Rinnai ByPass Servo Troubleshooting Manual
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Rinnai ByPass Servo Troubleshooting Manual

Rinnai ByPass Servo Troubleshooting Manual

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[Type text]
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.
Tankless
Water Heater
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
11112014GW

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  • Page 1 [Type text] Tankless Water Heater 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.
  • Page 2 Table of Contents Code Numbers Page # 03 ……………………………………………………………………………………………………………………………………………… 4 05 ……………………………………………………………………………………………………………………………………………… 5 10 ……………………………………………………………………………………………………………………………………………… 6 11 ……………………………………………………………………………………………………………………………………………… 8 12 ……………………………………………………………………………………………………………………………………………… 11 14 ……………………………………………………………………………………………………………………………………………… 15 16 ……………………………………………………………………………………………………………………………………………… 17 19 ……………………………………………………………………………………………………………………………………………… 18 25 ……………………………………………………………………………………………………………………………………………… 19 31 ……………………………………………………………………………………………………………………………………………… 20 32 ……………………………………………………………………………………………………………………………………………… 21 33 ………………………………………………………………………………………………………………………………………………...
  • Page 3 Toll-Free:1-800621-9419 • Phone: 678-829-1700 • www.rinnai.us © 2013 Rinnai America Corporation. 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.
  • Page 4 Code 03 Troubleshooting Procedure Power interruption during bath fill (Water will not flow when power returns) 1. Turn of all hot water fixtures in building. Next press the ON/OFF button on the temperature controller twice. 11112014GW...
  • Page 5 Code 05 Troubleshooting Procedure Bypass Servo 1. Turn off power supply to unit, reapply power. Fire up unit. If code 05 reappears replace bypass valve. 11112014GW...
  • Page 6 7. Verify all vent terminations meet Rinnai's recommendation from another vent termination on the same wall or roof. If multiple Rinnai's are installed at the location, each termination should have a minimum of twelve inches of separation when installed on the same plane. If the vents are not on the same plane you will need a five foot separation between vent terminations.
  • Page 7 Rinnai for proper gas pressure setting procedures. 13. Verify the manifold gas pressures and dip switches were properly set for your altitude. This information can be found under the front cover in the plastic holder. If missing, contact Rinnai for proper gas pressure setting procedures.
  • Page 8 Code 11 Troubleshooting Procedure No Ignition WARNING: You must be qualified to service gas systems before proceeding. 1. Verify all gas valves on gas system are open feeding the proper gas pressure to said appliance. 2. Verify all air was purged from gas lines after installation. 3.
  • Page 9 15. Verify that proper venting materials were used in this installation. They must use the correct venting material for class III appliances approved by Rinnai. See Rinnai venting instructions for details. 16. Verify proper altitude settings, see high altitude gas pressure setting procedure for dip switch and manifold gas pressure settings.
  • Page 10 If the condensate drain line is not connected please install one per Rinnai venting instructions. If a condensate line is in use, inspect the vent connector on top of water heater to ensure it’s not stopped up. In addition; check the condensate drain trap and line for blockage.
  • Page 11 This information is normally found in a plastic holder on the back side of the front panel. If procedure is not available contact Rinnai tech services for data. Verify correct dip switch settings before adjusting/checking gas pressures. Dip switch settings can be found in the gas pressure setting procedure.
  • Page 12 5. Ensure the proper venting materials were used in this installation. You must use concentric venting material for class III appliances approved by Rinnai. See Rinnai venting instructions for details. Verify venting component at unit's vent connection is fully engaged into top of water heater. Separate connection to check for proper connection.
  • Page 13 If the condensate drain line is not connected please install one per Rinnai venting instructions. If a condensate line is in use, inspect the vent connector on top of water heater to ensure it’s not stopped up. If stopped up remove vent pipe from unit and clean out all debris or build up in the trap or drain lines.
  • Page 14 Immediate code 12 or 19 no flame visible in burner box; This code appears when you first turn on the water supply. The water heater will go straight into a code 12 or 19 depending on model number of water heater. In all other codes including most code 12's the unit will try to fire three times.
