Rinnai FUA-E Service Manual Download | Manualshive

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Summary of Contents for FUA-E

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Page 2: ...ter heater is CE Marked as allowed by Technigas Certificate number E0940 5399 ID number 0461BQ0836 Date of Issue 23 Dec 2005 Quality System Standard ISO 9001 1994 The Design Development and Manufacture of Gas Water Heating Appliances done under Rinnai s Quality Management System is certified under the Quality Management System Standard ISO 9001 Registration Number JQ0003D Registered since February...

Page 3: ...rosecution Other persons should NOT attempt to install this equipment 2 Installation must be in accordance with the current issue of the following Building Regulations issued by the Department of the Environment Building Standards Scotland Regulations I E E Wiring regulations for electrical installations Gas safety Installation and Use Regulations current issue BS 5546 BS 5440 BS 6891 BS 5482 BS 6...

Page 4: ...sure vs Flow 16 Gas Conversion Procedure 17 Testing 19 Gas Pressure Setting 20 Dip Switch Setting 22 Troubleshooting the Infinity 16i 23 Remotes 24 Operational Flow Chart 25 Time Charts 26 Error Codes 27 Diagnostic Checks 29 Fault Finding Chart 39 Wiring Diagram 46 Diagnostic Points 47 Servicing Procedure 48 Dismantling for Service 49 Exploded Diagram 56 Parts List 61 Letter of Compliance 65 CE Ce...

Page 5: ...5 Glossary of Terms and Symbols ...

Page 6: ...ure of outgoing hot water is CONSTANTLY MONITORED by a BUILT IN SENSOR If the temperature of the outgoing hot water rises to more than 55 C the burner is shut OFF and only turned ON again when the temperature falls to below the selected temperature The burner lights automatically when the hot water tap is opened and extinguishes when the tap is closed IGNITION IS ELECTRONIC so there is no pilot li...

Page 7: ...Fusible Link 150 C Thermal Fuse Over temperature Lockout Thermistor 95 C Heater Mounted MC 45 SR EU Remote Controls Kitchen BC 45 SR EU or BSC 45 SR EU Bathroom BC 45 SR EU or BSC 45 SR EU Remote Cable Two core sheathed double insulated flex with min 0 55 mm2 G20 Nat Gas Press Low 1 8 mbar G20 Nat Gas Press High 9 0 mbar G25 Nat Gas Press Low 1 8 mbar G25 Nat Gas Press High 9 0 mbar G30 LPG Butane...

Page 8: ...cessive inlet pressure Opens at 15 bar closes at 12 bar Electrical Fuse 3A glass fuse prevents against over current Surge Protector prevents against over current Boil Dry Prevention If water flow sensor detects no flow gas supply is stopped Combustion Fan Speed Sensor In case of combustion fan defect no rotation of fan gas supply is stopped Temperature Cutout If the delivered hot water temperature...

Page 9: ...9 Dimensions ...

Page 10: ...e 2 are opened and the Burner lights The Flame Rod will ensure proper burning before Changeover Solenoid Valve 1 will open Temperature Setting With the Temperature Control Buttons on the controller the outlet temperature can be set from 37 60 When the temperature set point is above 50 the High Temperature Indicator glows Temperature can not be set above 48 while hot water is in use flowing The uni...

Page 11: ...11 Structure Diagram ...

Page 12: ...ner more steady combustion at the required capacity and allows the water heater to operate at very low flow rates and temperature rises 2 Flame Rod Monitors combustion characteristics inside the combustion chamber If the flame fails gas supply is stopped Works through rectification of the combustion flame An AC current is supplied to the flame rod Electrons can only pass from the rod to the burner...

Page 13: ...e PCB depending on the hot water flow and temperature The fan speed is compared to the current required to attain that speed for air proving If the fan current is over or under the parameters for the given speed the unit will shut down on air proving 6 Water Volume Servo with Water Flow Sensor 6 1 Water Flow Sensor Water flow sensing is done with a small turbine that spins when water travels throu...

Page 14: ...4 2 x 10 40 l min Since 40 is greater than 20 this flow rate must be mixed at the outlet How to read the charts on the following page The vertical axis indicates the selected temperature on the remote control and the horizontal axis indicates the flow of water in litres minute Remote control range is between 370 C and 600 C under normal conditions temperatures up to 750 C may be available if set o...

Page 15: ...4 L min min Flow Incoming Water Temp 10C 0 10 20 30 40 50 60 70 80 0 5 10 15 20 Hot Water Flowrate L min Hot Water Outlet Temp C I 2 4 L min min Flow Incoming Water Temp 20C 0 10 20 30 40 50 60 70 80 0 5 10 15 20 25 Hot Water Flowrate L min Hot Water Outlet Temp C I 2 4 L min min Flow I 20 L min max Flow Water Flow ...

