Tankless Water Heater Service Manual

Transcription

1 Tankless ater Heater Service Manual R42e... REU-V66 C42e... REU-V66C R5e... REU-V2020 C5e... REU-V2020C R70e... REU-V2526 R85e... REU-V252 C85e... REU-V252C R85ePLUS... REU-V252D C85ePLUS... REU-V252CD R98e... REU-V27 C98e... REU-V27C R98eASME... REU-V27-ASME C98eASME... REU-V27C-ASME V Series Trade Name Model Trade Name Model R5i... REU-V2520U C5i... REU-V2520UC R5i... REU-V2520UD C5i... REU-V2520UCD R85i... REU-V252U C85i... REU-V252UC R85iPLUS... REU-V252UD C85iPLUS... REU-V252UCD R98i... REU-V27U C98i... REU-V27UC R98iASME... REU-V27U-ASME C98iASME... REU-V27UC-ASME V5e... REU-VAM620 R6LSe... REU-VA2024D R75LSe... REU-VA2528D R75LSe... REU-VA2528D(A) R94LSe... REU-VA255D R98LSe... REU-VA27 R98LSeASME... REU-VA27-ASME VA Series Trade Name Model Trade Name Model R50LSi... REU-VA209UD R75LSi... REU-VA2528UD R75LSi... REU-VA2528UD(A) R94LSi... REU-VA255UD R98LSi... REU-VA27U R98LSiASME... REU-VA27U-ASME

2 Table of Contents General Information... Specifications... 4, 5 Schematic Diagrams... 6, 7 ault Isolation Electrical Diagnostic Points R/C42e, R/C5e,..., 2 R70e, R/C85e(PLUS), R/C5i(PLUS), R/C85i(PLUS)..., 4 R/C98e(ASME), R/C98i(ASME)... 5, 6 V5e, R6LSe... 7, 8 R50LSi, R75LSe, R75LSi, R94LSe, R94LSi... 9, 20 R98LSe(ASME), R98LSi(ASME)... 2, 22 ire Diagrams R/C42e, R/C5e... 2 R70e, R/C85e(PLUS) R/C5i(PLUS), R/C85i(PLUS) R/C98e(ASME), R/C98i(ASME) V5e, R6LSe R50LSi, R75LSe, R75LSi, R94LSe, R94LSi R98LSe(ASME), R98LSi(ASME) lushing the Heat Exchanger... 0 Component Replacement Instructions Gas Control Assembly R/C42e, R/C5e, V5e, R6LSe..., 2 R/C5i(PLUS), R70e, R/C85e(PLUS), R/C85i(PLUS), R50LSi, R75LSe, R75LSi, R94LSe, R94LSi..., 4 R/C98e(ASME), R/C98i(ASME), R98LSe(ASME), R98LSi(ASME)... 5, 6 an R/C42e, R/C5e, V5e, R6LSe... 7 R70e, R/C85e(PLUS), R75LSe, R94LSe... 8 R/C5i(PLUS), R/C85i(PLUS), R50LSi, R75LSi, R94LSi... 9 R/C98e(ASME), R/C98i(ASME), R98LSe(ASME), R98LSi(ASME) PC Board R/C42e, R/C5e... 4 V5e, R6LSe R/C5i(PLUS), R70e, R/C85e(PLUS), R/C85i(PLUS), R50LSi, R75LSe, R75LSi, R94LSe, R94LSi R/C98e(ASME), R/C98i(ASME), R98LSe(ASME), R98LSi(ASME) ater low Control Assembly R/C42e, R/C5e... 47, 48 V5e, R6LSe... 49, 50 R/C5i(PLUS), R50LSi, R75LSe, R75LSi... 5, 52 R/C85e(PLUS), R/C85i(PLUS), R94LSe, R94LSi... 5, 54 R/C98e(ASME), R/C98i(ASME), R98LSe(ASME), R98LSi(ASME) Heat Exchanger R/C42e, R/C5e, V5e, R6LSe R70e, R75LSe R/C85e(PLUS), R94LSe R/C5i(PLUS), R75LSi R/C85i(PLUS), R94LSi R/C98e(ASME), R98LSe(ASME) R/C98i(ASME), R98LSi(ASME) Gas Pressure Setting Procedure... 79, 80 Manifold Pressure Settings... 8, 82 Dip Switches... 8, 84 Key to Trade Names in this Manual: R/C Indicates both the residential and commercial versions. R/C42e includes R42e and C42e. (PLUS) Indicates that the Designer Plus models are included. R/C85ePLUS includes R85e, C85e, and R85ePLUS. On the side of the water heater, the trade name includes a D, as in R85De. (ASME) Indicates that the ASME models are included. R98LSe(ASME) includes the R98LSe and R98LSeASME. Rinnai ater Heater Service Manual 2

3 General Information Safety Definitions This is the safety alert symbol. This symbol alerts you to potential hazards that can kill or hurt you and others. DANGER ARNING CAUTION Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury. It may also be used to alert against unsafe practices. Using this Manual Repairs should be performed by a qualified service technician. The following information can be referenced for additional information. Operation and Installation Manual Hot ater System Design Manual Technical Sheets Technical Bulletins Technical Support Technicians are available to assist in servicing issues. Contact Rinnai Technical Services at Recommended Tools Volt/Ohm/Amp meter with test probes Digital manometer or U tube type manometer with 4 inch water column (.C.) scale, a hose and two /8 inch taps assorted wrenches including a /6 Allen wrench assorted screw drivers leak solution or leak detector Teflon tape ARNING There are a number of live tests that are required when fault finding this product. Extreme care should be used at all times to avoid contact with energized components inside the water heater. Before checking for resistance readings disconnect the power source to the unit and isolate the item from the circuit (unplug it). CAUTION Label all wires prior to disconnection when servicing controls. iring errors can cause improper and dangerous operation. Rinnai ater Heater Service Manual If any of the original wire as supplied with the appliance must be replaced, it must be replaced with type 8 AG wire or its equivalent.

