Rinnai Infinity 16i Service Manual

Service Manual

REU - 16 FUA - E

“Infinity 16 i”

Continuous Flow Water Heater

Important.

Read these instructions carefully before attempting service of this appliance. All work must be carried out by competent persons.

The Rinnai Infinity 16i water heater, when correctly installed, complies with the requirements of the United Kingdom Water Regulations / Byelaws (Scotland). These Products can be found listed in the Water Fittings and Materials Directory.

The Rinnai Infinity 16i water heater is CE Marked as allowed by Technigas. Certificate number E0940/5399 ID number 0461BQ0836 Date of Issue 23 Dec 2005

Quality System Standard

ISO 9001 - 1994

The Design, Development, and Manufacture of Gas Water Heating Appliances done under Rinnai’s Quality Management System is certified under the Quality Management System Standard ISO 9001.

Registration Number JQ0003D Registered since: February 1994 Certified by Japan Gas Appliances Inspection Association.

UK INSTRUCTIONS

This appliance may only be serviced or repaired by someone certified competent to do so. At the time of printing the only people deemed competent to install this appliance are those that are CORGI registered for this type of appliance in this type of location who have a current ACS certificate.

1. Gas safety (Installation & Use) regulations 1998 are the ‘Rules in force’. In your own interest and that of safety, it is law that all gas appliances are installed and serviced by competent persons in accordance with the above regulations. Failure to install appliances correctly could lead to prosecution. Other persons should NOT attempt to install this equipment.

2. Installation must be in accordance with the current issue of the following:

Building Regulations issued by the Department of the Environment Building Standards (Scotland) Regulations. I.E.E. Wiring regulations for electrical installations. Gas safety (Installation and Use) Regulations current issue. BS 5546 BS 5440 BS 6891 BS 5482 BS 6700 BS 6644 Institute of Gas Engineers Publications Local byelaws Water regulations Health and safety at work etc. Act 1974 IGE/UP/10 Part1 Edition 2. Building Regulation J

Please be sure that you are fully aware of your obligations and responsibilities under

these regulations.

Such other specifications and regulations that may supersede or complement the above documents.

Contents

Contents………………………………………………………………..…………………4

Glossary of Terms and Symbols.............................................................................5

Introduction.............................................................................................................6

Specification of 16i..................................................................................................7

Sensors and Safety Devices..................................................................................8

Combustion Specifications.....................................................................................8

Dimensions.............................................................................................................9

Schematic Diagram..............................................................................................10

Structure Diagram.................................................................................................11

Main Components.................................................................................................12

Water Flow............................................................................................................14

Water Pressure vs. Flow.......................................................................................16

Gas Conversion Procedure..................................................................................17

Testing..................................................................................................................19

Gas Pressure Setting............................................................................................20

Dip Switch Setting.................................................................................................22

Troubleshooting the Infinity 16i.............................................................................23

Remotes...............................................................................................................24

Operational Flow Chart.........................................................................................25

Time Charts..…………………………………………………………………......…….26

Error Codes.........................…………………………………………………….....….27

Diagnostic Checks………............……………………………………………............29

Fault Finding Chart…………………………...........................………………………39

Wiring Diagram..……………………………………............………………...............46

Diagnostic Points….………………………………………………......………..……...47

Servicing Procedure…….……………………………………………………………..48

Dismantling for Service……………………………………………………………......49

Exploded Diagram................................................................................................56

Parts List...............................................................................................................61

Letter of Compliance……………………………………………………....….............65

CE Certificate……………………………..……………………………………............66

Service Contact……………………………….…………………………….........……67

Glossary of Terms and Symbols

Introduction

The Rinnai Infinity hot water units represents the latest technology in continuous flow, temperature controlled hot water.

Features

• The Rinnai Infinity 16i will NEVER RUN OUT of hot water. As long as electricity,

water, and gas supplies are connected, hot water is available when hot water taps are open.

• Built into the main micro-processor is the facility to LIMIT THE MAXIMUM TEM-

PERATURE of the hot water supplied. The water temperature may be set to vari-

ous temperatures. This is particularly useful when the hot water unit is installed where young children or the infirm may be using the hot water. If required, the temperature can be changed via the control pad on the front of the unit or with a localised controller. For further information, please contact Rinnai.

• Rinnai Infinity internal units are powered flue appliances. This makes them COM-

PACT, saving both floor and wall space.

