rinnai m-series condensing boiler level ii installation ... m-series boiler l2 installation... ·...

ENHANCING LIVES BY CHANGING THE WAY WATER IS HEATED 1

Rinnai M-Series Condensing Boiler

Level II Installation Training


• Rinnai Resources

• The new Rinnai M-series Boiler Features and Benefits

• Installation Fundamentals

• Boiler Set Up & Commissioning

• Maintenance & Troubleshooting

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.

ISO Certification 9001

Scope includes latest

certification for PTC HQ,

assembly area, & distribution

centers

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


Features


M-Series Features

• Energy Star: 95% AFUE

• 8 Models• 4 Combi (60, 90, 120, 160 MBH)

• 4 (Solo) Heat Only (60, 90, 120, 160 MBH)

• Improved DHW capacity:• M90C, 120C 160C: 4.2 gpm @ 70°F rise

• M60C: 2.6 gpm @ 70°F rise

• New User Interface: Full Text Graphical

Display

• Improved Serviceability

• Outdoor Sensor Included

• Modulating Boiler Pump

• Integrated Freeze Protection

• CSA Certified Low Lead


M-Series Features

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

3.8 : 1

M120S M120C

95%120,000 BTU

35.2 kW 23,500 BTU6.9 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


M-Series Features

Exclusive Leading Edge Design Features

Stainless Steel Heat Exchanger

• Proven Water Tube, Down Fire Design

• Self Cleaning smooth tube

• Durable brazed joints

• 20 passes /89 Tubes

• Low NOx Emissions


M-Series Features

Heat Exchanger Design

• Superior efficiency & Low NOx

simultaneously

• Compact down-fired, water

tube heat exchanger

• Heat Exchanger orientation

Superior Manufacturing for

Durability

• Vacuum oven brazing process

• Competitors’ stainless heat

exchangers are welded at high

temperatures


• Rinnai Designed & Manufactured Ceramic Burner

• Rinnai has manufactured burners for over 50 years

• Rinnai has sold millions of burners around the world

M-Series Features

Pre Mix Combustion


EBM Papst Combustion Fan • Quiet & powerful fan automatically adjusts to longer vents• Fan speed adjustments overcome higher elevations with less

de-rating

EBM Papst Integrated Venturi• Pre-mixes the gas and air • Ensures safe, clean, reliable and efficient combustion

EBM Papst Negative Pressure Gas Valve• Allows full power at 3” minimum w.c. of NG• More tolerant of lower gas pressures and larger pressure drops

Intake Air Silencer• Low Noise: dBA 39-54• Compare to normal speech at 3 feet: 70 dBA

M-Series Features


• Adapts boiler flow rate to system

flow, improving thermal efficiency

• Quiet and Powerful

• Low electrical consumption and

improved efficiency

M-Series Features

Grundfos Modulating Pump

• No special piping needed for single zone systems.

• Up to 75’ of Copper Fin Tube Baseboard

• Up to 60’ to a hydro-coil air handler

• Bypass Valve

• Protects boiler pump when direct coupled


M-Series Features

• Asymmetric Flat Plate Heat Exchanger

• Larger passageways for higher boiler side flow

• Corrugation boosts efficiency & prevents scaling/blockage

• DHW Flow Sensor

• Activates @ 0.4gpm

• Water wheel design prevents sticking

• DHW Temperature Sensor

• Reads and controls DHW outlet Temperature

• Brass 3-way valve cartridge

• 120v 3-way valve actuator

• Diverts flow based

on demand type


M-Series Features

Combi DHW Operation


What is the average shower temperature (in Fahrenheit)?

What is the average cold water temperature in the US (in

Fahrenheit)?

Based on the above, what is the average ΔT

What is the average shower flow rate in GPM?

Using the above data with the below table, how many showers can

each boiler supply at once? How much hot water flow is

remaining?

Combi DHW Capacity: How much hot water is it?

ModelsMax. DHW flow (gpm)

ΔT 48 °F ΔT 64 °F ΔT 70 °FM060C 4.0 3.0 2.7M090C

6.1 4.4 4.2M120CM160C

106°F58°F

106-58= 48

2.1 GPM

ModelsMax. DHW flow (gpm) # Showers

ΔT 48 °F ΔT 64 °F ΔT 70 °F (106°F hot/58°F cold)M060C 4.0 3.0 2.7 1 (with 1.9 GPM remaining)M090C

6.1 4.4 4.2 2 (1.9 GPM remaining)M120CM160C

M-Series Features


Combi DHW Capacity: How much hot water is it?

