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Rinnai REU-V1616WF, Service Manual

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Rinnai REU-V1616WF Service Manual Download Page 46

Infinity REU-V1616WF

- 41 -

Issue 1 - 

21/11/03

 

©Rinnai

e. Remove the manifold and burner unit. [Refer to 

point 6].

f. Remove the fan motor. (3 screws)
g. Remove thermal fuse, overheat switch, igniter, back 

pressure joint and Heat exchanger (Assy).

13) Removal of the Thermal Fuse

a. Remove the heat exchanger [Refer 12].
b. Remove the thermal fuse.

Note:

 After replacing, install the thermal fuse as in the 

following diagrams.

Heat Exchanger Right

c. Remove one (1) screw of the bi-metal overheat 

switch.

Heat Exchanger Front

Heat Exchanger Back

Heat Exchanger Centre

Summary of Contents for REU-V1616WF

Page 1: ...REU V1616WF INFINITY 16 FE Internal Rinnai High Capacity Continuous Flow Gas Hot Water System SERVICE MANUAL ...

Page 2: ... 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 SAI Global ...

Page 3: ...he appliance This manual has been published by Rinnai Australia 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 a...

Page 4: ...taway Diagram 14 8 Operational Flow Chart 15 9 Operation Principles 16 10 Main Components 17 11 Time Charts 19 12 Wiring Diagram 20 13 Dip Switch Settings 21 14 Fault Finding 22 15 Component Circuit Value Table 24 16 Component and Circuit Checks 25 17 Maintenance Monitor Error History 31 18 Gas Pressure Gas Conversion Procedure 33 19 Dismantling for Service 34 20 Exploded Diagram 42 21 Parts List ...

Page 5: ...ilocalorie per hour kPa kilopascals LED light emitting diode L min Litres per minute mA milliamps MJ h megajoule per hour mm millimetres mmH2O millimetres of water gauge pressure OHS overheat switch PCB printed circuit board CPU central processing unit POT potentiometer rpm revolutions per minute SV solenoid valve ø diameter oC temperature rise above ambient POV modulating valve TE thermal efficie...

Page 6: ...nce It is COMPACT 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 3ºC above the selected temperature shown on the Digital Monitor or the pre set limit when Remote Controls are not fitted the burner will automatically go out The burner will ignite again once the outgoi...

Page 7: ...KQP 㧙 4 㧔 㧕 QNF YCVGT EQPPGEVKQP 㧙 4 㧕 QV YCVGT EQPPGEVKQP 㧙 4 㧕 IPKVKQP U UVGO KTGEV GNGEVTQPKE KIPKVKQP NGEVTKECN EQPUWORVKQP 0QTOCN 㧙 㨃 UVCPFD 㧙 㨃㧔 9 6 4GOQVG EQPVTQN 㧕 PVK HTQUV RTQVGEVKQP 㧙 㨃 㧔1RVKQPCN㧕 QV YCVGT ECRCEKV 㧔 4CKUGF 㧕 VQ OKP 6JGTOCN GHHKEKGPE 01 CH RRO KVEJGP EQPVTQNNGT 㧦 㨪 6GORGTCVWTG TCPIG YKVJ TGOQVG CVJTQQO EQPVTQNNGT 㧦 㨪 GHCWNV VGORGTCVWTG EQPVTQN YKVJQWV TGOQVG ޔ ޔ ޔ HCEVQT...

Page 8: ...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 tempe...

Page 9: ...ure rises by mixing hot water from the outlet of the water heater with cold water from the mains supply as illustrated below Water Flows can also be calculated by the following formula Q Heat energy available in kW 28 kW for the REU V1616WF C Specific heat of water 4 2KJ Kg C C does not change for the purpose of this calculation T Temperature rise required C Example What is the flow rate available...

Page 10: ... kPa Approx Gas Cons MJ h L sec L min L hr Min Water Pressure kPa Approx Gas Cons MJ h L sec L min L hr Min Water Pressure kPa Approx Gas Cons MJ h REU V1616WF Internal 18 125 20 125 0 27 16 960 72 125 0 22 13 2 792 60 125 0 19 11 4 684 44 125 0 17 10 2 612 35 125 Temp Rise º C Approx Min Max Gas Input MJ hour L sec L min L hr Min Water Pressure kPa Approx Gas Cons MJ h L sec L min L hr Min Water ...

