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Rinnai E110CP explosive ignition and low heat
I converted from forced hot water via oil to forced hot water via propane this past spring. My installer put in a Rinnai E110CP burner which also functions as tankless hot water for domestic.
My house size is approx. 1800 s.f. single story. I had an energy audit and they found ample insulation and adequate baseboard length and I have low E windows. I am aware that gas fired versus oil fired is different and that oil is a quicker & hotter heat, but I have a couple issues I need answers for.
First issue I experienced and one that is most concerning to us, is that upon cold ignition, the burner basically explodes. Very loud, shakes the house. I've had Rinnai's N. American Boiler Service Manager at my house 4 times now and my installer's been there well over 10 times. They've tweaked settings, ignitor gap etc... to no avail. Finally, my installer (who's been fantastic) convinced Rinnai to replace my burner, which they did. Unfortunately, the "new" burner had a broken plastic housing holding the computer circuit board so the re-used my old board. Question is, Can this board be the problem as it's still "exploding" and as of late I've no success with Rinnai even answering my inquiries. Their Service Manager even took an audio of the explosion to send to the factory but still no response. We've tried 4 different propane supplies so we know it's not an over methanol issue. I'm at wit's end here. One fix which seemed to work was when the Rinnai S. Mgr added an additional metal deflector plate to the burner housing causing more turbulence of the air/gas mixture, making a better mix. Unfortunately, Rinnai considered that an "unauthorized field adjustment" and he had to remove it. I've been told that the Rinnai burner will expel any gas mixture if it doesn't ignite properly, but I've also been told that it's not supposed to explode like it is... We're not real comfortable
Second issue I'm experiencing is that it takes approx 1 1/2 to 2 gallons of water flow via sink or shower/tub (no more than 20' from burner 1/2" insulated copper pipe) to get hot water. Is this normal for a gas fired burner? My old Burnham oil burner was easily twice as quick and twice as far away.
Last issue I'm experiencing is that even after setting the burner back to factory default, I don't get hot baseboards. Example. 20 degrees outdoor temp. At 4:30 AM my thermostat goes from 62 degrees F. to 70 degrees F. My old oil burner would get the house to temp in approx 40 minutes. With my Rinnai, at 6:30 AM, a full 2 hours later, it's still only up to 68 degrees F. I do have an outdoor sensor which has already been replaced, but if it's 20 degrees outside, shouldn't this burner come full on and give full heat?
Any help and/or answers will be greatly appreciated.