Installation manual | American Water Heater 701022 Water Heater User Manual

Gas Pressure Setting
Gas Pressure Setting
NOTE: For additional installation and commissioning information refer
to the Operation and Installation Manual.
High Pressure
Potentiometer
Burner
test point
SW1
Table 1
LPG
5"W.C.
8"W.C.
150 PSI /10.5"W.C. /13.5"W.C. 0.67"W.C. 0.83"W.C. 3.0"W.C. 3.7"W.C.
2
3
ANTI-FROST
HEATER
AC120V
HOT
NEUTRAL
GROUND
W
W
W
W
D6
W
W
W
1
GND
W BK D1
SURGE
PROTECTOR
W BK
1
GND
G/Y
3
(CN3)
FLAME ROD
H7
Y
O P R Y Y
W O
BK O
Y R
W BK
H2
MODULATING
SOLENOID VALVE POV O
O
H3
P
MAIN SOLENOID VALVE SV0 BK
H4
SOLENOID VALVE 1 SV1 R
BK
(CENTER)
H5
SOLENOID VALVE 2 SV2 O
BK
(LEFT)
H6
SOLENOID VALVE 3 SV3 Y
BK
(RIGHT)
R
W
FM
H1
OVERHEAT
SWITCH
RR
WATER FLOW
CONTROL DEVICE
THERMAL FUSES
R
BL
BR
Y
GY
F5
E1
COMBUSTION FAN
GY
R
BL
Y
BR
W
W
W
W
W
W
F4
F3
G
R
W
P
OUTGOING WATER
WATER THERMISTOR
DO NOT adjust the other dip switches unless specifically instructed
to do so. Incorrect Dip Switch Settings can cause the water heater
to operate in an unsafe condition and may damage the water heater
and void the warranty.
FREEZE PROTECTION
(OPTIONAL)
1
2
3
4
5
6
W
Y
BK
R
ON
F6
R
W
13
R Y
(CN12)
4
RBK
G/Y
1
BK
W
D
C
(CN1)
B
H
(CN2)
E
1
12
(CN5)
1
GY F
(CN7)
GND
1
3
1
2
3
4
5
6
O
F
F
(CN9)
A
O
F
F
1
2
3
4
5
6
7
8
WARNING
SW
No.
1
W RBK
1
2
3
4
5
6
ON
O
F
F
1
G
O
F
F
BR
O
Y
R
W
The original PC boards on the water heaters do not
have the bank of 6 dip switches. Only spare PC
boards have this bank.
1
2
3
4
5
6
7
8
5
ON
ON
O
F
F
G1
Adjust switches 2 and 3 in the bank of 8 depending on
your altitude according to the table below.
WY O RBR
705(Indoor)
705(Indoor-ASME)
LPG
NAT.G
BY-PASS FLOW
CONTROL DEVICE
Dip Switches Settings
High Altitude
MIN
MAX
Flame Rod:
Place one lead of your meter to the flame rod and the other to ground.
With the unit running you should read between 5-150 VAC. Set your
meter to the µ amp scale and series your meter in line with the flame
rod. You should read 1 µ amp or greater for proper flame circuit. In
the event of low flame circuit remove the flame rod and check for
carbon or damage.
Dip SW2
1
This unit has one inline (3) amp glass fuses. Remove the fuse and
check continuity through it. If you have continuity through the fuse
then it is good. Otherwise the fuse is blown and must be replaced.
W BK D
2
Amp Fuses:
IG
This unit has frost protection heaters mounted at different points to
protect the water heater from freezing. The heaters located on the
hot water outlet line should have a resistance reading of 180-207
ohms through each of these heaters. The heater located on the
heat exchanger piping should have a resistance reading of 156-180
ohms and the one located in the water flow sensor valve should
have a resistance reading 24-28 ohms.
FUSE
(3A)
1-3
Frost Protection:
(FM) Combustion Fan Motor:
Red - Black
6 ~ 45 VDC
N/A
E1
1-2
White - Black
5 ~ 10 VDC
9.2 ~ 9.4 K ohms
E1
2-4
Yellow - Black
11 ~ 13 VDC
3.5 ~ 3.9 K ohms
E1
2-3
Set your meter to the hertz scale. Reading across the white and black wires at terminals 2 and 4
you should read between 60 and 420 hertz.
Thermal Fuse / Overheat Switch:
F6
Red - White
11 ~ 13 VDC
Below 1 ohms
F6 - H12
H1
flame at flame rod.
• Measure micro amp output of sensor circuit with flame present.
• Replace flame rod.
IGNITER
B
sand paper.
