Rinnai Water Heater RL94iN Parts List

Controller

Priority Indicator

In Use Indicator

Indicates that hot water is being supplied.

Temperature Display

Indicates temperature setting or flashes error code.

Thermostat

WARNING

MC-91-2US

MC-91-1, MCC-91-1, MC-100V-1, and BC-100V-1 controllers are

Indicates that this controller is setting the water temperature.

Priority Button

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

ON/OFF Button

not compatible with Alternate Temperature Settings. Alternate Temperature Settings are for commercial applications only. DO NOT use the MC-91-1, MCC-91-1, MC-100V-1, or BC-100V-1 controllers when dip switches 2 and 3 (Dip SW2) are in the ON position.

Diagnostic Use of the Controller

1. To display the most recent diagnostic codes press and hold the “On/Off” button for 2 seconds on the MC-91 controller.

2. To enter or exit the maintenance monitor information mode press and hold the down button for 2 seconds and without releasing it press the ON/OFF button.

tinUataD.oN

Outgoing water temperature Degrees Fahrenheit

nim/lag 1.0etar wolf retaW

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).

Locking the Controller

The MC-91-2 controller can be locked or unlocked by pressing the Priority button and the up button together for 5 seconds. A beep will sound confirming that the controller is locked. The display will alternately show “LOC”, the temperature setting, and a diagnostic code if one has been activated. All of the controllers in the system are also locked. To unlock the controller press the Priority button and the up button together for 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

Short ﬂue length

RL94i /

*RLX94i

Long ﬂue length 0.61”W.C. 0.95”W.C. 2.3”W.C. 3.7”W.C.

Short ﬂue length

RL75i

Long ﬂue length 0.61”W.C. 0.95”W.C. 2.3”W.C. 3.7”W.C.

Water

Inlet Max

150 PSI

Gas Inlet Min./Max Forced Low Forced High

NAT. G LPG

4”W.C.

/10.5”W.C.

13.5”W.C.

4”W.C.

13.5”W.C.

8”W.C. /

Table 1

NAT. G LPG NAT. G LPG

0.61”W.C. 0.87”W.C.

0.61”W.C. 0.87”W.C. 2.5”W.C. 3.9”W.C.

3.0”W.C. /

*2.96”W.C.

4.8”W.C.

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

correct operation/sizing and correct as required.

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 , SV4 and POV) Gas valve and Modulating solenoids: (Set meter above 2K)

Wire color Voltage Resistance Connector # Pin #'s (Main) Black - Grey (SV1) Black - Blue (SV2) Black - Yellow 11 ~ 13 VDC 36 ~ 42 ohms B2 4 - 7 (SV3) Black - Red (SV4)

Black - Orange

(POV) Pink - Pink 2 ~ 15 VDC 67 ~ 81 ohms D1 1 - 2

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

Red - Pink N / A 44 ~ 52 ohms G2 3 - 4 White - Blue N / A 44 ~ 52 ohms G2 1 - 2 Grey - Brown N / A N / A G2 5 - 7 Grey - Orange N / A N / A G2 6 - 7

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

(QS) Water Flow Sensor:

Black - Red 11 ~ 13 VDC 5.5 ~ 6.2 K ohms L3 E10 - G7 Yellow - Black 4 ~ 7 VDC 1 ~ 1.4 Mega ohms L3 E1 - G7

By-pass Flow Control:

White - Blue

(IG) Ignition System:

Grey - Grey 90 ~ 110 VAC N / A C1 1 - 3

(FM) Combustion Fan Motor:

Red - Black 6 ~ 45 VDC N / A L2 5 - 6 White - Black 5 ~ 10 VDC N / A L2 3 - 5 Yellow - Black 11 ~ 13 VDC N / A L2 4 - 5

Set your meter to the hertz scale. Reading across the white and black wires at terminals 3 and 5 you should read between 60 and 420 hertz.

