Rinnai INFINITYREU-V3232W Service Manual
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Rinnai INFINITYREU-V3232W Service Manual

High capacity continuous flow gas hot water system
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INFINITY REU-V3232W
HD250E REU-V3232WC
SERVICE MANUAL
Infinity High Capacity Continuous Flow Gas Hot Water System

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Summary of Contents for Rinnai INFINITYREU-V3232W

  • Page 1 INFINITY REU-V3232W HD250E REU-V3232WC SERVICE MANUAL Infinity High Capacity Continuous Flow Gas Hot Water System...
  • Page 2 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.
  • Page 3 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.

  • Page 4: Table Of Contents

    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 - iii - Issue 1 - 8/09/03 ©Rinnai...

  • Page 5: Glossary Of Terms And Symbols

    ø diameter ∆ temperature rise above ambient modulating valve thermal efficiency thermistor temperature of incoming water temperature of outgoing water Infinity REU-V3232W / HD250E REU-V3232WC - v - Issue 1 - 8/09/03 ©Rinnai...

  • Page 6: Introduction

    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.

  • Page 7: Specifications

    System(optional) 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.

  • Page 8: Sensors And Safety Devices

    * * 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 Infinity REU-V3232W / HD250E REU-V3232WC - 3 - Issue 1 - 8/09/03 ©Rinnai...

  • Page 9: Water Flow Rates And Pressures

    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. Infinity REU-V3232W / HD250E REU-V3232WC - 4 - Issue 1 - 8/09/03 ©Rinnai...
  • Page 10 Table 1: Approximate Water Flows and Gas Usage - Rinnai Infinity REU-V3232W/WC Temperature ° L/min L/hr MJ/hr L/min L/hr MJ/hr L/min L/hr MJ/hr Rise C 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...

  • Page 11: Water Pressure

    As seen in the table below a minimum supply pressure of 180 kPa is required to operate at the rated flow of 32 L/min. In an actual installation, pressure losses in the plumbing system also need to be considered. Infinity REU-V3232W / HD250E REU-V3232WC - 6 - Issue 1 - 8/09/03 ©Rinnai...

  • Page 12: Dimensions

    4. Dimensions Infinity REU-V3232W / HD250E REU-V3232WC - 7 - Issue 1 - 8/09/03 ©Rinnai...

  • Page 13: Installation

    5. Installation External Wall Installation Important: Refer to the current versions of AG601/AS5601 and AS3500 for installation requirements. Infinity REU-V3232W / HD250E REU-V3232WC - 8 - Issue 1 - 8/09/03 ©Rinnai...

  • Page 14: Remote Controls

    (suggested height from floor at least 1500 mm). Controllers are water resistant, however, durability is improved when positioned outside the shower recess or at least 400 mm above the highest part of a sink, basin or bath. Infinity REU-V3232W /HD250E REU-V3232WC - 9 - Issue 1 - 8/09/03 ©Rinnai...

  • Page 15: Remote Controller Connection

    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.
  • Page 16 15.Replace cover of the Appliance. Ensure that the screw with the star washer is placed at the bottom right hand corner for earthing purposes. Remote control cables fig. 3 Infinity REU-V3232W /HD250E REU-V3232WC - 11 - Issue 1 - 8/09/03 ©Rinnai...
  • Page 17 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. Infinity REU-V3232W /HD250E REU-V3232WC - 12 - Issue 1 - 8/09/03 ©Rinnai...

  • Page 18: Cutaway Diagram

    7. Cutaway Diagram Infinity REU-V3232W /HD250E REU-V3232WC - 13 - Issue 1 - 8/09/03 ©Rinnai...

  • Page 19: Operational Flow Chart

    14 flashing Overheat switch activated Fan revolves for ignition Main solenoid valve ON Solenoid valve 1 ON Modulating valve ON cont. next page cont. next page cont. next page Infinity REU-V3232W /HD250E REU-V3232WC - 14 - Issue 1 - 8/09/03 ©Rinnai...
  • Page 20 Solenoid valve 2 OFF Solenoid valve 3 OFF 10 flashing Combustion faulty Modulating valve OFF Combustion indicator OFF Combustion fan OFF (after 65 seconds) HEX outgoing temp. < 60°C Infinity REU-V3232W /HD250E REU-V3232WC - 15 - Issue 1 - 8/09/03 ©Rinnai...

