rinnai i-series condensing boiler i-series... · 2019-08-29 · enhancing lives by changing the way...

ENHANCING LIVES BY CHANGING THE WAY WATER IS HEATED

Rinnai I-Series

Condensing Boiler

Level II Installation

Training

ENHANCING LIVES BY CHANGING THE WAY WATER IS HEATED ©Rinnai Corporation 2

• Rinnai Resources

• The new Rinnai I-series Boiler Features and Benefits

• Installation Fundamentals

• Boiler Set Up & Commissioning

• Maintenance & Troubleshooting

Agenda


About Rinnai

• Founded 1920

• 16 Countries

• World’s #1 Selling Brand Of

Tankless Water Heaters

• >600 R & D Engineers

• 100% Live Product Testing

Fast Facts:

• CSA Certified Testing Lab & Accredited Technicians

• Growing In 2018:

• R&D Innovation And Training Center Expanded (Peachtree City, GA)

• Manufacturing Tankless Product In The USA (Griffin, GA)

• Partnership with


Service & Support

Customer Service Applications Support Parts / Warranty

1-800-621-9419Available from 8 am to 8 pm EST, Monday - Friday

Dealers/Contractors: [email protected]: [email protected]

Technical Support Department

1- 888-RINNAIS (746-6247)This Phone Number is only provided to Technicians

FOR CALLS WHILE SERVICING PRODUCT

Office Hours:

Monday – Friday 8 a.m. to 8 p.m. EST

On Call hours:

24 / 7 / 365

mailto:[email protected]

mailto:[email protected]


www.rinnai-lms.com

Training Website


Features


I-Series Features

• Energy Star: 95-96% AFUE

• Simultaneous CH and DHW

• Precise DHW temperature control

• Improved DHW capacity

• Integrated DHW recirculation features

• Integrated 2-Zone pump relay

• Multiple venting solutions (length and

materials)

• Improved Serviceability


I-Series Features

Model AFUEMax Input

(BTU)Min Input

CH TurndownRatio

I060S 95.1% 60,000 CH

15,000 BTU

4.0 : 1

I090S 95.9% 90,000 CH 6.0 : 1

I120S 95.5% 120,000 CH 8.0 : 1

I150S 96% 150,000 CH 10.0 : 1

Model AFUEMax Input

(BTU)Min Input

CH TurndownRatio

DHW Performance

I060C 95.1%60,000 CH

160,000 DHW

15,000 BTU

4.0 : 1 CH10.6 : 1 DHW 4.1 gpm @

70°FTI090C 95.9%

90,000 CH160,000 DHW

6.0 : 1 CH10.6 : 1 DHW

I120C 95.5%120,000 CH

199,000 DHW8.0 : 1 CH

13.2 : 1 DHW5.2 gpm @

70°FT


I-Series Features

Stainless Steel Heat Exchanger

• 444 Stainless Tubes

• Better corrosion resistance &

heat transfer

• 316L/430 Stainless Body

• 1mm thickness tube wall

• Most competitors are 0.8mm

• Flat Plate Secondary Heat

Exchanger

• Brazed heat exchanger (not welded)

• Low NOx Emissions

Innovative Leading Edge Design Features


I-Series Features

Pre Mix Combustion

Zero Governor Gas Valve

Is more adaptable to ½” gas line and/or low gas pressure supply situations

Switching Venturi Valve

Mixes gas and air for up to 13 to 1 turn down ratios

Turbo Fan

Allows extended venting lengths


I-Series Features

Multi-Zone Capability

• 2 pump & thermostat

connections

• Multi-functional Pump

Relay

• Indirect DHW (Solo

Models)

• DHW Recirculation

• Zone Pump 2 can be

designated as a DHW

recirc pump


I-Series Features

Simultaneous DHW and Heat (Combi & Solo)

• Proportional 3-way valve

• DHW Priority or

Simultaneous DHW & CH


I-Series Features

Superior DHW temp and flow control (Combi Models)

• Rinnai water flow &

bypass control

technology ensure

more precise DHW

temp output

• NO mixing valve

needed (unless

required by local

code)


What is the average shower temperature (in Fahrenheit)?

What is the average cold water temperature in the US (in

Fahrenheit)?

Based on the above, what is the average ΔT

What is the average shower flow rate in GPM?

Using the above data with the below table, how many showers can

each boiler supply at once? How much hot water flow is

remaining?

Combi DHW Capacity: How much hot water is it?

ModelsMax. DHW flow (gpm)

ΔT 48 °F ΔT 64 °F ΔT 70 °FI060CI090C

6.0 4.5 4.1

I120C 7.5 5.6 5.1

106°F

58°F

106-58= 48

2.1 GPM

ModelsMax. DHW flow (gpm) # Showers

ΔT 48 °F ΔT 64 °F ΔT 70 °F (106°F hot/58°F cold)

I060CI090C

6.0 4.5 4.1 2 (with 1.8 GPM remaining)

I120C 7.5 5.6 5.1 3 (1.2 GPM remaining)

I-Series Features


Combi DHW Capacity: How much hot water is it?

