Tankless Water Heater Service Manual

Transcription

1 Tankless ater Heater Service Manual R42e... REU-V66 C42e... REU-V66C R5e... REU-V2020 C5e... REU-V2020C R70e... REU-V2526 R85e... REU-V252 C85e... REU-V252C R85ePLUS... REU-V252D C85ePLUS... REU-V252CD R98e... REU-V27 C98e... REU-V27C R98eASME... REU-V27-ASME C98eASME... REU-V27C-ASME V Series Trade Name Model Trade Name Model R5i... REU-V2520U C5i... REU-V2520UC R5i... REU-V2520UD C5i... REU-V2520UCD R85i... REU-V252U C85i... REU-V252UC R85iPLUS... REU-V252UD C85iPLUS... REU-V252UCD R98i... REU-V27U C98i... REU-V27UC R98iASME... REU-V27U-ASME C98iASME... REU-V27UC-ASME V5e... REU-VAM620 R6LSe... REU-VA2024D R75LSe... REU-VA2528D R75LSe... REU-VA2528D(A) R94LSe... REU-VA255D R98LSe... REU-VA27 R98LSeASME... REU-VA27-ASME VA Series Trade Name Model Trade Name Model R50LSi... REU-VA209UD R75LSi... REU-VA2528UD R75LSi... REU-VA2528UD(A) R94LSi... REU-VA255UD R98LSi... REU-VA27U R98LSiASME... REU-VA27U-ASME

2 Table of Contents General Information... Specifications... 4, 5 Schematic Diagrams... 6, 7 ault Isolation Electrical Diagnostic Points R/C42e, R/C5e,..., 2 R70e, R/C85e(PLUS), R/C5i(PLUS), R/C85i(PLUS)..., 4 R/C98e(ASME), R/C98i(ASME)... 5, 6 V5e, R6LSe... 7, 8 R50LSi, R75LSe, R75LSi, R94LSe, R94LSi... 9, 20 R98LSe(ASME), R98LSi(ASME)... 2, 22 ire Diagrams R/C42e, R/C5e... 2 R70e, R/C85e(PLUS) R/C5i(PLUS), R/C85i(PLUS) R/C98e(ASME), R/C98i(ASME) V5e, R6LSe R50LSi, R75LSe, R75LSi, R94LSe, R94LSi R98LSe(ASME), R98LSi(ASME) lushing the Heat Exchanger... 0 Component Replacement Instructions Gas Control Assembly R/C42e, R/C5e, V5e, R6LSe..., 2 R/C5i(PLUS), R70e, R/C85e(PLUS), R/C85i(PLUS), R50LSi, R75LSe, R75LSi, R94LSe, R94LSi..., 4 R/C98e(ASME), R/C98i(ASME), R98LSe(ASME), R98LSi(ASME)... 5, 6 an R/C42e, R/C5e, V5e, R6LSe... 7 R70e, R/C85e(PLUS), R75LSe, R94LSe... 8 R/C5i(PLUS), R/C85i(PLUS), R50LSi, R75LSi, R94LSi... 9 R/C98e(ASME), R/C98i(ASME), R98LSe(ASME), R98LSi(ASME) PC Board R/C42e, R/C5e... 4 V5e, R6LSe R/C5i(PLUS), R70e, R/C85e(PLUS), R/C85i(PLUS), R50LSi, R75LSe, R75LSi, R94LSe, R94LSi R/C98e(ASME), R/C98i(ASME), R98LSe(ASME), R98LSi(ASME) ater low Control Assembly R/C42e, R/C5e... 47, 48 V5e, R6LSe... 49, 50 R/C5i(PLUS), R50LSi, R75LSe, R75LSi... 5, 52 R/C85e(PLUS), R/C85i(PLUS), R94LSe, R94LSi... 5, 54 R/C98e(ASME), R/C98i(ASME), R98LSe(ASME), R98LSi(ASME) Heat Exchanger R/C42e, R/C5e, V5e, R6LSe R70e, R75LSe R/C85e(PLUS), R94LSe R/C5i(PLUS), R75LSi R/C85i(PLUS), R94LSi R/C98e(ASME), R98LSe(ASME) R/C98i(ASME), R98LSi(ASME) Gas Pressure Setting Procedure... 79, 80 Manifold Pressure Settings... 8, 82 Dip Switches... 8, 84 Key to Trade Names in this Manual: R/C Indicates both the residential and commercial versions. R/C42e includes R42e and C42e. (PLUS) Indicates that the Designer Plus models are included. R/C85ePLUS includes R85e, C85e, and R85ePLUS. On the side of the water heater, the trade name includes a D, as in R85De. (ASME) Indicates that the ASME models are included. R98LSe(ASME) includes the R98LSe and R98LSeASME. Rinnai ater Heater Service Manual 2

3 General Information Safety Definitions This is the safety alert symbol. This symbol alerts you to potential hazards that can kill or hurt you and others. DANGER ARNING CAUTION Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury. It may also be used to alert against unsafe practices. Using this Manual Repairs should be performed by a qualified service technician. The following information can be referenced for additional information. Operation and Installation Manual Hot ater System Design Manual Technical Sheets Technical Bulletins Technical Support Technicians are available to assist in servicing issues. Contact Rinnai Technical Services at Recommended Tools Volt/Ohm/Amp meter with test probes Digital manometer or U tube type manometer with 4 inch water column (.C.) scale, a hose and two /8 inch taps assorted wrenches including a /6 Allen wrench assorted screw drivers leak solution or leak detector Teflon tape ARNING 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. Before checking for resistance readings disconnect the power source to the unit and isolate the item from the circuit (unplug it). CAUTION Label all wires prior to disconnection when servicing controls. iring errors can cause improper and dangerous operation. Rinnai ater Heater Service Manual If any of the original wire as supplied with the appliance must be replaced, it must be replaced with type 8 AG wire or its equivalent.

4 Specifications V Series - Commercial - Outdoor Trade Name Model Max. BTU Min. BTU Max low [] gal/min (liters/min) Temperature Range C42e REU-V66C 20,000 7,00 (NG) 7,800 (LP) 4.2 (6) º (49-85 ºC) C5e REU-V2020C 50,000 9,000 (NG) 20,200 (LP) 5. (20) º (49-85 ºC) C85e REU-V252C 99,000 5, (2) º (7-85 ºC) C85ePLUS REU-V252CD 99,000 5, (2) º (7-85 ºC) C98e REU-V27C 27,000 9, (7) º (7-85 ºC) C98eASME REU-V27C-ASME 27,000 9, (7) º (7-85 ºC) V Series - Commercial - Indoor Trade Name Model Max. BTU Min. BTU Max low [] gal/min (liters/min) Temperature Range C5i REU-V2520UC 80,000 5, (20) º (49-85 ºC) C5iPLUS REU-V2520UCD 80,000 5, (20) º (49-85 ºC) C85i REU-V252UC 80,000 5, (2) º (7-85 ºC) C85iPLUS REU-V252UCD 80,000 5, (2) º (7-85 ºC) C98i REU-V27UC 27,000 9, (7) º (7-85 ºC) C98iASME REU-V27UC-ASME 27,000 9, (7) º (7-85 ºC) V Series - Residential - Outdoor Trade Name Model Max. BTU Min. BTU Max low [] gal/min (liters/min) Temperature Range 7,00 (NG) R42e REU-V66 20,000 7,800 (LP) 4.2 (6) º (7-60 ºC) R5e REU-V ,000 9,000 (NG) 20,200 (LP) 5. (20) º (7-60 ºC) R70e REU-V ,000 5, (26) º (7-60 ºC) R85e REU-V252 99,000 5, (2) º (7-60 ºC) R85ePLUS REU-V252D 99,000 5, (2) º (7-60 ºC) R98e REU-V27 27,000 9, (7) º (7-60 ºC) R98eASME REU-V27-ASME 27,000 9, (7) º (7-60 ºC) V Series - Residential - Indoor Trade Name Model Max. BTU Min. BTU Max low [] gal/min (liters/min) Temperature Range R5i REU-V2520U 80,000 5, (20) º (7-60 ºC) R5iPLUS REU-V2520U 80,000 5, (20) º (7-60 ºC) R85i REU-V252U 80,000 5, (2) º (7-60 ºC) R85iPLUS REU-V252UD 80,000 5, (2) º (7-60 ºC) R98i REU-V27U 27,000 9, (7) º (7-60 ºC) R98iASME REU-V27U-ASME 27,000 9, (7) º (7-60 ºC) [] Minimum activation flow is approximately 0.6 gallons/minute (2. liters/min) Rinnai ater Heater Service Manual 4

5 Specifications VA Series (LS Series) - Residential or Commercial - Outdoor Trade Name Model Max. BTU Min. BTU Max low [] gal/min (liters/min) R6LSe REU-VA2024D-US 50,000 Temperature Range 2,500 (NG) 20,600 (LP) 6. (24) º (7-60 ºC) [2] R75LSe REU-VA2528D-US 99,000 5, (28) º (7-60 ºC) [2] R75LSe REU-VA2528D(A)-US 80,000 5, (28) º (7-60 ºC) [2] R94LSe REU-VA255D-US 99,000 5, (5) º (7-60 ºC) [] R98LSe REU-VA27-US 27,000 9, (7) º (7-60 ºC) [] R98LSeASME REU-VA27-ASME 27,000 9, (7) º (7-60 ºC) [] VA Series (LS Series) - Residential or Commercial - Indoor Trade Name Model Max. BTU Min. BTU Max low [] gal/min (liters/min) Temperature Range R50LSi REU-VA209UD-US 50,000 5, (9) º (7-60 ºC) [2] R75LSi REU-VA2528UD-US 99,000 5, (28) º (7-60 ºC) [2] REU-VA2528UD(A)- R75LSi US 80,000 5, (28) º (7-60 ºC) [2] R94LSi REU-VA255UD-US-N 99,000 5, (5) º (7-60 ºC) [] R94LSi REU-VA255UD-US-P 90,000 5, (5) º (7-60 ºC) [] R98LSi REU-VA27U-US 27,000 9, (7) º (7-60 ºC) [] R98LSiASME REU-VA27U-ASME 27,000 9, (7) º (7-60 ºC) [] VA Series - Residential - Outdoor Trade Name Model Max. BTU Min. BTU Max low [] gal/min (liters/min) V5e REU-VAM620-US 20,000 Temperature Range 9,000 (NG) 20,200 (LP) 5. (20) º (7-60 ºC) [] Minimum activation flow is approximately 0.6 gallons/minute (2. liters/min) [2] Max temperature is 60 º (7 ºC) with the MCC-9 controller for commercial and hydronic applications only. [] Max temperature is 85 º (85 ºC) with the MCC-9 controller for commercial and hydronic applications only. 5 Rinnai ater Heater Service Manual

6 Schematic Diagrams Outdoor Model (NOT PRESENT ON ALL MODELS) (NOT PRESENT ON ALL MODELS) (LOCATED ON BRACKET NEAR AN ON SOME MODELS) Rinnai ater Heater Service Manual 6

7 Schematic Diagrams Indoor Model (NOT PRESENT ON ALL MODELS) (NOT PRESENT ON ALL MODELS) (LOCATED ON BRACKET NEAR AN ON SOME MODELS) 7 Rinnai ater Heater Service Manual

8 ault Isolation The Rinnai water heater has the ability to check its own operation continuously. If a fault occurs, an error code will flash on the display of the remote controller. This assists with diagnosing the fault and may enable you to overcome a problem without a service call. ARNING Some of the checks below may need to be done by a qualified service technician. Call a service technician for any remedy that involves gas or electricity. Call a service technician if you have any doubt or reservation about performing the remedy yourself. Accessing Operating Information Models MC-9 and MCC-9 To display the most recent error codes press and hold the On/Off button for 2 seconds. hile holding the On/ Off button press the button. The last 9 error codes will flash one after the other. To exit this mode press the On/Off and button as before. To display the water flow through the water heater press and hold the button for 2 seconds and without releasing the button press the On/Off button. To display the outlet water temperature press and hold the button for 2 seconds and without releasing the button press the On/Off button. Operation. ater low Begins. ater low Sensor sends pulses to the PC Board. PC Board senses flow greater than 0.6 GPM (approximate). iring Sequence begins. 2. iring Sequence. PC Board monitors inlet/outlet water temperature, temperature set point, and water flow rate. Combustion fan energized. Purges combustion chamber. Spark igniter begins sparking. Gas control valve opens to minimum fire rate. lame rod proves ignition. Spark igniter stops sparking. 4. Shut-down Sequence. PC Board senses flow rate less than 0.5 gpm (approximate). Gas control valve closes. ater flow control valve resets to standby position. Combustion fan runs for a short period of time at low speed. 5. Standby Mode. PC Board monitors water temperature and remote controls. reeze protection is activated as needed.. Normal Operation. PC Board monitors flame rod, fan motor frequency, outlet water temperature, controller temperature set point and water flow rate. Gas control valve modulates gas input to required firing rate. Combustion fan speed is adjusted for the required firing rate. ater flow control valve is adjusted as needed. Rinnai ater Heater Service Manual 8

9 ault Isolation Code ault Remedy 02 No burner operation during Service Call freeze protection mode 0 Power interruption during Bath ill (ater will not flow when power returns). 0 Air Supply or Exhaust Blockage Turn off all hot water taps. Press ON/O twice. Ensure Rinnai 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 EZConnect or MSA controls 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. 2 lame ailure 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 Rinnai 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 EZConnect or MSA controls 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. Remove flame rod and check for carbon build-up; clean with sand paper or emery cloth. Disconnect and reconnect 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. 9 Rinnai ater Heater Service Manual

10 ault Isolation Code ault Remedy 4 Thermal use 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 buildup. 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. 6 Over Temperature arning 2 Outgoing ater Temperature Sensor ault Heat Exchanger Outgoing Temperature Sensor ault 4 Combustion Air Temperature Sensor ault 52 Modulating Solenoid Valve Signal Abnormal 6 Combustion an ailure 65 ater low Control ault 7 SV0, SV, SV2, and SV Solenoid Valve Circuit ault 72 lame Sensing Device ault LC No code Scale Build-up in Heat Exchanger (when checking maintenance code history, 00 is substituted for LC ) Nothing happens when water flow is activated. 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. Check sensor wiring for damage. Measure resistance of sensor. Clean sensor of scale build-up. Replace sensor. Check sensor wiring for damage. Measure resistance of sensor. Clean sensor of scale build-up. Replace sensor. 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. Check modulating gas solenoid valve wiring harness for loose or damaged terminals. Measure resistance of valve coil. Ensure fan will turn freely. Check wiring harness to motor for damaged and/or loose connections. Measure resistance of motor winding. 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 state qualified or licensed contractor to service the appliance. Check wiring harness to all solenoids for damage and/or loose connections. Measure resistance of each solenoid valve coil. 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 or emery cloth. 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. lush heat exchanger. Refer to instructions in manual. Replace heat exchanger. NOTE: The LC code is the only code that will allow the unit to keep running. The display will alternate between the LC code and the temperature setting. The controller will continue to beep. The LC code will reset if power is turned off and then on. 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 water is flowing, 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. Rinnai ater Heater Service Manual 0

