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1. 75 12 14 Adjusting manifold gas pressure 76 12 15 Freeze protection system 18 12 16 Draining the T M1 and T M199 and cleaning the inlet water filter 80 53 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 12 1 A Diagnosing the T M1 and T M199 using the TM RE10 lt For a single T M1 or T M199 gt 1 Press and hold the HOT and COLD buttons simultaneously for at least 5 seconds to enter Diagnostics MOGE Buzzer stop Button ot 2 Number 0 will be displayed Fig 1 anuos 3 Scroll through the needed information mode iin by pressing the HOT or COLD buttons to inu scroll up or down Fig 2 HEATER ON 4 Once desired mode is displayed press the white button located under the Buzzer Stop button to select the mode The information for that mode will be displayed Fig 3 5 When the ON OFF button is pressed or 5 minutes have elapsed Power Cold without pressing any buttons the display will return to normal EEN 241 For example mode 7 will display the value of the electrical current of the AFR rod Fig 1 Fig 2 Fig 3 lt For multiple T M1 or T M199 s in the multi unit system gt 1 Press and hold the HOT and COLD buttons simultaneously for at least 5 seconds to enter Diagnostics Mode 2 Number 0 will be displayed Fig 1 3 Scroll to the desired T M1 or T M199 unit either 1 2 3 or 20 by
2. 38mm gt Water IN From Heat exchanger E be 27 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 10 11 Thermistors 027 Inlet EM187 Inlet E1 Mixing 019 Output EM186 Output E2 Output 044 Mixing EM179 Mixing E3 Inlet Measure cold hot water temperatures in the Water heater Unable to properly measure water temperatures within the Water Failure events heei Effects on the Water If the thermistors fail open or short error code appears before starting T M1 or T M199 Part heater if thermistor operation If resistance values are just off The Water heater will have fails temperature fluctuations in hot water Error codes when thermistors fails 1 Visual inspection connection breakage of wires and or debris on Diaanostic thermistor 9 2 Check voltages and resistance proper range of values shown below 311 Output 321 Inlet 331 Mixing Inlet White 42 White 68 F 20 C 12 7KQ Output White 12 White 122 F 50 C 4 27KQ Color Number of wires 176 F 80 C 1 69K O Mixing White 113 White see table below for more resistance values Inlet thermistor 42 E Output thermistor 12 E Mixing thermistor 113 Resistance values of thermistors as a function of temperature 30 00 25 00 20 00 15 00 Resisitance kQ 10 00 5 00
3. NO 35sec later Faucet Opens Flow sensor EM Above 0 75GPM YES No Fan motor NO operation 20sec later Fan motor stop operation Start Fan motor operation FM speed Above 1 000rpm No False flame detection Igniter ON success All Gas valves OFF Main gas valve ON SV2 ON Gas proprtional valve Main gas valve OFF Gas valve OFF Gas proprtional valve Igniter OFF Flame rod 5sec later detects Above 101 DC 1 04A YES FM speed 3 increase MaxBTU decreased Igniter OFF 3sec later p Proportional operation Unit under Abnormal combustion NO svi svs oF ie oe Hi limit switch Failure FM speed up is 15 BTU Change over point SV1 SV3 ON o Below water NO Flame rod unable or Flow adjustment to detect Flame YES OE pom mel tdown working Below NO 611 Te flow rate restriction YES Thermistors Open Short failure Flow adjustment to open position V Gas valve a devices YES circut failure sensed abnormal condition Fan motor stop operation Detect Abnormal Fan NO motor speed in Left unit 20sec All Gas valves OFF later 15 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 10 Component specifications Other than the Heat exchanger 10 6 and Computer board 10 13 the T M1 and T M199 share the same components A eo oO 17 10 2 GaS MANN OG reirte 18 ju NE
4. CONFIDENTIAL T M1 T M199 Service manual Version 1 02 3 Interior view Other than the case assembly No 1 front cover assembly No 2 heat exchanger No 3 and computer board No 20 the T M1 and T M199 share the same components Nalda sed L 2 1L TU E misg x OR L Ade NL kA A A en NN ee ECT A FA ry LZ i CONFIDENTIAL T M1 T M199 Service manual Version 1 02 4 List of main components in the internal view Other than the case assembly No 1 front cover assembly No 2 heat exchanger No 3 and computer board No 20 the T M1 and T M199 share the same components T M1 T M199 Takagi Common parts No Description Part Part For other units EM103 T M1 1 Case assembly 001 EM232 T M199 EM105 T M1 2 Front cover assembly 013 EM233 T M199 Heat Exchanger EM112 T M1 assembly EM240 T M199 9 wmv 0 Eme 16 ue 09 17 02 8 EM162 LP Manifold assembly 1 1 EM158 NG 5 1 Fan motor 0 87 19 Burner assembly 069 EM197 0 11 EM129 T M1 2 Computer board 1 EM235 T M199 Overheat cut off fuse pe CONFIDENTIAL T M1 T M199 Service manual Version 1 02 4 List of main components in the internal view uu T M1 T M199 Takagi Common parts No Description Part Part For other units Computer transformer 21 005 EM164 TD1 205 06 22 Transformer TD1 203 0 EM163 118 EM182 23 Surge absorber 119 EM1
5. 3 TN COTE DONES Wo Je O 3 y Dh CONFIDENTIAL T M1 T M199 Service manual Version 1 02 Burner assembly lu US L9 f N O 7 YA 83 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 Water way assembly Other than the heat exchanger assembly No 15 the T M1 and T M199 share the same components WH A e Tes LOY P a AN S Y N S SS y wA GO 6 84 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 14 Parts list Other than the case assembly No 1 front cover No 13 heat exchanger assembly No 15 and computer board No 111 all of the T M199 s components are the same as the T M1 ltem Part Description Common parts for other units EM103 T M1 EM232 T M199 EW001 Screw M410 w washer EM185 Back guard panel Computer transformer Case Assembly N O D 5 EM164 TD1 205 Transformer TD1 203 EM163 T EK061 Junction Box TK2 TKD20 s exo TK2 TKD20 EM105 T M1 13 Front cover EM233 T M199 EM112 T M1 15 Heat Exchanger Assembly EM240 T M199 16 emaz HitimiSwton TK2 TKD20 N m co O ring PA EPDM TK2 TKD20 TKJr TK1S OS SP 20 EZMOA Purple TH1 TM50 TM32 T K3 Pro 21 EM166 Heater Block 604 Heat Exchanger Fixing Plate 22 EK026 Back 85 Item 23 24 25 26 2 28 29 30 1 32 3 34 35 36 37 39 40 41 42 43 44 00 45
6. 46 7 9 50 Part EK028 EKO29 EM138 EK031 EM187 EM188 EM189 EM118 EZV20 EA126 EM190 EZN16 EX013 EM169 EM120 EZM16 EM115 EWOO9 EZV18 EM119 EWOOE EM179 EZMO6 EK046 EM170 EM100 EWOOO0 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 Description Common parts for other units Heat exchanger fixing plate Front OS SP TK2 TKD20 TK1S TKJr TK3 Pro TK2 TKD20 TM50 TM32 O ring JASO 1016 TH1 TK2 TKD20 TM32 EPDM Purple Screw M4 x 12 i Flow adjustment valve O ring P16 EPDM TK2 TKD20 TKJr TK1S TK3 OS SP Purple TH1 TM5O TM32 Pro sewn sewn O ring Po EPDM TK2 TKD20 TKJr TK1S OS SP Purple TK3 Pro TH1 TM50 TM32 Outlet drain plug Mixing connection pipe Water Outlet Screw M4 x 12 w washer 86 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 ltem Part Description Common parts for other units 51 EM116 Bypass valve EKO24 Silicon O ring M22 EM114 Bypass Connection EZV17 O ring JASO 1017 EM192 Fastener 16A O ring JASO 1021 EPDM 3 54 55 TK2 TKD20 TKJr TK1S T K3 OS SP TH1 Pro 57 58 59 1 2 63 64 EZN21 TM32 TM50 Purple EM222 TM32TMS0 TK2 TKD20 TKJr TK1S OS SP TH1 TM50 TK3 Pro TM32 80 EM203 Thermocouple Fixing Plate 7 0 N O O OD Oo al O1 al O 71 EM167 Wire clamp 60 72 13 T4 15 76 7 78 19 8 CONFIDENTIAL T M1 T M199 S
7. jo z 0 2325878 LI Na Y 5 G o P p P Ad LWOD lt 12345678 O o 0 0 DL Oooo TAL p n 2 E E c C c 100 0 c o E t a 0 50 x e es o D 35 cc 2c EYVELODE1E gt o a vA Te cas EP a di QT CONFIDENTIAL T M1 T M199 Service manual Version 1 02 7 Wiring diagram check points for diagnosis The table below applies to both the T M1 and the T M199 A 100V Power supply White Black AC90 110V A1 100V Power supply AC90 110V A2 120V Power supply White Black AC108 132V AC10 15V AC15V Line Fan motor White White 10 20 Q AC20V Line Control source AC15 25V Green Green in the computer board 0 4 0 8Q AC45 65V AC55V Line Flame rod Red Red 42 62Q B Igniter Purple Purple AC90 110V B1 Heater Black White AC90 110V DC 78 100V during operation Light blue blue at COM MV Red blue at COM SV1 C Gas valves Yellow blue at COM SV2 Green blue at COM SV3 0 9 1 7k0 Less than DC 1V Hi limit switch Red Red and less than 1 0 Q Less than DC 78 100V Overheat cutoff fuse Blue Blue and less than 1 0 11 DC 78 100V during operation 0 9 1 7kQ DC 78 100V during operation 0 9 1 5k Q DC 78 100V during operation 0 9 1 7k 0 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 Parts and Description Color of wires Normal Range DC14 16V Only Installed the TM RE20 Blue White Multi system connectors or TM MC01 Black White OV No
8. CONFIDENTIAL T M1 T M199 Service manual Version 1 02 12 13 Individual unit operation in the Multiple system while Multi unit controller the TM RE20 or the TM MC01 is under abnormal conditions Individual operation mode A multi unit system of T M1 or T M199s requires the Multi unit controller If the Multi unit controller undergoes abnormal conditions the T M1 or T M199s can operate as individual units If this happens the minimum flow rate of the system changes from 0 75 GPM to 0 75 GPM multiplied by the number of T M1 or T M199s Refer to the following example Ex Minimum flow rate of the a 5 unit multi unit system Under normal conditions 0 75GPM When the Multi unit controller fails 0 75 x 5 3 75GPM e Minimum flow rate of the multiple system depends on the number of the units installed in the multiple system e The set temperature of the units as individual units is the set temperature before the failed communication happened between T M1 or T M199 and the Multi unit controller e T M1 or T M199s will not work individually during with a failed Multi unit controller if the Individual jump cable on the T M1 or T M199 computer board is removed See the picture below e n order to make operation system effective during an abnormal condition the number of individual unit should be half of the total number of T M1 or T M199 installed in multiple system Individual jump cable ca ca O O ca ca ca
9. Malfunction description Cancellation method Disconnected short circuited inlet thermistor Turn off the power or water supply 1 Inlet thermistor fault Refer to section 10 11 Visual inspection connection breakage of wires and or debris on E3 thermistor Check voltage resistance between white amp white 42 Refer to Section 8 for proper range of values 47 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 Malfunction description Cancellation method Disconnected short circuited mixing thermistor Turn off the power or water supply 331 1 Mixing thermistor fault Refer to section 10 11 Visual inspection connection breakage of wires and or debris on E1 thermistor Check voltage resistance between white amp white 113 Refer to Section 8 for proper range of values Malfunction description Cancellation method Disconnected thermocouple Turn off the power or water supply Diagnosis 1 Thermocouple fault Refer to section 10 22 Visual inspection connection breakage of wires Malfunction description Cancellation method Turn off the power or water supply Diagnosis Checkpoint 1 Flow sensor fault Refer to section 10 8 Visual inspection connection breakage of wires and or debris on H2 impeller Check voltage resistance between red amp black or white amp black Malfunction description Cancellation method Fault of driving circuit for main gas solenoid valve MV The computer checks the condition of
