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Rinnai RCE-460PTR Service Manual

Fan convector
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SERVICE MANUAL
RCE-460PTR
RCE-560PTR
FAN CONVECTOR

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Summary of Contents for Rinnai RCE-460PTR

  • Page 1 SERVICE MANUAL RCE-460PTR RCE-560PTR FAN CONVECTOR...
  • Page 2 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...
  • Page 3 Produced by Customer Technical Services February 2000 No portion or part of this manual may be copied without prior permission from Rinnai Australia. Rinnai Australia takes no responsibility for the accuracy or otherwise of information contained in this manual, and reserves the right to make modifications and change specifications without notice.

  • Page 4: Table Of Contents

    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 Convector 460/560PTR ©Rinnai...

  • Page 5: Glossary Of Terms

    MJ/h megajoule per hour millimetres overheat switch printed circuit board central processing unit potentiometer revolutions per minute solenoid valve ø diameter ∆ ° temperature rise above ambient modulating valve thermistor Convector 460/560PTR - v - ©Rinnai...

  • Page 6: Introduction

    1. Introduction Development Background Rinnai have developed a Portable Convector/Air Purifier Space Heater with an air purifying capacity that exceeds existing models and meets recent aims to improve health. We recommend that replaceable parts and the location of the unit be changed yearly.

  • Page 7: Specifications

    /min) Air Flow Changeover High ~ Low (12 step automatic changeover) ø Convection Fan Line flow type 110x 328L Convection Fan Motor Condensor line 4 pole motor Filter Indicator ° Thermistor 65 C ON Convector 460/560PTR - 2 - ©Rinnai...
  • Page 8 Tilt Switch Device Steel Ball Method (within PCB unit) Over-current Protection 3-amp fuse Loose Primary Filter Detection Device Micro-switch Available gas types NG, LPG Electrical Frequency Converter 50Hz only Replacement Filter HEOT - 003 Convector 460/560PTR - 3 - ©Rinnai...

  • Page 9: Combustion Specification

    3. Combustion Specification Basic Combustion Specification Rinnai model reference RCE-460PTR RCE-560PTR Gas type Propane LPG(NZ) Propane LPG(NZ) Gas consumption (MJ/h) High Main injector size φ φ φ φ φ φ 2.15 1.40 1.40 2.15 1.40 1.40 Thermocouple spacer Restrictor φ...
  • Page 10 5,020 ∆° (Unit (Average 73.1) ° (Room temperature 26.0 Conditions: <Low Combustion> Test gas: Natural Measured Input: 5.40 MJ/h 1290 kcal/h Nominal Input: 5.50 MJ/h 1310 ∆° (Unit (Average 28.4) ° (Room temperature 26.0 Convector 460/560PTR - 5 - ©Rinnai...
  • Page 11 Average air velocity on High: 3.68 m/sec Average air velocity on Low: 2.32 m/sec ² Area of louvre: 0.018 m ³ Air flow rate on High: 3.97 m /min ³ Air flow rate on Low: 2.51 m /min Convector 460/560 PTR - 6 - ©Rinnai...
  • Page 12 4,300 ∆° (Unit (Average 65.6) ° (Room temperature 26.0 Conditions: <Low Combustion> Test gas: Natural Measured Input: 5.40 MJ/h 1290 kcal/h Nominal Input: 5.50 MJ/h 1310 ∆° (Unit (Average 28.4) ° (Room temperature 26.0 Convector 460/560PTR - 7 - ©Rinnai...
  • Page 13 Average air velocity on High: 3.26 m/sec Average air velocity on Low: 2.32 m/sec ² Area of louvre: 0.018 m ³ Air flow rate on High: 3.52 m /min ³ Air flow rate on Low: 2.51 m /min Convector 460/560 PTR - 8 - ©Rinnai...
  • Page 14 Air flow rate on Boost: 3.24 m /min ³ Air flow rate on High: 2.13 m /min ³ Air flow rate on Med: 1.80 m /min ³ Air flow rate on Low: 1.47 m /min Convector 460/560PTR - 9 - ©Rinnai...
  • Page 15 Operation Noise (dB (A)) High: 41 Low: 27 Measuring method: According to Japanese Industry Standards During Combustion Air Purifier Operation Noise (dB (A)) Boost: 45 High: 35 Med: 31 Low: 27 Measuring method: According to JEM1467 Convector 460/560 PTR - 10 - ©Rinnai...

