Rinnai Rice Cooker E50C Service Manual

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Page 1

Installation & Servicing

Instructions

High efﬁ ciency condensing gas boiler

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 of hazardous materials)* or loss of life. Refer to the user's information manual provided with this boiler. Installation and service must be performed by a licensed professional, service agency or the gas supplier (who must read and follow the supplied instructions before installing, servicing, or removing this boiler).

CAUTION!

The user manual is part of the documentation that is delivered to the installation's operator. Go through the information in this manual with the owner/operator and make sure that they are familiar with all necessary operating instructions.

Pictured: E50C

NOTICE!

Installation and service must be performed by a qualiﬁ ed installer, service technician or the gas supplier.

In the Commonwealth of Massachusetts this boiler must be installed by a licensed Plumber or Gas Fitter.

WARNING! If you do not follow these instructions exactly, a ﬁ re or explosion may result causing property damage, personal injury or loss of life.

- Do not store or use gasoline or other ﬂ ammable vapors and liquids in the vicinity of this or any other appliance.

- WHAT TO DO IF YOU SMELL GAS

- Do NOT try to light any appliance.

- Do NOT touch any electrical switch.

- Do NOT use any phone in your building.

- Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

- If you cannot reach your gas supplier, call the ﬁ re department.

Address: 103 International Drive, Peachtree City, GA, 30269

Toll-free: 1-800-621-9419 • Fax: 678-829-1666 • www.rinnai.us

8U.51.65.00 / 06.13 Changes reserved.

These instructions to be retained by user.

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Contents of instructions

These installation instructions contain important information for the safe installation, start-up and maintenance of boilers with capacities 50,000 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.

Subject to technical changes

Changes may be made without notice to the illustrations, process steps and technical data as a result of our policy of continuous improvement.

Updating of documentation

Please contact us if you have any suggestions for improvements or corrections.

Find our contact details on the back of this manual.

California Proposition 65 lists chemical substances known to the state to cause cancer, birth defects, death,

serious illness or other reproductive harm. This product may contain such substances, be their origin from fuel combustion (gas, oil) or components of the product itself.

Rinnai combi boiler comply with the State of California Lead Law (AB1953).

Installation & Servicing Instructions Rinnai E-Series

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Content

1 Safety and general instructions ........................................................4

1.1 Designated use ...................................................................4

1.2 Hazard deﬁ nitions ................................................................4

1.3 Symbol deﬁ nitions ...............................................................4

1.4 The following instructions must be followed ........................5

1.5 Follow these instructions for the space heating water .........6

1.6 Tools, materials and additional equipment ..........................6

1.7 Relevant Installation, Service and User manuals ................7

1.8 Disposal ...........................................................................7

2 Regulations and guidelines ..............................................................7

3 Description of the boiler ...................................................................8

4 Packaging and transportation ..........................................................9

4.1 Scope of delivery .................................................................9

4.2 Transportation .....................................................................9

5 Installation .........................................................................10

5.1 Requirements for the installation room .............................10

5.2 Fitting the boiler .................................................................11

5.3 Dimensions ........................................................................12

5.3.1 Clearances from boiler ......................................................13

5.4 Technical speciﬁ cations .....................................................14

6 Connecting the boiler .....................................................................15

6.1 Central heating system ......................................................15

6.1.3 Safety valve .......................................................................20

6.1.4 Low water cut off ...............................................................20

6.2 Boiler expansion tank ........................................................20

6.3 Underﬂ oor heating system (plastic pipes) ...........................20

6.4 Gas supply connection ......................................................20

6.4.1 Gas connection with natural gas .......................................21

6.5 Hot water supply ................................................................22

6.5.1 Domestic Water quality ......................................................22

6.5.2 Domestic water treatment Accessory ...............................22

6.5.3 DHW Expansion Tank ........................................................23

6.5.3 Installing a Thermostatic Mixing Valve .............................23

6.5.4 Installing a valve kit ...........................................................24

6.5.5 Pressure relief Valve ..........................................................24

6.5.6 Programming domestic hot water preheat ........................24

6.6 Condensate drain pipe ......................................................25

6.7 Vent system and air supply system ...................................26

6.7.1 Intake / Exhaust Guidelines ...............................................26

6.7.2a Examples vent and air supply systems (parallel) ..............27

6.7.2b Examples vent and air supply systems (low proﬁ le PP) ....28

6.7.3 Installation of the vent system ...........................................29

6.7.3.1 Conversion from parallel to concentric vent system ..........30

6.7.3.2 Installing air ﬁ lter ...............................................................30

6.7.4 Vent/air intake terminal position ........................................31

6.7.5 Direct vent closet and alcove installation ........................33

6.7.6 Dimensioning of the exhaust and air intake duct .............34

6.7.7 Combustion air and vent piping lengths. ...........................35

6.7.8 Calculation of compensation factor ...................................36

6.7.9 Room Air System (indoor combustion air) .........................37

7 Electrical connections ....................................................................40

8 Boiler controls .........................................................................44

8.1 Explanation of the function buttons ...................................45

9 Starting up: Filling and de-aerating the boiler and installation .......46

9.1 Requirements of the water system ....................................46

9.2 Filling the heating system ..................................................47

9.3 Hot water supply ................................................................48

10 Adjustments .........................................................................50

10.1 Altering adjustments ..........................................................50

10.2 Activating factory settings (green button function) ...........53

11 Isolating the boiler .........................................................................53

12 Commissioning .........................................................................54

12.1 Testing for gas leaks ..........................................................55

12.2 Testing the Ignition Safety shut off device .........................55

12.3 Checking the O2.................................................................56

12.4 Measuring the ionization current .......................................57

12.5 Installing the casing ...........................................................57

13 Maintenance .........................................................................58

13.1 Periodic examination of venting systems and boiler .........58

13.2 Inspection .........................................................................58

13.2.1 Visual inspection for general signs of corrosion ................59

13.2.2 Measuring the ionization current .......................................59

13.2.3 Measuring the inlet gas pressure ......................................59

13.2.4 Testing for gas leaks ..........................................................59

13.2.5 Carrying out a pressure test of the heating system ...........59

13.2.6 Checking venting systems .................................................59

13.3 Maintenance activities .......................................................60

13.3.1 Reset service interval counter ...........................................63

13.4 Limited warranty ................................................................63

14 Parts of the boiler .........................................................................64

15 Blocks and Errors .........................................................................65

15.1 Error indication (short reference) .......................................65

15.2 Blocks .........................................................................66

15.3 Errors .........................................................................67

15.4 Other Errors .......................................................................71

16 Spare parts .........................................................................72

17 Parts list vent system .....................................................................80

18 Common venting guidelines ...........................................................82

Appendix A - Outoor Reset Sensor Data and

Resistance table NTC sensors .......................................83

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1 Safety and general instructions

CAUTION

NOTICE

DANGER

WARNING

Please observe these instructions in the interest of your own safety.

1.1 Designated use

The boiler is designed for heating water for a central heating system and generating domestic hot water. The boiler is delivered with a burner controller (MCBA) preinstalled.The boiler can be ﬁ tted with a modulating outdoor reset sensor ARV12 (included with the boiler) or an On/Off thermostat or relay panel end switch (accessories).

1.2 Hazard deﬁ nitions

The following deﬁ ned terms are used throughout the documentation to bring attention to the presence of hazards of various risk levels. Notices give important information concerning the operation of the product.

DANGER:

Indicates the presence of hazards that will cause severe personal injury, death or substantial property damage.

WARNING:

Indicates the presence of hazards that can cause severe personal injury, death or substantial property damage.

CAUTION:

Indicates presence of hazards that will or can cause minor personal injury or property damage.

CAUTION

CAUTION:

Risk of electric shock. Indicates presence of hazards due to electric shock.

NOTICE:

Indicates special instructions on installation, operation or maintenance that are important but not related to personal injury or property damage.

1.3 Symbol deﬁ nitions

The following (safety) symbols may be encountered in these installation instructions and on the unit:

This symbol indicates that the unit must be stored away from freezing conditions.

This symbol indicates that the packaging and/or contents can be damaged as a result of insufﬁ cient care taken during transport.

This symbol indicates that, while still in its packaging, the unit must be protected from weather conditions during transport and storage.

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1.4 The following instructions must be followed

DANGER

WARNING

- The boiler must only be used for its designated purpose, as described in the Installation Instructions.

- Each unit is ﬁ tted 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 classiﬁ cation.

Only use the boiler with the accessories and spare parts listed.

- Other combinations, accessories and consumables may only be used if they are speciﬁ cally designed for the intended application and do not affect the system performance and the safety requirements.

- Maintenance and repairs must be performed by licensed professionals.

- Installation of a condensing gas boiler must be reported to the relevant gas utility company and have it approved.

- You are only allowed to operate the condensing gas boiler with the vent system that has been speciﬁ cally designed and approved for this type of boiler.

- Please note that local permission for the vent system and the condensate water connection to the public sewer system may be required.

You must also respect:

- The local building codes stipulating the installation rules.

- The local building codes concerning the air intake and outlet systems and the chimney connection.

- The regulations for the power supply connection.

- The technical rules established by the gas utility company concerning the connection of the gas connection to the local gas mains.

- The instructions and standards concerning the safety equipment for the water/ space heating system.

- The Installation Instructions for building heating systems.

- The boiler must be located in an area where leakage of the boiler or connections will not result in damage to the area adjacent to the boiler or to lower ﬂ oors of the structure. When such locations cannot be avoided, it is recommended that a suitable drain pan be installed under the boiler.

- The boiler must be installed in such way that the all components are protected from water (dripping, spraying, rain etc.) during boiler operation and service.

- The boiler must not be installed on or against carpeting.

- Do not restrict or seal any air intake or outlet openings.

- If you ﬁ nd any defects, you must inform the owner of the system of the defect and the associated hazard in writing.

In failure to properly commission the boiler as described in section 13 may result unreliable burner operation, reduced component life, and unsafe boiler operation.

DANGER. Gas is ﬂ ammable and may cause an explosion. Beware if you smell gas: there may be an explosion hazard!

If the information in these instructions is not followed exactly, a ﬁ re or explosion may result causing property damage, personal injury or death.

- Do not store or use gasoline or other ﬂ ammable vapors and liquids in the vicinity of this or any other appliance.

WHAT TO DO IF YOU SMELL GAS

- Do NOT try to light any appliance.

- Do NOT touch any electrical switch.

- Do NOT use any phone in your building.

- Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

- If you cannot reach your gas supllier, call the ﬁ re department.

Should overheating occur or the gas supply fail to shut off, do not turn off or disconnect the electrical supply to the pump. Instead, shut off the gas supply at a location external to the appliance.

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Chemicals that are corrosive in nature should not be stored or used near the boiler or vent termination.

NOTICE

1.5 Follow these instructions for the space heating water

Unsuitable heating system water can cause the formation of scale or sludge, which affects system efﬁ ciency. It can also cause corrosion and reduce life of the heat exchanger. – You must follow Rinnai guidelines for boiler water quality. – Thoroughly ﬂ ush the system prior to ﬁ lling. – Follow the Rinnai cleaning instructions. – Never use water that has been treated by a reverse osmosis, D.I., or distilled water

to soften the water to ﬁ ll the heating system.

– Do not use inhibitors or other additives unless approved by Rinnai for that purpose. – When freeze protection of the heating system is desired, only use Rinnai-approved

antifreezes. The allowed maximum concentration is 50%.

– When using oxygen-permeable pipes, e. g. for under ﬂ oor heating systems, you

must separate the system from the boiler using plate heat exchangers.

–

Valve off boiler while ﬂ ushing system, do not introduce any system cleaner into the boiler loop. Flush system thoroughly to remove all system cleaner before ﬁ lling boiler.

Approved antifreeze: • Rhomar RhoGard Mutli-Metal (AL safe) • Sentinel X500

(max. concentration 50%) • Noble Noburst AL • Fernox Alphi 11

Approved system cleaner: • Noble Noburst Hydronic System Cleaner • Fernox F3 Cleaner

• Rhomar Hydro-Solv 9100 • Sentinel X400

NOTICE

Approved inhibitors: • Rhomar Pro-tek 922 • Sentinel X100

• Noble Noburst AL inhibitor

NOTICE

The system cleaners from NoBurst, Rhomar, and Fernox are not to be used in the boiler. The boiler must be closed off (valved off) from the rest of the system or not connected while the cleaners are in the system. The system should then be drained and then thoroughly ﬂ ushed with clean water to remove all the system cleaner.

See Chapter 6 and 9 of this manual for additional information.

If problems occur when using sanitary water with a chlorine content higher than 150 mg/l, no recourse can be made to the terms of the limited warranty.

1.6 Tools, materials and additional equipment

For the installation and maintenance of the boiler you will need: – Standard tools for space heating, gas and water ﬁ tting – Digital manometer, capable of reading both positive and negative pressure – Combustion analyzer (intended for use with condensing boilers) – Digital multimeter – pH digital meter – Metric Allen wrenches – Metric socket wrenches In addition, a handtruck with a fastening belt is useful.

For maintenance of the boiler you will need, apart from standard tools for space heating, gas and water ﬁ ttings the following items:

- Boiler toolkit

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1.7 Relevant Installation, Service and User manuals

NOTICE

– 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.

2 Regulations and guidelines

The installation must comply to the requirements of the authority having jurisdiction or, in the absence of such requirements, to the latest edition of the National Fuel Gas Code, ANSI Z223.1/NFPA 54.

Where required by the authority having jurisdiction, the installation must comply to the Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ ASME CSD-1.

Install CO detectors per local regulations. Boiler requires an inspection every 2 years and maintenance every 4 years or 8000 hours. See maintenance section chapter 13.

Operating Limits of the boiler: Max. boiler temperature: 176 °F (80.0 °C) Max. operating pressure: 45 psi (3 bar) Max. Allowable Working Temperature ASME: 200 °F (93 °C) Max. Allowable Working Pressure ASME: 45 psi (3 bar)

The hot water distribution system must comply with all applicable codes and regulations. When replacing an existing boiler, it is important to check the condition of the entire hot water distribution system to ensure safe operation.

For installations in the Commonwealth of Massachusetts, the following local requirements apply in addition to all other applicable NFPA requirements:

For direct- vent boilers, mechanical-vent heating appliances or domestic hot water equipment, where the bottom of the vent terminal and the intake is installed below four feet above grade the following requirements must comply:

If not present on each ﬂ oor level where there are bedrooms, a carbon monoxide detector and alarm must be placed in a living area outside the bedrooms. The carbon monoxide detector and alarm must comply with NFPA 720 (2005 Edition).

2) A carbon monoxide detector and alarm shall be located in the room that houses the appliance and/or equipment and shall: a) Be powered by the same electrical circuit as the appliance and/or equipment

such that only one service switch services both the appliance and the carbon

monoxide detector; b) Have battery back-up power; c)

Meet ANSI/UL 2034 Standards and comply with NFPA 720 (2005 Edition); and

d) Have been approved and listed by a Nationally Recognized Testing Lab as

recognized under 527 CMR.

3) A product-approved vent terminal must be used, and if applicable, a product approved air intake must be used. Installation shall be performed in strict compliance with the manufacturer’s instructions. A copy of the installation instructions shall remain with the appliance and/or equipment at the completion of the installation.

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4) A metal or plastic identiﬁ cation plate shall be mounted at the exterior of the building, four feet directly above the location of vent terminal. The plate shall be of sufﬁ cient

size to be easily read from a distance of eight feet away, and read “Gas Vent Directly Below”.

For direct-vent boilers mechanical-vent heating boilers or domestic hot water equipment where the bottom of the vent terminal and the intake is installed higher than four feet above grade the following requirements must comply:

If not present on each ﬂ oor level where there are bedrooms, a carbon monoxide

1) detector and alarm must be placed in a living area outside the bedrooms. The carbon monoxide detector and alarm must comply with NFPA 720 (2005 Edition).

2) A carbon monoxide detector shall:

a) Be located in the room where the boiler and/or equipment is located; b) Be either hard-wired or battery powered or both; and: c) Shall comply with NFPA 720 (2005 Edition).

3) A product-approved vent terminal must be used, and if applicable, a productapproved air intake must be used. Installation shall be in strict compliance with the manufacturer’s instructions. A copy of the installation instructions shall remain with the appliance and/or equipment at the completion of the installation.

3 Description of the boiler

Room sealed boiler

The boiler retreives its combustion air from outside then discharges the ﬂ ue gasses to the outside.

Condensing

Retrieves heat as much as possible from the ﬂ ue gasses. Water condensates on the heat exchanger.

Modulating

Stepless higher or lower burning according to the heat demand.

The Rinnai E50C boiler is a room sealed, condensing and modulating central heating boiler, with an integrated DHW fascility.

The boiler is provided with a compact stainless steel heat exchanger with smooth tubes. This design is a well engineered principle using durable materials. The boiler burns gas for supplying heat. The heat is transferred in the heat exchanger to the water in the central heating system. By cooling down the exhaust gases condensate is formed. This results in high efﬁ ciency. The condensate, which has no effect on the heat exchanger and the function of the boiler, is drained through a condensate collector trap.

