
FREEZE PROTECTION
OPTION
WATER FLOW
SENSOR
F2
QS
R
Y
BK
1.5 ~ 3.0 K ohms
B
1-3
F1
W Y O R BR
5
R
Y
BK
Using a voltage meter set on the 200 ohm scale, you should have a resistance reading of 123 ~
137 ohms through each of these heaters. The heater located on the heat exchanger piping
should have a resistance reading of 109 ~ 121 ohms and the one located in the water flow
sensor valve has a resistance reading of 14 ~ 16 ohms. The one located in the outlet valve has
a resistance reading of 14 ~ 16. Voltage throughout this circuit should be 120 VAC.
This unit has an inline (3) amp glass fuse. Remove the fuse and check continuity through it. If
505
Adjust switches 2 and 3 in the bank of 8 depending on
your altitude according to the table below.
The original PC boards on the water heaters do not
have the bank of 6 dip switches. Only spare PC
boards have this bank.
O
F
F
O
F
F
ON
NAT.G
O
F
F
1
2
3
4
5
6
7
8
O
F
F
1
2
3
4
5
6
ON
ON
LPG
1
2
3
4
5
6
7
8
1
2
3
4
5
6
O
F
F
O
F
F
ON
ON
NAT.G
1
2
3
4
5
6
7
8
1
2
3
4
5
6
O
F
F
O
F
F
ON
W
W
HEAT EXCHANGER
THERMISTOR
W
W
OUTGOING WATER
THERMISTOR
F7
W
W
R
BL
BR
Y
GY
F3
F4
F5
ON
1
2
3
4
5
6
7
8
W
O
13
W
P
1
2
3
4
5
6
SW
No.
A
3
MODULATING VALVE
CURRENT ADJUSTING
(CN12)
FM
W
Y
BK
R
F6
OVERHEAT
SWITCH
H1
(CN5)
E
1
H
12
Y R
W BK
(CN2)
B
1
P P Y BR Y
R P
BK BL
SURGE
PROTECTOR
Y
BK
H7
SV2
SOLENOID VALVE 3
SV3
BL
BR
BL
BK
BR
BK
G/Y
GND
D1
1
3
3
1
D3
FROST SENSING
SWITCH
BL BL
(W) (W)
W
W
D2
BK
W
FUSE
(3A)
G/Y
GND
GND
1
P
BK
H6
SPARK
ELECTRODE
IG
IGNITER
3
H5
SOLENOID VALVE 2
GY
GY
(CN4)
D
REMOTE CONTROLLER
C1
GY
GY
Y
SV1
BK
BK
3
R
R
BL
BR
SOLENOID VALVE 1
B1
1
(CN1)
(CN3)
SV0
Gas type
Spare Parts Only
C
H3
MAIN SOLENOID VALVE
Gas pressure
1
2
3
4
5
6
O
F
F
POV PP
H4
1
2
3
4
5
6
7
8
O
F
F
1
Dip SW2
4
R
R
FLAME ROD
Dip SW1
(CN9)
1
WW
W R BK
R Y
H8
DO NOT adjust the other dip switches unless specifically instructed
to do so. Incorrect Dip Switch Settings can cause the water heater
to operate in an unsafe condition and may damage the water heater
and void the warranty.
P BL BR
F
GY
W
W
E1
MODULATING
SOLENOID VALVE
R BK
O
GY
R
BL
Y
BR
WATER FLOW
CONTROL DEVICE
H2
WARNING
High Altitude
(CN7)
MIN
THERMAL FUSES
305
LPG
ON
G
1
MAX
AIR TEMPERATURE
THERMISTOR
W :White
BK:Black
BR:Brown
R :Red
BL:Blue
Y :Yellow
P :Pink
O :Orange
G :Green
GY:Gray
for REU-EZC
(Optional)
G
R
INDOOR MODEL ONLY
10 ~ 13 VDC
This unit has five frost protection heaters mounted at different points inside the unit, to protect
Dip Switches Settings
COLOR CODING
G1
BY-PASS SERVO MODEL ONLY
COMBUSTION FAN
3
•
•
•
•
•
• Check gas type of unit and ensure it matches gas type being
•
•
2
Check sensor wiring for damage.
Measure resistance of sensor.
Clean sensor of scale build up.
Replace sensor.
34 Combustion Air Temperature Sensor Fault
14 Thermal Fuse
Water Heater should
read 5"W.C. - 10.5"W.C. on Natural Gas and 8"W.C. - 13.5"W.C.
Red - Red
Check sensor wiring for damage.
Measure resistance of sensor.
Clean sensor of scale build up.
Replace sensor.
