Rinnai M-Series Condensing Boiler Level II Installation Training ENHANCING LIVES BY CHANGING THE WAY WATER IS HEATED

Transcription

1 Rinnai M-Series Condensing Boiler Level II Installation Training 1

2 Agenda Rinnai Resources The new Rinnai M-series Boiler Features and Benefits Installation Fundamentals Boiler Set Up & Commissioning Maintenance & Troubleshooting 2

3 About Rinnai Founded in 1920 Based in Japan 20 Subsidiaries/86 Sales Offices Globally World s #1 selling brand of Tankless Water Heaters North America headquartered in Peachtree City, GA The highest standards of quality Over 600 R & D Engineers Rinnai is a leader in advanced automation and precision assembly Every product is tested under live conditions before shipping Rinnai America has its own state-ofthe-art CSA Certified Testing Lab & CSA Accredited Technicians 3

4 About Rinnai New North American Headquarters R&D Innovation and Training Center New building over 2X current sq. ft. ISO Certification 9001 Scope includes latest certification for PTC HQ, assembly area, & distribution centers US Tankless Manufacturing April 2018 Non-condensing Water Heaters Will reach >100,000 units by 2019 New 60+ Acre Production Facility in Griffin, GA 4

5 Service & Support Customer Service Applications Support Parts Department General calls, consumer questions, etc. General sizing questions, commercial applications. Order Service Repair Parts Available from 8 am to 8 pm EST, Monday - Friday Warranty Department Warranty claim issues. Available from 8 a.m. to 5 p.m. EST, Monday- Friday Tradesman: customerservice@rinnai.us Wholesaler: sales@rinnai.us 5

6 Service & Support CONTRACTORS ONLY DIRECT LINE RINNAIS ( ) Technical Support Department 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 Leave a message with on call agent You will get a call you back within 20 minutes 6

7 Training Website or trainingevents.rinnai.us 7

8 Rinnai Dealer Program 8

9 Features 9

10 M-Series Features Energy Star: 95% AFUE 8 Models 4 Combi (60, 90, 120, 160 MBH) 4 (Solo) Heat Only (60, 90, 120, 160 MBH) Improved DHW capacity: M90C, 120C 160C: F rise M60C: F rise New User Interface: Full Text Graphical Display Improved Serviceability Outdoor Sensor Included Modulating Boiler Pump Integrated Freeze Protection CSA Certified Low Lead 10

11 M-Series Features Solo Models Model AFUE Max Input Min NG Input M060S M060C M090S M090C M120S M120C M160S M160C 95% 95% 95% 95% 60,000 BTU 17.6 kw 17,000 BTU 90,000 BTU 5.0 kw 26.4 kw Turndown Ratio (NG) 3.5 : : : 1 120,000 BTU 35.2 kw 160,000 BTU 23,500 BTU 6.9 kw 5.1 : kw 6.8 : 1 Combi Models Model M060C M090C M120C M160C DHW Performance F T (10L/min@39 C T) F T (16L/min@39 C T) 11

12 M-Series Features Exclusive Leading Edge Design Features Stainless Steel Heat Exchanger Proven Water Tube, Down Fire Design Self Cleaning smooth tube Durable brazed joints 20 passes /89 Tubes Low NOx Emissions 12

13 M-Series Features Heat Exchanger Design Superior efficiency & Low NOx simultaneously Compact down-fired, water tube heat exchanger Heat Exchanger orientation Superior Manufacturing for Durability Vacuum oven brazing process Competitors stainless heat exchangers are welded at high temperatures 13

14 M-Series Features Pre Mix Combustion Rinnai Designed & Manufactured Ceramic Burner Rinnai has manufactured burners for over 50 years Rinnai has sold millions of burners around the world 14

15 M-Series Features EBM Papst Negative Pressure Gas Valve Allows full power at 3 minimum w.c. of NG More tolerant of lower gas pressures and larger pressure drops EBM Papst Combustion Fan Quiet & powerful fan automatically adjusts to longer vents Fan speed adjustments overcome higher elevations with less de-rating EBM Papst Integrated Venturi Pre-mixes the gas and air Ensures safe, clean, reliable and efficient combustion Intake Air Silencer Low Noise: dba Compare to normal speech at 3 feet: 70 dba 15

