Rinnai RC80HPi Technical Manual

Controller
In Use Indicator
Indicates that hot water
is being supplied.
Priority Indicator
Indicates that this
controller is setting the
Temperature Display
water temperature.
Indicates temperature
setting or flashes error
Priority Button
code.
When no water is
being supplied,
pressing this button
Thermostat
allows this controller to
set the water
temperature.
ON/OFF Button
Diagnostic Use of the Controller
1. To display error codes, press the ON/OFF button followed by
the thermostat button to cycle through the error codes.
2. To display the water flow through the water heater, press the
thermostat button (hold for 2 seconds) and then press the
ON/OFF button while continuing to hold the thermostat
button.
3. To display the outlet water temperature, press the
button (hold for 2 seconds) and then press the ON/OFF button
while continuing to hold the thermostat button.
To Change the Temperature Scale (ºF / ºC)
With the water heater turned off, press and hold the ON/OFF
button until the display changes to the other temperature scale
(about 5 seconds).
To Turn Off the Controller Sound (Mute)
To turn the sound off (mute), press and hold both the
thermostat buttons until a "beep" is heard (about 5 seconds).

Gas Pressure Setting

NOTE: For additional installation and commissioning information refer
to the Operation and Installation Manual.
WARNING
This appliance must be installed, serviced and removed by a trained
and qualified person. During pressure testing of the consumer piping,
ensure gas valve is turned off before unit is shut off. Failure to do so
may result in serious injury to yourself or damage to the unit.
APPLIANCE OPERATING PRESSURES
Table 1
Gas Inlet
Forced Low
Water
Min./Max
Inlet Max.
NAT.G LPG NAT.G LPG
5"W.C. 8"W.C.
RC80HPi 1 5 0 P I S 0 7 . " 0 W . . C 1 0 . " 6 W . . C
/10.5"W.C. /13.5"W.C.
Commissioning
With all gas appliances in operation at maximum gas rate, the
flowing inlet pressure at the incoming test point on the Rinnai
water heater should read 5" W.C. - 10.5" W.C. on natural gas
and 8" W.C. - 13.5 W.C. on propane gas. If the pressure is
lower, the gas supply is inadequate and the unit will not operate
to specification. Check the gas meter regulator and pipework for
correct operation/sizing and correct as required.

