Rinnai M-Series Condensing Boiler Level III Service ... M-Series Boiler L3 Service...

ENHANCING LIVES BY CHANGING THE WAY WATER IS HEATED 1

Rinnai M-Series Condensing Boiler

Level III Service & Troubleshooting Training


• Rinnai Resources

• Rinnai M-series Boiler Technical

Specification

• Periodic Maintenance

• Component Review and Replacement

• Sequence of Operation

• Key Controller Parameters

• Troubleshooting Fundamentals

Agenda


About Rinnai

The highest standards of quality

• Over 600 R & D Engineers

• Rinnai is a leader in advanced automation and precision assembly

• Every product is tested under live conditions before shipping

• Rinnai America has its own state-of-the-art CSA Certified Testing Lab & CSA Accredited Technicians

• Founded in 1920

• Based in Japan

• 20 Subsidiaries/86 Sales

Offices Globally

• World’s #1 selling brand of

Tankless Water Heaters

• North America headquartered

in Peachtree City, GA


About Rinnai

New North American Headquarters

R&D Innovation and Training Center New

building over 2X current sq. ft.

US Tankless Manufacturing

April 2018 Non-condensing Water Heaters

Will reach >100,000 units by 2019

New 60+ Acre Production Facility in Griffin, GA


Service & Support

1-800-621-9419Customer Service Applications Support Parts Department

General calls, consumer

questions, etc.

General sizing questions,

commercial applications.

Order Service

Repair Parts

Available from 8 am to 8 pm EST, Monday - Friday

Warranty Department

Warranty claim issues.

Available from 8 a.m. to 5 p.m. EST,

Monday- Friday

Tradesman: [email protected]: [email protected]

mailto:[email protected]

mailto:[email protected]


Service & Support

1- 888-RINNAIS (746 -6247)

Technical Support Department

This Phone Number is only provided to Technicians

FOR CALLS WHILE SERVICING PRODUCT

Office Hours:

Monday – Friday 8 a.m. to 8 p.m. EST

On Call hours:

24 / 7 / 365

Leave a message with on call agent

You will get a call you back within 20 minutes

CONTRACTORS ONLY DIRECT LINE


www.rinnai-lms.com or trainingevents.rinnai.us

Training Website


Rinnai Dealer Program


Specifications


M-Series Models

Model AFUE Max Input Min NG InputTurndownRatio (NG)

M060SM060C

95%60,000 BTU

17.6 kW 17,000 BTU5.0 kW

3.5 : 1

M090SM090C

95%90,000 BTU

26.4 kW

5.3 : 1

23,500 BTU6.9 kW

3.8 : 1

M120S M120C

95%120,000 BTU

35.2 kW 5.1 : 1

M160SM160C

95%160,000 BTU

46.9 kW 6.8 : 1

Model DHW Performance

M060C 2.6 gpm @ 70°FT (10L/min@39°CT)

M090CM120CM160C

4.2 gpm @ 70°FT (16L/min@39°CT)

Solo Models

Combi Models


• Minimal Maintenance 2yr / 4yr Service

Routines• Easy Access from Front & Left side

• More access to DHW Flat Plate

• Easier Access for service maintenance

• Best in Class Reliable Components• Honeywell, Grundfos, EBM Papst

• Brass 3 way valve cartridge

• DHW Flow Sensor

• Stainless Steel Heat Exchanger

• Quality Components Built for Easy Service• No tools required to remove

• Condensate Trap

• Electrode Assembly

• Burner Assembly <3 minute Removal

• Plate Heat Exchanger <3 minute Removal

Built for Long Life & Easy Service

M-Service Features


Rinnai Serial Nomenclature

Example Serial #

KF012345JB:

Manufactured in

June 2018

Each serial # begins with a 2 letter date codeThe M-Series serial # is

found on the boiler rating

plate label on the lower left

side and on all major

components

First Letter -

Year

Second Letter -

Month

A 2009 A January

B 2010 B February

C 2011 C March

D 2012 D April

E 2013 E May

F 2014 F June

G 2015 G July

H 2016 H August

J 2017 J September

K 2018 K October

L 2019 L November

M 2020 M December


Product Warranty

Description Residential Commercial

Primary Heat Exchanger 12 YRS 5 YRS

Boiler Parts 2 YRS

Labor 1 YR

Warranty covers: Warranty DOES NOT cover failure due to:

