INFINITY 16 e INFINITY 20 e SERVICE MANUAL Rinnai High Capacity Continuous Flow Gas Hot Water System Service Manual Infinity 16e and 20e
The Rinnai Infinity 32e and Heavy Duty 70e water heater, when correctly installed, comply 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 32e water heater is CE Marked for UK and Ireland as allowed by Technigas of Belgium.
Produced by Rinnai Technical Services Department August 2004 - Issue 1. No portion or part of this manual may be copied without prior permission from Rinnai U.K. Rinnai U.K. reserves the right to make modifications and change specifications without notice. WARNING 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 230 VOLTS POTENTIAL ALL SERVICE WORK MUST BE CARRIED OUT BY AN AUTHORISED PERSON.
Table of Contents Glossary of Terms and Symbols ................................................................................ iv 1. Introduction ................................................................................................................ 1 2. Specifications ............................................................................................................. 2 3. Water Flow Rates and Pressures ................................................................................ 5 4.
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 - feedforward 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 mmH2O - millimetres of water (gauge pressure) OHS - o
1. Introduction The Rinnai V-Series hot water units represents the latest technology in continuous flow, temperature controlled hot water. Features • The Infinity 16e and Infinity 20 NEVER RUNS OUT of hot water. Whilst electricity, water and gas supplies are connected, hot water is available whenever hot water taps are open. • Built into the main micro-processor is the facility to LIMIT THE MAXIMUM TEMPERATURE of the hot water supplied. The water temperature may be limited to various maximum temperatures.
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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.
3. Water Flow Rates and Pressures Water Flows Table 1 shows unmixed and mixed water flow rates and approximate gas consumptions for various temperature rises. The unmixed flow rates are the flow rates available at the given temperature rise directly at the outlet of the water heater. The mixed water flow rates are available at the given temperature rise by mixing hot water from the outlet of the water heater with cold water from the mains supply.
Service Manual Infinity 16e and 20e REU-V1616W/REU-V2018W/REU-V2020W 0.33 0.27 21-160 REU-V2020W -6- 21-160 REU-V2020W 0.19 0.15 18-125 20-125 REU-V1616W Models (All Pre-set Temperatures) L/sec 0.33 0.27 Approx. Min / Max Gas Input (MJ/hour) Temp Rise (º C) 18-125 20-125 Approx. Min / Max Gas L/sec Input (MJ/hour) REU-V1616W Models (All Pre-set Temperatures) 21-160 REU-V2020W - Ext. Temp Rise (º C) 18-125 20-125 REU-V16eW - Ext. Models (All Pre-set Temperatures) Approx.
Water Pressure As seen in the table below a minimum supply pressure of .80 bar 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. 9#6'4 24'5574' 81.7/' 9#6'4 81.7/' . OKP Infinity 20e Infinity 16e 0.75 1.2 1.0 Service Manual Infinity 16e and 20e REU-V1616W/REU-V2018W/REU-V2020W 2.0 9#6'4 24'5574' bar -7- 3.0 4.
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20e Service Manual Infinity 16e and 20e REU-V1616W/REU-V2018W/REU-V2020W -9- Issue 1 - 10/10/03 ©Rinnai
5. Remote Controls Remote Controls Remote Controllers are an optional extra. 'Standard' controllers can be fitted. Standard controllers allow temperature selection only. For detailed information regarding controller operation refer to the 'How to use your water heater' booklet supplied with the appliance. Other manufacturers' controllers are NOT compatible with this appliance. 120 MC-91-1A Standard Controller (Model MC-91) Up to 3 Standard Controllers can be fitted to the appliance.
Water Heater and Controller installation configurations "THIS APPLIANCE DELIVERS WATER NOT EXCEEDING 50ºC" 50º C H O T C O L D KITCHEN Temperature controller (optional) LAUNDRY Temperature controller (optional) BATHROOM Temperature controller (optional) G A S Diagram 1.
Connecting Three Controllers 6. Isolate the power supply 7. Remove the front cover from the Appliance (4 screws) fig.1. 8. Cut the spade connectors from 2 of the controller cables to be connected to the appliance (4 spade connectors should be cut off) and discard. Connect the wires from these two cables and terminate into two new spade connectors as shown in fig.3. Spade connectors are available from your local electrical component retailer. 9.
6. Cutaway Diagram 16e Part No. 1 2 3 4 5 6 7 8 9 10 Description Casing Assembly Front Panel Assembly Flue Outlet Overheat Switch Heat Exchanger Thermal Fuses Electrode Flame Rod Main Burner Combustion Chamber Front Plate Assembly Part No. 11 12 13 14 15 16 17 18 19 Description Manifold Assembly Transformer P.C.B.
