Rinnai REU-V1616WF User manual

REU-V1616WF
INFINITY 16 FE Internal
Rinnai High Capacity Continuous Flow Gas Hot Water System
SERVICE MANUAL

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.
SAI Global

© Copyright Rinnai Australia Pty Ltd ACN 005 138 769 ABN 74 005 138 769
All rights reserved
Produced by Technical Services Department
September 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. 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.
SM REU-V1616WF
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-V1616WF - iv - Issue 1 - 21/11/03 ©Rinnai
Table of Contents
Glossary of Terms and Symbols ................................................................................. v
1. Introduction ................................................................................................................ 1
2. Specifications ............................................................................................................. 2
3. Water Flow Rates and Pressures ................................................................................ 4
4. Dimensions ................................................................................................................ 7
5. Installation ................................................................................................................. 8
6. Remote Controls ...................................................................................................... 11
7. Cutaway Diagram .................................................................................................... 14
8. Operational Flow Chart ........................................................................................... 15
9. Operation Principles ................................................................................................ 16
10. Main Components .................................................................................................. 17
11. Time Charts ............................................................................................................ 19
12. Wiring Diagram ..................................................................................................... 20
13. Dip Switch Settings ............................................................................................... 21
14. Fault Finding .......................................................................................................... 22
15. Component Circuit Value Table ............................................................................ 24
16. Component and Circuit Checks ............................................................................. 25
17. Maintenance Monitor / Error History .................................................................... 31
18. Gas Pressure / Gas Conversion Procedure ............................................................. 33
19. Dismantling for Service ......................................................................................... 34
20. Exploded Diagram ................................................................................................. 42
21. Parts List ................................................................................................................ 46
SERVICE CONTACT POINTS ............................................................................... 50

Infinity REU-V1616WF - v - Issue 1 - 21/11/03 ©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
∆

Infinity REU-V1616WF - 1 - Issue 1 - 21/11/03 ©Rinnai
1. Introduction
The Rinnai V-Series hot water units represents the latest technology in continuous flow, temperature
controlled hot water.
Features
• The Infinity 16 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 55ºC. 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 3ºC 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.
• ‘Standard’ Remote Controllers are available as an optional extra. Depending on the models chosen,
these offer - Localised temperature control for up to one kitchen and two bathroom controllers
• 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.

Infinity REU-V1616WF - 2 - Issue 1 - 4/05/04 ©Rinnai
2. Specifications
Note 1: The default factory setting is 55ºC for REU-V1616WF. 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.
Controllers are available with default temperatures up to 75º 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.
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Infinity REU-V1616WF - 3 - Issue 1 - 21/11/03 ©Rinnai
Sensors and Safety Devices
• 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
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
* * 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).
Gas Type Injector
Size (mm)
Test Point (kPa) * * Gas Input (MJ/hr)
Low High Low High
Natural ø 1.7 0.21 0.74 20 125
Propane ø 1.25 0.22 0.92 20 125
°
°

Infinity REU-V1616WF - 4 - Issue 1 - 21/11/03 ©Rinnai
3. Water Flow Rates and Pressures
Water Flows
Table 1 shows unmixed 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. Higher mixed water flow rates may be available at low temperature rises by mixing hot water
from the outlet of the water heater with cold water from the mains supply as illustrated below:
Water Flows can also be calculated by the following formula :
Q = Heat energy available in kW = 28 kW for the REU-V1616WF
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 = 28
C = 4.2
M = 60 x ( 28 / (4.2 x 10) ) = 40 l/min. Since 40 is greater than 16 this flow rate is mixed.
°
∆°
°
°
∆°

