Rinnai Service Manual

Tankless Water Heater Service Manual
This manual provides service information for the models below. This table cross references each model to the applicable page number for internal component replacement instructions. WIRE DIAGRAM GAS CONTROL DIAGNOSTICS WATER FLOW CONTROL HEAT EXCHANGER PC BOARD Key to Trade Names in this Manual: R/C Indicates both the residential and commercial versions. R/C42e includes R42e and C42e. Indicates condensing water heater models.
RC
MODELS
(PLUS) Indicates that the Designer Plus models are included. R/C85ePLUS includes R85e, C85e, and R85ePLUS. On the side of the water heater, the trade name includes a D, as in R85De. (ASME) Indicates that the ASME models are included. R98LSe(ASME) includes the R98LSe and R98LSeASME. -VA,-VB The trade names R75LSe, R75LSi, R94LSe, and R94LSi have been given to both the VA and VB series of water heaters. Pay close attention to the particular model number when referencing electrical diagnostics, wire diagrams, gas pressures, replacement instructions, and for parts. When there is a difference VA or VB will be specified.
R/C42e, R/C53e R70e, R/C85e(PLUS) R/C53i(PLUS), R/C85i(PLUS) R/C98e(ASME) R/C98i(ASME) V53e, R63LSe R50LSi, R75LSi-VA R63LSe2, R75LSe-VA R94LSe-VA R94LSi-VA R75LSe-VB R75LSi-VB R94LSe-VB R94LSi-VB V53i R98LSe(ASME) R98LSi(ASME) RC80HPe RC80HPi RC98HPe RC98HPi
10 12 12 14 14 16 18 18 18 18 20 20 20 20 20 22 22 24 24 26 26
28 29 30 31 31 32 33 33 33 33 34 34 34 34 35 36 36 37 37 38 38
41 43 43 45 45 41 43 43 43 43 47 47 47 47 43 45 45 47 47 48 48
49 50 51 52 52 49 51 50 50 51 50 51 50 51 51 52 52 53 53 53 53
FAN
54 56 56 56 56 55 56 56 56 56 56 56 56 56 56 58 58 56 56 56 56
59 65 65 67 67 60 63 63 63 63 63 63 63 63 63 67 67 68 68 68 68
69 72 76 80 82 69 76 72 72 76 72 76 72 76 76 80 82 85 88 91 94
Some of the trade names for models were changed to indicate that their cartons included isolation valves and a pressure relief valve. For service and repair purposes the table below shows the equivalent models. Model with valves in carton RV53e RV53i RL75e RL75i RL94e RL94i RC80e RC80i RC98e RC98i Equivalent Model V53e V53i R75LSe-VB R75LSi-VB R94LSe-VB R94LSi-VB RC80HPe RC80HPi RC98HPe RC98HPi 100000098 Rev B
Table of Contents
General Information ....................................................3 Specifications .......................................................... 4-6 Schematic Diagrams ............................................... 7-9 Diagnostic Codes .................................................. 8-10 Electrical Diagnostic Points R/C42e, R/C53e, ................................................. 10, 11 R70e, R/C85e(PLUS), R/C53i(PLUS), R/C85i(PLUS) ............................. 12, 13 R/C98e(ASME), R/C98i(ASME) ........................... 14, 15 V53e, R63LSe ...................................................... 16, 17 R50LSi, R63LSe2, R75LSe-VA, R75LSi-VA, R94LSe-VA, R94LSi-VA ...................................... 18, 19 V53i, R75LSe-VB, R75LSi-VB, R94LSe-VB, R94LSi-VB ...................................... 20, 21 R98LSe(ASME), R98LSi(ASME) ......................... 22, 23 RC80HPe, RC80HPi ............................................ 24, 25 RC98HPe, RC98HPi ............................................ 26, 27 Wire Diagrams R/C42e, R/C53e ..........................................................28 R70e, R/C85e(PLUS) ..................................................29 R/C53i(PLUS), R/C85i(PLUS).....................................30 R/C98e(ASME), R/C98i(ASME) ..................................31 V53e, R63LSe .............................................................32 R50LSi, R63LSe2, R75LSe-VA, R75LSi-VA, R94LSe-VA, R94LSi-VA .............................................33 R75LSe-VB, R75LSi-VB, R94LSe-VB, R94LSi-VB ....34 V53i .............................................................................35 R98LSe(ASME), R98LSi(ASME) ................................36 RC80HPe, RC80HPi ...................................................37 RC98HPe, RC98HPi ...................................................38 Flushing the Heat Exchanger...................................39 Manual Draining of the Water Heater ......................40 Gas Control Assembly R/C42e, R/C53e, V53e, R63LSe ......................... 41, 42 R/C53i(PLUS), R70e, R/C85e(PLUS), R/C85i(PLUS), R50LSi, V53i, R63LSe2, R75LSe-VA, R75LSi-VA, R94LSe-VA, R94LSi-VA ...................................... 43, 44 R/C98e(ASME), R/C98i(ASME), R98LSe(ASME), R98LSi(ASME) ......................... 45, 46 RC80HPe, RC80HPi, R75LSe-VB, R75LSi-VB, R94LSe-VB, R94LSi-VB .............................................47 RC98HPe, RC98HPi ...................................................48 Fan R/C42e, R/C53e, V53e, R63LSe................................ 49 R70e, R/C85e(PLUS), R63LSe2, R75LSe, R94LSe........................................................ 50 R/C53i(PLUS), R/C85i(PLUS), R50LSi, V53i, R75LSi, R94LSi ................................................. 51 R/C98e(ASME), R/C98i(ASME), R98LSe(ASME), R98LSi(ASME) ............................... 52 RC80HPe, RC80HPi, RC98HPe, RC98HPi ............... 53 PC Board R/C42e, R/C53e ......................................................... 54 V53e, R63LSe ............................................................ 55 R/C53i(PLUS), R70e, R/C85e(PLUS), R/C85i(PLUS), R50LSi, R63LSe2, V53i, R75LSe, R75LSi, R94LSe, R94LSi, RC80HPe, RC80HPi, RC98HPe, RC98HPi .......... 56-57 R/C98e(ASME), R/C98i(ASME), R98LSe(ASME), R98LSi(ASME) ............................... 58 Water Flow Control Assembly R/C42e, R/C53e ................................................... 59, 60 V53e, R63LSe ...................................................... 61, 62 R/C53i, R70e, R50LSi, R63LSe2, V53i, R75LSe, R75LSi ................................................... 63, 64 R/C85e(PLUS), R/C85i(PLUS), R94LSe, R94LSi ................................................... 65, 66 R/C98e(ASME), R/C98i(ASME), R98LSe(ASME), R98LSi(ASME) ............................... 67 RC80HPe, RC80HPi, RC98HPe, RC98HPi ............... 68 Heat Exchanger R/C42e, R/C53e, V53e, R63LSe........................... 69-71 R70e, R/C85e(PLUS), R63LSe2, R75LSe, R94LSe................................................... 72-75 R/C53i(PLUS), R/C85i(PLUS), V53i, R50LSi, R75LSi, R94LSi ....................................... 76-79 R/C98e(ASME), R98LSe(ASME) .......................... 80-81 R/C98i(ASME), R98LSi(ASME) ............................ 82-84 RC80HPe .............................................................. 85-87 RC80HPi................................................................ 88-90 RC98HPe .............................................................. 91-93 RC98HPi................................................................ 94-96 Gas Pressure Setting Procedure ....................... 97-98 Manifold Pressure Settings .............................. 99-105 Dip Switches .................................................... 106-108
Rinnai Water Heater Service Manual
100000098 Rev B
General Information
Safety Definitions
This is the safety alert symbol. This symbol alerts you to potential hazards that can kill or hurt you and others.
DANGER WARNING CAUTION

Using this Manual
Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury. It may also be used to alert against unsafe practices.
Repairs should be performed by a qualified service technician. The following information can be referenced for additional information. Operation and Installation Manual Hot Water System Design Manual Technical Sheets Technical Bulletins
Technical Support
Technicians are available to assist in servicing issues. Contact Rinnai Technical Services at 1-800-621-9419.
Recommended Tools
Volt/Ohm/Amp meter with test probes Digital manometer or U tube type manometer with 14 inch water column (W.C.) scale, a hose and two 1/8 inch taps assorted wrenches including a 3/16 Allen wrench assorted screw drivers leak solution or leak detector Teflon tape
WARNING
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. Before checking for resistance readings disconnect the power source to the unit and isolate the item from the circuit (unplug it).
CAUTION
Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. If any of the original wire as supplied with the appliance must be replaced, it must be replaced with type 18 AWG wire or its equivalent.
100000098 Rev B
Specifications
V Series - Commercial - Outdoor
Trade Name Model Max. BTU Min. BTU 17,100 (NG) 17,800 (LP) 19,000 (NG) 20,200 (LP) 15,000 15,000 19,000 19,000 Max Flow [1] gal/min (liters/min) 4.2 5.3 8.5 8.5 9.8 9.8 (16) (20) (32) (32) (37) (37) Temperature Range
C42e C53e C85e C85ePLUS C98e C98eASME
REU-V1616WC REU-V2020WC REU-V2532WC REU-V2532WCD REU-V3237WC REU-V3237WC-ASME
120,000 150,000 199,000 199,000 237,000 237,000
120 - 185 F (49-85 C) 120 - 185 F (49-85 C) 98 - 185 F (37-85 C) 98 - 185 F (37-85 C) 98 - 185 F (37-85 C) 98 - 185 F (37-85 C)
V Series - Commercial - Indoor

Trade Name C53i C53iPLUS C85i C85iPLUS C98i C98iASME Model REU-V2520FFUC REU-V2520FFUCD REU-V2532FFUC REU-V2532FFUCD REU-V3237FFUC REU-V3237FFUC-ASME Max. BTU 180,000 180,000 180,000 180,000 237,000 237,000 Min. BTU 15,000 15,000 15,000 15,000 19,000 19,000 Max Flow [1] gal/min (liters/min) 5.3 5.3 8.5 8.5 9.8 9.8 (20) (20) (32) (32) (37) (37) Temperature Range 120 - 185 F (49-85 C) 120 - 185 F (49-85 C) 98 - 185 F (37-85 C) 98 - 185 F (37-85 C) 98 - 185 F (37-85 C) 98 - 185 F (37-85 C)
V Series - Residential - Outdoor

Trade Name Model Max. BTU Min. BTU 17,100 (NG) 17,800 (LP) 19,000 (NG) 20,200 (LP) 15,000 15,000 15,000 19,000 19,000 Max Flow [1] gal/min (liters/min) 4.2 5.3 7.0 8.5 8.5 9.8 9.8 (16) (20) (26) (32) (32) (37) (37) Temperature Range
R42e R53e R70e R85e R85ePLUS R98e R98eASME
REU-V1616W REU-V2020W REU-V2526W REU-V2532W REU-V2532WD REU-V3237W REU-V3237W-ASME
120,000 150,000 199,000 199,000 199,000 237,000 237,000
98 - 140 F (37-60 C) 98 - 140 F (37-60 C) 98 - 140 F (37-60 C) 98 - 140 F (37-60 C) 98 - 140 F (37-60 C) 98 - 140 F (37-60 C) 98 - 140 F (37-60 C)
V Series - Residential - Indoor

Trade Name R53i R53iPLUS R85i R85iPLUS R98i R98iASME Model REU-V2520FFU REU-V2520FFU REU-V2532FFU REU-V2532FFUD REU-V3237FFU REU-V3237FFU-ASME Max. BTU 180,000 180,000 180,000 180,000 237,000 237,000 Min. BTU 15,000 15,000 15,000 15,000 19,000 19,000 Max Flow [1] gal/min (liters/min) 5.3 5.3 8.5 8.5 9.8 9.8 (20) (20) (32) (32) (37) (37) Temperature Range 98 - 140 F (37-60 C) 98 - 140 F (37-60 C) 98 - 140 F (37-60 C) 98 - 140 F (37-60 C) 98 - 140 F (37-60 C) 98 - 140 F (37-60 C)
[1] Minimum activation flow is approximately 0.6 gallons/minute (2.3 liters/min)
100000098 Rev B
Specifications
VA Series (LS Series) - Residential or Commercial - Outdoor
Trade Name R63LSe R63LSe2 R75LSe R75LSe R94LSe R98LSe Model Max. BTU 150,000 150,000 199,000 180,000 199,000 237,000 237,000 Min. BTU 21,500 (NG) 20,600 (LP) 15,000 15,000 15,000 15,000 19,000 19,000 Max Flow [1] gal/min (liters/min) 6.3 6.3 7.5 7.5 9.4 9.8 9.8 (24) (24) (28) (28) (35) (37) (37) 98 - 140 F (37-60 C) [3] 98 - 140 F (37-60 C) [2] Temperature Range
REU-VA2024WD-US REU-VA2024WD(A)-US REU-VA2528WD-US REU-VA2528WD(A)-US REU-VA2528WD(A)-UC REU-VA2535WD-US REU-VA2535WD-UC REU-VA3237W-US
R98LSeASME REU-VA3237W-ASME
VA Series (LS Series) - Residential or Commercial - Indoor

Trade Name R50LSi R75LSi R75LSi Model REU-VA2019FFUD-US REU-VA2528FFUD-US REU-VA2528FFUD(A)US REU-VA2528FFUD(A)UC REU-VA2535FFUD-US REU-VA2535FFUD-UC REU-VA3237FFU-US REU-VA3237FFU-ASME Max. BTU 150,000 199,000 180,000 199,000 (NG) 190,000 (LPG) 237,000 237,000 Min. BTU 15,000 15,000 15,000 Max Flow [1] gal/min (liters/min) 5.0 7.5 7.5 (19) (28) 98 - 140 F (37-60 C) [2] (28) Temperature Range
R94LSi R98LSi R98LSiASME
15,000 19,000 19,000
9.4 9.8 9.8
(35) (37) (37) 98 - 140 F (37-60 C) [3]
VA Series - Residential - Outdoor

Trade Name Model Max. BTU Min. BTU 19,000 (NG) 20,200 (LP) Max Flow [1] gal/min (liters/min) 5.3 (20) Temperature Range
V53e
REU-VAM1620W-US
120,000
98 - 140 F (37-60 C)
[1] Minimum activation flow is approximately 0.6 gallons/minute (2.3 liters/min) [2] Max temperature is 160 F (71 C) with the MCC-91 controller for commercial and hydronic applications only. [3] Max temperature is 185 F (85 C) with the MCC-91 controller for commercial and hydronic applications only.
100000098 Rev B
Specifications
VB Series (LS Series) - Residential or Commercial - Outdoor
Trade Name R75LSe, RL75e R94LSe, RL94e Model Max. BTU 180,000 199,000 Min. BTU 9,900 (NG) 10,300 (LPG) 9,900 (NG) 10,300 (LPG) Max Flow [1] gal/min (liters/min) 7.5 9.4 (28) (35) Temperature Range 98 - 140 F (37-60 C) [2] 98 - 140 F (37-60 C) [3]
REU-VB2528WD-US REU-VB2735WD-US
VB Series (LS Series) - Residential or Commercial - Indoor

Trade Name Model Max. BTU Min. BTU 9,900 (NG) 10,300 (LPG) Max Flow [1] gal/min (liters/min) 7.5 9.4 (28) (35) Temperature Range
R75LSi, RL75i REU-VB2528FFUD-US R94LSi, RL94i REU-VB2735FFUD-US
180,000
98 - 140 F (37-60 C) [2] 98 - 140 F (37-60 C) [3]
199,000 (NG) 9,900 (NG) 190,000 (LPG) 10,300 (LPG)
VB Series - Residential - Indoor

Trade Name V53i, RV53i Model REU-VB2020FFU-US Max. BTU 150,000 Min. BTU 15,000 Max Flow [4] gal/min (liters/min) 5.3 (20) Temperature Range 98 - 140 F (37-60 C)
Condensing Series - Residential or Commercial - Outdoor

Trade Name RC80HPe, RC80e RC98HPe, RC98e Model Max. BTU 157,000 199,000 Min. BTU 9,500 (NG) 10,300 (LPG) 9,500 (NG) 10,300 (LPG) Max Flow [1] gal/min (liters/min) 8.0 9.8 (30) 98 - 140 F (37-60 C) [3] (37) Temperature Range
REU-KA2530WD-US REU-KA3237WD-US
Condensing Series - Residential or Commercial - Indoor

Trade Name RC80HPi, RC80i RC98HPi, RC98i Model Max. BTU Min. BTU 9,500 (NG) 10,300 (LPG) 9,500 (NG) 10,300 (LPG) Max Flow [1] gal/min (liters/min) 8.0 9.8 (30) 98 - 140 F (37-60 C) [3] (37) Temperature Range
REU-KA2530FFUD-US REU-KA3237FFUD-US
157,000 199,000
[1] Minimum activation flow is approximately 0.4 gallons/minute (1.5 liters/min); minimum flow is approximately 0.26 gallons/minute (1 liter/min). [2] Max temperature is 160 F (71 C) with the MCC-91 controller for commercial and hydronic applications only. [3] Max temperature is 185 F (85 C) with the MCC-91 controller for commercial and hydronic applications only. [4] Minimum activation flow is approximately 0.6 gallons/minute (2.3 liters/min).
100000098 Rev B
Diagnostic Codes
The Rinnai water heater has the ability to check its own operation continuously. If a fault occurs, an error code will flash on the display of the remote controller. This assists with diagnosing the fault and may enable you to overcome a problem without a service call.
WARNING
Some of the checks below may need to be done by a qualified service technician. Call a service technician for any remedy that involves gas or electricity. Call a service technician if you have any doubt or reservation about performing the remedy yourself.
Accessing Operating Information

Models MC-91 and MCC-91 To display the most recent error codes press and hold the On/Off button for 2 seconds. While holding the On/ Off button press the button. The last 9 error codes will flash one after the other. To exit this mode press the On/Off and button as before. To display the water flow through the water heater press and hold the button for 2 seconds and without releasing the button press the On/Off button. To display the outlet water temperature press and hold the button for 2 seconds and without releasing the button press the On/Off button.
Operation
1. Water Flow Begins. 4. Shut-down Sequence.
Water Flow Sensor sends pulses to the PC

Board.
Shut-down begins when the PC Board senses

the minimum flow rate which is 0.26 - 0.5 gpm depending on model. Gas control valve closes. Water flow control valve resets to standby position. Combustion fan runs for a short period of time at low speed.
PC Board senses flow. Firing Sequence begins when the flow exceeds
the minimum activation flow rate. 2. Firing Sequence. PC Board monitors inlet/outlet water temperature, temperature set point, and water flow rate. 5. Combustion fan energized. Purges combustion chamber. Spark igniter begins sparking. Gas control valve opens to minimum fire rate. Flame rod(s) proves ignition. Spark igniter stops sparking. Normal Operation. PC Board monitors flame rod, fan motor frequency, outlet water temperature, controller temperature set point and water flow rate. Gas control valve modulates gas input to required firing rate. Combustion fan speed is adjusted for the required firing rate. Water flow control valve is adjusted as needed.
Standby Mode.
PC Board monitors water temperature and

remote controls.
Freeze protection is activated as needed.
3.
100000098 Rev B
Diagnostic Codes
Code
02
Definition
No burner operation during freeze protection mode ONLY FOR NONCONDENSING MODELS Power interruption during Bath Fill (Water will not flow when power returns). Air Supply or Exhaust Blockage
Remedy
Service Call
03
Turn off all hot water taps. Press ON/OFF twice.
10
11
No Ignition
12
Flame Failure
14
Thermal Fuse
16
Over Temperature Warning
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. For non-condensing models, ensure condensation collar was installed correctly. Verify dip switches are set properly. Check fan for blockage. Check the fins in the heat exchanger. For condensing models, Burner Sensor Error (see code 31) 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. If flame is visible, check the flame rod circuit. 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. For non-condensing models, 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. Ensure flame rod is in proper position (wire should connect at 6 oclock position). Remove flame rod and check for carbon build-up; clean with sand paper or emery cloth. Disconnect and reconnect 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. Check the ground wire for the PC board. 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. Hard water must be treated to prevent scale build up or damage to the heat exchanger. Measure resistance of safety circuit. Ensure high fire and low fire manifold pressure is correct. Check for improper conversion of product. Check for restrictions in the intake and exhaust system. 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 blockage in the heat exchanger.
100000098 Rev B
Diagnostic Codes
Code
25
Definition
Condensate Trap Error ONLY FOR CONDENSING MODELS Burner Sensor Error ONLY FOR VB AND CONDENSING INDOOR MODELS Outgoing Water Temperature Sensor
Remedy
Condensate container is full. Check condensate drain for blockage. Replace condensate trap. Measure resistance of sensor. Replace sensor. Check sensor wiring for damage. Measure resistance of sensor. Clean sensor of scale build-up. Replace sensor. Check sensor wiring to be sure it has not been short circuited. Measure resistance of sensor. Clean sensor of scale build-up. Replace sensor. Check for restrictions in the intake and exhaust system. Check sensor wiring for damage. Measure resistance of sensor. Clean sensor of scale build-up. Check the fan blade to be sure it is tight on motor shaft and is in good condition. Replace sensor. Check modulating gas solenoid valve wiring harness for loose or damaged terminals. Measure resistance of valve coil. Ensure fan will turn freely. Check wiring harness to motor for damaged and/or loose connections. Measure resistance of motor winding. Check for proper voltage from PC board. The water flow control valve has failed to close during the bath fill function. Immediately turn off the water and discontinue the bath fill function. Contact a state qualified or licensed contractor to service the appliance. Check PC board switches (in the bank of 6 switches, #2 should be on for indoor models and off for outdoor models) Check the connection harness at the E connection on the PC board. Outdoor models should have 2 orange cables at #7 and 8 positions. Indoor models should not have cables at these positions. If this is incorrect then replace the sensor harness. Replace PC board For non-condensing, check wiring harness to all solenoids for damage and/or loose connections. Measure resistance of each solenoid valve coil. For condensing, replace PC board. Verify flame rod is touching flame when unit fires. Check all wiring to flame rod. Remove flame rod and check for carbon build-up; clean with sand paper or emery cloth. 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. Check sensor wiring and PC board to be sure they have not been damaged. Replace sensor. Flush heat exchanger. Refer to instructions in manual. Hard water must be treated to prevent scale build up or damage to the heat exchanger. Replace heat exchanger. NOTE: The LC code is the only code that will allow the unit to keep running. The display will alternate between the LC code and the temperature setting. The controller will continue to beep. The LC code will reset if power is turned off and then on. On controller, verify if unit is sensing flow. If not then check the items below. If unit is sensing flow then check the heat exchanger and outlet thermistors. Clean inlet water supply filter. On new installations ensure hot and cold water lines are not reversed. 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 your plumbing. Verify you have at least the minimum flow rate required to fire unit. Verify turbine spins freely. Measure the resistance of the water flow control sensor. If the display is blank and clicking is coming from the unit, disconnect the water flow servo motor (RD, BL, BR, GY, YL). If the display come on then replace the water flow servo motor.
31
32
33
Heat Exchanger Outgoing Temperature Sensor
34
52 61
Combustion Air Temperature Sensor ONLY FOR INDOOR NON-CONDENSING MODELS (EXCEPT R98LSi) Modulating Solenoid Valve Signal Abnormal Combustion Fan Failure
65
Water Flow Control
70
Sensor Harness Connection ONLY FOR CONDENSING MODELS Solenoid Valve Circuit
71
72
Flame Sensing Device
73
LC
Burner Sensor Circuit ONLY FOR VB AND CONDENSING INDOOR MODELS Scale Build-up in Heat Exchanger (when checking maintenance code history, 00 is substituted for LC) Nothing happens when water flow is activated.
No code
100000098 Rev B
Electrical Diagnostic Points

R/C42e, R/C53e
Wire Color
(TR) Transformer Black - White Blue - Brown (Main) Pink - Black (SV1) Black - Blue (SV2) Black - Yellow (POV) Pink - Pink (M) Water Flow Servo Red - Blue Gray - Brown Gray - Yellow Gray - Orange
Voltage
90 - 100 VAC 108 - 132 VAC
Resistance
51-63 ohms 51-63 ohms
Connector No. Pin No.s

