Rinnai Continuum REU2532-W Series Service Manual Download Page 65

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REU-2532W Series

Rinnai

PARTS LIST

Number

Description

Part Number

Quantity

111

Packing of Combustion Chamber

AU155-207-2

112

Lower Packing of Combustion Chamber

H73-214

113

Screw

C10D-5

114

Combustion Chamber

U245-260

Front Plate Assembly

115

Combustion Chamber Front Plate

U245-261

116

Electrode

H73-120

117

Flame Rod

AH41-216

118

Electrode Packing

AH66-398

119

Electrode Holder

AH66-393

120

Upper Packing of Combustion Chamber

U245-262

122

Fan Casing Assembly

CH51-615

123

Blower Motor

H89-261

127

Fan Connecting Bracket

BH29-606

128

Fan Connecting Packing

AU183-562

132

Combustion Chamber Bracket

U245-255

135

Flue Outlet Assembly

U245-1131

136

Flue Outlet

U245-1130

137

Flue Outlet Packing

U245-1122

138

Flue Outlet Packing - 6

AH24-653-6

140

Heat Exchanger Complete Assembly

U245-1310

400

“Water Inlet (3/4”NPT)

H73-501-2

401

Water Flow Servo & Sensor Assembly

M8E-6-5

402

Rectifier

M8D1-15

Summary of Contents for Continuum REU2532-W Series

Page 1: ...EU2532 WC Series Water Heaters SERVICE MANUAL Rinnai Corporation 103 International Drive Peachtree City Ga 30269 Telephone number 800 621 9419 No portion or part of this manual may be copied without p...

Page 2: ...completing the service and confirming that there are no water or gas leaks or incorrect wiring test operation of the appliance After confirming normal operation explain what was serviced to the custo...

Page 3: ...bustion Specifications 18 11 Dip Switch Positions 19 12 Water Flows 22 13 Main Components 24 14 Time Charts 26 15 Operation Flow Principle 28 16 Operation Principles 30 17 Error Messages 32 18 Diagnos...

Page 4: ...rtz IC integrated circuit BTU H British thermal units PSI Pounds per square inch LED light emitting diode GPM gallons per minute mA milliamps W C inches of water column mm millimeters Nox oxides of ni...

Page 5: ...the fan housing The by products of combustion on the external unit are expelled from the appliance through the flue outlet situated on the front of the appliance at the top The general layout of comp...

Page 6: ...nit has a secondary freeze prevention device that will allow the unit to fire for three seconds if the water temperature inside the appliance drops below 37 F This mode will heat the water inside the...

Page 7: ...elderly care centers etc where the water temperature can not exceed a certain set point Over Temperature Control All Continuum models incorporate a device to prevent the hot water temperature from ex...

Page 8: ...REU 2532W Series 8 Rinnai 3 Dimensions...

Page 9: ...REU 2532W Series 9 Rinnai 4 Installation Piping recommendation...

Page 10: ...is flowing Enhanced communication system between the remote controls allowing priority temperature selection from each remote control Remote controls offer self diagnostics in the event of a fault wi...

Page 11: ...m the remote control s connected to the Continuum water heater Power for the remote s is supplied from the PC board On the front of the PCB there are two screws labeled terminals for controls This is...

Page 12: ...ature outside the heat exchanger reaches 264 F If the thermal fuse melts it breaks an electronic circuit which in turn shuts off the power supply to the gas solenoids shutting the unit off Combustion...

Page 13: ...y monitored by the water temperature thermistor located near the outlet of the appliance If the outgoing water temperature reaches 5 F above the preset temperature the burner will automatically go out...

Page 14: ...int Temperature without remote Factory setting 120 F Temperature range with remote keypads connected BC 45 4US 96 120 F BSC 45 4US 96 120 F MC 45 4US 96 140 F MCC 45 4US 96 180 F Approved gas type Nat...

