Infiniti® Series Tankless (Condensing) Gas Water Heater SERVICE MANUAL Troubleshooting Guide and Instructions for Service (To be performed ONLY by qualified service providers) (Indoor) Models Covered by This Manual: Indoor Gas: RTG-K-160-N1 RTG-K-199-N1 RTG-L-160-N1 RTG-L-199-N1 Indoor Propane: RTG-K-160-X1 RTG-K-199-X1 RTG-L-160-X1 RTG-L-199-X1 Outdoor Gas: RTG-K-160-N2 RTG-K-199-N2 Outdoor Propane: RTG-K-160-X2 RTG-K-199-X2 TRAINING AND SERVICE INFORMATION This document is restricted to exclusive us
Table of Contents 1. INTRODUCTION ......................................................................................... 3 2. APPLIANCE DESCRIPTION ......................................................................3 2.1 2.2 APPLIANCE DESIGNATION ..................................................................................................... 3 AVAILABLE ACCESSORIES..................................................................................................... 4 3. INSTALLATION........
1. Introduction This manual is a complement to the instruction/operation manual delivered with the appliance, with the main important technical details that are relevant for the official service partners and trainers in the country. 2. Appliance Description This appliance is a fan pressurized gas water heater offering a wide range of modulation and installation advantages with both indoor and outdoor models available. 2.
2.2 Available Accessories Anti-Freeze Kit Allows the protection of the appliance against water freezing inside of its pipes / heat exchanger. The anti-freeze kit can be used where ambient temperatures are as low as -30°F/-35°C for short periods of time. Additional measures must be taken to the surrounding pipes connected to the unit in case it is installed in a place where freezing temperatures are constant.
3. Installation The installation manual of each product must be checked and used by the installer to optimize and leave the appliance in correct operation conditions. Check Lists for Technicians/Installers: 3.
Figure 3 – Wall mounting preparation using supplied wall hung bracket Figure 4 – Wall mounting for indoor appliance (left) and outdoor appliance (right) Page 6 6
3.2 Water Connections Requisite Water pipes were cleaned before being connected to the appliance? Observations Confirmation Inlet water filter was checked and is cleaned, ensuring the necessary water flow rate? Accessories for water connections are adequate and without water leak? Water pressure and flow are according to the appliance specifications? - Minimum pressure: 1.
3.3 Gas Connection Requisite The appliance is suitable for the available gas type? Confirmation Unit Supplied as NG (without gas flow restrictors) Unit set up for LP (with gas flow restrictors) Pressure reducer and gas pipe are adequate for the required pressure and gas flow? Refer to manual recommendations.
GAS MANOMETER Figure 5 – Manometer pipe connection to measure static/dynamic gas supply pressure 3.4 Appliance Performance Measure water flow and temperature increase to check temperature and instantaneous water flow, assuring correct operation of the appliance.
4.
4.1 Control Panel for User (Indoor Version) The control panel, located on the front cover of the appliance, allows the final user to control the operations needed. The following figures show the overall control panel and the display icons, respectively. See Table 8 for more display icon information.
Figure 9 – Display LCD Description Control Panel Operation: Power: • • To start the appliance, press the On/Off button. To shut down the appliance, press the On/Off button again. Reset Errors: • Some error codes can be solved by resetting the appliance. To do this, press and hold the On/Off button for more than 3 seconds. The appliance will initiate the start-up sequence. Set Water Temperature: • • • • By default, the unit is set for 120 °F.
Control Panel Sub-Menus: To access the sub-menus, simultaneously press the P, Up, and Down buttons for 3 seconds. The display should default to displaying P4.
P4 – Information Menu: Displays informational data regarding the unit. This submenu can be useful for diagnosing the appliance, as needed. P4 - Information OD - Operation Data OD 0d Chamber NTC - Water Temperature at exit of heat exchanger 1d Inlet NTC - Current temperature of the temperature sensor of the water inlet pipe 2d Outlet NTC - Current temperature of the temperature sensor of the water outlet pipe 3d Flow - Total water flow through the unit.
P9 – Purge: This menu allows the blower to run, purging the exhaust venting. To engage this function, use the Up and Down buttons to select P9. Within 2-5 seconds, the fan should begin working. To exit this function, use the Up and Down buttons to move to a different menu. SA – Settings: This menu allows several different settings for the appliance to be changed, such as recirculation loop, units (°F/°C), etc.
LM – Temperature Limit: This setting allows the maximum setpoint limit of the appliance to be set. The maximum temperature for a residential model is 140 °F. To change the limit, access the SL menu, and set the desired limit with the Up and Down buttons. You can also turn off the limit by selecting OF (off) in the limit menu. Pressing the P button for 3 seconds will save the changes. PE – Appliance Type: This menu allows changes to several options, including: appliance type, power, and model.
