Rinnai REU-K2430WG User manual

REU-K2430WG-AK
SERVICE MANUAL
To Suit Model:
ENVIROSMARTREU-K2430WG

All Rinnai products are certified by the
Australian Gas Association as compliant
to relevant Australian Standards.
Rinnai Australia Head Office is certified
as complying with ISO 9001 by 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

© Copyright Rinnai Australia Pty Ltd ABN 74 005 138 769
All rights reserved
Produced by Technical Support Department
No portion or part of this manual may be copied without prior permission from
Rinnai Australia.
Rinnai Australia 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 Support Department. We
welcome users of this manual to provide feedback and suggestions for improvement
purposes.
SM REU-K2430W-AK (Envirosmart)
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

REU-K2430WG-AK (Envirosmart)- iv - Issue 1 - 16/12/09 ©Rinnai
Table of Contents
1. Specifications ............................................................................................................. 2
2. Water Flow Rates and Pressure Characteristics ........................................................ 4
3. Dimensions ................................................................................................................ 5
4. Water Controllers ....................................................................................................... 6
5. Smartstart ................................................................................................................... 8
6. Cutaway Diagram ...................................................................................................... 9
7. Operational Flow Chart ........................................................................................... 10
8. Operation Principles ................................................................................................ 12
9. Main Components .................................................................................................... 13
10. Condensate Drain ................................................................................................... 14
11. Component Circuit Value Table ............................................................................ 15
12. Time Charts ............................................................................................................ 16
13. Wiring Diagram ..................................................................................................... 17
14. Dip Switch Settings ............................................................................................... 18
15. Fault Finding .......................................................................................................... 19
16. Component and Circuit Checks ............................................................................. 21
17. Maintenance Monitor / Error History .................................................................... 26
18. Gas Pressure Setting Procedure ............................................................................. 29
19. Gas Conversion Procedure ..................................................................................... 29
20. Dismantling for Service ......................................................................................... 30
21. Parts List ................................................................................................................ 39
22. Exploded Diagram ................................................................................................. 43

REU-K2430WG-AK (Envirosmart)- 1 - Issue 1 - 16/12/09 ©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


REU-K2430WG-AK (Envirosmart)- 2 - Issue 1 - 16/12/09 ©Rinnai
1. Specifications
Rinnai model number REU-2430WG-AK
Type of appliance Temperature controlled continuous flow gas hot water system
with condensing combustion system
Combustion system Room sealed, fan forced combustion
Installation External
Dimensions Width
Height
Depth
350 mm
600 mm
250 mm
Weight 27 Kg
Gas consumption (MJ/h) Natural gas:
Propane gas: Max 162 / Min 15.9 Max 162 / Min 16.7
Connections
Gas inlet R 3/4
Cold water connection R 3/4
Hot water connection R 3/4
Condensate outlet R 1/2
Electrical consumption Normal 50 W
Standby 2 W (with 1 water controller)
Anti-Frost protection 125 W
Hot water capacity (Raised 25°C) 2.3 to 24 L/min
Default temperature control
(without water controller) 40, 42, 50, 55, 60, 65, 75°C (Set by combination of dip switches on PCB)
Water flow control Water flow sensor, electronic water flow control device and
electronic by-pass flow control device.
Nominal operating water pressure 240 kPa ~ 1000 kPa
Minimum start-up water flow 2.4 L/min
Maximum war flow 30 L/min
Power supply Appliance
Water controller AC 240 Volts 50 Hz DC12 Volts
1. Up to 4 controllers can be fitted.
See below for the combination limitation of water controllers
Water controllers (optional) 2. Wireless controllers can be fitted in the same manner of
MC-91Q-2A
Kitchen control MC-100V-1A or MC-91Q-2A
Bathroom control BC-100V-1A or MC-91Q-2A
Second bathroom control BC-100V-1A or MC-91Q-2A
Third bathroom control MC-91Q-2A
Water Controller Cable
(Supplied with controller) Non-polarized two core cable.