F2 F3 E1 1~2 1~3 1~2 1~2 1~2 1~2 1~2 6~3 6~5 6~4
(SV1, SV2, SV3, POV) Gas Valve and Modulating Solenoids 80 - 100 VDC 2 - 15 VDC 11 - 13 VDC 4 - 6 VDC N/A 11 - 14 VDC 1.7 - 2 K ohms 67 - 81 ohms 22 - 26 ohms N/A N/A N/A E2 E3 C2 B1 B1 B1 B1
NOTE: At the B connector on the PCB: gray wire turns to black, orange wire turns to red (QS) Water Flow Sensor Black - Red Yellow - Black (IG) Ignition System Gray - Gray Red - Black White - Black Yellow - Black 90 - 100 VAC 6 - 45 VDC 5 - 10 VDC 11 ~ 13 VDC N/A N/A 9.2 - 9.4 K ohms 3.5 - 3.9 K ohms F1 A1 A1 A1 1~2 1~2 2~4 2~3 11 - 13 VDC 4 - 7 VDC 5.5 - 6.2 K ohms 1 - 1.4 mega ohms B3 B3 3~1 2~3
(FM) Combustion Fan Motor
With the meter set on hertz scale, 60-350 hertz should be across the red and yellow wires at terminals 2 and 3.
10
100000098 Rev B

R/C42e, R/C53e
Wire Color
Red - Red Flame Rod
Voltage
12 VDC
Resistance
below 1 ohm

B, C 6 (B) ~ 1 (C)
Thermal Fuse / Overheat Switch
Place one lead of the meter to the flame rod and the other to ground. Flame rod to ground should read 1 mega ohm with unit not running. With the unit running, 5-150 VAC should be read. If voltage range is incorrect then replace PC board. Set the meter to the amp scale and series the meter in line with the flame rod. Proper flame circuit should read 1 micro-amp or greater. If micro-amp range is incorrect then clean flame rod; replace flame rod if cleaning fails. Thermistors Check all thermistors by inserting meter leads into each end of the thermistor plug. Set the meter to the 20 K ohm scale and read resistance. Applying heat to the thermistor bulb should decrease the resistance. Applying ice to the thermistor bulb should increase the resistance. Typical resistance values are: 11.4-14 K ohm for 59F; 6.4-7.8 K ohm for 86F; 3.6-4.5 K ohm for 113F; 2.2-2.7 K ohm for 140F; 0.6-0.8 K ohm for 221F Outgoing Water Thermistor White - White White - White Surge Protector Blue - Brown Blue - Brown 108 - 132 VAC 108 - 132 VAC N/A N/A F4 F3 1~2 1~3 see above see above B4 B5 1~2 1~2
Heat Exchanger Temperature Thermistor
With the power off, check the continuity through the surge protector. Check by placing one meter lead on the top pin #1 and bottom pin #2. Check by placing one meter lead on the top pin #3 and bottom pin #1. If there is continuity across both sets of points, then the surge protector is good. Controller Terminals D1 Frost Protection There are electrical heating elements mounted at different points to protect the water heater from freezing. heaters located on the hot water outlet line heater located on heat exchanger piping heater located on water flow sensor Amp fuses There are two inline 3 amp glass fuses. Remove the fuse and check continuity through it. If there is continuity then the fuse is good. 26 - 30 ohms 81 - 86 ohms 16 - 19 ohms 10 - 13 VDC digital 1.5 - 1.9 K ohms D 1~3
11
100000098 Rev B

R70e, R/C85e(PLUS), R/C53i(PLUS), R/C85i(PLUS)
Wire Color
(TR) Transformer Black - White Blue - Brown (Main) Pink - Black (SV1) Black - Yellow (SV2) Black - Blue (SV3) Black - Brown (POV) Pink - Pink (M) Water Flow Servo Red - Blue Gray - Brown Gray - Yellow Gray - Orange
Voltage
90 - 100 VAC 108 - 132 VAC
Resistance
51-63 ohms 51-63 ohms

F9 F7 E1 1~2 1~3 1~2 1~2 1~2 1~2 1~2 1~2 6~3 6~5 6~4
(SV1, SV2, SV3, POV) Gas Valve and Modulating Solenoids E2 E3 E4 2 - 15 VDC 11 - 13 VDC 4 - 6 VDC N/A 11 - 14 VDC 67 - 81 ohms 22 - 26 ohms N/A N/A N/A C2
80 - 100 VDC
1.7 - 2 K ohms
B1 outdoor models B2 indoor models
NOTE: At the B connector on the PCB: gray wire turns to black, orange wire turns to red (QS) Water Flow Sensor Black - Red Yellow - Black 11 - 13 VDC 4 - 7 VDC 5.5 - 6.2 K ohms 1 - 1.4 mega ohms B1 outdoor models B2 indoor models 1~3 2~3
Bypass Flow Control (only on R/C85e, R/C85ePLUS, R/C85i, R/C85iPLUS) Brown - White Orange - White Yellow - White Red - White/Ground (IG) Ignition System Gray - Gray Red - Black White - Black Yellow - Black 90 - 100 VAC 6 - 45 VDC 5 - 10 VDC 11 ~ 13 VDC N/A N/A 9.2 - 9.4 K ohms 3.5 - 3.9 K ohms F8 A1 A1 A1 1~2 1~2 2~4 2~3 2 - 6 VDC (unit in operating mode) 15 - 35 K ohms G1 (plug between bypass and PCB) 1~5 2~5 3~5 4~5
12
100000098 Rev B

R70e, R/C85e(PLUS), R/C53i(PLUS), R/C85i(PLUS)
Wire Color
Voltage
Resistance
Connector No.
C3-B2 outdoor models C3-B3 indoor models
Pin No.s
Thermal Fuse / Overheat Switch Red - Red Flame Rod Place one lead of the meter to the flame rod and the other to ground. Flame rod to ground should read 1 mega ohm with unit not running. With the unit running, 5-150 VAC should be read. If voltage range is incorrect then replace PC board. Set the meter to the amp scale and series the meter in line with the flame rod. Proper flame circuit should read 1 micro-amp or greater. If micro-amp range is incorrect then clean flame rod; replace flame rod if cleaning fails. Thermistors Check all thermistors by inserting meter leads into each end of the thermistor plug. Set the meter to the 20 K ohm scale and read resistance. Applying heat to the thermistor bulb should decrease the resistance. Applying ice to the thermistor bulb should increase the resistance. Typical resistance values are: 11.4-14 K ohm for 59F; 6.4-7.8 K ohm for 86F; 3.6-4.5 K ohm for 113F; 2.2-2.7 K ohm for 140F; 0.6-0.8 K ohm for 221F Outgoing Water Thermistor White - White see above B4 outdoor models B5 indoor models B5 outdoor models B6 indoor models N/A N/A F6 F7 1~2 12 VDC below 1 ohm 1~1
Heat Exchanger Temperature Thermistor White - White Surge Protector Blue - Brown Blue - Brown 108 - 132 VAC 108 - 132 VAC 1~2 1~3 see above 1~2
With the power off, check the continuity through the surge protector. Check by placing one meter lead on the top pin #1 and bottom pin #2. Check by placing one meter lead on the top pin #3 and bottom pin #1. If there is continuity across both sets of points, then the surge protector is good. Controller Terminals D1 Frost Protection There are electrical heating elements mounted at different points to protect the water heater from freezing. heaters located on the hot water outlet line heater located on heat exchanger piping heater located on water flow sensor Amp fuses There are two inline 3 amp glass fuses. Remove the fuse and check continuity through it. If there is continuity then the fuse is good. 26 - 30 ohms 81 - 86 ohms 16 - 19 ohms 10 - 13 VDC digital 1.5 - 1.9 K ohms D 1~3
13
100000098 Rev B

R/C98e(ASME), R/C98i(ASME)
Wire Color
(Main) Pink - Black (SV1) Black - Red (SV2) Black - Orange (SV3) Black - Yellow (POV) Orange - Orange (M) Water Flow Servo Red - Blue Gray - Brown (closed position) Gray - Yellow (open position)
Voltage
Resistance
24 - 28 ohms
Connector No.
F1 (pins 1, 2) F2 (pins 1, 2) F3 (pins 1, 2) F4 (pins 1, 2) E2 (pins 1, 2) G6 (pins 1, 2) G6 (pins 5, 3) G6 (pins 5, 4)
Pin No.s
4 ~ 5(F) 3 ~ 4(F) 2 ~ 4(F) 1 ~ 4(F) 3 ~ 4(E) 5 ~ 6(G) 8 ~ 11(G) 7 ~ 11(G)
(SV1, SV2, SV3, POV) Gas Valve and Modulating Solenoids
11 - 13 VDC
37 - 43 ohms 67 - 81 ohms N/A Limiter On Limiter Off Limiter On Limiter Off
3 - 15 VDC 11 - 13 VDC below 1 VDC 4 - 6 VDC below 1 VDC 4 - 6 VDC
NOTE: At the G connector on the PCB: gray wire turns to black (QS) Water Flow Sensor Black - Red Yellow - Black Bypass Flow Control Brown - White Orange - White Yellow - White Red - White/Ground NOTE: At the G connector on the PCB: white wire turns to red (IG) Ignition System Gray - Gray Red - Black White - Black Yellow - Black 90 - 100 VAC 6 - 45 VDC 5 - 10 VDC 11 ~ 13 VDC N/A N/A N/A N/A C1 B1 B1 B1 1 ~ 2(C) 1 ~ 2(B) 2 ~ 4(B) 2 ~ 3(B) 2 - 6 VDC (unit in operating mode) 15 - 35 K ohms H1 (pins 1, 5) H1 (pins 2, 5) H1 (pins 3, 5) H1 (pins 4, 5) 1(H) ~ 9(G) 3(H) ~ 9(G) 4(H) ~ 9(G) 2(H) ~ 9(G) 11 - 13 VDC 4 - 7 VDC N/A N/A G3 (pins 3, 1) G3 (pins 2, 3) 9 ~ 15(G) 11 ~ 15(G)
With the meter set on hertz scale, 17-460 hertz should be across the white and black wires at terminals 2 and 4.
14
100000098 Rev B

R/C98e(ASME), R/C98i(ASME)
Wire Color
Thermal Fuse White - Red Overheat Switch Red - Red Flame Rod
Voltage
12 VDC 12 VDC
Resistance
below 1 ohm below 1 ohm

G1 (red) pin 1 - E3 (white) pin 1 G2 1~2
Place one lead of the meter to the flame rod and the other to ground. With the unit running, 5-150 VAC should be read. Set the meter to the amp scale and series the meter in line with the flame rod. Proper flame circuit should read 1 amp or greater. If not, then remove the flame rod and check for carbon build-up. Clean with sand paper or emery cloth. Thermistors Check all thermistors by inserting meter leads into each end of the thermistor plug. Set the meter to the 20 K ohm scale and read resistance. Applying heat to the thermistor bulb should decrease the resistance. Applying ice to the thermistor bulb should increase the resistance. Typical resistance values are: 11.4-14 K ohm for 59F; 6.4-7.8 K ohm for 86F; 3.6-4.5 K ohm for 113F; 2.2-2.7 K ohm for 140F; 0.6-0.8 K ohm for 221F Outgoing Water Thermistor White - White White - White Surge Protector Black - White Black - White 108 - 132 VAC 108 - 132 VAC N/A N/A D1 D2 1~3 see above see above G5 G4 1~2 1~2
With the power off, check the continuity through the surge protector. Check by placing one meter lead on the top pin #1 and bottom pin #2. Check by placing one meter lead on the top pin #2 and bottom pin #1. If there is continuity across both sets of points, then the surge protector is good. Controller Black - Black Frost Protection White - White White - White White - White 120 VAC * 60 VAC * 60 VAC* 150 ohms 360 ohms 360 ohms D4 D5 D6 1~2 1~2 1~2 10 - 13 VDC digital N/A A 1 ~ 3(A)
* only when Frost Sensing Switch (D3) is ON Amp fuses There are two inline 3 amp glass fuses. Remove the fuse and check continuity through it. If there is continuity then the fuse is good.
15
100000098 Rev B

V53e, R63LSe
Wire Color
(Main) Pink - Black (SV1) Black - Blue (SV2) Black - Yellow (POV) Pink - Pink (M) Water Flow Servo Red - Blue Gray - Brown Gray - Yellow
Voltage
Resistance
37 - 43 ohms

F5 F6 F7 F3 E5 (1, 2) E5 (5, 3) E5 (5, 4) 1~2 1~2 1~2 1~2 9 ~ 8 (E) 4 ~ 6 (E) 4 ~ 7 (E)
(SV1, SV2, SV3, POV) Gas Valve and Modulating Solenoids 11 - 13 VDC 2 - 15 VDC 11 - 13 VDC 4 - 6 VDC N/A 35 - 41 ohms 37 - 43 ohms 67 - 81 ohms 22 - 28 ohms N/A N/A
NOTE: At the E connector on the PCB: gray wire turns to black (QS) Water Flow Sensor Black - Red Yellow - Black (IG) Ignition System Gray - Gray Red - Black White - Black Yellow - Black 90 - 110 VAC 6 - 45 VDC 5 - 10 VDC 11 ~ 13 VDC N/A N/A 9.2 - 9.4 K ohms 3.5 - 3.9 K ohms B1 D1 D1 D1 1~2 1~2 4~2 3~2 11 - 13 VDC 4 - 7 VDC 5.5 - 6.2 K ohms 1 - 1.4 mega ohms E2 E2 3~1 2~3
With the meter set on hertz scale, 60-420 hertz should be across the white and black wires at terminals 2 and 4.
16
100000098 Rev B

V53e, R63LSe
Wire Color
Thermal Fuse / Overheat Switch Blue - White (thermal fuse side) Red - Blue (PCB side) Flame Rod
Voltage
Resistance
below 1 ohm

E6 F1 E6 F1 1~1 1~1
12 VDC
Place one lead of the meter to the flame rod and the other to ground. With the unit running, 5-150 VAC should be read. Set the meter to the amp scale and series the meter in line with the flame rod. Proper flame circuit should read 1 amp or greater. If not, then remove the flame rod and check for carbon and damage. Thermistors Check all thermistors by inserting meter leads into each end of the thermistor plug. Set the meter to the 20 K ohm scale and read resistance. Applying heat to the thermistor bulb should decrease the resistance. Applying ice to the thermistor bulb should increase the resistance. Typical resistance values are: 11.4-14 K ohm for 59F; 6.4-7.8 K ohm for 86F; 3.6-4.5 K ohm for 113F; 2.2-2.7 K ohm for 140F; 0.6-0.8 K ohm for 221F Outgoing Water Thermistor White - White Heat Exchanger Temperature Thermistor White - White Surge Protector Black - White Blue - Brown 108 - 132 VAC 108 - 132 VAC N/A N/A C2 C1 1~3 see above E3 1~2 see above E4 1~2
With the power off, check the continuity through the surge protector. Check by placing one meter lead on the top pin #1 and bottom pin #3. Check by placing one meter lead on the top pin #3 and bottom pin #1. If there is continuity across both sets of points, then the surge protector is good. Controller Terminals A1 Frost Protection heaters located on the hot water outlet line heater located on heat exchanger piping heater located on water flow sensor Amp fuses There are two inline 3 amp glass fuses. Remove the fuse and check continuity through it. If there is continuity then the fuse is good. 180 - 207 ohms 156 - 180 ohms 24 - 28 ohms 10 - 13 VDC 1.5 - 3.0 K ohms A 1~3
17
100000098 Rev B

R50LSi, R63LSe2, R75LSe-VA, R75LSi-VA, R94LSe-VA, R94LSi-VA
Wire Color
(Main) Pink - Black (SV1) Black - Yellow (SV2) Black - Blue (SV3) Black - Brown (POV) Pink - Pink (M) Water Flow Servo Red - Blue Gray - Brown Gray - Yellow
Voltage
Resistance

H5 1~2 1~2 1~2 1~2 1~2 10 ~ 9 (F) 5 ~ 7 (F) 5 ~ 8 (F)
(SV1, SV2, SV3, POV) Gas Valve and Modulating Solenoids H6 H7 H8 2 - 15 VDC 11 - 13 VDC 4 - 6 VDC N/A 67 - 81 ohms 22 - 26 ohms N/A N/A H3 F7 (1, 2) F7 (5, 3) F7 (5,4)
11 - 13 VDC
36.8 - 44.8 ohms
NOTE: At the F connector on the PCB: gray wire turns to black, orange wire turns to red (QS) Water Flow Sensor Black - Red Yellow - Black Brown - White Orange - White Yellow - White Red - White/Ground (IG) Ignition System Gray - Gray Red - Black White - Black Yellow - Black 90 - 110 VAC 6 - 45 VDC 5 - 10 VDC 11 ~ 13 VDC N/A N/A 9.2 - 9.4 K ohms 3.5 - 3.9 K ohms C1 E1 E1 E1 1~2 1~2 2~4 2~3 2 - 6 VDC (unit in operating mode) 15 - 35 K ohms G1 11 - 13 VDC 4 - 7 VDC 5.5 - 6.2 K ohms 1 - 1.4 mega ohms F2 F2 1~3 2~3 1~5 2~5 3~5 4~5
Bypass Flow Control (only on R94LSe and R94LSi)
18
100000098 Rev B

Wire Color
Thermal Fuse / Overheat Switch Red - Red (thermal fuse side) Red - Red (PCB side) Flame Rod
Voltage
Resistance
below 1 ohm

F6 H1 F6 H1 1~1 1~1
11 - 13 VDC
Place one lead of the meter to the flame rod and the other to ground. With the unit running, 5-150 VAC should be read. Set the meter to the amp scale and series the meter in line with the flame rod. Proper flame circuit should read 1 amp or greater. If not, then remove the flame rod and check for carbon and damage. Thermistors Check all thermistors by inserting meter leads into each end of the thermistor plug. Set the meter to the 20 K ohm scale and read resistance. Applying heat to the thermistor bulb should decrease the resistance. Applying ice to the thermistor bulb should increase the resistance. Typical resistance values are: 11.4-14 K ohm for 59F; 6.47.8 K ohm for 86F; 3.6-4.5 K ohm for 113F; 2.2-2.7 K ohm for 140F; 0.6-0.8 K ohm for 221F Outgoing Water Thermistor White - White Heat Exchanger Temperature Thermistor Pink - White Orange - White Surge Protector Black - White Blue - Brown 108 - 132 VAC 108 - 132 VAC N/A N/A D2 D1 1~3 1~3 see above see above F4 (1, 1) F3 (1, 1) 3 ~ 11 (F) 3 ~ 12 (F) Intake Air Thermistor (only on R50LSi, R75LSi, R94LSi) see above F5 (1, 1) 3 ~ 4 (F)
With the power off, check the continuity through the surge protector. Check by placing one meter lead on the top pin #1 and bottom pin #3. Check by placing one meter lead on the top pin #3 and bottom pin #1. If there is continuity across both sets of points, then the surge protector is good. Controller Terminals B1 Frost Protection There are electrical heating elements mounted at different points to protect the water heater from freezing. heaters located on the hot water outlet line heater located on heat exchanger piping heater located on water flow sensor Amp fuses There are two inline 3 amp glass fuses. Remove the fuse and check continuity through it. If there is continuity then the fuse is good. 180 - 207 ohms 156 - 180 ohms 24 - 28 ohms 10 - 13 VDC 1.5 - 3.0 K ohms B 1~3
19
100000098 Rev B

V53i, R75LSe-VB, R75LSi-VB, R94LSe-VB, R94LSi-VB Heat Exchanger and Outgoing Water Temperature Thermistors: 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. Frost Protection: This unit has frost protection heaters mounted at different points to protect the water heater from freezing.
COMPONENT MEASUREMENT POINT CN TEMP CONTROLLER THERMAL FUSE MOD. SOLENOID VALVE MAIN SOLENOID VALVE SOLENOID VALVE 1 SOLENOID VALVE 2 SOLENOID VALVE 3 SOLENOID VALVE 4 FLAME ROD 1 FLAME ROD 2 SURGE PROTECTOR SURGE PROTECTOR MAIN POWER CORD ANTI FROST HEATER A1 B1/E1 B2 B3 B4 B5 B6 B7 B8 M1 C1 C2 C3 C4 W-W 88-120 156-211 AC108-132V (DURING IGNITION) 15C/59F: 11.4-14.0 k 30C/86F: 6.4-7.8 k 45C/113F: 3.6-4.5 k 60C/140F: 2.2-2.7 k 105C/221F: 0.6-0.8 k FFU (INDOOR) MODELS W (OUTDOOR) MODELS FFU (INDOOR) MODELS W-Bk AC108-132V WIRE COLOR Bk-Bk W-W O-O P-Bk B-Bk (Y-Bk on V53i) Y-Bk (Bl-Bk on V53i) R-Bk O-Bk Y-FR R-FR OVER 1 A (DURING OPERATION) NOT ON V53i, RV53i DC11-13V / 37-43 DC11-13V BELOW 1 DC2-15V / 67-82
Amp Fuses: Indoor models have one inline (5) amp glass fuse. Outdoor models have one inline (3) amp glass fuse. 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. 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 micro amp scale. You should read 1 micro amp for proper flame circuit. In the event of low flame circuit remove the flame rod and check for carbon or damage.
RANGE OF VALUE REMARKS
NOT ON V53i, RV53i
IGNITOR HEAT EXCHANGER TH OUTGOING WATER TH1 OUTGOING WATER TH2 AIR TEMPERATURE TH
D1 E2 E3 E4 E5
Gy-Gy W-W W-W W-W W-W
20
100000098 Rev B

V53i, R75LSe-VB, R75LSi-VB, R94LSe-VB, R94LSi-VB
COMPONENT
MEASUREMENT POINT CN WIRE COLOR
RANGE OF VALUE
REMARKS
15C/59F: 21.5-23.8 k 30C/86F: 14.7-16.2 k BURNER THERMISTOR E6 Bk-Bk 200C/392F: 0.98-1.02 k 400C/752F: 210.0-223.9 600C/1112F: 85.7-92.7 R-Bk WATER FLOW SENSOR E7 Y-Bk Br-W BYPASS FLOW CONTROL G1 O-W Y-W R-W R-O P-O B-O WATER FLOW CONTROL G2 W-O R-P B-W Y-Gy Br-Gy R-Bk 30-50 BELOW DC1V (LIMITER ON) DC4-6 (LIMITER OFF) FULL OPEN POSITION FULL CLOSE POSITION DC11-13V (DC5-7V DURING OPERATION) DC12V (DC2-6V DURING OPERATION) 15-35 R94LS, RL94 (2735) MODELS ONLY DC4-7V (PULSE 20-300 Hz) DC11-13V R75LS, RL75, R94LS, RL94: ON: 1.5L/MIN (20Hz) OFF: 1.0L/MIN (13Hz) V53i, RV53i ON: 2.4L/MIN OFF: 1.7L/MIN FFU (INDOOR) MODELS
DC15-46V DC11-13V DC5-10V (PULSE 20-420 Hz)
COMBUSTION FAN
L1
Y-Bk W-Bk
21
100000098 Rev B

R98LSe(ASME), R98LSi(ASME)
Wire Color
(Main) Pink - Black (SV1) Black - Red (SV2) Black - Orange (SV3) Black - Yellow (POV) Orange - Orange (M) Water Flow Servo Red - Blue Gray - Brown Gray - Yellow
Voltage
Resistance
24 - 28 ohms

H3 H4 H5 H6 H2 F5 (1, 2) F5 (5, 3) F5 (5, 4) 1~2 1~2 1~2 1~2 1~2 9 ~ 10 (F) 5 ~ 7 (F) 5 ~ 8 (F)
(SV1, SV2, SV3, POV) Gas Valve and Modulating Solenoids 37 - 43 ohms 37 - 43 ohms 37 - 43 ohms 2 - 15 VDC 11 - 13 VDC 4 - 6 VDC N/A 67 - 81 ohms 22 - 28 ohms N/A N/A
11 - 13 VDC
NOTE: At the F connector on the PCB: gray wire turns to black (QS) Water Flow Sensor Black - Red Yellow - Black Bypass Flow Control Brown - White Orange - White Yellow - White Red - White/Ground (IG) Ignition System Gray - Gray Red - Black White - Black Yellow - Black 90 - 110 VAC 6 - 45 VDC 5 - 10 VDC 11 ~ 13 VDC N/A N/A 9.2 - 9.4 K ohms 3.5 - 3.9 K ohms C1 E1 E1 E1 1~2 1~2 2~4 2~3 2 - 6 VDC (unit in operating mode) 15 - 35 K ohms G1 1~5 2~5 3~5 4~5 11 - 13 VDC 4 - 7 VDC 5.5 - 6.2 K ohms 1 - 1.4 mega ohms F2 F2 1~3 2~3
22
100000098 Rev B

