Rinnai M Series Installation And Operation Manual Download Page 106

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106

Rinnai M

Series Condensing Boiler Combi Manual

PC Board Wiring for the above application example

Outdoor

Temperature Sensor

Pump

Zone Control

Low Water Cut-
off (If Required)

Thermostat

Air Handler
Control

Summary of Contents for M Series

Page 1: ...l 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...

Page 2: ...Mount the Boiler to the Wall 20 5 Venting 21 5 1 Guidelines 21 5 2 Venting Installation Sequence 22 5 3 Termination Considerations 22 5 4 Venting Options 23 6 Gas Supply 43 6 1 Connect the Gas Supply 43 6 2 Gas Operating Instructions 45 6 3 Gas Pipe Sizing Reference Tables 46 7 DHW System Piping 48 7 1 Guidelines 48 7 2 Instructions 48 7 3 Piping Diagram for a Basic DHW Installation 49 8 CH System...

Page 3: ...nostic Codes 86 12 7 Forced Hi Low Fire Modes 87 12 8 Freeze Protection 88 13 Maintenance 89 13 1 Owner Maintenance 89 13 2 Licensed Professional Maintenance 90 13 3 Test the Ignition Safety Shut Off Device 92 14 Appendices 93 14 1 Approved Cleaners Inhibitors and Antifreezes 93 14 2 Flush the CH Plumbing System 94 14 3 Boiler Parts 95 14 4 System Application Examples 103 14 5 Gas Conversion 109 1...

Page 4: ...lypropylene PRV Pressure Relief Valve PSI Pounds per square inch W C Inches water column For Your Records Dealer Name Located on left side of unit 1 A trained and qualified professional must install the boiler inspect it and leak test it before use The warranty will be voided due to any improper installation The trained and qualified professional should have skills such as Gas line sizing Connecti...

Page 5: ... or any other appliance Combustible construction refers to adjacent walls and ceiling and should not be confused with combustible or flammable products and materials Combustible and or flammable products and materials should never be stored in the vicinity of this or any gas appliance Always check the water temperature before entering a shower or bath 2 If the information in these instructions is ...

Page 6: ...er Immediately call a licensed professional to inspect the appliance and replace any part of the control system and any manual gas control valve which has been under water Do not use substitute materials Use only parts certified for the appliance Should overheating occur or the gas supply fail to shut off turn off the manual gas control valve to the appliance It is strongly recommended that you us...

Page 7: ...water For complete boiler information refer to the Rinnai M Series Condensing Boiler Installation Manual supplied with the boiler or visit rinnai us Topics in this section Front View Bottom View Components Specifications Dimensions Accessories How To Remove the Front Panel 3 Controller front cover removed Vent Connections Piping Connections visible below boiler ...

Page 8: ...eturn from CH System Primary Secondary Heating Kit CH Pressure Relief Valve supplied with boiler CH Supply Condensate Drain Domestic Hot Water Domestic Cold Water Gas CH Return Domestic Hot Water Pressure Relief Valve Central Heating Temperature Pressure Gauge supplied with boiler Gas Shut Off Valve All items are field supplied unless otherwise noted ...

Page 9: ...3 Fan with Integrated Venturi 4 Gas Valve 5 Ignition Unit 6 Silencer 7 Condensate Tray 8 Flue Gas Exhaust Air Intake with Measuring Points 9 Automatic De aerator 10 Control Panel 11 Pressure Sensor 12 Modulating Pump 13 Plate Heat Exchanger 14 Diverter Valve 15 Flow Sensor 16 Condensate Trap Located behind 6 Silencer Exhaust Intake ...

Page 10: ...mum NG 17 000 LP 31 500 NG 23 500 LP 73 500 Maximum Central Heating 60 000 90 000 120 000 160 000 Maximum DHW 103 000 160 000 Temperature Setting Central Heating Min Max 68 F 185 F 20 C 85 C DHW Min Max 104 F 149 F 40 C 65 C Water Content Central Heating 1 Gallon 3 8 Liters 1 4 Gallons 5 2 Liters 1 4 Gallons 5 2 Li ters 1 4 Gallons 5 2 Liters DHW 05 Gallons 2 Liters 08 Gallons 3 Liters 08 Gallons ...

Page 11: ...Rinnai M Series Condensing Boiler Combi Manual 11 Measurements in mm Vent Top Connections 3 in 80 mm PP 3 in PVC 3 5 in Concentric 2 in 60 mm PP 2 in PVC ...

Page 12: ... with Provided Adapters Gas 3 4 in NPT DWH In Cold Inlet 3 4 in NPT DHW Out Hot Outlet 3 4 in NPT CH In CH Return 1 in NPT CH Out CH Supply 1 in NPT Gas Central Heating Return Central Heating Supply Domestic Hot Water Outlet Gas Central Heating Return Domestic Cold Water Inlet ...

Page 13: ...by the boiler SCALECUTTER Filters and reduces the amount of scale entering the boiler allowing for greater boiler longevity SCALECUTTER REFILL CARTRIDGE Refill cartridge for the ScaleCutter filter assembly DHW ISOLATION VALVE KIT For quick isolation of the boiler DHW connections BOILER TOOLKIT PN 809000024 Set of specific tools recommended for boiler service PRIMARY SECONDARY HEATING KIT PN 803000...

Page 14: ... 3 1 Lift the tab slightly above the peg To remove carefully lift the panel up and off to release it from the boiler IMPORTANT Do not operate the boiler without the front panel installed The front panel should only be removed for service maintenance or replacing internal components TIP Be careful not to lose the screws You ll need them when reinstalling the front cover ...