Page 16: ...ter flow regulator that will throttle the flow rate back to make sure that the unit only supplies water at the required temperature If demand exceeds the capacity of the unit the unit will limit the water flow so the temperature does not alter The water heater s heat exchanger has a much higher pressure drop at high flow rates then at low flow rates For low pressure installations use higher temper...

Page 17: ...17 Gas Conversion Procedure ...

Page 18: ...18 Gas Conversion Procedure ...

Page 19: ... check the pressure at the test point on the inlet to the gas valve The pressure must be within the local defined limits for the type of gas that is being used If the pressure is lower the gas supply is inadequate and the water heater will not operate to specification Check gas meter regulator and pipework for correct operation sizing and rectify as required Note that the gas regulator on the appl...

Page 20: ...Fig 1 On is in the right hand position Off is in the left hand position 5 Attach pressure gauge to burner test point Fig 2 6 Turn ON the gas supply 7 Turn ON 230V power supply 8 If remote controllers are fitted turn the unit ON at the controller and select a maximum delivery temperature 9 Open a hot water tap fully CAUTION Ensure building occupants do not have access to hot water outlets during th...

Page 21: ...ery sensitive turn no more than a few degrees at a time then let the pressure settle down before turning it more 16 IMPORTANT Set dip switch no 7 and no 8 to OFF to return the appliance to Normal combustion 17 Close hot water tap 18 Turn OFF the gas supply and 230V power supply 19 Remove pressure gauge and replace sealing screw 20 Turn ON the gas supply and 230V power supply 21 Operate unit and ch...

Page 22: ...mbustion OFF ON 8 Combustion Dip Switches Explained GAS TYPE COMBUSTION LPG NAT GAS NORMAL OFF ON SW OFF ON SW OFF ON SW 1 off 1 on 7 off 2 off 2 off 8 off FORCED LOW COMPUTER PROGRAMMING OFF ON SW 7 on OFF ON SW 8 off 1 Computer programming 2 Switches 3 5 must be left FORCED HIGH 3 in the factory set position 4 for the Infinity 16i OFF ON SW 5 7 on 6 8 on 7 8 MAXIMUM TEMPERATURE OFF ON 4 Maximum ...

Page 23: ...out any user involvement Single or multiple water heaters with remote controllers The heaters will be required to be switched on using the ON OFF button on a remote controller Ensure that all taps water outlets are closed and no water is flowing through heaters Hot water system incorporating secondary recirculation pump Single or multiple water heaters without remote controllers The heater s will ...

Page 24: ...ower Button The flow will be displayed in L min Therefore 4 4 L min and 12 12 L min The Remote will also display the outgoing hot water thermistor read temperature by holding down the Temp Down Arrow Button and pressing the Power Button The temperature is shown in degrees Centigrade Remotes Digital Monitor Indicates the tem perature selected Error message flashes in the event of a fault Priority B...

Page 25: ...25 Operational Flow Chart ...

Page 26: ...26 Time Charts ...

Page 27: ...mal overload wire E incl Overheat switch black tophat style bi metal E Check Gas Type Dip Switches for Nat Gas or LPG manual Check gas pressure manual Check combustion dip switch manual 16 Over temp warning Unit operates then stops Check Gas Type Dip Switches for Nat Gas or LPG manual Check modulating solenoid valve D Check gas pressure manual Check combustion dip switch manual Check water flow se...

Page 28: ...t is on visual Check Gas Supply is okay S Check Flame Rod C Check Flue V Check Earth Wire H Check Power supply voltage N Cannot adjust the hot water tem perature via the controllers only if controllers are installed Check hot water outlet thermistor K Check Heat Ex outlet temperature thermistor K Check Gas Valves are open visual Check water flow servo G Check Non Return Valves and Mixers in System...

Page 29: ...he air outlet duct 2 in front one each side and take the fan out the left side of the heater B Ignition System The best check for the ignition electrode and sparker is to listen to the unit for the ticking sound as it sparks If it is ticking the sparker sub pcb is working Remove the electrode and visually inspect for damage Be sure to check the burner where the electrode should spark to The spark ...

Page 30: ...nd various points at the sensor end Check this while holding the ceramic insulator As the flame rod is metal the continuity should be very good throughout the whole length If the continuity is not strong then clean the flame rod with steel wool or emery cloth until there is continuity through the whole length of the flame rod With the unit in standby measure the voltage AC between the flame rod co...

Page 31: ...While the unit is lit put the leads into the plug and measure the voltage DC Only the Main SV and SV1 will open upon ignition SV2 will not have voltage unless the unit is on medium to high fire Main SV Pink Black 200 240 Vdc appx 6 5 k Ohms SV1 Black Blue 200 240 Vdc appx 8 0 k Ohms SV2 Black Yellow 200 240 Vdc appx 8 0 k Ohms Modu SV Pink Pink 2 15 Vdc 67 83 Ohms If the voltage is incorrect repla...

