Rinnai Circ-Logic RU80e, Service Manual

Page: 42 / 60

Condensing Water Heater Service Manual 42
100000354
KA Series Component Replacement Instructions
RC98HPi
Heat Exchanger
31. If replacing the lower (primary) heat exchanger,
transfer parts from old heat exchanger to new heat
exchanger. These include fan housing assembly,
connecting pipe to upper heat exchanger and
copper tee with new o
-
ring and clip, drain pipe from
copper tee.
32. Install heat exchanger assembly in case. Place
bottom in cabinet first. Attach with four screws. (two
at top back and two on bottom) Attach
reinforcement bracket with two screws.
33. Remove old gasket from flue connection assembly.
Install new gasket from kit. Attach flue connections
assembly with four screws.
Install water and drain lines
34. Install drain connecting pipe with new o
-
rings and
attach with new clips.
35. Install water inlet connecting pipe with new o
-
rings
to upper heat exchanger. Attach with new clip at
heat exchanger and at bottom to the by
-
pass valve
with one screw and bracket. Attach the other water
line with one screw and bracket.
36. Attach the hot water outlet line to the hot water
outlet fitting with one screw and bracket. Reconnect
condensate tube to upper heat exchanger.
Reconnect wire harness
37. Reconnect heat exchanger thermistor (upper left).
38. Install three anti frost heaters in clips at top of upper
heat exchanger.
39. Reconnect anti frost connectors at bottom of
cabinet. One green connector, one blue connector.
40. Reconnect burner sensor harness (lower right).
41. Reconnect thermal fuse harnesses (lower right).
Single white wire connector, single red wire
connector.
42. Reconnect the fan connector.
Install burner and burner cover plate
43. Install burner assembly with two screws. Replace
combustion chamber packing (in kit) on sight glass
plate. Install combustion chamber sight glass plate
with eight screws.
Install gas manifold
44. Remove packing from gas control assembly.
Discard. Install new packing, in kit, on gas control
assembly.
45. Remove the packing for manifold. Install new
packing, in kit, on gas manifold.
46. Attach the gas manifold with three machine screws
at the gas control assembly. Install seven pan head
screws on gas manifold to heat exchanger. Attach
wire harness ties. (six screws at outer edge, one
middle of gas manifold plate)
47. Install four connectors to the solenoids on the gas
manifold. (marked)
Reconnect flame rod connectors and electrode
48. Install two flame rod connectors. (marked )
49. Install ignitor bracket with one machine screw.
50. Attach ignitor high tension cord to the electrode.
51. Attach controller bracket with one machine screw
and one screw from power wire clamp. Install
controller in bracket.
Check
52. Turn on water supply, power supply, and gas
supply. Check for gas and water leaks. Perform
operational checks.
53. Install the front panel using four screws.