11 Electrical Diagnostic Points R/C42e, R/C5e ire Color Voltage Resistance Connector No. Pin No. s (TR) Transformer Black - hite VAC 5-6 ohms 9 ~ 2 Blue - Brown 08-2 VAC 5-6 ohms 7 ~ (SV, SV2, SV, POV) Gas Valve and Modulating Solenoids (Main) Pink - Black E ~ 2 (SV) Black - Blue VDC.7-2 K ohms E2 2 ~ (SV2) Black - Yellow E 2 ~ 4 (POV) Pink - Pink 2-5 VDC 67-8 ohms C2 ~ 4 (M) ater low Servo Red - Blue - VDC ohms B 9 ~ 0 Gray - Brown 4-6 VDC N/A B 5 ~ 7 Gray - Yellow N/A N/A B 5 ~ 8 Gray - Orange - 4 VDC N/A B 5 ~ 6 NOTE: At the B connector on the PCB: gray wire turns to black, orange wire turns to red (QS) ater low Sensor Black - Red - VDC K ohms B 5 ~ 6 Yellow - Black 4-7 VDC -.4 mega ohms B ~ 5 Bypass low Control (only on R/C85e, R/C85ePLUS, R/C85i, R/C85iPLUS) Brown - hite 4 ~ 5 Orange - hite 2-6 VDC 2 ~ 5 (unit in operating 5-5 K ohms G Yellow - hite mode) ~ 5 Red - hite/ground ~ 5 (IG) Ignition System Gray - Gray VAC N/A ~ 2 (M) Combustion an Motor Red - Black 6-45 VDC N/A A ~ 2 hite - Black 5-0 VDC K ohms A 2 ~ 4 Yellow - Black ~ VDC K ohms A 2 ~ ith the meter set on hertz scale, hertz should be across the red and yellow wires at terminals 2 and. Rinnai ater Heater Service Manual

12 Electrical Diagnostic Points R/C42e, R/C5e ire Color Voltage Resistance Connector No. Pin No. s Thermal use / Overheat Switch Red - Red 2 VDC below ohm B - C B6 ~ C lame Rod Place one lead of the meter to the flame rod and the other to ground. ith the unit running, 5-50 VAC should be read. Set the meter to the μ amp scale and series the meter in line with the flame rod. Proper flame circuit should read μ amp or greater. If not, then remove the flame rod and check for carbon and damage. Thermistors Check all thermistors by inserting meter leads into each end of the thermistor plug. Set the meter to the 20 K ohm scale and read resistance. Applying heat to the thermistor bulb should decrease the resistance. Applying ice to the thermistor bulb should increase the resistance. Typical resistance values are:.4-4 K ohm for 59 ; K ohm for 86 ; K ohm for ; K ohm for 40 ; K ohm for 22 Outgoing ater Thermistor hite - hite see above B B ~ B4 Heat Exchanger Temperature Thermistor hite - hite see above B B ~ B2 Surge Protector Blue - Brown 08-2 VAC N/A 4 ~ 2 Blue - Brown 08-2 VAC N/A ~ ith the power off, check the continuity through the surge protector. Check by placing one meter lead on the top pin # and bottom pin #2. Check by placing one meter lead on the top pin # and bottom pin #. If there is continuity across both sets of points, then the surge protector is good. Controller Terminals D 0 - VDC digital K ohms D ~ rost Protection There are electrical heating elements mounted at different points to protect the water heater from freezing. heaters located on the hot water outlet line 26-0 ohms heater located on heat exchanger piping 8-86 ohms heater located on water flow sensor 6-9 ohms Amp fuses There are two inline amp glass fuses. Remove the fuse and check continuity through it. If there is continuity then the fuse is good. Rinnai ater Heater Service Manual 2

13 Electrical Diagnostic Points R70e, R/C85e(PLUS), R/C5i(PLUS), R/C85i(PLUS) ire Color Voltage Resistance Connector No. Pin No. s (TR) Transformer Black - hite VAC 5-6 ohms 9 ~ 2 Blue - Brown 08-2 VAC 5-6 ohms 7 ~ (SV, SV2, SV, POV) Gas Valve and Modulating Solenoids (Main) Pink - Black E ~ 2 (SV) Black - Yellow E2 2 ~ VDC.7-2 K ohms (SV2) Black - Blue E 2 ~ 4 (SV) Black - Brown E4 2 ~ 5 (POV) Pink - Pink 2-5 VDC 67-8 ohms C2 ~ 4 (M) ater low Servo Red - Blue - VDC ohms B 9 ~ 0 Gray - Brown 4-6 VDC N/A B 5 ~ 7 Gray - Yellow N/A N/A B 5 ~ 8 Gray - Orange - 4 VDC N/A B 5 ~ 6 NOTE: At the B connector on the PCB: gray wire turns to black, orange wire turns to red (QS) ater low Sensor Black - Red - VDC K ohms B 5 ~ 6 Yellow - Black 4-7 VDC -.4 mega ohms B ~ 5 Bypass low Control (only on R/C85e, R/C85ePLUS, R/C85i, R/C85iPLUS) Brown - hite 4 ~ 5 Orange - hite 2-6 VDC 2 ~ 5 (unit in operating 5-5 K ohms G Yellow - hite mode) ~ 5 Red - hite/ground ~ 5 (IG) Ignition System Gray - Gray VAC N/A 8 ~ 2 (M) Combustion an Motor Red - Black 6-45 VDC N/A A ~ 2 hite - Black 5-0 VDC K ohms A 2 ~ 4 Yellow - Black ~ VDC K ohms A 2 ~ ith the meter set on hertz scale, hertz should be across the red and yellow wires at terminals 2 and. Rinnai ater Heater Service Manual

14 Electrical Diagnostic Points R70e, R/C85e(PLUS), R/C5i(PLUS), R/C85i(PLUS) ire Color Voltage Resistance Connector No. Pin No. s Thermal use / Overheat Switch Red - Red 2 VDC below ohm B - C B6 ~ C lame Rod Place one lead of the meter to the flame rod and the other to ground. ith the unit running, 5-50 VAC should be read. Set the meter to the μ amp scale and series the meter in line with the flame rod. Proper flame circuit should read μ amp or greater. If not, then remove the flame rod and check for carbon and damage. Thermistors Check all thermistors by inserting meter leads into each end of the thermistor plug. Set the meter to the 20 K ohm scale and read resistance. Applying heat to the thermistor bulb should decrease the resistance. Applying ice to the thermistor bulb should increase the resistance. Typical resistance values are:.4-4 K ohm for 59 ; K ohm for 86 ; K ohm for ; K ohm for 40 ; K ohm for 22 Outgoing ater Thermistor hite - hite see above B B ~ B4 Heat Exchanger Temperature Thermistor hite - hite see above B B ~ B2 Surge Protector Blue - Brown 08-2 VAC N/A 6 ~ 2 Blue - Brown 08-2 VAC N/A 7 ~ ith the power off, check the continuity through the surge protector. Check by placing one meter lead on the top pin # and bottom pin #2. Check by placing one meter lead on the top pin # and bottom pin #. If there is continuity across both sets of points, then the surge protector is good. Controller Terminals D 0 - VDC digital K ohms D ~ rost Protection There are electrical heating elements mounted at different points to protect the water heater from freezing. heaters located on the hot water outlet line 26-0 ohms heater located on heat exchanger piping 8-86 ohms heater located on water flow sensor 6-9 ohms Amp fuses There are two inline amp glass fuses. Remove the fuse and check continuity through it. If there is continuity then the fuse is good. Rinnai ater Heater Service Manual 4

15 Electrical Diagnostic Points R/C98e(ASME), R/C98i(ASME) ire Color Voltage Resistance Connector No. Pin No. s (SV, SV2, SV, POV) Gas Valve and Modulating Solenoids (Main) Pink - Black 4 ~ 5() (SV) Black - Red 2 ~ 4() - VDC ohms (SV2) Black - Orange 2 ~ 4() (SV) Black - Yellow 4 ~ 4() (POV) Orange - Orange - 5 VDC 67-8 ohms E2 ~ 4(E) (M) ater low Servo Red - Blue - VDC N/A G6 5 ~ 6(G) Gray - Brown (closed position) below VDC Limiter On 4-6 VDC Limiter Off G6 8 ~ (G) Gray - Yellow (open below VDC Limiter On position) 4-6 VDC Limiter Off G6 7 ~ (G) NOTE: At the G connector on the PCB: gray wire turns to black (QS) ater low Sensor Black - Red - VDC N/A G 9 ~ 5(G) Yellow - Black 4-7 VDC N/A G ~ 5(G) Bypass low Control Brown - hite (H) ~ 9(G) Orange - hite 2-6 VDC (H) ~ 9(G) (unit in operating 5-5 K ohms H Yellow - hite mode) 4(H) ~ 9(G) Red - hite/ground 2(H) ~ 9(G) NOTE: At the G connector on the PCB: white wire turns to red (IG) Ignition System Gray - Gray VAC N/A C ~ 2(C) (M) Combustion an Motor Red - Black 6-45 VDC N/A B ~ 2(B) hite - Black 5-0 VDC N/A B 2 ~ 4(B) Yellow - Black ~ VDC N/A B 2 ~ (B) ith the meter set on hertz scale, hertz should be across the white and black wires at terminals 2 and 4. 5 Rinnai ater Heater Service Manual

16 Electrical Diagnostic Points R/C98e(ASME), R/C98i(ASME) ire Color Voltage Resistance Connector No. Pin No. s Thermal use Blue - Red 2 VDC below ohm E6 0(G) ~ (E) Overheat Switch Blue - Red 2 VDC below ohm N/A lame Rod Place one lead of the meter to the flame rod and the other to ground. ith the unit running, 5-50 VAC should be read. Set the meter to the μ amp scale and series the meter in line with the flame rod. Proper flame circuit should read μ amp or greater. If not, then remove the flame rod and check for carbon build-up. Clean with sand paper or emery cloth. Thermistors Check all thermistors by inserting meter leads into each end of the thermistor plug. Set the meter to the 20 K ohm scale and read resistance. Applying heat to the thermistor bulb should decrease the resistance. Applying ice to the thermistor bulb should increase the resistance. Typical resistance values are:.4-4 K ohm for 59 ; K ohm for 86 ; K ohm for ; K ohm for 40 ; K ohm for 22 Outgoing ater Thermistor hite - hite see above G5 2 ~ (G) Heat Exchanger Temperature Thermistor hite - hite see above G4 4 ~ (G) Surge Protector Black - hite 08-2 VAC N/A D Black - hite 08-2 VAC N/A D2 ~ 2(D) ith the power off, check the continuity through the surge protector. Check by placing one meter lead on the top pin # and bottom pin #2. Check by placing one meter lead on the top pin #2 and bottom pin #. If there is continuity across both sets of points, then the surge protector is good. Controller Black - Black 0 - VDC digital N/A A ~ (A) rost Protection hite - hite 20 VAC * 50 ohms D4 N/A hite - hite 60 VAC * 60 ohms D5 N/A hite - hite 60 VAC* 60 ohms D6 N/A * only when rost Sensing Switch (D) is ON Amp fuses There are two inline amp glass fuses. Remove the fuse and check continuity through it. If there is continuity then the fuse is good. Rinnai ater Heater Service Manual 6

17 Electrical Diagnostic Points V5e, R6LSe ire Color Voltage Resistance Connector No. Pin No. s (SV, SV2, SV, POV) Gas Valve and Modulating Solenoids (Main) Pink - Black 7-4 ohms 5 8 ~ 9 (SV) Black - Blue - VDC 5-4 ohms 6 9 ~ 0 (SV2) Black - Yellow 7-4 ohms 7 9 ~ (POV) Pink - Pink 2-5 VDC 67-8 ohms ~ 4 (M) ater low Servo Red - Blue - VDC ohms E5 9 ~ 8 Gray - Brown 4-6 VDC N/A E5 4 ~ 5 Gray - Yellow N/A N/A E5 4 ~ 6 NOTE: At the E connector on the PCB: gray wire turns to black (QS) ater low Sensor Black - Red - VDC K ohms E2 ~ 4 Yellow - Black 4-7 VDC -.4 mega ohms E2 ~ 4 (IG) Ignition System Gray - Gray 90-0 VAC N/A B ~ 2 (M) Combustion an Motor Red - Black 6-45 VDC N/A D ~ 2 hite - Black 5-0 VDC K ohms D 4 ~ 2 Yellow - Black ~ VDC K ohms D ~ 2 ith the meter set on hertz scale, hertz should be across the white and black wires at terminals 2 and 4. 7 Rinnai ater Heater Service Manual

18 Electrical Diagnostic Points V5e, R6LSe ire Color Voltage Resistance Connector No. Pin No. s Thermal use / Overheat Switch Red - hite 2 VDC below ohm E6 E5 ~ lame Rod Place one lead of the meter to the flame rod and the other to ground. ith the unit running, 5-50 VAC should be read. Set the meter to the μ amp scale and series the meter in line with the flame rod. Proper flame circuit should read μ amp or greater. If not, then remove the flame rod and check for carbon and damage. Thermistors Check all thermistors by inserting meter leads into each end of the thermistor plug. Set the meter to the 20 K ohm scale and read resistance. Applying heat to the thermistor bulb should decrease the resistance. Applying ice to the thermistor bulb should increase the resistance. Typical resistance values are:.4-4 K ohm for 59 ; K ohm for 86 ; K ohm for ; K ohm for 40 ; K ohm for 22 Outgoing ater Thermistor hite - hite see above E4 2 ~ Heat Exchanger Temperature Thermistor Pink - hite see above E 2 ~ 0 Surge Protector Black - hite 08-2 VAC N/A C2 ~ Black - hite 08-2 VAC N/A C ith the power off, check the continuity through the surge protector. Check by placing one meter lead on the top pin # and bottom pin #. Check by placing one meter lead on the top pin # and bottom pin #. If there is continuity across both sets of points, then the surge protector is good. Controller Terminals A 0 - VDC K ohms A ~ rost Protection heaters located on the hot water outlet line ohms heater located on heat exchanger piping ohms heater located on water flow sensor ohms Amp fuses There are two inline amp glass fuses. Remove the fuse and check continuity through it. If there is continuity then the fuse is good. Rinnai ater Heater Service Manual 8

19 Electrical Diagnostic Points R50LSi, R75LSe, R75LSi, R94LSe, R94LSi ire Color Voltage Resistance Connector No. Pin No. s (SV, SV2, SV, POV) Gas Valve and Modulating Solenoids (Main) Pink - Black H5 6 ~ 7 (SV) Black - Yellow H6 5 ~ 6 - VDC ohms (SV2) Black - Blue H7 4 ~ 6 (SV) Black - Brown H8 ~ 6 (POV) Pink - Pink 2-5 VDC 67-8 ohms H 9 ~ 0 (M) ater low Servo Red - Blue - VDC ohms 7 9 ~ 0 Gray - Brown 4-6 VDC N/A 7 5 ~ 7 Gray - Yellow N/A N/A 7 5 ~ 8 NOTE: At the connector on the PCB: gray wire turns to black, orange wire turns to red (QS) ater low Sensor Black - Red - VDC K ohms 2 ~ Yellow - Black 4-7 VDC -.4 mega ohms 2 2 ~ Bypass low Control (only on R94LSe and R94LSi) Brown - hite ~ 5 Orange - hite 2-6 VDC 2 ~ 5 (unit in operating 5-5 K ohms G Yellow - hite mode) ~ 5 Red - hite/ground 4 ~ 5 (IG) Ignition System Gray - Gray 90-0 VAC N/A C ~ 2 (M) Combustion an Motor Red - Black 6-45 VDC N/A E ~ 2 hite - Black 5-0 VDC K ohms E 2 ~ 4 Yellow - Black ~ VDC K ohms E 2 ~ ith the meter set on hertz scale, hertz should be across the red and yellow wires at terminals 2 and 4. 9 Rinnai ater Heater Service Manual