10. will display heater if flame rod fails 2 The Water heater will not initiate the ignition process The 721 error code will display Error codes when the 111 121 721 flame rod fails 1 Visual inspection connection breakage of wires or soot buildup on Diagnostic rod 2 Check amperes proper range of values shown below Green Flame rod Stand by AC25 to 65V Between flame rod and Burning AC20 to 55V the computer board Color Number of wires Orange Flame rod Stand by Less than DC 0 15 y A Between flame rod and Burning More than DC 1 u A the computer board Flame rod is included in the part of 073 as the Rod Assembly The following picture shows the Rod Assembly 7 8 24mm 1 4 8 5mm 7 8 24mm y N I 1 1 4 34mm Te gt lt Leads to computer To Igniter board Flame rod 21 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 10 6 Heat exchanger EM112 TM1 T M1 or T M199 Part 015 Takagi Part Checkpoint EM240 TM199 Function Absorb heat from combustion and transfer it to water through the heat exchanger pipes 1 Clogged heat exchanger fins and or cracks on the heat exchanger walls 2 Leaking exhaust gas 3 Improper heat transfer can cause the water in heat exchanger to boil 4 Calcium deposits inside the pipe 1 Water leakage from the heat exchanger 2 Exhaust gas lea
11. 101 and 991 error code The T M1 or T M199 s 101 and 991 error code signifies imperfect abnormal combustion caused by insufficient intake air and or obstructions in the exhaust A If the 101 and 991 error code occurs please check the following What is the T M1 or T M199 s gas type liquid propane or natural gas How long has the T M1 or T M199 been installed and been in use Where is the T M1 or T M199 installed indoor outdoor attic etc What is the altitude elevation of the area of installation If installed indoors how long is the vent length If installed outdoors what type of vent cap is used ae XUL de SY Are there any obstructions in the intake air and or exhaust Damper sticking Vent Flaps installed on the Terminator e Snow build up around Terminator Installed in a closet No Ventilation or lack of combustion air 8 If installed in laundry room check the burner and heat exchanger Dust and lint may deposit in burner and heat exchanger 9 If installed in restaurant check the burner and fan motor Grease and dirt may deposit in burner and fan motor 10 Check if the manifold pressure of the Water heater is too high B How to clear the 101 and 991 error code after resolving the main root cause of the error On the computer board press and hold the Reset button simultaneously for at least 3 seconds until the Red light turns on Then press reset button on th
12. 44 2 40 8 37 4 34 0 30 6 27 2 23 8 20 4 17 0 13 6 10 2 0 3 4 2 0 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 12 11 Connections between Multi unit controller and water heaters The T M1 T M199 and T M32 can be intermixed with each other in a Multi unit system using either Multi unit controller TM MCO1 or TM RE20 Connection between the Water heaters and the TM MC01 gt If a multi unit system contains either a T M1 or T M199 and the TM MCO01 is used as the controller change dipswitch No 6 on the TM MC01 computer board to the ON position p test so re Dipswitch setting on Aaa the TM MC01 Is LS ed deu sd heehee EE a NOTICE No dipswitch changes are needed when using the TM RE20 When the T M1 or T M199 is connected with any T M32 as part of a Multi unit system with the TM RE10 or the TM RE30 temperature remote controllers the available set temperatures will default to what is available on a T M1 or T M199 from 99 F to 167 F 182 F as shown below Temperatures available under the Default Ce wo 102 vos 100 106 wo m ss wo ir Temperatures available under the High Temperature Mode Css 100 102 os 106 10 wo m ws v oe The maximum set temperature with the TM RE10 When the red jumper on the back of the TM RE10 is installed the maximum set temperature is 167 F If you remove the jumper the maximum set temperature will be 1
13. 8 16 5mm T N NS 1 3 8 36mm 7 8 22 5mm 49mm 7 8 26 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 10 10 Two way valve T M1 or T M199 Part 030 Takagi Part EM118 Checkpoint The two way valve controls the water flow from the heat exchanger in Function order to prevent low temperature corrosion caused by heat exchanger condensation when operation has stopped Eos 1 Water leakage from valve 2 The valve cannot modulate or make open close positions Effects on the Water 1 Water leakage from failed valve can damage other Water heater m DNO MU valve 2 Unable to control water flow from the heat exchanger 3 54 error code will appear before operation starts Error codes when two way valve fails 1 Visual inspection connection breakage of wires motor drive locked due Diagnostic to scale buildup and or water leakage 2 Check voltages and resistance proper range of values shown below Red Blue DC 10 0 13 0V during burning Orange Gray DC 14 0 16 0V during burning Yellow Gray Less than DC1V opened position components Color Number of wires Brown Gray Less than DC1V closed position Water OUT To mixing point 38mm i 14z22 4 lt ide 2 3 4 68 84mm ll 1 1 4 30mm
14. A SS ge c Using thermistors to measure temperatures the computer modulates the gas and water valves to ensure proper output water temperatures 8 When the tap is closed the T M1 or T M199 water heater shuts down CONFIDENTIAL T M1 T M199 Service manual Version 1 02 10 6 Wiring diagram The diagram below refers to both the
15. T M1 and the T M199 gt ON NI u o0 a L E O E x m 2 ES i 9 J9e3e9u DM q eS r Jo P 1 E 3 SI NTE CH J31B9Uu A aa O aa AA m Y Y de T 308 O E Bes de 3 Je4eeu HAM o nt NL i S 210 210 m n aine Tua o D C Cc 00 MoHo an Nee VI V V Oi IN o D m m m M S C Je3dnJuJea4ul DO 11N941 9 5 1009 7 Ney pueus c 0000000 q E p e ODO 1000 50d E o t lt j a NOM HOLIMS 5 e V eg e OO aL unss3ud E QUOI 22 cp E daa 000000 5 OO o Tada I O De OO 000 N ED OO N i i C O o gt 9 dnoo c OWUSY 4 E eio E V cb o SUBE SO ee del orana Hg aa A MO J Sacusud eve A 3 gs N LOZ B v 340d yy UOTS Ue3x f LL Zog E a Sade oon NT u pp Ly UO11U91X9 a B m oo 0
16. Thermocouple T M1 or T M199 Part 079 Takagi Part EM202 Checkpoint Checks flame conditions during combustion When Thermocouple detects unexpected flame conditions the Water heater s computer makes adjustments in the fan motor speed to Function compensate Unable to detect flame conditions when flame actually do occur Effects on the Water heater if the thermocouple fails Error codes when Thermocouple fails The fan motor speed cannot be modulated properly under abnormal flame conditions which can result in excessive CO emission 101 391 991 1 Visual inspection connection braking of wires 2 Check voltages proper range of values are shown below Color Number of wires Yellow Cupper DC1mV 9mV during combustion sensing element Diagnostic 7 8 22mm 13 3 8 340mm 5 8 16 5mm 3 8 10mm 39 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 10 23 Surge absorber 118 EM182 T M1 or T M199 Part Takagi Part Checkpoint N A 119 EM183 Protects the unit from high voltage and or high electric current caused by lightning Function There are 2 types of surge absorbers in the Water heater Surge absorber A is activated by voltage higher than 680V the other one is activated by voltage higher than 220V Eire cuente 1 Open failure of the absorber 2 Short failure of the absorber Effects on the Water 1 s to protect the computer bo
17. When the computer and temperature remote controller detects proper connections between the Water heater and the remote controller 741 error code will cease to display Diagnosis Checkpoint 1 Temperature remote controller TM RE10 or TM RE30 or PCB fault 2 Check for signs of power surges 51 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 Malfunction description Cancellation method Restoring proper cable connections between all the Water heater s and the multi unit controller TM MCO1 or TM RE20 When the computer detects proper connections between the multi unit controller and the Water heaters 761 error code will cease to display 1 Inspect cable connections between Multiple controller TM MCO1 or TM RE20 2 Check for signs of power surges Malfunction description Cancellation method Abnormal burning Turn off the power or water supply Refer to section 12 4 Press the reset button for 3 sec See section 12 4 Diagnosis Checkpoint 1 Check the gas type of the Water heater 2 Check how long the Water heater has been installed and in use 3 Check the installation place 4 Check the altitude elevation of area of where the Water heater installed 5 Check the vent length when the Water heater has been installed indoors 6 Check the type of vent cap when the Water heater has been installed outdoors 7 Check if there is any blockage in the intake air and or exhaust 8 Check if there is dust an
18. adeo Em 19 10 4 Gas valve aSssemiDly icsteosunsesgesco deris suusescssswnspbRu css Er sce xe Ee E arcaicas 20 Uu ioi Pe 21 SA 22 10 7 Flow adjustment VAIN GC su soxexixdastos eX s Ded sa ta tabseasecdavens 23 10 5 FOW AS OR A aa de ae dde cor io 24 10 9 Bypass VAIO acess kl persia NEPA aseaseeheyedeecaveu 25 10 10 Two way valve sisi 27 MO STM etas S scarlett 28 10 12 Freeze protection heaters menn 29 10435 Computer DOS de es ee tacui ada Ea dis 30 10 14 Transfo ea E E PU v EXTR ass eme PER VEU EVI EE Rire M a RU Scd 31 10 15 Computer transito Me us cue ius pci acid wi ettari up ini 32 jc 33 A MER 34 10 18 Freeze protection thermostat 30 10519 A ES NE TT 36 10 20 OvV rneal culto MUS una ia ios 37 10 21 Pressure WI Curro nes iia 38 10 22 TInemmocoubDlG nes nes SURVEFES ME QUE ri nasal iia dia 39 10223 Surge A SOR Tenere eea ia tooo bares 40 16 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 10 1 Burners T M1 or T M199 Part 069 TakagiPart EM197 Checkpoint N A There are 2 types of burners in the Water heater the gas rich burner stabilizes the flames within the combustion chamber and the air rich Function burner produces more heat in the combustion chamber The burners facilitate the air gas mixture necessary to produce the proper heat dur
19. and combustion chamber Upon detection communication between the computer board and gas valves will sever shutting down the Water heater instantly The 111 or 121 error code will display 1 Unable to detect the excessively high temperatures within the Water Failure events heater Effects on the Water 1 Flames from burner may penetrate a ruptured damaged heat heater if the overheat exchanger cutoff fuse fails 2 Gas valves will not operate Error codes when the overheat cutoff fuse fails 74 3 4 1900mm g ML y SS Y S I ANIELE KKKIKIKIKKKKKIKIKIKIKIKIKIKKKKKKKKKIQIQIGGIIQIQKQK NGS 18 1 8 460mm N 1 3 16 30mm 19 1 4 490mm 3 7 8 100mm Her SAR x i S IE OOOO IESO ee IEE 3 Tk NS E NSSSSSSSSSSSSSSSSSSSSSSSNS 11 DOY B L3 1 3 7 8 100mm 18 1 8 460mm 1 3 16 30mm 3 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 10 21 Pressure Switch T M1 or T M199 Part 086 Takagi Part EKDO8 Checkpoint Detects the pressure in the combustion chamber of the Water heater When there are any obstructions in the vent or if the heat exchanger is clogged with soot the unit s exhaust will have high CO emission Function since the pressure in the chamber increases and makes the fan motor push the combustion air but the vent or heat exchanger is clogged Pressure switch detects an excess pressure when the circuit
20. display CLR When you release the buttons Unit No LED s of the TM MCO1 will turn off Please wait until 7 seg LED display o 0 Set the Unit 10 Remove all the communication cable between the TM MC01 and the T M1s or T M199s 11 Reset the AC120V power supply of the TMMC01 12 Select Unit 1 of the T M1 or T M199 Connect the communication cable between the TM MCO1 and T M1 or T M199 1 13 The Unit No LED on the computer board of the TM MC01 will indicate light ON 14 Connect the communication cable between unit 1 and the next T M1 or T M199 you wish to assign unit 2 Repeat this from 2 to 3 and so on 15 Verify the unit of each water heater Press the Mode button on the computer board of each T M1s or T M199s and then the seg LED on the T M1 or T M199 will display the set number A A A A A QA A A Prioriry fic i P j Set on ine O 9 9 Sx BB BB Alarm 12345678 reset Computer board of the TM MCO 1 multi unit controller AC120V Power supply TM MCO01 multi unit controller 66 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 Case2 The T M1 s or the T M19