ModelsMax. DHW flow (gpm))

ΔT 48 °F ΔT 64 °F ΔT 70 °FM060C 4.0 3.0 2.7M090C

6.1 4.4 4.2M120CM160C

Using the data below, how many (2.1 GPM, 106°F) showers will each boiler

model supply in this area?

M-Series Features

Groundwater

Temp Map

IMPORTANT: A mixing valve must be installed to ensure constant hot water

temperatures are delivered at all times.


Compact, Lightweight

• Smaller footprint

• 10lbs less than E Series

• 30% less volume than E

Series

M-Series FeaturesFlexible Heating Connections

• ¾” & 1” NPT adapters for connections

• More Space between connections than E Series

Flexible Gas Connections & Simplified

Conversions

• Pre-Mix Combustion; 3” min w.c for natural gas

• Quick-n-Easy LP Gas Conversion (included)

Flexible Venting Option

• 2”, 3” PP, PVC & concentric adapters included

• PVC, CPVC, PP, SS & concentric venting

approved

• Low Profile and more terminations Approved

Plug & Play Wiring

• 120V Plug (6’ cord)

• Terminal block type connections

Intuitive Control

• New user interface with easy set up

• Scroll type menu navigation with knob


• Larger Display (Cool Blue)

• More informative at first

glance

• Full text, graphic and

icon display

• Integrated power switch

• Easier navigation controls

• Scroll knob

• BACK button

• OK button

• RESET button

• Chimney sweep (flue gas testing)

• Plain English, French (and other language) menus & messages

• Limited Parameters for ease of installation set up

Simplified Control

M-Series Features


M-Series Features

• Date & Time

• Outdoor Temp

• Heating Target Temp

• DHW Target Temp

• Burner Indicator

• Power Bar

• Pressure (psi)

• DHW Mode

• Current Operating Status

Simplified Control

Large Information Rich Display


Simplified Control

Each Fault Code Includes:

• Plain text description

• Recommended solution

• Date & Time Stamp

• (Optional) Contractor name and phone number

The last 10 codes are stored

M-Series Features


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 Features


M-Series Features

What installation advantages does

the M boiler have over the E boiler?

Check Your Knowledge

What performance advantages does

the M boiler have over the E boilers?

What is the warranty terms of the M

boiler in a residential application?

What is the AFUE of the M boiler?

Which M-Series combi model boilers are

capable of providing hot water to at least 2

showers simultaneously anywhere in the US?

• M90C

• M120C

• M160C

• 95%

• 12 years – hex

• 2 years – parts

• 1 year - labor

• Higher DHW Output

• Higher Heating Output (BTU &

temp)

• Control Dashboard Display

• Precise DHW Temp Control

• Longer vent maximums

• More space between connections

• Smaller/lighter units

• Self adjusts to vent length


Installation


For installation of the boiler these items are recommended:

• Large adjustable wrench & pipe wrench

• 5 in 1 screwdriver

• Flue gas analyzer and manometer

• Drill and hole saws

• Level

• Wire strippers

• pH meter or test strips

• Installation manual

Other Helpful Tools

• Smart phone / tablet

• Thermostat screwdriver

• Appliance dolly

• Empty 5gal. bucket, washing machine hoses

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

Recommended Installation Tools

M-Installation


ModelDimensions

(W x H x D)

Heat Only

Weight

Combi

Weight

M060

17.3” x 27.5” x 10.6”44 x 70 x 27 cm

77 lbs(35 kg)

82 lbs(37 kg)M090

M120 82 lbs(37 kg)

88 lbs(40 kg )M160

Co

nn

ect

ion

s Heating 3/4”

DHW 1/2”

Gas 1/2”

M-Installation


Boiler Accessories: What’s in the Box?

