Reliance Water Heaters 110 User manual

Maintenance sheet 62Q064-4
B. Error codes
03 (One time): Incorrect DIPswitch setting
・Check the DIPswitch settings on the PCB. Refer to Section D.
10 (Five times): Warning for the “99” error code
・Check the gas type of the house (and/or the building). If it's wrong gas type model, replace
the water heater to correct one.
・Check if there is any blockage (For example, Damper sticking, Vent Flaps installed on the
terminator, Snow build up around terminator, Installed in a closet (No ventilation or lack of
combustion air)) in the intake air and/or exhaust. Refer to the “Vent termination clearances”
of the installation manual.
・If the water heater is installed as a direct-vent system, check whether there is enough
distance between the intake air terminal and the exhaust terminal. Refer to the “Vent
termination clearances” of the Installation manual.
・Check if the total vent length doesn’t exceed 50 ft and the # of elbows is less than 5Ea.
・Check the altitude/elevation of area of where the water heater is installed. Refer to the
“High-altitude function” of Section D. And change the DIPswitch settings.
・Check if there is grease and/or dirt in the burner (Part #101) and the fan motor
(Part #103), especially if the water heater has been installed in a contaminated area.
・Check if there is dust and lint in the heat exchanger.
・Check the manifold pressure of the water heater. Refer to the Installation manual of the
water heter.
11 (Three times): Ignition failure
1. Check the gas supply and inlet gas pressure.
2. Check if the Hi-limit switch (Part #412) is properly functioning.
3. Check for connection/breakage of wires (Part #413, 708, 709, 712), burn marks on the
computer board (Part #701),and/or soot on the flame rod (Part #108). And then if the
O.H.C.F (Part #413) has a breakage, Consult the manufacturer.
4. Check if there is a buzzing spark ignition sound coming from the burner (Part #101)
when water heater prepares for combustion.
5. Listen for the double “clunk” sound coming from the gas valve assembly (Part #102)
when water heater goes into combustion.
6. (Only if no sparking and/or kick sound) Check the voltage on each wire to gas valve assembly
(Part #102) and/or the igniter (Part #711). Refer to “Appendix A” in Section C.
*No sparking sound >>>>> Refer to #1 at “Appendix A” in Section C.
*No kick sound >>>>> Refer to #2 at “Appendix A” in Section C.
7. Check if there is leaking from the heat exchanger (Part #401).
8. Check if there is dust and lint in nozzles of the manifold (Part #102).
9. Check the current on the flame rod (Part #108). Refer to #3 at “Appendix A” in Section C.
12 (Three times): Loss of flame
1. Check the gas supply and inlet gas pressure.
2. Check if the Hi-limit switch (Part #412) is properly functioning.
3. Check for connection/breakage of wires (Part #413, 708, 709, 712), burn marks on the
computer board (Part #701), and/or soot on the flame rod (Part #108). And then if the
O.H.C.F (Part #413) has a breakage, Consult the manufacturer.
4. Check if there is leaking from the heat exchanger (Part #401).
5. Check if there is dust and lint in nozzles of the manifold (Part #102).
6. Check the current on the flame rod (Part #108). Refer to #3 at “Appendix A” in Section C.
31,32 (Two times): Disconnected/short-circuited thermistor
・Check for connection/breakage of wires and/or debris on the thermistor (Part #407, 408).
・Check the thermistor resistance. Refer to “Appendix D” in Section C.
39 (Two times): Air-fuel ratio rod failure
・Check for connection/breakage of wires (Part #709) and/or soot on the flame rod
(Part #108).
51,55 (six times): Abnormal gas solenoid valve and main gas valve
・Check for connection/breakage of wires (Part #708) and/or burn marks on the computer
board (Part #701).
・Reset power supply of the water heater.
・
Check the voltage of each valve on the gas valve assembly (Part #102). Refer to
“Appendix C” in Section C.
61 (Four times): Fan motor fault
・Check for connection/breakage of wires, dust buildup in the fan motor (Part #103) and/or
burn marks on the computer board (Part #701).
・Check for frozen/corrosion of connectors of the fan motor (Part #103).
・Check the voltage between blue wire and each wire of the fan motor (Part #103), and check
resistance between white wire and red wire. Refer to “Appendix B” in Section C.
70 (One time): Computer board fault
・Check for connection/breakage of wires (Part #714) and/or burn marks on the computer
board (Part #701)
72 (Six times): False flame detection
1. Clean the flame rod (Part #108).
2. For indoor models, check if a condensate drain is installed on the vent collar of the water heater.
3. Check if there is leaking from the heat exchanger (Part #401).
74: Miscommunication between water heater and remote controller
1. Check the model type of the remote controller. Model No. 9007666005 (TK-RE02) is the
correct one.
