Rinnai RCB750AN User Manual

2 Rinnai Commercial Boiler Installation and Operation Manual

used under license by Rinnai America Corporaon. Rinnai America Corporaon connually updates

materials, and as such, content is subject to change without noce.

If the informaon in these instrucons is 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 licensed professional.

WARNING

Rinnai Commercial Boiler Installation and Operation Manual 3

1. Welcome ................................................................................................................................................ 5

1.1 To The Consumer ......................................................................................................................... 5

1.2 To The Installer ............................................................................................................................ 5

1.3 Acronyms and Abbreviaons ....................................................................................................... 5

2. Safety...................................................................................................................................................... 6

2.1 Safety Symbols ............................................................................................................................. 6

2.2 Safety Precauons ........................................................................................................................ 6

3. About the Boiler ..................................................................................................................................... 8

3.1 Front View ................................................................................................................................... 8

3.2 Back View .................................................................................................................................... 8

3.3 Components ................................................................................................................................ 9

3.4 Altude ...................................................................................................................................... 13

3.5 Specicaons ............................................................................................................................. 14

3.6 Dimensions ................................................................................................................................ 15

3.7 Included Accessories .................................................................................................................. 17

3.8 Oponal Accessories .................................................................................................................. 18

4. Installaon............................................................................................................................................ 20

4.1 Installaon Guidelines ............................................................................................................... 20

4.2 What You Will Need ................................................................................................................... 21

4.3 Choose an Installaon Locaon ................................................................................................. 22

4.4 Prepare the Boiler ...................................................................................................................... 25

4.5 Fill the Condensate Collector ..................................................................................................... 25

5. Venng ................................................................................................................................................. 26

5.1 Guidelines .................................................................................................................................. 26

5.2 Venng Installaon Sequence .................................................................................................... 27

5.3 Terminaon Consideraons ....................................................................................................... 27

5.4 PVC Venng Safety Switch ......................................................................................................... 28

5.5 Venng Opons .......................................................................................................................... 29

6. Gas Supply ............................................................................................................................................ 49

6.1 Connect the Gas Supply ............................................................................................................. 49

6.2 Gas Operang Instrucons ......................................................................................................... 50

6.3 Gas Pipe Sizing Reference Tables ............................................................................................... 51

7. CH System Piping .................................................................................................................................. 54

7.1 Guidelines .................................................................................................................................. 54

7.2 Instrucons ................................................................................................................................ 54

7.3 Common CH Components .......................................................................................................... 55

7.4 Hydraulic Separaon .................................................................................................................. 60

7.5 Connect the Pressure Relief Valves ............................................................................................ 62

7.6 Connect the Condensate Drain Line ........................................................................................... 63

8. DHW System Piping with Indirect Tank ................................................................................................ 64

8.1 Guidelines .................................................................................................................................. 64

8.2 Indirect Tank Control Opons .................................................................................................... 64

9. Power Supply ....................................................................................................................................... 69

9.1 Guidelines .................................................................................................................................. 69

9.2 Electrical Connecons ................................................................................................................ 70

9.3 Post-Power Supply Connecon Checklist ................................................................................... 73

10. Commissioning ................................................................................................................................... 74

10.1 Safety Precauons ................................................................................................................... 74

10.2 Filling Process .......................................................................................................................... 74

10.3 Deaeraon Process .................................................................................................................. 75

4 Rinnai Commercial Boiler Installation and Operation Manual

11. Post-Installaon Checklist .................................................................................................................. 76

12. Operaon ........................................................................................................................................... 78

12.1 Start-Up Informaon ................................................................................................................ 78

12.2 Control Panel ........................................................................................................................... 79

12.3 Error and Diagnosc Codes .................................................................................................... 101

12.4 Perform Combuson Analysis ................................................................................................ 108

12.5 Operang Informaon ........................................................................................................... 110

13. Maintenance .................................................................................................................................... 114

13.1 Owner Maintenance ............................................................................................................... 114

13.2 Licensed Professional Maintenance ....................................................................................... 115

13.3 Service of Heat Exchanger ...................................................................................................... 118

13.4 Instrucons to Clean Condensate Trap ................................................................................... 120

13.5 Test the Ignion Safety Shut O Device ................................................................................. 121

14. Appendices ....................................................................................................................................... 122

14.1 Flush the CH Plumbing System ............................................................................................... 122

14.2 Ladder Diagram...................................................................................................................... 126

14.3 Wi-Fi Connecvity .................................................................................................................. 127

14.4 Ethernet Connecvity ............................................................................................................ 128

14.5 Building Management System (BMS) .................................................................................... 129

14.6 Remove a Boiler from a Common Vent System ...................................................................... 132

14.7 Massachuses State Gas Regulaons..................................................................................... 133

14.8 Warranty ............................................................................................................................... 134

Rinnai Commercial Boiler Installation and Operation Manual 5

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.

ANSI

American Naonal Standards

Instute

Btu Brish Thermal Unit

CH Central Heang

SOLO

Heang only boiler capable of

DHW through an indirect tank

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

wc Inches water column

• 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

Condensing Boilers is accessible at:

rinnaipro.myabsorb.com.

Following is a list of common acronyms and

abbreviaons used in this manual:

• 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 “14.6 Massachuses State

Gas Regulaons” in this manual.

• 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.

Table 1: Acronyms and Abbreviaons

6 Rinnai Commercial Boiler Installation and Operation Manual

Safety alert symbol. Alerts you

to potenal hazards that can

kill or hurt you and others.

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.

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. (when connected

to an indirect tank)

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.

WARNING

DANGER

WARNING

CAUTION

Rinnai Commercial Boiler Installation and Operation Manual 7

• 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 and side panel installed. The front

and side 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 and return 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.

• This product burns gas to produce heat.

The appliance must be properly installed,

operated, and maintained to avoid

exposure to appreciable levels of carbon

monoxide and the installer is required to

conrm that at least one carbon monoxide

alarm is installed in the living space before

the appliance is put into operaon. It is

important for the carbon monoxide alarms

to be installed, maintained, and replaced

following the alarm manufacturer’s

instrucon and applicable local codes.

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.

• 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

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.

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.

8 Rinnai Commercial Boiler Installation and Operation Manual

The Rinnai Commercial Boiler is a floor-standing, gas-fired boiler designed to provide heating to the

building with the ability to connect an indirect tank for DHW production.

Topics in this section

• Front View

• Back View

• Components

• Altitude

• Specifications

• Dimensions

• Included Accessories

• Optional Accessories

Figure 1

Controller

Reset

Button

Controller

Reset

Button

Vent

Connections

Figure 2

Condensate

Drain

Central

Heating

Supply

Central

Heating

Return

Gas

Exhaust

Air Intake

Drain

Air Intake

Exhaust

Central

Heating

Return

Central

Heating

Supply

Gas

Condensate

Drain

RCB750AN / RCB1000AN RCB750AN / RCB1000AN

RCB500AN RCB500AN

Rinnai Commercial Boiler Installation and Operation Manual 9

RCB1000N shown

Flue Thermistor

Return Thermistor

Spark Generator

Water Flow Sensor

Ignion Electrode

Supply Thermistor

Supply Water Pipe

Fan

Flue Pressure

Switch

High Voltage

Connecon

Burner Door

Switch

Main Control

Check Valve

7-Inch Touch

Screen Display

Exhaust

Intake

Flame Rod

(Ionizaon Probe)

Refer to the next page for a descripon of each component.

Figure 3

RCB1000AN shown

Heat Exchanger

Return Water Pipe

Condensate Trap

Gas Valve

Air/Gas Mixer

Low Voltage

Connecon

Cascade Module

Figure 4

Webserver Card/

Wi-Fi Module

Temperature &

Pressure Gauge

Pressure Relief Valve

Caster and leveling

pads

10 Rinnai Commercial Boiler Installation and Operation Manual

RCB500AN shown

Flue Thermistor

Automac Air Vent

Return Thermistor

Spark Generator

Water Flow Switch

Ignion Electrode

Supply Thermistor

Supply Water Pipe

Fan

Flue Pressure

Switch

High Voltage

Connecon

Burner Door

Switch

Main Control

Check Valve

7-Inch Touch

Screen Display

Exhaust

Intake

Flame Rod

(Ionizaon Probe)

Refer to the next page for a descripon of each component.

Figure 5

Thermal Fuse

Heat Exchanger

Return Water Pipe

Condensate Trap

Gas Valve

Air/Gas Mixer

Low Voltage

Connecon

Cascade Module

Figure 6

Webserver Card/

Wi-Fi Module

RCB500AN shown

Caster and leveling

pads

Rinnai Commercial Boiler Installation and Operation Manual 11

Listed below are descripons of each boiler component. Refer to the previous page for component

illustraon.

Item Name Descripon

Return Thermistor

A sensor that monitors the water temperature returning into the

boiler.

Automac Air Vent A device used to bleed the air from the heang system.

Spark Generator

Applies high voltage through the spark electrode to ignite the

burner.

Water Flow Switch

A switch that monitors water ow when boiler receives a heat

demand. This switch will disable boiler operaon in case there is

a heat demand but the ow is not detected.

Supply Thermistor

A sensor that monitors the boiler outlet water temperature. The

control will shut down the boiler in case the temperature exceeds

a certain limit.

Ignion Electrode Provides direct spark to ignite the burner.

Supply Water Pipe

1-1/2 In for RCB500AN model and 2 In for RCB750AN and

RCB1000AN models.

Fan

Pulls air and gas through the air/gas mixer. Air and gas are

pre-mixed inside of the fan and are pushed into the burner for

combuson.

High Voltage Terminal

Strip

Contains connecon points for main power supply and all pumps

power.

Flue Pressure Switch

A safety device that monitors the pressure in the vent and shuts

down the appliance in case of blockage to avoid unsafe

condions.

Flue Thermistor

A sensor that monitors the ue gas exit temperature. The control

will shut down the boiler if the ue gas temperature gets too hot

to protect the ue pipe from overheang.

Burner Door Switch

A switch that will break the control circuit, shung down the

boiler in case the burner door temperature is too high.

Main Control

The integrated controller monitors and controls the system

operaon. The controller responds to internal and external

signals and controls the fan, gas valve, spark generator, and

pumps to meet the heat demand.

Flame Rod (Ionizaon

Probe)

Detects and monitors the presence of a ame.

Check Valve

Prevents ue gas back ow into the fan in case of negave

pressure in the boiler room in a power vent installaon. The

check valve also acts as back ow preventer in a common vent

system where mulple units are cascaded.

7-Inch Touch Screen

Display

The full-color touch screen allows a user friendly interface with

the boiler control.

Air/Gas Mixer

The venturi controls the mixture of air and gas before entering

the burner for combuson.

Low Voltage Terminal

Strip

Contains connecon points for low voltage input and output

signals.

Table 2: Boiler Component Descripons

12 Rinnai Commercial Boiler Installation and Operation Manual

Item Name Descripon

Thermal Fuse

A safety device that will stop the boiler operaon in case of unusual

temperature rise.

Heat Exchanger

The stainless steel condensing heat exchanger is eciently designed to

maximize heat transfer through the coils while providing protecon

against ue gas corrosion.

Return Water Pipe

1-1/2 In for RCB500AN model and 2 In for RCB750AN and RCB1000AN

models.

Condensate Trap

The high eciency heat exchange produces condensate during

operaon. The condensate trap manages the condensate disposal and

the built-in oat prevents ue gases to escape through the condensate

drain.

Gas Valve

The zero governor gas valve regulates the gas ow through the venturi

based on sucon from the fan.

Cascade Module

Used to establish communicaon between boiler in a cascade system by

connecng them to each other using two conductor 18-20 AWG

shielded wire.

Webserver Card/

Wi-Fi Module

The Webserver Card/Wi-Fi Module allows the installer to remotely

monitor the system operaon, pro-acvely opmize eciency, and aid

in troubleshoong. This card also establishes the communicaon

between main control board and user interface screen.

Temperature &

Pressure Gauge

This device show the current boiler supply temperature and system

pressure.

Pressure Relief

Valve

The boiler is supplied with a 75 PSI Pressure Relieve Valve. This is a

safety device that will relief pressure and prevent unsafe operaon in

case the system pressure is too high.

Caster and

leveling pads

The boiler is had built-in caster that can facilitate moving the boiler to its

installaon locaon. Also, the leveling pads can be used to level the

boiler once it is in place.

Boiler Name Plate

The ASME name plate (Figure 7) includes the Naonal Board (NB) and

Canadian Registraon Number (CRN) numbers.

Addional Components Not Shown in Images:

Burner The metal ber and stainless steel burner uses premixed air and gas to

provide a wide range of ring rates.

Outdoor Sensor Uses the outdoor temperature to adjust the unit setpoint to provide

greater eciency.

Cascade System

Sensor

In a cascade system, the master boiler requires a system supply sensor

to operate properly. The locaon of the sensor should be downstream

of the of the boiler connecon in the main system loop.

DHW Sensor/

Aquastat

Monitors and controls the temperature of an indirect tank.

Table 2 (Connued): Boiler Component Descripons (Connued)

Figure 7

Boiler

Name

Plate

Rinnai Commercial Boiler Installation and Operation Manual 13

This boiler can operate from sea level up to 10,200 feet [3,109 m]. The table below represents the

de-rates for each model, gas type, and altude. For proper operaon ensure to set the control for

proper gas type and altude. Tap the setup, boiler setup page on the boiler screen for proper gas

type and altude sengs. De-rate values are based on proper combuson sengs as

recommended in this manual. For installaon above 2,000  (609 m) in Canada, follow all

applicable local codes and regulaons.

NOTE: See control secon on how to change altude seng from the control panel.

ALTITUDE VENTING:

500 model ONLY: For altudes above 2,000  (609 m), vent length is reduced to 110  (33 m).

0 - 2000 

(0-609 m)

2001 - 5400 

(610 -1645 m)

5401 - 7700 

(1646 - 2346 m)

7701 - 10200 

(2347 - 3109 m)

Model

NG LP NG LP NG LP NG LP

RCB500AN 0.0 % 0.0 % 10.0 % 10.0 % 20.0 % 20.0 % 25.0 % 25.0 %

RCB750AN 0.0 % 0.0 % 10.0 % 10.0% 15.0 % 15.0 % 20.0 % 20.0 %

RCB1000AN 0.0 % 0.0 % 0.0 % 0.0% 10.0 % 10.0 % 15.0 % 15.0 %

NOTE: The values listed on the above table are the total percentage of boiler input de-rate for each

elevaon range.

Table 3

14 Rinnai Commercial Boiler Installation and Operation 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.

2 500 model ONLY: For altudes above 2,000  (609 m), vent length is reduced to 110  (33 m).

Table 4: Specicaons

Model RCB500AN RCB750AN RCB1000AN

Ignion System Direct Electronic Ignion

Dimensions (Appliance) - In. (mm) -

w, h, d

21.75 x 39.5 x 30.75

(550 x 1004 x 781)

28.5 x 44.5 x 51.75

(723 x 1127 x 1312)

Weight (Appliance) 243 lb (110 kg) 525 lb (238 kg) 567 lb (257 kg)

Dimensions (Shipping) - In. (mm) -

w, h, d

30 x 48 x 36

(770 x 1220 x 910)

38 x 57 x 60

(970 x 1450 x 1530)

Weight (Shipping) 300 lb (136 kg) 591 lb (268 kg) 633 lb (287 kg)

Heat Exchanger Surface Area 36.8 sq  60.9 sq  75.4 sq 

Gas

Consumpon

(Btu/h)

Minimum 50,000 75,000 99,000

Maximum 500,000 750,000 999,000

Temperature

Seng

CH (Minimum - Maximum) 86°F - 180°F (30°C - 82°C)

Indirect

Tank (DHW)

104°F - 176°F (40°C - 80°C)

Water Content 2.7 gal (10.1 lt) 6.6 gal (24.8 lt) 8.1 gal (30.6 lt)

Water Pressure

Minimum: 14.5 PSI (1 bar)

Maximum Allowable Water Pressure (MAWP): 160 PSI (1103 kPa)

PRV 75 PSI (5.2 bar) (Pressure Relieve Valve included with system)

Electrical Data

Normal 350 W 484 W 605 W

Standby 10 W

Max

Current

20 Amps

Fuse

Main controller: 2 x 6.3 Amps

Each Pump (Boiler, CH, DHW): 5 Amps

Gas

Supply Pressure

Natural Gas 3.5 in. - 10.5 in. wc (0.87 - 2.61 kPa)

Propane 8.0 in. - 13.5 in. wc (1.99 - 3.36 kPa)

Electric Connecons AC 120 Volts, 60 Hz

Cercaons ANSI Z21.13, CSA 4.9, ASME

Canada CRN Y6325.2C R5402.5C

Warranty

Heat Exchanger: 10 Years. All Other Parts & Components: 1 Year.

Reasonable Labor: 1 Year. See the “Rinnai Commercial Boiler

Warranty” for Complete Details

Venng

45° elbow is

equivalent to 3 

(1 m).

90° elbow is

equivalent to 6 

(2 m).

Opons:

• Direct Vent

• Non-Direct Vent (Room Air)

Materials

PVC, CPVC, PP and Stainless Steel

Vent Size

4 in. PVC/CPVC 6 in. PVC/CPVC

Exhaust

Vent Run (Min-Max): 10  (3 m) - 140  (43 m)

Intake

Vent Run (Min-Max): 0  (0 m) - 140  (43 m)

Rinnai Commercial Boiler Installation and Operation Manual 15

Measurements: in. [mm]

Connection Connection Size Minimum Pipe Size

Gas 1 in. NPT 1 in.

CH In (CH Return) 1-1/2 in. NPT 1-1/2 in.

CH Out (CH Supply) 1-1/2 in. NPT 1-1/2 in.

Condensate Drain 1 in. NPT 3/4 in.

Venting (Intake & Exhaust) 4 in. PVC/CPVC 4 in.

Dimensions: RCB500AN MODEL

Table 5

TOP

30-3/4

[781]

27-3/4

[704]

BACK

AIR INTAKE

EXHAUST

WATER SUPPLY

WATER RETURN

CONDENSATE DRAIN

GAS

7-1/4

[185]

10-3/4

[275]

17-1/2

[443]

2-1/2

[64]

4-3/8

[111]

13-5/16

[338]

9-3/4

[247]

3-3/8 - REF

[85] - REF

Measurements: in. [mm]

FRONT

39-1/2

[1004]

35-1/2

[903]

21-3/4

[550]

Figure 8

AIR INTAKE

16 Rinnai Commercial Boiler Installation and Operation Manual

Connection Connection Size Minimum Pipe Size

Gas 1-1/4 in. NPT 1-1/4 in.

CH In (CH Return) 2 in. NPT 2 in.

CH Out (CH Supply) 2 in. NPT 2 in.

Condensate Drain 1 in. NPT 3/4 in.

Venting (Intake & Exhaust) 6 in. PVC/CPVC 6 in.

Dimensions: RCB750AN & RCB1000AN MODELS

Table 6

SIDE

51-3/4

[1312]

[1143]

FRONT

44-1/2

[1127]

28-1/2

[723]

CONDENSATE DRAIN

BACK

AIR INTAKE

EXHAUST

WATER SUPPLY

WATER RETURN

ELECTRICAL

KNOCKOUTS

GAS

DRAIN

PRESSURE/TEMP GAUGE

3-3/8 - REF

[85] - REF

75 PSI PRV

[536]

4-5/8

[118]

11-1/2

[292]

[70]

17-3/4

[452]

29-5/8

[751]

36-1/2

[927]

13-3/4

[351]

13-3/4

[348]

[406]

[586]

Figure 9

Rinnai Commercial Boiler Installation and Operation Manual 17

Carefully unpack your boiler system and verify the following contents are included. If any items are

damaged or missing, contact your local dealer/distributor. Do not aempt to use any item that

appears damaged.

• Installaon and Operaon Manual

(this manual)

• User Manual

• Warranty Card

• Addional technical literature

included inside product box

• CSD-1 Form

DOCUMENTATION

TEMPERATURE & PRESSURE

GAUGE

PART #: 803000092

PRESSURE RELIEF VALVE, 75 PSI

OUTDOOR TEMPERATURE

SENSOR

PART #: 805000097

PART #: 807000224

Figure 10

SPARE FUSES - 2 X 6.3 A

(LOCATED INSIDE OF MAIN

CONTROL COVER)

INTAKE PIPE SCREWS (QTY 3)

4.8 X 25 MM SS PANHEAD PH2

(TAPPED TO INTAKE ADAPTER)

PART #: 803000079

PART #: 809000304

18 Rinnai Commercial Boiler Installation and Operation Manual

The following oponal accessories are available for the Rinnai Commercial Boiler.

Neutralizes the condensate

generated by the boiler.

CONDENSATE NEUTRALIZER

PART #: 804000074

Filters and eliminates debris (> 0.5 mm)

from entering the combuson chamber

for indirect venng (room air) piping.

AIR INLET FILTER

PART #: 803000050

In a cascade system the Master boiler

requires a system supply sensor in

order to operate properly. The locaon

of the sensor should be downstream of

the of the boiler connecon in the

main system loop.

CASCADE SYSTEM SENSOR

PART #: 803000051

GAS CONVERSION KIT

Converts the boiler gas type.

PART #: 803000083 - 500 NG

PART #: 803000084 - 500 PROPANE

PART #: 803000085 - 750 NG

PART #: 803000086 - 750 PROPANE

PART #: 803000087 - 1000 NG

PART #: 803000088 - 1000 PROPANE

Connued on next page

500 MODEL ONLY

To establish boiler communicaon with

Building Management System (BMS)

through BACnet.

BACNET ADAPTER

PART #: 803000078

To establish boiler communicaon with

Building Management System (BMS)

through LonWorks.

BACNET ADAPTER WITH LONWORKS

PART #: 803000080

Figure 11

Rinnai Commercial Boiler Installation and Operation Manual 19

Oponal Accessories (Connued)

This device limits the boiler supply

temperature and will shut the boiler down

in case of high temperature. It has a

manual reset funcon and complies with

CSD-1 requirements.

WATER TEMPERATURE HIGH LIMIT

PART #: 804000089

This device detects system water level

and will shut the boiler down in case the

water level is low. It has a manual reset

and complies with CSD-1 requirements.

LOW WATER CUT-OFF (LWCO)

PART #: 803000090

These devices monitor gas pressure

and will shut the boiler down in case

the gas pressure is too low or too high.

They have a manual reset funcon and

comply with CSD-1 requirements.

HIGH & LOW GAS PRESSURE SWITCHES

PART #: 803000091

Figure 11 A

20 Rinnai Commercial Boiler Installation and Operation Manual

THIS SECTION IS INTENDED

FOR THE INSTALLER

Installer qualicaons: A trained and qualied

professional must install the appliance,

inspect it, and leak test the boiler 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 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; and

training in installaon of condensing boilers.

Topics in this secon

• Installaon Guidelines

• What You Will Need

• Choose an Installaon Locaon

• Prepare the Boiler

• Fill the Condensate Collector

• This boiler is cered for installaon in

residenal and commercial applicaons.

• This boiler is suitable for combinaon

water heang through an indirect tank

and central heang.

• The installaon must conform with local

codes or, in the absence of local codes,

with the Naonal Fuel Gas Code, ANSI

Z223.1/NFPA 54, or the Natural Gas and

Propane Installaon Code, CSA B149.1. If

installed in a manufactured home, the

installaon must conform with the

Manufactured Home Construcon and

Safety Standard, Title 24 CFR, Part 3280

and/or CAN/SCA Z240 MH Series, Mobile

Homes.

• The appliance, when installed, must be

electrically grounded in accordance with

local codes or, in the absence of local

codes, with the Naonal Electrical Code,

ANSI/NFPA 70, or the Canadian

Electrical Code, CSA C22.1.

• The appliance and its main gas valve

must be disconnected from the gas

supply piping system during any

pressure tesng of that system at test

pressures in excess of 1/2 psi (3.5 kPa)

(13.84 in W.C.). For system tesng at

pressures less than or equal to 1/2 psi

(3.5 kPa) (13.84 in W.C.) the appliance

must be isolated from the gas supply

piping by closing its individual manual

shuto valve.

• You must follow the installaon

instrucons and those in secon

“5. Venng” for adequate combuson

air and exhaust.

• Should overheang occur or the gas

supply fail to shut o, turn o the

manual gas control valve to the

appliance.

• Combuson air must be free of

chemicals, such as chlorine or bleach,

that produce fumes. These fumes can

damage components and reduce the life

of your appliance.

• Where required by the authority having

jurisdicon, the installaon must comply

with the Standard for Controls and

Safety Devices for Automacally Fired

Boilers, ANSI/ASME CSD-1.

Rinnai Commercial Boiler Installation and Operation Manual 21

DO NOT install the boiler in an area

where water leakage of the unit or

connecons will result in damage to

the area adjacent to the appliance

or to lower oors of the structure.

When such locaons cannot be

avoided, it is required that a

suitable drain pan, adequately

drained, be installed under the

boiler. The pan must not restrict

combuson air ow.

DO NOT install the boiler in an area

with negave air pressure.

DO NOT obstruct the ow of

combuson and venlaon air.

DO NOT use substute parts that

are not authorized for this boiler.

DO NOT install the boiler on

carpeng.

DO NOT install boiler outdoors.

DO NOT

Gather the recommended tools and parts

before starng installaon.

Items Needed

• Boiler Pump

• Pressure relief valve for domesc hot

water (150 PSI / 10.3 Bar)

(as necessary, if using a separate

indirect tank).

• Pressure/Temperature Gauge

Note: When aaching the pressure/

temperature gauge, please comply

with applicable codes and the ASME

standard.

• Low loss header or closely spaced tee

• Expansion tank for a closed heang

system

• Air separator

• Standard tools for central heang, gas

ng, plumbing and electrical wiring.

• Digital manometer

• Combuson analyzer (intended for use

with condensing boilers)

• Digital mulmeter capable of reading

microamps

• pH digital meter or test strips

• For wall mounng bracket installaon:

− Level

− Screws (use appropriate screws for

type of wall construcon)

Other Items You May Need

• Pallet Jack, Forkli, or Hoist

• Ensure the wall is of sucient

strength to support the weight of the

boiler, piping and any other

components needed for installaon;

if it is not, please reinforce the wall as

appropriate.

• Operang limits of the boiler:

Maximum boiler set

point temperature:

180°F (82°C)

Maximum operang

pressure:

160 psi (11 bar)

Maximum allowable

working

temperature ASME:

210°F (99°C)

Maximum allowable

working pressure

ASME:

160 psi (11 bar)

Pressure Relief Valve

(shipped with unit):

75 psi (5.2 bar)

Table 7

22 Rinnai Commercial Boiler Installation and Operation Manual

Consideraon of care for your boiler should

include evaluaon of water quality.

• The water must be potable, free of

corrosive chemicals, sand, dirt, or other

contaminants.

• It is up to the installer to ensure the water

does not contain corrosive chemicals or

elements that can aect or damage the

boiler.

• Water that contains chemicals exceeding

the levels below can damage the boiler.

• The pH level must fall between 6.5 and

8.5.

• Total water hardness must fall between 5

and 12 grains per gallon.

• When water hardness is higher than

12 grains per gallon consult local

water treatment companies.

• Chloride concentraon must be less than

150 ppm (mg/l)

• Do not ll appliance to work with

water containing chlorides in excess

of 150 ppm (mg/l).

• Using chlorinated fresh water should

be acceptable as levels are typically

less than 5 ppm (mg/L).

• Do not connect the appliance to

directly heat swimming pool or spa

water.

• Total Dissolved Solids (TSD) must be

between 100 and 350 ppm (mg/l).

• Total dissolved solids are minerals,

salts, metals, and charged parcles

that are dissolved in water.

When choosing an installaon locaon, you

must ensure that clearances will be met and

that the vent length will be within required

limits. Consider the installaon

environment, water quality, and need for

freeze protecon. Requirements for the gas

line, water lines, electrical connecon, and

condensate disposal can be found in their

respecve installaon secons in this

manual.

This secon provides informaon on the

importance of water quality to the Rinnai

Condensing Boiler. The informaon is

intended to serve as general guidelines only

and is not a complete list of water quality

guidelines.

• The greater the amounts of TDS

present, the higher the corrosion

potenal due to increased

conducvity in the water.

• If using soened water to ll the

appliance, it is sll possible to have

high TDS. This water can be

corrosive. Consult local water

treatment companies for other

treatment soluons to reduce this

aect.

• Unsuitable heang system water can

cause the formaon of scale or sludge,

which aects system eciency. It can

also cause corrosion and reduce life of

the heat exchanger. It is crical to

monitor pH, hardness level, chlorides,

and TDS to prolong the life of the

appliance.

• Never use water that has been treated by

a reverse osmosis, deionized, or dislled

water to soen the water to ll the

heang system.

• Connual fresh makeup water will

reduce the life of the appliance. The

addion of oxygen carried in by the make

up water can cause internal corrosion in

the system.

• When using a make up water, It is

recommended to install a water meter to

monitor the amount of water being

introduced into the system. The total

annual make up water should not exceed

5% of the total system water volume.

• Oxygen permeable or rubber tubing is

not permied in the heang system

unless it is separated from the boiler by a

plate heat exchanger.