20 Electrical Diagnostic Points R50LSi, R75LSe, R75LSi, R94LSe, R94LSi ire Color Voltage Resistance Connector No. Pin No. s Thermal use / Overheat Switch Red - Red - VDC below ohm 6 H 6 ~ H2 lame Rod Place one lead of the meter to the flame rod and the other to ground. ith the unit running, 5-50 VAC should be read. Set the meter to the μ amp scale and series the meter in line with the flame rod. Proper flame circuit should read μ amp or greater. If not, then remove the flame rod and check for carbon and damage. Thermistors Check all thermistors by inserting meter leads into each end of the thermistor plug. Set the meter to the 20 K ohm scale and read resistance. Applying heat to the thermistor bulb should decrease the resistance. Applying ice to the thermistor bulb should increase the resistance. Typical resistance values are:.4-4 K ohm for 59 ; K ohm for 86 ; K ohm for ; K ohm for 40 ; K ohm for 22 Outgoing ater Thermistor hite - hite see above 5 ~ 4 Heat Exchanger Temperature Thermistor Pink - hite see above 4 ~ Intake Air Thermistor (only on R50LSi, R75LSi, R94LSi) Orange - hite see above ~ 2 Surge Protector Black - hite 08-2 VAC N/A D2 ~ Blue - Brown 08-2 VAC N/A D ~ ith the power off, check the continuity through the surge protector. Check by placing one meter lead on the top pin # and bottom pin #. Check by placing one meter lead on the top pin # and bottom pin #. If there is continuity across both sets of points, then the surge protector is good. Controller Terminals B 0 - VDC K ohms B ~ rost Protection There are electrical heating elements mounted at different points to protect the water heater from freezing. heaters located on the hot water outlet line ohms heater located on heat exchanger piping ohms heater located on water flow sensor ohms Amp fuses There are two inline amp glass fuses. Remove the fuse and check continuity through it. If there is continuity then the fuse is good. Rinnai ater Heater Service Manual 20

21 Electrical Diagnostic Points R98LSe(ASME), R98LSi(ASME) ire Color Voltage Resistance Connector No. Pin No. s (SV, SV2, SV, POV) Gas Valve and Modulating Solenoids (Main) Pink - Black ohms H 6 ~ 7 (SV) Black - Red 7-4 ohms H4 5 ~ 6 - VDC (SV2) Black - Orange 7-4 ohms H5 4 ~ 6 (SV) Black - Yellow 7-4 ohms H6 ~ 6 (POV) Orange - Orange 2-5 VDC 67-8 ohms H2 9 ~ 0 (M) ater low Servo Red - Blue - VDC ohms 5 9 ~ 0 Gray - Brown 4-6 VDC N/A 5 5 ~ 7 Gray - Yellow N/A N/A 5 5 ~ 8 NOTE: At the connector on the PCB: gray wire turns to black (QS) ater low Sensor Black - Red - VDC K ohms 2 ~ Yellow - Black 4-7 VDC -.4 mega ohms 2 2 ~ Bypass low Control Brown - hite ~ 5 Orange - hite 2-6 VDC 2 ~ 5 (unit in operating 5-5 K ohms G Yellow - hite mode) ~ 5 Red - hite/ground 4 ~ 5 (IG) Ignition System Gray - Gray 90-0 VAC N/A C ~ 2 (M) Combustion an Motor Red - Black 6-45 VDC N/A E ~ 2 hite - Black 5-0 VDC K ohms E 2 ~ 4 Yellow - Black ~ VDC K ohms E 2 ~ ith the meter set on hertz scale, hertz should be across the red and yellow wires at terminals 2 and 4. 2 Rinnai ater Heater Service Manual

22 Electrical Diagnostic Points R98LSe(ASME), R98LSi(ASME) ire Color Voltage Resistance Connector No. Pin No. s Thermal use / Overheat Switch Red - hite - VDC below ohm 6 H 6 ~ H2 lame Rod Place one lead of the meter to the flame rod and the other to ground. ith the unit running, 5-50 VAC should be read. Set the meter to the μ amp scale and series the meter in line with the flame rod. Proper flame circuit should read μ amp or greater. If not, then remove the flame rod and check for carbon and damage. Thermistors Check all thermistors by inserting meter leads into each end of the thermistor plug. Set the meter to the 20 K ohm scale and read resistance. Applying heat to the thermistor bulb should decrease the resistance. Applying ice to the thermistor bulb should increase the resistance. Typical resistance values are:.4-4 K ohm for 59 ; K ohm for 86 ; K ohm for ; K ohm for 40 ; K ohm for 22 Outgoing ater Thermistor hite - hite see above 4 ~ 4 Heat Exchanger Temperature Thermistor Pink - hite see above ~ Surge Protector Black - hite 08-2 VAC N/A D2 ~ Blue - Brown 08-2 VAC N/A D ~ ith the power off, check the continuity through the surge protector. Check by placing one meter lead on the top pin # and bottom pin #. Check by placing one meter lead on the top pin # and bottom pin #. If there is continuity across both sets of points, then the surge protector is good. Controller Terminals B 0 - VDC K ohms B ~ rost Protection There are electrical heating elements mounted at different points to protect the water heater from freezing. Voltage through this circuit should be 20 VAC. heater located on the hot water outlet line 5-85 ohms heater located on heat exchanger piping ohms heater located on water flow sensor 5-85 ohms Amp fuses There are two inline amp glass fuses. Remove the fuse and check continuity through it. If there is continuity then the fuse is good. Rinnai ater Heater Service Manual 22

23 iring Diagram R/C42e, R/C5e 2 Rinnai ater Heater Service Manual

24 iring Diagram R70e, R/C85e(PLUS) Rinnai ater Heater Service Manual 24

25 iring Diagram R/C5i(PLUS), R/C85i(PLUS) 25 Rinnai ater Heater Service Manual

26 iring Diagram R/C98i(ASME), R/C98e(ASME) Rinnai ater Heater Service Manual 26

27 MODULATING VALVE CURRENT ADJUSTING D (CN0) BK R 4 Y R E Y BL R BR BK Y P 2 Y (CN5) (CN) BK BL Gas pressure P Y P A P A C 2 MAX MIN (CN4) R (CN) 4 BR BL Dip S Dip S2 GY GY B REMOTE CONTROLLER BK BK SPARK GY GY IG ELECTRODE IGNITER GND O B (CN2) iring Diagram COLOR CODING BK:Black BR:Brown R :Red O :Orange Y :Yellow G :Green BL:Blue GY:Grey :hite P :Pink Spare Parts Only ROST SENSING SITCH BLBL ANTI-ROST HEATER C5 C C2 C4 BK ANTI-ROST HEATER USE (A) AC20 C20V BK V5e, R6LSe BK P BL BK Y BK HOT NEUTRAL GROUND D M Y BKR COMBUSTION AN G E BL BR G/Y C G R REEZE PROTECTION OPTION GND SURGE PROTECTOR G/Y E2 R Y BK R YBK GND ATER LO SENSOR QS E P HEAT EXCHANGER OUTGOING ATER THERMISTOR E4 OUTGOING ATER THERMISTOR 27 Rinnai ater Heater Service Manual E5 GY BL R BR Y R BL BR YGY ATER LO CONTROL DEVICE E6 THERMAL USES BL R 2 R OVERHEAT SITCH P MODULATING SOLENOID VALVE POV Y LAME ROD 4 5 SV0 MAIN SOLENOID VALVE 6 SV 7 SV2 SOLENOID VALVE (SMALL) SOLENOID VALVE 2 (LARGE)

28 iring Diagram R50LSi, R75LSe, R75LSi, R94LSe, R94LSi COLOR CODING BY-PASS SERVO MODEL ONLY BY-PASS LO CONTROL DEVICE REEZE PROTECTION OPTION ATER LO SENSOR 2 R R QS Y Y BK BK INDOOR MODEL ONLY AIR TEMPERATURE THERMISTOR HEAT EXCHANGER THERMISTOR OUTGOING ATER THERMISTOR 7 R BL BR Y GY ATER LO CONTROL DEVICE THERMAL USES H2 4 5 G R O P GY BL R BR Y E M COMBUSTION AN OVERHEAT SITCH R R BR O Y R 6 H G BK Y R R R O 5 Y ORBR P BL BR R Y (CN2) RBK G (CN7) G Y E 4 Y R BK (CN5) 2 (CN2) R P P RBK A (CN9) H P Y BR Y BK BL MAX MIN Dip S O O B (CN) Dip S2 C GY GY for REU-EZC (Optional) MODULATING VALVE CURRENT ADJUSTING Gas pressure Gas type 2 4 Spare Parts Only 5 6 (CN4) BK BK C B GY GY IGNITER IG :hite BK:Black BR:Brown R :Red BL:Blue Y :Yellow P :Pink O :Orange G :Green GY:Gray REMOTE CONTROLLER SPARK ELECTRODE GND MODULATING SOLENOID VALVE LAME ROD MAIN SOLENOID VALVE SOLENOID VALVE SOLENOID VALVE 2 SOLENOID VALVE H POV H4 P P Y SV0 SV SV2 SV H5 H6 H7 BK P Y BK BL BK H8 BR BK G/Y GND BL BR SURGE PROTECTOR D G/Y GND D2 BK (CN) BL BR BK D USE (A) BL BL () () BL BL AC20V HOT NEUTRAL GROUND D ROST SENSING SITCH D5 ANTI-ROST HEATER D4 ANTI-ROST HEATER Rinnai ater Heater Service Manual 28

29 iring Diagram R98LSe(ASME), R98LSi(ASME) for REU-EZC (Optional) BR O Y R Y OR BR BY-PASS LO CONTROL DEVICE MAX MODULATING VALVE CURRENT ADJUSTING G R MIN REEZE PROTECTION (OPTIONAL) Dip S O RBK A 2 Y G RBK ATER LO R R Y SENSOR QS YBK BK Gas pressure BL BR P 29 Rinnai ater Heater Service Manual P HEAT EXCHANGER ATER THERMISTOR Y R 4 OUTGOING ATER ATER THERMISTOR B B E 4 GY 2 (CN2) BK BK BL R BR Y R BL BR YGY Y BK R Y Y R P O ATER LO CONTROL DEVICE O BK O COMBUSTION AN M BK Y E R C IG GY GY GY GY IGNITER GND O H2 MODULATING SOLENOID VALVE POV H P USE (A) BK AC20V HOT NEUTRAL GROUND REMOTE CONTROLLER SPARK ELECTRODE 5 6 Gas type 4 Spare Parts Only 2 G G (CN7) 5 (CN9) (CN5) Dip S2 O H (CN2) (CN) C (CN4) D2 D (CN) BK 6 THERMAL USES R R H RR OVERHEAT SITCH BK SV0 MAIN SOLENOID VALVE BK H4 COLOR CODING :hite BK:Black BR:Brown R :Red BL:Blue Y :Yellow P :Pink O :Orange G :Green GY:Gray BL BL ROST SENSING SITCH D D4 D5 D6 ANTI-ROST HEATER A 5 G/Y SURGE PROTECTOR R BK SV SOLENOID VALVE (CENTER) D BK H5 G/Y Y LAME ROD O BK SV2 SOLENOID VALVE 2 (LET) H7 H6 Y BK GND GND SV SOLENOID VALVE (RIGHT)

30 lushing the Heat Exchanger An LC or 00 error code indicates the unit is beginning to lime up and must be flushed. ailure to flush the appliance will cause damage to the heat exchanger. Damage caused by lime build-up is not covered by the unit s warranty. After flushing, reset the LC fault code by turning off the power to the unit and turning the power back on.. Disconnect electrical power to the water heater. 2. Close the shutoff valves on both the hot water and cold water lines (V and V4).. Connect pump outlet hose (H) to the cold water line at service valve V2. 4. Connect drain hose (H) to service valve V. 5. Pour approximately 4 gallons of virgin, food grade, white vinegar or citric acid into pail. 6. Place the drain hose (H) and the hose (H2) to the pump inlet into the cleaning solution. 7. Open both service valves (V and V2) on the hot water and cold water lines. 8. Operate the pump and allow the cleaning solution to circulate through the water heater for at least 45 minutes. 9. Turn off the pump. 0. Rinse the cleaning solution from the water heater as follows: a. Remove the free end of the drain hose (H) from the pail. b. Close service valve, (V2), and open shutoff valve, (V4). Do not open shutoff valve, (V). c. Allow water to flow through the water heater for 5 minutes d. Close service valve, (V), and open shutoff valve, (V).. Disconnect all hoses. 2. ith (V4) closed, remove the in-line filter at the cold water inlet and clean out any residue. Place filter back into unit and open (V4).. Restore electrical power to the water heater. H V Rinnai ater Heater V V2 In-line ilter V4 Gas Supply Hot ater Line Cold ater Line 5gallonpailof virgin,food grade, white vinegar (or virgin, food grade, citric acid). H2 Circulating Pump H KEY /4" Ball Valve /4" Union Check Valve Pressure Relief Valve S Pressure Regulator Circulating Pump Boiler Drain Valve Solenoid Valve Rinnai ater Heater Service Manual 0

31 Component Replacement Instructions Gas Control Assembly R/C42e, R/C5e, V5e, R6LSe. Turn off the gas supply. 2. Turn off the 20 V power supply.. Remove four screws securing the front panel. Remove front panel. 4. Move aside the ignition line by pulling it out from the clear plastic tubing. (igure ) 5. Remove the six screws that attach the gas manifold to the combustion chamber (part of the heat exchanger assembly). (igure ) 6. Remove the three screws that attach the gas manifold to the gas valve. Pull out the gas manifold. (igure ) igure Ignition line Six screws Three screws Cable tie 7. Remove the screw on the gas valve holding the cable tie. 8. Remove the screws attaching the gas connection to the underneath side of the water heater. (igure 2) igure 2 Regulator screw access Gas connection attached with screws 9. Pull the gas connection down to disconnect it from the gas control assembly. 0. Pull out the gas control assembly. Remove the wire harness from the 4 solenoids. Rinnai ater Heater Service Manual

32 Component Replacement Instructions Gas Control Assembly R/C42e, R/C5e, V5e, R6LSe ARNING ailure to correctly assemble the components according to these instructions may result in a gas leak or explosion.. Install the gas valve and attach the wire harness to the 4 solenoids. (igure ) 2. Install the gas connection with screws. igure black / yellow (large solenoid) black / blue (small solenoid) SV0 black / pink POV pink / pink (connector not shown). Replace the two circular gaskets (included in kit) in the gas valve. Make sure that the ribbed side faces toward the manifold and that the flat side faces toward the gas valve. (igure 4) 4. Start the three screws that attach the gas manifold to the gas valve. Tighten the six screws that hold the gas manifold to the combustion chamber. inish tightening the three screws that hold the gas manifold to the gas valve. 5. Attach ignition line. 6. Perform the Gas Pressure Setting Procedure. igure 4 Circular gaskets Rinnai ater Heater Service Manual 2