21. l 1 Close the manual gas shut off valve E e PI 2 Turn off power to the T M1 or T M199 and then turn on again 3 Wait 30 seconds for water valves starts to completely open Then turn off power to the T M1 or T M199 yet again L Jm ra Wee fF E mr 5 Open all hot water taps in the house When the all water flow has ceased close all hot water p Hot aut Sas taps O23 Pressure Cold inlet i Relief valve I 6 Have a bucket or pan to catch the water from the T M1 or T M199 s drain plugs Unscrew the drain plugs to drain all the water out of the T M1 or T M199 7 Wait a few minutes to ensure all water has completely drained from unit 8 Clean the filter Inspect the water filter located within the cold inlet With a tiny brush clean the water filter of any debris which may have accumulated and reinsert the filter back into the cold water inlet 9 Securely screw the drain plugs back into place Hand tighten only 80 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 13 Components diagrams Case assembly Other than the case assembly No 1 and front cover No 13 the T M1 and T M199 share the 81 CONFIDENTIAL wo N 50 Cc TE ES 9f Co D 09 O O q q H 82 Computer board assembly Other than Part 111 the T M1 and T M199 share the same components P LI oce Y FO PRY E KA LA SSO BNR EX t s N AS Y
22. power coming from the transformer Failure events 2 The voltage from the power supply cannot be converted to 100VAC Emacs on the Water 1 The Water heater does not operate due to lack of power from heater if transformer fails transformer 2 A failed transformer can cause electrical damage to other electrical components within the Water heater Error codes when N A transformer fails 1 Visual inspection connection breakage of wires and or signs of electrical damage 2 Check voltages of the transformer Proper range of values shown below White Black AC108 132V Color Number of wires Brown Brown AC90 110V Diagnostic To power the computer board 100VAC 2 3 8 61mm n From the 120 VAC power supply 7 7 8 200mm je 1 3 8 37mm PARES d H 7 7 8 200mm 2 5 8 68mm 3 3 4 94mm 31 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 10 15 Computer transformer T M1 or T M199 Part 4005 TakagiPart EM164 Checkpoint A3 A4 A5 To transform voltage from 100V to the following AC 15V to the Fan motor AC 20V for control source in the computer board AC 55V to the flame rod 1 There is no power coming from the computer transformer Failure events 2 The voltage from power supply can not be converted Effects on the Water 1 The Water he
23. the proper mode 3 Press the INFO button to select the mode and the information to which the mode correlates to will display on the TM RE30 Fig 2 4 When the ON OFF button is pressed or 5 minutes have elapsed without pressing any buttons the display will return INFO BUZZER ON OFF to normal Button Button Button 99 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 lt For multiple T M1 or T M199 s in the Multi unit system gt 1 Press and hold the HOT and COLD buttons simultaneously for at least 5 seconds to enter Diagnostics Mode 2 0 will be displayed on the TM RE30 See Fig 1 3 Scroll to the desired T M1 or T M199 unit in the multi unit system by pressing the HOT or the COLD buttons to scroll up or down Fig 2 shows that unit 2 is being selecting NOTE The definition of the unit Z s 0 will yield information about the Multi unit system as a whole and numbers 1 2 3 20 will yield information about each of the individual T M1 or T M199 s installed in the Multi unit system In the Multi unit system of T M1 or T M199 s a maximum of 20 T M1 or T M199 s can be linked together 4 Press the INFO button to select the desired unit 5 When the desired unit is selected and fixed scroll up or down to the needed information mode of the unit by pressing the HOT or COLD buttons Fig 3 shows mod
24. 0 00 Temperature F 28 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 10 12 Freeze protection heaters 021 EM166 T M1 or T M199 Part Takagi Part Checkpoint B1 060 EM165 Prevents the heat exchanger water valves and water pipes within the Function Water heater from freezing The heaters are but one of the freeze protection devices in the Water heater Open circuit failure Ceramic heaters do not receive the voltage Failure events needed to heat up Effects on the Water Ceramic heaters do not activate allowing water contained in the heat heater if heater fails exchanger to freeze up possibly causing the heat exchanger to burst Error codes when N A heaters fails 1 Visual inspection connection breakage of wires and the condition of Diagnostic the heaters 2 Check whether those are in the normal range as shown in the following table Color Number of wires Black White AC90 110V during freeze protection operation 021 Heaters O O L D m D D I l l l l l l l o X 8 X o AD A 0 A 29 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 10 13 Computer board EM129 T M1 T M1 or T M199 Part 111 Takagi Part Checkpoint N A EM235 T M199 Controls the functions of most of the parts in the Water heater Malfunctioning computer When the computer board failed the control from the comp
25. 82 F When the set temperature is 182 F H is displayed on the TM RE10 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 lt Connection Diagram between Water heaters and Multi Unit controller gt The diagram below shows an example of how to connect between different water heaters the T M1 the T M199 or the T M32 and the Multi Unit Controller the TM MCO1 or the TM RE20 in a Multi unit system TM MCO1 or TM RE20 T M1 or T M199 T M32 T M1 or T M199 LOW PE Po LT 1 E WE M c ciu ge 00666666 r Remote Terminals for Water heaters lt Connection between the Multi Unit controller and different water heaters T M1 T M199 and T M32 gt When the TM MC01 is connected directly to the T M1 or T M199 connect the Terminals for Water heaters in the Multi Unit controller to the 201 connector in the T M1 or T M199 When the TM MCO1 is connected directly to the T M32 connect the Terminals for Water heaters in the TM MCO1 to the 3 connector in the T M32 lt Connections between the T M1 or T M199 and the T M32 gt f the
26. 83 25 GFI 123 EM207 TH1 TM32 TM50 26 Igniter 09 EM208 TK2 TKD20 TK1 27 Junction box assembly 0 EKO061 TK2 TKD20 9 0 thermostat 9 T 0 EM142 6 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 5 Schematic diagram The diagram below refers to both T M1 and the T M199 Exhaust Flame rod Hi limit SW X Heat Exchanger Output Thermistor O H C F Two way valve pt ILI Anna Igniter rod LUTE ZEEE yP m DOMAINE A7 Igniter El i Kam amp KE Thermocouple Flow sensor VENE l ji que i MO PUL ALA PLL FALLA UE URL ELE Burner TED Pe PE CDI XXE ND D Flow adjustment valve i E Fan motor T Gas solenoid valve 1 pom es Gas solenoid valve 2 Gas solenoid valve 3 Inlet Thermistor i i Gas proportional 4 1 Heater ex ST ABRA Mixing Thermistor m a Pressure SW VA A A AQ Drain plug Hot Cold Transformer Main gas valve Inlet drain plug filter When a hot water tap is opened cold water enters the T M1 or T M199 water heater The water flow sensor detects this water flow and sends this information to computer The computer initiates fan motor and sends signal to igniter to create ignition spark The main proportional and solenoid gas valves open to allow gas input The gas ignites and flames appear inside the burner chamber Water circulates through the heat exchanger and is heated up to the set temperature oo
27. 9 s are connected with the TM RE20 Clear the unit 1 Take off the front cover of the TM RE20 Multi unit controller and the T M1s or T M199s Press the MODE button on the computer board of the TM RE20 seg LED on the computer board of the TM RE20 will display O0 Press the SET button seg LED will display O 1 Press the MODE button 9 times Then the 7 seg LED will display O A Press the SET button seg LED will display __ FF Press the REMOTE CONTROL button and the PUMP TEST button at the same time While pressing both buttons the 7 seg LED will display CLR When you release the buttons Unit No LED s of the TM RE20 will turn off Please wait until 7 seg LED display o 0 Set the Unit 10 Remove all the communication cable between the Multi unit controller and the T M1s or T M199s 11 Reset the transformer connector of the TM RE20 12 Select Unit 1 of the T M1 or T M199 Connect the communication cable between the TM RE20 and T M1 or T M199 1 13 The Unit No LED on the computer board of the TM RE20 will indicate light ON 14 Connect the communication cable between unit 1 and the next T M1 or T M199 you wish to assign unit 2 Repeat this from 2 to 3 and so on 15 Verify the unit of each water heater Press the Mode button on the computer board of each T M1s or T M199s and then the seg LED on the T M1 or T M199
28. 9 Os A A IS 10 7 Wiring diagram checkpoints for diagnosis 11 8 Resistance values of the temperature thermistors 14 9 Operational flow Cl A E mE 15 10 Component specifications 0 ccc ccc cece eee cence eee eee III HI mne 16 11 Fault Analysis amp Specifications 41 12 Controls o AAA 52 19 Components dlagla MS pcia oscar 81 A e Ue II e a 85 PO ROMS msi ee 90 1 Specifications of the T M1 T M199 and T K3 T M1 T M199 H23 6 xW18 5 xD8 9 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 T K3 H20 5 xW13 8 xD8 5 Dimensions Weight 7Olbs AOlbs System INPUT Max N posa m 199 000 BTU h Ed f Min 25 000 11 000 Combustion Power vent Power vent Installation Indoor amp Outdoor Indoor Outdoor amp Direct vent Indoor Outdoor amp Direct vent Fan motor Combustion Manifold Pressure Flow rate PWM turbo fan LP 2 7 WC LP 2 2 WC Natural 2 2 WC Natural 1 8 WC LP 0 6 WC LP 0 6 WC Natural 0 5 WC Natural 0 5 WC 0 75GPM to 9 0GPM PWM turbo fan LP 4 3 WC Natural 2 5 WC LP 0 77 WC Natural 0 4 WC 0 5 GPM to 7 0 GPM Available set temperatures 99 F 182 F Default 122 F 99 F 185 F default 122 F Temperature dipswitch settings 113 F 122 F 140 F 182 F 104 F 113 F 122 F 131 F 140 F 158 F 176
29. CONFIDENTIAL T M1 T M199 Service manual Version 1 02 T M1 T M199 TAKAGI On Demand Water Heater Service manual i i 65 ud B i i n 66 j 1 pul y UE d 4 E Tiri Wig i hi i t dd i TE A 2 E e Dm mm OSE SL la e ERI A lp ER gt ae SS SS s M B Bot o aaan nt a SSS Se Tz z ie ey 7 EE E AA Y gt A En A gt EE LAS ILL 1 nn 1d d gt A EM m i E TEE ok ume m E 5 ee i is a e a a 1 T SS iam fla AA e AA _ F i e nn E Em oo LIAE AA mg em im a f pcm n SS AA ER L SSS LE a a M a rs i ha u CAN mew AAA a han au Mobius Water Heater Mobius Water Heater Model T M1 Model T M199 TAKAGI Industrial Co USA Inc 5 Whatney Irvine CA 92618 Toll Free 888 882 5244 USA Toll Free 877 877 4953 CANADA CONFIDENTIAL T M1 T M199 Service manual Version 1 02 Content 1 Specifications of the T M1 T M199 and the T M1 ccc cece cece eee eect eens ee eeeees 3 Ze EXC VICW eee eee des oia poa 4 2 MOOT Meat 6 4 List of main components in the interior view T ci A E mcm
30. F 185 F Water control Bypass valve Yes Yes Two way valve Yes No Thermistors Remote controller model 3 thermistors In Out Mixing TM RE10 TM RE30 3 thermistors In Out Mixing TM RE10 TM RE30 PCB model T M1 T M199 T K3 Indicators O Q O Burning LED Operating LED amp 7SEG LED Burning LED amp 7 SEG LED Power supply control Freeze protection GFI and Surge absorber Ceramic heaters and Auto FM system GFI Including surge absorber Ceramic heaters and Auto firing system Self combustion improvement Thermo couple detection system Air Fuel Ration detection system Features Easy Link system N A Yes Multiple system Yes The manifold pressure measurement is base on conditions without front cover 3 N A CONFIDENTIAL T M1 T M199 Service manual Version 1 02 2 Exterior view Other than the front cover and case assembly the T M1 and T M199 share the same components Front view Side view 18 1 2 470mm 15 3 4 399mm R 7 C 17 4 1 2 114mm LL 170mm 4 2101mm a O Le Ge J m a k N O Ps E E E E O O O N NAN NAN 00 i N N ri ep 09 N QN QN Y Y Y Y Y