• Thoroughly ush the system prior to

lling. While ushing, isolate the boiler.

• Do not introduce any system cleaner into

the boiler. Flush the system thoroughly

to remove all system cleaner before

lling the boiler with water.

• When freeze protecon of the heang

system is desired, use Rinnai-approved

anfreezes.

Rinnai Commercial Boiler Installation and Operation Manual 23

Producers Fernox Sennel Son ADEY

Inhibitors Protector F1/Alphi 11 X100, X500 Sion 212 MCI+

Noise Reducer X200

Universal Cleaner Restorer X300

Sludge Remover Protector F1, Cleaner F3 X400 Sion 212

Tightness Leaker Sealer F4

Treatment Type Prevenve Curave

Protector F1 X

Cleaner F3 X X

X100 X

X200 X

X300 X

X400 X

X500 X

Alphi 11 X

Leaker Sealer F4 X

Sion 212 X

MCI+ X

Table 9: Corrosion/Scale Treatment Types

Consult the glycol manufacturer for details

on the suggested mix of glycol and water for

the desired freeze protecon level and the de

-rate eect it will have on the boiler output.

NEVER use automove anfreeze. Use ONLY

inhibited propylene glycol soluons, which

are specically formulated for hydronic

heang system. Ethylene glycol is toxic and

can aack gaskets and seals used in hydronic

heang system. The allowed maximum

concentraon is 40 percent.

• Black oxide sludge (magnete - Fe304)

forms as a result of connuous electrolyc

corrosion in any system unprotected by an

inhibitor.

• Iron oxide (Fe203) (red oxide sludge) is

produced during oxygenaon. Scale

deposit is made up of lime scale contained

in most distributed water that seles over

the warmest surfaces of the system.

Sludge and scale do mix together and are

the cause of many eld problems on

heang applicaons. The presence of

these substances indicate that standard

precauons have not been implemented

and may void warranty.

• The chemical compability of several

products for the treatment of heang

water equipment has been tested on this

boiler’s heat exchanger.

• Rinnai recommends using the system

cleaners, corrosion/scale inhibitors in the

table below.

• Keep the system free of impuries,

construcon dust, sand, copper dust,

grease, carbon deposits, and welding ux

residue before and during boiler

assembly. Rinse the old system with clear

water mixed with a highly concentrated

rinse agent.

• More generally, it is advised to

implement any procedure necessary to

prevent or treat contaminaon.

Table 8: Corrosion/Scale Inhibitors and Recommended Suppliers

IMPORTANT

Replacement of components due to

water quality damage is not covered by

the warranty.

Approved System Anfreezes

Chem Frost 100%

Fernox Alphi 11

Hall-Chem Solar II

Noble Noburst AL

Rechochem Recofreeze AL

Rhomar RhoGar Mul-Metal (AL safe)

Sennel X500

Table 10: Approved System Anfreezes

IMPORTANT

• If replacing a boiler, add system cleaners

while the old boiler is installed and

operate the old boiler for heang for

several days to most eecvely clean the

system.

• The Rinnai boiler must be closed o

(valved o) from the rest of the system,

or not connected, while cleaners are in

the system.

• When cleaning is complete, drain the

system and then ush with clean water to

remove any sediment.

24 Rinnai Commercial Boiler Installation and Operation Manual

Use this checklist to ensure you have selected the correct locaon for the boiler.

Air surrounding the boiler, venng, and vent terminaon(s) is used for combuson and must be free

of any compounds that cause corrosion of internal components. These include corrosive compounds

that are found in aerosol sprays, detergents, bleaches, cleaning solvents, oil based paints/varnishes,

and refrigerants. The air in beauty shops, dry cleaning stores, photo processing labs, and storage

areas for pool supplies oen contains these compounds. The boiler, venng, and vent terminaon(s)

should not be installed in any areas where the air may contain these corrosive compounds.

□

The boiler is not exposed to corrosive compounds in the air.

□

The boiler locaon complies with the required clearances.

□

The planned combuson air and exhaust terminaon locaons meet the required clearances.

□

The water supply does not contain chemicals or exceed total hardness that will damage the

heat exchanger.

□

Ensure boiler is properly connected and grounded from 120 VAC, 60 Hz power source .

□

The installaon must conform with local codes or, in the absence of local codes, with the

Naonal Fuel Gas Code, ANSI Z223.1/NFPA 54, or the Natural Gas and Propane Installaon

Code, CSA B149.1.

Table 11: Minimum Clearances

Figure 12

Locaon Clearance

Top 4 in. (102 mm)

0 in. from vent

components

Boom

(Ground)

0 in. (0 mm)

Front 6 in. (152 mm)

Clearance for servicing

is 24 in. (610 mm) in

front of boiler

Back 18 in. (457 mm).

Sides

(Le and

Right)

2 in. (51 mm)

Clearance for servicing

is 24 in. (610 mm) on

the right side and 12

in. (305 mm) on the

le side.

Vent 0 in. (0 mm)

This image is not to scale and is for illustraon

purposes only.

Rinnai Commercial Boiler Installation and Operation Manual 25

Remove the boiler from the shipping

packaging and move it to the installation

location. NOTE: The boiler is equipped with

casters /leveling feet that makes it easy to

maneuver the boiler.

When moving the boiler, the leveling pads

should be raised to allow the wheels to touch

the ground and roll.

When the boiler is at its final installation

location, the leveling pads should be lowered

to ensure the boiler is stationary. The leveling

pads can be used to ensure the boiler is

leveled properly.

The condensate

collector must be

filled with water

prior to installing the

vent system.

Pour approximately

10 ounces (1.25

cups) of water

directly into the

boiler’s exhaust

port.

Instructions:

Before operation of the boiler, the condensate

collector must be filled with water. This is to prevent

the potential of exhaust gasses from entering the

building. Failure to fill the condensate collector could

result in severe personal injury or death.

Figure 15

WARNING

IMPORTANT

When installing the boiler, the boiler must be

level to ensure proper flow of condensation

inside the boiler heat exchanger. Boiler must

be level from side-to-side and front-to-back.

Exhaust

Port

Wheel

Thumb Wheel

- Turn the thumb wheel to the

le to raise the leveling pad.

- Turn the thumb wheel to the

right to lower the leveling pad.

Leveling Pad

FLOOR

Level

Figure 13

Figure 14

In order for condensation to drain properly

from the boiler collection system, the boiler

must be properly leveled. Use a level to verify

that the boiler is level from side-to-side and

front-to-back.

The boiler must be installed in an upright and

level position. Do not install the boiler upside

down or on its side.

IMPORTANT

26 Rinnai Commercial Boiler Installation and Operation Manual

• The boiler is rated ANSI Z21.13

Category IV (pressurized vent, likely to

form condensate in the vent) and

requires a special vent system

designed for pressurized venng.

• This boiler can be installed in direct

vent or non-direct (room air) vent

applicaons.

• When installed as Direct Vent, refer to

the following secon for a complete

list of approved vent manufacturers

and products: “5.5.1 Direct Vent:

Approved Vent Manufacturers and

Products.”

• Exhaust must be directly vented to

the outside. Combuson air can be

provided from outside (Direct Vent) or

from room air (Non-Direct Vent).

• If using room air (non-direct vent) for

combuson, ensure the required

volume of indoor air is available

according to the Naonal Fuel Gas

Code, ANSI Z223.1/NFPA 54.

• Avoid dips or sags in horizontal vent

runs by installing supports per the

vent manufacturer’s instrucons.

• Support horizontal vent runs every 4

 (1.2 m) and all vercal vent runs

every 6  (1.83 m) or as per vent

manufacturer’s instrucons or local

code requirements.

Topics in this secon

• Guidelines

• Venng Installaon Sequence

• Terminaon Consideraons

• PVC Venng Safety Switch

• Venng Opons

• Venng should be as direct as possible with

a minimum number of pipe ngs.

• For manufactured vent systems, vent

connecons must be rmly pressed

together so that the connecons form an

air ght seal. Follow the venng

manufacturer’s instrucons.

• Refer to the Schedule 40 PVC/CPVC

manufacturer for appropriate ngs,

solvents or joining methods.

• If venng reassembly is needed, follow the

steps for installing the venng in the

following secons. Make certain that the

vent piping and seals are not damaged.

Only use sealants, primers, or glues that are

approved for the vent material in use.

• Refer to the instrucons of the vent system

manufacturer for component assembly

instrucons.

• If the vent system is to be enclosed, it is

suggested that the design of the enclosure

shall permit inspecon of the vent system.

The design of such enclosure shall be

deemed acceptable by the installer or the

local inspector.

• Any issues resulng from improper vent

installaon will not be covered by warranty.

• DO NOT use cellular core PVC/CPVC.

• DO NOT use Radel, ABS, or galvanized

material to vent this appliance.

• DO NOT cover non-metallic vent pipe

and ngs with thermal insulaon.

• DO NOT combine vent components

from dierent manufacturers.

• Vent diameter cannot be less than 4 in.

for RCB500AN model and less than 6 in.

for RCB750AN and RCB1000AN models.

• DO NOT connect the venng system

with an exisng vent or chimney.

• DO NOT common vent with the vent

pipe of any other manufacturer’s boiler

or appliance.

WARNING

Rinnai Commercial Boiler Installation and Operation Manual 27

1. Determine the terminaon method - horizontal

or vercal, concentric or twin pipes

terminaons, etc.

2. Determine proper locaon for wall or roof

penetraon for each terminaon.

3. Install terminaon assembly as described in this

manual or in the vent manufacturer’s

installaon instrucons.

4. Install intake and exhaust piping from boiler to

terminaon.

5. Slope horizontal exhaust run towards the boiler

1/4 in per foot. DO NOT slope combuson air

pipe towards boiler.

6. Install vent supports and brackets allowing for

movement from expansion, or as per vent

manufacturer’s instrucons or local code

requirements.

7. (Oponal step) Install vent screen or room air

lter (not included with purchase) at intake and

exhaust terminaons as illustrated below.

Check to determine whether local codes

supersede the following clearances:

• Avoid terminaon locaons near a dryer

vent.

• Avoid terminaon locaons near

commercial cooking exhaust.

• Avoid terminaon locaons near any air

inlets.

• You must install a vent terminaon at least

12 in. above the ground or ancipated snow

level.

Vent Screen

• Press vent screen

inside of terminaon

piece/elbow.

• Secure vent screen to

the terminaon

piece/elbow with

screw.

The vent for this appliance shall not

terminate:

• Over public walkways.

• Near sot vents or crawl space vents

or other area where condensate or

vapor could create a nuisance or

hazard or cause property damage.

• Where condensate or vapor could

cause damage or could be detrimental

to the operaon of regulators

pressure relief valves, or other

equipment.

Listed below are important consideraons

for locang vent terminaon under a sot

(venlated or unvenlated or eave vent; or

to a deck or porch):

• Do not install vent terminaon under

a sot vent such that exhaust can

enter the sot vent.

• Install vent terminaon such that

exhaust and rising moisture will not

collect under eaves. Discoloraon to

the exterior of the building could

occur if installed too close.

• Do not install the vent terminaon too

close under the sot where it could

present recirculaon of exhaust gases

back into the combuson air intake of

the terminaon.

Horizontal porons of the venng system

shall be supported to prevent sagging:

• For category IV boilers, have

horizontal runs sloping upwards not

less than 1/4 in. per foot (21 mm/m)

from the boiler to the vent terminal;

• For category IV boilers, be installed so

as to prevent accumulaon of

condensate; and

• For category IV boilers, where

necessary, have means provided for

drainage of condensate.

Figure 16

28 Rinnai Commercial Boiler Installation and Operation Manual

The instructions in this section explain how to adjust boiler settings to

allow for higher exhaust temperatures. These instructions apply only for

installations using CPVC, listed Polypropylene, or stainless steel venting. If these instructions are

not followed exactly, a fire or carbon monoxide leak may result causing property damage,

personal injury, or death. DO NOT adjust boiler settings to allow higher exhaust temperatures

when venting with PVC.

This product is equipped with safety devices to control the exhaust temperature which allows for a

variety of venting materials to be used in its final installation. The boiler is set up from the factory to

be installed with a PVC venting system and a built-in control to limit the exhaust temperature to be

below 149°F (65°C). In high temperature applications where the exhaust temperature can exceed

149°F (65°C), CPVC, listed Polypropylene (PP), or stainless steel venting must be used. The choice of

venting materials may have an impact on overall performance. Also, If the vent material is other than

PVC (CPVC, listed PP or stainless steel) follow the procedure below to adjust the internal settings.

1. Press “Setup” on

the home screen

(Figure 17).

2. The first screen of the setup function appears. Press “Boiler Setup” menu to access the screen

shown below.

3. Change the parameter “Vent Pipe Material” from “PVC” to “Other” to allow for higher vent

temperature (Figure 18).

Select

“Other”

Figure 17

WARNING

Figure 18

Rinnai Commercial Boiler Installation and Operation Manual 29

Two venng opons are available: Direct Vent and Non-Direct Vent (Room Air).

If installing a direct vent opon, combuson

air must be drawn from the outside directly

into the boiler intake and exhaust must

terminate outdoors. The vent terminaon can

be twin pipe (2 separate penetraons, or

concentric with a single penetraon)

See the Direct Vent secon for complete details.

Direct Vent

Opon 1 Opon 2

Non-Direct Vent (Room Air)

See the Non-Direct Vent secon for complete

details.

If installing a non-direct vent (room air), indoor

air is used for combuson while exhaust vents

to the outside.

Exhaust

Figure 19 Figure 20

Combuson

air (oponal

intake lter)

Combuson

air

30 Rinnai Commercial Boiler Installation and Operation Manual

Following is a list of vent components and terminaons for Direct Vent installaons (concentric and twin pipe).

Install the correct venng for your model according to the venng manufacturer’s instrucons and the guidelines

below. The informaon below is correct at me of publicaon and is subject to change without noce. Contact the

vent manufacturer for quesons related to the vent system, products, part numbers and instrucons.

Manufacturer Phone Web Site Vent Material

Centrotherm 877-434-3432 www.centrotherm.us.com Polypropylene

IPEX

U.S.: 800-463-9572

Canada: 866-473-9462

www.ipexamerica.com, www.ipexinc.com PVC/CPVC

DuraVent 800-835-4429 www.duravent.com Polypropylene, Metal

Royal 800-232-5690 www.royalbuildingproducts.com PVC

ECCO Manufacturing 877-955-4805 www.eccomfg.com Polypropylene

DiversiTech 800-995-2222 www.diversitech.com PVC/CPVC

VENT TERMINATIONS (RCB50AN MODEL)

Table 12: Approved Vent Manufacturers

CONCENTRIC VENT TERMINATIONS (4 Inch)

4PPS-HKC

4”X6” PolyPro Horizontal Terminaon Kit

w/LB2

4PPS-HSTSL

4”x6” Horizontral Terminaon for

Commercial Systems

4PPS-VKC

4PPS-VK-TCC

4”x6” Vercal Terminaon Kit w/Black Cap

& LB2

4”x6” PolyPro Vercal Terminaon Kit w/

Terracoa Cap w/ LB2

FSEDVWMT04U 4” Universal Concentric Kit

FDVWMT04RH

FSEDVWMT04LH

Wall Mount Concentric Kit

FDVWT04 Remote Concentric Kit

Duravent

-PolyPro

Duravent

-FasNSeal

Diagram

Horizontal

Vercal

Product

Descripon

Manufacturer

Part Number/

Order Number

Manufacturer

Table 13

Rinnai Commercial Boiler Installation and Operation Manual 31

CONCENTRIC VENT TERMINATIONS (4 Inch) - CONT.

196021

197021

397021

System 636 Concentric Terminaon Kit -

PVC (white)

System 636 Concentric Terminaon Kit -

CPVC (grey)

System 1738 Concentric Terminaon Kit -

PVC (black)

190488

Horizontal Concentric Wall Terminaon-

Polypropylene

190295

Vercal Concentric Roof Terminaon-

Polypropylene

190483

4”x6” Horizontal Concentric Wall

Terminaon–Polypropylene

190484

4”x6” Vercal Concentric Roof Terminaon

-Polypropylene

4PPS-HTPC 4” Twin Pipe Terminaon-Polypropylene

ISLPT0404 4” Low Prole Wall Terminaon

196986

397986

System 636 FGV Low Prole Terminaon

Kit – PVC (Beige)

System 1738 FGV Low Prole Terminaon

Kit – PVC (Black)

IPEX

ECCO

Diagram

Horizontal

Vercal

Product

Descripon

Manufacturer

Part Number/

Order Number

Manufacturer

Duravent

Centrotherm

IPEX

Table 13 connue

32 Rinnai Commercial Boiler Installation and Operation Manual

TWIN PIPE TERMINATIONS (4 Inch) - CONT.

4PPS-E90BC 4” Black UV Resistant 90 elbow

4PPS-TBC 4” Black Terminaon Tee

FSBS4 4” Bird Screen 23°

FSTT4 4” Terminaon Tee

FSTB4 4” Terminaon Box

ISTT0420 4” Terminaon Tee

ISSNKL041 4” Snork

ISHT0445 4” Snout

286715 SGV Rain Cap

Duravent

-FasNSeal

Diagram

Horizontal

Vercal

Product

Descripon

Manufacturer

Part Number/

Order Number

Manufacturer

Centrotherm

Duravent

-PolyPro

IPEX

Table 13 connued

Rinnai Commercial Boiler Installation and Operation Manual 33

VENT TERMINATIONS (RCB750AN & RCB1000AN MODELS)

CONCENTRIC VENT TERMINATIONS (6 inch) - CONT.

6PPS-VTMC Vercal Terminaon

6PPS-HSTL Horizontal Terminaon

FSTT6 6 Inch Terminaon Tee

FSRC6 Rain Cap

ISLPT0606 Low Prole Wall Terminaon

ISTT0620 Terminaon Tee

ISEP06 End Pipe PP Gray

IAPRF06 Pitched Roof Flashing

IAFRF06 Flat Roof Flashing

190628 Single Wall Vercal Terminaon

190613 87 degree elbow - UV resistant

190611 45 degree elbow - UV resistant

Duravent

-PolyPro

Duravent

-FasNSeal

Diagram

Horizontal

Vercal

Product

Descripon

Manufacturer

Part Number/

Order Number

Manufacturer

Centrotherm

ECCO

Table 14

34 Rinnai Commercial Boiler Installation and Operation Manual

APPLIANCE ADAPTER (4 Inch and 6 Inch)

4PPS-AD-M Appliance Adapter for PVC Pipe - 4 Inch

4PPS-ADL

Appliance Adapter for PVC Coupler - 4 Inch

4PPS-04PVCM-4PPF

6PPS-06PVCM-6PPF

Male PVC Appliance Adapter - 4 Inch

Male PVC Appliance Adapter - 6 Inch

FSA-04M-4PPF

PVC to FasNSeal Appliance Adapter - 4 Inch

PVC to FasNSeal Appliance Adapter - 6 Inch

ISAGL0404

ISAGL0606

Appliance Adapter - PVC to PP - 4 Inch

Appliance Adapter - PVC to PP - 6 Inch

ISAAL0404

ISAAL0606

Appliance Adapter – PVC to PP - 4 Inch

Appliance Adapter – PVC to PP - 6 Inch

4PPSSAD Appliance Adapter-SS - 4 Inch

Duravent

-FasNSeal

Diagram

Horizontal

Vercal

Product

Descripon

Manufacturer

Part Number/

Order Number

Manufacturer

Centrotherm

Duravent

-PolyPro

ECCO

Table 14 connue

Rinnai Commercial Boiler Installation and Operation Manual 35

VARIOUS 4 in. and 6 in. SCHEDULE 40 PVC/CPVC TERMINATIONS

Approved Materials for Exhaust and Intake Pipe

Item Material

Standard for Installaon in North America

United States Canada

Pipe

(Intake or Exhaust)

SS AL29-4C Cered for direct vent category IV appliance

PVC Schedule 40/80 UL-1738 or ANSI/ASTM D1785

UL-1738 or ULC -S636

Intake pipe may be of

the materials listed in

this table.

PVC-DWV Schedule 40/80 UL-1738 or ANSI/ASTM D2665

CPVC Schedule 40/80 UL-1738 or ANSI/ASTM F441

Polypropylene UL-1738 or ULC-S636

Fing

(Intake or Exhaust)

PVC Schedule 40 UL-1738, ANSI/ASTM D2465 or D2666

PVC Schedule 80

UL-1738, ANSI/ASTM D2465 or

D26667

CPVC Schedule 40 UL-1738 or ANSI/ASTM F438

CPVC Schedule 80 UL-1738 or ANSI/ASTM F438

Pipe Cement and

Primer

PVC ANSI/ASTM D2564

ULC -S636

CPVC ANSI/ASTM F493

Pipe and Fings for

Intake Only

ABS ANSI/ASTM D2661 ANSI/ASTM D2661

Pipe Cement and

Primer for Intake

Only

ABS ANSI/ASTM D2235 ANSI/ASTM D2235

NOTICE: DO NOT USE CELLULER (FOAM) CORE PIPE FOR EXHAUST VENTING.

Refer to the PVC/CPVC manufacturer for appropriate ngs, solvents or joining methods.

Air Filter Screen

Tee

90° Elbow

45° Elbow

Product

Descripon

Diagram

Horizontal

Vercal

Table 16: Approved Materials for Exhaust and Intake Pipe

Table 15

36 Rinnai Commercial Boiler Installation and Operation Manual

Canadian Installaons

(CSA B149.1)

U.S. Installaons

(ANSI Z223.1 /NFPA 54)

Ref Descripon Direct Vent (Indoor Unit) Direct Vent (Indoor Unit)

A Clearance above grade, veranda, porch, deck, or balcony 12 in. (30 cm) 12 in. (30 cm)

B Clearance to window or door that may be opened 36 in. (91 cm)

4  (1.2 m) below or to side of

opening;

1  (30 cm) above opening

C Clearance to permanently closed window * *

Vercal clearance to venlated sot, located above the terminal within a

horizontal distance of 2  (61 cm) from the center line of the terminal

* *

E Clearance to unvenlated sot * *

F Clearance to outside corner * *

G Clearance to inside corner * *

Clearance to each side of center line extended above meter/regulator

assembly

* *

I Clearance to service regulator vent outlet

Above a regulator within 3 

(91 cm) horizontally of the vercal

center line of the regulator vent

outlet to a maximum vercal

distance of 15  (4 m)

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

combuson air inlet to any other appliance

36 in. (91 cm) 12 in. (30 cm)

K Clearance to a mechanical air supply inlet 6  (1.83 m)

3  (91 cm) above if within

10  (3 m) horizontally

Clearance above paved sidewalk or paved driveway located on public

property

7  (2.13 m) [1] *

M Clearance under veranda, porch, deck, or balcony 12 in. (30 cm) [2] *

AIR SUPPLY INLET

VENT TERMINAL

AREA WHERE TERMINAL

IS NOT PERMITTTED

SNOW

TERMINATION

Clearance in

Ref. A also

applies to

anticipated

snow line

Clearance to opposite wall is 24 in. (60 cm).

[1] A vent shall not terminate directly above a sidewalk or paved driveway that

is located between two single family dwellings and serves both dwellings.

[2] Permied only if veranda, porch, deck, or balcony is fully open on a mini-

mum of two sides beneath the oor.

 Clearances are in accordance with local installaon codes and the

requirements of the gas supplier.

The informaon below applies to Concentric and Twin Pipe.

Figure 21

Table 17: Direct Vent Terminaon Clearances - ANSI Z223.1 / NFPA54 for US and CAN/CSA B149.1 for Canada.

Table 18

Rinnai Commercial Boiler Installation and Operation Manual 37

12 in. (0.30 m)

Between terminals at same level

60 in. (1.52 m)

Between terminals at different levels

Note: 24 in. (0.61 m)

to wall or parapet

All terminations (horizontal and/or vertical) must

terminate 12 in. (0.30 m) above grade or anticipated

snow level.

Inside

Corner

12 in.

(0.30 m)

60 in. (1.52 m)

vertically between

terminals

“Y” Concentric

Fitting

6” (152 mm) Dia.

4” (102 mm) Dia.

Through all

4” (102 mm)

Dia.

Through all

6” (152 mm) Dia.

Rain Cap

Strap

Vent

Combustion

Air

Combustion

Air

Do Not Install U-Bend to

Rain Cap

Figure 22

Figure 23

12 in.

(0.30 m)

38 Rinnai Commercial Boiler Installation and Operation Manual

Twin Pipe Vercal Terminaon

of Mulple Boilers

12 in. (0.30 m)

minimum

12 in. (0.30

m) minimum

above

combuson

air opening

Roof

12 in. (0.30 m)

above grade or

ancipated snow

level

12 in. (0.30 m)

minimum

Combuson

Air

Exhaust

ACCEPTABLE ACCEPTABLE NOT ACCEPTABLE

90° Elbows,

Long Sweep

90° Elbows,

Short Sweep

90° Elbows,

Close Turn

Indicates area in which

intake cannot be located.

Intake

Ground/Grade/Snow Level

60 in.

(152 cm)

Min.

12 in.

(30 cm)

Min.

Intake

Exhaust

Intake

12 in.

(30 cm)

Min.

12 in.

(30 cm)

Min.

12 in.

(30 cm)

Min.

12 in.

(30 cm)

Min.

Figure 24

Figure 26

Horizontal Vent and

Combuson Air Piping

Sidewall Clearances

Combuson

Air Intake

Exhaust

12 in.

(0.30 m)

Figure 25

MODEL

RCB500AN

RCB750AN and

RCB1000AN

Vent Sizes 4 in. PVC/CPVC 6 in. PVC/CPVC

Min-Max Exhaust Vent Run

10 feet (3 meters) - 140  (43 m)

Min-Max Intake Vent Run

0 feet (0 meters) - 140  (43 m)

• 45° elbow is equivalent to 3  (1 m)

• 90° elbow is equivalent to 6  (2 m)

Vent length includes the addional venng, ngs and terminaons.

Table 19: Twin Pipe Maximum Equivalent Vent Lengths

Table 20

Rinnai Commercial Boiler Installation and Operation Manual 39

DO NOT apply PVC glues, solvents, or cleaners to the boiler’s combuson air or exhaust gasket connecons.

Failure to correctly assemble the components according to these instrucons may result in property damage,

personal injury, or death.

Exhaust Pipe: Align and slide down PVC/CPVC

pipe on the exhaust vent connecon.

NOTE: Ensure that the pipe passes through

the rubber gasket on the metal vent adapter

and also hits a stop on the vent connecon.

Secure the pipe to the intake air adapter

using 3 screws (supplied with appliance).

To secure the exhaust air vent pipe, ghten

the clamp aached on exhaust air vent using

a screwdriver.

WARNING

Combuson

Air Pipe

Exhaust Vent

Pipe

Air Intake: Align and slide down PVC/CPVC

pipe on the air intake connecon.

Exhaust Pipe: Align and insert the PVC/CPVC

pipe on the exhaust vent connecon.

NOTE: Ensure that the pipe passes through the

rubber gasket on the metal vent adapter and

also hits a stop on the vent connecon.

Secure the pipe to the intake air adapter

using 3 screws (supplied with appliance).

To secure the exhaust air vent pipe, ghten

the clamp aached on exhaust air vent using

a screwdriver.

Air Intake: Align and insert the PVC/CPVC

pipe on the air intake connecon unl it hits

a stop.

Combuson

Air Pipe

Exhaust Vent

Pipe

The intake and exhaust adapters on top of the appliance are designed to t 4 Inch PVC/CPVC pipe. When

using other vent materials such as PP and Stainless Steel pipes ensure to use an appliance adapter from the

pipe manufacturer to properly connect to the boiler adapters.

The intake and exhaust adapters on back of the appliance are designed to t 6 Inch PVC/CPVC pipe. When

using other vent materials such as PP and Stainless Steel pipes ensure to use an appliance adapter from the

pipe manufacturer to properly connect to the boiler adapters.

Figure 27

Figure 28

40 Rinnai Commercial Boiler Installation and Operation Manual

Rinnai cautions against installing the boiler in applications with venting in different

pressure planes. It is possible to have poor performance with this installation.

Slope horizontal exhaust 1/4 in. per foot towards the boiler. DO NOT slope combustion air pipe towards the boiler.

CAUTION

Combustion

Air

Exhaust

Single

Pipe

Tee not permissible for intake

termination

Exhaust and combustion air MUST NOT

be brought together into a single PVC

pipe using a pipe fitting.

Schedule 40 PVC/CPVC Standard

Upside Down

"U" Vertical Termination

Schedule 40 PVC/CPVC

Elbow or Tee Side Wall Termination

Schedule 40 PVC/CPVC

Tee Vertical Termination

PVC Low Profile Termination

Tee not

permissible for

intake

termination

Figure 29

WARNING

This conguraon requires the use

of a Concentric Vent Terminaon.

PVC/CPVC

IPEX / Royal Concentric

Side Wall Terminaon

PVC/CPVC

IPEX /Royal Concentric

Vercal

Terminaon

Schedule 40 PVC/CPVC Snorkel

Terminaon

This conguraon

requires the use of

a Concentric Vent

Terminaon.

