Installaton & Servcng Instructons Hgh effcency condensng gas boler E50CRN E75CRN/E110CRN Pctured: E50CRN E75CRN, E110CRN E75CRP, E110CRP E75CRP/E110CRP CAUTION! Read ths manual thoroughly before nstallng, servcng, puttng nto operaton or usng ths boler and vent system. WARNING! Improper nstallaton, adjustment, alteraton, servce or mantenance can cause property damage, personal njury (exposure to hazardous materals) or loss of lfe. Refer to the user's nformaton manual provded wth ths boler. Installaton and servce must be performed by a lcensed professonal, servce agency or the gas suppler (who must read and follow the suppled nstructons before nstallng, servcng, or removng ths boler). CAUTION! The user manual s part of the documentaton that s delvered to the nstallaton's operator. Go through the nformaton n ths manual wth the owner/operator and make sure that they are famlar wth all necessary operatng nstructons.! Installaton and servce must be performed by a qualfed nstaller, servce techncan or the gas suppler. In the Commonwealth of Massachusetts ths boler must be nstalled by a lcensed Plumber or Gas Ftter. Wall-hung Condensng Bolers: E50CR, E75CR, E110CR WARNING! If you do not follow these nstructons exactly, a fre or exploson may result causng property damage, personal njury or loss of lfe. - Do not store or use gasolne or other flammable vapors and lquds n the vcnty of ths or any other applance. - WHAT TO DO IF YOU SMELL GAS - Do NOT try to lght any applance. - Do NOT touch any electrcal swtch. - Do NOT use any phone n your buldng. - Immedately call your gas suppler from a neghbor s phone. Follow the gas suppler s nstructons. - If you cannot reach your gas suppler, call the fre department. Address: 103 Internatonal Drve, Peachtree Cty, GA, 30269 Toll-free: 1-800-621-9419 Fax: 678-829-1666 www.rnna.us 8U.51.60.10 / 01.17 Changes reserved. These nstructons to be retaned by user.
Contents of nstructons These nstallaton nstructons contan mportant nformaton for the safe nstallaton, start-up and mantenance of bolers wth capactes 50,000 through 110,000 BTU/hr. These nstallaton nstructons are ntended for lcensed professonals, who have the necessary knowledge and are approved for workng on heatng and gas systems. Subject to techncal changes Changes may be made wthout notce to the llustratons, process steps and techncal data as a result of our polcy of contnuous mprovement. Updatng of documentaton Please contact us f you have any suggestons for mprovements or correctons. Calforna Proposton 65 lsts chemcal substances known to the state to cause cancer, brth defects, death, serous llness or other reproductve harm. Ths product may contan such substances, be ther orgn from fuel combuston (gas, ol) or components of the product tself. 2
Content 1 Safety and general nstructons...4 1.1 Desgnated use...4 1.2 Hazard def ntons...4 1.3 Symbol def ntons...4 1.4 The followng nstructons must be followed...5 1.5 Follow these nstructons for the space heatng water...6 1.6 Tools, materals and addtonal equpment...6 1.7 Relevant Installaton, Servce and User manuals...7 1.8 Dsposal...7 2 Regulatons and gudelnes...7 3 Descrpton of the boler...8 4 Packagng and transportaton...9 4.1 Scope of delvery...9 4.2 Transportaton...9 5 Installaton...10 5.1 Requrements for the nstallaton room...10 5.2 Fttng the boler...11 5.3 Dmensons...12 5.3.1 Clearances from boler...13 5.4 Techncal specf catons...14 6 Connectng the boler...15 6.1 Central heatng system...15 6.1.3 Safety valve...20 6.1.4 Low water cut off...20 6.2 Boler expanson tank...20 6.3 Underfloor heatng system (plastc ppes)...20 6.4 Gas supply connecton...20 6.4.1 Gas connecton wth natural gas...21 6.5 Hot water supply...22 6.5.1 Domestc Water qualty...22 6.5.2 Domestc water treatment Accessory...22 6.5.3 DHW Expanson Tank...23 6.5.4 Installng a Thermostatc Mxng Valve...23 6.5.5 Installng a valve kt...24 6.5.6 Pressure relef Valve...24 6.5.7 Programmng domestc hot water preheat...24 6.6 Condensate dran ppe...25 6.7 Vent system and ar supply system...26 6.7.1 Intake / Exhaust Gudelnes...26 6.7.2a Examples vent and ar supply systems (parallel)...27 6.7.2b Examples vent and ar supply systems (low prof le PP)...28 6.7.3 Installaton of the vent system...29 6.7.3.1 Converson from parallel to concentrc vent system...30 6.7.3.2 Installng ar f lter...30 6.7.4 Vent/ar ntake termnal poston...31 6.7.5 Drect vent closet and alcove nstallaton...33 6.7.6 Dmensonng of the exhaust and ar ntake duct...34 6.7.7 Combuston ar and vent ppng lengths....35 6.7.8 Calculaton of compensaton factor...36 6.7.9 Room Ar System (ndoor combuston ar)...37 7 Electrcal connectons...40 8 Boler controls...44 8.1 Explanaton of the functon buttons...45 9 Startng up: Fllng and de-aeratng the boler and nstallaton...46 9.1 Requrements of the water system...46 9.2 Fllng the heatng system...47 9.3 Hot water supply...48 10 Adjustments...50 10.1 Alterng adjustments...50 10.2 Actvatng factory settngs (green button functon)...53 11 Isolatng the boler...53 12 Commssonng...54 12.1 Testng for gas leaks...55 12.2 Testng the Ignton Safety shut off devce...55 12.3 Checkng the O 2...56 12.4 Measurng the onzaton current...59 12.5 Installng the casng...57 13 Mantenance...58 13.1 Perodc examnaton of ventng systems and boler...58 13.2 Inspecton...58 13.2.1 Vsual nspecton for general sgns of corroson...59 13.2.2 Measurng the onzaton current...59 13.2.3 Measurng the nlet gas pressure...59 13.2.4 Testng for gas leaks...59 13.2.5 Carryng out a pressure test of the heatng system...59 13.2.6 Checkng ventng systems...59 13.3 Mantenance actvtes...60 13.3.1 Reset servce nterval counter...63 13.4 Lmted warranty...63 14 Parts of the boler...64 15 Blocks and Errors...65 15.1 Error ndcaton (short reference)...65 15.2 Blocks...66 15.3 Errors...67 15.4 Other Errors...72 16 Spare parts...84 17 Parts lst vent system...80 18 Common ventng gudelnes...82 Appendx A - Outoor Reset Sensor Data and Resstance table NTC sensors...83 3
1 Safety and general nstructons Please observe these nstructons n the nterest of your own safety. 1.1 Desgnated use The boler s desgned for heatng water for a central heatng system and generatng domestc hot water. The boler s delvered wth a burner controller (MCBA) prenstalled.the boler can be f tted wth a outdoor reset sensor (ncluded wth the boler) or an On/Off thermostat or relay panel end swtch (f eld suppled accessores). 1.2 Hazard defntons The followng def ned terms are used throughout the documentaton to brng attenton to the presence of hazards of varous rsk levels. Notces gve mportant nformaton concernng the operaton of the product.! DANGER! WARNING! CAUTION DANGER: Indcates the presence of hazards that wll cause severe personal njury, death or substantal property damage. WARNING: Indcates the presence of hazards that can cause severe personal njury, death or substantal property damage. CAUTION: Indcates presence of hazards that wll or can cause mnor personal njury or property damage. CAUTION CAUTION: Rsk of electrc shock. Indcates presence of hazards due to electrc shock. : Indcates specal nstructons on nstallaton, operaton or mantenance that are mportant but not related to personal njury or property damage. 4 1.3 Symbol defntons The followng (safety) symbols may be encountered n these nstallaton nstructons and on the unt: Ths symbol ndcates that the unt must be stored away from freezng condtons. Ths symbol ndcates that the packagng and/or contents can be damaged as a result of nsuffcent care taken durng transport. Ths symbol ndcates that, whle stll n ts packagng, the unt must be protected from weather condtons durng transport and storage.
1.4 The followng nstructons must be followed - The boler must only be used for ts desgnated purpose, as descrbed n the Installaton Instructons. - Each unt s f tted wth a data plate. Consult the detals on ths plate to verfy whether the boler s complant wth ts ntended locaton, e.g.: gas type, power source and ventng classf caton. - Only use the boler wth the accessores and spare parts lsted. - Other accessores and consumables may only be used f they are specf cally desgned for the ntended applcaton and do not affect the system performance and the safety requrements. - Mantenance and repars must be performed by lcensed professonals. - Gas utlty/suppler may requre reportng and/or approval of condensng gas boler nstallatons. - You are only allowed to operate the condensng gas boler wth the vent system that has been specf cally desgned and approved for ths type of boler. - Local codes governng the vent system and condensate water dsposal must be followed. You must also respect: - The local buldng codes stpulatng the nstallaton rules. - The local buldng codes concernng the ar ntake and outlet systems and the chmney connecton. - The regulatons for the power supply connecton. - The techncal rules establshed by the gas utlty company concernng the connecton to the local gas mans. - The nstructons and standards concernng the safety equpment for the water/ space heatng system. - The Installaton Instructons for buldng heatng systems. - The boler must be located n an area where leakage of the boler or connectons wll not result n damage to the area adjacent to the boler or to lower fl oors of the structure. When such locatons cannot be avoded, t s recommended that a sutable dran pan be nstalled under the boler. - The boler must be nstalled n such way that the all components are protected from water (drppng, sprayng, ran etc.) durng boler operaton and servce. - The boler must not be nstalled on or aganst carpetng. - Do not restrct or seal any ar ntake or outlet openngs. - If you f nd any defects, you must nform the owner of the system of the defect and the assocated hazard n wrtng.! WARNING! DANGER! WARNING! WARNING Falure to properly commsson the boler as descrbed n secton 13 may result n unrelable burner operaton, reduced component lfe, and unsafe boler operaton and may vod the product warranty. DANGER. Gas s flammable and may cause an exploson. Beware f you smell gas: there may be an exploson hazard! If the nformaton n these nstructons s not followed exactly, a f re or exploson may result causng property damage, personal njury or death. - Do not store or use gasolne or other fl ammable vapors and lquds n the vcnty of ths or any other applance. WHAT TO DO IF YOU SMELL GAS - Do NOT try to lght any applance. - Do NOT touch any electrcal swtch. - Do NOT use any phone n your buldng. - Immedately call your gas suppler from a neghbor s phone. Follow the gas suppler s nstructons. - If you cannot reach your gas supller, call the f re department. Should overheatng occur or the gas supply fal to shut off, do not turn off or dsconnect the electrcal supply to the pump. Instead, shut off the gas supply at a locaton external to the applance. 5
Chemcals that are corrosve n nature should not be stored or used near the boler or vent termnaton. 1.5 Boler System Water Requrements Unsutable heatng system water can cause the formaton of scale or sludge, whch affects system effcency. It can also cause corroson and reduce lfe of the heat exchanger. You must follow Rnna gudelnes for boler water qualty. Thoroughly fl ush the system pror to f llng. Follow the Rnna cleanng nstructons. Never use water that has been treated by a reverse osmoss, deonzed, or dstlled water to soften the water to f ll the heatng system. Do not use nhbtors or other addtves unless approved by Rnna for that purpose. When freeze protecton of the heatng system s desred, only use Rnna-approved antfreezes. The allowed maxmum concentraton s 50%. When usng oxygen-permeable ppes, e. g. for under fl oor heatng systems, you must separate the system from the boler usng plate heat exchangers. Valve off boler whle flushng system, do not ntroduce any system cleaner nto the boler loop. Flush system thoroughly to remove all system cleaner before fllng boler. Approved antfreeze: Rhomar RhoGard Mutl-Metal (AL safe) Sentnel X500 (max. concentraton 50%) Noble Noburst AL Fernox Alph 11 Approved system cleaner: Noble Noburst Hydronc System Cleaner Rhomar Hydro-Solv 9100 Fernox F3 Cleaner Sentnel X400 The system cleaners from NoBurst, Rhomar, and Fernox are not to be used n the boler. The boler must be closed off (valved off) from the rest of the system or not connected whle the cleaners are n the system. The system should then be draned and then thoroughly flushed wth clean water to remove all the system cleaner. Approved nhbtors: Rhomar Pro-tek 922 Noble Noburst AL nhbtor Sentnel X100 See Chapter 6 and 9 of ths manual for addtonal nformaton. If problems occur when usng potable water wth a chlorde content hgher than 150 mg/l, no recourse can be made to the terms of the lmted warranty. 6 1.6 Tools, materals and addtonal equpment For the nstallaton and mantenance of the boler you wll need: Standard tools for space heatng, gas and water f ttng Dgtal manometer, capable of readng both postve and negatve pressure Combuston analyzer (ntended for use wth condensng bolers) Dgtal multmeter capable of readng mcro-amps ph dgtal meter or test strps Metrc Allen wrenches Metrc socket wrenches In addton, a handtruck wth a fastenng belt s useful. For mantenance of the boler you wll need, apart from standard tools for space heatng, gas and water f ttngs the followng tems: - Boler toolkt
1.7 Relevant Installaton, Servce and User manuals Approved vent system User manual 1.8 Dsposal Dspose of the boler packagng n an envronmentally sound manner. Dspose of components of the heatng system (e.g. boler or control devce), that must be replaced n an envronmentally responsble manner. 2 Regulatons and gudelnes The nstallaton must comply wth the requrements of the authorty havng jursdcton or, n the absence of such requrements, wth the latest edton of the Natonal Fuel Gas Code, ANSI Z223.1/NFPA 54. Where requred by the authorty havng jursdcton, the nstallaton must comply wth the Standard for Controls and Safety Devces for Automatcally Fred Bolers, ANSI/ ASME CSD-1. Install CO detectors per local regulatons. Boler requres an nspecton every 2 years and mantenance every 4 years or 8000 hours. See mantenance secton chapter 13. Operatng Lmts of the boler: Max. boler set pont temperature: 176 F (80.0 C) Max. operatng pressure: 45 ps (3 bar) Max. Allowable Workng Temperature ASME: 200 F (93 C) Max. Allowable Workng Pressure ASME: 45 ps (3 bar) The hot water dstrbuton system must comply wth all applcable codes and regulatons. When replacng an exstng boler, t s mportant to check the condton of the entre hot water dstrbuton system to ensure safe operaton. FOR INSTALLATIONS IN THE COMMONWEALTH OF MASSACHUSETTS BEFORE INSTALLATION Ths drect-vent applance must be nstalled by a lcensed professonal. If you are not properly traned, you must not nstall ths unt. IMPORTANT: In the State of Massachusetts (248 CMR 4.00 & 5.00) For all sde wall horzontally vented gas fueled equpment nstalled n every dwellng, buldng or structure used n whole or n part for resdental purposes, ncludng those owned or operated by the Commonwealth and where the sde wall exhaust vent termnaton s less than seven (7) feet above f nshed grade n the area of the ventng, ncludng but not lmted to decks and porches, the followng requrements shall be satsf ed: 1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the tme of nstallaton of the sde wall horzontal vented gas fueled equpment, the nstallng plumber or gasf tter shall observe that a hard wred carbon monoxde detector wth an alarm and battery back-up s nstalled on the fl oor level where the gas equpment s to be nstalled. In addton, the nstallng plumber or gasf tter shall observe that a battery operated or hard wred carbon monoxde detector wth an alarm s nstalled on each addtonal level of the dwellng, buldng or structure served by the sde wall horzontal vented gas fueled equpment. It shall be the responsblty of the property owner to secure the servces of qualf ed lcensed professonals for the nstallaton of hard wred carbon monoxde detectors. 7
a. In the event that the sde wall horzontally vented gas fueled equpment s nstalled n a crawl space or an attc, the hard wred carbon monoxde detector wth alarm and battery back-up may be nstalled on the next adjacent fl oor level. b. In the event that the requrements of ths subdvson can not be met at the tme of completon of nstallaton, the owner shall have a perod of thrty (30} days to comply wth the above requrements; provded, however, that durng sad thrty (30} day perod, a battery operated carbon monoxde detector wth an alarm shall be nstalled. 2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxde detector as requred n accordance wth the above provsons shall comply wth NFPA 720 and be ANSI/UL 2034 lsted and IAS certf ed. 3 Descrpton of the boler The Rnna E-Seres Comb boler s a modulatng condensng central heatng boler, wth an ntegrated DHW capablty. Condensng Retreves heat as much as possble from the fl ue gasses. Water condenses on the heat exchanger. Modulatng Stepless hgher or lower burnng accordng to the heat demand. The boler s provded wth a compact stanless steel heat exchanger wth smooth tubes. The boler burns gas to supply heat. The heat s transferred n the heat exchanger to the water n the central heatng system. By coolng down the exhaust gases condensate s formed. Ths results n hgh eff cency. The condensate, whch has no effect on the heat exchanger and the functon of the boler, s draned through a condensate collector trap. The boler s provded wth an ntellgent control system (CMS Control Management System). The boler antcpates the heat demand of the central heatng system or the domestc hot water system. When an outdoor sensor s connected to the boler t wll operate weather dependantly usng outdoor reset. Ths means that the boler control measures the outsde temperature and supply temperature. Wth ths data the boler calculates the optmal supply temperature for the nstallaton. Outdoor reset lowers the bolers heatng supply temperature when the weather s warmer, matchng the heat loss of the buldng and maxmzng effcency. 8 Explanaton of the applance type: Rnna E110CRN E = Type 110 = Nomnal load n (x1000) BTU C = C = Comb N = Natural Gas (P = Propane Gas) Dfferent bolertypes: Comb boler wth ntegrated DHW capablty E50CRN E75CRN E75CRP E110CRN E110CRP
4 Packagng and transportaton 4.1 Scope of delvery The boler s suppled ready for use. Please check f the packagng s ntact. Check f all the tems lsted are ncluded n the delvery. The supply kt contents:! CAUTION 4.2 Transportaton Descrpton Amount E50CRN E75CRN E75CRP E110CRN E110CRP Part No. Fttng Kt complete: 804000088 804000046 804000047 Boler wth: Outdoor reset sensor 1 1 1 22mm compresson f ttng rng 4 4 4 Nut W1.1/8x1/14 22 Compresson f ttng 2 2 2 Adapter f ttng 22mm x 1"NPT ext. 2 2 2 Screw 4,8X16mm 4 4 4 Lne voltage nput connector 3 pole grey 1 1 1 Cap de-aerator 1 1 1 Water lock 1/2"NPT ext.x1/4"npt nt. 1 1 1 Mano-/thermometer 1/4"NPT 64 1 1 1 Safety valve 4 bar 3/4"NPT ext. 1 1 1 Flow restrctor FG 3.2 GPM brown 1 1 Flow restrctor FG 4.6 GPM green 1 15mm compresson f ttng rng 4 4 4 Adapter f ttng 15mm x 3/4"NPT ext. 2 2 2 Nut 15mm compresson f ttng 2 2 2 Concentrc fl ue adapter Ø80/125mm 1 Plug fl ue gas 2 Gasket ar supply Ø120 1 Cover ar supply Ø80 1 Gasket vent system/ar supply 1 Feed through + plug fl ue gas 1 1 Flue adapter 3" pps UL appr. 1 1 Ar supply adapter 3" pps UL appr. 1 1 Lp-rng fl ue ppe ø80 1 1 Wall mountng bracket HEX1/2S 1 1 1 Template 1 1 1 Installaton & Servce Instructons 1 1 1 User nformaton manual 1 1 1 Warranty document 1 1 1 ICSL book 1 1 1 The boler may be damaged when not secured properly. - Only transport the boler usng approprate transportaton equpment, such as a handtruck wth a fastenng belt or specal equpment for maneuverng steps. - When transportng the boler must be secured on the transportaton equpment to prevent t from fallng off. - Protect all parts aganst mpacts f they are to be transported. - Follow the transportaton markngs on the packagng. Packaged bolers must always be lfted and carred by two people, or you must use a handtruck or specal equpment for transport. 9