31. FF failure Always in the OFF mode always stays tripped 1 ON failure GFI cannot detect electrical leakage within the Water Effects on the Water heater heater if the GFI fails 2 OFF failure the Water heater does not receive any power from the GFI which means the Water heater cannot operate Error BOUES when the N A GFI fails 1 Visual inspection connection breakage of wires and or some signs of electrical damage on the GFI 2 Check the power supply to the GFI If the red LED on the GFI Diagnostic J lights up after pressing the test button the GFI is receiving power After verifying the power supply verify that 100VAC is entering and leaving the GFI Color Number of wires N A on 2 3 4 70mm le I 1 7 8 50mm gt 50mm Let 5 lnc 17 78 From transformer 33 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 10 17 Igniter T M1 or T M199 Part 099 Takagi Part EM208 Checkpoint To ignite the gas air mixtures when the Water heater is ready to burn Function gas on its burner surface The output voltage of the igniter
32. LJ Computer board 19 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 12 14 Adjusting manifold gas pressure The manifold gas pressure on the T M1 or T M199 can be adjusted by following the procedures below Adjusting the manifold pressure can cause unexpected combustion conditions j during operation which can cause a health hazard damage the T M1 or T M199 N and or shorten its lifespan Therefore changing the manifold pressure is not recommended unless there are very strong reasons to do so e g high elevation installations and with the consultation of Takagi USA WARNING Adjusting maximum manifold pressure 1 Ensure that T M1 or T M199 is not in operation 2 Remove the screw off the manifold port of the T M1 or T M199 Figure 1 3 Connect a manometer to the manifold port using a tube Figure 2 Ensure that this connection is secure enough to prevent gas leak 4 Run water through the T M1 or T M199 to activate its operation If presence of a gas leak is detected immediately shut off the T M1 or T M199 and inspect the tube manifold connection otherwise proceed onto the next step 5 To increase the manifold gas pressure insert the Manifold gas pressure Jumper see next page Figures 3 amp 4 into the Max port and turn the Maximum potentiometer clockwise To decrease the manifold gas pressure turn the Maximum potentiometer counter clockwise 6 After gas pressure has been set
33. M RE30 Please note that error codes are displayed differently depending on where its being read and whether it is a single unit installation or a multi unit installation A With a single unit installation Example If your unit fails on the 321 error inlet thermistor T M1 or T M199 computer board The 7 Seg LED will flash the 3 digit error code one digit at a time The 7 Seg LED will display 3 2 1 and will continually repeat these 3 digits TM RE10 and TM RE30 The remote controller however will display 321 on its screen in its entirety B With multi unit system installations Example If Unit 2 fails on the 321 error inlet thermistor e T M1 or T M199 computer board The unit that has the error in the multi unit system will display the error code on its 7 Seg LED in exactly the same way as if it were only a single Unit So in this example the 7 Seg LED on Unit 2 will display 3 2 41 just like in the single unit example above e TM RE10 or TM RE30 The remote controller will display 232 on its screen in its entirety The first 2 indicates that Unit 2 has the error The 32 indicates the first two digits of the 321 error code e TM RE20 or TM MCO01 The Unit LED on TM RE20 TM MCO1 will flash to inform which T M1 has the error code The TM RE20 and TM MC01 do not display the actual error codes on its seg LED The TM RE10 and TM RE30 will display
34. T M1 T M199 is the first unit connected to the multi unit controller connect the 202 connector in the T M1 or T M199 to the 3 connector in the T M32 that is next in line f the T M32 is the first unit connected to the multi unit controller connect the 4 connector in the T M32 to the 201 connector in the T M1 or T M199 that is next in line lt Connections between the T M1 and the T M199 gt Connect the 202 connector in the T M1 to the 201 connector in the T M199 next in line Connect the 202 connector in the T M199 to the 201 connector in the T M1 next in line 13 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 12 12 Operation time for unit rotation The Multi Unit controller the TM RE20 and the TM MCO1 controls T M1s or T M199s in the Multi unit system operations The priority unit will rotate when it reaches 100 ON OFF cycles or after 12 hours of operation NOTE The priority unit is the unit that turns on first when there is a hot water demand When there is a black out and or cut off for over 50 minutes priority unit will switch back to 1 unit Default Example 4 T M1 or T M199s Rotation A rotation occurs when ON OFF cycles x100 times or Hours of operation 12 hours AAA Ao B BI W Unit priority Next step unitpronty a 1 y 2 s amp Next step untpaonty s 4 lg gg 74
35. Y S 5 5 2 o 9 o mE i V 1 1 8 27 8mm LD O 2 1 2 64mm COLD 3 3 4 94mm GAS 8 3 4 225mm CONFIDENTIAL T M1 T M199 Service manual Version 1 02 T M1 Bottom view 7 179 HOT 5 125 GAS Top view 179mm 5 C125mm a E E E al th T O i T a L R Y ET E 2 O JE ES O d o o a Y i T 2 k S DN My va AN y y y y Z J T Q 109 gt SS L N O E O ol Al E I Q LO 1 2 11mm COLD me oz E N 2 5 8 68 1mm AC120V E Te gt TS 00 1 0 El Q E N 00 gt q B d N xw M x m LO T T Ni an N Y Bottom view Top view 7 179mm HOT _5 125mm GAS E E E O i A a all To o o o e O d e 9 K f D DN E O E N O Y o o MY f E B 6 ied LEN NN of WS J A M My VA CN y y y y J i l Q 09 gt AS N lt Ol O O wl E 1 2 11mm COLD O Ea I gt om O N 5 1 4 134mm ex x N 2 5 8 68 1mm AC120V E Te gt TS 00 1 0 l oOo E N w ie q tf SJ N O NS m LO T T Ni SN NS Y
36. all flow will go through to the heat exchanger When the temperature setting is 140 F 60 C or below the bypass valve will keep the water temperature of the heat exchanger between 149 F 65 C and 167 F 75 C 1 Water leakage from valve Failure event P 2 The valve cannot modulate or make open close positions Effects on the Water 1 Water leakage from failed valve can damage other Water heater Function heater if bypass valve components fails 2 Temperature fluctuations in the hot water output Error codes when bypass valve fails 1 Visual inspection connection breakage of wires Diagnostic 2 Check voltages and resistance proper range of values shown below White Blue DC12 0 14 5V Blue Black DC1 0 14 5V White Black 27 33 0 Blue Orange DC1 0 14 5V White Orange 27 330 Blue Green DC1 0 14 5V White Green 27 33 0 Blue Purple DC1 0 14 5V White Purple 27 33 0 Red Blue DC12 0 14 5V Brown Blue Less than DC1V Opened position Yellow Blue DC4 5 5 5V NOTE Pictures are on the following page Color Number of wires 25 CONFIDENTIAL T M1 T M199 Service manual 1787 3 4 2 7 8 72 5mm Version 1 02 10 9 Bypass valve Water IN ANAA T sg 1 Al Wyo ZA 88 2mm b e 3 3 43mm E E N NN ST 0 m N D M ii 5
37. ard if high vonage camas into die unit the computer board can be shorted out all operations of the unit heater if the fuse box fails can be stopped 2 The unit cannot operate because the absorber shorted out Error codes when the fuse box fails 1 Visual inspection bum marks on components and or Diagnostic connection breakage of wires 2 Check resistance and voltage proper range of values shown below Surge absorber A 118 680V Surge absorber B 119 220V J em lt Surge AbsorberA 118 CAUTION ae Surge AbsorberB 119 P 40 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 11 Fault Analysis amp Specifications Remarks 1 Proper range of values of voltage amp resistance shown below 2 Please refer to the wiring diagram for checkpoint positions 3 Remove power to the Water heater when checking for continuity disconnections resistance values etc Check Natural of Fault Diagnosis point No display on 1 Check the power supply 1 Check the power supply from the GFI to the PCB Refer to section12 3 2 Check the power supply line to the Water heater when remote is 2 Fault of GFI turned on Normal AC100V between white black Normal AC100V between brown brown 3 Fault of transformer 1 Disconnection breakage of wires Normal AC120V between white black Normal AC100V between brown brown 4 Blown fuse at PCB 5A 5 Fault of computer transformer Normal AC15V between w
38. ater does not operate due to lack of power from computer transformer 2 A failed transformer can cause electrical damage to other electrical components within the Water heater transformer fails 1 Visual inspection connection breakage of wires and or signs of electrical damage 2 Check voltages of the transformer Proper range of values shown below White White AC10 15V 10 20 Q Color Number of wires Green Green AC15 25V 0 4 0 8 Q Red Red AC45 65V 42 62 Q Function heater if transformer fails Diagnostic To Computer board for Flame rod Red Red 200mm 3 3 4 94mm 7 3 4 gt 35mm 72mm W To Computer board To Computer board for Fan motor Green Green White White gt Pata 2 3 4 260mm 42mm 2 Il From Main transformer Black Black 10 1172 32 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 10 16 GFI T M1 or T M199 Part 123 TakagiPart EM207 Checkpoint A A1 Detects electrical leakage in the Water heater Function Stops providing power to the Water heater in the case of electrical leakage Failure vent 1 ON failure Always in the ON mode never trips 2 O
39. combustion in the operation Failure events 2 Unexpected working caused by the connectors of the fan motor getting wet 3 Drops out from the bottom of the combustion chamber 1 The Water heater does not function properly 2 Failure to ignite or abnormal ignition 3 Unstable combustion conditions A CN fan motor fails 1 Visual inspection connection breakage of wires or dust causing Diagnostic electrical shortage 2 Voltage check proper range of voltages shown below Red Blue DC 100 160V Input Yellow Blue DC 14 16V Input Color Number of wires Orange Blue DC 2 3 5 0V Input Effects on the Water heater if fan motor fails Verify the fan motor speed using the Diagnostics Mode White Blue of the TM RE10 and the TM RE30 temperature remote controller See Section 12 1 for details 6 1 4 160 5mm 2 1 2 56mm 3 3 4 95 15mm 19 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 10 4 Gas valve assembly T M1 or T M199 Part 4103 Takagi Part M122 Checkpoint C H1 Opens and closes the gas pathways of the Water heater main and Function solenoid gas valves Modulates the gas flow from the gas inlet proportional gas valve Gas leak from the valves Failure events Unable to open close main and solenoid gas valves Unable to modulate the gas flow proportional gas valve Gas leak from t
40. d lint in burner and heat exchanger when the water heater has been installed in laundry room 9 Check if there is grease and dirt in burner and fan motor when the water heater has been installed in restaurant 10 Check the manifold pressure in the Water heater Miscommunication between multi unit controller TM MCO1 or TM RE20 and Water heaters 52 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 12 Controls and settings 12 1 A Diagnosing the T M1 and T M199 using the TM RE10 54 12 1 B Diagnosing the T M1 and T M199 using the TM RE30 55 12 2 Displaying error codes 58 12 3 Verifying functionality of computer board 60 12 4 Clearing the 101 and 991 error code 61 12 95 Thermocouple TUNCUON 2 288 oa 62 PEAD o O o ennnen EAA E i 63 12 7 Assigning unit numbers in the Multiple system 65 12 8 T M1 or T M199 ON OFF conditions Overview 68 12 9 T M1 or T M199 ON OFF conditions BTU requirements for Intermittent mode 69 12 10 Multi unit system ON OFF conditions 70 12 11 Connections between Multi unit controller and water heaters 72 12 12 Operation time for unit rotation 74 12 13 Individual unit operation in the Multiple system while Multi unit controller is under abnormal conditions Individual operation mode