16 M-Series Features Grundfos Modulating Pump Adapts boiler flow rate to system flow, improving thermal efficiency Quiet and Powerful Low electrical consumption and improved efficiency No special piping needed for single zone systems. Up to 75 of Copper Fin Tube Baseboard Up to 60 to a hydro-coil air handler Bypass Valve Protects boiler pump when direct coupled 16

17 M-Series Features Asymmetric Flat Plate Heat Exchanger Larger passageways for higher boiler side flow Corrugation boosts efficiency & prevents scaling/blockage DHW Flow Sensor 0.4gpm Water wheel design prevents sticking DHW Temperature Sensor Reads and controls DHW outlet Temperature Brass 3-way valve cartridge 120v 3-way valve actuator Diverts flow based on demand type 17

18 M-Series Features Combi DHW Operation 18

19 M-Series Features Combi DHW Capacity: How much hot water is it? What is the average shower temperature (in Fahrenheit)? What is the average cold water temperature in the US (in Fahrenheit)? 106 F 58 F Based on the above, what is the average ΔT What is the average shower flow rate in GPM? = 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? Max. DHW flow (gpm) # Showers ΔT 48 F ΔT 64 F ΔT 70 F (106 F hot/58 F cold) M060C (with 1.9 GPM remaining) M090C M120C M160C (1.9 GPM remaining) Models 19

20 M-Series Features Combi DHW Capacity: How much hot water is it? Using the data below, how many (2.1 GPM, 106 F) showers will each boiler model supply in this area? Groundwater Temp Map Max. DHW flow (gpm)) ΔT 48 F ΔT 64 F ΔT 70 F M060C M090C M120C M160C Models IMPORTANT: A mixing valve must be installed to ensure constant hot water temperatures are delivered at all times. 20

21 M-Series Features Compact, Lightweight Smaller footprint 10lbs less than E Series 30% less volume than E Series Flexible Heating Connections ¾ & 1 NPT adapters for connections More Space between connections than E Series Flexible Gas Connections & Simplified Conversions Pre-Mix Combustion; 3 min w.c for natural gas Quick-n-Easy LP Gas Conversion (included) Flexible Venting Option 2, 3 PP, PVC & concentric adapters included PVC, CPVC, PP, SS & concentric venting approved Low Profile and more terminations Approved Plug & Play Wiring 120V Plug (6 cord) Terminal block type connections Intuitive Control New user interface with easy set up Scroll type menu navigation with knob 21

22 M-Series Features Simplified Control Larger Display (Cool Blue) More informative at first glance Full text, graphic and icon display Integrated power switch Easier navigation controls Scroll knob BACK button OK button RESET button Chimney sweep (flue gas testing) Plain English, French (and other language) menus & messages Limited Parameters for ease of installation set up 22

23 M-Series Features Simplified Control Date & Time Outdoor Temp Heating Target Temp DHW Target Temp Burner Indicator Power Bar Pressure (psi) DHW Mode Current Operating Status Large Information Rich Display 23

24 M-Series Features Simplified Control Each Fault Code Includes: Plain text description Recommended solution Date & Time Stamp (Optional) Contractor name and phone number The last 10 codes are stored 24

25 M-Series Features Product Warranty Description Residential Commercial Primary Heat Exchanger 12 YRS 5 YRS Boiler Parts 2 YRS Labor 1 YR Warranty covers: Defects in materials/workmanship Indoor installations installed per the manual and all applicable code Warranty DOES NOT cover failure due to: Accident, abuse/misuse, alteration/misapplication Improper Installation/Maintenance Poor water quality, scale issues, freezing Please refer to the Documentation Set for full warranty details and guidelines 25

26 M-Series Features Check Your Knowledge What installation advantages does the M boiler have over the E boiler? What performance advantages does the M boiler have over the E boilers? What is the warranty terms of the M boiler in a residential application? What is the AFUE of the M boiler? Which M-Series combi model boilers are capable of providing hot water to at least 2 showers simultaneously anywhere in the US? Longer vent maximums More space between connections Smaller/lighter units Self adjusts to vent length Higher DHW Output Higher Heating Output (BTU & temp) Control Dashboard Display Precise DHW Temp Control 12 years hex 2 years parts 1 year - labor 95% M90C M120C M160C 26

