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Rinnai Q series, Troubleshooting Manual

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Rinnai Q series Troubleshooting Manual Download Page 21

                                                                                            21                                                                        

008082013GW

 

 

 

 

Due to insufficient 
ionization the burner 
has shut down after 

ignition 

Ionization flow, 
ionization cable or 

02 setting 

Ignition Failure Issue 

Flame Failure Issue 

Note: if ionization is lost while the flame is 
burning no E02 will occur - unit will attempt to 
relight 6 times.  E02 only occurs after 6 failed 
attempts for re-ignition.  
 
Propane gas with low BTU value or a brand 
new tank that may contain something other 

than pure propane may cause E02. Check 
against a good known source of gas.

 

The minimum ionization current 
should be 4 micro amps (Check 
INFO step 48, the O2 should be a 

minimum of 4.4% for NG or 4.8% 
for LP. 

Summary of Contents for Q series

Page 1: ...e 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 be repla...

Page 2: ... indication Short reference 5 BL 01 6 BL 05 7 BL 11 8 BL 12 9 BL 60 10 BL 67 11 BL 80 12 BL 81 13 BL 82 14 BL 84 15 BL 85 16 BL 86 17 E 00 18 E 01 19 E 02 20 E 03 21 E 04 22 E 05 23 E 07 24 E 11 25 E 12 26 E 13 27 E 14 28 E 18 29 E 19 30 E 24 31 E 26 32 E 28 33 E 29 34 E 31 35 ...

Page 3: ...51 Starting up filling and de aerating the boiler Water Requirements 52 Freeze Protection 53 Filling the heating system 54 Altering adjustments 55 PARAMETER mode 56 Information Service and Error Modes 57 Activating factory setting Green button function 58 Isolating the boiler 59 Reset service interval counter 60 2013 Rinnai America Corporation 103 International Drive Peachtree City GA 30269 Toll F...

Page 4: ...4 008082013GW ...

Page 5: ...5 008082013GW Parts of the Boiler ...

Page 6: ...ower Btu of boiler bL 67 Block 67 A T has been detected between flow and the return sensor whereas the burner is not in operation After the T has disappeared the block will clear itself bL 85 Block 85 The control has not detected water flow The venting cycle pro purge cycle has started If during this cycle water flow is detected the pro purge cycle stops the burner will then fire up Error E with a...

Page 7: ...EVER wire boiler safeties in parallel Refer to wiring diagram in the boiler manual Trace connections 24 and 25 above back to the MCBA These will be located on Plug X5 on the MCBA on pins 2 and 6 The 120 volt external pump is for E and QP model boilers Rectify error by determining which external contact is open If external contacts are not being used place jumper across terminals 24 25 ...

Page 8: ...oor sensor contact open not connected BL 05 Rectify error by determining if outdoor sensor is faulty wiring to senor is broken or damaged or if the connection at terminal 18 19 on main control board is properly connected ...

Page 9: ...tion of the boiler plumbing connections and all components 4 Check minimum and maximum temperature difference in Parameter step 46 and 47 5 Activated room sensor RS100 in non leading room closed thermostatic radiator valves Check pump height Should this be check pump head Do not understand Operation is normally possible for the hot water supply during the block The pump continues to operate at min...

Page 10: ... closed blocked water filter restriction in DHW tank to high 3 Verify proper installation of the boiler plumbing connections and all components 4 Ensure 3 way valve is functioning properly and is not clogged or full of pollution Operation is normally possible for the central heating installation during the block The pump continues to operate at minimum capacity during Rectify Issue Check following...

Page 11: ... be reprogrammed if the bL60 code clears up If after resetting the boiler the bL60 still appears you will need to replace the sub PC board and reprogram the MCBA The sub PC board must be from a conversation kit for the same gas type as your boiler If conversion parts are not locally accessible contact Rinnai Tech Support for assistance These parameters cannot be accessed in the field and may requi...

Page 12: ...red the block will disappear A temperature difference has been detected between the supply T1 sensor and the return T2 sensor while the burner is not in operation After the average ΔT has disappeared the blocking code will go away T2 Sensor T1 Sensor Check the supply T1 sensor and the return T2 sensor for the proper resistance valve Replace if found to be defective ...

Page 13: ...n place this sensor was never installed which means the circuit has somehow been jumped out Contact Rinnai tech support for assist if you get the bL80 without the T5 sensor being installed Inspect vent system and all air passages ways for blockage 212 F is the default temperature setting for parameter 84 Verify to see if the temperature setting for this parameter is set higher than the default If ...

