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INFINITY
Infinity 20 Internal
REU-2006FFU
SERVICE MANUAL
Infinity Compact Continuous Flow Gas Hot Water System
Proudly a member of The Australian Gas Association.
All of our products are AGA tested and approved.
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 Australian Standard 3498 by Quality
Assurance Services. Watermark certification is awarded to products with suitable fittings complying with safety and water contamination standards.
Comparative Energy Consumption tested to The
Australian Gas Association requirements of Australian
Gas Code AG 102. An energy rating of 5 stars refers to an efficiency of approximately 80%, that is, 80% of gas consumed is converted to useful heat.
ISO 9001
ISO 9002
AS 3498
AG 102
Model for Quality Assurance in design/development, production, installation and servicing, aimed primarily at achieving customer satisfaction by preventing nonconformity at all stages from design through to servicing.
Same as ISO 9001 but excluding design.
Authorisation requirements for plumbing products - water heaters and hot-water storage tanks, aimed at ensuring safe, quality products.
Approval requirements for gas water heaters as set by The Australian Gas Association and
Australian Liquefied Petroleum Gas Association Ltd, to ensure proper safety performance and quality levels are achieved.
© Copyright Rinnai Australia Pty Ltd
A.C.N. 005 138 769 All rights reserved
Produced by Customer Technical Services
Feb 2000
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.
WARNING
Failure to comply with these instructions may result in serious personal injury of damage to the appliance.
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
This manual has been compiled by Rinnai Australia Customer 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 supplying improved appliances as well as information, and specifications may be subject to alteration at any time.
SRV2006
Issue N o
2
Table of Contents
Glossary.............................................................................................................. i
22. Electrical Component Analysis ............................................................... 40
Glossary of Terms and Symbols
This glossary of terms and symbols is provided to assist you in understanding some of the language used throughout this manual. dB(A) -
DC -
AC
WFCD -
-
FB
Hz
IC kcal/h -
-
-
rpm
SV
ø
∆ o
C
POV
TE
TH
T
IN
T
OUT kPa
LED
L/min mA -
-
-
MJ/h mm -
mmH
2
O -
NO
X
-
OHS -
PCB
CPU
POT
-
-
-
-
-
-
-
-
-
-
-
sound pressure level in decibels, “A” range direct current alternating current water flow control device feedback information
Hertz integrated circuit kilocalorie per hour kilopascals light emitting diode
Litres per minute milliamps megajoule per hour millimetres millimetres of water (guage pressure) oxides of nitrogen (NO & NO
2
) overheat switch printed circuit board central processing unit potentiometer revolutions per minute solenoid valve diameter temperature rise above ambient modulating valve thermal efficiency thermistor temperature of incoming water temperature of outgoing water
Infiinity REU-2006FFU - i -
©Rinnai
1. Introduction
The brand name Infinity refers to “Endless Hot Water”. The REU-2006FFU has been developed in response to the growing changes in the lifestyle of the end user, and the increasing diversification and sophistication of demand in the marketplace.
The Infinity 20 (REU-2006FFU) offers advanced safety features, and an option to connect one, two, or three remote control pads for increased conrol. The Infinity 20 has been designed for internal installation, making it ideal for apartments or units.
The Infinity 20 is delivered with the maximum hot water temperature output set at 55 o
C, with or without remote controls connected, although it is possible to achieve a maximum of 75 o
C.
The front cover of each appliance in the new series is formed from 0.5 mm coated steel, secured to the main box assembly by 4 screws. Seals around the front cover and flue outlet prevent water from entering the appliance.
Air inlets are situated in the front panel. The general layout of components is shown on the cutaway
diagram on page 9. All components are supported within a box formed from 0.8 mm coated steel.
The heat exchanger occupies the top section of the box, and the burner is situated in a chamber formed from 0.8 mm aluminised steel attached to the bottom of the heat exchanger.
The air for combustion is supplied by a fan which is connected to the burner box by a duct at the left hand side of the appliance.
Gas and water controls are situated at the bottom right of the appliance, directly under the manifold.
The products of combustion are expelled from the appliance through a stainless steel nozzle situated on the upper front of the appliance.
The burner assembly is made up of identical stainless steel bunsen burners, secured by an aluminised steel framework. An aluminium manifold with 18 integrally moulded injectors supplies gas to the burners, and is attached to the lower front cover of the burner box.
There is one thermistor, located on the outgoing hot water supply tube, near the outlet of the water heater, and another room temperature thermistor.
Infiinity REU-2006FFU - 1 ©Rinnai
2. Features
Installation
The Infinity 20 is designed to be installed internally, hence requiring special Rinnai-approved flueing. Its light-weight, slim, and compact form enable easier installations improving appearance.
Remote controls (where fitted) are connected to the appliance by 2-core non-polar cable, ensuring easy wiring and eliminating misconnection problems.
Low Noise Level
Low noise level design enables these appliances to be installed in units, flats, townhouses, and other high density residential areas with little concern about noise disturbances.
Safety
Various safety devices controlled by a micro-computer ensure complete safety. Also, the anti-frost device (where fitted), automatically prevents the water inside the appliance from freezing by using
small electrical ceramic heaters connected to the pipework at strategic locations. See “Safety
Devices” on page 7 for further detail.
Economy
Direct electronic ignition to the main burner eliminates wasteful pilot gas consumption. The combustion fan rpm is proportionally controlled with gas consumption. This maintains high energy efficiency as the gas consumption changes.
Water Supply Control
The water supply capacity varies proportionally from 2.7 L/min to 20 L/min. A suitable volume of hot water can be supplied throughout all seasons with the incorporation of the water flow control device and water flow servo mechanism. The REU-2006FFUwill supply up to 20 L/min (maximum
unmixed), controlled by an automatic electro-mechanical water flow device. See page 14 for precise
details on water flow.
Water Temperature Control
With a remote control connected, the hot water control range is between 37 o
C and 55 o
C (in 13 steps). With or without a remote control connected the outgoing hot water temperature can be fixed to a maximum of 40 o
C, 50 o
C, 55 o
C, 75 o
C. This means that the new Infinity Series can be set to centres. The maximum temperature selectable on the bath remote control is 50 o
C (this is a regulation safety feature).
Over Temperature Protection
All Infinity models incorporate a device to prevent the hot water temperature exceeding the pre-set temperature by more than 3 o
C.
Temperature Locks
37 o
C and 43 o
C while the hot water is flowing. This helps to avoid inadvertently increasing increasing the temperature to a hazardous level whilst someone is in the shower. While the water is flowing, the remote control(s) can be turned off, but not on again.
Infiinity REU-2006FFU - 2 ©Rinnai
3. Dimensions
Note: All dimensions are in mm.
Infiinity REU-2006FFU - 3 ©Rinnai
4. Installation
Note: All dimensions are in mm. Pipework will vary in each installation.
Infinity REU-2006FFU - 4 ©Rinnai
5. Remote Controls
The MC-33-3A and BC-45-3A remotes were specifically designed for use with the new series of Infinity water heaters introduced in 1998.
Features include:
• Colour coordination to allow immediate recognition of the temperature
“hotter” and “cooler” buttons.
• Larger LED display.
• Water temperature adjustment only in the range of 37 o
C to 43 o
C whilst hot water is flowing.
• Different temperatures can be stored in the memory of each remote control.
• Enhanced communication system between the remote controls, allowing priority temperature selection at each remote control.
BC
KC
BSC
• A third remote control identified by model number BSC-45-3A is available for use in a second bathroom or ensuite. Contact Rinnai for further details.
Kitchen Remote Control
Bathroom Remote Control
Infiinity REU-2006FFU - 5 ©Rinnai
Suggested Connection Methods
There must be at least on cable from any remote control connecting with the Infinity water heater.
Connections
The following diagrams show methods of connection.
Infiinity REU-2006FFU - 6 ©Rinnai
6. Safety Devices
Flame Failure
Situated to the right of the burner at the front, the flame rod monitors combustion, preventing any discharge of gas to the burner if there is no flame, by sending a signal to the PCB which in turn isolates the gas.
Remaining Flame Safety Device
Also referred to as an Over Heat Switch. This device is fitted to a bend section at the inlet to the heat exchanger. If the flame remains on the burner after the tap is closed, and the water temperature inside the heat exchanger reaches 97 o
C
,
a DC 90 V bi-metal cut-off switch isolates the gas to the solenoids.
No Water
Should the incoming water flow become restricted or stop, then the water flow sensor will cease to send a magnetic pulse signal to the PCB, in turn isolating the flow of gas to the burner.
Fusible Link
temperature outside it reaches 129 o
C, the fusible link melts, breaking the electronic circuit. Current to the gas solenoid valve circuit is cut, and combustion stops, shutting down the unit.
Pressure Relief Valve
This spring and valve seating type valve located on the hot water outlet will release the built up pressure if the pressure inside the heat exchanger reaches 2100 kPa until 1500 kPa is maintained.
Combustion Fan Revolution Check
The combustion fan rpm are continually monitored by a magnetic pulse counter connected to the
PCB. If the fan revolutions deviate from the speed required for complete combustion, a signal is sent to the PCB and the revolutions adjusted accordingly.
