SERVICE MANUAL
RCE-460PTR
RCE-560PTR
FAN CONVECTOR
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© Copyright Rinnai Australia Pty Ltd
A.C.N. 005 138 769 All rights reserved
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.
Key to Warning Symbols
Failure to comply with the following instructions may result in serious
personal injuiry or damage to the appliance.
Be careful of possible electric shock. Wiring inside this appliance may
potentially be at 240 Volts.
Remove the plug from the source when carrying out any of the following
activities.
Read Fault Diagnosis and Wiring Diagram carefully to avoid incorrect wiring
Do not disassemble. Parts within cannot be exchanged or diagnosed faulty.
After completing the service and confirming that there are no water or gas leaks or
incorrect wiring, test operation of unit according to the Customer Operating Instructions.
After confirming normal operation, explain what was serviced to the customer and
operation principles if necessary.
This manual has been compiled by Rinnai Australia Customer Technical Services. While many
individuals have contributed to this publication, it will be successful only if you - the reader and
customer - find it useful. We would like to extend an invitation to users of this manual to make
contact with us, as your feedback and suggestions are valuable resources for us to include as
improvements. Rinnai are constantly working toward supplying improved appliances as well as
information, and specifications may be subject to alteration at any time.
SRV460/560
o
Issue N 1
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Table of Contents
Glossary of Terms ..................................................................................................... v
1. Introduction .............................................................................................................. 1
2. Specifications ............................................................................................................ 2
3. Combustion Specification ....................................................................................... 4
4. Dimensions ............................................................................................................. 11
5. Installation .............................................................................................................. 12
6. Schematic Diagram ............................................................................................... 13
7. Cut - Away Diagram ............................................................................................. 14
8. Operation Principles .............................................................................................. 15
9. Main Componentry ............................................................................................... 19
10. Operational Flow Chart ...................................................................................... 25
11. Error Code Messages .......................................................................................... 27
12. Diagnostic Points ................................................................................................. 34
13. Fault Finding Procedure ...................................................................................... 36
14. Fault Analysis ....................................................................................................... 39
15. Gas Conversion ................................................................................................... 45
16. Gas Pressure Setting Procedure ......................................................................... 46
17. Dismantling for Servicing ................................................................................... 47
18. Wiring Diagram ................................................................................................... 55
19. Block Diagram ..................................................................................................... 56
20. Time Charts ......................................................................................................... 57
Convector 460/560PTR
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Glossary of Terms
This glossary of terms and symbols is provided to assist you in understanding some of the language
used throughout this manual.
dB(A)
DC
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
sound pressure level in decibels, “A” range
direct current
AC
alternating current
Hertz
Hz
IC
integrated circuit
kilocalorie per hour
kilopascals
kcal/h
kPa
LED
mA
light emitting diode
milliamps
MJ/h
mm
OHS
PCB
CPU
POT
rpm
SV
megajoule per hour
millimetres
overheat switch
printed circuit board
central processing unit
potentiometer
revolutions per minute
solenoid valve
ø
diameter
∆ ° C
POV
TH
temperature rise above ambient
modulating valve
thermistor
Convector 460/560PTR
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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.
Features
• Air Purifier
1. Removes cigarette smoke, pollen, household dust and other micro-particles.
2. Use of the anti-bacterial and deodorising filter creates a comfortable space to live in (filter
indicator shows when it needs to be replaced.).
3. The dust sensor shows how clean the air is in a room.
4. The automatic function changes its operational level according to the cleanliness of the air in
the room. There are four levels of adjustment for manual operation.
5. The OFF Timers can be set in three steps.
• Heater
1. The various safety devices, fault history display, etc. are the same as the existing models.
2. “TR” model features dual ON/OFF Timer, remote control, economy mode, clock display &
child lock.
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2. Specifications
Model No.
RCE - 460 PTR
RCE - 560 PTR
Name of appliance
Output
Portable Convector
5.5~18MJ/h (5.0 kW)
5.5~21MJ/h (5.81 kW)
Width
Depth
Height
520
Dimensions (mm)
210 (base 305)
650
16.2
Weight (Kg)
Connections
Electrical
Gas
AC240V 50Hz (NZ : AC 230V)
Approved gas hose
Heating
High: 38 Low :31 (NG)
30 (Propane)
High: 39 Low :31 (NG)
30 (Propane)
Electrical
Consumption (W)
Air Purifying
Boost:27 High:22 Med:21 Low:20
Heat & Air Purifying
Max:56 Min:41 (5 on standby)
3
3
Heating Capacity
45m
52.5m
3
Air Purifying Capacity
45.6 m
Gas Type
NG
460PTR
560PTR
HI
LO
HI
18
5.5
18
6
HI
LO
HI
21
5.5
21
6
Gas Input (MJ/h)
LPG
LO
LO
Form
Slit type
Bunsen type
#30 Mesh
Main Burner
Air Filter
Method
Operation
Push Button
Operation
Ignition method
Room temperature
Gas flow control
Continuous spark, Main Direct Ignition
(Low-approx.10° C)16~26° C(High-Continuous High)
Control
High~Low (Modulating Control) 12-step automatic
changeover
Warm Air Outlet
Bottom front of unit
3
460PTR: 2.5~3.5
560PTR: 2.5~3.9
Air Volume (m /min)
Air Flow Changeover
High ~ Low (12 step automatic changeover)
Line flow type ø 110x 328L
Convection Fan
Convection Fan Motor
Filter Indicator
Condensor line 4 pole motor
Thermistor 65° C ON
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Air Purifier
Filter method (initial efficiency approx. 80%)
Activated Carbon (initial efficiency approx. 75%)
Push button
Anti-bacteria
Operation
Operation Changeover
Automatic Operation (High/Med/Low) and Manual
Operation (Boost/High/Med/Low)
OFF Timer
3 step changeover (1, 2, 4 hour)
Top of appliance
Louvre Location
3
Boost 3.3, Hi 2.2, Med 1.8, Lo 1.4
Airflow (m /min)
Air Purifier Fan
Sirocco Fan φ 160 x 80L
Air Purifier Fan Motor
Dust Sensor
Condensor line 4 pole motor
Particle Counter (scattered light method)
Calculated as on page 18
Filter Replacement Indicator
Incomplete Combustion Device
Flame Failure
Thermocouple method
Thermocouple method
Reverse Flame Device
Overheat Device
Bi-metal method OFF 150 5° C ON 125 10° C
Thermistor
Thermal fuse
level 4~12 70° C
216° C OFF
level 1~ 3 70° C
Power Failure Device
Within PCB unit
Tilt Switch Device
Steel Ball Method (within PCB unit)
3-amp fuse
Over-current Protection
Loose Primary Filter Detection Device
Available gas types
Micro-switch
NG, LPG
Electrical Frequency Converter
Replacement Filter
50Hz only
HEOT - 003
Convector 460/560PTR
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3. Combustion Specification
Basic Combustion Specification
Rinnai model reference
Gas type
RCE-460PTR
RCE-560PTR
NG
18
Propane LPG(NZ)
NG
21
Propane LPG(NZ)
Gas consumption (MJ/h) High
Low
18
6
18
6
21
6
21
6
5.5
φ 2.15
1
5.5
φ 2.15
1
Main injector size
φ 1.40
1
φ 1.40
1
φ 1.40
1
φ 1.40
1
Thermocouple spacer
A
B
0
0
0
0
0
0
*B
0
0
0
0
0
0
Restrictor
φ 20
0.65
7
φ 22
1.46
18
φ 22
1.46
18
φ 20
0.85
7
φ 22
1.91
18
φ 22
1.91
18
Regulator pressure (kPa) High
Low
Burner marking
X3C
X3P
X3P
X3C
X3P
X3P
Combustion method
Burner type
Bunsen burner
Slit
Solenoid valve
Direct Single Seated Valve Type
Rinnai Electronic Control
Modulating solenoid valve
* Level decided by gas type setting.