Page 11: ...elow a minimum supply pressure of 90 kPa is required to operate at the rated flow of 16 L min In an actual installation pressure losses in the plumbing system also need to be considered to determine the minimum supply pressure 9 6 4 24 5574 81 7 9 6 4 24 5574 M2C 9 6 4 81 7 OKP 4 7 8 9 ...

Page 12: ...SS 52 50 42 3 mm CONNECTION R 20mm R 15mm R 15mm 3 4 2 1 1 2 334 60 350 1 78 170 72 5 A 510 62 GAS 60 COLD 99 HOT 101 ELEC 9 40 78 125 CABLE ACCESS HOT WATER OUTLET COLD WATER INLET GAS CONNECTION 257 24 5 336 565 WALL INSTALLATION PITCH 549 WALL INSTALLATION PITCH 15 538 579 15 10 45 adjustable ...

Page 13: ...terial design used The use of Rinnai Vents Rinnai Part No VENTS will provide correct ventilation See installation instructions provided with the water heater for full details Note Incorrect ventilation can cause the appliance to operate in an unsatisfactory manner and can lead to a dangerous situation Flueing Install the Rinnai Infinity WF FE Flueing system in accordance with the instructions supp...

Page 14: ... location not to cause a nuisance The Rinnai REU V1616WF is a fan assisted appliance use the fan assisted clearances in AS5601 AG601 Clause 5 13 6 5 All Flue MUST be supported and be independent of the appliance in accordance with AS5601 AG601 Clause 5 13 4 2 and 5 13 4 3 Ensure the appliance can be removed without causing movement or displacement of the flue as per AS5601 AG601 clause 5 13 4 1 Te...

Page 15: ...Where the total vertical flue height does not exceed 2 metres the fitting of a Condensation Trap Drainage is not required As vertical height of flue installation is in excess of 2 metres a Condensation Trap Drainage MUST BE fitted Use combinations of fixed and adjustable flue lengths to position the installation as flue components can NOT be cut to size Use combinations of fixed and adjustable flu...

Page 16: ...trollers are water resistant however durability is improved when positioned outside the shower recess or at least 400mm above the highest part of a sink basin or bath DO NOT INSTALL THE CONTROLLERS NEAR A HEAT SOURCE SUCH AS A COOK TOP STOVE OR OVEN HEAT STEAM SMOKE AND HOT OIL MAY CAUSE DAMAGE IN DIRECT SUNLIGHT OUTDOORS UNLESS AN ENCLOSURE IS PROVIDED WHICH PROTECTS THE CONTROLLER AGAINST SUNLIG...

Page 17: ... terminals to the appliance with the power on RISK OF ELECTRICAL SHOCK Connecting One or Two Controllers 1 Isolate the power supply 2 Remove the front cover from the Appliance 4 screws as shown in fig 1 3 Thread the cable s through the cable access hole at the base of the appliance 4 Ensure the position of the terminals for controls shown on the printed circuit board COVER Connect the spade connec...

Page 18: ...r washer is placed at the bottom right hand corner for earthing purposes If the front cover of the appliance contains the following text THIS APPLIANCE DELIVERS WATER NOT EXCEEDING 50 C IN ACCORDANCE WITH AS 3498 IF YES No further action required IF NO You will need to program the Kitchen controller to enable selection of temperatures higher than 50º C STEP 1 For the controller in the KITCHEN only...

Page 19: ...Infinity REU V1616WF 14 Issue 1 21 11 03 Rinnai 7 Cutaway Diagram ...

Page 20: ...Infinity REU V1616WF 15 Issue 1 21 11 03 Rinnai 8 Operational Flow Chart ...

Page 21: ...e main solenoid and changeover solenoid valves open as required the spark generator activates and the spark electrode ignites the burner 2 Water Temperature Flow Control Volume Control The PCB will automatically control operation of the internal components to achieve the programmed temperature When a high temperature rise is required the PCB may cause the Water Flow Servo to close partially result...

Page 22: ...d by the PCB The PCB calculates the exact water flow from the frequency of pulses generated by the turbine A minimum flow rate of 2 4 l min is required for the burner to ignite Water flow control is achieved through the use of servo driven water flow control valve and fixed bypass Servo motor is controlled by the PCB The Water Flow Valve restricts the flow of water into the heat exchanger assembly...

