Rheem RTGH-RH10DV Service Manual
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Rheem RTGH-RH10DV Service Manual

Condensing tankless gas water heater
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CONDENSING TANKLESS GAS WATER HEATER
WARNING
If the information in these instructions is not followed exactly, a fire or explosion may result,
causing property damage, personal injury, or death.
– Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other
appliance.
– WHAT TO DO IF YOU SMELL GAS
· Do not try to light any appliance.
· Do not touch any electrical switch; do not use any phone in your building.
· Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions.
· If you cannot reach your gas supplier, call the fire department.
– Installation and service must be performed by a qualified installer, service agency or the gas supplier.
Service Manual
Models
199,000Btu / 180,000Btu
• Natural Gas ( NG ) / Liquid Propane Gas ( LP )

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Summary of Contents for Rheem RTGH-RH10DV

  • Page 1 CONDENSING TANKLESS GAS WATER HEATER Service Manual Models 199,000Btu / 180,000Btu • Natural Gas ( NG ) / Liquid Propane Gas ( LP ) WARNING If the information in these instructions is not followed exactly, a fire or explosion may result, causing property damage, personal injury, or death. – Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. – WHAT TO DO IF YOU SMELL GAS · Do not try to light any appliance. · Do not touch any electrical switch; do not use any phone in your building. · Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions. · If you cannot reach your gas supplier, call the fire department.

  • Page 2: Table Of Contents

    Chapter 1 Product Characteristics Specifications Dimensions Names of Components Hot Water Supply Capability Pressure Loss Characteristics Operating Principle Timing Logic Operation Flow Chart Freeze Protect Flow Chart Wiring Diagram Chapter 2 Components Description Circuit Board Temperature Thermistors Overheat Limit Switch Water Leakage Detector Gas Leak Detector Sensor Air Pressure Switch Flow Control Valve Flow Sensor Igniter Flame Detection Sensor Gas Valve Metal Fiber Premix Burner Water Mixing Valve Circulation Pump DHW Inlet Filter Heat Exchanger Condensate Trap Chapter 3 How to Use The Control Panel Control Panel Interface Control Panel Display...
  • Page 3 Changing the DHW Set Point 41 Status Display Mode Changing The Time Installer Mode Recirculation Mode Set the Recirculation Timer Type Setting the Recirculation Run Time Resetting The Recirculation Run Time Chapter 4 Troubleshooting Error Code List Error 10 Error 11 Error 16 Error 20 Error 29 Error 31 Error 32 Error 33 Error 35 Error 39 Error 40 Error 41 Error 43 Error 45 Error 60 Error 61 Error 65...
  • Page 4 Error 66 Error 67 Error 72 Error 73 Error 76 Error 78 Error 94 Chapter 5 Replacement Instructions 1. Circuit Board 2. Igniter 3. Flame Detection Sensor 4. Gas Leak Detector 5. Air Pressure Switch 6. Gas Valve 7. Flow Control Valve 8. Water Mixing Valve 9. Circulation Pump 10. AGM 11. Fan Assembly 12. Heat Exchanger 1. Cleaning the Water Heater Chapter 6 Maintenance 2. Maintenance Procedures 3. Flushing the Water Heater Chapter 7 Components Diagram Part I _ Case Part Memo...

  • Page 6: Chapter 1 Product Characteristics

    Chapter 1 Product Characteristics S pecifications Model Name RTGH-RH11DV RTGH-RH10DV 199,000 Btu/h 180,000 Btu/h 18,000 Btu/h 18,000 Btu/h Gas Input Rate High Altitude 180,000 Btu/h 180,000 Btu/h (2,500~4,500ft) 35°F Rise 11.0 Gal 9.9 Gal Hot Water Capacity 45°F Rise 8.5 Gal 7.7 Gal 77°F Rise...

  • Page 7: Dimensions

    Chapter 1 Product Characteristics D imensions 11.5" [292mm] 4.6" [117mm] 2.6" [67mm] 3.2" [81mm] 6.8" [173mm] 10.2" [260mm] 13.6" [346mm] DESCRIPTION DIAMETER Exhaust Outlet Pipe 3” (7.6 cm) Air Intake 3” (7.6 cm) DHW Outlet Adapter ¾” (1.9 cm) Condensate Adapter ½” (1.2 cm) Recirculation Return ¾”...

  • Page 8: Names Of Components

    Chapter 1 Product Characteristics N ame of Components Name of Component Name of Component Exhaust Outlet Collar ‘DHW’ Inlet Adapter Gas Inlet Adapter Ignition Trans Manual Power Switch Ignition Rod Water Flow Control Valve Over-heating Switch Air Pressure Switch Primary Heat Exchanger Flame Detection Sensor H/E Temperature Sensor Gas Valve Secondary Heat Exchanger...
  • Page 9 Chapter 1 Product Characteristics Hot Water Supply Capability 199,000Btu/hr 180,000Btu/hr [Winter]inlet water temp 48℉ [Winter]inlet water temp 48℉ Flow Rate[GPM] Flow Rate[GPM] [Spring/Fall]inlet water temp 64℉ [Spring/Fall]inlet water temp 64℉ Flow Rate[GPM] Flow Rate[GPM] [Summer]inlet water temp 82℉ [Summer]inlet water temp 82℉ Flow Rate[GPM] Flow Rate[GPM]...
  • Page 10 Chapter 1 Product Characteristics Pressure Loss Characteristics <CIRCULATION PUMP> Flow rate [GPM]...
  • Page 11 Chapter 1 Product Characteristics Operating Principle (Standard/External Mode) Standard Mode Air & Gas Mixing Burner Primary heat 1. Only POTABLE water may be plumbed through exchanger the water heater. Secondary heat exchanger 2. The water heater cannot be used for space heating applications. 3. Expansion tank is required if a backflow Recirculation preventer is installed.
  • Page 12 Chapter 1 Product Characteristics Operating Principle (Preheat or Internal Mode/ bYPS Recirculation Mode ) Air & Gas Preheat or Internal Recirculation Mode Mixing Burner Primary heat exchanger Preheat or Internal Recirculation Mode may be used without an installed recirculation Secondary heat exchanger pipe. The water heater is preheated and protected from freezing. Recirculation Pump Pressure Relief Valve...

  • Page 13: Gas Valve

    Chapter 1 Product Characteristics T iming Logic ■ Normal Ignition IGNITION GAS VALVE FLAME DETECTION 1s 1.5s 2s ■ Normal Shutdown IGNITION GAS VALVE FLAME DETECTION 30s ■ Ignition Failure (Error Code after 10 times) IGNITION GAS VALVE FLAME DETECTION 1s 1.5s 2s 10s 1.5s 2s...

  • Page 14: Shutdown Procedure

    Chapter 1 Product Characteristics H ot Water Mode Flow Chart Shutdown procedure POWER S/W ON Fix problem Hot water fixture closed AGM Zero Position setting Water Flow Control Valve H/L : Over-heating fault Water Flow Sensor Disconnect power Zero Position setting detected > 0.4 GPM Bypass Flow Control Valve Zero Position setting Water leakage is detected error flow control valve error Water flow control valve activates to...
  • Page 15 Chapter 1 Product Characteristics F reeze Protect Flow Chart ► Freeze Prevention control flow Freeze Prevention control flow ► Water leakage operation flow Water leakage operation flow Water leakage abnormal HX Thermistor Temp normal Water Flow Control Valve closed Hot Water Thermistor normal HX Thermistor Temp Circulation Pump Shutdown ≤ 46 ℉(8℃) Hot Water Thermistor Temp ≤...
  • Page 16 Chapter 1 Product Characteristics W iring Diagram...
  • Page 17 Chapter 1 Product Characteristics L adder Diagram...

