Rheem Technical Service Bulletin
1-800-432-8373
PowerVent with Honeywell Electronic Control
(PowerVent ESII and PowerVent ESII with Electronic Control)
Service Mode and Control Settings
Service Mode (Electronic Control Only)
Service Mode is entered by pressing down and holding all keys for 5 seconds. Alarm history of the connected appliance is displayed, alarms are indexed by "E1" for most recent alarm, "E2" for second alarm to "E9" for ninth alarm (alarm history can be scrolled by pressing "Up" and "Down" keys). Displayed alarm history can be cleared by pressing "Clear" key. If the alarm history is empty, dashes "--" are displayed instead of "E1", "E2" to "E9" and particular error numbers. Setup Mode is closed and enters User Mode after 5 minutes of user inactivity or when "Done" key is pressed.
Control Settings
| Setting | Value | Setting | Value |
|---|---|---|---|
| Set point Range | 90°F (32°C) to 160°F (71°C) | Flame Prove Igniter Off | 0.5 µA |
| "HOT" Set point | 120°F (49°C) | Flame Prove RUN | 0.7 µA |
| Differential | 15°F (9°C) | Flame Lost | < 0.5 µA |
| ECO Limit | 199°F (93°C) | Strong Flame | ≥ 1.5 µA |
Timings
| Ignition State | Timing |
|---|---|
| Soft Lockout | 5 minutes; then retries for main burner |
| ECO Limit Lockout | Indefinite |
| Flammable Vapor Sensor Lockout | Indefinite |
| Hardware Error Lockout / Hard lockout | Indefinite |
| Pre-purge | 2 seconds |
| Trial For Ignition | 90 seconds |
| Flame Stabilization Period | 3 seconds |
| Inter-purge | 90 seconds |
| Flame Failure Response Time | 1.5 seconds |
| Post-purge | 30 seconds |
| Pressure Switch Fault Delay (failed open/closed) | 2 minutes |
Error Code Flash Display
| Display Code | Gas Valve "Status" Flash Code | Control Status |
|---|---|---|
| None | Short flash once every four seconds | IDLE (no call for heat, no fault conditions) |
| None | "Heartbeat", alternates bright/dim | Call For Heat (no fault conditions) |
| 12 | One Flash, three second pause | Low flame signal (control continues to operate) |
| 44 | Two Flash, three second pause | Pressure switch failed closed |
| 46 | Three Flash, three second pause | Pressure switch failed open |
| 31 | Four Flash, three second pause | Thermal Cut Off limit lockout |
| 14 | Five Flash, three second pause | Flame out of sequence |
| 11 | Six-One Flash, three second pause | Failed trial for ignition |
| 45 | Six-Two Flash, three second pause | Recycle limit - PS/limit opened |
| 13 | Six-Three Flash, three second pause | Recycle limit - flame lost |
| 10 | Six-Five Flash, three second pause | Hard Lockout; manual reset required |
| 47 | Seven Flash, three second pause | Flammable vapor sensor lockout |
| 49 | Eight-One Flash, three second pause | FVS fault detected |
| 89 | Eight-Two Flash, three second pause | Temperature sensor fault detected |
| 15 | Eight-Three Flash, three second pause | Electronics fault detected |
| 93 | Eight-Four Flash, three second pause | Valve fault detected |
Troubleshooting: No Power or No Blower Motor
Indications: Nothing happens at all. No blower motor; no sounds.
Display: There is not a display code for this problem.
Troubleshooting Steps:
- Check wall plug power with a table lamp.
- Check that the unit is plugged in.
- Verify gas control switch is ON.
- Verify power to the gas control through the black wire (pin #1) on the gas valve Molex. Turn up thermostat on gas valve; observe blinking blue light; otherwise replace control.
- Turn thermostat all the way up. Verify power to the blower at the yellow wire (pin #3) on the gas valve Molex. Replace blower if there is power on the yellow wire, but no blower motor. Replace control if you have power on the black wire and not on the yellow wire.