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Warm Air Discharge Temperature Distribution - 560PTR (Heater)
Conditions:
<High Combustion>
Natural
Test gas:
Measured Input:
Nominal Input:
20.90 MJ/h
21.00 MJ/h
4,990 kcal/h
5,020
(Unit ∆°C)
56
70
56
60
54
75
82
81
80
77
76
75
71
66
64
72
80
81
79
79
75
85
94
90
89
68
78
85
86
87
61
61
72
74
74
71
61
61
61
58
(Average 73.1)
(Room temperature 26.0°C)
Conditions:
Test gas:
Measured Input:
Nominal Input:
<Low Combustion>
Natural
5.40 MJ/h
5.50 MJ/h
1290 kcal/h
1310
(Unit ∆°C)
22
25
22
23
22
26
30
31
32
33
27
27
27
27
27
26
28
30
33
33
26
31
36
39
41
25
29
32
34
35
24
23
28
29
29
29
24
24
24
23
(Average 28.4)
(Room temperature 26.0°C)
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Warm Air Discharge Velocity - 560PTR (Heater)
<High>
(Unit m/sec)
2.91
3.39
3.53
3.87
4.34
2.91
3.52
3.94
4.40
4.28
3.31
3.67
4.29
4.19
3.83
3.99
4.31
4.29
4.23
4.96
3.46
4.13
4.30
4.76
4.61
2.79
3.34
3.77
4.09
4.60
2.76
3.12
3.61
3.48
3.40
1.88
1.64
2.58
3.16
3.45
(Average 3.68)
<Low>
(Unit m/sec)
1.54
2.22
2.12
1.68
3.02
1.72
2.41
2.64
1.95
2.89
1.87
2.39
2.60
2.37
2.41
2.68
2.62
3.14
3.10
3.10
1.67
1.98
2.77
3.04
3.11
1.49
1.84
2.50
3.10
2.96
1.86
1.17
1.08
1.63
2.30
2.54
2.35
2.41
2.10
2.30
(Average 2.32)
Conditions
Convection Fan rpm
High: 840 rpm
Low: 550 rpm
Measured at full combustion
Average air velocity on High: 3.68 m/sec
Average air velocity on Low: 2.32 m/sec
Area of louvre: 0.018 m²
Air flow rate on High: 3.97 m³/min
Air flow rate on Low: 2.51 m³/min
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Warm Air Discharge Temperature Distribution - 460PTR (Heater)
Conditions:
<High Combustion>
Natural
Test gas:
Measured Input:
Nominal Input:
18.10 MJ/h
18.00 MJ/h
4,320 kcal/h
4,300
(Unit ∆°C)
53
63
52
53
52
67
74
74
74
72
68
66
62
58
56
63
69
69
70
69
65
71
79
78
80
63
72
79
82
85
55
54
65
65
67
66
54
55
54
51
(Average 65.6)
(Room temperature 26.0°C)
Conditions:
Test gas:
Measured Input:
Nominal Input:
<Low Combustion>
Natural
5.40 MJ/h
5.50 MJ/h
1290 kcal/h
1310
(Unit ∆°C)
22
25
22
23
22
26
30
31
32
33
27
27
27
27
27
26
28
30
33
33
26
31
36
39
41
25
29
32
34
35
24
23
28
29
29
29
24
24
24
23
(Average 28.4)
(Room temperature 26.0°C)
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Warm Air Discharge Velocity - 460PTR (Heater)
<High>
(Unit m/sec)
2.58
3.00
3.13
3.43
3.84
2.58
3.12
3.49
3.89
3.79
2.93
3.25
3.80
3.71
3.39
3.53
3.81
3.80
3.74
4.39
3.07
3.66
3.80
4.22
4.08
2.47
2.96
3.34
3.62
4.08
2.44
2.76
3.20
3.08
3.01
1.66
1.45
2.29
2.80
3.06
(Average 3.26)
<Low>
(Unit m/sec)
1.54
2.22
2.12
1.68
3.02
1.72
2.41
2.64
1.95
2.89
1.87
2.39
2.60
2.37
2.41
2.68
2.62
3.14
3.10
3.10
1.67
1.98
2.77
3.04
3.11
1.49
1.84
2.50
3.10
2.96
1.86
1.17
1.08
1.63
2.30
2.54
2.35
2.41
2.10
2.30
(Average 2.32)
Conditions
Convection Fan rpm
High: 800 rpm
Low: 550 rpm
Measured at full combustion
Average air velocity on High: 3.26 m/sec
Average air velocity on Low: 2.32 m/sec
Area of louvre: 0.018 m²
Air flow rate on High: 3.52 m³/min
Air flow rate on Low: 2.51 m³/min
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Air Discharge Velocity (Air Purifier) 460/560PTR
<Boost>
(Unit m/sec)
1.42
4.05
1.57
4.73
1.27
4.13
1.24
4.80
2.43
4.20
3.73
4.90
2.76
3.41
1.56
4.62
2.73
5.30
(Avg 3.27)
(Avg 2.15)
(Avg 1.81)
(Avg 1.49)
<High>
(Unit m/sec)
0.73
2.44
0.96
3.00
0.96
3.09
2.08
3.08
1.95
2.77
2.62
2.84
1.38
1.21
2.73
1.80
3.13
1.93
<Medium>
(Unit m/sec)
0.57
1.85
0.78
2.53
0.82
2.71
1.88
2.72
1.50
1.99
2.37
1.57
1.77
1.03
2.29
1.38
2.63
2.25
<Low>
(Unit m/sec)
0.47
1.28
0.72
1.94
0.82
2.33
1.57
2.20
1.36
1.90
1.48
1.89
1.19
1.54
0.88
1.93
1.28
2.00
Conditions
Air Purifier Fan rpm Boost: 1100 rpm
High: 740 rpm
Med: 670 rpm
Low: 600 rpm
Average air velocity on Boost: 3.27 m/sec
Average air velocity on High: 2.15 m/sec
Average air velocity on Med: 1.81 m/sec
Average air velocity on Low: 1.49 m/sec
Area of louvre: 0.0165 m²
Air flow rate on Boost: 3.24 m³/min
Air flow rate on High: 2.13 m³/min
Air flow rate on Med: 1.80 m³/min
Air flow rate on Low: 1.47 m³/min
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Noise Level - 460/560PTR
Heater
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
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4. Dimensions
Note: All dimensions are in millimetres
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5. Installation
The following clearances are recommended for installation.
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6. Schematic Diagram
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7. Cut - Away Diagram
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8. Operation Principles
Control Panel Layout
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Normal Heater Operation
• Press the Heat ON / OFF button.
• The ON/Combustion indicator illuminates green, and the convection motor starts
pre-purging.
• The Digital Display displays the present room temperature. After approximately 3 seconds, the
electrode starts discharging electricity, and at the same time, the solenoid valves and the
modulating valve open. After ignition, while the main burner is on “High”, the ON/Combustion
indicator illuminates red when the thermocouple detects the flame, and electrical discharge
ceases. (Forced combustion is carried out for approx. 60 sec on High).
• The PCB’s micro-computer regulates the room temperature and combustion time, and also con-
trols both using fuzzy logic until the preset room temperature is reached.
Temperature Control
• Room temperature can be adjusted as desired with the Temp / Time buttons.
Turning OFF the Heater
• Press the Heat ON / OFF button.
• The solenoids and modulating valve close and combustion ceases.
• The indicators will go out. (The digital display will show the present time.)
