advertisement
▼
Scroll to page 2
of 64
ENERGYSAVER RHFE-308FTR SERVICE MANUAL High Efficiency Power Flued Gas Space Heater Proudly a member of The Australian Gas Association. All of our products are AGA tested and approved. Distributed and serviced in Australia under a Quality System certified as complying with ISO 9002 by Quality Assurance Services. Rinnai New Zealand has been certified to ISO 9001 Quality Assurance by Telarc. Certified to Australian Standard 3498 by Quality Assurance Services. Watermark certification is awarded to products with suitable fittings complying with safety and water contamination standards. Comparative Energy Consumption tested to The Australian Gas Association requirements of Australian Gas Code AG 102. An energy rating of 5 stars refers to an efficiency of approximately 80%, that is, 80% of gas consumed is converted to useful heat. ISO 9001 ISO 9002 AS 3498 AG 102 Model for Quality Assurance in design/development, production, installation and servicing, aimed primarily at achieving customer satisfaction by preventing nonconformity at all stages from design through to servicing. Same as ISO 9001 but excluding design. Authorisation requirements for plumbing products - water heaters and hot-water storage tanks, aimed at ensuring safe, quality products. Approval requirements for gas water heaters as set by The Australian Gas Association and Australian Liquefied Petroleum Gas Association Ltd, to ensure proper safety performance and quality levels are achieved. © Copyright Rinnai Australia Pty Ltd A.C.N. 005 138 769 All rights reserved Produced by Customer Technical Services July 1998 No portion or part of this manual may be copied without prior permission from Rinnai Australia. Rinnai Australia takes no responsibility for the accuracy or otherwise of information contained in this manual, and reserves the right to make modifications and change specifications without notice. WARNING Failure to comply with these instructions may result in serious personal injury or damage to the appliance. ALL WIRING INSIDE THIS APPLIANCE MAY BE AT 240 VOLTS POTENTIAL ALL SERVICE WORK MUST BE CARRIED OUT BY AN AUTHORISED PERSON. DO NOT TEST FOR GAS ESCAPES WITH AN OPEN FLAME This manual has been compiled by Rinnai Australia Customer Technical Services. While many individuals have contributed to this publication, it will be successful only if you - the reader and customer - find it useful. We would like to extend an invitation to users of this manual to make contact with us, as your feedback and suggestions are valuable resources for us to include as improvements. Rinnai are constantly working toward supplying improved appliances as well as information, and specifications may be subject to alteration at any time. SRV308 Issue No1 Table of Contents Glossary of Terms and Symbols .......................................................................... i 1. Introduction .................................................................................................... 1 2. Dimensions ..................................................................................................... 2 3. Specification .................................................................................................... 3 4. Cut-Away Diagram ........................................................................................ 4 5. Installatio ...................................................................................................... 5 6. Performance Characteristics ......................................................................... 7 7. Schematic Diagram ..................................................................................... 10 8. Control Panel Layout .................................................................................. 11 9. Operating Principles ................................................................................... 12 10. Intelligent Timer [Pre-hea t ...................................................................... 14 11. Safety Devices ........................................................................................... 15 12. Operation Flow Chart .............................................................................. 18 13. Diagnostic Points ....................................................................................... 21 14. Wiring Diagram ........................................................................................ 22 15. Block Diagram ........................................................................................... 23 16. Time Charts ............................................................................................... 24 17. E2 PROM .................................................................................................. 27 18. Error Coded Messag e ............................................................................. 29 19. Fault Finding .............................................................................................. 30 20. Fault Analysis ............................................................................................ 33 21. Electrical Component Analysis ............................................................... 36 22. Testing ........................................................................................................ 40 23. Gas Conversion ......................................................................................... 42 24. Gas Pressure Setting Procedur ............................................................... 43 25. Dismantling for servic ............................................................................. 44 26. Exploded Diagram .................................................................................... 51 27. Parts List ..................................................................................................... 56 Appendix............................................................................................................ 59 Energysaver RHFE-308 FTR Rinnai Glossary of Terms and Symbols This glossary of terms and symbols is provided to assist you in understanding some of the language used throughout this manual. dB(A) - sound pressure level in decibels, “A” range DC - direct current AC - alternating current Hz - Hertz IC - integrated circuit kcal/h - kilocalorie per hour kPa - kilopascals LED - light emitting diode L/min - Litres per minute mA - milliamps MJ/h - megajoule per hour mm - millimetres mmH2O - millimetres of water (gauge pressure) NOX - oxides of nitrogen (NO & NO2) OHS - overheat switch PCB - printed circuit board CPU - central processing unit POT - potentiometer rpm - revolutions per minute SV - solenoid valve ø - diameter ∆ POV - modulating valve TH - thermistor Energysaver RHFE-308 FTR ©Rinnai 1. Introduction Background The RHFE-308FTR incorporates an improved modulating control system to provide comfortable heating. Other features of these appliances are improved safety, operation, installation, and maintenance features. Characteristics • Built into the main PCB is the software for connection to a central ON-OFF control. • Gas flow modulates in 7 steps between High and Low ensuring comfortable and efficient heating. • Includes a 24 hour digital clock and dual timer, and an economy mode function. This reduces gas consumption without affecting comfort. • Temperature control is monitored by “fuzzy logic” technology - relevance to each other. • All operation and temperature control is with user-friendly push buttons. • Improvements have been made to the rear convex section for clean-cut design. • If a problem occurs or service is required, an error coded message appears on the digital display to direct the service technician to the cause of the problem. • Information about any previous faults is stored in the PCB and can be recalled during servicing. About the 308FTR The bodywork is formed from 0.6 mm galvanised steel sheet, which forms a box to which the components, heat exchangers and blowers are attached. This is then covered by an outer case which is constructed from 0.6 mm galvanised steel sheet, and plastic mouldings. The combustion chamber is constructed from 1.0 mm hot dip aluminium coated steel sheet, located in the lower centre of the appliance. The heat exchanger is composed of two sub-heat exchanger sets. The left hand set, No1 is constructed of 1.0 mm aluminised steel. The right hand set, No2 is constructed of 0.8 mm stainless steel. The inlet of subheat exchanger No1 is connected to the outlet of the combustion chamber, the outlet is connected to subheat exchanger N o2. Sub-heat exchanger No2 consists of 3 “sub” sections, constructed from 0.8 mm stainless steel. The outlet of sub-heat exchanger N o2 is constructed from 0.5 mm stainless steel and connected to the flue by a concertina stainless steel