Schedule 40 PVC/CPVC

Side Wall Intake Vertical Exhaust

Tee not permissible

for intake

termination

Rinnai Commercial Boiler Installation and Operation Manual 41

Canadian Installaons

(CSA B149.1)

U.S. Installaons

(ANSI Z223.1 /NFPA 54)

Ref Descripon Other than Direct Vent (Room Air) Other than Direct Vent (Room Air)

A Clearance above grade, veranda, porch, deck, or balcony 12 in. (30 cm) 12 in. (30 cm)

B Clearance to window or door that may be opened 36 in. (91 cm)

4  (1.2 m) below or to side of opening;

1  (30 cm) above opening

C Clearance to permanently closed window * *

Vercal clearance to venlated sot, located above the

terminal within a horizontal distance of 2  (61 cm) from

the center line of the terminal

* *

E Clearance to unvenlated sot * *

F Clearance to outside corner * *

G Clearance to inside corner * *

Clearance to each side of center line extended above

meter/regulator assembly

* *

I Clearance to service regulator vent outlet

Above a regulator within 3  (91 cm)

horizontally of the vercal center line of

the regulator vent outlet to a maximum

vercal distance of 15  (4 m)

Clearance to non-mechanical air supply inlet to building or

the combuson air inlet to any other appliance

36 in. (91 cm)

4  (1.2 m) below or to side of opening;

1  (30 cm) above opening

K Clearance to a mechanical air supply inlet 6  (1.83 m)

3  (91 cm) above if within 10 

(3 m) horizontally

Clearance above paved sidewalk or paved driveway located

on public property

7  (2.13 m) [1] 7  (2.13 m)

M Clearance under veranda, porch, deck, or balcony 12 in. (30 cm) [2] *

AIR SUPPLY INLET

VENT TERMINAL

AREA WHERE TERMINAL IS

NOT PERMITTTED

SNOW

TERMINATION

Clearance in

Ref. A also

applies to

anticipated

snow line

Clearance to opposite wall is 24 in. (60 cm).

[1] A vent shall not terminate directly above a sidewalk or paved driveway that is

located between two single family dwellings and serves both dwellings.

[2] Permied only if veranda, porch, deck, or balcony is fully open on a minimum

of two sides beneath the oor.

 Clearances are in accordance with local installaon codes and the

requirements of the gas supplier.

Figure 30

Table 21: Room Air Terminaon Clearances

Table 22

42 Rinnai Commercial Boiler Installation and Operation Manual

Room Air Vertical Termination of Multiple Boilers

Exhaust Termination Clearances for Internal (Indoor) Room Air Applications

Exhaust

Roof

12 in. (0.30 m)

minimum

12 in. (0.30 m)

above grade or

anticipated snow

level

60 in. (1.52 m)

12 in.

(0.30 m)

Inside

Corner

Vertically

between

terminals

IMPORTANT

• Installation of Room Air must use listed Category IV venting.

• All terminations (horizontal and/or vertical) must terminate 12 in. above grade or anticipated

snow level.

Figure 31

Figure 32

Rinnai Commercial Boiler Installation and Operation Manual 43

MODEL RCB500AN RCB750AN and RCB1000AN

Vent Sizes 4 in. PVC/CPVC 6 in. PVC/CPVC

Min-Max Exhaust Vent Run

10 feet (3 meters) - 140 feet (43 meters)

Min-Max Intake Vent Run

0 feet (0 meters) - 140 feet (43 meters)

• 45° elbow is equivalent to 3  (1 m)

• 90° elbow is equivalent to 6  (2 m)

• This boiler requires adequate combuson air for venlaon and diluon of ue gases. Failure to provide

adequate combuson air can result in unit failure, re, explosion, serious bodily injury or death. Use the

following methods to ensure adequate combuson air is available for correct and safe operaon of this

boiler.

• Direct Venng is recommended in unusually ght buildings or in installaon locaons subject to

signicant negave air pressure.

Combuson air must be free of corrosive chemicals. Do not provide combuson air from corrosive

environments. Appliance failure due to corrosive air is not covered by warranty.

IMPORTANT

ACCEPTABLE ACCEPTABLE NOT ACCEPTABLE

90° Elbows,

Long Sweep

90° Elbows,

Short Sweep

90° Elbows,

Close Turn

Vent length includes the addional venng, ngs and terminaons.

For applicaons containing corrosive indoor air, this appliance must be installed as direct vent. DO NOT use

room air in applicaons where combuson air contains acid forming chemicals such as sulfur, uorine and

chlorine. These chemicals have been found to cause rapid damage and decay and can become toxic when

used as combuson air in gas appliances. Such chemicals can be found in, but not limited to bleach,

ammonia, cat lier, aerosol sprays, cleaning solvents, varnish, paint and air fresheners. Do not store these

products or similar products in the vicinity of this boiler.

Table 23: Room Air Maximum Equivalent Vent Lengths

WARNING

Table 24

44 Rinnai Commercial Boiler Installation and Operation Manual

Unconned Space

An unconned space is dened in Naonal Fuel Gas Code, ANSI Z223.1/NFPA 54 as “a space whose volume is

not less than 50 cubic feet per 1000 Btu/hr (4.8 m3 per kW per hour) of the aggregate input rang of all

appliances installed in that space. Rooms communicang directly with the space in which the appliances are

installed, through openings not furnished with doors, are considered a part of the unconned space.” If the

“unconned space” containing the appliance(s) is in a building with ght construcon, addional outside air

may be required for proper operaon. Outside air openings should be sized the same as for a conned

space.

Conned Space

A conned space is dened in the Naonal Fuel Gas Code, ANSI Z223.1/NFPA 54 as "a space whose volume is

less than 50 cubic feet per 1000 Btu/hr (4.8 m3 per kW per hour) of the aggregate input rang of all

appliances installed in that space." Examples include a small room, closet, alcove, ulity room, etc. A

conned space must have two combuson air openings. Size the combuson air openings based on the Btu

input for all gas ulizaon equipment in the space and the method by which combuson air is supplied.

Using Indoor Air For Combuson

When using air from other room(s) in the building, the total volume of the room(s) must be of adequate

volume (greater than 50 cubic feet per 1000 Btu/hr). Combuson air openings between joining rooms must

have at least 1 square inch of free area for each 1000 Btu/hr, but not less than 100 square inches each.

Using Outdoor Air For Combuson

Outdoor air can be provided to a conned space through two permanent openings, one commencing within

12 in. (0.30 m) of the top and one commencing within 12 in. (0.30 m) of the boom, of the conned space.

The openings shall communicate to the outside by one of two ways.

When communicang directly with the outdoors through horizontal ducts, each opening shall have a

minimum free area of 1 in

/2000 Btu/hr (1100 mm

/kW) of total input rang of all appliances in the conned

space.

Note: If ducts are used, the cross seconal area of the duct must be greater than or equal to the required

free area of the openings to which they are connected.

Louvers and Grills

When sizing the permanent opening consideraon must be taken for the design of the louvers or grills to

maintain the required free area required for all gas ulizing equipment in the space. If the free area of the

louver or grill design is not available, assume wood louvers will have 25% free area and metal louvers or grills

will have 75% free area. Under no circumstance should the louver, grill or screen have openings smaller than

1/4 in.

Examples: Wood: 10 in. x 12 in. x 0.25 = 30 in.

Metal: 10 in. x 12 in. x 0.75 = 90 in.

Rinnai Commercial Boiler Installation and Operation Manual 45

Combuson air provided to the appliance should not be taken from any area of the structure that

may produce a negave pressure (i.e. exhaust fans, powered venlaon fans).

Locaon

To maintain proper circulaon of combuson air two permanent openings (one upper, one lower) must be

posioned in conned spaces. The upper shall be within 12 in. (0.30 m) of the top of the

conned space and the lower opening shall be within 12 in. (0.30 m) of the boom of the conned space.

Openings must be posioned as to never be obstructed.

12 in.

(300 mm)

10 in.

(250 mm)

□

Verify all combuson air opening sizes are correct.

□

Ensure that the Combuson Air Requirements are followed that will provide sucient combuson

air for the appliance.

□

DO NOT use room air for combuson in applicaons where the indoor air is corrosive.

□

Verify that adequate combuson air is available for all appliances installed in the space.

□

Installaon complies with Naonal Fuel Gas Code, ANSI Z223.1/NFPA 54 as well as local and state

regulaons therein.

To prevent possible personal injury or death due to asphyxiaon, common venng with other

manufacturer’s induced dra appliances is not allowed.

IMPORTANT

Figure 33

WARNING

46 Rinnai Commercial Boiler Installation and Operation Manual

DO NOT apply PVC glues, solvents, or cleaners to the boiler’s combuson air or exhaust gasket connecons.

Failure to correctly assemble the components according to these instrucons may result in property damage,

personal injury, or death.

Exhaust Pipe: Align and slide down PVC/

CPVC pipe on the exhaust vent connecon.

NOTE: Ensure that the pipe passes through

the rubber gasket on the metal vent adapter

and also hits a stop on the vent connecon.

To secure the exhaust air vent pipe, ghten

the clamp aached on exhaust air vent using

a screwdriver.

WARNING

Intake Screen

(Not Supplied)

Exhaust Vent

Pipe

Air Intake: Secure the oponal intake

screen to the intake connecon using 3

screws (supplied with appliance).

Exhaust Pipe: Align and insert the PVC/CPVC

pipe on the exhaust vent connecon.

NOTE: Ensure that the pipe passes through the

rubber gasket on the metal vent adapter and

also hits a stop on the vent connecon.

Secure the pipe to the intake air adapter

using 3 screws (supplied with appliance).

To secure the exhaust air vent pipe, ghten

the clamp aached on exhaust air vent using

a screwdriver.

Air Intake: Align and insert the PVC/CPVC

pipe on the air intake connecon unl it hits

a stop.

Mesh

Screen

Exhaust Vent

Pipe

The intake and exhaust adapters on top of the appliance are designed to t 4 Inch PVC/CPVC pipe. When

using other vent materials such as PP and Stainless Steel pipes ensure to use an appliance adapter from the

pipe manufacturer to properly connect to the boiler adapters.

The intake and exhaust adapters on back of the appliance are designed to t 6 Inch PVC/CPVC pipe. When

using other vent materials such as PP and Stainless Steel pipes ensure to use an appliance adapter from the

pipe manufacturer to properly connect to the boiler adapters.

Combuson

Air Pipe

Install a mesh screen on the intake pipe to

prevent large debris from entering the

combuson chamber

Figure 35

Figure 34

Rinnai Commercial Boiler Installation and Operation Manual 47

Rinnai cauons against installing the boiler in applicaons with venng in dierent pressure planes.

It is possible to have poor performance with this installaon.

CAUTION

Schedule 40

PVC/CPVC Snorkel

Terminaon

Conguraon

Schedule 40

PVC/CPVC Standard

Upside Down "U"

Vercal Terminaon

Conguraon

Schedule 40

PVC/CPVC Elbow or

Tee Side Wall

Terminaon

Conguraon

Schedule 40

PVC/CPVC Tee

Vercal Terminaon

Conguraon

Figure 36

Air Inlet Filter

(Oponal)

Enlarged view of oponal air inlet lter.

Air Inlet Filter

(Oponal)

Air Inlet Filter

(Oponal)

Air Inlet Filter

(Oponal)

48 Rinnai Commercial Boiler Installation and Operation Manual

A maximum of four (4) RCB500AN Rinnai Commercial Boilers can be common vented. A maximum

of two (2) RCB750AN or RCB1000AN Rinnai Commercial Boilers can be common vented.Follow the

following guidelines to assure safe operaon:

1. Only common vent boiler of the same size and DO NOT exceed a maximum number of units

listed above.

2. DO NOT common vent Rinnai Commercial Boilers with other manufacturer’s products or other

models from Rinnai.

3. When common venng units, they must be wired and set-up to work as cascade.

4. Common venng system can be vented vercally or horizontally using direct vent or power

vent.

For detailed informaon about common venng including vent header size, approved venng, and

vent run, refer to separate “Rinnai Commercial Boiler Common Venng Installaon Instrucons” or

contact Rinnai.

Figure 37 (RCB500AN model shown)

Polypropylene (PP)

PVC / CPVC

Rinnai Commercial Boiler Installation and Operation Manual 49

• The boiler shall be installed such that the

gas ignition system components are

protected from water (dripping,

spraying, rain, etc.) during appliance

operation and service (circulator

replacement, condensate trap, control

replacement, etc.).

• A sediment trap must be provided

upstream of the gas controls.

• A manual gas shutoff valve between the

gas supply and the boiler must be

installed.

• A licensed professional must install the

gas supply.

• Turn off 120V power supply.

• Turn off the gas.

• Gas is flammable. Do not smoke or

provide other ignition sources while

working with gas.

• Do not turn on the boiler or gas until all

fumes are gone.

Topics in this section

• Connect the Gas Supply

• Gas Operating Instructions

• Gas Pipe Sizing Reference Tables

IMPORTANT

1. Check the type of gas and gas supply pressure before

connecting the boiler. If the boiler is not of the gas

type that the building is supplied with, converting the

gas type of the boiler is necessary. A gas conversion kit

is available and can be purchased as an accessory.

Remove the Gas connection cap from the gas pipe

connection on the boiler before connecting the gas

supply piping.

2. Check the gas supply pressure immediately upstream

at a location provided by the gas company. Supplied

gas pressure must be within the limits shown below:

Natural Gas: 3.5 in. - 10.5 in. wc (0.87 - 2.61 kPa)

Propane Gas: 8.0 in. - 13.5 in. wc (1.99 - 3.36 kPa)

Maximum gas pressure checked with no flow (lockup)

or with boiler on.

Minimum pressure checked with gas flowing and unit

running at 100% of the firing rate.

3. Before placing the appliance in operation, all joints

including the heater must be checked for gas tightness

by means of soap, gas leak detector solution, or an

equivalent nonflammable solution, as applicable.

Since some leak test solutions, including soap and

water, may cause corrosion or stress cracking, the

piping shall be rinsed with water after testing, unless it

has been determined that the leak test solution is

non-corrosive.

4. Use approved and appropriately sized connectors to

connect the boiler to the gas line. Purge the gas line of

any debris before connection to the boiler.

5. Any compound used on the threaded joint of the gas

piping shall be a type that resists the action of

liquefied petroleum gas (propane/LPG).

6. The gas supply line shall be gas tight, sized, and so

installed as to provide a supply of gas sufficient to

meet the maximum demand of the heater and all

other gas consuming appliances at the location

without loss of pressure. If in doubt about the size of

the gas line, refer to section “6.3 Gas Pipe Sizing

Reference Tables.”

7. Perform a leak and pressure test prior to operating

the boiler. If a leak is detected, do not operate the

boiler until the leak is repaired.

Figure 39

Figure 38

Union

WARNING

Gas Shut Off

Valve

Sediment

trap (drip leg)

Union

Gas Shut Off

Valve

Sediment

trap (drip leg)

50 Rinnai Commercial Boiler Installation and Operation Manual

WARNING: If you do not follow these instructions EXACTLY, a fire or explosion may

result causing property damage, personal injury or loss of life.

A This appliance does not have a pilot. It is equipped with an ignition device which

automatically lights the burner. Do not try to light the burner by hand.

B BEFORE OPERATING smell all around the appliance area for gas. Be sure to smell next to

the floor because some gas is heavier than air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS:

• DO NOT try to light any appliance.

• DO NOT touch any electric switch; DO NOT use any phone in your building.

• Immediately call your gas supplier from a neighbor’s phone. Follow the gas

supplier’s instructions.

• If you cannot reach your gas supplier, call the fire department.

C Use only your hand to turn the gas control valve. Never use tools. If the gas control valve

will not turn by hand, don’t try to repair it, call a qualified service technician. Force or

attempted repair may result in a fire or explosion.

D Do not use this appliance if any part has been under water. Immediately call a qualified

service technician to inspect the appliance and to replace any part of the control system

and any gas control which has been under water.

1. Set the temperature controller to the lowest setting.

2. Turn off all electric power to the appliance if service is to be performed.

3. Turn the manual gas control valve located at gas inlet of appliance clockwise to the

OFF position.

TO TURN OFF GAS TO APPLIANCE

1. STOP! Read the safety information above on this label.

2. Set the temperature controller to lowest setting.

3. Turn off all electric power to the appliance.

4. This appliance does not have a pilot. It is equipped with a direct ignition device which

automatically lights the burner. DO NOT try to light the burner by hand.

5. Turn the manual gas control valve located at gas inlet of appliance clockwise to the

OFF position.

6. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If

you smell gas, STOP! Follow “B” in the safety information above on this label. If you don’t

smell gas, go to the next step.

7. Turn the manual gas control valve located at gas inlet of appliance counterclockwise

to the ON position.

8. Turn on all electric power to the appliance.

9. Set the temperature controller to desired setting.

10. If the appliance will not operate, follow the instructions “To Turn Off Gas To Appliance”

and call your service technician or gas supplier.

OPERATING INSTRUCTIONS

FOR YOUR SAFETY READ BEFORE OPERATING

Rinnai Commercial Boiler Installation and Operation Manual 51

The gas supply must be capable of handling the enre

gas load required at the locaon. Gas line sizing is

based on gas type, the pressure drop in the system,

the gas pressure supplied, and gas line type. For gas

pipe sizing, refer to the Naonal Fuel Gas Code, ANSI

Z223.1/NFPA 54, or the Natural Gas and Propane

Installaon Code, CSA B149.1

For some tables, you will need to determine the cubic

feet per hour of gas required by dividing the gas input

by the heang value of the gas (available from the

local gas company). The gas input needs to include all

gas products at the locaon and the maximum Btu

usage at full load when all gas products are in use.

Use the table for your gas type and pipe type to nd

the pipe size required. The pipe size must be able to

provide the required cubic feet per hour of gas or the

required Btu/hr.

The informaon below is provided as an example. The

appropriate table from the applicable code must be

used.

Pressure Drop 0.5 in. w.c.

EXAMPLE

Rinnai Model Gas Input:

Addional Appliance Total Gas

Input:

Heang Value of Gas:

Cubic Feet Per Hour (CFH):

ANSWER:

100,000

Btu/hr

1,000

Btu/

1,000,000

Btu/hr

1,000,000+100,000

(CFH) =

1000

1,100

/HR

CFH =

For this example, the pipe

diameter must be at least 1-1/2

in. pipe size and maximum 30 

(9 m) in length.

A + B

(CFH) =

Instrucons: Enter values in empty boxes.

Rinnai Model Gas Input:

Addional Appliance Total Gas Input:

Heang Value of Gas:

Cubic Feet Per Hour (CFH):

ANSWER:

Btu/hr

Btu/

Btu/hr

(CFH) =

/HR CFH =

A + B

(CFH) =

GAS PIPE SIZING CALCULATION WORKSHEET

Natural Gas

Schedule 40 Metallic Pipe

Inlet Pressure: Less than 2 psi

Specic Gravity: 0.60

Informaon in table obtained

from NFPA 54, ANSI Z223.1.

Nominal Pipe Size (in.)

1 1 1/4 1 1/2 2 2 1/2 3

Length in  Capacity in Cubic Feet of Gas per Hour

10 (3) 678 1,390 2,090 4,020 6,400 11,300

20 (6) 957 1,430 2,760

N/A

44,00 7,780

30 (9) 768 1,150 2,220 3,530 6,250

40 (12) 657 985 1,900 3,020 5,350

50 (15) 583 873 1,680 2,680 4,740

60 (18) 528 791 1,520 2,430 4,290

70 (21) 486 728 1,400 2,230 3,950

80 (24) 452 677 1,300 2,080 3,670

90 (27) 424 635 1,220 1,950 3,450

100 (30) 400 600 1,160 1,840 3,260

Gas Pipe Sizing Reference Table

Table 25

52 Rinnai Commercial Boiler Installation and Operation Manual

EXAMPLE

Rinnai Model Gas Input:

Addional Appliance Total Gas Input:

Total Gas Input:

ANSWER:

= Btu/hr

Total Gas

Input

1,100,000

EXAMPLE

Rinnai Model Gas Input:

Addional Appliance total Gas Input:

Heang Value of Gas:

Cubic Feet Per Hour (CFH):

ANSWER:

100,000

Btu/hr

1,000

Btu/

1,000,000

Btu/hr

1,000,000+100,000

(CFH) =

1000

1,100



/HR

CFH =

For this example, the pipe diameter

must be at least 1 in. nominal pipe

size and maximum 20  (6 m) in

length.

A + B

(CFH) =

100,000

Btu/hr

1,000,000

Btu/hr

For this example, the pipe diameter

must be at least 1-1/4 in. nominal

pipe size and maximum 40  (12 m)

in length.

Total

Gas

Input

= A + B

Total

Gas

Input

300,000+100,000

Pressure Drop 0.5 in. w.c.

Nominal Inside Pipe Size (in.)

3/4 1 1 1/4 1-1/2 2 2-1/2

Length in 

(meters)

Capacity in Thousands of Btu/hr

10 (3) 608 1,150 2,350 3,520 6,790 10,800

20 (6)

N/A

787 1,620 2,420 4,660 7,430

30 (9) 632 1,300 1,940 3,750 5,970

40 (12) 541 1,110 1,660 3,210 5,110

50 (15) 985 1,480 2,840

N/A

4,530

60 (18) 892 1,340 2,570 4,100

70 (21) 821 1,230 2,370 3,770

80 (24) 763 1,140 2,200 3,510

90 (27) 716 1,070 2,070 3,290

100 (30) 677 1,010 1,950 3,110

Pressure Drop 3.0 in. w.c.

Schedule 40 Metallic Pipe

Inlet Pressure: Less than 2 psi

Specic Gravity: 0.6

Nominal Pipe Size (in.)

3/4 1 1 1/4 1-1/2 2 2-1/2 3

Length in 

(meters)

Capacity in Cubic Feet of Gas per Hour

10 (3)

949 1,790 3,670 1,580 3,050 4,680 8,580

20 (6)

652 1,230 2,520 1,090 2,090 3,340 5,900

30 (9)

524 986 2,030 873 1,680 2,680 4,740

40 (12)

448 844 1,730 747 1,440 2,290 4,050

50 (15)

397 748 1,540 662 1,280 2,030 3,590

60 (18)

360 678 1,390 600 1,160 1,840 3,260

70 (21)

331 624 1,280 552 1,060 1,690 3,000

80 (24)

308 580 1,190 514 989 1,580 2,790

90 (27)

N/A

544 1,120 482 928 1,480 2,610

100 (30)

514 1,060 455 877 1,400 2,470

Informaon in table obtained from

NFPA 54, ANSI Z223.1.

Informaon in table obtained from

NFPA 54, ANSI Z223.1.

Intended use: Inial supply pressure

of 8.0 in. w.c. or greater.

Schedule 40 Metallic Pipe

Inlet Pressure: 11 in. w.c.

Specic Gravity: 1.50

Natural Gas

Propane (Undiluted)

Gas Pipe Sizing Reference Table

Table 27

Table 26

Rinnai Commercial Boiler Installation and Operation Manual 53

The gas piping must be sized for the proper flow and length of pipe, to avoid excessive pressure

drop. Both the gas meter and the gas regulator must be properly sized for the total gas load. If you

experience a pressure drop greater than 1 inch w.c. (249 Pa), the meter, regulator, or gas line is

undersized or in need of service. Perform the steps below when checking inlet gas supply:

1. Turn OFF the electrical power to the unit.

2. Shut off the gas supply at the manual gas valve in the gas piping to the appliance.

3. Remove the front panel as shown in front panel removal instructions (see section “14.

Appendices”). Place the front panel in a safe place where it can not be damaged.

4. Locate the gas valve inlet measurement port (see figure below).

500 model: Use a Torx T-10 driver to undo the screw a half turn.

750 and 1000 models: Use a small flat head screw driver to undo the screw a half turn.

5. Slip a tube over the nipple and connect to a manometer (pressure taps have a 0.35” [9mm]

outer diameter).

6. Slowly turn ON the gas supply at the manual gas valve.

7. Restore the electrical power to the unit.

8. Use the boiler controller to adjust the temperature setpoint and call for heat.

9. Observe the gas supply pressure as the unit fires at 100% of the input rate. Percent Boiler

modulation (percentage) will be displayed on the home screen of the unit.

10. Ensure the inlet pressure is within the specified range. Minimum and maximum gas supply

pressures are specified in this section of the manual. If the gas pressure is out of range, contact

the gas utility, gas supplier, qualified installer or service agency to determine the necessary

steps to provide proper gas pressure to the control.

11. Turn OFF the electrical power to the unit.

12. Shut off the gas supply at the manual gas valve in the gas piping to the appliance.

13. Remove the manometer from the pressure tap located on the gas valve. Ensure that the screw

is closed and leak tight after the testing (Torque: 0.9 - 8.9 Lb-in [0.1 - 1 Nm]).

Manifold

Pressure Port

Inlet

Pressure

Port

Manometer

Manifold

Pressure Port

Inlet

Pressure

Port

Manometer

Figure 40

RCB500AN RCB750AN/RCB1000AN

54 Rinnai Commercial Boiler Installation and Operation Manual

• This boiler is designed to work in a

closed loop system with pressure no less

than 14.5 psi (100 kPa). NOTE: Non-

metallic system piping must have an

oxygen barrier to be considered a closed

loop.

• Purge the heang system to remove all

debris and air. Debris and air in the lines

will damage the boiler.

• When removing the plasc sealing caps

from the boiler connecons, water may

come out of the boiler due to live re

tesng during manufacturing.

• The boiler, when used in connecon with

a refrigeraon system, must be installed

so the chilled medium is piped in parallel

with the boiler with appropriate valves

to prevent the chilled medium from

entering the boiler.

• The boiler piping system of a hot water

boiler connected to heang coils located

in air handling units where they may be

exposed to refrigerated air circulaon

must be equipped with ow control

valves or other automac means to

prevent gravity circulaon of the boiler

water during the cooling cycle.

• Some installaons with mulple zone

valves may require a dierenal bypass,

which will prevent excessively high ow

rates through a single zone when the

other zone valves are closed.

• It is required to include an air separator

on the central heang supply of the

system.

• System piping should be insulated when

freezing is a potenal concern.

• All piping must comply with local, state,

naonal or ASME code as appropriate.

To connect the water supply, follow the

instrucons below.

For standard installaons, refer to the “Piping

Diagram for Basic Central Heang

Installaon” in this chapter.

Remove the caps and plumb the heang

supply and return lines to the heang return

connecon on the boom of the boiler. The

return and supply connecons are 1-1/2”

NPT for the RCB500AN model and 2” NPT to

RCB750AN and RCB1000AN models.

CAUTION

• Guidelines

• Instrucons

• Common CH Components

• Hydraulic Separaon

• Connect the Pressure Relief Valves

• Connect the Condensate Drain Line

Topics in this secon

The boiler may not be installed directly to

a heang system where polybutylene or

other oxygen permeable piping is used.

Water connecons to the boiler should

follow all state and local plumbing codes.

IMPORTANT

Figure 41

SUPPLY

RETURN

SUPPLY

RCB500AN

RCB750AN/RCB1000AN

Rinnai Commercial Boiler Installation and Operation Manual 55

Listed below are common components in a

Central Heang system. Refer to the diagram

on the next page.

• Expansion Tank — A properly sized

expansion tank charged to 2 PSI (14 kPa)

below the cold system pressure is required

to limit pressure changes in the heang

system. When replacing an expansion tank,

consult the expansion tank manufacturer

for sizing. Size the expansion tank for the

required system volume and capacity

according to the expansion tank

manufacturer’s instrucons.

• Air Separator — An air separator is needed

on the central heang supply side of the

system to remove any air that may be

present in the piping.

• Pressure/Temperature Gauge — The

current pressure and temperature will

alternately be displayed on the boiler

control panel. An external temperature

and pressure gauge is recommended to be

installed on the boiler supply pipe.

• Pressure Relief Valve (PRV) — A PRV

located directly on the supply side of the

boiler is required. A 75 PSI (517 kPa) PRV is

supplied with the boiler. This boiler has a

high-temperature shut-o device built-in

as a standard safety feature. Therefore, a

“pressure only” relief valve is required. DO

NOT install a relief valve with a pressure

rang in excess of 75 psi (517 kPa) - the

maximum allowable operang pressure of

the boiler. The relief valve capacity must

exceed the BTU/H input capacity of the

boiler.

• Oxygen Eliminaon — The boiler may

only be installed in a pressurized closed-

loop heang system, free of air and

other impuries. If using oxygen

permeable tubing in the central heang

system, a plate heat exchanger is

necessary to isolate the tubing and

boiler.

• Low Water Cut O (LWCO) — This

boiler has a factory-installed pressure

sensor type LWCO. The boiler's internal

LWCO is not serviceable or adjustable.

Check your local codes to determine if a

LWCO is required and if this device

conforms to the local code. If a LWCO is

required to be installed, the probe must

be located higher than the minimum

safe water level. When a LWCO is

installed, it must be wired back to the

appropriate terminal on the boiler.

• Water Fill Valve — Maintains proper

water pressure in the central heang

circuit.

• Back Flow Preventer — Use a back ow

preventer in the lling circuit to the

appliance as required by local code.

