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Rinnai REU-V1620WB, Service Manual

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Rinnai REU-V1620WB Service Manual Download Page 37

REU-V1620WG / REU-V1620WB / REU-V1620WS / REU-V2024WG

- 32 -

Issue 1 - 6/04/09 ©Rinnai

12)

Removal of 

Bypass Servo 

REU-V2632WC - (HD200E) ONLY

a. Remove fan motor (Refer to point 16)
b. Remove 3 pin connector
c. Remove 2 pin connector
d. Remove 6 pin connector and 5 pin connector
e. Remove bracket for water connection tube.

f. Removal of 

inlet water connection

g. Remove bypass servo and water flow servo
h. Remove fitting screws of bypass servo

i.

Flow sensor and water flow servo

13)

Removal of

 Anti Frost Switch

a. Remove 2 pin connection for anti frost switch
b. Remove Anti Frost switch

c. Anti Frost switch

Summary of Contents for REU-V1620WB

Page 1: ...SERVICE MANUAL To Suit Models REU V1620WG REU V1620WB REU V1620WS REU V2024WG Does NOT Suit any other Models ...

Page 2: ...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 Distributed and serviced in Australia under a Quality System certified as complying with ISO 9001 by SAI Global SAI Global ...

Page 3: ...d change specifications without notice Failure to comply with these instructions may result in serious personal injury or damage to the appliance 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 W A R N I N G All wiring inside this appliance may be at 240 Volts potential All s...

Page 4: ...ion Hz Hertz IC integrated circuit kPa kilopascals LED light emitting diode L min Litres per minute mA milliamps MJ h megajoule per hour mm millimetres 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 efficiency TH thermistor TIN tempe...

Page 5: ...ay Diagram 10 7 Operational Flow Chart 11 8 Operation Principles 12 9 Main Components 13 10 Time Charts 14 11 Wiring Diagram 15 12 Dip Switch Settings 16 13 Fault Finding 17 14 Component and Circuit Checks 19 15 Gas Pressure Setting Procedure 23 16 Gas Conversion Procedure 23 17 Maintenance Monitor Error History 24 18 Dismantling for Service 27 19 Parts List 36 REU V1620WG REU V1620WB REU V1620WS ...

Page 6: ...tion of dip switches on PCB NOTE 1620WS must be preset to 60 C Water flow control Water flow sensor Electronic water flow control device Maximum hot water capacity raised 25 C 16 L min Water pressure required to achieve maximum hot water capacity 75 kPa Maximum water flow 20 L min Water pressure required to achieve maximum hot water flow 120 kPa Minimum water flow 2 4 L min Power supply Appliance ...

Page 7: ...sed 25 C 20 L min Water pressure required to achieve maximum hot water capacity 120 kPa Maximum water flow 24 L min Water pressure required to achieve maximum water flow 160 kPa Minimum water flow for operation 2 4 L min Power supply Appliance AC 240 Volts 50 Hz Water controller DC 12 Volts Water controllers optional Wireless water controller only installations Wired Wireless Water Controller Inst...

Page 8: ...lectrical 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 power surges Surge Protector prevents against over current Boil Dry Prevention If water flow sensor detects no flow gas supply is stopped Combustion Fan Speed ...

Page 9: ...25 0 30 0 0 0 50 0 100 0 150 0 200 0 250 0 300 0 Inlet pressure kPa Outlet flow litres minute 1620 2024 P kPa 0 0 10 0 20 0 30 0 40 0 50 0 60 0 70 0 80 0 120 0 130 0 200 0 300 0 Q L min 0 0 4 9 7 6 9 7 11 5 12 7 14 4 15 8 16 6 20 0 20 0 20 0 20 0 P kPa 0 0 10 0 20 0 30 0 40 0 50 0 60 0 70 0 80 0 90 0 100 0 110 0 120 0 160 0 200 0 300 0 Q L min 0 0 4 2 6 7 9 3 11 0 12 2 13 6 15 1 16 1 17 1 18 2 19 ...

Page 10: ...om 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 K L BC 100V MC 100V MC 91Q 90 120 83 120 104 128 202 20 20 22 181 B D C K REU V1620WG REU V1620WB REU V1620WS 350 194 530 571 87 105 68 10 77 83 40 50 39 20 15 15 A E F J H I G L FITTING DIAMETER Please not...