Page 23: ... This is located on the lower left hand side of the heat exchanger and can be easily accessed without removing any components See note 3 Fig 2 8 On the cold water inlet servo valve located in the lower center of the unit remove the retaining screw and insert the Valve heating element 92094010 refit the retaining screw See note 4 Fig 2 9 Connect the polarized plugs for the Frost sensing switch 9209...

Page 24: ...IInfinity REU V1616WF 19 Issue 1 21 11 03 Rinnai 11 Time Charts Normal Combustion Mis Ignition Flame Failure Abnormal Pre Purge Air Supply Exhaust Blockage ...

Page 25: ...Infinity REU V1616WF 20 Issue 1 21 11 03 Rinnai 12 Wiring Diagram ...

Page 26: ...ed Dip Switch Settings REU V1616WF Dip Switches explained Bank 1 Gas Type Forced Low Combustion Bank 2 Computer programming Forced High Combustion Bank 2 Temperatures 60 Minute Timer operation Natural Gas 60 Minute Timer operation Gas Pressure Settings off on SW1 off on SW1 1 1 2 2 3 3 4 4 off on SW1 off on SW1 1 1 2 2 3 3 4 4 off on SW1 off on SW1 1 1 2 2 3 3 4 4 off on off on Bank 1 50 C 75 C 43...

Page 27: ...sed as illustrated below Fault Finding Table Describes possible faults and error codes page 23 Operational Flow Chart page 15 Component Circuit Value Table Summarises running and standby electrical values for all components page 24 Maintenance Monitor Error History Provides accumulated number of startups combustion time history of operational faults and readout of electrical values whilst unit ope...

Page 28: ...r outlet temperature thermistor 32 Outlet water thermistor flow Check hot water outlet thermistor 52 Modulating solenoid valve fault Unit stops without flame ignition Check modulating solenoid valve 61 Combustion fan rotation error Check combustion fan 71 Solenoid valve circuit error Unit does not operate Check gas valves 72 Flame rod circuit error Unit does not operate Check flame rod Appliance d...

Page 29: ... ROD Over DC1µA Flame Condition Modulating Valve B6 P P DC2 15V 65 85 B3 B4 Igniter C1 Gy Gy AC90 110V Main Solenoid Valve E1 P Bk DC80 100V 1 3 1 6k Solenoid Valve 1 E2 B Bk DC80 100V 1 7 2 1k Solenoid Valve 2 E3 Y Bk DC80 100V 1 7 2 1k F W W AC90 110V 11 13k F3 B Br 31 36k Component Normal Value On 2 4L min 33Hz Over 1980 PULSE min Off 1 7L min 23Hz Below 1380 PULSE min Notes Water Flow Control ...

Page 30: ...tation Sensor a Measure voltages between Black and Yellow of connector A1 Normal DC11 13V If normal proceed to b Faulty Replace PCB b Measure voltages between Black and White of connector A1 Normal DC2 10V If normal proceed to Sparker Circuit 2 Faulty Replace Combustion Fan 2 Sparker Circuit a Measure voltages between Grey and Grey of connector C1 Normal AC90 110V If Normal proceed to b Faulty Rep...

Page 31: ...id 1 if error indicator 11 is displayed a Disconnect Solenoid 1 connector E2 and measure resistance between Blue and Black Normal 1 7 2 1kΩ If normal proceed to b Faulty Replace Solenoid 1 b Measure voltage between Red and Black of Solenoid 1 connector Normal DC80 100V If normal proceed to Solenoid Valve 2 SV2 Circuit Faulty Replace PCB 5 Solenoid Valve 2 SV2 Circuit a Disconnect Solenoid Valve 2 ...

Page 32: ...Modulating Valve 7 Flame Rod Circuit Check flame rod Disconnect flame rod terminal B5 and re operate 72 indicated Proceed to 3 72 is not indicated check for electrical leaks from the flame rod Measure resistance between flame rod terminal B5 and appliance earth Normal 1MΩ If normal replace PCB Faulty Replace flame rod a Remove the Flame Rod terminal B5 repeat operation procedure if 72 is displayed...

