Rinnai REU-V1620WG Service Manual

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Operation & installation manual (40 pages)

Service manual (65 pages)

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SERVICE MANUAL

To Suit Models:

REU-V1620W

REU-V2024W

Does NOT Suit any other Models.

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Table of Contents

Summary of Contents for Rinnai REU-V1620WG

Page 1 SERVICE MANUAL To Suit Models: REU-V1620W REU-V1620W REU-V1620W REU-V2024W Does NOT Suit any other Models.
Page 2 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. Distributed and serviced in Australia under a Quality System certified as complying with ISO 9001 by...
Page 3 © Copyright Rinnai Australia Pty Ltd ABN 74 005 138 769 All rights reserved Produced by Engineering & Technical Group 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.
Page 4: Glossary Of Terms And Symbols
ø diameter  temperature rise above ambient modulating valve thermal efficiency thermistor temperature of incoming water temperature of outgoing water REU-V1620WG / REU-V1620WB / REU-V1620WS Issue 1 - 6/04/09 ©Rinnai - iv -...
Page 5: Table Of Contents
17. Maintenance Monitor / Error History ..............24 18. Dismantling for Service ..................27 19. Parts List ........................ 36 REU-V1620WG / REU-V1620WB / REU-V1620WS .............37 REU-V2024WG ........................40 20. Exploded Diagram ....................44 REU-V1620WG / REU-V1620WB / REU-V1620WS / REU-V2024WG - iii - Issue 1 - 6/04/09 ©Rinnai...
Page 6: Specifications
Cables are supplied with water controllers. Alternatively, two core sheathed (double insulated) flex with minimum cross sectional area of 0.5 m² may be used. Maximum individual cable runs should not exceed 50 m. REU-V1620WG / REU-V1620WB / REU-V1620WS / REU-V2024WG - 1 - Issue 1 - 14/04/09 ©Rinnai...
Page 7 Cables are supplied with water controllers. Alternatively, two core sheathed (double insulated) flex with minimum cross sectional area of 0.5 m² may be used. Maximum individual cable runs should not exceed 50 m. REU-V1620WG / REU-V1620WB / REU-V1620WS / REU-V2024WG - 2 - Issue 1 - 14/04/09 ©Rinnai...
Page 8 If the delivered hot water temperature rises above the required delivery Temperature Cutout: temperature for a number of seconds, the gas supply is stopped. Combustion Specifications Refer to dataplate on the appliance. REU-V1620WG / REU-V1620WB / REU-V1620WS / REU-V2024WG - 3 - Issue 1 - 14/04/09 ©Rinnai...
Page 9: Water Flow Rates And Pressures
40.0 50.0 60.0 70.0 80.0 90.0 100.0 110.0 120.0 160.0 200.0 300.0 Q(L/min) 11.0 12.2 13.6 15.1 16.1 17.1 18.2 19.2 20.0 24.0 24.0 24.0 REU-V1620WG / REU-V1620WB / REU-V1620WS / REU-V2024WG - 4 - Issue 1 - 6/04/09 ©Rinnai...
Page 10: Dimensions
Hot: Length (from base) Gas: Fitting Diameter Cold: Fitting Diameter Hot: Fitting Diameter * Please note that this measurement is to the left of the centre line. REU-V1620WG / REU-V1620WB / REU-V1620WS / REU-V2024WG - 5 - Issue 1 - 6/04/09 ©Rinnai...
Page 11: Water Controllers
Up to TWO BC-100V water controllers can be installed. The FOURTH water controllers in any installation MUST BE a MC-502RC / MC-503RC or a MC91Q. REU-V1620WG / REU-V1620WB / REU-V1620WS / REU-V2024WG - 6 - Issue 1 - 6/04/09 ©Rinnai...
Page 12 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. REU-V1620WG / REU-V1620WB / REU-V1620WS / REU-V2024WG - 7 - Issue 1 - 6/04/09 ©Rinnai...
