Installation & Servicing
Instructions
High efficiency condensing gas boiler
E75CN/E110CN
E75CP/E110CP
CAUTION!
Read this manual thoroughly before installing, servicing, putting
into operation or using this boiler and vent system.
WARNING!
Improper installation, adjustment, alteration, service or
maintenance can cause property damage, personal injury or
loss of life. Refer to this manual. For assistance or additional
information consult a qualified installer or the gas supplier.
CAUTION!
The user manual is part of the documentation that is delivered
to the installation's operator. Go through the information in this
manual with the owner/operator and make sure that he or she is
familair with all necessary operating instructions.
NOTICE!
Installation and service must be performed by a qualified
installer, service technician or the gas supplier.
In the Commonwealth of Massachusetts this boiler must be
installed by a licensed Plumber or Gas Fitter.
Pictured: E75CN, E110CN
E75CP, E110CP
WARNING!
If you do not follow these instructions exactly, a fire or explosion may
result causing property damage, personal injury or loss of life.
- Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
- WHAT TO DO IF YOU SMELL GAS
- Do NOT try to light any appliance.
- Do NOT touch any electrical switch.
- Do NOT use any phone in your building.
- Immediately call your gas supplier from a neighbor’s phone.
Follow the gas supplier’s instructions.
- If you cannot reach your gas supplier, call the fire department.
Address: 103 International Drive, Peachtree City, GA, 30269
Toll-free: 1-800-621-9419 • Fax: 678-829-1666 • www.rinnai.us
These instructions to be retained by user.
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Content
1
Safety and general instructions
4
4
4
4
5
6
6
6
6
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
Designated use
Hazard definitions
Symbol definitions
The following instructions must be followed
Follow these instructions for the space heating water
Tools, materials and additional equipment
Relevant Installation, Service and User manuals
Disposal
2
3
4
Regulations and guidelines
Description of the boiler
Packaging and transportation
7
8
9
4.1
4.2
Scope of delivery
Transportation
9
9
5
Installation
10
10
11
12
14
15
16
17
17
18
19
20
20
21
21
22
23
24
24
25
25
26
28
29
31
32
33
34
37
40
41
42
42
43
44
46
46
49
49
50
51
51
52
53
54
55
55
56
56
56
58
60
61
62
86
92
102
103
104
5.1
Requirements for the installation room
5.2
Fitting the boiler
5.3
Dimensions
5.3.1
5.3.2
5.4
Plumbing kits
Clearances from appliance
Technical specifications
6
Connecting the boiler
6.1
Central heating system
6.1.1
6.1.2
6.1.3
6.2
Plumbing Kit installation
Safety valve
Low water cut off
Expansion tank
6.3
6.4
Underfloor heating system (plastic pipes)
Gas supply connection
6.4.1. Gas connection with natural gas
6.4.2
6.5
Gas connection with propane gas
Hot water supply
6.6
Condensate drain pipe
6.7
Vent system and air supply system
Intake / Exhaust Guidelines
Examples vent and air supply systems
Installation of the vent system
Recommended vent/air intake terminal position
Dimensioning of the exhaust and air intake duct
Combustion air and vent piping lengths
Calculation of compensation factor
Room Air System (outdoor combustion air)
6.7.1
6.7.2
6.7.3
6.7.4
6.7.5
6.7.6
6.7.7
6.7.8
7
8
Electrical connections
Boiler controls
8.1
Explanation of the function buttons
9
Starting up: Filling and de-aerating the boiler and installation
9.1
9.2
9.3
Requirements of the water system
Filling the heating system
Hot water supply
10 Adjustments
10.1
10.2
Altering adjustments
Activating factory settings (green button function)
11 Isolating the boiler
12 Commissioning
12.1
12.2
12.3
12.4
12.5
12.6
12.7
Testing for gas leaks
Testing the Ignition Safety shut off device
Checking for contamination
Checking of the zero pressure control
Checking the O2
Measuring the ionization current
Installing the casing
13 Maintenance
13.1
13.2
13.2
13.3
Periodic examination of venting and boiler
Inspection
Maintenance activities
Warranty
14 Parts of the boiler
15 Blocks and errors
16 Other errors
17 Spare parts
18 Parts list vent system
19 Common venting guidelines
Appendix A Outdoor Reset Sensor Data
3
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1
Safety and general instructions
Please observe these instructions in the interest of your own safety.
1.1 Designated use
The boiler is designed for heating water for a central heating system and generating
domestichotwater.Theboilerisdeliveredwitha burnercontroller(MCBA)pre-installed.
The boiler can be fitted with a modulating outdoor reset sensor ARV12 (included with
the boiler) or an On/Off thermostat or relay panel end switch (accessories).
1.2 Hazard definitions
The following defined terms are used throughout the documentation to bring attention
to the presence of hazards of various risk levels. Notices give important information
concerning the operation of the product.
DANGER:
DANGER
Indicates the presence of hazards that will cause severe personal injury, death or
substantial property damage.
!
WARNING:
Indicates the presence of hazards that can cause severe personal injury, death or
substantial property damage.
WARNING
!
CAUTION:
CAUTION
Indicates presence of hazards that will or can cause minor personal injury or property
damage.
!
CAUTION:
CAUTION
Risk of electric shock. Indicates presence of hazards due to electric shock.
NOTICE:
Indicates special instructions on installation, operation or maintenance that are
important but not related to personal injury or property damage.
NOTICE
i
1.3 Symbol definitions
The following (safety) symbols may be encountered in these installation instructions
and on the unit:
This symbol indicates that the unit must be stored away from frost.
This symbol indicates that the packaging and/or contents can be damaged as
a result of insufficient care taken during transport.
This symbol indicates that, whilst still in its packaging, the unit must be
protected from weather conditions during transport and storage.
4
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1.4 The following instructions must be followed
-
The boiler must only be used for its designated purpose, as described in the
Installation Instructions.
-
Eachunitisfittedwithadataplate. Consultthedetailsonthisplatetoverifywhether
the boiler is compliant with its intended location, e.g.: gas type, power source and
venting classification.
-
-
Only use the boiler with the accessories and spare parts listed.
Other combinations, accessories and consumables must only be used if they are
specifically designed for the intended application and do not affect the system
performance and the safety requirements.
-
-
Maintenance and repairs must only performed by trained professionals.
Installation of a condensing gas boiler must be reported to the relevant gas utility
company and have it approved.
-
-
You are only allowed to operate the condensing gas boiler with the vent system
that has been specifically designed and approved for this type of boiler.
Please note that local permission for the vent system and the condensate water
connection to the public sewer system may be required.
You must also respect:
-
-
The local building codes stipulating the installation rules.
The local building codes concerning the air intake and outlet systems and the
chimney connection.
-
-
The regulations for the power supply connection.
The technical rules laid down by the gas utility company concerning the connection
of the gas connection to the local gas mains.
-
The instructions and standards concerning the safety equipment for the water/
space heating system.
-
-
The Installation Instructions for building heating systems.
The boiler must be located in an area where leakage of the boiler or connections
will not result in damage to the area adjacent to the boiler or to lower floors of
the structure. When such locations cannot be avoided, it is recommended that a
suitable drain pan be installed under the boiler.
-
The boiler must be installed in such way that the all components are protected
from water (dripping, spraying, rain etc.) during boiler operation and service.
The boiler must not be installed on or against carpeting.
Do not restrict or seal any air intake or outlet openings.
If you find any defects, you must inform the owner of the system of the defect and
the associated hazard in writing.
-
-
-
DANGER. Gas is flammable and may cause an explosion.
Beware if you smell gas: there may be an explosion hazard!
DANGER
!
If the information in these instructions is not followed exactly, a fire or explosion may
result causing property damage, personal injury or death.
-
Do not store or use gasoline or other flammable vapors and liquids in the vicinity
of this or any other appliance.
WARNING
WHAT TO DO IF YOU SMELL GAS
!
-
-
-
-
Do NOT try to light any appliance.
Do NOT touch any electrical switch.
Do NOT use any phone in your building.
Immediately call your gas supplier from a neighbor’s phone. Follow the gas
supplier’s instructions.
-
If you cannot reach your gas supllier, call the fire department.
Should overheating occur or the gas supply fail to shut off, do not turn off
or disconnect the electrical supply to the pump. Instead, shut off the gas
supply at a location external to the appliance.
5
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1.5 Follow these instructions for the space heating water
Unsuitable heating system water can cause the formation of scale or sludge, which
affects system efficiency. It can also cause corrosion and reduce life of the heat
exchanger.
– You must follow Rinnai guidelines for boiler water quality.
– Thoroughly flush the system prior to filling.
– Follow the Rinnai cleaning instructions.
– Never use water that has been treated by salt bedding exchangers, reverse
osmosis, D.I., or distilled water to soften the water to fill the heating system.
– Do not use inhibitors or other additives unless approved by Rinnai for that
purpose!
– When frost protection of the heating system is desired, only use Rinnai-approved
antifreezes, Noble Noburst Aluminum, or Rhomar RhoGard Aluminum Safe Multi-
Metal.
– When using oxygen-permeable pipes, e. g. for under floor heating systems, you
must separate the system from the boiler using plate heat exchangers.
– Valve off boiler while flushing system, do not introduce any system cleaner into the
boiler loop. Flush system thoroughly to remove all system cleaner before filling
boiler.
See the Rinnai Boiler Applications Manual and chapter 10 for additional information.
1.6 Tools, materials and additional equipment
For the installation and maintenance of the boiler you will need:
–
Standard tools for space heating, gas and water fitting
–
Digital manometer, capable of reading both positive and negative pressure
(accuracy -0.001” W.C.)
–
–
–
–
–
Combustion analyzer (intended for use with condensing boilers)
Digital multimeter
pH digital meter
Metric Allen wrenches
Metric socket wrenches
In addition, a handtruck with a fastening belt is useful.
For maintenance to the boiler you need, apart from standard tooling for space heating,
gas and water fitting the following items:
-
Rinnai toolkit Q and E-Series
1.7 Relevant Installation, Service and User manuals
– Vent system
– Rinnai Boiler Applications Manual
1.8 Disposal
– Dispose of the boiler packaging in an environmentally sound manner.
– Dispose of components of the heating system (e.g. boiler or control device), that
must be replaced in an environmentally responsible manner.
6
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2
Regulations and guidelines
The installation must comply to the requirements of the authority having jurisdiction
or, in the absence of such requirements, to the latest edition of the National Fuel Gas
Code, ANSI Z223.1/NFPA 54. In Canada, installation must be in accordance with the
requirements of CAN/CSA B149.1, Natural Gas and Propane Installation Code.
Where required by the authority having jurisdiction, the installation must comply to
the Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/
ASME CSD-1.
Install CO detectors per local regulations. Boiler requires an inspection every 2 years
and maintenance every 4 years or 4000 hours. See maintenance section chapter 14.
Operating Limits of the boiler:
Max. boiler temperature: 176 °F (80.0 °C)
Max. operating pressure: 45 psi (3 bar)
Max Allowable Working Temperature ASME: 200 °F (93 °C)
Max. Allowable Working Pressure ASME: 45 psi (3 bar)
The hot water distribution system must comply with all applicable codes and
regulations. When replacing an existing boiler, it is important to check the condition
of the entire hot water distribution system to ensure safe operation.
For installations in the Commonwealth of Massachusetts, the following local
requirements apply in addition to all other applicable NFPA requirements:
For direct- vent boilers, mechanical-vent heating appliances or domestic hot water
equipment, where the bottom of the vent terminal and the intake is installed below
four feet above grade the following requirements must comply:
NOTICE
i
1) If not present on each floor level where there are bedrooms, a carbon monoxide
detector and alarm must be placed in a living area outside the bedrooms. The
carbon monoxide detector and alarm must comply with NFPA 720 (2005 Edition).
2) A carbon Monoxide detector and alarm shall be located in the room that houses
the appliance and/or equipment and shall:
a) Be powered by the same electrical circuit as the appliance and/or equipment
such that only one service switch services both the appliance and the carbon
monoxide detector;
b) Have battery back-up power;
c) Meet ANSI/UL 2034 Standards and comply with NFPA 720 (2005 Edition); and
d) Have been approved and listed by a Nationally Recognized Testing Lab as
recognized under 527 CMR.
3) A product-approved vent terminal must be used, and if applicable, a product
approvedairintakemustbeused.Installationshallbeperformedinstrictcompliance
with the manufacturer’s instructions. A copy of the installation instructions shall
remain with the appliance and/or equipment at the completion of the installation.
4) Ametal or plastic identification plate shall be mounted at the exterior of the building,
four feet directly above the location of vent terminal. The plate shall be of sufficient
size to be easily read from a distance of eight feet away, and read “Gas Vent
Directly Below”.
7
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For direct-vent boilers mechanical-vent heating boilers or domestic hot water
equipment where the bottom of the vent terminal and the intake is installed higher
than four feet above grade the following requirements must comply:
1) If not present on each floor level where there are bedrooms, a carbon monoxide
detector and alarm must be placed in a living area outside the bedrooms. The
carbon monoxide detector and alarm must comply with NFPA 720 (2005 Edition).
2) A carbon monoxide detector shall:
a) Be located inn the room where the boiler and/or equipment is located;
b) Be either hard-wired or battery powered or both; and:
c) Shall comply with NFPA 720 (2005 Edition).
3) A product-approved vent terminal must be used, and if applicable, a product-
approved air intake must be used. Installation shall be in strict compliance with
the manufacturer’s instructions. A copy of the installation instructions shall remain
with the appliance and/or equipment at the completion of the installation.
3
Description of the boiler
Room sealed boiler
The boiler retreives its com-
bustion air from outside then
discharges the flue gasses to
the outside.
The Rinnai E boiler is a room sealed, condensing and modulating central heating
boiler, with an integrated DHW fascility.
The boiler is provided with a compact stainless steel heat exchanger with smooth
tubes. This design is a well thought out principle using durable materials.
The boiler burns gas for supplying heat. The heat is transferred in the heat exchanger
to the water in the central heating system. By cooling down the exhaust gases
condensate is formed. This results in high efficiency. The condensate, which has
no effect on the heat exchanger and the function of the boiler, is drained through
condensate collector trap.
Condensing
Retrieves heat as much as
possible from the flue gas-
ses. Water condensates on
the heat exchanger.
The boiler is provided with an intelligent control system (CMS Control Management
System). The boiler anticipates the heat demand of the central heating system or the
domestic hot water facility system.
Modulating
Stepless higher or lower
burning according to the heat
demand.
When an outdoor sensor is connected to the boiler it will operate weather dependantly
using outdoor reset. This means that the boiler control measures the outside
temperature and supply temperature. With this data the boiler calculates the optimal
supply temperature for the installation.
Explanation of the appliance type:
E = Type
Rinnai E110CN
110 = Nominal load in (x1000) BTU
C = C = Combi
N = Natural Gas (P = Propane Gas)
Different boilertypes:
Combi boiler with integrated DHW fascility
E75CN
E75CP
E110CN
E110CP
8
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4
Packaging and transportation
4.1 Scope of delivery
The boiler is supplied ready for use.
•
•
Please check if the packaging is intact.
Check if all the items listed are included in the delivery.
The supply kit is contents:
Boiler with casing;
•
•
•
•
•
•
•
•
Template;
Automatic air separator (inside the boiler); • Installation instructions;
Wall mounting suspension bracket;
Bronze adapter fittings;
3" PP exhaust adapters (x2);
Plumbing kit
•
•
•
•
User manual;
Service manual;
Outdoor sensor ARV12
3/4" gas shut off valve
Fixing material consisting of plugs and screws;
4.2 Transportation
CAUTION
The boiler may be damaged when not secured properly.
