Rinnai Brivis StarPro SP623UN User manual

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

Rinnai 2 Ducted Gas Heater IM
This page is intentionally blank

Rinnai 3 Ducted Gas Heater IM
Table of Contents
Warnings and Important Information 5
1. Scope 7
1.1 SP Heater Overview......................................................................................................................................... 7
1.2 BX5 Heater Overview....................................................................................................................................... 7
1.3 Installer Due Diligence for Changeovers ......................................................................................................... 8
Definitions................................................................................................................................................................... 8
Disclaimer................................................................................................................................................................... 8
2. General Product Guidelines 9
2.1 Application and Sizing...................................................................................................................................... 9
2.2 Inspection......................................................................................................................................................... 9
2.3 Unpacking the Heater ...................................................................................................................................... 9
2.4 Unloading or Lifting the Heater ........................................................................................................................ 9
2.5 Service Connection Guidelines...................................................................................................................... 10
2.5.1 Gas Inlet Connection ......................................................................................................................... 10
2.5.2 Electrical Power Supply ..................................................................................................................... 10
3. Heater Dimensions and Clearances 11
3.1 Heater Dimensions – SP4, SP5 and SP6...................................................................................................... 11
3.2 Heater Dimensions – BX5.............................................................................................................................. 12
3.3 Service Clearances – Internal........................................................................................................................ 13
3.3.1 Service Clearance Notes ................................................................................................................... 13
3.3.2 Internal Clearances............................................................................................................................ 13
3.4 Service Clearances – External....................................................................................................................... 14
3.4.1 Installation of Flashing ....................................................................................................................... 14
3.4.2 SP4, SP5 and SP6 External Clearances........................................................................................... 14
3.4.3 BX5 Service Clearances.................................................................................................................... 15
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 Orientation .............................................................................................................................................. 18
4.2.6 SP4 Heater Cabinet: Swap H1/H2 – H3............................................................................................ 18
4.2.7 SP5 and SP6 Heater Cabinet: Swap Any Combination of H1, H2 or H3.......................................... 18
Supply Air Switch Position – SP623U/630U/521U................................................................................................... 18
4.2.8 Supply Air Switch Position ................................................................................................................. 18
4.3 SP Series Gas Feed Tube Installation........................................................................................................... 19
5. Condensate Removal 20
5.1 Condensate Drain .......................................................................................................................................... 20
5.1.1 Install a Condensate Drain to an SP6 Universal and Internal Units.................................................. 20
6. Heater Positioning 21
6.1 Wall Cut-out Area........................................................................................................................................... 21
6.2 Splitting Heater for Assisted Lifting and Positioning ...................................................................................... 21
6.2.1 SP4 Universal Heater ........................................................................................................................ 21
6.2.2 SP5 Universal Heater ........................................................................................................................ 22
6.2.3 SP5 and SP6 Internal Heater ............................................................................................................ 22
6.2.4 SP6 Universal Heater ........................................................................................................................ 22

Rinnai 4 Ducted Gas Heater IM
6.3 Internal Installations ....................................................................................................................................... 23
6.3.1 Installation in the Roof Space............................................................................................................ 23
6.3.2 Installation Beneath the Floor............................................................................................................ 23
6.3.3 Ventilation Calculations...................................................................................................................... 23
6.4 External Installations ...................................................................................................................................... 24
6.4.1 SP4 – Installation of Flashing ............................................................................................................ 25
6.4.2 SP5 and SP6 – Installation of Flashing............................................................................................ 25
7. Flue Instructions and Clearances 26
7.1 Internal – SP Series ....................................................................................................................................... 26
7.1.1 General .............................................................................................................................................. 26
7.1.2 SP4 and SP5 Models – 100mm Non-corrosive Metal Flue............................................................... 26
7.1.3 SP6 Universal Models – 100mm Drainage Waste Vent (DWV) Flue................................................ 26
7.1.4 Remote Terminal (Part No. B018384) Internal Model Applications................................................... 27
7.2 External – SP Series Flue Terminal Clearances ........................................................................................... 28
7.2.1 Installation of Flue Terminal............................................................................................................... 28
7.3 External – BX5 Flue Terminal Clearances..................................................................................................... 29
8. Thermistor Installation 30
8.1 SP Series Thermistor Installation................................................................................................................... 30
8.2 BX5 Thermistor Installation............................................................................................................................ 30
9. Ducting and Outlets 32
9.2 Return Air Grille.............................................................................................................................................. 32
9.3 Return Air Pop Configuration Changes ......................................................................................................... 32
9.4 Outlet Chart Information................................................................................................................................. 33
10. Thermostat Installation 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
11.3.1 Connect Multiple Heaters to a Networker.......................................................................................... 39
11.3.2 Connect Dual Networkers.................................................................................................................. 39
11.3.3 Change a Networker from Slave to Master ....................................................................................... 40
11.3.4 Network 516 Manual.......................................................................................................................... 40
11.3.5 ZonePlus............................................................................................................................................ 40
12. Adaptive Zoning and Add-on Air Conditioning 41
12.1 Options........................................................................................................................................................... 41
12.2 Damper Motor Connections ........................................................................................................................... 41
12.3 Connect a Damper Motor to the Control Module........................................................................................... 42
13. Commissioning and Control Settings 43
13.1 SP4, SP5, SP6 and BX5 Heater Control Settings ......................................................................................... 43
13.2 SP4, SP5, SP6 and BX5 Commissioning Instructions .................................................................................. 45
13.2.1 Initial Damper Settings....................................................................................................................... 45
13.2.2 Initial Ignition and Gas Inlet Pressure Check .................................................................................... 45
13.2.3 Heater Temperature Settings and Fan Speed................................................................................... 45
13.3 Final Checks (SP4, SP5, SP6 and BX5 Heaters).......................................................................................... 47
13.4 Fault Code Identification on Heater PCB....................................................................................................... 47
14. Technical Specifications 49

