Rinnai R98LSi-ASME Service manual

Rinnai R98LSi-ASME Service manual

Tankless Water Heater

Service Manual

Trade Name Model

R42e .................... REU-V1616W

C42e .................... REU-V1616WC

R53e .................... REU-V2020W

C53e .................... REU-V2020WC

R70e .................... REU-V2526W

R85e .................... REU-V2532W

C85e .................... REU-V2532WC

R85ePLUS ........... REU-V2532WD

C85ePLUS ........... REU-V2532WCD

R98e .................... REU-V3237W

C98e .................... REU-V3237WC

R98eASME .......... REU-V3237W-ASME

C98eASME .......... REU-V3237WC-ASME

V Series

Trade Name Model

R53i ..................... REU-V2520FFU

C53i ..................... REU-V2520FFUC

R53i ..................... REU-V2520FFUD

C53i ..................... REU-V2520FFUCD

R85i ..................... REU-V2532FFU

C85i ..................... REU-V2532FFUC

R85iPLUS ............ REU-V2532FFUD

C85iPLUS ............ REU-V2532FFUCD

R98i ..................... REU-V3237FFU

C98i ..................... REU-V3237FFUC

R98iASME ........... REU-V3237FFU-ASME

C98iASME ........... REU-V3237FFUC-ASME

Trade Name Model

V53e .................... REU-VAM1620W

R63LSe ................ REU-VA2024WD

R75LSe ................ REU-VA2528WD

R75LSe ................ REU-VA2528WD(A)

R94LSe ................ REU-VA2535WD

R98LSe ................ REU-VA3237W

R98LSeASME ..... REU-VA3237W-ASME

VA Series

Trade Name Model

R50LSi ................. REU-VA2019FFUD

R75LSi ................. REU-VA2528FFUD

R75LSi ................. REU-VA2528FFUD(A)

R94LSi ................. REU-VA2535FFUD

R98LSi ................. REU-VA3237FFU

R98LSiASME ...... REU-VA3237FFU-ASME

Table of Contents

General Information

.................................................. 3

Specifications

........................................................ 4, 5

Schematic Diagrams

............................................. 6, 7

Fault Isolation

....................................................... 8-10

Electrical Diagnostic Points

R/C42e, R/C53e, ............................................ 11, 12

R70e, R/C85e(PLUS),

R/C53i(PLUS), R/C85i(PLUS) ........................ 13, 14

R/C98e(ASME), R/C98i(ASME) ...................... 15, 16

V53e, R63LSe ................................................. 17, 18

R50LSi, R75LSe, R75LSi, R94LSe, R94LSi ... 19, 20

R98LSe(ASME), R98LSi(ASME) .................... 21, 22

Wire Diagrams

R/C42e, R/C53e .................................................... 23

R70e, R/C85e(PLUS) ............................................ 24

R/C53i(PLUS), R/C85i(PLUS)............................... 25

R/C98e(ASME), R/C98i(ASME) ............................ 26

V53e, R63LSe ....................................................... 27

R50LSi, R75LSe, R75LSi, R94LSe, R94LSi ......... 28

R98LSe(ASME), R98LSi(ASME) .......................... 29

Flushing the Heat Exchanger

................................. 30

Component Replacement Instructions

Gas Control Assembly

R/C42e, R/C53e, V53e, R63LSe .................... 31, 32

R/C53i(PLUS), R70e, R/C85e(PLUS),

R/C85i(PLUS), R50LSi, R75LSe, R75LSi,

R94LSe, R94LSi ............................................. 33, 34

R/C98e(ASME), R/C98i(ASME),

R98LSe(ASME), R98LSi(ASME) .................... 35, 36

Fan

R/C42e, R/C53e, V53e, R63LSe .......................... 37

R70e, R/C85e(PLUS), R75LSe, R94LSe ............. 38

R/C53i(PLUS), R/C85i(PLUS),

R50LSi, R75LSi, R94LSi ....................................... 39

R/C98e(ASME), R/C98i(ASME),

R98LSe(ASME), R98LSi(ASME) .......................... 40

PC Board

R/C42e, R/C53e .................................................... 41

V53e, R63LSe ....................................................... 42

R/C53i(PLUS), R70e, R/C85e(PLUS),

R/C85i(PLUS), R50LSi, R75LSe, R75LSi,

R94LSe, R94LSi ............................................... 43-45

R/C98e(ASME), R/C98i(ASME),

R98LSe(ASME), R98LSi(ASME) .......................... 46

Water Flow Control Assembly

R/C42e, R/C53e .............................................. 47, 48

V53e, R63LSe ................................................. 49, 50

R/C53i(PLUS), R50LSi, R75LSe, R75LSi ....... 51, 52

R/C85e(PLUS), R/C85i(PLUS),

R94LSe, R94LSi .............................................. 53, 54

R/C98e(ASME), R/C98i(ASME),

R98LSe(ASME), R98LSi(ASME) .......................... 55

Heat Exchanger

R/C42e, R/C53e, V53e, R63LSe ...................... 56-58

R70e, R75LSe .................................................. 59-61

R/C85e(PLUS), R94LSe .................................. 62-64

R/C53i(PLUS), R75LSi ..................................... 65-68

R/C85i(PLUS), R94LSi ..................................... 69-73

R/C98e(ASME), R98LSe(ASME) ..................... 74-75

R/C98i(ASME), R98LSi(ASME) ....................... 76-78

Gas Pressure Setting Procedure

..................... 79, 80

Manifold Pressure Settings

.............................. 81, 82

Dip Switches

...................................................... 83, 84

Key to Trade Names in this Manual:

R/C Indicates both the residential and commercial versions. R/C42e includes

R42e and C42e.

(PLUS) Indicates that the Designer Plus models are included. R/C85ePLUS includes R85e,

C85e, and R85ePLUS. On the side of the water heater, the trade name includes a “D”, as in R85De.

(ASME) Indicates that the ASME models are included. R98LSe(ASME) includes the

R98LSe and R98LSeASME.

Rinnai Water Heater Service Manual 2

General Information

Safety Definitions

This is the safety alert symbol. This symbol alerts you to potential hazards that can kill or hurt you and others.

DANGER

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury. It may also be used to alert against unsafe practices.

Using this Manual

Repairs should be performed by a qualified service technician.

The following information can be referenced for additional information.

Operation and Installation Manual

• Hot Water System Design Manual

Technical Sheets

• Technical Bulletins

Technical Support

Technicians are available to assist in servicing issues. Contact Rinnai Technical Services at 1-800-621-9419.

Recommended Tools

Volt/Ohm/Amp meter with test probes

Digital manometer or U tube type manometer with 14 inch water column (W.C.) scale, a hose and two 1/8 inch taps

• assorted wrenches including a 3/16 Allen wrench

• assorted screw drivers

• leak solution or leak detector

Teflon tape

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 water heater. Before checking for resistance readings disconnect the power source to the unit and isolate the item from the circuit (unplug it).

CAUTION

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.

3

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.

Rinnai Water Heater Service Manual

Specifications

V Series - Commercial - Outdoor

Trade Name Model Max. BTU

C42e

C53e

C85e

C85ePLUS

C98e

C98eASME

REU-V1616WC

REU-V2020WC

REU-V2532WC

REU-V2532WCD

REU-V3237WC

REU-V3237WC-ASME

120,000

150,000

199,000

199,000

237,000

237,000

Min. BTU

17,100 (NG)

17,800 (LP)

19,000 (NG)

20,200 (LP)

15,000

15,000

19,000

19,000

Max Flow

[1] gal/min (liters/min)

4.2 (16)

5.3 (20)

8.5 (32)

8.5 (32)

9.8 (37)

9.8 (37)

Temperature Range

120 - 185 ºF (49-85 ºC)

120 - 185 ºF (49-85 ºC)

98 - 185 ºF (37-85 ºC)

98 - 185 ºF (37-85 ºC)

98 - 185 ºF (37-85 ºC)

98 - 185 ºF (37-85 ºC)

V Series - Commercial - Indoor

Trade Name Model Max. BTU

C53i

C53iPLUS

C85i

C85iPLUS

C98i

C98iASME

REU-V2520FFUC

REU-V2520FFUCD

REU-V2532FFUC

REU-V2532FFUCD

REU-V3237FFUC

REU-V3237FFUC-ASME

180,000

180,000

180,000

180,000

237,000

237,000

Min. BTU

15,000

15,000

15,000

15,000

19,000

19,000

Max Flow

[1] gal/min (liters/min)

5.3 (20)

5.3 (20)

8.5 (32)

8.5 (32)

9.8 (37)

9.8 (37)

Temperature Range

120 - 185 ºF (49-85 ºC)

120 - 185 ºF (49-85 ºC)

98 - 185 ºF (37-85 ºC)

98 - 185 ºF (37-85 ºC)

98 - 185 ºF (37-85 ºC)

98 - 185 ºF (37-85 ºC)

V Series - Residential - Outdoor

Trade Name Model Max. BTU

R42e

R53e

R70e

R85e

R85ePLUS

R98e

R98eASME

REU-V1616W

REU-V2020W

REU-V2526W

REU-V2532W

REU-V2532WD

REU-V3237W

REU-V3237W-ASME

120,000

150,000

199,000

199,000

199,000

237,000

237,000

Min. BTU

17,100 (NG)

17,800 (LP)

19,000 (NG)

20,200 (LP)

15,000

15,000

15,000

19,000

19,000

Max Flow

[1] gal/min (liters/min)

4.2 (16)

5.3 (20)

7.0 (26)

8.5 (32)

8.5 (32)

9.8 (37)

9.8 (37)

V Series - Residential - Indoor

Trade Name

R53i

R53iPLUS

R85i

R85iPLUS

R98i

R98iASME

Model

REU-V2520FFU

REU-V2520FFU

REU-V2532FFU

REU-V2532FFUD

REU-V3237FFU

REU-V3237FFU-ASME

Max. BTU

180,000

180,000

180,000

180,000

237,000

237,000

Min. BTU

15,000

15,000

15,000

15,000

19,000

19,000

Max Flow

[1] gal/min (liters/min)

5.3 (20)

5.3 (20)

8.5 (32)

8.5 (32)

9.8 (37)

9.8 (37)

[1] Minimum activation flow is approximately 0.6 gallons/minute (2.3 liters/min)

Rinnai Water Heater Service Manual

Temperature Range

98 - 140 ºF (37-60 ºC)

98 - 140 ºF (37-60 ºC)

98 - 140 ºF (37-60 ºC)

98 - 140 ºF (37-60 ºC)

98 - 140 ºF (37-60 ºC)

98 - 140 ºF (37-60 ºC)

98 - 140 ºF (37-60 ºC)

Temperature Range

98 - 140 ºF (37-60 ºC)

98 - 140 ºF (37-60 ºC)

98 - 140 ºF (37-60 ºC)

98 - 140 ºF (37-60 ºC)

98 - 140 ºF (37-60 ºC)

98 - 140 ºF (37-60 ºC)

4

Specifications

VA Series (LS Series) - Residential or Commercial - Outdoor

Trade Name Model Max. BTU Min. BTU Max Flow

[1] gal/min (liters/min)

R63LSe

R75LSe

REU-VA2024WD-US

REU-VA2528WD-US

R75LSe

R94LSe

REU-VA2528WD(A)-US

REU-VA2535WD-US

R98LSe

REU-VA3237W-US

R98LSeASME

REU-VA3237W-ASME

150,000

199,000

180,000

199,000

237,000

237,000

21,500 (NG)

20,600 (LP)

15,000

15,000

15,000

19,000

19,000

6.3 (24)

7.5 (28)

7.5 (28)

9.4 (35)

9.8 (37)

9.8 (37)

Temperature Range

98 - 140 ºF (37-60 ºC) [2]

98 - 140 ºF (37-60 ºC) [2]

98 - 140 ºF (37-60 ºC) [2]

98 - 140 ºF (37-60 ºC) [3]

98 - 140 ºF (37-60 ºC) [3]

98 - 140 ºF (37-60 ºC) [3]

VA Series (LS Series) - Residential or Commercial - Indoor

Trade Name Model Max. BTU

R50LSi

R75LSi

R75LSi

R94LSi

R94LSi

REU-VA2019FFUD-US

REU-VA2528FFUD-US

REU-VA2528FFUD(A)-

US

REU-VA2535FFUD-US-P

R98LSi

REU-VA3237FFU-US

R98LSiASME

REU-VA3237FFU-ASME

150,000

199,000

180,000

REU-VA2535FFUD-US-N

199,000

190,000

237,000

237,000

Min. BTU

15,000

15,000

15,000

15,000

15,000

19,000

19,000

Max Flow

[1] gal/min (liters/min)

5.0 (19)

7.5 (28)

7.5 (28)

9.4 (35)

9.4 (35)

9.8 (37)

9.8 (37)

Temperature Range

98 - 140 ºF (37-60 ºC) [2]

98 - 140 ºF (37-60 ºC) [2]

98 - 140 ºF (37-60 ºC) [2]

98 - 140 ºF (37-60 ºC) [3]

98 - 140 ºF (37-60 ºC) [3]

98 - 140 ºF (37-60 ºC) [3]

98 - 140 ºF (37-60 ºC) [3]

VA Series - Residential - Outdoor

Trade Name Model Max. BTU

V53e

REU-VAM1620W-US

120,000

Min. BTU

19,000 (NG)

20,200 (LP)

Max Flow

[1] gal/min (liters/min)

5.3 (20)

Temperature Range

98 - 140 ºF (37-60 ºC)

[1] Minimum activation flow is approximately 0.6 gallons/minute (2.3 liters/min)

[2] Max temperature is 160 ºF (71 ºC) with the MCC-91 controller for commercial and hydronic applications only.

[3] Max temperature is 185 ºF (85 ºC) with the MCC-91 controller for commercial and hydronic applications only.

5 Rinnai Water Heater Service Manual

(NOT PRESENT ON

ALL MODELS)

Schematic Diagrams

Outdoor Model

(NOT PRESENT ON

ALL MODELS)

(LOCATED ON BRACKET NEAR

FAN ON SOME MODELS)

Rinnai Water Heater Service Manual 6

(NOT PRESENT ON

ALL MODELS)

Schematic Diagrams

Indoor Model

(NOT PRESENT ON

ALL MODELS)

(LOCATED ON BRACKET NEAR

FAN ON SOME MODELS)

7 Rinnai Water Heater Service Manual

Fault Isolation

The Rinnai water heater has the ability to check its own operation continuously. If a fault occurs, an error code will flash on the display of the remote controller. This assists with diagnosing the fault and may enable you to overcome a problem without a service call.

WARNING

Some of the checks below may need to be done by a qualified service technician. Call a service technician for any remedy that involves gas or electricity. Call a service technician if you have any doubt or reservation about performing the remedy yourself.

Accessing Information

Models MC-91 and MCC-91

To display the most recent error codes press and hold the “On/Off” button for 2 seconds. While holding the “On/

Off” button press the ▲ button. The last 9 error codes will flash one after the other. To exit this mode press the

“On/Off” and ▲ button as before.

To display the water flow through the water heater press and hold the ▲ button for 2 seconds and without releasing the ▲ button press the “On/Off” button.

To display the outlet water temperature press and hold the ▼ button for 2 seconds and without releasing the ▼ button press the “On/Off” button.

Operation

Water Flow Sensor sends pulses to the PC

Board.

PC Board senses flow greater than 0.6 GPM

(approximate).

Firing Sequence begins.

2. Firing Sequence.

PC Board monitors inlet/outlet water temperature, temperature set point, and water flow rate.

Combustion fan energized. Purges combustion chamber.

Spark igniter begins sparking.

Gas control valve opens to minimum fire rate.

Flame rod proves ignition.

Spark igniter stops sparking.

3. Normal Operation.

PC Board monitors flame rod, fan motor frequency, outlet water temperature, controller temperature set point and water flow rate.

Gas control valve modulates gas input to required firing rate.

Combustion fan speed is adjusted for the required firing rate.

Water flow control valve is adjusted as needed.

4. Shut-down Sequence.

PC Board senses flow rate less than 0.5 gpm

(approximate).

Gas control valve closes.

Water flow control valve resets to standby position.

Combustion fan runs for a short period of time at low speed.

5. Standby

PC Board monitors water temperature and remote controls.

Freeze protection is activated as needed.

Rinnai Water Heater Service Manual 8

Fault Isolation

Code Fault

02

No burner operation during freeze protection mode

Remedy

Service Call

03

10

11

12

Power interruption during

Bath Fill (Water will not flow when power returns).

Air Supply or Exhaust

Blockage

No Ignition

Flame Failure

Turn off all hot water taps. Press ON/OFF twice.

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.

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.

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.

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.

Ensure flame rod wire is connected.

Remove flame rod and check for carbon build-up; clean with sand paper or emery cloth.

Disconnect and reconnect all wiring harnesses on unit and PC board.

Check all components for electrical short.

Check gas solenoid valves for open or short circuits.

Remove burner plate and inspect burner surface for condensation or debris.

9 Rinnai Water Heater Service Manual

Code Fault

14

Thermal Fuse

16

32

33

34

52

61

65

71

72

LC

No code

Over Temperature

Warning

Outgoing Water

Temperature Sensor

Fault

Heat Exchanger

Outgoing Temperature

Sensor Fault

Combustion Air

Temperature Sensor

Fault

Modulating Solenoid

Valve Signal Abnormal

Combustion Fan

Failure

Water Flow Control

Fault

SV0, SV1, SV2, and

SV3 Solenoid Valve

Circuit Fault

Flame Sensing Device

Fault

Remedy

Fault Isolation

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.

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 buildup. 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.

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 exhaust piping.

Check for clogged heat exchanger.

Check sensor wiring for damage.

Measure resistance of sensor.

Clean sensor of scale build-up.

Replace sensor.

Check sensor wiring for damage.

Measure resistance of sensor.

Clean sensor of scale build-up.

Replace sensor.

Check for restrictions in air flow around unit and vent terminal.