• The convection motor stops after post-purging (2~4 minutes).
Child Lock
• Press the Up and Down buttons simultaneously. The Child Lock indicator will illuminate.
• When setting the lock while heater is operating, only the Heat ON/OFF button responds. When
unit is off, the Heater ON /OFF button will not respond. (The Air Purifier can be operated.)
• The Up and Down buttons should be pressed simultaneously for approximately 2 seconds to
cancel the Child Lock.
Clock Setting
• Press the Set Times button once. The Clock indicator will flash.
• Press the Temp/Time buttons to adjust the time.
• Press the Set Times button five times to set the clock. The indicator will go out.
Setting Timers 1 and 2 (Heater)
• Press the Set Times button twice. Timer 1 “on” indicator will flash.
• Press the Temp/Time buttons to adjust to the starting time.
• Press the Set Times button again. The Timer 1 “off” indicator will flash.
• Press the Temp/Time buttons to adjust to the finishing time.
• Press the Set Times button three times to lock in the programmed times. The Digital Display will
show the current time. (The Timers can also be set during heater operation. In this instance,
combustion will cease and the Timer will go into stand-by mode. When in stand-by mode, the
set room temperature for the Timers cannot be modified. In order to modify the set room
temperature, revert the unit to its normal state, modify the set room temperature and press the
Timer button to complete setting.)
• The intelligent function will start the unit so that the room is warm at the set time.
• The Timer operates for the set time then automatically stops. (The Timer indicator starts flashing
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.
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• If the Heater button is pressed when the Timer is in stand-by mode or during combustion, the
unit will go into normal OFF mode.
Automatic-Economy Mode (Heater)
30 minutes after the present room temperature has reached
the set room temperature, the Economy function will start
operating automatically and the Economy indicator will
illuminate.
•After a room reaches the set temperature, the set room
temperature will decrease 3 times automatically, each
time dropping by a maximum of 1° C in 30 minute
intervals.
•If the set room temperature is “L”, “16”, “26” or “H” a
few minutes after operation has commenced, the auto-
economy function will not activate and the Economy indicator will not illuminate. (However,
once the auto-economy function has commenced, the unit will continue to operate in that mode
if set to the above temperatures.)
• The increments shown in the table below are based on a temperature gradient which is
calculated using the initial room temperature 1 minute after ignition, and the room temperature
5 minutes after ignition. (This is for when the room temperature is set between 17~25° C.)
Initial Room Temperature
Increment (° C)
<6.0° C
>6.0° C
>16.0° C
<16.0° C
<6.0° C
6.0° C~8.0° C
>8.0° C
0.3° C
0.7° C
0.7° C
0.7° C
0.7° C
0.7° C
1.0° C
1.0° C
0.7° C
Temperature
Gradient
• Even if the set room temperature is modified while auto-economy is operating, the auto-
economy function will continue.
• When the present room temperature is over 5° C less than the set room temperature while auto-
economy is operating, the auto-economy function will go into stand-by mode. (The Economy
indicator will go out.)
The comfort control alters combustion and fan speed more frequently to counteract the feeling of
cold air and activates at the 2nd phase of auto-economy operation, preventing discomfort from
overcooling and saving energy.
• The comfort control pattern is determined from within the PCB.
• Like auto-economy, the comfort control does not activate when the set room temperature is “L”,
“16”, “26”, or “H”.
• 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.)
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Automatic Air Purifier Operation
1. Turning ON
i) Press the “Air Purif” button. The Fan Speed “Auto” indicator will illuminate and the Air Purifier
fan will rotate on High. The Dust Indicator will illuminate green.
ii) After approximately 20 seconds, the fan speed will adjust automatically according to the
cleanliness of the air. (The Air Purifier fan will operate at levels High, Med, and Low.) The 3 dust
indicators will illuminate according to the degree of uncleanliness of the air in a room. (Red =
Exceedingly High, Orange = High, Green = Low.)
2. Adjusting the Fan Speed
i) Adjust to the desired Fan Speed with the Fan Speed button.
3. Turning OFF.
i) Press the “Air Purif” button.
ii) The Air Purifier Fan will stop.
iii) The Fan Speed changeover indicator and Dust Indicator will go out.
OFF Timer (Air Purifier)
• Press the OFF Timer button when the Air Purifier is operating and set the desired time (1, 2, or 4
hours).
• The Air Purifier will turn off after the set time period is lapsed.
Filter Replacement Indicator
When the air purifier has operated for 4000 hours, the filter replacement indicator (Purif Filter Chg)
will illuminate to let you know that the filter needs to be replaced. The operation time is calculated
as follows:
Air Cleaning Operation Time = 1/2 (Hours of automatic operation) + Hours of manual operation
The Reset Button - the filter replacement indicator must be reset by doing the following:
• When the “Purif Filter Chg” indicator is illuminated:
Press the reset button continuously for approximately 3 seconds to make the indicator go out and
to reset the hours of air purifier operation.
• 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.
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9. Main Componentry
Safety Devices
Incomplete Combustion Prevention
The Incomplete Combustion Prevention Device senses flame temperature using a sensor with a
thermocouple. Thermocouples are widely used as burner safety devices. The Incomplete
Combustion Safety Device is incorporated in a special burner structure connected to an electronic
sensor. Ignition, combustion and flame failure are monitored by this system, and main burner
abnormal combustion or incomplete combustion due to unclean air are electronically sensed as a
thermocouple change from flame temperature change prior to occurence.
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.
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Sensor Specification
Ignition Sensing ODS Sensing Voltage
Thermocouple Output
Drop Out
Time (sec)
Voltage (mV)
(mV)
Output at initial
check +2
NG: >18mV
LPG: >20mV
<35mV
<35mV
NG: level 4~12 14 1.5
level 1~3 14 1.5
LPG: level 4~12 16 1.5
level 1~3 16 1.5
Below 60
NG: >18mV
LPG: >20mV
“Drop Out” = Time until the gas is cut off after flame failure.
Sensing voltage varies depending on gas type. (Refer to combustion specifications)
Overheat Switches
If the air filter or air outlet becomes blocked, the overheat switch causes the solenoid valve to close
and operation to stop. The appliance can be re-lit when it has cooled. If the air filter or outlet
becomes blocked and the OHS fails, the thermal fuse will “blow”, causing the solenoid valve to close
and operation to stop. This is a “one-shot” fuse; therefore the appliance cannot be restarted until this
fuse has been replaced.
OHS Type
Thermistor
Thermal Fuse
Characteristics
level 4~12
1~3
Operates at
70° C
Cut Off Temp
0
216
° C
10
Reverse Flame Detection Device
Type
Characteristics
150 5 ° C
125 10° C
Reserve Flame
Detection Switch
(Bi-metal)
Operational
Temp.
OFF
Reset Temp.
ON
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
50° ~ 80°
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Surge Protection
Glass Fuse
3 Amp
Valves
Solenoid Valve
Solenoid Valve 1
DC90 V
Solenoid Valve 2
DC 90V
Voltage
Single Seated
Valve
Power Consumption
Below 5 W
Below 5 W
Modulating Valve
Voltage
<200mA
Below 1 W
Consumption
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Electrical
Type
Diameter Width
Air flow Rate
Fan (rpm)
3
(mm)
(mm)
m /min
Convection
Fan
Line
Flow
Fan
328
(Full Combustion)
High: 3.5(460PTR),
3.9(560PTR)
High:800 70 (460PTR)
840 70 (560PTR)
Low: 550 70
φ 110
Low: 2.5
Air Purifier Sirocco
Fan
80
Boost: 3.3
High: 2.2
Med: 1.8
Low: 1.4
φ 160
Boost: 1100 100
High: 740 100
Med: 670 100
Low: 600 100
Note: Air flow rate is measured using a duct.
