INSTALLATION AND OPERATION MANUAL M-Series Condensing Boiler Wall-Mounted, Gas-Fired Combi Boiler Central Heating and Domestic Hot Water MODELS M060C M090C M120C M160C Certified to ANSI Z21.13 and CSA 4.9 WARNING life. • • • If the information in these instructions are not followed exactly, a fire or explosion may result causing property damage, personal injury, or loss of Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
1. Welcome ........................................................................................................................... 4 2. Safety................................................................................................................................ 5 2.1 Safety Symbols ........................................................................................................................... 5 2.2 Safety Precautions ...................................................................
8.7 Connect the Condensate Drain Line ......................................................................................... 56 9. Power Supply .................................................................................................................. 58 9.1 Guidelines ................................................................................................................................. 58 9.2 Electrical Connections ........................................................................
1 Thank you for purchasing a Rinnai Condensing Boiler. Before installing and operating this boiler, be sure to read these instructions completely and carefully to familiarize yourself with the boiler’s features and functionality. • • • You must read the entire manual to properly operate the boiler. • Keep this manual for future reference. • As when using any appliance generating heat, there are certain safety precautions you should follow. See section “2.
2 WARNING • • • • • 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. 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.
• Do not use this appliance if any part has • • • • • • • 6 • Flammable liquids such as cleaning been under water. 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.
3 Topics in this section • • • • • • • Front View Bottom View Components Specifications Dimensions Accessories How To Remove the Front Panel The M-Series Condensing Boiler is a wall-mounted, gas-fired boiler designed to providing heating and domestic hot water. For complete boiler information, refer to the “Rinnai M-Series Condensing Boiler Installation Manual” supplied with the boiler, or visit rinnai.us.
DHW Central Gas Central DHW Cold Inlet Heating Heating Hot Outlet Supply Return All items are field-supplied unless otherwise noted.
Exhaust Intake ❽ ❷ ❹ ❸ ❾ ❺ ❶ ⓫ Located behind #6 (Silencer) ❻ ⓭ ❼ ❿ Located behind #6 (Silencer) ⓬ ⓯ ⓰ ⓮ 1 iCon Heat Exchanger 9 Automatic De-aerator 2 Burner Hood with Burner Cassette 10 Control Panel 3 Fan with Integrated Venturi 11 Pressure Sensor 4 Gas Valve 12 Modulating Pump 5 Ignition Unit 13 Plate Heat Exchanger 6 Silencer 14 Diverter Valve 7 Condensate Tray 15 Flow Sensor 8 Flue Gas Exhaust/Air Intake with Measuring Points 16 Condensate Trap Rinnai M-S
Model M060C Dimensions - w, h, d M090C M120C M160C 17 in. x 28 in. x 10 in. (439 mm x 699 mm x 264 mm) Weight 77 lb (35 kg) 83.6 lb (38 kg) Appliance Type Wall-Mounted, Gas-Fired Combi Boiler Installation Type Indoor Ignition System Direct Electronic Ignition Heat Exchanger Type Heat Exchanger Surface Area Gas Consumption (Btu/h) Temperature Setting iCon1 7.
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.
Gas Domestic Cold Water Inlet Domestic Hot Water Outlet Central Heating Supply Central Heating Return Connection 12 Connection Size 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.
The following optional accessories are available for the Rinnai M-Series Condensing Boiler. CONDENSATE NEUTRALIZER Neutralizes the condensate generated by the boiler. SCALECUTTER REFILL CARTRIDGE SCALECUTTER Filters and reduces the amount of scale entering the boiler allowing for greater boiler longevity. DHW ISOLATION VALVE KIT Refill cartridge for the ScaleCutter filter assembly. For quick isolation of the boiler DHW connections.
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. You Will Need: • 1 Philips head screwdriver Using a Philips head screwdriver, remove the 2 screws from the top of the boiler. TIP Be careful not to lose the screws. You’ll need them when reinstalling the front cover. 2 Lift the tab slightly above the peg. 3 To remove, carefully lift the panel up and off to release it from the boiler.
4 Topics in this section • • • • • Installation Guidelines What You’ll Need Items Included Choose an Installation Location Mount the Boiler to the Wall THIS SECTION IS INTENDED FOR THE INSTALLER Installer qualifications: A trained and qualified professional must install the appliance, inspect it, and leak test the boiler before use. The warranty will be voided due to any improper installation.
• Ensure the wall is of sufficient strength to support the weight of the boiler, piping and any other components needed for installation; if it is not, please reinforce the wall as appropriate. • Operating limits of the boiler: Maximum boiler set point temperature: 185°F (85°C) Maximum operating 45 psi (3.1 bar) pressure: Maximum allowable 210°F (99°C) working temperature ASME: Maximum allowable 45 psi (3.
Carefully unpack your boiler system and verify the following contents are included. If any items are damaged or missing, contact your local dealer/distributor. Do not attempt to use any item that appears damaged. RINNAI CONDENSING BOILER Vent top with integrated 3 in. PP (80 mm) Connections Integrated Items Refer to section “3.3 Components” for a complete list of integrated parts.