41. deactivate the T M1 or T M199 remove the manometer tube and replace the port screw Adjusting minimum manifold pressure 1 Ensure that T M1 or T M199 is not in operation 2 Remove the screw off the manifold port of the T M1 or T M199 Figure 1 3 Connect a manometer to the manifold port using a tube Figure 2 Ensure that this connection is secure enough to prevent gas leak 4 Run water through the T M1 or T M199 to activate its operation If presence of a gas leak is detected immediately shut off the T M1 or T M199 and inspect the tube manifold connection otherwise proceed onto the next step 5 To increase the manifold pressure insert the Manifold gas pressure Jumper see next page 76 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 Figures 3 amp 4 into the Min port and turn the Minimum potentiometer clockwise To decrease the manifold gas pressure turn the Minimum potentiometer counter clockwise 6 After gas pressure has been set deactivate the T M1 or T M199 remove the manometer tube and replace the port screw Figure 3 Figure 1 Manifold port Manifold gas pressure jumper Figure 2 Figure 4 MAX Potentiometer To Manometer Tube Computer board for Burner control 7 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 12 15 Freeze protection system There are two features to the T M1 or T M199 s freeze protection system the automatic fan motor system and
42. djusts water flow of the system during multi unit system operation 1 Water leakage from valve Failure events 2 The valve cannot modulate or make open close positions 3 Unable to control water flow in a multi unit system Effects on the Water 1 Water leakage from failed valve can damage other Water heater heater if flow components adjustment valve fails 2 Temperature fluctuations in the hot water output EE enu adjustment valve fails 1 Visual inspection connection breakage of wires motor drive locked Diagnostic due to scale buildup and or water leakage 2 Check voltages and resistance proper range of values shown below White Black DC 13 07 16 0V Color Number of wires White Black 15 30k Yellow Black Less than DC1V 48mm 2 3 4 73 3mm _ N E E TS E E al Ol Lt D 3 Water IN From Two way valve A 2 1 8 and Bypass way gt 50mm 1 7 8 n oem Water Out To Water outlet 23 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 10 8 Flow sensor T M1 or T M199 Part 059 Takagi Part EM143 Checkpoint H2 Function Detects and measures water flow rat
43. dless of what the actual water temperature is if switch fails open 1 Unable to shut down the Water heater if the water temperature from the heat exchanger exceeds 185 F 85 C Effects on the Water Note The mixing and outlet thermistors always act as backup hi limit heater if hi limit switch detectors to detect excessively high water temperatures in the fails heat exchanger 2 The Water heater is always shut down immediately after the pre check and the 141 error code will display Failure events Error codes when hi limit switch fails 1 Visual inspection connection breakage of wires Possibility also Diagnostic includes scale deposits inside the heat exchanger 2 Check voltages and resistance proper range of values shown below Color Number of wires Red Red DC Less than 1 0 Q When temperatures exceed 185 F 85 C the reset button trips and switch goes to OFF mode ON mode 185 F 85 C OFF mode to reset switch back to ON mode press the reset button Reset Button 3 4 18 Amm p J 5 8 15mm 36 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 10 20 Overheat cutoff fuse T M1 or T M199 Part 025 Takagi Part EM138 Checkpoint The overheat cutoff fuse contains solder with a melting point of 365 F 185 C Detects excessive temperatures within the Water heater especially Function around the heat exchanger
44. during ignition 4 Igniter fault Error code is attempts at 44 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 3 PCB fault 1 No voltage to main gas solenoid valve MV C Normal DC78 100V between COM blue amp 3 light blue during operation 2 No voltage to gas solenoid valve SV Error code is Normal DC78 100V between COM blue amp 53 yellow H1 during operation 3 No voltage to gas proportional valve VG three failed Normal DC0 3 6 4V between white amp red during operation attempts at 4 Gas solenoid valve fault 1 Main gas solenoid valve MV fault C Normal 0 9 1 7kQ between COM blue amp 3 light blue 2 Gas solenoid valve SV fault Normal 0 9 1 5kQ between COM blue amp 53 yellow 3 Gas proportional valve VG fault H1 Normal DCO 3 6 4V between white amp red during operation 5 Disconnected damaged O H C F Refer to section 10 20 C2 Visual inspection connection breakage of wires Normal 1 Q or less between blue blue 6 Disconnected damaged hi limit switch Refer to section 10 19 C1 Visual inspection connection breakage of wires Normal 1 Q or less between red amp red 7 Inspect flame rod 1 Check for any soot on the rod 2 Check the connection of ground wire make sure there is firm contact to the ground of the Water heater in this case the wire is contacted to the manifold surface 3 PCB fault Not Burning Stand by AC25 65V betwee
45. e 6 is being selected When selecting information please refer to the table on the next page for the proper mode 6 Press the INFO button to select the mode and information to which the mode correlates to will display on the TM RE30 Fig 4 7 When the ON OFF button is pressed or 5 minutes have elapsed without pressing any buttons the display will return to normal Fig 3 For example the figures above show how to arrive at the mixing temperature information for Unit 10 in a Multi Unit System 56 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 Description of mode numbers in Diagnostics Mode Whole multi unit system information 0 Individual T M1 or T M199 unit information 1 to 20 Total system flow rate O to 9999 x 0 1 GPM Total operation time 0 to 9999 hours 0 to 9999 x 100 times N A ON OFF cycles 0 to 9 times 0 to 999 times 0 to 20 units Fan motor speed 0 to 9999 rpm Quantity of connected T M1 or T M199 s eee t 0 to 20 units Inlet temperature 32 to 212 F Quantity of operational Over 212 F E5 T M1 or T M199 s Under 32 F E0 Set temperature 100 to 176 F Mixing temperature Operation time during Thermocouple included current rotation ON OFF cycles during current rotation 0 to 20 units Output temperature 0 to 999 minutes 0 to 999 X 0 1 A 0 to 999 times O to 999 x 0 1 GPM Bypass valve position 0 to 9999 clo
46. e GFI The 101991 error code should then be cleared Reset button Red light 61 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 12 5 Thermocouple function lt Function gt The thermocouple checks flame conditions during combustion based on Seebeck effect thermal electromotive force When thermocouple detects unexpected flame conditions the T M1 or T M199 s computer makes adjustments in the fan motor speed to ensure that air and fuel are always at a proper mixture ratio minimizing emissions lt Thermocouple normal range of values gt Unit mV Gas type LPG Natural Natural f the voltage from thermocouple is higher than the normal value the FM speed is increased These values are read with the front cover close The voltage from thermocouple can be confirmed in Diagnostic Mode Refer to p 57 Thermocouple stage 0 6 and 101 amp 991 error codes Condition of Thermocouple stage FM Stage i 991 Error code REINE 15 10d E rorcode 1 4 Gas rich or Air shortage In order to solve the air deficiency problem 12 np 99 the fan motor speed is automatically increased 0 and Thermocouple stage goes up 6 p ge g p 5 101 error code 3 7 In this stage the maximum input will be 0 Default condition reduced to 88 000 BTU h but not apply in a multi unit system the maximum input will stay the same 6 991 error code When the 101 o
47. e using a spinning impeller and magnetic pick up Unable to detect or measure any water flow rate Effects on the Water Ignition sequence does not start Water heater will not initiate any heater if flow sensor fails operation eel ede en O 441 only within Multi unit systems sensor fails 1 Visual inspection connection breakage of wires and or debris on Diagnostic impeller 2 Check voltages proper range of values shown below Red Black DC4 0 5 5V Input Color Number of wires DC1 0 4 0V pulse White Black GND 1 200 pulse min more than 20Hz Water OUT E Water IN Water OUT ur EL ESTAS 29mm Water IN 2 1 8 54 2mm a 2 1 8 54 2mm El CONFIDENTIAL T M1 T M199 Service manual Version 1 02 10 9 Bypass valve T M1 or T M199 Part 4051 TakagiPart EM116 Checkpoint J2 1 Mixes hot water from the heat exchanger with cold water from the water inlet in order to modulate and control the Water heater s outlet water temperature 2 Keeps the water temperature in the heat exchanger stable preventing low temperature corrosion caused by heat exchanger condensation oee these following conditions When the temperature setting is 149 F 65 C or over the bypass valve closes completely so
48. er gas flow from the manifold Effects on the Water which can cause poor combustion in the combustion chamber In this heater if the manifold case the thermocouple will detect an improper flame condition and fails computer will take safety measures 2 Gas leakage from the manifold Error codes when the manifold fails 1 Visual inspection Excessive dust deposit around the nozzles or cracks on the manifold 2 Check voltages and resistance proper range of values shown Diagnostic below 3 Check the inlet gas pressure If it is too high gas valve cannot be opened anete e s for BEES rich burners 1 1 4 35mm ka 666060 I 566000 D QU Y e i 060088 e One FE s a ZX ere e d 5 126 9mm 4 7 8 272mm 272mm 18 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 10 3 Fan motor T M1 or T M199 Part 087 Takagi Part EM126 Checkpoint To provide combustion air into the burner chamber and to exhaust flue Function das 1 Fan speed failure causing abnormal sounds with or without
49. ervice manual Version 1 02 Item Part Description Common parts for other units 81 EM178 Overheat cut off fuse EMTS TK2 TKD20 EM205 TK2 TKD20 TM199 TH1 EKDos TK2 TKD20 TH Hex head screw M4x12 82 83 84 5 87 88 EW004 w washer EM174 TK2 TKD20 TH1 EMs Manifold gasket B TK2 TKD20 TH EKN22 TKIS TACTA Em208 TK2 TKD20 105 emiz Gevaveus 104 EzP22 TH 105 EZP18 O ring P18 NBR Black TK2 TKD20 TH1 TK3 Pro wr EzP26 TH TMS 109 EKO22 TKJr TK1S 110 EM209 Gas Inlet Fixing Plate 3 4 5 97 NO 88 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 Description Common parts for other units EM129 T M1 Computer Board EM235 T M199 Nn TK2 TKD20 TKJr TK1S OS SP Wire clamp 60 TH1 TM50 TK3 Pro TM32 TH TM32 TM50 Screw M3 x 12 T BH 89 15 Revisions Version Description of changes 1 00 1 01 1 02 First version Revised by the R amp D and Takagi Japan Revised by the R amp D and Takagi Japan 90 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 Date 03 04 08 12 09 08 02 12 09