REU-K2430WG-AK (Envirosmart)- 3 - Issue 1 - 16/12/09 ©Rinnai
Sensors and Safety Functions
•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 97ºC for a number of seconds.
•Fusible Link: Situated on the heat exchanger, electrical 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 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
Refer dataplate on appliance

REU-K2430WG-AK (Envirosmart)- 4 - Issue 1 - 16/12/09 ©Rinnai
2. Water Flow Rates and Pressure Chartacterists
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㪊㪈㪅㪇 㪊㪈㪅㪇
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㪧㩿㫂㪧㪸
㪇㪅㪇 㪈㪇㪅㪇 㪉㪇㪅㪇 㪊㪇㪅㪇 㪋㪇㪅㪇 㪌㪇㪅㪇 㪍㪇㪅㪇 㪎㪇㪅㪇 㪏㪇㪅㪇 㪐㪇㪅㪇 㪈㪇㪇㪅㪇 㪈㪉㪇㪅㪇 㪈㪋㪇㪅㪇 㪈㪍㪇㪅㪇 㪈㪏㪇㪅㪇 㪈㪐㪇㪅㪇 㪉㪇㪇㪅㪇 㪉㪉㪇㪅㪇 㪉㪍㪇㪅㪇 㪊㪇㪇㪅㪇
㪋㪇㪇㪅㪇 㪌㪇㪇㪅㪇
㪨㩿㪣㪆㫄㫀㫅
㪇㪅㪇 㪋㪅㪋 㪎㪅㪎 㪈㪇㪅㪇 㪈㪈㪅㪍 㪈㪊㪅㪊 㪈㪋㪅㪎 㪈㪍㪅㪈 㪈㪎㪅㪉 㪈㪏㪅㪌 㪈㪐㪅㪋 㪉㪈㪅㪋 㪉㪊㪅㪉 㪉㪋㪅㪐 㪉㪍㪅㪍 㪉㪎㪅㪋 㪉㪏㪅㪇 㪉㪐㪅㪇 㪊㪇㪅㪌 㪊㪈㪅㪇
㪊㪈㪅㪇 㪊㪈㪅㪇
㪎㪌 㪎㪌
㪇㪈㪎
㪇㪐㪇
㪈㪊㪅㪏 㪈㪊㪅㪏
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㪇 㪌
㪈㪇 㪈㪌 㪉㪇 㪉㪌 㪊㪇 㪊㪌 㪋㪇
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㪙㪧㪪㩷㪽㫌㫃㫃㩷㪺㫃㫆㫊㪼

REU-K2430WG-AK (Envirosmart)- 5 - Issue 1 - 16/12/09 ©Rinnai
3. Dimensions
Condensate Connection Length (from base)
Dim' Description
AhtdiW
BhtpeD
CtinU-thgieH
DHeight - Including Brackets
EHot Water outlet (from wall)
FHot Water outlet (from centre)
GCold Water inlet (from wall)
HCold Water inlet (from centre)
KCondensate outlet (from wall)
LCondensate outlet (from centre)
Gas Connection Length (from base)
Cold Connection Length (from base)
Hot Connection Length (from base)
retemaiDgnittiF:saG
Condensate: Fitting Diameter
M
N
B
D
C
M
IGas Connection (from wall)
JGas Connection (from centre)
retemaiDgnittiF:dloC
retemaiDgnittiF:toH
A
E
F
J
L
H
I
G
K
N
FITTING DIAMETER
*Please note that this measurement is to the left of the centre line.
O
PR
Q
Dim' Description
MC-100V MC-91Q-2A
O821htdiW
P021thgieH
Q02htpeD
RDistance between
mounting hole centres 83
BC-100V
202
104
22
181
MC-91
90
120
20
83
REU-K2430WG
350
277
600
644
164.5
100
83
53
33
132
40
50
42
20
15
70.5
25
20
20