Wire Color
Red - White
Voltage
11 - 13 VDC
Resistance
below 1 ohm

F6 H1 1~1
Thermal Fuse / Overheat Switch F (pin 6), H (pin 12) Flame Rod Place one lead of the meter to the flame rod and the other to ground. With the unit running, 5-150 VAC should be read. Set the meter to the amp scale and series the meter in line with the flame rod. Proper flame circuit should read 1 amp or greater. If not, then remove the flame rod and check for carbon and damage. Thermistors Check all thermistors by inserting meter leads into each end of the thermistor plug. Set the meter to the 20 K ohm scale and read resistance. Applying heat to the thermistor bulb should decrease the resistance. Applying ice to the thermistor bulb should increase the resistance. Typical resistance values are: 11.4-14 K ohm for 59F; 6.4-7.8 K ohm for 86F; 3.6-4.5 K ohm for 113F; 2.2-2.7 K ohm for 140F; 0.6-0.8 K ohm for 221F Outgoing Water Thermistor White - White White - White Pink - White Surge Protector Black - White Blue - Brown 108 - 132 VAC 108 - 132 VAC N/A N/A D2 D1 1~3 1~3 see above see above see above F4 (1, 2) F3 F 3 ~ 4 (F) 1~2 3 ~ 11
With the power off, check the continuity through the surge protector. Check by placing one meter lead on the top pin #1 and bottom pin #3. Check by placing one meter lead on the top pin #3 and bottom pin #1. If there is continuity across both sets of points, then the surge protector is good. Controller Terminals B1 Frost Protection There are electrical heating elements mounted at different points to protect the water heater from freezing. Voltage through this circuit should be 120 VAC. heater located on the hot water outlet line heater located on heat exchanger piping heater located on water flow sensor Amp fuses There are two inline 3 amp glass fuses. Remove the fuse and check continuity through it. If there is continuity then the fuse is good. 335 - 385 ohms 156 - 180 ohms 335 - 385 ohms 10 - 13 VDC 1.5 - 3.0 K ohms B 1~3
23
100000098 Rev B

RC80HPe, RC80HPi
Heat Exchanger and Outgoing Water Temperature Thermistors: 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. Frost Protection: This unit has frost protection heaters mounted at different points to protect the water heater from freezing.
COMPONENT MEASUREMENT POINT CN TEMP CONTROLLER THERMAL FUSE MOD. SOLE. VALVE (POV) MAIN SOLE. VALVE (SV0) SOLENOID VALVE 1 SOLENOID VALVE 2 SOLENOID VALVE 3 SOLENOID VALVE 4 SURGE PROTECTOR SURGE PROTECTOR A PINS 1-3
Amp Fuses: This unit has one inline (7) amp glass fuse. 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. 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 micro amp scale. You should read 1 micro amp for proper flame circuit. In the event of low flame circuit remove the flame rod and check for carbon or damage.
RANGE OF VALUE WIRE COLOR Bk-Bk R-R B2: O-O B5: P-Bk B6: B-Bk B7: Y-Bk B3: R-Bk B4: O-Bk DC11-13V / 37-43 DC10-13V BELOW 1 DC2-15V / 67-82
B1 pin1 to E1 pin 1 B2 (1-2), B (10-11) B5 (1-2), B (7-8) B6 (1-2), B (6-7) B7 (1-2), B (5-7) B3 (1-2), B(4-7) B4 (1-2), B(3-7) C1 C2 1-3
Bk-W W-W
1-3
AC108-132V 10-20 35-50 110-150 90-110
HOT WATER OUTLET LINE
HEAT EXCHANGER PIPING

ANTI FROST HEATER
WATER FLOW SENSOR, HOT WATER OUTLET, DRAIN CONNECTION LATENT HEAT EXCHANGER (INDOOR MODEL ONLY)
IGNITOR HEAT EXCHANGER TH OUTGOING WATER TH1 OUTGOING WATER TH2
D1
1-2
Gy-Gy W-W W-W W-W
AC108-132V (DURING IGNITION) 15C/59F: 11.4-14.0 k 30C/86F: 6.4-7.8 k 45C/113F: 3.6-4.5 k 60C/140F: 2.2-2.7 k 105C/221F: 0.6-0.8 k
E2 (1, 2), E(5-10) E3 E4 1-2 3-4
24
100000098 Rev B

RC80HPe, RC80HPi
COMPONENT
MEASUREMENT POINT CN PINS 1-3 WIRE COLOR R-Bk
RANGE OF VALUE
DC11-13V
WATER FLOW SENSOR
E5 2-3 1-5 Y-Bk Br-W O-W Y-W R-W R or P -O B or W -O R-P B-W Y-Gy Br-Gy R-Bk Y-Bk W-Bk DC5-7V DURING OPERATION DC2-6V DURING OPERATION 15-35 DC4-7V; 1-1.4 M
BYPASS FLOW CONTROL
G1
2-5 3-5 4-5 3 or 4 - 8 1 or 2 - 8
WATER FLOW CONTROL
G2
3-4 1-2 7-5 7-6 1-2
30-50 BELOW DC1V (LIMITER ON) DC0-6 (LIMITER OFF)
DC6-45V DC11-13V; 3.5-3.9 k DC5-10V; 9.2-9.4 k; (PULSE 20-420 Hz)
COMBUSTION FAN
L1
2-3 2-4
25
100000098 Rev B

RC98HPe, RC98HPi
Heat Exchanger and Outgoing Water Temperature Thermistors: 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. Frost Protection: This unit has frost protection heaters mounted at different points to protect the water heater from freezing.
COMPONENT MEASUREMENT POINT CN TEMP CONTROLLER THERMAL FUSE MOD. SOLE. VALVE (POV) MAIN SOLE. VALVE (SV0) SOLENOID VALVE 1 SOLENOID VALVE 2 SOLENOID VALVE 3 SOLENOID VALVE 4 SURGE PROTECTOR SURGE PROTECTOR B1 PINS 1-3
Amp Fuses: This unit has one inline (7) amp glass fuse. 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. 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 micro amp scale. You should read 1 micro amp for proper flame circuit. In the event of low flame circuit remove the flame rod and check for carbon or damage.
RANGE OF VALUE WIRE COLOR Bk-Bk R-W O-O P-Bk Bl-Bk Y-Bk R-Bk O-Bk Bk-W AC108-132V W-W 180-207 156-180 24-28 DC11-13V / 37-43 DC10-13V BELOW 1 DC2-15V / 67-81 DC11-13V / 24-28
E1 pin 1 to B1 pin 1 B2 B3 B4 B5 B6 B7 C1 C2 1-2 1-2 1-2 1-2 1-2 1-2 1-3
1-3
HOT WATER OUTLET LINE ANTI FROST HEATER
HEAT EXCHANGER PIPING WATER FLOW SENSOR
IGNITOR
D1
1-2
Gy-Gy
AC90-110V (DURING IGNITION) 15C/59F: 11.4-14.0 k 30C/86F: 6.4-7.8 k 45C/113F: 3.6-4.5 k 60C/140F: 2.2-2.7 k 105C/221F: 0.6-0.8 k
HEAT EXCHANGER TH
E2
1-2
W-W
OUTGOING WATER TH1
E4 pins 3,4 to E8 pins 1-2
W-W
26
100000098 Rev B

RC98HPe, RC98HPi
COMPONENT
MEASUREMENT POINT CN PINS 1-3 WIRE COLOR R-Bk
RANGE OF VALUE
DC11-13V; 5.5-6.2 k
WATER FLOW SENSOR
F2 2-3 1-5 Y-Bk Br-W O-W Y-W R-W R or P -O B or W -O R-P B-W Y-Gy Br-Gy R-Bk Y-Bk W-Bk DC5-7V DURING OPERATION DC5-7V DURING OPERATION 30-50 30-50 BELOW DC1V (LIMITER ON) DC0-6 (LIMITER OFF) BELOW DC1V (LIMITER ON) DC0-6 (LIMITER OFF) DC2-6V DURING OPERATION 15-35 DC4-7V; 1-1.4 M
BYPASS FLOW CONTROL
G1
2-5 3-5 4-5 3 or 4 - 8 1 or 2 - 8 3-4
WATER FLOW CONTROL
G2
1-2 7-5 7-6 1-2
DC6-45V DC11-13V; 3.5-3.9 k DC5-10V; 9.2-9.4 k; (PULSE 20-420 Hz)
COMBUSTION FAN
E1
2-3 2-4
27
100000098 Rev B
Wiring Diagram
R/C42e, R/C53e
TRANSFORMER
28
100000098 Rev B
Wiring Diagram
R70e, R/C85e(PLUS)
TRANSFORMER
29
100000098 Rev B
Wiring Diagram
R/C53i(PLUS), R/C85i(PLUS)
HEAT EXCHANGER THERMISTOR OUTGOING WATER THERMISTOR AIR TEMEPRATURE THERMISTOR
TRANSFORMER
30
100000098 Rev B
Wiring Diagram
R/C98i(ASME), R/C98e(ASME)
31
100000098 Rev B
D
(CN10)
D1
4
(CN5)
E
13 G
Dip SW1
COLOR CODING
MAX MIN
COMBUSTION FAN E1
R Y R W Y P BL BR BK W 1
FM
MODULATING VALVE CURRENT ADJUSTING
R BK Y W
1 R BK Y W
FREEZE PROTECTION G R E2 OPTION
WATER FLOW QS SENSOR

W W
R Y BK
R Y BK
E3 Gas pressure E4 A
(CN4) O F F
1 2 3 4 5 6 7 8
BK:Black BR:Brown R :Red O :Orange Y :Yellow G :Green BL:Blue GY:Grey W :White P :Pink
HEAT EXCHANGER OUTGOING WATER THERMISTOR W P

Dip SW2
1 2 3 4 5 6

W W
(CN3)
OUTGOING WATER THERMISTOR

3 1 BK BK
W W A1 F B1
GY GY GY GY
Spare Parts Only

REMOTE CONTROLLER
E5
GY R BL Y BR 12 Y BK P R BL P Y P
WATER FLOW CONTROL DEVICE E6 F1

1 BR BL BL R
(CN1)
R BL BR Y GY
IG
IGNITER GND
SPARK ELECTRODE
Wiring Diagram
32
C 2
(CN2)
THERMAL FUSES B
4
F2 F3
POV
WR
OVERHEAT SWITCH
P P Y
MODULATING SOLENOID VALVE F4 F5
SURGE PROTECTOR C 2
1 3 3 1
W W
FROST SENSING SWITCH BLBL C5 ANTI-FROST HEATER C3

W W BL BR G/Y BK W W W
C4
WW
FLAME ROD
C1 GND
G/Y
FUSE (3A) GND

W BK
ANTI-FROST HEATER AC120V HOT NEUTRAL GROUND
P MAIN SOLENOID VALVE SV0 BK F6 SOLENOID VALVE 1 SV1 BL BK (SMALL) F7 Y SOLENOID VALVE 2 SV2 BK (LARGE)
V53e, R63LSe
100000098 Rev B
Wiring Diagram
COLOR CODING BY-PASS SERVO MODEL ONLY BY-PASS FLOW CONTROL DEVICE FREEZE PROTECTION OPTION WATER FLOW SENSOR F2
G R
G1
BR O Y R W
for REU-EZC (Optional)

W Y O R BR 5 1
F1
G
(CN7) MAX MIN
W :White BK:Black BR:Brown R :Red BL:Blue Y :Yellow P :Pink O :Orange G :Green GY:Gray
QS
R Y BK
R Y BK
INDOOR MODEL ONLY AIR TEMPERATURE THERMISTOR HEAT EXCHANGER THERMISTOR OUTGOING WATER THERMISTOR F7
R BL BR Y GY W W W W W W

1 2 3 4 5 6 7 8
F3 F4 F5
W O W P W W
GY R BL Y BR
O 13
R BK
GY 1
A
3
(CN9)
W R BK 1
Dip SW1
O F F
P BL BR R Y
WW
(CN5)
Gas pressure Gas type Spare Parts Only
Dip SW2
O F F
E
4 1 12
(CN2)
1 2 3 4 5 6
H
1
1 3
B1
BK BK REMOTE CONTROLLER
WATER FLOW CONTROL DEVICE
(CN12)
E1
FM
F6
W Y BK R
Y R W BK
P P Y BR Y R P BK BL
(CN1)
COMBUSTION FAN THERMAL FUSES H2 OVERHEAT SWITCH H3

POV P P Y R R R R
C
GY GY
(CN4)
C1
GY GY
IG
SPARK ELECTRODE GND
H1
IGNITER
MODULATING SOLENOID VALVE FLAME ROD
(CN3)
D
1
D3 FROST SENSING SWITCH

BL BL (W) (W) W W
BL BR
H4 MAIN SOLENOID VALVE SOLENOID VALVE 1 SOLENOID VALVE 2 SOLENOID VALVE 3

SV0 SV1 SV2 SV3
H5
P BK
H6
Y BK
D5 ANTI-FROST HEATER
H7
BL BK
SURGE PROTECTOR
BL BR G/Y
1 3 3 1
D2
BK W BL BL
D4 ANTI-FROST HEATER
H8
BR BK
D1
G/Y
FUSE (3A)
W BK
GND
GND
AC120V HOT NEUTRAL GROUND
33
100000098 Rev B
Wiring Diagram
R75LSe-VB, R75LSi-VB, R94LSe-VB, R94LSi-VB
FREEZE PROTECTION (OPTIONAL)
34
100000098 Rev B
Wiring Diagram
V53i
FREEZE PROTECTION (OPTIONAL)
35
100000098 Rev B
G1
BY-PASS FLOW CONTROL DEVICE

WY ORBR
BR O Y R W
A1 for REU-EZC (Optional) G

(CN7) MAX MIN
5 1
COLOR CODING
FREEZE PROTECTION G R (OPTIONAL) F1 F2 R R WATER FLOW Y Y QS BK BK SENSOR

RBK 3 1
(CN9) O F F
GY F
WRBK
Dip SW1
13 1 P BL BR WW
(CN5)
HEAT EXCHANGER WATER THERMISTOR

W P R Y
Dip SW2 O F F
1 2 3 4 5 6

F3 Gas pressure Gas type Spare Parts Only F4
W W
1 2 3 4 5 6 7 8
W W
W :White BK:Black BR:Brown R :Red BL:Blue Y :Yellow P :Pink O :Orange G :Green GY:Gray
OUTGOING WATER WATER THERMISTOR
F5 E
4 12
(CN2)
W W 1 1 3 1 BK BK
H B B1
WATER FLOW CONTROL DEVICE

(CN12)
R BL BR Y GY GY R BL Y BR Y R W BK O P R Y Y W O BK O
(CN1)
Wiring Diagram
36
F6
R W GY GY
(CN4)
REMOTE CONTROLLER
BL BL
FROST SENSING SWITCH D3

WW
W E1 Y COMBUSTION FAN FM BK R
THERMAL FUSES
R W
C
1
C1
GY GY
IG
IGNITER
SPARK ELECTRODE GND
W W
W W W W W
D4 D5 D6 FUSE (3A)
W W W W W W
OVERHEAT SWITCH R R H1 H2
POV
(CN3)
O O
W BK D2
1
ANTI-FROST HEATER
W BK G/Y 3
1
1 BK W
AC120V
SURGE PROTECTOR
MODULATING SOLENOID VALVE H3 P MAIN SOLENOID VALVE SV0 BK H4 SOLENOID VALVE 1 SV1 R BK (CENTER) H5 SOLENOID VALVE 2 SV2 O BK (LEFT) H6 SOLENOID VALVE 3 SV3 Y BK (RIGHT) FLAME ROD
Y
G/Y
W BK D1
HOT NEUTRAL GROUND H7 GND GND
100000098 Rev B
Wiring Diagram
RC80HPe, RC80HPi
G1
BY-PASS FLOW CONTROL DEVICE WATER FLOW SENSOR
Br O Y R W
Br O Y R W
Gy Br O Y W P B R W Bk R R
Gy Br O Y W P B R
G2 WATER FLOW CONTROL DEVICE
S-BMS/AIR HANDLER (OPTIONAL) REU-MSA (OPTIONAL)
QS
R Y Bk
R Y Bk
E5 E7 FREEZE PROTECTION R (OPTIONAL) W E4
Br O R Br P W R Y Bk Y R B
W R Bk
1
REU-EZC (OPTIONAL) COLOUR CODING
OUTGOING WATER THERMISTOR HEAT EXCHANGER THERMISTOR
W W W W
W W B B
G
12 (CN7)
11 1 MAX MODULATING VALVE MIN CURRENT ADJUSTING
(CN11)
E3
W W
E2
P P
R W Bk
Bk Bk W Bk Bk W
Dip SW1
1 2 3 4 5 6 7 8
BURNER FF MODEL ONLY THERMISTOR WATER LEVEL ELECTRODE COMBUSTION FAN

W Gr
E6
BWW Gr W Y
3 (CN9) 1
L1
GND
W Y Bk R
E
W Y Bk R 1 (CN12) R W 14
ON
Gas pressure setting

Gas Type Spare parts only
B8
Y R
W :White Bk:Black Br:Brown R :Red B :Blue Y :Yellow P :Pink O :Orange Gr:Green Gy:Gray Pu:Purple
FM
W Y Bk R
R O (CN5) 1 O
L
4
SHORT W MODEL ONLY
FF MODEL ONLY OVERHEAT SWITCH THERMAL FUSES OVERHEAT SWITCH MODULATING B2 SOLENOID VALVE POV
Bk R O P Bk R O P
Dip SW2 1 2 3 4 5 6
ON
RR R R WW
E1
Y R
B
FLAME ROD1 FLAME ROD2

M1
FF MODEL ONLY FROST SENSING SWITCH ANTI-FROST C 4 HEATER FF MODEL ONLY ANTI-FROST HEATER ANTI-FROST HEATER ANTI-FROST HEATER GND
B1
13
(CN2)
Y
1
3 (CN13) 1
Bk Bk
O Bk Y O OP B R
3 (CN1) (CN4)
A1 D1
Gy Gy
Temperature Controller
W W
C5
B3 SOLENOID SV3 Bk R VALVE 3 B4 SOLENOID Bk VALVE 4 SV4 O
O O
O O D
3 1 2
Gy Gy
IG
(CN3) Gr/Y Bk W
IGNITER
SPARK ELECTRODE
FUSE (7A)
Bk W
C6 C7
C
1
C3
Bk W
MAIN SOLENOID P SV0 Bk VALVE B6 SOLENOID SV1 B Bk VALVE 1 B7 SOLENOID Y VALVE 2 SV2 Bk
B5
B Y Bk
B Y Bk
GND
SURGE PROTECTOR C2 Bk 1 3 W 1 W W 3 C1 Gr/Y GND
Gr
AC120V 60Hz
37
100000098 Rev B
Wiring Diagram
RC98HPe, RC98HPi
38
100000098 Rev B
Flushing the Heat Exchanger

An LC or 00 error code indicates the unit is beginning to lime up and must be flushed. Failure to flush the appliance will cause damage to the heat exchanger. Damage caused by lime build-up is not covered by the units warranty. After flushing, reset the LC fault code by turning off the power to the unit and turning the power back on. 1. 2. 3. 4. 5. 6. 7. 8. Disconnect electrical power to the water heater. Close the shutoff valves on both the hot water and cold water lines (V3 and V4). Connect pump outlet hose (H1) to the cold water line at service valve (V2). Connect drain hose (H3) to service valve (V1). Pour 4 gallons of undiluted virgin, food grade, white vinegar into pail. Place the drain hose (H3) and the hose (H2) to the pump inlet into the cleaning solution. Open both service valves (V1 and V2) on the hot water and cold water lines. Operate the pump and allow the cleaning solution to circulate through the water heater for at least 1 hour at a rate of 4 gallons per minute (15.1 liters per minute). Turn off the pump. Rinse the cleaning solution from the water heater as follows: a. Remove the free end of the drain hose (H3) from the pail. Place in sink or outside to drain. b. Close service valve, (V2), and open shutoff valve, (V4). Do not open shutoff valve, (V3). c. Allow water to flow through the water heater for 5 minutes. d. Close shutoff valve (V4). When unit has finished draining remove the in-line filter at the cold water inlet and clean out any residue. Place filter back into unit and open valve (V4). e. Close service valve, (V1), and open shutoff valve, (V3). Disconnect all hoses. Restore electrical power to the water heater.
KEY
3/4" Ball Valve 3/4" Union Check Valve Pressure Relief Valve
Pressure Regulator Circulating Pump
Boiler Drain Valve

S Solenoid Valve
Rinnai Water Heater
9. 10.
In-line Filter
V1
V2
11. 13.
H3
V3
Hot Water Line
V4
Gas Supply
Cold Water Line
H2 H1 Circulating Pump
39
100000098 Rev B
Manual Draining of the Water Heater WARNING

To avoid burns, wait until the equipment cools down before draining the water. The water in the appliance will remain hot after it is turned off. * Use a wrench or other tool to unscrew the hot water drain plug. Hot water outlet Hot water drain plug * Cold water inlet
If the water heater is not going to be used during a period of possible freezing weather, it is recommended that the water inside the water heater be drained. To manually drain the water: 1. Shut off cold water supply, hot water valve and gas supply. 2. Turn off the temperature controller. 3. Disconnect the power to the water heater. 4. Remove the drain caps on both isolation valves and open both valves above the caps (blue and red valve handles). -OR- Open hot water drain plug at the hot water outlet. 5. Remove water filter to drain the cold water. 6. For condensing models unscrew the water drain plug from the drain line next to the hot water outlet and remove the condensate trap drain plug. Allow to drain. To resume normal operation: 1. Confirm that all water drain plugs are removed, that the gas supply is turned off, and that all taps are closed. 2. For condensing models insert the condensate trap drain plug and screw in the water drain plug. 3. Screw in the water filter in the cold water inlet. 4. Replace the drain caps and close both isolation valves. OR- Screw in the hot water drain plug. 5. Open the cold water supply and hot water valve. 6. Open a tap and confirm that water flows, and then close. 7. Turn on the power. 8. After confirming that the temperature controller is off, turn on the gas supply. 9. Turn on the temperature controller.
NON-CONDENSING
Water filter
Hot water outlet
Hot water drain plug*
Water filter
CONDENSING
Condensate trap drain plug
Water drain plug
Cold water inlet
Running a low volume of water through the water heater to prevent freezing If the temperature exceeds the ability of the water heater to freeze protect itself, or if power is lost, the following steps may prevent the water heater and external piping from freezing. (Units connected with EZConnect should be drained to prevent freezing if not in use.) 1. Turn the water heater off. 2. Close the gas supply valve. 3. Turn on a hot water tap to flow water about 0.1 gal/min or where the stream is about 0.2 inches thick. When the water heater or external piping has frozen 1. 2. 3. 4. Do not operate the water heater if it or the external piping is frozen. Close the gas and water valves and turn off the power. Wait until the water thaws. Check by opening the water supply valve. Check the water heater and the piping for leaks.
HOT
ON!
COLD
0.1 gal/min or about 0.2 inch thick
40
100000098 Rev B
Component Replacement Instructions

Gas Control Assembly
R/C42e, R/C53e, V53e, R63LSe
1. Turn off the gas supply. 2. Turn off the 120 V power supply. 3. Remove four screws securing the front panel. Remove front panel. 4. Move aside the ignition line by pulling it out from the clear plastic tubing. (Figure 1) 5. Remove the six screws that attach the gas manifold to the combustion chamber (part of the heat exchanger assembly). (Figure 1) 6. Remove the three screws that attach the gas manifold to the gas valve. Pull out the gas manifold. (Figure 1) Figure 1
Ignition line
Six screws Three screws Cable tie
7. Remove the screw on the gas valve holding the cable tie. 8. Remove the 3 screws attaching the gas connection to the underneath side of the water heater. (Figure 2) Figure 2 Regulator screw access
Gas connection attached with 3 screws
9. Pull the gas connection down to disconnect it from the gas control assembly. 10. Pull out the gas control assembly. Remove the wire harness from the 4 solenoids.
41
100000098 Rev B