tube. The combustion air fan draws combustion air from the outside atmosphere through the flue manifold pipe. Air is then blown into the combustion chamber via a rubber tube. Combustion products in the combustion chamber are pushed out into sub-heat exchanger No1, to sub-heat exchanger No2, and then into the 34 mm flue pipe which is connected through the flue manifold to the outside atmosphere. The flue system is connected with stainless steel concentric pipe. The inner pipe (34 mm diameter.) is the combustion gas outlet, and is connected to the outlet of sub-heat exchanger No2. The outer pipe (70 mm diameter) is the combustion air inlet and is connected to the inlet of the combustion fan air pipe. Various flue lengths are available. Ignition is continuous spark in conjunction with an electrically operated solenoid and control is monitored by the PCB. Gas passes through the R½ 15 (BSP) inlet fitting, then via a flange connection to the solenoid valves No1, N o2, a regulator modulating valve, aluminium injector manifold, before entering the burner. Energysaver RHFE-308 FTR - 1- ©Rinnai 2. Dimensions Note: All dimensions are in millimetres Energysaver RHFE-308 FTR -2- ©Rinnai 3. Specification Type of appliance Fan forced flued gas space heater Model RHFE-308FTR Dimensions Width Depth Height Weight Approx 17 kg Connections Electrical Gas - AC 240 V 50 Hz / 60 Hz - R½ 15 BSP male threa Electrical Consumption High: 39 W Low: 30 W Output 10.5 MJ/h Combustion system Stainless steel bunsen burne Ignition system Continuous electrical spark, direct to main burner Operation Finger touch control buttons Temperature control Electronic thermostat, modulating HI-LOW/OFF Temperature range LOW (10oC), 16 ~ 26oC (1oC increments), HIGH (continuous) Warm air outlet Bottom of appliance Air volume control HI ~ LOW (automatic)/OFF Timer operation Dual Timer - 24 hour, ON & OFF Timer Operation - 24 hour Clock - 24 hour digital display Temperature control - 26 oC limit when using timer program Indicator Burner ON, child lock, filter, economy, digital display, over-ride, clock setting, timer setting, timer, temperature display Operating buttons ON-OFF, up-down, child lock, economy, timer, clock setting, over-ride. Humidifier tray Capacity - 0.8 Litres Safety devices Flame failure Over heat Power failure Power surge Fan delay Pre-purge Room over heat Energysaver RHFE-308 FTR - 425 mm - 165 mm (with back spacer 250 mm) - 677 mm - flame rod - bi-metal switch (130 oC, 90oC) - thermal fuse (216oC) - thermistor (130~90oC) - PCB - 3 Amp fuse - micro computer timer (Max 210 secs - combustion fan, pre-purge timer, spark sensor - automatic cut off at 40 oC after 10 mins - 3- ©Rinnai 4. Cut-Away Diagram Energysaver RHFE-308 FTR -4- ©Rinnai 5. Installation NOTE: The information provided here is only a guide. For full details on installation procedures, please refer to the installation instructions in the customer’s operating instructions. This heater is not designed to be built in. The flue may be positioned directly under opening windows, with a minimum clearance of 150 mm. The flue is not designed to be positioned unde floors or below the level of the heater. The flue terminal should be positioned away from flammable materials. Flue fittings must be kept clear of flammabl materials. In areas subject to heavy snowfall, keep snow clear of flue terminal at all times. Energysaver RHFE-308 FTR - 5- ©Rinnai Recommended minimum clearances and distances from obstructions. Energysaver RHFE-308 FTR - 6- ©Rinnai 6. Performance Characteristics 1. Basic Combustion Specification Item Specification Rinnai model number RHFE-308 FTR Gas typ Gas consumption MJ/h NG Propane/LPG HI 13 13 LO 5 5 1.30 0.90 2 2 HI 0.60 1.04 LO 0.12 0.19 P P Injector size (∅ mm) Injector quantity Regulator pressure (kPa) Burner marking Combustion method Bunsen burner Burner type Stainless slit style Solenoid valve Direct single seated valve type Modulating solenoid valve Direct single seated valve type 2. Combustion Fan Speeds (rpm) Natural Propane/LPG Ignition 1710 1560 Re-ignition 1800 1680 Normal - High 3000 3090 Normal - Low 1440 1440 Energysaver RHFE-308 FTR - 7- ©Rinnai 3. Warm Air Discharge Temperature Distribution Condition: < High Combustion > Test gas: Measured input: Nominal input: Room temperature: Natural 12.55 MJ/h 13 MJ/h 25oC (Unit ∆oC) 24 24 55 9 45 72 64 18 56 81 83 36 62 66 77 42 68 43 70 45 42 39 57 45 Condition: < Low Combustion > Test gas: Measured input: Nominal input: Room temperature: Natural 5.27 MJ/h 5 MJ/h 25oC (Unit ∆oC) 10 17 30 9 23 39 38 13 29 48 42 28 35 44 46 37 37 28 43 34 22 26 31 28 4. Measurement Points Energysaver RHFE-308 FTR - 8- ©Rinnai 5. Warm Air Discharge Velocity Convection Fan rpm HIGH: 740 LOW: 550 22oC Room Temperature: (Unit: m/sec) 1.62 1.46 2.57 1.32 1.70 1.34 1.08 0.84 1.99 1.78 2.57 1.92 2.89 2.15 2.12 1.58 3.20 2.61 3.54 2.53 3.12 2.44 2.51 1.91 3.35 2.66 3.44 2.60 3.14 2.28 2.75 2.08 3.27 2.47 3.37 2.52 3.33 2.62 3.32 2.46 3.13 2.37 2.11 1.23 3.33 2.54 3.42 2.58 Air Flow: Average air velocity on High: 2.784 m/sec Average air velocity on Low: 2.10 m/sec Air flow rate on High: 3.82 m 3/min Air flow rate on Low: 2.89 m3/min Air flow outlet area: 0.0229 m2 6. Noise Level Unit: dB(A). High 36.5 Low 31.5 7. Thermal Efficiency Conditions: Horizontal mushroom flue with unit installed with back spacers. Gas Type Natural Propane Combustion Thermal Efficiency (%) High 81.3 Low 84.8 High 83.5 Low 88.1 8. Humidifier Capacity Method Tray Capacity Evaporation Evaporation 0.8 Litres 0.1 Litres/hour Note: Evaporation rate varies depending on conditions of use. Conditions: Standard setting: High combustion Measurement Method: According to JIS (Japanese Industrial Standard) Energysaver RHFE-308 FTR - 9- ©Rinnai 7. Schematic Diagram Energysaver RHFE-308 FTR - 10 - ©Rinnai 8. Control Panel Layout * Refer to “Appendix” on page 59 for explanation on setting clock and programming timers. Energysaver RHFE-308 FTR - 11 - ©Rinnai 9. Operating Principles 1. Normal Operation Push the ON/OFF Button to operate the appliance. The Power ON/Combustion Indicator will glow green. The combustion fan will run on high until pre-purge is completed. Pre-purge is completed after approximately 15 seconds, following which, the combustion fan will decrease revolutions to enable ignition to occur. After the combustion fan reaches a pre-determined speed, (depending on gas type) the electrode produces the spark to begin the ignition cycle. After the spark is sensed as having crossed the spark gap by the PCB, the solenoids (SV1 & SV2) as well as the modulating valve will open and allow gas to flow to the burner. The flame rod senses the flame on the main burner. After the flame is sensed, the Power ON/Combustion Indicator changes to red and the spark stops. After an additional 15 seconds the convection fan begins to operate. The room temperature is sensed by the temperature thermistor located at the rear of the appliance. The printed circuit board controls the air/gas ratio to the optimum level according to the selected temperature. The combustion fan is adjusted in conjunction with the opening degree of the modulating valve. The convection fan is adjusted in the same manner. 2. Thermostat Control The selected and room temperatures are displayed on the Time/Temp Display. Time and temperature are displayed alternately depending whether the heater is running or not. The selected temperature is altered by pressing the Time/Temperature Adjustment buttons. 3. Turning Off Simply press the ON/OFF Button. The solenoids, together with the modulating valve will close. The combustion fan will also stop, and all indicators will go out. After the burner extinguishes, the convection fan will continue to run for up to 210 seconds, ensuring the appliance is cool. 4. Economy Mode To engage the economy function press the Economy button while the heater is operational. The Economy Indicator will glow. Once the selected temperature has been reached, the economy function is designed to drop this temperature by a total of 2oC over a period of one hour. After 30 minutes the temperature will be reduced by 1 oC. After a further 30 minutes the temperature will be reduced by another 1oC. This does not result in a loss to the heating effectiveness, and is an energy saving feature. You may press the Economy button again at any time, to cancel the economy function. 