State 60E101 Parts List

31:

Incorrect d

ipswitch setting

Maaiinntteennaannccee sshheeeett

Troubleshooting

441: Flow Sensor

failure

(Only Easy

Link system)

・ Refer to the

“

101” error code

in this section.

Left

bank

Right bank

°C

Appendix B (For error code 611 & 621)

Change th

dipswitch

settings when the power supply is turning off.

DEFAULT is the factory setting.

FM speed is increased automatically.

The Gas Type and Model Type dipswitch should

The 341, 621 and 941 error codes are applied

the 520 Direc

t Vent Indoor model

nly.

Single unit is the same as the child unit.

I B1

Easy-Link system

High-altitude function

FM++

DEFAULT

Over

FM+

6600EE11001

If the error code is indicated on the 3-digit 7-Seg LED on the PCB (Part #701) of the water heater (and/or the remote controller), refer to Section B.

<< It takes long time to get hot water at the fixtures >>

・ 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.

<< The water is not hot enough or turns cold and stays cold >>

・ Compare the flow and temperature. Refer to the “Output temperature chart” of the

installation manual.

・ Check cross plumbing between cold water lines and hot water lines. ・ Check if the gas supply valve fully open, the gas line sized properly and the gas supplies

pressure enough. Refer to the “Gas supply and gas pipe sizing” of the installation manual.

・ Check the set temperature, and change the dipswitch setting. Refer to Section D. ・ Refer to “Water circuit” in this section.

<<The water is too hot>>

・ Check the set temperature, lower setting temperature.

<<The hot water is not available when a fixture is opened>>

・ Refer to the “Power supply circuit” and “Water circuit” in this section.

<<Fluctuation in hot water temperature>>

・ Check if the filter on the cold water inlet cleaned. (Part #409) ・ Check if the gas line sized properly and the supply gas pressure sufficient. ・ Check for cross connection between cold water lines and hot water lines. ・ Refer to “Water circuit” in this section.

<<Unit does not ignite when water goes through the water heater>>

・ Refer to the “Power supply circuit” and “Water circuit” in this section. ・

If you use th e remote controller, turn the power button on and then the green LED will lit.

・ Check if the filter on the cold water inlet cleaned. (Part #409)

B. Error codes

・ Check the dipswitch settings on the PCB. Refer to Section D.

101: Warning for the “991” error code

・

Check the gas type of t he water heater. If it ’s wrong gas typ e mode l, re place the water heater to correct o ne.

・ Check if there is any blockage (For example, Damper sticking, Vent Flaps i nstalled on the

terminator, Snow build up around terminator, Installed in a closet (No ventilation or lack of combustion air)) in the intake air and/or exhaust. Refer to the “Vent termination clearances” of the installation manual.

・ If the water heater is installed as a direct-vent system, check whether there are enough

distance between the intake air terminal and the exhaust terminal. Refer to the “ Vent termination clearances” of the installation manual.

・ Check if the total vent length doesn’t exceed 50 ft and the # of elbows is less than 5Ea. ・ Check the altitude/elevation of area of where the water heater installed. Refer to the

“High-altitude function” of the Section D. And change the dipswitch settings.

・ Check if there is grease and/or dirt in the burner (Part #101), and the fan motor (Part

#114), especially if the water heater has been installed in a contaminated area.

・ Check if there is dust and lint in heat exchanger. ・ Check the manifold pressure of the water heater. Refer to installation manual.

111: Ignition failure

1. Check gas supply and inlet gas pressure.

2. Check if the Hi-limit switch (Part #432) is properly functioning.

3. Check for connection/breakage of wires (Part #110, 404, 704, 705, 710, 719), burn marks on the computer board (Part #701), and/or soot on the flame rod (Part #106). And then if O.H.C.F (Part #008 and/or #404) is breakage, Consult the manufacturer.

4. Check if there is a buzzing spark ignition sound coming from the burner (Part #101) when water heater prepares for combustion.