Page 14: ...ing rain during extreme weather Methods to rectify A ORDER AND INSTALL A FLUE GAS SENSOR This may not be possible in cold weather when boiler must operate immediately if shipping the part is required B CHANGE PARA 80 TO 20 AND INSTALL LOW VOLTAGE JUMPER ON FLUE GAS PLUG plug located on upper left hand side of the heat exchanger in the harness PARA 20 setting causes the MCBA to look for an open clo...

Page 15: ...15 008082013GW Flue sensor or thermostat contact open ...

Page 16: ... factory jumper on the flue gas sensor is loose or has fallen out 212 F is the default temperature setting for parameter 84 Verify to see if the temperature setting for this parameter is set higher than the default If so inspect vent system for blockage ...

Page 17: ... tells the MCBA that the pump has started The air bubble will absorb that spike Bleed all air from the system If an additional expansion tank is placed in the system alongside an E boiler that tank can absorb the pump pressure spike as well You may need to isolate that tank to see if this corrects the issue with BL 85 An expansion that is not charged properly can cause the pump s pressure spike no...

Page 18: ...008082013GW The frequency of the power supply deviates more than or 1 5 Hz If using a back up generator ensure it is properly grounded and providing a clean steady voltage and sign wave of 59 3 to 60 8 Hz ...

Page 19: ...ler is not firing can trigger the E00 code Check whether the ionization cable and or the electrode are responsible for a short circuit Remove the plugs from the ionization cable connected to the control unit and to the electrode Now using a ohm meter take a measurement between the ionization connection and the ground Now refit it part by part until a short circuit takes place ...

Page 20: ...lock Check for a short circuit in the disconnected components Next switch on power to the control board with all the 24 volt components disconnected Reconnect the components one at a time if code E 01 appears when you plug up a component that component has a short circuit Rectify any short circuits or replace defective component causing short circuit ...

Page 21: ... flame is burning no E02 will occur unit will attempt to relight 6 times E02 only occurs after 6 failed attempts for re ignition Propane gas with low BTU value or a brand new tank that may contain something other than pure propane may cause E02 Check against a good known source of gas The minimum ionization current should be 4 micro amps Check INFO step 48 the O2 should be a minimum of 4 4 for NG ...

Page 22: ... valve Check across terminals 4 and 5 at plug X5 on the main control board See wiring diagram for your boiler for terminal locations In some cases an E03 is caused from a loose connection on wires to the gas valve This faulty connection may be in the Molex plug X5 on the MCBA Examine plug closely for bayonets that may have backed out of plastic casing ...

Page 23: ...ower is once again switched on if the error causing the interference is no longer present this message is The boiler automatically indicates this message if during an error read out the electrical power to the boiler is shut off After the power is once again switched on if the error causing the interference is no longer present this message is given ...

Page 24: ...e it onto the new control The controller will automatically load the program into the new control unit Check ribbon cable between the control unit and the display board A loose connection between these two points can cause communication issues between boards leading to an error code If ribbon cable is loose or damaged repair or replace cable as needed ...

Page 25: ...25 008082013GW E 06 Control unit error Moisture on the PC board check for leaks on or in the boiler Replace PC board if needed ...

Page 26: ...26 008082013GW Replace the control unit The controller will automatically load the program into the new control unit ...

Page 27: ...27 008082013GW ...

Page 28: ...Clean the pump and or filter when necessary Flush complete system VERY RARE THAT AIR IS AT FAULT If air is present it will be indicated by a gurgling noise Normally when an airlock is present a BL85 will be indicated ...

Page 29: ...29 008082013GW Replace the control unit The controller will automatically load the program into the new control unit ...

Page 30: ...n from an end switch or pump relay box connected to terms 22 and 23 Install isolating relay on 22 and 23 or replace faulty end switch or pump relay box connected to 22 and 23 NO VOLTAGE MUST COME INTO 22 and T3 flow sensor ground connection T3 flow sensor failure or controller failure To determine flow temperatures for T3 use the chart to the left for proper resistance values for a set temperature...

Page 31: ...31 008082013GW Signal maximum flow water temperature exceeded T1 212 F T1 Sensor Actual flow temperature should be verified before T1 is determined Check actual flow temperature ...