  • Page 18: Fan

    Chapter 1 Product Characteristics CONNECTOR DESCRIPTION HT SELV NO. OF LOCATION BOARD SILK EARTH GROUND Power Supply Line HT (120V~) Circulation Pump Igniter 65001WS-12 L(HT) UNUSED Gas Valve UNUSED Power Supply Neutral 9-12 AC Power COM Line RS485 + SELV (5V) SMW250-03 RS-485 RS485 - Unused SELV (30V)
  • Page 19 Chapter 1 Product Characteristics CONNECTOR DESCRIPTION HT SELV NO. OF LOCATION BOARD SILK Flame Detect Sensor OP.S Operating Water Temperature Sensor DH.S DHW Temperature Sensor Inlet Water Temperature Sensor SELV (5V) LWD1140-14 Exhaust Temperature Sensor BG.S Optional Temperature sensor OT.S Unused SP.S AGM Stepper Motor Coil / Y Phase SELV (24V) CN12 AGM Stepper Motor Coil / X Phase...
  • Page 20 Chapter 1 Product Characteristics CONNECTOR DESCRIPTION HT SELV NO. OF LOCATION BOARD SILK Optional Push Button SELV(5V) Unused SMW250-06 FLUX1 Water Flow Sensor SELV (5V) Fan RPM Check SMW250-10...
  • Page 21 Chapter 2 Components Description Check Point Model NGTH-9700C : Circuit Board (Circuit Board) Function The part for controlling all components contained in the water heater. Failure Event Abnormal Circuit Board operation. Effects All the features of the product will not work when the circuit board is damaged or broken. Error Code Er 73, Er 76, Er 78 Diagnostic Replace the Circuit Board. Color / Wire Number...
  • Page 22 Chapter 2 Components Description GB-220/210 Check Point Model HB-220/210 : Temperature Thermistor (Circuit Board) Monitors hot water temperature so that the unit can adjust or turn off the burner when the Function measured temperature rises above the set temperature. Failure Event Sensor malFeature Effects Product damage is caused. Error Code Er 16, Er 31, Er 32, Er 33, Er 35, Er 94 ① Check the connection around the temperature thermistors. Diagnostic ② Measure the resistance across the thermistor by using a multi-meter. ① Hot Water Outlet_GB-220 (Yellow/Yellow) : Connector ③,⑩ (Yellow/Yellow) ② DHW Inlet _HB-220 (Blue/Blue) : Connector ④,⑪ (Blue/Blue) Color / Wire Number ③ Exhaust_HB-210 (Blue/White) : Connector ⑤,⑫ (White/Blue) Black/Black) White/White) ④ Operating_GB-210 ( : Connector ②,⑨ ( Item Standard Temperature Resistance(kΩ) 77 ± 0.2 °F (8.520) Temperature – 25 ± 0.1 ℃ Resistance Type 122 ±...
  • Page 23 Chapter 2 Components Description Check Point Model T1-11 : Overheat Limit Switch CN11 (Circuit Board) The part for automatically blocking the product operation when the temperature Function is beyond the set. Failure Event Overheated water and burner temperature are not detected. Effects Product damage is caused. Error Code Er 20, Er 43 ① Check for continuity across the Overheat Limit Switch by using a multi-meter. Diagnostic ② Check the Dip Switch setting. ③ Check the nozzles. ① Heat exchanger outlet pipe (Red/Red) : Connector ⑧, ⑯ Color / Wire Number ② Burner case (Red/Red) : Connector ⑦, ⑮ Burner Limit Switch (302℉/150℃) 14 15 High Limit Switch (203℉/95℃)
  • Page 24 Chapter 2 Components Description Check Point Model Water Leakage Detector CN11 (Circuit Board) Monitors for water leakage.If water leakage is detected, the water heater will Function close the water supply valve. Failure Event Water leakage is not detected. Effects Damage of the product is caused by the water leakage. Error Code Er 45 Diagnostic Check the Water Leakage Detector connections. Color / Wire Number Water leakage detector (Brown) : Connector ②,⑩ 14 15...
  • Page 25 Chapter 2 Components Description Check Point Model Gas Leak Detection Sensor (Circuit Board) Function Monitors for gas leakage. If gas leakage is detected, the water heater will power down. Failure Event Gas leak detection sensor is not operated. Effects Explosion risks by leaking the gas. Error Code Er 40 ① Check the leakage around the gas valve and connected pipes by using soapy water. Diagnostic ② Check the burner assembly Color / Wire Number...

  • Page 26: Air Pressure Switch

    Chapter 2 Components Description Check Point Model SAPS 70F : Air Pressure Switch CN 11 (Circuit Board) The part for preventing the inflow of exhaust gas, when exhaust vent and exhaust Function passage are blocked by condensate. ① Combustion noise is generated. Failure Event ② Imperfect and lifting flame occurs. Effects Carbon monoxide exceeding the reference is discharged. The appliance is not working. Error Code Er 29 ① Check the connection around the Air Pressure Switch. ② Check the hose for blockage or bending. Diagnostic ③ Check the condensate passage. ④ Check voltage range of Air Pressure Switch. Color / Wire Number Air pressure switch (blue/blue) : connector ⑤, ⑬ 14 15...
  • Page 27 Chapter 2 Components Description Check Point Model T405-158R : Flow Control Valve CN 14 (Circuit Board) The part controlling the water quantity for supplying the stable hot water by detecting the Function water flow rate(More than 0.5gallon) in the pipes. Failure Event Water flow rate is not detected and water leakage occurs around the flow sensor. ① Ignition sequence does not start. Effects ② Operation of product is stopped once detecting water leakage. Error Code Er 65 ① Restart the product Diagnostic ② Check the connection around the flow sensor. [IWM (Inlet Water Modulation)] GND (yellow) : connector ① IWM Stepper motor position (green) : connector② VDD (white) : connector ③ Color / Wire Number IWM Stepper motor coil X phase (red) : connector ④ IWM Stepper motor coil Y phase (black) : connector ⑤ VDD (blue) : connector ⑥ IWM Stepper motor coil /X phase (orange) : connector ⑦ IWM Stepper motor coil /Y phase(brown) : connector ⑧ 1. PPS material Body 2. Hall sensor rated voltage DC5~18V 8mA. Max ■ Minimum Flow Rate : ON: 0.47gal (1.8 lpm) , OFF: 0.39 gal (1.5 lpm) ■ Maximum Operating Flow Rate : 11.1 gal (42 lpm) ① ② ③ ④ ⑤ ⑥ ⑦ ⑧ ①...
  • Page 28 Chapter 2 Components Description Check Point Model Flow Sensor : 7855P-083 (Circuit Board) Function This sensor detects water flow (more than 0.5 GPM) through DHW loop. Failure Event Water flow is not detected. Effects Domestic hot water set point is not achieved. Error Code ① Restart the appliance. Diagnostic ② Visual inspection : check flow sensor wiring for proper connection. ③ Visual inspection : check flow sensor for debris. ① Ground : Connector (blue ⑥) Color / Wire Number ② Flow Signal : Connector (white ⑤) ③ DC 5V : Connector (red ④) ① ② ③ ④ ⑤ ⑥...

