American Water Heater U273-1373-01, 705, 701022 User Manual

Controller

In Use Indicator

Indicates that hot water is being supplied.

Priority Indicator

Indicates that this controller is setting the

Temperature Display

Indicates temperature setting or flashes error code.

Thermostat

water temperature.

Priority Button

When no water is being supplied, pressing this button allows this controller to set the water temperature.

ON/OFF Button

Diagnostic Use of the Controller

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.

To Change the Temperature Scale (ºF / ºC)

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).

To Turn Off the Controller Sound (Mute)

To turn the sound off (mute), press and hold both the and thermostat buttons until a “beep” is heard (about 5 seconds).

Gas Pressure Setting

NOTE: For additional installation and commissioning information refer to the Operation and Installation Manual.

WARNING

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.

APPLIANCE OPERATING PRESSURES

Gas Inlet Min./Max

NAT.G

5"W.C.

/10.5"W.C.

705(Indoor)

705(Indoor-ASME)

Water

Inlet Max.

Commissioning

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.

Table 1

Forced Low Forced High

LPG NAT.G LPG NAT.G LPG

8"W.C.

/13.5"W.C.

.C.W"7.3.C.W"0.3.C.W"38.0.C.W"76.0ISP 051

Troubleshooting

Important Safety Notes

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).

(SV1, SV2, SV3 and POV) Gas valve and Modulating solenoids: (Set meter above 2K)

Wire color Voltage Resistance Connector # Pin #'s (Main) Pink - Black (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

(M) Water Flow Control Device Servo or Geared Motor:

Red - Blue 11 ~ 13 VDC 22 ~ 28 ohms F5 9 - 10 Grey - Brown 4 ~ 6 VDC N / A F5 5 - 7 Grey - Yellow N / A N / A F5 5 - 8

NOTE: The grey wire listed above turns to black at F connector on the PCB.

(QS) Water Flow Sensor:

Black - Red 11 ~ 13 VDC 5.5 ~ 6.2 K ohms F2 1 - 3 Yellow - Black 4 ~ 7 VDC 1 ~ 1.4 Mega ohms F2 2 - 3

By-pass Flow Control:

Orange - White 2 ~ 6 VDC Yellow - White

(IG) Ignition System:

Grey - Grey 90 ~ 110 VAC N / A C1 1 - 2

(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:

Red - White 11 ~ 13 VDC Below 1 ohms

11 ~ 13 VDC 24 ~ 28 ohms H3 6 - 7

2 ~ 15 VDC 67 ~ 81 ohms H2 9 - 10

5 - 11GetihW - nworB

(Unit in operating mode)

15 ~ 35 ohms

G1 2 - 5 G1 3 - 5

5 - 41GdnuorG - etihW-deR

F6 H1

F6 - H12

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 Switches Settings

Adjust switches 2 and 3 in the bank of 8 depending on your altitude according to the table below.

The original PC boards on the water heaters do not have the bank of 6 dip switches. Only spare PC boards have this bank.

WARNING

High Altitude

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.

Gas Pressure Setting

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.

1. Turn OFF the gas supply.

2. Turn OFF the 120 V power supply.

3. Remove the front panel from the appliance.

4. 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.

High Pressure Potentiometer

Burner

SW1

SW2

Spare Parts Only

test point

Fig. 1 Fig. 2

Regulator adjustment screw access plug

Fig. 3 Fig. 4

Fig. 5 Fig. 6

Heat Exchanger and Outgoing Water Temperature Thermistors:

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.

Example:

59°F = 11.4 ~ 14K 86°F = 6.4 ~ 7.8K 113°F = 3.6 ~ 4.5K

Outgoing Water Thermistor:

White - White N / A See example above F4 3 - 4

Heat Exchanger Temperature Thermistor:

Pink - White N / A See example above F3 3 - 11

Surge Protector:

Black - White 108 ~ 132 VAC N / A D2 1 - 3 Black - White 108 ~ 132 VAC N / A D1 1 - 3

140°F = 2.2 ~ 2.7K 221°F = 0.6 ~ 0.8K

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.