ModelsMax. DHW flow (gpm))

ΔT 48 °F ΔT 64 °F ΔT 70 °FI060CI090C

6.0 4.5 4.1

I120C 7.5 5.6 5.1

Using the data below, how many (2.1 GPM, 106°F) showers will each boiler

model supply in this area?

I-Series Features

Groundwater

Temp Map


I-Series Features

Integrated DHW Recirculation

• Rinnai Circ-Logic™

recirculation capability

• On-board Zone 2

pump control can be

designated for DHW

recirculation control

• With OR without a

dedicated return

• Thermal crossover

valve is compatible!


I-Series Features

Simplified Control

Mode(Parameter, Deaeration,

Service, etc)

Eco / Comfort Feature

CH ON/OFF Mode(SW setting required)

DHW ON/OFF

Display (CH/DHW)

CH active LED DHW active LED

Select / Enter Value

Change Value


I-Series Features

Simplified Control

Maintenance Mode(if in parameter, service,

deaeration, etc)

Eco Active

In UseFlame is active

Controller PriorityIf multiple controllers are

connected

CH Active ValueSetpoint CH/DHW, Current

Temp/Pressure, etc

Units of measurementF or C only

PSI or Bar only

Freeze Protection Active

Indirect Tank (Solo Models)

Flashing: ActiveSolid: Satisfied

DHW Active (Combi Models)

Outdoor Temp Sensor Active


I-Series Features

Point-of-use DHW Control

MC-601 DHW Temperature ControllerUp to 3 additional controllers allowedEach controller uses thermostat wire

connected to boiler


Product Warranty

Description Residential Commercial

Primary Heat Exchanger 12 YRS 5 YRS

Boiler Parts 5 YRS

Labor 1 YR

Warranty covers: Warranty DOES NOT cover failure due to:

Defects in

materials/workmanship

Accident, abuse/misuse,

alteration/misapplication

Indoor installations installed per

the manual and all applicable

code

Improper Installation/Maintenance

Poor water quality, scale issues, freezing

Please refer to the Documentation Set for full warranty details and guidelines

I-Series Features


Installation


ModelHeat Only

Weight

Combi

Weight

I06059 lbs 73 lbs

I090

I12062 lbs

76 lbs

I150 N/A

I-Installation


I-InstallationBoiler Accessories: What’s included…

GAS

LP conversion kit

PLUMBING

30 PSI pressure relief valve

Internal Pump (combi models)

VENTING

2” PVC/CPVC/PP adaptors

3”/5” concentric connection

2” Vent Screens

OTHER

Installation and User manuals

Outdoor temperature sensor

Wall mounting bracket & template

Connector for additional DHW temp controller

DHW Temp Controller Connector

LP Field Conversion KitAll I-Series Boilers ship as NG with this kit included


Location Location Location!

I-Installation

If applicable, verify room air

is sufficient

Verify vent length equivalency

Ensure clearances to

combustibles

Ensure service access

Ensure all local codes

are met

Verify grounded

3-prong outlet

Verify water supply quality

LOCATION CHECKLIST


I-Installation

Mounting / Clearances

• Bracket allows side-to-side adjustment

• Ensure the water heater is firmly secured at top & bottom to

support its weight

• Lift with front cover installed (from the sides)

Top / Sides

2” (0 to vent components)

Bottom

12”

Front

6” (24” for service)


Reference Installation manual for full details

Default

• Exhaust temp sensor ensures flue temps will not exceed 149°F

• This is to ensure flue gas temps will never exceed PVC limitations

When to adjust

• It is recommended to leave this intact

• If boiler is set for high temp (180°F)

And

• PVC is NOT USED

• CPVC, PP, Stainless is used

How to adjust

• Move DIP SW 8 to ON

• Set Parameter A2 to B

• Sensor is now set to 194°F

PVC Venting Safety Feature

I-Installation


Reference I/O manual for full details of approved vent materials

Overview

• Ubbink Concentric Polypropylene (3”/5” or 2”/4”)

• PolyPro (2” or 3”)• Centrotherm

• Duravent

• Ecco Manufacturing

• AL29-4c Stainless (Metal-fab/Heat-fab)

• PVC/CPVC (Schedule 40)

• PVC termination kits• IPEX

• Royal

• Diversitech

• Flexible chimney liners (PP / Metal)

