Rinnai RU199IN, RU199EP, CU199EN, CU199IP, CU199IN User Guide

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Page 1

To obtain Performance Data:

1. Press and hold the (Down) buon.

2. While holding the (Down) buon for 2 seconds, press and hold the “On/O” buon (hold both buons simultaneously).

3. Use the (Up) and (Down) buons to scroll to the desired performance informaon described below.

PERFORMANCE DATA ELECTRICAL DIAGNOSTICS DIAGNOSTIC CODES

# DATA UNIT

Water Flow Rate x0.1 gal/min

Outgoing Temperature °F

Combuson Hours x100 Hours

Combuson Cycles See following informaon

Fan Frequency Hz

Addional Controllers Connected See following informaon

Water Flow Control Posion 0=mid, 1=Open, 2=Closed

Inlet Temperature °F

Fan Current x10 mA

Total Bath Fill Amount gallons

HEX Outlet Temperature °F

By-Pass Flow Control Posion Degrees of opening

Freeze Protecon Temperature

(Indoor Unit Only)

°F

Freeze Protecon Temperature

(Outdoor Unit Only)

°F

Pump Hours x100 Hours

Pump Cycles See following informaon

Exhaust Temperature °F

DISPLAY CYCLE COUNT

000 to 999

x100 (0 to 99,900)

10– to 99-

x10,000 (100,000 to 990,000)

1-- to 6--

x1,000,000 (1,000,000 to 6,000,000)

See secon “Service Soon, 55” in the Installaon and Operaon Manual for more

informaon.

Seng 05 is available only if seng 04

is selected.

Comfort mode cycles the pump more frequently, ensuring the loop temperature remains higher (but also uses more energy).

Economy mode cycles the pump less oen, using less energy to maintain the circulaon loop temperature.

BMS = Building Management System

Seng 09 is available only if seng 08

is selected.

Selecng “High” will increase the water ow rate to the maximum capacity.

To adjust the parameters:

1. Press the “A” buon for 1 second.

3. Once the desired seng number is selected, use the “On/O” buon on the

controller to change the selecon for the seng number. Example: Display will

change from 01A to 01b for Maximum Temperature seng (as shown below).

4. To exit the parameters, press the “A” buon on the PC board for 1 second.

NOTE: Wiring diagram is available in manual and on the inside front cover.

Important Safety Notes

There are a number of (live) tests required when performing electrical

diagnoscs on this product. Proceed with cauon at all mes to avoid contact

with energized components inside the water heater. Only trained and

qualied service technicians should aempt 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).

Freeze Protecon

This unit has freeze protecon heaters mounted at dierent points to protect

the water heater from freezing. All of them should display a posive

resistance reading.

Flame Rod

Place one lead of your meter to the ame rod and the other to ground. With

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

micro (μ) amp scale and arrange meter leads in line with the ame rod. You

should read 1 μ amp or greater for proper ame circuit. In the event of low

ame circuit, remove the ame rod and check for carbon or damage.

Amp Fuses

This unit has two glass fuses located on the PC Board, one inline (10) amp and

one (4) amp glass fuse. Remove the fuses and check connuity through it. If

you have connuity through each fuse then it is funconing. Otherwise the

fuse is blown and must be replaced.

Thermistors

Check all thermistors by inserng 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.

Below are examples of typical temperatures and resistance readings.

(* Value to be measured while unit is in operaon)

To display diagnosc codes:

1. Turn o the water heater by pressing the “On/O” buon.

2. Press and hold the “On/O” for 2 seconds and then the (Up) buon simultaneously.

3. The last 9 maintenance codes display and ash one aer the other.

4. To exit diagnosc codes and return the water heater to normal operaon, press and hold the “On/O” buon

for 2 seconds and then the (Up) buon simultaneously.

5. Turn on the water heater by pressing the “On/O” buon.

Power interrupon during bath ll

(Water will not ow when power returns)

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

By-Pass Flow Control

• Measure resistance values of the by-pass ow control (See Electrical Diagnoscs).

• Replace By-Pass ow control device.

Air Supply or Exhaust Blockage/Condensate Trap is Full

• Ensure condensate line is not blocked.