Fan speed is measured using a finished product during air purifier operation.
Room Temperature Control Device
Set Temp Range
Room Temp Display Range
Differential
o
o
o
Thermistor
16 ~ 26 C
1 ~ 30 C
Approx. 0.5 C
Dust Sensor
Input
Detectable Particle Diameter
Detectable Density Range
3
AC 5V & DC 5V
approx. >1µ m
0~8000/0.01f
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Operating Principles
1. An air current is created by the heat generated from heater resistance guiding the surrounding
unclean air into the area where the detector is.
2. The lens projects infra-red light around the detector.
3. When dust passes through the detector area, infra-red light is scattered, and the sections of scat-
tered light are gathered with the lens into the Photo Tr.
4. The Photo TR converts scattered light into electrical signals. The signal is then processed within
the circuit emitting a dust signal.
Combustion
Burner
Type
Combustion Type
Burner Port Shape
Qty
Material
Main burner
Bunsen
Slit
1
Heat Resistant
Stainless Steel
Combustion Chamber (Combustion Box)
Material
SA1D-40
Thickness (mm)
Dimensions
0.6
0.5
As below
Heat Resistant Stainless Steel
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10. Operational Flow Chart
Heater ON
Power Point ON
Cause eliminated
Power Point OFF
No
No
73
I
Operation/Comb.
Ind. flashes (red)
Yes
71
II
Operation/Comb.
Ind. flashes (red)
Yes
I: Micro-computer and E2PROM's signal path normal
II: Solenoid valve and Modulation valve rotation normal
III: Gas disconnection device normal when tilting
C.M.: Convection Motor
No
ON/OFF SW.
Normal
70
1
R.F.: Reverse Flame
SV: Solenoid
Operation/Comb.
Ind. flashes (red)
Yes
ON/OFF sw. ON
A
Operation/Comb. Ind.
Illuminates (Green)
All indicators OFF
Display time6Room temp.
14
ON/OFF Switch OFF
R.F detection
sw.temp. fuse
No
No
Operation/Comb.
Ind. flashes (red)
2
Normal
Yes
Filter Ind. flashes
03
3
III
Operation/Comb.
Ind. flashes (red)
Yes
No
72
C.M. OFF
T/C output
<10mV
4
C.M med ON
Operation/Comb.
Ind. flashes (red)
Yes
(After a max. of 50 sec)
(a)
5
6
Conv. motor Hi ON
No
(10 sec after (a))
62
C.M. OFF
Fan motor
>6 r.p.m
Operation/Comb.
Ind. flashes (red)
Yes
(After max.255 sec)
C.M. OFF
5
Conv. motor Lo ON
Sparker ON
(After 0.2 sec)
(b)
7
8
8
9
Solenoid SV1 ON
Solenoid SV2 ON
POV Med ON
33
34
(Disconnection)
(Short circuit)
No
Overheat TH
Normal
Sparker OFF
Sparker OFF
10
C.M. med ON
Operation/Comb.
Ind. flashes (red)
SV1,SV2 OFF
POV OFF
Yes
Room Temp.
Thermistor
Normal
No
31
32
11
9
(Disconnection)
(Short circuit)
Yes
Operation/Comb.
Ind. flashes (red)
(After 5 sec)
POV Hi ON
(after approx. 3 sec.)
(30 sec. after (b))
Conv. motor OFF
No
T/C output
(Ú1mV)
*
Sparker OFF
11
C.M. med OFF
NG
PROP.G
16mV
LPG
(c)
Operation/Comb.
Ind. flashes (red)
SV1,SV2 OFF
POV OFF
14mV
16mV
Ú1 Igniton sensed
output is the initial T/C
check output +2mV
Yes
Operation/Comb. Indic.
Illuminates (Red)
(150~255 sec)
Conv. motor OFF
(min.3mV. max. 18mV)
5
5
Conv. motor med ON
Sparker OFF
SV1, SV2 OFF
Conv. motor Hi ON
Temp. check starts
(10 sec. after (c))
SV1, SV2 OFF
POV OFF
C.M Med ON
M.V POV OFF
C.M. med ON
5
C.M. Mod. control
14
03
12
16
70
62
00
M.V modulating. control
9
Operation/Comb.
Ind. flashes (red)
Operation/Comb.
Ind. flashes (red)
Operation/Comb.
Ind. flashes (red)
Operation/Comb.
Ind. flashes (red)
Operation/Comb.
Ind. flashes (red)
Operation/Comb.
Ind. flashes (red)
Operation/Comb.
Ind. flashes (red)
No
Filter Ind. flashes
OH Thermistor
activates (65EC)
Re-instatement
of power
Rev. flame detection
sw. OFF (150EC)
Yes
2
12
Filter indicator flashes
11
12
1
3
Thermal fuse
discon. (216EC)
Incomplete comb.
prevention safety
device is activated
(*mV, 5 sec)
Operation ceases
Power failure
2
Gas disconn. device
when tilting is
activated (50~80EC)
OFF Function act.
>40EC 10 min
Fan motor error
<350rpm, 4 sec)
ON/OFF switch
Error (for 15 sec)
Yes
OH thermistor
activated (70EC)
Safety device
activated
No
10
B
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Heater OFF
TIMER
ON/OFF Switch OFF
ON/OFF switch ON
Combustion A -> B
Display
Room Temp. 6Time
Timer switch ON
All Indicators OFF
SV1 SV2 OFF
Mod. valve OFF
C.M. (med) ON
Display
Room Temp. 6Time
Operation/comb. Ind.
illuminates (Green)
C.M. OFF
SV1 SV2 OFF
POV OFF
(150~255 sec)
C.M. (med) OFF
Timer Ind. illuminates
C.M. OFF
No
Pre-heat
time
Yes
Combustion A -> B
Timer Indicator flashes
No
Timer off
set up time
Yes
*When Timer 1 or Timer 2 is set up, the heater
will operate 1 cycle per day. (Within dotted line)
Then Timer 1 and Timer 2 are set up, the heater
will operate 2 cycles per day. (Within dotted line)
OFF TIMER
Air Purifying ON
ON/OFF switch ON
ON/OFF switch ON
Cause elimated
Air volume indicator
illuminates (auto)
Air volume indicator
illuminates (auto)
All indicators OFF
Dust indicator
illuminates (Green)
Dust indicator
illuminates (Green)
ON/OFF switch OFF
Air Purification
motor Hi ON
Air Purification
motor Hi ON
14
OFF timer switch ON
No
Automatic
operation
OFF Timer indicator
illuminates (1 hour)
Air purification motor OFF
Dust indicator OFF
Yes
Air volume indicator OFF
OFF timer sw. change
Air volume ind
Lo-Med-Hi-Boost
Dust Ind.
Dust Ind.
Dust Ind.
