Rinnai Fan Convector Heaters Level III Training 1
Fan Convector Heaters FC510 (RCE-391A) FC824 (RCE-691TA)
Internal Components FC510 (RCE-391A) FC824 (RCE-691TA)
Specifications Product specifications Model Gas Type FC510N (RCE-391AN) Natural Gas FC510P (RCE-391AP) Propane Gas Input Rating Input Rating Btu/hr. HIGH Btu/hr. LOW 10,000 10,000 5,500 5,600 Gas Inlet Pressure Manifold Pressure HI/LO Inches W.C. (mm) 3.5 – 10.5 inches W.C (89 – 267 mm W.C) 1.8 / 0.64 inches W.C. (47 / 16.3 mm W.C.) 8.0 - 13.0 inches W.C. (203 - 330 mm W.C. 3.2 / 1.12 inches W.C. (82 / 28.6 mm W.C.) Fan Motor CFM HI/LO Fuse (Amps) 67.8 Low 97.8 High 5 67.8 Low 97.
Specifications Component/Clearance Specifications FC510 (RCE-391A) FC824 ( RCE-691TA) Gas Connection 1/2" Male NPT 1/2" Male NPT Gas Control Electronic Electronic Burners Ceramic Burner Ceramic Burner Temperature Control Electronic Thermostat Electronic Thermostat Ignition Sdystem Electronic Spark Ignition Electronic Spark Ignition Electrical Connection AC 120V, 60 Hz., 19 Watts AC 120V, 60 Hz., 29 Watts Weight 22.1 Lbs. (10kg) 26.5 Lbs. (12kg) Dimensions Height: 19.
Ledger Plate Explanation & Warranty • The letters “RCE” indicates this is a “Rinnai Convection Export” heater. • The numbers “510 & 824” indicate the model number of heater. • The letter “T” indicates duel timers on 824 model, no “T” indicates single timer on 510 model. • The letter “A” indicates this is an American version. • The “FC” indicates Fan Convertor Heater. • These units are not suitable for use in bathrooms or bedrooms.
Sequence of Operation 1. Convection fan starts, drawing air in through the back of the cabinet and across the heat exchanger / burner chamber and out into the space. The PCB verifies fan rotation. Thermocouple 1 Gas Valve Solenoids 2. Once the fan is running at the proper speed, spark ignition begins. 3. After spark begins, the gas valve solenoids open allowing gas into the burner. 4. Ignition occurs and flame develops across the burner. Thermocouple 2 Combustion Chamber Spark Electrode POV SV1 5.
Modulating Technology • Variable speed technology – Modulating gas and air based on the heat loss at that moment • With on/off single stage operation, gas usage can be high due to alternating periods between maximum flame and no flame at all • The Fan Convector modulating technology has the ability to replace only the heat escaping the structure by continuously operating at heating levels based on the demand at that moment On / Off Single Stage Heating Appliance Continuous-Run Modulating Technology 74°
Installation Instructions • Do not install this appliance above 2,000ft. • Do not block the warm air discharge. • Do not allow anyone to sleep directly in front of the appliance. • Do not insert items into the louvers. • Do not place clothing or other flammable material on or near the appliance • Do not spray aerosols near the appliance while it is operating. Most aerosols contain butane gas which is flammable.
Installation Instructions • Do not unplug the appliance while it is operating or while the fan is on. • Do not use a plug in type timer with this appliance. • Do not install in a windy area such as facing a window or a door leading to the outside.
Code Limitations • Check Federal, State and/or local codes in your state before using vent-free products. Some areas of the country do not allow vent-free products. • International Fuel Gas Code Standard 620-6 under “Prohibited Use” states that; “One or more unvented room heaters shall not be used as a sole source of comfort heating in any dwelling unit”.
Servicing Fan Convector There’s very little service required on the Fan Convector heaters. Below you will find three items that can be checked and/or cleaned in the event you are experiencing problems with you appliance. NOTE; ALL Service must be performed by a qualified installer, service agency or gas technician. 1. Gas control valve – The gas valve can be checked by verifying the manifold gas pressures are properly set.