  • Page 29: Igniter

    Chapter 2 Components Description Check Point Model KI-790U : Igniter CN 9 (Circuit Board) The part for supplying the ignition energy to the burner by continuously discharging the Function high voltage. Failure Event Ignition is not generated. Effects Operation of product is stopped. Error Code Er 10 , Er 11 ① Visual inspection : Connection and/or breakage of wire. Diagnostic ② Check : voltage range Ignition Transformer (red) : connector ④ Color / Wire Number Ignition Transformer (red) : connector ⑩ Input voltage Output current Output voltage AC 120V 60Hz 15 ± 2kV 6 ± 2mA...
  • Page 30 Chapter 2 Components Description Check Point Model RS-100 : Flame Detection Sensor CN 7 (Circuit Board) Self-made part to indicate the normal status of burner by detecting the flame after Function igniting and inflowing the gas and air mixture. Failure Event Ignition fault. Effects Abnormal product operation. Error Code Er 10, Er 11, Er 39, Er 72 ① Check the discoloration of flame monitoring window. Diagnostic ② Check the connection around the flame detection sensor. ③ Check the flame sensor by using a multi-meter. Flame Detect Sensor (black) ① : connector ⑧ Color / Wire Number Flame Detect Sensor (red) ② : connector ① ① ② 1. Electrical Characteristics - Maximum workable voltage :DC 35V - Maximum allowable current :DC 30mA - Maximum power dissipation :DC 80mW 2. Optical characteristics - Dark current : 0.05uA/ MAX ( 0.6uA ) [Condition: 0LX (Intensity of illumination), 10V(Voltage) ] - Spectrum luminosity curve : 880nm ( Peak Sensitivity ) ① ② ③ ④ ⑤ ⑥ ⑦ - Range of sensing : 800 ~ 1000nm - Flame ON: DC 2.5V or less - Flame OFF: More than DC 2.5V...
  • Page 31 Chapter 2 Components Description Check Point Model AGM : Air Gas Mixer CN12 (Circuit Board) Function The part for supplying ideally the air and gas mixture to the heat exchanger. ① Imperfect combustion occurs. Failure Event ② lifting flame occurs. ① Abnormal product operation. Effects ② Carbon monoxide exceeding the reference is discharged. Error Code Er 67 ① Restart the water heater. Diagnostic ② Check the connection. ③ Check the fan intake. Air Gas Mixer (black) : ① connector (AGM / Y Phase) Air Gas Mixer (brown) : ② connector (AGM Y Phase) Air Gas Mixer (red) : ③ connector (AGM / X Phase) Color / Wire Number Air Gas Mixer (orange): ④ connector (AGM X Phase) Air Gas Mixer (yellow) : ⑤ connector (GND) Air Gas Mixer (green) : ⑥ connector (AGM Position Sensor) Air Gas Mixer (white) : ⑦ connector (DC 24V) 1. Operating Temperature : 0~60 ℃ 2. Using the gas pressure : 0.725 PSI (5 kPa) 3. Maximum amount of gas : 194 ft /hr (5.5 m /hr) (NG) 4. T/D(Turn/Down ratio) : 10:1(180,000Btu) ,11:1(199,000Btu) 5. Motor Specification - Type : Stepping Motor - Phase : 4 Phase - Drive type : Unipolar Drive / V-Constant - Supply Power : < 24 VDC (Non-continuous operation) - Phase excitation system : 2-2 - Step angle : 7.5 deg(2-2Phase), (1-2 Phase : 3.75 deg) - Direction of rotation : CW / CCW (Bidirectional)
  • Page 32 Chapter 2 Components Description Check Point Model VK4115V1022 : Gas Valve (Circuit Board) The part for controlling electrically the supplied gas volume and for performing Function optimally the combustion. ① Gas leakage occurs. Failure Event ② Gas valve is not operated. (Unable to open/close) ③ Gas flow is not modulated. (Proportional gas valve) ①...
  • Page 33 Chapter 2 Components Description Check Point Model KBP-126H : Fan (Circuit Board) Function The part for supplying the air and gas into the burner required for the combustion. ① Abnormal noise occurs at the fan. Failure Event ② Abnormal fan speed(RPM). ③ Poor connection. ① Abnormal combustion. Effects ②...

  • Page 34: Metal Fiber Premix Burner

    Chapter 2 Components Description Check Point Model Metal Fiber Premix Burner (Circuit Board) Function The part supplying the heat source by mixing and combusting the air and gas. ① Unable to initialize/sustain combustion. Failure Event ② Soot occurs on the surface of burner. ③ Gas leakage occurs from burner. ① Abnormal combustion. Effects ② Unstable flame generation. ③ Ignition failure. Error Code Diagnostic Check the debris on the burner surface and unstable flame. Color / Wire Number The design of the Premix Burner significantly reduces the amount of emitted carbon monoxide (CO), nitrous oxides (NOx), and other harmful flue gas components by regulating the air-fuel ratio unlike a typical Bunsen burner.

  • Page 35: Water Mixing Valve

    Chapter 2 Components Description Check Point Model SFCV-KR : Water Mixing Valve CN 10 (Main PCB) The part for controlling the temperature of hot water by mixing the cold and hot water in Function order to prevent the burns and supply the constant temperature of hot water. ① Water leakage occurs around the water mixing valve. Failure Event ② Abnormal valve operation. ① Operation of product is stopped once detecting water leakage. Effects ② The temperature of hot water is not constant. Error Code Er 16, Er 66 ① Restart the product. Diagonostic ② Check the connection around the water mixing valve. ③ Check range of voltage. [Water Mixing Valve] DHM Y Phase (black) : connector ① DHM Y Phase (brown) : connector ② DHM X Phase (red) : connector ③ Color / Wire Number DHM X Phase (orange) : connector ④ GND (yellow) : connector ⑤ DHM Position sensor (green) : connector ⑥ Flow2 sensor (blue) : connector ⑦ DC 14V (white) : connector ⑧ 1. Cold water and hot water mixed 2. Step Control Motor Applied. 3.

  • Page 36: Circulation Pump

    Chapter 2 Components Description Check Point Model GPD15-5S: Circulation Pump (Circuit Board) Function Provides circulation through the heat exchanger. Failure Event Water flow is not detected. ① Unit does not operate. Effects ② Circulation pump is not operating. Error Code Er 44, Er 60 ① Visual inspection : check wiring for proper connection. Diagnostic ② Check supply voltage. Color / Wire Number Internal CH primary circulation pump : Connector (blue ⑨, brown ③)

  • Page 37: Dhw Inlet Filter

    Chapter 2 Components Description Check Point Model DHW Inlet Filter (Circuit Board) Function The part consists of durable STS, PPS material for filtering out debris and heavy metals. Failure Event Input capacity of cold water is not constant and thermal efficiency is poor. Effects Noise at the heat exchanger is generated and pipes are blocked by the debris. Error Code Diagnostic Clean the DHW Inlet filter. Color / Wire Number Inlet water filter...

  • Page 38: Heat Exchanger

    Chapter 2 Components Description Check Point Model Heat Exchanger(STS) (Circuit Board) The part for heating the hot water by Absorbing the high-temperature heat generated at Function the burner. ① Water or exhaust gas leakage. Failure Event ② Abnormal heat exchange. ① Operation of product is stopped. Effects ② Exhaust gas leakage. ③ Abnormal noise occurs. Error Code Er 20, Er 33, Er 43, Er 94 Diagnostic Check the heat exchanger surface for cracks or leaks. Color / Wire Number 1. Heat exchange method : Instantaneous 2. Material : SUS 3. Construction : SUS brazing...