27 Installation 27

28 M-Installation Recommended Installation Tools For installation of the boiler these items are recommended: Large adjustable wrench & pipe wrench 5 in 1 screwdriver Flue gas analyzer and manometer Drill and hole saws Level Wire strippers ph meter or test strips Installation manual Other Helpful Tools Smart phone / tablet Thermostat screwdriver Appliance dolly Empty 5gal. bucket, washing machine hoses Rinnai Boiler Tool Kit. (Part # ) 28

29 M-Installation Connections Model Dimensions (W x H x D) Heat Only Weight Combi Weight Heating 3/4 M060 M090 M120 M x 27.5 x x 70 x 27 cm 77 lbs (35 kg) 82 lbs (37 kg) 82 lbs (37 kg) 88 lbs (40 kg ) DHW 1/2 Gas 1/2 29

30 M-Installation Boiler Accessories: What s in the Box? Boiler installation/user and conversion manuals 3 x 5 concentric vent adapter Twin pipe 80mm (3 PP) vent adapter Installed on boiler Two 3 PVC vent adapters Two 2 PVC/PP venting adapters Two 1 bushings for system connection Two 3/4 bushings for DHW connection 30 PSI pressure relief valve NG to LP conversion kit 3/4 bushing for gas connection Boiler condensate trap kit Outdoor temperature sensor Wall mounting bracket (and template) Electrical connectors: Installed on boiler control 30

31 M-Installation Location Location Location! LOCATION CHECKLIST Verify vent length equivalency If applicable, verify room air is sufficient Ensure clearances to combustibles Ensure service access Verify water supply quality Verify grounded 3-prong outlet Ensure all local codes are met 31

32 M-Installation Mounting / Clearances Wall bracket is 16.5 and mounts to 16 on center studs Bracket allows adjustment ½ side to side to align venting Mounting: Level bracket and fix to wall Lift boiler and drop back lip over the bracket Provide Clearances 2 minimum clearance to combustibles 12 service clearance recommended on left side and in front of the boiler 32

33 M-Installation Approved Venting Materials 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) 33

34 M-Installation What is the vent equivalency? Is this vent system within specification? 3/5 Concentric PP Vent Equivalency Examples PP PVC / CPVC 90 Elbow Elbow /5 Condensing Horizontal or Vertical Termination Kit IPEX PVC Concentric Kit Maximum Equivalent Vent Lengths Concentric PP PVC / CPVC / PP Model 2/4 3/5 2 PVC 3 PVC M060/M090S M090C/M120/M Vent equivalencies vary Refer to I/O manual for details M090S 34

35 M-Installation 2 PVC w/ipex concentric termination 3 M090C What is the vent equivalency? Is this vent system within specification? Vent Equivalency Examples PP PVC / CPVC 90 Elbow Elbow /5 Condensing Horizontal or Vertical Termination Kit IPEX PVC Concentric Kit 20 Maximum Equivalent Vent Lengths Concentric PP PVC / CPVC / PP Model 2/4 3/5 2 PVC 3 PVC M060/M090S M090C/M120/M Note: In 2 pipe systems, use longest pipe (in/out) to determine maximum 35

36 M-Installation Installing the Concentric Venting Adapter The boiler comes with the 2 pipe adapter installed. To install the concentric: Twist the 2 pipe adapter counterclockwise, lift straight up Insert 3X5 concentric adapter, twist clockwise to lock in place 3x5 to 2x4 Reducing Elbow New 2 x 4 horizontal concentric vent kits will fit on the boiler concentric adapter 36

37 M-Installation Concentric Venting Green Label = Condensing Black Label = Non-Condensing DO NOT USE! Roof Termination Sidewall Termination WARNING: Horizontal terminations extending too far off the wall allow exhaust to recirculate into the air intake which could damage the boiler PP can easily be cut with hand saw or snips. Be sure to deburr all cuts Cut Internal PP pipe 7/16 (10mm) Longer than Outer Pipe 37

38 M-Installation Two Pipe 3 Venting The boiler comes ready for 3 (2-pipe) PP venting 3 PP For PVC Venting: Install 3 PVC Adapters (included) 3 PVC 38