• Ensure internal air lter is clean with no obstrucons. (Indoor Only)

• Ensure High Altude seng. (See Parameter Sengs)

• Ensure Combuson air and Exhaust vents are not blocked and approved venng

materials are being used. (Indoor Only)

• Ensure vent length is within limits. (Indoor Only)

• Check fan for debris and ensure wheel turns freely.

• Verify check valve is not stuck between fan casing and burner body.

No Ignion (Heater Not Turning On)

• 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 gas type and inlet gas pressure are correct.

• Bleed all air from gas lines.

• Check the ground wire for the PC Board.

• Ensure ame rod wire is connected.

• Ensure igniter is operaonal. (See Electrical Diagnoscs)

• Check gas solenoid valves for open or short circuits.

(See Electrical Diagnoscs)

• Verify gas orice is correct.

No Flame

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

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

• Ensure ame rod wire is connected.

• Ensure gas type and inlet gas pressure is correct.

• Bleed all air from gas lines.

Heat Exchanger Overheat

• Measure resistance of Overheat Switch. (See Electrical Diagnoscs)

• Check heat exchanger surface for hot spots which indicate blockage due to scale

build-up.

• Refer to instrucons in manual for ushing heat exchanger. Hard water must be

treated to prevent scale build up or damage to the heat exchanger.

• Ensure it is not forced Hi seng.

Venturi Control

• Ensure the Venturi motor is operang correctly. (See Electrical Diagnoscs)

• Replace gas valve assembly.

• Clear diagnosc code by reseng the main power supply to the water heater.

High Outgoing Temperature

(safety shutdown because water heater is too hot)

• Conrm fan motor is funconing correctly.

• Replace the gas valve assembly.

Venturi Blockage

• Ensure Venturi isn't blocked.

• Please call Rinnai technical department.

Electrical Grounding

• Check all components for electrical short.

Data Transfer Error

• If the PCB has been replaced, ensure the data transfer process has been

completed.

Condensate Pump (Accessory)

• Conrm wire connecons and harness are good.

• Ensure condensate reservoir is empty and condensate pump is operang.

Outgoing Thermistor

Heat Exchanger Thermistor

• Check sensor wiring for damage.

• Measure resistance of sensor. (See Electrical Diagnoscs)

• Clean sensor of scale build-up.

• Replace sensor.

Exhaust Thermistor

Freeze Protecon Thermistor

• Check sensor wiring for damage.

• Measure resistance of sensor. (See Electrical Diagnoscs)

• Replace sensor.

Inlet Thermistor

• Check sensor wiring for damage.

• Measure resistance of sensor. (See Electrical Diagnoscs)

• Clean sensor of scale build-up.

• Replace sensor.

Gas Valve

• Check ame rod and wire for damage.

• Check gas solenoid valve for open or short circuit. (See Electrical

Diagnoscs)

• Replace gas valve assembly.

• Please call Rinnai technical department.

High Exhaust Gas Temperature

• Ensure Heat Exchanger ns are clean and not blocked.

• Conrm inlet water temperature is not too high.

• Clear diagnosc code by reseng the main power supply to the water

heater.

Combuson Fan

• Check the motor wire harness for loose or damaged connecons.

• Measure resistance of motor wire harness. (See Electrical Diagnoscs)

• Ensure the combuson fan spins freely.

Recirculaon Low Flow

• Ensure bypass plug is removed and bypass lter is installed. (COV Mode)

• Ensure both the inlet water lter and bypass lter are clean and free of

debris.

• Ensure Parameter seng are correctly set for recirculaon mode.

• Ensure Pump supply voltage.

• Ensure air is removed from the recirculaon line.

Water Flow Control

• Measure resistance values of the water ow control (See Electrical

Diagnoscs)

• The water ow control valve has failed to close during the bath ll

funcon. Immediately turn o the water and disconnue the bath ll

funcon. Contact a licensed professional to service the appliance.

PC Board

• Replace PC Board

Solenoid Valve Circuit

• Ensure dip switch on PC board is in the OFF posion.

• Ensure gas control wire is not loose or damaged.

• Ensure heater circuit is not grounded.