Rinnai 5 Ducted Gas Heater IM
WARNING
READ ALL INSTRUCTIONS BEFORE USING THE APPLIANCE.
Always comply with the following precautions to avoid dangerous situations and to ensure
optimum performance.
Failure to carefully read and follow all instructions in this manual can result in equipment
malfunction, property damage, personal injury and/or death.
DANGER: Indicates an imminently hazardous situation which, if not avoided, will result in
personal injury or death.
WARNINGS: Indicates a potentially hazardous situation which, if not avoided, could result in
personal injury or death.
CAUTIONS: Indicates a potentially hazardous situation which, if not avoided, could result in
minor or moderate injury or damage to the appliance. It may also be used to alert against unsafe
practices.
WARNING
REGULATORY / INSTALLATION
This appliance shall be installed in accordance with:
• Manufacturer’s Installation Instructions.
• Current AS/NZS 5601, AS/NZS 5141 and AS/NZ 3000.
• AS 4254 - Ductwork for air-handling systems in buildings.
• HB 276-2004 – A Guide to Good Practice.
• Local Gas and Electricity 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. Improper lifting may result in
serious injury.
Take care when opening or unpacking this appliance. Failure to do so may result in serious injury
or product failure.
DO NOT modify the electrical wiring of this appliance. If the control power wiring is damaged
or deteriorated then it must be replaced by an authorised person. Failure to do so may result in
electric shock, re, serious injury or product failure.
DO NOT install the heater on an unstable or non level surface or where there may be a danger
of it falling. It may result in death, serious injury, or product failure.
DO NOT install the outdoor unit where noise may cause nuisance.
NOTE
A NOTE ON ILLUSTRATIONS
The illustrations used in this manual are for explanatory purposes only and the shape of your unit
may vary slightly from that which is shown in this manual.
WARNINGS AND IMPORTANT INFORMATION

Rinnai 6 Ducted Gas Heater IM
NOTE
The manufacturer cannot guarantee compatibility and support for anyone using 3rd party
accessory/devices (device) on any of their appliances.
The suitability, compatibility or functional 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 e󰀨ects of 3rd party devices on the operation, performance or reliability of this
appliance is not covered by the manufacturer’s product warranty.

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 ueing congurations. Although
recommended return air grilles and allowable duct outlet quantities are specied, 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 qualied 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 Specications section.
1.2 BX5 Heater Overview
The BX520 and BX526 ducted heaters are designed primarily to replace Bu󰀨alo 85 and Bu󰀨alo 120 heaters
respectively. Their conguration allows for seamless changeover onto an existing base box, where applicable, with
identical service connections, capacities and airows commensurate with the original units. They also incorporate
on-board controls providing greater exibility for thermostat and zone control options.

