Rinnai INFINITYREU-V3232W User manual

INFINITY REU-V3232W
HD250E REU-V3232WC
Infinity High Capacity Continuous Flow Gas Hot Water System
SERVICE MANUAL

ISO 9001 Model for Quality Assurance in design/development, production, installation and
servicing, aimed primarily at achieving customer satisfaction by preventing nonconformity
at all stages from design through to servicing.
ISO 9002 Same as ISO 9001 but excluding design.
AG 102 Approval requirements for gas water heaters as set by The Australian Gas Association and
Australian Liquefied Petroleum Gas Association Ltd, to ensure proper safety performance
and quality levels are achieved.
Proudly a member of The Australian Gas Association.
All of our products are AGA tested and approved.
Distributed and serviced in Australia under a Quality
System certified as complying with ISO 9002 by
Quality Assurance Services.
Rinnai New Zealand has been certified to ISO 9001 Quality
Assurance by Telarc.
Certified to WaterMark by Quality Assurance
Services. WaterMark certification is awarded to
products and fittings complying with safety and water
contamination standards.
Comparative Energy Consumption tested to The Australian
Gas Association requirements of Australian Gas Code
AG 102.
An energy rating of 5 stars refers to an efficiency of
approximately 80%, that is, 80% of gas consumed is
converted to useful heat.

© Copyright Rinnai Australia Pty Ltd ABN 74 005 138 769 ACN 005 138 769
All rights reserved
Produced by Customer Technical Services
August 2003 - Issue 1
No portion or part of this manual may be copied without prior permission from Rinnai Australia.
Rinnai Australia takes no responsibility for the accuracy or otherwise of information contained in
this manual, and 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 Australia Technical Services. We welcome users of
this manual to provide feedback and suggestions for improvement purposes.
REU-V3232W
REU-V3232WC
Issue No1
WARNING
ALL WIRING INSIDE THIS APPLIANCE MAY BE AT 240 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 -v - 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
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 efficiency
TH - thermistor
TIN - temperature of incoming water
TOUT - temperature of outgoing water
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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 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 is delivered with a maximum preset temperature of 55 C for
REU-V3232W and 65º C for REU-V3232WC. If required, the temperature limits can be changed by a
service technician. For further information, please contact Rinnai.
• 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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Infinity REU-V3232W / HD250E REU-V3232WC - 2 - Issue 1 - 8/09/03 ©Rinnai
2. Specifications
Note 1: The default factory setting is 55° C for REU-V3232W and 65° C for REU-V3232WC. The unit can be ordered from Rinnai 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, except 95° C.
Conversion to 95° C must be performed by Rinnai.
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 and 95° C settings.
Note 2: Unit will operate at lower pressures but the maximum rated flow of 32L/min. will not be achieved.
Note 3: 95° C setting is not suitable for Flow and Return systems.
Type of appliance Temperature controlled 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 REU-V3232W
REU-V3232WC
Installation Externally mounted
Dimensions Width －470mm
Height －600mm
Depth －220mm
Weight 29 kilograms
Maximum / Minimum
Gas consumption
Natural gas：250～21MJ/h
Propane gas：250～21MJ/h
Connections Gas connection －R3/4 (20A）
Cold water connection －R3/4 (20A）
Hot water connection －R3/4 (20A）
Ignition system Direct electronic ignition
Electrical consumption Normal －83 W
Standby －12 W（With 1 Remote control ）
With Anti-frost protection －100 W
Hot water capacity（Raised 25℃） 32 to 2.4 L/min
Thermal efficiency 80%
Kitchen controller（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.
Minimum operating water pressure(Note 2) 180 kPa
Nominal operating water pressure 200 kPa～1000 kPa
Minimum operating water flow (Note 2): 2.4 L/min
Maximum operating water flow 32 L/min
Power supply Appliance －AC 240 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 2060 kPa. Closes 1470 kPa
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

Infinity REU-V3232W / HD250E REU-V3232WC - 3 - Issue 1 - 8/09/03 ©Rinnai
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
2100kPa, closes at 1500kPa.
• 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 1.13 kPa (NG) and 2.75 kPa (Propane).
* * * Value for New Zealand LPG
Gas Type Injector
Size (mm)
Nominal TPP (kPa) * * Gas Input (MJ/hr)
Low High Low High
Natural
1.05
0.18 0.74 20 250
1.65
Propane
( NZ LPG )
0.65
0.35
1.76
( 1.53 ) * * *
20 250
0.95
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Infinity REU-V3232W / HD250E REU-V3232WC - 4 - Issue 1 - 8/09/03 ©Rinnai
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. If M is >32, the water is
mixed.
Q = Heat energy available in kW = 56kW for the REU-V3232W/WC
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 with an incoming water temperature of 10 C and a required temperature 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.
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Infinity REU-V3232W / HD250E REU-V3232WC - 5 - Issue 1 - 8/09/03 ©Rinnai
Table 1: Approximate Water Flows and Gas Usage - Rinnai Infinity REU-V3232W/WC
Temperature
Rise C
51015
L/min L/hr MJ/hr L/min L/hr MJ/hr L/min L/hr MJ/hr
unmixed 32.0 1920.0 50.0 32.0 1920.0 100.0 32.0 1920.0 150.0
mixed 160.0 9600.0 250.0 80.0 4800.0 250.0 53.0 3200.0 250.0
Temperature
Rise C
20 25 30
L/min L/hr MJ/hr L/min L/hr MJ/hr L/min L/hr MJ/hr
unmixed 32.0 1920.0 200.0 32.0 1920.0 250.0 26.5 1589.0 250.0
mixed 40.0 2400.0 250.0 32.0 1920.0 250.0 26.5 1589.0 250.0
Temperature
Rise C
(unmixed and
mixed)
35 40 45
L/min L/hr MJ/hr L/min L/hr MJ/hr L/min L/hr MJ/hr
22.7 1362.0 250.0 19.9 1191.0 250.0 17.7 1059.0 250.0
Temperature
Rise C
(unmixed and
mixed)
50 55 60
L/min L/hr MJ/hr L/min L/hr MJ/hr L/min L/hr MJ/hr
15.9 953.0 250.0 14.4 867.0 250.0 13.2 794.0 250.0
Temperature
Rise C
(unmixed and
mixed)
65 70 75
L/min L/hr MJ/hr L/min L/hr MJ/hr L/min L/hr MJ/hr
12.2 733.0 250.0 11.3 681.0 250.0 10.6 635.0 250.0
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
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