5 Installaton 5.1 Requrements for nstallaton locaton! DANGER - Ths boler s ntended for ndoor nstallatons only. - The room where the boler wll be placed must always be free from freezng condtons. - Do not store or use gasolne or other flammable vapors and lquds n the vcnty of ths or any other applance. - Never use or store any chlornated detergents or halogenated hydrocarbons (e.g. n spraycans, solvents and detergents, pants, adhesves) n proxmty of the boler. - The boler must be nstalled n such a way that t s protected from water (drppng, sprayng, ran, etc.) durng boler operaton and servce (crculator replacement, condensate trap, control replacement, etc.) 10
5.2 Mountng the boler - Remove the packagng materals. - Lay the boler on ts back durng unpackng. Remove the cover from the boler. Ths part may be left off durng nstallaton. It must be placed on the boler and fxed wth the screw behnd the door and n the 4 quck releases before the boler s started up. Turn the boler to ts sde and remove the wall bracket from the back of the boler by removng the 2 screws. The boler can be mounted practcally to any wall wth the suspenson bracket and the enclosed mountng equpment. - The wall must be fl at and of suffcent strength n order to be able to securely hold and support the boler weght wth ts water content. - Take note of the necessary space around the boler for nstallaton of ventng system, ppework and servcng. See drawng on pages 12 and 13. - Drll the necessary holes usng the template - Install the mountng bracket to the wall - The boler must be nstalled usng the ncluded mountng hardware.! CAUTION! WARNING Lftng and carryng precautons: To avod personal njury please follow these recommendatons: - Always lft the boler wth 2 people or use specal equpment. - When lftng the boler, bend the knees, and keep the back straght and feet apart. - Do not lft and twst at the same tme. - Lft and carry the boler close to the body. - Wear protectve clothng and gloves to protect from any sharp edges. Lft the boler only by the boler's rear wall. Do not lft usng the ppes on the bottom of the boler or the vent connectons on the top of the boler. 11
5.3 Dmensons E50CRN C F E D V E75CRN E75CRP E110CRN E110CRP F C E D V A A f w g k r c P Q RS f w g k r c P Q RS T U H O G N J K B T T H O G N J K B dmensons f gure 1 12 dmensons table 1
wall 5.3.1 Clearances from boler celng Mn. 10" / 250mm 15.7" 400 24" 600 2" 50 2" 50 servce clearances to the boler f gure 4 Mnmum requred clearances to combustbles Mnmum requred clearances to non-combustbles Requred servce clearances All types All types All types nch / mm nch / mm nch / mm Top of boler 0" 0" 10" / 250 Back of boler 0" 0" 0" Front of boler 1" / 25 1" / 25 24" / 600 Left sde of boler 0" 0" 2" / 50 Rght sde of boler 0" 0" 2" / 50 Floor / Ground to bottom of boler 0" 0" clearances to the boler table 3 For closet nstallaton: clearance s 1 / 25mm from the front. 10" / 250 30" / 762 s recommended Vent 0" 0" 0" 13
5.4 Techncal specfcatons Techncal specf catons Table 4 14
6 Connectng the boler The boler has the followng ppe connecton; - The central heatng crcut ppes. - The gas supply ppe. Provded wth a 3/4" male thread. See further chapter 6.4; - Cold and hot water ppes for domestc hot water (DHW). These consst of 3/4" MNPT x 15mm compresson adapter f ttngs. See further chapter 6.5; - The condensaton dran ppe. It conssts of an oval 7/8" (22 mm) plastc ppe. The dran ppe can be connected to ths by means of an open connecton. If the open connecton s f tted n a dfferent locaton, then the ppe can be lengthened by means of a 1 1/4" (32 mm) PVC sleeve. See further chapter 6.6; - The vent system and ar supply system. It conssts of a twn ppe connecton that wll accept 80mm fl ue and ntake ar or wth the use of the ncluded adapters 3 PVC/CPVC fl ue and ntake. See further chapter 6.7. The ppes to be connected to the boler must be cleaned before connectng n order to prevent drt from enterng and damagng the boler. Compresson fttngs. Parts: 1. Nut 2. Ferrule 3. Fttng Fttng nstructons: 1 2 Clean ppe ends thoroughly. The outsde surface has to be smooth before fttng. 1. Push the complete fttng over the ppe as far as possble. Ferrule should be over the ppe completely. 3 2. Turn the nut handtght clockwse. 3. Use 2 wrenches, one to hold the fttng on ts place, the other for tghten the nut clockwse n 3/4 turn. 15
6.1 Central heatng system Connect the central heatng system accordng to ts nstructons. When removng the plastc sealng caps from the ppes, water may come out of the boler due to lve fre testng durng manufacturng. The boler, when used n connecton wth a refrgeraton system, must be nstalled so the chlled medum s pped n parallel wth the boler wth approprate valves to prevent the chlled medum from enterng the boler. The boler ppng system of a hot water boler connected to heatng cols located n ar handlng unts where they may be exposed to refrgerated ar crculaton must be equpped wth flow control valves or other automatc means to prevent gravty crculaton of the boler water durng the coolng cycle. Some nstallatons wth multple zone valves may requre a dfferental bypass, ths wll prevent excessvely hgh flow rates through a sngle zone when the other zone valves are closed. 16 Boler basc ppng f g. 5
- Boler system fl ushng (Not Boler heat exchanger) When replacng an exstng boler the heatng system shall be flushed wth an approved system cleaner (refer to system cleaner lst) before the new boler s added to the system. If the old boler has already been removed a bypass must be pped n when the new boler s nstalled n order to facltate the flushng of the system. The boler must be valved off from the system, whle the system s flushed. No system cleaner should ever enter the boler heat exchanger due to ts caustc nature whch could damage the heat exchanger. 1. Close the shutoff valves on both the supply and return connectons on the plumbng kt (V1 and V2). 2. Open the bypass valve (V4). 3. Connect pump outlet hose (H1) to the purge staton (BD1) and connect H2 to the nlet of the pump and place the other end n the pal. 4. Connect dran hose (H3) to the return sde purge staton (BD2). 5. Pour the system cleaner nto a pal and follow the system cleaner nstructons on crculaton tme and volume to be added to the system. 6. Close the valve (V3) 7. Operate the pump (P1) and crculate the cleaner through the system for requred tme as establshed by the cleaner manufacturer. 8. Once the tme requred by the system cleaner manufacturer has been met place the hose (H3) n a dran. 9. Close the purge staton (BD1) 10. Open the auto feed on the system (F1) and allow water to rnse the system for whchever s greater; 10 mnutes or the requred rnse tme by the system cleaner manufacturer. Boler system flushng f g. 7 17
11. If the nstallaton s a zone system be sure to purge out each zone ndvdually 12. Close the auto feed on the system (F1) 13. Close the return sde purge staton (BD2) and dsconnect the hose (H3). 14. Open the man valve on the system return (V3) 15. Close the bypass valve below the boler (V4). 16. Open shutoff valves on both the supply and return connectons below the boler (V1 and V2). 17. Clean out the drt trap 18. Test the ph of the water that wll be used for f llng the system 19. Test the water hardness of the water that wll be used for f llng the system 20. Use the proper water treatment to ensure the ph and water hardness are wthn the Rnna boler water qualty gudelnes 21. The boler and system may now be f lled. The followng s a lst of approved system cleaners, nhbtors, and antfreeze. Approved antfreeze: Rhomar RhoGard Mutl-Metal (AL safe) Sentnel X500 Noble Noburst AL Fernox Alph 11 Approved system cleaner: Noble Noburst Hydronc System Cleaner Rhomar Hydro-Solv 9100 Fernox F3 Cleaner Sentnel X400 The system cleaners from NoBurst, Rhomar, and Fernox are NOT to be used n the boler. The boler must be closed off (valved off) from the rest of the system or not connected whle the cleaners are n the system. The system should then be draned and then thoroughly flushed wth clean water to remove all the system cleaner. Approved nhbtors: Rhomar Pro-tek 922 Noble Noburst AL nhbtor Sentnel X100 - Connect the expanson tank to the system. See chapter 6.2. - Connect the ppes so that they are free from stran. 18 Water f lter f gure 8 The boler has a self-adjustng and self-protectng control system for the load and the pump capacty. By ths means, the temperature dfference between the supply and return water s checked and controlled. If the nstallaton resstance s over the stated value; the load wll be adjusted untl an acceptable temperature dfference between supply and return water has been obtaned. If, after ths, the temperature dfference s stll not acceptable then the boler wll swtch off and wat untl an acceptable temperature has arsen. If an unacceptable temperature s detected, the control wll repeatedly try to acheve water fl ow over the boler. If not the boler wll swtch off. As standard the boler s provded wth a water f lter n the return ppe of the boler, so that debrs from the central heatng water s prevented from affectng the boler.
To protect the entre heatng system we recommend nstallng a drt partcle trap n the return crcut. When the boler s nstalled to an exstng heatng system ths trap s requred. Use of a Y straner s not permtted as substtute for a drt trap. - Poston H3 (f gure 7) s a garden hose thread boler dran, that can be used to dran the boler or add water treatment addtves to the system, such as nhbtors or glycol. - For nformaton on locatng the expanson tank and system f ll, please see the Rnna Boler Applcatons Manual. The boler s desgned to be used on pressurzed heatng systems only (closed loop). If the boler s to be nstalled n a system that utlzes zone pumps and not zone valves a low loss header plumbng kt should also be nstalled (part number: 804000061). If the pressure drop n the loop/system s greater than the avalable head pressure from the boler pump a low loss header plumbng kt should be used (part number: 804000061). 14 32.3 12 27.7 PSI 10 8 6 4 E110CR E50CR/E75CR 23.0 18.5 13.8 9.2 Feet of head 2 4.6 0 0 0 2 4 6 8 10 12 Q [gallons/mn] UPER 20-58 (max.) UPER 20-78 (max.) Pressure drop E75C/E50C Pressure drop E110C pump ndex lnes graph 1 pump capacty table 5 19
6.1.1 Safety valve An ASME 30 ps pressure relef valve s ncluded wth the boler and must be ftted before any shut off valve n the system. 6.1.2 Low water cut off The Rnna E boler has a factory nstalled pressure sensor type Low Water Cut Off (LWCO). Check your local codes to see f a Low Water Cut Off s requred (LWCO) and f ths devce conforms to local code. The boler's nternal low water cut off s not servceable or adjustable. 6.2 Boler expanson tank Choose an expanson tank volume, of whch s geared to the nstallaton s water capacty. The pre-charge pressure depends on the nstallaton heght above the expanson tank. Ft the expanson tank nto the return ppe as close as possble to the boler return connecton. The expanson tank should be sourced locally. Please refer to the expanson tank manufacturer for further nformaton. Fll the expanson tank to a mnmum of 14.5 ps. The boler cannot be used wth an open type expanson tank. 6.3 Underfloor heatng system (plastc ppes) When usng oxygen-permeable tubng, e. g. for underfl oor heatng systems, the system must be separated usng plate heat exchangers. No recourse can be made to the terms of the lmted warranty n the event of falure to observe the regulatons pertanng to plastc underfloor heatng ppes. 6.4 Gas supply connecton 20! DANGER! WARNING! DANGER Only work on gas lnes f you are lcensed for such work. If these nstructons are not followed exactly, a fre or exploson may result causng property damage, personal njury or death. Rnna wall mounted E bolers are bult to run on ther specfed gas type ether Natural Gas or Lqud Propane (not for E50CRN). The gas type the boler s sutable for s ndcated on the packagng and on the boler by a blue label wth Natural Gas and on the dentfcaton plate on the boler. Frst check the dentfcaton plate on the boler for the sutable gas type. Do not use the boler for another type of gas than ndcated on the dentfcaton plate of the boler. Ths wll cause mproper functonng and can damage the boler.
Natural gas: resume wth chapter 6.4.1 When propane gas s desred, the boler can be converted to propane gas by means of a converson kt. Rnna Part number: E50CR: 803000014 E75CR: 804000015 E110CR: 804000016 Propane gas: resume wth chapter 6.4.2 When natural gas s desred, the boler (not for E50CRN) can be converted to natural gas by means of a converson kt. Rnna Part number: E75CR: 804000023 E110CR: 804000024 6.4.1 Gas connecton wth natural gas The gas supply connecton must comply wth local regulatons or, f such regulatons do not exst, wth the Natonal Fuel Gas Code, ANSI Z 223.1. Ppe szng for natural gas Contact gas suppler to sze the gas supply lne and meter. Gas ppng A sedment trap must be nstalled upstream of the boler. The boler gas ppe s equpped wth external 3/4" M-NPT thread. Use approprate sealng. The connecton to the boler must nclude a sutable method of dsconnecton and a gas control valve must be nstalled adjacent to the boler for solaton purposes. The nomnal nlet gas pressure measured at the boler should be 7" W.C. (18 mbar) for Natural gas (Gas A). Maxmum pressure wth no fl ow (lockup) or wth the boler runnng s 10.5 nches W.C. Mnmum pressure wth the gas fl owng (verfy durng boler startup) s 3.0 nches W.C. Sedment trap f gure 10 The gas ppe must be properly supported and connected to the boler. Make sure that the gas ppe system does not contan drt, partcularly wth new ppes.! DANGER Always check the safety of the gas ppe system by means of a bubble test usng leak-search spray. The boler must be solated from the gas supply ppng system by closng ts ndvdual manual shutoff valve durng any pressure testng of the gas supply ppng system at test pressures equal to or greater than 1/2 PSI (3.5 kpa). 21
6.4.2 Gas connecton wth propane gas (not for E50CRN) The gas supply connecton must comply wth local regulatons or, f such regulatons do not exst, wth the Natonal Fuel Gas Code, ANSI Z 223.1. Ppe szng for propane gas - Contact gas suppler to sze ppes, tanks, and gas pressure regulator. Propane Supply Pressure Requrements - Adjust propane supply regulator provded by the gas suppler for 14 nches W.C. maxmum pressure. - Pressure requred at gas valve nlet pressure port: - Maxmum 13.5 nches W.C. wth no fl ow (lockup) or wth boler runnng. - Mnmum 8 nches W.C. wth gas fl owng (verfy durng boler startup).! DANGER Ensure that the hgh gas pressure regulator s nstalled at least 6 to 10 feet upstream of the boler. Gas ppng - A sedment trap must be provded upstream of the gas shut off valve. The boler ppe s equpped wth external 3/4" M-NPT thread. Use approprate sealng. The connecton to the boler must nclude a sutable method of dsconnecton. A gas shut off valve must be nstalled adjacent to the boler for solaton purposes. The nomnal nlet workng gas pressure measured at the boler should be 11 nch W.C. for Propane gas. Gas shut off valve onto boler f gure 10a The gas ppe must be properly supported and connected to the boler. Make sure that the gas ppe system does not contan drt, partcularly wth new ppes.! DANGER Always check the safety of the gas ppe system by means of a bubble test usng leak-search spray. The boler must be solated from the gas supply ppng system by closng ts ndvdual manual shutoff valve durng any pressure testng of the gas supply ppng system at test pressures equal to or greater than 1/2 PSI (3.5 kpa). 22
6.5 Hot water supply Connecton of the drnkng water nstallaton should be performed accordng to the natonal secondary drnkng water regulatons.! DANGER Do NOT use toxc chemcals, such as those used for boler treatment n potable water heatng systems used for space heatng. The santary water ppes can be connected to the nstallaton by use of adapter f ttngs. The cold water nlet on the Comb bolers must be equpped wth the followng components (counted n the water fl ow drecton): Flow restrctor (suppled), pressure relef valve, Expanson vessel 87 PSI / 6bar (potable water, blue). The 3/4" NPT adapter f ttng wth fl ow reducng valve must be f tted n the cold water connecton. Identf caton colors fl ow restrctor: E50CR: Brown E75CR: Brown E110CR: Green A fl ow restrctor s suppled wth the boler n a 3/4"NPT adapter f ttng. The quantty of water s vrtually unaffected by the water pressure. When there s a water pressure lower than 22PSI / 1.5 bar t s advsable to remove the nsde mechansm of the flow restrctor. 6.5.1 Domestc Water qualty Approprate steps must be taken to ensure the brazed plate heat exchanger does not become plugged by scale caused by hard water or sedment. If the plate heat exchanger becomes plugged by ether scalng from hard water or sedment t s not the responsblty of Rnna. Maxmum Level Total Hardness Up to 200 mg / L Alumnum * Up to 0.2 mg / L Chlordes * Up to 250 mg / L Copper * Up to 1.0 mg / L Iron * Up to 0.3 mg / L Manganese * Up to 0.05 mg / L ph * 6.5 to 8.5 TDS (Total Dssolved Solds) * Up to 500 mg / L Znc * Up to 5 mg / L * Source: Part 143 Natonal Secondary Drnkng Water Regulatons If problems occur when usng santary water outsde of the above stated requrements, no recourse can be made to the terms of the lmted warranty. 6.5.2 Domestc water treatment Accessory Rnna offers a domestc water treatment devce that can help reduce scale buld up. Ths devce can be nstalled on the ncomng cold water lne for any comb boler. For addtonal nformaton on contact Rnna. 23
6.5.3 DHW Expanson Tank A domestc water expanson tank could be requred by local code. Check local code to determne f t s requred. If a comb boler s nstalled n a closed water supply system, such as one havng a backfl ow preventer n the cold water supply lne, means shall be provded to control thermal expanson. Contact the water suppler or local plumbng nspector on how to control thermal expanson. 6.5.4 Installng a Thermostatc Mxng Valve A thermostatc mxng valve shall be nstalled on all E comb bolers on the domestc hot water sde to prevent scaldng. Ths valve wll regulate the water temperature leavng the brazed plate heat exchanger. See the f gure 11 for the suggested ppng. 24 DHW ppng wth thermostatc mxng valve f g. 11 DANGER Hot water can be dangerous, especally for nfants or chldren, the elderly, or nfrm. There s hot water scald potental f the thermostat s set too hgh. Water temperatures over 125º F (51º C) can cause severe burns or scaldng resultng n death. Hot water can cause frst degree burns wth exposure for as lttle as: 3 seconds at 140º F (60º C) 20 seconds at 130º F (54º C) 8 mnutes at 120º F (48º C) Test the temperature of the water before placng a chld n the bath or shower. Do not leave a chld or an nfrm person n the bath unsupervsed.