Maintenance Cleaning Air Filters: Both air filters should be cleaned frequently during the heating season. 1. Unscrew the black cap (Phillips screw in the center of large filter) securing the air filter. Pull the filter up and away from the unit. 2. Remove the small filter simply by pulling the two tabs away from the unit. 2 3. Place both filters in warm water and wash all dust and dirt out the filter. 4. Dry filter with a soft cloth.
Error Codes & Troubleshooting 14
Fault Codes An error code will flash on the unit’s display when a fault occurs. Refer to the list of error codes below for details on your unit’s fault code. All troubleshooting and repairs should be made by a licensed contractor.
Fault Codes – Check thermistor wiring for damage, loose or broken connections or wires.
Wiring Diagram
Electrical Components Values Diagnostic Points Components Convection Fan Motor Mark CFM Wire Colors Value Pin # 3&4 Blue - Brown 10 - 12 VDC Blue - Yellow 2,000 - 5,000 Pulses/Min. (33 - 84 Hz) 2K - 10 KΩ 1&3 Blue - Red 11 - 14 VDC 0.
Warnings 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 heater. Only trained and qualified service Technicians should attempt to repair this product. Before checking for resistance readings, disconnect the power Source to the unit and isolate the item from the circuit (unplug it).
Warnings Failure to correctly assemble the components according to the instructions contained within this presentation May result in a gas leak or explosion Inspect all gaskets/packings for signs of damage or corrosion. Gaskets/packings found to contain damage or that Appear questionable MUST BE REPLACED. Failure to replace damage or questionable gaskets may result in gas leak or explosion.
TC1 & TC2 Milli-volt Readings Procedure for measuring TC1 & TC2 Thermocouple Outputs 1. Set voltage meter to read at least 35 milli-volts. Insert meter leads into the output test port holes on the rear of the unit, see below for proper test ports for each thermocouple.
Gas Valve Removal Caution: Shut off gas and power supply to the unit before proceeding. 1. 2. 3. 4. Disconnect gas piping to unit at the inlet gas connection shown below. Disconnect the POV gas solenoid valve wiring harness, (red & white wires). Disconnect SV1 & SV2 gas solenoids valves, (blue & brown wires). Remove (1) screw from retainer on the burner gas feed line. Slip retainer off the feed line, pull gas line out of the gas valve assembly. Replace O-ring on this line. 5.
P.C. Board Removal Caution: Disconnect the power and gas from the unit before proceeding. 1. Remove (1) screw from plastic P.C. board casing, front of unit 1/3 the way up the unit. 2. Lift up on the P.C. board casing and pull board out of unit. 3. Disconnect all wire connectors from P.C. board. Take care not to stress the connections when unplugging them. Press in on the latch to release the connector before unplugging connection. You can use a small screw driver to push in on these latches.
Safety Circuit Caution: Shut off gas and power supply to the unit before proceeding. 1. Burner sensor mounted on the left hand side of the burner assembly is designed to detect the burner temperature. If combustion conditions cause the burner temperature to drop below a predetermined temperature, the sensor will shut the unit off and flash an error code related to the fault. 2.
Igniter & Igniter Module Removal Caution: Shut off gas and power supply to the unit before proceeding. Igniter/electrode: 1. To remove the igniter unplug the black/green wires from the igniter. The green wire has a latch that has to be pushed in, in order to release the connector. Remove cover plate with (1) screw. 2. Remove (2) screws from igniter bracket assembly, pull igniter/bracket assembly out of unit. 3. Replace igniter gasket before reassembling in reverse order. Igniter Module: 4.
Burner Assembly Removal Next Seven Slides
Burner Assembly Removal Caution: Shut off gas and power supply to the unit before proceeding. 1. Remove louver assembly by removing (3) screws as shown below. 2. Remove (2) screws from each side of the front cover, then pull cover away from unit.
