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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

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Summary of Contents for RHFE-431WTA

Page 1: ...1FA 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 ...

Page 2: ...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 a...

Page 3: ...d 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 WARN...

Page 4: ...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 ...

Page 5: ...on 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 d...

Page 6: ... 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 displa...

Page 7: ... 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 exa...

Page 8: ... 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 ai...

Page 9: ...mage 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 ...

Page 10: ...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 Ev...

Page 11: ...g this product Extreme care should be used at all times to avoid contact with energized components inside the furnace You MUST be a qualified service person before proceeding with these test instructions Before checking resistance readings turn off power source to unit and then isolate each item to be checked from the circuit by unplugging it When setting gas pressures on one of these units please...

Page 12: ...8 F 39 k ohms 86 F 23 k ohms FR Flame Rod Flame rod yellow wire pin 27 Low fire current should be 1 3 to 2 0 micro amps Fa High fire current should be 4 to 8 micro amps depending on gas type being used NOTE Improperly setup and or converted units can soot and cause carbon to accumulate on flame rods This will cause hard lockouts If carbon is found on the flame rod remove and clean carbon from rod ...

Page 13: ...ess the on off button and you should be able to read continuity through this switch each time the button is pressed TB Terminal Block This terminal is located on the right rear upper portion of the unit On direct vents the jumper should be across terminals 2 and 3 On units with vent extensions over four feet this jumper should be across terminals 1 and 2 IMPORTANT INFORMATION CONCERNING HARD LOCKO...

Page 14: ...14 Rinnai Direct Vent Service Manual RHFE 431FA Series RHFE 556FA FTRA Wire Diagram ...

Page 15: ...Rinnai Direct Vent Service Manual 15 RHFE 556FAIII Wire Diagram ...

Page 16: ...16 Rinnai Direct Vent Service Manual RHFE 556FTRAIII Wire Diagram ...

Page 17: ... RHFE 431FA natural gas units are 1 15mm or 0 045 part AU129 210x02 1 15 Orifice sizes for the RHFE 431FA II natural gas units are 1 00mm or 0 039 part AU129x210x02 1 00 Orifice size for the RHFE 431FA III natural gas units are 1 13mm or 0 044 part AU129 210x02 1 13 5 Ensure gas type listed on rating plate matches gas type connected to unit 6 Check for proper dip switch settings on PC board Proper...

Page 18: ...s not exceed thirteen feet and two elbows Maximum vertical run is eight feet then the vent must run horizontal 13 Ensure jumper for vent extension on rear of your unit is connected to proper terminals Terminals 2 and 3 are for direct vent terminals 1 and 2 are used for vent extension of four feet or more 14 Check thermistor by inserting meter leads into each end of the thermistor plug Set your met...

Page 19: ...witch 2 ON switch 3 OFF and switch 4 OFF Proper settings for the RHFE 556FA and the RHFE 556FTRA natural gas units is switch 1 is OFF switch 2 ON switch 3 OFF and switch 4 OFF Proper settings for the RHFE 556FA III and the RHFE 556FTRA III natural gas unit is switch 1 is OFF switch 2 OFF switch 3 OFF and switch 4 OFF 7 Inspect wall vent to ensure it is not clogged or restricted in any way For prop...

Page 20: ...f the thermistor plug Set your meter to the 200k scale and read resistance You should be able to apply heat to the thermistor bulb and see the resistance decrease then place some ice to thermistor and the resistance should increase 15 Check flame rod circuit on low fire Cycle unit down to low flame for ten minutes then take flame circuit reading The reading should be above 1 2 micro amps 16 Ensure...

Page 21: ... ohms 22 23 Blue Yellow 130 185 VAC 200 400 ohms 23 32 Grey Grey 110 120 VAC 10 14 ohms 17 18 Purple Purple 4 5 5 5 VAC 1 2 ohms 24 25 Black Yellow 165 185 VAC 200 212 ohms 22 32 Brown Purple 2 2 2 8 VAC 0 7 1 2 ohms 24 28 Blue Red 85 110 VAC see below 33 36 WIRE COLOR VOLTAGE RESISTANCE READING PIN NUMBERS WARNING There are a number of live tests that are required when fault finding this product ...