6.5.5 Installng a valve kt A means to solate the domestc plate heat exchanger for cleanng must be provde at nstallaton. Refer to f gure 10 for proper ppng layout. A Rnna valve kt can be used on domestc water ppes for all comb bolers to allow for cleanng of the plate heat exchanger and nstallaton the domestc hot water pressure relef valve. Rnna recommends the use of a plumbng nstallaton kt when connectng the domestc water lnes to the boler. Use of ths kt wll assst n fl ushng the fl at plate heat exchanger n areas where water qualty ssues exst, as well as mprove overall product servceablty. 6.5.6 Pressure relef Valve - An approved pressure relef valve s requred by Rnna for all water heatng systems. - The relef valve must comply wth the standard for Relef Valves and Automatc Gas Shutoff Devces for Hot Water Supply Systems ANSI Z21.22 and/or the standard Temperature, Pressure, Temperature and Pressure Relef Valves and Vacuum Relef Valves, CAN1-4.4. - The relef valve must be rated up to 150 ps and to at least the maxmum BTU/hr of the applance. - The dscharge from the pressure relef valve should be pped to the ground or nto a dran system to prevent exposure or possble burn hazards to humans or other plant or anmal lfe. Follow local codes. Water dscharged from the relef valve could cause severe burns nstantly, scalds, or death. - The pressure relef valve must be manually operated once a year to check for correct operaton. - The relef valve should be added to the hot water outlet lne accordng to the manufacturer nstructons. DO NOT place any other type valve or shut off devce between the relef valve and the comb boler. - Do not plug the relef valve and do not nstall any reducng f ttngs or other restrctons n the relef lne. The relef lne should allow for complete dranage of the valve and the lne. - If a relef valve dscharges perodcally, ths may be due to thermal expanson n a closed water supply system. Contact the water suppler or local plumbng nspector on how to correct ths stuaton. Do not plug the relef valve. - Rnna does not requre a combnaton temperature and pressure relef valve for ths applance. However local codes may requre a combnaton temperature and pressure relef valve. - If a comb boler s nstalled n a closed water supply system, such as one havng a backfl ow preventer n the cold water supply lne, means shall be provded to control thermal expanson. Contact the water suppler or local plumbng nspector on how to control thermal expanson. 6.5.7 Programmng domestc hot water preheat When plate warmng s selected the brazed plate heat exchanger s kept warm and ths reduces the wat tme for domestc hot water by approxmately 1 mnute. When ths settng s turned off the wat tme for DHW s ncreased by approxmately 1 mnute. E50CRN Only: Plate warmng can only be deactvated when the flow swtch accessory (part number 803000015) has been nstalled. If no flow swtch s nstalled and parameter 36 s altered from the factory settng no DHW producton wll be possble. 25
If plate warmng s selected consder the followng. Ths product s a domestc hot water prorty boler; therefore contnuous flow n the DHW system (perhaps due to a leaky fxture) may cause the boler to reman n DHW mode thus preventng the heatng system from adequately functonng. In the event the DHW system has a leak, ths feature should be turned off untl ths problem can be corrected. Ths selecton can be done wth the f rst dgt of Parameter 36. Domestc hot water preheat ON = 1x (Factory settng) Domestc hot water preheat OFF = 2x See chapter 10 how to change a parameter. The domestc hot water preheat settng s desgned to ncrease the comfort of the home owner and reduce water consumpton by reducng the wat tme for hot water at the f xture. Ths comfort settng wll create a slght ncrease n the gas usage of the boler, but ths wll be offset by the reducton n wasted water at the f xture. 6.6 Condensate dran ppe Ths boler produces condensate. Condensate must be draned otherwse the boler wll not functon and can cause product or property damage. The condensaton dran ppe should be connected to a dran n the buldng by means of an open connecton. By ths means the possblty of dran gases effectng the boler s prevented. The dran connecton should have a mnmum dameter of 1.25" / 32mm. Install the condensaton dran ppe accordng to applcable local code. If the condensate outlet of the boler s lower than the publc sewage system a condensate pump must be used. The condensate produced by the boler has a ph value between 3 and 4. Install a neutralzaton unt f requred by local code. It s recommended, but not requred to nstall a condensate neutralzer. Rnna offers a condensate neutralzer desgned to work wth all boler models. The condensate neutralzer kt comes wth all the necessary f ttngs and mountng materal. PVC ppe must be suppled by the nstallaton contractor. Rnna part number: 804000074 Do not dran the condensaton water to the external ran gutter because of the danger of freezng and blockage of the dran. Before puttng the boler nto operaton fll the condensate trap wth 1.27 cups / 300 ml of water. If the boler wll be nstalled n a hgh temperature nstallaton such as baseboard wth a supply temperature of 160 F or above, fll the condensate trap wth mneral ol nstead of water. Use materals approved by the authorty havng jursdcton. In absence of such authorty, PVC and CPVC ppe must comply wth ASTM D1785, F441 or D2665. Cement and prmer must comply wth ASTM D2564 or F493. Perodc cleanng of the condensate dsposal system must be carred out. See the Rnna Boler Applcaton Manual for further nformaton and for a ppng dagram for the condensate. 26
6.7 Vent system and ar supply system Provsons for combuston and ventlaton ar must be made n accordance wth secton, Ar for Combuston and Ventlaton of the Natonal Flue Gas Code, ANSI Z223.1, or applcable provsons of the local buldng codes. - Do not store chemcals near the boler or n rooms where the ar s beng suppled to the boler. See the lst on page 10. - Do not allow the fl ue gases of other applances to enter the boler. - Keep cabnet free of mosture In the event that the system has actuated to shut off the man burner gas, do not attempt to place the boler n operaton. Contact a qualfed servce agency. 6.7.1 Intake / Exhaust Gudelnes Refer to the specf c nstructons on your vent product for addtonal nstallaton requrements. For drect vent bolers, proper reassembly and resealng of the vent-ar ntake system s requred. You must use vent components that are certf ed and lsted wth ths model. Do not combne vent components from dfferent manufacturers. Ventng should be as drect as possble wth a mnmum number of ppe f ttngs. Avod dps or sags n horzontal vent runs by nstallng supports per the vent manufacturer s nstructons. Support horzontal vent runs every four feet and all vertcal vent runs every sx feet or n accordance wth local codes. Vent dameter may be reduced to 2" (see table 9). The boler s unsutable to nstall on a common vent nstallaton, see also chapter 18. Do not connect the ventng system wth an exstng vent or chmney. Do not common vent wth the vent ppe of any other boler or applance. Vent connectons must be f rmly pressed together so that the gaskets form an ar tght seal. Refer to the nstructons of the vent system manufacturer for component assembly nstructons. If the vent system s to be enclosed, t s suggested that the desgn of the enclosure shall permt nspecton of the vent system. The desgn of such enclosure shall be deemed acceptable by the nstaller or the local nspector. If t becomes necessary to access an enclosed vent system for servce or repars, Rnna s not responsble for any costs or dffcultes n accessng the vent system. The lmted warranty does not cover obtanng access to an enclosed vent system. The nstructons for the nstallatons of the ventng system shall specfy that the horzontal portons of the ventng system shall be supported to prevent saggng; the methods of and ntervals for support shall be specfed. These nstructons shall also specfy that the ventng system: For category I, II and IV bolers, have horzontal runs slopng upwards not less than 1/4" per foot (21mm/m) from the boler to the vent termnal; For category III bolers, slope shall be as specfed n the boler manufacturer's nstructons; For category II and IV bolers, be nstalled so as to prevent accumulaton of condensate; and For category II and IV bolers, where necessary, have means provded for dranage of condensate. 27
6.7.2a Examples vent and ar supply systems (parallel) Wall thckness for vent termnaton nstallaton: Mnmum: 100mm / 4 Maxmum: 508mm / 20 Examples sealed combustons Horzontal wth concentrc termnaton fgure 12A Horzontal wth parallel termnaton f gure 12B 10" MINIMUM INSIDE EDGE T`O INSIDE EDGE 12" OVER MAXIMUM SNOW LEVEL OR 24" WHICHEVER IS GREATER Vertcal vent and horzontal ar ntake f gure 12C Vertcal wth concentrc termnaton f gure 12D Vertcal wth parallel termnaton f gure 12E 28
6.7.2b Examples vent and ar supply systems (concentrc) Wall thckness for vent termnaton nstallaton: Mnmum: 100mm / 4 Maxmum: 508mm / 20 Examples wall termnals Short termnaton wth wall termnal f gure 13A Termnaton wth wall termnal on hgher level f gure 13B Examples roof termnals Short termnaton wth roof termnal f gure 13C Termnaton wth roof termnal and bends f gure 13D 29
6.7.2 c Examples vent and ar supply systems (PP Twn Ppe and Flex) Vertcal twn ppe termnaton fgure 13F Horzontal twn ppe elbow termnaton f gure 13G 30 Horzontal twn ppe concentrc termnaton fgure 13H Horzontal twn ppe elbow termnaton below grade fgure 13J
Flex through chmney termnaton fgure 13K Flex through B vent as a chase termnaton fgure 13L 31
6.7.2 d Boler Exhaust Vent Hanger and Support (Rgd Ppes) The purpose of ths secton s to provde more nformaton about Rnna s requrement that the vent system nstalled wth the Rnna boler must be approprately supported. As we state elsewhere n ths manual, "place ppe supports every 4 feet (1219 mm) of horzontal run, begnnng wth the support near the boler to prevent movement n f ttngs and allow boler to be free from any stran or weght on boler or f ttngs." For Horzontal ppes, the f rst support should be placed as close as possble after the f rst elbow. These requred vent supports are crtcal to prevent movement n f ttngs and to allow the boler to be free from any stran or weght assocated wth the nstalled f ttngs and/or vent ppe system. Installaton of the ventng system MUST comply wth the respectve vent manufacturer s nstructons. Addtonally, to ensure structural ntegrty, the nstaller MUST select hangers, supports, and restrants whch are able to wthstand all statc and dynamc loadng condtons whch act upon the vent ppng system and the assocated Rnna boler. Hangers, supports, and restrants shall be 100% corroson proof, UV resstant, and mpact resstant. Exhaust vent ppe MUST be securely fastened to the structure to avod movement. The f rst hanger support MUST be located drectly after the f rst elbow on the f rst horzontal vent secton or as close thereto as possble to ensure no movement. (see example below). Use hangers that wll not score or damage vent ppes and are accepted by local codes. 32 Recommended ppe hanger and support for PVC/CPVC ppes f gure 13M The nformaton provded s an effort to assst you n better understandng the requrements to secure the ventng. Ths document has been compled from generally accepted engneerng prncples and standards from the Amercan Natonal Standards Insttute and other pertnent documents. The specf catons heren are ntended as a gude only and t s the responsblty of the engneer/desgner or nstaller to select approprate support and to use ths gude n conjuncton wth all applcable codes and/or standards.
6.7.3 Installaton of the vent system Consult local and state codes pertanng to specal buldng code and fre department requrements. Adhere to natonal code requrements. Follow the lsted maxmum length of vent systems, whch are boler output dependent. The maxmum permssble lengths are lsted n table 9, chapter 6.7.6. Decde how to nstall the exhaust and ar ntake system. You can choose between: - Parallel system (see chapter 6.7.2a) The parallel connecton s provded standard ntally on the E50CRN. The boler connecton dameter s 2x 3" (80mm). In ths case a separate suppled kt, wth 2 vent adapters 3" should be f tted on top of the boler, to whch the ventng and ar supply system can be f tted, wth or wthout elbow peces. The maxmum permssble ppe length s set out n table 9, chapter 6.7.6. The E75CR and E110CR bolers are provded standard ntally wth a concentrc connecton, but can be converted to a parallel system wth suppled adapters. - Concentrc system (see chapter 6.7.2b) The concentrc connecton s provded standard ntally on the E75CR and E110CR. The boler connecton dameter s concentrc 80/125mm) to whch the concentrc ventng and ar supply system can be f tted, wth or wthout elbow peces. The maxmum permssble ppe length s set out n table 9, chapter 6.7.6. The E50CRN boler s provded standard ntally wth a parallel connecton, but can be converted to a concentrc system wth wth an optonal adapter (Part nr. 808000023). - Room Ar System (ndoor combuston ar) The boler can use room ar for combuston. If ths opton s selected the boler must be provded wth a parallel vent system. A sngle exhaust ppe can then be f tted. It s requred to use a room ar f lter (Part nr. 808000025) when usng ndoor ar for combuston. See chapter 6.7.3.2 for nstallaton. The maxmum permssble ppe length s set out n table 9, chapter 6.7.6. Rnna strongly recommends the use of the room ar flter when a Room Ar System (ndoor combuston ar) s used. When the boler s nstalled n any of the areas lsted n chapter 5.1, "Areas lkely to have contamnants" or any area exposed to the contamnants lsted n chapter 5.1, then sealed combuston s requred. We advse to nstall a vent system out of the ventng system program suppled by Rnna (See chapter 19 Parts lst Vent system). For further nformaton about the avalable components of the ventng and ar supply system we recommend you consult Rnna and the Installaton nstructons and parts lst documentaton. 33
6.7.3.1 Boler converson from parallel to concentrc (E50CRN) 808000023 2 3 4 1 6 5 A Concentrc vent adapter (Part. nr. 808000023) conssts of: 1. Cover ar ntake 2. Gasket 3" 3. Gasket 5" 4. Concentrc adapter 5. Plugs for measurng ponts 6. Gasket 3" A. Push the 2 clps of both 3" connectons slghtly nwards B B. Pull both 3" connectons out of the boler C C. Connect the concentrc vent adapter. - Check f all rubber seals (2, 3, 5 and 6) are postoned on the concentrc vent adapter - Push the concentrc vent adapter n the boler, n the boler exhaust ppe untl 'CLICK' - Press the 3" cover (1) n the connecton at the back untl 'CLICK'.. OK 34 boler converson from parallel to concentrc f gure 14a
6.7.3.2 Boler converson from concentrc to parallel (E75CR/E110CR) A A. 1. Push the 2 clps slghtly outwards B B. 2. Pull the concentrc adaptor out of the boler 3. Press the cover n the connecton at the back from nsde out C C. 4. Push the 3" ar ntake connector nto the connecton at the back of the boler 5. Pull the rubber seal around the bottom of the exhaust connector 6. Push the exhaust connector n the boler, n the boler exhaust ppe untl 'CLICK' 7. Push the rubber plug n open poston n the O 2 measurng openng and close the stop. OK D. Connect the parallel vent system. boler converson from concentrc to parallel f gure 14b 6.7.3.3 Installng ar flter placng ar f lter on ar ntake f gure 14c 1. Pull the 3" connectons out of ar ntake of the boler 2. Push the ar f lter nto the ar ntake on top of the boler. See f gure 14c. The equvalent length of the combuston room ar f lter s 12ft (3.66m). 35
6.7.4 Vent/ar ntake termnal poston Termnals should be postoned as to avod products of combuston enterng openngs nto buldngs or other vents. Mantan 12 of clearance above the hghest antcpated snow level or grade or, whchever s greater. Please refer to your local codes for the snow level n your area. Postons de termnal f gure 15 Ref Descrpton Canadan Installatons - Drect Vent and non Drect Vent US Installatons Drect Vent US Installatons non Drect Vent A B Clearance above grade, veranda, porch, deck, or balcony Clearance to wndow or door that may be opened 12 nches (30 cm) 12 nches (30 cm) 12 nches (30 cm) 6 nches (15 cm) for applances < 10,000 Btuh (3 kw), 12 nches (30 cm) for applances > 10,000 Btuh (3 kw) and < 100,000 Btuh (30 kw), 36 nches (91 cm) for applances > 100,000 Btuh (30 kw) 6 nches (15 cm) for applances < 10,000 Btuh (3 kw), 9 nches (30 cm) for applances > 10,000 Btuh (3 kw) and < 50,000 Btuh (30 kw), 12 nches (91 cm) for applances > 50,000 Btuh (30 kw) 4 feet (1.2 m) below or to sde of openng; 1 foot (300 mm) above openng C Clearance to permanently closed wndow * * * D Vertcal clearance to ventlated soff t, located above the termnal wthn a horzontal dstance of 2 feet (61 cm) from the center lne of the termnal * * * E Clearance to unventlated soff t * * * F Clearance to outsde corner * * * G Clearance to nsde corner * * * 36 H Clearance to each sde of center lne extended above meter/regulator assembly 3 feet (91 cm) wthn a heght 15 feet (4.5 m) above the meter/regulator assembly * * I Clearance to servce regulator vent outlet 36 nches (91 cm) * * J Clearance to nonmechancal ar supply nlet to buldng or the combuston ar nlet to any other applance 6 nches (15 cm) for applances < 10,000 Btuh (3 kw), 9 nches (30 cm) for K L M Clearance to a mechancal ar supply nlet Clearance above paved sdewalk or paved drveway located on publc property Clearance under veranda, porch, deck, or balcony 6 nches (15 cm) for applances < 10,000 Btuh (3 kw), 12 nches (30 cm) for applances > 10,000 Btuh (3 kw) and < 100,000 Btuh (30 kw), 36 nches (91 cm) for applances > 100,000 Btuh (30 kw) applances > 10,000 Btuh (3 kw) and < 50,000 Btuh (30 kw), 12 nches (91 cm) for applances > 50,000 Btuh (30 kw) 6 feet (1.83 m) 3 feet (91 cm) above f wthn 10 feet (3 m) horzontally 4 feet (1.2 m) below or to sde of openng; 1 foot (300 mm) above openng 3 feet (91 cm) above f wthn 10 feet (3 m) horzontally 7 feet (2.13 m) [1] * 7 feet (2.13 m) 12 nches (30 cm) [2] * * [1] A vent shall not termnate drectly above a sdewalk or paved drveway that s located between two sngle famly dwellngs and serves both dwellngs. [2] Permtted only f veranda, porch, deck, or balcony s fully open on a mnmum of two sdes beneath the fl oor. * For clearances not specf ed n ANSI Z223.1/NFPA 54 or CSA B149.1, clearances are n accordance wth local nstallaton codes and the requrements of the gas suppler. clearances of ventng system termnals table 6
