Rinnai REU-2007W User manual

INFINITY




 !
!"#$%$&

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.
AS 3498 Authorisation requirements for plumbing products - water heaters and hot-water storage tanks,
aimed at ensuring safe, quality products.
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 Australian Standard 3498 by Quality
Assurance Services. Watermark certification is
awarded to products with suitable 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
May 2000
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 inthis manual.
Key to Warning Symbols
Failure to comply with the following instructions may result in serious personal injury or
damage to the appliance.
Be careful ofpossible electric shock. Wiringinside this appliance may potentially be at 240 Volts.
Remove the plug form the power source when carrying out any of the following activities.
Read Fault Diagnosis and Wiring Diagram carefully to avoid incorrect wiring.
Do not disassemble. Parts within cannot be exchanged or diagnosed faulty.
Please follow instructions in chapters to ensure safe and appropriate service.
After completing the service and confirming that there are no water or gas leaks or
incorrect wiring, test operation of the appliance. After confirming normal operation,
explain what was serviced to the customer and operation principles if necessary.
This manual has been compiled by Rinnai Australia Product 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
supplying improved appliances as well as information, and specifications may be subject to alteration at any
time.
SRV2007/8,2408,2424
Issue
m
3.1

 
'(
Glossary of Terms and Symbols ................................................................................ v
1. Introduction .............................................................................................................. 1
2. Features ..................................................................................................................... 2
3. Dimensions ............................................................................................................... 3
4. Installation ................................................................................................................ 4
5. Remote Controls ...................................................................................................... 5
6. Safety Devices .......................................................................................................... 7
7. Specification ............................................................................................................. 8
8. Cut-away Diagram ................................................................................................... 9
9. Schematic Diagram ............................................................................................... 11
10. Combustion Specification ................................................................................... 12
11. Dip Switch Positions ............................................................................................ 13
12. Water Flows ......................................................................................................... 17
13. Gas Consumption ................................................................................................ 21
14. Main Components ............................................................................................... 23
15. Time Charts ......................................................................................................... 26
16. Operation Flow Principle ................................................................................... 29
17. Operation Principles ........................................................................................... 31
18. Error Messages ..................................................................................................... 33
19. Diagnostic Points ................................................................................................. 34
20. Wiring Diagram ................................................................................................... 35
21. Fault Diagnosis ..................................................................................................... 36
22. Electrical Component Analysis .......................................................................... 45
23. Gas Conversion ................................................................................................... 49
24. Gas Pressure Setting Procedure ......................................................................... 50
25. Dismantling for service ....................................................................................... 51
26. Exploded Diagram .............................................................................................. 57
27. Parts List ............................................................................................................... 61

Infinity REU-2007,2008,2408,2424 - v - ©Rinnai

This glossary of terms and symbols is provided to assist you in understanding some of the language
used throughout this manual.
dB(A) - sound pressure level in decibels, “A” range
DC - direct current
AC - alternating current
WFCD - water flow control device
FB - feedback 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 (guage pressure)
NOX- oxides of nitrogen (NO & NO2)
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-2007,2008,2408,2424 - 1 - ©Rinnai
)* +
The brand name Infinity refers to “Endless Hot Water”. The Infinity series has been developed in
response to the growing changes in the lifestyle of consumers, and the increasing diversification and
sophistication of demand in the marketplace.
The Infinity series offers reduced cost, advanced safety features, and an option to connect one, two,
or three remote control pads.
The Infinity series is delivered with the maximum hot water temperature of 55oC, with or without
remote controls connected.
The Heavy Duty 20 is ideally suited for commercial or hydronic situations, as it is possible to obtain
a maximum outgoing hot water temperature of 75 C (with remote control connected) or 85 C
(without remote control connected) - see page 16 for details on requirements for setting the Heavy
Duty 20 to provide 85 C outgoing hot water.
$(,
The front cover of each appliance in the new series is formed from 0.6 mm coated steel, secured to
the main box assembly by 4 screws. Seals around the front cover and flue outlet prevent water from
entering the appliance.
Air inlets are situated in the front panel. The general layout of components is shown on the cutaway
diagram on page 9 to page 10. All components are supported within a box formed from 0.8 mm
coated steel.
The heat exchanger occupies the top section of the box, and the burner is situated in a chamber
formed from 0.8 mm aluminised steel attached to the bottom of the heat exchanger.
The air for combustionis supplied by afan which is connected to the burner box by a duct at the left
hand side of the appliance.
Gas and water controls are situated at the bottom right ofthe appliance, directly under the manifold.
The products of combustion are expelled from the appliance through a flue outlet situated on the
front of the appliance, at the top.
The burner assembly is made up of 18 identical stainless steel bunsen burners, secured by an
aluminised steel framework. An aluminium manifold with 18 integrally moulded injectors supplies
gas to the burners, and is attached to the lower front cover of the burner box.
There is one thermistor, it is located on the outgoing hot water supply tube, near the outlet of the
heater.
°°
°

