Rinnai Continuum REU2532-W Series User manual

Continuum and Integrity

REU2532-W and REU2532-WC

Series Water Heaters

SERVICE MANUAL

Rinnai Corporation

103 International Drive

Peachtree City, Ga. 30269

Telephone number (800)621-9419

No portion or part of this manual may be copied without prior permission from Rinnai Corporation.

REU-2532W Series 2 Rinnai

Key to Warning Symbols

Failure to comply with the following instructions may results in serious personal injury or

damage to the appliance.

Be careful of possible electric shock. Wiring inside this appliance may potentially be at 120

volts.

Disconnect power supply to unit when carrying out the following service repairs.

Read Fault Diagnosis and Wiring Diagram carefully to avoid incorrect wiring.

Do not disassemble. Parts within can not be exchanged or diagnosed faulty.

Please follow instructions in chapters to ensure safe and appropriate service.

After completing the service and confirming that there are no water or gas leaks or incorrect wiring,

test operation of the appliance. After confirming normal operation, explain what was serviced to the

customer and the operating principles, if necessary.

The information in this manual was compiled by Rinnai 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 is

constantly working toward supplying improved appliances as well as information, and specifications

may be subject to alteration at any time.

REU-2532W Series 3 Rinnai

Table of Contents

Glossary of Terms and Symbols .............................................................................................................. 4

1. Introduction .................................................................................................................................. 5

2. Features......................................................................................................................................... 6

3. Dimensions .................................................................................................................................... 8

4. Installation .................................................................................................................................... 9

5. Remote Controls......................................................................................................................... 10

6. Safety Devices ............................................................................................................................. 12

7. Specification................................................................................................................................ 14

8. Cut-away Diagram ............................................................................................................... ..... 16

9. Schematic Diagram .................................................................................................................... 17

10. Combustion Specifications ........................................................................................................ 18

11. Dip Switch Positions................................................................................................................... 19

12. Water Flows ................................................................................................................................ 22

13. Main Components ...................................................................................................................... 24

14. Time Charts ................................................................................................................................ 26

15. Operation Flow Principle .......................................................................................................... 28

16. Operation Principles .................................................................................................................. 30

17. Error Messages........................................................................................................................... 32

18. Diagnostic Points ........................................................................................................................ 34

19. Wiring Diagram ......................................................................................................................... 35

20. Fault Diagnosis ........................................................................................................................... 36

21. Electrical Component Analysis ................................................................................................. 37

22. Gas Conversion........................................................................................................................... 47

23. Gas Pressure Setting Procedure................................................................................................ 52

24. Dismantling for Service ............................................................................................................. 54

25. Exploded Diagram ..................................................................................................................... 60

26. Parts List ..................................................................................................................................... 64

27. Troubleshooting Sheets .............................................................................................................. 69

REU-2532W Series 4 Rinnai

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) - sound pressure level in decibels, “A” range

DC - direct current

AC - alternating current

WFCD - water flow control device

FB - feedback information

Hz. - hertz

IC - integrated circuit

BTU/H - British thermal units

PSI - Pounds per square inch

LED - light emitting diode

GPM - gallons per minute

mA - milliamps

W.C. - inches of water column

mm - millimeters

Nox - oxides of nitrogen NO & NO

2

OHS - overheat switch

PCB - printed circuit board

CPU - central processing unit

POT - potentiometer

rpm - revolutions per minute

SV - solenoid valve

∅∅

∅ - diameter

∆∆

∆

°°

°F - delta T or temperature rise above ambient

POV - modulating valve

TE - thermal efficiency

TH - thermistor

T

IN -

temperature of incoming water

T

out

- temperature of outgoing water

REU-2532W Series 5 Rinnai

1. Introduction

The brand name Continuum refers to “Endless Hot Water”. The new Continuum series has been

developed in response to the growing changes in the lifestyle of our customers, and the increasing

diversification and sophistication of demand in the marketplace.

The Continuum series offers reduced cost with advanced safety features, and an option to connect one,

two, or three remote temperature control pads to the residential units. The commercial units only allow

one keypad per heater.

The Continuum REU-2532 series is delivered with the maximum hot water temperature output set at

120 °F without the remote control. When using controllers you can adjust your hot water output from 96

– 120 °F using the “BC” and “BSC” controllers. The “MC” control will allow water temperature

adjustments from 96 – 140 °F, and the “MCC” control used only with the commercial unit, allows

adjustments from 96 - 180°F. .

About the Continuum

The front cover of each appliance in the new series is formed from 0.6 mm coated steel. Secured to the

main box assembly by (4) screws. Seals around the front cover prevent water from entering the

appliance.

