Rinnai Sensei N-Series Service Presentation Download Page 24

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11/6/2018

Enhancing Lives By Changing The Way Water Is Heated

Gas Valve and Fan Motor Removal

Summary of Contents for Sensei N-Series

Page 1: ...1 11 6 2018 2015 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL Enhancing Lives By Changing The Way Water Is Heated Rinnai N Series Level III Service Presentation Version 01032018GW...

Page 2: ...is necessary as a copper heat exchanger could become clogged by corrosion b Burner Why use stainless steel mesh To eliminate resonance noise in the event the burner is compromised or the flame become...

Page 3: ...cedure allows you to confirm your settings with the controller s display e Gas Valve Why use a zero governor gas valve Rinnai switched to this valve system in order to satisfy the PVC 2 air exhaust ve...

Page 4: ...inside heat exchanger as high as possible the WFSV was relocated g Pressure relief valve Why was the pressure relief valve moved When the WFSV was relocated there was a possibility pressure inside the...

Page 5: ...roduct and burner maintenance l Maximum Flow Rate Allows for higher flow rates in warm ground water areas m Condense Drain Code Eliminated A blocked condense drain will post code 10 same as flue block...

Page 6: ...6 11 6 2018 2015 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL Enhancing Lives By Changing The Way Water Is Heated N Series Water Heaters External Model Internal Model...

Page 7: ...8 0 GPM 6 1 GPM 4 4 GPM 92 RU160e REU N2530W US RU180i REU N2934FF US 15K 180K 0 4 GPM 9 0 GPM 6 9 GPM 4 9 GPM 92 RU180e REU N2934W US RU199i REU N3237FF US 15K 199K 0 4 GPM 9 8 GPM 7 7 GPM 5 5 GPM 9...

Page 8: ...on Flow Rate approx Max Flow Rate 30 Rise Max Flow Rate 50 Rise Max Flow Rate 70 Rise Uniform Energy Factor UEF CU160i REU N2530FFC US 15K 160K 0 4 GPM 8 0 GPM 6 1 GPM 4 4 GPM 96 thermal Efficiency CU...

Page 9: ...nai s listed and tested vent systems Electrical System MUST be properly sized for load at location Refer to the National Electrical Code for details Each unit requires 120 Volts AC 4 amp grounded circ...

Page 10: ...orders Monday Friday from 8 a m to 8 p m EST Ship from 8 00 a m to 6 30 p m EST Online ordering Rinnai Parts Store 24 7 Warranty Department Available in office from 8 a m to 5 p m EST Monday Friday Te...

Page 11: ...nied with replacement procedures 3 N Series Parameter Settings See Owner s Manual for complete details Some parameter settings will required adjustments especially those for higher set point temperatu...

Page 12: ...ves By Changing The Way Water Is Heated Primary Service Tools For service troubleshooting and component replacement the following tools are needed 2 Phillips Head magnetic Small Phillips Head U Tube D...

Page 13: ...To remove front cover press in on the plastic strip with your thumb at the red circles shown on the picture to the right Pull strip out away from the unit Under the plastic strip you will find four Ph...

Page 14: ...Way Water Is Heated 1 Remove screw shown below to pull controller from unit 2 Unplug the 15 wire connector J on the P C board 3 To add additional remote controllers use the wiring harness provided wi...

Page 15: ...15 11 6 2018 2015 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL Enhancing Lives By Changing The Way Water Is Heated Flame Rod Electrode Sight Glass Plate Removal...

Page 16: ...Remove 3 screws shown with red circles 2 Unplug yellow flame rod wire 3 Unplug black electrode cable and green wire to casing 4 Remove sight grass plate flame rods and electrode from unit 5 Before re...

Page 17: ...17 11 6 2018 2015 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL Enhancing Lives By Changing The Way Water Is Heated Heat Exchanger Thermistor Removal...

Page 18: ...pulling retainer clip off thermistor Pull thermistor out of position Ensure O ring is intact and in good condition before reinstalling it Make sure the retainer clip is installed in the proper orienta...

