Rinnai Water Heater QP85N Service Manual

Installation & Servicing

Instructions

High efﬁ ciency condensing gas boiler

Q Premier

QP85N / QP130N

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 familair with all necessary operating instructions.

NOTICE!

Installation and service must be performed by a licensed

Pictured: QP130N

professional, 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

These instructions to be retained by user.

8U.51.54.02/10.13 Changes reserved.

Contents of instructions

These installation instructions contain important information for the safe installation, start-up and maintenance of boilers with capacities 85,000 through 130,000 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 boilers comply with the State of California Lead Law (AB1953).

Installation & Servicing Instructions Rinnai Q Premier

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 ..........................7

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 ...................................................................10

Installation .........................................................................11

5.1 Requirements for the installation room .............................11

5.2 Fitting the boiler .................................................................12

5.3 Dimensions ........................................................................13

5.3.1 Clearences from the boiler ................................................16

5.4 Technical speciﬁ cations .....................................................17

6 Connecting the boiler .....................................................................18

6.1 Central heating system ......................................................19

6.1.2 Safety Valve and Temperature and Pressure Gauge ........25

6.1.3 Low water cut off ...............................................................25

6.2 Boiler expansion tank ........................................................26

6.3 Underﬂ oor heating system (plastic pipes) ...........................26

6.4 Gas connection .................................................................27

6.4.1. Gas connection with natural gas .......................................27

6.4.2 Gas connection with propane gas .....................................28

6.5 Hot water supply ................................................................29

6.5.1 Domestic Water quality ......................................................29

6.5.2 Domestic water treatment Accessory ...............................29

6.5.3 DHW Expansion Tank ........................................................30

6.5.4 Installing a Thermostatic Mixing Valve .............................30

6.5.5 Installing a valve kit ...........................................................30

6.5.6 Pressure relief valve for Combi boilers ..............................31

6.6 Condensate drain pipe ......................................................31

6.7 Vent system and air supply system ...................................32

6.7.1 Intake / Exhaust Guidelines ...............................................32

6.7.2a Examples vent and air supply systems (concentric) .........33

6.7.2b Examples vent and air supply systems (parallel) ..............34

6.7.3 Installation of the vent system ...........................................35

6.7.3.1 Boiler conversion from concentric to parallel ....................36

6.7.3.2 Placing air ﬁ lter .................................................................36

6.7.4 Recommended vent/air intake terminal position ...............37

6.7.5 Direct vent closet and alcove installation ........................39

6.7.6 Dimensioning of the exhaust and air intake duct .............40

6.7.7 Combustion air and vent piping lengths. ...........................41

6.7.8 Calculation of compensation factor ...................................42

6.7.9 Room Air System (indoor combustion air) .........................43

7 Electrical connections ....................................................................46

8 Controls .........................................................................47

9 Boiler controls .........................................................................50

9.1 Explanation of the function buttons ...................................51

10 Starting up: Filling and de-aerating the boiler and installation .......52

10.1 Requirements of the water system ....................................52

10.2 Filling the heating system ..................................................53

10.3 Hot water supply ................................................................54

11 Adjustments .........................................................................56

11.1 Altering adjustments ..........................................................56

11.2 Activating factory settings (green button function) ...........59

12 Isolating the boiler .........................................................................59

13 Commissioning .........................................................................59

13.1 Testing for gas leaks ..........................................................61

13.2 Testing the Ignition Safety shut off device .........................61

13.3 Checking the O

13.4 Measuring the ionization current .......................................63

13.5 Installing the casing ...........................................................64

14 Maintenance .........................................................................64

14.1 Periodic examination of venting systems and boiler .........64

14.2 Inspection .........................................................................64

14.2.1 Visual inspection for general signs of corrosion ................65

14.2.2 Measuring the ionization current .......................................65

14.2.3 Measuring the inlet gas pressure ......................................65

14.2.4 Testing for gas leaks ..........................................................65

14.2.5 Carrying out a pressure test of the heating system ...........65

14.2.6 Checking venting systems .................................................65

14.3 Maintenance activities .......................................................66

14.3.1 Reset service interval counter ...........................................68

14.4 Limited warranty ................................................................68

15 Parts of the boiler .........................................................................69

16 Blocks and Errors .........................................................................70

16.1 Error indication (short reference) .......................................70

16.2 Blocks .........................................................................71

16.3 Errors .........................................................................72

16.4 Other Errors .......................................................................76

17 Spare parts .........................................................................78

18 Parts list vent system .....................................................................86

19 Common venting guidelines ...........................................................88

Appendix A - Outoor Reset Sensor Data .............................................89

Appendix B - Resistance table NTC sensors ......................................90

.................................................................62

Installation & Servicing Instructions Rinnai Q Premier

1 Safety and general instructions

CAUTION

WARNING

NOTICE

DANGER

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, if applicable, generating domestic hot water. The boiler is delivered with a burner controller (MCBA) pre-installed.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.

