
ATH3
Maintenance sheet
68A166-1
A. Troubleshooting
If the error code is indicated on the green LED (Refer to Section C) 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 is fully open, the gas line is sized properly and the gas
・
supplies enough pressure. Refer to the “Gas supply and gas pipe sizing” of the
Installation manual.
Check the set temperature, and change the set temperature with the remote controller
・
or the DIPswitch setting. Refer to Section D.
Refer to the “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 is cleaned. (Part #406)
・
Check if the gas line is sized properly and the supply gas pressure is sufficient.
・
Check for cross connection between cold water lines and hot water lines.
・
Refer to the “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 the remote controller, turn the power button on and then check if the
・
STAND BY LED will light up.
Check if the filter on the cold water inlet is cleaned (Part #406).
・
Refer to the “Water circuit” in this section.
・
B. Error codes
031: Incorrect DIPswitch setting
Check the DIPswitch settings on the PCB. Refer to Section D.
・
101: Warning for the “991” error code
Check the gas type of the house (and/or the building).
・
Check if there is any blockage in the intake air and/or exhaust. Refer to the “Venting
・
Instructions” of the Installation manual.
If the water heater is installed as a direct-vent system, check whether there is enough
・
distance between the intake air terminal and the exhaust terminal. Refer to the “Vent
termination clearances” of the Installation manual.
Check the total vent length. Refer to the "Venting instructions" of the Installation manual.
・
Check the altitude/elevation of area of where the water heater is installed. Refer to the
・
“High-altitude function” of 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 #103), especially if the water heater has been installed in a contaminated area.
Check if there is dust and lint in the heat exchanger.
・
Check the manifold pressure of the water heater. Refer to the Installation manual of the water heater.
・
111: Ignition failure
1. Check the gas supply and inlet gas pressure.
2. Check if the Hi-limit switch (Part #412) is properly functioning.
3. Check for connection/breakage of wires (Part #413, 708, 709, 710, 712), and/or soot on the
flame rod (Part #108). And then if the O.H.C.F (Part #413) has a 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 valve assembly (Part #102)
when water heater goes into combustion.
6. (Only if sparking and/or kick sound) Check the voltage on each wire to gas valve assembly
(Part #102) and/or the igniter assembly (Part #711). Refer to “Appendix A” in Section C.
*No sparking sound >>>>> Refer to #1 at “Appendix A” in Section C.
*No kick sound >>>>> Refer to #2 at “Appendix A” in Section C.
7. Check if there is leaking from the heat exchanger (Part #401).
8. Check if there is dust and lint in nozzles of the manifold (Part #102).
9. Check the current on the flame rod (Part #108). Refer to #3 at “Appendix A” in Section C.
121: Loss of flame
1. Check the gas supply and inlet gas pressure.
2. Check if the Hi-limit switch (Part #412) is properly functioning.
3. Check for connection/breakage of wires (Part #413, 708, 709, 712), burn marks on the
computer board (Part #701), and/or soot on the flame rod (Part #108). And then if the
O.H.C.F (Part #413) has a breakage, Consult the manufacturer.
4. Check if there is leaking from the heat exchanger (Part #401).
5. Check if there is dust and lint in nozzles of the manifold (Part #102).
6. Check the current on the flame rod (Part #108). Refer to #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 the thermistor (Part #407, 408, 411, 715, 718).
・
Check the thermistor resistance. Refer to “Appendix D” in Section C.
・
391: Air-fuel ratio rod failure
Check for connection/breakage of wires (Part #709) and/or soot on the flame rod (Part #108).
・
441: Flow sensor failure (Only Easy-Link system)
Check for connection/breakage of wires and/or debris on the flow sensor impeller (Part #402).
・
*The 341, 751 and 941 error codes are applied to the 540 (T-H3)
Indoor models only.
<<The fan motor is still spinning after operation has stopped>>
This is normal. After operation has stopped, the fan motor keeps running from 15 to 70
・
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 is installed, press the “ON/OFF” button of the remote controller, and
make sure that the STAND BY LED next to the “ON/OFF” button of the remote controller is lit.
Restart the water heater.
2. Check if the green 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 #703), 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 green LED on the PCB (Part #701) isn’t lit, some electrical parts can be broken. Consult
the manufacturer.
<<Water circuit>>
1. If you use the remote controller, turn the power button on and then check if the
STAND BY LED will light up.
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 (at the default set temperature) to operate.
3. Check for reverse connection and cross connection.
4. Check if the filter on the cold water inlet is cleaned (Part #406).
5. Check if there is no debris or obstruction on the fixtures.
6. Check if water ways in the water heater are frozen. If so, unfreeze them. And refer to the
Installation manual to protect your water heater from freezing.