Page 11: ...talled 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 wireless controller has been programmed to the transceiver correctly as per wireless controller installation instructions Con...

Page 12: ...e Question 2 Fig 5 Fig 6 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 S...

Page 13: ...e 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 signif...

Page 14: ... n t r o l 7 0 0 k P a V a l v e M a n d a t o r y Cold Water Supply Smartstart installed with Rinnai gas boosted solar hot water system Refer to Rinnai manuals supplied with appliances for important installation information Installations MUST conform to local regulations Rinnai Smartstart Unit Manual Activation Switch not supplied Water controllers MUST NOT be used Solar Pump Controller Box PTR V...

Page 15: ...20WS REU V2024WG 10 Issue 1 6 04 09 Rinnai 6 Cutaway Diagram Note This cutaway diagram is of a general nature Some details may be different on some models Part No Name Material 0 1 2 3 4 2 4 4 1 4 0 5 4 4 3 4 4 6 4 7 4 89 6 4 7 4 89 ...

Page 16: ...REU V1620WG REU V1620WB REU V1620WS REU V2024WG 11 Issue 1 6 04 09 Rinnai 7 Operational Flow Chart ...

Page 17: ...CB 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 resulting in a lower flow rate to achieve the programmed temperature This is a necessary operational feature of the unit When operating in Bath Fill mode the signal from the water flow sensor is a...

Page 18: ...ng Bath fill operation Water flow control is achieved through the use of servo driven water flow and fixed bypass valves Note only some models have a bypass valve fitted Both servo motors are controlled by the PCB The Water Flow Valve restricts the flow of water into the heat exchanger assembly if the programmed temperature cannot be achieved During normal operation cold water from the inlet valve...

Page 19: ...V1620WB REU V1620WS REU V2024WG 14 Issue 1 6 04 09 Rinnai 10 Time Charts Normal Combustion Note By pass control device fitted to model 2630 only Mis Ignition Flame Failure Abnormal Pre Purge Air Supply Exhaust Blockage ...

Page 20: ...FUSES R W Bk or B R B R R E 1 OVERHEAT SWITCH I 2 I 1 MODULATING SOLENOID VALVE POV I 3 P P I 4 Y FLAME ROD I 5 SV1 I 7 I 6 SV0 Y Bk SV2 Bk P B Bk MAIN SOLENOID VALVE SOLENOID VALVE 1 SOLENOID VALVE 2 SMALL LARGE SURGE PROTECTOR F 1 3 1 Br B Gr Y GND F 2 Br B 3 1 GND FUSE 3A B Br AC240V 50Hz Br B Gr Y GND Y Y F 6 Y Y ANTI FROST HEATER B B F 4 FROST SENSING SWITCH Y Y K only F 3 Y Y F 5 ANTI FROST ...

Page 21: ...TROL DEVICE Br Gy Y Gy R B BELOW DC1V LIMITER ON DC11 13V DC4 6V LIMITER OFF FULL OPEN POSITION OPERATE ELECTRICITY BELOW DC1V LIMITER ON DC4 6V LIMITER OFF ON2 4L MIN 33Hz OVER 1980PULSE MIN GND F3 B Br A1 COMBUSTION FAN 6 OVER DC1μA FLAME ROD I 4 7 10 11 12 14 15 C 11 4 14 0kΩ 30 C 6 4 7 8kΩ 45 C 3 6 4 5kΩ 60 C 2 2 2 7kΩ 105 C 0 6 0 8kΩ I 5 I 7 OFF1 7Ｌ MIN 23Hz BELOW 1380PULSE MIN E5 20 400Hz DC...

Page 22: ...nding Table is used as illustrated below Fault Finding Table Describes possible faults and error codes page 18 Operational Flow Chart page 11 Diagnostic Points Table Summarises running and standby electrical values for all components page 16 Wiring Diagram page 15 Maintenance Monitor Error History Provides accumulated number of startups combustion time history of operational faults and readout of ...

Page 23: ... Check modulating solenoid valve 61 Combustion fan rotation error Check combustion fan 65 Water flow control device error Water flow is not controlled Water temperature too low Check water flow servo 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 does not operate at all No display on the water contro...

