Rinnai REU-KBM3237FFUDHD-E User manual

Service Manual
REU-KBM3237FFUDHD-E
HDC 1600i Low NOx
REU-KBM3237WDHD-E
HDC 1600e Low NOx
Continuous Flow Water Heater

2
STOP
Do not attempt to Service this appliance if you are not
qualified. This can void the warranty.
This manual must be read in its entirety before Servicing
the appliance.
If you are unsure of any point contact Rinnai UK
SERVICE INSTRUCTIONS

3
Service Information Page 4
Service Procedure Page 5-6
Gas Pressure Setting Page 7-8
Dip Switch Setting Page 9
Temperature Setting Page 10
Contact Information Page 12
CONTENTS

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 All Rinnai products should be Serviced at least once a year.
 The correct service kit should be acquired before commencing the service.
 The service kit will include all gaskets you may need.
 If you do not use the correct service kit and any gaskets or seals are broken in the
course of inspection the appliance in question has to be shut down until the
damaged gasket or seal is replaced.
 If the appliance continues to operate with damaged gaskets or seals this could
affect the performance or correct safe operation of the appliance.
 Servicing is required to maintain the appliances warranty.
 If there are any questions with regards any part of the service please contact the
Technical Department at Rinnai UK.
Service Kit Contents
The service kit contains the following items
 Full Electrode Kit
 Water Inlet Filter.
The Part Numbers Required for the appliances associated with this service manual are
as follows
Electrode Kit — HDC1600iKBX-Kit A
Water Inlet Filter — P50iVR-406
SERVICE

5
Service Procedure
The service of the HDC1600 Series is fairly straight forward and should take
approximately no longer than 30 minutes. Please ensure you have an Electrode kit for
this model as this is required at least every 12-24 months depending on the usage.
Follow the steps below.
 Isolate the appliance by the plug or fused spur and isolate the gas supply.
 Ensure the appliance is cool enough for the Electrode Kit to be removed. Remove
the Spark Electrode, Ionisation Electrode and Thermo Couple and either clean or
replace.
 Refit the Electrode Kit
 Unplug the Fan Motor and remove the two screws highlighted below
 Remove the Noise Filter from the fan using the 3 screws.
 Inspect the Fan Motor Impeller and clean with a soft brush if required
SERVICE

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Service Procedure
 Reinstate the gas supply and the mains electrical supply
 Fire the appliance up ensuring there is a good flow going through the water heater
and ensure the Electrode Kit is not leaking POC’s.
 Carry out a visual inspection of the heat exchanger and joints to check for any
leaks.
 Shut appliance down and connect a Digital Manometer on to the test point that is
highlighted in the diagrams on the page “Setting Gas Pressures”.
 Using the correct procedure check the Low and High Fire Gas Pressures, again
using the Setting Gas Pressures page and note them down on your report sheet.
 With the appliance in Normal Operation mode you can carry out a Flue Gas
Analysis if you wish to do so. Please see the below table for normal operating
parameters. If you have concerns over any readings please contact the Rinnai UK
Technical Department.
 Check the Dip Switches are set correctly using the Dip Switch Setting page.
 Isolate the water supply and check the Water Inlet Filter on the cold connection to
the water heater.
The service on the Rinnai Water Heater is now complete however please carry out full
checks of the system and flue system to ensure both of these are functioning correctly. If
there is a fault on either of these two systems this could affect the correct operation of
the appliance.
SERVICE
aCO (ppm) 77
bCO2 (%) 8.41
cFlue Gas Temp (°C) 46℃
dRatio (%) 0.0107 (CO air free)