Infinity REU-V1616WF - 5 - Issue 1 - 21/11/03 ©Rinnai
Table 1: Approximate Water Flows and Gas Usage Table - REU-V1616WF
Temp
Ris
e
(
º C
)
Approx. Min
/ Max Gas
Input
(MJ/hour)
*
L/sec
L/min L/hr
Min Water
Pressure
(kPa)
Approx
Gas
Cons.
(MJ/h)
*
L/sec
L/min L/hr
Min Water
Pressure
(kPa)
Approx
Gas
Cons.
(MJ/h)
*
L/sec
L/min L/hr
Min Water
Pressure
(kPa)
Approx
Gas
Cons.
(MJ/h)
*
L/sec
L/min L/hr
Min Water
Pressure
(kPa)
Approx
Gas
Cons.
(MJ/h)
REU-V1616WF - Internal 18-125
20-125 0.27 16 960 72 25 0.27 16 960 72 50 0.27 16 960 72 75 0.27 16 960 72 100
Temp
Ris
e
(
º C
)
Approx. Min
/ Max Gas
Input
(MJ/hour)
*
L/sec
L/min L/hr
Min Water
Pressure
(kPa)
Approx
Gas
Cons.
(MJ/h)
*
L/sec
L/min L/hr
Min Water
Pressure
(kPa)
Approx
Gas
Cons.
(MJ/h)
*
L/sec
L/min L/hr
Min Water
Pressure
(kPa)
Approx
Gas
Cons.
(MJ/h)
*
L/sec
L/min L/hr
Min Water
Pressure
(kPa)
Approx
Gas
Cons.
(MJ/h)
REU-V1616WF - Internal 18-125
20-125 0.27 16 960 72 125 0.22 13.2 792 60 125 0.19 11.4 684 44 125 0.17 10.2 612 35 125
Temp
Ris
e
(
º C
)
Approx.
Min / Max
Gas Input
(MJ/hour)
*
L/sec
L/min L/hr
Min Water
Pressure
(kPa)
Approx
Gas
Cons.
(MJ/h)
*
L/sec
L/min L/hr
Min Water
Pressure
(kPa)
Approx
Gas
Cons.
(MJ/h)
*
L/sec
L/min L/hr
Min Water
Pressure
(kPa)
Approx
Gas
Cons.
(MJ/h)
*
L/sec
L/min L/hr
Min Water
Pressure
(kPa)
Approx
Gas
Cons.
(MJ/h)
REU-V1616WF - Internal 18-125
20-125 0.15 9 540 29 125 0.13 8 480 24 125 0.12 7.2 434 21 125 0.11 6.6 396 20 125
Models (All Pre-set Temperatures)
* Flows (L/Sec) are unmixed, at the outlet of the water heater.
20
25 30 35 40
51015
605045
Models (All Pre-set Temperatures)
Models (All Pre-set Temperatures)
55

Infinity REU-V1616WF - 6 - Issue 1 - 21/11/03 ©Rinnai
Water Pressure
As seen in the table below a minimum supply pressure of 90 kPa is required to operate at the rated flow of
16 L/min. In an actual installation, pressure losses in the plumbing system also need to be considered to
determine the minimum supply pressure.
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

Infinity REU-V1616WF - 7 - Issue 1 - 21/11/03 ©Rinnai
4. Dimensions
A DIMENSION
GAS
COLD
HOT
CABLE
ACCESS
52
50
42
3
(mm) CONNECTION
R (20mm)
R (15mm)
R (15mm)
34
2
1
12
334
60
350
1
78
170
72.5
A
510
62(GAS)
60(COLD)
99(HOT)
101(ELEC.)
940
78125
CABLE ACCESS
HOT WATER
OUTLET
COLD WATER INLET
GAS CONNECTION
257
24.5
336
565(WALL INSTALLATION PITCH) 549(WALL INSTALLATION PITCH)
15
538
579
15
10 ~ 45
(adjustable)

