Rinnai Infinity 32e User manual

INFINITY 32eand HD70e
Infinity High Capacity Continuous Flow Gas Hot Water System
SERVICE MANUAL

The Rinnai Infinity32e and
HeavyDuty70e water heater,
when correctly installed, comply
with the requirements of the
United Kingdom Water Regula-
tions / Byelaws (Scotland).
These Products can be found
listed in the Water Fittings and
Materials Directory.
The Rinnai Infinity32e water heater
is CE Marked for UK and Ireland as
allowed by Technigas of Belgium.
Certificate number E0715/5344
ID number 0461BO0715
Date of Issue 14 July2003
Quality System Standard
ISO 9001 - 1994
The Design, Development, and Manufacture of Gas Water Heating Appliances
done under Rinnai’s Quality Management System is certified under the Quality
Management System Standard ISO 9001.
Registration Number JQ0003D
Registered since: February 1994
Certified by Japan Gas Appliances Inspection Association.

Produced by Rinnai Technical Services Department
August 2004- Issue 1.
No portion orpart of this manual may becopied without prior permission from Rinnai U.K.
Rinnai U.K. reserves the right to make modifications and 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 U.K. 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 are constantly working toward supply improved appliances as well as information, and
specifications may be subject to alteration at any time.
Issue No1
WARNING
ALL WIRING INSIDE THIS APPLIANCE MAY BE AT 230 VOLTS POTENTIAL
ALL SERVICE WORK MUST BE CARRIED OUT BY AN AUTHORISED PERSON.
DO NOT TEST FOR GAS ESCAPES WITH AN OPEN FLAME

Infinity REU-V3232W / HD250E REU-V3232WC - iii - Issue 1 - 8/09/03 ©Rinnai
Table of Contents
Glossary of Terms and Symbols ................................................................................ iv
1. Introduction ................................................................................................................ 1
2. Specifications ............................................................................................................. 2
3. Water Flow Rates and Pressures ................................................................................ 4
4. Dimensions ................................................................................................................ 7
5. Installation ................................................................................................................. 8
6. Remote Controls ........................................................................................................ 9
7. Cutaway Diagram .................................................................................................... 13
8. Operational Flow Chart ........................................................................................... 14
9. Operation Principles ................................................................................................ 16
10. Main Components .................................................................................................. 17
11. Time Charts ............................................................................................................ 18
12. Wiring Diagram ..................................................................................................... 19
13. Dip Switch Settings ............................................................................................... 20
14. Fault Finding .......................................................................................................... 22
15. Component Circuit Value Table ............................................................................ 25
16. Component and Circuit Checks ............................................................................. 26
17. Maintenance Monitor / Error History .................................................................... 37
18. Gas Pressure Setting Procedure ............................................................................. 39
19. Gas Conversion Procedure ..................................................................................... 41
20. Dismantling for Service ......................................................................................... 43
21. Exploded Diagram ................................................................................................. 49
22. Parts List ................................................................................................................ 53
SERVICE CONTACT POINTS ............................................................................... 57

Infinity REU-V3232W / HD250E REU-V3232WC -iv - Issue 1-8/09/03 ©Rinnai
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
kW-kilowatts
LED - light emitting diode
L/min - Litres per minute
mA - milliamps
mbar -millibars of pressure
mm - millimetres
bar -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 efficiency
TH - thermistor
TIN - temperature of incoming water
TOUT - temperature of outgoing water
∆

Infinity REU-V3232W / HD250E REU-V3232WC - 1 - Issue 1 - 8/09/03 ©Rinnai
1. Introduction
The Rinnai V-Series hot water units represents the latest technology in continuous flow, temperature
controlled hot water.
Features
•The Infinity 32 and HD70e 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. This
is particularly useful when the hot water unit is installed where young children or the infirm may be
using the hot water.The Infinity 32e is delivered with a maximum preset temperature of 55 degree C
and 65º C for the Heavy Duty 70e. If required, the temperature limitscanbe changedby a
service technician. For further information, please contact RinnaiUK.
• The Infinity is a power flued appliance. 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 3 C 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 outgoing hot water temperature falls below
the temperature shown on the Digital Monitor (or the pre-set limit).
• The burner lights automatically when the hot water tap is opened, and goes out when the tap is closed.
IGNITION IS ELECTRONIC, therefore there is not pilot light. When the hot water tap is off, no gas is
used.
• ’Deluxe’ or ’Standard’ Remote Controllers are available as an optional extra. Depending on the models
chosen, these offer the following additional features :
- Bath fill function
- Voice Prompting
- Localised Temperature Control for up to one kitchen and two bathroom controllers
- Clock
• Temperatures selected at the controllers are retained in the SYSTEM MEMORY.
• Operating NOISE LEVEL IS VERY LOW.
• ERROR MESSAGES ARE DISPLAYED on the Remote Controllers, assisting with service.
°

