Rinnai 1001T Service Manual

INTRODUCTION

* One

touch ON/OFF control.

*

Warm air distribution is from the bottom of the heater.

*

Three step automatic heat and fan control with the electronic thermostat.

*

Installation of the flue system requires only an 80 mm hole through a wall to the exterior of

the building.

*

The thermistor controls the room temperature within the range of 12.5 * 3°C to 35 + 7°C

with a differential of 1.5 +

*

In the event of a malfunction, one or more of the various safety devices will be activated,

ensuring complete safety.

OST.

The outer casing of the appliance is formed from 0.8 mm galvanised and painted steel, secured to the main body assembly. The bodywork is formed from 1.2 mm galvanised steel sheet, forming a casing to which the heat exchanger, blower assembly, solenoid valves, printed circuit board and other componentry is attached.

The general layout of components is shown in the cut-away diagram on page 9. The heat exchanger is composed of two (2) sub-heat exchangers which are constructed from 0.5 mm stainless steel sheet. A combustion chamber is connected to the sub-heat exchangers, which in turn are connected to the flue system.

The combustion chamber, constructed occupies the middle of the appliance. Its dimensions are 622 mm wide x 94 mm deep x 319 mm high. The burner is composed of two (2) large burners and one (1) small burner. The large burners are slit port

0.5 x 7 mm, and the number of slits is 103 for each burner. The small burner is also a slit port bunsen

The air for combustion, both primary and secondary is supplied by a 134 mm diameter Sirocco fan. The air is drawn

right hand side of the combustion chamber. The primary air ports are adjustable within the range

of 0 to 135

by a screw.

type made of 1 mm stainless steel sheet, with 95, 0.5 x 7 mm slits.

mm2

bunsen

by means of the aeration shutters. The aeration shutter adjusting rod is fixed

type, made of 1 mm stainless steel sheet. The burner slit sizes are

from

the outside enviroment through the flue system and into the lower

f?om

1.0 mm hot dip aluminium coated steel sheet,

Three injectors are mounted inside the gas connection tubes, where they connect to each burner. The gas inlet connection is an R

%“/

15 male thread, located at the rear on the

left

hand side

[viewed from the rear] and situated approximately 400 mm through the inlet to the double block solenoid valve No.1 and No.2 , then on to the regulator which supplies the gas to the (central ) connection tube, injector and finally into the lower part of the combustion chamber where it is ignited on the burner. When the appliance is operating on HI, the gas also passes through solenoid valve No.3 whic h in turn allows the gas suppl y to the HI burners to be ignited.

Prior to ignition any combustion product or raw gas remaining in the combustion chamber is purged by the combustion fan, preventing explosive ignition or flame vitiation by any remaining by-products.

Ignition is by the continuous spark method in conjunction with the solenoid valves and micro switch. The spark is monitored and controlled by the printed circuit board. The spark gap is 3.0

f

0.8 mm. [Generated voltage is llkv]

The products of combustion pass through the combustion chamber and sub-heat exchangers, heating the room air before being expelled outside via the concentric dual pipe flue system.

Ai r is drawn in through the steel mesh filters located at the top of the rear panel by the centrifugal convection fans and blown onto the outer surface of the combustion chamber and sub-heat exchangers, before passing over the open vessel type humidifier out into the room

through the louvres, located at the bottom front of the outer cover. The average humidification

is 300 cc/h WI setting].

LOW

operating burner via a 10 mm diameter alurninium

fro m

floor level. The gas passes

The humidifier tray is fabricated from 0.6 mm cold rolled carbon steel sheet, black enamellecl with a maximum capacity of 3 litres of water. Any condensation in the flue manifold is drained

into the humidifier tray.

The warm air outlet consists of six (6) fixed horizontal louvres and eight (8) vertical adjustable air guides.