REU-K2430WG-AK (Envirosmart)- 6 - Issue 1 - 16/12/09 ©Rinnai
4. Water Controllers
All watercontrollersmustbeinstalledinaccordance withthe relevant operation/installationinstructions supplied with
the water heater or water controllers.
Troubleshooting
Controller not showing display - (Wired Controllers)
• Check that the correct number and combination of controllers have been installed for the specific model
Infinity. Refer to controller compatibility table below.
• Check controller is turned ON.
• Check there is 12VDC power supply available to the controller from the Ezi-connect terminals.
• If there is 12VDC available from the Ezi Connect but no controller display, check wiring between Ezi-connect
and controller is sound.
• If there is no power from the Ezi-connect terminals, but the hot water functions correctly, replace PCB.
Error Code 12 as soon as hot water tap is turned ON.
• Check 12VDC internal wiring to Ezi-connect terminal is not crushed or shortened.
• Rectify wiring and re-close Ezi-connect cover carefully.
Controller not showing display - (Wireless Controllers)
• Ensure transceiver module is mounted in the correct location, as per wireless controller installation instructions.
• Ensure 2 x AA batteries are in good working order and installed 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.
Controller Compatibility Table
Care should be taken to ensure power supply to the Infinity is isolated when connecting /
disconnecting controller wiring or transponder on wireless controllers. Failure to isolate
power supply may result in damage to the appliance PCB.
Care should be taken when closing the Ezi-connect access panel, to ensure internal wiring
for controllers is not shortened or crushed.
WirelessOnly
Installation A maximum of 4 wireless water controllers can be fitted with the following limitation:
Only ONE MC-502RC can be set as the Master Controller.
Wired &
Wireless
Installations
A maximum of 4 water controllers can be fitted. Any combination of deluxe, universal and
wireless controllers can be used with the following limitation:
Only ONE master controller can be installed. This can be a MC-100V, a MC-91Q (when
programmed as a master controller) or a MC-502RC water controller.
Up to TWO BC-100V water controllers can be installed.
The FOURTH water controllers in any installation MUST BE a MC-502RC or a
MC91Q.
NOTE

REU-K2430WG-AK (Envirosmart)- 7 - Issue 1 - 16/12/09 ©Rinnai
PROGRAMMING FOR THE ‘UNIVERSAL’ WATER CONTROLLER (MC-91Q)
Are there four water controllers connected?
IF NO: (You have three water controllers or fewer), go to Question 2.
IF YES: You will need to activate the fourth water controller as follows:
STEP 1: For the water controller in the KITCHEN ONLY, press and hold the
‘Transfer’ and ‘On/Off’ buttons simultaneously (see Fig. 5) until a
‘beep’ is heard (approximately 5 seconds).
STEP 2: Check that the display on ALL FOUR water controllers is lit and
displaying a temperature when ‘switched on’. If any ONE of the
controller displays two dashes (see Fig. 6) repeat STEP 1.
This completes the activation procedure for the fourth controller, you
may ignore 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).
STEP 2: When the controller fitted in the KITCHEN is switched On, it should be
possible to select temperatures higher than 50°C. If not, repeat STEP 1.
Fig. 7
If the water controller in the kitchen is replaced, repeat STEP 1 above for the replacement
controller.
If the water controller in the kitchen 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 bathroom to the
kitchen.
QUESTION
QUESTION
NOTE

REU-K2430WG-AK (Envirosmart)- 8 - Issue 1 - 16/12/09 ©Rinnai
5. Smartstart
At least one temperature controller model MC-91Q must be used in conjunction with the water heater and
the Smartstart® system. Alternatively, if Water Controllers cannot be used a manual activation switch is
available. See separate service manual.
The installation of the water heater and water controllers must be performed in accordance with the
operating/installation instructions supplied with the water heater.
The Smartstart® system is designed for domestic installations. However, it may be suitable for certain non
domestic installations. See separate service manual for more information.
Principle of operation (Fig.2)
The "Smartstart®" system heats the water in the pipework water connected between the water heater and
the 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 significant
energy savings because water is not heated unnecessarily whilst retaining the benefits of traditional flow
and return systems.
A schematic of the Smartstart® system installed in conjunction with a Rinnai continuous flow water heater
and water controller is shown in Fig.2 below.
If problems are experienced with Smartstart® operation refer to the Smartstart® service manual.
H
O
T
C
O
L
D
G
A
S
Cold Inlet Mains
Smartstart®
Module
Rinnai Continuous
Flow Water Heater
Hot Water
Outlet
Hot Water
Outlet
Fig.2
Heating Loop Flow
Heating Loop Return
One or more
MC-91Q
Controllers
Preheat Button