  • Page 21: Operation Principles

    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. Infinity REU-V3232W /HD250E REU-V3232WC - 16 - Issue 1 - 8/09/03 ©Rinnai...

  • Page 22: Main Components

    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. Infinity REU-V3232W /HD250E REU-V3232WC - 17 - Issue 1 - 8/09/03 ©Rinnai...

  • Page 23: Time Charts

    11. Time Charts Normal Combustion Miss-Ignition / Flame Failure Abnormal Pre-Purge (AIr Supply/Exhaust Blockage) Infinity REU-V3232W /HD250E REU-V3232WC - 18 - Issue 1 - 8/09/03 ©Rinnai...

  • Page 24: Wiring Diagram

    12. Wiring Diagram Infinity REU-V3232W /HD250E REU-V3232WC - 19 - Issue 1 - 8/09/03 ©Rinnai...

  • Page 25: Dip Switch Settings

    For gas conversion instructions refer to page 41. Normal Combustion Forced ‘Low’ Combustion Forced ‘High’ Combustion Computer Programming Switch is always in OFF position for REU-V3232W/WC Infinity REU-V3232W /HD250E REU-V3232WC - 20 - Issue 1 - 8/09/03 ©Rinnai...
  • Page 26 Such markings appear near the data plate, located on the burner cover and or on the bypass servo wiring loom. A unit set to between 40° C and 85° C MUST BE returned to Rinnai and specifically modified to deliver 95° C.

  • Page 27: Fault Finding

    Detailed information on (page 37) how to check all components. (page 26) Dismantling for Service Detailed information on how to remove and replace components. (page 43) Infinity REU-V3232W /HD250E REU-V3232WC - 22 - Issue 1 - 8/09/03 ©Rinnai...

  • Page 28: Item

    6, 18, Check combustion fan 05 and 09 fan rotation error Water flow Check water flow servo control device error. Water flow is not controlled. Water temperature too low. Infinity REU-V3232W /HD250E REU-V3232WC - 23 - Issue 1 - 8/09/03 ©Rinnai...
  • Page 29 4. Check water flow servo. fitted. 5. Check bypass servo. Anti-frost 1. Check anti-frost heater heater does not components operate. 2. Check frost sensing switch Infinity REU-V3232W /HD250E REU-V3232WC - 24 - Issue 1 - 8/09/03 ©Rinnai...

  • Page 30: Component Circuit Value Table

    Solenoid Valve 1 R-Bk 1.8~2.2k DC80~100V Solenoid Valve 2 Or-Bk 1.8~2.2k DC80~100V Solenoid Valve 3 Y-Bk 1.8~2.2k AC90~110V 12~21 AC12~18V Gr-Gr 2.4~4.3 Transformer AC30~50V Br-Gy 2.2~3.9 AC180~220V Y-Gy 300~530 Infinity REU-V3232W /HD250E REU-V3232WC - 25 - Issue 1 - 8/09/03 ©Rinnai...