4 Specifications V Series - Commercial - Outdoor Trade Name Model Max. BTU Min. BTU Max low [] gal/min (liters/min) Temperature Range C42e REU-V66C 20,000 7,00 (NG) 7,800 (LP) 4.2 (6) º (49-85 ºC) C5e REU-V2020C 50,000 9,000 (NG) 20,200 (LP) 5. (20) º (49-85 ºC) C85e REU-V252C 99,000 5, (2) º (7-85 ºC) C85ePLUS REU-V252CD 99,000 5, (2) º (7-85 ºC) C98e REU-V27C 27,000 9, (7) º (7-85 ºC) C98eASME REU-V27C-ASME 27,000 9, (7) º (7-85 ºC) V Series - Commercial - Indoor Trade Name Model Max. BTU Min. BTU Max low [] Temperature Range gal/min (liters/min) C5i REU-V2520UC 80,000 5, (20) º (49-85 ºC) C5iPLUS REU-V2520UCD 80,000 5, (20) º (49-85 ºC) C85i REU-V252UC 80,000 5, (2) º (7-85 ºC) C85iPLUS REU-V252UCD 80,000 5, (2) º (7-85 ºC) C98i REU-V27UC 27,000 9, (7) º (7-85 ºC) C98iASME REU-V27UC-ASME 27,000 9, (7) º (7-85 ºC) V Series - Residential - Outdoor Trade Name Model Max. BTU Min. BTU Max low [] Temperature Range gal/min (liters/min) 7,00 (NG) R42e REU-V66 20,000 7,800 (LP) 4.2 (6) º (7-60 ºC) R5e REU-V ,000 9,000 (NG) 20,200 (LP) 5. (20) º (7-60 ºC) R70e REU-V ,000 5, (26) º (7-60 ºC) R85e REU-V252 99,000 5, (2) º (7-60 ºC) R85ePLUS REU-V252D 99,000 5, (2) º (7-60 ºC) R98e REU-V27 27,000 9, (7) º (7-60 ºC) R98eASME REU-V27-ASME 27,000 9, (7) º (7-60 ºC) V Series - Residential - Indoor Trade Name Model Max. BTU Min. BTU Max low [] Temperature Range gal/min (liters/min) R5i REU-V2520U 80,000 5, (20) º (7-60 ºC) R5iPLUS REU-V2520U 80,000 5, (20) º (7-60 ºC) R85i REU-V252U 80,000 5, (2) º (7-60 ºC) R85iPLUS REU-V252UD 80,000 5, (2) º (7-60 ºC) R98i REU-V27U 27,000 9, (7) º (7-60 ºC) R98iASME REU-V27U-ASME 27,000 9, (7) º (7-60 ºC) [] Minimum activation flow is approximately 0.6 gallons/minute (2. liters/min) Rinnai ater Heater Service Manual 4

5 Specifications VA Series (LS Series) - Residential or Commercial - Outdoor Trade Name Model Max. BTU Min. BTU Max low [] gal/min (liters/min) R6LSe REU-VA2024D-US 50,000 Temperature Range 2,500 (NG) 20,600 (LP) 6. (24) º (7-60 ºC) [2] R75LSe REU-VA2528D-US 99,000 5, (28) º (7-60 ºC) [2] R75LSe REU-VA2528D(A)-US 80,000 5, (28) º (7-60 ºC) [2] R94LSe REU-VA255D-US 99,000 5, (5) º (7-60 ºC) [] R98LSe REU-VA27-US 27,000 9, (7) º (7-60 ºC) [] R98LSeASME REU-VA27-ASME 27,000 9, (7) º (7-60 ºC) [] VA Series (LS Series) - Residential or Commercial - Indoor Trade Name Model Max. BTU Min. BTU Max low [] gal/min (liters/min) Temperature Range R50LSi REU-VA209UD-US 50,000 5, (9) º (7-60 ºC) [2] R75LSi REU-VA2528UD-US 99,000 5, (28) º (7-60 ºC) [2] REU-VA2528UD(A)- R75LSi US 80,000 5, (28) º (7-60 ºC) [2] R94LSi REU-VA255UD-US-N 99,000 5, (5) º (7-60 ºC) [] R94LSi REU-VA255UD-US-P 90,000 5, (5) º (7-60 ºC) [] R98LSi REU-VA27U-US 27,000 9, (7) º (7-60 ºC) [] R98LSiASME REU-VA27U-ASME 27,000 9, (7) º (7-60 ºC) [] VA Series - Residential - Outdoor Trade Name Model Max. BTU Min. BTU Max low [] gal/min (liters/min) V5e REU-VAM620-US 20,000 Temperature Range 9,000 (NG) 20,200 (LP) 5. (20) º (7-60 ºC) [] Minimum activation flow is approximately 0.6 gallons/minute (2. liters/min) [2] Max temperature is 60 º (7 ºC) with the MCC-9 controller for commercial and hydronic applications only. [] Max temperature is 85 º (85 ºC) with the MCC-9 controller for commercial and hydronic applications only. 5 Rinnai ater Heater Service Manual

6 Schematic Diagrams Outdoor Model (NOT PRESENT ON ALL MODELS) (NOT PRESENT ON ALL MODELS) (LOCATED ON BRACKET NEAR AN ON SOME MODELS) Rinnai ater Heater Service Manual 6

7 Schematic Diagrams Indoor Model (NOT PRESENT ON ALL MODELS) (NOT PRESENT ON ALL MODELS) (LOCATED ON BRACKET NEAR AN ON SOME MODELS) 7 Rinnai ater Heater Service Manual

8 ault Isolation The Rinnai water heater has the ability to check its own operation continuously. If a fault occurs, an error code will flash on the display of the remote controller. This assists with diagnosing the fault and may enable you to overcome a problem without a service call. ARNING Some of the checks below may need to be done by a qualified service technician. Call a service technician for any remedy that involves gas or electricity. Call a service technician if you have any doubt or reservation about performing the remedy yourself. Accessing Operating Information Models MC-9 and MCC-9 To display the most recent error codes press and hold the On/Off button for 2 seconds. hile holding the On/ Off button press the button. The last 9 error codes will flash one after the other. To exit this mode press the On/Off and button as before. To display the water flow through the water heater press and hold the button for 2 seconds and without releasing the button press the On/Off button. To display the outlet water temperature press and hold the button for 2 seconds and without releasing the button press the On/Off button. Operation. ater low Begins. ater low Sensor sends pulses to the PC Board. PC Board senses flow greater than 0.6 GPM (approximate). iring Sequence begins. 2. iring Sequence. PC Board monitors inlet/outlet water temperature, temperature set point, and water flow rate. Combustion fan energized. Purges combustion chamber. Spark igniter begins sparking. Gas control valve opens to minimum fire rate. lame rod proves ignition. Spark igniter stops sparking. 4. Shut-down Sequence. PC Board senses flow rate less than 0.5 gpm (approximate). Gas control valve closes. ater flow control valve resets to standby position. Combustion fan runs for a short period of time at low speed. 5. Standby Mode. PC Board monitors water temperature and remote controls. reeze protection is activated as needed.. Normal Operation. PC Board monitors flame rod, fan motor frequency, outlet water temperature, controller temperature set point and water flow rate. Gas control valve modulates gas input to required firing rate. Combustion fan speed is adjusted for the required firing rate. ater flow control valve is adjusted as needed. Rinnai ater Heater Service Manual 8