2. Inspect the connections between the water heater and remote controller. Refer to the
“Remote controller connections” of the Installation manual.
3. Check the power supply of the water heater.
4. If this error code appears only on the Red LED in the PCB (Part #701), check the voltage
on the remote controller terminal on the PCB. Refer to “Appendix E” in Section C.
5. If this error code appears only on the remote controller, replace the PCB (Part #701).
6. If this error code appears on both the PCB (Part #701) and the remote controller, replace
the remote controller.
99 (Five times): Imperfect combustion
・Refer to the “10” error code in this section.
C. Wiring diagram and check point of the water heater
Appendix A (For error code 11)
Check the following points during ignition stage.
# 1. Refer to check point “B” on the wiring diagram above.
Check the voltage between purple wires.
(Normal: 90 to 110 VAC)
This check point is normal?
Yes >> Replace the igniter (Part #711).
No >> Go to Next.
# 2. Refer to check points “C” and “H1” on the wiring diagram above.
Check the voltages below:
C: Between blue wire and light blue wire (#3).
(Normal: 78 to 100 VDC)
C: Between blue wire and orange wire (#53).
(Normal: 78 to 100 VDC)
H1: Check the voltage between white wire and red wire.
(Normal: 1 to 15 VDC)
These check points are normal?
Yes >> Replace the gas valve assembly (Part #102).
No >> Replace the PCB (Part #701).
# 3. Check the current through the orange flame rod wire (Part #709).
(Normal: more than 1 μA)
This check point is normal during operation?
Yes >> Replace the PCB (Part #701).
No >> Replace the flame rod (Part #108).
Appendix B (For error code 61)
Refer to check point “G” in the diagram to the left and the following.
•Check the voltage between red wire and blue wire.
(Normal: 110 to 160 VDC)
•Check the voltage between yellow wire and blue wire.
(Normal: 13 to 17 VDC)
•Check the voltage between orange wire and blue wire.
(Normal: 2.0 to 6.5 VDC)
All check points are normal?
Yes >> Replace the fan motor (Part #103).
No >> Replace the PCB (Part #701).
Appendix C (For error code 51 and 55)
Refer to check point “C” in the diagram to the left and the following.
Check the voltage on the each valve on the gas valve assembly.
•Between blue wire and light blue wire (#3) (Normal: 78 to 100 VDC).
•Between blue wire and green wire (#9) (Normal: 78 to 100 VDC).
•Between blue wire and orange wire (#53) (Normal: 78 to 100 VDC).
•Between blue wire and red wire (#73) (Normal: 78 to 100 VDC).
All check points are normal?
Yes >> Replace the gas valve assembly (Part #102).
No >> Replace the PCB (Part #701).
Appendix D (For error code 31 and 32)
•Outlet thermistor (Find the marking of No.113 on the connector)
Check point “E1”
•Inlet thermistor (Find the marking of No.42 on the connector)
Check point “E2”
Check the resistance between black wire and black wire.
Temperature °F 50 59 68 77 86 95
°C 10 15 20 25 30 35
Resistance kΩ 15.4 12.6 10.3 8.5 7.0 5.9
All check points are normal?
Yes >> Replace the PCB (Part #701).
No >> Replace the thermistor (Part #407, 408).
Appendix E (For error code 74)
Refer to check point “F” on the wiring diagram above.
Check the voltage on the remote controller terminal on the PCB.
(Normal: 11 to 25 VDC)
This check point is normal?
Yes >> Replace the remote controller.
No >> Replace the PCB (Part #701).
If the error code is indicated on the Red LED (Refer to the Section C) on the PCB (Part #701) of the
water heater (and/or the remote controller), refer to Section B.
<< It takes long time to get hot water at the fixtures >>
・The time it takes to deliver hot water from the water heater to your fixtures depends
on the length of piping between the two. The longer the distance or the bigger the
pipes, the longer it will take to get hot water.
・If you would like to receive hot water to your fixtures quicker, you may want to
consider a hot water recirculation system.
<< The water is not hot enough or turns cold and stays cold >>
・Compare the flow and temperature. Refer to the “Output temperature chart” of the
Installation manual.
・Check cross plumbing between cold water lines and hot water lines.
・Check if the gas supply valve is fully open, the gas line is sized properly and the gas
supplies pressure enough. Refer to the “Gas supply and gas pipe sizing” of the
Installation manual.