Termnals should be postoned as to avod products of combuston enterng openngs nto buldngs or other vents.! CAUTION! CAUTION Mantan 12 of clearance above the hghest antcpated snow level or grade or, whchever s greater. Please refer to your local codes for the snow level n your area. The termnaton shall be at least 4 feet (1,220 mm) dstance from electrc meters, gas meters, regulators and relef equpment. (for room ar applcaton only) Horzontal vent systems should always be nstalled slopng towards the boler (mn. 21 mm/m, 1/4 / feet), n order to avod condensate retanng n the vent system. Wth the condensate runnng back to the boler the rsk of ce formng at the termnal s reduced. The whole route of the exhaust vent system must be nstalled upwards, never downwards, completely nor partly. Place ppe supports every 4 feet (1219 mm) of horzontal run, begnnng wth the support near the boler to prevent movement n fttngs and allow boler to be free from any stran or weght on boler or fttngs. The termnal should be located where dspersal of combuston products s not mpeded and wth due regard for the damage or dscoloraton that mght occur to buldng products or vegetaton n the vcnty (see fg 15 and 16). In certan weather condtons condensaton may also accumulate on the outsde of the ar nlet ppe. Such condtons must be consdered and where necessary nsulaton of the nlet ppe may be requred. In cold and/or humd weather water vapor may condense on leavng the vent termnal. The effect of such water condensaton must be consdered. The termnal must be located n a place not lkely to cause a nusance. Cellular or Foam core PVC, CPVC and Radel s not permtted for use wth the boler. The applcaton of any type of nsulaton s prohbted for use wth any Plastc ventng system. Approval codes for nstallaton of ventng system table 7 37
12" (300 mm) mnmum 12" (300 mm) mnmum EXHAUST INTAKE 12" (300 mm) mnmum 12" (300 mm) mnmum 12" (300 mm) mnmum Termnal postons PVC f gure 16 6.7.5 Drect vent closet and alcove nstallaton! WARNING For closet and alcove nstallaton, CPVC materal, nstead of PVC, must be used n a closet/alcove structure. Falure to follow ths warnng could result n fre, personal njury, or death. 1 (25mm) mnmum clearance around vent ppes 15 386mm Rnna strongly suggests the use of PPs ventng for all closet and alcove nstallatons. For non drect vent room ar applcatons see sectons 6.7.5 and 6.7.8. 6 148mm 11 268mm 1 (25mm) mnmum clearance around vent ppes 15 386mm 6 148mm 11 268mm 10 254mm 10 254mm Closed door 38 2 50mm 8 200mm 2 8 50mm 200mm 1 25,4mm 1 (25mm) mnmum clearance around hot water ppes Closet nstallaton f gure 17 2 50mm 8 200mm 8 200mm 2 50mm Open front 6 152mm 1 (25mm) mnmum clearance around hot water ppes Alcove nstallaton f gure 18
6.7.6 Dmensonng of the exhaust and ar ntake duct! DANGER The wall mounted boler must be vented and suppled wth combuston and ventlaton ar as descrbed n ths secton. Ensure the vent and ar ppng and the combuston ar supply comply wth these nstructons regardng vent system, ar system, and combuston ar qualty. Inspect fnshed vent and ar ppng thoroughly to ensure all are artght and comply wth the nstructons provded and wth all requrements of applcable codes. Falure to provde a properly nstalled vent and ar system may cause severe personal njury or death.! WARNING Use only the materal lsted n Rnna's vent documentaton for vent ppe, and fttngs. Falure to comply could result n severe personal njury, death or substantal property damage. Installaton must comply wth local requrements and wth the Natonal Fuel Gas Code, ANSI Z223.1.! WARNING For closet and alcove nstallaton, CPVC materal (nstead of PVC) must be used n a closet/alcove structure. Falure to follow ths warnng could result n fre, personal njury, or death. All vent ppes must be connected and properly supported, and the exhaust must be ptched a mnmum of a 1/4 /foot (21 mm/m) back to the boler (to allow dranage of condensate). Please refer to the ventng manufacturer's manual to see f a larger ptch s requred for specfc ventng systems. The ventng system manufacturer's requred ventng ptch must always be followed f larger than 1/4 (21 mm). Combuston ar ppng from the outsde MUST comply to the requrements of the authorty havng jursdcton or, n the absence of such requrements, to the latest edton of the Natonal Fuel Gas Code, ANSI Z223.1/NFPA 54. 39
6.7.7 Combuston ar and vent ppng lengths. In the table below you wll f nd the maxmum equvalent ppe length of the vent/ar system based on 2" and 3" dameter. These lengths are for sngle ppe (room ar) and twn ppe and concentrc ventng systems. Equvalent vent length table 9 Equvalent frcton loss of PVC/CPVC table 9a Equvalent frcton loss of Centrotherm PPS table 9b Calculaton of equvalent length vent system Choose the vent type and f ll out the correspondng table. * See equvalent length tables and equvalent frcton loss tables for 2" and 3" above. 40 Parallel system Length tube Combuston ar Vent Concentrc system Length concentrc tube, boler to roof horzontal Number of elbows 90 x 6* Number of elbows 45 x 3* Concentrc termnal Add 5 ft.* Total Multply wth factor Example of calculaton: 2" Twn tube (parallel) wth termnal Combuston ar length : 40 ft wth elbow 3 x 87 Vent length : 40 ft wth elbow 2 x 87, elbow 2 x 45 Calculaton: Equvalent Ar Length : (40+3x12+2) x 0.5 = 39 ft Equvalent Vent Length : (40+2x12+2x6+2) x 0.5 = 39 ft + Total = 78 ft. Equvalent length ft ft ft ft ft 0.5 ft ft ft ft ft ft 0.5 ft ft Total equvalent length Number of elbows 90 x 6* Number of elbows 45 x 3* Concentrc termnal Add 2 ft.* Total Multply wth factor Total equvalent length ft ft ft ft ft 1.0 ft
6.7.8 Calculaton of compensaton factor The compensaton factor elmnates or reduces the natural effect of derate of maxmum nput caused by the resstance of the vent system and/or the mpact of the alttude. 1. Determne the Compensaton Factor Vent System CF(V) n the table below. Compensaton factor vent system CP(V) table 10 2. Determne the Compensaton Factor Alttude CF(A) n the table below. Compensaton factor alttude CP(A) table 11 Any applcaton or nstallaton above 10,000 must be revewed by Rnna's Engneerng group. Ths s to ensure the product s nstalled and the overall system s desgned properly and that the unts are commsoned properly. Not nvolvng of Rnna's Engneerng group would result n no support of the product and no warranty.! WARNING 3. Calculate the Compensaton Factor Total CF(T): CF(T) = CF(V) + CF(A) The result s the settng for Parameter 73. Change parameter 73 accordng to ths result. See Chapter 10.1 how to change parameters. Example of calculaton: E50CRN Eq. lenth vent system (taken from prevous example) 44 ft CF(V) = 2 Alttude 7,200ft CF(A) = 42 + CF(T) = 44 Parameter settng (Par. 73) = 44 Do not overcompensate the boler by settng a hgher value than calculated, otherwse the boler could be damaged. 41
6.7.9 Room Ar System (ndoor combuston ar) When usng ndoor ar, Rnna strongly recommends the use of an ndoor ar flter, P/N 808000025.! WARNING Ths boler requres adequate combuston ar for ventlaton and dluton of flue gases. Falure to provde adequate combuston ar can result n unt falure, fre, exploson, serous bodly njury or death. Use the followng methods to ensure adequate combuston ar s avalable for correct and safe operaton of ths boler. Important: Combuston ar must be free of corrosve chemcals. Do not provde combuston ar from corrosve envronments. Applance falure due to corrosve ar s not covered by the lmted warranty. Combuston ar must be free of acd formng chemcals such as sulfur, fl uorne and chlorne. These chemcals have been found to cause rapd damage and decay and can become toxc when used as combuston ar n gas applances. Such chemcals can be found n, but not lmted to bleach, ammona, cat ltter, aerosol sprays, cleanng solvents, varnsh, pant and ar fresheners. Do not store these products or smlar products n the vcnty of ths boler. Unconfned Space: An unconf ned space s def ned n NFPA #54 "as a space whose volume s not less than 50 cubc feet per 1000 Btu/hr (4.8 m3 per kw per hour) of the aggregate nput ratng of all applances nstalled n that space. Rooms communcatng drectly wth the space n whch the applances are nstalled, through openngs not furnshed wth doors, are consdered a part of the unconf ned space." If the unconf ned space contanng the applance(s) s n a buldng wth tght constructon, outsde ar may stll be requred for proper operaton. Outsde ar openngs should be szed the same as for a conf ned space. 25FT 36FT 25FT 36FT 42 NOTE: 8FT CEILING NOTE: 8FT CEILING Unconf ned Space 91,300 BTU Boler Unconf ned Space 200,000 BTU Boler Unconf ned space f gure 19
Confned Space: (Small Room, Closet, Alcove, Utlty Room, Etc.) A conf ned space s def ned n the NFPA #54 as "a space whose volume s less than 50 cubc feet per 1000 Btu/hr (4.8 m3 per kw per hour) of the aggregate nput ratng of all applances nstalled n that space." A conf ned space must have two combuston ar openngs. Sze the combuston ar openngs based on the BTU nput for all gas utlzaton equpment n the space and the method by whch combuston ar s suppled: Usng ndoor ar for combuston Usng outdoor ar for combuston Louvers and Grlls When szng the permanent openng as llustrated n f gure 17, consderaton must be taken for the desgn of the louvers or grlls to mantan the requred free area requred for all gas utlzng equpment n the space. If the free area of the louver or grll desgn s not avalable, assume wood louvers wll have 25% free area and metal louvers or grlls wll have 75% free area. Under no crcumstance should the louver, grll or screen have openngs smaller than ¼. Example: Wood: 10 n x 12 n x 0.25 = 30 n2 Metal: 10 n x 12 n x 0.75 = 90 n2 Locaton To mantan proper crculaton of combuston ar two permanent openngs (one upper, one lower) must be postoned n conf ned spaces. The upper shall be wthn 12 nches of the conf ned space and the lower openng shall be wthn 12 nches of the bottom of the conf ned space. Openngs must be postoned as to never be obstructed. Combuston ar provded to the boler should not be taken from any area of the structure that may produce a negatve pressure (.e. exhaust fans, powered ventlaton fans). Gas Vent / Boler Exhaust 12n. MAX OUTLET AIR DUCT INLET AIR DUCT BOILER PERMANENT OPENINGS 10" (250mm) 12n. MAX 12" (300mm) Louvers and grlls f gure 20 BOILER 43
Usng Indoor Ar For Combuston When usng ar from other room(s) n the buldng, the total volume of the room(s) must be of adequate volume (Greater than 50 cubc feet per 1000 Btu/hr). Each combuston ar openng must have at least one square nch of free area for each 1000 Btuh, but not less than 100 square nches each. Usng Outdoor Ar For Combuston Outdoor ar can be provded to a conf ned space through two permanent openngs, one commencng wthn 12 n. (300mm) of the top and one commencng wthn 12 (300mm) of the bottom, of the conf ned space. The openngs shall communcate to the outsde by one of two ways: drectly through horzontal ducts ndrectly through vertcal ducts When communcatng drectly wth the outdoors through horzontal ducts, each openng shall have a mnmum free area of 1 n 2 /2000 Btu/hr (1100 mm 2 /kw) of total nput ratng of all applances n the confned space. Note: If ducts are used, the cross sectonal area of the duct must be greater than or equal to the requred free area of the openngs to whch they are connected. When communcatng ndrectly wth the outdoors through vertcal ducts, each openng shall have a mnmum free area of 1 n 2 /4000 Btu/hr (550 mm 2 /kw) of total nput ratng of all applances n the confned space. Combuston ar to the applance can be provded from a well ventlated attc or crawl space. Gas Vent / Boler Exhaust Gas Vent / Boler Exhaust OUTLET AIR DUCT OUTLET AIR BOILER BOILER 44 INLET AIR DUCT Gas Vent / Boler Exhaust INLET AIR DUCT [Ends 1Ft (300mm) above floor] BOILER OUTLET AIR INLET AIR Ventlaton Louvers for unheated crawl space Louvers and grlls f gure 21
7 Electrcal connectons The electrcal connectons to the boler must be electrcally grounded n accordance wth all applcable local codes and the latest revson of the Natonal Electrcal Code, ANSI/NFPA-70. Devces such as, outdoor sensor, room thermostat or temperature control, and temperature sensor or thermostat are all connected to the nternal connecton termnal. The connecton termnal s stuated behnd the Control Tower. Connectng ncomng power Install a 120V man swtch next to the boler as servce man swtch of the boler. Lead the cable through the back part of the boler usng a stran relef and lead the cable through the cable supports to the Control Tower. Use a step drll bt to create a knockout n the grey plastc cover of the boler for a stran relef. Connect a power supply cable to the cable harness termnal strp that connects to both the power swtch on the front of the Control Tower and the termnal strp wth postons 1, 2, and 3 on the nsde of the Control Tower. CAUTION CAUTION CAUTION! CAUTION The boler must be electrcally grounded n accordance wth local codes, or n absence of local codes, wth the Natonal Electrcal Code, ANSI/INFPA 70. RISK OF ELECTRIC SHOCK. Once the man power supply s on then there s 120V on termnals 1 to 12 when the man swtch next to the boler s swtched on. - No changes may be made to the wrng of the boler; - All connectons should be desgned n accordance wth the applcable regulatons; - Label all wres pror to dsconnecton when servcng controls. Wrng errors can cause mproper and dangerous operaton. 45
The Rnna room thermostat and controls must be connected to ther allocated connectons. All other types or makes of room thermostats or controls whch are used must have a Volt free contact. When usng an on/off thermostat or control, t may be necessary to calbrate the antcpatng resstance to prevent too hgh temperature fl uctuatons. As a standard rule ths means mercury thermostats. Ths resstance wre s present n the Control Tower and must be connected to termnals 23 and 27. The antcpatng resstance n the room thermostat has to be set at 0.11 A. For more detaled questons regardng the components whch are not suppled, the dstrbutor should be contacted. When wrng an RS100 t s suggested that a jumper be placed on termnals 22 and 23 so that n the event the control s damaged the boler wll stll fre based on outdoor reset. A jumper should also be used when commssonng or trouble shootng the boler. Power stealng thermostats cannot be connected to termnals 22 and 23. Connecton termnal E-Seres 120 V~ 120 V~ 120 V~ 120 V~ Cylnder connecton Outsde Bus Power supply three-way valve DHW sensor Controller sensor N L N L N L N L CH DHW N A B 8U.35.60.00 Room therm. On / Off External safety contact 24 V~ 100 ma 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 man power supply 120 Volts Rnna only 120 Volts Rnna only 120 Volts Rnna only nternal or external three-way valve motor and tank sensor ARV12 outdoor sensor Bus room thermostat RS100 On/off thermostat or control (Volt free) External safety contact! CAUTION CAUTION Termnals 4 to 11 are for Rnna use only and not for use n any nstallaton. Connecton termnal f gure 22 46
120V 120V 120V 5 24 V~ 100 ma External safety contact Room therm. On / Off Bus Controller Outsde sensor Cylnder connecton 120 V~ 120 V~ 120 V~ 120 V~ DHW sensor three-way valve Power supply N L N L N L N L CH DHW N A B 10 11 1 2 3 4 5 6 7 8 9 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 8U.35.60.00 Flowswtch* Hgh Lmt Swtch T 220 F X7 E-Prom Label all wres pror to dconnecton when servcng or replacng controls. Wrng errors can cause mproper and dangerous operaton! CAUTION electrcal dagram f gure 23 47
48 electrcal ladder dagram f gure 23a
8 Boler controls The boler s provded wth a fully automatc mcroprocessor control, called CMS Control Management System. Ths control smplf es operaton by undertakng all major control functons. Intally when power to the unt s swtched on t wll reman on standby. There s no ndcaton LED on, untl one of the program buttons s pressed. The control panel dsplay wll show the relevant state. When the boler nstallaton s empty the dsplay wll show FILL. The varous parameters can be called up n two ways: The Good-state or standard read out The f rst way shows a smple dsplay read out. The boler n operaton wll always show 'Good'. When a message s necessary ths wll be shown nstead of Good. Example Example Techncal read out The second way s a techncal read out. In normal stuatons the followng wll be shown: on the left the status n whch the boler s actve; on the rght the supply temperature n F; Alternately ndcated by: the water pressure n the nstallaton n PSI. When a message (error or blockng code) s necessary ths wll be shown nstead of the techncal read out. To swtch over from the Good-state to the Techncal read out (and vce versa): - Press the STEP-button for 5 seconds. When the system has been flled the automatc de-aeraton program starts, when a program has been selected, by pressng the button for Central Heatng, DHW or pump program (, of ). The program takes 17 mnutes and stops automatcally. After ths the unt wll functon normally. (See also 'Fllng and de-aerate the boler and nstallaton, chapter 9). On a call for heatng or hot water the control system wll select the requred water control temperature. Ths water temperature s called the T-set value. On a call for central heatng the boler gntes frst at low nput. The nput s then changed slowly to match the load requred. The boler operates n ths way to avod excessve water noses and temperature overshoot. On a call for domestc hot water supply the T-set value of central heatng return water temperature s montored. Dependng on the amount of domestc water whch s wthdrawn from the DHW f xture, the central heatng return water temperature, from whch the nput s adjusted, wll vary. Operaton ndcaton (n the f rst dsplay poston by techncal read out) 0 1 2 3 4 5 6 7 8 9 A No heat demand Fan pre/post purge Ignton phase Burner actve on central heatng Burner actve on DHW Fan check Burner off when room thermostat s demandng or burner off when DHW s callng Pump overrun phase for central heatng Pump overrun phase for hot water Burner off because of to hgh fl ow temperature Automatc de-aeraton program 49
8.1 Explanaton of the functon buttons 2 1 3 4 7 6 5 8 Boler control panel f gure 24 Only lcensed professonals who are traned for servcng these bolers are permtted to make alteratons n the controller to calbrate the boler to the nstallaton. 1. Dsplay. See prevous page for further nformaton. 2. ON-OFF Swtch (Placed separately next to the boler) Ths swtch turns the power supply to the boler on or off.! CAUTION Only turn the boler off usng ths swtch, when the burner s off. 3. Central Heatng program button. Swtchng the Central Heatng on or off (LED on/off); 4. Hot Water program button. Swtchng the Domestc Hot Water (DHW) faclty on or off (LED on/off); 5. Pump program button. adjusts the pump to contnuous water crculaton n the central heatng system (LED on), or accordng to the pump overrun tmes on the relevant programs (LED off); 50 When the pump s swtched on contnuously t can lead to undesred heatng up of the central heatng system durng the summer. If the boler s nstalled n a zoned system and the constant recrculaton functon (5 pump program button) s actvated then a dfferental pressure bypass valve or a low loss header plumbng kt s requred to be nstalled. 6 Mode-button. After brefl y pressng, a selecton of the data chapters can be retreved. After pressng for 5 seconds t s possble to enter the code as descrbed n chapter 11.3; 7 Step-button. After brefl y pressng, the water pressure can be retreved and pages per chapter can be retreved. After pressng for 5 seconds t swtches from the Good-state to techncal read out and vce versa; 8 Reset-button. After brefl y pressng, for: - unlockng errors; - endng the access code; After pressng for 5 seconds an operatng stop s made, for example, for actvatng the automatc ventng program. Some buttons have other functons.these functons are only actve accordng to the procedure descrbed n chapter 11, adjustment has to be changed or data must be retreved from the CMS. The other functons are: 3. Central Heatng program button : + functon; 4. Hot Water program button: - functon; 5. Pump program button : store-functon, whch means that by means of ths button a modfed settng s conf rmed; 7. Step-button: scrollng n a data chapter.