5. Child Lock To activate the child lock press the Child Lock button. The Lock Indicator will glow. If the child lock is activated during normal operation, then no functions other than the ON/OFF Button will be operable until the lock is released. If the child lock is activated whilst the appliance is OFF, then the complete range of functions will be locked. Energysaver RHFE-308 FTR - 12 - ©Rinnai 6. Filter Indicator When the air filter becomes covered in dust and the temperature inside the appliance rises, the Filter Indicator will glow. 7. Fuzzy Logic a. The Purpose of Auto Comfort [Fuzzy Logic] The main aim of the Auto Comfort function is to heat a room by controlling the flow of the warm air coming from the heater. This increases heating efficiency as well as improving control over the flow of warm air being discharged by the appliance. In order to achieve comfortable heating, it is preferable to avoid cold drafts or draughts from the appliance. Also, for increased efficiency it is important to reduce overheating in the room and concentrate heating in the area where people are most often situated. Fuzzy Logic is used in order to achieve the following improved heating pattern. Standard Control Fuzzy Control 'Room temperature' and 'the time elapsed since the start of combustion’ are the basis for fuzzy logic. Th means of control is the speed of the convection fan and modulation of gas combustion. b. Fuzzy Logic Summarised In the case of a conventional fan heater, the convection fan operates normally from the time of ignition, and a cold draught may accompany the flow of air from the appliance. To solve this problem, fuzzy logic controls the speed of the convection fan after taking into consideration the room temperature at the time of ignition. For example, in the case of the room temperature being low, the fan is made to rotate at a low speed, raising the discharge air temperature. As the room temperature rises, the speed of the convection fan is gradually increased. In this way it is possible to ensure a comfortable volume of warmed air whilst decreasing the possibility of cold draughts immediately after ignition. The fan speed increases proportionally as time passes and the room gradually heats up. This improves the warm air distribution, assisting in a reduction of stratification throughout the room and resulting in more effective heating conditions. The PCB then continually monitors the room temperature, and adjusts the fan speed according to the conditions at the time. 8. Clock and Timer Setting and Operation Refer to “Appendix” on pa ge59 of this manual. 9. Intelligent Timer [Pre Heat] This function enables the room to be heated to the pre-set temperature prior to the time programmed in the On Timer. See Intelligent Timer [Pre-heat]” on pa ge14 for more information. Energysaver RHFE-308 FTR - 13 - ©Rinnai 10. Intelligent Timer [Pre-heat] The Intelligent 2-way 24-hour programmed dual digital Timer [Pre-Heat] function operates in conjunction with either “On-Timer”. It enables the pre-set temperature to be reached by the time programmed by starting ignition up to an hour before the time programmed to start heating. The actual ignition time is calculated using the difference between the room temperature and set temperature and the warming-up time which elapsed the last time the appliance was used. The maximum time ignition will precede the pre-set time is 1 hour. The following chart illustrates how the intelligent timer operates. The two timers can be programmed and used individually, or sequentially. Timer operation, once set, will remain on stand-by for the next day after the final OFF sequence, unless ON/OFF switch is pressed. Energysaver RHFE-308 FTR - 14 - ©Rinnai 11. Safety Devices Flame rod sensor Senses main burner ignition and shuts off the solenoid valves when the flame current drops below 0.1 µA. Spark sensing circuit Senses the location of spark and opens the solenoid valves only when the spark location is confirmed as correct. Pre-purge circuit Purges heat exchanger and flue prior to spark commencing. Combustion fan rpm sensing circuit Senses the operation of the combustion fan and maintains a pre-determined rotation speed. Overheat protection switches Shuts off the solenoid valves and cut off gas supply in the case of over heating. i) Bimetal OHS1 Operates at 130 ± 5°C Recovery at 115 ± 7°C ii) Bimetal OHS2 Operates at 90 ± 5°C Recovery at 75 ± 7°C iii) Thermal Fuse Cuts out at 216 ± 2°C (one shot) iv) Thermistor Operates at 130 ~ 90 oC (High ~ Low). Fan delay The convection fan starts after a short delay to avoid cold draughts, and keeps running after burner extinction to allow the unit to cool down. ON AT OFF AT 15 sec, after ignition commences max. 210 sec, after combustion Power failure circuit Shuts off the solenoid valves if a power power failure occurs. The unit will relight after the power is restored, and the clock time will be slow by the amount of time the power was off. Thermistor Type Temperature Control Controls room temperature within the range of 16~26oC in 1 oC steps. Energysaver RHFE-308 FTR - 15 - ©Rinnai 10. Overheat Control Method The overheat thermistor activates the overheat sensor and the filter indicator, as well as increasing the fan rpm. (A) Overheat Sensor The overheat thermistor activates at different temperatures for different gas rates (combustion). (B) Filter Indicator Note 1: Once the overheat limit temperature has been sensed and the filter indicator begins flashing, it will not go out, even if the temperature falls below the limit. Note 2: Once the filter indicator begins flashing, gas input is limited to roughly 88% of high combustion. Energysaver RHFE-308 FTR - 16 - ©Rinnai (C) Convection Fan RPM Increas The fan rpm increases to compensate for a reduction in air flow due to a clogged air filter or other causes. The convection fan rpm is normally determined by combustion level. The speed increases by approximately 100 rpm at High. Energysaver RHFE-308 FTR - 17 - ©Rinnai 12. Operation Flow Chart Connect power cord and turn power ON Problem eliminated 73 No EProm transmission Normal ON/Combustion indicator flashes red Yes 1 Turn ON/OFF switch ON A Problem eliminated ON/Combustion indicator flashes green Room temp. displayed All indicators OFF a Turn ON/OFF switch OFF 71 No SV circuit Normal ON/Combustion indicator flashes red Yes 14 2 OHS & TF Normal No Filter indicator flashes ON/Combustion indicator flashes red Yes 3 O.H Thermistor Normal (After 2 Sec from a) No 34 (short circuit) ON/Combustion indicator flashes red Yes 4 Room Temp.Thermistor Normal (After 2 Sec from a) 33 (open circuit) No 34 (short circuit) Yes 6 Flame rod current below 0.1A 33 (open circuit) ON/Combustion indicator flashes red (After 20 Sec from a) No 72 ON/Combustion indicator flashes red Yes Combustion Fan HI ON 15 61 (After 15 Sec) No Combustion Fan >1710 rpm Combustion Fan OFF ON/Combustion indicator flashes red Yes Combustion Fan LOW 6 (After 10 Sec) Flame rod current below 0.1A 72 (After 20 Sec) No Combustion Fan OFF ON/Combustion indicator flashes red Yes 9 Combustion fan > ignition + 60 rpm 10 Sparker activates No 61 (After 30 Sec) Combustion Fan OFF ON/Combustion indicator flashes red Yes Spark sensing Normal (After 2 Sec) No Combustion Fan OFF 53 Sparker OFF ON/Combustion indicator flashes red Yes 11 b Solenoid SV1 Opens Solenoid SV2 Opens 12 Solenoids SV1, 2 close Mod. Valve half opens Yes No 15 sec after b 6 Flame sensed above >1A c Modulating Valve closes 11 Combustion Fan OFF ON/Combustion indicator flashes red No Yes ON/Combustion indicator flashes red Sparker OFF Sparker OFF Solenoids SV1, 2 close Yes Spark sensor Normal No (After 1 sec) Modulating Valve closes 53 Combustion Fan OFF ON/Combustion indicator flashes red Sparker OFF Combust'n fan (med) ON C H B Energysaver RHFE-308 FTR - 18 - ©Rinnai H B C Temp. control begins (Less than 255 sec) Convection Fan OFF Convection Fan ON Convection Fan MED OFF OH Thermistor Temp. normal 14 Combustion Fan OFF No Solenoid Valve Closed Yes Filter indicator flashes red Less than 5 times A No 4 Combustion rate < medium Yes Modulating Valve HI Combustion Fan HI Modulating Control (Combustion Fan) Convection Fan HI Modulating Control (Convection Fan) 90 secs>ignition No Flame Senser Device Operates Power failure Yes Room temp.