・Check the set temperature, and change the set temperature with the remote controller
or the DIPswitch setting. Refer to Section D.
・Refer to the “Water circuit” in this section.
<<The water is too hot>>
・Check the set temperature, lower setting temperature.
<<The hot water is not available when a fixture is opened>>
・Refer to the “Power supply circuit” and “Water circuit” in this section.
<<Fluctuation in hot water temperature>>
・Check if the filter on the cold water inlet is cleaned (Part #406).
・Check if the gas line is sized properly and the supply gas pressure is sufficient.
・Check for cross connection between cold water lines and hot water lines.
・Refer to the “Water circuit” in this section.
<<Unit does not ignite when water goes through the water heater>>
・Refer to the “Power supply circuit” and “Water circuit” in this section.
・If you use the remote controller, turn the power button on and then check if the
set temperature will be displayed on the screen.
・Check if the filter on the cold water inlet is cleaned (Part #406).
A. Troubleshooting <<The fan motor is still spinning after operation has stopped>>
・This is normal. After operation has stopped, the fan motor keeps running from 15 to 70
seconds in order to re-ignite quickly, as well as purge all the exhaust gas out of the flue.
<<Abnormal sound from water heater>>
・An abnormal sound from the water heaters is caused by not enough air supply or wrong
installations. The water heater needs more combustion air. Refer to the “10” error code
in the section B.
<<Power supply circuit>>
1. If the remote controller is installed, press the “ON/OFF” button of the remote controller, and
make sure that the set temperature is displayed on the remote controller.
Restart the water heater.
2. Check if the Red LED on the PCB (Part #701) of the water heater is lit for a few seconds right
after the power is supplied. If so, the power supply circuit of the water heater is under
normal condition. Next, refer to the “Water circuit” in this section.
3. Check the fuse on the surge box (Part #703), and if it has a brown spot, need to replace it.
4. Check the power supply, and make sure that the water heater has 120 VAC.
5. If the Red LED on the PCB (Part #701) isn’t lit, some electrical parts can be broken. Consult
the manufacturer.
<<Water circuit>>
1. If you use the remote controller, turn the power button on and then check if the
set temperature will be displayed on the screen.
2. Open all hot water faucets, and make sure that there is enough water flow. This
water heater needs at least 0.5 GPM water flow (at the default set temperature) to operate.
3. Check for reverse connection and cross connection.
4. Check if the filter on the cold water inlet is cleaned (Part #406).
5. Check if there is no debris or obstruction on the fixtures.
6. Check if water ways in the water heater are frozen. If so, unfreeze them. And refer to the
Installation manual to protect your water heater from freezing.
7. Check if the inlet water pressure is higher than 40 psi. And if it’s lower than 40 psi, need
to increase the pressure.
8. Check for connections and breakage of wires (Part #402).
9. Check if the motor drive of the flow adjustment valve (Part #402) is locked due to scale
buildup, and/or water leakage. If so, Consult the manufacturer.
ATKJ2
D. DIPswitch settings on the computer board of the water heater
Change the DIPswitch settings when the power supply is turned off.
The dark square is the direction the DIPswitch should be set to. DEFAULT is the factory setting.
High-altitude function
DEFAULT
(0 to 2,000 ft.)
OFF
ON
1 2 3 4 5 6 7 8
FM+
(2,000 to 4,000 ft.)
OFF
ON
1 2 3 4 5 6 7 8
FM++
(4,000 to 6,000 ft.)
OFF
ON
1 2 3 4 5 6 7 8
FM speed is increased automatically.
The numbers in parentheses below are the numbers of blinking of the Red LED on the PCB to indicate the error codes.
DIPswitches
The DIPswitches have certain special functions and generally should not need adjustment.
They have settings for four functions, shown below.
The Gas type DIPswitch should already be properly preset from the factory.
Gas type
Propane
OFF
ON
1 2 3 4 5 6 7 8
Natural gas
OFF
ON
1 2 3 4 5 6 7 8
Model type
110 Indoor
(T-KJr2-IN)
OFF
ON
1 2 3 4 5 6 7 8
110 Outdoor
(T-KJr2-OS)
OFF
ON
1 2 3 4 5 6 7 8
The Model type DIPswitch should already
be properly preset from the factory.
