Rinnai aiM 65 M/S User manual

Rev: RINNAI Service manual (English)
Date:14/05/2019
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1. Introduction
1.1. General Warnings / Warranty Issues
Please refer and use the information in the content of this manual textbook. Obey the
instructions, warnings and advices. The warnings and instructions are the matter of your and your
his manual textbook are mostly in the order of the start of
comissioning with the unpacking of the device towards decomissioning and disassembling.
The neutral keeping position of your device unless it is hanged on a wall or a hanging structure is
horizontal with front side (the side including the control panel, on which the RINNAI LOGO is also
written) directed upwards. Especially please refer to this information in case of heat exchanger
assembling or disassembling.
Care to keep this user manual textbook with safety . Read all the instructions.
Warranty
manual and has been firstly started by RINNAI authorized services.
Period of Warranty
The period of natural gas combusting and flue gas condensing devices is 2 years.
General Information
Natural gas is an environment friendly fuel. Your device is a high valued State-of-the-Art and are
equipped with the highest technology safety precautions.
The yearly
maintenance by RINNAI authorised services.

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2. Description and Definitions of The Product
2.1. Boiler Panel and Human Machine Interface
The front panel is seen as in the below image for the slave boilers which are used for cascade operation.
Panel light
Appearance
Explanation
No light - Boiler standby
Blue Permanent Burner operation
Red Blinking Boiler error
Magenta Temporary continuous At first energizing the boiler with electricity or while parameters loading.

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2.2. Technical Specifications
PROPERTY UNIT aiM 65 aiM 85 aiM 115 aiM 150
Types Proper for Cascade Setup
Master (M) /
Slave (S)
Master (M) / Slave
(S)
Master (M) /
Slave
(S)
Master (M) / Slave
(S)
Fuel
Natural Gas (G20) +
LPG (G31)
Natural Gas (G20) +
LPG (G31)
Natural Gas (G20) +
LPG (G31)
Natural Gas (G20) +
LPG (G31)
Upstream Pressure (Inlet)
mbar
21
21
21
21
Fuel Consumption @ Maximum Load
m
3
/h
6,87
8,83
11,
19
15,11
Fuel Consumption @ Minimum Load
m
3
/h
1,35
1,76
2,39
3,07
Technical Parameters wrt. ErP Directive
P
n
Nominal Heat Output
kW
64
85
108
145
P
4
Heat Output @ Max L.
(80/60
o
C)
kW
61,6
81,2
105,3
143,7
P
1
Heat Output @ Part L.
(50/30
o
C)
kW
20,7
25,3
35,1
46
s
Seasonal Space Heating Energy Efficiency
%
91
93
93
91
4
Useful Efficiency @ Max L.
(80/60
o
C)
%
87,3
86
87,8
89,2
1
Useful Efficiency @ Part L.
(50/30
o
C)
%
97,7
97,5
97,6
96,7
P
stby
Standby Heat Losses
W
68
80
102
121
P
ign
Ignition Burner Energy Consumption
kW
1,75
2,92
2,3
2,16
L
wA
Sound Power Level (Indoors)
dB
58,8
61,9
64,7
67,4
NOx
Emissions of Nitrogen Oxides
mg/kWh
44,2
46,2
45,5
54,6
NOx Class
-
6
6
6
6
Boiler Nominal Heat Output / Efficie
ncy
Maximum / Minimum Output (50/30
o
C)
kW
67,2 / 13,4
90,1 / 18,5
116,3 / 23,5
153,9 / 30,7
Maximum (P
4
) / Minimum Output (80/60
o
C)
kW
61,6 / 12
81,2 / 16,5
105,3 / 21,3
143,7 / 28,2
Output @ Fan Ignition RPM (50/30
o
C)
kW
27,5
44,3
55,9
60,1
E
fficiency (
50/30
o
C
Max./ Min. Load
)
%
105,8 / 107,3
106 / 108,6
107,7 / 108,6
106,2 / 105,8
Efficiency (
80/60
o
C
Max./ Min. Load
)
%
97 / 95,8
95,6 / 97,2
97,5 / 98,6
99,1 / 97,2
Maximum Backpressures / Fluegas Flowrate
Backpressure (Max. / Min
. Load)
Pa
137 / 79
210 / 105
177 / 102
282 / 87
Backpressure (Ignition) Pa 106 116 146 118
Fluegas Flowrate (Maximum Load - 50/30
o
C) g/s 24,7 34,9 46,3 58,2
Fluegas Flowrate (Maximum Load - 80/60
o
C) g/s 30,0 37,7 49,5 64,2
CO2 Conc. (Max. / Min Load) (50/30
o
C) % 9,12 / 9,12 9,0 / 9,0 8,90 / 9,15 9,27 / 9,06
Flue Temp. (Max. / Min. Load) (50/30
o
C) oC 63,3 / 40,4 51,6 / 34,2 50,8 / 39,5 54,4 / 43,8
Flue Temp. (Max. / Min. Load) (80/60
o
C) oC 82,7 / 64,1 70,0 / 62,7 71,5 / 61,0 74,5 / 65,0
Electrical Properties
Electrical Input (Voltage/Frequency) VAC/Hz 230 / 50 230 / 50 230 / 50 230 / 50
Electrical Fuse A 6,3 6,3 6,3 6,3
Electrical Consumption in Standby W 2,64 2,64 2,64 2,64
Electrical Consumption Max. / Min. Load W 95,4 / 18,8 109,7 / 15,6 143,3 / 19,0 284,2 / 21,0
Installations / Connections
Gas Connection inch
Heating Circuit (Inlet / Outlet) inch
DHW Circuit (Inlet / Outlet) inch
Maximum Water Pressure of Operation bar 4,5 6 6 6
Minimum Water Pressure of Operation bar 1 1 1 1
Boiler Hydraulic Loss Max Load (50/30
o
C) mWC 5,4 2,9 3,6 5,0
Boiler Hydraulic Loss Max Load (80/60
o
C) mWC 4,6 2,5 3,0 4,5
Water Flowrate @ Max. Load - (50/30
o
C) mWC 2,8 3,7 4,8 6,3
Boiler water fill up volume lt 3,4 6,6 8,2 10,1
General Properties
Boiler Net Dimensions (W x D x H) mm 493 x 540 x 627 493 x 540 x 797 493 x 540 x 797 493 x 635 x 797
Packaged Dimensions (W x D x H) mm 565 x 740 x 760 565 x 910 x 760 565 x 910 x 760 565 x 910 x 850
Boiler Weight (Empty / Full) kg 54,6 / 58 68,7 / 75,3 75,2 / 83,4 88,6 / 98,7
Packaged Weight kg 58,6 72,7 79,2 92,6
Chimney Pipe Diameters (exhaust/air intake) mm 100 / 150 100 / 150 100 / 150 100 / 150
Type -
Hermetic / full
condensing
Hermetic / full
condensing
Hermetic / full
condensing
Hermetic / full
condensing
Control Panel -
Electronic and Push
Button
Electronic and Push
Button
Electronic and Push
Button
Electronic and Push
Button
Ignition System - Electronic Electronic Electronic Electronic

