Rinnai ByPass Servo Troubleshooting Manual Download Page 19 | Manualshive

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11112014GW

Code 25 Troubleshooting Procedure

Condensate Trap is full

1.

Inspect condensate drain line for blockage.

2.

Inspect condensate trap and tank inside cabinet for blockage.

3.

Ensure condensate line has an air gap between the units and drain line leaving the
water heater.

4.

Check sensor wiring harness for loose, broken or damaged connections from sensor
back to PC board.

5.

If condensate tank is draining and the unit is still throwing a code 25 replace condensate
tank with sensor.

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Summary of Contents for ByPass Servo

Page 1: ...r source to unit and then isolate each item to be checked from the circuit by unplugging it When setting gas pressures on one of these units please check the complete model number you are trouble shooting Gas pressures and dip switches can vary among models Always check the rating plate for complete information and follow directions If any of the original wire as supplied with the appliance must b...

Page 2: ...2 11112014GW Table of Contents Code Numbers Page 03 4 05 5 10 6 11 8 12 11 14 15 16 17 19 18 25 19 31 20 32 21 33 22 34 23 41 24 51 25 52 26 57 27 58 28 61 29 63 30 65 31 70 32 71 33 72 34 73 35 ...

Page 3: ... 1 MC 91 2 Controller 43 Rinnai America Corporation 103 International Drive Peachtree City GA 30269 Toll Free 1 800621 9419 Phone 678 829 1700 www rinnai us 2013 Rinnai America Corporation Rinnai is continually updating and improving products therefore specifications are subject to change without prior notice Local state provincial and federal codes must be adhered to prior to and upon installatio...

Page 4: ...de 03 Troubleshooting Procedure Power interruption during bath fill Water will not flow when power returns 1 Turn of all hot water fixtures in building Next press the ON OFF button on the temperature controller twice ...

Page 5: ...5 11112014GW Code 05 Troubleshooting Procedure Bypass Servo 1 Turn off power supply to unit reapply power Fire up unit If code 05 reappears replace bypass valve ...

Page 6: ...l result in improperly sealed joints which will lead to code 10 or exhaust gas leakage 3 Inspect the vent system to ensure all clearances around vent terminations were met Improper clearances will result in recirculation of combustion gases 4 Verify dip switch for vent length was set to the proper position for your application First determine total vent length each ninety degree elbow counts as si...

Page 7: ...t the burner and heat exchanger fins If unable to clean the heat exchanger with compressed air replace the heat exchanger CAUTION Always wear safety glasses and a mask when blowing out the burner WARNING You must be qualified to service gas systems before proceeding with the following items listed below 12 Verify low and high fire manifold gas pressures are set correctly Some model units have a bu...

Page 8: ...there will be no voltage present unless the unit is going through the ignition cycle 7 Make sure the ceramic sparker electrode is tight in its mounting bracket You should not be able to move it with your finger if gasket is intact If loose remove it and clean with dollar bill Reinstall using new gasket and ensure it is tight when the installation is finished If the electrode is loose the tip can d...

Page 9: ...C with black iron piping There are a number of approved gas piping system out there make sure you refer to the manufacture s or International Plumbing Code book for pressure drops on gas piping and pressures you are using for proper pressure drops allowed If pressure drop excesses that mentioned above for black iron gas systems your system could be undersized please recheck sizing The issue could ...

Page 10: ...l wiring harnesses throughout unit for water or moisture in electrical connections If any connections appear to be damp or wet dry them out and try to find out what is causing this 21 If using an MSA or MSB system isolate the unit giving trouble from the system during troubleshooting If unit operates when isolated the issue may be in the electronic staging system MSA or MSB 22 Other suggestions WA...

Page 11: ... in the building firing on high fire The allowable pressure drop for propane is 0 5 inches of water column This pressure drop is based on the International Plumbing Code when operating on gas pressures up to 14 inches W C with black iron piping There are a number of approved gas piping system out there make sure you refer to the manufacture s or International Plumbing Code book for pressure drops ...

Page 12: ...entation before removal After removing it clean it before re installing Re install the flame rod in the same orientation as it was before removal You MUST replace the flame rod igniter gasket before reassembly Note a loose flame rod is called a floating flame rod and will result in code 12 s Flame rods should never have to be replaced unless the white ceramic is cracked or broken or the flame rod ...

Page 13: ... ensure all two stages regulators are installed at least six foot away from appliance Ensure when appliance shuts off the pressure from the two stage regulator doesn t exceed the maximum inlet pressure for the appliance To check this connect your manometer up to the test port on the bottom of the water heater The inlet pressures should never exceed 10 inches water column for natural gas or 13 5 in...