  • Page 31: Component And Circuit Checks

    Disconnect connector (J ) and measure resistance between both terminals of the sparker. Ω Normal: > 1M If not sparking, adjust or replace ignition plug. Faulty: Replace Sparker. Infinity REU-V3232W /HD250E REU-V3232WC - 26 - Issue 1 - 8/09/03 ©Rinnai...
  • Page 32 If normal,, proceed to Faulty: Replace Solenoid Valve 2. Measure voltage between Orange and Black of Solenoid Valve connector. Normal: DC80~100V If normal, proceed to Thermal fuse Circuit. Faulty: Replace PCB. Infinity REU-V3232W /HD250E REU-V3232WC - 27 - Issue 1 - 8/09/03 ©Rinnai...
  • Page 33 Check the gas secondary pressure change when set temperature on the remote control changes from 37 to 55 Normal: If secondary pressure changes, go to Water Flow Servo Circuit. Faulty: Replace Modulating Valve. Infinity REU-V3232W /HD250E REU-V3232WC - 28 - Issue 1 - 8/09/03 ©Rinnai...
  • Page 34 If normal, check other possible causes for flame failure (is gas valve open?, is the filter blocked? etc.). If faulty, tighten the earth lead, PCB, power cord and surge arrester. Infinity REU-V3232W /HD250E REU-V3232WC - 29 - Issue 1 - 8/09/03 ©Rinnai...
  • Page 35 Normal: DC 4~7V If normal, proceed to 2. Faulty: Replace water flow sensor. Note: For controller readout of water flow whilst operational refer maintenance monitor (chapter 17) No. 1. Infinity REU-V3232W /HD250E REU-V3232WC - 30 - Issue 1 - 8/09/03 ©Rinnai...
  • Page 36 If normal, proceed to Water Flow Servo Circuit If faulty, replace Heat Exchanger Outlet Thermistor. Note: For controller readout of thermistor temperature whilst operational refer maintenance monitor (chapter 17) No. 11. Infinity REU-V3232W /HD250E REU-V3232WC - 31 - Issue 1 - 8/09/03 ©Rinnai...
  • Page 37 Normal: <1Ω If normal go to step Electrical Fuse 13. Faulty: Replace fuse/s (3Ax2). Check for a short next time it’s turned off. Infinity REU-V3232W /HD250E REU-V3232WC - 32 - Issue 1 - 8/09/03 ©Rinnai...
  • Page 38 If normal, proceed to 4. Faulty: Replace transformer. Note) The above transformer voltages are meas- ured while the appliance is in standby mode - not while it is operating. Infinity REU-V3232W /HD250E REU-V3232WC - 33 - Issue 1 - 8/09/03 ©Rinnai...
  • Page 39 Faulty: Because normal voltage is not given due a short circuit, despite the PCB being in normal state, check Water Flow Servo circuit. If solution is not given from the above replace PCB. Infinity REU-V3232W /HD250E REU-V3232WC - 34 - Issue 1 - 8/09/03 ©Rinnai...
  • Page 40 ) and measure resistance between Yellow and Yellow on each conector on heater side. Ω Normal: 653 If normal, proceed to c. Faulty: Replace Anti-frost Heater B (assy). Infinity REU-V3232W /HD250E REU-V3232WC - 35 - Issue 1 - 8/09/03 ©Rinnai...
  • Page 41 18. Frost Sensing Switch Disconnect relay connector (J ) and measure resistance between Blue and Blue. Ω Normal: < 1 If normal, check wiring (AC240V circuit). Faulty: Replace Frost Sensing Switch. Infinity REU-V3232W /HD250E REU-V3232WC - 36 - Issue 1 - 8/09/03 ©Rinnai...

  • Page 42: Maintenance Monitor / Error History

    *Note 2 Remote Control Connections Bathroom Remote Controls connected Display “0” Additional remote Kitchen remote “1” “0 1” Water flow servo present recognising positioning None 0~2 *Note 3 Infinity REU-V3232W /HD250E REU-V3232WC - 37 - Issue 1 - 8/09/03 ©Rinnai...
  • Page 43 To return to normal operation. • Press the ON/OFF button again while holding the Water Temperature “UP” (Hotter) button. • This feature will automatically shut down after 3 minuets. Infinity REU-V3232W /HD250E REU-V3232WC - 38 - Issue 1 - 8/09/03 ©Rinnai...

  • Page 44: Gas Pressure Setting Procedure

    Set the Infinity to 'Forced Low' combustion by setting No. 2 dipswitch of the bottom (SW2) set of dip switches to 'ON'. (fig 3) 10) Check the burner test point pressure. fig. 3 Infinity REU-V3232W /HD250E REU-V3232WC - 39 - Issue 1 - 8/09/03 ©Rinnai...
  • Page 45 DURING PRESSURE TESTING OF THE INSTALLATION ENSURE GAS COCK SITUATED BEFORE UNIT IS SHUT OFF. FAILURE TO DO SO MAY RESULT IN SERIOUS DAMAGE TO THE APPLIANCE AND POSSIBLE INJURY. Infinity REU-V3232W /HD250E REU-V3232WC - 40 - Issue 1 - 8/09/03 ©Rinnai...