Check sensor wiring for damage.

Measure resistance of sensor.

Clean sensor of scale build-up.

Ensure fan blade is tight on motor shaft and is in good condition.

Replace sensor.

Check modulating gas solenoid valve wiring harness for loose or damaged terminals.

Measure resistance of valve coil.

Ensure fan will turn freely.

Check wiring harness to motor for damaged and/or loose connections.

Measure resistance of motor winding.

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.

Check wiring harness to all solenoids for damage and/or loose connections.

Measure resistance of each solenoid valve coil.

Scale Build-up in Heat

Exchanger (when checking maintenance code history, “00” is substituted for “LC”)

Nothing happens when water flow is activated.

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 or emery cloth.

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.

Flush heat exchanger. Refer to instructions in manual.

Replace heat exchanger.

NOTE: The LC code is the only 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.

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.

Rinnai Water Heater Service Manual 10

Electrical Diagnostic Points

R/C42e, R/C53e

Wire Color Voltage Resistance Connector No. Pin No.’s

(TR) Transformer

Black - White

Blue - Brown

(SV1, SV2, SV3, POV) Gas Valve and Modulating Solenoids

(Main) Pink - Black

(SV1) Black - Blue

(SV2) Black - Yellow

(POV) Pink - Pink

90 - 100 VAC

108 - 132 VAC

80 - 100 VDC

2 - 15 VDC

51-63 ohms

51-63 ohms

1.7 - 2 K ohms

67 - 81 ohms

F9

F7

E1

E2

E3

C2

(M) Water Flow Servo

Red - Blue

Gray - Brown

Gray - Yellow

11 - 13 VDC

4 - 6 VDC

N/A

22 - 26 ohms

N/A

N/A

B1

B1

B1

Gray - Orange 11 - 14 VDC N/A B1

NOTE: At the B connector on the PCB: gray wire turns to black, orange wire turns to red

(QS) Water Flow Sensor

Black - Red 11 - 13 VDC 5.5 - 6.2 K ohms B3

Yellow - Black 4 - 7 VDC 1 - 1.4 mega ohms B3

Bypass Flow Control

(only on R/C85e, R/C85ePLUS, R/C85i, R/C85iPLUS)

Brown - White

Orange - White

Yellow - White

2 - 6 VDC

(unit in operating mode)

15 - 35 K ohms G1

Red - White/Ground

(IG) Ignition System

Gray - Gray 90 - 100 VAC N/A F1

1 ~ 2

1 ~ 3

1 ~ 2

2 ~ 3

2 ~ 4

3 ~ 4

9 ~ 10

5 ~ 7

5 ~ 8

5 ~ 6

5 ~ 6

1 ~ 5

4 ~ 5

2 ~ 5

1 ~ 5

3 ~ 5

1 ~ 2

(FM) Combustion Fan Motor

Red - Black

White - Black

6 - 45 VDC

5 - 10 VDC

N/A

9.2 - 9.4 K ohms

A1

A1

1 ~ 2

2 ~ 4

Yellow - Black 11 ~ 13 VDC 3.5 - 3.9 K ohms A1

With the meter set on hertz scale, 60-350 hertz should be across the red and yellow wires at terminals 2 and 3.

2 ~ 3

11 Rinnai Water Heater Service Manual

Electrical Diagnostic Points

R/C42e, R/C53e

Wire Color Voltage Resistance Connector No. Pin No.’s

Thermal Fuse / Overheat Switch

Red - Red 12 VDC below 1 ohm B - C B6 ~ C1

Flame Rod

Place one lead of the meter to the flame rod and the other to ground. With the unit running, 5-150

VAC should be read. Set the meter to the µ amp scale and series the meter in line with the flame rod. Proper flame circuit should read 1 µ amp or greater. If not, then remove the flame rod and check for carbon and damage.

Thermistors

Check all thermistors by inserting meter leads into each end of the thermistor plug. Set the meter to the 20 K ohm scale and read resistance. Applying heat to the thermistor bulb should decrease the resistance. Applying ice to the thermistor bulb should increase the resistance. Typical resistance values are: 11.4-14 K ohm for 59°F; 6.4-7.8 K ohm for 86°F; 3.6-4.5 K ohm for 113°F; 2.2-2.7 K ohm for 140°F; 0.6-0.8 K ohm for 221°F

Outgoing Water Thermistor

White - White see above

Heat Exchanger Temperature Thermistor

White - White see above

B B3 ~ B4

B B3 ~ B12

Surge Protector

Blue - Brown

Blue - Brown

108 - 132 VAC

108 - 132 VAC

N/A

N/A

F4

F3

1 ~ 2

1 ~ 3

With the power off, check the continuity through the surge protector. Check by placing one meter lead on the top pin #1 and bottom pin #2. Check by placing one meter lead on the top pin #3 and bottom pin #1. If there is continuity across both sets of points, then the surge protector is good.

Controller

Terminals D1

10 - 13 VDC digital

1.5 - 1.9 K ohms D 1 ~ 3

Frost Protection

There are electrical heating elements mounted at different points to protect the water heater from freezing. heaters located on the hot water outlet line heater located on heat exchanger piping

26 - 30 ohms

81 - 86 ohms heater located on water flow sensor 16 - 19 ohms

Amp fuses

There are two inline 3 amp glass fuses. Remove the fuse and check continuity through it. If there is continuity then the fuse is good.

Rinnai Water Heater Service Manual 12

Electrical Diagnostic Points

R70e, R/C85e(PLUS),

R/C53i(PLUS), R/C85i(PLUS)

Wire Color Voltage Resistance Connector No. Pin No.’s

(TR) Transformer

Black - White

Blue - Brown

90 - 100 VAC

108 - 132 VAC

51-63 ohms

51-63 ohms

F9

F7

(SV1, SV2, SV3, POV) Gas Valve and Modulating Solenoids

(Main) Pink - Black

(SV1) Black - Yellow

(SV2) Black - Blue

(SV3) Black - Brown

(POV) Pink - Pink

80 - 100 VDC

2 - 15 VDC

1.7 - 2 K ohms

67 - 81 ohms

E1

E2

E3

E4

C2

(M) Water Flow Servo

Red - Blue

Gray - Brown

Gray - Yellow

11 - 13 VDC

4 - 6 VDC

N/A

22 - 26 ohms

N/A

N/A

B

B

B

Gray - Orange 11 - 14 VDC N/A B

NOTE: At the B connector on the PCB: gray wire turns to black, orange wire turns to red

1 ~ 2

1 ~ 3

1 ~ 2

2 ~ 3

2 ~ 4

2 ~ 5

3 ~ 4

9 ~ 10

5 ~ 7

5 ~ 8

5 ~ 6

(QS) Water Flow Sensor

Black - Red

Yellow - Black

11 - 13 VDC

4 - 7 VDC

5.5 - 6.2 K ohms

1 - 1.4 mega ohms

Bypass Flow Control

(only on R/C85e, R/C85ePLUS, R/C85i, R/C85iPLUS)

B

B

Brown - White

Orange - White

Yellow - White

Red - White/Ground

2 - 6 VDC

(unit in operating mode)

15 - 35 K ohms G1

5 ~ 6

1 ~ 5

4 ~ 5

2 ~ 5

1 ~ 5

3 ~ 5

(IG) Ignition System

Gray - Gray 90 - 100 VAC N/A F8 1 ~ 2

(FM) Combustion Fan Motor

Red - Black 6 - 45 VDC N/A A1 1 ~ 2

White - Black

Yellow - Black

5 - 10 VDC

11 ~ 13 VDC

9.2 - 9.4 K ohms

3.5 - 3.9 K ohms

A1

A1

With the meter set on hertz scale, 60-350 hertz should be across the red and yellow wires at terminals 2 and 3.

2 ~ 4

2 ~ 3

13 Rinnai Water Heater Service Manual

Electrical Diagnostic Points

R70e, R/C85e(PLUS),

R/C53i(PLUS), R/C85i(PLUS)

Wire Color Voltage Resistance Connector No. Pin No.’s

Thermal Fuse / Overheat Switch

Red - Red 12 VDC below 1 ohm B - C B6 ~ C1

Flame Rod

Place one lead of the meter to the flame rod and the other to ground. With the unit running, 5-150

VAC should be read. Set the meter to the µ amp scale and series the meter in line with the flame rod. Proper flame circuit should read 1 µ amp or greater. If not, then remove the flame rod and check for carbon and damage.

Thermistors

Check all thermistors by inserting meter leads into each end of the thermistor plug. Set the meter to the 20 K ohm scale and read resistance. Applying heat to the thermistor bulb should decrease the resistance. Applying ice to the thermistor bulb should increase the resistance. Typical resistance values are: 11.4-14 K ohm for 59°F; 6.4-7.8 K ohm for 86°F; 3.6-4.5 K ohm for 113°F; 2.2-2.7 K ohm for 140°F; 0.6-0.8 K ohm for 221°F

Outgoing Water Thermistor

White - White see above

Heat Exchanger Temperature Thermistor

White - White see above

B B3 ~ B4

B B3 ~ B12

Surge Protector

Blue - Brown

Blue - Brown

108 - 132 VAC

108 - 132 VAC

N/A

N/A

F6

F7

1 ~ 2

1 ~ 3

With the power off, check the continuity through the surge protector. Check by placing one meter lead on the top pin #1 and bottom pin #2. Check by placing one meter lead on the top pin #3 and bottom pin #1. If there is continuity across both sets of points, then the surge protector is good.

Controller

Terminals D1

10 - 13 VDC digital

1.5 - 1.9 K ohms D 1 ~ 3

Frost Protection

There are electrical heating elements mounted at different points to protect the water heater from freezing. heaters located on the hot water outlet line heater located on heat exchanger piping

26 - 30 ohms

81 - 86 ohms heater located on water flow sensor 16 - 19 ohms

Amp fuses

There are two inline 3 amp glass fuses. Remove the fuse and check continuity through it. If there is continuity then the fuse is good.

Rinnai Water Heater Service Manual 14

Electrical Diagnostic Points

R/C98e(ASME),

R/C98i(ASME)

Wire Color Voltage Resistance Connector No. Pin No.’s

(SV1, SV2, SV3, POV) Gas Valve and Modulating Solenoids

(Main) Pink - Black

(SV1) Black - Red

(SV2) Black - Orange

11 - 13 VDC 24 - 28 ohms

(SV3) Black - Yellow

(POV) Orange - Orange 3 - 15 VDC 67 - 81 ohms

(M) Water Flow Servo

Red - Blue

Gray - Brown (closed position)

11 - 13 VDC below 1 VDC

4 - 6 VDC

N/A

Limiter On

Limiter Off

Gray - Yellow (open position) below 1 VDC

4 - 6 VDC

Limiter On

Limiter Off

NOTE: At the G connector on the PCB: gray wire turns to black

(QS) Water Flow Sensor

Black - Red

Yellow - Black

11 - 13 VDC

4 - 7 VDC

N/A

N/A

F1

F2

F3

F4

E2

G6

G6

G6

4 ~ 5(F)

3 ~ 4(F)

2 ~ 4(F)

1 ~ 4(F)

3 ~ 4(E)

5 ~ 6(G)

8 ~ 11(G)

7 ~ 11(G)

G3

G3

9 ~ 15(G)

11 ~ 15(G)

Bypass Flow Control

Brown - White

Orange - White

2 - 6 VDC

(unit in operating mode)

15 - 35 K ohms

Yellow - White

Red - White/Ground

NOTE: At the G connector on the PCB: white wire turns to red

(IG) Ignition System

Gray - Gray 90 - 100 VAC N/A

H1

1(H) ~ 9(G)

3(H) ~ 9(G)

4(H) ~ 9(G)

2(H) ~ 9(G)

C1 1 ~ 2(C)

(FM) Combustion Fan Motor

Red - Black

White - Black

6 - 45 VDC

5 - 10 VDC

N/A

N/A

B1

B1

1 ~ 2(B)

2 ~ 4(B)

Yellow - Black 11 ~ 13 VDC N/A B1 2 ~ 3(B)

With the meter set on hertz scale, 17-460 hertz should be across the white and black wires at terminals 2 and 4.

15 Rinnai Water Heater Service Manual

Electrical Diagnostic Points

R/C98e(ASME),

R/C98i(ASME)

Wire Color Voltage Resistance Connector No. Pin No.’s

Thermal Fuse

Blue - Red

Overheat Switch

Blue - Red

12 VDC below 1 ohm E6 10(G) ~ 1(E)

12 VDC below 1 ohm F1 N/A

Flame Rod

Place one lead of the meter to the flame rod and the other to ground. With the unit running, 5-150

VAC should be read. Set the meter to the µ amp scale and series the meter in line with the flame rod. Proper flame circuit should read 1 µ amp or greater. If not, then remove the flame rod and check for carbon build-up. Clean with sand paper or emery cloth.

Thermistors

Check all thermistors by inserting meter leads into each end of the thermistor plug. Set the meter to the 20 K ohm scale and read resistance. Applying heat to the thermistor bulb should decrease the resistance. Applying ice to the thermistor bulb should increase the resistance. Typical resistance values are: 11.4-14 K ohm for 59°F; 6.4-7.8 K ohm for 86°F; 3.6-4.5 K ohm for 113°F; 2.2-2.7 K ohm for 140°F; 0.6-0.8 K ohm for 221°F

Outgoing Water Thermistor

White - White see above G5 12 ~ 13(G)

Heat Exchanger Temperature Thermistor

White - White see above G4 4 ~ 13(G)

Surge Protector

Black - White

Black - White

108 - 132 VAC

108 - 132 VAC

N/A

N/A

D1

D2

1 ~ 2(D)

With the power off, check the continuity through the surge protector. Check by placing one meter lead on the top pin #1 and bottom pin #2. Check by placing one meter lead on the top pin #2 and bottom pin #1. If there is continuity across both sets of points, then the surge protector is good.

Controller

Black - Black

10 - 13 VDC digital

Frost Protection

White - White

White - White

White - White

120 VAC *

60 VAC *

60 VAC*

* only when Frost Sensing Switch (D3) is ON

N/A

150 ohms

360 ohms

360 ohms

A1

D4

D5

D6

1 ~ 3(A)

N/A

N/A

N/A

Amp fuses

There are two inline 3 amp glass fuses. Remove the fuse and check continuity through it. If there is continuity then the fuse is good.

Rinnai Water Heater Service Manual 16

Electrical Diagnostic Points

V53e, R63LSe

Wire Color Voltage Resistance Connector No. Pin No.’s

(SV1, SV2, SV3, POV) Gas Valve and Modulating Solenoids

(Main) Pink - Black 37 - 43 ohms

11 - 13 VDC (SV1) Black - Blue

(SV2) Black - Yellow

(POV) Pink - Pink 2 - 15 VDC

35 - 41 ohms

37 - 43 ohms

67 - 81 ohms

(M) Water Flow Servo

Red - Blue

Gray - Brown

11 - 13 VDC

4 - 6 VDC

22 - 28 ohms

N/A

Gray - Yellow N/A N/A

NOTE: At the E connector on the PCB: gray wire turns to black

F5

F6

F7

F3

E5

E5

E5

8 ~ 9

9 ~ 10

9 ~ 11

3 ~ 4

9 ~ 8

4 ~ 5

4 ~ 6

(QS) Water Flow Sensor

Black - Red

Yellow - Black

(IG) Ignition System

Gray - Gray

11 - 13 VDC

4 - 7 VDC

5.5 - 6.2 K ohms

1 - 1.4 mega ohms

E2

E2

3 ~ 4

1 ~ 4

90 - 110 VAC N/A B1 1 ~ 2

(FM) Combustion Fan Motor

Red - Black

White - Black

6 - 45 VDC

5 - 10 VDC

N/A

9.2 - 9.4 K ohms

D1

D1

1 ~ 2

4 ~ 2

Yellow - Black 11 ~ 13 VDC 3.5 - 3.9 K ohms D1 3 ~ 2

With the meter set on hertz scale, 60-420 hertz should be across the white and black wires at terminals 2 and 4.

17 Rinnai Water Heater Service Manual

Electrical Diagnostic Points

V53e, R63LSe

Wire Color Voltage Resistance Connector No. Pin No.’s

Thermal Fuse / Overheat Switch

Red - White 12 VDC below 1 ohm E6 F1 E5 ~ F1

Flame Rod

Place one lead of the meter to the flame rod and the other to ground. With the unit running, 5-150

VAC should be read. Set the meter to the µ amp scale and series the meter in line with the flame rod. Proper flame circuit should read 1 µ amp or greater. If not, then remove the flame rod and check for carbon and damage.

Thermistors

Check all thermistors by inserting meter leads into each end of the thermistor plug. Set the meter to the 20 K ohm scale and read resistance. Applying heat to the thermistor bulb should decrease the resistance. Applying ice to the thermistor bulb should increase the resistance. Typical resistance values are: 11.4-14 K ohm for 59°F; 6.4-7.8 K ohm for 86°F; 3.6-4.5 K ohm for 113°F; 2.2-2.7 K ohm for 140°F; 0.6-0.8 K ohm for 221°F

Outgoing Water Thermistor

White - White see above

Heat Exchanger Temperature Thermistor

Pink - White see above

E4

E3

2 ~ 3

2 ~ 10

Surge Protector

Black - White 108 - 132 VAC

108 - 132 VAC

N/A

N/A

C2

C1

1 ~ 3

Black - White

With the power off, check the continuity through the surge protector. Check by placing one meter lead on the top pin #1 and bottom pin #3. Check by placing one meter lead on the top pin #3 and bottom pin #1. If there is continuity across both sets of points, then the surge protector is good.

Controller

Terminals A1 10 - 13 VDC 1.5 - 3.0 K ohms

Frost Protection

heaters located on the hot water outlet line 180 - 207 ohms heater located on heat exchanger piping heater located on water flow sensor

156 - 180 ohms

24 - 28 ohms

A 1 ~ 3

Amp fuses

There are two inline 3 amp glass fuses. Remove the fuse and check continuity through it. If there is continuity then the fuse is good.