REU-K2430WG-AK (Envirosmart)- 9 - Issue 1 - 16/12/09 ©Rinnai
6. Cutaway Diagram

REU-K2430WG-AK (Envirosmart)- 10 - Issue 1 - 16/12/09 ©Rinnai
7. Operational Flow Chart
Continued next page

REU-K2430WG-AK (Envirosmart)- 11 - Issue 1 - 16/12/09 ©Rinnai

REU-K2430WG-AK (Envirosmart)- 12 - Issue 1 - 16/12/09 ©Rinnai
8. Operation Principles
Hot Water Operation
1) Ignition
• Activate controllers (if fitted) and open the hot water tap (for full details regarding operation of water controllers
refer to the ‘Operation / Installation manual supplied with water heater).
• 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. The fan motor sends an electrical
pulse signal to the PCB. If fan rotation is OK, the main solenoid and changeover solenoid valves open as
required, the spark generator activates and the spark electrode ignites the burner.
2) Water Temperature and Flow
• The PCB 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 Sensor 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 also used by the PCB to compute
the volume of water that has been passed through the unit at any instant whilst the bath is filling.
3) Shut Down
• When operating in ‘Bath Fill’ mode, the PCB causes the Water Flow Sensor to close when the programmed Bath
Fill volume has passed through the unit. Alternatively, flow is stopped when the user closes the hot water tap.
• When water flow stops, the water flow sensor stops rotating and the pulse signal to the PCB stops. The PCB then
causes the main solenoid and solenoid valves to close and the burner is extinguished. The combustion fan will
continue to operate for some time to purge the combustion chamber.

REU-K2430WG-AK (Envirosmart)- 13 - Issue 1 - 16/12/09 ©Rinnai
9. Main Components
1) Printed Circuit Board (PCB)
• 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.
• Gas flow rate is controlled by the modulating valve assembly and three changeover solenoid valves to
always ensure constant outlet water temperature, regardless of flow rate or incoming water temperature.
• The modulating valve is electronically controlled by the PCB using signals from the water flow sensor,
water flow control device, bypass flow control device, water temperature thermistors and combustion
fan speed sensor. The modulating valve directs gas to the three changeover solenoid valves.
• The three changeover solenoid valves direct gas to each of the three burner banks independently. Any
one, two or all of the solenoid valves may be open during operation.
• Gas flow is modulated between 16 and 162 MJ/hr by a combination of the modulating valve and
changeover solenoid positions.
• The maximum gas rate is predetermined and the appliance cannot be overloaded when correctly
installed.
3) Water Flow Control
• Water flow is detected by a turbine coupled to a magnetic pulse generating device. The magnetic pulses
are detected and counted by the PCB. The PCB calculates the exact water flow from the frequency of
pulses generated by the turbine, as well as the volume of water that has passed through the unit at any
instant during ‘Bath Fill’ operation. A minimum flow rate of 2.4 l/min. is required for the burner to
ignite.
• Water flow control is achieved through the use of servo driven water flow and bypass valves. 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. Also, when the Bath Fill
function is activated, flow of water is stopped when the bath is full. During normal operation, cold water
from the inlet valve is mixed with hot water from the heat exchanger outlet.
4) Air Supply Control
• Air for combustion is supplied by a centrifugal fan driven by a variable speed DC motor. The voltage to
the motor is determined by the PCB based on water flow, delivered water temperature and programmed
water temperature. The actual fan speed is monitored by a magnetic pulse counter. This counter emits a
signal to the PCB. From the voltage supplied to the DC motor and the fan speed signal, the PCB
determines whether an error condition exists with the fan.
5) Combustion System
The combustion chamber is housed within the heat exchanger assembly and comprises:
• A three chamber aluminium alloy manifold multiple integral injectors, arranged in two rows of sixteen.
The middle chamber houses six injectors, the left chamber, ten, and the right chamber, sixteen injectors.
Gas flow to each chamber is controlled by an electronic solenoid valve (refer ‘Gas Flow Control’
above).
• A burner assembly comprising sixteen identical modular stainless steel bunsen burners secured by an
aluminised steel framework. The manifold is attached to the front of the burner module. Each bunsen
burner is supplied by two injectors.
• A combustion chamber. Integrated into the combustion chamber front panel are the flame rod and two
ignition electrodes.