Page 15: ... 3280 and or CAN SCA Z240 MH Series Mobile Homes The appliance when installed must be electrically grounded in accordance with local codes or in the absence of local codes with the National Electrical Code ANSI NFPA 70 or the Canadian Electrical Code CSA C22 1 The appliance and its main gas valve must be disconnected from the gas supply piping system during any pressure testing of that system at t...

Page 16: ... or equivalent components for quick isolation of the boiler for service and or maintenance CH System Air Separator Standard tools for central heating gas fitting plumbing and electrical wiring Combustion analyzer intended for use with condensing boilers Digital manometer capable of reading both positive and negative pressure Digital multimeter capable of reading microamps pH digital meter or test ...

Page 17: ...NTING BRACKET 30 PSI PRESSURE RELIEF VALVE For Central Heating Systems OUTDOOR TEMPERATURE SENSOR DOCUMENTATION Installation and Operation Manual this manual User Manual ISCL Conversion Manual LIQUID PROPANE FIELD CONVERSION KIT This boiler is configured for Natural Gas only Use this kit to convert to Propane Gas if needed Contents include Vent top with integrated 3 in PP 80 mm Connections CONVERS...

Page 18: ... the formation of scale or sludge which affects system efficiency It can also cause corrosion and reduce life of the heat exchanger Never use water that has been treated by a reverse osmosis deionized or distilled water to soften the water to fill the heating system For Domestic Hot Water systems if you install the boiler in an area that is known to have hard water or that causes scale build up th...

Page 19: ...in from vent components Bottom Ground 12 in 305 mm Front 6 in 152 mm Clearance for servicing is 24 in 610 mm in front of boiler Back 0 in Sides Left and Right 2 in 51 mm Vent 0 in The boiler is not exposed to corrosive compounds in the air The boiler location complies with the required clearances The planned combustion air and exhaust termination locations meet the required clearances The water su...

Page 20: ... requires the boiler to be level You Will Need Rinnai Condensing Boiler Wall Mounting Bracket Boiler Mounting Template Insert the top mounting lip of the boiler onto the wall mounting bracket Make sure the wall mounting bracket is attached to the wall and can hold the weight of the boiler before you fully let go Instructions Wall Mounting Bracket Level Use the appropriate screws for the wall const...

Page 21: ...fittings For manufactured vent systems vent connections must be firmly pressed together so that the connections form an air tight seal Follow the venting manufacturer s instructions Refer to the Schedule 40 PVC CPVC manufacturer for appropriate fittings solvents or joining methods If venting reassembly is needed follow the steps for installing the venting in the following sections Make certain tha...

Page 22: ...se property damage Where condensate or vapor could cause damage or could be detrimental to the operation of regulators pressure relief valves or other equipment Listed below are important considerations for locating vent termination under a soffit ventilated or unventilated or eave vent or to a deck or porch Do not install vent termination under a soffit vent such that exhaust can enter the soffit...

Page 23: ...hrough the interior tube while combustion air enters through the outer layer Exhaust Twin Pipe Combustion air and exhaust vent directly through separate penetrations Direct Vent Concentric and Twin Pipe Room air filter accessory Option 1 Room Air Option 2 Combustion air Combustion air Exhaust Combustion air Exhaust Combustion air See Direct Vent section for complete details See Room Air section fo...

Page 24: ...raVent 800 835 4429 www duravent com Royal 800 232 5690 www royalbuildingproducts com ECCO Manufacturing 877 955 4805 www eccomfg com DiversiTech 800 995 2222 www diversitech com Z FLEX 603 669 5136 www z flex com 2 in 4 in CONCENTRIC VENT TERMINATIONS 229011NPP 229012NPP 229013NPP 2 4 Condensing Horizontal Termination Kit 8 7 in 2 4 Condensing Horizontal Termination Kit 12 in 2 4 Condensing Horiz...

Page 25: ...4 in Vertical Termination Cap Kit Concentric 20 2PPS HKL 2 in x 4 in Horizontal Termination Kit Concentric 20 190288 2 in x 4 in Concentric Horizontal Termination 5 190295 2 in x 4 in Concentric Vertical Termination 5 CVENT 2 2 in x 4 in Concentric Horizontal Termination 20 2ZDCTH24 2 in x 4 in Concentric Horizontal Termination 5 2ZDCTV24 2 in x 4 in Concentric Roof Termination 5 ROYAL CENTROTHERM...

Page 26: ... 3 in x 20 in 20 196106 197107 FGV Concentric Vent Kit 3 in x 32 in 20 196116 197117 FGV Concentric Vent Kit 3 in x 44 in 20 52CVKGVS6503 PVC 52CVKGVSF9003 CPVC PVC CPVC Concentric Vent Kit 3 in x 20 in 20 52CVKGVS6503 32 PVC 52CVKGVSF9003 32 CPVC PVC CPVC Concentric Vent Kit 3 in x 32 in 20 52CVKGVS6503 44 PVC 52CVKGVSF9003 44 CPVC PVC CPVC Concentric Vent Kit 3 in x 44 in 20 SC03HT Horizontal Te...

Page 27: ...20 3PPS HKL 3 in x 5 in Horizontal Termination Kit Concentric 20 190388 3 in x 5 in Concentric Horizontal Termination 5 190395 3 in x 5 in Concentric Vertical Termination 5 CVENT 3 3 in x 5 in Concentric Horizontal Termination 20 2ZDCTH35 3 in x 5 in Concentric Horizontal Termination 5 2ZDCTV35 3 in x 5 in Concentric Roof Termination 5 METAL FAB DURAVENT Manufacturer Manufacturer Part Number Produ...