• Check inside burner chamber for any foreign material blocking
(CN4)
1-3
1-3
1.5 ~ 3.0 K ohms
• 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
W
W
N/A
N/A
WW
1-2
10 ~ 13 VDC
72 Flame Sensing Device Fault
Wiring Diagram
P BL BR
C1
3 - 11
HEAT EXCHANGER
WATER THERMISTOR
(IG) Ignition System:
Grey - Grey
90 ~ 110 VAC
See example above F3
1
2
3
4
5
6
7
8
1-5
2-5
3-5
4-5
3-4
O
F
F
G1
G1
G1
G1
Remote Controls:
Terminals B1
connections.
• Measure resistance of each solenoid valve coil.
1
By-pass Flow Control:
Brown - White
Orange - White
2 ~ 6 VDC
15 ~ 35 ohms
(Unit in operating mode)
Yellow - White
Red-White - Ground
See example above F4
•
•
•
With the power off you can check the continuity through the surge
protector. Place a meter lead on the top pin #1 of the surge
protector and pin #3 on the bottom of the surge protector. Check
across the top pin #3 and bottom pin #1. If you read continuity
across these two points then the surge protector is good. If you do
not get continuity then replace the surge protector.
1-3
2-3
• Check wiring harness to all solenoids for damage and/or loose
LC Scale Build-up in Heat Exchanger (when checking
used.
maintenance code history “00” is substituted for “LC”)
Check for restrictions in air flow around unit and vent terminal.
• Flush heat exchanger. Refer to instructions in manual.
Check for low water flow in a circulating system causing shortcycling.
• Replace heat exchanger.
Ensure dip switches are set to the proper position.
No Code (Nothing happens when water flow is activated.)
Check for foreign materials in combustion chamber and/or
• Clean inlet water supply filter.
exhaust piping.
• On new installations ensure hot and cold water lines are not
Check heat exchanger for cracks and/or separations.
reversed.
Check heat exchanger surface for hot spots which indicate
•
Check for bleed over. Isolate unit from building by turning off
blockage due to scale build up. Refer to instructions in manual
hot water line to building. Isolate the circulating system if
for flushing heat exchanger.
present. Open your pressure relief valve; if unit fires, there is
Measure resistance of safety circuit.
bleed over in your plumbing.
Ensure high fire and low fire manifold pressure is correct.
•
Ensure you have at least the minimum flow rate required to fire
Check for improper conversion of product.
unit.
• Ensure turbine spins freely.
• Measure the resistance of the water flow control sensor.
• Remote control does not light up but you have 12 VDC at the
terminals for controls.
3
5.5 ~ 6.2 K ohms
F2
1 ~ 1.4 Mega ohms F2
71 SV0, SV1, SV2, and SV3 Solenoid Valve Circuit Fault
D5
•
•
221°F = 0.6 ~ 0.8K
D2
D1
If blank screen is present on remote control then the flow control
has shorted out. Unplug flow control. If remote lights up and unit
starts operating then replace flow control assembly.
GY
GY
9 - 10
5-7
5-8
65 Water Flow Servo Faulty (does not stop flow properly)
R
Y
BK
(M) Water Flow Control Device Servo or Geared Motor:
Red - Blue
11 ~ 13 VDC
22 ~ 28 ohms
F5
Grey - Brown
4 ~ 6 VDC
N/A
F5
Grey - Yellow
N/A
N/A
F5
NOTE: The grey wire listed above turns to black at F connector on the PCB.
Outgoing Water Thermistor:
White - White
N/A
Heat Exchanger Temperature Thermistor:
Pink - White
N/A
Surge Protector:
Black - White
108 ~ 132 VAC
Black - White
108 ~ 132 VAC
connections.
• Measure resistance of motor winding.
GY
GY
Fig. 6
86°F = 6.4 ~ 7.8K
113°F = 3.6 ~ 4.5K
(SV1, SV2, SV3 and POV) Gas valve and Modulating solenoids: (Set meter above 2K)
Wire color
Voltage
Resistance
Connector # Pin #'s
(Main) Pink - Black 11 ~ 13 VDC
24 ~ 28 ohms
H3
6-7
(SV1) Black - Red
11 ~ 13 VDC
37 ~ 43 ohms
H4
5-6
(SV2) Black - Orange 11 ~ 13 VDC
37 ~ 43 ohms
H5
4-6
(SV3) Black - Yellow 11 ~ 13 VDC
37 ~ 43 ohms
H6
3-6
(POV) Orange - Orange 2 ~ 15 VDC
67 ~ 81 ohms
H2
9 - 10
N/A
•
•
Check all thermistors by inserting meter leads into each end of the
thermistor plug. Set your meter to the 20 K scale and read
resistance. Applying heat to the thermistor bulb should decrease
the resistance. Applying ice to the thermistor bulb should increase
the resistance. See below for examples of typical temperatures and
resistance readings.