33 Component Replacement Instructions Gas Control Assembly R/C5i(PLUS), R70e, R/C85e(PLUS), R/C85i(PLUS), R50LSi, R75LSe, R75LSi, R94LSe, R94LSi. Turn off the gas supply. 2. Turn off the 20 V power supply.. Remove four screws securing the front panel. Remove front panel. 4. Pull out wire harness connector at the gas manifold assembly. See igure. 5. Move aside the ignition line by pulling it out from the clear plastic tubing. 6. Remove the six screws that attach the gas manifold to the combustion chamber (part of the heat exchanger assembly). 7. Remove the three screws that attach the gas manifold to the gas valve. Pull out the gas manifold. Ignition line Six screws ire harness connector PC Board (dip switches) Three screws igure 8. Remove the four screws attaching the gas connection to the underneath side of the water heater. See igure 2. Regulator screw access igure 2 Gas connection attached with 4 screws 9. Pull the gas connection down to disconnect it from the gas control assembly. 0. Pull out the gas control assembly. Remove the wire harness from the 4 solenoids. ARNING ailure to correctly assemble the components according to these instructions may result in a gas leak or explosion.. Replace the O-ring (included in kit) where the assembly attaches to the gas connection. Make sure the old O-ring is removed and discarded. Install the new gas control assembly. Rinnai ater Heater Service Manual

34 Component Replacement Instructions Gas Control Assembly R/C5i(PLUS), R70e, R/C85e(PLUS), R/C85i(PLUS), R50LSi, R75LSe, R75LSi, R94LSe, R94LSi 2. Attach wire harness to the 4 solenoids as shown in igure below. SV2 black / blue SV black / yellow SV0 black / pink igure POV pink / pink (connector not shown). Install the gas manifold using 2 new packings (included in kit) between the manifold and the heat exchanger. Replace the two circular gaskets (included in kit) in the gas valve. Make sure that the ribbed side faces toward the manifold and that the flat side faces toward the gas valve. (igure 5). Upper packing Lower packing (U shaped) Circular gaskets in gas valve igure 4 igure 5 4. Start the three screws that attach the gas manifold to the gas valve. Tighten the six screws that hold the gas manifold to the combustion chamber. inish tightening the three screws that hold the gas manifold to the gas valve. 5. Attach wiring harness connector (black & brown wires) to the gas manifold. 6. Attach ignition line. 7. Perform the Gas Pressure Setting Procedure. Rinnai ater Heater Service Manual 4

35 Component Replacement Instructions Gas Control Assembly. Turn off the gas supply. 2. Turn off the 20 V power supply.. Remove four screws securing the front panel. Remove front panel. 4. On indoor models, remove the bracket holding the controller ( screw). (igure ) 5. Move aside the ignition line by pulling it out from the clear plastic tubing. (igure ) 6. Remove the 5 screws that attach the gas manifold to the combustion chamber (part of the heat exchanger assembly). (igure 2) 7. Remove the 2 screws that attach the gas manifold to the gas valve. These screws are machine screws and must be used at these locations. (igure 2) 8. Pull out the gas manifold and remove the connector at the ignitor at the left side of the gas manifold. 9. Remove the screws attaching the gas connection to the underneath side of the water heater. (igure ) 0. Remove the screw attaching the gas valve to the rear of the case.. Pull the gas connection down to disconnect it from the gas control assembly. Bracket screw igure (indoor models) 5 screws (gas manifold) R/C98e(ASME), R/C98i(ASME), R98LSe(ASME), R98LSi(ASME) 2 machine screws (gas valve) igure 2 ater line connections Regulator screw access igure Gas connection attached with screws 5 Rinnai ater Heater Service Manual

36 Component Replacement Instructions Gas Control Assembly R/C98e(ASME), R/C98i(ASME), R98LSe(ASME), R98LSi(ASME) ARNING ailure to correctly assemble the components according to these instructions may result in a gas leak or explosion. 2. Pull out the gas control assembly. Remove the wire harness from the 2 solenoids.. Install the gas valve and attach the wire harness to the 2 solenoids. (igure 4) black / orange orange / orange igure 4 4. Install the gas connection with screws. 5. Replace the circular gasket (included in kit) in the gas valve. Make sure that the ribbed side faces toward the manifold and that the flat side faces toward the gas valve. (igure 5) 6. Start the 2 screws that attach the gas manifold to the gas valve. Tighten the 5 screws that hold the gas manifold to the combustion chamber. inish tightening the 2 screws that hold the gas manifold to the gas valve. 7. Attach ignition line. 8. On indoor models, install the bracket with the controller. 9. Perform the Gas Pressure Setting Procedure. Gasket igure 5 Rinnai ater Heater Service Manual 6

37 Component Replacement Instructions an R/C42e, R/C5e, V5e, R6LSe. Turn off the gas supply. 2. Turn off the 20 V power supply.. Turn off the water supply. 4. Remove four screws securing the front panel. Remove front panel. 5. On the V5e and R6LSe, remove the screws () holding the bracket with the surge protector. (igure ) 6. Disconnect the wire harness at the fan assembly. (igure 2) 7. On the V5e and R6LSe, remove the screw attaching the bracket with the ignitor to the bottom of the burner case. (igure 2) 8. Remove the three screws attaching the fan sub -assembly to the fan casing. (igure ) 9. Pull out the fan sub-assembly. 0. Install the new fan sub-assembly and tighten with three screws.. On the V5e and R6LSe, install the bracket with the ignitor with one screw. 2. Attach the wire harness to the fan assembly (white, yellow, black, red wires).. On the V5e and R6LSe, install the bracket with the surge protector with three screws. 4. Install front panel using 4 screws. 5. Turn on water supply, power supply, and gas supply. igure igure 2 ire Harness Connector 2 screws at bottom screw igure screws 7 Rinnai ater Heater Service Manual

38 Component Replacement Instructions an R70e, R/C85e(PLUS), R75LSe, R94LSe. Turn off the gas supply. 2. Turn off the 20 V power supply.. Turn off the water supply. 4. Remove four screws securing the front panel. Remove front panel. 5. Disconnect wire harness at the fan assembly. Disconnect the air temperature thermistor (two white wires) at the connection with the white and orange wires within the wire bundle. 6. Pull out the harness attached to the solenoid on the manifold to make room to pull out the fan assembly. 7. Remove the two screws that attach the fan assembly to the bottom of the burner. igure Two screws Solenoid on the manifold ire harness connection on the fan assembly 8. Pull out the fan assembly. 9. Install the fan assembly by inserting the tab on the fan assembly into the slot at the base of the heat exchanger and attaching with two screws. 0. Attach the wire harness to the solenoid on the gas manifold (brown, black wires).. Attach the wire harness to the fan assembly (white, yellow, black, red wires). 2. Attach the air temperature thermistor (white, white wires) to the wire harness.. Install front panel using 4 screws. 4. Turn on water supply, power supply, and gas supply. Rinnai ater Heater Service Manual 8

39 Component Replacement Instructions an R/C5i(PLUS), R/C85i(PLUS), R50LSi, R75LSi, R94LSi. Turn off the gas supply. 2. Turn off the 20 V power supply.. Turn off the water supply. 4. Remove four screws securing the front panel. Remove front panel. 5. Disconnect wire harness at the fan assembly. Disconnect the air temperature thermistor (two white wires) at the connection with the white and orange wires within the wire bundle. 6. Pull out the harness attached to the solenoid on the manifold to make room to pull out the fan assembly. 7. Loosen the ducting from the fan assembly by pinching open the metal clamp. Ducting and metal clamp 2 screws igure Solenoid on the manifold water flow servo assembly connection ater outlet connection ire harness connection on the fan assembly ire harness bundle (air temperature thermistor connection to orange / white wires) 8. Remove the two screws that attach the fan assembly to the bottom of the burner. 9. Pull out the fan assembly. 0. Install the fan assembly by inserting the tab on the fan assembly into the slot at the base of the heat exchanger and attaching with two screws.. Push ducting over fan assembly inlet and secure with metal clamp. 2. Attach the wire harness to the solenoid on the gas manifold (brown, black wires).. Attach the wire harness to the fan assembly (white, yellow, black, red wires). 4. Attach the air temperature thermistor (white, white wires) to the wire harness. 5. Install front panel using 4 screws. 6. Turn on water supply, power supply, and gas supply. 9 Rinnai ater Heater Service Manual

40 Component Replacement Instructions an R/C98e(ASME), R/C98i(ASME), R98LSe(ASME), R98LSi(ASME). Turn off the gas supply. 2. Turn off the 20 V power supply.. Turn off the water supply. 4. Remove four screws securing the front panel. Remove front panel. 5. On indoor models, remove the bracket holding the controller ( screw). (igure ) 6. Disconnect the wire harness at the fan assembly. (igure 2) 7. Remove the three screws attaching the fan motor to the fan casing. (igure ) 8. Pull out the fan motor. 9. Install the new fan motor and tighten with three screws. 0. Attach the wire harness to the fan assembly (white, yellow, black, red wires).. On indoor models, install the bracket with the remote controller. 2. Install front panel using 4 screws.. Turn on water supply, power supply, and gas supply. Bracket screw igure (indoor models) ire Harness Connector screws igure 2 Rinnai ater Heater Service Manual 40

41 Component Replacement Instructions PC Board. Turn off the gas supply. 2. Turn off the 20 V power supply.. Turn off the water supply. 4. Remove four screws securing the front panel. Remove front panel. 5. Remove the plastic guard covering the front of the PC board. 6. Remove the controller connections. 7. Remove the screws securing the grounding cables. 8. If a surge protector with terminals is installed, then remove this board by removing two screws. This board should be re-installed on the replacement PC board. 9. Remove the two screws at the top and bottom of the PC board. 0. Pull out the PC board, remove plastic cover, and remove the connections.. Adjust dip switches on the new PC board. Switches -8 (S): Configure the dip switches the same as on the original PC board. If necessary, refer to the Dip Switch section or to the Operation and Installation Manual for more information on these dip switches. Switches -4 (S2): Configure according to the table. S2 setup O - Propane Gas ON - Natural Gas igure Burner test point Surge protector board with terminals R/C42e, R/C5e Screw Potentiometer S S2 2 O position for models prior to these serial numbers: (on these units, the front panel does not have an R or C trade name, unless the front panel has been replaced) V66, V66C V2020, V2020C V252, V252C V252U, V252UC V2520U, V2520UC V ON position for other models, serial numbers O position 4 O - Residential Models ON - Commercial Models 4 Rinnai ater Heater Service Manual Screw Grounding cables 2. Attach connections and plastic cover.. Insert PC board and attach with two screws. 4. Attach the grounding cables with screws. 5. Attach connections for the controller. 6. Perform the Gas Pressure Setting Procedure.

42 Component Replacement Instructions PC Board V5e, R6LSe. Turn off the gas supply. 2. Turn off the 20 V power supply.. Turn off the water supply. 4. Remove four screws securing the front panel. Remove front panel. 5. Remove the screw connecting the PC board to the back of the water heater casing. 6. Pull out the PC board and remove the connections. 7. Adjust dip switches on the new PC board. Replacement PC boards have an additional bank of 6 dip switches. Adjust as follows: Switches -8 (S): Configure the dip switches the same as on the original PC board. If necessary, refer to the Dip Switch section or to the Operation and Installation Manual for more information on these dip switches. Switches -6 (S2): Configure according to the diagrams below based on your model and gas type. igure Screw Potentiometer S S2 Burner test point 8. Attach connections and insert PC board. Insert the tab on the PC board into the hole in the bottom of the case. Attach with one screw. 9. Perform the Gas Pressure Setting Procedure. Propane (LPG) Natural Gas (NG) Switch No. Switch No. O S2 setup for V5e ON O ON S2 setup for R6LSe Propane (LPG) Natural Gas (NG) Switch No. Switch No. O ON O ON Rinnai ater Heater Service Manual 42

43 Component Replacement Instructions PC Board R/C5i(PLUS), R70e, R/C85e(PLUS), R/C85i(PLUS), R50LSi, R75LSe, R75LSi, R94LSe, R94LSi. Turn off the gas supply. 2. Turn off the 20 V power supply.. Turn off the water supply. 4. Remove four screws securing the front panel. Remove front panel. 5. Remove the plastic guard covering the front of the PC board. 6. Remove the controller connections. 7. If a surge protector with terminals is installed, then remove this board by removing two screws. This board should be re-installed on the replacement PC board. 8. Remove the two screws at the top and bottom of the PC board. 9. Pull out the PC board, remove plastic cover, and remove the connections. 0. Adjust dip switches on the new PC board. Switches -8 (S): Configure the dip switches the same as on the original PC board. If necessary, refer to the Dip Switch section or to the Operation and Installation Manual for more information on these dip switches. V Series (R70e, R/C85e, R/C5i, R/C85i) Switches -4 (S2): Configure according to the table. VA Series (R50LSi, R75LSe, R94LSe, R75LSi, R94LSi) Switches -6 (S2): Replacement PC boards for the VA series have an additional bank of 6 dip switches. Configure according to the diagrams based on your model and gas type.. Attach connections and plastic cover. 2. Insert PC board and attach with two screws.. If a surge protector with terminals was installed on the original PC board, remove it and install it on the new PC board. See igure. 4. Attach connections for the remote controller. 5. Attach plastic guard. 6. Perform the Gas Pressure Setting Procedure. Screw Remote controller terminals (NOT for 20 V power) If these 2 terminals are present then this is a surge protector board with terminals to connect freeze protection solenoid valves and should be installed with the new PC board. Attached with 2 screws Screw igure 4 Rinnai ater Heater Service Manual

44 Component Replacement Instructions PC Board R/C5i(PLUS), R70e, R/C85e(PLUS), R/C85i(PLUS), R50LSi, R75LSe, R75LSi, R94LSe, R94LSi S2 setup for V Series (R70e, R/C85e, R/C5i, R/C85i) 2 O - Propane Gas ON - Natural Gas O position for models prior to these serial numbers: (on these units, the front panel does not have an R or C trade name, unless the front panel has been replaced) V66, V66C V2020, V2020C V252, V252C V252U, V252UC V2520U, V2520UC V ON position for other models, serial numbers O position 4 O - Residential Models ON - Commercial Models Rinnai ater Heater Service Manual 44