39 M-Installation Two Pipe 2 Venting For 2 PVC or 2 PP: Install gray 2 adapters into PVC adapters. These adapters fit 2 PVC and 2 PP (Included) 2 PVC 2 PP 39

40 M-Installation Room Air Intake Room Air Filter (12 equivalency) Room Air Elbow & Screen Room Air for combustion may only be used if adequate fresh air is available 50 cubic feet per 1,000 btu If not, additional measures must be taken to provide adequate air. Most M boiler models require 8000 cu ft of space (1000 ft 2 with an 8 ft ceiling) Air Filter part number:

41 M-Installation Vent Termination Options Two-Pipe Low Profile Termination Two-Pipe Sidewall Concentric Two-Pipe Vertical Concentric PP flexible Liner (PP or Metal) Room Air 41

42 M-Installation Vent Termination Options Room Air Two-Pipe Room Air Two-Pipe Sidewall Termination Sidewall Termination Vertical Termination Vertical Termination 42

43 M-Installation Sidewall Vent Termination Clearances See next slide for NFPA required vent terminal clearances 43

44 Ref M-Installation Sidewall Vent Termination Clearances (Direct Vent) Clearance ANSI Z223.1 (NFPA 54) or Rinnai Requirement (see manual) U.S. Direct Vent Canadian Direct/Non- Direct Vent A Clearance above grade, veranda, porch, deck, balcony or expected snowline 12 (30 cm) 12 (30 cm) B Clearance to window or door that maybe opened 12 (30 cm) 36 (91 cm) H Clearance to side of center line extended above meter/regulator assembly [1] 36 (91 cm) within a height 15 (5 m) above the meter/regulator I Clearance to service regulator vent outlet 36 (91 cm) 36 (91 cm) J Clearance to non-mechanical air supply inlet to building or the combustion air inlet to any other appliance (91 cm) K Clearance to a mechanical air supply inlet 36 (91 cm) above if within 10 feet (3 m) horizontally 6 (2 m) L Clearance above paved sidewalk or driveway located on public property Not Permitted [2] 7 (2.25 m) M Clearance under veranda, porch, deck, or balcony** 12 [3] 12 (30 cm) 1. Clearances must comply with local building code and gas supplier requirements 2. Also not permitted above a shared walkway or driveway between located between two single family dwellings. 3. Permitted only if area is fully open on a minimum of two sides beneath the floor. 44

45 M-Installation Sidewall Vent Termination Clearances (Room Air) Ref Clearance ANSI Z223.1 (NFPA 54) or Rinnai Requirement (see manual) U.S. Non-Direct Vent Canadian Direct/Non- Direct Vent A Clearance above grade, veranda, porch, deck, balcony or expected snowline 12 (30 cm) 12 (30 cm) B Clearance to window or door that maybe opened 4 36 (91 cm) H Clearance to side of center line extended above meter/regulator assembly Local Code 36 (91 cm) within a height 15 (5 m) above the meter/regulator I Clearance to service regulator vent outlet 36 (91 cm) 36 (91 cm) J Clearance to non-mechanical air supply inlet to building or the combustion air inlet to any other appliance 4 36 inches (91 cm) K Clearance to a mechanical air supply inlet 3 feet (91 cm) above if within 10 feet (3 m) horizontally 6 feet (2 m) L Clearance above paved sidewalk or driveway located on public property Not Permitted [2] 7 feet (2.25 m) j M Clearance under veranda, porch, deck, or balcony 12 [3] 12 inches (30 cm) k Tech Tip: Some clearances are increased when using room air in the US (see manual for details!) Example: Clearance to window/door/mechanical inlet is 4 vs 12 45

46 M-Installation Sidewall Vent Termination Considerations AVOID Terminations near Dryer Vents Commercial Cooking Exhaust Air inlets into the building Where exhaust cannot easily dissipate NEVER Install terminations: Over Public Walkways Near Soffit/Crawl Space Vents where condensate can be problematic Where condensate could damage regulators, PRV s, or other equipment Where exhaust can enter the soffit vent or reenter the combustion intake vent NOTE: If more stringent, local codes will supersede the above 46