Defects in

materials/workmanship

Accident, abuse/misuse,

alteration/misapplication

Indoor installations installed per

the manual and all applicable

code

Improper Installation/Maintenance

Poor water quality, scale issues, freezing

Please refer to the Documentation Set for full warranty details and guidelines

M-Series Warranty


User Menu: Controller main screen icons

M-Controller

• AUTO

• Outdoor reset (outside) temp

• Service routine needed

• Freeze protection active

• DHW (with box) –

DHW demand

• Heat panel (with box) –

CH demand

• Burner Active (w/power

bar)

• Bottom line descriptor (operating mode)

• ECO – DHW Comfort Mode OFF

(COMFORT will show if ON)

– Outdoor reset Active

• Heat generation lock – External safety

circuit open (LWCO, etc)

• CH or DHW Pump Overrun – 0.5-5

minute pump operation after demand


007 is a service menu that grants access to technical level adjustments

007 Service Mode

1.From the controller

Home screen, press

BACK and OK

buttons

simultaneously for 7

seconds

2.Turn the wheel

to 007, press OK

3.Navigate the

menu

M-Controller

• Altitude

• Outdoor Reset Parameters

• Frequency of Maintenance

• Component Testing

• Fault Code Information

• Diagnostic Features

• Other Setup Features


Maintenance


For service of the boiler these items are recommended:

• Large adjustable wrench

• 4mm & 5mm hex bit

• 8mm socket or nut driver

• 5 in 1 screwdriver

• Flue gas analyzer and manometer

• Installation manual

Other Helpful Tools

• Smart phone / tablet

• Thermostat screwdriver

• Multi-meter (volt/ohm/micoamp)

• 4 Year Service Kit (Part # model specific)

• Rinnai Boiler Tool Kit – . (Part # 809000024)

Recommended Service Tools

M-Service


Setting the Service Warning Frequency

M-Maintenance

• After completing the installation and commissioning, set the service frequency to notify the end user when the boiler is due for (recommended) service

• A warning code 3P9 will display when the counter expires

• The boiler will continue to operate (a wrench icon appear on home screen)

007 Menu Description Detail

8.5.0 Sets period of time for

service notification

Default is 12 months – Rinnai’s 1st

recommended service frequency is 24 months

8.5.1 Activates notification feature Default is OFF (0), must change to ON (1) for

the frequency warning to post

8.5.2 Resets notification counter After maintenance is complete, this resets the

counter and clears the warning


Service Warning Contact Info

M-Maintenance

M-Series Boilers also allow the contractor to enter his/her company name and phone number

• This will display with the periodic service warning

• This will also display with fault codes

• Enter the 007 menu → Configuration Wizard → Service Options → Service Center Data

• Enter company name and phone number


Inspect the boiler, vent system, and surroundings. Check system pressure,

gas pressure and flue gas O₂%.

Inspect and clean the

condensate trap

Visually inspect flame, Verify proper

O2

M-2 Year Service

Discuss boiler performance with end user

View error code history

(parameter 8.6.0)


Inlet gas pressure testing:

• Close manual gas shut-off valve

• Connect manometer to inlet test port

• Operate all appliances on the gas service at

full power to test load gas pressure at the

boiler gas valve test port (see figure at right)

Fuel TypeMinimum Load Gas Pressure

In. w.c.OptimalIn. w.c

MaximumIn. w.c

NG (Natural Gas) 3.0” 7.0” 10.5”

LPG (Liquid Propane) 8.0” 12.0” 13.5”

Gas Valve Inlet Test Port

Verify Incoming Gas Pressure

M-2 Year Service


Reference I/O manual for full details of approved vent materials

Verify Venting Installation

M-2 Year Service


Pressure requirements

19 psi

Minimum requirement

for normal operation

20 psi

Recommendation for

fill valve setting

10-14 psi

Warning 1P4 / ΔT reduced

(until 19 psi is re-

established)

<10 psi

Fault 108

Boiler inoperable

until 19 PSI is re-

established (air

purge begins)

18

1614

12

10 20

TIP: Boiler display pressure should not vary more than 5 psi from the system

pressure gauge. If so, drain boiler, remove and clean the pressure sensor

and gauge. Replace as needed.