Rinnai Water Heater Service Manual 18

Electrical Diagnostic Points

R50LSi, R75LSe, R75LSi,

R94LSe, R94LSi

Wire Color Voltage Resistance Connector No. Pin No.’s

(SV1, SV2, SV3, POV) Gas Valve and Modulating Solenoids

(Main) Pink - Black

(SV1) Black - Yellow

11 - 13 VDC 36.8 - 44.8 ohms

(SV2) Black - Blue

(SV3) Black - Brown

(POV) Pink - Pink 2 - 15 VDC 67 - 81 ohms

H5

H6

H7

H8

H3

(M) Water Flow Servo

Red - Blue

Gray - Brown

11 - 13 VDC

4 - 6 VDC

22 - 26 ohms

N/A

F7

F7

Gray - Yellow N/A N/A F7

NOTE: At the F connector on the PCB: gray wire turns to black, orange wire turns to red

6 ~ 7

5 ~ 6

4 ~ 6

3 ~ 6

9 ~ 10

9 ~ 10

5 ~ 7

5 ~ 8

(QS) Water Flow Sensor

Black - Red

Yellow - Black

11 - 13 VDC

4 - 7 VDC

5.5 - 6.2 K ohms

1 - 1.4 mega ohms

Bypass Flow Control

(only on R94LSe and R94LSi)

Brown - White

Orange - White

Yellow - White

2 - 6 VDC

(unit in operating mode)

15 - 35 K ohms

Red - White/Ground

F2

F2

G1

1 ~ 3

2 ~ 3

1 ~ 5

2 ~ 5

3 ~ 5

4 ~ 5

(IG) Ignition System

Gray - Gray 90 - 110 VAC N/A C1 1 ~ 2

(FM) Combustion Fan Motor

Red - Black

White - Black

6 - 45 VDC

5 - 10 VDC

N/A

9.2 - 9.4 K ohms

E1

E1

1 ~ 2

2 ~ 4

Yellow - Black 11 ~ 13 VDC 3.5 - 3.9 K ohms E1

With the meter set on hertz scale, 60-420 hertz should be across the red and yellow wires at terminals 2 and 4.

2 ~ 3

19 Rinnai Water Heater Service Manual

Electrical Diagnostic Points

R50LSi, R75LSe, R75LSi,

R94LSe, R94LSi

Wire Color Voltage Resistance Connector No. Pin No.’s

Thermal Fuse / Overheat Switch

Red - Red 11 - 13 VDC below 1 ohm F6 H1 F6 ~ H12

Flame Rod

Place one lead of the meter to the flame rod and the other to ground. With the unit running, 5-150

VAC should be read. Set the meter to the µ amp scale and series the meter in line with the flame rod. Proper flame circuit should read 1 µ amp or greater. If not, then remove the flame rod and check for carbon and damage.

Thermistors

Check all thermistors by inserting meter leads into each end of the thermistor plug. Set the meter to the 20 K ohm scale and read resistance. Applying heat to the thermistor bulb should decrease the resistance. Applying ice to the thermistor bulb should increase the resistance. Typical resistance values are: 11.4-14 K ohm for 59°F; 6.4-7.8 K ohm for 86°F; 3.6-4.5 K ohm for 113°F; 2.2-2.7 K ohm for 140°F; 0.6-0.8 K ohm for 221°F

Outgoing Water Thermistor

White - White see above

Heat Exchanger Temperature Thermistor

Pink - White see above

Intake Air Thermistor

(only on R50LSi, R75LSi, R94LSi)

Orange - White see above

F5

F4

3 ~ 4

3 ~ 11

F3 3 ~ 12

Surge Protector

Black - White

Blue - Brown

108 - 132 VAC

108 - 132 VAC

N/A

N/A

D2

D1

1 ~ 3

1 ~ 3

With the power off, check the continuity through the surge protector. Check by placing one meter lead on the top pin #1 and bottom pin #3. Check by placing one meter lead on the top pin #3 and bottom pin #1. If there is continuity across both sets of points, then the surge protector is good.

Controller

Terminals B1 10 - 13 VDC 1.5 - 3.0 K ohms B 1 ~ 3

Frost Protection

There are electrical heating elements mounted at different points to protect the water heater from freezing. heaters located on the hot water outlet line 180 - 207 ohms heater located on heat exchanger piping 156 - 180 ohms heater located on water flow sensor 24 - 28 ohms

Amp fuses

There are two inline 3 amp glass fuses. Remove the fuse and check continuity through it. If there is continuity then the fuse is good.

Rinnai Water Heater Service Manual 20

Electrical Diagnostic Points

R98LSe(ASME),

R98LSi(ASME)

Wire Color Voltage Resistance Connector No. Pin No.’s

(SV1, SV2, SV3, POV) Gas Valve and Modulating Solenoids

(Main) Pink - Black 24 - 28 ohms

(SV1) Black - Red

(SV2) Black - Orange

11 - 13 VDC

37 - 43 ohms

37 - 43 ohms

(SV3) Black - Yellow

(POV) Orange - Orange 2 - 15 VDC

37 - 43 ohms

67 - 81 ohms

(M) Water Flow Servo

Red - Blue 11 - 13 VDC 22 - 28 ohms

Gray - Brown

Gray - Yellow

4 - 6 VDC

N/A

N/A

N/A

NOTE: At the F connector on the PCB: gray wire turns to black

(QS) Water Flow Sensor

Black - Red

Yellow - Black

11 - 13 VDC

4 - 7 VDC

5.5 - 6.2 K ohms

1 - 1.4 mega ohms

Bypass Flow Control

Brown - White

Orange - White

Yellow - White

Red - White/Ground

2 - 6 VDC

(unit in operating mode)

15 - 35 K ohms

H3

H4

H5

H6

H2

F5

F5

F5

F2

F2

G1

6 ~ 7

5 ~ 6

4 ~ 6

3 ~ 6

9 ~ 10

9 ~ 10

5 ~ 7

5 ~ 8

1 ~ 3

2 ~ 3

1 ~ 5

2 ~ 5

3 ~ 5

4 ~ 5

(IG) Ignition System

Gray - Gray 90 - 110 VAC N/A C1 1 ~ 2

(FM) Combustion Fan Motor

Red - Black

White - Black

6 - 45 VDC

5 - 10 VDC

N/A

9.2 - 9.4 K ohms

E1

E1

1 ~ 2

2 ~ 4

Yellow - Black 11 ~ 13 VDC 3.5 - 3.9 K ohms E1

With the meter set on hertz scale, 60-420 hertz should be across the red and yellow wires at terminals 2 and 4.

2 ~ 3

21 Rinnai Water Heater Service Manual

Electrical Diagnostic Points

R98LSe(ASME),

R98LSi(ASME)

Wire Color Voltage Resistance Connector No. Pin No.’s

Thermal Fuse / Overheat Switch

Red - White 11 - 13 VDC below 1 ohm F6 H1 F6 ~ H12

Flame Rod

Place one lead of the meter to the flame rod and the other to ground. With the unit running, 5-150

VAC should be read. Set the meter to the µ amp scale and series the meter in line with the flame rod. Proper flame circuit should read 1 µ amp or greater. If not, then remove the flame rod and check for carbon and damage.

Thermistors

Check all thermistors by inserting meter leads into each end of the thermistor plug. Set the meter to the 20 K ohm scale and read resistance. Applying heat to the thermistor bulb should decrease the resistance. Applying ice to the thermistor bulb should increase the resistance. Typical resistance values are: 11.4-14 K ohm for 59°F; 6.4-7.8 K ohm for 86°F; 3.6-4.5 K ohm for 113°F; 2.2-2.7 K ohm for 140°F; 0.6-0.8 K ohm for 221°F

Outgoing Water Thermistor

White - White see above

Heat Exchanger Temperature Thermistor

Pink - White see above

F4 3 ~ 4

Surge Protector

Black - White

Blue - Brown

108 - 132 VAC

108 - 132 VAC

N/A

N/A

D2

D1

1 ~ 3

1 ~ 3

With the power off, check the continuity through the surge protector. Check by placing one meter lead on the top pin #1 and bottom pin #3. Check by placing one meter lead on the top pin #3 and bottom pin #1. If there is continuity across both sets of points, then the surge protector is good.

Controller

Terminals B1 10 - 13 VDC 1.5 - 3.0 K ohms

F3

B

3 ~ 11

1 ~ 3

Frost Protection

There are electrical heating elements mounted at different points to protect the water heater from freezing. Voltage through this circuit should be 120 VAC. heater located on the hot water outlet line 335 - 385 ohms heater located on heat exchanger piping 156 - 180 ohms heater located on water flow sensor 335 - 385 ohms

Amp fuses

There are two inline 3 amp glass fuses. Remove the fuse and check continuity through it. If there is continuity then the fuse is good.

Rinnai Water Heater Service Manual 22

Wiring Diagram

R/C42e, R/C53e

23 Rinnai Water Heater Service Manual

Wiring Diagram

R70e, R/C85e(PLUS)

Rinnai Water Heater Service Manual 24

Wiring Diagram

R/C53i(PLUS),

R/C85i(PLUS)

25 Rinnai Water Heater Service Manual

Wiring Diagram

R/C98i(ASME),

R/C98e(ASME)

Rinnai Water Heater Service Manual 26

Wiring Diagram

V53e, R63LSe

CA HO

GY GY

P P

27

G R

R Y BK

W P

W W W W

R BL BR Y GY

Rinnai Water Heater Service Manual

BL BK

Y BK

BY-PASS SERVO MODEL ONLY

BY-PASS FLOW

CONTROL DEVICE

G

1

BR

O

Y

R

W

FREEZE PROTECTION

OPTION

WATER FLOW

SENSOR

F

2

QS

Y

BK

R

BK

F

1

G

R

INDOOR MODEL ONLY

AIR TEMPERATURE

THERMISTOR

HEAT EXCHANGER

THERMISTOR

W

W

F

3

W

O

W

W

F

4

W

P

W

W

F

5

W

W

OUTGOING WATER

THERMISTOR

F

7

WATER FLOW

CONTROL DEVICE

R

BL

BR

Y

GY

GY

R

BL

Y

BR

E

1

FM

COMBUSTION FAN

W

Y

BK

R

THERMAL FUSES

H

2 OVERHEAT

SWITCH

R

R

F

6

H

1

R

R

MODULATING

SOLENOID VALVE

FLAME ROD

MAIN SOLENOID VALVE

SOLENOID VALVE 1

SOLENOID VALVE 2

SOLENOID VALVE 3

H

3

POV

P

P

Y

H

4

SV0

SV1

SV2

SV3

H

5

H

6

P

BK

H

7

Y

BK

BL

BK

H

8

BR

BK

Wiring Diagram

R50LSi, R75LSe, R75LSi,

R94LSe, R94LSi

13

5

W Y O R BR

G

1

(CN7)

O

P BL BR

R Y

R BK

W W

4

G Y

E

1

F

1

(CN5)

12

(CN2)

A

3

(CN9)

W R BK

1

MAX

MIN

O

F

F

Dip SW1

3

4

1

2

5

6

7

8

O

F

F

Dip SW2

3

4

5

1

2

6

H

1

B

1

(CN12)

W

Y

BK

R

R P

P P

BK

Y

BL

BR Y

(CN1)

3

C

GY

GY

(CN4) for REU-EZC

(Optional)

MODULATING VALVE

CURRENT ADJUSTING

Gas pressure

Gas type

Spare Parts Only

BK

BK

B

1

C

1

GY

GY

IGNITER

REMOTE CONTROLLER

IG

COLOR CODING

W :White

BK:Black

BR:Brown

R :Red

BL:Blue

Y :Yellow

P :Pink

O :Orange

G :Green

GY:Gray

SPARK

ELECTRODE

GND

(CN3)

BL

BR

D

1

3

G/Y

GND

SURGE

PROTECTOR

BL

BR

D

1

3

1

G/Y

1

3

D

2

BK

W

GND

W BK

FUSE

(3A)

W

W

BL BL

(W) (W)

D

3

FROST SENSING

SWITCH

D

5

ANTI-FROST HEATER

BL BL

D

4

ANTI-FROST HEATER

NEUTRAL

GROUND

Rinnai Water Heater Service Manual 28

Wiring Diagram

W W

W W

W W

R98LSe(ASME),

R98LSi(ASME)

GY GY

O F F

1 2

O F F

Y BK

29

BR O

R W

G R

R Y BK

W P

W W W W

R BL BR Y GY

R W

R BK O BK Y BK

Rinnai Water Heater Service Manual

Flushing the Heat Exchanger

An “LC” or “00” error code indicates the unit is beginning to lime up and must be flushed. Failure to flush the appliance will cause damage to the heat exchanger. Damage caused by lime build-up is not covered by the unit’s warranty. After flushing, reset the LC fault code by turning off the power to the unit and turning the power back on.

1. Disconnect electrical power to the water heater.

2. Close the shutoff valves on both the hot water and cold water lines (V3 and V4).

3. Connect pump outlet hose (H1) to the cold water line at service valve V2.

4. Connect drain hose (H3) to service valve V1.

5. Pour approximately 4 gallons of virgin, food grade, white vinegar or citric acid into pail.

6. Place the drain hose (H3) and the hose (H2) to the pump inlet into the cleaning solution.

7. Open both service valves (V1 and V2) on the hot water and cold water lines.

8. Operate the pump and allow the cleaning solution to circulate through the water heater for at least 45 minutes.

9. Turn off the pump.

10. Rinse the cleaning solution from the water heater as follows: a. Remove the free end of the drain hose (H3) from the pail. b. Close service valve, (V2), and open shutoff valve, (V4).

Do not open shutoff valve, (V3). c. Allow water to flow through the water heater for 5 minutes d. Close service valve, (V1), and open shutoff valve, (V3).

11. Disconnect all hoses.

12. With (V4) closed, remove the in-line filter at the cold water inlet and clean out any residue. Place filter back into unit and open (V4).

13. Restore electrical power to the water heater.

H3

V1

Rinnai

Water Heater

V3

V2

I n-line

Filter

V4

Gas Supply

Cold Water Line

Hot Water Line

H2

H1

5 gallon pail of virgin, food grade, white vinegar (or virgin, food grade, citric acid)

.

Circulating Pump

3/4" Ball Valve

3/4" Union

Check Valve

Pressure Relief Valve

KEY

S

Pressure Regulator

Circulating Pump

Boiler Drain Valve

Solenoid Valve

Rinnai Water Heater Service Manual 30

Component Replacement Instructions

Gas Control Assembly

R/C42e, R/C53e, V53e, R63LSe

1. Turn off the gas supply.

2. Turn off the 120 V power supply.

3. Remove four screws securing the front panel. Remove front panel.

4. Move aside the ignition line by pulling it out from the clear plastic tubing. (Figure 1)

5. Remove the six screws that attach the gas manifold to the combustion chamber (part of the heat exchanger assembly). (Figure 1)

6. Remove the three screws that attach the gas manifold to the gas valve. Pull out the gas manifold.

(Figure 1)

Figure 1

Ignition line

Six screws

Three screws

Cable tie

7. Remove the screw on the gas valve holding the cable tie.

8. Remove the 3 screws attaching the gas connection to the underneath side of the water heater.

(Figure 2)

Figure 2

Regulator screw access

Gas connection attached with 3 screws

9. Pull the gas connection down to disconnect it from the gas control assembly.

10. Pull out the gas control assembly. Remove the wire harness from the 4 solenoids.

31 Rinnai Water Heater Service Manual

Component Replacement Instructions

Gas Control Assembly

R/C42e, R/C53e, V53e, R63LSe

WARNING

Failure to correctly assemble the components according to these instructions may result in a gas leak or explosion.

11. Install the gas valve and attach the wire harness to the 4 solenoids. (Figure 3)

12. Install the gas connection with 3 screws.

Figure 3 black / yellow (large solenoid) black / blue (small solenoid)

SV0 black / pink

POV pink / pink

(connector not shown)

13. Replace the two circular gaskets (included in kit) in the gas valve. Make sure that the ribbed side faces toward the manifold and that the flat side faces toward the gas valve. (Figure 4)

14. Start the three screws that attach the gas manifold to the gas valve. Tighten the six screws that hold the gas manifold to the combustion chamber. Finish tightening the three screws that hold the gas manifold to the gas valve.

15. Attach ignition line.

16. Perform the Gas Pressure Setting Procedure.

Figure 4

Circular gaskets

Rinnai Water Heater Service Manual 32

Component Replacement Instructions

Gas Control Assembly

R/C53i(PLUS), R70e, R/C85e(PLUS), R/C85i(PLUS),

R50LSi, R75LSe, R75LSi, R94LSe, R94LSi

1. Turn off the gas supply.

2. Turn off the 120 V power supply.

3. Remove four screws securing the front panel. Remove front panel.

4. Pull out wire harness connector at the gas manifold assembly. See Figure 1.

5. Move aside the ignition line by pulling it out from the clear plastic tubing.

6. Remove the six screws that attach the gas manifold to the combustion chamber (part of the heat exchanger assembly).

7. Remove the three screws that attach the gas manifold to the gas valve. Pull out the gas manifold.

Ignition line

Six screws

Wire harness connector

PC Board (dip switches)

Three screws

Figure 1

8. Remove the four screws attaching the gas connection to the underneath side of the water heater.

See Figure 2.

Regulator screw access

Gas connection attached with 4 screws Figure 2

9. Pull the gas connection down to disconnect it from the gas control assembly.

10. Pull out the gas control assembly. Remove the wire harness from the 4 solenoids.

WARNING

Failure to correctly assemble the components according to these instructions may result in a gas leak or explosion.

11. Replace the O-ring (included in kit) where the assembly attaches to the gas connection. Make sure the old O-ring is removed and discarded. Install the new gas control assembly.

