new water heating technology and its fit in today’s ...energy.sc.gov/files/tankless water heaters...

10/30/17© 2014 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL

Enhancing Lives By Changing The Way Water Is Heated1

New Water Heating Technology and Its Fit in Today’s Commercial

Environment



• History• Global Presence• Rinnai North America Experience and Expertise• Fabrication and Assembly• Tankless Water Heater• Advantages• Common Vent• Accessories• Installation Requirements• Installation Examples• Supporting Materials

Agenda



http://www.rinnai.com/en/profile/history

History

1920 1932 1944 1956 1968 1980 1992 2004

DedicatedCommercial Team

TanklessRack

System

Condensing Tankless and Boilers

Completed In-House CSA Certified Lab

Italy

Tankless Water Heater

Vietnam

Singapore

Direct Vent Furnace

Infrared Gas Burners Infrared Heater

United Kingdom

New Zealand

Manufactured Aircraft Parts

America

Rinnai Founded by Mr. Naito and Mr. Hayashi

Korea

Australia

Stoves / Ranges / Ovens / Hot Water Units

Taiwan

America

http://www.rinnai.com/en/profile/history



Global Presence

• Operations in 13 countries• Over 7000 employees worldwide• One of the LARGEST gas appliance manufacturers in the world



• Based in Nagoya, Japan• Established in 1920 • 10,000 employees worldwide• One of the world’s largest gas appliance manufacturers• Largest share of the Japanese markets• The number-one selling brand of tankless gas water heater

in North America

RINNAI GLOBAL HEADQUARTERS

• The Leader in Gas Technology throughout the world

• Extensive product offerings of gas appliances: water heaters, boilers, furnaces, cooking products and dryers

• Consolidated 2013 turnover: approx $2.8 Billion

RINNAI’S GLOBAL PRESENCE

A Global Leader in Gas Appliances



North American Headquarters

Peachtree City, Georgia HeadquartersOutside Atlanta, Georgia

OrganizationIn US since 1974• Over 150 employees throughout North America• Sales, Marketing, Customer Service, Application Engineering, Tech Support,

Manufacturing• Distribution centers : Peachtree City, GA and Sparks, NV• Rinnai’s network of field employees includes service and sales managers with vast

experience in the plumbing, HVAC, appliance, hydronic, and building industries• Over 200 additional manufacturer’s representatives throughout North America

Products• Direct Vent Wall Furnaces and Vent-Free Heaters – Since 1990• Water heaters – Since 1999• Condensing Boilers – Since 2009



Technology Leadership through Research and Development

A Commitment to Maintain Technology Leadership

• More than 4% of net sales allocated to R&D expense annually• More than 600 R&D engineers• All manufacturing facilities are ISO 9001 and or ISO 14001 certified• All products have been approved by the Canada Standards Association (CSA) and

American National Standards Institute (ANSI)• Uncompromised focus on quality in design, manufacturing and marketing



Quality Focused

• Advanced automation and precision assembly processes make Rinnai’s manufacturing facilities an industry model for efficiency, and extensive inspection and testing protocols

• Every product undergo a series of live fire testing before being shipped – every single product!

Inspection & Testing

Manufacturing & Assembly



Market Leadership

• Committed to CHANGE the way water is heated…– Tankless has continued to increase its

share and Rinnai has led the charge and maintains a dominant market share position

• Focused efforts in all segments that can and will drive category and Rinnai growth– Residential

• Replacement• New SF/MF Construction

– Commercial Applications• Valued Engineered Applications• Emergency Replacement

– Energy Segment

– Domestic Manufacturing In Griffin, GA, April 2018

Market Share

Rinnai



North America Commercial Experience

With over 17 years of commercial experience, Rinnai is now providing a modular, factory assembled, and redundant tankless hot water system.



Fabrication and Assembly

Utilizing quality methods and procedures, each TRS is assembled by trained operators in a controlled environment and fully tested prior to shipment

• Dedicated assembly facility in Peachtree City, Georgia• Comprehensive incoming supplier quality control• Detailed assembly process with quality and inspection checks• Pass / Fail manifold testing on every rack system• Capacity to assemble 70 systems per month• System traceability• Each order is built per customer requirements