Page 19: ...19 11 6 2018 2015 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL Enhancing Lives By Changing The Way Water Is Heated Outgoing Water Thermistor Removal...

Page 20: ...e any hot water or water pressure remaining in the system 1 Remove the outgoing water temperature thermistor shown below with red arrow Remove Phillips head screw and pull thermistor out of position e...

Page 21: ...21 11 6 2018 2015 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL Enhancing Lives By Changing The Way Water Is Heated Bi metal Over Heat Switch...

Page 22: ...cuit activates based on the temperature range listed below Bi metal switch automatically reset once the temperature drops below the activation point 1 Overheat switch located on the right side of the...

Page 23: ...eat Exchanger bi metal opens at 230 and resets at 203 If the outlet thermistor detects 9 F over the temperature set point The heat exchanger bi metal will post a code 14 on the controller The flame wi...

Page 24: ...24 11 6 2018 2015 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL Enhancing Lives By Changing The Way Water Is Heated Gas Valve and Fan Motor Removal...

Page 25: ...wer and gas 1 Unplug red fan motor connector 2 Unplug pink exhaust temperature thermistor connector 3 Unplug gas valve 8 pin connector 4 Unplug gas valve 2 pin connector 5 Unplug pink heat exchanger b...

Page 26: ...Remove fan motor assembly from gas valve remove 4 screws from bottom of fan housing shown in red circles 2 Replace O ring between fan assembly and gas valve 1 Combustion Fan Gas Valve Removal Fan Exha...

Page 27: ...and CONFIDENTIAL Enhancing Lives By Changing The Way Water Is Heated Heat Exchanger Assembly Which includes the air box burner Secondary Heat Exchanger The Sensei Heat Exchanger is made of 444 Stainl...

Page 28: ...Unplug heat exchanger thermistor follow wire down to green connector 2 Unplug ceramic heater at green connector and unclip ceramic heater from secondary heat exchanger feed line 3 Unplug bi metal swi...

Page 29: ...bled from system 1 Remove stainless steel clip stamped 18 28 on hot water outlet line Pull line loose from fitting 2 Remove stainless steel clip stamped 14 23 on bypass line Pull line loose from fitt...

Page 30: ...e red circles 2 Remove 4 screws from the secondary heat exchanger bracket 3 Remove 1 screw from black plastic air box top center of water heater 4 Lift bottom of secondary heat exchanger out towards y...

Page 31: ...emove caulking material at the four corners of the heat exchanger Make sure surface is clean flat to maintain airtightness Caulking material is not needed for replacement heat exchanger Burner gasket...

Page 32: ...hanger fixing screw Replace secondary heat exchanger gasket Ensure surface is clean before installing new gasket Repace duct fixing screws 4 screws with white coating Replace O rings in water circuit...

Page 33: ...33 11 6 2018 2015 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL Enhancing Lives By Changing The Way Water Is Heated Air Box Removal...

Page 34: ...America Corporation PROPRIETARY and CONFIDENTIAL Enhancing Lives By Changing The Way Water Is Heated Air Box Removal 1 Remove the 9 screws shown in red circles and pull the air box away from primary s...

Page 35: ...35 11 6 2018 2015 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL Enhancing Lives By Changing The Way Water Is Heated Primary Secondary Heat Exchanger Disassembly...

Page 36: ...s By Changing The Way Water Is Heated 1 Remove 14 screws shown in red circles separate secondary primary heat exchangers see example to right Primary Secondary Heat Exchanger Disassembly Bottom view o...

Page 37: ...37 11 6 2018 2015 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL Enhancing Lives By Changing The Way Water Is Heated Burner Disassembly...

Page 38: ...y Changing The Way Water Is Heated Burner Disassembly 1 Remove 8 screws shown in red circles pull burner plate and burner assembly from unit The burner right bottom fits in inside the burner plate pic...

Page 39: ...39 11 6 2018 2015 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL Enhancing Lives By Changing The Way Water Is Heated Water Flow Servo Valve Removal...