59°F = 11.4 ~ 14K
140°F = 2.2 ~ 2.7K
Example:
There are a number of (live) tests that are required when fault
finding this product. Extreme care should be used at all times to
avoid contact with energized components inside the water heater.
Only trained and qualified service technicians should attempt to
repair this product. Before checking for resistance readings,
disconnect the power source to the unit and isolate the item from
the circuit (unplug it).
• Ensure fan will turn freely.
• Check wiring harness to motor for damaged and/or loose
D4
Troubleshooting
61 Combustion Fan Failure
• Check gas type of unit and ensure it matches gas type being
•
•
Fig. 5
or damage terminals.
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 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 multi-unit connections 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.
Check flame rod for carbon build-up.
Disconnect and re-connect 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.
Fig. 4
Heat Exchanger and Outgoing Water Temperature
Thermistors:
Important Safety Notes
(QS) Water Flow Sensor:
Black - Red
11 ~ 13 VDC
Yellow - Black
4 ~ 7 VDC
Fig. 3
• Check modulating gas solenoid valve wiring harness for loose
W
W
With all gas appliances in operation at maximum gas rate, the
flowing inlet pressure at the incoming test point on the Rinnai
water heater should read 5" W.C. - 10.5" W.C. on natural gas
and 8" W.C. - 13.5" W.C. on propane gas. If the pressure is
lower, the gas supply is inadequate and the unit will not operate
to specification. Check the gas meter regulator and pipework for
correct operation/sizing and correct as required.
52 Modulating Solenoid Valve Signal Abnormal
14 Thermal Fuse
Regulator adjustment
screw access plug
Commissioning
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.
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
R
Y
BK
NAT.G
•
•
•
•
•
• Check that the gas is turned on at the water heater and gas
QS
LPG
34 Combustion Air Temperature Sensor Fault
12 Flame Failure
WATER FLOW
SENSOR
NAT.G
Forced High
Check sensor wiring for damage.
Measure resistance of sensor.
Clean sensor of scale build up.
Replace sensor.
• Measure resistance of valve coil.
Dip SW1
LPG
Forced Low
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 multi-unit connections 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.
•
•
•
•
•
•
•
•
•
•
F1
705(Indoor-ASME)
Fig. 2
• Check that the gas is turned on at the water heater, gas meter,
F2
NAT.G
705(Indoor)
Fig. 1
Gas Inlet
Min./Max
Water
Inlet Max.
SW2
Spare Parts
Only
•
•
•
•
11 No Ignition
COLOR CODING
APPLIANCE OPERATING PRESSURES
1
33 Heat Exchanger Outgoing Temperature Sensor Fault
WW
This appliance must be installed, serviced and removed by a trained
and qualified person. During pressure testing of the consumer piping,
ensure gas valve is turned off before unit is shut off. Failure to do so
may result in serious injury to yourself or damage to the unit.
Check sensor wiring for damage.
Measure resistance of sensor.
Clean sensor of scale build up.
Replace sensor.
D3
WARNING
•
•
•
•
W
W
To turn the sound off (mute), press and hold both the
and
thermostat buttons until a “beep” is heard (about 5 seconds).
32 Outgoing Water Temperature Sensor Fault
Ensure 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.
SPARK
ELECTRODE
To Turn Off the Controller Sound (Mute)
•
•
•
•
•
•
•
C1
With the water heater turned off, press and hold the ON/OFF
button until the display changes to the other temperature scale
(about 5 seconds).
10 Air Supply or Exhaust Blockage
FROST SENSING
SWITCH
To Change the Temperature Scale (ºF / ºC)
exhaust piping.
• Check for clogged heat exchanger.
BL BL
1. To display error codes, press the ON/OFF button followed by
the
thermostat button to cycle through the error codes.
2. To display the water flow through the water heater, press the
thermostat button (hold for 2 seconds) and then press the
ON/OFF button while continuing to hold the
thermostat
button.
3. To display the outlet water temperature, press the
thermostat
button (hold for 2 seconds) and then press the ON/OFF button
while continuing to hold the
thermostat button.
• Turn off all hot water taps. Press ON/OFF twice.
REMOTE CONTROLLER
Diagnostic Use of the Controller
• Check for foreign materials in combustion chamber and/or
B1
ON/OFF Button
cycling.
power returns)
MODULATING VALVE
CURRENT ADJUSTING
Thermostat
Turn OFF the gas supply.
