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Rinnai RCE-460PTR Service Manual Download Page 55

Convector 460/560PTR

- 50 -

©Rinnai

7. Removal of the Surge Protector and 

Sparker Unit

CAUTION

240 Volt exposure. Isolate the electrical supply to 

the appliance and reconfirm with the neon 

screwdriver or multimeter.

a. Follow section 3 (Removal of the Front 

Panel).

b. Remove two (2) screws from the surge pro-

tector sparker unit bracket.

c. Lift from bracket

d. Disconnect all leads.

e. Disconnect sparker unit from PCB and sole-

noid loom. (Note: the sparker unit comes 
complete with wiring loom for solenoids as 
shown below.)

8. Removal of the Overheat Switch

CAUTION

240 Volt exposure. Isolate the electrical supply to 

the appliance and reconfirm with the neon 

screwdriver or multimeter.

a. Follow section 3 (Removal of the Front 

Panel).

b. Remove surge protector/sparker assy 

  

c. Remove the two (2) screws from the OHS.

9. Removal of the Thermocouple

CAUTION

240 Volt exposure. Isolate the electrical supply to 

the appliance and reconfirm with the neon 

screwdriver or multimeter.

a. Follow section 3 (Removal of the Front 

Panel).

b. Remove one (1) screw securing the cover 

plate

c. Lift and remove bracket (2 screws).

Summary of Contents for RCE-460PTR

Page 1: ...SERVICE MANUAL RCE 460PTR RCE 560PTR FAN CONVECTOR ...

Page 2: ... 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 Comparative Energy Consumption tested to The Australian Gas Association requirements of Austra...

Page 3: ...iring Do not disassemble Parts within cannot be exchanged or diagnosed faulty 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 sugg...

Page 4: ...7 Cut Away Diagram 14 8 Operation Principles 15 9 Main Componentry 19 10 Operational Flow Chart 25 11 Error Code Messages 27 12 Diagnostic Points 34 13 Fault Finding Procedure 36 14 Fault Analysis 39 15 Gas Conversion 45 16 Gas Pressure Setting Procedure 46 17 Dismantling for Servicing 47 18 Wiring Diagram 55 19 Block Diagram 56 20 Time Charts 57 21 Parts List 66 22 Exploded Diagrams 72 ...

Page 5: ... range DC direct current AC alternating current Hz Hertz IC integrated circuit kcal h kilocalorie per hour kPa kilopascals LED light emitting diode mA milliamps MJ h megajoule per hour mm millimetres OHS overheat switch PCB printed circuit board CPU central processing unit POT potentiometer rpm revolutions per minute SV solenoid valve ø diameter C temperature rise above ambient POV modulating valv...

Page 6: ...ro particles 2 Use of the anti bacterial and deodorising filter creates a comfortable space to live in filter indicator shows when it needs to be replaced 3 The dust sensor shows how clean the air is in a room 4 The automatic function changes its operational level according to the cleanliness of the air in the room There are four levels of adjustment for manual operation 5 The OFF Timers can be se...

Page 7: ...m3 Air Purifying Capacity 45 6 m3 Comb Specifications Gas Input MJ h Gas Type 460PTR 560PTR NG HI 18 HI 21 LO 5 5 LO 5 5 LPG HI 18 HI 21 LO 6 LO 6 Main Burner Form Slit type Method Bunsen type Air Filter 30 Mesh Heater Specifications Operation Operation Push Button Ignition method Continuous spark Main Direct Ignition Control Room temperature Low approx 10 C 16 26 C High Continuous High Gas flow c...

Page 8: ...an Motor Condensor line 4 pole motor Dust Sensor Particle Counter scattered light method Filter Replacement Indicator Calculated as on page 18 Safety Devices Incomplete Combustion Device Thermocouple method Flame Failure Thermocouple method Reverse Flame Device Bi metal method OFF 150 5 C ON 125 10 C Overheat Device Thermistor level 4 12 70 C level 1 3 70 C Thermal fuse 216 C OFF Power Failure Dev...