TANKLESS WATER HEATER



Condensing Water Heater

1. Concentric or PVC / CPVC Air Intake

2. Ceramic Top Down Burner

3. Primary Heat Exchanger

4. Secondary Heat Exchanger

5. Integrated Condensate Trap

6. Integrated Digital Controller

7. Built-in Surge Protector & PC Board

8. Modulating Gas Valve



Bypass

FR

SV1SV2 SV3

Igniter

TC Sensor

Primary Heat Exchanger

PCB

/ Sur

ge P

rote

ctor

Secondary Heat Exchanger

Con

dens

ate

Trap

CombustionFan

Incoming Air Exhaust

Water flowcontrol valve

Modulating Gas Valve/POV

Water Flow Sensor

Out goingTemperatureThermistor

HeatExchangerThermistor

SV0 or SVMain

1. Water flow begins:• Water flow sensor sends pulses to the PCB.• When flow exceeds approximately *0.4 gpm the ignition sequence begins.

2. Ignition Sequence:• Combustion fan starts, drawing air in from the venting and through the unit.• Spark igniter begins sparking.• Gas control assembly opens to the low fire rate.• When the flame rods have proven flame the spark igniter stops sparking.

3. Normal Operation:• PCB monitors flame rods, TC Sensor, flame characteristic, fan motor frequency, outlet

water temperature, temperature set point, and water flow rate.• Gas valve assembly and fan speed modulate gas and air input to meet user demand.• If water flow demand is very small, only SV1 will allow gas to burner. The flame rod

(FR) will monitor this minimum fire state.• If water flow demand is large, flame can develop across the entire burner.• Water is preheated in the secondary (latent) heat exchanger.• Water is heated further as it passes through the heat exchanger multiple times.• Heat exchanger can strategically overheat the water while the bypass tempers the

water down to the set point temperature. This can provide for higher flow rates.• The water flow control valve will adjust as needed to maintain output temperature.• Due to the efficient combustion, condensation will form and drain into the condensate

trap and through drain at the bottom of the unit.

4. Shut-down Sequence:• PCB senses flow rate less than *0.26 gpm.• Gas control valve closes & water flow control valve resets to a standby position.• Combustion fan will then run for a period of time to purge the combustion chamber.

5. Standby Mode:• PCB monitors all components.

* Model Dependent

Sequence of Operation



TANKLESS RACK SYSTEM

AdvantagesSystem Design



1.Efficiency

2.Reliability

3.Flexibility

TRS Advantages

A single, self contained system consisting of multiple tankless units which replaces one larger heat source. Three key advantages are:



TRS Efficiency

Load Tracking Through Precise Modulation

13:1 Single Engine Turn Down Ratio

Allows Multiple Engines to Communicate Seamlessly Modulating Firing Rate Based on Demand

MSB Controller:

Up To 25 Units Can Communicate:327:1 Turn Down Ratio



TRS Efficiency – Continued

What is turndown ratio?

The description of a gas products ability to modulate its flame and btu delivery

Modulation is defined by Turndown Ratio Turndown Ratio:

A products maximum fuel input divided by its minimum fuel input.

Example: A 1,000,000 btu modulating boiler with a minimum fuel inputof 250,000 btu’s would have turndown ratio of 4:1

1,000,000 divided by 250,000 = 4:1 Turn Down Ratio




2 Engine / 400k BTU : 26:1 TDR

5 Engine / 1m BTU : 65:1 TDR

10 Engine / 2m BTU : 130:1 TDR

Modulating and tracking the load from:

15,000 BTU’s to 4.9M BTU’s

.26 GPM to 245 GPM

Maintaining Temperatures +/- 2 Degrees



Example: 250 Unit Hotel

We can Track the Load from:

One Fixture

to

The Entire Hotel Under Peak Demand

Energy Savings Energy Savings Energy Savings


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http://www.google.com/url?sa=i&rct=j&q=hotel+pictures&source=images&cd=&cad=rja&docid=sdMwpYMKPpQ96M&tbnid=ZymVuCXIm45N1M:&ved=0CAUQjRw&url=http://www.halongbaycruise.org/product&ei=y4glUfaXNcH-iwLjtIC4DA&bvm=bv.42661473,d.cGE&psig=AFQjCNELG0xMliUYwYxHxFUoXBgrKjy-rA&ust=1361500639956000




The Most Efficient Method for Heating High Volumes of Water

+True CondensingLoad Tracking



TRS Reliability

Reliability Through Redundancy

Individual Engines Can Be Taken Off Line With No Interruption of Hot Water Service



Example: 1,000,000 btu System

One unit disabled: 50% loss of DHWTank disabled: 100% loss of DHW One unit disabled: loss of 16% DHW