Turn OFF the 120 V power supply.
Remove the front panel from the appliance.
Check the gas type using the data plate on the side of the unit.
If using a spare PC board, check that the gas type switches are
in the correct position (dip switch 1 of SW2: ON for natural gas,
NG, and OFF for propane, LPG). See dip switch settings
section below. (ON is towards the right and OFF is towards the
left.)
5. Attach the pressure gauge to the burner test point, located on
the gas control (Fig. 2).
6. Turn ON the gas supply.
7. Turn ON the 120 V power supply.
8. If a controller is installed, turn the unit ON with the controller.
Select the maximum delivery temperature and open all
available hot water taps at full.
9. Set the unit to ‘Forced Low’ combustion by setting No. 7 dip
switch of the SW1 set to ON (Fig. 3).
10. Check the burner test point pressure.
11. Remove the rubber access plug and adjust the regulator screw
on the modulating valve (Fig. 4) as required in Table 1.
Replace the rubber access plug.
12. Set the unit to ‘Forced High’ combustion by setting both No. 7
and No. 8 dip switches of the SW1 set to ON (Fig. 5). Ensure
maximum water flow.
13. Check the burner test point pressure.
14. Adjust the high pressure potentiometer (POT) on the PC board
as required to the pressure shown in Table 1.
15. Return the unit to normal operation by setting dip switches 7
and 8 of the SW1 set back to OFF (Fig. 6). Close all water
taps.
16. Turn OFF the gas supply and 120 V power supply.
17. Remove the pressure gauge and install sealing screw.
18. Turn ON the gas supply and 120 V power supply.
19. Operate the unit and check for gas leaks at the test point.
20. Install the front panel.
03 Power interruption during Bath fill (Water will not flow when
BK
BK
Priority Button
When no water is
being supplied,
pressing this button
allows this controller to
set the water
temperature.
1.
2.
3.
4.
• Check for restrictions in air flow around unit and vent terminal.
• Check for low water flow in a circulating system causing short-
• Service Call
A1
2-Unit Connection
(Optional)
Temperature Display
Indicates temperature
setting or flashes error
code.
16 Over Temperature Warning
02 No burner operation during freeze protection mode
Gas type
Spare Parts Only
Priority Indicator
Indicates that this
controller is setting the
water temperature.
Error Codes
Gas pressure
In Use Indicator
Indicates that hot water
is being supplied.
Ensure gas pressure check under Commissioning has been
completed first! The regulator is electronically controlled and
factory pre-set. Under normal circumstances it does not require
adjustment during installation. Make adjustments only if the unit is
not operating correctly and all other possible causes for incorrect
operation have been eliminated.
W :White
BK:Black
BR:Brown
R :Red
BL:Blue
Y :Yellow
P :Pink
O :Orange
G :Green
GY:Gray
Controller
NOTES
High Altitude
Off
Off
Level 0
0-2000 ft
(0-610 m)
Off
On
Level 1
2001-5200 ft
(610-1585 m)
On
Off
Level 2
5201-7700 ft
(1585-2347 m)
On
On
Level 3
7701-10200 ft
(2347-3109 m)
705 Indoor
070 00012 36676 0
U273-1373(01)
EXPLODED VIEW - CABINET
EXPLODED VIEW - INTERNALS
REMOTE CONTROLLER
EXPLODED VIEW - INTERNALS
EXPLODED VIEW - ELECTRICAL
703
Number
001
002
004
005
007
010
011
012
013
014
015
017
018
019
020
021
022
100
101
102
103
103
104
104
113
114
115
116
117
118
121
122
123
124
125
125
Description
Casing Assembly
Heat Protection Plate
Front Panel Assembly
Remote Controller Packing
Wall Fitting Bracket
Front Panel Packing-Top
Front Panel Packing-Side
Connection Reinforcement Panel
Bag for Installation Manual
Seal Packing
Rubber Bushing
Rubber Bushing
Reinforcement Plate
Air Intake Vent
ϕ 100 Seal Plate
