American Water Heater 701022 Water Heater User Manual
Contents
1. 6 VDC 4 G1 ion Yellow White Unit in operating mode 15 35 ohms G1 Frost Protection Red White Ground G1 10 13 VDC 1 5 3 0 K ohms B GROUND COLOR CODING oe H5 W BK e ll Ena This unit has frost protection heaters mounted at different points to protect the water heater from freezing The heaters located on the C1 hot water outlet line should have a resistance reading of 180 207 ohms through each of these heaters The heater located on the heat exchanger piping should have a resistance reading of 156 180 ohms and the one located in the water flow sensor valve should have a resistance reading 24 28 ohms IG Ignition System Grey Grey 90 110 VAC FM Combustion Fan Motor Red Black 6 45 VDC N A E1 White Black 5 10 VDC 9 2 94Kohms E1 Yellow Black 11 13 VDC 3 5 3 9Kohms E1 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 Thermal Fuse Overheat Switch Red White 11 13 VDC Flame Rod Place one lead of your meter to the flame rod and the other to ground With the unit running you should read between 5 150 VAC Set your meter to the u amp scale and series your meter in line with the flame rod You should read 1 u amp or greater for proper flame circuit In the event of low flame circuit remove the flame rod and check2. Attach the pressure gauge to the burner test point located on the gas control Fig 2 Turn ON the gas supply Turn ON the 120 V power supply If a controller is installed turn the unit ON with the controller Select the maximum delivery temperature and open all available hot water taps at full Set the unit to Forced Low combustion by setting No 7 dip switch of the SW1 set to ON Fig 3 10 Check the burner test point pressure 11 Remove the rubber access plug and adjust the regulator screw on the modulating valve Fig 4 as required in Table 1 Replace the rubber access plug 12 Set the unit to Forced High combustion by setting both No 7 and No 8 dip switches of the SW1 set to ON Fig 5 Ensure maximum water flow 13 Check the burner test point pressure 14 Adjust the high pressure potentiometer POT on the PC board as required to the pressure shown in Table 1 15 Return the unit to normal operation by setting dip switches 7 and 8 of the SW1 set back to OFF Fig 6 Close all water taps 16 Turn OFF the gas supply and 120 V power supply 17 Remove the pressure gauge and install sealing screw 18 Turn ON the gas supply and 120 V power supply 19 Operate the unit and check for gas leaks at the test point 20 Install the front panel Temperature Display Indicates temperature setting or flashes error code Air Supply or Exhaust Blockage riority Button When no water is being supplied press
3. for carbon or damage N A PRY SPARK ELECTRODE REMOTE CONTROLLER SURGE PROTECTOR w GND Spare Parts Onl GY GY GNITER 1R Amp Fuses This unit has one inline 3 amp glass fuses Remove the fuse and check continuity through it If you have continuity through the fuse then it is good Otherwise the fuse is blown and must be replaced 2 Unit Connection Optional MODULATING VALVE CURRENT ADJUSTING Gas pressure Gas type F6 H1 Below 1 ohms F6 H12 7 K e Dip SW Dip SW2 MAX MIN E 0 12990999F o9 H gt BR G 705 Indoor 705 Indoor ASME LPG NAT G WRBK rax cy 000999900920 Dip Switches Settings Adjust switches 2 and 3 in the bank of 8 depending on your altitude according to the table below I FLAME ROD 1 Ww 13 m 71 0O Sa The original PC boards on the water heaters do not have the bank of 6 dip switches Only spare PC boards have this bank J W Y BK R TR o core i
4. 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 LC Scale Build up in Heat Exchanger when checking With all gas appliances in operation at maximum gas rate the maintenance code history 00 is substituted for LC flowing inlet pressure at the incoming test point on the Rinnai water heater should read 5 W C 10 5 W C on natural gas and 8 W C 13 5 W C on propane gas If the pressure is lower the gas supply is inadequate and the unit will not operate to specification Check the gas meter regulator and pipework for correct operation sizing and correct as required e Flush heat exchanger Refer to instructions in manual e Replace heat exchanger 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 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 a
