Rinnai RHFE-551FA, RHFE-1001FA, RHFE-1001FA/VA, RHFE-201FA, RHFE-263FA Service Manual

...

Direct Vent

Service Manual

RHFE-551FA RHFE-1001FA RHFE-1001FA/VA RHFE-201FA RHFE-263FA, FAII RHFE-431FA, FAII, FA III, WTA RHFE-556FA, FAII, FA III, FTRA, FTRAIII, WTA RHFE-1004FA

This document, 200000014 (11/3/2008), supersedes and replaces the Direct Vent Service Manual, TDM-DV-2004.

Table of Contents

General Information .................................... 3

Specifications .............................................. 4

Sequence of Operations ............................. 5

1004F

Troubleshooting Information ................ 48

Wiring Diagram .................................... 50

Lockout Check List .............................. 51

Fault Isolation

Accessing Fault Codes ......................... 6, 7

Fault Isolation Codes ............................ 8, 9

Fault Isolation - Other Issues .................. 10

431FA Series, 556FA/FTRA Series

Troubleshooting ..................................... 11

Wiring Diagrams

431FA Series, 556FA/FTRA ............. 14

556FAIII ............................................ 15

556FTRAIII ........................................ 16

Lockout Check List 431FA Series .......... 17

Lockout Check List 556FA/FTRA Series 19

431WTA, 556WTA

Troubleshooting .................................... 21

Wiring Diagrams (431WTA) ................... 24

Wiring Diagrams (556WTA) ................... 25

Lockout Check Lists ............................... 26

551FA, 1001FA, 1001FA/VA

Troubleshooting (551FA)........................ 28

Wiring Diagram (551FA) ......................... 31

Troubleshooting (1001FA) ...................... 32

Wiring Diagram (1001FA) ....................... 34

Troubleshooting (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

Extension Installation Requirements ........ 52

Vent Kits and Extension Sets ................... 53

Vent Extension Covers ............................. 54

Installations at Altitude .............................. 54

Gas Pressure Setting Procedure

(201FA, 263FA, 263FAII) .................... 55

(431FA/WTA, 556FA/WTA) ................. 57

(1004FA) ............................................. 59

Dip Switch Settings ................................... 61

Checking Micro-Amps

(431, 556, 201, 263) ................................. 62

Setting up the U Tube Manometer

(431, 556, 201, 263) ................................. 63

Thermistor ................................................ 64

Flame Rectification ................................... 64

Setting a Maximum Temperature

(431, 556, 201, 263) ................................. 64

Harmonic Noise (1004FA) ........................ 65

Wire Diagram Abbreviations ..................... 65

Removal of “OF” on New PC Board

Installation ................................................ 66

2 Rinnai Direct Vent Service Manual

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.

DANGER

WARNING CAUTION

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.

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.

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

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).

CAUTION

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.

Rinnai Direct Vent Service Manual 3

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.

Specifications

1001FA

1001FA/VA

1004FA 551FA

Series, WTA

556FA/FTRA

W.C.

11-13 in

8-13 in

(279-330 mm)

W.C.

(279-330 mm)

W.C.

(279-330 mm)

W.C.

(203-330 mm)

-267 mm) W.C.

5.0-10.5 in (127

NA NA

267 mm) W.C.

4.5-10.5 in (114-

82%

80.6%

Natural Gas:

Propane Gas:

81%

80.6%

Propane Gas:

5.0-10.5 in (127-

267 mm) W.C.

60 Hz,

120 watts

AC 120V,

60 Hz,

120 watts

AC 120V,

60 Hz,

121 watts

AC 120V,

60 Hz,

55 watts

AC 120V,

WTA

431FA Series,

201FA 263FA, FAII

3,000-8,000 5,500-11,000 8,200-16,700 8,200-21,500 10,500-38,400 22,000 (max) 38,400 (max)

BTU Input NG

80.8%

Natural Gas:

Propane Gas:

80%

Natural Gas:

Propane Gas:

80.6%

3,000-8,000 5,700-11,000 8,200-16,700 8,200-20,700 10,500-36,500 21,000 (max) 36,500 (max)

Natural Gas:

Propane Gas:

BTU Input LP

AFUE Rating

81%

80%

83.4%

3.5-10.5 in

4.5-10.5 in

Gas Supply

W.C.

(89-267 mm)

W.C.

(89-267 mm)

W.C.

(114-267 mm)

Pressure (NG)

W.C.

