Rinnai Tankless Water Heater Performance and Diagnostics

Performance Data

To Obtain Performance Data:

1. Press and hold the [Down] button.
2. While holding the [Down] button for 2 seconds, press and hold the [On/Off] button (hold both buttons simultaneously).
3. Use the [Up] and [Down] buttons to scroll to the desired performance information.

Performance Data Table

Note on Cycle Counts:

• Combustion Cycles: x100 (0 to 99,900)
• Pump Cycles: x10,000 (100,000 to 990,000)
• Additional Controllers Connected: x1,000,000 (1,000,000 to 6,000,000)

Controller Connection Status:

• MC: Connected [1], Not Connected [0]
• BC: Connected [_1_], Not Connected [_0_]
• BSC & BSC2: Connected [2__ (QTY2)], Not Connected [0__]

Default display is 100. '_' depends on connection status of another controller.

Parameter Settings

To Adjust the Parameters:

1. Press the [A] button for 1 second.
2. Use the [Up] and [Down] buttons on the controller to select a setting number (See Parameter Settings Table).
3. Once the desired setting number is selected, use the [On/Off] button on the controller to change the selection for the setting number. Example: Display will change from 01A to 01b for Maximum Temperature setting.
4. To exit the parameters, press the [A] button on the PC board for 1 second.

Parameter Settings Table

Manifold Pressure Settings

Ensure gas pressure check under Commissioning has been completed first. The regulator is electronically controlled and factory pre-set. Adjustments are typically not required unless the unit is not operating correctly and all other possible causes have been eliminated.

Procedure:

1. Turn off the gas supply.
2. Turn off the 120 V power supply.
3. Remove the front panel from the appliance.
4. Turn on the 120 V power supply.
5. Check the gas type using the data plate on the side of the unit and parameter setting 10 (A=LPG, b=NG).
6. Remove sealing screw and attach the manometer to the burner test point on the manifold.
7. Turn on the gas supply.
8. Flow water through the water heater at the maximum flow rate obtainable (at least 3 gallons per minute recommended to prevent shut-off or damage).
9. Press and hold the [B] button. "IF" will appear on the display.
10. Press and hold the [A] button. "Forced Low" will appear on the display.
11. Press and hold the [A] button again. "Forced High" will appear on the display.
12. While in "Forced Low" or "Forced High", use the [Up] button to increase pressure and the [Down] button to decrease pressure.
13. To exit "Forced Low" or "Forced High", press and hold the [B] button. "2L" will appear on the display.
14. Press and hold the [B] button again. "3C" will appear on the display (Indoor models only).
15. Press and hold the [B] button again. "4t" will appear on the display.
16. Press and hold the [B] button again. The set temperature will appear on the display (indoor models only).
17. Close hot water taps.
18. Turn off the gas supply and 120 V power supply.
19. Remove the manometer and re-install sealing screw.
20. Turn on the gas supply and 120 V power supply.
21. Operate the unit and check for gas leaks.
22. Install the front panel.

Note: For additional installation and commissioning information, refer to the Installation and Operation Manual.

WARNING: This appliance must be installed, serviced and removed by a trained and qualified person. During pressure testing of the consumer piping, ensure the gas valve is turned off before the unit is shut off. Failure to do so may result in serious injury or damage.

Commissioning Gas Pressure Requirements

With all gas appliances in operation at maximum gas rate, the following inlet gas pressure at the incoming test point on the Rinnai water heater should read:

• Natural Gas: 4 in. wc - 10.5 in. wc
• Propane Gas: 8 in. wc - 13.0 in. wc

If the pressure is lower, the gas supply is inadequate. Check the gas meter regulator and pipework for correct operation/sizing and correct as required.

Note: The table seems to have a slight discrepancy in how the "Forced Low" and "Forced High" values are presented relative to the model numbers. The provided text lists them separately. I will present them as they appear.

Electrical Diagnostics

Visit www.rinnai-lms.com for additional troubleshooting resources.

Note: Wiring diagram is available in the manual and on the inside front cover.

Important Safety Notes: Live tests are required. Proceed with caution to avoid contact with energized components. Only trained and qualified service technicians should attempt repair. Before checking resistance, disconnect power and isolate the component.