Installation & Servicing Instructions Rinnai Q Premier

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 a licensed professional.

- 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.

Installation & Servicing Instructions Rinnai Q Premier

WHAT TO DO IF YOU SMELL GAS

WARNING

- 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 boiler.

NOTICE

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

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

Installation & Servicing Instructions Rinnai Q Premier

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 the Rinnai Boiler Applications Manual or Chapter 6 and 10 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 that is capable of reading both positive and negative pressures – 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:

- Rinnai toolkit Q and E-Series

1.7 Relevant Installation, Service and User manuals

– Approved vent system – Rinnai Boiler Applications Manual – 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. In Canada, installation must be in accordance with the requirements of CAN/CSA B149.1, Natural Gas and Propane Installation Code.

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 or 4000 hours and maintenance every 4 years or 8000 hours. See maintenance section chapter 14.

Operating Limits of the boiler: Max. boiler temperature: 176 °F (80 °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.

Installation & Servicing Instructions Rinnai Q Premier

NOTICE

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 boiler and/or equipment and shall: a) Be powered by the same electrical circuit as the boiler and/or equipment such

that only one service switch services both the boiler and the carbon monoxide detector;

b) Have battery back-up power;

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

c) 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 boiler and/or equipment at the completion of the installation.

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

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 product-

approved 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 boiler and/or equipment at the completion of the installation.

Installation & Servicing Instructions Rinnai Q Premier

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 Q Premier boiler is a room sealed, condensing and modulating central heating boiler, with an integrated DHW cylinder.

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 type indication: Rinnai QP130N QP = Type 130 = Nominal load in (x1,000) BTU N = Natural Gas

4 Packaging and transportation

4.1 Scope of delivery

The boiler is supplied ready for use.

• Please check if the packaging is intact.

• Check if all the items listed are included in the delivery.

The supply kit contents:

Part No. Description Amoun

Boiler with:

ARV1215U Outdoor reset sensor ARV12 1

44323420 Cover air supply Ø120/Ø80 1

44323510 Gasket vent system ø80 1

44440520 Flue pipe Ø 80 PP 1

44472600 Lip-ring flue pipe ø80 1

44770110 Flue adapter Ø80/Ø3" pps UL appr. 2

44021000 Gasket set hydraulics (5x EPDM) 5

44637900 Gasket set gas (6x Fiber) 1

8U51540x Installation & Service Instructions 1

8U52540x User information manual 1

8U304000 Warranty document 1

8U300600 ICSL book 1

QP85N

QP130N

Installation & Servicing Instructions Rinnai Q Premier

CAUTION

4.2 Transportation

CAUTION

WARNING

CAUTION

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.

The boiler is delivered on a pallet in a card board box. After removing the packaging certain parts of the casing can be removed to reduce weight for indoor transportation as follows (see ﬁ gure 1):

1. Open the smoke glass door;

2. Remove the 2 screws just below the upper edge;

3. Lift the front top part at the front;

4. Close the smoke glass door and pull the complete front panel at the top towards

you;

1 3 4

removing boiler casing ﬁ gure 1

Store all removed parts after transportation and during installation in a safe place.

Lift the boiler only by the boiler's grips and the rear wall. See ﬁ gure 2. Use protective gloves.

When tilting the boiler, testing water may drain from the boiler.

Reassembly of the components is done in reverse order.

Make sure the pins are positioned correctly in the snap locks.

Installation & Servicing Instructions Rinnai Q Premier

grips ﬁ gure 2

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 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 Q Premier

5.2 Fitting the boiler

CAUTION

NOTICE

WARNING

- Remove the packaging materials.

- Leave the boiler on its pallet during unpacking. When unpacking, the casing

can be removed from the boiler. This part can be kept seperate during installation. It must be reinstalled on the boiler and ﬁ xed with the screws behind the door before the boiler is started up.

The boiler can be placed on most ﬂ oor surfaces. The boiler is not allowed or approved to be installed on carpet ﬂ ooring.