Approved Venting Materials

I-Installation


I-Installation

Vent Diameter

Vent Type

All I-Series Models

I60S/C, I90S/C, I120S/C, I150S

Maximum Equivalent Length in Feet

Condensing Concentric Vent2” x 4” Concentric (Direct Vent) 65

3” x 5” Concentric (Direct Vent) 150

2” or 3” PVC/CPVC/PP (2-Pipe, Direct Vent)2" PVC/CPVC/PP (2-Pipe - Direct Vent) 65

3" PVC/CPVC/PP (2-Pipe - Direct Vent) 150

3” Centrotherm PP, Vent System (2-Pipe - Direct Vent) 150

2” or 3” PVC/CPVC/PP (Single-Pipe, Room Air)2" PVC/CPVC/PP (Single Pipe – Room Air) 65

3" PVC/CPVC/PP (Single Pipe – Room Air) 150

2” PP Flex Vent 50

Equivalent lengths – 2” x 4” / 3” x 5” concentric vent & 2” / 3” Twin Pipe PVC/CPVC/PP venting

90⁰ Elbow = 6 feet 45⁰ Elbow = 3 feet

IMPORTANT: Refer to all applicable manuals for details.

• Termination components may have an additional equivalency

• 2-Pipe installations: only use the longer length of exhaust OR intake (not additive)

• Common vent is not allowed on I-Series boilers

Maximum Vent Equivalency Quick Reference (Same as Sensei)


I-Installation

• Vent equivalencies vary

• Refer to I/O manual for details

• IPEX termination = 20’

equivalency

• Note: In 2 pipe systems, use

longest pipe (in/out) to

determine maximum

3/5” Concentric PP

3’

What is the vent equivalency?

Is this vent system within specification?

2” PVC w/IPEX concentric

termination

3’

2’

1.5’

10”


Cut Internal PP pipe 7/16”

(10mm) Longer than Outer Pipe

PP can easily be cut with hand saw or snips. Be sure to

deburr all cuts

WARNING:

Horizontal terminations

extending too far off

the wall allow exhaust

to recirculate into the

air intake which could

damage the boiler

Roof

Termination

Sidewall

Termination

Concentric Venting

Green Label = Condensing

Black Label = Non-CondensingDO NOT USE!

I-Installation


I-Installation

Refer to the water heater’s operation and installation manual for each termination’s equivalent length and specific clearances.

Installation: Concentric (Direct) Venting

2”/4” Concentric Horizontal with 3”/5” adaptor

3”/5” Concentric Horizontal

2”/4” Concentric Vertical with

3”/5” adaptor

3”/5” Concentric Vertical


I-Installation


IPEX or

Royal

concentric

vent

termination.

Installation: Two Pipe Venting / Direct Vent

Two-Pipe

Horizontal Concentric

Two-Pipe

Vertical Concentric

Two-Pipe

Horizontal Snorkel

Two-Pipe

Horizontal Tee (Elbow also allowed)

Two-Pipe

“U” Vertical Termination

Two-Pipe

Tee Vertical Termination

Unbalanced Horizontal Intake /

Vertical Exhaust


I-Installation

2” or 3” PVC/CPVC

Low Profile Horizontal

Termination.

Refer to the operation

and installation

manual for each

termination’s

equivalent length and

specific clearances.

Horizontal twin pipe low profile vent termination example.

Installation: Two Pipe Venting / Direct Vent


I-Installation

Horizontal Snorkel


Installation: Room air / Non - Direct Vent

Horizontal Elbow (Tee also allowed)

“U” Vertical Termination

Tee Vertical Termination


I-Installation

Vertical Non-Direct Vent / Room Air flexible vent termination examples.

Installation: Room air / Non - Direct Vent

Refer to the water

heater’s operation

and installation

manual for each

termination’s

equivalent length

and specific

clearances.

IMPORTANT

• Vertical terminations only

• Room air only

• No angles > 45°

• Max 50’ length

• Only combine with other Ubbink

PP single pipe components

• Can be fed thru (unused) B-Vent


I-Installation

Installation: Examples of Termination Equivalent Lengths

Concentric Horizontal Termination = 5 feet PVC Concentric Horizontal/Vertical Termination = 20 feet

( Ipex or Royal )

PVC Low Profile Horizontal Termination

= 5 feet

( Ipex or Royal )

Concentric

Vertical

Termination

= 5 feet

PVC Two Pipe

Wall Termination

Kit = 16 feet

( Ipex or Royal )

See the Installation Manual for

more complete equivalent

length information.