>40C for over 10 mins 4 16 O.H. Thermistor within range 2 Overheat Switch No.1 > 130 C > 90 Sec from c 16 Yes 4 No Operation stops No No ON/Combustion indicator flashes red Yes Power reinstated Safety Devices Operate No 12 No Yes Room temp. within 2C of set temp. Modulating Control (POV) Modulating Valve (POV) Closed Yes Overheat Switch No.2 > 90C ON/Combustion indicator flashes red Room temp > Set temp by over 1 C 1 ON/OFF SW failure Combustion Motor rpm abnormal 70 61 ON/Combustion indicator flashes red ON/Combustion indicator flashes red Thermal Fuse melts Yes Temperature Control OFF d 14 Filter indicator flashes red Solenoids SV1, 2 OFF ON/Combustion indicator flashes red Modulating Valve Closed Combustion Fan OFF ON/Combustion indictor green Convection Fan MED ON (Less than 60 sec) Convection Fan OFF 4 Room temp > Set temp No 4 Room >Set temp within 2 C No Yes Yes No 10 mins after d Yes Energysaver RHFE-308 FTR - 19 - ©Rinnai OFF ECONOMY TIMER OPERATION ON/OFF Switch OFF Economy Switch ON ON/OFF Switch ON Economy Indicator ON Timer Switch ON Room Temperature drops max. 2C Timer Indicator ON Temperature Control ON No Yes Solenoids SV1,2 OFF Modulating Valve OFF Economy Switch OFF Pre-Heat set up Time Combustion Fan OFF Convection Fan MED Economy Indicator OFF Temperature Control Operates Operation/Combustion Indicator OFF Change from Room & Set Temp to clock No Yes Timer indicator flashes Normal operation start All Indicators OFF Set-up Time Convection Fan No (Less than 255 sec) Yes Normal Operation Stops Energysaver RHFE-308 FTR - 20 - ©Rinnai 13. Diagnostic Points * * “Flow” denotes references on the “Operation Flow Chart” on page 18. “CN” denotes connector number on the “Wiring Diagram” on page 22. Flow CN Component Wire Colour Value (Normal) 1 I ON-OFF Switch red - blue blue - blue DC 3 ~ 10V, resistance 1 Ω (current flows when switched on) Less than DC 1 V; < 4 Ω (current flows) 2 3 4 H Overheat Circuit white - black H1 Overheat SW 1 white - red H2 Overheat SW 2 red - black H3 Thermal Fuse white - white A Overheat Thermistor white - white 0.6 ~ 523 kΩ ( < 0.6 kΩ: short, >523 kΩ: open temperature 20°C: 78 k Ω, 100°C: 3.6 kΩ, 150°C: 1.1 k Ω Room Temp. Thermistor yellow-yellow 1.8 ~ 844 kΩ ( < 1.8 kΩ: short, >844 kΩ: open temperature 0°C: 123 k Ω, 20°C: 39 kΩ, 40°C: 14 k Ω A < DC 1 V < 1 Ω (current flows) 6 E1 Flame Rod yellow-yellow < DC 0.1 µA 7 G Combustion Fan red -black DC 7 ~ 40 V; > 10 M Ω white - black DC 1 ~ 4 V; > 3420 pulse/min (> 57 Hz black - white below ignition revolution + 120 rpm initial ignition LP: 3480, NG: 3600 pulse/min re-ignition LP: 3720, NG: 3780 pulse/min 9 G Combustion Fan 10 F Sparker blue-red AC 85 ~ 110 V 11 F Solenoids 1 & 2 black - yellow DC 78 ~ 100V, 1.3 ~ 2.2 k Ω 12 H Modulating Valv grey - grey DC 1 ~ 15 V (low ~ high) 80 ~ 100 Ω A Over-heat Thermistor white - white high (filter low indicator flashes below 50 Hz; 2.2 kΩ 14 G Combustion Fan white - black high (normal rpm) low LP: 5760, NG: 5700 pulse/min 15 16 A Over-heat Thermistor white - white high (OHS on) low 17 D Convection Fan flashes below 8.6 kΩ LP: 3000, NG: 3240 pulse/min operates belo 1.7 k Ω operates below 5.3 k Ω AC 50 ~ 108 V (low ~ high), 90 ~ 180 Ω grey - pink Transformer Values Wiring Diagram E B Australia [240 V] New Zealand [230 V] Yellow - Blue AC 130 ~ 180 V; 200 ~ 400 Ω AC 130 ~ 180 V; 200 ~ 400 Ω Blue - Black AC 10 ~ 16 V; 1 ~ 3 Ω AC 10 ~ 16 V; 1 ~ 3 Ω Red - Red AC 25 ~ 50 V; 1 ~ 3 Ω AC 25 ~ 50 V; 1 ~ 3 Ω Grey - Grey Energysaver RHFE-308 FTR AC 216 ~ 264 - 21 - AC 207 ~ 253 V ©Rinnai 14. Wiring Diagram Energysaver RHFE-308 FTR - 22 - ©Rinnai 15. Block Diagram Energysaver RHFE-308 FTR - 23 - ©Rinnai 16. Time Charts Energysaver RHFE-308 FTR - 24 - ©Rinnai Energysaver RHFE-308 FTR - 25 - ©Rinnai Energysaver RHFE-308 FTR - 26 - ©Rinnai 17. E2 PROM Memory Function for Error History, Estimated Combustion Time, and Estimated Number of Operations E2 PROM (Electrically Eraseable and Programmable Read Only Memory) is a ROM in which data is electronically programmed or erased. Programmed data will be stored semi-permanently even if the power fails or is disconnected. The most recent data on the past nine errors, estimated combustion time and estimated number of operations are included in the information stored in E2 PROM. • How to Read the Data Confirm the unit is off, press “/\”, “\/” and “Economy” buttons at the same time for at least 2.5 seconds (a beep will be heard once). The data will be displayed on the LED display in the following order: Error Messages, Estimated Combustion Time, Estimated Number of Operations. • Data Display The most recent error message (No. 1) will be displayed first, then it will be followed by up to eight previous errors (No. 2~9) displayed for 2 seconds each, as shown below. Following this, Estimated Combustion Time and Estimated Number of Operations data will be displayed for 4 seconds each as in the example below (No error messages “-- . --” will be displayed if no errors were recorded). Estimated Combustion Time will be displayed as below if between 0 ~ 9,999 hours. However, if it is more than 10,000 hours, then “H” is added to the beginning of the display. Hours will be rounded up to the nearest 100 as shown below. 9999 hours 10000~10099 hours 10100~10199 hours Estimated Number of Operations will be displayed as below (1=10 times) if between 10 ~ 99,999 times. However, if it is more than 100,000 times, then “H” is added to the beginning of the display. Operations will be rounded up to the nearest 1000. 99990~99999 times 100000~100999 times 101000~101999 times *Note: Estimated Number of Operations is the number of ON-OFF movements on the solenoid valve. Energysaver RHFE-308 FTR - 27 - ©Rinnai • Deleting Data from E2 PROM Confirm the unit is turned off, and press “/\”, “\/”, “Economy” and “Lock” buttons at the same time for at least 1 second. (Lock beep will be heard once and another beep wil be heard a second later). Digital display turns off and displays “- - : - -” when the data is deleted completely. However, the data on Estimated Combustion Time and Estimated Number of Operations cannot be deleted. Once recorded in E2 PROM, the data is protected from power failures. Permanent Data • Modulating Valve Supplement CurrentValue (HIGH) • Modulating Valve Supplement CurrentValue (LOW) • Convection Fan Supplement CurrentValue (HIGH) • Convection Fan Supplement CurrentValue (LOW) • Estimated Combustion Time • Estimated Number of Operations Deletable Data** (initial settings) • • • • • • Error History (none) Clock (12:00 am) Economy Operation (OFF) Lock (OFF) Preset RoomTemperature (22 oC) ON Timer (06:00 am) ** This data can be deleted as described above. Energysaver RHFE-308 FTR - 28 - ©Rinnai 18. Error Coded Messages Error is displayed as a number on clock flashing. (Filter indicator will also flash in the case of overheat.) Error Code Probable Cause Comments Ref † --:-- Power failure When power failure is sensed operation stops. - 11 Miss ignition Flame current does not reach 0.1µA within the given time, after solenoid valve opens. 6 12 Flame failure Flame rod current remains below 0.1 µA for 3 seconds during initial combustion. 6 14 Over heat safety device High-limit temperature thermal fuse has activated. or 2 16 Over temperature cut off Room temperature is sensed as being above 40oC for longer than 10 minutes. 4 31 Room temperature thermistor disconnection Room temperature thermistor open circuit 4 32 Room temperature thermistor short circuit Room temperature thermistor wire trapped, touching bare metal 4 33 High-limit thermistor disconnection High limit thermistor open circuit for over 2 seconds 3 34 High-limit thermistor short circuit High limit thermistor short for over 2 seconds 3 thermistor Sparker not OFF within 20 seconds at time of ignition 53 Abnormal spark sensed 1st spark sensed not within 2 seconds - 2nd spark sensed spark not continuous for 1 second after solenoid valve opens 61 Abnormal combustion fan motor rpm Speed is not achieved within time or goes over speed level 15 70 ON/OFF switch failure ON/OFF switch on continuously for more than 15 seconds 1 71 Solenoid valve check Solenoid valve(s) (SV1, SV2) signal and response signal are different. 11 72 Flame rod failure Flame rod current should not go below 0.1µA within 20 seconds of starting. 6 Communication failure Data transfer between CPU and E 2PROM fails. - 73 † Refers to the number on the operational flow chart, page 18, and diagnostic points, page 21. * To reset error codes, press the ON switch while the error code is showing. This will not reset error codes “71" and “73"; power needs to be reset to erase these codes. Energysaver RHFE-308 FTR - 29 - ©Rinnai 19. Fault Finding Main Faults and their Remedies * Numbers on the right hand side of this table refer to “Causes of Faults and Suggested Remedies” on pa ge31. Fault Symptom Error Codes The Economy indicator will not come ON. * Confirm that Economy Mode has been selected * Confirm electrical cord is securely into the power point After having pressed the ON OFF switch the appliance will not operate. * Check gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . * Confirm no gas escapes . . . . . . . . . . . . . . . . . . . . . . * Check for air in the gas supply . . . . . . . . . . . . . . . . * Reconfirm gas type specified . . . . . . . . . . . . . . . . . 1 1 1 1 Insufficient heating. * Check selected room temperature setting . . . . . . . . * Check for blocked air filter . . . . . . . . . . . . . . . . . . . * Check for an obstruction in the warm air flow . . . . * Reconfirm gas pressure at appliance . . . . . . . . . . . . 2 3 4 1 Burner goes out during operation. * Ensure flue terminal is not blocked . . . . . . . . . . . . . * Ensure air filter is not blocked . . . . . . . . . . . . . . . . * Power Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . * Check for an obstruction in the warm air flow . . . . * Reconfirm gas type specified * Confirm no gas escapes . . . . . . . . . . . . . . . . . . . . . . * Check for flash back . . . . . . . . . . . . . . . . . . . . . . . . * Check for high room temperature . . . . . . . . . . . . . . * Reconfirm electrical supply at power point . . . . . . 