PSI

M-2 Year Service


Review Fault Code History

• Enter 007 Menu

• Select Complete Menu

• View Parameter 8.6.0

• Take note of time/date

• Recent errors may indicate a problem with a boiler part or the installation (gas pressure, water pressure, venting)

M-2 Year Service


• Service mode (Chimney Active) allows boiler to be forced into a specific fire-rate

• This is primarily used when verifying O₂ levels, load and max gas pressures

• IMPORTANT: Boiler must have a very high load (CH or DHW) during this setting

Verify O₂ Levels (Flue gas testing)

1.From the Home

screen, press and

hold the Chimney

Active button for 7

second

2.The following

screen appears

indicating the

Chimney Active

mode is active

3.Chimney Active

Use the selector to

adjust. Press OK

• 100% (max fire)

• 0% (low fire)

4.To exit Chimney

Active mode,

press the Back

button until the

Home screen

appears

Chimney Active

100%

M-2 Year Service


Flue Gas TestingMaximum Input Minimum Input

Model NG O₂% LP O₂% NG O₂% LP O₂%M060

4.7 – 4.9

5.0 – 5.2Min values should be

0.4-1.6 higher than the measured max value

4.7-5.5M090SM090C

4.2 – 4.4M120M160

Throttle Screw for O₂ adjustment

M-2 Year Service

Tip: clockwise adjustment

of screw increases O₂, counterclockwise

decreases


• No tools required to remove

• Twist & pull sealing ring down (white)

• Flip lever up (grey)

• Rotate and pull down siphon cup and

pipe to remove

• Clean

• Check O-ring, replace if necessary,

• Apply silicon lubricant to O-ring to

ease re-installation

M-2 Year ServiceCondensate Trap Inspection


Overview

M-4 Year Service

• Purchase 4-year Maintenance Kit (model dependent)

• Includes all required gaskets!

• Remove condensate trap

• Remove air supply silencer

• Remove internal gas pipe

• Remove burner top clamp rods

• Remove burner, fan & hood

• Vacuum burner / replace gaskets

• Vacuum top of heat exchanger

• Remove electrode assembly


Burner / Fan Removal

M-4 Year Service

• Remove air supply silencer by unlocking Velcro fastener and pulling up

• Remove internal gas pipe with adjustable wrench

• Unplug two (2) fan connectors



M-4 Year Service

• Rotate the lock tabs ¼ turn inward with 4mm hex bit

• Push down on burner and slide rods forward to remove

• DO NOT BREAK RED TABS!



M-4 Year Service

• Gently pull burner/fan assembly forward

• DO NOT DRAG ceramic burner against hex

• After removal, use vacuum brush to clean top tubes of the heat exchanger as needed

• IMPORTANT: Do not allow dirt and debris to fall into the heat exchanger

• DO NOT use compressed air and gas to clean the top of the heat exchanger


Burner Cartridge Service

M-4 Year Service

• To separate cartridge from housing, release T-clip (with flat head screwdriver)

• Vacuum ceramic cartridge (NEVER BLOW AIR INTO CARTRIDGE!)

• IMPORTANT: Both orange gaskets must be replaced if burner is removed. DO NOT REUSE EXISTING GASKETS!


Burner / Fan Separation

M-Service Features

• Loosen left screw (8mm)

• Remove right screw (8mm)

• Inspect fan impeller, blow air into venturi if needed to clean

• If fan is separated from burner, gasket MUST be replaced!


Electrode Assembly

M-4 Year Service

• Remove three (3) connectors from electrode assembly

• Lift tab to remove electrode assembly

• Gasket MUST be replaced if the assembly is removed!

• Electrode gap is 3-4mm

• Confirm new assembly gap before install

• NOTE: This assembly must be replaced during 4 year service frequency


Component Review/Removal


Heat Exchanger Sensors


• T1 – Supply temperature (wet well)

• T2 – Return temperature (dry well)

• Pressure sensor (unscrew to remove)


Pump Removal


• Boiler must be drained and isolated

• Unplug pump power connector & PWM connector (next to white insert)

• Loosen pump nuts

• Ensure new gaskets are installed

• Upon reinstall rotate top pipe out, then back after starting bottom nut

• Note pump direction arrow


Heat Exchanger Removal



• Remove air supply silencer, internal gas pipe, condensate trap, burner/fan assembly, electrode ignition

• Remove condensate tray (2 ea5mm hex bit screws)

• Note gasket in rear of tray – ensure

it remains intact




• Remove pins on supply & return lines

• Gently pull supply and return lines away from hex

• Pump nut must be loosened

• Swing return pipe away from hex

• Rotate pump to front of unit




• Remove two (2) 5mm bottom screws

• Loosen two (2) 5mm top screws

• Lift heat exchanger up, then away from body

• Replace all gaskets / O-rings exposed during process (included with new heat exchanger)