33 Rinnai Water Heater Service Manual

Component Replacement Instructions

Gas Control Assembly

R/C53i(PLUS), R70e, R/C85e(PLUS), R/C85i(PLUS),

R50LSi, R75LSe, R75LSi, R94LSe, R94LSi

12. Attach wire harness to the 4 solenoids as shown in Figure 3 below.

SV2 black / blue SV1 black / yellow

SV0 black / pink

POV pink / pink

(connector not shown)

Figure 3

13.

Install the gas manifold using 2 new packings (included in kit) between the manifold and the heat exchanger. Replace the two circular gaskets (included in kit) in the gas valve. Make sure that the ribbed side faces toward the manifold and that the flat side faces toward the gas valve. (Figure 5).

Upper packing

Lower packing

(U shaped)

Circular gaskets in gas valve

Figure 4

Figure 5

14.

Start the three screws that attach the gas manifold to the gas valve. Tighten the six screws that hold the gas manifold to the combustion chamber. Finish tightening the three screws that hold the gas manifold to the gas valve.

15. Attach wiring harness connector (black & brown wires) to the gas manifold.

16. Attach ignition line.

17. Perform the Gas Pressure Setting Procedure.

Rinnai Water Heater Service Manual 34

Component Replacement Instructions

Gas Control Assembly

R/C98e(ASME), R/C98i(ASME),

R98LSe(ASME), R98LSi(ASME)

1. Turn off the gas supply.

2. Turn off the 120 V power supply.

3. Remove four screws securing the front panel.

Remove front panel.

4. On indoor models, remove the bracket holding the controller (1 screw). (Figure 1)

5. Move aside the ignition line by pulling it out from the clear plastic tubing. (Figure 1)

6. Remove the 5 screws that attach the gas manifold to the combustion chamber (part of the heat exchanger assembly). (Figure 2)

7. Remove the 2 screws that attach the gas manifold to the gas valve. These screws are machine screws and must be used at these locations. (Figure 2)

8. Pull out the gas manifold and remove the connector at the ignitor at the left side of the gas manifold.

9. Remove the 3 screws attaching the gas connection to the underneath side of the water heater. (Figure 3)

10. Remove the screw attaching the gas valve to the rear of the case.

11. Pull the gas connection down to disconnect it from the gas control assembly.

Bracket screw

Figure 1

(indoor models)

5 screws

(gas manifold)

2 machine screws

(gas valve)

Figure 2 Water line connections

Regulator screw access

35

Figure 3

Rinnai Water Heater Service Manual

Gas connection attached with 3 screws

Component Replacement Instructions

Gas Control Assembly

R/C98e(ASME), R/C98i(ASME),

R98LSe(ASME), R98LSi(ASME)

WARNING

Failure to correctly assemble the components according to these instructions may result in a gas leak or explosion.

12. Pull out the gas control assembly. Remove the wire harness from the 2 solenoids.

13. Install the gas valve and attach the wire harness to the 2 solenoids. (Figure 4) black / orange orange / orange

Figure 4

14. Install the gas connection with 3 screws.

15. Replace the circular gasket (included in kit) in the gas valve. Make sure that the ribbed side faces toward the manifold and that the flat side faces toward the gas valve. (Figure 5)

16. Start the 2 screws that attach the gas manifold to the gas valve. Tighten the 5 screws that hold the gas manifold to the combustion chamber. Finish tightening the 2 screws that hold the gas manifold to the gas valve.

17. Attach ignition line.

18. On indoor models, install the bracket with the controller.

19. Perform the Gas Pressure Setting Procedure.

Gasket

Figure 5

Rinnai Water Heater Service Manual 36

Component Replacement Instructions

Fan

R/C42e, R/C53e, V53e, R63LSe

1. Turn off the gas supply.

2. Turn off the 120 V power supply.

3. Turn off the water supply.

4. Remove four screws securing the front panel.

Remove front panel.

5. On the V53e and R63LSe, remove the screws

(3) holding the bracket with the surge protector.

(Figure 1)

Figure 1

6. Disconnect the wire harness at the fan assembly. (Figure 2)

7. On the V53e and R63LSe, remove the screw attaching the bracket with the ignitor to the bottom of the burner case. (Figure 2)

8. Remove the three screws attaching the fan sub

-assembly to the fan casing. (Figure 3)

9. Pull out the fan sub-assembly.

Figure 2

10. Install the new fan sub-assembly and tighten with three screws.

11. On the V53e and R63LSe, install the bracket with the ignitor with one screw.

12. Attach the wire harness to the fan assembly

(white, yellow, black, red wires).

13. On the V53e and R63LSe, install the bracket with the surge protector with three screws.

14. Install front panel using 4 screws.

15. Turn on water supply, power supply, and gas supply.

2 screws at bottom

Wire Harness Connector

1 screw

Figure 3

3 screws

37 Rinnai Water Heater Service Manual

Component Replacement Instructions

Fan

R70e, R/C85e(PLUS),

R75LSe, R94LSe

1. Turn off the gas supply.

2. Turn off the 120 V power supply.

3. Turn off the water supply.

4. Remove four screws securing the front panel. Remove front panel.

5. Disconnect wire harness at the fan assembly. Disconnect the air temperature thermistor (two white wires) at the connection with the white and orange wires within the wire bundle.

6. Pull out the harness attached to the solenoid on the manifold to make room to pull out the fan assembly.

7. Remove the two screws that attach the fan assembly to the bottom of the burner.

Figure 1 Two screws

Solenoid on the manifold

Wire harness connection on the fan assembly

8. Pull out the fan assembly.

9. Install the fan assembly by inserting the tab on the fan assembly into the slot at the base of the heat exchanger and attaching with two screws.

10. Attach the wire harness to the solenoid on the gas manifold (brown, black wires).

11. Attach the wire harness to the fan assembly (white, yellow, black, red wires).

12. Attach the air temperature thermistor (white, white wires) to the wire harness.

13. Install front panel using 4 screws.

14. Turn on water supply, power supply, and gas supply.

Rinnai Water Heater Service Manual 38

Component Replacement Instructions

Fan

R/C53i(PLUS), R/C85i(PLUS),

R50LSi, R75LSi, R94LSi

1. Turn off the gas supply.

2. Turn off the 120 V power supply.

3. Turn off the water supply.

4. Remove four screws securing the front panel. Remove front panel.

5. Disconnect wire harness at the fan assembly. Disconnect the air temperature thermistor (two white wires) at the connection with the white and orange wires within the wire bundle.

6. Pull out the harness attached to the solenoid on the manifold to make room to pull out the fan assembly.

7. Loosen the ducting from the fan assembly by pinching open the metal clamp.

2 screws

Figure 1

Ducting and metal clamp water flow servo assembly connection

Solenoid on the manifold

Wire harness connection on the fan assembly

Wire harness bundle

(air temperature thermistor connection to orange / white wires)

Water outlet connection

8. Remove the two screws that attach the fan assembly to the bottom of the burner.

9. Pull out the fan assembly.

10. Install the fan assembly by inserting the tab on the fan assembly into the slot at the base of the heat exchanger and attaching with two screws.

11. Push ducting over fan assembly inlet and secure with metal clamp.

12. Attach the wire harness to the solenoid on the gas manifold (brown, black wires).

13. Attach the wire harness to the fan assembly (white, yellow, black, red wires).

14. Attach the air temperature thermistor (white, white wires) to the wire harness.

15. Install front panel using 4 screws.

16. Turn on water supply, power supply, and gas supply.

39 Rinnai Water Heater Service Manual

Fan

Component Replacement Instructions

R/C98e(ASME), R/C98i(ASME),

R98LSe(ASME), R98LSi(ASME)

1. Turn off the gas supply.

2. Turn off the 120 V power supply.

3. Turn off the water supply.

4. Remove four screws securing the front panel.

Remove front panel.

5. On indoor models, remove the bracket holding the controller (1 screw). (Figure 1)

6. Disconnect the wire harness at the fan assembly. (Figure 2)

7. Remove the three screws attaching the fan motor to the fan casing. (Figure 3)

8. Pull out the fan motor.

9. Install the new fan motor and tighten with three screws.

10. Attach the wire harness to the fan assembly

(white, yellow, black, red wires).

11. On indoor models, install the bracket with the remote controller.

12. Install front panel using 4 screws.

13. Turn on water supply, power supply, and gas supply.

Bracket screw

Figure 1

(indoor models)

Wire Harness Connector

Figure 2

3 screws

Rinnai Water Heater Service Manual 40

Component Replacement Instructions

PC Board

1. Turn off the gas supply.

2. Turn off the 120 V power supply.

3. Turn off the water supply.

4. Remove four screws securing the front panel.

Remove front panel.

5. Remove the plastic guard covering the front of the

PC board.

6. Remove the controller connections.

7. Remove the screws securing the grounding cables.

8. If a surge protector with terminals is installed, then remove this board by removing two screws. This board should be re-installed on the replacement PC board.

9. Remove the two screws at the top and bottom of the

PC board.

10. Pull out the PC board, remove plastic cover, and remove the connections.

11. Adjust dip switches on the new PC board.

Figure 1

R/C42e, R/C53e

Screw

Potentiometer

SW1

SW2

Switches 1-8 (SW1): Configure the dip switches the same as on the original PC board. If necessary, refer to the Dip Switch section or to the Operation and Installation Manual for more information on these dip switches.

Burner test point

41

Switches 1-4 (SW2): Configure according to the table.

1

2

4

SW2 setup

OFF - Propane Gas

ON - Natural Gas

OFF position for models prior to these serial numbers: (on these units, the front panel does not have an “R” or “C” trade name, unless the front panel has been replaced)

V1616W, V1616WC

V2020W, V2020WC

V2532W, V2532WC

06.02-000001

05.07-000001

05.05-117257

V2532FFU, V2532FFUC 05.05-117257

V2520FFU, V2520FFUC 05.05-109539

ON position for other models, serial numbers

Surge protector board with terminals

Screw

Grounding cables

OFF - Residential Models

ON - Commercial Models

13. Insert PC board and attach with two screws.

14. Attach the grounding cables with screws.

15. Attach connections for the controller.

16. Perform the Gas Pressure Setting Procedure.

Rinnai Water Heater Service Manual

PC Board

Component Replacement Instructions

V53e, R63LSe

1. Turn off the gas supply.

2. Turn off the 120 V power supply.

3. Turn off the water supply.

4. Remove four screws securing the front panel.

Remove front panel.

5. Remove the screw connecting the PC board to the back of the water heater casing.

6. Pull out the PC board and remove the connections.

7. Adjust dip switches on the new PC board.

Replacement PC boards have an additional bank of

6 dip switches. Adjust as follows:

Switches 1-8 (SW1): Configure the dip switches the same as on the original PC board. If necessary, refer to the Dip Switch section or to the Operation and Installation Manual for more information on these dip switches.

Switches 1-6 (SW2): Configure according to the diagrams below based on your model and gas type.

8. Attach connections and insert PC board. Insert the tab on the PC board into the hole in the bottom of the case. Attach with one screw.

9. Perform the Gas Pressure Setting Procedure.

Figure 1

Screw

Potentiometer

SW1

SW2

Burner test point

SW2 setup for V53e

Propane (LPG) Natural Gas (NG)

Switch No.

Switch No.

O

F

F

ON

1

2

3

4

5

6

O

F

F

ON

1

2

3

4

5

6

SW2 setup for R63LSe

Propane (LPG) Natural Gas (NG)

Switch No.

Switch No.

O

F

F

ON

3

4

1

2

5

6

O

F

F

ON

3

4

1

2

5

6

Rinnai Water Heater Service Manual 42

PC Board

Component Replacement Instructions

R/C53i(PLUS), R70e, R/C85e(PLUS), R/C85i(PLUS),

R50LSi, R75LSe, R75LSi, R94LSe, R94LSi

1. Turn off the gas supply.

2. Turn off the 120 V power supply.

3. Turn off the water supply.

4. Remove four screws securing the front panel.

Remove front panel.

5. Remove the plastic guard covering the front of the

PC board.

6. Remove the controller connections.

7. If a surge protector with terminals is installed, then remove this board by removing two screws. This board should be re-installed on the replacement PC board.

8. Remove the two screws at the top and bottom of the

PC board.

9. Pull out the PC board, remove plastic cover, and remove the connections.

10. Adjust dip switches on the new PC board.

Switches 1-8 (SW1): Configure the dip switches the same as on the original PC board. If necessary, refer to the Dip Switch section or to the Operation and Installation Manual for more information on these dip switches.

V Series (R70e, R/C85e, R/C53i, R/C85i)

Switches 1-4 (SW2): Configure according to the table.

VA Series (R50LSi, R75LSe, R94LSe, R75LSi,

R94LSi)

Switches 1-6 (SW2):

Replacement PC boards for the VA series have an additional bank of 6 dip switches. Configure according to the diagrams based on your model and gas type.

11. Attach connections and plastic cover.

12. Insert PC board and attach with two screws.

13. If a surge protector with terminals was installed on the original PC board, remove it and install it on the new PC board. See Figure 1.

14. Attach connections for the remote controller.

15. Attach plastic guard.

16. Perform the Gas Pressure Setting Procedure.

Screw

Remote controller terminals

(NOT for 120 V power)

If these 2 terminals are present then this is a surge protector board with terminals to connect freeze protection solenoid valves and should be installed with the new

PC board.

Attached with 2 screws

Screw

Figure 1

43 Rinnai Water Heater Service Manual

PC Board

Component Replacement Instructions

R/C53i(PLUS), R70e, R/C85e(PLUS), R/C85i(PLUS),

R50LSi, R75LSe, R75LSi, R94LSe, R94LSi

SW2 setup for V Series (R70e, R/C85e, R/C53i, R/C85i)

1

2

OFF - Propane Gas

ON - Natural Gas

OFF position for models prior to these serial numbers: (on these units, the front panel does not have an “R” or “C” trade name, unless the front panel has been replaced)

V1616W, V1616WC

V2020W, V2020WC

V2532W, V2532WC

06.02-000001

05.07-000001

05.05-117257

V2532FFU, V2532FFUC 05.05-117257

V2520FFU, V2520FFUC 05.05-109539

V2526W 05.05-110434

ON position for other models, serial numbers

4

OFF - Residential Models

ON - Commercial Models

Rinnai Water Heater Service Manual 44

PC Board

Component Replacement Instructions

R/C53i(PLUS), R70e, R/C85e(PLUS), R/C85i(PLUS),

R50LSi, R75LSe, R75LSi, R94LSe, R94LSi

VA Series (R50LSi, R75LSe, R94LSe, R75LSi, R94LSi)

SW2 setup for R94LSi

(REU-VA2535FFUD-US)

(REU-VA2535FFUD-UC)

Propane (LPG) Natural Gas (NG)

Switch No.

Switch No.

O

F

F

ON

1

2

3

4

5

6

O

F

F

ON

1

2

3

4

5

6

SW2 setup for R94LSe

(REU-VA2535WD-US)

(REU-VA2535WD-UC)

Propane (LPG) Natural Gas (NG)

Switch No.

Switch No.

O

F

F

ON

1

2

3

4

5

6

O

F

F

ON

1

2

3

4

5

6

SW2 setup for R50LSi

(REU-VA2019FFUD-US)

Propane (LPG) Natural Gas (NG)

Switch No.

Switch No.

O

F

F

ON

4

5

6

1

2

3

O

F

F

ON

4

5

6

1

2

3

SW2 setup for R75LSi

(REU-VA2528FFUD-US)

Propane (LPG) Natural Gas (NG)

Switch No.

Switch No.

O

F

F

ON

1

2

3

4

5

6

O

F

F

ON

1

2

3

4

5

6

SW2 setup for R75LSe

(REU-VA2535WD-US)

Propane (LPG) Natural Gas (NG)

Switch No.

Switch No.

O

F

F

ON

4

5

6

1

2

3

O

F

F

ON

4

5

6

1

2

3

NOTE: The diagrams below are for the -UC models of the R50LSi, R75LSi, and R75LSe.

SW2 setup for R50LSi

(REU-VA2019FFUD-UC)

Propane (LPG) Natural Gas (NG)

Switch No.

Switch No.

O

F

F

ON

3

4

5

6

1

2

O

F

F

ON

3

4

5

6

1

2

Propane (LPG) Natural Gas (NG)

Switch No.

O

F

F

SW2 setup for R75LSi

(REU-VA2528FFUD-UC)

ON

3

4

5

6

1

2

Switch No.

O

F

F

ON

3

4

5

6

1

2

O

F

F

SW2 setup for R75LSe

(REU-VA2535WD-UC)

Propane (LPG) Natural Gas (NG)

Switch No.

Switch No.

ON

5

6

3

4

1

2

O

F

F

ON

5

6

3

4

1

2

45 Rinnai Water Heater Service Manual

Component Replacement Instructions

PC Board

1. Turn off the gas supply.

2. Turn off the 120 V power supply.

3. Remove four screws securing the front panel.

Remove front panel.

4. Remove the surge protector (2 screws)

5. Remove the 2 screws connecting the PC board to the water heater casing.

6. Pull out the PC board and remove the connections.

7. Adjust dip switches on the new PC board.

Switches 1-8 (SW1):

Configure the dip switches the same as on the original PC board. If necessary, refer to the

Dip Switch section or to the Operation and

Installation Manual for more information on these dip switches.

Switches 1-4 (SW2) or Switches 1-6 (SW2):

Configure according to the diagrams based on your model and gas type.

Figure 1

R/C98e(ASME), R/C98i(ASME),

R98LSe(ASME), R98LSi(ASME)

Burner test point

Screw

Potentiometer

SW1

SW2

Surge protector

8. Attach connections and insert PC board.

Attach with 2 screws.

9. Attach the surge protector with 2 screws.

10. Perform the Gas Pressure Setting

Procedure.

SW2 setup for R98e, R98i

Propane (LPG) Natural Gas (NG)

Switch No.

Switch No.

