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Rinnai Brivis StarPro Brivis StarPro SP535UN, Installation Manual

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Rinnai Brivis StarPro Brivis StarPro SP535UN Installation Manual Download Page 7

Rinnai 

7 

Ducted Gas Heater IM

1.  SCOPE

This installation manual is intended to be used as a guideline for the installation of Gas Fired Central Heaters. 

It covers only the installation and commissioning of the heater and the allowable flueing configurations. Although 

recommended return air grilles and allowable duct outlet quantities are specified, it does not cover the actual ducting 

design required to suit the installation.

This installation manual is based on Australian codes. For all other applications, please refer to local codes and 

regulations.

These  heaters  must  be  installed  and  serviced  only  by  qualified  personnel. This  manual  applies  to  the  following 

models:

6 Series Heaters

5 Series Heaters

4 Series Heaters

Universal

Internal

Universal

External

Internal 

Universal

SP615UN

SP615IN

SP521UN

BX520EN

SP521IN

SP415UN

SP623UN

SP623IN

SP521UN XA

SP521IN-XA

SP421UN

SP623UN XA

SP623IN XA

SP530UN

BX526EN

SP530IN

SP430UN

SP630UN

SP630IN

SP530UN XA

SP530IN-XA

SP435UN

SP630UN XA

SP630IN XA

SP535UN

SP535IN

SP635UN

SP635IN

1.1 

SP Heater Overview

SP6 series heaters are condensing heaters.
SP4 and SP5 series heaters are non-condensing heaters.
Universal models may be used in both internal and external applications.

For more details refer to Technical Specifications section.

1.2 

BX5 Heater Overview

The  BX520  and  BX526  ducted  heaters  are  designed  primarily  to  replace  Buffalo  85  and  Buffalo  120  heaters 

respectively. Their configuration allows for seamless changeover onto an existing base box, where applicable, with 

identical service connections, capacities and airflows commensurate with the original units. They also incorporate 

on-board controls providing greater flexibility for thermostat and zone control options.

Summary of Contents for Brivis StarPro Brivis StarPro SP535UN

Page 1: ...Brivis StarPro Ducted Gas Heater Installation Manual SP623 UN BX5 SP521IN PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE INSTALLING THIS PRODUCT by ...

Page 2: ...Rinnai 2 Ducted Gas Heater IM This page is intentionally blank ...

Page 3: ...5 4 Heater Configuration 16 4 1 Heater Duct Pop Installation 16 4 2 Duct Connection Configuration Options 16 Return Air Orientation 17 4 2 1 SP430U and SP435U Fan Cabinet Swap F1 F2 17 4 2 2 SP415U SP421U Fan Cabinet Swap F1 F2 F3 17 4 2 3 SP5U and SP6U Fan Cabinet Swap F1 F2 17 4 2 4 SP5U and SP6U Fan Cabinet Swap F1 F2 F3 17 4 2 5 SP5 and SP6 Internal Fan Cabinet Swap F1 F2 F3 17 Supply Air Orie...

Page 4: ...ation 35 10 1 SP and BX5 Series Thermostat Positioning Guidelines 35 10 2 Programmable and Manual Thermostat Installation 35 10 2 1 Connect a Programmable Thermostat 35 10 2 2 Connect a Manual Thermostat 36 11 Networker Installation Single and Multiple Connections 38 11 1 Networker Installation 38 11 2 Connect a Networker to SP or BX5 Series Heaters 38 11 3 Connect a Networker to a BX5 Heater 38 1...

Page 5: ...lectricity Authorities SuperSizeGuide Building Code of Australia BCA including local OH S requirements Environment Authorities This appliance must be installed maintained and removed by an Authorised Person For continued safety of this appliance it must be installed and maintained in accordance with the manufacturers instructions This appliance is heavy use 2 people or mechanical lifting device Im...

Page 6: ...ctional performance of any 3rd party device is entirely the responsibility of the device s supplier or installer Any 3rd party device technical installation operation performance or other enquiries need to be referred to the device s supplier or installer Any adverse effects of 3rd party devices on the operation performance or reliability of this appliance is not covered by the manufacturer s prod...

Page 7: ...Internal Universal SP615UN SP615IN SP521UN BX520EN SP521IN SP415UN SP623UN SP623IN SP521UN XA SP521IN XA SP421UN SP623UN XA SP623IN XA SP530UN BX526EN SP530IN SP430UN SP630UN SP630IN SP530UN XA SP530IN XA SP435UN SP630UN XA SP630IN XA SP535UN SP535IN SP635UN SP635IN 1 1 SP Heater Overview SP6 series heaters are condensing heaters SP4 and SP5 series heaters are non condensing heaters Universal mode...

