Service manual

06/2010
CONTENTS
Section 1. Definition of Terms
Section 2. Description of Operation
Section 3. Trouble-Shooting the RV500
3.1 Water Leak
3.2 Gas Leak
3.3 No Green LED flash or Green LED stays on, but does not flash
3.4 Green LED flashes, but no ignition attempt (no igniter, no gas)
3.5 Green LED flashes, but no ignition (igniter sparks, no gas)
3.6 Green LED flashes, but no ignition (no igniter sparks, no gas flows, no smell)
3.7 The unit ignites, but will not rise above ignition burn or water at faucet is cool
3.8 Large fluctuations in temperature
3.9 During a ‘Navy’ style shower water is cold for a short time after turning off and then
back on
3.10 Pressure relief valve leaks
3.11 During an automatic calibration procedure (AutoCal) the unit shuts down and restarts
3.12 Exhaust is smoking
Section 4. Water flow system
4.1 Cold water bypass
4.2 Flowmeter checkout
4.3 T-in, T-mid, T-out Thermister and T-set readout
4.4 Using the water system pump
Section 5. Service Code Diagnostics
Section 6. Repair and Replacement Guide
SM500-01 Circuit board
SM500-02 DSI
SM500-03 Electrical drawer
SM500-04 Hood
SM500-05 Heat exchanger / burner assembly
SM500-06 Heat exchanger assembly
SM500-07 T-in
SM500-08 T-mid
SM500-09 T-out
SM500-10 Burner
SM500-11 Igniter
SM500-12 Flowmeter assembly
SM500-13 Gas solenoid
SM500-14 Modulating valve
SM500-15 Automatic calibration (AutoCal)
SM500-16 Testing the RV500
SM500-17 Winter/Cold Weather Protection