9 Startng up: Fllng and de-aeratng the boler and nstallaton! CAUTION CAUTION Observe the followng rules of safety: - All work on the unt must take place n a dry envronment. - Rnna unts may never be n operaton wthout ther housng, except n connecton wth mantenance or adjustments (see Chapter 12 and 13). - Never allow electrcal or electronc components to come nto contact wth water. Carry out the followng tasks n connecton wth mantenance, etc. to an alreadynstalled unt: - Shut down all programs - Close the gas shut off valve - Shut off the power at the man power swtch - Close the servce valves (system supply and return) Take note of the followng when mantenance or adjustments are needed: - The unt must be able to functon durng these actvtes; for ths reason, the unt s supply voltage, gas pressure and water pressure must be mantaned. Ensure that ths s not a source of potental danger durng these actvtes.! WARNING Followng mantenance or other actvtes; always check the nstallaton of all parts through whch gas flows (wth bubble test usng leak-search spray). 9.1 Requrements of the water system Before f llng the heatng system, the complete system, ncludng all zones, must be thoroughly cleaned and fl ushed to remove sedment. Flush untl clean water runs free of sedment. Rnna suggests usng an approved system cleaner to fl ush the system, but not the boler. Always use Rnna approved antfreezes. See the lst at the end of ths chapter. Never use reverse osmoss, deonzed, or dstlled water for f llng the heatng system.! WARNING Do not use petroleum-based cleanng or sealng compounds n the boler system. Damage of seals and gaskets n boler and system could occur, resultng n property damage.! WARNING The central heatng nstallaton needs to be f lled wth potable water. Use only potable water or approved glycol for fllng the heatng system. When the water hardness of the fllng water exceeds > 10.5 gpg (200 mg/l) the water has to be treated untl below the maxmum value of 10.5 gpg (200 mg/l). The ph value of the nstallaton water must be between 6.5 and 8.5. Check the ph value usng proper equpment or by havng the water analyzed by a water treatment company. If ph dffers from above, contact Rnna engneerng for further assstance. Component or product damage as a result of falng to adhere to the water qualty requrements wll not be covered by the lmted warranty. 51
! WARNING Freeze protecton Freeze protecton for new or exstng systems must use glycol that s specally formulated for ths purpose. Ths ncludes nhbtors, whch prevent the glycol from attack the metallc components. Ths should be for mult-metallc components. Make certan to check that the system fl ud s correct for the glycol concentraton and nhbtor level. The system should be tested at least once a year and as recommended by the producer of the glycol soluton. The allowed maxmum concentraton s 50%. Use only Rnna approved nhbtors. See below for an approved lst of nhbtors. Use only nhbted propylene glycol solutons, whch are specally formulated for central heatng systems. Ethylene glycol s toxc and can attack gaskets and seals used n the boler and system. Approved glycols are lsted below. Addtves n the nstallaton water are not permtted. Approved antfreeze: Rhomar RhoGard Mutl-Metal (AL safe) Sentnel X500 (max. concentraton 50%) Noble Noburst AL Fernox Alph 11 Approved system cleaner: Noble Noburst Hydronc System Cleaner Rhomar Hydro-Solv 9100 Fernox F3 Cleaner Sentnel X400 The system cleaners from NoBurst, Rhomar, and Fernox are not to be used n the boler. The boler must be closed off (valved off) from the rest of the system or not connected whle the cleaners are n the system. The system should then be draned and then thoroughly flushed wth clean water to remove all the system cleaner. Approved nhbtors: Rhomar Pro-tek 922 Noble Noburst AL nhbtor Sentnel X100 9.2 Fllng the heatng system For f llng or toppng off the nstallaton you use the f llng loop accordng to the followng procedure: 1 Swtch on the power supply; 52 2 The dsplay wll show FILL; 3 All functons off (heatng, DHW and pump ); 4 Push brefl y the 'STEP'-button: P XX (XX = water pressure n PSI); 5 Open the f llng loop (Indcaton on dsplay ncreases); 6 Fll up slowly to 16 to 18 PSI; 7 STOP appears on the dsplay; 8 Close the f llng loop; 9 De-aerate the complete nstallaton, start at the lowest pont; 10 Check the water pressure and f necessary top t up; 11 Close the f llng loop; 12 Actvate the functons n use (heatng, DHW and/or pump );
13 If A XX appears on the dsplay, wat for 17 mnutes; 14 Check the water pressure and f necessary top t up to 16 to 18 PSI 15 Close the f llng loop; 16 Press the STEP -button; 17 Be sure that the f llng loop s closed. 18 After the automatc de-aeraton program (A XX) s fnshed the boler wll return to the Good state or Techncal read out. Check the water pressure regularly and top off the nstallaton when necessary. The workng pressure of the nstallaton should be between 16 and 18 PSI when the system s cold. It can take a whle before all ar has dsappeared from a flled nstallaton. Especally n the frst week noses may be heard whch ndcate the presence of ar. The automatc ar vent n the boler wll remove ths ar, whch means the water pressure can reduce durng ths perod and therefore toppng off wth water wll have to be done. Durng normal use the followng messages can occur wth the necessary follow up: Water pressure s too low (<10 PSI), FILL ndcaton remans contnuously vsble, the boler s taken out of operaton. The nstallaton needs to be topped off. Water pressure s too low (<12 PSI), fl ashng FILL wll alternate wth ndcaton of water pressure, boler power of 50% s possble. The nstallaton needs to be topped off. Water pressure s too hgh (>42 PSI), f HIGH ndcaton remans contnuously vsble, the boler s taken out of operaton. The nstallaton pressure needs to be decreased by dranng water. 9.3 Hot water supply Apply water pressure to the DHW f xture (open man valve and/or stop valve for the f xture). Allow ar to release from the DHW f xture by openng a hot water shut off valve. Leave the shut off valve open for as long as requred untl all ar has dsappeared from the DHW f xture and the ppes and only water s fl owng from the shut off valve. 53
FOR YOUR SAFETY READ BEFORE OPERATING WARNING: If you do not follow these nstructons exactly, a fre or exploson may result causng property damage, personal njury or loss of lfe. A. Ths applance does not have a plot. It s equpped wth an gnton devce whch automatcally lghts the burner. Do NOT try to lght the burner by hand. B. BEFORE OPERATING smell all around the applance area for gas. Be sure to smell next to the floor because some gas s heaver than ar and wll settle on the floor. WHAT TO DO IF YOU SMELL GAS - Do NOT try to lght any applance. - Do NOT touch any electrcal swtch. - Do NOT use any phone n your buldng. - Immedately call your gas suppler from a neghbor s phone. Follow the gas suppler s nstructons. - If you cannot reach your gas suppler, call the fre department. C. Use only your hand to push n or turn the gas control knob. Never use tools. If the knob wll not push n or turn by hand, don t try to repar t, call a lcensed professonal. Force or attempted repar may result n a fre or exploson. D. Do not use ths applance f any parts have been under water. Immedately call a lcensed professonal to nspect the applance and to replace any part of the control system and any gas control whch has been under water. OPERATING INSTRUCTIONS 54 1. STOP! Read the safety nformaton above ths label. 2. Turn off al electrcal power of the applance. 3. Set the thermostat or other operatng control to the lowest settng. 4. Ths applance s equpped wth an gnton devce whch automatcally lghts the burner. Manual Gas Valve (Man valve) Do NOT try to lght the burner by hand. 5. Close man gas shut off valve. 6. Wat (5) mnutes to clear out any gas. Then smell for gas. Includng near the floor. If you smell gas, STOP! Follow B n the safety nformaton above on ths label. If you don t smell gas, go to the next step. 7. Open man shut off valve. 8. Set the thermostat or other operaton control to desred settng. 9. Turn on all electrc power to the applance. CLOSE OPEN 10. If the applance wll not operate, follow the nstructons To Turn Off Gas To Applance and call your servce techncan or gas suppler. TO TURN OFF GAS TO APPLIANCE 1. Turn off all electrc power to the applance f servce s to be performed. 2. Set the thermostat or other operatng control to the lowest settng. 3. Close man gas shut off valve. 8U.34.01.01 / 11.12
10 Adjustments When the boler s nstalled the software has already been pre-programmed at the factory. All software adjustments of the boler control are already pre-programmed for a heatng system wth radators/convectors wth a supply temperature of 176 F. The adjustments are descrbed n the Parameter chapter on the followng page. In certan cases parameters have to be altered n case of : - Lower supply temperature - Hgh alttude/long vent length - Mnmum boler supply temperature! CAUTION The ventng / alttude calculaton must always be performed durng commssonng of the boler. Read through the Parameter chapter to adjust the boler to ts nstallaton. Contact Rnna n case of doubt. Only lcensed professonals who are traned for servcng these bolers are permtted to make alteratons n the controller to calbrate the boler to the nstallaton. 10.1 Alterng adjustments STEP 1 STEP 2 STEP 3 Press the Mode-button for 5 seconds. The dsplay shows COdE followed by an arbtrary number; Press by means of the + or the - button untl the code C123 s shown; Press the STORE-button to confrm the code (code blnks1 x). Now you have acces to the nstaller level. There are 4 chapters: Parameters Informaton chapter (no adjustments possble) Servce chapter Error-chapter (no adjustments possble) The content of the chapters s descrbed on the followng pages. STEP 4 STEP 5 STEP 6 STEP 7 STEP 8 Press brefly the MODE-button to select one of the 4 chapters,.e. PARA; Press brefly and release the STEP-button to select a Parameter (parameter vsble on the left, value on the rght) ; Alter the value, f necessary/possble, by means of the + or the - button Press brefly on the STORE-button to confrm the alteraton. When you have to change more values, repeat from step 5. Press once or more on the MODE-button untl StBY or Good s shown: After a few seconds the text StBY wll be replaced by the techncal read-out or Good-state (Dependng from the poston the acces code s entered) When you want to return from an arbtrary poston to the orgnal read out press once or more on the MODE-button untl StBY s shown. If no sngle button s used wthn 20 mnutes the dsplay wll return automatcally to ts orgnal read-out (Good state or techncal read out) 55
56 DESCRIPTION 1 176 F maxmum supply temperature CH 68-176 F 2* 00 type of CH nstallaton: 00-04 No pre-selecton made. Radators, ar heatng, or convectors: T max. supply 176 F K factor heatng curve 2.3; gradent 10 F/mn; gear dfferental 10 F 00 01 DO NOT USE radators wth large surface areas or underfloor heatng as addtonal heatng: 02 T max. supply 158 F K factor heatng curve 1.8; gradent 10 F/mn; gear dfferental 10 F under floor heatng wth radators as addtonal heatng: 03 T max. supply 140 F; K factor heatng curve 1.5; gradent 8 F/mn; gear dfferental 8 F full under floor heatng: 04 T max. supply 122 F; K factor heatng curve 1.0; gradent 6 F/mn; gear dfferental 6 F 3 max. maxmum power CH n kw (.. x3415 =.. BTU/hr) mn-max 4* 00 control prncpal wth on / off thermostat: 100 % on / off thermostat 00 constant water crculaton 22&23 closed contact day curve operaton, open contact nght curve operaton 01 5* 23 2.3 heatng curve K-factor (see also heatng curve graph) 02 0.2-3.5 35 6* 1.4 heatng curve exponent (see also heatng curve graph) 1.1-1.4 7* 14 F heatng curve clmate zone (see also heatng curve graph) -4-32 F 10* 0 F fne adjustment heatng curve day temperature -8 to 10 F 11* 0 F fne adjustment heatng curve nght temperature -8 to 10 F 14 10 F/mn. gradent speed F/mn. 0-28 F/mn. 15* 00 Booster after nght decrease*: no 00 yes 01 23-4 F Frost Temperature -4 to 50 F 27 100 F Mnmum T-set CH 0-158 F 36 E50CR: 00 Type of three way valve and DHW capablty E75CR: 20 VC 2010 / VC 8010 x0 E110CR: 20 Warmng functon plate heat exchanger ON 1x Warmng functon plate heat exchanger OFF 2x 43 max. Maxmum power DHW n kw (.. x3415 =.. BTU/hr) mn-max 49 100% Maxmum pump capacty heatng 100 % 73 0 Alttude and ventng CFT. See chapter 6.7.7 0-100 89 00 Address No functon -01 Bus thermostat 00 90 01 Dsplay readng C and Bar 00 F and PSI 01.... Info Mode INFO DESCRIPTION.... 1 F supply water temperature T1 4 F return water temperature T2 5 F DHW temperature T3 7 F outdoor temperature T4 8 F flue gas temperature T5 (optonal sensor) 16 % actual power n % 17 kw actual power n kw (.. x3415 =.. BTU/hr) 18 kw actual load n kw (.. x3415 =.. BTU/hr) 20 ndcaton bus communcaton 21 GJ consumpton total n GJ (.. x 33 =.. m3) 22 GJ consumpton CH n GJ (.. x 33 =.. m3) 23 GJ consumpton DHW n GJ (.. x 33 =.. m3) 24 h total number of burner run hours 25 h number of burner run hours CH 26 h number of burner run hours DHW 32 h total number of hours counter 37 h total number of run hours pump CH and DHW 46 h wthn how many hours s servce requred...