Page 33: ...lace Thermal Fuse if after confirming there is no damage to the appliance 10 Overheat Switch Circuit Measure resistance between Overheat Switch terminals Normal 1Ω If normal replace PCB Faulty Replace Overheat Switch Note If Thermal fuse or Overheat Switch were faulty a Check heater for damage b Confirm gas type and combustion dipswitch settings c Confirm test point pressure 11 Water Flow Sensor a...

Page 34: ... open Normal DC4 6V Faulty Replace Water Flow Servo and Water Flow Sensor 13 Hot Water Outlet Thermistor Circuit Check Hot Water Thermistor if error code 32 is displayed Disconnect relay connector B1 and measure resistance White White When disconnected resistance 1MΩ When short circuit resistance 1 Ω Normal Check Heat exchanger outlet thermistor Faulty Replace hot water outlet thermistor If normal...

Page 35: ...ure voltage between white and white on the F1 Normal AC207 264V Faulty replace surge protector unit 16 Transformer Check for the transformer a Measure the voltage between white and white on the transmission connector F Normal AC90 110V 11 13 Ω 17 Remote Control Check the voltage between the 2 core remote control cable Measure the voltage between terminals on the remote control terminal D Normal DC...

Page 36: ...ivate the maintenance monitor Press the ON OFF button a second time to set the controller in the ON mode This feature can now be used with the appliance in operation 2 The maintenance number will be shown in the Water Temperature display 3 Data will be shown in the Clock display 4 To select the required maintenance number press the Water Temperature UP and DOWN buttons Display Monitor Contents No ...

Page 37: ...e Closed Display 1 0 2 08 Inlet water temperature PCB recognition value Example 25 25 C C 0 999 09 Hot water fan current flow value Example 6 x 10 60 mA 10 mA 0 999 10 Bath fill Not applicable Error History To Display Error Memory History This feature will show the last 10 faults in sequence 1 Turn off at the ON OFF button This can be done during operation 2 Press the ON OFF button while holding t...

Page 38: ...ce rubber access plug 10 High Setting a To set the appliance to Forced High combustion switch both No 3 and No 4 dipswitches of SW1 to ON fig 5 Ensure maximum water flow b Check the burner test point pressure c Adjust the high pressure Potentiometer POT fig 1 on the Printed Circuit Board PCB refer to correct gas type setting Table 2 11 IMPORTANT Re set dipswitches No s 3 4 of SW2 to OFF to return ...

Page 39: ...val of EMC sub board 35 4 Remove of Transformer 36 5 Removal of the Igniter 36 6 Removal of the manifold burner unit 36 7 Removal of the Gas Control 37 8 Removal of the flame rod and ignition plug 38 9 Removal of the outgoing heater thermistor 38 10 Removal of the Water Flow Servo 39 11 Removal of the fan motor 39 12 Removal of the Heat Exchanger 40 13 Removal of the Thermal Fuse 41 Unless otherwi...

Page 40: ...electrical supply from wall socket 1 Removal of the Front Panel a Remove four 4 screws 2 Removal of PCB Unit a Disconnect earth 1 screw b Disconnect harness from the terminal 2 screws c Dislodge hook and remove the PCB unit 1 screw d Remove protection cover e Disconnect five 5 connectors from PCB PCB 3 Removal of EMC Sub Board a Remove earth 1 screw b Disconnect 2 connectors c Remove the sub board...

Page 41: ...he terminal 2 screws d Remove the transformer 2 screws e Remove the transformer from bracket 2 screws Transformer 5 Removal of the Igniter a Remove the igniter 1 screw b Remove the 3 pin connector Grey grey c Remove the high tension lead Igniter 6 Removal of the Manifold Burner unit a Remove ignition lead black and flame rod Yellow b Remove the manifold 9 screws 2 ignition leads ...

Page 42: ...t f Remove the damper 3 screws 7 Removal of the Gas Control a Remove the manifold Refer 6 b Take out the back pressure tube c Remove gas connection and gas control screws 4 screws d Remove the gas control 1 screw e Take out the gas control from body and remove connector of modulation valve Pink Pink Main valve Pink Blk Solenoid valve 1 Blue Blk and solenoid valve 2 Ylw Blk Gas Control Assy ...

Page 43: ... rod terminal and high tension lead b Remove the flame rod and ignition plug 2 screws Flame rod Electronic gasket Electrode holder Ignition lead Ignition target 9 Removal of Outgoing Heater Thermistor a Remove thermistor screws 1 screw b Disconnect and remove the connector White White Outgoing water thermistor ...