Page 9: ...ctor size 2 15 1 40 1 40 2 15 1 40 1 40 Thermocouple spacer A 1 1 1 1 1 1 B 0 0 0 0 0 0 B 0 0 0 0 0 0 Restrictor 20 22 22 20 22 22 Regulator pressure kPa High 0 65 1 46 1 46 0 85 1 91 1 91 Low 7 18 18 7 18 18 Burner marking X3C X3P X3P X3C X3P X3P Combustion method Bunsen burner Burner type Slit Solenoid valve Direct Single Seated Valve Type Modulating solenoid valve Rinnai Electronic Control φ φ ...

Page 10: ...erature 26 0 C Conditions Low Combustion Test gas Natural Measured Input 5 40 MJ h 1290 kcal h Nominal Input 5 50 MJ h 1310 Unit C Room temperature 26 0 C 56 75 76 72 75 68 61 61 Average 73 1 70 82 75 80 85 78 61 72 56 81 71 81 94 85 61 74 60 80 66 79 90 86 61 74 54 77 64 79 89 87 58 71 22 26 27 26 26 25 24 23 Average 28 4 25 30 27 28 31 29 24 28 22 31 27 30 36 32 24 29 23 32 27 33 39 34 24 29 22 ...

Page 11: ...Air flow rate on High 3 97 m min Air flow rate on Low 2 51 m min 2 91 2 91 3 31 3 99 3 46 2 79 2 76 1 88 Average 3 68 3 39 3 52 3 67 4 31 4 13 3 34 3 12 1 64 3 53 3 94 4 29 4 29 4 30 3 77 3 61 2 58 3 87 4 40 4 19 4 23 4 76 4 09 3 48 3 16 4 34 4 28 3 83 4 96 4 61 4 60 3 40 3 45 1 54 1 72 1 87 2 68 1 67 1 49 1 86 1 17 Average 2 32 2 22 2 41 2 39 2 62 1 98 1 84 2 35 1 08 2 12 2 64 2 60 3 14 2 77 2 50...

Page 12: ...erature 26 0 C Conditions Low Combustion Test gas Natural Measured Input 5 40 MJ h 1290 kcal h Nominal Input 5 50 MJ h 1310 Unit C Room temperature 26 0 C 53 67 68 63 65 63 55 54 Average 65 6 63 74 66 69 71 72 54 65 52 74 62 69 79 79 55 65 53 74 58 70 78 82 54 67 52 72 56 69 80 85 51 66 22 26 27 26 26 25 24 23 Average 28 4 25 30 27 28 31 29 24 28 22 31 27 30 36 32 24 29 23 32 27 33 39 34 24 29 22 ...

Page 13: ...Air flow rate on High 3 52 m min Air flow rate on Low 2 51 m min 2 58 2 58 2 93 3 53 3 07 2 47 2 44 1 66 Average 3 26 3 00 3 12 3 25 3 81 3 66 2 96 2 76 1 45 3 13 3 49 3 80 3 80 3 80 3 34 3 20 2 29 3 43 3 89 3 71 3 74 4 22 3 62 3 08 2 80 3 84 3 79 3 39 4 39 4 08 4 08 3 01 3 06 1 54 1 72 1 87 2 68 1 67 1 49 1 86 1 17 Average 2 32 2 22 2 41 2 39 2 62 1 98 1 84 2 35 1 08 2 12 2 64 2 60 3 14 2 77 2 50...

Page 14: ... on Low 1 49 m sec Area of louvre 0 0165 m Air flow rate on Boost 3 24 m min Air flow rate on High 2 13 m min Air flow rate on Med 1 80 m min Air flow rate on Low 1 47 m min 1 42 1 57 1 27 1 24 2 43 3 73 2 76 1 56 2 73 Avg 3 27 4 05 4 73 4 13 4 80 4 20 4 90 3 41 4 62 5 30 0 73 0 96 0 96 2 08 1 95 2 62 1 38 1 21 1 80 Avg 2 15 2 44 3 00 3 09 3 08 2 77 2 84 1 93 2 73 3 13 0 57 0 78 0 82 1 88 1 50 1 9...

Page 15: ... Level 460 560PTR Heater Measuring method According to Japanese Industry Standards During Combustion Air Purifier Measuring method According to JEM1467 Operation Noise dB A High 41 Low 27 Operation Noise dB A Boost 45 High 35 Med 31 Low 27 ...