P1 – Maximum Power: This menu allows adjustment to the fuel/air ratio at maximum power. This is a manual adjustment; before proceeding, read about the procedure in the Installation/Operation manual. P1 P1 - Maximum Power A1 High Fire Air Adjustment L1 High Fire Gas Adjustment b1 Low Power Air Flow Calibration rP Reset Parameters IC Ionization Correction E Exit P2 – Minimum Power: This menu allows adjustment to the fuel/air ratio at minimum power.
On / Off button The main switch is assembled on the PCB and disconnects the unit. Anti-Freeze function is assured even in the OFF position Note: When pressed for 3 seconds or longer, errors are reset. Program Button - Used to enter in to different services: “Enter” in service mode Scroll in the service mode menu Save value or adjust set values Save a temperature set (user) Selection button Used to select temperature values, adjustments and navigation on parameters inside the visualisation mode.
Symbol Description Temperature Unit: ºC – default value ºF – alternative value Power bar indicator: Indication of the current operation power Flame indication: Indication of flame in the burner Observation Selection can be done by changing default value on service mode Indicative Value (in %) Note: each line corresponds to 10% Symbol displayed when ionization is detected - flame presence Warning symbol: Combined with an error indication / warning code indicates a faulty performance Tap symbol: Indica
Figure 11 – Disassembling the Control Panel for Installer To disassemble this HMI, the necessary steps are the following: 1. Pull the HMI (Remember that a cable is still connected. 2. Disconnect the cable. 3. Loosen the 2 screws. 4. Rotate the base of the HMI and pull it. 5. Remove the support of the HMI.
4.3 Condensate Siphon The appliance includes a condensate siphon which stores condensate generated during operation from the condensate collector below the stainless-steel condensing heat exchanger. The siphon must also connect to an adequate PVC drainage pipe (1) to drain the acidic condensate once full. As this unit is a high-efficiency appliance, condensate flow can be as high as 2 gallons per hour at full power.
4.4 Heat Cell The heat cell includes a heat exchanger with flame sight window, ignition and ionization electrodes, condensing unit, and condensate collector. 1 – Burner 2 – Electrodes 3 – Copper Heat exchanger 4 – Stainless Steel Condensing unit 5 – Condensate collector Figure 14 – Heat Cell To disassemble the heat cell from the metal box the necessary steps are the following: 1. Remove the condensate collector (2 screws) 2. Remove the control unit (2 screws and cables) 3.
4.5 Gas Manifold The gas manifold is a gas distribution pipe with integrated drilled injectors. Figure 15 – Disassembling the manifold from the heat cell To disassemble the manifold from the burner the necessary steps are the following: 1. Remove the fan 2. Disconnect the solenoids from the top left of the manifold 3. Disconnect the segmentation safety valves 4. Remove the HMI for installer (see figure 13). In the first picture the HMI is already removed except its base. 5.
1 – Burner segment 1 2 – Burner segment 2 3 – Burner segment 3 4 – Gas restrictor seal 5 – Gas seal 6 – Segmentation safety valves Figure 16 – Disassembling the Manifold Page 24 24
As shown in the previous figure, the manifold contains 3 solenoids valves (SV) that are responsible for the release of gas in each burner segment. This allows the unit to have 6 burner level stages according to the solenoid combination: Stage 1 – SV 1 Stage 2 – SV 2 Stage 3 – SV1 + SV2 Stage 4 – SV3 Stage 5 – SV1 + SV3 Stage 6 – SV1 + SV2 + SV3 The manifold is only available as one spare part. However, for maintenance purposes it may be required to open the manifold.
Figure 18 – Gas Restrictor Diaphragm for Propane Operation Figure 19 – Gas Conversion Procedure for LPG Operation For gas restrictor conversion, the manifold doesn’t need to be disassembled. The steps for restrictor conversion are: 1. Disassemble the gas restrictor seal by removing the 4 screws. 2. If the appliance is working with NG, there is no restrictor inside. If the appliance is working with LPG, there is a rubber diaphragm with 3 restrictors. 3.
4.6 Fan The control unit monitors the primary air flow to the burner by varying the fan motor power supply voltage (DC), ensuring a correct variable speed according to the output needed. The fan motor provides an additional control signal to enable/disable operation and the speed of the fan is measured by the feedback signal provided by the fan’s motor. The signal consists of a square wave with a frequency proportional to the speed of the fan.