5 3 8 4 11 12 14 16 Power failure. 1 6 7 8 * Confirm no gas escapes (at connection) . . . . . . . . . 1 * Product of combustion leak . . . . . . . . . . . . . . . . . . . 9 Gas odour. † Check Points / Remedy --:-- * Power failure ( > 0.2 seconds ................ 8 Error is displayed as room temperature LEDs flashing Energysaver RHFE-308FTR - 30 - ©Rinnai Causes of Faults and Suggested Remedies 1. Gas supply 5. Flue terminal In cases of miss ignition, insufficient heating and gas smell, check that: If flame failure occurs during normal operation, check that: • The gas supply pressure is correct. • The specified gas type is correct for the area. • There are no breaks/escapes in gas supply. • There is no air in the gas supply. ⇒ Check the gas pressure at both the meter and the • The flue terminal on the exterior wall is not obstructed in any way. appliance. ⇒ Air in the gas line will prevent the appliance from igniting. terminal or a thick build up of spider webs. 6. Flash back protection 2. Thermostat setting If flame failure occurs during normal operation, check: When the room does not reach the selected temperature, or the appliance will not remain alight, check that: • The flue terminal air intake is not blocked. • For dust or foreign material on the burner. • Combustion specification and gas type. ..... 12 flashing ⇒ Check in particular for shrubs growing over the flue • The selected temperature is not set lower than the room temperature. ⇒ Select the required temperature setting with the UP/ ..... 12 flashing 7. Room temperature DOWN selection buttons. 3. Blocked air filter • Is the room temperature unusually high? ⇒ 10 minutes after having sensed 40°C the appliance will If insufficient heating or lockout occurs, check that: automatically go out. ..... 16 flashing • The air filter is not blocked with dust. ⇒ If the air filter is blocked, the safety device will operate. 8. Power failure ..... 14 flashing • If there has been a power failure for 0.2 seconds or longer. Current time will be displayed on display when “set times” button is pressed once. (Time will be slow by duration of power failure). ⇒ The filter must be cleaned at least once per month. 4. Air flow obstruction ..... --:-- flashing If insufficient heating or lockout occurred, check that: • There are no obstacles in front of the appliance or louvres. 9. Smell of products of combustion ..... 14 flashing If there is a smell of gas or products of combustion, check that: ⇒ There should be no articles within one (1) metre of the • The flue manifold behind appliance has not come undone. ⇒ The products of combustion are leaving the appliance front of the appliance. through the flue terminal. Energysaver RHFE-308FTR - 31 - ©Rinnai Before contacting Rinnai, please check the following points. These points are part of the normal operation of the unit. At Ignition Is the heater plugged in? Is there a power failure? Have the fuse or breaker blown at the switchboard? Are the air filter, flue, or warm air outlet blocked? Are Timers set? Clear Timers and operate again. Is the central timer on? (where fitted) Heater does not operate. Warm air does not flow when the burner lights. The fan is started automatically after a short delay. This is to allow the heat exchanger to warm up. Smoke or strange smells are produced on the first trial light up after installation. This is caused by grease or oil and dust on the heat exchanger and will stop after a short time. Sharp clicking noises at ignition, or when the unit cuts down on the thermostat, or goes out. This is simply expansion noise from the heat exchanger. During Combustion Clunking noise when the thermostat operates. This is the sound of the solenoid gas valves. Unit is not heating room? Is the air filter or warm air outlet blocked? Is the set temperature high enough? Are the doors and windows of the room closed? Air filter or louvres are blocked or obstructed. Allow heater to cool, clean air filter, operate again. Heater will not reignite after overheating. Heater does not reignite. Repair is necessary. When the Unit is Turned Off Convection fan continues to run after turning off. This is to remove the residual heat from the heat exchanger, the fan will stop when the heater cools down. Other Points Steam is discharged from the flue terminal. High efficiency appliances tend to discharge water vapour on cold days, this is normal. Unit cuts off without apparent reason. Check is central timer is switched off (where fitted), or whether filters are blocked, (dirty filters will cause the heater to overheat). Power failure. When power is restored, the appliance will begin to heat if it was on at the time of power failure. Clock will be delayed by the length of the power failure. Remote control does not operate. Check battery. Try moving closer to the heater. Energysaver RHFE-308FTR - 32 - ©Rinnai 20. Fault Analysis A. After having operated the appliance and: i) ii) iii) iv) The combustion fan doesn’t begin to rotate, or suddenly stops after running for a short time. There is no spark (after 30 seconds). The solenoids do not open, preventing gas flow to the burners. The convection fan does not begin to rotate, approximately 15 seconds after ignition. Is there electrical supply 2. Is the 3 amp fuse blown? NO 1. Confirm the connection at the wall socket YES a. The appliance does not operate. i) ii) iii) iv) v) vi) vii) Open circuit or loose pin connector on PCB or wiring loom. ON/OFF button faulty. ... 70 flashing Faulty Printed Circuit Board. Control panel PCB faulty. OHS is ‘OPEN’. (‘CLOSED’ Normal) ... 14 and filter indicator flashing Thermal fuse has melted. Solenoid circuit is faulty. .... 71 flashing b. The combustion fan doesn’t rotate, or the appliance fails after a short time. i) ii) iii) iv) v) vi) vii) Combustion fan shaft allen screw loose. An obstruction in the combustion fan is preventing it from rotating. Combustion fan does not go over1710 rpm. ... 61 flashing The flame rod current is greater than 0.1 µA during pre-purge.... 72 flashing The combustion fan rpm not below ignition rpm + 60. ... 61 flashing Faulty spark generator. ... 53 flashing Faulty PCB. c. There is no spark. i) ii) iii) iv) v) High tension cord disconnected or broken. Insulation leak from the high tension cord, (Spark sound is not regular). The spark gap is not correct (normal spark gap is 3.5 ± 0.5 mm). Weak or shorting spark. Faulty PCB. d. The solenoids do not open, preventing gas flow to the burners. i) ii) iii) iv) Open circuit or loose pin connectors on PCB or wiring loom. Faulty solenoid, or coil. Faulty sparker, (no spark is sensed). Faulty PCB (no current to SV). Energysaver RHFE-308 FTR - 33 - ©Rinnai e. The convection fan doesn’t rotate. i) ii) iii) iv) Convection fan shaft allen screw loose. An obstruction in the convection fan is preventing it from rotating. Flame rod faulty. Faulty PCB. B. After repeated efforts to operate the appliance, it will not ignite. ... 11 flashing i) ii) iii) iv) v) Air in the gas supply line. Incorrect gas pressure. Incorrect gas type, or a kink or break in the gas supply. Faulty or weak spark. Blocked injector. Is the combustion specification correct? C. There is the sound of ignition, however the ‘combustion’ injector does not glow red. After 15 seconds the spark stops and mis-ignition occurs. Miss-ignition Ignition OK 1. Faulty indicator/incorrect wiring. 2. Faulty PCB. Confirm the flame rod current. No Has the current risen above 1.0 µA. Yes 1. Check combustion specification, gas type, and gas pressure. 2. Check the combustion condition. 3. Check flame rod is firmly positioned. 4. Check the flame rod lead. Faulty PCB Energysaver RHFE-308 FTR - 34 - ©Rinnai D. The flame fails during normal operation. 1. Power failure for 0.2 seconds or longer. ... “ : ” flashing when power reinstated 2. Safety devices are activated. * Room temperature is sensed at above 40°C for 10 minutes. ... 16 flashing * Air filter is blocked and the OHS is activated. ... 14 and filter indicator flashing * Obstruction in the flue terminal. ... 12 flashing * Blockage or insufficient gas supply. ... 12 flashing * Gas pressure is abnormally low. * The area surrounding the flue terminal may be restricted. * Obstruction in front of the heater. ... 14 and filter indicator flashing 3. Safety Devices activated no fault evident. Have you ensured that the connectors are in the correct positions, and also the wiring is not disconnected anywhere? Flame failure 30~60 mins after ignition. “12” flashing. Is flame rod current > 1.0 µA? No Yes Faulty PCB. 1. Confirm specification of regulator, restrictor, injector, etc.. 2. Check condition of flame rod and burner. 