• Dirt Trap — Protects the boiler from

debris in the plumbing system. It is

recommended to install dirt trap in a

retrot installaon to remove debris le

in the system.

• Magnec separator — This device is

recommended to be installed in a

retrot system containing cast iron and/

or steel pipe. It should be located in the

heang return line as close as possible

to the boiler.

• Boiler Circulator Pump — A properly

sized pump should be installed on the

return line pumping into the boiler. The

pump should be sized according to the

pressure losses of the boiler and the

related heang system.

56 Rinnai Commercial Boiler Installation and Operation Manual

• Purge Valve - The boiler purge valve is

used to eliminate air from the system

during start-up.

• Boiler Isolaon Valves - Full port ball

valves must be used. Any other type of

valves may cause ow restricon to the

boiler.

Common CH Components Connued

CH System Common Components Diagram

• Boiler Piping - Boiler piping must be sized

properly to avoid unnecessary ow

reducon and poor boiler performance. The

minimum pipe size is 1-1/2 inch for

RCB500AN model and 2 Inch for RCB750AN

and RCB1000AN models.

• Flow Check Valve - Check valves are

important to prevent reverse ow condion

when the pump is not operang (o-cycle).

SYSTEM

RETURN

Pressure Relief

Valve (supplied

with boiler)

Closely spaced—tee

(may be substituted

with LLH)

Figure 42

Low Water

Cut Off

(if required by

local code)

Temperature &

Pressure Gauge

Purge Valve

SYSTEM

SUPPLY

Water fill valve

Backflow

Preventer

Ball Valve

Expansion tank

Air Separator

Dirt Trap

Isolation valve

Boiler Pump

Flow check valve

Isolation valve

Piping Diagram Symbols Legend

Rinnai Commercial Boiler Installation and Operation Manual 57

NOTES:

• Primary/Secondary piping must be used (closely spaced tees or low loss header).

• All closely spaced tees shall be within 4 pipe diameters center to center spacing.

• The minimum boiler piping must be at least 1-1/2 inch for RCB500AN model and 2 Inch for

RCB750AN and RCB1000AN models. Do not downsize boiler heang loop.

• It is recommended to use a check valve to prevent reverse ow and/or gravity circulaon when

pump is in o-cycle.

• Boiler pump must be properly sized to ensure proper ow rate through the boiler and related

piping. (minimum ow rate must be maintained to prevent short cycling)

• System ow rate should always be greater than boiler primary loop ow rate when the boiler is

in operaon to prevent short cycling.

This is not an engineering drawing; it is intended only as a guide and not as a replacement for professional

engineering project drawings. This drawing is not intended to describe a complete system. It is up to the

contractor or engineer to determine the necessary components and conguraon of the parcular system to

be installed. The drawing does not imply compliance with local building code requirements. It is the

responsibility of the contractor or engineer to ensure the installaon is in accordance with all local building

codes. Confer with local building ocials before installaon.

Figure 43

MAIN POWER

BOILER PUMP

POWER INPUT AUX 1 AUX 2 QX1 QX2 QX3

L N G L N G L N G L N G L N G L N G

BX1 B3-8 B9 H5 H4 H3 BX2 PWM UX2 UX3 H6-1 H6-2 H6-3

OUTDOOR SENSOR

ROOM THERMOSTAT 1

+ - + - + - + -

LOW VOLTAGE CONNECTION

HIGH VOLTAGE CONNECTION

ZONE

CONTROL

PANEL

OUTDOOR

SENSOR

ROOM

THERMOSTAT-1

BOILER

PUMP

58 Rinnai Commercial Boiler Installation and Operation Manual

NOTES:

• Primary/Secondary piping must be used (closely spaced tees or low loss header).

• All closely spaced tees shall be within 4 pipe diameters center to center spacing.

• The minimum boiler piping must be at least 1-1/2 inch for RCB500AN model and 2 Inch for

RCB750AN and RCB1000AN models. Do not downsize boiler heang loop.

• It is recommended to use a check valve to prevent reverse ow and/or gravity circulaon

when pump is in o-cycle.

• Boiler pump must be properly sized to ensure proper ow rate through the boiler and related

piping (minimum ow rate must be maintained to prevent short cycling)

• System ow rate should always be greater than boiler primary loop ow rate when the boiler

is in operaon to prevent short cycling.

Figure 44

This is not an engineering drawing; it is intended only as a guide and not as a replacement for professional

engineering project drawings. This drawing is not intended to describe a complete system. It is up to the

contractor or engineer to determine the necessary components and conguraon of the parcular system to

be installed. The drawing does not imply compliance with local building code requirements. It is the

responsibility of the contractor or engineer to ensure the installaon is in accordance with all local building

codes. Confer with local building ocials before installaon.

ZONE

CONTROL

PANEL

OUTDOOR

SENSOR

ROOM

THERMOSTAT-1

BOILER

PUMP

MAIN POWER

BOILER PUMP

CH PUMP

POWER INPUT AUX 1 AUX 2 QX1 QX2 QX3

L N G L N G L N G L N G L N G L N G

BX1 B3-8 B9 H5 H4 H3 BX2 PWM UX2 UX3 H6-1 H6-2 H6-3

OUTDOOR SENSOR

ROOM THERMOSTAT 1

+ - + - + - + -

LOW VOLTAGE CONNECTION

HIGH VOLTAGE CONNECTION

Rinnai Commercial Boiler Installation and Operation Manual 59

Figure 45

MAIN POWER

BOILER PUMP

CH PUMP

POWER INPUT AUX 1 AUX 2 QX1 QX2 QX3

L N G L N G L N G L N G L N G L N G

BX1 B3-8 B9 H5 H4 H3 BX2 PWM UX2 UX3 H6-1 H6-2 H6-3

OUTDOOR SENSOR

ROOM THERMOSTAT 1

+ - + - + - + -

LOW VOLTAGE CONNECTION

HIGH VOLTAGE CONNECTION

CASCADE SYSTEM SENSOR

MAIN POWER

BOILER PUMP

POWER INPUT AUX 1 AUX 2 QX1 QX2 QX3

L N G L N G L N G L N G L N G L N G

BX1 B3-8 B9 H5 H4 H3 BX2 PWM UX2 UX3 H6-1 H6-2 H6-3

+ - + - + - + -

LOW VOLTAGE CONNECTION

HIGH VOLTAGE CONNECTION

MASTER UNIT

FOLLOWER UNIT

ZONE

CONTROL

PANEL

OUTDOOR

SENSOR

ROOM

THERMOSTAT-1

BOILER

PUMP

BOILER

PUMP

MASTER FOLLOWER

CASCADE SYSTEM

SENSOR

This is not an engineering drawing; it is intended

only as a guide and not as a replacement for

professional engineering project drawings. This

drawing is not intended to describe a complete

system. It is up to the contractor or engineer to

determine the necessary components and

conguraon of the parcular system to be

installed. The drawing does not imply

compliance with local building code

requirements. It is the responsibility of the

contractor or engineer to ensure the installaon

is in accordance with all local building codes.

Confer with local building ocials before

installaon.

NOTES:

• Primary/Secondary piping must be used (closely spaced tees or low loss header).

• All closely spaced tees shall be within 4 pipe diameters center to center spacing.

• The minimum boiler piping must be at least 1-1/2 inch for RCB500AN model and 2 Inch for

RCB750AN and RCB1000AN models. Do not downsize boiler heang loop.

• It is recommended to use a check valve to prevent reverse ow and/or gravity circulaon when

pump is in o-cycle.

• Boiler pump must be properly sized to ensure proper ow rate through the boiler and related

piping (minimum ow rate must be maintained to prevent short cycling)

• Indirect Water Heater Applicaon—Ensure boiler output does not exceed indirect water heater

transfer capability.

• System ow rate should always be greater than boiler primary loop ow rate when the boiler is

in operaon to prevent short cycling.

60 Rinnai Commercial Boiler Installation and Operation Manual

Rinnai requires the use of hydraulic separaon between the boiler and central heang system.

Hydraulic separaon and primary/secondary piping allow two or more circulators in a hydronic

system to operate independently, without interfering with ow in connecng piping circuits.

NOTE

Examples of Hydraulic Separaon

Closely spaced tees and low loss headers are common examples of hydraulic separators and are

used to separate the boiler loop from the central heang loop.

When Rinnai Commercial Boilers are in use with Rinnai air handlers, please reference the air

handler Installaon and Operaon Manual for installaon and performance details.

IMPORTANT

For closely spaced tee installations, the

separation at the header is to be no

more than four pipe diameters.

Low Loss

Header

Low Loss Header Primary/Secondary Piping

Closely spaced tees

IMPORTANT

If using a low loss header, install the

PRV and shut off valves between the

boiler and low loss header (as

illustrated in the above image).

Figure 46

Rinnai Commercial Boiler Installation and Operation Manual 61

The Rinnai Commercial Boiler does not have an included boiler pump. An external boiler pump

must be installed and sized to the ow rate and pressure drop through the boiler, system piping,

and system components. Larger systems, or systems with large pressure drops, should incorporate

a form of hydraulic separaon, such as closely spaced tees or a low loss header.

Model

Minimum

Pipe Size

20°F 25°F 30°F

35°F

GPM Ft/Hd

GPM Ft/Hd GPM Ft/Hd

RCB500 1-1/2 In.

49 41 39 22 32 17 28 13

RCB750 2 In.

73 12 58 8 49 6 42 4

RCB1000 2 In.

97 16 78 10 65 7 55 5

Model

Number of Units / Common Header Pipe Sizes (inches)

2 3 4 5 6 7 8

RCB500

3 4 4 4 5 5 6

RCB750

4 4 5 6 6 6 8

RCB1000

4 5 6 6 8 8 8

Recommended pipe sizing when using mulple units:

Circulator sizing informaon based on temperature rises:

Table 29: Pipe Sizing with Mulple Units

Table 28: Circulator Sizing Informaon

62 Rinnai Commercial Boiler Installation and Operation Manual

An approved pressure relief valve is required

by the American Naonal Standard (ANSI

Z21.13) and ASME Boiler and Pressure Vessel

Code, Secon IV (Heang Boilers) for all water

heang systems and shall be accessible for

servicing (an approved pressure relief valve is

supplied with the boiler). When connecng a

pressure relief valve, follow the guidelines

below:

• The pressure relief valve must comply with

the standard for Relief Valves and

Automac Gas Shuto Devices for Hot

Water Supply Systems ANSI Z21.22, the

standard Temperature, Pressure,

Temperature and Pressure Relief Valves

and Vacuum Relief Valves, CAN1-4.4, and/

or the ANSI/ASME Boiler and Pressure

Vessel Code, Secon IV (Heang Boilers).

• The pressure relief valve must be rated up

to 75 psi for central heang systems, and

to at least the maximum Btu/hr of the

appliance.

• The discharge from the pressure relief

valve should be piped to the ground or into

a drain system per local codes.

• The pressure relief valve must be manually

operated once a year to check for correct

operaon.

• The discharge line from the pressure relief

valve should pitch downward and

terminate 6 in. (152 mm) above drains

where discharge will be clearly visible.

Water discharged from the pressure relief

valve could cause severe burns instantly or

death from scalds.

• The discharge end of the line shall be plain

(unthreaded) and a minimum of 3/4 in.

nominal pipe diameter. The discharge line

material must be suitable for water at

least 180° Fahrenheit.

• If a pressure relief valve discharges

periodically, this may be due to thermal

expansion in a closed water supply system.

Contact the water supplier or local

plumbing inspector on how to correct this

situaon. Do not plug the pressure relief

valve.

• The American Naonal Standard (ANSI

Z21.13) does not require a combinaon

temperature and pressure relief valve for

this appliance. However, local codes may

require a combinaon temperature and

pressure relief valve.

• Protect pressure relief valve and pressure

relief valve discharge line from freezing.

Do not plug or restrict ow of the pressure

relief valve.

IMPORTANT

An ASME 75 psi safety pressure relief

valve is included with the boiler and must

be ed before any shut o valve in the

system.

• DO NOT plumb the pressure relief

valve with the condensate drain; both

must be plumbed independently to

drain.

• DO NOT plug the pressure relief valve

and do not install any reducing ngs

or other restricons in the relief line.

The pressure relief line should allow

for complete drainage of the valve

and the line.

• DO NOT place any other valve or

shuto device between the pressure

relief valve and the boiler.

WARNING

Rinnai Commercial Boiler Installation and Operation Manual 63

• Do not plumb the condensate drain with

the pressure relief valve; both must be

plumbed independently to drain.

• All condensate must drain and be

disposed of according to local codes.

• Use only corrosion resistant materials for

the condensate drain lines such as PVC

pipe or plasc hose.

• The condensate drain pipe (along its enre

length) must be at least 3/4 inches.

• The condensate drain pipe should be as

short as possible and have a downward

pitch.

• Condensaon drain lines installed in areas

that are subject to freezing temperatures

should be wrapped with an approved

supplemental heat source. Install per

manufacturer’s instrucons.

• Slope the condensate drain lines toward

the inside oor drain or condensate

pump.

• If the condensate drain pipe is closed or

stuck, the drain water will come out from

the side hole on the condensate drain pipe

connecon.

• The end of the condensate drain pipe

should be open to the atmosphere. The

end should not be under water or other

substances.

• If a oor drain is not available or the drain

is above the level of the condensate drain,

a condensate pump should be installed.

• Use a tee at the condensate connecon

with a branch vercally up and open to

atmosphere to prevent a vacuum that

could obstruct the ow of condensate

from the boiler.

CORRECT

Pipe open to

atmosphere

Pipe submerged

in water

NOT CORRECT

Water level

EXTERNAL TRAP

NOT REQUIRED

DO NOT

• DO NOT connect the condensate drain

line with an air condioning evaporator

coil drain.

• Boilers have an integrated condensate

trap. DO NOT install an external

condensate trap.

• A condensate neutralizer kit is available from

Rinnai. The kit allows condensate to ow

through neutralizing media that raises the pH

of the condensate to a level that will help

prevent corrosion of the drain and public

sewer system. Refer to secon “3.7 Included

Accessories” for more informaon.

• Before operaon of the boiler, the condensate

collector must be lled with water.

• Refer to neutralizer Installaon Manual and

local codes for neutralizer installaon

guidelines.

Figure 48

Figure 47

To Drain

Condensate

Drain Pump

Figure 49

Neutralizer

Open to

Atmosphere

To Drain

Open to

Atmosphere

64 Rinnai Commercial Boiler Installation and Operation Manual

Topics in this secon

• Guidelines

• Indirect Tank Control Opons

• The piping (including soldering materials)

and components connected to this

appliance must be approved for use in

potable water systems.

• Purge the water line to remove all debris

and air. Debris will damage the boiler.

• DHW must not be connected to a system

that was previously used with a non-

potable water heang appliance.

• DO NOT introduce toxic chemicals such as

those used for boiler water treatment to

the potable water used for central heang

into the DHW system.

Hot water can cause rst degree burns

with exposure for as lile as:

• 3 seconds at 140°F (60°C)

• 20 seconds at 130°F (54°C)

• 8 minutes at 120°F (49°C)

Children, disabled, or elderly are at

highest risk of being scalded. Feel water

before bathing or showering.

Water temperatures

over 125° F (52° C)

can cause severe

burns or scalding

resulng in death.

DANGER

This boiler provides DHW through an indirect

tank. The boiler incorporates temperature

control features for the boiler and indirect

tank controls, including indirect tank heang

priority.

HOT

BURN

The indirect tank temperature is controlled

through either a thermistor (default) or

thermostat/aqua-stat.

• Thermistor (Default): The Indirect Tank

temperature setpoint range is 104°F to

176°F. Connect the thermistor to the low

voltage terminal labeled ‘DHW sensor’.

When a thermistor is connected, the boiler

will automacally recognize the

temperature in the tank. Once the setpoint

is selected, the boiler will automacally

calculate the supply temperature setpoint

in order to eciently sasfy the Indirect

Tank demand. The maximum boiler supply

temperature is 180°F (82°C). The higher

the supply temperature to the tank, the

quicker the tank will heat up.

• Thermostat: If thermostat control of the

tank is desired, the thermostat connects to

the low voltage terminal labeled ‘DHW

sensor’. Set the Indirect Setpoint to match

the seng of the Aqua-Stat mounted on

the tank. Once the setpoint is selected, the

boiler will automacally calculate the

supply temperature setpoint in order to

eciently sasfy the Indirect Tank

demand. The maximum boiler supply

temperature is 180°F (82°C). The higher

the supply temperature to the tank, the

quicker the tank will heat up.

Rinnai Commercial Boiler Installation and Operation Manual 65

NOTES:

• Primary/Secondary piping must be used (closely spaced tees or low loss header).

• All closely spaced tees shall be within 4 pipe diameters center to center spacing.

• The minimum boiler piping must be at least 1-1/2 inch for RCB500AN model and 2 Inch for

RCB750AN and RCB1000AN models. Do not downsize boiler heang loop.

• It is recommended to use a check valve to prevent reverse ow and/or gravity circulaon when

pump is in o-cycle.

• Boiler pump must be properly sized to ensure proper ow rate through the boiler and related

piping (minimum ow rate must be maintained to prevent short cycling)

• Indirect Water Heater Applicaon—Ensure boiler output does not exceed indirect water heater

transfer capability.

• System ow rate should always be greater than boiler primary loop ow rate when the boiler is

in operaon to prevent short cycling.

WARNING

Low temperature heang zones must be protected with a mixing valve if

running simultaneous DHW and Central Heang.

This is not an engineering drawing; it is intended only as a guide and not

as a replacement for professional engineering project drawings. This

drawing is not intended to describe a complete system. It is up to the

contractor or engineer to determine the necessary components and

conguraon of the parcular system to be installed. The drawing does

not imply compliance with local building code requirements. It is the

responsibility of the contractor or engineer to ensure the installaon is in

accordance with all local building codes. Confer with local building

ocials before installaon.

+ - + - + - + -

MAIN POWER

BOILER PUMP

DHW PUMP

POWER INPUT AUX 1 AUX 2 QX1 QX2 QX3

L N G L N G L N G L N G L N G L N G

BX1 B3-8 B9 H5 H4 H3 BX2 PWM UX2 UX3 H6-1 H6-2 H6-3

OUTDOOR SENSOR

ROOM THERMOSTAT 1

+ - + - + - + -

LOW VOLTAGE CONNECTION

HIGH VOLTAGE CONNECTION

DHW SENSOR/AQUASTAT

Figure 50

ZONE

CONTROL

PANEL

OUTDOOR

SENSOR

ROOM

THERMOSTAT-1

BOILER

PUMP

DHW

PUMP

DHW SENSOR /

AQUASTAT

66 Rinnai Commercial Boiler Installation and Operation Manual

MAIN POWER

BOILER PUMP

DHW PUMP

POWER INPUT AUX 1 AUX 2 QX1 QX2 QX3

L N G L N G L N G L N G L N G L N G

BX1 B3-8 B9 H5 H4 H3 BX2 PWM UX2 UX3 H6-1 H6-2 H6-3

OUTDOOR SENSOR

ROOM THERMOSTAT 1

+ - + - + - + -

LOW VOLTAGE CONNECTION

HIGH VOLTAGE CONNECTION

DHW SENSOR/AQUASTAT

NOTES:

• Primary/Secondary piping must be used (closely spaced tees or low loss header).

• All closely spaced tees shall be within 4 pipe diameters center to center spacing.

• The minimum boiler piping must be at least 1-1/2 inch for RCB500AN model and 2 Inch for

RCB750AN and RCB1000AN models. Do not downsize boiler heang loop.

• It is recommended to use a check valve to prevent reverse ow and/or gravity circulaon when

pump is in o-cycle.

• Boiler pump must be properly sized to ensure proper ow rate through the boiler and related

piping (minimum ow rate must be maintained to prevent short cycling)

• Indirect Water Heater Applicaon—Ensure boiler output does not exceed indirect water heater

transfer capability.

• System ow rate should always be greater than boiler primary loop ow rate when the boiler is in

operaon to prevent short cycling.

WARNING

Low temperature heang zones must be protected with a mixing valve if

running simultaneous DHW and Central Heang.

This is not an engineering drawing; it is

intended only as a guide and not as a

replacement for professional engineering

project drawings. This drawing is not intended

to describe a complete system. It is up to the

contractor or engineer to determine the

necessary components and conguraon of the

parcular system to be installed. The drawing

does not imply compliance with local building

code requirements. It is the responsibility of the

contractor or engineer to ensure the

installaon is in accordance with all local

building codes. Confer with local building

ocials before installaon.

Figure 51

ZONE

CONTROL

PANEL

OUTDOOR

SENSOR

ROOM

THERMOSTAT-1

BOILER

PUMP

DHW

PUMP

DHW SENSOR /

AQUASTAT

Rinnai Commercial Boiler Installation and Operation Manual 67

This is not an engineering drawing; it is intended only as a guide and not as a replacement for

professional engineering project drawings. This drawing is not intended to describe a complete

system. It is up to the contractor or engineer to determine the necessary components and

conguraon of the parcular system to be installed. The drawing does not imply compliance with

local building code requirements. It is the responsibility of the contractor or engineer to ensure the

installaon is in accordance with all local building codes. Confer with local building ocials before

installaon.

MAIN POWER

BOILER PUMP

DHW PUMP

POWER INPUT AUX 1 AUX 2 QX1 QX2 QX3

L N G L N G L N G L N G L N G L N G

BX1 B3-8 B9 H5 H4 H3 BX2 PWM UX2 UX3 H6-1 H6-2 H6-3

OUTDOOR SENSOR

ROOM THERMOSTAT 1

+ - + - + - + -

LOW VOLTAGE CONNECTION

HIGH VOLTAGE CONNECTION

CASCADE SYSTEM SENSOR

MAIN POWER

BOILER PUMP

POWER INPUT AUX 1 AUX 2 QX1 QX2 QX3

L N G L N G L N G L N G L N G L N G

BX1 B3-8 B9 H5 H4 H3 BX2 PWM UX2 UX3 H6-1 H6-2 H6-3

+ - + - + - + -

LOW VOLTAGE CONNECTION

HIGH VOLTAGE CONNECTION

MASTER UNIT

FOLLOWER UNIT

ZONE

CONTROL

PANEL

OUTDOOR

SENSOR

ROOM

THERMOSTAT-1

BOILER

PUMP

DHW SENSOR / AQUASTAT

DHW

PUMP

BOILER

PUMP

CASCADE SYSTEM SENSOR

Figure 52

68 Rinnai Commercial Boiler Installation and Operation Manual

NOTES:

• Primary/Secondary piping must be used (closely spaced tees or low loss header).

• All closely spaced tees shall be within 4 pipe diameters center to center spacing.

• The minimum boiler piping must be at least 1-1/4 inch. Do not downsize boiler heang loop.

• It is recommended to use a check valve to prevent reverse ow and/or gravity circulaon when

pump is in o-cycle.

• Boiler pump must be properly sized to ensure proper ow rate through the boiler and related

piping (minimum ow rate must be maintained to prevent short cycling)

• Indirect Water Heater Applicaon - Ensure boiler output does not exceed indirect water heater

transfer capability.

• System ow rate should always be greater than boiler primary loop ow rate when the boiler is

in operaon to prevent short cycling.

Rinnai Commercial Boiler Installation and Operation Manual 69

IMPORTANT

• Do not use an extension cord or

adapter plug with the boiler.

• If an external electrical source is

ulized, the boiler, when installed,

must be electrically bonded to

ground in accordance with the

requirements of the authority having

jurisdicon or, in the absence of

such requirements, with the

Naonal Electrical Code, ANSI/NFPA

70, and/or the Canadian Electrical

Code Part I, CSA C22.1, Electrical

Code.

When connecng the power supply, follow

these guidelines:

• Connect 120 VAC power wiring to the line

voltage power terminals.

• The boiler requires 120 VAC, 60 Hz power

from a properly grounded circuit.

• A 20 amp (recommended) fused disconnect

or service switch must be installed as

required by the code.

• Do not rely on the gas or water piping to

ground the boiler. Ground locaons are

provided inside the boiler.

• The wiring diagram is located on the inside

of the boiler front cover.

To avoid possible electrical shock hazard,

turn o electrical power supply to the

boiler before:

• Performing repairs or installaon to

internal components or accessories.

• Making wiring connecons and/or

changes to the wiring terminals on

the boiler.

• No changes may be made to the wiring of

the boiler.

• All connecons should be designed in

accordance with the applicable

regulaons.

• Label all wires prior to disconnecon

when servicing controls. Wiring errors can

cause improper and dangerous operaon.

• Verify proper operaon aer servicing.

A manually-operated remote switch should

be located outside the boiler room door for

shung down the boiler. Consideraon

should be given to protect the switch

against tampering. If there is more than one

door to the boiler room, a switch should be

located at each door.

Topics in this secon

• Guidelines

• Electrical Connecons

• Post-Power Supply Connecon

Checklist

WARNING

CAUTION

70 Rinnai Commercial Boiler Installation and Operation Manual

24VDC POWER OUTPUT

View of electrical connecons with boiler side panel removed.

Figure 53

+ - + - + - + -

BX1 B3-8 B9 H5 H4 H3 BX2 PWM UX2 UX3 H6-1 H6-2 H6-3

CASCADE SYSTEM SENSOR

DHW SENSOR/AQUASTAT

OUTDOOR SENSOR

ROOM THERMOSTAT 1

ROOM THERMOSTAT 2

0-10 VDC INPUT

OPTIONAL SENSOR

PWM MODULATING PUMP

ANALOG OUTPUT

HIGH/LOW GAS PRESSURE SWITCH

WATER TEMPERATURE HIGH LIMIT

LWCO

BMS

A+ B– G

A+ B– REF

+ - + - + - + - A+ B- G

ON (closed)

OFF (open)

+ - + - + - + -

Cascade Communicaon Connecon

1. When connecng an outdoor sensor, ensure to move the DIP switch to the OFF posion. The board is

supplied with a built-in resistor to provide a false outside temperature in order to eliminate an error code

on the screen.

2. When connecng a safety input to terminals H6, ensure to move the DIP switch to OFF posion. These DIP

switches also can be sued to trouble shoot which safety input is causing the error code.

BMS

WSC

MAIN POWER

INTERNAL FAN

AUXILIARY POWER

BOILER PUMP

CH PUMP

DHW PUMP

POWER INPUT AUX 1 AUX 2 QX1 QX2 QX3

L N G L N G L N G L N G L N G L N G

5A 5A 5A 5A 5A

24+ 24-

A+ B-

WS COMM

24+ 24

24DC OUT

24+ 24

Rinnai Commercial Boiler Installation and Operation Manual 71

• PWM Modulang Pump

Not used (PWM)

• UX2 / UX3 Analog Output (0-10V)

This connecon is used to provide 0-10V signal

for boiler modulaon. U2; U3.

• Safety Inputs

Use terminals H6-1, H6-2, and H6-3 to connect

external safety devices (Gas Pressure Switches,

Water Temperature High Limit, and LWCO).

NOTE: These terminals are jumped from the

factory with DIP switches (On posion). Ensure

to set the DIP switches to OFF posion when

connecng external devices.

• Modbus / BACnet

Connect the Modbus / BACnet interface

module to the low voltage terminal BMS.

• Cascade Connecon

Connect boilers with each other by using a pair

of 22 gauge wires connected to the cascade

modules located next to the low voltage

terminals. When more than 2 units are

connected, the units located between 2 or

more boilers will take 2 sets of wires to create

a daisy-chain connecon.

• Rinnai recommends the use of spade connectors or

similar components for wiring to the screw

terminals.

• Ensure that the insulaon of the wire is not exposed

to contact any other components besides the

terminal.

• If exposed wiring contacts to any other exposed

wiring or metal components, an electrical short may

occur and cause damage to the PCB or other

connected components.

• Use proper size of screwdriver for prevenng the

screw on the terminal from breaking.

• Do not use an electric or torque screwdriver for

wiring on the PC Board.

• Wiring should pass through the grommets provided

at the boom of the boiler.

• Use the proper diameter and size of wiring.

CAUTION

Low Voltage Connecons (Signal Terminals):

• Cascade Sensor (system supply sensor)

Connect the cascade system sensor to

the low voltage terminal BX1. On a

mulple unit installaon a system sensor

must be used and mounted to the supply

pipe of the system loop.

• DHW Sensor / thermostat

Connect the Indirect tank sensor or

thermostat (aqua stat) to the low voltage

terminal B3-8. The control is set at the

factory (default seng) to use a tank

sensor. In order to use an thermostat

please refer to control secon on how to

set parameters accordingly.

• Outdoor Temperature Sensor

Connect the outdoor sensor to the low

voltage terminal B9. When an outdoor

sensor is connected, the boiler will

operate using the outdoor reset curve.

The control provides opons to set two

separate outdoor reset curves for each

room thermostat connecon. If xed

temperature operaon is desired, do not

install outdoor sensor. NOTE: This

connecon is set from the factory with a

xed temperature. Ensure to set the DIP

switch to OFF posion when using an

outdoor sensor.

• Room Thermostat

Connect the room thermostats to the low

voltage terminal H5 and H4, for room

thermostat 1 and 2, respecvely. The

room thermostat 1 is enabled from the

factory. The room thermostat 2 is

disabled from the factory, in order to use

this connecon, a parameter will need to

be enabled in the control (refer to the

control secon). NOTE: Room thermostat

2 cannot be used if an Indirect Tank is

connected to the boiler.

