American Water Heater 701022 - Manual

705 Indoor
U273-1373(01)
705(Indoor)
705(Indoor-ASME)
Power interruption during Bath fill (Water will not flow when
power returns)
• Turn off all hot water taps. Press ON/OFF twice.
03
Error Codes
• 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.
Air Supply or Exhaust Blockage
• 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.
Flame Failure
• Service Call
No burner operation during freeze protection mode 02
10
• 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.
No Ignition 11
• 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.
Thermal Fuse 14
• 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/or
exhaust piping.
• Check for clogged heat exchanger.
Over Temperature Warning 16
• Check sensor wiring for damage.
• Measure resistance of sensor.
• Clean sensor of scale build up.
• Replace sensor.
Outgoing Water Temperature Sensor Fault 32
• Check sensor wiring for damage.
• Measure resistance of sensor.
• Clean sensor of scale build up.
• Replace sensor.
Heat Exchanger Outgoing Temperature Sensor Fault 33
• 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.
Combustion Air Temperature Sensor Fault 34
• Check modulating gas solenoid valve wiring harness for loose
or damage terminals.
• Measure resistance of valve coil.
Modulating Solenoid Valve Signal Abnormal 52
• Ensure fan will turn freely.
• Check wiring harness to motor for damaged and/or loose
connections.
• Measure resistance of motor winding.
Combustion Fan Failure 61
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.
Water Flow Servo Faulty (does not stop flow properly) 65
• Check wiring harness to all solenoids for damage and/or loose
connections.
• Measure resistance of each solenoid valve coil.
SV0, SV1, SV2, and SV3 Solenoid Valve Circuit Fault 71
• 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
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 flame rod.
Flame Sensing Device Fault 72
• Flush heat exchanger. Refer to instructions in manual.
• Replace heat exchanger.
Scale Build-up in Heat Exchanger (when checking
maintenance code history “00” is substituted for “LC”) LC
• Clean inlet water supply filter.
• On new installations ensure hot and cold water lines are not
reversed.
• Check for bleed over. Isolate unit from building by turning off
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.
• Ensure you have at least the minimum flow rate required to fire
unit.
• 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
terminals for controls.
No Code (Nothing happens when water flow is activated.)
12
Wiring Diagram
A
3 1
W 3 1
B
1 2
O F F Dip SW1
3 8 7 6 5 4
F 4
W W
B 1
BK BK
MIN MAX
MODULATING VALVE CURRENT ADJUSTING Gas pressure
F 3
W W
W P W W
OUTGOING WATER WATER THERMISTOR HEAT EXCHANGER WATER THERMISTOR
Y BR O R W
BR R
O Y W
BK R
W
2-Unit Connection (Optional)
1
13
WATER FLOW SENSOR
BK
F 2
Y R
R Y BK
QS
BY-PASS FLOW CONTROL DEVICE
Y
BK R
FREEZE PROTECTION (OPTIONAL)
G W W
P
BL R BR Y GY
WATER FLOW CONTROL DEVICE
R BL BR Y GY
G R
R BL
BR Y
COMBUSTION FAN
FM
R BK Y W
E 1
W 41
Y BK
R 1
1
MODULATING SOLENOID VALVE
POV
H 2
O O
H 7
Y
FLAME ROD
H 3
SV1
H 5 H 4
SV0
O BK
SV2
BK P R BK
MAIN SOLENOID VALVE
SOLENOID VALVE 1 (CENTER) SOLENOID VALVE 2 (LEFT)
Y
Y O
BK
O O (CN2)
R
P
W 12
1
SOLENOID VALVE 3 (RIGHT)
H 6 Y BK
SV3
GY
C 1
IG
GY GY
IGNITER
GND
GY
FUSE (3A)
BK
W
AC120VAC120V HOT NEUTRAL HOT NEUTRAL GROUND
GND
BK
REMOTE CONTROLLER
SPARK ELECTRODE
5 4
Spare Parts Only Gas type
1 2 3
O F F Dip SW2
6
C D
E
F
G
H
F 1
G 1
(CN3)
(CN4)
(CN1)
(CN12)
(CN5)
(CN7)
(CN9)
5
3
D 2 D 1
1
WB
K
WB
K
G/Y
SURGE PROTECTOR
GND
R W
RR
H 1 F 6
THERMAL FUSES
OVERHEAT SWITCH
R W
COLOR CODING W :White BK:Black BR:Brown R :Red BL:Blue Y :Yellow P :Pink O :Orange G :Green GY:Gray
BL
BL W
W W W W
W
ANTI-FROST HEATER
D 5
D 3
FROST SENSING SWITCH
W W
D 6
W
W
D 4
W
W W
W W
1
F 5
A 1
1
G/Y
705(Indoor)
705(Indoor-ASME)
Water
Inlet Max.