!
-
-
Only transport the boiler using appropriate transportation equipment, such as a
handtruck with a fastening belt or special equipment for maneuvering steps.
When shipping the boiler must be secured on the transportation equipment to
prevent it from falling off.
-
-
Protect all parts against impacts if they are to be transported.
Follow the transportation markings on the packaging.
•
Packaged boilers must always be lifted and carried by two people, or you must
use a handtruck or special equipment for transport.
9
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5
Installation
5.1 Requirements for the installation room
-
-
The room where the boiler will be installed must always be frost free.
Do not store or use gasoline or other flammable vapors and liquids in the
vicinity of this or any other appliance.
DANGER
!
-
-
-
Never use or store any chlorinated detergents or halogenated hydrocarbons
(e.g. in spraycans, solvents and detergents, paints, adhesives) in proximity
of the boiler.
The boiler must be installed in such a way that it is protected from water
(dripping, spraying, rain, etc.) during boiler operation and service (circulator
replacement, condensate trap, control replacement, etc.)
This boiler is for intended for indoor installations only.
Products to avoid present in boiler room
and/or around combustion air intake
Spray cans containing chloro-/fluorcarbons
Ammonium and/or ammonium solutions
Permanent wave solutions
Chlorinated waxes and/or cleaners
Swimming pool chemicals based on chlorine
Calcium chloride used for thawing
Sodium chloride used for water softening
Refrigerant leaks
Paint or varnish removers
Hydrochloric acid/muriatic acid
Cements and glues
Antistatic fabric softeners used in clothes dryers
Chlorine-type bleaches, detergents, and cleaning solvents
found in household laundry rooms
Adhesives used to fasten building products and
other similar products
Areas likely to have contaminants
Dry cleaning/laundry areas and establishments
Swimming pools
Metal fabrication plants
Beauty shops
Refrigeration repair shops
Photo processing plants
Auto body shops
Plastic manufacturing plants
Furniture refinishing areas and establishments
New building construction
Remodeling areas
Garages with workshops
10
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5.2 Fitting the boiler
-
Remove the packaging materials.
-
Lay the boiler on its back during unpacking. Remove the casing from the
boiler. This part can be left apart during installation. It must be placed on the
boiler and fixed with the screw behind the door and in the 4 quick releases
before the boiler is started up.
NOTICE
i
Turn the boiler to its side and remove the wall bracket from the back of the
boiler by removing the 2 screws.
NOTICE
i
The boiler can be mounted practically to any wall with the suspension bracket and the
enclosed mounting equipment.
-
The wall must be flat and of sufficient strength in order to be able to securely hold
and support the boiler weight with its water content.
-
Take note of the necessary space around the boiler for installation of venting
system, pipework and servicing. See drawing on pages 12 to 15.
The location of the boiler can be determined by using the template supplied with the
boiler documentation. Remember to account for the spacing of the plumbing kit.
-
-
Drill the necessary holes using the template
Install the mounting bracket to the wall using the supplied mounting materials
CAUTION
Lifting and carrying precautions:
To avoid personal injury please follow these recommendations:
!
-
-
Always lift the boiler with 2 people or use special equipment.
When lifting the boiler, bend the knees, and keep the back straight and feet
apart.
-
-
-
Do not lift and twist at the same time.
Lift and carry the boiler close to the body.
Wear protective clothing and gloves to protect from any sharp edges.
Lift the boiler only by the boiler's rear wall.
Dispose the packaging materials.
WARNING
!
-
11
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5.3 Dimensions
ceiling
D
G
C
F
E
V
2"
50
0.4"
10
B
A
Q
R
S
J
T
P
H
U
N
K
L
dimensions
figure 1
Boiler type
Combi
E75CN
E110CN
E75CP
inches / mm
25.6" / 650
E110CP
inches / mm
25.6" / 650
34.3" / 870
19.7" / 500
15.6" / 395
13.2" / 335
4.7" / 120
10.6" / 270
9.8" / 250
5.9" / 150
13.8" / 350
15.9" / 405
11.2" / 285
8.5" / 215
8.5" / 215
1.6" / 40
A
B
C
D
E
F
G
H
J
Height
Height with expansion tank
Width
Depth
Left side / vent
Center to center / vent and air supply
Back / vent
19.7" / 500
15.6" / 395
13.2" / 335
4.7" / 120
10.6" / 270
9.8" / 250
5.9" / 150
13.8" / 350
15.9" / 405
11.2" / 285
8.5" / 215
0.7" / 19
Left side / gas pipe
Left side / supply pipe
K
L
Left side / return pipe
Left side / condensate pipe
Left side / cold water pipe
Left side / hot water pipe
Pipe length of g*
N
P
Q
R
S
T
Pipe length of c*
1.6" / 40
Pipe length of f, r, k and w*
Back / Center of pipe c, k and w*
Back / Center of pipe f, g and r*
Pipe length vent co-axial
Pipe length vent parallel
2" / 50
1" / 26
6.3" / 160
1" / 26
U
2" / 50
2" / 50
3.7" / 95
3.7" / 95
V
7" / 177
7" / 177
dimensions
table 1
12
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Connection for combustion air supply and vent system
f
w g k
r
c
f
w g k
r
c
boiler connections / mounting points
figure 2
Boiler type
Combi
E75CN
E75CP
E110CN
E110CP
Vent system / Combustion air supply
Gas pipe - g
80/125mm
80/125mm
3/4"M-NPT
0.87" x 3/4"M-NPT /
22mm
0.87" x 3/4"M-NPT /
22mm
0.87" / 22mm
0.59" x 3/4"M-NPT /
15mm
3/4"M-NPT
G3/4"x
3/4"M-NPT
G3/4"x
3/4"M-NPT
0.87" / 22mm
G1/2"x
3/4"M-NPT
G1/2"x
Supply pipe - f
Return pipe - r
Condensate pipe - c
Cold water pipe - k
0.59" x 3/4"M-NPT /
15mm
Hot water pipe - w
3/4"M-NPT
connection diameters
table 2
13
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5.3.1
Plumbing Kits
Rinnai supplies with each type of boiler a Plumbing kit. Find below the dimensions.
See chapter 6.1 for additional information.
(REF. 16.07)
(REF. 5.12)
200mm
Plumbing Kit 1
Suitable for:
7.87
E75CN / E75CP
E110CN / E110CP
1 1/4”
1 1/4”
plumbing kit 1
figure 3
14
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5.3.2
Clearances from boiler
ceiling
Min. 10" /
250mm
2"
50
0.4"
10
15.7"
400
24"
600
service clearances to the boiler
figure 4
Minimum required clearances
Minimum required clearances
Recommended
to combustibles
All types
inch / mm
2" / 50
to non-combustibles
service clearances
All types
inch / mm
10" / 250
0
All types
inch / mm
2" / 50
0"
Top of boiler
Back of boiler
0"
Front of boiler
Left side of boiler
Right side of boiler
Floor / Ground
6" / 150
2" / 50
2" / 50
12" / 300
0"
6" / 150
2" / 50
2" / 50
12" / 300
0"
24" / 600
2" / 50
2" / 50
30" / 762
0"
Vent
clearances to the boiler
table 3
For closet installation: clearance is 1” / 25mm from the front.
Low Loss Header
Clearances to combustible and non-Combustible is 0 inch for sides, top, front and floor/ground
15
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5.4 Technical specifications
E-Series
Natural gas
E75CN E110CN
Propane gas
Boiler type
E75CP
E110CP
Input Hs CH
BTU/hr
kW
75,000
22
110,000
32
75,000
22
110,000
32
Propane orifice diameter
Display indication at start-up
Qn Output non-condensing CH
inch / mm
n.a.
22.t
n.a.
32.t
0.16" / 4.15
22.tP
0.20" / 5.2
32.tP
BTU/hr
kW
67,500
98,000
67,500
98,000
19.8
74,100
21.7
28.8
108,000
31.7
19.8
74,100
21.7
28.8
108,000
31.7
Qn Output EN677 efficiency CH
Qn Output AFUE CH
BTU/hr
kW
BTU/hr
kW
72,400
21.2
105,700
30.7
72,400
21.2
105,700
30.7
Efficiency at 98.6/86°F (36/30°C) part load,
Hs, EN677 CH
AFUE according IBR
%
%
98.8
96.5
99.0
96.1
98.8
96.5
99.0
96.1
O2 (at full load)
%
4.4 - 4.7
4.8 - 5.1
Electr. power consumption max.
Electr. power consumption stand by
Current
W
W
V/Hz
A
145
14
120Vac/60Hz
5AF & 4AT
Fuse rating
Degree of protection acc. EN 60529
Weight (empty)
Water content CH
IPX4D (IPX0D in case of room air)
lbs / kg
gallon / liter
gallon / liter
min
91 / 39
0.9 / 3.5
0.13 / 0.5
101 / 40
1.3 / 5
0.18 / 0.7
91 / 39
0.9 / 3.5
0.13 / 0.5
101 / 40
1.3 / 5
0.18 / 0.7
Water content DHW
After run time pump CH
After run time pump DHW
PMS Water pressure min.-max.
5
1
min
PSI / bar
14-43 / 1-3
150 / 10
PMW Water pressure DHW max.
PSI / bar
°F / °C
Flow temperature max.
Pump type
Available pump height CH
Approvals
176 / 80
UPS20-48
3.8 / 26
UPS20-58
0.7 / 5
UPS20-48
3.8 / 26
UPS20-58
0.7 / 5
PSI / kPa
ASME, CSA
DHW flow (at 50°F)
DHW flow (at 10°C)
DHW flow (at 75°F)
DHW flow (at 23.9°C)
DHW temperature (Tin=50°F (10°C)
gallon/min
liter/min
gallon/min
liter/min
°F / °C
4.6
17.4
3.2
4.6
17.4
3.2
2.1
7.9
2.1
7.9
12.1
12.1
176 / 80
Pressure difference DHW
Content expansion vessel
Pre-charge pressure expansion vessel
PSI / bar
gallon / liter
PSI / bar
2.9 / 0.2
2.1 / 8
4.4
3.1 / 12
2.9 / 0.2
2.1 / 8
4.4
3.1 / 12
14.5 / 1
CSA number
2183087
Technical specifications
Table 4
16
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6
Connecting the boiler
The boiler has the following connection pipes;
-
-
-
-
The central heating circuit pipes.
These must connected to the plumbing kit by means of adapter fittings.
See further chapter 6.1;
The gas supply pipe.
It is provided with a 3/4" male thread into which the tail piece of the gas valve can
be screwed. See further chapter 6.4;
Cold and hot water pipes for domestic hot water (DHW).
These consist of 3/4" (15 mm) copper pipe and can be connected to the installation
by means of 1/2" M-NPT adapter fittings. See further chapter 6.5;
The condensation drain pipe.
It consists of an oval 1" (22 mm) plastic pipe. The drain pipe can be connected to
this by means of an open connection. If the open connection is fitted in a different
location, then the pipe can be lengthened by means of a 1 1/4" (32 mm) PVC
sleeve. See further chapter 6.6;
-
The vent system and air supply system.
Itconsistsofaconcentricconnection3"/5"(80/125mm). Theboilercanbeconverted
to a twin pipe connection that will accept 80mm flue and intake air or with the use
of the included adapters 3” PVC/CPVC flue and intake. See further chapter 6.7.
The pipe to be connected to the boiler must be cleaned before connecting in
order to prevent dirt from entering and damaging the boiler.
NOTICE
i
6.1 Central heating system
Connect the central heating system according to its instructions.
The boiler pipes can be connected to the installation by means of compression fittings.
Reducers should be used for connecting to thick-walled pipe (welded or threaded).
When removing the plastic sealing caps from the pipes, dirty testing water
may drain from the boiler.
NOTICE
i
A Plumbing Kit must be fitted to the boiler.
NOTICE
i
The boiler, when used in connection with a refrigeration system, must
be installed so the chilled medium is piped in parallel with the boiler with
appropriate valves to prevent the chilled medium from entering the boiler.
NOTICE
i
The boiler piping system of a hot water boiler connected to heating coils
located in air handling units where they may be exposed to refrigerated air
circulation must be equipped with flow control valves or other automatic
means to prevent gravity circulation of the boiler water during the cooling
cycle.
NOTICE
i
17
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6.1.1
Plumbing Kit installation
Rinnai supplies specific Plumbing Kits with each boiler type, which must be fitted
directly underneath the boiler on the supply and return pipe. Use of the Rinnai boiler
without the plumbing kit will result in the void of warranty.
NOTICE
i
To protect the entire heating system we recommend installing a dirt particle
trap in the return circuit. When the boiler is installed to an existing heating
system this trap is required. Use of a Y strainer is not permitted as substitute
for a dirt trap.
-
-
Install shut-off valves immediately before and after the dirt particle filter to allow
the filter to be cleaned.
Position 3 (figure 6) is a garden house thread boiler drain, that can be used to
drain the boiler or add water tratment additives to the system, such as inhibitors
or glycol.
NOTICE
i
-
-
Position 4 (figure 6) is the supply connectionfor an idirect tank when used with the
optinal 3-way valve kit.
For information on locating the expansion tank and system fill, please see the
Rinnai Boiler Applications Manual.
Thoroughly flush all pipes and radiators. We recommend the use of a Rinnai
approved system cleaner. Refer to the Rinnai Boiler Applications Manual for
an approved list of Rinnai system cleaners.
-
Refer to the installation template and chapter 5.3 for the pipe connection
dimensions.
-
Fit the bronze adapter fittings, supplied with the boiler (fig. 5, pos. 4) first to the
Plumbing Kit and then to the boiler.
-
-
Connect the expansion tank to the system. See chapter 6.2.
Connect the pipes so that they are free from strain.
Compression fittings.
Parts:
1. Nut
2. Ferrule
3. Fitting
4
1
2
Fitting instructions:
1. Plumbing kit
2. Safety valve
3. Filling connection
4. Bronze adapter fittings
5. Service valves
6. Flow 1 1/4"
1. Push the complete
fitting over the pipe as
far as possible. Ferrule
should be over the
pipe completely.
1
2
5
3
7. Return 1 1/4"
8. External pump
2. Turn the nut handtight
clockwise.
6
7
3
3. Use 2 wrenches, one
to hold the fitting on
its place, the other
for tighten the nut
clockwise in 3/4 turn.
8
Plumbing Kit installation
fig. 5
18
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The boiler has a self-adjusting and self-protecting control system for the load and the
pump capacity. By this means the temperature difference between the supply and return
water is checked and controlled.
If the installation resistance is over the stated value; the load will be adjusted until
an acceptable temperature difference between supply and return water has been
obtained. If, after this, the temperature difference is still not acceptable then the boiler
will switch off and wait until an acceptable temperature has arisen.
If an unacceptable temperature is detected, the control will repeatedly try to achieve
water flow over the boiler. If not the boiler will switch off.
The electrical side of an external circulation pump (fig. 6, pos. 8) can be connected
to the Control Tower. This pump thus switches simultaneously to the boiler pump.
The maximum absorbed current consumption of the external circulation pump may
not exceed 120V, 2 Amp. If a pump with a larger current draw is required an isolation
relay must be used. See the Rinnai BoilerApplications Manual for further information.
The extra external pump must be selected according the installation resistance and
required flow.
As standard the boiler is provided with a water filter in the return pipe of the boiler, so
that debris of the central heating water is prevented from affecting the boiler.
