Reliance Water Heaters 110 Maintenance Guidance

Maintenance sheet
ATKJ2
62Q064-4
A. Troubleshooting
If the error code is indicated on the Red LED (Refer to the Section C) on the PCB (Part #701) of the
water heater (and/or the remote controller), refer to Section B.
<< It takes long time to get hot water at the fixtures >>
・The time it takes to deliver hot water from the water heater to your fixtures depends
on the length of piping between the two. The longer the distance or the bigger the
pipes, the longer it will take to get hot water.
・If you would like to receive hot water to your fixtures quicker, you may want to
consider a hot water recirculation system.
<< The water is not hot enough or turns cold and stays cold >>
・Compare the flow and temperature. Refer to the "Output temperature chart" of the
Installation manual.
・Check cross plumbing between cold water lines and hot water lines.
・Check if the gas supply valve is fully open, the gas line is sized properly and the gas
supplies pressure enough. Refer to the "Gas supply and gas pipe sizing" of the
Installation manual.
・Check the set temperature, and change the set temperature with the remote controller
or the DIPswitch setting. Refer to Section D.
・Refer to the "Water circuit" in this section.
<<The water is too hot>>
・Check the set temperature, lower setting temperature.
<<The hot water is not available when a fixture is opened>>
・Refer to the "Power supply circuit" and "Water circuit" in this section.
<<Fluctuation in hot water temperature>>
・Check if the filter on the cold water inlet is cleaned (Part #406).
・Check if the gas line is sized properly and the supply gas pressure is sufficient.
・Check for cross connection between cold water lines and hot water lines.
・Refer to the "Water circuit" in this section.
<<Unit does not ignite when water goes through the water heater>>
・Refer to the "Power supply circuit" and "Water circuit" in this section.
・If you use the remote controller, turn the power button on and then check if the
set temperature will be displayed on the screen.
・Check if the filter on the cold water inlet is cleaned (Part #406).
B. Error codes
The numbers in parentheses below are the numbers of blinking of the Red LED on the PCB to indicate the error codes.
03 (One time): Incorrect DIPswitch setting
・Check the DIPswitch settings on the PCB. Refer to Section D.
10 (Five times): Warning for the "99" error code
・Check the gas type of the house (and/or the building). If it's wrong gas type model, replace
the water heater to correct one.
・Check if there is any blockage (For example, Damper sticking, Vent Flaps installed on the
terminator, Snow build up around terminator, Installed in a closet (No ventilation or lack of
combustion air)) in the intake air and/or exhaust. Refer to the "Vent termination clearances"
of the installation manual.
・If the water heater is installed as a direct-vent system, check whether there is enough
distance between the intake air terminal and the exhaust terminal. Refer to the "Vent
termination clearances" of the Installation manual.
・Check if the total vent length doesn't exceed 50 ft and the # of elbows is less than 5Ea.
・Check the altitude/elevation of area of where the water heater is installed. Refer to the
"High-altitude function" of Section D. And change the DIPswitch settings.
・Check if there is grease and/or dirt in the burner (Part #101) and the fan motor
(Part #103), especially if the water heater has been installed in a contaminated area.
・Check if there is dust and lint in the heat exchanger.
・Check the manifold pressure of the water heater. Refer to the Installation manual of the
water heter.
11 (Three times): Ignition failure
1. Check the gas supply and inlet gas pressure.
2. Check if the Hi-limit switch (Part #412) is properly functioning.
3. Check for connection/breakage of wires (Part #413, 708, 709, 712), burn marks on the
computer board (Part #701),and/or soot on the flame rod (Part #108). And then if the
O.H.C.F (Part #413) has a breakage, Consult the manufacturer.
4. Check if there is a buzzing spark ignition sound coming from the burner (Part #101)
when water heater prepares for combustion.
5. Listen for the double "clunk" sound coming from the gas valve assembly (Part #102)
when water heater goes into combustion.
6. (Only if no sparking and/or kick sound) Check the voltage on each wire to gas valve assembly
(Part #102) and/or the igniter (Part #711). Refer to "Appendix A" in Section C.
*No sparking sound >>>>> Refer to #1 at "Appendix A" in Section C.
*No kick sound >>>>> Refer to #2 at "Appendix A" in Section C.
7. Check if there is leaking from the heat exchanger (Part #401).
8. Check if there is dust and lint in nozzles of the manifold (Part #102).
9. Check the current on the flame rod (Part #108). Refer to #3 at "Appendix A" in Section C.
12 (Three times): Loss of flame
1. Check the gas supply and inlet gas pressure.
2. Check if the Hi-limit switch (Part #412) is properly functioning.
3. Check for connection/breakage of wires (Part #413, 708, 709, 712), burn marks on the
computer board (Part #701), and/or soot on the flame rod (Part #108). And then if the
O.H.C.F (Part #413) has a breakage, Consult the manufacturer.