• Boiler Management System (0-10V

Input)

Connect the BMS to the low voltage

terminal H3. An external control may be

used to control the setpoint of the boiler.

NOTE: This control does not take priority

over a room thermostat.

• Oponal Sensor

Not used (BX2)

Figure 54

Cascade Communicaon Connecon

72 Rinnai Commercial Boiler Installation and Operation Manual

Rinnai Commercial Boiler Installation and Operation Manual 73

□

Conrm that the electricity is supplied from a 120 VAC, 60 Hz power source and is in a

properly grounded circuit.

□

Conrm that an extension cord or adapter plug has NOT been used with the boiler.

□

Conrm connecon terminals are connected correctly.

Connector Pin Marking Descripon Voltage

1 N

Main Power

Supply

120VAC

2 PE

3 L

4 L

QX2 / CH Pump 120V AC 5 PE

6 N

7 L1/NO

QX3 / DHW

PUMP

120V AC

8 PE

9 N

10 L1/NC Not Used

11 L

QX1 / Boiler

Pump

120V AC 12 PE

13 N

14 L

AUX2 / Auxiliary

Power

120V AC 15 PE

16 N

17 L

Fan Power 120V AC 18 P

19 N

1 L Gas Valve

Power

120V AC

2 N

3 L Spark

Generator

120V AC

4 N

5 Ion Not used -

X3 - Ion

Ionizaon

Current

1 +15V Not used -

2 H7

Air Pressure

Switch

3 H3 0-10V Input -

4 RESET Reset -

5 +5V Not Used -

6 BX4/B7 Return Sensor -

7 GND Ground -

8 B2 Supply Sensor -

X5...

External Safety

Input

- H6

3 -

BX1 / Cascade

Sensor

4 GND

Connector Pin Marking Descripon Voltage

...X5

5 -

BX2 / Oponal Sensor -

6 GND

7 -

BX3 / Flue Gas Sensor -

8 GND

9 -

B3 /38 / DHW Sensor -

10 GND

11 -

B9 / Outdoor Sensor -

12 GND

1 - H1 / Pressure Sensor

2 GND H1 / Pressure Sensor

3 +15V Not Used

4 +5V H1 / Pressure Sensor

5 -

H5 / Room

Thermostat 1

6 GND

7 -

H4 / Room

Thermostat 2

8 GND

CL+ BSB

CL- BSB

G+ Not used

4-6

- Not used

1 GND

Fan PWM -

2 +24

3 HALL

4 PWM

X10

1 -

UX2 - PWM / 0-10V -

2 GND

3 -

UX3 - PWM / 0-10V -

4 GND

X11 1-14 - Cascade Module -

X15

1 GND

PUMP PWM -

2 PWM

X17 - PE Ionizaon Ground -

X18

1 -

Internal Safety Input 120V AC

2 -

X30 1-9 - LED Backlight

X50 1-5 - Not Used -

X60 1-6 - Not Used -

Table 30: Connectors

74 Rinnai Commercial Boiler Installation and Operation Manual

Failure to properly commission the boiler as

described in this secon may result in

unreliable and unsafe burner operaon and

reduced component life.

THIS SECTION IS INTENDED

FOR THE INSTALLER

This boiler must be commissioned by a

licensed professional. Installer qualicaons:

A trained and qualied professional must

install the appliance, inspect it, and leak test

the boiler 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 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; and training in installaon of

condensing boilers.

Boiler commissioning is a procedure used

aer boiler installaon to ensure the system

and boiler were installed correctly and ready

for operaon.

1. Ensure all boiler components are installed

correctly.

2. Open the air vent inside the boiler.

3. Power on the boiler.

4. Open the ll valve on the lling circuit.

5. Check the pressure on the pressure gauge.

Fill the boiler to a minimum of 14.5 PSI (100

kPa) water pressure and a maximum of 70

PSI (483 kPa).

6. Check the heang system for leaks.

7. Begin the deaeraon process shown in the

next secon (“10.3 Deaeraon Process”).

• Work on the boiler must be carried out

by a licensed professional, using

correctly calibrated instruments with

current test cercaon. The

commissioning instrucons are

intended for licensed professionals who

have the necessary knowledge and are

approved for working on heang and

gas systems.

• The fan will operate when power is

inially provided to perform a safety

check on the boiler.

• The boiler and its individual shut o

valve must be disconnected from the

gas supply piping system during any

pressure tesng of that system at test

pressures in excess of 1/2 PSI (3.5 kPa).

• Before the boiler is red for the rst

me:

− Ensure the boiler and system are

fully de-aerated

− Purge the gas line between the gas

meter and boiler

− Prime the pump (as described in

this secon)

IMPORTANT

Topics in this secon

• Safety Precauons

• Filling Process

• Deaeraon Process

Do not ll the boiler unless permanent

power is available. Freeze protecon is not

available if the boiler is not lled, air

purged, and supplied with power and gas.

WARNING

Rinnai Commercial Boiler Installation and Operation Manual 75

DO NOT operate the boiler without performing deaeraon process. Perform deaeraon during

commissioning or if any part of the system has been opened or disconnected. Failure to properly

deaerate the boiler and system may result in damage to the boiler, which is not covered by the

boiler warranty.

Deaeraon is an eecve method of purging air from the boiler aer the system has been lled or

serviced.

1. Fill the boiler to a minimum of 14.5 PSI (100 kPa) water pressure and a maximum of 70 PSI (483

kPa).

2. The deaeraon process should be performed for at least 15 minutes if all three (3) pumps

terminals are being used.

3. Aer approximately one week, all air in the system should be eliminated via the air separator in

the piping system.

Press the SERVICE icon on the boiler home page. It will prompt the user to enter a password. In

order to access the SERVICE page, the control will prompt the user to select the access level and

enter password. The password for Installer is 9419. The technician and Engineer user levels can

ONLY be accessed by a Rinnai employee.

Use the Pump Service Mode to manually energize each pump individually to remove air from the

system. It is recommended to run each pump for a minimum of ve (5) minutes in order to purge

the air from the system. Run the Boiler Pump to remove air from the primary boiler circuit. If and

indirect tank is being used, also run the DHW Pump to remove air from the DHW piping. Then move

to each central heang zones to remove air from the system side (Run CH-1 Pump and/or DHW

Pump (If assigned for a CH-2 zone).

NOTE: It is crical that the Pump Service Mode is set to No Test when the deaeraon service has

been completed.

WARNING

76 Rinnai Commercial Boiler Installation and Operation Manual

Complete the following checklist when boiler installaon is complete. You should be able to answer

YES to each queson. If you answer NO, installaon is not complete. Refer to the applicable secon

in this manual for addional informaon.

INSTALLATION LOCATION YES NO

Have you veried the unit, vent and air intakes meet the clearance requirements?

 

VENTING YES NO

Have all corrosive compounds been removed from around the combuson air intake of

the boiler?

 

Have you followed the combuson air requirements to provide sucient combuson air

for the boiler?

 

Are the correct venng products for the installed model being ulized?

 

Have you installed the vent screen(s) for Schedule 40 PVC/CPVC vent applicaons if

applicable?

 

Have you veried the vent system does not exceed maximum length?

 

SYSTEM PIPING YES NO

Have the water lines been purged of all debris and the lter cleaned?

 

Have you veried the supply and return water lines to the boiler are not interchanged?

 

Does the water supply to the boiler have adequate pressure? Is it free of chemicals? Did

you verify it does not exceed total hardness that will damage the heat exchanger?

 

Have you veried that no toxic chemicals were introduced to the potable water?

 

Did you drain the boiler if not intended to be used immediately?

 

Have water quality issues (if any) been addressed?

 

Have you performed the leak and pressure test for the boiler and plumbing system?

 

CONDENSATE DRAIN YES NO

Did you verify the condensate drain pipe is as short as possible and has a downward

pitch toward the drain or condensate pump?

 

Is all condensate drained and disposed of as per local codes?

 

Did you use ONLY corrosion resistant materials for the condensate drain lines?

 

Did you verify the condensate drain pipe along its enre length is at least the same

diameter as the drain line?

 

Did you check to ensure the condensaon drain lines are protected from freezing?

 

Have you veried the condensate drain line is not plumbed with the pressure relief

valve?

 

Have you conrmed the condensate drain line is not connected with an air condioning

evaporator coil drain?

 

This boiler has an integrated condensate trap. Have you veried that an external

condensate trap is not installed?

 

Have you conrmed the end of the condensate drain pipe is open to atmosphere?

 

Has an air gap been installed in the condensate drain line?  

Table: Post-Installaon Checklist

Rinnai Commercial Boiler Installation and Operation Manual 77

GAS SUPPLY YES NO

Did you verify the gas system is appropriately sized?

 

Did you verify the boiler is rated for the gas type supplied?  

Have you performed a gas line and connection leak test?

 

Did you install a manual gas control valve in the gas line to the boiler?

 

Is the inlet gas pressure within limits?

 

Did you purge the gas line of any debris before connecting the boiler?

 

PRESSURE RELIEF VALVE (PRV)

YES NO

Does the PRV comply with the standard for Relief Valves and Automatic Gas Shutoff De-

vices for Hot Water Supply Systems ANSI Z21.22, and/or the standard Temperature, Pres-

sure, Temperature and Pressure Relief Valves and Vacuum Relief Valves, CAN1-4.4?

 

Did you verify the heating system PRV is rated to 75 PSI?

 

Is the discharge from the PRV piped to the ground or into a drain system as per local

codes?

 

Is the discharge line from the PRV installed downward and does it terminate 6 in. (152

mm) above the drains?

 

Is the discharge end of the line plain (unthreaded) and a minimum of 3/4 in. diameter?

 

Is the discharge line material suitable for at least 180° F water?

 

Did you take measures to protect the PRV and PRV discharge line from freezing?

 

Have you verified the PRV is not plumbed with the condensate drain line?

 

Have you verified the PRV is not plugged and that reducing fittings, valves, or other re-

strictions are not installed in the relief line?

 

POWER SUPPLY

YES NO

Did you confirm that the electricity is supplied from 120 VAC, 60 Hz power source and is

in a properly grounded circuit?

 

Did you confirm that an extension cord or an adapter plug has NOT been used with the

boiler?

 

COMMISSIONING

YES NO

Was the boiler filled to 14.5 - 70 PSI?

 

Was the deaeration process performed on the boiler?

 

Post-Installation Checklist (Continued)

78 Rinnai Commercial Boiler Installation and Operation Manual

IMPORTANT

• On inial startup of the system, it is necessary to manually run the pumps from the service

page to remove all air from the system piping and boiler. Failure to properly deaerate the

boiler and system may result in damage to the boiler, which is not covered by the boiler

warranty.

• It can take up to a week before all the air has disappeared from a newly-lled and

pressurized installaon. During the rst week of operaon, noises can be heard which

indicate the presence of air. The automac air vent in the boiler and air separator in the

heang system will remove the air, which means the water pressure will reduce some

during this period; therefore, addional water is necessary to maintain proper pressure in

the heang system. Water pressure needed for operaon:

− The boiler is in normal operaon between 14.5 - 70 PSI (100 - 483 kPa).

− The maximum pressure permied inside the heat exchanger is 160 PSI (1103 kPa).

− The pressure relief valve supplied with the boiler is rated to 75 PSI (517 kPa).

Topics in this secon

• Start-Up Informaon

• Control Panel

• Error and Diagnosc Codes

• Perform Combuson Analysis

• Operang Informaon

Rinnai Commercial Boiler Installation and Operation Manual 79

ITEM DESCRIPTION FUNCTION

1 RINNAI

The Rinnai logo will return the user to the home page (shown). This page will

provide informaon regarding the boiler operaon.

2 SETUP

This page will allow the user to adjust and customize parameters, such as outdoor

reset curve(s), and others. NOTE: This page should only be accessed by qualied

service technician.

3 VIEW

The view screen shows the state of the appliance and its internal components

(temperature values, switches condion, water pressure, fan speed, and all other

inputs and outputs).

4 GRAPH

The graph page allows the user to monitor real me system informaon

(temperature, pressure, pump operaon, and fan speed).

5 SERVICE

This page allows for a dierent user level selecon by choosing user from the

dropdown menu and enter a password to access parameters from basic to crical

funcons.

6 LEFT PANE

This pane provides informaon about boiler internal temperature and pressure. It

also incudes date and me. NOTE: Date and me can be changed from the setup

page.

7 CENTER PANE

This pane shows informaon about demand, boiler modulaon, error messages,

setpoint, fan speed, and ionizaon current. The center pane changes color to show

the boiler status: Dark Gray - standby; Light Gray - Running; Red - Error Code (hard

lockout), Yellow - Error Code (so lockout); Orange - service reminder

8 EXTERNAL

This pane shown informaon about external devices connect to the boiler (outdoor

sensor, system sensor, indirect tank sensor/thermostat, pump status, and Wi-Fi ).

❶

❷

❸

❹

❺

❼ ❽

Table 31: Home Screen

❻

80 Rinnai Commercial Boiler Installation and Operation Manual

NO. DESCRIPTION FUNCTION

CENTRAL HEATING

CH-1 Boiler

Temperature Setpoint

This parameter is used to set the boiler supply temperature setpoint for CH-1

manually if an outdoor sensor is not used. When an outdoor reset funcon is

desired use the Outdoor Reset Curve page to set the boiler min and max

temperatures. Range: 86°F [30°C] - 180°F [82°C]; Default: 180°F [82°C]

CH-2 Boiler

Temperature Setpoint

This parameter is used to set the boiler supply temperature setpoint for CH-2

manually if an outdoor sensor is not used. When an outdoor reset funcon is

desired use the Outdoor Reset Curve page to set the boiler min and max

temperatures. Range: 86°F [30°C] - 180F [82°C]; Default: 180°F [82°C]

Central Heang

Switching On

Dierenal

This parameter is used to set the temperature dierenal when the boiler will

light up the burner. For instance if the boiler setpoint is 180°F [82°C] and this

parameter is set to 20°F [11°C], the boiler will ONLY re when the actual supply

temperature is below 160°F [71°C]. Range: 0°F [0°C] - 36°F [20°C]

DOMESTIC HOT WATER

DHW Temperature

Setpoint

This parameter is used to set the temperature setpoint for the DHW indirect tank.

Range: 104°F [40] - 176°F [80°C]; Default: 120°F [49°C]

DHW Switching On

Dierenal

This parameter is used when a DHW indirect tank is controlled via a sensor. This

parameter sets the temperature dierenal when the DHW tank will call for heat

demand. For instance if the Indirect tank setpoint is 120°F [49°C] and this

parameter is set to 9°F [5°C], the boiler will ONLY acvates the DHW demand

when tank temperature is below 111°F [44°C]. Range: 0°F [0°C] - 36°F [20°C]

Boiler Supply

Temperature Oset for

DHW

When there is a DHW demand, the boiler temperature setpoint will be the DHW

temperature setpoint + this parameter. For instance if DHW temperature setpoint

is 120°F [49°C] and this parameter is set to 36°F [20°C] the boiler supply setpoint

for DHW will be 156°F [69°C]. Range: -4°F [-20°C] - 108°F [60°F], Default: 36°F

[20°C]

Table 32: Setup Page

To access the SETUP page, the control will prompt the user to select the access level and enter

password. The password for Installer is 9419. The technician and Engineer user levels can ONLY

be accessed by a Rinnai employee.

Quick Setup

Rinnai Commercial Boiler Installation and Operation Manual 81

An outdoor sensor is provide with the boiler. The boiler control allows for two customizable

outdoor reset curves for each head demand from room thermostats one and two. The graph below

represents outdoor reset curve for heang circuit one. To set the second outdoor reset curve press

on the arrow at the boom right corner of the page. Set the minimum and maximum boiler supply

temperatures along with minimum and maximum outside temperatures to set outdoor reset

curves. The warm weather shutdown is the temperature value at which the boiler will ignore the

call for heat. Use the outdoor reset power icon to enable or disable the outdoor reset curve. When

an outdoor sensor is not being used the boiler will operate using the maximum boiler temperature

value set in this table. When the outdoor reset curve is not intended to be used, the boiler setpoint

can be set from the quick setup page and the outdoor reset curve should be disabled. See next

page for outdoor reset temperature guideline.

NO. DESCRIPTION FUNCTION

Warm Weather

Shutdown (All Circuits)

This parameter is used to set the outside temperature to disable boiler operaon

for central heang due to warm weather. Range: 46°F [8°C] - 86°F [30°C]; Default:

75°F [24°C]

Enable Outdoor Reset

Curve (All Circuits)

This parameter is used to enable or disable the outdoor reset curve funcon.

Range: On - O; Default: On

Boiler Temperature

Minimum (CH-1)

This parameter sets the minimum boiler supply temperature for the outdoor

reset curve. Range: 86°F [30°C] - Boiler Temperature Maximum; Default: 86°F

[30°C]

Boiler Temperature

Maximum (CH-1)

This parameter the sets the maximum boiler supply temperature for the outdoor

reset curve. Range: Boiler Temperature Minimum - 180°F [82°C]; Default: 180°F

[82°C]

Outside Temperature

Minimum (CH-1)

This parameter sets the minimum boiler outside temperature for the outdoor

reset curve. Range: -40°F [-40°C] - Outside Temperature Maximum; Default: 5°F

[-15°C]

Outside Temperature

Maximum (CH-1)

This parameter the sets the maximum outside temperature for the outdoor reset

curve. Range: Boiler Temperature Minimum - Warm Weather Shutdown; Default:

68°F [20°C]

Table 33

82 Rinnai Commercial Boiler Installation and Operation Manual

Outdoor reset is a built-in funcon to help maximize the eciency of the boiler. The design of this

funcon is to adjust the target temperature of the boiler relave to the outdoor ambient

temperature via the exible outdoor reset curve opons included in the boiler setup page. The

outdoor ambient temperature is observed via the provided outdoor temperature sensor.

NOTE: When a DHW indirect tank is installed as a heang zone, and the outside temperature may

exceed the maximum limit of warm weather shutdown (86°F), the outdoor reset must be disabled.

During warm weather shutdown, the boiler will not provide any heat to the indirect tank if it is

connected to the boiler as a heang zone.

The outdoor temperature sensor (1 kOhm) should be mounted to avoid direct sun light (to prevent

obtaining false reading of the outdoor temperature) ideally on a North facing wall of the house.

The sensor should also be mounted away from any vent, duct, or other device that may create an

arcial heat source. The sensor should then be wired back to the outdoor temperature sensor

terminal on the boiler. Refer to the wiring secons for more informaon.

North Facing Wall

Type of Heat Emier

Typical Minimum Supply

Temperature

Typical Maximum Supply

Temperature

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

Unit Heater 130 - 140°F 160 - 180°F

Base Board Convectors 100 - 140°F 140 - 180°F

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

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

Below are some typical target temperatures for various heat emiers. These are basic guidelines;

thus, check with the emier manufacturer or consult your heang design engineer.

Outdoor Temperature

Sensor

Figure 55

Table 34

Rinnai Commercial Boiler Installation and Operation Manual 83

NO. DESCRIPTION FUNCTION

Boiler Setup

Central Heang

Mode

This funcon enables or disables the central heang mode (Room Thermostat 1, Room

Thermostat 2, and 0-10V input funcons). Range: On - O; Default: On NOTE: Requires

Technician or Engineer level for access.

Vent Pipe

Material

This parameter will set the ue temperature limit based on the material used for venng.

When set to PVC, the boiler will start to reduce modulaon when the vent temperature

reaches 140°F [60°C] and will shutdown at 149°F [65°C]. When set as others (CPVC, PP, and

FNS), the boiler will reduce modulaon when the vent temperature reaches 198°F [92°C]

and will shutdown and lockout at 207°F [97°C]. Ensure to use the proper venng material

and appropriate parameter seng depending on the applicaon to prevent damage to the

vent pipe or boiler short cycling. Range: PVC- Others. Default: PVC

0-10V Input

Control

This parameter is used to select the two dierent modes of 0-10V operaon or disable the

0-10V funcon. Range: Boiler Modulaon, Boiler Setpoint, O; Default: O. NOTE: It is

recommended to avoid running low voltage wires in parallel to high voltage wiring to avoid

induced voltage. False voltage signal will cause the boiler to operate when it is not needed.

Voltage

Minimum

(0-10V)

This parameter sets the minimum voltage for the 0-10V input funcon. Range: 0V - 10V;

Default: 2V. NOTE: DO NOT change the default seng. Requires Technician or Engineer

level for access.

Supply

Temperature

Minimum

(0-10V)

This parameter sets the minimum boiler supply temperature or modulaon percentage for

0-10V input operaon. For instance when the input voltage is set to 2V, the boiler supply

setpoint is 86°F [30°C]. Range: 86°F [30°C] - Supply Temperature Maximum (0-10V);

Default: 86°F [30°C]

Voltage

Maximum (0-10V)

This parameter sets the maximum voltage for the 0-10V input funcon. Range: 0V - 10V;

Default: 10V. NOTE: DO NOT change the default seng. Requires Technician or Engineer

level for access.

Supply

Temperature

Maximum (0-10V)

This parameter sets the maximum boiler supply temperature or modulaon percentage for

0-10V input operaon. For instance when the input voltage is set to 10V, the boiler supply

setpoint is 180°F [82°C]. Range: Supply Temperature Minimum (0-10V); - 180°F [82°C] -

Default: 180°F [82°C]

Outdoor Frost

Protecon

Setpoint

This funcon will alert the boiler about an outside freeze condion based on the set value.

The boiler will monitor the supply temperature before acvang the freeze protecon

mode. Range: 40°F [4] - 60°F [16]. NOTE: Requires Technician or Engineer level for access.

Table 35

84 Rinnai Commercial Boiler Installation and Operation Manual

NO. DESCRIPTION FUNCTION

Boiler Setup (cont.)

Central Heang 1

(CH-1)

This parameter enables or disables CH-1 room thermostat operaon.

Range: On - O; Default: On. NOTE: Do not disable this parameter.

Central Heang 2

(CH-2)

This parameter enables or disables CH-2 room thermostat operaon.

Range: On - O; Default: O. NOTE: ONLY enable this parameter if you intend

to replace the DHW zone with a second CH zone. The DHW pump needs to be

assigned as CH-2 pump in the pump setup page for proper operaon.

11 Fuel Type

This funcon will assign the proper fan speed for NG or LP gas depending on the

selecon. Range: NG - LP; Default: LP

12 Elevaon

This funcon will assign the proper fan speed for each elevaon selecon.

Range: 0-2000 ; 2001-5400 ; 5401-7700 ; 7701-10200; Default: 0-2000

Central Heang

Switching On

Dierenal

This parameter is used to set the temperature dierenal when the boiler will

light up the burner. For instance if the boiler setpoint is 180°F [82°C] and this

parameter is set to 20°F [11°C], the boiler will ONLY re when the actual supply

temperature is below 160°F [71°C]. Range: 0°F [0°C] - 36°F [20°C] ; Default: 20°F

[11°C]

NO. DESCRIPTION FUNCTION

DHW Setup

DHW Operang

Mode

This funcon enables or disables DHW operaon (Aquastat or Sensor). Range:

On - O; Default: On NOTE: Requires Technician or Engineer level for access.

2 DHW Sensor

This parameter allows the user to choose either a 10K Ohm sensor (thermistor)

or an Aquastat (thermostat) to control the DHW indirect tank demand. In

Aquastat mode the control is looking for either an open (no demand) or closed

(demand) contact. In Sensor mode the control is reading the actual

temperature against the setpoint to determine heat demand. When a sensor is

accidentally selected and aquastat is used, the boiler will present an error code

when aquastat is closed. Range: Aquastat - Sensor; Default: Aquastat

Table 35 connue

Table 36

Rinnai Commercial Boiler Installation and Operation Manual 85

NO. DESCRIPTION FUNCTION

DHW Setup (cont.)

DHW Temperature

Setpoint

This parameter allows the user to set the DHW indirect tank temperature.

NOTE: When an aquastat is used ensure to match this parameter with the

seng on the mechanical aquastat to ensure proper operaon. The control

will use this value to set the boiler supply temperature for DHW.

Range: 104°F [40°C] - 176°F [80°C]; Default: 120°F [49°C].

4 DHW Priority Time

This parameter sets the DHW priority me in case there are both DHW and

Central Heang demands. The control will priorize DHW demand for the set

me and then switch to central heang demand. The control will switch

between the two demands unl one or both are sased.

Range: 10 - 600 Minutes; Default: 30 Minutes

Boiler Supply

Temperature Oset for

DHW

When there is a DHW demand, the boiler temperature setpoint will be the

DHW temperature setpoint + this parameter. For instance if DHW temperature

setpoint is 120°F [49°C] and this parameter is set to 36°F [20°C] the boiler

supply setpoint for DHW will be 156°F [69°C]. Range: -4°F [-20°C] - 108°F [60°F],

Default: 36°F [20°C]

DHW Switching On

Dierenal

This parameter is used when a DHW indirect tank is controlled via a sensor.

This parameter sets the temperature dierenal when the DHW tank will call

for heat demand. For instance if the Indirect tank setpoint is 120°F [49°C] and

this parameter is set to 9°F [5°C], the boiler will ONLY acvate the DHW

demand when tank temperature is below 111°F [44°C].

Range: 0°F [0°C] - 36°F [20°C]; Default: 9°F [5°C]

7 Boiler Pump with DHW

This parameter will allow the user to enable the boiler pump to operate during

a DHW demand. For instance, if the DHW indirect tank is piped in the system

loop as one of the heang zones, the boiler pump can be enabled to deliver

the heat to the system loop. NOTE: It is crical to ensure low temperature

zones are protected via mixing valve to prevent overheang due to higher

seng of boiler supply temperature for DHW. Range: On - O; Default: O

DHW Setup

Table 36 connue

86 Rinnai Commercial Boiler Installation and Operation Manual

NO. DESCRIPTION FUNCTION

Pump Setup

Pump Overrun Time -

Allows boiler and CH pumps to connue to run aer the ame is turned o,

when a CH demand is terminated.

Range: 0-240 Minutes; Default: 1 Minute

Pump Overrun Time -

DHW

Allows the DHW pump to connue to run aer the ame is turned o, when a

DHW demand is terminated.

Range: 0-240 Minutes; Default: 1 Minute

3 Pump Assignment QX2

This parameter can be used to assign the CH-1 Pump to run with a room

thermostat call (room thermostat 1) or Using a 0-10V for Boiler Temperature

control. When using Room thermostat, it should to set to CH-1 Pump, when

using 0-10V for boiler temperature control it should be set to Q15 pump.

Range: CH-1 Pump, Q15. Default: Q15

4 Pump Assignment QX3

This parameter can be used to assign the DHW pump terminal to be used as a

DHW pump , CH-2 pump, or Q15 (0-10V operang for boiler temperature

control). In case a DHW indirect tank is not used and a second heang zone is

desired, this parameter can be set to CH-2. Also CH-2 thermostat needs to be

enabled from the boiler setup page. Range: Boiler Pump; CH-1 Pump; CH-2

Pump; DHW Pump; Cascade Pump Q25; Default: DHW Pump

5 Funcon Output UX2

When Burner Modulaon is selected, this parameter can be used to read boiler

status and modulaon informaon via a 0-10V signal. 0-0.5V - Boiler in error

State; 0.5V - 1V - Boiler in O state, standby, pre-purge, post-purge...; 1V -

10V—represents 0% - 100% modulaon.

Range: None, Boiler Pump, DHW Pump, CH-1 Pump, CH-2 Pump, Burner

Modulaon; Default: Burner Modulaon.

6 Funcon Output UX3

When Burner Modulaon is selected, this parameter can be used to read boiler

status and modulaon informaon via a 0-10V signal. 0-0.5V - Boiler in error

State; 0.5V - 1V - Boiler in O state, standby, pre-purge, post-purge...; 1V -

10V—represents 0% - 100% modulaon.

Range: None, Boiler Pump, DHW Pump, CH-1 Pump, CH-2 Pump, Burner

Modulaon; Default: Burner Modulaon.

Table 37

Rinnai Commercial Boiler Installation and Operation Manual 87

NO. DESCRIPTION FUNCTION

Cascade

Released Integral

Source Seq

Controls the units release on a cascade system. The higher the value the

quicker is the release. Range: 0-500 C*min; Default: 51 C*min

Reset Integral Source

Seq

Controls when the units are shut-down in a cascade system When the value is

decreased, heat sources are switched o at a faster rate. Range: 0-500 C*min;

Default: 21 C*min

3 Switch-On Delay - CH

Sets the wait me to release units in a cascade system during a heat demand.

For instance when a unit is released for a heat demand in a cascade system

due to the modulaon load, this unit will wait for this set me before igning

the burner. Range: 0-120 Minutes; Default: 5 Minutes

4 Leading Producer

This parameters sets the rst unit that will be energized in a cascade system.

The boiler automacally follows the lead-lag strategy according to the

operang hours. Range: 1-8; Default: 1 (Master Boiler)

5 Restart Time Lock

The restart lock prevents a deacvated heat source from being switched on

again. It is released again only aer the set me elapsed. This prevents too

frequent switching acons of the heat source and ensure stable plant

operang states. Range: 0-1800 Seconds; Default: 300 Seconds

6 Device Address

This parameter sets the cascade address of the device.