See next

slide for

NFPA

required vent

terminal

clearances

Sidewall Vent Termination Clearances

I-Installation


Ref Clearance ANSI Z223.1 (NFPA 54) or Rinnai Requirement (see manual) U.S. Direct Vent Canadian Direct

A Clearance above grade, veranda, porch, deck, balcony or expected snowline 12” 12” (30 cm)

B Clearance to window or door that maybe opened 12” 36” (91 cm)

I Clearance to service regulator vent outlet *3’ horizontally with 15’

max vertical

JClearance to non-mechanical air supply inlet to building or the combustion

air inlet to any other appliance 12”

36” (91 cm)

K Clearance to a mechanical air supply inlet3’ above if within 10’

horizontally6‘ (2 m)

L Clearance above paved sidewalk or driveway located on public property *7’ (2.25 m) – not

allowed between 2 structures

M Clearance under veranda, porch, deck, or balcony** *12” (30 cm) – must be

open on 2-sides

Sidewall Vent Termination Clearances (Direct Vent)

*Refer to Local Code Guidelines for any unlisted clearances

Clearances must comply with local building code and gas supplier requirements

I-Installation


Tech Tip: Some clearances are increased when using room air in the US (see manual for details!)

Sidewall Vent Termination Clearances (Room Air)

Ref Clearance ANSI Z223.1 (NFPA 54) or Rinnai Requirement (see manual) U.S. Non-Direct Vent Canadian Non-Direct Vent

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

B Clearance to window or door that maybe opened1’ above

4’ below or sides36” (91 cm)

I Clearance to service regulator vent outlet *3’ horizontally with 15’ max

vertical

JClearance to non-mechanical air supply inlet to building or the

combustion air inlet to any other appliance

1’ above

4’ below or sides

36’ (91 cm)

K Clearance to a mechanical air supply inlet3’ above if within 10’

horizontally6‘ (2 m)

LClearance above paved sidewalk or driveway located on public

property7’

7’ (2.25 m) – not allowed between 2 structures

M Clearance under veranda, porch, deck, or balcony *12” (30 cm) – must be open on

2-sides

I-Installation

*Refer to Local Code Guidelines for any unlisted clearances

Clearances must comply with local building code and gas supplier requirements


Sidewall Vent Termination Considerations

AVOID

Terminations near

NEVER

Install terminations:

Dryer Vents Over Public Walkways

Commercial Cooking Exhaust Near Soffit/Crawl Space Vents where

condensate can be problematic

Air inlets into the building Where condensate could damage

regulators, PRV’s, or other equipment

Where exhaust cannot easily

dissipate

Where exhaust can enter the soffit vent or

reenter the combustion intake vent

NOTE: If more stringent, local codes will supersede the above

I-Installation


Multiple Horizontal Vent Terminations

I-Installation


Multiple Vertical Vent Terminations

I-Installation


I-Installation

Gas

• ¾” male

Pipe Connections (NPT)

DHW

• ¾” male

Boiler (heating system)

• 1” male

Condensation Drain

• ½” male

Gas shutoff

& drip leg


Gas Line Sizing Example – Natural Gas

I-Installation

Using the

provided table

and example,

what size gas

line is required

for the

following

installations?

• 10 ft

• 50 ft

• 80 ft


NG to LP Gas ConversionIMPORTANT: Refer to Gas Conversion instruction in manual for more detail

• Blue orifice = NG

• Red/Pink orifice = LP

• Both are clearly labeled

• Parameter A0

• A = NG

• b = LP

I-Installation

• All units ship as NG with LP kit included

• No gas pressure setting required

• Ensure new rating plate is complete

and attached


DHW Connections (Combi Models)

• ¾” Male NPT connections

• Recommended DHW Pressure Range: 10–80 psi

• 150 psi or lower PRV is required

• An isolation valve kit is recommended (field supplied)

• A Thermostatic Mixing Valve may be required by local codes (not

by manufacturer)

Rinnai Isolation

Valve Kit MIVK-T-LW

I-Installation


Heating System Connections

I-Installation

• 1” Male NPT connections

• 30 psi PRV provided

• Recommended Pressure: 17 – 26 PSI

• Fill valve and expansion must be set to this range

• Min / Max Pressure: 13 – 45 PSI


Condensate Drainage

• ½” NPT

• Ensure air gap

• Condensate trap included

• Neutralize per local code

• Boiler includes condensate

pump safety switch

connection

• Fault code 250

I-Installation


Primary / Secondary Piping:

Advantages

• Also known as Hydraulic Separation

• System & boiler flow rates are

independent of each other

• Ensures proper flow to heating

zones

• Gives correct boiler flow and full

boiler output power

• Allows for multi temperature

systems

• Protects individual components in

the system

I-Installation


I-Installation

Determining Boiler Pump Size for Solo ModelsBoiler

Model

Recommended Pump Model

Grundfos Taco Bell & Gossett Armstrong

i060SUPS 15-42 007-IFC

NRF-25 Astro 230Cii090S

i120S UPS 15-58 008-IFC

i150S UPS 26-99 0011-IFC N/A Astro 280Ci

Pump

recommendations are

based on primary

secondary piping


Primary Secondary Piping Options

Closely Spaced Tees

• Simple DIY primary secondary piping solution

• Tees should be as close as practical

• Header pipe should be larger diameter than boiler pipes

• Include PRV fitting above boiler isolation valves

I-Installation



I-Installation

Rinnai closely spaced tee

accessory for Combi boilers

Part # 807000212

Rinnai closely spaced tee

accessory for Solo boilers

Part # 807000213

Pump - field

supplied



Third Party Boiler Plumbing Kits and Low Loss Headers

• Boiler Plumbing kits are available from several manufacturers that include pre-

made closely spaced tees.