Page 22: ... apply heat to the thermistor bulb and see the resistance decrease Then apply ice to the thermistor bulb and the resistance should increase Pins 5 and 6 on the P C board EXAMPLES 41 ºF 91 k ohms 50 ºF 65 k ohms 68 ºF 39 k ohms 86 ºF 23 k ohms FM Convection fan motor RHFE 431 LP UNITS RHFE 556 LP UNITS Lo fire 46 Hz Lo fire 47 Hz Hi fire 82 Hz Hi fire 106 Hz RHFE 431 NG UNITS RHFE 556 NG UNITS Lo f...

Page 23: ...ans one of these switch thermal fuses is open Isolate the open switch or thermal fuse and replace the defective component OH TH Overheat Thermistor Check resistance reading across pins 9 and 10 at terminal A on the PC board Proper readings should be 0 6 k and 523 k A reading below 0 6 k ohms indicates a short and a reading above 523k indicates an open circuit IMPORTANT INFORMATION CONCERNING HARD ...

Page 24: ...24 Rinnai Direct Vent Service Manual RHFE 431WTA Wire Diagram ...

Page 25: ...Rinnai Direct Vent Service Manual 25 RHFE 556WTA Wire Diagram ...

Page 26: ...31WTA propane gas units are 0 85mm or 0 033 part AU129 210x02 0 85 Orifice sizes for the RHFE556 431WTA natural gas are 1 13mm or 0 044 part AU129 210x02 1 13 5 Ensure gas type listed on rating plate matches gas type connected to unit 6 Check for proper dip switch settings on PC board ___ Proper settings for the RHFE 556WTA propane gas units are switch 1 is ON switch 2 is OFF switch 3 is OFF switc...

Page 27: ...or 0 5 2 4 ohms Across the blue and yellow wires pins 23 and 32 you should have 130 185 VAC or 200 400 ohms Across the two gray wires pins 17 and 18 you should have 110 120 VAC or 10 14 ohms ___ Across the two purple wires pins 24 and 25 you should have 4 5 6 VAC or 1 2 ohms ___ Across the purple and brown wires pins 24 and 28 you should have 2 3 VAC ___ Across the black and yellow wires pins22 an...

Page 28: ... to ignite 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 You MUST be a qualified service person before proceeding with these test instructions Before checking resistance readings turn off power source to unit and then isolate each item to be checked fr...

Page 29: ...ry side 16 21 ohms Red Black 98 105 secondary side 24 29 ohms TR1 Transformer PS Pressure switch White Ground Check from both white wires to ground to ensure circuit is complete 9 12 VDC In order to eliminate this switch as a cause of failure shut the power off to the unit and jump out this switch Restart unit If it functions replace air pressure switch RT Slide temperature control To check slide ...

Page 30: ... transformer TR1 Set your meter to read continuity Turn the control knob to the on position You should read continuity through the safety circuit at this time If not you need to confirm which switch is defective and replace that component To check voltage through the safety circuit place your leads in the black wire connection at transformer TR1 and the grey wire connection at the nine pin connect...

Page 31: ...Rinnai Direct Vent Service Manual 31 RHFE 551FA Wire Diagram ...

Page 32: ...peed 95 105 VAC 100 140 ohms 18 26 White black hi speed 95 105 VAC 42 62 ohms 18 25 TR1 Transformer Black White primary 110 125 VAC 19 20 ohms n a Grey Grey secondary 95 105 VAC 19 20 ohms n a 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 You MUST be a...

Page 33: ...setup and or converted units can soot and cause hard lockouts If carbon is found on any one flame rod remove all three rods and clean carbon from them Then you need to confirm your manifold gas pressure and air rod settings Also check to ensure proper orifices were placed in the unit IMPORTANT INFORMATION CONCERNING HARD LOCKOUTS Other items that can cause hard lockouts are improper sized gas line...