Component Testing

• Freeze Protection: Units have freeze protection heaters. All should display a positive resistance reading.
• Flame Rod: Place meter leads on the flame rod and ground. When attempting ignition, read more than 0.5VAC.
• Amp Fuses: Two glass fuses on the PC Board: one 10A, one 4A. Check continuity. (RE140i/e does not have a 4A fuse).
• Thermistors: Check resistance by inserting meter leads into each end of the thermistor plug. Use the 20 K scale. Applying heat should decrease resistance; applying ice should increase resistance.

Typical Thermistor Resistance Readings

Electrical Circuit Table

(* Value to be measured while unit is in operation)

Diagnostic Codes Display

To Display Diagnostic Codes:

1. Turn off the water heater using the [On/Off] button.
2. Press and hold the [On/Off] button for 2 seconds, then press and hold the [Up] button simultaneously.
3. The last 9 maintenance codes will display and flash sequentially.
4. To exit diagnostic codes and return to normal operation, press and hold the [On/Off] button for 2 seconds, then press and hold the [Up] button simultaneously.
5. Turn on the water heater using the [On/Off] button.

Troubleshooting Diagnostic Codes

Code 1 0: Air Supply or Exhaust Blockage

• Ensure approved venting materials are used.
• Check that nothing is blocking the flue inlet or exhaust.
• Check all vent components for proper connections.
• Ensure vent length matches parameter settings.
• Verify High Altitude setting is correct.
• Check fan for blockage.

Code 1 1: No Ignition (Heater Not Turning On)

• Check gas supply at heater, meter, or cylinder. Ensure propane tank has gas.
• Bleed air from the gas line.
• Ensure appliance is properly grounded.
• Ensure gas type and pressure are correct.
• Ensure gas line, meter, and/or regulator are sized properly.
• Verify parameter settings are correct.
• Ensure igniter is operational and wiring harness is not damaged.
• Check gas solenoid valves for open circuits.
• Ensure flame rod wire is connected and check flame rod for carbon build-up.
• Remove burner cover and ensure burners are seated properly.
• Remove burner plate; inspect burner surface for condensation/debris.
• Check the ground wire for the PC board.

Code 1 2: No Flame

• Check gas supply at heater, meter, or cylinder. Ensure propane tank has gas.
• Check for obstructions in the flue outlet.
• Ensure gas line, meter, and/or regulator are sized properly.
• Ensure gas type and pressure are correct.
• Bleed air from gas lines.
• Ensure proper venting material was installed and condensation collar is correct.
• Ensure vent length is within limits.
• Verify parameter settings are correct.
• Check power supply for loose connections, proper voltage, and voltage drops.
• Ensure flame rod wire is connected and check flame rod for carbon build-up.
• Disconnect and reconnect all wiring harnesses.
• Check gas solenoid valves for open circuits.
• Remove burner plate; inspect burner surface for condensation/debris.

Code 1 4: Thermal Fuse

• Check for restrictions in air flow around unit and vent terminal.
• Check gas type of unit matches gas type being used.
• Check for low water flow in a circulating system causing short-cycling.
• Check for foreign materials in combustion chamber and exhaust piping.
• Check heat exchanger for cracks or separations.
• Check heat exchanger surface for hot spots (scale build-up). Refer to manual for flushing instructions. Treat hard water.
• Measure resistance of safety circuit.
• Ensure high fire and low fire manifold pressure is correct.
• Check for improper gas conversion.

Code 1 6: High Outgoing Temperature

• Check for restrictions in air flow around unit and vent terminal.
• Check for low water flow in a circulating system causing short-cycling.
• Check for foreign materials in combustion chamber and exhaust piping.
• Check for blockage in the heat exchanger.
• Check the thermistor sensor and clean sensor of scale build-up.

Code 1 9: Electrical Grounding

• Check all components for electrical short.

Code 32: Outgoing Water Temperature Thermistor

• Check sensor wiring for damage.
• Measure resistance of sensor (See Electrical Diagnostics).
• Clean sensor of scale build-up.
• Replace sensor if necessary.

Code 33: Heat Exchanger Thermistor

• Check sensor wiring for damage.
• Measure resistance of sensor (See Electrical Diagnostics).
• Replace sensor if necessary.