Automatic Frost Protection
(Option only)
When the outdoor temperature drops below 3.5
o
C, the frost sensing device is activated, and the anti-frost heaters prevent the water in the appliance from freezing. These anti-frost heaters remain
ON until the outdoor temperature rises to 11.5
o
C. There are 5 x 16 Watt anti-frost heaters located at various points in the main water flow area of the appliance. The anti-frost protection device will prevent freezing down to -20 o
C in a no wind situation, and -15 o
C in a windy situation.
3
o
C Over Temperature Cut-off
The temperature of the outgoing hot water is constantly monitored by the water temperature thermistor located near the outlet of the appliance. If the outgoing water temperature rises to more than 3 o
C above the preset temperature, the burner will automatically go out. The burner will only ignite again once the outgoing hot water temperature falls below the preset temperature.
Infiinity REU-2006FFU - 7 ©Rinnai
7. Specification Overview
Type of Appliance
Operation
Exhaust System
Rinnai Model Number
Maximum Gas Rate
Water Flow (L/min)
Default Temperature Settings
(with or without remote)
Temp. Range (with remote)
Approved Gas Types
Installation
Dimensions
Weight
Efficiency
Noise Level
Connections
Ignition System
Gas Consumption (High/Low)
Electrical Consumption (Watt)
Water Temperature Control
Water Flow Control
Operating Pressure
Power Supply
Safety Devices
Remote Control
Remote Control Cable
Temperature controlled continuous gas hot water system
With or without remote controls
Forced flue (FF)
REU-2006FFU
NG: 159 MJ/h; LPG: 160MJ/h
Minimum: 2.7 (25 o
rise); unmixed:18; mixed: 20
40, 50, 55, 75 o
C
37 to 55 o
C in 13 steps
Natural; Propane (New Zealand only - LPG)
Internally mounted
Width: 350 mm; Height: 610 mm; Depth: 200 mm
20 kilograms
80%
50 dB(A)
Gas (right); Cold (centre); Hot (left): R 3/4 / 20A
Direct electronic ignition, continuous spark
160 / 20 MJ/h
Normal: 64; Standby: 6; Automatic frost protection: 112
Simulation feedforward and feedback
Water flow sensor and automatic water flow control device
Minimum: 200 kPa; Nominal: 200 to 830 kPa
Appliance: AC 230.240 V 50Hz
Remote Control: DC 12V (digital)
Flame failure: flame rod
Boiling protection: 95 o
C hot wtaer output thermistor (25 secs)
Boil dry: water flow sensor
Remaining flame[OHS]: 97 o
C bi-metal; 152 o
C thermal fuse
Fusible link: 129 o
C
Pressure relief valve: opens - 2100 kPa, closes - 1500 kPa
Auto. frost protection: bi-metal sensor & anti-frost heaters
Combustion fan rpm check: integrated circuit system
Over current: glass fuse (3 Amp)
Kitchen: MC-33-3A; Bath: BC-45-3A; 2nd Bath: BSC-45-3A
12 Volt, non-polarised two-core cable
Infiinity REU-2006FFU - 8 ©Rinnai
8. Cut-away Diagram
Infiinity REU-2006FFU - 9 ©Rinnai
9. Schematic Diagram
Infiinity REU-2006FFU - 10 ©Rinnai
10. Combustion Specification
Input
Injector Size (mm)
Damper Marking
Primary Pressure
Secondary Pressure - Low
- High
Burner Type
Dip Switch Positions
Maximum Capacity
Modulating Valve (POV)
Combustion Fan
Minimum Capacity
Modulating Valve (POV)
Combustion Fan
Slow Ignition
Modulating Valve (POV)
Combustion Fan mA
Hz mA
Hz mA
Hz
MJ/h kcal/h mm kPa kPa kPa
REU-2006FFU
Natural Gas Propane
(Australia)
160
38000
160
38000
1.6
B
1.13
0.069
0.62
LP
0.95
E
2.8
0.157
1.80
LP
LPG (NZ)
160
38000
0.95
E
2.8
0.167
1.76
LP
125/125
152/127
22/20
63/55
96/92
110/100
220/215
148/128
24/20
62/55
157/138
110/100
204/206
152/145
25/20
62/55
155/145
110/100
Infinity REU-2006FFU - 11 ©Rinnai
11. Dip Switch Positions
Please do not adjust the dip switch positions before reading this information.
Dip switches 1 ~ 8 are provided so that the water heater can be set to different operating configurations. In some instances, such as nursing homes or even domestic situations, it may be necessary to limit the temperature of the hot water coming from the units.
The set-up configuration for the water heater differs depending on:
• Gas type
• Temperature limiting requirements
Dip Switches explained
1 & 2: Gas type (used only during conversion)
3 & 4: Fixed hot water temperature without remote control connected
5 & 6: Upper limit hot water temperature with remote control connected
7 & 8: Combustion control
without remote connected.
The REU-2006FFU model is delivered with the maximum hot water temperature limited to 55 o by default. The maximum temperature of hot water can be limited to 40 o
C, 50 o
C, 55 o
C, or 75 o
C.
C
Dip Switch Settings for the Older PCB
Gas Type
1
2
OFF
OFF
LPG
(NZ only)
ON
OFF
Natural Gas
Fixed Hot Water Temperature without Remote Control Connected
3
4
OFF
OFF
55 o
C
OFF
ON
40 o
C
ON
OFF
50 o
C
OFF
ON
ON
ON
Propane
(Aust. only)
75 o
C
Upper Limit Hot Water Temperature with Remote Control Connected
5
6
OFF
OFF
55 o
C
OFF
ON
40 o
C
ON
OFF
50 o
C
Combustion Control
ON
ON
75 o
C
7
8
OFF
OFF
Normal ON
OFF
Forced Low OFF
ON
Forced High
Dip switches 3 and 4 should be set to provide a maximum hot water temperature of 40 o
C, 50 o
C or
55 o
C if a remote is connected to ensure a safe default temperature in case the remotes become disconnected.
Infiinity REU-2006FFU - 12 ©Rinnai
Dip Switch Settings for the newer PCB
2
3
No.
Model
1 REU-2006FFU-A-NC
4
REU-2006FFU-A-NC
REU-2006FFFU-ZK-2C
REU-2006FFU-ZK-2C
Carried out from
6.7.99
Gas Type
NG
6.7.99
LPG
Yet to be carried out * NG
Yet tobe carried out * LPG
.
* “Yet to be carried out” means none have been produced since the modificaiton of the PCB.
Dip Switches explained
off on SW off
Serial No.
99.07.100653~
99.07.100161~
From July production
From July production
Gas Type
Computer Programming on
Temperature
SW 9 - Flue
Length
Combustion Control off on SW
Combustion Control
off on SW off on SW
Infinity REU-2006FFU
off
Normal
Combustion
Flue Length (Note 2)
Forced
Low on
SW 9 - Off for long flue
Computer Programming (Sw No.3)
off on SW
SW 9 - On for short flue
Switched 'Off' for all models
Forced
High
- 13 ©Rinnai
off on SW
Gas Type
LPG (NZ model only) off on SW
LPG (Australian model only) off on SW
Natural Gas (all models)
Temperatures
Controllers / No Controllers off on SW
40
o
C off on SW
50 o
C off on SW
55 o
C off on SW
75 o
C
Notes: a) Black squares indicate the position of switches.
b) Position of switch 9 must be determined from the calculation in the Installation Instructions or
Service Manual.
Infinity REU-2006FFU - 14 ©Rinnai
Flue Length
9
OFF Long ON Short
To help prevent condensation in the flue, the combustion fan has two settings. Dip switch number 9 controls the combustion fan speed. This switch position will determine the fan speed to compensate for back pressure when using extended flues. Switch number 9 is normally set to the “OFF” position;
°
When installing the FFU model using an extended flue, you will need to decide which position switch No. 9 should be in. The following formula must be used to determine the position. To calculate when to turn the switch “ON”, use the following formula to calculate “D”.
D = L + (M x 2) L = Length of flue in metres.
M = Number of bends.
When D is 7 or more, turn switch number 9 to the “OFF” psoition.
When 45
0
bends are used, calculate using the following formula:
D = L + (M x 2)
Examples: 2 metres of flue, and 2 x 90 bends
D = 2 + (2 x 2),
°
→
D = 2 + 4,
→
D = 6
⇒
Dip Switch 9 “ON”
3 metres of flue, and 2 x 90 bends
D = 3 + (2 x 2),
°
→
D = 3 + 4,
→
D = 7
⇒
Dip Switch 9 “OFF”
If D geater than 13, the flue is too long or there are too many bends.
Do not alter dip switches before checking posistion requirement using the above formula.
Infinity REU-2006FFU - 15 ©Rinnai
12. Water Flows
A simple calculation of the water flow rate, in litres per minute, can be made using the charts on the next page, or simply using the formula provided below. The charts on the following pages indicate the water flow from the Infinity at various combinations of incoming water temperatures, and the selected temperature at the remote control.
a)How to read the charts:
The vertical plane indicates the selected temperature at the remote, and the horizontal plane indicates the flow of water in litres per minute. Remote control range is between 37 o
C and 75 o
C, therefore the water flow charts only show the temperatures in that range. The temperature rise is the difference between the temperature of the incoming water and the selected temperature at the remote controls.