05
illuminates (Green)
lluminates (Orange)
illuminates (Red)
Air purification motor
Lo-Med-Hi-Boost
No
Air Purificaiton
motor Lo ON
Air Purificaiton
motor med ON
Air Purificaiton
motor Hi ON
Operation/combustion
indicator flashes (Red)
Set up time
has passed
Dust indicator
Green-orange-Red
15
Yes
Operation ceases
Pre-filter comes off
detection
16
Yes
Safety device
activated
Air Purifying OFF
ON/OFF Switch OFF
No
Air volume Ind. OFF
Dust indicator OFF
Air Purification motor
OFF
Convector 460/560PTR
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11. Error Code Messages
Error Code Messages
Error
Code
Content
Diagnostic Check Point
00
03
05
11
12
Power re-instatement while ON/OFF switch ON
Gas interrupted due to Tilt Switch activation
Detection of Loose Primary Filter
Mis-ignition
-
Check Tilt Switch
Check Primary Filter
Check Thermocouple Output
Check Thermocouple Output
Incomplete Combustion Activation
Flame Failure
14
14
Overheat Thermistor Activation
Reverse Flame Safety Device
Check Overheat Thermistor
Check Reverse Flame Sensor
Switch
14
16
Thermal Fuse Melted
Check Thermal Fuse
Check Room Temperature
Thermistor
High Temp. Cut off (10 minutes at > 40° C)
31
32
Room Temperature Thermistor broken circuit
Room Temperature Thermistor short circuit
Check Room Temperature
Thermistor
Check Room Temperature
Thermistor
33
34
62
70
Overheat Thermistor broken circuit
Overheat Thermistor short circuit
Faulty Fan Motor rpm
Check Overheat Thermistor
Check Overheat Thermistor
Check Convection Fan Motor
Heater ON/OFF switch abnormal
Check Control PCB
(ON/OFF Switch)
71
72
72
Solenoids or modulating valve circuit abnormal
Thermocouple initial value abnormal
-
Check Thermocouple output
Check Thermocouple output
Thermocouple high cut-out
(> 48mV for 5 secs)
2
73
-
Communication Error between PCB & E PROM
* If the safety devices activate while either (or both) the heater and air purifier are operating, both
will cease operating.
* When the unit is off, press the “override” and “∨” buttons simultaneously for at least 2.5 seconds
to display the following at 2.5 second intervals in this order:
Error History (No. 1 (most recent) ~ No. 5);
Estimated Combustion Time (x100H);
Combustion Frequency (x100 times);
Estimated Air Purifier Operation Time (x100H); and
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.
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Memory Function for Maintenance Data
The 5 most recent error messages and the estimated time of combustion, combustion frequency,
2
estimated time of air purifier operation, and air purifier operation time are stored, as well as E
PROM.
<How to recall data>
While the unit is off, press the “override” and “∨” buttons simultaneously for at least 2.5 seconds to
bring up the error history on the display. The error history will display the following in a 2.5 second
cycle : the 5 most recent error messages (the most recent is No. 1; No.5 the oldest), estimated time
of combustion, combustion frequency, estimated time of air purifier operation, and air purifier
operation time.
Example.
Item
Digital Display
Comments
Error History
No. 1 (Latest Error)
Sudden Extinction
No. 2
Power Failure
No. 3
Mis-ignition
No. 4
Mis-ignition
No. 5
No error
Combustion Time
1300 hours
Not displayed if below 100 hours
Combustion Frequency
3700 times
Not displayed if below 100 times
Estimated Air Purifier Opera-
tion Time
5000 hours
Not displayed if below 100 hours
Air Purifier Operation Time
Note 1
5000 hours
Not displayed if below 100 hours
2
<How to Reset> (Same as Initialisation of E PROM)
• While the unit is OFF, press all three buttons “∧”, “∨”, and “override” simultaneously for at least
2.5 seconds.
• The digital display will go out, and “88:88” will be displayed when resetting has been com-
pleted, then “--:--” will be displayed.
(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.
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ꢀ
( ꢁ3520ꢁ'DWD
2
E PROM data will not be erased during a power failure. However, this data is divided into 2 groups
where one of the groups of data can be reset at the external control pads.
[Permanent Data]
• Modulating Valve Current Supplement • Present Time
Value
[Deletable Data]
(Initial Setting)
( 0:00 AM)
• Fan Current Supplement Value
• Estimated Combustion Time
• Combustion Frequency
• Error History
• Timer 1 Time
• Timer 2 Time
(None)
( 6:00 AM)
( 6:00PM)
( 22° C)
• Estimated Air Purifier Operation Time • Set Room Temperature
• Air Purifier Operation
Time
( 0 Hours)
<Resetting>
Refer to “How to Reset” under “Memory Function for Maintenance Data”.
<Test Mode and Adjustable Mode>
There is a Test Switch on the PCB.
Test Switch
Normal OFF
Gas Conversion
Mode
If it is changed over to gas conversion mode while the unit is OFF and with the test button ON, the
present gas type code will be displayed.
The gas type code will change with the “∧” and “∨” temperature buttons.
a. 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.
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Low Pressure Mode
High Pressure Mode
Test
Button
Normal OFF
Test Mode
Decision Level
Adjustment Mode
Sensitivity
Selection Mode
The unit will go into Test Mode when the Test Switch is switched ON while the unit is operating.
The unit will go into each of the following modes during Test Mode : Low Pressure Mode, High
Pressure Mode, Decision Level Adjustment Mode, and Sensitive Selection Mode.
• Test Mode...................................................Disables the temperature controls and allows you to
change the level manually. (Cancels when the test
switch is turned on again, or when combustion ceases.)
The level can be raised/lowered with the temperature
control buttons “∧” and “∨”, however, if they are con-
tinuously pressed for at least 0.5 seconds, it will change
to level 12 or level 1.
• Low Pressure Mode...................................The modulating valve electric current value for low
combustion can be adjusted with the temperature “∧”
and “∨” buttons. After adjusting, the data will be stored
when Timer 1 is switched ON.
• High Pressure Mode .................................The modulating valve electric current value for high
combustion can be adjusted, with the temperature “∧”
and “∨” buttons. After adjusting, the data will be stored
when Timer 1 is switched ON.
• Decision Level Adjustment Mode...........The maximum flame failure detection level can be
adjusted with the temperature “∨” button, and the mini-
mum with the temperature “∧” button. They can be set
in the following order: 12mV, 14mV, 16mV, 18mV.
After adjusting, the data will be stored when Timer 1 is
switched ON.
• Sensitivity Selection Mode .......................The sensitivity can be changed over from 1 to 2, and
vice versa, with the temperature “∨” button. After
adjusting, the data will be stored when Timer 1 is
switched ON. It is factory set at sensitivity level 2.
* To reset each mode, press the ON/OFF button to turn the unit OFF.
* 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.
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<LED display during Test/Adjustment Mode>
1. During Gas Conversion Mode (left side of display)
Gas Type
NG
13
LPG
LP
Gas Type Code
Displayed
2. During Test Mode
The first and second digits of the LED display the level.
The third and fourth digits of the LED display the entered data.
The first and second digits will display:
5 second test delay
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
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5. Standard Level Mode
12mV
14mV
16mV
18mV
High
Low
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A function called “factory mode”* has been added to confirm appliance settings.
*Displays set manufacturing values.
1. Operation Method
Press the “∧” button continuously, then the “Heat” button.
2. Display Contents
The set values for the Appliance Type Code, Gas Type Code, Flame Failure Detection Level, Dust
Sensor Level will be displayed in that order at 2.5 second intervals.
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
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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.
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ꢂꢀꢃꢁꢁ'LDJQRVWLFꢁ3RLQWV
Flow Chart CN Wire Colour Measurement Value
Part
o
o
N
N
blue-blue
switch OFF: 90~100kΩ
ON: 10~30 kΩ
1
2
B
Heater Switch
Thermal Fuse
16 17
white-white
38
G
G
<1Ω
black-white
Reverse Flame
Sensor Switch
<DC 1V
<1Ω
1
3
4
N
E
-
DC 4~6 V
Tilt Switch
black-white
<DC 10mV
Thermocouple
Hi~Lo
AC 45~90V
Convection Fan
Motor
5
J
blue-yellow
black-white
150~300 Ω
DC 1~4V
>6 rpm (0.4Hz)
Convection Fan
Motor
6
7
D
GND
red-black
white-white
DC 4~6V
K
K
AC 90 ~110V
Sparker
brown-brown DC 80~100V
brown brown
K
-
2.0~3.0kΩ
8
Solenoid Valve
1
2
yellow yellow
K
yellow-yellow
red-white
2.0 ~ 3.0kΩ
Hi~Lo DC 0.1~2.0V
16~26Ω
Modulating Solenoid
Valve
9
G
G
36-37
10° C 115~135kΩ
20° C 70~85kΩ
40° C 25~40kΩ
10
white-white
Overheat Thermistor
2
10° C 58~73kΩ
yellow-yellow 20° C 33~44kΩ
Room Temp.
