● H167-0771-1X01(00)
If the information in these instructions are not followed exactly, a fire or explosion may result causing property damage, personal injury, or loss of life. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. WHAT TO DO IF YOU SMELL GAS − Do not try to light any appliance. − Do not touch any electrical switch; do not use any phone in your building. − Immediately call your gas supplier from a neighbor’s phone.
9. Power Supply ........................................................................................................................................... 63 9.1 Guidelines ...................................................................................................................................................... 63 9.2 Electrical Connections ................................................................................................................................... 64 9.
1 Thank you for purchasing a Rinnai Condensing Boiler. Before installing and operating this boiler, be sure to read these instructions completely and carefully to familiarize yourself with the boiler’s features and functionality. • You must read the entire manual to • • properly operate the boiler. • Keep this manual for future reference. • As when using any appliance generating heat, there are certain safety precautions you should follow. See section “2.
2 WARNING • • • • • If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury, or death. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. WHAT TO DO IF YOU SMELL GAS: − Do not try to light any appliance. − Do not touch any electrical switch; do not use any phone in your building. − Immediately call your gas supplier from a neighbor’s phone.
• Do not use this appliance if any part has • • • • • • • 6 been under water. Immediately call a licensed professional to inspect the appliance and replace any part of the control system and any manual gas control valve which has been under water. Do not use substitute materials. Use only parts certified for the appliance. Should overheating occur or the gas supply fail to shut off, turn off the manual gas control valve to the appliance.
3 Topics in this section • • • • • • Front View Bottom View Components Specifications Dimensions Accessories DHW DHW Hot Outlet Cold Inlet The I-Series Condensing Boiler is a wallmounted, gas-fired boiler designed to providing heating and domestic hot water. For complete boiler information, refer to the “Rinnai I-Series Condensing Boiler Installation Manual” supplied with the boiler, or visit rinnai.us.
All items are field-supplied unless otherwise noted.
Intake Exhaust Flue Gas Exhaust Air Intake Air Inlet Filter Combustion Test Port Fan with Integrated Venturi Burner Assembly Gas Valve Ignition Unit Heat Exchanger Silencer Pressure Sensor Air Vent PC Board Cover Integrated Pump Control Panel Diverter Valve Flow Sensor PC Board Removed Bypass Servo Valve Condensate Trap Rinnai I-Series Condensing Boiler Combi Manual Plate Heat Exchanger Water Flow Servo Valve 9
Model i060C Dimensions - w, h, d Weight i120C 18.5 in. x 26.4 in. x 11.45 in. (471 mm x 671mm x 290 mm) 73.0 lb (33 kg) 76.1 lb (34.5 kg) Appliance Type Wall-Mounted, Gas-Fired Combi Boiler Installation Type Indoor Ignition System Direct Electronic Ignition Heat Exchanger Surface Area Gas Consumption (Btu/hr) DHW Specification 9.3 sq ft 10.9 sq ft Minimum Maximum (CH) 15,000 60,000 Maximum (DHW) 90,000 120,000 160,000 199,000 Minimum Activation Flow Rate 0.4 GPM (1.
Measurements: in. (mm) Vent Connection: 2 in. (51 mm) nominal PVC/Polypropylene or 3 in./5 in.
Domestic Hot Water Domestic Cold Water Gas Condensate Drain Central Heating Return Central Heating Supply Connection 12 Connection Size Gas 3/4 in. NPT DWH In (Cold Inlet) 3/4 in. NPT DHW Out (Hot Outlet) 3/4 in. NPT CH In (CH Return) 1 in. NPT CH Out (CH Supply) 1 in. NPT Condensate Outlet 1/2 in.
The following optional accessories are available for the Rinnai I-Series Condensing Boiler. CONDENSATE NEUTRALIZER Part #: 804000074 Neutralizes the condensate generated by the boiler. SCALECUTTER REFILL CARTRIDGE Part #: 103000039 SCALECUTTER Part #: 103000038 Filters and reduces the amount of scale entering the boiler allowing for greater boiler longevity. DHW ISOLATION VALVE KIT Part #: MIVK-T-LW Refill cartridge for the ScaleCutter filter assembly.
4 Topics in this section • • • • • • Installation Guidelines What You’ll Need Items Included Choose an Installation Location Mount the Boiler to the Wall Fill the Condensate Collector THIS SECTION IS INTENDED FOR THE INSTALLER Installer qualifications: A trained and qualified professional must install the appliance, inspect it, and leak test the boiler before use. The warranty will be voided due to any improper installation.
• Ensure the wall is of sufficient strength to support the weight of the boiler, piping and any other components needed for installation; if it is not, please reinforce the wall as appropriate. • Operating limits of the boiler: Maximum boiler set point temperature: 180°F (82 °C) Gather the recommended tools and parts before starting installation. Items Needed • • Maximum operating 45 psi (3.1 bar) pressure: Maximum allowable 210°F (99°C) working temperature ASME: Maximum allowable 45 psi (3.
Carefully unpack your boiler system and verify the following contents are included. If any items are damaged or missing, contact your local dealer/distributor. Do not attempt to use any item that appears damaged. INTEGRATED ITEMS Vent top with integrated 2 in. PVC and 3 in. X 5 in. Concentric Vent Adapter Air Supply Filter Pump Refer to section “3.3 Components” for a complete list of integrated parts.
When choosing an installation location, you must ensure that clearances will be met and that the vent length will be within required limits. Consider the installation environment, water quality, and need for freeze protection. Requirements for the gas line, water lines, electrical connection, and condensate disposal can be found in their respective installation sections in this manual. • Unsuitable heating system water can cause the formation of scale or sludge, which affects system efficiency.
Air surrounding the boiler, venting, and vent termination(s) is used for combustion and must be free of any compounds that cause corrosion of internal components. These include corrosive compounds that are found in aerosol sprays, detergents, bleaches, cleaning solvents, oil based paints/varnishes, and refrigerants. The air in beauty shops, dry cleaning stores, photo processing labs, and storage areas for pool supplies often contains these compounds.