• NOTE: T1 temp sensor and deaerator (can vent) must be moved to new heat exchanger


Gas Valve Removal


• Disconnect gas valve electrical connection

• Remove caps covering screws on top of cabinet

• Remove two (Philips head) screws

• Gently pull gas valve away from supply pipe

• Replace any gaskets/o-rings that are exposed (included with new gas valve)

• Leak check connections as needed

• After replacement, verify pressure and O₂


DHW Combi Assembly


• T3 – DHW temperature sensor is located to the left of side of the plate heat exchanger (isolate DHW before removal)

• The flow sensor is a rotating wheel that actuates DHW priority at 0.4 gpm. Flow is maintained as low as 0.26 gpm.

• It is NOT recommended to remove (only in instances where flow is not detected & if replacement sensor is on hand)

• The 3-way valve actuator can be removed with a single clip


Plate Heat Exchanger Removal (Combi Models)



• In order to have clearance to remove, the 3-way valve actuator must be removed

• Remove two (2) 4mm hex bit screws

• Replace O-rings that have been exposed (4 each)

• Ensure new plate is installed in proper orientation (markings-up)


Sequence of Operation


Ignition sequence


Boiler in Standby

DHW or Heat Demand

Setpoint (Tset) calculated (CH/DHW)

Prestart checks:-Fan rpm

-Heat Exchanger temp T1 ≤ Tset - 6°F -Dynamic water pressure check

-Flame current check

Gas valve opens / Ignition (initial power 70%)

4 second flame current check (>0.8 µA)

If no flame detected, 4 second reset then re-ignition

(up to 5 total attempts)

Once flame is detected, boiler modulates to min power/max pump (for

CH) and max power/max pump (for DHW)

Code 5P1, 5P2


CH (with outdoor reset)


Boiler in Standby

Heat Demand (TT closed)

Setpoint (Tset) calculated using outdoor reset

Ignition Sequence

Burner modulates to minimum power / pump runs at high power

Gradient control will slowly increase T1 supply temperature to T1 target

ΔT Control monitoring maintains ≈ 36°F by modulating pump speed

Supply temperature determined by outdoor reset curve

Burner OFF if T1 ≥ T-set by 9°F OR demand ends (TT open)

Burner ON if demand still present and T1 ≤ T-set by 5°F

When heat demand ends, CH pump runs for 1 minute. A new heat demand will not restart the burner for 5 minutes after the last heat

demand ends


Combi DHW (w/demand)


Boiler in Standby

DHW demand (flow sensor ≥0.4 gpm)

Ignition Sequence

Burner modulates to match T3 DHW temperature to the DHW Tset

Burner OFF if T3 ≥ T-set by 9°F OR flow sensor ≤0.26 gpm

Burner restarts if demand still present and T1 ≤ T-set by 5°F

DHW pump overrun begins (30 seconds if T1<167°F, 3 minutes if T1>167°F)


Combi DHW (comfort mode)


Boiler in Standby

T2 ≤ DHW Comfort Mode setpoint

Setpoint (T-set) calculated

Ignition Sequence

Modulation (DHW Comfort Mode=low load)

T1=Setpoint (T-set), boiler modulates based on T2

Burner OFF if T2 ≥ Comfort Mode setpoint (model dependent)

DHW pump overrun begins (30 seconds if T1 < 167 °F, 3 minutes if T1>167°F)


Solo Indirect Tank DHW (w/10KΩ sensor)


Boiler in Standby

DHW demand (T3 < Setpoint - 2°F )

Setpoint (T-set) calculated

Ignition

Modulation (DHW=max load)

T1=Setpoint (T-set), boiler modulates based on T3

Burner OFF if T3 > 5°F + Setpoint OR T2 > 14°F + Setpoint

DHW pump overrun begins (30 seconds if T1<167°F, 3 minutes if T1>167°F)


Freeze Protection


Boiler Freeze Protection

If T1<47°F, boiler pump runs for 2 minutes

Solo models: If tank sensor T3<47°F, burner fires until

T3>57°F

Combi models: 3-way valve alternates per 1 minute

If T1<39°F, burner will fire for 30 seconds in low fire (or when T1>47°F)

System Freeze Protection

If outdoor sensor between 35 and 25°F, boiler pump will operate 10 minutes every 6 hours

If outdoor sensor ≤ 24°F, boiler pump operates continuously

This feature can be disabled in parameter 2.9.1

This feature cannot be disabled


Other considerations


• Every 24 hours, if there is no heat demand (CH or DHW), the pump will be started for 10 seconds and the 3-way valve will be exercised