Page 28: ...tion 10 2PPS HSTL 2 in Single Horizontal Termination 6 2PPS TBL 2 in Black UV Resistant Tee 5 196984 FGV PVC Low Profile Termination Kit 5 081216 FGV PVC Wall Termination Kit 16 52SWVKGVS6502 PVC Side Wall Vent Kits 5 52WTVKGVS6502 PVC Wall Vent Kits 16 HVENT 2 2 in Low Profile Horizontal Vent Kit 5 CENTROTHERM DURAVENT Manufacturer Manufacturer Part Number Product Description Diagram Horizontal V...

Page 29: ...tion 10 3PPS HSTL 3 in Single Horizontal Termination 5 3PPS TBL 3 in Black UV Resistant Tee 6 196985 FGV PVC Low Profile Termination Kit 5 081219 FGV PVC Wall Termination Kit 16 52SWVKGVS6503 PVC Side Wall Vent Kits 5 52WTVKGVS6503 PVC Wall Vent Kits 16 HVENT 3 3 in Low Profile Horizontal Vent Kit 5 CENTROTHERM DURAVENT Manufacturer Manufacturer Part Number Product Description Diagram Horizontal V...

Page 30: ...D2564 CPVC Schedule 40 ANSI ASTM F493 PVC Vent Screens Termination Vent Screens Polyethylene 2 in Vent Screens included in carton box IPEX Part Number 196050 3 in Vent Screens IPEX Part Number 196051 Exhaust piping must be of solid core material Refer to the PVC CPVC manufacturer for appropriate fittings solvents or joining methods Manufacturer Vent Material Ubbink PVC Outer Vent Polypropylene Inn...

Page 31: ...let to a maximum vertical distance of 15 ft 4 m J Clearance to non mechanical air supply inlet to building or the combustion air inlet to any other appliance 36 in 91 cm 12 in 30 cm K Clearance to a mechanical air supply inlet 6 ft 1 83 m 3 ft 91 cm above if within 10 ft 3 m horizontally L Clearance above paved sidewalk or paved driveway located on public property 7 ft 2 13 m 1 M Clearance under v...

Page 32: ...el 60 in 1 52 m Between terminals at different levels Note 24 in 0 61 m to wall or parapet Inside Corner 12 in 0 30 m 12 in 0 30 m 60 in 1 52 m vertically between terminals Vent Sizes 3 in X 5 in 2 in X 4 in Boiler Model Number M060C M090C M120C M160C M060C M090C M120C M160C Vent Lengths 60 ft 18 m 30 ft 9 m 150 ft 46 m 140 ft 43 m 45 elbow is equivalent to 3 ft 1 m 90 elbow is equivalent to 6 ft ...

Page 33: ...the venting termination according to the diagrams and instructions in this manual Slope the venting 1 4 in per foot toward the appliance according to the vent manufacturer s installation instructions Dispose of condensate per local codes IMPORTANT Remove the vent top slightly twist counter clockwise and pull up Discard vent top if desired Pull up Slightly twist counter clockwise Insert the concent...

Page 34: ...0 m minimum Wall Horizontal Vent and Combustion Air Piping Combustion air termination not permitted in shaded area Vent Sizes 3 in PVC 3 in 80 mm PP 2 in PVC 2 in 60 mm PP Boiler Model Number M060C M090C M120C M160C M060C M090C M120C M160C Vent Lengths 60 ft 18 m 30 ft 9 m 150 ft 46 m 140 ft 43 m 45 elbow is equivalent to 3 ft 1 m 90 elbow is equivalent to 6 ft 2 m 12 in 0 30 m minimum 12 in 0 30 ...

Page 35: ... damage personal injury or death WARNING Install 3 in 80 mm Polypropylene PP 1 This boiler is equipped with a 3 in PVC pipe connection With the use of a pipe reducer installers can use a 2 in pipe for the combustion air and exhaust Insert 3 in 80 mm PP piping Install 3 in PVC Insert the 3 in PVC adapter onto the vent top 1 2 Insert 3 in PVC piping Install 2 in PVC or PP 60 mm Install 2 in PVC or P...

Page 36: ... 2 in or 3 in Schedule 40 PVC CPVC Standard Upside Down U Vertical Termination Configuration 2 in or 3 in Schedule 40 PVC CPVC Elbow or Tee Side Wall Termination Configuration 2 in or 3 in Schedule 40 PVC CPVC Tee Vertical Termination Configuration 2 in or 3 in PVC Low Profile Termination Configuration This configuration requires the use of a Concentric Vent Termination This configuration requires...

Page 37: ...rtical distance of 15 ft 4 m J Clearance to non mechanical air supply inlet to building or the combustion air inlet to any other appliance 12 in 30 cm for appliances 10 000 Btuh 3 kW and 100 000 Btuh 30 kW 36 in 91 cm for appliances 100 000 Btuh 30 kW 4 ft 1 2 m below or to side of opening 1 ft 300 mm above opening K Clearance to a mechanical air supply inlet 6 ft 1 83 m 3 ft 91 cm above if within...

Page 38: ...oom Air Applications Exhaust Roof 12 in 0 30 m minimum 12 in 0 30 m above grade or anticipated snow level 60 in 12 in 12 in 0 30 m Inside Corner 1 52 m Vertically between terminals IMPORTANT Installation of Room Air must use listed Category IV venting All terminations horizontal and or vertical must terminate 12 in above grade or anticipated snow level ...

Page 39: ...rt air filter or elbow into 3 in PVC intake air fitting ROOM AIR INSTALLATION INSTRUCTIONS Air Filter Elbow Vent Sizes 2 in PVC 2 in 60 mm PP 3 in PVC 3 in 80 mm PP 2 in 51mm Ubbink Flex Boiler Model Number M060C M090C M120C M160C M060C M090C M120C M160C M060C M090C M120C M160C Vent Lengths 60 ft 18 m 30 ft 9 m 150 ft 46 m 140 ft 43 m 60 ft 18 m 30 ft 9 m 45 elbow is equivalent to 3 ft 1 m 90 elbo...