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Fault Detection and Warning - YES -
error code on
screen
YES -
error code on
screen
YES -
error code on
screen
YES -
error code on
screen
Floor Heating Application
-
YES
YES
YES
YES
Cascade Operation
-
256 items
maximum
256 items
maximum
25
6 items
maximum
256 items
maximum
Frost Protection
-
YES
YES
YES
YES
Time Programming / Holiday Mode
-
YES
YES
YES
YES
Parametric Tuning Hardware
-
User monitor HMI
/ PC
User monitor HMI
/ PC
User monitor HMI
/ PC
User monitor HMI
/ PC
2.3. Product Declerations of Conformity (ErP Directive)

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2.4. System General View / Sub-System and Components
2.4.1. aiM 65 M/S
No Item
1 PRESSURE SENSOR
2 FLUEGAS SENSOR
3 FAN
4 HEAT EXCHANGER
5 IGNITION + IONIZATION ELECTRODE
6 RETURNING PIPE TO EXCHANGER
7 OUTGOING PIPE FROM EXCHANGER
8 BOILER RETURN TEMPERATURE SENSOR
9 AIR PURGE VALVE 1/2"
10 GAS VALVE
11 VENTURI
12 LIMIT THERMOSTAT
13 MAINBOARD ASSEMBLY
14 CONDENSATE SYPHON + DRAIN HOSE
15 BOILER OUTFLOW TEMPERATURE SENSOR

Rev: RINNAI Service manual (English)
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2.4.2. aiM 85 M/S, 115 M/S, 150 M/S
No Item No Item
1 PRESSURE SENSOR 9 AIR PURGE VALVE 1/2"
2 FLUEGAS SENSOR 10 GAS VALVE
3 FAN 11 VENTURI
4 HEAT EXCHANGER 12 IONIZATION ELECTRODE
5 IGNITION ELECTRODE 13 MAINBOARD ASSEMBLY
6 RETURNING PIPE TO EXCHANGER 14 CONDENSATE SYPHON + DRAIN HOSE
7 OUTGOING PIPE FROM EXCHANGER 15 BOILER OUTFLOW TEMPERATURE SENSOR
8 BOILER RETURN TEMPERATURE SENSOR