• The temperature of outgoing hot water is CONSTANTLY MONITORED by a

BUILT-IN SENSOR. If the temperature of the outgoing hot water rises to more than

55°C the burner is shut OFF and only turned ON again when the temperature falls to below the selected temperature.

• The burner lights automatically when the hot water tap is opened, and extinguishes

when the tap is closed. IGNITION IS ELECTRONIC, so there is no pilot light. When the hot water tap is off, no gas is used.

• The 16i has a built in controller on the front of the unit for easy control. Two addi-

tional external temperature controllers can be mounted remotely from the heater.

This offers the following additional features: Localised temperature setting. Diagnostic message. Error Codes.

• Temperatures selected at the controllers are retained in the SYSTEM MEMORY

when the controller gives up priority or the system is turned off. Temperatures over

C will revert to 550C when power and/or priority is regained.

• Operating NOISE LEVEL IS VERY LOW.

• ERROR MESSAGES ARE DISPLAYED on the Temperature Controllers, assisting

with service.

• FROST PROTECTION device built in as standard.

Specification of 16i

Type of Appliance Temp Controlled Continuous Flow Gas Water Heater Operation With / Without remotes (Kitchen, Bathroom, etc.) Flue System Room Sealed, Forced Draught Flue Installation Internally Mounted only Available Temps 37C - 48C (1 deg Increments) 50, 55, 60

Dimensions Height 675 mm

Weight 15 kg

Connections Cold Water 1/2 in bsp

Ignition System Direct Electronic Ignition Noise Level 49 dB(A) Nox 55 ppm Max Water Temp Control Simulation feed forward and feedback

Boil Dry Water Flow Sensor Remaining Flame 97 C bimetal switch Safety Devices Over current Glass Fuse 3 Amp

Combustion Fan Integrated circuit system Fusible Link 150 C Thermal Fuse

Remote Controls Kitchen BC-45-SR-EU or BSC-45-SR-EU

Remote Cable

Width 370 mm

Depth 130 + 45 mm

Gas 1/2 in bsp

Hot Water 1/2 in bsp

Flame Failure Flame Rod

Over pressure Pressure Relief Valve 15 bar open, 12 bar close

Over temperature Lockout Thermistor 95 C Heater Mounted MC-45-SR-EU

Bathroom BC-45-SR-EU or BSC-45-SR-EU

Two core sheathed (double insulated) flex with min 0.55 mm

G20 Nat Gas Press Low 1.8 mbar G20 Nat Gas Press High 9.0 mbar G25 Nat Gas Press Low 1.8 mbar G25 Nat Gas Press High 9.0 mbar G30 LPG (Butane) Press Low 2.2 mbar G30 LPG (Butane) Press High 11.4 mbar G31 LPG (Propane) Press Low 2.2 mbar G31 LPG Propane) Press High 14.2 mbar Gas Consumption Low (Gross) G20 Nat Gas 4.7 kW 0.4 m3/hr G25 Nat Gas 4.0 kW 0.4 m3/hr G30 LPG (Butane) 4.9 kW 0.35 kg/hr G31 LPG (Propane) 4.9 kW 0.35 kg/hr Gas Consumption High (Gross) G20 Nat Gas 34.9 kW 3.26 m3/hr G25 Nat Gas 29.6 kW 3.26 m3/hr G30 LPG (Butane) 36.8 kW 2.6 kg/hr G31 LPG (Propane) 36.5 kW 2.6 kg/hr Max Flow raised 25C 15.2 L/min Min Operation Flow 2.4* L/min Water Pressure Nom. 1.1 - 7.0 bar Power Supply 230 V / 50 Hz Electric Consumption 68 Watts

Sensors and Safety Devices

• Heat Exchanger Thermistor: Measures hot water temperature at heat exchanger outlet. If

water temperature reaches a predetermined limit, gas supply is stopped.

• Hot Water Delivery Thermistor: Measures hot water temperature at the outlet valve (i.e. the

‘mixed’ temperature).

• Flame Rod: Monitors combustion characteristics inside the combustion chamber. If the flame

fails, gas supply is stopped.

• Overheat Switch: Situated on the heat exchanger, gas supply is stopped when water

temperature reaches 97ºC for a number of seconds.

• Fusible Link: Situated on the heat exchanger, electrical power supply is stopped if the

temperature exceeds 150ºC.

• Water Pressure Relief Valve: Safeguards the water circuit against excessive inlet pressure.

