Rinnai I Series User manual

Rinnai I-Series Condensing Boiler Combi Manual
Central Heang and Domesc Hot Water
INSTALLATION AND OPERATION MANUAL
I-Series Condensing Boiler
Wall-Mounted, Gas-Fired Combi Boiler
Cered to ANSI Z21.13
and CSA 4.9
COMBI MODELS
i060C (REB-A1847FF-US)
i090C (REB-A2647FF-US)
i120C (REB-A3558FF-US)
READ AND SAVE THIS MANUAL
If the informaon in these instrucons are not followed exactly, a re or explosion may
result causing property damage, personal injury, or loss of life.
• Do not store or use gasoline or other ammable vapors and liquids in the vicinity of this or any other appliance.
• WHAT TO DO IF YOU SMELL GAS
− Do not try to light any appliance.
− Do not touch any electrical switch; do not use any phone in your building.
− Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instrucons.
− If you cannot reach your gas supplier, call the re department.
• Installaon and service must be performed by a qualied installer, service agency or the gas supplier.
WARNING

2 Rinnai I-Series Condensing Boiler Combi Manual
1. Welcome...................................................................................................................................................4
2. Safety........................................................................................................................................................5
2.1 Safety Symbols..................................................................................................................................................... 5
2.2 Safety Precauons ............................................................................................................................................... 5
3. About the Boiler ........................................................................................................................................ 7
3.1 Front View............................................................................................................................................................ 7
3.2 Boom View ........................................................................................................................................................ 8
3.3 Components......................................................................................................................................................... 9
3.4 Specicaons ..................................................................................................................................................... 10
3.5 Dimensions ........................................................................................................................................................ 11
3.6 Accessories......................................................................................................................................................... 13
4. Installaon .............................................................................................................................................. 14
4.1 Installaon Guidelines ....................................................................................................................................... 14
4.2 What You’ll Need............................................................................................................................................... 15
4.3 Items Included ................................................................................................................................................... 16
4.4 Choose an Installaon Locaon......................................................................................................................... 17
4.5 Mount the Boiler to the Wall............................................................................................................................. 19
4.6 Fill the Condensate Collector............................................................................................................................. 20
5. Venng.................................................................................................................................................... 21
5.1 Guidelines .......................................................................................................................................................... 21
5.2 Venng Installaon Sequence........................................................................................................................... 22
5.3 Terminaon Consideraons .............................................................................................................................. 22
5.4 PVC Venng Safety Switch................................................................................................................................. 23
5.5 Venng Opons................................................................................................................................................. 25
6. Gas Supply............................................................................................................................................... 46
6.1 Connect the Gas Supply..................................................................................................................................... 46
6.2 Gas Operang Instrucons ................................................................................................................................ 47
6.3 Gas Pipe Sizing Reference Tables....................................................................................................................... 48
7. DHW System Piping ................................................................................................................................. 50
7.1 Guidelines .......................................................................................................................................................... 50
7.2 Instrucons........................................................................................................................................................ 50
7.3 Piping Diagram for a Basic DHW Installaon..................................................................................................... 51
8. CH System Piping ..................................................................................................................................... 52
8.1 Guidelines .......................................................................................................................................................... 52
8.2 Instrucons........................................................................................................................................................ 52
8.3 Common CH Components ................................................................................................................................. 53
8.4 Piping Diagram for a Basic CH System (Without Hydraulic Separaon)............................................................ 55
8.5 Piping Diagram for a Basic CH System (With Hydraulic Separaon) ................................................................. 56
8.6 Hydraulic Separaon.......................................................................................................................................... 57
8.7 Connect the Pressure Relief Valves (DHW and CH)........................................................................................... 59
8.8 Connect the Condensate Drain Line .................................................................................................................. 60
8.9 Condensate Pump Safety Switch Wiring ........................................................................................................... 61