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2.5.3. Boiler and Sanitary Connection Dimensions (Same for Master and Slave Boilers)
BOILER TYPE A DEPTH
(mm)
B HEIGHT
(mm)
C BOILER
OUTFLOW
D BOILER
RETURN
aiM 65 M/S 540 627
aiM 85 M/S, aiM 115 M/S 540 797
aiM 150 M/S 635 797

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2.5.4. Installed Cascade System Dimensions
o. Every additional collector pipe
adds nearly on the total height of the installed system.
2.5.5. Sanitary Needs For a Long Boiler Life and Proper Operation
Whether your system will be self operating or in a cascade setup, the installations must always include
Oxygen seperator
Hydraulic header (in PVC circuitry, a plate
heat exchanger should be used)
Silt Trap / Strainer
Expansion vessel (per each boiler)
in order for a long life of your device and the validity of your warranty.

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There a shutter valve (manual and/or automatic) between the expansion vessel and the
boiler due to dangerous situations for human health.
Extras / Warnings For Proper Installations
pressure losses of the heat exchanger coupled with the pump characteristic curves can be found in
the further pages of the text.
The con iginated) is in
acidic contamination thus must be neutralized before drainage to earth. For further information
Section 4.2. Condensate Syphon Circuit and Condensate Neutralization
A 24 lt expansion vessel should be connected per an aiM boiler in the primary circuit. The
expansion vessels for the secondary circuit region must be properly selected by the contractor firm.
2.5.6. Minimum Free Space Dimensions To Be Left Between the Boiler and the Walls
The minimum dimensions of free space to be left between the boiler and the walls taking the ergonomy of
the service personnel into account while working is stated in the below image as seen.
The LMS 14 boiler controller card has a frost protection system for a possible situation of water freezing
due to low air temperatures. In order for this property to be active, the system must be connected to
ystem parameters
menu. This advantageous property of the card is advised to be teken into account when to be used in
places like low temperature boiler rooms.
When coaxial flue pipe is used for exhaust and fresh air intake in order to prevent the possibility of
mixing of the flue gas to inhaled (sucked) fresh air, the flue pipe should be at correct distances when
installed from the roof and side walls of the building.

Rev: RINNAI Service manual (English)
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2.5.7. Device Mechanical Circuitry (Hydraulic, Gas, Exhaust)
The schematic diagram of aiM Condensing Boiler explaining the operation tool and functions in the simplest
manner is seen above. The exhaust flue system does not only consist of a pipe only. Operating for this
purpose, it should also safely be able to supply the fresh air needed for a clean combustion to the
combustion chamber of the heat exchanger. This is only possible by commissioning a confirmative flue pipe
system to the directives up to date. Detailed additional information can be found at Section 3.5 Flue Pipe
System and Components .

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2.6. Water Management
2.6.1. Circulating Pump Technical Properties and Characteristic Curves
The list of appropriate pumps to be used with aiM is seen below. The pumps can be purchased with its
additional sanitary and electrical connection equipment. The devices are A type high energy class pumps
which are conformative with the ErP energy regulations up to date. They are energized and driven by the
LMS 14 boiler control card and 230 VAC PWM signal.
In order to make the electrical connections, it is unneccesary to be able to reach the LMS 14 card. The
connections can be easily done via the electrical terminals located at the back side of the boiler front user
panel. It is also an advantage of your aiM boiler that the user panel can also easily be detached from its pins
and turned around the panel pivots.
When using appropriate pipe and installation dimensions, the pump should be chosen to be capable of
circulating water between the boiler and hydraulic header. Whether using a hydraulic header or a plate
heat exchanger between the return and outflow, the needed head rise may also differ so that the pump
should be selected carefully. The LMS 14 card adjusts the pump speed to set the temperature difference
between cold water inlet and hot water outlet to 20 oC constant value.
Plate Heat
Exchanger
Hydraulic
Header
Plate Heat Exchanger Hydraulic Header
Boiler
Model
Water
Flow
[m3/h]
Needed Head Rise
[mWC]
Pump with
PWM signal
Constant /
Variable
Pressure
Tunable
Pump
Pump with
PWM signal
Constant /
Variable
Pressure
Tunable
Pump
aiM 65 M/S 2,8 7,4 5,7 Grundfos
UPML 25-105 /
130 PWM
Wilo
Yonos
PARA HF
25/10
Grundfos
UPML 25-105 /
130 PWM
Wilo
Yonos
PARA HF
25/7
aiM 85 M/S 3,7 4,9 3,2 Grundfos
UPML 32-105 /
180 PWM
Wilo
Yonos
PARA HF
30/10
Grundfos
UPML 32-105 /
180 PWM
Wilo
Yonos
PARA HF
30/10
aiM 115 M/S 4,8 5,7 3,9 Wilo
Stratos Para 30
/ 1-12
Wilo
Yonos
PARA HF
30/12
Grundfos
UPMXL GEO 32-
125 / 180 PWM
Wilo
Yonos
PARA HF
30/10
aiM 150 M/S 6,3 7,3 5,6 Wilo
Stratos Para 30
/ 1-12
Wilo
Yonos
PARA HF
30/12
Wilo
Stratos Para 30
/ 1-12
Wilo
Yonos
PARA HF
30/10
Depending on the aiM type, boiler total pressure drop curves are as seen below.