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2. Specifications
Note 1: The default factory setting is 55° C for Infinity 32e and 65°CforHD 70e.Theunit can be ordered fromRinnai UK to be pre-set
to any of the other temperatures listed. The unit can be pre-set to any of the temperatures listed by a suitably qualified person.
Controllers are available with default temperatures up to 75° C. When fitted with controllers, only temperatures not exceeding the default
temperatures can be selected. When fitted without controllers, the unit will deliver water at the default temperature. Controllers are not available
with 85° C setting.
Note 2: Unit will operate at lower pressures but the maximum rated flow of 32L/min. will not be achieved.
Typeofappliance Temperaturecontrolled continuous flow gas ho
t
wate
r
syste
m
Operation With / without remote controls, mounted in kitchen, bathroom etc.
Exhaust system Forced Flue
Rinnai model number Infinity 32e
Heavy Duty 70e
Installation Externally mounted
Dimensions Width －470mm
Height －600mm
Depth －220mm
Weight 29 kilograms
Maximum / Minimum
Gas consumption
Natural gas：69 - 5.6kW
Propane gas：69 - 5.6kW
Connections Gas connection －3/4inch BSP
Cold waterconnection －3/4 inch BSP
Hot water connection －3/4 inch BSP
Ignition system Direct electronic ignition
Electrical consumption Normal －83 W
Standby －12 W（With 1Remotecontrol）
With Anti-frost protection －100 W
Hot watercapacity（Raised25℃） 32 to 2.7 L/min
Thermalefficiency81%
Kitchencontroller（MC):37 - 55℃Temperature range
(with remote) Bathroom controller (BC)：37- 50℃
Default temperature control
(without remote)
40℃、43℃、50℃、55℃、60℃、65℃、75℃、85℃
（Set by combination of Dip switches on PCB ）
Water flow control Electronic Water flow sensor, flow control & heat exch.
By-pass flow control.
Minimumoperating water pressure(Note 2)1.8bar
Nominaloperating water pressure2.0 bar - 10.0 bar
Minimumoperatingwaterflow2.7L/min
Maximum operating water flow 32 L/min
Power supplyAppliance－AC230 Volts 50Hz
Remote control －DC 12 Volts （Digital ）
Noise Level 49 dB(A)
Flame failure －Flame rod
Boil dry －Water flow sensor
Remaining flame （OHS ）－97℃bi-metal switch
Over temperature －95℃lockout thermistor
Fusible link －129℃Thermal Fuse
Pressure relief valve－Opens 20.6bar.Closes 14.7bar
Combustion fan rpm check －Integrated circuit system
Safety device
Over current －Glass fuse （3 Amp.）
Kitchen control －MC-91-1A or MC-70-2A
Bathroom control －MC-91-1A or BC-70-2A
Remote control optional
Second bathroom control －MC-91-1A or BC-70-2A
Remote Controller Cable ( optional ) Two core sheathed (double insulated), flex with min. cross-sectional area of 0.5m²
Manifold Electronic Control
System(optional) MSA-S

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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.
• Overheat Switch: Situated on the heat exchanger, gas supply is stopped when water temperature
reaches 97 C for a number of seconds.
• Fusible Link: Situated on the heat exchanger, electrical power supply is stopped if the temperature
exceeds 129 C.
• Water Pressure Relief Valve: Safeguards the water circuit against excessive inlet pressure. Opens at
21.0bar,closes at15.0bar.
• 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
* * The TPP is measured with the cover ‘off’ the appliance at the regulator test point with supply pressures
of 20 mbar (NG) and37 mbar (Propane).
Gas Type Injector
Size (mm)
Nominal TPP (mbar)* * Gas Input (kW)
Low High Low High
Natural
1.05
1.87.45.6 69
1.65
Propane 0.65
3.5 5.6 69
0.95
°
°

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3. Water Flow Rates and Pressures
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.
Water Flows can also be calculated by the following formula:
M = 60 x ( Q / C x T )
Where M = Water flow rate in litres/minute. If M is ≤ to 32, the water is unmixed, the entire flow goes
through the water heater. If M > 32 the hot water from the unit is mixedwith cold water.
Q=Heat energy available in kW = 56kW for theInfinity 32e and 70e
C=Specific heat of water = 4.2KJ/Kg C. This doesnot change for the purpose of this calculation.
T = Temperature rise required ( C)
Example:
What is the flow rate available with an incoming watertemperature of 10 C and a requiredtemperature of
20 C?
T = 20 - 10 = 10 C
Q = 56
C = 4.2
M = 60 x ( 56 / (4.2 x 10) ) = 80 l/min. Since 80 is greater than 32, this flow rate is mixed. This result
corresponds with the value in Table 1.
∆
°
∆°
°
°
∆°

Infinity REU-V3232W / HD250E REU-V3232WC - 5 - Issue 1 - 8/09/03 ©Rinnai
Table 1: Approximate Water Flows and Gas Consumption - Rinnai Infinity 32e and 70e
Temperature
Rise C
51015
L/min L/hr kW L/min L/hr kW L/min L/hr kW
thru unit 32 1920 13.932192027.8 32192041.7
maximum 160 9600 69 80480069 53320069
Temperature
Rise C
20 25 30
L/min L/hr kW L/min L/hr kW L/min L/hr kW
thru unit 32 1920 55.6 32192069 26.5158969
maximum 40 2400 69 32192069 26.5158969
Temperature
Rise C
thru unit
35 40 45
L/min L/hr kW L/min L/hr kW L/min L/hr kW
22.7 1362 69 19.91191 69 17.7105969
Temperature
Rise C
thru unit
50 55 60
L/min L/hr kWL/min L/hr kW L/min L/hrkW
15.9953 69 14.4867 69 13.279469
Temperature
Rise C
thru unit
65 70 75
L/min L/hr kW L/min L/hr kW L/min L/hr kW
12.2 73369 11.3 68169 10.663569
Temperature
Rise C
(unmixed and
mixed)
80 85 90
L/min L/hr MJ/hr L/min L/hr MJ/hr L/min L/hr MJ/hr
9.9 596.0 250.0 9.3 561.0 250.0 8.8 530.0 250.0
°
°
°
°
°
°

Infinity REU-V3232W / HD250E REU-V3232WC - 6 - Issue 1 - 8/09/03 ©Rinnai
Water Pressure
As seen in the table below a minimum supply pressure of 1.8bar is required tooperate at the rated flow
of 32 L/min. In an actual installation, pressure losses in the plumbing system also need to be considered.

Infinity REU-V3232W / HD250E REU-V3232WC - 7 - Issue 1 - 8/09/03 ©Rinnai
4. Dimensions

Infinity REU-V3232W / HD250E REU-V3232WC - 8 - Issue 1 - 8/09/03 ©Rinnai
5. Installation
External Wall Installation
Important:
Refer to the current versions of
the standards and regulations
for installation requirements.

Infinity REU-V3232W /HD250E REU-V3232WC - 9 - Issue 1 - 8/09/03 ©Rinnai
120
90
20
MC-91-1A
195
97
22
BC-70-2A
6. Remote Controls
Remote Controls
Remote Controllers are an optional extra. 'Standard' and 'Deluxe' controllers can be
fitted.
Standard controllers allow temperature selection only. Deluxe controllers have
temperature selection, bath-fill and voice prompting functions. 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.
Standard Controller (Model MC-91)
Up to 4 Standard Controllers can be fitted to the appliance. They are normally
installed in the areas where the majority of hot water is used, for example, the
kitchen, bathroom, ensuite and laundry.
Deluxe Kitchen Remote Control (MC-70) and (BC-70A)
Deluxe controllers have 'Kitchen' (MC-70-2A) and 'Bathroom' (BC-70-2A) versions. 'Kitchen' controls are
intended for the Kitchen or other convenient area where the majority of hot water is used. Bathroom
Controllers are intended to be fitted in the bathroom or ensuite and allow the user to have a bath filled to
the required level and temperature automatically.
Up to three ‘Deluxe’ Controllers can be connected as follows:
Positioning of Controllers
Controllers must be installed in shaded and clean locations. They should be fitted out of reach of children
(suggested height from floor at least 1500 mm). Controllers are water resistant, however, durability is
improved when positioned outside the shower recess or at least 400 mm above the highest part of a sink,
basin or bath.
Kitchen Bathroom Ensuite
MC70-2A
MC70-2A BC70-2A
MC70-2A BC70-2A BC70-2A