Infinity REU-2007,2008,2408,2424 - 2 - ©Rinnai
* 

The light-weight, slim, and compact form enable easier, improved appearance installations. The
remote controls (where fitted) are connected to the appliance by 2-core non-polar cable, ensuring
easy wiring and eliminating misconnection problems.
&%&-
Low noise level design enables these appliances to be installed in units, flats, townhouses, and other
high density residential areas with little concern about noise disturbances.
!
Various safety devices controlled by a micro-computer ensure complete safety. Also, the anti-frost
device (where fitted), automatically prevents the water inside the appliance from freezing by using
small electrical ceramic heaters connected to the pipework at strategic locations.

Direct electronic ignition to the main burner eliminates wasteful pilot gas consumption. The
combustion fan rpm is proportionally controlled with gas consumption. This maintains high energy
efficiency as the gas consumption changes.
 ! 
The water supply capacity varies proportionally from 2.7 L/min to 24 L/min. A suitable volume of
hot water can be supplied throughout all seasons by the water flow control device and water flow
servo mechanism. The REU-2408andREU-2008 modelswill supply up to21 L/min, and REU-2424
model will supply up to 24L/min, (maximum unmixed), controlled by an automatic electro-
mechanical water flow device. The REU-2007 model will supply up to 15 L/min at water
temperature of 15 C, (maximum unmixed), controlled by a mechanical water flow control device.
See page 17 for precise details on water flow.
 '   
With a remote control connected, the hot water control range is between 37 C and 55 C (in 13
steps). With or without a remote control connected the outgoing hot water temperature can be fixed
to a maximum of 40 C, 43 C, 50 C, 55 C, 60 C, 65 C or 75 C and in the case of the Heavy
Duty 20 with no remote, 85 C can be reached. This means that the Infinity Series can be set to
comply withvarious State laws on temperature controlin homes, child care centres, and elderly care
centres. The maximum temperature selectable on the bath remote control is 50 C (this is a safety
feature).
.- '  / 
All Infinity models incorporate a device to prevent the hot water temperature exceeding the pre-set
temperature by more than 3 C.
'  &0
With the remote control(s) connected, the pre-set water temperature can only be altered between
37 C and 43 C while the hot water is flowing. This helps to avoid inadvertently increasing the
temperature to a hazardous level whilst someone is in the shower. While the water is flowing, the
remote control(s) can be turned off, but not on again.
°
°°
°°°°°° °
°
°
°
°°

Infinity REU-2007,2008,2408,2424 - 3 - ©Rinnai
1*2
Note: All dimensions are in mm.

Infinity REU-2007,2008,2408,2424 - 4 - ©Rinnai
*
Note: All dimensions are in mm. Pipework will vary in each installation.