9 ault Isolation Code ault Remedy 02 No burner operation during Service Call freeze protection mode 0 Power interruption during Bath ill (ater will not flow when power returns). 0 Air Supply or Exhaust Blockage Turn off all hot water taps. Press ON/O twice. Ensure Rinnai approved venting materials are being used. Check that nothing is blocking the flue inlet or exhaust. Check all vent components for proper connections. Ensure vent length is within limits. Ensure condensation collar was installed correctly. Verify dip switches are set properly. Check fan for blockage. No Ignition Check that the gas is turned on at the water heater, gas meter, or cylinder. Ensure gas type and pressure is correct. Ensure gas line, meter, and/or regulator is sized properly. Bleed all air from gas lines. Verify dip switches are set properly. Ensure appliance is properly grounded. Disconnect EZConnect or MSA controls to isolate the problem. Ensure igniter is operational. Check igniter wiring harness for damage. Check gas solenoid valves for open or short circuits. Remove burner cover and ensure all burners are properly seated. Remove burner plate and inspect burner surface for condensation or debris. 2 lame ailure Check that the gas is turned on at the water heater and gas meter. Check for obstructions in the flue outlet. Ensure gas line, meter, and/or regulator is sized properly. Ensure gas type and pressure is correct. Bleed all air from gas lines. Ensure proper Rinnai venting material was installed. Ensure condensation collar was installed properly. Ensure vent length is within limits. Verify dip switches are set properly. Ensure appliance is properly grounded. Disconnect keypad. Disconnect EZConnect or MSA controls to isolate the problem. Check power supply for loose connections. Check power supply for proper voltage and voltage drops. Ensure flame rod wire is connected. Remove flame rod and check for carbon build-up; clean with sand paper or emery cloth. Disconnect and reconnect all wiring harnesses on unit and PC board. Check all components for electrical short. Check gas solenoid valves for open or short circuits. Remove burner plate and inspect burner surface for condensation or debris. 9 Rinnai ater Heater Service Manual

10 ault Isolation Code ault Remedy 4 Thermal use Check gas type of unit and ensure it matches gas type being used. Check for restrictions in air flow around unit and vent terminal. Check for low water flow in a circulating system causing short-cycling. Ensure dip switches are set to the proper position. Check for foreign materials in combustion chamber and/or exhaust piping. Check heat exchanger for cracks and/or separations. Check heat exchanger surface for hot spots which indicate blockage due to scale buildup. Refer to instructions in manual for flushing heat exchanger. Measure resistance of safety circuit. Ensure high fire and low fire manifold pressure is correct. Check for improper conversion of product. 6 Over Temperature arning 2 Outgoing ater Temperature Sensor ault Heat Exchanger Outgoing Temperature Sensor ault 4 Combustion Air Temperature Sensor ault 52 Modulating Solenoid Valve Signal Abnormal 6 Combustion an ailure 65 ater low Control ault 7 SV0, SV, SV2, and SV Solenoid Valve Circuit ault 72 lame Sensing Device ault LC No code Scale Build-up in Heat Exchanger (when checking maintenance code history, 00 is substituted for LC ) Nothing happens when water flow is activated. Check for restrictions in air flow around unit and vent terminal. Check for low water flow in a circulating system causing short-cycling. Check for foreign materials in combustion chamber and/or exhaust piping. Check for clogged heat exchanger. Check sensor wiring for damage. Measure resistance of sensor. Clean sensor of scale build-up. Replace sensor. Check sensor wiring for damage. Measure resistance of sensor. Clean sensor of scale build-up. Replace sensor. Check for restrictions in air flow around unit and vent terminal. Check sensor wiring for damage. Measure resistance of sensor. Clean sensor of scale build-up. Ensure fan blade is tight on motor shaft and is in good condition. Replace sensor. Check modulating gas solenoid valve wiring harness for loose or damaged terminals. Measure resistance of valve coil. Ensure fan will turn freely. Check wiring harness to motor for damaged and/or loose connections. Measure resistance of motor winding. The water flow control valve has failed to close during the bath fill function. Immediately turn off the water and discontinue the bath fill function. Contact a state qualified or licensed contractor to service the appliance. Check wiring harness to all solenoids for damage and/or loose connections. Measure resistance of each solenoid valve coil. Ensure flame rod is touching flame when unit fires. Check all wiring to flame rod for damage. Remove flame rod and check for carbon build-up; clean with sand paper or emery cloth. Check inside burner chamber for any foreign material blocking flame at flame rod. Measure micro amp output of sensor circuit with flame present. Replace flame rod. lush heat exchanger. Refer to instructions in manual. Replace heat exchanger. NOTE: The LC code is the only code that will allow the unit to keep running. The display will alternate between the LC code and the temperature setting. The controller will continue to beep. The LC code will reset if power is turned off and then on. Clean inlet water supply filter. On new installations ensure hot and cold water lines are not reversed. Check for bleed over. Isolate unit from building by turning off hot water line to building. Isolate the circulating system if present. Open your pressure relief valve; if water is flowing, there is bleed over in your plumbing. Ensure you have at least the minimum flow rate required to fire unit. Ensure turbine spins freely. Measure the resistance of the water flow control sensor. Rinnai ater Heater Service Manual 0

11 Electrical Diagnostic Points R/C42e, R/C5e ire Color Voltage Resistance Connector No. Pin No. s (TR) Transformer Black - hite VAC 5-6 ohms 9 ~ 2 Blue - Brown 08-2 VAC 5-6 ohms 7 ~ (SV, SV2, SV, POV) Gas Valve and Modulating Solenoids (Main) Pink - Black E ~ 2 (SV) Black - Blue VDC.7-2 K ohms E2 2 ~ (SV2) Black - Yellow E 2 ~ 4 (POV) Pink - Pink 2-5 VDC 67-8 ohms C2 ~ 4 (M) ater low Servo Red - Blue - VDC ohms B 9 ~ 0 Gray - Brown 4-6 VDC N/A B 5 ~ 7 Gray - Yellow N/A N/A B 5 ~ 8 Gray - Orange - 4 VDC N/A B 5 ~ 6 NOTE: At the B connector on the PCB: gray wire turns to black, orange wire turns to red (QS) ater low Sensor Black - Red - VDC K ohms B 5 ~ 6 Yellow - Black 4-7 VDC -.4 mega ohms B ~ 5 Bypass low Control (only on R/C85e, R/C85ePLUS, R/C85i, R/C85iPLUS) Brown - hite 4 ~ 5 Orange - hite 2-6 VDC 2 ~ 5 (unit in operating 5-5 K ohms G Yellow - hite mode) ~ 5 Red - hite/ground ~ 5 (IG) Ignition System Gray - Gray VAC N/A ~ 2 (M) Combustion an Motor Red - Black 6-45 VDC N/A A ~ 2 hite - Black 5-0 VDC K ohms A 2 ~ 4 Yellow - Black ~ VDC K ohms A 2 ~ ith the meter set on hertz scale, hertz should be across the red and yellow wires at terminals 2 and. Rinnai ater Heater Service Manual