M-Installation

• Boiler installation/user and conversion manuals

• 3” x 5” concentric vent adapter

• Twin pipe 80mm (3” PP) vent adapter Installed on boiler

• Two 3” PVC vent adapters

• Two 2” PVC/PP venting adapters

• Two 1” bushings for system connection

• Two 3/4” bushings for DHW connection

• 30 PSI pressure relief valve

• NG to LP conversion kit

• 3/4” bushing for gas connection

• Boiler condensate trap kit

• Outdoor temperature sensor

• Wall mounting bracket (and template)

• Electrical connectors: Installed on boiler control


Location Location Location!

M-Installation

If applicable, verify room air

is sufficient

Verify vent length equivalency

Ensure clearances to

combustibles

Ensure service access

Ensure all local codes

are met

Verify grounded

3-prong outlet

Verify water supply quality

LOCATION CHECKLIST


M-Installation

Mounting / Clearances

• Wall bracket is 16.5” and

mounts to 16” on center studs

• Bracket allows adjustment ½”

side to side to align venting

• Mounting:

• Level bracket and fix to wall

• Lift boiler and drop back lip

over the bracket

• Provide Clearances

• 2” minimum clearance to

combustibles

• 12” service clearance

recommended on left side

and in front of the boiler


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

Overview

• Ubbink Concentric Polypropylene (3”/5” or 2”/4”)

• PolyPro (2” or 3”)• Centrotherm

• Duravent

• Ecco Manufacturing

• AL29-4c Stainless (Metal-fab/Heat-fab)

• PVC/CPVC (Schedule 40)

• PVC termination kits• IPEX

• Royal

• Diversitech

• Flexible chimney liners (PP / Metal)

Approved Venting Materials

M-Installation


ModelConcentric PP PVC / CPVC / PP

2/4” 3/5” 2” PVC 3” PVC

M060/M090S 60’ 150’ 60’ 150’

M090C/M120/M160 30’ 140’ 30’ 140’

Maximum Equivalent Vent Lengths

M-Installation

• Vent equivalencies vary

• Refer to I/O manual for details

M090S

Vent Equivalency Examples PP PVC / CPVC

90° Elbow 6 5

45° Elbow 3 2.5

3/5 Condensing Horizontal or

Vertical Termination Kit5

IPEX PVC Concentric Kit 20

3/5” Concentric PP

3’

What is the vent equivalency?

Is this vent system within specification?


ModelConcentric PP PVC / CPVC / PP

2/4” 3/5” 2” PVC 3” PVC

M060/M090S 60’ 150’ 60’ 150’

M090C/M120/M160 30’ 140’ 30’ 140’

Maximum Equivalent Vent Lengths

Note: In 2 pipe systems, use longest pipe (in/out) to determine maximum

M-Installation

M090C

Vent Equivalency Examples PP PVC / CPVC

90° Elbow 6 5

45° Elbow 3 2.5

3/5 Condensing Horizontal or

Vertical Termination Kit5

IPEX PVC Concentric Kit 20

2” PVC w/IPEX

concentric

termination

3’

2’

1.5’

10”

What is the vent equivalency?

Is this vent system within specification?


The boiler comes with the 2 pipe

adapter installed. To install the

concentric:

• Twist the 2 pipe adapter

counterclockwise, lift straight up

• Insert 3X5” concentric adapter,

twist clockwise to lock in place

Installing the Concentric Venting Adapter

New 2” x 4” horizontal concentric

vent kits will fit on the boiler

concentric adapter

3x5 to 2x4 Reducing Elbow

M-Installation


Cut Internal PP pipe 7/16”

(10mm) Longer than Outer Pipe

PP can easily be cut with hand saw or snips. Be sure to

deburr all cuts

WARNING:

Horizontal terminations

extending too far off

the wall allow exhaust

to recirculate into the

air intake which could

damage the boiler

Roof

Termination

Sidewall

Termination

Concentric Venting

Green Label = Condensing

Black Label = Non-CondensingDO NOT USE!

M-Installation


Two Pipe 3” Venting

The boiler comes ready for 3” (2-pipe) PP venting

3”PP 3”PVC

For PVC Venting: Install 3” PVC Adapters

(included)

M-Installation


Two Pipe 2” Venting

For 2” PVC or 2” PP: Install gray 2” adapters into PVC adapters.

