Oil-Fired Water Heater for Hydronic Heating OM-128HH...a SERVICE MANUAL Semi On-Demand Oil-Fired Water Heater OM-122DW Oil-Fired Water Heater for Hydronic Heating OM-128HH ブック

a

SERVICE MANUAL

Semi On-Demand Oil-Fired Water Heater

OM-122DW Oil-Fired Water Heater for Hydronic Heating

OM-128HH

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1

CONTENTS

SECTION 1: DESCRIPTION

SPECIFICATIONS ................................................................................................ 2

CONTROL PANEL ............................................................................................... 3

CONSTRUCTION ................................................................................................ 3

DIMENSIONAL OUTLINE .................................................................................... 4

WIRING DIAGRAM .............................................................................................. 5

OUTLINE OF OPERATION .................................................................................. 6

DESCRIPTION OF FUNCTIONAL COMPONENTS AND PARTS ........................ 7

SECTION 2: OPERATION

OBSERVE THE FOLLOWING ITEMS FOR SAFE OPERATION ......................... 15

FUEL ................................................................................................................. 16

STARTING OPERATION .................................................................................... 18

HOW TO STOP OPERATION ............................................................................ 20

DIFFRENTIAL SWITCH AND DIP SWITCH (OM-128HH ONLY) ....................... 22

WIRING FOR A CIRCULATION PUMP (OM-128HH ONLY) .............................. 22

WIRING FOR A TIMER (OM-128HH ONLY) ...................................................... 23

SECTION 3: DISASSEMBLING

HOW TO DISASSEMBLE .................................................................................. 24

SECTION 4: REASSEMBLING

PRECAUTIONS ON REASSEMBLY .................................................................. 40

DIRECTIONS FOR REASSEMBLY .................................................................... 40

SECTION 5: TIME CHART

TIME CHART ..................................................................................................... 44

SECTION 6: TROUBLESHOOTING

HOW TO ADJUST THE WATER HEATER USED AT A HIGH ALTITUDE ........... 55

HOW TO USE OF THE ELECTRICAL CIRCUIT TESTER .................................. 56

HOW TO MEASURE SMOKE DENSITY ............................................................ 58

TROUBLESHOOTING CHECK LIST ................................................................. 59

TROUBLESHOOTING GUIDE ........................................................................... 72

PARTS DESCRIPTION .................................................................................... 124

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2

SECTION 1: DESCRIPTION

SPECIFICATIONS

Model: OM-122DW OM-128HH

Type: Combustion System Oil Pressure Vapor System Oil Pressure Vapor SystemAir Intake/Exhaust Direct Vent or Chimney Vent Direct Vent or Chimney VentHeating Supply System Semi On-Demand Hidronic HeatingSource of Water Domestic Water Heating —

Ignition: High Voltage Discharge Spark High Voltage Discharge Spark

Fuel: ASTM D3699 1-K Kerosene, ASTM D3699 1-K Kerosene,ASTM D396 Low Sulfur No. 1 or No. 2 Fuel Oil, ASTM D396 Low Sulfur No. 1 or No. 2 Fuel Oil,ASTM D975 Ultra Low Sulfur Diesel (ULSD) ASTM D975 Ultra Low Sulfur Diesel (ULSD)

Efficiency: 88 % (1) 87 %

Hot Water Input: 148,000 BTU/h 148,000 BTU/h

Fuel Consumption: 1.05 gal/h 1.05 gal/h

Heat Exchanger Capacity: 5.10 gal/h 5.10 gal/h

Fuel System: External tank (2) External tank (2)

Dimensions (W × H × D): 12-5/8” × 27-3/4” × 22-1/2” 12-5/8” × 27-3/4” × 22-1/2”

Weight: 79 lbs. Empty 77 lbs. Empty

Vent Pipe Hole: 4-3/4” diameter 4-3/4” diameter

Maximum Length of 10 ft., 3 bends or less 10 ft., 3 bends or lessVent Pipe System:

Electrical Rating: 120 Volts AC, 60 Hz 120 Volts AC, 60 HzIgnition - 120W Ignition - 120WBurning - 98W Burning - 98W

Required Accessories: Fuel filter, Fuel filter,Flue pipe installation kit (Part #20476440) Temp & pressure relief valve,Chimney installation adapter kit Flue pipe installation kit (Part #20476440)(Part #20476430 or #20476415) Chimney installation adapter kit

(Part #20476430 or #20476415)

Safety Device: Ignition safety device, Ignition safety device,Heat exchanger bi-metal switch, High limit thermistor, Temperature fuse, Heat exchanger bi-metal switch,Fusible link valve Temperature fuse,

Fusible link valve

Exhaust Air Temperature: Less than 500˚F Less than 350˚F

Nozzle: Quantity of Vapor 0.85 GPH 0.85 GPHSpraying Angle 60˚ 60˚Spray Pattern Delavan Type XA Delavan Type XA

Temperature Fuse: 282˚F 282˚F

Electric Current Fuse: 5 A, 7 A 5 A, 7 A

(1) Heat and vaporized water are produced by the combustion process of this water heater.

This rating does not take into account heat loss due to condensation of water vapor.

(2) External tank to be purchased from local suppliers.

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3

ON/OFF

POWER

THERMOSTAT

BHOT

A

COLD

VERY HOT

130 F

WARNINGBURNEROPERATION

Temp Selector Knob Power Switch

Operation Lamp

Burner Lamp

Warning Lamp

ON/OFF

POWER

THERMOSTAT

BHOT

A

COLD

VERY HOT

130 F

WARNINGBURNEROPERATION

Temp Selector Knob Power Switch

Operation Lamp

Burner Lamp

Warning Lamp

Main Circuit Board

Fuel PumpIgnition Transformer

Fusible Link Valve

Air Pressure Switch

Inteke Air Duct

Burner

Heat Exchanger Bi-Metal Switch

Flame Sensor

Strainer

Heat Exchanger

Thermistor

Heat Exchanger

Fuel PumpIgnition Transformer

Fusible Link Valve

Air Pressure Switch

Intake Air Duct

Burner

Heat Exchanger Bi-Metal Switch

Flame Sensor

Strainer

Thernistor

Main Circuit Board

High Limit Thermistor

CONTROL PANEL

CONSTRUCTION

OM-122DW

OM-128HH

OM-122DW OM-128HH

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4

DIMENSIONAL OUTLINE

Type (A)MONTH (March)

YEAR (2014)Lot#

CLASSIFICATION

OM-122DW TYPEA

OM-128HH TYPEA

Serial No. E 0 3 OM122A

PRODUCTION YEAR2014~

PRODUCTION YEAR2014~

OM-128HH

OM-122DW

Temperature andPressure Relief ValveInstallation Opening(NPT 3/4") Female

Exhaust Outletø2-3/4"(ø70mm)

Air Intake Inletø2-3/4"(ø70mm)

Access Cover

Junction Box

22-1

/2"(

570m

m)

6-1/

4"(1

60m

m)

7-1/

2"(1

91m

m)

4-3/

4"(1

19m

m)

8-1/

2"(2

15m

m)

27-3

/4"(

705m

m)

3-9/

16"

(91m

m)

23"(

585m

m)

12-5/8"(320mm)

Drain Outlet(NPT 1/2") Male Fuel Line

Front Panel

Water SupplyInlet(NPT 3/4") Male

Hot Water SupplyOutlet (NPT 3/4") Male

3/16" (5mm)

4-5/16" (110mm) 5-1/8" (130mm)

22-1

/2”

(570

mm

)

6-1/

4”(1

60m

m)

8-1/

2”(2

15m

m)

3/16” (5mm)

12-5/8” (320mm)

Access Cover

Air Intake Inletø2-3/4”(ø70mm)

Temperature andPressure Relief ValveInstallation Opening(NPT 3/4”) Female

Exhaust Outletø2-3/4”(ø70mm)

23”(

585m

m)

3-9/

16”

(91m

m)

Fuel LineDrain Outlet(NPT 1/2” Male) Junction Box

Front Panel

Hot Water Outlet(NPT 1-1/4”Male)

Cold Water Inlet(NPT 1-1/4” Male)

705

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5

5

WIRING DIAGRAM

OM-122DW

OM-128HH

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OUTLINE OF OPERATION

• When the “Power switch” of the Water Heater is turned “ON”, the Burner 2 is prepared for combustion and then the Blower motor starts rotating to be ready for prepurging. After approx. 6 seconds, the Electrode 4 starts pre-ignition. Approximately 4 seconds after this, the Fuel pump 5 starts for combustion. After this combustion starts, the Electrode 4 provides a discharge of approximately 5 seconds for postignition and then stops its discharge. If Burner 2 combustion is detected by the Flame sensor 6, combustion continues. The water in the Heat exchanger 7 is heated and when the temperature of the Thermistor 8 reaches the temperature set by the Temp selector knob 9, the Burner 2 automatically stops combustion. After that, when the temperature of the Thermistor 8 becomes lower than that set by the Temp selector knob 9, the Burner 2 automatically starts combustion in the same order as previously mentioned. The stop and start operation of combustion will be repeated automatically.

NOTE: The sequence of the operation varies by model. The details are given in section 5, “TIME CHART”.