• This verifies pump operation

• 1P9 fault code will post if the PCB does not see an increase in pressure when the pump is energized (this is a blocking code)

• 140 fault code will occur this happens twice consecutively (this requires a RESET

• This also prevents the diverter valve from sticking

• Anti-legionella Logic

• Every 7 days, M-Series Solo boilers will automatically bring an indirect tank to 149°F

• This counter begins at install

• This feature can be disabled at Parameter 2.5.7


Parameters


Boiler parameters (Chapter 2)

Parameters

PARA Default Range Description

2.0.0 140°F 104 - 140°FDHW setpoint temp (also achieved by pressing

BACK and turning dial on home screen)

2.0.3 194°F 176 - 194°FMax Water Temp (absolute max)

Will limit outdoor reset curve settings

2.0.4 0 0-10,200 Will allow you to set higher than 10.2K but no effect

2.0.6 9°F/min 0-27°F/minHow quickly boiler reaches setpoint from cold start

Early models have C to F conversion error (-32)

2.2.4 ON ON/OFFDisables outdoor reset sensor (also available from

AUTO function in main menu (CH) or 4.2.1)

2.2.80 – Combi

2 – Solo

0=all Combi models

1=Solo boiler with 10KΩ NTC thermistor in DHW indirect tank

2=Solo boiler with aquastat in DHW indirect tank

2.4.9 0 -5 to +5°FOutdoor reset temp sensor correction

May need if outdoor reset is in direct sunlight, etc.

2.5.0 0

0=Eco (off)

1=Schedule

2=Comfort

DHW Comfort Mode

Also available from home screen (DHW)


Boiler parameters (Chapter 2)

Parameters


2.5.7 10=OFF

1=ONAnti-legionella Cycle (Solo models only)

2.6.0 OFF ON/OFF Activates manual mode for component testing

2.6.1 OFF ON/OFF Manual control of pump with burner off

2.6.2 OFF ON/OFF Manual control of fan with burner off

2.6.3 OFF ON/OFF Manual control of 3-way valve with burner off

2.7.0 OFF ON/OFF Forces chimney mode (same as button)

2.7.1 OFF ON/OFFForces Air purge (or turn off – same as holding

BACK for 7 seconds)

2.8.0 NAOK=YES

ESC=NO

Resets all parameters to factory defaults

(green button)

2.9.0 10=NO

1=NC

External Safety contact (LWCO, etc)

(NOTE: DO NOT USE OPTION 2)

2.9.1 10=OFF

1=ON

System (plant) frost protection, pump operation

based on outdoor temp sensor value


Heating (Z1) parameters (Chapter 4)

Parameters


4.2.0 10=Low Temp

1= High TempOutdoor reset curve presets (see separate slides)

4.2.1 30=OFF

3=ON

Thermoregulation: outdoor temperature reset

Also available from AUTO function in main menu

(CH) or 2.2.4

DO NOT USE 1,2, or 4

4.2.2LT=1.0

HT=1.5

LT=0.2-1.0

HT=1.0=3.5

Slope of outdoor reset curve (see separate slides),

depends on 4.2.0 setting

4.2.3 0Depends on

curve settingsHeating curve offset (parallel shift)

4.2.5LT=122°F

HT=185°F

LT=68-122°F

HT=68-185°FMaximum supply temp (°F)

4.2.6 68°FLT=68-122°F

HT=68-185°FMinimum supply temp (°F)


Service parameters (Chapter 8)

Parameters

PARA Unit Description

8.0.1 Hours Total pump hours

8.0.3 Hours Total hours boiler on power (electricity)

8.0.4 Hours Total fan hours

8.0.5 Cycles Total fan cycles

8.0.6 Cycles Total CH flame ignitions

8.0.7 Cycles Total DHW flame ignitions

8.1.0 Hours Total CH burner hours

8.1.1 Hours Total DHW burner hours (add w/CH for absolute total)

8.1.2 Occurrence Total number of flame faults

8.1.3 Cycles Total ignition cycles

8.2.1 OFF/ON PCB signal if fan is ON or OFF

8.2.2 RPM Fan speed

8.2.3 0-100% Pump speed

8.2.4 3-way valve position 0=DHW, 1=CH



Parameters


8.2.5 l/min DHW rate (note this is in liters multiply by .264 for GPM)

8.2.7 % Pump modulation (will never read above 90%)