45 Component Replacement Instructions PC Board R/C5i(PLUS), R70e, R/C85e(PLUS), R/C85i(PLUS), R50LSi, R75LSe, R75LSi, R94LSe, R94LSi VA Series (R50LSi, R75LSe, R94LSe, R75LSi, R94LSi) S2 setup for R94LSi (REU-VA255UD-US) (REU-VA255UD-UC) Propane (LPG) Natural Gas (NG) Switch No. Switch No. S2 setup for R94LSe (REU-VA255D-US) (REU-VA255D-UC) Propane (LPG) Natural Gas (NG) Switch No. Switch No. O ON O ON O ON O ON S2 setup for R50LSi (REU-VA209UD-US) Propane (LPG) Natural Gas (NG) Switch No. Switch No. S2 setup for R75LSi (REU-VA2528UD-US) Propane (LPG) Natural Gas (NG) Switch No. Switch No. S2 setup for R75LSe (REU-VA255D-US) Propane (LPG) Natural Gas (NG) Switch No. Switch No. O ON O ON O ON O ON O ON O ON NOTE: The diagrams below are for the -UC models of the R50LSi, R75LSi, and R75LSe. S2 setup for R50LSi (REU-VA209UD-UC) Propane (LPG) Natural Gas (NG) Switch No. Switch No. O ON O ON Propane (LPG) Natural Gas (NG) Switch No. Switch No. O S2 setup for R75LSi (REU-VA2528UD-UC) ON O ON Propane (LPG) Natural Gas (NG) Switch No. Switch No. O S2 setup for R75LSe (REU-VA255D-UC) ON O ON Rinnai ater Heater Service Manual

46 Component Replacement Instructions PC Board. Turn off the gas supply. 2. Turn off the 20 V power supply.. Remove four screws securing the front panel. Remove front panel. 4. Remove the surge protector (2 screws) 5. Remove the 2 screws connecting the PC board to the water heater casing. 6. Pull out the PC board and remove the connections. 7. Adjust dip switches on the new PC board. Switches -8 (S): Configure the dip switches the same as on the original PC board. If necessary, refer to the Dip Switch section or to the Operation and Installation Manual for more information on these dip switches. Switches -4 (S2) or Switches -6 (S2): Configure according to the diagrams based on your model and gas type. igure Burner test point R/C98e(ASME), R/C98i(ASME), R98LSe(ASME), R98LSi(ASME) Screw Potentiometer S S2 Surge protector 8. Attach connections and insert PC board. Attach with 2 screws. 9. Attach the surge protector with 2 screws. 0. Perform the Gas Pressure Setting Procedure. S2 setup for R98e, R98i Propane (LPG) Natural Gas (NG) Switch No. Switch No. Screw S2 setup for C98e, C98i Propane (LPG) Natural Gas (NG) Switch No. Switch No. O ON 2 4 O ON 2 4 O ON 2 4 O ON 2 4 S2 setup for R98LSi Propane (LPG) Natural Gas (NG) Switch No. Switch No. S2 setup for R98LSe Propane (LPG) Natural Gas (NG) Switch No. Switch No. O ON O ON O ON O ON Rinnai ater Heater Service Manual 46

47 Component Replacement Instructions ater low Control Assembly R/C42e, R/C5e NOTICE Due to design changes, the new valve may appear different than the installed valve in color, size, and in the number of wires in the harness connections.. Turn off the gas supply. 2. Turn off the 20 V power supply.. Turn off the water supply. Drain all water from the appliance. 4. Remove four screws securing the front panel. Remove front panel. Remove the water flow assembly 5. Remove 2 screws and bracket at the water flow assembly. The bracket can be left on the water line. Pull out the water line. (igure ) igure 2 screws and bracket (water flow assembly) 6. Remove the screws attaching the water inlet to the underneath side of the water heater. (igure 2). igure 2 ater inlet 47 Rinnai ater Heater Service Manual

48 Component Replacement Instructions ater low Control Assembly R/C42e, R/C5e 7. Pull out the water flow servo assembly and disconnect the cable harnesses. (igure ) A.water flow sensor harness (black/yellow/red wires) B.remove water flow servo harness (red/blue/brown/yellow/gray or red/blue/brown/orange/yellow/ gray wires) C.heating element igure heating element connector water flow servo connector water flow sensor connector Assemble 8. Place the new water flow assembly inside the water heater and attach the cable harnesses. 9. Replace the O-ring on the water inlet (included in kit). Attach the water flow assembly through the bottom of the compartment to the water inlet using screws. The shorter screw can be installed first to connect the water flow assembly to the bottom of the compartment. Then install the 2 longer screws through the water inlet. 0. Replace the O-ring on the water line (included in kit). Attach the water line to the water flow assembly with 2 screws and bracket.. Install the front panel using 4 screws. Turn on the water supply, power supply, and gas supply. 2. Open a hot water tap and ensure there are no leaks at the water heater. Rinnai ater Heater Service Manual 48

49 Component Replacement Instructions ater low Control Assembly V5e, R6LSe. Turn off the gas supply. 2. Disconnect the 20 V power supply.. Turn off the water supply. Drain all water from the appliance. 4. Remove four screws securing the front panel. Remove front panel. Remove the water flow assembly 5. Remove the bracket holding the surge protector. 6. Remove 2 screws and bracket at the water flow assembly. Pull out the water line. (igure ) igure bracket with surge protector 2 screws and bracket (water flow assembly) 7. Remove the screws attaching the water inlet to the underneath side of the water heater. (igure 2). igure 2 ater inlet 49 Rinnai ater Heater Service Manual

50 Component Replacement Instructions ater low Control Assembly V5e, R6LSe 8. Pull out the water flow servo assembly and disconnect the cable harnesses. (igure ) a. water flow sensor harness (black/yellow/red wires) b. remove water flow servo harness (red/blue/brown/yellow/gray or red/blue/brown/orange/yellow/ gray wires) at the water flow assembly c. heating element igure water flow sensor harness water flow servo harness heating element Assemble 9. Place the new water flow assembly inside the water heater and attach the cable harnesses. 0. Replace the O-ring on the water inlet (included in kit). (igure 4) Attach the water flow assembly through the bottom of the compartment to the water inlet using screws. The shorter screw can be installed first to connect the water flow assembly to the bottom of the compartment. Install the 2 longer screws through the water inlet. igure 4 O-ring. Replace the O-ring on the water line (included in kit). Attach the water line to the water flow assembly with 2 screws and bracket. 2. Install the bracket with the surge protector.. Install the front panel using 4 screws. 4. Turn on the water supply, power supply, and gas supply. 5. Open a hot water tap and ensure there are no leaks at the water heater. Rinnai ater Heater Service Manual 50

51 Component Replacement Instructions ater low Control Assembly R/C5i(PLUS), R50LSi, R75LSe, R75LSi NOTICE Due to design changes, the new valve may appear different than the installed valve in color, size, and in the number of wires in the harness connections.. Turn off the gas supply. 2. Turn off the 20 V power supply.. Turn off the water supply. Drain all water from the appliance. 4. Remove four screws securing the front panel. Remove front panel. Remove the water flow assembly 5. Remove screw and bracket at the water flow assembly. The bracket can be left on the water line. Pull out the water line. (igure ) igure screw and bracket (water flow assembly) 6. Remove the 4 screws attaching the water inlet to the underneath side of the water heater. (igure 2). igure 2 ater inlet 5 Rinnai ater Heater Service Manual

52 Component Replacement Instructions ater low Control Assembly R/C5i(PLUS), R50LSi, R75LSe, R75LSi 7. Pull out the water flow servo assembly and disconnect the cable harnesses. (igure ) A.water flow sensor harness (black/yellow/red wires) B.water flow servo harness (red/blue/brown/yellow/gray or red/blue/brown/orange/yellow/gray wires) C.heating element water flow servo connector igure heating element connector water flow sensor connector Assemble 8. Place the new water flow assembly inside the water heater and attach the cable harnesses. 9. Replace the O-ring on the water inlet (included in kit). Attach the water flow assembly through the bottom of the compartment to the water inlet using 4 screws. The 2 shorter screws can be installed first to connect the water flow assembly to the bottom of the compartment. Then install the 2 longer screws through the water inlet. 0. Replace the O-ring on the water line (included in kit). Attach the water line to the water flow assembly with screw and bracket.. Install the front panel using 4 screws. 2. Turn on the water supply, power supply, and gas supply.. Open a hot water tap and ensure there are no leaks at the water heater. Rinnai ater Heater Service Manual 52

53 Component Replacement Instructions ater low Control Assembly R/C85e(PLUS), R/C85i(PLUS), R94LSe, R94LSi NOTICE Due to design changes, the new valve may appear different than the installed valve in color, size, and in the number of wires in the harness connections.. Turn off the gas supply. 2. Turn off the 20 V power supply.. Turn off the water supply. Drain all water from the appliance. 4. Remove four screws securing the front panel. Remove front panel. Remove an Assembly (igure ) 5. Disconnect wire harness at the fan assembly. Disconnect the air temperature thermistor (two white wires) at the connection with the white and orange wires within the wire bundle. 6. Pull out the harness attached to the solenoid on the manifold to make room to pull out the fan assembly. 7. Remove the 2 screws that attach the fan assembly to the bottom of the burner. 8. On indoor models, loosen the ducting from the fan assembly by pinching open the metal clamp. 9. Pull out the fan assembly. igure 2 screws Ducting and metal clamp (indoor models only) Solenoid on the manifold ire harness connection on the fan assembly ire harness bundle (connection to orange / white wires) Remove the water flow assembly (igure 2) 0. Remove 2 screws and 2 brackets at the water flow servo assembly. The brackets can be left on the water lines. Pull out the water lines. igure 2 ater flow servo assembly connections 5 Rinnai ater Heater Service Manual

54 Component Replacement Instructions ater low Control Assembly. Remove the 4 screws attaching the water inlet to the underneath side of the water heater. R/C85e(PLUS), R/C85i(PLUS), R94LSe, R94LSi igure ater inlet 2. Disconnect the cable harnesses (igure 4): a. water flow sensor harness (black/yellow/red wires) b. bypass servo assembly harness (white/red/yellow/orange/brown wires) c. water flow servo harness (red/blue/brown/yellow/gray or red/blue/brown/orange/yellow/gray wires) d. heating element igure 4 water flow servo connector water flow sensor connector water flow servo connector heating element connector. Pull out the water flow servo assembly and bypass servo assembly. 4. Remove 2 screws in order to separate the bypass servo assembly from the water flow servo assembly. (igure 5) Assemble igure 5 5. Replace the O-ring (included in kit) between the water flow servo assembly and the bypass servo assembly. Attach the new water flow servo assembly to the bypass servo assembly with 2 screws. 6. Place inside the water heater and attach the cable harnesses. 7. Replace the O-ring on the water inlet (included in kit). Attach the water flow assembly to the water inlet using 4 screws. The 2 shorter screws can be installed first to connect the water flow assembly to the bottom of the compartment. Then install the 2 longer screws through the water inlet. 8. Replace the O-ring on the water lines (included in kit). Attach the two water lines to the bypass servo assembly with screw each. 9. Install the fan assembly by inserting the tab on the fan assembly into the slot at the base of the heat exchanger and attaching with two screws. 20. On indoor models, push the ducting over the fan assembly inlet and secure with the metal pinch clamp. 2. Attach the wire harness to the fan assembly (white, yellow, black, red wires). 22. Install the front panel using 4 screws. 2. Turn on the water supply, power supply, and gas supply. 24. Open a hot water tap and ensure there are no leaks at the water heater. Rinnai ater Heater Service Manual 54

55 Component Replacement Instructions ater low Control Assembly R/C98e(ASME), R/C98i(ASME), R98LSe(ASME), R98LSi(ASME). Turn off the gas supply. 2. Turn off the 20 V power supply.. Turn off the water supply. Drain all water from the appliance. 4. Remove four screws securing the front panel. Remove front panel. 5. Remove 2 screws and 2 brackets at the water flow servo assembly. Pull out the water lines. (igure ) 6. Remove the water flow sensor and the heating element. (igure ) 7. Remove the 4 screws attaching the water inlet to the underneath side of the water heater. (igure 2) 8. Pull out the water flow servo assembly and bypass servo assembly. Remove the wire harness from the water servo valve. (igure ) 9. Remove 2 screws in order to separate the bypass servo assembly from the water flow servo assembly. (igure ) 0. Replace the O-ring (included in kit) between the water flow servo assembly and the bypass servo assembly. Attach the new water flow servo assembly to the bypass servo assembly with 2 screws.. Attach the wire harness to the water servo valve. 2. Place inside the water heater.. Attach the water flow assembly to the water inlet using 4 screws. The 2 shorter screws can be installed first to connect the water flow assembly to the bottom of the compartment. Install the 2 longer screws through the water inlet. 4. Insert the heating element and attach the water flow sensor. 5. Replace the O-ring on the water lines (included in kit). Attach the two water lines to the bypass servo assembly with screw each. 6. Install the front panel using 4 screws. 7. Turn on the water supply, power supply, and gas supply. 8. Open a hot water tap and ensure there are no leaks at the water heater. ater lines igure ater flow sensor Heating element ater inlet igure 2 Bypass servo ire harness Screws (2) ater flow servo igure 55 Rinnai ater Heater Service Manual

56 Component Replacement Instructions Heat Exchanger R/C42e, R/C5e, V5e, R6LSe. Turn off the gas supply. 2. Turn off the 20 V power supply.. Turn off the water supply. Drain all water from the appliance. 4. Remove four screws securing the front panel. Remove front panel. 5. On the V5e and R6LSe, remove the screws () holding the bracket with the surge protector. (igure ) 6. Disconnect the wire harness at the fan assembly. (igure 2) 7. On the V5e and R6LSe, remove the screw attaching the bracket with the ignitor to the bottom of the burner case. (igure 2) 8. Remove screws and brackets securing the water line connections. (igure ) 9. Remove the 6 screws that attach the gas manifold to the combustion chamber (part of the heat exchanger assembly). (igure ) 0. Remove the screws that attach the gas manifold to the gas valve. These screws are machine screws and must be used at these locations. (igure ). Pull out the gas manifold. igure ater Connections 6 screws (gas manifold) screw Bracket machine screws (gas valve) igure 2 ire Harness Connector Rinnai ater Heater Service Manual 56

57 Component Replacement Instructions Heat Exchanger R/C42e, R/C5e, V5e, R6LSe 2. Remove the clips and screws (5 for the V5e and R/C42; 6 for the R/C5 and R6LSe) attaching the burner cover plate to the combustion chamber. (igure ). Remove the 2 screws attaching the burner to the heat exchanger. Pull out the burner. (igure ) 4. Remove the wire harness attachments - sensors, heating elements, fusible link brackets. Ensure that the small O-ring at the thermistor is removed. 5. Remove the 4 screws connecting the heat exchanger to the casing. (igures 4 and 5) 6. Pull out the assembly. Remove the brackets on the side and back holding the fusible link. Disconnect the red wire to the overheat switch from the rest of the wire harness in order to slide off the fusible link. 7. Remove the fan assembly (4 screws) and install it on the new heat exchanger. 8. Remove the flue outlet (7 screws) and install it on the new heat exchanger. 9. Install the largest O-ring (included in kit) over the water outlet tube and the smaller O-ring (included in kit) over the water inlet tube. (igure ) 20. Install the fusible link onto the new heat exchanger. Connect the red wire to the wire harness. 2. Attach brackets at the back and side holding the fusible link. 22. Install the 4 screws at the top and bottom of the heat exchanger to the casing. (igures 4 and 5) 2. Insert the burner and place the burner cover plate into position. Attach the burner cover plate first with screws (5 for the V5e and R/C42; 6 for the R/C5 and R6LSe) and then attach the burner with 2 screws. (igure ) igure Screws attaching burner Burner cover plate igure 4 Top attachment screws igure 5 Bottom attachment screws 57 Rinnai ater Heater Service Manual

