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Rinnai REU-K2430WG Service Manual

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

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Summary of Contents for Rinnai REU-K2430WG

  • Page 1 REU-K2430WG-AK SERVICE MANUAL To Suit Model: REU-K2430WG ENVIROSMART...
  • 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 ALL SERVICE WORK MUST BE CARRIED OUT BY AN AUTHORISED PERSON. DO NOT TEST FOR GAS ESCAPES WITH AN OPEN FLAME 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.

  • Page 4: Table Of Contents

    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 - iv - Issue 1 - 16/12/09 ©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 REU-K2430WG-AK (Envirosmart - 1 - Issue 1 - 16/12/09 ©Rinnai...

  • Page 6: Specifications

    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 - 2 - Issue 1 - 16/12/09 ©Rinnai...
  • Page 7 • 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 - 3 - Issue 1 - 16/12/09 ©Rinnai...

  • Page 8: Water Flow Rates And Pressure Characteristics

    2. Water Flow Rates and Pressure Chartacterists REU-K2430WG-AK (Envirosmart - 4 - Issue 1 - 16/12/09 ©Rinnai...

  • Page 9: Dimensions

    Condensate: Fitting Diameter * Please note that this measurement is to the left of the centre line. Dim' Description Distance between mounting hole centres REU-K2430WG-AK (Envirosmart - 5 - Issue 1 - 16/12/09 ©Rinnai...

  • Page 10: Water Controllers

    MC-502RC water controller. Wireless Installations 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. REU-K2430WG-AK (Envirosmart - 6 - Issue 1 - 16/12/09 ©Rinnai...
  • Page 11 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-K2430WG-AK (Envirosmart - 7 - Issue 1 - 16/12/09 ©Rinnai...

  • Page 12: Smartstart

    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.

  • Page 13: Cutaway Diagram

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

  • Page 14: Operational Flow Chart

    7. Operational Flow Chart Continued next page REU-K2430WG-AK (Envirosmart - 10 - Issue 1 - 16/12/09 ©Rinnai...
  • Page 15 REU-K2430WG-AK (Envirosmart - 11 - Issue 1 - 16/12/09 ©Rinnai...

  • Page 16: Operation Principles

    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 - 12 - Issue 1 - 16/12/09 ©Rinnai...

  • Page 17: 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. REU-K2430WG-AK (Envirosmart - 13 - Issue 1 - 16/12/09 ©Rinnai...

  • Page 18: Condensate Drain

    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.

  • Page 19: Component Circuit Value Table

    35 - 41 Ω DC 11 - 13V SOLENOID VALVE 2 Y - Bk 35 - 41 Ω (MIDDLE) DC 11 - 13V SOLENOID VALVE 3 Br - Bk 35 - 41 Ω (LARGE) Infinity REU-V2626W / HD200E REU-V2632WC - 15 - ©Rinnai...

  • Page 20: Time Charts

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

  • Page 21: Wiring Diagram

    13. Wiring Diagram REU-K2430WG-AK (Envirosmart - 17 - Issue 1 - 16/12/09 ©Rinnai...

  • Page 22: Dip Switch Settings

    14. Dip Switch Settings Contact Rinnai for Dipswitch settings. REU-K2430WG-AK (Envirosmart - 18 - Issue 1 - 16/12/09 ©Rinnai...

  • Page 23: Fault Finding

    Detailed information on Provides accumulated number of startups, how to check all combustion time, history components. of operational faults and (page 21) readout of electrical values whilst unit operational. (page 26) REU-K2430WG-AK (Envirosmart - 19 - Issue 1 - 16/12/09 ©Rinnai...
  • Page 24 2. Check heat exchanger outlet thermistor. 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-K2430WG-AK (Envirosmart - 20 - Issue 1 - 16/12/09 ©Rinnai...

  • Page 25: Component And Circuit Checks

    Normal: DC11~13V If normal, proceed to Faulty: Replace PCB Measure voltage between Main Solenoid connectors.  Normal: 24~28 If normal, proceed to 4. Solenoid Valve SV Faulty: Replace Main Solenoid. REU-K2430WG-AK (Envirosmart - 21 - Issue 1 - 16/12/09 ©Rinnai...
  • Page 26 Check the gas secondary pressure change when set temperature on the water control changes from 37°C to 55°C. Normal: If secondary pressure changes, go to 11. Water Flow Servo Circuit. Faulty: Replace Modulating Valve. REU-K2430WG-AK (Envirosmart - 22 - Issue 1 - 16/12/09 ©Rinnai...
  • Page 27 Normal: DC 4~7V If normal, proceed to 2.Sparker Circuit. Faulty: Replace water flow sensor. Note: For controller readout of water flow whilst operational refer maintenance monitor. (Chapter 17) No. 1. REU-K2430WG-AK (Envirosmart - 23 - Issue 1 - 16/12/09 ©Rinnai...
  • Page 28 Check whether or not the fuse (3A) x 2 has blown by measuring the resistance. Normal: <1 If normal go to step 14. Electrical Fuse Faulty: Replace fuse/s (3Ax2). Check for a short next time it’s turned off. REU-K2430WG-AK (Envirosmart - 24 - Issue 1 - 16/12/09 ©Rinnai...
  • Page 29 Faulty: Replace Anti-frost Heater. 16.Frost Sensing Switch Disconnect relay connector (F ) and measure resistance between Blue-Blue.  Normal: < 1 If normal, check wiring (AC240V circuit). Faulty: Replace Frost Sensing Switch. REU-K2430WG-AK (Envirosmart - 25 - Issue 1 - 16/12/09 ©Rinnai...