Page 40: ...se outlet water line Pull copper line away from WFSV 2 Remove stainless steel clip stamped 10 17 holding PRV line in place Pull line loose from bypass valve 3 Unplug WFSV control valve seven wire conn...

Page 41: ...41 11 6 2018 2015 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL Enhancing Lives By Changing The Way Water Is Heated Bypass Valve Flow Turbine Removal...

Page 42: ...etainers Pull water lines loose from bypass valve assembly 2 Unplug red three wire connector black yellow red wires 3 Unplug lite blue four wire connector red blue pink white wires 4 Remove 1 screw ho...

Page 43: ...pliers and slide the turbine assembly out of the bypass valve To disassemble turbine remove end cap and impeller from the turbine housing Clean all components with running water and a soft brush and...

Page 44: ...44 11 6 2018 2015 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL Enhancing Lives By Changing The Way Water Is Heated Condensate Trap Removal...

Page 45: ...ater Is Heated Condensate Trap Removal 1 Compress clamp and slide off drain pipe and condense trap connection 2 Unplug ceramic heater for condensate trap 3 Remove 2 screws holding condensate trap to t...

Page 46: ...46 11 6 2018 2015 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL Enhancing Lives By Changing The Way Water Is Heated P C Board Removal...

Page 47: ...inet disconnect all wiring harness connections on board Take care not to stress the connections when unplugging them Press in on the latch to release each connector before unplugging it A small screw...

Page 48: ...ay Water Is Heated Product Reassembly Re assemble in opposite order of disassembly All screws should be placed in the correct location DO NOT over tighten screws All wiring harness connections must be...

Page 49: ...49 11 6 2018 2015 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL Enhancing Lives By Changing The Way Water Is Heated Accessory Connections...

Page 50: ...ng Harness Part 105000249 Optional Accessory Harnesses Connector Locations Cascade Communication harness IN Cascade Communication harness OUT Part REU EZC 2 is the wiring harness shown above This harn...

Page 51: ...51 11 6 2018 2015 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL Enhancing Lives By Changing The Way Water Is Heated Electrical Values and Fault Codes...

Page 52: ...vent possible damage to plugs 3 Know your meter and how to set it for each type of measurement Always set meter to next highest value from range listed in troubleshooting sheets Ohms or resistance VAC...

Page 53: ...America Corporation PROPRIETARY and CONFIDENTIAL Enhancing Lives By Changing The Way Water Is Heated Power Supply 1 Check for 120 V A C Power Supply to the water heater Plug CN1 a Connector A pin 1 wh...

Page 54: ...Lives By Changing The Way Water Is Heated Power Supply Fuse When measuring resistance always make sure the power supply to the unit is turned off and the component being check is isolated from the P C...

Page 55: ...ing Lives By Changing The Way Water Is Heated Pump Circuit Fuse When measuring resistance always make sure the power supply to the unit is turned off and the component being check is isolated from the...

Page 56: ...itch When measuring resistance always make sure the power supply to the unit is turned off and the component being check is isolated from the P C board 1 Measure resistance and or voltage of the Overh...

Page 57: ...oid Valve When measuring resistance always make sure the power supply to the unit is turned off and the component being check is isolated from the P C board 1 Measure resistance and or voltage of the...

Page 58: ...ponent being check is isolated from the P C board Voltage readings will occur when fan motor is energized 1 Measure voltage of the Fan Motor on P C board at Connector D a Connector D red wire pin 4 bl...

Page 59: ...off and the component being check is isolated from the P C board 1 Measure resistance of Outgoing Water Thermistor on P C board at Connector H a Connector H white wire pin 2 turns black at P C board...

Page 60: ...being check is isolated from the P C board 1 Measure resistance of Inlet Water Thermistor on P C board at Connector H a Connector H white wire turns black at P C board pin 2 white wire pin 4 at red a...