58 Component Replacement Instructions Heat Exchanger R/C42e, R/C5e, V5e, R6LSe 24. Make sure that the black gaskets (igure 6) are intact on the gas control assembly. Make sure that the ribbed side faces toward the manifold and that the flat side faces toward the gas valve. 25. Attach the gas manifold with machine screws at the gas control assembly. (igure ) 26. Attach the gas manifold with 6 screws at heat exchanger. (igure ) 27. Connect wire harness attachments. Replace the O-ring (included in kit) at the thermistor. 28. Install the bracket with the ignitor. (igure 2) 29. Attach the ignition line at the burner cover plate. 0. Attach the wire harness to the fan assembly (white, yellow, black, red wires).. Attach the brackets to the water line connections. (igure ) 2. On the V5e and R6LSe, install the bracket with the surge protector ( screws). (igure ). Install the front panel using 4 screws. 4. Turn on the water supply, power supply, and gas supply. 5. Check for gas leaks. Black gaskets igure 6 Rinnai ater Heater Service Manual 58

59 Component Replacement Instructions Heat Exchanger R70e, R75LSe. Turn off the gas supply. 2. Turn off the 20 V power supply.. Turn off the water supply. Drain all water from the appliance. 4. Remove four screws securing the front panel. Remove front panel. Burner cover plate Gas Manifold PC Board Gas Control Valve an Assembly Remove an Assembly (igure 2) 5. Disconnect wire harness at the fan assembly. Disconnect the air temperature thermistor (two white wires) at the connection with the white and orange wires within the wire bundle. 6. Pull out the harness attached to the solenoid on the manifold to make room to pull out the fan assembly. 7. Remove the 2 screws that attach the fan assembly to the bottom of the burner. 8. Pull out the fan assembly. igure igure 2 2 screws Solenoid ire harness connection Disconnect ater Lines (igure ) 9. Remove screw from the water outlet bracket. Remove the bracket by rotating and moving it up toward the bend in the tube where the diameter is smaller. 0. Remove screw and bracket at the water flow servo assembly. igure ater outlet connection ater flow servo assembly connection 59 Rinnai ater Heater Service Manual

60 Component Replacement Instructions Heat Exchanger R70e, R75LSe Disconnect PC Board (igure 4). Remove screw connecting the PC Board to the heat exchanger assembly. Remove Gas Manifold (igure 4) 2. Remove the 6 screws that attach the gas manifold to the combustion chamber (part of the heat exchanger assembly).. Remove the screws that attach the gas manifold to the gas valve. These screws are machine screws and must be used at these locations. 4. Pull out the ignition line and remove the gas manifold. igure 4 Ignition line 6 screws (gas manifold) PC Board screw machine screws (gas valve) Remove Burner and Burner Cover Plate (igure 5) 5. Remove the 8 screws attaching the burner cover plate to the combustion chamber. Move the cover plate to the side. It is not necessary to disconnect the wire harness from the burner cover plate. 6. Remove the 2 screws attaching the burner to the heat exchanger. Pull out the burner. 7. Unscrew the ignition line connection. (igure 5) 8 screws (burner cover plate) igure 5 2 screws (burner) Ignition line connection Disconnect ire Harness Attachments and Screws Holding the Heat Exchanger 8. Remove the wire harness attachments - sensors, heating elements, fusible link brackets. Ensure that the small O-ring in the thermistor is removed. (igure 6) 9. Remove screws behind the fan. (igure 7) 20. Remove 2 screws above the exhaust. Pull assembly from the unit. (igure 8) igure 7 igure 8 screws 2 screws Rinnai ater Heater Service Manual 60

61 Component Replacement Instructions Heat Exchanger R70e, R75LSe ARNING ailure to correctly assemble the components according to these instructions may result in a gas leak or explosion. Installation 2. Install the largest O-ring (included in kit) over the water outlet tube and the two smaller O-rings (included in kit) over the bypass servo tubes. (igure ) 22. Remove any other attached items and install on the new heat exchanger. 2. Install the new heat exchanger using 2 screws above the exhaust and screws behind the fan. (igures 7, 8) Connect Pressure Tube and ire Harness Attachments 24. Connect wire harness attachments. 25. Connect the pressure tube. 26. Attach the ignition line connection with screw. Install Burner and Burner Cover Plate (igure 5) 27. Replace the combustion chamber packing (included in kit) removing any residue from old packing. Insert the burner and place the burner cover plate into position. Attach the burner cover plate first with 8 screws and then attach the burner with 2 screws. Install Gas Manifold and Connect PC Board 28. Make sure that the two black packings (igure 9) are intact on the gas control assembly. Make sure that the ribbed side faces toward the manifold and that the flat side faces toward the gas valve. Attach the gas manifold with machine screws at the gas control assembly. Replace the lower and upper packings (included in kit) for the manifold plate removing any residue. 29. Attach the gas manifold with 6 screws at heat exchanger. 0. Attach the ignition line at the burner cover plate.. Attach the PC Board to the heat exchanger with screw. Connect ater Lines (igure ) 2. Attach the water outlet line and bracket with screw.. Attach the line to the water flow servo assembly with screw and bracket. Install an Assembly (igure 2) 4. Install the fan assembly by inserting the tab on the fan assembly into the slot at the base of the heat exchanger and attaching with two screws. 5. Attach the wire harness to the solenoid on the gas manifold (brown, black wires). 6. Attach the wire harness to the fan assembly (white, yellow, black, red wires). 7. Attach the air temperature thermistor (white, white wires) to the wire harness. 8. Install the front panel using 4 screws. 9. Turn on the water supply, power supply, and gas supply. 40. Check for gas leaks. 6 Rinnai ater Heater Service Manual igure 9

62 Component Replacement Instructions Heat Exchanger R/C85e(PLUS), R94LSe. Turn off the gas supply. 2. Turn off the 20 V power supply.. Turn off the water supply. Drain all water from the appliance. 4. Remove four screws securing the front panel. Remove front panel. igure Burner cover plate Gas Manifold PC Board Gas Control Valve an Assembly Remove an Assembly (igure 2) 5. Disconnect wire harness at the fan assembly. Disconnect the air temperature thermistor (two white wires) at the connection with the white and orange wires within the wire bundle. 6. Pull out the harness attached to the solenoid on the manifold to make room to pull out the fan assembly. 7. Remove the 2 screws that attach the fan assembly to the bottom of the burner. 8. Pull out the fan assembly. igure 2 2 screws Solenoid ire harness connection Disconnect ater Lines (igure ) 9. Remove screw from the water outlet bracket. Remove the bracket by rotating and moving it up toward the bend in the tube where the diameter is smaller. 0. Remove 2 screws and 2 brackets at the bypass servo assembly. igure ater outlet connection Bypass servo assembly connections Rinnai ater Heater Service Manual 62

63 Component Replacement Instructions Heat Exchanger R/C85e(PLUS), R94LSe Disconnect PC Board (igure 4). Remove screw connecting the PC Board to the heat exchanger assembly. Remove Gas Manifold (igure 4) 2. Remove the 6 screws that attach the gas manifold to the combustion chamber (part of the heat exchanger assembly).. Remove the screws that attach the gas manifold to the gas valve. These screws are machine screws and must be used at these locations. Ignition line igure 4 6 screws (gas manifold) PC Board screw machine screws (gas valve) Remove Burner and Burner Cover Plate (igure 5) 4. Pull out the ignition line and remove the gas manifold. 5. Remove the 8 screws attaching the burner cover plate to the combustion chamber. Move the cover plate to the side. It is not necessary to disconnect the wire harness from the burner cover plate. 6. Remove the 2 screws attaching the burner to the heat exchanger. Pull out the burner. 8 screws (burner cover plate) igure 5 2 screws (burner) Ignition line connection Disconnect ire Harness Attachments and Screws Holding the Heat Exchanger 7. Unscrew the ignition line connection. (igure 5) 8. Remove the wire harness attachments - sensors, heating elements, fusible link brackets. Ensure that the small O-ring in the thermistor is removed. (igure 6) 9. Remove screws behind the fan. (igure 7) igure 7 igure 8 screws 2 screws 6 Rinnai ater Heater Service Manual

64 Component Replacement Instructions Heat Exchanger R/C85e(PLUS), R94LSe ARNING ailure to correctly assemble the components according to these instructions may result in a gas leak or explosion. Installation 20. Remove 2 screws above the exhaust. Pull assembly from the unit. (igure 8) 2. Install the largest O-ring (included in kit) over the water outlet tube and the two smaller O-rings (included in kit) over the bypass servo tubes. (igure ) 22. Remove any other attached items and install on the new heat exchanger. Connect Pressure Tube and ire Harness Attachments 2. Install the new heat exchanger using 2 screws above the exhaust and screws behind the fan. (igures 7, 8) 24. Connect wire harness attachments. Install Burner and Burner Cover Plate (igure 5) 25. Connect the pressure tube. Attach the ignition line connection with screw. Install Gas Manifold and Connect PC Board 26. Replace the combustion chamber packing (included in kit) removing any residue from old packing. Insert the burner and place the burner cover plate into position. Attach the burner cover plate first with 8 screws and then attach the burner with 2 screws. 27. Make sure that the two black packings (igure 9) are intact on the gas control assembly. Make sure that the ribbed side faces toward the manifold and that the flat side faces toward the gas valve. Attach the gas manifold with machine screws at the gas control assembly. Replace the lower and upper packings (included in kit) for the manifold plate removing any residue. Connect ater Lines (igure ) 28. Attach the gas manifold with 6 screws at heat exchanger. 29. Attach the ignition line at the burner cover plate. igure 9 Install an Assembly (igure 2) 0. Attach the PC Board to the heat exchanger with screw.. Attach the water outlet line and bracket with screw. 2. Attach the two lines to the bypass servo assembly with screw and bracket for each line.. Install the fan assembly by inserting the tab on the fan assembly into the slot at the base of the heat exchanger and attaching with two screws. 4. Attach the wire harness to the solenoid on the gas manifold (brown, black wires). 5. Attach the wire harness to the fan assembly (white, yellow, black, red wires). 6. Attach the air temperature thermistor (white, white wires) to the wire harness. 7. Install the front panel using 4 screws. Turn on the water supply, power supply, and gas supply. Check for gas leaks. Rinnai ater Heater Service Manual 64

65 Component Replacement Instructions Heat Exchanger R/C5i(PLUS), R75LSi. Turn off the gas supply. 2. Turn off the 20 V power supply.. Turn off the water supply. Drain all water from the appliance. 4. Remove four screws securing the front panel. Remove front panel. Remove an Assembly (igure 2) 5. Disconnect wire harness at the fan assembly. Disconnect the air temperature thermistor (two white wires) at the connection with the white and orange wires within the wire bundle. 6. Pull out the harness attached to the solenoid on the manifold to make room to pull out the fan assembly. 7. Remove the 2 screws that attach the fan assembly to the bottom of the burner. 8. Loosen the ducting from the fan assembly by pinching open the metal clamp. 9. Pull out the fan assembly. igure Burner cover plate Gas Manifold PC Board Gas Control Valve an Assembly Disconnect ater Lines and PC Board (igure 2) 0. Remove screw from the water outlet bracket. Remove the bracket by rotating and moving it up toward the bend in the tube where the diameter is smaller.. Remove the screw and bracket at the water flow servo assembly. 2. Remove screw connecting the PC Board to the heat exchanger assembly. Ducting and metal clamp 2 screws igure 2 PC board screw Solenoid on the manifold water flow servo assembly connection ater outlet connection ire harness connection on the fan assembly ire harness bundle (air temperature thermistor connection to orange / white wires) 65 Rinnai ater Heater Service Manual

66 Component Replacement Instructions Heat Exchanger R/C5i(PLUS), R75LSi Remove Gas Manifold (igure ). Remove the 6 screws that attach the gas manifold to the combustion chamber (part of the heat exchanger assembly). 4. Remove the screws that attach the gas manifold to the gas valve. These screws are machine screws and must be used at these locations. 5. Pull out the ignition line and remove the gas manifold. igure Ignition line 6 screws (gas manifold) PC Board screw machine screws (gas valve) Remove Burner and Burner Cover Plate (igure 4) 6. Remove the 8 screws attaching the burner cover plate to the combustion chamber. Move the cover plate to the side. It is not necessary to disconnect the wire harness from the burner cover plate. 7. Remove the 2 screws attaching the burner to the heat exchanger. Pull out the burner. 8. Disconnect the pressure tube from the heat exchanger and unscrew the ignition line connection. 8 screws (burner cover plate) igure 4 2 screws (burner) Pressure tube Ignition line connection Rinnai ater Heater Service Manual 66

67 Component Replacement Instructions Heat Exchanger R/C5i(PLUS), R75LSi Disconnect ire Harness Attachments 9. Remove the wire harness attachments - sensors, heating elements, fusible link brackets. Ensure that the small O-ring in the thermistor is removed. Remove Heat Exchanger and Air Intake/Exhaust 20. Remove 8 screws connecting the assembly to the water heater casing assembly. (igures 6a, 6b) Near fan assembly location At right and left upper corners of water heater igure 6a screws 2 screws igure 6b 2 screws screw Separate the Heat Exchanger from the Air Intake/Exhaust 2. Pull out the assembly. Remove brackets on the side and back holding the fusible link. 22. Remove the 9 screws at the cover plate over the air intake passage. (igure 7) 2. Remove the 4 screws attaching the heat exchanger to the air intake/exhaust assembly. (igure 8) igure 7 igure 8 9 screws (cover plate) 24. Pull apart the heat exchanger and air intake/exhaust assembly. (igure 9) 4 screws 25. Remove 4 screws attaching the bracket on top of the heat exchanger. Pull off the bracket. (igure 0) 4 screws (bracket) igure 9 igure 0 ARNING ailure to correctly assemble the components according to these instructions may result in a gas leak or explosion. 67 Rinnai ater Heater Service Manual