TRS Reliability – Continued



TRS Reliability – Continued

• Run Time is Balanced Among All The Units

• Firing Sequence is Rotated Based on Run Time

• Evens Wear and Lengthens Overall Lifespan of the System

MSB Cascade Controller - Lead Lag



TRS Flexibility

Indoor OutdoorSeparateTogether

Free StandingWall Mounted

Individual VentCommon Vent



TRS Flexibility – Continued

• Multi-family

• Healthcare

• Hospitality

• Dormitory/University

• Food Service26

Applications



Two Unit Design

Specification TRS02 TRS02IL TRW02

System Capacity 15,200 – 398,000 Btu

Flow Rate 7.6 GPM @ 100° F ΔT

Turn Down Ratio 26 to 1

Water Manifold 2” Copper

Gas Manifold 1 ¼” Schedule 40 Steel MNPT

Frame Powder Coat Aluminum

H x L x D 57.7” x 44” x 28.6”

Weight 210 208 204

Shipping Weight 406 404 400



Three Unit Design

Specification TRS03 TRS03IL TRW03

System Capacity 15,200 – 597,000 Btu

Flow Rate 11.4 GPM @ 100° F ΔT

Turn Down Ratio 39 to 1

Water Manifold 2” Copper

Gas Manifold 1 ¼” Schedule 40 Steel MNPT


H x L x D 62” x 55” x 36” 62” x 75” x 36”

Weight 284 291

Shipping Weight 480 487



Four to Six Unit Design

Specification TRS04 TRS05 TRS06

System Capacity 15,200 – 796,000 Btu 15,200 – 995,000 Btu 15,200 – 1,194,000 Btu

Flow Rate 15.2 GPM @ 100° F ΔT 19.0 GPM @ 100° F ΔT 22.8 GPM @ 100° F ΔT

Turn Down Ratio 52 to 1 65 to 1 78 to 1

Water Manifold 2” Copper 2 ½” Copper

Gas Manifold 1 ¼” Sch 40 Steel MNPT 1 ½” Sch 40 Steel MNPT


H x L x D 62” x 55” x 36” 62” x 75” x 36”

Weight 357 452 526

Shipping Weight 553 649 722



• Warranty: 6-year heat exchanger / tank, 5-year parts and

up to 2 years labor

• Built standard with C199 Commercial Tankless Water Heater

- Commercial ENERGY STAR® certified with 96% Thermal

Efficiency

- Ultra Low NOx compliant

- 199,000 BTU

• Approved for high altitude up to 10,200 ft (3,109 m)

• Integrated temperature controller that provides 98°F to 185°F, (no external controller required)

• Fueled by Natural Gas or Liquid Propane

• Assembled with individually certified components

• First Hour Rating: 315 gal / Recovery: 231 gal (@ 100°F ΔT)

• Multiple venting options (concentric, two pipe, room air,

common vent)

The Demand Duo



Features

• Perfect for emergency replacement situations

• Easy and cost effective maintenance – all parts replaceable

• Built-in freeze protection for tankless unit down to -22⁰F, (gas/electricity is required).

• Scale build-up detection.

• Built-in error codes for easy of troubleshooting.

• Temperature settings displayed in Celsius or Fahrenheit.

• System comes with the isolation valves already installed

• Meets points contribution to LEED projects.

• Flame rod validate presence of flame failure.

• Over heat bi-metal sensor(s).

• Integrated boiling protection.

• Heat exchanger thermal fuse protection.

• Direct electronic ignition (no standing pilot).

• Combustion fan senses blocked intake or exhaust flue.



Sequence of Operation

T1

Controller

1. The water heating process begins when the controller detects a specific tank water temperature at the T1 sensor. (This activation temperature varies with set temperature).

2. The controller will then activate the pump which circulates water from the bottom of the tank through the tankless engine.

3. The flow sensor in the engine detects this flow. The engine then starts and begins heating water to the set temperature.

4. Heated water flows out of the tankless unit into the tank, near the top.

5. The controller continues to monitor the T1 sensor and de-activates the pump when the water in the tank reaches the proper temperature.

6. Once the pump is turned off the tankless engine will shut down and go into a standby mode until the controller begins the process again.