Servce Mode SERV DESCRIPTION 1 OFF boler n operaton wth burner functon on OFF - max. 2 OFF fan adjustable and burner off OFF - max. 3 OFF pump adjustable wth burner on OFF - max. 4 OFF showroom poston ON = actve and OFF = non actve ON - OFF.... Error Mode ERRO DESCRIPTION Err.L - Err.5 Last saved error untl 5 last prevous errors 1 error code 2 operaton status boler 3 F supply water temperature T1 4 F return water temperature T2 5 kw load (.. x3415 =.. BTU/hr) 6 % pump capacty Parameter-, Info-, Servce- and Error-chapters Table 12 * Most of the data n ths table can be requested by the RS100. Most of the adjustments whch are stated n ths table are unnecessary when n combnaton wth the Rnna RS100 thermostat and wll be taken care of by the RS100 tself and do not have to be adjusted. For further nformaton regardng to the RS100 thermostat refer to the Rnna RS100 nstallaton manual. 230 Outdoor reset 212 2.30 Heat curve day Heat curve nght 194 176 2.30 1.80 1.50 fl ow water temperature n F 158 1.80 1.50 140 1.00 122 1.00 104 86 68 50-4.0-0.4 3.2 6.8 10.4 14.0 17.6 21.2 24.8 28.4 32.0 35.6 39.2 42.8 46.4 50.0 53.6 57.2 60.8 64.4 68.0 outsde temperature n F heatng lne adjustments Parameter Step 6 and 7 graph 2 57
10.2 Actvatng factory settngs (green button functon) To actvate the factory settngs agan please follow the next procedure (Note: all altered adjustments wll be set back to ther orgnal factory settngs that are accessble n the current servce level the boler s n ether user or 123): - Select, when necessary, the techncal read out; - Select wth the MODE-button chapter PARA; - Press the STORE-button. The word "Copy" wll appear and the factory settngs are actve agan. 11 Isolatng the boler Some stuatons requre turnng the entre boler off. By swtchng off the three buttons wth the LED's for central heatng, hot water and pump program (, or ), the boler s swtched off. Do not shut off the power of the boler, whch means the crculaton pump and the three-way valve are actvated once every 24 hours n order to prevent these parts from sezng up.! CAUTION In the event of freezng danger wth an solated boler t s advsable to dran the boler and/or the nstallaton. 58
12 Commssonng Work on the boler must be carred out by a lcensed professonal, usng correctly calbrated nstruments wth current test certfcaton. These nstallaton nstructons are ntended for lcensed professonals, who have the necessary knowledge and are approved for workng on heatng and gas systems. Before the boler s f red, ensure that the boler and the system are well de-aerated and free of ar. Purge the gas lne between the gas meter and the boler.! WARNING Falure to properly commsson the boler as descrbed n secton 13 may result unrelable burner operaton, reduced component lfe, and unsafe boler operaton. The boler and ts ndvdual shut off valve must be dsconnected from the gas supply ppng system durng any pressure testng of that system at test pressures n excess of 1/2 PSI (3.5kPa). To commsson the boler the casng has to be removed. - remove the 4 screws A,B,C and D n the quck releases of the casng (fgure 25); - remove the screw E behnd the door on the front of the casng (f gure 25); - remove t towards the front. Installng casng f gure 25 The boler settngs, such as burner pressure and adjustment of the ar quantty are unnecessary n most cases, due to the fact that the boler operates wth a zero pressure control. Ths means the correct gas quantty s controlled by the sucton operaton of the fan. The f ne adjustment of the zero pressure, whch s carred out at the factory s once-only, whch means that adjustng of ths value s unnecessary. Only n case of replacng of the gas valve, ventur and/or fan wll the zero pressure adjustment have to be checked and, f necessary, adjusted to the rght value.! WARNING! DANGER The ventur must always be checked and adjusted when t s out of range see secton 12.3 on O 2 adjustment. Always check the nstallaton of all parts through whch gas flows (by bubble test usng leak-search spray). Pump commssonng f gure 26 Pump commssonng procedure should be followed before the boler s f red for the f rst tme: 1. Remove the vent pump screw 2. Use a small fl at head screw drver to ensure the mpeller spns freely. 3. When the mpeller spns freely and water exts though the vent port the pump s ready for operaton. 4. Replace the vent screw Durng the commssonng of the boler the Rnna Installaton, Commssonng, and Servce card must be f lled out. 59
12.1 Testng for gas leaks Pror to start-up of the boler you must check the external tghtness of the gas supply valve and conf rm ths n the start-up report.! WARNING - Before leak testng the boler, ensure all parts of the boler such as electroncs and wrng are properly covered and protected from the leak testng agent. - Do not spray the leak testng agent onto cables, plugs, electrcal connecton lnes or electronc crcut boards. Do not allow t to drp onto them ether.! DANGER Leaks may be caused to ppes and screw connectons durng commssonng and mantenance actvtes. - Carry out a proper leak test. - Only use approved leak detecton agents for leak detecton. - Dsconnect the heatng system from the power supply. - Check the exteror tghtness of new condut sectons up to and ncludng the drect sealng pont on the gas burner f ttng. The maxmum test pressure allowed on the nput of the gas burner f ttng s 14 nch W.C. (35mbar). 12.2 Testng the Ignton Safety shut off devce - Swtch off system usng the Central Heatng button and the DHW button - Dsconnect the plug and socket connecton of the onzaton cable. - Swtch on the sytem usng the Central Heatng button and the DHW button. - Press the MODE-button for 5 seconds. - The dsplay wll show COdE followed by an arbtrary number; - Select by means of the or the button the code C123; 60! WARNING - Press the Store-button to conf rm the code (code blnks 1 x); - Press the MODE-button untl SERV s shown; - Press the STEP-button once untl 1 s shown; alternately 1 and OFF wll be shown. - Press the button once; Check f the boler does one start-up attempt and four restart attempts. After the last start-up attempt, the boler wll lock out. The gas valve s shut off. The E02 code s blnkng n the dsplay. - Connect the plug and socket connecton of the onzaton cable. - Press the reset button. - Check f the boler starts-up. Do not touch the nsde of the gnton cable whle t s dsconnected durng start up of the boler.
12.3 Checkng the O 2 at full load (Step 1/3) The O 2 percentage settng s requred to be checked at commssonng, mantenance and faults and adjusted f needed.! WARNING The O 2 percentage s requred to be checked and adjusted after a converson from NG to LP or from LP to NG. Ths process must be done wth a calbrated combuston analyzer that has been set to the correct gas type. The O 2 check conssts of 2 steps or, f necessary, 3 steps: Step 1: Step 2: Step 3: Check on full load Check on low load Adjustment (f necessary). Step 1: O 2 check on full load The O 2 settng s preset at the factory, for all equpment unts. A calbrated O 2 check must be carred out durng commssonng. - Put the boler nto operaton and take care that t can delver ts heat. a Set the full load You can set the full load of the boler as follows: - Press the MODE-button for 5 seconds. - The dsplay wll show COdE followed by an arbtrary number; - Select by means of the or the button the code C123; - Press the Store-button to conf rm the code (code blnks 1 x); - Press the MODE-button untl SERV s shown; - Press the STEP-button once untl 1 s shown; alternately 1 and OFF wll be shown. - Calbrate the O 2 meter ; - Place the probe of the O 2 meter nto the check pont (see f g. 27); - Press the button untl the maxmum value (n kw) s acheved; The boler wll burn on full load (value on dsplay n kw) value n BTU/hr = x3415 checkpont O 2 f gure 27 - Check whether the O 2 values that are lsted below correspond to the measured value. After ths settng has been made, once more test the O 2 value at low load (see Step 2 on page 62). If there are any changes n the result, then these must be corrected (see Step 3 on page 63) Choose the rght O 2 value accordng the knd of gas (Natural Gas or Propane Gas). Wrong adjustment may result causng property damage, personal njury or death. O 2 check on full load (Step 1) Full load Natural Gas Propane Gas Nomnal 4.7% Nomnal 5.1% O 2 Mnmum 3.6%, maxmum 5.5% Mnmum 4.1%, maxmum 5.8% Values vald wth closed ar box. 61
12.3.1 Checkng the O 2 at low load (Step 2/3) Step 2: O 2 check on low load Settng the low load The low load of the boler can be set by you as follows: - Press the button untl the mnmum value (n kw) s acheved; The boler wll burn on low load (value on dsplay n kw) value n BTU/hr = x3415 When adjustng from max. to mn. load t s advsable to stop at medum load to allow the boler to stablze. Adjustng quckly from max. to mn. could force the boler nto an error state. - Use the measurng tool to carry out a O 2 check. The detected values must le n the measurng range shown below. a checkpont O 2 f gure 27 The O 2 value at low load must le hgher than the O 2 value at full load. The measurng procedure must be carred out, untl a constant measurng result s acheved. Please take up contact wth Rnna, f the values should le outsde of the applcable tolerances. Swtchng off - Press the - button untl s shown (keep button pressed). Wth ths the procedure has ended. Choose the rght O 2 value accordng the knd of gas (Natural Gas or Propane Gas). Wrong adjustment may result causng property damage, personal njury or death. O 2 check on low load (Step 2) Low load Natural Gas Propane Gas Mnmal 0.5% hgher than measured on full load Mnmal 0.2% hgher than measured on full load O 2 Maxmum 7.5% Maxmum 7.3% Values are vald wth closed cover/ar box. 62
12.3.2 Settngs on the gas valve (Step 3/3) Step 3: Adjustment on the gas valve. Only f the measured values are outsde the range of the table on the prevous page. - Open the boler as descrbed on page 59. - Remove the black cover of the gas valve by unscrewng the sealed screw. a checkpont O 2 f gure 27 - Set the boler on full load (see Step 1) - The O 2 values are set by usng an Allen key (4 mm), or a large fl at head screwdrver, on the screw b. Please observe the followng rotatng drecton: - Clockwse means more O 2 - Counterclockwse means less O 2 b adjustment screw O 2 f g. 28 After ths settng has been made, once more test the O 2 value at full load and low load. See Step 1 and 2. - Replace the black cover on the gas valve and secure t wth the screw. For hgh alttude nstallatons, elevatons between 2000 ft and 4500 ft (600 m and 1350 m), n Canadan area t s requred to fll out the Hgh Alttude Label. Place the f lled out Hgh Alttude Label on the controller supportng frame, on the left sde of the ratng plate. Hgh Alttude Label (example) Adjustment of the gas valve n case the measured values les out of range of the values on full load (Step 3) Full load Natural Gas Propane Gas O 2 4.7% 5.1% Values vald wth closed ar box. 63
12.4 Measurng the onzaton current - Swtch off the system usng the Central Heatng button and the DHW button - Dsconnect the plug and the socket connecton on the probe and connect the measurng devce n seres. See f gure 29. Select the μa drect current range on the measurng devce. The measurng devce must have a resoluton of at least 1 μa. - Swtch on the sytem usng the Central Heatng button and the DHW button. - Press the MODE-button for 5 seconds. - The dsplay wll show COdE followed by an arbtrary number; Ionzaton test f gure 29 - Select by means of the or the button the code C123; - Press the Store-button to conf rm the code (code blnks 1 x); - Press the MODE-button untl SERV s shown; - Press the STEP-button once untl 1 s shown; alternately 1 and OFF wll be shown. - Press the button untl the maxmum value (n kw) s acheved; The boler wll burn on full load (value on dsplay n kw) value n BTU/hr = x3415 - Measure the onzaton. When the boler s n full load the onzaton current must be > 4 μa and wrte down ths value n the log book. - Press the button untl OFF s shown (keep button pressed). - Swtch off the system usng the Central Heatng button and the DHW button - Dsconnect the measurng devce and restore the plug and the socket connecton on the probe. - Swtch on the sytem usng the Central Heatng button and the DHW button. 64 12.5 Installng the casng - Install the cover on the boler and close all 4 quck releases of the casng - Tghten the 4 screws A,B,C and D n the quck releases (fgure 30); - Tghten the screw E behnd the door on the front of the casng (f gure 30); Installng casng f gure 30
13 Mantenance Mantenance or changes to the boler may only be carred out by a lcensed professonal. To protect yourself from harm, before performng mantenance: - Turn off the electrcal power supply by swtchng off the boler at the mans power swtch or by turnng off the electrcty at the crcut breaker. - Turn off the gas at the manual gas valve, usually located below the boler. - Turn off the ncomng water supply. Ths can be done at the solaton valve usually located below the boler or by turnng off the water supply to the buldng. 13.1 Perodc examnaton of ventng systems and boler The nspecton of the boler and ventng system should be done every 2 years or 4000 hours and full mantenance every 4 years or 8000 hours of operaton, whchever occurs f rst. When dong ths the crcumstances of the boler s locaton must be taken nto account. From ths one can determne whether to devate from ths advce. Please contact Rnna for further gudance on the frequency and servce requrements. Contact detals can be found on the back page of ths manual. 13.2 Inspecton Preparng the boler for nspecton To carry out the mantenance actvtes please follow the next procedure: - Swtch off the power supply; - Shut off the gas; - Valve off the boler from the system usng the boler solaton valves n the plumbng kt. - Remove the 4 screws A,B,C and D n the quck releases of the casng (fgure 31); - Remove the screw E behnd the door on the front of the casng (f gure 31); - Remove t towards the front. - Clean the casng wth a cloth wth a smple (non-abrasve) cleanng agent; Removng casng f gure 31 65
13.2.1 Vsual nspecton for general sgns of corroson - Check all gas and water ppes for sgns of corroson. - Replace any ppes that are corroded. 13.2.2 Measurng the onzaton current See subsecton 12.5 Measurng the onzaton current". 13.2.3 Measurng the nlet gas pressure See subsecton 6.4.1 and.2 Gas connecton wth natural gas" and "Gas connecton wth propane. 13.2.4 Testng for gas leaks See subsecton 12.1 Testng for gas leaks. 13.2.5 Carryng out a pressure test of the heatng system See chapter 9.2 Fllng the heatng system. 13.2.6 Checkng ventng systems Check the followng ponts: - Is the prescrbed combuston ar/fl ue system used? - Have the nstructons for conf gurng the fl ue system as specf ed n the relevant Installaton nstructon for the fl ue gas system been observed? - Check ar ntake and/or ar f lter and fl ue gas for obstructon, polluton or damage. When an ar flter s used the ar flter must be replaced yearly on bolers operatng n normal crcumstances. The condtons (eg. supply ar qualty) n whch the boler s nstalled should be taken nto account. Ths wll show whether the frequency of replacement should be reduced or ncreased. If n doubt, contact RINNAI. 66
13.3 Mantenance actvtes 2 9 1 The fan unt and burner cassette (f gure 32 to 34) (every 4 year mantenace) - Remove the electrcal connecton plug from the gas valve (1) and fan motor (2); - Loosen the nut (3) of the gas ppe under the gas valve; - Replace the gasket wth a new one; - Loosen the front cross head screw (4) of the black plastc slencer; - After ths turn the two clampng rods (9 and 10) ¼ turn and remove them by pullng them forward. Note the correct turnng drecton (red ndcator. fg. 34); - Slghtly lft the fan unt and remove t towards the front of the heat exchanger; - Remove the burner cassette out of the fan unt; - Check the burner cassette for wear, polluton and possble cracks. Clean the burner cassette wth a soft brush and vacuum cleaner. 4 3 fan unt and gas valve f gure 32 10 If burners are cracked replace the complete burner cassette; - Replace the gaskets between burner and fan unt and the gasket between fan unt and heat exchanger; - Check the ventur and the gas-ar dstrbuton plate for polluton and clean ths part, f necessary wth a soft brush and vacuum cleaner. If the ar box contans a lot of drt t s plausble that the fan tself s drty as well. To clean ths, the fan has to be removed from the hood and the ventur. Clean the fan wth a soft brush and a vacuum cleaner. Replace the gasket and ensure that all gaskets of the fan parts are mounted correctly. f gure 33! DANGER Clampng rods f gure 34 Heat exchanger (every 4 year mantenance) - Check the heat exchanger for contamnaton. Clean ths f necessary wth a soft brush and a vacuum cleaner. Prevent debrs from fallng down nto the heat exchanger. Flushng the heat exchanger from the top down s not permtted Ref ttng of the components s done n reverse order. Make sure that durng refttng the clampng rods they are put n the rght poston. They should be turned vertcal. If the boler should actvate wth clampng rods n the wrong poston t wll cause property damage, personal njury or loss of lfe. Ignton electrode (every 4 year mantenance) Ths can be checked by measurng the onzaton current. The mnmum onzaton current has to be hgher than 4μA on full load. If the nspecton glass s damaged the complete electrode must be replaced. Replace the gnton assembly after every 4 year, whchever occurs frst. Replacement goes as follows: - Remove the electrcal connectons of the electrode; - Press the clps on both sdes of the electrode to both sdes and remove the complete electrode; - Remove and replace the gasket; Ref ttng of the components s done n reverse order. 67
8 9 7 Condensate trap and condensate tray (f gure 35-37) (2 and 4 year mantenance) Step 1: Condensate trap - Frst remove the screw (7); - Pull the condensaton cup (8) downwards, out of the condensate tray (14) Check ths for mpurtes. If there s not a lot of mpurtes t s not necessary to clean the condensate tray (Go to Step 3). If there s a lot of mpurtes n the cup t s necessary to remove and clean the condensate tray accordng Step 2; - Check the O-rng (9) of the cup and replace f necessary; - Clean the parts by fl ushng t wth clean water; - Grease the O-rng agan wth acd free O-rng grease to make f ttng easer; - If there s a leak at the condensate trap (8) replace complete condensate trap by # 809000100; Sphon f gure 35 13 11 14 12 Condensate tray f gure 36! DANGER Step 2: Condensate tray - Remove the plug from the fl ue gas sensor f present; - Turn the two short clampng rods (11 and 12) ¼ turn and remove them by pullng them forward; Note the rght turnng drecton (red ndcator); - Lft the exhaust ppe (13) out of the condensate tray (14); - Press the condensate tray (14) carefully downwards and remove t by pullng t forward; - Replace the gasket between condensate tray and heat exchanger wth a new one; - Clean the condensate tray wth water and a hard brush; - Check the condensate tray for leaks. Step 3: Ref ttng s done n reverse order. Note that all gaskets seals completely. Make sure that durng refttng the clampng rods they are put n the rght poston. They should be turned vertcal. If the boler should actvate wth clampng rods n the wrong poston t wll cause property damage, personal njury or loss of lfe. 68 Clampng rods f gure 37! DANGER! WARNING! WARNING Put the boler nto operaton and check the O 2 (see chapter 13.3). If replacement of new gaskets and burner mentoned n ths chapter s not done wthn the servce nterval subscrbed by Rnna the boler can be damaged and may cause property damage, personal njury or loss of lfe. Use only orgnal spare parts suppled by Rnna. If non approved parts are used the boler can be damaged and may cause property damage, personal njury or loss of lfe. Use of non-rnna parts wll result n the vodng of the lmted warranty. Do not use substtute materals. Use only parts certfed wth the applance. Cleanng the Brazed Plate Heat exchanger (Every 2 year mantenance or as needed based on water qualty) The brazed plate heat exchanger should be cleaned at the servce nterval every 2 years. Falure to fl ush the brazed plate heat exchanger wll cause damage to t. Follow the procedure below for cleanng the brazed plate heat exchanger. 1. Turn off the DHW functon on the boler. 2. Close the shutoff valves on both the hot water and cold water lnes (V3 and V4). 3. Connect pump outlet hose (H1) to the hot water lne at servce valve (V1).