8-13 in

(203-330 mm)

W.C.

8-13 in

(203-330 mm)

W.C.

8-13 in

(203-330 mm)

Gas Supply

Pressure (LP)

60 Hz,

AC 120V,

60 Hz,

AC 120V,

60 Hz,

AC 120V,

Electrical

Connection

4 Rinnai Direct Vent Service Manual

40 watts

47 watts

42 watts

27-34 dB(A) 31-38 dB(A) 32-38 dB(A) 32-41 dB(A) 37-47 dB(A) 35-44 dB(A) 35-46 dB(A)

Sound Level

(at high fire)

37 lbs (17 kg) 51 lbs (23 kg) 51 lbs (23 kg) 90 lbs (41 kg) 74 (34 kg) 110 (50 kg)

39.4 lbs

48.3-78.6 96.4-128.5 110.5-141.3 110.5-162.7 203.4-360.6 135-189 179-289

Fan CFM

(17.9 kg)

Weight

Sequence of Operations

1. The blower (combustion) motor fan starts and purges the combustion and heat exchanger chambers making sure that they are clear. The green LED light is on.

2. The blower stages down and the ignition module powers the spark igniter and spark occurs. When the spark is sensed as being correct, the PCB allows voltage to the solenoid gas valves and gas enters the chamber. Ignition occurs and the flame rod begins to prove flame. The blower motor stages back up to high. When the burner is on the LED glows red indicating the burner is on. If the flame is correct and a secure ground is available, then the flame rod produces micro-amps and the unit will fire trying to reach your set room temperature.

3. The convection (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 determine the firing rate, fan speed, and run time. When the set temperature is reached, the red indicator will return to green indicating the burner is off. The convection fan will continue to run cooling the exchangers and electronics for about 4 minutes.

5. The LED will be green indicating the unit is on standby. When the structure temperature drops, the process starts over again.

6. Fresh air for combustion is drawn from outside and exhaust air is eliminated to the outside. Moisture coming from the vent outside is normal as most high efficient units produce moisture.

Rinnai Direct Vent Service Manual 5

Fault Isolation

If there is a malfunction the appliance may shut down as a safety precaution and display a fault code to assist in diagnosing the problem. The fault code will flash in the display on the control panel.

Fault codes should be used to assist in identifying the cause of the failure.

Accessing Fault Codes

Up to 10 fault codes are stored in the PC Board and can be recalled by simultaneously pressing the “Economy” button and both temperature control buttons for 2.5 seconds while the appliance is turned 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.

After the problem has been corrected, the fault code will clear only after the appliance has been turned off and back on. The code will be stored into the memory.

Some faults may cause a hard lockout where the appliance shuts off and corrective action is required before the appliance will operate.

Models with analog controls:

The fault code will display by lighting up 1 to 4 of the temperatures at the same time. For example, if the temperatures 60, 64, and 68 are lit up then the fault code is 60*64*68 - Abnormal Combustion Fan RPM.

LO 60 64 68 72 76 80 HI

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 displayed.

On models RHFE-201FA, RHFE-263FA, RHFE-263FAII, and RHFE-1004FA:

The codes in memory are numbered 1 through 10 with “1” as the most recent. The temperature display will show “1” and then show the most recent fault code. A “2” will then be displayed followed by the second most recent fault code. The 10 most recent fault codes will be displayed in this manner.

SET ROOM

1 61

SET ROOM

2 14

1 61 2 14

6 Rinnai Direct Vent Service Manual

Accessing Operation History

RHFE-431WTA, RHFE-556WTA

SET ROOM

RHFE-201FA, RHFE-263FA, RHFE-263FAII, RHFE-1004FA, RHFE-556FTRA

After the fault codes, the heater will display the combustion hours, combustion cycles (number of times the unit is turned on and off), and power failure frequency.

50 82

18 42

1 25

50 82

18 42

1 25

5082 combustion hours

18420 combustion cycles (multiply displayed number by 10)

125 power failures

RHFE-431FA, RHFE-556FA

After the fault codes, the heater will display the combustion hours and combustion cycles (number of times the unit is turned on and off). The combustion time will display first in two parts followed by the combustion cycles displayed in two parts.

Combustion Time

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 example below.

LO 60 64 68 72 76 80 HI

This indicates the first 8 digits as follows: 0 1 0 0 0 0 0 1

This indicates the next 8 digits as follows: 1 1 0 1 0 0 0 0

2. Use a calculator with binary and decimal functions. Set the 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 example below.

