American Water Heater 701022 installation manual Controller, Gas Pressure Setting, Wiring Diagram

Controller

Gas Pressure Setting

Ensure gas pressure check under Commissioning has been completed first! The regulator is electronically controlled and

In Use Indicator Indicates that hot water is being supplied.

Temperature Display Indicates temperature setting or flashes error code.

Thermostat

Diagnostic Use of the Controller

Priority Indicator Indicates that this controller is setting the water temperature.

Priority Button

When no water is being supplied, pressing this button allows this controller to set the water temperature.

ON/OFF Button

factory pre-set. Under normal circumstances it does not require adjustment during installation. Make adjustments only if the unit is not operating correctly and all other possible causes for incorrect operation have been eliminated.

1.	Turn OFF the gas supply.
2.	Turn OFF the 120 V power supply.
3.	Remove the front panel from the appliance.
4.	Check the gas type using the data plate on the side of the unit.
	If using a spare PC board, check that the gas type switches are
	in the correct position (dip switch 1 of SW2: ON for natural gas,
	NG, and OFF for propane, LPG). See dip switch settings
	section below. (ON is towards the right and OFF is towards the
	left.)
5.	Attach the pressure gauge to the burner test point, located on
	the gas control (Fig. 2).
6.	Turn ON the gas supply.
7.	Turn ON the 120 V power supply.

1.To display error codes, press the ON/OFF button followed by the thermostat button to cycle through the error codes.

2.To display the water flow through the water heater, press the thermostat button (hold for 2 seconds) and then press the ON/OFF button while continuing to hold the thermostat button.

3.To display the outlet water temperature, press the thermostat button (hold for 2 seconds) and then press the ON/OFF button while continuing to hold the thermostat button.

To Change the Temperature Scale (ºF / ºC)

With the water heater turned off, press and hold the ON/OFF button until the display changes to the other temperature scale (about 5 seconds).

To Turn Off the Controller Sound (Mute)

To turn the sound off (mute), press and hold both the and thermostat buttons until a “beep” is heard (about 5 seconds).

8.	If a controller is installed, turn the unit ON with the controller.
	Select the maximum delivery temperature and open all
	available hot water taps at full.
9.	Set the unit to ‘Forced Low’ combustion by setting No. 7 dip
	switch of the SW1 set to ON (Fig. 3).

10.Check the burner test point pressure.

11.Remove the rubber access plug and adjust the regulator screw on the modulating valve (Fig. 4) as required in Table 1. Replace the rubber access plug.

12.Set the unit to ‘Forced High’ combustion by setting both No. 7 and No. 8 dip switches of the SW1 set to ON (Fig. 5). Ensure

maximum water flow.

13.Check the burner test point pressure.

14.Adjust the high pressure potentiometer (POT) on the PC board as required to the pressure shown in Table 1.

15.Return the unit to normal operation by setting dip switches 7 and 8 of the SW1 set back to OFF (Fig. 6). Close all water taps.

16.Turn OFF the gas supply and 120 V power supply.

17.Remove the pressure gauge and install sealing screw.

18.Turn ON the gas supply and 120 V power supply.

19.Operate the unit and check for gas leaks at the test point.

20.Install the front panel.

Gas Pressure Setting

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

WARNING

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

APPLIANCE OPERATING PRESSURES

Table 1

	Water	Gas Inlet		Forced Low		Forced High
		Min./Max
	Inlet Max.
		NAT.G	LPG	NAT.G	LPG	NAT.G	LPG
705(Indoor)	150 PSI	5"W.C.	8"W.C.	0.67"W.C.	0.83"W.C.	3.0"W.C.	3.7"W.C.
705(Indoor-ASME)		/10.5"W.C.	/13.5"W.C.

Commissioning

With all gas appliances in operation at maximum gas rate, the flowing inlet pressure at the incoming test point on the Rinnai water heater should read 5" W.C. - 10.5" W.C. on natural gas and 8" W.C. - 13.5" W.C. on propane gas. If the pressure is lower, the gas supply is inadequate and the unit will not operate to specification. Check the gas meter regulator and pipework for correct operation/sizing and correct as required.