• Replace PC Board.

Flame Rod

• Check ame rod and wire for damage.

• Verify HEX is not leaking.

(SS) Service Soon (Flush Heat Exchanger)

• 55 is a me-based service indicator set during installaon. See secon

“3.12 Parameter Sengs” for addional details on seng and changing the 55 indicator.

• 55 indicates that it is me for service. The heat exchanger should be

ushed to prevent damage (refer to secon “5.3 Flushing the Heat Exchanger” for more informaon). Hard water must be treated to

prevent scale build-up or damage to the heat exchanger.

• To reset the 55 code, push the On/O buon on the temperature

controller 5 mes in 5 seconds.

NO CODE - Nothing happens when water ow is acvated

• Verify you have at least the minimum ow rate required to re unit.

• Measure the resistance of the water ow control sensor.

(See Electrical Diagnoscs)

• Clean inlet water supply lter.

• On new installaons ensure hot and cold water lines are not reversed.

Cascade Diagnosc Display (Commercial units only)

• With cascade connecons, display will ash between “SE” and the

selected set temperature when an error code is displayed on any secondary unit .

Maintenance Indicator

• Placeholder in Diagnosc code history

indicang that a service provider performed maintenance or service.

• Enter this code aer performing

service by pressing (Up) , (Down) and On/O simultaneously.

• FF is visible on the monitor.

PARAMETER SETTINGS

Performance Data Table

Parameter Sengs Table

Electrical Circuit Table

2. Use the (Up) and (Down) buon on the controller to select a seng number

(See Parameter Sengs Table).

0 1 A

0 1 B

COMPONENT WIRE COLOR VOLTAGE RESISTANCE

COMPONENT PCB

CONNECTOR CONNECTOR PIN

Spark

Electrode

Red-Black 11~13VDC*

34 K ~ 40 K

ohms

D2 D 12-21

Combuson

Fan

Red-Black 7~48VDC* N/A D3 D 4-6

White-Black 10~12VDC* N/A D3 D 10-6

Yellow-Black 11~13VDC* N/A D3 D 8-6

Water Flow

Control Device

Red-Pink

N/A 44~52 ohms

D4 D 18-20

White-Blue D4 D 16-14

Grey-Orange 12~14VDC N/A D4 D 30-12

Venturi

Control Device

Blue-White

N/A 35~41 ohms

D5 D 5-7

Yellow-Red D5 D 11-9

Black-Red 12~14 VDC

N/A

D5 D 30-12

Black-Brown

less than

1VDC*

D5 D 30-25

Black-Grey

less than

1VDC*

D5 D 30-23

By-Pass Flow

Control Device

Red-Pink

N/A 44~52 ohms

D6 D 15-13

White-Blue D6 D 17-19

Gas Solenoid

Valve

Yellow-Black 11~13VDC* 18~22 ohms D7 D 29-27

Outgoing

Thermistor

White-White

N/A See Example

3-2

Blue-Blue 8-11

Inlet

Thermistor

White-White H2 H 4-2

Exhaust

Thermistor

White-White H3 H 2-5

Heat

Exchanger

Thermistor

White-White H4 H 2-6

Freeze

Protecon

Thermistor

Yellow-Black H5 H 2-7

Overheat

Switch

Black-Black 11~13 VDC

less than 1

ohm

H6 H 28-14

Water Flow

Sensor

Black-Red 11~13 VDC

N/A

H7 H 30-12

Yellow-Black 4~7 VDC* H7 H 12-30

Addional

Controller(s)

White-White 10~13 VDC N/A K - -

Temperature Resistance Readings

59°F 11.4 - 14KΩ

86°F 6.4 - 7.8KΩ

113°F 3.6 - 4.5KΩ

140°F 2.2 - 2.7KΩ

221°F 0.6 - 0.8KΩ

CONTROLLER MODEL CONNECTED NOT CONNECTED

__1 __0

_1_ _0_

BSC & BSC2

1__, 2__ (QTY2) 0__

Default display is

100.

depends on connecon status of another controller.