Remote Controls:

Te rminals B1 10 ~ 13 VDC 1.5 ~ 3.0 K ohms B 1 - 3

Frost Protection:

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.

Amp Fuses:

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.

705(Indoor)

705(Indoor-ASME)

NAT.GLPG

4 5 6 7 8

4 5 6

4 5 6 7 8

4 5 6

Error Codes

No burner operation during freeze protection mode

• Service Call

Power interruption during Bath fill (Water will not flow when

power returns)

• Turn off all hot water taps. Press ON/OFF twice.

Air Supply or Exhaust Blockage

• 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.

No Ignition

• Check that the gas is turned on at the water heater, gas meter,

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.

Flame Failure

• Check that the gas is turned on at the water heater and gas

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.

Thermal Fuse

• Check gas type of unit and ensure it matches gas type being

used.

• Check for restrictions in air flow around unit and vent terminal.

• Check for low water flow in a circulating system causing short-

cycling.

• Ensure dip switches are set to the proper position.

• Check for foreign materials in combustion chamber and/or

exhaust piping.

• Check heat exchanger for cracks and/or separations.

• Check heat exchanger surface for hot spots which indicate

blockage due to scale build up. Refer to instructions in manual for flushing heat exchanger.

• Measure resistance of safety circuit.

• Ensure high fire and low fire manifold pressure is correct.

• Check for improper conversion of product.

Wiring Diagram

BL:Blue

BK:Black

BR:Brown

R :Red

38765

Dip SW1

BKRW

(CN9)

YBKR G

WATER FLOW

SENSOR

Y :Yellow

P :Pink

O :Orange

GY:Gray

G :Green

Gas pressure

Spare Parts Only

Gas type

123

Dip SW2

(CN5)

WWP

BL BR

HEAT EXCHANGER

WATER THERMISTOR

OUTGOING WATER

2-Unit Connection

(Optional)

BRROYW

ORW

BY-PASS FLOW

CONTROL DEVICE

W :White

COLOR CODING

MODULATING VALVE

CURRENT ADJUSTING

MIN

MAX

(CN7)

FREEZE PROTECTION

(OPTIONAL)

Over Temperature Warning

• Check for restrictions in air flow around unit and vent terminal.

• Check for low water flow in a circulating system causing short-

• Check for foreign materials in combustion chamber and/or

• Check for clogged heat exchanger.

Outgoing Water Temperature Sensor Fault

• Check sensor wiring for damage.

• Measure resistance of sensor.

• Clean sensor of scale build up.

• Replace sensor.

Heat Exchanger Outgoing Temperature Sensor Fault

• Check sensor wiring for damage.

• Measure resistance of sensor.

• Clean sensor of scale build up.

• Replace sensor.

Combustion Air Temperature Sensor Fault

• 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

• Replace sensor.

Modulating Solenoid Valve Signal Abnormal

• Check modulating gas solenoid valve wiring harness for loose

• Measure resistance of valve coil.

Combustion Fan Failure

• Ensure fan will turn freely.

• Check wiring harness to motor for damaged and/or loose

• Measure resistance of motor winding.

Water Flow Servo Faulty (does not stop flow properly)

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.

SV0, SV1, SV2, and SV3 Solenoid Valve Circuit Fault

• Check wiring harness to all solenoids for damage and/or loose

• Measure resistance of each solenoid valve coil.

Flame Sensing Device Fault

• 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

• Check inside burner chamber for any foreign material blocking

• Measure micro amp output of sensor circuit with flame present.

• Replace flame rod.

Scale Build-up in Heat Exchanger (when checking

maintenance code history “00” is substituted for “LC”)

• Flush heat exchanger. Refer to instructions in manual.

• Replace heat exchanger.

No Code (Nothing happens when water flow is activated.)

• Clean inlet water supply filter.