Opens at 15 bar, closes at 12 bar.

• Electrical Fuse: (3A glass fuse) prevents against over-current. Surge Protector: prevents

against over-current.

• Boil Dry Prevention: If water flow sensor detects no flow, gas supply is stopped.

• Combustion Fan Speed Sensor: In case of combustion fan defect (no rotation of fan) gas

supply is stopped.

• Temperature Cutout: If the delivered hot water temperature rises above the required delivery

temperature for a number of seconds, the gas supply is stopped.

Combustion Specifications

Injector

Gas Type

Natural Gas

(G20)

Propane (G31) 37 2.2 14.2 4.9 36.5

The secondary gas pressure is set with the cover off the unit and a manometer measuring the pressure from the gas valve (regulator) test point

size

(mm)

1.3 20 1.8 9.0 4.7 34.9

Damper

Nat Gas

LPG

Primary

Pressure (mbar)

Secondary Pressure

(mbar)

Low High Low High

Gas Input [Gross]

(kW)

Dimensions

Schematic Diagram

HOT WATER SUPPLY OPERATION

Ignition

Press ON/OFF Button of Optional Remote Control to turn on unit . The remote control display and priority LED will light up. When a hot water tap is opened the Water Flow Sensor revolves and sends a pulse signal to the Printed Circuit Board (PCB.) When the PCB detects a water flow over 2.4 L/min it compares the temperature at the Hot Water Thermistor to the set point and begins the ignition process; the Combustion Fan starts first. Once the chamber has been purged and the air proving has made the Electrode begins to spark to Earth. The Main

Solenoid Valve and Changeover Solenoid Valve 2 are opened and the Burner lights. The Flame Rod will ensure proper burning before Changeover Solenoid Valve 1 will open.

Temperature Setting

With the Temperature Control Buttons on the controller the outlet temperature can be set from 37 - 60℃. When the temperature set point is above 50℃ the High Temperature Indicator glows. Temperature can not be set above 48℃ while hot water is in use (flowing.) The unit will continually monitor the outgoing temperature and can fully modulate the performance with the

Modulating Valve and the Servo Control.

Standby

When the hot water tap is closed the PCB no longer receives a pulse signal from the Water Flow Sensor. The PCB shuts the Main Solenoid Valve and Change-over Solenoid Valves and the Burner extinguishes. The combustion fan will run on to post purge the chamber.

Structure Diagram

Main Components

1. Gas Control Unit

1.1 Modulating Valve This device is used by the PCB to adjust the volume of gas to the burner in proportion to the volumetric flow rate of water in order to maintain a supply of constant temperature hot water amid changes in water flow rates and incoming temperatures.

1.2 Change-over Solenoid Valves Additional solenoid valves are included to section the burner and stage the control in 3 steps. This gives the Burner more steady combustion at the required capacity and allows the water heater to operate at very low flow rates and temperature rises.

2. Flame Rod Monitors combustion characteristics inside the combustion chamber. If the flame fails, gas supply is stopped. Works through rectification of the combustion flame. An AC current is supplied to the flame rod. Electrons can only pass from the rod to the burner, and never from the burner to the rod, so the resultant DC current is used to prove combustion. When the DC current is present the burner has normal combustion, if the DC current is not present (or an AC current is present) the unit shuts the solenoid valve.

Main Components

3. Thermal Fuse

The thermal fuse is an electric link which must be intact for the unit to operate. If the thermal fuse reaches a set temperature it will melt and the unit will shut down. The thermal fuse must be replaced if it melts. It is to protect against over heating and heat exchanger splits where water may leak out and be superheated into steam.

4. Overheat Safety (Bi-metal Switch)

This Bi-metal Switch is fixed at the bend of the Heat Exchanger hot water outlet. If the temperature outlet from the heat exchanger reaches 97 and the solenoid valve circuit is broken. This will cease combustion in case of overheat.

5. Combustion Fan

The combustion fan supplies primary air into the wing burners and secondary air up through the Bunsen style burners. The fan is DC low voltage and the speed is controlled by the PCB depending on the hot water flow and temperature. The fan speed is compared to the current required to attain that speed for air proving. If the fan current is over or under the parameters for the given speed the unit will shut down on air proving.

6. Water Volume Servo with Water Flow Sensor

6.1 Water Flow Sensor Water flow sensing is done with a small turbine that spins when water travels through it in the correct direction. Each of the four fins on the turbine has a small magnet on it. Outside of the valve there is a magnetic sensor that detects the speed that the turbine is revolving. The revolution speed is input to the PCB which relates this speed to the water flow volume and determines whether it is sufficient for ignition.