  • Page 39: Condensate Trap

    Chapter 2 Components Description Check Point Model Siphon : Condensate Trap (Circuit Board) Function The part for reliably discharging the condensate generated by the combustion. Failure Event Condensate fails to drain freely and backs up in the exhaust line. 1. Product corrosion and degradation due to excessive condensate buildup. Effects 2. Blockage of air flow. Error Code Er 29 Diagnostic Check the hose for blockage or bending. Color / Wire Number...

  • Page 40: Chapter 3 How To Use The Control Panel

    Chapter 3 How to Use The Control Panel A. CONTROL PANEL Press This Button Less than 5 Seconds Cancel/ Return Hold This Button More than 5 Seconds Press this Button Less than 5 When Control Panel Power is ON status Display Seconds Change DHW set- Mdoe When Control Panel Power is OFF Installer Point Temperature 100-120°F Mode (38-49°C)

  • Page 41: Changing The Dhw Set Point

    Chapter 3 How to Use The Control Panel DESIRED HOT WATER TEMPERATURE : 120 °F CURRENT TIME : AM 1:39 CURRENT DAY : MONDAY TIMER SETTING : MONDAY 5:00~6:30 , 18:00~20:00 Figure 34 – Example Display ▪ C. START-UP SEQUENCE After the appliance is powered ON, the LCD display shows a sequence of information. The icons will flash, followed by various indicators that describe the appliance controller and software versions.

  • Page 42: Status Display Mode

    Chapter 3 How to Use The Control Panel Figure 35 – DHW Set-Point Screens Press the button when the display panel is powered ON to change the DHW Set-Point. The DHW icon and current set-point will display and flash. This indicates that the DHW Set-Point can be changed. Factory DHW Set-Point is 120°F(49°C).

  • Page 43: Changing The Time

    Chapter 3 How to Use The Control Panel Parameter Detail Description Current Flow Unit A:Li or GA Flow Unit (Li: Liters/min, GA: Gallons/min) b:Fr Fan Speed (RPM) Current Fan Speed RPM Value Lock Mode is In Use (ON) or Unused (OFF) C:Lc Lock Mode Allows user to lock out any temperature change.

  • Page 44: Installer Mode

    Chapter 3 How to Use The Control Panel ▪ G. INSTALLER MODE Installer Mode will activate when button is pressed and held for five seconds while the water heater display is powered Off. Figure 38– Installer Mode Screens Index Default Parameter Description Allows the Installer to View the Unit Error History 1:EH Error History Range: E0:XX –...
  • Page 45 Chapter 3 How to Use The Control Panel Index Default Parameter Description Enables Cascade Mode on the water heater. 12:Cn Cascade Range: on – Cascade is used, oFF – Cascade is not used NOTE: 12:Cn must be set to On to select 13:Eh Enables Common Venting on the water heater. 13:Eh Common Vent Range: on –...
  • Page 46 Chapter 3 How to Use The Control Panel 4. Next, turn the dial to 7:RM. Press the Dial button. “ItnL”will flash when the 7:RM setting is ready to be changed. 5. Turn the dial to “Itnl” to turn on Internal Recirculation Mode, or “Etnl” to use External Recirculation, or “tt24” to use Title 24 application, or “bYPS”...

  • Page 47: Set The Recirculation Timer Type

    Chapter 3 How to Use The Control Panel The following section details the various Recirculation Timer Functions. Step 1: Set the Recirculation Timer Type. Setting Detail Description Allows the installer to customize the Recirculation Function. The recirculation day and time values must be set in Step 2, SEt. When set in Smart Auto-Learn, the pump will run in Standard Mode for the first seven (7) days.

  • Page 48: Setting The Recirculation Run Time

    Chapter 3 How to Use The Control Panel ▪ 2. Setting the Recirculation Run Time (Pro9 Recirculation Timer) NOTE: This step is only necessary if “Pro9” was selected as the Recirculation Timer Type. If “Auto” was selected the water heater will automatically program its recirculation operating patterns. a.

  • Page 49: Resetting The Recirculation Run Time

    Chapter 3 How to Use The Control Panel f. Turn the dial .The start time on the screen will change in increments of thirty (30) minutes. When the desired start time appears on the screen, press the button to select and store it. Next, turn the dial until the desired end time appears on the display.
  • Page 50 Chapter 3 How to Use The Control Panel Figure 48 – Resetting the Recirculation Run Time d. The Recirculation Run Time has now been reset to the factory default settings. Press to return to Standby Mode. NOTICE If hot water is not used for more than thirty (30) hours, the recirculation program will be stopped and the water heater will automatically go into Vacation Mode and display the vacation icon...
  • Page 51 Chapter 3 How to Use The Control Panel ▪ J. ERROR MODE When the water heater encounters an error, the display will flash “Er” followed by a numerical code. The water heater shall enter a soft lockout condition if the error is such that it can return to normal operation once the condition relieves itself (overheat conditions, NTC open or shorts, etc.).
  • Page 52 Chapter 3 How to Use The Control Panel Error Code Error Code Description Possible Remedies Press the Power button to clear the Error Code. High Limit Overheat 1. Inspect the High Limit Overheat switch. Ensure proper connections. Er:20 Switch – Closed is Normal, 2. Check High Limit Overheat switch resistance. If resistance is zero, Open is Fault replace the switch.

  • Page 53: Error

    Chapter 3 How to Use The Control Panel Error Code Error Code Description Possible Remedies Press the Power button to clear the Error Code. If Error happens again: 1. Check the vent connections for blockages. Fan Speed too High Er:41 2. Check the burner assembly. with Flame On 3.
  • Page 54 Chapter 3 How to Use The Control Panel Error Code Error Code Description Possible Remedies Press the Power button to clear the Error Code. If Error happens again: 1. Turn power OFF and ON at the main power switch internal to the water Er:66 Mixing Valve Error heater.
  • Page 55 Chapter 4 Troubleshooting Error code Meaning Condition If flame extinction issue repeats 8 Flame Loss (Manual restore) times while combusting error code 10 will appear. Failure event If flame loss occurs 8 consecutive times during combustion, the Er.10 will be displayed, the burner will turn off the flame, and the fan will post-purge. Check point ② Check wire ① Check gas color of connector. valve connecting (CN 9 : Purple/ line. Purple ⑥,⑫ ) ③ Check flame ④ Check wire detector sensor's color of connector. connecting line (CN 7 : red ① , and fixed spot. black ⑧) ⑤ Check the flue. (Air intake& exhuast pipe) ⑥ If the above issues are operating normally, replace circuit board.
  • Page 56 Chapter 4 Troubleshooting Error code Meaning Condition During burning operation, if it failed Ignition failure (Manual restore) to ignite 10 times continuously, error code 11 will appear. Failure event If it failed to detect flame during ignition sequence pre-purge time will exceed 10 secs, and post-purge will be performed after the ignition causes manual restore error. Check point ② Check wire ① Check flame color of connector. detector sensor’s (CN 7 : red ① , connecting line black ⑧) and fixed spot. ③ Check color changes of flame observation port. After separating stop ring by seeing color changes, replace the flame observation port. ■ From more than DC 2.5V after ignition safety cut-off will appear ① When setting before ignition is less than DC 2.5V : Replace flame sensor. ② When setting before ignition is more than DC 2.5V : Replace the flame observation glass and gasket.
  • Page 57 Chapter 4 Troubleshooting Error code Meaning Condition In the case of DHW mode, when the Operating Temperature Operating Temperature and DHW and DHW Temperature Sensor temperature are detected higher (Automatic restore) than 199℉ (93℃), error code 16 will appear. Failure event When Operating Temperature and DHW temperature are more than 199℉ (93℃), DHW overheating error issue will appear and all the outputs except post-purge will stop. When lower than 176℉(80℃) it will restore automatically. Check point 199,000Btu 180,000Btu 199,000Btu 180,000Btu Fire (LP) (LP) (NG) (NG) Normal (LP) Fire ① Check the Circuit Board dip switch settings.
  • Page 58 Chapter 4 Troubleshooting Error code Meaning Condition When the High Limit Switch High Limit Switch Abnormality temperature is overheated, error (Manual restore) code 20 will appear. Failure event An Er. 20 will display if the temperature of the heating water exiting the primary heat exchanger exceeds the High Limit Switch's default settings. Combustion will stop and the fan will continue to run for post- purge. Check point ① Inspect the High Limit Switch when error code appears even if the heating supply temperature is not too high. ② Check connector and if no problem, measure High Limit Switch located at heat exchanger outlet and replace when the multi-meter value shows '0L'. (Normal value is '0~0.5Ω'.) (CN 11 : red ⑧, ⑯) ③ Check the circulation pump speed setting as speed. High Limit Switch (203℉/95℃) 14 15...