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GAS PRESSURE SETTING
The working gas pressure on the water heater is electronically controlled and factory set.
Under normal circumstances it does not require adjustment during installation. The
pressure should be checked when the unit is installed and each time it is serviced to ensure
that it is correct. Contact Rinnai before attempting to alter the gas pressure if you are
unsure of what to do. Incorrect adjustment can void the warranty.
1. Turn 'OFF' the gas supply.
2. Turn 'OFF' 230V power supply.
3. Remove the front cover from the appliance (4 screws).
4. Check gas type using the dataplate on the side of the casing and confirm the dip switches
(Fig. 1) are in the correct position for the type of gas (Nat. or LPG)* you are using (see
page 40).
5. Attach pressure gauge to burner test point (Fig. 2).
6. Turn 'ON' the gas supply.
7. Turn 'ON' 230V power supply.
8.If remote controllers are fitted, turn the unit 'ON' at the controller and select a maximum
delivery temperature.
9. Open hot water taps fully to reach max flowrate. (CAUTION: Ensure building
occupants do not have access to hot water outlets during this procedure.) If there
is not enough water flowing, the water heater might shut off or damage due to
overheating.
* Simply changing the position of the dip switches will not convert the unit
from one gas type to the other. The conversion procedure requires a change of
injector manifold.
Contact Rinnai if you want to convert the appliance to a different gas family.
NOTE
Fig. 1
Fig. 2

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10. Move switch No. 8 of SW1 to 'ON' position (Fig. 3).
11. Push the PCB board switch A for one second (Fig. 4).
12. Calibrate “forced low” combustion using switch A (up) and
B (down) as required.
13. Move switch No. 8 of SW1 to 'OFF' position and then back
to ‘ON’ position (Fig. 6).
14. Push the PC board switch B for one second (Fig. 4).
15. Calibrate “forced high” combustion using switch A (up) and
B (down) as required.
16. Move switch No. 8 of SW1 to 'OFF' position (Fig. 5).
17. Close hot water taps and turn ‘OFF’ the gas supply and
230V power supply.
18. Remove pressure gauge and replace sealing screw. Turn
‘ON’ the gas supply and power.
19. Operate unit and check gas leaks.
20. Replace the front cover of the appliance.
GAS PRESSURE SETTING
Fig. 4
LOW Gas
Internal External
Short flue
position
Long flue
position -
NG G20 1,2 1,3 1,2
LPG G30
G31 1,3 1,4 1,3
Air /
Prop. G230 1,4 1,5 1,4
(pressures in mbar)
Fig. 3
Fig. 4
Fig. 5
Fig. 6
HIGH Gas
Internal External
Short flue
position
Long flue
position -
NG G20 7,6 8,5 8,1
LPG G30
G31 9,2 9,7 8,9
Air /
Prop. G230 9,0 9,8 9,2
(pressures in mbar)

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DIP SWITCH SETTING
SW1
No. Switches Explained
1Model choiceA-1
2
Temperature selection
3
4
5
6Gas TypeA-1
7Gas TypeB-1
8Forced Combusiton
SW2
No. Switches Explained
1Model choiceA-2
2Model choiceB-1
3Recirculation Mode
4Interval time to ON of
Recirculation Mode
5Commercial setting
6Gas TypeA-2
7Gas TypeB-2
8Model choiceB-2
LEGEND:
Black Section indicates
position of dip switch.
OFF ON OFF ON
OFF ON
【Model Type】
FF-Long FF-Short W FF-Long
Common vent1 (factory setting) (factory setting) Common vent2(FE)
Off On Off On Off On Off On
SW1 1SW1 1SW1 1SW1 1
Off On Off On Off On Off On
SW2 1 SW2 1 SW2 1 SW2 1 2222
8888
C13, C33, C53,
C83P (same area
with air intake and
exhaust).
C13, C33, C53. A3. B33P,
C83P (different area
with air intake and
exhaust).
【Gas Type】Set No.6,7 switches both SW1 and SW 2
LPG Off On G20 Off On G230 Off On
SW1 6SW1 6SW1 6
777
Off On Off On Off On
SW2 6SW2 6SW2 6
777

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TEMPERATURE SETTING