Page 13: Smartstart
A schematic of the Smartstart® system installed in conjunction with a Rinnai continuous flow water heater and temperature controller is shown in Fig.2 below.
Page 14 Principle of Operation - Solar Hot Water Systems Only Figure 3 - Principle of Operation - Solar Hot Water Systems Only REU-V1620WG / REU-V1620WB / REU-V1620WS / REU-V2024WG - 9 - Issue 1 - 6/04/09 ©Rinnai...
Page 15: Cutaway Diagram
:DWHU &RQQHFWLQJ 3LSH &RSSHU 6XUJH 3URWHFWRU %\3DVV 3LSH &RSSHU 2XWJRLQJ :DWHU 7KHUPLVWRU &RPEXVWLRQ )DQ +RW :DWHU &RQQHFWLQJ 3LSH &RSSHU 6WDWXV 0RQLWRU +HDW ([FKDQJHU 7KHUPLVWRU :' :& 21/< REU-V1620WG / REU-V1620WB / REU-V1620WS / REU-V2024WG - 10 - Issue 1 - 6/04/09 ©Rinnai...
Page 16: Operational Flow Chart
7. Operational Flow Chart REU-V1620WG / REU-V1620WB / REU-V1620WS / REU-V2024WG - 11 - Issue 1 - 6/04/09 ©Rinnai...
Page 17: Operation Principles
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-V1620WG / REU-V1620WB / REU-V1620WS / REU-V2024WG - 12 - Issue 1 - 6/04/09 ©Rinnai...
Page 18: 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 ignition electrode(s). REU-V1620WG / REU-V1620WB / REU-V1620WS / REU-V2024WG - 13 - Issue 1 - 6/04/09 ©Rinnai...
Page 19: Time Charts
10. Time Charts Normal Combustion Note: By pass control device fitted to model 2630 only. Mis-Ignition / Flame Failure Abnormal Pre-Purge (Air Supply/Exhaust Blockage) REU-V1620WG / REU-V1620WB / REU-V1620WS / REU-V2024WG - 14 - Issue 1 - 6/04/09 ©Rinnai...
Page 20: Wiring Diagram
11. Wiring Diagram REU-V1620WG / REU-V1620WB / REU-V1620WS / REU-V2024WG - 15 - Issue 1 - 6/04/09 ©Rinnai...
Page 21: Dip Switch Settings
37∼43Ω DC11∼13V SOLENOID VALVE 1 B-Bk 35∼41Ω (SMALL) DC11∼13V SOLENOID VALVE 2 Y-Bk 37∼43Ω (LARGE) 12. Dip Switch Settings Contact Rinnai for Dip Switch Settings. REU-V1620WG / REU-V1620WB / REU-V1620WS / REU-V2024WG - 16 - Issue 1 - 6/04/09 ©Rinnai...
Page 22: Fault Finding
Detailed information on (page 24) how to check all components. (page 19) Dismantling for Service Detailed information on how to remove and replace components. (page 27) REU-V1620WG / REU-V1620WB / REU-V1620WS / REU-V2024WG - 17 - Issue 1 - 6/04/09 ©Rinnai...
Page 23 3. Check gas valves 4. Check water flow servo. 5. Check bypass servo. Anti-frost heater does not operate. 1. Check anti-frost heater components 2. Check frost sensing switch REU-V1620WG / REU-V1620WB / REU-V1620WS / REU-V2024WG - 18 - Issue 1 - 6/04/09 ©Rinnai...
Page 24: Component And Circuit Checks
If normal, proceed to b.). Faulty: Replace PCB b) Measure resistance between Main Solenoid connectors.  Normal: 37~43 If normal, proceed to Solenoid Valve SV Faulty: Replace Main Solenoid. REU-V1620WG / REU-V1620WB / REU-V1620WS / REU-V2024WG - 19 - Issue 1 - 6/04/09 ©Rinnai...
Page 25 Check the gas burner pressure changes when set temperature on the water control changes from 37°C to 55°C. Normal: Burner gas pressure changes. Go to Water Flow Servo Circuit. Faulty: Burner gas pressure does not change. Replace Modulating Valve. REU-V1620WG / REU-V1620WB / REU-V1620WS / REU-V2024WG - 20 - Issue 1 - 6/04/09 ©Rinnai...
Page 26 If normal, proceed to 2. Faulty: Replace water flow sensor. Note: For controller readout of water flow whilst operational refer maintenance monitor. (Chapter 15) No. 1. REU-V1620WG / REU-V1620WB / REU-V1620WS / REU-V2024WG - 21 - Issue 1 - 6/04/09 ©Rinnai...