5. Controller In Use Indicator Indicates that hot water is being supplied Priority Indicator Indicates that this Gas Pressure Setting Ensure gas pressure check under Commissioning has been completed first The regulator is electronically controlled and factory pre set Under normal circumstances it does not require adjustment during installation Make adjustments only if the unit is not operating correctly and all other possible causes for incorrect operation have been eliminated 02 No burner operation during freeze protection mode e Service Call 03 Power interruption during Bath fill Water will not flow when power returns 16 Over Temperature Warning 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 Turn off all hot water taps Press ON OFF twice controller is setting the water temperature Turn OFF the gas supply Turn OFF the 120 V power supply Remove the front panel from the appliance Check the gas type using the data plate on the side of the unit If using a spare PC board check that the gas type switches are in the correct position dip switch 1 of SW2 ON for natural gas NG and OFF for propane LPG See dip switch settings section below ON is towards the right and OFF is towards the left
6. O D MAAN e A R MBR 0 Y R W P BK R BK BK Y BK gt amp MAIN SOLENOID VALVE Sv TAO COMBUSTION FAN T nm aan 2 IO WV MODULATING SOLENOID VALVE R X BK OPTIONAL WATER FLOW SENSOR Q CENTER SOLENOID VALVE 2 WARNING DO NOT adjust the other dip switches unless specifically instructed to do so Incorrect Dip Switch Settings can cause the water heater to operate in an unsafe condition and may damage the water heater and void the warranty RIGHT FREEZE PROTECTION fG 4 High Altitude SOLENOID VALVE 1 SOLENOID VALVE 3 HEAT EXCHANGER WATER THERMISTOR OUTGOING WATER WATER w OR To OVERHEAT SWITCH BY PASS FLOW CONTROL DEVICE ARNEY THERMAL FUSES WATER FLOW CONTROL DEVICE SW ele oft on 705 Indoor 070 00012 36676 0 No 2 Level 0 Level 1 Level 2 Level 3 High Altitude 0 2000 ft 2001 5200 ft 5201 7700 ft 7701 10200 ft Off 0 610 m 610 1585 m 1585 2347 m 2347 3109 m U273 1373 01 EXPLODED VIEW CABINET EXPLODED VIEW INTERNALS REMOTE CONTROLLER EXPLODED VIEW INTERNALS EXPLODED VIEW ELECT
7. Orange 2 15 VDC 67 81 ohms H2 M Water Flow Control Device Servo or Geared Motor Red Blue 11 13 VDC 22 28 ohms F5 Grey Brown 4 6 VDC N A F5 Grey Yellow N A N A F5 NOTE The grey wire listed above turns to black at F connector on the PCB QS Water Flow Sensor Black Red 11 13 VDC Yellow Black 4 7VDC 59 F 11 4 14K 86 F 6 4 7 8K 113 F 3 6 4 5K 140 F 2 2 2 7K 221 F 0 6 0 8K Outgoing Water Thermistor White White N A Heat Exchanger Temperature Thermistor Pink White N A Surge Protector Black White 108 132 VAC N A D2 1 3 Black White 108 132 VAC N A D1 1 3 With the power off you can check the continuity through the surge protector Place a meter lead on the top pin 1 of the surge protector and pin 3 on the bottom of the surge protector Check across the top pin 3 and bottom pin 1 If you read continuity across these two points then the surge protector is good If you do not get continuity then replace the surge protector Remote Controls Terminals B1 See example above F4 See example above F3 3 11 HEATER w ANTI FROST 5 5 6 2Kohms F2 1 1 4 Mega ohms F2 AC120V HOT NEUTRAL By pass Flow Control Brown White G1 Orange White 2