4.7 Gas Valve It is possible to control gas flow to the burner by the modulating gas valve (MV) in addition to the control unit. The gas valve is composed of an additional solenoid identified as safety valve (SV1) releasing the modulated gas to and from the solenoid gas valve. Safety Solenoid Valve The safety valve (SV) is the first safety element that releases gas to the burner. The second safety level elements are the solenoid valves in the gas manifold of the burner.
4.8 Heat Exchanger The copper heat exchanger has different size and fin amounts according to the appliance model (160 or 199). This configuration ensures the sealed heat transfer from the flame heat to the water that flows through the copper pipes. Figure 22 – Heat exchanger To disassemble the heat exchanger from the entire heat cell the necessary steps are the following: 1. Disassemble the heat cell from the appliance (See Section 4.4) 2. Remove burner (8 screws). Remove condensing unit (8 screws). 3.
4.9 Water Valve The inlet water valve contains the flow sensor responsible for the flow rate detection and a motor stepper responsible for the maximum water flow control through the unit. Figure 23 – Inlet Water Valve Water flow is measured by a turbine flow sensor that is fed by a DC signal and gives a feedback signal proportional to the measured water flow (see Table 9). • • Minimum Flow rate to start up the appliance: 0.45 gpm (1.7 l/min) Flow rate to shut off the appliance: < 0.5 gpm (1.
Figure 24 – Inlet Water Valve Composed by a Motor Stepper (left) and a Flow Sensor (right) In order to disassemble the water valve, it is necessary to remove the clips attaching the valve to the water piping. Note that the motor stepper and the flow sensor are one only spare part. However, for maintenance purposes it may be required to open the water valve. 4.
Removing Circulation Pump for Servicing 1. Remove the Water Valve prior to pump service (refer to Section 4.8). Once the Water Valve has been removed, disconnect the pump harness.
2. Remove clips holding the anti-freeze resistors, then remove the anti-freeze heaters from the water pipes as shown below. Figure 26 – Step 2: Unclip Anti-Freeze Resistors from the water pipes Unclip Both 3. Remove the clips holding in the pump outlet and inlet pipes. Remove Clips Figure 27– Step 3: Remove the clips holding in the pump outlet and inlet pipes.
4. Using a T20 Torx driver, remove the 4 screws holding the pump bracket. Remove Screws Figure 28– Step 3: Remove 4 Screws 5. Finish disconnecting the pump inlet pipe and remove the circulation pump from the cabinet. 6. Service circulation pump as necessary. Reverse Steps 1-5 to reassemble circulation pump once servicing is complete.
4.11 Water Temperature Sensors The outlet and inlet water temperature is measured by a 10kΩ NTC (See Table 13). Both NTC are equal, but connected to different cable colors (blue wires to inlet water / red wires to outlet water). Figure 29 – Outlet Water Temperature Sensor (left) and Inlet Water Temperature Sensor (right) 4.
4.13 Electrodes The spark generation is started immediately before opening the gas valve and stopped when ionization is sensed. The flame is sensed through an ionization electrode, and detection is granted for ionization currents greater than 0.5 micro-amps (µA).
Ignition Electrode To prevent harder than necessary ignition cycles and to ensure the correct gas supply and burner stability conditions, the following situation is verified during the safety time period. During each ignition attempt, the system monitors the ionization signal; this signal drives the start of normal operation. However, in the case where the ionization signal is not detected during the ignition sequence, the failure code EA will flash on the display.
Ionization Electrode Flame is sensed through an ionization electrode, and detection is granted for ionization currents higher than 0.5 µA. The two ionization electrodes are spaced to allow flame detection on both sides of the burner. 5. Working Principle / Electric Measurements Water Flow Detection and Solar Mode Operation Solar Mode Operation Water Flow Calculation Procedure Water Flow = Power (T set – T in) Flow < 0.45 Flow ≥ 0.