Air inlets are situated in the front panel of the 2532 external unit. Air passes through the inlets and is

drawn into the combustion chamber at the left side of the fan housing. The by-products of combustion

on the external unit are expelled from the appliance through the flue outlet situated on the front of the

appliance, at the top. The general layout of components can be seen in the cut-away diagram, see table

of contents for page number. All components are suppported within the unit’s casing, which is made

from 0.8 mm coated steel.

The heat exchanger occupies the top section of the casing, and the burner is situated in a chamber

formed from 0.8 mm aluminized steel, attached to the bottom of the heat exchanger. The copper tubing

material used in the heat exchanger consist of, Phosphorus Dioxide Copper, (C1220P). The material

used to solder the heat exchanger pipes is, Phosphorus Bronze Brazing, (main components are P, Ag,

and Cu) (JIS No. BcuP-2). None of these materials contain lead.

The air for combustion is supplied by a fan, which is connected to the burner box by a duct at the left

side of the appliance, directly under the burner.

Gas and water controls are situated at the bottom right of the appliance, directly under the manifold. The

“O”ring material on the water and gas connections are made from EPDM, (Ethylene Propylene Diene)

rubber.

The burner assembly is made up of (16) identical stainless steel Bunsen burners, secured by an

aluminized steel framework. Each burner is capable of handling up to 11,250 BTU’s. An aluminum

manifold with (32) integrally molded injectors supplies gas to the burners, and is attached to the front

lower cover of the burner box.

REU-2532W Series 6 Rinnai

2. Features

Installation

The lightweight, slim, compact design enables ease of installation and improved appearance. The remote

controls (where fitted) are connected to the appliance by (2) core non-polar cable, or low voltage

thermostat wire, ensuring easy wiring and eliminating problems of mis-connections. Since the remotes

use a 12 VDC digital signal, there’s no-way you can cross up the wiring. You can connect the black

wires to black wires at one terminal, black and white at another, and still not short the units out.

Low Noise Level

Low noise level design enables these appliances to be installed in apartment units, 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 automatically prevents the water inside the appliance from freezing by using small electrical

ceramic heaters, connected to the pipe-work at strategic locations throughout the appliance. The unit has

a secondary freeze prevention device that will allow the unit to fire for three seconds if the water

temperature inside the appliance drops below 37 °F. This mode will heat the water inside the unit back

up to 57 °F. The anti-frost devices should prevent the unit from freeze-ups down to the –30 °F, in a no

wind situation. This feature functions as long as the unit has power and gas.

Economy

Direct ignition to the main burner eliminates wasteful pilot gas consumption. The combustion fan rpm is

proportionally controlled with the gas consumption. This maintains high energy efficiency, as the gas

consumption changes with increased or decreased water flows. The unit’s thermal efficiency rating is;

0.85 for (LP) units and 0.79 for natural gas units.

Water Supply Control

The water supply capacity varies proportionally from 0.5 to 8.5 GPM’s. A suitable volume of hot water

can be supplied throughout all seasons by the water flow control device and water flow

servomechanism. The Continuum 2532 series will supply up to 6.5 GPM’s at a 50°F rise or up to 8.5

GPM’s at a 35 degree rise, controlled by an automatic electro-mechanical water control flow device.

Details pertaining to water flows can be found in the water flow charts in this manual.

REU-2532W Series 7 Rinnai

Water Temperature Control

With an “MC” remote control connected, the hot water control range at the key pad is 96 – 140 °F. The

“BC” and “BSC” key pads allow for adjustments between 96 – 120 °F. The “MCC” key pad allows the

commercial unit to be adjusted from 96 – 180 ° F. This allows the Continuum to be set to comply with

various State codes pertaining to maximum water temperatures allowed for homes, child care centers,

elderly care centers, etc. where the water temperature can not exceed a certain set point.

Over Temperature Control

All Continuum models incorporate a device to prevent the hot water temperature from exceeding the

pre-set temperature by more than 4 °F.

Temperature Locks

With the remote control(s) connected, the pre-set water temperature can only be altered between 96 –

110 °F while water is flowing. Also, if the remote control circuit fails while water is flowing, the unit

defaults back to 100 °F. That prevents inadvertently increasing the temperature to a hazardous level

while someone is in the shower. This is an Anti-Scald feature.

REU-2532W Series 8 Rinnai

3. Dimensions

REU-2532W Series 9 Rinnai

4. Installation

Piping recommendation.

REU-2532W Series 10 Rinnai

5. Remote Controls

The MC45-4US, BC45-4US, BSC45-4US , and the MCC45-4US remote key pads were specifically designed

for use with the Continuum water heaters.