Page 8: ...rve best practice can lead to costly call backs for installers unnecessary manufacturer warranty calls and a poor customer experience With our policy of continuous improvement we reserve the right to change or discontinue at any time specifications or designs without notice Definitions Shall Indicates a mandatory requirement of this manual Should Indicates a recommended requirement of this manual ...

Page 9: ...tment or the Technical Specifications at the rear of this manual Note All installations should only be carried out by a qualified tradesperson Installations at altitudes above 1000m above sea level may require main burner injector upgrading Please contact the Customer Service Centre for advice 2 2 INSPECTION This appliance has been inspected and tested at the time of manufacture and packaging and ...

Page 10: ...an maintain its required incoming gas pressure at maximum consumption with all other gas appliances operating at their maximum capacity at the same time as the heater 2 5 2 Electrical Power Supply The heater is pre wired with a 3 pin plug and lead and shall be plugged into a standard 10 Amp 220 240V fixed switched socket outlet adjacent to the heater in a convenient location so it can be turned OF...

Page 11: ...428 214 222 658 478 419 991 209 222 110 517 574 300 300 SP530UN XA 14 550 275 222 707 526 419 1083 209 222 250 565 574 400 400 SP530UN 14 550 275 247 707 526 539 1083 270 247 250 565 539 350 350 SP535UN 14 550 275 247 707 526 539 1083 270 247 250 565 539 450 450 SP615UN 14 428 214 222 658 478 419 991 209 222 110 517 574 300 300 SP623UN XA 14 428 214 222 658 478 419 991 209 222 110 517 574 350 350 ...

Page 12: ...C D E F G H I øSa øRa SP615IN 634 1021 395 594 440 440 15 513 224 300 300 SP623IN 634 1021 395 594 440 440 15 513 224 300 300 SP623IN XA 634 1021 395 594 440 440 15 513 224 350 350 SP630IN 684 1070 547 643 491 490 15 563 253 350 350 SP630IN XA 684 1070 547 643 491 490 15 563 253 400 400 SP635IN 684 1070 547 643 491 490 15 563 253 450 450 SP515IN 634 1021 395 594 440 440 15 513 224 300 300 SP521IN ...

Page 13: ...Method 2 Method 3 and Method 4 below The SP430 and SP435 can be installed in accordance with Method 1 and Method 2 only 3 3 2 Internal Clearances Method 1 In Ceiling and Under Floor Diagram 4 Method 1 Clearances Method 2 In Ceiling and Under Floor Diagram 5 Method 2 Clearances 750mm Minimum Fan Cabinet Heat Exchanger Cabinet 250 mm Minimum 750mm Minimum Service Clearance Heat Exchanger Cabinet Fan...

Page 14: ...as for servicing it is important to provide additional length in the ducting connected to the pops 3 4 2 SP4 SP5 and SP6 External Clearances Front A minimum of 500mm must be provided at the side facing away from the house End A minimum of 300mm must be provided at each end of the heater Top A minimum of 1000mm must be provided above the heater roof This clearance must be maintained for the entire ...

Page 15: ...mum of 500mm must be provided at the side facing away from the house End A minimum of 300mm must be provided at each end of the heater Top A minimum of 1000mm must be provided above the heater roof This clearance must be maintained for the entire surface area of the heater roof Diagram 9 BX5 Clearances 1000 mm min 500 mm min Service Clearance 500 mm min 300 mm min 300 mm min Side View Plan View Se...

Page 16: ...inlet to the back or to the side of the unit to suit the specific installation Change Duct Connection Locations Simplistically the heater unit is made up of two cabinets a heater cabinet air heating components and a fan cabinet supply air fan Diagram 10 identifies three pop positions on the heater cabinet H1 H2 and H3 and three pop positions on the fan cabinet F1 F2 and F3 Diagram 10 Duct Connecti...

Page 17: ... F2 panels d Install F1 and F2 panels in the required positions e Install F3 panel and handle f Install the lid 4 2 4 SP5U and SP6U Fan Cabinet Swap F1 F2 F3 a Remove the lid Diagram 10 b Remove the F3 handle and then remove the panel c Press the pre cut opening for the flue from F1 F2 panel as required d Install the panels in the required positions Install the end panel and handle last e Ensure t...