Thermal Fuse / Overheat Switch:

White - White 11 ~ 13 VDC Below 1 ohms

11 ~ 13 VDC 24 ~ 28 ohms D1 B3 - B4 11 ~ 13 VDC 36 ~ 42 ohms B3 4 - 6

11 ~ 13 VDC 36 ~ 42 ohms B4 4 - 5 11 ~ 13 VDC 35 ~ 41 ohms B1 4 - 8

N / A

44 ~ 52 ohms

G1 10 - 11

B8 B7

12 - 131GRed - Pink

B1 - E10

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 water supply.

3. Remove the front panel (four screws).

4. Check the gas type using the data plate on the side of the unit. Confirm that the gas type switch is in the correct position (switch 1 of Dip SW2 is ON for natural gas, NG, and OFF for propane gas, LPG.) Figure 1.

5. Remove the screw and attach the manometer to the burner test point located on the gas control. Figure 2.

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 off or sustain damage due to overheating.)

8. Move switch 8 of Dip SW1 to ON. Figure 3.

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

10. Calibrate “Forced Low” combustion using switch A (up) and switch B (down).

11. Move switch 8 of Dip SW1 to OFF and then back to ON. Figure 6.

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

13. Calibrate “Forced High” combustion using switch A (up) and switch B (down).

14. Move switch 8 of Dip SW1 to OFF. Figure 5.

15. Close hot water taps.

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

17. Remove manometer and re-install allen head plug.

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

19. Operate the unit and check for gas leaks.

20. Install the front panel using four screws.

Dip SW1

Dip SW2

Fig. 1

Fig. 2

Dip SW1

Fig. 3

Fig. 4

Dip SW1 Dip SW1

Fig. 5

Fig. 6

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.

Heat Exchanger, Outgoing Water Temperature and Inlet 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:

Outgoing Water Thermistor:

White - White N / A See example above E5 2 - 3 Blue - Blue N / A See example above E5 4 - 5

Heat Exchanger Temperature Thermistor:

Pink - Pink

Inlet Thermistor:

White - White N / A See example above E7 4 - 9

Remote Controls:

Terminals J 10 ~ 13 VDC 1.5 ~ 3.0 K ohms J 1 - 2

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

N / A See example above E4 4 - 7

140°F = 2.2 ~ 2.7KΩ 221°F = 0.6 ~ 0.8KΩ

Frost Protection:

This unit has frost protection heaters mounted at different points to protect the water heater from freezing. All of them should show a positive resistance reading.

Amp Fuses:

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

Diagnostic Codes

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.

•

Verify dip switches are set properly.

•

Check fan for blockage.

•

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.

•

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.

•

Check the ground wire for the PC board.

•

Thermal Fuse

Ensure dip switch 5 in second bank of switches (white) is in 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.

•

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.

•

Electrical Grounding

Check all components for electrical short.

•

Outgoing Water Temperature Sensor

Heat Exchanger Outgoing Temperature 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 condition.

•

Replace sensor.

•

Wire Diagram

Inlet Water Temperature Sensor

Check sensor wiring for damage.

•

Measure resistance of sensor.

•

Clean sensor of scale build-up.

•

Replace sensor.

•

Modulating Solenoid Valve Signal

Check modulating gas solenoid valve wiring harness for

•

loose or damaged terminals. Measure resistance of valve coil.

•

Combustion Fan

Ensure fan will turn freely.

•

Check wiring harness to motor for damaged and/or loose

•

connections. Measure resistance of motor winding.

•

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.

PC Board

Check PC board DIP switches for correct positons.

•

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

•

Replace PC board.

•

Solenoid Valve Circuit

Replace the PC Board.

•

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.

•

Water leakage detected

Turn off water supply and contact licenced professional.

•

LC#

(when checking Scale Build-up in Heat Exchanger

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.

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.

Dip Switches Settings

Adjust switches 2 and 3 of Dip SW1 (upper side) depending on your altitude according to the table below.

Dip SW1

High Altitude

Dip SW2

WARNING

DO NOT adjust the other dip switches unless specifically instructed to do so. Incorrect Dip Switch Settings can cause the Rinnai water heater to operate in an unsafe condition and may damage the water heater and void the warranty.