Controllers Connected

Combuson Cycles

Pump Cycles

SETTING

DESCRIPTION

SELECTION

E F

Maximum Set

Temperature

Residenal:

120°F

Commercial:

140°F

Residenal:

140°F

Commercial:

185°F

High Altude

(Installaon

Locaon)

0 - 2,000  (0 - 610 m)

2,001 - 5,400 

(610 - 1,646 m)

5,401 - 7,700 

(1,646 - 2,347 m)

7,701 - 10,200 

(2,347 - 3,109 m)

Service Soon1

Disabled 0.5 Year 1 Year 2 Years

Recirculaon

Sengs

Recirculaon

(Dedicated)

Recirculaon

Mode2

Comfort Economy

Control Switch

BMS3

Air Handler

(AH)

Units in Standby

(EZ Connect)

2 1

Cascade Secondary Primary

Units in Standby

(Cascade)4

1 2 3 4 5 6

Gas Type

(Factory Set)

NG LPG

Maximum

Flow Rate5

Standard High

Without

Pump

With Pump

Water Heater

Model

(Factory set

values and not

adjustable)

199

(3237)

180

(2934)

160

(2530)

130

(2024)

Internal (Indoor)

External

(Outdoor)

Default is A for all sengs below except 10, 12, 13, and 14 which are factory set.

07000012336367

U334-0781(00)

