Installation & Servicing Instructions High efficiency condensing gas boiler E60SRN/E85SRN/E110SRN E60SRP/E85SRP/E110SRP 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 (exposure to hazardous materials) or loss of life. Refer to the user's information manual provided with this boiler.
Contents of instructions These installation instructions contain important information for the safe installation, start-up and maintenance of boilers with capacities 60,000 through 110,000 BTU/hr. These installation instructions are intended for licensed professionals, who have the necessary knowledge and are approved for working on heating and gas systems.
Content 2 3 4 5 6 Safety and general instructions ........................................................4 1.1 Designated use ...................................................................4 1.2 Hazard definitions ................................................................4 1.3 Symbol definitions ...............................................................4 1.4 The following instructions must be followed ........................5 1.5 Follow these instructions for the space heating water ......
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. The boiler is delivered with a burner controller (MCBA) pre-installed.The boiler can be fitted with a outdoor reset sensor (included with the boiler) or an On/Off thermostat or relay panel end switch (field supplied accessories). 1.
1.4 The following instructions must be followed - The boiler must only be used for its designated purpose, as described in the Installation Instructions. Each unit is fitted with a data plate. Consult the details on this plate to verify whether 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.
i NOTICE at a location external to the appliance. Chemicals that are corrosive in nature should not be stored or used near the boiler or vent termination. 1.5 Boiler System Water Requirements 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.
1.7 Relevant Installation, Service and User manuals – Approved vent system – User 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.
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.
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 contents: Description E60SRN E60SRP Part No. Fitting Kit complete: Amount E85SRN E85CRP E110SRN E110SRP 803000022 Boiler with: Outdoor reset sensor 1 1 22mm compression fitting ring 4 4 1 4 Nut W1.1/8x1/14 22 Compression fitting 2 2 2 Adapter fitting 22mm x 1"NPT ext.
5 Installation 5.1 Requirements for installation location ! DANGER - Installation & Servicing Instructions Rinnai E-Series - 10 This boiler is intended for indoor installations only. The room where the boiler will be placed must always be free from freezing conditions. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. Never use or store any chlorinated detergents or halogenated hydrocarbons (e.g.
5.2 Mounting the boiler i NOTICE i NOTICE - Remove the packaging materials. - Lay the boiler on its back during unpacking. Remove the cover from the boiler. This part may be left off 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. Turn the boiler to its side and remove the wall bracket from the back of the boiler by removing the 2 screws.
5.3 Dimensions E60SRN E60SRP E85SRN E85SRP E110SRN E110SRP F C D E V A f S T g r c PQR H G J K B dimensions figure 1 6\VWHP Installation & Servicing Instructions Rinnai E-Series %RLOHU W\SH 12 $ % & ' ( ) * + . 3 4 5 6 7 9 +HLJKW :LGWK 'HSWK /HIW VLGH YHQW &HQWHU WR FHQWHU YHQW DQG DLU VXSSO\ %DFN YHQW /HIW VLGH JDV SLSH /HIW VLGH VXSSO\ SLSH /HIW VLGH UHWXUQ SLSH /HIW VLGH FRQGHQVDWH SLSH 3LSH OHQJWK RI J 3LSH OHQJWK RI F 3LSH OHQJWK RI I DQG U %DFN &HQWHU RI SLSH F %DFN
5.3.1 Clearances from boiler ceiling Min. 10" / 250mm 24" 600 2" 50 wall 15.7" 400 2" 50 figure 4 Minimum required clearances to combustibles All types inch / mm 0" 0" 1" / 25 0" 0" Minimum required clearances to non-combustibles All types inch / mm 0" 0" 1" / 25 0" 0" Floor / Ground to bottom of boiler 0" 0" Vent 0" 0" Top of boiler Back of boiler Front of boiler Left side of boiler Right side of boiler clearances to the boiler For closet installation: clearance is 1” / 25mm from the front.