47 M-Installation Multiple Horizontal Vent Terminations 47

48 M-Installation Multiple Vertical Vent Terminations 48

49 M-Installation Gas Connection In the absence of local code, refer to NFPA 54 (US) or B149 (Canada) Gas pressure regulator recommended to be at least 6 feet from boiler Gas meter and regulators must be sized for the total building load Install a sediment trap and manual gas shut off valve as shown below ½ brass MNPT gas connection ¾ (gas) brass bushing included Size gas appliance connectors for boiler BTU Refer to the installation manual for gas line sizing details, and follow local code 49

50 M-Installation Gas Line Sizing Example Natural Gas Using the provided table and example, what size gas line is required for the following installations? 10 ft 50 ft 80 ft 50

51 M-Installation All M-Series Boilers ship configured for Natural Gas This Simple & Quick LP conversion kit is included with each boiler 51

52 M-Installation NG to LP Gas Conversion WARNING: Refer to Gas Conversion manual for complete instructions Remove internal gas line by loosening nuts from both ends Insert brass orifice with O-ring into venturi. Re-install gas line & tighten nuts Install EEPROM chip on main board & turn on boiler Hold button 7 seconds to bypass air purge Flash Memory Detected is shown. Press After boiler restarts, turn off power and remove EEPROM chip Test flue gases, adjust O 2 setting (see manual) Place new data plate over original 52

53 M-Installation DHW Connections ½ Male NPT connections Optional ¾ bushings provided A Thermostatic Mixing Valve is required on combi models DHW Pressure Range: psi 150 psi or lower PRV is required An isolation valve kit is recommended Rinnai Isolation Valve Kit MIVK-T- LW 53

54 M-Installation Heating System Connections ¾ Male NPT connections 1 bushings provided Required for 120/160 models Optional for 90/60 models Temperature & Pressure Gauge (1/4 NPT) provided 30 psi PRV provided Heat Exchanger Rated to 45psi Determine if primary secondary boiler piping is needed. 54

55 M-Installation Primary Secondary Piping: What does it do for you? When a water tube boiler is directly connected to the hydronic system, the maximum system flow and heating capacity may be reduced. Primary secondary piping allows connected hydronic loops to operate with independent flow rates. The system can have a higher flow rate than the boiler. 55

56 M-Installation Primary Secondary Piping: Direct Coupled Boiler Piping Advantages Simple, less costly installation. No external pump needed Great for single zone systems Disadvantages System flow is limited to boiler pump head, which can limit heating output. Not allowed when system pressure drop is >10.4 ft (4.3 psi). Tech Tip: Because of high flow requirements, M160/M120 boilers must be piped primary secondary and can not be direct coupled. 56

57 M-Installation Available Pump Head If the boiler is operating at 6 GPM: How much pressure drop is in the boiler? How much pump head room remains for a direct-coupled system? Extra Credit: How is 6 GPM determined? 57

58 M-Installation Primary / Secondary Piping: Closely Spaced Tees and LLHs Advantages Ensures proper flow to heating zones and with external pump(s) Gives correct boiler flow and full boiler output power Allows for multi temperature systems Disadvantages More installation labor and materials Reduced system efficiency when boiler flow is higher than system flow 58

59 M-Installation 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 59

60 M-Installation Primary Secondary Piping Options Rinnai offers as a prefabricated accessory: Part #

61 M-Installation Primary Secondary Piping Options Third Party Boiler Plumbing Kits and Low Loss Headers Boiler Plumbing kits are available from several manufacturers that include premade closely spaced tees. Hydraulic Separators and LLHs are available that also function as air separators and dirt traps. 61

62 M-Installation Condensate Drainage Internal condensate drain assembly must be fieldinstalled (included with boiler) Refer to manual for details 62

63 M-Installation Boiler Control Line Voltage Connections **Do Not USE** 120vac Input (Power cord factory installed) **Do Not USE** System Pump Relay (120vac Output) Power source must be properly grounded Do NOT use an extension cord Ensure all connections are correct NOTE: System Pump Relay is active whenever boiler pump is energized 63

64 M-Installation Boiler Control The boiler control (top spine of assembly includes screw terminal plugs for easy connections External Safety: Optional for NC LWCO or high limit. DHW: (Solo models) Optional for aquastat, 10k Ω indirect tank sensor or relay end switch. OT Bus On / Off: For thermostat or multi-zone relay end-switch Outdoor temp sensor: Included with boiler 64