Rinnai I-Series Condensing Boiler Combi Manual 3
9. Power Supply...........................................................................................................................................63
9.1 Guidelines .......................................................................................................................................................... 63
9.2 Electrical Connecons........................................................................................................................................ 64
9.3 Post-Power Supply Connecon Checklist .......................................................................................................... 64
10. Commissioning.......................................................................................................................................65
10.1 Safety Precauons ........................................................................................................................................... 65
10.2 Filling Process................................................................................................................................................... 65
10.3 Deaeraon Process .......................................................................................................................................... 66
11. Post-Installaon Checklist ...................................................................................................................... 68
12. Operaon ..............................................................................................................................................70
12.1 Start-Up Informaon........................................................................................................................................ 70
12.2 Control Panel.................................................................................................................................................... 71
12.3 Basic Operaon Sengs .................................................................................................................................. 73
12.4 Parameter Sengs........................................................................................................................................... 84
12.5 Outdoor Reset Control..................................................................................................................................... 89
12.6 DHW Recirculaon Funcon............................................................................................................................ 94
12.7 Simultaneous CH and DHW Operaon ............................................................................................................ 98
12.8 Diagnosc Codes............................................................................................................................................ 100
12.9 Forced Hi/Low Fire Modes............................................................................................................................. 105
13. Maintenance........................................................................................................................................ 106
13.1 Owner Maintenance ...................................................................................................................................... 106
13.2 Licensed Professional Maintenance .............................................................................................................. 107
13.3 Test the Ignion Safety Shut O Device ........................................................................................................ 110
14. Appendices.......................................................................................................................................... 111
14.1 Approved Cleaners, Inhibitors and Anfreezes ............................................................................................ 111
14.2 Flush the CH Plumbing System...................................................................................................................... 112
14.3 Flush the DHW Heat Exchanger .................................................................................................................... 113
14.4 System Applicaon Examples ....................................................................................................................... 114
14.5 Gas Conversion .............................................................................................................................................. 120
14.6 Wiring Diagram .............................................................................................................................................. 124
14.7 Ladder Diagram.............................................................................................................................................. 125
14.8 CH Pressure Drop and Flow Curve................................................................................................................ 126
14.9 DHW Pressure Drop and Flow Curve ............................................................................................................ 127
14.10 Guidelines for Addional DHW Controller (Oponal) ................................................................................. 128
14.11 Remove a Boiler from a Common Vent System........................................................................................... 130
14.12 Massachuses State Gas Regulaons.......................................................................................................... 131
14.13 Warranty...................................................................................................................................................... 132

4 Rinnai I-Series Condensing Boiler Combi Manual
Thank you for purchasing a Rinnai Condensing
Boiler. Before installing and operang this
boiler, be sure to read these instrucons
completely and carefully to familiarize
yourself with the boiler’s features and
funconality.
• You must read the enre manual to
properly operate the boiler.
• Keep this manual for future reference.
• As when using any appliance generang
heat, there are certain safety precauons
you should follow. See secon “2.2 Safety
Precauons” for detailed safety
precauons.
• Be sure your boiler is installed by a
licensed installer.
• If installing in the state of Massachuses,
read secon “14.12 Massachuses State
Gas Regulaons” in this manual.
ANSI American Naonal Standards
Instute
Btu Brish Thermal Unit
CH Central Heang
DHW Domesc Hot Water
GPM Gallons per minute
LP Liquid Propane
LWCO Low Water Cut O
NG Natural Gas
PP Polypropylene
PRV Pressure Relief Valve
PSI Pounds per square inch
W.C. Inches water column
For Your Records
Dealer Name:
Located on le
side of unit
1
• A trained and qualied professional
must install the boiler, inspect it, and
leak test it before use. The warranty
will be voided due to any improper
installaon.
• The trained and qualied professional
should have skills such as:
− Gas line sizing
− Connecng gas lines, water lines,
valves, and electricity
− Knowledge of applicable naonal,
state, and local codes
− Installing venng through a wall
or roof
− Training in installaon of
condensing boilers. Training on
Rinnai I-Series Condensing Boilers
is accessible at
www.trainingevents.rinnai.us.
• Read all instrucons in this manual
before installing the boiler. The boiler
must be installed according to the
exact instrucons in this manual.
• Proper installaon is the responsibility
of the installer.
• When installaon is complete, leave
this manual with the boiler or give the
manual directly to the consumer.
Following is a list of common acronyms and
abbreviaons used in this manual:
Dealer Phone:
Purchase Date:
Serial #:

