Rinnai REU-V2632FFUG, REU-VM2632FFUC Service Manual

SERVICE MANUAL

o Suit Models:

Does NOT Suit Other Models

REU-V2632FFUG REU-VM2632FFUC

DRDAFT

All Rinnai products are certified by the

Distributed and serviced in Australia under a Quality System certified as complying with ISO 9001 by SAI Global

SAI Global

Australian Gas Association as compliant to relevant Australian Standards.

Rinnai Australia Head Office is certified as complying with ISO 9001 by SAI Global.

Rinnai New Zealand has been certified to ISO 9001 Quality Assurance by Telarc.

All Rinnai products are Certified to WaterMark by SAI Global. WaterMark certification is awarded to products and fittings complying with safety and water contamination standards.

Glossary of Terms and Symbols



dB(A) - sound pressure level in decibels, “A” range

DC - direct current

AC - alternating current

WFCD - water flow control device

FB - feedback information

FF - feed forward information

Hz - Hertz

IC - integrated circuit

kcal/h - kilocalorie per hour

kPa - kilopascals

LED - light emitting diode

L/min - Litres per minute

mA - milliamps

MJ/h - megajoule per hour

mm - millimetres

O - millimetres of water (gauge pressure)

mmH

OHS - overheat switch

PCB - printed circuit board

CPU - central processing unit

POT - potentiometer

rpm - revolutions per minute

SV - solenoid valve

ø - diameter

C - temperature rise above ambient

POV - modulating valve

TE - thermal efficiency

TH - thermistor

OUT

Infinity REU-V2632FFUG / HD200i REU-VM2632FFUC - iii - Issue 1 - 16/12/09 ©Rinnai

- temperature of incoming water

- temperature of outgoing water

WARNING

No portion or part of this manual may be copied without prior permission from Rinnai Australia.

Rinnai Australia reserves the right to make modifications and change specifications without notice.

W A R N I N G

Failure to comply with these instructions may result in serious personal injury or damage to the appliance.

• All wiring inside this appliance may be at 240 Volts potential.

• All service work must be carried out by an authorised person.

This manual has been published by Rinnai Australia Engineering & Technical Group.

We welcome users of this manual to provide feedback and suggestions for improvement purposes.

Table of Contents

Glossary of Terms and Symbols ......................... ....................................................... iii

1. Specifications ............................................................................................................. 1

2. Water Flow Rates and Pressures ................................................................................ 3

3. Dimensions ................................................................................................................ 4

4. Water Controllers ....................................................................................................... 5

5. Smartstart ................................................................................................................... 7

6. Operational Flow Chart ............................................................................................. 8

7. Cutaway Diagram .................................................................................................... 10

8. Operation Principles ................................................................................................ 11

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

10. Time Charts ............................................................................................................ 13

11. Wiring Diagram ..................................................................................................... 14

12. Component Circuit Value Table ............................................................................ 15

13. Dip Switch Settings ............................................................................................... 16

14. Fault Finding .......................................................................................................... 17

15. Component and Circuit Checks ............................................................................. 19

16. Maintenance Monitor / Error History .................................................................... 24

17. Gas Pressure Setting Procedure ............................................................................. 27

18. Gas Conversion Procedure ..................................................................................... 27

19. Dismantling for Service ......................................................................................... 29

20. Parts List ................................................................................................................ 37

21. Exploded Diagram ................................................................................................. 41

SERVICE CONTACT POINTS .................................. ............................................. 45

Infinity REU-V2632FFUG / HD200i REU-VM2632FFUC - v - Issue 1 - 16/12/09 ©Rinnai

1. Specifications

Rinnai model number

Type of appliance Temperature controlled continuous flow gas hot water system

Combustion system Room sealed, fan forced combustion

Installation Internal

Dimensions Width

Weight 21 kilograms

Gas consumption (Min. / Max.) Natural gas:

Connections Gas connection

Ignition system Direct electronic ignition

Electrical consumption Normal

Delivery Temperatures 40°C, 42°C, 50°C, 55°C, 65°C, 75°C & 85°C

Water flow control Water flow sensor, electronic water flow control device and electronic

Maximum hot water capacity, raised @ 25°C

Water pressure required to achieve maximum water flow

Minimum water flow for operation 2.4 L/min

Power supply Appliance - AC 240 Volts 50 Hz

Water controllers (optional)

Water Controller Cable (Supplied with controller) Non-polarized two core cable.

REU-V2632FFU REU-VM2632FFUC

Height Depth

Propane gas:

Cold water connection Hot water connection

Standby

(set by combination of dip switches on PCB)

By-Pass flow control device.