Page 18: ...heat Switch c Remove H1 or H2 panels d Remove the H1 or H2 internal panels four screws each behind insulation e Install the internal panels in the required positions f Install the external panels Install the end panel and handle last g Install the lid Note Ensure the overheat switch loom is not tangled tight or pinched Supply Air Switch Position SP623U 630U 521U 4 2 8 Supply Air Switch Position Al...

Page 19: ...ied with a gas feed to be in the controls area beneath the lid The gas feed shall be installed on to the heater gas valve and tested for leaks For Universal heaters install the gas feed tube as follows a Change the pop duct connection locations as required This ensures the pre cut blanking plate is removed from the correct cabinet panel b Remove the pre cut blanking plate covering the hole in the ...

Page 20: ...increase diameter size Under no circumstances should any part of the tube sag or run uphill Special consideration is required for installation in areas experiencing sub zero temperature as condensate could freeze in the drain In these cases larger diameter drainage piping is required Approximately 2 to 3 litres per hour of condensate may be produced under continuous running conditions depending on...

Page 21: ...eater being installed Diagram 14 Wall Cut out Area 6 2 SPLITTING HEATER FOR ASSISTED LIFTING AND POSITIONING Not applicable BX5 Models The SP series heaters can be split for ease of installation 6 2 1 SP4 Universal Heater a Remove the lid four screws b Disconnect the gas valve overheat pressure switch loom igniter and flame sensor from the PCB c Disconnect the flue pipe d Remove the screws fasteni...

Page 22: ...inet compartment by removing the single screw d Remove the 2 screws fastening the fan cabinet tabs to the heat exchanger cabinet These are located at the top of the fan cabinet on the heater s split line e Pivot the fan cabinet upwards high enough to dislodge the lower locking tabs fixed to the fan cabinet near the base f The heater is now split in two g Protect the exposed looms and tabs from dam...

Page 23: ... is used the supporting platform must be covered with a fire resistant material 6 3 2 Installation Beneath the Floor There must be a minimum clearance of 200mm between any part of the appliance and the lowest part of the floor structure In addition to this refer to Service Clearances 3 3 internal or external The heater must be located within 2m of the access opening or with a minimum clearance of ...

Page 24: ...ented to outside or into a roof space vented to outside Properties Approved for Construction after 31st March 2014 c Determine if the rating per cubic metre of the space is greater than 0 4 MJ hr Example Unit rating Ur 120MJ hr Room volume Rv 1m x 1m x 2 4m 2 4m3 Ur Rv 120 2 4 50 MJ hr per m3 As the result is greater than 0 4 MJ hr per cubic metre of the space additional ventilation is required Re...

Page 25: ...ied with associated flashing kit 6 4 2 SP5 and SP6 Installation of Flashing For installation details refer to the instructions supplied with associated flashing kit Note To allow the heater to be moved out from the wall such as for servicing it is important to provide additional length in the ducting connected to the pops ...

Page 26: ...odels 100mm Drainage Waste Vent DWV Flue Level Invert Taper LIT All SP6 internal model heaters are supplied with an LIT fitting in the controls area beneath the lid The LIT must be installed to the heater flue outlet The flue outlet connection can be found behind an installer instruction label The field supplied flue is connected to the unit via a 100mm drain waste vent pipe DWV to AS NZS 1260 and...

Page 27: ... Table 7 Maximum Flue Bends and Terminals All SP6 Universal Models 100mm DWV Flue Heater Orientation Flue Orientation 90º Bends Up to 4 Terminal Type Standard Vertical 25m 100mm DWV Plain Vent Cowl Horizontal 25m Remote Flue Terminal Lay down Vertical 25m 100mm DWV Plain Vent Cowl Horizontal 25m Remote Flue Terminal Note One 45º bend is equivalent to one half 90º bend and all vertical flue orienta...

Page 28: ...t No B021385 Remove the label and insert the flue terminal firmly into the flue outlet socket in the correct orientation to ensure the flue gases are expelled away from the house refer to Diagram 19 Diagram 19 Flue Terminal Installation LEVEL CONCRETE BASE IMPORTANT ENSURE THE FLUE OPENING POINTS AWAY FROM THE WALL GROUND LEVEL FLASHING WALL OPEN AREA OF FLUE TERMINAL Note The flue terminal must b...

Page 29: ...ctly to ensure flue gases are expelled away from the house refer to Diagram 19 Heaters should be positioned to ensure the following minimum clearances exist when measured from the edges of the flue 75mm Wall From the wall against which the heater is mounted From a drain pipe or soil pipe 300mm Flue Cowl or Intake From a flue terminal cowl or combustion air intake Below eaves balconies or other pro...