50. he temperature setting is too high The hot water is not 1 Make sure the unit gets a 120V 60Hz power supply 2 If the remote controller is used check whether the power button is turned on Is opened 3 Check that the filter on the cold water inlet is clean 4 Check whether the hot water fixture is sufficiently open to draw at least 0 75 GM through the water heater 5 Check that the filter on the cold water inlet is clean 6 Check whether or not the unit is frozen 7 Check if there is enough gas in the tank for propane units The fan motor is still 1 This is normal operation After operation has stopped the fan motor keeps its running for 35 seconds in order to re ignite quickly as well as purge all the exhaust gas out of the flue available when a fixture spinning after operation has stopped Abnormal sounds 1 Check the gas type of the Water heater 2 Check how long the Water heater has been installed and in use 3 Check the installation place 4 Check the altitude elevation of area of where the Water heater installed 5 Check the vent length when the Water heater has been installed indoors 6 Check the type of vent cap when the Water heater has been installed outdoors Check if there is any blockage in the intake air and or exhaust 8 Check if there is dust and lint in burner and heat exchanger when the water heater has been installed in laundry room 9 Check if there is grease and dirt in burner and fan
51. he unit Effects on the Water 2 Excess carbon monoxide emissions heater if valves fails Lack of water temperature control No flames Error cages when the 111 121 510 701 valves fails 1 Visual inspection connection breakage of wires 2 Listen for clunk sounds from the gas valves opening right after fan motor initiates Diagnostic 3 Check voltages and resistance of coils proper range of values shown below 4 Check the inlet gas pressure If it is too high gas valve cannot be opened Blue Light blue MV DC 78 100V during operation 0 9 1 7K Q Blue Red SV4 DC 78 100V during operation 0 9 1 7K Q Blue Yellow SV DC 78 100V during operation 0 9 1 5K OQ Blue Green SV3 DC 78 100V during operation 0 9 1 7KQ White Red Proportional Valve Color Number of wires DC 0 3 6 4V during operation 60 85k Q Main gas valve Proportional 4 1 4 110 5mm 4 3 4 121mm 7 178mm CONFIDENTIAL T M1 T M199 Service manual Version 1 02 10 5 Flame rod T M1 or T M199 Part 073 Takagi Part EM199 Checkpoint Function To detect flames while unit is in operation 1 Unable to detect flames when flames actually do occur Failure events 2 Detecting a false flame when no flames actually occur 1 The Water heater stops operating The 111 and or 121 error Effects on the Water code s
52. hite white fan motor Normal AC20V between green green Power source for computer board Normal AC55V between red red flame rod 6 Fault of PCB 1 No voltage at remote control terminal Normal 14V DC 16V DC between black white 7 Disconnection short circuit grounding of remote wires Normal 14V DC 16V DC between black white 8 Fault of PCB of remote control 1 Check for normal voltage at terminal t takes long time to 1 The time it takes to deliver hot water from the Water heater to your fixtures depend on the length of piping between them The longer the distance and or the bigger the pipes the longer it will take to get hot water temperature remote controller even get hot water at the fixtures The water is not hot 1 Check cross pluming between cold water lines and hot water lines 2 Check whether the gas supply pressure is enough 3 Check whether the temperature setting is too low The hot water turns 1 Check whether the flow rate enough to keep the Water heater running 2 Check if there is a recirculation system installed and check also if the recirculation line has enough check valves 3 Check that the filter on the cold water inlet is clean 4 Check that the fixtures are free from debris and obstructions enough cold and stays cold 41 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 Natural of Fault Diagnosis Checkpoint The water is too hot 1 Check whether t
53. in the pressure switch trips and then the 211 error code will occur Failure cuentc 1 ON failure Always in ON mode 2 OFF failure Always in OFF mode 1 In the Always the ON failure The 211 error code will display and Effects on the Water the operation is stopped heater if the pressure 2 In the Always the OFF failure The unit can work and the 211 switch fails error code is not displayed In this case the unit can emit the excess CO from the exhaust chamber Error codes when the pressure switch fails Visual inspection connection breakage of wires Base port Detection port a x rx E E y f EL E _2 3 4 70 5mm D YAMATAKE pedum teem C40650301 2 N 43 d m N Ca 1 a Se r at M T E nt EE x gt dIN MI N t 3 e _ s M CE M SI Ss La E e T y f E Jo EL ie 14 x 2 S y x Ny gt 7 8 22 3mm al E E NM gl mA y 00 E LL S A LO TX LES Ty CONFIDENTIAL T M1 T M199 Service manual Version 1 02 10 22
54. ing the combustion reaction Unable to initialize sustain combustion Dust or soot deposit on the burner surface Cracks on the burners Gas leakage from burners An unexpected combustion Effects on the Water 2 Unstable flame conditions and or flame loss heater if burners fails Ignition failure Back firing Visual inspection excessive dust deposit on the burner surface and or Diagnostic unstable flame conditions during operation Color Number of wires Failure events 182 9mm 7 1 4 10 5 8 270mm f it I A 1 A 140 5mm mad Ooo 5 17 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 10 2 Gas manifold EM162 LP T M1 or T M199 Part 091 Takagi Part Checkpoint N A EM158 NG 1 The manifold distributes gas from the gas valves to the burners The manifold has two types of the nozzles one type for gas rich Function burners 17 nozzles and the other for air rich burners 16 nozzles 2 There are 3 zones within the manifold to ensure efficient combustion operation 1 Dust deposit on the manifold 2 Gas leakage from a failed manifold Failure events 3 Ignition failure 4 Imperfect combustion 1 The burners cannot receive prop
55. ion 1 02 12 10 Multi unit system ON OFF conditions In the Multi unit systems the amount of T M1 or T M199 s called on to activate depends on the FLOW RATE and the SET TEMPERATURE 1 Condition required to activate an additional T M1 or T M199 Flow rate required to activate additional T M1 or T M199 A x n Where n number of currently activated T M1 or T M199 s and A is dependent on the set temperature See table below Set temperature Factor A F je GPM L min 35 12 70 00 24 9 2 Condition required to reduce the number of activated T M1 or T M199 s A In the case of reducing down from 2 T M1 or T M199 s to 1 T M1 or T M199 Flow rate A 1 7 B All other cases Flow rate A X n 2 3 Example Set temperature 122 F in a 20 unit system and priority unit is No 1 See the next page 70 To activate additional T M1 or T M199 s No 1 ON 0 75 No 2 ON Flow rate Unit No GPM L min 3 4 3 0 12 9 25 7 38 6 51 5 64 3 17 2 103 0 115 9 128 7 141 6 154 4 167 3 180 2 193 0 205 9 218 8 231 6 244 5 71 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 To reduce number of activated T M1 or T M199 s Flow rate Cas 61 2 231 6 Unit No No 20 OFF No 19 OFF No 18 OFF No 17 OFF No 16 OFF No 15 OFF No 14 OFF No 13 OFF No 12 OFF No 11 OFF No 10 OFF No 9 OFF No 8 OFF No 7 OFF No 6 OFF No 5 OFF No 4 OFF No 3 OFF No 2 OFF No 1 OFF 54 4 51 0 47 6
56. is more than 14kV 1 Unable to ignite during the ignition process Fail t ne 2 Makes attempts to ignite at all times 1 The Water heater cannot ignite during the ignition process and the Effects on the Water 111 or 121 error codes will display heater if the igniter fails 2 No effects on the Water heater however the durability of the igniter wears down Error codes when Igniter fails e 00 1 Visual inspection connection breakage of wires and or an Diagnostic observed weak spark 2 Check voltages proper range of values shown below NOTE The high voltage igniter cable and the purple wires do not come with EM208 High voltage Ignite cable DC14kV Y gt Power supply terminal 23 6 l _2 1 4 58mm 34 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 10 18 Freeze protection thermostat T M or T M199 Part 4090 Takagi Part EM142 Checkpoint B1 Temperature detecting device which prevents the pipes within the Water heater from freezing When this device detects temperatures below 36 5 F 2 5 C inside the Water heater power is supplied to the electric heaters to prevent the Water heater from freezing 1 ON failure Always senses freezing temperatures regardless of Failure events actual temperature 2 OFF failure Never senses freezing temperature
57. k the dipswitch settings on PCB 43 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 Malfunction description Cancellation method On the PCB press the INC and DEC poh ie ps us eU due buttons simultaneously for 3 sec Then Refer to section 12 4 turn the power off Diagnosis Checkpoint 1 Check the gas type of the Water heater 2 Check how long the Water heater has been installed and in use 3 Check the installation place 4 Check the altitude elevation of area of where the Water heater installed 5 Check the vent length when the Water heater has been installed indoors 6 Check the type of vent cap when the Water heater has been installed outdoors 7 Check if there is any blockage in the intake air and or exhaust 8 Check if there is dust and lint in burner and heat exchanger when the water heater has been installed in laundry room 9 Check if there is grease and dirt in burner and fan motor when the water heater has been installed in restaurant 10 Check the manifold pressure in the Water heater Malfunction description Cancellation method 1 Check gas supply and inlet pressure Refer to section 1 2 Check the igniter Refer to section 10 17 Visual inspection connection breakage of wires and or observed weak spark shown after 1 Cracks soot on igniter rod three failed 2 Improper gap between burner amp igniter rod Normal gap 0 16 3 PCB fault ignition Normal AC 90 110V at 7 purple purple
58. kage if this occurs an overheat cutoff fuse is in place to detect this event and immediately stop the Water heater from operating 3 Abnormal sounds during combustion 4 Hi limit switch trips or water leaks from the pipe Failure events Effects on the Water heater if the heat exchanger fails 1 Visual inspection soot deposits cracks on the heat exchanger walls and or water leakage from the heat exchanger Error codes when the heat exchanger fails 2 In the event of abnormal sounds during combustion Diagnostic A Inspect for soot buildup inside the heat exchanger B Inspect for scale buildup inside the heat exchanger pipes Scale buildup obstructs proper heat transfer to the water thereby overheating the heat exchanger and causing damage Color Number of wires N A 7 7 8 200 2mm Exhaust box ay E E n e St lO St N a N T M199 is different from that of the T M1 T M1 Galvanized Steel T M199 Stainless steel 22 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 10 7 Flow adjustment valve T M1 or T M199 Part 8037 Takagi Part EM120 Checkpoint 1 Controls water flow to properly control the output hot water Function temperature 2 A
59. lt Tout where Ti is the temperature of inlet thermistor and Tou is the temperature of the output thermistor and Tyx is the temperature of the mixing thermistor 78 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 Automatic fan motor system e Electrical power is required for this feature to operate e The computer will continually check the temperatures of the inlet outlet and mixing thermistors e This function is enabled by the Automatic fan motor connector inserted on the computer board See a next page lt Activate condition gt When the computer checks for these temperatures the Automatic fan motor system will activate if Tout lt 39 F AND Tou Tin 5 F where Ti is the temperature of inlet thermistor and Toy is the temperature of the output thermistor Deactivate condition When the computer checks for these temperatures the Automatic fan motor system will activate if Tin gt 46 F and Tout gt 46 F and Tux gt 46 F OR Tin gt 39 F and Tout gt 39 F and Tux gt 39 F and Flow sensor detects flow rate for 1min OR Tin lt Tout where Ti is the temperature of inlet thermistor and Tou is the temperature of the output thermistor and T yx is the temperature of the mixing thermistor Automatic fan motor connector Computer board 79 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 12 16 Draining the T M1 T M199 and cleaning the inlet water filter