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 #402).
9. Check if the motor drive of the flow adjustment valve (Part #402) is locked due to scale
buildup, and/or water leakage. If so, Consult the manufacturer.
510,551: Abnormal main gas solenoid valve and gas solenoid valve
Check for connection/breakage of wires (Part #708) and/or burn marks on the computer board (Part #701).
・
Reset power supply of the water heater.
・
Check the voltage of each valve on the gas valve assembly (Part #102). Refer to “Appendix C” in Section C.
・
611: Fan motor fault
Check for connection/breakage of wires, dust buildup in the fan motor (Part #103) and/or
・
burn marks on the computer board (Part #701).
Check for frozen/corrosion of connectors of the fan motor (Part #103).
・
Check the voltage between blue wire and each wire of the fan motor (Part #103). Refer to
・
“Appendix B” in Section C.
651: Flow adjustment valve fault (Only Easy-Link system)
Inspect the flow adjustment valve (Part #402), for connection/breakage of wires, locked
・
motor drive due to scale buildup, and/or water leakage.
Check the voltage between black wire and red wire. Refer to “Appendix F” in Section C.
・
661: Bypass valve fault
Inspect the bypass valve (Part #403), for connection/breakage of wires, locked motor drive
・
due to scale buildup, and/or water leakage.
Check the voltage between brown wire and red wire. Refer to “Appendix F” in Section C.
・
701: Computer board fault
Check for connection/breakage of wires (Part #714), and check the resistance between
・
white wire and red wire. Refer to “Appendix A” in Section C.
711: Gas solenoid valve drive circuit failure
Refer to the “111” and “121” error codes in this section.
・
721: False flame detection
1. Clean the flame rod (Part #108).
2. Check if there is leaking from the heat exchanger (Part #401).
741: Miscommunication between water heater and remote controller
1. Check the model type of the remote controller. Model No. 9008172005 (TM-RE40) is the correct one.
2. Inspect the connections between the water heater and remote controller. Refer to the
“Remote controller connections” of the Installation manual.
3. Check the power supply of the water heater.
4. If this error code appears only on the green LED in the PCB (Part #701), check the voltage on
the remote controller terminal on the PCB. Refer to “Appendix E” in Section C.
5. If this error code appears only on the remote controller, replace the PCB (Part #701).
6 . If this error code appears on both the PCB (Part #701) and the remote controller, replace the remote controller.
751*: Miscommunication between water heater and temperature controller
1. Check the power supply of the water heater.
2. If this error code appears only on the green LED in the PCB (Part #701), check the voltage on
the remote controller terminal on the PCB. Refer to “Appendix E” in Section C.
3. If this error code appears only on the temperature controller, replace the PCB (Part #701).
4. If this error code appears on both the PCB (Part #701) and the temperature controller,
replace the temperature controller.
761: Miscommunication between Parent unit and Child units for Easy-link system
Check if the connections between the parent unit and the child units are correct. Refer to
・
the “Easy-Link system” section in the Installation manual.
941*: Abnormal exhaust temperature (Only 540 (T-H3) Indoor models)
Check for connection/breakage of wires, dust buildup in the fan motor (Part #103) and/or
・
burn marks on the computer board (Part #701).
Check the exhaust thermistor resistance. Refer to "Appendix D" in Section C.
・
991: Imperfect combustion
Refer to the “101” error code in this section.
・
C. Wiring diagram and check point of the water heater
W: WHITE
R: RED
G: GREEN
FM
Flame rod
Ground
Gas
Propor-
onal
Val ve
Bypass
Valve
DIPswitches
Appendix A (For error code 111)
Check the following points during ignition stage.
# 1. Refer to check point “B” on the wiring diagram above.
Check the voltage between purple wires. (Normal: 108 to 132 VAC)
This check point is normal?
Yes >> Replace the igniter assembly (Part #711).
No >> Go to Next.
# 2. Refer to check points “C” and “H1” on the wiring diagram above.
Check the voltages below:
C: Between blue wire and light blue wire (#3). (Normal: 93 to 120 VDC)
C: Between blue wire and orange wire (#53).
(Normal: 93 to 120 VDC)
H1: Check the voltage between white wire and red wire.
(Normal: 1 to 15 VDC)
These check points are normal?
Yes >> Replace the gas valve assembly (Part #102).
No >> Replace the PCB (Part #701).
# 3. Check the current through the yellow flame rod wire (Part #709).
(Normal: more than 5 μA)
This check point is normal during operation?