Dip SW

No.

Off

High Altitude

Off

Level 0

0-2000 ft

(0-610 m)

Off

2001-5200 ft

(610-1585 m)

NOTES

Level 1

RL94i

O F F

RL94i, RLX94i

NAT.GLPG

4 5 6 7 8

4 5

Level 2

1 2 3 4 5 6 7 8

1 1 2 3 4 5 6 6 6 6 7 7 7 7 8

O F F

5201-7700 ft

Off

(1585-2347 m)

RL75i

NAT.GLPG

1 2 3 4 5 6 7 8

1 1 2 3 4 5

O F F

7701-10200 ft

(2347-3109 m)

1 2 3 4 5 6 7 8

2 3 4 5

Level 3

RL94i (VC2837FFUD-US) RLX94i (VC2737FFUD-US) RL75i (VC2528FFUD-US)

0700001 2313153

U307-0732(00)

TENIBAC-WEIVDEDOLPXE

EXPLODED VIEW - INTERNALS

801

802

149

009

010

145

146

147

148

008

144

802

801

008

735

734

004

001

800

002

119

118

110

117

114

708

713

710

709

810

707

111

116

115

109

133

103

104

813

815

107

106

814

141

2528only2837, 2737only

815

812

146

143

733

717

108

810

716

152

414

128

127

153

132

121

122

141

135

137

151

125

016

006

016

EXPLODED VIEW - INTERNALS

404

805

2528only

805

2837, 2737only

413

403

407

406

404

804

813

100

727

461

800

401

413

830

101

803

112

706

EXPLODED VIEW - ELECTRICAL

728

714

725

741

732

136

811

740

2837, 2737only

703

702

700

805

409

804

730

810

408

822

412

814

807

821

813

402

818

400

819

405

807

819

101

830

817

102

820

742

719

731

724

726

720

RL94i

(VC2837)

RLX94i

(VC2737)

Item Description Part Number Qty

004 CONNECTION REINFORCEMENT 109000261 1 1

008 FRONT PANEL PACKING U245-3185-4 2 2 009 TEMPERATURE CONTROL 105000186 1 1 010 TEMPERATURE CONTROL PLATE 109000263 1 1

100 GAS CONTROL ASSEMBLY 106000085 1 1 101 TEST PORT SET SCREW C10D-5 2 2

103 BURNER UNIT ASSY (LPG) 106000072 1 1 103 BURNER UNIT ASSY (NG) 106000073 1 1 104 BURNER CASE FRONT PANEL 106000074 1 1

108 BURNER CASE BACK PANEL 106000075 1 1

110 MANIFOLD ASSEMBLY (LPG) 106000078 1 1 110 MANIFOLD ASSEMBLY (NG) 106000079 1 1 111 COMB CHAMBER PACKING UPPER 106000080 1 1 112 COMB CHAMBER PACKING LOWER 106000081 1 1 114 COMB CHAMBER FRONT PANEL 106000082 1 1 115 COMB CHAMBER PACKING - 2 106000083 1 1

118 ELECTRODE BRACKET 105000156 1 1 119 ELECTRODE PACKING 121 BACK PRESSURE CONNECTOR U242-312 1 1 122 TUBE G 125 FAN MOTOR ASSEMBLY 108000061 1 1

127 FAN CONNECTING BRACKET 108000062 1 1 128 FAN CONNECTING BRACKET PACKI 132 HEAT EXCHANGER BRACKET 109000265 1 1 133 HEAT EXCHANGER BRACKET 109000266 1 1

141 HEAT EXCHANGER BRACKET 109000269 2 2

105000157 1 1

109000198 1 1

N 108000063 1 1

RL75i

Qty

11852000901YDOBNIAM100 22952000901TEKCARBLLAW200

11292000901LENAPTNORF600

22791000901REVOCWERCS610

11560000601TELNISAG4/3201

11462000901GNIKCAP601

7171450000601SRENRUB701

11670000601)GPL(REPMAD901

11770000601)GN(REPMAD901

11971000501EDORTCELE611 22390000501DOREMALF711

11460000801TELNIRIA531 11762000901TEKCARBNAF631 11862000901GNIKCAPLAES731

(VC2528)