O

F

F

ON

1

2

3

4

O

F

F

ON

1

2

3

4

Screw

SW2 setup for C98e, C98i

Propane (LPG) Natural Gas (NG)

Switch No.

Switch No.

O

F

F

ON

1

2

3

4

O

F

F

ON

1

2

3

4

SW2 setup for R98LSi

Propane (LPG) Natural Gas (NG)

Switch No.

Switch No.

O

F

F

ON

3

4

5

6

1

2

O

F

F

ON

3

4

5

6

1

2

Rinnai Water Heater Service Manual

SW2 setup for R98LSe

Propane (LPG) Natural Gas (NG)

Switch No.

Switch No.

O

F

F

ON

3

4

5

6

1

2

O

F

F

ON

3

4

5

6

1

2

46

Component Replacement Instructions

Water Flow Control Assembly

R/C42e, R/C53e

NOTICE

Due to design changes, the new valve may appear different than the installed valve in color, size, and in the number of wires in the harness connections.

1. Turn off the gas supply.

2. Turn off the 120 V power supply.

3. Turn off the water supply. Drain all water from the appliance.

4. Remove four screws securing the front panel. Remove front panel.

Remove the water flow assembly

5. Remove 2 screws and bracket at the water flow assembly. The bracket can be left on the water line.

Pull out the water line. (Figure 1)

Figure 1

2 screws and bracket

(water flow assembly)

6. Remove the 3 screws attaching the water inlet to the underneath side of the water heater.

(Figure 2).

Figure 2

Water inlet

47 Rinnai Water Heater Service Manual

Component Replacement Instructions

Water Flow Control Assembly

R/C42e, R/C53e

7. Pull out the water flow servo assembly and disconnect the cable harnesses. (Figure 3)

A.water flow sensor harness (black/yellow/red wires)

B.remove water flow servo harness (red/blue/brown/yellow/gray or red/blue/brown/orange/yellow/ gray wires)

C.heating element

Figure 3

heating element connector water flow servo connector water flow sensor connector

Assemble

8. Place the new water flow assembly inside the water heater and attach the cable harnesses.

9. Replace the O-ring on the water inlet (included in kit). Attach the water flow assembly through the bottom of the compartment to the water inlet using 3 screws. The shorter screw can be installed first to connect the water flow assembly to the bottom of the compartment. Then install the 2 longer screws through the water inlet.

10. Replace the O-ring on the water line (included in kit). Attach the water line to the water flow assembly with 2 screws and bracket.

11. Install the front panel using 4 screws. Turn on the water supply, power supply, and gas supply.

12. Open a hot water tap and ensure there are no leaks at the water heater.

Rinnai Water Heater Service Manual 48

Component Replacement Instructions

Water Flow Control Assembly

V53e, R63LSe

1. Turn off the gas supply.

2. Disconnect the 120 V power supply.

3. Turn off the water supply. Drain all water from the appliance.

4. Remove four screws securing the front panel. Remove front panel.

Remove the water flow assembly

5. Remove the bracket holding the surge protector.

6. Remove 2 screws and 1 bracket at the water flow assembly. Pull out the water line. (Figure 1)

Figure 1

bracket with surge protector

2 screws and bracket

(water flow assembly)

7. Remove the 3 screws attaching the water inlet to the underneath side of the water heater.

(Figure 2).

Figure 2

Water inlet

49 Rinnai Water Heater Service Manual

Component Replacement Instructions

Water Flow Control Assembly

V53e, R63LSe

8. Pull out the water flow servo assembly and disconnect the cable harnesses. (Figure 3) a. water flow sensor harness (black/yellow/red wires) b. remove water flow servo harness (red/blue/brown/yellow/gray or red/blue/brown/orange/yellow/ gray wires) at the water flow assembly c. heating element

Figure 3

water flow sensor harness water flow servo harness heating element

Assemble

9. Place the new water flow assembly inside the water heater and attach the cable harnesses.

10. Replace the O-ring on the water inlet (included in kit). (Figure 4) Attach the water flow assembly through the bottom of the compartment to the water inlet using 3 screws. The shorter screw can be installed first to connect the water flow assembly to the bottom of the compartment. Install the 2 longer screws through the water inlet.

Figure 4

O-ring

11. Replace the O-ring on the water line (included in kit). Attach the water line to the water flow assembly with 2 screws and bracket.

12. Install the bracket with the surge protector.

13. Install the front panel using 4 screws.

14. Turn on the water supply, power supply, and gas supply.

15. Open a hot water tap and ensure there are no leaks at the water heater.

Rinnai Water Heater Service Manual 50

Component Replacement Instructions

Water Flow Control Assembly

R/C53i(PLUS), R50LSi,

R75LSe, R75LSi

NOTICE

Due to design changes, the new valve may appear different than the installed valve in color, size, and in the number of wires in the harness connections.

1. Turn off the gas supply.

2. Turn off the 120 V power supply.

3. Turn off the water supply. Drain all water from the appliance.

4. Remove four screws securing the front panel. Remove front panel.

Remove the water flow assembly

5. Remove 1 screw and bracket at the water flow assembly. The bracket can be left on the water line.

Pull out the water line. (Figure 1)

Figure 1

1 screw and bracket

(water flow assembly)

6. Remove the 4 screws attaching the water inlet to the underneath side of the water heater.

(Figure 2).

Figure 2

Water inlet

51 Rinnai Water Heater Service Manual

Component Replacement Instructions

Water Flow Control Assembly

R/C53i(PLUS), R50LSi,

R75LSe, R75LSi

7. Pull out the water flow servo assembly and disconnect the cable harnesses. (Figure 3)

A.water flow sensor harness (black/yellow/red wires)

B.water flow servo harness (red/blue/brown/yellow/gray or red/blue/brown/orange/yellow/gray wires)

C.heating element water flow servo connector

Figure 3

heating element connector water flow sensor connector

Assemble

8. Place the new water flow assembly inside the water heater and attach the cable harnesses.

9. Replace the O-ring on the water inlet (included in kit). Attach the water flow assembly through the bottom of the compartment to the water inlet using 4 screws. The 2 shorter screws can be installed first to connect the water flow assembly to the bottom of the compartment. Then install the 2 longer screws through the water inlet.

10. Replace the O-ring on the water line (included in kit). Attach the water line to the water flow assembly with 1 screw and bracket.

11. Install the front panel using 4 screws.

12. Turn on the water supply, power supply, and gas supply.

13. Open a hot water tap and ensure there are no leaks at the water heater.

Rinnai Water Heater Service Manual 52

Component Replacement Instructions

Water Flow Control Assembly

R/C85e(PLUS), R/C85i(PLUS),

R94LSe, R94LSi

NOTICE

Due to design changes, the new valve may appear different than the installed valve in color, size, and in the number of wires in the harness connections.

1. Turn off the gas supply.

2. Turn off the 120 V power supply.

3. Turn off the water supply. Drain all water from the appliance.

4. Remove four screws securing the front panel. Remove front panel.

Remove Fan Assembly (Figure 1)

5. Disconnect wire harness at the fan assembly. Disconnect the air temperature thermistor (two white wires) at the connection with the white and orange wires within the wire bundle.

6. Pull out the harness attached to the solenoid on the manifold to make room to pull out the fan assembly.

7. Remove the 2 screws that attach the fan assembly to the bottom of the burner.

8. On indoor models, loosen the ducting from the fan assembly by pinching open the metal clamp.

9. Pull out the fan assembly.

Figure 1

2 screws

Ducting and metal clamp

(indoor models only)

Solenoid on the manifold

Wire harness connection on the fan assembly

Wire harness bundle

(connection to orange / white wires)

Remove the water flow assembly (Figure 2)

10. Remove 2 screws and 2 brackets at the water flow servo assembly. The brackets can be left on the water lines. Pull out the water lines.

53

Water flow servo assembly connections

Rinnai Water Heater Service Manual

Figure 2

Component Replacement Instructions

Water Flow Control Assembly

R/C85e(PLUS), R/C85i(PLUS),

R94LSe, R94LSi

11. Remove the 4 screws attaching the water inlet to the underneath side of the water heater.

Figure 3

Water inlet

12. Disconnect the cable harnesses (Figure 4): a. water flow sensor harness (black/yellow/red wires) b. bypass servo assembly harness (white/red/yellow/orange/brown wires) c. water flow servo harness (red/blue/brown/yellow/gray or red/blue/brown/orange/yellow/gray wires) d. heating element

Figure 4

water flow servo connector water flow servo connector water flow sensor connector heating element connector

13. Pull out the water flow servo assembly and bypass servo assembly.

14. Remove 2 screws in order to separate the bypass servo assembly from the water flow servo assembly. (Figure 5)

Assemble

Figure 5

15. Replace the O-ring (included in kit) between the water flow servo assembly and the bypass servo assembly.

Attach the new water flow servo assembly to the bypass servo assembly with 2 screws.

16. Place inside the water heater and attach the cable harnesses.

17. Replace the O-ring on the water inlet (included in kit). Attach the water flow assembly to the water inlet using

4 screws. The 2 shorter screws can be installed first to connect the water flow assembly to the bottom of the compartment. Then install the 2 longer screws through the water inlet.

18. Replace the O-ring on the water lines (included in kit). Attach the two water lines to the bypass servo assembly with 1 screw each.

19. Install the fan assembly by inserting the tab on the fan assembly into the slot at the base of the heat exchanger and attaching with two screws.

20. On indoor models, push the ducting over the fan assembly inlet and secure with the metal pinch clamp.

21. Attach the wire harness to the fan assembly (white, yellow, black, red wires).

22. Install the front panel using 4 screws.

23. Turn on the water supply, power supply, and gas supply.

24. Open a hot water tap and ensure there are no leaks at the water heater.

Rinnai Water Heater Service Manual 54

Component Replacement Instructions

Water Flow Control Assembly

R/C98e(ASME), R/C98i(ASME),

R98LSe(ASME), R98LSi(ASME)

1. Turn off the gas supply.

2. Turn off the 120 V power supply.

3. Turn off the water supply. Drain all water from the appliance.

4. Remove four screws securing the front panel. Remove front panel.

5. Remove 2 screws and 2 brackets at the water flow servo assembly. Pull out the water lines. (Figure 1)

6. Remove the water flow sensor and the heating element. (Figure 1)

7. Remove the 4 screws attaching the water inlet to the underneath side of the water heater. (Figure 2)

8. Pull out the water flow servo assembly and bypass servo assembly. Remove the wire harness from the water servo valve. (Figure 3)

9. Remove 2 screws in order to separate the bypass servo assembly from the water flow servo assembly.

(Figure 3)

10. Replace the O-ring (included in kit) between the water flow servo assembly and the bypass servo assembly.

Attach the new water flow servo assembly to the bypass servo assembly with 2 screws.

11. Attach the wire harness to the water servo valve.

12. Place inside the water heater.

13. Attach the water flow assembly to the water inlet using

4 screws. The 2 shorter screws can be installed first to connect the water flow assembly to the bottom of the compartment. Install the 2 longer screws through the water inlet.

14. Insert the heating element and attach the water flow sensor.

15. Replace the O-ring on the water lines (included in kit).

Attach the two water lines to the bypass servo assembly with 1 screw each.

16. Install the front panel using 4 screws.

17. Turn on the water supply, power supply, and gas supply.

18. Open a hot water tap and ensure there are no leaks at the water heater.

Figure 1

Figure 2

Water flow sensor

Heating element

Bypass servo

Water lines

Water inlet

Wire harness

Screws (2)

Water flow servo

Figure 3

55 Rinnai Water Heater Service Manual

Component Replacement Instructions

Heat Exchanger

R/C42e, R/C53e, V53e, R63LSe

1. Turn off the gas supply.

2. Turn off the 120 V power supply.

3. Turn off the water supply. Drain all water from the appliance.

4. Remove four screws securing the front panel. Remove front panel.

5. On the V53e and R63LSe, remove the screws (3) holding the bracket with the surge protector. (Figure 1)

6. Disconnect the wire harness at the fan assembly. (Figure 2)

7. On the V53e and R63LSe, remove the screw attaching the bracket with the ignitor to the bottom of the burner case. (Figure

2)

8. Remove screws and brackets securing the water line connections. (Figure 1)

9. Remove the 6 screws that attach the gas manifold to the combustion chamber (part of the heat exchanger assembly). (Figure

1)

10. Remove the 3 screws that attach the gas manifold to the gas valve. These screws are machine screws and must be used at these locations. (Figure 1)

11. Pull out the gas manifold.

Figure 1

Water Connections

6 screws

(gas manifold)

1 screw

Bracket

3 machine screws

(gas valve)

Figure 2 Wire Harness Connector

Rinnai Water Heater Service Manual 56

Component Replacement Instructions

Heat Exchanger

R/C42e, R/C53e, V53e, R63LSe

12. Remove the clips and screws (5 for the

V53e and R/C42; 6 for the R/C53 and

R63LSe) attaching the burner cover plate to the combustion chamber. (Figure 3)

13. Remove the 2 screws attaching the burner to the heat exchanger. Pull out the burner.

(Figure 3)

14. Remove the wire harness attachments - sensors, heating elements, fusible link brackets. Ensure that the small O-ring at the thermistor is removed.

15. Remove the 4 screws connecting the heat exchanger to the casing. (Figures 4 and 5)

16. Pull out the assembly. Remove the brackets on the side and back holding the fusible link. Disconnect the red wire to the overheat switch from the rest of the wire harness in order to slide off the fusible link.

17. Remove the fan assembly (4 screws) and install it on the new heat exchanger.

18. Remove the flue outlet (7 screws) and install it on the new heat exchanger.

19. Install the largest O-ring (included in kit) over the water outlet tube and the smaller

O-ring (included in kit) over the water inlet tube. (Figure 1)

20. Install the fusible link onto the new heat exchanger. Connect the red wire to the wire harness.

21. Attach brackets at the back and side holding the fusible link.

22. Install the 4 screws at the top and bottom of the heat exchanger to the casing.

(Figures 4 and 5)

23. Insert the burner and place the burner cover plate into position. Attach the burner cover plate first with screws (5 for the V53e and R/C42; 6 for the R/C53 and R63LSe) and then attach the burner with 2 screws.

(Figure 3)

Figure 3

Figure 4

Figure 5

Screws attaching burner

Top attachment screws

Burner cover plate

Bottom attachment screws

57 Rinnai Water Heater Service Manual

Component Replacement Instructions

Heat Exchanger

R/C42e, R/C53e, V53e, R63LSe

24. Make sure that the black gaskets

(Figure 6) are intact on the gas control assembly. Make sure that the ribbed side faces toward the manifold and that the flat side faces toward the gas valve.

25. Attach the gas manifold with 3 machine screws at the gas control assembly.

(Figure 1)

26. Attach the gas manifold with 6 screws at heat exchanger. (Figure 1)

27. Connect wire harness attachments.

Replace the O-ring (included in kit) at the thermistor.

28. Install the bracket with the ignitor.

(Figure 2)

29. Attach the ignition line at the burner cover plate.

30. Attach the wire harness to the fan assembly (white, yellow, black, red wires).

31. Attach the brackets to the water line connections. (Figure 1)

32. On the V53e and R63LSe, install the bracket with the surge protector (3 screws). (Figure 1)

33. Install the front panel using 4 screws.

34. Turn on the water supply, power supply, and gas supply.

35. Check for gas leaks.

Black gaskets

Figure 6

Rinnai Water Heater Service Manual 58

Component Replacement Instructions

Heat Exchanger

R70e, R75LSe

1. Turn off the gas supply.

2. Turn off the 120 V power supply.

3. Turn off the water supply. Drain all water from the appliance.

4. Remove four screws securing the front panel.

Remove front panel.

Burner cover plate

Gas Manifold

PC Board

Gas Control

Valve

Fan Assembly

Figure 1

Remove Fan Assembly (Figure 2)

5. Disconnect wire harness at the fan assembly.

Disconnect the air temperature thermistor

(two white wires) at the connection with the white and orange wires within the wire bundle.

6. Pull out the harness attached to the solenoid on the manifold to make room to pull out the fan assembly.

7. Remove the 2 screws that attach the fan assembly to the bottom of the burner.

8. Pull out the fan assembly.

Figure 2

Disconnect Water Lines (Figure 3)

9. Remove 1 screw from the water outlet bracket. Remove the bracket by rotating and moving it up toward the bend in the tube where the diameter is smaller.

10. Remove 1 screw and 1 bracket at the water flow servo assembly.

Figure 3

Water outlet connection

2 screws Solenoid

Wire harness connection

Water flow servo assembly connection

59 Rinnai Water Heater Service Manual

Component Replacement Instructions

Heat Exchanger

R70e, R75LSe

Disconnect PC Board (Figure 4)

11. Remove 1 screw connecting the PC

Board to the heat exchanger assembly.

Remove Gas Manifold (Figure 4)

12. Remove the 6 screws that attach the gas manifold to the combustion chamber

(part of the heat exchanger assembly).

13. Remove the 3 screws that attach the gas manifold to the gas valve. These screws are machine screws and must be used at these locations.

14. Pull out the ignition line and remove the gas manifold.

Ignition line

6 screws (gas manifold)

PC Board screw

3 machine screws

(gas valve)

Figure 4

Remove Burner and Burner Cover Plate (Figure 5)

15. Remove the 8 screws attaching the burner cover plate to the combustion chamber. Move the cover plate to the side. It is not necessary to disconnect the wire harness from the burner cover plate.

16. Remove the 2 screws attaching the burner to the heat exchanger. Pull out the burner.

17. Unscrew the ignition line connection. (Figure 5)

Figure 5

8 screws

(burner cover plate)

2 screws (burner)

Ignition line connection

Disconnect Wire Harness Attachments and Screws Holding the Heat Exchanger

18. Remove the wire harness attachments - sensors, heating elements, fusible link brackets. Ensure that the small O-ring in the thermistor is removed. (Figure 6)

19. Remove 3 screws behind the fan. (Figure 7)

20. Remove 2 screws above the exhaust. Pull assembly from the unit. (Figure 8)

Figure 7

Figure 8

3 screws

2 screws

Rinnai Water Heater Service Manual 60

Component Replacement Instructions

Heat Exchanger

R70e, R75LSe

WARNING

Failure to correctly assemble the components according to these instructions may result in a gas leak or explosion.