R/C42e, R/C53e, V53e, R63LSe
WARNING
Failure to correctly assemble the components according to these instructions may result in a gas leak or explosion. Figure 3 black / yellow (large solenoid) black / blue (small solenoid) SV0 black / pink POV pink / pink (connector not shown)
11. Install the gas valve and attach the wire harness to the 4 solenoids. (Figure 3) 12. Install the gas connection with 3 screws.
13. Replace the o-ring between the gas valve and the gas connection. 14. Replace the two circular gaskets (included in kit) in the gas valve. (Figure 4) Make sure that the ribbed side faces toward the manifold and that the flat side faces toward the gas valve. 15. Start the three screws that attach the gas manifold to the gas valve. Tighten the six screws that hold the gas manifold to the combustion chamber. Finish tightening the three screws that hold the gas manifold to the gas valve. 16. Attach ignition line. 17. Perform the Gas Pressure Setting Procedure.
Figure 4
Circular gaskets
42
100000098 Rev B

1. Turn off the gas supply. 2. Turn off the 120 V power supply. 3. Remove four screws securing the front panel. Remove front panel. 4. Indoor models only: Remove the temperature controller and bracket by sliding up and out of the slots. On the V53i remove the status monitor from the bottom of the manifold (one screw). 5. Pull out wire harness connector at the gas manifold assembly. See Figure 1. 6. Move aside the ignition line by pulling it out from the clear plastic tubing. 7. Remove the six screws that attach the gas manifold to the combustion chamber (part of the heat exchanger assembly). 8. Remove the three screws that attach the gas manifold to the gas valve. Pull out the gas manifold. R/C53i(PLUS), R70e, R/C85e(PLUS), R/C85i(PLUS), R50LSi, R63LSe2, V53i, R75LSe-VA, R75LSi-VA, R94LSe-VA, R94LSi-VA
Ignition line
Six screws Wire harness connector PC Board (dip switches) Three screws Figure 1 9. Remove the four screws attaching the gas connection to the underneath side of the water heater. Figure 2.
Regulator screw access Figure 2 Gas connection attached with 4 screws
10. Pull the gas connection down to disconnect it from the gas control assembly. 11. Pull out the gas control assembly. Remove the wire harness from the 4 solenoids.
WARNING
Failure to correctly assemble the components according to these instructions may result in a gas leak or explosion.
12. Replace the O-ring (included in kit) where the assembly attaches to the gas connection. Make sure the old Oring is removed and discarded. Install the new gas control assembly.
43
100000098 Rev B

R/C53i(PLUS), R70e, R/C85e(PLUS), R/C85i(PLUS), R50LSi, R63LSe2, V53i, R75LSe-VA, R75LSi-VA, R94LSe-VA, R94LSi-VA
12. Attach wire harness to the solenoids as shown in Figure 3 below. R/C53i(PLUS), R70e, R/C85e(PLUS), R/C85i(PLUS), R50LSi, R63LSe2, R75LSe-VA, R75LSi-VA, R94LSe-VA, R94LSi-VA
MAIN SOLENOID VALVE SV0 SOLENOID VALVE 1 SV1 SOLENOID VALVE 2 SV2 SOLENOID VALVE 3 SV3
P BK Y BK BL BK BR BK
POV P
V53i
MAIN SOLENOID VALVE SOLENOID VALVE 1 SOLENOID VALVE 2 SOLENOID VALVE 3
Figure 3
MODLATING SOLENOID VALVE
13. Remove old packing from gas manifold. Install the gas manifold using 2 new packings (included in kit) between the manifold and the heat exchanger. (Figure 4). 14. Replace the two circular gaskets (included in kit) in the gas valve (Figure 5). Make sure that the ribbed side faces toward the manifold and that the flat side faces toward the gas valve.
Upper packing Lower packing (U shaped)
Circular gaskets (from kit) in gas valve
Figure 4
Figure 5
15. Start the three screws that attach the gas manifold to the gas valve. Tighten the six screws that hold the gas manifold to the combustion chamber. Finish tightening the three screws that hold the gas manifold to the gas valve. 16. Attach wiring harness connector (black & brown wires) to the gas manifold. 17. For indoor models only, install the temperature controller and bracket or for the V53i install the status monitor. 18. Attach ignition line. 19. Perform the Gas Pressure Setting Procedure.
44
100000098 Rev B

1. Turn off the gas supply. 2. Turn off the 120 V power supply. 3. Remove four screws securing the front panel. Remove front panel. 4. On indoor models, remove the bracket holding the controller (1 screw). (Figure 1) 5. Move aside the ignition line by pulling it out from the clear plastic tubing. (Figure 2) 6. Disconnect 3 solenoid harnesses from the bottom of the manifold. 7. Remove the 5 screws that attach the gas manifold to the combustion chamber (part of the heat exchanger assembly). (Figure 2) 8. Remove the 2 screws that attach the gas manifold to the gas valve. These screws are machine screws and must be used at these locations. (Figure 2) 9. Pull out the gas manifold and remove the connector at the ignitor at the left side of the gas manifold. 10. Remove the 3 screws attaching the gas connection to the under side of the water heater. (Figure 3) 11. Remove the screw attaching the gas valve to the rear of the case. (Figure 2) 12. Pull the gas connection down to disconnect it from the gas control assembly. Figure 1 (indoor models) 5 screws (gas manifold) 2 machine screws (gas valve) Bracket screw R/C98e(ASME), R/C98i(ASME), R98LSe(ASME), R98LSi(ASME)
Figure 2
Water line connections
Screw (gas valve, step 11) Regulator screw access
Figure 3
Gas connection attached with 3 screws
45
100000098 Rev B

R/C98e(ASME), R/C98i(ASME), R98LSe(ASME), R98LSi(ASME)
WARNING
13. Pull out the gas control assembly. Remove the wire harness from the 2 solenoids. 14. Remove old o-ring from gas connection and install new o-ring from kit. 15. Install the gas valve and attach the wire harness to the 2 solenoids. (Figure 4)
black / orange
orange / orange Figure 4
16. Install the gas connection with 3 screws. 17. Replace the circular gasket (included in kit) in the gas valve. (Figure 5) Make sure that the ribbed side faces toward the manifold and that the flat side faces toward the gas valve. 18. Reconnect gray/gray harness to ignitor module before installing manifold. 19. Remove old packing from manifold and install new packing. 20. Start the 2 screws that attach the gas manifold to the gas valve. Tighten the 5 screws that hold the gas manifold to the combustion chamber. Finish tightening the 2 screws that hold the gas manifold to the gas valve. 21. Install screw attaching the gas valve to the back of the cabinet. 22. Install he 3 solenoid valve harness to the manifold. 23. Attach ignition line. 24. On indoor models, install the bracket with the controller. 25. Perform the Gas Pressure Setting Procedure. Figure 5 Gasket
46
100000098 Rev B

1. Turn off gas supply. 2. Turn off water supply. 3. Turn off 120v power supply. 4. Remove four screws securing the front panel. Remove front panel. Remove controller assembly (indoor model only) 5. RC80HPi: Remove temperature controller. Remove two screws for temperature controller bracket. Remove bracket. VB Models: Slide controller bracket up and out of the slots on the cabinet. Remove gas manifold and gas valve 6. Disconnect high tension cord from ignitor. 7. Disconnect flame rod wires. (yellow and red) 8. Remove six pan head screws from manifold (six screws outer edge) and three machine screws, at bottom of manifold, to gas valve. 9. Disconnect ignitor module harness, mounted on manifold. (gray/gray) 10. Disconnect the two solenoid wire harnesses at bottom of manifold. Remove manifold plate. 11. Remove the four screws attaching the gas connection to the bottom side of water heater. 12. Pull the gas connection down to disconnect it from the gas control assembly. 13. Pull out the gas control assembly. Remove the three solenoid wire harnesses. Ignitor Manifold Flame rods RC80HPi, RC80HPe, R75LSe-VB, R75LSi-VB, R94LSe-VB, R94LSi-VB
17. Remove old packing from gas manifold. Install new packing from kit to the manifold plate. 18. Reconnect two solenoid wire harnesses to manifold. 19. Reconnect ignitor module harness. 20. Start the three screws that attach the gas manifold to the gas valve. Install and tighten the six screws that hold the gas manifold to the combustion chamber. Tighten the three screws that hold the gas manifold to the gas valve. 21. Reconnect high tension cord to ignitor. 22. Reconnect flame rod wires. (yellow and red) Install temperature controller assembly (indoor model only) 23. RC80HPi: Install temperature controller bracket with two screws. Install temperature controller. VB Models: Slide controller bracket into the slots on the cabinet. Testing and close up 24. After calibrating the low and high gas pressure settings, install the front panel using four screws.
WARNING
Failure to correctly assemble the components according to these instructions may result in a gas leak or explosion. Install gas valve and gas manifold 14. Install the gas control assembly and connect the wire harness to the three solenoids. 15. Discard o-ring from gas connection. Install new o-ring from kit. Install the gas connection with four screws. 16. Replace the circular gaskets (included in kit) in the gas valve. Ensure that the ribbed side faces outward.
47
100000098 Rev B

1. Turn off gas supply. 2. Turn off water supply. 3. Turn off 120v power supply. 4. Remove four screws securing the front panel. Remove front panel. Remove controller assembly (indoor model only) 5. Remove temperature controller. Remove two screws for temperature controller bracket. Remove bracket. Remove gas manifold and gas valve 6. Disconnect high tension cord from electrode. Remove one screw for electrode bracket. Remove bracket from manifold. 7. Disconnect flame rod wires. (yellow and red) 8. Remove seven pan head screws from manifold (six screws outer edge, one screw in middle) and three machine screws, at bottom of manifold, to gas valve. 9. Disconnect the four solenoid wire harnesses at bottom of manifold. Remove manifold plate. 10. Remove the three screws attaching the gas connection to the bottom side of water heater. 11. Pull the gas connection down to disconnect it from the gas control assembly. 12. Pull out the gas control assembly. Remove the two solenoid wire harnesses. Install gas valve and gas manifold 13. Install the gas control assembly and connect the wire harness to the two solenoids. 14. Install the gas connection with three screws. 15. Replace the circular gasket (included in kit) in the gas valve. Ensure that the ribbed side faces outward. 16. Remove packing from manifold. Install new packing from kit to the gas manifold. 17. Start the three screws that attach the gas manifold to the gas valve. Install and tighten the seven screws that hold the gas manifold to the combustion chamber. Tighten the three screws that hold the gas manifold to the gas valve. Manifold RC98HPi, RC98HPe
18. Connect the four solenoid wire harnesses at the bottom of the manifold. Install electrode bracket with one screw to gas manifold. Connect high tension cord to electrode. Install temperature controller assembly (indoor model only) 19. Install temperature controller bracket with two screws. Install temperature controller. Testing and close up 20. After calibrating the low and high gas pressure settings (see next page), install the front panel using four screws.
48
100000098 Rev B

Fan
1. Turn off the gas supply. 2. Turn off the 120 V power supply. 3. Turn off the water supply. 4. Remove four screws securing the front panel. Remove front panel. 5. On the V53e and R63LSe, remove the screws (3) holding the bracket with the surge protector. (Figure 1) 6. Disconnect the wire harness at the fan assembly. (Figure 2) 7. On the V53e and R63LSe, remove the screw attaching the bracket with the ignitor to the bottom of the burner case. (Figure 2) 8. Remove the three screws attaching the fan sub -assembly to the fan casing. (Figure 3) 9. Pull out the fan sub-assembly. 10. Install the new fan sub-assembly and tighten with three screws. 11. On the V53e and R63LSe, install the bracket with the ignitor with one screw. 12. Attach the wire harness to the fan assembly (white, yellow, black, red wires). 13. On the V53e and R63LSe, install the bracket with the surge protector with three screws. 14. Install front panel using 4 screws. 15. Turn on water supply, power supply, and gas supply. Wire Harness Connector Figure 2 1 screw Figure 1 R/C42e, R/C53e, V53e, R63LSe
2 screws at bottom
Figure 3
3 screws
49
100000098 Rev B

Fan
1. Turn off the gas supply. 2. Turn off the 120 V power supply. (The fan may be damaged if it is removed with power still applied.) 3. Turn off the water supply. 4. For VB models, remove the screw covers by pressing them down and sliding them off horizontally. 5. Remove four screws securing the front panel. Remove front panel. 6. For V and VA models, disconnect wire harness at the fan assembly. For VB models disconnect wire harness at the Molex connector. 7. For V and VA models, pull out the harness attached to the solenoid on the manifold to make room to pull out the fan assembly. 8. Remove the two screws that attach the fan assembly to the bottom of the burner. 9. Pull out the fan assembly. 10. Install the fan assembly by inserting the tab on the fan assembly into the slot at the base of the heat exchanger and attaching with two screws. 11. For V and VA models, attach the wire harness to the solenoid on the gas manifold (brown, black wires). 12. Attach the wire harness to the fan assembly (white, yellow, black, red wires). 13. Install front panel using 4 screws. For VB models, slide on screw covers. 14. Turn on water supply, power supply, and gas supply. R70e, R/C85e(PLUS), R63LSe2, R75LSe, R94LSe
V and VA Models
Two screws attaching the fan Two screws attaching the ignitor bracket
VB Models
Two screws attaching the fan
Solenoid on the manifold
Wire harness connection on the fan assembly Wire harness Molex connection
50
100000098 Rev B

Fan
1. Turn off the gas supply. 2. Turn off the 120 V power supply. (The fan may be damaged if it is removed with power still applied.) 3. Turn off the water supply. 4. For VB models, remove the screw covers by pressing them down and sliding them off horizontally. 5. Remove four screws securing the front panel. Remove front panel. 6. For VB models, remove the controller bracket. 7. For V and VA models, disconnect wire harness at the fan assembly. For VB models disconnect wire harness at the Molex connector. 8. For V and VA models, pull out the harness attached to the solenoid on the manifold to make room to pull out the fan assembly. 9. Remove the air temperature thermistor (two white wires) at the connection with the (white and orange wires on VA models) / (white and yellow wires on VB models) within the wire bundle. 10. Loosen the ducting from the fan assembly by pinching open the metal clamp. 11. Remove the two screws that attach the fan assembly to the bottom of the burner. 12. Pull out the fan assembly. 13. Install the fan assembly by inserting the tab on the fan assembly into the slot at the base of the heat exchanger and attaching with two screws. 14. Push ducting over fan assembly inlet and secure with metal clamp. 15. For V and VA models, attach the wire harness to the solenoid on the gas manifold (brown, black wires). 16. Attach the wire harness to the fan assembly (white, yellow, black, red wires). 17. Attach the air temperature thermistor (O/W on VA models; O/Y on VB models). 18. For VB models, install the controller bracket. 19. Install front panel using 4 screws. For VB models, slide on screw covers. 20. Turn on water supply, power supply, and gas supply. R/C53i(PLUS), R/C85i(PLUS), R50LSi, V53i, R75LSi, R94LSi
V and VA Models
2 screws Solenoid on the manifold Wire harness connection Metal clamp
VB Models
2 screws Ducting and metal clamp
Wire harness Molex connection Thermistor Molex connection
51
100000098 Rev B

Fan
1. Turn off the gas supply. 2. Turn off the 120 V power supply. 3. Turn off the water supply. 4. Remove four screws securing the front panel. Remove front panel. 5. On indoor models, remove the bracket holding the controller (1 screw). (Figure 1) 6. Disconnect the wire harness at the fan assembly. (Figure 2) 7. Remove the three screws attaching the fan motor to the fan casing. (Figure 2) 8. Pull out the fan motor. 9. Install the new fan motor and tighten with three screws. 10. Attach the wire harness to the fan assembly (white, yellow, black, red wires). 11. On indoor models, install the bracket with the remote controller. 12. Install front panel using 4 screws. 13. Turn on water supply, power supply, and gas supply. Figure 1 (indoor models) Bracket screw R/C98e(ASME), R/C98i(ASME), R98LSe(ASME), R98LSi(ASME)
Wire Harness Connector Figure 2
3 screws
52
100000098 Rev B

RC80HPe, RC80HPi 1. Turn off gas supply. 2. Turn off water supply. 3. Turn off 120v power supply. 4. (Indoor model only) Remove temperature controller. Remove two screws for temperature controller bracket. Remove bracket. 5. Disconnect fan harness connector (white, yellow, black, red). 6. Remove two screws at top of fan assembly. 7. Remove fan assembly. 8. Install new fan assembly. 9. Reinstall two screws at top of fan assembly. 10. Reconnect fan harness connector (white, yellow, black, red). 11. (Indoor model only) Reinstall temperature controller bracket with two screws. Install temperature controller in bracket. 12. Turn on 120v power. Turn on water supply. Turn on gas supply.
Fan
1. Turn off gas supply.
RC98HPe, RC98HPi
2. Turn off water supply. 3. Turn off 120v power supply. 4. (Indoor model only) Remove temperature controller. Remove two screws for temperature controller bracket. Remove bracket. 5. Disconnect high tension cord from electrode. Remove one screw for electrode module bracket. Remove electrode bracket from gas manifold. 6. Disconnect fan harness connector (white, yellow, black red). 7. Remove three screws and lock washers to fan motor. 8. Remove fan motor from housing between the copper pipes. 9. Install fan motor. Ensure fan motor is clocked correctly for harness connector. 10. Reinstall three screws and lock washers to fan motor. 11. Reinstall electrode module bracket to gas manifold with one screw. Install high tension cord to electrode. 12. (Indoor model only) Reinstall temperature controller bracket with two screws. Install temperature controller in bracket. 13. Turn on 120v power. Turn on water supply. Turn on gas supply.
2 screws
Fan Motor
53
100000098 Rev B

PC Board
1. Turn off the gas supply. 2. Turn off the 120 V power supply. 3. Turn off the water supply. 4. Remove four screws securing the front panel. Remove front panel. 5. Lift up the plastic guard covering the front of the PC board. 6. Remove the controller connections. 7. Remove the screws securing the grounding cables. 8. If a surge protector with terminals is installed, then remove this board by removing two screws. This board should be re-installed on the replacement PC board. 9. Remove the two screws at the top and bottom of the PC board. 10. Pull out the PC board, remove plastic cover, and remove the connections. 11. Adjust dip switches on the new PC board. Switches 1-8 (SW1): Configure the dip switches the same as on the original PC board. If necessary, refer to the Dip Switch section or to the Operation and Installation Manual for more information on these dip switches. Switches 1-4 (SW2): Configure according to the table. SW2 setup 1 OFF - Propane Gas ON - Natural Gas OFF position for models prior to these serial numbers: (on these units, the front panel does not have an R or C trade name, unless the front panel has been replaced) 2 V1616W, V1616WC V2020W, V2020WC V2532W, V2532WC V2532FFU, V2532FFUC V2520FFU, V2520FFUC V2526W 06.02-000001 05.07-000001 05.05-117257 05.05-117257 05.05-109539 05.05-110434 SW1 SW2 Figure 1 Screw R/C42e, R/C53e
Potentiometer
Burner test point
Surge protector board with terminals
Screw
Grounding cables
12. Attach connections and plastic cover. 13. Insert PC board and attach with two screws. 14. Attach the grounding cables with screws. 15. Attach connections for the controller. 16. Perform the Gas Pressure Setting Procedure.
ON position for other models, serial numbers 3 4 OFF position OFF - Residential Models ON - Commercial Models
54
100000098 Rev B

PC Board
1. Turn off the gas supply. 2. Turn off the 120 V power supply. 3. Turn off the water supply. 4. Remove four screws securing the front panel. Remove front panel. 5. Remove the screw connecting the PC board to the back of the water heater casing. 6. Remove the ground wire at the bottom of the cabinet. 7. Pull out the PC board and remove the connections. 8. Adjust dip switches on the new PC board. Replacement PC boards have an additional bank of 6 dip switches. Adjust as follows: Switches 1-8 (SW1): Configure the dip switches the same as on the original PC board. If necessary, refer to the Dip Switch section or to the Operation and Installation Manual for more information on these dip switches. Switches 1-6 (SW2): Configure according to the diagrams below based on your model and gas type. 9. Attach connections and insert PC board. Insert the tab on the PC board into the hole in the bottom of the case. Attach with one screw. 10. Perform the Gas Pressure Setting Procedure. Potentiometer V53e, R63LSe
Figure 1
Screw
SW1 SW2
Burner test point
SW2 setup for V53e Propane (LPG) Natural Gas (NG)
SW2 setup for R63LSe Propane (LPG) Natural Gas (NG)
Switch No.
ON O F F 1 2 3 4 5 6
Switch No.
ON O F F 1 2 3 4 5 6
Switch No.
ON O F F 1 2 3 4 5 6
Switch No.
ON O F F 1 2 3 4 5 6
55
100000098 Rev B

PC Board
1. Turn off the gas supply. 2. Turn off the 120 V power supply. 3. Turn off the water supply. 4. Remove four screws securing the front panel. Remove front panel. 5. Lift up the plastic guard covering the front of the PC board. 6. Remove the controller connections and the two ground wires at the bottom of the cabinet. 7. If a surge protector with terminals is installed, then remove this board by removing two screws. This board should be re-installed on the replacement PC board. 8. Remove the two screws at the top and bottom of the PC board. 9. Pull out the PC board, remove plastic cover, and remove the connections. 10. Adjust dip switches on the new PC board. Switches 1-8 (SW1): Configure the dip switches the same as on the original PC board. If necessary, refer to the Dip Switch section or to the Operation and Installation Manual for more information on these dip switches. V Series (R70e, R/C85e, R/C53i, R/C85i) Switches 1-4 (SW2): Configure according to the table. VA and VB Series (R50LSi, R63LSe2, R75LSe, R94LSe, R75LSi, R94LSi) Switches 1-6 (SW2): Replacement PC boards for the VA and VB series have an additional bank of 6 dip switches. Configure according to the diagrams based on your model and gas type. NOTE: The V53i (VB2020FFU) does not have the SW2 dip switch. 11. Attach connections and plastic cover. 12. Insert PC board and attach with two screws. 13. If a surge protector with terminals was installed on the original PC board, remove it and install it on the new PC board. See Figure 1. 14. Attach connections for the remote controller. 15. Attach plastic guard. 16. Install two ground wires at the bottom of the cabinet. 17. Perform the Gas Pressure Setting Procedure. 4 3 2 Screw Figure 1 R/C53i(PLUS), R70e, R/C85e(PLUS), R/C85i(PLUS), R50LSi, R63LSe2, V53i, R75LSe, R75LSi, R94LSe, R94LSi, RC80HPe, RC80HPi, RC98HPe, RC98HPi
Remote controller terminals (NOT for 120 V power) If these 2 terminals are present then this is a surge protector board with terminals to connect freeze protection solenoid valves and should be installed with the new PC board. Attached with 2 screws Screw SW2 setup for V Series (R70e, R/C85e, R/C53i, R/C85i) 1 OFF - Propane Gas ON - Natural Gas OFF position for models prior to these serial numbers: (on these units, the front panel does not have an R or C trade name, unless the front panel has been replaced) V1616W, V1616WC V2020W, V2020WC V2532W, V2532WC V2532FFU, V2532FFUC V2520FFU, V2520FFUC V2526W OFF position OFF - Residential Models ON - Commercial Models 06.02-000001 05.07-000001 05.05-117257 05.05-117257 05.05-109539 05.05-110434
ON position for other models, serial numbers
56
100000098 Rev B

