Rinnai MC-195T-US User Manual

Controller

Gas Pressure Setting

Ensure gas pressure check under Commissioning has been

TIME Icon

LOCK Icon

PRIORITY Icon

LOCK

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

CIRCULATION Icon

not operating correctly and all other possible causes for incorrect

operation have been eliminated.

1.

Turn OFF the gas supply.

TEMPERATURE Icon

2.

Turn OFF the water supply.

3.

Remove the front panel (four screws).

COMBUSTION Icon

WATER TEMPERATURE

4. Check the gas type using the data plate on the side of the unit.

TIMER SETTING Icon Confirm that the gas type switch is in the correct position (SW1 in DIPSW2 is ON for natural gas, NG, and OFF for

propane gas, LPG.) Figure 1.

TIMER 1 & 2 Icon

5.

Remove the screw and attach the manometer to the burner test

point located on the gas control. Figure 2.

ON/OFF Icon

OVERRIDE/SELECT

6. Turn on the gas supply and the power supply.

7.

Flow water through the water heater at the maximum flow rate

obtainable. (At least 3 gallons per minute is recommended. If

there is not enough water flowing, the water heater could shut

Diagnostic Use of the Controller

off or sustain damage due to overheating.)

8.

Move SW8 in DIPSW1 to ON. Figure 3.

1. To display the most recent diagnostic codes press and hold the

9.

Push the PC board switch A for one second. Figure 4.

“On/Off” button for 2 seconds on the MC-195T controller.

10.

Calibrate “Forced Low” combustion using switch A (up) and

2. To enter or exit the maintenance monitor information mode press

and hold the down button for 2 seconds and without releasing it

switch B (down).

press the ON/OFF button.

11. Move SW8 in DIPSW1 to OFF and then back to ON. Figure 6.

12.

Push the PC board switch B for one second. Figure 4.

No.

Data

Unit

13.

Calibrate “Forced High” combustion using switch A (up) and

01

Water flow rate

0.1 gal/min

switch B (down).

02

Outgoing water temperature

Degrees Fahrenheit

14.

Move SW8 in DIPSW1 to OFF. Figure 5.

To Change the Temperature Scale (ºF / ºC)

15.

Close hot water taps.

With the water heater turned on, press FUNCTION button to reach

16. Turn off gas supply and 120 V power supply.

Function 4. Once at Function for use▲ and ▼to select 1 for F and

17.

Remove manometer and re-install screw.

2 for C.

18. Turn on the gas supply and 120 V power supply.

To Turn Off the Controller Sound (Mute)

19.

Operate the unit and check for gas leaks.

With the water heater turned on, press FUNCTION button to reach

20.

Install the front panel using four screws.

Function 2. Once at Function for use▲ and ▼to select ON or OFF.

Locking the Controller

The MC-195T controller can be locked or unlocked by pressing and holding the LOCK button for approximately 3 seconds.

Gas Pressure Setting

NOTE: For additional installation and commissioning information refer

Burner

to the Operation and Installation Manual.

test point

WARNING

serviced and removed by a trained

This appliance must be installed,

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

Table 1

Fig. 2

Water

Gas Inlet Min./Max

Forced Low

Forced High

Fig. 1

Inlet Max

Nat. G

LPG

Nat. G

LPG

Nat. G

LPG

Short fluelength

4” W.C.

8” W.C.

0.51”W.C.

0.52”W.C.

3.1”W.C.

3.7”W.C.

RUR98i

150 PSI

Long fluelength

/10.5”W.C.

/13.5”W.C.

0.53”W.C.

0.55”W.C.

3.3”W.C.

3.9”W.C.

Fig. 3

Fig. 4

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 4” 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

Fig. 5

Fig. 6

correct operation/sizing and correct as required.

Troubleshooting

Place one lead of your meter to the flame rod and the other to ground.

Flame Rod:

Important Safety Notes

With the unit running you should read between 5-150 VAC. Set your

There are a number of (live) tests that are required when fault

meter to the μ amp scale and series your meter in line with the flame

finding this product. Extreme care should be used at all times to

rod. You should read 1 μ amp or greater for proper flame circuit. In

avoid contact with energized components inside the water heater.

the event of low flame circuit remove the flame rod and check for

Only trained and qualified service technicians should attempt to

carbon or damage.

repair this product. Before checking for resistance readings,

Heat Exchanger, Outgoing Water Temperature and

disconnect the power source to the unit and isolate the item from

the circuit (unplug it).