5. Listen for the double “clunk” sound coming from the gas valves assembly (Part #118) when water heater goes into combustion.

6. (Only no sparking and/or kick sound) Check voltage on each wire to gas valves assembly (Part #118) and/or the igniter (Part #123). Refer to the “Appendix A” in Section C.

*No sparking sound >>>>> Refer to the #1 at “Appendix A” in Section C. *No kick sound >>>>> Refer to the #2 at “Appendix A” in Section C.

7. Check if there is leaking from heat exchanger (Part #401 or 456)

8. Check if there is dust and lint in nozzles of the manifold (Part #118).

9. Check current on the flame rod (Part #106). Refer to the #3 at “Appendix A” in Section C.

121: Loss of flame

1. Check gas supply and inlet gas pressure.

2. Check if the Hi-limit switch (Part #432) is properly functioning.

4. Check if there is leakage from heat exchanger (Part #401 or 456).

5. Check if there is dust and lint in nozzles of the manifold (Part #118).

6. Check current on the flame rod (Part #106). Refer to the #3 at “Appendix A” in Section C.

311,321,331,341*: Disconnected/short-circuited thermistor

・

Check for connection/breakage of wires and/or debris on thermistor (Part #422, 433, 418, 706, 707,721).

・ Check thermistor resistance. Refer to the “Appendix D” in Section C.

391: Air-fuel Ratio Rod failure

・

Check for connection/breakage of wires (Part #710) and/or soot on the AFR rod. (Part #106).

<<The fan motor still spinning after operation has stopped>>

・ This is normal. After operation has stopped, the fan motor keeps running for 35 seconds

in order to re-ignite quickly, as well as purge all the exhaust gas out of the flue.

<<Abnormal sound from water heater>>

・ An abnormal sound from the water heaters is caused by not enough air supply or wrong

installations. The water heater needs more combustion air. Refer to the “101” error code in the Section B.

<<Power supply circuit>>

1. If the remote controller installed, press the “ON/OFF” button of the remote controller, and make sure that the green LED on the “ON/OFF” button of the remote controller is lit. Restart the water heater.

2. Check if that the 3-digit 7-Seg LED on the PCB (Part #701) of the water heater is lit. If so, the power supply circuit of the water heater is under normal condition. Next, refer to the “Water circuit” in this section.

3. Check the fuse on the surge box (Part #715), and if it has a brown spot, need to replace it.

4. Check the power supply, and make sure that the water heater has 120 VAC.

5. If the 3-digit 7-Seg LED on the PCB (Part #701) isn’t lit, some electrical parts can be broken. Consult the manufacturer.

<<Water circuit>>

1. If you set the remote controller, turn the power button on and then the green LED will lit.

2. Open all hot water faucets, and make sure that there is enough water flow. This water heater needs at least 0.5 GPM water flow to operate.

3. Check for reverse connection and cross connection.

4. Check if the filter on the cold water inlet cleaned. (Part #409)

5. Check if there is no debris or obstruction on the fixtures.

6. Check if water ways in the water heater are frozen. If s o, unfreeze them. And refer to installation manual to protect your water heater from freeze.

7. Check if the inlet water pressure is higher than 40 psi. And if it’s lower than 40 psi, need to increase the pressure.

8. Check for connections and breakage of wires (Part #423, 429).

9. Check if the motor drive of the water control valve (Part #423) is locked due to scale buildup, and/or water leakage, Consult the manufacturer.

・ Check

for

connection/breakage of wires and/or debris on impeller (Part #429, 708).

510,551: Abnormal Main and Gas Solenoid Valve

・ Check

・ Reset power supply of the water heater. ・ Check voltage on the each valve on the gas valves assembly (Part #118). Refer to the

for

connection/breakage of wires (Part #705) and/or burn marks on the computer

board (Part #701).

“Appendix C” in Section C.