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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 sunlight and
dust ingress.
•Against a metal wall unless the wall is earthed in accordance with current regulations.
Remote Controller Connection
Remote controls operate at extra low voltage (12 Volts DC) which is supplied from the appliance.
Controllers are supplied with 15 m of electrical cable. The cable wires for connection to the appliance are
fitted with spade terminals.
Extension cables are available from Rinnai. Alternatively, a two core sheathed (double insulated) flex with
minimum cross-sectional area of 0.5 mm² can be used. Maximum cable length is 50 m.
For connection refer to the “CONNECTING REMOTE CONTROL CABLES” section.
Water Heater and Controller installation configurations
If the front cover of the appliancecontains "Max. 50 deg C unit" install it in accordance with Diagram 1 below:
If the front cover of the appliance does NOT contain the above text install it in accordance with Diagram 2:
IMPORTANT: If the appliance is to deliver water primarily for the purposes of personal hygiene in an
early childhood centre, primary or secondary school, nursing home or similar facility for young, aged, sick
or disabled persons aTemperature Limiting Device (TLD), such as a Thermostatic Mixing Valve,
may be required even if the appliance is set to 50º C or less. For these types of applications contact
Rinnai UK.
50º C
KITCHEN
Temperatur
e
controller
(optional)
Temperatur
e
controller
(optional)
Temperatur
e
controller
(optional)
Temperatur
e
controller
(optional)
LAUNDRY
BATHROOM
ENSUITE
H
O
T
C
O
L
D
G
A
S
Diagram 1. 50º C Appliance
KITCHEN
Temperature
controller
(optional)
Temperature
controller
(optional)
LAUNDRY BATHROOM
Temperature
controller
(optional)
Temperature
controller
(optional)
ENSUITE
TLD
H
O
T
C
O
L
D
G
A
S
Diagram 2. Not a 50º C Appliance
Note: TLD = Temperature Limiting Device.

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Connecting Remote Control Cables
Do not attempt to connect the remote control cable 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) fig. 1.
3. Thread the cable(s) through the cable access hole at the base
of the appliance.
4. Connect the spade connectors to the terminals marked
"Remote Control" on the printed circuit board (fig. 2).
Polarity is not important. Either wire colour can be
connected to either terminal.
5. Replace cover of the Appliance. Ensure that the screw with
the star washer is placed at the bottom right hand corner for
earthing purposes.
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. Thread the 3 cables through the cable access hole at the base
of the appliance. Connect the 4 spade connectors to the
terminals marked "Remote Control" on the printed circuit
board (fig.2). Polarity is not important. Either wire colour
can be connected to either terminal.
10.Replace cover of the Appliance. Ensure that the screw with
the star washer is placed at the bottom right hand corner for
earthing purposes.
Connecting Four Standard Controllers
11.Isolate the power supply
12.Remove the front cover from the Appliance (4 screws) fig 1.
13.Cut the spade connectors from all four controller cables to be
connected to the appliance (8 spade connectors should be cut
off) and discard. Connect the wires from two cables and
terminate into two new spade connectors as shown in (fig. 3).
Repeat for the remaining two cables. Spade connectors are
available from your local electrical component retailer.
14.Thread the 4 cables through the cable access hole at the base
of the appliance. Connect the 4 spade connectors to the
terminals marked "Remote Control" on the printed circuit
board (fig 2). Polarity is not important. Either wire colour
can be connected to either terminal.
15.Replace cover of the Appliance. Ensure that the screw with
the star washer is placed at the bottom right hand corner for
earthing purposes.
fig.1
fig.2
fig. 3
New spade connectors
Cable
wires Cable
wires
Remote control cables
195
97
22
BC-70-2A

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MC-91A Controller Programming
Question 1: Are four Controllers connected ?
IF YES: You will need to activate the fourth controller.
STEP 1:
For the Controller in the ‘KITCHEN’ only, press and hold the
‘Transfer’ and ‘On/Off’ buttons simultaneously (see fig. 1) until a
‘beep’ is heard (approximately 5 seconds).
STEP 2:
Check that the display on ALL FOUR controllers is lit and
displaying a temperature when ‘switched on’. If any ONE of the
controller displays two dashes (see fig. 2) in the display repeat
STEP 1.
This completes the activation procedure. Ignore Question 2.
IF NO: (You have three controllers or fewer), go to Question 2.
Question 2: Does your kitchen controller temperature go above 50 deg C?
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, press and hold the 'Transfer' and 'On/Off' buttons
simultaneously (see fig 1.) 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 50º C. If not, repeat Step 1.
Note:
• If the kitchen controller is replaced, repeat STEP 1 above for the replacement controller.
• If the kitchen controller 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 from the bathroom to the kitchen.
Fig 2.

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7. Cutaway Diagram

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8. Operational Flow Chart
Bypass flow control device
fully open
Insert power plug
Safety device normal
ON/OFF switch ON
Remote control normal
ON/OFF indicator ON
Hot water tap open
Water flow sensor ON
2.7 L/min or more
Set HW temp
50°C or more
Bypass control closed
Combustion fan ON
Fan rotaion
detected normal
Initial check normal
Sparker ON
Water flow control device
fully open
YES
YES
NO
YES
NO
Fan revolves for ignition
Main solenoid valve ON
Solenoid valve 1 ON
Modulating valve ON
Cause eliminated
Remove power plug from socket
Water flow control device
fully open
Bypass flow control device
fully open
ON/OFF indicator OFF
ON/OFF switch OFF
Error code indicator OFF
Water flow sensor OFF
Hot water tap closed
Combustion fan OFF
(after 5 seconds)
1
2
3
4
5
(a)
6
11
12
13
A
Control circuit short
False flame sensed
Solenoid valve circuit faulty
Modulating valve faulty
Outgoing thermistor faulty
HEX outgoing thermistor faulty
Thermal fuse activated
Overheat switch activated
Combustion fan rotation
abnormal (12.5 secs after (a))
Air supply and combustion air
duct blocked
61 flashing
10 flashing
12 flashing
72 flashing
71 flashing
52 flashing
32 flashing
33 flashing
14 flashing
6
7
8
9
9
10
Hot water temp.
= fixed temp.
YES
NO
NO
YES
NO
NO
cont. next pagecont. next page cont. next page
YES

Infinity REU-V3232W /HD250E REU-V3232WC - 15 - Issue 1 - 8/09/03 ©Rinnai
A
12 flashing
14 flashing
16 flashing
12 flashing
32 flashing
33 flashing
52 flashing
61 flashing
71 flashing
10 flashing
Flame detected
(>1uA)
Combustion indicator ON
Sparker OFF
Gas modulating control ON
Solenoid valve 2 ON
Solenoid valve 3 ON
Water flow control ON
Fan control normal
Auto. fan
revolution control
Input down
operation
Safety device normal
HEX outgoing
temp. > 95°C
Main solenoid valve OFF
Solenoid valve 1 OFF
Solenoid valve 2 OFF
Solenoid valve 3 OFF
Modulating valve OFF
Combustion indicator OFF
Combustion fan OFF
HEX outgoing
temp. < 60°C
(after 65 seconds)
NO
YES
YES
NO
YES
YES
NO
Max. fan revolution
(2 seconds)
Solenoid valve 1 OFF
Main solenoid valve OFF
Modulating valve OFF
Ignition failure
< 2 times
Sparker OFF
(after 4 secs)
Modulating valve OFF
Solenoid valve 3 OFF
Solenoid valve 2 OFF
Solenoid valve 1 OFF
Main solenoid valve OFF
11 flashing
Flame current abnormal
Thermal fuse activated
Outgoing water temperature
>105°C
Control circuit short
Outgoing thermistor faulty
HEX outgoing thermistor faulty
Modulating valve faulty
Combustion fan rotation
abnormal
Solenoid valve circuit faulty
Combustion faulty
Combustion indicator OFF
B
NO
YES
NO
14
15
16
from previous page from previous page from previous page
YES
NO
NO
YES