60. motor when the water heater has been installed in restaurant 10 Check the manifold pressure in the Water heater come from the unit 42 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 Natural of Fault Malfunction description Cancellation method au Fluctuation Fault of gas solenoid valves SV amp SV3 ae Foi waler during change of the combustion stage temperature Fault of flow adjustment valve 1 Check whether the filter in cold water inlet is cleaned 2 Check whether the gas supply pressure is adequate 3 Check for cross connections between cold water lines and hot water lines 4 Fault of PCB in the Water heater 1 No voltage to gas solenoid valve SV Normal DC78 100V between COM blue amp 9 red during operation 2 No voltage to gas solenoid valve SV Normal DC78 100V between COM blue amp 73 green during operation 5 Gas solenoid valve SV fault 1 No voltage to gas solenoid valve SV Normal 0 9 1 7kQ between COM blue amp 9 red 2 No voltage to gas solenoid valve SV3 Normal 0 9 1 7kQ between COM blue amp 73 green 6 PCB fault No voltage to flow adjustment valve Normal DC 10 0 13 0V between white black Normal DC 1V less between yellow black 7 Flow adjustment valve fault Normal 15 30 9 between white black Malfunction description Cancellation method CE Dipswitch setting fault Turn off the power or water supply Diagnosis Checkpoint Chec
61. multiple system Mixing thermistor White White Output thermistor White White See table on p 14 Inlet thermistor White White Remote controller Black White DC14 16V Red Blue DC100 160V G Fan motor Yellow Blue DC14 16V Orange Blue DC2 3 5 0V H1 Gas proportional Valve White Red at COM DC 0 3 6 4V during burning 60 85 Q Red Black DC4 5 5V H2 Flow sensor White Black GND DC1 4V 1 200Pulse min Stand by AC25 65V Orange Green Burning AC20 55V Flame rod Orange Flame rod Stand by Less than DCO 15 uA Between flame rod and l Burning More than DC1 u A the computer board 12 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 Parts and Description Color of wires Normal Range White Black DC 10 0 13 0V Flow adjustment valve White Black 1530 Q Yellow Black Less than DC1V White Blue DC12 0 14 5V Blue Black DC1 0 14 5V White Black 27330 Blue Orange DC1 0 14 5V White Orange 27330 Blue Green DC1 0 14 5V White Green 27330 Bypass flow adjustment valve Blue Purple DC1 0 14 5V White Purple 27330 Red Blue DC12 0 14 5V Brown Blue Less than DC1V Opened position Yellow Blue DC4 5 5 5V Red Blue DC10 0 13 0V during burning Orange Gray DC14 0 16 0V during burning Yellow Gray Less than DC1V opened position Two way valve Brown Gray Less than DC1V closed position DC1 9mV during the maxi
62. mum and Thermocouple Green Yellow normal burning More than 9mV abnormal burning 4 0 5 5V Normal Pressure switch Pink Pink Less than 1 0V abnormal Less than 1 0 Q abnormal CONFIDENTIAL T M1 T M199 Service manual Version 1 02 8 Resistance values of the temperature thermistors The T M1 and T M199 use the same thermistors Resistance values at different temperatures Temperature F vs Resistance kQ 30 00 25 00 20 00 15 00 10 00 Resisitance k Q 5 00 0 00 20 40 60 80 100 120 140 160 180 200 220 Temperature F Temperature C vs Resistance kQ 30 00 25 00 20 00 15 00 10 00 Resisitance k Q 5 00 0 00 0 10 20 30 40 50 60 70 80 90 100 Temperature C 14 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 9 Operational flow chart The diagram below refers to both T M1 and the T M199 Hi limit switch failure Unit power supply ee Oe A OFF Gas valve circut failure Inlet TH failure Operation Switch OFF fe TH failure Flow sensor OFF Mixing TH failure NK E DERI Faucet Close Computer board failure False Dipswitch settings Fan motor fault 611 2 Way valve Open check Bypass valve Open check 18sec later Flow adjustment alve Open check 18sec later Operation SW ON Pre check NORMAL
63. n orange amp green Burning AC20 55V between orange amp green Not Burning Stand by Less than DC 0 15 u A between orange amp flame rod During operation more than DC1u A through the flame rod wire orange amp flame rod 4 Flame rod fault 8 Check if hi limit switch is properly functioning shown after ignition 45 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 Malfunction description Cancellation method Flame blows out Turn off the power or water supply 121 1 Check gas supply and pressure Refer to section 1 2 PCB fault 1 No voltage to gas main solenoid valve MV C Normal DC78 100V between COM blue amp 3 light blue during operation 2 No voltage to gas solenoid valve SV Normal DC78 100V between COM blue amp 53 yellow during operation 3 No voltage to gas proportional valve VG H1 Normal DCO 3 6 4V between white amp red during operation 3 Gas solenoid fault 1 Main gas solenoid valve MV fault C Normal 0 9 1 7kQ between COM blue amp 3 light blue 2 Gas solenoid valve SV fault Normal 0 9 1 5kQ between COM blue amp 53 yellow 3 Gas proportional valve VG fault H1 Normal DCO 3 6 4V between white amp red during operation 4 Check for soot on the flame rod 1 Clean the flame rod 2 PCB fault Not Burning Stand by AC25 65V between orange amp green Burning AC20 55V between orange amp green Not Burni
64. ng Stand by Less than DC 0 15 u A between orange amp flame rod During operation more than DC1u A through the flame rod wire orange amp flame rod 4 Flame rod fault 5 Disconnected damaged O H C F Refer to section 10 20 C2 Visual inspection connection breakage of wires Normal 1 Q or less between blue amp blue Error code is shown after three failed attempts at ignition 46 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 Malfunction description Cancellation method Hi limit switch trip Reset hi limit switch Diagnosis Checkpoint 1 Fault of hi limit switch Refer to section 10 19 Visual inspection connection breakage of wires Normal Less than 1 Q between red amp red Malfunction description Cancellation method Exhaust vent termination Turn off the power or water supply 1 Check for blockage of the exhaust run 2 Check vent installation location for strong winds 3 Fault of pressure switch Refer to section 10 21 Visual inspection connection breakage of wires Normal Less than 1 Q between pink amp pink Malfunction description Cancellation method Disconnected short circuited output thermistor Turn off the power or water supply 311 1 Output thermistor fault Refer to section 10 11 Visual inspection connection breakage of wires and or debris on E2 thermistor Check voltage resistance between white amp white 12 Refer to Section 8 for proper range of values
65. ng operation Normal DC 2 3 5 0V between orange amp blue during operation Normal DC 4 0 15V between white blue during operation G Verify fan motor speed of the Water heater using the diagnostics mode of the TM RE10 or TM RE30 temperature remote controller oee section 12 1 How to diagnose the Water heater using the TM RE10 or TM RE30 Visual inspection of PCB connection breakage of wires and or burn marks on the computer board 49 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 Malfunction description Cancellation method Flow adjustment valve fault Turn off the power or water supply 1 PCB and flow adjustment valve fault Refer to section 10 7 amp 10 13 Visual inspection of Flow adjustment valve connection breakage of wires motor drive locked due to scale buildup and or water leakage Normal DC 10 0 13 0V between white black Normal DC 15 30Q between white black Normal Less than DC1V between yellow black Visual inspection of PCB connection breakage of wires and or burn marks on the computer board Malfunction description Cancellation method 1 Fault of PCB and bypass valve Refer to section 10 9 amp 10 13 Visual inspection of bypass connection breakage of wires motor drive locked due to scale buildup and or water leakage Normal DC 12 0 14 5V between white blue Normal DC 1 0 14 5V between blue black Normal 27 33 Q between white black Normal DC 1 0 14 5V between blue o
66. nit number Mode button Press the mode button button on T M1 or T M199 computer board The 7 seg LED will then display the 7 seg LED assigned number for that T M1 unit NOTE In a single unit installation the numbering system is disabled O Elfo Computer board B How to reset and reconfigure the numbering of units The T M1 or T M199 can be connected with the Multi unit controller the TM RE20 or the TM MC201 The unit from the numbering system of TM RE20 or TM MCO1 is assigned to each unit randomly so they will not necessarily be in order from left to right There are the procedures how to reset the unit and to set it manually Please refer to p 65 and p 66 for detail information 65 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 Case1 The T M1 s or the T M199 s are connected with the TM MC01 Clear the unit 1 Take off the front cover of the TM MCO1 Multi unit controller and the T M1s or T M199s 2 Press the MODE button on the computer board of the TM MC01 3 seg LED on the computer board of the TM MC01 will display O _ 4 Press the SET button 5 seg LED will display O 1 6 Press the MODE button 9 times Then the 7 seg LED will display O A T Press the SET button 8 seg LED will display FF 9 Press the BYPASS REMOTE CONTROL button and the PUMP TEST at the same time While pressing both buttons the 7 seg LED will
67. pressing the HOT or COLD buttons to scroll up or down 0 will yield information on the whole multi unit system Fig 2 4 Once desired is displayed press the white button located under the Buzzer Stop button to select the either a particular T M1 or T M199 unit or the whole multi unit system The number 1 will then display right next to that selected Fig 3 5 Scroll through the mode s by pressing the HOT or COLD buttons Fig 4 6 Once desired mode is displayed press the white button located under the Buzzer Stop button to select the mode The information for that mode will be displayed Fig 5 7 When the ON OFF button is pressed or 5 minutes have elapsed without pressing any buttons the display will return to normal Fig 1 Fig 2 Fig 3 Fig 4 Fig 5 For example this sequence will display the flow rate information of the second T M1 or T M199 unit 54 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 12 1 B Diagnosing the T M1 and T M199 using the TM RE30 lt Fora single T M1 or T M199 gt 1 Press the HOT button and the COLD button HOT simultaneously for at least 5 seconds to enter Diagnostic TIME Button COLD mode Button Button 2 Scroll up or down to the needed information mode of the T M1 or T M199 by pressing the HOT or COLD buttons Fig 1 shows mode 5 being selected When selecting information please refer to the table on p 56 for
68. r 991 error code appears see section 12 4 62 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 12 6 Dipswitch settings There are two banks of dipswitches upper and lower Upper Bank bank on the T M1 or T M199 computer board They of dipswitches have certain special functions as shown on the following table and generally should not need adjustment Carefully verify the functions of each Lower Bank dipswitch before changing any settings OT CIPSWIGINES The functions of the upper bank of dipswitches Output temperature settings See table to the right Default 122 F 63 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 FM and FM See the table to the right 0 NO SHEER INO FEFE rirdi rd Pa Ex J PA PAPI A dece A dum ust ome 4 T 8 LS TEL O 7 e 64 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 12 7 Assigning unit numbers in the Multiple system Each T M1 or T M199 in a Multiple system is assigned a random unit This is why the T M1 or T M199 s will not necessarily be numbered in order from left to right or right to left A How to display the u