Page 32: ...32 008082013GW T2 Sensor located under T1 sensor Signal maximum return water temperature exceeded T2 212 F ...

Page 33: ...e Transducer T2 sensor T1 and T2 swapped T2 temperature is measured to be higher than T1 Check resistance value of T1 and T2 See resistance chart under error 19 for resistance values Replace T and or T2 if found to be defective ...

Page 34: ...34 008082013GW Replace MCBA board main board ...

Page 35: ...nal from fan motor Check the wiring harness to the fan motor and control unit Check power supply to motor during combustion process should be 24 volts DC Fan motor wiring harness constant 24 volts DC Tachometer cable Feedback signal ...

Page 36: ... 5 during the starting sequence If during fan check 5 the fan remains spinning more than 150 rpms an E29 will occur Causes Wind driving into a concentric terminal Replace with 90 degree terminal or for best results use a roof terminal Venting running a long distance in a cold attic space causing a thermo syphon after fan check Use room air for combustion if conforming to NFPA 111 guidelines for ro...

Page 37: ...37 008082013GW T1 Sensor Internal shut down of supply sensor T1 T1 sensor short circuit is indicated by low ohm reading Replace defective sensor see resistance values in chart on E 18 above ...

Page 38: ...38 008082013GW Shut down of return sensor T2 T2 sensor short circuit is indicated by low ohm reading Replace defective sensor Refer to resistance chart on E 19 above ...

Page 39: ...39 008082013GW T1 Sensor Contact for supply sensor T1 open indicated by infinite ohm reading ...

Page 40: ...40 008082013GW T2 Sensor Contact for the return sensor T2 open indicated by infinite ohm reading Remove the plug from the flow sensor as a result of which error 32 occurs ...

Page 41: ...41 008082013GW ...

Page 42: ...42 008082013GW ...

Page 43: ...43 008082013GW Electrical short circuit possible water damage to MCBA main board ...

Page 44: ...s error is displayed there is no software on the MCBA or display A RINNAI conversion kit specific for the boiler model and fuel type must be installed Follow the conversion kit instructions to load the software to the MCBA ...

Page 45: ...45 008082013GW Q Series ribbon cable problem or defective key pad Replace ribbon cable Ribbon cable problem ...

Page 46: ...flue gas temperature Adjust parameter 84 default 212 F See location of T5 sensor below If red cap is installed T5 sensor is not being used T5 Senor if installed Moisture on the flue gas sensor wires or terminals could cause a false temperature reading ...

Page 47: ...47 008082013GW E 115 Replace MCBA board ...

Page 48: ...e it is plugged in properly This is the low voltage fuse that is located directly next to the PCB board transformer The OEM fuse has colored stripes the spare fuse located on control cover is a clear glass Please verify the amp rating 4 amp on the metal rim of the fuse before installing it It must be the same amperage as the fuse being replaced ...

Page 49: ...49 008082013GW Additional Troubleshooting Instructions ...

Page 50: ...50 008082013GW ...

Page 51: ...51 008082013GW Checking the O2 Setting ...

Page 52: ...52 008082013GW Burner off while there is a demand for central heat of DHW Burner off when room thermostat is demanding or burner off when DHW is calling Boiler Controls ...

Page 53: ...53 008082013GW Pressing R or the reset button for more than 5 seconds will activate a 17 minute de aeration cycle This LED should never be left on Explanation of the function buttons ...

Page 54: ...54 008082013GW Starting up Filling and de aerating the boiler and installation Requirements of the water system ...

Page 55: ...55 008082013GW ...

Page 56: ...e installation when necessary The working pressure of the installation should be between 16 and 18 PSI when the system is cold Adjust your auto feed to 16 18 PSI Note You must have either a hot water or heat demand to activate de aeration Filling the heating system ...

Page 57: ...57 008082013GW Altering adjustments ...

Page 58: ...r 10 the Flow switch is still in the circuit and if it sticks closed it can keep the boiler locked in DHW and code 6 with appear on the screen Unplug flow switch as it is not needed Do not waste time taking switch out and cleaning it just unplug it electrically PARA 36 Q combi 01 factory setting load sharing on 00 Alternate setting Load sharing off MCBA thinks a grey non modulating valve is being ...

Page 59: ...59 008082013GW ...

Page 60: ...60 008082013GW Activating factory settings Green button function ...

Page 61: ...61 008082013GW Isolating the boiler ...

Page 62: ...62 008082013GW Reset service interval counter ...

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