• Hydraulic Separators and LLHs are available that also function as air separators

and dirt traps.

I-Installation


Boiler Connections

I-Installation

Combi: Internal pumpSolo: Boiler pump (field supplied)

(120 VAC / 2.0 amp max)

Combi: Z2 or DHW recirc pumpSolo: Z2 or Indirect tank pump or

Diverter valve(120 VAC / 2.0 amp max)

Z1 pump(120 VAC / 2.0 amp max)

24 VAC external output(0.7 amp max)

T/T 1

T/T 2 orCombi: recirc timerSolo: Indirect tank

thermostat

LWCO/ safetyNC

Outdoor Reset Temp Sensor Solo Only:

Indirect tank thermistor

(10KΩ)

Note Jumper!

Bottom left corner of PCBColor coding

matches control to pump assignments


Setup & Commissioning


This 15 minute program will clear air from

the boiler

Recommend 20 psi in boiler at

commissioning

This does not run automatically!

To initiate:

• Press the DHW then CH buttons together

OR

Air Purge (De-aeration)

Air purge required for new installations or when system pressure has dropped

<13 psi. Any resulting damage will not be covered under warranty.

I-Setup

• Press and hold top left test button on PC board

• The maintenance icon will display while activated

• Use same sequence to deactivate


Pressure requirements

13 psi

Minimum required for normal operation

I-Setup

20 psi

Recommendation for

fill valve setting

7-13 psi

Warning 430 /

Reduced DHW

<7 psi

Fault 430

Boiler inoperable

13 17

20

26

LWCO not required

per NFPA 54 due to

this pressure control

technology

7

5


User Menu: Setting CH Setpoint Temp

I-Setup

• Press . The CH icon will display

• Use the arrows to adjust value

• IMPORTANT: The select button must be

used to enter the value

CH Max Supply Temp

IMPORTANT: CH temp adjustment only affects

operation when Outdoor reset curve 4 is

selected

• Parameter 01, value D


Boiler CH Mode of Operation

I-Setup

CH Mode ON

IMPORTANT: CH mode is a special mode of operation

that allows the boiler pump to run continuously

• Boiler does not fire from room thermostat call for heat

• Boiler fires based on water temp

• This is a common design practice in Europe

• Most North American systems do not operate to

this design

• To engage this mode, DIP SW 2 must be turned ON

• The bottom-left button turns the boiler ON/OFF in this

mode

• This is the ONLY time this LED will be illuminated


User Menu: DHW Operation & Setpoint Temp

I-Setup

DHW Supply Temp

• DHW LED MUST be ON for any DHW

operation

To adjust DHW temperature:

• Press until the LED above it illuminates

• The DHW icon displays

• Combi icon

• Solo with Indirect Tank icon

• Use the arrows to adjust value

• IMPORTANT: The select button must be

used to enter the value


Eco Mode

I-Setup

Combi Models

Eco mode disables the DHW comfort mode

• Comfort mode keeps the boiler warm and allow

quickest delivery of hot water to the fixtures.

Solo Models

When Eco is enabled:

• During call for heat

• When return temp is 75% of target temp

• Flame is off for five (5) minutes

• Every 15 or 30 minutes depending on Parameter 48

• If call ends, process resets

Call for

heat

begins

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70

OFF OFF OFF


Altitude setting must be complete before

operation. See manual for complete

details.

Setting Altitude

I-Setup

Altitude DIP SW 6 DIP SW 7

0 – 2,000 ft (Default) OFF OFF

2,001 – 5,400 ft ON OFF

5,401 – 7,700 ft OFF ON

7,701 – 10,200 ft ON ON

No gas pressure setting required after setting altitude


Inlet gas pressure testing:

• Leak test all connections before

operation.

• It is recommended that all gas

pressure regulators are > 6 ft.

upstream of the boiler

• Operate all appliances on the gas

service at full power to test load gas

pressure at the boiler gas valve test

port (see figure at right)

Fuel TypeMinimum Load Gas Pressure

In. w.c.Maximum

In. w.c

NG (Natural Gas) 3.5” 10.0”

LPG (Liquid Propane) 8.0” 13.5”

Gas Valve Inlet Test Port

Gas Pressure Testing

I-Commissioning


Flue Gas Testing

I-Setup

Due to the innovative self-compensating zero governor gas

valve, Rinnai does not require flue gas testing on I-Series

boilers

• Test port is not provided

• If testing is required by utilities, state, or local jurisdictions:

• Measure at termination

• Provide test port in venting (see below)

• Ensure cover is on unit

• Use local code-accepted values as needed (usually a

CO number)Plan Ahead!

