Rinnai RHFE-551FA Manual de usuario

Direct Vent

Service Manual

RHFE-551FA

RHFE-1001FA

RHFE-1001FA/VA

RHFE-201FA

RHFE-263FA, FAII

RHFE-431FA, FAII, FAIII, WTA

RHFE-556FA, FAII, FAIII, FTRA, FTRAIII, WTA

RHFE-1004FA

This document, 200000014 (11/3/2008),

supersedes and replaces the Direct Vent

Service Manual, TDM-DV-2004.

2 Rinnai Direct Vent Service Manual

Table of Contents

General Information .................................... 3

Specifications.............................................. 4

Sequence of Operations ............................. 5

Fault Isolation

Accessing Fault Codes......................... 6, 7

Fault Isolation Codes............................ 8, 9

Fault Isolation - Other Issues.................. 10

431FA Series, 556FA/FTRA Series

Troubleshooting ..................................... 11

Wiring Diagrams

431FA Series, 556FA/FTRA ............. 14

556FAIII ............................................ 15

556FTRAIII........................................ 16

Lockout Check List 431FA Series .......... 17

Lockout Check List 556FA/FTRA Series 19

431WTA, 556WTA

Troubleshooting .................................... 21

Wiring Diagrams (431WTA) ................... 24

Wiring Diagrams (556WTA) ................... 25

Lockout Check Lists ............................... 26

551FA, 1001FA, 1001FA/VA

Troubleshooting (551FA)........................ 28

Wiring Diagram (551FA)......................... 31

Troubleshooting (1001FA)...................... 32

Wiring Diagram (1001FA)....................... 34

Troubleshooting (1001FA/VA)................ 35

Wiring Diagram (1001FA/VA)................. 37

Lockout Check List

(100FA, 1001FA/VA, 551FA) ................. 38

201FA, 263FA, 263FAII

Troubleshooting (201FA)........................ 40

Wiring Diagram (201FA)......................... 42

Block Diagram (201FA) .......................... 43

Troubleshooting (263FA, 263FAII) ......... 44

Wiring Diagram (263FA, 263FAII) .......... 46

Block Diagram (263FA, 263FAII) ........... 47

1004F

Troubleshooting Information................ 48

Wiring Diagram.................................... 50

Lockout Check List .............................. 51

Extension Installation Requirements ........ 52

Vent Kits and Extension Sets ................... 53

Vent Extension Covers ............................. 54

Installations at Altitude.............................. 54

Gas Pressure Setting Procedure

(201FA, 263FA, 263FAII) .................... 55

(431FA/WTA, 556FA/WTA) ................. 57

(1004FA) ............................................. 59

Dip Switch Settings................................... 61

Checking Micro-Amps

(431, 556, 201, 263) ................................. 62

Setting up the U Tube Manometer

(431, 556, 201, 263) ................................. 63

Thermistor ................................................ 64

Flame Rectification ................................... 64

Setting a Maximum Temperature

(431, 556, 201, 263) ................................. 64

Harmonic Noise (1004FA) ........................ 65

Wire Diagram Abbreviations ..................... 65

Removal of “OF” on New PC Board

Installation ................................................ 66

Rinnai Direct Vent Service Manual 3

General Information

Safety Definitions

This is the safety alert symbol. This symbol alerts you to potential hazards that can kill or hurt you and

others.

Indicates an imminently hazardous situation which, if not avoided, will result in death or

serious injury.

Indicates a potentially hazardous situation which, if not avoided, could result in death or

serious injury.

Indicates a potentially hazardous situation which, if not avoided, could result in minor or

moderate injury. It may also be used to alert against unsafe practices.

DANGER

CAUTION

WARNING

Recommended Tools

• Volt/Ohm/Amp meter with test probes

• U tube type manometer with 14 inch water column (W.C.) scale, two hoses and two 1/8 inch taps

• assorted wrenches including a 3/16 Allen wrench

• assorted screw drivers

• leak solution or leak detector

Using this Manual

Repairs should be performed by a qualified service technician.

The following information can be referenced for additional information.

• Operation and Installation Manual

• Conversion Manual

• Technical Bulletins

Technical Support

Technicians are available to assist in servicing issues. Contact Rinnai Technical Services at 1-800-621-9419.

WARNING

There are a number of live tests that are required when fault finding this product. Extreme care should be used at

all times to avoid contact with energized components inside the furnace. Before checking for resistance readings

disconnect the power source to the unit and isolate the item from the circuit (unplug it).

If any of the original wire as supplied with the appliance must

be replaced, it must be replaced with type 18 AWG wire or its

equivalent.