Error Code Troubleshooting
Error 10: Hard Lockout
Indications: The control is in hard lockout.
Troubleshooting Steps:
- Low gas supply pressure
- Carbon buildup on electrode
- Igniter Wire damage
- Pilot tube restriction
- Main burner supply tube restriction
Display:
Six-Five Flash, three second pause
Solution:
- See Error Code history for most recent fault code (on DISPLAY models only).
- This lockout can only be cleared by manually cycling the control power.
Error 11: Failed Trial for Ignition
Indications: Failed trial for ignition; Maximum ignition attempts. If flame is not sensed during the Trial period, the igniter turns off, the pilot valve closes, the control runs the inducer through Post-purge then turns off the inducer and enters Soft Lockout and flashes the Soft Lockout error code. The control remains in Soft Lockout for 5 minutes before responding to the demand for heat. If the control has entered Soft Lockout three times, the control will enter hard lockout.
Troubleshooting Steps:
- Low gas supply pressure
- Carbon buildup on electrode
- Igniter Wire damage
- Combustion air blockage
- Pilot tube restriction
Display:
Six-One Flash, three second pause
Solution:
- Verify gas pressure with rating plate on water heater.
- Clean spark electrode and pilot hood with steel wool.
- Verify igniter spark at electrode.
- Verify air inlet holes on side of water heater are clean and clear.
- Inspect pilot tube for obstructions.
- This lockout can only be cleared by manually cycling the control power.
Error 12: Low Flame Signal
Indications: Low flame signal (control continues to operate)
Troubleshooting Steps:
- Low gas supply pressure
- Carbon buildup on electrode
- Pilot tube restriction
Display:
One Flash, three second pause
Solution:
- Verify gas pressure with rating plate on water heater.
- Clean spark electrode and pilot hood with steel wool.
- Inspect pilot tube for obstructions.
Error 13: Flame Lost During RUN
Indications: Flame lost during RUN: During the heating cycle, the pilot flame is lost. The control turns off the pilot and main valves, runs Inter-purge, increments the Recycle Count and, if the Recycle count limit has not been reached, begins another Trial for Ignition. If the Recycle Count Limit has been reached, the control enters soft lockout. The control remains in soft lockout for 15 minutes before responding to the Demand for Heat. This clears the Recycle Count to allow for another set of "Recycle Count Limit" recycles. A total of three such sets of ignition trials including the first ignition trial set to be attempted. If the control has entered soft lockout for the total number of ignition trials as specified above the control will enter hard lockout. This lockout can be cleared by manually cycling the control power.
Troubleshooting Steps:
- Check pilot flame to insure flame is not lifting away from flame sense hood – when main burner ignites.
- Check static and dynamic gas supply to insure pressure is maintained when main burner lights.
- Check for leaking pilot supply tube.
- Check for carbon/soot buildup on pilot grounding strap.
- Baffle or Baffle collar is not in correct position.
Display:
Six-Three Flash, three second pause
Solution:
- Verify gas pressure with rating plate.
- Clean pilot supply hood to enhance flame rectification readings.
- Reposition pilot igniter into proper position.
- Replace pilot igniter.
- If blower motor is hot to the touch, then inspect baffling and baffle collar.
- Inspect baffle and baffle collar for proper positioning.
Error 14: Flame Sensed Out Of Sequence
Indications: Flame Sensed Out Of Sequence - the control only looks for pilot flame when the inducer is running. If flame is present when the pilot valve is not open, the control proceeds to Wait Flame Lost and flashes the Flame out Of Sequence error code. Blower remains on.
Troubleshooting Steps:
- Pilot or main burner valve has failed open.
Display:
Five Flash, three second pause
Solution:
- Recycle heater to verify error code.
- Replace gas control valve.
Error 15: Electronics Fault Detected
Indications: Electronics fault detected - The electronic control module contains a relay for communicating with the display.
Troubleshooting Steps:
- Panel fault.
- Gas control fault.