LO 60 64 68 72 76 80 HI

2. Use a calculator with binary and decimal functions. Set the calculator to binary, “BIN”, and enter the 16 digits.

(1 1 0 0 1 0 0 0 0 0 1 1 0 0 0 1 in the example above.)

3. Press the decimal function, “DEC”, and multiply the displayed number by 10 to obtain the combustion cycles.

The combustion cycles in this example is 512,490.

This indicates the first 8 digits as follows: 1 1 0 0 1 0 0 0

This indicates the next 8 digits as follows: 0 0 1 1 0 0 0 1

Rinnai Direct Vent Service Manual 7

Fault Isolation Codes

Analog

Indicator

Light

LO-HI PF --

60 11 Missed Ignition Flame rod current

LO 12 Flame Failure Flame rod current

Digital

LED

:--

Name

Definition Corrective Action

Power Failure Electric power has

been lost while the appliance was running

does not reach 1.0 microamp within a certain time after the solenoid opens.

remains below 1.0 microamp for 3 seconds during initial combustion

Check that the power cord is firmly inserted into the electrical outlet.

Check the 3 amp fuse. Check whether the fuse or breaker has blown at

the switch board.

Check that the flame rod is firmly positioned. Check the flame rod lead. Check the flame rod for carbon build up. Check that the correct gas is being used. Check the supply pressure at the meter and at

the appliance. Check that there are no leaks in the gas supply

line or appliance. Check for air in the gas supply.

Check that the correct gas is being used. Check the supply pressure at the meter and at

the appliance. 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

HI 16 Over

Temperature

Cut Off

72 76 31 Room

Temperature

Thermistor

Disconnection

76 80 32 Room

temperature

thermistor short

circuit

High limit temperature thermistor or thermal fuse has activated

Room temperature is above 104ºF for longer than 10 minutes

Room temperature thermistor circuit is open

Room temperature thermistor wire is trapped or touching bare metal.

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 air flow is not blocked.

(There should be a clearance of 40 inches in front of the appliance.)

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 air flow is not blocked.

(There should be a clearance of 40 inches in front of the appliance.)

Check the circuit. (troubleshooting)

8 Rinnai Direct Vent Service Manual

Fault Isolation Codes

Analog

Indicator

Light

64 68 72 33 High-limit

68 72 76 34 High-limit

LO 60 64 53 Abnormal spark

60 64 68 61 Abnormal

Digital

LED

Name

Definition Corrective Action

thermistor

disconnection

thermistor short

circuit

sensed

Combustion Fan

RPM

High limit thermistor circuit is open.

High limit thermistor wire is trapped or touching bare metal.

• Sparker is not off within 20 seconds of ignition.

• 1st spark is not sensed within 2 seconds

• 2nd spark is not continuous for 1 second after solenoid valve opens

RPM is not achieved within a certain time or exceeds the RPM limit.

Check the circuit. (troubleshooting)

Replace sparker

Check for obstacle preventing fan from turning freely. Check wiring harness to motor for damage or loose connections.

64 68 70 ON/OFF Switch

Failure

LO 60 71 Solenoid Valve

Failure

80 72 Flame Rod

Failure

72 76 80

NA 49 Pressure Sensor No signal from the

NA 99 Flue Block The pressure sensor

60 64 68

72 76

73 Communication

Failure

NA Flue Block Flue blockage has

The ON/OFF switch connects continuously for more than 15 seconds.

For either solenoid valve, SV1 or SV2, the signal and response signal are different.

Flame rod output does not cease within 20 seconds

Data transfer between CPU and E2PROM fails.

pressure sensor.

signal is below its limit.

been detected based on fan speed.

Check the circuit. (troubleshooting) Replace switch.

Check the circuit. (troubleshooting) Replace gas valve.

Check the circuit. (troubleshooting) Replace flame rod.

Disconnect the power and re-apply power.

Check the circuit. (troubleshooting)

Check the flue and termination for proper installation and blockage.

Rinnai Direct Vent Service Manual 9

Fault Isolation - Other Issues

AT IGNITION:

Heater does not operate.

Warm air does not flow when the burner lights.

Smoke or strange smells are produced on the first trial light up after installation.

Sharp clicking noised at ignition, or when unit shuts down, or goes out.

DURING COMBUSTION:

Clunking noise when the thermostat operates.