611,621*: Fan motor and Exhaust Fan motor fault

・ Check

・ Check for frozen/corrosion of connectors of the fan motor (Part #114,124). ・ Check voltage between blue wire and each wire of the fan motor (Part #114,124) during

for

connection/breakage of wires, dust buildup in the fan motor/Exhaust fan motor

(Part #114,124) and/or burn marks on the computer board (Part #701).

operation. Refer to the “Appendix B” in Section C.

631: Abnormal External Pump

・ Check whether the pump connected to PCB (Part #701) works properly.

651,661: Water control valve fault (Only Easy-Link system)

・ Check the water control valve (Part #423), connection/breakage of wires (Part #423),

motor drive locked due to scale buildup, and/or water leakage.

・ Check voltage between black wire and red wire. Refer to the “Appendix F” in Section C.

701: Computer board fault

・ Check for connection/breakage of wires (Part #708) and/or burn marks on the computer

board (Part #701).

711: Hi-limit switch trip/ Gas solenoid valve drive circuit failure

・ Check connection/breakage of wires (Part #705) and/or burn marks on the computer

board (Part #701).

721: False flame detection

1. Clean the flame rod (Part #106).

2. For indoor models, check if condensate drain is installed on the vent collar of the water heater.

3. Check if there is leaking from heat exchanger (Part #401 or 456).

741: Miscommunication between water heater and remote controller

1. Check the model type of the remote controller. Model name 9007603005 is the correct one.

2. Inspect for the connections between the water heater and remote controller. Refer to “Remote controller connections” section in the Installation manual.

3. Check the power supply of the water heater.

4. If this error code appears only the 3-digit 7-Seg LED on the PCB (Part #701), check the voltage on the remote controller terminal on the PCB. Refer to the

“Appendi x E” in

Section C.

5. If this error code appears only remote controller, replace the PCB (Part #701).

6. If this error code appears both the PCB (Part #701) and the remote controller, replace the remote controller.

761:

Miscommunication between Parent unit and Child units for Easy-link system

・ Check if connection between the parent unit and the child units are correct. Refer to

“Easy-Link system” section in the Installation manual.

941*:

Abnormal exhaust temperature (Only 520 Direct Vent Indoor)

・ Check if the set temperature is higher than 140°F (60°C) and the system is Recirculation. ・ Check exhaust thermistor resistance. Refer to the “Appendix D” in Section C.

991: Imperfect combustion

C. Wiring Diagram and check point of the Water heater

BK: BLACK

G: GREEN

Output thermistor

Inlet thermistor

Mixing thermistor

Exhaust thermistor

Hi-limit switch for exhaust

O.H.C.F

AC 120

Groun

Appendix A (For error code 111)

Check these points during ignition stage.

# 1. Refer check point “B2” on the wiring diagram above.

# 2. Refer check point “C” and “H1” on the wiring diagram above.

# 3. Check current thought the orange flame rod wire (Part #710).

(Normal: more than 1μA)

R: RED

O: ORANGE

MI N bu tto n

MAX b ut to n

Inc re a se bu tt on

Nu mb er di sp la y bu tt on

Err or c al l bu tto n

Proportional Valve

Flow

Sensor

BL BL

SV2

SV1

SV3

Surge bo

Trans forme

W: WHITE

Y: YELLOW

R R

BK BK BK

Groun

L ef t ba nk

of d ip sw it ch es

520 Di re ct Ven t In do or O nly

Hi- lim it sw itc h

De cr ea se bu tt on

OFF

123 456

23 456

9109

R ig ht b an k

of d ip sw it ch es

Pum p po rt

Fan motor

BL: BLUE

BR:BROWN

7 S eg L ED

520 Di re ct Ve nt I ndo or O nly

Fan motor for exhaust

P: PURPLE

LB:LIGHT BLUE

Bur ni ng l am p

BK BL

Water Control valve

Ala rm

por t

P P

Check voltage between purple wires.

(Normal: AC 90 to 110 V)

This Check point is normal? Yes >> Replace the igniter (Part #123) No >> Go to Next

Check the voltage bellows.