Display:
Eight-Three Flash, three second pause
Solution:
- Recycle heater to verify error code.
- Replace display panel.
- Replace gas control valve.
Error 31: ECO Limit Lockout
Indications: ECO limit lockout - Water temperature sensed in excess of ECO limit (199°F) - the control immediately turns off pilot and main valves and enters ECO Limit Lockout. During ECO Limit Lockout, the inducer motor runs continuously.
Troubleshooting Steps:
- Thermal well fault (see below).
- Gas control fault.
Display:
Four Flash, three second pause
Solution:
- The sensed water temperature must be below 120°F.
- Power must be cycled to remove the control from ECO limit hard lockout.
Water temperature sensor fault: Measure the OHMS resistance between pins 1 and 2; then measure the resistance between pins 3 and 2. The two numbers should be the same. See chart on last page to convert OHMS to temperature.
Diagram Description: A simple circuit diagram shows a temperature sensor with pins labeled 1, 2, 3, and ECO, connected to a multimeter measuring resistance (Ω).
Error 44: PS Failed Closed
Indications: PS Failed Closed at start of Call for Heat - the control waits four seconds then begins to flash error code (44). The control waits 2 minutes, and then turns on the inducer for 30 seconds. The inducer shuts off after 30 seconds and the control returns to waiting for the pressure switch to open. The control will attempt this sequence 5 times before entering into a hard lockout.
Troubleshooting Steps:
- Pressure switch tube blockage.
- Faulty pressure switch.
Display:
Two Flash, three second pause
Solution:
- Inspect pressure switch tube for blockage.
- Do continuity test on pressure switch. If there is continuity, replace pressure switch.
- The hard lockout will require a manual power cycle of the control to clear the hard lockout.
Error 45: Recycle Limit - PS/Limit Opened
Indications: Recycle limit - PS/limit opened – Maximum number of retries has occurred. Unit is in hard lock-out.
Troubleshooting Steps:
- Check venting to insure pressure switch is not momentarily opening as the appliance warms.
- Check vent outlet for wind-gust problems.
- Check PS wiring.
- Check PS rubber tube for blockage.
- Check over temp switch.
- Faulty pressure switch.
Display:
Six-Two Flash, three second pause
Solution:
- Correct any PVC vent issues.
- Repair wiring or clear tube blockage.
- Replace pressure switch.
- The hard lockout will require a manual power cycle of the control to clear the hard lockout.
Error 46: Pressure Switch Failed Open
Indications: Pressure switch failed open (failed to close) – at the beginning of the heat cycle the control runs the inducer for 30 seconds waiting for the Pressure Switch to close. If the PS does not close in 30 seconds, the inducer turns off and the control flashes PS Failed Open error code. The control waits in this PS Failed Open mode for 2 minutes before turning on the inducer and trying for another 30 seconds to see the PS close. This cycle repeats for a maximum of five times before entering a hard lockout.
Troubleshooting Steps:
- Vent blockage or improper installation.
- Switch tube blockage.
- Faulty pressure switch.
- Blower improper operation.
- Over temperature switch open.
Display:
Three Flash, three second pause
Solution:
- Inspect venting run for blockage.
- Verify over temp switch is cool to the touch.
- Inspect pressure switch tube for blockage.
- Check blower for proper operation.
- Replace pressure switch.
- The hard lockout will require a manual power cycle of the control to clear the hard lockout.
TIP: Rule out the water heater with the following process. Remove all PVC venting from the blower assy. Recycle water heater for main burner. ✓ IF the water heater goes to main burner, then the water heater is not at fault. Check venting. IF the water heater does NOT go to main burner, then we have a part problem with the water heater.
Error 47: Flammable Vapor Sensor Lockout
Indications: Flammable vapor sensor lockout - The control immediately turns off all outputs (valves closed, inducer off, ignition off). Control enters hard lockout and registers Flammable Vapor Present error code.
Troubleshooting Steps:
- Gasoline or other flammable gas (hydrocarbons) was detected by the flammable vapor sensor.
