Replacing the Gas Control Assembly of Rinnai Tank-less Water heater - Different models
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.
5. Remove the six screws that attach the gas manifold to the combustion chamber (part of the heat exchanger assembly).
6. Remove the three screws that attach the gas manifold to the gas valve. Pull out the gas manifold.
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.
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.
11. Install the gas valve and attach the wire harness to the 4 solenoids.
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. 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
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.
5. Remove the six screws that attach the gas manifold to the combustion chamber (part of the heat exchanger assembly).
6. Remove the three screws that attach the gas manifold to the gas valve. Pull out the gas manifold.
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.
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.
11. Install the gas valve and attach the wire harness to the 4 solenoids.
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. 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
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.
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.
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.
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.
9.
Remove the four screws attaching the gas connection to the underneath side of
the water heater.
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.
11. Pull out the gas control assembly. Remove the wire harness from the 4 solenoids.
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
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.
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.
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.
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.
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.
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).
5. Move aside the ignition line by pulling it out from the clear plastic tubing.
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).
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.
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.
11. Remove the screw attaching the gas valve to the rear of the case.
12. Pull the gas connection down to disconnect it from the gas control assembly.
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.
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.
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.
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.
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
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.
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.
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.
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.
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.
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.
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
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
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.
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.