Burner Assembly Removal 1. Remove (4) screws on the FC510, (3) on the FC824 ,as shown below. 2. Unplug 15 pin connector from P.C. board. 3. Pull top panel away from unit.
Burner Assembly Removal Caution: Shut off gas and power supply to the unit before proceeding. 1. Disconnect the burner gas line from the gas control valve, (1) screw. Pull retainer clip off burner gas line. Pull gas line loose from the gas control valve. Verify O-ring is intact and in good condition. 2. Unplug the fan motor wiring harness from the P.C. board. 3. Unplug (10) pin safety circuit wiring harness from the P.C. board. 4. Unplug the POV gas solenoid valve. 5. Unplug (2) pin connector at P.C.
Burner Assembly Removal 1. Remove the (4) screws on the rear of the unit. 2. Remove (1) screw from left side of burner housing down next to floor base. 3. Slide the complete burner and fan assembly out of the unit.
Burner Assembly Removal 1. Remove the burner sensor on the left hand side of the burner housing, (3) screws. Pull the burner sensor retainer clip off the tab. 2. Remove the pilot assembly sensor and burner plate located on the right hand side of the burner housing, (4) screws. 3. Remove the cover plate off the igniter (1) screw and the (2) screws in combustion box. Pull igniter out of unit.
Burner Assembly Removal 1. Remove (2) screws from bracket and pull loose from unit. 2. Remove (4) screws for the combustion box cover and remove cover. 3. Remove (2) screws from burner assembly cover and remove cover.
Burner Assembly Removal 1. 2. 3. 4. Remove (3) screws holding burner assembly to heater housing. Slide burner assembly out of the burner chamber from right side of unit. Complete burner assembly after removed from unit. Install new burner assembly in reverse order.
Cleaning Burner Assembly
Cleaning Burner Caution: Shut off gas/power supply to the unit before proceeding. Wear safety glasses to preform task below. 1. Follow procedure for removing burner assembly, with exception to pulling the burner. The burner does not have to be removed to clean it. 2. Inspect burner for damage and/or cracks before proceeding. 3. Blow the ceramic burner out using 120 psi of compressed air. Hold the air nozzle back about six inches from surface during this process.
Cleaning ODS Pilot Orifice
Cleaning ODS Pilot Orifice Caution: Shut off gas/power supply to the unit before proceeding. Wear safety glasses to preform task below. 1. Remove front cover on unit (4) screws. 2. Locate pilot and burner orifice on the right hand side of unit, center of burner housing. 3. Blow out the orifices shown in picture 1 with 120 psi of compressed air. Hold the air nozzle back at least six inches from all components to prevent damage from the high pressure air. 4.
Fan Motor/Squirrel Cage Blower Removal Next Six Slides
Fan Motor Removal Caution: Shut off gas and power supply to the unit before proceeding. 1. Remove louver assembly by removing (3) screws as shown below. 2. Remove (2) screws from each side of the front cover, then pull cover away from unit.
Fan Motor Removal 1. Remove (1) holding the igniter module in place and (1) screw holding ground wire in place. 2. Remove (2) screws holding partition board in place. 3. Unplug fan motor from P.C. board.
Fan Motor Removal 1. 2. 3. 4. Remove (2) screws on the rear of unit. Remove (2) screws on left side of burner housing. Remove (2) screws on right side of burner housing. Slide fan motor and housing assembly out of the unit.
Fan Motor Removal 1. Remove (4) screws holding fan motor to unit’s housing. 2. Loosen screw on fan motor shaft and pull fan motor loose from unit.
Squirrel Cage Blower Wheel Removal 1. Remove (2) screws on squirrel cage bearing housing assembly, left hand side of unit. Remove bearing housing. 2. Loosen screw on fan motor shaft, right side of unit. Slide blower wheel out of unit from left side of unit. 3. Reassemble in the reverse order.
The End Fan Convection Heater Service Training 44