12 Electrical Diagnostic Points R/C42e, R/C5e ire Color Voltage Resistance Connector No. Pin No. s Thermal use / Overheat Switch Red - Red 2 VDC below ohm B - C B6 ~ C lame Rod Place one lead of the meter to the flame rod and the other to ground. ith the unit running, 5-50 VAC should be read. Set the meter to the µ amp scale and series the meter in line with the flame rod. Proper flame circuit should read µ amp or greater. If not, then remove the flame rod and check for carbon and damage. Thermistors Check all thermistors by inserting meter leads into each end of the thermistor plug. Set the meter to the 20 K ohm scale and read resistance. Applying heat to the thermistor bulb should decrease the resistance. Applying ice to the thermistor bulb should increase the resistance. Typical resistance values are:.4-4 K ohm for 59 ; K ohm for 86 ; K ohm for ; K ohm for 40 ; K ohm for 22 Outgoing ater Thermistor hite - hite see above B B ~ B4 Heat Exchanger Temperature Thermistor hite - hite see above B B ~ B2 Surge Protector Blue - Brown 08-2 VAC N/A 4 ~ 2 Blue - Brown 08-2 VAC N/A ~ ith the power off, check the continuity through the surge protector. Check by placing one meter lead on the top pin # and bottom pin #2. Check by placing one meter lead on the top pin # and bottom pin #. If there is continuity across both sets of points, then the surge protector is good. Controller Terminals D 0 - VDC digital K ohms D ~ rost Protection There are electrical heating elements mounted at different points to protect the water heater from freezing. heaters located on the hot water outlet line 26-0 ohms heater located on heat exchanger piping 8-86 ohms heater located on water flow sensor 6-9 ohms Amp fuses There are two inline amp glass fuses. Remove the fuse and check continuity through it. If there is continuity then the fuse is good. Rinnai ater Heater Service Manual 2

13 Electrical Diagnostic Points R70e, R/C85e(PLUS), R/C5i(PLUS), R/C85i(PLUS) ire Color Voltage Resistance Connector No. Pin No. s (TR) Transformer Black - hite VAC 5-6 ohms 9 ~ 2 Blue - Brown 08-2 VAC 5-6 ohms 7 ~ (SV, SV2, SV, POV) Gas Valve and Modulating Solenoids (Main) Pink - Black E ~ 2 (SV) Black - Yellow E2 2 ~ VDC.7-2 K ohms (SV2) Black - Blue E 2 ~ 4 (SV) Black - Brown E4 2 ~ 5 (POV) Pink - Pink 2-5 VDC 67-8 ohms C2 ~ 4 (M) ater low Servo Red - Blue - VDC ohms B 9 ~ 0 Gray - Brown 4-6 VDC N/A B 5 ~ 7 Gray - Yellow N/A N/A B 5 ~ 8 Gray - Orange - 4 VDC N/A B 5 ~ 6 NOTE: At the B connector on the PCB: gray wire turns to black, orange wire turns to red (QS) ater low Sensor Black - Red - VDC K ohms B 5 ~ 6 Yellow - Black 4-7 VDC -.4 mega ohms B ~ 5 Bypass low Control (only on R/C85e, R/C85ePLUS, R/C85i, R/C85iPLUS) Brown - hite 4 ~ 5 Orange - hite 2-6 VDC 2 ~ 5 (unit in operating 5-5 K ohms G Yellow - hite mode) ~ 5 Red - hite/ground ~ 5 (IG) Ignition System Gray - Gray VAC N/A 8 ~ 2 (M) Combustion an Motor Red - Black 6-45 VDC N/A A ~ 2 hite - Black 5-0 VDC K ohms A 2 ~ 4 Yellow - Black ~ VDC K ohms A 2 ~ ith the meter set on hertz scale, hertz should be across the red and yellow wires at terminals 2 and. Rinnai ater Heater Service Manual

14 Electrical Diagnostic Points R70e, R/C85e(PLUS), R/C5i(PLUS), R/C85i(PLUS) ire Color Voltage Resistance Connector No. Pin No. s Thermal use / Overheat Switch Red - Red 2 VDC below ohm B - C B6 ~ C lame Rod Place one lead of the meter to the flame rod and the other to ground. ith the unit running, 5-50 VAC should be read. Set the meter to the µ amp scale and series the meter in line with the flame rod. Proper flame circuit should read µ amp or greater. If not, then remove the flame rod and check for carbon and damage. Thermistors Check all thermistors by inserting meter leads into each end of the thermistor plug. Set the meter to the 20 K ohm scale and read resistance. Applying heat to the thermistor bulb should decrease the resistance. Applying ice to the thermistor bulb should increase the resistance. Typical resistance values are:.4-4 K ohm for 59 ; K ohm for 86 ; K ohm for ; K ohm for 40 ; K ohm for 22 Outgoing ater Thermistor hite - hite see above B B ~ B4 Heat Exchanger Temperature Thermistor hite - hite see above B B ~ B2 Surge Protector Blue - Brown 08-2 VAC N/A 6 ~ 2 Blue - Brown 08-2 VAC N/A 7 ~ ith the power off, check the continuity through the surge protector. Check by placing one meter lead on the top pin # and bottom pin #2. Check by placing one meter lead on the top pin # and bottom pin #. If there is continuity across both sets of points, then the surge protector is good. Controller Terminals D 0 - VDC digital K ohms D ~ rost Protection There are electrical heating elements mounted at different points to protect the water heater from freezing. heaters located on the hot water outlet line 26-0 ohms heater located on heat exchanger piping 8-86 ohms heater located on water flow sensor 6-9 ohms Amp fuses There are two inline amp glass fuses. Remove the fuse and check continuity through it. If there is continuity then the fuse is good. Rinnai ater Heater Service Manual 4

15 Electrical Diagnostic Points R/C98e(ASME), R/C98i(ASME) ire Color Voltage Resistance Connector No. Pin No. s (SV, SV2, SV, POV) Gas Valve and Modulating Solenoids (Main) Pink - Black 4 ~ 5() (SV) Black - Red 2 ~ 4() - VDC ohms (SV2) Black - Orange 2 ~ 4() (SV) Black - Yellow 4 ~ 4() (POV) Orange - Orange - 5 VDC 67-8 ohms E2 ~ 4(E) (M) ater low Servo Red - Blue - VDC N/A G6 5 ~ 6(G) Gray - Brown (closed position) below VDC Limiter On 4-6 VDC Limiter Off G6 8 ~ (G) Gray - Yellow (open below VDC Limiter On position) 4-6 VDC Limiter Off G6 7 ~ (G) NOTE: At the G connector on the PCB: gray wire turns to black (QS) ater low Sensor Black - Red - VDC N/A G 9 ~ 5(G) Yellow - Black 4-7 VDC N/A G ~ 5(G) Bypass low Control Brown - hite (H) ~ 9(G) Orange - hite 2-6 VDC (H) ~ 9(G) (unit in operating 5-5 K ohms H Yellow - hite mode) 4(H) ~ 9(G) Red - hite/ground 2(H) ~ 9(G) NOTE: At the G connector on the PCB: white wire turns to red (IG) Ignition System Gray - Gray VAC N/A C ~ 2(C) (M) Combustion an Motor Red - Black 6-45 VDC N/A B ~ 2(B) hite - Black 5-0 VDC N/A B 2 ~ 4(B) Yellow - Black ~ VDC N/A B 2 ~ (B) ith the meter set on hertz scale, hertz should be across the white and black wires at terminals 2 and 4. 5 Rinnai ater Heater Service Manual