Insert the top bracket into the wall mounting bracket. Make sure the wall mounting bracket is attached to the wall and can hold the weight of the boiler before you fully let go. You Will Need: • • Rinnai Condensing Boiler Wall Mounting Bracket Supplied by Installer: • • • Level Four screws for mounting bracket installation Screws for top and bottom bracket installation Use appropriate screws for type of wall construction.
Securely screw the top and bottom brackets into the wall, making sure the screws are flush with the wall. • Use any of the holes in the top and bottom brackets. • Make sure the securing method is sufficient to support the weight of the boiler. Refer to the boiler weight in section “3.4 Specifications” of this manual. IMPORTANT The boiler must be installed in an upright and level position. Do not install the boiler upside down or on its side.
5 Topics in this section • • • • • Guidelines Venting Installation Sequence Termination Considerations PVC Venting Safety Switch Venting Options • I-Series boilers can be installed in direct vent or non-direct vent applications. • When installed as Direct Vent, refer to the following section for a complete list of approved vent manufacturers and products: “5.5.1 Direct Vent: Approved Vent Manufacturers and Products.” • Venting should be as direct as possible with a minimum number of pipe fittings.
The vent for this appliance shall not terminate: • Over public walkways. • Near soffit vents or crawl space vents 1. Determine the termination method—horizontal or vertical, concentric, or twin pipes, etc. 2. Determine proper location for wall or roof penetration for each termination. 3. Install termination assembly as described in this manual or in the vent manufacturer’s installation instructions. 4. Install air and vent piping from boiler to termination. 5.
The instructions in this section explain how to adjust boiler settings to allow for higher exhaust temperatures. These instructions apply only for installations using CPVC, listed Polypropylene, or stainless steel venting. If these instructions are not followed exactly, a fire or carbon monoxide leak may result causing property damage, personal injury, or death. WARNING DO NOT adjust boiler settings to allow higher exhaust temperatures when venting with PVC.
5. Press the Mode button on the controller. 01-A 6. Press the (Up) or Select button. (Down) arrows until A2-A appears in the display. Then, press the A2-A Select button 7. Press the (Up) or (Down) arrows until A2- appears in the display. Then, press the Select button. A2Select button 8. The boiler is now set to allow higher exhaust temperatures. To exit parameter settings and enter normal operation mode, press the Mode button. 9.
Two venting options are available: Direct Vent and Non-Direct Vent (Room Air). Option 1 Direct Vent (Concentric and Twin Pipe) See the Direct Vent section for complete details. Concentric Pipe Combustion air and exhaust vent directly through a single concentric connection. Hot exhaust exits through the interior pipe, while combustion air enters through the outer pipe. Twin Pipe Combustion air and exhaust vent directly through separate penetrations.
Following is a list of vent components and terminations for Direct Vent installations (concentric and twin pipe). Install the correct venting for your model according to the venting manufacturer’s instructions and the guidelines below. The information below is correct at time of publication and is subject to change without notice. Contact the vent manufacturer for questions related to the vent system, products, part numbers and instructions. Manufacturer Phone Web Site Ubbink 800-621-9419 www.rinnai.
Equivalent Length (ft) Vertical Horizontal Diagram Product Description Manufacturer Part Number Manufacturer 2 in./4 in. CONCENTRIC VENT TERMINATIONS (Continued) CENTROTHERM ROYAL 52CVKGVS6502 PVC Concentric Vent Kit 2 in. x 16 in. 20 52CVKGVS6502-28 PVC Concentric Vent Kit 2 in. x 28 in. 20 52CVKGVS6502-40 PVC Concentric Vent Kit 2 in. x 40 in. 20 ICRT2439 20 DURAVENT 2PPS-VKL/VK-TCL ECCO 2 in. x 4 in. Concentric Roof Termination 2 in. x 4 in.
Equivalent Length (ft) Vertical Horizontal Diagram Product Description Manufacturer Manufacturer Part Number 3 in./5 in. CONCENTRIC VENT TERMINATIONS UBBINK 3 in./5 in. CONCENTRIC VENT TERMINATIONS 223174PP 3/5 Condensing Horizontal Term Kit 8.7 in. 223176PP 3/5 Condensing Horizontal Term Kit 12 in. 223177PP 3/5 Condensing Horizontal Term Kit 21 in. 223186PP 3/5 Condensing Horizontal Diverter Termination Kit 19 in.
Equivalent Length (ft) Vertical Horizontal Diagram Product Description Manufacturer Part Number Manufacturer 3CGRLSV Vertical Adapter 3CGRLSH Horizontal Adapter 3CGRVT Vertical Termination 3CGRHT Horizontal Termination 3PPS-VKL/VK-TCL 3 in. x 5 in. Vertical Termination Cap KitConcentric 3PPS-HKL 190388 ECCO 1 6 5 DURAVENT METAL-FAB 3 in./5 in. CONCENTRIC VENT TERMINATIONS (Continued) 190395 16 20 3 in. x 5 in. Horizontal Termination Kit-Concentric 20 3 in. x 5 in.
Equivalent Length (ft) Vertical Horizontal Diagram Product Description Manufacturer Part Number Manufacturer 2 in. TWIN PIPE TERMINATIONS DURAVENT CENTROTHERM 2 in. TWIN PIPE TERMINATIONS ISELL0287UV 2 in. 87° Long PPS-UV ISTT0220 2 in. Termination Tee ISLPT0202 2 in. Low Profile Wall Termination 5 2PPS-HTPL 2 in. Twin Pipe Termination 10 2PPS-HSTL 2 in. Single Horizontal Termination 6 2PPS-TBL 2 in.
Equivalent Length (ft) Vertical Horizontal Diagram Product Description Manufacturer Manufacturer Part Number 3 in. TWIN PIPE TERMINATIONS DURAVENT CENTROTHERM 3 in. TWIN PIPE TERMINATIONS ISELL0387UV 3 in. 87° Long PPS-UV ISTT0320 3 in. Termination Tee ISLPT0303 3 in. Low Profile Wall Termination 5 3PPS-HTPL 3 in. Twin Pipe Termination 10 3PPS-HSTL 3 in. Single Horizontal Termination 5 3PPS-TBL 3 in.