  • Page 30: 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. Note: REU-V3232W/WC uses Maintenance Numbers 1-12. REU-K2430WG-AK (Envirosmart - 26 - Issue 1 - 16/12/09 ©Rinnai...
  • Page 31 0 = Closed 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-K2430WG-AK (Envirosmart - 27 - Issue 1 - 16/12/09 ©Rinnai...
  • Page 32 Clock display. 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 minutes. REU-K2430WG-AK (Envirosmart - 28 - Issue 1 - 16/12/09 ©Rinnai...

  • Page 33: Gas Pressure Setting Procedure

    18. Gas Pressure Setting Procedure Refer separate Rinnai document behind front cover of appliance. 19. Gas Conversion Procedure Refer separate document available from Rinnai. REU-K2430WG-AK (Envirosmart - 29 - Issue 1 - 16/12/09 ©Rinnai...

  • Page 34: Dismantling For Service

    17. Removal of Thermal Fuse.........38 Unless otherwise stated, re-assembly is the reverse of dismantling. REU-K2430WG-AK (Envirosmart - 30 - Issue 1 - 16/12/09 ©Rinnai...

  • Page 35: Removal Of The Front Panel

    Ensure O-rings are not lost or damaged. 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-K2430WG-AK (Envirosmart - 31 - Issue 1 - 16/12/09 ©Rinnai...

  • Page 36: Removal Of Transformer

    Removal 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-K2430WG-AK (Envirosmart - 32 - Issue 1 - 16/12/09 ©Rinnai...

  • Page 37: Removal Of The Gas Control

    Remove gas connection. a. 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-K2430WG-AK (Envirosmart - 33 - Issue 1 - 16/12/09 ©Rinnai...

  • Page 38: Removal Of Flame Rod And Spark Plug

    Remove flame rod terminal and tighten sparker lead. b. Remove flame rod and spark plug. 11) Removal of Heat Exchanger Thermistor a. Remove thermistor holder b. Remove 2 pin connector a. Remove of High Tension lead REU-K2430WG-AK (Envirosmart - 34 - Issue 1 - 16/12/09 ©Rinnai...

  • Page 39: Removal Of Bypass Servo

    Removal of inlet water connection c. Anti Frost switch g. Remove bypass servo and water flow servo h. Remove fitting screws of bypass servo Flow sensor and water flow servo REU-K2430WG-AK (Envirosmart - 35 - Issue 1 - 16/12/09 ©Rinnai...

  • Page 40: Removal Of Anti Frost Heater

    Remove fan motor from housing via. 3 screws 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-K2430WG-AK (Envirosmart - 36 - Issue 1 - 16/12/09 ©Rinnai...

  • Page 41: Removal Of Heat Exchanger

    Remove heat exchanger screws k. Pull out heat exchanger screws Remove manifold and burner unit. m. Remove thermal fuse, over heat switch, sparker, hex thermistor and back pressure joint. REU-K2430WG-AK (Envirosmart - 37 - Issue 1 - 16/12/09 ©Rinnai...

  • Page 42: Removal Of Thermal Fuse

    Remove heat exchanger. b. 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-K2430WG-AK (Envirosmart - 38 - Issue 1 - 16/12/09 ©Rinnai...

  • Page 43: Parts List

    21. Parts List NOTE: Some Part details may have changed since publication of this manual. Contact Rinnai to confirm spare parts details before ordering. Effective: 6/06/2007 Supercedes: N/A REU-K2430WG-AK / REU-K2430WG(50)-AK PART NAME RA Part Number 11 DIGIT CODE 001 CASE, Outer...
  • Page 44 434 INLET DRAIN VALVE 92097138 333-380-000 436 VALVE DRAIN 92097120 337-034-000 521 Drain Tube 513-0019000 524 Pin Band (15.5) 553-129-000 525 Pin Band (17.5) 553-131-000 546 BRKT FLAME ROD 92086388 508-836-000 REU-K2430WG-AK (Envirosmart - 40 - Issue 1 - 16/12/09 ©Rinnai...
  • Page 45 235-369-000 731 HARNESS TEMP SENSOR 92099002 235-379-000 732 HEATER A-FROST A 92091845 235-383-000 735 HEATER A-FROST B 92091947 235-381-000 736 SWITCH THERMAL 92097187 234-444-000 737 Anti Frost Heater Clip 537-155-000 REU-K2430WG-AK (Envirosmart - 41 - Issue 1 - 16/12/09 ©Rinnai...
  • Page 46 Effective: 6/06/2007 Supercedes: N/A REU-K2430WG-AK / REU-K2430WG(50)-AK PART NAME RA Part Number 11 DIGIT CODE 738 Anti Frost Heater Clip 537-0194000 888 Operation Manual(RAU) 623-344-700 888 Operation Manual(RNZ) 623-349-800 REU-K2430WG-AK (Envirosmart - 42 - Issue 1 - 16/12/09 ©Rinnai...

  • Page 47: Exploded Diagram

    22. Exploded Diagram NOTE: Some Part details may have changed since publication of this manual. Contact Rinnai to confirm spare parts details before ordering. REU-K2430WG-AK (Envirosmart - 43 - Issue 1 - 16/12/09 ©Rinnai...
  • Page 48 REU-K2430WG-AK (Envirosmart - 44 - Issue 1 - 16/12/09 ©Rinnai...
  • Page 49 REU-K2430WG-AK (Envirosmart - 45 - Issue 1 - 16/12/09 ©Rinnai...
  • Page 50 REU-K2430WG-AK (Envirosmart - 46 - Issue 1 - 16/12/09 ©Rinnai...
  • Page 51 REU-K2430WG-AK (Envirosmart - 47 - Issue 1 - 16/12/09 ©Rinnai...
  • Page 52 Fax: 1300 300 141* *Cost of a local call Higher from mobile or public phones. 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 Hot Water Service Line requires a service, please call our Hot Water Service Line.

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