69. range Normal 27 33 Q between white orange Normal DC 1 0 14 5V between blue green J2 Normal 27 33 Q between white green Normal DC 1 0 14 5V between blue purple Normal 27 33 Q between white purple Normal DC 12 0 14 5V between red blue Normal Less than DC1V between brown blue valve in open position Normal DC 4 5 5 5V between yellow blue Visual inspection of PCB connection breakage of wires and or burn marks on the computer board 50 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 Malfunction description Cancellation method 1 PCB fault 1 Fault of preparation for the output thermistor operation Turn off the power or water supply 2 Fault of driving circuit for Gas Proportional Valve VG Diagnosis Checkpoint 1 Check the PCB and or gas proportional valve Refer to section 10 4 amp 10 13 Visual inspection PCB connection breakage of wires and or burn marks on the computer board Visual inspection gas proportional valve connection breakage of wires of the gas proportional valve Normal 607 85 Q between white red Malfunction description Cancellation method False flame detection Turn off the power or water supply 721 Diagnosis 1 False flame detection 5 sec Flame rod Insulated resistance fault Malfunction description Cancellation method Restoring proper cable connections between the Water heater and the Remote controller TM RE10 or Miscommunication between Water heater TM RE30
70. s Function 1 The freeze protection heaters will always be ON causing heat damage to components inside the Water heater 2 The freeze protection heaters will never be able to turn on even under freezing temperatures causing freeze damage to the Water heater Effects on the Water heater if the freeze protection thermostat fails Error codes when the freeze protection N A thermostat fails 1 Visual inspection connection breakage of wires and or the body has been broken 2 Check resistance and voltage proper range of values shown below Diagnostic Black Black ON mode 90 VAC 110 VAC and less than 1 Q itself OFF mode less than 1 VAC and more than 1M Q Color Number of wires Activation and deactivation temperature of the T M1 s or T M199 s freeze protection system ON mode 36 5 F 6 3 F 2 7 F 2 5 C 3 5 C 1 0 C 1 1 4 33 5mm gt 1 2 14mm 1 4 5 6mm 35 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 10 19 Hi limit switch T M1 or T M199 Part 016 TakagiPart EM212 Checkpoint Based on bi metal thermal expansion Function Detects excessively high water temperature more than 185 F or 85 C in pipes of the heat exchanger 1 Unable to detect excessively high water temperatures if switch fails closed 2 Continuous detection of excessively high water temperatures regar
71. se position O Ratio of hot water and cold water 0 to 999 Error code history displays most recent error code Error code history displays 2 most recent error code Error code history displays 3 most recent error code Clears memory in error code history Clears memory in error code history N A TM RE30 Simultaneously press the INFORMATION button and the BUZZER buttons on the TM RE30 while in mode 14 for at least 5 seconds to completely clear the memory in the error code history TM RE10 Simultaneously press the Buzzer stop button and the White button located under the Buzzer stop button on the TM RE10 while in mode E for at least 5 seconds to completely clear the memory in the error code history Buzzer stop Button under button Mode s after 9 will be displayed as a number e g 10 11 16 on the TM RE30 On the TM RE10 Mode s after 9 will be displayed as hexadecimal values going from A to 0 After 16 0 the TM RE10 and the TM RE30 will cycle back to 1 again 57 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 12 2 Displaying error codes If the T M1 or T M199 is undergoing abnormal conditions the computer will display the error code to indicate the source of the problem The error codes are displayed on the 7 seg LED of the T M1 or T M199 computer board and on the remote controller TM RE10 or T
72. the Turn off the power supply main gas valve immediately after every operation 1 PCB and or main gas valve fault Refer to section 10 4 amp 10 13 Visual inspection of gas valves connection breakage of wires Normal DC78 100V between COM blue amp 3 light blue C during operation Visual inspection of PCB connection breakage of wires and or burn marks on the computer board 2 Main gas valve fault MV 48 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 Malfunction description Cancellation method Fault of two way valve The computer board cannot detect open Turn off the power supply and closed limit stops of the two way valve within 18 sec 1 Fault of two way valve Refer to section 10 10 Visual inspection connection breakage of wires and or drive motor locked due to scale buildup and or water leakage J3 Normal DC10 0 13 0V between red amp blue during operation Normal DC14 0 16 0V between orange amp gray during operation Normal Less than DC1V between yellow amp gray valve in opened position Normal Less than DC1V between brown amp gray valve in closed position Malfunction description Cancellation method 1 PCB and fan motor fault Refer to section 10 3 amp 10 13 Visual inspection of fan motor connection breakage of wires or dust buildup causing electrical shortage Normal DC 100 160V between red amp blue during operation Normal DC 14 16V between yellow amp blue duri
73. the ceramic heating blocks The automatic fan motor system allows the T M1 or T M199 to briefly do fan motor operation and the ceramic heating blocks will heat up whatever portion of the heat exchanger the blocks are strapped to The automatic fan motor mainly focuses on providing freeze protection from the back flow of the venting The seven heating blocks focus on protecting the inlet and outlet piping inside the T M1 or T M199 as well as the front drum pipe The conditions to activate either feature are different from each other However the two features are not mutually exclusive because they focus on different areas of the T M1 or T M199 As long as each particular feature s activation requirements are met it is possible for both features to operate at the same time Ceramic heating blocks e Electrical power is required for this feature to operate e The blocks will activate based on what the freeze protection thermostat senses or all thermistors The thermostat is located on the fan motor lt Activate condition gt Tin lt 39 F OR Toit lt 39 F OR Tux lt 39 F OR That lt 36 5 F where Ti is the temperature of inlet thermistor and Toy is the temperature of the output thermistor and T thermostat IS the temperature of the thermostat lt Deactivate condition gt Tin gt 46 F and Tout gt 46 F and Tix gt 46 F OR Tin gt 39 F and Tout gt 39 F and Tux gt 39 F and Flow sensor detects flow rate for 1min OR Tin
74. the error codes instead T M1 T M1 T M1 T M199 T M199 T M199 1 2 3 Ne m KL 7 P4 TT NM T N Su CU Remote TM RE10 Optional 58 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 Computer board of TM RE20 multi unit controller Priolity Multi system Mode set alarm Remote contrpl RE10 jo o 7 seg LED Unit2 Unit3 Unit4 Unit5 o O Unit6 Unit7 Unit8 Unit9 Unit10 O O O O O Unit11 Unit1i2Unit13Unit14Unit15 Uni t1 Set o 5 Uni t16 Unit17 Uni t8 Uni t 19 Uni t20 O O O Las nn im ol oo Clear error CE memor y test Fr 2un it priority Re cir saving Select by pulling out connecter The Unit LEDs Computer board of TM MC01 multi unit controller Prioriry Mode set D o D 7 Set on line nes Set Bypass remote 12345678 Call Pump teset Alarm N The Unit LEDs 59 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 12 3 Verifying functionality of computer board 1 Check the power supply to the GFI If the red light turns on after pressing the test button on the GFI the GFI is receiving power After verifying power press the reset button to turn off the light 2 Press on GFI RESET ON button 3 When the computer board works properly this green LED will be lit 60 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 12 4 Clearing the
75. tions needed to turn the T M1 or T M199 OFF OR Inlet temperature is higher than the set temperature OR Output temperature is over 194 F OR The water flow rate is less than 0 53 GPM 68 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 12 9 T M1 or T M199 ON OFF conditions BTU requirements for Intermittent mode A Calculating the T M1 or T M199 s ON OFF conditions Condition needed to turn the T M1 or T M199 ON Tset Tin GPM x 500 gt 14 880 and Present inlet temp lt Inlet temp when stopping a combustion 5 4 F Condition needed to turn the T M1 or T M199 OFF Tse 5 4 F Tin x GPM x 500 lt 11 900 or Tin Tse Where Tse Set temperature and Tin Inlet temperature B Calculation example Set temperature Tse 122 F Flow rate 2 5 GPM Condition needed to turn the T M1 or T M199 ON 122 Tin x 2 5 x 500 gt 14 880 Tin lt 110 1 F Condition needed to turn the T M1 or T M199 OFF 122 5 4 Ti x 2 5 x 500 lt 11 900 Tin gt 117 9 F The output temperature at that moment will be 134 F C ON OFF table Set temperature Flow rate GPM F 1 0 1 5 2 0 2 5 3 0 3 5 4 0 Re ae A ne Ca E E ae EEBEOLOGECIECAECAEC 3E 3 EE MEE e a RETIRE UT EE Gk IE E PPC NE NE NES ON 113 OFF ON 122 OFF ON 131 OFF ON 140 OFF ON 158 OFF 167 OFF 148 6 156 5 160 5 1629 164 5 165 6 166 4 182 on 69 CONFIDENTIAL T M1 T M199 Service manual Vers
76. uter board and or to the Multi system control will be abnormal The following are the typical examples of when the computer fail 1 Unable to control proper combustion during operation 2 Unable to detect correct signals from any all Water heater sensors 3 Unable to control water valves which may cause output temperature fluctuations 4 Errors in its self diagnostics In order to self diagnose properly the computer sends a low voltage signal into its circuit When the computer does not detect a return signal from this circuit the 701 error code will appear 5 Unable to communicate other Water heater s and or the TM MC01 or TM RE20 during the multi unit system operations Error codes when the computer board fails Visual inspection connection breakage of wires and or burn marks on Diagnostic the computer board Color Number of wires N A Effects on the Water heater if the computer board fails 327mm 12 778 L TESTS 199 8mm 30 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 10 14 Transformer T M1 or T M199 Part 006 Takagi Part EM163 Checkpoint A1 A2 To transform input voltage from 120VAC to 100VAC Every electrical component of the Water heater is designed to only work with a 100VAC power supply therefore the Water heater comes Function equipped with this transformer 1 There is no
77. will display the set number om m Priolity im H H cde Y set sex ELE lome Jn No o OMAN DOA ROI cinis e Remote contrp ey op O gt as 2 it7 Unit8 Uni e O O O ols it11 Uni t12 Uni t13 Uni t14 Uni c OA O O O O O test C 7 it16 Uni t17 Uni t18 Uni t19 Uni reset O O O O O Clear error es memor y test Freeze store Re cir 2unit prdtect ion priority Transformer connector Computer board of the TM RE20 multi unit controller TM RE20 multi unit controller 67 CONFIDENTIAL T M1 T M199 Service manual Version 1 02 12 8 T M1 or T M199 ON OFF conditions Overview The following table shows T M1 or T M199 ON OFF conditions See the table below ON OFF Conditions The BTU requirement is more than 14 875 BTU h AND The water flow rate is more than 0 75 GPM The BTU requirement is less than 11 900 BTU h in this condition when T M1 or T M199 computer board calculates a BTU it will add 5 4 F 3 C into the set temperature Refer to section 12 9 Conditions needed to turn the T M1 or T M199 ON Condi

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