Yes >> Replace the PCB (Part #701).
No >> Replace the flame rod (Part #108).
Appendix F (For error code 651 and 661)
Error code 651 : Refer to check point “J” on the wiring diagram above. Check the voltage between black wire and red wire. (Normal: 7 to 16 VDC)
Error code 661 : Refer to check point “J1” on the wiring diagram above. Check the voltage between brown wire and red wire. (Normal: 3 to 11 VDC)
This check point is normal?
Yes >> Error code 651: Replace the Flow adjustment valve (Part #402). / Error code 661: Replace the Bypass valve (Part #403).
No >> Replace the PCB (Part #701).
BK: BLACK
BL: BLUE
O: ORANGE
Igniter rod
R
BL
Y
O
W
O
G
Y
AFR rod
R
W
R
Y
W
1
BL
2
3
4
BR
65
87
1
2
3
654
Green LED
MAX buon
MIN buon
Increase buon
Decrease buon
H1
J1
ON
ON
LB: LIGHT BLUE
Y: YELLOW
BR: BROWN
IG
I
BK
BK
E3
E2
E1
P
P
540
Indoor
Only
BK
BK
BK
B
P: PURPLE
540 Outdoor Only
Heater
Heater
Heater
PCB
A
G
3
9
53
C
73
J
H2
540
Indoor
Only
exchanger Heat
thermistor
Inlet thermistor
Outlet thermistor
G
C1
C2
D1
L
Y
Y
W
BK
G
Ground
Hi-
BL
limit
BL
switch
BL
BL
BL
BL
O.H.C.F
BL
LB
O
R
R
BK
Flow
R
W
Sensor
BK
W
D2
W
BL
Temperature controller
R
BK
W
BK
K1
W
W
K2
540 Indoor Only
Heater
Heater
Heater
Heater
Thermostat
BK
SW
MV
SV1
SV2
A2
SV3
Flow
Adjust-
Ground
ment
Valve
BK
W
BK
F
Remote controller
W
W
thermistor
Exhaust
Hi-limit switch
for exhaust
W
Surge
box
W
BK
120 VAC
G
1
2
Parent
Appendix B (For error code 611)
Refer to check point “G” in the diagram to the left and the following.
•
Check the voltage between red wire and blue wire (Normal: 132 to 192 VDC).
Y
•
Check the voltage between yellow wire and blue wire (Normal: 13 to 17 VDC).
•
Check the voltage between orange wire and blue wire (Normal: 2.0 to 6.5 VDC).
Y
All check points are normal?
Y
Yes >> Replace the fan motor (Part #103).
B1
No >> Replace the PCB (Part #701).
Y
BK
Appendix C (For error code 510 and 551)
Refer to check point “C” in the diagram to the left and the following.
Check the voltage on each valve on the gas valve assembly.
W
•
BK
Between blue wire and light blue wire (#3) (Normal: 93 to 120 VDC).
•
Between blue wire and green wire (#9) (Normal: 93 to 120 VDC).
A1
•
Between blue wire and orange wire (#53) (Normal: 93 to 120 VDC).
•
Between blue wire and red wire (#73) (Normal: 93 to 120 VDC).
All check points are normal?
Yes >> Replace the gas valve assembly (Part #102).
No >> Replace the PCB (Part #701).
Appendix D (For error code 311, 321, 331, 341, and 941)
•
Outlet thermistor (Find the marking of No.113 on the connector)
Check point “E1”
•
Inlet thermistor (Find the marking of No.42 on the connector)
Check point “E2”
•
Heat exchanger thermistor (Find the marking of No.12 on the connector)
Check point “E3”
Check the resistance between black wire and black wire.
Temperature
Resistance kΩ 15.4 12.6 10.3 8.5 7.0 5.9
• Exhaust thermistor
Check point “K1”
Check the resistance between white wire and white wire.
Temperature
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 >> Replace the thermistor (Part #407, 408, 411, 718).
Appendix E (For error code 741 and 751)
Error code 741: Refer to check point “F” on the wiring diagram above.
Error code 751 : Refer to check point “L” on the wiring diagram above.
Check the voltage on the remote controller and/or temperature controller
on the PCB. • Between black wire and white wire. (Normal: 11 to 25 VDC)
This check point is normal?
Yes >> Replace the remote controller and/or temperature controller.
No >> Replace the PCB (Part #701).
°F 50 59 68 77 86 95
°C 10 15 20 25 30 35
°F 50 59 68 77 86 95
°C 10 15 20 25 30 35
D. DIPswitch settings on the computer board of the water heater
Locate the bank of DIPswitches at the bottom left of the computer board of the unit.