C: Between blue wire and light blue wire (#3).

(Normal: DC78 to 100 V)

C: Between blue wire and orange wire (#53).

(Normal: DC78 to 100 V)

H1: Check the voltage between white wire and red wire.

(Normal: DC 1 to 15 V)

These check points are normal? Yes >> Replace the gas valves assembly. (Part #118) No >> Replace the PCB. (Part #701)

This check point is normal during operation? Yes >> Replace the PCB. (Part #701) No >> Replace the flame rod. (Part #106)

W W

R R

900 76 030 05 Rem ot e con tr oll er por t

Flame rod

Ground

Air-fuel ratio rod

Heaters

Freeze protection thermostat

Igniter rod

Refer check point

“G1”

“G2”

in the diagram to the left and followings.

・ Check voltage between red wire and blue wire.

(Normal: DC 110 to 160 V)

Parent

・ Check voltage between yellow wire and blue wire.

(Normal: DC 13 to 17 V)

・ Check voltage between orange wire and blue wire

(Normal: DC 2.0 to 6.5 V)

All check points are normal? Yes >> Re place th e fan mo to r and Exhaust f an motor. ( Part #1 14&1 24) No >> Replace the PCB. (Part #701)

Appendix C (For error code: 510 & 551)

Refer check point “C” in the diagram to the left and followings. Check voltage on the each valve on the gas valves assembly.

・

Between blue wire and light blue wire (#3). (Normal: DC 78 to 100 V)

・ Between blue wire and green wire. (#9) (Normal): DC 78 to 100 V) ・ Between blue wire and orange wire (#53). (Normal: DC 78 to 100 V) ・ Between blue wire and red wire (#73). (Normal: DC 78 to 100 V)

All check points are normal? Yes >> Replace the gas valves assembly. (Part #118) No >> Replace the PCB. (Part #701)

Appendix D (For error code: 311, 321, 331, 341 and 941)

・ Mixing thermistor ( Find the marking of No.113 on the connector)

Check point “E1”

・ Output thermistor (Find the marking of No.12 on the connector)

Check point “E2”

・ Inlet thermistor (Find the marking of No.42 on the connector)

Check point “E3”

Check resistance between black wire and black wire.

Temperature

Resistance kΩ 15.4 12.6 10.3 8.5 7.0 5.9

°F 50 59 68 77 86 95

10 15 20 25 30 35

・ Exhaust t hermistor (Find the marking of No.52 on the connector)

Check point “K1”

Check resistance between white wire and white wire.

Temperature

°F 50 59 68 77 86 95

10 15 20 25 30 35

Resistance kΩ 19.5 15.9 13.0 10.7 8.9 7.4

All check points are normal? Yes >> Replace the PCB. (Part #701)

No >>

Repl ace th e wrong thermistor. (Part #422 , 433, 418 , 70 6)

Appendix E (For error code 741)

Refer check point “F” on the wiring diagram above. Check voltage on the remote controller terminal on the PCB. (Normal: DC 11 to 25 V)

This check point is normal? Yes >> Replace the remote controller. No >> Replace the PCB. (Part #701)

Appendix F (For error code 651 & 661)

Refer check point “J” on the wiring diagram above. Check voltage between blue wire and brown wire. (Normal: DC 13 to 16 V)

This check point is normal? Yes >> Replace the Water control valve. (Part #423) No >> Replace the PCB. (Part #701)

D. Dipswitch Settings on the computer board of the water heater

The dark square is the direction the dipswitch should be set to.

already be properly preset from the factory.

