Rinnai ENERGYSAVER RHFE-308FTR Service Manual Download

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ENERGYSAVER

RHFE-308FTR

High Efficiency Power Flued Gas Space Heater

SERVICE MANUAL

Summary of Contents for ENERGYSAVER RHFE-308FTR

Page 1: ... ENERGYSAVER RHFE 308FTR High Efficiency Power Flued Gas Space Heater SERVICE MANUAL ...

Page 2: ...erformance and quality levels are achieved 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 Ass...

Page 3: ... 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 consta...

Page 4: ...erating 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 servi...

Page 5: ... 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 soleno...

Page 6: ... in the lower centre of the appliance The heat exchanger is composed of two sub heat exchanger sets The left hand set No 1 is constructed of 1 0 mm aluminised steel The right hand set No 2 is constructed of 0 8 mm stainless steel The inlet of sub heat exchanger No 1 is connected to the outlet of the combustion chamber the outlet is connected to sub heat exchanger N o 2 Sub heat exchanger No 2 cons...

Page 7: ...Energysaver RHFE 308 FTR 2 Rinnai 2 Dimensions Note All dimensions are in millimetres ...

Page 8: ...ents 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 26oC 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 ...

Page 9: ...Energysaver RHFE 308 FTR 4 Rinnai 4 Cut Away Diagram ...

Page 10: ...ns 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...

Page 11: ...Energysaver RHFE 308 FTR 6 Rinnai Recommended minimum clearances and distances from obstructions ...

Page 12: ...on MJ h HI 13 13 LO 5 5 Injector size mm 1 30 0 90 Injector quantity 2 2 Regulator pressure kPa HI 0 60 1 04 LO 0 12 0 19 Burner marking P P Combustion method Bunsen burner Burner type Stainless slit style Solenoid valve Direct single seated valve type Modulating solenoid valve Direct single seated valve type Natural Propane LPG Ignition 1710 1560 Re ignition 1800 1680 Normal High 3000 3090 Normal...

Page 13: ... 55 MJ h Nominal input 13 MJ h Room temperature 25oC Unit oC Condition Low Combustion Test gas Natural Measured input 5 27 MJ h Nominal input 5 MJ h Room temperature 25oC Unit oC 4 Measurement Points 24 24 55 9 45 72 64 18 56 81 83 36 62 66 77 42 68 43 70 45 42 39 57 45 10 17 30 9 23 39 38 13 29 48 42 28 35 44 46 37 37 28 43 34 22 26 31 28 ...

Page 14: ...back spacers 8 Humidifier Capacity Note Evaporation rate varies depending on conditions of use Conditions Standard setting High combustion Measurement Method According to JIS Japanese Industrial Standard 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...

Page 15: ...Energysaver RHFE 308 FTR 10 Rinnai 7 Schematic Diagram ...

Page 16: ...Energysaver RHFE 308 FTR 11 Rinnai 8 Control Panel Layout Refer to Appendix on page 59 for explanation on setting clock and programming timers ...

Page 17: ...lected 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 ind...

Page 18: ...e 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 discharg...

Page 19: ...tart 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...

Page 20: ...f 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 90o C 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 1...

Page 21: ...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 ...

Page 22: ...ion 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 ...

Page 23: ...n indicator flashes red 71 Filter indicator flashes 14 ON Combustion indicator flashes red 33 open circuit 34 short circuit ON Combustion indicator flashes red 33 open circuit 34 short circuit ON Combustion indicator flashes red After 2 Sec from a After 2 Sec from a ON Combustion indicator flashes red 72 After 20 Sec from a Combustion Fan OFF After 15 Sec Combustion Fan OFF No No After 10 Sec Afte...

Page 24: ...Convection Fan No Yes Yes Safety Devices Operate Modulating Valve HI Combustion Fan HI Convection Fan HI No 90 Sec from c Room temp Set temp by over 1 C Temperature Control OFF Solenoids SV1 2 OFF Modulating Valve Closed Combustion Fan OFF ON Combustion indictor green Convection Fan MED ON Convection Fan OFF Room temp Set temp Yes Yes No No No Yes Room Set temp within 2 C No 10 mins after d Yes No...

Page 25: ...m Set Temp to clock All Indicators OFF Convection Fan ECONOMY Economy Switch ON Economy Indicator ON Less than 255 sec No Room Temperature drops max 2 C Economy Switch OFF Economy Indicator OFF Temperature Control Operates TIMER OPERATION ON OFF Switch ON Timer Switch ON Timer Indicator ON Pre Heat set up Time No Timer indicator flashes Normal operation start Set up Time Normal Operation Stops No ...