6.2 Water Volume Flow Servo The water volume is adjusted by opening and closing the water flow valve with the servo motor. This will limit the maximum hot water flow to 20 L/min, and will limit the water flow further when the burner is at high fire to ensure the temperature setpoint it met.

C the bi metal switch will open

Water Flow

The figures on the following page show the available water flow rates for different outlet temperatures based on a range of inlet temperatures. Regardless of the output capacity the maximum flow rate is limited to 20 litres/minute.

Water Flows can also be calculated by the following formula:

M = 60 x ( Q / C x T )

Where M = Water flow rate in litres/minute. If M is greater than 20, the water must be mixed down at the point of use as the maximum flow rate of the unit is limited to 20. Q = Heat energy output in kW = 28 kW for the Infinity 16i (the heat input to the water) C = Specific heat of water = 4.2KJ/Kg C. Constant for this calculation. T = Temperature rise required ( C)

Example: What is the flow rate available with an incoming water temperature of 10 C and a required temperature of 20 C ? T = 20 - 10 = 10 C Q = 28 C = 4.2 M = 60 x ( 28 / (4.2 x 10) ) = 40 l/min. Since 40 is greater than 20 this flow rate must be mixed at the outlet.

How to read the charts on the following page.

The vertical axis indicates the selected temperature on the remote control and the horizontal axis indicates the flow of water in litres/ minute. Remote control range is between 37 normal conditions (temperatures up to 75 temperature rise is the difference between the Incoming Water Temp and the Hot Water Outlet Temp as selected on the controller.

Select the appropriate chart based on incoming water temperature. Draw a horizontal line across the graph from the selected temperature at the controller until it intersects the curve. From this point draw a vertical line until it intersects the axis. The value at this point of the axis is the maximum flow rate available. If the value is over 20 litres/minute a higher temperature will have to be used on the controller and the water temperature mixed down at the outlet.

C may be available if set on the dip switches.) The

C and 600 C under

Water Flow

Incoming Water Temp 5C

70 60 50

40 30

20 10

Hot Water Outlet Temp C

0 5 10 15

2.4 L/min min Flow

Hot Water Flowrate L/min

Incoming Water Temp 10C

80 70 60 50 40 30 20 10

Hot Water Outlet Temp C

2.4 L/min

0 5 10 15 20

min Flow

Hot Water Flowrate L/min

Incoming Water Temp 20C

80 70 60

50 40 30

20 10

Hot Water Outlet Temp C

2.4 L/min

0 5 10 15 20 25

min Flow

20 L/min

max Flow

Hot Water Flowrate L/min

Water Pressure vs. Flow

The water pressure vs. flow characteristics are as follows:

Regardless of how high the incoming water pressure is it is not possible to obtain more than 20 L/min from the Rinnai Infinity 16i. In order to have this much flow the temperature rise must be low enough that the unit has the capacity to satisfy the temperature setpoint for this flow rate. For higher temperature rises the flow rate will be lower, regardless of the incoming pressure.

The water heater has a water flow regulator that will throttle the flow rate back to make sure that the unit only supplies water at the required temperature. If demand exceeds the capacity of the unit, the unit will limit the water flow so the temperature does not alter.

The water heater’s heat exchanger has a much higher pressure drop at high flow rates then at low flow rates. For low pressure installations use higher temperature set points.

In order to achieve maximum flow rate 1.5 bar pressure is required. The unit will operate on lower pressures. It is advisable to have at least 1.1 bar pressure.

）

L/min

（

VOLUME

WATER

012345678

WATER　PRESSURE（bar

）

Gas Conversion Procedure

Testing

1. Purge gas, hot water and cold water supply lines before making the final connection of the water heater. Swarf in either the gas or water supplies may cause damage.

2. Turn on gas and cold water supplies.

3. Test for water leaks and gas escapes near the unit.

4. Isolate gas and electric supply. Remove test point screw located on the inlet gas pipework below the heater and attach pressure gauge.

5. Turn the power on at the switch and turn on gas. Warning: There are 230V AC live supplies inside the heater.

6. If remote controllers are fitted, turn the controller on, select the maximum delivery temperature and open ALL available hot water outlets. If remote controllers are not fitted, simply open all available hot water outlets. (CAUTION: Ensure building occupants do not have access to hot water outlets during this procedure).