1 2 3 4 5 6 7 8 9

1 0

Model type

5 2 0 D i r e ct V e n t I n d oor

1 2 3 4 5 6 7 8 9

1 0

5 2 0 O u t d o o r

Gas type

Pr opan e

1 2 3 4 5 6 7 8 9

1 0

Natural Gas

1 2 3 4 5 6 7 8 9 1

(2,500 to

4,000 ft)

(0 to

2,500 ft)

1 2 3 4 5 6 7 8 9

1 0

1 2 3 4 5 6 7 8 9 1

(4,000 to

5,000 ft)

1 2 3 4 5 6 7 8 9 1

5,000 ft:

Consult the manufacturer

Par ent Un it

1 2 3 4 5 6 7 8 9

1 0

Child

Uni t

DE FA UL T

1 2 3 4 5 6 7 8 9

1 0

E. Components Diagram / Parts List

Case assembly

011

012

152

156

124

051

Item# Part# Description

001 002 003 004 005 006 007 008

319143-009 319143-010 319143-011 319143-012 319143-013 319143-014 319143-015 319143-016

Burner assembly

15 2

10 5

10 6

710

10 7

151

10 8

12 2

152

71 2

15 2

123

05 3

152

014

013

152

002

009

005

008

520 Direct Vent Indoor

Case assembly for 520 Indoor

Front cover for 520 Indoor

Intake air port assembly

Brackets

Back guard panel

Junction box Rubber bush

O.H.C.F for co mbu stion chambe r

10 2

110

11 7

70 8

15 5

154

103

12 8

15 5

15 2

104

109

71 0

702

152

11 1

12 0

052

704

703

006

054

Item# Part# Description

009 010 011 012 013 014 015 016

15 2

116

101

118

12 1

05 4

003

007

010

052

319143-017 319143-018 319143-019 319143-020 319143-021 319143-022 319143-023 319143-024

113

125

11 9

705

004

052

001

004

051

Fastener

Condensate drain port

Duct Duct gasket A Duct gasket B

Duct cover plate

Case assembly for 520 Outd oor

Front cover for 520 Outdoor

15 2

11 2

152

153

052

520 Outdoor

702

152

016

005

008

009

152

703

006

054

Item# Part# Description

051

11 4

052 053 054 055 101 102 103 104 105 106

107 108 109 110 111 112 113 114 116 117

118

119 120 121 122

123 124 125 126 127 128 150 151 152 153 154

155 156 157

319143-025 319143-026 319143-027 319143-028 319143-029 319143-030 319143-031 319143-032 319143-033 319143-034 319143-035

319143-036 319143-037 319143-038 319143-039 319143-040 319143-041 319143-042 319143-043 319143-044 319143-045 319143-046

319143-047

319143-048 319143-049 319143-050 319143-051

319143-052 319143-053 319143-054 319143-055 319143-056 319143-057 319143-058 319143-059 319143-060 319143-061 319143-062

319143-063 319143-329 319143-206

Screw M4x12 (W/Washer)

High voltage ign iter c able

Fan motor for exhaust HX protection plate (Front) HX protection plate (Right) HX protection plate (Left)

Pan Screw M4x12 (W/Washer)

Hex head screw M4x8

004

007

010

052

crew M4x10 (Coated)