Page 14: ...t will not occur on the immediate code 12 The fan motor may try to come on but immediately goes into a code The immediate code 12 or 19 is an indication of a short circuit within the appliance Could be a short in a wiring harness water flow control or bypass valve or any other component within the DC circuit One way to track this down is to unplug one component at a time and try to cycle the unit ...

Page 15: ...n the SW2 bank of dip switches is in the OFF position If in the ON position this will cause a code 14 as this switch is used to de energize disconnect the gas valve circuit This applies only to the VC KB models It does not apply to V VA VB or KA products 2 Verify the unit is connected to the proper gas type see rating plate for gas type of unit 3 Check to ensure this unit has ever been converted f...

Page 16: ...find debris build up inside the heat exchanger that has led to a code 14 replace the heat exchanger 11 Inspect the front sides and back of the heat exchanger surface for cracks separations discoloration or damage of any kind If you find any of the above mentioned items replace the heat exchanger 12 Inspect all components inside the water heater cabinet for signs of excessive heat damage Take note ...

Page 17: ...r low flow in circulation system causing short cycling WARNING Turn off the electrical gas and water supply to the water heater before proceeding 2 Check for foreign materials in combustion chamber and or exhaust piping 3 Check for blockage in the heat exchanger fins 4 Clean out heat exchanger fins or replace heat exchanger ...

Page 18: ...18 11112014GW Code 19 Troubleshooting Procedure Electrical Grounding 1 Check all components for electrical short ...

Page 19: ... and tank inside cabinet for blockage 3 Ensure condensate line has an air gap between the units and drain line leaving the water heater 4 Check sensor wiring harness for loose broken or damaged connections from sensor back to PC board 5 If condensate tank is draining and the unit is still throwing a code 25 replace condensate tank with sensor ...

Page 20: ...g exceeds 30 milli volts or is less than 8 milli volts the unit will go into a code 31 If the thermocouple mV output is above 30 mV during combustion that indicates the unit may be over fired WARNING You must be qualified to service gas systems before proceeding Verify your high fire manifold pressures If gas pressures are found to be within specifications remove burner manifold and burners Check ...

Page 21: ...otice the thermistor resistance reading start to drop when heat is applied A simple way to apply heat is to place the thermistor bulb between your thumb and another finger and apply pressure The heat from your body will cause the resistance reading to decrease If the thermistor reading starts to decrease with heat applied normally that indicates the component is functioning properly The resistance...

Page 22: ...e the thermistor resistance reading start to drop when heat is applied A simple way to apply heat is to place the thermistor bulb between your thumb and another finger and apply pressure The heat from your body will cause the resistance reading to decrease If the thermistor reading starts to decrease with heat applied normally that indicates the component is functioning properly The resistance rea...

Page 23: ...t re fire the unit to see if you still get a code 34 If so proceed to item 3 below 3 Verify the unit is connected to the proper gas type see rating plate for gas type of unit 4 Check to ensure this unit has ever been converted from one gas type to another If it was converted verify conversion was performed per manufacturer s specifications See conversion procedure for the model number unit at your...

Page 24: ...ug Then apply heat to the sensor bulb You will notice the sensor resistance reading start to drop when heat is applied A simple way to apply heat is to place the sensor bulb between your thumb and another finger and apply pressure The heat from your body will cause the resistance reading to decrease If the sensor reading starts to decrease with heat applied normally that indicates the component is...

Page 25: ...g to decrease If the sensor reading starts to decrease with heat applied normally that indicates the component is functioning properly The resistance reading will increase if ice is placed against the bulb Typical resistance values are 11 4 14K ohms at 59 degrees F 6 4 7 7K ohms at 86 F 3 6 4 5K ohms at 113 F 2 2 2 7K at 140 F or 0 6 0 8K at 221 F If sensor readings are correct re install this com...

Page 26: ...sistance reading is found to be within specification proceed to item 3 below Note Resistance readings can vary from meter to meter based on the meter s accuracy range and battery life A weak battery can affect readings replace your battery if in doubt before performing service In addition make sure you have you meter set to the correct resistance ohm setting and the component being checked is isol...

Page 27: ...loose broken or damaged connections from sensor back to PC board 2 Verity unit is connected to the proper type gas Example if a natural gas unit should be connected to natural gas 3 WARNING You must be qualified to service gas systems before proceeding Verify low high fire manifold pressures are set properly See gas pressure setting procedures for pressure setting at your elevation 4 If unit was e...

Page 28: ...in operation To reset this code you must correct the problem with the bi metal switch first Then you have to turn the power off to the appliance and then turn it back on This is called a hard reset 1 Check sensor wiring harness for loose broken or damaged connections from sensor back to PC board 2 This code indicates a scale build up inside the secondary heat exchanger and it needs to be flushed t...