Infinity REU-V1616WF - 8 - Issue 1 - 21/11/03 ©Rinnai
5. Installation
Ventilation
The REU-V1616WF is is not a room sealed appliance, therefore
adequate fixed ventilation must be provided as per AS5601/
AG601/ 2002 Clause 5.4 to 5.4.5.
Air for combustion must be replaced, preferably from outside
atmosphere. Ensure that the area in which the appliance is
installed has adequate fixed ventiliation. (See table below).
When calculating the ventilation requirements, care should be
taken to allow for obstructions in the vent material / design used.
The use of Rinnai Vents (Rinnai Part No. ‘VENTS’) will
provide correct ventilation. See installation instructions
provided with the water heater for full details.
Note: Incorrect ventilation can cause the appliance to operate in an unsatisfactory manner and can
lead to a dangerous situation.
Flueing
Install the Rinnai Infinity WF (FE) Flueing system in accordance with the instructions supplied with the
flue terminal. The Rinnai REU-V1616WF can only be installed with the Rinnai approved WF Flue system.
Non Rinnai Flueing systems must not be used.
Permanent opening fo
r
free ventilation area
(Rinnai Part No. VENTS)
Terminal
Ventilation
Permanent opening for
free ventilation area
(Rinnai Part No. VENTS)

Infinity REU-V1616WF - 9 - Issue 1 - 21/11/03 ©Rinnai
Flueing Options
Flueing Options
Direct Flueing with Wall Terminal: (Fig.1) b) Extended Direct Flueing with Wall Terminal: (Fig.2)
c) Vertical Flueing with Roof Terminal (Fig.3)
Use combinations of
fixed and adjustable
flue lengths to position
the installation, as flue
components can NOT
be cut to size.
Ensurea3°fallto
the flue terminal.
Important Installation Notes:
The components of this flueing system CAN NOT BE
CUT use telescopic components to achieve the required
length.
The flue system MUST be installed to comply with
AS5601/AG601 Clause 5.13.
Ensure that positioning of the flue terminal complies with
the requirements of AG5601/AG601. Warning: The flue
products can reach temperatures above 200°C. The flue
terminal is to terminate in a location, not to cause a
nuisance.
The Rinnai REU V1616WF is a fan-assisted appliance;
use the fan-assisted clearances in AS5601/AG601
Clause 5.13.6.5
All Flue MUST be supported and be independent of the
appliance in accordance with AS5601/AG601 Clause
5.13.4.2 and 5.13.4.3.
Ensure the appliance can be removed without causing
movement or displacement of the flue, as per
AS5601/AG601 clause 5.13.4.1. Telescopic components
extended to a minimum of 55mm can be used as a slip
socket.
Caution: The “O” Rings in all components are pre-
greased; ensure they are not damaged when joining.
When preparing the wall and ceiling penetrations, cover
the flue spigot to prevent debris from entering the
appliance.
The mounting brackets on the appliance can be adjusted
from 15mm to 50mm to allow for irregularities in the walls
and length of the flue components.
1.8 m to floor
5
230 ~ 300
88 18772 ~ 400
5
Ventilated spacer 120
The maximum and minimum wall
depth is dependent on kit used.
*
*
(Fig.1)
(Fig.3)
(Fig.2)
a)

Infinity REU-V1616WF - 10 - Issue 1 - 21/11/03 ©Rinnai
Extended and Direct Flueing with Wall and Room Terminals
Condensate Drain
The condensate trap will collect condensate from the flue system. This condensate must be drained to the
outside of the building via a condensate drain pipe. In accordance with the installation instructions supplied
with the flue terminal.
The Direct flueing wall terminal can be extended using the methods as shown in (Fig.5)
The total flue length should not exceed 9m and the number of 90° bends should not exceed 3.
When total vertical rise of flue exceeds 2 m a Condensation Trap / Drainage MUST BE fitted (Fig.5, Method 4.).
Note: The through wall terminal is equivalent to a 1m length and counts as one 90° bend, these factors must be
taken into account when sizing a through wall installation.
1100
2000
195 155
500
150mm ceiling
ring supplied
with roof
terminal
Combustible
clearance
110mm
350
Where the total vertical flue height does not exceed 2 metres,
the fitting of a Condensation Trap / Drainage is not required.
As vertical height of flue installation is in excess of 2 metres,
a Condensation Trap / Drainage MUST BE fitted.
Use combinations of
fixed and adjustable
flue lengths to position
the installation, as flue
components can NOT
be cut to size.
Use combinations of
fixed and adjustable
flue lengths to position
the installation, as flue
components can NOT
be cut to size.
Method 1.
Method 3.
Method 2.
Flue Terminal
Flue Terminal
Flue Terminal
Ensurea3°fallto
the flue terminal.
Ensure a 3° fall to
theflueterminal.
Total vertical rise
not in excess of 2m
Method 4.
Flue Terminal
Ensurea3°falltothe
Condensate Trap.
The terminal clearances in AS5601 / AG601 do not apply to the Infinity REU V1616WF Water Heaters installed
side by side. The appliances are AGA certified to be installed side by side as shown in (Fig.6), allowing for a
horizontal distance of 155mm between flues.
The minimum distance of 500mm between the underside of the cowl and the nearest part of the roof must still be
met.
(Fig.4)(Fig.5)