Page 32: ... the red wire from connector C and the other lead into the half of Connector A5 that is attached to the bimetal switch Measure the resistance through this overheat circuit Resistance should be less than 1 Ohm If the resistance is greater than 1 Ohm test each individual sensor to find which one is faulty and replace it AFTER checking the heater for damage Check that the gas type and combustion dip ...

Page 33: ...ack 4 6 Vdc Incorrect replace flow servo motor Red Blue 11 13 Vdc Voltage only present when servo is should be moving To remove the flow servo first unclip the cold water pipe in the unit two screws and pull out the copper pipe connection Bend this out of the way gently Then remove four screws from underneath Now remove the flow servo full assembly H Earth Lead Check to make sure that all earth le...

Page 34: ... but the unit does not start the sensor is faulty If it is not spinning it may need freeing up If its spins and the unit starts then there is a water flow problem no water is flowing through the unit Check that the unit is not piped up with cold flow into the hot outlet K Thermistors Check all thermistors by unplugging thermistor lead and inserting meter ends into both sides of thermistor plug and...

Page 35: ...hot water outlet and the valve that has been isolated the only water that will travel through the water heater will be mains water at fairly constant temperature Measure the outlet temperature at this drain off point If the temperature is constant and correct for the setpoint then the water heater is working as it should and you need to find the mixing valve or non return valve that is faulty It i...

Page 36: ...ite White 200 240 Vac If incorrect confirm power to pcb then replace pcb 11 20 Ohms If incorrect replace transformer Conn D Brown Blue 12 14 Vac 0 7 1 3 Ohms Yellow Blue 200 240 Vac Orange Orange 50 60 Vac If any of these are incorrect replace the transformer assuming the White White voltage is correct Q Filter Below the water heater on the cold water connection is a brown or black plug Isolate th...

Page 37: ... supply This is easy when operating on natural gas and is done by checking the inlet pressure Other things to check are the meter size compared to other appliances total offtakes If the unit has just been installed there may be air in the line be sure it is fully purged If the unit is on LPG make sure that you visually examine the tank or bottles to be sure they are not freezing up If they are the...

Page 38: ...is located at the top left of the heat exchanger It is a black top hat style bi metal switch It is a normally open contact so to prove it is working it must be cooled to about 5 C At this temperature the resistance in the switch can be tested it should be less than 1 Ohm V Check Flue If there are combustion problems they could be due to the flue Is the flue too long The maximum flue run is 6 5m le...

Page 39: ...39 Diagnostic Checks Fault Finding Chart ...

Page 40: ...40 Fault Finding Chart ...

Page 41: ...41 Fault Finding Chart ...

Page 42: ...42 Fault Finding Chart ...

Page 43: ...43 Fault Finding Chart ...

Page 44: ...44 Fault Finding Chart ...

Page 45: ...45 Fault Finding Chart ...

Page 46: ...46 Wiring Diagram ...

Page 47: ... B1 R Bk DC6 40V fan on More than 1200 pulse min Y Bk DC11 13V standby or on W Bk DC2 10V pulse 20 400Hz fan on FLAME ROD C2 Y earth More than DC1μA At ignition HOT WATER THERMISTOR A4 W W 15 11 4 14 0kΩ 30 6 4 7 8kΩ 45 3 6 4 5kΩ 60 2 2 2 7kΩ 105 0 6 0 8kΩ Measure Thermis tor side small wire AIR INTAKE THERMISTOR A3 Y Bk Y 15 20 1 17 9kΩ 30 10 2 8 9kΩ 45 5 5 4 7kΩ 60 3 1 2 6kΩ 105 0 7 0 5kΩ Measur...

Page 48: ...nisation and ignition probes Check flue terminal for blockages or potential blockages check that flue is in good condition Check all electrical connections are reconnected The gas pressures should then be re set The procedure is detailed in the manual Verify temperature control by checking temperature at outlet bear in mind that there will be pipework losses Check all gas joints inside the unit wi...

Page 49: ...49 Dismantling for Service ...

Page 50: ...50 Dismantling for Service ...

Page 51: ...51 Dismantling for Service ...

Page 52: ...52 Dismantling for Service ...

Page 53: ...53 Dismantling for Service ...

Page 54: ...54 Dismantling for Service ...

Page 55: ...55 Dismantling for Service ...

Page 56: ...56 Exploded Diagram ...

Page 57: ...57 Exploded Diagram ...

Page 58: ...58 Exploded Diagram ...

Page 59: ...59 Exploded Diagram ...

Page 60: ...60 Exploded Diagram ...

Page 61: ...61 Parts List ...

Page 62: ...62 Parts List ...

Page 63: ...63 Parts List ...

Page 64: ...64 Parts List ...

Page 65: ...65 Letter of Compliance ...

Page 66: ...66 CE Certificate ...

Page 67: ......

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