Air Filter Screen Equivalent Length (ft) Vertical Horizontal Diagram Product Description VARIOUS 2 in. OR 3 in. SCHEDULE 40 PVC/CPVC TERMINATIONS N/A Tee 5 90° Elbow 5 45° Elbow 2.
The information below applies to Concentric and Twin Pipe. TERMINATION Clearance in Ref. A also applies to anticipated snow line X AIR SUPPLY INLET V VENT TERMINAL AREA WHERE TERMINAL IS NOT PERMITTTED SNOW Ref A B C Description Clearance above grade, veranda, porch, deck, or balcony Clearance to window or door that may be opened Clearance to permanently closed window Canadian Installations (CSA B149.1) U.S. Installations (ANSI Z223.1 /NFPA 54) Direct Vent (Indoor Unit) 12 in. (30 cm) 36 in.
Between terminals at different levels 60 in. (1.52 m) Note: 24 in. (0.61 m) to wall or parapet 12 in. (0.30 m) 12 in. (0.30 m) 60 in. (1.52 m) vertically between terminals Inside Corner Between terminals at same level 12 in. (0.30 m) All terminations (horizontal and/or vertical) must terminate 12 in. (0.30 m) above grade or anticipated snow level. Vent Sizes: 2 in. X 4 in. 3 in. X 5 in.
The instructions below apply to concentric vent sizes 2 in. x 4 in. and 3 in. x 5 in. Remove and discard screw from concentric flue connection. Horizontal Wall Terminations 2 in. x 4 in. and 3 in. x 5 in. Remove exhaust adapter ring (discard for concentric venting configurations). Vertical Roof Terminations 2 in. x 4 in. and 3 in. x 5 in. Install the concentric vent. Ensure it is properly seated. Concentric Vent Secure the vent pipe to the concentric flue connection with the supplied screw.
Twin Pipe Vertical Termination of Multiple Boilers Horizontal Vent and Combustion Air Piping 12 in. (0.30 m) minimum Intake 12 in. (0.30 m) minimum Exhaust 12 in. (0.30 m) minimum above combustion air opening Combustion Air 60 in. (152 cm) Min. 12 in. (0.30 m) above grade or anticipated snow level Roof Exhaust Sidewall Clearances 12 in. (30 cm) Min. Intake 12 in. (30 cm) Min. Intake 12” 12 in. (30 cm) Min. Exhaust 4” Vent Lengths: Indicates area in which intake cannot be located. • 2 in.
This boiler is equipped with a 2 in. PVC pipe connection. With the use of a pipe reducer, installers can use a 3 in. pipe for the combustion air and exhaust. WARNING DO NOT apply PVC glues, solvents, or cleaners to the boiler’s combustion air or exhaust gasket connections. Failure to correctly assemble the components according to these instructions may result in property damage, personal injury, or death. Remove and discard the screw from the combustion air vent connection.
Slope horizontal exhaust 1/4 in. per foot towards the boiler. DO NOT slope combustion air pipe towards the boiler. CAUTION Rinnai cautions against installing the boiler in applications with venting in different pressure planes. It is possible to have poor performance with this installation. This configuration requires the use of a Concentric Vent Termination. This configuration requires the use of a Concentric Vent Termination. 2 in. or 3 in.
TERMINATION Clearance in Ref. A also applies to anticipated snow line X AIR SUPPLY INLET V VENT TERMINAL AREA WHERE TERMINAL IS NOT PERMITTTED SNOW Ref A Description Clearance above grade, veranda, porch, deck, or balcony Canadian Installations (CSA B149.1) Other than Direct Vent (Room Air) 12 in. (30 cm) U.S. Installations (ANSI Z223.1 /NFPA 54) Other than Direct Vent (Room Air) 12 in. (30 cm) 36 in. (91 cm) 4 ft (1.
Room Air Vertical Termination of Multiple Boilers 12 in. (0.30 m) minimum Exhaust 12 in. (0.30 m) above grade or anticipated snow level Roof Exhaust Termination Clearances for Internal (Indoor) Room Air Applications 12 in. 12 in. (0.30 m) 60 in. (1.52 m) Vertically between terminals Inside Corner IMPORTANT • • 40 Installation of Room Air must use listed Category IV venting. All terminations (horizontal and/or vertical) must terminate 12 in. above grade or anticipated snow level.
• 2 in. PVC • 2 in. (60 mm) PP Vent Sizes • 3 in. PVC • 3 in. (80 mm) PP 65 ft (20 m) Vent Lengths 150 ft (46 m) Ubbink Rolux® Flexible Vent System: • 2 in. (60 mm) PP 50 ft (15 m) • 45° elbow is equivalent to 3 ft (1 m) • 90° elbow is equivalent to 6 ft (2 m) Vent length includes the additional venting, fittings and terminations.
Unconfined Space An unconfined space is defined in National Fuel Gas Code, ANSI Z223.1/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 unconfined space.
Location To maintain proper circulation of combustion air two permanent openings (one upper, one lower) must be positioned in confined spaces. The upper shall be within 12 in. (0.30 m) of the top of the confined space and the lower opening shall be within 12 in. (0.30 m) of the bottom of the confined space. Openings must be positioned as to never be obstructed. 12 in. (300 mm) 10 in.
Remove and discard screw from combustion air vent connection. Remove and discard the combustion air vent cap. Install the combustion air vent pipe. Ensure it is properly seated. Secure the combustion air vent pipe to the combustion air vent connection with the supplied screw. Place the vent screen inside the elbow and secure with the supplied screw. Use the vent screen for environments where room air is dusty. Notes: • 2 in. vent screen supplied with boiler. • Vent screen is available as an accessory.
CAUTION Rinnai cautions against installing the boiler in applications with venting in different pressure planes. It is possible to have poor performance with this installation. 2 in. or 3 in. Schedule 40 PVC/CPVC Snorkel Termination Configuration 2 in. or 3 in. Schedule 40 PVC/CPVC Standard Upside Down "U" Vertical Termination Configuration 2 in. or 3 in. Schedule 40 PVC/CPVC Elbow or Tee Side Wall Termination Configuration 2 in. or 3 in.