Unit is not heating room.

Is the heater plugged in?

Have the fuses or breaker blown at the fuse box / breaker panel?

Is there a power failure?

Is the air filter blocked?

Is anything blocking the outlet for the hot air?

Is the flue blocked?

The fan is started automatically after a short delay. This is to allow the heat exchanger to warm up, helping to avoid cold draughts.

This is caused by grease, oil, or dust on the heat exchanger and will stop after a short time.

This is simply expansion noise from the heat exchanger.

This is the sound of the solenoid gas valves opening and closing.

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.

Heater will not re-ignite after overheating Even after unit has cooled down, the heater does not ignite again. Repair

Allow heater to cool, clean air filter, and operate again.

is necessary by a qualified service provider.

DURING COMBUSTION:

Convection fan continues to run after turning OFF

This is to remove the residual heat from the heat exchanger. The fan will stop when the heater cools down.

OTHER POINTS:

Steam is discharged from the flue terminal.

Unit shuts off without apparent reason. Check whether filters are blocked. Dirty filters will cause the heater to

Power Failure

High efficiency appliances tend to discharge water vapor on cold days. This is normal.

overheat.

Switch OFF, then ON again when power is restored to re-set controls.

10 Rinnai Direct Vent Service Manual

Troubleshooting

RHFE-556FA/FTRA Series

RHFE-431FA Series

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

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 check the complete model number you are troubleshooting. Gas pressures and dip switches can vary among models. Always check the rating plate for complete information and follow directions.

(TR) Transformer:

Read Voltage across:

be a qualified service person before proceeding with these test instructions.

WIRE COLOR VOLTAGE RESISTANCE PIN NO.

White - White 98 - 105 VAC 6 - 19 ohms 26 - 30

Red - Red 28 - 50 VAC 1 - 3 ohms 24 - 28

Black - Blue 10 - 15 VAC 0.5 - 2 ohms 25 - 29

Blue - Yellow 130 - 185 VAC 200 - 400 ohms 23 - 29

Gray - Gray 110 - 120 VAC 10 - 14 ohms 19 - 20

(SP) Sparker Board:

WIRE COLOR

Blue - Red

Set your voltage meter on the 400k scale, unplug the (5) pin connector on the sparker board. When reading across the two lugs the blue and red wire connect to, you should read somewhere between 100k and 120k ohms of resistance. When checking the spark sensing circuit, check across the orange wire (pin #35) and grey wire (pin #32) on your 40 VDC scale. You should read between 4 - 5 VDC. During the spark this voltage will drop to approximately 0 VDC. Once unit ignites the voltage will go back up to 4 - 5 VDC.

(POV, SV1, and SV2) Gas valve solenoids:

WIRE COLOR VOLTAGE RESISTANCE * PIN NO.

Gray - Gray

Black - Yellow 85 - 90 VDC 1,300 - 2,000 ohms 31 - 34

*Remember, when reading the resistance of a solenoid coil, you should read across the lugs on the coil.

VOLTAGE

85 - 110 VAC

4.5 VDC low fire to

11.5 VDC high fire

RESISTANCE READING

see below

80 - 100 ohms 43 - 45

PIN NUMBERS

33 - 36

Rinnai Direct Vent Service Manual 11

Troubleshooting

(BL) Combustion Motor:

NOTE: If your meter does not have a hertz scale, please

refer to voltage and resistance readings listed below. If you have a hertz scale, check the following items first. Hertz reading across black white wires, pins 41 and 42.

Voltage and resistance check for (BL).

WIRE COLOR VOLTAGE RESISTANCE PIN NO.

RHFE-431 - LP UNITS

Lo fire - 44 Hz.

Hi fire - 81 Hz.

RHFE-431 NG UNITS

Lo fire - 44 Hz.

Hi fire - 81 Hz.

RHFE-431FA Series

RHFE-556FA/FTRA Series

RHFE-556 LP UNITS

Lo fire - 47 Hz.

Hi fire - 106 Hz.

RHFE-556 NG UNITS

Lo fire - 48 Hz.

Hi fire - 106 Hz.

Red - Yellow

Black - White N/A 9.4 k - 9.9 k ohms 41 - 42

(FM) Convection fan motor:

WIRE COLOR VOLTAGE RESISTANCE PIN NO.

Red - Gray

(TH) Thermistor:

Check the thermistor by inserting meter leads into each end of 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 apply ice to the thermistor bulb and the resistance should increase.