The boiler is provided with an intelligent control system (CMS Control Management System). The boiler anticipates the heat demand of the central heating system or the domestic hot water facility system.

When an outdoor sensor is connected to the boiler it will operate weather dependantly using outdoor reset. This means that the boiler control measures the outside temperature and supply temperature. With this data the boiler calculates the optimal supply temperature for the installation.

Explanation of the appliance type: Rinnai E50C E = Type 50 = Nominal load in (x1000) BTU C = C = Combi

Different boilertypes:

Combi boiler with integrated DHW facility E50C

Installation & Servicing Instructions Rinnai E-Series

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4 Packaging and transportation

CAUTION

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:

Part No. Description Amoun

Install Parts Bag E50C:

Boiler with:

ARV1215U Outdoor reset sensor ARV12 1 44215900 Compression ring Ø22 brass 4 44237500 Compression ring Ø15 brass 4 44357010 Screw 4,8X16mm 4 44380900 Line voltage input connector 3 pole grey 1 44457400 Nut W1.1/8x1/14 22 Compression fitting 2 44527600 Cap de-aerator 1 44748300 Flow restriction MR01 FG 7,6L white 1 44765910 Adapter fitting 15mm x 3/4"NPT ext. 2 44786700 Water lock 1/2"NPT x 1/4"NPT 1 44786800 T/P Gauge 1/4"NPT 1 44786900 Safety valve 3/4"NPT 1 44840100 Adapter fitting 22mm x 1"NPT ext. 2 71035700 Nut 15mm compression fitting 2

E50C

804000088

44839200

8U51650x Installation & Service Instructions 1 8U52650x User information manual 1 8U304000 Warranty document 1 8U300600 ICSL book 1

4.2 Transportation

The boiler may be damaged when not secured properly.

- Only transport the boiler using appropriate transportation equipment, such as a handtruck with a fastening belt or special equipment for maneuvering steps.

- When shipping the boiler must be secured on the transportation equipment to prevent it from falling off.

- Protect all parts against impacts if they are to be transported.

- Follow the transportation markings on the packaging.

• Packaged boilers must always be lifted and carried by two people, or you must

use a handtruck or special equipment for transport.

Wall mounting suspension bracket 1

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5 Installation

5.1 Requirements for the installation room

DANGER

- The room where the boiler will be placed must always be free from freezing conditions.

- Do not store or use gasoline or other ﬂ ammable vapors and liquids in the vicinity of this or any other appliance.

- Never use or store any chlorinated detergents or halogenated hydrocarbons (e.g. in spraycans, solvents and detergents, paints, adhesives) in proximity of the boiler.

- The boiler must be installed in such a way that it is protected from water (dripping, spraying, rain, etc.) during boiler operation and service (circulator replacement, condensate trap, control replacement, etc.)

- This boiler is for intended for indoor installations only.

Products to avoid present in boiler room and/or around combustion air intake

Spray cans containing chloro-/fluorcarbons Ammonium and/or ammonium solutions Permanent wave solutions (hair product) Chlorinated waxes and/or cleaners Swimming pool chemicals based on chlorine Calcium chloride used for thawing Sodium chloride used for water softening Refrigerant leaks Paint or varnish removers Hydrochloric acid/muriatic acid Cements and glues Antistatic fabric softeners used in clothes dryers Chlorine-type bleaches, detergents, and cleaning solvents found in household laundry rooms

Adhesives used to fasten building products and other similar products

Areas likel

Dry cleaning/laundry areas and establishments Swimming pools Metal fabrication plants Beauty shops Refrigeration repair shops Photo processing plants Auto body shops Plastic manufacturing plants Furniture refinishing areas and establishments New building construction Remodeling areas Garages with workshops

to have contaminants

Installation & Servicing Instructions Rinnai E-Series

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5.2 Fitting the boiler

CAUTION

NOTICE

WARNING

- Remove the packaging materials.

- Lay the boiler on its back during unpacking. Remove the casing from the boiler. This part can be left apart during installation. It must be placed on the boiler and ﬁ xed 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.

The boiler can be mounted practically to any wall with the suspension bracket and the enclosed mounting equipment.

- The wall must be ﬂ at and of sufﬁ cient strength in order to be able to securely hold and support the boiler weight with its water content.

- Take note of the necessary space around the boiler for installation of venting system, pipework and servicing. See drawing on pages 12 to 15.

- Drill the necessary holes using the template

- Install the mounting bracket to the wall

Lifting and carrying precautions: To avoid personal injury please follow these recommendations:

- Always lift the boiler with 2 people or use special equipment.

- When lifting the boiler, bend the knees, and keep the back straight and feet apart.

- Do not lift and twist at the same time.

- Lift and carry the boiler close to the body.

- Wear protective clothing and gloves to protect from any sharp edges.

Lift the boiler only by the boiler's rear wall. Do not lift using the pipes on the bottom of the boiler or the vent connections on the top of the boiler.

- Dispose the packaging materials.

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5.3 Dimensions

Connection for combustion

air supply and vent system

f w g k r c

Q R

dimensions figure 1

Combi

Dimensions Connection diameter

Boiler t

A Height 25.6" / 650 B Width 19.7" / 500 C Depth 15.6" / 395 D Left side / vent 13.2" / 335 E Center to center / vent and air supply 4.7" / 120 F Back / vent 10.6" / 270 G Left side / gas pipe 9.8" / 250 g 3/4"M-NPT H Left side / supply pipe 5.9" / 150 f 0.59" x 1"M-NPT / 22mm J Left side / return pipe 13.8" / 350 r 0.59" x 1"M-NPT / 22mm K Left side / condensate pipe 15.9" / 405 c 0.87" / 22mm N Left side / cold water pipe 11.2" / 285 k 0.59" x 3/4"M-NPT / 15mm O Left side / hot water pipe 8.5" / 215 w 0.59" x 3/4"M-NPT / 15mm P Pipe length of g 8.5" / 215 Q Pipe length of c 1.6" / 40 R Pipe length of k and w 6.3" / 160 S Back / Center of pipe c, k and w 1" / 26 T Back / Center of pipe f, g and r* 2" / 50

E50C E50C

inches / mm inches / mm

V Pipe length vent parallel 7" / 177 x 3" / 80mm

dimensions table 1

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Page 13

5.3.1 Clearances from boiler

ceiling

Min. 10" /

250mm

15.7" 400

wall

24" 600

2" 50

service clearances to the boiler figure 4

Minimum required clearances

to combustibles

All types All types

inch / mm inch / mm inch / mm Top of boiler 0" 0" 10" / 250 Back of boiler 0" 0" 0" Front of boiler 1" / 25 1" / 25 24" / 600 Left side of boiler 0" 0" 2" / 50 Right side of boiler 0" 0" 2" / 50

Floor / Ground to bottom of boiler

Vent 0" 0" 0"

clearances to the boiler table 3

0" 0"

Minimum required clearances

to non-combustibles

Required

service clearances

ll types

10" / 250 30" / 762

is recommended

For closet installation: clearance is 1” / 25mm from the front.

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5.4 Technical speciﬁ cations

(

)

(

)

E-Series

Combi

Boiler type E50C

Input Hs CH BTU/hr 50,000

kW 14.7

Output non-condensing CH

Output EN677 efficiency CH

Output AFUE CH

Efficiency at 98.6/86°F (36/30°C) part load, Hs, EN677 CH AFUE according IBR

(at full load)

Electr. power consumption max. W 145 Electr. power consumption stand by W 14 Current V/Hz 120Vac/60Hz Fuse rating A 5AF & 4AT Degree of protection acc. EN 60529 Weight (empty) Water content CH Water content DHW After run time pump CH min 5 After run time pump DHW min 1

Water pressure min.-max.

Water pressure DHW max.

Flow temperature max. Pump type UPS20-48 Available pump height CH PSI / kPa 3.8 / 26 Approvals ASME, CSA

DHW flow DHW flow

at 'T75°F at 'T41.7°C

Max. DHW flow rate

DHW temperature (T

=50°F (10°C)

Pressure difference DHW PSI / bar 2.9 / 0.2

BTU/hr 45,000 kW 13.2 BTU/hr 49,400 kW 14.5 BTU/hr 47,800 kW 14.0

%98.8

95.6

% Natural gas: 4.4 - 4.7 (Propane: 4.8 - 5.1)

IPX4D (IPX0D in case of room air) lbs / kg gallon / liter gallon / liter

91 / 39

0.9 / 3.5

0.13 / 0.5

PSI / bar 14 - 43 / 1 - 3

PSI / bar 150 / 10 °F / °C

gallon/min liter/min

176 / 80

2.1

7.9 gallon/min 2.1 liter/min 7.9

°F / °C 140 / 60

CSA number 2183087 CRN number 8101.7CL

Technical specifications Table 4

Installation & Servicing Instructions Rinnai E-Series

Page 15

6 Connecting the boiler

NOTICE

The boiler has the following connection pipes;

- The central heating circuit pipes.

These must connected to the system by means of 1" (22mm) adapter ﬁ ttings.

See further chapter 6.1;

- The gas supply pipe.

It is provided with a 3/4" male thread into which the tail piece of the gas valve can

be screwed. See further chapter 6.4;

- Cold and hot water pipes for domestic hot water (DHW). These consist of 3/4" (15 mm) copper pipe and can be connected to the installation

by means of 3/4" M-NPT adapter ﬁ ttings. See further chapter 6.5;

- The condensation drain pipe.

It consists of an oval 1" (22 mm) plastic pipe. The drain pipe can be connected to

this by means of an open connection. If the open connection is ﬁ tted in a different location, then the pipe can be lengthened by means of a 1 1/4" (32 mm) PVC sleeve. See further chapter 6.6;

- The vent system and air supply system.

It consists of a twin pipe connection that will accept 80mm ﬂ ue and intake air or with the use of the included adapters 3” PVC/CPVC ﬂ ue and intake. See further chapter

6.7.

The pipes to be connected to the boiler must be cleaned before connecting in order to prevent dirt from entering and damaging the boiler.

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Page 16

6.1 Central heating system

NOTICE

Connect the central heating system according to its instructions.

The boiler pipes can be connected to the installation by means of compression ﬁ ttings. Reducers should be used for connecting to thick-walled pipe (welded or threaded).

When removing the plastic sealing caps from the pipes, dirty testing water may drain from the boiler.

The boiler, when used in connection with a refrigeration system, must be installed so the chilled medium is piped in parallel with the boiler with appropriate valves to prevent the chilled medium from entering the boiler.

The boiler piping system of a hot water boiler connected to heating coils located in air handling units where they may be exposed to refrigerated air circulation must be equipped with ﬂ ow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle.

Some installations with multiple zone valves may require a differential bypass, this will prevent excessively high ﬂ ow rates through a single zone when the other zone valves are closed.

Optional LWCO

hermostat

Air

Separator

Bypass for system

ushing only

Dirt Trap

Pressure

gauge

Manual Fill

Valve

Automatic Fill

Valve

Purge Station

Back ow preventer

Ball valve

Boiler basic piping ﬁ g. 5

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Page 17

- Boiler system ﬂ ushing (Not Boiler heat exchanger)

When replacing an existing boiler the heating system should be ﬂ ushed with the old boiler in place 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 ﬂ ushing of the system. The boiler must be valved off from the system, while the system is ﬂ ushed. No system cleaner should ever enter the boiler heat exchanger due to its caustic nature which could damage the heat exchanger.

1. Close the shutoff valves on both the supply and return connections on the plumbing kit (V1 and V2).

2. Open the bypass valve (V4).

3. Connect pump outlet hose (H1) to the purge station (BD1) and connect H2 to the inlet of the pump and place the other end in the pail.

4. Connect drain hose (H3) to the return side purge station (BD2).

5. Pour the system cleaner into a pail and follow the system cleaner instructions on circulation time and volume to be added to the system.

6. Close the valve (V3)

7. Operate the pump (P1) and circulate the cleaner through the system for required time as established by the cleaner manufacturer.

8. Once the time required by the system cleaner manufacturer has been met place the hose (H3) in a drain.

9. Close the purge station (BD1)

10. Open the auto feed on the system (F1) and allow water to rinse the system for whichever is greater; 10 minutes or the required rinse time by the system cleaner manufacturer.

V1 V2

BD1 BD2

Boiler system ﬂ ushing ﬁ g. 7

System cleaner

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Page 18

11. If the installation is a zone system be sure to purge out each zone individually

NOTICE

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 plumbing kit (V4).

16. Open shutoff valves on both the supply and return connections on the plumbing kit (V1 and V2).

17. Clean out the dirt trap

18. Test the pH of the water that will be used for ﬁ lling the system

19. Test the water hardness of the water that will be used for ﬁ lling the system

20. Use the proper water treatment to ensure the pH and water hardness are within the Rinnai boiler water quality guidelines

21. The boiler and system may now be ﬁ lled.

The following is a list of approved system cleaners, inhibitors, and antifreeze.

Approved antifreeze:

• Rhomar RhoGard Mutli-Metal (AL safe) • Sentinel X500

• Noble Noburst AL • Fernox Alphi 11

Approved system cleaner:

• Noble Noburst Hydronic System Cleaner • Fernox F3 Cleaner

• Rhomar Hydro-Solv 9100 • Sentinel X400

The system cleaners from NoBurst, Rhomar, and Fernox are NOT to be used in the boiler. The boiler must be closed off (valved off) from the rest of the system or not connected while the cleaners are in the system. The system should then be drained and then thoroughly ﬂ ushed with clean water to remove all the system cleaner.

Approved inhibitors:

• Rhomar Pro-tek 922 • Sentinel X100

• Noble Noburst AL inhibitor

- Connect the expansion tank to the system. See chapter 6.2.

- Connect the pipes so that they are free from strain.

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Page 19

NOTICE

Water ﬁ lter ﬁ gure 8

The boiler has a self-adjusting and self-protecting control system for the load and the pump capacity. By this means, the temperature difference between the supply and return water is checked and controlled.

If the installation resistance is over the stated value; the load will be adjusted until an acceptable temperature difference between supply and return water has been obtained. If, after this, the temperature difference is still not acceptable then the boiler will switch off and wait until an acceptable temperature has arisen. If an unacceptable temperature is detected, the control will repeatedly try to achieve water ﬂ ow over the boiler. If not the boiler will switch off.

As standard the boiler is provided with a water ﬁ lter in the return pipe of the boiler, so that debris from the central heating water is prevented from affecting the boiler.

The boiler is designed to be used on pressurized heating systems only (closed loop).

The maximum available head pressure from the boiler pump for the system is 2 psi = 4.6 feet of head.

If the boiler is to be installed in a system that utilizes zone pumps and not zone valves a low loss header plumbing kit should also be installed (part number: 804000061).

If the pressure drop in the loop/system is greater than the available head pressure from the boiler pump a low loss header plumbing kit should be used (part number:

804000061).

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Page 20

6.1.3 Safety valve

NOTICE

DANGER

WARNING

NOTICE

An ASME 30 psi pressure relief valve is included with the boiler and must be ﬁ tted before any shut off valve in the system.

6.1.4 Low water cut off

The Rinnai E50C boiler has a factory installed pressure switch type Low Water

NOTICE

Cut Off (LWCO). Check your local codes to see if a Low W ater Cut Off is required (LWCO) and if this device conforms to local code.

The Low water cut off is not serviceable.

6.2 Boiler expansion tank

Choose an expansion tank volume, of which is geared to the installation’s water capacity. The pre-charge pressure depends on the installation height above the expansion tank. Fit the expansion tank into the return pipe as close as possible to the boiler return connection. The expansion tank should be sourced locally. Please refer to the expansion tank manufacturer for further information.

NOTICE

Fill the expansion tank to a minimum of 14.5 psi.

NOTICE

The boiler cannot be used with an open type expansion tank.

6.3 Underﬂ oor heating system (plastic pipes)

When using oxygen-permeable pipes, e. g. for underﬂ oor heating systems, the system must be separated using plate heat exchangers.

No recourse can be made to the terms of the limited warranty in the event of failure to observe the regulations pertaining to plastic underﬂ oor heating pipes.

6.4 Gas supply connection

Only work on gas lines if you are licensed for such work. If these instructions are not followed exactly, a ﬁ re or explosion may result causing property damage, personal injury or death.

Rinnai wall mounted E boilers are built to run on Natural Gas. The gas type the boiler is suitable for is indicated on the packaging and on the boiler by a blue label with Natural Gas and on the identiﬁ cation plate on the boiler. First check the identiﬁ cation plate on the boiler for the suitable gas type.

Do not use the boiler for another type of gas than indicated on the identiﬁ cation plate of the boiler. This will cause improper functioning and can damage the boiler.

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:803000014.

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Page 21

6.4.1 Gas connection with natural gas

NOTICE

DANGER

NOTICE

Sediment trap ﬁ gure 10

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.

Pipe sizing for natural gas

Contact gas supplier to size the gas supply line and meter.

Gas piping

A sediment trap must be installed upstream of the gas controls.

The boiler gas pipe is equipped with external 3/4" M-NPT thread, onto which the tail piece of the gas shut off valve can be connected. Use appropriate sealing.

The connection to the boiler must include a suitable method of disconnection and a gas control valve must be installed adjacent to the boiler for isolation purposes. The nominal inlet gas pressure measured at the boiler should be 7" W.C. (18 mbar) for Natural gas (Gas A). Maximum pressure with no ﬂ ow (lockup) or with the boiler running is 10.5 inches W.C. Minimum pressure with the gas ﬂ owing (verify during boiler startup) is

3.0 inches W.C.

The gas pipe must be ﬁ tted to the gas valve free from any strain.

Make sure that the gas pipe system does not contain dirt, particularly with new pipes.

Always check the safety of the gas pipe system by means of a bubble test using leak-search spray.

The boiler and its individual shut off valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 PSI (3.5kPa).

The boiler must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 PSI (3.5 kPa).

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Page 22

6.5 Hot water supply

NOTICE

Connection of the drinking water installation should be performed according to the national secondary drinking water regulations.

DANGER

Identiﬁ cation colors ﬂ ow regulators: E50C: White

6.5.1 Domestic Water quality

Do NOT use toxic chemicals, such as those used for boiler treatment in potable water heating systems used for space heating.

The sanitary water pipes can be connected to the installation by use of adapter ﬁ ttings. The cold water inlet on the Combi boilers must be equipped with the following components (counted in the water ﬂ ow direction): Flow regulator valve (supplied), Safety group, Expansion vessel 87 PSI / 6bar (potable water, blue).

The 3/4" NPT adapter ﬁ tting with ﬂ ow reducing valve must be ﬁ tted in the cold water connection. A ﬂ ow regulator valve is supplied with the boiler in a 3/4"NPT adapter ﬁ tting. The ﬂ ow regulator valve ensures that a quantity of water is supplied which has a outlet temperature of 120°F (assuming a cold water temperature of 45°F). The quantity of water is virtually unaffected by the water pressure.

When there is a water pressure lower than 22PSI / 1.5 bar it is advisable to remove the inside mechanism of the ﬂ ow reducing valve.

Appropriate steps must be taken to ensure the brazed plate heat exchanger does not become plugged by scale caused by hard water or sediment. If the plate heat exchanger becomes plugged by either scaling from hard water or sediment it is not the responsibility of Rinnai.

1. Water hardness for DHW

When there is a water hardness of more than 6 to 7 grains hardness for domestic water, a water softener must be installed on the inlet side of the DHW connection.

2. Sediment in DHW

If there is sediment in your domestic water supply a sediment ﬁ lter or other suitable device should be used to remove it before the water enters the brazed plate heat exchanger.

3. Water Chemistry for DHW

The water used for domestic must have a water pH between 6.0 and 8.0, contain less than 1.7 gpg (20 mg/l) of Sodium, and a concentration of Chlorine less than 5.8 gpg (100 mg/L).

If problems occur when using sanitary water outside of the above stated requirements, no recourse can be made to the terms of the limited warranty.

6.5.2 Domestic water treatment Accessory

Rinnai offers a domestic water treatment device that can help reduce scale build up. This device can be installed on the incoming cold water line for any combi boiler. For additional information on contact Rinnai.

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Page 23

6.5.3 DHW Expansion Tank

A domestic water expansion tank could be required by local code. Check local code to determine if it is required. If a combi boiler is installed in a closed water supply system, such as one having a backﬂ ow preventer in the cold water supply line, means shall be provided to control thermal expansion. Contact the water supplier or local plumbing inspector on how to control thermal expansion.

6.5.3 Installing a Thermostatic Mixing Valve

A thermostatic mixing valve should be installed on all E combi boilers on the domestic hot water side to prevent scalding. This valve will regulate the water temperature leaving the brazed plate heat exchanger. See the ﬁ gure 10 for the suggest piping.

Mixed water

to ﬁ xtures

Cold water

Sediment ﬁ lter

WRIK-LF-F kit (WRIK-LF-F 3/4" threaded connection) WRIK-C kit (WRIK-C 3/4" sweat connection)

DHW piping with thermostatic mixing valve ﬁ g. 11

Thermostatic

mixing valve

Shut off valve

DHW Pressure

Relief Valve

System Supply System Return

Drain valve

DANGER

Hot water can be dangerous, especially for infants or children, the elderly, or infirm. There is hot water scald potential if the thermostat is set too high.

Water temperatures over 125º F (51º C) can cause severe burns or scalding resulting in death.

Hot water can cause first degree burns with exposure for as little as: 3 seconds at 140º F (60º C) 20 seconds at 130º F (54º C) 8 minutes at 120º F (48º C) Test the temperature of the water before placing a child in the bath or

shower. Do not leave a child or an infirm person in the bath unsupervised.

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Page 24

6.5.4 Installing a valve kit

NOTICE

A means to isolate the domestic plate heat exchanger for cleaning must be provide at installation. Refer to ﬁ gure 10 for proper piping layout. A Rinnai valve kit can be used on domestic water connections for all combi boilers to allow for cleaning of the plate heat exchanger and installation the domestic hot water pressure relief valve.

• Rinnai recommends the use of the WRIK-LF-F (3/4” NPT thread connection) or WRIK-C kit (WRIK-C (3/4” sweat connection) when connecting the domestic water lines to the boiler

• Use of this kit will assist in ﬂ ushing the ﬂ at plate heat exchanger in areas where water quality issues exist, as well as improve overall product serviceability

6.5.5 Pressure relief Valve

- An approved pressure relief valve is required by Rinnai for all water heating systems.

- The relief valve must comply with the standard for Relief Valves and Automatic Gas Shutoff Devices for Hot Water Supply Systems ANSI Z21.22 and/or the standard Temperature, Pressure, Temperature and Pressure Relief Valves and Vacuum Relief Valves, CAN1-4.4.

- The relief valve must be rated up to 150 psi and to at least the maximum BTU/hr of the appliance.

- The discharge from the pressure relief valve should be piped to the ground or into a drain system to prevent exposure or possible burn hazards to humans or other plant or animal life. Follow local codes. Water discharged from the relief valve could cause severe burns instantly, scalds, or death.

- The pressure relief valve must be manually operated once a year to check for correct operation.

- The relief valve should be added to the hot water outlet line according to the manufacturer instructions. DO NOT place any other type valve or shut off device between the relief valve and the combi boiler.

- Do not plug the relief valve and do not install any reducing ﬁ ttings or other restrictions in the relief line. The relief line should allow for complete drainage of the valve and the line.

- If a relief valve discharges periodically, this may be due to thermal expansion in a closed water supply system. Contact the water supplier or local plumbing inspector on how to correct this situation. Do not plug the relief valve.

- Rinnai does not require a combination temperature and pressure relief valve for this appliance. However local codes may require a combination temperature and pressure relief valve.

- If a combi boiler is installed in a closed water supply system, such as one having a backﬂ ow preventer in the cold water supply line, means shall be provided to control thermal expansion. Contact the water supplier or local plumbing inspector on how to control thermal expansion.

6.5.6 Programming domestic hot water preheat

When plate warming is selected the brazed plate heat exchanger is kept warm and this reduces the wait time for domestic hot water by approximately 1 minute. When this setting is turned off the wait time for DHW is increased by approximately 1 minute.

Plate warming can only be deactivated when the ﬂ ow switch accessory (part number 805000043) has been installed. If no ﬂ ow switch is installed and parameter 36 is altered from the factory setting no DHW production will be possible.

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Page 25

If plate warming is selected consider the following.

NOTICE

This product is a domestic hot water priority boiler; therefore continuous ﬂ ow in the DHW system (perhaps due to a leaky ﬁ xture) may cause the boiler to remain in DHW mode — thus preventing the heating system from adequately functioning. In the event the DHW system has a leak, this feature should be turned off until this problem can be corrected.

This selection can be done with the ﬁ rst digit of Parameter 36. Domestic hot water preheat ON = 1x (Factory setting) Domestic hot water preheat OFF = 2x See chapter 10 how to change a parameter.

The domestic hot water preheat setting is designed to increase the comfort of the home owner and reduce water consumption by reducing the wait time for hot water at the ﬁ xture. This comfort setting will create a slight increase in the gas usage of the boiler, but this will be offset by the reduction in wasted water at the ﬁ xture.

6.6 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 1.3" / 32mm.

i i

NOTICE

Install the condensation drain pipe according to applicable local code.

If the condensate outlet of the boiler is lower than the public sewage system a condensate pump must be used. The condensate produced by the boiler has a pH value between 3 and 4. Install a neutralization unit if required by local code. It is recommended, but not required to install a condensate neutralizer. Rinnai offers a condensate neutralizer designed to work with all boiler models. The condensate neutralizer kit comes with all the necessary ﬁ ttings and mounting material. PVC pipe must be supplied by the installation contractor. Rinnai part number: 804000074

Do not drain the condensation water to the external rain gutter because of the danger of freezing and blockage of the drain.

Before putting the boiler into operation ﬁ ll the condensate trap with 1.27 cups / 300 ml of water. If the boiler will be installed in a high temperature installation

such as baseboard with a supply temperature of 160°F or above, ﬁ ll the condensate trap with mineral oil instead of water.

Use materials approved by the authority having jurisdiction. In absence of such authority, PVC and CPVC pipe must comply with ASTM D1785, F441 or D2665. Cement and primer must comply with ASTM D2564 or F493.

Periodic cleaning of the condensate disposal system must be carried out. See the Rinnai Boiler Application Manual for further information and for a piping diagram for the condensate.

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Page 26

NOTICE

6.7 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.

- 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 ﬂ ue gases of other appliances to enter the boiler.

- Keep cabinet free of moisture

In the event that the system has actuated to shut off the main burner gas, do not attempt to place the boiler in operation. Contact a qualiﬁ ed service agency.

6.7.1 Intake / Exhaust Guidelines

Refer to the speciﬁ c instructions on your vent product for additional installation requirements.

• For direct vent boilers, proper reassembly and resealing of the vent-air intake system is required.

• You must use vent components that are certiﬁ ed and listed with this model.

• Do not combine vent components from different manufacturers.

• Venting should be as direct as possible with a minimum number of pipe ﬁ ttings.

• Avoid dips or sags in horizontal vent runs by installing supports per the vent manufacturer’s instructions.

• Support horizontal vent runs every four feet and all vertical vent runs every six feet or in accordance with local codes.

• Vent diameter must not be reduced.

• The boiler is unsuitable to install on a common vent installation, see also chapter 18.

• Do not connect the venting system with an existing vent or chimney.

• Do not common vent with the vent pipe of any other combi boiler or appliance.

• Vent connections must be ﬁ rmly pressed together so that the gaskets form an air tight seal.

• Refer to the instructions of the vent system manufacturer for component assembly instructions.

• If the vent system is to be enclosed, it is suggested that the design of the enclosure shall permit inspection of the vent system. The design of such enclosure shall be deemed acceptable by the installer or the local inspector.

If it becomes necessary to access an enclosed vent system for service or repairs, Rinnai is not responsible for any costs or difﬁ culties in accessing the vent system. The limited warranty does not cover obtaining access to an enclosed vent system.

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Page 27

6.7.2a Examples vent and air supply systems (parallel)

Wall thickness for vent termination installation: Minimum: 100mm / 4” Maximum: 508mm / 20”

Horizontal with concentric termination figure 12A

Examples sealed combustions

Horizontal with parallel termination figure 12B

10" MINIMUM INSIDE EDGE

T`O INSIDE EDGE

Vertical vent and horizontal air intake

figure 12C

12" OVER

MAXIMUM

SNOW LEVEL

OR 24"

WHICHEVER IS

GREATER

Vertical with concentric termination

figure 12D

Vertical with parallel termination

figure 12E

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Page 28

6.7.2b Examples vent and air supply systems (low proﬁ le PP)

Wall thickness for vent termination installation: Minimum: 100mm / 4” Maximum: 508mm / 20”

Short termination with wall terminal

figure 13A

Examples wall terminals

Termination with wall terminal on higher level

figure 13B

Short termination with roof terminal

figure 13C

Examples roof terminals

Termination with roof terminal and bends

figure 13D

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Page 29

6.7.3 Installation of the vent system

NOTICE

Consult local and state codes pertaining to special building code and ﬁ re department requirements. Adhere to national code requirements.

Follow the listed maximum length of vent systems, which are boiler output dependent. The maximum permissible lengths are listed in table 9, chapter 6.7.6.

Decide how to install the exhaust and air intake system. You can choose between:

- Parallel system (see chapter 6.7.2a)

The parallel connection is provided standard initially. The boiler concentric connection diameter is 2x 80mm. In this case a seperate supplied kit, with 2 vent adapters 3" should be ﬁ tted on top of the boiler, to which the venting and air supply system can be ﬁ tted, with or without elbow pieces. The maximum permissible pipe length is set out in table 9, chapter 6.7.6.

- Concentric system (see chapter 6.7.2b)

The boiler can be converted to a concentric system with an optional adapter (Part nr. 808000023). It is possible to use a concentric connection of 3"/5" (80/125 mm). In this case a optional kit, with 1 concentric ﬂ ue adapter, 3" cover and gaskets should be ﬁ tted instead of the 3" connections on top of the boiler. See chapter 6.7.3.1 for installation. The maximum permissible pipe length is set out in table 9, chapter 6.7.6.

- Room Air System (outdoor combustion air)

The boiler can use room air for combustion. If this option is selected the boiler must be kept in initially standard parallel vent system. A single exhaust pipe can then be ﬁ tted. It is required to use a room air ﬁ lter (Part nr. 808000025) when using indoor air for combustion. See chapter 6.7.3.2 for installation. The maximum permissible pipe length is set out in table 9, chapter 6.7.6.

Rinnai strongly recommends the use of the room air ﬁ lter when a Room Air System (indoor combustion air) is used.

When the boiler is installed in any of the areas listed in chapter 5.1, "Areas likely to have contaminants" or any area exposed to the contaminants listed in chapter 5.1, then sealed combustion is required.

We advise to install a vent system out of the venting system program supplied by Rinnai (See chapter 19 Parts list Vent system). For further information about the available components of the venting and air supply system we recommend you consult Rinnai and the Installation instructions and parts list documentation.

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Page 30

6.7.3.1 Boiler conversion from parallel to concentric

808000023

2 3

4 1

Concentric vent adapter (Part. nr. 808000023) consists of:

1. Cover air intake

2. Gasket 3"

3. Gasket 5"

4. Concentric adapter

5. Plugs for measuring points

6. Gasket 3"

3 4 5 6

A. Push the 2 clips slightly outwards

B. Pull the 3" connection out of the boiler

C. Push out the 5" cover from the vent connection (=air intake)

D. Connect the concentric vent adapter.

- Check if all rubber seals (2, 3, 5 and 6) are positioned on the concentric vent

adapter

- Push the concentric vent adapter in the boiler, in the boiler exhaust pipe until

'CLICK'

- Press the 3" cover (1) in the connection at the back until 'CLICK'.

boiler conversion from parallel to concentric ﬁ gure 14a

6.7.3.2 Installing air ﬁ lter

Push the air ﬁ lter into the air intake on top of the boiler. See ﬁ gure 14b.

The equivalent length of the combustion room air ﬁ lter is 12ft (3.66m).

placing air ﬁ lter on air intake

Installation & Servicing Instructions Rinnai E-Series

ﬁ gure 14b

Page 31

6.7.3 Vent/air intake terminal position

Terminals should be positioned as to avoid products of combustion entering openings into buildings or other vents.

Maintain 12” of clearance above the highest anticipated snow level or grade or, whichever is greater. Please refer to your local codes for the snow level in your area.

Terminal positions figure 15

Ref Description US Installations Direct Vent US Installations non Direct

A Clearance above grade, veranda, porch, deck, or balcony 12 inches (30 cm) 12 inches (30 cm)

B Clearance to window or door that may be opened 6 inches (15 cm) for appliances < 10,000 Btuh (3

C Clearance to permanently closed window * *

D Vertical clearance to ventilated sofﬁ t, located above the

terminal within a horizontal distance of 2 feet (61 cm) from the center line of the terminal

E Clearance to unventilated sofﬁ t**

F Clearance to outside corner * *

G Clearance to inside corner * *

H Clearance to each side of center line extended above meter/

regulator assembly

I Clearance to service regulator vent outlet * *

J Clearance to nonmechanical air supply inlet to building or

the combustion air inlet to any other appliance

K Clearance to a mechanical air supply inlet 3 feet (91 cm) above if within 10 feet (3 m)

L Clearance above paved sidewalk or paved driveway located

on public property

M Clearance under veranda, porch, deck, or balcony * *

kW), 9 inches (30 cm) for appliances > 10,000 Btuh

(3 kW) and < 50,000 Btuh (30 kW), 12 inches (91

cm) for appliances > 50,000 Btuh (30 kW)

6 inches (15 cm) for appliances < 10,000 Btuh (3

kW), 9 inches (30 cm) for appliances > 10,000 Btuh

(3 kW) and < 50,000 Btuh (30 kW), 12 inches (91

cm) for appliances > 50,000 Btuh (30 kW)

horizontally

* 7 feet (2.13 m)

4 feet (1.2 m) below or to side of opening; 1 foot (300 mm) above

3 feet (91 cm) above if within 10 feet (3

Vent

opening

m) horizontally

[1] A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings. [2] Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the ﬂ oor. * For clearances not speciﬁ ed in ANSI Z223.1/NFPA 54 or CSA B149.1, clearances are in accordance with local installation codes and the requirements of the gas supplier.

clearances of venting system terminals table 6

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Page 32

NOTICE

CAUTION

NOTICE

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.