Inlet Thermistors:

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

Check all thermistors by inserting meter leads into each end of the

Wire color

Voltage

Resistance

Connector #

Pin #'s

thermistor plug. Set your meter to the 20 K scale and read

(Main) Black - Pink

11 ~ 13 VDC

24 ~ 28 ohms

B1

3 - 4

(SV1) Black - Blue

11 ~ 13 VDC

35 ~ 41 ohms

B3

4 - 6

resistance. Applying heat to the thermistor bulb should decrease

(SV2) Black - Yellow

11 ~ 13 VDC

35 ~ 41 ohms

B2

4 - 7

the resistance. Applying ice to the thermistor bulb should increase

(SV3) Black - Red

11 ~ 13 VDC

39 ~ 42 ohms

B4

4 - 5

the resistance. See below for examples of typical temperatures and

(POV) Yellow - Yellow

2 ~ 15 VDC

67 ~ 81 ohms

D1

1 - 2

resistance readings.

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

Example:

59°F = 11.4 ~ 14K

140°F = 2.2 ~ 2.7K

Red - Pink

N / A

44 ~ 52 ohms

G2

3 - 4

86°F = 6.4 ~ 7.8K

221°F = 0.6 ~ 0.8K

White - Blue

N / A

44 ~ 52 ohms

G2

1 - 2

113°F = 3.6 ~ 4.5K

Grey - Brown

N / A

N / A

G2

5 - 7

Outgoing Water Thermistor:

Grey - Orange

N / A

N / A

G2

6 - 7

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

White - White

N / A

See example above

E6

2 - 3

Blue - Blue

N / A

See example above

E6

4 - 5

(QS) Water Flow Sensor:

Heat Exchanger Temperature Thermistor:

Black - Red

11 ~ 13 VDC

N / A

L3

E10 - G7

Pink - Pink

N / A

See example above

E5

4 - 7

Yellow - Black

4 ~ 7 VDC

N / A

L3

E1 - G7

Inlet Thermistor:

By-pass Flow Control:

White - White

N / A

See example above

E9

4 - 9

Red - Pink

N / A

44 ~ 52 ohms

G1

12 - 13

Remote Controls:

White - Blue

G1

10 - 11

(IG) Ignition System:

Terminals J

10 ~ 13 VDC

1.5 ~ 3.0 K ohms

J

1 - 2

Frost Protection:

Grey - Grey

110 ~ 130 VAC

N / A

C1

1 - 3

This unit has frost protection heaters mounted at different points to

(FM) Combustion Fan Motor:

protect the water heater from freezing. All of them should show a

Red - Black

6 ~ 45 VDC

N / A

L2

5 - 6

positive resistance reading.

White - Black

5 ~ 10 VDC

9.60 ~ 9.75 K ohms

L2

3 - 5

Yellow - Black

11 ~ 13 VDC

3.90 ~ 4.05 K ohms

L2

4 - 5

Recirculation Pump:

White - Black

108 ~ 132 VAC

17 ~ 21 ohms

H1

1 - 2

Set your meter to the hertz scale. Reading across the white and black wires at terminals 3 and 5

Amp Fuses:

you should read between 60 and 420 hertz.

Thermal Fuse / Overheat Switch:

This unit has one inline (10) amp glass fuse. Remove the fuse and

check continuity through it. If you have continuity through the fuse

Red - White

11 ~ 13 VDC

Below 1 ohms

B8

B1 - G8

B7

then it is good. Otherwise the fuse is blown and must be replaced.

Dip Switches Settings

Recirculation DIP Switch Settings

Adjust SW2 and 3 in DIPSW1(tan) depending on your

Operation

SW 4 in

SW 7 in

SW 8 in

DIPSW2

DIPSW2

DIPSW2

altitude according to the table below.

Pump OFF

OFF

OFF

OFF

Dedicated Return

Economy Mode

OFF

ON

OFF

High Altitude

RUR98i

Comfort Mode

OFF

ON

ON

LPG

NAT.G

Cross Over Short Loop

Economy Mode

ON

ON

OFF

O

ON

O

ON

DIPSW 1

1

1

Comfort Mode

ON

ON

ON

F

2

F

2

F

3

F

3

Economy Mode

ON

OFF

OFF

4

4

Cross Over Long Loop

5

5

Comfort Mode

ON

OFF

ON

6

6

7

7

8

8

WARNING

DIPSW 2

O

ON

1

O

ON

1

F

2

F

2

DO NOT adjust the other dip switches unless specifically instructed

F

3

F

3

to do so. Incorrect Dip Switch Settings can cause the Rinnai water

4

4

5

5

heater to operate in an unsafe condition and may damage the water

6

6

7

7

heater and void the warranty.

8

8

SW

NOTES

No.

2

Off

Level 0

Off

Level 1

On

Level 2

On

Level 3

High Altitude

0-2000 ft

2001-5200 ft

5201-7700 ft

7701-10200 ft

3

Off

On

Off

On

(0-610 m)

(610-1585 m)

(1585-2347 m)

(2347-3109 m)

Diagnostic Codes

03Power interruption during Bath fill (Water will not flow when power returns)

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

05 Bypass Servo

• Replace bypass servo

10 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.