  • Page 59: Error 29

    Chapter 4 Troubleshooting Error code Meaning Condition When APS at condensate Air Pressure Switch (APS) discharging outlet is abnormal , Abnormality (Manual restore) error 29 will appear. Failure event Air pressure increase is most likely the result of an obstruction in the exhaust air flow line - for example, excessive condensate buildup or a blockage in the vent termination. Check point ① Check APS and circuit board ⑤ Check the exhaust pipe connection. blockage and Air Inlet Filter ② Verify that the condensate trap and clogging. drain pipe are free of obstructions. ③ Check condensate discharging outlet is blocked by foreign substances. ④ Check the connecting hose between the condensate trap and APS. ⑥ If above ①,②,③ check points are normal, check the APS connector to the multimeter. Replace APS when the multi-meter value shows '0L'. (Normal value is '0~0.5Ω'.) 0 Ω...
  • Page 60 Chapter 4 Troubleshooting Error code Meaning Condition DHW Inlet Thermistor Open When no response at DHW In- or Short Circuit let Thermistor, error code 31 will (Automatic restore) appear. Failure event When DHW Inlet Thermistor’s wiring line located at DHW Inlet connection is disconnected. Check point ① Verify that the DHW Inlet Thermistor is properly secured in the cold water connection. Verify proper connection of the DHW Inlet Thermistor's wiring to the circuit board. (CN7 : blue ④ , blue ⑪ ) DHW Inlet (blue/blue) ② Measure resistance across the DHW Inlet Thermistor with a multi-meter. If the multi-meter displays 0Ω (short circuit), replace the DHW Inlet Thermistor.
  • Page 61 Chapter 4 Troubleshooting Error code Meaning Condition When no response at DHW Outlet DHW Outlet Thermistor Open or Thermistor, error code 32 will Short (Automatic restore) appear. Failure event When DHW Outlet Thermistor’s wiring line located at DHW connection is disconnected. Check point ① Verify that the DHW Outlet Thermistor is properly secured in the DHW water connection. Verify proper connection of the DHW Outlet Thermistor's wiring to the circuit board. (CN7 : Yellow ③ , Yellow ⑩ ) Hot Water Outlet (Yellow/Yellow) ② Measure resistance across the DHW Out- let Thermistor with a multi-meter. If the multi- meter displays 0Ω (short circuit), replace the DHW Thermistor.
  • Page 62 Chapter 4 Troubleshooting Error code Meaning Condition Operating Thermistor Open or When no response at operating Short Circuit Thermistor, error code 33 will (Automatic restore) appear. Failure event When operating Thermistor’s wiring line located at Hot Water Outlet Pipe is disconnected. Check point ① Verify that the Operating Thermistor is properly secured in the Hot water supply connection. Verify proper connection of the Operating Thermistor's wiring to the circuit board. Operating (black/black) ② Measure resistance across the Operating Thermistor with a multi-meter. If the multi- meter displays 0Ω (short circuit), replace the OperatingThermistor. - The wires of CN 7 in circuit board : White/White (②,⑨) - Operating thermistor : Wire color (Black), Connector color ① ② ③ ④ ⑤ ⑥ ⑦ (Black) ⑧...
  • Page 63 Chapter 4 Troubleshooting Error code Meaning Condition Exhaust Thermistor Open or When no response at Exhaust Short Circuit Thermistor, error code 35 will (Automatic restore) appear. Failure event When Exhaust Thermistor’s wiring line located at Exhaust is disconnected. Check point ① Verify that the Exhaust Thermistor is properly secured in the exhaust connection. Verify proper connection of the Exhaust Thermistor's wiring to the circuit board. (CN7 : White ⑤, Blue ⑫) Exhaust (White / Blue) ② Measure resistance across the Exhaust Thermistor with a multi-meter. If the multi-meter displays 0Ω (short circuit), replace the Exhaust Thermistor.
  • Page 64 Chapter 4 Troubleshooting Error code Meaning Condition If false flame is detected after False flame sensing combustion is ended error code 39 (Automatic restore) will appear. Failure event After completion of the water heater combustion flame detection sensor detects In case the flame generated. Check point ① check the front cover will be closed. ■ From more than DC 2.5V after ignition safety cut-off will appear ① When setting before ignition is less than DC 2.5V : Replace flame sensor. ② When setting before ignition is more than DC 2.5V : Replace the flame observation glass and gasket. ITEM Normal Value Before ignition More than DC 2.5V After ignition Less than DC 2.5V...
  • Page 65 Chapter 4 Troubleshooting Error code Meaning Condition When gas leakage is detected Gas leakage during operation error code 40 will (Manual restore) appear. Failure event Stop all of the outputs except fan when detecting gas leakage signal for over 1 sec, it restores automatically after 5 min. When detecting more than 10 min continuously or 3 times in a hour, restore error manually. When leakage doesn’t occur for one hour, past leakage history will be deleted. Check point ① Turn off the gas. ② Check leakage part with using soapy water at the gas valve and flue joint, and re-assemble when leakage is found. Check condition of o-ring and packing and replace it. ③ Check joint condition of burner parts. ④ Verify the venting so it is installed correctly.
  • Page 66 Chapter 4 Troubleshooting Error code Meaning Condition When fan speed exceeds normal Excess Fan Speed detected values during combustion, error (Manual restore) code 41 will appear. Failure event The circuit board has Fan Speed data. Before ignition, compare with standard Fan Speed before ignition and error appears when exceeding standard range, stop all of the outputs except post-purge. Check point ① Check APS and circuit board connection. ② Verify that the condensate trap and drain pipe are free of obstructions. ③ Check the exhaust and intake pipes for blockage. ④ To reset this error code, the power needs to be disconnected and then reconnected.
  • Page 67 Chapter 4 Troubleshooting Error code Meaning Condition Burner Limit Switch’s temperature Burner Limit Switch abnormality is above the acceptable range, (Manual restore) error code 43 will appear. Failure event Stop all of the outputs except fan when Burner Limit Switch attached on burner upper plate shows temperature above 302℉(150℃). Check point ① Check conditions of burner limit switch connected with burner and circuit board, and disconnection. ② Check connector and if no problem, measure burner limit switch located at burner head and replace overheating switch when the multi-meter value shows '0L'. (Normal value is '0~0.5Ω'.) (CN 11 : Red ⑦, ⑮) Burner Limit Switch (302℉/150℃)
  • Page 68 Chapter 4 Troubleshooting Error code Meaning Condition When the Water Leakage Detector Water Leakage detects water, error code 45 will (Manual restore) appear. Failure event Stop all of the outputs except fan when the Water Leakage Detector attached on base under plate detected the water, it restores manually. Check point ① Close the water inlet valve. ② Check the Water Leakage Detector's wire. (CN11 : brown ②, ⑩) ③ If there is standing water, find the leakage area, replace the part.
  • Page 69 Chapter 4 Troubleshooting Error code Meaning Condition When DHW is overheated than Hot Water Temperature default temperature, the error Abnormality. code 60 is occurred. (Manual restore) Failure event DHW temperature is over 167℉(75℃) and when the error occurred, close Cold water inlet valve and operate the pump. Check point Hot Water Outlet (CN7:③ yellow/ ⑩ yellow) ① When DHW temperature is overheated, the error is ① ② ③ ④ ⑤ ⑥ ⑦ occurred to minimize the damage by the overheated DHW. ② If the error is occurred when DHW temperature is not ⑧ ⑨ ⑩ ⑪ ⑫ ⑬ ⑭ reached to set temperature, check DHW temperature sensor. ③ If there is standing water, find the leakage area, replace the part. ④ If the error is occurred when DHW temperature is overheated(over 167℉(75℃)), inspect DIP switch setting. (Default : No.6&7 OFF) ⑤ If circulation pipe has error, after recirculation operating the error is occurred when DHW on demand. ⑥ Check that the recirculation operating is normal.
  • Page 70 Chapter 4 Troubleshooting Error code Meaning Condition When the Fan RPM Sensor is Fan RPM Sensor Abnormality abnormal state, error code 61 will (Automatic restore) appear. Failure event Stop all of the outputs when Fan RPM Sensor is connected to an abnormal state. (Refer to installation manual) Check point ① Check wiring line connection carefully. • Fan Start Coil (white) ⓔ : connector ④ • RPM Sensor (yellow) ⓓ : connector ⑥ • GND (blue) ⓒ : connector ② • VDD (red) ⓑ : connector ③ • Fan End Coil (black) ⓐ : connector ⑤ ① ② ③ ④ ⑤ ⑥...
  • Page 71 Chapter 4 Troubleshooting Error code Meaning Condition ① Occurs manual restore error. ② Not able to supply hot water to the set temperature when flow Flow Control Valve error rate exceeds hot water heater’s (Manual restore) capacity. ③ Flow rate doesn’t increase during malfunction when valve is locked. Failure event Not able to sense reference point or motor doesn’t rotate due to malfunction. Check point ① Check error code sign after turning off and on the power. ② Check wiring line connection carefully. ③ Verify proper connection of the Flow Control Valve Thermistor's wiring to the circuit board. (CN14 : ①Yellow,②Green,③White,④Red,⑤Black, ⑥Blue,⑦Ornage,⑧Brown) ① ② ③ ④ ⑤ ⑥ ⑦ ⑧ ⑨ ③ If above ①, ② operates abnormally replace Flow Control Valve.
  • Page 72 Chapter 4 Troubleshooting Error code Meaning Condition ① Occurs manual restore error. Water Mixing Valve Abnormality ② Water leakage occurs around (Manual restore) the water mixing valve. ③ Abnormal valve operation. Failure event Operation of product is stopped once detecting water leakage.The temperature of hot water is not constant. Check point ① Check error code sign after turning off and on the power. [Water Mixing Valve] DHM Y Phase (black) : connector ① DHM Y Phase (brown) : connector ② DHM X Phase (red) : connector ③ DHM X Phase (orange) : connector ④ GND (yellow) : connector ⑤ DHM Position sensor (green) : connector ⑥ Flow2 sensor (blue) : connector ⑦ DC 14V (white) : connector ⑧ ① ② ③ ④ ⑤ ⑥ ⑦ ⑧ ③ If above ①, ② operates normally replace valve ④ If above issues operates well replace Circuit Board.