Temperature set
113 °F
(45 °C)
OFF
ON
1 2 3 4 5 6 7 8
122 °F (50 °C)
Default
OFF
ON
1 2 3 4 5 6 7 8
131 °F
(55 °C)
OFF
ON
1 2 3 4 5 6 7 8
140 °F
(60 °C)
OFF
ON
1 2 3 4 5 6 7 8
W: WHITE
R: RED
BK: BLACK
P: PURPLE
LB: LIGHT BLUE
BL: BLUE
G: GREEN
Y: YELLOW
O: ORANGE BR: BROWN
7 8
3
9
53
73
G
W
BK
BK
BK
LB
G
O
R
BL
BLBL
BL
BL
BL
BL
W
YBL
O
R
ＢＫ
ＷＲ
W
R
Y
G
O
65432
1
BK
R
BK
OFF
PP
PP
BR
BR
120 VAC
G
BK
W
W
BK
BR
BR
W
BK
BK
Remote
controller
Flow
Adjust
Valve
Gas
Propor-
tional
Valve
Surge
box
Trans-
former
IG
Hi-
limit
MV
SV1
SV3
FM
Flow
Sensor
Inlet
thermistor
Outlet
thermistor
Dipswitches
Increase button
Decrease button
MIN button
MAX button
Red LED
Ground
Heater
Heater
Thermostat
Ground
SW
SV2
O.H.C.F
PCB
Igniter rod
Air-fuel ratio rod
Flame rod Ground
AA1
A2
B
B1
C1
C2
C
G
I
H1
H2 J
F
E1
E2
A3
9007666005
(TK-RE02)

E. Components diagram / Parts list
Case assembly
Temperature
remote controller
722
110 Outdoor (T-KJr2-OS)110 Indoor (T-KJr2-IN)
052
004
001
720
704
721
052
702
003 052
052
007
002
051
050
052
004
001
704
006
053
005
066
056
052
053
702
052
007
002
050
Water outlet secon
C456
460
409
454
408 064
455
410
Water inlet secon
B
402
461
458
052
415
064
460
456
404
406
457
405
454
407
Water way assembly
C
B
451
414
401
414
063
412
450
452
413 453
463
Burner assembly
101
709
111
712
110
065
108
107 106
109
105
104
059
052
053
706
121
703
053
704
705
053
053
059
103
112
113
114
708
150
102
119
151
118
052
062
055
714
053
711
712
053
120
053
067
053
701
713
058
115
061
055
401
101
709
111
Burner assembly
Manifold
Assembly
110 Indoor (T-KJr2-IN) only
Exhaust secon for
110 Outdoor (T-KJr2-IN)
401
153
154
053
152
Item
#
Part #
Description
110
model
T-KJr2
model
001 319143-159
319143-172
EK415
EK432
Case assembly for 110 Indoor (T-KJr2-IN)
for 110 Outdoor (T-KJr2-OS)
002 319143-163
319143-173
EK419
EK433
Front cover for 110 Indoor (T-KJr2-IN)
for 110 Outdoor (T-KJr2-OS)
003
004
005
006
007
319143-150
319143-184
319143-014
319143-128
319143-338
EK401
EKJ09
EKJ64
EKJ66
EX00M
Air blockage plate for 110 Indoor (T-KJr2-IN)
Bracket
Junction box
Junction box inner plate
Back guard panel for 110 (T-KJr2) model
050
051
052
053
319143-025
319143-325
319143-026
319143-060
EW000
EW001
EW002
EW003
Screw M4×12 (W/Washer)
Screw M4×10 (W/Washer)
Screw M4×10 (Coated)
Screw M4x10
054
055
056
319143-326
319143-063
319143-372
EW004
EW005
EX014
Hex head screw M4×12 (W/Washer)
Hex head screw M4x8
Screw M4x10
058
059
061
062
063
064
065
066
067
319143-327
319143-061
319143-201
319143-062
319143-087
319143-328
319143-059
319143-143
319143-048
EW008
EW00H
EKK31
EW006
EW00A
EW009
EW00D
EC00X
EM167
Screw M3x10
Pan screw M4x12 (W/Washer)
Tap tight screw M4x12 FEZN
Pan screw M4x10
Screw M3x6
Screw M4x6
Pan screw M4x8
Nylon clamp
Wire clamp 60
Item
#
Part #
Description
110
model
T-KJr2
model
101 319143-161 EK417 Burner assembly for 110 (T-KJr2) model
102 319143-169
319143-165
EK429
EK421
Manifold with gas valve assembly LP for 110
(T-KJr2) model
Manifold with gas valve assembly NA for 110
(T-KJr2) model
103 319143-347 EX02E Fan motor for 110 (T-KJr2) model
104 319143-341 EX00V Burner holder gasket for 110 (T-KJr2) model
105
106
107
319143-031
319143-033
319143-034
EKK2X
EKK2V
EKK2W
Burner gasket
Burner window