4. Flame failure (makes a loud noise). 1. Blocked flue terminal). 2. Dust in the burner terminal 3. Incorrect gas type or pressure setting 5. Flame faillure occurs between 2 and 3 minutes after ignition. “12” flshing. No Is flame rod current greater than 1.0 µA? *Is the gas pressure normal? *Is the flame rod faulty? Yes Combustion fan motor control may be faulty PCB faulty Energysaver RHFE-308 FTR - 35 - ©Rinnai 21. Electrical Component Analysis * Before starting inspection, check wiring harness and double check that all connectors are tight. * Before carrying out checks marked ∗, remove power cord from wall socket. Nature of Fault A. "12:00" fails to flash when power cord is pugged in, and temperature is not displayed when unit is turned on (normal sequence can not proceed). Examination Point Diagnostic Point 1) Is the voltage correct? Check electric socket and voltage. ((2) Blown or defective fuse? 1. Measure fuse resistance. AC 230 - 240 V Y/N Yes Go to (2). No <1Ω Action Repair electric source. Yes Go to (3). No Replace fuse. Go to (2) - 2. (D) Grey - Pink 90 - 180 Ω Yes Go to (2) - 3. (G) Red - Black >1MΩ Yes Go to (2) - 4. *4. Measure resistance (E) White - White 5-20 Ω. o f tran sfor m er after (E) Red - Red removing 8P connector. 1 - 8 Ω. (E) Black - Blue 0.5 - 3Ω (E) Blue - Yellow 250-450 Ω. Yes Go to (2) - 5. (F) Black - Yellow SV1 1.3-2.2KΩ. SV2 1.3-2.2KΩ. Yes Go to (2) - 6. (H) Grey - Grey 80 - 100 Ω Yes Replace PCB. (E) Red - Red AC 24 - 41V (E) Black-Yellow AC 10 -17V (E) Blue-Yellow AC 130 - 180 V Yes Replace PCB. *2. Measure convection motor coil resistance after removing 2P connector. * 3. Measure combustion motor coil resistance after removing 4 connector. * 5. Remove solenoid valve lead wires (SV 1, SV2 ) and measure coil r e si s t a n c e b e t w ee n terminals. * 6. Remove modulating valve lead wire(s) (POV) and measure coil resistance between terminals. (3) Is the transformer Check transformer OK? secondary voltage. Energysaver RHFE-308 FTR Values - 36 - No No No No No No Replace convection motor. Replace combustion motor. Replace transformer. Replace solenoid valve. Replace modulating valve. Replace transformer. ©Rinnai B. Error code appears soon after turning heater on (normal sequence cannot proceed). (4) Is overheat switch ∗ With ON/OFF switch (H1) White-Red 1 or 2 OFF? <1Ω OFF, check continuity (... 14 flashing) between both terminals. (H2) Black - Red If unit over heated, it <1Ω will turn back ON once the unit cools down. (5) Overheat thermistor broken/short circuit? (broken...33 flashes (short...34 flashes) C. No spark Yes Go to (6). No Replace overheat switch 1 and/or 2. ∗ Measure resistance (A) White-White Yes Replace PCB between unit and t h e r m i s to r ( D i f f e r s according to temperature) 20oC 78 kΩ 100oC 3.6 kΩ No Replace thermistor (6) Has the thermal ∗ With ON/OFF switch (H 3) White-White fuse melted? 0Ω OFF, check continuity (... 14 flashing) between both terminals. Yes Replace PCB. (7) Is the combustion ∗ Check combustion motor wiring OK? motor coil resistance (... 61 flashing) using same procedure as (2)-3 above. Yes Go to (9). Red - Yellow >1 M Ω No No Replace temperature fuse. Replace combustion motor. (8) Is there any spark Check connection visu- Good connection leakage due to loose or ally and by hand. and no leakage. d i sco n n ec t ed h i gh tension lead Yes Go to (10). (9) Is the spark unit Measure sparker input voltage low? voltage. Yes Replace sparker. (F) Blue - Red AC 85 - 110 V No No Connect properly. Replace PCB. D. Spark fails to (10) Are the solenoid ∗1. Check solenoid (F) Black - Yel- Yes Go to (11) - 2. low produce ignition v a l v es ( S V 1 , S V 2 ) valve coil resistance No Replace solenoid (s tops a f t e r ON? using same procedure SV1 1.3 - 2.2 k Ω. valve. approx. 15 sec.) SV2 1.3 - 2.2 k Ω. as (2)-5 above. (... 11 flashing) 2. Check solenoid (F) Black - Yel- Yes Go to (12). valves terminal voltage. low DC 78 - 100 No Replace PCB. V (11) Is the modulating 1 . C h e c k t e s t p o i n t Is it at the specified Yes C h e c k i n j e c t o r / valve (POV) OK? pressure. pressure? damper. (Modulating valve P 2) No Go to (12) - 2. 2. Check position of SW6 switches on PCB. Refer to (Gas changeover switch) ∗3. Check modulating (H) Grey - Grey valve coil resistance. 80 - 100 Ω Yes Go to (12) - 3. No Yes A d j u s t r e g u l a t o r pressure. If it does no match, replace PCB. No E.Ignition occurs, but combustion indicator does not operate. ( S p a r k e r st o p s after approx. 15 sec) (... 11 flashing) (12) Is the modulating Measure test point Is it at the preset valve OK? pressure as in (12)-1 2 pressure? above. Energysaver RHFE-308 FTR - 37 - Replace modulating valve. Yes Go to (14) after checking injector and damper. No (E1) Yellow (13) Is the current of ∗ Check flame rod cirthe flame rod (FR) cuit current. (Discon- Yellow flame rod >1.0 µA. circuit >1.0 µA . nect, measure between connector and lead.) Set to proper position A dju st regulator pressure. Yes Replace PCB. No Replace flame rod. ©Rinnai F. Heater does not (14) Is the thermistor ∗ Disconnect thermisreach preset room OK? tor from unit and meastemperature. ure resistance between terminals. As there may be some variance due to temperature setting, use the chart at the right as a guide. (A) Yellow Yellow 0 oC : 123 kΩ 20oC : 39 kΩ G. Heater stops (15) Shut off mecha- Check flame rod circuit (E1) Yellow during use (turns nism activated. current. flame rod > 1.0 off prematurely: (... 12 flashing) µA. broken indicator (Disconnect, motor). measure between connector and lead.) Yes Replace PCB. No Replace thermistor. Yes Check for dust, FR wire and connector. No Replace PCB ( 1 6 ) O F F f u n c t io n Was the heater used for Over ten minutes activated. a long period at a high at above 40oC. (... 16 flashing) temperature? Yes Explain usage. (17) Overheat switch 1. Check for dust on air activated. filter, convection fan (... 14 flashing) and air outlet. Yes Clean. Is the dust build up extreme? No No Replace PCB. Go to (18) - 2. 2. Check combustion specifications Correct? 3. Is the convection fa revolution speed correct? Measure motor coil resistance. See (2)-2. (D) Grey - Pink 90 - 180 Ω Yes Go to (18) - 4. 4. Check voltage at 2P terminal D on PCB (convection fan) . HIGH - LOW AC 50 - 108 V Yes Check fan lock / obstruction, spin, etc. H . A l l o t h e r Are there any loose or problems. defective connections? Yes Go to (18) - 3. No No No Adjust accordingly Replace motor. Replace PCB. Yes Repair Note: If a problem is not remedied by replacing the appropriate part, the wiring harness is defective (short circuit, open circuit and/or defective connectors). Check for any short or open circuit. Lightly wiggle wires and harness to check for loose or faulty connectors. Energysaver RHFE-308 FTR - 38 - ©Rinnai 22. Testing Test Mode Summary Test Mode 1 - This mode cancels temperature control, and starts combustion mode. Test Mode 2 - This mode controls the modulating valve and convection fan (Normally, this test mode is used when converting gas type and changing the PCB). * Operating Procedures and Indicator (A) Test Mode 1 Operating Procedures Illuminated Indicators 1. Turn the appliance on (combustion indicator illuminates). LOW Press test mode switch (SW 5) at top of the PCB (combustion mode changes to “Low” test mode). 2. Change combustion and convection fan mode using the MEDIUM Temperature/Time setting switch located on the control panel. The mode changes from LOW time the “/\” switch is pressed. The mode changes HIGH “\/” switch is pressed. → MED → HIGH each HIGH → MED → LOW each time the 3. Return operation to normal by pressing the test mode switch Displays temperature. (SW 5) again. Note: Indicators (digital display “00" and “22", “24", “26" and “HIGH” indicators) show that modulating valve and/or convection fan adjustment is complete. Digital Display Sections of the digital display show that the following adjustments have been completed: 1) Modulating Valve (LOW) 2) Modulating Valve (HIGH) 3) Convection Fan (LOW) 4) Convection Fan (HIGH) The indicators will be off when the PCB unit is replaced. Indicators will illuminate after test mode 2 adjustment is completed. 2. Indicators (digital display “LO”, “Cu”, “Hi” and “LO”, “16", “18", “20" indicators) may be flashing at times. This means the combustion mode is in transition (eg. Changing from LOW → MED). The indicators will glow steadily once combustion mode stabilises. (B) Test Mode 2 (Adjusting Modulating Valve) See “Gas Pressure Setting Procedure” on pag e43. Energysaver RHFE-308 FTR - 40 - ©Rinnai (C) Test Mode 2 (Adjusting Convection Fan rpm) Convection fan rpm is prerecorded in the PCB unit software. Therefore, adjustment is not required when the PCB unit is replaced. Operating Procedure Indicators 1. Turn the appliance on (combustion indicator illuminates). Press test mode switch (SW 5) at the top of the PCB (combustion mode changes to “LO” Test mode). 