8.2.8 kW Boiler power during operation (multiply by 3412 for BTU)

8.2.9 PSI Actual PSI (also on home screen)

8.3.0 °F CH Flow Setpoint, also called T-set

8.3.1 °F T1 (Supply temp)

8.3.2 °F T2 (Return temp)

8.3.3 °F T3 combi (DHW temp)

8.3.5 °F Outdoor temp sensor (also on home screen)

8.4.0 °F Indirect tank temp



Parameters


8.5.0 Months Maintenance frequency

8.5.1 ON/OFF Maintenance frequency activation

8.5.2 0/1 Maintenance frequency reset

8.5.4 SW Version (display board)

8.5.5 SW version (main PCB)

8.7.5 Flame Rod Current


Fault Codes & Troubleshooting


Troubleshooting

WHEN TROUBLESHOOTING IT IS IMPORTANT TO REMEMBER….

• REMEMBER ALL RESOURCES AVAILABLE TO YOU

• Rinnai documentation (Installation Manuals, Technical Bulletins, Application

manuals, etc)

• Rinnai Technical Support

• Rinnai Website and Partner Portal: www.rinnai.us

• Rinnai LMS Training Portal: www.rinnai-LMS.com

• REMEMBER THE QUALITY OF THE PRODUCT

• Rinnai’s quality control is second to none. Every Rinnai Product is fired and tested

at the factory.

• If it is a new install, look to the installation. It is probably not a manufacturing issue

•REMEMBER THE BASICS

• Use parameters info to validate operation and error code history to see recent

problems

• Jump terminals TT to confirm boiler will respond to a heat call

http://www.rinnai.us/

http://www.rinnai-lms.com/


TroubleshootingNo Heat, No DHW (With no fault code)

• Is the boiler in air purge (De-aeration)?

This 7 minute program initiates when:

• Anytime boiler is powered on

• Boiler water pressure drops < 10 psi

• Is “Heat generation lock” displayed on

home screen?

• Check external safety contact circuit

• LWCO

• Overheat slab sensor


TroubleshootingNo Heat (With no fault code and DHW functioning)

No box around rad symbol with heat demand

• User menu in Summer Mode? (No target

temp and bar shown on right side of home

screen)

• User menu OFF (screen will be blank)

• OK→Summer/Winter/Off

• Recommended to keep in Winter at all times

• Is the TT circuit (blue screw terminal) closed?

• Is Tstat calling or relay end switch is closed.

• TT terminal can be jumped to test

• Is Warm Weather Shut Down Active?

• Ensure outdoor temp sensor reading is <71°F

• If sensor reading is unreasonably high

• Test sensor resistance and wiring

• Examine sensor location for heat source

• Sunlight, exhaust, uninsulated wall mount


TroubleshootingNo Heat (With no fault code)

Box around rad symbol with heat demand

• If “CH Pump Over Run” shown on home

screen, boiler is off on temperature.

• Check 8.3.0 CH target temp

• Check 8.3.1 CH Flow (supply) temp

• Verify all outdoor reset parameters

• If boiler supply temperature is above target

temperature, 3 way valve may be stuck in DHW position

• This could be an actuator failure

• Activate manual mode (2.6.0)

• Set 3-way valve to CH on the manual

menu off the home screen

• Remove actuator from 3-way valve

• If heating operation is restored, check actuator

and replace if needed


TroubleshootingSlow Heating (With no fault code)

• Check the Hydronic System

• Are system pumps working?

• Are zone valves open?

• Are boiler supply and system supply temperatures similar?

• If system supply is much lower, system flow is very high

• What is the system ΔT?

• If <12 F, check for emitter problems or over-pumping

• If >40 F, system flow may be too low. Check for restriction or

external pump issue

• Verify All outdoor reset parameters


TroubleshootingVerifying Outdoor Reset Parameters

• 2.0.6 Temperature Gradient (ramp up)

• Increase if <9°F

• This will allow the boiler to heat

the system faster

• 4.2.3 Heating Curve Offset

(or turning dial on controller Home

screen)

• This setting shifts the outdoor reset

target temperature up or down

• When the offset is negative the

boiler supply temperature will be

relatively low

• Increase to zero or a positive

number to raise current supply

temperature


TroubleshootingVerifying Outdoor Reset Parameters

• 4.2.0 Low or High outdoor reset curve.