PC Board
R/C53i(PLUS), R70e, R/C85e(PLUS), R/C85i(PLUS), R50LSi, R63LSe2, V53i, R75LSe, R75LSi, R94LSe, R94LSi RC80HPe, RC80HPi, RC98HPe, RC98HPi
Note carefully the full model number of the unit. NOTE: The V53i (VB2020FFU) does not have the SW2 dip switch.
SW2 Bank of 6 R50LSi REU-VA2019FFUD-US R50LSi REU-VA2019FFUD-UC R75LSi REU-VA2528FFUD-US REU-VA2528FFUD(A)-US R75LSe REU-VA2528WD-US REU-VA2528WD(A)-US
NG 1 2 3 4 5 6 ON ON ON ON ON OFF SW2 Bank of 6
LPG OFF ON ON ON ON OFF
NG ON ON ON OFF OFF OFF
LPG OFF ON ON OFF OFF OFF
NG ON ON OFF ON OFF OFF
LPG OFF ON OFF ON OFF OFF
NG OFF OFF OFF ON OFF OFF
LPG ON OFF OFF ON OFF OFF
R94LSi REU-VA2535FFUD-US REU-VA2535FFUD-UC REU-VB2735FFUD-US R75LSi REU-VA2528FFUD-UC REU-VB2528FFUD-US
R94LSe REU-VA2535WD-US REU-VA2535WD-UC REU-VB2735WD-US R75LSe REU-VA2528WD-UC REU-VB2528WD-US
R63LSe2 RUE-VA2024WD(A)-UC
NG 1 2 3 4 5 6 ON ON OFF OFF OFF OFF SW2 Bank of 6
LPG OFF ON OFF OFF OFF OFF RC98HPi NG LPG OFF ON OFF OFF OFF OFF
NG ON OFF OFF OFF OFF OFF RC98HPe NG ON OFF OFF OFF OFF OFF LPG OFF OFF OFF OFF OFF OFF
LPG OFF OFF OFF OFF OFF OFF RC80HPi NG ON ON ON OFF OFF OFF LPG OFF ON ON OFF OFF OFF
NG ON OFF ON OFF OFF OFF
LPG OFF OFF ON OFF OFF OFF
RC80HPe NG ON OFF ON OFF OFF OFF LPG OFF OFF ON OFF OFF OFF
1 2 3 4 5 6
ON ON OFF OFF OFF OFF
57
100000098 Rev B

PC Board
1. Turn off the gas supply. 2. Turn off the 120 V power supply. 3. Remove four screws securing the front panel. Remove front panel. 4. Remove the 2 screws connecting the PC board to the water heater casing. 5. Pull out the PC board and remove the connections. 6. Adjust dip switches on the new PC board. 7. Attach connections and insert PC board. Switches 1-8 (SW1): Configure the dip switches the same as on the original PC board. If necessary, refer to the Dip Switch section or to the Operation and Installation Manual for more information on these dip switches. Switches 1-4 (SW2) or Switches 1-6 (SW2): Configure according to the diagrams based on your model and gas type. Screw Attach with 2 screws. 8. Perform the Gas Pressure Setting Procedure. SW1 SW2 Figure 1 Burner test point Potentiometer Screw R/C98e(ASME), R/C98i(ASME), R98LSe(ASME), R98LSi(ASME)
Surge protector
SW2 Bank of 6 NG 1 2 3 4 5 6 ON
R98i LPG OFF OFF OFF OFF
R98e NG ON ON OFF OFF LPG OFF ON OFF OFF NA NG ON
C98i LPG OFF OFF OFF ON
C98e NG ON ON OFF ON LPG OFF ON OFF ON
R98LSi NG ON ON OFF OFF OFF OFF LPG OFF ON OFF OFF OFF OFF
R98LSe NG ON OFF OFF OFF OFF OFF LPG OFF OFF OFF OFF OFF OFF
OFF OFF OFF
OFF OFF ON
58
100000098 Rev B

Water Flow Control Assembly
R/C42e, R/C53e
NOTICE
Due to design changes, the new valve may appear different than the installed valve in color, size, and in the number of wires in the harness connections.
1. Turn off the gas supply. 2. Turn off the 120 V power supply. 3. Turn off the water supply. Drain all water from the appliance. 4. Remove four screws securing the front panel. Remove front panel.
Remove the water flow assembly

5. Remove 2 screws and bracket at the water flow assembly. The bracket can be left on the water line. Pull out the water line. (Figure 1) Figure 1
2 screws and bracket (water flow assembly)
6. Remove the 3 screws attaching the water inlet to the under side of the water heater.
(Figure 2).
Figure 2
Water inlet
59
100000098 Rev B

R/C42e, R/C53e
7. Pull out the water flow servo assembly and disconnect the cable harnesses. (Figure 3) A. water flow sensor harness (black/yellow/red wires) B. water flow servo harness (red/blue/brown/yellow/gray or red/blue/brown/orange/yellow/gray wires) C. heating element Figure 3 heating element connector water flow servo connector
water flow sensor connector
Assemble
8. Place the new water flow assembly inside the water heater and attach the cable harnesses. 9. Replace the O-ring on the water inlet (included in kit). Attach the water flow assembly through the bottom of the compartment to the water inlet using 3 screws. The shorter screw can be installed first to connect the water flow assembly to the bottom of the compartment. Then install the 2 longer screws through the water inlet. 10. Replace the O-ring on the water line (included in kit). Attach the water line to the water flow assembly with 2 screws and bracket. 11. Install the front panel using 4 screws. Turn on the water supply, power supply, and gas supply. 12. Open a hot water tap and ensure there are no leaks at the water heater.
60
100000098 Rev B

1. Turn off the gas supply. 2. Disconnect the 120 V power supply. 3. Turn off the water supply. Drain all water from the appliance. 4. Remove four screws securing the front panel. Remove front panel. V53e, R63LSe

5. Remove the bracket holding the surge protector (one screw on top of the bracket and two from the bottom of the cabinet. 6. Remove 2 screws and 1 bracket at the water flow assembly. Pull out the water line. (Figure 1) Figure 1
bracket with surge protector
2 screws and bracket (water flow assembly)
7. Remove the 3 screws attaching the water inlet to the under side of the water heater. (Figure 2).
Figure 2
Water inlet
61
100000098 Rev B

V53e, R63LSe
8. Pull out the water flow servo assembly and disconnect the cable harnesses. (Figure 3) a. water flow sensor harness (black/yellow/red wires) b. water flow servo harness (red/blue/brown/yellow/gray or red/blue/brown/orange/yellow/gray wires) at the water flow assembly c. heating element
Figure 3 water flow sensor harness
water flow servo harness
heating element
Assemble
9. Place the new water flow assembly inside the water heater and attach the cable harnesses. 10. Replace the O-ring on the water inlet (included in kit). (Figure 4) Attach the water flow assembly through the bottom of the compartment to the water inlet using 3 screws. The shorter screw can be installed first to connect the water flow assembly to the bottom of the compartment. Install the 2 longer screws through the water inlet. Figure 4 O-ring
11. Replace the O-ring on the water line (included in kit). Attach the water line to the water flow assembly with 2 screws and bracket. 12. Install the bracket with the surge protector. 13. Install the front panel using 4 screws. 14. Turn on the water supply, power supply, and gas supply. 15. Open a hot water tap and ensure there are no leaks at the water heater.
62
100000098 Rev B

R/C53i, R70e, R50LSi, R63LSe2, V53i, R75LSe, R75LSi
NOTICE
Due to design changes, the new valve may appear different than the installed valve in color, size, and in the number of wires in the harness connections.
1. Turn off the gas supply. 2. Turn off the 120 V power supply. 3. Turn off the water supply. Drain all water from the appliance. 4. (On VB models, remove the screw covers by pressing them down and sliding them off horizontally.) Remove four screws securing the front panel. Remove front panel.

5. Remove 1 screw and bracket at the water flow assembly. The bracket can be left on the water line. Pull out the water line. (Figure 1) 6. Remove the controller bracket (on indoor models only).
Figure 1
1 screw and bracket (water flow assembly)
7. Remove the 4 screws attaching the water inlet to the underneath side of the water heater. (Figure 2). Figure 2
Water inlet
63
100000098 Rev B

R/C53i, R70e, R50LSi, R63LSe2, V53i, R75LSe, R75LSi
8. Pull out the water flow servo assembly and disconnect the cable harnesses. (Figure 3) A. water flow sensor harness (black/yellow/red wires) B. water flow servo harness (red/blue/brown/yellow/gray or red/blue/brown/orange/yellow/gray wires) C. heating element D. For VB models remove the ceramic heater from the valve body
water flow servo connector
Figure 3
heating element connector
water flow sensor connector
Assemble
9. Place the new water flow assembly inside the water heater and attach the cable harnesses. For VB models, re-install the ceramic heater. 10. Replace the O-ring on the water inlet (included in kit). Attach the water flow assembly through the bottom of the compartment to the water inlet using 4 screws. The 2 shorter screws can be installed first to connect the water flow assembly to the bottom of the compartment. Then install the 2 longer screws through the water inlet. 11. Replace the O-ring on the water line (included in kit). Attach the water line to the water flow assembly with 1 screw and bracket. 12. Install the controller bracket (on indoor models only). 13. Install the front panel using 4 screws. (On VB models, slide on the screw covers.) 14. Turn on the water supply, power supply, and gas supply. 15. Open a hot water tap and ensure there are no leaks at the water heater.
64
100000098 Rev B

R/C85e(PLUS), R/C85i(PLUS), R94LSe, R94LSi
NOTICE
Due to design changes, the new valve may appear different than the installed valve in color, size, and in the number of wires in the harness connections. Figure 1 2 screws Solenoid on the manifold (V, VA models) Wire harness connection on the fan assembly Ducting and metal clamp (indoor models only)
1. Turn off gas supply. 2. Turn off water supply. Drain all water from appliance. 3. Turn off 120v power supply. 4. (On VB models, remove screw covers.) Remove four screws securing the front panel. Remove front panel. Remove controller assembly (indoor VB model only) 5. Remove one screw from ignitor module bracket. Remove bracket. 6. Remove temperature controller and bracket by sliding up and out of slots on cabinet. Remove ignitor module (outdoor VB model only) 7. Remove two screws from ignitor module bracket. Remove bracket and module. Remove fan assembly (Figure 1) 8. Disconnect fan motor harness. 9. Disconnect air inlet thermistor harness. (indoor model only) 10. Release the fan duct from the left side by pinching open the metal clamp. (indoor model only) 11. Remove two screws that attach the fan assembly to the bottom of the combustion chamber. 12. Remove fan assembly. On V and VA models, remove the solenoid harness on the manifold to make room to pull out the fan assembly. Remove water flow servo valve and bypass valve 13. Remove two screws and brackets at the bypass valve. Remove two copper tubes. 14. Remove two screws attaching the water inlet to the bottom of the water heater cabinet. (Figure 3) 15. Remove two screws attaching the water flow servo valve to the bottom of the water heater cabinet. 16. Disconnect the wire harnesses (water flow sensor harness - black, yellow, red wires; bypass servo assembly harness - white, red, yellow, orange, brown wires; water flow servo valve harness - 5-8 multicolored wires depending on model). (Figure 4)
Figure 2
Water flow servo assembly connections
Figure 3
Water inlet
65
100000098 Rev B

17. For VB models only, remove one screw that is securing ceramic heater. Remove ceramic heater from water flow servo assembly. 18. Pull out the water flow servo assembly and bypass servo assembly. 19. Remove two screws to separate the bypass servo assembly from the water flow servo assembly. (Figure 5) Reinstall water flow servo valve and bypass valve 20. Replace the O-ring (included in kit) between the water flow servo assembly and the bypass servo assembly. Attach the water flow servo assembly to the bypass assembly with two screws. 21. Place inside the heater and attach the wire harnesses. 22. For VB models only, reinstall ceramic heater. 23. Replace the O-ring on the water inlet (included in kit). Attach the water flow assembly to the bottom of the water heater cabinet using two short screws. Then install the two longer screws through the water inlet. 24. Replace the O-ring on the copper lines (included in kit). Attach the two copper lines to the bypass valve, with one bracket and one screw for each line. Reinstall fan assembly 25. Reconnect fan motor harness. 26. Reconnect air inlet thermistor harness. (indoor model only) 27. Reinstall the fan duct. (indoor model only) 28. Install two screws that attach the fan assembly to the bottom of the combustion chamber. Install controller assembly (indoor VB model only) 29. Reinstall temperature controller and bracket. 30. Reinstall ignitor module bracket with one screw. Install ignitor module (outdoor VB model only) 31. Install bracket and ignitor module with two screws. Close up 32. Turn on the water supply, power supply, and gas supply. 33. Open hot water tap and ensure there are no leaks at the water heater. 34. Install front panel using four screws. Reinstall screw covers. heating element connector water flow sensor R/C85e(PLUS), R/C85i(PLUS), R94LSe, R94LSi
Figure 4
Figure 5
66
100000098 Rev B

1. Turn off the gas supply. 2. Turn off the 120 V power supply. 3. Turn off the water supply. Drain all water from the appliance. 4. Remove four screws securing the front panel. Remove front panel. 5. Remove 2 screws and 2 brackets at the water flow servo assembly. Pull out the water lines. (Figure 1) 6. Disconnect the wiring harnesses from the water flow sensor, heating element, water flow servo assembly, and bypass servo assembly. (Figure 1) 7. Remove the 4 screws attaching the water inlet to the underneath side of the water heater. (Figure 2) 8. Pull out the water flow servo assembly and bypass servo assembly. (Figure 3) 9. Remove 2 screws in order to separate the bypass servo assembly from the water flow servo assembly. (Figure 3) 10. Replace the O-ring (included in kit) between the water flow servo assembly and the bypass servo assembly. Attach the new water flow servo assembly to the bypass servo assembly with 2 screws. 11. Reconnect the wire harnesses (4). 12. Place inside the water heater. 13. Attach the water flow assembly to the water inlet using 4 screws. The 2 shorter screws can be installed first to connect the water flow assembly to the bottom of the compartment. Install the 2 longer screws through the water inlet. 14. Replace the O-ring on the water lines (included in kit). Attach the two water lines to the bypass servo assembly with 1 screw each. 15. Install the front panel using 4 screws. 16. Turn on the water supply, power supply, and gas supply. 17. Open a hot water tap and ensure there are no leaks at the water heater. Wire harness Screws (2) Water flow servo Bypass servo Figure 2 Water inlet Water lines R/C98e(ASME), R/C98i(ASME), R98LSe(ASME), R98LSi(ASME)
Figure 1
Water flow sensor
Heating element
Figure 3
67
100000098 Rev B

1. Turn off gas supply. 2. Turn off water supply. Drain all water from appliance. 3. Turn off 120v power supply. 4. Remove four screws securing the front panel. Remove front panel. Remove controller assembly (indoor models only) 5. Remove temperature controller. Remove two screws for temperature controller bracket. Remove bracket. Remove water flow servo valve 6. Remove two screws and brackets at the bypass valve. Remove two copper tubes. (Figure 1). 7. Remove four screws attaching the water inlet to the bottom of the water heater cabinet. 8. Disconnect the wire harnesses (water flow sensor harness - black, yellow, red wires; bypass servo assembly harness - white, red, yellow, orange, brown wires, water flow servo valve harness - gray, brown, orange, yellow, white, pink, blue, red). Remove heating element. 9. Pull out the water flow servo assembly and bypass servo assembly. 10. Remove two screws in order to separate the bypass servo assembly from the water flow servo assembly. Reinstall water flow servo valve 11. Replace the O-ring (included in kit) between the water flow servo assembly and the bypass servo assembly. Attach the new water flow servo assembly to the bypass assembly with two screws. 12. Place inside the heater and attach the wire harnesses. Install heating element. 13. Replace the O-ring on the water inlet (included in kit). Attach the water flow assembly to the water inlet using four screws. The two shorter screws can be installed first to connect the water flow assembly to the bottom of the cabinet. Then install the two longer screws through the water inlet. 14. Replace the O-ring on the water lines (included in kit). Attach the two water lines to the bypass valve, with one bracket and one screw for each line. Water flow servo assembly connections RC80HPe, RC80HPi, RC98HPe, RC98HPi Install controller assembly (indoor models only) 15. Install temperature controller bracket with two screws. Install temperature controller. 16. Turn on the water supply, power supply, and gas supply. 17. Open hot water tap and ensure there are no leaks at the water heater. 18. Install front panel using four screws.
68
100000098 Rev B

Heat Exchanger
1. Turn off the gas supply. 2. Turn off the 120 V power supply. 3. Turn off the water supply. Drain all water from the appliance. 4. Remove four screws securing the front panel. Remove front panel. 5. On the V53e and R63LSe, remove the screws (3) holding the bracket with the surge protector. (Figure 1) 6. Disconnect the wire harness at the fan assembly. (Figure 2) 7. Remove screws and brackets securing the water line connections. (Figure 1) 8. Remove the 3 screws that attach the gas manifold to the gas valve. These screws are machine screws and must be used at these locations. (Figure 1) 9. Remove the 6 screws that attach the gas manifold to the combustion chamber (part of the heat exchanger assembly). (Figure 1) 10. Pull out the gas manifold. 1 screw R/C42e, R/C53e, V53e, R63LSe
Figure 1
Water Connections 6 screws (gas manifold)
Bracket
3 machine screws (gas valve)
Figure 2
Wire Harness Connector
69
100000098 Rev B

Heat Exchanger
11. Remove the clips and screws (5 for the V53e and R/C42; 6 for the R/C53 and R63LSe) attaching the burner cover plate to the combustion chamber. (Figure 3) 12. Remove the 2 screws attaching the burner to the heat exchanger. Pull out the burner. (Figure 3) 13. Disconnect wire harnesses: A. Thermal fuse connectors (two) from bundle near PCB (BK to RD and WT to RD) B. Disconnect overheat bimetal from upper right heat exchanger. C. Heat exchanger thermistor connector from bundle near PCB (WT/WT to WT/ PK) D. Heating element connectors: water flow servo assembly, hot water outlet, heat exchanger heating elements (at bottom left), frost sensing switch (bottom center). E. Ignitor harness in front of fan housing (GY/GY) 14. Remove the 4 screws connecting the heat exchanger to the casing. (Figures 4 and 5) 15. Pull out the assembly. IMPORTANT: Take note of wire harness routing prior to removal. 16. Remove overheat bimetal from upper right heat exchanger. (one screw) Install on new heat exchanger. 17. Remove thermistor and o ring from upper left heat exchanger. (two screws, one clip) Install thermistor and new o ring (in kit) on new heat exchanger. 18. Remove thermal fuse harness and clips from around heat exchanger. Install on new heat exchanger and connect to overheat bimetal connector. 19. Remove heating elements and clips from heat exchanger. Install on new heat exchanger. 20. Remove ignitor module and bracket from bottom of combustion chamber. Figure 4 Top attachment screws R/C42e, R/C53e, V53e, R63LSe
Figure 3
Screws attaching burner
Burner cover plate
Figure 5
Bottom attachment screws
70
100000098 Rev B

Heat Exchanger
21. Remove the fan assembly (four screws) and install on new heat exchanger. 22. Install ignitor module and bracket on new heat exchanger. 23. Remove the flue outlet (seven screws) and install on the new heat exchanger. 24. Install the largest O-ring (included in kit) over the water outlet tube and the smaller O-ring (included in kit) over the water inlet tube. (Figure 1) 25. Install the 4 screws at the top and bottom of the heat exchanger to the casing. (Figures 4 and 5) 26. Insert the burner and place the burner cover plate into position. Attach the burner cover plate first with screws (5 for the V53e and R/C42; 6 for the R/C53 and R63LSe) and then attach the burner with 2 screws. (Figure 3) 27. Make sure that the black gaskets (Figure 6) are intact on the gas control assembly. Make sure that the ribbed side faces toward the manifold and that the flat side faces toward the gas valve. 28. Attach the gas manifold with 3 machine screws at the gas control assembly. (Figure 1) 29. Attach the gas manifold with 6 screws at heat exchanger. (Figure 1) 30. Connect wire harnesses: A. Thermal fuse connectors (two) from bundle near PCB (BK to RD and WT to RD) B. Heat exchanger thermistor connector from bundle near PCB (WT/WT to WT/PK) C. Heating element connectors: water flow servo assembly, hot water outlet, heat exchanger heating elements (at bottom left), frost sensing switch (bottom center). D. Ignitor harness in front of fan housing (GY/GY). 31. Attach the wire harness to the fan assembly (white, yellow, black, red wires). 32. Attach the brackets to the water line connections. (Figure 1) 33. On the V53e and R63LSe, install the bracket with the surge protector (3 screws). (Figure 1) 34. Install the front panel using 4 screws. 35. Turn on the water supply, power supply, and gas supply. Figure 6 R/C42e, R/C53e, V53e, R63LSe
Black gaskets
71
100000098 Rev B

Heat Exchanger
1. Turn off the gas supply. 2. Turn off the 120 V power supply. 3. Turn off the water supply. Drain all water from the appliance. 4. Remove four screws securing the front panel. Remove front panel. 5. On VB models, remove one screw from ignitor module bracket. Remove bracket. R70e, R/C85e(PLUS), R63LSe2, R75LSe, R94LSe
Burner cover plate Gas Manifold
PC Board Gas Control Valve Fan Assembly Remove Fan Assembly (Figure 2)
6. Disconnect wire harness at the fan assembly. 7. On V and VA models, pull out the harness attached to the solenoid on the manifold to make room to pull out the fan assembly. 8. Remove the 2 screws that attach the fan assembly to the bottom of the burner. 9. Pull out the fan assembly. Wire harness connection 2 screws Solenoid Figure 1
Figure 2
Disconnect Water Lines (Figure 3)

10. Remove 1 screw from the water outlet bracket. Remove the bracket by rotating and moving it up toward the bend in the tube where the diameter is smaller. 11. For models with a bypass valve, remove 2 screws and 2 brackets at the bypass servo assembly. For models without a bypass valve, remove 1 screw and 1 bracket at the water flow servo assembly.
Figure 3 Water outlet connection Water flow servo assembly connection
Disconnect PC Board (Figure 4)

12. Remove 1 screw connecting the PC Board to the heat exchanger assembly.
72
100000098 Rev B

Heat Exchanger
Remove Gas Manifold (Figure 4)
13. Remove the 3 screws that attach the gas manifold to the gas valve. These screws are machine screws and must be used at these locations. 14. Remove the 6 screws that attach the gas manifold to the combustion chamber (part of the heat exchanger assembly). 15. Pull out the ignition line and remove the gas manifold. 16. On VB models, disconnect the two solenoid harnesses form the manifold (black/red and black/orange). Ignition line 6 screws (gas manifold) PC Board screw 3 machine screws (gas valve) Figure 4 8 screws (burner cover plate) R70e, R/C85e(PLUS), R63LSe2, R75LSe, R94LSe
Remove Burner and Burner Cover Plate (Figure 5)

17. Remove the 8 screws attaching the burner cover plate to the combustion chamber. Move the cover plate to the side. It is not necessary to disconnect the wire harness from the burner cover plate. 18. Remove the 2 screws attaching the burner to the heat exchanger. Pull out the burner. Figure 5
2 screws (burner) Ignition line connection
Disconnect Wire Harness Attachments and Screws Holding the Heat Exchanger
19. Disconnect the wire harnesses: A. 1. Thermal fuse connector(s) from bundle near PCB (RD/RD to RD/RD) VB Models: (WT to RD and WT to WT) B. 2. Heat exchanger thermistor connector from bundle near PCB. (WT/WT to PK/WT) VB Models: (WT/WT to PK/PK) C. 3. Heating element connectors: water flow servo assembly, hot water outlet, heat exchanger heating elements (at bottom), frost sensing switch (bottom center). NOTE: Some models do not have a connector at water outlet or water flow servo heating elements and must be removed from the assembly. D. 4. Ignitor module harness (GY/GY) N/A for VB models 20. Remove 3 screws behind the fan. (Figure 6) 21. Remove 2 screws above the exhaust. Pull assembly from the unit. (Figure 7)
Figure 7
Figure 8
3 screws 2 screws
73
100000098 Rev B

Heat Exchanger
R70e, R/C85e(PLUS), R63LSe2, R75LSe, R94LSe
WARNING
Installation
22. Install the largest O-ring (included in kit) over the water outlet tube and the two smaller O-rings (included in kit) over the bypass servo tubes. (Figure 3) 23. Relocate water heater components: Important: Take note of wire harness routing prior to removal. A. Remove overheat bimetal from upper left heat exchanger. (one screw) Remove thermal fuse harness and clips from around heat exchanger. Install bimetal and thermal fuse on new heat exchanger. B. Remove thermistor and o ring from upper right heat exchanger. Install thermistor and new o ring (in kit) on new heat exchanger. C. Remove heating elements, sensor and clips from heat exchanger. Install on new heat exchanger. D. Remove ignitor module from bottom of combustion chamber. Install on new heat exchanger. 24. Install the new heat exchanger using 2 screws above the exhaust and 3 screws behind the fan. (Figures 6, 7) 25. Connect wire harnesses: A. Thermal fuse connector(s) from bundle near PCB (RD/RD to RD/RD) VB Models: (WT to RD and WT to WT) B. Heat exchanger thermistor connector from bundle near PCB. (WT/WT to PK/WT) VB Models: (WT/WT to PK/PK) C. Heating element connectors: water flow servo assembly, hot water outlet, heat exchanger heating elements (at bottom), frost sensing switch (bottom center). NOTE: Some models do not have a connector at water outlet or water flow servo heating elements and must be reinstalled. D. Ignitor module harness (GY/GY) N/A for VB models 26. (Figure 5) Replace the combustion chamber packing (included in kit) removing any residue from old packing. Insert the burner and place the burner cover plate into position. Attach the burner cover plate first with 8 screws and then attach the burner with 2 screws.
Install Gas Manifold and Connect PC Board

27. Make sure that the two black packings (Figure 8) are intact on the gas control assembly. Make sure that the ribbed side faces toward the manifold and that the flat side faces toward the gas valve.Attach the gas manifold with 3 machine screws at the gas control assembly. Replace the lower and upper packings (included in kit) for the manifold plate removing any residue. 28. On VB models, connect the two solenoid harnesses from the manifold (black/ red and black/orange). 29. Attach the gas manifold with 6 screws at heat exchanger. 30. Attach the ignition line at the burner cover plate. 31. Attach the PC Board to the heat exchanger with 1 screw. Figure 8
74
100000098 Rev B

Heat Exchanger
Connect Water Lines (Figure 3)
32. Attach the water outlet line and bracket with 1 screw. 33. Depending on model, attach the line to the water flow servo assembly with 1 screw and 1 bracket or attach the lines to the bypass valve with 1 screws and 1 brackets for each line. R70e, R/C85e(PLUS), R63LSe2, R75LSe, R94LSe
Install Fan Assembly (Figure 2)

34. Install the fan assembly by inserting the tab on the fan assembly into the slot at the base of the heat exchanger and attaching with two screws. 35. Attach the wire harness to the solenoid on the gas manifold (brown, black wires). 36. Attach the wire harness to the fan assembly (white, yellow, black, red wires). 37. On VB models, install the ignitor module bracket with one screw. 38. Install the front panel using 4 screws. Turn on the water supply, power supply, and gas supply. Check for gas leaks.

