Rinnai E- Series Programming manual

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E- Series Boiler
Troubleshooting Manual
WARNING
There are a number of live tests that are require when fault fin ing this pro uct. Extreme care shoul be use
at all times to avoi contact with energize components insi e the pro uct.
You MUST be a qualifie service person before procee ing with these test instructions.
Before checking resistance rea ings, turn off power source to unit an then isolate each item to be checke
from the circuit by unplugging it.
When setting gas pressures on one of these units, please check the complete mo el number you are trouble-
shooting. Gas pressures an ip switches can vary among mo els. Always check the rating plate for complete
information an follow irections.
If any of the
original wire as supplie with the appliance must
be replace , it must be replace with type 18 AWG wire or its
equivalent.
Label all wires prior to isconnection when
servicing controls. Wiring errors can cause
improper an angerous operation.
CAUTION

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Table of Contents
Co e Numbers Page #
Boiler Description …………………………………………………………………………………………………………………………. 4
Error in ication (Short reference) ………………………………………………………………………………………………... 5
BL 01 …………………………………………………………………………………………………………………………………………….. 6
BL 05 …………………………………………………………………………………………………………………………………………….. 7
BL 11 …………………………………………………………………………………………………………………………………………….. 8
BL 12 …………………………………………………………………………………………………………………………………………….. 9
BL 60 …………………………………………………………………………………………………………………………………………….. 10
BL 67 …………………………………………………………………………………………………………………………………………….. 11
BL 80 …………………………………………………………………………………………………………………………………………….. 12
BL 81 …………………………………………………………………………………………………………………………………………….. 13
BL 82 …………………………………………………………………………………………………………………………………………….. 14
BL 84 …………………………………………………………………………………………………………………………………………..… 15
BL 85 …………………………………………………………………………………………………………………………………………….. 16
BL 86 …………………………………………………………………………………………………………………………………………..… 17
E 00 ………………………………………………………………………………………………………………………………………………. 18
E 01 ………………………………………………………………………………………………………………………………………………. 19
E 02 …………………………………………………………………………………………………………………………………………….… 20
E 03 …………………………………………………………………………………………………………………………………………….… 21
E 04 …………………………………………………………………………………………………………………………………………….… 22
E 05 …………………………………………………………………………………………………………………………………………….… 23
E 07 …………………………………………………………………………………………………………………………………………….… 24
E 11 …………………………………………………………………………………………………………………………………………….… 25
E 12 …………………………………………………………………………………………………………………………………………….… 26
E 13 …………………………………………………………………………………………………………………………………………….… 27
E 14 …………………………………………………………………………………………………………………………………………….… 28
E 18 …………………………………………………………………………………………………………………………………………….… 29
E 19 …………………………………………………………………………………………………………………………………………….… 30
E 24 …………………………………………………………………………………………………………………………………………….… 31
E 26 …………………………………………………………………………………………………………………………………………….… 32
E 28 …………………………………………………………………………………………………………………………………………….… 33
E 29 …………………………………………………………………………………………………………………………………………….… 34
E 31 ……..……………………………………………………………………………………………………………………………………….. 35

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E 32 ….…………..……………………………………………………………………………………………………………………………… 36
E 36 ....…..……………………………………………………………………………………………………………………………………… 37
E 37 …..…………….………………………………………………………..……………………………………………………………….... 38
E 41 …………………………………………………………..…………………………………………………………………………..……… 39
E 42 …………………………………………………………………………………………………………………………………………..….. 40
E 44 ………………………………………………………………………………………………………………………………………………. 41
E 68 ………………………………………………………………………………………………………………………………………………. 42
E 69 ………………………………………………………………………………………………………………………………………………. 43
E 80 ………………………………………………………………………………………………………………………………………………. 44
E 115 …………………………………………………………………………………………………………………………………………….. 45
Fuse …………………………………………………………………………………………………………………………………………….… 46
Central heating but no omestic hot water…………………………………………………………………………………… 47
Hot water but no central heating …………………………………………………………………………………………….…... 47
Central heating installation gets hot without being requeste ……………………………………………….…... 47
Insufficient quantity of hot water …………………………………………………………………………………………….…... 48
Temperature rop of the DHW (Combi) ……………………………………………………………………………………….. 48
Ra iators o not get hot enough or warming up takes too long …………………………………………………... 48
Checking the 0
2
…………………………………………………………………………………………………………………………….. 49
Boiler Controls ………………………………………………………………………………………...…………………………………... 50
Explanation of the function buttons ……………………………………………………………………………………..…….… 51
Starting up – filling an e-aerating the boiler & Water Requirements….………………………………….….. 52
Freeze Protection………………………………………………………………………………………………………………………….. 53
Filling the heating system ………………………………………………………………………………………………………..…... 54
Altering a justments ……………………………………………………………………………………………………………………. 55
PARAMETER mo e ………………………………………………………………………………………………………………………. 56
Information, Service an Error Mo es …………………………………………………………………………………………. 57
Activating factory setting (Green button function) ………………………………………………………………………. 58
Isolating the boiler ……………………………………………………………………………………………………………………..….59
Reset service interval counter ……………………………………………………………………………………………………… 60
© 2013 Rinnai America Corporation • 103 International Drive, Peachtree City, GA 30269
Toll-Free:1-800621-9419 • Phone: [phone] • www.rinnai.us
Rinnai is continually up ating an improving pro ucts; therefore, specifications are subject to change without
prior notice. Local, state, provincial an fe eral co es must be a here to prior to an upon installation.