Label all wires prior to disconnection when

servicing controls. Wiring errors can cause

improper and dangerous operation.

CAUTION

4 Rinnai Direct Vent Service Manual

Specifications

201FA 263FA, FAII

431FA Series,

WTA 556FA/FTRA

Series, WTA 1004FA 551FA 1001FA

1001FA/VA

BTU Input NG 3,000-8,000 5,500-11,000 8,200-16,700 8,200-21,500 10,500-38,400 22,000 (max) 38,400 (max)

BTU Input LP 3,000-8,000 5,700-11,000 8,200-16,700 8,200-20,700 10,500-36,500 21,000 (max) 36,500 (max)

AFUE Rating

Natural Gas:

80.6%

Propane Gas:

83.4%

Natural Gas:

80%

Propane Gas:

80%

Natural Gas:

80.8%

Propane Gas:

81%

Natural Gas:

80.6%

Propane Gas:

81%

Natural Gas:

80.6%

Propane Gas:

82%

NA NA

Gas Supply

Pressure (NG)

4.5-10.5 in

(114-267 mm)

W.C.

3.5-10.5 in

(89-267 mm)

W.C.

3.5-10.5 in

(89-267 mm)

W.C.

5.0-10.5 in (127-

267 mm) W.C.

5.0-10.5 in (127-

267 mm) W.C.

4.5-10.5 in (114-

267 mm) W.C.

5.0-10.5 in (127

-267 mm) W.C.

Gas Supply

Pressure (LP)

8-13 in

(203-330 mm)

W.C.

8-13 in

(203-330 mm)

W.C.

8-13 in

(203-330 mm)

W.C.

8-13 in

(203-330 mm)

W.C.

11-13 in

(279-330 mm)

W.C.

11-13 in

(279-330 mm)

W.C.

11-13 in

(279-330 mm)

W.C.

Electrical

Connection

(at high fire)

AC 120V,

60 Hz,

42 watts

AC 120V,

60 Hz,

47 watts

AC 120V,

60 Hz,

40 watts

AC 120V,

60 Hz,

55 watts

AC 120V,

60 Hz,

121 watts

AC 120V,

60 Hz,

120 watts

AC 120V,

60 Hz,

120 watts

Sound Level 27-34 dB(A) 31-38 dB(A) 32-38 dB(A) 32-41 dB(A) 37-47 dB(A) 35-44 dB(A) 35-46 dB(A)

Fan CFM 48.3-78.6 96.4-128.5 110.5-141.3 110.5-162.7 203.4-360.6 135-189 179-289

Weight 39.4 lbs

(17.9 kg) 37 lbs (17 kg) 51 lbs (23 kg) 51 lbs (23 kg) 90 lbs (41 kg) 74 (34 kg) 110 (50 kg)

Rinnai Direct Vent Service Manual 5

Sequence of Operations

1. The blower (combustion) motor fan starts and purges the combustion and heat exchanger

chambers making sure that they are clear. The green LED light is on.

2. The blower stages down and the ignition module powers the spark igniter and spark

occurs. When the spark is sensed as being correct, the PCB allows voltage to the

solenoid gas valves and gas enters the chamber. Ignition occurs and the flame rod begins

to prove flame. The blower motor stages back up to high. When the burner is on the LED

glows red indicating the burner is on. If the flame is correct and a secure ground is

available, then the flame rod produces micro-amps and the unit will fire trying to reach your

set room temperature.

3. The convection (room blower) will start on low speed circulating warm air into the structure.

After the PCB compares the set temperature to the room temperature, the seven stage gas

valve and fan control will fire the unit at the most efficient rate to obtain the comfort level as

set.

4. The negative co-efficient thermistor will sense the room temperature at the floor level and

will provide feedback to the PCB to determine the firing rate, fan speed, and run time.

When the set temperature is reached, the red indicator will return to green indicating the

burner is off. The convection fan will continue to run cooling the exchangers and

electronics for about 4 minutes.

5. The LED will be green indicating the unit is on standby. When the structure temperature

drops, the process starts over again.

6. Fresh air for combustion is drawn from outside and exhaust air is eliminated to the outside.

Moisture coming from the vent outside is normal as most high efficient units produce

moisture.

6 Rinnai Direct Vent Service Manual

Fault Isolation

If there is a malfunction the appliance may shut down

as a safety precaution and display a fault code to

assist in diagnosing the problem. The fault code will

flash in the display on the control panel.

Fault codes should be used to assist in identifying the

cause of the failure.