NOTICE
i
When using more than one boiler in an installation please refer to the cascade
installation instructions.
NOTICE
i
The boiler is designed to be used on pressurized heating systems only.
32.3
14
27.7
23.0
18.5
13.8
9.2
12
10
8
6
4
2
4.6
0
0
0
2
4
6
8
10
12
Q [gallons/min]
UPS 20-48
25%
UPS 20-58
100%
Resistance E75C
Resistance E110C
pump index lines
graph 1
19
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6.1.2
NOTICE
6.1.3
Safety valve
An ASME 30 psi pressure relief valve is installed on the plumbing kit included
with the boiler.
i
Low water cut off
The Rinnai E boiler has a factory installed pressure switch type Low Water Cut
Off (LWCO). Check your local codes to see if a Low Water Cut Off is required
(LWCO) and if this device conforms to local code. See the Rinnai Boiler
Applications Manual for further information.
NOTICE
i
The Low water cut off is not serviceable.
6.2
Expansion tank
The E-Series boilers are equiped with an internal expansion tank.
The tank of the E75CN and E75CP is positioned inside the boiler casing. This
expansion tank has a pre-charge pressure of 14.5 PSI / 1 Bar and a capacity of 2.1
gallon / 8 litres.
The tank of the E110CN and E110CP is positioned directly beneath the boiler and
together with the casing forms a single entity with the boiler.
The casing can be removed by pulling forwards. The expansion tank has a pre-charge
pressure of 14.5 PSI / 1 Bar and a capacity of 3.1 gallon / 12 litres.
If a larger capacity expansion tank is needed for the installation a standard expansion
vessel should be fitted additionally.
In that case choose an expansion tank volume, of which the summary is geared to
the installation’s water capacity. The pre-charge pressure depends on the installation
height above the expansion tank. Fit the expansion tank into the return pipe as close
as possible to the boiler. The extra expansion tank should be sourced locally. Please
refer to the expansion tank manufacturer for further information.
NOTICE
i
Fill the expansion tank to a minimum of 14.5 psi.
20
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6.3
Underfloor heating system (plastic pipes)
Whenusingoxygen-permeablepipes, e. g. forunderfloorheatingsystems, thesystem
must be separated using plate heat exchangers.
No recourse can be made to the terms of the warranty in the event of failure
to regard the regulations pertaining to plastic underfloor heating pipes.
NOTICE
i
6.4
Gas supply connection
Only work on gas lines if you are licensed for such work.
If these instructions are not followed exactly, a fire or explosion may result
causing property damage, personal injury or death.
DANGER
!
Rinnai wall mounted boilers are built to run on Natural Gas or Propane Gas.
The gas type the boiler is suitable for is indicated on the packaging and on
the boiler by a blue label with Natural Gas or a green label with Propane Gas
and on the identification plate on the boiler.
WARNING
!
First check the identification plate on the boiler for the suitable gas type.
Do not use the boiler for another type of gas than indicated on the
identification plate of the boiler. This will cause improper functioning and can
damage the boiler.
DANGER
!
Natural gas:
Propane gas:
resume with chapter 6.4.1
resume with chapter 6.4.2
21
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6.4.1.
Gas connection with natural gas
The gas supply connection must comply with local regulations or, if such
regulations do not exist, with the National Fuel Gas Code, ANSI Z 223.1.
For Canada, the gas connection must comply with local regulations or, if
such regulations do not exist, with the CAN/CSA B149.1, Natural Gas and
Propane Installation Code.
NOTICE
i
Pipe sizing for natural gas
Contact gas supplier to size the gas supply line and meter.
Gas piping
A sediment trap must be installed upstream of the gas controls.
The boiler gas pipe is equiped with external 3/4" M-NPT thread, onto which the tail
piece of the gas shut off valve can be connected. Use appropiate sealing.
The connection to the boiler must include a suitable method of disconnection and a gas
control valve must be installed adjacent to the boiler for isolation purposes. The nominal
inlet gas pressure measured at the boiler should be 7" W.C. (18 mbar) for Natural gas
(Gas A). Maximum pressure with no flow (lockup) or with the boiler running is 10.5
inches W.C. Minimum pressure with the gas flowing (verify during boiler startup) is
5.0 inches W.C.
The gas pipe must be fitted to the gas valve free from any strain.
Sediment trap
figure 7
NOTICE
i
Make sure that the gas pipe system does not contain dirt, particularly with
new pipes.
DANGER
Always check the safety of the gas pipe system by means of a bubble test
using leak-search spray.
!
The boiler and its individual shut off valve must be disconnected from the
gas supply piping system during any pressure testing of that system at test
pressures in excess of 1/2 PSI (3.5kPa).
NOTICE
i
The boiler must be isolated from the gas supply piping system by closing its
individual manual shutoff valve during any pressure testing of the gas supply
piping system at test pressures equal to or less than 1/2 PSI (3.5 kPa).
NOTICE
i
22
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6.4.2
Gas connection with propane gas
The gas supply connection must comply with local regulations or, if such
regulations do not exist, with the National Fuel Gas Code, ANSI Z 223.1.
For Canada, the gas connection must comply with local regulations or, if
such regulations do not exist, with the CAN/CSA B149.1, Natural Gas and
Propane Installation Code.
NOTICE
i
Pipe sizing for propane gas
-
Contact gas supplier to size pipes, tanks, and 100% lockup gas pressure
regulator.
Propane Supply Pressure Requirements
-
Adjust propane supply regulator provided by the gas supplier for 14 inches W.C.
maximum pressure.
-
Pressure required at gas valve inlet pressure port:
- Maximum 14 inches W.C. with no flow (lockup) or with boiler running.
- Minimum 8 inches W.C. with gas flowing (verify during boiler startup).
Ensure that the high gas pressure regulator is installed at least 6 to 10 feet
upstream of the boiler.
DANGER
!
Gas piping
-
-
Use a gas shut off valve compatible with propane gases.
A sediment trap must be provide upstream of the gas controls.
The boiler pipe is equiped with external 3/4" M-NPT thread, onto which the tail piece
of the gas shut off valve can be screwed. Use appropriate sealing.
The connection to the boiler must include a suitable method of disconnection.
A gas control valve must be installed adjacent to the boiler for isolation purposes. The
nominal inlet working gas pressure measured at the boiler should be 12 inch W.C.
(30mbar) for Propane gas (Gas E).
The gas pipe must be fitted to the gas valve free from any strain.
Gas shut off valve onto boiler
figure 7
Make sure that the gas pipe system does not contain dirt, particularly with
new pipes.
NOTICE
i
Always check the safety of the gas pipe system by means of a bubble test
using leak-search spray.
DANGER
!
The boiler and its individual shut off valve must be disconnected from the
gas supply piping system during any pressure testing of that system at test
pressures in excess of 1/2 PSI (3.5kPa).
NOTICE
i
The boiler must be isolated from the gas supply piping system by closing its
individual manual shutoff valve during any pressure testing of the gas supply
piping system at test pressures equal to or less than 1/2 PSI (3.5 kPa).
NOTICE
i
23
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6.5
Hot water supply
Connection of the drinking water installation should be performed according to the
national secondary drinking water regulations.
Do NOT use toxic chemicals, such as are used for boiler treatment in potable
water heating systems used for space heating.
DANGER
!
The sanitary water pipes can be connected to the installation by use of adapter
fittings. The cold water inlet on the Combi boilers must be equiped with the following
components (counted in the water flow direction):
Flow regulator valve (supplied), Safety group, Expansion vessel 87 PSI / 6bar (potable
water, blue).
The 3/4" NPT adapter fitting with flow reducing valve must be fitted in the cold water
connection.
A flow regulator valve is supplied with the boiler in a 3/4"NPT adapter fitting. The
flow regulator valve ensures that a quantity of water is supplied which has a outlet
temperature of 120°F (assuming a cold water temperature of 45°F). The quantity of
water is virtually unaffected by the water pressure.
When there is a water pressure lower than 22PSI / 1.5 bar it is advisable to
remove the inside mechanism of the flow reducing valve.
NOTICE
i
6.6 Condensate drain pipe
This boiler produces condensate. Condensate must be drained otherwise the boiler
will not function and can cause property damage.
The condensation drain pipe should be connected to a drain in the building by means
of an open connection. By this means the possibility of drain gases effecting the boiler
is prevented. The drain connection should have a minimum diameter of 1.3" / 32mm.
Install the condensation drain pipe according to the applicable rules and
regulations.
If the condensate outlet of the boiler is lower than the public sewage system a
condensate pump must be used.
The condensate produced by the boiler has a pH value between 3 and 4.
Install a neutralization unit if required by the local code. It is recommended, but not
required to install a condensate neutralizer.
Do not drain the condensation water to the external rain gutter because of
the danger of freezing and blockage of the drain.
NOTICE
i
Before putting the boiler into operation fill the condensate trap with 1.27
cups / 300 ml of water. If the boiler will be installed in a high temperature
installation such as baseboard, then fill the condensate trap with mineral oil
instead of water.
NOTICE
i
Use materials approved by the authority having jurisdiction. In absence of such
authority, PVC and CPVC pipe must comply with ASTM D1785, F441 or D2665.
Cement and primer must comply with ASTM D2564 or F493.
NOTICE
i
For Canada, use CSA or ULC certified PVC or CPVC pipe, fittings and cement.
Periodic cleaning of the condensate disposal system must be carried out. See
the Rinnai Boiler Application Manual for further information and for a piping
NOTICE
i
diagram for the condensate.
24
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6.7 Vent system and air supply system
Provisionsforcombustionandventilationairmustbemadeinaccordancewithsection,
Air for Combustion and Ventilation of the National Flue Gas Code, ANSI Z223.1,
or Sections 7.2, 7.3 of 7.4 of CAN/CGA B149.1, Installation Codes, or applicable
provisions of the local building codes.
-
Do not store chemicals near the boiler or in rooms where the air is being supplied
to the boiler. See the list on page 10.
-
-
Do not allow the flue gases of other appliances to enter the boiler.
Keep cabinet free of moisture
In the event that the system has actuated to shut off the main burner gas,
do not attempt to place the boiler in operation. Contact a qualified service
agency.
NOTICE
i
6.7.1
Intake / Exhaust Guidelines
Refer to the specific instructions on your vent product for additional installation
requirements.
•
•
•
•
You must use vent components that are certified and listed with this model.
Do not combine vent components from different manufacturers.
Venting should be as direct as possible with a minimum number of pipe fittings.
Avoid dips or sags in horizontal vent runs by installing supports per the vent
manufacturer’s instructions.
•
Support horizontal vent runs every four feet and all vertical vent runs every six
feet or in accordance with local codes.
•
•
•
•
•
Vent diameter must not be reduced.
The boiler is unsuitable to install on a common vent installation, see also chapter 19.
Do not connect the venting system with an existing vent or chimney.
Do not common vent with the vent pipe of any other water heater or appliance.
Vent connections must be firmly pressed together so that the gaskets form an air
tight seal.
•
•
Refer to the instructions of the vent system manufacturer for component assembly
instructions.
If the vent system is to be enclosed, it is suggested that the design of the enclosure
shall permit inspection of the vent system. The design of such enclosure shall be
deemed acceptable by the installer or the local inspector.
If it becomes necessary to access an enclosed vent system for service or
repairs, Rinnai is not responsible for any costs or difficulties in accessing
the vent system. Warranty does not cover obtaining access to an enclosed
vent system.
NOTICE
i
25
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6.7.2a
Examples vent and air supply systems (concentric)
Wall thickness for vent termination installation:
Examples wall terminals
Minimum:
Maximum:
100mm / 4”
508mm / 20”
Short termination with wall terminal
Termination with wall terminal on higher level
figure 9A
figure 9B
Examples roof terminals
Short termination with roof terminal
figure 10A
Termination with roof terminal and bends
figure 10B
26
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6.7.2b
Examples vent and air supply systems (parallel)
Wall thickness for vent termination installation:
Examples sealed combustions
Minimum:
Maximum:
100mm / 4”
508mm / 20”
Horizontal with parallel termination
figure 11B
Horizontal with concentric termination
figure 11A
10" MINIMUM INSIDE EDGE
T`O INSIDE EDGE
12" OVER
MAXIMUM
SNOW LEVEL
OR 24"
WHICHEVER IS
GREATER
Vertical vent and horizontal air intake
figure 11C
Vertical with concentric termination
figure 11D
Vertical with parallel termination
figure 11E
27
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6.7.3
Installation of the vent system
Consult local and state codes pertaining to special building code and fire department
requirements. Adhere to national code requirements.
NOTICE
i
Follow the listed maximum length of vent systems, which are boiler output dependent.
The maximum permissible lengths are listed in table 9, chapter 6.7.6.
NOTICE
i
Decide how to install the exhaust and air intake system. You can choose between:
-
Concentric system (see page 26)
The concentric connection is provided standard initially.
The boiler concentric connection diameter is 3"/5" (80/125 mm), to which the venting and air
supply system can be fitted, with or without elbow pieces. The maximum permissible pipe length
is displayed in table 9, chapter 6.7.6.
-
Parallel system (see page 27)
The boiler can be converted to a parallel system with supplied adapters.
It is possible to use a parallel pipe connection of 2x 3". In this case a seperate supplied kit, with
2 vent adapters 3" (ø80mm), cover 5" (ø125mm), vent exhaust pipe and gaskets should be
fitted instead of the concentric vent adapter on top of the boiler. See figure 12 for installation.
The maximum permissible pipe length is set out in table 9, chapter 6.7.6.
-
Room Air System (outdoor combustion air)
The boiler can use room air for combustion. If this option is selected the boiler must first be
converted to the Parallel system. A single exhaust pipe can then be fitted. It is required to use
a room air filter when using indoor air for combustion. The maximum permissible pipe length
is set out in table 9, chapter 6.7.6.
We advise to install a vent system out of the venting system program supplied by
Rinnai (See chapter 19 Parts list Vent system). For further information about the
available components of the venting and air supply system we recommend you
consult Rinnai and the Installation instructions and parts list documentation.
NOTICE
i
A
B
C
D
10
9
7
6
8
4
2
3
5
1
boiler conversion from concentric to parallel
figure 12
A. 1. Push the 2 clips slightly outwards
B. 2. Pull the concentric adaptor out of the boiler
3. Press the cover in the connection at the back from inside out
C. 4. Push the 3" adapter into the connection at the back of the boiler (= air intake)
5. Pull the rubber seal around the bottom of the exhaust connector
6. Push the exhaust connector in the boiler, in the boiler exhaust pipe until 'CLICK'
7. Push the 5" cover over the exhaust connector in the 5" opening until 'CLICK'
8. Push the rubber plug in open position in the O2 measuring opening and close the stop.
9. Push the gasket around the top of the exhaust connector
10. Push the 3" exhaust adaptor in the exhaust connector.
D. Connect the parallel vent system.
28
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6.7.4
Recommended vent/air intake terminal position
Terminals should be positioned as to avoid products of combustion entering openings into buildings or other vents.
Maintain 12” of clearance
above the highest
anticipated snow level
or grade or, whichever is
greater. Please refer to
your local codes for the
snow level in your area.