DISTINGUISHING T & FT/VA

The

RHFE-1OOlF T

main difference is in the printed circuit board The RHFE-lOOlFT/V A can be identified by the

appears printed on the printed circuit board. The

1OOlF A

This manual provides information on servicing and fault finding for both FT and versions. Where data differs between the appliances, seperate sets of information are provided. The differing information is: time charts; diagnostic points; block and wiring diagrams; operational flow chart; electrical component analysis; and parts list.

and has a ceramic resistor attached to it by 2 white wires.

and the RHFE-1OOlFTN A are basically the same appliance. However, the

P.C.B. ]

markin,,

and its related wiring harnesses.

a

Rinnai-RBC

RHFE-1OOl T

RHF-lOOlF(VA) ,

P.C.B. is marked

which

RHFE-

FTNA

All other information is common to both appliances. Please ensure that yo u have identified the heater correctly before attempting servicing as

well as when ordering spare parts.

Chang e to FT/VA model

occure d

in September 1992

SPECIFICATION

Type of appliance Model Exhaust system

Dimensions

Weight Gas type Gas controls Heated air volume Connections

Efficiency

Combustion system

Ignition system Temperature control Temperature range

(m3/min)

Forced flue gas space heater.

-

1001 FT. RHFE - 1001 FTNA.

RHFE Mushroom -

Width = 930 mm.

Depth

Height 41 Kg [Standard]. Natural, Solenoid and combined regulator. HI - 8.1 LOW Electrical - 240 V

Gas Approx 85 Forced combustion with stainless bunsen burner. Automatic flame sensing continuous spark. OFF

-

12.s0c + 3°C [LOW).

35.O”C k

AA/A/B/C/DIE

= 330 mm with spacers.

= 670 mm.

L.P.G./Propane,

-

5.0

50

Hz.

-

RX

(l5mm).

%.

MED - HI [Slide mechanism]. Electronic thermostat control.

7°C [HI-j.

Differential of 1.5

Co-axial approved.

T.L.P.

[NZ:

230 V 50 Hz].

& OYC].

Warm air outlet Humidifier tray capacity Fan control Timer operation

Indicators

Safety devices

Bottom of appliance at front. [Adjustable] Approx 3 Iitres. Evaporation rate 300 cc/h.

& Fan switch.

PCB 12 hr delay slide operated timer.

-

rONJ

rCOMBUSTION] -

rTlMERJ

O.H.S.- Bi-metal.

No.1- OFF app 130 +

No.2 - OFF app 65 + Thermal fuse Flame failure - flame rod. Flame rectification] Fan switch - Bi-metal.

ON- 60 + 5°C.

OFF Power failure -Power failure circuit. Air pressure -

- 6.0 & 2mm

ON

OFF - 4.8 + 2mm H,O.

green.

red.

-

green.

Melt s at 152

+ 5°C.

43

Air pressure differential.

Morning

ON app 110 + 10°C.

YC,

ON app 50 + 10°C.

5”C,

+

2°C.

H1O.

or evening

heati@

Power surge- 5 Amp fuse. Pre-ignition

- Spark sensor.

I

1,

COMBUSTION SPECIFICATION

PERFORMANCE CHARACTERISTICS

I

Model

G=typc

Combustion method

Input

Electrical Consumption

HI burners

LIiS

RI-iSX-ar

burner

LOWburner

R&IS front

Regulator pressure

mJ/h]

Damper

Opening

burner

Injector

Damperopening injector

Fprt]

HI

LOW

HI

watts]

LOW

RI-IS

LHS

size

HI

RHFE - 1OOlFT

Natural

Stainless steel

37

14.5 18.6

s/10

5/10

1.65 mm x2

7110

1.75 mm

Xl

0.98

RHFE-

I

bunsen

I

1OOlFTNA

T.L.P.

type burner.

37 38

110

65

5/10

3.25 mm x2

4110

3.25 mm 1.05 mm

xl xl

0.45

Propane/L.P.G.

16.5

4110

0.95 mm

X2

4/10

I

2.75

2.

OPERATING NOISE LEVELS

3. EFFICIENCY

Convection Fan

Air Flow

HI

LOW

I

8.1

m3/min

5.0

m3/min

Standard noise levels

HI

I

35 dB(A)

Fan Speed

840 510 rpm

_

rpm

LOUVRE TEMPERATURES

4.