Page 44: ...pull off inlet water tube Take care with O ring c Remove screws of inlet water connection and water flow servo 4 screws d Pull off 6 pin connector of the water flow servo Red Black Yellow Brown Blue e Take out water flow servo with sensor Water Flow servo with flow sensor 11 Removal of the Fan Motor a Remove inlet water tube 1 screw b Remove combustion fan mounting screws and pull off 3 screws c R...

Page 45: ...or for igniter White and 4 pin connector for fan motor Black d Pull off back pressure tube e Remove mounting screws for manifold and gas control 2 screws Refer 6 a Remove top panel sealing plate 2 screws b Remove heat exchanger mounting screws 2 screws a Remove heat exchanger mounting screws 2 screws b Remove inlet water connection tube 1 screw c Remove outgoing water connection tube 1 screw d Tak...

Page 46: ...t switch igniter back pressure joint and Heat exchanger Assy 13 Removal of the Thermal Fuse a Remove the heat exchanger Refer 12 b Remove the thermal fuse Note After replacing install the thermal fuse as in the following diagrams Heat Exchanger Right c Remove one 1 screw of the bi metal overheat switch Heat Exchanger Front Heat Exchanger Back Heat Exchanger Centre ...

Page 47: ...Infinity REU V1616WF 42 Issue 1 21 11 03 Rinnai 20 Exploded Diagram ...

Page 48: ...Infinity REU V1616WF 43 Issue 1 21 11 03 Rinnai ...

Page 49: ...Infinity REU V1616WF 44 Issue 1 21 11 03 Rinnai ...

Page 50: ...Infinity REU V1616WF 45 Issue 1 21 11 03 Rinnai ...

Page 51: ... 922 000 1 103 MANIFOLD A LP U243 200 A 92093897 101 496 000 1 103 MANIFOLD G NG U243 200 G 92093905 101 604 000 1 104 DAMPER A LP U243 314 A 92095462 140 659 000 1 104 DAMPER E NG U243 314 E 92095470 140 701 000 1 106 CASE Brn Fr U243 311 098 0182000 1 108 CASE Brn Rr CH46 219 098 434 000 1 109 PLATE Comb Rect BU196 243 146 072 000 1 110 BURNER B3A1 4 92073451 157 060 LPG 14 111 DISTRIBUTOR U243 ...

Page 52: ...H73 511 92083773 017 268 000 1 403 PLUG Filter 2 H73 510 2 92089036 196 037 000 1 404 RECTIFIER M8D1 15 330 107 000 1 405 6 592 DWHU ORZ M8E 4 3 A 92085414 301 082 000 1 410 CONNECTION Hot Water U217 441 333 303 000 1 411 STRAP Hot Water Plug AU129 526 553 043 000 1 412 DRAIN BU129 520 C 92081751 337 048 000 1 700 PCB U243 1170 92093954 210 607 000 1 701 PROTECTOR Surge U243 1165 537 0161000 1 702...

Page 53: ...RNESS Fuse U250 1612 290 0645000 1 721 HARNESS 2 Fuse U250 1612 2 92094002 290 0646000 1 722 HEATER Antifrost U250 1552 92094010 235 318 000 1 800 BOLT ZIHD0510UK 501 577 000 6 801 SCREW Tapping Earth CP 80452 501 737 000 1 802 SCREW FT ZFAB0445SZ 501 891 000 2 803 SCREW Cup CP 21478 412 501 400 000 2 804 SCREW Thermistor U217 449 501 295 000 1 805 SCREW U217 510 501 296 000 2 820 O RING M10B 13 4...

Page 54: ...Infinity REU V1616WF Issue 1 21 11 03 Rinnai Notes ...

Page 55: ...3 9271 6625 Fax 03 9271 6622 Help Line Sales Service Tel 1300 555 545 Fax 1300 555 655 Hot Water Service Line Tel 1800 000 340 Help Line Spare Parts Technical Info Tel 1300 366 388 Fax 1300 300 141 NEW ZEALAND LTD Internet www rinnai co nz E mail sales rinnai co nz Head Office New Zealand 691 Mt Albert Road Royal Oak Auckland P O Box 24 068 Tel 09 625 4285 Fax 09 624 3018 24 hr Service Tel 0800 74...

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