Page 26: ... µA 7 G Combustion Fan red black DC 7 40V 10 MΩ white black DC 1 4 V 3420 pulse min 57 Hz 9 G Combustion Fan black white below ignition revolution 120 rpm initial ignition LP 3480 NG 3600 pulse min re ignition LP 3720 NG 3780 pulse min 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 14 A Over heat T...

Page 27: ...Energysaver RHFE 308 FTR 22 Rinnai 14 Wiring Diagram ...

Page 28: ...Energysaver RHFE 308 FTR 23 Rinnai 15 Block Diagram ...

Page 29: ...Energysaver RHFE 308 FTR 24 Rinnai 16 Time Charts ...

Page 30: ...Energysaver RHFE 308 FTR 25 Rinnai ...

Page 31: ...Energysaver RHFE 308 FTR 26 Rinnai ...

Page 32: ...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 Fol lowing 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 dis...

Page 33: ...me and Estimated Number of Operations cannot be deleted Once recorded in E2 PROM the data is protected from power failures This data can be deleted as described above Permanent Data Deletable Data initial settings Modulating Valve Supplement CurrentValue HIGH Modulating Valve Supplement CurrentValue LOW Convection Fan Supplement CurrentValue HIGH Convection Fan Supplement CurrentValue LOW Estimate...

Page 34: ...as being above 40o C 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 thermisto...

Page 35: ...nfirm no gas escapes 1 Check for air in the gas supply 1 Reconfirm gas type specified 1 Insufficient heating Check selected room temperature setting 2 Check for blocked air filter 3 Check for an obstruction in the warm air flow 4 Reconfirm gas pressure at appliance 1 Burner goes out during operation 12 14 16 Ensure flue terminal is not blocked 5 Ensure air filter is not blocked 3 Power Failure 8 C...

Page 36: ...ck that There are no obstacles in front of the appliance or louvres 14 flashing There should be no articles within one 1 metre of the front of the appliance 5 Flue terminal If flame failure occurs during normal operation check that The flue terminal on the exterior wall is not obstructed in any way 12 flashing Check in particular for shrubs growing over the flue terminal or a thick build up of spi...

Page 37: ...rmostat 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 ...

Page 38: ...has melted vii Solenoid circuit is faulty 71 flashing b The combustion fan doesn t rotate or the appliance fails after a short time i Combustion fan shaft allen screw loose ii An obstruction in the combustion fan is preventing it from rotating iii Combustion fan does not go over1710 rpm 61 flashing iv The flame rod current is greater than 0 1 µA during pre purge 72 flashing v The combustion fan rp...

Page 39: ...e or a kink or break in the gas supply iv Faulty or weak spark v Blocked injector Is the combustion specification correct C There is the sound of ignition however the combustion injector does not glow red Miss ignition Ignition OK After 15 seconds the spark stops and mis ignition occurs Confirm the flame rod current 1 Faulty indicator incorrect wiring 2 Faulty PCB Has the current risen above 1 0 µ...

Page 40: ... activated no fault evident Have you ensured that the connectors are in the correct posi tions and also the wiring is not disconnected anywhere Flame failure 30 60 mins after ignition 12 flashing Is flame rod current 1 0 µA Flame failure makes a loud noise Faulty PCB 1 Confirm specification of regulator restrictor injector etc 2 Check condition of flame rod and burner 1 Blocked flue terminal 2 Dus...

Page 41: ...moving2Pconn ector D Grey Pink 90 180 Ω Yes Go to 2 3 No Replace convection motor 3 Measure combus tion motor coil resist ance after removing 4 connector G Red Black 1 M Ω Yes Go to 2 4 No Replacecombustion motor 4 Measure resistance of transformer after removing8Pconnector E White White 5 20 Ω E Red Red 1 8 Ω E Black Blue 0 5 3Ω E Blue Yellow 250 450 Ω Yes Go to 2 5 No Replace transformer 5 Remov...

Page 42: ... Measure sparker input voltage F Blue Red AC 85 110 V Yes Replace sparker No Replace PCB D Spark fails to produce ignition stops after approx 15 sec 11 flashing 10 Are the solenoid valves SV1 SV2 ON 1 Check solenoid valve coil resistance using same procedure as 2 5 above F Black Yel low SV1 1 3 2 2 k Ω SV2 1 3 2 2 k Ω Yes Go to 11 2 No Replace solenoid valve 2 Check solenoid valvesterminalvoltage ...