Page 24: ... White of connector B1 Normal DC5 10V 20 400Hz If normal proceed to Sparker Circuit 2 Faulty Replace Combustion Fan 2 Igniter Circuit a Measure resistance between Grey Grey of connector C1 Normal AC207 264V If Normal proceed to b Faulty Replace PCB b Disconnect connector C1 and measure resistance between both terminals of the sparker Normal 1M If not sparking adjust or replace ignition plug Faulty...

Page 25: ...ector I7 Normal DC11 13V If normal proceed to b Faulty Replace PCB b Measure resistance between Solenoid Valve 2 connectors Normal 37 43 If normal proceed to Modulating Valve Circuit Faulty Replace Solenoid Valve 2 6 Modulating Solenoid Valve POV a Measure voltage between pink pink wires of the modulating solenod valve I3 Normal DC2 0 15V If normal proceed to c Faulty Replace PCB b Measure resista...

Page 26: ...od terminal I4 Normal voltage AC100 160V If normal check all power inputs into PCB If power inputs okay replace PCB Faulty Replace Flame Rod c Check if the Flame Rod is securely fitted Normal Check all power inputs into PCB If power inputs okay replace PCB Faulty Adjust the fitting of the Flame Rod Check all appliance earth connections are clean and secure 8 Thermal Fuse Circuit Check the Thermal ...

Page 27: ...efer maintenance monitor 12 Surge Protector F1 a Check the electrical fuses between F2 and F3 Normal resistance across fuse 1 If blown replace with fuses of the correct rating 240V 3A If okay go to b b Check supply voltage at F2 Voltage between blue and brown wires 207 264 V If supply voltage incorrect check power supply to appliance If okay go to c c Check voltage at F1 Voltage between blue and b...

Page 28: ...WB REU V1620WS REU V2024WG 23 Issue 1 6 04 09 Rinnai 15 Gas Pressure Setting Procedure Refer seperate Rinnai document behind front cover of appliance 16 Gas Conversion Procedure Refer seperate document availabe from Rinnai ...

Page 29: ...ilable where the appliances are connected with a deluxe controller This will enable service personnel to locate the maintenance history and faulty components with the appliance in operation NB When the maintenance information error history is shown use only one controller If two or more water controllers are used at the same time it may not operate correctly To display Maintenance Information 1 Wi...

Page 30: ...t water operation frequency Example 6 600 Operations 100 0 999 05 Hot water fan frequency Hz pulses sec 0 999 Note 1 06 Water control connection none 0 or 1 Note 2 Bathroom Controller Additional controller Kitchen controller 0 1 Controls connected Display No 0 Yes 1 07 Water flow servo present recognising positioning None 0 2 Note 3 Servo Position Open Centre Closed Display 1 0 2 08 Inlet water te...

Page 31: ...o 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 the Water Temperature UP Hotter button The Sequence will be shown in the Water Temperature display Error Code will be shown in the Clock display See service Manual for error codes Where there are less than a t...

Page 32: ... Unit 28 3 Removal of the Water Flow Sensor Servo and Bypass Servo 28 4 Removal of the Bypass Servo 29 5 Removal of Transformer 29 6 Removal of Sparker 29 7 Removal of the Manifold and Burner unit 29 8 Removal of the Gas Control 30 9 Removal of Flame rod and spark plug 31 10 Removal of Outgoing Water Thermistor 31 11 Removal of Heat Exchanger Thermistor 31 12 Removal of Bypass Servo 32 13 Removal ...

Page 33: ... a Remove the front panel Refer Item 1 b Remove two 2 PCB unit fixing screws and pull out forward 3 Removal of the Water Flow Sensor Servo and Bypass Servo a Remove the front panel Refer Item 1 b Remove two 2 screws and locking plates located on the water supply pipe and bypass pipe Pull bypass pipe and water supply pipe forward to clear servo valves Ensure O rings are not lost or damaged 4 Remova...

Page 34: ...efer to 2 b Remove 100 V harness and 2 pin connection c Removal Transformer 6 Removal of Sparker a Remove sparker b Remove 3 pin connector c Remove high tension cord 7 Removal of the Manifold and Burner unit a Remove high tension cord and flame rod b Remove 2 pin connection of the solenoid valve c Remove manifold ...