Ensure venting

has a test port

if needed!

2” X

2” X

½”

PV

C w

/plu

g


Outdoor Reset Technology

I-Setup

Bo

iler

Su

pp

ly

Tem

pera

ture

Outdoor Temperature 0o F70o F

104o F

180o F

Low

High

Bu

ild

ing

Hea

t L

oss

The boiler uses the outdoor sensor to improve efficiency by matching the heat output to the heat loss of the building


Q: When is it acceptable to disable outdoor reset?

A: Never

I-Setup

With outdoor reset

Without outdoor reset


Outdoor Reset Sensor

An outdoor temperature sensor is included with every I-Series boiler

I-Setup

Sensor Installation

Recommend Required

North side of structure Not in direct sunlight

5-10 feet above ground Areas prone to snow drifts

DIP SW 1 Must be OFF (default)


Outdoor Reset Curve – Presets (Parameter 1)

I-Setup

80 75 70 65 60 55 50 45 40 35 30 25 20 15 10 5 0 -5 -10 -15 -20

200

190

180

170

160

150

140

130

120

110

100

90

80

70

60

Outdoor Temp F°

Boile

r S

upply

Tem

p F

°

Curve 1 (default) – Baseboard, (value A)

Curve 2 – Staple up Radiant (Value B)

Curve 3 – High temp AH, Undersized Baseboard

(Value C)

Curve 4 – Custom (next slide, Value D)


Outdoor Reset Curve – Custom Curves

I-Setup

80 75 70 65 60 55 50 45 40 35 30 25 20 15 10 5 0 -5 -10 -15 -20

200

190

180

170

160

150

140

130

120

110

100

90

80

70

60

Outdoor Temp F°

Boile

r S

upply

Tem

p F

°

180°F max temp

104°F min temp

Curve 4

• Target Setpoint (max temp)

• Slope bottom = max temp - 36°F• Slope peak is at (outdoor temp of) 14°F

• Slope bottom is at (outdoor temp of) 68°F

• Min temp will not fall below 104°F


Outdoor Reset Curve – Min/Max Temp Guidelines

I-Setup

Type of Heat Emitter Typical Minimum

Supply Temperature

Typical Maximum

Supply Temperature

Hydronic Air Handler 120 - 140°F 140 - 180°F

Unit Heater 130 - 140°F 160 - 180°F

Base Board convectors 100 - 140°F 140 - 190°F

Cast Iron / Panel Radiator 90 - 120°F 140 - 180°F

Undermount Radiant 100 -120°F 120 - 150°F

Poured concrete radiant 80 - 90°F 110 - 130°F

*NOTE: These are basic guidelines. Please check with manufacturer of emitter or

consult your heating design engineer.

Note: I-Series boilers have a minimum temp of 104°F.

A mixing valve is needed for lower values.


Outdoor Reset – Boost Feature

I-Setup

80 75 70 65 60 55 50 45 40 35 30 25 20 15 10 5 0 -5 -10 -15 -20

200

190

180

170

160

150

140

130

120

110

100

90

80

70

60

Outdoor Temp F°

Boile

r S

upply

Tem

p F

°

180°F max temp

Boost

Parameter 2 – when on, if call for heat

exceeds 30 or 60 minutes, boiler temp raises

to max temp (of curve) until call ends• A = OFF

• B = 30 minutes

• C = 60 minutes

104°F min temp


DHW Recirculation (Combi Models)

Pump 2 can be designated for DHW recirculation

I-Setup

DIP SW 3 Must be ON (default is OFF)

Recirculation configuration can be either of the following (set Para 12):

• Crossover – Value A (Default)

• Thermal bypass is not included

• Dedicated Return Line –Value B

Thermal Bypass for

Crossover Recirculation

Part# 107000143



I-Setup

Dedicated Return Setup

• Ensure check valves, isolation valves, and expansion tank are installed correctly

• Pump ON until DHW return water is setpoint - 6°F (or 20 minutes)

• Pump OFF based on DHW setpoint temp (see table)

DHW setpoint

（°F）Pump OFF

（minutes）100 28

110 19

120 14

130 11

140 9

• Pump size is dependent on pressure loss of

loop

• GTK15, GTK03, Grundfos 15-55, or

equivalent are adequate in most applications



I-Setup

Crossover Setup

Thermal bypass must be installed at farthest fixture

• Recommend only one per system

• Pump ON until crossover valve closes (DHW flow ≤ 0.26 GPM)

• Not to exceed 20 minutes

• Pump OFF for 10 minutes

• Pump size is dependent

on pressure loss of loop

• GTK15, GTK03,

Grundfos 15-55, or

equivalent are

adequate in most

applications



I-Setup

A timer relay can be connected to set schedule

• Connect to T/T2 terminal

• DIP SW 3 must be ON (default)

• Para 13 must be set to A (default)

Combi: Pump 2 as DHW recirc pump

24 VAC external output(0.7 amp max) Combi: T/T 2 as

recirc timer

DIN 930247

IMPORTANT: Improper wiring of external devices to boiler can damage both the device and the boiler!