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)

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.

The whole route of the vent system must be installed upwards, never downwards, completely nor partly.

Place pipe supports every 4 feet (1219 mm) of horizontal run, beginning with the support near the boiler to prevent movement in ﬁ ttings and allow boiler to be free from any strain or weight on boiler or ﬁ ttings.

The terminal should be located where dispersal of combustion products is not impeded and with due regard for the damage or discoloration that might occur to building products or vegetation in the vicinity (see ﬁ g 15 and 16).

In certain weather conditions condensation may also accumulate on the outside of the air inlet pipe. Such conditions must be considered and where necessary insulation of the inlet pipe may be required. In cold and/or humid weather water vapor may condense on leaving the vent terminal. The effect of such ‘water condensation’ must be considered.

The terminal must be located in a place not likely to cause a nuisance. Cellular or Foam core PVC is not permitted for use with the boiler.

pproval Codes for Installation

Item Description Flue Material United States

Plastic Vent and/or air pipes and fittings

Plastic Pipe cement and primer

Item Description Flue Material Manufacturer Approval code

Stainless steel vent systems Stainless Steel Heat Fab

Stainless steel vent systems Stainless Steel Simpson Dura-Vent

Stainless steel vent systems Stainless Steel Ubbink

Plastic Vent System PPS Ubbink ULC S636

Plastic Vent System PVC/CPVC IPEX ULC S636 System 636 Plastic Vent System PPS Centrotherm ULC S636 and UL 1738 Innoflue

PVC Schedule 40 ANSI/ASTM D1785 PVC - DWV ANSI/ASTM D2665 CPVC Schedule 40 ANSI/ASTM F441 PVC ANSI/ASTM D2564 CPVC ANSI/ASTM F493

US/CAN

UL1738 Concentric

twin pipe

UL1738 Flexible liner UL1738 Concentric

twin pipe

Canada

ULC S636

Flue system

Saf-T Vent SC Saf-T Vent EZ Seal

FastNSeal Flex FastNSeal

Rolux Condensing Vent System Rolux Condensing Vent System

Approval codes for installation of venting system table 7

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Page 33

12" (300 mm)

WARNING

minimum

EXHAUST

12" (300 mm)

minimum

INTAKE

12" (300 mm)

minimum

Terminal positions PVC figure 16

12" (300 mm)

minimum

12" (300 mm)

minimum

6.7.4 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 ﬁ re, personal injury, or death.

Rinnai strongly suggests the use of PPs venting for all closet and alcove installations. For non direct vent room air applications see sections 6.7.5 and

6.7.8.

1”(25mm) minimum clearance

around vent pipes

15”

386mm

6”

148mm

11”

268mm

1”(25mm) minimum clearance

around vent pipes

15”

386mm

6”

148mm

11”

268mm

10”

254mm

Closed door

1”

25,4mm

2”

50mm

2”

50mm

1”(25mm) minimum clearance

around hot water pipes

Closet installation ﬁ gure 17

8”

200mm

8”

200mm

10”

254mm

Open front

152mm

2”

50mm

2”

50mm

1”(25mm) minimum clearance

around hot water pipes

Alcove installation ﬁ gure 18

8”

200mm

8”

200mm

6”

Installation & Servicing Instructions Rinnai E-Series

Page 34

6.7.5 Dimensioning of the exhaust and air intake duct

NOTICE

DANGER

NOTICE

WARNING

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 ﬁ nished vent and air piping thoroughly to ensure all are airtight and comply with the instructions provided and with all requirements of applicable codes.

Failure to provide a properly installed vent and air system may cause severe personal injury or death.

Use only the material listed in Rinnai's vent documentation for vent pipe, and ﬁ ttings. Failure to comply could result in severe personal injury, death or substantial property damage.

Installation must comply with local requirements and with the National Fuel Gas Code, ANSI Z223.1.

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 ﬁ re, personal injury, or death.

All vent pipes must be connected and properly supported, and the exhaust must be pitched a minimum of a 1/4”/foot (21 mm/m) back to the boiler (to allow drainage of condensate). Please refer to the venting manufacturer's manual to see if a larger pitch is required for speciﬁ c venting systems. The venting system manufacturer's required venting pitch must always be followed if larger than 1/4” (21 mm). Ubbink concentric condensing venting requires a pitch of ¾”/ foot (6mm/m).

Combustion air piping from the outside MUST comply to the requirements of the authority having jurisdiction or, in the absence of such requirements, to the latest edition of the National Fuel Gas Code, ANSI Z223.1/NFPA 54.

Installation & Servicing Instructions Rinnai E-Series

Page 35

6.7.6 Combustion air and vent piping lengths.

In the table below you will ﬁ nd the maximum equivalent pipe length of the vent/air system based on 3" diameter. These lengths are for single pipe (room air) and twin pipe.

Boiler type 3” Max Vent equivalent length 3” Max Air equivalent length

E50C 100 feet 100 feet

Equivalent vent length table 8

Fittings or Piping Equivalent PVC

feet m

45 degree elbow 3 0.91 90 degree elbow 6 1.83 plastic pipe per foot 1 0.30 concentric vent kit 3 0.91

Equivalent friction loss of PVC/CPVC table 9

Centrotherm PPs Equivalent lengths for piping fittings

feet meters

45 degree elbow 6 1,83 87 degree long elbow 12 3,66 Termination Tee 12 3,66 Twin Pipe to Concentric Adapter 4 1,22 Low profile wall termination 12 3,66 Velocity Cone 12 3,66

Equivalent friction loss of Centrotherm PPC table 9a

Parallel system

Length tube Number of

elbows 90°

Combustion air

ft ft ft ft ft 0.5 ft

ent

ft ft ft ft ft 0.5 ft

Concentric system

Length concentric tube, boiler to roof

Number of elbows 90°

horizontal

ft ft ft ft ft 1.0 ft

Calculation of equivalent length vent system

Choose the vent type and ﬁ ll out the corresponding table.

* See equivalent length tables above.

Total Multiply with

factor

Total equivalent len

Total Multiply with

factor

Total equivalent

x 6*

Number of

elbows 45°

x 3*

Number of elbows 45°

x 3*

Concentric

terminal

dd 5 ft.

Concentric

terminal

dd 2 ft.

Example of calculation:

Twin tube (parallel) with terminal Combustion air length : 24 ft with elbow 3 x 90° Vent length : 24 ft with elbow 2 x 90°, elbow 2 x 45°

Equivalent

length

Calculation: Equivalent Air Length : (24+3x6+2) x 0.5 = 23 ft

Equivalent Vent Length : (24+2x6+2x3+2) x 0.5 = 23 ft +Total = 46 ft.

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Page 36

6.7.7 Calculation of compensation factor

WARNING

NOTICE

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.

Eq. length (ft)

min max CF (V)

010 0 11 20 0 21 30 0 31 40 1 41 60 2 61 80 3 81 100 4

Compensation factor vent system CP(V) table 10

2. Determine the Compensation Factor Altitude CF(A) in the table below.

Boiler type

E50C

Altitude (ft)

min max CF (A)

01 0 1,000 2,000 6 2,000 3,000 12 3,000 4,000 18 4,000 5,000 24 5,000 6,000 30 6,000 7,000 36 7,000 8,000 42 8,000 9,000 48 9,000 10,000 54

Compensation factor altitude CP(A) table 11

Any application or installation above 10,000 must be reviewed by Rinnai's Engineering group. This is to ensure the product is installed and the overall system is designed properly and that the units are commisioned properly. Not involving of Rinnai's Engineering group would result in no support of the product and no warranty.

3. Calculate the Compensation Factor Total CF(T):

CF(T) = CF(V) + CF(A)

Boiler type

E50C

The result is the setting for Parameter 73.

Change parameter 73 according to this result. See Chapter 10.1 how to change parameters.

Example of calculation: E50C Eq. lenth vent system (taken from previous example) 46 ft CF(V) = 2 Altitude 7,200ft CF(A) = 42 + CF(T) = 44

Parameter setting (Par. 73) = 44

Do not overcompensate the boiler by setting a higher value than calculated, otherwise the boiler could be damaged.

Installation & Servicing Instructions Rinnai E-Series

Page 37

6.7.8 Room Air System (indoor combustion air)

When using indoor air, Rinnai strongly recommends the use of an indoor air ﬁ lter, P/N 808000025.

WARNING

This boiler requires adequate combustion air for ventilation and dilution of ﬂ ue gases. Failure to provide adequate combustion air can result in unit failure, ﬁ re, 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.

Important: Combustion air must be free of corrosive chemicals. Do not provide combustion air from corrosive environments. Appliance failure due to corrosive air is not covered by the limited warranty. Combustion air must be free of acid forming chemical such as sulfur, ﬂ uorine and chlorine. These chemicals have been found to cause rapid damage and decay and can become toxic when used as combustion air in gas appliances. Such chemicals can be found in, but not limited to bleach, ammonia, cat litter, aerosol sprays, cleaning solvents, varnish, paint and air fresheners. Do not store these products or similar products in the vicinity of this boiler.

Unconﬁ ned Space:

An unconﬁ ned space is deﬁ ned in NFPA #54 "as a space whose volume is not less than 50 cubic feet per 1000 Btu/hr (4.8 m3 per kW per hour) of the aggregate input rating of all appliances installed in that space. Rooms communicating directly with the space in which the appliances are installed, through openings not furnished with doors, are considered a part of the unconﬁ ned space." If the “unconﬁ ned space” containing the appliance(s) is in a building with tight construction, outside air may still be required for proper operation. Outside air openings should be sized the same as for a conﬁ ned space.

25FT

NOTE: 8FT CEILING

Unconﬁ ned Space

91,300 BTU Boiler

Unconfined space figure 19

Unconﬁ ned Space

200,000 BTU Boiler

36FT

NOTE: 8FT CEILING

Installation & Servicing Instructions Rinnai E-Series

Page 38

Conﬁ ned Space:

(Small Room, Closet, Alcove, Utility Room, Etc.) A conﬁ ned space is deﬁ ned 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 conﬁ ned space must have two combustion air openings. Size the combustion air openings based on the BTU input for all gas utilization equipment in the space and the method by which combustion air is supplied: Using indoor air for combustion Using outdoor air for combustion

Louvers and Grills

When sizing the permanent opening as illustrated in ﬁ gure 17, consideration must be taken for the design of the louvers or grills to maintain the required free area required for all gas utilizing equipment in the space. If the free area of the louver or grill design is not available, assume wood louvers will have 25% free area and metal louvers or grills will have 75% free area. Under no circumstance should the louver, grill or screen have openings smaller than ¼”.

Example: Wood: 10 in x 12 in x 0.25 = 30 in2 Metal: 10 in x 12 in x 0.75 = 90 in2

Location

To maintain proper circulation of combustion air two permanent openings (one upper, one lower) must be positioned in conﬁ ned spaces. The upper shall be within 12 inches of the conﬁ ned space and the lower opening shall be within 12 inches of the bottom of the conﬁ ned space. Openings must be positioned as to never be obstructed.

Combustion air provided to the boiler should not be taken from any area of the structure that may produce a negative pressure (i.e. exhaust fans, powered ventilation fans).

Gas Vent / Boiler Exhaust

OUTLET AIR DUCT

BOILER

PERMANENT

OPENINGS

12in. MAX

12"

(300mm)

BOILER

INLET AIR DUCT

Louvers and grills figure 20

Installation & Servicing Instructions Rinnai E-Series

10"

(250mm)

Page 39

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 conﬁ ned space through two permanent openings, one commencing within 12 in. (300mm) of the top and one commencing within 12” (300mm) of the bottom, of the conﬁ ned space. The openings shall communicate to the outside by one of two ways: directly through horizontal ducts indirectly through vertical ducts

When communicating directly with the outdoors through horizontal ducts, each opening shall have a minimum free area of 1 in

/2000 Btu/hr (1100 mm2/kW) of total input rating of all appliances in the conﬁ ned space. Note: If ducts are used, the cross sectional area of the duct must be greater than or equal to the required free area of the openings to which they are connected.

When communicating indirectly with the outdoors through vertical ducts, each opening shall have a minimum free area of 1 in2/4000 Btu/hr (550 mm2/kW) of total input rating of all appliances in the conﬁ ned space. Combustion air to the appliance can be provided from a well ventilated attic or crawl space.

Gas Vent / Boiler Exhaust

OUTLET AIR DUCT

BOILER

Gas Vent / Boiler Exhaust

OUTLET

AIR

BOILER

INLET

INLET AIR DUCT

Gas Vent / Boiler Exhaust

INLET AIR DUCT

[Ends 1Ft (300mm)

above floor]

BOILER

OUTLET

AIR

Ventilation Louvers for unheated crawl space

Louvers and grills figure 21

Installation & Servicing Instructions Rinnai E-Series

Page 40

7 Electrical connections

CAUTION

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.

Connecting incoming power

Install a 120V main switch next to the boiler as service main switch of the boiler. Lead the cable through the back part of the boiler using a strain relief and lead the cable through the cable supports to the Control Tower. Use a step drill bit to create a knockout in the grey plastic cover of the boiler for a strain relief. Connect a power supply cable to the cable harness terminal strip that connects to both the power switch on the front of the Control Tower and the terminal strip with positions 1, 2, and 3 on the inside of the Control Tower.

CAUTION

The boiler must be electrically grounded in accordance with local codes, or in absence of local codes, with the National Electrical Code, ANSI/INFPA 70.

RISK OF ELECTRIC SHOCK.

Once the main power supply is on then there is 120V on terminals 1 to 12 when the main switch next to the boiler is switched on.

- 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.

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Page 41

CAUTION

120 V~

120 V~ 120 V~ 120 V~

Power supply

Cylinder connection

8U.35.60.00

Outside sensor

Bus

Controller

24 V~

100 mA

123 456 789 12 13 14 15 16 17

19 20 21

23 24 25 26 27

NLNL NL NL

DHW N AB

DHW

sensor

three-way valve

Room therm.

On / Off

External

safety

contact

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 ﬂ uctuations. As a standard rule this means mercury thermostats. This resistance wire is present in the Control Tower and must be connected to terminals 23 and 27. The anticipating resistance in the room thermostat has to be set at 0.11 A. For more detailed questions regarding the components which are not supplied, the distributor should be contacted.

When wiring an RS100 it is suggested that a jumper be placed on terminals 22 and 23 so that in the event the control is damaged the boiler will still ﬁ re based on outdoor reset. A jumper should also be used when commissioning or trouble shooting the boiler.

NOTICE

Power stealing thermostats cannot be connected to terminals 22 and 23.

Connection terminal E-Series

main power supply

120 Volts

Rinnai only

120 Volts

Rinnai only

internal or external

three-way valve motor

and

tank sensor

ARV12 outdoor sensor

Bus room thermostat

RS100

On/off thermostat or

External safety contact

control (Volt free)

120 Volts

CAUTION

Terminals 4 to 11 are for Rinnai use only and not for use in any installation.

Connection terminal ﬁ gure 22

Installation & Servicing Instructions Rinnai E-Series

Page 42

120V

T 220°F

High Limit Switch

Flowswitch

24 V~

100 mA

safety

contact

External

23 24 25 26 27

Room

therm.

On / Off

Bus

Controller

19 20 21

sensor

Outside

DHW

sensor

N AB

DHW

Cylinder connection

three-way valve

8U.35.60.00

NLNL NL NL

120 V~

Label all wires prior to diconnection when servicing or replacing

controls. Wiring errors can cause improper and dangerous operation

CAUTION

E-Prom

Installation & Servicing Instructions Rinnai E-Series

120 V~ 120 V~ 120 V~

Power supply

123 456 789 12 13 14 15 16 17

electrical diagram figure 23

Page 43

Installation & Servicing Instructions Rinnai E-Series

electrical ladder diagram figure 23a

Page 44

8 Boiler controls

The boiler is provided with a fully automatic microprocessor control, called CMS Control Management System. This control simpliﬁ es 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. The various parameters can be called up in two ways:

The Good-state or standard read out

The ﬁ rst way shows a simple display read out. The boiler in operation will always show 'Good'. When a message is necessary this will be shown instead of Good.

Technical read out

The second way is a technical read out. In normal situations the following will be shown:

Example

• on the left the status in which the boiler is active;

• on the right the supply temperature in °F; Alternately indicated by:

• the water pressure in the installation in PSI. When a message (error or blocking code) is necessary this will be shown instead of the technical read out.

NOTICE

T o switch over from the Good-state to the Technical read out (and vice versa):

- Press the STEP-button for 5 seconds.

When the system has been ﬁ lled the automatic de-aeration program starts, when a program has been selected, by pressing the button for Central Heating, DHW or pump

program ( , of ). The program takes 17 minutes and stops automatically. After this the unit will function normally. (See also 'Filling and de-aerate the boiler and installation, chapter 9).