Troubleshooting

Important Safety Notes
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 water heater.
Only trained and qualified service technicians should attempt to
repair this product. Before checking for resistance readings,
disconnect the power source to the unit and isolate the item from
the circuit (unplug it).
(SV1, SV2, SV3 , SV4 and POV) Gas valve and Modulating solenoids: (Set meter above 2K)
Wire color Voltage Resistance Connector #
(SV0) Pink - Black 11 ~ 13 VDC 37 ~ 43 ohms B5
(SV1) Blue - Black 11 ~ 13 VDC 37 ~ 43 ohms B6
(SV2) Yellow - Black 11 ~ 13 VDC 37 ~ 43 ohms B7
(SV3) Red - Black 11 ~ 13 VDC 37 ~ 43 ohms B3
(SV4) Orange - Black 11 ~ 13 VDC 37 ~ 43 ohms B4
(POV) Orange - Orange 2 ~ 15 VDC 67 ~ 81 ohms B2
(M) Water Flow Control Device Servo:
Red or Pink - Orange G2
5 ~ 7 VDC N / A
Blue or White - Orange G2
Red - Pink G2
N / A 30 ~ 50 ohms
Blue - White G2
Gray - Yellow G2
0 ~ 6 VDC N / A
Gray - Brown G2
NOTE: The grey wire listed above turns to black at G connector on the PCB.
(QS) Water Flow Sensor:
Black - Red 11 ~ 13 VDC N / A E5
Yellow - Black 4 ~ 7 VDC 1 ~ 1.4 Mega ohms E5
By-pass Flow Control:
r B w o - n W h e t i G 1
Orange - White 2 ~ 6 VDC G1
15 ~ 35 ohms
Yellow - White G1
(Unit in operating mode)
R d e W - t i h - e r G u o d n G 1
(IG) Ignition System:
Grey - Grey 90 ~ 110 VAC N / A D1
(FM) Combustion Fan Motor:
Red - Black 6 ~ 45 VDC N / A L1
White - Black 5 ~ 10 VDC 9.2 ~ 9.4 K ohms L1
Yellow - Black 11 ~ 13 VDC 3.5 ~ 3.9 K ohms L1
Set your meter to the hertz scale. Reading across the white and black wires at terminals 2 and 4
you should read between 60 and 420 hertz.
Thermal Fuse / Overheat Switch:
B1
Red - White 11 ~ 13 VDC Below 1 ohms
E1
Flame Rod:
Place one lead of your meter to the flame rod and the other to ground.
With the unit running you should read between 5-150 VAC. Set your
Dip Switches Settings
Adjust switches 2 and 3 in the bank of 8 depending on
your altitude according to the table below.
The original PC boards on the water heaters do not
have the bank of 6 dip switches. Only spare PC
boards have this bank.
High Altitude
SW
No.
Level 0
2 Off
High Altitude 0-2000 ft
3 Off
(0-610 m)
Gas Pressure Setting
Ensure gas pressure check under Commissioning has been
completed first! The regulator is electronically controlled and
factory pre-set. Under normal circumstances it does not require
adjustment during installation. Make adjustments only if the unit is
not operating correctly and all other possible causes for incorrect
operation have been eliminated.
1. Turn OFF the gas supply.
2. Turn OFF the 120 V power supply.
3. Remove the front panel from the appliance.
4. Check the gas type using the data plate on the side of the unit.
If using a spare PC board, check that the gas type switches are
in the correct position (dip switch 1 of SW2: ON for natural gas,
NG, and OFF for propane, LPG). See dip switch settings
section below. (ON is towards the right and OFF is towards the
left.) (Fig. 1).
5. Attach the pressure gauge to the burner test point, located on
the gas control (Fig. 2).
6. Turn ON the gas supply.
7. Turn ON the 120 V power supply.
8. If a controller is installed, turn the unit ON with the controller.
Select the maximum delivery temperature and open all
available hot water taps at full.
9. Set the unit to "Forced Low" combustion by setting No. 7 dip
switch of the SW1 set to ON (Fig. 3).
10. Check the burner test point pressure.
thermostat
11. Remove the rubber access plug and adjust the regulator screw
on the modulating valve (Fig. 4) as required in Table 1.
Replace the rubber access plug.
12. Set the unit to "Forced High" combustion by setting both No. 7
and No. 8 dip switches of the SW1 set to ON (Fig. 5). Ensure
maximum water flow.
13. Check the burner test point pressure.
14. Adjust the high pressure potentiometer (POT) on the PC board
as required to the pressure shown in Table 1.
15. Return the unit to normal operation by setting dip switches 7
and 8 of the SW1 set back to OFF (Fig. 6). Close all water
taps.
and
16. Turn OFF the gas supply and 120 V power supply.
17. Remove the pressure gauge and install sealing screw.
18. Turn ON the gas supply and 120 V power supply.
19. Operate the unit and check for gas leaks at the burner test point.
20. Install the front panel.
High Pressure
Potentiometer
SW1
1
SW2
Spare Parts
Only
Fig. 1
Forced High
NAT.G LPG
. 2 " 9 W . . C . 3 " 7 W . . C
Fig. 3
Fig. 5
meter to the µ amp scale and series your meter in line with the flame
rod. You should read 1 µ amp or greater for proper flame circuit. In
the event of low flame circuit remove the flame rod and check for
carbon or damage.
Heat Exchanger and Outgoing Water Temperature
Thermistors:
Check all thermistors by inserting meter leads into each end of the
thermistor plug. Set your meter to the 20 K scale and read
resistance. Applying heat to the thermistor bulb should decrease
the resistance. Applying ice to the thermistor bulb should increase
the resistance. See below for examples of typical temperatures and
Pin #'s
resistance readings.
7 - 8
Example: 59°F = 11.4 ~ 14K
6 - 7
86°F = 6.4 ~ 7.8K
5 - 7
113°F = 3.6 ~ 4.5K
4 - 7
3 - 7
Outgoing Water Thermistor:
10 - 11
White - White
N / A See example above
Blue - Blue
3 or 4 - 8 Heat Exchanger Temperature Thermistor:
1 or 2 - 8
Pink - Pink N / A See example above E2
3 - 4
Surge Protector:
1 - 2
Black - White 108 ~ 132 VAC N / A
7 - 5
White - White 108 ~ 132 VAC N / A
7 - 6
With the power off you can check the continuity through the surge
protector. Place a meter lead on the top pin #1 of the surge
protector and pin #3 on the bottom of the surge protector. Check
1 - 3
across the top pin #3 and bottom pin #1. If you read continuity
2 - 3