Simultaneous CH and DHW (Combi models)

Settings to operate CH and DHW simultaneously:

I-Setup

DIP SW 4 Must be ON (default is OFF for DHW Priority)

Parameter 14

• If CH target is > 140°F, simultaneous operation will be disabled

• This can protect heat emitters, flooring, etc.

• ON (default) – Value A

• OFF – Value B

• If turning this para OFF, a zone mixing valve or station may be required!

Parameter 15

• Additional CH during simultaneous operation

• Proportional valve favors CH

• OFF (Default) – Value A

• ON – Value B


Indirect DHW Tank (Solo models)

I-Setup

DIP SW 3 – designates Pump 2 terminals for indirect tank

• Must be ON (default)

DIP SW 4 – sets type of temp control

Solo: Z2 or Indirect tank pump or Diverter valve

(120 VAC / 2.0 amp max)

T/T 2 orSolo: Indirect tank

thermostat

Solo Only:Indirect tank thermistor

• Thermistor (OFF) – temp set

at controller

• Thermostat/Aquastat (ON) –

on/off value (set at tank)

• Boiler Supply temp default is

180°F for both (see para 30 to

lower)



Settings to operate CH and DHW simultaneously:

I-Setup

Parameter 33

• Value A (default) – DHW priority

• Value B – Simultaneous CH & DHW

Parameter 35

• If CH target is > 140°F, simultaneous operation will be disabled

• This can protect heat emitters, flooring, etc.

• ON (default) – Value A

• OFF – Value B

• If turning this para OFF, a zone mixing valve or station may be required!



DHW Priority Recovery Limit

I-Setup

Parameter 34

• Ensures system does not dwell in DHW with no CH

• Value is time limit of DHW priority before returning to CH

• Value A (default) – 60 minutes

• Value B – 40 minutes

• Value C – 90 minutes

• NOTES:

• After 60 minutes of CH, if there is still a DHW demand, system will switch

• Not applicable with simultaneous DHW and CH

• This feature also aids in CH freeze protection


Accessing the Parameter Menu

I-Setup

• Hold the red test button for five seconds, then

• Press the MODE button

• Press UP or Down arrows to locate a parameter

• Press the Select button to allow changes tothat parameter

• Press UP or Down arrowsto change value

• Press Select to save

• Press red test button ORMode button to exit


I-SetupKey Installation-Related Diagnostic Codes (see manual for full list)

Fault Description Detail

100Air supply / Exhaust /

Condensate trap blockage

Check condensate trap, ensure air gap and no 2nd trap,

check entire vent system

110 Ignition Failure Check incoming gas pressure, vent system, room air

requirements, gas type, etc120 Flame Failure

170 Venturi BlockageCheck for condensate / vent blockage. Reset code per

tech data sheet.

181 Indirect Tank Temp (Solo)Ensure Indirect Tank temp sensor and system is setup

correctly (including parameter 30)

250 Condensate pump safety Inspect condensate pump and its safety circuit

371 Indirect Tank Thermistor Ensure DIP SW 4 is set correctly

393 Outdoor Reset Sensor Verify connection, DIP SW 1 setting

430 CH High/Low Water Pressure Warning: 7-13 psi, Lockout <7 psi, >30 psi

443 Low Water Cutoff circuit open Ensure circuit or jumper is not open

540 High Exhaust tempVerify vent material / exhaust temp per service menu, DIP

SW 8, & Para A2 settings

631DHW Recirculation Pump

(Recirc flow too low) (Combi)

Ensure DHW system is setup correctly, including all

parameters (esp. para 12)


I-SetupInstallation Issues with no Diagnostic Code (see manual for full list)

Description Detail

Nothing happens when

DHW flow is activated

Verify DHW piping, clean inlet filter, etc

Check DHW flow rate in performance service menu

Decreasing or fluctuating

DHW flow or temp

Verify gas pressure & venting

Verify DHW piping, clean inlet filter, etc

Boiler does not fire with a

call for heat

Supply or return temp may be too high (verify system piping

including hydraulic separator configuration)

DHW recirc not operating

(Combi)

Ensure DHW recirc pump configuration and wiring

Verify DIP SW 3 and PARA 12 & 13 settings

Verify any external timer connections & settings

Boiler does not respond to

call from indirect tank temp

sensor

Tank priority time has ended, verify para 34

Nothing happens when CH

temp is raised on controller

If curve parameter (01) is set to A, B, or C (curves 1-3), this is

normal. Set to D (custom curve 4) to allow CH temp adjustment

at controller.