•Verify dip switches are set properly.

•Check fan for blockage.

•Burner Sensor (see code 31)

11 No Ignition

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

• If the system is propane, make sure that gas is in the tank.

• Ensure appliance is properly grounded.

• 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 igniter is operational.

• Check igniter wiring harness for damage.

• Check gas solenoid valves for open or short circuits.

• Remove burner cover and ensure burners are properly seated.

• Remove burner plate; inspect burner surface for condensation/debris.

• Check the ground wire for the PC board.

12 No Flame

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

•Check for obstructions in the flue outlet.

•If the system is propane, make sure that gas is in the tank.

•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.

•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 reconnect all wiring harnesses on unit and PC board.

•Check for DC shorts at components.

•Check gas solenoid valves for open or short circuits.

•Remove burner plate; inspect burner surface for condensation/debris.

14 Thermal Fuse

•Ensure SW5 in DIPSW2(white) is in the off position.

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

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

•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 exhaust piping.

•Check heat exchanger for cracks 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. Hard water must be treated to prevent scale build up or damage to the heat exchanger.

•Measure resistance of safety circuit.

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

•Check for improper conversion of product.

16 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-cycling.

•Check for foreign materials in combustion chamber and exhaust piping.

•Check for blockage in the heat exchanger.

19 Electrical Grounding

• Check all components for electrical short.

25 Condensate Trap

•Condensate trap is full. Check condensate trap and drain pipe for blockage.

•Replace condensate trap.

31 Burner Sensor

•Measure resistance of sensor.

•Replace sensor.

32Outgoing Water Temperature Sensor

33Heat Exchanger Outgoing Temperature Sensor

41Outside Temperature Sensor

51Inlet Water Temperature Sensor

•Check sensor wiring for damage.

•Measure resistance of sensor.

•Clean sensor of scale build-up.

•Replace sensor.

52 Modulating Solenoid Valve Signal

•Check modulating gas solenoid valve wiring harness for loose or damaged terminals.

•Measure resistance of valve coil.

57 Burner

• Contact a service provider.

58 Secondary Heat Exchanger

•There is scale build up in the secondary heat exchanger and it needs to be flushed to prevent damage. Refer to the flushing instructions in the manual. Hard water must be treated to prevent scale build up or damage to the heat exchanger.

61 Combustion Fan

•Ensure fan will turn freely.

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

•Measure resistance of motor winding.

63 Circulation Pump

• Ensure cold inlet and hot outlet valves are open to plumbing.

• Inspect/clean inlet filter for debris.

• If application is using thermal bypass valve inspect/clean pump filter. If

• installed with dedicated return, inspect return line.

• If draining pump, purge air from recirculation pipe before running fixture.

• If installed in a cold climate, open hot water fixture and run for 5 min.

• Repalce Pump.

65 Water Flow Servo

•The water flow control valve has failed to close during the bath fill function. Immediately turn off the water and discontinue the bath fill function. Contact a licensed professional.

70 PC Board

•Check PC board DIP switches for correct positons.

•Check the connection harness at the connection on the PC board.

•Replace PC board.

71 Solenoid Valve Circuit

• Replace the PC Board.

72 Flame Sensing Device

• Verify flame rod is touching flame when unit fires.

• Check all wiring to flame rod.

• Remove flame rod;check for carbon build-up; clean with sand paper.

• Check inside burner chamber for any foreign material blocking flame at flame rod.

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

• Replace the PC Board.

73 Burner Sensor Circuit

•Check sensor wiring and PC board for damage.

•Replace sensor.

LC#	Scale Build-up in Heat Exchanger (when checking
	maintenance code history “00” is substituted for “LC”)

•LC0~LC9 indicates that there is scale build up in the heat exchanger and that the heat exchanger needs to be flushed to prevent damage. Refer to the flushing instructions in the manual. Hard water must be treated to prevent scale build up or damage to the heat exchanger.

•To operate the water heater temporarily until the heat exchanger can be flushed, push the On/Off button on the temperature controller 5 times. Repeated LC# codes will eventually lock out the water heater.

FF Maintenance Performed

•Indicates a service provider performed maintenance or repair. Enter this code by pressing up, down, and ON/OFF simultaneously.

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 reversed.

•Verify you have at least the minimum flow rate required to fire unit.

•Check for cold to hot cross over. Isolate circulating system if present.

•Turn off cold water to the unit, open pressure relief valve; if water continues to flow, there is bleed over in your plumbing.

•Verify turbine spins freely.

•Measure the resistance of the water flow control sensor.

•If the display is blank and clicking is coming from the unit, disconnect the water flow servo motor (GY, BR, O, W, P, BL, R). If the display comes on then replace the water flow servo motor.

Wire Diagram

RUR98i (KBP3237FFUD-US)

070	00012	37150	4	U306-1460(00)X01