Item Description Part Number

143 HEAT EXCHANGER ASSEMBLY 107000099 1 143 HEAT EXCHANGER ASSEMBLY 107000108 1 144 FLUE CONNECTION ASSEMBLY 108000068 1 1

151 AIR INLET ASSEMBLY 108000069 1 1 152 DUCT PACKING UPPER 108000070 1 1 153 DUCT PACKING LOWER 108000071 1 1

401 WATER FLOW SERVO & SENSOR 107000090 1 1

403 BY-PASS SERVO ASSEMBLY 107000091 1

SAPYBDEXIF604

408 HOT WATER OUTLET (3/4 NPT) 107000092 1 408 HOT WATER OUTLET (3/4 NPT) 107000104 1

461 WATER FLOW TURBINE 107000088 1 1

707 HIGH TENSION CORD BH38-710-240 1 1 708 ELECTRODE SLEEVE AU206-218 1 1 709 THERMISTOR 710 RETAINER (THERMISTOR) CP-90172 1 1

105000114 1 1

01SSENRAH81GWA917

RL94i

(VC2837)

RLX94i

Qty

1223-112UTEKCARBPOTS904

2390000701REVOC314 1090000501PILC414

1851000501DRAOBCP007

RL75i

(VC2737)

(VC2528)

RL94i

Qty Item Description Part Number Qty

720 POWER CORD ASSEMBLY CP-90580 1 1 724 SENSOR HARNESS-1 105000163 1

724 SENSOR HARNESS-5 105000191 1 11932000901LAESTELNI541 22810000801GNIR-O641 11071000901LAESEPIP741 11171000901PAC841 11042000901GNIKCAP941

112-105-37HTELNIRETAW004

1151-1D8MREIFITCER204

12013-96HATEKCARBEPIP404 11810000901DNABGULP504 1301000701S 1872000901PILC704

16781-261UATEKCARBPOTS904 11S-015-89HYLBMESSARETLIF214 1 1

1981000501DRAOBCP007 11742000901REVOC207 11842000901REVOCCE307 11081000501ROTINGI607

22072000901PILCRETAEH317 8810X076-052UREDLOHESUF417 22172000901PILCRETAEH617 11127-001UAPILCRETAEH717 112610005

726 POWER SUPPLY HARNESS 105000183 1

727 WATER FLOW SENSOR 105000176 1 1

728 IGNITOR BRACKET 109000272 1 1

730 TWIN THERMISTOR 105000108 1 1

731 SOLENOID HARNESS 105000168 1 1

732 INLET AIR THERMISTOR

733 THERMISTOR

105000029 1 1

H111-650 1

734 SENSOR BRACKET 109000273 1 1

NIR-O218

819 HEXAGON HEAD SCREW ZQAA0512UK 3 3

820 HEXAGON HEAD SCREW ZQAA0514UK 2 2

821 HEXAGON HEAD SCREW ZQAA0508UK 1 1

(VC2837)

RLX94i

(VC2737)

Qty

1761000501SSENRAHESUF527

181-2-B01MGNIR-O418

RL75i

(VC2528)

1 1

11972000901WERCS537 11451000501RETAEH047 11961000501RETAEH147 11171000501RETAEH247 88CP-30580-2WERCSSSURT008 4408503-PCWERCSSSURT108 4410X481-33UAREHSAWNOLYN208 22082000901WERCS308 22944-712UWERCS408 23KU014-38802-PCWERCS508 22471-84UAREHSAWCITSALP708 334-2-B01MGNIR-O018 113-2-B01MGNIR-O118 101-2-B01MG 2381-2-B01MGNIR-O318

2161-2-B01MGNIR-O418 1241-2-B01MGNIR-O518 1142-1-B01MGNIR-O718 11181000901GNIKCAP818

2208503-PCWERCS228 224-31-B01MGNIR-O038 11442000001LAUNAM888 11542000001TEEHSHCET988