EXAMPLES: 41 °F = 91 k ohms

50 °F = 65 k ohms 68 °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. Then you will need to confirm manifold gas pressure, proper air dampers and ensure vent is clear. Also, check for proper orifices.

1-2 VDC low fire to 7.6

-18 VDC high fire

80-94 VAC low fire to

95-104 VAC high fire

1.2 - 1.8 mega ohms 39 - 40

90-180 ohms 21 - 22

12 Rinnai Direct Vent Service Manual

Troubleshooting

, H2 and H3) Safety Circuit:

Check for continuity across pins 44 and 46 at terminal H on the PC board. If you have no continuity, this means one of these switch/thermal fuses is open. Replace defective component.

(OH - TH) Overheat Thermistor:

Check resistance reading across pins 12 and 13 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.

(MS) On/Off Control:

To check to ensure the on/off button is functioning, unplug terminal I. Place (1) lead of your meter on the red wire for pin #66 and the other lead on the blue wire for pin#68. Now press 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 LOCKOUTS:

Other items that can cause lockouts are: Improperly converted units, spider webs in burner and air intake of vent system, improperly sized gas lines, low gas pressures or pressure drops due to other appliances on the gas system, improper ground or no ground at receptacle, supply regulators freezing up or defective, voltage drops or bad receptacle, winds in excess of 30 to 40 MPH causing turbulence inside the vent terminal, etc.

RHFE-556FA/FTRA Series

RHFE-431FA Series

Rinnai Direct Vent Service Manual 13

Wire Diagram

RHFE-431FA Series

RHFE-556FA/FTRA

14 Rinnai Direct Vent Service Manual

Wire Diagram

RHFE-556FAIII

Rinnai Direct Vent Service Manual 15

Wire Diagram

RHFE-556FTRAIII

16 Rinnai Direct Vent Service Manual

Lock Out Checklist

1. Check high fire manifold differential pressure, gas pressure should be:

2. Check low fire manifold differential pressure, gas pressure should be:

3. Ensure proper secondary air damper has been installed.

4. Ensure unit has proper size orifices in it.

5. Ensure gas type listed on rating plate matches gas type connected to unit.

6. Check for proper dip switch settings on PC board:

9. Check all wire connections for loose and/or broken pins or connections. Disconnect electrical power before

4.4" WC on the RHFE-431FA and the RHFE-431FA-II propane units.

2.8" WC on the RHFE-431FA-III propane unit.

2.1" WC on the RHFE-431FA natural gas unit.

3.5" WC on the RHFE-431FA-II natural gas unit.

2.4" WC on the RHFE-431FA-III natural gas unit.

1" WC on the RHFE-431FA and the RHFE-431FA-II propane units.

0.8" WC on the RHFE-431FA-III propane unit.

0.4" WC on the RHFE-431FA natural gas unit.

0.8" WC on the RHFE-431FA-II natural gas unit.

0.7" WC on the RHFE-431FA-III natural gas unit.

Propane secondary air damper has (15) small holes in it.

Natural gas secondary air damper has (1) large hole cut out in it, 1 1/4" x 1 3/4".

Orifice sizes for the RHFE-431FA and the RHFE-431FA-II propane unit are 0.75 mm or 0.029", part #

AU129-210x02-0.75.

Orifice sizes for the RHFE-431FA-III propane units are 0.85mm or 0.033" - part # AU129-210x02- 0.85.

Orifice sizes for the 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.

Proper settings for the RHFE-431FA and the RHFE-431FA-II propane unit is switch #1 is ON, switch #2

, switch #3 ON, and switch #4 ON.

OFF

Proper settings for the RHFE-431FA-III propane unit is, switch #1 is ON, switch #2 ON, switch #3 ON, and

switch #4 ON

Proper settings for the RHFE-431FA and the RHFE-431FA-II natural gas units is switch #1 is OFF, switch

, switch #3 ON, and switch #4 ON.

#2 ON

Proper settings for the RHFE-431FA-III natural gas unit is switch #1 is OFF, switch #2 OFF, switch #3 ON,

and switch #4 ON

Inspect wall vent to ensure it is not clogged or restricted in any way. For proper inspection of the

combustion chamber air way, vent MUST

Remove flame rod and electrode and inspect for cracks and/or carbon buildup. Clean flame rod and

electrode with sand paper. Also, check electrode gap setting, should be 1/8" - 3/16".

performing above task.

be removed from wall.