Thermistor
11
12
F
40° C 9~19kΩ
(NG) >DC 14mV
black-white
E
Thermocouple
(LP) >DC 16mV
black-white
DC 1~4V
Convection Fan
Motor
13
14
D
>350 rpm (24Hz)
DC 3~8V
GND
red-black
Air Purifier Fan
Motor
AC 45~100V
60~150Ω
H
blue-yellow
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AC 3~7V
O
black-black
grey-black
31 ~43Ω
DC 4~6V
1.8~2.2kΩ
15
16
Dust Sensor
Dust indicator colour Voltage
P
grey-violet
white-white
green-orange
orange-red
<1Ω (ON)
DC 0.8~2.2V
DC 1.1~2.5V
C
Micro-Switch
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Wire Colour No.
Measurement Value
grey - grey
AC 207~264V
33~45Ω
white - white
blue - blue
AC 90~110V
8~20Ω
AC 8~12V
1~4Ω
brown - brown
violet - voilet
black - black
AC 8~12V
1~4Ω
AC 10~15V
0.5~2Ω
AC 3~7V
0.5~2Ω
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Gas Type
NG
High
800
870
Low
550
480
550
480
460PTR
560PTR
LPG
NG
840
950
LPG
Convector 460/560PTR
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Service Call System
Check Points (No.’s refer to causes outlined in the following pages)
Appliance does not operate after • Check electrical cord is connected to the power point.
having pressed ON/OFF switch. • Confirm power supply.
(ON/Combustion indicator does • Check Function Lock (Indicator).
not illuminate green.)
Ignition does not occur.
(ON/Combustion Indicator
does not illuminate red.)
(Error code “11”)
• Check gas type matches that supplied to appliance.
No sparker noise even when
Heater ON/OFF button is
pressed
• This appliance uses a muted sparker and makes a different
sound to older units.
Auto-economy indicator does
not illuminate.
• This appliance has an auto-economy function which automati-
cally starts operating (“Economy” indicator illuminates) 30
minutes after a room reaches the set temperature. However,
the auto-economy function will not operate if the temperature
is set to L, 16, 26, or H.
Room does not warm up.
• Blocked air filter .....................................................................3
• Warm air outlet short circuit (obstruction)...........................4
Flame Failure.
• Power failure.
• Check gas type
Error Code “12”
Error Code “14”
Error Code “00”*
• Strong wind against appliance.
*When power is restored after
power failure.
There is a smell of gas.
• Safety device operating.
Air Purifier does not operate
• Check electrical cord is connected to the power point.
when “Purif ON/OFF” button is • Confirm power supply.
pressed.
• Loose primary filter. (Error code 05)....................................8
Dust sensor does not illuminate • Installation location (size of room)
red even if cigarette smoke is
present.
• Straight after power cord is connected.
Y The dust indicator will illuminate green while the dust sensor is
stabilising (for approx. 1 min. after power re-instatement of for
approx 20 sec. after air purifier commences operation).
• Dust sensor lens is dirty.......................................................... 9
Dust sensor indicator stays red. • Air in room is not clean.
Smoke and odours become hard • Filter is not clean
to remove from room.
Heater becomes noisy.
(Clean the filter. If there is no change, replace with new
filter.)..................................................................................... 10
Convector 460/560PTR
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1. Gas Supply
<Ignition does not occur> <Room does not warm up> <Smell of gas>
• Is the gas supply fully open?
• Is the gas hose bent?
• Is the gas supply squashed?
• Is the gas hose too long?
• Is the gas supply connected correctly?
YEnsure the gas supply is fully open.
YIgnition problems can be caused by poor gas supply, or air in the supply line. (There may be a
gaseous odour until ignition.)
2. Preset Temperature
<Room does not warm up>
• Is the set temperature lower than the current room temperature? (Appliance switches to
“Low” approx. 1 minute after ignition)
YSet the room temperature higher than the present room temperature.
YAdjust to the desired room temperature with the room temperature control buttons.
3. Air Filter Blockage
<Room does not warm up> <Extinguishes suddenly>
• Is the air filter blocked by dust or is a curtain touching it?
• Has the safety device been activated by the dust blockage? (Error Code 14)
YClean the filter at least once a month.
4. Warm Air Short Circuit (Obstructions)
<Room does not warm up> <Extinguishes suddenly>
• Are there any obstructions in front of the warm air outlet? (Error Code 14)
YDo not cover or place any obstructing objects within 1 m of the warm air outlet.
5. Insufficient Ventilation
<Extinguishes suddenly>
• Is the room sufficiently ventilated? (Error Code 12)
YDuring use, ventilate the room every hour by turning on a fan for 1 minute or by opening a
window.
6. Exhaust Smell From Appliance
<There is a gaseous smell>
YThis appliance emits exhaust by-products into the room. When igniting/extinguishing, there
may be a slight smell.
7. Reverse Flame
<Extinguishes suddenly>
• Is the air filter blocked by dust or is a curtain touching it?
• Is there any blockage in the burner or restrictor?
• Is combustion, gas pressure etc. normal? (Error Code 14)
8. Loose Primary Filter
<Air Purifier does not operate>
• If the primary filter is incorrectly installed, the micro-switch will not activate and the air puri-
fier will not operate. (Error Code 05)
9. Unclean Dust Sensor Lens
<Dust Indicator will not illuminate red>
• 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.
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10. Unclean Filter Cartridge
<Smoke and odours are not removed> <Heater becomes noisy>
• The replacement period for the filter cartridge will vary due to use and location of installa-
tion, however, it should be replaced yearly.
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Condition
Cause and Explanation
Ignition is slow and cold air is When the ON/OFF switch is pressed, ignition occurs, however,
blown from appliance
ignition could be delayed due to air in the gas supply line.
Combustion Indicator (red) will not illuminate until the thermocou-
ple has heated up. There will be a delay of a few seconds after igni-
tion.
Warm air continues to blow
The fan stops after releasing all residual heat from within the appli-
even after switching appliance ance.
OFF
(approx. 255 secs if filter indicator flashes)
Clicking sound when the
burner ignites.
Normal ignition sound. The extent of the sound will depend on gas
pressure and burner temperature.
(Sound is of re-ignition straight after extinction.)
Resonant sound after ignition. Movement of the flame as it travels across the burner.
This will soon go.
After ignition/extinction there This is the sound of the combustion chamber metal expanding/
is a ticking or clicking noise. contracting due to heat, and is normal.
The heater does not ignite
upon initial use.
There may be air in the gas supply, preventing the appliance ignit-
ing immediately. If ignition does not occur after 30 seconds, the
spark will stop and the heater will lockout. Turn the heater off to
reset before attempting ignition again.
There is smoke or an unusual There may be grease or a smell of smoke when first using the appli-
smell upon initial use
ance. This will stop after a short period. Increase the ventilation
when using the appliance.
Slight odour upon burner
ignition/extinction.
There may be a slight odour upon ignition/extinction of burner.
(This will go once flame becomes stable.)
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Note: Before carrying out resistance checks, disconnect power.
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a. the convection fan does not begin to rotate.
b. the solenoid valves do not open.
c. there is no spark.