8. RICAL Quantity PARTS LIST Quantity Quantity 705 705 705 705 705 705 Number Description Parts Number Indoor Indoor ASME Description Parts Number Indoor Indoor ASME Number Description Parts Number Indoor Indoor ASME 001 Casing Assembly 701022 150 1 002 Heat Protection Plate 701022 154 004 Front Panel Assembly 701022 155 005 Remote Controller Packing 701022 159 007 Wall Fitting Bracket 701022 160 010 Front Panel Packing Top 701022 162 011 Front Panel Packing Side 701022 163 012 Connection Reinforcement Panel 701022 164 013 Bag for Installation Manual 701022 165 014 Seal Packing 701022 023 015 Rubber Bushing 701022 008 017 Rubber Bushing 701022 020 018 Reinforcement Plate 701022 166 019 Air Intake Vent 701022 167 020 100 Seal Plate 701022 168 021 Duct Bracket 701022 169 022 Fan Rectifier 701022 170 100 Gas Connection 3 4 NPT 701022 027 101 Screw 701022 171 102 Gas Control Kit 701022 172 103 Manifold Assembly A LPG 701022 173 103 Manifold Assembly B Nat G 701022 174 104 Burner Unit Assembly Nat G 701022 175 104 Burner Unit Assembly LPG 701022 153 113 Combustion Chamber Front Plate 701022 182 114 Combustion Chamber Front Plate Packing 701022 183 115 Electrode Kit 701022 036 116 Flame Rod Kit 701022 184 117 Electrode Packing 701022 185 118 Electrode Holder 701022 039 121 Electrode Sleeve 701022 093 122 Solenoid Valve Cover 701022 186 123 Upper Combustion C
9. er 701022 229 726 Remote Controller Bracket 701022 231 800 Screw 701022 122 801 Washer 701022 232 802 Screw 701022 233 803 Washer 701022 128 804 Screw 701022 234 805 Screw 701022 121 806 Screw 701022 235 807 Screw 701022 236 808 Screw 701022 237 809 Screw 701022 238 810 Screw 701022 125 811 O ring 701022 137 812 O ring 701022 133 813 O ring 701022 134 814 O ring 701022 135 815 O ring 701022 136 816 O ring 701022 130 817 Packing 701022 239 820 Screw 701022 240 821 Screw 701022 241 822 Screw 701022 141 823 Screw 701022 242 824 Screw 701022 142 888 Manual 315897 000 889 Installation Manual Tech Sheet 701022 244 Package Spec Sheet 701022 246 Manual 3 4 Gas Control Valve 701022 247 l l i se ss se ss ss ss ss ss ss es DO OC SC COO Se Se se Se SO COP SO SO a i so st IT Oo aA SS SS SS Ip Ro Oo S _ messes se se se se ss ss sO Ol SC Aa DO Sl OC MSO SO SO al Set Po oO PO PO PND HSH KS KS eK oer tC OPO SE Ss M M M M A Ce O A Po oO Po POND HH HS KS eK oer l OPO Se Ss M M u A ss A ss M tS A A 2 2 wry B YH YH DY w WY oO Cc 2 worm B DH H PDH w WY Oo Cc
10. followed by the A thermostat button to cycle through the error codes 2 To display the water flow through the water heater press the A thermostat button hold for 2 seconds and then press the ON OFF button while continuing to hold the A thermostat button To display the outlet water temperature press the W thermostat button hold for 2 seconds and then press the ON OFF button while continuing to hold the W thermostat button 34 Combustion Air Temperature Sensor Fault 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 To Change the Temperature Scale F C Replace sensor With the water heater turned off press and hold the ON OFF button until the display changes to the other temperature scale about 5 seconds Modulating Solenoid Valve Signal Abnormal e Check modulating gas solenoid valve wiring harness for loose or damage terminals To Turn Off the Controller Sound Mute e Measure resistance of valve coil To turn the sound off mute press and hold both the A and W thermostat buttons until a beep is heard about 5 seconds Flame Failure Check that the gas is turned on at the water heater and gas Combustion Fan Failure meter Check for obstructions in the flue outlet Ensure gas line meter and or regulator is sized pro
11. hamber Packing 701022 187 124 Lower Combustion Chamber Packing 701022 188 125 Heat Exchanger Kit 701022 189 125 Heat Exchanger Kit ASME 701022 158 Flue Outlet Vent Packing 701022 191 1 Flue Outlet Vent Assembly 701022 192 100 Packing 701022 193 Blower Motor 701022 194 Fan Casing Assembly 701022 195 Fan Connecting Bracket 701022 197 Fan Connecting Packing 701022 198 39 Bell Mouth 701022 199 Water Inlet 3 4 NPT 701022 069 Plug Band 701022 200 Water Filter Assembly 701022 082 Water Flow Control Assembly Kit 701022 203 Rectifier 701022 204 Bypass Servo Assembly 701022 074 Stop Bracket 701022 075 Water Flow Servo Cover 701022 205 Hot Water Outlet 3 4 NPT 701022 206 Plug Band 701022 207 Drain Valve 701022 081 Stop Bracket 701022 208 PCB 701022 209 Surge Protector 701022 210 PCB Cover Front 701022 211 PCB Cover