Page 40: ...icating 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 additional outside air may be required for proper operation Outside air openings should be sized the same as for a confined space Confined Space A con...

Page 41: ...ative pressure i e exhaust fans powered ventilation fans Location To maintain proper circulation of combustion air two permanent openings one upper one lower must be positioned in confined spaces The upper shall be within 12 in 0 30 m of the top of the confined space and the lower opening shall be within 12 in 0 30 m of the bottom of the confined space Openings must be positioned as to never be ob...

Page 42: ...edule 40 PVC CPVC Snorkel Termination Configuration 2 in or 3 in Schedule 40 PVC CPVC Standard Upside Down U Vertical Termination Configuration 2 in or 3 in Schedule 40 PVC CPVC Elbow or Tee Side Wall Termination Configuration 2 in or 3 in Schedule 40 PVC CPVC Tee Vertical Termination Configuration Ubbink flexible venting approved for vertical non direct vent room air applications only Refer to th...

Page 43: ...rovided upstream of the gas controls A manual gas shutoff valve between the gas supply and the boiler must be installed A licensed professional must install the gas supply Turn off 120V power supply Turn off the gas Gas is flammable Do not smoke or provide other ignition sources while working with gas Do not turn on the boiler or gas until all fumes are gone Topics in this section Connect the Gas ...

Page 44: ...o meet the maximum demand of the heater and all other gas consuming appliances at the location without loss of pressure If in doubt about the size of the gas line refer to section 6 3 Gas Pipe Sizing Reference Tables 8 Perform a leak and pressure test prior to operating the boiler If a leak is detected do not operate the boiler until the leak is repaired Gas connection 3 4 in MNPT connection Gas F...

Page 45: ...d to replace any part of the control system and any gas control which has been under water 1 Set the temperature controller to the lowest setting 2 Turn off all electric power to the appliance if service is to be performed 3 Turn the manual gas control valve located at gas inlet of appliance clockwise to the OFF position TO TURN OFF GAS TO APPLIANCE 1 STOP Read the safety information above on this...

Page 46: ...uired Btu hr The information below is provided as an example The appropriate table from the applicable code must be used Instructions Enter values in empty boxes Rinnai Model Gas Input Additional Appliance Total Gas Input Heating Value of Gas Cubic Feet Per Hour CFH ANSWER B Btu hr C Btu ft3 A Btu hr CFH FT3 HR CFH A B CFH C GAS PIPE SIZING CALCULATION WORKSHEET Natural Gas Schedule 40 Metallic Pi...

Page 47: ...cific Gravity 1 50 Natural Gas Propane Undiluted Nominal Inside Pipe Size in 1 2 3 4 1 1 1 4 Length in ft meters Capacity in Thousands of Btu hr 10 3 291 608 1 150 2 350 20 6 200 418 787 1 620 30 9 160 336 632 1 300 40 12 137 287 541 1 110 50 15 122 255 480 985 60 18 110 231 434 892 80 24 101 212 400 821 100 30 94 197 372 763 EXAMPLE Rinnai Model Gas Input Additional Appliance total Gas Input Heat...

Page 48: ...entral Heating for more information Attach the 1 2 in FNPT x 3 4 in MNPT connection fitting to the hot and cold fittings on the bottom of the boiler To connect the water supply follow the instructions below For standard installations refer to the Piping Diagram for Basic DHW Installation on the next page Plumb the hot water supply line to the DHW hot outlet connection on the bottom of the boiler P...

Page 49: ...is intended only as a guide and not as a replacement for professional engineering project drawings This drawing is not intended to describe a complete system It is up to the contractor or engineer to determine the necessary components and configuration of the particular system to be installed The drawing does not imply compliance with local building code requirements It is the responsibility of th...

Page 50: ... prevent excessively high flow rates through a single zone when the other zone valves are closed To connect the water supply follow the instructions below For standard installations refer to the Piping Diagram for Basic Central Heating Installation in this chapter Attach the 3 4 in FNPT x 1 in MNPT connection fitting to the supply and return heating fittings on the bottom of the boiler Topics in t...

Page 51: ... on the supply side of the boiler is required The PRV must be 3 4 in with at least 30 PSI 207 kPa and a maximum of 45 PSI 310 kPa A 30 PSI 207 kPa PRV is supplied with the boiler A port for the central heating PRV is present in the Primary Secondary Heating Kit accessory offered by Rinnai Oxygen Elimination The boiler may only be installed in a pressurized closed loop heating system free of air an...

Page 52: ...ith boiler Dirt Trap Backflow preventer Fill valve with pressure gauge Expansion tank Air separator Pressure Gauge supplied with boiler Low Water Cut Off if required by local code Ball valve System Supply System Return CH System Common Components Diagram Primary Secondary Heating Kit ...

Page 53: ...lled The drawing does not imply compliance with local building code requirements It is the responsibility of the contractor or engineer to ensure the installation is in accordance with all local building codes Confer with local building officials before installation Heat Emitter Thermostat Outdoor Sensor Optional Low Water Cut Off LWCO This schematic shows an example of a simple single zone system...

Page 54: ...re and multi zone systems Examples of Hydraulic Separation Closely spaced tees and low loss headers are common examples of hydraulic separators and can be used to separate the boiler loop from the central heating loop Low Loss Header Distance no more than four pipe diameters IMPORTANT For closely spaced tee installations the separation at the header is to be no more than four pipe diameters Closel...

Page 55: ...mm above drains where discharge will be clearly visible An ASME 30 psi safety pressure relief valve is included with the boiler and must be fitted before any shut off valve in the system DO NOT plumb the pressure relief valve with the condensate drain both must be plumbed independently to drain DO NOT plug the pressure relief valve and do not install any reducing fittings or other restrictions in ...

Page 56: ...side hole on the condensate drain pipe connection If a floor drain is not available or the drain is above the level of the condensate drain a condensate pump should be installed A condensate neutralizer kit is available from Rinnai The kit allows condensate to flow through neutralizing media that raises the pH of the condensate to a level that will help prevent corrosion of the drain and public se...

Page 57: ...bber elbow with flexible drain pipe 1 on the condensate tray 2 4 Lead the long black flexible pipe 4 through the free hole of the boiler frame and press it in the T piece 3 5 Lead the other end of the flexible pipe outside the boiler to the drain 6 Fill the condensate drain outer tube 5 with 150 ml about 5 oz of water 7 Apply multi purpose grease or lubricant to the top of the o ring on the conden...

Page 58: ...quipped with a three prong grounding plug for your protection against shock hazard The plug should be plugged directly into a properly grounded three prong receptacle Do not cut or remove the grounding terminal from this plug Disconnect incoming power to the boiler by removing the three prong plug before Performing repairs or installation to internal components or accessories Making wiring connect...

Page 59: ... To access the controller remove the front panel see section 3 7 How to Remove the Front Panel for detailed instructions 120 V power supply to boiler DO NOT USE This terminal is for Rinnai use only and not for use in any installation System Pump Relay Energized on a call for heat Controller Top Connections External safety contact Remove jumper to use DO NOT USE Outdoor temperature sensor DO NOT US...

Page 60: ...ng boilers Training for Rinnai Condensing Boilers is accessible online at www trainingevents rinnai us Work on the boiler must be carried out by a licensed professional using correctly calibrated instruments with current test certification The commissioning instructions are intended for licensed professionals who have the necessary knowledge and are approved for working on heating and gas systems ...

Page 61: ...firmed before testing O2 The boiler front cover must be in place for accurate flue gas testing NOTICE The O2 percentage is required to be checked and adjusted after a conversion from Natural Gas to Liquid Propane or from Liquid Propane to Natural Gas Setting the O2 at maximum input must be performed with a calibrated combustion analyzer that is set to the correct gas type WARNING Table Nominal O2 ...

Page 62: ...parameters by following the steps in the Adjust O2 Percentages section 5 When adjustments are complete place the plug back into the flue gas test port 6 On the controller press and hold the Back button until the Home screen appears in the window This section is required only if it is necessary to adjust O2 percentages Rotate the screw on the gas valve assembly slowly Allow the boiler to operate fo...

Page 63: ...g or if any part of the system has been opened or disconnected Failure to properly purge air from the boiler and system may result in damage to the boiler which is not covered by the boiler warranty To bypass the air purge process press and hold the BACK button for approximately seven seconds This will put the boiler back into normal operation mode The boiler s internal air purge process is an eff...

Page 64: ...er are not interchanged Does the water supply to the boiler have adequate pressure Is it free of chemicals Did you verify it does not exceed total hardness that will damage the heat exchanger Have you verified that no toxic chemicals were introduced to the potable water Did you drain the boiler if not intended to be used immediately Have water quality issues if any been addressed Have you performe...

Page 65: ... terminate 6 in 152 mm above the drains Is the discharge end of the line plain unthreaded and a minimum of 3 4 in diameter Is the discharge line material suitable for at least 180 F water Did you take measures to protect the PRV and PRV discharge line from freezing Have you verified the PRV is not plumbed with the condensate drain line Have you verified the PRV is not plugged and that reducing fit...

Page 66: ...therefore additional water is necessary to maintain proper pressure in the heating system Water pressure needed for operation The boiler is in normal operation between 14 PSI and 43 5 PSI Below 10 1 PSI the boiler will have an error code Fault 108 on the display and be blocked from operation Increasing the heating system water pressure will be necessary for operation Between 10 PSI and 14 PSI oper...

Page 67: ...options Back Press to go back one screen Reset Press to reset a fault code See Reset Fault Code section in this section for more information OK Press to select an item Chimney Active Service Mode Press to enter into service mode which allows adjustment of high fire low fire and O2 settings See Chimney Active Service Mode section in this section for more information Boiler Display Displays boiler s...

Page 68: ...mation Fire level status Scale rises as the temperature increases HOT COOL Visual illustration of current central heating temperature Central heating status symbol A box around the radiator symbol indicates central heating is in operation Current date and time Outdoor temperature Current central heating system water pressure High fire maximum of six bars Low fire DHW comfort or economy mode is act...

Page 69: ...ht Complete Menu Press OK 3 Turn the selector wheel to highlight Screen Settings Press OK 4 Turn the selector wheel to highlight Time Date Press OK 5 Edit the following screen 6 Press Save 7 To exit press the Back button until the Home screen appears on the display To change the unit of measurements appearing on the boiler display follow the steps below 1 From the controller Home screen press OK 2...

Page 70: ...urn the boiler on or off press the Power switch I On O Off From the controller Home screen press OK Turn the selector wheel to highlight Complete Menu Press OK CH Settings is highlighted Press OK CH Setpoint Temp is highlighted Press OK Home screen 2 3 4 1 ...

Page 71: ...lable temperature settings minimum to maximum 68 F 185 F 20 C 85 C Press the Back button until the Home screen appears on the display 5 6 7 NOTE Z2 and Z3 are not active controls on this boiler From the controller Home screen press BACK Turn the selector wheel to the desired DHW setpoint temperature The boiler will automatically save the new setpoint temperature after five seconds Home screen 2 1 ...

Page 72: ...time selections This selection requires more energy use than when disabled but not as much energy use as the Always Active option Option 3 Disabled The boiler operates and produces hot water however it will not maintain the primary heat exchanger temperature for quicker hot water production This selection saves some energy but requires longer time to provide hot water to the hot water fixtures Alw...

Page 73: ...Turn the selector wheel to highlight Complete Menu Press OK Home screen 2 1 Turn the selector wheel to highlight DHW Settings Press OK 3 Turn the selector wheel to highlight Comfort Function Press OK Disabled is selected Press OK Comfort mode is disabled To exit press the Back button until the Home screen appears on the display The message below appears ...

Page 74: ...ars To enable the Time Based comfort mode setting follow the steps below 7 8 6 Press the Back button one time The following screen appears Select Time program Select one of the two options Free Time Programming user defined times for when comfort mode is active Preset programs options for preset times for comfort mode to be active DHW is selected Press OK 9 Turn the selector wheel to highlight Set...

Page 75: ...unction in main menu CH or 4 2 1 2 2 8 0 Combi 2 Solo 0 all Combi models 1 Solo boiler with 10KΩ NTC thermistor in DHW indirect tank 2 Solo boiler with aquastat in DHW indirect tank 2 4 9 0 5 to 5 F Outdoor reset temp sensor correction May need if outdoor reset is in direct sunlight etc 2 5 0 2 0 Eco off 1 Schedule 2 Comfort DHW Comfort Mode Also available from home screen DHW 2 5 7 1 0 OFF 1 ON A...

Page 76: ...ure reset Also available from AUTO function in main menu CH or 2 2 4 DO NOT USE 1 2 or 4 4 2 2 LT 0 8 HT 2 0 LT 0 2 1 0 HT 1 0 3 5 Slope of outdoor reset curve see separate slides depends on 4 2 0 setting 4 2 3 0 Depends on curve settings Heating curve offset parallel shift 4 2 5 LT 122 F HT 185 F LT 68 122 F HT 68 185 F Maximum supply temp F 4 2 6 68 F LT 68 122 F HT 68 185 F Minimum supply temp ...

Page 77: ... 5 l min DHW rate note this is in liters multiply by 264 for GPM 8 2 7 Pump modulation will never read above 90 8 2 8 kW Boiler power during operation multiply by 3412 for BTU 8 2 9 PSI Actual PSI also on home screen 8 3 0 F CH Flow Setpoint also called T set 8 3 1 F T1 Supply temp 8 3 2 F T2 Return temp 8 3 3 F T3 combi DHW temp 8 3 5 F Outdoor temp sensor also on home screen 8 4 0 F Indirect tan...

Page 78: ...urn the selector wheel to highlight Complete Menu Press OK Home screen 2 3 1 To follow is an example of how to adjust parameters on the M Series Boiler The 007 Menu is where all parameters can be adjusted All commonly adjusted parameters can be accessed in the Complete Menu Turn the selector wheel to highlight 2 Boiler Parameters Press OK 4 The first digit shown is the first value in the parameter...

Page 79: ...ss OK Turn the selector wheel to highlight 2 0 4 Altitude Press OK 5 6 Press the Back button until the Home screen appears on the display Scroll to the desired altitude and press OK Note Altitude is displayed in Feet FT measurements 7 8 The parameter had now been updated to the set value ...

Page 80: ... boiler parameters The outdoor ambient temperature is observed via the provided outdoor temperature sensor The outdoor temperature sensor should be mounted on a North facing wall of the house below an eave to avoid direct sunlight to prevent obtaining a false reading of the outdoor temperature The sensor should also be mounted away from any vent duct or other device that may create an artificial h...

Page 81: ...eter Settings Table for more information Outdoor Temperature Sensor The boiler comes equipped with several outdoor reset curves which are different target temperature lines dependent on the outdoor temperature The selected curve should be based off of the type of heat emitter and the target temperature desired The steeper the curve higher the value the quicker the system will come up to temperatur...

Page 82: ...consult your heating design engineer Below are some typical target temperatures for various heat emitters Key Outdoor Reset Parameters Parameter Address Description Value 4 2 0 Curve Presets 1 High temperature all apps except in floor slab radiant applications 2 Low temperature in floor slab radiant apps 4 2 2 Slope High value steep slope Low value gradual slope 4 2 5 Maximum temperature Raises lo...

Page 83: ...ton 107 Flow Check 5 Failed The return water temperature is more than 63 F higher than the supply water temperature and the burner is on CH Operation Press the Reset button 108 Supply Pressure is below Minimum Pressure The supply pressure is below minimum pressure and the burner is on The burner is off with the supply pressure below the minimum pressure and air purge is active for 40 seconds CH Op...

Page 84: ...t PC Board error PC Board Press the Reset button 309 Gas Relay Check Failed Flame detected for 3 seconds after the gas valve closed PC Board Press the Reset button 3P9 Scheduled Maintenance Call Service The maintenance timer has expired PC Board Reset the monthly timer for the next maintenance interval reminder 501 No Flame Detected Flame not detected Flame ignition detection Press the Reset butto...

Page 85: ...appears Do you really want to perform the reset Press OK to reset the error Press the ESC keyboard button to cancel reset and return to the previous screen To reset the fault code press the RESET button The Reset in Progress message appears The Fault Solved message appears After the code is reset the Home screen automatically appears 1 2 3 4 5 6 ...

Page 86: ...s as the technical code Turn the selector wheel to highlight Complete Menu Press OK Turn the selector wheel to highlight 8 Service Param Press OK Home screen 2 3 4 1 5 Turn the selector wheel to highlight 8 6 Error History Press OK 6 Option 8 6 0 Last 10 Errors is highlighted Press OK 7 Scroll to view the last 10 errors Error description Error number Time and date when error occurred ...

Page 87: ... Chimney Active service mode defaults to 100 Use the selector wheel to adjust between 0 to 100 and then press OK 0 boiler will run on low fire low load 100 boiler will run on maximum fire full load To exit Chimney Active service mode press the Back button until the Home screen appears on the display The following screen appears indicating that Chimney Active service mode is active This section sho...

Page 88: ...f the Supply Temperature thermistor T1 observes a temperature less than 47 F the boiler pump will run for 2 minutes The internal three way valve will alternate every minute to ensure circulation through both the primary heat exchanger and the plate heat exchanger If T1 observes a temperature less than 39 F the burner will fire for 30 seconds or until the T1 sensor observes a temperature higher tha...

Page 89: ...est the Ignition Safety Shut Off Device If you encounter a problem that is difficult to solve stop the operation and immediately contact a licensed professional MONTHLY Boiler Area Verify the area is free of combustible materials gasoline and other flammable vapors and liquids Verify the area is clean from dust and obstructions Verify the air intake area is free of any contaminants listed in the b...

Page 90: ...rap Remove the sediment and then return the plug Do not use a wrench to tighten the condensate drain as this could cause the connection to break Condensation Drain Confirm the condensation drain line is not blocked or clocked Ensure the condensation drain pump if utilized is working correctly Draining Water When the system will be shutdown for a long period of time seasonal shutdown close the shut...

Page 91: ...antifreezes 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 The allowed maximum concentration is 50 percent Coast Area Installations Installations located in or near coastal areas may require additional maintenance due to corrosive airborne ocean salt I...

Page 92: ...ntrol panel press and hold the Service Mode button for approximately 7 seconds 5 The boiler initiates one start up attempt and four restart attempts After the last start up attempt the boiler locks out and the gas valve shuts off Code 501 No Flame Detected appears on the controller display 6 Reconnect the wiring connection to the flame rod Be careful not to touch the inside of the wiring connectio...

Page 93: ... RhoGard Mutli Metal AL safe Sentinel X500 Below is a list of approved system cleaners inhibitors and antifreezes for use in hydronic plumbing systems utilizing Rinnai boilers IMPORTANT If replacing a boiler add system cleaners while the old boiler is installed and operate the old boiler for heating for several days to most effectively clean the system The Rinnai boiler must be closed off valved o...

Page 94: ...tem with water 2 Isolate the boiler from the CH system 3 Fill the CH system with an approved cleaner and circulate through the system 4 If the installation is a zone system utilizes multiple zones flush out each zone individually 5 Flush the CH system with water again ensuring all zones have been flushed 6 Clean out the dirt trap per manufacturer s instructions 7 The boiler and system may now be f...

Page 95: ...09000161 1 1 1 1 12 Front cover 809000145 1 1 1 1 13 Screw M5 x 12 mm 809000019 2 2 2 2 14 Hinge 809000146 2 2 2 2 50 2 pipe adapter 802000005 1 1 1 1 51 3 in PVC adapter 802000006 2 2 2 2 53 Measurement port plug 808000024 1 1 1 1 54 Gas valve screw plug 809000148 1 1 1 1 55 3 5 Concentric Adapter 802000008 1 1 1 1 56 2 Flue Adapter 802000007 1 1 1 1 50 ...

Page 96: ...96 Rinnai M Series Condensing Boiler Combi Manual Heat Exchanger ...

Page 97: ...807000138 1 1 1 40 Stainless Steel Screw M6x12 809000163 2 2 2 2 41 Condensate trap latch 807000139 1 1 1 1 42 Flue gasket 802000002 1 1 1 1 43 Exhaust vent box 802000003 1 1 1 1 44 Flue condensate tray gasket 802000004 1 1 1 1 46 De aerator 807000024 1 1 1 1 47 Clamp bar 809000147 2 2 2 2 48 Silencer 808000038 1 1 1 1 49 Silencer gasket 808000039 1 1 1 1 99 Water control assembly retention clip 8...

Page 98: ...98 Rinnai M Series Condensing Boiler Combi Manual Hydraulic Parts Pipes ...

Page 99: ...1 1 88 Cold water supply pipe 807000150 1 1 1 1 89 De Aerator o ring Ø13 94 x 2 62 mm 809000028 1 1 1 1 90 Water control assembly return 807000151 1 1 1 1 91 3 way valve cartridge 807000152 1 1 1 1 92 O ring Ø18 x 2 mm 809000162 1 1 1 1 93 Flow restrictor yellow 807000154 1 Flow restrictor blue 807000155 1 1 1 94 3 way valve pump pipe 807000156 1 1 1 1 95 O ring Ø21 89 x 2 62 mm 809000088 5 5 5 5 ...

Page 100: ...PT 807000168 2 2 2 2 126 O Ring Ø21 82 x 3 53 mm 807000153 3 3 3 3 128 Screw M5x12 809000045 2 2 2 2 129 Flow sensor retention clip 809000151 1 1 1 1 130 Gas valve 806000034 1 1 1 1 131 3 4 in gas valve gasket 809000062 1 1 1 1 133 Yellow silicone o ring Ø13 94 x 2 62 mm 809000055 1 1 1 1 134 Gas pipe to gas valve 806000047 1 1 1 1 135 Gas pipe gas valve to fan 806000048 1 1 1 1 136 3 way valve ac...

Page 101: ...Rinnai M Series Condensing Boiler Combi Manual 101 Electrical Components Solo Only ...

Page 102: ...53 1 1 1 1 150 Hinge support 809000154 2 2 2 2 152 Fuse 4A 250V 805000068 1 1 1 1 153 Screw terminal white 805000069 1 1 1 1 Screw terminal blue 805000071 1 1 1 1 Screw terminal red 805000072 1 1 1 1 154 Wire harness 805000073 1 1 1 1 155 Power Cord 805000074 1 1 1 1 156 Controller gasket 809000155 1 1 1 1 157 Controller scroll wheel 809000156 1 1 1 1 159 Controller cover 809000157 1 1 1 1 160 On ...