Terminal positions
figure 14
Ref
A
Description
Canadian Installations - Direct Vent
US Installations Direct Vent
US Installations
non Direct Vent
and non Direct Vent
Clearance above grade, veranda, porch,
deck, or balcony
12 inches (30 cm)
12 inches (30 cm)
12 inches (30 cm)
B
Clearance to window or door that may
be opened
6 inches (15 cm) for appliances < 10,000 6 inches (15 cm) for appliances < 10,000 4 feet (1.2 m) below or to
Btuh (3 kW), 12 inches (30 cm) for ap-
pliances > 10,000 Btuh (3 kW) and <
Btuh (3 kW), 9 inches (30 cm) for ap- side of opening; 1 foot (300
pliances > 10,000 Btuh (3 kW) and <
mm) above opening
100,000 Btuh (30 kW), 36 inches (91 cm) 50,000 Btuh (30 kW), 12 inches (91 cm)
for appliances > 100,000 Btuh (30 kW)
for appliances > 50,000 Btuh (30 kW)
C
D
Clearance to permanently closed window
*
*
*
*
*
*
Vertical clearance to ventilated sof-
fit, located above the terminal within a
horizontal distance of 2 feet (61 cm) from
the center line of the terminal
E
F
Clearance to unventilated soffit
Clearance to outside corner
Clearance to inside corner
*
*
*
*
*
*
*
*
*
*
*
G
H
Clearance to each side of center line ex- 3 feet (91 cm) within a height 15 feet (4.5
tended above meter/regulator assembly
Clearance to service regulator vent outlet
Clearance to nonmechanical air supply
inlet to building or the combustion air inlet Btuh (3 kW), 12 inches (30 cm) for ap-
to any other appliance
m) above the meter/regulator assembly
I
36 inches (91 cm)
*
*
J
6 inches (15 cm) for appliances < 10,000 6 inches (15 cm) for appliances < 10,000 4 feet (1.2 m) below or to
Btuh (3 kW), 9 inches (30 cm) for ap- side of opening; 1 foot (300
pliances > 10,000 Btuh (3 kW) and < mm) above opening
100,000 Btuh (30 kW), 36 inches (91 cm) 50,000 Btuh (30 kW), 12 inches (91 cm)
pliances > 10,000 Btuh (3 kW) and <
for appliances > 100,000 Btuh (30 kW)
for appliances > 50,000 Btuh (30 kW)
K
L
Clearance to a mechanical air supply
inlet
6 feet (1.83 m)
3 feet (91 cm) above if within 10 feet (3 3 feet (91 cm) above if wit-
m) horizontally
*
hin 10 feet (3 m) horizontally
7 feet (2.13 m)
Clearance above paved sidewalk or
paved driveway located on public
property
7 feet (2.13 m) [1]
M
Clearance under veranda, porch, deck,
or balcony
12 inches (30 cm) [2]
*
*
[1] A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves
both dwellings.
[2] Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor.
* For clearances not specified in ANSI Z223.1/NFPA 54 or CSA B149.1, clearances are in accordance with local installation codes and the
requirements of the gas supplier.
clearances of venting system terminals
table 6
29
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6.7.4
Recommended vent/air intake terminal position
Terminals should be positioned as to avoid products of combustion entering
openings into buildings or other vents.
NOTICE
i
Maintain 12” of clearance above the highest anticipated snow level or grade
or, whichever is greater. Please refer to your local codes for the snow level in
your area.
CAUTION
!
The termination shall be at least 4 feet (1,220 mm) for the US and 6 feet (1,830
mm) for Canada distance from electric meters, gas meters, regulators and
relief equipment. (for room air application only)
CAUTION
!
Horizontal vent systems should always be installed sloping towards the
boiler (min. 21 mm/m, 1/4 “/ feet), in order to avoid condensate retaining in
the vent system. With the condensate running back to the boiler the risk of
ice forming at the terminal is reduced.
NOTICE
i
The whole route of the vent system must be installed upwards, never
downwards, completely nor partly.
NOTICE
i
Place pipe supports every 4 feet (1219 mm) of horizontal run, beginning with
the support near the boiler to prevent movement in fittings and allow boiler
to be free from any strain or weight on boiler or fittings.
NOTICE
i
The terminal should be located where dispersal of combustion products is
not impeded and with due regard for the damage or discolouration that might
occur to building products in the vicinity (see fig 14 and 15).
NOTICE
i
Approval Codes for Installation
Item Description
Plastic Vent and/or air
pipes and fittings
Flue Material
PVC Schedule 40 ANSI/ASTM D1785
PVC - DWV ANSI/ASTM D2665
CPVC Schedule 40 ANSI/ASTM F441
United States
PVC
CPVC
ANSI/ASTM D2564
ANSI/ASTM F493
Plastic Pipe cement and
primer
Item Description
Flue Material
Manufacturer
US/CAN
Flue system
Stainless steel vent
systems
Plastic Vent and/or air
pipes and fittings
concentric Saf-T Vent SC
twin pipe Saf-T Vent EZ Seal
Rolux Condensing
AL29-4C
PPS
Heat Fab
Ubbink
UL1738
Vent System
Approval codes for installation of venting system
table 7
Fittings or Piping Equivalent
feet
m
45 degree elbow
90 degree elbow
plastic pipe per foot
concentric vent kit
3
6
1
3
0.91
1.83
0.30
0.91
12" (300 mm)
12" (300 mm)
minimum
minimum
EXHAUST
Equivalent friction loss of PVC/CPVC
table 8
INTAKE
12" (300 mm)
minimum
12" (300 mm)
minimum
12" (300 mm)
minimum
Terminal positions PVC
figure 15
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In certain weather conditions condensation may also accumulate on the
outside of the air inlet pipe. Such conditions must be considered and where
necessary insulation of the inlet pipe may be required.
In cold and/or humid weather water vapor may condense on leaving the vent
terminal. The effect of such ‘water condensation’ must be considered.
NOTICE
i
The terminal must be located in a place not likely to cause a nuisance.
Use the Instructions of the Rinnai venting system for installation and service.
Cellular or Foam core PVC is not permitted for use with the boiler.
6.7.5
Dimensioning of the exhaust and air intake duct
The wall mounted boiler must be vented and supplied with combustion and
ventilation air as described in this section.
Ensure the vent and air piping and the combustion air supply comply with
these instructions regarding vent system, air system, and combustion air
quality.
DANGER
!
Inspect finished vent and air piping thoroughly to ensure all are airtight and
comply with the instructions provided and with all requirements of applicable
codes.
WARNING
!
Failure to provide a properly installed vent and air system may cause severe
personal injury or death.
NOTICE
i
Use only the material listed in Rinnai's vent documentation for vent pipe, and
fittings. Failure to comply could result in severe personal injury, death or
substantial property damage.
WARNING
!
Installation must comply with local requirements and with the National Fuel
Gas Code, ANSI Z223.1 for U.S installations or CSA B 149.1 for Canadian
installations.
NOTICE
i
For closet and alcove installation, CPVC material (instead of PVC) must be
used in a closet/alcove structure. Failure to follow this warning could result
in fire, personal injury, or death.
NOTICE
i
All vent pipes must be connected and properly supported, and the exhaust
must be pitched a minimum of a 1/4” inch per foot back to the boiler (to allow
drainage of condensate). Please refer to the venting manufacturer's manual
to see if a larger pitch is required for specific venting sytems.
For the Room Air System, combustion air piping from the outside MUST BE
used. Use of combustion air from indoor rooms using louvers, plenums, or
any other devices is not authorized.
See the Rinnai Boiler Applications Manual for further information on venting.
31
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6.7.6 Combustion air and vent piping lengths.
In the table below you find the maximum equivalent pipe length of the vent/air system
based on 3" diameter. These lengths are for single pipe (room air), twin pipe, and
concentric venting systems.
Boiler type
E75
E110
3” Max Vent equivalent length
3” Max Air equivalent length
100 feet
100 feet
100 feet
100 feet
Equivalent vent length
table 9
Calculation of equivalent length vent system
Choose the vent type and fill out the corresponding table.
* When determining equivalent combustion air and vent length, add 6 feet for each
90° elbow, 3 feet for each 45° elbow, 5 feet for the concentric terminal in the Parallel
System, and 2 feet for the concentric terminal in the Concentric System .
Parallel system
Length tube
Number of
elbows 90°
x 6*
Number of
elbows 45°
x 3*
Concentric
terminal
Add 5 ft.*
Total
Multiply with
factor
Equivalent
length
Combustion air
Vent
ft
ft
ft
ft
ft
ft
ft
ft
ft
ft
0.5
0.5
ft
ft
ft
Total equivalent length
Concentric system
Length concentric
tube, boiler to roof
horizontal
Number of
elbows 90°
x 6*
Number of
elbows 45°
x 3*
Concentric
terminal
Total
Multiply with Total equivalent
factor
length
Add 2 ft.*
ft
ft
ft
ft
ft
1.0
ft
Example of calculation:
Twin tube (parallel) with terminal
Combustion air length
Vent length
: 24 ft
: 24 ft
with elbow 3 x 90°
with elbow 2 x 90°, elbow 2 x 45°
Calculation:
Equivalent Air Length
: (24+3x6+2) x 0.5
=
=
23 ft
Equivalent Vent Length
: (24+2x6+2x3+2) x 0.5
23 ft +Total
=
46 ft.
32
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6.7.7 Calculation of compensation factor
Thecompensationfactoreliminatesorreducesthenaturaleffectofderateofmaximum
input caused by the resistance of the vent system and/or the impact of the altitude.
1. Determine the Compensation Factor Vent System CF(V) in the table below.
Eq. length (ft)
Boiler type
E75 E110
CF (V)
min
0
max
10
0
0
0
1
2
3
4
0
0
2
4
6
11
21
31
41
61
81
20
30
40
60
80
100
8
10
Compensation factor vent system CP(V)
table 10
2. Determine the Compensation Factor Altitude CF(A) in the table below.
Altitude (ft)
Boiler type
E75, E110
min
0
max
1
CF (A)
0
1,000
2,000
3,000
4,000
5,000
6,000
7,000
8,000
9,000
2,000
3,000
4,000
5,000
6,000
7,000
8,000
9,000
10,000
6
12
18
24
30
36
42
48
54
Compensation factor altitude CP(A)
table 11
Any application or installation above 10,000 must be reviewed by Rinnai's
Engineering group. This is to ensure the product is installed and the overall
system is designed properly and that the units are commisioned properly.
Not involving of Rinnai's Engineering group would result in no support of the
product and no warranty.
NOTICE
i
3. Calculate the Compensation Factor Total CF(T):
CF(T) = CF(V) + CF(A)
The result is the setting for Parameter 73.
Change parameter 73 according to this result. See Chapter 10.1 how to change
parameters.
Example of calculation:
E110
Eq. lenth vent system (taken from previous example)
Altitude
WARNING
!
46 ft
CF(V) = 6
7,200ft CF(A) = 42 +
CF(T) = 48
Parameter setting (Par. 73) = 48
Do not overcompensate the boiler by setting a higher value than calculated,
otherwise the boiler could be seriously damaged.
33
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6.7.8 Room Air System (indoor combustion air)
When using indoor air, Rinnai strongly recommends the use of an indoor air
filter, P/N 808000025.
This boiler requires adequate combustion air for ventilation and dilution of flue gases.
Failure to provide adequate combustion air can result in unit failure, fire, explosion,
serious bodily injury or death. Use the following methods to ensure adequate
combustion air is available for correct and safe operation of this water heater.
Important: Combustion air must be free of corrosive chemicals. Do not provide
combustion air from corrosive environments. Appliance failure due to corrosive air is
not covered by warranty.
Combustion air must be free of acid forming chemical such as sulfur, fluorine and
chlorine. These chemicals have been found to cause rapid damage and decay and
can become toxic when used as combustion air in gas appliances. Such chemicals
can be found in, but not limited to bleach, ammonia, cat litter, aerosol sprays, cleaning
solvents, varnish, paint and air fresheners. Do not store these products or similar
products in the vicinity of this water heater.
Unconfined Space:
An unconfined space is defined in NFPA #54 "as a space whose volume is not less
than 50 cubic feet per 1000 Btu/hr (4.8 m3 per kW per hour) of the aggregate input
rating of all appliances installed in that space. Rooms communicating directly with
the space in which the appliances are installed, through openings not furnished with
doors, are considered a part of the unconfined space." If the “unconfined space”
containing the appliance(s) is in a building with tight construction, outside air may
still be required for proper operation. Outside air openings should be sized the same
as for a confined space.
25FT
36FT
25FT
36FT
NOTE: 8FT CEILING
NOTE: 8FT CEILING
Unconfined Space
Unconfined Space
200,000 BTU Boiler
91,300 BTU Boiler
Unconfined space
figure 16
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Confined Space:
(Small Room, Closet, Alcove, Utility Room, Etc.)
A confined space is defined in the NFPA #54 as "a space whose volume is less than
50 cubic feet per 1000 Btu/hr (4.8 m3 per kW per hour) of the aggregate input rating
of all appliances installed in that space."Aconfined space must have two combustion
air openings. Size the combustion air openings based on the BTU input for all gas
utilization equipment in the space and the method by which combustion air is supplied:
Using indoor air for combustion
Using outdoor air for combustion
Louvers and Grills
When sizing the permanent opening as illustrated in figure 17, consideration must be
taken for the design of the louvers or grills to maintain the required free area required
for all gas utilizing equipment in the space. If the free area of the louver or grill design
is not available, assume wood louvers will have 25% free area and metal louvers or
grills will have 75% free area. Under no circumstance should the louver, grill or screen
have openings smaller than ¼”.
Example:
Wood: 10 in x 12 in x 0.25 = 30 in2
Metal: 10 in x 12 in x 0.75 = 90 in2
Location
To maintain proper circulation of combustion air two permanent openings (one up-
per, one lower) must be positioned in confined spaces. The upper shall be within 12
inches of the confined space and the lower opening shall be within 12 inches of the
bottom of the confined space. Openings must be positioned as to never be obstructed.
Combustion air provided to the appliance should not be taken from any area of the
structure that may produce a negative pressure (i.e. exhaust fans, powered ventila-
tion fans).
Gas Vent / Boiler Exhaust
12in. MAX
BOILER
PERMANENT
OPENINGS
OUTLET AIR DUCT
12in. MAX
BOILER
12"
(300mm)
10"
INLET AIR DUCT
(250mm)
Louvers and grills
figure 17
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Using Indoor Air For Combustion
When using air from other room(s) in the building, the total volume of the room(s) must
be ofadequate volume (Greater than 50 cubic feetper 1000 Btu/hr). Each Combustion
air opening must have at least one square inch of free area for each 1000 Btuh, but
not less than 100 square inches each.
Using Outdoor Air For Combustion
Outdoor air can be provided to a confined space through two permanent openings,
one commencing within 12 in. (300mm) of the top and one commencing within 12”
(300mm) of the bottom, of the confined space. The openings shall communicate to
the outside by one of two ways:
directly through horizontal ducts
indirectly through vertical ducts
When communicating directly with the outdoors through horizontal ducts,
each opening shall have a minimum free area of 1 in2/2000 Btu/hr (1100 mm2/
kW) of total input rating of all appliances in the confined space.
Note: If ducts are used, the cross sectional area of the duct must be greater
than or equal to the required free area of the openings to which they are con-
nected.
When communicating indirectly with the outdoors through vertical ducts,
each opening shall have a minimum free area of 1 in2/4000 Btu/hr (550 mm2/
kW) of total input rating of all appliances in the confined space. Combus-
tion air to the appliance can be provided from a well ventilated attic or crawl
space.