These adapters fit 2” PVC and 2” PP

(Included)

2”PP2”PVC

M-Installation


Room Air Filter (12’ equivalency) Room Air Elbow & Screen

Room Air Intake

• Room Air for combustion may only be used if adequate fresh air is available

• 50 cubic feet per 1,000 btu

• If not, additional measures must be taken to provide adequate air.

• Most M boiler models require 8000 cu ft of space (1000 ft2 with an 8 ft

ceiling)

• Air Filter part number: 808000025

M-Installation


Vent Termination Options

Two-Pipe

Low Profile Termination

Two-Pipe

Sidewall Concentric

PP flexible Liner (PP or Metal)

Room Air

Two-Pipe

Vertical Concentric

M-Installation


Room Air

Sidewall Termination

Two-Pipe

Sidewall Termination

Two-Pipe

Vertical Termination

Room Air

Vertical Termination

Vent Termination Options

M-Installation


See next

slide for

NFPA

required vent

terminal

clearances

Sidewall Vent Termination Clearances

M-Installation


RefClearance ANSI Z223.1 (NFPA 54) or Rinnai Requirement (see manual)

U.S. Direct VentCanadian Direct/Non-

Direct Vent

A Clearance above grade, veranda, porch, deck, balcony or expected snowline 12” (30 cm) 12” (30 cm)

B Clearance to window or door that maybe opened 12” (30 cm) 36” (91 cm)

H Clearance to side of center line extended above meter/regulator assembly [1]36” (91 cm) within a

height 15’(5 m) above the meter/regulator

I Clearance to service regulator vent outlet 36” (91 cm)’ 36“ (91 cm)

JClearance to non-mechanical air supply inlet to building or the combustion

air inlet to any other appliance 12”

36” (91 cm)

K Clearance to a mechanical air supply inlet36” (91 cm) above if within 10 feet (3 m)

horizontally6‘ (2 m)

L Clearance above paved sidewalk or driveway located on public property Not Permitted [2] 7’ (2.25 m)

M Clearance under veranda, porch, deck, or balcony** 12” [3] 12” (30 cm)

Sidewall Vent Termination Clearances (Direct Vent)

1. Clearances must comply with local building code and gas supplier requirements

2. Also not permitted above a shared walkway or driveway between located

between two single family dwellings.

3. Permitted only if area is fully open on a minimum of two sides beneath the floor.

M-Installation


Tech Tip: Some clearances are increased when using room air in the US (see manual for details!)

Example: Clearance to window/door/mechanical inlet is 4’ vs 12”

Sidewall Vent Termination Clearances (Room Air)

RefClearance ANSI Z223.1 (NFPA 54) or Rinnai Requirement (see manual)

U.S. Non-Direct VentCanadian Direct/Non-

Direct Vent

A Clearance above grade, veranda, porch, deck, balcony or expected snowline 12” (30 cm) 12” (30 cm)

B Clearance to window or door that maybe opened 4’ 36” (91 cm)

H Clearance to side of center line extended above meter/regulator assembly Local Code36” (91 cm) within a

height 15’(5 m) above the meter/regulator

I Clearance to service regulator vent outlet 36” (91 cm) 36” (91 cm)

JClearance to non-mechanical air supply inlet to building or the combustion

air inlet to any other appliance 4’

36 inches (91 cm)

K Clearance to a mechanical air supply inlet3 feet (91 cm) above

if within 10 feet (3 m) horizontally

6 feet (2 m)

L Clearance above paved sidewalk or driveway located on public property Not Permitted [2] 7 feet (2.25 m) j

M Clearance under veranda, porch, deck, or balcony 12” [3] 12 inches (30 cm) k

M-Installation


Sidewall Vent Termination Considerations

AVOID

Terminations near

NEVER

Install terminations:

Dryer Vents Over Public Walkways

Commercial Cooking Exhaust Near Soffit/Crawl Space Vents where

condensate can be problematic

Air inlets into the building Where condensate could damage

regulators, PRV’s, or other equipment

Where exhaust cannot easily

dissipate

Where exhaust can enter the soffit vent or

reenter the combustion intake vent

NOTE: If more stringent, local codes will supersede the above

M-Installation


Multiple Horizontal Vent Terminations

M-Installation


Multiple Vertical Vent Terminations

M-Installation


• ½” brass MNPT gas connection

• ¾” (gas) brass bushing included

• Size gas appliance connectors

for boiler BTU

• Refer to the installation manual

for gas line sizing details, and

follow local code

• In the absence of local code, refer to

NFPA 54 (US) or B149 (Canada)

• Gas pressure regulator recommended

to be at least 6 feet from boiler

• Gas meter and regulators must be

sized for the total building load

• Install a sediment trap and manual gas

shut off valve as shown below

Gas Connection

M-Installation


Gas Line Sizing Example – Natural Gas

M-Installation

Using the

provided table

and example,

what size gas

line is required

for the

following

installations?