5.4 Technical specifications ( 6HULHV %RLOHU W\SH ,QSXW &+ ,QSXW '+: +HDWLQJ FDSDFLW\ 2 DW IXOO ORDG (OHFWULFDO SRZHU FRQVXPSWLRQ PD[ (OHFWULFDO SRZHU FRQVXPSWLRQ VWDQG E\ &XUUHQW )XVH UDWLQJ 'HJUHH RI SURWHFWLRQ DFF (1 :HLJKW HPSW\ :DWHU FRQWHQW &+ $IWHU UXQ WLPH SXPS &+ 306 :DWHU SUHVVXUH PLQ PD[ 6XSSO\ WHPSHUDWXUH PD[ 3XPS W\SH $YDLODEOH SXPS KHLJKW &+ $SSURYDOV &6$ QXPEHU &51 QXPEHU Installation & Servicing Instructions Rinnai E-Series Technical specifications 14 %78 KU N: %78 KU N: %
6 Connecting the boiler The boiler has the following pipe connection; - The central heating circuit pipes. - The gas supply pipe. Provided with a 3/4" male thread. See further chapter 6.4; - The condensation drain pipe. It consists of an oval 7/8" (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.
6.1 Central heating system Installation & Servicing Instructions Rinnai E-Series Connect the central heating system according to its instructions. 16 i NOTICE When removing the plastic sealing caps from the pipes, water may come out of the boiler due to live fire testing during manufacturing.
- Boiler system flushing (Not Boiler heat exchanger) When replacing an existing boiler the heating system shall be flushed with an approved system cleaner (refer to system cleaner list) before the new boiler is added to the system. If the old boiler has already been removed a bypass must be piped in when the new boiler is installed in order to facilitate the flushing of the system. The boiler must be valved off from the system, while the system is flushed.
manufacturer. 11. If the installation is a zone system be sure to purge out each zone individually 12. Close the auto feed on the system (F1) 13. Close the return side purge station (BD2) and disconnect the hose (H3). 14. Open the main valve on the system return (V3) 15. Close the bypass valve below the boiler (V4). 16. Open shutoff valves on both the supply and return connections below the boiler (V1 and V2). 17. Clean out the dirt trap 18.
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. NOTICE - i Position H3 (figure 7) is a garden hose thread boiler drain, that can be used to drain the boiler or add water treatment additives to the system, such as inhibitors or glycol.
6.1.1 i NOTICE 6.1.2 i NOTICE Safety valve An ASME 30 psi pressure relief valve is included with the boiler and must be fitted before any shut off valve in the system. Low water cut off The Rinnai E boiler has a factory installed pressure sensor 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. The boiler's internal low water cut off is not serviceable or adjustable . 6.
Natural gas: resume with chapter 6.4.1 When propane gas is desired, the boiler can be converted to propane gas by means of a conversion kit. Rinnai Part number: E60SR: 803000016 E85SR: 803000018 E110SR: 803000020 Propane gas: resume with chapter 6.4.2 When natural gas is desired, the boiler can be converted to natural gas by means of a conversion kit. Rinnai Part number: E60SR: 803000017 E85SR: 803000018 E110SR: 803000021. 6.4.
6.4.2 i NOTICE 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. Pipe sizing for propane gas - Contact gas supplier to size pipes, tanks, and gas pressure regulator.
6.5 Condensate drain pipe This boiler produces condensate. Condensate must be drained otherwise the boiler will not function and can cause product or 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 1.25" / 32mm. Install the condensation drain pipe according to applicable local code.
6.6 Vent system and air supply system Provisions for combustion and ventilation air must be made in accordance with section, Air for Combustion and Ventilation of the National Flue Gas Code, ANSI Z223.1, or applicable provisions of the local building codes. - i NOTICE 6.6.1 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.
6.6.
6.6.
Examples vent and air supply systems (PP Twin Pipe and Flex) Vertical twin pipe termination figure 13F Horizontal twin pipe elbow termination figure 13G Horizontal twin pipe concentric termination figure 13H Horizontal twin pipe elbow termination below grade figure 13J Installation & Servicing Instructions Rinnai E-Series 6.6.
Installation & Servicing Instructions Rinnai E-Series Flex through chimney termination 28 figure 13K Flex through B vent as a chase termination figure 13L
6.6.2 d Boiler Exhaust Vent Hanger and Support (Rigid Pipes) The purpose of this section is to provide more information about Rinnai’s requirement that the vent system installed with the Rinnai boiler must be appropriately supported. As we state elsewhere in this manual, "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.
6.6.3 Installation of the vent system i NOTICE Consult local and state codes pertaining to special building code and fire department requirements. Adhere to national code requirements. i NOTICE Follow the listed maximum length of vent systems, which are boiler output dependent. The maximum permissible lengths are listed in table 9, chapter 6.6.6. Decide how to install the exhaust and air intake system. You can choose between: - Parallel system (see chapter 6.6.
6.6.3.1 A Boiler conversion from concentric to parallel A. 1. Push the 2 clips slightly outwards B B. 2. Pull the concentric adaptor out of the boiler 3. Press the cover in the connection at the back from inside out C C. 4. Push the 3" air intake connector into the connection at the back of the boiler 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.
6.6.4 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.
i NOTICE ! CAUTION ! CAUTION The termination shall be at least 4 feet (1,220 mm) distance from electric meters, gas meters, regulators and relief equipment. (for room air application only) i NOTICE 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.
12" (300 mm) minimum 12" (300 mm) minimum EXHAUST INTAKE 12" (300 mm) minimum 12" (300 mm) minimum 12" (300 mm) minimum Terminal positions PVC 6.6.5 ! figure 16 Direct vent closet and alcove installation 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. WARNING Rinnai strongly suggests the use of PPs venting for all closet and alcove installations.
6.6.6 ! DANGER 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. 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.
6.6.7 Combustion air and vent piping lengths. In the table below you will find the maximum equivalent pipe length of the vent/air system based on 2" and 3" diameter. These lengths are for single pipe (room air) and twin pipe and concentric venting systems. 0D[LPXP (TXLYDOHQW /HQJWK 'LPHQVLRQ LQ )HHW DQG 0HWHUV 0RGHO 9HQW 7\SH 6SHFLILF ,WHP 9HQW W\SH ´ 336 6LQJOH 3LSH 5RRP $LU 7ZLQ 3LSH ´ 336 6LQJOH 3LSH 5RRP $LU 7ZLQ 3LSH ´ 336 7ZLQ 3LSH WR ´ ´ 336 &QFWUF 7HUPLQDWLRQ
6.6.8 Calculation of compensation factor The compensation factor eliminates or reduces the natural effect of derate of maximum 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. (T OHQJWK IW ( 65 PLQ PD[ Compensation factor vent system CP(V) %RLOHU W\SH ( 65 ( 65 &) 9 table 10 2.
6.6.9 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 boiler.
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." A confined space must have two combustion air openings.
Using Indoor Air For Combustion When using air from other room(s) in the building, the total volume of the room(s) must be of adequate volume (Greater than 50 cubic feet per 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.
7 ! External domestic hot water tanks WARNING Note the local codes for requirements for connecting an external hot water cylinder to the boiler. The installation must comply to these codes. Depending on the domestic hot water requirements and comfort preferences various external hot water tanks can be connected to the boiler. Connecting an external hot water tank to the E-Series solo boilers can be done in 2 ways: 1.
8 Electrical connections The electrical connections to the boiler must be electrically grounded in accordance with all applicable local codes and the latest revision of the National Electrical Code, ANSI/NFPA-70. Devices such as, outdoor sensor, room thermostat or temperature control, and temperature sensor or thermostat are all connected to the internal connection terminal. The connection terminal is situated behind the Control Tower.
i NOTICE i NOTICE i 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. When using an on/off thermostat or control, it may be necessary to calibrate the anticipating resistance to prevent too high temperature fluctuations. As a standard rule this means mercury thermostats.
3 4 electrical diagram 2 5 N 1 120 V~ N L 120 V~ Power supply 6 L 7 8 N 120 V~ 9 L L 11 N 10 120 V~ 12 13 14 15 16 17 Cylinder connection DHW three-way valve sensor CH DHW N 18 19 20 A 21 B Bus Outside sensor Controller 22 23 Room therm. On / Off 24 25 External safety contact Installation & Servicing Instructions Rinnai E-Series 8U.35.60.
Installation & Servicing Instructions Rinnai E-Series electrical ladder diagram figure 23a
9 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 boiler installation is empty the display will show FILL.
9.1 Explanation of the function buttons 2 1 3 7 4 6 5 8 Boiler control panel i NOTICE figure 24 Only licensed professionals who are trained for servicing these boilers are permitted to make alterations in the controller to calibrate the boiler to the installation. 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.
10 Starting up: Filling and de-aerating the boiler and installation ! CAUTION i NOTICE i NOTICE ! WARNING CAUTION Observe the following rules of safety: - 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 132 and 14). - Never allow electrical or electronic components to come into contact with water.
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.
13 If A XX appears on the display, wait for 17 minutes; 14 Check the water pressure and if necessary top it up to 16 to 18 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.
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.
11 Adjustments When the boiler is installed the software has already been pre-programmed at the factory. All software adjustments of the boiler control are already pre-programmed for a heating system with radiators/convectors with a supply temperature of 176°F. The adjustments are described in the Parameter chapter on the following page.
3DUDPHWHU 0RGH 3$5$ 1 2* )$&725< 176°F 00 DESCRIPTION maximum supply temperature CH type of CH installation: No pre-selection made. Radiators, air heating, or convectors: T max. supply 176°F K factor heating curve 2.3; gradient 10°F/min; gear differential 10°F 5$1*( 68 - 176°F 00 - 04 00 01 3 4* max. 00 5* 6* 7* 10* 11* 14 15* 2.3 1.4 14°F 0°F 0°F 10°F/min. 00 23 27 36 43 49 73 89 -4°F 100°F 00 max. 100% 0 00 90 01 .
Service Mode 1 2 3 4 SERV 9$/8( OFF OFF OFF OFF DESCRIPTION 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 5$1*( OFF - max. OFF - max. OFF - max. ON - OFF . . . . Error Mode 9$/8( ERRO DESCRIPTION Err.L - Err.5 Last saved error until 5 last previous errors 1 error code 2 operation status boiler 3 °F supply water temperature T1 4 °F return water temperature T2 5 kW load (.. x3415 = ..
11.2 Activating factory settings (green button function) To activate the factory settings again please follow the next procedure (Note: all altered adjustments will be set back to their orignial factory settings that are accessible in the current service level the boiler is in either user or 123): - 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.
13 i Commissioning Work on the boiler must be carried out by a licensed professional, using correctly calibrated instruments with current test certification. These installation instructions are intended for licensed professionals, who have the necessary knowledge and are approved for working on heating and gas systems. NOTICE 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.
13.1 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. ! WARNING ! DANGER - Before leak testing the boiler, ensure all parts of the boiler such as electronics and wiring are properly covered and protected from the leak testing agent. - Do not spray the leak testing agent onto cables, plugs, electrical connection lines or electronic circuit boards. Do not allow it to drip onto them either.
13.3 Checking the O2 at full load (Step 1/3) The O2 percentage setting is required to be checked at commissioning, maintenance and faults and adjusted if needed. i NOTICE ! WARNING The O2 percentage is required to be checked and adjusted after a conversion from NG to LP or from LP to NG. This process must be done with a calibrated combustion analyzer that has been set to the correct gas type.
12.3.1 Checking the O2 at low load (Step 2/3) Step 2: O2 check on low load Setting the low load The low load of the boiler can be set by you as follows: - i - a i figure 27 NOTICE button until the minimum value (in kW) is achieved; The boiler will burn on low load (value on display in kW) value in BTU/hr = x3415 When adjusting from max. to min. load it is advisable to stop at medium load to allow the boiler to stabilize. Adjusting quickly from max. to min. could force the boiler into an error state.
12.3.2 Settings on the gas valve (Step 3/3) Step 3: Adjustment on the gas valve. i Only if the measured values are outside the range of the table on the previous page. NOTICE a checkpoint O2 figure 27 - Open the boiler as described on page 59. - Remove the black cover of the gas valve by unscrewing the sealed screw. - Set the boiler on full load (see Step 1) - The O2 values are set by using an Allen key (4 mm), or a large flat head screwdriver, on the screw “b”.
13.4 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 29. 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.
14 i NOTICE Maintenance Maintenance or changes to the boiler may only be carried out by a licensed professional. To protect yourself from harm, before performing maintenance: - Turn off the electrical power supply by switching off the boiler at the mains power switch or by turning off the electricity at the circuit breaker. Turn off the gas at the manual gas valve, usually located below the boiler. Turn off the incoming water supply.
14.2.1 Visual inspection for general signs of corrosion - 14.2.2 Check all gas and water pipes for signs of corrosion. Replace any pipes that are corroded. Measuring the ionization current See subsection 13.5 “Measuring the ionization current". 14.2.3 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 Testing for gas leaks See subsection 13.1 “Testing for gas leaks”. 14.2.
14.3 Maintenance activities i NOTICE 2 9 1 4 The fan unit and burner cassette (figure 32 to 34) (every 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; - Replace the gasket with a new one; - 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.
9 7 8 Siphon figure 35 13 14 11 Condensate tray ! 12 figure 36 Condensate trap and condensate tray (figure 35-37) (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).
Visual inspection of the flame (2 and 4 year maintenance) 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. 38). The flame pattern should be as shown in the figures below.
15 Parts of the boiler 4 2 1 7 3 13 12 5 6 T1 15 P1 T2 C G A 9 8 10 11 Rinnai E60SR 1 2 3 4 5 6 heat exchanger ignition unit fan unit air inlet damper gas valve automatic de-aerator T1 supply sensor T2 return sensor figure 41 7 8 9 10 11 12 ceramic burner cassette operating panel Control Tower (CMS) water filter return CH circulation pump exhaust P1 water pressure sensor 13 combustion air supply 14 CSA Data Plate (serial number) 15 ASME / NB / CRN data plate G A R C gas pipe supply c
16 Blocks and Errors 16.1 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 blocking 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. The following is a list of some messages. Blocks with a number in the last 2 positions.
16.2 Blocks An error, which has been detected, is indicated on the display by a block message. Blocks can be temporary in nature. The controller will do everything possible to prevent a system lock and temporarily switching off the boiler as a result of a block. Please see below for a summary of blocks. with a figure on the last 2 characters. Blocks Description Solution External safety contact open Rectify error as a result of which by determining contact is open.
16.3 Errors Code Description Solution Incorrect flame formation. boiler has not been burning but an ionization flow (flame) has still been detected Check whether the ionization cable and/or the electrode are responsible for a possible short-circuit. Remove the plugs from the ionization cable connected to the control unit and to the electrode. Now using a universal meter take a measurement between the ionization connection and the ground, now refit it part by part until a short-circuit takes place.
Code Description Solution Control unit error 1 Anticipation resistance wire not When a power stealing room stat device is placed the connection terminal present needs to be provided with the special anticipation resistance wire. 2 Software error control unit. Software error control unit. Replace the control unit. Remove the E-Prom from the defective control unit and place it onto the new control unit .The controller will automatically load the program into the new control unit.
Code Description Solution No signal from the fan The fan is not running. 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. Replace the fan Negative pressure on vent system (pressure difference) Check vent system. Vent system and air intake system must be installed according installation instructions. IF vent system is OK: Replace fan internal shut down of supply sensor T1 Check the data in Error mode.
Description Solution contact for return sensor T2 open Check the data in Error mode. Boiler data during error: 1 Error = 37 2 Operational status = 00 3 Flow temp. = xx* 4 Return temp. = -22 5 kW burner = 00** 6 % pomp = xx* * = variable values **= x3415=BTU/hr 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 32 occurs Replace the sensor. Control unit error Software error control unit.
16.4 Other Errors Complaint Description Central heating but no domestic hot water 1. Hot water but no central heating Central heating installation gets hot without being requested Installation & Servicing Instructions Rinnai E-Series radiators do not get hot enough or warming them up takes too long 74 -Key of the DHW program is not switched on Solution Switch on DHW program on the Control Tower 32. T3 DHW sensor in external cylinder defective Replace DHW sensor 4.
Installation & Servicing Instructions Rinnai E-Series
17 Spare parts Parts casing and rear wall E-Series 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.
1 2 3 4 5 6 7 8 76 77 78 80 81 82 83 84 85 86 87 88 89 GASKET CASING E CASING SET BOILER COVER BOLT M5X20 (SET OF 5 BOLTS) SPRING DOOR CASING GASKET CONTROLS DOOR CASING E USER MANUAL E-SERIES INSTALLATION MANUAL E-SERIES BRACKET E75C, E110C, Q85S & Q130S COVER AIR SUPPLY Ø80mm CONCENTRIC FLUE ADAPTOR 80/125"MM GASKET AIR INTAKE ø80 SHR FLUE GAS CONNECTOR 3" AIR INTAKE CONNECTOR 3" FLUE GAS PIPE OSS1 FLUE GAS PIPE OSS2/3/4 PLUG MEASURING POINT PARALLEL FLUE PIPE GASKET FLUE GAS PIPE PP GASKET AIR SUPPLY ø1
Parts heat exchanger E-Series 45 46 30 47 31 51 64 52 32 53 33 54 34 35 55 56 36 49 37 83 38 39 40 59 41 43 60 44 61 62 Installation & Servicing Instructions Rinnai E-Series 63 78
30 CLAMP BAR TOP PART H.EX. LONG 31 TOP PART HEAT EXCH. SET OSS1 TOP PART HEAT EXCH. SET OSS2 32 BOLT M 5X16 (5 PER PACKAGE) 33 GASKET FAN/TOP PART H.EX.
Parts pipes E-Series 138 121 122 113 112 Installation & Servicing Instructions Rinnai E-Series 304 80 308 91 92 93 94 94a 95 104 103 105 106a 106 107 109 111
91 O-RING ø21.89X2.62 GASLINE 92 GASKET FITTING 3/4" GASV. 93 GAS PIPE E60S/E85S GAS PIPE E110S 94 GAS FITTING OSS1/2 E 94a O-RING ø13,94X2,62 YELLOW SILI Q 95 FITTING GAS VALVE 3/4" 103 PIPE RET. FILTER-PUMP E 104 CONNECTION SET 22 X 3/4" M-NPT 105 FILTER RETURN PIPE 106 FILTER CAP 106a O-RING ø25,07 X 2,62 3WV 107 NUT M35 ø30 109 CONDENSATE COLLECTOR 111 TRAP - E SERIES 112 O-RING ø40X3,53 TRAP TRAY O RING ø18,72X2,62 18 2X2 62 EPDM (3 PER PACKAGE) 113 O-RING 121 PIPE FLOW. E60S & E85S PIPE FLOW.
Parts electrical components E-Series 162 T1 supply sensor 160 T2 return sensor 166 T5 flue gas sensor 168 HLS high limit switch 161 P1 162 160 161 water pressure sensor 168 170 166 Installation & Servicing Instructions Rinnai E-Series 168 82
Rinnai Part Number Item Description 805000041 805000046 805000015 805000018 805000021 805000016 805000022 805000010 805000011 809000093 805000025 805000026 805000027 809000094 807000126 807000127 805000032 805000034 805000050 805000035 805000036 805000037 805000039 808000020 805000038 806000019 805000033 805000047 140 HARNESS E STICKER CONNECTION TERMINAL CONNECTOR 2-POLE PURPLE CONNECTOR 3-POLE GRAY CONNECTOR 4-POLE BROWN CONNECTOR 2-POLE BLACK CONNECTOR 6-POLE BLUE 141 TRAFO 120V/24V SCREW 3,5X 9,5 VER
18 Parts list vent system 9HQW 3URGXFWV /LVWHG DQG 7HVWHG 9HQW 3URGXFWV IRU ( &5 ( 65 ( &5 ( 65 ( 65 ( &5 4 6 43 4 6 43 4 6 4 & DQG 4 6 0DQXIDFWXUHU +HDWIDE 7\SH &RQFHQWULF 7ZLQ 3LSH 0DQXIDFWXUHU ,3(; 7\SH 0DQXIDFWXUHU 6LPSVRQ 'XUD 9HQW 7\SH 0DQXIDFWXUHU 7\SH Installation & Servicing Instructions Rinnai E-Series DuraVent (PolyPro) 84 'HVFULSWLRQV '*9 &RQF $LU ,QWDNH 7HH '*9 &RQF ; /HQJWK '*9 &RQF ; /HQJWK '*9 &RQF +RU] 7HUP
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Vent Manufacturer Contact Information for Installation Instructions and Parts Lists: Heat-Fab Telephone: 800-772-0739 Fax: 413-863-4803 cystsvc@heat-fab.com www.heatfab.com IPEX Telephone: 800-463-9572 905-403-0264 Fax: 905-403-9195 www.ipexamerica.com Installation & Servicing Instructions Rinnai E-Series Simpson Dura-Vent Telephone: 518-463-7284 Fax: 518-463-5271 sales@duravent.com www.protechinfo.com 86 Rinnai/Ubbink Telephone: 800-621-9419 Fax: 678-829-1666 www.rinnai.
Appendix A - Outoor Reset Sensor Data and Resistance table NTC sensors 12 k: R 100 ° C 950 : B25/85 3750 K Temperature coefficient -4,2 %/K Temp [°C] NTC [kOhm] -30 171.70 -20 98.82 -10 58.82 0 36.10 10 22.79 20 14.77 25 12.00 30 9.81 40 6.65 50 4.61 60 3.25 70 2.34 80 1.71 90 1.27 100 0.95 110 0.73 120 0.
Appendix B - Optional accessories B.1 Low Loss Header Rinnai supplies optional for each type of boiler a Low Loss Header. Find below the dimensions. Plumbing Kit 1 Part. no.: 804000061 Suitable for: E60SRN / E60SRP E85SRN / E85SRP E110SRN / E110SRP 2.0” 50mm 4.7” 119mm 12.5” 319mm 10.2” 260mm 16” 406mm 5.2” 131mm 2.2” 55mm 5.6” 143mm 9” 229mm 14.2” 360mm 16.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. P shut off valve system circulator check valve balancing valve boiler drain valve dirt trap air separator automatic fill valve back flow preventer expansion tank bypass for system cleaning Low Loss Header T V1 V2 Service valve Service valve 11 7 1 6 2 5 8 9 3 10 4 Boiler basic piping fig. 5 Compression fittings. Parts: 1. Nut 1 2 2 i Clean pipe ends thoroughly. The outside sur face has to be smooth before fitting. 1.
B.2 Side mounting kit for the Low Loss header A side mounting kit for the low loss header is available as an accessory. This kit relocates the low loss header from directly below the boiler to the left side of the boiler only. The kit includes all the parts required to relocate the low loss header including all mounting brackets and material. This kit provides an alternative to for installations with height limitations and allows for an alternative piping installation.
Appendix C - Approved system cleaners, inhibitors and antifreeze The following is a list of approved system cleaners, inhibitors, and antifreeze. • Sentinel X500 • Fernox Alphi 11 Approved system cleaner: • Noble Noburst Hydronic System Cleaner • Rhomar Hydro-Solv 9100 • Fernox F3 Cleaner • Sentinel X400 The system cleaners from NoBurst, Rhomar, and Fernox are NOT to be used in the boiler.
07/2016 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 • 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 Toll Free: (800) 621-9419 • Tel: (678) 829-1700 • Fax: (678) 829-1666 • E-mail: info@rinnai.us • Internet: www.rinnai.us E. & O. E. This renewed publication cancels all previous installation instructions. The company reserves the right to change the specifications and dimensions without prior notice.