• In the event the Water Heater is overheated due to a defective circuit in the temperature control equipment, the

High limit switch 0 or the High limit thermister (OM-128HH Only) is activated to automatically stop the operation of the Water Heater.

• When operation of the Water Heater is stopped by a safety device, no operation restart can be made unless resetting by hand. In some cases, no operation restart can be made unless a part is replaced.

• The final operation stop of the Water Heater is made by turning the Power switch 1 “Off”.

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DESCRIPTION OF FUNCTIONAL COMPONENTS AND PARTS

BURNER ASSEMBLY

OM-122DW/OM-128HH (Part #20476842)

• The Burner assembly is composed of the Fuel pump, the Fuel nozzle, the Blower motor, and the Flame sensor. They are controlled by the Main circuit board for the Burner operation.

1. FUEL PUMP 2. BLOWER MOTOR 3. FUEL NOZZLE 4. ELECTRODE 5. BURNER TOP 6. IGNITION TRANSFORMER 7. FLAME SENSOR 8. TEMPERATURE FUSE

NOTE: For the unfastened Temperature fuse on the Bunner assembly, hook the shorter side of the Protection tube on the Bracket of the Muffler assembly by contacting with the Muffler assembly.

FUEL NOZZLE

OM-122DW/OM-128HH (Part #20476626)

• Fuel oil is compressed by the Fuel pump and it is ejected and atomized at high speed through the orifice of the Nozzle. Fuel oil is circulated in the inside of the Nozzle for its efficient atomization before ejection. If the pressure of the oil to be sent through the Nozzle is reduced, the diameter of each atomized particle increases and the expansion angle (or atomizing angle) at which fuel is ejected through the Nozzle is decreased to worsen the condition of combustion. It is, therefore, necessary to maintain the ejection pressure of the Fuel pump at an appropriate level. The ejection rate more or less varies with the viscosity (and temperature) of fuel oil.

• The structure of the Nozzle is shown in the above figure. The Filter screens fuel and eliminates dust and dirt. The distributor and the spiral room eject fuel at high speed.

• The Nozzle is rated as shown in the table. It shows the flow rate, spray angle, and spray pattern.

OM-122DW/OM-128HHFlow rate 0.85 GPHSpray angle 60˚Spray pattern Type XAManufacturing company Delavan Inc.

OM-122DW/OM-128HH

DELAVAN Type XA

OM-122DW/OM-128HH

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FUEL PUMP

OM-122DW/OM-128HH (Part #20476819)

• A single phase 120V (60Hz) current is rectified to a half wave by a diode (rectifying element). This voltage is applied to the coil of the Fuel pump and the combination of intermittent electromagnetic force and a spring moves the plunger up and down. This action activates the plunger interlocking piston to reciprocally and alternately open and close the Suction valve and the discharge valve. The Fuel pump is provided with an accumulator to minimize the pulses of discharge pressure and a return valve for pressure adjustment. The Electromagnetic valve is also present in the Fuel pump to stop the operation of the Fuel pump and stop the supply of fuel oil. The Fuel pump has a pressure increasing time adjusting device and a pressure adjusting device capable of adjusting the rise of pressure step by step. This is called the step-up combustion mechanism.

OM-122DW/OM-128HH

Type of model VSRM63-UL (OM-122)Electrical rating AC120V (60Hz) Half wave rectifyingPower consumption 29.5WSet pressure 192 PSI ±2.84 PSI (13.5 kgf/cm2 ± 0.2 kgf/cm2)

• The fuel delivery passage from the Fuel tank to the Fuel pump operate with negative pressure. Therefore, if the Fuel strainer is plugged or if the Fuel supply line leaks air from the joints, the Fuel pump will make noises. Precautions should be taken to avoid this problem.

• Foreign substances contaminate the fuel oil and may clog the Discharge valve and the Suction valve or corrode the inside of the Fuel pump. Precautions should be taken not to allow the fuel to be contaminated with water or dust and to remove such foreign substances if found.

• If the heat output of the Burner appears extremely low, the Fuel line (especially inside of the Nozzle) may be plugged with foreign substances. This is often mistaken to be the Fuel pump pressure problem.

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IGNITION TRANSFORMER (Part #20476818)

• The lgnition transformer stores resonant energy from the LC (coil and condenser). This energy is released to the primary side of the voltage increasing coil by the switching action of the SCR (silicon

control element). During ignition high voltage charge is generated on the secondary side of the voltage increasing coil.

WARNINGRISK OF ELECTRIC SHOCK.DO NOT TOUCH IGNITION TRANSFORMER.DISCONNECT POWER CORD BEFORE REMOVING.

Model K-115-17Electrical rating AC120V (60Hz)Output voltage (Peak value) 17 kVInput current (Average value) Less than 150 mAOutput current (Peak value) 65 mAGrounding type Grounding at the neutral point

BLOWER MOTOR (Part #20476437)

Model IB-842-075Electrical rating AC 120 V (60 Hz)Power consumption 90 W

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FUEL STRAINER (Part #20476487)

• The Fuel strainer is used to prevent foreign substances (such as water and dust) from flowing into the Fuel pump.

• Foreign substances in the fuel may plug the Fuel nozzle, disrupt the operation of the Fuel pump, or prevent ignition or combustion. Inspect the Strainer periodically.

Fuel filter cartridge (Part #17185384)

FUSIBLE LINK VALVE (Part #10005597)

• The Fusible link valve automatically shuts off the flow of fuel if the temperature of the inside of the water heater becomes abnormal.

Model 100F

Pressure resistance 10 PSI

Operating temperature FUSE UNIT SET 165˚F

• If the Fusible link valve closes, operation can not be restored by resetting the Power switch. The Fusible link valve must be serviced.

MAIN CIRCUIT BOARD

OM-122DW (Part #20476812), OM-128HH (Part #20476912)

• The Main circuit board controls the water heating temperature, igniter discharge, operating functions, and various functional controls.

• Main controller circuits; 1 Pre-purging timer circuit 2 Ignition trial timer circuit 3 Electric current circuit 4 Post purge circuit 5 Alarm circuit 6 Flame detecting circuit 7 Temperature detecting circuit 8 Hi-limit circuit 9 Thermistor breaking circuit

SW 1

No. OM-122DW OM-128HH

3 OFF OFF

2 OFF ON

1 OFF ON

DIP Switch

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TRANSFORMER (Part #20476817)

• The Transformer reduces the 120V power source to supply necessary voltage to each component.

• If the Transformer does not have continuity, the Water Heater will not function.

Black color - Black color AC120V

Blue color - Blue color Approx AC13.7V

Orange color - Orange color Approx AC10.5V

FLAME SENSOR (Part #20476811)

• The electrical resistance of the Flame sensor changes with the intensity of light that strikes the receiving surface. This characteristic is used to stop the operation of the Burner by interacting with the Main circuit board.

• If the light receiving surface of the Flame sensor is stained with dust or soot, it will not operate properly. Periodically inspect the light receiving surface at least every six months. Use a piece of soft cloth to clean the light receiving surface, if stained.

Model CDS-106HFA

Resistance while in no combustion More than 180 KΩResistance while in normal combustion Less than 30 KΩPosition of light receiving surface Top

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THERMISTOR (Part #20476873)

• The Thermistor is used to regulate the temperature of the heated water. It automatically operates the Burner when the temperature of the water drops below the set temperature and stops heating when the temperature of water rises higher than the set temperature.

The temperature control system is composed of the Temperature sensing thermistor, the variable resistor at the temperature setting section, the IC at the control section, and the Transistor at the switching section. The control section and the Switches are integrated. Electric resistance of the Thermistor is reduced as the temperature of water increases. Electric resistance increases as the temperature decreases. The Thermistor interacts with the Main circuit board for automatic burner operation. The Thermistor is used for both a temperature regulator and an overheat preventive device.

• The sensing temperature and the resistance of the Thermistor for this water heater are as shown in the following table.

Water Temp.50°F 68°F 86°F 95°F 104°F 113°F 122°F 131°F 140°F 149°F 158°F 167°F 176°F

10°C 20°C 30°C 35°C 40°C 45°C 50°C 55°C 60°C 65°C 70°C 75°C 80°C

Thermistor sensing resistance (kΩ) 15.3 10.3 7.1 5.9 4.9 4.1 3.5 3.0 2.5 2.1 1.8 1.6 1.4

The above resistance values have been rounded to the nearest unit. The above resistance values show the Thermistor sensing temperatures, which are different from the temperatures of the hot water discharge.

HIGH LIMIT THERMISTOR (THERMISTOR B) (Part #20476974) (OM-128HH ONLY)

• The High limit thermistor is used to prevent the water from boiling in the Heat exchanger when the Thermistor fails. The characteristic is the same as the above thermistor.

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HIGH LIMIT SWITCH

OM-122DW (Part #20476406)OM-128HH (Part #20476706)

• The High limit switch stops the operation of the water heater if the temperature of the Heat exchanger rises abnormally due to a malfunction of the Temperature regulator.

OM-122DW OM-128HH

Model US-603U US-603U

Activating temperature

75˚C ± 4˚C (167˚F ± 7˚F) (Contact point Off )

95˚C ± 4˚C (203˚F ± 7˚F) (Contact point Off )

Manual reset temperature less than 35˚C (95˚F) less than 55˚C (131˚F)

• If the Bimetal switch on the Heat exchanger is activated, re-operation of the water heater cannot be accomplished by resetting the “Power switch”. To restart operation, first press the Reset button of the Bimetal high limit switch on the Heat exchanger and then press the “Power switch”.