Page 30: ...e thermistor lead is secured to timbers or duct outer casing to prevent damage If the first BTO fitting is installed more than 3m away from the heater an additional duct joiner installer supplied will be required so that the thermistor assembly can be fitted correctly Install the joiner between 1m and 3m away from the heater ensuring the thermistor can reach this joint After making this modificati...

Page 31: ... tab Push Push up to the inner face of basebox First hole with mounting screw supplied Heater Coil up excess loom Base box Note The thermistor bracket is affixed with supplied mounting screw at the discharge pop The loom can be installed either left or right handed to be confirmed by installer Remove bracket from heat exchanger and install as shown above Be careful not to pinch the loom ...

Page 32: ...te It is important that the ducting should be well insulated It is mandatory under building codes to install insulated fire rated duct 9 2 RETURN AIR GRILLE If a filter is fitted to the return air grille make sure it is easily accessible for regular cleaning Table 8 gives the minimum recommended return air grille sizes for each model heater Table 8 Minimum Recommended Return Air Grille Selection W...

Page 33: ... properly balanced There is not a limit maximum number of floor outlets so Table 9 lists the typical number for each heater model Half figures such as 1 5 indicate one outlet fully open and another outlet half open for example in a bathroom Refer to Section 13 2 The outlet chart is divided into four columns as follows A The maximum number of outlets that should remain fully open for a ceiling outl...

Page 34: ...P521U 785 12 13 5 1 5 SP521U XA 830 14 13 5 1 5 SP530U 1045 16 24 7 2 SP530U XA 1108 17 24 7 2 SP535U 1133 17 24 7 2 5 SP5 Heaters Internal SP521IN 785 12 13 5 1 5 SP521IN XA 830 14 13 5 1 5 SP530IN 1080 17 24 7 2 SP530IN XA 1140 17 24 7 2 SP535IN 1160 17 24 7 2 5 SP4 Heaters Universal SP415U 620 10 12 6 2 SP421U 621 10 12 6 2 SP430U 918 16 23 7 2 SP435U 1004 17 23 7 3 BX5 Heaters External BX520EN...

Page 35: ...ay from warm air outlets such as radiation from the sun fireplaces radio and television sets and nearby warm pipes and ducts Avoid Cold Spots Keep the thermostat away from draughts such as from doorways stairwells windows and return air inlets Avoid Dead Spots Keep the thermostat away from areas of less than normal air circulation such as behind doors in alcoves or in corners Interference From Oth...

Page 36: ...res to thermostat terminals A and B d Ensure the thermostat batteries are correctly installed and mount the thermostat level on the wall refer to and follow the installation guide supplied with the thermostat Note Use only alkaline batteries as other types of battery can cause unpredictable operation as the batteries become depleted e Install the thermostat front cover f Connect the wiring to the ...

Page 37: ...Rinnai 37 Ducted Gas Heater IM Diagram 25 BX5 Manual Thermostat Manual Thermostat BX5 Terminal Block W R ...

Page 38: ...aw the wires from the wall cavity and feed them through the opening in the backing plate d Connect the cable to the terminal connections on the backing plate before mounting it on the wall and reassembling the networker e Connect the other end of the cable to the terminals marked TW1 and TW2 in the heater s electronic control module refer to Diagram 26 Note To connect multiple heaters refer to Sec...

Page 39: ...s can be connected to a single SP series heater to provide dual controls This is particularly useful with adaptive zoning to enable dedicated zone control For example one networker can be used to control one zone while the other networker is used to control another zone Heater settings can be adjusted from either networker and will remain common to both networkers That is when a heater setting is ...

Page 40: ...arameters are not available from slave networkers Therefore after a networker is configured as a slave the master networker must be used to access the parameters Diagram 29 Networker Identification Networker ID Parameter Value 11 3 3 Change a Networker from Slave to Master a Detach the networker from the backing plate The controller powers down b While continually pressing Key 3 and Key 5 mount th...

Page 41: ... RJ12 socket connectors preconfigured for Belimo 24V damper motors RJ Socket Connections The plastic cover on the PCB includes moulded cut outs to enable access to the RJ12 socket For each socket to be used press out and remove the cut out and connect the RJ plug from the Belimo damper motor If not a Belimo damper motor confirm suitability of the terminal on the damper motor before connecting to t...

Page 42: ...TOR TO THE CONTROL MODULE Diagram 32 24VAC Power Open Power Close Damper Motor Diagram 33 24VAC Power Open Spring Return Damper Motor Diagram 34 240VAC Power Open Power Close Damper Motor ZONE B ZONE A N C 0V N O N C 0V N O Close Common Open Damper Motor 24VAC Power Open Power Close RJ12 Connectors ZONE B ZONE A N C 0V N O N C 0V N O Active Neutral Damper Motor 24VAC Power Open Spring Return RJ12 ...