- The ﬂ oor 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 the venting

system, pipework and for servicing. See drawing in section 5.3.

Lift the boiler only by the boiler's grips and the rear wall. See ﬁ gure 3a.

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.

position boiler grips Q Premier ﬁ gure 3a

- Dispose the packaging materials.

adjustment feet Q Premier ﬁ gure 3b

Lift the boiler in it's up right position and place the boiler in it's deﬁ ned place. Use the adjustment feet to position the boiler vertical using a plumb rule. See ﬁ gure 3b.

Protect all parts against impacts during transportation and installation.

Installation & Servicing Instructions Rinnai Q Premier

5.3 Dimensions

PP QQ RR

M M

dimensions Q Premier figure 4

Installation & Servicing Instructions Rinnai Q Premier

Dimensions

Boiler type

QP85N

QP130N

inch / mm

Height

Height including vent connection

Width

Depth

Center boiler / vent

Back / vent

Center to center / vent and air supply

Connection side: left right

H Bottom side boiler /

J Bottom side boiler /

K Bottom side boiler /

L Bottom side boiler /

M Bottom side boiler /

N Bottom side boiler /

O Bottom side boiler / condensate pipe 26.0" / 662 26.0" / 662

P Center boiler /

Q Center boiler /

R Center boiler /

S Back boiler / center of all pipe connections

supply pipe 48.4" / 1230 48.4" / 1230 return pipe 45.7" / 1160 45.7" / 1160 hot water pipe 42.9" / 1090 gas pipe 42.9" / 1090 cold water pipe 40.2" / 1020 DHW circulation return pipe 40.2" / 1020 DHW circulation return pipe 37.4" / 950 cold water pipe 37.4" / 950 gas pipe 34.6" / 880 hot water pipe 34.6" / 880

Connection side:

gas pipe ( g* ) hot water pipe ( h* ) DHW circulation return pipe ( x* ) cold water pipe ( c* ) supply pipe ( s* ) return pipe ( r* )

61.8" / 1570

64.5" / 1640

23.6" / 600

25.2" / 640 3,7" / 95

18.5" / 470

4.7" / 122

top

6.9" / 175

4.1" / 105

1.4" / 35

1.2" / 30

* See figure 5

dimensions table 1

Installation & Servicing Instructions Rinnai Q Premier

8U442600

Dimensions

h c r s x g

Connection for combustion air supply and vent system

boiler connections figure 5

Boiler type

QP85N

QP130N

Vent system / Combustion air supply Gas pipe

g 3/4"M-NPT Supply pipe s Return pipe r Cold water pipe c Hot water pipe h DHW circulation return pipe x Condensate pipe d

connection diameters table 2

80/125mm

3/4"M-NPT

3/4"M-NPT 3/4"M-NPT 3/4"M-NPT 3/4"M-NPT

1" / 25mm

Installation & Servicing Instructions Rinnai Q Premier

Minimum required clearances

to combustibles

Minimum required clearances

to non-combustibles

Recommended

service clearances

All types

ll types

inch / mm inch / mm inch / mm Top of boiler 0" 0" 10" / 250 Back of boiler 0" 0" 0 Front of boiler * 6" / 150 6" / 150 24" / 600 Left side of boiler 0" 0" 2" / 50 Right side of boiler 0" 0" 2" / 50 Vent 0" 0" 0"

5.3.1 Clearences from the boiler

ceiling

wall

Min. 10" / 250mm

15.7" 400

24" 600

2" 50

service clearances to the boiler figure 6

clearances to the boiler table 3

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

Installation & Servicing Instructions Rinnai Q Premier

5.4 Technical speciﬁ cations

(

)

(

)

(

)

(

)

Q Premier

Boiler type QP85N QP130N

Input Hs CH BTU/hr 85,000 130,000

kW 25 38

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 % 95.4 95.4

(at full load)

Electr. power consumption max. W Electr. power consumption stand by W Current V/Hz 120Vac/60Hz 120Vac/60Hz Fuse rating A 5AF & 4AT 5AF & 4AT Degree of protection acc. EN 60529 IPX0D IPX0D Weight (empty) lbs / kg Water content CH gallon / liter 0.9 / 3.5 1.3 / 5 Water content DHW gallon / liter Water content Plumbing Kit gallon / liter 0.58 / 2.2 0.58 / 2.2 After run time pump CH min 5 5 After run time pump DHW min 1 1 P

Water pressure min.-max.

Water pressure DHW max.