across these two points then the surge protector is good. If you do
not get continuity then replace the surge protector.
1 5 -
Temperature Controller:
2 - 5
3 - 5
Terminals A1 10 ~ 13 VDC 1.5 ~ 3.0 K ohms
4 5 -
Frost Protection:
This unit has frost protection heaters mounted at different points to
1 - 2
protect the water heater from freezing. The heaters located on the
hot water outlet line should have a resistance reading of 10-20 ohms
through each of these heaters. The heater located on the heat
1 - 2
2 - 4
exchanger piping should have a resistance reading of 35-50 ohms
2 - 3
and the one located in the water flow sensor valve, hot water out let
and drain connection should have a resistance reading 110-150 ohms.
The heater located on the latent heat exchanger should have a
resistance reading 90-110 ohms.
B13 - E9
Amp Fuses:
This unit has one inline (7) amp glass fuse. Remove the fuse and
check continuity through it. If you have continuity through the fuse
then it is good. Otherwise the fuse is blown and must be replaced.
RC80HPi
LPG NAT.G
ON ON
Move dip switch 1 to OFF for
O 1 O 1
long flue lengths. See below.
F 2 F 2
3 3
F F
4 4
Adjustment for long flue length:
5 5
1. Determine theequivalent length using the
6 6
formula:
7 7
8 8
Equivalent length = Straight lengths + [no. of 90º
ON ON
elbows x 6]
O 1 O 1
(Two 45º elbows = one 90º elbow)
2 2
F F
2. If the equivalent length is greater than 21 ft then
3 3
F F
move dip switch no. 1 to OFF. If the equivalent
4 4
5 5 tength is longer than 41 ft the heater may not
6 6
work properly. The installer should be called.
WARNING
DO NOT adjust the other dip switches unless specifically instructed
to do so. Incorrect Dip Switch Settings can cause the Rinnai water
heater to operate in an unsafe condition and may damage the water
heater and void the warranty.
NOTES
Level 1 Level 2
Off On On
2001-5200 ft 5201-7700 ft
On Off On
(610-1585 m) (1585-2347 m)
Power interruption during Bath Fill (Water will not flow when
03
power returns).
• Turn off all hot water taps. Press ON/OFF twice.
10 Air Supply or Exhaust Blockage
• Ensure Rinnai approved venting materials are being used.
• Check that nothing is blocking the flue inlet or exhaust.
• Check all vent components for proper connections.
• Ensure vent length is within limits.
• Ensure condensation collar was installed correctly.
• Verify dip switches are set properly.
• Check fan for blockage.
• Burner Sensor Error (see code 31)
• Check the fins in the heat exchanger.
11 No Ignition
• Check that the gas is turned on at the water heater, gas meter,
or cylinder.
• Ensure gas type and pressure is correct.
• Ensure gas line, meter, and/or regulator is sized properly.
• Bleed all air from gas lines.
• Verify dip switches are set properly.
• Ensure appliance is properly grounded.
• Disconnect EZConnect™ or MSA controls to isolate the
problem.
• Ensure igniter is operational.
• Check igniter wiring harness for damage.
• Check gas solenoid valves for open or short circuits.
• Remove burner cover and ensure all burners are properly
seated.
• Remove burner plate and inspect burner surface for
condensation or debris.
12 Flame Failure
• Check that the gas is turned on at the water heater and gas
meter. Check for obstructions in the flue outlet.
• Ensure gas line, meter, and/or regulator is sized properly.
• Ensure gas type and pressure is correct.
• Bleed all air from gas lines.
• Ensure proper Rinnai venting material was installed.
• Ensure condensation collar was installed properly.
• Ensure vent length is within limits.
• Verify dip switches are set properly.
Burner
Test Point
• Ensure appliance is properly grounded.
• Disconnect keypad.
• Disconnect EZConnect™ or MSA controls to isolate the
problem.
• Check power supply for loose connections.
• Check power supply for proper voltage and voltage drops.
Regulator adjustment
screw access plug
• Ensure flame rod wire is connected.
• Check flame rod for carbon build-up.
Fig. 2
• Disconnect and reconnect all wiring harnesses on unit and PC
board.
• Check for DC shorts at components.
• Check gas solenoid valves for open or short circuits.
• Remove burner plate and inspect burner surface for
condensation or debris.
• Check the ground wire for the PC board.
Regulator adjustment
screw access plug
14 Thermal Fuse
Fig. 4
• Check gas type of unit and ensure it matches gas type being
used.
• Check for restrictions in air flow around unit and vent terminal.
• Check for low water flow in a circulating system causing short-
cycling.
• Ensure dip switches are set to the proper position.
Fig. 6
• Check for foreign materials in combustion chamber and/or
exhaust piping.
• Check heat exchanger for cracks and/or separations.
• Check heat exchanger surface for hot spots which indicate
blockage due to scale build-up.
Refer to instructions in manual for flushing heat exchanger.
• Measure resistance of safety circuit.
• Ensure high fire and low fire manifold pressure is correct.
• Check for improper conversion of product.
16 Over Temperature Warning
• Check for restrictions in air flow around unit and vent terminal.
• Check for low water flow in a circulating system causing short-
cycling.
• Check for foreign materials in combustion chamber and/or
140°F = 2.2 ~ 2.7K
exhaust piping.
221°F = 0.6 ~ 0.8K
• Check for clogged heat exchanger.
E4 E3 - E4
E3 E6 - E5
5 - 10
C2 1 - 3
C1 1 - 3
BY-PASS FLOW
CONTROL DEVICE
A 1 - 3
OUTGOING WATER
THERMISTOR
HEAT EXCHANGER
THERMISTOR
FF MODEL ONLY
WATER LEVEL ELECTRODE
FF MODEL ONLY
THERMAL FUSES
MODULATING
SOLENOID VALVE
B
3
SOLENOID
Bk Bk
SV3
VALVE 3
R
B
R
4
SOLENOID
Bk
SV4
VALVE 4
O O
B
5
MAIN SOLENOID
P
P
SV0
VALVE
Bk
B
6
SOLENOID
B
B
SV1
VALVE 1
Bk
B
Y
7
SOLENOID
Y
SV2
VALVE 2
Bk Bk
Level 3
7701-10200 ft
(2347-3109 m)