REU-N,NC

100000505

Page 2

139 Clip 105000090

ITEM

DESCRIPTION

PART NUMBER

001 Residenal Cabinet Body FF 109000592 1 1

002 Commercial Cabinet Body FF 109000593

003 Lower Wall Mount Bracket 109000281

004 Upper Wall Mount Bracket 109000594

007 Connecon Reinforcement Plate 109000595

008 Rubber Bushing 109000634

010 Residenal Screw & Washer-Grey 106000645

011 Commercial Screw & Washer-Black 109000596

012 Combuson Chamber Support Plate 109000597

013 Truss Screw 109000598

015 Igniter Bracket 109000599

016 Igniter Assembly 105000230

017 Grounding Screw CP-80452

018 Controller Bracket FF 109000600

019 Controller 105000260

020 Thermistor Sensor 105000261

021 Thermistor Grommet 109000490

030 Residenal Cabinet Body W 109000601

031 Commercial Cabinet Body W 109000602

033 Rubber Bushing CF79-41020-A

034 Controller Bracket W 109000603

040 Residenal Front Cover Panel FF 109000604

041 Commercial Front Cover Panel FF 109000605

042 Residenal Front Cover Panel W 109000606

043 Commercial Front Cover Panel W 109000607

044 Screw Cover 109000230

045 Front Panel Packing - Top 109000120

046 Front Panel Packing - Side W 109000608

047 Front Panel Packing - Side FF 109000121

100 Burner Assembly - Large 106000113

101 Burner Gasket - Large 109000609

102 Burner Plate Assembly - Large 106000114

103 Combuson Check Valve Assembly 107000262

105 Burner Assembly - Small 106000115

106 Burner Gasket - Small 109000610

107 Burner Plate Assembly - Small 106000116

110 Combuson Fan Assembly 108000081

111 Fan Mounng Packing 109000611

112 O-Ring 109000612

113 Hexagon Head Screw ZQAA0514UK

114 Gas Valve Assembly with Orice 106000117

115 O-Ring 109000252

116 Gas Connecon Pipe 106000118

117 Gas Tube Bracket 109000635

118 Inlet Gas Supply Connecon 106000119

119 Inlet Gas Test Port Screw C10D-5

120 O-Ring M10B-13-4

121 Noise Filter 106000120

130 Heat Exchanger Assembly - Large 107000263

131 Heat Exchanger Assembly - Small 107000264

133 Heater Bracket 109000613

135 Over Heat Sensor (OHS) 105000231

136 OHS Bracket 109000614

137 Heat Exchanger Insulator 107000265

138 Thermistor 105000262

1 1 1 1 1 1 1 1

440 Hot Water Supply Connecon Pipe 107000277

442 Clip 109000638

443 Retenon Clip U211-322X01

450 Bypass Pipe Assembly 107000278

1 1 1 1

409 Flow Turbine Assembly 107000319

410 Water Supply Connecon Pipe 107000271

411 O-Ring M10B-2-14

412 Retenon Clip AH69-310

413 Clip 109000244

414 Plug Band 109000018

420 Secondary Connecng Pipe 107000272

430 Connecon Pipe Assembly - Large 107000273

431 Heat Exchanger Pipe Connecon 107000274

432 O-Ring 107000325

433 Pipe Bracket 109000637

434 Retenon Clip 109000496

435 Hot Water Connecon ng 107000275

436 Connecon Pipe Assembly-Small 107000276

1 1 1 1

406 Bypass Servo Assembly 107000270

407 Cover 107000093

408 Inlet Water Thermistor 107000318

1 1 1 1 1 1 1 1

3 3 3 3 3 3 3 3

1 1 1 1 1 1 1 1

2 2 2 2 2 2 2 2

1 1 1 1 1 1 1 1

1 1 1 1

2 2 2 2 2 2 2 2

1 1 1 1 1 1 1 1

1 1 1 1

401 Water Supply Filter Plug Assembly 107000317

403 Water Flow Sensor Assembly 107000269

404 Clip 109000636

405 O-Ring 107000324

2 2 2 2

230 Exhaust Duct Assembly W 108000088

233 Front Exhaust Seal W 109000624

234 Thermistor 105000263

400 3/4 Water Supply Connecon 107000316

1 1

221 Air Supply Filter 108000086

222 Air Supply Connecon 108000087

223 Air Supply Gasket - 2 inch 109000624

2 2 2 2

2 2 2 2 2 2 2 2

2 2 2 2

1 1 1 1

1 1

1 1 1 1

1 1

210 Flue Connecon Assembly 108000083

212 Exhaust Pipe Connecon Port-2” 108000084

213 Exhaust Gasket—2 inch 109000623

215 Air Supply Pipe Seal Ring 108000093

220 Air Supply Box 108000085

1 1 1 1 1 1 1 1

1 1

153 Electrode Packing 109000617

154 Electrode Plate 109000618

155 Electrode Heater Bracket 109000619

156 Electrode Sleeve 109000620

200 Exhaust Duct Assembly FF 108000082