4. Check if there is leaking from the heat exchanger (Part #401).
5. Check if there is dust and lint in nozzles of the manifold (Part #102).
6. Check the current on the flame rod (Part #108). Refer to #3 at "Appendix A" in Section C.
<<The fan motor is still spinning after operation has stopped>>
・This is normal. After operation has stopped, the fan motor keeps running from 15 to 70
seconds in order to re-ignite quickly, as well as purge all the exhaust gas out of the flue.
<<Abnormal sound from water heater>>
・An abnormal sound from the water heaters is caused by not enough air supply or wrong
installations. The water heater needs more combustion air. Refer to the "10" error code
in the section B.
<<Power supply circuit>>
1. If the remote controller is installed, press the "ON/OFF" button of the remote controller, and
make sure that the set temperature is displayed on the remote controller.
Restart the water heater.
2. Check if the Red LED on the PCB (Part #701) of the water heater is lit for a few seconds right
after the power is supplied. If so, the power supply circuit of the water heater is under
normal condition. Next, refer to the "Water circuit" in this section.
3. Check the fuse on the surge box (Part #703), and if it has a brown spot, need to replace it.
4. Check the power supply, and make sure that the water heater has 120 VAC.
5. If the Red LED on the PCB (Part #701) isn't lit, some electrical parts can be broken. Consult
the manufacturer.
<<Water circuit>>
1. If you use the remote controller, turn the power button on and then check if the
set temperature will be displayed on the screen.
2. Open all hot water faucets, and make sure that there is enough water flow. This
water heater needs at least 0.5 GPM water flow (at the default set temperature) to operate.
3. Check for reverse connection and cross connection.
4. Check if the filter on the cold water inlet is cleaned (Part #406).
5. Check if there is no debris or obstruction on the fixtures.
6. Check if water ways in the water heater are frozen. If so, unfreeze them. And refer to the
Installation manual to protect your water heater from freezing.
7. Check if the inlet water pressure is higher than 40 psi. And if it's lower than 40 psi, need
to increase the pressure.
8. Check for connections and breakage of wires (Part #402).
9. Check if the motor drive of the flow adjustment valve (Part #402) is locked due to scale
buildup, and/or water leakage. If so, Consult the manufacturer.
31,32 (Two times): Disconnected/short-circuited thermistor
・Check for connection/breakage of wires and/or debris on the thermistor (Part #407, 408).
・Check the thermistor resistance. Refer to "Appendix D" in Section C.
39 (Two times): Air-fuel ratio rod failure
・Check for connection/breakage of wires (Part #709) and/or soot on the flame rod
(Part #108).
51,55 (six times): Abnormal gas solenoid valve and main gas valve
・Check for connection/breakage of wires (Part #708) and/or burn marks on the computer
board (Part #701).
・Reset power supply of the water heater.
・ Check the voltage of each valve on the gas valve assembly (Part #102). Refer to
"Appendix C" in Section C.
61 (Four times): Fan motor fault
・Check for connection/breakage of wires, dust buildup in the fan motor (Part #103) and/or
burn marks on the computer board (Part #701).
・Check for frozen/corrosion of connectors of the fan motor (Part #103).
・Check the voltage between blue wire and each wire of the fan motor (Part #103), and check
resistance between white wire and red wire. Refer to "Appendix B" in Section C.
70 (One time): Computer board fault
・Check for connection/breakage of wires (Part #714) and/or burn marks on the computer
board (Part #701)
72 (Six times): False flame detection
1. Clean the flame rod (Part #108).
2. For indoor models, check if a condensate drain is installed on the vent collar of the water heater.
3. Check if there is leaking from the heat exchanger (Part #401).
74: Miscommunication between water heater and remote controller
1. Check the model type of the remote controller. Model No. 9007666005 (TK-RE02) is the
correct one.
2. Inspect the connections between the water heater and remote controller. Refer to the
"Remote controller connections" of the Installation manual.
3. Check the power supply of the water heater.
4. If this error code appears only on the Red LED in the PCB (Part #701), check the voltage
on the remote controller terminal on the PCB. Refer to "Appendix E" in Section C.
5. If this error code appears only on the remote controller, replace the PCB (Part #701).
6. If this error code appears on both the PCB (Part #701) and the remote controller, replace
the remote controller.
99 (Five times): Imperfect combustion
・Refer to the "10" error code in this section.
C. Wiring diagram and check point of the water heater
PCB
A A1
SW
BK BR
C1
BL W BR
Hi-
BL
limit
G Ground BR
BL BL
BL BL Heater
Trans-
O.H.C.F C2
B1 BK former
Heater
BK
BL
MV
Thermostat
B
SV1 P P IG
LB 3
P P
Igniter rod
G 9
Air-fuel ratio rod
SV2
C
O 53 Y
I
G
R 73
O W
SV3
Ground
Flame rod BK
W
O
G A3
FM Gas
Y H1 W
Propor-
BL
tional
R
Valve
R
ＢＫ
Flow H2 G
Ｗ
Sensor
Ｒ
J
BK Flow
Adjust Ground
R
Inlet Valve
thermistor
9007666005
BK E2
F
(TK-RE02)
Outlet
thermistor
Remote
E1 controller
BK
1 2 3 4 5 6 7 8
Dipswitches
OFF
Red LED
Increase button
MIN button
Decrease button MAX button
W: WHITE BK: BLACK LB: LIGHT BLUE
R: RED BL: BLUE Y: YELLOW
G: GREEN O: ORANGE BR: BROWN P: PURPLE
Appendix A (For error code 11)
Check the following points during ignition stage.