Heat Exchanger
1. 2. 3. 4. 5. 6. Turn off the gas supply. Turn off the 120 V power supply. Turn off the water supply. Drain all water from the appliance. Remove four screws securing the front panel. Remove front panel. On VB models except the VB2020, remove one screw from ignitor module bracket. Remove bracket. Remove temperature controller and bracket by sliding up and out of slots on cabinet. On the VB2020, remove one screw from the status monitor assembly at the gas manifold. Remove module.
R/C53i(PLUS), R/C85i(PLUS), V53i, R50LSi, R75LSi, R94LSi
Figure 1
Burner cover plate Gas Manifold PC Board Gas Control Valve Fan Assembly
Remove Fan Assembly (Figure 2)

7. Disconnect wire harness at the fan assembly. Disconnect the air temperature thermistor (two white wires) at the connection with the white and orange wires within the wire bundle. On V and VA models and VB2020, pull out the harness attached to the solenoid on the manifold to make room to pull out the fan assembly. Remove the 2 screws that attach the fan assembly to the bottom of the burner.
8.
9.
10. Loosen the ducting from the fan assembly by pinching open the metal clamp. Pull out the fan assembly.
Disconnect Water Lines and PC Board (Figure 2)

11. Remove 1 screw from the water outlet bracket. Remove the bracket by rotating and moving it up toward the bend in the tube where the diameter is smaller. 12. For models with a bypass valve, remove 2 screws and 2 brackets at the bypass servo assembly. For models without a bypass valve, remove 1 screw and 1 bracket at the water flow servo assembly. 13. Remove 1 screw connecting the PC Board to the heat exchanger assembly.
2 screws Ducting and metal clamp
Figure 2 PC board screw Solenoid on the manifold
water flow servo assembly connection
Wire harness connection on the fan assembly Wire harness bundle (air temperature thermistor connection to orange / white wires)
Water outlet connection
76
100000098 Rev B

Heat Exchanger
Remove Gas Manifold (Figure 3)
14. Remove the 3 screws that attach the gas manifold to the gas valve. These screws are machine screws and must be used at these locations. 15. Remove the 6 screws that attach the gas manifold to the combustion chamber (part of the heat exchanger assembly). 16. Pull out the ignition line and remove the gas manifold. 17. On VB models except the VB 2020, disconnect the two solenoid harnesses from the manifold (black/red and black/ orange).
R/C53i(PLUS), R/C85i(PLUS), V53i, R50LSi, R75LSi, R94LSi Figure 3
Ignition line 6 screws (gas manifold)
PC Board screw 3 machine screws (gas valve)
Remove Burner and Burner Cover Plate (Figure 4)

18. Remove the 8 screws attaching the burner cover plate to the combustion chamber. Move the cover plate to the side. It is not necessary to disconnect the wire harness from the burner cover plate. 19. Remove the 2 screws attaching the burner to the heat exchanger. Pull out the burner. 20. Disconnect the pressure tube from the heat exchanger. 21. Disconnect wire harnesses: A. B. C.
Figure 4 8 screws (burner cover plate) 2 screws (burner) Pressure tube Ignition line connection
Thermal fuse connector(s) from bundle near PCB (RD/RD to RD/RD) VB Models: (WT to RD and WT to WT) Heat exchanger thermistor connector from bundle near PCB. (WT/WT to PK/WT) VB Models: (WT/WT to PK/PK) Heating element connectors: water flow servo assembly, hot water outlet, heat exchanger heating elements (at bottom), frost sensing switch (top left heat exchanger). NOTE: Some models do not have a connector at water outlet or water flow servo heating elements and must be removed from the assembly. Ignitor module harness (GY/GY) N/A for VB models VB models only: Burner sensor from bundle near PCB. (BK/BK)
D. E.
22. Remove 8 screws connecting the assembly to the water heater casing assembly. (Figures 6, 7)
Near fan assembly location Figure 6 3 screws
At right and left upper corners of water heater 2 screws Figure 7 2 screws
1 screw
77
100000098 Rev B

Heat Exchanger
23. Pull out the assembly. Remove 3 brackets on the side and back holding the fusible link. 24. Remove the 9 screws at the cover plate over the air intake passage. (Figure 8) 25. Remove the 4 screws attaching the heat exchanger to the air intake/exhaust assembly. (Figure 9)
Figure 8 9 screws (cover plate)
Figure 9
4 screws
26. Pull apart the heat exchanger and air intake/exhaust assembly. (Figure 10) 27. Remove 4 screws attaching the bracket on top of the heat exchanger. Pull off the bracket. (Figure 11)
4 screws (bracket)
Figure 10
Figure 11 Failure to correctly assemble the components according to these instructions may result in a gas leak or explosion.
WARNING
28. Install the O-ring (included in kit) over the water outlet tube and the O-ring (included in kit) over the water flow servo tube or bypass tube. (Figure 2) 29. Install the bracket over the replacement heat exchanger. Push evenly on both sides of the bracket. Attach with four screws. (Figure 10) 30. Push the heat exchanger into the air intake/exhaust assembly. Attach with four screws. (Figure 8) 31. Attach the cover plate over the air intake passage with 9 screws. (Figure 7) 32. Relocate water heater components: Important: Take note of wire harness routing prior to removal. A. Remove overheat bimetal from upper left heat exchanger. (one screw) Remove thermal fuse harness and clips from around heat exchanger. Install bimetal and thermal fuse on new heat exchanger. Use 2 clips on back and 1 clip on side for thermal fuse Remove thermistor and o ring from upper right heat exchanger. Install thermistor and new o ring (in kit) on new heat exchanger. Remove heating elements, sensor and clips from heat exchanger. Install on new heat exchanger.Remove ignitor module from bottom of combustion chamber. Install on new heat exchanger. VB models only: Remove burner sensor from right side of heat exchanger. Install with new gasket (in kit) on new heat exchanger.
B. C. D.
78
100000098 Rev B

Heat Exchanger
33. (Figures 6a, 6b) Slide the assembly into the casing assembly and attach with 8 screws starting at the top of the water heater. 34. Connect wire harness attachments. (Figure 5) A. B. C. Thermal fuse connector(s) at bundle near PCB (RD/RD to RD/RD) VB Models: (WT to RD and WT to WT) Heat exchanger thermistor connector at bundle near PCB. (WT/WT to PK/WT) VB Models: (WT/WT to PK/PK) Heating element connectors: water flow servo assembly, hot water outlet, heat exchanger heating elements (at bottom), frost sensing switch (top left heat exchanger). NOTE: Some models do not have a connector at water outlet or water flow servo heating elements. Ignitor module harness (GY/GY) N/A for VB models VB models only: Burner sensor from bundle near PCB. (BK/BK)
D. E.
35. Connect the pressure tube. 36. (Figure 4) Replace the combustion chamber packing (included in kit) removing any residue from old packing. Insert the burner and place the burner cover plate into position. Attach the burner cover plate first with 8 screws and then attach the burner with 2 screws. 37. Make sure that the two black packings (Figure 12) are intact on the gas control assembly. Make sure that the ribbed side faces toward the manifold and that the flat side faces toward the gas valve.Attach the gas manifold with 3 machine screws at the gas control assembly. Replace the lower and upper packings (included in kit) for the manifold plate removing any residue. 38. For VB models except the VB2020, connect the two solenoid harnesses from the manifold (black/red and black/orange). 39. 40. 41. 42. 43. Attach the gas manifold with 6 screws at heat exchanger. Attach the ignition line at the burner cover plate. Figure 12 Attach the PC Board to the heat exchanger with 1 screw. (Figure 2) Attach the water outlet line and bracket with 1 screw. Depending on model, attach the line to the water flow servo assembly with 1 screw and 1 bracket or attach the lines to the bypass valve with 1 screws and 1 brackets for each line.
44. (Figure 2) Install the fan assembly by inserting the tab on the fan assembly into the slot at the base of the heat exchanger and attaching with two screws. 45. Push the ducting over the fan assembly exit and secure with the metal pinch clamp. 46. On V and VA models and VB2020, attach the wire harness to the solenoid on the gas manifold (brown, black wires). 47. Attach the wire harness to the fan assembly (white, yellow, black, red wires). 48. Attach the air temperature thermistor (white, white wires) to the wire harness. 49. For VB models except the VB2020, install the ignitor module bracket with one screw. 50. Install temperature controller and bracket. For the VB2020, install the status monitor assembly with one screw. 51. Install the front panel using 4 screws. 52. Turn on the water supply, power supply, and gas supply. Check for gas leaks.
79
100000098 Rev B

Heat Exchanger
1. 2. 3. 4. 5. Turn off the gas supply, the 120 V power supply, and the water supply. Drain all water from the appliance. Remove four screws securing the front panel. Remove front panel. Disconnect wire harness at the fan assembly, the electrical connections to the 3 solenoid valves, and the ignition line. Remove 3 screws and brackets securing the water line connections. (Figure 1) Remove the 2 screws that attach the gas manifold to the gas valve. These screws are machine screws and must be used at these locations. (Figure 1) Remove the 5 screws that attach the gas manifold to the combustion chamber (part of the heat exchanger assembly). (Figure 1) Pull out the gas manifold and remove the connector at the ignitor at the left side of the gas manifold. (GY/GY) Remove the 9 screws attaching the burner cover plate to the combustion chamber. (Figure 2) Remove the 2 screws attaching the burner to the heat exchanger. Pull out the burner. (Figure 2)
R/C98e(ASME), R98LSe(ASME) 5 screws (gas manifold) 2 machine screws (gas valve)
6.
7. 8. 9.
10. Disconnect wire harnesses: A. B. C. D. Thermal fuse connectors (two) from bundle on left side of heat exchanger (WT to WT and RD to RD) Disconnect overheat bimetal from upper right heat exchanger. Heat exchanger thermistor connector from bundle on left side of heat exchanger (WT/WT to WT/PK) Heating element connectors: water flow servo assembly, hot water outlet, heat exchanger heating elements (at bottom left), frost sensing switch (bottom center).
Figure 1
11. Remove the 4 screws connecting the heat exchanger to the casing. (Figure 3) 12. Pull out the assembly. 13. Relocate water heater components: Important: Take note of wire harness routing prior to removal. A. Remove overheat bimetal from upper right heat exchanger. (one screw) Install on new heat exchanger. B. Remove thermistor and o ring from upper left heat exchanger. (two screws, one clip) Install thermistor and new o ring (in kit) on new heat exchanger. C. Remove thermal fuse harness and clips from around heat exchanger. Install on new heat exchanger by sliding the harness between the water outlet and inlet tubes (figure 4) and connect to overheat bimetal connector. D. Remove heating elements and clips from heat exchanger. Install on new heat exchanger. E. Remove the fan assembly (four screws) and install on new heat exchanger. Figure 4 F. Remove the flue outlet (six screws) and install on the new heat exchanger. Figure 5
Figure 2
9 screws (burner cover plate)
2 screws (burner)
Top screws
Figure 3
Bottom screws
80
100000098 Rev B

Heat Exchanger
14. Install the largest O-ring (included in kit) over the water outlet tube and the two smaller O-rings (included in kit) over the water inlet tubes. (Figure 4) 15. Attach brackets at the back and side holding the fusible link. 16. Install the 4 screws at the top and bottom of the heat exchanger to the casing. (Figure 3) 17. Insert the burner and place the burner cover plate into position. Attach the burner cover plate first with 9 screws and then attach the burner with 2 screws. (Figure 2) 18. Replace the electrode gasket. (Figure 6) 19. Make sure that the black gasket (Figure 7) is intact on the gas control assembly. Make sure that the ribbed side faces toward the manifold and that the flat side faces toward the gas valve. Replace the lower and upper gaskets (included in kit) for the manifold plate removing any residue. (Figure 8) 20. Attach the electrical connector (GY/GY) to the ignitor on the manifold and attach the gas manifold with 2 machine screws at the gas control assembly. (Figure 1) 21. Attach the gas manifold with 5 screws at heat exchanger. (Figure 1) 22. Connect wire harness attachments: A. Thermal fuse connectors (two) at bundle on left side of heat exchanger (WT to WT and RD to RD). B. Overheat bimetal at upper left heat exchanger. C. Heat exchanger thermistor connector at bundle on left side of heat exchanger (WT/WT to WT/PK). D. Heating element connectors: water flow servo assembly, hot water outlet, heat exchanger heating elements (at bottom left), frost sensing switch (bottom center). 23. Attach the ignition line at the burner cover plate. 24. Attach the 3 electrical connectors to the solenoid valves. 25. Attach the wire harness to the fan assembly (white, yellow, black, red wires). 26. Attach the brackets to the water line connections. (Figure 1) 27. Install the front panel using 4 screws. Turn on the water supply, power supply, and gas supply. Check for gas leaks.
R/C98e(ASME), R98LSe(ASME) 4 locations
Figure 4
Water outlet tube
Water inlet tubes
Figure 5
Electrode Gasket
Figure 6
Gasket
Figure 7
Figure 8 Gaskets
81
100000098 Rev B

Heat Exchanger
1. Turn off the gas supply. 2. Turn off the 120 V power supply. 3. Turn off the water supply. Drain all water from the appliance. 4. Remove four screws securing the front panel. Remove front panel. 5. Remove the bracket holding the controller (1 screw). (Figure 1) 6. Disconnect wire harness at the fan assembly, the electrical connections to the 3 solenoid valves, and the ignition line. 7. Remove 3 screws and brackets securing the water line connections. (Figure 2) 8. Remove the 2 screws that attach the gas manifold to the gas valve. These screws are machine screws and must be used at these locations. (Figure 2) 9. Remove the 5 screws that attach the gas manifold to the combustion chamber (part of the heat exchanger assembly). (Figure 2) 10. Pull out the gas manifold and remove the connector at the ignitor at the left side of the gas manifold. (GY/GY) 11. Remove the 9 screws attaching the burner cover plate to the combustion chamber. (Figure 3) 12. Remove the 2 screws attaching the burner to the heat exchanger. Pull out the burner. (Figure 3) 13. Disconnect wire harnesses: A. Thermal fuse connectors (two) from bundle on left side of heat exchanger (WT to WT and RD to RD) B. Disconnect overheat bimetal from upper right heat exchanger. C. Heat exchanger thermistor connector from bundle on left side of heat exchanger (WT/WT to WT/PK) Figure 2 D. Heating element connectors: water flow servo assembly, hot water outlet, heat exchanger heating elements (at bottom left), frost sensing switch (bottom center). 14. Remove the 3 screws at the seal plate at the top of the water heater. Remove the seal plate and gasket. (Figure 4) 15. Remove flue outlet vent (4 screws). (Figure 5) 16. Remove the 4 screws connecting the heat exchanger to the back of the casing. (Figure 6) 17. Pull out the assembly. (It is hooked on brackets in the casing.) Figure 3 9 screws (burner cover plate) 2 screws (burner) Figure 1 5 screws (gas manifold) 2 machine screws (gas valve) Bracket screw R/C98i(ASME), R98LSi(ASME)
82
100000098 Rev B

Heat Exchanger
18. Relocate water heater components: A. Remove overheat bimetal from upper right heat exchanger. (one screw) Install on new heat exchanger. B. Remove thermistor and o ring from upper left heat exchanger. (two screws, one clip) Install thermistor and new o ring (in kit) on new heat exchanger. C. Remove thermal fuse harness and clips from around heat exchanger. Install on new heat exchanger by sliding the harness between the water outlet and inlet tubes (figure 7) and connect to overheat bimetal connector. D. Remove heating elements and clips from heat exchanger. Install on new heat exchanger. E. Remove the fan assembly (four screws) and install on new heat exchanger. Figure 7 19. Install the largest O-ring (included in kit) over the water outlet tube and the two smaller O-rings (included in kit) over the water inlet tubes. (Figure 7) 20. Install the heat exchanger hooking it on the brackets in the back. 21. Install the 4 screws at the top and bottom of the heat exchanger to the back of the casing. (Figure 6) 22. Install the flue outlet vent (4 screws) and seal plate (3 screws) and gasket at the top of the water heater. (Figures 4 and 5) 23. Insert the burner and place the burner cover plate into position. Attach the burner cover plate first with 9 screws and then attach the burner with 2 screws. (Figure 3) 24. Replace the electrode gasket. (Figure 8) 25. Make sure that the black gasket (Figure 9) is intact on the gas control assembly. Make sure that the ribbed side faces toward the manifold and that the flat side faces toward the gas valve. Replace the lower and upper gaskets (included in kit) for the manifold plate removing any residue. (Figure 10) 26. Attach the electrical connector (GY/GY) to the ignitor on the manifold and attach the gas manifold with 2 machine screws at the gas control assembly. (Figure 2) 27. Attach the gas manifold with 5 screws at heat exchanger. (Figure 2) Figure 7 Water outlet tube Water inlet tubes Bottom screws 4 locations Top left screw Top right screw R/C98i(ASME), R98LSi(ASME)
Figure 4
Figure 5
Figure 6
83
100000098 Rev B

Heat Exchanger
28. Connect wire harness attachments: A. Thermal fuse connectors (two) at bundle on left side of heat exchanger (WT to WT and RD to RD) B. Connect overheat bimetal at upper right heat exchanger. C. Heat exchanger thermistor connector at bundle on left side of heat exchanger (WT/WT to WT/PK) D. Heating element connectors: water flow servo assembly, hot water outlet, heat exchanger heating elements (at bottom left), frost sensing switch (bottom center). 29. Attach the ignition line at the burner cover plate. 30. Attach the 3 electrical connectors to the solenoid valves. 31. Attach the wire harness to the fan assembly (white, yellow, black, red wires). 32. Attach the brackets to the water line connections. (Figure 2) 33. Install the front panel using 4 screws. 34. Turn on the water supply, power supply, and gas supply. 35. Check for gas leaks. Figure 9 Gasket R/C98i(ASME), R98LSi(ASME)
Figure 8
Electrode Gasket
Figure 10
Gaskets
84
100000098 Rev B

Heat Exchanger
RC80HPe
These instructions are for replacing the lower (primary) heat exchanger or the upper (secondary) heat exchanger.
WARNING
Failure to correctly assemble the components according to these instructions may result in a gas leak or explosion. 10. Remove eight screws for the combustion chamber sight glass plate. Remove plate. 11. Remove two screws attaching the burner to the heat exchanger. Pull out the burner. Remove fan 12. Disconnect fan harness. 13. Remove two screws from fan assembly. 14. Remove fan. Disconnect water lines 15. Remove one screw from hot water line bracket. Remove bracket by rotating and moving it up toward the bend in the tube where the diameter is smaller. 16. Remove two screws and two brackets at by-pass valve assembly. 17. Remove clips from drain connecting pipe. Remove drain connecting pipe.
2. Turn off water supply. Drain all water from the appliance. 3. Turn off 120V power supply. 4. Remove four screws securing the front panel. Remove front panel. Remove gas manifold 5. Disconnect high tension cord from ignitor. 6. Disconnect flame rod wires. (yellow and red) 7. Remove the three machine screws where manifold meets gas valve. Then remove six screws from manifold. 8. Disconnect ignitor module harness, mounted on manifold. (gray/gray) 9. Disconnect the two solenoid wire harnesses at bottom of manifold. Remove manifold plate. Flame Rod Connectors (Step 6) Manifold (Step 7)
Combustion chamber sight glass plate (Step 10) Fan (Steps 12-14)
Ignitor (Step 5, 8) Solenoid connectors (Step 9) Drain pipe clip (Step 17) Water outlet (Step 15)
Machine screws (Step 7) By-pass valve (Step 16)
85
100000098 Rev B

Heat Exchanger
18. Disconnect condensate tube from upper heat exchanger. RC80HPe
25. Remove three screws on front where upper and lower heat exchangers meet. Discard screws. Turn heat exchanger over; remove six screws on back Disconnect wire harnesses where upper and lower heat exchangers meet. Discard screws. Separate the upper heat exchanger 19. Disconnect heat exchanger thermistor (upper right). from the lower heat exchanger. 20. Disconnect anti frost heater connector at bottom of Installation cabinet. One blue connector. 21. Disconnect thermal fuse harnesses (lower right). Two single white wire connectors. Remove heat exchanger 26. Install new gasket from kit onto the upper heat exchanger. (Remove the old gasket if the upper heat exchanger is not new.) Attach upper heat exchanger to lower heat exchanger with new screws from kit. (six screws on back, three screw on front)
22. Remove three screws at bottom of heat exchanger. Remove two screws at top back of heat exchanger. Remove two screws at top on reinforcement bracket 27. If replacing lower (primary) heat exchanger, for upper heat exchanger. transfer wiring from old heat exchanger to new heat exchanger. Ensure proper routing of harnesses. 23. Remove heat exchanger assembly. These include thermal fuse, bi-metal, heat 24. If replacing the upper (secondary) heat exchanger thermistor, and ceramic heaters. exchanger, remove clips from two upper heat 28. Transfer parts from old heat exchanger to new heat exchanger copper pipes. Disconnect pipes. exchanger. Remove eight screws from flue outlet assembly. Discard screws. 29. If replacing the upper (secondary) heat Remove two screws from reinforcement bracket. exchanger, install connecting pipe to upper heat Discard screws. exchanger and copper tee with new o-ring and clip; and connecting pipe between upper heat exchanger and bypass valve with new o-ring and clip. Install the flue outlet assembly (8 screws) and the reinforcement bracket (2 screws).
Upper (secondary) heat exchanger
Flue outlet (Step 24)
Condensate tube clip (Step 18) Thermistor (Step 19)
Lower (primary) heat exchanger
86
100000098 Rev B