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Bi
-
metal high
Parts of the Boiler

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Information displayed in “Tech Readout Mode”. To enter this
mode press and hold the “STEP” button for 5 seconds.
Operation Indication
0 - No heat demand
1 - Fan pre/post purge
2 - Ignition phase
3 - Burner active on central heating
4 - Burner active on DHW
5 - Fan check
6 - Burner off when either DHW or room thermostat is calling *
(See note 2 below).
7- Pump overrun phase for central heating
8- Pump overrun phase for hot water
9 - Burner off because of too high flow temperature
A - Automatic de-aeration program
F – Fan test still activate in Service mo e
H Burner test still activate in Service mo e
*Note 2; (E Boiler) a continuous co e 6 can mean there is a small hot
water leak triggering the plate heat exchanger sensor to call continually
for DHW in turn locking out space heating in DHW priority. Switch PARA
36 to 20 (flow switch only) an then repair leak.
A detected error is indicated on the display by means of a blocking or error messages. A distinction should be made between
these two messages due to the fact that a blocking code can be of a temporary nature, however, error messages are fixed
“lockouts” or hard lockouts. The control will try its utmost to prevent a lockout and will temporary switch off the unit by blocking it,
below is a list of some messages the unit will display.
Blocks: bL with a number in the last two positions indicates the type of blocking code.
bL 01 Block 01: External safety contact cut off.
bL 05 Block 05: Outdoor reset sensor not connected.
bL 60 Block 60: Incorrect parameter setting of the minimum or maximum power (Btu) of boiler.
bL 67
Block 67: A ∆T has been detected between flow and the return sensor whereas the burner is not in operation. After the
∆T has disappeared the block will clear itself.
bL 85 Block 85: The control has not detected water flow. The venting cycle (pro-purge) cycle has started.
If during this cycle water flow is detected, the pro-purge cycle stops, the burner will then fire up.
Error: Ewith a number in the last two positions indicates the type of error code.
E 00 Error 00: Poor flame forming.
E 02 Error 02: No flame forming.
E 04 Error 04: Adjustment or error due to voltage interruption.
E 05 Error 05: Adjustment.
E 12 Error 12: High limit stat.
E 18 Error 18: Maximum flow temperature exceeded.
E 19 Error 19: Maximum return water temperature exceeded.
E 28 Error 28: Fan revolutions not being measured by control board.
Flame present when burner is off, electrical interference, poor
ground, and flame sensing wire disconnected during off cycle.
E 69 Error 69: No or incorrect display.
FUSE FUSE: 24 V fuse defective or blown.
Block an Errors
-
Error in ication (short reference)
NOTE; if the unit appears to be fine but doesn’t run and no
error code is displayed check;
a. That the desired programming is on; set to
either Central Heating and/or Domestic Hot
Water.
b. The unit is not in the Showroom Mode
______________________________________
Explanation of T Sensors:
T1- Supply sensor - Water leaving heat exchanger mounts
in flow of water.
T2 - Return water sensor, surface mounted.
T3 - Domestic hot water flow sensor,. Q175C uses a
surface mount sensor. Q models with optional 3-way valve
use a sensor designed to be used in a well. (QP uses a
well)
T4 – Outdoor reset sensor, mounted outside building.
T5 - Flue gas sensor - Optional sensor not included with
boiler.