Installation

21. Install the largest O-ring (included in kit) over the water outlet tube and the two smaller O-rings (included in kit) over the bypass servo tubes. (Figure 3)

22. Remove any other attached items and install on the new heat exchanger.

23. Install the new heat exchanger using 2 screws above the exhaust and 3 screws behind the fan. (Figures 7, 8)

Connect Pressure Tube and Wire Harness Attachments

24. Connect wire harness attachments.

25. Connect the pressure tube.

26. Attach the ignition line connection with 1 screw.

Install Burner and Burner Cover Plate (Figure 5)

27. Replace the combustion chamber packing (included in kit) removing any residue from old packing. Insert the burner and place the burner cover plate into position. Attach the burner cover plate first with 8 screws and then attach the burner with 2 screws.

Install Gas Manifold and Connect PC Board

28. Make sure that the two black packings (Figure 9) are intact on the gas control assembly. Make sure that the ribbed side faces toward the manifold and that the flat side faces toward the gas valve. Attach the gas manifold with 3 machine screws at the gas control assembly. Replace the lower and upper packings (included in kit) for the manifold plate removing any residue.

29. Attach the gas manifold with 6 screws at heat exchanger.

30. Attach the ignition line at the burner cover plate.

31. Attach the PC Board to the heat exchanger with 1 screw.

Figure 9

Connect Water Lines (Figure 3)

32. Attach the water outlet line and bracket with 1 screw.

33. Attach the line to the water flow servo assembly with 1 screw and 1 bracket.

Install Fan Assembly (Figure 2)

34. Install the fan assembly by inserting the tab on the fan assembly into the slot at the base of the heat exchanger and attaching with two screws.

35. Attach the wire harness to the solenoid on the gas manifold (brown, black wires).

36. Attach the wire harness to the fan assembly (white, yellow, black, red wires).

37. Attach the air temperature thermistor (white, white wires) to the wire harness.

38. Install the front panel using 4 screws.

39. Turn on the water supply, power supply, and gas supply.

40. Check for gas leaks.

61 Rinnai Water Heater Service Manual

Component Replacement Instructions

Heat Exchanger

R/C85e(PLUS), R94LSe

1. Turn off the gas supply.

2. Turn off the 120 V power supply.

3. Turn off the water supply. Drain all water from the appliance.

4. Remove four screws securing the front panel.

Remove front panel.

Figure 1

Burner cover plate

Gas Manifold

PC Board

Gas Control

Valve

Fan Assembly

Remove Fan Assembly (Figure 2)

5. Disconnect wire harness at the fan assembly.

Disconnect the air temperature thermistor

(two white wires) at the connection with the white and orange wires within the wire bundle.

6. Pull out the harness attached to the solenoid on the manifold to make room to pull out the fan assembly.

7. Remove the 2 screws that attach the fan assembly to the bottom of the burner.

8. Pull out the fan assembly.

Disconnect Water Lines (Figure 3)

9. Remove 1 screw from the water outlet bracket. Remove the bracket by rotating and moving it up toward the bend in the tube where the diameter is smaller.

10. Remove 2 screws and 2 brackets at the bypass servo assembly.

Figure 2

2 screws

Figure 3

Solenoid

Wire harness connection

Water outlet connection

Rinnai Water Heater Service Manual

Bypass servo assembly connections

62

Component Replacement Instructions

Heat Exchanger

R/C85e(PLUS), R94LSe

Disconnect PC Board (Figure 4)

11. Remove 1 screw connecting the PC

Board to the heat exchanger assembly.

Remove Gas Manifold (Figure 4)

12. Remove the 6 screws that attach the gas manifold to the combustion chamber (part of the heat exchanger assembly).

13. Remove the 3 screws that attach the gas manifold to the gas valve. These screws are machine screws and must be used at these locations.

Figure 4

Ignition line

6 screws (gas manifold)

PC Board screw

3 machine screws

(gas valve)

Remove Burner and Burner Cover Plate (Figure 5)

14. Pull out the ignition line and remove the gas manifold.

15. Remove the 8 screws attaching the burner cover plate to the combustion chamber. Move the cover plate to the side. It is not necessary to disconnect the wire harness from the burner cover plate.

16. Remove the 2 screws attaching the burner to the heat exchanger. Pull out the burner.

8 screws

(burner cover plate)

Figure 5

2 screws (burner)

Ignition line connection

Disconnect Wire Harness Attachments and Screws Holding the Heat Exchanger

17. Unscrew the ignition line connection. (Figure 5)

18. Remove the wire harness attachments - sensors, heating elements, fusible link brackets. Ensure that the small O-ring in the thermistor is removed. (Figure 6)

19. Remove 3 screws behind the fan. (Figure 7)

Figure 7

Figure 8

3 screws

2 screws

63 Rinnai Water Heater Service Manual

Component Replacement Instructions

Heat Exchanger

R/C85e(PLUS), R94LSe

WARNING

Failure to correctly assemble the components according to these instructions may result in a gas leak or explosion.

Installation

20. Remove 2 screws above the exhaust. Pull assembly from the unit. (Figure 8)

21. Install the largest O-ring (included in kit) over the water outlet tube and the two smaller O-rings (included in kit) over the bypass servo tubes. (Figure 3)

22. Remove any other attached items and install on the new heat exchanger.

Connect Pressure Tube and Wire Harness Attachments

23. Install the new heat exchanger using 2 screws above the exhaust and 3 screws behind the fan. (Figures 7, 8)

24. Connect wire harness attachments.

Install Burner and Burner Cover Plate (Figure 5)

25. Connect the pressure tube. Attach the ignition line connection with 1 screw.

Install Gas Manifold and Connect PC Board

26. Replace the combustion chamber packing (included in kit) removing any residue from old packing. Insert the burner and place the burner cover plate into position. Attach the burner cover plate first with 8 screws and then attach the burner with 2 screws.

27. Make sure that the two black packings (Figure 9) are intact on the gas control assembly. Make sure that the ribbed side faces toward the manifold and that the flat side faces toward the gas valve. Attach the gas manifold with 3 machine screws at the gas control assembly. Replace the lower and upper packings (included in kit) for the manifold plate removing any residue.

Connect Water Lines (Figure 3)

28. Attach the gas manifold with 6 screws at heat exchanger.

29. Attach the ignition line at the burner cover plate.

Figure 9

Install Fan Assembly (Figure 2)

30. Attach the PC Board to the heat exchanger with 1 screw.

31. Attach the water outlet line and bracket with 1 screw.

32. Attach the two lines to the bypass servo assembly with 1 screw and 1 bracket for each line.

33. Install the fan assembly by inserting the tab on the fan assembly into the slot at the base of the heat exchanger and attaching with two screws.

34. Attach the wire harness to the solenoid on the gas manifold (brown, black wires).

35. Attach the wire harness to the fan assembly (white, yellow, black, red wires).

36. Attach the air temperature thermistor (white, white wires) to the wire harness.

37. Install the front panel using 4 screws. Turn on the water supply, power supply, and gas supply. Check for gas leaks.

Rinnai Water Heater Service Manual 64

Component Replacement Instructions

Heat Exchanger

R/C53i(PLUS), R75LSi

1. Turn off the gas supply.

2. Turn off the 120 V power supply.

3. Turn off the water supply. Drain all water from the appliance.

4. Remove four screws securing the front panel.

Remove front panel.

Remove Fan Assembly (Figure 2)

5. Disconnect wire harness at the fan assembly.

Disconnect the air temperature thermistor

(two white wires) at the connection with the white and orange wires within the wire bundle.

6. Pull out the harness attached to the solenoid on the manifold to make room to pull out the fan assembly.

7. Remove the 2 screws that attach the fan assembly to the bottom of the burner.

8. Loosen the ducting from the fan assembly by pinching open the metal clamp.

9. Pull out the fan assembly.

Figure 1

Burner cover plate

Gas Manifold

PC Board

Gas Control

Valve

Fan Assembly

Disconnect Water Lines and PC Board (Figure 2)

10. Remove 1 screw from the water outlet bracket. Remove the bracket by rotating and moving it up toward the bend in the tube where the diameter is smaller.

11. Remove the screw and bracket at the water flow servo assembly.

12. Remove 1 screw connecting the PC Board to the heat exchanger assembly.

2 screws

Ducting and metal clamp water flow servo assembly connection

Figure 2

PC board screw

Solenoid on the manifold

Wire harness connection on the fan assembly

Wire harness bundle

(air temperature thermistor connection to orange / white wires)

Water outlet connection

65 Rinnai Water Heater Service Manual

Component Replacement Instructions

Heat Exchanger

R/C53i(PLUS), R75LSi

Remove Gas Manifold (Figure 3)

13. Remove the 6 screws that attach the gas manifold to the combustion chamber (part of the heat exchanger assembly).

14. Remove the 3 screws that attach the gas manifold to the gas valve. These screws are machine screws and must be used at these locations.

15. Pull out the ignition line and remove the gas manifold.

Figure 3

Ignition line

6 screws (gas manifold)

PC Board screw

3 machine screws

(gas valve)

Remove Burner and Burner Cover Plate (Figure 4)

16. Remove the 8 screws attaching the burner cover plate to the combustion chamber. Move the cover plate to the side. It is not necessary to disconnect the wire harness from the burner cover plate.

17. Remove the 2 screws attaching the burner to the heat exchanger. Pull out the burner.

18. Disconnect the pressure tube from the heat exchanger and unscrew the ignition line connection.

Figure 4

8 screws

(burner cover plate)

Pressure tube

2 screws (burner)

Rinnai Water Heater Service Manual

Ignition line connection

66

Component Replacement Instructions

Heat Exchanger

R/C53i(PLUS), R75LSi

Disconnect Wire Harness Attachments

19. Remove the wire harness attachments - sensors, heating elements, fusible link brackets. Ensure that the small O-ring in the thermistor is removed.

Remove Heat Exchanger and Air Intake/Exhaust

20. Remove 8 screws connecting the assembly to the water heater casing assembly. (Figures 6a, 6b)

Near fan assembly location At right and left upper corners of water heater

Figure 6a

3 screws 2 screws

Figure 6b

2 screws

1 screw

Separate the Heat Exchanger from the Air Intake/Exhaust

21. Pull out the assembly. Remove 3 brackets on the side and back holding the fusible link.

22. Remove the 9 screws at the cover plate over the air intake passage. (Figure 7)

23. Remove the 4 screws attaching the heat exchanger to the air intake/exhaust assembly. (Figure 8)

Figure 7 Figure 8

9 screws

(cover plate)

24. Pull apart the heat exchanger and air intake/exhaust assembly. (Figure 9)

4 screws

25. Remove 4 screws attaching the bracket on top of the heat exchanger. Pull off the bracket. (Figure

10)

4 screws

(bracket)

Figure 10

Figure 9

67

WARNING

Failure to correctly assemble the components according to these instructions may result in a gas leak or explosion.

Rinnai Water Heater Service Manual

Component Replacement Instructions

Heat Exchanger

R/C53i(PLUS), R75LSi

Install Packings and Bracket

26. Install the O-ring (included in kit) over the water outlet tube and the O-ring (included in kit) over the water flow servo tube. (Figure 2)

27. Install the bracket over the replacement heat exchanger. Push evenly on both sides of the bracket. Attach with four screws. (Figure 10)

Combine the Heat Exchanger and the Air Intake/Exhaust Assembly

28. Push the heat exchanger into the air intake/exhaust assembly. Attach with four screws. (Figure 8)

29. Attach the cover plate over the air intake passage with 9 screws. (Figure 7)

Install Heat Exchanger and Air Intake/Exhaust Assembly (Figures 6a, 6b)

30. Attach the fusible link to the back (2 brackets) and side (1 bracket). Slide the assembly into the casing assembly and attach with 8 screws starting at the top of the water heater.

Connect Pressure Tube and Wire Harness Attachments

31. Connect wire harness attachments. (Figure 5)

32. Connect the pressure tube. Attach the ignition line connection with 1 screw. (Figure 4)

Install Burner and Burner Cover Plate (Figure 4)

33. Replace the combustion chamber packing (included in kit) removing any residue from old packing. Insert the burner and place the burner cover plate into position. Attach the burner cover plate first with 8 screws and then attach the burner with 2 screws.

Install Gas Manifold and Connect PC Board

34. Make sure that the two black packings (Figure 11) are intact on the gas control assembly. Make sure that the ribbed side faces toward the manifold and that the flat side faces toward the gas valve. Attach the gas manifold with 3 machine screws at the gas control assembly. Replace the lower and upper packings (included in kit) for the manifold plate removing any residue.

35. Attach the gas manifold with 6 screws at heat exchanger.

36. Attach the ignition line at the burner cover plate.

37. Attach the PC Board to the heat exchanger with 1 screw.

Figure 11

Connect Water Lines (Figure 2)

38. Attach the water outlet line and bracket with 1 screw.

39. Attach the two lines to the bypass servo assembly with 1 screw and 1 bracket for each line.

Install Fan Assembly (Figure 2)

40. Install the fan assembly by inserting the tab on the fan assembly into the slot at the base of the heat exchanger and attaching with two screws.

41. Push the ducting over the fan assembly exit and secure with the metal pinch clamp.

42. Attach the wire harness to the solenoid on the gas manifold (brown, black wires).

43. Attach the wire harness to the fan assembly (white, yellow, black, red wires).

44. Attach the air temperature thermistor (white, white wires) to the wire harness.

45. Install the front panel using 4 screws.

46. Turn on the water supply, power supply, and gas supply.

47. Check for gas leaks.

Rinnai Water Heater Service Manual 68

Component Replacement Instructions

Heat Exchanger

R/C85i(PLUS), R94LSi

1. Turn off the gas supply.

2. Turn off the 120 V power supply.

3. Turn off the water supply. Drain all water from the appliance.

4. Remove four screws securing the front panel.

Remove front panel.

Figure 1

Burner cover plate

Gas Manifold

Remove Fan Assembly (Figure 2)

5. Disconnect wire harness at the fan assembly.

Disconnect the air temperature thermistor

(two white wires) at the connection with the white and orange wires within the wire bundle.

6. Pull out the harness attached to the solenoid on the manifold to make room to pull out the fan assembly.

7. Remove the 2 screws that attach the fan assembly to the bottom of the burner.

8. Loosen the ducting from the fan assembly by pinching open the metal clamp.

9. Pull out the fan assembly.

PC Board

Gas Control

Valve

Fan Assembly

Figure 2

2 screws

Ducting and metal clamp

Solenoid on the manifold

Wire harness connection on the fan assembly

Wire harness bundle

(air temperature thermistor connection to orange / white wires)

69 Rinnai Water Heater Service Manual

Component Replacement Instructions

Heat Exchanger

R/C85i(PLUS), R94LSi

Disconnect Water Lines (Figure 3)

10. Remove 1 screw from the water outlet bracket. Remove the bracket by rotating and moving it up toward the bend in the tube where the diameter is smaller.

11. Remove 2 screws and 2 brackets at the bypass servo assembly.

Figure 3

Water outlet connection

Bypass servo assembly connections

Disconnect PC Board (Figure 4)

12. Remove 1 screw connecting the PC Board to the heat exchanger assembly.

Remove Gas Manifold (Figure 4)

13. Remove the 6 screws that attach the gas manifold to the combustion chamber (part of the heat exchanger assembly).

14. Remove the 3 screws that attach the gas manifold to the gas valve. These screws are machine screws and must be used at these locations.

15. Pull out the ignition line and remove the gas manifold.

Figure 4

Ignition line

6 screws (gas manifold)

PC Board screw

3 machine screws

(gas valve)

Rinnai Water Heater Service Manual 70

Component Replacement Instructions

Heat Exchanger

R/C85i(PLUS), R94LSi

Remove Burner and Burner Cover Plate (Figure 5)

16. Remove the 8 screws attaching the burner cover plate to the combustion chamber. Move the cover plate to the side. It is not necessary to disconnect the wire harness from the burner cover plate.

17. Remove the 2 screws attaching the burner to the heat exchanger. Pull out the burner.

Figure 5

8 screws

(burner cover plate)

Pressure tube

2 screws (burner)

Disconnect Gas Line and Wire Harness Attachments

18. Disconnect the pressure tube from the heat exchanger and unscrew the ignition line connection.

(Figure 5)

19. Remove the wire harness attachments - sensors, heating elements, fusible link brackets. Ensure that the small O-ring in the thermistor is removed. (Figure 6)

Sensors

Figure 6

Ignition line connection

Thermistor

Brackets for fusible link

Heating elements

71 Rinnai Water Heater Service Manual

Component Replacement Instructions

Heat Exchanger

R/C85i(PLUS), R94LSi

Remove Heat Exchanger and Air Intake/Exhaust

20. Remove 8 screws connecting the assembly to the water heater casing assembly. (Figures 7a, 7b)

Near fan assembly location At right and left upper corners of water heater

Figure 7a

3 screws 2 screws

Figure 7b

2 screws

1 screw

Separate the Heat Exchanger from the Air Intake/Exhaust

21. Pull out the assembly. Remove 3 brackets on the side and back holding the fusible link.

22. Remove the 9 screws at the cover plate over the air intake passage. (Figure 8)

23. Remove the 4 screws attaching the heat exchanger to the air intake/exhaust assembly. (Figure 9)

Figure 8 Figure 9

9 screws

(cover plate)

4 screws

24. Pull apart the heat exchanger and air intake/exhaust assembly. (Figure 10)

25. Remove 4 screws attaching the bracket on top of the heat exchanger. Pull off the bracket. (Figure 11)

4 screws

(bracket)

Figure 11

Figure 10

WARNING

Failure to correctly assemble the components according to these instructions may result in a gas leak or explosion.