Infinity REU-2007,2008,2408,2424  
3* 
The MC-33-3A, BC-45-3A, and BSC-45-
3A remote controls were specifically
designed for use with the Infinity water
heaters manufactured from March 1997.
Features include:
• Colour coordination to allow immedi-
ate recognition of the temperature
“hotter” and “cooler” buttons.
•LargerLEDdisplay.
• Water temperature adjustment only in
the range of 37 C to 43 C whilst hot
water is flowing.
• Different temperatures can be stored
in the memory of each individual
remote control.
Kitchen Remote Control
• Enhanced communication system
between the remote controls,allowing
priority temperature selection at each
remote control.
• A third remote control identified by
model number BSC-45-3A is
available for use in a second
bathroom or ensuite. Contact Rinnai
for further details.
Bathroom Remote Control
°°
MC
BSC
BC

Infinity REU-2007,2008,2408,2424  
!44+#,+
There must be at least on cable from any remote control connecting with the Infinity water heater.
Connections
The following diagrams show methods of connection.

  
5*!2-
 
Situated to the right of the burner at the front, the flame rod monitors combustion, preventing any
discharge of gas to the burner if there is no flame, by sending a signal to the PCB which in turn
isolates the gas.
.- / 2-
Also referred to as anOver Heat Switch. This device is fittedto a bend section at the inlet to the heat
exchanger. If the flame remains on the burner after the tap is closed, and the water temperature
inside the heat exchanger reaches 97 C, an DC 12 volt bi-metal cut-off switch isolates the gas to the
solenoids.
%
Should the incoming water flow become restricted or stop, then the water flow sensor will cease to
send a magnetic pulse signal to the PCB, in turn isolating the flow of gas to the burner.
', 
Wrapped around the entire surface of the heat exchanger, if the heat exchanger burns out, or the
temperature outsideit reaches 129 C, the thermal fusemelts, breakingthe electroniccircuit. Current
to the gas solenoid valve circuit is cut, and combustion stops, shutting down the unit.
/  "-
This spring and valve seating type valve located on the hot water outlet will release the built up
pressure if the pressure inside the heat exchanger reaches 2100 kPa until 1500 kPa is maintained.
(-,0
The combustion fan rpm are continually monitored by a magnetic pulse counter connected to the
PCB. If the fan revolutions deviate from the speed requiredfor complete combustion, a signal issent
to the PCB and the revolutions adjusted accordingly. (If not the unit shuts down)
$ / 6.+78
When the outdoor temperature drops and the temperature inside the appliance below 3.5 C, the
frost sensing device is activated, and the anti-frost heaters prevent the water in the appliance from
freezing. These anti-frost heaters remain ON until the temperature inside the appliance rises to
11.5 C. There are 5 x 16 Watt anti-frost heaters located at various points in the main water flow area
of the appliance. The anti-frost protection device will prevent freezing down to -20 C in a no wind
situation, and -15 C in a windy situation.
1 .- '  .
The temperature of the outgoing hot water is constantly monitored by the water temperature
thermistor located near the outlet of the appliance. If the outgoing water temperature reaches 3 C
above the preset temperature, the burner will automatically go out. The burner will only ignite again
once the outgoing hot water temperature falls below the preset temperature.
°
°
°
°°
°
°
°