  • Page 16: Dimensions

    4. Dimensions Note: All dimensions are in millimetres Convector 460/560PTR - 11 - ©Rinnai...

  • Page 17: Installation

    5. Installation The following clearances are recommended for installation. Convector 460/560PTR - 12 - ©Rinnai...

  • Page 18: Schematic Diagram

    6. Schematic Diagram Convector 460/560PTR - 13 - ©Rinnai...

  • Page 19: Cut - Away Diagram

    7. Cut - Away Diagram Convector 460/560PTR - 14 - ©Rinnai...

  • Page 20: Operation Principles

    8. Operation Principles Control Panel Layout Convector 460/560PTR - 15 - ©Rinnai...

  • Page 21: Temperature Control

    5 minutes before the unit ceases operation and continues to flash after operation has ceased.) • If the same button is pressed twice when the Timer is in stand-by mode, the unit will go into normal OFF mode. Convector 460/560PTR - 16 - ©Rinnai...
  • Page 22 • During comfort control when the present room temperature is at least 5 C less than the set room temperature, the comfort control will end and the auto-economy function will go into stand-by mode. (The Economy indicator will go out.) Convector 460/560PTR - 17 - ©Rinnai...
  • Page 23 • When the “Purif Filter Chg” indicator is out: Press the reset button continuously for approximately 3 seconds to illuminate the indicator momentarily (for 0.5 sec) and to reset the hours of air purifier operation. Convector 460/560PTR - 18 - ©Rinnai...

  • Page 24: Main Componentry

    The amplifier amplifies the thermocouple output by a few volts (20 ~ 30 m V) and any changes are checked against the comparator. If the output is lower than the standard voltage of the comparator, the solenoid valve closes. Convector 460/560PTR - 19 - ©Rinnai...
  • Page 25 Reset Temp. ° Tilt Switch Safety Device Normally, the tilt circuit is open, but the steel ball rolls when the unit is tilted, closing the circuit. Steel Ball Tilt Switch Activating Angle ° ~ 80° Convector 460/560PTR - 20 - ©Rinnai...
  • Page 26 3 Amp Valves Solenoid Valve Solenoid Valve 1 Solenoid Valve 2 Voltage DC90 V DC 90V Single Seated Valve Power Consumption Below 5 W Below 5 W Modulating Valve Voltage <200mA Consumption Below 1 W Convector 460/560PTR - 21 - ©Rinnai...
  • Page 27 Set Temp Range Room Temp Display Range Differential Thermistor 16 ~ 26 1 ~ 30 Approx. 0.5 Dust Sensor Input Detectable Particle Diameter Detectable Density Range AC 5V & DC 5V µ approx. >1 m 0~8000/0.01f Convector 460/560PTR - 22 - ©Rinnai...
  • Page 28 Combustion Burner Type Combustion Type Burner Port Shape Material Main burner Bunsen Slit Heat Resistant Stainless Steel Combustion Chamber (Combustion Box) Material Thickness (mm) Dimensions SA1D-40 As below Heat Resistant Stainless Steel Convector 460/560PTR - 23 - ©Rinnai...
  • Page 29 Convector 460/560PTR - 24 - ©Rinnai...

  • Page 30: Operational Flow Chart

    Fan motor error ON/OFF switch device is activated when tilting is >40EC 10 min <350rpm, 4 sec) OH thermistor Error (for 15 sec) Safety device Power failure (*mV, 5 sec) activated (50~80EC) activated (70EC) activated Convector 460/560PTR - 25 - ©Rinnai...
  • Page 31 Hi ON indicator flashes (Red) has passed Dust indicator Green-orange-Red Operation ceases Pre-filter comes off detection Safety device Air Purifying OFF activated ON/OFF Switch OFF Air volume Ind. OFF Dust indicator OFF Air Purification motor Convector 460/560PTR - 26 - ©Rinnai...