65 M-Installation Optional DHW 3-way valve for M-Solo Boiler Connections for (3 rd party) DHW 3-way valve control is on back of control assembly (solo boilers only) Follow valve manufacturer s guidelines Example: VC4011ZZ11 Honeywell, 2-position, line volt actuator VCZMR6100 Honeywell, 1" 3-Way Female NPT Valve Assembly 65

66 M-Installation Check Your Knowledge What is the minimum incoming gas pressure allowed for NG M-Series boilers? 3 w.c. (dynamic / full load) Is the Ubbink PP flexible liner listed as an approved vent system for M-Series boilers No, but it doesn t have to be since it is used with room air (Category IV) M-Series 2-pipe vent systems require an average vent length (between intake and exhaust) to be used to determine equivalency? True/False: M90 boilers can be direct coupled to a heating system? What is the diameter for CH connections? What is the diameter for DHW connections? No, use the longest length True, M60/M90 boilers have enough pump head remaining for direct coupling. ¾ male NPT / 1 bushings included (& required for 120/160 models) ½ NPT / ¾ bushings included When is the system pump relay electrical connection energized? Anytime the internal pump is energized (not just CH demand) 66

67 Setup & Commissioning 67

68 M-Setup Initial Power On When first powered up, the control will prompt to set language, time, date & units. 1. Select your language from the drop down menu. Press OK to save. 2. Date and Time will be displayed Select a digit with the scroll wheel and open by pressing OK Scroll to adjust digit with scroll wheel and save setting by pressing OK Selecting Auto on Legal Hour will automatically adjust time for daylight savings. Save all changes by selecting SAVE at the bottom of the screen and pressing OK 3. Set the measurement units to USA or International (Celsius and Bar). 4. The boiler will then automatically run a 7-minute air purge program. 68

69 M-Setup User Menu: Setting the Time If time has not been set it will flash Press OK Complete Menu Time & Date Legal Hour setting will automatically adjust for daylight savings if set to AUTO 69

70 M-Setup User Menu: Setting Units of Measurement Press OK Complete Menu System measurement unit Select USA system or International system (metric) 70

71 M-Setup User Menu: Other controller recommendations Keep Time Program / Manual in manual mode CH time programs inactive Keep Summer / Winter in winter mode CH Setpoint Only Z1 is active Do not set Z2 or Z3 71

72 M-Setup User Menu: Controller main screen icons Freeze protection active Service interval due Outdoor reset (outside) temp DHW (with box) DHW demand Heat panel (with box) CH demand ECO DHW Comfort Mode OFF AUTO Outdoor reset Active Burner Active (w/power bar) Heat generation lock External safety circuit open (LWCO, etc) 72

73 M-Setup Automatic Air Purge (De-aeration) This 7 minute program to clear air from the boiler will run automatically when: Anytime boiler is powered on Boiler water pressure drops < 10 psi Boiler pressure sensor is unable to prove pump operation Air purge clears air from the boiler water through its air vent. A minimum of 19 psi (with boiler pump on) is required for completion of the air purge. IMPORTANT: If boiler is powered on after service without a drop in system pressure, the air purge can be bypassed by holding the BACK button for 7 seconds. Never bypass air purge on a new installation or when system pressure has dropped <10 psi. Any resulting damage will not be covered under warranty 73

74 M-Setup Pressure requirements psi Warning 1P4 / ΔT reduced (until 19 psi is reestablished) LWCO not required per NFPA 54 due to this pressure control technology <10 psi Fault 108 Boiler inoperable until 19 PSI is reestablished (air purge begins) PSI psi Minimum requirement for normal operation 20 psi Recommendation for fill valve setting 74

75 M-Setup User Menu: Setting DHW Setpoint Temp Press OK Select Complete Menu DHW Settings DHW comfort Setpoint Temp Scroll to desired DHW temp Tech TIP: A quicker way to set DHW Setpoint Temp: Press BACK and turn the dial! 75