CH LED will not illuminate

CH heat mode is continuous pump. This is not a customary

operation. DIP SW 2 must be adjusted to allow this. The CH

icon (not LED) is used to determine if heating is active.


I-SetupInstallation Issues with no Diagnostic Code (see manual for full list)

Description Detail

Simultaneous CH & DHW

not operating correctlyVerify DIP SW 4 setting and all related parameters

Supply temp ≠ Controller

setting

This is normal with outdoor reset control

Simultaneous CH/DHW operation, supply temp may = DHW

temp

CH capacity is insufficient

Verify system installation and settings, DIP SW and Para

settings (including outdoor reset settings)

During simultaneous CH/DHW operation CH volume is reduced

Pump or fan operating

with no demand

Pump/fan can operate during freeze protection or post

combustion


I-SetupKey Installation DIP SW Settings

DIP SW Description Default

1 Outdoor Reset ON/OFF ON

3Combi: Pump, T/T 2 = DHW Recirculation

Solo: Pump, T/T 2 = Indirect Tank

C: OFF

S: ON

4Combi: Simultaneous DHW and CH

Solo: Indirect Tank Thermistor or Thermostat

C: DHW Priority

S: Thermistor

6/7 Altitude ≤ 2000’

8 Vent type for high temp applications PVC

Key Installation Parameters

Parameter Description Default

00 Pressure / Temp cycle on display ON

01 Outdoor Reset Curve Curve 1

02 CH Boost (with outdoor reset) OFF

03 Warm Weather Shutdown OFF


I-SetupKey Installation DIP SW / Parameters

Parameter Description Default

10 Combi: Max DHW Setpoint 120°F

12Combi: DHW Recirc type (Crossover / Dedicated

Return)Crossover

13 Combi: DHW timer in use ON

14Combi: CH temp limit while in simultaneous with

DHWON

15 Combi: CH boost while in simultaneous with DHW OFF

33 Solo: Simultaneous CH & DHW with Indirect Tank OFF

34 Solo: Indirect Tank Priority Time 60 minutes

35 Solo: CH temp limit while in simultaneous with DHW ON

44 Freeze Protection for Z1/Z2 pumps OFF

A0 Gas Type NG

A2 Vent Material Used (with DIP SW 8) PVC


Maintenance


Rinnai Annual Maintenance

• Visual inspection of unit and surroundings

• Gas pressure & venting

• System pressure and components

Clean and inspect the condensate

trap

Visually inspect flame

I-Maintenance

Verify with end user comfort

and operational satisfaction

View fault code history

(Press Then )


Rinnai Maintenance (as needed)

Clean and inspect the DHW inlet filter

Clean and inspect insect

filter

I-Maintenance

Flush the DHW plate heat exchanger

(when LC code appears or proactively as needed)


Simple Teardown Demonstration

I-Maintenance

All parts designed for ease of service


I-MaintenanceKey Installation Performance Data Menu Items

(See manual for all items)

Menu # Description

1 PSI

2 DHW Flow Rate (X 0.1 GPM)

3 Supply Temp

4 Return Temp

6 Exhaust Temp

7 Outgoing DHW Temp

8 Inlet DHW Temp

153-Way Valve Position (0=mid, 1=DHW,

2=CH)

31 Outdoor Temp

41 Combustion Hours (X 10)

42 Combustion Cycles (X 100)

To enter Performance

Data Menu

Press 1st, then

simultaneously


Applications


Common System Components

I-Applications

Boiler Pump

(solo models)


Single Zone (Combi Model)

Outdoor Sensor

I-Applications


Two-Zone system (Combi Model)

Outdoor Sensor

I-Applications


Outdoor Sensor

I-Applications

Multi-Zone system (Combi Model)


Two-Zone system with Indirect Hot Water (Solo Model)

Outdoor Sensor

Boiler Pump

Indirect Tank Pump

T/T 1 to Zone

Controller

T/T 2 to Indirect Tank Thermostat

& Tank Thermostat

I-Applications


Two-Zone system with Indirect Hot Water (Solo Model)

Outdoor Sensor

Boiler Pump

Indirect Tank Pump

T/T 1 to Zone

Controller

& Tank Thermistor

Indirect Tank Thermistor

I-Applications


Rinnai Dealer Program


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to partner with

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rinnai i-series condensing boiler i-series... · 2019-08-29 · enhancing lives by changing the way...

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