Features include:

 Color coordination to allow immediate recognition of the temperature “hot” and “cold” buttons.

 Large LED display. Temperature adjustments in two degree increments from 96 – 110 °F, then two five

degree increments from 110 – 115 °F , and 115 °F - 120 °F , on the BC, BSC and MC controllers.

 The “MC” controller has two additional ten degree increments, from 120 to 130, and 130 to 140 °F.

 The BC, BSC and MC controls are for domestic use. The MCC control allows the temperature to be adjusted

from 96°F - 180°F , this control is used only for commercial units.

 Water temperature adjustment only in the range of 96 – 110 °F while hot water is flowing. Anti-Scald feature

defaults unit back to 100 °F, if remote fails or becomes disconnected while water is flowing.

 Enhanced communication system between the remote controls, allowing priority temperature selection from

each remote control.

 Remote controls offer self-diagnostics in the event of a fault with the unit, simplifying service calls. To

retrive the last ten error codes press and hold the green button down, while holding this button down press the

red button. This will gi ve you a fault code history. To reset, turn the power supply off to the unit , then

reapply power.

 Flashes “LC” in the event of a liming condition. To reset the “LC” mode, power must be turned off to the

unit and then reapplied.



To measure the flow rate through the unit using the remote control, press the red button and hold it

down while the unit is operational, while holding the red button down press the green button. This

will give you the gallons per minute flowing through the heater.

 To measure the water heater’s output water temperature press the blue button and hold it

down while the unit is operational, while holding the blue button down press the green button. This

will give you the water temperature being delivered by the unit.

REU-2532W Series 11 Rinnai

6. Suggested Connection Methods for Remotes

There must be at least one cable from the remote control(s) connected to the Continuum water heater.

Power for the remote(s) is supplied from the PC board. On the front of the PCB, there are two screws

labeled terminals for controls. This is the 12VDC digital power supply for the remotes. Use low voltage

thermostat wire when wiring up the keypads.

REU-2532W Series 12 Rinnai

7. Safety Devices

Flame Failure

Situated to the right of the burner in the front of the combustion chamber, the flame rod monitors the

combustion process. This sensor monitors the flame intensity, while the PCB compares this signal to the

feed back signal from the combustion fan motor, water flow control, and gas flow through the POV

valve. If any one of the feedback signals are incorrect, the unit will shut off, preventing discharge of

gas to the burner.

Over Heat Protection Device

Also referred to as an Over Heat Switch. This device is fitted to a bend section at the left side of the heat

exchanger. If the flame remains on to the burner after the tap is closed and the water temperature inside

the heat exchanger reaches 194 ° F, a 12 volt DC bi-metal cut-off switch will shut off the gas supply to

the solenoids.

No Water

Should the incoming water flow become restricted or stop, the water flow sensor will cease to send a

magnetic pulse signal to the PCB, in turn preventing gas to flow into the combustion chamber. If you

have restricted flow, first check to ensure the inline water filter is not clogged up.

Thermal Fuse

Wrapped around the entire surface of the heat exchanger you will find a thermal fuse. This device

activates in the event the heat exchanger burns out, or the temperature outside the heat exchanger

reaches 264 °F. If the thermal fuse melts, it breaks an electronic circuit which in turn shuts off the

power supply to the gas solenoids, shutting the unit off.

Combustion Fan Revolution Check

The combustion fan rpm’s are continually monitored by a magnetic pulse generator 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 adjust accordingly. (If not the unit shuts down)

Automatic Frost Protection

When the temperature inside the appliance drops below 37 °F , the frost sensing device inside the

appliance activates the anti-frost heaters to prevent the water inside the unit from freezing. The anti-

frost heaters remain ON until the temperature inside the appliance rises to 57 °F. There are five (16) watt

anti-frost heaters located at various points throughout the main water flow area of the appliance. The

unit also incorporates the ability to fire for (3) seconds in the event the anti-frost heaters can not keep

the water temperature from dropping below 37 °F. This unique feature will heat the water in the lines

inside the appliance back up to 57 °F. Both of the above features function as long as the unit has

power and gas. There is an optional freeze protection system that can be added to the unit’s piping. See

the auto drain down drawing in the product Owner’s manual for instructions on how to install the option

freeze protection in the event of a power failure in cold climates.

REU-2532W Series 13 Rinnai

5 °F 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 reaches 5 °F 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.