RHFE-431FA Series

Rinnai Direct Vent Service Manual 17

Lock Out Checklist

10. Check resistance on all three gas solenoid valve coils. Unplug each coil before reading resistance. Set your meter on the 2k scale, you should read somewhere between 1,200 to 1,900 ohms across SV1 and SV2. Coils SV1 and SV2 each have (1) yellow and (1) black wire. The POV valve with two gray wires should read somewhere between 80 - 100 ohms of resistance. Next plug the coils back up and turn the unit on. When the unit is going through the ignition cycle you should have 90 VDC to SV1 and SV2 solenoids. Make sure you have your meter set to read 100 VDC. Across the POV coil you will read somewhere between 1 - 35 VDC. If the unit goes to lockout before you have time to read all the coils, you may have to cycle it two or three times.

11. Check for voltage and resistance readings across transformer listed below. Remember any time you are taking resistance readings, disconnect power to the unit and isolate item being checked.

12.

13.

14.

15.

16.

17.

18.

19.

20. If further assistance is needed, please contact your distributor. If they are unable to assist you with repairs,

NOTE: Before any items/products are to be returned to Rinnai, you must first obtain a return authorization number. Any items returned without this number will be returned at owner's/shipper's expense.

Across the two white wires you should have 100 VAC or 11.2 ohms.

Across the two red wires you should have 30 VAC or 1.6 ohms.

Across the black and blue wires you should have 13.5 VAC or 1.4 ohms.

Across the blue and yellow output wire from the transformer you should have 155 VAC or 250 ohms.

Across the two gray wires you should have 120 VAC or 12 ohms.

Ensure the vent assembly does not exceed thirteen feet and two elbows. Maximum vertical run is eight

feet, then the vent must

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.

Check thermistor by inserting meter leads into each end of 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.

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.

Ensure unit is plugged into a properly grounded outlet. Do not assume you have a ground, check with your voltage meter.

Check for proper polarity of the receptacle.

Check ignition circuit, when unit is in the process of ignition, you should have 100 VAC across the blue and red wires connected to the ignition module.

Check for frozen regulators in supply lines.

contact Rinnai America's service department at 1-800-621-9419.

run horizontal.

RHFE-431FA Series

18 Rinnai Direct Vent Service Manual

Lock Out Checklist

1. Check high fire manifold differential pressure, gas pressure should be:

2. Check low fire manifold differential pressure, gas pressure should be:

3. Ensure proper secondary air damper has been installed.

4. Ensure unit has proper size orifices in it.

5. Ensure gas type listed on rating plate matches gas type connected to unit.

6. Check for proper dip switch settings on PC board:

9. Check all wire connections for loose and/or broken pins or connections. Disconnect electrical power before

10.

4.5" WC on the RHFE-556FA/FTRA and the RHFE-556FA/FTRA-III propane gas units.

3.8" WC on the RHFE-556FA/FTRA and the RHFE-556FA/FTRA-III on natural gas.

0.8" WC on the RHFE-556FA/FTRA and the RHFE-556FA/FTRA-III propane gas units.

0.7" WC on the RHFE-556FA/FTRA and the RHFE-556FA/FTRA-III natural gas units.

Propane secondary air damper has (15) small holes in it - PART # 556F-208-5.

Natural gas secondary air damper has (1) large hole cut out in it, 1 1/4" x 1 3/4" - part # 556F-208-7.

Orifice sizes for the RHFE-556FA/FTRA and the RHFE-556FA/FTRA-III propane gas units are 0.85mm or

0.033" - part # AU129-210x02-0.85.

Orifice sizes for the RHFE-556FA/FTRA and the RHFE-556FA/FTRA-III natural gas are 1.13mm or 0.044" –part # AU129-210x02-1.13.

Proper settings for the RHFE-556FA and the RHFE-556FTRA propane unit is switch #1 is ON, switch #2

, switch #3 OFF and switch #4 OFF.

OFF

Proper settings for the RHFE-556FA-III and the RHFE-556FTRA-III propane unit is, switch #1 is ON, switch #2 ON

Proper settings for the RHFE-556FA and the RHFE-556FTRA natural gas units is switch #1 is OFF, switch #2 ON

Proper settings for the RHFE-556FA-III and the RHFE-556FTRA-III natural gas unit is switch #1 is OFF, switch #2 OFF

Inspect wall vent to ensure it is not clogged or restricted in any way. For proper inspection of the combustion chamber air way, vent MUST

Remove flame rod and electrode and inspect for cracks and/or carbon buildup. Clean flame rod and electrode with sand paper. Also, check electrode gap setting, should be 1/8" - 3/16".

performing above task.