20e Part No. 1 2 3 4 5 6 7 8 9 10 Description Casing Assembly Front Panel Assembly Flue Outlet Overheat Switch Heat Exchanger Thermal Fuses Electrode Flame Rod Main Burner Combustion Chamber Front Plate Assembly Part No. 11 12 13 14 15 16 17 18 19 Description Manifold Assembly Transformer P.C.B.
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8. Operation Principles Hot Water Operation 1. Ignition • • • Activate controllers (if fitted) and open the hot water tap (for full details regarding operation of controllers refer to the ‘How To Use Your Water Heater’ booklet). When water flows through the unit, the water flow sensor rotates and sends an electrical ‘pulse’ signal to the Printed Circuit Board (PCB). This signal is proportional to the water flow rate. The PCB sends electrical current to the combustion fan motor causing it to turn.
9. Main Components 1) Printed Circuit Board • The Printed Circuit Board controls all operational functions including Air Supply Control, Gas Control, Water Flow Measurement, Water Flow Control, Combustion System and all sensors and safety devices. 2) Gas Flow Control • During normal operation, the PCB keeps the main solenoid valve open whilst there is flow through the unit and the burner needs to be lit.
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12. Dip Switch Settings Dip Switch Settings 16e, 20e Dip Switches explained Gas Type Bank 1 off Bank 1 on off SW1 SW2 1 2 3 1 2 3 4 Temperatures (See Page 2) Bank 2 off on Gas Type LPG Bank 1 on off SW1 on SW2 1 2 3 4 1 2 3 4 Model settings Gas Pressure Settings Natural Gas Temperature settings with or without controllers.
13. Fault Finding If there is a fault with the appliance, and controllers are installed, a numerical fault code may appear on the digital display controller. If controllers are not installed, one may be fitted to find out the fault code. Fault finding without controllers (and thus fault codes) is possible but more time consuming. To diagnose and rectify faults, the Fault Finding Table is used as illustrated below: Fault Finding Table Describes possible faults and error codes.
Fault Finding Table Code on Controller Fault 03 Power interruption during Bathfill. Water will not flow when power restored. 10 Combustion fan current too high. Unit operates, then stops. Table E No ignition. Unit stops without flame igniting 11 C Flame Failure / Earth Leakage 12 Thermal fuse and/or overheat switch activated. Unit operates, then stops. 14 Over temperature warning. Unit operates, then stops.
14. Component Circuit Value Table Measurement Point Table reference Component Normal Value CN Surge Protection Water Flow Control Device A Note Wire Colour B-Br AC207~264V R(CN2-NO.4)-B ±DC11~13V (Only When Operating) Operate Electricity R(CN4-NO.
15. Component and Circuit Checks 1. Combustion Fan Circuit Check the Motor Check the combustion fan if the error indicator displays “61”. Measure voltages between Black and Red of the PCB connector (A). Normal: DC15~46V (when fan ON) DC0V (when fan OFF) If normal proceed to check the rotation sensor Faulty: Replace PCB Check for the Fan Rotation Sensor a.) Measure voltages between Black and Yellow of connector (A). Normal: DC11~13V If normal proceed to b.). Faulty: Replace PCB. b.
4. Solenoid Valve 1 (SV2) Circuit Check Solenoid 1 if error indicator “11” is displayed. a.) Disconnect Solenoid 1 connector (E2) and measure resistance between Blue and Black. Normal: 1.7 ~2.0kΩ If normal, proceed to b. Faulty: Replace Solenoid 1. b.) Measure voltage between Blue and Black of Solenoid 1 connector. Normal: DC80~100V If normal, proceed to Solenoid Valve 2 (SV3) Circuit Faulty: Replace PCB. 5. Solenoid Valve 2 (SV2) Circuit a.
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 again check the Hot water outlet thermistor.
10. Overheat Switch Circuit Measure resistance between Overheat Switch terminals. (B4). 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.) Measure voltage between Red - Black of relay connector (B2). Normal: DC 11~13V If normal, proceed to b. Faulty: Replace PCB. b.
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. Normal Temp. Resistance 15oC 11.4∼14 kΩ 30oC 6.4~7.8 kΩ 45oC 3.6~4.5 kΩ 60oC 2.2~2.7 kΩ If normal proceed to Flame Rod circuit.
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 11~13V If normal, replace the remote control after confirming that the cable hasn’t been damaged or shorted. Faulty: Because normal voltage is not given due a short circuit, despite the PCB being in normal state, check Water Flow Servo circuit. If solution is not given from the above replace PCB. 18. Anti-frost Heater Circuit a.
16. Maintenance Monitor / Error History INFINITY 20e INFINITY 16e A deluxe controller (MC70-2A) should only be fitted to the above water heater models, for the purpose of enabling service personnel to locate the error history and fault find operational appliances. NB. Use only one controller, when accessing the maintenance information, error history, as two or more remote controls may cause incorrect operation. To display Maintenance Information 1.