Infinity REU-V1616WF - 11 - Issue 1 - 21/11/03 ©Rinnai
6. Remote Controls
Remote Controls
Remote Controllers are an optional extra. 'Standard' controllers can be fitted.
Standard controllers allow temperature selection only. 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 3 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.
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 1500mm). Controllers are water resistant, however, durability is
improved when positioned outside the shower recess or at least 400mm above the highest part of a sink,
basin or bath.
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 AS/NZ3000.
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.
120
90
20
MC-91-1A

Infinity REU-V1616WF - 12 - Issue 1 - 21/11/03 ©Rinnai
Water Heater and Controller installation configurations
If the front cover of the appliance contains the following text install it in accordance with Diagram 1 below
"THIS APPLIANCE DELIVERS WATER
NOT EXCEEDING 50ºC IN ACCORDANCE WITH AS 3498"
:
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 as defined in AS/NZ3500.4 a Temperature Limiting Device (TLD), such as a
Tempering Valve, may be required even if the appliance is set to 50º C or less. For these types of
applications contact Rinnai.
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) as shown in
fig. 1.
3. Thread the cable(s) through the cable access hole at the base of the
appliance.
4. Ensure the position of the terminals for controls shown on the
printed circuit board COVER. Connect the spade connectors to the
terminals on the P.C.B. (Fig. 2). Polarity is not important. Either
wire colour can be connected to either terminal.
Connect cord anchorage clip to controller wire.
5. Replace cover of the appliance, ensuing that the screw with the star
washer is placed at the bottom right hand corner for earthing
purposes.
50º C
KITCHEN
Temperature
controller
(optional)
Temperature
controller
(optional)
Temperature
controller
(optional)
LAUNDRY
BATHROOM
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)
TLD
H
O
T
C
O
L
D
G
A
S
Diagram 2. Not a 50º C Appliance
Note: TLD = Tem
p
erature Limitin
g
Device.
fig.1.

Infinity REU-V1616WF - 13 - Issue 1 - 21/11/03 ©Rinnai
Connecting Three Controllers
1. Isolate the power supply.
2. Remove the front cover from the Appliance (4 screws) as shown in fig.1.
3. 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.
4. Thread the 3 cables through the cable access hole at the base
of the appliance.
5. Ensure the position of the terminals for controls shown on
the Printed Circuit Board COVER. Connect the 4 spade
connectors to the terminals on the P.C.B. (fig 2). Polarity is
not important. Either wire colour can be connected to either
terminal.
Connect cable clamp around controller wiring to provide
cord anchorage.
6. Replace cover of the appliance, ensuring that the screw with
the star washer is placed at the bottom right hand corner for
earthing purposes.
If the front cover of the appliance contains the following text, "THIS APPLIANCE
DELIVERS WATER NOT EXCEEDING 50° C IN ACCORDANCE WITH AS 3498"
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
TERMINALS
FOR CONTROLS
REMOTE CONTROL
CABLE
CABLE CLUMP
fig. 3
New spade connectors Cable wires
Cable wires
Remote control cables
fig.1

Infinity REU-V1616WF - 14 - Issue 1 - 21/11/03 ©Rinnai
7. Cutaway Diagram

Infinity REU-V1616WF - 15 - Issue 1 - 21/11/03 ©Rinnai
8. Operational Flow Chart