Select the appropriate chart depending on the incoming water temperature. Draw a horizontal line across the graph from the selected temperature at the remote until it intersects the curve. At this point draw the line in the vertical direction. The water flow is indicated where the line intersects the bottom of the chart.
b)How to calculate water f lows:
The following information is an outline of the formula required to measure accurately the flow rate in litres per minute, as well as being the base for the charts on the next page. The most useful way in which this formula can be utilised, is to calculate the water flow rate where there is maximum gas input of 160MJ/h or 188MJ/h depending on the model.
Where:
#
*
T
IN
=
T
OUT
=
IN =
TE =
Q =
Incoming water temperature.
Gas input
#
.
Thermal efficiency*.
Water flow in litres per minute.
This is the maximum gas input converted from MJ/h into kilocalories. As 1 kilocalorie raises the temperature of 1 litre of water by 1 degree centigrade, the method of calculation is to multiply the input in MJ/h by 239.
Thermal efficiency may be in the range of 78% to 90%, depending on the temperature rise and water flow. For the purpose of the following calculation we have assumed an efficiency of 80%.
Example Data
IN = 45000kcal/h
TE = 80%
Q = Water flow in Litres per minute
Calculation
IN x TE = (
T
OUT
-
T
IN
) x 60 x Q
4500 x 0.8 = (60 - 15) x 60 x Q
36000 = 45 x 60 x Q
45
= 60 x Q
800 = 60 x Q
60
= Q
13.3 L/min
Infiinity REU-2006FFU - 14 ©Rinnai
Unmixed Water Flows
The chart opposite indicates that the water flow rate of the REU-2006FFU will, at a preset
The chart opposite indicates that the water flow rate of the REU-2006FFU will, at a preset
The chart opposite indicates that the water flow rate of the REU-2006FFU will, at a preset
Mixed Water Flows for the REU-2006FFU
Ouput water temperature
Output water volme
Incoming Incoming with mixing
40 L/min with mixing
40 L/min
Incoming with mixing
40 L/min
Incoming
17.1 L/min
Incoming Incoming
13.3 L/min 10.9 L/min
Infinity REU-2006FFU - 15 ©Rinnai
13. Gas Consumption
The most common unit used to calculate the energy required to heat water is the kilocalorie.
If the full gas rate is not required to provide the required water temperature rise, [ ie - when the temperature selected at the remote controls is lower, or the incoming water temperature is higher ]; the amount of gas that the water heater is going to use to carry out a specific heating task will change proportionally to these variables. The actual gas rate is based upon the following calculation.
Calculating Gas Input
Formula: (T
OUT
- T
IN
) x Q x 60 = IN MJ/h
239 x TE
See previous page for an explanation of TIN, TOUT, IN, TE and Q.
Example data
T
IN
=15 o
C
T
OUT
=60 o
C
IN=Gas input in MJ/h
TE=80%
Q=10 L/min
Calculation
(60 - 15) x 10 x 60=IN MJ/h
239 x 0.8
45 x 10 x 60=IN MJ/h
239 x 0.8
27000 (Kcal/h)=IN MJ/h
191.2
141 MJ/h=IN
The Infinity is able to control both the water and gas flows. The gas input varies depending on the water flow and incoming and outgoing water temperatures. The chart on the following page is an approximate guide to the gas input according to the various temperature rises and water flows.
To calculate the approximate gas input, first select the appropriate curve representing the water flow in litres/minute [L/min]. From the base line draw a vertical line at the point where the required temperature rise in degrees celcius ( o
C) is indicated. This can be calculated by subtracting the incoming water temperature from the selected temperature on the remote control. Draw a horizontal line from the point where the vertical line intersects the curve. The point where the horizontal line intersects the left hand vertical line (Gas Input), shows the approximate gas input in MJ/h.
Infiinity REU-2006FFU - 16 ©Rinnai
This chart is an approximate gide to the gas input according to various temperature rises and water flows. See previous page, last paragraph for the explanation on how to calculate approximate gas consumption in MJ/h
Infinity REU-2006FFU - 17 ©Rinnai
14. Main Components
14.1 Mechanical Water Regulator
Rinnai's unique water regulator mechanism ensures the hot water is maintained with no noticeable change to the desired temperature during use, even if water pressure drops due to another tap being turned on and increasing the demand.
The following graph shows that the maximum flow is approximately 20 L/min for the 2006. This maximum flow is reached at 130 kPa and 290 kPa inlet pressure respectively.
Note: Although the 2006 will operate at very low water pressures, maximum performance is not reached unless the incoming pressure is 130 kPa or more.
14.2 Preset Bypass
A preset volume of cold water is mixed with water heated in the heat exchanger. This increases the capacity of the appliance.
14.3 Burner
The burner assembly is made up of 18 identical stainless steel bunsen burners, secured by an aluminised steel framework. An aluminium manifold with 18 integral injectors supplies gas to the burners, and is attached to the front lower cover of the burner box.
14.4 Changeover Solenoid Valve
The changeover solenoid increases the flexibility of the regulator/modulating valve by supplying gas to the right hand side of the burner only, [up to 40% input] or both sides of the burner, [40% input]
+ [40 - 100% input] through the tandem manifold.
Infiinity REU-2006FFU - 18 ©Rinnai
14.5 Combustion Fan
Air for combustion is supplied by a centrifugal fan driven by a DC motor.
After a pre-purge period of 0.2 seconds, the fan speed is controlled by the PCB to provide the correct volume of air for combustion. The calculation for the fan speed is based upon incoming water temperature, water flow and the temperature selected on the remote controls.
The actual speed of the motor is continuously monitored by a magnetic pulse sensor. This sensor emits 4 pulses per rotation of the fan. This is the fan feedback or confirmation data processed by the PCB and used for 2 operations.
1. The fan speed is constantly crected to provide optimum combustion conditions.
2. To determine the opening degree of the modulating gas valve, so that the gas rate always matches the volume of air for combustion, as well as the input required to heat the water.
The reason for controlling the opening degree of the modulating gas valve based upon data from the combustion fan is that the gas valve is able to react much more quickly to a change in control signal than the combustion fan. Controlling the gas valve based upon data from the combustion fan means that combustion remains satisfactory, even if there are sudden changes in input conditions.
14.6 Water Flow Sensor
Water flow is detected by a turbine/magnetic pulse generating device. Water flows through the turbine/magnetic sensor providing information to the PCB by generating a pre-determined number of pulses in proportion to the water flow. These pulses are counted by the PCB - no pulse indicates no water flow. The frequency of the magnetic pulses increases as the water flow increases, this enables the PCB to calculate the exact water flow, and determine the water flow in litres/minute.
As soon as the required water flow is detected, the PCB activates the combustion fan. The combustion fan speed is monitored by a magnetic pulse sensor. The output from this sensor is processed by the PCB which opens the gas modulating valve to a degree proportional to the fan speed. See above for further details on the combustion fan.
Infinity REU-2006FFU - 19 ©Rinnai
14.7 Water Flow Sensor and Water Flow Control Device
The water flow control consists of a plug and barrel valve which is rotated by a motor to increase or decrease the volume of water passing through the heat exchanger.
The REU-2006 has an automatic water flow control device.
Infiinity REU-2006FFU - 20 ©Rinnai
15. Time Charts
During Normal Combustion
Misignition / Sudden Misfire
Infiinity REU-2006FFU - 21 ©Rinnai
Unsatisfactory Pre-purge (Water supply closed etc)
Infiinity REU-2006FFU - 22 ©Rinnai
16. Operation Flow Principle
Insert power plug in socket
1
Fuse/elec.
leak safety device normal?
2
Yes
Unit operation normal
Yes
ON/OFF Switch ON
ττττ
ττττ
No
No
Set Temp displayed ττττ
A
3
4
Hot water tap open a
Water flow sensor ON
2.7 L/min or more
Yes
Combustion fan ON
Fan rotation detector normal?
Pre-purge
Initial check normal?