Flow temperature max. °F / °C 176 / 80 176 / 80 Pump type UPER 20-58 UPER 20-78 Approvals ASME, CSA ASME, CSA DHW flow DHW flow DHW flow DHW flow

at 'T50°F at 'T27.8°C at 'T75°F at 'T41.7°C

First hour rating gallon/hour

Pressure difference DHW PSI / bar 4.3 / 0.3 4.3 / 0.3

BTU/hr 77,000 117,000 kW 22.5 34.2 BTU/hr 84,000 127,600 kW 24.7 37.3 BTU/hr 82,000 117,000 kW 24.1 36.5

% 98.8 98.2

% 4,4 - 4,7 4,4 - 4,7

172 199

14 14

236 / 107 243 / 110

24 / 90 24 / 90

PSI / bar 14-43 / 1-3 14-43 / 1-3

PSI / bar

145 / 10 145 / 10

gallon/min 3.1 4.1 liter/min 11.73 15.5 gallon/min 2.1 3,2 liter/min 7.95 12.1

liter/hour

141 534

211 799

CSA number CRN number

Technical specifications table 4

8101.7CL 8101.7CL

Installation & Servicing Instructions Rinnai Q Premier

6 Connecting the boiler

NOTICE

8U442600

DANGER

The boiler has the following connections, which can be positioned to the top, left side or right side from the boilers by means of the pre-bend pipe kits. The connections on the back of the boiler are engineered to work with only the Rinnai pre-bend pipe kits. Nuts and gaskets are supplied with the boiler;

hcx

- The central heating circuit pipes.

It is provided with a 3/4" male thread onto which the supply and return pipes of

the heating system can be screwed according to the instructions in chapter 6.1;

- The gas supply pipe.

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

be screwed. See further chapter 6.4;

- The condensation drain pipe.

It consists of a 1" (25 mm) ﬂ exible plastic pipe. The drain pipe can be connected

to this by means of an open connection. See further chapter 6.6;

- The vent system and air supply system.

It consists of a concentric connection 3"/5" (80/125 mm). The boiler can be converted to 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.

- Cold and hot water pipes for domestic hot water (DHW). It is provided with a 3/4" male thread onto which the cold and hot water pipes and

hot water circulation return pipe of the DHW system can be screwed according to the instructions in chapter 6.5;

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

Use the supplied gaskets in the 1" ﬁ ttings. Use the special ﬁ berring (indicated on the gasket package) for the 1" gas pipe ﬁ tting. If these instructions are not followed exactly, a ﬁ re or explosion may result causing property damage, personal injury or death.

h c r s x g

Installation & Servicing Instructions Rinnai Q Premier

boiler connections ﬁ gure 7

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 NPT ﬁ ttings.

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

A low loss header is pre-installed in the boiler . The low loss header not provided with service valves. Service valves must be installed on the supply and return connection pipes of the boiler. Dielectric unions are not provided with the boiler . Dielectric unions must be installed on the supply and return connection pipes of 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.

WARNING

6.1.1 Pre-bend Kit and Installation

Rinnai provides 3 Pre-bend Plumbing Kit options; top, right side, and left side. One of these options must be selected at the time of purchase. The pre-bend kit must be ﬁ tted directly in the back of the boiler on the heating water supply pipe, heating water return pipe, domestic cold water pipe, domestic hot water pipe, domestic recirculation water pipe, and the gas pipe.

When installing these pre-bend pipes care must be taken. Ensure that the ﬁ rst two ribs on the threaded ﬁ tting at the end of the pre-bend pipe are visible on the outside of the boiler; this will provide enough surface area to correctly use a backing wrench. Always using a backing wrench to ensure that the pipe is not damaged during installation, see ﬁ gure 7a and 7b for the correct position of the backing wrench. Always use a backing wrench when attaching pipes and ﬁ ttings to the boiler. If a backing wrench is not used damage to the boiler piping might occur.

Failure to properly use a backing wrench could result in damage or broken pipes in the boilers. Damage to the boiler and piping caused by incorrect installation is not covered by the warranty.

ﬁ gure 7a ﬁ gure 7b

Installation & Servicing Instructions Rinnai Q Premier

Service valve

Boiler basic piping ﬁ gure 8

1. shut off valve

2. system circulator

3. check valve

4. balancing valve

5. boiler drain valve

6. dirt trap

7. air separator

8. automatic ﬁ ll valve

9. back ﬂ ow preventer

10. expansion tank (in case the content of the built-in expansion tank is not sufﬁ cient)

11. bypass for system cleaning

12. ASME 30 psi pressure relief valve

13. Temperature and pressure gauge

Installation & Servicing Instructions Rinnai Q Premier

The factory supplied pressure relief valve and temperature and pressure gauge

NOTICE

(gpm)

must be installed before any shut-off valves.