  • Page 32: Error Code Messages

    Actual Air Purifier Operation Time (x100H). * When the unit is off, press the “override” and “ ∧ ” and “ ∨ ” buttons simultaneously for 2.5 seconds to reset Error History and Actual Air Purifier Operation Time. Convector 460/560PTR - 27 - ©Rinnai...
  • Page 33 (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 actual operation time after initialisation when the reset button is pressed. Convector 460/560PTR - 28 - ©Rinnai...
  • Page 34 When the “ ∨ ” button is pressed “13” (NG) “LP” b. When the “ ∧ ” button is pressed. “LP” “13” (NG) The gas type code will be stored in memory if the test button is pressed again. Convector 460/560PTR - 29 - ©Rinnai...
  • Page 35 * If the Timer 1 button is not pressed during each mode, the updated setting will be cancelled and the data will not be stored in memory. * If the data is stored, it will return to test mode and the entered information will be displayed. Convector 460/560PTR - 30 - ©Rinnai...
  • Page 36 Level 1 Level 12 The third and fourth digits will display: for no entry for gas type for low pressure for high pressure for standard level 3. Low Pressure Mode 4. High Pressure Mode Convector 460/560PTR - 31 - ©Rinnai...
  • Page 37 3. Display Contents Information a. Appliance Type Code RCE - 560 PTR RCE - 460 PTR b. Gas Type Code For NG For LP c. Flame Failure Detection Level Values 12mV 14mV 16mV 18mV Convector 460/560PTR - 32 - ©Rinnai...
  • Page 38 An example of High Flame Failure Detection Level 12mV, and Low Flame Failure Detection Level 18mV d. Dust Sensor Level Level 1 Level 2 e. Afterwards, it will revert back to the normal temperature display. Convector 460/560PTR - 33 - ©Rinnai...

  • Page 39: Diagnostic Points

    ° Ω 40 C 9~19k (NG) >DC 14mV black-white Thermocouple (LP) >DC 16mV black-white DC 1~4V Convection Fan >350 rpm (24Hz) Motor red-black DC 3~8V Air Purifier Fan AC 45~100V blue-yellow 60~150 Ω Motor Convector 460/560PTR - 34 - ©Rinnai...
  • Page 40 - blue AC 8~12V Ω brown - brown AC 8~12V Ω violet - voilet AC 10~15V 0.5~2 Ω black - black AC 3~7V Ω 0.5~2 &RQYHFWLRQ )DQ USP ± Gas Type High 460PTR 560PTR Convector 460/560PTR - 35 - ©Rinnai...

  • Page 41: Fault Finding Procedure

    • Air in room is not clean. Smoke and odours become hard • Filter is not clean to remove from room. (Clean the filter. If there is no change, replace with new Heater becomes noisy. filter.) ..................10 Convector 460/560PTR - 36 - ©Rinnai...
  • Page 42 • The sensitivity of the dust sensor decreases when the lens becomes dirty. Clean the lens as stated in the customer instruction manual and place the sticker on the right side of the unit. Convector 460/560PTR - 37 - ©Rinnai...
  • Page 43 This will stop after a short period. Increase the ventilation when using the appliance. Slight odour upon burner There may be a slight odour upon ignition/extinction of burner. ignition/extinction. (This will go once flame becomes stable.) Convector 460/560PTR - 38 - ©Rinnai...

  • Page 44: Fault Analysis

    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”). Ω Normal Value 0 ° (Melts at 216 Convector 460/560PTR - 39 - ©Rinnai...
  • Page 45 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 injector. 6. Incorrect combustion specification. (Injector, restrictor, regulator pressure etc). Convector 460/560PTR - 40 - ©Rinnai...
  • Page 46 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 Convector 460/560PTR - 41 - ©Rinnai...
  • Page 47 Reverse Flame (With large noise) and flame fails. Error code "14" 1. Blocked air filter. 2. Blocked burner or restrictor. 3. Dust or foreign matter in the combustion chamber. 4. Incorrect combustion specification or pressure setting. Convector 460/560PTR - 42 - ©Rinnai...
  • Page 48 1. Air purifier fan shaft grub screw loose. 2. An obstruction in the air purifier fan is preventing the fan from rotating. Open circuit or bad connection in motor circuit. Motor Coil Normal Value Ω 60~150 4. Faulty PCB. Convector 460/560PTR - 43 - ©Rinnai...
  • Page 49 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 change from green, to orange, to red. Convector 460/560PTR - 44 - ©Rinnai...