26 L/min

140 kPa

Water controller - DC 12 Volts

1. Up to 4 controllers can be fitted. See below for the combination limitation of water controllers

2. Wireless controllers can be fitted in the same manner of MC-91Q-2A

Kitchen control MC-100V-1A or MC-91Q-2A

Bathroom control BC-100V-1A or MC-91Q-2A

Second bathroom control BC-100V-1A or MC-91Q-2A

Third bathroom control MC-91Q-2A

350 mm 600 mm 259 mm

16~195 MJ/h 16~195 MJ/h

R3/4 (20A) R3/4 (20A) R 3/4 (20A)

45 W 2 W (with 1 water controller)

Infinity REU-V2632FFUG / HD200i REU-VM2632FFUC - 1 - Issue 1 - 16/12/09 ©Rinnai

Sensors and Safety Functions

• Hot Water Delivery Thermistor: Measures hot water temperature at the appliance outlet connec-

tion (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 exch anger, ga s supply is stopped when wate r temperature

reaches 97ºC for a number of seconds.

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

exceeds 129ºC.

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

at 2060 kPa, closes at 1470 kPa.

• 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

See dataplate on appliance.

Infinity REU-V2632FFUG / HD200i REU-VM2632FFUC - 2 - Issue 1 - 16/12/09 ©Rinnai

2. Water Flow Rates and Pressures

Water Flow vs Pressure Graphs

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Inlet pressure (kPa)

Outlet flow (litres/minute)

))8

REU-V2632WC & FFU

P(kPa) 0 20 30 40 50 60 70 80 100 120 140 150 200 300 Q(L/min)@Tset37 0 11.3 14.8 16.9 19 20.8 22.8 24.2 27 29.8 32 32 32 32 Q(L/min)@Tset60 0 6.4 10.4 13 15 16.5 18 19.4 21 22.5 23.5 23.8 24

Water flow rate and pressure characteristics as shown below.

Infinity REU-V2632FFUG / HD200i REU-VM2632FFUC - 3 - Issue 1 - 16/12/09 ©Rinnai

3. Dimensions

Dimensions Description

A Width B Depth C Height - Unit D Height - Including Brackets E Hot Water outlet (from wall) F Hot Water outlet (from centre) G Cold Water inlet (from wall) H Cold Water inlet (from centre)

I Gas Connection (from wall)

J Gas Connection (from centre)

Gas: Length (from base) Cold: Length (from base) Hot: Length (from base) Gas: Fitting Diameter Cold: Fitting Diameter Hot: Fitting Diameter

BC-100V

MC-100V

MC-91Q

120

120104

128

202

202022

181

FITTING

DIAMETER

* Please note that this measurement is to the left of the centre line.

REU-V2632FFUG

REU-VM2632FFUC

350

234.5 ~ 274.5 600 641

91 ~ 131

110

70 ~ 110

27 *

99 ~139

89 41 51 42 20 20 20

Infinity REU-V2632FFUG / HD200i REU-VM2632FFUC - 4 - Issue 1 - 16/12/09 ©Rinnai

4. Water Controllers

NOTE

water controllers must be installed in accordance with the relevant operation/installation instructions supplied with the water heater or controllers.

Care should be taken to ensure power supply to the Infinity is isolated when connecting / disconnecting controller wiring or transponder on wireless controllers. Failure to isolate power supply may result in damage to the appliance PCB.

Care should be taken when closing the Ezi-connect access panel, to ensure internal wiring for controllers is not shortened or crushed.

Troubleshooting Water Controller not showing display - (Wired Water Controllers)

• Check that the correct number and combination of co ntrollers have b een installed for the specific model Infinity. Refer to controller compatibility table below.

• Check water controller is turned ON.

• Check there is 12VDC power supply available to the controller from the Ezi-connect terminals.

• If there is 12VDC available from the Ezi Connect but no controller display, check wiring between Ezi-connect and controller is sound.

• If there is no power from the Ezi-connect terminals, but the hot water functions correctly, replace PCB.

Error Code 12 as soon as hot water tap is turned ON.

• Check 12VDC internal wiring to Ezi-connect terminal is not crushed or shorted.

• Rectify wiring and re-close Ezi-connect cover carefully.

Water Controller not showing display - (Wireless Water Controllers)

• Ensure transceiver module is mounted in the correct location, as per wireless controller installation instructions.