[1] Ionization sensor [2] Fan [3] Ignition electrode [4] Power supply [5] Connection for anti freeze kit [6] Connection for remote control [7] Gas valve - Modulation [8] Water bypass valve [9] Manifold solenoid 3 [10] Manifold solenoid 1 [11] Manifold solenoid 2 [12] Gas valve – Safety Solenoid [13] Thermofuse [14] Water flow sensor [15] Exhaust temperature sensor [16] Exhaust temperature sensor in heat exchanger [17] Water outlet bypass temperature sensor [18] Cabinet air temperature sensor [19] Heat Exch
[1] Ionization sensor [2] Fan [3] Ignition electrode [4] Power supply [5] Connection for anti freeze kit [6] Connection for remote control [7] Gas valve - Modulation [8] Water bypass valve [9] Manifold solenoid 3 [10] Manifold solenoid 1 [11] Manifold solenoid 2 [12] Gas valve – Safety Solenoid [13] Thermofuse [14] Water flow sensor [15] Exhaust temperature sensor [16] Exhaust temperature sensor in heat exchanger [17] Water outlet bypass temperature sensor [18] Cabinet air temperature sensor [19] Heat Exch
ID 14 Component Description Measuring Wire Colors Value Remarks Red-Blue GND 5 VDC Control power Water Flow Sensor Yellow-Blue GND 22 Water Valve Stepper Motor Black – Red 8 Bypass Water Valve Red – Red ≈ 2.5 to 2.9 VDC On: ≥ 0.45 gpm (1.7l/min) (pulse frequency ~Hz) Note: See Table 9 to check correspondence between water flow and frequency signal. 5 V dc When replaced by a new spare part, calibration is needed using MF parameter in PA (Actuator) menu of display.
Operating Temperature (ºC) -10 -5 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 Operating Temperature (ºF) 14 23 32 41 50 59 68 77 86 95 104 113 122 131 140 149 158 167 176 185 194 203 212 221 230 Resistance (KΩ) 1373 1034 784.7 600 462.1 358.4 279.9 220 174 138.5 110.9 89.24 72.24 58.78 48.08 39.51 32.63 27.07 22.56 18.88 15.87 13.39 11.34 9.642 8.
Figure 34 – Diagram Water NTC Operating Temperature (ºC) 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 Operating Temperature (ºF) 32 41 50 59 68 77 86 95 104 113 122 131 140 149 158 167 176 185 194 203 212 221 230 R min (KΩ) 30.34 23.674 18.617 14.749 11.768 9.454 7.644 6.218 5.089 4.188 3.466 2.883 2.41 2.009 1.683 1.416 1.197 1.016 0.866 0.741 0.637 0.549 0.475 R nominal (KΩ) 30.4 25.902 20.247 15.95 12.657 10.115 8.138 6.589 5.367 4.398 3.624 3.002 2.5 2.092 1.759 1.486 1.26 1.
The following pictures show cable location in each connector on the PCB (printed circuit board): Figure 35 – Sensor Connector with 22 pins Figure 36 – Water Valve and Cascading System Connector with 12 pins Page 44 44
ID 1 Component Description Ionization electrode Measuring Wire Colors White wire to ionization electrode Brown-Blue GND 2 Combustion fan Mechanically modulated valve (MV1) Main safety solenoid 12 valve (SSV) Solenoid valve 10 (SV1) Solenoid valve 11 (SV2) Solenoid valve 9 (SV3) 7 Red-Blue GND Value Multimeter in position for current measurement, with scale for µA range of values Ionization current > 0.5 µA ~ 0 – 45 V DC ~ 10.8 – 13.
Figure 38 – Gas and Bypass Valve Connector with 14 pins Figure 39 – Fan Connector with 8 pins Figure 40 – Ignition Transformer Page 46 46
Figure 41 – Inside View of the Control Unit Figure 42 – Power supply and anti-freeze connector with 6 pins Page 47 47
6. After Sales Service In order to ensure a correct start-up of the appliance and a correct function after any intervention on the appliance, the service manual must be read and main recommendations followed to avoid wrong diagnostic / components replacement and premature failures.
Figure 43 – Confirmation of HMI Configuration (gas type) 3rd – Configuration of the New PCB - Switch ON electrical supply. - Follow configuration tips in HMI. Question Region Selection Appliance Power Type Options USA eV Europe 160 kBTU 199 kBTU Residential Commercial 4th Combustion Parameters Configuration - Confirm P7 = NG or change it to LPG in case of unit operating with Propane. - Confirm nO (in PE) = Indoor or change it to Outdoor in case of outdoor unit.
P0 (not used) P1 Maximum Power Set point Normal Mode P2 Minimum Power See Combustion - gas power adjustments section for more details P3 Connectivity P4 Information P5 Start-up Delay P6 Units Set P7 Gas Type P8 Backlight control P9 Purge mode PA Calibration of components PC Cascading mode U1 Auto Adjust L1 U2 Auto Adjust L2 Table 15 – Service Mode Parameters List (1st level) 50 Page 50
Combustion – Gas Power Adjustment Parameters The adjustment of the appliance for minimum (P2) / maximum (P1) power operation may be needed under the following conditions: - Gas valve replacement – run the U1 and U2 to find L1 / L2 values according characteristic of new gas valve; Fan replacement – use flue gas analyzer as described in manual to find correct setting of A1 / A2 (air flow); The following image indicates the 2 measurement points to be used: A) Fan Pressure Measurement Point B) Gas Pressure
To keep the appliance in P1 (maximum power adjustment), it is important to assure a minimum water flow, otherwise the appliance will jump automatically to P2 (minimum power).