Side 701022 088 Ignitor Bracket 701022 213 Ignitor 701022 091 High Tension Cord 701022 214 Ignitor Cover 701022 215 120V Anti Frost Heater Assembly 701022 216 Anti Frost Heater Clip 701022 102 Anti Frost Heater Clip 701022 151 Anti Frost Heater Clip 701022 218 120V Valve Heater Assembly 701022 219 Thermal Fuse Harness 701022 221 Thermal Fuse Clip 701022 222 Thermistor 701022 120 717 Thermistor Clip 701022 095 1 718 Frost Sensing Switch 701022 223 720 Fuse Harness 701022 224 721 Power Supply Harness 701022 226 722 Ignitor Harness 701022 227 723 Sensor Harness 701022 228 724 Power Cord 701022 107 725 Remote Controll
12. ing this button allows this controller to set the water temperature Ensure approved venting materials are being used 32 Outgoing Water Temperature Sensor Fault 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 e Check sensor wiring for damage e Measure resistance of sensor e Clean sensor of scale build up e Replace sensor Thermostat ON OFF Button 33 Heat Exchanger Outgoing Temperature Sensor Fault e Check sensor wiring for damage e Measure resistance of sensor e Clean sensor of scale build up e Replace sensor Diagnostic Use of the Controller 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 multi unit connections 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 1 To display error codes press the ON OFF button
13. perly Ensure gas type and pressure is correct Bleed all air from gas lines Ensure proper 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 multi unit connections 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 e Ensure fan will turn freely e Check wiring harness to motor for damaged and or loose connections e Measure resistance of motor winding Water Flow Servo Faulty does not stop flow properly 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 SVO SV1 SV2 and SV3 Solenoid Valve Circuit Fault e Check wiring harness to all solenoids for damage and or loose connections e Measure resistance of each solenoid valve coil Gas Pressure Setting NOTE For additional installation and commissioning information refer
14. t 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 Heat Exchanger and Outgoing Water Temperature Thermistors Troubleshooting Important Safety Notes Check all thermistors by inserting meter leads into each end of the thermistor plug Set your meter to the 20 K scale and read resistance Applying heat to the thermistor bulb should decrease the resistance Applying ice to the thermistor bulb should increase the resistance See below for examples of typical temperatures and resistance readings Example 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 Only trained and qualified service technicians should attempt to repair this product Before checking for resistance readings disconnect the power source to the unit and isolate the item from the circuit unplug it SV1 SV2 SV3 and POV Gas valve and Modulating solenoids Set meter above 2K Wire color Voltage Resistance Connector _ Pin s Main Pink Black 11 13 VDC 24 28 ohms H3 6 7 SV1 Black Red __ 11 13 VDC 37 43 ohms H4 SV2 Black Orange 11 13 VDC 37 43 ohms H5 SV3 Black Yellow _ 11 13 VDC 37 43 ohms H6 POV Orange
15. to the Operation and Installation Manual A WARNING This appliance must be installed serviced and removed by a trained and qualified person During pressure testing of the consumer piping ensure gas valve is turned off before unit is shut off Failure to do so may result in serious injury to yourself or damage to the unit p High Pressure Potentiometer nine Burner test point GSES zs Flame Sensing Device Fault 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 APPLIANCE OPERATING PRESSURES Fabia Gas Inlet Min Max Forced Low Forced High ji LI LI LI g PG PG PG 5 w c 8 W C 5 F RGI no s w c 713 5 w c 0 67 W C 0 83 W C 3 0 W C 3 7 W C zis JEN g Regulator adjustment screw access plug 705 Indoor 705 Indoor ASME Commissioning Thermal Fuse 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
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