Range: Standalone; Master, Follower 1, …, Follower 7. Default: Standalone

7 Leading Strategy

This parameter sets the cascade leading strategy.

Range: :Late on, early o; Late on, late o; Early on, late o.

Default: Early on, late o.

Late on, early o - Addional boilers are switched on as late as possible

(output band max) and switched o again as early as possible (output band

max). This means that the smallest possible number of boilers are in

operaon, or addional boilers operate with short on mes.

Late on, late o - Addional boilers are switched on as late as possible (output

band max) and switched o again as a late as possible (output band min). This

leads to the smallest possible number of boiler switched on/o acons for

the boiler.

Early on, late o—Addional boilers are switched on as early as possible

(output band min) and switched o again as late as possible (output band min).

This means that the largest possible number of boilers are in operaon, or

addional boilers operate with the longest possible on me.

8 Output Band Minimum

The heat sources are switched on and o according to the selected lead

strategy while giving consideraon to the preset output band.

NOTE: To deacvate the impact of the output band, the limit values must be

set to 0% and 100%, and the lead strategy to be selected is Late on, late o.

Range: 0-100%; Default: 40%

9 Output Band Maximum

The heat sources are switched on and o according to the selected lead

strategy while giving consideraon to the preset output band.

NOTE: To deacvate the impact of the output band, the limit values must be

set to 0% and 100%, and the lead strategy to be selected is Late on, late o.

Range: 0-100%; Default: 90%

10 Cascade Rotaon Time

This parameter sets the me for leading source rotaon is a cascade system.

The boiler loads in a cascaded system can be inuenced by dening the order

of a lead lag boiler.

Range: 10-990 Hours; Default: 50 Hours

Table 38

88 Rinnai Commercial Boiler Installation and Operation Manual

NO. DESCRIPTION FUNCTION

Cascade (cont.)

Cascade Rotaon

Exclusion

This parameter excludes unit from cascade rotaon.

Range: None, First, Last, First and Last. Default: None

12 Cascade System Sensor

Assigns cascade supply sensor BX1 connecon as B10, cascade system sensor.

Range: On-O; Default: O

NOTE: This parameter must be on for a proper operaon of a cascade system.

Forced

Time Basic Stage

Unit will run at min rate and wait for the set me before starng to modulate .

Range: 0-1200 Seconds; Default: 60 Seconds

14 Switch-on Delay - DHW

Sets the wait me to release units in a cascade system during a DHW demand.

For instance when a unit is released for a DHW demand in a cascade system

due to the modulaon load, this unit will wait for this set me before igning

the burner. Range: 0-120 Minutes; Default: 2 Minutes

15. Cascade Master

As soon as more than one heat source is present, the controller with unit

address 1 assumes the role of cascade master. It acvates the required

funcon and shows the addional operang menus with the cascaded related

parameters. Detecon of the master role can be automac (Auto) or can be

switched as xed (always). Range: Auto-Always; Default: Auto.

16 Setpoint Compensaon

This funcon will add an oset value to the boiler setpoint above the cascade

system sensor temperature setpoint.

Range: 1-100; Default: 36°F [20°C]

Table 38 connue

Rinnai Commercial Boiler Installation and Operation Manual 89

NO. DESCRIPTION FUNCTION

BMS

1 Modbus Address

Sets the Modbus Address for BMS.

Range: 0-2; Default: 1

2 Baud Rate

Sets the Baud Rate for BMS.

Range: 4800, 9600, 19200, 38400, 115200; Default: 1115200

3 Parity

Sets the Parity for BMS.

Range: None, Even, Odd; Default: Even

4 Stop Bits

Sets the Stop Bits for BMS.

Range: 1 Bit - 2 Bits; Default: 1 Bit

5 Apply Seng

This parameter is used to apply the sengs aer making changes to the

parameters listed above.

Table 40

Table 39

NO. DESCRIPTION FUNCTION

BMS

Wi-Fi or Ethernet

Enable/Disable

This Parameter is used to enable or disable Wi-Fi or Ethernet connecvity.

Range: On-O; Default: O. NOTE: ONLY enable Wi-Fi when connecng the

boiler to a router.

2 Forget Network

This funcon is available in case there is a need to forget the current Wi-Fi

connecvity and connect to a new Wi-Fi. Press the icon to forget network.

3 Ethernet Sengs

This parameter is used to congure Ethernet connecon (enable or disable

DHCP). Use this funcon to congure IP address, Subnet Mask, and Default

Gateway.

90 Rinnai Commercial Boiler Installation and Operation Manual

NO. DESCRIPTION FUNCTION

System

1 Set Date and Time

This funcon can be used to set the current Date and Time . The user also has

opons to select a me zone. The clock will adjust automacally for day light

savings based on me zone.

Adjust Screensaver

Time

Sets the screensaver me. This me is also related to how long the system will

maintain the Installer, Technician, or Engineer logged in.

Range: 1-99 Minutes; Default: 10 Minutes

3 Save Sensor

At midnight, the controller saves the statuses at the sensor terminals, provided

controller has been in operaon for at least 2 hours. If a sensor drops out aer

saving, the controller generates an error message. This seng is used to

ensure immediate saving of sensors. This becomes a requirement when, for

instance, a sensor is removed because it is no longer needed.

Range: On - O Default: O

4 System Unit

Use this funcon to change the system of units from Imperial (F, Psi, Btu) to

Metric (C, Bar, kWh), or vice-versa.

Range: Imperial - Metric O; Default: Imperial

5 Ethernet Sengs This funcon can ONLY be accessed by a Rinnai employee.

6 User Logout

This funcon can be used to logout of SETUP or SERVICE pages, and to change

user level once logged in.

Table 41

Rinnai Commercial Boiler Installation and Operation Manual 91

NO. DESCRIPTION FUNCTION

Maintenance

1 Maintenance Interval

Sets the boiler maintenance interval in months.

Range: 1-240 Months; Default: 12 Months

Burner Hours Since

Last Maintenance

Sets the boiler maintenance interval based on burner run hours.

Range: 100 - 10,000 Hours; Default: 1500 Hours

Burner Cycles Since

Last Maintenance

Sets the boiler maintenance interval based on ignion cycles.

Range: 100 - 65,500 Cycles; Default: 9000 Cycles

Table 42

92 Rinnai Commercial Boiler Installation and Operation Manual

VIEW - Boiler State:

The view funcon can be used to monitor boiler operaon. NOTE: Password is not required to

access this page.

NO. DESCRIPTION FUNCTION

Boiler State

1 Minimum Fan Speed

Displays the minimum fan speed setpoint of the boiler based on model, gas

type, and elevaon

2 Maximum Fan Speed

Displays the maximum fan speed setpoint of the boiler based on model, gas

type, and elevaon

3 Ignion Fan Speed Displays boiler ignion speed setpoint

4 Fan Speed Actual Displays the current fan speed

5 Fan Setpoint Displays the current fan setpoint

6 Current Fan Control Displays the current fan PWM (as a percentage)

7 Burner Modulaon

Displays the current boiler modulaon from 0% - 100%. 0% represents the

minimum boiler input rate, and 100% represents the maximum boiler input

rate.

8 Ionizaon Current

Display the current ionizaon current of the ame in uA. The boiler will

exnguish the ame when the ionizaon current is less than 0.8 uA.

9 Room thermostat CH-1

Displays the status of the room thermostat CH-1 connecon. The contact is

normally open and will display open when a room thermostat is not connected

or the demand for heat is o. The state will change to closed when a room

thermostat is connected and calling for heat demand.

10 Room thermostat CH-2

Displays the status of the room thermostat CH-2 connecon. The contact is

normally open and will display open when a room thermostat is not connected

or the demand for heat is o. The state will change to closed when a room

thermostat is connected and calling for heat demand.

Table 43

Rinnai Commercial Boiler Installation and Operation Manual 93

NO. DESCRIPTION FUNCTION

VIEW - Boiler State (cont.)

Room Thermostat CH-1

State

Display a message regarding the state of the room thermostat CH-1

Room Thermostat CH-2

State

Display the a message regarding state of the room thermostat CH-1

13 DHW State Display the a message regarding DHW demand state

14 0-10VDC Input (H3) Displays 0-10VDC input signal to control the boiler temperature setpoint

15 Boiler State Displays the current status of the boiler

16 Burner State

Displays the current status of burner operaon (standby, pre-purge, post-

purge, running, …)

17 Water Pressure Sensor

The water pressure sensor state is normally closed when water pressure

voltage is more than 5VDC. Below 5VDC the state will change to open and the

control will generate an error code.

Water Pressure Sensor

Voltage

Displays the current input voltage for water pressure sensor

19 Air Pressure Switch

The air pressure switch is normally closed during normal operaon. The switch

will open in case of a vent or condensate blockage and the control will

generate an error code.

20 Safety Input

Displays the status of the external safety inputs (High and Low Gas Pressure

Switches, Water Temperature High Limit, LWCO).

Table 43 connue

94 Rinnai Commercial Boiler Installation and Operation Manual

NO. DESCRIPTION FUNCTION

VIEW - Boiler Temperature

1 Boiler Setpoint

Displays the boiler acve temperature setpoint. In case there are demands

from both room thermostats (CH-1 and CH-2), the boiler setpoint will be the

highest setpoint. NOTE: A mixing valve must be used to protect the lower

temperature zone.

2 Boiler Setpoint (CH-1) Displays the boiler acve setpoint of room thermostat CH-1

3 Boiler Setpoint (CH-2) Displays the boiler acve setpoint of room thermostat CH-2

4 Boiler Setpoint (DHW)

Displays the boiler acve setpoint for an indirect tank demand. This setpoint is

equal to DHW temperature setpoint + Boiler Supply Temperature Oset for

DHW (on SETUP—DHW Setup page)

5 Boiler Setpoint (0-10V)

Displays the boiler acve setpoint or modulaon setpoint for 0-10VDC input

demand.

6 Outdoor Temperature

Displays the current outside temperature when an outdoor temperature

sensor is connected to the boiler

7 Flue Temperature Displays the current ue temperature

8 Supply Temperature Displays the actual boiler supply temperature

9 Return Temperature Displays the actual boiler return temperature

10 Delta-T

Displays the actual boiler temperature dierenal (Dierence between Supply

and Return temperatures)

11 Pressure Displays the system pressure from the built-in water pressure sensor

Indirect Storage Tank

Temperature—Setpoint

Displays the indirect storage tank acve setpoint

Indirect Storage Tank

Temperature—Actual

Displays the actual indirect storage tank temperature. NOTE: This will ONLY

display a value when a temperature sensor is being used to control the indirect

storage tank.

Table 44

Rinnai Commercial Boiler Installation and Operation Manual 95

NO. DESCRIPTION FUNCTION

VIEW - Pumps

1 Boiler Pump (Q1) Displays the current state of boiler pump (on / o)

2 Boiler Pump (Q1) Speed Not used

3 CH Pump (Q2)

Displays the current state of CH pump (on / o). NOTE: This is for CH-1 room

thermostat connecon zone.

4 DHW Pump (Q3)

Displays the current state of DHW pump (on / o). NOTE: If DHW pump is assigned as a

CH-2 pump from SETUP-DHW Setup page, then this will represent the state of the CH-2

pump for CH-2 room thermostat connecon zone.

5 DHW Pump (Q3) Speed Not used

6 UX2 Displays the value of 0-10V output signal for UX2 connecon

7 UX3 Displays the value of 0-10V output signal for UX3 connecon

8 P1 Displays the PWM value in % for P1 connecon.

Table 45

96 Rinnai Commercial Boiler Installation and Operation Manual

NO. DESCRIPTION FUNCTION

VIEW - Cascade

1 Bars explanaon

White Color - Units not available in the cascade system (missing)

Gray Color - Units available and not released for operaon in the cascade system

(standby, or service mode acve)

Yellow - Unit temporarily not available or outside temperature limit acve

Green - Units are released to operate in the cascade system

Red - Unit in a hard lockout state

2 Master Displays the status message of the Master unit.

3 Follower 1 Displays the status message of the Follower 1 unit.

4 Follower 2 Displays the status message of the Follower 2 unit.

5 Follower 3 Displays the status message of the Follower 3 unit.

6 Follower 4 Displays the status message of the Follower 4 unit.

7 Follower 5 Displays the status message of the Follower 5 unit.

8 Follower 6 Displays the status message of the Follower 6 unit.

9 Follower 7 Displays the status message of the Follower 7 unit.

NO. DESCRIPTION FUNCTION

VIEW - History

1 Table explanaon

The table shows historical data of error codes with date and me stamp of when the

error occurred and when the error was resolved. Once the error has been cleared the

line will change color from gray to green.

2 Burner Hours Run Shows total burned run hours

3 Burner Starts Stage 1 Shows total ignion cycles

Table 47

Table 46

Rinnai Commercial Boiler Installation and Operation Manual 97

NO. DESCRIPTION FUNCTION

VIEW - History (cont.…)

4 Hours Run Heang Displays the run hours for Central Heang (CH) mode

5 DHW Hours Run Displays the run hours for DHW mode

6 Reset Error Code This will clear the error history (ONLY available for Rinnai employees)

7 List of Error Codes This page accumulave error codes. This list can ONLY be reset by a Rinnai employee.

NO. DESCRIPTION FUNCTION

VIEW - Info

1 MAC ID Displays boiler MAC ID for Wi-Fi connecon

2 HMI Version Displays the rmware version of the touch panel—HMI

3 Webserver Card Version

Displays the rmware version of the webserver card (located on the boom of the

boiler)

4 LMS14 Parameter Version Display the parameter le version of the main control board (LMS14)

5 Device Model

Displays the boiler model (RCB301AN, RCB399AN, RCB500AN, RCB750AN, OR

RCB1000AN)

6 Fuel Type Displays the fuel type NG or LP

7 Elevaon () Displays the elevaon seng

Table 47 connue

Table 48

98 Rinnai Commercial Boiler Installation and Operation Manual

The graph function can be used to monitor boiler operation and aid in troubleshooting.

NOTE: Password is not required to access this page.

In order to activate each data point the boxes next to each parameter needs to be activate with a check

mark. As long as the current graphical page remains active a total of 10 minutes, data will be shown on the

screen. Once the user leaves the screen the graph will clear and start from the current time. There are four

different graphs (Temperatures, Pumps, Fan Speed / Ion. Curr., Cascade, and Water Pressure), and ONLY

one of the graphs can be viewed at once.

Scan the QR code on this screen to access the literature for the appliance.

Rinnai Commercial Boiler Installation and Operation Manual 99

The service page can be used during boiler commissioning. This is useful to manually run the pumps and

remove air from the system. Also, it can be used for combuson analysis by running the unit at minimum

and maximum ring rate or any other ring rate in between. NOTE: The service mode operaon will auto-

macally end aer 4 hours unless it is manually turned o by the user. NOTE: It is extremely important to

turn-o the service mode aer boiler commissioning to avoid issues during normal operaon.

NO. DESCRIPTION FUNCTION

LEFT PANE

1 Pump Service Mode

This funcon is used to manually run each one of the pumps individually. This is a

useful means to check pumps for operaon and remove air from the system during

deaeraon process. NOTE: ONLY one pump can be energized at a me. Once the

tesng is completed, press “No Test” to de-energize the pump.

2 Output Test

This funcon can be used to test the operaon of 0-10V and PWM output signals. The

values are in terms of percentage. For instance if the user is looking for 4V, then 40%

should be entered. The readable values can be conrmed from VIEW - Pumps page.

3 Demand Test

This funcon can be used to test funconality of room thermostat connecon without

any wiring connected to the boiler terminals. These contacts are normally open (NO).

By clicking on Normally Closed (NO), this will close the room thermostat connecon

and the boiler will get a demand for heat. NOTE: It is very crical to return these values

to the default seng (NO) once the tesng is completed.

Table 49

100 Rinnai Commercial Boiler Installation and Operation Manual

NO. DESCRIPTION FUNCTION

CENTER PANE

4 Service Mode

Service mode can be used to manually re the unit and adjust its ring rate. Press on

the ON icon in front of Service mode to acvate a call for heat. Once the demand for

heat is acve, the two LED lights under Service Mode Status (right pane) will illuminate.

The ring rate can be adjusted by clicking on MIN (this will bring the boiler to the

minimum ring rate), MAX (this will bring the boiler to its maximum ring rate), or

percentage box (will prompt the user to enter a value between 0% and 100%).

NOTE: The boiler target setpoint will be 180F once this mode is acve. It is important

for the user to ensure there is enough head load connected to the boiler to dissipate

the heat. During this mode all 3 pumps will be energized, it is also crical to ensure not

to overheat an indirect tank that is connected to the boiler.

The remaining informaon on the center pane are to view ONLY.

RIGHT PANE

5 Maintenance

The informaon showing (Burner Run Hours Since Maintenance, Burner Cycles Since

Maintenance, and Time Since Maintenance) are used to display boiler operaon since

last maintenance service. Once the service has been performed , the user can click on

Maintenance Reset box to reset the counter.

6 Service Mode Stats

This is read only informaon. Once the service mode has been acvated both LED

indicators will turn green to conrm operaon.

7 Service Notes

Click on Service Notes box to enter notes, contact informaon for the record. See info

below for more details.

To add new notes, double tap the screen on an empty line under the message. A conrmaon box will pop-up.

Click on conrm, then a new text box will pop up to for the user to type the informaon. Once the informaon

has been entered, click on conrm to save the content.

To edit previous messages, double click on the desired message. It will be highlighted in blue and conrmaon

will pop-up. Click on Modify Message to make changes to current message, or Delete Message to delete

current selected message.

Table 49 connue

Rinnai Commercial Boiler Installation and Operation Manual 101

Some of the checks below should be performed by a licensed professional.

Consumers should never aempt any acon that they are not qualied to perform.

Error

Code

Message

Remedies

NOTE: The numbers in parenthesis are diagnosc codes associated with each

error code

Outdoor sensor fault

(B9)

The error will auto-reset once the issue is resolved (610)

NOTE: This error code does not prevent boiler operaon; However, it will

prevent any other error codes to show on the home page.

1- Check the outdoor sensor connecon to ensure it is not open or not

connected (if not connected, the jumper should remain in place - supplied from

the factory) - check connuity

2- Check outdoor sensor wiring to ensure it is connected properly (1 kOhm

sensor supplied from the factory) - check connuity

3- Check the resistance of the outdoor sensor and compare to the value shown

on the resistance value table

4- Replace the outdoor sensor if malfuncon is detected

5- If the issue persists, replace the main control board

Boiler Supply

temperature sensor

fault (B2)

The error will auto reset once the issue is resolved (unless the diagnosc code is

2- manual reset required)

1- Check supply temperature sensor wiring to ensure it is connected properly

(10 kOhm sensor) - check connuity

2- Check supply temperature sensor to ensure it is not short or open (2)

3- Check the resistance of the supply temperature sensor and compare to the

value shown on the resistance value table (737, 591, 249, 552)

4- Replace the supply temperature sensor if malfuncon is detected.

5- If the issue persists, replace the main control board

Cascade temperature

sensor fault (B10)

The error will auto-reset once the issue is resolved

NOTE: This error code does not prevent boiler operaon; However, it will

prevent any other error codes to show on the home page.

1- Check cascade temperature sensor wiring to ensure it is connected properly

(10 kOhm sensor)

2- Check cascade temperature sensor to ensure it is not short or open

3- Check the resistance of the cascade temperature sensor and compare to the

value shown on the resistance value (Table 51: Temperature vs. Resistance).

The cascade temperature sensor is ONLY required on the Master boiler.

Conrm the cascade address is set correctly. Ensure the cascade sensor is set

correctly on SETUP - cascade setup page. If everything is set correctly, use the

save sensor opon on SETUP - system setup to congure this sensor.

4- Replace the supply temperature sensor if malfuncon is detected.

5- If the issue persists, replace the main control board

WARNING

The list of error codes with occurrence day and me and with clear date and me are saved in the History page.

This informaon can be accessed via the boiler controller by clicking on VIEW - History.

Table 50

102 Rinnai Commercial Boiler Installation and Operation Manual

Error

Code

Message

Remedies

NOTE: The numbers in parenthesis are diagnosc codes associated with each

error code

Flue gas

temperature

sensor fault (BX3)

The error will auto reset once the issue is resolved (unless the diagnosc code is

0 or 540 - manual reset required)

1- Check ue gas temperature sensor wiring to ensure it is connected properly

(10 kOhm sensor) - check connuity

2- Check ue gas temperature sensor to ensure it is not short (543 or 0) or

open (544 or 540)

3- Check the resistance of the ue gas temperature sensor and compare to the

value shown on the resistance value (Table 51: Temperature vs. Resistance).

4- Replace the ue gas temperature sensor if malfuncon is detected.

5- If the issue persists, replace the main control board

Return

temperature

sensor fault (B7)

The error will auto reset once the issue is resolved (unless the diagnosc code is

0- manual reset required)

1- Check return temperature sensor wiring to ensure it is connected properly

(10 kOhm sensor) - check connuity

2- Check return temperature sensor to ensure it is not short (441) or open (442)

3- Check the resistance of the return temperature sensor and compare to the

value shown on the resistance value table (52, 738, 250, 0)

4- Replace the return temperature sensor if malfuncon is detected.

5- If the issue persists, replace the main control board

DHW

temperature

sensor/

thermostat fault

(B3)

The error will auto-reset once the issue is resolved (55)

NOTE: This error code does not prevent boiler operaon; However, it will

prevent any other error codes to show on the home page.

1- Check what type of device is used to control the indirect tank temperature

(sensor or aquastat). Verify that the sengs on the boiler (SETUP-DHW Setup)

match the applicaon

2- Check the DHW temperature sensor connecon to ensure it is not open or

not connected (if an aquastat is being used ensure the correct seng is used on

SETUP-DHW setup page)

3- Check DHW temperature sensor wiring to ensure it is connected properly (10

kOhm sensor) - check connuity

4- Check the resistance of the DHW temperature sensor and compare to the

value shown on the resistance value table

5- Replace the DHW temperature sensor / Aquastat if malfuncon is detected

6- If the issue persists, replace the main control board

LPB short-circuit

or no bus power

supply

The error will auto-reset once the issue is resolved (67)

1- Check cascade communicaon cable to ensure the wires are not shorted

2- Ensure the cable connecon from cascade module to the main control board

is connected properly and secured

3- If the problem persists and the unit is not cascaded with other units,

disconnect the cascade module from the main controller.

NOTE: LPB is the cascade bus (the power comes directly form the main

controller)

LPB address

collision

The error will auto-reset once the issue is resolved (67)

NOTE: This error code will ONLY happens if there are two or more units

connected with each other.

1- Check to ensure the cascade addresses for the units in the cascade system

are unique. For instance if there are one or more units set as Master, the LPB

address collision error code will be displayed.

Table 50 connue

Rinnai Commercial Boiler Installation and Operation Manual 103

Error

Code

Message

Remedies

NOTE: The numbers in parenthesis are diagnosc codes associated with each

error code

BSB-Wire short-circuit

or no communicaon

The error will auto reset once the issue is resolved (595)

1- Ensure the wiring from the Webserver card/Wi-Fi Module and LMS is not

jumped or disconnected.

NOTE: BSB is the communicaon between the Webserver card/Wi-Fi Module and

main controller.

Data loss in EEPROM The error will auto reset once the issue is resolved (618)

This error code should only happen during ashing of the main controller at the

factory.

1- Loss of data on EEPROM - replace the main control board

105 Maintenance message

The error will auto reset once the maintenance interval has been reset (87)

1- Perform the boiler service as recommended by the manufacturer

2- Once the service has been performed, access the SERVICE page and perform a

maintenance reset.

110

SLT lock-out

SLT - Safety Limit

Thermostat (electronic)

This error code requires a manual reset

1- Boiler return temperature not possible (< 32°F [0°C]) - (424)

2- Boiler supply temperature not possible (<32°F [0°C]) - (422)

3- Boiler supply temperature not possible (>255°F [124°C]) - (422, 809 )

4- Safety Limit Thermostat (SLT) is open (551, 412) - check connuity of

thermofuse, burner door switch and jumper on high voltage terminal block)

5- Boiler return temperature > 208°F (98°C) - (425)

6- Boiler Supply Temperature > 208°F (98°C) - (419, 430, 432)

7- Boiler temperature rises faster than allowed (5.4°F [3°C]) - (426, 437)

8- Reset criteria (boiler temperature less than boiler temperature setpoint and

Delta-T less than 72°F [40°C] for error 426 not reached - (427)

9- Delta T (dierence between supply and return) is higher than 101°F (56°C) -

(428)

10- Reset criteria (Delta-T less than 36°F [20°C] aer error 433 not reached)-(429)

11- Boiler return temperature is higher than boiler supply temperature + 27°F

(15°C) - (420, 431)

12- Boiler return temperature is higher than/equal to boiler supply temperature

+ 31°F (17°C) - (420)

13- Supply temperature increases aer the burner is o - residual heat (436)

14- Delta-T (dierence between supply and return) is greater than 72°F [40°C) -

(433, 438)

15- Supply temperature exceeds 208°F (98°C) - (432)

111

Temperature limiter

safety shut-down

The error will auto reset once the supplied temperature is below 203°F (95°C)

(264)

1- Supply temperature has exceeded 203°F (95°C) (264)

117

Water pressure too high

(H1)

The error will auto reset once the water pressure decreases to less than 83 PSI

(5.7 bars) (566)

1- Ensure the water pressure in the system does not exceed 87 PSI (6 bar). This is

very unlikely since the maximum seng on the factory supplied pressure relieve

valve is 75 PSI

2- If the actual pressure in the system has been conrmed to be below 87 PSI,

replace the water pressure sensor.

118

Water pressure too low

(H1)

The error will auto reset once the water pressure is at least 16 PSI (1.1 bar) (566)

NOTE: The boiler will reduce the output power when pressure in the system is

between 12 PSI (0.8 bar) - 20 PSI (1.4 bar). The boiler will connue to operate and

an error code will be displayed on the home screen. When the pressure increases

above 20 PSI (1.4 bar) the error will disappear. If the pressure decreases below 12

PSI (0.8 bar) the boiler will shut-down and keep the error code.

1- Ensure the water pressure in the system is at least 12 PSI (0.8 bar). Check the

pressure seng on the water auto feed to the boiler loop. Check for water leaks

in the system piping.

2- If the pressure in the system is sll below 16 PSI (1.2 bar), replace the water

pressure sensor.

Table 50 connue

104 Rinnai Commercial Boiler Installation and Operation Manual

Error

Code

Message

Remedies

NOTE: The numbers in parenthesis are diagnosc codes associated with

each error code

125

Maximum boiler

temperature exceeded

Boiler pump and fan

will connue to run to

dissipate the heat.

The error will auto reset once the boiler supply temperature decreases

below 203F (95C) minus the boiler switch on dierenal, 20°F (11°C) -

default sengs.

NOTE: The boiler will start reducing the ring rate when supply

temperature reaches 190°F (88°C)

1- The boiler temperature has reached 203F (95C) (286, 500, 740)

2- No temperature change on supply sensor aer ame (501)

3 - No temperature change on return sensor aer ame (502)

128

Loss of ame in

operaon (10 mes)

This error code requires a manual reset

1- Loss of ame in operaon (625)

2- Ionizaon current has fallen below 0.8uA (854)

3- Ensure the boiler electrical connecon is properly grounded to the

ground source.

4- Monitor the gas pressure to the unit while in operaon. The gas

pressure should be within the limits specied in this manual.

5 - Check the ame signal on the display. It should be above 0.8uA when

the burner is lit. The ame current should be stable aer the boiler has

been ring for at least one minute and it is normally between 3 - 7uA. if

the ame current is less than 0.8uA, disassemble the burner door and

check the ionizaon probe quality and distance to the burner (clean if

necessary).

130

Flue gas temperature

maximum limit

exceeded (BX3)

This error code will automacally reset if the issue is resolved within 10

minutes. Otherwise a manual reset is required.

1- Ensure the proper seng is being used for the ue pipe venng

material. If the ue temperature for the applicaon is higher than 149°F

(65C), vent material other than PVC must be used and the seng for

the ue gas temperature limit must be set to other on the controller

(SETUP-Boiler Setup).

2- The control will limit the ue temperature to 149°F (65°C) for PVC

pipe and 207°F (97°C) for other venng materials. The boiler will

automacally start to modulate when the vent temperature reaches

140F (60°C for PVC and 194°F (90°C) for other venng material. The

control will shut down and monitor the vent temperature for 10

minutes. If the temperature exceeds the value shown here aer 10

minutes the control will lock-out.

3- Check ue gas temperature resistance and compare to the value

listed on the resistance table

4- Ensure the correct gas type is used. If the unit is Natural Gas and

Propane gas is connected to the unit this will cause boiler overheang

and unsafe condions.

133

Safety me for

establishment of ame

exceeded (4 mes)

This error code requires a manual reset

1- The boiler failed to ignite four mes during one heat call (625)

2- Check electrical connecon to the unit and check for proper

grounding and polarity.