Change the DIPswitch settings when the power supply is turned off.
The dark square is the direction the DIPswitch should be set to. DEFAULT is the factory setting.
<Upper bank of DIPswitches>
Vent settings (Indoor models only)
3" venting
4" venting
Set DIPswitches shown in the table above depending on the vent length.
Upper bank
5 to 20 ft (DEFAULT) 21 to 40 ft 41 to 70 ft
5 to 50 ft (DEFAULT) 51 to 100 ft N/A
ON
ON
<Lower bank of
DIPswitches>
ON
Temperature set
120 °F (49 °C)
DEFAULT
140 °F (60 °C)
Easy-Link system
ON
ON
OFF
Lower bank
Parent Unit
Child Unit
(DEFAULT)
Single unit is the same as the child unit.
Gas type*
Propane
Natural
Gas
*Factory setting
High-altitude function
ON
ON
Indoor models
DEFAULT DEFAULT
Up to 2,500 ft Up to 2,000 ft
Up to 5,000 ft Up to 4,000 ft
Up to 7,500 ft Up to 6,000 ft
Up to 10,100 ft Over 6,000 ft
FM speed is increased automatically.
ON
ON
ON
ON
ON
Model type*
Indoor model
Outdoor model
Outdoor models
ON
ON
ON
ON
Consult the
manufacturer

E. Components diagram / Parts list
Case assembly
052
003
007
050
717
713
052
008
702
704
052
002
050
Temperature remote controller
Burner assembly
Burner assembly
053
053
107
108
709
110
062
109
102
121
711
106
111
707
062
711
055
114
063
104
115
112
053
150
057
117
719
714
101
113
Manifold
assembly
055
004
001
708
065
116
117
119
151
118
051
105
724
052
053
103
004
054
Outdoor modelsIndoor models
702
006
005
002
052
Bypass section
403
456
460
462
B
Temperature contoller
Indoor models
056
401
Item #
540 models T-H3 models
001 N/A
002 319143-507
003
004
005
006
007
008
009
050
051
052
053
054
055
056
057
058
059
060
061
062
063
064
065
N/A
319143-508
319143-509
N/A
319143-510
319143-511
319143-512
319143-513
319143-018
319143-025
319143-325
319143-026
319143-060
319143-326
319143-063
N/A
319143-201
319143-087
319143-328
319143-438
N/A
319143-059
319143-048
N/A
319143-330
704
458
001
A
Part #
467
451
462
451
414
722
EK159
EK164
EK158
EK174
EK170
EK162
EK190
EK171
EK161
EK160
EKH23
EW000
EW001
EW002
EW003
EW004
EW005
EW018
EKK31
EW00A
EW009
EKK37
EK191
EW00D
EM167
EK230
EW00B
Water way assembly
453
F
412
058
473
064
462
468
473
468
462
064
E
415
A
466
723
Case assembly for Indoor models
Case assembly for Outdoor models
Front cover for Indoor models
Front cover for Outdoor models
Intake air port assembly
Power supply cord assembly
Chamber fixing plate
Condensate drain port
Screw M4×12 (W/Washer)
Screw M4×10 (W/Washer)
Screw M4×10 (Coated)
Hex head screw M4×12 (W/Washer)
Hex head screw M4x8
Pan screw M4x20
Tap tight screw M4x12 FEZN
Screw M3x6 SUS3
B
451
D
Description
Bracket
Junction box
Back guard panel
Screw M4x10
Screw M3x6
Screw M4x6
Screw M4x12
Screw M3x6
Pan screw M4x8
Wire clamp 60
Screw M4x10
414
E
463
052
465
418
413
452
472
418
152
153
456
D
460
458
052
406
457
405
402
461
454
404
417
059
407
Water intlet secon
471
718
415
470
053
F
401
459
454
411
Water outlet secon
455
C
463
464
455
469
Item #
101
102
103 319143-443
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
121
150
151
152
153
401
402
403
404
416
450
414
703
009
052
Part #
540 models T-H3 models
319143-514
319143-515
319143-516
319143-043
319143-031
319143-282
319143-033
319143-034
319143-517
319143-037
319143-036
319143-038
319143-518
319143-519
319143-044
319143-045
319143-032
319143-042
319143-520
319143-455
319143-342
319143-522
319143-350
319143-057
319143-523
319143-524
319143-548
319143-463
319143-464
319143-193
EK192
EK181
EK182
EK109
EKK25
EKK2X
EM381
EKK2V
EKK2W
EK193
EKK0F
EKK32
EKN61
EK183
EK169
EKK2Y
EKK2K
EKK0G