76 M-Setup User Menu: DHW Comfort Function Comfort mode enables the boiler to maintain heat exchanger temperature. This allows hot water to arrive quicker to fixtures. Refer to the Installation Manual for setup. Comfort mode has three options: Disabled (Default Setting) No continuous heating of heat exchanger What are the pros/cons of each? Comfort Savings Always Active Continuous hot water all day long Comfort Savings Time Based Scheduled program to activate during high DHW demand times Comfort Savings 76

77 M-Setup Setting Altitude Altitude setting must be complete before operation. See manual for complete details. 1.From the controller Home screen, press BACK and OK buttons simultaneously 2.Turn the wheel to 007, press OK 3.Navigate the menu as follows. 4.Select altitude (ft) and press OK 5.Press BACK to Home Screen 77

78 M-Commissioning Gas Pressure Testing Fuel Type Minimum Load Gas Pressure In. w.c. Optimal In. w.c Maximum In. w.c NG (Natural Gas) LPG (Liquid Propane) 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) Gas Valve Inlet Test Port 78

79 M-Commissioning Chimney Mode (Flue gas testing) Chimney Active mode allows boiler to be forced into a specific fire-rate. This is primarily used when verifying O₂ levels (by forcing operation to 100% high fire and 0% low fire). IMPORTANT: Boiler must have adequate load (CH or DHW) during this setting 1.From the Home screen, press and hold the Chimney Active button for 7 second 2.The following screen appears indicating the Chimney Active mode is active Chimney Active 100% 3.Chimney Active Use the selector to adjust. Press OK 0% (low fire) 100% (max fire) 4.To exit Chimney Active mode, press the Back button until the Home screen appears 79

80 M-Commissioning Flue Gas Testing Maximum Input Minimum Input Model NG O₂% LP O₂% NG O₂% LP O₂% M M090S Min values should be M090C higher than the M120 M measured max value Throttle Screw for O₂ adjustment Example: Boiler: M090C, Gas: NG High measurement: 4.2 Low measurement: 5.5 Is this in range? 80

81 Boiler Supply Temperature Building Heat Loss M-Setup Outdoor Reset Technology The boiler uses the outdoor sensor to improve efficiency by matching the heat output to the heat loss of the building 185 o F High 70 o F 70 o F Outdoor Temperature 0 o F Low 81

82 M-Setup Outdoor Reset Sensor An outdoor temperature sensor is included with every M-Series boiler Sensor Installation Recommend Required North side of structure Not in direct sunlight 5-10 feet above ground Areas prone to snow drifts 82

83 Boiler Supply Temp F M-Setup Outdoor Reset Curve - Presets F max temp (high preset) High temp curve is default Use for all applications except in-floor (slab) radiant applications 122 F max temp (low preset) High Curve Low Curve Low temp curve is for In-floor (slab) radiant applications Outdoor Temp F 83

84 Boiler Supply Temp F M-Setup Outdoor Reset Curve Min/Max Temp Max temp (adjustable) Min temp (adjustable) Outdoor Temp F Max and Min temp parameters can be adjusted to meet application and customer s needs 84

85 M-Setup Outdoor Reset Curve Min/Max Temp Guidelines Type of Heat Emitter Typical Minimum Supply Temperature Typical Maximum Supply Temperature Hydronic Air Handler F F Unit Heater F F Base Board convectors F F Cast Iron / Panel Radiator F F Undermount Radiant F F Poured concrete radiant F F *NOTE: These are basic guidelines. Please check with manufacturer of emitter or consult your heating design engineer. 85

86 Boiler Supply Temp F M-Setup Outdoor Reset Curve - Slope Outdoor Temp F *1.5 High Curve *0.6 Low Curve Which is more efficient: a steep slope or gradual slope? Curve slope parameters can also be adjusted to meet the customer s needs Slope adjustments change the max boiler temp vs. outdoor temp Steeper slope = max boiler reached at warmer outdoor temp (vs preset) Gradual slope = max boiler reached at colder outdoor temp (vs preset) 86

87 M-Setup Outdoor Reset Curve Offset (parallel shift) Turning the controller knob applies a parallel shift to the boiler heating curve (+/- 24 F) This is a quick and easy adjustment the end user can make as well 87