Page 34: ...34 Rinnai Direct Vent Service Manual RHFE 1001FA Wire Diagram ...

Page 35: ...95 105 VAC 100 140 ohms 26 28 White black hi speed 95 105 VAC 42 62 ohms 27 28 TR1 Transformer Black White primary 110 125 VAC 19 20 ohms n a Grey Grey secondary 95 105 VAC 19 20 ohms n a 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 You MUST be a qual...

Page 36: ... Low fire flame current should be 1 2 to 2 0 micro amps The micro symbol on your meter will look like this µ Improperly setup and or converted units can soot and cause hard lockouts If carbon is found on any one flame rod remove all three rods and clean carbon from them Then you need to confirm your manifold gas pressure and air rod settings Also check to ensure proper orifices were placed in the ...

Page 37: ...Rinnai Direct Vent Service Manual 37 RHFE 1001FA VA Wire Diagram Wire Diagram Block Diagram ...

Page 38: ...s and inspect for cracks and or carbon buildup Clean flame rods and electrode with some type sandpaper Also check electrode for proper gap setting 0 12 0 16 7 Check all wire connections for loose or broken pins or connectors Disconnect electrical power before performing this task 8 Check resistance on all three gas valve solenoids Unplug each coil before checking resistance Set you meter on the 2K...

Page 39: ...tor operation by inserting meter leads into each end of thermistor plug Disconnect yellow to yellow from PCB set your meter on the 200K scale Your should be able to apply heat to the thermistor bulb and see resistances decrease Place some ice on thermistor bulb and resistances should increase 10 Check current on all flame rods ___RHFE 551 FA only has one flame rod On the low burner this current sh...

Page 40: ... across Voltage Potential Read resistance Pin Numbers Black Yellow 85 90 VDC 700 1000 Ω Pin 1 4 Resistance across each coils terminals should be 1400 2000 Ω when isolated POV Modulating Gas Valve Connector G Read voltage across Voltage Potential Read resistance Pin Numbers Grey Grey 6 16 VDC 80 90 Ω Pin 2 6 BL Combustion Blower Motor Connector G DC Motor 37VDC 8 Watts Read voltage across Voltage P...

Page 41: ...eter leads into Yellow to Yellow Apply heat to the thermistor bulb The resistance will decrease Apply cold and the resistance will increase Examples of readings 41ºF 91KΩ 50ºF 65KΩ 68ºF 39KΩ 86ºF 23KΩ OH TH Over Heat Thermistor Connector H Disconnect connector H from PCB Set your meter to the proper Ω scale Place your meter leads into White to White A reading below 0 38kΩ indicates a short A readi...

Page 42: ...42 Rinnai Direct Vent Service Manual RHFE 201FA Wire Diagram ...

Page 43: ...Rinnai Direct Vent Service Manual 43 RHFE 201FA Block Diagram ...

Page 44: ...4 Read voltage across Voltage Potential Read resistance Pin Numbers SV1 Yellow Black hold 85 90 VDC 1400 2000 Ω 1 4 SV2 Yellow Black assist 85 90 VDC 1400 2000 Ω 1 4 POV Gray Gray 6 16 VDC 80 90 Ω 2 6 Resistance across each coils terminals should be 1400 2000 Ω when isolated BL Combustion Fan Motor Connector CN8 DC Motor 37VDC 8 Watts Read voltage across Voltage Potential Read resistance Pin Numbe...

Page 45: ... converted units can soot and cause hard lockouts If carbon is found on the flame rod clean the carbon from it Then you need to confirm your manifold differential gas pressure on Hi fire and Lo fire is correct Insure primary and secondary air dampers are correct Also check to ensure proper orifices were placed in the unit IMPORTANT INFORMATION CONCERNING HARD LOCKOUTS Other items that can cause ha...

Page 46: ...46 Rinnai Direct Vent Service Manual RHFE 263FA RHFE 263FAII Wire Diagram ...