Pump

Tankless Engine



TRS COMMON VENT



PPtl/PVC Common Vent

• 8”/6”/4” PPtl specifically engineered for Rinnai TRS solutions

• Now introducing Sch40 PVC common vent up to 6 units. Reducing the cost of the install

• Common vent headers are push fit designed for easy and quick installation

• Common vent capabilities up to 8 tankless (1.5MBtu) units on single vent system

• Maximum equivalent vent length up to 100’, longer than individual units

• Common vent solutions requires only two terminations, reducing the number of penetrations through building exterior

• Approved for installations up to 10,200’

Two TRS04s with common vent



PPtl/PVC Common Vent – Options

Back to Back Configuration In-line Configuration

Max Equivalent Vent Length

# of Water Heaters Exhaust Intake

1 – 7 100 ft 100 ft

8 41 ft 41 ft



COMMERCIAL ACCESSORIES



Controls – Cascade

Electronically modulates firing rate for 2 to 25 tankless water heaters

• System size from 15,200Btu up to 4.9MBtu • GPM flow rate from 0.4 GPM up to 94 GPM*• Automatically rotates unit activation so that

each tankless has equal run-time• Activates tankless units needed to supply the

hot water demand at that time• System temperature controlled from

“master” unit

*based on 100°F ∆T

MSB-M controller



Controls – Temperature

For systems that require temperatures greater than 140°F (60°C), the MCC-91 controller will be needed. Provides temperature settings up to 185°F (85°C).



Controls – Maintenance Indication Switch

When a tankless unit experiences a fault or error, the MIS provides a visual display with the use of an indication lamp and/or audible alert with a buzzer or doorbell, or combination of the two.

• Low voltage microprocessor (24V AC) the fits inside the water heater (if higher voltage is needed, an external relay is required)

• Operates in normally open (NO) or normally closed (NC) position

• Can interface with a building management system (BMS)

• Can monitor individually or as system



INSTALLATION



Installation – Continued

Important factors when sizing:

Incoming Ground Water Temperature

Hot Water Demand and Desired Temperature

Available Gas Load

Altitude

Sizing




GPM Demand @

(Target Temp – Incoming Temp) Rise/

One Engine GPM @ Rise=

Number of Engines Required

Sizing

Rinnai Engineering Official Sizing Free on Every Job



Sizing Methodologies

• America Society of Heating Refrigeration and Air-Conditioning Engineers (ASHRAE) Handbook– Tankless (no storage)– Water Supply Fixture Units– Modified Hunter’s Curve

• American Society of Plumbing Engineer (ASPE) Handbook– Tankless w/storage systems– GPH

• Online Sizing Calculator

http://staging.partners.rinnai.us/sizing-Calculator




∆T Temperature Rise (°F)

Wat

er F

low

(gp

m)

63

GPM vs. GPH

RU98Flow Curve

63° Temp rise

6 GPM

360 GPH

Incoming water is 57° and requested temperature is 120°



Engineering Services

• Sizing, design and quotation assistance• In-house and offsite consultation to Owners, Engineers, Architects,

Mechanical Contractors, etc. • Plumbing system knowledge• Cost/Savings Calculations• Custom Engineered Water Heating Solutions

- Pumps- Controls - Tank - MIS (BMS compatible) - Design drawings



INSTALLATION EXAMPLES



63 Unit Multi Family Installed: TRS06e

Replaced: (2) Raypak 500K BTU(1) 270 Gal Storage

Saved on Equipment CostSaved on Installation Time & Cost

Example



Hospitality 41 Room High End Beach Front Resort

Installed: 8 Unit Wall Mount TRS

Replaced: AO Smith Tank Type

Increased Efficiency Increased Reliability for High End Guests

Example



GovernmentCounty Courthouse

Installed: TRS06i W/ Common VentReplaced: 1M BTU WM Boiler W/ 700 Gal Storage

Energy Savings and Space Savings

Example



Multi-Use FacilityInstalled: TRS06i + TRS04i w/ Common Vent

Replaced: 1M BTU WM Boiler W/ 250 Gal Storage

Energy Savings and Space Savings

Example



SUPPORT



Application Engineering SupportSizing'sDrawingsApplicationsPiping InstallationsQuestions

24/7/365 Technical Support

866.383.0707

Support

866.383.0707

[email protected]



Commercial Website

All technical and marketing collateral can be found on the commercial website:

www.rinnai.us/commercial

http://www.rinnai.us/commercial



Application Form

There are two ways to obtain a sizing from our application engineers:

1. Complete the application form and email to [email protected]

OR

2. Call 1-866-383-0707, follow prompts to application group

In either case, the application form is used to obtain the necessary information to provide an accurate sizing.

mailto:[email protected]



Thank you

new water heating technology and its fit in today’s ...energy.sc.gov/files/tankless water heaters...

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