Yes
No
10 seconds after (a)
Supply/exhaust blocked
10 seconds after (a)
Combustion fan abnormal
False flame faulty
No
5
Solenoid valve circuit abnormal
Outgoing Hot water thermistor abnorma
6
Air supply thermistor abnormal
7
8
Thermal fuse melted
Overheat switch faulty
Eliminate cause
Pull out power plug
Unit operation indicator OFF
ττττ
ON/OFF Switch OFF
Error display OFF
Water flow sensor OFF
Hot water tap closed
10 Flashing
Combustion fan OFF
( after 5 seconds )
ττττ
61 Flashing
ττττ
ττττ
72 Flashing
71 Flashing
ττττ
ττττ
32 Flashing
34 Flashing
ττττ
14 Flashing
ττττ
ττττ
ττττ
OFF
Hot water tap closed
Water flow sensor OFF
Combustion indicator OFF
ττττ
Main gas solenoid valve OFF
Hot water solenoid valve OFF
(Changeover solenoid valve OFF)
Gas modulating valve OFF
A
Post fan stops
(10 sec)
Yes
ON/OFF switch OFF
Unit operation indicator OFF
ττττ Only applicable when remote control is connected
No
ττττ
ττττ
9
10
11
12
Fan Ignition rpm
Sparker ON
Main gas solenoid ON
Hot water solenoid valve ON
Gas modulating valve ON
Pre-purge (2 sec)
13
Flame detected
(1µA or over)
Yes
Sparker OFF
Combustion indicator Illuminates
14
(Change-over solenoid ON)
No
ττττ
Gas modulating valve OFF
Hot water solenoid valve OFF
Main gas solenoid valve OFF
Sparker OFF
( after 4 seconds )
Yes
No
Ignition failure
( 3 attempts )
Gas modulating valve OFF
(Changeover solenoid valve OFF)
Hot water solenoid valve OFF
Main gas solenoid OFF
(Sparker OFF)
ττττ
11 Flashing
Combustion indicator OFF
15
Hot water is detected
Fan Control
Fan rpm control
Gas modulating valve control
Change-over solenoid valve control
Yes
*1
12 Flashing
Flame failure safety device operational
(less than 1µA)
No
Safety device normal?
*1 2408, 2008 series operation only
61 Flashing
Combustion fan rotation abnormal
(16.7Hzor less)
16 Flashing 32 Flashing
Outgoing hot water temp. 95 EC or less
Outgoing hot water thermistor
(open or short circuit)
34 Flashing
Air supply thermistor abnormal
(open or short circuit)
14 Flashing
Thermal fuse melted overheat switch operating
71 Flashing
Solenoid valve circuit abnormal
Infiinity REU-2006FFU - 23 ©Rinnai
17. Operation Principles
control is fitted, the default temperature is 40 o
C, 43 o
C, 50 o
C, 55 o
C, 60 o
C, 65 o
C, 75 o
C depending
on the position of dip switch numbers 3 to 6 (see page 12).
When the unit is first plugged into 240 Volts, the PCB assumes an incoming water temperature of
25 o
C, this prevents the appliance starting on HIGH, and producing very hot water the first time it is used.
The data used to determine the outgoing water temperature initially is incoming water flow, and the remote control pre-set temperature.
From the incoming water flow and remote control pre-set temperature data, the CPU is able to determine a suitable gas rate to kick the appliance off, once a hot water tap opens.
This calculation of temperature rise and water flow is called simulation feed-forward.
The water heater calculates incoming water temperature by subtracting the theoretical temperature rise from the outgoing hot water temperature, to establish the correct gas flow.
When a hot water tap is opened, water begins to flow through the appliance. The turbine in the water flow sensor begins to revolve. The revolution speed is proportional to the water flow. A sensor located inside the device relays information in the form of magnetic pulses to the main PCB to determine whether or not water is flowing, and also, the volume of water flowing. When a predetermined water flow is sensed, the ignition sequence begins.
The combustion fan pre-purges the combustion chamber. A rev counter on the combustion fan indicates the fan rpm to the main PCB. Once the pre-purge cycle is completed, the PCB controls the fan rpm by varying the DC voltage to the fan motor. This maintains the correct air/gas ratio throughout the time the water heater is in use, to ensure good combustion.
The gas is ignited by direct electronic spark and the flame is sensed by the flame rod. The opening degree of the modulating valve is determined by the combustion fan speed.
The changeover valve directs gas to one side or both sides of the burner. At the point where the changeover valve opens or closes, the modulating valve is instantly re-adjusted by the PCB to compensate for the change in the number of burners in use. From the information provided by the water flow sensor and the water temperature thermistor, the PCB determines how much gas is required to heat the water to the temperature selected on the remote control.
The PCB is programmed to provide the maximum volume of water possible at a given temperature rise. As the water flow from the tap is increased, the PCB increases the gas and air flow to the burner.
Once the maximum gas rate is reached the PCB begins to control the water flow through the appliance in order to maintain the preset temperature. This is achieved by the PCB turning the valve within the water flow control device by means of a stepping motor.
The water flow control device operates at high water flows and/or high temperature rises. When the temperature rise is low, or the water flow is restricted by the hot water tap, then the device may not
be required to operate. [See section on “Main Components” on page 18, for clarification].
There is no direct connection between the mechanical water flow control device with water flow sensor and the PCB, therefore, there could be occasions when the input required to heat the water exceeds the capacity of the appliance, and water at a temperature lower than that requested on the remote control is output. In this case, manually reducing the water flow at the tap will increase the temperature.
Infiinity REU-2006FFU - 24 ©Rinnai
Once hot water is flowing the water temperature thermistor senses the outgoing water temperature.
The PCB continually makes adjustments in order to maintain a constant temperature; [adjusting both the gas input and water flow where necessary.] It also continually monitors the combustion fan rpm adjusting the gas rate to match.
When the hot water tap is turned off, the water flow sensor stops revolving, and the magnetic pulse ceases, indicating to the PCB that there is no water flowing, in turn the PCB closes the gas valves.
The combustion fan continues to operate for 65 seconds. This is to provide quicker ignition when the tap is turned on and off in rapid succession, as it removes the need for a pre-purge cycle, and allows the burner to re-light immediately when a hot water tap is opened again.
The PCB stores data on the calculated incoming water temperature, ready for when the hot water is turned on again. The data is used to calculate the initial gas flow.
Infinity REU-2006FFU - 25 ©Rinnai
18. Error Messages
Error messages are displayed as numbers flashing on the remote controls.
X = Does not operate
Error
Code
-
Problem Symptom
Water flow sensor faulty Does not operate
Main
Solenoid
Valve
X
71
72
32
-
61
11
Solenoid valve driving circuit faulty
Does not operate
Flame sensing device faulty
Does not operate
Short or faulty wiring in water temperature thermistor
Does not operate
Water flow control device faulty
Water flow is not controlled, water temperature incorrect
Combustion fan faulty After 12.5 seconds operation
Sparker faulty Stops without flame igniting
X
X
X
-
-
X
Solenoid
Valve
X
X
X
X
-
-
X
Changeover
Solenoid
Valve
X
Combustion
Fan
Sparker
X X
X
X
X
-
X
-
X
X
X
X
-
-
X
X
X
-
X
X
X -
11
11
Main solenoid value faulty
Solenoid valve faulty
Stops without flame igniting
Stops without flame igniting
Incorrect water temperature
-
Changeover solenoid valve faulty
12
16
14
14
Flame sensing device faulty
Outgoing water temperature abnormal
Remaining flame safety device operating
Thermal fuse
faulty/blown
Stops second time burner has been extinguised
Operates, then stops
Operates, then stops
Operates, then stops
-
-
X
X
X
X
X
-
X
X
X
X
-
X
X
X
X
X
-
-
X
X
X
X
-
-
X
X
X
X
Infiinity REU-2006FFU - 26 ©Rinnai
19. Diagnostic Points
9
10
7
8
Flow
Chart
No.
Measurement Point
CN Wire Colour
1
2
3
4
5
E
J a
1 d h a
2 red - red black - black red - black yellow - black white - black checkpin white - white
6
11
12
13
14
15 a
1 c
1 b
G g
1
G c
2 c
3
G
I
1 white - white white - red red - red grey - grey pink - black yellow - black pink - pink yellow - earth blue - black red - blue orange - grey
Normal Value
AC 90~110 V
DC 11~13 V
DC 11~13 V
DC 2~10 V
DC 2~7 V
55~170 Hz
Thermistor resistance
15oC 11.4~14 k
Ω
30oC 6.4~7.8 k
Ω
45oC 3.6~4.5 k
Ω
75oC 1.4~1.8 k
Ω
Thermistor resistance
15oC 11.4~14 k
Ω
30oC 6.4~7.8 k
Ω
45oC 3.6~4.5 k
Ω
75oC 1.4~1.8 k
Ω
Less than 1
Ω
Less than 1
Ω
AC 90~110 V
DC 80~100 V
0.9~1.3 k
Ω
DC 80~100 V
1.3~1.9 k
Ω
DC 0.5~25 V
65~90
Ω
AC 40~150 V
(Over DC 1uA)
DC 80~100 V
1.5~1.9 k
Ω
DC 11~13 V
10~30
Ω
DC 11~13 V
Component
Electrical Fuse
Remote Controls
Water Flow Sensor
Combustion Fan Motor
Water Temperature Thermistor
Air Temperature Thermistor
Thermal Fuse
Over Heat Switch
Sparker
Main Gas Solenoid Valve
Hot Water Supply Solenoid Valve
Gas Modulating Valve
Flame Rod
Changeover Solenoid Vlave
Water Flow Servo
Infinity REU-2006FFU - 27 ©Rinnai
CN d
D
B
B
B
Wire Colour red - red green - green orange - orange brown - grey yellow - grey
Normal Value (Electrical Pressure /
Resistance
AC 90~110 V
15~21
Ω
AC 16~20 V
6~10
Ω
AC 13~30 V
1.4~1.8
Ω
AC 30~50 V
6~10
Ω
AC 180~220 V
1.4~0.6 k
Ω
Infinity REU-2006FFU - 28 ©Rinnai
20. Wiring Diagram
COLOUR
CODING
W: White
Bk: Black
Br: Brown
R: Red
B: Blue
Y: Yellow
P: Pink
Or: Orange
Gr: Green
Gy: Grey
Infinity REU-2006FFU - 29 ©Rinnai
21. Fault Diagnosis
Appliance will not operate (main control PCB not displayed)
1) Is the electrical fuse broken?