  • Page 73: Circuit Board

    Chapter 4 Troubleshooting Error code Meaning Condition Unable to sense proper positioning AGM Abnormality of AGM motor, error code 67 will (Manual restore) appear. Failure event During initialization or AGM check, the AGM motor rotates so that the position can be determined by the circuit board. If there is a discrepancy between the movement of the motor and the circuit board's input (i.e. AGM motor is stuck in one position and cannot rotate), Er. 67 is displayed. Er. 67 must be cleared manually. Check point ① Check error code sign after turning off and on the power. ② Check wiring line connection carefully. ③ If above ①, ② operates abnormally replace AGM. ④ If AGM is moving normally after a hard reset but still doing an Er 67, replace the circuit board with the newest version.
  • Page 74 Chapter 4 Troubleshooting Error code Meaning Condition Flame Detected before Igniter When detected the flame before Abnormality (Automatic restore) ignition, error code 72 will appear. Failure event When flame detected during no operation then error occurs and s ignition. When flame after pre-purge and then flame is still shown even after pre-purge 10 times then manual restore error occurs. After combustion and post pre-purge is completed but flame is still shown then block ignition sequence performance by occurring error during no operation. Flame detecting error restores automatically when flame disappears. Check point ① Check the front cover will be closed. ■ From more than DC 2.5V after ignition safety cut-off will appear ① When setting before ignition is less than DC 2.5V : Replace flame sensor. ② When setting before ignition is more than DC 2.5V : Replace the flame observation glass and gasket. ITEM Normal Value Before ignition More than DC 2.5V After ignition Less than DC 2.5V ② To reset this error code, the power needs to be disconnected and then reconnected.
  • Page 75 Chapter 4 Troubleshooting Error code Meaning Condition DIP Switch Setting Abnormality When Dip switch is set abnormally, (Automatic restore) error code 73 will appear. Failure event This error occurs if the Dip switches on the circuit board are changed or moved when the water heater is plugged into power. Check point ① Set accurately by checking capacity on the rating plate attached to the side of water heater and Dip Switch specification listed on the manual. Dip Switch State Gas Type NG : ON LP:OFF High Fire 6: ON 7: OFF Low Fire 6: OFF 7: ON 6, 7 Normal Fire 6: OFF 7: OFF 199,000Btu 180,000Btu 199,000Btu 180,000Btu Fire...
  • Page 76 Chapter 4 Troubleshooting Error Meaning Condition Communication Error between When communication with display Control Panel and Circuit Board panel is not stabilished for 10 minutes, (Automatic restore) error code 76 will appear. Fault Connection error between control panel and circuit board. Check point ① Check connections from circuit board to Control Panel. ② To reset this error code, the power needs to be disconnected and then reconnected.
  • Page 77 Chapter 4 Troubleshooting Error Meaning Condition Cascade Communication When the unit operating is stopped, Abnormality error code 78 occurred. Failure event Under ‘ Cascade communication failure ’ , ‘ Setting error ’ , ‘ Back flow of the Exhausted Gas ’ and ‘ Gas Leak ’ , Er78 occurred. Check point ① Check Quick Connect cable. ② Check the settings of 12:Cn in ‘ Installer Mode ’ . ③ When Er40(Gas Leak), Er61(Fan error) or Er67(AGM error) have occurred, Cascade Communication error (Er78) occurs to protect ‘Back Flow’ of the exhausted gas. In case of Er45(Water Leak), both units shut down to minimize the property damage due to an internal leak. ④Check that one of the above errors is occurred.
  • Page 78 Chapter 4 Troubleshooting Error code Meaning Condition Overheating Exhaust Thermistor Exhaust temperature exceeds (The water heater shuts down selected cutoff temperature. when the exhaust temperature (Manual restore) exceeds 149°F (65°C).) Failure event It occurs when exhaust gas emission is faulty due to exhaust flue blockage. When excessive amount of gas inflows due to higher set of dip switch than its hot water heater capacity, exhaust gas temperature will increase more than excess temperature. Exhaust gas temperature may be high due to heat exchanger's malfunction. Check point ① Turn off the water heater for at least 30 minutes, and then restart it. ② Check Exhaust Thermistor’s wiring connected at exhaust duct is disconnected. And check circuit boards socket. (CN7 : White ⑤, Blue ⑫) ③ Check for any obstructions in the vent pipe.
  • Page 79 Chapter 5 Replacement Instructions Main components Replacement Instructions 1. Circuit Board 13. Turn the power on. (Use the manual switch) 1. Close the gas shut off valve and water valve. 14. Enter ’Installer Mode’,'Status Mode' from control 2. Turn the power on. panel. 3. Enter 'Installer Mode','Status Mode' from control 15. Set the values for 4:FH,5:FL,J:AG. panel. (See page 44,45) (These are the numbers you wrote down in Step 4) 4. On a piece of paper, write down the factory settings in 16. Save the values for 4:FH,5:FL,J:AG. the 'Installer Mode' for 4:FH,5:FL,'Status Mode' J:AG. 17. Turn the unit on and ensure proper operation. These numbers MUST be recorded before the old circuit 18. Test operation. board is removed, the valves are specific to the unit. If carbon dioxide and manifold pressure values 5. Turn the power off water heater. (Use the manual are matched with Table 1 in the low fire combustion, switch) switch dip switch from low to high fire and check 6. Unplug connectors on Circuit board. carbon dioxide and manifold pressure values. If the values are matched with Table 1, shut off the unit and close the gas valve. Then disconnect the hose that is connected to the manifold pressure port, then tighten the screw for the manifold pressure port, and return the dipswitch back to normal condition. Finally, close the front cover. NOTE When assemble connector, check wiring color and locations to avoid any mistakes. 7.Loosen two screws to remove Circuit board. Table 1 Manifold 'LP' type 'NG' type pressure...