The pressure relief valve and the temperature and pressure gauge must be installed as shown in ﬁ gures 9a and 9b.

Installed pressure relief valve and T/P gauge on the side ﬁ gure 9a

T o protect the entire heating system we recommend installing a dirt particle trap in the return circuit. When the boiler is installed to an existing heating system this trap is required. Use of a Y strainer is not permitted as a substitute for a dirt trap.

- Install shut-off valves immediately before and after the dirt particle ﬁ lter to allow the trap to be cleaned.

- Figure 10 is the location of a garden hose thread boiler drain that can be used to drain the boiler or add water treatment additives to the system such as inhibitors or glycol.

- For information on locating an additional expansion tank and system ﬁ ll, please see the Rinnai Boiler Applications Manual.

Internal boiler drain connection ﬁ gure 10

Thoroughly ﬂ ush all pipes and radiators. We recommend the use of a Rinnai approved system cleaner. Please refer to the list of approved Rinnai system cleaners in this chapter.

- Refer to the installation template and chapter 5.3 for the pipe connection dimensions.

To ensure the correct heat transfer the system piping must be sized correctly. The piping should be increased in size upon exiting the boiler at the end of the prebend kits to properly suit the system. Table 5 provided shows the correct piping sizes based on the maximum ﬂ ow rate for piping and system Delta T.

Installed pressure relief valve and T/P gauge on the top ﬁ gure 9b

Upon exiting of the boiler cabinet all external piping must be properly supported. The boiler and internal boiler piping are not intended to support the system piping.

Pipe size Maximum

flow rate

1" 8 40,000 80,000 120,000 160,000 1 ¼" 14 70,000 140,000 210,000 280,000 1 ½" 22 110,000 220,000 330,000 440,000

Pipe size and related ﬂ ow rate table 5

10°F ''T

(btus)

20°'T

(btus)

30°F'T

(btus)

40°F'T

(btus)

Installation & Servicing Instructions Rinnai Q Premier

- 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 (V1 and V2).

2. Open the bypass valve (V4).

3. Connect pump outlet hose (H1) to the supply side purge station (BD1)

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. Operate the charging pump (CP) and charge the system with the required volume of system cleaner

7. Close the supply side purge station (BD1)

8. Turn on the system pump(s) (SP) and circulate the cleaner through the system for required time as established by the cleaner manufacturer.

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

10. Turn off the system pump(s) (SP)

11. Close the main valve on the system return (V3) and open the return side purge station (BD2).

12. 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.

BD1

V1 V2

BD2

Drain

System cleaner

Boiler system ﬂ ushing ﬁ gure 11

Installation & Servicing Instructions Rinnai Q Premier

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

NOTICE

14. Close the auto feed on the system (F1)

15. Close the return side purge station (BD2) and disconnect the hose (H3).

16. Open the main valve on the system return (V3)

17. Close the bypass valve (V4).

18. Open shutoff valves on both the supply and return connections (V1 and V2).

19. Clean out the dirt trap

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

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

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

23. 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.

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.

Installation & Servicing Instructions Rinnai Q Premier

Water ﬁ lter ﬁ gure 12

If the installation resistance is over the stated value; the pump will rotate at maximum capacity and 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. The electrical side of the external circulation pump (ﬁ g. 8, pos. 2) can be connected to the Control Tower. This pump thus switches simultaneously to the boiler pump. The maximum absorbed current consumption of the external circulation pump may not exceed 120V, 2 Amp. If a pump with a larger current draw is required an isolation relay must be used. See the Rinnai Boiler applications manual for further information. The extra external pump must be selected according to the installation resistance

and required ﬂ ow. As standard the boiler is provided with a water ﬁ lter in the return pipe of the boiler (ﬁ g.

12), so that debris from the central heating water is prevented from affecting the boiler.