Rinnai 8 Ducted Gas Heater IM
1.3 Installer Due Diligence for Changeovers
Modern ducted gas heaters, even those that are physically ‘like-for-like’, typically have di󰀨erent technical specications
and control systems to existing, older models. Modern units usually have higher Star Ratings, which are accompanied
by higher airows. Higher e󰀩ciency heaters with modulating gas valves also operate di󰀨erently to non-modulating
units.
When doing a direct unit change over:
• Do a comprehensive inspection of the entire existing system to ensure it is ‘t for purpose’ with the new heater
• Check existing items that are not being replaced; i.e. ensure the soundness and suitability of all ttings and
controls for use with the new ducted gas heater (e.g. Duct sizes, Flue, Return Air grille size, Thermostat, Zoning
etc.)
• Correctly commission the new ducted gas heater – where possible, align it with the performance characteristics
of the original system – do not leave units at the factory default settings unless you are absolutely certain the
settings are appropriate
Failure to observe 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, specications
or designs without notice.
Definitions
Shall
Indicates a mandatory requirement of this manual.
Should
Indicates a recommended requirement of this manual.
Any deviations from these instructions may, at the discretion of the manufacturer, void the warranty. As a result, the
customer and/or installer may be charged a fee for non-product warranty related call outs. Also note that failure to
comply with these instructions may preclude company service personnel from being able to service the unit.
Disclaimer
IMPORTANT: This document is a guide only. Laws, regulations and industry standards can vary between States and Territories.
Accordingly, this guide must be read in conjunction with, and subject to, all laws, regulations and industry standards
applicable in the State or Territory in which the products are installed. You must ensure that the installation of the
products will comply with those laws, regulations and standards, and that the products recommended to customers
are fit for the purpose for which they are intended.

Rinnai 9 Ducted Gas Heater IM
2. GENERAL PRODUCT GUIDELINES
2.1 APPLICATION AND SIZING
These heaters are designed to provide a central source of heat for a ducted central heating system.
The heaters should not be installed downstream from an air washer, an evaporative cooler or refrigerative cooling
system. Nor are they designed to be installed on a marine craft, houseboat, or any similar environment.
The heaters must be installed in accordance with these instructions and related regulations, codes, standards, and
authorities. These include but may not be limited to:
• AS/NZS 3000 - Electrical Installations
• AS/NZS 5601 - Gas Installations
• AS 4254 - Ductwork for air-handling systems in buildings
• HB 276 - A Guide to Good Practice
• AS/NZS 5141 - Residential Climate Control Systems
• Local Gas and Electricity Authority Codes
• Product Sizing Guide
• Local Building Regulations
• Environment Authorities
• National Construction Code of Australia (NCC)
Note: The manufacturer assumes no responsibility for equipment installed in violation of any code, regulations and these installation
instructions..
It is recommended the Product Sizing Guide is followed in estimating heating requirements and for system design
that will result in efficient installation and provide a higher level of comfort and economical operation.
For the hourly input and the gas type to be used, refer to the appliance data label located inside the service
compartment 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 released for
transportation without known damage. Upon receipt, inspect the exterior for evidence of rough handling in shipment.
Ensure that the appliance is labelled correctly for the gas to which it is intended to be connected. If a discrepancy or
damage to the appliance is identified DO NOT install the appliance and report findings back to supplier.
2.3 UNPACKING THE HEATER
Some heaters are supplied on a pallet with a plastic sleeve. To unpack:
Cut and remove the external plastic packaging and dispose of thoughtfully.
Remove heater from pallet (if supplied).
Some heaters are supplied with a base box assembly wrapped with a removable plastic film to protect the surface.
Note: Always remove and dispose of the plastic film before mounting the heater onto the base box.
2.4 UNLOADING OR LIFTING THE HEATER
When unloading or lifting the heater, ensure lifting equipment is in good operating condition and capable of lifting
the total load. Be sure there is a clear area to place the heater down, which is within reach of the lifting equipment.
Note: Do not use the lifting handles provided to lift the heater above head height. If fitting the heater to elevated heights such as a
roof, use suitable lifting equipment.

Rinnai 10 Ducted Gas Heater IM
2.5 SERVICE CONNECTION GUIDELINES
2.5.1 Gas Inlet Connection
• All piping must be in accordance with AS/NZS 5601 and any local gas regulations.
• The connection point for universal and external model heaters is a female G3/4 compression fitting to AS 3688.
This is either located on the outer cabinet of the heater, or supplied loose within the heater.
• The connection point for internal model heaters is a male G3/4 compression fitting to AS 3688.
• A gas cock shall be fitted in the gas line adjacent to the heater and in a convenient location so it can be turned
OFF quickly and easily.
• The gas supply shall in no way interfere with any servicing of the heater.
Note: The gas supply must be installed by a licensed gas fitter. The gas pipe and gas meter should be sized so the heater can
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 OFF quickly and easily.
Note: A qualified electrician must install the 220 to 240 volt wiring according to local regulations.
IMPORTANT: Switch OFF the power and unplug the heater before touching any wiring. If any electrical wiring is damaged, it must
be replaced by the manufacturer, its service agents or an electrically qualified technician, in order to avoid a hazard.
The electricity supply must be 220-240V at 50Hz, and supplied by an authorised power supplier. Generators should
never be used to supply this system as their output may be incompatible with, or prone to damage electronic
components of the heater.