Page 43: ...d 12 flashing Check flame rod circuit current E1 Yellow flame rod 1 0 µA Disconnect measure between connector and lead Yes Check for dust FR wire and connector No Replace PCB 16 OFF function activated 16 flashing Was the heater used for a long period at a high temperature Over ten minutes at above 40oC Yes Explain usage No Replace PCB 17 Overheat switch activated 14 flashing 1 Check for dust on ai...

Page 44: ...ombustion 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 Operating Procedures Illuminated Indicators 1 Turn the appliance on combustion indicator illuminates Press test mode switch SW 5 at top of the PCB combustion mode changes to Low test mode LO...

Page 45: ...n 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 t...

Page 46: ...e 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 re assembling 9 Remove manifold Take care with gasket see 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 se...

Page 47: ...once see PCB dip switch position opposite 5 Adjust the LOW pressure to the correct pressure see table below with the and buttons on the control panel The RHFE 308FTR has E2 PROM operation there should be no need to adjust the modulating valve screw 6 Press SW4 again to lock in the low pressure setting HIGH 7 Press SW3 to set the appliance on forced HIGH 8 Adjust the HIGH pressure to the correct pr...

Page 48: ... 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 ot...

Page 49: ...l Panel PCB CAUTION 240 volt potential inside applaince Disconnect electrical supply 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 e Grip control panel cover...

Page 50: ... unit d Remove four 4 screws securing the motor to the casing and remove fan motor cover 4 Removal of Heat Exchanger CAUTION 240 volt potential inside appliance Disconnect electical supply a Remove front panel assembly see section1 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 ...

Page 51: ... n Remove flue spigot three 3 screws o Remove five 5 heat exchanger securing screws p Grip heat exchanger and pull forward to remove Note Refer section 5 f g to disconnect burne from heat exchanger complete assembly 5 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 f...

Page 52: ...move front heat shield see section 4 b d c Remove two 2 screws using a stubby phillips screwdriver 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 c Lift PCB on right hand side and gently manoeuvre it out d Disconne...

Page 53: ...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 10 Removal of Main Transformer CAUTION 240 volt potential exposure Isolate the applaince and reconfirm with a neon screwdriver or multimeter a Remove front panel assy see section 1 b Remove main PCB see section 7 b e c Remove one 1 sec...

Page 54: ... 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 4 c d e Remove overheat thermistor see section 4 e 13 Removal of Thermal Fuse CAUTION 240 volt potential exposure Isolate the applaince and reco...

Page 55: ...Energysaver RHFE 308 FTR 51 Rinnai 26 Exploded Diagram ...

Page 56: ...Energysaver RHFE 308 FTR 52 Rinnai ...

Page 57: ...Energysaver RHFE 308 FTR 53 Rinnai ...

Page 58: ...Energysaver RHFE 308 FTR 54 Rinnai ...

Page 59: ...Energysaver RHFE 308 FTR 55 Rinnai ...

Page 60: ...549 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 90177114 1 024 Cable Clip 6698 2 025 Thermistor Holder 90165267 4252 1 026 Wiring Clip 2043 2 027 Back Spacer Top B 90103409 3577 1 028 Cord Bush 90177...

Page 61: ...or 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 3 127 O Ring 2239 3 128 Gas Supply ConnectionTube Assembly 90123134 3856 1 129 O Rin...

Page 62: ... Mounting Bracket 1 700 P C B 90120288 4393 1 701 Control Panel PCB Assembly 90179136 4394 1 702 Transformer Australia 90117011 1 702 Transformer New Zealand 3116 1 703 Sparker 90175829 2958 1 704 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...

Page 63: ...Energysaver RHFE 308 FTR 59 Rinnai Appendix ...

Page 64: ...k NSW 2164 Tel 02 9609 2111 Fax 02 9609 5260 South Australia Service Tel 08 8345 0292 Fax 08 8345 4760 Emergency Hot Water Tel 08 8345 5185 140 Days Road Ferryden Park SA 5010 Western Australia Service Tel 08 9478 3355 Fax 08 9277 2531 Emergency Hot Water Tel 08 9324 4145 18 Belgravia Street Belmont WA 6104 Queensland Service Tel 07 3209 4622 Fax 07 3209 4722 Emergency Hot Water Tel 1800 255 266 1...

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