2. Press convection fan adjusting switch LO (SW). Sections of the indicators will flash to show that adjustment is in progress. 3. Adjust by using the Temperature/Time setting SW located above the control panel. “/\” SW increases and “\/” decreases the rpm. 4. Once the adjustment is complete, press SW2 again. Low current supplement value is recorded in E2PROM and will be confirmed. Indicators will stop flashing and will glow steadily. 5. Press convection fan adjustment SW HI (SW1) located at top of PCB unit. (Combustion mode changes to “HI” test mode) 6. Adjust by using the Temp/Time setting SW located above the control panel. “/\” SW increases and “\/ ” decreases the rpm. 7. Press SW1 again, once the adjusting is completed. High current supp valve is recorded on E2PROM and will be confirmed. Indicators will stop flashing and will glow steadily. 8. Return operation to normal by pressing the test Displays temperature. mode SW (SW 5) again. Note: The convection fan rpm changes by approximately 10~15 rpm each time “\/” or “/\” SW is pressed. Energysaver RHFE-308 FTR - 41 - ©Rinnai 23. Gas Conversion * Disconnect electrical supply and isolate gas supply. 1. Remove bottom trim. (see diagram 1) 2. Remove screws inside bottom louvre, pull complete front panel forward at bottom, unclip from escutcheon panel and remove from heater. 3. Replace small gas label on gas inlet. 4. Replace large gas label on back of appliance. 5. Place “new” very small gas label (indicating new gas type) over existing one on data plate. Diagram 1. 6. Complete details on conversion sticker, place sticker on the inside front cover. 7. Undo main gas tube connection at manifold, push tube down. 8. Remove “O’ ring from manifold connection and refit to main gas tube (to avoid trapping “O” ring when reassembling). 9. Remove manifold. Take care with gasket (see diagram 3). Diagram 2. Diagram 3. 10. Remove damper (3 screws). (see diagram 4) 11. Replace the damper. 12. Remove 2 injectors. 13. Fit new injectors (see diagram 4) 14. Refit manifold, secure with screws. Take care with gasket. Diagram 4. 15. Connect main gas tube; take care with “O” ring. 16. Reconnect appliance to electricity and gas. 17. Follow gas pressure setting procedure, (see next page). 18. Check for gas escapes. Diagram 5 19. Replace front cover Diagram 6 Energysaver RHFE-308 FTR - 42 - ©Rinnai 24. Gas Pressure Setting Procedure 1. 2. 3. Set dip switch (SW6) to correct position (see diagram opposite). Remove test pressure point screws from heat exchanger manifold (B) and gas valve (A). Connect pressure gauge to both test points (connect one side of gauge to one point, and the other side of the gauge to the opposite point). If using an electronic manometer, connect th side to the heat exchanger test point and side to the gas valve test point. Turn appliance ON. LOW 4. 5. 6. When the combustion indicator comes on, push SW5 once (see PCB dip switch position opposite). Adjust the LOW pressure to the correct pressure (see table below) with the “/\” and “\/” buttons on the control panel. (The RHFE-308FTR has E 2PROM operation; there should be no need to adjust the modulating valve screw). Press SW4 again to lock in the low pressure setting. HIGH 7. 8. Press SW3 to set the appliance on forced HIGH. Adjust the HIGH pressure to the correct pressure (see table below) using the “\/” and “/\” buttons on the control panel. 9. Press SW3 again to lock in the high pressure setting. 10. Press SW5 again to return the appliance to normal operation. 11. Turn the appliance OFF. 12. Disconnect the pressure gauge and replace the test point screw. Natural Gas Propane Gas HIGH 0.60 kPa 1.04 kPa LOW 0.12 kPa 0.19 kPa Energysaver RHFE-308 FTR - 43 - ©Rinnai 25. Dismantling for service NOTE: Before proceeding with dismantling, be sure to follow the CAUTION instructions before each explanation. Item Page 1. Removal of the Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 2. Removal of the Top Panel, Control Panel / PCB Unit . . . . . . . . . . . . . . . . . . . . . 45 3. Removal of the Convection Fan Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 4. Removal of the Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 5. Removal of the Burner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 6. Removal of the Flame Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 7. Removal of the Main PCB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 8. Removal of the Combustion Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 9. Removal of the Sparker PCB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 10. Removal of the Main Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 11. Removal of the Gas Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 12. Removal of the RoomTemperature Thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . 50 13. Removal of the Thermal Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Unless otherwise stated, re-assembly is the reverse of dismantling Energysaver RHFE-308 FTR - 44 - ©Rinnai 1) 2) Removal of Front Panel CAUTIO 240 volt potential inside applaince. Disconnect electrical supply. Removal of Top Panel, Control Panel, and Control Panel PCB. CAUTION 240 volt potential inside applaince. Disconnect electrical supply. a. Grip sides of skirt and pull forward to remove. a. Remove front panel assembly, see section 1. b. Remove (2) two screws, one on each side of control panel. c. Release (3) three multi-pin connectors from main PCB, releasing the control panel PCB harness from wire clip on main PCB casing. d. Lift both sides of ocntrol panel and pull forward to remove. b. Remove seven (7) screws to release louvre & front panel. e. Grip control panel cover and lift up, applying light strength on one side to disconnect the hinge pin from control assembly. c. Grip bottom left and right hand corners of front panel, pull forward to release. f. Unscrew seven (7) screws to remove control PCB from control panel. Energysaver RHFE-308 FTR - 45 - ©Rinnai 3) 4) Removal of Convection Fan Motor Removal of Heat Exchanger CAUTIO 240 volt potential inside appliance Disconnect electical supply. CAUTION 240 volt potential inside appliance Disconnect electical supply. a. Remove front panel assembly, see section1. b. Remove top panel and control panel assembly, see section 2 b)~d). c. Loosen allen screw securing the fan blade to the fan motor shaft using a 3 mm allen key (from back of unit). a. Remove front panel assembly, see section 1. b. Remove one (1) earth connection on front heat shield. c. Release fusible link (pull down) on front of heat shield. d. Release five (5) screws securing heat shield. e. Disconnect overheat switch and thermistor, two (2) screws. d. Remove four (4) screws securing the motor to the casing and remove fan motor cover. f. Disconnect flame sensing lead (pull hard). g. Remove spark sensing lead, and high tension lead (pull off gently). Energysaver RHFE-308 FTR - 46 - ©Rinnai h. Remove blanking panel, one (1) screw. n. Remove flue spigot, three (3) screws. i. o. Remove five (5) heat exchanger securing screws. Remove side panel, one (1) screw. p. Grip heat exchanger and pull forward to remove. j. Remove one (1) gas supply tube securing screw and one (1) air intake tube securing tube. Note: Refer section 5 f)~g) to disconnect burne from heat exchanger complete assembly. 5) k. Rotate clip at end of gas supply tube and push down on tube to release from manifold. l. Disengage gas supply tube. m. Remove two (2) burner securing screws and cable tie, to remove gas supply tube. Energysaver RHFE-308 FTR Removal of Burner CAUTION 240 volt potential exposure. Isolate the applaince and reconfirm with a neon screwdriver or multimeter. a. Remove front panel assembly, see section 1. b. Remove front heat shield, see section 4 b) ~ d). c. Remove blanking panel, one (1) screw. d. Remove spark sensing lead, and high tension lead (pull off gently). e. Remove one (1) gas supply tube securing screw. - 47 - ©Rinnai f. Remove six (6) burner cover screws. 7) Removal of Main PCB CAUTION 240 volt potential exposure. Isolate the applaince and reconfirm with a neon screwdriver or multimeter. a. Remove front panel assembly, see section 1. b. Release PCB by removing two (2) screws on left hand side. g. Gently manoeuvre burner and cover forward and out of burner chamber by pulling on manifold. Take care not to damage gasket. 