Page 43: ...nstallation airflow requirements It is recommended that a fan speed of at least 1000 be selected as lower speeds are more likely to result in overheating if the system has not been balanced correctly 2 H01 ID02 1350 COOLING MAXIMUM FAN SPEED SETTING The fan RPM setting for normal cooling operation This setting can be adjusted from 500 to 1350 3 H01 ID03 950 HEATING ZONING MINIMUM FAN SPEED SETTING...

Page 44: ...eating mode DO NOT SET BELOW 1000 9 H01 ID09 0 DO NOT ADJUST 10 H01 ID10 30 Damper motor Open Close time can be adjusted between 5 and 240 seconds factory default 30 seconds Adjust Networker Parameters Adjust heater parameters via a networker as follows a Press Key 5 Clock setting mode displays Confirm that the clock display is flashing b Press and hold Key 2 and Key 4 until Installer parameter ac...

Page 45: ...ock out with an error code If this occurs take note of the code and reset the heater refer to the Operation manual Initially the fan will run at a low speed approximately 500 RPM and then to ramp up to the preset fan speed for heating refer to Table 10 Item 1 h Wait for the heater to operate for at least 1 minute and then measure the gas inlet pressure While all other gas appliances are operating ...

Page 46: ...hermistor set temperature to achieve a 35º to 40ºC rise and avoid modulation If the heater still reaches the thermistor set temperature or the rise is greater than 40ºC increase the fan speed c With a ceiling outlet system which usually requires a higher fan speed if the heater reaches the thermistor set temperature and modulates this is unlikely increase the thermistor set temperature and or incr...

Page 47: ... operation of the system j Issue any required documentation to the relevant people authorities in regard to the installation of the heater the gas connection and the power supply For example a Certificate of Compliance and Certificate of Electrical Safety 13 4 FAULT CODE IDENTIFICATION ON HEATER PCB If the heater fails to start the fault may display on the heater control board with a dual L E D fl...

Page 48: ... Air Overheat 48 4 8 Pressure Lost 60 6 0 Motor Open Circuit 69 6 9 Fuse Blown 24Vac 2A 50 5 0 Ignition Lockout 51 5 1 Rollout No Gas 54 5 4 Rollout Lockout 56 5 6 Pressure Switch Stuck Open 57 5 7 Pressure Switch Stuck Closed 58 5 8 Pressure Switch Fail To reset the appliance and clear a lockout fault press and hold the CLEAR button for three seconds on the heater control board or reset through a...

Page 49: ...6 13 SP521UN External 90 N A 21 N A 300 0 26 0 39 700 675 645 615 61 315 4 2 6 13 SP521UN XA Internal 90 N A 21 N A 350 0 28 0 42 830 800 770 735 61 315 4 2 6 15 SP521UN XA External 90 N A 21 N A 350 0 28 0 42 740 710 685 655 61 315 4 2 6 13 SP530UN Internal 130 N A 30 N A 350 0 36 0 54 1145 1113 1078 1045 80 650 4 3 6 18 SP530UN External 130 N A 30 N A 350 0 36 0 54 997 965 929 893 80 650 4 3 6 1...

Page 50: ...650 4 3 6 18 SP535IN 150 N A 35 N A 450 0 39 0 58 1245 1215 1190 1160 72 650 4 3 6 22 SP615IN 58 N A 14 N A 300 0 26 0 39 695 665 630 595 57 315 4 2 6 10 SP623IN 86 N A 23 23 300 0 26 0 39 765 745 720 695 59 315 4 2 6 13 SP623IN XA 86 86 23 23 350 0 28 0 42 795 775 755 730 59 315 4 2 6 13 SP630IN 110 N A 29 29 350 0 36 0 54 1125 1110 1085 1065 72 650 4 3 6 18 SP630IN XA 110 110 29 29 400 0 38 0 57...

Page 51: ...Rinnai 51 Ducted Gas Heater IM NOTES ...

Page 52: ...pliance be serviced at least every 2 years With our policy of continuous improvement we reserve the right to change or discontinue at any time specifications or designs without notice Australia Pty Ltd ABN 74 005 138 769 100 Atlantic Drive Keysborough Victoria 3173 P O Box 460 Braeside Victoria 3195 AU45204 Product Sales Service National Help Line Tel 1300 555 545 Fax 1300 555 655 Monday to Friday...

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