Check resistance on all three gas solenoid valve coils. Unplug each coil before reading resistance. Set your meter on the 2k scale, you should read somewhere between 1,200 to 1,900 ohms across SV1 and SV2. Coils SV1 and SV2 each have (1) yellow and (1) black wire. The POV valve with two gray wires should read somewhere between 80 - 100 ohms of resistance. Next plug the coils back up and turn the unit on. When the unit is going through the ignition cycle you should have 90 VDC to SV1 and SV2 solenoids. Make sure you have your meter set to read 100 VDC. Across the POV coil you will read somewhere between 1 - 35 VDC. If the unit goes to lockout before you have time to read all the coils, you may have to cycle it two or three times.

, switch #3 OFF and switch #4 OFF.

, switch #3 OFF and switch #4 OFF

be removed from wall.

RHFE-556FA/FTRA Series

Rinnai Direct Vent Service Manual 19

Lock Out Checklist

11. Check for voltage and resistance readings across transformer listed below. Remember any time you are taking resistance readings, disconnect power to the unit and isolate item being checked.

12.

13.

14.

15.

16.

17.

18.

19.

20. If further assistance is needed, please contact your distributor. If they are unable to assist you with repairs,

Across the two white wires you should have 100 VAC or 11.3 ohms.

Across the two red wires you should have 30 VAC or 1.6 ohms.

Across the black and blue wires you should have 13.5 VAC or 1.4 ohms.

Across the blue and yellow output wire from the transformer should have 155 VAC or 250 ohms.

Across the two gray wires you should have 120 VAC or 12 ohms.

Ensure the vent assembly does not exceed thirteen feet and two elbows. Maximum vertical run is eight

feet, then the vent must

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.

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.

Ensure unit is plugged into a properly grounded outlet. Do not assume you have a ground, check with your voltage meter.

Check for proper polarity of the receptacle.

Check ignition circuit, when unit is in the process of ignition, you should have 100 VAC across the blue and red wires connected to the ignition module.

Check for frozen regulators in supply lines.

contact Rinnai America's service department at 1-800-621-9419.

run horizontal.

RHFE-556FA/FTRA Series

20 Rinnai Direct Vent Service Manual

Troubleshooting

RHFE-431WTA RHFE-556WTA

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

Before checking resistance readings, turn off power source to unit and then isolate each item to be checked from the circuit by unplugging it.

(TR) Transformer:

Read Voltage across:

be a qualified service person before proceeding with these test instructions.

WIRE COLOR

White - White

Red - Red

Black - Blue

Blue - Yellow

Grey - Grey

VOLTAGE

130 - 185 VAC

110 - 120 VAC

98 - 105 VAC

28 - 50 VAC

10 - 15 VAC

RESISTANCE

READING

6 - 19 ohms

1 - 3 ohms

0.5 - 2.5 ohms

200 - 400 ohms

10 - 14 ohms

NUMBERS

21 - 27

30 - 31

22 - 23

23 - 32

17 - 18

Purple - Purple 4.5 - 5.5 VAC

Black - Yellow 165 - 185 VAC 200 - 212 ohms 22 - 32

Brown - Purple 2.2 - 2.8 VAC 0.7 - 1.2 ohms 24 - 28

(SP) Sparker Board:

WIRE COLOR

Blue - Red 85 - 110 VAC see below 33 - 36

Set your voltage meter on the 400k scale, unplug the (5) pin connector on the sparker board. When reading across the two lugs the blue and red wire connect to, you should read somewhere between l00k and 120k ohms of resistance. When checking the spark sensing circuit, check across the orange wire (pin #35) and gray wire (pin #32) on your 40 VDC scale. You should read between 4 - 5 VDC. During the spark this voltage will drop to approximately 0 VDC. Once unit ignites the voltage will go back up to 4 - 5 VDC.

VOLTAGE

1 - 2 ohms

RESISTANCE

READING

24 - 25

NUMBERS

Rinnai Direct Vent Service Manual 21

+ 47 hidden pages

Rinnai RHFE-551FA, RHFE-1001FA, RHFE-1001FA/VA, RHFE-201FA, RHFE-263FA Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual