Rinnai Q series Troubleshooting Manual
There are a number of live tests that are required when fault finding this product. Extreme care should be used
If any of the
original wire as supplied with the appliance must
Label all wires prior to disconnection when
CAUTION
Q - Series Boiler
Troubleshooting Manual
WARNING
at all times to avoid contact with energized components inside the product.
You MUST be a qualified service person before proceeding with these test instructions.
Before checking resistance readings, turn off power source to unit and then isolate each item to be checked
from the circuit by unplugging it.
When setting gas pressures on one of these units, please check the complete model number you are troubleshooting. Gas pressures and dip switches can vary among models. Always check the rating plate for complete
information and follow directions.
servicing controls. Wiring errors can cause
improper and dangerous operation.
be replaced, it must be replaced with type 18 AWG wire or its
equivalent.
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Table of Contents
Code Numbers Page #
Boiler Description …………………………………………………………………………………………………………………………. 4
Error indication (Short reference) ………………………………………………………………………………………………... 5
BL 01 …………………………………………………………………………………………………………………………………………….. 6
BL 05 …………………………………………………………………………………………………………………………………………….. 7
BL 11 …………………………………………………………………………………………………………………………………………….. 8
BL 12 …………………………………………………………………………………………………………………………………………….. 9
BL 60 …………………………………………………………………………………………………………………………………………….. 10
BL 67 …………………………………………………………………………………………………………………………………………….. 11
BL 80 …………………………………………………………………………………………………………………………………………….. 12
BL 81 …………………………………………………………………………………………………………………………………………….. 13
BL 82 …………………………………………………………………………………………………………………………………………….. 14
BL 84 …………………………………………………………………………………………………………………………………………..… 15
BL 85 …………………………………………………………………………………………………………………………………………….. 16
BL 86 …………………………………………………………………………………………………………………………………………..… 17
E 00 ………………………………………………………………………………………………………………………………………………. 18
E 01 ………………………………………………………………………………………………………………………………………………. 19
E 02 …………………………………………………………………………………………………………………………………………….… 20
E 03 …………………………………………………………………………………………………………………………………………….… 21
E 04 …………………………………………………………………………………………………………………………………………….… 22
E 05 …………………………………………………………………………………………………………………………………………….… 23
E 07 …………………………………………………………………………………………………………………………………………….… 24
E 11 …………………………………………………………………………………………………………………………………………….… 25
E 12 …………………………………………………………………………………………………………………………………………….… 26
E 13 …………………………………………………………………………………………………………………………………………….… 27
E 14 …………………………………………………………………………………………………………………………………………….… 28
E 18 …………………………………………………………………………………………………………………………………………….… 29
E 19 …………………………………………………………………………………………………………………………………………….… 30
E 24 …………………………………………………………………………………………………………………………………………….… 31
E 26 …………………………………………………………………………………………………………………………………………….… 32
E 28 …………………………………………………………………………………………………………………………………………….… 33
E 29 …………………………………………………………………………………………………………………………………………….… 34
E 31 ……..……………………………………………………………………………………………………………………………………….. 35
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E 32 ….…………..……………………………………………………………………………………………………………………………… 36
E 36 ....…..……………………………………………………………………………………………………………………………………… 37
E 37 …..…………….………………………………………………………..……………………………………………………………….... 38
E 41 …………………………………………………………..…………………………………………………………………………..……… 39
E 42 …………………………………………………………………………………………………………………………………………..….. 40
E 44 ………………………………………………………………………………………………………………………………………………. 41
E 68 ………………………………………………………………………………………………………………………………………………. 42
E 69 ………………………………………………………………………………………………………………………………………………. 43
E 80 ………………………………………………………………………………………………………………………………………………. 44
E 115 …………………………………………………………………………………………………………………………………………….. 45
Fuse …………………………………………………………………………………………………………………………………………….… 46
Central heating but no domestic hot water…………………………………………………………………………………… 47
Hot water but no central heating …………………………………………………………………………………………….…... 47
Central heating installation gets hot without being requested ……………………………………………….…... 47
Insufficient quantity of hot water …………………………………………………………………………………………….…... 48
Temperature drop of the DHW (Combi) ……………………………………………………………………………………….. 48
Radiators do not get hot enough or warming up takes too long …………………………………………………... 48
Checking the 02 …………………………………………………………………………………………………………………………….. 49
Boiler Controls ………………………………………………………………………………………...…………………………………... 50
Explanation of the function buttons ……………………………………………………………………………………..…….… 51
Starting up – filling and de-aerating the boiler & Water Requirements….………………………………….….. 52
Freeze Protection………………………………………………………………………………………………………………………….. 53
Filling the heating system ………………………………………………………………………………………………………..…... 54
Altering adjustments ……………………………………………………………………………………………………………………. 55
PARAMETER mode ………………………………………………………………………………………………………………………. 56
Information, Service and Error Modes …………………………………………………………………………………………. 57
Activating factory setting (Green button function) ………………………………………………………………………. 58
Isolating the boiler ……………………………………………………………………………………………………………………..….59
Reset service interval counter ……………………………………………………………………………………………………… 60
© 2013 Rinnai America Corporation • 103 International Drive, Peachtree City, GA 30269
Toll-Free:1-800621-9419 • Phone: 678-829-1700 • www.rinnai.us
Rinnai is continually updating and improving products; therefore, specifications are subject to change without
prior notice. Local, state, provincial and federal codes must be adhered to prior to and upon installation.
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Parts of the Boiler
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A detected error is indicated on the display by means of a blocking or error messages. A distinction should be made between
Block 67: A ∆T has been detected between flow and the return sensor whereas the burner is not in operation. After the
Flame present when burner is off, electrical interference, poor
Block and Errors
- Error indication (short reference)
these two messages due to the fact that a blocking code can be of a temporary nature, however, error messages are fixed
“lockouts” or hard lockouts. The control will try its utmost to prevent a lockout and will temporary switch off the unit by blocking it,
below is a list of some messages the unit will display.
Blocks: bL with a number in the last two positions indicates the type of blocking code.
bL 01 Block 01: External safety contact cut off.
bL 05 Block 05: Outdoor reset sensor not connected.
bL 60 Block 60: Incorrect parameter setting of the minimum or maximum power (Btu) of boiler.
bL 67
∆T has disappeared the block will clear itself.
bL 85 Block 85: The control has not detected water flow. The venting cycle (pro-purge) cycle has started.
If during this cycle water flow is detected, the pro-purge cycle stops, the burner will then fire up.
Error: E with a number in the last two positions indicates the type of error code.
E 00 Error 00: Poor flame forming.
E 02 Error 02: No flame forming.
E 04 Error 04: Adjustment or error due to voltage interruption.
E 05 Error 05: Adjustment.
E 12 Error 12: High limit stat.
E 18 Error 18: Maximum flow temperature exceeded.
E 19 Error 19: Maximum return water temperature exceeded.
E 28 Error 28: Fan revolutions not being measured by control board.
ground, and flame sensing wire disconnected during off cycle.
E 69 Error 69: No or incorrect display.
FUSE FUSE: 24 V fuse defective or blown.
Information displayed in “Tech Readout Mode”. To enter this
mode press and hold the “STEP” button for 5 seconds.
Operation Indication
0 - No heat demand
1 - Fan pre/post purge
2 - Ignition phase
3 - Burner active on central heating
4 - Burner active on DHW
5 - Fan check
6 - Burner off when either DHW or room thermostat is calling *
(See note 2 below).
7- Pump overrun phase for central heating
8- Pump overrun phase for hot water
9 - Burner off because of too high flow temperature
A - Automatic de-aeration program
F – Fan test still activated in Service mode
H Burner test still activated in Service mode
*Note 2; (E Boiler) a continuous code 6 can mean there is a small hot
water leak triggering the plate heat exchanger sensor to call continually
for DHW in turn locking out space heating in DHW priority. Switch PARA
36 to 20 (flow switch only) and then repair leak.
NOTE; if the unit appears to be fine but doesn’t run
and no error code is displayed check;
a. That the desired programming is on; set to
either Central Heating and/or Domestic Hot
Water.
b. The unit is not in the Showroom Mode
______________________________________
Explanation of T Sensors:
T1- Supply sensor - Water leaving heat exchanger
mounts in flow of water.
T2 - Return water sensor, surface mounted.
T3 - Domestic hot water flow sensor,. Q175C uses
a surface mount sensor. Q models with optional 3way valve use a sensor designed to be used in a
well. (QP uses a well)
T4 – Outdoor reset sensor, mounted outside
building.
T5 - Flue gas sensor - Optional sensor not included
with boiler.
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The 120 volt external pump is for
E and QP model boilers
Rectify error by determining which external
contact is open. If external contacts are not being
used place jumper across terminals 24 & 25
If multiple boiler safeties are to be wired in series check with your local inspector or the local or State
codes to see if this is allowed in your area before proceeding. NEVER wire boiler safeties in parallel.
Refer to wiring diagram in the boiler manual. Trace connections 24 and 25 above back to the MCBA.
These will be located on Plug X5 on the MCBA on pins 2 and 6.
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Outdoor sensor contact
BL
05
8
open (not connected)
Rectify error by determining if outdoor sensor
is faulty, wiring to senor is broken or damaged
or if the connection at terminal 18/19 on main
control board is properly connected.
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Maximum average ΔT of T1 supply
BL 11
operate at minimum capacity during the block.
Rectify Issue,
sensor and T2 return sensor for central
heating is repeatedly exceeded.
Operation is normally possible for the hot water
supply during the block. The pump continues to
Check following
1. Check flow through the heating system.
2. Possible causes: radiator shut off valves closed, blocked water filter.
3. Verify proper installation of the boiler plumbing, connections and all components.
4. Check minimum and maximum temperature difference in Parameter step 46 and 47.
5. Activated room sensor (RS100) in non leading room (closed thermostatic radiator
valves?) Check pump height. Should this be check pump head? Do not understand
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Maximum average ΔT of supply
BL 12
continues to operate at minimum capacity during
Rectify Issue,
sensor and return sensor for hot
water is repeatedly exceeded.
Operation is normally possible for the central
heating installation during the block. The pump
Check following
1. Check flow through the boiler and DHW tank.
2. Possible causes: radiator shut off valves closed, blocked water filter, restriction in DHW tank to high.
3. Verify proper installation of the boiler plumbing, connections and all components.
4. Ensure 3 way valve is functioning properly and is not clogged or full of pollution.
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NOTE; in order to reset all parameters in your boiler back to factory defaults follow the “Activating Factory Settings”
(Green button function) instructions found in your owner’s manual. CUATION: All parameters you adjusted will now
have to be reprogrammed if the bL60 code clears up. If after resetting the boiler the bL60 still appears, you will need to
replace the sub-PC board and reprogram the MCBA. The sub PC board must be from a conversation kit for the same gas
type as your boiler.
If conversion parts are not locally accessible contact Rinnai Tech Support for assistance. These parameters cannot be
accessed in the field and may require special instructions in an emergency situation.
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A temperature difference has been detected
A temperature difference has been detected
between the supply T1 sensor and the return T2
between the supply and return sensor while
sensor while the burner is not in operation. After
the burner is not in operation. After the
the average ΔT has disappeared, the blocking
average ΔT has disappeared, the block will
code will go away.
disappear.
Check the supply T1 sensor and the return T2
sensor for the proper resistance valve. Replace if
T1 Sensor
T2 Sensor
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T5 sensor is registering too high of a
and installed on the boiler.
temperature. This error can only occur if
the optional T5 sensor is was purchased
This is the location of the T5 sensor if installed.
If the red tab is in place this sensor was never
installed, which means the circuit has
somehow been jumped out. Contact Rinnai
tech support for assist if you get the bL80
without the T5 sensor being installed.
Inspect vent system and all air passages
ways for blockage
212˚F is the default temperature setting for
parameter 84. Verify to see if the temperature
setting for this parameter is set higher than
the default. If so, inspect vent system for
blockage.
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Explanation: The bL81 can be triggered if the flue gas plug has gotten wet and then dried out. (MCBA sees resistance when wet and
then sees no resistance when dry) This tricks the MCBA into thinking that a flue gas sensor was installed and then removed in which
the bL 81 is triggered. Moisture can come from a clog, broken or dry condensate trap. Moisture can be from a leaking concentric
vent pipe or from driving rain during extreme weather.
Methods to rectify:
A. ORDER AND INSTALL A FLUE GAS SENSOR (This may not be possible in cold weather when boiler must operate
immediately, if shipping the part is required.
B. CHANGE PARA 80 TO 20 AND INSTALL LOW VOLTAGE JUMPER ON FLUE GAS PLUG - (plug located on upper left hand side
of the heat exchanger in the harness) (PARA 20 setting causes the MCBA to look for an open/ close circuit and ignores any
variable resistance values like moisture or a thermistor.
C. INSTALL A 10K OHM RESISTOR ACROSS FLUE GAS TERMINALS. This will make the MCBA think that the flue gas is at a safe
temperature level (90 F)
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Flue sensor or thermostat contact open
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212˚F is the default temperature setting for
parameter 84. Verify to see if the temperature
setting for this parameter is set higher than
the default. If so, inspect vent system for
blockage.
This can occur on a Q Boiler when the factory
jumper on the flue gas sensor is loose or has
fallen out.
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Check
for
use of balancing valves
.
AIR: if boiler, inner boiler piping, or Low Loss
Header has a large air bubble in it the
pressure sensor will not see the pressure
spike that the pump generates when it starts.
The pressure spike is what tells the MCBA that
the pump has started.
The air bubble will absorb that spike. Bleed all
air from the system.
If an additional expansion tank is placed in the
system alongside an E-boiler that tank can
absorb the pump pressure spike as well. You
may need to isolate that tank to see if this
corrects the issue with BL 85.
An expansion that is not charged properly can
cause the pump’s pressure spike not to be
seen by the sensor causing a BL85.
Expansion tank pressure should be air charged
to match whatever water fill pressure that is
chosen for the closed loop. (Always above
14.5 psi)
Expansion tanks must be air charged only
when there is no water pressure on the wet
side of the diaphragm or the tank is removed
from the system. Once charged to the correct
air pressure it may be placed into the system
and the water fill pressure now may be set to
match the new tank pressure.
Check the installation for the presence of air.
If there is a secondary pump installed and it
is not hydraulically separated, it could cause
a loss of pressure difference.
Check to ensure the pump is functioning and/or water
pressure sensor is working properly.
Ensure water pressure sensor is not clogged or defective.
Inspect water filter for debris.
Check pump for proper operation and flow rates.
Check for proper wiring of pump.
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The frequency of the power supply deviates more
than + or - 1.5 Hz.
If using a back-up generator ensure it is
properly grounded and providing a clean
steady voltage and sign wave of 59.3 to 60.8
Hz.
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Boiler has not been
burning but an
ionization flow
(flame) has been
detected.
Check whether the ionization cable and/or the electrode
are responsible for a short circuit. Remove the plugs from
the ionization cable connected to the control unit and to
the electrode. Now using a ohm meter take a
measurement between the ionization connection and the
ground. Now refit it part by part until a short circuit takes
place.
NOTE: Inadvertently unplugging the ionization
cable or spark igniter wire while the boiler is
not firing can trigger the E00 code.
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