Electrical fuse short circuit check a. Disconnect the power from the power point.
b. Check for electrical fuse (3A) short circuits with a multimeter
Normal: less than 1 S
If normal, go to 2).
Faulty: Replace the electrical fuse (3A)
Check for any shorts if it switches off.
2) Is the transformer normal?
Transformer check.
a. Measure the voltage in between the red wires of the relay connector (d).
Normal: AC90 ~ 110 V
If normal, go to b.
Faulty: Check whether AC 90 ~ 110 V is flowing between the electrical fuse terminal and the water flow control unit.
b. Measure the voltages with connector (B) on top of the main panel.
Normal: orange -orange
AC 13 ~ 30 V brown - grey
AC 30 ~ 50 V yellow - grey
AC 180 ~ 220 V
If normal, go to c.
Faulty: Replace the thermistor.
Infiinity REU-2006FFU - 30 ©Rinnai
Refer to diagram on bottom of previous page.
3) Is the control PCB normal?
c. Measure voltage between green - green of connector (D) on the top of the main panel.
Normal: AC 16 ~ 20 V
If normal, go to 3).
Faulty: Replace the transformer.
Caution: Transformer voltages are measured when the unit is in standby.
Voltage check between 2 core cables of the remote control.
a. Measure the voltage between terminals at the remote control terminal (h).
Normal: DC 11 ~ 13 V
If normal, check for broken cables or shorts and replace the remote control.
Faulty: Replace the water flow control.
Combustion doesn’t occur (control PCB displayed)
1) Is the water flow sensor normal?
a. Measure the voltage between red and black of the relay connector (a
2
Normal: DC 11 ~ 13 V
).
If normal, go to b.
Faulty: Replace water flow control.
b. Measure the voltage between yellow and black of the relay connector (a
2
Normal: DC 2 ~ 10 V
)
If normal, go to 2).
Faulty: Replace the water flow sensor.
Infinity REU-2006FFU - 31 ©Rinnai
2) Fault display “72” is displayed
Checking the flame rod.
a. Detach the flame rod terminal (b), turn it on and repair.
(“72” is displayed)
Proceed to check item 3) below.
(“72” is not displayed)
Check for electrical leaks from the flame rod.
Measure resistance between flame rod terminal (b) and fuselage earth.
Normal: At least 1 MS
If normal, replace the water flow control.
Faulty: Replace the flame rod.
3) Is the water temperature thermistor normal?
If fault display displays “32”, check the water temperature thermistor.
a. Detach the relay connector (a
1
), and measure the resistance between white and white.
When disconnection occurs: resistance is at least 1MS.
When short has occurred: resistance is below 1S.
If normal, go to 4).
If there is an error, replace the water temperature thermistor.
4) Is the air temperature thermistor normal?
If fault display “34”, check the air temperature thermistor.
a. Detach the relay connector (a
3
) measure the resistance between white and white.
When disconnection occurs: resistance is at least 1 MS.
When short occurs: resistance is less than
1S.
If normal, go to 5.
If error occurs, replace air temperature thermistor.
Infiinity REU-2006FFU - 32 ©Rinnai
5) Is the combustion fan normal?
6) Is the sparker normal?
7) Is the main gas solenoid valve (SV
1
) normal?
Checking the motor
If fault display displays “61”, check the combustion fan.
a. Measure the voltage between black and red of the connector (E).
Normal: DC 6 ~ 40 V (when fan is ON)
DC 0 V (when fan is OFF)
If normal, go to b.
Faulty: Replace the water flow control
Checking the rotation sensor section b. Measure the voltage between black and yellow of the connector (E).
Normal: DC 11 ~ 13 V
If normal, go to b.
Faulty: Replace the water flow control.
c. Measure the voltage between black and white of the connector (E).
Normal: DC 2 ~ 7 V
If normal, go to 6).
Faulty: Replace the combustion fan.
a. Measure the voltage between grey and grey of connector (g
1
).
Normal: AC 90 ~ 110 V
If normal, go to b.
Faulty: Replace the water flow control.
b. Detach connector (g
1
) and measure the resistance between both terminals of the sparker.
Normal: At least 1 MS.
If it is not sparking, adjust or replace the ignition plug.
Faulty: Replace the sparker.
Infinity REU-2006FFU - 33 ©Rinnai
If fault display displays “11”, check the main gas solenoid valve.
a. Detach the connector on the main gas solenoid valve, and measure the resistance between pink and black.
Normal: 0.9 ~ 1.3 kS.
If normal, go to b.
Faulty: Replace the main gas solenoid valve.
b. Measure the voltage between pink and black of the connector from the main gas solenoid valve.
Normal: DC 80 ~ 100 V
If normal, go to 8).
Faulty: Replace water flow control
8) Is the hot water supply solenoid valve (SV
2
) normal?
If fault display displays “11”, check the hot water supply solenoid valve.
a. Detach the hot water supply solenoid connector, and measure the resistance between yellow and black.
Normal: 1.3 ~ 1.9 kS
If normal, go to b.
Faulty: Replace the hot water supply solenoid valve.
b. Measure the voltage between yellow and black of the connector from the hot water supply solenoid valve.
Normal: DC 80 ~ 100 V
If normal, go to 9).
Faulty: Replace the water flow control.
9) Is the changeover solenoid valve (SV
3
) normal?
Infiinity REU-2006FFU - 34 ©Rinnai
10) Is the safety device panel?
a. Detach the connector on the changeover solenoid valve, and measure the resistance between blue and black.
Normal: 1.5 ~ 1.9 kS.
If normal, go to b.
Faulty: Replace the changeover solenoid valve.
b. Measure the voltage between blue and black of the connector on the changeover solenoid valve.
Normal: DC 80 ~ 100 V
If normal, go to 10).
Faulty: Replace the water flow control.
If fault display displays “14”, check the following points.
a. Check the thermal fuse.
Detach relay connector (c
2
) and measure the resistance between red and white.
Normal: Less than 1S
If normal, go to b.
Faulty: After checking for any damage to the appliance and, if there are no other errors, replace the thermal fuse.
b. Check the overheat prevention device (bimetal switch). Measure the resistance between both terminals of the bi-metal switch (c
3
).
Normal: Less than 1S.
If normal, go to c.
Faulty: Replace the remaining flame safety device.
c. Check harnesses.
Self-check operates if the earth is connected to the main body for harness tearability (especially water flow sensor, modulating valve remote control cable etc,.
Check harnesses within the appliance.
Replace the water flow control unit if above steps a~ c are normal.
Infinity REU-2006FFU
Combustion occurs but flame fails
- 35 ©Rinnai
1) Is the flame rod normal?
a. Measure the voltage between the flame rod terminal (b) and the appliance earth.
Normal: AC 40 ~ 150 V
If normal, go to b.
Faulty: Replace the water flow control.
b. Check whether the flame rod is loose.
If normal, replace the water flow control.
If faulty, adjust the flame rod so it is not loose.
2) Is the earth lead wire normal?
a. Check whether the earth lead wire has come loose (disconnection from round terminal) or if any shorts have occurred.
If normal, check for any other causes for flame failure (eg. gas valve is open, blocked filter, etc)
If faulty, reconnect the earth lead wire.
Hot water supply temperature cannot be adjusted
1) Is the water temperature thermistor normal?
a. Detach relay connector (a
1
) and measure the resistance between white and white.
Normal (Standards)
Temperature: 15 o
C, 30 o
C, 45 o
C, 75 o
C
Resistance: 12.3, 7.0, 4.1, 1.6. [kS]
If normal, go to 2).
Faulty: Replace water temperature thermistor.
Infiinity REU-2006FFU - 36 ©Rinnai
2) Is the changeover solenoid valve (SV
3
) normal?
a. Detach the changeover solenoid valve, and measure the resistance between blue and black.
Normal: 950 ~ 1420 S.
If normal, go to b.
Faulty: Replace the changeover solenoid valve.
b. Measure the voltage between the blue and black on the changeover solenoid connector.
Normal: DC 80 ~ 100 V
If normal, go to 3).
Faulty: Replace the water flow control unit.
3) Is the modulating valve normal?
a. Detach quick connector on the modulating valve and measure the resistance between both terminals.
Normal: 65 ~ 90S
If normal, go to b.
Faulty: Replace the modulating valve.
b. Measure the voltage between the orange and orange quick connectors on the modulating valve.
Normal: DC 0.5 ~ 25 V
If normal, go to c.
Faulty: Replace water flow control.
c. Check the gas secondary pressure change when the remote control temperature has been modified from 35 to 75 o
C.
Normal: If the secondary pressure changes, go to 4).
Faulty: Replace the modulating valve.
Infinity REU-2006FFU - 37 ©Rinnai
4) Is the water flow servo normal?
a. Detach the relay connector and measure the resistance between red and blue on the water flow servo side.