Flushng 4. Connect dran hose (H3) to servce valve (V2). 5. Pour approxmately 4 gallons of vrgn, food grade, whte vnegar or ctrc acd nto pal. 6. Place the dran hose (H3) and the hose (H2) to the pump (CP) nlet nto the cleanng soluton. 7. Open both servce valves (V1 and V2) on the hot water and cold water lnes. 8. Operate the pump (CP) and allow the cleanng soluton to crculate through the brazed plate heat exchanger for at least 45 mnutes. 9. Turn off the pump (CP). 10. Rnse the cleanng soluton from the brazed plate heat exchanger as follows: a. Remove the free end of the dran hose (H3) from the pal b. Close servce valve, (V2), and open shutoff valve, (V4). Do not open shutoff valve, (V3). c. Dsconnect both H1 and H3 from the servce valves d. Connect H3 to V1 and place the end of the hose n a dran e. Allow water to fl ow through the brazed plate heat exchanger for 5 mnutes f. Close servce valve, (V1), and open shutoff valve, (V3). 11. Dsconnect all hoses. Dranng Flushng and dranng f gure 38 69
Vsual nspecton of the flame (2 and 4 year mantenance) The burner must fl ame evenly over the entre surface when operatng correctly. The fl ame must burn wth a clear, blue, stable fl ame. Check the fl ame through the nspecton glass n the gnton probe (f g. 38). The fl ame pattern should be as shown n the f gures below. SATISFACTORY Ignton probe blue fl ame Inspecton glass f gure 39 UNSATISFACTORY Ignton probe yellow fl ame Water f lter f gure 40 Further checks: - Inspect the pressure relef valve - Clean the water f lter n the return ppe - Check the ph of the water or glycol/water mxture. The combuston must be checked and adjusted f requred at both the 2 year/4000 hour and 4 year/8000 hour servce ntervals wth a properly workng combuston analyzer. Verfy proper operaton after servcng. Always reset the servce nterval counter after full mantenance nterval (every 4 years or 8000 hours of operaton). 13.3.1 Reset servce nterval counter 70 13.4 Lmted warranty At 8000 hours of use, SERVICE wll scroll across the dsplay. Good wll dsplay as well alternatvely. To reset the 8000 hour servce notf caton: - Enter the 1st Ter Settngs: 123 Code - Brefl y press Mode agan untl the Servce Chapter s dsplayed (SERV) - Hold the Store button untl SERV fl ashes once the servce notf caton wll no longer show durng normal operaton and the countdown to servce wll reset to 8000. For warranty condtons refer to the warranty suppled wth the boler.
14 Parts of the boler 4 2 1 7 3 15 14 5 6 T1 P1 T2 17 T3 A W G K R C 8 16 10 9 12 13 Rnna E-Seres f gure 41 1 heat exchanger 2 gnton unt 3 fan unt 4 ar nlet damper 5 gas valve 6 automatc de-aerator 7 ceramc burner cassette 8 plate heat exchanger DHW T1 supply sensor T2 return sensor T3 sensor DHW 9 operatng panel 10 Control Tower (CMS) 11 water f lter return CH 12 three-way valve 13 crculaton pump 14 exhaust 15 combuston ar supply 16 CSA Data Plate (seral number) P1 water pressure sensor 17 ASME / NB / CRN data plate G gas ppe A supply central heatng R return central heatng C condensate ppe K cold water ppe W hot water ppe 71
15 Blocks and Errors 15.1 Error ndcaton (short reference) A detected error s ndcated on the dsplay by means of blockng or error messages. A dstncton should be made between these two messages due to the fact that blockng can be of a temporary nature, however, error messages are f xed lockngs. The control wll try ts utmost to prevent lockng and wll temporarly swtch off the unt by blockng t. The followng s a lst of some messages. Blocks wth a number n the last 2 postons. Block 01: External safety contact cut off Block 05: Outdoor sensor not connected Block 60: Incorrect parameter settng of the mnmum or maxmum power. Block 67: A T has been detected between fl ow and return sensor whereas the burner s not n operaton. After the T has dsappeared the block wll clear. Block 85: The control has not detected a water fl ow. The ventng cycle s started. If durng ths cycle water fl ow s detected, the ventng cycle s ended and the burner s released. Error wth a number n the last two postons. Error 00: Error 02: Error 04: Error 05: Error 12: Error 18: Error 19: Error 28: Error 69: Poor fl ame-formng no fl ame-formng adjustment or error for voltage nterrupton adjustment hgh lmt stat maxmum fl ow temperature exceeded maxmum return temperature exceeded number of revolutons not reported back from fan no or ncorrect dsplay FUSE: 24V fuse defectve The followng pages descrbes more detaled follow up nstructons for solvng blockngs, errors and practcal crcumstances. These nstructons are only for lcensed professonal. 72
15.2 Blocks An error, whch has been detected, s ndcated on the dsplay by a block message. Blocks can be temporary n nature. The controller wll do everythng possble to prevent a system lock and temporarly swtchng off the boler as a result of a block. Please see below for a summary of blocks. Blocks wth a f gure on the last 2 characters. Code Descrpton Soluton External safety contact open Rectfy error as a result of whch by determnng contact s open. Or repar nterconnecton between 24/25 Outdoor sensor contact open (not connected) Incorrect parameter settng for the mnmum or maxmum power A temperature dfference has been detected between the supply and return sensor whlst the burner s not n operaton. After the average T has dsappeared, the block wll dsappear. fl ue sensor temperature too hgh Rectfy error as a result of whch by determnng contact s open or outdoor sensor s not connected. Connect outdoor sensor or repar wrng (poston 18/19) or replace outdoor sensor. Call Rnna Check the supply and return sensor for the resstance value and replace the defectve sensor Check the nstallaton for any external heat source and rectfy ths Check vent system fl ue sensor or thermostat contact open fl ue sensor or thermostat contact closed fl ue gas thermostat contact open no water fl ow can be detected through the controller. De-aeraton cycle s started. When water fl ow s detected durng ths cycle, the de-aeraton cycle s termnated and the burner s released. The controller checks the water pressure durng statc and dynamc stuaton. The frequence of the power supply devates more than + or -1.5Hz Call Rnna Call Rnna Check vent system or check parameter 84 for default - check the nstallaton for the presence of ar;if there s a secondary pump nstalled and t s not hydraulcly separated, t could cause pressure dfferences. - check the use of balancng valves check f the pump s functonng and/or that the water pressure sensor s workng properly; Polluted pump; Polluted water pressure sensor; Polluted water f lter; Wrng of pump. check the man power supply 73
15.3 Errors Code Descrpton Soluton Incorrect fl ame formaton. boler has not been burnng but an onzaton fl ow (fl ame) has stll been detected Check whether the onzaton cable and/or the electrode are responsble for a possble short-crcut. Remove the plugs from the onzaton cable connected to the control unt and to the electrode. Now usng a unversal meter take a measurement between the onzaton connecton and the ground, now ref t t part by part untl a short-crcut takes place. Rectfy the short-crcut and f necessary replace ths part. 24 Volt short-crcut Check the 24 Volt connecton. Remove all plugs wth 24 Volt connectons such as: fan, pump, any three-port valve and 24 Volt plug to the connectng block. Check short crcut of dsconnected components. Swtch on power agan to the control unt wth the components dsconnected. Reconnect the components, whch have been checked and are workng. Rectfy the short-crcut or replace the short-crcuted component. No fl ame formaton Check the data n Error mode. Boler data durng error. 1 error = 02 2 operatonal status = 02 3 supply temp. = xx* 4 return temp. = xx* 5 kw burner = xx** 6 % pump = xx* * = varable value **= x 3451 = BTU/hr 74 1 No temperature dfference between supply (3) and return (4) 2 There s a temperature dfference between supply (3) and return (4) Control unt error The controller has detected a program error Boler has not been able to gnte any gas or has not receved any gas. Boler tres to start 6 tmes wth an ncreasng startng load after the safety tme Check whether: - the gas valve s open; - there s power to the gas valve; - that the gas valve opens The mnmum gas pre-pressure durng the start must be a mnmum of 7"W.C. (17 mbar), check the 24 Volts n the gas durng gnton block s open poston Boler has gone out after gnton. Due to nsuff cent onzaton the burner has gone out after gnton Ionzaton fl ow, onzaton cable or the O 2 settng. The mnmum onzaton current should be 4 μa, the O 2 should be a mnmum of 4.4% for NG or 4.8% for LP Connector not plugged nto the gas valve or defect n the wrng of the gas valve. Software error control unt. Replace the control unt. The dsplay wll automatcally load the program nto the new controller. Reset the boler. the boler automatcally ndcates ths message f durng an error read-out the electrcal power to the boler s shut off. After the power has once agan swtched on, f the error causng the nterference s no longer present, ths message s gven. Rectfy the precedng error, If Error 04 perssts, and precedng errors do not occur, replace controller. Control unt error Check 120V stablty. If voltage s devatng more between +10% and -15% the electrcal power supply needs to stablsed. The error perssts after reset Software error control unt. Replace the control unt. Remove the E-Prom from the defectve control unt and place t onto the new control unt.the controller wll automatcally load the program nto the new control unt. Control unt error Mosture on the PCB. Check f there s water leakng on or n the boler. Stop leak and replace MCBA controller
Code Descrpton Soluton Control unt error 1 Antcpaton resstance wre not present When a power stealng room stat devce s placed the connecton termnal needs to be provded wth the specal antcpaton resstance wre. 2 Software error control unt. Software error control unt. Replace the control unt. Remove the E-Prom from the defectve control unt and place t onto the new control unt.the controller wll automatcally load the program nto the new control unt. Hgh lmt stat open Supply temperature too hgh. Caused by - presence of ar - possble polluted mpeller of the crculaton boler pump - polluted nternal f lter Check de-aerator. Replace when necessary the automatc de-aerator and restart boler for de-aeratng programm (17mn.) Check water fl ow over system. Clean when necessary the pump and or f lter. Flush complete system Check adjustment of balancng valves Control unt error Software error control unt. Replace the control unt. Remove the E-Prom from the defectve control unt and place t onto the new control unt.the controller wll automatcally load the program nto the new control unt. - T1 fl ow sensor ground connecton - T1 fl ow sensor falure - controller falure Sgnal maxmum fl ow water temperature exceeded (T 1 > 212 F). Sgnal maxmum return water temperature exceeded (T 2 >212 F). T1 and T2 (swapped). Controller falure Check the data n Error mode. Boler data durng error: 1 Error = 14 2 Operatonal status = 00 3 Flow temp. = -22 4 Return temp. = xx* 5 kw burner = 00** 6 % pomp = xx* * = varable values **= x3415=btu/hr A temperature of - 36 s dsplayed at poston 3. Check the wrng and/or measure the resstance of the fl ow sensor. The resstance should be approx. 12 kohm at 77 F. (See table n Appendx B) If necessary, replace the fl ow sensor - check for resstance on 16 and 17 f usng a 3rd part DHW control - f resstance s present on 16 and 17 wth 3rd party control contacts on control are not fully open Check actual fl ow temperature. suddenly ncrease caused by completely hydraulc shut off of the boler (f lter, pump, thermostat valve, servce valve) Check fl ow sensor NTC1. measure the resstance value (see Appendx B) Exchange defectve part f necessary. Change control unt when error perssts. Check actual return temperature. Increase of temperature caused by external heatng source? Check return sensor NTC 2. Measure the resstance value (see Appendx B) Exchange defectve part f necessary. Change control unt when error perssts T2 temperature s measured to be hgher than T1. Check resstance value of T1 and T2 (See Appendx B) and replace T1 or T2. Replace controller 75
Code Descrpton Soluton No sgnal from the fan The fan s not runnng. Check the wrng to the fan and the control unt and/ or the 24 volt power supply to the fan Wrng and voltage are OK and error s repeated. Replace the fan Negatve pressure on vent system (pressure dfference) nternal shut down of supply sensor T1 Check vent system. Vent system and ar ntake system must be nstalled accordng nstallaton nstructons. IF vent system s OK: Replace fan Check the data n Error mode. Boler data durng error: 1 Error = 31 2 Operatonal status = 00 3 Flow temp. = 230 4 Return temp. = xx* 5 kw burner = 00** 6 % pomp = xx* * = varable values **= x3415=btu/hr Check the wrng. check the wrng for the sensor The wrng s OK but the error s repeated. Remove the plug from the fl ow sensor as a result of whch Error 36 occurs Replace the sensor. Shut down of return sensor T2 Check the data n Error mode. Boler data durng error: 1 Error = 32 2 Operatonal status = 00 3 Flow temp. = xx* 4 Return temp. = 230 5 kw burner = 00** 6 % pomp = xx* * = varable values **= x3415=btu/hr Check the wrng. check the wrng for the sensor The wrng s OK but the error s repeated. Remove the plug from the fl ow sensor as a result of whch Error 37 occurs Replace the sensor. 76 contact for supply sensor T1 open Check the data n Error mode. Boler data durng error: 1 Error = 36 2 Operatonal status = 00 3 Flow temp. = -22 4 Return temp. = xx* 5 kw burner = 00** 6 % pomp = xx* * = varable values **= x3415=btu/hr Check the wrng. check the wrng for the sensor The wrng s OK but the error s repeated. Remove the plug from the fl ow sensor as a result of whch Error 31 occurs Replace the sensor.
Code Descrpton Soluton contact for return sensor T2 open Check the data n Error mode. Boler data durng error: 1 Error = 37 2 Operatonal status = 00 3 Flow temp. = xx* 4 Return temp. = -22 5 kw burner = 00** 6 % pomp = xx* * = varable values **= x3415=btu/hr Check the wrng. check the wrng for the sensor The wrng s OK but the error s repeated. Remove the plug from the fl ow sensor as a result of whch Error 32 occurs Replace the sensor. Control unt error Control unt error Electrcal leakage to ground. No software present Flue gas temperature to hgh (adjustment parameter 84 - default 212 F) Fuse on controller PCB defectve or Cable transformer not connected Software error control unt. Replace the control unt. Remove the E-Prom from the defectve control unt and place t onto the new control unt.the controller wll automatcally load the program nto the new control unt. Software error control unt. Replace the control unt. Remove the E-Prom from the defectve control unt and place t onto the new control unt.the controller wll automatcally load the program nto the new control unt. Mosture on controller PCB. Check f there s water leakng on or n the boler. Stop water leak and replace controller. Remove the E-Prom from the defectve control unt and place t onto the new control unt.the controller wll automatcally load the program nto the new control unt. Replace fl ue sensor or adjust parameter 84 to default Replace fuse. A 4A and 5A spare fuse can be found on the back sde of the Control Tower. 77
15.4 Other Errors Complant Descrpton Soluton Central heatng but no domestc hot water 1. -Key of the DHW program s not swtched on 2. Flow swtch s not workng properly. 3. T3 DHW sensor n plate heat exchanger defectve Swtch on DHW program on the Control Tower Check fl ow and/or check for mpurtes. Check on functonng. Replace f necessary. Replace DHW sensor 78 Hot water but no central heatng Central heatng nstallaton gets hot wthout beng requested Insuffcent quantty of hot water Temperature drop of the DHW (Comb) radators do not get hot enough or warmng them up takes too long 4. When usng RS100 - Check tmer tmes for DHW program, f necessary reset - RS100 does not respond to DHW program - See RS100 nstallaton nstructons 5. Three-port valve s not crculatng to DHW 1. -Key of the central heatng program s not swtched on. 2. Room thermostat (on/off) s not gvng any sgnal to the boler. 3. RS100 wth outdoor sensor (Room sensor-on) 4. Three-port valve s not crculatng to central heatng poston. 1. -Key pump program s on. 2. Drt n three-port valve or threeport valve cartrdge s bndng. 1. Hot and cold water connecton to the boler mxed up. - Check wrng. - If necessary replace the three-port valve motor. Swtch on central heatng program Check room thermostat - Outdoor temperature s hgher than 70 F, dependng upon the Eco-temperature set (70 F s the default). Check Info chapter Step 7 or temperature s hgher than the Eco temperature set (see RS100 nstallaton nstructons). - Check tmer program and set room temperature. Check wrng, replace the three-port valve motor. Swtch off. Clean or replace. Check left = hot, rght = cold 2. Incorrect fl ow reducng valve. - Check for the type and for contamnaton, f necessary replace (Comb) and/or clean. - Check the comfort synchronsng valve for the correct settng n accordance wth the nstallaton nstructons. 3. In the absence of postve results Lme scale n plate heat exchanger. If necessary descale or replace 1. Hot and cold water connecton to Check left = hot, rght = cold the boler mxed up 2. Flow reducng valve. Check fl ow reducng valve for the correct type n accordance wth the nstallaton nstructons 3. DHW power for the boler s set too low. 1. Check settng of room thermostat or RS100 2. Supply water temperature too low. - Check PARA chapter Step No. 43 - Check the functonng and wrng of the DHW sensor T3. See nstallaton and user manual RS100 Check settng PARA chapter Step No. 1 and ncrease f necessary 3. Incorrect choce of nstallaton PARA chapter Step No. 2 f necessary change. 4. Installaton resstance too hgh (gven an average T > 36 F the boler decreases the load). - See nstallaton nstructons. - Check / clean water f lter check dmensons of ppes.