Error Codes

Condensate Trap Error
25
• Condensate container is full.
• Check condensate drain for blockage.
• Replace condensate trap.
Burner Sensor Error
31
• Measure resistance of sensor.
• Replace sensor.
Outgoing Water Temperature Sensor Fault
32
• Check sensor wiring for damage.
• Measure resistance of sensor.
• Clean sensor of scale build-up.
• Replace sensor.
33 Heat Exchanger Outgoing Temperature Sensor Fault
• Check sensor wiring for damage.
• Measure resistance of sensor.
• Clean sensor of scale build-up.
• Replace sensor.
52 Modulating Solenoid Valve Signal Abnormal
• Check modulating gas solenoid valve wiring harness for loose
or damaged terminals.
• Measure resistance of valve coil.
61 Combustion Fan Failure
• Ensure fan will turn freely.
• Check wiring harness to motor for damaged and/or loose
connections.
• Measure resistance of motor winding.
Water Flow Control Fault
65
• The water flow control valve has failed to close during the bath
fill function. Immediately turn off the water and discontinue the
bath fill function. Contact a state qualified or licensed
contractor to service the appliance.
71 SV0, SV1, SV2, SV3 and SV4 Solenoid Valve Circuit Fault
• Replace the PC board.
72 Flame Sensing Device Fault
• Ensure flame rod is touching flame when unit fires.
• Check all wiring to flame rod for damage.
• Remove flame rod and check for carbon build-up; clean with
sand paper.
• Check inside burner chamber for any foreign material blocking
flame at flame rod.
• Measure micro amp output of sensor circuit with flame present.
• Replace flame rod.
73 Burner Sensor Circuit Error
• Check sensor wiring and PC board for damage.
• Replace sensor.
LC Scale Build-up in Heat Exchanger (when checking
maintenance code history, "00" is substituted for "LC")
• Flush heat exchanger. Refer to instructions in manual.
• Replace heat exchanger.
• NOTE: The LC code is the only error code that will allow the
unit to keep running. The display will alternate between the LC
code and the temperature setting. The controller will continue
to beep.
• The LC code will reset if power is turned off and then on.
No Code
• Clean inlet water supply filter.
• On new installations ensure hot and cold water lines are not
reversed.
• Check for bleed over. Isolate unit from building by turning off
hot water line to building. Isolate the circulating system if
present. Open your pressure relief valve; if water is flowing,
there is bleed over in your plumbing.
• Ensure you have at least the minimum flow rate required to fire
unit.
• Ensure turbine spins freely.
• Measure the resistance of the water flow control sensor.
• Check for DC shorts at components.