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2.6.3. Water Fill / Drainage From The Circuit
In order to achieve an efficient operation or to uncommission the system, it should be known how
to fill or drane water from the water circuit.
The maximum water pressure level can be 6 bars in the installation for aiM 85, 115, and
150. The standard equipment of your product due to first unpacking is a 6 bar purge valve.
The maximum water pressure level can be 4,5 bar in the installation for aiM 65. The
standard equipment of your product due to first unpacking is a 4,5 bar purge valve.
The water pressure should be between 1 to 1,5 bars in cold conditions. The system water
pressure should be risen up if the value drops below this range.
ready for using and no plug like similar connections or equipment should be connected.
2.6.4. Hardness and Conductivity of Water, Fur Layer
The heating circuitry should be well cleaned before first fill up. In the first fill up, only use drinking water.
If the water supplied to the system does not carry the mentioned properties, additionaly a
refinement system should also be installed.
Only use drinking water when refilling up the water circuit for any reason.
the first
circulating cycle whilst a steady flow regyme is reached.
If an Aluminum component is being used in the circuit (i.e. Aluminum radiators) the level should be
pH < 8,5.
The maximum allowed hardness (MAH) values for the water to be used in the heating circuit is
designated with reference to VDI 2035 and must be in the range 5 Fr < MAH < 15 Fr.
Settled Total System Power (kW) Hardness
<600 5 - 15 0,5 1,5
>600 5 7 0,5 - 0,7
The maximum total hardness and corresponding maximum conductivity is related to the boiler
capacity and the total volume of the circuitry installation.
2.7. Over
It is not preferred that the temperature difference between the inflow water and the outflow water may
exceed a certain limit. The main reason is to protect the heat exchanger of your device from thermal over-
stresses. This function may lowe
system minimum value or due to design and safety purposes, it could take the boiler to start prevention
mode (lockout).

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viour is as follows:
Parametre
[3916.1] Max temp differential
flow/return T > [MaxTdiff flow/return] : Load %20 lowered
- If the value is higher than [maximum let ] value, the boiler load is lowered by
%20.
[6604.1] SLT T diff low-fire T > [MaxTdiff flow/return] + [SLT delta-T
Offset] : partial load
Output reduced to minimum
- If the T value is higher than [maximum let T] + [6604.1] boiler load lowered to
minimum.
[6605.1]
SLT T diff start prev
T > [MaxTdiff flow/return] + [SLT delta-T
Offset] : start prevention
[3921.1] Number of errors delta-T
within 24 h
-
If the
T
value is
higher than
[
maximum let
T
] + [
6605.1

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3. Unpacking and Assembling The Product
3.1. General and Safety Warnings
3.1.1. Informations and Safety Warnings About the Circuit
There is a high important issue to be cared of which is: Neither on the hot water outlet branch nor
cold water return inlet branch, there should be no manual or automatic controlled valve of any
kind to exist.
In such a case :
1)
whether water inlet branch or outlet branch
(the final position should be permitting water
flow)
Attention: The arm should be in the same
direction as the line.
2) LEAVE THE VALVES AS IT STAYS IF INITIALLY
3)
ve as
shown in the left image red arrow.
4) A RINNAI authorized service should be
connected before re-operation!
As can be noticed from the above warnings, for a
correct and safe operation of the high pressure safety
purge valve, the right order starting from the boiler
should be
i. Safety Purge Valve and Expansion Vessel connection
ii. Boiler Circulating Pump
iii. Strainer (optional - advised to be used)
iv. Manual valve

