Rinnai Q series Troubleshooting Manual
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Rinnai Q series Troubleshooting Manual

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Troubleshooting Manual
WARNING
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 product.
You MUST be a qualified service person before proceeding with these test instructions.
Before checking resistance readings, turn off power source to unit and then isolate each item to be checked
from the circuit by unplugging it.
When setting gas pressures on one of these units, please check the complete model number you are trouble-
shooting. Gas pressures and dip switches can vary among models. Always check the rating plate for complete
information and follow directions.
CAUTION
Label all wires prior to disconnection when
servicing controls. Wiring errors can cause
improper and dangerous operation.
Q - Series Boiler
If any of the original wire as supplied with the appliance must
be replaced, it must be replaced with type 18 AWG wire or its
equivalent.
1
008082013GW

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Summary of Contents for Rinnai Q series

  • Page 1 Q - Series Boiler Troubleshooting Manual WARNING 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 product. You MUST be a qualified service person before proceeding with these test instructions. Before checking resistance readings, turn off power source to unit and then isolate each item to be checked from the circuit by unplugging it.

  • Page 2: Table Of Contents

    Table of Contents Code Numbers Page # Boiler Description …………………………………………………………………………………………………………………………. 4 Error indication (Short reference) ………………………………………………………………………………………………... 5 BL 01 …………………………………………………………………………………………………………………………………………….. 6 BL 05 …………………………………………………………………………………………………………………………………………….. 7 BL 11 …………………………………………………………………………………………………………………………………………….. 8 BL 12 …………………………………………………………………………………………………………………………………………….. 9 BL 60 …………………………………………………………………………………………………………………………………………….. 10 BL 67 …………………………………………………………………………………………………………………………………………….. 11 BL 80 ……………………………………………………………………………………………………………………………………………..

  • Page 3: Table Of Contents

    © 2013 Rinnai America Corporation • 103 International Drive, Peachtree City, GA 30269 Toll-Free:1-800621-9419 • Phone: 678-829-1700 • www.rinnai.us Rinnai is continually updating and improving products; therefore, specifications are subject to change without prior notice. Local, state, provincial and federal codes must be adhered to prior to and upon installation. 008082013GW...
  • Page 4 008082013GW...
  • Page 5 Parts of the Boiler 008082013GW...

  • Page 6: Error Indication (Short Reference)

    Block and Errors - Error indication (short reference) A detected error is indicated on the display by means of a blocking or error messages. A distinction should be made between these two messages due to the fact that a blocking code can be of a temporary nature, however, error messages are fixed “lockouts”...
  • Page 7 Rectify error by determining which external contact is open. If external contacts are not being The 120 volt external pump is for used place jumper across terminals 24 & 25 E and QP model boilers If multiple boiler safeties are to be wired in series check with your local inspector or the local or State codes to see if this is allowed in your area before proceeding.
  • Page 8 BL 05 Outdoor sensor contact open (not connected) Rectify error by determining if outdoor sensor is faulty, wiring to senor is broken or damaged or if the connection at terminal 18/19 on main control board is properly connected. 008082013GW...
  • Page 9 BL 11 Maximum average ΔT of T1 supply sensor and T2 return sensor for central heating is repeatedly exceeded. Operation is normally possible for the hot water supply during the block. The pump continues to operate at minimum capacity during the block. Rectify Issue, Check following 1.
  • Page 10 BL 12 Maximum average ΔT of supply sensor and return sensor for hot water is repeatedly exceeded. Operation is normally possible for the central heating installation during the block. The pump continues to operate at minimum capacity during Rectify Issue, Check following 1.
  • Page 11 MCBA. The sub PC board must be from a conversation kit for the same gas type as your boiler. If conversion parts are not locally accessible contact Rinnai Tech Support for assistance. These parameters cannot be accessed in the field and may require special instructions in an emergency situation.
  • Page 12 A temperature difference has been detected A temperature difference has been detected between the supply T1 sensor and the return T2 between the supply and return sensor while sensor while the burner is not in operation. After the burner is not in operation. After the the average ΔT has disappeared, the blocking average ΔT has disappeared, the block will code will go away.
  • Page 13 This is the location of the T5 sensor if installed. If the red tab is in place this sensor was never installed, which means the circuit has somehow been jumped out. Contact Rinnai tech support for assist if you get the bL80 without the T5 sensor being installed.
  • Page 14 Explanation: The bL81 can be triggered if the flue gas plug has gotten wet and then dried out. (MCBA sees resistance when wet and then sees no resistance when dry) This tricks the MCBA into thinking that a flue gas sensor was installed and then removed in which the bL 81 is triggered.
  • Page 15 Flue sensor or thermostat contact open 008082013GW...
  • Page 16 This can occur on a Q Boiler when the factory jumper on the flue gas sensor is loose or has fallen out. 212˚F is the default temperature setting for parameter 84. Verify to see if the temperature setting for this parameter is set higher than the default.
  • Page 17 Check the installation for the presence of air. AIR: if boiler, inner boiler piping, or Low Loss If there is a secondary pump installed and it Header has a large air bubble in it the is not hydraulically separated, it could cause pressure sensor will not see the pressure a loss of pressure difference.
  • Page 18 The frequency of the power supply deviates more than + or - 1.5 Hz. If using a back-up generator ensure it is properly grounded and providing a clean steady voltage and sign wave of 59.3 to 60.8 008082013GW...
  • Page 19 Boiler has not been burning but an ionization flow (flame) has been detected. Check whether the ionization cable and/or the electrode are responsible for a short circuit. Remove the plugs from the ionization cable connected to the control unit and to the electrode.
  • Page 20 E 01 24 volt short circuit Remove all 24 volt connectors, such as: fan, pump, any three port valve and the 24 volt plug to the connecting block. Check for a short circuit in the disconnected components. Next; switch on power to the control board with all the 24 volt components disconnected.
  • Page 21 Ignition Failure Issue Flame Failure Issue Ionization flow, ionization cable or 02 setting Due to insufficient ionization the burner has shut down after ignition The minimum ionization current should be 4 micro amps (Check INFO step 48, the O2 should be a minimum of 4.4% for NG or 4.8% for LP.
  • Page 22 Control unit error - Connector not plugged into the gas valve or defect in the wiring harness to the gas valve. Check for 24 volts DC at gas valve. In some cases an E03 is caused from a loose Check across terminals 4 and 5 at plug X5 on the main connection on wires to the gas valve.
  • Page 23 The boiler automatically indicates this message if during an error read-out the electrical power to The boiler automatically indicates this message if the boiler is shut off. After the power is once again during an error read-out the electrical power to switched on, if the error causing the interference is the boiler is shut off.
  • Page 24 Check ribbon cable between the control unit and the display board. A loose connection between these two points can cause communication issues between boards leading to an error code. If ribbon cable is loose or damaged, repair or replace cable as needed. If error persist after reset Software error control unit, replace control unit.
  • Page 25 E 06 Control unit error Moisture on the PC board, check for leaks on or in the boiler. Replace PC board if needed. 008082013GW...
  • Page 26 Replace the control unit. The controller will automatically load the program into the new control unit. 008082013GW...
  • Page 27 008082013GW...
  • Page 28 VERY RARE THAT AIR IS AT FAULT. If air is present it will be indicated by a gurgling noise. Normally when an airlock is present a BL85 will be indicated Clean the pump and/or filter when necessary. Flush complete system 008082013GW...
  • Page 29 Replace the control unit. The controller will automatically load the program into the new control unit. 008082013GW...
  • Page 30 T3 flow sensor ground connection T3 flow sensor failure or controller failure To determine flow temperatures for T3 use the chart to the left for proper resistance values for a set temperature. When no discrepancies are found on the sensors it may be a leakage of current coming in from an end switch or pump relay box connected to terms 22 and 23.
  • Page 31 Signal maximum flow water temperature exceeded 212⁰F). Actual flow Check actual flow temperature should be temperature verified before T1 is determined. T1 Sensor 008082013GW...
  • Page 32 Signal maximum return water temperature exceeded (T2 212⁰F). T2 Sensor located under T1 sensor 008082013GW...
  • Page 33 T2 (swapped). T2 temperature is measured to be higher than T1. Check resistance value of T1 and T2 (See resistance chart under error 19 for resistance values. Replace T! and/or T2 if found to be defective. T1 Pressure Transducer T2 sensor 008082013GW...
  • Page 34 Replace MCBA board, main board. 008082013GW...
  • Page 35 No feedback signal from fan motor. Check the wiring harness to the fan motor and control unit. Check power supply to motor during combustion process, should be 24 volts DC. Fan motor wiring harness constant 24 volts DC. Tachometer cable Feedback signal 008082013GW...
  • Page 36 There is a negative pressure on vent system (Pressure difference). Check to see if fan motor is spinning. Vent system and air intake must be installed according to the installation instructions. The E29 is triggered immediately after fan check code 5 during the starting sequence. If during fan check 5 the fan remains spinning more than 150 rpms an E29 will occur.
  • Page 37 Internal shut down of supply sensor T1. T1 sensor short circuit is indicated by low ohm reading. Replace defective sensor, see resistance values in chart on E 18 above. T1 Sensor 008082013GW...
  • Page 38 Shut down of return sensor T2, T2 sensor short circuit is indicated by low ohm reading. Replace defective sensor. Refer to resistance chart on E 19 above. 008082013GW...
  • Page 39 Contact for supply sensor T1 open, indicated by infinite ohm reading. T1 Sensor 008082013GW...
  • Page 40 Contact for the return sensor T2 open, indicated by infinite ohm reading. Remove the plug from the flow sensor as a result of which error 32 occurs. T2 Sensor 008082013GW...
  • Page 41 008082013GW...
  • Page 42 008082013GW...
  • Page 43 Electrical short circuit, possible water damage to MCBA, main board 008082013GW...
  • Page 44 If this error is displayed, there is no software on the MCBA or display. A RINNAI conversion kit specific for the boiler model and fuel type must be installed. Follow the conversion kit instructions to load the software to the MCBA.
  • Page 45 Ribbon cable problem. Q-Series ribbon cable problem or defective key pad. Replace ribbon cable 008082013GW...
  • Page 46 T5 sensor is reading too high of a flue gas temperature. (Adjust parameter 84 – default 212 ⁰F) See location of T5 sensor below. If red cap is installed, T5 sensor is not being used. Moisture on the flue gas sensor wires or terminals could cause a false temperature reading.
  • Page 47 E 115 Replace MCBA board 008082013GW...

  • Page 48: Fuse

    Check fuse mounted on PC board to see if it blown. In addition, check transformer output and wiring harness for transformer to ensure it is plugged in properly. This is the low voltage fuse that is located directly next to the PCB board transformer. The OEM fuse has colored stripes;...
  • Page 49 Additional Troubleshooting Instructions 008082013GW...
  • Page 50 008082013GW...
  • Page 51 Checking the O Setting 008082013GW...

  • Page 52: Boiler Controls

    Boiler Controls Burner off while there is a demand for central heat of DHW. Burner off when room thermostat is demanding or burner off when DHW is calling. 008082013GW...

  • Page 53: Explanation Of The Function Buttons

    Explanation of the function buttons This LED should never be left on. Pressing R or the reset button for more than 5 seconds will activate a 17 minute de-aeration cycle. 008082013GW...
  • Page 54 Starting up: Filling and de-aerating the boiler and installation Requirements of the water system 008082013GW...
  • Page 55 008082013GW...

  • Page 56: Filling The Heating System

    Filling the heating system Note: You must have either a hot water or heat demand to activate de-aeration Check the water pressure regularly and top off the installation when necessary. The working pressure of the installation should be between 16 and 18 PSI when the system is cold.

  • Page 57: Altering Adjustments

    Altering adjustments 008082013GW...
  • Page 58 See additional definitions below PARA 36 E Combi. setting definitions 00 = activation by temperature drop for DHW (no plate warming) 10 = activation by temperature drop for DHW (plus plate warming) 20 = flow switch activation only DHW. (No plate warming/ no temp actuation) In either setting above - 00 or 10 the Flow switch is still in the circuit and if it sticks "closed"...
  • Page 59 008082013GW...

  • Page 60: Activating Factory Setting (Green Button Function)

    Activating factory settings (Green button function) 008082013GW...

  • Page 61: Isolating The Boiler

    Isolating the boiler 008082013GW...

  • Page 62: Reset Service Interval Counter

    Reset service interval counter 008082013GW...

Table of Contents