6 Topics in this section • • • Connect the Gas Supply Gas Operating Instructions Gas Pipe Sizing Reference Tables WARNING • A licensed professional must install the gas supply. Turn off 120V power supply. Turn off the gas. Gas is flammable. Do not smoke or provide other ignition sources while working with gas. Do not turn on the boiler or gas until all fumes are gone.
FOR YOUR SAFETY READ BEFORE OPERATING WARNING: If you do not follow these instructions EXACTLY, a fire or explosion may result causing property damage, personal injury or loss of life. A. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand. B. BEFORE OPERATING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.
The gas supply must be capable of handling the entire gas load required at the location. Gas line sizing is based on gas type, the pressure drop in the system, the gas pressure supplied, and gas line type. For gas pipe sizing, refer to the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or the Natural Gas and Propane Installation Code, CSA B149.
Natural Gas EXAMPLE Rinnai Model Gas Input: Pressure Drop 3.0 in. w.c. Intended use: Initial supply pressure of 8.0 in. w.c. or greater. Information in table obtained from NFPA 54, ANSI Z223.1. Schedule 40 Metallic Pipe Inlet Pressure: Less than 2 psi Specific Gravity: 0.
7 Topics in this section • Guidelines • Instructions • Piping Diagram for Basic DHW Installation To connect the water supply, follow the instructions below. For standard installations, refer to the Piping Diagram for Basic DHW Installation on the next page. • The piping (including soldering materials) and components connected to this appliance must be approved for use in potable water systems. Purge the water line to remove all debris and air. Debris will damage the boiler.
IMPORTANT The CH piping and components have been removed from this diagram for clarity. Please reference section “8. CH System Piping” for details on proper CH piping. Condensate Drain Line Heating Supply Hot Water Supply Line Heating Return Cold Water Supply Line The above image is not an engineering drawing; it is intended only as a guide and not as a replacement for professional engineering project drawings. This drawing is not intended to describe a complete system.
8 Topics in this section • • • • • • • • • • • • • 52 Guidelines Instructions Common CH Components Piping Diagram for a Basic CH System (With Hydraulic Separation) Hydraulic Separation Connect the Pressure Relief Valves (DHW and CH) Connect the Condensate Drain Line Condensate Pump Safety Switch Wiring Purge the heating system to remove all debris and air. Debris and air in the lines will damage the boiler.
Plumb the heating supply line to the heating supply connection on the bottom of the boiler. Listed below are common components in a Central Heating system. Refer to the diagram on the next page. • Expansion Tank — A properly sized expansion tank charged to 2 PSI (14 kPa) below the cold system pressure is required to limit pressure changes in the heating system. When replacing an expansion tank, consult the expansion tank manufacturer for sizing.
Common CH Components Continued • Water Fill Valve — Maintains proper water pressure in the central heating circuit. • Back Flow Preventer — Use a back flow preventer in the filling circuit to the appliance as required by local code. • Low Water Cut Off (LWCO) — This boiler has a factory-installed pressure sensor type LWCO. The boiler's internal LWCO is not serviceable or adjustable. Check your local codes to determine if a LWCO is required and if this device conforms to the local code.
CH System Common Components Diagram Low Water Cut Off (if required by local code) Pressure Relief Valve (supplied with boiler) Pressure Gauge Air separator Primary-Secondary Heating Kit Dirt Trap System Return System Supply Backflow preventer Expansion tank Fill valve with pressure gauge Rinnai I-Series Condensing Boiler Combi Manual Ball valve 55
Optional Low Water Cut-Off (LWCO) Outdoor Sensor IMPORTANT This schematic shows an example of a simple single zone system with primary/secondary piping by hydraulic separation. Thermostat Purge Station Heat Emitter This is not an engineering drawing; it is intended only as a guide and not as a replacement for professional engineering project drawings. This drawing is not intended to describe a complete system.
Rinnai requires the use of hydraulic separation between the boiler and central heating system. Hydraulic separation and primary/secondary piping allow two or more circulators in a hydronic system to operate independently, without interfering with flow in connecting piping circuits. NOTE When Rinnai I-Series Boilers are in use with Rinnai air handlers, please reference the air handler Installation and Operation Manual for installation and performance details.
Low Loss Header Pressure Relief Valve To Heating Supply Shut Off Valves Low Loss Header From Heating Return IMPORTANT If using a low loss header, install the PRV and shut off valves between the boiler and low loss header (as illustrated in the above image).
WARNING Water discharged from the pressure relief valve could cause severe burns instantly or death from scalds. • The discharge end of the line shall be plain (unthreaded) and a minimum of 3/4 in. nominal pipe diameter. The discharge line material must be suitable for water at least 180° Fahrenheit. • If a pressure relief valve discharges An approved pressure relief valve is required by the American National Standard (ANSI Z21.
• • Do not plumb the condensate drain with the pressure relief valve; both must be plumbed independently to drain. • All condensate must drain and be disposed of according to local codes. • Use only corrosion resistant materials for the condensate drain lines such as PVC pipe or plastic hose. • The condensate drain pipe (along its entire length) must be at least 1/2 in.
4. Select an appropriate length of wire (18 AWG or greater) and strip the insulation off the ends. Follow the wiring guidelines established by the National Electrical Code (NEC). To connect the condensate drain pipe: 1. Apply thread sealant to 1/2 in. NPT condensate drain port. 2. By hand, thread 1/2 in. NPT fitting onto condensate drain port. 3. Follow the steps in the next section: “8.8 Condensate Pump Safety Switch Wiring.” IMPORTANT 5.
Condensate Pump Safety Switch Installation Boiler To Condensate Pump Safety Switch Wires Wire Nut Connecting Two Wires Installer-Supplied Wires Safety Switch Wires* Condensate Pump (installer-supplied) Includes internal safety switch and power cord. Power cord must be plugged into power source. * Safety switch wires connect to the NO and COM contacts on the safety switch.
9 CAUTION Topics in this section • Guidelines Electrical Connections Post-Power Supply Connection Checklist • • • • • WARNING • Do not use an extension cord or adapter plug with the boiler.