After the problem has been corrected, the fault code

will clear only after the appliance has been turned off

and back on. The code will be stored into the memory.

Some faults may cause a hard lockout where the

appliance shuts off and corrective action is required

before the appliance will operate.

Accessing Fault Codes

Up to 10 fault codes are stored in the PC Board and can be recalled by simultaneously pressing the “Economy”

button and both temperature control buttons for 2.5 seconds while the appliance is turned OFF. After the buttons

are released, the fault codes will be displayed in 2 second intervals beginning with the most recent fault code.

Models with analog controls and models with digital LED’s each have their own set of fault codes.

On models RHFE-431WTA, RHFE-556WTA, RHFE-556FTRA:

Under SET the codes in memory are numbered 1 through 10 with “1” as the

most recent. Under ROOM the fault code will be displayed.

Models with analog controls:

The fault code will display by lighting up 1 to 4 of the temperatures at

the same time. For example, if the temperatures 60, 64, and 68 are lit

up then the fault code is 60*64*68 - Abnormal Combustion Fan RPM.

On models RHFE-201FA, RHFE-263FA, RHFE-263FAII, and

RHFE-1004FA:

The codes in memory are numbered 1 through 10 with “1” as the most

recent. The temperature display will show “1” and then show the most

recent fault code. A “2” will then be displayed followed by the second

most recent fault code. The 10 most recent fault codes will be displayed

in this manner.

SET ROOM

1 61

SET ROOM

2 14

1 61 2 14

LO 60 64 68 72 76 80 HI

Rinnai Direct Vent Service Manual 7

RHFE-431WTA,

RHFE-556WTA

5082 combustion hours

18420 combustion cycles (multiply displayed number by 10)

125 power failures

Accessing Operation History

RHFE-431FA, RHFE-556FA

After the fault codes, the heater will display the combustion hours and combustion cycles (number of times the

unit is turned on and off). The combustion time will display first in two parts followed by the combustion cycles

displayed in two parts.

Combustion Time

1. The temperature display will indicate a 16 digit binary number. A light indicates a “1”. A position not lighted,

indicates a “0”. Read this number using the example below.

LO 60 64 68 72 76 80 HI

This indicates the first 8 digits as follows: 0 1 0 0 0 0 0 1

This indicates the next 8 digits as follows: 1 1 0 1 0 0 0 0

2. Use a calculator with binary and decimal functions. Set the calculator to binary, “BIN”, and enter the 16 digits.

(0 1 0 0 0 0 0 1 1 1 0 1 0 0 0 0 in the example above.)

3. Press the decimal function, “DEC”, and the combustion time in hours will display. The combustion hours in

this example is 16848.

Combustion Cycles

1. The temperature display will indicate a 16 digit binary number. A light indicates a “1”. A position not lighted,

indicates a “0”. Read this number using the example below.

This indicates the first 8 digits as follows: 1 1 0 0 1 0 0 0

This indicates the next 8 digits as follows: 0 0 1 1 0 0 0 1

2. Use a calculator with binary and decimal functions. Set the calculator to binary, “BIN”, and enter the 16 digits.

(1 1 0 0 1 0 0 0 0 0 1 1 0 0 0 1 in the example above.)

3. Press the decimal function, “DEC”, and multiply the displayed number by 10 to obtain the combustion cycles.

The combustion cycles in this example is 512,490.

50 82

18 42

1 25

SET ROOM

50 82

18 42

1 25

After the fault codes, the heater will display the

combustion hours, combustion cycles (number of times

the unit is turned on and off), and power failure

frequency.

RHFE-201FA,

RHFE-263FA,

RHFE-263FAII,

RHFE-1004FA,

RHFE-556FTRA

8 Rinnai Direct Vent Service Manual

Analog

Indicator

Light

Digital

LED Name Definition Corrective Action

LO-HI PF --

:--

Power Failure Electric power has

been lost while the

appliance was running

Check that the power cord is firmly inserted into

the electrical outlet.

Check the 3 amp fuse.

Check whether the fuse or breaker has blown at

the switch board.

60 11 Missed Ignition Flame rod current

does not reach 1.0

microamp within a

certain time after the

solenoid opens.

Check that the flame rod is firmly positioned.

Check the flame rod lead.

Check the flame rod for carbon build up.

Check that the correct gas is being used.

Check the supply pressure at the meter and at

the appliance.

Check that there are no leaks in the gas supply

line or appliance.

Check for air in the gas supply.

LO 12 Flame Failure Flame rod current

remains below 1.0

microamp for 3

seconds during initial

combustion

Check that the correct gas is being used.