On a call for heating or hot water the control system will select the required water control temperature. This water temperature is called the T-set value. On a call for central heating the boiler ignites ﬁ rst at low input. The input is then changed slowly to match the load required. The boiler operates in this way to avoid excessive water noises and temperature overshoot. On a call for domestic hot water supply the T-set value of central heating return water temperature is monitored. Depending on the amount of domestic water which is withdrawn from the DHW fascility, the central heating return water temperature, from which the input is adjusted, will vary.

Operation indication

(in the ﬁ rst display position by technical read out)

No heat demand

Fan pre/post purge

Ignition phase

Burner active on central heating

Burner active on DHW

Fan check

Burner off when room thermostat is demanding or burner off when DHW is calling

Pump overrun phase for central heating

Pump overrun phase for hot water

Burner off because of to high ﬂ ow temperature

Automatic de-aeration program

Installation & Servicing Instructions Rinnai E-Series

Page 45

8.1 Explanation of the function buttons

CAUTION

NOTICE

When the pump is switched on continuously it can lead to undesired heating up of the central heating system during the summer.

Boiler control panel 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.

Only turn the boiler off using this switch, when the burner is off..

3. Central Heating program button.

Switching the Central Heating on or off (LED on/off);

4. Hot Water program button.

Switching the Domestig Hot Water (DHW) facility on or off (LED on/off);

5. Pump program button.

adjusts the pump to continuous water circulation in the central heating system (LED on), or according to the pump overrun times on the relevant programs (LED off);

6 Mode-button.

After brieﬂ y pressing, a selection of the data chapters can be retrieved. After pressing for 5 seconds it is possible to enter the code as described in chapter

11.3;

7 Step-button.

After brieﬂ y pressing, the water pressure can be retrieved and pages per chapter

can be retrieved.

After pressing for 5 seconds it switches from the Good-state to technical read out

and vice versa;

8 Reset-button.

After brieﬂ y pressing, for:

- unlocking errors;

- ending the access code; After pressing for 5 seconds an operating stop is made, for example, for activating

the automatic venting program.

Some buttons have other functions.These functions are only active according to the procedure described in chapter 11, adjustment has to be changed or data must be retreived from the CMS. The other functions are:

3. Central Heating program button :

4. Hot Water program button:

5. Pump program button : store-function, which means that by means

7. Step-button: scrolling in a data chapter.

+ function;

- function;

of this button a modiﬁ ed setting is conﬁ rmed;

Installation & Servicing Instructions Rinnai E-Series

Page 46

9 Starting up: Filling and de-aerating the boiler and installation

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 12 and 13).

- Never allow electrical or electronic components to come into contact with water.

NOTICE

Carry out the following tasks in connection with maintenance, etc. to an alreadyinstalled unit:

- Shut down all programs

- Close the gas shut off valve

- Shut off the power at the main power switch

- Close the service valves (system supply and return)

NOTICE

Take note of the following when maintenance or adjustments are needed:

- The unit must be able to function during these activities; for this reason, the unit’s supply voltage, gas pressure and water pressure must be maintained. Ensure that this is not a source of potential danger during these activities.

Following maintenance or other activities; always check the installation of all parts through which gas ﬂ ows (with bubble test using leak-search spray).

9.1 Requirements of the water system

Before ﬁ lling the heating system, the complete system, including all zones, must be thoroughly cleaned and ﬂ ushed to remove sediment. Flush until clean water runs free of sediment. Rinnai suggests using an approved system cleaner to ﬂ ush the system, but not the boiler. Always use Rinnai approved antifreezes. See the list at the end of this chapter. Never use reverse osmosis, D.I., or distilled water for ﬁ lling the heating system.

Do not use petroleum-based cleaning or sealing compounds in the boiler system. Damage of seals and gaskets in boiler and system could occur, resulting in property damage.

The central heating installation needs to be ﬁ lled with potable water.

Use only potable water or approved glycol for ﬁ lling the heating system. When the water hardness of the ﬁ lling water exceeds > 10.5 gpg (200 mg/L) and the volume of the installation > 20L/kW (5.2 gallons/3,412 BTU) the water has to be treated until below the maximum value of 10.5 gpg (200 mg/L). The pH value of the installation water must be between 6.5 and 8.5.

Check the pH value using proper equipment or by having the water analyzed by a water treatment company. If pH differs from above, contact Rinnai engineering for further assistance.

Component or product damage as a result of failing to adhere to the water quality requirements will not be covered by the limited warranty.

Installation & Servicing Instructions Rinnai E-Series

Page 47

Freeze protection

NOTICE

WARNING

NOTICE

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 ﬂ uid is correct for the glycol concentration and inhibitor level. The system should be tested at least once a year and as recommended by the producer of the glycol solution. The allowed maximum concentration is 50%.

Use only Rinnai approved inhibitors. See below for an approved list of inhibitors.

Use only inhibited propylene glycol solutions, which are specially formulated for central heating systems. Ethylene glycol is toxic and can attack gaskets and seals used in the boiler and system. Approved glycols are listed below.

Additives in the installation water are not permitted.

Approved antifreeze: • Rhomar RhoGard Mutli-Metal (AL safe) • Sentinel X500

(max. concentration 50%) • Noble Noburst AL • Fernox Alphi 11

Approved system cleaner: • Noble Noburst Hydronic System Cleaner • Fernox F3 Cleaner

• Rhomar Hydro-Solv 9100 • Sentinel X400

Approved inhibitors: • Rhomar Pro-tek 922 • Sentinel X100

• Noble Noburst AL inhibitor

9.2 Filling the heating system

For ﬁ lling or topping off the installation you use the ﬁ lling loop according to the following procedure:

1 Switch on the power supply;

2 The display will show FILL;

3 All functions off (heating , DHW and pump );

4 Push brieﬂ y the 'STEP'-button: P XX (XX = water pressure in PSI);

5 Open the ﬁ lling loop (Indication on display increases);

6 Fill up slowly to 16 to 18 PSI;

7 STOP appears on the display;

8 Close the ﬁ lling loop;

9 De-aerate the complete installation, start at the lowest point;

10 Check the water pressure and if necessary top it up;

11 Close the ﬁ lling loop;

12 Activate the functions in use (heating , DHW and/or pump );

Installation & Servicing Instructions Rinnai E-Series

Page 48

13 If A XX appears on the display, wait for 17 minutes;

NOTICE

14 Check the water pressure and if necessary top it up to 16 to 18 PSI

15 Close the ﬁ lling loop;

16 Press the ‘STEP’-button;

17 Be sure that the ﬁ lling loop is closed.

After the automatic de-aeration program (A XX) is ﬁ nished the boiler will return to

the Good state or Technical read out.

Check the water pressure regularly and top off the installation when necessary. The working pressure of the installation should be between 16 and 18 PSI when the system is cold.

It can take a while before all air has disappeared from a ﬁ lled installation. Especially in the ﬁ rst week noises may be heard which indicate the presence of air. The automatic air vent in the boiler will remove this air, which means the water pressure can reduce during this period and therefore topping off with water will have to be done.

During normal use the following messages can occur with the necessary follow up:

Water pressure is too low (<10 PSI), FILL indication remains continuously visible, the boiler is taken out of operation. The installation needs to be topped off.

9.3 Hot water supply

Apply the water pipe pressure to the DHW fascility (open main valve and/or stop valve of the safety group).

Vent the DHW fascility and the hot water installation by opening a hot water shut off valve. Leave the shut off valve open for as long as required until all air has disappeared from the DHW fascility and the pipes and only water is ﬂ owing from the shut off valve.

Water pressure is too low (<12 PSI), flashing FILL will alternate with indication of water pressure, boiler power of 50% is possible. The installation needs to be topped off.

Water pressure is too high (>42 PSI), if HIGH indication remains continuously visible, the boiler is taken out of operation. The installation pressure needs to be decreased by draining water.

Installation & Servicing Instructions Rinnai E-Series

Page 49

FOR YOUR SAFETY READ BEFORE OPERATING

WARNING: If you do not follow these instructions

exactly, a ﬁ re 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 ﬂ oor

because some gas is heavier than air and will settle on the ﬂ oor.

WHAT TO DO IF YOU SMELL GAS

- Do NOT try to light any appliance.

- Do NOT touch any electrical switch.

- Do NOT use any phone in your building.

- Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

- If you cannot reach your gas supplier, call the ﬁ re department.

C. Use only your hand to push in or turn the gas control knob. Never use tools.

If the knob will not push in or turn by hand, don’t try to repair it, call a licensed professional. Force or attempted repair may result in a ﬁ re or explosion. D. Do not use this appliance if any parts have been under water. Immediately call a licensed

professional to inspect the appliance and to replace any part of the control system and any gas

control which has been under water.

OPERATING INSTRUCTIONS

1. STOP! Read the safety information above this label.

2. Turn off al electrical power of the appliance.

3. Set the thermostat or other operating control to the lowest setting.

4. This appliance is equipped with an ignition device which automatically lights the burner. Do NOT try to light the burner by hand.

5. Close main gas shut off valve.

6. Wait (5) minutes to clear out any gas. Then smell for gas. Including near the ﬂ oor. If you smell gas, STOP! Follow “B” in the safety information above on this label. If you don’t smell gas, go to the next step.

7. Open main shut off valve.

8. Set the thermostat or other operation control to desired setting.

9. Turn on all electric power to the appliance.

10. If the appliance will not operate, follow the instructions “To Turn Off Gas To Appliance” and call your service technician or gas supplier.

Manual Gas Valve (Main valve)

OPEN

TO TURN OFF GAS TO APPLIANCE

1. Turn off all electric power to the appliance if service is to be performed.

2. Set the thermostat or other operating control to the lowest setting.

3. Close main gas shut off valve.

8U.34.01.01 / 11.12

Installation & Servicing Instructions Rinnai E-Series

Page 50

10 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. In certain cases parameters have to be altered in case of :

- Lower supply temperature

- High altitude/long vent length

- Minimum boiler supply temperature

CAUTION

NOTICE

The venting / altitude calculation must always be performed during commissioning of the boiler.

Read through the Parameter chapter to adjust the boiler to its installation. Contact Rinnai in case of doubt.

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.

10.1 Altering adjustments

STEP 1

Press the Mode-button for 5 seconds.

The display shows COdE followed by an arbitrary number;

STEP 2

Press by means of the + or the - button until the code C123 is shown;

STEP 3

Press the STORE-button to conﬁ rm the code (code blinks1 x).

Now you have acces to the installer level. There are 4 chapters:

• Parameters

•

• Error-chapter (no adjustments possible) The content of the chapters is described on the following pages.

STEP 4

Press brieﬂ y the MODE-button to select one of the 4 chapters, i.e. PARA;

STEP 5

Press brieﬂ y and release the STEP-button to select a Parameter

(parameter visible on the left, value on the right) ;

STEP 6

Alter the value, if necessary/possible, by means of the + or the - button

Information chapter (no adjustments possible) Service chapter

STEP 7

Press brieﬂ y on the STORE-button to conﬁ rm the alteration.

When you have to change more values, repeat from step 5.

STEP 8

Press once or more on the MODE-button until StBY or Good is shown: After a few seconds the text StBY will be replaced by the technical read-out

or Good-state (Depending from the position the acces code is entered)

When you want to return from an arbitrary position to the original read out

press once or more on the MODE-button until StBY is shown.

If no single button is used within 20 minutes the display will return automatically to its

NOTICE

original read-out (Good state or technical read out)

Installation & Servicing Instructions Rinnai E-Series

Page 51

Parameter Mode

PARA FACTORY

DESCRIPTION

RANGE

.. . .

1 176°F maximum supply temperature CH 68 - 176°F 2* 00 type of CH installation: 00 - 04

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

01 DO NOT USE

radiators with large surface areas or underfloor heating as additional heating: T max. supply 158°F K factor heating curve 1.8; gradient 10°F/min; gear differential 10°F

under floor heating with radiators as additional heating: T max. supply 140°F; K factor heating curve 1.5; gradient 8°F/min; gear differential 8°F

full under floor heating: T max. supply 122°F; K factor heating curve 1.0; gradient 6°F/min; gear differential 6°F

3 max. maximum power CH in kW (.. x3415 = .. BTU/hr) min-max 4* 00 control principal with on / off thermostat:

100 % on / off thermostat 00 constant water circulation 22&23 closed contact day curve operation,

open contact night curve operation

5* 2.3 heating curve K-factor (see also heating curve graph) 0.2 - 3.5 6* 1.4 heating curve exponent (see also heating curve graph) 1.1 - 1.4 7* 14°F heating curve climate zone (see also heating curve graph) -4 - 32°F 10* 0°F fine adjustment heating curve day temperature -8 to 10°F 11* 0°F fine adjustment heating curve night temperature -8 to 10°F 14 10°F/min. gradient speed °F/min. 0 - 28°F/min. 15* 00 Booster after night decrease*:

no 00

yes 01 23 26°F Frost Temperature -4 to 50°F 27 32°F Minimum T-set CH 0 - 158°F 36 10 Type of three way valve and DHW fascility

VC 2010 / VC 8010 x0

Warming function plate heat exchanger ON 1x

Warming function plate heat exchanger OFF 2x 43 max. Maximum power DHW in kW (.. x3415 = .. BTU/hr

)

min-ma

49 100% Maximum pump capacity heating 100 % 73 0 Altitude and venting CFT. See chapter 6.7.7 0 - 100 89 00 Address

No function -01

Bus thermostat 00 90 01 Display reading

°C and Bar 00

°F and PSI 01

.. . .

Info Mode

INFO

FACTORY

DESCRIPTION

RANGE

.. . .

1 °F supply water temperature T1 4 °F return water temperature T2 5 °F DHW temperature T3 7 °F outdoor temperature T4 8 °F flue gas temperature T5 (optional sensor) 16 % actual power in % 17 kW actual power in kW (.. x3415 = .. BTU/hr) 18 kW actual load in kW (.. x3415 = .. BTU/hr) 20 indication bus communication 21 GJ consumption total in GJ (.. x 33 = .. m3) 22 GJ consumption CH in GJ (.. x 33 = .. m3) 23 GJ consumption DHW in GJ (.. x 33 = .. m3) 24 h total number of burner run hours 25 h number of burner run hours CH 26 h number of burner run hours DHW 32 h total number of hours counter 37 h total number of run hours pump CH and DHW 46 h within how many hours is service required

Installation & Servicing Instructions Rinnai E-Series

Page 52

Service Mode

SERV

1 OFF boiler in operation with burner function on OFF - max. 2 OFF fan adjustable and burner off OFF - max. 3 OFF pump adjustable with burner on OFF - max. 4 OFF showroom position ON = active and OFF = non active ON - OFF

VALUE

DESCRIPTION

.. . .

RANGE

Error Mode

ERRO

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 = .. BTU/hr) 6 % pump capacity

Parameter-, Info-, Service- and Error-chapters Table 12

VALUE

DESCRIPTION

* Most of the data in this table can be requested by the RS100. Most of

NOTICE

the adjustments which are stated in this table are unnecessary when in combination with the Rinnai RS100 thermostat and will be taken care of by the RS100 itself and do not have to be adjusted. For further information regarding to the RS100 thermostat refer to the Rinnai RS100 installation manual.

230

212

194

176

158

140

122

104

2.30

1.80

1.50

1.80

1.50

1.00

ﬂ ow water temperature in °F

Outdoor reset

Heat curve day Heat curve night

Installation & Servicing Instructions Rinnai E-Series

heating line adjustments Parameter Step 6 and 7 graph 2

-4.0

-0.4

3.2

6.8

10.4

14.0

17.6

21.2

outside temperature in °F

24.8

28.4

32.0

35.6

39.2

42.8

46.4

50.0

53.6

57.2

60.8

64.4

68.0

Page 53

10.2 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.

11 Isolating the boiler

Some situations require turning the entire boiler off. By switching off the three buttons with the LED's for central heating, hot water and

pump program ( , or ), the boiler is switched off. Do not shut off the power of the boiler, which means the circulation pump and the three-way valve are activated once every 24 hours in order to prevent these parts from seizing up.

CAUTION

In the event of freezing danger with an isolated boiler it is advisable to drain the boiler and/or the installation.

Installation & Servicing Instructions Rinnai E-Series

Page 54

12 Commissioning

Work on the boiler must be carried out by a licensed professional, using

NOTICE

correctly calibrated instruments with current test certiﬁ cation. These installation instructions are intended for licensed professionals, who have the necessary knowledge and are approved for working on heating and gas systems.

Before the boiler is ﬁ red, 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.

WARNING

NOTICE

Installing casing ﬁ gure 25

WARNING

DANGER

Failure to properly commission the boiler as described in section 13 may result unreliable burner operation, reduced component life, and unsafe boiler operation.

The boiler and its individual shut off valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 PSI (3.5kPa).

To commission the boiler the casing has to be removed.

remove the 4 screws A,B,C and D in the quick releases of the casing (ﬁ gure 25);

- remove the screw E behind the door on the front of the casing (ﬁ gure 25);

- remove it towards the front.

