Rinnai REU-KA2530FFUD-US Service Manual page 36

KA Series Component Replacement Instructions
Heat Exchanger
33. If replacing the lower (primary) heat exchanger,
transfer parts from old heat exchanger to new heat
exchanger. These include connecting pipe between
upper heat exchanger and copper tee with new o-
rings and clips, connecting pipe between upper heat
exchanger and bypass valve with new o-ring and
clip.
34. Install heat exchanger assembly in case. Place
bottom in cabinet first. Attach with five screws. (two
at top back and three on bottom) Attach
reinforcement bracket with two screws.
35. Remove old gasket from flue connection assembly.
Install new gasket from kit. Attach flue connections
assembly with four screws.
Install water and drain lines
36. Install drain connecting pipe with new o-rings and
attach with new clips.
37. Attach water inlet connecting pipe with new o-rings
at by-pass valve with one screw and bracket. Attach
other water line with one screw and bracket.
38. Attach the hot water outlet line to the hot water
outlet fitting with one screw and bracket. Reconnect
condensate tube at upper heat exchanger.
Reconnect wire harness
39. Reconnect heat exchanger thermistor (upper right).
40. Install three anti frost heaters in clips at top of upper
heat exchanger.
41. Reconnect anti frost connectors at bottom of
cabinet. One blue connector.
42. Reconnect burner sensor harness (lower right).
43. Reconnect thermal fuse harnesses (lower right).
Two single white wire connectors.
Install burner and burner cover plate
44. Install burner assembly with two screws. Remove
combustion chamber packing on sight glass plate.
Install new packing, in kit, on sight glass plate.
Install combustion chamber sight glass plate with
eight screws.
Install fan
45. Reinstall fan with two screws. Install fan connector.
Condensing Water Heater Service Manual
Install gas manifold
46. Remove packing from gas control assembly.
Discard. Install new packing, in kit, on gas control
assembly.
47. Remove the packing for manifold. Install new
packing, in kit, on gas manifold.
48. Reconnect ignitor module harness, mounted on
manifold. (gray/gray)
49. Install two connectors to the solenoids on the gas
manifold. (marked)
50. Attach the gas manifold with three machine screws
at the gas control assembly. Install six screws on
gas manifold to heat exchanger. Attach wire
harness ties.
Reconnect flame rod connectors and electrode
51. Install two flame rod connectors. (marked )
52. Attach ignitor high tension cord to the electrode.
53. Attach controller bracket with one machine screw
and one screw from power wire clamp. Install
controller in bracket.
54. Turn on water supply, power supply, and gas
supply. Check for gas and water leaks. Perform
operational checks.
55. Install the front panel using four screws.
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