Gas Vent / Boiler Exhaust
Gas Vent / Boiler Exhaust
OUTLET
AIR
OUTLET AIR DUCT
BOILER
BOILER
INLET
AIR
INLET AIR DUCT
Ventilation Louvers for
unheated crawl space
Gas Vent / Boiler Exhaust
OUTLET
AIR
BOILER
INLET AIR DUCT
[Ends 1Ft (300mm)
above floor]
Louvers and grills
figure 18
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7
Electrical connections
The electrical connections to the boiler must be made in accordance with all applicable
local codes and the latest revision of the National Electrical Code, ANSI/NFPA-70.
Installations should also conform with CSA C22.1 Canadian Electrical Code Part 1
if installed in Canada.
Devicessuchas,outdoorsensor,roomthermostatortemperaturecontrol,temperature
sensororthermostatandanexternalpumpareallconnectedtotheinternalconnection
terminal. The connection terminal is situated behind the Control Tower.
Connecting incoming power
Install a 120V main switch next to the boiler as service main switch of the boiler.
Lead the cable through the back part of the boiler using a strain relief and lead the
cable through the cable supports to the Control Tower.
Connect a power supply cable to the cable harness terminal strip that connects to
both the power switch on the front of the Control Tower and the terminal strip with
positions 1, 2, and 3 on the inside of the Control Tower.
The boiler must be electrically grounded in accordance with local codes, or
in absence of local codes, with the National Electrical Code, ANSI/INFPA 70
and/or the CSA C22.1, Electrical Code.
CAUTION
RISK OF ELECTRIC SHOCK.
Once the main power supply is on then there is 120V on terminals 1 to 12 if the main
switch next to the boiler is switched on.
CAUTION
-
-
No changes may be made to the wiring of the boiler;
All connections should be designed in accordance with the applicable
regulations;
NOTICE
The Rinnai room thermostat and controls must be connected to their allocated
connections. All other types or makes of room thermostats or controls which
are used must have a Volt free contact.
i
Whenusinganon/offthermostatorcontrol, itispossiblethatananticipatingresistance
must be calibrated in order to prevent too high temperature fluctuations.As a standard
rule this means mercury thermostats. This resistance wire is present in the Control
Tower and must be connected to clamps 23 and 27. The anticipating resistance in
the room thermostat has to be set at 0.11 A.
For more detailed questions regarding the components which are not supplied, the
distributor should be contacted.
Connection terminal E-Series
Room
therm.
On / Off
120 V~
120 V~
120 V~
Ext.controller
24 V~
Bus
Controller
External
safety
contact
120 V~
N
Cylinder connection
three-way valve
Outside
sensor
Power supply
External pump
DHW
100 mA
N
L
L
CH DHW
N
sensor
4
5
6
10 11
7
CAUTION
CAUTION
!
Make sure that the power consumption of each of the terminals
4-5-6, 7-8-9 and10-11 does not exceed 230W or 2 Amp.
Connection terminal
figure 19
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5
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8
Boiler controls
The boiler is provided with a fully automatic microprocessor control, called CMS
Control Management System. This control simplifies operation by undertaking all
major control functions. Initially when power to the unit is switched on it will remain on
standby. There is no indication LED on, until one of the program buttons is pressed.
The control panel display will show the relevant state. When the installation is empty
the display will show FILL.
The various parameters can be called up in two ways:
The Good-state or standard read out
The first way shows a simple display read out.
The boiler in operation will always show 'Good'. When a message is necessary this
will be shown instead of Good.
Technical read out
Thesecondwayisatechnicalreadout. Innormalsituationsthefollowingwillbeshown:
Example
Example
•
•
on the left the status in which the boiler is active;
on the right the supply temperature in °F;
Alternately indicated by:
the water pressure in the installation in PSI.
•
When a message (error or blocking code) is necessary this will be shown instead of
the technical read out.
To switch over from the Good-state to the Technical read out (and vice versa):
- Press the STEP-button for 5 seconds.
NOTICE
i
When the system has been filled the automatic de-aeration program starts, when a
program has been selected, by pressing the button for Central Heating, DHW or pump
program (
,
of
). The program takes 17 minutes and stops automatically.
After this the unit will function normally. (See also 'Filling and de-aerate the boiler and
installation, chapter 9).
On a call for heating or hot water the control system will select the required water
control temperature. This water temperature is called the T-set value. On a call for
central heating the boiler ignites first at low input. The input is then changed slowly to
match the load required. The boiler operates in this way to avoid excessive water noises
and temperature overshoot. On a call for domestic hot water supply the T-set value
of central heating return water temperature is monitored. Depending on the amount of
domestic water which is withdrawn from the DHW fascility, the central heating return
water temperature, from which the input is adjusted, will vary.
Operation indication
(in the first display position by technical read out)
No heat demand
0
Fan pre/post purge
1
Ignition phase
2
Burner active on central heating
3
Burner active on DHW
4
Fan check
5
Burner off when room thermostat is demanding
6
Pump overrun phase for central heating
7
Pump overrun phase for hot water
8
Burner off because of to high flow temperature
9
Automatic de-aeration program
A
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8.1 Explanation of the function buttons
2
1
7
6
3
4
8
5
Boiler control panel
figure 16
Only qualifiedpersonel who are trained for servicing these boilers are permitted
to make alterations in the controller to calibrate the boiler to the installation.
NOTICE
i
1. Display. See previous page for further information.
2. ON-OFF Switch (Placed separately next to the boiler)
This switch turns the power supply to the boiler on or off.
Only turn the boiler off using this switch, when the burner is off..
CAUTION
!
3. Central Heating program button.
Switching the Central Heating on or off (LED on/off);
4. Hot Water program button.
Switching the Domestig Hot Water (DHW) facility on or off (LED on/off);
5. Pump program button.
adjusts the pump to continuous water circulation in the central heating system (LED
on), or according to the pump overrun times on the relevant programs (LED off);
NOTICE
i
6
7
Mode-button.
After briefly pressing, a selection of the data chapters can be retrieved.
After pressing for 5 seconds it is possible to enter the code as described in chapter
11.3;
Step-button.
When the pump is
switched on continuously
it can lead to undesired
heating up of the central
heating system during the
summer.
After briefly pressing, the water pressure can be retrieved and pages per chapter
can be retrieved.
After pressing for 5 seconds it switches from the Good-state to technical read out
and vice versa;
8
Reset-button.
After briefly pressing, for:
- unlocking errors;
- ending the access code;
After pressing for 5 seconds an operating stop is made, for example, for activating
the automatic venting program.
Some buttons have other functions.These functions are only active when according
to the procedure described in chapter 10, adjustment has to be changed or data must
be retreived from the CMS. The other functions are:
3. Central Heating program button : + function;
4. Hot Water program button:
5. Pump program button :
- function;
store-function, which means that by means
of this button a modified setting is confirmed;
scrolling in a data chapter.
7. Step-button:
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9
Starting up: Filling and de-aerating the boiler and installation
CAUTION
Observe the following rules of safety:
CAUTION
!
-
-
All work on the unit must take place in a dry environment.
Rinnai units may never be in operation without their housing, except in connection
with maintenance or adjustments (see Chapter 12 and 13).
-
Never allow electrical or electronic components to come into contact with water.
NOTICE
NOTICE
i
Carry out the following tasks in connection with maintenance, etc. to an already-
installed unit:
-
-
-
-
Shut down all programs
Close the gas shut off valve
Shut off the power at the main power switch
Close the service valves (system supply and return)
NOTICE
Take note of the following when maintenance or adjustments are needed:
NOTICE
-
The unit must be able to function during these activities; for this reason, the unit’s
supply voltage, gas pressure and water pressure must be maintained. Ensure that
this is not a source of potential danger during these activities.
i
Following maintenance or other activities; always check the installation of all
parts through which gas flows (with bubble test using leak-search spray).
WARNING
!
9.1 Requirements of the water system
Before filling the heating system, the complete system, including all zones, must be
thoroughly cleaned and flushed to remove sediment. Flush until clean water runs free
of sediment. Rinnai suggests using an approved system cleaner to flush the system,
but not the boiler. See the Rinnai Boiler Applications Manual for furtherinformation
and for a list of approved cleaners.
ApprovedantifreezesareNobleNoburstAluminum, RhomarRhoGardAluminumSafe
Multi-Metal. Never use salt bedding exchangers, reverse osmosis, D.I., or distilled
water for filling the heating system.
Do not use petroleum-based cleaning or sealing compounds in the boiler
system. Damage of seals and gaskets in boiler and system could occur,
resulting in substantial property damage.
WARNING
!
The central heating installation needs to be filled with potable water.
Use only potable water or approved glycol for filling the heating system.
When the water hardness of the filling water exceeds > 10.5 gpg (200 mg/L)
and the volume of the installation > 20L/kW (5.2 gallons/3,412 BTU) the water
has to be treated until below the maximum value of 10.5 gpg (200 mg/L).
The pH value of the installation water must be between 6.5 and 8.5.
WARNING
!
Check the The pH value using a digital pH meter that has been properly calibrated
or by having the water analyzed by a water treatment company.
If pH differs from above, contact Rinnai engineering for further assistance.
Failure to adhere to the water quality requirements will result in a void of war-
ranty.
NOTICE
i
42
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Freeze protection
Freeze protection for new or existing systems must use glycol that is specially
formulated for this purpose. This includes inhibitors, which prevent the glycol from
attack the metallic components. This should be for multi-metallic components.
Make certain to check that the system fluid is correct for the glycol concentration and
inhibitor level. The system should be tested at least once a year and as recommended
by the producer of the glycol solution.
Use only Rinnai approved inhibitors. See the Rinnai BoilerApplications Manual
for an approved list of inhibitors.
NOTICE
i
Use only inhibited propylene glycol solutions, which are specially formulated
for central heating systems. Ethylene glycol is toxic and can attack gaskets
and seals used in the boiler and system. Approved glycols ae listed in the
Rinnai Boiler Applications Manual.
WARNING
!
Additives in the installation water are not permitted.
NOTICE
i
9.2 Filling the heating system
Forfillingortoppinguptheinstallationyouusethefillingloopaccordingtothefollowing
procedure:
1
Switch on the power supply;
2 The display will show FILL;
All functions off (heating
4 Push briefly the 'STEP'-button: P XX (XX = water pressure in PSI);
Open the filling loop (Indication on display increases);
6 Fill up slowly to 22 to 25 PSI;
STOP appears on the display;
8 Close the filling loop;
De-aerate the complete installation, start at the lowest point;
3
, DHW
and pump );
5
7
9
10 Check the water pressure and if necessary top it up;
11 Close the filling loop;
12 Activate the functions in use (heating
, DHW
and/or pump );
13 If A XX appears on the display, wait for 17 minutes;
14 Check the water pressure and if necessary top it up to 22 to 25 PSI
15 Close the filling loop;
16 Press the ‘STEP’-button;
17 Be sure that the filling loop is closed.
18 After the automatic de-aeration program (A XX) is finished the boiler will return to
the Good state or Technical read out.
Check the water pressure regularly and top off the installation when necessary.
The working pressure of the installation should be between 22 and 25 PSI when the
system is cold.
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NOTICE
It can take a while before all air has disappeared from a filled installation.
Especially in the first week noises may be heard which indicate the presence
of air. The automatic air vent in the boiler will remove this air, which means
the water pressure can reduce during this period and therefore topping off
with water will have to be done.
i
During normal use the following messages can occur with the necessary follow up:
Water pressure is too low (<10 PSI), FILL
indication remains continuously visible,
the boiler is taken out of operation. The
installation needs to be topped off.
Water pressure is too low (<14,5 PSI),
flashing FILL will alternate with indication
of water pressure, boiler power of 50%
is possible. The installation needs to be
topped off.
Water pressure is too high (>52,2 PSI),
if HIGH indication remains continuously
visible,theboileristakenoutofoperation.
The installation pressure needs to be
decreased by draining water.
9.3 Hot water supply
Apply the water pipe pressure to the DHW fascility (open main valve and/or stop
valve of the safety group).
Vent the DHW fascility and the hot water installation by opening a hot water shut off
valve. Leave the shut off valve open for as long as required until all air has disappeared
from the DHW fascility and the pipes and only water is flowing from the shut off valve.
44
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FOR YOUR SAFETY READ BEFORE OPERATING
WARNING: If you do not follow these instructions
exactly, a fire or explosion may result causing
property damage, personal injury or loss of life.
A. This appliance does not have a pilot. It is equipped with an ignition device which automatically
lights the burner. Do NOT try to light the burner by hand.
B. BEFORE OPERATING smell all around the appliance area for gas. Be sure to smell next to the floor
because some gas is heavier than air and will settle on the floor.
WHAT TO DO IF YOU SMELL GAS
- Do NOT try to light any appliance.
- Do NOT touch any electrical switch.
- Do NOT use any phone in your building.
- Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s
instructions.
- If you cannot reach your gas supplier, call the fire department.
C. Use only your hand to push in or turn the gas control knob. Never use tools.
If the knob will not push in or turn by hand, don’t try to repair it, call a qualified service technician.
Force or attempted repair may result in a fire or explosion.
D. Do not use this appliance if any parts have been under water. Immediately call a qualified service
technician to inspect the appliance and to replace any part of the control system and any gas
control which has been under water.
OPERATING INSTRUCTIONS
1. STOP! Read the safety information above this label.
2. Turn off al electrical power of the appliance.
3. Set the thermostat or other operating control to the lowest setting.
4. This appliance is equipped with an ignition device
which automatically lights the burner.
Do NOT try to light the burner by hand.
5. Close main gas shut off valve.
Manual Gas Valve (Main valve)
CLOSE OPEN
6. Wait (5) minutes to clear out any gas. Then smell for
gas. Including near the floor.
If you smell gas, STOP! Follow “B” in the safety
information above on this label.
If you don’t smell gas, go to the next step.
7. Open main shut off valve.
8. Set the thermostat or other operation control to desired setting.
9. Turn on all electric power to the appliance.
10.If the appliance will not operate, follow the instructions “To Turn Off Gas To Appliance” and call your
service technician or gas supplier.
TO TURN OFF GAS TO APPLIANCE
1. Turn off all electric power to the appliance if service is to be performed.
2. Set the thermostat or other operating control to the lowest setting.
3. Close main gas shut off valve.
8U.34.01.00 / 05.09
45
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10
Adjustments
When the boiler is installed it is ready for use. All adjustments of the boiler control
are already pre-programmed for a heating system with radiators/convectors with a
supply temperature of 185°F.The adjustments are described in the Parameter chapter
on page 44.
In certain cases parameters have to be altered in case of :
-
-
Lower supply temperature
High altitude/long vent length
Read through the Parameter chapter to adjust the boiler to its installation.
Contact Rinnai in case of doubt.
Only qualifiedpersonel who are trained for servicing these boilers are permitted
to make alterations in the controller to calibrate the boiler to the installation.
NOTICE
i
11.1 Altering adjustments
Press the Mode-button for 5 seconds.
The display shows COdE followed by an arbitrary number;
STEP 1
STEP 2 Press by means of the + or the - button until the code C123 is shown;
Press the STORE-button to confirm the code (code blinks1 x).
STEP 3
Now you have acces to the installer level. There are 4 chapters:
•
•
•
•
Parameters
Information chapter (no adjustments possible)
Service chapter
Error-chapter (no adjustments possible)
The content of the chapters is described on the following pages.
STEP 4 Press briefly the MODE-button to select one of the 4 chapters, i.e. PARA;
STEP 5
Press once or more briefly on the STEP-button to select a Parameter
(parameter visible on the left, value on the right) ;
Alter the value, if necessary/possible, by means of the + or the - button
STEP 6
STEP 7
Press briefly on the STORE-button to confirm the alteration.
When you have to change more values, repeat from step 5.