• Only total slab radiant applications should use the low temperature curve

• 4.2.2 Slope

• If curve slope is too low, the boiler may not heat effectively in colder weather

• The 1.5 default setting works well with a newer tight building

• Increase setting to 2.0 for an average house and 2.5 for an older drafty house

• 4.2.5 Max supply temperature

• If set too low, boiler may

not heat effectively in

colder weather

• 4.2.6 Min supply temp

• When set too low, the boiler

may not heat effectively in

mild weather

• The minimum

recommended setting for

baseboard is 100°F


Outdoor Reset Curve – Min/Max Temp Guidelines

Troubleshooting

Type of Heat Emitter 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 - 190°F

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

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

Poured concrete radiant 80 - 90°F 110 - 130°F

*NOTE: These are basic guidelines. Please check with manufacturer of emitter or

consult your heating design engineer.

Verifying Outdoor Reset Parameters


Other flow or pressure-related issues

(with no fault code)

Closely Spaced Tees

• Poor hydraulic separation design will cause boiler to:

• Struggle to maintain proper ΔT

• Struggle to maintain proper temp

• Short cycle

• If Tees are too far apart:

• Primary loop will have pressure drop

• The system pump will influence the boiler (not

good)

• System piping should be (at least) one pipe size

larger than primary (boiler) loop

• If not, boiler flow will reduce

• System pump will influence the boiler flow

Troubleshooting


Other flow or pressure-related issues

(with no fault code)

Troubleshooting

System issues

• M120/160 models cannot

be direct coupled

• External pumps can

interfere with boiler flow

and temperature control

• When multiple zones have

different head loss, lower

flow zones will get less heat

from the boiler.

• Solution: primary/secondary

boiler piping


TroubleshootingNo Domestic Hot Water (With no fault code and CH

functioning)

• DHW temp and bar should display on left side of home screen

• If temp and vertical bar are missing, ensure “Heating Only” mode is not

selected

• If so change to “Winter”


TroubleshootingNo Domestic Hot Water (With no fault code and CH

functioning)

• If needed, isolate boiler and confirm

DHW flow

• Check for crossover

• Verify mixing valve setting

• Reverse flow (backward piping)

• Ensure check valves are functioning

• If DHW temp is present on controller, look for box around faucet icon

• If missing, the boiler has not recognized a DHW demand

• Confirm DHW at parameter 8.2.5

• Activation flow is 0.4 gpm

• If flow is >0.4 gpm, check T3 DHW temperature sensor at parameter 8.3.3

• If flow is <0.4 gpm, check for blocked flow restrictor or flat plate

• If faucet box is present

• Check 3-way valve actuator position at parameter 8.2.4

• If 0, remove actuator and check action

• Ensure cartridge is not stuck in heating


19 psi

Minimum requirement

for normal operation

Troubleshooting

20 psi

Recommendation for

fill valve setting

10-14 psi

Warning 1P4 / ΔT reduced

(until 19 psi is re-

established)

<10 psi

Fault 108

Boiler inoperable

until 19 PSI is re-

established (air

purge begins)

18

1614

12

10 20

LWCO not required

per NFPA 54 due to

this pressure control

technology

PSI

Pressure Fault Codes: 1P4 & 108


TroubleshootingPump Verification Fault Codes: 1P9 & 140

During a call for heat (CH or DHW), boiler PCB fails to see an increase in pressure (at

sensor) when pump is energized

• 1P9 is blocking code

• 140 is fault (2 successive 1P9 codes) and will require RESET

≈

Verify the Boiler Pump is operational, and spins

freely

• Remove flat screw on front of pump and insert a

4mm Allen wrench into front of pump and verify it

spins freely. Temporarily remove condensate hose

and trap if needed for access

Verify boiler pressure gauge and

controller PSI are reading

accurately

• When boiler pump is off, these

should be within 1-2 psi

• When boiler pump is on,

controller psi will be higher


TroubleshootingOther Pressure-related Fault Codes: 102 & 109

• 102 – Pressure sensor values are

out of range

Verify pressure sensor is

connected and seated properly

• Replace if needed

• 109 (reset required) – Pressure sensor

value exceeds 43 PSI

• If proper 30 PSI PRV is connected

and functioning, this should NEVER

occur

Verify operation of PRV and autofill valve

• Replace pressure sensor


TroubleshootingIgnition and Flame Fault Codes:5XX

• 5P1 (warning code) – Flame not detected on 1st ignition attempt (will try again)

• 5P2 (warning code) – Flame not detected on 2nd ignition attempt (will try again)

• 501 (reset required) – Flame not detected after 5 ignition attempts

• 5P3 (warning code) – Flame rod current lost after successful ignition (boiler will ignite

again)

• 504 – (reset required) – Flame rod current lost after success ignition (boiler will require

RESET)

• REMINDER: If ignition assembly is removed (for inspection), gasket must be

replaced!