High Pressure

Potentiometer

Burner test point

SW1

1

SW2

Spare Parts

Only

Fig. 1 Fig. 2

Regulator adjustment screw access plug

Fig. 3 Fig. 4

Fig. 5 Fig. 6

Troubleshooting

Important Safety Notes

There are a number of (live) tests that are required when fault finding this product. Extreme care should be used at all times to avoid contact with energized components inside the water heater. Only trained and qualified service technicians should attempt to repair this product. Before checking for resistance readings, disconnect the power source to the unit and isolate the item from the circuit (unplug it).

(SV1, SV2, SV3 and POV) Gas valve and Modulating solenoids: (Set meter above 2K)

Wire color	Voltage	Resistance	Connector #	Pin #'s
(Main) Pink - Black	11 ~ 13 VDC	24 ~ 28 ohms	H3	6	- 7
(SV1) Black - Red	11 ~ 13 VDC	37 ~ 43 ohms	H4	5	- 6
(SV2) Black - Orange	11 ~ 13 VDC	37 ~ 43 ohms	H5	4	- 6
(SV3) Black - Yellow	11 ~ 13 VDC	37 ~ 43 ohms	H6	3	- 6
(POV) Orange - Orange	2 ~ 15 VDC	67 ~ 81 ohms	H2	9	- 10
(M) Water Flow Control Device Servo or Geared Motor:
Red - Blue	11 ~ 13 VDC	22 ~ 28 ohms	F5	9	- 10
Grey - Brown	4 ~ 6 VDC	N / A	F5	5	- 7
Grey - Yellow	N / A	N / A	F5	5	- 8

NOTE: The grey wire listed above turns to black at F connector on the PCB.

(QS) Water Flow Sensor:

Black - Red	11 ~ 13 VDC		5.5 ~ 6.2 K ohms	F2	1 - 3
Yellow - Black	4	~ 7 VDC	1 ~ 1.4 Mega ohms	F2	2 - 3
By-pass Flow Control:
Brown - White	2	~ 6 VDC		G1	1 - 5
Orange - White			15 ~ 35 ohms	G1	2 - 5
Yellow - White	(Unit in operating mode)			G1	3 - 5
Red-White - Ground				G1	4 - 5
(IG) Ignition System:
Grey - Grey	90 ~ 110 VAC		N / A	C1	1 - 2
(FM) Combustion Fan Motor:
Red - Black	6	~ 45 VDC	N / A	E1	1 - 2
White - Black	5	~ 10 VDC	9.2 ~ 9.4 K ohms	E1	2 - 4
Yellow - Black	11 ~ 13 VDC		3.5 ~ 3.9 K ohms	E1	2 - 3

Set your meter to the hertz scale. Reading across the white and black wires at terminals 2 and 4 you should read between 60 and 420 hertz.

Thermal Fuse / Overheat Switch:

Red - White	11 ~ 13 VDC	Below 1 ohms	F6	F6 - H12
			H1

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 ∝ amp scale and series your meter in line with the flame rod. You should read 1 ∝ amp or greater for proper flame circuit. In the event of low flame circuit remove the flame rod and check for carbon or damage.

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. See below for examples of typical temperatures and resistance readings.

	Example:		59°F = 11.4 ~ 14K		140°F = 2.2 ~ 2.7K
			86°F = 6.4 ~ 7.8K		221°F = 0.6 ~ 0.8K
			113°F = 3.6 ~ 4.5K
Outgoing Water Thermistor:
White - White		N / A		See example above		F4	3	- 4
Heat Exchanger Temperature Thermistor:
Pink - White		N / A		See example above		F3	3	- 11
Surge Protector:
Black - White		108 ~ 132 VAC		N / A		D2	1	- 3
Black - White		108 ~ 132 VAC		N / A		D1	1	- 3

With the power off you can check the continuity through the surge protector. Place a meter lead on the top pin #1 of the surge protector and pin #3 on the bottom of the surge protector. Check across the top pin #3 and bottom pin #1. If you read continuity across these two points then the surge protector is good. If you do not get continuity then replace the surge protector.