STEP 8
Press once or more on the MODE-button until StBY or Good is shown:
After a few seconds the text StBY will be replaced by the technical read-out
or Good-state (Depending from the position the acces code is entered)
When you want to return from an arbitrary position to the original read out
press once or more on the MODE-button until StBY is shown.
If no single button is used within 20 minutes the display will return automatically to its
original read-out (Good state or technical read out)
NOTICE
i
46
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Parameter Mode
PARA
FACTORY DESCRIPTION
RANGE
.
.
.
.
1
186°F
00
maximum supply temperature CH
type of CH installation:
68 - 186°F
2*
01 DO NOT USE
02
radiators with large surface areas or underfloor heating as additional heating:
T max. supply 158°F K factor heating curve 1.8; gradient 10°F/min; gear differential 10°F
under floor heating with radiators as additional heating:
03
T max. supply 140°F; K factor heating curve 1.5; gradient 8°F/min; gear differential 8°F
full under floor heating:
04
T max. supply 122°F; K factor heating curve 1.0; gradient 6°F/min; gear differential 6°F
3
4*
max.
00
maximum power CH in kW (.. x3415 = .. BTU/hr)
control principal with on / off thermostat:
100 % on / off thermostat
min-max
00
100 % on / off weather dependant
01
5*
2.3
heating curve K-factor (see also heating curve graph)
0.2 - 3.5
6*
1.4
heating curve exponent (see also heating curve graph)
heating curve climate zone (see also heating curve graph)
fine adjustment heating curve day temperature
fine adjustment heating curve night temperature
gradient speed °F/min.
1.1 - 1.4
7*
14°F
0°F
0°F
-4 - 32°F
10*
11*
14
-8 to 10°F
-8 to 10°F
0 - 28°F/min.
10°F/min.
00
15*
Booster after night decrease*:
no
00
yes
01
23
27
31
36
26°F
32°F
132°F
20
Frost Temperature
-4 to 50°F
0 - 158°F
68 - 176°F
Minimum T-set CH
DHW temperature
Type of three way valve DHW fascility
VC 2010 / VC 8010
x0
Flowswitch
2x
43
49
73
89
max.
100%
0
Maximum power DHW in kW (.. x3415 = .. BTU/hr)
Maximum pump capacity heating
Altitude and venting CFT. See chapter 6.7.7
Address
min-max
100 %
0 - 100
00
No function
-01
00
Bus thermostat
Display reading
°C and Bar
°F and PSI
.
90
01
00
01
.
.
.
Info Mode
INFO
FACTORY DESCRIPTION
RANGE
.
.
.
.
1
°F
supply water temperature T1
4
5
°F
°F
return water temperature T2
DHW temperature T3
7
°F
outdoor temperature T4
8
°F
%
kW
kW
flue gas temperature T5 (optional sensor)
actual power in %
actual power in kW (.. x3415 = .. BTU/hr)
actual load in kW (.. x3415 = .. BTU/hr)
indication bus communication
consumption total in GJ (.. x 33 = .. m3)
consumption CH in GJ (.. x 33 = .. m3)
consumption DHW in GJ (.. x 33 = .. m3)
total number of burner run hours
number of burner run hours CH
number of burner run hours DHW
total number of hours counter
16
17
18
20
21
22
23
24
25
26
32
GJ
GJ
GJ
h
h
h
h
37
46
.
h
h
.
total number of run hours pump CH and DHW
within how many hours is service required
.
47
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Service Mode
SERV
VALUE
DESCRIPTION
RANGE
OFF - max.
OFF - max.
OFF - max.
ON - OFF
.
1
2
3
4
.
OFF
OFF
OFF
OFF
.
boiler in operation with burner function on
fan adjustable and burner off
pump adjustable with burner on
showroom position ON = active and OFF = non active
.
Error Mode
ERRO
VALUE
DESCRIPTION
Err.L - Err.5
1
2
3
4
5
6
Last saved error until 5 last previous errors
error code
operation status boiler
supply water temperature T1
return water temperature T2
load (.. x3415 = .. BTU/hr)
pump capacity
°F
°F
kW
%
Parameter-, Info-, Service- and Error-chapters
Table 12
* Most of the data in this table can be requested by the RS100. Most of the
adjustments which are stated in this table are unnecessary when in combina-
tion with the Rinnai RS100 thermostat and will be taken care of by the RS100
itself and do not have to be adjusted. For further information regarding to the
RS100 thermostat refer to the Rinnai RS100 installation manual.
NOTICE
i
Outdoor reset
230
Heat curve day
212
Heat curve night
2.30
194
1.80
176
2.00
1.75
158
140
1.50
122
1.00
104
1.00
0.50
86
68
50
outside temperature in °F
heating line adjustments Parameter Step 6 and 7
graph 2
48
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10.2 Activating factory settings (green button function)
Toactivatethefactorysettingsagainpleasefollowthenextprocedure(Note:allaltered
adjustments will be set back to their orignial factory settings):
-
-
-
Select, when necessary, the technical read out;
Select with the MODE-button chapter PARA;
Press the STORE-button.
The word "Copy" will appear and the factory settings are active again.
11
Isolating the boiler
Some situations require turning the entire boiler off.
By switching off the three buttons with the LED's for central heating, hot water and
pump program ( or ), the boiler is switched off. Do not shut off the power
,
of the boiler, which means the circulation pump and the three-way valve are activated
once every 24 hours in order to prevent these parts from seizing up.
In the event of frost danger during an isolated boiler it is advisable to drain
the boiler and/or the installation.
CAUTION
!
49
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12
Commissioning
Work on the boiler must be carried out by a competent person, using
correctly calibrated instruments with current test certification.
These installation instructions are intended for professional installers, who
have the necessary knowledge and are approved for working on heating and
gas systems.
NOTICE
i
Before the boiler is fired, ensure that the boiler and the system are well de-aerated
and free of air. Purge the gas line between the gas meter and the boiler.
The boiler and its individual shut off valve must be disconnected from the
gas supply piping system during any pressure testing of that system at test
pressures in excess of 1/2 PSI (3.5kPa).
NOTICE
i
To commission the boiler the casing has to be removed.
-
-
-
remove the 4 screws A,B,C and D in the quick releases of the casing (figure 17);
remove the screw E behind the door on the front of the casing (figure 17);
remove it towards the front.
The boiler settings, such as burner pressure and adjustment of the air quantity are
unnecessary, due to the fact that the boiler operates with a zero pressure control.
This means the correct gas quantity is controlled by the suction operation of the fan.
The fine adjustment which is carried out at the factory is once-only, which means
that adjusting of these values is unnecessary. Only in case of replacing of the gas
valve, venturi and/or fan, the zero pressure and the incorrect O2 adjustment has to
be checked and, if necessary, adjusted at the right value.
Always check the installation of all parts through which gas flows (by bubble
test using leak-search spray)
DANGER
!
During the commissioning of the boiler the Rinnai Installation, Commissioning, and
Service card must be filled out.
Removing casing
figure 17
50
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12.1 Testing for gas leaks
Prior to start-up of the boiler you must check the external tightness of the gas supply
valve and confirm this in the start-up report.
-
-
Cover endangered positions before leak testing.
Do not spray the leak testing agent onto cables, plugs, electrical connec-
tion lines or electronic circuit boards. Do not allow it to drip onto them
either.
WARNING
!
Leaks may be caused to pipes and screw connections during commissioning
and maintenance activities.
DANGER
!
-
-
Carry out a proper leak test.
Only use approved leak detection agents for leak detection.
-
-
Disconnect the heating system from the power supply.
Check the exterior tightness of new conduit sections up to and including the direct
sealing point on the gas burner fitting. The maximum test pressure allowed on
the input of the gas burner fitting is 14 inch W.C. (35mbar).
12.2 Testing the Ignition Safety shut off device
-
Switch off system using the Central Heating button and the DHW button
-
Disconnect the plug and socket connection of the ionization cable.
-
-
-
Switch on the sytem using the Central Heating button and the DHW button.
Press the MODE-button for 5 seconds.
The display will show COdE followed by an arbitrary number;
-
-
-
-
Select by means of the
or the
button the code C123;
Press the Store-button to confirm the code (code blinks 1 x);
Press the MODE-button until SERV is shown;
Press the STEP-button once until 1 is shown;
alternately 1 and OFF will be shown.
-
Press the
button once;
Check if the boiler does one start-up attempt and four restart attampts.
After the last start-up attempt, the boiler will lock out. The gas valve is shut off.
The E02 code is blinking in the display.
-
-
-
Connect the plug and socket connection of the ionisation cable.
Press the reset button.
Check if the boiler starts-up.
Do not touch the inside of the igntion cable while it is disconnected during
start up of the boiler.
WARNING
!
51
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12.3 Checking for contamination
In order to be able to check the boiler for contamination in the following running
NOTICE
i
years it is advisable to measure the maximum air displacement in the boiler
when putting the boiler into operation. This value can be different with each
type of boiler.
In order to be able to measure this value follow the next procedure:
-
-
Press the MODE-button for 5 seconds.
The display will show COdE followed by an arbitrary number;
-
-
-
-
Select by means of the
or the
button the code C123;
Press the Store-button to confirm the code (code blinks 1 x);
Press the MODE-button until SERV is shown;
Press the STEP-button until 2 is shown;
alternately 2 and OFF will be shown.
-
Turn open the upper measuring nipple on the gas valve (fig. 18);
-
Connect the hose of the digital pressure gauge to the upper measuring nipple of
the gas valve
Check point contamination
figure 18
-
Press the
button until the maximum value is achieved;
The fan will function to its maximum revolutions (burner stays off)
-
Measure the under pressure and write down this value.
NOTICE
i
At the next servicing visit this value may drop 20% of its original value on
the moment of installation. When this value is dropped more than 20% the
boiler needs maintanance.
-
Press the
button until OFF is shown (keep button pressed)
With this the procedure is finished.
52
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12.4 Checking of the zero pressure control
The zero pressure control is set at the factory. To measure this value you need
a difference pressure gauge with a range of +0,2 to -0,8 mbar (+0.08 to -0.001”
W.C.). Follow the next procedure:
NOTICE
i
-
-
Press the MODE-button for 5 seconds.
The display will show COdE followed by an arbitrary number;
-
-
-
-
Select by means of the
or the
button the code C123;
Press the Store-button to confirm the code (code blinks 1 x);
Press the MODE-button until SERV is shown;
Press the STEP-button once until 1 is shown;
alternately 1 and OFF will be shown.
-
Turn the upper measuring nipple on the gas valve open (fig. 19);
-
Connect the hose of the digital pressure gauge to the upper measuring nipple of
the gas valve
-
-
Press the
button until the minimum value is achieved;
The fan will function to its minimum revolutions (burner is active)
Measure the negative pressure.
Value should be 0 to -4Pa (0 to -0.04 mbar or 0 to -0.016" W.C.).
Check point contamination
figure 19
-
If the zero pressure deviates too much:
-
-
-
Remove black cover of the gas valve
Remove cap with Torx screwdriver (fig. 20)
Turn slightly the Torx screw behind the cap:
Turn left is positive pressure deviation
Turn right is negative pressure deviation
Adjustment zero pressure
figure 20
-
-
Ending this procedure is done by pressing the Reset button.
Proceed by checking the O2 value and correct it if necessary.
53
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12.5 Checking the O2
The O2 percentage is factory-set. This has to be checked at commissioning,
maintance and faults.
NOTICE
i
This can be checked by means of the following procedure:
-
Remove the black cover of the gas valve by unscrewing the sealed screw.
-
Put the boiler into operation and take care that it can deliver its heat;
Tip: If there is no demand for heat on CH, turn the hot water tap completely open
and measure the O2.
i
-
-
Press the MODE-button for 5 seconds.
The display will show COdE followed by an arbitrary number;
-
-
-
-
Select by means of the
or the
button the code C123;
Press the Store-button to confirm the code (code blinks 1 x);
Press the MODE-button until SERV is shown;
Press the STEP-button once until 1 is shown;
alternately 1 and OFF will be shown.
-
-
Calibrate the O2 meter ;
Place the probe of the O2 meter into the check point (see fig. 21);
-
-
Press the
button until the maximum value (in kW) is achieved;
The boiler will burn on full load (value on display in kW)
value in BTU/hr = x3415
checkpoint CO2
Check the O2 percentage:
Natural gas: full load:
min. load:
Propane: full load:
min. load:
figure 21
between 4.4% and 4.7%
between (setting of full load +0.2%) and 6.0%
between 4.8% and 5.1%
between (setting of full load +0.2%) and 6.0%
Example:Full load set on 4.6% O2 (natural gas) then the minimum load setting should
be between 4.8% and 6% O2
NOTICE
i
Choose the right O2 value according the kind of gas (Natural Gas or Propane
Gas). Wrong adjustment may result causing property damage, personal
injury or death.
-
-
Let the O2 meter do its measuring procedure.
Adjust, if necessary, the adjustment screw to correct the O2 value
(see fig. 22).
adjustment screw CO2
figure 22
Ending the O2 measuring procedure:
-
Press the - button until OFF is shown (keep button pressed).
With this the procedure has ended..
-
Replace the black cover on the gas valve and fix it with the screw.
54
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12.6 Measuring the ionization current
-
-
Switch off the system using the Central Heating button and the DHW button
Disconnect the plug and the socket
connection on the probe and connect the
measuring device in series. See figure 23.
Select the µA direct current range on the measuring
device. The measuring device must have a resolution
of at least 1 µA.
-
Switch on the sytem using the Central Heating button
and the DHW button.
-
-
Press the MODE-button for 5 seconds.
The display will show COdE followed by an arbitrary
number;
Ionization test
figure 23
-
-
-
-
Select by means of the
or the
button the code C123;
Press the Store-button to confirm the code (code blinks 1 x);
Press the MODE-button until SERV is shown;
Press the STEP-button once until 1 is shown;
alternately 1 and OFF will be shown.
-
-
Press the
button until the maximum value (in kW) is achieved;
The boiler will burn on full load (value on display in kW)
value in BTU/hr = x3415
Measure the ionization. When the boiler is in full load the ionization current must
be > 4 µA and write down this value in the log book.
-
-
-
Press the
button until OFF is shown (keep button pressed).
Switch off the system using the Central Heating button and the DHW button
Disconnect the measuring device and restore the plug and the socket connection
on the probe.
-
Switch on the sytem using the Central Heating button and the DHW button.
12.7 Installing the casing
-
-
-
Install the cover on the boiler and clos all 4 quick releases of the casing
Tighten the 4 screws A,B,C and D in the quick releases (figure 24);
Tighten the screw E behind the door on the front of the casing (figure 24);
Installing casing
figure 24
55
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13
Maintenance
Maintenance or changes to the boiler may only be carried out by a qualified
technician.
NOTICE
i
13.1 Periodic examination of venting systems and boiler
The inspection of the boiler and venting system should be done every 2 years and
full maintenance every 4 years or 4000 hours of operation, whichever occurs first..
When doing this the circumstances of the boiler’s location must be taken into account.
From this one can determine whether to deviate from this advice.
Please contact Rinnai for further guidance on the frequency and service
requirements. Contact details can be found on the back page of this manual.
NOTICE
i
13.2 Inspection
Preparing the boiler for inspection
To carry out the maintenance activities please follow the next procedure:
-
-
-
switch off the power supply;
shut off the gas;
valve off the boiler from the system using the boiler isolation valves in the plumbing
kit.