• On new installations ensure hot and cold water lines are not

• Check for bleed over. Isolate unit from building by turning off

• Ensure you have at least the minimum flow rate required to fire

• 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

FROST SENSING

SWITCH

W W

BL BL

REMOTE CONTROLLER

(CN2)

12 1

BLRBR

BRYGY

(CN12)

WATER FLOW

(CN1)

OBKO

BK W

RBKY

COMBUSTION FAN

CONTROL DEVICE

WATER THERMISTOR

cycling.

exhaust piping.

condition.

or damage terminals.

connections.

sand paper.

flame at flame rod.

reversed.

hot water line to building. Isolate the circulating system if present. Open your pressure relief valve; if unit fires, there is bleed over in your plumbing.

unit.

terminals for controls.

ANTI-FROST

HEATER

SPARK

ELECTRODE

FUSE

GND

IGNITER

(CN4)

MODULATING

OVERHEAT

SWITCH

POV

SOLENOID VALVE

THERMAL FUSES

GROUND

AC120VAC120V

NEUTRAL

HOT

(3A)

BK W

WBK

(CN3)

SV0

MAIN SOLENOID VALVE

SURGE

PROTECTOR

G/Y

WBK

G/Y

FLAME ROD

SV1

SV2

SOLENOID VALVE 1

(CENTER)

SOLENOID VALVE 2

GND

SV3

(LEFT)

SOLENOID VALVE 3

(RIGHT)

SW No.

High Altitude

Off

Level 0

0-2000 ft

(0-610 m)

Off

NOTES

Level 1

2001-5200 ft

(610-1585 m)

5201-7700 ft

Off

(1585-2347 m)

Level 2

7701-10200 ft

(2347-3109 m)

Level 3

705 Indoor

070 00012 36676 0

U273-1373(01)

EXPLODED VIEW - CABINET EXPLODED VIEW - INTERNALS

REMOTE CONTROLLER

EXPLODED VIEW - ELECTRICALEXPLODED VIEW - INTERNALS

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

703

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

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)

Par ts Number 701022-150 701022-154 701022-155 701022-159 701022-160 701022-162 701022-163 701022-164 701022-165 701022-023 701022-008 701022-020 701022-166 701022-167 701022-168 701022-169 701022-170 701022-027 701022-171 701022-172 701022-173 701022-174 701022-175 701022-153 701022-182 701022-183 701022-036 701022-184 701022-185 701022-039 701022-093 701022-186 701022-187 701022-188 701022-189 701022-158

Quantity

705

(Indoor)

1 1 1 1 2 2 2 1 1 1 1 1 1 1 1 2 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

705

(Indoor-ASME)

1 1 1 1 2 2 2 1 1 1 1 1 1 1 1 2 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

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

PA RTS LIST

Description Flue Outlet Vent Packing Flue Outlet Vent Assembly ϕ 100 Packing Blower Motor Fan Casing Assembly Fan Connecting Bracket Fan Connecting Packing

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

Par ts Number 701022-191 701022-192 701022-193 701022-194 701022-195 701022-197 701022-198 701022-199 701022-069 701022-200 701022-082 701022-203 701022-204 701022-074 701022-075 701022-205 701022-206 701022-207 701022-081 701022-208 701022-209 701022-210 701022-211 701022-088 701022-213 701022-091 701022-214 701022-215 701022-216 701022-102 701022-151 701022-218 701022-219 701022-221 701022-222 701022-120

Quantity

705

(Indoor)

1 1 2 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 2 1 9 2

705

(Indoor-ASME)

1 1 2 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 2 1 9 2

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

Par ts 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

(Indoor)

1 1 1 1 1 1 1 1 1 4 4 2 7

8 1 5 2 3 1 1 3 1 2 1 2 1 2 1 4 2 3 1 1 1 1

705

(Indoor-ASME)

1 1 1 1 1 1 1 1 1 4 4 2 7

8 1 5 2 3 1 1 3 1 2 1 2 1 2 1 4 2 3 1 1 1 1