Install Packings and Bracket

26. Install the largest O-ring (included in kit) over the water outlet tube and the two smaller O-rings (included in kit) over the bypass servo tubes. (Figure 3)

27. Install the bracket over the replacement heat exchanger. Push evenly on both sides of the bracket. Attach with four screws. (Figure 11)

Rinnai Water Heater Service Manual 72

Component Replacement Instructions

Heat Exchanger

R/C85i(PLUS), R94LSi

Combine the Heat Exchanger and the Air Intake/Exhaust

28. Push the heat exchanger into the air intake/exhaust assembly. Attach with four screws. (Figure 9)

29. Attach the cover plate over the air intake passage with 9 screws. (Figure 8)

Install Heat Exchanger and Air Intake/Exhaust Assembly (Figures 7a, 7b)

30. Attach the fusible link to the back (2 brackets) and side (1 bracket). Slide the assembly into the casing assembly and attach with 8 screws starting at the top of the water heater.

Connect Pressure Tube and Wire Harness Attachments

31. Connect wire harness attachments. (Figure 6)

32. Connect the pressure tube.

33. Attach the ignition line connection with 1 screw. (Figure 5)

Install Burner and Burner Cover Plate (Figure 5)

34. Replace the combustion chamber packing (included in kit) removing any residue from old packing. Insert the burner and place the burner cover plate into position. Attach the burner cover plate first with 8 screws and then attach the burner with 2 screws.

Install Gas Manifold and Connect PC Board (Figure 4)

35. Make sure that the two black packings (Figure 12) are intact on the gas control assembly. Make sure that the ribbed side faces toward the manifold and that the flat side faces toward the gas valve. Attach the gas manifold with 3 machine screws at the gas control assembly. Replace the lower and upper packings (included in kit) for the manifold plate removing any residue.

36. Attach the gas manifold with 6 screws at heat exchanger.

37. Attach the ignition line at the burner cover plate.

Figure 12

Connect Water Lines (Figure 3)

38. Attach the PC Board to the heat exchanger with 1 screw.

39. Attach the water outlet line and bracket with 1 screw.

40. Attach the two lines to the bypass servo assembly with 1 screw and 1 bracket for each line.

Install Fan Assembly (Figure 2)

41. Install the fan assembly by inserting the tab on the fan assembly into the slot at the base of the heat exchanger and attaching with two screws.

42. Push the ducting over the fan assembly exit and secure with the metal pinch clamp.

43. Attach the wire harness to the solenoid on the gas manifold (brown, black wires).

44. Attach the wire harness to the fan assembly (white, yellow, black, red wires).

45. Attach the air temperature thermistor (white, white wires) to the wire harness.

46. Install the front panel using 4 screws.

47. Turn on the water supply, power supply, and gas supply.

48. Check for gas leaks.

73 Rinnai Water Heater Service Manual

Component Replacement Instructions

Heat Exchanger

R/C98e(ASME), R98LSe(ASME)

5 screws

(gas manifold)

2 machine screws

(gas valve)

1. Turn off the gas supply.

2. Turn off the 120 V power supply.

3. Turn off the water supply. Drain all water from the appliance.

4. Remove four screws securing the front panel. Remove front panel.

5. Disconnect wire harness at the fan assembly, the electrical connections to the 3 solenoid valves, and the ignition line.

6. Remove 3 screws and brackets securing the water line connections. (Figure 1)

7. Remove the 5 screws that attach the gas manifold to the combustion chamber

(part of the heat exchanger assembly).

(Figure 1)

8. Remove the 2 screws that attach the gas manifold to the gas valve. These screws are machine screws and must be used at these locations. (Figure 1)

9. Pull out the gas manifold and remove the connector at the ignitor at the left side of the gas manifold.

10. Remove the 9 screws attaching the burner cover plate to the combustion chamber. (Figure 2)

11. Remove the 2 screws attaching the burner to the heat exchanger. Pull out the burner. (Figure 2)

12. Remove the wire harness attachments - sensors, heating elements, fusible link brackets. Ensure that the small O-ring at the thermistor is removed.

13. Remove the 4 screws connecting the heat exchanger to the casing. (Figure 3)

14. Pull out the assembly. Remove the brackets on the side and back holding the fusible link. Slide off the fusible link.

Figure 1 Water line connections

Figure 2 9 screws

(burner cover plate)

2 screws

(burner)

Top screws

Figure 3 Bottom screws

Rinnai Water Heater Service Manual 74

Component Replacement Instructions

Heat Exchanger

R/C98e(ASME), R98LSe(ASME)

15. Remove the fan assembly (4 screws) and install it on the new heat exchanger. (Figure 4)

16. Remove the flue outlet (6 screws) and install it on the new heat exchanger. (Figure 5)

17. Install the largest O-ring (included in kit) over the water outlet tube and the two smaller O-rings

(included in kit) over the water inlet tubes.

(Figure 4)

18. Slide the fusible link between the water outlet and inlet tubes and onto the new heat exchanger. (Figure 4)

19. Attach brackets at the back and side holding the fusible link.

20. Install the 4 screws at the top and bottom of the heat exchanger to the casing. (Figure 3)

21. Insert the burner and place the burner cover plate into position. Attach the burner cover plate first with 9 screws and then attach the burner with 2 screws. (Figure 2)

22. Replace the electrode gasket. (Figure 6)

Figure 5

23. Make sure that the black gasket (Figure 7) is intact on the gas control assembly. Make sure that the ribbed side faces toward the manifold and that the flat side faces toward the gas valve.

Replace the lower and upper gaskets (included in kit) for the manifold plate removing any residue. (Figure 8)

Figure 6

24. Attach the electrical connector to the ignitor on the manifold and attach the gas manifold with 2 machine screws at the gas control assembly.

(Figure 1)

25. Attach the gas manifold with 5 screws at heat exchanger. (Figure 1)

26. Connect wire harness attachments.

27. Attach the ignition line at the burner cover plate.

28. Attach the 3 electrical connectors to the solenoid valves.

29. Attach the wire harness to the fan assembly

(white, yellow, black, red wires).

Figure 7

30. Attach the brackets to the water line connections.

(Figure 1)

31. Install the front panel using 4 screws. Turn on the water supply, power supply, and gas supply.

Check for gas leaks.

Figure 8

75

4 locations

Figure 4

Water outlet tube

Rinnai Water Heater Service Manual

Gaskets

Water inlet tubes

Electrode

Gasket

Gasket

Component Replacement Instructions

Heat Exchanger

R/C98i(ASME), R98LSi(ASME)

1. Turn off the gas supply.

2. Turn off the 120 V power supply.

3. Turn off the water supply. Drain all water from the appliance.

4. Remove four screws securing the front panel. Remove front panel.

5. Remove the bracket holding the controller (1 screw). (Figure 1)

6. Disconnect wire harness at the fan assembly, the electrical connections to the 3 solenoid valves, and the ignition line.

7. Remove 3 screws and brackets securing the water line connections. (Figure 2)

8. Remove the 5 screws that attach the gas manifold to the combustion chamber

(part of the heat exchanger assembly).

(Figure 2)

9. Remove the 2 screws that attach the gas manifold to the gas valve. These screws are machine screws and must be used at these locations. (Figure 2)

10. Pull out the gas manifold and remove the connector at the ignitor at the left side of the gas manifold.

11. Remove the 9 screws attaching the burner cover plate to the combustion chamber. (Figure 3)

12. Remove the 2 screws attaching the burner to the heat exchanger. Pull out the burner. (Figure 3)

13. Remove the wire harness attachments - sensors, heating elements, fusible link brackets. Ensure that the small O-ring at the thermistor is removed.

Bracket screw

Figure 1

5 screws

(gas manifold)

Figure 2

2 machine screws

(gas valve)

Water line connections

Figure 3 9 screws

(burner cover plate)

Rinnai Water Heater Service Manual

2 screws

(burner)

76

Component Replacement Instructions

Heat Exchanger

R/C98i(ASME), R98LSi(ASME)

14. Remove the 3 screws at the seal plate at the top of the water heater. Remove the seal plate and gasket. (Figure 4)

15. Remove flue outlet vent (4 screws).

(Figure 5)

16. Remove the 4 screws connecting the heat exchanger to the back of the casing.

(Figure 6)

17. Pull out the assembly. (It is hooked on brackets in the casing.) Remove the brackets on the side and back holding the fusible link. Slide off the fusible link.

18. Remove the fan assembly (4 screws) and install it on the new heat exchanger.

(Figure 7)

19. Install the largest O-ring (included in kit) over the water outlet tube and the two smaller O-rings (included in kit) over the water inlet tubes. (Figure 7)

20. Slide the fusible link between the water outlet and inlet tubes and onto the new heat exchanger. (Figure 7)

21. Attach brackets at the back and side holding the fusible link. Install the heat exchanger hooking it on the brackets in the back.

22. Install the 4 screws at the top and bottom of the heat exchanger to the back of the casing. (Figure 6)

23. Install the flue outlet vent (4 screws) and seal plate (3 screws) and gasket at the top of the water heater. (Figures 4 and 5)

Figure 4

Top left screw Top right screw

Figure 6

Bottom screws

Figure 5

4 locations

77

Figure 7

Water outlet tube Water inlet tubes

Rinnai Water Heater Service Manual

Component Replacement Instructions

Heat Exchanger

R/C98i(ASME), R98LSi(ASME)

24. Insert the burner and place the burner cover plate into position. Attach the burner cover plate first with 9 screws and then attach the burner with 2 screws.

(Figure 3)

25. Replace the electrode gasket. (Figure 8)

26. Make sure that the black gasket (Figure

9) is intact on the gas control assembly.

Make sure that the ribbed side faces toward the manifold and that the flat side faces toward the gas valve. Replace the lower and upper gaskets (included in kit) for the manifold plate removing any residue. (Figure 10)

27. Attach the electrical connector to the ignitor on the manifold and attach the gas manifold with 2 machine screws at the gas control assembly. (Figure 2)

28. Attach the gas manifold with 5 screws at heat exchanger. (Figure 2)

29. Connect wire harness attachments.

30. Attach the ignition line at the burner cover plate.

31. Attach the 3 electrical connectors to the solenoid valves.

32. Attach the wire harness to the fan assembly (white, yellow, black, red wires).

33. Attach the brackets to the water line connections. (Figure 2)

34. Install the front panel using 4 screws.

35. Turn on the water supply, power supply, and gas supply.

36. Check for gas leaks.

Figure 8

Gasket

Figure 9

Figure 10

Electrode Gasket

Gaskets

Rinnai Water Heater Service Manual 78

Gas Pressure Setting Procedure

CAUTION

Do not touch the areas at or near the heat exchanger or combustion chamber. These areas become very hot and could cause burns.

Figure 1

Potentiometer (POT)

1. Remove the front panel (four screws).

2. Calibrate the low fire and high fire settings as follows:

A. Remove the allen head plug and attach the manometer to the burner test point located on the gas control. (Figure 1, 2, or 3)

Burner test point Dip switches (SW1)

Models R/C42e, R/C53e, V53e, R63LSe

Figure 2

Potentiometer (POT)

Figure 3

Potentiometer (POT)

Burner test point Dip switches (SW1)

Models R70e, R75LSe, R/C85e, R94LSe,

R50LSi, R/C53i, R75LSi, R/C85i, R94LSi

Burner test point Dip switches (SW1)

Models R/C98e, R98LSe, R/C98i, R98LSi

79 Rinnai Water Heater Service Manual

Gas Pressure Setting Procedure

B. Turn on the gas supply.

C. Turn on the power supply.

D. Flow water through the water heater at the maximum flow rate obtainable. (At least 3 gallons per minute is recommended.)

E. Move No. 7 dip switch of the SW1 bank to the

ON position to calibrate “Forced Low” combustion. (Figure 5)

F. Check the burner test point pressure.

G. Remove the rubber access plug (Figure 4) and adjust the regulator screw on the modulating valve to obtain the correct low fire manifold pressure. Refer to the table for your gas type, model, and altitude. Install rubber access plug.

H. Move No. 7 and No. 8 dip switches of the SW1 bank to the ON position to calibrate “Forced

High” combustion. (Figure 6)

I. Check the burner test point pressure.

J. Adjust the high pressure Potentiometer (POT)

(Figure 1, 2, or 3) on the PC Board to obtain the correct high fire manifold pressure. Refer to the table for your gas type, model, and altitude.

K. Move No. 7 and No. 8 back to the OFF position to return the appliance to “Normal” combustion.

(Figure 7)

L. Close hot water taps.

M. Turn off gas supply and 120 V power supply.

N. Remove manometer and re-install allen head plug.

O. Turn on the gas supply and 120 V power supply.

P. Operate the unit and check for gas leaks.

3. Install the front panel using four screws.

Figure 4

Access plug

Figure 5

Forced Low

Switch No.

O

F

F

ON

1

2

3

4

5

6

7

8

Figure 6

Forced High

Switch No.

O

F

F

ON

1

2

3

4

5

6

7

8

Figure 7

Normal

Switch No.

O

F

F

ON

1

2

3

4

5

6

7

8

Rinnai Water Heater Service Manual 80

Manifold Gas Pressure Settings

V Series - Outdoor

R42e,C42e

Natural Gas

Altitude less than 5000 ft

(1524 m)

6000 ft (1829 m)

7000 ft (2134 m)

8000-10000 ft

(2438 - 3048 m)

High Fire Low Fire

3.5

3.4

3.3

3.2

0.73

0.71

0.69

0.67

Propane Gas

Altitude less than 2000 ft

(610 m)

3000 ft (914 m)

4000 ft (1219 m)

5000 ft (1524 m)

High Fire Low Fire

3.3

3.0

2.7

2.3

0.72

0.65

0.58

0.50

R53e,C53e

Altitude less than 2000 ft

(610 m)

3000 ft (914 m)

4000 ft (1219 m)

5000-10000 ft

(1524 - 3048 m)

High Fire Low Fire

3.7

3.5

3.4

3.2

0.74

0.71

0.68

0.64

Altitude less than 2000 ft

(610 m)

High Fire Low Fire

3.5 0.74

R85e(PLUS),

C85e(PLUS)

Altitude less than 10000 ft

(3048 m)

High Fire Low Fire

3.4 0.56

R70e

Altitude less than 10000 ft

(3048 m)

High Fire Low Fire

3.4 0.56

Altitude less than 2000 ft

(610 m)

3000 ft (914 m)

4000 ft (1219 m)

5000 ft (1524 m)

6000 ft (1829 m)

7000-10000 ft

(2134 - 3048 m)

High Fire Low Fire

5.1

4.8

4.5

4.3

4.2

0.88

0.83

0.78

0.73

0.72

4.1 0.71

Altitude less than 10000 ft

(3048 m)

High Fire Low Fire

5.1 0.88

R98e(ASME),

C98e(ASME)

Altitude less than 2000 ft

(610 m)

3000 ft (914 m)

4000 ft (1219 m)

5000 ft (1524 m)

6000 ft (1829 m)

7000 ft (2134 m)

8000-10000 ft

(2438 - 3048 m)

81

High Fire Low Fire

2.8

2.7

2.6

2.4

2.3

2.2

2.1

0.66

0.63

0.60

0.57

0.54

0.52

0.50

Altitude less than 2000 ft

(610 m)

3000 ft (914 m)

4000 ft (1219 m)

5000 ft (1524 m)

6000-10000 ft

(1829 - 3048 m)

Rinnai Water Heater Service Manual

High Fire Low Fire

3.8

3.6

3.3

3.1

0.80

0.75

0.69

0.64

3.0 0.63

Manifold Gas Pressure Settings

V Series - Indoor

Natural Gas

R53i(PLUS),

C53i(PLUS),

R85i(PLUS),

C85i(PLUS)

Altitude less than 10000 ft

(3048 m)

High Fire Low Fire

3.7 0.77

Propane Gas

Altitude less than 2000 ft

(610 m)

3000 ft (914 m)

4000 ft (1219 m)

5000 ft (1524 m)

6000 ft (1829 m)

7000 ft (2134 m)

8000 ft (2438 m)

9000 ft (2743 m)

10000 ft (3048 m)

High Fire Low Fire

4.2

4.0

3.9

3.7

3.7

3.6

3.6

3.4

3.2

0.93

0.90

0.86

0.82

0.82

0.80

0.80

0.79

0.75

R98i(ASME),

C98i(ASME)

Altitude less than 2000 ft

(610 m)

3000 ft (914 m)

4000 ft (1219 m)

5000-10000 ft

(1524 - 3048 m)

High Fire Low Fire

3.0

2.8

2.7

2.5

0.67

0.64

0.60

0.56

Altitude less than 2000 ft

(610 m)

3000 ft (914 m)

4000 ft (1219 m)

5000 ft (1524 m)

High Fire Low Fire

3.7

3.5

3.3

3.0

0.83

0.78

0.73

0.67

Manifold Gas Pressure Settings

VA Series

V53e (REU-VAM1620W) using NATURAL GAS

Dip Switch Setting

#2 OFF, #3 OFF

Altitude

0-2000 ft (0-610 m)

#2 OFF, #3 ON

#2 ON, #3 OFF

#2 ON, #3 ON

2001-5200 ft (610-1585 m)

5201-7700 ft (1585-2277 m)

7701-10200 ft (2277-3109 m)

Max Rate

inches W.C.

Min

inches W.C.

2.5 0.73

2.4

2.4

2.4

0.7

0.7

0.9

V53e (REU-VAM1620W) using PROPANE GAS

Dip Switch Setting Altitude

#2 OFF, #3 OFF

#2 OFF, #3 ON

#2 ON, #3 OFF

#2 ON, #3 ON

0-2000 ft (0-610 m)

2001-5200 ft (610-1585 m)

5201-7700 ft (1585-2277 m)

7701-10200 ft (2277-3109 m)

Max Rate

inches W.C.

Min

inches W.C.