Page 61: ...ated from the P C board 1 Measure resistance or voltage of Water Flow Control Device WFSV on P C board at Connector D a Connector D red wire turns black at P C board pin 30 pink wire pin 20 44 52 at r...

Page 62: ...nce always make sure the power supply to the unit is turned off and the component being check is isolated from the P C board 1 Measure resistance of Exhaust Temperature Thermistor on P C board at Conn...

Page 63: ...make sure the power supply to the unit is turned off and the component being check is isolated from the P C board 1 Measure resistance of Heat Exchanger Thermistor on the P C board at Connector H a Co...

Page 64: ...st be turned on to the appliance for this section of troubleshooting 1 Measure voltage of Water Flow Sensor on P C board at Connector H D on P C board a Connector D black wire pin 30 red wire pin 12 s...

Page 65: ...tance always make sure the power supply to the unit is turned off and the component being check is isolated from the P C board 1 Measure voltage of Freeze Protection Thermistor on the P C board at Con...

Page 66: ...l Valve When measuring resistance always make sure the power supply to the unit is turned off and the component being check is isolated from the P C board 1 Measure resistance of By Pass Flow Control...

Page 67: ...Servo on the P C board at Connector D a Connector D Red wire pin 12 Black wire pin 30 at the P C board 12 14 VDC when 120 VAC is on feeding unit at black arrows b Connector D Brown wire pin 25 Black w...

Page 68: ...Electrode When measuring resistance always make sure the power supply to the unit is turned off and the component being check is isolated from the P C board 1 Measure resistance or voltage of Igniter...

Page 69: ...r supply to the unit is turned off and the component being check is isolated from the P C board 1 Measure voltage of Additional Remote Controller s on the P C board at Connector CN211 a Connector CN21...

Page 70: ...ves By Changing The Way Water Is Heated Freeze Protection Heater Circuit Power must be turned on to the appliance for this section of troubleshooting 1 Check for 120 VAC to Freeze Protection Heater Ci...

Page 71: ...71 11 6 2018 2015 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL Enhancing Lives By Changing The Way Water Is Heated Maintenance Diagnostic Codes Diagram...

Page 72: ...Way Water Is Heated Maintenance Diagnostic Codes Diagram 120 Volt Power Supply 10 amps 11 12 71 51 70 Defective PC board Color coding BK Black BR Brown R Red O Orange Y Yellow G Green B Blue PR Purple...

Page 73: ...roducts should be less than 4 amps in units without a circulation pump built in or connected to the unit N Series Water Heaters requires 120 VAC 60 Hz 4 amp properly grounded circuit power source when...

Page 74: ...ntrollers Connected Connected or not 1 Connected 2 Not connected 07 Water Flow Servo Position Position 0 Partially Open 1 Open 2 Closed 08 Inlet Water Temperature Deg Fahrenheit Calculated Inlet Water...

Page 75: ...ons X1 000 gallons A2 Total water usage x1 000 000 gallons Total gallons X1 000 000 gallons C0 Total Calorie 1 Kcal min X1Kcal min C1 Total Calorie 1 000 Kcal min X1 000 Kcal min C2 Total Calorie 1 00...

Page 76: ...all vent components for proper connections Ensure vent length is within limits Check fan for blockage and proper operation Verify high altitude parameter was properly set Ensure exhaust check valve b...

Page 77: ...uri Confirm the appropriate orifice venturi is being used in the gas valve Replace fan 12 Flame Failure Check for obstructions in the flue outlet If the system is propane ensure the tank has adequate...

Page 78: ...Safety shutdown outlet water temperature exceeded 203 F 95 C Check for restrictions in air flow around the vent terminal Check fan for proper operation Check for foreign materials in the combustion c...

Page 79: ...Inlet Water Temperature Thermistor 52 Gas Valve Check flame rod wiring for loose broken or damaged components or connections Check gas solenoid wire harness for loose or damaged terminals Measure resi...

Page 80: ...ure water flow servo valve did not fail in the closed position Ensure parameters are properly set for the type circulation mode being used Cross Over or dedicated mode See owner s manual for details 6...