16 Electrical Diagnostic Points R/C98e(ASME), R/C98i(ASME) ire Color Voltage Resistance Connector No. Pin No. s Thermal use Blue - Red 2 VDC below ohm E6 0(G) ~ (E) Overheat Switch Blue - Red 2 VDC below ohm N/A lame Rod Place one lead of the meter to the flame rod and the other to ground. ith the unit running, 5-50 VAC should be read. Set the meter to the µ amp scale and series the meter in line with the flame rod. Proper flame circuit should read µ amp or greater. If not, then remove the flame rod and check for carbon build-up. Clean with sand paper or emery cloth. Thermistors Check all thermistors by inserting meter leads into each end of the thermistor plug. Set the meter to the 20 K ohm scale and read resistance. Applying heat to the thermistor bulb should decrease the resistance. Applying ice to the thermistor bulb should increase the resistance. Typical resistance values are:.4-4 K ohm for 59 ; K ohm for 86 ; K ohm for ; K ohm for 40 ; K ohm for 22 Outgoing ater Thermistor hite - hite see above G5 2 ~ (G) Heat Exchanger Temperature Thermistor hite - hite see above G4 4 ~ (G) Surge Protector Black - hite 08-2 VAC N/A D Black - hite 08-2 VAC N/A D2 ~ 2(D) ith the power off, check the continuity through the surge protector. Check by placing one meter lead on the top pin # and bottom pin #2. Check by placing one meter lead on the top pin #2 and bottom pin #. If there is continuity across both sets of points, then the surge protector is good. Controller Black - Black 0 - VDC digital N/A A ~ (A) rost Protection hite - hite 20 VAC * 50 ohms D4 N/A hite - hite 60 VAC * 60 ohms D5 N/A hite - hite 60 VAC* 60 ohms D6 N/A * only when rost Sensing Switch (D) is ON Amp fuses There are two inline amp glass fuses. Remove the fuse and check continuity through it. If there is continuity then the fuse is good. Rinnai ater Heater Service Manual 6

17 Electrical Diagnostic Points V5e, R6LSe ire Color Voltage Resistance Connector No. Pin No. s (SV, SV2, SV, POV) Gas Valve and Modulating Solenoids (Main) Pink - Black 7-4 ohms 5 8 ~ 9 (SV) Black - Blue - VDC 5-4 ohms 6 9 ~ 0 (SV2) Black - Yellow 7-4 ohms 7 9 ~ (POV) Pink - Pink 2-5 VDC 67-8 ohms ~ 4 (M) ater low Servo Red - Blue - VDC ohms E5 9 ~ 8 Gray - Brown 4-6 VDC N/A E5 4 ~ 5 Gray - Yellow N/A N/A E5 4 ~ 6 NOTE: At the E connector on the PCB: gray wire turns to black (QS) ater low Sensor Black - Red - VDC K ohms E2 ~ 4 Yellow - Black 4-7 VDC -.4 mega ohms E2 ~ 4 (IG) Ignition System Gray - Gray 90-0 VAC N/A B ~ 2 (M) Combustion an Motor Red - Black 6-45 VDC N/A D ~ 2 hite - Black 5-0 VDC K ohms D 4 ~ 2 Yellow - Black ~ VDC K ohms D ~ 2 ith the meter set on hertz scale, hertz should be across the white and black wires at terminals 2 and 4. 7 Rinnai ater Heater Service Manual

18 Electrical Diagnostic Points V5e, R6LSe ire Color Voltage Resistance Connector No. Pin No. s Thermal use / Overheat Switch Red - hite 2 VDC below ohm E6 E5 ~ lame Rod Place one lead of the meter to the flame rod and the other to ground. ith the unit running, 5-50 VAC should be read. Set the meter to the µ amp scale and series the meter in line with the flame rod. Proper flame circuit should read µ amp or greater. If not, then remove the flame rod and check for carbon and damage. Thermistors Check all thermistors by inserting meter leads into each end of the thermistor plug. Set the meter to the 20 K ohm scale and read resistance. Applying heat to the thermistor bulb should decrease the resistance. Applying ice to the thermistor bulb should increase the resistance. Typical resistance values are:.4-4 K ohm for 59 ; K ohm for 86 ; K ohm for ; K ohm for 40 ; K ohm for 22 Outgoing ater Thermistor hite - hite see above E4 2 ~ Heat Exchanger Temperature Thermistor Pink - hite see above E 2 ~ 0 Surge Protector Black - hite 08-2 VAC N/A C2 ~ Black - hite 08-2 VAC N/A C ith the power off, check the continuity through the surge protector. Check by placing one meter lead on the top pin # and bottom pin #. Check by placing one meter lead on the top pin # and bottom pin #. If there is continuity across both sets of points, then the surge protector is good. Controller Terminals A 0 - VDC K ohms A ~ rost Protection heaters located on the hot water outlet line heater located on heat exchanger piping heater located on water flow sensor ohms ohms ohms Amp fuses There are two inline amp glass fuses. Remove the fuse and check continuity through it. If there is continuity then the fuse is good. Rinnai ater Heater Service Manual 8

19 Electrical Diagnostic Points R50LSi, R75LSe, R75LSi, R94LSe, R94LSi ire Color Voltage Resistance Connector No. Pin No. s (SV, SV2, SV, POV) Gas Valve and Modulating Solenoids (Main) Pink - Black H5 6 ~ 7 (SV) Black - Yellow H6 5 ~ 6 - VDC ohms (SV2) Black - Blue H7 4 ~ 6 (SV) Black - Brown H8 ~ 6 (POV) Pink - Pink 2-5 VDC 67-8 ohms H 9 ~ 0 (M) ater low Servo Red - Blue - VDC ohms 7 9 ~ 0 Gray - Brown 4-6 VDC N/A 7 5 ~ 7 Gray - Yellow N/A N/A 7 5 ~ 8 NOTE: At the connector on the PCB: gray wire turns to black, orange wire turns to red (QS) ater low Sensor Black - Red - VDC K ohms 2 ~ Yellow - Black 4-7 VDC -.4 mega ohms 2 2 ~ Bypass low Control (only on R94LSe and R94LSi) Brown - hite ~ 5 Orange - hite 2-6 VDC 2 ~ 5 (unit in operating 5-5 K ohms G Yellow - hite mode) ~ 5 Red - hite/ground 4 ~ 5 (IG) Ignition System Gray - Gray 90-0 VAC N/A C ~ 2 (M) Combustion an Motor Red - Black 6-45 VDC N/A E ~ 2 hite - Black 5-0 VDC K ohms E 2 ~ 4 Yellow - Black ~ VDC K ohms E 2 ~ ith the meter set on hertz scale, hertz should be across the red and yellow wires at terminals 2 and 4. 9 Rinnai ater Heater Service Manual