202 O-Ring 108000018

203 Exhaust Duct Packing 109000621

204 Thermistor 105000235

205 O-Ring 107000323

206 Exhaust Packing 109000646

207 Thermistor Screw 109000622

14 12 14 12 14 12 14 12

2 2 2 2 2 2 2 2

1 1 1 1 1 1 1 1

1 1 1 1

1 1 1 1 1 1 1 1

4 4 4 4

150 Electrode/Flame Rod Assembly 105000232

151 Electrode 105000233

152 Flame Rod 105000234

1 2 1 2 1 2 1 2

1 1 1 1

1 1 1 1 1 1 1 1

147 Condensate Drain Tube 107000268

1 1

RU199i | RU180i

RU199e | RU180e

RU160i | RU130i

RU160e | RU130e

CU199i

CU199e

CU160i

CU160e

140 Secondary Heat Exchanger 107000266 1 1 1 1 1 1 1 1

141 Secondary Heat Exchanger Bracket 109000615

142 Secondary Heat Exchanger Gasket 109000616

145 Condensate Trap 107000267

ITEM

DESCRIPTION

PART NUMBER

1 1 1 1 1 1 1 1

1 1 1 1

801 Screw CP-30583

802 Screw ZBA0408UK

803 Screw 109000640

804 Screw 109000648

805 Screw 109000178

806 Screw 109000649

807 Screw U217-449

808 Screw ZFAB0406SZ

809 Screw 109000641

810 Screw 109000642

811 Screw 109000655

812 Screw 109000650

813 Screw ZAD0408UK

814 Screw 109000651

815 Screw ZHAA0412UK

816 Bracket Screw CP-20883-410UK

817 Screw ZFDB0410SZ

818 Screw 109000643

819 Screw 109000652

850 Cold Water Isolaon Valve 107000284

851 Hot Water Isolaon Valve 107000285

860 Wall Bracket 109000628

1 1 1 1

750 Remote Control Harness 105000249

751 External Pump Harness 105000250

800 Screw ZFDB0408UD

1 1 1 1 1 1 1 1

2 2 2 2 2 2 2 2

5 5 5 5 5 5 5 5

1 1 1 1 1 1 1 1

6 6 6 6 6 6 6 6

2 2 2 2 2 2 2 2

3 3 3 3 3 3 3 3

1 1 1 1 1 1 1 1

1 1 1 1

1 1 1 1 1 1 1 1

3 3 3 3 3 3 3 3

1 1 1 1 1 1 1 1

2 2 2 2 2 2 2 2

1 1 1 1 1 1 1 1

1 1 1 1

462 Hot water Supply Connecon 107000280

465 Outlet Thermistor 107000320

470 PRV Connecon Pipe 107000281

471 O-Ring 107000326

472 Clip 109000278

475 Pressure Relief Valve Connecon 107000282

476 Pressure Relief Valve Assembly 107000283

700 PC Board Assembly - Residenal 105000236

701 PCB Electrical Cover 109000626

702 PCB EC Cover 109000627

705 PC Board Assembly - Commercial 105000237

710 Power Cord Assembly FF 105000238

711 Power Cord Assembly W 105000239

712 Sensor Harness 105000240

715 Heater Harness 105000241

716 Heater Harness 105000242

719 Igniter Ground Harness 105000243

720 Freeze Protecon Heater FF 105000244

721 Freeze Protecon Heater W 105000245

723

724

725 Freeze Protecon Valve Heater 105000248

730 Heater Clip A AU124-618X01

731 Heater Clip C U250-625

732 Freeze Protecon Heater Clip 109000251

733 Freeze Protecon Heater Bracket 109000647

Heat Exch. Freeze Protecon

Assy

Secondary Heat Exch. Freeze

Protecon Assy

RU199i | RU180i

RU199e | RU180e

RU160i | RU130i

RU160e | RU130e

CU199i

CU199e

CU160i

CU160e

452 Clip 109000639 1 1 1 1 1 1 1 1

460 Hot Water Servo Valve Assembly 107000279

ITEM

1 1 1 1 1 1 1 1

1 1 1 1

2 2 2 2

1 1 1 1

4 4 4 4 4 4 4 4

1 1 1 1 1 1 1 1

1 1 1 1

DESCRIPTION

105000246

10500247 1 1 1 1 1 1 1 1

PART NUMBER

RU199i, CU199i 103000076

RU199e, CU199e 103000077

RU180i 103000078

RU180e 103000079

RU160i, CU160i 103000080

RU160e, CU160e 103000081

RU130i 103000082

42 42 42 42 42 42 42 42

5 5 5 5 5 5 5 5

4 4 4 4 4 4 4 4

5 5 5 5 5 5 5 5

4 4 4 4 4 4 4 4

9 9 9 9 9 9 9 9

1 1 1 1 1 1 1 1

4 4 4 4 4 4 4 4

8 8 8 8 8 8 8 8

2 2 2 2 2 2 2 2

5 5 5 5 5 5 5 5

1 2 1 2 1 2 1 2

2 2 2 2

1 1 1 1 1 1 1 1

1 1 1 1

3 3 3 3 3 3 3 3

4 4 4 4 4 4 4 4

2 2 2 2 2 2 2 2

3 3 3 3 3 3 3 3

1 1 1 1

1 1 1 1 1 1 1 1

2 2 2 2 2 2 2 2

1 1 1 1

1 1 1 1 1 1 1 1

1 1 1 1

1 1 1 1 1 1 1 1

1 1 1 1

1 1 1 1 1 1 1 1

1 1 1 1

1 1 1 1 1 1 1 1

1 1 1 1

1 1 1 1 1 1 1 1

1 1 1 1

1 1 1 1 1 1 1 1

2 2 2 2 2 2 2 2

1 1 1 1 1 1 1 1

RU199i | RU180i

RU199e | RU180e

RU160i | RU130i

RU160e | RU130e

CU199i

CU199e

CU160i

CU160e

18 13 18 13 18 13 18 13

15 15 15 15 15 15 15 15

RU130e 103000083

Gas Conversion Kits