1. Confirm the connection at the wall socket.
NO
Is there electrical supply?
YES
Normal Value
AC90~110V
2. Is the 3 amp fuse blown?
Normal Value
0Ω (125V/3A)
a. The sequence does not continue.
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”).
Normal Value 0Ω
(Melts at 216°C)
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b. The convection fan does not begin to rotate.
1. Convection fan shaft grub screw loose.
2. An obstruction in the convection fan is preventing the fan from rotating.
3. Open circuit or bad connection in motor circuit. (Error code "62")
Normal Value
150~300Ω
Motor Coil
4. Faulty PCB.
c. The solenoid valves do not open
1. Broken wiring or loose pin connectors.
2. Solenoid coil wiring is broken or shorted.
Normal Value:
2.0~3.0kΩ
SV
SV
1
2
Modulating Normal Value
Valve 16~26Ω
3. Faulty PCB. (No DC90V circuit to solenoid.)
d. There is no spark
1. High tension cord disconnected or broken.
2. Leak due to broken electrode etc.
3. Incorrect spark gap (Normal spark electrode gap is 2.2 ~ 3.0 mm).
4. Faulty PCB.
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1. Air is in the gas supply.
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).
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30 seconds after ignition, the spark stops and miss-ignition occurs.
Miss-ignition
1. Faulty indicator
No miss-ignition
2. Faulty PCB
Confirm thermocouple
output
Thermocouple Output Checking Method
(Connect the multimeter to the output checking
terminal at the back of the appliance).
Output Checking Terminal (Lower s , Upper ⊕)
Is the output NG:14mV LP:16mV DC or above?
1. Check combustion specification, gas type, and gas
pressure.
2. Check the combustion.
NO
3. Check thermocouple is firmly fixed.
4. Check the thermocouple (for short circuit/breakage).
5. Check the thermocouple height.*
YES
*specification varies depending on the gas type
Faulty PCB
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1. Power failure. All indicators turned off. Heater ON/OFF Switch ON after power reinstatement.
2. Heater has been tilted. Tilt switch has activated. (Error code “03”).
3. A safety device has activated.
• Air filter is blocked and OHS is activated. (Error code “14”)
• Incomplete Combustion Prevention Device (ODS) is activated due to insufficient ventilation.
• Kink/block in the gas supply hose. Hose too long. (Error code “12”)
• Gas pressure is abnormally low.
• There is a breeze against the unit.
• Clearances around the appliance are insufficient.
• Obstructions in front of the heater. (Refer to Installation Instructions).
Safety devices are activated
4.
Check wiring is not broken or pin connectors loose.
Flame failure occurs between 30 minutes to 1 hour after ignition. (Error code “12”)
Incomplete combustion prevention device (ODS) possibly early cut-off.
Check thermocouple output.
Confirm thermocouple output (mV) is stable and as shown in the table below.
Measure the output at High and Low combustion
High Combustion
≥18 mV
Low Combustion
≥18 mV
NG
LP
≥20 mV
≥20 mV
YES
NO
1. Check the regulator pressure, restrictor and injector all
conform to the specification.
2. Faulty thermocouple and /or burner.
3. Check specification of thermocouple bracket, Thermocouple
spacer etc.
Faulty PCB
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.
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a. the air purifier fan does not begin to rotate.
NO
Is there electrical supply?
YES
1. Confirm the connection at the wall socket.
Normal Value
AC90~110V
2. Is the 3 amp fuse blown?
Normal Value
0Ω (125V.3A)
a. The sequence does not continue.
1. Broken wiring or loose pin connectors. (Open circuit)
2. Faulty control panel PCB. (Air Purifier ON/OFF button)
3. Faulty PCB.
4. Loose primary filter. (Error code "05")
b. The air purifier fan does not begin to rotate.
1. Air purifier fan shaft grub screw loose.
2. An obstruction in the air purifier fan is preventing the fan from rotating.
3. Open circuit or bad connection in motor circuit.
Motor Coil Normal Value
60~150Ω
4. Faulty PCB.
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Confirming simple operation of dust sensor
Necessary equipment
Infra-red TV remote control
1. Remove the dust sensor cover on the right hand side of the appliance. (The dust sensor is inside
the triangular opening.)
2. Press the air purifier button to turn it ON. The dust indicator will illuminate green.
* If the power cord has just been plugged in, carry out this step after one minute has passed.
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.
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1. Remove the front panel (see “Removal of the Front Panel Assembly” on page 48).
2. Remove the filter (see “Removal of the Purifier Filter” on page 48).
3. Replace small gas label on gas inlet, and large gas label on back of appliance.
4. Place new very small gas label on Data Plate.
5. Complete details on conversion sticker, place sticker inside front panel.
6. Remove convection fan and combustion chamber assemblies (see “Removal of the Convection
Fan Assy on page 52) to gain access to the burner.
7. Remove the burner assembly (see “Removal of the Spark Electrode” on page 53) and replace.
8. Remove the overheat switch from the burner and replace (2 screws).
9. Remove the secondary aeration cover (6 screws).
10. Remove the electrode (2 screws) and burner blanking plate
and fit to the new burner.
11. Fit restrictor to new burner assembly.
12. Refit the new burner to the combustion chamber.
13. Refit Thermocouple with spacer (A & B) fold on bracket
facing to the right (see diagram below).
14. Replace the blanking plate, electrode assembly, overheat
switch, thermocouple assembly, combustion chamber hood cover, gas supply connection, and
connection tube clips.
LP
NG
Installation direction
of thermocouple
installation panel
15. Slide combustion chamber back and screw into place.
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
Height
High
Low
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1. Gas Type Changeover
a. When the unit is off, press the test switch at the top of the PCB for at least 0.3 seconds; The
unit will go into gas type changeover mode. The present gas type code will be shown on the left
side of the display (NG(13), LP(LP), or Towns Gas(6C)).
b. Choose the gas type code with the “∧”(Up) and “∨” (Down) buttons.
c. The gas type code will be stored in memory when the test switch is pressed again. The display
will go out and will return to its normal off state.
2. Modulating Valve G Adjustment, Entering Detection Level
a. Press Heat ON/OFF button to operate heater.
b. Press test switch at top of PCB twice; The unit will go into low pressure test mode. “PL” will
be shown on the left side of the display.
c. Adjust low combustion secondary pressure with the “∧” (increase gas volume) and “∨”
(decrease gas volume) buttons.
d. Press the ON Timer button. When the left side of the display changes to “01”, the low pres-
sure test data will be stored in memory.
e. Next, press the test switch twice; The unit will go into high pressure test mode. “PH” will be
shown on the left side of the display.
f. Adjust high combustion secondary pressure with the “∧” and “∨” buttons.
g. Press the ON Timer button. When the left side of the display changes to “12”, the high com-
bustion test data will be stored in memory.
(If the test switch and the ON/OFF button are pressed instead of the ON Timer button in steps
4~7, the test pressures will be cancelled.)
h. Press the test switch 3 times. The unit will go into detection level adjustment mode. Numbers
will be shown on the display.
i. Adjust the low detection level with the “∧” button and the high with the “∨” button. The two
digits on the left of the display will show the high value, and the two digits on the right of the dis-
play will show low. The display will show “12” Y “14” Y “16” Y “18”.
j. 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.)
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e.g.