20 Electrical Diagnostic Points R50LSi, R75LSe, R75LSi, R94LSe, R94LSi ire Color Voltage Resistance Connector No. Pin No. s Thermal use / Overheat Switch Red - Red - VDC below ohm 6 H 6 ~ H2 lame Rod Place one lead of the meter to the flame rod and the other to ground. ith the unit running, 5-50 VAC should be read. Set the meter to the µ amp scale and series the meter in line with the flame rod. Proper flame circuit should read µ amp or greater. If not, then remove the flame rod and check for carbon and damage. Thermistors Check all thermistors by inserting meter leads into each end of the thermistor plug. Set the meter to the 20 K ohm scale and read resistance. Applying heat to the thermistor bulb should decrease the resistance. Applying ice to the thermistor bulb should increase the resistance. Typical resistance values are:.4-4 K ohm for 59 ; K ohm for 86 ; K ohm for ; K ohm for 40 ; K ohm for 22 Outgoing ater Thermistor hite - hite see above 5 ~ 4 Heat Exchanger Temperature Thermistor Pink - hite see above 4 ~ Intake Air Thermistor (only on R50LSi, R75LSi, R94LSi) Orange - hite see above ~ 2 Surge Protector Black - hite 08-2 VAC N/A D2 ~ Blue - Brown 08-2 VAC N/A D ~ ith the power off, check the continuity through the surge protector. Check by placing one meter lead on the top pin # and bottom pin #. Check by placing one meter lead on the top pin # and bottom pin #. If there is continuity across both sets of points, then the surge protector is good. Controller Terminals B 0 - VDC K ohms B ~ rost Protection There are electrical heating elements mounted at different points to protect the water heater from freezing. heaters located on the hot water outlet line ohms heater located on heat exchanger piping ohms heater located on water flow sensor ohms Amp fuses There are two inline amp glass fuses. Remove the fuse and check continuity through it. If there is continuity then the fuse is good. Rinnai ater Heater Service Manual 20

21 Electrical Diagnostic Points R98LSe(ASME), R98LSi(ASME) ire Color Voltage Resistance Connector No. Pin No. s (SV, SV2, SV, POV) Gas Valve and Modulating Solenoids (Main) Pink - Black ohms H 6 ~ 7 (SV) Black - Red 7-4 ohms H4 5 ~ 6 - VDC (SV2) Black - Orange 7-4 ohms H5 4 ~ 6 (SV) Black - Yellow 7-4 ohms H6 ~ 6 (POV) Orange - Orange 2-5 VDC 67-8 ohms H2 9 ~ 0 (M) ater low Servo Red - Blue - VDC ohms 5 9 ~ 0 Gray - Brown 4-6 VDC N/A 5 5 ~ 7 Gray - Yellow N/A N/A 5 5 ~ 8 NOTE: At the connector on the PCB: gray wire turns to black (QS) ater low Sensor Black - Red - VDC K ohms 2 ~ Yellow - Black 4-7 VDC -.4 mega ohms 2 2 ~ Bypass low Control Brown - hite ~ 5 Orange - hite 2-6 VDC 2 ~ 5 (unit in operating 5-5 K ohms G Yellow - hite mode) ~ 5 Red - hite/ground 4 ~ 5 (IG) Ignition System Gray - Gray 90-0 VAC N/A C ~ 2 (M) Combustion an Motor Red - Black 6-45 VDC N/A E ~ 2 hite - Black 5-0 VDC K ohms E 2 ~ 4 Yellow - Black ~ VDC K ohms E 2 ~ ith the meter set on hertz scale, hertz should be across the red and yellow wires at terminals 2 and 4. 2 Rinnai ater Heater Service Manual

22 Electrical Diagnostic Points R98LSe(ASME), R98LSi(ASME) ire Color Voltage Resistance Connector No. Pin No. s Thermal use / Overheat Switch Red - hite - VDC below ohm 6 H 6 ~ H2 lame Rod Place one lead of the meter to the flame rod and the other to ground. ith the unit running, 5-50 VAC should be read. Set the meter to the µ amp scale and series the meter in line with the flame rod. Proper flame circuit should read µ amp or greater. If not, then remove the flame rod and check for carbon and damage. Thermistors Check all thermistors by inserting meter leads into each end of the thermistor plug. Set the meter to the 20 K ohm scale and read resistance. Applying heat to the thermistor bulb should decrease the resistance. Applying ice to the thermistor bulb should increase the resistance. Typical resistance values are:.4-4 K ohm for 59 ; K ohm for 86 ; K ohm for ; K ohm for 40 ; K ohm for 22 Outgoing ater Thermistor hite - hite see above 4 ~ 4 Heat Exchanger Temperature Thermistor Pink - hite see above ~ Surge Protector Black - hite 08-2 VAC N/A D2 ~ Blue - Brown 08-2 VAC N/A D ~ ith the power off, check the continuity through the surge protector. Check by placing one meter lead on the top pin # and bottom pin #. Check by placing one meter lead on the top pin # and bottom pin #. If there is continuity across both sets of points, then the surge protector is good. Controller Terminals B 0 - VDC K ohms B ~ rost Protection There are electrical heating elements mounted at different points to protect the water heater from freezing. Voltage through this circuit should be 20 VAC. heater located on the hot water outlet line 5-85 ohms heater located on heat exchanger piping ohms heater located on water flow sensor 5-85 ohms Amp fuses There are two inline amp glass fuses. Remove the fuse and check continuity through it. If there is continuity then the fuse is good. Rinnai ater Heater Service Manual 22

23 iring Diagram R/C42e, R/C5e 2 Rinnai ater Heater Service Manual

24 iring Diagram R70e, R/C85e(PLUS) Rinnai ater Heater Service Manual 24

25 iring Diagram R/C5i(PLUS), R/C85i(PLUS) 25 Rinnai ater Heater Service Manual

26 iring Diagram R/C98i(ASME), R/C98e(ASME) Rinnai ater Heater Service Manual 26

27 MODULATING VALVE CURRENT ADJUSTING D (CN0) BK R 4 Y R E Y BL R BR BK Y P 2 Y (CN5) (CN) BK BL Gas pressure P Y P A P A C 2 MAX MIN (CN4) R (CN) 4 BR BL Dip S Dip S2 GY GY B REMOTE CONTROLLER BK BK SPARK GY GY IG ELECTRODE IGNITER GND O B (CN2) iring Diagram COLOR CODING BK:Black BR:Brown R :Red O :Orange Y :Yellow G :Green BL:Blue GY:Grey :hite P :Pink Spare Parts Only ROST SENSING SITCH BLBL ANTI-ROST HEATER C5 C C2 C4 BK ANTI-ROST HEATER USE (A) AC20 C20V BK V5e, R6LSe BK P BL BK Y BK HOT NEUTRAL GROUND D M Y BKR COMBUSTION AN G E BL BR G/Y C G R REEZE PROTECTION OPTION GND SURGE PROTECTOR G/Y E2 R Y BK R YBK GND ATER LO SENSOR QS E P HEAT EXCHANGER OUTGOING ATER THERMISTOR E4 OUTGOING ATER THERMISTOR 27 Rinnai ater Heater Service Manual E5 GY BL R BR Y R BL BR YGY ATER LO CONTROL DEVICE E6 THERMAL USES BL R 2 R OVERHEAT SITCH P MODULATING SOLENOID VALVE POV Y LAME ROD 4 5 SV0 MAIN SOLENOID VALVE 6 SV 7 SV2 SOLENOID VALVE (SMALL) SOLENOID VALVE 2 (LARGE)