Verify:

• Flame / spark ignition through site glass

• Gas Pressure

• Vent issues (blockage, clearances, equivalencies)

• Proper gas conversion/altitude settings

• NOTE: If boiler successfully starts, check flue gas

O₂% and flame current (Parameter 8.7.5)

• Minimum flame current is 0.8 µAmps


TroubleshootingGas Valve-related Fault Codes:309 & 502

• 309 – (reset required) – Flame rod current detected for 3 seconds AFTER gas valve

signal (120V) OFF

Verify:

• Flame present after CH/DHW call ends

• If there is no flame, check flame rod, wiring, etc.

• If there is flame, verify 120V signal to gas valve OFF

• If signal OFF, replace gas valve as needed

• If signal still ON, replace PCB as needed

• Replace valve if needed

• Flame rod wiring, proper grounding, etc.

• 502 – (reset required) – Flame rod current detected BEFORE gas valve powered ON

(120V)

Verify:

• Flame present before gas valve “clicks” open

• Replace valve if needed

• Flame not present before gas valve clicks open

• Verify flame rod wiring, proper grounding, etc.


TroubleshootingTemp Sensor-related Fault Codes: 11X & 20X

• 110 – T1 (Supply) temp sensor values out of range (wet well)

• 112 – T2 (Return) temp sensor values out of range (dry well)

• 201 – T3 (Combi models, DHW) temp sensor values out of range (wet well)

Verify:

• Temp values – available at parameters 8.3.1 (T1), 8.3.2 (T2), 8.3.3 (T3)

• Sensor resistance wiring, resistance values (see table)

• Replace sensor if needed, etc.

• 114 – Outdoor reset temp sensor not detected or values out of range

Verify:

• Outdoor reset is required for system. If not, disable at parameter 2.2.4 or 4.2.1

• Temp values – available at parameter 8.3.5



• 203 – Tank temp sensor (Solo models) values out of range

Verify:

• Parameter setting 2.2.8

• Temp values – available at parameter 8.4.0




TroubleshootingTemp Sensor-related Fault Codes

• Refer to the Owner’s/Installation manual for

temperature sensor resistance tables


TroubleshootingOver-temp Fault Code: 101

• 101 – (reset required) – T1 (supply) or T2 (return) sensor detects water temperature is

>212° F for 3 seconds.

Verify:

• No air in boiler

• Run air purge (parameter

2.7.1)

• Boiler pump operation

• T1 or T2 sensor resistance

wiring, resistance values (see

table)

• Replace sensor if needed,

etc.


TroubleshootingFan Fault Code: 612

• 612 – (reset required) – Fan speed out of range (rpm too high or low)

Verify:

• Fan installed and

connected correctly

• Replace as

needed

• If fan is running

continuously, control

connection may be off

• If fan does not run

when control

connection is off,

check voltage on line

connection


TroubleshootingPCB Fault Codes: 303 & 306

• 303 or 306 – (reset required) – PCB error

Verify:

• PCB wiring, supply

voltage, proper ground

• Replace as

needed (contact

technical support)


TroubleshootingReset Fault Code: 304

• 304 – (reset required) – RESET button pressed (to clear code) more than 5 times in

less than 15 minutes

Wait 15 minutes for next

reset


TroubleshootingVoltage Measurements

Due to the intuitive controller, parameter menu, and fault code detail, very few

electrical measurements are required for troubleshooting

• Temperature sensors – see manual for resistance tables

• All internal temp resistors are 10KΩ

• The outdoor reset temp sensor is 1KΩ

• Flame rod current – parameter 8.7.5 will display PCB reading of flame rod

current. Meter not required.

• Fan voltage – 120 vac (108-132 vac)

• Gas valve – 120 vac (108-132 vac)

• Pump – 120 vac (108-132 vac)

• 3-way valve – 120 vac (108-132 vac)

• Contact technical support if you feel additional troubleshooting guidance


TroubleshootingWiring Block


END of Training

Rinnai M-Series Condensing Boiler Level III Service ... M-Series Boiler L3 Service...

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Transcript of Rinnai M-Series Condensing Boiler Level III Service ... M-Series Boiler L3 Service...