• 10 ft

• 50 ft

• 80 ft


M-Installation

All M-Series Boilers ship configured for Natural Gas

This Simple & Quick LP conversion kit is included

with each boiler


NG to LP Gas Conversion

• Install EEPROM chip on main board & turn on

boiler

• Hold button 7 seconds to bypass air purge

• “Flash Memory Detected” is shown. Press

• After boiler restarts, turn off power and remove

EEPROM chip

• Test flue gases, adjust O2 setting (see manual)

Place new data plate over original

• Remove internal gas line by loosening nuts

from both ends

WARNING: Refer to Gas Conversion manual for complete instructions

• Insert brass orifice with O-ring into venturi. Re-install

gas line & tighten nuts

M-Installation


DHW Connections

• ½” Male NPT connections

• Optional ¾” bushings

provided

• A Thermostatic Mixing Valve

is required on combi models

• DHW Pressure Range:

40–150 psi

• 150 psi or lower PRV is

required

• An isolation valve kit is

recommended

Rinnai Isolation

Valve Kit MIVK-T-

LW

M-Installation


Heating System Connections

M-Installation

• ¾” Male NPT connections

• 1” bushings provided

• Required for 120/160

models

• Optional for 90/60 models

• Temperature & Pressure Gauge

(1/4 NPT) provided

• 30 psi PRV provided

• Heat Exchanger Rated to 45psi

• Determine if primary secondary boiler piping is needed.


Primary Secondary Piping: What does it do for you?

Primary secondary piping allows

connected hydronic loops to operate with

independent flow rates. The system can

have a higher flow rate than the boiler.

When a water tube boiler is directly

connected to the hydronic system,

the maximum system flow and

heating capacity may be reduced.

M-Installation


Primary Secondary Piping: Direct Coupled Boiler Piping

Advantages• Simple, less costly installation.

• No external pump needed

• Great for single zone systems

Disadvantages• System flow is limited to boiler pump

head, which can limit heating output.

• Not allowed when system pressure

drop is >10.4 ft (4.3 psi).

M-Installation

Tech Tip: Because of high flow

requirements, M160/M120 boilers

must be piped primary secondary

and can not be direct coupled.


If the boiler is operating at 6 GPM:

• How much pressure drop is in the boiler?

• How much pump head room remains for a direct-coupled system?

Extra Credit:

How is 6 GPM

determined?

M-Installation

Available Pump Head


Primary / Secondary Piping:

Closely Spaced Tees and LLHs

Advantages

• Ensures proper flow to heating

zones and with external pump(s)

• Gives correct boiler flow and full

boiler output power

• Allows for multi temperature

systems

Disadvantages

• More installation labor and

materials

• Reduced system efficiency when

boiler flow is higher than system

flow

M-Installation


Primary Secondary Piping Options

Closely Spaced Tees

• Simple DIY primary secondary piping solution

• Tees should be as close as practical

• Header pipe should be larger diameter than boiler pipes

• Include PRV fitting above boiler isolation valves

M-Installation



M-Installation

Rinnai offers as a

prefabricated accessory:

Part # 803000023



Third Party Boiler Plumbing Kits and Low Loss Headers

• Boiler Plumbing kits are available from several manufacturers that include pre-

made closely spaced tees.

• Hydraulic Separators and LLHs are available that also function as air separators

and dirt traps.