Rinnai I-Series Condensing Boiler Combi Manual 5
Indicates an imminently hazardous
situaon which, if not avoided, will
result in personal injury or death.
Indicates a potenally hazardous
situaon which, if not avoided, could
result in personal injury or death.
Indicates a potenally hazardous situaon
which, if not avoided, could result in minor
or moderate injury. It may also be used to
alert against unsafe pracces.
DANGER
WARNING
This manual contains the following important
safety symbols. Always read and obey all
safety messages.
The following precauons apply to the
installer and consumer. Read and follow all
instrucons in this secon.
• Before operang, smell all around the
appliance area for gas. Be sure to smell
next to the oor because some gas is
heavier than air and will sele on the
oor.
• Keep the area around the appliance
clear and free from combusble
materials, gasoline, and other
ammable vapors and liquids.
• Do not store or use gasoline or other
ammable vapors and liquids in the
vicinity of this or any other appliance.
• Combusble construcon refers to
adjacent walls and ceiling and should
not be confused with combusble or
ammable products and materials.
Combusble and/or ammable
products and materials should never be
stored in the vicinity of this or any gas
appliance.
• Always check the water temperature
before entering a shower or bath.
2
• If the informaon in these instrucons
is not followed exactly, a re or
explosion may result causing property
damage, personal injury, or death.
• Do not store or use gasoline or other
ammable vapors and liquids in the
vicinity of this or any other appliance.
• WHAT TO DO IF YOU SMELL GAS:
− Do not try to light any appliance.
− Do not touch any electrical
switch; do not use any phone in
your building.
− Immediately call your gas
supplier from a neighbor’s
phone. Follow the gas supplier’s
instrucons.
− If you cannot reach your gas
supplier, call the re department.
• Installaon and service must be
performed by a qualied installer,
service agency or the gas supplier.
• The warning signs in this manual are
here to prevent injury to you and
others. Please follow them explicitly.
Safety alert symbol. Alerts you
to potenal hazards that can
kill or hurt you and others.
WARNING
CAUTION

6 Rinnai I-Series Condensing Boiler Combi Manual
WARNING
This product can expose you to
chemicals including lead, lead
compounds and carbon disulde which
are known to the State of California to
cause cancer, birth defects or other
reproducve harm. For more
informaon, visit
www.P65Warnings.ca.gov.
• Flammable liquids such as cleaning
solvents, aerosols, paint thinners,
adhesives, gasoline and propane must be
handled and stored with extreme care.
These ammable liquids emit ammable
vapors and when exposed to an ignion
source can result in a re hazard or
explosion. Flammable liquids should not be
used or stored in the vicinity of this or any
other gas appliance.
• DO NOT operate the boiler without the
front panel installed. The front panel
should only be removed for service/
maintenance or replacing internal
components.
• BURN HAZARD. Hot exhaust and vent may
cause serious burns. Keep away from the
boiler. Keep small children and animals
away from the boiler.
• Heang supply, return and domesc hot
water outlet pipes leaving the boiler can be
hot to touch.
• Install the vent system per local and
naonal codes.
• Do not install this boiler above 10,200 
(3,109 m).
• Do not obstruct combuson air to the
boiler.
• Rinnai recommends that every home have
a carbon monoxide (CO) alarm in the
hallway near bedrooms in each sleeping
area. Check baeries monthly and replace
them annually.
• California law requires the following
Proposion 65 warning to be provided:
• Do not use this appliance if any part has
been under water. Immediately call a
licensed professional to inspect the
appliance and replace any part of the
control system and any manual gas control
valve which has been under water.
• Do not use substute materials. Use only
parts cered for the appliance.
• Should overheang occur or the gas
supply fail to shut o, turn o the manual
gas control valve to the appliance.
• It is strongly recommended that you use a
trained and qualied professional who has
aended a Rinnai installaon training class
to adjust parameter sengs.
• Do not use an extension cord or adapter
plug with this appliance.
• Any alteraon to the appliance or its
controls can be dangerous and will void
the warranty.
• To protect yourself from harm, before
performing maintenance:
− Turn o the electrical power supply by
unplugging the power cord or by
turning o the electricity at the circuit
breaker. (The boiler controller does
not control the electrical power.)
− Turn o the gas at the gas control,
usually located immediately below the
boiler.
− Turn o the incoming water supply.
This can be done at the isolaon valve
immediately below the boiler for the
domesc hot water. Turning o the
water for the central heang system is
done at the boiler system lling staon
shut-o valve or the main water
supply to the building.
− Use only your hand to turn the manual
gas control valve. Never use tools. If
the manual gas control valve will not
turn by hand, do not try to repair it;
call a trained and qualied
professional. Force or aempted
repair may result in a re or explosion.
• Proper venng is required for the safe
operaon of this appliance. Failure to
properly vent this appliance can result in
death, personal injury and/or property
damage.

Rinnai I-Series Condensing Boiler Combi Manual 7
The I-Series Condensing Boiler is a wall-mounted, gas-red boiler designed to providing heang
and domesc hot water.
For complete boiler informaon, refer to the “Rinnai I-Series Condensing Boiler Installaon
Manual” supplied with the boiler, or visit rinnai.us.
Topics in this secon
• Front View
• Boom View
• Components
• Specicaons
• Dimensions
• Accessories
3
Controller
Vent Connecons
Piping Connecons

8 Rinnai I-Series Condensing Boiler Combi Manual
Gas
DHW
Cold Inlet
DHW
Hot Outlet
Central
Heang
Supply
Central
Heang
Return
Supply to CH System
Return from CH System
Primary-Secondary Heang Kit
CH Pressure Relief Valve (supplied
with boiler)
CH Supply
Condensate Drain
Domesc Hot Water
Domesc Cold Water
Gas
CH Return
Domesc Hot Water Pressure Relief Valve
Central Heang Pressure Gauge
Gas Shut O Valve
All items are eld-supplied unless otherwise noted.

Rinnai I-Series Condensing Boiler Combi Manual 9
ExhaustIntake
Air Inlet Filter
Fan with Integrated Venturi
Gas Valve
Heat Exchanger
Silencer
Pressure Sensor
Integrated Pump
Diverter Valve
Burner Assembly
Ignion Unit
PC Board Cover
PC Board Removed
Control Panel
Air Intake Flue Gas Exhaust
Flow Sensor
Air Vent
Plate Heat Exchanger
Water Flow Servo Valve
Bypass Servo Valve
Condensate Trap

10 Rinnai I-Series Condensing Boiler Combi Manual
1 Maximum gas supply pressure must not exceed the value specied by the manufacturer.
Rinnai products are connually being updated and improved; therefore, specicaons are subject to change
without prior noce.
Model i060C i090C i120C
Dimensions - w, h, d 18.5 in. x 26.4 in. x 10.9 in. (471 mm x 671mm x 276 mm)
Weight 73.0 lb (33 kg) 76.1 lb (34.5 kg)
Appliance Type Wall-Mounted, Gas-Fired Combi Boiler
Installaon Type Indoor
Ignion System Direct Electronic Ignion
Heat Exchanger Surface Area 9.3 sq  10.9 sq 
Gas
Consumpon
(Btu/hr)
Minimum 15,000
Maximum (CH) 60,000 90,000 120,000
Maximum (DHW) 160,000 199,000
DHW
Specicaon
Minimum Acvaon Flow Rate 0.4 GPM (1.5 L/min)
Minimum Operaon Flow Rate 0.26 GPM (1.0 L/min)
Maximum Flow Rate 7.9 GPM (30 L/min) 9.8 GPM (37 L/min)
Flow Rate at 70°F (39°C) rise 4.1 GPM (15 L/min) 5.1 GPM (19 L/min)
Temperature
Seng
CH (Minimum - Maximum) 104°F - 180°F (40°C - 82°C)
DHW (Minimum - Maximum) 98°F - 140°F (37°C - 60°C)
Water
Content
CH 0.75 gal 0.75 gal 0.88 gal
DHW 0.05 gal 0.05 gal 0.05 gal
Water
Pressure
CH Minimum: 13 PSI (90 kPa) Maximum: 45 PSI (310 kPa)
Recommended: 17-26 PSI (117-180 kPa)
Pressure Relief Valve for CH
(included with system) 30 PSI (207 kPa)
DHW Minimum: 2 PSI (10 kPa) / Maximum: 150 PSI (1,034 kPa)
(Recommend 10-80 PSI for maximum performance)
Grundfos Pump Model UPS 15-78
Sound Level CH: 42 dB(A)
DHW: 44 dB(A) CH: 42 dB(A) DHW: 47 dB(A)
Electrical Data
Normal (CH) 144 W 158 W 158 W
Normal (DHW) 174 W 174 W 194 W
Standby 4 W
Max Current 6 Amps
Fuse 10 Amps x 2
Gas Supply
Pressure1
Natural Gas 3.5 in. - 10.5 in. W.C. (0.87 - 2.61 kPa)
Propane 8.0 in. - 13.5 in. W.C. (1.99 - 3.36 kPa)
Electric Connecons AC 120 Volts, 60 Hz
Cercaons ANSI Z21.13, CSA 4.9, ASME