  • Page 15 Procedure for checking these pressures can be found on the back side of the front cover. If you need assistance contact Rinnai technical services 24/7 for details on now to check these pressures. You must have a manometer to check operating gas pressures.
  • Page 16 9. Check system operation to see if the water heater is continuously short cycling. If so, heat from short cycling can transfer into the copper heat exchange and trip the bi-metal switch. Investigate to see what is causing the short cycling such as aqua-stats with a low delta T. Increase set point of aqua-stat by at least twenty degrees lower than the water heater's set point.
  • Page 17 Code 16 Troubleshooting Procedure Over Temperature Warning (Safety shutdown because unit is too hot) 1. Check for low flow in circulation system causing short cycling. WARNING: Turn off the electrical, gas and water supply to the water heater before proceeding. 2.
  • Page 18 Code 19 Troubleshooting Procedure Electrical Grounding 1. Check all components for electrical short. 11112014GW...
  • Page 19 Code 25 Troubleshooting Procedure Condensate Trap is full 1. Inspect condensate drain line for blockage. 2. Inspect condensate trap and tank inside cabinet for blockage. 3. Ensure condensate line has an air gap between the units and drain line leaving the water heater.
  • Page 20 Btu content gas. In other words the thermocouple is not senses a high enough temperature inside the combustion chamber due to pressures or gas issues. Verify your forced low fire gas pressure. If pressure is found to be within specifications, contact Rinnai tech support for assistance. 4. Replace thermocouple. 11112014GW...
  • Page 21 Code 32 Troubleshooting Procedure Outgoing Water Temperature Thermistor Fault 1. Check thermistor wiring harness for loose, broken or damaged connections from thermistor back to PC board. 2. CAUTION: Turn off water supply to the water heater and drain system down before proceeding. With no water left in hot water supply lines remove the thermistor and check for scale build up on thermistor.
  • Page 22 Code 33 Troubleshooting Procedure Heat exchanger outgoing thermistor 1. Check thermistor wiring harness for loose, broken or damaged connections from thermistor back to PC board. 2. CAUTION: Turn off water supply to the water heater and drain system down before proceeding. With no water left in hot water supply lines remove the thermistor and check for scale build up on thermistor.
  • Page 23 Procedure for checking these pressures can be found on the back side of the front cover. If you need assistance contact Rinnai technical services 24/7 for details on now to check these pressures. You must have a manometer to check operating gas pressures.
  • Page 24 Code 41 Troubleshooting Procedure Freeze Protection Sensor for External Units NOTE: If the KB water heater’s freeze protection sensor/thermistor is unplugged/cut/shorted, it will not allow the water heater to fire up but will show a code 41. If the VC water heater’s freeze protection sensor/thermistor is unplugged/cut/shorted, it will allow the water heater to fire up.
  • Page 25 Code 51 Troubleshooting Procedure Inlet Water Temperature Sensor 1. Check sensor wiring harness for loose, broken or damaged connections from sensor back to PC board. 2. CAUTION: Turn off water supply to the water heater and drain system down before proceeding With no water left in hot water supply lines remove the sensor and check it for scale build up.
  • Page 26 The proper resistance reading for this coil can be found in the Tech Data Sheet found on the back side of the unit’s front panel or in the Rinnai Water Heater Service Manual for that model unit. If you find the coil to be open replace the gas valve. If resistance reading is found to be within specification, proceed to item #3 below.
  • Page 27 Code 57 Troubleshooting Procedure Burner Overheat Bi-metal Switch A code 57 will appear when one of the two bi-metals opens on the rear of the burner assembly. The code 57 will appear regardless to whether or not the unit is in operation. To reset this code you must correct the problem with the bi-metal switch first.
  • Page 28 Code 58 Troubleshooting Procedure Secondary Heat Exchanger Sensor A code 58 will appear when one of the two bi-metals opens on the secondary heat exchanger opens. These bi-metals are located on the rear of the secondary heat exchanger where the air box connects to the heat exchanger.