Code 34: Combustion Air Temperature Thermistor Fault

• Check for restrictions in air flow around unit and vent terminal.
• Check sensor wiring for damage.
• Measure resistance of sensor.
• Ensure fan blade is tight on motor shaft and in good condition.
• Replace sensor if necessary.

Code 41: Freeze Protection Thermistor

• Check sensor wiring for damage.
• Measure resistance of sensor (See Electrical Diagnostics).
• Replace sensor if necessary.

Code 51: Inlet Water Temperature Thermistor

• Check sensor wiring for damage.
• Measure resistance of sensor (See Electrical Diagnostics).
• Replace sensor if necessary.

Code 52: Modulating Solenoid Valve Signal

• Check modulating gas solenoid valve wiring harness for loose or damaged terminals.
• Measure resistance of valve coil.

Code 6 1: Combustion Fan

• Ensure fan turns freely.
• Check wiring harness to motor for damage/loose connections.
• Measure resistance of motor winding.

Code 6 3: Recirculation Low Flow

• Ensure the inlet water filter is clean.
• Ensure parameter settings are correct for recirculation mode.
• Ensure pump supply voltage.
• Check wiring harness to pump and PCB for damage/loose connections.
• Ensure air is removed from the recirculation line.

Code 6 5: Water Flow Servo

• Measure resistance and voltage of the water flow control.
• Ensure harness and connector are not wet.
• If PC Board voltage is abnormal, replace PC Board; otherwise, replace water flow servo valve.

Code 6 6: Bypass Flow Servo

• Measure resistance and voltage of the bypass servo valve.
• Ensure harness and connector are not wet.
• If PC Board voltage is abnormal, replace PC Board; otherwise, replace bypass servo valve.

Code 7 0: PC Board

• Check connection harness at the PC board.
• Replace PC board.

Code 7 1: Solenoid Valve Circuit

• Ensure dip switch on PC board is OFF.
• Check gas solenoid valves for short circuits or grounding.
• Ensure heater circuit is not grounded.
• Replace PC Board.

Code 7 2: Flame Sensing Device

• Verify flame rod touches flame during firing.
• Check flame rod and wire for damage.
• Remove flame rod; check for carbon build-up; clean with sandpaper.
• Check inside burner chamber for foreign material blocking flame at flame rod.
• Check resistance to the cabinet.
• If no issue with flame rod or wiring, replace PC Board.

Code 7 9: Water Leak Detected

• Turn off water supply and contact a licensed professional.

Code LC: Scale Build-up in Heat Exchanger (When checking maintenance code history, "00" is substituted for "LC")

• LC indicates scale build-up in the heat exchanger; flush the heat exchanger to prevent damage. Refer to flushing instructions in the manual. Treat hard water.
• After flushing, reset LC code as instructed.
• Contact Rinnai technical department.

Code SS: Service Soon (Flush Heat Exchanger)

• SS is a time-based service indicator set during installation. Refer to parameter settings for details.
• SS indicates it is time for service; flush the heat exchanger to prevent damage. Treat hard water.
• To reset the SS code, press [On/Off] button on the temperature controller 5 times in 5 seconds.

NO CODE: Nothing happens when water flow is activated

• Clean inlet water supply filter.
• On new installations, ensure hot and cold water lines are not reversed.
• Verify minimum flow rate required to fire the unit.
• Check for cold-to-hot cross-over. Isolate circulating system if present. Turn off cold water to the unit, open pressure relief valve; if water continues to flow, there is bleed-over in plumbing.
• Verify turbine spins freely.
• Measure the resistance of the water flow control sensor.
• If display is blank and clicking is heard, disconnect the water flow servo motor. If display comes on, replace the water flow servo motor.

Code FF: Maintenance Indicator

• Placeholder for maintenance/service performed.
• To display FF: Press and hold [Up] and [Down] buttons simultaneously for 2 seconds after performing service.
• FF is visible on the monitor.

Parts List

Thermal Fuse Location: When replacing the heat exchanger, the thermal fuse must be properly installed and secured. The illustration shows the general placement of thermal fuses on the heat exchanger flanges.

The following table lists replacement parts for Rinnai models RE199e, RE180e, RE160e, and RE140e.

Rinnai America Corporation continually updates materials, and as such, content is subject to change without notice. For further information, contact Rinnai at 1-800-621-9419 or visit www.rinnai.us.