Page 16: ...Convector 460 560PTR 11 Rinnai 4 Dimensions Note All dimensions are in millimetres ...

Page 17: ...Convector 460 560PTR 12 Rinnai 5 Installation The following clearances are recommended for installation ...

Page 18: ...Convector 460 560PTR 13 Rinnai 6 Schematic Diagram ...

Page 19: ...Convector 460 560PTR 14 Rinnai 7 Cut Away Diagram ...

Page 20: ...Convector 460 560PTR 15 Rinnai 8 Operation Principles Control Panel Layout ...

Page 21: ...on will not respond The Air Purifier can be operated The Up and Down buttons should be pressed simultaneously for approximately 2 seconds to cancel the Child Lock Clock Setting Press the Set Times button once The Clock indicator will flash Press the Temp Time buttons to adjust the time Press the Set Times button five times to set the clock The indicator will go out Setting Timers 1 and 2 Heater Pr...

Page 22: ...nd the room temperature 5 minutes after ignition This is for when the room temperature is set between 17 25 C Even if the set room temperature is modified while auto economy is operating the auto economy function will continue When the present room temperature is over 5 C less than the set room temperature while auto economy is operating the auto economy function will go into stand by mode The Eco...

Page 23: ... Air Purifier Press the OFF Timer button when the Air Purifier is operating and set the desired time 1 2 or 4 hours The Air Purifier will turn off after the set time period is lapsed Filter Replacement Indicator When the air purifier has operated for 4000 hours the filter replacement indicator Purif Filter Chg will illuminate to let you know that the filter needs to be replaced The operation time ...

Page 24: ...pecial burner structure connected to an electronic sensor Ignition combustion and flame failure are monitored by this system and main burner abnormal combustion or incomplete combustion due to unclean air are electronically sensed as a thermocouple change from flame temperature change prior to occurence The amplifier amplifies the thermocouple output by a few volts 20 30 m V and any changes are ch...

Page 25: ...use therefore the appliance cannot be restarted until this fuse has been replaced Reverse Flame Detection Device Tilt Switch Safety Device Normally the tilt circuit is open but the steel ball rolls when the unit is tilted closing the circuit Ignition Sensing Voltage mV ODS Sensing Voltage mV Thermocouple Output Drop Out Time sec Output at initial check 2 NG level 4 12 14 level 1 3 14 LPG level 4 1...

Page 26: ...nnai Surge Protection Valves Solenoid Valve Modulating Valve Glass Fuse 3 Amp Solenoid Valve 1 Solenoid Valve 2 Single Seated Valve Voltage DC90 V DC 90V Power Consumption Below 5 W Below 5 W Voltage 200mA Consumption Below 1 W ...

Page 27: ...n Fan rpm Convection Fan Line Flow Fan 110 328 Full Combustion High 3 5 460PTR 3 9 560PTR Low 2 5 High 800 460PTR 840 560PTR Low 550 Air Purifier Fan Sirocco 160 80 Boost 3 3 High 2 2 Med 1 8 Low 1 4 Boost 1100 High 740 Med 670 Low 600 Set Temp Range Room Temp Display Range Differential Thermistor 16 26oC 1 30oC Approx 0 5oC Input Detectable Particle Diameter Detectable Density Range AC 5V DC 5V a...

Page 28: ...a infra red light is scattered and the sections of scat tered light are gathered with the lens into the Photo Tr 4 The Photo TR converts scattered light into electrical signals The signal is then processed within the circuit emitting a dust signal Combustion Burner Combustion Chamber Combustion Box Type Combustion Type Burner Port Shape Qty Material Main burner Bunsen Slit 1 Heat Resistant Stainle...

Page 29: ...Convector 460 560PTR 24 Rinnai ...

Page 30: ...of 50 sec 33 Operation Comb Ind flashes red 34 31 Operation Comb Ind flashes red 32 Operation Comb Ind flashes red 11 62 Operation Comb Ind flashes red 12 Cause eliminated Power Point OFF All indicators OFF ON OFF Switch OFF C M OFF C M OFF After max 255 sec Disconnection Short circuit C M med ON SV1 SV2 OFF POV OFF Disconnection Short circuit Conv motor OFF C M med OFF SV1 SV2 OFF POV OFF After 5...