3 - Check the ignion transformer wiring connecon for reverse

polarity.

4- Check for sparks through the sight glass on the burner door.

5- If there is spark but no ame, monitor the stac gas pressure to

ensure it is within the limits specied in this manual

6- Check for vent or condensate blockage.

7- If the problem persists, remove the burner door and inspect the

ignion electrodes (check for gaps and distance to the burner. Clean if

necessary)

Table 50 connue

Rinnai Commercial Boiler Installation and Operation Manual 105

Error

Code

Message

Remedies

NOTE: The numbers in parenthesis are diagnosc codes

associated with each error code

151 BMU internal fault

This error requires a manual reset

Internal error on the main controller (630)

1- Error at closing(330) or opening (331) ignion relay

2- Error at closing (332) or opening (333) gas valve relay 1

3- Error at closing (336) or opening (337) the safety relay

4- Replace the main controller

152 Parameterizaon error

This error will auto-reset once the issue is resolved unless

diagnosc code is 780, 781, 782, 851, 840 or 853 - manual reset

required

This error happens when seng parameters on the main

controller. For instance if the fan speeds are not set within the

min and max range set on the main controller.

153 Unit manually locked

This error code requires a manual reset (press reset buon for

less than 10 seconds)

1- Unit manually locked (reset buon pressed more than 10 sec-

onds)

160

Fan speed threshold not

reached

This error code requires a manual reset

NOTE: These error codes happen in case the impeller on the fan

gets stuck.

1- Fan speed threshold not reached: home run (377)

2- Fan speed threshold not reached: standby (378)

3- Fan speed threshold not reached: ignion (379)

4- Fan speed threshold not reached: pre-purge (380)

5- Fan speed threshold not reached : post-purge (381)

6- Fan speed threshold not reached : in operaon (233, 749)

162

Air pressure switch does

not close

This error code requires a manual reset (9)

1- Air pressure switch is normally closed and will open in case of

condensate or vent blockage.

2- Check the pressure switch wiring—check connuity.

3- Check vent pipe and condensate trap for blockage.

Disconnect the hose from the air pressure switch and check for

operaon. If the unit operates normal, either condensate on

vent pipe is blocked. If the unit does not operate check pressure

switch.

4- Check the pressure switch wiring to ensure it is normally

closed when the unit is on standby.

5- If the issue persists replace the air pressure switch.

164

Flow/pressure switch

HC fault

This error will auto-reset once the issue is resolved

1– Water ow is not detected aer receiving a heat demand

(562)

2– Ensure the pump is operaonal and providing adequate ow

rate.

3– Ensure the ow switch is connected properly and facing the

ow direcon.

4– Ensure the return and supply pipes are connected correctly.

5– Check connuity to ensure the ow switch contact is closed

when there is no water ow and closed with water ow.

183

Unit in parameteriza-

on mode

This error code requires a manual reset

1- Unit in parameterizaon mode (301)

2- Unit in parameterizaon mode (770 - parameter sck)

Table 50 connue

106 Rinnai Commercial Boiler Installation and Operation Manual

Error

Code

Descripon

Remedies

NOTE: The numbers in parenthesis are diagnosc codes associated with each

error code

217 Sensor fault

This error code will auto-reset once the issue is resolved

1- Short-circuit of ionizaon electrode (765, 766). The ionizaon current is

shorted to ground.

2- Check the condensate trap to ensure the condensate is draining properly. If

there is water in the heat exchanger in contact with the ionizaon electrode

this error code will appear.

317

Grid frequency OOR This error code will auto-reset once the frequency is back within the range

NOTE: This error code happens when the power frequency is out of the range

[42 Hz - 72 Hz]

1- Mains frequency outside specicaon (275, 461)

353

Cascade temperature sen-

sor missing (B10)

This error code will auto-reset once the issue is resolved

NOTE: On a cascade system, a cascade temperature sensor is required to be

installed on the system loop. Once a sensor is connected to the unit, the main

controller recognized the sensor. If the sensor gets disconnected this error code

will be shown. If the unit is no longer set as a cascade, the sensor must be disa-

bled from the cascade setup menu, and save sensor funcon must be applied

from the system setup menu.

1- Cascade temperature sensor missing (B10) (139)

384

Extraneous light This error code requires a manual reset (625)

NOTE: This error code happens if unit detects fan while the gas valve is not en-

ergized (false ame)

385

Main under voltage This error code will auto-reset once the voltage is back within the range

NOTE: This error code happens when the voltage is out of the range [102V -

132V]

1- Voltage outside of the range (554, 555)

386 Fan speed tolerance

This error code requires a manual reset

1- Fan speed out of tolerance (+/-300 rpm): home run (387)

2- Fan speed out of tolerance (+/-300 rpm): standby (388)

3- Fan speed out of tolerance (+/-1200 rpm): ignion (374, 382, 383)

4- Fan speed out of tolerance (+/-1200 rpm): pre-purge (389,531)

5- Fan speed out of tolerance (+/-1200 rpm): post-purge (390, 532, 534)

6- Fan speed out of tolerance (+/-1200 rpm): in operaon (232, 750, 375, 385,

386)

Other possible issues without an error code:

1. There is call for heat, pumps are running however the unit is not ring. Check boiler acve setpoint and

compare with boiler actual supply temperature values. The boiler will ONLY re when the acve setpoint is

equal or higher than the boiler actual temperature plus the dierenal.

2. The main screen is blank. Ensure the CAT5 cable is properly connected to the main screen (it must be

connected to port RS485). Check the webserver card/Wi-Fi Module located on the boom of the unit to

ensure it is geng power. If so, please check the wiring from webserver card/Wi-Fi Module to the HMI for

proper connecon (see wiring diagram for details).

3. The temperature values on the main screen are all zeros. Ensure the webserver card/Wi-Fi Module is

properly connected to the main controller and is geng power.

Table 50 connue

Rinnai Commercial Boiler Installation and Operation Manual 107

Supply Temperature Sensor

Return Temperature Sensor Flue

Temperature Sensor

Cascade System Sensor

DHW Temperature Sensor

Outdoor Temperature Sensor

Temperature [°F] Resistance [Ω]

-22 13034

-13 9889

-4 7578

5 5861

14 4574

23 3600

32555

32 2857

25339

41 2284

19873

50 1840

15699

59 1492

12488

68 1218

10000

77 1000

8059

86 827

6535

95 687

104

5330

104 575

113

4372

113 483

122

3605

122 407

131

2989

140

2490

149

2084

158

1753

167

1481

176

1256

185

1070

194

915

203

786

212

677

Table 51: Temperature vs. Resistance

108 Rinnai Commercial Boiler Installation and Operation Manual

WARNING

Combuson analysis must be performed by a trained and qualied

professional.

To perform a combuson analysis:

1. Remove the boiler’s front panel by removing the two screws that secure the panel.

2. 500 model: Remove the combuson analysis port plug and insert the gas analyzer probe into the

port (Figure 56).

750 and 1000 models: Drill a hole on the exhaust pipe to insert the combuson analyzer probe.

Ensure to have a piece of aluminum tape to plug the hole once the test is completed (Figure 57).

3. Use the SERVICE page on the boiler home screen to manually run the unit at maximum and

minimum ring rate to check for proper combuson adjustment. This boiler has an automac

ignion system. When the main burner has lit, the ame symbol will on the home page will

illuminate and the modulaon percentage will show on the home page. The maximum ring rate

is 100% of modulaon and the minimum ring rate is 0% of modulaon.

Figure 56

Figure 57

Test Port Plug

Combuson Analysis Port and Plug

Test Port

Aluminum Tape

Rinnai Commercial Boiler Installation and Operation Manual 109

TYPE OF GAS CO2 RANGE (%) CO LIMIT (PPM) CO2 TARGET (%)

8.5 - 9.7

< 175 PPM

9.0

PROPANE

9.5 - 10.5

< 175 PPM

10.0

5. For RCB500AN model: Aer measurement, remove the gas analyzer probe, and replace the

combuson analysis port plug.

Add another statement for RCB750AN / RCB100AN models: Aer measurement, remove the

gas analyser probe, and cover the test port (drilled hole) using aluminium tape.

Informaon in table applies to both Minimum and Maximum ring rates.

IMPORTANT: When making adjustments to the gas valve, it is crical to make a small adjustment

rst, then wait for the combuson to sele before making further adjustments. The boiler is

pre-set at the factory and only a slight adjustment should be made to the gas valve for tuning.

Make adjustments to the minimum ring rate rst, and then proceed to the maximum ring rate

adjustment.

Table 52:

4 Use a combuson analyzer to verify CO2 is within the range listed in the table below for both minimum

and maximum ring rates. If a combuson analyzer is not available:

• For minimum ring rate, adjust the oset screw counterclockwise to decrease CO2 and clockwise to

increase CO2 (Figures 58 and 59).

• For maximum ring rate, adjust the throle screw to increase or decrease the CO2. See Figures 60

and 61 for steps on increasing or decreasing CO2.

IMPORTANT: When making adjustments to the gas valve, it is crical to make a small adjustment rst,

then wait for the combuson to sele before making further adjustments. The boiler is pre-set at the

factory and only a slight adjustment should be made to the gas valve for tuning. Make adjustments to the

minimum ring rate rst, and then proceed to the maximum ring rate adjustment.

Throle

Screw

Figure 60

Reduce

Torx Plug

Figure 58

Reduce

Oset

Screw

Adjustment screw is located on both sides of the gas

valve. Only one side needs to be adjusted.

Throle

Screw

Reduce

Figure 61

Adjustment screw is located on both sides of the

gas valve. Only one side needs to be adjusted.

Oset

Screw

Reduce

Figure 59

110 Rinnai Commercial Boiler Installation and Operation Manual

Freeze Protecon (priority 1):

The electronic management system of the boiler includes protecon against frost. If the

water temperature falls below 41°F [5°C], the burner starts up and the boiler pump runs to provide

a water temperature of 46°F [8°C] + Boiler Oset 9°F [5°C] + Boiler Dierenal 20°F [11°C]. Once

the target temperature has been reached the burner will turn o, the boiler pump will connue to

run and turn o aer post purge period. This funcon only works if boiler is turned on, the gas

supply is ON and the water pressure is correct. NOTE: The boiler will not engage in freeze

protecon mode if there are any so or hard lockout error codes.

Service (priority 2):

When service mode is acvated, the relays are no longer energized and deenergized

according to the control state, but are set to a predened manual control state in accordance with

their funcons (For instance: QX1- Boiler Pump; QX2 - CH-1 Pump; QX3 -DHW pump). The relay

outputs are set to a state where heat is provided, independent of their hydraulic funcon. When a

service mode is acvated for a heat call, all three pumps will be energized. It is important to ensure

that there is sucient heat load connected to the appliance before operang the unit at full ring

rate. With service mode each pump can be run independently to either purge air from the system

or test the relays for proper operaon.

Domesc Hot Water (DHW) (priority 3):

The boiler can be connected to an indirect tank to provide domesc hot water (DHW). The

control allows for a tank sensor or aquastat (thermostat) connecon to the low voltage terminal.

The boiler is shipped with aquastat as a default seng to control an indirect tank. Ensure to set the

DHW temperature to match the seng of the mechanical aquastat installed on the tank. When a

tank sensor is connected, the DHW sensor opon on the boiler setup page needs to be changed to

sensor. The control has an oset parameters that will set the boiler supply temperature to a higher

temperature in order to meet the demand of the indirect tank (default is + 20°F [11°C]). For

instance if the indirect tank is set to 120°F, the boiler will supply 140°F to the indirect tank coil.

MODES

OPERATION

Freeze protecon

Service

DHW

Sensor

Aquastat

Room T/T 1

Room T/T 2

0-10V Input

Outdoor Reset

Cascade

Sensor

Rinnai Commercial Boiler Installation and Operation Manual 111

DHW Pump (QX3):

When either a sensor or aquastat is connected to the low voltage signal, the boiler will

acknowledge the demand and will run the DHW pump to sasfy the DHW demand. If an indirect

tank is not used, this pump can be assigned to run when there is a call for room thermostat 2.

When an indirect tank is piped on the system loop, there is an opon on the DHW setup page to

enable boiler pump to run during a DHW call. NOTE: It is crical to protect a low temperature zone

with a mixing valve when the boiler temperature for DHW is higher than the low temperature zone

setpoint.

Central Heang (CH) (priority 4):

Room Thermostat

There are two head demands connecons available on this control. These inputs commands

the boiler to provide hot water for central heang. Each demand has its own setpoint and outdoor

reset curves. The rst room thermostat connecon is enabled form the factory. The second room

thermostat is disabled from the factory. In case an indirect tank is not being used, the DHW pump

can be assigned for room thermostat 2 (CH-2 pump) from Setup Pump Setup page. When there are

mulple demands acve, the control will gives priority to the demand with the highest set point.

NOTE: It is very crical to protect a low temperature zone to avoid overheang or damages to the

heang system. For instance, Assume room thermostat 1 setpoint is 160°F, room thermostat 2

setpoint is 120°F, and both have a call for heat. The boiler will deliver a temperature of 160°F unl

both demands are sased or will deliver 120°F once demand from room thermostat 1 is sased.

Outdoor Reset Curve:

Outdoor reset is a built-in funcon to help maximize the eciency of the boiler. The design

of this funcon is to adjust the target temperature of the boiler relave to the outdoor ambient

temperature via the outdoor reset curve opons included in the boiler setup page. The outdoor

ambient temperature is observed via the provided outdoor temperature sensor. There are two

outdoor rest opons available on the setup page, one for each room thermostat connecons.

0-10VDC Input (Boiler Setpoint or Boiler Modulaon):

The boiler can be controlled and acvated via a Building Management System (BMS) using a

0-10VDC signal. There two possible opons to control the boiler via this signal: Boiler Setpoint and

Boiler Modulaon. These funcons are predened with two xed points (min. voltage / min.

setpoint or modulaon), (max. voltage / max. setpoint or modulaon). The request for heat

becomes acve when the applied voltage is 200mV and will remain acve as long as the voltage is a

minimum of 150 mV. NOTE: It is crical to keep the 0-10V input voltage wiring away from the line

voltage wiring to avoid induced voltage which may cause the boiler to be energized when not

desired. The following graphs are linear representaon of the 0-10V operaon.

112 Rinnai Commercial Boiler Installation and Operation Manual

Boiler Pump (QX1):

The boiler pump will run anyme there is a central heang demand. This pump will also run

during a freeze protecon or service mode. There is an opon in the controller to enable boiler

pump to run during a DHW demand (in case an indirect tank is piped on the system loop).

CH-1 Pump (QX2):

The CH-1 pump will run when there is a call for heat from room thermostat 1 or there is a

demand from 0-10V input with boiler modulaon opon. In case 0-10V input with boiler setpoint is

desired the Pump Assignment QX2 needs to be Q15 under Setup - Pump page.

Cascade:

When mulple boilers are installed they can be wired and programmed to work in a

cascade system. A maximum of eight units can be controlled from a single control. In this

applicaon one boiler would be assigned as a Master control and all others would be assigned as

follower controls. The Master control sequences the operaon of other members in the cascade

system using the eciency opmizaon control method. The room thermostat connecons, 0-10V

input, outdoor sensor, cascade system sensor get connected on the Master boiler. Once a call for

heat is received, the control will determine the system setpoint. Each boiler in the cascade system

will have a setpoint up to 20F [11C] higher than the system setpoint to account for heat loss on the

primary loop piping. Once the actual system temperature gets close to the target system

temperature each boiler setpoint will be lowered accordingly to maintain the required temperature

on the system loop.

Similar approach can be sued for DHW operaon. If the enre cascade system will be used

to sasfy DHW demand, the indirect tank sensor / aquastat only needs to be connected to the

Master boiler and will control the DHW demand accordingly. In this applicaon, the boiler

temperature for each unit will be the indirect tank setpoint + DHW oset + Cascade Setpoint

Compensaon. If desired, the DHW oset can be set to zero in this case. If only certain units are

intended for the DHW applicaon, there is a parameter in the setup-cascade page to set DHW as a

separate circuit. In this case each unit intended to be dedicated for DHW applicaon needs to have

DHW separate circuit parameter set to ON. If only one unit is dedicated for DHW applicaon either

a sensor or an aquastat can be used and must be connected on this specic unit. If more units are

dedicated for DHW, and aquastat must be used and connected in parallel to each unit. In this

applicaon, the boiler temperature for each unit will be the indirect tank setpoint + DHW oset.

To establish a cascade system:

1. Set the address of each unit under Setup Cascade page. The Master must be addressed as

Master, the followers can be addressed from Follower 1 thru Follower 7. NOTE: The

addressed must be unique otherwise there will be an error code.

2. Enable the cascade system sensor on the Master boiler ONLY. Connect the cascade system

to the master boiler low voltage signal. NOTE: The cascade sensor must be installed on the

system supply piping as close a possible to the low loss heater or closely spaced tees. The

cascade sensor (10kOhm) is surface mount type and it might need to be insulated in case

of heat loss.

3. Connect units to each other using 18 or 20 gauge wires (maximum total length for 18

gauge wire is 262  [80 m]; for 20 gauge wire is 131  [40 m]). The Master and last

follower units will take a pair of wires, all other units in between will take 2 pair of wires to

create a daisy chain connecon.

4. The units are set from the factory to rotate every 50 hours in order to balance the run

hours. All other parameters in the cascade setup are oponal depending on the system

applicaon.

Rinnai Commercial Boiler Installation and Operation Manual 113

Boiler Safety Features:

Gradient liming:

During operaon, if the boiler supply temperature is rising too quickly, the control will start to

modulate down and reduce the ring rate down to the lowest seng to prevent overheang (in

case of no ow condions).

Reverse ow detecon:

During operaon, the boiler will monitor both supply and return temperatures to ensure the return

temperature is not much higher than the supply temperature (in case of reverse ow or

malfuncon of either supply or return thermistors).

Flow monitoring

The boiler is equipped with a water ow switch to ensure the boiler operates safely. The

switch monitors water ow when boiler receives a heat demand. This switch will disable boiler

operaon in case there is a heat demand but the ow is not detected.

Supply Temperature, and Flue Temperature Supervision

The control monitors the boiler supply temperature thermistor, when this temperature

exceeds 190°F [88°C] the control will reduce the output power. If this temperature connues to rise

and exceeds 203°F [95°C] the control will shutdown the burner unl it cools o. The control will

shutdown and lockout if the supply temperature exceeds 208°F [98°C] - manual reset required.

The ue temperature is monitored by a sensor located on the secondary heat exchanger.

There are two sengs on the controller to monitor this temperature based on the material used for

venng. The following table explains the limits and control behavior for each selecon. The boiler

will modulate to maintain the ue temperature below the sengs shown in the table below. In

case the temperature exceeds the maximum limit, the boiler will shutdown and run the fan in post-

purge mode. If the temperature drops within ten minutes the boiler will return to normal

operaon, otherwise it will go into a lockout state.

Vent Material Flue gas temperature

output reducon

Flue gas temperature

output reducon to

minimum ring rate

Flue gas temperature

switch o limit

PVC 140°F [60°C] 145°F [63°C] 149°F [65°C]

OTHERS 198°F [92°C] 203°C [95°C] 207°F [97°C]

Air pressure switch, Burner door limit switch, and thermal fuse (500 model ONLY)

The control is equipped with a pressure switch to monitor the vent pressure and

condensate trap water level. In case the pressure in the vent exceeds 4 in. WC or the condensate

trap water level is 4 in. above the air pressure switch connecon port the unit will shutdown and

go into an error state.

The boiler is equipped with a switch located on the burner door and thermal fuse located

on the back of the heat exchanger set to 500°F [260°C] , and 605°F [318°C], respecvely. These

switches prevents overheang in case of abnormal operaon of the appliance or premature

deterioraon of the insulaon disk located on the back of the combuson chamber.

Table 53

114 Rinnai Commercial Boiler Installation and Operation Manual

• Maintenance is required to maintain

safe operaon of the boiler.

• The boiler must be inspected annually

by a licensed professional. Repairs and

maintenance shall be performed by a

licensed professional. The licensed

professional must verify proper

operaon aer servicing.

• Keep the boiler area clear and free

from combusble materials, gasoline,

and other ammable vapors and

liquids.

• 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 manual gas

control valve, 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 or by turning o the

water supply to the building.

Topics in this secon

• Owner Maintenance

• Licensed Professional Maintenance

• Service of Heat Exchanger

• Instrucons to Clean Condensate

Trap

• Test the Ignion Safety Shut O

Device

If you encounter a problem that is

dicult to solve, stop the operaon

and immediately contact a licensed

professional.

MONTHLY

Boiler Area

• Verify the area is free of combusble

materials, gasoline and other

ammable vapors and liquids.

• Verify the area is clean from dust and

obstrucons

• Verify the air intake area is free of any

contaminants listed in the boiler

Installaon and Operaon Manual. Any

contaminants in the boiler intake air

vicinity must be removed. If they

cannot be removed, contact a licensed

professional.

Piping

• Inspect all water, gas, and

condensaon piping for leaks. Look for

signs of leaking lines or corrosion.

• Conrm the condensaon line is not

blocked. If a condensaon drain pump

is used, conrm the condensaon drain

pump operates correctly.

Venng

• Verify the boiler vent discharge and air

intake is clean and free of obstrucons.

• Check for leakage, damage, or

deformaon of venng.

Boiler

• Verify the boiler is free from any

abnormal situaons, such as diagnosc

error codes, loud noises, leakage or

other potenal issues.

• Check that the pressure on the

controller display or external pressure

gauge indicates 20-70 psi (138-483

kPa).

WARNING

Table 54

Rinnai Commercial Boiler Installation and Operation Manual 115

ANNUALLY

Vent System • Inspect for blockages or damage.

• Inspect vent screen or room air lter (if using) for debris and blockages.

Clean if needed.

Fan and Motors Clean dust and dirt from fan and motor (motors are permanently lubricated

and do not require lubricaon).

Controller Clean by using a so, damp cloth. Do not use solvents.

Pressure

Conrm the pressure is within the proper range between 20-70 PSI (1.3 -4.8

Bar). If the pressure is lower than the specied range, add water unl in the

proper range.

Pressure Relief

Valve

Check the operaon of pressure relief valve manually once a year. In doing so,

it will be necessary to take precauons with regard to the discharge of

potenally scalding hot water under pressure. Ensure discharge has a safe

place to ow. Contact with your body or other property may cause damage or

harm.

Heang System

Dirt Trap

Clean annually. Be sure to close the shut o valves under the boiler. Aer

cleaning and installing the lter, purge the air.

Expansion Tank Perform annual checks as recommended by the manufacturer to ensure proper

operaon.

Condensaon

Trap

Check if the trap contains sediment. To remove sediment, unplug the boom of

the condensate trap. Remove the sediment, and then return the plug. Do not

use a wrench to ghten the condensate drain as this could cause the

connecon to break.

Condensaon

Drain

• Conrm the condensaon drain line is not blocked or clocked.

• Ensure the condensaon drain pump (if ulized) is working correctly.

• Inspect the condensate neutralizer (if ulized) to ensure the condensate is

draining properly, and there is adequate amount of neutralizing agent

available.

Draining Water When the system will be shutdown for a long period of me (seasonal

shutdown), close the shuto valves below the boiler and drain the boiler to

protect it from potenal freeze damage.

Tesng the pressure relief valve should only be

performed by a licensed professional. Water

discharged from the pressure relief valve could cause severe burns

instantly or death from scalds.

WARNING

Table 55

116 Rinnai Commercial Boiler Installation and Operation Manual

Water Quality Conrm the water quality. Refer to secon “4.3.1 Water Quality Guidelines” to

determine if the water needs to be treated or condioned, and for complete

water quality guidelines. DHW must be potable, free of corrosive chemicals,

sand, dirt, or other contaminates. It is up to the installer to ensure the water

does not contain corrosive chemicals or elements that can aect or damage the

heat exchanger. Water that contains chemicals exceeding the levels required

aect and damage the heat exchanger. Replacement of the heat exchanger due

to water quality damage is not covered by the warranty.

Snow

Accumulaon

• Verify the area around the ue terminal is free of snow and ice. The boiler will

not funcon properly if the combuson air or exhaust vent pipes are impeded

(blocked or parally blocked) by obstrucons.

• Verify the condensate drain line is free of snow and ice. Ensure the line is not

blocked or clogged and that condensate is owing freely.

Freeze

Protecon

• Freeze protecon for new or exisng systems must use glycol that is specially

formulated for this purpose. This includes inhibitors, which prevent the glycol

from aacking the metallic components. The glycol should be for mul-

metallic components. Check that the system uid is correct for the glycol

concentraon and inhibitor level. The system should be tested at least once a

year and as recommended by the producer of the glycol soluon.

Coastal Area

Installaons

Installaons located in or near coastal areas may require addional maintenance

due to corrosive airborne ocean salt. If corrosion is observed on the body of the

boiler, the boiler shall be inspected to ensure proper operaon and repaired or

replaced, if necessary.

Cleaning It is imperave that control compartments, burners, and circulang air

passageways of the boiler be kept clean. Check burner ame for proper color.

Once ignited, the ame must cover the surface of the burner. The ame must

burn with a clear, blue, stable ame. If the ame does not have this appearance,

complete the following steps:

• Turn o and disconnect electrical power. Allow to cool.

• Remove the front panel.

• Use a vacuum to remove dust from the main burner and fan blades. Do not

use a wet cloth or spray cleaners on the burner. Do not use volale

substances such as benzene and thinners; they may ignite or fade the paint.

• Inspect the combuson chamber and clean if needed. Follow the cleaning

procedure listed in this manual.

Condensate Trap Cleaning:

• Inspect the condensate drain assembly inside the boiler and your external

drain system.

• Remove any debris that may be present in the condensate removal system.

Table 55 connue

Rinnai Commercial Boiler Installation and Operation Manual 117

Intake Filter

Inspecon:

• To maintain opmum performance, periodically inspect the air lter.

• If the air lter appears to have lint and/or dust build up, follow the

cleaning procedure described below.

• If the air lter appears damaged, contact a trained and qualied

professional for a replacement air lter assembly.

Cleaning:

• Clean the Air Filter: With mild dish soap and a so bristle brush, scrub the

lter area of the air lter door. With clean water, rinse the soap o the

lter.

• Dry the Air Filter: With a lint free towel, dry the air lter.

AFTER SERVICING: VISUAL INSPECTION OF FLAME

Verify proper operaon aer servicing. The burner must ame evenly over the enre surface when

operang correctly. The ame must burn with a clear, blue, stable ame. See the parts breakdown

of the burner for the locaon of the view ports. The ame paern should be as shown in the

images below:

SATISFACTORY

FRONT VIEW

BLUE FLAME

FLAME ROD

YELLOW OR GREEN FLAME

FLAME ROD

UNSATISFACTORY

FRONT VIEW

Freeze Protecon Operaon

The electronic management system of

the boiler includes protecon against frost.

When the boiler detects low outdoor ambient

temperatures, the boiler will begin its freeze

protecon operaon. When freeze protecon is

in operaon, the pump may circulate water

and/or the boiler may re to prevent the boiler

from freezing. Ensure power and gas are

supplied to the boiler for freeze protecon to

funcon. The internal freeze protecon will not

necessarily prevent the system piping from

freezing. If the water temperature falls below

41°F [5°C], the burner starts up and the boiler

pump runs to provide a water temperature of

46°F [8°C] + Boiler Oset 9°F [5°C] + Boiler

Dierenal 20°F [11°C].

Once the target temperature has been

reached the burner will turn o, the boiler

pump will connue to run and turn o aer

post purge period. This funcon only works if

boiler is turned on, the gas supply is ON and

the water pressure is correct. NOTE: The boiler

will not engage in freeze protecon mode if

there are any so or hard lockout error codes.

When the system needs to be

shutdown for extended periods of me, the

power and gas supply should be disconnected

from the boiler. The boiler and all system

piping should then be drained. Freezing

damage may occur if there is water remaining

in the boiler or system piping. The plumbing

lines should also be blown out via compressed

air.

Air Inlet Filter

Figure 63

Figure 62

Table 55 connue

118 Rinnai Commercial Boiler Installation and Operation Manual

If the gaskets are damaged DO NOT reuse, the gaskets must be replaced.

WARNING

Fiber Gasket

Burner Door Gasket

Burner Door

Brush

(Not Provided)

1. Before beginning this procedure, ensure to disconnect the electrical power to the boiler and

close the gas ball valve external to the unit. It is very important to wait for the boiler to cool

down to the touch before connuing with this process.

2. Remove the front panels and visually inspect the water level in the condensate trap to ensure it

is draining properly.

3. Disconnect the wiring connecon from the ignion electrodes, ionizaon probe, and burner

door switch (located on burner door).

4. Disconnect the incoming ex line to the venturi by removing the nut. Detach the fan assembly

from the heat exchanger by removing 4 nuts located towards the back of the unit.

5. Remove the 6 nuts to disassemble the burner door from the heat exchanger (follow the

sequence as shown in the Figure below). Carefully slide out the burner door to clear the studs

on the heat exchanger (pull while rotang to clear any obstrucon and avoid damaging the

components on the burner door assembly).