-
-
-
-
remove the 4 screws A,B,C and D in the quick releases of the casing (figure 25);
remove the screw E behind the door on the front of the casing (figure 26);
remove it towards the front.
clean the casing with a cloth with a simple (non-abrasive) cleaning agent;
Removing casing
figure 25
Removing casing
figure 26
56
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14.2.1
Visual inspection for general signs of corrosion
-
-
Check all gas and water pipes for signs of corrosion.
Replace any pipes that are corroded.
14.2.2
14.2.3
Measuring the ionization current
See subsection 12.6 “Measuring the ionization current".
Measuring the inlet gas pressure
See subsection 6.4.1 and .2 “Gas connection with natural gas" and "Gas connection
with propane”.
14.2.4
14.2.5
14.2.6
14.2.7
Checking and adjusting the gas/air ratio
See subsection 12.4 “Checking of the zero pressure control”.
Testing for gas leaks
See subsection 12.1 “Testing for gas leaks”.
Carrying out a pressure test of the heating system
See chapter 9.2 “Filling the heating system”.
Checking venting systems
Check the following points:
-
-
Is the prescribed combustion air/flue system used?
Have the instructions for configuring the flue system as specified in the relevant
Installation instruction for the flue gas system been observed?
-
Check air intake and flue gas for obstruction or damage.
57
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13.2 Maintenance activities
The fan unit and burner cassette (figure 27 to 29) (2 and 4 year maintenace)
-
-
-
-
-
remove the electrical connection plug from the gas valve (1) and fan motor (2);
loosen the nut (3) of the gas pipe under the gas valve;
NOTICE
replace the gasket with a new one;
i
loosen the front cross head screw (4) of the black plastic silencer;
after this turn the two clamping rods (9 and 10) ¼ turn and remove them by pulling
them forward. Note the correct turning direction (red indicator. fig. 29);
slightly lift the fan unit and remove it towards the front of the heat exchanger;
remove the burner cassette out of the fan unit;
2
-
-
-
9
checktheburnercassetteforwear, pollutionandpossiblecracks. Cleantheburner
cassette with a soft brush and vacuum cleaner.
1
4
3
fan unit and gas valve
figure 27
NOTICE
i
If burners are cracked replace the complete burner cassette;
-
replace the gaskets between burner and fan unit and the gasket between fan
unit and heat exchanger;
10
-
check the venturi and the gas-air distribution plate for pollution and clean this part,
if necessary with a soft brush and vacuum cleaner. If the air box contains a lot
of dirt it is plausible that the fan itself is dirty as well. To clean this, the fan has to
be removed from the hood and the venturi. Clean the fan with a soft brush and a
vacuum cleaner. Replace the gasket and ensure that all gaskets of the fan parts
are mounted correctly.
figure 28
Heat exchanger (2 and 4 year maintenance)
-
check the heat exchanger for contamination. Clean this if necessary with a soft
brush and a vacuum cleaner. Prevent dirt falling down into the heat exchanger.
Flushing the heat exchanger from the top down is not permitted
NOTICE
i
Refitting of the components is done in reverse order.
Make sure that during refitting the clamping rods they are put in the right
position. They should be turned vertical.
If the boiler should activated with clamping rods in the wrong position it will
cause serious property damage, personal injury or loss of life.
DANGER
!
Ignition electrode (4 year or 4000 hour maintenance)
The replacement of the electrode is only necessary when the electrode is worn off.
This can be checked by measuring the ionisation current. The minimum ionisation
current has to be higher than 4µA on full load.
If the inspection glass is damaged the complete electrode must be replaced.
Replace the ignition assembly after 4 years or 4000 hours, whichever occurs first.
Replacement goes as follows:
Clamping rods
figure 29
-
-
remove the electrical connections of the electrode;
presstheclipsonbothsidesoftheelectrodetobothsidesandremovethecomplete
electrode;
-
remove and replace the gasket;
Refitting of the components is done in reverse order.
58
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9
Condensate trap and condensate tray (figure 30-32) (2 and 4 year maintenance)
Step 1: Condensate trap
-
first remove the screw (7);
-
pull the condensation cup (8) downwards, out of the condensate tray (14)
Check this for impurities. If there is not a lot of impurities it is not necessary to
clean the condensate tray (Go to Step 3). If there is a lot of impurities in the cup
it is necessary to remove and clean the condensate tray according Step 2;
check the O-ring (9) of the cup and replace if necessary;
clean the parts by flushing it with clean water;
7
-
-
-
-
grease the O-ring again with acid free O-ring grease to make fitting easier;
if there is a leak at the condensate trap (8) replace complete condensate trap by
S4421200;
8
Step 2: Condensate tray
-
remove the plug from the flue gas sensor if present;
turn the two short clamping rods (11 and 12) ¼ turn and remove them by pulling
them forward; Note the right turning direction (red indicator);
lift the exhaust pipe (13) out of the condensate tray (14);
press the condensate tray (14) carefully downwards and remove it by pulling it
forward;
Siphon
figure 30
-
-
-
13
-
-
-
replace the gasket between condensate tray and heat exchanger by a new one;
clean the condensate tray with water and a hard brush;
check the condensate tray on leaks.
14
12
11
Step 3: Refitting is done in reverse order.
Condensate tray
figure 31
Note that all gaskets seals completely.
Make sure that during refitting the clamping rods they are put in the right
position. They should be turned vertical.
If the boiler should activated with clamping rods in the wrong position it will
cause serious property damage, personal injury or loss of life.
DANGER
!
Put the boiler into operation and check the O2 (see page 50).
Clamping rods
figure 32
If replacement by new gaskets and burner mentioned in this chapter is not done
within the service interval subscribed by Rinnai the boiler can be damaged and
will cause serious property damage, personal injury or loss of life.
DANGER
!
Use only original spare parts supplied by Rinnai. If other parts will be used
the boiler can be damaged and will cause serious property damage, personal
injury or loss of life. Use of non-Rinnai parts will result in the void of warranty.
WARNING
!
59
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Visual inspection of the flame
The burner must flame evenly over the entire surface when operating correctly. The
flame must burn with a clear, blue, stable flame.
Check the flame through the inspection glass in the ignition probe (fig. 33).
The flame pattern should be as shown in the figures below.
SATISFACTORY
Ignition probe
blue flame
Inspection glass
figure 33
UNSATISFACTORY
Ignition probe
yellow flame
Further checks:
-
-
-
Inspect the pressure relief valve
Clean the water filter in the return pipe
Check the pH of the water or glycol/water mixture.
Verify proper operation after servicing.
13.4 Warranty
For warranty conditions refer to the warranty card supplied with the boiler.
60
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14
Parts of the boiler
4
2
1
3
5
7
15 14
6
T1
P1
T5
T2
T3
A
W
G
K
R
C
8
16
9
10
12 13
Rinnai E-Series
figure 32
1 heat exchanger
2 ignition unit
3 fan unit
4 air inlet damper
5 gas valve
6 automatic de-aerator
7 ceramic burner cassette
9 operating panel
10 Control Tower (CMS)
11 water filter return CH
12 three-way valve
13 circulation pump
14 exhaust
15 combustion air supply
16 data plate
8 plate heat exchanger DHW
G gas pipe
T1 supply sensor
T2 return sensor
T3 sensor DHW and flow switch
P1 water pressure sensor
A supply central heating
R return central heating
C condensate pipe
K cold water pipe
W hot water pipe
61
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15
Blocks and Errors
Error indication (short reference)
A detected error is indicated on the display by means of blocking or error messages.
A distinction should be made between these two messages due to the fact that bloc-
king can be of a temporary nature, however, error messages are fixed lockings. The
control will try its utmost to prevent locking and will temporarily switch off the unit by
blocking it. Hereunder is a list of some messages.
Blocks
with a number in the last 2 positions.
Block 01:
External safety contact cut off
Block 11:
Maximum T of flow and return sensor in central heating has repeatedly been exceeded. Du-
ring the block normal operation of the hot water supply is possible. The pump continues to operate
at minimum capacity during the block.
Block 12:
Maximum T of flow and return sensor in domestic hot water has repeatedly been exceeded.
During the block normal operation of the central heating installation is possible. During the block the
pump continues to operate at minimum capacity.
Block 60:
Incorrect parameter setting of the minimum or maximum power.
Block 67:
AT has been detected between flow and return sensor whereas the burner is not in operation.
After the T has disappeared the block will clear.
Block 85:
The control has not detected a water flow. The venting cycle is started. If during this cycle water
flow is detected, the venting cycle is ended and the burner is released.
Error
with a number in the last two positions.
Error 00: Poor flame-forming
Error 01: short-circuit of 24 volt circuit
Error 02: no flame-forming
Error 04: adjustment or error for voltage interruption
Error 05: adjustment
Error 12: fuse 24 volt/3AT faulty
Error 18: maximum flow temperature exceeded
Error 19: maximum return temperature exceeded
Error 28: number of revolutions not reported back from fan
Error 69: no or incorrect display
62
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The following pages describes more detailed follow up instructions for sol-
ving blockings, errors and practical circumstances. These instructions are
only for Rinnai trained installers and technicians.
NOTICE
i
15.1 Blocks
An error, which has been detected, is indicated on the display by a block message.
Blockscanbetemporaryinnature.Thecontrollerwilldoeverythingpossibletoprevent
a system lock and temporarily switching off the boiler as a result of a block. Please
see below for a summary of blocks.
Blocks
with a figure on the last 2 characters.
15.1.1
Block 01
external safety contact broken
external safety
contact is active
rectify error as a result of which by determining
contact is broken
or make interconnection between 24/25
63
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15.1.2
Block 11
maximum average T of supply and return
sensor for central heating is repeatedly
exceeded. Operation is normally possible
for the hot water supply during the block.
The pump continues to operate at minimum
capacity during the block.
check flow
through the
installation
seetheinstallationinstructionsforthehydraulic
connections to the boiler
(3-Way-Thermostatic valve, Plumbing Kit
installed?)
possible causes: (radiator) shut-off valves
closed or blocked water filter
activeted room sensor (RS101) in non leading
room (closed thermostatic radiator valves?)
check pump height.
check minimum and maximum Temperature
difference in Parameter Step 46 + 47.
64
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15.1.3
Block 12
maximum average T of supply and return
sensor for hot water is repeatedly exceeded.
Operation is normally possible for the central
heatinginstallationduringtheblock.Thepump
continues to operate at minimum capacity
during the block.
check flow through
the boiler and DHW
fascility
see the installation instructions for the hydraulic
connections to the boiler
possiblecauses:(radiator)shut-offvalvesclosed
or blocked water filter
resistance (coil) in DHW fascility to high
(see pump height)
check 3-way-valve on function and pollution.
15.1.4
Block 60
incorrect parameter setting for the minimum
or maximum power
Execute
Parameter-Reset.
an incorrect setting has been detected. The
factory settings are activated after the "green
key function" is executed:
Make sure that the text
on the display. Continue to press the Store
key until appears on the display. The
can be seen
factory settings are now copied and the boiler
will come into operation normally.
65
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15.1.5
Block 67
a temperature difference has been detected
between the supply and return sensor whilst
the burner is not in operation. After the
average T has disappeared, the block will
disappear.
check the sensors
NTC 1 and NTC 2
check the supply and return sensor for the
resistance value and replace the defective
sensor
check the installation for any external heat
source and rectify this
66
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15.1.6
Block 85
no water flow can be detected through the
controller. De-aeration cycle is started. When
water flow is detected during this cycle, the
de-aeration cycle is terminated and the burner
is released.
check the boiler
pump
check the installation for the presence of air;
If there is a secondary pomp installed and
it is not hydraulicly seperated could cause
pressure differences.
check that the pump is functioning and/or
that the water pressure sensor is working
properly;
Polluted pump;
Wiring of pump or water pressure sensor;
15.1.7
Block 86
The frequence of the power supply deviates
more than 2,5Hz (<57,5Hz, >62,5Hz)
check the main
power supply
67
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15.2 Errors
A detected error is indicated on the display by an Error message. Error messages
are permanent locks which can only be removed by pressing the reset key. The
controller will make every possible attempt to prevent the lock. Below is a summary
of the Errors.
Error
with one figure on the last 2 characters.
15.2.1
Error 00
incorrect flame formation.
boiler has not been
burning but an
ionisation flow (flame)
has still been detected
check whether the ionisation cable and/or the
electrode are responsible for a possible short-
circuit. Remove the plugs from the ionisation
cable connected to the control unit and to
the electrode. Now using a universal meter
take a measurement between the ionisation
connection and the ground, now refit it part by
part until a short-circuit takes place.
rectify the short-circuit
and if necessary
replace this part.
68
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15.2.2
Error 01
24 Volt short-circuit
disconnect voltage
from the boiler and
check the fuse F2
as a result of a 24 Volt short-circuit inside or
outside the boiler the fuse F2 will have blown.
This fuse is placed in the control unit and
can be seen after the black covering cap is
removed.
check the 24 Volt
connection
remove all plugs with 24 Volt connections
such as: fan, pump, any three-port valve and
24 Volt plug to the connecting block.
check the
disconnected
components for
short-circuiting
switch on power again to the control unit with
thecomponentsdisconnected. Reconnect the
components, which have been checked and
are working.
rectify the short-
circuit or replace
the short-circuited
component
69
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15.2.3
Error 02
no flame formation
check the data
in Error mode
boiler data during error
1 error
2 operational
status
3 supply temp.
4 return temp.
5 kW burner
6 % pump
no temperature
there is a temperature
difference between
supply (3) and
return (4)
difference between
supply (3) and
return (4)
1 = 02
2 = 02
3 = xx*
4 = xx*
5 = xx**
6 = xx*
boiler has not been
able to ignite any gas
or has not received any
gas
boiler has gone out
after ignition
* = variable value
**= x 3451 = BTU/hr
boiler tries to start
6 times with an
increasing starting
load after the safety
time
due to insufficient
ionisation the burner
has gone out after
ignition
ionisation flow,
ionisation cable or the
O2 setting
check whether:
- the gas valve is
open;
- thereispowertothe
gas valve;
- that the gas valve
opens
the minimum gas
preliminary pressure
during the start must
be a minimum of 7"W.
C. (17 mbar), check
the 24 Volts in the gas
during ignition block’s
open position
the minimum
ionisation flow should
be 4 µA, the O2 should
be 4.7 %
70
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15.2.4
Error 03
control unit error
software error con-
trol unit
replace the control unit. The controller will
automatically load the program into the new
control unit.
15.2.5
Error 04
the controller has detected a pro-
gram error
reset the boiler
the boiler automatically indicates this mes-
sage if during an error read-out the voltage
to the boiler is removed.After the voltage has
once again returned, if the error causing the
interference is no longer present, this mes-
sage is given.
rectify the prece-
ding error
71
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15.2.6
Error 05
control unit error
check the ribbon
cable between
the control unit
and the display
incorrect data will be detected in case of a poor
connection between the control unit and the
display. If necessary, replace the ribbon cable
between these two components.
the error persists
after reset
software error
control unit.
replace the control unit. The controller will
automatically load the program into the new
control unit.
72
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15.2.7
Error 07
control unit error
software error
control unit.
check the gas valve
replace the control unit. The controller will
automatically load the program into the new
control unit.
73
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15.2.8
Error 11
control unit error
check the interface
and the ribbon
cable between the
control unit and the
display
incorrect data will be detected in case of a
poor connection between the control unit and
the display or if the interface is incorrectly
positioned. If necessary, replace the ribbon
cable between these two components.
the error persists
after reset
software error
control unit
replace the control unit. The controller will
automatically load the program into the new
control unit.