  • Page 80: Igniter

    Chapter 5 Replacement Instructions Main components Replacement Instructions 2. Igniter 1. Close the gas shut off valve 6. Loosen two screws to separate igniter from the 2. Turn the power off. bracket. 3. Disconnect the wiring to the igniter. 7. Separate igniter from bracket by unlocking the plastic tabs on the back side of the bracket. 4. Remove the cable connected to the ignition plug. 8. Replace igniter with new component. 9. Assemble in the reverse order as the part was removed. 10. Open the gas shut off valve. 11. Turn the power on. 12. Turn the unit on and ensure proper operation. NOTE 1. Ensure the igniter is properly secured. 5. Loosen two screws to separate igniter from the water heater cabinet.

  • Page 81: Flame Detection Sensor

    Chapter 5 Replacement Instructions Main components Replacement Instructions 3. Flame Detection Sensor 4. Gas Leak Detector 1. Close the gas shut off valve. 1. Close the gas shut off valve. 2. Turn the power off. 2. Turn the power off. 3. By using a hand screwdriver, remove 4 screws of 3. Disconnect the electrical connection to the flame the front cover. detection sensor. 4. Disconnect all the electrical connection to the ( Push and hold the button on the back side of the circuit board. connection to remove.) 5. Loosen two screws to remove the circuit board. 4. Rotate flame detection sensor 45 degrees clockwise and pull forward. 6. Replace the circuit board with new component. 7. Assemble in the reverse order as the part was removed. 8. Assemble connectors on circuit board. 9. Open the gas shut off valve 10. Turn the power on. 11. Turn back the water valve in the opening direction. 12. Test operation. (Please refer to page 81 for 5. Replace flame detection sensor with new combustion characteristics test.) component. 6. Assemble in the reverse order as the part was removed. 7. Open the gas shut off valve. 8. Turn the power on. 9. Turn the unit on and ensure proper operation. NOTE 1. Check fixed condition of the part.

  • Page 82: Air Pressure Switch

    Chapter 5 Replacement Instructions Main components Replacement Instructions 5. Air Pressure Switch 1. Close the gas shut off valve. 5. Loosen bracket’s two screws and separate 2. Turn the power off. air pressure switch from the cabinet. 3. Disconnect the electrical connection to the APS. 6. Replace air pressure switch with new component. 7. Assemble in the reverse order as the part was removed. 8. Open the gas shut off valve. 9. Turn the power on. 10. Open water valves (Hot water and DHW) 4. Separate hose from air pressure switch. 11. Turn the unit on and ensure proper operation. Connect a hose to the connector marked 'H' character.

  • Page 83: Gas Valve

    Chapter 5 Replacement Instructions Main components Replacement Instructions 6. Gas Valve 1. Close the gas shut off valve. 8. Remove the bracket’s two screws and separate 2. Turn the power off. gas valve from the cabinet. 3. Close all water valve (Hot water and DHW) 4. Loosen the fastened screws of the case front bracket. 9. Replace the gas valve with new component. 6. Disconnect the electrical connection to the Check the o-rings for damage, if damaged, replace with gas valve. new o-rings. 10. Assemble in the reverse order as the part was removed. 11. Open the gas shut off valve. 12. Turn the power on. 13. Open water valves (Hot water and DHW) 14. Turn the unit on and ensure proper operation. NOTE 1. Replace it with the new gas valve. 2. Check wire condition connected to gas valve. 3. Make sure the packing is inserted correctly when assembling the nuts. 4. Compare to the manifold pressure with pressure indicated at the rating plate after connecting gas valve.

  • Page 84: Flow Control Valve

    Chapter 5 Replacement Instructions Main components Replacement Instructions Flow Control Valve 1. Close the gas shut off valve. 9. Loosen this nut from HEX pipe. 2. Turn the power off. 3. Place a bucket under the unit and rag under valve to collect the residual water from the water heater. 4. Disconnect the electrical power to the water heater. 5. Close the both DHW inlet and hot water valve. 6. Open the Hot water faucets completely. 7. Disconnect all the electrical connection to the circuit board. Loosen the three screws to remove the Circuit Board and Circuit Board Bracket in one piece. 10. Remove the flow valve in the direction of the arrow. 8. Remove two clips connected to the Flow Control Valve and remove the wire connection to the Flow Control Valve. 11. Replace the Flow Control Valve with new spare part. Check the o-rings for damage, if damaged, replace with new o-rings. 12. Assemble in the reverse order as the part was removed. 13. Open the gas shut off valve. 14. Turn the power on. 15. Open water valves (Hot water and DHW). 16. Turn the unit on and ensure proper operation. NOTE 1. Check wire condition connected to flow valve. 2. Make sure the o-ring is inserted correctly when assembling the pipe.

  • Page 85: Water Mixing Valve

    Chapter 5 Replacement Instructions Main components Replacement Instructions 8. Water Mixing Valve 1. Close the gas shut off valve. 10. Separate water mixing valve and outlet pipe. 2. Turn the power off. 3. Place a bucket under the unit and rag under valve to collect the residual water from the water heater. 4. Disconnect the electrical power to the water heater. 5. Close the both DHW inlet and hot water valve. 6. Open the Hot water faucets completely. 7. Disconnect all the electrical connection to the circuit board. Loosen the three screws to remove the Circuit Board and Circuit Board Bracket in one piece. 11. Remove the water mixing valve and replace with new spare part. Check the o-rings for damage, if damaged, replace with new o-rings. 12. Assemble in the reverse order as the part was removed. 13. Switch water valve to open. 14. Switch manual power switch to open. 8. Separate connector connected with water mixing 15. Switch main gas valve to open. valve. 16. Test operation. 9. Remove two clips connected with water mixing valve and outlet pipe.