W BK
D5
ANTI-FROST HEATER
D4
BL BL
ANTI-FROST HEATER
AC120V
HOT
NEUTRAL
GROUND
NOTES
High Altitude
Off
Off
Level 0
0-2000ft
(0-610m)
Off
On
Level 1
2001-5200ft
(610-1585m)
On
Off
Level 2
5201-7800ft
(1585-2377m)
On
On
Level 3
7801-10200ft
(2377-3109m)
505(VA2532WD)
305(VA2520WD)
070 00012 36616 6
U287-1193(00)
EXPLODED VIEW - CABINET
EXPLODED VIEW - INTERNALS
806
002
807
808
001
015
711
716
005
017
801
710
709
002 808
007
143
810
802
137
717
135
114
011
004
718
138
013
014
008
003
103
116
118
016
708
119
117
707
012
132
006
706
113
812
REMOTE CONTROLLER
110
803
125
EXPLODED VIEW - ELECTRICAL
EXPLODED VIEW - INTERNALS
725
729
100
721
818
101
413
401
727
813
724
403
815
713
723
408
409
814
804
805
404
805
722
726
730 810
410
822
816
712
411
807
819
702
821
700
817
102
101
820
402
405
813
400
814
701
703
820
715
412
Number
001
002
003
004
005
006
007
008
011
012
013
014
015
016
017
100
101
102
103
103
103A
110
110
113
114
116
117
118
119
119A
125
125B
132
135
Description
Main Body (W)
Wall Mounting Bracket (W)
Rubber Bushing
Connection Reinforcement Panel
Heat Protection Plate
Front Panel
Front Panel Packing
Front Panel Packing Side
Screw Cover
Screw Cover Lid
Cable Access Assy
Rubber Bushing
Rain Hood
Packing
Screw Cover Assy
Gas Control Assembly
Test Port Set Screw
Gas Connection (3/4" NPT)
Burner Unit Assy (LPG)
Burner Unit Assy (NG)
24 Damper (NG)
Manifold Assembly (LPG)
Manifold Assembly (W-NG)
Pressure Point Sealing Screw
Combustion Chamber Sightglass Plate
Electrode
Flame Rod
Electrode Packing
Electrode Holder
Sparker Bracket
Fan Assembly
Fan Casing All Assembly
Combustion Chamber Fan Bracket
Flue Outlet
Parts Number
701022-005
701022-007
701022-008
701022-009
701022-010
701022-012
701022-013
701022-014
701022-017
701022-018
701022-019
701022-021
701022-022
701022-023
701022-024
701022-025
701022-026
701022-027
701022-028
701022-029
701022-030
701022-031
701022-033
701022-034
701022-035
701022-036
701022-037
701022-038
701022-039
701022-040
701022-044
701022-045
701022-047
701022-049
Quantity
505
305
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
4
4
1
1
1
1
1
1
1
1
2
2
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
PARTS LIST
Number
137
138
143
143
400
401
401
402
403
404
404
405
408
409
410
411
412
413
700
700
701
701
702
703
706
707
708
709
710
711
712
713
715
716
Description
Flue Outlet Gasket
Seal Packing
Heat Exchanger Assembly
Heat Exchanger Assembly
Water Inlet (3/4" NPT)
Water Flow Servo & Sensor Assembly
Water Flow Servo & Sensor Assembly
Rectifier
By-pass Servo Assembly
Stop Bracket
Stop Bracket
Plug Band
Hot Water Outlet (3/4" NPT)
Stop Bracket
Plug Band (small)
Drain Valve
Water Filter Assy
Cover
PCB
PCB
Surge Protector
Surge Protector with terminal (optional)
PCB cover - side
PCB cover - front
Ignitor
High Tension Cord
Electrode Sleeve
Thermistor - Heat Exchanger
Thermistor Clip Large
Temperature Fuse Clip
Frost Sensing Switch
Anti Frost Heater (120V)
Valve Heater (120V) Assembly
Antifrost Heater Clip B
Parts Number
701022-052
701022-054
701022-061
701022-062
701022-070
701022-071
701022-072
701022-073
701022-074
701022-075
701022-076
701022-077
701022-078
701022-079
701022-080
701022-081
701022-082
701022-083
701022-084
701022-085
701022-086
701022-087
701022-089
701022-090
701022-091
701022-092
701022-093
701022-094
701022-095
701022-096
701022-097
701022-099
701022-100
701022-102
Quantity
305
505
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
5
5
1
1
1
1
1
1
2
2
Number
717
718
721
722
723
724
724
725
726
727
729
730
801
802
803
804
805
806
807
808
810
812
813
814
815
816
817
818
819
820
821
822
888
889
Description
Antifrost Heater Clip A
Antifrost Heater Clip C
Fuse Harness (W)
Power Harness
Solenoid Valve Harness
Sensor Harness
Sensor Harness
Thermal Fuse Harness Assy
Ignitor Harness
Flow Sensor
Remote Controller Harness
Thermistor
Screw
Resin Washer
O-ring
Thermistor Stop Screw
Screw
Screw
Resin Washer
Screw
O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
Packing
Screw
Screw
Screw
Screw
Manual
Tech Sheet
Parts Number
701022-103
701022-105
701022-109
701022-110
701022-111
701022-114
701022-115
701022-116
701022-117
701022-118
701022-119
701022-120
701022-122
701022-123
701022-124
701022-125
701022-126
701022-127
701022-128
701022-129
701022-131
701022-132
701022-133
701022-134
701022-135
701022-136
701022-137
701022-138
701022-139
701022-140
701022-141
701022-142
701022-144
701022-146
Quantity
305
505
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
4
4
4
3
3
1
1
2
3
2
2
2
2
4
4
2
2
1
1
1
2
2
2
1
2
1
1
1
1
2
2
2
2
4
4
2
2
3
3
1
1
1
1
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