Display:
Seven Flash, three second pause
Solution:
- Check for flammable vapors around water heater.
- Verify FVS sensor resistance ~ 11 KΩ -45 KΩ.
- Replace FVS sensor if >45 KΩ.
- Reset gas control valve. Hard lockout to be cleared when the power is manually cycled, the control dial is rotated through the HOT setting 7 times within 30 seconds and the resistance of the sensor is within the normal operation range.
Error 49: FVS Fault Detected
Indications: FVS fault detected - The control immediately turns off all outputs (valves closed, inducer off, ignition off) and enters Hardware Error Lockout and registers Flammable Vapor Device Interface/Miswiring error code.
Troubleshooting Steps:
- Flammable vapor sensor resistance is out of range (well below or well above parameters).
- Wiring to FV sensor is faulty (open).
- Gas control is faulty.
Display:
Eight-One Flash, three second pause
Solution:
- Verify FVS sensor resistance ~ 11 KΩ -45 KΩ.
- Replace sensor and wiring harness.
- Replace control if new sensor does not work.
- Hard lockout will be cleared when the power is manually cycled, the control dial is rotated through the HOT setting 7 times within 30 seconds and the resistance of the sensor is within the normal operation range.
Error 89: Thermal Well Fault
Indications: Thermal well fault - Temperature Sensors not reading the same temperature within ± 5.5 °F (measure when water temperature is changing less than 1 °F/minute) - the control immediately turns off all outputs (valves closed, inducer off, ignition off) and enters Hardware Fault Lockout. Hardware Fault Lockout self clears if the fault clears for at least 15 seconds.
Troubleshooting Steps:
- Thermal well fault.
- Water temperature sensor fault. Measure the OHMS resistance between pins 1 and 2; then measure the resistance between pins 3 and 2. The two numbers should be the same. See chart on last page to convert OHMS to temperature.
Display:
Eight-Two Flash, three second pause
Solution:
- Recycle power to verify error.
- Replace thermal well.
- Recycle power to verify error.
- Replace thermal well.
Diagram Description: A simple circuit diagram shows a temperature sensor with pins labeled 1, 2, 3, and ECO, connected to a multimeter measuring resistance (Ω).
Error 91: Communications Error
Indications: Communications Error - when display does not detect any gas control valve. User display is periodically checking the connection to the water heater.
Troubleshooting Steps:
- Display and gas control valve are not talking to each other.
Display:
None. Heater works without remote. This error code is for the display only.
Solution:
- Recycle power to verify error.
- Verify control molex correct at gas valve.
Error 93: Valve Fault Detected
Indications: Valve fault detected.
Troubleshooting Steps:
- Gas control valve needs to be reset or has been damaged.
Display:
Eight-Four Flash, three second pause
Solution:
- Recycle power to verify error.
- Replace gas control.
Reset Gas Control
This will clear the current fault and force the unit to recycle for ignition.
- Turn temperature control knob all the way clockwise.
- Recycle power to the heater (both blower and gas valve).
- Rotate the temp knob all the way to the left, then back to the right. You must cross the midline seven (7) times to reset the gas valve.
- Unit should return to normal operations if all faults have been cleared and repaired. You will hear the blower motor come on.
- Set water temperature to a safe setting of 120°F or less.
Replacing the Gas Control
The electronic component for the gas valve is replaceable without draining the water from the tank. To replace just the electronic control portion:
- Turn off the blower and the gas valve. Unplug the water heater.
- Remove wiring harnesses from the gas valve.
- Remove main burner supply tube and pilot supply tube.
- Remove / disconnect gas supply line.
- Grab the bottom of the gas valve (at the main burner supply tube area) and lift up and out at the same time. There are two small plastic locking tabs that will release.
- The electronic component will slide up and off the thermal well still installed in the tank.
- Replace the control in reverse order.
- Reconnect fuel supply lines and tubes.
- Reconnect wiring harnesses.
- Recycle power to the water heater.