Normal: 10 ~ 30S
If normal, go to b.
Faulty: Replace the water flow servo with water flow sensor.
b. Detach the relay connector and measure the voltage between orange (+) and grey(-) on the water flow control side.
Normal: DC 11 ~ 13 V
If normal, go to c.
Faulty: Replace the water flow control.
c. Leaving the relay connector (I
1
) connected
(no water flow, water servo open), measure the voltage between brown and grey.
Normal: DC 4 ~ 6 V
Faulty: Change water flow servo with sensor.
d. Leaving the relay connector (I
1
) connected
(no water flow, water servo open), measure the voltage between yellow and grey.
Normal: Less than DC 0.5 V
Faulty: Change water flow servo with sensor.
The freeze prevention heater does not activate
1) Is the freeze prevention heater normal?
a. Detach the relay connector (f
2
) and measure the resistance between blue and blue on the heater side.
Normal: 625S
If normal, go to b.
Faulty: Replace freeze prevention heater D (assy).
Infiinity REU-2006FFU - 38 ©Rinnai
b. Detach relay connector (f
1
) and measure the resistance between blue and blue on the heater side.
Normal: 104S
If normal, go to 2).
Faulty: Replace freeze prevention heater (assy)
2) Is the frost sensing switch normal?
a. Detach the relay connector (f
2
) and measure the resistance between white and white.
Measure at room temperature of 7 ± 3 o
C.*
Normal: Less than 1 S if normal, check the wiring (AC100V circuit)
Faulty: Replace the frost sensing switch.
* Where the low room temperature cannot be
achieved, please cool with iced water etc.
Infinity REU-2006FFU - 39 ©Rinnai
22. Electrical Component Analysis
Before starting inspection, re-check wiring harnesses and double check that all connections are tight.
Before carrying out checks marked with *, remove power cord from wall plug.
Nature of
Fault
Examination
Point
Diagnostic Point Values
Y/
N
Action
A. The On indicator does not light up after switching the unit on.
1. Is the power cord plugged in?
2. Is supply voltage correct?
Inspect visually
Measure voltage at power point.
Is it plugged in?
AC 240 V
(NZ 230 V)
Yes
No
Go to A-2.
Plug in cord
Yes Go to A - 3.
No Check power supply circuit.
Check fuses.
3. Check 3
Amp electrical fuses.
* Disconnect and measure resistance to confirm if fuse is blown.
Normal< 1 MS
Is fuse blown? Yes Go to A - 4 and replace fuse.
No Go to A - 5.
4. Check for short circuits.
i) Measure the resistance of each solenoid valve.
* Remove connector G from the PCB before measuring.
Pink - Black
0.9 ~ 1.3 kS
Yellow - Black
1.3 ~ 1.9 kS
Blue - Black
1.5 ~ 1.9 kS
Are values within those specified at left?
N.B. Measure after checking that there areno broken wires or shorts.
Yes Go to A-5-ii)
No Replace faulty solenoid valves.
5. Check
240V-100V transformer.
ii) Measure the sparker resistance.
* Disconnect the sparker connector g
1
and measure the resistance between both terminals.
Is resistance >
1MS?
Yes Go to A-4-iii)
No Replace sparker iii) Check wiring Are there any shorts?
Yes Rectify/
Replace
No Replace PCB i) Measure voltage between red-red connector d.
AC 90~110 V Yes
No
Go to A-5-ii)
Replace PCB.
Repair
N
o
1
2
3
4
5
6
7
Infiinity REU-2006FFU - 40 ©Rinnai
Nature of
Fault
Examination
Point
Diagnostic Point Values
Y/
N
Action
ii) Measure voltage at connectors b, d with appliance on
“standby”.
Green-Green
AC16 ~ 20 V
Orange-Orange
AC13 ~ 30 V
Brown-Grey
AC30 ~ 50 V
Yellow-Grey
AC180 ~ 220 V
Are values within those specified at left?
6. Check the remote control.
Measure voltage between control terminals at h.
Yes
No
Go to A-6.
Replace transformer.
DC11 ~ 13 V. Yes Check cable for shorts/ broken wires; replace remote control.
No Replace PCB.
B. Digital monitor lights up, but there is no combustion.
1. Check water flow sensor.
i) Measure voltage between red-black at connector a2.
ii) Measure voltage btween yellowblack at connector a
2
.
DC11 ~ 13 V. Yes
No
Go to B-1-ii)
Replace PCB
DC2 ~ 10 V. Yes Go to B-ii).
No Replace water flow sensor.
Error code
“72” displayed
2. Check flame rod.
* Measure resistance between flame rod terminal
(b) and earth.
Resistance >
1MS?
Yes Replace PCB.
No Replace flame rod.
Error code
“32” displayed
3. Check outgoing water temperature thermistor.
* Disconnect and measure resistance of connector a
1
.
Open circuit:>1MS
Short circuit: <1S
Are values as shown at left?
Yes Replace thermistor.
No Go to B-4.
Error code
“34” displayed
4. Check air temperature thermistor.
Error code
“61” displayed
5. Check combustion fan.
* Disconnect and measure resistance of connector a
1
.
Open circuit:>1MS
Short circuit: <1S i) Check motor.
Measure voltage between black-red at connector E.
Are values as shown at left?
DC6 ~ 40 V
(Fan ON)
DC 0 V
(Fan OFF)
Yes Replace thermistor.
No
Yes
No
Thermistor
Go to B-5-ii).
Replace PCB.
Repair
N
o
8
9
10
11
12
13
14
15
16
17
Infinity REU-2006FFU - 41 ©Rinnai
Nature of
Fault
Examination
Point
Diagnostic Point Values
Y/
N
Action
Error code
“11” diaplayed
6. Check sparker.
ii) * Disconnect connector E from
PCB; measure resistance between black (+) -red
(COM)
Is resistance between
3.9K~4.9KS
Yes
No
Go to B-5-iii).
Replace combustion fan iii) Check rotation sensor. Measure resistance between black-white at connector E.
DC11 ~ 13V Yes Go to B-5-iv).
No Replace PCB.
iv) Measure resistance between black-white at connector E.
DC2 ~ 7 V.
Yes Go to B-6.
No Replace combustion fan i) Measure voltage between grey-grey at connector g
1
.
AC90~110 V. Yes Go to B-6-ii).
No Replace PCB.
ii) * Disconnect connector g
1
; measure resistance between terminals.
Is resistance >
1MS?
Yes Go to B-6-iii).
No Replace sparker.
iii) Confirm spark. Sparking?
Yes Go to B-7.
7. Check main gas solenoid valve (SV
1
).
No Adjust/replace electrode..
i) * Disconnect main solenoid connector G from
PCB. Measure resistance between pink-black.
0.9 ~ 1.3kS? Yes Go to B-7-ii).
No Replace main solenoid (SV
1
).
ii) Measure voltage between pink-black main solenoid connector.
DC80~100V Yes Go to B-8.
No Replace PCB.
8. Check solenoid valve
(SV
2
).
i) * Disconnect solenoid connector
G from PCB; measure resistance between yellowblack.
1.3 ~ 1.9kS?
Yes Go to B-8-ii).
No Replace solenoid (SV
2
).
ii) Measure voltage between yellowblack solenoid connector.
DC80~100V Yes Go to B-9.
No Replace PCB.
Repair
N
o
18
19
20
21
22
23
24
25
26
27
Infiinity REU-2006FFU - 42 ©Rinnai
Nature of
Fault
Examination
Point
Diagnostic Point Values
Y/
N
Action
Error code
“14” displayed
C.
Combustion occurs but flame fails.
9. Check changeover solenoid valve
(SV
3
).
i) * Disconnect changeover solenoid connector
G from PCB; measure resistance between blueblack.
1.5~1.9kS?
Yes Go to B-9-ii).
No Replace solenoid (SV
3
).
10. Check thermal fuse.
ii) Measure resistance between blue-black on solenoid connector.
DC80~100V Yes Go to B-10.
No Replace PCB.
* Disconnect connector c
2
; measure resistance between white-red.
Resistance value < 1S?
Yes Go to B-11.
No Replace thermal fuse.
11. Check overheat switch (bimetal)
* Disconnect OHS fastener terminal; measure resistance between terminals.
Resistance value < 1S?
Yes Replace PCB.
No Replace remaining flame safety device (bimetal SW).
1. Check flame rod.
i) Measure voltage between flame rod terminal b and appliance earth.
AC40~150V Yes Go to C-1-ii).
No Replace PCB.
Error code
“12” displayed
D. Cannot adjust water temperature.
1. Check outgoing thermistor.
ii) Confirm the flame rod isn’t loose.
2. Check earth lead.
Check for short/ open circuits, and bad earth lead connection (to round terminals)
Is it secure?
Are connections
OK?
Yes Go to C-2.
No Adjust flame rod.
Yes Check other causes for flame failure.
No Adjust/replace earth lead.
Yes Go to D-2.
Disconnect connector a
1
; measure resistance between whitewhite.
for temperature at various resistances.
Resistance values match table on
No Replace thermistor.