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
If multiple boiler safeties are to be wired in series check with your local inspector or the local or State
codes to see if this is allowed in your area before proceeding. NEVER wire boiler safeties in parallel.
Refer to wiring diagram in the boiler manual. Trace connections 24 and 25 above back to the MCBA.
These will be located on Plug X5 on the MCBA on pins 2 and 6.
The 120 volt external pump is for
E an QP mo el boilers
WARNING: Turn off power supply before
installing jumper. Rectify error by etermining
which external contact is open. If external
contacts are not being use place jumper across
terminals 24 & 25

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Maximum average ΔT of T1 supply
sensor an T2 return sensor for central
heating is repeate ly excee e .
BL 11
1. Check flow through the heating system.
2. Possible causes: ra iator shut off valves close , blocke water filter.
3. Verify proper installation of the boiler plumbing, connections an all components.
4. Check minimum an maximum temperature ifference in Parameter step 46 an 47.
5. Activate room sensor (RS100) in non lea ing room (close thermostatic ra iator
valves?) Check pump height. Shoul this be check pump hea ? Do not understand
Operation is normally possible for the hot water
supply uring the block. The pump continues to
operate at minimum capacity uring the block.
Rectify Issue,
Check following

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Maximum average ΔT of supply
sensor an return sensor for hot
water is repeate ly excee e .
BL 12
1. Check flow through the boiler an DHW tank.
2. Possible causes: ra iator shut off valves close , blocke water filter, restriction in DHW tank to high.
3. Verify proper installation of the boiler plumbing, connections an all components.
4. Ensure 3 way valve is functioning properly an is not clogge or full of pollution.
Operation is normally possible for the central
heating installation uring the block. The pump
continues to operate at minimum capacity uring
Rectify Issue,
Check following

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NOTE; in order to reset all parameters in your boiler back to factory defaults follow the “Activating Factory
Settings” (Green button function) instructions found in your owner’s manual. CAUTION: All parameters you
adjusted will now have to be reprogrammed if the bL60 code clears up. If after resetting the boiler the bL60
still appears, you will need to replace the sub-PC board and reprogram the MCBA. The sub PC board must be
from a conversation kit for the same gas type as your boiler.
WARNING: Before replacing the sub PC board or installing a conversion kit turn off the gas and electrical
supply to the boiler.
If conversion parts are not locally accessible contact Rinnai Tech Support for assistance. These parameters
cannot be accessed in the field and may require special instructions in an emergency situation.

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A temperature ifference has been etecte
between the supply an return sensor while
the burner is not in operation. After the
average ΔT has isappeare , the block will
isappear.
A temperature ifference has been etecte
between the supply T1 sensor an the return T2
sensor while the burner is not in operation. After
the average ΔT has isappeare , the blocking
co e will go away.
T2 Sensor
T1 Sensor
Check the supply T1 sensor an the return T2 sensor for
the proper resistance valve. Replace if foun to be
efective. WARNING: Turn off power an water supply
to boiler before removing the T1 or T2 sensor.

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T5 sensor is registering too high of a
temperature. This error can only occur if
the optional T5 sensor is was purchase
an installe on the boiler.
This is the location of the T5 sensor if installe .
If the re tab is in place this sensor was never
installe , which means the circuit has
somehow been jumpe out. Contact Rinnai
tech support for assist if you get the bL80
without the T5 sensor being installe .
Inspect vent system an all air passages
ways for blockage
212˚F is the efault temperature setting for
parameter 84. Verify to see if the temperature
setting for this parameter is set higher than
the efault. If so, inspect vent system for
blockage. CAUTION: ensure all vent
components are properly seate when re-
installe .

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Explanation: The bL81 can be triggere if the flue gas plug has gotten wet an then rie out. (MCBA sees resistance when wet an
then sees no resistance when ry) This tricks the MCBA into thinking that a flue gas sensor was installe an then remove in which
the bL 81 is triggere . Moisture can come from a clog, broken or ry con ensate trap. Moisture can be from a leaking concentric
vent pipe or from riving rain uring extreme weather.
WARNING: Turn off power an water supply to the boiler before removing or installing any parts.
Metho s to rectify:
A. ORDER AND INSTALL A FLUE GAS SENSOR (This may not be possible in col weather when boiler must operate
imme iately, if shipping the part is require .
B. CHANGE PARA 80 TO 20 AND INSTALL LOW VOLTAGE JUMPER ON FLUE GAS PLUG - (plug locate on upper left han si e
of the heat exchanger in the harness) (PARA 20 setting causes the MCBA to look for an open/ close circuit an ignores any
variable resistance values like moisture or a thermistor.
C. INSTALL A 10K OHM RESISTOR ACROSS FLUE GAS TERMINALS. This will make the MCBA think that the flue gas is at a safe
temperature level (90 F)

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Flue sensor
Explanation: The bL81 can be triggere if the flue gas plug has gotten wet an then rie out. (MCBA sees resistance when wet an
then sees no resistance when ry) This tricks the MCBA into thinking that a flue gas sensor was installe an then remove in which
the bL 81 is triggere . Moisture can come from a clog, broken or ry con ensate trap. Moisture can be from a leaking concentric
vent pipe or from riving rain uring extreme weather.
WARNING: Turn off power an water supply to the boiler before removing or installing any parts.
Metho s to rectify:
D. ORDER AND INSTALL A FLUE GAS SENSOR (This may not be possible in col weather when boiler must operate
imme iately, if shipping the part is require .
E. CHANGE PARA 80 TO 20 AND INSTALL LOW VOLTAGE JUMPER ON FLUE GAS PLUG - (plug locate on upper left han si e
of the heat exchanger in the harness) (PARA 20 setting causes the MCBA to look for an open/ close circuit an ignores any
variable resistance values like moisture or a thermistor.
F. INSTALL A 10K OHM RESISTOR ACROSS FLUE GAS TERMINALS. This will make the MCBA think that the flue gas is at a safe
temperature level (90 F)

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This can occur when PARA 84 has been
change to 20 an the fiel installe jumper is
loose or remove .
212˚F is the efault temperature setting for
parameter 84. Verify to see if the temperature
setting for this parameter is set higher than
the efault. If so, inspect vent system for
blockage.

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Check the installation for the presence of air.
If there is a secon ary pump installe an it
is not hy raulically separate , it coul cause
a loss of pressure ifference.
Check to ensure the pump is functioning an /or water
pressure sensor is working properly.
WARNING: Turn off power an water supply to the boiler
before removing or installing any parts.
Ensure water pressure sensor is not clogge or efective.
Inspect water filter for ebris.
Check pump for proper operation an flow rates.
Check for proper wiring of pump.
Check for use of balancing valves.
AIR: if boiler, inner boiler piping, or Low Loss
Hea er has a large air bubble in it the
pressure sensor will not see the pressure
spike that the pump generates when it starts.
The pressure spike is what tells the MCBA that
the pump has starte .
The air bubble will absorb that spike. Blee all
air from the system.
If an a itional expansion tank is place in the
system alongsi e an E-boiler that tank can
absorb the pump pressure spike as well. You
may nee to isolate that tank to see if this
corrects the issue with BL 85.
An expansion that is not charge properly can
cause the pump’s pressure spike not to be
seen by the sensor causing a BL85.
Expansion tank pressure shoul be air charge
to match whatever water fill pressure that is
chosen for the close loop. (Always above
14.5 psi)
Expansion tanks must be air charge only
when there is no water pressure on the wet
si e of the iaphragm or the tank is remove
from the system. Once charge to the correct
air pressure it may be place into the system
an the water fill pressure now may be set to
match the new tank pressure.

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The frequency of the power supply eviates more
than + or - 1.5 Hz.
If using a back-up generator ensure it is
properly groun e an provi ing a clean
stea y voltage an sign wave of 59.3 to 60.8
Hz.

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Boiler has not been
burning but an
ionization flow
flame) has been
detected.
NOTE: Ina vertently unplugging the ionization
cable or spark igniter wire while the boiler is
not firing can trigger the E00 co e.
Check whether the ionization cable an /or the electro e
are responsible for a short circuit. Remove the plugs from
the ionization cable connecte to the control unit an to
the electro e. Now using a ohm meter take a
measurement between the ionization connection an the
groun . Now refit it part by part until a short circuit takes
place.
WARNING: Turn off power an water supply to the boiler before removing or installing any parts.

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24 volt short circuit
E 01
Remove all 24 volt connectors, such as: fan, pump, any three port valve an the 24 volt plug to the connecting
block. Check for a short circuit in the isconnecte components. Next; switch on power to the control boar with all
the 24 volt components isconnecte . Reconnect the components one at a time, if co e E 01 appears when you
plug up a component, that component has a short circuit. Rectify any short circuits or replace efective component
causing short circuit.

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Due to insufficient
ionization the burner
has shut own after
ignition
Ionization flow,
ionization cable or
02 setting
Ignition Failure Issue
Flame Failure
Issue
Note: if ionization is lost while the flame is
burning no E02 will occur - unit will attempt to
relight 6 times. E02 only occurs after 6 faile
attempts for re-ignition.
Propane gas with low BTU value or a bran
new tank that may contain something other
than pure propane may cause E02. Check
against a goo known source of gas.
The minimum ionization current
shoul be 4 micro amps (Check
INFO step 48, the O2 shoul be a
minimum of 4.4% for NG or 4.8%
for LP.
WARNING: Turn off power an water supply to the boiler before removing or installing any parts. If checking
gas pressures you MUST be qualifie gas technician to service the gas system on this appliance.