HI Combustion

54

80

78

58

61

60

LOW Combustion

30

38

38 35

31

30

59 66

82

62

54

53

54

36

45

30

28

29

:

38

Input

MJRI

36 32

86 80

63 94

55

52 70

52

:

14.5 MJ/h

46 36 34

60

40

33

29

28

77 75 ’ 63

74

61

68 46

47 44

40

52

69 85

72

76

73

60

42 34

42

77 64 68

61

57

43

71

51

34

33

Temperatures are above ambient.

72

85 63

61

59

55

49 26

59

39

33

32

31

45

59

58 58

36

37 30

31

30

37

67

53 56

55

34

35

30 29

30

31

unit: oc

Unit:

OC

44

51

52

56

26

30

5.

AIR

VELCKXI-Y

HI Combustion

LOW Combustion

I

3.8 4.0 3.8

3.4

4.1

0.7 0.7 0.65

1.55 1.7 1.7

1.05 1.95 1.9

1.8

2.2 2.2 1.7 2.1 1.95 2.5 2.0 1.7 1.3

3.7

3.8 3.6 3.9 4.2 4.3 3.5

3.9 3.9 3.9

3

._

0

0.7

1.0 2.0

0.7 0.6

1.45

4.1 4.1

1.35

1.5

0.95

1.45

1.8

0.8

I.15

4.2

[Unit:

1.2

1.0

3.8

m/set]

I

1.7

1.9

2.2 2.4 2.3

1

2.3

1

2.0

2.5 2.6 2.5

1

2.0

1

SURFACE TEMPERATURES

6.

Temperatures were taken with the appliance operating on Natural Gas at 38 AI1

temperatures shown are “C above ambient.

In

x

II

x

In

X

c

W/h.

X

N

%

-11

OPERATION

Normal Operation Operating the Timer

After the ON/OFF button is set to the

ON position, the glow. The combustion fan will begin to rotate, and pre-purge begins.

As pressure rises in the heat exchanger the pressure switch will operate, and after approximately 10 seconds the spark will occur.

The spark sensor checks that the spark has

occured Solenoids No.1 and No.2 will open to allow the gas to flow and ignite on the LOW burner [LOW combustion]. When the flame rod senses the flame, the

rcombustionj

As the spark ceases, solenoid No.3 will open allowing the gas to on the HI burner depending on the thermostat position. Approximately 30 seconds after the flame rod senses the flame, the convection fan will begin to operate, and warm air will

flow through the louvres at the front of the appliance.

across the spark gap.

rONJ indicator will

indicator will glow.

flow

and ignite

[HI

combustion],

Press the ON/OFF button to the ON position. Position the thermostat control knob in the desired position. Decide upon the number of hours delay after which you would like the heater to begin heating, and move the vertical slide timer select knob accordingly. If the delay is

less than 2 hours, the slide timer should be moved to 12 hours then back to the desired delay. The

rcombustion]

will go out and the

will glow.

When the time of ignition arrives, the

[timer1

ignition sequence will occur and the

[ON] indicator will glow.

When

rcombustionj

and

rONj

indicators

[timer-J

indicator will go out, the

the burner ignites, the

indicator will glow.

indicator

Room Temperature Control

Temperature is selected by positioning the horizontal thermostat control knob to the desired locationalong the slide.

Turning OFF

After the ON/OFFbutton is set to the OFF position, solenoids No. 1,

No.3 will shut off the gas supply to the burners and the combustion fan will stop. The

rONA

indicator and indicators will go out. Several minutes later the fan switch will turn off, and the convection fan will stop.

rcombustion]

No.2, &

Action

Operation

Gas passage & electrical circuitry

Remarks

Insert plug into wall

socket.

c

0

.I

Y

rrl

5

.-

0 b

.I

k

ON/OFF button to ON

Current

through to

micro switch.

[MS]

Gas through

to solenoid.

ISVJ

= sv,

MV,

MV, = SV,

Micro switch

[MS] is

activated.

*

240 + 100 inside appliance

position.

TONJ

indicator

5

.-

d

.C &

glows green.

AC

Combustion fan operates on HI.

(Pre-purge)

No obstacles in gas supply connection tube.

If there is air in the supply line, then it will take time to ignite the appliance upon

initial ignition.

Confirm power supply if

r0NJ

indicator doesn’t glow.