• Ensure 2 x AA batteries are in good working order and installed with the correct polarity within the wireless controller. (Battery polarity details on rear of wireless controller)

• Ensure distance between wireless controller and transceiver does not exceed 50 metres.

• Ensure channel has been allocated to each wireless controller.

• Ensure w ireless co ntroller has been pro grammed to the transceiver correctly , as per wireless controller installation instructions.

Water Controller Compatibility Table

A l l

Wireless Only

Installation

Wired & Wireless

Installations

A maximum of 4 wireless water controllers can be fitted with the following limitation:

Only ONE

A maximum of 4 water controllers can be fi tted. Any combination of delux e, universal and wireless controllers can be used with the following limitation:

Only ONE programmed as a master controller) or a MC-502RC/MC-503RC water controller.

Up to TWO

The FOURTH or a MC91Q.

MC-502RC / MC-503RC can be set as the Master Controller.

master controller can be installed. This can be a MC-100V, a MC-91Q (when

BC-100V water controllers can be installed.

water controllers in any installation MUST BE a MC-502RC / MC-503RC

PROGRAMMING FOR THE ‘UNIVERSAL’ WATER CONTROLLER (MC-91Q)

QUESTION

NOTE

Are there four water controllers connected?

IF NO: (You have three water controllers or fewer), go to Question 2.

IF YES: You will need to activate the fourth water controller as follows:

STEP 1: For the water co ntroller in the KITCHEN ONLY, press and h old the

‘Transfer’ and ‘On/Off’ b uttons si multaneously (see Fig. 5) unt il a ‘beep’ is heard (approximately 5 seconds).

STEP 2: Check th at th e di splay o n A LL FOU R water con trollers is l it an d

displaying a tem perature wh en ‘swi tched on ’. If any ONE of the controller displays two dashes (see Fig. 6) repeat STEP 1.

This completes the activation proced ure for the fourth co ntroller, you may ignore Question 2.

Is the water heater marked to state it delivers water not exceeding 50°C?

IF YES: No further action required.

IF NO: You will need to program the kitchen controller to enable selection of

temperatures higher than 50°C.

STEP 1: For the controller in the KITCHEN ONLY, press and hold the

‘Transfer’ and ‘On/Off’ buttons simultaneously (Fig. 7) until a ‘beep’ is heard (approximately 5 seconds).

STEP 2: When the controller fitted in the KITCHEN is switched On, it should be

possible to select temperatures higher than 50°C. If not, repeat STEP 1.

Fig. 5

Fig. 6

Fig. 7

If the water controller in the kitchen is replaced, repeat STEP 1 above for the replacement controller.

If the water controller in the kitchen is swapped with another controller (for example, the controller fitted in a bathroom), repeat STEP 1 for the controller moved from the kitchen to the bathroom. Then perform STEP 1 for the controller moved fro m bathroom to the kitchen.

5. Smartstart

H O T

C O L D

G A S

Cold Inlet Mains

Smartstart®

Module

Rinnai Continuous Flow Water Heater

Hot Water

Outle t

Hot Water

Outle t

HeatingLoopFlow

Heating Loop Return

Oneor more

MC-91Q

Controllers

Preheat Button

At least one temperature controller model MC-91Q must be used in conjunction with the water heater and the Smartstart® system. Alt ernatively, if water c ontrollers cannot be used a manual a ctivation switch must be used. Water Controllers cannot be used with the REU-V2426WS model.

At least one water controller model MC-91Q must be used in conjunction with the water heater and the Smartstart® system. Alternatively, if water contro llers cannot be used a manual activation switch is available. Refer to the installation manual for the Smartstart® system.

The installation of th e water heat er and wat er controllers must be performed in acc ordance with the operating/installation instructions supplied with the water heater. The Smartstart® system is designed for domestic installations. However, it may be suitable for certain non domestic installations.

Principle of operation

The "Smartstart®" system heats the water in the pipework water connected between the water heater and the hot water outlets before any outlets are opened using the 'flow and return' pipework principle. This results in water savings and reduced waiting time for heated water delivery from the outlet when opened.

Traditional 'flow and return' systems usually keep the water in the pipework heated continuously. The Smartstart® system however, only heats the water before the outlet is opened. This results in significant energy savings because water is not heated unnecessarily whilst retaining the benefits of traditional flow and return systems.

A schematic of the Smartstart® system installed in conjunction with a Rinnai continuous flow water heater and water controller as shown below.

If problems are experienced with Smartstart® operation refer to the Smartstart® Service Manual.

6. Operational Flow Chart

Operational Flow Chart - Continued

7. Cutaway Diagram

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