REU-K2430WG-AK (Envirosmart)- 14 - Issue 1 - 16/12/09 ©Rinnai
10. Condensate Drain
The ENVIROSMART REU-K2430WG water heater generates condensate continuously at a rate of up to 5 litres
per hour as a by-product of highly efficient gas burner system. This condensate must be drained via a pipe to a
suitable point of discharge. Because the condensate is a by-product of gas combustion it is mildly acidic. For this
reason copper tube and fittings MUST NOT be used as it will corrode. Instead, Rinnai recommend plastic pipes
and fittings such as Unplasticised Polyvinyl Chloride (UPVC) or Polyethylene (PE) which is commonly used for
irrigation piping.
Refer to installation instruction for more information regarding Condensate Drainage.

Infinity REU-V2626W / HD200E REU-V2632WC - 15 - ©Rinnai
11. Component Circuit Value Table
FLOW
CHART
No. COMPONENT MEASUREMENT POINT
CN
WIRE COLOUR
NOTE
1SURGE PROTECTOR AC 207 - 264 V
DC 11 - 13V
REMOTE CONTROL
3
R-Bk
WATER FLOW SENSOR
4
5
Gy-Gy
IGNITER
P-Bk
MAIN SOLENOID VALVE
B-Bk
P-P
THERMAL FUSES R-R
W-P
Y-Bk DC 4 - 7V (PULSE 20-320Hz)
R-Bk DC 15 - 46V
AC 207 – 264V
DC 11 - 13V
24 - 28 Ω
67 - 81Ω
MODULATING
SOLENOID VALVE
Y-Bk
BELOW 1Ω
WATER FLOW
CONTROL DEVICE
Br - Gy
Y-Gy
R-B
BELOW DC 1V(LIMITER OFF)
+/- DC10 - 13V
DC 4 - 6V(LIMITER OFF) FULL OPEN POSITION
OPERATE ELECTRICITY
BELOW DC 1V(LIMITER OFF)
ON 2.4L/MIN (33Hz)
OVER 1980PULSE/MIN
GND
B-Br
COMBUSTION FAN
6
OVER DC 1μA
FLAME ROD7
10
11
12
14
20 - 400Hz
2
16
SOLENOID VALVE 1
SOLENOID VALVE 2
NORMAL VALUE
FULL CLOSE POSITION
FLAME CONDITION
GND
W-Bk
Y-Bk
Y - FLAME ROD
9
(SMALL)
(MIDDLE)
OUTGOING WATER
THERMISTOR
BY-PASS FLOW
CONTROL DEVICE
Br - W
O-W
Y-W
R-W
DC 12V (OPERATING DC2-6V)
15 - 35Ω
Bk - Bk
8
HEAT EXCHANGER
THERMISTOR
13
GND
GND
W-W
15 SOLENOID VALVE 3
(LARGE) Br - Bk
DC 4 - 6V(LIMITER ON)
(ONLY WHEN OPERATING)
DC 11 - 13V
BELOW 1380PULSE/MIN
OFF 1.7L/MIN (23Hz)
DC 11 - 13V
15°C … 11.4 - 14.0 kΩ
30°C … 6.4 - 7.8 kΩ
45°C … 3.6 - 4.5 kΩ
60°C … 2.2 - 2.7 kΩ
105°C … 0.6 - 0.8 kΩ
DC 11 - 13V
35 - 41 Ω
DC 11 - 13V
35 - 41 Ω
DC 11 - 13V
35 - 41 Ω
F3
E5
H1
A1
E2
B1
I4
I3
E3
E4
I1
E1
C1
I5
I6
I7
I8

REU-K2430WG-AK (Envirosmart)- 16 - Issue 1 - 16/12/09 ©Rinnai
12. Time Charts
Normal Combustion
Mis-Ignition / Flame Failure
Abnormal Pre-Purge (Air Supply/Exhaust Blockage)