If ON/OFF button is in ON position at

time of placing

electrical plug into wall socket, unit won’t operate due to power failure safety

circuit.

Air pressure switch is activated. Spark

g

.II

Y

.I

5

.I

CL

0 z

-4 z

.L

2

#

occurs approximately

10 seconds after

current passes

through the

P.C.B. unit.

Solenoids SV,

&

gas ignites on the LOW

burner.

SV, open and

AC

Spark sense checks that the spark has occured across the spark gap.

Combustion fan operates from HI to

*

LOW

Action

Operation

Gas passage & electrical circuitry

Remarks

[Combustionj

indicator glows after senses a flame.

5

.-

U

.”

EE

.cr

0

z

.C

g

‘Eb &

2 seconds later

SV,

combustion fan operates on HI.

Combustion continues as FR, and flame.

Convection fan

operates with in

32 seconds of flame sense.

Position the temp control knob to the desired

8

.-

position.

3

As the thermistor senses the room temp, the P.C.B. adjusts the burner setting

automatically.

$ ?

.I

L

a’

The convection fan operates for

30 seconds on HI after burner setting changes

to

FRI

opens and

FR,

sense a

LOW.

AC

Mu; uvr

Two attempts at

ignition occur. Appliance will

lock out if

ignition does not occur the second time.

Appliance locks out if

FR2

and FR, cease to sense a flame.

When the appliance modulates from LOW to OFF, the

rcombustionj

indicator goes out, within a few minutes the fan switch

IFS]

goes OFF and fan stops.

ON/OFF

Solenoids close. button to OFF position.

3 m

E

.I

z

%

0”

Combustion fan

stops operating.

After a delay,

fan switch goes

OFF and the

convection fan

stops.

The electrical plug must not be

removed from the wall socket whilst the convection fan is operating.

DIAGNOSTIC POINTS -FT

Note:

Main switch Blue - Red

Over heat switch No. I Over heat switch No.2

Thermal fuse Blue LED 1 Yellow LED 2

LED 3 Red

Combustion fan

Air pressure switch white - White

Numbers under wire colours indicate pin markers on wiring diagram. See page 19

MEA- POINTS

COMPONENT

I

WIRE

coLouRs

Blue - Blue

Red

White

White - Orange

4

VOLTAGE OR

RESISTANCE

VALUES

I

-

Blue

-

White DC 14 - 23 Volts

-

White

-

Black

-

Black

- 5

I

Below AC 1 Volt Below AC 1 Volt

Below AC 1 Volt

Above 1 M

DC

30 - 40 Volts

AC 90 -

AC 90 -110 Volts LOW

Below DC 1 Volt

110 Volts HI

120 - 180

200-3OOs2

Q

Flame rod No.

Flame rod No.2

Flame rod No.3 Blue - F R

Solenoid

SolenoidvalveNo.2

SolenoidvalveNo.3

Convection fan

Sparker

Fan switch

1

valveNo.

1

I

Yellow

White -Blue

White

White-Black

White - Red

White

Red

White - White

-

F R

13

Red

-

F R

12

11

29 -30

-

Blue

29 -30

29-31

-

Black

-

White

-

29

28

AC 90 -

I

Above 0.8

DC 80

DC 80-

DC 80

DC 80 -

-

110 Volts

1.3

-1.8 k 110 Volts

1.3

-1.8 k 100 Volts

-

1.3

-1.8 k

110 Volts LOW

100 - 140

110 Volts HI

50 - 70

100 Volts

Above 1 M

Below AC 1 Volt

PA

Q

f2

Q

Thermistor Yellow - Yellow

-

Red

Slide control

Ceramic resistor

White

9

-

8

White - Black

9

-

10

White

-

White 1.8 k

Approx 30 k

10°C

=$

app 65 k

20°C 9 app 39 k

Q

- 0

OQ- approx 30 k

C?

Q Q

Q

!I

Rinnai 1001T Service Manual

CONTENTS

INTRODUCTION

SPECIFICATION

COMBUSTION SPECIFICATION

PERFORMANCE CHARACTERISTICS

OPERATING NOISE LEVELS

LOUVRE TEMPERATURES

SURFACE TEMPERATURES

OPERATION

DIAGNOSTIC POINTS -FT