M-Installation


Condensate Drainage

• Internal condensate drain

assembly must be field-

installed (included with

boiler)

• Refer to manual for details

M-Installation


Boiler Control Line Voltage Connections

• Power source must be properly grounded

• Do NOT use an extension cord

• Ensure all connections are correct

• NOTE: System Pump Relay is active

whenever boiler pump is energized

M-Installation

**Do Not USE**

120vac Input(Power cord factory installed)

**Do Not USE**

System Pump Relay(120vac Output)


Boiler Control

The boiler control (top

spine of assembly

includes screw terminal

plugs for easy

connections

M-Installation

• OT Bus On / Off: For

thermostat or multi-zone relay

end-switch

• Outdoor temp sensor:

Included with boiler

• External Safety: Optional

for NC LWCO or high limit.

• DHW: (Solo models)

Optional for aquastat, 10k

Ω indirect tank sensor or

relay end switch.


Optional DHW 3-way valve for M-Solo Boiler

Connections for (3rd party) DHW 3-way valve control is on back of control

assembly (solo boilers only)

• Follow valve manufacturer’s guidelines

• Example:

• VC4011ZZ11 Honeywell, 2-position, line volt actuator

• VCZMR6100 Honeywell, 1" 3-Way Female NPT Valve Assembly

M-Installation


What is the minimum incoming gas pressure

allowed for NG M-Series boilers?


Is the Ubbink PP flexible liner listed as an

approved vent system for M-Series boilers

M-Series 2-pipe vent systems require an

average vent length (between intake and

exhaust) to be used to determine equivalency?

True/False: M90 boilers can be direct

coupled to a heating system?

When is the system pump relay

electrical connection energized?

Anytime the internal pump is

energized (not just CH demand)

True, M60/M90 boilers have enough

pump head remaining for direct

coupling.

No, use the longest length

No, but it doesn’t have to be since it

is used with room air (Category IV)

3” w.c. (dynamic / full load)

M-Installation

What is the diameter for CH connections? ¾” male NPT / 1” bushings included

(& required for 120/160 models)

What is the diameter for DHW connections? ½” NPT / ¾” bushings included


Setup & Commissioning


M-Setup

Initial Power On

When first powered up, the control will prompt to set

language, time, date & units.

1. Select your language from the drop down menu. Press

“OK” to save.

2. Date and Time will be displayed

• Select a digit with the scroll wheel and open by pressing

OK

• Scroll to adjust digit with scroll wheel and save setting

by pressing OK

• Selecting “Auto“ on Legal Hour will automatically adjust

time for daylight savings.

• Save all changes by selecting SAVE at the bottom of

the screen and pressing OK

3. Set the measurement units to USA or International

(Celsius and Bar).

4. The boiler will then automatically run a 7-minute air purge

program.


User Menu: Setting the Time

If time has not been set it will flash

• Press OK→Complete

Menu→Time & Date

• Legal Hour setting will

automatically adjust for daylight

savings if set to AUTO

M-Setup


User Menu: Setting Units of Measurement

• Press OK→Complete

Menu→System

measurement unit

• Select USA system or

International system

(metric)

M-Setup


User Menu: Other controller recommendations

M-Setup

• Keep Time Program / Manual in

manual mode

• CH time programs inactive

• Keep Summer / Winter in winter

mode

• CH Setpoint

• Only Z1 is active

• Do not set Z2 or Z3


User Menu: Controller main screen icons

M-Setup

• AUTO – Outdoor reset Active

• Outdoor reset (outside) temp

• Service interval due

• Freeze protection active

• DHW (with box) –

DHW demand

• Heat panel (with box) –

CH demand

• Burner Active (w/power

bar)

• Heat generation lock – External

safety circuit open (LWCO, etc)

• ECO – DHW Comfort Mode OFF


This 7 minute program to clear air from

the boiler will run automatically when:

• Anytime boiler is powered on

• Boiler water pressure drops < 10 psi

• Boiler pressure sensor is unable to

prove pump operation

Automatic Air Purge (De-aeration)

IMPORTANT: If boiler is powered on after service without a drop in

system pressure, the air purge can be bypassed by holding the BACK

button for 7 seconds.

Never bypass air purge on a new installation or when system pressure has

dropped <10 psi. Any resulting damage will not be covered under warranty

M-Setup

Air purge clears air from the boiler water through its air vent.

A minimum of 19 psi (with boiler pump on) is required for

completion of the air purge.