EKK2D
EX019
EK117
EX00D
EK163
EZP18
EK042
EK157
EK177
EK250
EK129
EKD58
EKK1U
Surge box
703
706
Manifold with gas valve assembly LP
Manifold with gas valve assembly NA
Fan motor for Indoor models
Fan motor for Outdoor models
Fan damper for Indoor models
Burner damper NA
Burner holder gasket
Combustion chamber tube
O-ring P18 NBR (Black)
O-ring P20 NBR (Black)
Silicon ring for Outdoor models
Exhaust port for Outdoor models
Primary heat exchanger assembly
Flow adjustment valve / Flow sensor
C
458
462
409
052
Description
Burner assembly
Burner gasket
Burner window
Rod holder gasket
Flame rod
Igniter rod
Rod holder
Rod cap
Burner damper LP
Manifold gasket A
Manifold gasket B
Pressure port
Gas inlet
Gas inlet ring
Surge box plate
Bypass valve
Water inlet
053
455
121
709
454
408
410
063
417
713
Item #
405
406
407
408
409
410
411
412
413
414
415
416
417
418
450
451
452
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
473
701
702
703
704
706
707
708
709
711
713
714
715
716
717
718
719
721
722
723
724 319143-485 ER014 Temperature remote controller
Computer board assembly
701
714
403
716
715
Part #
540 models T-H3 models
319143-197
319143-198
319143-465
319143-190
319143-530
319143-199
319143-096
319143-095
319143-149
319143-531
319143-532
319143-533
319143-534
319143-468
319143-549
319143-550
319143-088
319143-125
319143-066
319143-146
319143-082
319143-080
319143-100
319143-091
319143-083
319143-097
319143-105
319143-226
319143-205
319143-112
319143-535
319143-536
319143-538
319143-539
319143-540
319143-541
319143-106
319143-111
319143-104
319143-542
319143-545
319143-334
320273-128
319143-427
319143-546
319143-141
319143-491
319143-492
319143-493
319143-479
319143-496
319143-497
319143-498
319143-499
319143-191
319143-500
319143-131
319143-484
319143-501
319143-502
319143-503
EKK2B
EKK2C
EK137
EKK1A
EK208
EKK2E
EKK2T
EKN34
EK333
EK209
EK210
EK211
EK231
EK105
EK251
EK256
EKK27
EK031
EKK26
EK029
EZM04
EZM06
EZM14
EZM15
EZM16
EKH30
EKK24
EM192
EKK39
EX12K
EK217
EK218
EK220
EK222
EK226
EK228
EX13H
EX13L
EKH6G
EK229
EK176
EX00B
EK280
EK146
EK143
EKK4V
EK165
EK168
EK166
EK153
EK184
EK185
EK167
EK179
EKK1M
EX13C
EKH6E
EK152
EK180
EK173
EK178
Secondary heat exchanger for Indoor models
Secondary heat exchanger for Outdoor models
Switch wire with thermostat for Indoor models
Switch wire with thermostat for Outdoor models
Exhaust thermistor for Indoor models
Temperature controller for Indoor models
709
711
708
715
722
721
707
Description
Inlet drain plug
Inlet water filter
Inlet thermistor
Outlet thermistor
Water outlet
Outlet drain plug
Heat exchanger thermistor
Hi-Limit switch
Overheat-cut-off fuse
Inlet heater for Indoor models
Inlet heater for Outdoor models
Stainless heat exchanger out pipe
120 VAC wire for Indoor models
120 VAC wire for Outdoor models
120 VAC Power ON-OFF switch
Cable clamp for Indoor models
Pipe heater
Drain tube
Inlet heater
Pipe heater fixing plate
Heater fixing plate 16
Fuse fixing plate 18
Fuse fixing plate 14
O-ring P4 FKM
O-ring P6 FKM
O-ring P14 FKM
O-ring P15 FKM
O-ring P16 FKM
Fastener “4-11”
Fastener “14-22”
Fastener “16A”
Fastener “16-25A”
Fastener “6-15”
Flat heater
Drain pipe
Cold pipe
Header connection
Drain port
Thermistor fixing plate
Exhaust thermistor gasket
Hi-limit switch for exhaust
Gasket
Computer board
Rubber grommet
Surge box
Remote controller wire
Gas valve wire
Flame rod wire
Igniter assembly
Proportional gas valve wire
24V cables
Computer board cover
Remote fixing plate
Exhaust Hi-limit switch wire
Fixing plate
713
103
402
402