Devices such as the room thermostat, outdoor temperature sensor, zones pumps, and relay controls are connected to the boiler PC Board. Item # ❶ ❷ ❸ PC Board ❽ Connection Item Note ❶ Internal Pump Connection ❷ External Pump Connection 2 120 VAC, Max 2.0 A ❸ External Pump Connection 1 120 VAC, Max 2.
10 Topics in this section • • • Safety Precautions Filling Process Deaeration Process THIS SECTION IS INTENDED FOR THE INSTALLER This boiler must be commissioned by a licensed professional. Installer qualifications: A trained and qualified professional must install the appliance, inspect it, and leak test the boiler before use. The warranty will be voided due to any improper installation.
You Will Need: • Philips head screwdriver 1. Remove the boiler’s front panel by removing the four screws that secure the panel. Note: Alternately, on initial installation, you may press and hold the DHW button then simultaneously press the CH button on the control panel instead of removing the boiler’s front panel. 2. On the PC Board, press and hold the top, left black button shown below.
Deaeration is an effective method of purging air from the boiler after the system has been filled or serviced. While the boiler is running the deaeration process, the Maintenance Required icon (see right image) appears on the controller display. Do not bypass deaeration during commissioning or if the system pressure has dropped below 13 PSI (90 kPa). If there is any chance that air has entered the system, deaeration is critical to prevent damage to the boiler.
11 Complete the following checklist when boiler installation is complete. You should be able to answer YES to each question. If you answer NO, installation is not complete. Refer to the applicable section in this manual for additional information.
PRESSURE RELIEF VALVE (PRV) YES NO Does the PRV 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.
12 Topics in this section • Start-Up Information • Control Panel • Basic Operation Settings • Parameter Settings • Outdoor Reset Control • DHW Recirculation Function • Simultaneous CH and DHW Operation • Diagnostic Codes • Forced Hi/Low Fire Modes IMPORTANT • On initial startup of the system, it is necessary to put the boiler into a deaeration process to remove all air from the system piping and boiler.
❽ ❶ ❼ MODE ❷ ❸ Eco ❾ ❹ ❿ ❺ ❻ ❶ MODE Selects various boiler settings. ❹ ❷ Up/Down Arrows Scrolls through available menu options including adjusting the temperature. ❸ Eco Selects Eco or Comfort operation mode. Central Heating (CH) From the factory, this option is turned off by default. The boiler runs off thermostat inputs on the control board. For any adjustments, contact a trained and qualified professional for setting assistance.
When the boiler is turned on, the main screen (also called the home screen) appears in the display. ❶ ❷ ❸ ❹ ❺ ⓫ ❻ ❼ ❿ ❽ ❾ ❶ ❷ Maintenance Mode Icon ❼ Unit of Measurement for Temperature Appears when the boiler is in Parameter Settings Mode, Deaeration Mode, Performance Data Mode, Error History Mode, etc. ❽ Unit of Measurement for Pressure Eco Setting Active Eco maintains temperature in the primary heat exchanger to provide quicker delivery of hot water to fixtures.
To adjust the DHW setpoint temperature, follow the steps below. 20 Pri. PSI Pri. 20 PSI LED If the LED above the DHW button is not illuminated, press the DHW button. If the LED above the DHW button is illuminated, proceed to Step 2. Pri. 104°F Adjust the temperature with the Up and Down arrows until the appropriate temperature is displayed. Rinnai I-Series Condensing Boiler Combi Manual Press the Switch Operation Mode button until the DHW Active icon appears on the home screen. Pri.
The Central Heating (CH) setpoint temperature is not adjustable in outdoor reset control unless the custom heating curve (Curve 4) is selected. If Parameter 01 is set to “d” (Curve 4), follow the steps below to change the CH target temperature. For more information, see section “12.4.1 Parameter Settings Table” > Parameter 01 > Selection “d” (Curve 4).
Domestic Hot Water Comfort Modes are settings that would either supply quicker delivery of hot water to fixtures or save energy in the boiler operation. • Eco Mode (Default) (Eco icon illuminates) The boiler operates and produces hot water; however, it will not maintain the primary heat exchanger temperature for quicker hot water production. This selection saves some energy, but requires a longer time to provide hot water to the hot water fixtures.
To change the units of measurement appearing on the boiler display, follow the steps below. 1:F 1: F Press the Mode button. Press the Up or Down arrows to select a unit. Press the Select button. • F = U.S. Measurements (°F/PSI) • C = Metric (°C/bar) To turn the control panel click sound on or off, follow the steps below. 2: On Press the Mode button twice. 2:on should appear on the display. Press the Up or Down arrows to select ON or OFF. 76 2:Off Press the Select button.
To turn the child lock function on or off, follow the steps below. IMPORTANT • When Child Lock mode is enabled, the only function available is to turn off Central Heating (by pressing the Central Heating button on the controller); this occurs only if DIP switch 2 is set to the ON position. See section “12.3.8 PC Board DIP Switches” for more information. • If using multiple controllers, Child Lock can be set only on the controller that has priority.
To view the boiler’s performance data, follow the steps below. no . 01 While continuing to hold the (Down) button, press and hold the Domestic Hot Water button (press and hold both buttons down at the same time). Press and hold the (Down) button for two seconds. To exit performance data: no 120°F . 02 6.8 Use the (Up) and (Down) buttons to scroll to the desired performance data number described in the Performance Data Table in this section.
IMPORTANT Unit of measurement (°F/°C, PSI/bar, and GPM/LPM) will vary depending on unit of measure selection. # DATA UNIT 01 Water Pressure PSI/bar 02 Water Flow Rate x0.
DIP Switches ❷ PC Board ❸ ❹ Item # 80 PC Board Switch # ❶ Primary Function ❺ Notes 1 Button 1 Forced Hi/Low Fire Modes Refer to section “12.9 Forced Hi/Low Fire Modes” 2 Button 2 Deaeration Mode Refer to section “10. Commissioning” 3 Button 3 Data Transfer Mode This is for transferring PCB data when replacing the PCB. Refer to the instructions included in the replacement parts. 4 Button 4 (Red Button) Parameter Settings Refer to section “12.