Page 81: ...clean inlet water supply filter Ensure the minimum activation water flow rate is met Ensure hot and cold water lines are not reversed cross connected Ensure there is not a crossover cross connection s...

Page 82: ...82 11 6 2018 2015 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL Enhancing Lives By Changing The Way Water Is Heated Warranty Maintenance...

Page 83: ...rts and Components 5 Years 5 Years Reasonable Labor 1 Year 1 Year Notes The heat exchanger warranty will be 15 years or 12 000 operation hours whichever occurs first From date of purchase period of co...

Page 84: ...ally thereafter Before removing the inlet filter ensure that the water supply has been turned off and all pressure in the hot water system has been drained off by opening a hot water tap to ensure no...

Page 85: ...85 11 6 2018 2015 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL Enhancing Lives By Changing The Way Water Is Heated Maintenance...

Page 86: ...rate of 4 GPM 15 1 L min 10 Turn off the pump 11 Rinse the cleaning solution from the water heater by a Remove the free end of the drain hose H3 from the pail and place in a suitable drain b Close se...

Page 87: ...of the structure a suitable drain pan MUST be installed under the appliances Rinnai recommends the use of water treatment in hard water areas Water heaters utilizing a circulation system will require...

Page 88: ...88 11 6 2018 2015 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL Enhancing Lives By Changing The Way Water Is Heated Gas Requirements...

Page 89: ...will also occur with incorrect venting Installation may operate correctly until winter then furnace kicks on and gas demand increases Now gas system is determined to be undersized due to not taking in...

Page 90: ...es of water column on Natural or 0 5 inches on Propane gas when using black iron piping with all gas appliances firing on high fire If using a gas piping other than black iron please refer to that man...

Page 91: ...ng The Way Water Is Heated Gas Conversion Process 1 Disconnect the electrical power 2 Turn off the gas supply 3 Remove 4 screws securing the front panel remove of unit 4 Locate orifice cover plate on...

Page 92: ...ng Figure 2 7 Install the new inner and outer gaskets on to the new orifice Figure 2 8 Install new orifice into housing Check the gas type displayed on the orifice Red Orifice is LPG Blue Orifice is N...

Page 93: ...93 11 6 2018 2015 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL Enhancing Lives By Changing The Way Water Is Heated Programming Parameter Settings...

Page 94: ...0 610 m Installations over 2 001 ft require a parameter change These units can be installed in applications up to 10 200 ft Maximum Water Flow Rate the rate at which water flows through the water hea...

Page 95: ...0 610 m Installations over 2 001 ft require a parameter change These units can be installed in applications up to 10 200 ft Maximum Water Flow Rate the rate at which water flows through the water hea...

Page 96: ...es By Changing The Way Water Is Heated Adjusting Parameters 1 Locate the PC Board lower right side of unit 2 Locate the two push buttons A and B on the PC Board 3 Press the A button 4 Use the and down...

Page 97: ...setting number is selected use the On Off button on the controller to change the selection for that setting number Example Display will change from 01A to 01b for Maximum Temperature setting as shown...

Page 98: ...0 F Residential 185 F Commercial 02 High Altitude Level 0 0 2 000 ft 0 610M Level 1 2 001 ft 5 400ft 610m 1 646m Level 2 5 401ft 7 700ft 1 646m 2 347m Level 3 7 701ft 10 200ft 2 347m 3 109m 03 Service...

Page 99: ...p temperature remains higher but also uses more energy Economy mode cycles the pump less often using less energy to maintain the circulation loop temperature 3 BMS Building Management System 4 Setting...

Page 100: ...d temperature setting 01A or 01b 2 Press the On Off button to scroll through the available temperature settings 3 When the desired temperature setting appears in the display press the top push button...

Page 101: ...Changing The Way Water Is Heated Adjust Altitude 1 Press and hold the top push button A on the PC Board for 1 second The display will initially indicate the active temperature setting 01A or 01b 2 Pr...

Page 102: ...de setting 4 When the desired altitude setting appears in the display press the top push button A on the PC board for 1 second to save the setting and return the water heater to normal operation mode...

Page 103: ...The Way Water Is Heated Adjust Maximum Flow Rate 1 Press and hold the top push button A on the PC Board for 1 second The display will initially indicate the active temperature setting 01A or 01b 2 Pre...

Page 104: ...On Off button on the controller to scroll to the desired Maximum Flow Rate setting 4 When the desired altitude setting appears in the display press the top push button A on the PC Board for 1 second...

Page 105: ...ng The Way Water Is Heated To Obtain Performance Data 1 Press and hold the Down button 2 While holding the Down button for 2 seconds press and hold the On Off button hold both buttons simultaneously 3...

Page 106: ...tion 05 Fan Frequency Hz 06 Additional Controllers Connected See following information 07 Water Flow Servo Position 0 mid 1 Open 2 Closed 08 Inlet Temperature F 09 Fan Current x10 mA 10 Total Bath Fil...

Page 107: ...Is Heated Performance Data Details CONTROLLER MODEL CONNECTED NOT CONNECTED MC 001 000 BC 010 000 BSC BSC2 100 200 QTY2 000 Performance Data 06 Additional Controllers Connected to Product CYCLE COUNT...

Page 108: ...Pipe Direct Vent 2 units 65 65 4 PVC CPVC Dual Pipe Direct Vent 2 units 65 150 6 PVC CPVC Dual Pipe Direct Vent 2 units 65 150 PVC CPVC PP NON DIRECT COMMON VENT Room Air RESIDENTIAL 3 PVC CPVC Singl...

Page 109: ...Air 3 Units 150 150 150 150 150 150 6 Vent Dual Pipe Direct Vent Single Pipe Room Air 4 Units 150 150 150 150 150 150 6 Vent Dual Pipe Direct Vent Single Pipe Room Air 5 Units 150 150 150 150 6 Vent D...

Page 110: ...up to 24 water heaters can be electronically connected The cascade connection enables all connected water heaters to modulate operation and function as one single hot water source The connection will...

Page 111: ...e Cascade Cable to the Cascade OUT accessory port on the first primary water heater s PC Board 2 Connect the other end of the Cascade cable to the Cascade IN accessory port on the next secondary water...

Page 112: ...e in the standby mode Standby units will maintain operation with the water flow control valve in the Open position The standby units will be ready to fire when sufficient water flow is detected The re...

Page 113: ...gs the display will be as shown below Primary Secondary 1 Secondary 2 Secondary 3 When the Primary unit is designated through parameter setting 08 the displays will show the set temperature Secondary...

Page 114: ...IDENTIAL Enhancing Lives By Changing The Way Water Is Heated Servicing or Replacing a Cascading Unit While servicing or replacing a unit using Rinnai s cascade system you MUST isolate that unit from t...

Page 115: ...RIETARY and CONFIDENTIAL Enhancing Lives By Changing The Way Water Is Heated Servicing or Replacing a Cascading Unit Once service or unit replacement is complete reconnect the cascade cables back to t...

Page 116: ...116 11 6 2018 2015 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL Enhancing Lives By Changing The Way Water Is Heated Voltage and Resistance Values...

Page 117: ...black Less than 1 ohm or 11 13 VDC 4 Measure resistance and or voltage of the Main Gas Valve Solenoid Plug D7 a Connector D black wire pin 27 yellow wire pin 29 18 22 ohms or 11 13 VDC 5 Measure resi...

Page 118: ...r D grey wire turns black before getting to board pin 30 orange wire pin 12 12 14 VDC 9 Measure resistance of Exhaust Temperature Thermistor Plug H3 a Connector H white wire pin 2 turns black before g...

Page 119: ...Servo Plug D5 a Connector D Red wire pin 12 Black wire pin 30 at the P C board 12 14 VDC when 120 VAC b Connector D Brown wire pin 25 Black wire pin 30 at the P C board Less than 1 VDC c Connector D G...

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