Duct Bracket
Fan Rectifier
Gas Connection (3/4"NPT)
Screw
Gas Control Kit
Manifold Assembly-A (LPG)
Manifold Assembly-B (Nat.G)
Burner Unit Assembly(Nat.G)
Burner Unit Assembly(LPG)
Combustion Chamber Front Plate
Combustion Chamber Front Plate Packing
Electrode Kit
Flame Rod Kit
Electrode Packing
Electrode Holder
Electrode Sleeve
Solenoid Valve Cover
Upper Combustion Chamber Packing
Lower Combustion Chamber Packing
Heat Exchanger Kit
Heat Exchanger Kit(ASME)
Quantity
705
705
(Indoor)
(Indoor-ASME)
Parts Number
701022-150
1
1
701022-154
1
1
701022-155
1
1
701022-159
1
1
701022-160
2
2
701022-162
2
2
701022-163
2
2
701022-164
1
1
701022-165
1
1
701022-023
1
1
701022-008
1
1
701022-020
1
1
701022-166
1
1
701022-167
1
1
701022-168
1
1
701022-169
2
2
701022-170
1
1
701022-027
1
1
701022-171
2
2
701022-172
1
1
701022-173
1
1
701022-174
1
1
701022-175
1
1
701022-153
1
1
701022-182
1
1
701022-183
1
1
701022-036
1
1
701022-184
1
1
701022-185
1
1
701022-039
1
1
701022-093
1
1
701022-186
1
1
701022-187
1
1
701022-188
1
1
701022-189
1
701022-158
1
-
Quantity
705
705
(Indoor-ASME)
(Indoor)
Parts Number
701022-191
1
1
701022-192
1
1
701022-193
2
2
701022-194
1
1
701022-195
1
1
701022-197
1
1
701022-198
1
1
701022-199
1
1
701022-069
1
1
701022-200
1
1
701022-082
1
1
701022-203
1
1
701022-204
1
1
701022-074
1
1
701022-075
2
2
701022-205
1
1
701022-206
1
1
701022-207
1
1
701022-081
1
1
701022-208
1
1
701022-209
1
1
701022-210
1
1
701022-211
1
1
701022-088
1
1
701022-213
1
1
701022-091
1
1
701022-214
1
1
701022-215
1
1
701022-216
1
1
701022-102
2
2
701022-151
2
2
701022-218
1
1
701022-219
2
2
701022-221
1
1
701022-222
9
9
701022-120
2
2
PARTS LIST
Number
131
132
133
150
151
153
154
155
400
401
402
405
406
407
408
409
410
411
412
413
700
701
702
703
704
705
706
707
708
709
710
711
712
714
715
716
Description
Flue Outlet Vent Packing
Flue Outlet Vent Assembly
ϕ 100 Packing
Blower Motor
Fan Casing Assembly
Fan Connecting Bracket
Fan Connecting Packing
ϕ 39 Bell Mouth
Water Inlet (3/4"NPT)
Plug Band
Water Filter Assembly
Water Flow Control Assembly Kit
Rectifier
Bypass-Servo Assembly
Stop Bracket
Water Flow Servo Cover
Hot Water Outlet (3/4"NPT)
Plug Band
Drain Valve
Stop Bracket
PCB
Surge Protector
PCB Cover-Front
PCB Cover-Side
Ignitor Bracket
Ignitor
High Tension Cord
Ignitor Cover
120V Anti Frost Heater Assembly
Anti Frost Heater Clip
Anti Frost Heater Clip
Anti Frost Heater Clip
120V Valve Heater Assembly
Thermal Fuse Harness
Thermal Fuse Clip
Thermistor
Number
717
718
720
721
722
723
724
725
726
800
801
802
803
804
805
806
807
808
809
810
811
812
813
814
815
816
817
820
821
822
823
824
888
889
-
Description
Thermistor Clip
Frost Sensing Switch
Fuse Harness
Power Supply Harness
Ignitor Harness
Sensor Harness
Power Cord
Remote Controller
Remote Controller Bracket
Screw
Washer
Screw
Washer
Screw
Screw
Screw
Screw
Screw
Screw
Screw
O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
Packing
Screw
Screw
Screw
Screw
Screw
Manual
Installation Manual (Tech Sheet)
Package Spec Sheet
Manual 3/4" Gas Control Valve
Parts Number
701022-095
701022-223
701022-224
701022-226
701022-227
701022-228
701022-107
701022-229
701022-231
701022-122
701022-232
701022-233
701022-128
701022-234
701022-121
701022-235
701022-236
701022-237
701022-238
701022-125
701022-137
701022-133
701022-134
701022-135
701022-136
701022-130
701022-239
701022-240
701022-241
701022-141
701022-242
701022-142
315897-000
701022-244
701022-246
701022-247
Quantity
705
705
(Indoor) (Indoor-ASME)
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
4
4
4
2
2
7
7
10
10
8
8
1
1
5
5
2
2
3
3
1
1
1
1
3
3
1
1
2
2
1
1
2
2
1
1
2
2
1
1
4
4
2
2
3
3
1
1
1
1
1
1
1
1
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