DIP Switch # Function Description OFF (Default) ON 1 Outdoor Temperature Sensor Enables or Disables the Outdoor Temperature Sensor Outdoor Temperature Sensor in Use Outdoor Temperature Sensor Not in Use 2 Thermostat Usage Changes the mode between Thermostat Usage and Central Heating Button Thermostat Used Central Heating ON button used.
To change the altitude, follow the steps below. 1. Remove the boiler’s front panel by removing the four screws that secure the panel. 2. Locate the PC Board (lower left side of unit) (see below). 3. Locate the DIP switches on the PC Board (see below). 4. Adjust DIP switches 6 and 7 to on or off based on the altitude settings in the table below.
Thermostat Usage (Default Setting) This is the default setting for the boiler. This setting enables the boiler to operate in CH from a call for heat from the room thermostat or zone controller. In this setting, the Central Heating button is not functional except as an Error Reset or other setting. Central Heating Button IMPORTANT Central Heating Mode on the I-Series Boiler is not designed for typical room thermostat control systems.
1. 2. 3. 4. Remove the boiler’s front panel by removing the four screws that secure the panel. Locate the PC Board (lower left side of unit). Locate the red button on the PC Board. Press and hold the red button for five seconds. PC Board Press and Hold Red Button for Five Seconds 5. Press the Mode button on the controller. 01-A 6. Press the (Up) or (Down) arrows to select a parameter setting number. Then, press the Select button. 11-A 7.
Parameter Number 00 01 02 03 10 11 12 Setting Description Selection A Pressure Indication on the Control Panel The current pressure will cycle on the controller Yes display. If an external pressure gauge is present, it is permissible to change the setting to "No." Outdoor Reset Curve This parameter is available when Dip Switch 1 is in the OFF (default) position. Select the proper curve from below. See section “12.5 Outdoor Reset Control” for more information.
Parameter Number Selection Setting Description DHW Recirculation with Timer Relay Input This parameter is available when DIP switch 3 is in the ON position. This enables an external timer to also control the timing for DWH recirculation to more directly correspond to the customers needs. CH Temperature Limitation During Simultaneous Operation This parameter is available when DIP switch 3 or 4 is in the ON position.
Parameter Number 40 41 42 Setting Description Linked Operation Between CH Pump 1 and 2 This parameter enables linked operation between the CH Pump 1 and 2. For example, when T/T 1 is active, both pump 1 and 2 are ON. The T/T wire must be connected to the T/T1 connection. When it is desired to utilize DHW Recirculation via DIP switch 3, this parameter will not be available. The DIP switch must be in the OFF (default) position for this parameter to be enabled.
Parameter Number Selection Setting Description A b Default When Boiler is Installed in a Warm Room Normal Quick Freeze Protection Level This selects the freeze protection level. Selecting “B” will prevent the boiler from operating in freeze protection mode more than believed necessary. 45 C The Differential Temperature from Ceasing Fire to Firing Again How much temperature drop is permitted by the supply water thermistor before the boiler will fire again.
Outdoor reset is a built-in function to help maximize the efficiency of the boiler. The design of this function is to adjust the target temperature of the boiler relative to the outdoor ambient temperature via the four outdoor reset curve options included in the boiler parameters. The outdoor ambient temperature is observed via the provided outdoor temperature sensor.
1. Remove the boiler’s front panel by removing the four screws that secure the panel. 2. Locate the PC Board (lower left side of unit). 3. Connect the outdoor sensor to the terminals shown below using minimum 18 AWG wiring to the two terminals provided in the enclosure. 4. Locate the DIP switches on the PC Board (see below). Ensure that DIP switch 1 is in the OFF (Default) position (this ensures the boiler will operate based on the outdoor temperature). 5.
The boiler has four outdoor reset heating curves, which are different target temperature lines dependent on the outdoor temperature. The selected curve should be based off of the type of heat emitter and the target temperature desired. The heating curves are described below.
Curve 4 Curve 4 is a custom curve based on the target setpoint temperature of the boiler the customer selects. The maximum temperature is the target temperature. The minimum temperature is 36°F (20°C) lower than the target temperature with a minimum of 86°F (30°C). See example curves below.
Boost mode allows the boiler to override the target temperature determined by the outdoor reset control, and will boost the boiler target temperature to the setting of Parameter 01 after a continuous run time or an interval as selected in Parameter 02. The boost function is active until the call for heat is satisfied or the boiler cycles off.
The I-Series Combi boiler has the capability to control DHW recirculation via an external recirculation pump. While the default setting for recirculation is “off,” when DIP switch 3 is turned “on,” the DHW recirculation function becomes available. An optional 24 V timer can be used to set the time intervals and duration of recirculation. When utilizing the domestic hot water recirculation function, the external pump must be wired to the Pump 2 terminal on the PC Board.
Crossover Mode Plumbing Diagram This diagram is not a complete piping diagram; it shows DHW piping only (Central Heating piping is not displayed). Recirculation Pump Wiring Timer (Optional) Thermal Bypass Valve installed at furthest fixture in plumbing system. Recirculation Pump Hot Water Supply Line Gas Supply Line Cold Water Supply Line Expansion Tank When the recirculation logic starts, the pump will operate as described below.
Note: Rinnai strongly recommends installing insulation to the hot water and dedicated return lines to decrease the amount of heat loss. Dedicated Mode Plumbing Diagram IMPORTANT This diagram is not a complete piping diagram; it shows DHW piping only (Central Heating piping is not displayed).
Step 1: Set DIP Switches and Parameter Settings 1. Remove the boiler’s front panel. 2. Locate the PC Board (lower left side of unit). 3. Locate the DIP switches on the PC Board (see below). Adjust DIP switch 3 to the ON position. PC Board ON DIP Switch 3 4. Locate the Parameter Settings button on the PC Board (red button). Press and hold the red button for five seconds to enter into Parameter Settings mode. 5. Adjust Parameters 12 and 13 to the desired settings shown in the table below.