Page 27 At room temperature resistance should be > 1 M Cool switch to below 2° C then measure resistance.  Resistance should be < 1M Faulty: Replace Frost Sensing Switch. REU-V1620WG / REU-V1620WB / REU-V1620WS / REU-V2024WG - 22 - Issue 1 - 6/04/09 ©Rinnai...
Page 28: Gas Pressure Setting Procedure
15. Gas Pressure Setting Procedure Refer seperate Rinnai document behind front cover of appliance. 16. Gas Conversion Procedure Refer seperate document availabe from Rinnai. REU-V1620WG / REU-V1620WB / REU-V1620WS / REU-V2024WG - 23 - Issue 1 - 6/04/09 ©Rinnai...
Page 29: Maintenance Monitor / Error History
The maintenance number will be shown in the Water Temperature display. Data will be shown in the Clock display. To select the required maintenance number, press the Water Temperature "UP" and "DOWN" buttons. REU-V1620WG / REU-V1620WB / REU-V1620WS / REU-V2024WG - 24 - Issue 1 - 6/04/09 ©Rinnai...
Page 30 250 = Half open 500 = Open To return to normal operation • Press the ON/OFF button again while holding down the Water Temperature "DOWN" (Cooler) button. REU-V1620WG / REU-V1620WB / REU-V1620WS / REU-V2024WG - 25 - Issue 1 - 6/04/09 ©Rinnai...
Page 31 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. REU-V1620WG / REU-V1620WB / REU-V1620WS / REU-V2024WG - 26 - Issue 1 - 6/04/09 ©Rinnai...
Page 32: Dismantling For Service
17. Removal of Thermal Fuse.........35 Unless otherwise stated, re-assembly is the reverse of dismantling. REU-V1620WG / REU-V1620WB / REU-V1620WS / REU-V2024WG - 27 - Issue 1 - 6/04/09 ©Rinnai...
Page 33: Removal Of The Front Panel
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. REU-V1620WG / REU-V1620WB / REU-V1620WS / REU-V2024WG - 28 - Issue 1 - 6/04/09 ©Rinnai...
Page 34: Removal Of Transformer
7) Removal of the Manifold and Burner unit a. Remove high tension cord and flame rod. b. Remove 2 pin connection of the solenoid valve c. Remove manifold. REU-V1620WG / REU-V1620WB / REU-V1620WS / REU-V2024WG - 29 - Issue 1 - 6/04/09 ©Rinnai...
Page 35: Removal Of The Gas Control
Remove combustion chamber front panel. b. Remove burner unit. a. Pull off connectors for gas control modulation valve and solenoid valve. c. Pull off burner unit REU-V1620WG / REU-V1620WB / REU-V1620WS / REU-V2024WG - 30 - Issue 1 - 6/04/09 ©Rinnai...
Page 36: Removal Of Flame Rod And Spark Plug
Remove flame rod and spark plug. 11) Removal of Heat Exchanger Thermistor 2632WC ONLY a. Remove thermistor holder b. Remove 2 pin connector a. Remove of High Tension lead REU-V1620WG / REU-V1620WB / REU-V1620WS / REU-V2024WG - 31 - Issue 1 - 6/04/09 ©Rinnai...
Page 37: Removal Of Bypass Servo
Remove bracket for water connection tube. c. Anti Frost switch Removal of inlet water connection g. Remove bypass servo and water flow servo h. Remove fitting screws of bypass servo REU-V1620WG / REU-V1620WB / REU-V1620WS / REU-V2024WG - 32 - Issue 1 - 6/04/09 ©Rinnai...
Page 38: Removal Of Anti Frost Heater
15) Removal of the Fan Motor a. Remove 4 pin connector to fan motor. b. Remove 2 pin connector of solenoid valve. c. Remove fan motor screws (x 2) REU-V1620WG / REU-V1620WB / REU-V1620WS / REU-V2024WG - 33 - Issue 1 - 6/04/09 ©Rinnai...
Page 39: Removal Of Heat Exchanger
Pull out heat exchanger screws Remove manifold and burner unit. m. Remove thermal fuse, over heat switch, sparker, hex thermister and back pressure joint. REU-V1620WG / REU-V1620WB / REU-V1620WS / REU-V2024WG - 34 - Issue 1 - 6/04/09 ©Rinnai...
Page 40: Removal Of Thermal Fuse