Repair
N
o
28
29
30
31
32
33
34
35
36
37
Infinity REU-2006FFU - 43 ©Rinnai
Nature of
Fault
Examination
Point
Diagnostic Point Values
Y/
N
Action
2. Check changeover solenoid.
3. Check modulating valve.
i) * Disconnect solenoid connector
G from PCB; measure resistance between blueblack.
1.5~1.9kS.
Yes Go to D-2-ii).
No Replace solenoid (SV
3
).
ii) Measure voltage between blue-black solenoid (SV
3
) connector.
DC80~100V Yes Go to D-3.
No Replace PCB.
i) * Disconnect modulating valve terminal; measure resistance between terminals.
65 ~ 90 S?
Yes Go to D-3-ii).
No Replace modulating valve ii) Disconnect modulating valve terminal; measure voltage between both terminals.
DC0.5~25V iii) Check gas secondary voltage when the temperature set on the remote controls changes between
37~75 o
C.
Are there secondary voltage changes?
Yes
No Replace PCB.
Yes
Go to D-3-iii).
Go to D-4.
No Replace modulating valve.
4. Check water flow servo.
i) Measure resistance between red-blue water flow servo connector I
1
.
10 ~ 30 S?
Yes Go to D-4-ii).
No Replace water flow servo with sensor.
ii) Measure voltage between orange (+)
- grey (-) water flow servo connector I
1
.
DC11~13V Yes Go to -4-iii).
No Replace PCB.
iii) Measure voltage between brown-grey water flow servo connector I
1
(when water not flowing).
DC4 ~ 6V Yes Go to D-4-iv).
No Replace water flow servo with sensor.
iv) Measure voltage between yellowgrey water flow servo connector I
1
(when water not flowing).
< DC 0.5V
Yes Normal
No Replace water flow servo with sensor.
Repair
N
o
38
39
40
41
42
43
44
45
46
Infiinity REU-2006FFU - 44 ©Rinnai
Nature of
Fault
E. Anti-frost heater does not work.
Examination
Point
Diagnostic Point Values
Y/
N
Action
1. Check antifrost heater.
2. Check frost sensing switch.
i) * Disconnect connector f
2
; measure resistance between blue-blue.
600~650S?
Yes Go to E-1-ii).
No Replace antifrost heater
(assy).
ii) * Disconnect connectors f
1
and f
2
; measure resistance between white-white. (Short circuit connector f
3 and measure).
96~112S?
Yes Go to E-2.
No Replace antifrost B (assy).
* Disconnect connector f3; measure resistance between whitewhite. Room temperature <
7
±3o
C.
Is resistance <
1S?
Yes Check wiring.
No Replace frost sensing switch.
Repair
N
o
47
48
49
Infinity REU-2006FFU - 45 ©Rinnai
23. Gas Conversion
1. Remove outer cover, 4 screws. (see diagram 1)
2. Delete “gas type marking” from the combustion chamber cover and replace with “new gas type”.
(Use a black marking pen)
3. Delete gas type from small paper sticker on bottom edge of inner casing.
4. Replace small gas label on gas inlet.
5. Replace large gas label on top of appliance.
6. Place “new” very small gas label (indicating new gas type) over existing one on data plate.
7. Complete details on conversion sticker, place sticker on the inside front cover.
8. Remove PCB protective plastic cover.
9. Remove combustion chamber cover, 11 screws.
(see diagram 2)
10.Remove manifold, 5 screws. (see diagram 3)
11.Remove damper (3 screws). (see diagram 4)
12.Replace the burner unit (2 screws). (see diagram 4)
13.Remove 18 injectors.
14.Fit new injectors (18) (see diagram 4)
15.Fit Damper. (Natural Gas marked “B” / Propane
Damper marked “E”).
16.Refit manifold, check “O” rings are correctly positioned.
17. Refit combustion chamber cover. Attach flame sensor and sparker lead.
18.Connect appliance to gas, water, and electricity.
19.Follow gas pressure setting procedure, (see next page).
20.Check for gas escapes with soapy water.
21.Disconnect appliance from services (if in workshop).
22.Replace front cover, star washer must be on bottom right hand screw.
Diagram 1.
Diagram 2.
Diagram 3.
Diagram 4.
Diagram 5
Diagram 6
Infiinity REU-2006FFU - 46 ©Rinnai
24. Gas Pressure Setting Procedure
1) Check gas type switch is in correct position (see page 12).
2) Remove concealed pressure point screws from manifold, and remove concealed pressure point screws from combustion chamber.
3) Attach pressure gauge to pressure test points. (check pressures of sections A and B with manometer)
Turn power on. (connect to power)
4) Press ON switch on the main PCB.
5) Set No. 7 switch to ON. Remove plug in base of heater for access to regulator screw. Adjust regulator screw on modulating valve.
Pressure Setting Low
NG 0.06 kPa
PROP 0.16 kPa
LPG (NZ) 0.17 kPa
6) Switch No.7 “OFF” and switch No. 8 “ON”. Adjust pressure by POT on PCB. when completed, switch
No. 8 to “OFF”.
Pressure Setting High
NG 0.62 kPa
PROP 1.80 kPa
LPG (NZ) 1.76 kPa
7) Return switch No. 7 and No. 8 switches to the “OFF” position.
8) Turn heater off.
9) Remove gauge, replace screw.
10) Replace plug in base.
Infiinity REU-2006FFU - 47 ©Rinnai
25. Dismantling for service
NOTE: Before proceeding with dismantling, be sure to follow the
CAUTION
instructions before each explanation.
Item
Page
1.
2.
3.
Removal of the Water Flow Sensor and Water Flow Control. . . . . . . . . . . . . . . . .49
4.
5.
6.
Removal of the Water Temperature Thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
7.
8.
9.
Unless otherwise stated, re-assembly is the reverse of dismantling
Infiinity REU-2006FFU - 48 ©Rinnai
IMPORTANT
For some areas of dismatling you may need to isolate any or all of the following:
2) Removal of Water Flow Control
* Isolate gas supply.
* Disconnect electrical supply from wall socket.
* Isolate water supply.
* Drain all water from appliance.
The following diagram may be of assistance.
CAUTION
240 volt potential exposure. Isolate the applaince and reconfirm with a neon screwdriver or multimeter.
a. Remove the 2 screws on the water flow control and pull out towards you.
(phillips driver)
1) Removal of Front Panel
CAUTION
240 volt potential exposure. Isolate the applaince and reconfirm with a neon screwdriver or multimeter.
a. Remove the four (4) screws holding the panel in place. (phillips driver)
3) Removal of Water Flow Sensor with
Water Flow Servo
CAUTION
240 volt potential exposure. Isolate the applaince and reconfirm with a neon screwdriver or multimeter.
a. Remove the screw from the water supply connection pipe on the heat exchanger, remove the metal lock and pull the water supply connection pipe out towards you.
Handle O-ring carefully.
(phillips driver)
Infinity REU-2006FFU - 49 ©Rinnai
b. Remove four (4) screws from the water supply connection and pull out the water supply connection.
Handle O-ring carefully. (phillips driver)
5) Removal of Combustion Fan
CAUTION
240 volt potential exposure. Isolate the applaince and reconfirm with a neon screwdriver or multimeter.
a. Detach the sparker, refer to section 4.
b. Remove the three (3) screws from the main control PCB and pull towards you.
(phillips driver)
4) Removal of Sparker
CAUTION
240 volt potential exposure. Isolate the applaince and reconfirm with a neon screwdriver or multimeter.
a. Remove one (1) screw from the sparker panel and pull out the sparker.
(phillips driver).
b. Remove one (1) screw from the sparker and detach the sparker (phillips driver) c. Remove the three (3) screws from the combustion fan and pull towards you.
(phillips driver)
Infiinity REU-2006FFU - 50 ©Rinnai
6) Removal of Water Temperature
Thermistor
CAUTION
240 volt potential exposure. Isolate the applaince and reconfirm with a neon screwdriver or multimeter.
a. Remove the two (2) screws from the outgoing hot water thermistor and detach the outgoing hot water thermistor.
8) Removal of Transformer
CAUTION
240 volt potential exposure. Isolate the applaince and reconfirm with a neon screwdriver or multimeter.
a. Detach the water flow control (Assy), refer to section 2.
b. Pull out the connector on the hot water supply solenoid valve.
c. Remove the two (2) screws on the transformer and detach the transformer.
7) Removal of Air Supply Thermistor
CAUTION
240 volt potential exposure. Isolate the applaince and reconfirm with a neon screwdriver or multimeter.
a. Detach the sparker, refer to section 4.
b. Remove the screw on the air supply thermistor and detach the air supply thermistor (phillips driver)
9) Removal of Manifold and Burner
CAUTION
240 volt potential exposure. Isolate the applaince and reconfirm with a neon screwdriver or multimeter.
a. Detach the sparker, refer section 4.
(1 screw) b. Detach the front panel of the combustion chamber.
(12 screws)
Infinity REU-2006FFU - 51 ©Rinnai
c. Remove the manifold (5 screws) c. Remove the screw from the gas control
(assy) and pull out the gas control.
d. Pull the burner unit out.
10) Removal of Gas Control
CAUTION
240 volt potential exposure. Isolate the applaince and reconfirm with a neon screwdriver or multimeter.
a. Remove the manifold, refer section 9.
b. Remove the four (4) screws from the gas connection and pull out the gas connection.
Handle O-ring carefully. (phillips driver)
11) Removal of Heat Exchanger
CAUTION
240 volt potential exposure. Isolate the applaince and reconfirm with a neon screwdriver or multimeter.
a. Pull the water flow unit towards you, refer section 2.1
b. Pull out the water supply connection pipe on the heat exchanger, refer section 3.1.
c. Detach the main control PCB, refer section
5.2.
d. Remove the screw from the hot water supply connection pipe on the heat exchanger and pull the hot water supply connection pipe towards you.
Handle O-ring carefully. (phillips driver)
Infiinity REU-2006FFU - 52 ©Rinnai
e. Detach the three (3) screws on the manifold. (phillips driver) h. Detach the 2 screws on the heat exchanger unit.
f. Detach the air supply container cover (8 screws).
i. Remove the connectors on the various harness.
j. Slide the heat exchanger unit downwards, and pull towards you.
g. Detach the screws found within the exhaust pipe set.
Infinity REU-2006FFU - 53 ©Rinnai
12) Removal of Thermal Fuse
CAUTION
240 volt potential exposure. Isolate the applaince and reconfirm with a neon screwdriver or multimeter.
a. Pull the heat exchanger unit towards you, refer section 11.1 ~ 11.10
b. Detach the thermal fuse. After removing the thermal fuse, replace it as shown in the diagram below.
13) Removal of Anti-Frost Device
a. Pull out the heat exchanger unit, refer section 11.1 ~ 11.10.
b. Detach the freeze prevention device.
Infiinity REU-2006FFU - 54 ©Rinnai
26. Exploded Diagram
Infiinity REU-2006FFU - 55 ©Rinnai
Infiinity REU-2006FFU - 56 ©Rinnai
Infinity REU-2006FFU - 57 ©Rinnai
Infiinity REU-2006FFU - 58 ©Rinnai
27. Parts List
No Part Name
001 Main Body Assembly - Standard
001 Main Body Assembly - Salt Resistant
004 Heat Shield
007 Front Panel Assembly - Standard
007 Front Panel Assembly - Salt Resistant
012 Wall Bracket
016 Front Panel Packing
017 Front Panel Packing - Side
018 Connection Reinforcement Panel
019 Gas Control Bracket
020 Installation Sheet Storage Pouch
021 Rubber Plug
022 Cable Connection
023 Cable Seal Packing
100 R¾ / 20 Gas Connection
101 Test Point Screw
103 Gas Control Assembly
104 Manifold (Assembly) - NG
104 Manifold (Assembly) - LPG
105 Damper (LPG, Propane Gas)
[Damper not required for Natural Gas]
106 Burner Case Front
107 Sound Proofing Panel
110 Burners (Front)
111 Burner Case Back Panel
112 Comb. Chamber Front Panel (Complete Assy)
113 Combustion Chamber Front Panel (Assy)
114 Combustion Chamber Packing - Top
115 Combustion Chamber Packing - Bottom
116 Ignition Target
117 Flame Rod
118 Flame Rod Bracket
119 Air Pressure Test Point
121 Heat Exchanger Complete Assy B
RA Part No RNZ Part No QTY
920881561
3044
3047
3768
3896
2
1
2
1
1
1
1
1
1
1
1
1
1
1
92081587
92081595
92071364
92081629
92081637
92072891
92044577
92048131
3074
3083
3125
3089
3136
3393
3396
3397
3018
2645
1
1
1
1
1
1
1
18
1
1
1
1
1
1
1
1
1
1
2
1
Infiinity REU-2006FFU - 59 ©Rinnai
No Part Name
122 Draining Panel
123 Air Supply Plate Assy
124 Air Supply Plate Bracket
125 Air Plate Inlet Packing
126 Flue Duct
127 Air Supply Plate Fixing
128 Anti-Vibration Packing
129 Air Supply Duct Cover
130 Flue Outlet Assembly
131 Flange Packing
132 O-Ring P75
133 Back Pressure Tube Assy
134 Back Pressure Tube
135 Fan Motor Assembly
136 Fan Casing Assy
137 U-Bellmouth
138 Fan Bracket
139 Fan Bracket Packing
140 Fan . Combustion Chamber Bracket
141 Pressure Point Packing
142 Pressure Test Point Screw
200 ø110 Flue Adaptor
400 R¾ / 20 Water Inlet Connection
401 Water Inlet Filter (Assy)
402 Water Rectifier
403 Water Flow Servo & Sensor (Assy)
404 Anti-frost Heater Fixing Plate
408 R¾ / 20 Water Outlet Connection
409 Pressure Relief Valve Band
410 Pressure Relief Valve C
411 Valve Hose End
413 Solenoid Valve Harness
414 Fan Motor Harness
415 Sensor Motor Harness
416 Water Flow Servo Harness
Infiinity REU-2006FFU - 60 -
RA Part No RNZ Part No QTY
92071570
92066976
92068907
2662
2663
2664
2665
2666
2667
3982
2668
2669
9995
9994
2680
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
92081702
92062280
92072701
92073568
92081744
92081751
1
1
1
1
1
1
1
1
1
1
1
1
1
3059
3839
3048
3058
2038
3055
3626
3070
3034
2686
3071
©Rinnai
No Part Name
418 Flame Rod Harness
419 Power Supply Harness
700 PCB (Assy)
702 EC Cover
703 PCB Cover
704 Power Supply Cord
705 Sparker
706 Sparker Installation Bracket
707 Transformer Assembly
708 240V Anti-frost Heater L Assy
709 Heater Bracket D
710 Heater Bracket
711 Over Heat Switch
712 Thermal Fuse and Harness
713 “F” Fixing Band A
714 Thermistor
715 Thermistor Clip - Large
716 Air Temperature Thermistor
717 Frost Sensing Switch
718 240V Anti-frost Heater M Assy
720 Transformer Assy (240 ~ 100 V)
721 Transformer Bracket
722 Transformer Cover
900 “O” Ring (P24)
901 Packing
903 “O” Ring (P3)
904 “O” Ring (P4)
905 “O” Ring (P7)
906 “O” Ring (P12)
907 “O” Ring (P14)
908 “O” Ring (P18)
RA Part No RNZ Part No QTY
2691
2692
1
1
92072586
92072776
92072768
92072750
92072651
92073675
92071380
92069079
92063593
92072735
92081926
92075126
92071448
92062249
92062348
92063551
92062207
92071182
1
1
1
1
1
1
1
1
1
1
1
1
4
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
3043
2035
2034
2032
3045
2856
2869
3029
3882
3986
3976
3854
3061
2693
3041
3040
2695
2851
3067
3559
3619
2974
3832
3849
1106
3826
3627
Infinity REU-2006FFU - 61 ©Rinnai
SERVICE CONTACT POINTS
AUSTRALIA PTY. LTD.
A.C.N. 005 138 769
Internet: http://www.rinnai.com.au
Victoria :
E-mail: [email protected]
Helpline: Tel: 1300 366 388
Service
Spare Parts
Tel: (03) 9271 6699 Fax: (03) 9271 6688
Tel: (03) 9271 6600 Fax: (03) 9271 6688
Sales
Tel: (03) 9271 6666 Fax: (03) 9271 6611
Emergency Hot Water
Tel: (1800) 632 386
10-11 Walker Street, Braeside, VIC 3195
Tel: (03) 9271 6625 Fax: (03) 9271 6622
New South Wales: Service
Sales
Tel: (02) 9609 2600 Fax: (02) 9729 0467
Tel: (02) 9609 2888 Fax: (02) 9609 5260
Emergency Hot Water
Tel: (02) 9729 0468
South Australia:
Western Australia: Service
Tel: (08) 9478 3355 Fax: (08) 9277 2531
Emergency Hot Water
Tel: (08) 9324 4145
18 Belgravia Street, Belmont, WA 6104
Queensland:
62 Elizabeth Street, Wetherill Park, NSW 2164
Tel: (02) 9609 2111 Fax: (02) 9609 5260
Service
Tel: (08) 8345 0292 Fax: (08) 8345 4760
Emergency Hot Water
Tel: (08) 8345 5185
140 Days Road, Ferryden Park, SA 5010
Service
Tel: (07) 3209 4622 Fax: (07) 3209 4722
Emergency Hot Water
Tel: 1800 255 266.
1/6 Booran Drive, Logan Central, QLD 4114
Tasmania:
Service
Contact Rinnai Melbourne on:
Tel: (03) 9271 6699 Fax: (03) 9271 6688
Tel: (03) 9271 6625 Fax: (03) 9271 6622
NEW ZEALAND LTD.
Internet: http://www.ralenti.co.nz/rinnai
24 hr Service
E-mail: [email protected]
Tel: (09) 625 4285 Fax: (09) 624 3018
Tel: 0800 746624 (0800 Rinnai)
691 Mt. Albert Road, Royal Oak, Auckland
P O Box 24-068
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