Pan screw M4x10

Screw M4x10

Pan screw M3x10

Burner assembly

Burner gasket

Burner holder gasket

Burner window

Rod holder gasket

Flame rod

Rod holder

Igniter rod

Rod cap

Damper

Urethane tube

Pressure port

Fan motor Manifold gasket A Manifold gasket B

Manifold assembly

with gas valve

assembly LP

Manifold assembly

with gas valve

assembly NA

Wire clamp 60

Gas inlet ring

Gas inlet

Igniter plate

Igniter

O-ring P20 NBR

Screw M4x8

Pan screw M4x8

Screw M4x10

Pan screw M4x10

Flange gasket for fan motor

Silicon ring

Water way assembly

450

520 Direct Vent Indoor

417

452

419

433

450

447

417

448

420

454

152

459

Item# Part# Description

701 702 703 704

705 706

001

707 708 709 710 711 712 713 714

715 716 717 718 719

720 721 319143-415 Exhaust thermistor wire

152

114

712

441

442

410

706

420

454

409

462

720

445

428

436

152

408

440

444

462

126

424

425

451

150

453

407

152

701

710

157

423

438

709

443

432

426

455

437

463

010

152

460

152

435

420

455

150

419

422

427

413

449

446

462

405

430

423

414

429

414

421

454

405

052

152

443

437

417

437

443

452

414

419

052

415

414

412

411

052

015

052

431

004

418

427

416

Computer board assembly

714

055

715

713

053

717

716

715

053

711

713

704

719

055

708

707

721

705

711

402

434

406

457

458

414

319143-126 319143-127 319143-128 319143-129

319143-130 319143-131

319143-132 319143-133 319143-134 319143-135 319143-136 319143-137 319143-138 319143-139

319143-140 319143-141 319143-142 319143-143 319143-144

319143-145

420

401

403

127

520 Outdoor

461

Computer board

Junction box inner plate

Freeze protection and

EH-IG wire for 520 Indoor

Gas valve wire

Exhaust thermistor

Thermistors wire

Proportion al gas valve wire

Pump and multi-cable

Flame rod wire

PCB fixing plate

AC120V Transformer

connecting wire

AC120V po wer ON-OFF switch

Freeze protection and

EH-IG wire for 520 Outdoor

Exhaust fan motor wire

404

Transformer

assembly

Switch wire

AC120V wire

Surge box

PCB cover

Nylon clamp

Item# Part# Description

401

456

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

319143-064

319143-065 319143-066 319143-067 319143-068 319143-069 319143-070

319143-071

319143-072 319143-073 319143-074 319143-075 319143-076 319143-077 319143-078 319143-079 319143-080 319143-081 319143-082 319143-083

319143-084 319143-085 319143-086 319143-087 319143-088 319143-089 319143-090 319143-091 319143-092 319143-093 319143-094 319143-095 319143-096 319143-097 319143-098 319143-099 319143-100 319143-101 319143-102

Heat exchanger assem bly

Fuse fixing plate 18

Overheat-cut-off fuse

O-ring P25 FKM

Water inlet filter

O-ring JASO# 1021 FKM

O-ring JASO# 1016 FKM

Fastener “16AG”

Outlet drain plug

Mixing thermistor

O-ring P16 FKM

Inlet thermistor

Water control valve

Pipe heater f ixing plate

Pipe heater 120

Pan screw M4x6 (W/Washer)

O-ring P15 FKM

Output thermistor

Fastener “4-11”

O-ring JASO# 1017 FKM

O-ring P14 FKM

exchanger plate gasket A

441

319143-103

exchanger plate gasket B 442 443 444 445

446 447 448

449 450 451 452 453 454 455 456

319143-104 319143-105 319143-106 319143-107

319143-108 319143-109 319143-110

319143-111 319143-112 319143-113 319143-114 319143-115 319143-116 319143-117 319143-118

Hi-limit switch for exhaust

Fastener “14-22”

Thermistor fixing plate

Secondary heat exchanger plate

Secondary heat exchanger

Secondary heat

exchanger out plate

Exhaust thermistor gasket

Fastener “6-15”

O-ring P12 FKM

Heat exchanger assembly

for 520 Outdoor 457 458

459 460 461 462 463

319143-119 319143-120

319143-121 319143-122 319143-123 319143-124 319143-125

O-ring P3 EPDM

Secondary heat

exchanger drain plug

Exhaust chamber assembly Secondary heat exchanger plate

Heater fixing plate 20 Heater fixing plate 16

for 520 Indoor

Silicon ring

Heater 101

Drain port Filter plug

Water inlet

Heater plate

Outlet heater

O-ring P6 FKM

O-ring P4 FKM

Cold pipe

Screw M3x6

Flow sensor

Hot pipe

Joint elbow

Hi-limit switch

Water outlet

Drain tube

Secondary heat

Drain pipe

Band B Header

Flat heater

3 array heater

Exhasut port