Page 29: ...ness for loose broken or damaged connections from fan motor back to PC board 2 Remove fan motor with power supply to product turned off Inspect blower wheel to ensure it turns freely 3 Check fan housing for debris that could prevent the fan wheel from turning 4 Measure fan motor winding resistance see technical data sheet behind front cover or in service manual for proper resistance readings If wi...

Page 30: ...ns per minute through the unit press the UP button for 3 seconds followed by the ON OFF button The display will display a number that number is your flow rate Example 5 0 5 gpm 21 2 1 gpm If the flow rate is below 1 3 gpm perform the following checks a Bleed all air from the system tank and pump b Clean the inlet water filter c Verify you have the proper water supply to the appliance at a flow rat...

Page 31: ...vo valve has failed to close during the bath fill function Immediately turn off the water flow and discontinue the bath fill function 4 WARNING Turn off the electrical gas and water supply to the water heater before proceeding Replace water flow control servo If the water flow servo motor is disconnected when the unit tries to cycle the product will post a code 65 This will shut the unit down unti...

Page 32: ...off the electrical gas and water supply to the water heater before proceeding 1 Check all wiring harnesses at the connection to the PC board to ensure they are not loose broken or damaged 2 Check all dip switches to ensure they are set to the proper position 3 Replace PC board ...

Page 33: ... the heat exchanger is leaking replace it and any other components damaged due to that leak If the moisture is caused by condensation running back into the unit from the vent system make provisions to stop this by installing a condensate drain line at the top of said unit 3 Check voltage to SVO and SV1 while unit is trying to fire If you have proper voltage but keep getting an error code proceed t...

Page 34: ...back to PC board 2 Ensure flame rod is touching flame when unit fires 3 Remove flame rod and check for carbon build up Clean flame rod as necessary 4 Check inside burner for debris build up that may be shorting out flame rod If debris on the burner is touching flame rod this could cause a short circuit and throw a code 72 5 Measure micro amp output from flame rod should maintain a minimum of 1 mic...

Page 35: ...of your unit This information can also be found in the product s service manual 3 WARNING You must be qualified to service gas systems before proceeding Confirm low high fire manifold gas pressures are set to factory specification per alitiube unit is installed at Manifold gas pressure settings and directions can be found on the tech sheet under front panel of the unit or in the service manual 4 R...

Page 36: ...eat exchanger and all piping inside the unit for leaks 3 If no leaks are found inspect inside of cabinet for signs of water pooling on bottom pan of water heater Wipe or blow out any water found in cabinet Dry off leak sensor and restart unit 4 If no water is found in cabinet unplug sensor and fire water heater If unit operates with sensor unplugged replace sensor and screw ...

Page 37: ...ate required to fire the unit 4 Ensure water flow control turbine spins freely 5 Measure the resistance of the water flow control sensor see technical data sheet behind front cover of unit for proper readings 6 Check for bleed overs isolate unit from building by turning off hot water line to building Next isolate the circulation system if present Open your pressure relief valve if water is flowing...

Page 38: ... there is a scale build up in the heat exchanger and that it needs to be flushed to prevent damage Refer to the flushing instructions in the owner s manual Hard water must be treated to prevent scale build up or damage to the heat exchanger The above codes will lock the unit out requiring a reset function see below how to reset To operate the water heater temporarily until the heat exchanger can b...

Page 39: ... a service provider performed maintenance or repair The serviceman will enter the following code FF after making repairs to the product That flags the system indicating all codes after the FF took place after he made his repairs You can enter the FF code by pressing the up down and ON OFF buttons simultaneously ...

Page 40: ... We are trying to ensure water is not bypassing the water heater through a faulty check valve in the return loop After shutting off the ball valve in the circulating loop all water flow should stop If not you may still have a faulty fixture 4 Proceed to all fixtures with single handle levers shut off the cold water ball valve at each fixture one at a time Check flow after shutting off the cold wat...

Page 41: ...ging due to under sized meters regulators gas lines or systems tanks etc Must ensure gas system is sized properly Check inlet gas pressure while the unit is operating looking for inlet gas pressures surging up and down This would indicate an issue with the gas supply e Inlet water pressure fluctuating causing the unit to cycling on off on low flows Can be caused by fluctuating water supplies due t...

Page 42: ...cold water sandwich is created j Loose or bad electrical connection inside the water heater or power supply to product Power supply could be dropping out momentarily due to a component heating up loose wiring connections etc k Low flow shower heads especially in area with high ground water temperatures ...

Page 43: ...43 11112014GW How to retrieve flow rate temperature output ...

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