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TEMPERATURE FUSE (Part #20476820)

• If the internal temperature of the water heater rises abnormally, its operation is stopped.

Operating temperature 139°C ± 2°C (282°F ± 3.6°F)

• When the Temperature fuse is activated, water heater operation cannot be made by resetting the Power switch. The Temperature fuse must be replaced.

AIR PRESSURE SWITCH (Part #20476885)

• Operation of the Burner is automatically stopped if the flow rate of the Blower motor decreases or if the air intake opening of the Flue pipe is plugged.

Model C6065M337:2

ON pressure 285Pa

OFF pressure 250Pa

HEAT EXCHANGER

OM-122DW (Part #20476845) OM-128HH (Part #20476945)

*In case of replacement of the heat exchanger for BS-36UFF (Type B) or OM-147 (Type A), remove the hole cap and install the empty burning preventive electrode.

411

mm

291

mm

(The

rmis

tor)

(Wat

er s

upp

ly p

ipe

open

ing)

(Hole cap)*

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BAFFLE PLATE

OM-122DW (Part #20476423) OM-128HH (Part #20476743)

WATER SUPPLY PIPE

OM-122DW (Part #20476879)

SECTION 2: OPERATION

OBSERVE THE FOLLOWING ITEMS FOR SAFE OPERATION

• This Manual contains important instructions for safe operation of this Water Heater, including DANGER, WARNING, and CAUTION. The persons who use this Water Heater should follow all the safety instructions thoroughly.

DANGER indicates an imminently hazardous situation which, if not stopped, will result in death or serious injury.

WARNING indicates a potentially hazardous situation which, if not prevented, could result in death or serious injury.

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

NOTE: explains precautions for safe operation which should be fully observed.

280 mm

284ｍｍ

367ｍｍ

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FUEL

WARNING

Never use any fuel other than ASTM D3699 1-K Kerosene, ASTM D396 Low Sultur No. 1 or No. 2 Fuel Oil, or ASTM D975 Ultra Low Sulfur Diesel (ULSD).NEVER USE GASOLINE! Use of such fuels can result in an explosion and/or fire and cause injury.

CAUTION

If storage procedure of kerosene or fuel oil is controlled by local codes, follow these regulations.

• DO NOT use fuel which are mixed with highly volatile oils such as gasoline, thinner, degenerated or deteriorated kerosene, contaminated fuel, or water contaminated fuel.

• Store fuel in a place which is free of heat from a fire, rain, dust, and direct sunlight.

HOW TO REFUEL

• Before refueling, make sure that the Fuel tank is free of heat or fire in its vicinity. Special care is to be taken not to let water and dust enter into the Fuel tank.

• After finishing refueling, securely close the Fuel tank cap.

• Completely remove spilled Fuel.

PRECAUTIONS FOR FUEL SHORTAGE AND AIR REMOVING

• Check the oil level in the Fuel tank from time to time. Be sure to refuel before the Fuel tank runs out.

• When first using the water heater after it is installed or refueled, it may not be ignited due to air left in the Fuel supply line. If so, remove air from the Fuel line with the following procedure.

1. Press to turn the Power switch off.

2. Disconnect the Power plug from the receptacle.

3. Make sure that there is no heat or fire in the vicinity of the Fuel tank, the Fuel feed line, and the water heater.

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4. Place a drip tray under the Fuel strainer. Loosen the screw on top of the Fuel strainer to remove air completely.

5. After air is removed, tighten the screw on the Strainer. Wipe up fuel spills immediately.

6. Place a drip tray under the Strainer which is attached to the left lower part of the water heater. Next loosen and remove the screw from the top of the Strainer. Sufficiently remove air from the Strainer.

Also remove the trapped air thoroughly from the Strainer in the inside of the unit.

7. After removing air from the Fuel strainer, securely tighten the screw. Cleanly wipe fuel spills.

NOTE:Insufficient air removal may cause mis-ignition or terminate combustion.

8. Securely connect the Power plug to the receptacle.

9. Press to turn the Power switch on.

10. If no ignition occurs, turn off the Power switch and after approximately 10 seconds turn the Switch On again. If ignition does not take place after a few repetitions of ignition action, go over the operation of 1 through 10 until ignition occurs.

11. If ignition still does not occur, ask a trained technician to check and repair the unit. Supply the technician with sufficient information of model and trouble. Make sure to turn the power off and disconnect the Power plug from the receptacle. Be sure to close the Fuel feed valve of the Fuel tank until the technician reaches your location.

NOTE:Precautions should be taken not to empty the Fuel tank (and the Fuel supply line).

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STARTING OPERATION

1. Fully open the Fuel supply valve on the Fuel tank.

2. Press the Power switch to turn the unit on. The Operation lamp will light up. After this, the water heater will automatically operate according to the temperature setting.

NOTE:The Burner lamp is only lighted while the Burner is in the combustion mode.

CAUTION

• Precautionsshouldbetakennottoscaldyourselfwithhotwaterwhichhasbeenheatedabruptly.Thetemperature was set at 130°F when the Heater was shipped out of the factory.

Adjusting the temperature should be done after making sure that no one is using heated water in any part of the building. All the members of your family must realize the importance of “High Temperature Caution” before adjusting the temperature of heated water for the water heater.

• Riskofscaldinjury! Before taking a shower, expose your hand to the shower water to be sure the temperature of the water

is proper.

OTHER CAUTIONS

A change in the volume of water used will change the temperature of heated water even if the heater is not readjusted. If hot water is used at more than two places at the same time, the temperature of heated water may vary significantly.

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IF IGNITION FAILURE OCCURES

• Read the instructions mentioned on Page 16, “Precautions for the Fuel shortage and Air Removing”. Also check the following items.

1. Press the “Power switch” to turn the operation off.

2. Disconnect the Power plug from the Power receptacle.

3. Make sure that there is no other heat or fire in the vicinity of the Fuel tank, the Fuel line, and the Water heater unit.

4. Make sure also that the Fusible link valve is “fully open”.

5. Make sure that the Fuel tank is free of water. If not, remove water through the Drain valve.

6. Place a drip tray or something similar under the Drain valve of the Fuel tank. Next, release the Drain valve to drain water off completely.

7. After completely draining water off, securely close the Drain valve. Remove fuel spills immediately.

8. Make sure that the Drain cup of the Fuel strainer that is attached to the Fuel tank is free of water after the above cleaning.

9. Place a tray under the Fuel strainer of the Fuel tank. Fully open the Fuel feed valve of the Fuel tank. Remove the Hexagon bolt from the Strainer. Remove the Drain cup. Then drain water off completely. After draining water off, attach the Drain cup in the correct position.

10. Make sure that the Drain cup of the Strainer attached to the lower corner of the heater has no water left.

11. Place a drip tray under the Drain cup of the Strainer. Make sure that the Fuel feed valve of the Fuel tank is fully closed. Turn the Drain cup of the Strainer to drain the Strainer. Be sure to remove water completely. After completely removing water, securely reassemble the Drain cup to its position.

12. The insufficient removal of water may lead to an ignition failure or cause burning to cease.

13. Securely insert the Power plug into the Power receptacle.

14. Press to turn the Power switch on.

15. If no ignition can be made, turn the Power switch off and, after approximately 10 seconds, again press to turn the Power switch on. If ignition cannot be made after a few times of repetitions of this operation, see the items 1 to 10 of “PRECAUTIONS FOR FUEL SHORTAGE AND AIR REMOVING” on Page 16.

16. If the above ignition failure occurs, ask a technician for inspection. When requesting this inspection, supply full information about the failure to the technician, including the name of model or type and the details of the failure. Be sure to turn the Power switch off and disconnect the Power plug from the receptacle. Next, fully close the Fuel supply valve of the Fuel tank and wait for the technician’s visit.

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HOW TO STOP OPERATION

1. To stop the operation of the water heater, press the Power switch off.

2. Fully close the Fuel supply valve of the Fuel tank.

TEMPERATURE OF HOT WATER AND TEMPERATURE SELECTOR

• Even though the temperature of the hot water is set with the Temp selector knob, the water supply temperature may vary due to a change in water volume or plumbing conditions. Before exposing yourself to heated water, feel its temperature with your hand to check to see if the temperature is acceptable.

• The temperatures listed in the following table should be used for reference. Adjust the temperature of the hot water by referring to the table.

• The Temp selector knob was set at 130°F before the water heater was shipped from the manufacturing plant.

• The temperatures shown in the table are calculated from data using short plumbing and a cold water supply temperature of 69°F.

OM-122DW OM-128HH

Position of the Temperature selector knob

Temperature of heated water

Position of the Temperature selector knob

Temperature of heated water

VERY HOT Approx. 155°F VERY HOT Approx. 180°F

B Approx. 150°F B Approx. 160°F

HOT Approx. 120°F HOT Approx. 125°F

A Approx. 90°F A Approx. 95°F

COLD Approx. 70°F COLD Approx. 70°F

OTHER PRECAUTIONS

• For themostconvenientandcomfortableuse, install acold/hotmixing faucet.Use a faucetwhichprovides a minimum variation of mixed cold/hot water supply temperature. (Temperature/Pressure Balanced)

• Afterattaching thecold/hotmixing faucet, turn theWaterheater temperatureselector knob to the“Very Hot” position. Sufficient care is to be taken not to scald yourself with hot water due to the incorrect operation. Also make sure that other water sources are not in service while the temperature of the hot water is being adjusted. It is important that each of the family members recognizes the “High Temperature Caution” while the temperature adjustment is being made.