7. The gas pressure check must be carried out with all other appliances on the same main operating at maximum capacity to ensure that there is sufficient gas pressure.

8. With all appliances on the same main operating at high fire check the pressure at the test point on the inlet to the gas valve. The pressure must be within the local defined limits for the type of gas that is being used. If the pressure is lower, the gas supply is inadequate and the water heater will not operate to specification. Check gas meter, regulator and pipework for correct operation/sizing and rectify as required. Note that the gas regulator on the appliance is electronically controlled and factory pre-set. Under normal circumstances it does not need adjustment during installation.

UK the gas pressure must be at least 20 mbar for G20 Natural Gas as used in

UK. For G31 Propane as used in the UK the pressure must be at least 34.5 mbar.

9. Close hot water outlets.

10.Inspect and clean the strainer and the filter located on the cold water inlet pipe. This procedure may need to be repeated to ensure the strainer remains clear.

11.If temperature controllers are fitted, it is necessary to test their operation through the complete range of functions.

12.Confirm the hot water delivery temperature using a thermometer. If controllers are fitted, compare the measured value to the set point.

13.After testing is completed, explain to the user the functions and operation of the water heater and temperature controllers.

Gas Pressure Setting

The working gas pressure on the water heater is electronically controlled and factory set. Under normal circumstances it does not require adjustment during installation. Perform this procedure only if the unit is not operating correctly and all other possible causes for

incorrect operation have been eliminated.

to alter the gas pressure. Failure to do so could void the warranty.

1. Turn 'OFF' the gas supply.

2. Turn 'OFF' 230V power supply.

3. Remove the front cover from the appliance.

4. Check gas type dip switches no.1 and no. 2 are in the correct position for the type of gas (Nat. or LPG)* you are using. See Fig. 1

Contact Rinnai before attempting

off on

On is in the right hand position, Off is in the

left hand position.

5. Attach pressure gauge to burner test point. (Fig. 2)

6. Turn 'ON' the gas supply.

7. Turn 'ON' 230V power supply.

8. If remote controllers are fitted, turn the unit 'ON' at the controller and select a maximum delivery temperature.

9. Open a hot water tap fully. (CAUTION: Ensure

building occupants do not have access to hot water outlets during this procedure.) Wait for the unit to

light.

10.Set the Rinnai Infinity to 'Forced Low' combustion by setting No. 7 dipswitch to 'ON'. (Fig. 3)

1 -Nat. Gas 2 -Nat. Gas 3 4 5 6 7 8

off on

1 -LPG 2 -LPG 3 4 5 6 7 8

off on

Fig. 3

Fig. 1

Fig. 2

1 2 3 4 5 6 7 8

* Note: Simply changing the position of the dip switches will not convert the unit from one gas type to the other. The conversion procedure requires a change of injector manifold. Contact Rinnai or your supplier.

Gas Pressure Setting

11.Check the burner test point operating pressure.

12. Remove rubber access plug and adjust the regulator screw on the modulating valve (Fig. 4) as required to the pressure below. Replace rubber access plug.

N.G 1.8 mbar

G20 G25

1.8 mbar

Adjustment Point

Fig. 4

LPG 2.2 mbar

G30 G31

2.2 mbar

13. Set the Rinnai Infinity to 'Forced High' combustion by setting no. 7 and no. 8 dipswitches to 'ON'. (Fig.5) Ensure maximum water flow.

14. Check the burner test point pressure.

15. Adjust the high pressure potentiometer on the Printed Circuit Board above SW1 (Fig. 6) to the pressure shown below. The potentiometer is very sensitive, turn no more than a few degrees at a time; then let the pressure settle down before turning it more.

N.G 9.0 mbar

LPG 14.2 mbar

G20 G25

G30 G31

9.0 mbar

14.2 mbar

16. IMPORTANT: Set dip switch no. 7 and no. 8

to 'OFF' to return the appliance to 'Normal' combustion.

17. Close hot water tap.

18. Turn OFF the gas supply and 230V power supply.

19. Remove pressure gauge, and replace sealing screw.

20. Turn 'ON' the gas supply and 230V power supply.

21. Operate unit and check for gas leaks at test

point.

22. Replace the front cover of the appliance.

off on

High Press.

Potentiometer

CAUTION

1 2 3 4 5 6 7 8

Fig. 5

Fig. 6

+ 46 hidden pages