79
E75CN/E110CN E75CP/E110CP CAUTION! Read ths manual thoroughly before nstallng, servcng, puttng nto operaton or usng ths boler and vent system. WARNING! Improper nstallaton, adjustment, alteraton, servce or mantenance can cause property damage, personal njury or loss of lfe. Refer to ths manual. For assstance or addtonal nformaton consult a qualfed nstaller or the gas suppler. CAUTION! The user manual s part of the documentaton that s delvered to the nstallaton's operator. Go through the nformaton n ths manual wth the owner/operator and make sure that he or she s famlar wth all necessary operatng nstructons.! Installaton and servce must be performed by a qualfed nstaller, servce techncan or the gas suppler. In the Commonwealth of Massachusetts ths boler must be nstalled by a lcensed Plumber or Gas Ftter. Pctured: E75CN, E110CN E75CP, E110CP Hgh effcency condensng gas boler E75CN / E110CN WARNING! If you do not follow these nstructons exactly, a fre or E75CP / E110CP exploson may result causng property damage, personal njury or loss of lfe. - Do not store or use gasolne or other flammable vapors and lquds n the vcnty of ths or any other applance. - WHAT TO DO IF YOU SMELL GAS - Do NOT try to lght any applance. - Do NOT touch any electrcal swtch. - Do NOT use any phone n your buldng. - Immedately call your gas suppler from a neghbor s phone. Follow the gas suppler s nstructons. - If you cannot reach your gas supller, call the fre department. WARNING! If you do not follow these nstructons exactly, a fre or exploson may result causng property damage, personal njury or loss of lfe. - Do not store or use gasolne or other flammable vapors and lquds n the vcnty of ths or any other applance. - WHAT TO DO IF YOU SMELL GAS These nstructons to be retaned by user. - Do NOT try to lght any applance. - Do NOT touch any electrcal swtch. - Do NOT use any phone n your buldng. - Immedately call your gas suppler from a neghbor s phone. Follow the gas suppler s nstructons. - If you cannot reach your gas supller, call the fre department. Notce! Ths manual must be retaned for future reference. 16 Spare parts Parts casng and rear wall E-Seres Installaton & Servcng Instructons Hgh effcency condensng gas boler U s e r m a n u a l 8 U.52.6000/03.09 Changes reserve d 8 U.51.60.00/02.09 Changes reserved. 78 81 84 82 89 77 80 76
Rnna Part E50CRN E75CRN E110CRN Item Art. No. Descrpton Number E75CRP E110CRP N P N P OSS1 OSS1 OSS2 1 S4479500 GASKET CASING E 809000073 X X X X X 2 S4479300 CASING SET 809000074 X X X X X 3 S4447200 BOILER COVER BOLT M5X20 (SET OF 5 BOLTS) 809000127 X X X X X 4 S4479400 SPRING DOOR CASING 809000075 X X X X X 5 S4479100 GASKET CONTROLS 809000076 X X X X X 6 S4735900 DOOR CASING E 809000077 X X X X X 7 8U52600X USER MANUAL E-SERIES 800000012 X X X X X 8 8U51600X INSTALLATION MANUAL E-SERIES 800000013 X X X X X 76 S4341610 BRACKET E75C, E110C, Q85S & Q130S 809000065 X X X X X 77 S4323310 COVER AIR SUPPLY Ø80mm 807000075 X X X X X 78 AA1CA05U CONCENTRIC FLUE ADAPTOR 80/125"MM 808000023 X X X X X 80 S4323510 GASKET AIR INTAKE ø80 SHR 809000047 X X X X X 81 S4857200 FLUE GAS CONNECTOR 3" 808000030 X X X X X 82 S4857100 AIR INTAKE CONNECTOR 3" 808000031 X X X X X 83 S4662600 FLUE GAS PIPE OSS1 808000032 X X X S4662700 FLUE GAS PIPE OSS2/3/4 808000033 X X 84 S4521600 PLUG MEASURING POINT PARALLEL FLUE PIPE 808000028 X X X X X 85 S4472600 GASKET FLUE GAS PIPE PP 809000048 X X X X X 86 S4323710 GASKET AIR SUPPLY ø125mm 809000049 X X X X X 87 S4415220 QUICK RELEASE SMALL E 809000078 X X X X X 88 S4415120 QUICK RELEASE LARGE E 809000079 X X X X X 89 S4675800 PLUG MEASURING POINT CONCENTRIC FLUE PIPE 808000030 X X X X X 81
Parts heat exchanger E-Seres 45 30 31 64 32 33 46 47 51 52 53 54 34 35 36 55 56 49 37 38 83 39 40 41 59 43 44 60 61 62 63 82
Rnna Part E50CRN E75CRN E110CRN Item Art. No. Descrpton Number E75CRP E110CRP N P N P OSS1 OSS1 OSS2 30 S4310800 CLAMP BAR TOP PART H.EX. LONG 809000014 X X X X X 31 S4735000 TOP PART HEAT EXCH. SET OSS1 807000010 X X X S4735100 TOP PART HEAT EXCH. SET OSS2 807000011 X X 32 S4313100 BOLT M 5X16 (5 PER PACKAGE) 809000015 X X X X X 33 S4305700 GASKET FAN/TOP PART H.EX. 809000016 X X X X X 34 S4337610 GASKET GAS VALVE - VENTURI 809000017 X X X X X S4325610 GASKET VENTURI - FAN 809000018 X X X X X 35 S4318810 VENTURI OSS1 807000013 X X X S4318920 VENTURI OSS2 807000014 X X 36 S4418710 BOLT M5X12GR FASE ZSDIN7985 (5 PER PACKAGE) 809000019 X X X X X 38 S4329400 O-RING ø5,00x2,00 FLOW SENSOR (5 PER PACKAGE) 809000080 X X X X X 37 S4709800 GASKET IONISATION/IGNITION OSS 809000020 X X X X X 39 S4309500 GASKET SILENCER-VENTURI 809000021 X X X X X 40 S4347510 DAMPER OSS1 807000016 X X X S4325510 DAMPER OSS2 807000017 X X 41 S4167500 SCREW TAPTITE M5X8 CK-PD (3 PER PACKAGE) 809000022 X X X X X 43 S4778600 HEAT EXCHANGER OSS1 ASME 807000019 X X X S4778700 HEAT EXCHANGER OSS2 ASME 807000020 X X S4278100 BOILER TOOL KIT 809000024 X X X X X 44 S4709500 GASKET CONDENSATE TRAY OSS1 809000025 X X X S4714900 GASKET CONDENSATE TRAY OSS2 809000026 X X 45 S4380600 CAP DE-AERATOR SHR (3 PER PACKAGE) 807000023 X X X X X 46 S4419110 DE-AERATOR CHROME 807000024 X X X X X 47 S4342300 O-RING ø13,94x2,62 DE-AER. (2 PER PACKAGE) 809000028 X X X X X 51 S4709100 GASKET H.E./TOP PART OSS1 809000030 X X X S4718400 GASKET H.E./TOP PART OSS2 809000031 X X 52 S4717200 GASKET BURNER/TOP PART OSS1 809000033 X X X S4717300 GASKET BURNER/TOP PART OSS2 809000034 X X 53 S4714600 BURNER CASSETTE SET OSS1 806000010 X X X S4714700 BURNER CASSETTE SET OSS2 806000011 X X 54 S4730900 SET INSOLATION PIPE PLATE L+R 809000036 X X X X X 55 S4338900 O-RING ø17,12x2,62 PLUG HEATEXCH. (3 PER PACKAGE) 809000103 X X X X X 56 METAL PLUG HEAT EXCH 1/2" 809000115 X X X X X 59 S4307900 LIP-RING ø63 AMGAS 809000038 X X X S4304200 LIP-RING ø80 AMGAS 809000039 X X 60 S4339200 PLUG FLUE GAS SENSOR 809000040 X X X X X 61 S4730600 CONDENSATE TRAY OSS1 809000041 X X X S4730700 CONDENSATE TRAY OSS2 809000042 X X 62 S4310700 CLAMP BAR COND.TRAY 809000044 X X X X X 63 S4440000 BOLT M 5X12 IMBUS VERZ. (3 PER PACKAGE) 809000045 X X X X X 64 S4558000 COVER GAS VALVE 809000046 X X X X X 83
Parts ppes E-Seres 137 117 118 119 119a 119b 138 121 122 123 124 125 126 127 128 129 130 113 112 96a 139 146 304 308 91 92 93 94 94a 95 104 103 96 97 99 100 101 108 102 105 131 106 107 109 111 98 108 106a 84
Rnna Part E50CRN E75CRN E110CRN Item Art. No. Descrpton Number E75CRP E110CRP N P N P OSS1 OSS1 OSS2 91 S4334500 O-RING ø21.89x2.62 GASLINE 809000061 X X X X X 92 S4340830 GASKET FITTING 3/4" GASV. 809000062 X X X X X 93 S4321900 GAS PIPE E75C 806000020 X X X S4333800 GAS PIPE E110C 806000021 X X 94 S4772900 GAS FITTING OSS1/2 E 806000015 X X X X X 94a S4328710 O-RING ø13,94x2,62 YELLOW SILI Q 809000055 X X X X X 95 S4340900 FITTING GAS VALVE 3/4" 806000016 X X X X X 96 S4420200 PIPE BEND ø15 COLD WATER E50C 807000119 X 96a S4420200 PIPE BEND ø15 COLD WATER E 807000082 Opton X X X X 97 S4401500 PIPE ø15 COLD WATER 807000083 X X X X X 98 S4779000 CONNECTION SET 15 X 3/4" NPT INCL FLOW RESTRICTOR E50 BROWN 807000072 X X X S4779100 CONNECTION SETG1/2" X 3/4" NPT INCL FLOW RESTRICTOR E110 GREEN 807000073 X X 99 SOCKET FITTING 15MM 809000144 X 100 S1035700 NUT 1/2" G BRASS COMPR. 15 809000070 X X X X X 101 S4237500 FERRULE COMPR FITTING 15MM 809000069 X X X X X 102 S4402400 T-PIECE T3 E 807000048 X X X X X S4329400 O-RING ø5,00x2,00 FLOW SENSOR 5X 809000080 X X X X X 103 S4402301 PIPE RET-3WV FILTER E 807000049 X X X X X 104 S4766000 CONNECTION SET 22 X 3/4" M-NPT 807000069 X X X X X 105 S4317500 FILTER RETURN PIPE 807000029 X X X X X 106 S4317610 FILTER CAP PRESSURE EQUALIZ.TUBE CONN. 807000121 X X X X X 106a S4158300 O-RING ø25,07 X 2,62 3WV 809000058 X X X X X 107 S4259500 NUT M35 ø30 809000059 X X X X X 108 O-RING ø5,00x2,00 FLOW SENSOR (5 PER PACKAGE) 809000080 X 109 S4421300 CONDENSATE COLLECTOR 809000081 X X X X X 111 S4421200 TRAP - E SERIES 809000100 X X X X X 112 S4309900 O-RING ø40x3,53 TRAP TRAY 809000084 X X X X X 113 S4443200 O-RING ø18,72x2,62 EPDM (3 PER PACKAGE) 809000052 X X X X X 117 S4401600 PIPE ø15 HOT WATER 807000053 X X X X X 118 S4440000 BOLT M 5X12 IMBUS VERZ. (3 PER PACKAGE) 809000045 X X X X X 119 S4462400 PLATE EXCHANGER 24KW PF/ESHR 807000054 X X X S4722600 PLATE EXCHANGER 35KIW PF/ESHR 807000055 X X 119a S4360500 O-RING ø21,89x2,62 EPDM CH (2 PER PACKAGE) 809000088 X X X X X 119b S4342300 O-RING ø13,94x2,62 DHW (2 PER PACKAGE) 809000028 X X X X X 121 S4401201 PIPE FLOW.PL.EXCH-CH E75 & E50C 807000058 X X X S4401301 PIPE FLOW.PL.EXCH-CH E110C 807000059 X X S4307220 BOLT M6X20 SS IMB.BP.4,2 (3 PER PACKAGE) 809000089 3X 3X 3X 3X 3X 122 S1003810 GASKET PUMP (2 PER PACKAGE) 809000056 X X X X X 123 S4436700 PIPE 3WV-PUMP 807000060 X X X X X 124 S4259500 NUT M35 ø30 809000059 3X 3X 3X 3X 3X S4259800 O-RING ø26.70 X 1.78 (3 PER PACKAGE) 809000091 3X 3X 3X 3X 3X S4161300 FITTING SET 3 WAY VALVE 807000062 X X X X X 125 S4308200 THREE WAY V. HOUSING VC O-RING 809000057 X X X X X 126 S4268400 CARTRIDGE 3WV 807000030 X X X X X 127 S4371700 FLANGE 3WV 807000063 X X X X X 128 S4259800 O-RING ø26.70 X 1.78 (3 PER PACKAGE) 809000091 X X X X X 129 S4401401 PIPE PL.EXCH-3WV E 807000064 X X X X X 130 S4440000 BOLT M 5X12 IMBUS VERZ. (3 PER PACKAGE) 809000045 X X X X X 131 PRESSURE EQUALIZATION TUBE E50C 807000122 X X X X X 137 S4765900 CONNECTION SET 15 X 3/4" M-NPT 807000068 X X X X X 138 S4322320 O-RING ø29.74x3.53 FLOW/RET.(2 PER PACKAGE) 809000064 2X 2X 2X 2X 2X 139 FLOWSWITCH CONVERSION KIT 803000015 Opton 304 S4789600 SAFETY VALVE 3/4" NPT 807000077 X X X X X 308 S4793800 T&P GAUGE 1/4"NPT + LOCK 1/2" 807000081 X X X X X 85
Parts electrcal components E-Seres 162 T1 supply sensor 160 T2 return sensor 167 T3 DHW sensor 166 T5 flue gas sensor 168 HLS hgh lmt swtch 162 160 161 168 161 P1 water pressure sensor 166 170 167 168 86 146
Rnna Part E50CRN E75CRN E110CRN Item Art. No. Descrpton Number E75CRP E110CRP N P N P OSS1 OSS1 OSS2 140 S4768200 HARNESS E 805000041 X X X X X 8U352200 STICKER CONNECTION TERMINAL 805000046 X X X X X S4320300 CONNECTOR 2-POLE PURPLE 805000015 X X X X X S4380900 CONNECTOR 3-POLE GRAY 805000018 X X X X X S4320600 CONNECTOR 4-POLE BROWN 805000021 X X X X X S4320500 CONNECTOR 2-POLE BLACK 805000016 X X X X X S4350600 CONNECTOR 6-POLE BLUE 805000022 X X X X X 141 S4764800 TRAFO 120V/24V 805000010 X X X X X S4370300 SCREW 3,5X 9,5 VERZ.D7983 (5 PER PACKAGE) 805000011 X X X X X 142 S4417100 CASING CONTR.UNIT BACK E 809000093 X X X X X 143 S4773100 CONTROL UNIT MCBA 5417 E RAC 805000025 X X X X X S4769300 FUSE 5AF (3 PER PACKAGE) 805000026 X X X X X S4463500 FUSE 4 AT (250v) (3 PER PACKAGE) 805000027 X X X X X 144 S4417000 CASING CONTR.UNIT FRONT E 809000094 X X X X X 145 S4334910 3WAY VALVE ACTUATOR VC2010 805000030 X X X X X S4768300 HARNESS DHW E 805000042 X X X X X 146 S4498900 FLOW SWITCH 2,5L E 805000043 Opton X X X X 147 S4883800 PUMP UPER 20-58 120V 807000126 X X X S4883900 PUMP UPER 20-78 120V 807000127 X X 160 S4309700 NTC T2/T3 805000032 X X X X X 161 S4466300 WATERPRESSURE SENSOR 805000034 X X X X X S4435400 WATER PRESSURE SENSOR CABLE 805000050 X X X X X 162 S4307420 NTC T1/T3 805000035 X X X X X 163 S4710100 IGNITION ELECTRODE+GASKET OSS 805000036 X X X X X S4323800 IGNITION CABLE SHR 805000037 X X X X X S4323900 IONISATION WIRE SHR 805000039 X X X X X 164 S4773200 FAN NRG 118 OSS1/2 808000020 X X X X X S4768100 HARNESS FAN 120V 805000038 X X X X X 165 S4754800 GAS VALVE 806000019 X X X X X 167 S4307420 NTC T1/T3 805000035 X X X X X 168 S4765300 HIGH LIMIT SWITCH 805000033 X X X X X 170 ARV1215U OUTDOOR RESET SENSOR ARV12 805000047 X X X X X Parts converson kts Propane and Natural gas E-Seres 87
17 Parts lst vent system 88 DuraVent (PolyPro)
89
Vent Manufacturer Contact Informaton for Installaton Instructons and Parts Lsts: Heat-Fab Telephone: 800-772-0739 Fax: 413-863-4803 cystsvc@heat-fab.com www.heatfab.com IPEX Telephone: 800-463-9572 905-403-0264 Fax: 905-403-9195 www.pexamerca.com Smpson Dura-Vent Telephone: 518-463-7284 Fax: 518-463-5271 sales@duravent.com www.protechnfo.com Rnna/Ubbnk Telephone: 800-621-9419 Fax: 678-829-1666 www.rnna.us York Internatonal Telephone: 405-364-4040 877-874-7378 www.york.com/products/untary/ CENTROTHERM Eco System Telephone: 877-434-3432 Fax: 518-618-3166 nfo@centrotherm.us.com www.centrotherm.us.com 90
Appendx A - Outoor Reset Sensor Data and Resstance table NTC sensors R 25 C R 100 C B 25/85 Temperature coeffcent 12 k 950 3750 K -4,2 %/K Temp NTC 12K F (12k /77 F) supply sensor T1 return sensor T2 DHW sensor T3 outsde sensor T4 flue gas sensor T5 Temp [ C] NTC [kohm] -30 171.70-20 98.82-10 58.82 0 36.10 10 22.79 20 14.77 25 12.00 30 9.81 40 6.65 50 4.61 60 3.25 70 2.34 80 1.71 90 1.27 100 0.95 110 0.73 120 0.56 NTC [kohm] 200 180 160 140 120 100 80 60 40 20 0-40 -20 0 20 40 60 80 100 120 Temp [ C] -4 98,000-0.4 90,000 3.2 82,000 6.8 74,000 10.4 66,000 14 58,000 17.6 53,500 21.2 49,000 24.8 45,000 28.4 40,500 32 36,000 35.6 33,500 39.2 30,900 42.8 28,200 46.4 25,600 50 23,000 53.6 21,400 57.2 19,900 60.8 18,100 64.4 16,600 68 15,000 71.6 14,000 75.2 12,900 78.8 11,900 82.4 10,850 86 9,800 89.6 9,100 93.2 8,500 96.8 7,900 100.4 7,200 104 6,500 113 5,600 122 4,600 131 4,000 140 3,400 158 2,300 176 1,700 194 1,300 212 950 Resstance table NTC-Sensors 91
Appendx B - Optonal accessores B.1 Low Loss Header Rnna supples optonal for each type of boler a Low Loss Header. Fnd below the dmensons. Plumbng Kt 1 Part. no.: 804000061 Sutable for: E50CRN E75CRN / E75CRP E110CRN / E110CRP 2.0 50mm 4.7 119mm 12.5 319mm 10.2 260mm 16 406mm 2.2 55mm 5.6 143mm 5.2 131mm 14.2 360mm 9 229mm 16.4 416mm plumbng kt 1 fgure 3 92 Low Loss Header Clearances to combustble and non-combustble s 0 nch for sdes, top, front and fl oor/ground The recommended servce clearance to the bottom from the low loss header s 12 nches. The plumbng kt s not ntended to support the weght of the ppng. Approprate ppng supports should be used to support all attached ppng to the boler and plumbng kt.