Heat Exchanger
30. Install heat exchanger assembly in case. Place bottom in cabinet first. Attach with five screws. (two at top back and three on bottom). Attach reinforcement bracket with two screws. Install water and drain lines 31. Install drain connecting pipe with new o-rings and attach with new clips. 32. Attach connecting pipe to by-pass valve with one screw and bracket. Attach other water line with one screw and bracket. 33. Attach the hot water outlet line to the hot water outlet fitting with one screw and bracket. Reconnect condensate tube to upper heat exchanger. Reconnect wire harness 34. Reconnect heat exchanger thermistor (upper right). 35. Reconnect anti frost connector at bottom of cabinet. One blue connector. 36. Reconnect thermal fuse harnesses (lower right). Two single white wire connectors. Install burner and burner cover plate 37. Install burner assembly with two screws. Remove combustion chamber packing on sight glass plate. Install new packing, in kit, on sight glass plate. Install combustion chamber sight glass plate with eight screws. Install fan 38. Reinstall fan with two screws. Install fan connector. Install gas manifold 39. Remove packing from gas control assembly. Discard. Install new packing, in kit, on gas control assembly. 40. Remove the packing for manifold. Install new packing, in kit, on gas manifold. 41. Reconnect the two solenoid wire harnesses at bottom of manifold. 42. Reconnect ignitor module harness, mounted on manifold. (gray/gray) RC80HPe 43. Attach the gas manifold with three machine screws at the gas control assembly. Install six screws on gas manifold to heat exchanger. Attach wire harness ties. Reconnect flame rod connectors and igniter 44. Install two flame rod connectors. (marked ) 45. Attach ignitor high tension cord to the electrode. 46. Turn on water supply, power supply, and gas supply. Check for gas and water leaks. Perform operational checks. 47. Install the front panel using four screws.
87
100000098 Rev B

Heat Exchanger
RC80HPi
WARNING
Failure to correctly assemble the components according to these instructions may result in a gas leak or explosion. 10. Disconnect the two solenoid wire harnesses at bottom of manifold. Remove manifold plate. 11. Remove eight screws for the combustion chamber sight glass plate. Remove plate. 12. Remove two screws attaching the burner to the heat exchanger. Pull out the burner. Remove fan 13. Disconnect fan harness. 14. Remove two screws from fan assembly. 15. Remove fan. Disconnect water lines 16. Remove one screw from hot water line bracket. Remove bracket by rotating and moving it up toward the bend in the tube where the diameter is smaller. 17. Remove two screws and two brackets at by-pass valve assembly. 18. Remove clips from drain connecting pipe. Remove drain connecting pipe.
2. Turn off water supply. Drain all water from the appliance. 3. Turn off 120V power supply. 4. Remove four screws securing the front panel. Remove front panel. Remove controller assembly 5. Remove temperature controller. Remove two screws for temperature controller bracket. Remove bracket. Remove gas manifold 6. Disconnect high tension cord from ignitor. 7. Disconnect flame rod wires. (yellow and red) 8. Remove three machine screws where manifold meets the gas valve, then remove six screws from the manifold. 9. Disconnect ignitor module harness, mounted on manifold. (gray/gray) Flame Rod Connectors (Step 7) Manifold (Step 8)
Combustion chamber sight glass plate (Step 11)
Ignitor (Step 6, 9) Solenoid connectors (Step 10) Drain pipe clip (Step 18) Water outlet (Step 16)
Fan (Step 13-15)
88
100000098 Rev B

Heat Exchanger
19. Disconnect condensate tube from upper heat exchanger. RC80HPi
29. Remove three screws on front where upper and lower heat exchangers meet. Discard screws. Turn heat exchanger over; remove six screws on back Disconnect wire harnesses where upper and lower heat exchangers meet. Discard screws. Separate the upper heat exchanger 20. Disconnect heat exchanger thermistor (upper right). from the lower heat exchanger. 21. Remove three anti frost heaters from clips at top of 30. If replacing the upper (secondary) heat heat exchanger. exchanger, then remove fourteen screws to 22. Disconnect anti frost heater connectors at bottom of separate it from the air inlet box assembly. Discard cabinet. One blue connector. screws and remove air inlet box assembly. Remove the old gasket from the air inlet box 23. Disconnect burner sensor harness (lower right). assembly. Install new gasket from kit. Attach air 24. Disconnect thermal fuse harnesses (lower right). inlet box assembly with new screws (fourteen) from Two single white wire connectors. kit. Ensure reinstallation of reinforcement bracket on top of air inlet box assembly. Remove heat exchanger 25. Remove three screws at bottom of heat exchanger. Installation Remove two screws at top back of heat exchanger. 31. Install new gasket from kit onto the upper heat Remove two screws at top on reinforcement bracket exchanger. (Remove the old gasket if the upper for upper heat exchanger. heat exchanger is not new.) Attach upper heat exchanger to new lower heat exchanger with new 26. Remove four screws for flue connection assembly. screws from kit. (six screws on back, three screw on Remove flue connection. front) 27. Remove heat exchanger assembly. 32. If replacing the lower (primary) heat exchanger, 28. Remove clips and connecting pipe between upper transfer wiring from old heat exchanger to new heat heat exchanger and copper tee on left side. exchanger. Ensure proper routing of harnesses. These include burner sensor with new gasket, thermal fuse, bi-metal, ceramic heaters.
Upper (secondary) heat exchanger
Anti frost heaters/clips (Step 21)
Condensate tube clip (Step 19) Thermistor (Step 20)
89
100000098 Rev B

Heat Exchanger
RC80HPi
33. If replacing the lower (primary) heat exchanger, Install gas manifold transfer parts from old heat exchanger to new heat 46. Remove packing from gas control assembly. exchanger. These include connecting pipe between Discard. Install new packing, in kit, on gas control upper heat exchanger and copper tee with new oassembly. rings and clips, connecting pipe between upper heat exchanger and bypass valve with new o-ring and 47. Remove the packing for manifold. Install new clip. packing, in kit, on gas manifold. 34. Install heat exchanger assembly in case. Place bottom in cabinet first. Attach with five screws. (two at top back and three on bottom) Attach reinforcement bracket with two screws. 35. Remove old gasket from flue connection assembly. Install new gasket from kit. Attach flue connections assembly with four screws. Install water and drain lines 36. Install drain connecting pipe with new o-rings and attach with new clips. 48. Reconnect ignitor module harness, mounted on manifold. (gray/gray) 49. Install two connectors to the solenoids on the gas manifold. (marked) 50. Attach the gas manifold with three machine screws at the gas control assembly. Install six screws on gas manifold to heat exchanger. Attach wire harness ties. Reconnect flame rod connectors and igniter
51. Install two flame rod connectors. (marked ) 37. Attach water inlet connecting pipe with new o-rings at by-pass valve with one screw and bracket. Attach 52. Attach ignitor high tension cord to the electrode. other water line with one screw and bracket. 53. Attach controller bracket with one machine screw and one screw from power wire clamp. Install 38. Attach the hot water outlet line to the hot water controller in bracket. outlet fitting with one screw and bracket. Reconnect condensate tube at upper heat exchanger. Reconnect wire harness 39. Reconnect heat exchanger thermistor (upper right). 40. Install three anti frost heaters in clips at top of upper heat exchanger. 41. Reconnect anti frost connectors at bottom of cabinet. One blue connector. 42. Reconnect burner sensor harness (lower right). 43. Reconnect thermal fuse harnesses (lower right). Two single white wire connectors. Install burner and burner cover plate 44. Install burner assembly with two screws. Remove combustion chamber packing on sight glass plate. Install new packing, in kit, on sight glass plate. Install combustion chamber sight glass plate with eight screws. Install fan 45. Reinstall fan with two screws. Install fan connector. 54. Turn on water supply, power supply, and gas supply. Check for gas and water leaks. Perform operational checks. 55. Install the front panel using four screws.
90
100000098 Rev B

Heat Exchanger
RC98HPe
WARNING
Failure to correctly assemble the components according to these instructions may result in a gas leak or explosion. 9. Remove eight screws for the combustion chamber sight glass plate. Remove plate. 10. Remove two screws attaching the burner to the heat exchanger. Pull out the burner. Disconnect water lines 11. Remove one screw from hot water line bracket. Remove bracket by rotating and moving it up toward the bend in the tube where the diameter is smaller. 12. Remove two screws and two brackets at by-pass valve assembly.
2. Turn off water supply. Drain all water from the appliance. 3. Turn off 120V power supply. 4. Remove four screws securing the front panel. Remove front panel. Remove gas manifold 5. Disconnect high tension cord from ignitor. Remove one screw for ignitor bracket. Remove ignitor bracket from manifold. 6. Disconnect flame rod connectors. (yellow and red)
13. Remove lower clip from drain connecting pipe. 7. Remove seven pan head screws from manifold (six 14. Remove the clip on the heat exchanger inlet pipe on screws on the outer edge, one screw in middle), the right side of heat exchanger. Remove the two and three machine screws, at bottom of manifold, to anti frost heaters from pipe. Remove heat gas valve. exchanger inlet pipe. 8. Disconnect the four connectors from the solenoids 15. Disconnect condensate tube from upper heat at bottom of manifold. Remove manifold plate. exchanger. Flame Rod Connectors (Step 6) Manifold (Step 7)
Ignitor (Step 5) Solenoid connectors (Step 8) Drain pipe clip (Step 13) Water outlet (Step 11)
91
100000098 Rev B

Heat Exchanger
Disconnect wire harnesses 16. Disconnect heat exchanger thermistor (upper right). 17. Disconnect anti frost heater connector at bottom of cabinet. One blue and one green connector. 18. Disconnect thermal fuse harnesses (lower right). Single white wire connectors and single red wire connector. Remove heat exchanger RC98HPe 22. Remove three screws on front where upper and lower heat exchangers meet. Discard screws. Turn heat exchanger over; remove six screws on back where upper and lower heat exchangers meet. Discard screws. Separate the upper heat exchanger from the lower heat exchanger. Installation 23. Install new gasket from kit onto the upper heat exchanger. (Remove the old gasket if the upper heat exchanger is not new.) Attach upper heat exchanger to lower heat exchanger with new screws from kit. (six screws on back, three screw on front)
19. Remove two screws at bottom of heat exchanger. Remove two screws at top back of heat exchanger. Remove two screws at top on reinforcement bracket 24. If replacing the lower (primary) heat exchanger, for upper heat exchanger. Upper frost sensing transfer wiring from old heat exchanger to new heat switch is secured on reinforcement bracketset exchanger. Ensure proper routing of harnesses. aside. These include thermal fuse, bi-metal, ceramic 20. Remove heat exchanger assembly. heaters. 21. If replacing the upper (secondary) heat 25. Transfer parts from old heat exchanger to new heat exchanger, remove clips from two upper heat exchanger. exchanger copper pipes. Disconnect pipes. 26. If replacing the upper (secondary) heat Remove eight screws from flue outlet assembly. exchanger, install connecting pipe to upper heat Discard screws. exchanger and copper tee with new o-ring and clip; Remove two screws from reinforcement bracket. and connecting pipe between upper heat Discard screws. exchanger and bypass valve with new o-ring and clip. Install the flue outlet assembly (8 screws) and the reinforcement bracket (2 screws).
Flue outlet (Step 21) Upper (secondary) heat exchanger Inlet pipe and clip (Step 14)
Thermistor (Step 16)
Condensate tube clip (Step 15)
92
100000098 Rev B

Heat Exchanger
27. Install heat exchanger assembly in case. Place bottom in cabinet first. Attach with four screws. (two at top back and two on bottom). Install reinforcement bracket with two screws. Ensure the frost sensing switch is installed. Install water and drain lines 28. Install drain connecting pipe with new o-rings and attach with new clips. 29. Attach connecting pipe to by-pass valve with one screw and bracket. Attach other water line with one screw and bracket. RC98HPe 38. Attach the gas manifold with three machine screws at the gas control assembly. Install seven screws on gas manifold to heat exchanger. Attach wire harness ties. Reconnect flame rod connectors and igniter 39. Install two flame rod connectors. (marked) 40. Install ignitor bracket with one machine screw. 41. Attach ignitor high tension cord to the electrode. 42. Turn on water supply, power supply, and gas supply. Check for gas and water leaks. Perform operational checks.
30. Attach the hot water outlet line to the hot water outlet fitting with one screw and bracket. Reconnect 43. Install the front panel using four screws. condensate tube to upper heat exchanger. Reconnect wire harness 31. Reconnect heat exchanger thermistor (upper left). 32. Reconnect anti frost connector at bottom of cabinet. One blue and one green connector. 33. Reconnect thermal fuse harnesses (lower right). Single white wire connectors and single red wire connector. Install burner and burner cover plate 34. Install burner assembly with two screws. Remove combustion chamber packing on sight glass plate. Install new packing, in kit, on sight glass plate. Install combustion chamber sight glass plate with eight screws. Install gas manifold 35. Remove packing from gas control assembly. Discard. Install new packing, in kit, on gas control assembly. 36. Remove the packing for manifold. Install new packing, in kit, on gas manifold. 37. Reconnect the four connectors at bottom of manifold.
93
100000098 Rev B

Heat Exchanger
RC98HPi
WARNING
Failure to correctly assemble the components according to these instructions may result in a gas leak or explosion. 8. Remove seven pan head screws from manifold. (Six screws on outer edge, one screw in middle and three machine screws from bottom of manifold to gas valve.) 9. Remove four connectors from the solenoids at the bottom of the manifold. Remove manifold. 10. Remove eight screws for the combustion chamber sight glass plate. Remove plate. 11. Remove two screws attaching the burner to the heat exchanger. Pull out the burner. Disconnect water lines 12. Remove one screw from hot water line bracket. Remove bracket by rotating and moving it up toward the bend in the tube where the diameter is smaller. 13. Remove two screws and two brackets at by-pass valve assembly. 14. Remove lower clip from drain connecting pipe.
2. Turn off water supply. Drain all water from the appliance. 3. Turn off 120V power supply. 4. Remove four screws securing the front panel. Remove front panel. Remove controller assembly 5. Remove temperature controller. Remove two screws for temperature controller bracket. Remove bracket. Remove gas manifold 6. Remove high tension cord from ignitor. Remove one screw for ignitor bracket. Remove ignitor bracket from manifold. 7. Remove red and yellow flame rod connectors.
Flame Rod Connectors (Step 7) Manifold (Step 8)
Ignitor (Step 6) Solenoid connectors (Step 9) Drain pipe clip (Step 14) Water outlet (Step 12)
94
100000098 Rev B

Heat Exchanger
RC98HPi
15. Remove the clip on the heat exchanger inlet pipe on 26. Remove anti frost heater from connecting pipe between upper heat exchanger and copper tee on right side of heat exchanger. Remove the two anti left side. Remove clips and connecting pipe. frost heaters from pipe. Remove heat exchanger inlet pipe. 27. Remove three screws on front, where upper and lower heat exchangers meet. Discard screws. Turn 16. Disconnect condensate tube from upper heat heat exchanger over; remove six screws on back exchanger. where upper and lower heat exchangers meet. Disconnect wire harness Discard screws. Separate the upper heat exchanger from the lower heat exchanger. 17. Disconnect heat exchanger thermistor (upper left). 28. If replacing the upper (secondary) heat exchanger, then remove fourteen screws to separate it from the air inlet box assembly. Discard 19. Disconnect anti frost heater connectors at bottom of screws and remove air inlet box assembly. cabinet. (one green connector with cables leading to Remove the old gasket from the air inlet box the right side, one blue connector.) assembly. Install new gasket from kit. Attach air inlet box assembly with new screws (fourteen) from 20. Disconnect burner sensor harness (lower right). kit. Ensure reinstallation of reinforcement bracket 21. Disconnect thermal fuse harnesses (lower right). on top of air inlet box assembly. Single white wire connector, single red wire Installation connector. 18. Remove three anti frost heaters from clips at top of heat exchanger. 29. Install new gasket from kit onto the upper heat exchanger. (Remove the old gasket if the upper Remove heat exchanger heat exchanger is not new.) Attach upper heat exchanger to the lower heat exchanger with new 23. Remove two screws at bottom of heat exchanger. screws from kit. (six screws on back, three screw on Remove two screws at top back of heat exchanger. front) Remove two screws at top on reinforcement bracket for upper heat exchanger. Upper frost sensing 30. If replacing the lower (primary) heat exchanger, switch is secured on reinforcement bracket, set transfer wiring from old heat exchanger to new heat aside. exchanger. Ensure proper routing of harnesses. 22. Disconnect fan connector. 24. Remove four screws for flue connection assembly. Remove flue connection. 25. Remove heat exchanger assembly. These include burner sensor with new gasket, thermal fuse, bi-metal, ceramic heaters.
Anti frost heaters/clips (Step 18) Upper (secondary) heat exchanger Inlet pipe clip (Step 15)
Thermistor (Step 17) Condensate tube clip (Step 16)
95
100000098 Rev B

Heat Exchanger
31. If replacing the lower (primary) heat exchanger, transfer parts from old heat exchanger to new heat exchanger. These include fan housing assembly, connecting pipe to upper heat exchanger and copper tee with new o-ring and clip, drain pipe from copper tee. 32. Install heat exchanger assembly in case. Place bottom in cabinet first. Attach with four screws. (two at top back and two on bottom) Attach reinforcement bracket with two screws. 33. Remove old gasket from flue connection assembly. Install new gasket from kit. Attach flue connections assembly with four screws. Install water and drain lines 34. Install drain connecting pipe with new o-rings and attach with new clips. 35. Install water inlet connecting pipe with new o-rings to upper heat exchanger. Attach with new clip at heat exchanger and at bottom to the by-pass valve with one screw and bracket. Attach the other water line with one screw and bracket. RC98HPi 45. Remove the packing for manifold. Install new packing, in kit, on gas manifold. 46. Attach the gas manifold with three machine screws at the gas control assembly. Install seven pan head screws on gas manifold to heat exchanger. Attach wire harness ties. (six screws at outer edge, one middle of gas manifold plate) 47. Install four connectors to the solenoids on the gas manifold. (marked) Reconnect flame rod connectors and igniter 48. Install two flame rod connectors. (marked ) 49. Install ignitor bracket with one machine screw. 50. Attach ignitor high tension cord to the electrode. 51. Attach controller bracket with one machine screw and one screw from power wire clamp. Install controller in bracket. Check 52. Turn on water supply, power supply, and gas supply. Check for gas and water leaks. Perform operational checks.
36. Attach the hot water outlet line to the hot water outlet fitting with one screw and bracket. Reconnect 53. Install the front panel using four screws. condensate tube to upper heat exchanger. Reconnect wire harness 37. Reconnect heat exchanger thermistor (upper left). 38. Install three anti frost heaters in clips at top of upper heat exchanger. 39. Reconnect anti frost connectors at bottom of cabinet. One green connector, one blue connector. 40. Reconnect burner sensor harness (lower right). 41. Reconnect thermal fuse harnesses (lower right). Single white wire connector, single red wire connector. 42. Reconnect the fan connector. Install burner and burner cover plate 43. Install burner assembly with two screws. Replace combustion chamber packing (in kit) on sight glass plate. Install combustion chamber sight glass plate with eight screws. Install gas manifold 44. Remove packing from gas control assembly. Discard. Install new packing, in kit, on gas control assembly.
96
100000098 Rev B
Gas Pressure Setting Procedure CAUTION

Do not touch the areas at or near the heat exchanger or combustion chamber. These areas become very hot and could cause burns. 1. Remove the front panel (four screws). 2. Calibrate the low fire and high fire settings as follows: A. Remove the allen head plug and attach the manometer to the burner test point located on the gas control. (Figure 1-5) Figure 2 Potentiometer (POT) Burner test point Dip switches (SW1) Figure 1 Potentiometer (POT)
Models R/C42e, R/C53e, V53e, R63LSe Potentiometer (POT)
Figure 3
Burner test point
Dip switches (SW1) Burner test point Dip switches (SW1)
Models R70e, R75LSe, R/C85e, R94LSe, R50LSi, R/C53i, R75LSi, R/C85i, R94LSi Potentiometer (POT)
Models R/C98e, R98LSe, R/C98i, R98LSi Figure 5 Potentiometer (POT)
Figure 4
Burner test point
Dip switches (SW1)
Burner test point
Dip switches (SW1)
Models RC98HPe, RC98HPi
Models RC80HPe, RC80HPi
97
100000098 Rev B
Gas Pressure Setting Procedure

B. Turn on the gas supply. C. Turn on the power supply. D. Flow water through the water heater at the maximum flow rate obtainable. (At least 3 gallons per minute is recommended. If there is not enough water flowing, the water heater could shut off or sustain damage due to overheating.) E. Move No. 7 dip switch of the SW1 bank to the ON position to calibrate Forced Low combustion. (Figure 5) F. Check the burner test point pressure. G. Remove the rubber access plug (Figure 4) and adjust the regulator screw on the modulating valve to obtain the correct low fire manifold pressure. Refer to the Manifold Gas Pressure Settings section, page 101-105. Install rubber access plug. H. Move No. 7 and No. 8 dip switches of the SW1 bank to the ON position to calibrate Forced High combustion. (Figure 6) I. J. Check the burner test point pressure. Adjust the high pressure Potentiometer (POT) (Figure 1-5) on the PC Board to obtain the correct high fire manifold pressure. Refer to the Manifold Gas Pressure Settings section, page 101-105. Figure 6 Forced High Figure 5 Forced Low Access plug Figure 4
Switch No.
ON O F F 1 2 3 4 5 6 7 8
Switch No.
ON O F F 1 2 3 4 5 6 7 8
K. Move No. 7 and No. 8 back to the OFF position to return the appliance to Normal combustion. (Figure 7) L. Close hot water taps. Figure 7 Normal M. Turn off gas supply and 120 V power supply. N. Remove manometer and re-install allen head plug. O. Turn on the gas supply and 120 V power supply. P. Operate the unit and check for gas leaks. 3. Install the front panel using four screws.
Switch No.
ON O F F 1 2 3 4 5 6 7 8
98
100000098 Rev B
Manifold Gas Pressure Settings

V Series - Outdoor
Natural Gas
R42e,C42e Altitude less than 5000 ft (1524 m) 6000 ft (1829 m) 7000 ft (2134 m) 8000-10000 ft High Fire 3.5 3.4 3.3 3.2 Low Fire 0.73 0.71 0.69 0.67
Propane Gas
Altitude less than 2000 ft (610 m) 3000 ft (914 m) 4000 ft (1219 m) 5000 ft (1524 m) High Fire 3.3 3.0 2.7 2.3 Low Fire 0.72 0.65 0.58 0.50
R53e,C53e
Altitude less than 2000 ft 3000 ft (914 m) 4000 ft (1219 m) 5000-10000 ft
High Fire 3.7 3.5 3.4 3.2
Low Fire 0.74 0.71 0.68 0.64
Altitude less than 2000 ft
High Fire 3.5
Low Fire 0.74
R85e(PLUS), C85e(PLUS)
Altitude less than 10000 ft
High Fire 3.4
Low Fire 0.56
Altitude less than 2000 ft (610 m) 3000 ft (914 m) 4000 ft (1219 m) 5000 ft (1524 m) 6000 ft (1829 m) 7000-10000 ft (2134 - 3048 m)
High Fire 5.1 4.8 4.5 4.3 4.2 4.1
Low Fire 0.88 0.83 0.78 0.73 0.72 0.71
R70e
Altitude less than 10000 ft (3048 m)
High Fire 3.4
Low Fire 0.56
Altitude less than 10000 ft (3048 m)
High Fire 5.1
Low Fire 0.88
R98e(ASME), C98e(ASME)
Altitude less than 2000 ft (610 m) 3000 ft (914 m) 4000 ft (1219 m) 5000 ft (1524 m) 6000 ft (1829 m) 7000 ft (2134 m) 8000-10000 ft (2438 - 3048 m)
High Fire 2.8 2.7 2.6 2.4 2.3 2.2 2.1
Low Fire 0.66 0.63 0.60 0.57 0.54 0.52 0.50
Altitude less than 2000 ft (610 m) 3000 ft (914 m) 4000 ft (1219 m) 5000 ft (1524 m) 6000-10000 ft (1829 - 3048 m)
High Fire 3.8 3.6 3.3 3.1 3.0
Low Fire 0.80 0.75 0.69 0.64 0.63
99
100000098 Rev B