  • Page 29 Code 61 Troubleshooting Procedure Combustion fan Motor WARNING: Before servicing fan motor turn off power supply to the unit. Never attempt to plug up or unplug motor while power is supplied to product. Failure to follow this procedure could lead to damaged components including fan motor.
  • Page 30 Code 63 Troubleshooting Procedure Circulation Flow Rate dropped below 1.3 GPM WARNING: Turn off the water supply to the water heater before removing the inlet water filter. 1. Using the temperature controller see if unit is producing flow. To display the recovery flow rate in gallons per minute through the unit, press the “UP”...
  • Page 31 Code 65 Troubleshooting Procedure Water Flow Servo 1. Check wiring harness to the water flow servo for loose, broken or damaged connections from servo back to PC board. 2. Turn off the power to the water heater and then reapply to see if code resets. 3.
  • Page 32 Code 70 Troubleshooting Procedure PC Board Fault WARNING: Turn off the electrical, gas and water supply to the water heater before proceeding. 1. Check all wiring harnesses at the connection to the PC board to ensure they are not loose, broken or damaged.
  • Page 33 Code 71 Troubleshooting Procedure SV0, SV1, SV2, SV3 Solenoid Valve Fault WARNING: Turn off the electrical, gas and water supply to the water heater before proceeding. 1. Check wiring harnesses to SV0, SV1, SV2 and SV3 for loose, broken or damaged connections from gas valve solenoids back to PC board.
  • Page 34 Code 72 Troubleshooting Procedure Flame Sensing Device Fault WARNING: Turn off the electrical, gas and water supply to the water heater before proceeding. 1. Check wiring harnesses to flame rods for broken or damaged connections from flame rod back to PC board. 2.
  • Page 35 Code 73 Troubleshooting Procedure Burner Thermocouple Fault 1. Check wiring harness at burner thermocouple back to PC board for loose, broken or damaged wiring or connections. 2. Verify all dip settings are set to the proper alitiube per the tech sheet found under the front panel of your unit.
  • Page 36 Code 79 Troubleshooting Procedure Water Leakage Detected 1. Check wiring harness at leak detector for loose, broken or damaged wiring or connections. 2. Check the heat exchanger and all piping inside the unit for leaks. 3. If no leaks are found inspect inside of cabinet for signs of water pooling on bottom pan of water heater.
  • Page 37 No Code Troubleshooting Procedure Nothing happens when water flow is activated 1. Clean water inlet filter to water heater. 2. On new installations ensure the hot/cold water lines are not reversed. 3. Ensure you have the minimum flow rate required to fire the unit. 4.
  • Page 38 Code LC, LC0 – LC9 Troubleshooting Procedure Scale build-up in Heat Exchanger WARNING: Turn off the electrical and supply to the water heater before proceeding. 1. Flush heat exchanger per recommended flushing procedure found in unit’s owner’s manual. 2. NOTE; the LC, LC0 – LC9 codes are the only codes that will allow a unit to continue to operate. The display will alternate between the LC codes and the temperature setting.
  • Page 39 Code FF Troubleshooting Procedure Indicates a serviceman has serviced product This code indicates a service provider performed maintenance or repair. The serviceman will enter the following code FF after making repairs to the product. That flags the system indicating all codes after the FF took place after he made his repairs.
  • Page 40 1. Have customer explain problem. 2. Turn off hot water ball valve on the Rinnai valve kit at the water heater. This should shut off the water flow to all hot water fixtures at the location. Turn on a hot water fixture to check and see if any water continues to flow at that fixture.
  • Page 41 Cold Water Sandwich caused by Low Flow: 1. Open fixture and record flow rate using the water heater’s temperature control pad. 2. Shut off hot/cold water feed lines to the water heater, remove inlet water filter and check for debris, clean if necessary. Re-install filter, turn on water supply. Open the same tap again and recheck your flow rate to see if it increased.
  • Page 42 when the water is turned back on within a few minutes of the demand system cycling, and cold water sandwich is created. Loose or bad electrical connection inside the water heater or power supply to product. Power supply could be dropping out momentarily due to a component heating up, loose wiring connections, etc.
  • Page 43 How to retrieve flow rate/temperature output 11112014GW...

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