68 Heat Exchanger Install Packings and Bracket Component Replacement Instructions R/C5i(PLUS), R75LSi 26. Install the O-ring (included in kit) over the water outlet tube and the O-ring (included in kit) over the water flow servo tube. (igure 2) 27. Install the bracket over the replacement heat exchanger. Push evenly on both sides of the bracket. Attach with four screws. (igure 0) Combine the Heat Exchanger and the Air Intake/Exhaust Assembly 28. Push the heat exchanger into the air intake/exhaust assembly. Attach with four screws. (igure 8) 29. Attach the cover plate over the air intake passage with 9 screws. (igure 7) Install Heat Exchanger and Air Intake/Exhaust Assembly (igures 6a, 6b) 0. Attach the fusible link to the back (2 brackets) and side ( bracket). Slide the assembly into the casing assembly and attach with 8 screws starting at the top of the water heater. Connect Pressure Tube and ire Harness Attachments. Connect wire harness attachments. (igure 5) 2. Connect the pressure tube. Attach the ignition line connection with screw. (igure 4) Install Burner and Burner Cover Plate (igure 4). Replace the combustion chamber packing (included in kit) removing any residue from old packing. Insert the burner and place the burner cover plate into position. Attach the burner cover plate first with 8 screws and then attach the burner with 2 screws. Install Gas Manifold and Connect PC Board 4. Make sure that the two black packings (igure ) are intact on the gas control assembly. Make sure that the ribbed side faces toward the manifold and that the flat side faces toward the gas valve. Attach the gas manifold with machine screws at the gas control assembly. Replace the lower and upper packings (included in kit) for the manifold plate removing any residue. 5. Attach the gas manifold with 6 screws at heat exchanger. 6. Attach the ignition line at the burner cover plate. 7. Attach the PC Board to the heat exchanger with screw. igure Connect ater Lines (igure 2) 8. Attach the water outlet line and bracket with screw. 9. Attach the two lines to the bypass servo assembly with screw and bracket for each line. Install an Assembly (igure 2) 40. Install the fan assembly by inserting the tab on the fan assembly into the slot at the base of the heat exchanger and attaching with two screws. 4. Push the ducting over the fan assembly exit and secure with the metal pinch clamp. 42. Attach the wire harness to the solenoid on the gas manifold (brown, black wires). 4. Attach the wire harness to the fan assembly (white, yellow, black, red wires). 44. Attach the air temperature thermistor (white, white wires) to the wire harness. 45. Install the front panel using 4 screws. 46. Turn on the water supply, power supply, and gas supply. 47. Check for gas leaks. Rinnai ater Heater Service Manual 68

69 Component Replacement Instructions Heat Exchanger R/C85i(PLUS), R94LSi. Turn off the gas supply. 2. Turn off the 20 V power supply.. Turn off the water supply. Drain all water from the appliance. 4. Remove four screws securing the front panel. Remove front panel. igure Burner cover plate Gas Manifold PC Board Remove an Assembly (igure 2) 5. Disconnect wire harness at the fan assembly. Disconnect the air temperature thermistor (two white wires) at the connection with the white and orange wires within the wire bundle. 6. Pull out the harness attached to the solenoid on the manifold to make room to pull out the fan assembly. Gas Control Valve an Assembly 7. Remove the 2 screws that attach the fan assembly to the bottom of the burner. 8. Loosen the ducting from the fan assembly by pinching open the metal clamp. 9. Pull out the fan assembly. igure 2 2 screws Ducting and metal clamp Solenoid on the manifold ire harness connection on the fan assembly ire harness bundle (air temperature thermistor connection to orange / white wires) 69 Rinnai ater Heater Service Manual

70 Heat Exchanger Disconnect ater Lines (igure ) Component Replacement Instructions R/C85i(PLUS), R94LSi 0. Remove screw from the water outlet bracket. Remove the bracket by rotating and moving it up toward the bend in the tube where the diameter is smaller.. Remove 2 screws and 2 brackets at the bypass servo assembly. igure ater outlet connection Bypass servo assembly connections Disconnect PC Board (igure 4) 2. Remove screw connecting the PC Board to the heat exchanger assembly. Remove Gas Manifold (igure 4). Remove the 6 screws that attach the gas manifold to the combustion chamber (part of the heat exchanger assembly). 4. Remove the screws that attach the gas manifold to the gas valve. These screws are machine screws and must be used at these locations. 5. Pull out the ignition line and remove the gas manifold. igure 4 Ignition line 6 screws (gas manifold) PC Board screw machine screws (gas valve) Rinnai ater Heater Service Manual 70

71 Component Replacement Instructions Heat Exchanger R/C85i(PLUS), R94LSi Remove Burner and Burner Cover Plate (igure 5) 6. Remove the 8 screws attaching the burner cover plate to the combustion chamber. Move the cover plate to the side. It is not necessary to disconnect the wire harness from the burner cover plate. 7. Remove the 2 screws attaching the burner to the heat exchanger. Pull out the burner. 8 screws (burner cover plate) igure 5 2 screws (burner) Pressure tube Ignition line connection Disconnect Gas Line and ire Harness Attachments 8. Disconnect the pressure tube from the heat exchanger and unscrew the ignition line connection. (igure 5) 9. Remove the wire harness attachments - sensors, heating elements, fusible link brackets. Ensure that the small O-ring in the thermistor is removed. (igure 6) Sensors igure 6 Thermistor Brackets for fusible link Heating elements 7 Rinnai ater Heater Service Manual

72 Component Replacement Instructions Heat Exchanger R/C85i(PLUS), R94LSi Remove Heat Exchanger and Air Intake/Exhaust 20. Remove 8 screws connecting the assembly to the water heater casing assembly. (igures 7a, 7b) Near fan assembly location At right and left upper corners of water heater igure 7a screws 2 screws igure 7b 2 screws screw Separate the Heat Exchanger from the Air Intake/Exhaust 2. Pull out the assembly. Remove brackets on the side and back holding the fusible link. 22. Remove the 9 screws at the cover plate over the air intake passage. (igure 8) 2. Remove the 4 screws attaching the heat exchanger to the air intake/exhaust assembly. (igure 9) igure 8 igure 9 9 screws (cover plate) 24. Pull apart the heat exchanger and air intake/exhaust assembly. (igure 0) 4 screws 25. Remove 4 screws attaching the bracket on top of the heat exchanger. Pull off the bracket. (igure ) 4 screws (bracket) igure 0 ARNING igure ailure to correctly assemble the components according to these instructions may result in a gas leak or explosion. Install Packings and Bracket 26. Install the largest O-ring (included in kit) over the water outlet tube and the two smaller O-rings (included in kit) over the bypass servo tubes. (igure ) 27. Install the bracket over the replacement heat exchanger. Push evenly on both sides of the bracket. Attach with four screws. (igure ) Rinnai ater Heater Service Manual 72

73 Heat Exchanger Component Replacement Instructions Combine the Heat Exchanger and the Air Intake/Exhaust R/C85i(PLUS), R94LSi 28. Push the heat exchanger into the air intake/exhaust assembly. Attach with four screws. (igure 9) 29. Attach the cover plate over the air intake passage with 9 screws. (igure 8) Install Heat Exchanger and Air Intake/Exhaust Assembly (igures 7a, 7b) 0. Attach the fusible link to the back (2 brackets) and side ( bracket). Slide the assembly into the casing assembly and attach with 8 screws starting at the top of the water heater. Connect Pressure Tube and ire Harness Attachments. Connect wire harness attachments. (igure 6) 2. Connect the pressure tube.. Attach the ignition line connection with screw. (igure 5) Install Burner and Burner Cover Plate (igure 5) 4. Replace the combustion chamber packing (included in kit) removing any residue from old packing. Insert the burner and place the burner cover plate into position. Attach the burner cover plate first with 8 screws and then attach the burner with 2 screws. Install Gas Manifold and Connect PC Board (igure 4) 5. Make sure that the two black packings (igure 2) are intact on the gas control assembly. Make sure that the ribbed side faces toward the manifold and that the flat side faces toward the gas valve. Attach the gas manifold with machine screws at the gas control assembly. Replace the lower and upper packings (included in kit) for the manifold plate removing any residue. 6. Attach the gas manifold with 6 screws at heat exchanger. 7. Attach the ignition line at the burner cover plate. igure 2 Connect ater Lines (igure ) 8. Attach the PC Board to the heat exchanger with screw. 9. Attach the water outlet line and bracket with screw. 40. Attach the two lines to the bypass servo assembly with screw and bracket for each line. Install an Assembly (igure 2) 4. Install the fan assembly by inserting the tab on the fan assembly into the slot at the base of the heat exchanger and attaching with two screws. 42. Push the ducting over the fan assembly exit and secure with the metal pinch clamp. 4. Attach the wire harness to the solenoid on the gas manifold (brown, black wires). 44. Attach the wire harness to the fan assembly (white, yellow, black, red wires). 45. Attach the air temperature thermistor (white, white wires) to the wire harness. 46. Install the front panel using 4 screws. 47. Turn on the water supply, power supply, and gas supply. 48. Check for gas leaks. 7 Rinnai ater Heater Service Manual

74 Component Replacement Instructions Heat Exchanger R/C98e(ASME), R98LSe(ASME). Turn off the gas supply. 2. Turn off the 20 V power supply.. Turn off the water supply. Drain all water from the appliance. 4. Remove four screws securing the front panel. Remove front panel. 5. Disconnect wire harness at the fan assembly, the electrical connections to the solenoid valves, and the ignition line. 6. Remove screws and brackets securing the water line connections. (igure ) 7. Remove the 5 screws that attach the gas manifold to the combustion chamber (part of the heat exchanger assembly). (igure ) 8. Remove the 2 screws that attach the gas manifold to the gas valve. These screws are machine screws and must be used at these locations. (igure ) 9. Pull out the gas manifold and remove the connector at the ignitor at the left side of the gas manifold. 0. Remove the 9 screws attaching the burner cover plate to the combustion chamber. (igure 2). Remove the 2 screws attaching the burner to the heat exchanger. Pull out the burner. (igure 2) 2. Remove the wire harness attachments - sensors, heating elements, fusible link brackets. Ensure that the small O-ring at the thermistor is removed.. Remove the 4 screws connecting the heat exchanger to the casing. (igure ) 4. Pull out the assembly. Remove the brackets on the side and back holding the fusible link. Slide off the fusible link. 5 screws (gas manifold) igure igure 2 9 screws (burner cover plate) Top screws 2 machine screws (gas valve) ater line connections 2 screws (burner) igure Bottom screws Rinnai ater Heater Service Manual 74

75 Component Replacement Instructions Heat Exchanger R/C98e(ASME), R98LSe(ASME) 5. Remove the fan assembly (4 screws) and install it on the new heat exchanger. (igure 4) 6. Remove the flue outlet (6 screws) and install it on the new heat exchanger. (igure 5) 7. Install the largest O-ring (included in kit) over the water outlet tube and the two smaller O-rings (included in kit) over the water inlet tubes. (igure 4) 8. Slide the fusible link between the water outlet and inlet tubes and onto the new heat exchanger. (igure 4) 9. Attach brackets at the back and side holding the fusible link. 20. Install the 4 screws at the top and bottom of the heat exchanger to the casing. (igure ) 2. Insert the burner and place the burner cover plate into position. Attach the burner cover plate first with 9 screws and then attach the burner with 2 screws. (igure 2) 22. Replace the electrode gasket. (igure 6) 2. Make sure that the black gasket (igure 7) is intact on the gas control assembly. Make sure that the ribbed side faces toward the manifold and that the flat side faces toward the gas valve. Replace the lower and upper gaskets (included in kit) for the manifold plate removing any residue. (igure 8) 24. Attach the electrical connector to the ignitor on the manifold and attach the gas manifold with 2 machine screws at the gas control assembly. (igure ) 25. Attach the gas manifold with 5 screws at heat exchanger. (igure ) 26. Connect wire harness attachments. 27. Attach the ignition line at the burner cover plate. 28. Attach the electrical connectors to the solenoid valves. 29. Attach the wire harness to the fan assembly (white, yellow, black, red wires). 0. Attach the brackets to the water line connections. (igure ). Install the front panel using 4 screws. Turn on the water supply, power supply, and gas supply. Check for gas leaks. 4 locations igure 4 ater outlet tube ater inlet tubes igure 5 Electrode Gasket igure 6 Gasket igure 7 igure 8 Gaskets 75 Rinnai ater Heater Service Manual

76 Component Replacement Instructions Heat Exchanger R/C98i(ASME), R98LSi(ASME). Turn off the gas supply. 2. Turn off the 20 V power supply.. Turn off the water supply. Drain all water from the appliance. 4. Remove four screws securing the front panel. Remove front panel. 5. Remove the bracket holding the controller ( screw). (igure ) 6. Disconnect wire harness at the fan assembly, the electrical connections to the solenoid valves, and the ignition line. 7. Remove screws and brackets securing the water line connections. (igure 2) 8. Remove the 5 screws that attach the gas manifold to the combustion chamber (part of the heat exchanger assembly). (igure 2) 9. Remove the 2 screws that attach the gas manifold to the gas valve. These screws are machine screws and must be used at these locations. (igure 2) 0. Pull out the gas manifold and remove the connector at the ignitor at the left side of the gas manifold.. Remove the 9 screws attaching the burner cover plate to the combustion chamber. (igure ) 2. Remove the 2 screws attaching the burner to the heat exchanger. Pull out the burner. (igure ). Remove the wire harness attachments - sensors, heating elements, fusible link brackets. Ensure that the small O-ring at the thermistor is removed. Bracket screw igure 5 screws (gas manifold) igure 2 2 machine screws (gas valve) ater line connections igure 9 screws (burner cover plate) 2 screws (burner) Rinnai ater Heater Service Manual 76

77 Component Replacement Instructions Heat Exchanger R/C98i(ASME), R98LSi(ASME) 4. Remove the screws at the seal plate at the top of the water heater. Remove the seal plate and gasket. (igure 4) 5. Remove flue outlet vent (4 screws). (igure 5) 6. Remove the 4 screws connecting the heat exchanger to the back of the casing. (igure 6) 7. Pull out the assembly. (It is hooked on brackets in the casing.) Remove the brackets on the side and back holding the fusible link. Slide off the fusible link. 8. Remove the fan assembly (4 screws) and install it on the new heat exchanger. (igure 7) 9. Install the largest O-ring (included in kit) over the water outlet tube and the two smaller O-rings (included in kit) over the water inlet tubes. (igure 7) 20. Slide the fusible link between the water outlet and inlet tubes and onto the new heat exchanger. (igure 7) 2. Attach brackets at the back and side holding the fusible link. Install the heat exchanger hooking it on the brackets in the back. 22. Install the 4 screws at the top and bottom of the heat exchanger to the back of the casing. (igure 6) 2. Install the flue outlet vent (4 screws) and seal plate ( screws) and gasket at the top of the water heater. (igures 4 and 5) igure 4 igure 5 Top left screw Top right screw igure 6 Bottom screws 4 locations igure 7 ater outlet tube 77 Rinnai ater Heater Service Manual ater inlet tubes

78 Component Replacement Instructions Heat Exchanger R/C98i(ASME), R98LSi(ASME) 24. Insert the burner and place the burner cover plate into position. Attach the burner cover plate first with 9 screws and then attach the burner with 2 screws. (igure ) 25. Replace the electrode gasket. (igure 8) 26. Make sure that the black gasket (igure 9) is intact on the gas control assembly. Make sure that the ribbed side faces toward the manifold and that the flat side faces toward the gas valve. Replace the lower and upper gaskets (included in kit) for the manifold plate removing any residue. (igure 0) 27. Attach the electrical connector to the ignitor on the manifold and attach the gas manifold with 2 machine screws at the gas control assembly. (igure 2) 28. Attach the gas manifold with 5 screws at heat exchanger. (igure 2) 29. Connect wire harness attachments. 0. Attach the ignition line at the burner cover plate.. Attach the electrical connectors to the solenoid valves. 2. Attach the wire harness to the fan assembly (white, yellow, black, red wires).. Attach the brackets to the water line connections. (igure 2) 4. Install the front panel using 4 screws. 5. Turn on the water supply, power supply, and gas supply. 6. Check for gas leaks. igure 8 Gasket igure 9 igure 0 Electrode Gasket Gaskets Rinnai ater Heater Service Manual 78