Page 31: ... Temp 6Time SV1 SV2 OFF POV OFF C M med OFF Timer Ind illuminates Operation comb Ind illuminates Green C M OFF Pre heat time Timer Indicator flashes When Timer 1 or Timer 2 is set up the heater will operate 1 cycle per day Within dotted line Then Timer 1 and Timer 2 are set up the heater will operate 2 cycles per day Within dotted line Dust Ind lluminates Orange All Indicators OFF Combustion A B N...

Page 32: ...5 Detection of Loose Primary Filter Check Primary Filter 11 Mis ignition Check Thermocouple Output 12 Incomplete Combustion Activation Flame Failure Check Thermocouple Output 14 Overheat Thermistor Activation Check Overheat Thermistor 14 Reverse Flame Safety Device Check Reverse Flame Sensor Switch 14 Thermal Fuse Melted Check Thermal Fuse 16 High Temp Cut off 10 minutes at 40 C Check Room Tempera...

Page 33: ...s Initialisation of E2 PROM While the unit is OFF press all three buttons and override simultaneously for at least 2 5 seconds The digital display will go out and 88 88 will be displayed when resetting has been com pleted then will be displayed Additional combustion time combustion rpm and additional air purifier operation time will not be reset Note 1 This operation time will be displayed as the ...

Page 34: ...it is OFF and with the test button ON the present gas type code will be displayed The gas type code will change with the and temperature buttons a When the button is pressed b When the button is pressed The gas type code will be stored in memory if the test button is pressed again Permanent Data Modulating Valve Current Supplement Value Fan Current Supplement Value Estimated Combustion Time Combus...

Page 35: ...ons After adjusting the data will be stored when Timer 1 is switched ON Decision Level Adjustment Mode The maximum flame failure detection level can be adjusted with the temperature button and the mini mum with the temperature button They can be set in the following order 12mV 14mV 16mV 18mV After adjusting the data will be stored when Timer 1 is switched ON Sensitivity Selection Mode The sensitiv...

Page 36: ...he LED display the level The third and fourth digits of the LED display the entered data The first and second digits will display The third and fourth digits will display 3 Low Pressure Mode 4 High Pressure Mode Gas Type NG LPG Gas Type Code 13 LP Displayed 5 second test delay Level 1 Level 12 for no entry for gas type for low pressure for high pressure for standard level ...

Page 37: ...inuously then the Heat button 2 Display Contents The set values for the Appliance Type Code Gas Type Code Flame Failure Detection Level Dust Sensor Level will be displayed in that order at 2 5 second intervals 3 Display Contents Information a Appliance Type Code b Gas Type Code c Flame Failure Detection Level Values 12mV 14mV 16mV 18mV RCE 560 PTR RCE 460 PTR For NG For LP 12mV 14mV 16mV 18mV High...

Page 38: ...560PTR 33 Rinnai An example of High Flame Failure Detection Level 12mV and Low Flame Failure Detection Level 18mV d Dust Sensor Level e Afterwards it will revert back to the normal temperature display Level 1 Level 2 ...

Page 39: ...rpm 0 4Hz red black DC 4 6V 7 K white white AC 90 110V Sparker 8 K brown brown DC 80 100V Solenoid Valve K1 brown brown yellow yellow 2 0 3 0k K2 yellow yellow 2 0 3 0k 9 G red white 36 37 Hi Lo DC 0 1 2 0V Modulating Solenoid Valve 16 26 10 G2 white white 10 C 115 135k 20 C 70 85k 40 C 25 40k Overheat Thermistor 11 F yellow yellow 10 C 58 73k 20 C 33 44k 40 C 9 19k Room Temp Thermistor 12 E black...

Page 40: ... DC 0 8 2 2V orange red DC 1 1 2 5V 16 C white white 1 ON Micro Switch Wire Colour No Measurement Value grey grey AC 207 264V 33 45 white white AC 90 110V 8 20 blue blue AC 8 12V 1 4 brown brown AC 8 12V 1 4 violet voilet AC 10 15V 0 5 2 black black AC 3 7V 0 5 2 Gas Type High Low 460PTR NG 800 550 LPG 870 480 560PTR NG 840 550 LPG 950 480 Ω Ω Ω Ω Ω Ω Ω Ω Ω ...