Page 15: ...control cable Non polarized two core cable Top of heater Front of heater Sides of heater Back of heater Clearances from combustibles Ground Top of heater Front of heater Sides of heater Back of heater...

Page 16: ...REU 2532W Series 16 Rinnai 9 Cut way Diagram REU 2532 FFU Series...

Page 17: ...REU 2532W Series 17 Rinnai 10 Schematic Diagram REU 2532W Series...

Page 18: ...consumption Maximum Btu s 199 000 199 000 Upper 1 15 0 75 Injector Diameter Lower 1 8 1 15 Main Burner B3A7 1 Lean and Rich Bunsen Burner Main Damper H73 115 Upper 6 Lower Not Used Minimum Supply 6 W...

Page 19: ...set or check the manifold gas pressures on this appliance When dip switch 7 is placed in the ON position it places the appliance into forced low fire When dip switches 7 and 8 are placed in the ON po...

Page 20: ...n checking and or setting manifold gas pressures Dip switch 7 and 8 are used to place the appliance into forced high fire Before making any adjustments to these switches please ensure you follow the g...

Page 21: ...tial Units Residential Units REU 2532 W REU 2532 W Propane Gas Model Natural Gas Model Dip Switch Settings Dip Switch Settings SW1 SW2 SW1 SW2 1 Off 1 Off 1 Off 1 On 2 On 2 Off 2 On 2 Off 3 Off 3 Off...

Page 22: ...appropriate temperature rise Draw a vertical line up the graph from the selected temperature rise until it intersects the curve The point at where these lines intersect indicates flow at that temperat...

Page 23: ...you need the following information requested water temperature and inlet water temperature Next subtract the inlet water temperature from the requested temperature to get your delta T or temperature...

Page 24: ...heat exchanger 3 Burner The burner assembly is made up of 16 identical stainless steel Bunsen burners secured by an aluminized steel framework An aluminum manifold with 32 integral injectors supplies...

Page 25: ...mbustion fan is Controlling the gas valve based upon data from the combustion fan means that combustion remains satisfactory even if there are sudden changes in input conditions 1 Water Flow Sensor an...

Page 26: ...REU 2532W Series 26 Rinnai 15 Time Charts External Unit...

Page 27: ...REU 2532W Series 27 Rinnai...

Page 28: ...gas valve SV1 OPEN Sparker ON Solenoid valve SV3 OPEN Solenoid valve SV0 Closed Solenoid valve SV1 Closed Solenoid valve SV2 Closed Pre purge of combustion fan 2 seconds Overheat bi metal switch faul...

Page 29: ...shing 12 Flashing Flame failure less than 1 micro amp Water temperature over 200 degrees Thermistor faulty open or short circuit Combustion fan rpm s abnormal Flue restriction or block 71 Flashing 52...

Page 30: ...water flow sensor begins to revolve The revolution speed is proportional to the heater flow A sensor located inside the device relays information in the form of magnetic pulses to the main PCB to dete...

Page 31: ...e PCB that there is no water flowing in turn the PCB closes the gas valves The combustion fan continues to operate for 65 seconds This is to provide quicker ignition when the tap is turned on and off...

Page 32: ...ppliance is properly grounded Check gas solenoid valves for open or short circuits Check power supply for loose connections Check power supply for proper voltage and voltage drops Disconnect all MSA c...

Page 33: ...ons Ohm out each solenoid 72 Flame Sensing Device Faulty Check micro amps produced by flame rod Remove flame rod and check for carbon build up clean will sand paper Ensure flame rod is touching flame...

Page 34: ...lse min Off 0 6 gal min 20 Hz Below 1200 pulse min Yellow Black Gnd DC 4 7 V Pulse 17 460 Hz Combustion Fan A1 Red Black DC 6 45 V Yellow Black DC 11 13 V White Black Gnd DC 6 45 V 33 400 Hz Flame Rod...

Page 35: ...REU 2532W Series 35 Rinnai 20 REU 2532W Series Wiring...

Page 36: ...REU 2532W Series 36 Rinnai 21 Block Diagram...