07 Water flow servo present recognising positioning None 0~2 *Note 3 *Note 3 Water Flow Servo Positioning Servo Position Display 08 09 10 Open “1” Centre “0” Inlet water temperature (PCB recognition value) (Example 25 = 25°C) Hot water fan current flow value (Example 6 x 10 = 60 mA) Bath fill amount (this counts the litres during bath fill operation).
17. Gas Pressure Setting Procedure The regulator on the Infinity is electronically controlled and factory pre-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. 1) Turn 'OFF' the gas supply 2) Turn 'OFF' 240V power supply. 3) Remove the appliance cover. 4) Check gas type switches (fig.
11) Remove rubber access plug and adjust the regulator screw on the modulating valve (fig. 4) as required to the pressure. Table 1. Replace rubber access plug. 12) Set the Infinity to 'Forced High' combustion by setting both No. 3 and No. 4 dip switches of the bottom (SW1) set to 'ON'. (fig. 5) ensure maximum water flow. fig. 4 13) Check the burner test point pressure. 14) Adjust the high pressure Potentiometer (POT) on the Printed Circuit Board (PCB) as required to the pressure shown Table 2. (fig. 1).
18. Gas Conversion Procedure Conversion Method Warning-Ensure that the power cords is disconnected from the power point (240V potential) and isolate gas supply. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Remove outer cover, 4 screws. Delete "Natural" from the combustion chamber cover and replace with "Propane". (Use a black marking pen). Delete gas type from small paper sticker on bottom edge of inner casing. Replace small gas label on gas inlet.
19. Dismantling for Service 240 volt potential exposure. Isolate the appliance and reconfirm with a multimeter. Item Page 1. Removal of the Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 2. Removal of the PCB Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 3. Removal of the Water Flow Sensor, Servo and Bypass Servo . . . . . . . . . . . . . . . . . 37 4. Removal of the Sparkers . . . .
IMPORTANT For some areas of dismantling you may need to isolate any or all of the following: * Isolate gas supply. * Disconnect electrical supply from wall socket. * Isolate water supply. * Drain all water from appliance. 1) Removal of Front Panel a. Remove four (4) screws. 3) Removal of the Water Flow Sensor and Servo. a. Remove one (1) screw and pull off heat exchanger inlet water connection tube. b. Remove lock bracket and pull off inlet water connection tube. Ensure O- ring not lost or damaged.
6) Removal of Outgoing Water Thermistor a. Remove one (1) screw of Heat Exchanger outlet water tube. b. Unlock bracket and pull off inlet water tube. Ensure O-ring is not lost or damaged. c. Remove one (1) screw and pull off outgoing water thermistor. a. Remove flame rod terminal (yellow) b. Remove combustion chamber front panel (6 screws) c. Remove two (2) screws and pull off the burner unit. 7) Removal of Transformer a. Remove PCB (refer item 2) b. Remove two (2) screws and pull off transformer.
. . 9) Removal of Gas Control a. Remove manifold (refer item 8) b. Remove front panel (4 screws). (refer item 1). c. Remove four (4) screws on gas connection inlet and gas control (assy), and pull out the gas connection. Handle O-ring carefully. h. Pull off Heat Exchanger 10) Removal of Heat Exchanger a. Remove PCB (refer item 2) b. Remove Heat Exchanger inlet water tube (refer item 3) c. Remove outlet water tube (refer item 6). d. Remove three (3) screws from the manifold (refer item 8). e.
When Thermal Fuse is replaced, mount the thermal fuse as follows: Heat Exchanger LH side Heat Exchanger RH side Heat Exchanger Front Heat Exchanger Back Service Manual Infinity 16e and 20e REU-V1616W/REU-V2018W/REU-V2020W - 40 - Issue 1 - 10/10/03 ©Rinnai
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Infinity 16e and 20e Service Manual Infinity 16e and 20e REU-V1616W/REU-V2018W/REU-V2020W - 42 - Issue 1 - 10/10/03 ©Rinnai
Infinity 16e and 20e Service Manual Infinity 16e and 20e REU-V1616W/REU-V2018W/REU-V2020W - 43 - Issue 1 - 10/10/03 ©Rinnai
Infinity 16e and 20e Service Manual Infinity 16e and 20e REU-V1616W/REU-V2018W/REU-V2020W - 44 - Issue 1 - 10/10/03 ©Rinnai
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Notes Service Manual Infinity 16e and 20e REU-V1616W/REU-V2018W/REU-V2020W Issue 1 - 10/10/03 ©Rinnai
SERVICE CONTACT POINTS Rinnai UK LTD. 9 Christleton Court Manor Park Runcorn Cheshire WA7 1ST Tel. 01928 531870 Fax. 01928 531880 E-mail. info@rinnaiuk.com Web. www.rinnaiuk.