NOTICE

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

QP85

PSI

024681012

Q [gallons/min]

UPER 20-58 25% UPER 20-58 100% Resistance Q385

QP85

pump index lines UPER 20-58 graph 1a

32.3

27.7

23.0

18.5

13.8

9.2

4.6

32.3

QP130

27.7

Feet of head

PSI

024681012

Installation & Servicing Instructions Rinnai Q Premier

pump index lines UPER 20-78 graph 1b

UPER 20-78 25%

Q [gallons/min]

UPER 20-78 100%

QP130

Resistance Q3130

23.0

18.5

13.8

9.2

4.6

Feet of head

6.1.2 Safety Valve and Temperature and Pressure Gauge

NOTICE

An ASME 30 psi pressure relief valve is included with the boiler.

A temperature and pressure gauge is included with the boiler.

6.1.3 Low water cut off

The Rinnai Q Premier boiler has a factory installed pressure switch type Low Water Cut Off (LWCO). Check your local codes to see if a Low Water Cut Off is required (LWCO) and if this device conforms to local code. See the Rinnai Boiler Applications Manual for further information.

The Low water cut off is not serviceable.

Installation & Servicing Instructions Rinnai Q Premier

6.2 Boiler expansion tank

NOTICE

An expansion tank is part of the boiler for the closed loop heating system only. The expansion tank has a content of 3.17 gallons / 12 liters and a pre-charge pressure of

14.5 psi / 1 bar. Depending on the size of the installation the expansion tank must be

appropriate to the water content of the installation. The pre-charge pressure depends on the installation height above the mounted expansion tank. When necessary installing an additonal expansion tank is possible to get to the appropiate summary of the expansion volume. The additional expansion tank is NOT a part of the delivery and should be sourced locally. Please refer to the expansion tank manufacturer for further information.

Fill the additional expansion tank to a minimum of 14.5 psi. For the boiler to function correctly, it is necessary to connect the additional

expansion tank to the installation according to ﬁ gure 7.

See the Rinnai Boiler Applications Manual for further information regarding placement of the expansion tank in the system.

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 ﬂ oor heating systems, you must separate the system 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.

Installation & Servicing Instructions Rinnai Q Premier

6.4 Gas connection

NOTICE

DANGER

WARNING

DANGER

NOTICE

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 boilers are built to run on Natural Gas or Propane 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 or a green label with Propane 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: refer to chapter 6.4.1 Propane gas: refer to chapter 6.4.2

6.4.1. Gas connection with natural gas

The gas supply connection must comply with local regulations or, if such regulations do not exist, with the National Fuel Gas Code, ANSI Z 223.1. For Canada, the gas connection must comply with local regulations or, if such regulations do not exist, with the CAN/CSA B149.1, Natural Gas and Propane Installation Code.

Sediment trap ﬁ gure 13a

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 working 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 4.0 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).

Installation & Servicing Instructions Rinnai Q Premier

6.4.2 Gas connection with propane gas

NOTICE

DANGER

NOTICE

The Rinnai Q Premier boiler is sold as a NG product. Conversion kits from natural gas to propane can be purchased for the Q Premier boiler separately.

Pipe sizing for propane gas

- Contact gas supplier to size pipes, tanks, and 100% lockup gas pressure regulator.

Propane Supply Pressure Requirements

- Adjust propane supply regulator provided by the gas supplier for 14 inches W.C. maximum pressure.

- Pressure required at gas valve inlet pressure port:

- Maximum 14 inches W.C. with no ﬂ ow (lockup) or with boiler running.

- Minimum 8 inches W.C. with gas ﬂ owing (verify during boiler startup).

Ensure that the high gas pressure regulator is installed at least 6 to 10 feet upstream of the boiler.

Gas piping

- Use a gas shut off valve compatible with propane gas.

- A sediment trap must be provided upstream of the gas controls.

Gas shut off valve onto boiler ﬁ gure 13b

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

The connection to the boiler must include a suitable method of disconnection. A gas control valve must be installed adjacent to the boiler for isolation purposes. The nominal inlet working gas pressure measured at the boiler should be 12 inch W.C. (30mbar) for Propane gas (Gas E).

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).

For information on converting a boiler to propane see the Q Premier propane conversion kit manual.

Installation & Servicing Instructions Rinnai Q Premier

6.5 Hot water supply

NOTICE

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

DANGER

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 the pre-bend kits. The cold water inlet on the boiler must be equipped with the following components (counted in the water ﬂ ow direction): Flow regulator valve, Safety group, Expansion vessel 87 PSI / 6bar (potable water, blue).

DANGER

6.5.1 Domestic Water quality

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

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.

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 indirect tank water heater.

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 contact Rinnai.

Installation & Servicing Instructions Rinnai Q Premier

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