REU-2532W Series 14 Rinnai

8. SPECIFICATIONS

Type of appliance Temperature controlled continuous flow gas hot water system

Operation With/without remote controls

Exhaust system Direct Vent - Forced combustion

Rinnai model number REU-2532W REU-2532W-C

Maximum/Minimum gas rate (Input

Btu’s)

199,000 Btu’s – 15,000 Btu’s Natural gas

199,000 Btu’s – 15,000 Btu’s Propane Gas

Thermal Efficiency Natural Gas 84%. Propane Gas 85%

Energy Factor (EF) Natural Gas 0.82 Propane Gas 0.84

Capacity (Gallons 1

st

. Hour @ 90 ºF

rise)

Natural Gas 218 Propane Gas 227

NOx Emissions (at 3% 0

2

) Less than 40 ppm

Hot water capacity (35°F rise)

0.5 to 8.5 GPM’s

Hot water capacity (50°F rise)

0.5 to 6.5 GPM’s

Setpoint Temperature (without

remote)

Factory setting - 120°F

Temperature range with remote

keypads connected

BC-45-4US 96 - 120°F

BSC-45-4US 96 - 120°F

MC-45-4US 96 - 140°F

MCC-45-4US 96 - 180°F

Approved gas type Natural or Propane – Ensure unit matches supply gas type.

Installation Outdoor installation ONLY

Dimensions Height 23

5

/8

”

Width 13

3

/

4

”

Depth 8

7

/8

”

Weight 46 Lbs.

Noise levels 49 dB’s

Connections Gas supply ¾” MNPT

Cold water inlet ¾” MNPT

Hot water outlet ¾” MNPT

Ignition system Direct electronic ignition

Electrical consumption Normal 63 watts

Standby 5.5 watts

Anti-frost protection 84 watts

Water temperature control Simulation feedforward and feedback

Water flow control Water flow sensor and automatic electro-mechanical water

control devise

Recommended Minimum water

supply pressure

20 PSI (Rinnai recommends 50-80 PSI for maximum

performance)

Maximum water supply pressure 150 PSI

REU-2532W Series 15 Rinnai

Specifications cont.

Power Supply Appliance – 120 Volts A.C. – 60 Hz.

Remote control 12 volt D.C. (Digital)

Flame failure

Boiling protection

Remaining flame (OHS)

Fusible link

Automatic frost protection

Combustion fan rpm check

Safety Devises

Over current

Remote control BC–45-4US

BSC-45-4US

MC-45-4US

MCC-45-4US

Remote control cable Non-polarized two core cable

Top of heater

Front of heater

Sides of heater

Back of heater

Clearances from combustibles

Ground

Top of heater

Front of heater

Sides of heater

Back of heater

Bottom of heater

Clearances from non combustibles

Installations within RGB-25 Recess Box: Clearances

from combustibles to recess box top, bottom, back and

sides = 0”

Clearances from Eaves, Porches,

Overhangs

Top of heater 36”

Minimum and maximum gas supply

pressure

Natural Gas: Minimum 6” W.C.

(NAT.) Maximum 10.5”

W.C.

Manifold Gas Pressure

Warranty

REU-2532W Series 16 Rinnai

9. Cut-way Diagram

REU-2532-FFU Series

REU-2532W Series 17 Rinnai

10. Schematic Diagram

REU-2532W Series

REU-2532W Series 18 Rinnai

11. Combustion Specifications

Model: REU-2532W Series

Item

Gas Type Natural Propane

Minimum Btu’s 15,000 15,000 Gas consumption

Maximum Btu’s 199,000 199,000

Upper Ø1.15

Ø0.75

Injector Diameter

Lower

Ø1.8 Ø1.15

Main Burner B3A7-1

(Lean and Rich Bunsen Burner)

Main Damper H73-115

(Upper: Ø6, Lower: Not Used)

Minimum Supply 6” W.C. 10” W.C.

Maximum Supply 10.5” W.C. 13.5” W.C.

Minimum Manifold 0.56” W.C. 0.88” W.C.

Gas Pressure

Supply/Manifold

Maximum Manifold 3.4” W.C. 5.1” W.C.

REU-2532W Series 19 Rinnai

12. DIP SWITCHES

Contact Rinnai for dip switch settings when changing PC board or setting up unit for special applications. Failure to set dip

switches to the proper position will result in damage to the unit, property damage, personal injury or death. DO NOT,

adjust dip switches unless you have written permission from Rinnai. Call 1(800)621-9419 to set-up a special training class

pertaining to dip switch functions.

The dip switches on this appliance can be adjusted to deliver water temperatures from 108°F - 180°F, only for commercial

type applications, and to check/reset low/high fire manifold pressures, and to set the unit up to operate on a different gas

type in the event the unit was converted from one gas type to another. In residential applications these switches should

never be readjusted from the factory setting. The factory default temperature setting is 120°F.