Page 47: ...Rinnai Direct Vent Service Manual 47 RHFE 263FA RHFE 263FAII Block Diagram ...

Page 48: ... Black Pink 85 90 VDC 1200 2000 Ω 2 5 POV Gray Gray 6 16 VDC 80 90 Ω 2 6 BL Combustion Fan Motor Connector CN8 DC Motor 37VDC 8 Watts Read voltage across Voltage Potential Read resistance Pin Numbers Black White 7 12 VDC 8 10 KΩ 7 8 Yellow White 4 5 VDC 4 6 KΩ 4 8 Red White 10 30 VDC N A 3 8 WARNING There are a number of live tests that are required when fault finding this product Extreme care sho...

Page 49: ...he electrode Low fire flame current should be 1 2 to 2 0 micro amps µ amps Improperly setup and or converted units can soot and cause hard lockouts If carbon is found on the flame rod clean the carbon from it Confirm that your manifold differential gas pressure on Hi fire and Lo fire is correct Insure primary and secondary air dampers are correct Check to ensure proper orifices were placed in the ...

Page 50: ...50 Rinnai Direct Vent Service Manual RHFE 1004FA Wire Diagram ...

Page 51: ...2000 ohms for SV3 Power unit back up and set your meter to read 100 VDC scale cycle unit and check voltage to each coil You should read 85 90 VDC at each coil If unit goes to lockout before you have time to read all coils you may have to cycle it two or three times 9 Ensure the air pressure switch is functioning properly Ohm out the micro switch located on the pressure switch Continuity will be re...

Page 52: ...ust be accessible All pipe stoppers connectors screws and hangars must be used as per the directions The seals must be air tight for both the exhaust and the intake air supply hose The intake air hose must equal the exhaust hose length to maintain a balanced flue system The 431 556 Series units have a terminal block on the back that must be changed as per directions for any extension set This term...

Page 53: ...d in 1999 Vent Kits for the RHFE 1001FA Series KIT NO WALL THICKNESS FOT 175 or 1001F 1670 3 to 4 1 2 FOT 176 or 1001F 1671 4 1 2 to 9 1 2 FOT 177 or 1001F 1672 9 1 2 to 15 3 4 FOT 178 or 1001F 1673 15 3 4 to 23 5 8 FOT 179 or 1001F 1674 23 5 8 to 31 1 2 Vent Extensions for the RHFE 263 431 556 Series KIT NO NAME FOT 155 Extension Set 20 FOT 156 Extension Set 40 FOT 157 Extension Set 80 FOT 158 El...

Page 54: ...lows operation up to 10 200 feet 3109 m The correct altitude is entered using switches on the PC board and the appliance control buttons When installing these models follow the Gas Pressure Setting Procedure for your model This procedure adjusts the gas input pressure and the PC board settings When replacing a PC board adjust the PC board settings according to the replacement part instructions Mod...

Page 55: ...st points CAUTION Do not touch any other areas on the PC board besides the SW switches while power is supplied to the appliance Parts of the PC board are supplied with 120 volts AC NOTE Some PC Boards before version ED 263 V6 E4 will have only L1 L2 A1 and A2 codes On these boards L2 and A2 are for altitudes above 2000 ft 610 m See the figure to locate the label indicating the version L1 Propane g...

Page 56: ...r gas type and altitude If necessary adjust the high fire pressure using the and buttons Press the SW1 switch to record into memory 17 Press the SW1 switch 2 times After pushing the SW1 switch 2 times the LED display will display 78 If the LED shows any thing other than 78 call Rinnai Technical Support at 1 800 621 9419 for assistance 18 Press the ON OFF button again The LED display turns blank an...

Page 57: ... is pushed The but ton increases the pressure each time it is pushed 7 Press the SW3 button to lock in the high pressure 8 Press the SW5 button to exit the programming mode and return the appliance to its normal operating mode 9 Press the ON OFF button to turn the appliance off 10 Remove manometer and install the test point screws Operate the unit and Normal Operating Sequence When you press the O...