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A smaller package containing the set of high pressure safety purge valve montage accesories will
be included/found when you unpack the boiler package. This set is of 4 components which are in
the zipped-pack. The package content differs for aiM 65 M and aiM 65 S models.
For aiM 85-115-150 M/S models:
TEE Reducer
Nipple
TEE Reducer
6 bar safety purge valve
For aiM 65 M/S models:
4,5 bar safety purge valve
All the sanitary or ot
It is advised for your product to be used/comissioned with the proper Pump and Accessories Kit
which can be purchased via the RINNAI Authorized Services network. The additional set

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equipments which are seen in the following image are not included in the standard package of
your product. You can purchase the additional pump set using authorized services and use in your
installation.
On the hot water outlet branch: parts numbered 1 and 2 are used.
On the cald water return inlet - branch (pump pressurization side): parts numbered 2,3,4,5 and 6
will be used. The line and signal cables of the circulating pump are also included in the additional
pack.
The selection table for proper selection of circulating pumps can be found in the previous
chapter with additional technical details.

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3.1.2. Safety Warnings and useful Information About the Heat Exchanger, Fan and the
Venturi
Do not remove the front and/or side panels of your boiler while the device is in operation. This is a
safety precaution. Your device will get out of warranty in case of detection of any previous
opening of the panels.
Only RINNAI authorised services are capable of doing such operations.
Whether you are a service personnel or not, do not put any part of your body through inlet
of the air suction (figured below).
Do not throw in or let any tiny object to enter from the air suction (what meant is: the inlet
of the venturi).
or
plastic parts etc. inside the boiler volume before closing (mounting) the front and side
panels.
Safety Warnings and Useful Information About the Heat Exchanger, Fan and the Venturi
Your device has a State-of-the-Art heat exchanger which is higly capable of tuning the correct
gas/air ratio beneath the natural gas combustion limits for optimal operation. The burner of the
heat exchangers (both ISO or DUO range)
Stabilizing the flame consistently, regulating pressure fluctuations arising from the gas line
and using the gas fuel at best performance
Using the high condensation performance on the flue gas passing around the water
carrying coils, transferring the inner energy (sensible heat) of water vapor to the primary
circuit of your installation at best performance
are the main forecoming advantages of your boiler.

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Fig.A. aiM 65 M/S type heat exchanger (Sermeta ISO 7+2)
Fig.B. aiM 85, 115, 150 M/S type heat exchanger (Semeta DUO range)
Once underlining
make RINNAI authorised services. One of the main and
most important issues about boiler maintenance is the maintenance steps implied on the heat
exchanger. It is advised to use Sentinel brand cleaning and care products for a long duration and
high efficient life of your boiler. The below table consists of the so called products with the
corerespondant benefits.
Field of use
Sentinel Product
Benefit
Corrosion / lime fur layer
inhibitor
X100, X500
Prevents
Sound preventi
on
X200
Prevents
Cleaning
X300
Problem solver
Dirt vanishing
X400
Problem solver
Antifreeze
X500
Prevents
Leakage
Anti
-
leakage products
Prevents

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3.1.2.1. Heat Exchanger Hanging System (Patented PT2014/15542)
Your aiM boiler has important structural advantages and the primer of these is the specially developed heat
exchanger hanging system. The developed design has been patented. The system is made up of three main
components as seen below.
The heat exchanger
connection plate is
directly connected to the
heat exchanger.
The chassis (backplate
sheet metal standing
between the heat
exchanger and the wall) is
between the heat
exchanger connection
plate and the hang
connection plate.
The hanging plate is the first plate member from wallside towards the boiler.
The heat exchanger + heat exchanger connection plate + chassis (not shown in the above figure) +
hang connection plate is a whole sandwich structure.
or on the
aiM boiler hanging console.
The system reliability has been examined (water) filled up by advanced structural engineering
calculations and has been validated by numerous experimental trials in boiler operation.
It has been possible to reduce the system weight in a big amount with the sake of this innovative
design.
Authorised service intervention ergonomy has been highly increased.
3.1.2.2. Limit Thermostat
For aiM 65 M/S models, the limit thermostat is located on the outlet pipe branch from the heat exchanger.
For aiM 85-115-150 M/S models the limit thermostat is located on the front side (user side) of the DUO
heat exchanger.