88 M-Setup Outdoor Reset Curve Parameter Adjustments 1.From the controller Home screen, press BACK and OK buttons simultaneously 2.Turn the wheel to 007, press OK 3.Navigate the menu as follows. Parameter Address Key Outdoor Reset Parameters Description Curve Presets Value 1=High temp, (all apps except infloor (slab) radiant applications 2= Low temp, (in-floor) slab radiant apps Slope High value = steep slope Low value = gradual slope Max temp Raises / lowers peak of slope Min temp Raises / lowers bottom of slope 4.To exit, press the Back button until the Home screen appears on the display 88

89 M-Setup Key Installation-Related Fault Codes (see manual for full list) Warnings will not require Boiler Reset Lockouts will require Boiler Reset Fault Code Description Detail 1P4 Filling needed 108 FILL Supply pressure <14 psi (Screen Blocked/will not clear until 19 psi) Supply pressure <10 psi (Reset is not required but operation will cease until pressure=19 psi) 1P9 Pump verification No pressure change after pump energized 140 Pump verification No pressure change after pump energized 5P1/5P2 1 st /2 nd ignition failure Burner failed to ignite on 1 st or 2 nd attempts 501 No ignition after 5 th attempt Intervention required 5P3 Loss of flame Flame lost after ignition 504 Loss of flame Intervention required 114 Outdoor sensor unavailable No sensor detected (Screen Blocked) 89

90 Maintenance 90

91 M-Maintenance Built for Long Life & Easy Service Minimal Maintenance 2yr / 4yr Service Intervals Easy Access from Front & Left side More access to DHW Flat Plate Easier Access for service maintenance Best in Class Reliable Components Honeywell, Grundfos, EBM Papst Brass 3 way valve cartridge DHW Flow Sensor Stainless Steel Heat Exchanger Quality Components Built for Easy Service No tools required to remove Condensate Trap Electrode Assembly Burner Assembly <3 minute Removal Plate Heat Exchanger <3 minute Removal 91

92 M-Maintenance Simple Teardown Demonstration Remove cover Flip down control Remove condensate trap Remove air intake silencer Remove internal gas pipe Remove burner top clamp rods Remove burner, fan & hood Remove burner Remove electrode assembly 92

93 M-Maintenance Setting the Service Interval After completing the installation and commissioning, set the monthly service interval to notify the end user when the boiler is due for (recommended) service A warning code 3P9 will display when the counter expires The boiler will continue to operate (a wrench icon appear on home screen) 007 Parameter Description Detail Sets period of time for service notification Default is 12 months Rinnai s 1 st recommended service interval is 24 months Activates notification feature Default is OFF (0), must change to ON (1) for the interval warning to post Resets notification counter After maintenance is complete, this resets the counter and clears the warning 93

94 M-Maintenance Service Interval Contact Info M-Series Boilers also allow the contractor to enter his/her company name and phone number This will display when the service interval is due This will also display with fault codes Enter the 007 menu Configuration Wizard Service Options Service Center Data 94

95 M-Maintenance Rinnai 2 Year Service Clean and inspect the condensate trap Visual inspection of unit and surroundings, gas pressure, venting, and system pressure Verify with end user comfort and operational satisfaction View fault code history (parameter 8.6.0) Visually inspect flame, Verify proper O2 95

96 M-Maintenance Rinnai 4 year Service Repeat 2-year service interval Purchase 4-year Maintenance Kit (model dependent) Replace ignition assembly Clean and inspect the fan housing & venturi Inspect and clean hood, condensate tray Vacuum burner cartridge (replace gaskets) NOTE: Do not blow air into the heat exchanger or burner cartridge. 96

97 M-Installation Check Your Knowledge At initial power-on, what key information must be entered into the M-Series controller At what water pressure will the M-Series boiler cease to operate (or heat water) How long is the M-Series de-aerate (or air purge) cycle? True/False: The higher the BTU rate, the higher the O₂ measurement List M-Series key outdoor reset parameters (description) True/False: All M-Series ignition failures will require a manual reset of the fault code What is required for a 2 year hour service interval? Date, Time, Units of measurement < 10 PSI 7 minutes False, the greater the combustion, the lower the O₂ measurement Curve Preset, Slope, Max Temp, Min Temp False, only after 5 failed attempts will the boiler require a manual reset Visually inspect unit, venting, flame Verify, gas pressure, O₂, system PSI Clean/inspect condensate trap, fault history 97

98 END of Training 98