  
*!
Type of appliance Temperature controlled continuous flow gas hot water system.
Operation With or without remote controls, mounted in kitchen, bathroom, or ensuite.
Exhaust system Forced combustion
Rinnai model No. REU-2007 REU-2008 REU-2408 REU-2424
Maximum gas rate 160 MJ/h 160 MJ/h 188 MJ/h 188 MJ/h
Hot water capacity, unmixed 2.7 to 11.5 L/min 2.7 to 20 L/min 2.7 to 20 L/min 2.7 to 24 L/min
Hot water capacity, mixed (25 C rise) 2.7 to 20 L/min 2.7 to 20 L/min 2.7 to 24 L/min 2.7 to 24 L/min
Default temperature (without remote)
Set using switches on PCB 40,43,50,55,60,65,75 C 40,43,50,55,60,65,
75 C and 85 C
Maximum temperature ceilings
(remote connected) 40, 43, 50, 55, 60, 65, 75 C (set by combination of switches on PCB)
Temperature range (with remote) 37 to 55 C in 13 steps
Approved gas types Natural; Propane; (New Zealand only - LPG)
Installation Externally mounted.
Dimensions Width - 350 mm. Height - 600 mm.
Depth- 170 mm.
Weight 18 kilograms.
Efficiency rating 80%
Noise level 49 dB(A)
Connections Gas supply- R:/20A.
Cold water inlet- R:/20A.
Hot water outlet- R:/20A.
Ignition system Direct electronic ignition.
Minimum gas rate 21 MJ/h
Electrical consumption Normal- 49 Standby- 8
Anti frost protection - 80
55
8
80
55 Watts
8 Watts
80 Watts
Water temperature control Simulation feedforward and feedback.
Water flow control Water flow sensor and automatic electro-mechanical water flow control device
Minimum operating pressure 200 kPa
Nominal operating pressure 200 ~ 1200 kPa
Power supply Appliance- AC240 Volts 50 Hz
Remote control- DC12 Volts (Digital)
Safety devices
Flame failure- Flame rod.
Boiling protection- 105 C lockout thermistor (25 seconds)
Remaining flame [OHS]- 97 C bi-metal switch
Thermal fuse- 129 C
Pressure relief valve- Opens-2100kPa, closes-1500 kPa
Automatic frost protection- Bi-metal sensor & anti-frost heaters
Combustion fan rpm check- Integrated circuit system
Over current- Glass fuse (5 Amp).
Remote control MC-33-3A- Kitchen control BC-45-3A- Bathroom control
BSC-45-3A- Ensuite or 2nd bathroom control
Remote control cable Non polarised two-core cable
°
°°°
°
°
°
°
°

  
*24 
 99

  
 

Infinity REU-2007,2008,2408,2424 - 11 - ©Rinnai
:*!,24 

  
)*(!
Note: Where LPG details are not specified in brackets, Propane and LPG details are common.
The REU-2008, 2408, 2424 Series are not approved for use on Town Gas
* Indicated by an imprint on actual component.
# LPG - New Zealand only.
2007/2008 2408 2424
Input NG/Propane
LPG # HI MJ/h 160 188 (180) 188 (180)
LO 21 21 21
Gas Consumption NG/Propane
LPG # HI kW 44.2 52.3 (50) 52.3 (50)
LO 5.93 5.93 5.93
Integral Injector size
(18) NG mm 1.7 1.7 1.7
Propane/LPG # 1.0 1.0 1.0
Damper* (1 piece) NG NIL NIL NIL
Propane/LPG # A A A
Pressure
NG HI kPa 0.65 0.90 0.90
LO 0.08 0.08 0.08
Propane/LPG # HI kPA 1.60 (1.51) 2.26 (1.90) 2.26 (1.90)
LO 0.17 (0.15) 0.17 (0.15) 0.17 (0.15)
Burner type NG/
Propane NG/ Propane NG/ Propane
Dip Switch positions Refer to page 13
Maximum Capacity
Modulating Valve (mA) NG
mA
120 147 147
Propane 189 229 229
LPG # 181 208 208
Combustion Fan (Hz) NG Hz 220 264 264
Propane/LPG # 242 272 272
Minimum Capacity
Modulating Valve (mA) NG mA 20 20 20
Propane/LPG # 20 20 20
Combustion Fan (Hz) NG Hz 96 96 96
Propane/LPG # 87 87 87
Slow Ignition
Modulating Valve (mA) NG
mA
88 91 91
Propane 144 152 152
LPG # 140 140 140
Fan (Hz) NG Hz 160 160 160
Propane/LPG # 160 160 160
∅∅∅
∅∅∅