  • Page 86: Circulation Pump

    Chapter 5 Replacement Instructions Main components Replacement Instructions 9. Circulation Pump 1. Close the gas shut off valve. 9. Using a hand screwdriver, remove three screws 2. Turn the power off. on the pump fixing bracket and remove the clip to 3. Place a bucket under the unit and rag around pump separate pump from the HEX water pipe. to collect the residual water from the water heater. 4. Disconnect the electrical power to the water heater. 5. Close the DHW inlet valve. 6. Drain water from the hot water & DHW loop. 7. Remove wire connector connected to circulation pump. 8.Loosen the nut on the pump and HEX pipe, loosen wire tie. 10. Remove the circulation pump with the HEX water pipe in the direction of the arrow. And disconnect the connector for High Limit Switch and HEX Thermistor. 11. Remove HEX water pipe from the pump. 12. Replace the pump with new part. Check the o-rings for damage, if damaged, replace with new o-rings. 13. Assemble in the reverse order as the part was removed. 14. Open the gas shut off valve. 15. Turn the power on. 16. Open water valves (Hot water and DHW). 17. Turn the unit on and ensure proper operation. NOTE 1. Check wire condition connected to pump. 2. Make sure the o-ring is inserted correctly when assembling the pipe.

  • Page 87: Agm

    Chapter 5 Replacement Instructions Main components Replacement Instructions 10. AGM 1. Close the gas shut off valve. NOTE 2. Turn the power off. AGM comes with the Gas Mixer Body, if the Gas 3. Close all water valve (Hot water and DHW) Mixer Body is damaged, replace it, otherwise this 4. Disconnect the electrical connection to the AGM. part is not used. 5. By using a hand screwdriver, remove 2 screws of the AGM. ■ Warning : AGM Mounting Position. 6. Replace AGM with new component. 7. Assemble in the reverse order as the part was removed. 8. Open the gas shut off valve. 9. Turn the power on. 10. Open water valves (Hot water and DHW) 11. Turn the unit on and ensure proper operation.

  • Page 88: Fan Assembly

    Chapter 5 Replacement Instructions Main components Replacement Instructions 11. Fan Assembly 8. Remove 3 screws of the AGM plate. 1. Close the gas shut off valve. 2. Turn the power off. 3. Close all water valve (Hot water and DHW) 4. Disconnect the electrical connection to the AGM. 5. By using a hand screwdriver, remove 2 screws of the AGM. 9. Using a hand screw driver or crescent wrench, remove the 4 screws to the Fan assembly. 6. Remove 3 screws of the air intake pipe and loosen gas pipe nut. 10. Replace the gas valve with new part. Check the o-rings for damage, if damaged, replace with new o-rings. 11. Assemble in the reverse order as the part was removed. 12. Open the gas shut off valve. 13. Turn the power on. 14. Open water valves (Hot water and DHW) 7. Loosen burner head bracket’s 2 screws and 15. Turn the unit on and ensure proper operation. separate from burner.

  • Page 89: Heat Exchanger

    Chapter 5 Replacement Instructions Main components Replacement Instructions 12. Heat Exchanger 9. Unplug wire connectors that attach to the wiring 1. Close the gas shut off valve. harness.(Burner Overheat switch, Ignition plug) 2. Turn the power on/off button “On”. 3. Turn and leave open the hot water fixtures/ faucets for more than 2 minute and close. * An 11 Error Code may appear on the control panel. This is not a malfunction of the unit. Do not turn Power ON/OFF Button OFF. 4. Close the water supply valve and disconnect the electrical power supplied to the unit. 5. Fully open all hot water fixtures/faucets. 6. Open all drain plugs and drain the water out of the unit. 7. When the water is completely drained, replace all drain plugs and close the hot water fixtures/faucets. 10. Loosen the fastened screws of the case front bracket. 11. Remove Flame Detector connector. Cold Water Filter Use a coin. 8. Remove Control Panel from water heater case. (Disconnect the wires to the Control Panel. Loosen four screws to remove Control Panel & bracket.)
  • Page 90 Chapter 5 Replacement Instructions Main components Replacement Instructions 2) Remove Fan connector. 11. Unplug connectors on Circuit Board. 12. Loosen the three screws to remove the Circuit Board and Circuit Board Bracket as one piece. 3) Loosen three screws to remove air pipe. Separate intake pipe attached to AGM. 13. Remove two clips and then pull out the Condensate Hose. 4) Loosen gas pipe nut connected with AGM. By using a hand screwdriver, remove 2 screws of the AGM. 14. Remove the Fan assembly. 1) Remove AGM connector. 5) Loosen burner plate bracket’s by loosen two screws as shown.
  • Page 91 Chapter 5 Replacement Instructions Main components Replacement Instructions 6) Remove the Fan assembly in the direction of the 17. Loosen ten screws to remove Heat Exchanger. arrow. Pull out the Heat Exchanger inside case. 15. Loosen water pipe nut connected with Heat 18.Disassemble the screws of the disassembled heat Exchanger. exchanger and assembled bracket to remove the bracket. Replace the Heat Exchanger assembly with the Burner and Exhaust Pipe. Check the o-rings for damage, if damaged, replace with new o-rings. O-ring 16. Remove four screws on the top of case. 19. Assemble in the reverse order as the part was removed. 20. Open the gas shut off valve. 21. Open all water valves. 22. Turn the power on. (Use the manual switch) 23. Turn the unit on and ensure proper operation.

  • Page 92: Chapter 6 Maintenance

    Chapter 6 Maintenance 1. Cleaning the Water Heater 1. Cleaning Air Intake Filter To properly maintain the water heater, you should check air intake filter every month. If not, you will encounter a problem with combustion specifications. To clean air intake filter: 1. Press the Power button on the control panel to 4.

  • Page 93: Maintenance Procedures

    Chapter 6 Maintenance Maintenance Procedures DANGER The water heater must be inspected and serviced annually, preferably at the start of the heating season, by a qualified service technician. In addition, the maintenance and care of the water heater as outlined in this manual must be performed by the user/ owner to assure maximum efficiency and reliability.
  • Page 94 Chapter 6 Maintenance Visually inspect the intake piping for any signs of blockage. Inspect the entire length of the intake pipe to ensure piping is intact and all joints are properly sealed. Inspect the intake pipe bracing. Ensure bracing is undamaged and in good condition. Notify a qualified service technician if any problems are found.

  • Page 95: Flushing The Water Heater

    Chapter 6 Maintenance 3. Flushing the Water Heater Flushing the Water Heater Flushing the heat exchanger is a complicated procedure that should only be performed by a qualified service technician. NOTE: Improper maintenance WILL VOID water heater warranty. 1. Disconnect electrical power to the water heater. 2.

  • Page 96: Chapter 7 Components Diagram

    Chapter 7 Components Diagram PART I _ CASE PART Ref # Description Ref # Description Front Cover Hot Water Pipe Assembly 1-1. Control Panel Bracket Rocker Switch 1-2. Control Panel Window Condensate Trap Exhaust Assembly Control Panel Air Intake Assembly Circulation Pump Air Intake Filter Mixing Valve Cold Water Valve Assembly...

  • Page 97: Memo

    Memo...
  • Page 98 Service Manual RHEEM AMERICA Corporation...

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