28 iring Diagram R50LSi, R75LSe, R75LSi, R94LSe, R94LSi COLOR CODING BY-PASS SERVO MODEL ONLY BY-PASS LO CONTROL DEVICE REEZE PROTECTION OPTION ATER LO SENSOR 2 R R QS Y Y BK BK INDOOR MODEL ONLY AIR TEMPERATURE THERMISTOR HEAT EXCHANGER THERMISTOR OUTGOING ATER THERMISTOR 7 R BL BR Y GY ATER LO CONTROL DEVICE THERMAL USES H2 4 5 G R O P GY BL R BR Y E M COMBUSTION AN OVERHEAT SITCH R R BR O Y R 6 H G BK Y R R R O P 5 R Y ORBR BL BR Y (CN2) RBK G (CN7) G Y E 4 Y R BK (CN5) 2 (CN2) R P P RBK A (CN9) H P Y BR Y BK BL MAX MIN Dip S O O B (CN) Dip S2 C GY GY for REU-EZC (Optional) MODULATING VALVE CURRENT ADJUSTING Gas pressure Gas type 2 4 Spare Parts Only 5 6 (CN4) BK BK C B GY GY IGNITER IG :hite BK:Black BR:Brown R :Red BL:Blue Y :Yellow P :Pink O :Orange G :Green GY:Gray REMOTE CONTROLLER SPARK ELECTRODE GND MODULATING SOLENOID VALVE LAME ROD MAIN SOLENOID VALVE SOLENOID VALVE SOLENOID VALVE 2 SOLENOID VALVE H POV H4 P P Y SV0 SV SV2 SV H5 H6 H7 BK P Y BK BL BK H8 BR BK G/Y GND BL BR SURGE PROTECTOR D G/Y GND D2 BK (CN) BL BR BK D USE (A) BL BL () () BL BL AC20V HOT NEUTRAL GROUND D ROST SENSING SITCH D5 ANTI-ROST HEATER D4 ANTI-ROST HEATER Rinnai ater Heater Service Manual 28

29 iring Diagram R98LSe(ASME), R98LSi(ASME) for REU-EZC (Optional) BR O Y R Y OR BR BY-PASS LO CONTROL DEVICE MAX MODULATING VALVE CURRENT ADJUSTING G R MIN REEZE PROTECTION (OPTIONAL) Dip S O RBK A 2 Y G RBK ATER LO R R Y SENSOR QS YBK BK Gas pressure BL BR P 29 Rinnai ater Heater Service Manual P HEAT EXCHANGER ATER THERMISTOR Y R 4 OUTGOING ATER ATER THERMISTOR B B E 4 GY 2 (CN2) BK BK BL R BR Y R BL BR YGY Y BK R Y Y R P O ATER LO CONTROL DEVICE O BK O COMBUSTION AN M BK Y E R C IG GY GY GY GY IGNITER GND O H2 MODULATING SOLENOID VALVE POV H P USE (A) BK AC20V HOT NEUTRAL GROUND REMOTE CONTROLLER SPARK ELECTRODE 5 6 Gas type 4 Spare Parts Only 2 G G (CN7) 5 (CN9) (CN5) Dip S2 O H (CN2) (CN) C (CN4) D2 D (CN) BK 6 THERMAL USES R R H RR OVERHEAT SITCH BK SV0 MAIN SOLENOID VALVE BK H4 COLOR CODING :hite BK:Black BR:Brown R :Red BL:Blue Y :Yellow P :Pink O :Orange G :Green GY:Gray BL BL ROST SENSING SITCH D D4 D5 D6 ANTI-ROST HEATER A 5 G/Y SURGE PROTECTOR R BK SV SOLENOID VALVE (CENTER) D BK H5 G/Y Y LAME ROD O BK SV2 SOLENOID VALVE 2 (LET) H7 H6 Y BK GND GND SV SOLENOID VALVE (RIGHT)

30 lushing the Heat Exchanger An LC or 00 error code indicates the unit is beginning to lime up and must be flushed. ailure to flush the appliance will cause damage to the heat exchanger. Damage caused by lime build-up is not covered by the unit s warranty. After flushing, reset the LC fault code by turning off the power to the unit and turning the power back on.. Disconnect electrical power to the water heater. 2. Close the shutoff valves on both the hot water and cold water lines (V and V4).. Connect pump outlet hose (H) to the cold water line at service valve V2. 4. Connect drain hose (H) to service valve V. 5. Pour approximately 4 gallons of virgin, food grade, white vinegar or citric acid into pail. 6. Place the drain hose (H) and the hose (H2) to the pump inlet into the cleaning solution. 7. Open both service valves (V and V2) on the hot water and cold water lines. 8. Operate the pump and allow the cleaning solution to circulate through the water heater for at least 45 minutes. 9. Turn off the pump. 0. Rinse the cleaning solution from the water heater as follows: a. Remove the free end of the drain hose (H) from the pail. b. Close service valve, (V2), and open shutoff valve, (V4). Do not open shutoff valve, (V). c. Allow water to flow through the water heater for 5 minutes d. Close service valve, (V), and open shutoff valve, (V).. Disconnect all hoses. 2. ith (V4) closed, remove the in-line filter at the cold water inlet and clean out any residue. Place filter back into unit and open (V4).. Restore electrical power to the water heater. H V Rinnai ater Heater V V2 In-line ilter V4 Gas Supply Hot ater Line Cold ater Line 5gallonpailof virgin,food grade, white vinegar (or virgin, food grade, citric acid). H2 Circulating Pump H KEY /4" Ball Valve /4" Union Check Valve Pressure Relief Valve S Pressure Regulator Circulating Pump Boiler Drain Valve Solenoid Valve Rinnai ater Heater Service Manual 0

31 Component Replacement Instructions Gas Control Assembly R/C42e, R/C5e, V5e, R6LSe. Turn off the gas supply. 2. Turn off the 20 V power supply.. Remove four screws securing the front panel. Remove front panel. 4. Move aside the ignition line by pulling it out from the clear plastic tubing. (igure ) 5. Remove the six screws that attach the gas manifold to the combustion chamber (part of the heat exchanger assembly). (igure ) 6. Remove the three screws that attach the gas manifold to the gas valve. Pull out the gas manifold. (igure ) igure Ignition line Six screws Three screws Cable tie 7. Remove the screw on the gas valve holding the cable tie. 8. Remove the screws attaching the gas connection to the underneath side of the water heater. (igure 2) igure 2 Regulator screw access Gas connection attached with screws 9. Pull the gas connection down to disconnect it from the gas control assembly. 0. Pull out the gas control assembly. Remove the wire harness from the 4 solenoids. Rinnai ater Heater Service Manual

32 Component Replacement Instructions Gas Control Assembly R/C42e, R/C5e, V5e, R6LSe ARNING ailure to correctly assemble the components according to these instructions may result in a gas leak or explosion.. Install the gas valve and attach the wire harness to the 4 solenoids. (igure ) 2. Install the gas connection with screws. igure black / yellow (large solenoid) black / blue (small solenoid) SV0 black / pink POV pink / pink (connector not shown). Replace the two circular gaskets (included in kit) in the gas valve. Make sure that the ribbed side faces toward the manifold and that the flat side faces toward the gas valve. (igure 4) 4. Start the three screws that attach the gas manifold to the gas valve. Tighten the six screws that hold the gas manifold to the combustion chamber. inish tightening the three screws that hold the gas manifold to the gas valve. 5. Attach ignition line. 6. Perform the Gas Pressure Setting Procedure. igure 4 Circular gaskets Rinnai ater Heater Service Manual 2