Page 35: ...ifold Assembly a Remove combustion chamber front panel b Remove burner unit c Pull off burner unit 8 Removal of the Gas Control a Remove manifold refer to point 7 b Remove back tube c Remove gas connection a Pull off connectors for gas control modulation valve and solenoid valve ...

Page 36: ...inal and tighten sparker lead b Remove flame rod and spark plug a Remove of High Tension lead 10 Removal of Outgoing Water Thermistor a Remove thermistor fixing screw b Remove 2 pin connection outgoing water thermistor Heat Exchanger Thermistor 11 Removal of Heat Exchanger Thermistor 2632WC ONLY a Remove thermistor holder b Remove 2 pin connector ...

Page 37: ...Remove 2 pin connector d Remove 6 pin connector and 5 pin connector e Remove bracket for water connection tube f Removal of inlet water connection g Remove bypass servo and water flow servo h Remove fitting screws of bypass servo i Flow sensor and water flow servo 13 Removal of Anti Frost Switch a Remove 2 pin connection for anti frost switch b Remove Anti Frost switch c Anti Frost switch ...

Page 38: ...ection of Anti Frost heater b Remove bracket on hot water connection c Remove Anti Frost heater 15 Removal of the Fan Motor a Remove 4 pin connector to fan motor b Remove 2 pin connector of solenoid valve c Remove fan motor screws x 2 d Remove fan motor assembly by sliding forward e Remove fan motor from housing via 3 screws ...

Page 39: ...od terminal of high tension cord e Remove anti frost heater switch f Remove 2 pin connector g Remove 3 pin connector h Remove fixing screws of the heat exchanger unit i Remove heat exchanger screws j Remove Bypass tube REU V2630 Models ONLY k Pull out heat exchanger screws l Remove manifold and burner unit m Remove thermal fuse over heat switch sparker hex thermister and back pressure joint ...

Page 40: ...WG 35 Issue 1 6 04 09 Rinnai 17 Removal of Thermal Fuse a Remove heat exchanger b Remove Thermal Fuse After removal of thermal fuse fitting procedure is as follows Heat Exchanger Front Heat Exchanger Left Heat Exchanger Right Heat Exchanger Right ...

Page 41: ...WG 36 Issue 1 6 04 09 Rinnai 19 Parts List NOTE Some Part details may have changed since publication of this manual Contact Rinnai to confirm spare parts details before ordering REU V1620WG REU V1620WB REU V1620WS on page 37 REU V2024WG on page 40 ...

Page 42: ...05000 1 1 1 015 Piping Reinforce 044 156 000 1 1 1 100 Inlet 3 4 Gas 92081587 106 290 000 1 1 1 101 Screw Test Point 92099956 501 275 005 2 2 2 102 Gas Control 92095018 120 0015000 1 1 1 103 Manifold LP 92093624 101 592 000 1 1 1 103 Manifold NG 92093632 101 593 000 1 1 1 104 Manifold Packing Upper 580 0106000 1 1 1 105 Manifold Packing Lower 580 0107000 1 1 1 106 Burner Case Front 098 0624000 1 1...

Page 43: ...097906 333 300 000 1 1 1 401 Plug Band 553 119 000 1 1 1 402 Filter Water O Large 92083773 196 062 000 1 1 1 404 Rectifier 330 107 000 1 1 1 405 Water Flow Servo 92099957 301 152 000 1 1 1 406 Water Flow Servo Cover 098 1445000 1 1 1 408 Connection 1 2 H W 92098458 333 303 000 1 1 1 409 Hot Water Plug Band 553 043 000 1 1 1 410 Valve Press Relief 92081751 337 048 000 1 1 1 700 PCB Main 92099958 20...

Page 44: ...mistor 92095030 233 246 000 1 1 1 725 Harness Remote Control 92099961 290 1288000 1 1 1 800 Earth Screw 501 889 000 1 1 1 801 Truss Screw 501 973 010 3 3 3 802 Screw 501 0064000 3 3 3 803 Tapping Screw 501 737 000 1 1 1 804 Thermistor Fixing Screw 501 295 000 1 1 1 820 O Ring 90195165 520 300 010 2 2 2 821 O Ring Gas Con 92072859 520 043 010 1 1 1 822 O Ring Gas Control 92096502 580 180 000 2 2 2 ...