Rod holder gasket
108 319143-339 EX00R Flame rod for 110 (T-KJr2) model
109 319143-373 EX00S Igniter rod for 110 (T-KJr2) model
110
111
319143-340
319143-038
EX00U
EKN61
Rod holder for 110 (T-KJr2) model
Rod cap
112 319143-170 EK430 Burner damper for 110 (T-KJr2) model
113
114
115
319143-044
319143-045
319143-160
EKK2Y
EKK2K
EK416
Manifold gasket A
Manifold gasket B
Fan damper for 110 Indoor (T-KJr2-IN)
118
119
120
319143-050
319143-049
319143-051
EKK1E
EKK2Z
EKK1B
Gas inlet
Gas inlet ring
Igniter plate
121 319143-213 EKK4H Surge box plate for 110 (T-KJr2)
150
151
152
319143-350
319143-057
319143-370
EZP18
EK042
EK442
O-ring P18 NBR (Black)
O-ring P20 NBR (Black)
Silicon ring for 110 Outdoor (T-KJr2-OS)
153 319143-216 EKK53 Rain protection plate in Exhaust chamber
for 110 Outdoor (T-KJr2-OS)
154 319143-219 EKK56 Exhaust port
Item
#
Part #
Description
110
model
T-KJr2
model
401 319143-162
319143-166
EK418
EK426
Heat exchanger assembly
for 110 Indoor (T-KJr2-IN)
for 110 Outdoor(T-KJr2-OS)
402 319143-167 EK427 Flow adjustment valve/Flow sensor for
110 (T-KJr2)
404
405
406
319143-193
319143-197
319143-198
EKK1U
EKK2B
EKK2C
Water inlet
Inlet drain plug
Inlet water filter
407 319143-214 EKK4J Inlet thermistor for 110 (T-KJr2)
408 319143-218 EKK55 Outlet thermistor for 110 (T-KJr2)
409
410
319143-194
319143-199
EKK1V
EKK2E
Water outlet
Outlet drain plug
412 319143-228 EM212 Hi-Limit switch for 110 (T-KJr2)
413
414
415
319143-149
319143-200
319143-078
EK333
EKK2R
EKK2P
Overheat-cut-off fuse
Heater
Inlet heater
450
451
452
453
454
319143-088
319143-125
319143-066
319143-146
319143-082
EKK27
EK031
EKK26
EK029
EZM04
Pipe heater fixing plate
Heater fixing plate 16
Fuse fixing plate 18
Fuse fixing plate 14
O-ring P4 FKM
455
456
457
319143-080
319143-100
319143-091
EZM06
EZM14
EZM15
O-ring P6 FKM
O-ring P14 FKM
O-ring P15 FKM
458
460
461
463
319143-083
319143-105
319143-226
319143-065
EZM16
EKK24
EM192
EKN50
O-ring P16 FKM
Fastener “14-22”
Fastener “16A”
Silicon ring for 110 Indoor (T-KJr2)
Computer board assembly
719 408 407
402 402 714
709
707
701
710
708
103
Item
#
Part #
Description
110
model
T-KJr2
model
701
702
319143-164
319143-182
EK420
EKH09
Computer board for 110 (T-KJr2) model
Transformer
703
704
319143-168
319143-427
319143-222
EK428
EK146
EKK5M
Surge box
AC120V wire for Indoor models
AC120V wire for 110 Outdoor (T-KJr2-OS)
705 319143-155 EK408 Transformer wire for 110 (T-KJr2) model
706
707
319143-141
319143-154
EKK4V
EK407
AC120V Power ON-OFF switch
Switch wire for 110 (T-KJr2) model
708 319143-207 EKK3K Gas valve wire for 110 (T-KJr2)
709 319143-171 EK431 Flame rod wire for 110 (T-KJr2) model
710 319143-209
319143-210
EKK3R
EKK40
EH-IG wire for 110 Indoor (T-KJr2-IN)
EH-IG wire with freeze protection thermostat
for 110 Outdoor (T-KJr2-OS)
711
712
319143-052
319143-039
EKN74
EKK2M
Igniter
High voltage igniter cable
713 319143-185 EKJ59 Freeze protection thermostat for
110 Indoor (T-KJr2-IN)
714
719
319143-220
319143-212
EKK58
EKK49
Proportional gas valve wire for 110 (T-KJr2)
Computer board cover for 110 (T-KJr2)
720
721
319143-426
319143-425
EK148
EW022
Rubber grommet for Indoor models
Cable strap for Indoor models
722 9007666005 TK-RE02 Temperature remote controller for 110 (T-KJr2)