Wire Diagram

G
1
Br Br
O O
Y Y
R R
W W
R R
WATER FLOW
QS
Y Y
SENSOR
Bk Bk
E
E
5
7
Br O R Br P W
ANTI-FROST UNIT R
R Y Bk Y R B
(OPTIONAL)
W
E G
4
W
W
W W 12 1
W
B (CN7)
11 1
(CN11)
W B
E
3 E
2
W P
R Dip SW1
W
P
W Bk 1
2
E
6 W 3
BURNER
4
Bk
Bk
5
THERMISTOR
B W W
Bk
Bk 3 1
6
(CN9)
Gr
P W Y 7 ｝
W W
8
I
Gr → ON
E
GND
L
Dip SW2
1
14 (CN5) 1
R O 1
W W W
COMBUSTION FAN
Y Y 2
FM Y O
3
Bk Bk Bk
SHORT 4
R R
R L
5
W MODEL ONLY 6
OVERHEAT → ON
1 4
SWITCH
E
RR (CN12) Y
1
R
R R
R W B
M
WW B W
OVERHEAT (CN2) Y
3 1
1
(CN13)
SWITCH
13 1
O O
Bk Y
A
B 3 1
O P B R
2
(CN1)
O O
POV
(CN4)
O O
1
Gy
Bk D
2 Gy
R
(CN3)
3
Gr/Y
C
O W
Bk
1
P
B
Y
Bk
070 00012 30385 7
(Nothing happens when water flow is activated.)
Gy Gy
Br Br
O O
G
Y Y 2
W W
WATER FLOW
P P
CONTROL DEVICE
B B
R R
W S-BMS/AIR
(OPTIONAL)
Bk
HANDLER
R
R
REU-MSA (OPTIONAL)
W
REU-EZC (OPTIONAL)
R
Bk
COLOUR CODING
W :White
Bk:Black
MODULATING VALVE
MAX Br:Brown
CURRENT ADJUSTING
R :Red
MIN
B :Blue
Y :Yellow
P :Pink
O :Orange
Gr:Green
Gas pressure setting
Gy:Gray
Pu:Purple
Gas Type
Spare parts only
B
8
Y FLAME ROD1 FF MODEL ONLY
FLAME ROD2
R
M
FROST SENSING
1
SWITCH
ANTI-FROST
Temperature
Bk HEATER
C
4
W
Controller FF MODEL
Bk
W
ONLY
A
1
C
ANTI-FROST
5
HEATER
FUSE
D C
1 6 ANTI-FROST
(7A)
Gy
IG
SPARK HEATER
Gy
C
7
ELECTRODE W Bk
IGNITER
C
3
ANTI-FROST
Bk W
SURGE HEATER
Gr
PROTECTOR
C
2
Bk W
1
3
GND
W
W
1
3
AC120V 60Hz
C
1 Gr/Y
GND
GND
RC80HPi
(KA2530FFUD-US)
U290-761(00)