Page 45: ...1 013 Harness Easy Connect 92099955 106 651 000 1 014 Cable Seal Packing 92099984 580 0105000 1 015 Piping Reinforce 044 156 000 1 100 Inlet 3 4 Gas 92081587 106 290 000 1 101 Screw Test Point 92099956 501 275 005 2 102 Gas Control 92095018 120 0015000 1 103 Manifold LP 92093764 101 594 000 1 103 Manifold NG 92093814 101 595 000 1 104 Manifold Packing Upper 580 0108000 1 105 Manifold Packing Lower...

Page 46: ...67 055 788 000 1 131 Exhaust Opening Packing 580 592 000 1 132 Front Panel Seal Packing 580 600 000 1 150 Fan Comb 92093665 222 512 000 1 151 Fan Casing 035 870 000 1 Fan Comb Assembly 222 612 000 1 400 Inlet 1 2 Water 92097906 333 300 000 400 Inlet 3 4 Water 92099968 333 301 NPB 1 401 Plug Band 553 119 000 1 402 Filter Water O Large 92083773 196 062 000 1 404 Rectifier 330 107 000 1 405 Water Flo...

Page 47: ...00 1 710 Fuse Harness 2 92099959 290 1284000 1 711 Heater Anti Frost 92098318 213 001 000 1 712 Switch Thermal 92097187 234 444 000 1 713 Heater Fixing Plate 537 0440000 4 715 Harness Electric Power 92095027 290 1285000 1 716 Harness Magnet Valve 92095028 290 1286000 1 717 Sensor Harness 92099960 290 1292000 1 717 Sensor Harness 92099962 290 1295000 718 Fuse Thermal 92099621 290 0492000 1 719 Ther...

Page 48: ... 520 043 010 1 822 O Ring Gas Control 92096502 580 180 000 2 825 O Ring Thermistor 92062249 520 209 010 1 826 O Ring 92062348 520 281 010 1 827 O Ring Heat Exchanger 92072800 520 255 010 1 828 O Ring Heat Exchanger 92062207 520 193 010 1 829 O Ring Heat Exchanger Inlet 92062199 520 048 010 1 830 O Ring In Out Water 92071182 520 049 010 1 888 Operation Manual 623 344 700 1 888 Operation Manual 623 ...

Page 49: ...REU V1620WG REU V1620WB REU V1620WS REU V2024WG 44 Issue 1 6 04 09 Rinnai 20 Exploded Diagram REU V1620WG REU V1620WB REU V1620WS 000 ...

Page 50: ...REU V1620WG REU V1620WB REU V1620WS REU V2024WG 45 Issue 1 6 04 09 Rinnai ...

Page 51: ...REU V1620WG REU V1620WB REU V1620WS REU V2024WG 46 Issue 1 6 04 09 Rinnai ...

Page 52: ...REU V1620WG REU V1620WB REU V1620WS REU V2024WG 47 Issue 1 6 04 09 Rinnai ...

Page 53: ...REU V1620WG REU V1620WB REU V1620WS REU V2024WG 48 Issue 1 6 04 09 Rinnai REU V2024WG ...

Page 54: ...REU V1620WG REU V1620WB REU V1620WS REU V2024WG 49 Issue 1 6 04 09 Rinnai ...

Page 55: ...REU V1620WG REU V1620WB REU V1620WS REU V2024WG 50 Issue 1 6 04 09 Rinnai ...

Page 56: ...REU V1620WG REU V1620WB REU V1620WS REU V2024WG 51 Issue 1 6 04 09 Rinnai ...

Page 57: ...r public phones Hot Water Service Line Tel 1800 000 340 Australia Pty Ltd ABN 74 005 138 769 Internet www rinnai com au E mail enquiry rinnai com au 123 45678 90123 4 Rinnai has a Service and Spare Parts network with personnel who are fully trained and equipped to give the best service on your Rinnai appliance If your appliance requires service please call our Hot Water Service Line Rinnai recomme...

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