Page 41: ...ir filter 3 Warm air outlet short circuit obstruction 4 Inadequate gas supply 1 Flame Failure Error Code 12 Error Code 14 Error Code 00 When power is restored after power failure Insufficient ventilation 5 Blocked air filter 3 Power failure Warm air outlet short circuit obstruction 4 Check gas type Strong wind against appliance Inadequate gas supply pipe bent crimped 1 Reverse flame 7 There is a s...

Page 42: ...does not warm up Extinguishes suddenly Are there any obstructions in front of the warm air outlet Error Code 14 YDo not cover or place any obstructing objects within 1 m of the warm air outlet 5 Insufficient Ventilation Extinguishes suddenly Is the room sufficiently ventilated Error Code 12 YDuring use ventilate the room every hour by turning on a fan for 1 minute or by opening a window 6 Exhaust ...

Page 43: ...ound The extent of the sound will depend on gas pressure and burner temperature Sound is of re ignition straight after extinction Resonant sound after ignition Movement of the flame as it travels across the burner This will soon go After ignition extinction there is a ticking or clicking noise This is the sound of the combustion chamber metal expanding contracting due to heat and is normal The hea...

Page 44: ...ectrical supply YES 1 Confirm the connection at the wall socket 2 Is the 3 amp fuse blown a The sequence does not continue 1 Broken wiring or loose pin connectors Open circuit 2 Faulty control panel PCB Heater ON OFF button 3 Faulty PCB 4 Thermal fuse has melted Error Code 14 Normal Value 0Ω Melts at 216 C Normal Value AC90 110V Normal Value AC90 110V Normal Value AC90 110V Normal Value 0 125V 3A ...

Page 45: ...rted 3 Faulty PCB No DC90V circuit to solenoid d There is no spark 1 High tension cord disconnected or broken 2 Leak due to broken electrode etc 3 Incorrect spark gap Normal spark electrode gap is 2 2 3 0 mm 4 Faulty PCB 0 1 2 3 1 1 Air is in the gas supply 2 Incorrect gas pressure primary 3 Incorrect gas type or kink in the gas supply hose or the hose is too long 4 Faulty sparker 5 Blocked inject...

Page 46: ... stops and miss ignition occurs Confirm thermocouple output 1 Check combustion specification gas type and gas pressure 2 Check the combustion 3 Check thermocouple is firmly fixed 4 Check the thermocouple for short circuit breakage 5 Check the thermocouple height specification varies depending on the gas type Faulty PCB 1 Faulty indicator 2 Faulty PCB Is the output NG 14mV LP 16mV DC or above No mi...

Page 47: ...ken or pin connectors loose Measure the output at High and Low combustion YES NO Safety devices are activated Flame failure occurs between 30 minutes to 1 hour after ignition Error code 12 Incomplete combustion prevention device ODS possibly early cut off Check thermocouple output Confirm thermocouple output mV is stable and as shown in the table below High Combustion Low Combustion LP 20 mV 20 mV...

Page 48: ...nnectors Open circuit 2 Faulty control panel PCB Air Purifier ON OFF button 3 Faulty PCB 4 Loose primary filter Error code 05 b The air purifier fan does not begin to rotate 1 Air purifier fan shaft grub screw loose 2 An obstruction in the air purifier fan is preventing the fan from rotating 3 Open circuit or bad connection in motor circuit 4 Faulty PCB YES Normal Value AC90 110V Normal Value 0 12...

Page 49: ...ar opening 2 Press the air purifier button to turn it ON The dust indicator will illuminate green If the power cord has just been plugged in carry out this step after one minute has passed 3 After at least 20 seconds has passed face the remote control in the direction of the triangular opening and press the volume buttons continuously for 10 20 seconds 4 Within 20 seconds the dust indicator will c...

Page 50: ...ch from the burner and replace 2 screws 9 Remove the secondary aeration cover 6 screws 10 Remove the electrode 2 screws and burner blanking plate and fit to the new burner 11 Fit restrictor to new burner assembly 12 Refit the new burner to the combustion chamber 13 Refit Thermocouple with spacer A B fold on bracket facing to the right see diagram below 14 Replace the blanking plate electrode assem...