33 Component Replacement Instructions Gas Control Assembly R/C5i(PLUS), R70e, R/C85e(PLUS), R/C85i(PLUS), R50LSi, R75LSe, R75LSi, R94LSe, R94LSi. Turn off the gas supply. 2. Turn off the 20 V power supply.. Remove four screws securing the front panel. Remove front panel. 4. Pull out wire harness connector at the gas manifold assembly. See igure. 5. Move aside the ignition line by pulling it out from the clear plastic tubing. 6. Remove the six screws that attach the gas manifold to the combustion chamber (part of the heat exchanger assembly). 7. Remove the three screws that attach the gas manifold to the gas valve. Pull out the gas manifold. Ignition line Six screws ire harness connector PC Board (dip switches) Three screws igure 8. Remove the four screws attaching the gas connection to the underneath side of the water heater. See igure 2. Regulator screw access igure 2 Gas connection attached with 4 screws 9. Pull the gas connection down to disconnect it from the gas control assembly. 0. Pull out the gas control assembly. Remove the wire harness from the 4 solenoids. ARNING ailure to correctly assemble the components according to these instructions may result in a gas leak or explosion.. Replace the O-ring (included in kit) where the assembly attaches to the gas connection. Make sure the old O-ring is removed and discarded. Install the new gas control assembly. Rinnai ater Heater Service Manual

34 Component Replacement Instructions Gas Control Assembly R/C5i(PLUS), R70e, R/C85e(PLUS), R/C85i(PLUS), R50LSi, R75LSe, R75LSi, R94LSe, R94LSi 2. Attach wire harness to the 4 solenoids as shown in igure below. SV2 black / blue SV black / yellow SV0 black / pink igure POV pink / pink (connector not shown). Install the gas manifold using 2 new packings (included in kit) between the manifold and the heat exchanger. Replace the two circular gaskets (included in kit) in the gas valve. Make sure that the ribbed side faces toward the manifold and that the flat side faces toward the gas valve. (igure 5). Upper packing Lower packing (U shaped) Circular gaskets in gas valve igure 4 igure 5 4. Start the three screws that attach the gas manifold to the gas valve. Tighten the six screws that hold the gas manifold to the combustion chamber. inish tightening the three screws that hold the gas manifold to the gas valve. 5. Attach wiring harness connector (black & brown wires) to the gas manifold. 6. Attach ignition line. 7. Perform the Gas Pressure Setting Procedure. Rinnai ater Heater Service Manual 4

35 Component Replacement Instructions Gas Control Assembly. Turn off the gas supply. 2. Turn off the 20 V power supply.. Remove four screws securing the front panel. Remove front panel. 4. On indoor models, remove the bracket holding the controller ( screw). (igure ) 5. Move aside the ignition line by pulling it out from the clear plastic tubing. (igure ) 6. Remove the 5 screws that attach the gas manifold to the combustion chamber (part of the heat exchanger assembly). (igure 2) 7. Remove the 2 screws that attach the gas manifold to the gas valve. These screws are machine screws and must be used at these locations. (igure 2) 8. Pull out the gas manifold and remove the connector at the ignitor at the left side of the gas manifold. 9. Remove the screws attaching the gas connection to the underneath side of the water heater. (igure ) 0. Remove the screw attaching the gas valve to the rear of the case.. Pull the gas connection down to disconnect it from the gas control assembly. Bracket screw igure (indoor models) 5 screws (gas manifold) R/C98e(ASME), R/C98i(ASME), R98LSe(ASME), R98LSi(ASME) 2 machine screws (gas valve) igure 2 ater line connections Regulator screw access igure Gas connection attached with screws 5 Rinnai ater Heater Service Manual

36 Component Replacement Instructions Gas Control Assembly R/C98e(ASME), R/C98i(ASME), R98LSe(ASME), R98LSi(ASME) ARNING ailure to correctly assemble the components according to these instructions may result in a gas leak or explosion. 2. Pull out the gas control assembly. Remove the wire harness from the 2 solenoids.. Install the gas valve and attach the wire harness to the 2 solenoids. (igure 4) black / orange orange / orange igure 4 4. Install the gas connection with screws. 5. Replace the circular gasket (included in kit) in the gas valve. Make sure that the ribbed side faces toward the manifold and that the flat side faces toward the gas valve. (igure 5) 6. Start the 2 screws that attach the gas manifold to the gas valve. Tighten the 5 screws that hold the gas manifold to the combustion chamber. inish tightening the 2 screws that hold the gas manifold to the gas valve. 7. Attach ignition line. 8. On indoor models, install the bracket with the controller. 9. Perform the Gas Pressure Setting Procedure. Gasket igure 5 Rinnai ater Heater Service Manual 6

37 Component Replacement Instructions an R/C42e, R/C5e, V5e, R6LSe. Turn off the gas supply. 2. Turn off the 20 V power supply.. Turn off the water supply. 4. Remove four screws securing the front panel. Remove front panel. 5. On the V5e and R6LSe, remove the screws () holding the bracket with the surge protector. (igure ) 6. Disconnect the wire harness at the fan assembly. (igure 2) 7. On the V5e and R6LSe, remove the screw attaching the bracket with the ignitor to the bottom of the burner case. (igure 2) 8. Remove the three screws attaching the fan sub -assembly to the fan casing. (igure ) 9. Pull out the fan sub-assembly. 0. Install the new fan sub-assembly and tighten with three screws.. On the V5e and R6LSe, install the bracket with the ignitor with one screw. 2. Attach the wire harness to the fan assembly (white, yellow, black, red wires).. On the V5e and R6LSe, install the bracket with the surge protector with three screws. 4. Install front panel using 4 screws. 5. Turn on water supply, power supply, and gas supply. igure igure 2 ire Harness Connector 2 screws at bottom screw igure screws 7 Rinnai ater Heater Service Manual

38 Component Replacement Instructions an R70e, R/C85e(PLUS), R75LSe, R94LSe. Turn off the gas supply. 2. Turn off the 20 V power supply.. Turn off the water supply. 4. Remove four screws securing the front panel. Remove front panel. 5. Disconnect wire harness at the fan assembly. Disconnect the air temperature thermistor (two white wires) at the connection with the white and orange wires within the wire bundle. 6. Pull out the harness attached to the solenoid on the manifold to make room to pull out the fan assembly. 7. Remove the two screws that attach the fan assembly to the bottom of the burner. igure Two screws Solenoid on the manifold ire harness connection on the fan assembly 8. Pull out the fan assembly. 9. Install the fan assembly by inserting the tab on the fan assembly into the slot at the base of the heat exchanger and attaching with two screws. 0. Attach the wire harness to the solenoid on the gas manifold (brown, black wires).. Attach the wire harness to the fan assembly (white, yellow, black, red wires). 2. Attach the air temperature thermistor (white, white wires) to the wire harness.. Install front panel using 4 screws. 4. Turn on water supply, power supply, and gas supply. Rinnai ater Heater Service Manual 8