6) Removal of Flame Rod CAUTIO 240 volt potential exposure. Isolate the applaince and reconfirm with a neon screwdriver or multimeter. a. Remove front panel assembly, see section 1. b. Remove front heat shield, see section 4 b)~d). c. Remove two (2) screws (using a stubby phillips screwdriver). Energysaver RHFE-308 FTR c. Lift PCB on right hand side and gently manoeuvre it out. d. Disconnect all multi-pin connectors, and wire harness from clips of PCB casing. e. Remove one (1) earth connection on front heat shield and one (1) earth connection on convection fan housing. - 48 - ©Rinnai 8) 10) Removal of Main Transformer Removal of Combustion Fan CAUTION 240 volt potential exposure. Isolate the applaince and reconfirm with a neon screwdriver or multimeter. CAUTIO 240 volt potential exposure. Isolate the applaince and reconfirm with a neon screwdriver or multimeter. a. Remove front panel assembly, see section 1. b. Remove main PCB, see section 7 b)~e). c. Remove four (4) combustion fan securing screws. a. Remove front panel assy, see section 1. b. Remove main PCB, see section 7 b)~e). c. Remove one (1) securing screw from transformer mounting bracket. d. Pull forward. 11) Removal of Gas Control d. Grip fan motor plate and pull forward to remove fan from casing. e. Remove connector from fan motor. CAUTION 240 volt potential exposure. Isolate the applaince and reconfirm with a neon screwdriver or multimeter. Note: Arrow should be aligned when fan assembly is replaced. 9) a. Turn off gas supply at the meter and disconnect appliance from installation. b. Remove front panel assy, see section 1. c. Release solenoid connectors and gas supply tube securing screw (1), release gas supply tube. Take care with O-ring. Removal of Sparker PCB CAUTIO 240 volt potential exposure. Isolate the applaince and reconfirm with a neon screwdriver or multimeter. a. Remove front panel assembly, see section 1. b. Remove one (1) earth lead from heat shield. c. Disconnect 5-pin power supply connector. d. Unclip sparker PCB from main PCB housing from securing lugs on side. Energysaver RHFE-308 FTR - 49 - ©Rinnai d. Remove four (4) screws surrounding the gas inlet flange at back of heater. 13) Removal of Thermal Fuse CAUTION 240 volt potential exposure. Isolate the applaince and reconfirm with a neon screwdriver or multimeter. a. Turn off gas at meter and disconnect appliance from installation. b. Remove front panel assembly; see section 1. c. Unclip thermal fuse from support bracket (pull down). e. Pull gas control assembly forward to remove from appliance. Note: Ensure test point screw is fitted to gas controls, if fitting new control. 12) Removal of Room Thermistor Note: Room temperature thermiator and heat exchanger overheat thermistor are connected together as one harness. CAUTIO 240 volt potential exposure. Isolate the applaince and reconfirm with a neon screwdriver or multimeter. a. Remove front panel assembly; see section 1. b. Remove top and right hand side rear spacer panels. c. Reach in behind appliance and unclip thermistor from purse locks. d. Remove five (5) screws securing heat shield and lift heat shield off; see section 4c)~d). e. Remove overheat thermistor; see section 4-e). Energysaver RHFE-308 FTR d. Disconnect wire connector along harness to release completely from appliance. - 50 - ©Rinnai 26. Exploded Diagram Energysaver RHFE-308 FTR - 51 - ©Rinnai Energysaver RHFE-308 FTR - 52 - ©Rinnai Energysaver RHFE-308 FTR - 53 - ©Rinnai Energysaver RHFE-308 FTR - 54 - ©Rinnai Energysaver RHFE-308 FTR - 55 - ©Rinnai 27. Parts List No Part Name RA Part No RNZ Part No 90104367 QTY 001 Rear Panel Assembly A 1 002 Top Panel Support 003 Filter Clip, Side 90102161 2 004 Filter Clip 90102179 1 005 Rear Panel Heat Shield 006 Floor Mounting Bracket 3541 2 007 Back Spacer Bracket 3542 2 008 Control Cover Assembly 90115114 3545 1 009 Front Panel B 90113358 3546 1 010 Louvre Assembly 90113887 3547 1 011 Bottom Trim Assembly B 90115106 3548 1 012 Strike 3038 2 013 L/H Side Panel B 90113317 3549 1 014 R/H Side Panel B 90113333 3553 1 015 Humidifier Tray 90113390 3554 1 016 Latch 3028 2 017 Front Foot 90165663 3403 2 018 Foot 90165655 3405 2 019 Air Filter Assembly B 90113150 3576 1 020 Bush 1 021 Bush 1 023 Electrical Cord Fixing Plate 024 Cable Clip 025 Thermistor Holder 026 Wiring Clip 027 Back Spacer, Top B 028 Cord Bush 029 Clip 030 Back Spacer, R/H Assembly 031 1 1 90177114 1 6698 2 4252 1 2043 2 90103409 3577 1 90177106 2048 1 6684 2 90103417 3578 1 Back Spacer, L/H Assembly 90171026 3579 1 100 Heat Exchanger Complete Assembly 90120387 3580 1 101 OHS Bracket 1 102 Flame Rod Bracket 1 103 Flame Rod Packing 104 Flame Rod 105 Combustion Chamber Fixing Bracket Energysaver RHFE-308 FTR 90165267 90173113 3069 1 4299 1 1 - 56 - ©Rinnai No Part Name RA Part No RNZ Part No QTY 106 Heat Exchanger Bracket 1 107 Sealing Bracket Assembly 2 108 Flange 2 109 Burner Box Assembly 1 110 Burner Assembly 111 Burner Clip Assembly 112 Burner Box Packing 90175662 4231 1 113 Primary Air Damper (Propane/LPG) 90179144 3588 1 113 Primary Air Damper (NG) 90179466 3592 1 114 Secondary Air Damper (Propane/LPG) 90179474 3593 1 114 Secondary Air Damper (NG) 90179482 3594 1 115 Fixing Plate Packing 90175670 116 Electrode Bracket 117 Electrode 118 90170630 3091 2 1 1 3096 1 90175696 3097 1 Electrode Packing 90173105 3098 1 119 Injector Manifold 90121757 120 Main Injector (Propane/LPG) 90159658 2393 2 120 Main Injector (NG) 90159633 3092 2 121 Manifold Packing 3094 1 122 Warm Air Sealing Bracket 1 123 Burner Box Mounting Plate Assembly 1 124 Heat Exchanger Packing B 90175563 4306 1 125 Gas Control Assy A (Prop/LPG-production only) 90120312 3595 1 125 Gas Control Assy C (NG - common spare) 90176520 3596 1 126 Pressure Test Point Screw 127 O-Ring 128 Gas Supply ConnectionTube Assembly 129 1 3 2239 3 3856 1 O-Ring 2389 2 130 Pressure Test Point 4204 2 132 Combustion Fan Complete Assembly 3995 1 133 Combustion Fan Casing Assembly 134 Mounting Rubber 135 Motor Fixing Screw 136 Combustion Chamber ConnectionTubeTop 3996 1 137 ConnectionTube Packing 3997 1 138 Combustion Chamber ConnectionTube Bottom 3998 1 139 Rubber Connection Tube Clip 3103 1 140 Air Inlet C 4367 1 141 Air Inlet Packing 4053 1 Energysaver RHFE-308 FTR 90123134 90117029 1 4364 7 3 90123043 - 57 - ©Rinnai No Part Name RA Part No RNZ Part No QTY 144 Flexible Intake Hose 90122961 4041 1 145 Air Inlet Elbow 90122953 4040 1 146 Flue Elbow Assembly 3999 1 147 Stopper Clip Assembly 3455 1 148 Elbow Cover 4371 1 149 Ring 90165374 4171 1 150 Clamp 90178146 4373 2 151 Mushroom Flue A 1 400 Convection Fan Casing Assembly 1 401 Sirroco Fan Assembly 402 Motor Base 403 Convection Fan Motor & Harness 90116328 4392 1 404 Capacitor 90179490 3107 1 405 Heat Shield 1 406 Thermal Fuse Fixing Panel 1 407 OHS 2 Mounting Bracket 1 408 P.C.B. Mounting Bracket 1 700 P.C.B. 90120288 4393 1 701 Control Panel PCB Assembly 90179136 4394 1 702 Transformer - Australia 90117011 702 Transformer - New Zealand 703 Sparker 704 90165358 90116872 4391 1 1 1 3116 1 2958 1 High Tension Cord Assembly B 4383 1 705 Electrode Sleeve 3395 1 706 Over Heat Switch (130oC) 90178567 4385 1 707 Over Heat Switch (90oC) 90178575 4384 1 708 Room Temperature & Overheat Thermistor Assy 90177502 4386 1 709 Solenoid Valve Harness 4389 1 710 Thermal Fuse Harness 4395 1 711 Main Harness Assembly 4387 1 712 Electrical Cord Assembly 4396 1 713 Power Cord Assembly 3115 1 714 Top Panel Complete Assembly 4397 1 715 Flame Rod Lead 4398 1 716 Combustion Motor Harness A 4399 1 717 Cord Packing Energysaver RHFE-308 FTR 90175829 90120544 1 - 58 - ©Rinnai Appendix Energysaver RHFE-308 FTR - 59 - ©Rinnai SERVICE CONTACT POINTS AUSTRALIA PTY. LTD. A.C.N. 005 138 769 Internet: http://www.rinnai.com.au E-mail: [email protected] Victoria : Tel: 1300 366 388 Tel: (03) 9271 6699 Fax: (03) 9271 6688 Tel: (03) 9271 6600 Fax: (03) 9271 6688 Tel: (03) 9271 6666 Fax: (03) 9271 6611 Tel: (1800) 632 386 Helpline: Service Spare Parts Sales Emergency Hot Water 10-11 Walker Street, Braeside, VIC 3195 Tel: (03) 9271 6625 Fax: (03) 9271 6622 New South Wales: Service Sales Emergency Hot Water Tel: (02) 9609 2600 Fax: (02) 9729 0467 Tel: (02) 9609 2888 Fax: (02) 9609 5260 Tel: (02) 9729 0468 62 Elizabeth Street, Wetherill Park, NSW 2164 Tel: (02) 9609 2111 Fax: (02) 9609 5260 South Australia: Service Emergency Hot Water Tel: (08) 8345 0292 Fax: (08) 8345 4760 Tel: (08) 8345 5185 140 Days Road, Ferryden Park, SA 5010 Western Australia: Service Emergency Hot Water Tel: (08) 9478 3355 Fax: (08) 9277 2531 Tel: (08) 9324 4145 18 Belgravia Street, Belmont, WA 6104 Queensland: Service Emergency Hot Water Tel: (07) 3209 4622 Fax: (07) 3209 4722 Tel: 1800 255 266. 1/6 Booran Drive, Logan Central, QLD 4114 Tasmania: Service Contact Rinnai Melbourne on: Tel: (03) 9271 6699 Fax: (03) 9271 6688 Tel: (03) 9271 6625 Fax: (03) 9271 6622 NEW ZEALAND LTD. Internet: http://www.ralenti.co.nz/rinnai 24 hr Service E-mail: [email protected] Tel: (09) 625 4285 Fax: (09) 624 3018 Tel: 0800 746624 (0800 Rinnai) 691 Mt. Albert Road, Royal Oak, Auckland P O Box 24-068
advertisement
* Your assessment is very important for improving the workof artificial intelligence, which forms the content of this project
Related manuals
advertisement