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HOT WATER SUPPLY FLOW RATES AND TEMPERATURES

OM-122DW

SEASON INCOMING WATER TEMP HOT WATER TEMP FLOW RATE

SUMMER 80˚F 120˚F (40˚F RISE) 6.1 GPM

SPRING & FALL 60˚F 120˚F (60˚F RISE) 4.0 GPM

WINTER 40˚F 120˚F (80˚F RISE) 3.0 GPM

OM-128HHSEASON INCOMING WATER TEMP HOT WATER TEMP FLOW RATE

SUMMER 80˚F 120˚F (40˚F RISE) 6.2 GPM

SPRING & FALL 60˚F 120˚F (60˚F RISE) 4.1 GPM

WINTER 40˚F 120˚F (80˚F RISE) 3.1 GPM

NOTE:If a continuous supply of high temperature hot water is necessary, reduce the flow rate of outgoing hot water. On the contrary, if low temperature hot water is necessary, the flow rate of hot water may be increased or cold water may be mixed at the faucet.The flow rates are calculated under the conditions of standard installation and normal usage so that they will vary according to installation, usage and temperature.

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DIFFERENTIAL SWITCH AND DIP SWITCH (OM-128HH ONLY)

WARNING: Never change the DIP SWITCH for OM-122DW.

NOTE: Make sure that the Power supply cord is disconnected when changing the position of DIP Switch is selected.

The differential switch on the Main circuit board controls does not change the Heat exchanger water temperature. The Switch can be set at a delta (on/off) of 3.6°F (2°C), 18°F (10°C), or 36°F (20°C). A higher delta reduces burner short cycling.

NOTE: The position of DIP Switch is set to 18°F differential from factory.

1. Select the position Differential switch by the DIP Switch (SW1).2. Select the differential range by the DIP Switch, No.2 or No.3.3. Make sure that the DIP Switch No.1 is “ON” position.

WIRING FOR A CIRCULATION PUMP(AVAILABLE FROM A PLUMBING SUPPLY COMPANY) (OM-128HH ONLY)

This water heater is equipped with a power terminal for the Circulation pump. You can operate the Circulation pump in conjunction with the Power switch of the water heater by connecting the Pump to the “K” terminal of the Circuit board.

When the Power switch is “ON”, the power terminal for the Circulation pump “K” constantly outputs AC120V. Any Circulation pump that operates in AC120V and consumes 300W or less can be connected to the power terminal “K”. Use the Attached lead wire for the Circulation pump for wiring according to the instruction of diagram below.

Remove the open-terminal connected to the “K” terminal.Connect to the Circulation pump using the attached couplers (Red).See the wiring diagram below for wiring to the Circuit board.Connect the Lead wire for the Circulation pump to the “K” terminal of the Circuit board.

How to use the coupler

3

2

1

No. DIFF 3.6˚F (2˚C)

OFF

OFF

18˚F (10˚C)

OFF

ON

ON

36˚F (20˚C)

ON

ON

3

SW1

DIP Switch2

1 Main Circuit BoardSW1

Circulation pump(available on the market)

Main Circuit Board

(K)

Make3/16 in.(4-5mm)space.

Lead wire forcirculation pump

Stopper

Power lead wireof the externalcirculation pump

K

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WIRING FOR A TIMER(AVAILABLE FROM AN ELECTRICAL SUPPLY COMPANY) (OM-128HH ONLY)

This water heater is equipped with the connection terminal for the timer. This terminal has no-voltage (also known as dry contacts) contact. You can operate the unit with the timer by connecting the timer (option) to the terminal for timer connection “L” on the Circuit board.When the Power switch of the water heater is “ON” and the signal from no-voltage contact on the timer connection terminal “L” is “OFF”, the water heater stops operation and the Operation lamp blinks to indicate stand-by mode.

Remove the Short-circuit terminal connected to the “L” terminal and connect the cord of the timer (option) using the attached couplers (white).Connect the Lead wire for timer to the “L” terminal of the Circuit board.Other available timers can be connected to the unit only through a relay. Use a relay with gold contact.

How to use the coupler

WARNING: Do not energize the connection terminal of the timer with voltage, as it may damage the Circuit board.

Timer(L)

Main Circuit Board

3

SW1

2

1

Timer(available from an electricalsupply company)

Make3/16 in.(4-5mm)space.

Lead wire fortimer

Stopper

Power lead wireof the timer

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SECTION 3: DISASSEMBLING

HOW TO DISASSEMBLE

• When disassembling or repairing, always put on gloves. • Be sure to follow the following instructions for disassembling the water heater unit. • Be sure to disconnect the Power plug from the receptacle before inspecting, repairing, or disassembling the water

heater. • Fully close the Fuel feed valve on the Fuel tank. • Fully close the water feed faucet. • Burnt or corroded bolts or screws which are used in the combustion area should be sprayed with a corrosion

resisting lubricant before being removed. • Care is to be taken not to lose or misplace the Parts and the Bolts. It is advisable that the Bolts or screws are kept

in or on the part where they are removed.

HOW TO DISASSEMBLE BURNER UNIT

(1) Remove four (4) screws from the access cover by phillips screw driver.

(2) Pull out the connectors of G, H, F, Q and D from the Main circuit board in a horizontal direction while holding the connector lock of the Main circuit board.

(3) Keep these connectors inside of the Water heater unit in a manner that they do not become damaged.

(4) Next release the two (2) screws from the Front panel and remove the Front panel. These screws have a lock nut and therefore cannot be taken out of the Panel.

(5) Remove the two (2) terminals from the Air pressure switch.

NOTE:When removing the two (2) terminals above, be careful of sharp edges on surrounding parts. DO NOT cut yourself. DO NOT apply undue force when removing the terminals, or the Air pressure switch may be accidentally broken.

(6) Release the Binding band.

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(7) Use a wrench (17mm) on the Hex nut on the top of the Fuel pump to stop the Hex nut from turning and also use a wrench (12mm) to remove the Flare nut.

(8) Next use a wrench (14mm) to secure the Fuel supply line so that it can not turn and then use a wrench (12mm) to remove the Flare nut from the Fuel feed pipe.

(9) Remove the three (3) screws from the Intake air duct with a phillips screw driver.

(10) Remove the Intake air duct.

(11) Rotate the Intake air pipe clockwise to face its open end toward the rear of the unit.

NOTE:This relocation of the Intake air pipe is intended to prevent repair or maintenance personnel from being hurt by the Pipe end.

(12) Remove the Screw (1 pc.) from the Motor ground wire with a phillips screw driver.

(13) Remove the Locking band with pliers, to remove the Air pressure switch tube.

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(14) Remove the three (3) nuts from the Burner by using a phillips or flat head screw driver.

(15) After taking the previously disconnected lead wires out, pull the Entire burner unit out.

NOTE:When taking the Burner unit out, be careful not to damage the lead wires and the Fusible link valve.

HOW TO REMOVE THE BURNER TOP

NOTE:Allow the Burner top to cool completely before removing it.

(16) Remove the Burner according to above-mentioned paragraphs (1) to (15).

(17) Remove the three screws from the Burner top with a phillips screw driver.

(18) Pull off the Burner top.

HOW TO REMOVE THE NOZZLE

(19) Remove the Burner according to the paragraphs (1) to (15).

(20) Disassemble the Burner top according to paragraphs (16) to (18).

(21) Secure the Nozzle with an adjustable wrench of 150mm so that it cannot turn and next remove the Nozzle by using a 150mm adjustable wrench.

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(22) When the Nozzle becomes loose, remove it by hand.

HOW TO REMOVE THE BLOWER MOTOR

(23) Remove the Burner according to the paragraphs (1) to (15).

(24) Remove the Blower motor by removing the four screws with the phillips screw driver.

NOTE:Since the Blower motor is heavy, support it with your hand when removing the Bolts.

HOW TO REMOVE THE FLAME SENSOR

(25) Remove the Burner according to the paragraphs of (1) to (15).

(26) Remove the two (2) bolts from the Igniter transformer with a phillips screw driver.

(27) Next remove the four (4) screws from the Blower bracket C with a phillips screw driver.

(28) Take apart the Blower bracket C and the Blower bracket assembly.

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(29) Pull the High voltage lead from the electrode by taking the boot of lead.

(30) Pull the Flame sensor out by taking the Lead wire.

HOW TO REMOVE THE FUEL PUMP

(31) Remove the Burner according to the paragraphs of (1) to (15).(32) Use a 150mm adjustable wrench on the Hexagon-shaped nut on the top of the

Fuel pump to ensure that the Nut does not move while removing the Flare nut with a 12mm wrench.

(33) Remove the two (2) bolts from the Fuel pump with a phillips screw driver.

HOW TO REMOVE THE IGNITER TRANSFORMER

(34) Remove the Burner according to the paragraphs (1) to (15).