V Series - Indoor
Natural Gas
R53i(PLUS), C53i(PLUS), R85i(PLUS), C85i(PLUS) Altitude less than 10000 ft (3048 m) High Fire 3.7 Low Fire 0.77
Propane Gas
Altitude less than 2000 ft (610 m) 3000 ft (914 m) 4000 ft (1219 m) 5000 ft (1524 m) 6000 ft (1829 m) 7000 ft (2134 m) 8000 ft (2438 m) 9000 ft (2743 m) 10000 ft (3048 m) High Fire 4.2 4.0 3.9 3.7 3.7 3.6 3.6 3.4 3.2 Low Fire 0.93 0.90 0.86 0.82 0.82 0.80 0.80 0.79 0.75
R98i(ASME), C98i(ASME)
Altitude less than 2000 ft (610 m) 3000 ft (914 m) 4000 ft (1219 m) 5000-10000 ft (1524 - 3048 m)
High Fire 3.0 2.8 2.7 2.5
Low Fire 0.67 0.64 0.60 0.56
Altitude less than 2000 ft (610 m) 3000 ft (914 m) 4000 ft (1219 m) 5000 ft (1524 m)
High Fire 3.7 3.5 3.3 3.0
Low Fire 0.83 0.78 0.73 0.67
100
100000098 Rev B
VA Models
Natural Gas (Gaz Naturel) MAX VENT Dip Switch #1 is OFF Max Rate inches W.C. Min Rate inches W.C. Max Rate inches W.C. Min Rate inches W.C. Max Rate inches W.C. Min Rate inches W.C. Max Rate inches W.C. MIN VENT Dip Switch #1 is ON MAX VENT Dip Switch #1 is OFF MIN VENT Dip Switch #1 is ON Min Rate inches W.C. Propane Gas (Gaz propane)
Dip Switch Setting Altitude
R50LSi (REU-VA2019FFU)
2.0 1.7 1.7 1.8 3.3 2.8 2.4 2.1 0.5 2.1 0.5 0.5 2.4 0.5 0.5 2.8 0.6 3.3 3.4 3.2 0.52 3.3 0.52 5.0 0.9 1.8 0.9 2.8 0.7 1.7 0.7 2.8 0.9 1.1 0.92 1.0 1.1 1.1 0.7 1.8 0.7 3.1 1.0 0.52 2.0 0.52 3.2 0.92 3.2 3.0 2.8 2.8 5.0 3.4 3.4 3.2 0.92 1.1 1.1 1.4 0.92 1.0 1.2 1.1
#2 OFF, #3 OFF 0-2000 ft (0-610 m)
#2 OFF, #3 ON
2001-5200 ft (610-1585 m)
#2 ON, #3 OFF
5201-7700 ft (1585-2277 m)

2.7 2.8 2.4 2.1 0.5 2.1 0.5 2.4 0.5 2.8 0.52 2.7 0.52 0.5 0.5 0.5 4.4 3.3 3.4 3.2 0.92 1.0 1.1 1.1 4.4 3.4 3.4 3.2 0.92 1.0 1.2 1.1 3.3 2.8 2.4 2.1 3.0 2.7 2.7 2.5 0.5 0.5 0.5 0.67 0.7 0.8 1.7 0.52 3.3 2.8 2.4 2.1 3.0 2.7 2.7 2.5 0.52 0.6 0.5 0.5 0.67 0.7 0.8 1.2 5.0 3.3 3.4 3.2 3.7 2.9 3.0 2.8 0.92 1.0 1.1 1.1 0.83 0.83 0.83 0.83 5.0 3.4 3.4 3.2 3.7 2.9 3.0 2.8 0.92 1.0 1.2 1.1 0.83 0.83 0.9 1.2
#2 ON, #3 ON
7701-10200 ft (2277-3109 m)
R75LSi (REU-VA2528FFU-US)
#2 OFF, #3 OFF 0-2000 ft (0-610 m)
#2 OFF, #3 ON
2001-5200 ft (610-1585 m)
#2 ON, #3 OFF
5201-7700 ft (1585-2277 m)
101
#2 ON, #3 ON
7701-10200 ft (2277-3109 m)
R75LSi(A) (REU-VA2528FFU(A)-US) (REU-VA2528FFU(A)-UC)
#2 OFF, #3 OFF 0-2000 ft (0-610 m)
#2 OFF, #3 ON
2001-5200 ft (610-1585 m)
#2 ON, #3 OFF
5201-7700 ft (1585-2277 m)
#2 ON, #3 ON
7701-10200 ft (2277-3109 m)
R94LSi (REU-VA2535FFU-US) (REU-VA2535FFU-UC)
#2 OFF, #3 OFF 0-2000 ft (0-610 m)
#2 OFF, #3 ON
2001-5200 ft (610-1585 m)
#2 ON, #3 OFF
5201-7700 ft (1585-2277 m)
#2 ON, #3 ON
7701-10200 ft (2277-3109 m)
100000098 Rev B
R98LSi (REU-VA3237FFU)
VA Models
Natural Gas (Gaz Naturel) Altitude Max Rate inches W.C. 2.5 2.4 2.4 2.4 1.7 1.6 1.5 1.5 2.0 1.7 1.7 1.5 0.5 0.56 0.55 0.70 0.70 0.5 0.4 0.53 0.9 0.7 2.0 2.0 2.4 2.0 2.0 1.8 3.0 2.8 2.7 2.7 0.7 2.2 0.73 2.4 Min Rate inches W.C. Max Rate inches W.C.
Propane Gas (Gaz propane) Min Rate inches W.C. 0.75 0.9 0.8 0.7 0.61 0.7 0.7 0.8 0.88 0.90 1.00 0.80
Dip Switch Setting
V53e (REU-VAM1620W)
0-2000 ft (0-610 m) 2001-5200 ft (610-1585 m) 5201-7700 ft (1585-2277 m) 7701-10200 ft (2277-3109 m) 0-2000 ft (0-610 m) 2001-5200 ft (610-1585 m) 5201-7700 ft (1585-2277 m) 7701-10200 ft (2277-3109 m) 0-2000 ft (0-610 m) 2001-5200 ft (610-1585 m) 5201-7700 ft (1585-2277 m) 7701-10200 ft (2277-3109 m)
#2 OFF, #3 OFF
#2 OFF, #3 ON
#2 ON, #3 OFF
#2 ON, #3 ON
R63LSe (REU-VA2024W)
#2 OFF, #3 OFF
#2 OFF, #3 ON
#2 ON, #3 OFF
102
#2 ON, #3 ON
R63LSe2 (REU-VA2024W(A)-US)
#2 OFF, #3 OFF
#2 OFF, #3 ON
#2 ON, #3 OFF
#2 ON, #3 ON
100000098 Rev B
VA Models
Natural Gas (Gaz Naturel) Altitude Max Rate inches W.C. 3.3 3.3 3.3 3.1 0.7 4.0 0.9 4.0 0.7 4.0 0.56 5.0 0.88 1.1 0.9 0.9 Min Rate inches W.C. Max Rate inches W.C. Min Rate inches W.C. Propane Gas (Gaz propane)
Dip Switch Setting
R75LSe (REU-VA2528W-US)
0-2000 ft (0-610 m) 2001-5200 ft (610-1585 m) 5201-7700 ft (1585-2277 m) 7701-10200 ft (2277-3109 m)
#2 OFF, #3 OFF
#2 OFF, #3 ON
#2 ON, #3 OFF
#2 ON, #3 ON

0-2000 ft (0-610 m) 2001-5200 ft (610-1585 m) 5201-7700 ft (1585-2277 m) 7701-10200 ft (2277-3109 m) 3.1 0.7 3.3 0.9 3.3 0.7 2.9 0.56 4.2 4.0 4.0 4.0 0.88 1.1 0.9 0.9 0-2000 ft (0-610 m) 2001-5200 ft (610-1585 m) 5201-7700 ft (1585-2277 m) 7701-10200 ft (2277-3109 m) 0-2000 ft (0-610 m) 2001-5200 ft (610-1585 m) 5201-7700 ft (1585-2277 m) 7701-10200 ft (2277-3109 m) 2.5 2.5 2.5 2.8 3.1 3.3 3.3 3.3 0.56 0.7 0.9 0.7 0.65 0.7 0.7 0.7 5.1 4.0 4.0 4.0 3.8 3.0 3.0 3.0 0.88 1.1 0.9 0.9 0.80 0.80 0.80 0.80
R75LSe(A) (REU-VA2528W(A)-US) (REU-VA2528W(A)-UC)
#2 OFF, #3 OFF
#2 OFF, #3 ON
#2 ON, #3 OFF
#2 ON, #3 ON
103
R94LSe (REU-VA2535W-US) (REU-VA2535W-UC)
#2 OFF, #3 OFF
#2 OFF, #3 ON
#2 ON, #3 OFF
#2 ON, #3 ON
R98LSe (REU-VA3237W)
#2 OFF, #3 OFF
#2 OFF, #3 ON
#2 ON, #3 OFF
100000098 Rev B
#2 ON, #3 ON
VB Models
Natural Gas (Gaz Naturel) Altitude Max Rate inches W.C. Min Rate inches W.C. Max Rate inches W.C. Min Rate inches W.C. Propane Gas (Gaz propane)
Dip Switch Setting
V53i (REU-VB2020FFU-US)
0-2000 ft (0-610 m) 2001-5200 ft (610-1585 m) 5201-7700 ft (1585-2277 m) 7701-10200 ft (2277-3109 m)
#2 OFF, #3 OFF
2.1 (54) 2.3 (58) 2.0 (51) 2.0 (51) 2.9 (74) 2.5 (64) 2.6 (66) 2.4 (61) 2.3 (58) 2.9 (74) 2.9 (74) 2.9 (74) 3.4 (86) 2.6 (66) 2.6 (66) 2.5 (64) 2.8 (71) 3.1 (79) 3.0 (76) 3.0 (76) 0.44 (11) 0.50 (13) 0.45 (11) 0.50 (13) 0.55 (14) 0.50 (13) 0.60 (15) 0.65 (17) 0.44 (11) 0.50 (13) 0.50 (13) 0.50 (13) 0.55 (14) 0.60 (15) 0.55 (14) 0.55 (14) 4.5 (114) 3.2 (81) 3.5 (89) 2.8 (71) 4.2 (107) 4.2 (107) 3.8 (97) 3.3 (84) 5.4 (137) 3.8 (97) 3.5 (89) 2.9 (74) 5.0 (127) 4.2 (107) 4.1 (104) 3.7 (94) 0.60 (15) 2.8 (71) 0.60 (15) 3.0 (76) 0.60 (15) 3.1 (79)
0.57 (14)
3.4 (87)
0.98 (25) 0.95 (24) 1.0 (25) 1.0 (25) 0.96 (24) 1.00 (25) 1.00 (25) 0.95 (24) 0.93 (24) 0.90 (23) 0.80 (20) 0.90 (23) 0.96 (24) 1.00 (25) 1.00 (25) 1.00 (25) 0.93 (24) 0.90 (23) 0.90 (23) 0.80 (20)
#2 OFF, #3 ON
#2 ON, #3 OFF
#2 ON, #3 ON
R75LSi (REU-VB2528FFUD-US)
0-2000 ft (0-610 m) 2001-5200 ft (610-1585 m) 5201-7700 ft (1585-2277 m) 7701-10200 ft (2277-3109 m)

0-2000 ft (0-610 m) 2001-5200 ft (610-1585 m) 5201-7700 ft (1585-2277 m) 7701-10200 ft (2277-3109 m) 0-2000 ft (0-610 m) 2001-5200 ft (610-1585 m) 5201-7700 ft (1585-2277 m) 7701-10200 ft (2277-3109 m) 0-2000 ft (0-610 m) 2001-5200 ft (610-1585 m) 5201-7700 ft (1585-2277 m) 7701-10200 ft (2277-3109 m)
#2 OFF, #3 OFF
#2 OFF, #3 ON
#2 ON, #3 OFF
#2 ON, #3 ON
R75LSe (REU-VB2528WD-US)
104
#2 OFF, #3 OFF
#2 OFF, #3 ON
#2 ON, #3 OFF
#2 ON, #3 ON
R94LSi (REU-VB2735FFUD-US)
#2 OFF, #3 OFF
#2 OFF, #3 ON
#2 ON, #3 OFF
#2 ON, #3 ON
R94LSe (REU-VB2735WD-US)
#2 OFF, #3 OFF
#2 OFF, #3 ON
#2 ON, #3 OFF
100000098 Rev B
#2 ON, #3 ON
Condensing Models
Natural Gas (Gaz Naturel) MAX VENT Dip Switch #1 is OFF Max Rate inches W.C. Min Rate inches W.C. Max Rate inches W.C. Min Rate inches W.C. Max Rate inches W.C. Min Rate inches W.C. Max Rate inches W.C. MIN VENT Dip Switch #1 is ON MAX VENT Dip Switch #1 is OFF MIN VENT Dip Switch #1 is ON Min Rate inches W.C. Propane Gas (Gaz propane)
Dip Switch Setting Altitude
RC80HPi (REU-KA2530FFUD-US) 3.00 2.90 2.90 2.90 0.55 2.85 0.55 3.40 1.00 0.55 2.90 0.55 3.80 0.90 0.70 3.20 0.70 3.80 0.90 0.81 2.90 0.70 3.80 1.11 3.7 3.9 3.9 3.5 1.06 0.70 0.55 0.55
#2 OFF, #3 OFF 0-2000 ft (0-610 m)
#2 OFF, #3 ON
2001-5200 ft (610-1585 m)
#2 ON, #3 OFF
5201-7700 ft (1585-2277 m)

2.70 2.40 2.40 2.40 0.80 2.40 0.90 0.80 2.40 0.80 0.80 2.40 0.80 3.60 3.60 3.20 1.08 2.40 0.85 4.00 1.46 1.30 1.20 1.10 3.60 3.30 3.30 3.20 1.22 1.10 1.10 1.00
#2 ON, #3 ON
7701-10200 ft (2277-3109 m)
RC98HPi (REU-KA3237FFUD-US)
#2 OFF, #3 OFF 0-2000 ft (0-610 m)
#2 OFF, #3 ON
2001-5200 ft (610-1585 m)
#2 ON, #3 OFF
5201-7700 ft (1585-2277 m)
105
Natural Gas (Gaz Naturel) Altitude Max Rate inches W.C.
2.70 2.90 2.90 2.90
#2 ON, #3 ON
7701-10200 ft (2277-3109 m)
Propane Gas (Gaz propane) Min Rate inches W.C.

0.61 0.60 0.60 0.60
Dip Switch Setting
Max Rate inches W.C.

3.60 3.70 3.70 3.40
Min Rate inches W.C.

0.92 1.00 1.00 1.00
RC80HPe (REU-KA2530WD-US)
#2 OFF, #3 OFF
0-2000 ft (0-610 m)
#2 OFF, #3 ON
2001-5200 ft (610-1585 m)
#2 ON, #3 OFF
5201-7700 ft (1585-2277 m)
#2 ON, #3 ON
7701-10200 ft (2277-3109 m)
RC98HPe (REU-KA3237WD-US) 2.20 2.20 2.20 2.20 0.63 0.70 0.70 0.70 3.10 3.10 3.10 3.00 1.00 1.00 1.00 1.00
#2 OFF, #3 OFF
0-2000 ft (0-610 m)
#2 OFF, #3 ON
2001-5200 ft (610-1585 m)
100000098 Rev B
#2 ON, #3 OFF
5201-7700 ft (1585-2277 m)
#2 ON, #3 ON
7701-10200 ft (2277-3109 m)
Dip Switch Settings

V Series
SW1 Bank OFF - Long Flue ON - Short Flue and Outdoor Models 1 Long flue is defined as: 0 elbows and length is greater than 21 ft 1 elbow and length is greater than 15 ft 2 elbows and length is greater than 9 ft ON position OFF position OFF position OFF position OFF position OFF position - Used for low fire and high fire settings. Refer to the gas pressure setting procedure. 3 4 2 SW2 Bank 1 OFF - Propane Gas ON - Natural Gas OFF position for models prior to these serial numbers: (on these units, the front panel does not have an R or C trade name, unless the front panel has been replaced) V1616W, V1616WC 06.02-000001 V2020W, V2020WC 05.07-000001 V2532W, V2532WC 05.05-117257 V2532FFU, V2532FFUC 05.05-117257 V2520FFU, V2520FFUC 05.05-109539 V2526W 05.05-110434 ON position for other models, serial numbers OFF position OFF - Residential Models ON - Commercial Models
2 3 4 5 6 7 8
VA Series (-US models; model name ends in US; for -UC models refer to the next page)
SW1 Bank OFF - Long Flue ON - Short Flue and Outdoor Models 1 Long flue is defined as: 0 elbows and length is greater than 21 ft 1 elbow and length is greater than 15 ft 2 elbows and length is greater than 9 ft Settings dependent on altitude
2001-5200 ft (610-1585 m) #2: OFF #3: ON 5201-7700 ft (1585-2347 m) #2: ON #3: OFF 7701-10200 ft (2347-3109 m) #2: ON #3: ON
SW2 Bank (present on replacement PC boards only) 1 2 OFF - Propane Gas ON - Natural Gas OFF - Outdoor model ON - Indoor model OFF - R63LSe, R75LSe, R75LSi, R94LSe, R94LSi, R98LSe(ASME), R98LSi(ASME) ON - R50LSi, V53e OFF - V53e, R63LSe, R94LSe, R94LSi, R98LSe(ASME), R98LSi(ASME) ON - R50LSi, R75LSe, R75LSi OFF - V53e, R63LSe, R75LSe, R75LSi, R94LSe, R94LSi, R98LSe(ASME), R98LSi(ASME) ON - R50LSi OFF position
2 3
0-2000 ft (0-610 m) #2: OFF #3: OFF
5 6
OFF - if using MC-91 controller ON - if using MC-45 controller OFF - 120F default temperature without a controller ON - 140F default temperature without a controller OFF position OFF position - Used for low fire and high fire settings. Refer to the gas pressure setting procedure.
5 6 7 8
106
100000098 Rev B
Dip Switch Settings

VA Series (-UC Models; model name ends in UC)
R75LSe-VA R75LSi-VA R94LSe-VA R94LSi-VA REU-VA2528WD-UC REU-VA2528FFUD-UC REU-VA2535WD-UC REU-VA2535FFUD-UC
These models have a default maximum temperature of 120 F (49 C) and an option to increase the maximum temperature to 140 F (60 C). Temperature settings from 125-140 F (52-60 C) are available by setting dip switch 6 to ON in the SW1 bank of 8 dip switches. Other dip switch positions may be defined differently than for the non -UC models. SW1 Bank OFF - Long Flue ON - Short Flue and Outdoor Models 1 Long flue is defined as: 0 elbows and length is greater than 21 ft 1 elbow and length is greater than 15 ft 2 elbows and length is greater than 9 ft Settings dependent on altitude
2001-5200 ft (610-1585 m) #2: OFF #3: ON 5201-7700 ft (1585-2347 m) #2: ON #3: OFF 7701-10200 ft (2347-3109 m) #2: ON #3: ON
SW2 Bank (present on replacement PC boards only) 1 2 3 4 5 6 OFF - Propane Gas ON - Natural Gas OFF - Outdoor model ON - Indoor model OFF position OFF position OFF position OFF position
2 3
0-2000 ft (0-610 m) #2: OFF #3: OFF
OFF - if using MC-91 controller ON - if using MC-45 controller OFF - 120F default temperature without a controller ON - 140F default temperature without a controller OFF - 120F maximum temperature without an MCC-91 controller ON - 140F maximum temperature without an MCC-91 controller OFF position - Used for low fire and high fire settings. Refer to the gas pressure setting procedure.
6 7 8
107
100000098 Rev B
Dip Switch Settings

VB and Condensing Series
R75LSe-VB, R75LSi-VB, R94LSe-VB, R94LSi-VB, V53i, RC80HPi, RC80HPe, RC98HPe, RC98HPi SW1 Bank OFF - Long Flue ON - Short Flue and Outdoor Models 1 Long flue is defined as: 0 elbows and length is greater than 21 ft 1 elbow and length is greater than 15 ft 2 elbows and length is greater than 9 ft Settings dependent on altitude
0-2000 ft (0-610 m) #2: OFF #3: OFF 2001-5200 ft (610-1585 m) #2: OFF #3: ON 5201-7700 ft (1585-2347 m) #2: ON #3: OFF 7701-10200 ft (2347-3109 m) #2: ON #3: ON
2 3
4 5
OFF OFF - 120F default temperature without a controller ON - 140F default temperature without a controller R75LSe-VB, R75LSi-VB, R94LSe-VB, R94LSi-VB, RC80HPi, RC80HPe, RC98HPe, RC98HPi* OFF - 120F maximum temperature without an MCC-91 controller ON - 140F maximum temperature without an MCC-91 controller V53i OFF - Propane ON - Natural Gas * R75LSe-VB, R75LSi-VB, R94LSe-VB, R94LSi-VB, RC80HPi, RC80HPe, RC98HPe, RC98HPi models have a default maximum temperature of 120 F (49 C) and an option to increase the maximum temperature to 140 F (60 C). Temperature settings from 125-140 F (52-60 C) are available by setting dip switch 6 to ON in the SW1 bank of 8 dip switches.
7 8
OFF position - Used for low fire and high fire settings. Refer to the gas pressure setting procedure.
SW2 Bank (present on replacement PC boards only) Note: Not present on V53i PC boards. 1 2 3 4 5 6 OFF - Propane Gas ON - Natural Gas OFF - Outdoor model ON - Indoor model OFF - R75LSe-VB, R75LSi-VB, R94LSe-VB, R94LSi-VB, RC98HPe, RC98HPi ON - RC80HPi, RC80HPe OFF position OFF position OFF position
108
100000098 Rev B
Notes
109
100000098 Rev B
Notes
110
100000098 Rev B
Notes
111
100000098 Rev B
100000098 Rev B
2011 Rinnai America Corporation
7/2011

Rinnai Service Manual

Uploaded by

Copyright:

Available Formats

Rinnai Service Manual

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Rinnai Service Manual

Uploaded by

Copyright:

Available Formats

Tankless Water Heater Service Manual

Rinnai Water Heater Service Manual

DANGER WARNING CAUTION

Rinnai Water Heater Service Manual

C42e C53e C85e C85ePLUS C98e C98eASME

REU-V1616WC REU-V2020WC REU-V2532WC REU-V2532WCD REU-V3237WC REU-V3237WC-ASME

120,000 150,000 199,000 199,000 237,000 237,000

V Series - Commercial - Indoor

V Series - Residential - Outdoor

R42e R53e R70e R85e R85ePLUS R98e R98eASME

REU-V1616W REU-V2020W REU-V2526W REU-V2532W REU-V2532WD REU-V3237W REU-V3237W-ASME

120,000 150,000 199,000 199,000 199,000 237,000 237,000

V Series - Residential - Indoor

[1] Minimum activation flow is approximately 0.6 gallons/minute (2.3 liters/min)

Rinnai Water Heater Service Manual

REU-VA2024WD-US REU-VA2024WD(A)-US REU-VA2528WD-US REU-VA2528WD(A)-US REU-VA2528WD(A)-UC REU-VA2535WD-US REU-VA2535WD-UC REU-VA3237W-US

VA Series (LS Series) - Residential or Commercial - Indoor

R94LSi R98LSi R98LSiASME

15,000 19,000 19,000

9.4 9.8 9.8

(35) (37) (37) 98 - 140 F (37-60 C) [3]

VA Series - Residential - Outdoor

Rinnai Water Heater Service Manual

VB Series (LS Series) - Residential or Commercial - Indoor

R75LSi, RL75i REU-VB2528FFUD-US R94LSi, RL94i REU-VB2735FFUD-US

98 - 140 F (37-60 C) [2] 98 - 140 F (37-60 C) [3]

199,000 (NG) 9,900 (NG) 190,000 (LPG) 10,300 (LPG)

VB Series - Residential - Indoor

Condensing Series - Residential or Commercial - Outdoor

Condensing Series - Residential or Commercial - Indoor

Rinnai Water Heater Service Manual

Accessing Operating Information

Water Flow Sensor sends pulses to the PC

Shut-down begins when the PC Board senses

PC Board monitors water temperature and

Freeze protection is activated as needed.

Rinnai Water Heater Service Manual

Turn off all hot water taps. Press ON/OFF twice.

Over Temperature Warning

Rinnai Water Heater Service Manual

Heat Exchanger Outgoing Temperature Sensor

Water Flow Control

Flame Sensing Device

Rinnai Water Heater Service Manual

Electrical Diagnostic Points

Connector No. Pin No.s

(FM) Combustion Fan Motor

Rinnai Water Heater Service Manual

Electrical Diagnostic Points

Connector No. Pin No.s

Thermal Fuse / Overheat Switch

Heat Exchanger Temperature Thermistor

Rinnai Water Heater Service Manual

Electrical Diagnostic Points

Connector No. Pin No.s

B1 outdoor models B2 indoor models

(FM) Combustion Fan Motor

Rinnai Water Heater Service Manual

Electrical Diagnostic Points

Rinnai Water Heater Service Manual