# 1. Refer to check point "B" on the wiring diagram above.
Check the voltage between purple wires.
(Normal: 90 to 110 VAC)
This check point is normal?
Yes >> Replace the igniter (Part #711).
No >> Go to Next.
# 2. Refer to check points "C" and "H1" on the wiring diagram above.
Check the voltages below:
C: Between blue wire and light blue wire (#3).
(Normal: 78 to 100 VDC)
C: Between blue wire and orange wire (#53).
(Normal: 78 to 100 VDC)
H1: Check the voltage between white wire and red wire.
(Normal: 1 to 15 VDC)
These check points are normal?
Yes >> Replace the gas valve assembly (Part #102).
No >> Replace the PCB (Part #701).
# 3. Check the current through the orange flame rod wire (Part #709).
(Normal: more than 1 μA)
This check point is normal during operation?
Yes >> Replace the PCB (Part #701).
No >> Replace the flame rod (Part #108).
D. DIPswitch settings on the computer board of the water heater
Change the DIPswitch settings when the power supply is turned off.
The dark square is the direction the DIPswitch should be set to. DEFAULT is the factory setting.
The DIPswitches have certain special functions and generally should not need adjustment.
They have settings for four functions, shown below.
Gas type
ON 1 2 3 4 5 6 7 8 ON 1 2 3 4 5 6 7 8
Propane Natural gas
OFF OFF
The Gas type DIPswitch should already be properly preset from the factory.
High-altitude function Model type
DEFAULT ON 1 2 3 4 5 6 7 8 110 Indoor
(0 to 2,000 ft.) (T-KJr2-IN)
OFF
ON 1 2 3 4 5 6 7 8
FM+ 110 Outdoor
(2,000 to 4,000 ft.) (T-KJr2-OS)
OFF
The Model type DIPswitch should already
ON 1 2 3 4 5 6 7 8
FM++
be properly preset from the factory.
(4,000 to 6,000 ft.)
OFF
FM speed is increased automatically.
Appendix B (For error code 61)
Refer to check point "G" in the diagram to the left and the following.
BR
• Check the voltage between red wire and blue wire.
(Normal: 110 to 160 VDC)
W
BK Check the voltage between yellow wire and blue wire.
•
(Normal: 13 to 17 VDC)
W
BK
Check the voltage between orange wire and blue wire.
•
A2
(Normal: 2.0 to 6.5 VDC)
Surge
box All check points are normal?
Yes >> Replace the fan motor (Part #103).
No >> Replace the PCB (Part #701).
120 VAC
Appendix C (For error code 51 and 55)
Refer to check point "C" in the diagram to the left and the following.
Check the voltage on the each valve on the gas valve assembly.
Between blue wire and light blue wire (#3) (Normal: 78 to 100 VDC).
•
Between blue wire and green wire (#9) (Normal: 78 to 100 VDC).
•
Between blue wire and orange wire (#53) (Normal: 78 to 100 VDC).
•
Between blue wire and red wire (#73) (Normal: 78 to 100 VDC).
•
All check points are normal?
Yes >> Replace the gas valve assembly (Part #102).
No >> Replace the PCB (Part #701).
Appendix D (For error code 31 and 32)
Outlet thermistor (Find the marking of No.113 on the connector)
•
Check point "E1"
Inlet thermistor (Find the marking of No.42 on the connector)
•
Check point "E2"
Check the resistance between black wire and black wire.
°F 50 59 68 77 86
Temperature
°C 10 15 20 25 30
Resistance kΩ 15.4 12.6 10.3 8.5 7.0
All check points are normal?
Yes >> Replace the PCB (Part #701).
No >> Replace the thermistor (Part #407, 408).
Appendix E (For error code 74)
Refer to check point "F" on the wiring diagram above.
Check the voltage on the remote controller terminal on the PCB.
(Normal: 11 to 25 VDC)
This check point is normal?
Yes >> Replace the remote controller.
No >> Replace the PCB (Part #701).
DIPswitches
Temperature set
ON 1 2 3 4 5 6 7 8
113 °F ON 1 2 3 4 5 6 7 8
(45 °C)
OFF
OFF
ON 1 2 3 4 5 6 7 8
ON 1 2 3 4 5 6 7 8
122 °F (50 °C)
OFF
Default
OFF
131 °F ON 1 2 3 4 5 6 7 8
(55 °C)
OFF
ON 1 2 3 4 5 6 7 8
140 °F
(60 °C)
OFF
95
35
5.9