Page 51: ... low pres sure test data will be stored in memory e Next press the test switch twice The unit will go into high pressure test mode PH will be shown on the left side of the display f Adjust high combustion secondary pressure with the and buttons g Press the ON Timer button When the left side of the display changes to 12 the high com bustion test data will be stored in memory If the test switch and ...

Page 52: ... Transformer 49 6 Removal of the Dust Sensor 49 7 Removal of the Surge Protector and Sparker Unit 50 8 Removal of the Overheat Switch 50 9 Removal of the Thermocouple 50 10 Removal of the PCB 51 11 Removal of the Gas Control Assembly 51 12 Removal of the Heater Filter 51 13 Removal of the Convection Fan Assy 52 14 Removal of the Combustion Chamber 52 15 Removal of the Spark Electrode 53 16 Removal...

Page 53: ...efer to section 3 Removal of Front Panel d Remove the screw from the indicator and dis engage the two 2 clips from the securing bracket e Disconnect 3 three wiring loom connectors from PCB 3 Removal of the Front Panel CAUTION 240 Volt exposure Isolate the electrical supply to the appliance and reconfirm with the neon screwdriver or multimeter a Remove three 3 bottom screws 1 on each side 1 at fron...

Page 54: ... or multimeter a Follow section 3 Removal of the Front Panel b Remove one 1 screw from the right hand bracket c Disconnect 3 connectors main PCB surge protector and dust sensor Follow section 6 to remove dust sensor d Disengage transformer 6 Removal of the Dust Sensor CAUTION 240 Volt exposure Isolate the electrical supply to the appliance and reconfirm with the neon screwdriver or multimeter a Fo...

Page 55: ...er unit comes complete with wiring loom for solenoids as shown below 8 Removal of the Overheat Switch CAUTION 240 Volt exposure Isolate the electrical supply to the appliance and reconfirm with the neon screwdriver or multimeter a Follow section 3 Removal of the Front Panel b Remove surge protector sparker assy c Remove the two 2 screws from the OHS 9 Removal of the Thermocouple CAUTION 240 Volt e...

Page 56: ...Volt exposure Isolate the electrical supply to the appliance and reconfirm with the neon screwdriver or multimeter a Follow section 3 Removal of the Front Panel b Disconnect the gas supply hose at the rear of the appliance c Remove one 1 screw from the front of the gas supply tube upper to remove Note Don t lose O rings from gas tube d Remove two 2 screws from front of the gas supply tube lower e ...

Page 57: ...d and disconnect wires from PCB 14 Removal of the Combustion Chamber CAUTION 240 Volt exposure Isolate the electrical supply to the appliance and reconfirm with the neon screwdriver or multimeter a Follow section 3 Removal of the Front Panel b Remove heater filter follow section 12 c Remove two 2 screws from the rear of the appliance middle d Remove the surge protector and sparker unit Follow sect...

Page 58: ...e appliance and reconfirm with the neon screwdriver or multimeter a Follow section 3 Removal of the Front Panel b Follow section 14 Removal of the Combus tion Chamber c Remove the spark electrode Follow section 15 d Follow section 8 c Removal of the Overheat Switch e Remove one 1 screw from the locating bracket top f Lift and remove locating bracket g Remove one 1 screw from the other end of the c...

Page 59: ...sconnect from the PCB 18 Removal of the Injector a Follow section 3 Removal of the Front Panel b Remove four 4 screws 2 from bracket 2 from injector block c Remove one 1 screw from gas tube upper d Disengage the gas supply tube top and bot tom e Remove the injector block and pull the injec tor free Note Remove the o rings and fit them onto the pipes before refitting ...

Page 60: ...Convector 460 560PTR 55 Rinnai 9 Legend bl blue r red w white y yellow v violet bk black gy grey or orange br brown gr green ...

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Page 70: ...Convector 460 560PTR 65 Rinnai ...

Page 71: ...7 7 AUSTRALIA PTY LTD A C N 005 138 769 10 11 Walker Street Braeside VIC 3195 0 1 2 3 4 5 3 2 3 0 5 6 4 7 860 NEW ZEALAND LTD 9 1 2 1 1 2 3 ...

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