The set-up configuration for the water heater differs depending on:

Gas type

Maximum water flow selected

Temperature limiting requirements

Application type

“SW1” row of dip switches

1. Not Used

2. Fixed water temperature with or without remote.

3. To select a desired water temperature for commercial applications

4. To select a desired water temperature for commercial applications

5. To select a desired water temperature for commercial applications

6. Flow switch activated or de-activated and temperature selection for commercial applications.

7. Combustion control (Forced low fire).

8. Combustion control (Forced high fire).

Combustion control switches are used to set or check the manifold gas pressures on this appliance. When dip

switch #7 is placed in the “ON” position, it places the appliance into forced low fire. When dip switches #7 and

#8 are placed in the “ON” position, it places the unit into forced high fire. Before placing the unit into forced

low or high fire, you MUST ensure you have maximum water flow through the appliance. Open several

faucets throughout the residence before proceeding. After checking or setting manifold gas pressures, dip

switches 7 and 8 MUST be placed in the “OFF” position, to return the appliance to a normal operating

mode. Failure to place these switches to the “OFF” position will cause the unit to mal-function.

The REU-2532 series water heaters comes from the factory set to deliver a water temperature of 120 °F, the REU-2532-C

series is set to deliver 120°F. However, the commercial series will allow water temperature adjustments up to 180°F for

applications such as; hotels, car washes, laundry mats, hospitals, farms, processing plants, etc., that require water

temperatures above 120°F. Temperatures above 120 °F are not recommended due to burn hazards. Please use extreme

caution if adjusting water temperatures above 120 °F.

Explanation of “SW1” Dip Switches;

(Switch #1) at SW1” row of switches comes from the factory in the “OFF” position. This switch presently is not used.

(Switch #2) Fixed Water Temperature with or without Remote. When this switch is set to the “OFF” position, switches

3 – 6 can be adjusted to a pre-determined position that will not allow the remote pad to be adjusted above a selected

temperature. When set to the “ON” position and no keypad is being used, the unit can be set to deliver a set temperature

from 108, 120, 130, etc. DO NOT make adjustments without written permission from Rinnai.

REU-2532W Series 20 Rinnai

(Switches 3,4, & 5) Temperature Adjustment Switches. Switches #3, 4, and 5 are used to set fixed temperatures with or

without the remote keypads. Contact Rinnai for dip switch settings when changing the unit’s PC board or setting up special

applications. Failure to set dip switches to the proper position will result in damage to the unit, property damage,

personal injury or death. DO NOT, adjust switches unless you have written permission directly from Rinnai. Call

1(800)621-9419 to set-up a special training class pertaining to dip switch functions.

(Switch #6) Flow Switch and Temperature Adjustments. Rinnai offers a flow switch that can serve as an anti-scald

device. This switch is installed in-line with each bathroom. Therefore, if someone was using water above 120°F and a tap

was turned on in one of the bathrooms, the unit would automatically default back to 120°F to prevent scalding. When dip

switch #6 is set to the “ON” position this function is activated. At the present time this switch is not used in the U.S.

market, due to anti-scald devices and/or pressure balancing valves presently being used in our market.

(Switches 7& 8) Low/High Fire Combustion Control Switches. Dip switch # 7 is used to place the unit into forced low

fire when checking and/or setting manifold gas pressures. Dip switch #7 and #8 are used to place the appliance into forced

high fire. Before making any adjustments to these switches, please ensure you follow the gas pressure setting procedure

found in this manual.

“SW2” row of Dip Switches

1. Gas type (Used only when replacing PCB or converting unit)

2. Lime control switch activated or de-activated.

3. Plus three degrees or plus six degrees differential.

4. Type of unit. (Residential or commercial)

(SW2) Explanation of SW2 row of Dip Switches

(Switch #1) Gas Type Switch. When set to the “OFF” position the unit is setup to operate on propane gas, in the “ON”

position it is setup for natural gas.

(Switch #2) Lime Control Switch. Set dip switch #2 to the “OFF” position to activate the lime control function. To

deactivate this function place this switch in the “ON” position.

(#3) Temperature Differential Switch. The temperature of the outgoing water is constantly monitored by the outlet

temperature thermistor. If the outlet water temperature rises to more than 5.4°F above the preset temperature, the burner

will automatically go out when dip switch #3 is in the “OFF” position. The burner will ignite again once the outlet water

temperature falls below the preset temperature. If this switch is set to the “ON” position it will allow a 10.8 °F rise.

(Switch #4) Type of Unit. Danger; do not adjust this dip switch. Adjusting this will result in damage to the unit,

property damage, personal injury or death.

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