Step 2: Connect Wiring to PC Board 6. Wire the external DHW recirculation pump to the DHW_Pump Terminal connection on the PC Board (see A below). 7. If using a timer: • Wire the 24V AC timer circuit to the 24V AC for External Output connection (see B). • Wire the timer C and NO contacts to the T/T 2 connection (see C). A DHW_Pump Terminal B Recirculation Pump 24V AC for External Output C T/T 2 Timer Terminals T 24V AC Input Terminals C • Timer receives power from the PC Board.
The boiler has the capability to operate simultaneously between central heating and domestic hot water. The boiler can control dividing the flow between the domestic hot water plate heat exchanger and the central heating circuit. The boiler is set to a default domestic hot water priority operation. If it is desired to have simultaneous operation of central heating and domestic hot water, follow the steps below. 1. Remove the boiler’s front panel by removing the four screws that secure the panel. 2.
Diagnostic Codes Some of the checks below should be performed by a licensed professional. Consumers should never attempt any action that they are not qualified to perform. WARNING 021 This code will display when DHW is in continuous operation for extended periods of time. • Ensure there are no open faucets. • Ensure there are no leaks in fixtures or the plumbing system. Display Diagnostic Codes To display diagnostic codes, follow the steps below. 1.
140 Heat Exchanger Overheat • Overheat switch is tripped. • Measure the resistance of the Overheat Switch.* • Check the heat exchanger surface for hot • • • • • • • • spots which may indicate blockage due to scale buildup. Ensure the boiler pump is not locked up. Ensure that all of the valves in the CH circuit are open. Ensure the boiler and CH circuit does not have a freezing condition. The surface of the heat exchanger may turn to a black color as stainless steel is tempered even in normal conditions.
430 High/Low Water Pressure • • • • • 631 DHW Recirculation Pump • If the water pressure is too low, add water into the system until at least 13 PSI is observed. Ensure there are no leaking components in the CH system. If the pressure is too high, adjust the pressure to a maximum of 30 PSI. Ensure the pressure relief valve and water fill are working correctly. Ensure deaeration has been performed. • • • • 443 Low Water Cut-Off (LWCO) • • • Ensure the LWCO device is working correctly.
700 PC Board • • No Nothing happens when DHW water flow is Code activated PC Board circuit error. Replace PC Board. • 710 Solenoid Valve Circuit • • • • Ensure Dip switch 5 on the PC Board is in the OFF position (default). Ensure the gas control wire is not loose or damaged. Replace the PC Board. 720 Flame Rod • • • • • Check the flame rod and wire for damage. Ensure the flame rod and wire are not wet. If there is no issue with the flame rod or wiring, replace the PC Board.
No Code The boiler does not operate with the CH button • If DIP switch 2 is OFF, CH operation (the light on the CH button is off) will operate via the room thermostat. Supply temperature is different No Code from the setting temperature on the controller • No Code DHW recirculation does not begin • • • • • • • No Code Simultaneous DHW and CH is not functional • • • • No Code Ensure DIP switch 4 is ON.
WARNING This section should be performed by a licensed professional. Consumers should never attempt any action that they are not qualified to perform. 1. Remove the boiler’s front panel by removing the four screws that secure the panel. 2. Locate the PC Board (lower left side of unit). 3. Press and hold the right-side, black button. DIP Switches Button PC Board 4. The controller displays FL (the boiler is now in forced low fire condition). 5. Press the right-side, black button again.
13 Topics in this section • • • Owner Maintenance Licensed Professional Maintenance Test the Ignition Safety Shut Off Device WARNING If you encounter a problem that is difficult to solve, stop the operation and immediately contact a licensed professional. WARNING • • • • 106 Maintenance is required to maintain safe operation of the boiler. The boiler must be inspected annually by a licensed professional. Repairs and maintenance shall be performed by a licensed professional.
ANNUALLY Vent System • Inspect for blockages or damage. • Inspect vent screen or room air filter (if using) for debris and blockages. Clean if needed. Fan and Motors Clean dust and dirt from fan and motor (motors are permanently lubricated and do not require lubrication). Controller Clean by using a soft, damp cloth. Do not use solvents. Pressure Confirm the pressure is within the proper range (between 17-26 PSI). If the pressure is lower than the specified range, add water until in the proper range.
Pump Lock Confirm the pump operates smoothly. The boiler operates pump lock operation at least in 48 hours for all of system pumps. If it is pump locked, rotate the cap in front of pump by flat driver. Water Quality Confirm the water quality. Refer to section “4.4.1 Water Quality Guidelines” to determine if the water needs to be treated or conditioned. DHW must be potable, free of corrosive chemicals, sand, dirt, or other contaminates.
Intake Filter Inspection: • To maintain optimum performance, periodically inspect the air filter. • If the air filter appears to have lint and/or dust build up, follow the cleaning procedure described below. • If the air filter appears damaged, contact a trained and qualified professional for a replacement air filter assembly. Cleaning: • Clean the Air Filter: With mild dish soap and a soft bristle brush, scrub the filter area of the air filter door. With clean water, rinse the soap off the filter.
1. Ensure the boiler is not currently firing and the flame rod is not hot. 2. Remove the boiler front panel. 3. Disconnect the wiring connection from the flame rod (located on front of the boiler under the burner). Remove wiring connection Boiler front side WARNING Do not touch the inside of the wiring connection while it is disconnected. 4. Place the boiler in operation by either a call for heat or by turning on a Domestic Hot Water fixture. 5.
14 Below is a list of approved system cleaners, inhibitors, and antifreezes for use in hydronic plumbing systems utilizing Rinnai boilers.
When replacing an existing boiler, the heating system shall be flushed with an approved system cleaner before the new boiler is added to the system. The Rinnai boiler must be isolated from the system while the system is flushed. No system cleaner should ever enter the boiler heat exchanger due to its caustic nature which could damage the heat exchanger. Reference section “14.1 Approved Cleaners, Inhibitors and Antifreezes” in the Appendix for an approved list of system cleaners, inhibitors, and antifreezes.