Page 37: ...Disconnect unit from power supply b Measure resistance to check the electric fuse 3 amp Normal less than 1 If normal proceed to check item 2 below Faulty Replace 3 amp glass fuse If the fuse blows aga...

Page 38: ...replacing the remote control Faulty Replace PCB No combustion despite remote control indication 1 Is the water flow sensor normal Check the water flow sensor a Check the voltage at PCB connector B4 re...

Page 39: ...ormal 1 M or more If normal replace the PCB unit Faulty Replace the flame rod See page 43 for additional information and reading pertaining to the flame rod 3 Is the water temperature thermistor norma...

Page 40: ...l check item c below Faulty Replace the PCB unit c Measure voltage at connector A1 black and white wires Normal 6 45 VDC or 9 9 4 K 33 400 Hz If normal proceed to check item 5 below Faulty Replace the...

Page 41: ...ver solenoid SV1 a Disconnect the change over solenoid SV1 connector and measure resistance at the solenoid terminals Normal 1 7 2 1 K If normal check b below Faulty Replace the change over solenoid S...

Page 42: ...Disconnect the changeover solenoid SV3 connector and measure the resistance at the solenoid terminals Normal 1 7 2 1 K If normal check b below Faulty Replace the changeover solenoid SV3 b Measure the...

Page 43: ...the flame rod terminal C1 and the appliance earth Normal 5 150 VAC from yellow to ground If normal check b below Faulty Replace the PCB unit b Check that the flame rod attachment is not loose Normal...

Page 44: ...5 K 140 F 2 2 2 7 K 221 F 0 6 0 8 Normal Proceed to check item 2 below Faulty Replace the water temperature thermistor 2 Is the change over solenoid SV1 normal a Disconnect the changeover solenoid SV...

Page 45: ...l a Disconnect connector B2 and measure the resistance of the water flow servo red blue wires Normal 19 24 If normal proceed to b Faulty Replace the water flow servo and sensor b Disconnect connector...

Page 46: ...left for location of this element These are white wires Normal 100 110 If normal proceed to check item 2 below Faulty Replace defective anti frost heater assembly c Check resistance of the two heat ex...

Page 47: ...o to A 6 Yes Go to A 6 2 1 Measure resistance of each solenoid valve Remove connector E from the PCB before measuring Pink Black SV0 1 7 2 1K Yellow Black SV1 1 7 2 1K Brown Black SV2 1 7 2 1K Are val...

Page 48: ...voltage between yellow black at connector B4 4 7 VDC No Replace water flow sensor 12 Yes Replace PCB 13 Error code 72 displayed on the digital monitor 2 Check flame rod Measure resistance between flam...

Page 49: ...2 1 Disconnect connector E from the PCB Measure resistance between yellow black SV1 1 7 2 1K No Replace SV1 25 Yes Go to B 8 7 Check solenoid valve SV1 2 Measure voltage between yellow black of SV1 c...

Page 50: ...ature at various resistance Resistance values match table on page 44 No Replace water temperature thermistor 36 Yes Go to D 2 2 1 Disconnect solenoid connector E from PCB and measure the resistance be...

Page 51: ...Anti frost heater located in the water valve 46 Yes Go to E 2 2 Read resistance of the heating element that is mounted on the front of the heat exchanger White wires 100 110 No Replace anti frost hea...

Page 52: ...rew Adjust the regulator screw to achieve the correct gas pressure See figure 1 for location of the regulator adjustment screw Below are the proper pressures for Low fire per gas type Propane 0 88 w c...

Page 53: ...g the proper water temperature as set on the controller at your outlets If controllers are not being used the output temperature should be 120 F Figure 1 Figure 2 High pressure setting Pot Regulator a...

Page 54: ...mpt to repair this product Item Page 1 Removal of the Front Panel 55 2 Removal of the PC Board 55 3 Removal of the Water Flow Control and Sensor 55 4 Removal of the Sparker 56 5 Removal of the Combust...