79 Gas Pressure Setting Procedure CAUTION Do not touch the areas at or near the heat exchanger or combustion chamber. These areas become very hot and could cause burns. igure Potentiometer (POT). Remove the front panel (four screws). 2. Calibrate the low fire and high fire settings as follows: A. Remove the allen head plug and attach the manometer to the burner test point located on the gas control. (igure, 2, or ) Burner test point Dip switches (S) Models R/C42e, R/C5e, V5e, R6LSe igure 2 Potentiometer (POT) igure Potentiometer (POT) Burner test point Dip switches (S) Models R70e, R75LSe, R/C85e, R94LSe, R50LSi, R/C5i, R75LSi, R/C85i, R94LSi Burner test point Dip switches (S) Models R/C98e, R98LSe, R/C98i, R98LSi 79 Rinnai ater Heater Service Manual

80 B. Turn on the gas supply. Gas Pressure Setting Procedure C. Turn on the power supply. D. low water through the water heater at the maximum flow rate obtainable. (At least gallons per minute is recommended.) igure 4 E. Move No. 7 dip switch of the S bank to the ON position to calibrate orced Low combustion. (igure 5). Check the burner test point pressure. G. Remove the rubber access plug (igure 4) and adjust the regulator screw on the modulating valve to obtain the correct low fire manifold pressure. Refer to the table for your gas type, model, and altitude. Install rubber access plug. H. Move No. 7 and No. 8 dip switches of the S bank to the ON position to calibrate orced High combustion. (igure 6) I. Check the burner test point pressure. J. Adjust the high pressure Potentiometer (POT) (igure, 2, or ) on the PC Board to obtain the correct high fire manifold pressure. Refer to the table for your gas type, model, and altitude. K. Move No. 7 and No. 8 back to the O position to return the appliance to Normal combustion. (igure 7) L. Close hot water taps. M. Turn off gas supply and 20 V power supply. N. Remove manometer and re-install allen head plug. O. Turn on the gas supply and 20 V power supply. P. Operate the unit and check for gas leaks.. Install the front panel using four screws. igure 5 orced Low igure 6 orced High igure 7 Normal Access plug Switch No. ON O Switch No. O ON Switch No. O ON Rinnai ater Heater Service Manual 80

81 Manifold Gas Pressure Settings V Series - Outdoor Natural Gas Propane Gas R42e,C42e Altitude High ire Low ire Altitude High ire Low ire less than 5000 ft (524 m) less than 2000 ft (60 m) ft (829 m) ft (94 m) ft (24 m) ft (29 m) ft ( m) ft (524 m) R5e,C5e Altitude High ire Low ire less than 2000 ft (60 m) ft (94 m) ft (29 m) ft ( m) Altitude High ire Low ire less than 2000 ft (60 m) R85e(PLUS), C85e(PLUS) Altitude High ire Low ire less than 0000 ft (048 m) Altitude High ire Low ire less than 2000 ft (60 m) ft (94 m) ft (29 m) ft (524 m) ft (829 m) ft ( m) R70e Altitude High ire Low ire less than 0000 ft (048 m) Altitude High ire Low ire less than 0000 ft (048 m) R98e(ASME), C98e(ASME) Altitude High ire Low ire less than 2000 ft (60 m) ft (94 m) ft (29 m) ft (524 m) ft (829 m) ft (24 m) ft ( m) Altitude High ire Low ire less than 2000 ft (60 m) ft (94 m) ft (29 m) ft (524 m) ft ( m) Rinnai ater Heater Service Manual

82 Manifold Gas Pressure Settings V Series - Indoor Natural Gas Propane Gas R5i(PLUS), C5i(PLUS), R85i(PLUS), C85i(PLUS) Altitude High ire Low ire less than 0000 ft (048 m) Altitude High ire Low ire less than 2000 ft (60 m) ft (94 m) ft (29 m) ft (524 m) ft (829 m) ft (24 m) ft (248 m) ft (274 m) ft (048 m) R98i(ASME), C98i(ASME) Altitude High ire Low ire less than 2000 ft (60 m) ft (94 m) ft (29 m) ft ( m) Altitude High ire Low ire less than 2000 ft (60 m) ft (94 m) ft (29 m) ft (524 m) Manifold Gas Pressure Settings VA Series V5e (REU-VAM620) using NATURAL GAS Dip Switch Setting Altitude Max Rate inches.c. Min Rate inches.c. #2 O, # O ft (0-60 m) #2 O, # ON ft ( m) #2 ON, # O ft ( m) #2 ON, # ON ft ( m) V5e (REU-VAM620) using PROPANE GAS Dip Switch Setting Altitude Max Rate inches.c. Min Rate inches.c. #2 O, # O ft (0-60 m) #2 O, # ON ft ( m) #2 ON, # O ft ( m) #2 ON, # ON ft ( m) Revised 0/7/2009 Rinnai ater Heater Service Manual 82

83 Manifold Gas Pressure Settings VA Series R6LSe (REU-VA2024) using NATURAL GAS Dip Switch Setting Altitude Max Rate inches.c. Min Rate inches.c. #2 O, # O ft (0-60 m) #2 O, # ON ft ( m) #2 ON, # O ft ( m) #2 ON, # ON ft ( m) R6LSe (REU-VA2024) using PROPANE GAS Dip Switch Setting Altitude Max Rate inches.c. Min Rate inches.c. #2 O, # O ft (0-60 m) #2 O, # ON ft ( m) #2 ON, # O ft ( m) #2 ON, # ON ft ( m) R6LSe2 - REU-VA2024(A) using NATURAL GAS Dip Switch Setting Altitude Max Rate inches.c. Min Rate inches.c. #2 O, # O ft (0-60 m) #2 O, # ON ft ( m) #2 ON, # O ft ( m) #2 ON, # ON ft ( m) R6LSe2 - REU-VA2024(A) using PROPANE GAS Dip Switch Setting Altitude Max Rate inches.c. Min Rate inches.c. #2 O, # O ft (0-60 m) #2 O, # ON ft ( m) #2 ON, # O ft ( m) #2 ON, # ON ft ( m) Rinnai ater Heater Service Manual Revised 0/7/2009

84 Manifold Gas Pressure Settings VA Series R50LSi (REU-VA209U) Dip Switch Setting Altitude MAX VENT (Dip Switch # is O) Max Rate inches.c. Min Rate inches.c. MIN VENT (Dip Switch # is ON) Max Rate inches.c. Min Rate inches.c. #2 O, # O ft (0-60 m) #2 O, # ON ft ( m) #2 ON, # O ft ( m) #2 ON, # ON ft ( m) R75LSi (REU-VA2528U), R94LSi (REU-VA255U) Dip Switch Setting Altitude MAX VENT (Dip Switch # is O) Max Rate inches.c. Min Rate inches.c. MIN VENT (Dip Switch # is ON) Max Rate inches.c. Min Rate inches.c. #2 O, # O ft (0-60 m) #2 O, # ON ft ( m) #2 ON, # O ft ( m) #2 ON, # ON ft ( m) R75LSi(A) (REU-VA2528U(A)) using NATURAL GAS Dip Switch Setting using NATURAL GAS using NATURAL GAS Altitude MAX VENT (Dip Switch # is O) Max Rate inches.c. Min Rate inches.c. MIN VENT (Dip Switch # is ON) Max Rate inches.c. Min Rate inches.c. #2 O, # O ft (0-60 m) #2 O, # ON ft ( m) #2 ON, # O ft ( m) #2 ON, # ON ft ( m) R75LSe (REU-VA2528), R94LSe (REU-VA255) using NATURAL GAS Dip Switch Setting Altitude Max Rate inches.c. Min Rate inches.c. #2 O, # O ft (0-60 m) #2 O, # ON ft ( m). 0.7 #2 ON, # O ft ( m). 0.9 #2 ON, # ON ft ( m). 0.7 R75LSe(A) (REU-VA2528(A)) using NATURAL GAS Dip Switch Setting Altitude Max Rate inches.c. Min Rate inches.c. #2 O, # O ft (0-60 m) #2 O, # ON ft ( m). 0.7 #2 ON, # O ft ( m). 0.9 #2 ON, # ON ft ( m). 0.7 Revised 0/7/2009 Rinnai ater Heater Service Manual 84

85 Manifold Gas Pressure Settings VA Series R50LSi (REU-VA209U) Dip Switch Setting Altitude MAX VENT (Dip Switch # is O) Max Rate inches.c. Min Rate inches.c. MIN VENT (Dip Switch # is ON) Max Rate inches.c. Min Rate inches.c. #2 O, # O ft (0-60 m) #2 O, # ON ft ( m) #2 ON, # O ft ( m) #2 ON, # ON ft ( m) R75LSi (REU-VA2528U), R94LSi (REU-VA255U) Dip Switch Setting Altitude MAX VENT (Dip Switch # is O) Max Rate inches.c. Min Rate inches.c. MIN VENT (Dip Switch # is ON) Max Rate inches.c. Min Rate inches.c. #2 O, # O ft (0-60 m) #2 O, # ON ft ( m) #2 ON, # O ft ( m) #2 ON, # ON ft ( m) R75LSi(A) (REU-VA2528U(A)) using PROPANE GAS Dip Switch Setting using PROPANE GAS using PROPANE GAS Altitude MAX VENT (Dip Switch # is O) Max Rate inches.c. Min Rate inches.c. MIN VENT (Dip Switch # is ON) Max Rate inches.c. Min Rate inches.c. #2 O, # O ft (0-60 m) #2 O, # ON ft ( m) #2 ON, # O ft ( m) #2 ON, # ON ft ( m) R75LSe (REU-VA2528), R94LSe (REU-VA255) using PROPANE GAS Dip Switch Setting Altitude Max Rate inches.c. 85 Rinnai ater Heater Service Manual Min Rate inches.c. #2 O, # O ft (0-60 m) #2 O, # ON ft ( m) 4.0. #2 ON, # O ft ( m) #2 ON, # ON ft ( m) R75LSe(A) (REU-VA2528(A)) using PROPANE GAS Dip Switch Setting Altitude Max Rate inches.c. Min Rate inches.c. #2 O, # O ft (0-60 m) #2 O, # ON ft ( m) 4.0. #2 ON, # O ft ( m) #2 ON, # ON ft ( m)

86 Manifold Gas Pressure Settings VA Series R98LSi (REU-VA27U) Dip Switch Setting R98LSe (REU-VA27) using NATURAL GAS Dip Switch Setting using NATURAL GAS Altitude Altitude MAX VENT (Dip Switch # is O) Max Rate inches.c. Min Rate inches.c. Max Rate inches.c. MIN VENT (Dip Switch # is ON) Max Rate inches.c. Min Rate inches.c. #2 O, # O ft (0-60 m) #2 O, # ON ft ( m) #2 ON, # O ft ( m) #2 ON, # ON ft ( m) Min Rate inches.c. #2 O, # O ft (0-60 m) #2 O, # ON ft ( m) #2 ON, # O ft ( m) #2 ON, # ON ft ( m) R98LSi (REU-VA27U) Dip Switch Setting using PROPANE GAS Altitude MAX VENT (Dip Switch # is O) Max Rate inches.c. Min Rate inches.c. MIN VENT (Dip Switch # is ON) Max Rate inches.c. Min Rate inches.c. #2 O, # O ft (0-60 m) #2 O, # ON ft ( m) #2 ON, # O ft ( m) #2 ON, # ON ft ( m) R98LSe (REU-VA27) using PROPANE GAS Dip Switch Setting Altitude Max Rate inches.c. Min Rate inches.c. #2 O, # O ft (0-60 m) #2 O, # ON ft ( m) #2 ON, # O ft ( m) #2 ON, # ON ft ( m) Rinnai ater Heater Service Manual 86

87 Dip Switch Settings V Series S Bank O - Long lue ON - Short lue and Outdoor Models Long flue is defined as: 0 elbows and length is greater than 2 ft elbow and length is greater than 5 ft 2 elbows and length is greater than 9 ft 2 ON position O position 4 O position 5 O position 6 O position 7 O position - Used for low fire and high fire settings. Refer to the gas pressure setting 8 procedure. S2 Bank 2 O - Propane Gas ON - Natural Gas O position for models prior to these serial numbers: (on these units, the front panel does not have an R or C trade name, unless the front panel has been replaced) V66, V66C V2020, V2020C V252, V252C V252U, V252UC V2520U, V2520UC V ON position for other models, serial numbers O position 4 O - Residential Models ON - Commercial Models VA Series (for -UC models refer to the next page) S Bank ft (0-60 m) O - Long lue ON - Short lue and Outdoor Models Long flue is defined as: 0 elbows and length is greater than 2 ft elbow and length is greater than 5 ft 2 elbows and length is greater than 9 ft Settings dependent on altitude ft ( m) ft ( m) ft ( m) #2: O #2: O #2: ON #2: ON #: O #: ON #: O #: ON O - if using MC-9 controller 4 ON - if using MC-45 controller O - 20º default temperature without a controller 5 ON - 40º default temperature without a controller 6 O position 7 O position - Used for low fire and high fire settings. Refer to the gas pressure setting 8 procedure. S2 Bank (present on replacement PC boards only) 2 4 O - Propane Gas ON - Natural Gas O - Outdoor model ON - Indoor model O - R6LSe, R75LSe, R75LSi, R94LSe, R94LSi, R98LSe(ASME), R98LSi(ASME) ON - R50LSi, V5e O - V5e, R6LSe, R94LSe, R94LSi, R98LSe(ASME), R98LSi(ASME) ON - R50LSi, R75LSe, R75LSi O - V5e, R6LSe, R75LSe, R75LSi, 5 R94LSe, R94LSi, R98LSe(ASME), R98LSi(ASME) ON - R50LSi 6 O position 87 Rinnai ater Heater Service Manual

88 Dip Switch Settings VA Series (-UC Models) If the model name on the side of the water heater ends with -UC (ex. REU-VA255UD-UC ), then these units have a default maximum temperature of 20º (49º C) and an option to increase the maximum temperature to 40 º (60 ºC). Temperature settings from º (52-60 ºC) are available by setting dip switch 6 to ON in the S bank of 8 dip switches. Other dip switch positions may be defined differently than for the non -UC models. S Bank ft (0-60 m) O - Long lue ON - Short lue and Outdoor Models Long flue is defined as: 0 elbows and length is greater than 2 ft elbow and length is greater than 5 ft 2 elbows and length is greater than 9 ft Settings dependent on altitude ft ( m) ft ( m) ft ( m) #2: O #2: O #2: ON #2: ON #: O #: ON #: O #: ON S2 Bank (present on replacement PC boards only) 2 O - Propane Gas ON - Natural Gas O - Outdoor model ON - Indoor model O - R6LSe, R75LSe, R75LSi, R94LSe, R94LSi, R98LSe(ASME), R98LSi(ASME) ON - R50LSi, V5e 4 O position 5 O position 6 O position O - if using MC-9 controller 4 ON - if using MC-45 controller O - 20º default temperature without a controller 5 ON - 40º default temperature without a controller O - 20º maximum temperature without an MCC-9 controller 6 ON - 40º maximum temperature without an MCC-9 controller 7 O position - Used for low fire and high fire settings. Refer to the gas pressure setting 8 procedure. Rinnai ater Heater Service Manual 88

89 Notes 89 Rinnai ater Heater Service Manual

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