Page 103: ...ing applications When using external pumps Large zoned systems High flow applications Systems with high differential pressures Systems with high pressure drops For pressure curve information refer to the following sections in the Appendix 14 8 CH Pressure Drop and Flow Curve 14 9 DHW Pressure Drop and Flow Curve This picture illustrates a suggested arrangement Some of the fittings are optional ...

Page 104: ...104 Rinnai M Series Condensing Boiler Combi Manual PC Board Wiring for the above application example Outdoor Temperature Sensor Thermostat Pump Zone Control Low Water Cut off If Required ...

Page 105: ... Boiler Combi Manual 105 Outdoor Temperature Sensor Thermostat 1 Pump Zone Control Low Water Cut off If Required Thermostat 2 Thermostat 3 Zone Valve 3 Zone Valve 2 Zone Valve 1 PC Board Wiring for the above application example ...

Page 106: ...6 Rinnai M Series Condensing Boiler Combi Manual PC Board Wiring for the above application example Outdoor Temperature Sensor Pump Zone Control Low Water Cut off If Required Thermostat Air Handler Control ...

Page 107: ...s Condensing Boiler Combi Manual 107 PC Board Wiring for the above application example Outdoor Temperature Sensor Thermostat 1 Zone Control Low Water Cut off If Required Thermostat 2 Thermostat 3 Pump 3 Pump 2 Pump 1 ...

Page 108: ...ai M Series Condensing Boiler Combi Manual PC Board Wiring for the above application example Outdoor Temperature Sensor Thermostat 1 Zone Control Low Water Cut off If Required Thermostat 2 Pump 3 Pump 2 Pump 1 ...

Page 109: ...lect the gas type The gas supply shall be shut off prior to disconnecting the electrical power before proceeding with the conversion CAUTION Do not touch any other areas on the PC board other than the described buttons while power is supplied to the appliance Parts of the PC board are supplied with 120 volts AC CAUTION Do not touch the areas at or near the heat exchanger or hot water lines These a...

Page 110: ...ply by turning off the gas control valve 4 Remove the boiler s front panel For details see section 3 7 How to Remove the Front Panel 5 Remove the air supply damper Unclip the Velcro piece Lift up the air supply damper to remove and gently place aside 6 Unscrew the gas valve and gas venturi connections Air supply damper 8 Pull out the yellow gasket from the gas venturi Gas line 7 Remove the gas lin...

Page 111: ...and unclip the 6 tabs from the front panel 14 Remove the front housing of the PC Board 15 Insert the EEPROM key included with conversion kit into the connector on the PC Board 19 Press the Back button for approximately 7 seconds Your psi values may differ than the values shown in image Controller top view Controller bottom Screw terminals 16 Reattach the PC Board front housing and screw terminals ...

Page 112: ...ect power to the boiler b Remove the front housing of the PC Board c Remove the EEPROM key from the connector 25 Reattach the PC Board front housing and screw terminals Clip the 6 tabs back into place 26 Connect electrical power to the boiler The boiler will be back in normal operating mode with the proper gas type parameters 27 Replace the boiler front panel 28 The conversion process is complete ...

Page 113: ...Rinnai M Series Condensing Boiler Combi Manual 113 ...

Page 114: ...114 Rinnai M Series Condensing Boiler Combi Manual ...

Page 115: ...ies Condensing Boiler Combi Manual 115 0 1 2 3 4 5 6 7 8 9 10 20 15 25 30 10 5 0 Water Flow GPM Pressure Loss Feet of Head Pressure drop curve applies to all M Series Condensing Boilers M060C M090C M120C and M160C ...

Page 116: ...116 Rinnai M Series Condensing Boiler Combi Manual Water Flow GPM Pressure Loss Feet of Head 35 30 25 0 5 10 15 20 0 0 5 1 1 5 2 2 5 3 3 5 4 ...

Page 117: ... 387 34 93 2 6 811 5 41 0 2 284 36 96 8 6 271 6 42 8 2 186 38 100 4 5 779 7 44 6 2 093 40 104 0 5 330 8 46 4 2 004 42 107 6 4 921 9 48 2 1 920 44 111 2 4 547 10 50 0 1 840 46 114 8 4 205 11 51 8 1 763 48 118 4 3 892 12 53 6 1 690 50 122 0 3 605 13 55 4 1 621 52 125 6 3 343 14 57 2 1 555 54 129 2 3 102 15 59 0 1 492 56 132 8 2 880 16 60 8 1 433 58 136 4 2 677 17 62 6 1 375 60 140 0 2 490 18 64 4 1 ...

Page 118: ...urn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers 4 Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously 5 Test for spillage at the draft hood relief opening after five minutes of main burner operatio...

Page 119: ... property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors A In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic the hard wired carbon monoxide detector with alarm and battery back up may be installed on the next adjacent floor level B In the event that the re...

Page 120: ...tes if the product is moved or reinstalled at a new location 1 Parts replaced during recommended maintenance procedures are not covered by this Limited Warranty What Will Rinnai Do Rinnai will repair or replace the covered product or any part or component that is defective in materials or workmanship as set forth in the above table Rinnai will pay reasonable labor charges associated with the repai...

Page 121: ...emical agents are used such as but not limited to chlorine hair spray or hair dyes Damage or failure caused by contaminated air including but not limited to sheetrock particles plasterboard particles dust dirt or lint entering the boiler or any of its components Incorrect sizing A failure of any component in the Hydronic system not supplied by Rinnai Any other causes other than defects in material...

Page 122: ...122 Rinnai M Series Condensing Boiler Combi Manual 800000063 03 6 2019 ...

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