Pressure requirements

19 psi

Minimum requirement

for normal operation

M-Setup

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


User Menu: Setting DHW Setpoint Temp

M-Setup

• Press OK

• Select Complete

Menu→DHW Settings→

DHW comfort Setpoint Temp

• Scroll to desired DHW temp

Tech TIP: A quicker way to set DHW Setpoint Temp: Press BACK and turn the dial!


User Menu: DHW Comfort Function

M-Setup

Comfort mode enables the boiler to

maintain heat exchanger temperature.

This allows hot water to arrive quicker to

fixtures. Refer to the Installation Manual

for setup.

Comfort mode has three options:

• Disabled (Default Setting)

• No continuous heating of heat

exchanger

• Always Active

• Continuous hot water all day long

• Time Based

• Scheduled program to activate

during high DHW demand times

What are the pros/cons of each?

Comfort

Savings

Comfort

Savings

Comfort

Savings


Altitude setting must be complete before

operation. See manual for complete

details.

Setting Altitude

1.From the controller

Home screen, press

BACK and OK

buttons

simultaneously

2.Turn the wheel

to 007, press OK

3.Navigate the

menu as follows. 4.Select altitude (ft)

and press OK

5.Press BACK to

Home Screen

M-Setup


Inlet gas pressure testing:

• Leak test all connections before operation.

• It is recommended that all gas pressure

regulators are > 6 ft. upstream of the boiler

• 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

Gas Pressure Testing

M-Commissioning


• Chimney Active mode allows boiler to be forced into a specific fire-rate.

• This is primarily used when verifying O₂ levels (by forcing operation to 100%

high fire and 0% low fire).

• IMPORTANT: Boiler must have adequate load (CH or DHW) during this setting

Chimney Mode (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

• 0% (low fire)

• 100% (max fire)

4.To exit Chimney

Active mode,

press the Back

button until the

Home screen

appears

M-Commissioning

Chimney Active

100%


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-Commissioning

Example:

Boiler: M090C, Gas: NG

High measurement: 4.2

Low measurement: 5.5

Is this in range?


Outdoor Reset Technology

M-Setup

Bo

iler

Su

pp

ly

Tem

pera

ture

Outdoor Temperature 0o F70o F

70o F

185o F

Low

High

Bu

ild

ing

Hea

t L

oss

The boiler uses the outdoor sensor to improve efficiency by matching the heat output to the heat loss of the building


Outdoor Reset Sensor

An outdoor temperature sensor is included with every M-Series boiler

M-Setup

Sensor Installation

Recommend Required

North side of structure Not in direct sunlight

5-10 feet above ground Areas prone to snow drifts


Outdoor Reset Curve - Presets

M-Setup

80 75 70 65 60 55 50 45 40 35 30 25 20 15 10 5 0 -5 -10 -15 -20

200

190

180

170

160

150

140

130

120

110

100

90

80

70

60

High temp curve is default

Use for all applications

except in-floor (slab) radiant

applications

High Curve

Low Curve

Outdoor Temp F°

Boile

r S

upply

Tem

p F

°

185°F max temp (high preset)

122°F max temp

(low preset)

Low temp curve is for In-floor

(slab) radiant applications


M-Setup

80 75 70 65 60 55 50 45 40 35 30 25 20 15 10 5 0 -5 -10 -15 -20

200

190

180

170

160

150

140

130

120

110

100

90

80

70

60

Outdoor Temp F°

Boile

r S

upply

Tem

p F

°

Max and Min temp

parameters can be

adjusted to meet

application and

customer’s needs

Max temp (adjustable)

Min temp (adjustable)

Outdoor Reset Curve – Min/Max Temp


Outdoor Reset Curve – Min/Max Temp Guidelines

M-Setup

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.


Outdoor Reset Curve - Slope

M-Setup

70 65 60 55 50 45 40 35 30 25 20 15 10 5 0 -5 -10 -15 -20

190

180

170

160

150

140

130

120

110

100

90

80

70

60

High Curve

Low Curve

Outdoor Temp F°

Boile

r S

upply

Tem

p F

°

• Curve slope parameters can also be adjusted to meet the customer’s needs

• Slope adjustments change the max boiler temp vs. outdoor temp

• Steeper slope = max boiler reached at warmer outdoor temp (vs preset)

• Gradual slope = max boiler reached at colder outdoor temp (vs preset)

*1.51.2

1.0

0.8 *0.6

0.4

0.2

2.02.53.03.5

Which is more efficient: a

steep slope or gradual slope?