When choosing an installation location, you must ensure that clearances will be met and that the vent length will be within required limits. Consider the installation environment, water quality, and need for freeze protection. Requirements for the gas line, water lines, electrical connection, and condensate disposal can be found in their respective installation sections in this manual. This section provides information on the importance of water quality to the Rinnai Condensing Boiler.
Air surrounding the boiler, venting, and vent termination(s) is used for combustion and must be free of any compounds that cause corrosion of internal components. These include corrosive compounds that are found in aerosol sprays, detergents, bleaches, cleaning solvents, oil based paints/varnishes, and refrigerants. The air in beauty shops, dry cleaning stores, photo processing labs, and storage areas for pool supplies often contains these compounds.
You Will Need: • • • 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. Rinnai Condensing Boiler Wall Mounting Bracket Boiler Mounting Template Supplied by Installer: • • • Level Four screws for mounting bracket installation Screws for top and bottom bracket installation Use appropriate screws for type of wall construction.
5 Topics in this section • • • • Guidelines Venting Installation Sequence Termination Considerations Venting Options • M-Series boilers can be installed in direct vent or non-direct vent applications. • When installed as Direct Vent, refer to the following section for a complete list of approved vent manufacturers and products: “5.4.1 Direct Vent: Approved Vent Manufacturers and Products.” • Venting should be as direct as possible with a minimum number of pipe fittings.
• Avoid termination locations near commercial cooking exhaust. • Avoid termination locations near any air inlets. • You must install a vent termination at least 12 in above the ground or anticipated snow level. 1. Determine the termination method— horizontal or vertical, concentric, or twin pipes, etc. The vent for this appliance shall not terminate: 2. Determine proper location for wall or roof penetration for each termination. 3.
Two venting options are available: Direct Vent and Non-Direct Vent (Room Air). Option 1 Direct Vent (Concentric and Twin Pipe) See Direct Vent section for complete details. Twin Pipe Concentric Pipe Combustion air and exhaust vent directly through a single concentric connection. Hot exhaust exits through the interior tube, while combustion air enters through the outer layer. Exhaust Exhaust Combustion air Option 2 Room Air Combustion air and exhaust vent directly through separate penetrations.
Following is a list of vent components and terminations for Direct Vent installations (concentric and twin pipe). Install the correct venting for your model according to the venting manufacturer’s instructions and the guidelines below. The information below is correct at time of publication and is subject to change without notice. Contact the vent manufacturer for questions related to the vent system, products, part numbers and instructions. Manufacturer Phone Web Site Ubbink 800-621-9419 www.rinnai.
Equivalent Length (ft) Vertical Horizontal Diagram Product Description Manufacturer Part Number Manufacturer 2 in./4 in. CONCENTRIC VENT TERMINATIONS (Continued) PVC Concentric Vent Kit 2 in. x 16 in. 20 52CVKGVS6502-28 PVC Concentric Vent Kit 2 in. x 28 in. 20 52CVKGVS6502-40 PVC Concentric Vent Kit 2 in. x 40 in. 20 CENTROTHERM ROYAL 52CVKGVS6502 ICRT2439 20 DURAVENT 2PPS-VKL/VK-TCL ECCO 2 in. x 4 in. Concentric Roof Termination 2 in. x 4 in.
Equivalent Length (ft) Vertical Horizontal Diagram Product Description Manufacturer Manufacturer Part Number 3 in./5 in. CONCENTRIC VENT TERMINATIONS UBBINK 3 in./5 in. CONCENTRIC VENT TERMINATIONS 223174PP 223176PP 223177PP 3/5 Condensing Horizontal Termination Kit 8.7 in. 3/5 Condensing Horizontal Termination Kit 12 in. 3/5 Condensing Horizontal Termination Kit 21 in. 5 223186PP 3/5 Condensing Horizontal Diverter Termination Kit 19 in.
Equivalent Length (ft) Vertical Horizontal Diagram Product Description Manufacturer Part Number Manufacturer METAL-FAB 3 in./5 in. CONCENTRIC VENT TERMINATIONS (Continued) 3CGRLSV Vertical Adapter 3CGRLSH Horizontal Adapter 3CGRVT Vertical Termination 3CGRHT Horizontal Termination 1 6 5 16 ECCO DURAVENT 3PPS-VKL/VK-TCL 3 in. x 5 in. Vertical Termination Cap Kit-Concentric 20 3PPS-HKL 3 in. x 5 in. Horizontal Termination Kit-Concentric 20 190388 3 in. x 5 in.
Equivalent Length (ft) Vertical Horizontal Diagram Product Description Manufacturer Part Number Manufacturer 2 in. TWIN PIPE TERMINATIONS IPEX DURAVENT CENTROTHERM 2 in. TWIN PIPE TERMINATIONS ISELL0287UV 2 in. 87° Long PPS-UV 6 ISTT0220 2 in. Termination Tee 6 ISLPT0202 2 in. Low Profile Wall Termination 5 2PPS-HTPL 2 in. Twin Pipe Termination 2PPS-HSTL 2 in. Single Horizontal Termination 6 2PPS-TBL 2 in.