This boiler includes a service indicator/reminder (also called an LC diagnostic code). When selected in the parameter settings, an LC code will display on the controller indicating that it is time to flush and service the boiler. Failure to flush the boiler will cause damage to the plate heat exchanger. Damage caused by lime build-up is not covered by the boiler’s warranty. Rinnai strongly recommends installation of isolation valves to allow for flushing of the plate heat exchanger. 1.
IMPORTANT Primary/secondary piping is necessary in the following applications: • When using external pumps • Large zoned systems • High flow applications • Systems with high differential pressures • Systems with high pressure drops For pressure curve information, refer to the following sections in the Appendix. • 14.8 CH Pressure Drop and Flow Curve • 14.9 DHW Pressure Drop and Flow Curve Legend: Refer to the legend below for the system applications shown in this section.
Optional LWCO Thermostat Purge Station PC Board Wiring for the above application example External pump connection 1 T/T 1 Connection Thermostat Pump Rinnai I-Series Condensing Boiler Combi Manual 115
PC Board Wiring for the above application example T/T 1 Connection Zone Control Pump 116 Thermostat 1 Thermostat 2 Rinnai I-Series Condensing Boiler Combi Manual
PC Board Wiring for the above application example External pump connection 2 External pump connection 1 T/T 1 Connection T/T 2 Connection Pump 2 Pump 1 Thermostat 1 Thermostat 2 Rinnai I-Series Condensing Boiler Combi Manual 117
PC Board Wiring for the above application example T/T 1 Connection Wires To End Switch on Zone Controller Pump 1 Pump 2 Pump 3 Zone Control Thermostat 1 118 Thermostat 2 Thermostat 3 Rinnai I-Series Condensing Boiler Combi Manual
For this application, ensure Parameter 41 is set to “b” for linked operation between the main boiler pump and CH pump 1. Note: Heat emitter must be radiator with thermostatic heads.
This boiler is configured for Natural Gas only. To convert to Propane Gas, follow the instructions in this section. WARNING • • The conversion kit shall be installed by a qualified service agency in accordance with the manufacturer’s instructions and all applicable codes and requirements of the authority having jurisdiction. The information in these instructions must be followed exactly to minimize the risk of fire or explosion or to prevent property damage, personal injury or death.
1. Confirm that the inlet gas pressure is between the minimum and maximum pressures allowed for this boiler. 2. Disconnect electrical power to the boiler. 3. Turn off the boiler’s gas supply by turning off the gas control valve. 4. Remove the boiler’s front panel by removing the four screws that secure the panel. 5. Locate the orifice cover plate on top portion of gas valve (Figure 1). 6. Remove the three screws securing the orifice cover plate (Figure 1). Figure 1 Orifice Cover Plate Three screws 7.
1. Locate the PC Board (lower left side of unit) (Figure 3). 2. Locate the red button on the PC Board (Figure 3). 3. Press and hold the red button for five seconds (Figure 3). Figure 3 PC Board Press and Hold Red Button for Five Seconds 4. Press the Mode button on the controller. 5. Scroll to parameter Select button. 01-a AO and press the A0-a 6. Press the (Up) or (Down) arrows to select the appropriate gas type.
1. Check the normal operating sequence: a. When you press the ON/OFF button, the LED display will illuminate, the combustion fan will begin to run if water is flowing, and the spark will ignite the main burner. b. This boiler has an automatic ignition system. When the main burner has lit, the “In Use” lamp will glow red and the spark will stop. 2. Visual inspection of flame: a. Check that the burner flames are operating normally. The flame can be seen through the circular window above the burner.
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55 Pressure Loss (Feet of Head) 50 45 i120C i060C and i090C 40 35 30 25 20 15 10 5 0 0 1 2 3 4 5 6 7 8 9 10 11 Water Flow (GPM) 126 Rinnai I-Series Condensing Boiler Combi Manual 12
70 Pressure Loss (Feet of Head) 60 i060C and i090C 50 40 i120C 30 20 10 0 0 1 2 3 4 5 6 7 8 9 10 Water Flow (GPM) Rinnai I-Series Condensing Boiler Combi Manual 127 11
The MC-601 controller is available as an accessory and must be purchased separately (detailed installation instructions are included with controller purchase). When an MC-601 controller is connected to the boiler, the set temperature of DHW can be changed on the controller, rather than the boiler. • • • • • The temperature controller should be out of reach of small children. Avoid locations where the temperature controller may become hot (near an oven or heat emitter). Avoid locations in direct sunlight.
A maximum of three temperature controllers can be installed for a boiler or bank of boilers (including the controller built into the boiler). Connect the controller cable to the mating terminal at the bottom of the PC Board. • Use the connecter (included) for wiring to remote controller. • Wire the connecter and remote controller, and insert the connecter on remote controller.
The following information is required by ANSI Z21.13: If a boiler is removed from a common vent system, the common vent system is likely to be too large for proper venting of the remaining appliances connected to it. The instructions shall include the test procedure set forth below: At the time of removal of an existing boiler, the following steps shall be followed with each other appliances remaining connected to the common venting system are not in operation. 1.
FOR GAS MODELS SOLD IN MASSACHUSETTS NOTICE BEFORE INSTALLATION: This direct-vent appliance must be installed by a properly trained licensed professional. If you are not properly trained, you must not install this unit. IMPORTANT: In the State of Massachusetts (248 CMR 4.00 & 5.
Limited Warranty for I-Series Boiler Models Boiler Models: • Combi: i060C, i090C, i120C • Solo: i060S, i090S, i120S, i150S What Is Covered? The Rinnai Standard Limited Warranty covers any defects in materials or workmanship when the product is installed and operated according to Rinnai written installation instructions, subject to the terms within this Limited Warranty document. This Limited Warranty applies only to products that are installed in the United States and Canada.
How Do I Get Service? You must contact a trained and qualified professional for the repair of a product under this Limited Warranty. For the name of a trained and qualified professional, please contact your place of purchase, visit the Rinnai website (www.rinnai.us), call Rinnai at 1-800-6219419 or write to Rinnai at 103 International Drive, Peachtree City, Georgia 30269. Proof of purchase is required to obtain warranty service.
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