CLEANING THE HEAT EXCHANGER:

6. Inspect the insulaon disk located on the rear of the combuson chamber. Use a nylon brush

and vacuum to clean combuson residue located inside of the combuson chamber.

NOTE: DO NOT use a metal brush. Using a metal brush will cause irreparable damage to the heat

exchanger.

7. Rinse with clean water. NOTE: Do not rinse the target wall insulaon located on the back of the

combuson chamber. If required spray with white vinegar or a cleaning product suitable for

stainless steel (leave to work for 3 to 5 minutes).

8. Inspect the burner door insulaon disk and gaskets (replace if they are damaged).

9. Check whether the surface of the burner is damaged in any way . Replace burner and its gaskets

if they are damaged. To disassemble the burner, remove 5 screws securing the burner inlet

channel to the burner door. To install new burner, ensure to install it with the burner cap facing

down to ensure the burner ange sits at on the burner door.

Figure 64

RCB500AN

model

shown

Rinnai Commercial Boiler Installation and Operation Manual 119

Burner

Ionizaon Probe

Ignion

Electrode

INSPECTING BURNER DOOR ASSEMBLY:

10. Inspect the ignion and ionizaon electrodes. Check the gas of ignion electrodes. Check the

distance from ignion electrode to the burner and check the gap from ionizaon probe to the

burner.

A B C

4.5MM +/- 0.5 10.5MM +/- 1

11. Replace the electrodes if they are damaged or the gap and/or distance to the burner is out of

the specicaons shown in the above table. NOTE: Do not remove the ignion or ionizaon

electrode unless you have spare gaskets and spare parts with gasket available. Most likely the

gasket will get damaged when electrodes are removed.

12. Reassemble the components in the reverse way they were disassembled. NOTE: Ensure to

install the burner door using torque sequence as shown in Figure below. Ensure all gaskets are

in good condion or replace them if necessary. All screws must be ght and torqued according

to the table below.

For Model: RCB500AN

Components Burner Door Nuts (M6) Burner Inlet Chanel Screws (M5) Electrodes Screws (M4)

Torque 44.5 Lb-in (5 Nm) 31 Lb-in (3.5 Nm) 22 Lb-in (2.5 Nm)

For Models: RCB750AN / RCB1000AN

Components Burner Door Nuts (M10) Burner Inlet Chanel Screws (M5) Electrodes Screws (M4)

Torque 442.5 Lb-in (50 Nm) 31 Lb-in (3.5 Nm) 22 Lb-in (2.5 Nm)

Figure 65

Table 57

Table 56

Figure 66

Burner Door

Nuts

Burner Inlet

Chanel Screws

Electrodes

Screws

RCB500AN

model

shown

RCB500AN model shown

120 Rinnai Commercial Boiler Installation and Operation Manual

If the gaskets/O-rings are damaged DO NOT reuse, they must be replaced.

WARNING

The condensate trap must be lled with water during all mes of boiler operaon to avoid ue gas

emission from the condensate drain line. Failure to ll the trap could result in severe personal

injury or death.

1. Before beginning this procedure, ensure to disconnect the electrical power to the boiler and

close the gas ball valve external to the unit. It is very important to wait for the boiler to cool

down to the touch before connuing with this process.

2. Remove the boiler front panel and locate the condensate trap.

3. Loosen the clamp and remove the hose connected to the inlet of the condensate trap.

Disconnect the clear hose from the APS connected on the side of the condensate trap inlet

connecon.

4. Loosen the nut on the discharge of the condensate trap. NOTE: Inspect the gasket and replace

if needed.

5. Remove the condensate trap assembly for inspecon. Remove the cap located on the boom

of the condensate trap and clean with fresh water. Inspect the oang ball and O-rings located

inside of the condensate trap and ensure the ball is oang freely.

Floang ball (acts

as a check valve)

O-ring

Cap

Stopper

INLET

OUTLET

Figure 67

Figure 68

Clamp

RCB1000AN model shown

Rinnai Commercial Boiler Installation and Operation Manual 121

4. Place the boiler in operaon by a call for heat (using room thermostat or from service page).

5. The boiler iniates one start-up aempt followed by three restart aempts.

Aer the last start-up aempt, the boiler locks out and the gas valve shuts o. Code ‘133 Safety

me for establishment of ame’ appears on the controller display which indicates ignion

system safety shuto.

6. Reconnect the wiring connecon to the ame rod. Be careful not to touch the inside of the

wiring connecon. To reset the error, press the reset buon located on the right side of the

display panel on 500 model, and under the display panel assembly for 750 and 1000 models .

The boiler starts up.

1. Remove the boiler front panel.

2. Ensure the boiler is not currently ring and the ame rod is not hot to touch.

3. Disconnect the wiring connecon from the ame rod (located on burner door—lower side)

7. Replace the boiler front panel.

8. The boiler may now go back into normal operaon.

Do not touch the inside of the wiring connecon while it is disconnected.

WARNING

Figure 70

Figure 69

Flame Rod

Plug

Reset Buon

RCB1000AN model shown

122 Rinnai Commercial Boiler Installation and Operation Manual

When replacing an exisng boiler, the

heang system shall be ushed with an

approved system cleaner before the new

boiler is added to the system.

The Rinnai boiler must be isolated from the

system while the system is ushed. No

system cleaner should ever enter the boiler

heat exchanger due to its causc nature

which could damage the heat exchanger.

Instrucons

1. Flush the CH system with water.

2. Isolate the boiler from the CH system.

3. Fill the CH system with an approved

cleaner and circulate through the system.

4. If the installaon is a zone system (ulizes

mulple zones), ush out each zone

individually.

5. Flush the CH system with water again,

ensuring all zones have been ushed.

6. Clean out the dirt trap per manufacture’s

instrucons.

7. The boiler and system may now be lled

through the ll valves.

8. If using glycol, ensure it is an approved

glycol and rao.

9. Verify water quality is within the stated

values in secon “4.3.1 Water Quality

Guidelines.”

IMPORTANT

• Water should be within guidelines for

water quality listed in secon “4.3.1

Water Quality Guidelines.”

• Use the proper water treatment to

ensure the pH and water hardness are

within the Rinnai boiler water quality

guidelines listed in secon “4.3.1 Water

Quality Guidelines.”

• Test the pH of the water that will be

used for lling the system.

Rinnai Commercial Boiler Installation and Operation Manual 123

Front Panel Removal Instrucons (750 & 1000 Models):

1. Use two handles to move up to front panel in order for the hooks to clear the slots holding the

front panel in place (A in Figure 72).

2. Pull the panel out and remove it from the boiler (B in Figure 72).

3. Place the removed front panel at a safe locaon unl it can be remounted aer the service.

A B

Figure 72

Front Panel Removal Instrucons (500 Model):

1. Use a Phillips head screwdriver to remove four (4) screws securing the angle panel around the

display assembly (A in Figure 71). Place it is safe locaon unl it is needed for re-assembly.

2. Use a Phillips head screwdriver to remove two screws securing the front panel (B in Figure 71).

Slide the panel up to clear the pins on the boom, then pull it out to remove it from the boiler.

3. Place the removed front panel at a safe locaon unl it can be remounted aer the service.

A B

Screws

Figure 71

124 Rinnai Commercial Boiler Installation and Operation Manual

Side Panel Removal Instrucons (500 Model):

1. Remove the front panel as shown in front panel removal instrucons. Place the front panel on

a safe place where it can not be damaged.

2. Remove two screws for each panel from the front of the boiler, then rotate the side panel out

to clear the boom part of the side panel (A in Figure 73).

3. Pull the panel forward to clear the locking mechanism on the back side then pull the panel out

(B in Figure 73).

4. Place the removed side panel at a safe locaon unl it can be remounted aer the service.

Screws

Figure 73

Side Panel Removal Instrucons (750 and 1000 Models):

1. Use two handles to move up to front panel in order for the hooks to clear the slots holding the

front panel in place (A in Figure 74).

2. Pull the panel out and remove it from the boiler (B in Figure 74).

3. Place the removed side panel at a safe locaon unl it can be remounted aer the service.

Figure 74

Rinnai Commercial Boiler Installation and Operation Manual 125

Top Panel Removal Instrucons (750 and 1000 Models):

1. Remove the front le side panel to gain access to the electrical connecons.

2. Disconnect the display LAN cable from the high voltage connecon board, remove the quick

disconnects for reset buon cable and LED indicator cable.

3. The top panel assembly (with display) is secured in place with 6 locking pins. Pull up the top

panel from the four corners to disconnect it from the boiler.

4. Place the removed top panel at a safe locaon unl it can be remounted aer the service.

Figure 75

Figure 76

Boiler Liing Instrucons (750 and 1000 Models):

Due to heavy weight, it might be dicult to move the appliance to certain locaon. The appliance

has built-in casters that facilitates to move them around on at surfaces. Also the unit can be

picked up using pallet jack or forkli if needed. In some circumstances the unit might need to be

lied to go through an area with limited access. In this case, follow the steps below:

1. Follow the above instrucon to remove the top panel assembly (Figure 75).

2. Use the provided liing lugs on the heat exchanger to li the boiler (Figure 76).

Place the removed side panel at a safe locaon unl it can be remounted aer the service.

Liing Lugs

126 Rinnai Commercial Boiler Installation and Operation Manual

Rinnai Commercial Boiler Installation and Operation Manual 127

The Rinnai Commercial Boiler is shipped out of the factory with built-in Wi-Fi. In order to connect

the unit to Wi-Fi follow the steps below:

1. Access the boiler SETUP page under Wi-Fi sub-menu to enable Wi-Fi.

2. Use a smart phone, tablet, or computer with Wi-Fi access and search for the device, the

name should be Boiler - xxxxxxxxxxxx (Figure A). The digits in front of the boiler represent

the boiler MAC ID. If there are mulple devices in the same boiler room, check for the

correct MAC ID of the device being connected from the VIEW page sub-menu info. NOTE:

If the device was previously connected to Wi-Fi and new connecon is being established,

press forget Wi-Fi icon on the boiler SETUP page under Wi-Fi submenu to forget previous

connecon.

3. On the Wi-Fi list, click on Boiler - xxxxxxxxxxxx to connect to the device. A new screen will

pop-up and prompt for a password. The password is 123456789. Enter the password then

click Join to connect to the device (Figure B).

4. Once the credenals are veried, the screen will disappear and new window will pop-up to

congure Wi-Fi. In case this window does not show up automacally, go to internet

browser and type the following address: 192.168.4.1 (Figure C).

5. Click on congure Wi-Fi window to enter Wi-Fi credenals for the network intended for

this connecon (Figure D).

6. New screen will pop-up while the credenals are being saved and veried. Once the

connecon has been established the screen will disappear.

7. Verify on the boiler home page (top right corner) for connecvity.

8. Follow next steps on Rinnai Central app to add the device to the user account.

Figure A Figure B Figure D

Figure E

Figure C

128 Rinnai Commercial Boiler Installation and Operation Manual

The Rinnai Commercial Boiler is shipped out of the factory with built-in Wi-Fi. If Wi-Fi signal is not

available at the installaon site or if the signal is poor, the boiler can be hardwired and connected

via an ethernet port. Follow the steps below:

1. Connect a LAN cable (CAT 5 or CAT 6) from the Webserver Card to the Network device.

2. From the Home screen, click on SETUP and select the appropriate user and enter the

password to gain access to SETUP page.

3. Once in the SETUP page, click on Wi-Fi submenu on the le.

4. Select Ethernet opon (default is O).

5. Once Ethernet opon is selected, then click on the arrow for Ethernet Sengs .

6. If DHCP is enable on the network (it varies from site to site - user preference), then click on

the DHCP icon to enable DHCP. The unit should connect to the network. Verify on the Wi-Fi

home page for connecvity.

7. If DHCP is disabled. Disable the DHCP on the Wi-Fi screen , under Ethernet Sengs.

8. Enter the Device IP, Subnet Mask, and Default Gateway into the related led on the

screen. Once the process is completed, click on Apply Sengs to save the conguraon.

Verify on the Wi-Fi home page for connecvity.

Figure 77

Ethernet connecon

port

Webserver Card

Rinnai Commercial Boiler Installation and Operation Manual 129

This secon of the manual provides guidelines for the use of Modbus communicaon system with

Rinnai Commercial Boiler (RCB) appliances.

1. Disconnect the electrical power before beginning the process. Failure to do so could result

in electrical shock, property/appliance damage, serious personal injury , or death.

2. Ensure to have a Modbus master device such as a Building Management System (BMS) or a

computer with Modbus master soware, and an RS-485 serial port or USB port with a

converter to RS-485.

3. Wire the BMS to the Modbus connecons on the low voltage terminals labeled BMS

(A+; B- ; REF).

4. On the boiler screen enter the SETUP page and click on BMS to access the Modbus

conguraon.

Modbus Address:

Addresses 1 - 20 (Default: 1) are free to be assigned to Modbus devices on the bus. Each

address can be assigned to ONLY one Modbus device on the bus.

Baud Rate:

All devices must have the same baud rate. The baud rate (communicaon speed) can be set on

the control display to 4800, 9600, 19200, 38400 or default (115200) baud. The higher the value

the higher is the speed, but less number of devices can be connected and the cable length gets

shorter. This boiler, as well as any other device on the same bus and the Modbus master, must

have the same baud rate seng. Select the highest baud rate that oers the most reliable

communicaon performance over the bus. Some things that can aect communicaons are:

Long wire runs; Wire quality; A noisy electrical environment; The number of devices on the

bus. These condions may require using a lower baud rate.

Parity & Stop Bits:

All devices must have the same parity and stop bits. The parity & stop bits parameters of the

Modbus must be set to match the rest of the devices on the bus. Although it is common to set

serial devices to use no parity, seng the parity to even or odd may improve communicaons

reliability on all connected devices on the bus. This parameter has 6 possible selecons which

should be sucient to establish communicaon with other devices (Parity none - 1 stop bits;

Parity none - 2 stop bits; Parity eve - 1 stop bits; Parity even - 2 stop bits; Parity odd - 1 stop

bits; Parity odd - 2 stop bits).

Apply Sengs:

Click on apply sengs buon to save parameters aer adjustments.

130 Rinnai Commercial Boiler Installation and Operation Manual

MODBUS LIST

MODBUS

POINT NAME POINT

RESOLUTION

RELATED LINE

NUMBER

READ (R) or

WRITE (W)

UNIT

600 FLUE TEMPERATURE x10 8316 R °C | °F

601 SUPPLY TEMPERATURE x10 8310 R °C | °F

602 RETURN TEMPERATURE x10 8314 R °C | °F

603 WATER PRESSURE x10 9005 R BAR | PSI

604 BOILER SETPOINT x10 8311 R °C | °F

605 ERROR CODE - 6700 R -

606 DIAGNOSTIC CODE - 6705 R -

607 FLAME CURRENT x10 8329 R µA

608 CURRENT FAN SPEED - 8323 R RPM

609 OUTDOOR TEMPERATURE x10 8700 R °C | °F

610

SYSTEM TEMPERATURE

ACTUAL

x10 8318 R °C | °F

611

SYSTEM TEMPERATURE

SETPOINT

x10 8319 R °C | °F

612 DHW TEMPERATURE ACTUAL x10 8830 R °C | °F

613 DHW TEMPERATURE SETPOINT x10 1610 R °C | °F

614 BOILER STATE - 8005 R -

615 DHW STATE - 8003 R -

616 HC1 STATE - 8000 R -

617 HC2 STATE - 8001 R -

618 BURNER STATE - 8009 R -

619 MODULATION - 8326 R %

620 MINIMUM FAN SPEED LF - 9524 R rpm

621 MAXIMUM FAN SPEED HF - 9529 R rpm

622 IGNITION FAN SPEED - 9512 R rpm

623 FAN SETPOINT - 8324 R. rpm

624 CURRENT FAN CONTROL - 8325 R %

625 ROOM THERMOSTAT CH1 - 7865 R -

626 ROOM THERMOSTAT CH2 - 7860 R -

627

THERMOSTAT STATE CH1

DEMAND

- 8749 R -

628

THERMOSTAT STATE CH2

DEMAND

- 8779 R -

629 0-10V INPUT H3 x10 7854 R V

630 WATER PRESSURE SENSOR H1 - 7841 R -

631 WATER PRESSURE VOLTAGE x10 7840 R V

632 AIR PRESSURE SWITCH H7 - 7874 R -

633 GAS PRESSURE SWITCH H6 - 7872 R -

634 BURNER RUN HOURS - 8330 R h

Table 58

Rinnai Commercial Boiler Installation and Operation Manual 131

MODBUS LIST

MODBUS

POINT NAME POINT

RESOLUTION

RELATED LINE

NUMBER

READ (R) or

WRITE (W)

UNIT

635 IGNITION CYCLES - 8331 R -

636 RUN HOURS HEATING - 8338 R h

637 RUN HOURS DHW - 8339 R h

638 TOTAL GAS ENERGY HC - 8378 R kWh

639 TOTAL GAS ENERGY DHW - 8379 R kWh

640 TOTAL GAS ENERGY CH & DHW - 8380 R kWh

641 GAS ENERGY FOR CH - 8381 R kWh

642 GAS ENERGY FOR DHW - 8382 R kWh

643 GAS ENERGY FOR CH & DHW - 8383 R kWh

644 BOILER PUMP Q1 - 8031 R -

645 BOILER PUMP Q1 SPEED - 8308 R %

646 CH PUMP Q2 - 9032 R -

647 DHW PUMP Q3 - 9033 R -

648 DHW PUMP Q3 SPEED - 8825 R %

649 UX2 - 7717 / 7719 R V | %

650 UX3 - 7725 / 7726 R V | %

651 P1 - 7714 R %

652 CASCADE MASTER INFO - 8101 R -

653 CASCADE FOLLOWER 1 INFO - 8103 R -

654 CASCADE FOLLOWER 2 INFO - 8105 R -

655 CASCADE FOLLOWER 3 INFO - 8107 R -

656 CASCADE FOLLOWER 4 INFO - 8109 R -

657 CASCADE FOLLOWER 5 INFO - 8111 R -

658 CASCADE FOLLOWER 6 INFO - 8113 R -

659 CASCADE FOLLOWER 7 INFO - 8115 R -

660 WEB SERVER CARD VERSION x1000 - R -

661 LMS PARAMETER VERSION 1 - 6230 R -

662 LMS PARAMETER VERSION 2 - 6231 R -

663 IMPERIAL/METRIC SELECTION 0-1 - R -

NOTE: For the switches state: 0 - Open ; 1 - Closed

Table 58 connue

132 Rinnai Commercial Boiler Installation and Operation Manual

The following informaon is required by ANSI Z21.13:

NOTE: Not all statements are applicable to this appliance.

If a boiler is removed from a common vent system, the common vent system is likely to be too large

for proper venng of the remaining appliances connected to it.

The instrucons shall include the test procedure set forth below:

At the me of removal of an exisng boiler, the following steps shall be followed with each other

appliances remaining connected to the common venng system are not in operaon.

1. Seal any unused openings in the common venng system.

2. Visually inspect the venng system for proper size and horizontal pitch and determine

there is no blockage or restricon, leakage, corrosion and other deciencies which could

cause an unsafe condion.

3. Insofar as is praccal, close all building doors and windows and all doors between the

space in which the appliances remaining connected to the common venng system are

located and other spaces of the building. Turn on clothes dryers and any appliance not

connected to the common venng system. Turn on any exhaust fans, such as range hoods

and bathroom exhausts, so they will operate at maximum speed. Do not operate a

summer exhaust fan. Close replace dampers.

4. Place in operaon the appliance being inspected. Follow the lighng instrucons. Adjust

thermostat so appliance will operate connuously.

5. Aer it has been determined that each appliance remaining connected to the common

venng system properly vents when tested as outlined above, return doors, windows,

exhaust fans, replace dampers, and any other gas-burning appliance to their previous

condion of use.

6. Any improper operaon of the common venng system should be corrected so the

installaon conforms with the Naonal Fuel Gas Code, ANSI Z223.1/NFPA 54, and/or the

Natural Gas and Propane Installaon Code, CAN/CSA B149.1. When resizing any poron of

the common venng system, the common venng system should be resized to approach

the minimum size as determined using the appropriate tables in Chapter 13 of the

Naonal Fuel Gas Code, ANSI Z223.1/NFPA 54, and/or the Natural Gas and Propane

Installaon Code, CAN/CSA B149.1.

Rinnai Commercial Boiler Installation and Operation Manual 133

FOR GAS MODELS SOLD IN MASSACHUSETTS

NOTICE BEFORE INSTALLATION:

This direct-vent appliance must be installed by a properly trained licensed professional. If you are

not properly trained, you must not install this unit.

IMPORTANT: In the State of Massachuses (248 CMR 4.00 & 5.00):

For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or

structure used in whole or in part for residenal purposes, including those owned or operated by

the Commonwealth and where the side wall exhaust vent terminaon is less than 7  above

nished grade in the area of the venng, including but not limited to decks and porches, the

following requirements shall be sased:

1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the me of installaon of the side wall

horizontal vented gas fueled equipment, the installing plumber or gaser shall observe that a

hard wired carbon monoxide detector with an alarm and baery back-up is installed on the

oor level where the gas equipment is to be installed. In addion, the installing plumber or

gaser shall observe that a baery operated or hard wired carbon monoxide detector with an

alarm is installed on each addional level of the dwelling, building or structure served by the

side wall horizontal vented gas fueled equipment. It shall be the responsibility of the property

owner to secure the services of qualied licensed professionals for the installaon of hard

wired carbon monoxide detectors

A In the event that the side wall horizontally vented gas fueled equipment is installed in a

crawl space or an ac, the hard wired carbon monoxide detector with alarm and baery

back-up may be installed on the next adjacent oor level.

B In the event that the requirements of this subdivision can not be met at the me of

compleon of installaon, the owner shall have a period of thirty (30) days to comply with

the above requirements; provided, however, that during said thirty (30) day period, a

baery operated carbon monoxide detector with an alarm shall be installed.

2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in

accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed

and IAS cered.

3. SIGNAGE. A metal or plasc idencaon plate shall be permanently mounted to the exterior

of the building at a minimum height of 8  above grade directly in line with the exhaust vent

terminal for the horizontally vented gas fueled heang appliance or equipment. The sign shall

read, in print size no less than one-half (1/2) inch in size, "GAS VENT DIRECTLY BELOW. KEEP

CLEAR OF ALL OBSTRUCTIONS.”

4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled

equipment shall not approve the installaon unless, upon inspecon, the inspector observes

carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR

5.08(2)(a)1 through 4.

134 Rinnai Commercial Boiler Installation and Operation Manual

Models: RCB500AN, RCB750AN, and RCB1000AN

What Is Covered?

The Rinnai Standard Limited Warranty covers any defects in materials or workmanship when the

product is installed and operated according to Rinnai published product specicaons, subject to

the terms within this Limited Warranty document. This Limited Warranty applies only to products

that meet the requirements of a “qualied product installaon” and are originally installed in the

United States and Canada. Improper installaon may void this Limited Warranty. A “qualied

product installaon” consists of the following: (1) installed by a company or individual which (a)

holds a current government issued license which ceres the company or individual is qualied to

install and service commercial gas boilers in the state where the product is located, if such licensing

is required; and, (b) has successfully completed Rinnai commercial gas boiler product training at an

approved Rinnai training facility and/or by a remote training program Rinnai authorized trainer, and

(2) installaon, startup, operaon and service is performed in compliance with (a) all Rinnai

published engineering, applicaon, installaon, startup and service documentaon, (b) all

applicable federal, state and local laws, (c) applicable plumbing, electrical, mechanical and building

codes and best industry standards. This Limited Warranty is subject to the condions that the

Rinnai boiler has been installed per the “qualied product installaon” terms and ongoing and

proper maintenance has been performed, according to Rinnai Installaon and Service

documentaon, by a professional, licensed (if required) heang contractor. Proof of the required

service and maintenance tasks being completed must be kept in the provided Rinnai Installaon,

Commissioning and Service Record. This Limited Warranty coverage, as set out in the table below,

extends to the original end use purchaser and subsequent owners, but only while the product

remains at the site of the original installaon, and terminates if the product is moved or reinstalled

at a new locaon.

[1]

Parts replaced during recommended maintenance procedures are not covered by this Limited

Warranty.

Item Period of Coverage (from date of purchase)

Heat Exchanger 10 Years

All Other Parts and Components

[1]

1 Year

Reasonable Labor

1 Year

What Will Rinnai Do?

Rinnai will repair or replace the covered product or any part or component that is defecve in

materials or workmanship as set forth in the above table for products which meet the “qualied

product installaon” requirements. Rinnai will pay reasonable labor charges associated with the

repair or replacement of any such part or component during the term of the labor warranty period.

All repair parts must be genuine Rinnai parts. All repairs or replacements must be performed by a

qualied professional who is properly trained to do the type of repair.

Replacement of the product may only be authorized by Rinnai at its sole discreon. Rinnai does not

authorize any person or company to assume for it any obligaon or liability in connecon with the

replacement of the product. If Rinnai determines that repair of a product is not possible, Rinnai

may replace the product with a comparable product at Rinnai’s sole discreon. The warranty claim

for product parts and labor may be denied if a component or product returned to Rinnai is found to

be free of defects in material or workmanship; damaged by improper installaon, use or operaon;

or damaged during return shipping.

Table 59

Rinnai Commercial Boiler Installation and Operation Manual 135

How To Obtain Service: For the name of a trained and qualied professional, please contact your place of

purchase, visit the Rinnai website (www.rinnai.us), call Rinnai at 1-800-621-9419 or write to Rinnai at 103

Internaonal Drive, Peachtree City, Georgia 30269.

Proof of purchase is required to obtain warranty service. You may show proof of purchase with a dated

sales receipt, or by registering within 90 days of purchasing the product. To register your Rinnai

Commercial Boiler, please visit www.rinnai.us. For those without internet access, please call 1-800-621-

9419. Receipt of registraon by Rinnai will constute proof-of-purchase for this product. Registraon of

product installed in new home construcon may be veried with a copy of the closing papers provided by

the inial home buyer. However, registraon is not necessary in order to validate this Limited Warranty.

What is Not Covered? This Limited Warranty does not cover any failures, heat exchanger leakage, or

operang dicules due to the following:

• Accident, abuse, or misuse

• Alteraon or Misapplicaon

• Force majeure

• Improper installaon (such as but not limited to inadequate water quality, condensate damage,

improper venng, incorrect gas type, incorrect gas or water pressure, or absence of a drain pan

under the product)

• Improper maintenance (such as but not limited to scale build-up, freeze damage, or vent blockage)

• Improper water quality or the use of unapproved anfreeze or other chemical addives in the

boiler system

• Installaon of the boiler in a heang system where polybutylene pipe without an oxygen barrier is

used

• Any installaon that is not closed loop or where oxygen may enter the heang system

• Use in or around areas where chemical agents are used (such as but not limited to chlorine, hair

spray, or hair dyes)

• Damage or failure caused by contaminated air, including, but not limited to sheetrock parcles,

plasterboard parcles, dust, dirt, or lint entering the boiler or any of its components

• Incorrect sizing

• A failure of any component in the Hydronic system not supplied by Rinnai

• Any other causes other than defects in materials or workmanship

This Limited Warranty does not cover any product used in an applicaon that uses chemically treated

water such as a pool or spa heater.

This Limited Warranty does not cover any other costs including but not limited to lodging, fuel,

transportaon, handling, etc. incurred during in the installaon, removal, replacement, repair,

maintenance, troubleshoong or complying with Naonal, State or Local building, mechanical or

electrical codes nor any expenses associated with providing substute or temporary equipment and/or

service during me in which product is inoperable or not being ulized pending repair or replacement

under this Limited Warranty.

If you purchase a Rinnai product from an unauthorized dealer, or if the original factory serial number has

been removed, defaced or altered, your Rinnai warranty will not be valid.

Limitaon on Warranes: No one is authorized to make any other warranes on behalf of Rinnai America

Corporaon. Except as expressly provided herein, there are no other warranes, expressed or implied,

including, but not limited to warranes of merchantability or tness for a parcular purpose, which

extend beyond the descripon of the warranty herein.

This Limited Warranty shall not be aected, extended, or enlarged and no addional obligaon or liability

will be incurred by Rinnai providing technical informaon, applicaons recommendaons, or equipment

modicaons to any enty or person who is related to the design, equipment selecon, installaon,

operaon, maintenance, service, or repair of the product.

Any implied warranes of merchantability and tness arising under state law are limited in duraon to

the period of coverage provided by this Limited Warranty, unless the period provided by state law is less.

Some states do not allow limitaons on how long an implied Limited Warranty lasts, so the above

limitaon may not apply to you.

Rinnai shall not be liable for indirect, incidental, special, consequenal, or other similar damages that may

arise, including lost prots, damage to person or property, loss of use, inconvenience, or liability arising

from improper installaon, service, or use. Some states do not allow the exclusion or limitaon of

incidental or consequenal damages, so the above limitaon may not apply to you.

This Limited Warranty gives you specic legal rights, and you may also have other rights which vary from

state to state.

Rinnai RCB750AN

Product's Documents

Rinnai Commercial Boiler Floor Owners Installation and Operation Manual English

Specifications

Rinnai RCB750AN Questions and Answers