Remote Controls:

Terminals B1 10 ~ 13 VDC 1.5 ~ 3.0 K ohms B 1 - 3

Frost Protection:

This unit has frost protection heaters mounted at different points to protect the water heater from freezing. The heaters located on the hot water outlet line should have a resistance reading of 180-207 ohms through each of these heaters. The heater located on the heat exchanger piping should have a resistance reading of 156-180 ohms and the one located in the water flow sensor valve should have a resistance reading 24-28 ohms.

Amp Fuses:

This unit has one inline (3) amp glass fuses. Remove the fuse and check continuity through it. If you have continuity through the fuse then it is good. Otherwise the fuse is blown and must be replaced.

Wiring Diagram

ANTI-FROST HEATER

SWITCH

W W

W

D4

W

COLORCODING

SENSINGFROST

WW

WD6 W FUSE (3A)

NEUTRAL GROUND

W :White

BK:Black BR:Brown R :Red

BL:Blue

Y :Yellow

P :Pink O:Orange

G :Green

GY:Gray

BLBL

D3

W WW W WW D5

W

AC120V

HOT

BK

W

2-Unit Connection (Optional)

MODULATING VALVE

CURRENT ADJUSTING

Spare Parts Only

REMOTE CONTROLLER

SPARK ELECTRODE

IG

GND

D2

G/Y SURGE PROTECTOR

D1

A1

Gas pressure

Gas type

B1

BK BK

C1

GY

GY

IGNITER

W BK

1

1

W BK

GND

SW1

1 2 3 4

2 3 4 5

3

1

1

GY GY

(CN4)

D

G/Y

GND

Dip

O

F

5 6 7 8

DipSW2

1

O F F

6

B

(CN1)

C

(CN3) 1 BK W

3

MAX

MIN

WRBK A 3 1 F

(CN9)

H (CN2)1

P R Y Y BK O

Y

H7

O

O

(CN5)

(CN7)

F

1

1 12

R

W

ROD

G

GY

BK

Dip Switches Settings

705(Indoor-ASME)

705(Indoor)

Adjust switches 2 and 3 in the bank of 8 depending on

LPG

NAT.G

O

ON

1

O

ON

1

your altitude according to the table below.

F

2

F

2

F

3

F

3

4

4

5

5

The original PC boards on the water heaters do not

6

6

7

7

have the bank of 6 dip switches. Only spare PC

8

8

ON

ON

boards have this bank.

O

O

1

1

F

2

F

2

F

3

F

3

4

4

5

5

6

6

High Altitude

WARNING

DO NOT adjust the other dip switches unless specifically instructed

to do so. Incorrect Dip Switch Settings can cause the water heater

to operate in an unsafe condition and may damage the water heater

and void the warranty.

SW

NOTES

No.

2

Off

Level 0

Off

Level 1

On

Level 2

On

Level 3

High Altitude

0-2000 ft

2001-5200 ft

5201-7700 ft

7701-10200 ft

3

Off

On

Off

On

(0-610 m)

(610-1585 m)

(1585-2347 m)

(2347-3109 m)

BL BR WW

E 4

Y

WY ORBR

51

RBK

W

FLAME

R Y

(CN12)

P

13

O O

W Y BK R

R W

H2

POV

6

H1

R BK

O BK

Y BK

O Y R

G

F1

W

P

W W

BR

FM

THERMAL FUSESF

SWITCH R R MODULATING SOLENOID VALVE

P BK

F3

W

F4 W W

SV1

SV2

SV3

G1 BR BY-PASS FLOW CONTROL DEVICE W

FREEZE PROTECTION (OPTIONAL) R

R Y BK

GY

R Y BK

F2

QS

HEAT EXCHANGER

WATERTHERMISTOR W

OUTGOING WATER WATERTHERMISTOR

F5 GYR BLR BRBL YY WATER FLOW CONTROL DEVICE

E1 COMBUSTIONFAN

R W OVERHEAT

H3

MAIN SOLENOIDVALVESV0

H4 SOLENOIDVALVE1 (CENTER)

H5 SOLENOIDVALVE2 (LEFT)

H6 SOLENOIDVALVE3 (RIGHT)

WATER FLOW SENSOR

070 00012 36676 0