Check the supply pressure at the meter and at

the appliance.

Check that there are no leaks in the gas supply

line or appliance.

Check for air in the gas supply.

68 14 Overheat Safety

Device

High limit temperature

thermistor or thermal

fuse has activated

Check that the correct gas is being used.

Check the supply pressure at the meter and at

the appliance.

Check that the flue terminal is not blocked.

Check that the air filter is not blocked.

Check that the warm air flow is not blocked.

(There should be a clearance of 40 inches in front

of the appliance.)

HI 16 Over

Temperature

Cut Off

Room temperature is

above 104ºF for

longer than 10

minutes

Check that the correct gas is being used.

Check the supply pressure at the meter and at

the appliance.

Check that the flue terminal is not blocked.

Check that the air filter is not blocked.

Check that the warm air flow is not blocked.

(There should be a clearance of 40 inches in front

of the appliance.)

72 76 31 Room

Temperature

Thermistor

Disconnection

Room temperature

thermistor circuit is

open

Check the circuit. (troubleshooting)

76 80 32 Room

temperature

thermistor short

circuit

Room temperature

thermistor wire is

trapped or touching

bare metal.

Check the circuit. (troubleshooting)

Fault Isolation Codes

Rinnai Direct Vent Service Manual 9

Analog

Indicator

Light

Digital

LED Name Definition Corrective Action

64 68 72 33 High-limit

thermistor

disconnection

High limit thermistor

circuit is open.

Check the circuit. (troubleshooting)

68 72 76 34 High-limit

thermistor short

circuit

High limit thermistor

wire is trapped or

touching bare metal.

Check the circuit. (troubleshooting)

LO 60 64 53 Abnormal spark

sensed

• Sparker is not off

within 20 seconds of

ignition.

• 1st spark is not

sensed within 2

seconds

• 2nd spark is not

continuous for 1

second after

solenoid valve

opens

Replace sparker

60 64 68 61 Abnormal

Combustion Fan

RPM

RPM is not achieved

within a certain time or

exceeds the RPM

limit.

Check for obstacle preventing fan from turning

freely.

Check wiring harness to motor for damage or

loose connections.

64 68 70 ON/OFF Switch

Failure

The ON/OFF switch

connects continuously

for more than 15

seconds.

Check the circuit. (troubleshooting)

Replace switch.

LO 60 71 Solenoid Valve

Failure

For either solenoid

valve, SV1 or SV2, the

signal and response

signal are different.

Check the circuit. (troubleshooting)

Replace gas valve.

80 72 Flame Rod

Failure

Flame rod output does

not cease within 20

seconds

Check the circuit. (troubleshooting)

Replace flame rod.

72 76 80

73 Communication

Failure

Data transfer between

CPU and E2PROM

fails.

Disconnect the power and re-apply power.

NA 49 Pressure Sensor No signal from the

pressure sensor.

Check the circuit. (troubleshooting)

NA 99 Flue Block The pressure sensor

signal is below its limit.

Check the flue and termination for proper

installation and blockage.

60 64 68

72 76

NA Flue Block Flue blockage has

been detected based

on fan speed.

Check the flue and termination for proper

installation and blockage.

Fault Isolation Codes

10 Rinnai Direct Vent Service Manual

Heater does not operate. Is the heater plugged in?

Have the fuses or breaker blown at the fuse box / breaker panel?

Is there a power failure?

Is the air filter blocked?

Is anything blocking the outlet for the hot air?

Is the flue blocked?

AT IGNITION:

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, helping to avoid cold draughts.

Smoke or strange smells are produced

on the first trial light up after installation.

This is caused by grease, oil, or dust on the heat exchanger and will stop

after a short time.

Sharp clicking noised at ignition, or

when unit shuts down, 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 opening and closing.

Unit is not heating room. Is the air filter blocked?

Is the set temperature high enough?

Is the warm air outlet blocked by anything?

Are the doors and windows of the room closed?

Was the appliance correctly sized for the space?

Air filter is blocked or the louvers are

blocked.

Allow heater to cool, clean air filter, and operate again.

Heater will not re-ignite after overheating Even after unit has cooled down, the heater does not ignite again. Repair

is necessary by a qualified service provider.

DURING COMBUSTION:

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 vapor on cold days.

This is normal.

Unit shuts off without apparent reason. Check whether filters are blocked. Dirty filters will cause the heater to

overheat.

Power Failure Switch OFF, then ON again when power is restored to re-set controls.

Fault Isolation - Other Issues

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