The P2 mode can be accessed in the service mode, depending on adjustment and/or confirmation need.
The access to the data visualization mode, is made by entering first in the “service mode” and then, scrolling to the parameter “P4” of the adjustment mode. Diagnostic mode and visualization mode Installer Level Technician Level Comments This mode helps the installer in the startup to check parameters such as water flow through the appliance and inlet / outlet temperatures This mode helps the technician to find some information useful to adjust and to check functionality of the appliance.
Not existing Temperature of air in room sealed box Last 10 Failures for diagnostic purposes until Temperature read by box sensor ºC or ºF Failure 1 is last failure occurred Failure 2 occurred before Failure1 Failure 3 occurred before Failure2 Failure 4 occurred before Failure3 Failure 5 occurred before Failure4 Failure 6 occurred before Failure5 Failure 7 occurred before Failure6 Failure 8 occurred before Failure7 Failure 9 occurred before Failure8 Failure 10 occurred before Failure9 Table 22 – Visual
Cascading Mode Parameter This mode allows the installer to configurate the units to operate in cascading (optional kit with cable required) Deactivation of cascading mode Selection as Master Selection as Slave Press “P” for > 3 sec to define unit as Master (only 1 unit in system) Press “P” for > 3 sec to define / confirm unit as slave Table 24 – PC 7. Maintenance To ensure continued efficient operation of the appliance, checking and servicing the appliance at regular intervals is recommended.
L641 – O-rings in contact with water HFt1 v5 – Gaskets in contact with gas Figure 47 – Recommended Lubricants for Connections Cleaning the Filter For the cleaning of the filter, first loosen the nut (1), then remove the filter (2) that is fixed in the body of the inlet water valve. Clean the filter with water and / or air pressure. Assembly is reverse of disassembly. Figure 48 – Water Filter Removal Inspect and clean the heat exchanger when needed.
Figure 49 – Heat Exchanger Cleaning Heat Exchanger Fin Coils Inspect the heat exchanger fin coils for soot build-up or blockage. If there is evidence of soot build-up or blockage, the heat exchanger should be removed by a professional and cleaned thoroughly. Soot is an indication of incomplete combustion and a clear sign of a serious problem. Venting, gas pressure, and flue gases should be examined to determine the cause of the problem.
Descaling Using a Pump ▶ ▶ ▶ ▶ ▶ ▶ ▶ ▶ ▶ ▶ ▶ ▶ ▶ ▶ ▶ ▶ ▶ ▶ Disconnect the electrical supply from the water heater. Shut off the water supply to the water heater. Open hot water taps to drain and relieve pressure from the plumbing system. Shut off hot water valve to the water heater. Connect a line (A) from the outlet of the circulating pump (installer supplied) to the inlet drain connection on the water heater. Using another line (B), connect the outlet drain connection of the water heater.
Figure 51 – Heat Exchanger Replacement of Parts Any service work must be carried out by a competent person such as the technician indicated by the after sales organization. Before any service operation, turn off the gas supply at the main gas service valve. When replacing components, always use the supplied gaskets / sealings provided with the parts and / or always order the maintenance kit.
8. Trouble Shooting Display Description Solution Either cold or hot water temperature sensor fault Check temperature sensors and associated connections. A1 Temperature inside the cabinet is above 158 °F. The appliance automatically regulates the performance of the appliance to avoid overheating. ▶ External air temperature is above 140 °F. ▶ Check for flue leakage inside the appliance or in concentric vent.
Display Description Solution Air in the water circuit (commissioning). Water flow above maximum value specified ( 9.24GPM). ▶ Disconnect the appliance and purge hydraulic circuit.1) ▶ Check that water pressure does not exceed 150 psi. - Vent blockage during operation (Flue vent outlet or air vent inlet). Insufficient combustion air. - Air flow insufficient for start-up (Before flame ignition). - Flue outlet vent blockage (exhaust pressure above siphon water column). Excessive flue vent pressure.
Display Description Solution ▶ To unlock, reset the appliance by touching the ON/OFF button for 3 sec. ▶ If the problem persists check the ignition electrode or the ionization electrode. EE Modulating gas solenoid valve disconnected. ▶ Check valve connection. EF Wrong gas type. ▶ Natural gas appliance supplied with liquid propane gas. ▶ Liquid propane gas appliance supplied with NG. F2 ECU internal error ▶ To unlock, reset the appliance by touching the ON/OFF button for 3 sec.
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