74
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15.2.9
Error 12
short-circuit 24 Volt
remove the
voltage from the
boiler and check
fuse F2
due to the 24 volt short-circuit inside or
outside the boiler, fuse F2 has blown. This
fuse is positioned in the control unit and can
be seen when the black covering lid has been
removed.
check the 24 Volt
connections
remove all plugs with 24 volt connections such
as: fan, pump, any three-port valve and 24 volt
plug to the connecting block
check the
disconnected
parts for wear
and tear
reconnect power to the control unit with the
disconnected parts. Reconnect the parts
which have been checked and are working
properly.
rectify the short-
circuit or replace
the short-circuited
component
75
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15.2.10
Error 13
control unit error
software error
control unit
replace the control unit. The controller will
automatically load the program into the new
control unit.
76
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15.2.11
Error 14
Temp
°F
NTC 12K
(12k:/77°F)
supply sensor T1
return sensor T2
DHW sensor T3
outside sensor T4
flue gas sensor T5
flow sensor ground connection
-4
-0.4
3.2
6.8
10.4
14
98,000
90,000
82,000
74,000
66,000
58,000
53,500
49,000
45,000
40,500
36,000
33,500
30,900
28,200
25,600
23,000
21,400
19,900
18,100
16,600
15,000
14,000
12,900
11,900
10,850
9,800
check the data
in Error mode
boiler data during error
17.6
21.2
24.8
28.4
32
35.6
39.2
42.8
46.4
50
53.6
57.2
60.8
64.4
68
71.6
75.2
78.8
82.4
86
1 error
2 operational
status
3 flow temp.
4 return temp.
5 kW burner
6 % pump
1 = 14
2 = 00
3 = -22
4 = xx*
5 = 00
6 = xx*
89.6
93.2
96.8
100.4
104
113
122
131
140
158
176
194
212
9,100
8,500
7,900
7,200
6,500
5,600
4,600
4,000
3,400
2,300
1,700
1,300
*= variable values
a temperature of
- 36 is displayed
at position 3
checkthewiringand/ormeasuretheresistance
of the flow sensor. The resistance should be
approx. 12 kOhm at 77°F.
950
if necessary,
replace the flow
sensor
Resistance table NTC-Sensors
77
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15.2.12
Error 18
Temp
°F
NTC 12K
(12k:/77°F)
supply sensor T1
return sensor T2
DHW sensor T3
outside sensor T4
flue gas sensor T5
Signal maximum flow water temperature
exceeded (T1 > 212°F).
-4
-0.4
3.2
6.8
10.4
14
98,000
90,000
82,000
74,000
66,000
58,000
53,500
49,000
45,000
40,500
36,000
33,500
30,900
28,200
25,600
23,000
21,400
19,900
18,100
16,600
15,000
14,000
12,900
11,900
10,850
9,800
check actual flow
temperature
17.6
21.2
24.8
28.4
32
35.6
39.2
42.8
46.4
50
53.6
57.2
60.8
64.4
68
71.6
75.2
78.8
82.4
86
suddenly increase caused by completely
hydraulic shut off of the boiler (filter,
pump, thermostat valve, service valve)
check flow
sensor NTC1
measure the resistance value (see table)
exchange defective
part if necessary.
Change control unit
when error persists
89.6
93.2
96.8
100.4
104
113
122
131
140
158
176
194
212
9,100
8,500
7,900
7,200
6,500
5,600
4,600
4,000
3,400
2,300
1,700
1,300
950
Resistance table NTC-Sensors
78
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15.2.13
Error 19
Temp
°F
NTC 12K
(12k:/77°F)
supply sensor T1
return sensor T2
DHW sensor T3
outside sensor T4
flue gas sensor T5
Signal maximum return water temperature
exceeded (T2>212°F).
-4
-0.4
3.2
6.8
10.4
14
98,000
90,000
82,000
74,000
66,000
58,000
53,500
49,000
45,000
40,500
36,000
33,500
30,900
28,200
25,600
23,000
21,400
19,900
18,100
16,600
15,000
14,000
12,900
11,900
10,850
9,800
check
actual return
temperature
17.6
21.2
24.8
28.4
32
35.6
39.2
42.8
46.4
50
53.6
57.2
60.8
64.4
68
71.6
75.2
78.8
82.4
86
Increase of temperature cause by external
heating source?
check return
sensor NTC 2.
measure the resistance value (see table)
exchange defective
part if necessary.
Change control unit
when error persists
89.6
93.2
96.8
100.4
104
113
122
131
140
158
176
194
212
9,100
8,500
7,900
7,200
6,500
5,600
4,600
4,000
3,400
2,300
1,700
1,300
950
Resistance table NTC-Sensors
79
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15.2.14
Error 28
no signal from the fan
the fan is not
spinning
check fuse F3, this fuse is positioned in the
control unit and can be seen once the black
covering lid has been removed
fuse is working
and the error is
repeated
check the wiring to the fan and the control unit
and/or the 24 volt power supply to the fan
wiring and voltage
are OK and error
is repeated
check for any possible contamination, which
might be impeding the fan impeller or check
the air temperature in the airbox. When
temperature is higher than 158°F find cause
and take precautions for repeating
if necessary,
replace the fan
80
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15.2.15
Error 31
internal shut down of supply sensor T1
check the data
in Error mode
boiler data during error
1 error
2 operational
status
3 supply temp.
4 return temp.
5 kW burner
6 % pump
1 = 31
2 = 00
3 = 230
4 = xx*
5 = 00
6 = xx*
*= variable value
check the wiring
check the wiring for the sensor
the wiring is OK
but the error is
repeated
remove the plug from the flow sensor as a
result of which Error 36 occurs
replace the
sensor
81
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15.2.16
Error 32
shut down of return sensor T2
check the data
in Error mode
boiler data during error
1 error
2 operational
status
3 supply temp.
4 return temp.
5 kW burner
6 % pump
1 = 32
2 = 00
3 = xx*
4 = 230
5 = 00
6 = xx*
*= variable value
check the wiring
check the wiring for the sensor
the wiring is OK
but the error is
repeated
remove the plug from the return sensor as a
result of which Error 37 occurs
replace the
sensor
82
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15.2.17
Error 36
contact for supply sensor T1 open
check the data
in Error mode
boiler data during error
1 error
2 operational
status
3 supply temp.
4 return temp.
5 kW burner
6 % pump
1 = 36
2 = 00
3 = -22
4 = xx*
5 = 00
6 = xx*
*= variable value
check the wiring
check the wiring for the sensor
the wiring is OK
but the error is
repeated
remove the plug from the flow sensor as a
result of which Error 31 occurs
replace the
sensor
83
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15.2.18
Error 37
contact for return sensor T2 open
check the data
in Error mode
boiler data during error
1 error
2 operational
status
3 supply temp.
4 return temp.
5 kW burner
6 % pump
1 = 37
2 = 00
3 = xx*
4 = -22
5 = 00
6 = xx*
*= variable value
check the wiring
check the wiring for the sensor to make sure
it is not broken
the wiring is OK
but the error is
repeated
connect the wiring from the return sensor with
one another as a result of which Error 32
occurs
replace the
sensor
84
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15.2.19
Error 41
control unit error
software error
control unit
replace the control unit. The controller will
automatically load the program into the new
control unit.
15.2.20
Error 42
control unit error
software error
control unit
replace the control unit. The controller will
automatically load the program into the new
control unit.
85
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16
Other errors
16.1 Central heating but no hot water
central heating but no
domestic hot water
-Key of the hot
water program is not
switched on
switch on DHW program on the Control
Tower
DHW sensor of
flowswitch defective
replace DHW sensor or flowswitch
when using RS101
- check timer times for DHW program,
if necessary reset
- RS101 does not respond to DHW program
- see RS101 installation instructions
three-port valve is not
circulating to DHW
fuse F2 MCBA defective
check wiring
if necessary replace the three-port valve
motor
86
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16.2 Hot water but no central heating
hot water but no
central heating
-Key of the central
heating program is not
switched on
switch on central heating program
room thermostat (on/
off) is not giving any
signal to the boiler
check room thermostat
RS100 with outdoor
sensor
(Room sensor-On)
outdoor temperature is higher than 70°F,
depending upon the Eco-temperature set
(70°F is the default). Check Info chapter
Step 7 or temperature is higher than the
Eco temperature set (see RS100 installation
instructions).
Check timer program and set room
temperature
three-port valve
is not circulating
to central heating
position
check wiring, replace the three-port valve
motor
87
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16.3 Central heating installation gets hot without being requested
central heating installation gets hot
without being requested
-Key pump program
is on
switch off
dirt in three-port valve
or three-port valve
cartridge is getting
jammed
clean or replace
88
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16.4 Insufficient quantity of hot water
insufficient quantity of hot water
hot and cold water
connection to the boiler
mixed up
check left = hot, right = cold
incorrect flow reducing
valve
check for the type and for contamination, if
necessary replace and/or clean.
in the absence of
positive results
check for lime scale
lime scale in the plate
heat exchanger
if necessary descale or replace
89
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16.5 Temperature drop of the DHW
Temperature drop of the DHW
flow reducing valve
check flow reducng valve for the correct
type in accordance with the installation
instructions
DHW power for the
boiler is set too low
-
-
check PARA chapter Step No. 43
check the functioning and wiring of the
DHW sensor T3
90
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16.6 Radiators do not get hot enough or warming up takes too long
radiators do not get hot enough or
warming them up takes too long
check setting of
room thermostat
or RS101
supply water
temperature too low
Check setting PARA chapter Step No. 1 and
increase if necessary
incorrect choice of
installation
PARA chapter Step No. 2 if necessary
change
installation resistance
too high (given an
average T > 36°F the
boiler decreases the
load)
see installation instructions
check / clean water filter check dimensions
of pipes
91
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17
Spare parts
.
d e v r
e s e r
s e g n a h
C
9 0 . 2 0 / 0 0 . 0 6 . 1 5 .
U 8
d e v r
e s e r
s e g n a h
C
9 0 . 3 0 / 0 0 0 6 . 2 5 .
U 8
92
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93
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94
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95
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96
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97
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98
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99
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100
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101
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18
Parts list vent system
Vent Products
Listed and Tested Vent Products for E75C, E110C, Q85S, Q130S, Q175S, Q175C and Q205S
Manufacturer
Heatfab
Descriptions
DGV 3"/5" Conc Air Intake Tee 3"
DGV 3"/5" Conc X 12" Length
DGV 3"/5" Conc X 31" Length
DGV 3"/5" Conc Horz Term Adapter
DGV 3"/5" Conc Vert Term Adapter
Rain Cap
3"- Adapter to fit into 80 mm Flue Collar
3"- 12 Length
3"- 31" Length
3"- 90 Deg Tr Elbow
3"- Screen Termination
3"- Round Wall Thimble Pate
3"- Tall Cone Flashing, Flat- 2/12 Pitch
Descriptions
Parts #
DGV03TAD3
DGV03L12
DGV03L36
DGV03HT
DGV03VT
SGV300
adapter
SGV302
SGV307
SGV314
SGV392
SGV393
SGV3TCF
Parts #
Manufacturer
IPEX
Concentric Vent Termination
PVC - FGV Concentric Kit
PVC - FGV Wall Termination Kit
CPVC - FGV Concentric Vent Kit
Termination Vent Screen
Descriptions
1CT0303
196006
81219
197009
196051
Manufacturer
Parts #
Rinnai/ Ubbink
1 Meter Sections of PP/PVC, 3”/5”
90 Degree, Male x Female, PP/PVC, 3”/5”
Horizontal PP Termination, 21 inch
Vertical PP Termination
224080
224078
223175
184162
Manufacturer
Descriptions
Parts #
York International 3” PVC Concentric Vent Termination
1CT0303
Miscellaneous
Terminal
General PVC 1120 3” SCH 40 DWV ASTM D 2665 900 Elbow
Air Intake Pipe
Vent Pipe
PVC 1120 3” SCH 40 DWV ASTM D 2665
PVC 1120 3” SCH 40 DWV ASTM D 2665
Vent Manufacturer Contact Information for Installation Instructions and Parts Lists:
Rinnai/Ubbink
Telephone:
Fax:
Heat-Fab
Telephone:
Fax:
Email:
Web Site:
800-621-9419
678-829-1666
www.rinnai.us
800-772-0739
413-863-4803
www.heatfab.com
Web Site:
IPEX
York International
Telephone:
800-463-9572
905-403-0264
905-403-9195
Telephone:
405-364-4040
877-874-7378
www.york.com/products/unitary/
Fax:
Web Site:
Web Site:
www.ipexamerica.com
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19
Common venting guidelines
Do not common vent with the vent pipe of any other boiler or appliance. However,
when an existing boiler is removed from a common venting system, the common
venting system is likely to be too large for proper venting of the appliances remaining
connected to it. At the time of removal of an existing boiler, the following steps shall
be followed with each appliance remaining connected to the common venting system
placed in operation, while the other appliances remaining connected to the common
venting system are not in operation:
(a) Seal any unused openings in the common venting system.
(b) Visually inspect the venting system for proper size and horizontal pitch and deter-
mine there is no blockage or restriction, leakage, corrosion and otherdeficiencies
which could cause an unsafe condition.
(c) Insofar as is practical, close all building doors and windows and all doors between
the space in which the appliances remaining connected to thecommon venting
system are located and other spaces of the building. Turn on clothes dryers and
any appliance not connected to the common venting system. Turn on any exhaust
fans, such as range hoods and bathroom exhausts, so they will operate at maxi-
mum speed. Do not operate a summer exhaust fan. Close fireplace dampers.
(d) Place in operation the appliance being inspected. Follow the lighting instructions.
Adjust thermostat so appliance will operate continuously
(e) Test for spillage at the draft hood relief opening after 5 minutes of mainburner
operation. Use the flame of a match or candle, or smoke from acigarette, cigar or
pipe.
(f) After it has been determined that each appliance remaining connected to the com-
mon venting system properly vents when tested as outlined above,return doors,
windows, exhaust fans, fireplace dampers and any other gas burning appliance
to their previous condition of use.”
(g) Any improper operation of the common venting system should be corrected so the
installation conforms with the National Fuel Gas Code,ANSI Z223.1/NFPA54 and/
or CAN/CSA B149.1, Natural Gas and Propane Installation Code. When resizing
any portion of the common venting system, the common venting system should
be resized to approach the minimum size as determined using the appropriate
tables in Part 11 of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or
CAN/CSA B149.1, Natural Gas and Propane Installation Code.
103
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Appendix A - Outoor Reset Sensor Data
R 25 °C
12 kΩ
R 100 ° C
950 Ω
B25/85
3750 K
-4,2 %/K
Temperature coefficient
Temp
[°C]
NTC
[kOhm]
200
180
160
140
120
100
80
-30
-20
-10
0
171.70
98.82
58.82
36.10
22.79
14.77
12.00
9.81
10
60
20
40
25
20
30
0
-40
-20
0
20
40
60
80
100
120
40
6.65
Temp [°C]
50
4.61
60
3.25
70
2.34
80
1.71
90
1.27
100
110
120
0.95
0.73
0.56
104
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800000012 9/2009
Distributor for the USA
R i n n a i A m e r i c a C o r p o r a t e
•
Toll Free: (800) 621-9419 • Tel: (678) 829-1700 • Fax: (678) 829-1666 • E-mail: [email protected] • Internet: www.rinnai.us
1 0 3 I n t e r n a t i o n a l D r i v e
•
P e a c h t r e e C i t y , G A 3 0 2 6 9
E. & O. E.
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