(35) Remove the two (2) bolts from the Igniter transformer with a phillips screw driver.

(36) Next remove the four (4) screws from the Blower bracket C-assembly with a phillips screw driver.

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(37) Take apart the Blower bracket C-assembly and the Blower bracket assembly.

(38) Pull the High voltage lead from the electrode by holding the boot of the lead.

(39) Remove the Rubber bushing for the High voltage lead from the Blower bracket assembly.

(40) Disconnect the High voltage lead from the Blower bracket assembly.

NOTE:Care must be taken not to damage the High voltage lead when disconnecting it from the Blower bracket assembly.

HOW TO DISASSEMBLE THE ELECTRODE

(41) Remove the Burner according to paragraphs (1) to (15).(42) Remove the Blower motor according paragraph (24).(43) Remove the Fuel pump according to paragraphs (32) and (33).

(44) Use a 12mm wrench to hold the Fuel feed pipe nipple in so that it does not turn and then remove the Fuel feed pipe with a 12mm wrench.

(45) Remove the grommets from the Blower bracket assembly.

(46) Hold and pull out the Flame sensor toward you.

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(47) Remove the two (2) screws from the Igniter transformer with a phillips screw driver.

(48) Remove the four (4) screws from the Blower bracket C-assembly by the phillips screw driver.

(49) Separate the Blower bracket C-assembly from the Blower bracket assembly.

(50) Pull the High voltage lead out of the electrode by holding its boot.

(51) Take off the Rubber bushings for the High voltage leads from the Blower bracket assembly.

(52) Disconnect the High voltage leads from the Blower bracket assembly.

NOTE:Be careful not to damage the High voltage leads when being removed from the Blower bracket assembly.

(53) Remove the two (2) screws from the Pump bracket by using a phillips screw driver.

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(54) Remove the five (5) screws from the Blower bracket by using a phillips screw driver.

(55) Remove the Blower bracket assembly while removing the Fuel feed pipe from the hole.

(56) Remove the four (4) screws from the Burner bracket with a phillips screw driver.

(57) Remove the one (1) screw from the electrode by using a phillips screw driver.

HOW TO REMOVE THE FUEL STRAINER AND THE FILTER ELEMENT

(58) Use a wrench (14mm) to secure the Fuel supply line so that it can not turn and then use a wrench (12mm) to remove the Flare nut from the Fuel feed pipe.

(59) Secure the Strainer with a 150mm adjustable wrench so that it does not move. Next remove an union with a 14mm wrench.

(60) Secure the union with a 19mm wrench so that it does not move. Next remove the Strainer with a 150mm adjustable wrench.

(61) Take the Drain cup off the Fuel strainer by turning the Cup by hand.

NOTE:If it is hard to turn the Drain cup, use a wrench, adjustable wrench, or a pipe wrench.

(62) Turn the Filter element to remove it.

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HOW TO REMOVE THE FUSIBLE LINK VALVE

(63) Remove the Fusible link valve and the Fuel strainer by referring to the paragraphs (58) to (60).

(64) Remove the two (2) screws from the Fusible link valve coupling with a phillips screw driver.

(65) Pull the Fusible link valve assembly out of the Left side panel.

(66) Fasten an adjustable wrench to the Fusible link valve to prevent movement and then remove the Fuel feed pipe joint by using a 19mm wrench.

(67) Remove the Fusible link valve coupling.

HOW TO REMOVE THE MAIN CIRCUIT BOARD

(68) Remove the Front panel by referring to the paragraph (1).

(69) Pull out all the Connectors from the Main circuit board in a horizontal direction while releasing its connector lock.

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(70) Remove the four (4) screws from the Main circuit board with a phillips screw driver.

(71) The Main circuit board and the Controller case will come off at the same time.

HOW TO REMOVE THE TRANSFORMER

(72) Remove the Front panel by referring to paragraph (1).

(73) Remove the Main circuit board by referring to paragraphs (69) to (71).

(74) Remove the four (4) screws from the Controller base with a phillips screw driver.

(75) Remove the two (2) screws from the Transformer with a phillips screw driver.

HOW TO REMOVE THE OPERATION PANEL

(76) Remove the Front panel according to paragraph (1).(77) Pull off the Connectors of the Remote controller from the Main circuit board in a

horizontal direction.(78) Take the Front panel apart according to paragraph (4).(79) Take off the Binding band according to paragraph (6).

(80) Loosen the screw (1 pc.) on the Temperature selector knob by using a 2mm hexagon wrench and remove the Temperature selector knob.

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(81) Remove the two (2) screws from the Switch bracket with a phillips screw driver.

(82) Remove the Operation panel from the Top panel by placing your hand at the rear side.

HOW TO REMOVE THE AIR PRESSURE SWITCH

(83) Remove the two terminals of the Air pressure switch according to paragraphs (4) to (5).

(84) Remove the Band from the Air pressure switch tube by using pliers.

(85) Remove the Air pressure switch tube.

(86) Remove the two (2) screws from the Air pressure switch with a phillips screw driver.

NOTE:Hold the Air pressure switch when removing the two (2) screws, or it may otherwise drop easily.

HOW TO REMOVE THE JUNCTION BOX

(87) Remove the Burner according to paragraphs (1) to (15).(88) Pull out Connector-E from the Main circuit board while releasing the lock of the

connector of the Main circuit board.

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(89) Place Connector-E into the unit to prevent the Lead wires from being damaged.(90) Remove the two (2) screws from the Junction cover with a phillips screw driver.

(91) Remove the four (4) screws from the Junction box with a phillips screw driver.

HOW TO DISASSEMBLE THE TERMINAL BOARD

(92) Remove the Burner as per paragraphs (1) to (15).(93) Remove the Junction box as per paragraphs (88) to (91).(94) Remove the four (4) screws from the Terminal board which are connected with the

Lead wires and the Power cord.

(95) Remove the screw from the Ground wire with a phillips screw driver.

(96) Remove the two (2) screws from the Terminal board with a phillips screw driver.

HOW TO DISCONNECT THE POWER CORD

(97) Remove the Burner as per paragraphs (1) to (15).(98) Remove the Junction box as per paragraphs (88) to (91).

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(99) Remove the two (2) screws from the Terminal board which is connected to the Power cord.

(100) Remove the Cord bushing which is used to secure the Cord, by using pliers.

(101) Carefully disconnect the Power cord from the Junction box so that the Lead wires are not damaged.

HOW TO REMOVE THE HIGH LIMIT SWITCH

(102) Release the two (2) screws from the Front panel and then remove the Front panel.

(103) Remove the High limit switch from the Bracket to which it is attached.

(104) Remove the two (2) terminals from the High limit switch.

HOW TO REMOVE THE THERMISTOR

(105) Release the two (2) screws from the Front panel and then remove the Front panel.

(106) Disconnect the Connector-A from the Main circuit board while releasing its connector lock.

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(107) Remove the Thermistor fixing plate, Thermistor, and O-ring (P4) from the Heat exchanger after removing the Quick fastener.

HOW TO REMOVE THE HIGH LIMIT THERMISTOR (OM-128HH ONLY )

(108) Release the two (2) screws from the Front panel and then remove the Front panel.

(109) Disconnect the Connector-T from the Main circuit board while releasing its connector lock.

(110) Remove the Thermistor fixing plate, High limit switch, and O-ring (P4) from the Heat exchanger after removing the Quick fastener.

HOW TO REMOVE THE MUFLLER AND THE INSULATOR

(111) Move the Insulating cloth cover and next remove the Screw to remove the Flexible exhaust pipe. Next remove the Flexible exhaust pipe from the Muffler assembly.

NOTE:Before starting the above work, make sure that the Flexible exhaust pipe has been cooled.

(112) Remove the five (5) screws to disassemble the Top panel (back) with a phillips screw driver.

(113) Remove the Insulator.

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(114) Remove the four (4) screws from the Muffler assembly with a phillips screw driver.

(115) Remove the Temperature fuse on the Muffler assembly to disassemble the Muffler assembly.

(116) Remove the Insulator and the Heat exchanger gasket.

HOW TO DISMOUNT THE HEAT EXCHANGER

(117) Disconnect all the connectors from the Main circuit board, as per paragraphs (68) to (69).

(118) Remove the Muffler assembly, Insulator, and the Gasket as per paragraphs (111) to (116).

(119) Remove the Burner as per paragraphs (1) to (15).

(120) Remove the High limit switch as per paragraphs (103) and (104).

(121) Remove the Thermistor as per paragraphs (106) to (107).

(122) Remove the High l imit thermistor as per paragraphs (109) to (110). (OM-128HH ONLY)

(123) Remove the Front panel as per paragraph (4).

(124) Remove the two (2) terminals from the Air pressure switch as per paragraph (5).

(125) Carefully peel off the Sealing tapes from the right and left side panels and remove the two (2) screws from the Front panel bracket. Remove the Front panel bracket.

(126) Remove the five (5) screws to disassemble the Top panel (Back) with a phillips screw driver.

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(127) Remove the six (6) screws to disassemble the Left side panel with a phillips screw driver.

(128) Remove the five (5) screws to disassemble the Right side panel with a phillips screw driver.