- Set the water temperature not to exceed 120° F.
- Check for safe water heater operations.
Temperature to Resistance Thermistor Chart (10kΩ Resistor)
| F° | Resistance | F° | Resistance | F° | Resistance |
|---|---|---|---|---|---|
| 32 | 32,654 | 91 | 7,096 | 153 | 1,943 |
| 34 | 34,367 | 93 | 6,806 | 154 | 1,876 |
| 36 | 32,654 | 95 | 6,530 | 156 | 1,813 |
| 37 | 31,030 | 97 | 6,266 | 158 | 1,752 |
| 39 | 29,498 | 99 | 6,014 | 160 | 1,693 |
| 41 | 28,052 | 100 | 5,774 | 162 | 1,637 |
| 43 | 26,686 | 102 | 5,546 | 163 | 1,582 |
| 45 | 25,396 | 104 | 5,327 | 165 | 1,530 |
| 46 | 24,171 | 106 | 5,117 | 167 | 1,480 |
| 48 | 23,013 | 108 | 4,918 | 169 | 1,431 |
| 50 | 21,913 | 109 | 4,727 | 171 | 1,385 |
| 52 | 20,883 | 111 | 4,544 | 172 | 1,340 |
| 54 | 19,903 | 113 | 4,370 | 174 | 1,297 |
| 55 | 18,972 | 115 | 4,203 | 176 | 1,255 |
| 57 | 18,090 | 117 | 4,042 | 178 | 1,215 |
| 59 | 17,255 | 118 | 3,889 | 180 | 1,177 |
| 61 | 16,464 | 120 | 3,743 | 181 | 1,140 |
| 63 | 15,714 | 122 | 3,603 | 183 | 1,104 |
| 61 | 15,000 | 124 | 3,469 | 185 | 1,070 |
| 63 | 14,323 | 126 | 3,340 | 187 | 1,037 |
| 64 | 13,681 | 127 | 3,217 | 189 | 1,005 |
| 66 | 13,071 | 129 | 3,099 | 190 | 974 |
| 68 | 12,493 | 131 | 2,986 | 192 | 944 |
| 70 | 11,942 | 133 | 2,878 | 194 | 915 |
| 72 | 11,418 | 135 | 2,774 | 196 | 889 |
| 73 | 10,921 | 136 | 2,675 | 198 | 861 |
| 75 | 10,449 | 138 | 2,579 | 199 | 836 |
| 77 | 10,000 | 140 | 2,488 | 201 | 811 |
| 79 | 9,571 | 142 | 2,400 | 203 | 787 |
| 81 | 9,164 | 144 | 2,315 | 205 | 764 |
| 82 | 8,776 | 145 | 2,235 | 207 | 742 |
| 84 | 8,407 | 147 | 2,157 | 208 | 721 |
| 86 | 8,056 | 149 | 2,083 | 210 | 700 |
| 88 | 7,720 | 151 | 2,011 | 212 | 680 |
| 90 | 7,401 |
Connection Diagram
The connection diagram illustrates the wiring of the PowerVent ESII with Honeywell Electronic Control. Key components and their connections are:
- Inducer: Connected to the control module.
- Pressure Switch (NO - Normally Open): Connected to the control module.
- Inducer Temperature Switch (NC - Normally Closed): Connected to the control module.
- Electronic Control Module: Features terminals labeled 1 through 5, and others like TS1, TS2, FV, and common.
- Gas Valve: Connected to the control module via terminals 1, 2, 3.
- Terminal Box: Connects field wiring (120VAC, Neutral, Ground) to the display and control module.
- Display: Connects to the terminal box.
- Pilot Electrode Assembly: Connected to the gas valve.
Wire Color Codes:
- BK = BLACK
- BL = BLUE
- G = GREEN
- R = RED
- W = WHITE
- Y = YELLOW
The diagram shows power inputs (120VAC, 24VAC) and how sensors (temperature, pressure) and actuators (inducer, gas valve) are wired to the electronic control.