Remove Thermal Fuse. After removal of thermal fuse fitting procedure is as follows: Heat Exchanger Front Heat Exchanger Right Heat Exchanger Left Heat Exchanger Right REU-V1620WG / REU-V1620WB / REU-V1620WS / REU-V2024WG - 35 - Issue 1 - 6/04/09 ©Rinnai...
Page 41: Parts List
Some Part details may have changed since publication of this manual. Contact Rinnai to confirm spare parts details before ordering. “REU-V1620WG / REU-V1620WB / REU-V1620WS” on page 37 “REU-V2024WG” on page 40 REU-V1620WG / REU-V1620WB / REU-V1620WS / REU-V2024WG - 36 - Issue 1 - 6/04/09 ©Rinnai...
Page 42: Reu-V1620Wg / Reu-V1620Wb / Reu-V1620Ws
111 Combustion Chamber Front Panel 019-715-000 112 Combustion Chamber Front Panel Upper 580-591-000 113 Electrode 92086974 202-156-000 114 Electrode FR 92093640 230-057-000 115 Packing Electrode RH 92086990 580-507-000 REU-V1620WG / REU-V1620WB / REU-V1620WS / REU-V2024WG - 37 - Issue 1 - 6/04/09 ©Rinnai...
Page 43 537-0619000 706 Surge Arrestor 92093699 210-605-000 707 Sub Circuit Board Cover 098-1855000 708 Bracket 537-0618000 709 Elec Cord 92089051 206-226-000 710 Harness Fuse 92099959 290-1284000 REU-V1620WG / REU-V1620WB / REU-V1620WS / REU-V2024WG - 38 - Issue 1 - 6/04/09 ©Rinnai...
Page 44 828 O-Ring Heat Exchanger 92062207 520-193-010 829 O-Ring Heat Exchanger Inlet 92062199 520-048-010 830 O-Ring In/Out Water 92071182 520-049-010 888 Operation Manual 623-344-700 889 Establishment Manual K23-366-800 REU-V1620WG / REU-V1620WB / REU-V1620WS / REU-V2024WG - 39 - Issue 1 - 6/04/09 ©Rinnai...
Page 45: Reu-V2024Wg
Burner Assembly 157-138-000 110 Burner Case Rear 098-403-000 111 Combustion Chamber Front Panel 019-1676000 112 Combustion Chamber Front Panel Upper 580-596-000 113 Electrode 92086974 202-156-000 REU-V1620WG / REU-V1620WB / REU-V1620WS / REU-V2024WG - 40 - Issue 1 - 6/04/09 ©Rinnai...
Page 46 92098458 333-303-000 408 Water Outlet (3/4") 92099970 333-304-000 409 Hot Water Plug Band 553-043-000 410 Valve Press Relief 92081751 337-048-000 700 PCB Main 92099958 200-0418000 REU-V1620WG / REU-V1620WB / REU-V1620WS / REU-V2024WG - 41 - Issue 1 - 6/04/09 ©Rinnai...
Page 47 722 Thermistor 92095030 233-246-000 725 Remote Control Harness 92099961 290-1288000 800 Earth Screw 501-889-000 801 Truss Screw 501-973-010 802 Screw 501-0064000 803 Tapping Screw 501-737-000 REU-V1620WG / REU-V1620WB / REU-V1620WS / REU-V2024WG - 42 - Issue 1 - 6/04/09 ©Rinnai...
Page 48 829 O-Ring Heat Exchanger Inlet 92062199 520-048-010 830 O-Ring In/Out Water 92071182 520-049-010 888 Operation Manual 623-344-700 888 Operation Manual 623-342-100 889 Establishment Manual K23-366-800 REU-V1620WG / REU-V1620WB / REU-V1620WS / REU-V2024WG - 43 - Issue 1 - 6/04/09 ©Rinnai...
Page 49: Exploded Diagram
20. Exploded Diagram REU-V1620WG/REU-V1620WB/REU-V1620WS REU-V1620WG / REU-V1620WB / REU-V1620WS / REU-V2024WG - 44 - Issue 1 - 6/04/09 ©Rinnai...
Page 57 Hot Water Service Line Tel: 1800 000 340 Rinnai has a Service and Spare Parts network with personnel who are fully trained and equipped to give the best service on your Rinnai appliance. If your appliance requires service, please call our Hot Water Service Line. Rinnai recommends that this appliance be serviced every 3 years.

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Reu-v2024wg Reu-v1620wb Reu-v1620ws

Rinnai REU-V1620WG Service Manual

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18. Dismantling for Service

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