  • Page 50: Gas Conversion

    16. Replace and refit injector and filter. 17. Reconnect gas and electrical supplies. 18. Carry out gas pressure setting procedure on page 46. 19. Replace the front panel. Thermocouple High Height Convector 460/560PTR - 45 - ©Rinnai...

  • Page 51: Gas Pressure Setting Procedure

    Press the ON Timer button. When the left of the display changes to “12”, the detection level will be stored in memory. k. Press the Heat ON/OFF button to turn the heater off. (If the heater is not turned off, it will not return to its normal state.) Convector 460/560PTR - 46 - ©Rinnai...

  • Page 52: Dismantling For Servicing

    18.Removal of the Injector ..........54 8QOHVV RWKHUZLVH VWDWHG UHDVVHPEO\ LV WKH UHYHUVH RI GLVPDQWOLQJ Convector 460/560PTR - 47 - ©Rinnai...

  • Page 53: Removal Of The Purifier Filter

    Remove the screw from the indicator and dis- engage the two (2) clips from the securing bracket. c. Remove one (1) screw from the bottom secur- ing bracket. e. Disconnect 3 (three) wiring loom connectors from PCB. Convector 460/560PTR - 48 - ©Rinnai...

  • Page 54: Removal Of The Transformer

    Follow section 3 (Removal of the Front Panel). b. Remove one (1) screw from the right hand bracket. Convector 460/560PTR - 49 - ©Rinnai...

  • Page 55: Removal Of The Surge Protector And Sparker Unit

    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 )ROORZ VHFWLRQ  E DQG  F  Convector 460/560PTR - 50 - ©Rinnai...

  • Page 56: Removal Of The Pcb

    11.Removal of the Gas Control Assembly 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). Convector 460/560PTR - 51 - ©Rinnai...

  • Page 57: Removal Of The Convection Fan Assy

    Remove one (1) gas supply tube securing screw, as per section 11 c. e. Slide fan forward and disconnect wires from h. Unclip the connectors in the harness and PCB. manouvre the combustion chamber out of the appliance completely. Convector 460/560PTR - 52 - ©Rinnai...

  • Page 58: Removal Of The Spark Electrode

    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). Convector 460/560PTR - 53 - ©Rinnai...

  • Page 59: Removal Of The Thermistor

    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. Convector 460/560PTR - 54 - ©Rinnai...

  • Page 60: Wiring Diagram

     :LULQJ 'LDJUDP Legend bl: blue r: red w: white y: yellow v: violet bk: black gy: grey or: orange br: brown gr: green Convector 460/560PTR - 55 - ©Rinnai...

  • Page 61: Block Diagram

     %ORFN 'LDJUDP Convector 460/560PTR - 56 - ©Rinnai...

  • Page 62: Time Charts

     7LPH &KDUWV Convector 460/560PTR - 57 - ©Rinnai...
  • Page 63 Convector 460/560PTR - 58 - ©Rinnai...
  • Page 64 Convector 460/560PTR - 59 - ©Rinnai...
  • Page 65 Convector 460/560PTR - 60 - ©Rinnai...
  • Page 66 Convector 460/560PTR - 61 - ©Rinnai...
  • Page 67 Convector 460/560PTR - 62 - ©Rinnai...
  • Page 68 Convector 460/560PTR - 63 - ©Rinnai...
  • Page 69 Convector 460/560PTR - 64 - ©Rinnai...
  • Page 70 Convector 460/560PTR - 65 - ©Rinnai...

  • Page 71: Parts List

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