The boiler settings, such as burner pressure and adjustment of the air quantity are unnecessary in most cases, due to the fact that the boiler operates with a zero pressure control. This means the correct gas quantity is controlled by the suction operation of the fan. The ﬁ ne adjustment of the zero pressure, which is carried out at the factory is once-only, which means that adjusting of this value is unnecessary. Only in case of replacing of the gas valve, venturi and/or fan will the zero pressure adjustment have to be checked and, if necessary, adjusted to the right value.

The venturi must always be checked and adjusted when it is out of range see section 12.3 on O2 adjustment.

Always check the installation of all parts through which gas ﬂ ows (by bubble test using leak-search spray).

Pump commissioning procedure should be followed before the boiler is ﬁ red for the ﬁ rst time:

1. Remove the vent pump screw

2. Use a small ﬂ at head screw driver to ensure the impeller spins freely.

3. When the impeller spins freely and water exits though the vent port the pump is ready for operation.

4. Replace the vent screw

During the commissioning of the boiler the Rinnai Installation, Commissioning, and Service card must be ﬁ lled out.

Pump commissioning figure 26

Installation & Servicing Instructions Rinnai E-Series

Page 55

12.1 Testing for gas leaks

WARNING

Prior to start-up of the boiler you must check the external tightness of the gas supply valve and conﬁ rm this in the start-up report.

- Before leaking 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.

DANGER

Leaks may be caused to pipes and screw connections during commissioning and maintenance activities.

- Carry out a proper leak test.

- Only use approved leak detection agents for leak detection.

- Disconnect the heating system from the power supply.

- Check the exterior tightness of new conduit sections up to and including the direct

sealing point on the gas burner ﬁ tting. The maximum test pressure allowed on the input of the gas burner ﬁ tting is 14 inch W.C. (35mbar).

12.2 Testing the Ignition Safety shut off device

- Switch off system using the Central Heating button and the DHW button

- Disconnect the plug and socket connection of the ionization cable.

- Switch on the sytem using the Central Heating button and the DHW button.

- Press the MODE-button for 5 seconds.

- The display will show COdE followed by an arbitrary number;

- Select by means of the

- Press the Store-button to conﬁ rm the code (code blinks 1 x);

- Press the MODE-button until SERV is shown;

- Press the STEP-button once until 1 is shown; alternately 1 and OFF will be shown.

- Press the button once; Check if the boiler does one start-up attempt and four restart attempts. After the last start-up attempt, the boiler will lock out. The gas valve is shut off. The E02 code is blinking in the display.

- Connect the plug and socket connection of the ionization cable.

- Press the reset button.

- Check if the boiler starts-up.

Do not touch the inside of the igntion cable while it is disconnected during start up of the boiler.

or the button the code C123;

Installation & Servicing Instructions Rinnai E-Series

Page 56

12.3 Checking the O

NOTICE

The O2 percentage setting is required to be checked at commissioning, maintenance and faults and adjusted if needed.

WARNING

The O 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.

This can be checked by means of the following procedure:

- Remove the black cover of the gas valve by unscrewing the sealed screw.

- Put the boiler into operation and take care that it can deliver its heat;

Tip: If there is no demand for heat on CH, turn the hot water tap completely open and measure the O2.

- Press the MODE-button for 5 seconds.

- The display will show COdE followed by an arbitrary number;

- Select by means of the or the button the code C123;

- Press the Store-button to conﬁ rm the code (code blinks 1 x);

- Press the MODE-button until SERV is shown;

- Press the STEP-button once until 1 is shown; alternately 1 and OFF will be shown.

percentage is required to be checked and adjusted after a conversion

checkpoint O2

adjustment screw O

figure 27

fig. 28

- Calibrate the O2 meter ;

- Place the probe of the O2 meter into the check point (see ﬁ g. 27);

- Press the button until the maximum value (in kW) is achieved; The boiler will burn on full load (value on display in kW) value in BTU/hr = x3415

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.

- Check the O2 percentage: Natural Gas: full load: between 4.4% and 4.7% min. load: setting of full load +0.2% or greater Propane: full load: between 4.8% and 5.1% min. load: setting of full load +0.2% or greater

Example:Full load set on 4.6% O be 4.8% or greater.

Choose the right O Gas). Wrong adjustment may result causing property damage, personal injury or death.

value according the kind of gas (Natural Gas or Propane

(natural gas) then the minimum load setting should

- Let the O2 meter do its measuring procedure.

- Adjust, if necessary, the adjustment screw to correct the O2 value (see ﬁ g. 28). Allow boiler to stabilize before reading the new value.

Installation & Servicing Instructions Rinnai E-Series

Page 57

Ending the O2 measuring procedure:

- Press the - button until is shown (keep button pressed). With this the procedure has ended..

- Replace the black cover on the gas valve and secure it with the screw.

12.4 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 ﬁ gure 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.

- The display will show COdE followed by an arbitrary number;

Ionization test ﬁ gure 29

- Select by means of the or the button the code C123;

- Press the Store-button to conﬁ rm the code (code blinks 1 x);

- Press the MODE-button until SERV is shown;

- Press the STEP-button once until 1 is shown;

alternately 1 and OFF will be shown.

- Press the button until the maximum value (in kW) is achieved;

The boiler will burn on full load (value on display in kW) value in BTU/hr = x3415

- Measure the ionization. When the boiler is in full load the ionization current must be > 4 μA and write down this value in the log book.

- Press the

- Switch off the system using the Central Heating button and the DHW button

- Disconnect the measuring device and restore the plug and the socket connection on the probe.

- Switch on the sytem using the Central Heating button and the DHW button.

12.5 Installing the casing

button until OFF is shown (keep button pressed).

Installing casing ﬁ gure 30

- Install the cover on the boiler and close all 4

- Tighten the 4 screws A,B,C and D in the quick releases (ﬁ gure 30);

- Tighten the screw E behind the door on the front of the casing (ﬁ gure 30);

quick releases of the casing

Installation & Servicing Instructions Rinnai E-Series

Page 58

13 Maintenance

NOTICE

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. This can be done at the isolation valve usually located below the boiler or by turning off the water supply to the building.

13.1 Periodic examination of venting systems and boiler

The inspection of the boiler and venting system should be done every 2 years or 4000 hours and full maintenance every 4 years or 8000 hours of operation, whichever occurs ﬁ rst. When doing this the circumstances of the boiler’s location must be taken into account. From this one can determine whether to deviate from this advice.

Please contact Rinnai for further guidance on the frequency and service requirements. Contact details can be found on the back page of this manual.

13.2 Inspection

Preparing the boiler for inspection

To carry out the maintenance activities please follow the next procedure:

- Switch off the power supply;

- Shut off the gas;

- Valve off the boiler from the system using the boiler isolation valves in the plumbing

- Remove the screw E behind the door on the front of the casing (ﬁ gure 31);

- Remove it towards the front.

- Clean the casing with a cloth with a simple (non-abrasive) cleaning agent;

kit. Remove the 4 screws A,B,C and D in the quick releases of the casing (ﬁ gure 31);

Removing casing

Installation & Servicing Instructions Rinnai E-Series

ﬁ gure 31

Page 59

13.2.1 Visual inspection for general signs of corrosion

NOTICE

- Check all gas and water pipes for signs of corrosion.

- Replace any pipes that are corroded.

13.2.2 Measuring the ionization current

See subsection 12.5 “Measuring the ionization current".

13.2.3 Measuring the inlet gas pressure

See subsection 6.4.1 and .2 “Gas connection with natural gas" and "Gas connection with propane”.

13.2.4 Testing for gas leaks

See subsection 12.1 “Testing for gas leaks”.

13.2.5 Carrying out a pressure test of the heating system

See chapter 9.2 “Filling the heating system”.

13.2.6 Checking venting systems

Check the following points:

- Is the prescribed combustion air/ﬂ ue system used?

- Have the instructions for conﬁ guring the ﬂ ue system as speciﬁ ed in the relevant Installation instruction for the ﬂ ue gas system been observed?

- Check air intake and/or air ﬁ lter and ﬂ ue gas for obstruction, pollution or damage.

When an air ﬁ lter is used the air ﬁ lter must be replaced yearly on boilers operating in normal circumstances. The conditions (eg. supply air quality) in which the boiler is installed should be taken into account. This will show whether the frequency of replacement should be reduced or increased. If in doubt, contact RINNAI.

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Page 60

13.3 Maintenance activities

NOTICE

fan unit and gas valve ﬁ gure 32

The fan unit and burner cassette (ﬁ gure 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. Note the correct turning direction (red indicator. ﬁ g. 34);

- Slightly lift the fan unit and remove it towards the front of the heat exchanger;

- Remove the burner cassette out of the fan unit;

- Check the burner cassette for wear, pollution and possible cracks. Clean the burner cassette with a soft brush and vacuum cleaner.

If burners are cracked replace the complete burner cassette;

- Replace the gaskets between burner and fan unit and the gasket between fan unit and heat exchanger;

- Check the venturi and the gas-air distribution plate for pollution and clean this part, if necessary with a soft brush and vacuum cleaner. If the air box contains a lot of dirt it is plausible that the fan itself is dirty as well. To clean this, the fan has to be removed from the hood and the venturi. Clean the fan with a soft brush and a vacuum cleaner. Replace the gasket and ensure that all gaskets of the fan parts are mounted correctly.

figure 33

DANGER

Clamping rods figure 34

Installation & Servicing Instructions Rinnai E-Series

Heat exchanger (every 4 year maintenance)

- Check the heat exchanger for contamination. Clean this if necessary with a soft brush and a vacuum cleaner. Prevent debris from falling down into the heat exchanger.

Flushing the heat exchanger from the top down is not permitted

Reﬁ tting of the components is done in reverse order.

Make sure that during reﬁ tting the clamping rods they are put in the right position. They should be turned vertical. If the boiler should activate with clamping rods in the wrong position it will cause property damage, personal injury or loss of life.

Ignition electrode (every 4 year maintenance) This can be checked by measuring the ionization current. The minimum ionization current has to be higher than 4μA on full load.

If the inspection glass is damaged the complete electrode must be replaced.

Replace the ignition assembly after every 4 year, whichever occurs ﬁ rst. Replacement goes as follows:

- Remove the electrical connections of the electrode;

- Press the clips on both sides of the electrode to both sides and remove the complete electrode;

- Remove and replace the gasket;

Reﬁ tting of the components is done in reverse order.

Page 61

WARNING

Siphon figure 35

Condensate trap and condensate tray (ﬁ gure 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). If there is a lot of impurities in the cup it is necessary to remove and clean the condensate tray according Step 2;

- Check the O-ring (9) of the cup and replace if necessary;

- Clean the parts by ﬂ ushing it with clean water;

- Grease the O-ring again with acid free O-ring grease to make ﬁ tting easier;

- If there is a leak at the condensate trap (8) replace complete condensate trap by # 809000100;

Step 2: Condensate tray

- Remove the plug from the ﬂ ue gas sensor if present;

- Turn the two short clamping rods (11 and 12) ¼ turn and remove them by pulling them forward; Note the right turning direction (red indicator);

- Lift the exhaust pipe (13) out of the condensate tray (14);

- Press the condensate tray (14) carefully downwards and remove it by pulling it forward;

- Replace the gasket between condensate tray and heat exchanger with a new one;

- Clean the condensate tray with water and a hard brush;

- Check the condensate tray for leaks.

Condensate tray figure 36

DANGER

Clamping rods figure 37

DANGER

Step 3: Reﬁ tting is done in reverse order.

Note that all gaskets seals completely.

Put the boiler into operation and check the O

If replacement of new gaskets and burner mentioned in this chapter is not done within the service interval subscribed by Rinnai the boiler can be damaged and may cause property damage, personal injury or loss of life.

Use only original spare parts supplied by Rinnai. If non approved parts are used the boiler can be damaged and may cause property damage, personal injury or loss of life. Use of non-Rinnai parts will result in the voiding of the limited warranty .

Do not use substitute materials. Use only parts certiﬁ ed with the appliance.

(see chapter 13.3).

Cleaning the Brazed Plate Heat exchanger (Every 2 year maintenance or as needed based on water quality)

The brazed plate heat exchanger should be cleaned at the service interval every 2 years. Failure to ﬂ ush the brazed plate heat exchanger will cause damage to it. Follow the procedure below for cleaning the brazed plate heat exchanger.

1. Turn off the DHW function on the boiler.

2. Close the shutoff valves on both the hot water and cold water lines (V3 and V4).

3. Connect pump outlet hose (H1) to the hot water line at service valve (V1).

Installation & Servicing Instructions Rinnai E-Series

Page 62

Flushing

4. Connect drain hose (H3) to service valve (V2).

5. Pour approximately 4 gallons of virgin, food grade, white vinegar or citric acid into pail.

6. Place the drain hose (H3) and the hose (H2) to the pump (CP) inlet into the cleaning solution.

7. Open both service valves (V1 and V2) on the hot water and cold water lines.

8. Operate the pump (CP) and allow the cleaning solution to circulate through the brazed plate heat exchanger for at least 45 minutes.

9. Turn off the pump (CP).

10. Rinse the cleaning solution from the brazed plate heat exchanger as follows:

a. Remove the free end of the drain hose (H3) from the pail b. Close service valve, (V2), and open shutoff valve, (V4). Do not open shutoff

valve, (V3). c. Disconnect both H1 and H3 from the service valves d. Connect H3 to V1 and place the end of the hose in a drain e. Allow water to ﬂ ow through the brazed plate heat exchanger for 5 minutes f. Close service valve, (V1), and open shutoff valve, (V3).

11. Disconnect all hoses.

Mixed water

to ﬁ xtures

Thermostatic

mixing valve

Cold water

Draining

Cold water

Sediment ﬁ lter

Vinegar

Sediment ﬁ lter

Thermostatic mixing valve

Mixed water

to ﬁ xtures

System Supply System Return

Drain

Installation & Servicing Instructions Rinnai E-Series

Flushing and draining figure 38

System Supply System Return

Page 63

Inspection glass figure 39

Visual inspection of the ﬂ ame (2 and 4 year maintenance)

The burner must ﬂ ame evenly over the entire surface when operating correctly. The ﬂ ame must burn with a clear, blue, stable ﬂ ame.

Check the ﬂ ame through the inspection glass in the ignition probe (ﬁ g. 38).

The ﬂ ame pattern should be as shown in the ﬁ gures below.

SATISFACTORY

Ignition probe blue ﬂ ame

UNSATISFACTORY

Ignition probe

Water filter figure 40

NOTICE

13.3.1 Reset service interval counter

yellow ﬂ ame

Further checks:

- Inspect the pressure relief valve

- Clean the water ﬁ lter in the return pipe

- Check the pH of the water or glycol/water mixture.

The combustion must be checked and adjusted if required at both the 2 year/4000 hour and 4 year/8000 hour service intervals with a properly working combustion analyzer.

Verify proper operation after servicing. Always reset the service interval counter after full maintenance interval (every 4 years or 8000 hours of operation).

At 8000 hours of use, “SERVICE” will scroll across the display. “Good” will display as well alternatively. To reset the 8000 hour service notiﬁ cation:

- Enter the 1st Tier Settings: 123 Code

- Brieﬂ y press “Mode” again until the Service Chapter is displayed (SERV)

- Hold the “Store” button until SERV ﬂ ashes once—the service notiﬁ cation will no longer show during normal operation and the countdown to service will reset to

8000.

13.4 Limited warranty

For warranty conditions refer to the warranty supplied with the boiler.

Installation & Servicing Instructions Rinnai E-Series

Page 64

14 Parts of the boiler

4 2 1 3 15 514 6

Rinnai E-Series figure 41

1 heat exchanger 2 ignition unit 3 fan unit 4 air inlet damper 5 gas valve 6 automatic de-aerator 7 ceramic burner cassette 8 plate heat exchanger DHW

T1 supply sensor T2 return sensor T3 sensor DHW

Installation & Servicing Instructions Rinnai E-Series

9 operating panel 10 Control Tower (CMS) 11 water ﬁ lter return CH 12 three-way valve 13 circulation pump 14 exhaust 15 combustion air supply 16 CSA Data Plate (serial number)

P1 water pressure sensor

12 1316 9

17 ASME / NB / CRN data plate

G gas pipe A supply central heating R return central heating C condensate pipe K cold water pipe W hot water pipe

Page 65

15 Blocks and Errors

15.1 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 ﬁ xed 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.

Block 01:

External safety contact cut off

Block 05:

Outdoor sensor not connected

Block 60:

Incorrect parameter setting of the minimum or maximum power.

Block 67: A T has been detected between ﬂ ow and return sensor whereas the burner is not in operation. After the T has disappeared the block will clear.

Block 85: The control has not detected a water ﬂ ow. The venting cycle is started. If during this cycle water ﬂ ow is detected, the venting cycle is ended and the burner is released.

Error with a number in the last two positions.

Error 00: Poor ﬂ ame-forming

Error 02: no ﬂ ame-forming

Error 04: adjustment or error for voltage interruption

Error 05: adjustment

Error 12: high limit stat

Error 18: maximum ﬂ ow temperature exceeded

Error 19: maximum return temperature exceeded

Error 28: number of revolutions not reported back from fan

Error 69: no or incorrect display

FUSE: 24V fuse defective

NOTICE

The following pages describes more detailed follow up instructions for solving blockings, errors and practical circumstances. These instructions are only for licensed professional.

Installation & Servicing Instructions Rinnai E-Series

Page 66

15.2 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. Blocks

Code Description Solution

External safety contact open Rectify error as a result of which by determining contact is open.

Outdoor sensor contact open (not connected)

Maximum average T of supply and return sensor for central heating is repeatedly exceeded. Operation is normally possible for the hot water supply during the block. The pump continues to operate at minimum capacity during the block.

Maximum average T of supply and return sensor for hot water is repeatedly exceeded. Operation is normally possible for the central heating installation during the block. The pump continues to operate at minimum capacity during the block.

Incorrect parameter setting for the minimum or maximum power

A temperature difference has been detected between the supply and return sensor whilst the burner is not in operation. After the average T has disappeared, the block will disappear.

ﬂ ue sensor temperature too high Check vent system

with a ﬁ gure on the last 2 characters.

Or repair interconnection between 24/25

Rectify error as a result of which by determining contact is open or outdoor sensor is not connected. Connect outdoor sensor or repair wiring (position 18/19) or replace outdoor sensor.

Check ﬂ ow through the installation. See the installation instructions for the hydraulic connections to the boiler (3-Way-Thermostatic valve, Plumbing Kit installed?) Possible causes: (radiator) shut-off valves closed or blocked water ﬁ lter Activeted room sensor (RS101) in non leading room (closed thermostatic radiator valves?) Check pump height. Check minimum and maximum Temperature difference in Parameter Step 46 + 47.

Check ﬂ ow through the boiler and DHW tank See the installation instructions for the hydraulic connections to the boiler Possible causes: (radiator) shut-off valves closed or blocked water ﬁ lter resistance (coil) in tank to high (see pump height) Check 3-way-valve on function and pollution.

Call Rinnai

Check the supply and return sensor for the resistance value and replace the defective sensor

Check the installation for any external heat source and rectify this

ﬂ ue sensor or thermostat contact open

ﬂ ue sensor or thermostat contact closed

ﬂ ue gas thermostat contact open Check vent system

no water ﬂ ow can be detected through the controller. De-aeration cycle is started. When water ﬂ ow is detected during this cycle, the de-aeration cycle is terminated and the burner is released. The controller checks the water pressure during static and dynamic situation.

The frequence of the power supply deviates more than + or -1.5Hz

Installation & Servicing Instructions Rinnai E-Series

Call Rinnai

or check parameter 84 for default

- check the installation for the presence of air;If there is a secondary pump installed and it is not hydraulicly separated, it could cause pressure differences.

- check the use of balancing valves

check if the pump is functioning and/or that the water pressure sensor is

working properly; Polluted pump; Polluted water pressure sensor; Polluted water ﬁ lter; Wiring of pump.

check the main power supply

Page 67

15.3 Errors

Code Description Solution

Incorrect ﬂ ame formation. boiler has not been burning but an ionization ﬂ ow (ﬂ ame) has still been detected

24 Volt short-circuit Check the 24 Volt connection. Remove all plugs with 24 Volt connections such

No ﬂ ame formation Check the data in Error mode. Boiler data during error.

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 reﬁ t it part by part until a short-circuit takes place.

Rectify the short-circuit and if necessary replace this part.

as: fan, pump, any three-port valve and 24 Volt plug to the connecting block.

Check short circuit of disconnected components. Switch on power again to the control unit with the components disconnected. Reconnect the components, which have been checked and are working.

Rectify the short-circuit or replace the short-circuited component.

1 error = 02 2 operational status = 02 3 supply temp. = xx* 4 return temp. = xx* 5 kW burner = xx** 6 % pump = xx* * = variable value **= x 3451 = BTU/hr

1 No temperature difference

between supply (3) and return (4)

2 There is a temperature difference

between supply (3) and return (4)

Control unit error Connector not plugged into the gas valve or defect in the wiring of the gas

The controller has detected a program error

Control unit error Check 120V stability. If voltage is deviating more between +10% and -15%

The error persists after reset Software error control unit. Replace the control unit. Remove the E-Prom from

Control unit error Moisture on the PCB. Check if there is water leaking on or in the boiler.

Boiler has not been able to ignite any gas or has not received any gas. Boiler tries to start 6 times with an increasing starting load after the safety time

Check whether:

- the gas valve is open;

- there is power to the gas valve;

- that the gas valve opens The minimum gas pre-pressure during the start must be a minimum of 7"W.C. (17 mbar), check the 24 Volts in the gas during ignition block’s open position

Boiler has gone out after ignition. Due to insufﬁ cient ionization the burner has gone out after ignition

Ionization ﬂ ow, ionization cable or the O current should be 4 μA, the O2 should be a minimum of 4.4% for NG or 4.8% for LP

valve.

Software error control unit. Replace the control unit. The display will automatically load the program into the new controller.

Reset the boiler. the boiler automatically indicates this message if during an error read-out the electrical power to the boiler is shut off. After the power has once again switched on, if the error causing the interference is no longer present, this message is given.

Rectify the preceding error, If Error 04 persists, and preceding errors do not occur, replace controller.

the electrical power supply needs to stabilised.

the defective control unit and place it onto the new control unit .The controller will automatically load the program into the new control unit.

setting. The minimum ionization

Stop leak and replace MCBA controller

Installation & Servicing Instructions Rinnai E-Series

Page 68

Code Description Solution

Control unit error

1 Anticipation resistance wire not

present

2 Software error control unit. Software error control unit. Replace the control unit. Remove the E-Prom from

High limit stat open Supply temperature too high. Caused by

Control unit error Software error control unit. Replace the control unit. Remove the E-Prom from

- T1 ﬂ ow sensor ground connection

- T1 ﬂ ow sensor failure

- controller failure

Signal maximum ﬂ ow water temperature exceeded (T 212°F).

Signal maximum return water temperature exceeded (T2>212°F).

T1 and T2 (swapped). T2 temperature is measured to be higher than T1. Check resistance value

Controller failure Replace controller

When a power stealing room stat device is placed the connection terminal needs to be provided with the special anticipation resistance wire.

the defective control unit and place it onto the new control unit .The controller will automatically load the program into the new control unit.

- presence of air

- possible polluted impeller of the circulation boiler pump

- polluted internal ﬁ lter

Check de-aerator. Replace when necessary the automatic de-aerator and restart boiler for de-aerating programm (17min.)

Check water ﬂ ow over system. Clean when necessary the pump and or ﬁ lter. Flush complete system

Check adjustment of balancing valves

the defective control unit and place it onto the new control unit .The controller will automatically load the program into the new control unit.

Check the data in Error mode. Boiler data during error: 1 Error = 14 2 Operational status = 00 3 Flow temp. = -22 4 Return temp. = xx* 5 kW burner = 00** 6 % pomp = xx* * = variable values **= x3415=BTU/hr

A temperature of - 36 is displayed at position 3. Check the wiring and/or measure the resistance of the ﬂ ow sensor. The resistance should be approx. 12 kOhm at 77°F. (See table in Appendix B)

If necessary, replace the ﬂ ow sensor

- check for resistance on 16 and 17 if using a 3rd part DHW control

- if resistance is present on 16 and 17 with 3rd party control contacts on control are not fully open

Check actual ﬂ ow temperature. suddenly increase caused by completely hydraulic shut off of the boiler (ﬁ lter, pump, thermostat valve, service valve)

Check ﬂ ow sensor NTC1. measure the resistance value (see Appendix B)

Exchange defective part if necessary. Change control unit when error persists.

Check actual return temperature. Increase of temperature caused by external heating source?

Check return sensor NTC 2. Measure the resistance value (see Appendix B)

Exchange defective part if necessary. Change control unit when error persists

of T1 and T2 (See Appendix B) and replace T1 or T2.

Installation & Servicing Instructions Rinnai E-Series

Page 69

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)

internal shut down of supply sensor T1

Shut down of return sensor T2 Check the data in Error mode. Boiler data during error:

Check vent system. Vent system and air intake system must be installed according installation instructions.

IF vent system is OK: Replace fan

Check the data in Error mode. Boiler data during error: 1 Error = 31 2 Operational status = 00 3 Flow temp. = 230 4 Return temp. = xx* 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 ﬂ ow sensor as a result of which Error 36 occurs

Replace the sensor.

1 Error = 32 2 Operational status = 00 3 Flow temp. = xx* 4 Return temp. = 230 5 kW burner = 00** 6 % pomp = xx* * = variable values **= x3415=BTU/hr

Check the wiring. check the wiring for the sensor

contact for supply sensor T1 open

The wiring is OK but the error is repeated. Remove the plug from the ﬂ ow sensor as a result of which Error 37 occurs

Replace the sensor.

Check the data in Error mode. Boiler data during error: 1 Error = 36 2 Operational status = 00 3 Flow temp. = -22 4 Return temp. = xx* 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 ﬂ ow sensor as a result of which Error 31 occurs

Replace the sensor.

Installation & Servicing Instructions Rinnai E-Series

Page 70

Code Description Solution

contact for return sensor T2 open

Control unit error Software error control unit. Replace the control unit. Remove the E-Prom

Electrical leakage to ground. Moisture on controller PCB. Check if there is water leaking on or in the

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 ﬂ ow sensor as a result of which Error 32 occurs

Replace the sensor.

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.

boiler.

Stop water leak and replace controller.

No software present 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.

Flue gas temperature to high (adjustment parameter 84 default 212°F)

Fuse on controller PCB defective or Cable transformer not connected

Replace ﬂ ue sensor or adjust parameter 84 to default

Replace fuse.

A 4A and 5A spare fuse can be found on the back side of the Control Tower.

Installation & Servicing Instructions Rinnai E-Series

Page 71

15.4 Other Errors

Complaint Description Solution

Central heating but no domestic hot water

Hot water but no central heating

Central heating installation gets hot without being requested

Insufﬁ cient quantity of hot water

Temperature drop of the DHW (Combi)

radiators do not get hot enough or warming them up takes too long

-Key of the DHW program is

not switched on

2. Flow switch is not working properly.

3. T3 DHW sensor in plate heat exchanger defective

4. When using RS100 - Check timer times for DHW program,

5. Three-port valve is not circulating to DHW

2. Room thermostat (on/off) is not

3. RS100 with outdoor sensor

(Room sensor-On)

4. Three-port valve is not

2. Dirt in three-port valve or three-

1. Hot and cold water connection to

2. Incorrect ﬂ ow reducing valve. - Check for the type and for contamination, if

3. In the absence of positive results Lime scale in plate heat exchanger. If necessary

1. Hot and cold water connection to

2. Flow reducing valve. Check ﬂ ow reducing valve for the correct type in

3. DHW power for the boiler is set

1. Check setting of room

2. Supply water temperature too

3. Incorrect choice of installation PARA chapter Step No. 2 if necessary change.

-Key of the central heating

program is not switched on.

giving any signal to the boiler.

circulating to central heating position.

-Key pump program is on.

port valve cartridge is binding.

the boiler mixed up.

the boiler mixed up

too low.

thermostat or RS100

low.

Switch on DHW program on the Control Tower

Check ﬂ ow and/or check for impurities. Check on functioning. Replace if necessary.

Replace DHW sensor

if necessary reset

- RS100 does not respond to DHW program

- See RS100 installation instructions

- Check wiring.

- If necessary replace the three-port valve motor.

Switch on central heating program

Check room thermostat

- Outdoor temperature is higher than 70°F, depending upon the Eco-temperature set (70°F is the default). Check Info chapter Step 7 or temperature is higher than the Eco temperature set (see RS100 installation instructions).

- Check timer program and set room temperature.

Check wiring, replace the three-port valve motor.

Switch off.

Clean or replace.

Check left = hot, right = cold

necessary replace (Combi) and/or clean.

- Check the comfort synchronising valve for the

correct setting in accordance with the installation instructions.

descale or replace

Check left = hot, right = cold

accordance with the installation instructions

- Check PARA chapter Step No. 43

- Check the functioning and wiring of the DHW sensor

T3.

See installation and user manual RS100

Check setting PARA chapter Step No. 1 and increase if necessary

4. Installation resistance too high (given an average T > 36°F the boiler decreases the load).

- See installation instructions.

- Check / clean water ﬁ lter check dimensions of pipes.

Installation & Servicing Instructions Rinnai E-Series

Page 72

16 Spare parts

Parts casing and rear wall E-Series

User information manual

High ef¿ ciency condensing gas boiler

E50C15

E50C20

WARNING!

Installation and service must be

performed by a licensed professional,

service agency or the gas supplier.

WARNING! If you do not follow these instructions exactly, a ¿ re or explosion may result causing property damage, personal injury or loss of life.

- Do not store or use gasoline or other À ammable vapors and liquids in the vicinity of this or any other appliance.

- WHAT TO DO IF YOU SMELL GAS

- Do NOT try to light any appliance.

- Do NOT touch any electrical switch.

- Do NOT use any phone in your building.

- Immediately call your gas supplier from a

neighbor’s phone. Follow the gas supplier’s instructions.

- If you cannot reach your gas supplier, call the ¿ re

department.

Address: 103 International Drive, Peachtree City, GA, 30269 Toll-free: 1-800-621-9419  Fax: 678-829-1666  www.rinnai.us

Notice! This manual must be retained for future reference.

Installation & Servicing

Instructions

High ef¿ ciency condensing gas boiler

CAUTION!

Read this manual thoroughly before installing, servicing, putting into operation or using this boiler and vent system.

WARNING!

CAUTION!

NOTICE!

Pictured: E50C15

Installation and service must be performed by a quali¿ ed

E50C20

installer, service technician or the gas supplier.

In the Commonwealth of Massachusetts this boiler must be installed by a licensed Plumber or Gas Fitter.

WARNING! If you do not follow these instructions exactly, a ¿ re or explosion may result causing property damage, personal injury or loss of life.

- Do not store or use gasoline or other À ammable vapors and liquids in the vicinity of this or any other appliance.

- WHAT TO DO IF YOU SMELL GAS

- Do NOT try to light any appliance.

- Do NOT touch any electrical switch.

- Do NOT use any phone in your building.

- Immediately call your gas supplier from a neighbor’s phone.

Follow the gas supplier’s instructions.

- If you cannot reach your gas supplier, call the ¿ re department.

Address: 103 International Drive, Peachtree City, GA, 30269 Toll-free: 1-800-621-9419  Fax: 678-829-1666  www.rinnai.us

These instructions to be retained by user.

8U.52.65.00 /05.13 Changes reserved

8U.51.65.00 / 05.13 Changes reserved.

Installation & Servicing Instructions Rinnai E-Series

Page 73

Description

FLUE ADAPTER 80

808000022

Item

1 GASKET CASING E 2 CASING SET

BOILER COVER BOLT M5X20 (SET OF 5 BOLTS)

4 SPRING DOOR CASING 5 GASKET CONTROLS 6 DOOR CASING E50C

USER MANUAL E50C

INSTALLATION MANUAL E50C 800000048 X

BRACKET E75C, E110C, Q85S & Q130S

GASKET AIR INTAKE ø80 SHR

mm x

COVER AIR SUPPLY Ø125mm

FLUE GAS SYSTEM PP SET OSS1

PLUG MEASURING POINT PARALLEL FLUE PIPE

GASKET FLUE GAS PIPE PP

GASKET AIR SUPPLY ø125mm

86 87 QUICK RELEASE SMALL E 88 QUICK RELEASE LARGE E

Art. No. / Référence

809000073 X 809000074 X 809000127 X 809000075 X 809000076 X 809000143 X 800000047 X

809000065 X 809000047 X

808000029 X 808000010 X 808000028 X 809000048 X 809000049 X 809000078 X 809000079 X

E50C

OSS1

Installation & Servicing Instructions Rinnai E-Series

Page 74

Parts heat exchanger E-Series

30 31

64 32 33

34 35 36

40 41

60 61 62

Installation & Servicing Instructions Rinnai E-Series

Page 75

Description

GASKET SILENCER-VENTURI

809000021

O-RING ø17,12X2,62 PLUG HEATEXCH.(3 PER PACKAGE)

809000103

Item

CLAMP BAR TOP PART H.EX. LONG

TOP PART HEAT EXCH. SET OSS1

BOLT M 5X16 (5 PER PACKAGE)

GASKET FAN/TOP PART H.EX.

GASKET GAS VALVE - VENTURI

GASKET VENTURI - FAN VENTURI OSS1

BOLT M5X12GR FASE ZSDIN7985 (5 PER PACKAGE)

O-RING ø5,00X2,00 FLOW SENSOR (5 PER PACKAGE)

GASKET IONISATION/IGNITION OSS

Art. No. / Référence

809000014 X 807000010 X 809000015 X 809000016 X 809000017 X 809000018 X 807000013 X 809000019 X 809000080 X 809000020 X

E50C

OSS1

DAMPER OSS1

SCREW TAPTITE M5X8 CK-PD (3 PER PACKAGE)

HEAT EXCHANGER OSS1 ASME

BOILER TOOL KIT GASKET CONDENSATE TRAY OSS1

CAP DE-AERATOR SHR (3 PER PACKAGE)

DE-AERATOR CHROME

O-RING ø13,94X2,62 DE-AER. (2 PER PACKAGE)

BOLT M 3X30 VERZ.DIN84/4.8 (3 PER PACKAGE)

GASKET H.E./TOP PART OSS1

GASKET BURNER/TOP PART OSS1

BURNER CASSETTE SET OSS1

SET INSOLATION PIPE PLATE L+R

METAL PLUG HEAT EXCH 1/2"

LIP-RING ø63 AMGAS

PLUG FLUE GAS SENSOR

CONDENSATE TRAY OSS1

CLAMP BAR COND.TRAY

BOLT M 5X12 IMBUS VERZ. (3 PER PACKAGE)

COVER GAS VALVE

807000016 X 809000022 X 807000019 X 809000024 X 809000025 X 807000023 X 807000024 X 809000028 X 809000029 X 809000030 X 809000033 X 806000010 X 809000036 X

809000115 X 809000038 X 809000040 X 809000041 X 809000044 X 809000045 X 809000046 X

Installation & Servicing Instructions Rinnai E-Series

Page 76

9594 105 106 107131

108 106a

109

111

117137

118 119 119a 119b 121138 123 124 125 126 127 128

129 130

122

104 103

101

100

102

308

304

9996

112

113

94a

108146139

96a

Parts pipes E-Series

Installation & Servicing Instructions Rinnai E-Series

Page 77

Description

WHITE

3,53

O Gø 0 3,53

Item

O-RING ø21.89X2.62 GASLINE

GASKET FITTING 3/4" GASV.

92 93 GAS PIPE E75C

GAS FITTING OSS1/2 E

O-RING ø13,94X2,62 YELLOW SILI Q

94a

FITTING GAS VALVE 3/4"

PIPE BEND ø15 COLD WATER E50C

PIPE BEND ø15 COLD WATER E

96a

PIPE ø15 COLD WATER E75C

CONNECTION SET 15 X 3/4" NPT INCL FLOW RESTRICTOR E75

SOCKET FITTING 15MM

NUT 1/2" G BRASS COMPR. 15

100

FERRULE COMPR FITTING 15MM

101 102 T-PIECE T3 E 103 PIPE RET-3WV FILTER E 104 CONNECTION SET 22 X 1" M-NPT

FILTER RETURN PIPE

105 106 FILTER CAP PRESSURE EQUALIZ.TUBE CONN.

O-RING ø25,07 X 2,62 3WV

106a

NUT M35 ø30

107

O-RING ø5,00X2,00 FLOW SENSOR (5 PER PACKAGE)

108 109 CONDENSATE COLLECTOR

TRAP - E SERIES

111

-RINGø40X

112 113 O-RING ø18,72X2,62 EPDM (3 PER PACKAGE) 117 PIPE ø15 HOT WATER E75C

BOLT M 5X12 IMBUS VERZ. (3 PER PACKAGE)

118 119 PLATE EXCHANGER 24KW PF/ESHR

119a O-RING ø21,89X2,62 EPDM CH (2 PER PACKAGE)

O-RING ø13,94X2,62 DHW (2 PER PACKAGE)

119b

121 PIPE FLOW.PL.EXCH-CH E75 & E50C

BOLT M6X20 SS IMB.BP.4,2 (3 PER PACKAGE) GASKET PUMP (2 PER PACKAGE)

122 123 PIPE 3WV-PUMP E110C

NUT M35 ø30

124

O-RING ø26.70 X 1.78 (3 PER PACKAGE) FITTING SET 3 WAY VALVE THREE WAY V. HOUSING VC O-RING

125

CARTRIDGE 3WV

126 127 FLANGE 3WV

O-RING ø26.70 X 1.78 (3 PER PACKAGE)

128 129 PIPE PL.EXCH-3WV E

BOLT M 5X12 IMBUS VERZ. (3 PER PACKAGE)

130 131 PRESSURE EQUALIZATION TUBE E50C 137 CONNECTION SET 15 X 3/4" M-NPT

O-RING ø29.74X3.53 FLOW/RET.(2 PER PACKAGE)

138

FLOWSWITCH CONVERSION KIT

139 304 SAFETY VALVE 3/4" NPT 308 T&P GAUGE 1/4"NPT + LOCK 1/2"

TRAP TRAY

Art. No. / Référence

809000061 X 809000062 X 806000020 X 806000015 X 809000055 X 806000016 X 807000119 X 807000082 Optional 807000083 X

807000072 X

809000144 X 809000070 X 809000069 X 807000048 X 807000049 X 807000120 X 807000029 X 807000121 X 809000058 X 809000059 X 809000080 X 809000081 X 809000100 X 809000084 X 809000052 X 807000053 X 809000045 X 807000054 X 809000088 X 809000028 X 807000058 X 809000089 3X 809000056 X 807000061 X 809000059 3X 809000091 3X 807000062 X 809000057 X 807000030 X 807000063 X 809000091 X 807000064 X 809000045 X 807000122 X 807000068 X 809000064 2X 803000015 Optional 807000077 X 807000081 X

E50C

OSS1

Installation & Servicing Instructions Rinnai E-Series

Page 78

Parts electrical components E-Series

162 T1 supply sensor 160 T2 return sensor 167 T3 DHW sensor 166 T5 ﬂ ue gas sensor 168 HLS high limit switch

152 150 151

161 P1 water pressure sensor

168

170

166

167

168

Installation & Servicing Instructions Rinnai E-Series

146

Page 79

Description

143

CONTROL UNIT MCBA5417 E RAC

805000025

IONISATION WIRE SHR

805000039

Item

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 TRAFO 120V/24V

141

SCREW 3,5X 9,5 VERZ.D7983 (5 PER PACKAGE)

142 CASING CONTR.UNIT BACK E

Art. No. / Référence

805000041 X 805000046 X 805000015 X 805000018 X 805000021 X 805000016 X 805000022 X 805000010 X 805000011 X 809000093 X

E50C

OSS1

FUSE 5AF (3 PER PACKAGE) FUSE 4 AT (250v) (3 PER PACKAGE)

144 CASING CONTR.UNIT FRONT E

3WAY VALVE ACTUATOR VC2010

145

HARNESS DHW E

146 FLOW SWITCH 2,5L E

PUMP UPS20-48 120V

147

NTC T2/T3

160

WATERPRESSURE SENSOR

161

WATER PRESSURE SENSOR CABLE NTC T1/T3

162

IGNITION ELECTRODE+GASKET OSS

163

IGNITION CABLE SHR

FAN NRG 118 OSS1/2

164

HARNESS FAN 120V GAS VALVE

165

NTC T1/T3

167

HIGH LIMIT SWITCH

168 170 OUTDOOR RESET SENSOR ARV12

805000026 X 805000027 X 809000094 X 805000030 X 805000042 X 805000043 X 807000038 X 805000032 X 805000034 X 805000050 X 805000035 X 805000036 X 805000037 X

808000020 X 805000038 X 806000019 X 805000035 X 805000033 X 805000047 X

Parts conversion kits Propane gas E-Series

Propane Conversion Kit Parts

Gasket Gas valve - venturi 809000017 X Gasket Fitting 3/4" Gas valve 809000062 X EE-Prom E-Series

Gas Conversion Sticker E50CP Conversion Kit label 8U340801 X Conversion Kit Data Label E50CP Instructions Sheets Conversion Kit 8U606500 X Propane orifice diameter inch / mm 0.16" / 4.15 Display indication at start-up 15t.P

LPG 803000014

E50CP

Installation & Servicing Instructions Rinnai E-Series

Page 80

17 Parts list vent system

Vent Products

Listed and Tested Vent Products for E50C, E75C, E110C, Q85S, QP85, Q130S, QP130, Q175S, Q175C and Q205S

Manufacturer Descriptions Parts #

Heatfab

Concentric

Twin Pipe

Manufacturer Descriptions Parts #

IPEX Concentric Vent Termination 1CT0303

Manufacturer Descriptions Parts #

Simpson Dura-Vent 3" (76mm) SS flexible lining system 3SFLEX-XX 294590

Manufacturer Descriptions Parts #

Rinnai/ Ubbink 1 Meter Sections of PP/PVC, 3”/5” 224080

Stainless Steel: 1 Meter Sections of SS/PVC, 3"/5" 224204SS

DGV 3"/5" Conc Air Intake Tee 3" DGV03TAD3 DGV 3"/5" Conc X 12" Length DGV03L12 DGV 3"/5" Conc X 31" Length DGV 3"/5" Conc Horz Term Adapter DGV03HT DGV 3"/5" Conc Vert Term Adapter DGV03VT Rain Cap SGV300 3"- Adapter to fit into 80 mm Flue Collar adapter 3"- 12 Length SGV302 3"- 31" Length SGV307 3"- 90 Deg Tr Elbow SGV314 3"- Screen Termination SGV392 3"- Round Wall Thimble Pate SGV393 3"- Tall Cone Flashing, Flat- 2/12 Pitch SGV3TCF

PVC - FGV Concentric Kit 196006 PVC - FGV Wall Termination Kit 81219 CPVC - FGV Concentric Vent Kit 197009 Termination Vent Screen 196051

3" (76mm) FasNSeal Flex-to-FasNSeal Adapter female 304003 3" (76mm) FasNSeal-to-FasNSeal Adapter Flexible male 304103 80mm to 3" Appliance Adapter FSA-80MM3 Vertical termination 300325 3" (76mm) Bend 90 Degree 300160 3x5 AL294C Concentric (12" Straight Pipe) 35CVS-12 3x5 AL294C Concentric (36" Straight Pipe) 35CVS-36 3x5 AL294C Concentric (48" Staight Pipe) 35CVS-48 3x5 AL294C Concentric (90° Elbow) 35CVS-E90 3x5 AL294C Concentric (45° Elbow) 35CVS-E45 3x5 AL294C Concentric (Wall Strap) 35CVS-WS 3x5 AL294C Concentric (Horizontal Cap) 35CVS-HC 3x5 AL294C Concentric (Vertical Cap) 35CVS-VC 3x5 Sealed Combustion 6" Vent Length SC-0603 3x5 Sealed Combustion 12" Vent Length SC-1203 3x5 Sealed Combustion 18" Vent Length SC-1803 3x5 Sealed Combustion 24" Vent Length SC-2403 3x5 Sealed Combustion 36" Vent Length SC-36-3 3x5 Sealed Combustion Adjustable Vent Length SC-AVL3 3x5 Sealed Combustion 94° Elbow SC-94033 Wall Kit (w/Cap) FSSCWMK35 Roof Kit (w/cap) FSSCTRK35

90 Degree, Male x Female, PP/PVC, 3”/5” 224078 Horizontal PP Termination, 21 inch 223175 Vertical PP Termination 184162 Condensing Raised Horizontal Termination Snorkel Kit 224047PP Condensing 45 Deg. Vent Pipe Elbow 2 pcs 224077PP

90 Degree, Male x Female, SS/PVC, 3"/5" 224201SS Horizontal SS Termination, 21 inch 223178SS Vertical SS Termination 184221SS

DGV03L36

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Page 81

Manufacturer Descriptions Parts #

York International 3” PVC Concentric Vent Termination 1CT0303

Manufacturer Descriptions Parts #

CentroTherm 3"/4" B-Vent Chimney Cover IABC0304

3"/5" B-Vent Chimney Cover IABC0305 3"/6" B-Vent Chimney Cover IABC0306 3"/7" B-Vent Chimney Cover IABC0307 3'' Connector Ring IANS03 3" Support Clamp IASC03 3'' Spacer IASP03 3" Screens PPs-UV Black IASPP03 3'' Bird Screen SS IASSS03 3'' Wall Plate Black IAWP03B 3'' Wall Plate White IAWP03W 3'' Twin Pipe to 3''/5'' Concentric Adaptor ICTC0335 3" Base Support ISBS0387 3'' Chimney Cover SS w/PPs-UV End Pipe ISCM03 3'' Chimney Cover PPs-UV Black ISCP03 3'' Chimney Cover SS w/SS End Pipe ISCS03 3" x 45 Elbow ISEL0345 3" x 87 Elbow ISEL0387 3" x 45 Elbow Long ISELL0345 3" x 45° Elbow Long PPs-UV Black ISELL0345UV 3" x 87 Elbow Long ISELL0387 3" x 87° Elbow Long PPs-UV Black ISELL0387UV 3" x 87° Sweep Elbow ISELR0387 3" x 20" End Pipe PPs-UV Black ISEP03 3" x 39" End Pipe PPs-UV Black ISEP0339 3" Single Wall EDPM Gasket ISGE03 3" Horizontal Drain Tee ISHDT03 3" Low Profile Wall Termination ISLPT0303 3" Tee IST03 3" Test Port ISTP03 3" Termination Tee Long ISTT0320 3" x 12" Vent Length ISVL031 3" x 24" Vent Length ISVL032 3" x 24" Vent Length PPs-UV Black ISVL032UV 3" x 36" Vent Length ISVL033 3" x 39" Vent Length UV Black ISVL0339UV 3" x 72" Vent Length ISVL036 3''/5'' Concentric Roof Termination PPs-UV ICRT3539 3"/5" Concentric Wall Termination PPs-UV ICWT352 3" to 2" Velocity Cone ISVC0302

Miscellaneous

Terminal General PVC 1120 3” SCH 40 DWV ASTM D 2665 900 Elbow Air Intake Pipe PVC 1120 3” SCH 40 DWV ASTM D 2665 Vent Pipe PVC 1120 3” SCH 40 DWV ASTM D 2665

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Page 82

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

Simpson Dura-Vent

Telephone: 518-463-7284 Fax: 518-463-5271 sales@duravent.com www.protechinfo.com

18 Common venting guidelines

Do not common vent with the vent pipe of any other boiler or appliance. However, when an existing boiler is removed from a common venting system, the common venting system is likely to be too large for proper venting of the appliances remaining connected to it. At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation:

Rinnai/Ubbink

Telephone: 800-621-9419 Fax: 678-829-1666 www.rinnai.us

York International

Telephone: 405-364-4040 877-874-7378 www.york.com/products/unitary/

CENTROTHERM Eco System

Telephone: 877-434-3432 Fax: 518-618-3166 info@centrotherm.us.com www.centrotherm.us.com

(a) Seal any unused openings in the common venting system. (b) Visually inspect the venting system for proper size and horizontal pitch and determine

there is no blockage or restriction, leakage, corrosion and otherdeﬁ ciencies which could cause an unsafe condition.

the space in which the appliances remaining connected to thecommon venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close ﬁ replace dampers.

(d) Place in operation the appliance being inspected. Follow the lighting instructions.

Adjust thermostat so appliance will operate continuously

(e) Test for spillage at the draft hood relief opening after 5 minutes of mainburner

operation. Use the ﬂ ame of a match or candle, or smoke from acigarette, cigar or pipe.

(f) After it has been determined that each appliance remaining connected to the

common venting system properly vents when tested as outlined above,return doors, windows, exhaust fans, ﬁ replace dampers and any other gas burning appliance to their previous condition of use.”

(g) Any improper operation of the common venting system should be corrected so the

installation conforms with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/ or CAN/CSA B149.1, Natural Gas and Propane Installation Code. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part 11 of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CAN/CSA B149.1, Natural Gas and Propane Installation Code.

Installation & Servicing Instructions Rinnai E-Series

Page 83

Appendix A - Outoor Reset Sensor Data and Resistance table NTC sensors

R 25 °C

R 100 ° C

25/85

Temp [°C]

-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 0.56

NTC [kOhm]

12 k:

950 :

K 0573

K/% 2,4- tneiciffeoc erutarepmeT

200

180

160

140

120

100

NTC [kOhm]

-40 -20 0 20 40 60 80 100 120

Temp [°C]

Temp NTC 12K

77°F)

°F

(12k

supply sensor T1

return sensor T2 DHW sensor T3

outside sensor T4

flue gas sensor T5

-4 98,000

-0.4 90,000

3.2 82,000

6.8 74,000

10.4 66,000 14 58,000

17.6 53,500

21.2 49,000

24.8 45,000

28.4 40,500 32 36,000

35.6 33,500

39.2 30,900

42.8 28,200

46.4 25,600 50 23,000

53.6 21,400

57.2 19,900

60.8 18,100

64.4 16,600 68 15,000

71.6 14,000

75.2 12,900

78.8 11,900

82.4 10,850 86 9,800

89.6 9,100

93.2 8,500

96.8 7,900

100.4 7,200 104 6,500 113 5,600 122 4,600 131 4,000 140 3,400 158 2,300 176 1,700 194 1,300 212 950

Resistance table NTC-Sensors

Installation & Servicing Instructions Rinnai E-Series

Page 84

800000048 06/2013

Distributor for the USA

Rinnai America Corporate • 103 International Drive • Peachtree City, GA 30269 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 speciﬁ cations and dimensions without prior notice.

Rinnai Rice Cooker E50C Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual