Rinnai R98LSe-ASME User manual

Power interruption during Bath fill (Water will not flow when
power returns)
•Turn off all hot water taps. Press ON/OFF twice.
03
Error Codes
•Ensure 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.
Air Supply or Exhaust Blockage
•Check that the gas is turned on at the water heater and gas
meter. Check for obstructions in the flue outlet.
•Ensure gas line, meter, and/or regulator is sized properly.
•Ensure gas type and pressure is correct.
•Bleed all air from gas lines.
•Ensure proper 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.
•Check flame rod for carbon build-up.
•Disconnect and re-connect all wiring harnesses on unit and PC
board.
•Check all components for electrical short.
•Check gas solenoid valves for open or short circuits.
•Remove burner plate and inspect burner surface for
condensation or debris.
Flame Failure
•Service Call
No burner operation during freeze protection mode
02
10
•Check that the gas is turned on at the water heater, gas meter,
or cylinder.
•Ensure gas type and pressure is correct.
•Ensure gas line, meter, and/or regulator is sized properly.
•Bleed all air from gas lines.
•Verify dip switches are set properly.
•Ensure appliance is properly grounded.
•Disconnect 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.
No Ignition
11
•Check gas type of unit and ensure it matches gas type being
used.
•Check for restrictions in air flow around unit and vent terminal.
•Check for low water flow in a circulating system causing short-
cycling.
•Ensure dip switches are set to the proper position.
•Check for foreign materials in combustion chamber and/or
exhaust piping.
•Check heat exchanger for cracks and/or separations.
•Check heat exchanger surface for hot spots which indicate
blockage due to scale build up. Refer to instructions in manual
for flushing heat exchanger.
•Measure resistance of safety circuit.
•Ensure high fire and low fire manifold pressure is correct.
•Check for improper conversion of product.
Thermal Fuse
14
•Check for restrictions in air flow around unit and vent terminal.
•Check for low water flow in a circulating system causing short-
cycling.
•Check for foreign materials in combustion chamber and/or
exhaust piping.
•Check for clogged heat exchanger.
Over Temperature Warning
16
•Check sensor wiring for damage.
•Measure resistance of sensor.
•Clean sensor of scale build up.
•Replace sensor.
Outgoing Water Temperature Sensor Fault
32
•Check sensor wiring for damage.
•Measure resistance of sensor.
•Clean sensor of scale build up.
•Replace sensor.
Heat Exchanger Outgoing Temperature Sensor Fault
33
•Check for restrictions in air flow around unit and vent terminal.
•Check sensor wiring for damage.
•Measure resistance of sensor.
•Clean sensor of scale build up.
•Ensure fan blade is tight on motor shaft and is in good
condition.
•Replace sensor.
Combustion Air Temperature Sensor Fault
34
•Check modulating gas solenoid valve wiring harness for loose
or damage terminals.
•Measure resistance of valve coil.
Modulating Solenoid Valve Signal Abnormal
52
•Ensure fan will turn freely.
•Check wiring harness to motor for damaged and/or loose
connections.
•Measure resistance of motor winding.
Combustion Fan Failure
61
If blank screen is present on remote control then the flow control
has shorted out. Unplug flow control. If remote lights up and unit
starts operating then replace flow control assembly.
Water Flow Servo Faulty (does not stop flow properly)
65
•Check wiring harness to all solenoids for damage and/or loose
connections.
•Measure resistance of each solenoid valve coil.
SV0, SV1, SV2, and SV3 Solenoid Valve Circuit Fault
71
•Ensure flame rod is touching flame when unit fires.
•Check all wiring to flame rod for damage.
•Remove flame rod and check for carbon build-up; clean with
sand paper.
•Check inside burner chamber for any foreign material blocking
flame at flame rod.
•Measure micro amp output of sensor circuit with flame present.
•Replace flame rod.
Flame Sensing Device Fault
72
•Flush heat exchanger. Refer to instructions in manual.
•Replace heat exchanger.
Scale Build-up in Heat Exchanger (when checking
maintenance code history “00” is substituted for “LC”)
LC
•Clean inlet water supply filter.
•On new installations ensure hot and cold water lines are not
reversed.
•Check for bleed over. Isolate unit from building by turning off
hot water line to building. Isolate the circulating system if
present. Open your pressure relief valve; if unit fires, there is
bleed over in your plumbing.
•Ensure you have at least the minimum flow rate required to fire
unit.
•Ensure turbine spins freely.
•Measure the resistance of the water flow control sensor.
•Remote control does not light up but you have 12 VDC at the
terminals for controls.
No Code (Nothing happens when water flow is activated.)
12
Wiring Diagram
Gas Pressure Setting
Remote Controller
Water
Inlet Max.
Gas Inlet
Min./Max Forced Low
Table 1
Forced High
NAT.G
5"W.C.
/10.5"W.C. 8"W.C. /13.5"W.C.
LPG NAT.G LPG NAT.G LPG
150 PSI 0.65"W.C. 0.80"W.C. 2.8"W.C. 3.8"W.C.
R98LSe
R98LSe-ASME
APPLIANCE OPERATING PRESSURES
U273-1364(00)
Dip Switches Settings
SW NOTES
No.
2
3
Level 0
0-2000ft
(0-610m)
High Altitude Level 1 2001-5200ft
(610-1585m)
Level 2
5201-7800ft
(1585-2377m)
Level 3
7801-10200ft
(2377-3109m)
Off
On
On
Off
On
On
Off
Off
Adjust switches 2 and 3 in the bank of 8 depending on
your altitude according to the table below.
The original PC boards on the water heaters do not
have the bank of 6 dip switches. Only spare PC
boards have this bank.
High Altitude
NAT.GLPG
R98LSe
R98LSe-ASME
1
O
F
F
2
3
4
5
6
7
8
ON
O
F
F
ON
O
F
F
3
4
5
6
7
8
ON
O
F
F
ON
1
2
6
5
4
3
2
11
2
3
4
5
6
should read 5"W.C. - 10.5"W.C. on Natural Gas and 8"W.C. - 13.5"W.C.
WARNING
DO NOT adjust the other dip switches unless specifically instructed
to do so. Incorrect Dip Switch Settings can cause the Rinnai water
heater to operate in an unsafe condition and may damage the water
heater and void the warranty.
(Ensure gas pressure check under Commissioning has been completed
first !)
Check gas type using data plate on side of unit.
If using spare PC board, check gas type switches (Fig.1) are in the
correct position. (dip switch 1 of SW2 ‘ON’ = NG, ‘OFF’ = LPG)
See Dip Switch Settings section below.
Note: ‘ON’ towards right, ‘OFF’ towards left.
Set the Rinnai Water Heater to ‘Forced Low’ combustion by setting
No.7 dip switch of the (SW1) set of dip switches to ‘ON’. (Fig.3).
controller,
R98LSe(VA3237W)
R98LSe-ASME
070 00012 35237 4
A
3 1
W
3
1
B
1 2
O
F F
Dip SW1
3 8 7 6 5 4
F
4
W W
B
1
BK BK
MIN
MAX
MODULATING VALVE CURRENT ADJUSTING
Gas pressure
F
3
W WW
P W
W
OUTGOING WATER WATER THERMISTOR
HEAT EXCHANGER WATER THERMISTOR
Y
BR
O R WBRROYW
BKRW
for REU-EZC (Optional)
1
13
WATER FLOW SENSOR
BK
F
2
Y RR
Y
BK
QS
BY-PASS FLOW CONTROL DEVICE
YBKR
FREEZE PROTECTION (OPTIONAL)
G
WWP
BL
R
BR
Y
GY
WATER FLOW CONTROL DEVICE
R
BL BR
Y
GY
G R
R
BL BR
Y
COMBUSTION FAN FM
R
BK
Y W
E
1
W
4 1
YBKR
1
1
MODULATING SOLENOID VALVE
POV
H
2
O O
H
7
Y
FLAME ROD
H
3
SV1
H
5
H
4
SV0
O
BK
SV2
BK
P R
BK
MAIN SOLENOID VALVE
SOLENOID VALVE 1 (CENTER)
SOLENOID VALVE 2 (LEFT)
YY
OBKOO
(CN2)
RP
W
12 1
SOLENOID VALVE 3 (RIGHT)
H
6Y
BK
SV3
GY
C
1
IG
GY GY
IGNITER GND
GY
FUSE (3A)
BK
W
AC120VAC120V
HOT
NEUTRAL
HOT
NEUTRAL
GROUND
GND
BK
REMOTE CONTROLLER
SPARK
ELECTRODE
5 4
Spare Parts Only
Gas type
1 2 3
O
F F
Dip SW2
6
C
D
E
F
G
H
F
1
G
1
(CN3)
(CN4)
(CN1)
(CN12)
(CN5)
(CN7)
(CN9)
5
3
D
2
D
1
1
WBK
WBK
G/Y
SURGE PROTECTOR
GND
R
W
RR
H
1
F
6
THERMAL FUSES
OVERHEAT SWITCH
R W
COLOR CODING
W :White BK:Black BR:Brown
R :Red
BL:Blue Y :Yellow
P :Pink O :Orange
G :Green
GY:Gray
BL BL
W
W W W W
W
ANTI-FROST HEATER
D
5
D
3
FROST SENSING SWITCH
W
W
D
6
W
W
D
4
WW
W
W
W
1
F
5
A
1
1
G/Y
Regulator adjustment
screw access plug
Burner
test point
SW1
SW2
High Pressure
Potentiometer
1
Spare Parts
Only
Troubleshooting
OutgoingWaterThermistor:
White - White N / A See example above F4 3 - 4
Heat ExchangerTemperatureThermistor:
Pink - White N / A See example above F3 3 - 11
Surge Protector:
Black - White 108 ~ 132 VAC N / A D2 1 - 3
Black - White 108 ~ 132 VAC N / A D1 1 - 3
Remote Controls:
Terminals B1 10 ~ 13 VDC 1.5 ~ 3.0 K ohms B 1 - 3
(SV1, SV2,SV3 and POV) Gas valve and Modulating solenoids: (Set meter above 2K)
(Main) Pink - Black
Wire color Voltage Resistance Connector # Pin #'s
11 ~ 13 VDC 24 ~ 28 ohms H3 6 - 7
(SV1) Black - Red 11 ~ 13 VDC 37 ~ 43 ohms H4 5 - 6
(SV2) Black - Orange 11 ~ 13 VDC 37 ~ 43 ohms H5 4 - 6
(M)Water Flow Control Device Servo or Geared Motor:
NOTE:The grey wire listed above turns to black at F connector on the PCB.
Set your meter to the hertz scale. Reading across the white and black wires at terminals 2 and 4
you should read between 60 and 420 hertz.
Grey - Brown 4 ~ 6 VDC N / A F5 5 - 7
Red - Blue 11 ~ 13 VDC 22 ~ 28 ohms F5 9 - 10
(QS)Water Flow Sensor:
Black - Red 11 ~ 13 VDC 5.5 ~ 6.2 K ohms F2 1 - 3
(IG) Ignition System:
Grey - Grey 90 ~ 110VAC N / A C1 1 - 2
Yellow - Black 4 ~ 7 VDC 1 ~ 1.4 Mega ohms F2 2 - 3
Thermal Fuse / Overheat Switch:
Red - White 11 ~ 13 VDC Below 1 ohms F6 F6 - H12
H1
Grey -Yellow N / A N / A F5 5 - 8
(FM) Combustion Fan Motor:
White - Black 5 ~ 10 VDC 9.2 ~ 9.4 K ohms E1 2 - 4
Red - Black 6 ~ 45 VDC N / A E1 1 - 2
Yellow - Black 11 ~ 13 VDC 3.5 ~ 3.9 K ohms E1 2 - 3
By-pass Flow Control:
Orange - White 2 ~ 6VDC 15 ~ 35 ohms G1 2 - 5
Yellow - White (Unit in operating mode) G1 3 - 5
Brown - White G1 1 - 5
Red-White - Ground G1 4 - 5
(SV3) Black -Yellow 11 ~ 13 VDC 37 ~ 43 ohms H6 3 - 6
(POV) Orange - Orange 2 ~ 15 VDC 67 ~ 81 ohms H2 9 - 10
This unit has six frost protection heaters mounted at different points inside the unit, to protect
140°F = 2.2 ~ 2.7KΩ
221°F = 0.6 ~ 0.8KΩ
59°F = 11.4 ~ 14KΩ
86°F = 6.4 ~ 7.8KΩ
113°F = 3.6 ~ 4.5KΩ
This unit has an inline (3) amp glass fuse. Remove the fuse and check continuity through it. If
Heat Exchanger and Outgoing WaterTemperatureThermistors:
#3
Using a voltage meter set on the 200 ohm scale, you should have a resistance reading. The
heater located on the heat exchanger piping should have a resistance reading of 139 ~ 161
ohms and the one located in the water flow sensor valve has a resistance reading of 335 ~ 385
ohms. The one located in the outlet valve has a resistance reading of 335 ~ 385. Voltage
throughout this circuit should be 120 VAC.