2.4

2.2

2.0

2.0

0.75

0.9

0.8

0.7

Revised 10/7/2009 Rinnai Water Heater Service Manual 82

Manifold Gas Pressure Settings

VA Series

R63LSe (REU-VA2024W) using NATURAL GAS

Dip Switch Setting

#2 OFF, #3 OFF

Altitude

0-2000 ft (0-610 m)

#2 OFF, #3 ON

#2 ON, #3 OFF

#2 ON, #3 ON

2001-5200 ft (610-1585 m)

5201-7700 ft (1585-2277 m)

7701-10200 ft (2277-3109 m)

R63LSe (REU-VA2024W) using PROPANE GAS

Dip Switch Setting

#2 OFF, #3 OFF

Altitude

0-2000 ft (0-610 m)

#2 OFF, #3 ON

#2 ON, #3 OFF

#2 ON, #3 ON

2001-5200 ft (610-1585 m)

5201-7700 ft (1585-2277 m)

7701-10200 ft (2277-3109 m)

Max Rate

inches W.C.

Min

inches W.C.

1.7 0.53

1.6

1.5

1.5

0.4

0.5

0.5

Max Rate

inches W.C.

Min

inches W.C.

2.4 0.61

2.0

2.0

1.8

0.7

0.7

0.8

R63LSe2 - REU-VA2024W(A) using NATURAL GAS

Dip Switch Setting Altitude

#2 OFF, #3 OFF

#2 OFF, #3 ON

#2 ON, #3 OFF

#2 ON, #3 ON

0-2000 ft (0-610 m)

2001-5200 ft (610-1585 m)

5201-7700 ft (1585-2277 m)

7701-10200 ft (2277-3109 m)

Max Rate

inches W.C.

Min

inches W.C.

2.0

1.7

1.7

1.5

0.56

0.55

0.70

0.70

R63LSe2 - REU-VA2024W(A) using PROPANE GAS

Dip Switch Setting Altitude

#2 OFF, #3 OFF

#2 OFF, #3 ON

#2 ON, #3 OFF

#2 ON, #3 ON

0-2000 ft (0-610 m)

2001-5200 ft (610-1585 m)

5201-7700 ft (1585-2277 m)

7701-10200 ft (2277-3109 m)

Max Rate

inches W.C.

3.0

2.8

2.7

2.7

Min Rate

inches W.C.

0.88

0.90

1.00

0.80

83 Rinnai Water Heater Service Manual Revised 10/7/2009

Manifold Gas Pressure Settings

VA Series

R50LSi (REU-VA2019FFU) using

NATURAL GAS

Dip Switch

Setting

Altitude

#2 OFF, #3 OFF 0-2000 ft (0-610 m)

#2 OFF, #3 ON 2001-5200 ft (610-1585 m)

#2 ON, #3 OFF 5201-7700 ft (1585-2277 m)

#2 ON, #3 ON

Dip Switch

Setting

7701-10200 ft (2277-3109 m)

R75LSi (REU-VA2528FFU),

R94LSi (REU-VA2535FFU) using

NATURAL GAS

Altitude

#2 OFF, #3 OFF 0-2000 ft (0-610 m)

#2 OFF, #3 ON 2001-5200 ft (610-1585 m)

MAX VENT

(Dip Switch #1 is OFF)

Max Rate

inches W.C.

2.0

1.7

1.7

Min Rate

inches W.C.

0.52

0.7

0.7

1.8 0.9

MAX VENT

(Dip Switch #1 is OFF)

Max Rate

inches W.C.

Min Rate

inches W.C.

3.3

2.8

0.52

0.5

#2 ON, #3 OFF

#2 ON, #3 ON

5201-7700 ft (1585-2277 m)

7701-10200 ft (2277-3109 m)

2.4

2.1

0.5

0.5

R75LSi(A) (REU-VA2528FFU(A)) using NATURAL GAS

Dip Switch

Setting

Altitude

MAX VENT

(Dip Switch #1 is OFF)

Max Rate

inches W.C.

Min Rate

inches W.C.

#2 OFF, #3 OFF 0-2000 ft (0-610 m) 2.7 0.52

#2 OFF, #3 ON

#2 ON, #3 OFF

#2 ON, #3 ON

2001-5200 ft (610-1585 m)

5201-7700 ft (1585-2277 m)

7701-10200 ft (2277-3109 m)

2.8

2.4

2.1

0.5

0.5

0.5

MIN VENT

(Dip Switch #1 is ON)

Max Rate

inches W.C.

2.0

1.8

1.7

Min Rate

inches W.C.

0.52

0.7

0.7

1.8 0.9

MIN VENT

(Dip Switch #1 is ON)

Max Rate

inches W.C.

Min Rate

inches W.C.

3.3

2.8

0.52

0.6

2.4

2.1

0.5

0.5

MIN VENT

(Dip Switch #1 is ON)

Max Rate

inches W.C.

Min Rate

inches W.C.

2.7 0.52

2.8

2.4

2.1

0.5

0.5

0.5

R75LSe (REU-VA2528W), R94LSe (REU-VA2535W) using NATURAL GAS

Dip Switch Setting

#2 OFF, #3 OFF

#2 OFF, #3 ON

#2 ON, #3 OFF

Altitude

0-2000 ft (0-610 m)

2001-5200 ft (610-1585 m)

5201-7700 ft (1585-2277 m)

Max Rate

inches W.C.

3.3

3.3

3.3

3.1 #2 ON, #3 ON 7701-10200 ft (2277-3109 m)

R75LSe(A) (REU-VA2528W(A)) using NATURAL GAS

Dip Switch Setting

#2 OFF, #3 OFF

#2 OFF, #3 ON

#2 ON, #3 OFF

#2 ON, #3 ON

Altitude

0-2000 ft (0-610 m)

2001-5200 ft (610-1585 m)

5201-7700 ft (1585-2277 m)

7701-10200 ft (2277-3109 m)

Max Rate

inches W.C.

2.9

3.3

3.3

3.1

Revised 10/7/2009 Rinnai Water Heater Service Manual

Min Rate

inches W.C.

0.56

0.7

0.9

0.7

Min Rate

inches W.C.

0.56

0.7

0.9

0.7

84

Manifold Gas Pressure Settings

VA Series

R50LSi (REU-VA2019FFU) using

PROPANE GAS

Dip Switch

Setting

Altitude

#2 OFF, #3 OFF 0-2000 ft (0-610 m)

#2 OFF, #3 ON

#2 ON, #3 OFF

#2 ON, #3 ON

2001-5200 ft (610-1585 m)

5201-7700 ft (1585-2277 m)

7701-10200 ft (2277-3109 m)

R75LSi (REU-VA2528FFU),

R94LSi (REU-VA2535FFU) using

PROPANE GAS

Dip Switch

Setting

Altitude

#2 OFF, #3 OFF 0-2000 ft (0-610 m)

#2 OFF, #3 ON

#2 ON, #3 OFF

#2 ON, #3 ON

2001-5200 ft (610-1585 m)

5201-7700 ft (1585-2277 m)

7701-10200 ft (2277-3109 m)

MAX VENT

(Dip Switch #1 is OFF)

Max Rate

inches W.C.

3.2

3.1

2.8

2.8

Min Rate

inches W.C.

0.92

1.0

0.9

1.1

MAX VENT

(Dip Switch #1 is OFF)

Max Rate

inches W.C.

5.0

3.3

3.4

3.2

Min Rate

inches W.C.

0.92

1.0

1.1

1.1

R75LSi(A) (REU-VA2528FFU(A)) using PROPANE GAS

Dip Switch

Setting

Altitude

#2 OFF, #3 OFF 0-2000 ft (0-610 m)

#2 OFF, #3 ON 2001-5200 ft (610-1585 m)

#2 ON, #3 OFF 5201-7700 ft (1585-2277 m)

#2 ON, #3 ON 7701-10200 ft (2277-3109 m)

MAX VENT

(Dip Switch #1 is OFF)

Max Rate

inches W.C.

4.4

3.3

3.4

3.2

Min Rate

inches W.C.

0.92

1.0

1.1

1.1

MIN VENT

(Dip Switch #1 is ON)

Max Rate

inches W.C.

3.2

3.0

2.8

2.8

Min Rate

inches W.C.

0.92

1.1

1.1

1.4

MIN VENT

(Dip Switch #1 is ON)

Max Rate

inches W.C.

5.0

3.4

3.4

3.2

Min Rate

inches W.C.

0.92

1.0

1.2

1.1

MIN VENT

(Dip Switch #1 is ON)

Max Rate

inches W.C.

4.4

3.4

3.4

3.2

Min Rate

inches W.C.

0.92

1.0

1.2

1.1

R75LSe (REU-VA2528W), R94LSe (REU-VA2535W) using PROPANE GAS

Dip Switch Setting

#2 OFF, #3 OFF

#2 OFF, #3 ON

#2 ON, #3 OFF

#2 ON, #3 ON

Altitude

0-2000 ft (0-610 m)

2001-5200 ft (610-1585 m)

5201-7700 ft (1585-2277 m)

7701-10200 ft (2277-3109 m)

R75LSe(A) (REU-VA2528W(A)) using PROPANE GAS

Max Rate

inches W.C.

5.1

4.0

4.0

4.0

Dip Switch Setting

#2 OFF, #3 OFF

#2 OFF, #3 ON

#2 ON, #3 OFF

#2 ON, #3 ON

Altitude

0-2000 ft (0-610 m)

2001-5200 ft (610-1585 m)

5201-7700 ft (1585-2277 m)

7701-10200 ft (2277-3109 m)

Max Rate

inches W.C.

4.2

4.0

4.0

4.0

85 Rinnai Water Heater Service Manual

Min Rate

inches W.C.

0.88

1.1

0.9

0.9

Min Rate

inches W.C.

0.88

1.1

0.9

0.9

Manifold Gas Pressure Settings

VA Series

R98LSi (REU-VA3237FFU) using

NATURAL GAS

Dip Switch

Setting

Altitude

#2 OFF, #3 OFF 0-2000 ft (0-610 m)

#2 OFF, #3 ON

#2 ON, #3 OFF

#2 ON, #3 ON

2001-5200 ft (610-1585 m)

5201-7700 ft (1585-2277 m)

7701-10200 ft (2277-3109 m)

MAX VENT

(Dip Switch #1 is OFF)

Max Rate

inches W.C.

3.0

2.7

2.7

2.5

Min Rate

inches W.C.

0.67

0.7

0.8

1.7

MIN VENT

(Dip Switch #1 is ON)

Max Rate

inches W.C.

3.0

2.7

2.7

2.5

Min Rate

inches W.C.

0.67

0.7

0.8

1.2

R98LSe (REU-VA3237W) using NATURAL GAS

Dip Switch Setting

#2 OFF, #3 OFF

#2 OFF, #3 ON

#2 ON, #3 OFF

#2 ON, #3 ON

Altitude

0-2000 ft (0-610 m)

2001-5200 ft (610-1585 m)

5201-7700 ft (1585-2277 m)

7701-10200 ft (2277-3109 m)

Max Rate

inches W.C.

2.8

2.5

2.5

2.5

Min Rate

inches W.C.

0.65

0.7

0.7

0.7

R98LSi (REU-VA3237FFU) using

PROPANE GAS

Dip Switch

Setting

Altitude

#2 OFF, #3 OFF 0-2000 ft (0-610 m)

#2 OFF, #3 ON

#2 ON, #3 OFF

#2 ON, #3 ON 7701-10200 ft (2277-3109 m)

MAX VENT

(Dip Switch #1 is OFF)

Max Rate

inches W.C.

3.7

Min Rate

inches W.C.

0.83

2.8 0.83

MIN VENT

(Dip Switch #1 is ON)

Max Rate

inches W.C.

3.7

Min Rate

inches W.C.

0.83

2.8 1.2

R98LSe (REU-VA3237W) using PROPANE GAS

Dip Switch Setting

#2 OFF, #3 OFF

#2 OFF, #3 ON

#2 ON, #3 OFF

#2 ON, #3 ON

Altitude

0-2000 ft (0-610 m)

2001-5200 ft (610-1585 m)

5201-7700 ft (1585-2277 m)

7701-10200 ft (2277-3109 m)

Max Rate

inches W.C.

3.8

3.0

3.0

3.0

Min Rate

inches W.C.

0.80

0.80

0.80

0.80

Rinnai Water Heater Service Manual 86

Dip Switch Settings

V Series

SW1 Bank

1

OFF - “Long Flue”

ON - “Short Flue” and Outdoor Models

“Long flue” is defined as:

0 elbows and length is greater than 21 ft

1 elbow and length is greater than 15 ft

2 elbows and length is greater than 9 ft

SW2 Bank

1

2

OFF - Propane Gas

ON - Natural Gas

OFF position for models prior to these serial numbers: (on these units, the front panel does not have an “R” or “C” trade name, unless the front panel has been replaced)

V1616W, V1616WC

V2020W, V2020WC

V2532W, V2532WC

06.02-000001

05.07-000001

05.05-117257

V2532FFU, V2532FFUC 05.05-117257

V2520FFU, V2520FFUC 05.05-109539

V2526W 05.05-110434

ON position for other models, serial numbers

7

8

OFF position - Used for low fire and high fire settings. Refer to the gas pressure setting procedure.

4

OFF - Residential Models

ON - Commercial Models

VA Series

(for -UC models refer to the next page)

SW1 Bank

1

OFF - “Long Flue”

ON - “Short Flue” and Outdoor Models

“Long flue” is defined as:

0 elbows and length is greater than 21 ft

1 elbow and length is greater than 15 ft

2 elbows and length is greater than 9 ft

2

3

Settings dependent on altitude

0-2000 ft

(0-610 m)

#2: OFF

#3: OFF

2001-5200 ft

(610-1585 m)

#2: OFF

#3: ON

5201-7700 ft

(1585-2347 m)

#2: ON

#3: OFF

7701-10200 ft

(2347-3109 m)

#2: ON

#3: ON

SW2 Bank

(present on replacement PC boards only)

1

2

3

4

5

OFF - Propane Gas

ON - Natural Gas

OFF - Outdoor model

ON - Indoor model

OFF - R63LSe, R75LSe, R75LSi, R94LSe,

R94LSi, R98LSe(ASME),

R98LSi(ASME)

ON - R50LSi, V53e

OFF - V53e, R63LSe, R94LSe, R94LSi,

R98LSe(ASME), R98LSi(ASME)

ON - R50LSi, R75LSe, R75LSi

OFF - V53e, R63LSe, R75LSe, R75LSi,

R94LSe, R94LSi, R98LSe(ASME),

R98LSi(ASME)

ON - R50LSi

4

5

OFF - if using MC-91 controller

ON - if using MC-45 controller

OFF - 120ºF default temperature without a controller

ON - 140ºF default temperature without a controller

7

OFF position - Used for low fire and high fire settings. Refer to the gas pressure setting

8 procedure.

87 Rinnai Water Heater Service Manual

Dip Switch Settings

VA Series (-UC Models)

If the model name on the side of the water heater ends with “-UC” (ex. “REU-VA2535FFUD-UC”), then these units have a default maximum temperature of 120º F (49º C) and an option to increase the maximum temperature to

140 ºF (60 ºC). Temperature settings from 125-140 ºF (52-60 ºC) are available by setting dip switch 6 to ON in the SW1 bank of 8 dip switches. Other dip switch positions may be defined differently than for the non -UC models.

SW1 Bank

1

OFF - “Long Flue”

ON - “Short Flue” and Outdoor Models

“Long flue” is defined as:

0 elbows and length is greater than 21 ft

1 elbow and length is greater than 15 ft

2 elbows and length is greater than 9 ft

2

3

Settings dependent on altitude

0-2000 ft

(0-610 m)

#2: OFF

#3: OFF

2001-5200 ft

(610-1585 m)

#2: OFF

#3: ON

5201-7700 ft

(1585-2347 m)

#2: ON

#3: OFF

7701-10200 ft

(2347-3109 m)

#2: ON

#3: ON

4

5

OFF - if using MC-91 controller

ON - if using MC-45 controller

OFF - 120ºF default temperature without a controller

ON - 140ºF default temperature without a controller

6

OFF - 120ºF maximum temperature without an

MCC-91 controller

ON - 140ºF maximum temperature without an

MCC-91 controller

7

OFF position - Used for low fire and high fire settings. Refer to the gas pressure setting

8 procedure.

SW2 Bank

(present on replacement PC boards only)

1

2

3

OFF - Propane Gas

ON - Natural Gas

OFF - Outdoor model

ON - Indoor model

OFF - R63LSe, R75LSe, R75LSi, R94LSe,

R94LSi, R98LSe(ASME),

R98LSi(ASME)

ON - R50LSi, V53e

Rinnai Water Heater Service Manual 88

Notes

89 Rinnai Water Heater Service Manual

Rinnai’s other fine products

Rinnai America Corporation

103 International Drive

Peachtree City, GA 30269

TOLL FREE: 1-800-621-9419

FAX: 678-829-1666 www.rinnai.us

Tankless Water Heaters

• Residential and Commercial Applications

• Continuous Hot Water

• Up to 9.8 GPM

• High

• Propane or Natural Gas

• Internal or External Installation

• Digital Temperature Control

• Small, Compact Design

Direct Vent Furnaces

• High

• Cool-to-the-touch

• Blower

Cabinet

• Vent Terminal A Included

• 556 and 1004 Models Available in Beige, White and Silver

• Gas Conversion Kit Included

Direct-Vent Fireplace, RHFE-750ETR

• Up to 83% AFUE Energy Efficiency

Installation

• Available in Four Options of Fronts

• Remotes and Fan Included

• Gas Conversion Kit Available

Hydronic Air Handler

Designed for Use with Rinnai Systems

Domestic Hot Water Priority

Optional Programmable Thermostat

Zero Clearance to Combustibles

Accommodates Standard Cased-Coils

Register your product at www.rinnairegistration.com or call 1-866-RINNAI1 (746-6241)

© 2008 Rinnai America Corporation

100000098

9/2008

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