Page 55: ...r 2 Removal of PC board CAUTION 120 volt potential exposure Isolate the appliance and reconfirm power has been disconnected using a multi meter a Remove the two 2 screws holding the PCB in place with...

Page 56: ...reconfirm power has been disconnected using a multi meter a Remove one 1 Phillips screw that secures the sparker module to the unit casing b Disconnect high tension lead and connector 5 Removal of the...

Page 57: ...moval of Burner Manifold and the Burner CAUTION 120 volt potential exposure Isolate the appliance and reconfirm power has been disconnected using a multi meter a To remove the burner manifold remove 6...

Page 58: ...this connection c Disconnect connectors from solenoids note which connector goes to each solenoid alone with the proper wire colors Pull gas valve assembly out of unit 10 Removal of Heat Exchanger CA...

Page 59: ...connected using a multi meter This process may involve removing the heat exchanger if the thermo fuse on the rear of the heat exchanger is blown a The REU 2532 has four thermal fuses see picture below...

Page 60: ...REU 2532W Series 60 Rinnai 26 EXPLODED VIEW CABINET...

Page 61: ...REU 2532W Series 61 Rinnai EXPLODED VIEW INTERNALS...

Page 62: ...REU 2532W Series 62 Rinnai EXPLODED VIEW INTERNALS...

Page 63: ...REU 2532W Series 63 Rinnai EXPLODED VIEW ELECTRICAL...

Page 64: ...Panel Packing Side AU115 163 1 009 Cable Connection BU56 602 N 1 010 Cable Seal Packing AU169 126 1 011 Seal Packing AU105 113 1 100 Gas Control Assembly C36E 41 S 1 101 Screw AU39 965 2 102 Gas Conne...

Page 65: ...66 398 1 119 Electrode Holder AH66 393 1 120 Upper Packing of Combustion Chamber U245 262 1 122 Fan Casing Assembly CH51 615 1 123 Blower Motor H89 261 1 127 Fan Connecting Bracket BH29 606 1 128 Fan...

Page 66: ...all AU103 413 1 411 Drain Valve AU142 444 1 702 PCB Cover Side BU195 507 1 703 PCB Cover Front BU168 707 1 704 Transformer Assembly ET 281 1 705 PCB Bracket U245 257 1 706 Ignitor EI 189 1 707 High Te...

Page 67: ...ss U245 610 1 726 Mold Type Over Heat Switch BU129 824 2 1 730 PCB U245 1200 1 731 Surge Protector BU195 1873 1 732 Frost Sensing Switch H73 750 1 733 120V Anti Frost Heater Assembly U245 1320 1 734 S...

Page 68: ...M10B 2 14 2 816 O ring M10B 2 7 1 817 O ring M10B 1 24 1 818 Packing C36E1 6 2 888 V2532W Owner s Manual U245 1360 1 Package Spec Sheet PWB 261 1 Manual 3 4 gas control valve BU195 1865 1 Kitchen remo...

Page 69: ...V3 and POV Gas valve and Modulating solenoids Set meter above 2K SV0 Pink Black 80 100 VDC 1 8K 2K ohms E1 1 2 SV1 Black Yellow 80 100 VDC 1 8K 2K ohms E2 2 3 SV2 Black Blue 80 100 VDC 1 8K 2K ohms E3...

Page 70: ...esistance decrease Then apply some ice to the thermistor and the resistance should increase See below for examples of temperatures and resistance reading at those temperatures Example 59 F 11 4 14K 86...

Page 71: ...sistance reading of 81 86 ohms and the one located in the water flow sensor valve has a resistance reading of 16 19 ohms Voltage throughout this circuit should be 120 VAC 3 Amp Fuses This unit has two...

Page 72: ...ulti step set back thermostats The Infra reds Vent free radiant heaters 99 9 efficient Heat like the sun Portable Cooking Products One two and two burner with broiler models Perfect for camping a picn...

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