Page 58: ...al and maintenance is required Visual Inspection of Flame Install the front panel and bottom cover Final Assembly NORMAL Flame Rod Long clear blue stable flames ABNORMAL Yellow flames or orange color Flame Rod Model Gas Type High Fire Low Fire 431 Series Natural Gas 2 4 in 61 mm 0 7 in 18 mm Propane 2 8 in 71 mm 0 8 in 20 mm Natural Gas 3 8 in 97 mm 0 7 in 18 mm Propane 4 5 in 114 mm 0 8 in 20 mm ...

Page 59: ...level altitude A2 Natural gas unit at high altitude 6 Press the SW1 test button to record the gas type code into memory The LED display turns blank and the unit returns to the normal off mode You are now ready to program in your correct low fire and high fire gas pressure setting Follow the procedure below for setting the manifold gas pressure Do not adjust gas pressure on this appliance using the...

Page 60: ...15 Press the ON OFF button again The LED display turns blank and the appliance returns to the normal OFF mode 17 Remove manometer and install Allen head screws Operate the unit and CAUTION Do not insert hands or objects into the circulation fans while they are running Injury or mechanical malfunction may occur CAUTION Do not touch the areas at or near the heat exchanger or burner These areas becom...

Page 61: ...L GAS RHFE 556WTA ON OFF PROPANE ON OFF NATURAL GAS RHFE 556FA FTRA Series ON OFF PROPANE ON OFF NATURAL GAS RHFE 431WTA ON OFF PROPANE ON OFF NATURAL GAS RHFE 431FA Series The other models RHFE 201FA RHFE 263FA Series RHFE 551FA RHFE 1001 Series and RHFE 1004FA do not have dip switches ...

Page 62: ...ro amps 3 Place the meter in series with the flame rod a the disconnected Molex 4 Operate the appliance and view the flame development in the view window 5 Read the micro amps on the meter for high fire and low fire conditions NOTE Volt meters differ in style and configuration It is the technician s responsibility to know the tools and how to set up for operations and testing ...

Page 63: ...ad the differential pressure add from zero upward and from zero downward Differential pressures must be re set if the PC board or gas control valve is replaced or if the appliance is converted for gas type ONE HOSE FROM U TUBE TO PRESSURE PORT ON BURNER MANIFOLD 1 8 NPT TAP ONE HOSE FROM U TUBE TO PRESSURE PORT ON GAS CONTROL VALVE 1 8 NPT TAP ...

Page 64: ...e flame and is used to determine flame presence The signal can only be produced by the flame Short circuits dirty contacts and other fault situations cannot simulate the rectified signal The FGA section of the PC board sends an amplified signal to the main PC board to indicate flame presence allowing the gas valves to remain open Temperature Resistance Resistance decreases as the temperature incre...

Page 65: ...e may come from the RHFE 1004FA using propane gas This harmonic noise can be attributed to varying gas compositions and is more prevalent on new tank sets that may still have high traces of methanol in the system The adjustments recommended are not detrimental to the operation of the appliance in any way PROCEDURE 1 Perform the Gas Pressure Setting Procedure During this procedure set the low fire ...

Page 66: ...ral gas unit at high altitude RHFE 201FA RHFE 263FA FAII RHFE 1004FA Removal of OF on New PC Board Installation 4 Press the SW1 test button to record the gas type code into memory The LED will display F1 If not shown use the and buttons to obtain F1 5 Press the Test button to enter this code into memory 6 The LED will display the temperature scale Use the and buttons to select the Fahrenheit or Ce...

Page 67: ...Rinnai Direct Vent Service Manual 67 Notes ...

Page 68: ...ai Systems Domestic Hot Water Priority Optional Programmable Thermostat Zero Clearance to Combustibles Accommodates Standard Cased Coils Direct Vent Fireplace RHFE 750ETR Up to 83 AFUE Energy Efficiency Zero Clearance Installation Available in Four Options of Fronts Remotes and Fan Included Gas Conversion Kit Available Tankless Water Heaters Residential and Commercial Applications Continuous Hot W...

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