Gas Inlet
Min./Max Forced Low Forced High
NAT.G
5"W.C.
/10.5"W.C.
8"W.C.
/13.5"W.C.
LPG NAT.G LPG NAT.G LPG
. C . W " 7 . 3 . C . W " 0 . 3 . C . W " 3 8 . 0 . C . W " 7 6 . 0 I S P 0 5 1
Table 1
NAT.G LPG
1 O
F
F 2
3
4
5
6
7
8
ON
O
F
F
ON
O
F
F
3
4
5
6
7
8
ON
O
F
F
ON
1
2
6
5
4
3
2
1 1
2
3
4
5
6
Regulator adjustment
screw access plug
Burner
test point
SW1
SW2
High Pressure
Potentiometer
1
Spare Parts
Only
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
Remote Controls:
Terminals B1 10 ~ 13 VDC 1.5 ~ 3.0 K ohms B 1 - 3
(SV1, SV2, SV3 and POV) Gas valve and Modulating solenoids: (Set meter above 2K)
(Main) Pink - Black
Wire color Voltage Resistance Connector # Pin #'s
11 ~ 13 VDC 24 ~ 28 ohms H3 6 - 7
(SV1) Black - Red 11 ~ 13 VDC 37 ~ 43 ohms H4 5 - 6
(SV2) Black - Orange 11 ~ 13 VDC 37 ~ 43 ohms H5 4 - 6
(M) Water Flow Control Device Servo or Geared Motor:
NOTE: The grey wire listed above turns to black at F connector on the PCB.
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.
Grey - Brown 4 ~ 6 VDC N / A F5 5 - 7
Red - Blue 11 ~ 13 VDC 22 ~ 28 ohms F5 9 - 10
(QS) Water Flow Sensor:
Black - Red 11 ~ 13 VDC 5.5 ~ 6.2 K ohms F2 1 - 3
(IG) Ignition System:
Grey - Grey 90 ~ 110 VAC N / A C1 1 - 2
Yellow - Black 4 ~ 7 VDC 1 ~ 1.4 Mega ohms F2 2 - 3
Thermal Fuse / Overheat Switch:
Red - White 11 ~ 13 VDC Below 1 ohms F6 F6 - H12 H1
Grey - Yellow N / A N / A F5 5 - 8
(FM) Combustion Fan Motor:
White - Black 5 ~ 10 VDC 9.2 ~ 9.4 K ohms E1 2 - 4
Red - Black 6 ~ 45 VDC N / A E1 1 - 2
Yellow - Black 11 ~ 13 VDC 3.5 ~ 3.9 K ohms E1 2 - 3
By-pass Flow Control:
Orange - White 2 ~ 6 VDC 15 ~ 35 ohms G1 2 - 5
Yellow - White (Unit in operating mode) G1 3 - 5
5 - 1 1 G e ti h W - n w o r B
5 - 4 1 G d n u o r G - e ti h W - d e R
(SV3) Black - Yellow 11 ~ 13 VDC 37 ~ 43 ohms H6 3 - 6
(POV) Orange - Orange 2 ~ 15 VDC 67 ~ 81 ohms H2 9 - 10
Gas Pressure Setting
APPLIANCE OPERATING PRESSURES
Controller
Thermostat
ON/OFF Button
In Use Indicator
Indicates that hot water
is being supplied.
Temperature Display
Indicates temperature
setting or flashes error
code.
Priority Indicator
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.
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).
NOTE: For additional installation and commissioning information refer
to the Operation and Installation Manual.
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.
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.
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.
WARNING
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).
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.
140 °F = 2.2 ~ 2.7K
221 °F = 0.6 ~ 0.8K
59 °F = 11.4 ~ 14K
86 °F = 6.4 ~ 7.8K
113 °F = 3.6 ~ 4.5K
Example:
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.
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.
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
SW
NOTES
No.
2
3
Level 0
0-2000 ft
(0-610 m)
High Altitude
Level 1
2001-5200 ft
(610-1585 m)
Level 2
5201-7700 ft
(1585-2347 m)
Level 3
7701-10200 ft
(2347-3109 m)
Off
On
On
Off
On
On
Off
Off
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.
High Altitude
WARNING
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.
Fig. 1 Fig. 2
Fig. 3 Fig. 4
Fig. 5 Fig. 6
070 00012 36676 0