  
))*2!,/
Please do not adjust the DIP Switch Positions before reading this information
The dip switches are provided so that the water heater can be set to different operating
configurations. In some instances such as nursing homes or even domestic situations, it may be
necessary to limit the temperature of the hot water coming from the units.
The set-up configuration for the water heater differs depending on:
•Gastype
• Maximum water flow select
• Temperature limiting requirements
• Alternate type
2/!,;+
Top switch settings 1 ~ 8
1: Gas type (used only during conversion)
2: To select maximum water flow volume
3 to 5: To select fixed temperature without remote
6 to 8: To select maximum temperature with remote connected
4 to 8 for modified PCB (see settings). To select the temperature
with or without remote connected.
Note: PCB were modified in April & May 1999 to accommodate
the temperature flow switch to operate without control (see for
settings). Dip switch settings for temperature with or without
controls have changed since modifications. Please check serial
number prior to adjusting.
Bottom switch settings 1 ~ 3
1: Factory use (To select the capacity of appliance)
2 & 3: Combustion control
The Infinity model series are delivered with maximum hot water temperature limited to 55 C,
however the maximum temperature of hot water can be fixed to 40 C, 43 C, 50 C, 55 C, 60 C, 65 C, or
75 C.
A further maximum temperature of 85 C can be achieved only on the Heavy Duty 20 without a remote
control connected, refer page 16 for specific details.
°
°°°°°°
°
°

  
)* '
Only alter gas type positions when converting. For conversion instructions refer to page 49.
* #; !
1* '  &4
There are different positions, depending on the temperature limit required and whether the remote
controls are connected or not.
2!,!4 / #++/<
 
40 C43 C 50 C 55 C 60 C 65 C75 C85 C
(Heavy Duty 20 only)
(*  ,   =,> +
40 C43 C50 C50 C55 C60 C65 C75 C
If dip switches 6, 7 & 8 are set to any of the positions shown above and the remotes become
disconnected, the outgoing water temperature will automatically default to the temperature set on
switches 3, 4 & 5 (as shown above).
We recommend that switches 3, 4 & 5 be set to the OFF position to ensure a 55 C default setting. This
will provide a safe default temperature if the remote controls become disconnected.
Note: Checktoseewhethertheby-passtubehasnotbeensqueezedorcut-off.Ifso,theunitisnotsuitable
for use in the 55 C default mode.
°°°°°°° °
°° ° ° ° °° °
°
°
Without
Remote
With
Remote

  
2!,!4 ++/<
Note: a) The black squares indicate the position of switches.
b) It will be noted that some dip switch configurations are the same for a given temperature whether controllers
are connected or not. These similarities are not mistakes.
c) If remote controls are connected and the maximum pre-set temperature is above 55 C, in the event that the
remote control becomes faulty or disconnected, the maximum preset temperature will revert to 55 C.
No. Model Carried out form Gas Type Serial No.
1
2
REU-2408W-A-NC
REU-2408W-AK-NC
06.05.99
01.05.99
19.05.99
14.05.99
LP
NG
LP
NG
99.05.00481~
99.05.002691~
99.05.000061~
99.05.000221~
3
4
REU-2424W-A-NC
REU-2424W-AK-NC
01.05.99
01.05.99
10.05.99
01.05.99
LP
NG
LP
NG
99.05.000362~
99.05.002931~
99.05.000141~
99.05.000421~
5
6
REU-2008W-A-NC
REU-2008W-AK-NC
01.05.99
22.04.99
30.04.99
01.05.99
LP
NG
LP
NG
99.05.000261~
99.04.001420~
99.05.000046~
99.05.000086~
off on SW1 off on SW1 off on SW1 off on SW1
4 4 4 4
5 5 5 5
6 6 6 6
7 7 7 7
8 8 8 8
off on SW1 off on SW1 off on SW1
4 4 4
5 5 5
6 6 6
7 7 7
8 8 8
60 oC65
oC75 oC
Temperatures - Remotes Connected
40oC43
oC50 oC55 oC
off on SW1 off on SW1 off on SW1 off on SW1
4 4 4 4
5 5 5 5
6 6 6 6
7 7 7 7
8 8 8 8
off on SW1 off on SW1 off on SW1 off on SW1
4 4 4 4
5 5 5 5
6 6 6 6
7 7 7 7
8 8 8 8
75 oC
Temperatures - Remotes Not Connected
40oC43
oC50 oC55 oC
85 oC 2424
only
60 oC65
oC
°°