Equivalent Length (ft) Vertical Horizontal Diagram Product Description Manufacturer Part Number Manufacturer 3 in. TWIN PIPE TERMINATIONS DIVERSITECH ROYAL IPEX DURAVENT CENTROTHERM 3 in. TWIN PIPE TERMINATIONS ISELL0387UV 3 in. 87° Long PPS-UV ISTT0320 3 in. Termination Tee ISLPT0303 3 in. Low Profile Wall Termination 3PPS-HTPL 3 in. Twin Pipe Termination 3PPS-HSTL 3 in. Single Horizontal Termination 3PPS-TBL 3 in.
Air Filter Screen Equivalent Length (ft) Vertical Horizontal Diagram Product Description VARIOUS 2 in. OR 3 in. SCHEDULE 40 PVC/CPVC TERMINATIONS N/A Tee 5 90° Elbow 5 45° Elbow 2.
The information below applies to Concentric and Twin Pipe. TERMINATION Clearance in Ref. A also applies to anticipated snow line X AIR SUPPLY INLET V VENT TERMINAL AREA WHERE TERMINAL IS NOT PERMITTTED SNOW Ref A B C Description Clearance above grade, veranda, porch, deck, or balcony Clearance to window or door that may be opened Clearance to permanently closed window Canadian Installations (CSA B149.1) U.S. Installations (ANSI Z223.1 /NFPA 54) Direct Vent (Indoor Unit) 12 in. (30 cm) 36 in.
Between terminals at different levels 60 in. (1.52 m) 12 in. (0.30 m) Note: 24 in. (0.61 m) to wall or parapet 12 in. (0.30 m) 60 in. (1.52 m) vertically between terminals Inside Corner Between terminals at same level 12 in. (0.30 m) All terminations (horizontal and/or vertical) must terminate 12 in. (0.30 m) above grade or anticipated snow level. Vent Sizes 2 in. X 4 in. 3 in. X 5 in.
The instructions below apply to concentric vent sizes 2 in. x 4 in. and 3 in. x 5 in. Remove the vent top (slightly twist counter-clockwise and pull up). Discard vent top if desired. Horizontal Wall Terminations 2 in. x 4 in. and 3 in. x 5 in. Slightly twist counter-clockwise Vertical Roof Terminations Pull up Insert the concentric adapter and rotate clockwise until locked in place. 2 in. x 4 in. and 3 in. x 5 in.
Horizontal Vent and Combustion Air Piping 12 in. (0.30 m) minimum Wall 12 in. (0.30 m) minimum Exhaust Zone 12 in. (0.30 m) minimum above combustion air opening 60 in. (1.5 m) minimum Exhaust Combustion Air Exhaust 12 in. (0.30 m) above grade or anticipated snow level Roof 12 in. (0.30 m) minimum Combustion Air 12 in. (0.30 m) above grade or anticipated snow level Combustion air termination not permitted in shaded area • • Vent Sizes • • 2 in. PVC 2 in. (60 mm) PP 3 in. PVC 3 in.
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. DO NOT apply PVC glues, solvents, or cleaners to the boiler’s combustion air or exhaust gasket connections. Failure to correctly assemble the components according to these instructions may result in property damage, personal injury, or death. WARNING Install 3 in. (80 mm) Polypropylene (PP) 1 Insert 3 in. (80 mm) PP piping. Install 3 in.
Slope horizontal exhaust 1/4 in. per foot towards the boiler. DO NOT slope combustion air pipe towards the boiler. CAUTION Rinnai cautions against installing the boiler in applications with venting in different pressure planes. It is possible to have poor performance with this installation. This configuration requires the use of a Concentric Vent Termination. This configuration requires the use of a Concentric Vent Termination. 2 in. or 3 in.
TERMINATION Clearance in Ref.
Room Air Vertical Termination of Multiple Boilers 12 in. (0.30 m) minimum Exhaust 12 in. (0.30 m) above grade or anticipated snow level Roof Exhaust Termination Clearances for Internal (Indoor) Room Air Applications 12 in. 12 in. (0.30 m) 60 in. (1.52 m) Vertically between terminals Inside Corner IMPORTANT • • 38 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.
ROOM AIR: INSTALLATION INSTRUCTIONS Insert air filter or elbow into 3 in. PVC intake air fitting. Elbow Air Filter Vent Sizes • • • • 2 in. PVC 2 in. (60 mm) PP Boiler Model Number M060C M090C, M120C, M160C Vent Lengths 60 ft (18 m) 30 ft (9 m) 3 in. PVC 3 in. (80 mm) PP M060C M090C, M120C, M160C 2 in.
WARNING • 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. Direct Venting is recommended in unusually tight buildings or in installation locations subject to significant negative air pressure.
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 connected. Louvers and Grills When sizing the permanent opening 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.
CAUTION Rinnai cautions against installing the boiler in applications with venting in different pressure planes. It is possible to have poor performance with this installation. 2 in. or 3 in. 2 in. or 3 in. Schedule 40 PVC/CPVC Snorkel Termination Configuration Schedule 40 2 in. or 3 in. 2 in. or 3 in.
6 Topics in this section • • • Connect the Gas Supply Gas Operating Instructions Gas Pipe Sizing Reference Tables WARNING • • • • • 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.
Gas Fitting Connection 1. If the system requires a 3/4 in. connection, attach the 1/2 in. FNPT x 3/4 in. MNPT connection fitting to the gas fitting on the bottom of the boiler. 2. Check the type of gas and gas supply pressure before connecting the boiler. If the boiler is not of the gas type that the building is supplied with, converting the gas type of the boiler is necessary. A gas conversion kit is included with the boiler. Refer to section “14.
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.
The gas supply must be capable of handling the entire GAS PIPE SIZING CALCULATION WORKSHEET gas load required at the location. Gas line sizing is based on gas type, the pressure drop in the system, Instructions: Enter values in empty boxes. the gas pressure supplied, and gas line type. For gas Rinnai Model Gas Input: pipe sizing, refer to the National Fuel Gas Code, ANSI A Btu/hr Z223.1/NFPA 54, or the Natural Gas and Propane Installation Code, CSA B149.
Natural Gas EXAMPLE Rinnai Model Gas Input: Pressure Drop 3.0 in. w.c. Intended use: Initial Schedule 40 Metallic Pipe supply pressure of 8.0 in. Inlet Pressure: Less than 2 psi w.c. or greater. Specific Gravity: 0.6 Information in table obtained from NFPA 54, ANSI Z223.1 - 2015. Nominal Pipe Size (in.
7 Topics in this section • Guidelines • Instructions • Piping Diagram for Basic DHW Installation 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. IMPORTANT • The piping (including soldering materials) • • • • • and components connected to this appliance must be approved for use in potable water systems. Purge the water line to remove all debris and air. Debris will damage the boiler.
Tempered Hot Water Supply to Fixtures Mixing Valve Heating Supply Heating Return Hot Water Supply Line Cold Water Supply Line Condensate Drain Line Sediment Filter (Recommended) This is not an engineering drawing; it 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.
8 • Topics in this section • • • • • • • • • • • • 50 Guidelines Instructions Common CH Components Piping Diagram for a Basic CH System (With Hydraulic Separation) Hydraulic Separation Connect the Pressure Relief Valves (DHW and CH) Connect the Condensate Drain Line • • It is required to include an air separator on the central heating supply of the system. System piping should be insulated when freezing is a potential concern.
Plumb the heating supply and return lines to the heating supply connection on the bottom of the boiler. It is required to use primary/secondary piping to the heating system. • Pressure/Temperature Gauge — The current pressure and temperature will alternately be displayed on the boiler control panel. A port for an external gauge is present in the PrimarySecondary Heating Kit accessory offered by Rinnai. • Pressure Relief Valve (PRV) — A PRV located directly on the supply side of the boiler is required.
CH System Common Components Diagram Low Water Cut Off (if required by local code) Pressure Relief Valve (supplied with boiler) Pressure Gauge (supplied with boiler) Air separator Primary-Secondary Heating Kit Dirt Trap System Return System Supply Backflow preventer Expansion tank 52 Fill valve with pressure gauge Ball valve Rinnai M-Series Condensing Boiler Combi Manual
IMPORTANT Optional Low Water Cut-Off (LWCO) Outdoor Sensor This schematic shows an example of a simple single zone system with primary/secondary piping by hydraulic separation. Pump Relay Thermostat Purge Station Heat Emitter This is not an engineering drawing; it 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.
Rinnai requires hydraulic separation between the boiler and central heating system. Hydraulic separators allow for no pump curve matching or flow calculation; this is ideal for multi-temperature 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.
WARNING Water discharged from the pressure relief valve could cause severe burns instantly or death from scalds. • The discharge end of the line shall be plain (unthreaded) and a minimum of 3/4 in. nominal pipe diameter. The discharge line material must be suitable for water at least 180° Fahrenheit. • If a pressure relief valve discharges An approved pressure relief valve is required by the American National Standard (ANSI Z21.
• • Do not plumb the condensate drain with the pressure relief valve; both must be plumbed independently to drain. • All condensate must drain and be disposed of according to local codes. • Use only corrosion resistant materials for the condensate drain lines such as PVC pipe or plastic hose. • The condensate drain pipe (along its entire length) must be at least 1/2 in.
Connect the Condensate Drain Kit Tools/Materials Required Multi-purpose grease or lubricant Verify Contents Item # Item Qty a Elbow with flexible pipe 1 b T-piece, elbow and flexible pipe assembly 1 c Flexible drain pipe 1 d Condensate drain inner tube 1 e Condensate drain outer tube 1 f Condensate collector cover 1 Instructions Reference Figure 1 for the following instructions. 1.
9 CAUTION Topics in this section • Guidelines Electrical Connections Post-Power Supply Connection Checklist • • • No changes may be made to the wiring of the boiler. • All connections should be designed in accordance with the applicable regulations. • Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. • Verify proper operation after operation servicing. WARNING • Do not use an extension cord or adapter plug with the boiler.
Devices such as the room thermostat and outdoor temperature sensor are connected to the connection terminal. The connection terminals are located on the top and back of the controller. To access the controller, remove the front panel (see section “3.7 How to Remove the Front Panel” for detailed instructions).
10 IMPORTANT • Work on the boiler must be carried out Topics in this section • • • Safety Precautions Instructions Air Purge Process THIS SECTION IS INTENDED FOR THE INSTALLER This boiler must be commissioned by a licensed professional. Installer qualifications: A trained and qualified professional must install the appliance, inspect it, and leak test the boiler before use. The warranty will be voided due to any improper installation.
3. Remove the vent pump screw. 4. Scroll to ON and press OK. 5. Scroll to 100% and press OK. 6. The boiler is now at maximum input. 4. Use a flat head screwdriver to ensure the impeller spins freely. 5. When the impeller spins freely and water exits though the vent port, the pump is ready for operation. 7. After the boiler has run for approximately one minute, the O2 percentages displayed on the combustion analyzer should match the ranges shown in the table below.
Step 3: Set the O2 at Minimum Input THIS SECTION IS INTENDED FOR THE INSTALLER 1. While still in service mode (as described in the previous step), use the scroll wheel to adjust to 0%. 2. Press OK. 3. The boiler is now at minimum input. 4. After the boiler has run for approximately one minute, the O2 value displayed on the combustion analyzer should read a value as shown in the Nominal O2 Percentages table (see section Step 2: Set the O2 at Maximum Input). Example: If maximum input value is 4.
The boiler comes equipped with an automatic air purge process. This is a seven minute process designed to eliminate air in the water. The air purge program will start whenever the water pressure in the boiler gets below 10 PSI or when the boiler is powered on. The boiler will eliminate air from the water through the air vent on the heat exchanger. A minimum of 19 PSI is needed to complete the air purge process.
11 Complete the following checklist when boiler installation is complete. You should be able to answer YES to each question. If you answer NO, installation is not complete. Refer to the applicable section in this manual for additional information.
CONDENSATE DRAIN (Continued) Have you confirmed the condensate drain line is not connected with an air conditioning evaporator coil drain? This boiler has an integrated condensate trap.
12 Topics in this section • Start-Up Information • Control Panel • Basic Operation Settings • Parameter Settings • Outdoor Reset Control • Diagnostic Codes • Forced High/Low Fire Modes • Freeze Protection IMPORTANT • On initial startup of the system, it is necessary to put the boiler into an air purge process to remove all air from the system piping and boiler. The boiler will not immediately fire up and begin operation.
Slowly lower the protective panel on the front cover to access the control panel. Control panel ❼ ❸ ❺ ❶ ❷ ❹ ❶ I O ❻ Power (On/Off) Press to turn the boiler on or off. (I = On O = Off) ❸ Back Press to go back one screen. ❹ Reset See Reset Fault Code section (in this section) for more information ❺ OK Press to select an item. Rinnai M-Series Condensing Boiler Combi Manual Chimney Active (Service Mode) Press to enter into service mode which allows adjustment of high fire/low fire and O2 settings.
When the boiler is turned on, the main screen (also called the home screen) appears in the display.
To change the language appearing on the boiler display, follow the steps below. To change the unit of measurements appearing on the boiler display, follow the steps below. 1. From the controller Home screen, press OK. 1. From the controller Home screen, press OK. 2. Turn the selector wheel to highlight Complete Menu. Press OK. 2. Turn the selector wheel to highlight Complete Menu. Press OK. 3. Turn the selector wheel to highlight Screen Settings. Press OK. 3.
To turn the boiler on or off, press the Power switch. I = On O = Off 1 From the controller Home screen, press OK. 3 CH Settings is highlighted. Press OK. Home screen 2 70 Turn the selector wheel to highlight Complete Menu. Press OK. 4 CH Setpoint Temp is highlighted. Press OK.
5 The option T set Z1 is highlighted. Press OK. 1 NOTE: Z2 and Z3 are not active controls on this boiler. 6 Home screen Turn the selector wheel to until the desired target CH temperature appears on the display. Press OK. Available temperature settings (minimum to maximum): 68°F - 185°F (20°C - 85°C) 7 From the controller Home screen, press BACK. 2 Turn the selector wheel to the desired DHW setpoint temperature. The boiler will automatically save the new setpoint temperature after five seconds.
Comfort mode is a domestic hot water setting that enables the boiler to fire up more often to maintain the heat exchanger temperature. This enables quicker delivery of hot water to fixtures. 2 Turn the selector wheel to highlight Complete Menu. Press OK. By default, comfort mode is always active. To disable or set schedule, follow the steps below for Option 2 or Option 3. Comfort mode has three options: Option 1: Always Active (Default) This option provides continuous hot water all day long.
Disabled To disable Comfort mode, follow the steps below. 1 4 Turn the selector wheel to highlight Comfort Function. Press OK. From the controller Home screen, press OK. Home screen 5 2 3 Turn the selector wheel to highlight Complete Menu. Press OK. Turn the selector wheel to highlight DHW Settings. Press OK. Rinnai M-Series Condensing Boiler Combi Manual Disabled is selected. Press OK. The message below appears. 6 Comfort mode is disabled.
5 Time Based To enable the Time Based comfort mode setting, follow the steps below. 1 From the controller Home screen, press OK. Turn the selector wheel to highlight Time Based. Press OK. The message below appears. Home screen 2 3 4 Turn the selector wheel to highlight Complete Menu. Press OK. Turn the selector wheel to highlight DHW Settings. Press OK. Turn the selector wheel to highlight Comfort Function. Press OK. 6 Press the Back button one time. The following screen appears.
Boiler Parameters PARA Default Range Description 2.0.0 140°F 104 - 140°F DHW setpoint temp (also achieved by pressing BACK and turning dial on home screen) 2.0.3 194°F 176 - 194°F Max Water Temp (absolute max) Will limit outdoor reset curve settings 2.0.4 0 0-10,200 Will allow you to set higher than 10.2K but no effect 2.0.6 9°F/min 0-27°F/min How quickly boiler reaches setpoint from cold start ON/OFF AUTO function is the outdoor reset control.
PARA Default Range Description 2.8.0 NA OK=YES ESC=NO Resets all parameters to factory defaults (green button) 2.9.0 1 0=NO 1=NC External Safety contact (LWCO, etc) (NOTE: DO NOT USE OPTION 2) 2.9.1 1 0=OFF 1=ON System (plant) frost protection, pump operation based on outdoor temp sensor value Heating Parameters PARA Default Range Description 4.2.0 1 0=Low Temp 1= High Temp Outdoor reset curve presets 4.2.
PARA Unit Description 8.0.7 Cycles Total DHW flame ignitions 8.1.0 Hours Total CH burner hours 8.1.1 Hours Total DHW burner hours (add w/CH for absolute total) 8.1.2 Occurrence Total number of flame faults 8.1.3 Cycles Total ignition cycles 8.2.1 OFF/ON PCB signal if fan is ON or OFF 8.2.2 RPM Fan speed 8.2.3 0-100% Pump speed 8.2.4 3-way valve position 0=DHW, 1=CH 8.2.5 l/min DHW rate (note this is in liters multiply by .264 for GPM) 8.2.
To follow is an example of how to adjust parameters on the M-Series Boiler. Change the Altitude 1 From the controller Home screen, press the BACK and OK buttons at the same time for 7 seconds. 3 Turn the selector wheel to highlight Complete Menu. Press OK. Home screen All commonly adjusted parameters can be accessed in the Complete Menu. 2 Turn the selector wheel so that 007 appears as the technical code. 4 The “007” Menu is where all parameters can be adjusted.
5 Option 2.0 General is highlighted. Press OK. 6 Turn the selector wheel to highlight 2.0.4 Altitude. Press OK. 7 Scroll to the desired altitude and press OK. 8 Press the Back button until the Home screen appears on the display. Note: Altitude is displayed in Feet (FT) measurements. The parameter had now been updated to the set value.
Outdoor reset is a built-in function to help maximize the efficiency of the boiler. The design of this function is to adjust the target temperature of the boiler relative to the outdoor ambient temperature via the four outdoor reset curve options included in the boiler parameters. The outdoor ambient temperature is observed via the provided outdoor temperature sensor.
1. 2. 3. 4. Remove the boiler’s front panel by removing the four screws that secure the panel. Locate the HMI at the bottom of the unit. Connect the outdoor sensor to the terminals shown. Set parameters 4.2.0-4.2.6 as appropriate for your application (see section “12.4.1 Parameter 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.
Below are some typical target temperatures for various heat emitters. Type of Heat Emitter Typical Minimum Supply Temperature Typical Maximum Supply Temperature Hydronic Air Handler 120 - 140°F 140 - 180°F Unit Heater 130 - 140°F 160 - 180°F Base Board convectors 100 - 140°F 140 - 190°F Cast Iron / Panel Radiator 90 - 120°F 140 - 180°F Undermount Radiant 100 -120°F 120 - 150°F 80 - 90°F 110 - 130°F Poured concrete radiant *NOTE: These are basic guidelines.
WARNING Some of the checks below should be performed by a licensed professional. Consumers should never attempt any action that they are not qualified to perform. When the boiler detects an error, a 3-digit blocking or fault code appears on the controller display. • A blocking code is a temporary error that can be automatically corrected by the boiler. • A fault code requires the error to be reset and/or corrected for the boiler to go back into a normal operating mode.
Code Description 1P1 Flow Check 1 Failed 1P2 Flow Check 3 Failed 1P3 Flow Check 4 Failed 1P4 Filling Needed Combi Domestic 201 Hot Water NTC Damaged Tank NTC Sensor 203 Damaged Reason(s) Change in supply temperature of 12.
1 When an error occurs, the fault code and description appear on the display. 2 To reset the fault code, press the RESET button. 4 The Reset in Progress message appears. 5 The Fault Solved message appears. 6 3 After the code is reset, the Home screen automatically appears.
1 4 Turn the selector wheel to highlight 8 Service Param. Press OK. 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. From the controller Home screen, press the BACK and OK buttons at the same time for 7 seconds. Home screen 2 3 Turn the selector wheel so that 007 appears as the technical code. Turn the selector wheel to highlight Complete Menu. Press OK. 7 Scroll to view the last 10 errors.
Chimney Active (Service Mode) WARNING This section should be performed by a licensed professional. Consumers should never attempt any action that they are not qualified to perform. The Chimney Active (service mode) button puts the boiler into service mode which allows adjustment of high fire/low fire and O2 settings. To enter Chimney Active (service mode): 1 From the controller Home screen, press and hold the Chimney Active button for approximately 7 seconds.
The boiler is equipped with two different methods of freeze protection, one for the boiler itself and one for the system. If 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.
13 Topics in this section • • • Owner Maintenance Licensed Professional Maintenance Test the Ignition Safety Shut Off Device WARNING If you encounter a problem that is difficult to solve, stop the operation and immediately contact a licensed professional. WARNING • • • • Maintenance is required to maintain safe operation of the boiler. The boiler must be inspected annually by a licensed professional. Repairs and maintenance shall be performed by a licensed professional.
TWO YEAR SERVICE Vent System • Inspect for blockages or damage. • Inspect vent screen or room air filter (if using) for debris and blockages. Clean if needed. Fan and Motors Clean dust and dirt from fan and motor (motors are permanently lubricated and do not require lubrication). Controller Check diagnostic code history. Pressure Confirm the pressure is within the proper range (between 17-26 PSI). If the pressure is lower than the specified range, add water until in the proper range.
Snow Accumulation • Verify the area around the flue terminal is free of snow and ice. The boiler will Freeze Protection • Freeze protection for new or existing systems must use glycol that is specially Coast Area Installations Installations located in or near coastal areas may require additional maintenance due to corrosive airborne ocean salt. If corrosion is observed on the body of the boiler, the boiler shall be inspected to ensure proper operation and repaired or replaced, if necessary.
1. Ensure the boiler is not currently firing and the flame rod is not hot. 2. Remove the boiler front panel. 3. Disconnect the wiring connection from the flame rod (located on the left side of the boiler). Boiler left side WARNING Remove the wiring connection Do not touch the inside of the wiring connection while it is disconnected. 4. On the control panel, press and hold the Service Mode button for approximately 7 seconds. 5. The boiler initiates one start-up attempt and four restart attempts.
14 Below is a list of approved system cleaners, inhibitors, and antifreezes for use in hydronic plumbing systems utilizing Rinnai boilers.
When replacing an existing boiler, the heating system shall be flushed with an approved system cleaner 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 to facilitate the flushing of the system. The Rinnai boiler must be isolated from the system while the system is flushed. No system cleaner should ever enter the boiler heat exchanger due to its caustic nature which could damage the heat exchanger.
Boiler Casing 50 Item # Description Part Number Quantity M060C M090C M120C M160C 10 Boiler Mounting Bracket 809000161 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.
Heat Exchanger 96 Rinnai M-Series Condensing Boiler Combi Manual
Heat Exchanger (Continued) Item # Description Part Number Quantity M060C M090C M120C M160C 30 Screw M5x16 809000015 2 2 2 2 31 Gasket 808000037 1 1 1 1 32 Burner hood 806000035 1 - - - 806000036 - 1 1 1 33 Gasket kit 806000037 1 - - - 806000038 - 1 1 1 34 Burner 806000032 1 - - - 806000033 - 1 1 1 36 Electrode gasket 805000062 1 1 1 1 37 Heat exchanger 807000169 1 - - - 807000170 - 1 1 1 38 Condensate tray gasket 807000135 1 - -
Hydraulic Parts/Pipes 98 Rinnai M-Series Condensing Boiler Combi Manual
Hydraulic Parts/Pipes (Continued) Item # Description Part Number Quantity M060C M090C M120C M160C 79 Condensate collector kit 807000140 1 1 1 1 80 Condensate drain kit 807000141 1 1 1 1 81 Condensate drain o-ring Ø28.25 x 2.62 mm 807000142 1 1 1 1 82 Condensate drain inner tube 807000143 1 1 1 1 83 Condensate drain tube o-ring Ø37.69 x 3.
Hydraulic Parts/Pipes (Continued) Item # Description Part Number Quantity M060C M090C M120C M160C 104 Pipe Return Elbow 807000163 1 1 1 1 105 Supply Pipe to Heat Exchanger 807000164 1 1 1 1 110 Allen head bolt M5 x10 mm 809000150 4 4 4 4 114 Bypass valve kit 807000167 1 1 1 1 115 Gas/DHW connection fitting 1/2 in. FNPT x 3/4 in. MNPT 806000041 3 3 3 3 116 Supply/return fitting 3/4 in. FNPT x 1 in. MNPT 807000168 2 2 2 2 126 O-Ring Ø21.82 x 3.
*Solo Only Electrical Components Rinnai M-Series Condensing Boiler Combi Manual 101
Electrical Components (Continued) Item # Description Part Number Quantity M060C M090C M120C M160C 142 Ignition control box 805000060 1 1 1 1 146 controller casing/back 809000152 1 1 1 1 147 PC Board 805000055 1 1 1 1 148 Key pad 805000067 1 1 1 1 149 Controller casing/front 809000153 1 1 1 1 150 Hinge support 809000154 2 2 2 2 152 Fuse 4A (250V) 805000068 1 1 1 1 Screw terminal-white 805000069 1 1 1 1 Screw terminal-blue 805000071 1 1 1 1 S
IMPORTANT Primary/secondary piping is necessary in the following 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 Legend: Refer to the legend below for the system applications shown in this section.
PC Board Wiring for the above application example Low Water Cutoff (If Required) Zone Control Pump Thermostat Outdoor Temperature Sensor 104 Rinnai M-Series Condensing Boiler Combi Manual
PC Board Wiring for the above application example Zone Valve 1 Low Water Cutoff (If Required) Zone Control Zone Valve 2 Zone Valve 3 Pump Thermostat 1 Thermostat 3 Outdoor Temperature Sensor Thermostat 2 Rinnai M-Series Condensing Boiler Combi Manual 105
PC Board Wiring for the above application example Low Water Cutoff (If Required) Zone Control Air Handler Control Pump Outdoor Temperature Sensor Thermostat 106 Rinnai M-Series Condensing Boiler Combi Manual
PC Board Wiring for the above application example Pump 1 Low Water Cutoff (If Required) Zone Control Pump 2 Pump 3 Thermostat 1 Thermostat 3 Outdoor Temperature Sensor Thermostat 2 Rinnai M-Series Condensing Boiler Combi Manual 107
PC Board Wiring for the above application example Pump 1 Low Water Cutoff (If Required) Zone Control Pump 2 Pump 3 Thermostat 1 108 Thermostat 2 Outdoor Temperature Sensor Rinnai M-Series Condensing Boiler Combi Manual
This boiler is configured for Natural Gas only. To convert to Propane Gas, follow the instructions in this section. WARNING • • The conversion kit shall be installed by a qualified service agency in accordance with the manufacturer’s instructions and all applicable codes and requirements of the authority having jurisdiction. The information in these instructions must be followed exactly to minimize the risk of fire or explosion or to prevent property damage, personal injury or death.
1. Confirm that the inlet gas pressure is between the minimum and maximum pressures allowed for this boiler. 2. Disconnect electrical power to the boiler. 3. Turn off the boiler’s gas supply 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 7. Remove the gas line and place aside.
9. Remove the Liquid Propane restrictor in the gas venturi. 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. 10. Replace the yellow gasket into the gas venturi. 16. Reattach the PC Board front housing and screw terminals. 17. Connect electrical power and power up the boiler. 18. The Airpurge active screen appears on the boiler display. 11. Reconnect the gas valve, gas venturi connections and gas line. 12.
20. The Flash Memory Detected screen appears. Select COPY and Press OK. 23. After a few seconds, the boiler automatically turns on and goes into Airpurge active mode. Your psi values may differ than the values shown in image. 21. The following screen appears indicating data parameters have been copied to the Mainboard. 22. The Home screen briefly appears on the display and then the boiler turns off. 24. To remove the EEPROM key from the PC Board: a. Disconnect power to the boiler b.
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Rinnai M-Series Condensing Boiler Combi Manual
Pressure Loss (Feet of Head) 30 25 20 15 10 5 0 0 1 2 3 4 5 6 7 8 9 Water Flow (GPM) * Pressure drop curve applies to all M-Series Condensing Boilers (M060C, M090C, M120C and M160C).
Pressure Loss (Feet of Head) 35 30 25 20 15 10 5 0 0 0.5 1 1.5 2 2.5 3 3.
Supply Sensor (T1) Return Sensor (T2) Outdoor Reset Sensor (T4) DHW Sensor (T3) NTC1k (25°C) NTC10k (25°C) Temperature Temperature Resistance Temperature Temperature Resistance (°C) (°F) (Ω) (°C) (°F) (Ω) -10 14.0 4.574 -10 14.0 55.047 -9 15.8 4.358 0 32.0 32.555 -8 17.6 4.152 10 50.0 19.873 -7 19.4 3.958 12 53.6 18.069 -6 21.2 3.774 14 57.2 16.447 -5 23.0 3.600 16 60.8 14.988 -4 24.8 3.435 18 64.4 13.674 -3 26.6 3.279 20 68.0 12.488 -2 28.4 3.131 22 71.6 11.417 -1 30.2 2.990 24 75.2 10.449 0 32.0 2.
The following information is required by ANSI Z21.13: If a boiler is removed from a common vent system, the common vent system is likely to be too large for proper venting of the remaining appliances connected to it. The instructions shall include the test procedure set forth below: At the time of removal of an existing boiler, the following steps shall be followed with each other appliances remaining connected to the common venting system are not in operation. 1.
FOR GAS MODELS SOLD IN MASSACHUSETTS NOTICE BEFORE INSTALLATION: This direct-vent appliance must be installed by a properly trained licensed professional. If you are not properly trained, you must not install this unit. IMPORTANT: In the State of Massachusetts (248 CMR 4.00 & 5.
Limited Warranty for M-Series Boiler Models Boiler Models: • • Combi: M060C, M090C, M120C, M160C Solo: M060S, M090S, M120S, M160S What Is Covered? The Rinnai Standard Limited Warranty covers any defects in materials or workmanship when the product is installed and operated according to Rinnai written installation instructions, subject to the terms within this Limited Warranty document. This Limited Warranty applies only to products that are installed correctly in the United States and Canada.
How To Obtain Service For the name of a trained and qualified professional, please contact your place of purchase, visit the Rinnai website (www.rinnai.us), call Rinnai at 1-800-621-9419 or write to Rinnai at 103 International Drive, Peachtree City, Georgia 30269. Proof of purchase is required to obtain warranty service. You may show proof of purchase with a dated sales receipt, or by registering within 90 days of purchasing the product. To register your Rinnai Condensing Boiler, please visit www.rinnai.us.
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