- Isolate gas supply
- Disconnect electrical supply from wall socket
ITEM
PAGE
1. Removal of the Purifier Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2. Removal of the Control Panel Assy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3. Removal of the Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4. Removal of the Purifier Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5. Removal of the Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6. Removal of the Dust Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7. Removal of the Surge Protector and Sparker Unit . . . . . . . . . . . . . . . . . . . . . . . . . 50
8. Removal of the Overheat Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
9. Removal of the Thermocouple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
10.Removal of the PCB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
11.Removal of the Gas Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
12.Removal of the Heater Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
13.Removal of the Convection Fan Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
14.Removal of the Combustion Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
15.Removal of the Spark Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
16.Removal of the Main Burner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
17. Removal of the Thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
18.Removal of the Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
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1. Removal of the Purifier Filter
3. Removal of the Front Panel
CAUTION
CAUTION
240 Volt exposure. Isolate the electrical supply to 240 Volt exposure. Isolate the electrical supply to
the appliance and reconfirm with the neon
the appliance and reconfirm with the neon
screwdriver or multimeter.
screwdriver or multimeter.
a. Remove three (3) bottom screws (1 on each
side, 1 at front).
a. Remove the thumb screw (1 screw).
b. Remove the Primary Filter, then the Purifier
Filter.
b. Follow sections 2. a. and b.
c. Lift the front panel slightly, and pull towards
you.
2. Removal of the Control Panel Assy
CAUTION
4. Removal of the Purifier Fan Assembly
240 Volt exposure. Isolate the electrical supply to
the appliance and reconfirm with the neon
screwdriver or multimeter.
CAUTION
240 Volt exposure. Isolate the electrical supply to
the appliance and reconfirm with the neon
screwdriver or multimeter.
a. Remove 5 screws (1 on each side, 3 at the
back.).
a. Follow section 3 (Removal of the Front
Panel).
b. Lift from the back first, then disengage from
the catches on the front panel.
b. Remove the top securing bracket (3 screws).
c. Remove the Front Panel (refer to section 3 -
Removal of Front Panel).
d. 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.
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d. Remove the eight (8) screws securing the fan c. Disconnect 3 connectors (main PCB, surge
housing to the back panel.
protector and dust sensor. Follow section 6 to
remove dust sensor.)
d. Disengage transformer.
6. Removal of the Dust Sensor
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).
e. Remove the capacitor to the right of the fan
housing (1 screw) and wiring loom from the
main PCB.
b. Remove two (2) screws.
f. Further disassembly would be required to
replace motor as shown below.
c. Remove protective plastic cover. (2 screws)
d. Remove two (2) connectors.
5. Removal of the Transformer
CAUTION
240 Volt exposure. Isolate the electrical supply to
the appliance and reconfirm with the neon
screwdriver or multimeter.
ꢀ
e. Further disassembly would be required to
replace the dust sensor as shown below
a. Follow section 3 (Removal of the Front
Panel).
b. Remove one (1) screw from the right hand
bracket.
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7. Removal of the Surge Protector and
Sparker Unit
c. Remove the two (2) screws from the OHS.
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).
9. Removal of the Thermocouple
b. Remove two (2) screws from the surge pro-
tector sparker unit bracket.
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).
b. Remove one (1) screw securing the cover
plate
c. Lift from bracket
d. Disconnect all leads.
e. Disconnect sparker unit from PCB and sole-
noid loom. (Note: the sparker unit comes
complete with wiring loom for solenoids as
shown below.)
c. Lift and remove bracket (2 screws).
8. Removal of the Overheat Switch
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).
b. Remove surge protector/sparker assy
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d. Disconnect connector from PCB.
b. Disconnect the gas supply hose at the rear of
the appliance.
e. Remove the two (2) screws securing the
bracket and disengage from burner assy (top
and bottom).
c. Remove one (1) screw from the front of the
gas supply tube upper to remove.
Note: Don’t lose O-rings from gas tube.
d. Remove two (2) screws from front of the gas
supply tube lower.
f. Remove one (1) screw to release the
thermocouple from the bracket (side).
e. Remove gas tube.
10.Removal of the PCB
f. Remove the gas control securing screws
(three (3) from the rear of the appliance).
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).
b. Remove one (1) screw, lift and pull forward.
Unclip all connectors.
12.Removal of the Heater Filter
CAUTION
240 Volt exposure. Isolate the electrical supply to
the appliance and reconfirm with the neon
screwdriver or multimeter.
a. Remove the bottom screw (large) and pull the
filter in an upwards direction to remove.
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).
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13.Removal of the Convection Fan Assy
14.Removal of the Combustion Chamber
CAUTION
CAUTION
240 Volt exposure. Isolate the electrical supply to 240 Volt exposure. Isolate the electrical supply to
the appliance and reconfirm with the neon
the appliance and reconfirm with the neon
screwdriver or multimeter.
screwdriver or multimeter.
a. Follow section 3 (Removal of the Front
Panel).
a. Follow section 3 (Removal of the Front
Panel).
b. Follow section 7 c (Removal of the Surge
Protector and Sparker Unit).
b. Remove heater filter (follow section 12).
c. Remove two (2) screws from the rear of the
appliance (middle).
c. Remove bracket (two (2) screws).
d. Remove the surge protector and sparker unit
(Follow section 7 c).
e. Remove bracket.
d. Remove six (6) fan assembly securing screws
at the bottom of the appliance, and at the bot-
tom back of the appliance.
f. Remove the two (2) securing screws on both
sides of the combustion chamber base.
g. Remove one (1) gas supply tube securing
screw, as per section 11 c.
e. Slide fan forward and disconnect wires from
PCB.
h. Unclip the connectors in the harness and
manouvre the combustion chamber out of
the appliance completely.
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15.Removal of the Spark Electrode
f. Lift and remove locating bracket.
CAUTION
g. Remove one (1) screw from the other end of
the combustion chamber (middle).
240 Volt exposure. Isolate the electrical supply to
the appliance and reconfirm with the neon
screwdriver or multimeter.
h. Remove thermocouple assy (follow section
9).
a. Follow section 3 (Removal of the Front
Panel).
b. Follow section 14 (Removal of the Combus-
tion Chamber.)
c. Remove two (2) screws to remove the elec-
trode bracket.
i. Lift top tab to release the burner and pull out
of combustion chamber in the direction of
the gas supply tube.
j. Remove the six (6) screws to remove the
burner cover shield.
16.Removal of the Main Burner
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).
b. 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 -
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17. Removal of the Thermistor
a. Follow section 3 (Removal of the Front
Panel).
b. Pry open the two (2) locating clips with a
screwdriver and disconnect from the PCB.
18.Removal of the Injector
a. Follow section 3 (Removal of the Front
Panel).
b. Remove four (4) screws (2 from bracket, 2
from injector block).
c. 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
Download from Www.Somanuals.com. All Manuals Search And Download.
ꢂꢌꢃꢁꢁ:LULQJꢁ'LDJUDP
Legend
bl: blue
bk: black
r: red
gy: grey
w: white
or: orange
y: yellow
br: brown
v: violet
gr: green
Convector 460/560PTR
- 55 -
©Rinnai
Download from Www.Somanuals.com. All Manuals Search And Download.
ꢂꢍꢃꢁꢁ%ORFNꢁ'LDJUDP
Convector 460/560PTR
- 56 -
©Rinnai
Download from Www.Somanuals.com. All Manuals Search And Download.
ꢀꢅꢃꢁꢁ7LPHꢁ&KDUWV
Convector 460/560PTR
- 57 -
©Rinnai
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Convector 460/560PTR
- 58 -
©Rinnai
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Convector 460/560PTR
- 59 -
©Rinnai
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Convector 460/560PTR
- 60 -
©Rinnai
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Convector 460/560PTR
- 61 -
©Rinnai
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Convector 460/560PTR
- 62 -
©Rinnai
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Convector 460/560PTR
- 63 -
©Rinnai
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Convector 460/560PTR
- 64 -
©Rinnai
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Convector 460/560PTR
- 65 -
©Rinnai
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