(129) Remove the quick fastener to disassemble the Water supply pipe. (OM-122DW ONLY)

(130) Remove the Hot water outlet pipe with the 300mm adjustable wrench. (OM-122DW ONLY)

(131) Remove the four (4) flange nuts to remove the Heat exchanger with a 8mm box wrench.

HOW TO REMOVE THE O-RING FROM THE WATER SUPPLY PIPE (OM-122DW ONLY)

(132) Remove the Burner as per paragraphs (1) to (15).

(133) Remove the two (2) quick fasteners from the Water supply pipe and next pull out the Water supply pipe.

(134) Remove the two (2) O-rings (P12.5) from the Water supply pipe.

HOW TO REMOVE THE BAFFLE PLATE

(135) Remove the Muffler assembly, Insulator, and Gasket as per paragraphs (111) to (116).

(136) Pull the Baffle plates up and out of the Heat exchanger.

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SECTION 4: REASSEMBLING

PRECAUTIONS ON REASSEMBLY

• When reassembling this product, strictly observe the following precautions:

WARNING• Electrical shocksorcontactwithmovingpartsmay result in serious injury.Reassembly tobe

conducted by a specialist.

OTHER PRECAUTIONS• Beforereassembly,makesurethatthePower plug is disconnected from the power outlet.• Beforereassembly,makesurethatthefueloftheFuel tanks supply valve is fully closed.• Beforereassembly,makesurethattheMain valve on the Water supply piping is fully closed.• Inreassemblingtheproduct,usethesamestepsinreverseordertothosefordisassembly.Incorrect

reassembly may be hazardous, resulting in not only poor performance, but also in damage to the product, fires, and air pollution.

DIRECTIONS FOR REASSEMBLY

1. Before connecting wire connectors to the Main circuit board, be sure that the Alphabetic characters inscribed on the Connector correspond to those on the Circuit board.

2. Refer to the color designations in the wiring diagram when connecting the Power plug cord to the Terminal block.

3. Before remounting the Screw which had a toothed lock washer before removal, thread the Washer back into the position as it was on a screw.

4. Position of the Nozzle in relation to electrode rod.

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5. Be careful not to over tighten the Flare nut. This may damage the flared section of the Copper piping.

6. When attaching the Nozzle to the Nozzle adapter, be careful not to damage or dirty the surface of the adapter where it comes into contact with the Nozzle. DO NOT apply any type of liquid packings or sealing agent to the threaded section of the Nozzle adapter.

7. The Flame sensor must face the proper direction. Mount the Flame sensor so that the detecting surface is oriented toward the top of the Burner. The Sensor bracket must also be oriented correctly.

(a) Insert the Flame sensor into the Plastic bracket.

Caution: To install the Flame sensor, make the protruding section at the side of the Flame sensor agree with the slot on the Bracket and insert the Flame sensor firmly up to the bottom.

Note: Use pliers with long tapered noses to nip and install the Flame sensor, which facilitates installation work.

8. Secure the Electrode holder plate securely to make sure that the electrode does not become loosened. Before attaching the Plate using screws supplied, coat the threaded section of each screw with Three Bond 1401B screw-locking agent to prevent loosening and rusting. Such a screw-locking agent also has a sealing effect.

Protruding section of flame sensor Slot position of bracket

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9. To install the Burner top, make the “UP” marked position of the Burner top agree with the Blower installation position (upper side).

10. Before connecting the Fusible link valve to the joint, seal the threaded section of the joint with the Teflon sealing tape.

11. Before attaching the Fuel strainer to the joint, seal the threaded section of the joint with the Teflon sealing tape.

12. Tighten the Drain cup of the Fuel strainer securely to prevent oil leakage.

13. After disconnecting, make sure to reclasp the Lead wires into their original position.

14. When connecting the Air pressure switch tube to the Air pressure switch, clamp the tubing securely to prevent air leakage.

“UP” marked position of Burner top

Blower installation position

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15. Before mounting the Thermistor or the High limit thermistor (OM-128HH only) on the Heat exchanger, install the O-ring.

16. Place the Insulator in the center of the Heat exchanger assembly and fill in the space between the Insulator and the Heat exchanger edge using the Heat exchanger gasket (Part#20476393).

17. For the unfastened the Temperature fuse on the Burner assembly, hook the shorter side of the Protection tube on the Bracket of the Muffler assembly by contacting with the Muffler assembly.

18. Before threading the O-rings onto parts, lubricate them with water to avoid damage due to friction. (OM-122DW only)

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SECTION 5: TIME CHART

44

SECTION 5: TIME CHART

(OM-128HH ONLY)

T4orless

45

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4544

SECTION 5: TIME CHART

45

(OM-128HH ONLY)

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4646

(OM-128HH ONLY)

47

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4746 47

(OM-128HH ONLY)

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4848

(OM-128HH ONLY)

49

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4948 49

(OM-128HH ONLY)

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5050

(OM-128HH ONLY)

51

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5150 51

(OM-128HH ONLY)

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5252

(OM-128HH ONLY)

T1 : 6sT2 : 4sT3 : 5sT4 : 10sT5 : 30sT13 : 1s

53

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5352 53

(OM-128HH ONLY)

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SECTION 6: TROUBLESHOOTING

Tools and Materials Required for Repair

Phillips screwdriver Electrical strapper setStreight edge driver Vinyl insulating tape11 mm wrench Aluminum tape12 mm wrench Teflon sealing tape17 mm wrench Silicone sealant (Three Bond 5211C)19 mm wrench Oil compound (G747 manufactured by Shin-8 mm Box screwdriver Etsu Chemical)10 mm Box screwdriver Lubricant (CRC5-56)14 mm Box screwdriver Screw-locking agent (Three Bond 1401B)2.0 mm allen wrench Scissors150 mm adjustable wrench Utility knife300 mm adjustable wrench Thermometer (0 to 100°C)375 mm adjustable wrench Pressure gauge setPipe wrench Vernier calipersElectric circuit tester Scale (Ruler)Needle nose pliers Tooth brushWire cutter RagAdjustable pliers O-ringWater pliers Smoke tester and measuring paper for smoke Soldering iron TesterSolder

Solder remover

The tools and materials listed above are likely to be required for repair, not for installation.This listing is for reference only. Select and use the appropriate tools and materials according to the particular repair requirements.

Although not all listed tools and materials are required, as many of them as possible should be made available. Most repairs can be performed with these listed tools and materials.

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HOW TO ADJUST THE WATER HEATER USED AT A HIGH ALTITUDE

How to adjust the setting pressure of the fuel pump:

(Flue Pipe Connection)

Altitude Necessity of adjusting pressure of the Fuel pump Setting Pressure Flow Rate Remarks

0~1640 ft(0~500 m) No

192 PSI(13.5 kgf/cm2)

1.05 gal/h(3.97 L/h)

1640~3280 ft(500~1000 m) Yes

171 PSI(12.0 kgf/cm2)

Turn the Pressure adjusting screw 90° counterclockwise.

1.00 gal/h(3.77 L/h)

Setting pressure of the Fuel pump in the left column is a rough guide.Adjust the pressure within 149~192 PSI (10.5~13.5 kgf/cm2) depend ing on the installation condition and extension length of the Exhaust pipe.

3280~4920 ft(1000~1500 m) Yes

149 PSI(10.5 kgf/cm2)

Turn the Pressure adjusting screw 180°

counterclockwise.

0.94 gal/h(3.57 L/h)

(Chimney Connection)

Altitude Necessity of the Adjusting pressure of the Fuel pump Setting Pressure Flow Rate Remarks

0~3280 ft(0~1000 m) No

192 PSI(13.5 kgf/cm2)

1.05 gal/h(3.97 L/h)

3280~4920 ft(1000~1500 m) Yes

171 PSI(12.0 kgf/cm2)

Turn the Pressure adjusting screw 90° counterclockwise.

1.00 gal/h(3.77 L/h)

Setting pressure of the Fuel pump in the left column is a rough guide.Adjust the pressure within 171~192 PSI (12.0~13.5 kgf/cm2) depend ing on the installation condition and extension length of the Exhaust pipe.

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WARNING:This Water Heater is designed to be used no more than 4,922 FT. (1,500 m) above sea level. Burner adjustments are required when: (1) water heater is installed with the Flue pipe (#20476440) above 1,640 FT. (500 m); (2) Water Heater is installed with Chimney kit (#20476430) above 3,280 FT. (1,000 m). Failure to make appropriate adjustment may cause combustion failure.

CAUTION:Adjusting of the setting pressure for the Fuel pump is to be performed while checking the condition of smoke by smoke tester. The inspection opening is located at the root of the Exhaust pipe, as shown in the section of the Upper panel. Read the explanation given on the Upper panel carefully. After collecting the smoke, set the packing on the inspection opening and then place the Cover. The collected smoke is checked by “BACHARACH OIL BURNER SMOKE SCALE”, of which scale number “0” implies no problem.

HOW TO USE THE ELECTRICAL CIRCUIT TESTER

Example Tester: SK-6511 manufactured by Kaise K.K.

• Component name

• Notes for Use

1. Before measurement, make sure that the Rotary-type power function switch is set to the correct position.

2. The maximum permissible AC and DC input voltage range is 500V. Do not apply voltages exceeding +500V, as serious accident or damage to the tester may result.

3. Always keep the body of the tester and probes clean and dry. Before operating, check that all components are free of damage.

4. The tester is a precision instrument. Be careful not to expose it to strong shock or vibration. Avoid storing the tester in hot and damp places.

5. Do not scrub the tester with abrasives and do not wipe it with benzine, alcohol, or other volatile organic solvents.

6. Avoid changing range suddenly when measuring voltages and currents.

INDICATOR

POWER FUNCTION SWITCH

PROBE

ブック 1.indb 56 2014/06/06 16:34:25

57

• Measurement1. AC voltage measurement procedure

a. Set the Power function switch to the AC. V position. The LED marked “AC” will light.

b. Connect the black probe to the grounding terminal and the red probe to the live terminal of the circuit and read the indication on the tester.

2. Resistance (Ω) measurement procedure

a When measuring the internal resistance of the circuit, make sure to cut off power to the circuit (disconnect the power plug from the outlet) and allow internal capacitor(s) to discharge.

b. Set the Power function switch to the Ω position. “10.00 MΩ” will be displayed and the top digit “1” will blink.

c. Connect the tester across the Intended thermistor or resistor and read the indication on the tester.

3. Continuity ( ) measurement procedure

a. When measuring an internal element of the circuit, make sure to cut off power to the circuit (disconnect the power plug from the outlet) and allow internal capacitor(s) to discharge.

b. Set the Power function switch to the position.c. Connect the tester across the circuit. If the resistance value is from 1.5 to

15.0 kilo-ohms, a buzzer will sound and a “ ” mark will be displayed. For more accurate measurement, use the resistance measurement procedure shown above in item 3.

4. Diode measurement procedure

a. Before measuring an internal element of the circuit, turn off the Power of the circuit (disconnect the power plug cord from the outlet) and allow its internal capacitor(s) to discharge.

b. Set the Power function switch to the position.c. Connect the black probe to the anode and the red probe to the cathode of

the diode and check that the tester displays the same value as that displayed before the diode was connected.

d. Next, connect the probes in the opposite direction to that above in item c. If the resulting value is about half that which was measured in c, it can be judged that the diode is normal.

Bimetal Switch

AC 250V

Circuit

Connector “G”

Connector “J1” Connector “P”

Connector “F”

Black

Red

ブック 1.indb 57 2014/06/06 16:34:26

58

HOW TO MEASURE SMOKE DENSITY

1. Remove the two (2) screws from the Exhaust pipe to remove the Cover and Gasket.

2. Set “Bacharach Oil Burner smoke scale” and insert the point of Smoke tester.

3. Pull the lever of the tester and check the scale. The allowable Bacharach smoke is a No. 0 point.

4. Secure the cover with the two (2) screws after measuring.

Measuring hole

Smoke Tester

Secure the cover with two screws after measuring.

Bacharach oil burner smoke scale

Exhaust pipe

Gasket

Cover

Screw

ブック 1.indb 58 2014/06/06 16:34:26

59

TROUBLESHOOTING CHECK LIST

IMPORTANT

When repairing this product, especially if several years have passed since its initial operation, remove the Burner assembly from the heat exchanger and check the top of the Burner for soot. If the end or inside of the Burner top is dirty with soot, remove it using a tooth brush.Perform the above, irrespective of the section to be repaired.

ブック 1.indb 59 2014/06/06 16:34:26

60

(O) L

amp

: OP

ER

ATI

ON

LA

MP

(B

) Lam

p: B

UR

NE

R L

AM

P (

W) L

amp

: WA

RN

ING

LA

MP

“

” in

dic

ates

the

lam

p o

n. “

”

ind

icat

es t

he la

mp

off

.Q

uick

che

ck li

st fo

r tr

oub

lesh

ootin

g

Faul

tN

o.La

mp

ind

icat

ion

and

sta

tus

Che

cked

for

Ref

eren

ce p

age

Par

ts n

eed

edP

art

#To

ols

need

ed

1O

per

atio

n

Bur

ner

War

ning

Aft

er t

urni

ng

the

pow

er

switc

h on

, no

ne o

f the

la

mp

s (O

), (B

), or

(W),

light

up

.Th

e un

it d

oes

not

star

t op

erat

ion.

1.

Ear

th le

akag

e b

reak

er is

not

tur

ned

on.

2.

Che

ck t

he P

lug.

3.

Imp

rop

er in

stal

latio

n

4.

Imp

rop

er in

stal

latio

n

5.

Vol

tage

dro

p

1.

Ear

th le

akag

e b

reak

er is

not

tur

ned

on.

2.

Che

ck t

he p

lug.

3.

Imp

rop

er in

stal

latio

n

4.

Imp

rop

er in

stal

latio

n

5.

Imp

rop

er in

stal

latio

n

6.

Bro

ken

the

Pow

er c

ord

7.

Loos

ened

scr

ew t

hat

fast

ens

the

Lead

w

ire o

f the

ter

min

al b

lock

.

8.

Bro

ken

lead

wire

of t

he t

erm

inal

blo

ck

9.

Loos

ened

scr

ew t

hat

fast

ens

the

Le

ad w

ire o

f the

ter

min

al b

lock

.

10.

Def

ectiv

e th

e Tr

ansf

orm

er

11.

Bro

ken

the

Fuse

12.

Bro

ken

the

Lead

wire

of t

he P

ower

sw

itch

13.

Def

ectiv

e t

he P

ower

sw

itch

14.

Def

ectiv

e th

e C

ontr

olle

r su

bst

rate

Whe

n th

is

cond

ition

oc

curs

at

star

t-up

of

the

unit.

Faul

t N

o. 1

-(1)

, < It

em 1

> P

.72

Faul

t N

o. 1

-(1)

, < It

em 2

> P

.72

Faul

t N

o. 1

-(1)

, < It

em 3

> P

.73

Faul

t N

o. 1

-(1)

, < It

em 4

> P

.73

Faul

t N

o. 1

-(1)

, < It

em 5

> P

.73

Faul

t N

o. 1

-(1)

, < It

em 1

> P

.72

Faul

t N

o. 1

-(1)

, < It

em 2

> P

.72

Faul

t N

o. 1

-(1)

, < It

em 3

> P

.73

Faul

t N

o. 1

-(1)

, < It

em 4

> P

.73

Faul

t N

o. 1

-(2)

, < It

em 5

> P

.74

Faul

t N

o. 1

-(2)

, < It

em 6

> P

.75

Faul

t N

o. 1

-(2)

, < It

em 1

> P

.74

Faul

t N

o. 1

-(2)

, < It

em 8

> P

.76

Faul

t N

o. 1

-(2)

, < It

em 9

> P

.76

Faul

t N

o. 1

-(2)

, < It

em 1

0 >

P.7

7

Faul

t N

o. 1

-(2)

, < It

em 1

1 >

P.7

7

Pow

er c

ord

Term

inal

blo

ck le

ad

wire

Tran

sfor

mer

Fuse

Mai

n ci

rcui

t b

oard

Mai

n ci

rcui

t b

oard

• Te

ster

• Te

ster

• N

eed

le n

ose

plie

rs

• W

ire c

utte

r

• In

sula

ting

tap

e

• S

old

erin

g iro

n

•Sol

der

•Sol

der

ab

sorb

er

• P

hilli

ps

scre

w d

river

• S

hort

circ

uit

set

2047

5535

2047

6817

2047

6812

(OM

-122

DW)

2047

6912

(OM

-128

HH)

ブック 1.indb 60 2014/06/06 16:34:26

61

“ ”

ind

icat

es t

he la

mp

on.

“

” in

dic

ates

the

lam

p o

ff.

(O) L

amp

: OP

ER

ATI

ON

LA

MP

(B

) Lam

p: B

UR

NE

R L

AM

P (

W) L

amp

: WA

RN

ING

LA

MP

Q

uick

che

ck li

st fo

r tr

oub

lesh

ootin

g

Faul

tN

o.La

mp

ind

icat

ion

and

sta

tus

Che

cked

for

Ref

eren

ce p

age

Par

ts n

eed

edP

art

#To

ols

need

ed

Op

erat

ion

Bur

ner

War

ning

Igni

tion

doe

s no

t ta

ke p

lace

ev

en w

hen

the

(O) l

amp

lig

hts

up.

Tem

per

atur

e of

hot

-wat

er

sup

ply

doe

s no

t ris

e.

1.

Wat

er is

alre

ady

boi

ling.

2.

The

Tem

per

atur

e se

lect

or k

nob

is s

et t

o a

low

er p

ositi

on

3.

Bro

ken

the

Lead

wire

of t

he T

emp

erat

ure

sele

ctor

4.

Def

ectiv

e th

e Te

mp

erat

ure

sele

ctor

5.

Def

ectiv

e th

e Th

erm

isto

r

6.

Def

ectiv

e th

e M

ain

circ

uit

boa

rd

1.

Mor

e ho

t w

ater

is b

eing

sup

plie

d t

han

spec

ified

.

2.

Imp

rop

er s

ettin

g of

the

Tem

per

atur

e se

lect

or k

nob

3.

Def

ectiv

e th

e Th

erm

isto

r

4.

Set

pre

ssur

e of

the

Fue

l pum

p is

too

low

.

5.

Bro

ken

the

Lead

wire

of t

he T

emp

erat

ure

sele

ctor

6.

Def

ectiv

e th

e Te

mp

erat

ure

sele

ctor

7.

Def

ectiv

e th

e C

ontr

olle

r su

bst

rate

Faul

t N

o. 2

, < It

em 1

> P

.78

Faul

t N

o. 2

, < It

em 2

> P

.78

Faul

t N

o. 2

, < It

em 3

> P

.78

Faul

t N

o. 2

, < It

em 4

> P

.79

Faul

t N

o. 2

, < It

em 5

> P

.80

Faul

t N

o. 2

, <R

efer

ence

> P

.79

Faul

t N

o. 2

, < It

em 6

> P

.80

Faul

t N

o. 3

, < It

em 1

> P

.81

Faul

t N

o. 3

, < It

em 1

> P

.81

Faul

t N

o. 2

, < It

em 4

> P

.79

Faul

t N

o. 2

, < It

em 5

> P

.80

Faul

t N

o. 2

, <R

efer

ence

> P

.79

Faul

t N

o. 3

, < It

em 5

> P

.82

Faul

t N

o. 2

, < It

em 3

> P

.78

Faul

t N

o. 3

, < It

em 7

> P

.83

Lam

p c

ircui

t b

oard

Ther

mis

tor

Mai

n ci

rcui

t b

oard

Ther

mis

tor

Mai

n ci

rcui

t b

oard

Mai

n ci

rcui

t b

oard

• Te

ster

• N

eed

le n

ose

plie

rs

• In

sula

ting

tap

e

• S

old

erin

g iro

n

• S

old

er

• S

old

er r

emov

er

• P

hilli

ps

scre

w d

river

• 17

mm

wre

nch

• 2.

0mm

alle

n w

renc

h

• S

ealin

g ta

pe

• S

hort

circ

uit

set

• W

ire c

utte

r

• Te

ster

• S

hort

circ

uit

set

• N

eed

le n

ose

plie

rs

• W

ire c

utte

r

• P

ress

ure

gaug

e se

t

• In

sula

ting

tap

e

• S

old

erin

g iro

n

• S

old

er

• S

old

er r

emov

er

• P

hilli

ps

scre

w d

river

• 17

mm

wre

nch

• S

ealin

g ta

pe

2 3

2047

6873

2047

6812

2047

6912

2047

6873

2047

6812

(OM

-122

DW)

2047

6912

(OM

-128

HH)

ブック 1.indb 61 2014/06/06 16:34:26

62

(O) L

amp

: OP

ER

ATI

ON

LA

MP

(B

) Lam

p: B

UR

NE

R L

AM

P (

W) L

amp

: WA

RN

ING

LA

MP

“

” in

dic

ates

the

lam

p o

n. “

”

ind

icat

es t

he la

mp

off

.Q

uick

che

ck li

st fo

r tr

oub

lesh

ootin

g

Faul

tN

o.La

mp

ind

icat

ion

and

sta

tus

Che

cked

for

Ref

eren

ce p

age

Par

ts n

eed

edP

art

#To

ols

need

ed

Op

erat

ion

Bur

ner

War

ning

The

(W) l

amp

com

es o

n 1

to

2 se

cond

s

afte

r th

e (O

)

lam

p li

ghts

up, b

ut t

he

unit

doe

s no

t

star

t

Op

erat

ion

Bur

ner

War

ning

The

(W) l

amp

com

es o

n 6

seco

nds

afte

r

the

(O) l

amp

light

s up

, but

the

unit

doe

s

not

star

t

1.

Bro

ken

the

Lead

wire

of t

he T

emp

erat

ure

cont

rol v

olum

e kn

ob

2.

Def

ectiv

e th

e Te

mp

erat

ure

cont

rol

volu

me

knob

3.

Def

ectiv

e th

e Th

erm

isto

r

1.

The

Flam

e se

nsor

is n

ot s

ecur

ely

inse

rted

in

to t

he B

urne

r (o

r, in

to t

he lo

ck p

ositi

on).

Faul

t N

o. 2

, <Ite

m 3

> P

.78

Faul

t N

o. 2

, <Ite

m 4

> P

.79

Faul

t N

o. 2

, <Ite

m 5

> P

.80

Faul

t N

o. 2

, <R

efer

ence

> P

.79

Faul

t N

o. 5

, <Ite

m 1

> P

.85

Lam

p c

ircui

t b

oard

Ther

mis

tor

Flam

e se

nsor

• 15

0 m

m a

djus

tabl

e w

renc

h•

300

mm

adj

usta

ble

wre

nch

• 37

5 m

m a

djus

tabl

e w

renc

h•

Pip

e w

renc

h•

Sea

ling

tap

e•

Sho

rt c

ircui

t se

t•

Nee

dle

nos

e p

liers

• In

sula

ting

tap

e•

Sol

der

ing

iron

• S

old

er•

Sol

der

rem

over

• P

hilli

ps

scre

w d

river

• Te

ster

• 17

mm

wre

nch

• To

oth

bru

sh•

Wire

cut

ter

4 5

2047

6873

2047

6811

ブック 1.indb 62 2014/06/06 16:34:27

63

(O) L

amp

: OP

ER

ATI

ON

LA

MP

(B

) Lam

p: B

UR

NE

R L

AM

P (

W) L

amp

: WA

RN

ING

LA

MP

“

” in

dic

ates

the

lam

p o

n. “

”

ind

icat

es t

he la

mp

off

.Q

uick

che

ck li

st fo

r tr

oub

lesh

ootin

g

Faul

tN

o.La

mp

ind

icat

ion

and

sta

tus

Che

cked

for

Ref

eren

ce p

age

Par

ts n

eed

edP

art

#To

ols

need

ed

Op

erat

ion

Bur

ner

War

ning

The

(W) l

amp

co

mes

on

6 se

cond

s af

ter

the

(O) l

amp

lig

hts

up, b

ut

the

unit

doe

s no

t st

art

2.

The

unit

is o

per

ated

with

the

Fro

nt p

anel

op

en.

3.

Fuel

is a

ccum

ulat

ed in

the

Com

bus

tion

cham

ber

.

4.

Mal

func

tion

due

to

smol

der

ing,

rem

ains

of

ref

ract

ory

mat

eria

l whi

ch, h

as s

oake

d

up fu

el.

5.

Def

ectiv

e th

e Fl

ame

sens

or

6.

Def

ectiv

e th

e Fl

ame

sens

or

7.

Def

ectiv

e th

e M

ain

circ

uit

boa

rd

1.

Out

of f

uel.

2.

Fuel

is n

ot s

upp

lied

.

3.

Imp

rop

er in

stal

latio

n of

the

Fue

l pip

e

4.

Def

ectiv

e th

e Fu

el p

ipe

5.

Clo

ggin

g of

the

Fue

l fee

d v

alve

, the

Fue

l st

rain

er a

nd t

he F

ull l

ine.

6.

Clo

ggin

g-up

with

dus

t in

sid

e th

e D

rain

cu

p o

f the

Fue

l str

aine

r

7.

Wat

er a

ccum

ulat

ed in

sid

e th

e D

rain

cup

of

the

Fue

l str

aine

r

8.

Clo

gged

filte

r

9.

Air

lock

insi

de

the

Fuel

str

aine

r or

the

Fu

el li

ne

10.

Wat

er in

sid

e th

e Fu

el t

ank

11.

Inco

rrec

t co

nnec

ting

of t

he F

uel l

ine

Faul

t N

o.5,

<Ite

m 1

> P

.85

Faul

t N

o.5,

<Ite

m 2

> P

.85

Faul

t N

o.5,

<Ite

m 3

> P

.85

Faul

t N

o.6-

(2),

<Ite

m 1

> P

.87

Faul

t N

o.6-

(2),

<Ite

m 2

> P

.87

Faul

t N

o.6-

(2),

<Ite

m 3

> P

.87

Faul

t N

o.6-

(2),

<Ite

m 4

> P

.88

Faul

t N

o.6-

(2),

<Ite

m 5

> P

.88

Faul

t N

o.6-

(2),

<Ite

m 6

> P

.88

Faul

t N

o.6-

(2),

<Ite

m 7

> P

.89

Faul

t N

o.6-

(2),

<Ite

m 8

> P

.89

Faul

t N

o.6-

(2),

<Ite

m 9

> P

.89

Flam

e se

nsor

Flam

e se

nsor

Mai

n ci

rcui

t b

oard

Fuel

pip

e

Fuel

filte

r ca

rtrid

ge

No

zzle

, F

uel

pip

e A

, F

uel

pip

e ni

pp

le,

Fue

l p

ipe

B,

Fue

l p

ipe

C,

Fu

el

pip

e co

up

ling

, F

use

va

lve,

F

use

va

lve

cou

plin

g,

Ste

el

pip

e,

Str

ain

er,

Str

ain

er

coup

ling

, N

ipp

le,

Fla

re n

ut

• 15

0 m

m a

djus

tabl

e w

renc

h

• 30

0 m

m a

djus

tabl

e w

renc

h

• P

ipe

wre

nch

• S

ealin

g ta

pe

• 12

mm

wre

nch

• 17

mm

wre

nch

• 19

mm

wre

nch

• P

hilli

ps

scre

w d

river

• S

trei

ght

edge

driv

er

5

Op

erat

ion

Bur

ner

War

ning

The

(W) l

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