M-Setup

Outdoor Reset Curve – Offset (parallel shift)

• Turning the controller knob applies a parallel shift to the boiler

heating curve (+/- 24°F)

• This is a quick and easy adjustment the end user can make as well


1.From the controller

Home screen, press

BACK and OK

buttons

simultaneously

2.Turn the wheel

to 007, press OK

3.Navigate the

menu as follows.

M-Setup

Outdoor Reset Curve – Parameter Adjustments

Key Outdoor Reset Parameters

Parameter

Address

Description Value

4.2.0 Curve

Presets

1=High temp, (all apps except in-

floor (slab) radiant applications

2= Low temp, (in-floor) slab

radiant apps

4.2.2 Slope High value = steep slope

Low value = gradual slope

4.2.5 Max temp Raises / lowers peak of slope

4.2.6 Min temp Raises / lowers bottom of slope

4.To exit, press the

Back button until the

Home screen

appears on the

display


M-Setup

Key Installation-Related Fault Codes (see manual for full list)

Warnings will not require Boiler Reset Lockouts will require Boiler Reset

Fault Code Description Detail

1P4 Filling neededSupply pressure <14 psi (Screen Blocked/will

not clear until ≥19 psi)

108 FILLSupply pressure <10 psi (Reset is not required

but operation will cease until pressure=19 psi)

1P9 Pump verification No pressure change after pump energized

140 Pump verification No pressure change after pump energized

5P1/5P2 1st/2nd ignition failure Burner failed to ignite on 1st or 2nd attempts

501 No ignition after 5th attempt Intervention required

5P3 Loss of flame Flame lost after ignition

504 Loss of flame Intervention required

114 Outdoor sensor unavailable No sensor detected (Screen Blocked)


Maintenance


• Minimal Maintenance 2yr / 4yr Service Intervals• 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-Maintenance


Simple Teardown Demonstration

M-Maintenance

• Remove cover

• Flip down control

• Remove condensate trap

• Remove air intake silencer

• Remove internal gas pipe

• Remove burner top clamp rods

• Remove burner, fan & hood

• Remove burner

• Remove electrode assembly


Setting the Service Interval

M-Maintenance

• After completing the installation and commissioning, set the monthly service interval 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

Parameter

Description Detail

8.5.0 Sets period of time for

service notification

Default is 12 months – Rinnai’s 1st

recommended service interval is 24 months

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

the interval warning to post

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

counter and clears the warning


Service Interval Contact Info

M-Maintenance

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

• This will display when the service interval is due

• This will also display with fault codes

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


Rinnai 2 Year Service

Visual inspection of unit and surroundings, gas pressure,

venting, and system pressure

Clean and inspect the condensate

trap

Visually inspect flame, Verify proper

O2

M-Maintenance

Verify with end user comfort and operational satisfaction

View fault code history

(parameter 8.6.0)


• Repeat 2-year service

interval

• Purchase 4-year

Maintenance Kit (model

dependent)

• Replace ignition assembly

• Clean and inspect the

fan housing & venturi

• Inspect and clean hood,

condensate tray

• Vacuum burner cartridge

(replace gaskets)

• NOTE: Do not blow air

into the heat exchanger or

burner cartridge.

M-MaintenanceRinnai 4 year Service


At initial power-on, what key information

must be entered into the M-Series controller


At what water pressure will the M-Series

boiler cease to operate (or heat water)

How long is the M-Series de-aerate

(or air purge) cycle?

True/False: The higher the BTU rate,

the higher the O₂ measurement

What is required for a 2 year hour

service interval?

Visually inspect unit, venting, flame

Verify, gas pressure, O₂, system PSI

Clean/inspect condensate trap, fault history

False, the greater the combustion,

the lower the O₂ measurement

7 minutes

< 10 PSI

Date, Time, Units of measurement

M-Installation

List M-Series key outdoor reset

parameters (description)

Curve Preset, Slope, Max

Temp, Min Temp

True/False: All M-Series ignition failures will

require a manual reset of the fault code

False, only after 5 failed attempts

will the boiler require a manual reset


END of Training

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