EXPLODEDVIEW - CABINET EXPLODEDVIEW - INTERNALS
EXPLODEDVIEW - ELECTRICALEXPLODEDVIEW - INTERNALS
PARTS LIST
Parts Number
109000067
H73-065
109000069
BU195-121
BU195-167
AU103-106
U273-115
CP-80736
AU105-113
BU56-602-N
109000071
CF79-41020-A
U273-113
CU195-1866
AU39-965
C36Q-7-AS
U273-200-A
U273-200-B
U273-240
106000024
U273-235
106000025
U211-266-2
U211-267
104000023
U250-295
AH66-398
AH66-393
AU206-218
U211-1027
U211-264
U211-268
U273-275-C-S
U273-1390-C
Quantity
R98LSe
1
1
1
2
1
2
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
-
R98LSe-ASME
1
1
1
2
1
2
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
-
1
Description
Casing Assembly
Heat Protection Plate
Front Panel Assembly
Wall Installation Bracket
Front Panel Packing-Top
Front Panel Packing-Side
Connection Reinforcement Panel
Bag for Installation Manual
Seal Packing
Cable Access
Cable Access Packing
Rubber Bushing
Reinforcement Plate
Gas Connection(3/4"NPT)
Screw
Gas Control Assembly
Manifold Assembly-A(LPG)
Manifold Assembly-B(Nat.G)
Burner Unit Assembly(LPG)
Burner Unit Assembly(Nat.G)
Damper(LPG)
Damper(Nat.G)
Combustion Chamber Front Plate
Combustion Chamber Front Plate Packing
Electrode
Flame Rod
Electrode Packing
Electrode Holder
Electrode Sleeve
Solenoid Valve Cover
Upper Combustion Chamber Packing
Lower Combustion Chamber Packing
Heat Exchanger Complete Assembly
Heat Exchanger Complete Assembly
Number
001
002
004
007
010
011
012
013
014
015
016
017
018
100
101
102
103
103
104
104
105
105
113
114
115
116
117
118
121
122
123
124
125
125
R98LSe-ASME
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
2
1
Quantity
R98LSe
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
2
1
Parts Number
U211-351
U211-352
AH24-653-4
U250-565
CH51-615
U273-335
U211-552
U273-330-A
H73-501-2
U250-631
H98-510-S
107000019
M8D1-15
M6J-1-4
AH69-310
H112-508
U273-320
AU103-413
AU142-444
U211-322
105000053
105000014
U273-355-US
105000016
U273-225
EI-144
BH38-710-240
U273-226
U273-380
CF29-742
105000027
AU124-618
U273-381
105000055
Number
131
132
133
150
151
153
154
156
400
401
402
405
406
407
408
409
410
411
412
413
700
701
702
703
704
705
706
707
708
709
710
711
712
714
Description
Flue Outlet
Flue Outlet Packing
Flue Outlet Packing-4
Blower Motor
Fan Casing Assembly
Fan Connecting Bracket
Fan Connecting Packing
Fan Motor All Assembly
Water Inlet (3/4"NPT)
Plug Band
Water Filter Assembly
Water Flow Servo & Sensor Assembly
Rectifier
Bypass-Servo Assembly
Stop Bracket
Water Flow Servo Cover
Hot Water Outlet (3/4"NPT)
Plug Band
Drain Valve
Stop Bracket
PCB
Surge Protector
PCB Cover-Front
PCB Cover-Side
Ignitor Bracket
Ignitor
High Tension Code
Ignitor Cover
120V Anti Frost Heater Assembly
Anti Frost Heater Clip
Anti Frost Heater Clip
Anti Frost Heater Clip
120V Valve Heater Assembly
Thermal Fuse Harness
Parts Number
CP-80531
H111-650
CP-90172
H73-750
U273-370
105000056
U273-372
105000057
CP-30580
AU33-184
ZBD0508UD
AU48-174
ZFDB0408UD
CP-30583
CP-80452
ZFDB0412SZ
CP-30627-412
CP-20883-408UK
U217-449
M10B-1-24
M10B-2-18
M10B-2-16
M10B-2-14
M10B-2-7
M10B-2-4
C36F8-1
ZQAA0512UK
ZQAA0514UK
ZQAA0508UK
ZBA0512UK
100000040
100000050
100000047
R98LSe-ASME
9
2
1
1
1
1
1
1
4
4
2
5
8
5
1
5
2
3
1
1
3
1
2
1
2
1
1
4
2
3
1
1
1
Quantity
R98LSe
9
2
1
1
1
1
1
1
4
4
2
5
8
5
1
5
2
3
1
1
3
1
2
1
2
1
1
4
2
3
1
1
1
Description
Thermal Fuse Clip
Thermistor
Thermistor Clip
Frost Sensing Switch
Fuse Harness
Power Supply Harness
Ignitor Harness
Sensor Harness
Screw
Washer
Screw
Washer
Screw
Screw
Screw
Screw
Screw
Screw
Screw
O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
Packing
Screw
Screw
Screw
Screw
Operation/Instruction Manual
Tech Sheet
Front Panel Label(98)
Number
715
716
717
718
720
721
722
723
800
801
802
803
804
805
806
807
808
809
810
811
812
813
814
815
816
817
821
822
823
824
888
889
900
703