  • Page 46: Gas Conversion Procedure

    Replace the manifold (complete assembly) and the packing. (7 screws) Note: Do not loose or damage the O-ring when reassembling. Ensure connections for the solenoid and sparker lead are made properly. Infinity REU-V3232W /HD250E REU-V3232WC - 41 - Issue 1 - 8/09/03 ©Rinnai...
  • Page 47 Change over the gas conversion switches (1 ~ 4) on the PCB unit Reset Gas pressurs as per instructions in 18. Gas Pressure Setting Procedure. (page 39) Infinity REU-V3232W /HD250E REU-V3232WC - 42 - Issue 1 - 8/09/03 ©Rinnai...

  • Page 48: Dismantling For Service

    11. Removal of the Thermal Fuse and OHS........47 Unless otherwise stated, re-assembly is the reverse of dismantling. Infinity REU-V3232W /HD250E REU-V3232WC - 43 - Issue 1 - 8/09/03 ©Rinnai...

  • Page 49: Removal Of The Front Panel

    O-rings are not lost or damamged.. 2) Removal of the PCB Unit a. Remove the front panel. (Refer Item 1.) b. Remove two (2) PCB unit fixing screws and pull out forward. Infinity REU-V3232W /HD250E REU-V3232WC - 44 - Issue 1 - 8/09/03 ©Rinnai...

  • Page 50: Removal Of The Sparkers

    Remove PCB unit (assembly). (Refer Item 2.) forward and slide to the side to remove fan. c. Remove two (2) transformer screws and pull out forward (2 screws). Infinity REU-V3232W /HD250E REU-V3232WC - 45 - Issue 1 - 8/09/03 ©Rinnai...

  • Page 51: Removal Of The Gas Inlet, Solenoids And Flame Rod

    Remove one (1) gas control (assy) screw and pull out gas control (assy). f. Remove two (2) burner retaining screws, then remove combustion chamber front panel (9 screws). Infinity REU-V3232W /HD250E REU-V3232WC - 46 - Issue 1 - 8/09/03 ©Rinnai...

  • Page 52: Removal Of The Heat Exchanger

    Take out the heat exchanger unit. Refer to 10). c. Remove the thermal fuse. Note: After replacing, install the thermal fuse as in the following diagrams. Heat Exchanger RHS Heat Exchanger Front Infinity REU-V3232W /HD250E REU-V3232WC - 47 - Issue 1 - 8/09/03 ©Rinnai...
  • Page 53 Heat Exchanger Back d. Remove one (1) screw of the bi-metal overheat switch. Infinity REU-V3232W /HD250E REU-V3232WC - 48 - Issue 1 - 8/09/03 ©Rinnai...

  • Page 54: Exploded Diagram

    21. Exploded Diagram Infinity REU-V3232W /HD250E REU-V3232WC - 49 - Issue 1 - 8/09/03 ©Rinnai...
  • Page 55 Infinity REU-V3232W /HD250E REU-V3232WC - 50 - Issue 1 - 8/09/03 ©Rinnai...
  • Page 56 Infinity REU-V3232W /HD250E REU-V3232WC - 51 - Issue 1 - 8/09/03 ©Rinnai...
  • Page 57 Infinity REU-V3232W /HD250E REU-V3232WC - 52 - Issue 1 - 8/09/03 ©Rinnai...

  • Page 58: Parts List

    22. Parts List REU-V3232W-AK-NC REU-V3232WC-AK-NC Infinity REU-V3232W /HD250E REU-V3232WC - 53 - Issue 1 - 8/09/03 ©Rinnai...
  • Page 59 REU-V3232W-AK-NC REU-V3232WC-AK-NC Infinity REU-V3232W /HD250E REU-V3232WC - 54 - Issue 1 - 8/09/03 ©Rinnai...
  • Page 60 REU-V3232W-AK-NC REU-V3232WC-AK-NC Infinity REU-V3232W /HD250E REU-V3232WC - 55 - Issue 1 - 8/09/03 ©Rinnai...
  • Page 61 Notes Infinity REU-V3232W /HD250E REU-V3232WC - 56 - Issue 1 - 8/09/03 ©Rinnai...

  • Page 62: Service Contact Points

    Internet: www.rinnai.co.nz E-mail: sales@rinnai.co.nz Head Office, New Zealand 691 Mt. Albert Road, Royal Oak, Auckland P O Box 24-068 Tel: (09) 625 4285 Fax: (09) 624 3018 24 hr Service Tel: 0800 746624 (0800 Rinnai) REU-V3232W / REU-V3232WC SM 2003...

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