Rinnai 11 Ducted Gas Heater IM
3. HEATER DIMENSIONS AND CLEARANCES
3.1 HEATER DIMENSIONS –SP4, SP5 AND SP6
Diagram 1. SP4, SP5 and SP6 Universal Heater Dimensions (SP6U illustrated)
Table 1. SP4, SP5 and SP6 Universal Heater Dimensions (mm)
UNIVERSAL
MODEL A B C D E F G H J K L M N øSa øRa
SP415UN 14 397 197 235 625 467 448 845 197 235 95 495 447 300 300
SP421UN 14 397 197 235 625 467 448 845 197 235 95 495 447 300 300
SP430UN 14 549 197 235 644 487 497 923 237 235 250 515 487 350 350
SP435UN 14 549 197 235 644 487 497 923 237 235 250 515 487 400 400
SP521UN-XA 14 428 214 222 658 478 419 991 209 222 110 517 574 350 350
SP521UN 14 428 214 222 658 478 419 991 209 222 110 517 574 300 300
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
SP623UN 14 428 214 222 658 478 419 991 209 222 110 517 574 300 300
SP630UN-XA 14 550 275 247 707 526 539 1083 270 247 250 565 539 400 400
SP630UN 14 550 275 247 707 526 539 1083 270 247 250 565 539 350 350
SP635UN 14 550 275 247 707 526 539 1083 270 247 250 565 539 450 450
Note: SP4, SP5 and SP6 Universal models are approved for internal or external applications.
A
E
F
D
C
POWER LEAD
K
ØRa
FLUE OUTLET
M
L
JN
G
H
B
GAS INLET
ØSa

Rinnai 12 Ducted Gas Heater IM
Diagram 2. SP5/6 Internal Heater Dimensions
Table 2. SP5/6 Internal Heater Dimensions (mm)
INTERNAL MODEL A B C D E F G H J øSa øRa
SP521IN 634 1021 395 594 440 440 15 513 224 300 300
SP521IN-XA 634 1021 395 594 440 440 15 513 224 350 350
SP530IN 684 1070 547 643 491 490 15 563 253 350 350
SP530IN-XA 684 1070 547 643 491 490 15 563 253 400 400
SP535IN 684 1070 547 643 491 490 15 563 253 450 450
SP615IN 634 1021 395 594 440 440 15 513 224 300 300
SP623IN 634 1021 395 594 440 440 15 513 224 350 350
SP623IN-XA 684 1070 547 643 491 490 15 563 253 350 350
SP630IN 684 1070 547 643 491 490 15 563 253 400 400
SP630IN-XA 684 1070 547 643 491 490 15 563 253 450 450
3.2 HEATER DIMENSIONS –BX5
Diagram 3. BX5 Heater Dimensions
FLUE
TERMINAL
GAS
INLET
Ø P M
K
L
N
J
A
B
F
D
H
E
G
C
SP6 & SP5 Internal
SP5 External
Dimension
[mm] A B 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 634 1021 395 594 440 440 15 513 224 300 300
SP521IN-XA 634 1021 395 594 440 440 15 513 224 350 350
SP530IN 684 1070 547 643 491 490 15 563 253 350 350
SP530IN-XA 684 1070 547 643 491 490 15 563 253 400 400
SP535IN 684 1070 547 643 491 490 15 563 253 450 450
Dimension
[mm] A B C D E F G H I J K L M N øSa øRa
SP521EN 657 1046 416 15 104 520 211 - 620 - 210 - 224 480 300 300
SP521EN-XA 657 1046 416 15 104 520 - 230 - 580 - 231 224 480 350 350
SP530EN 707 1096 568 15 255 570 236 - 620 - 236 - 249 530 350 350
SP530EN-XA 707 1096 568 15 255 570 - 261 - 570 - 261 249 530 400 400
C
J
øSa
B
E
D
F
G
A
H
øRa
(SP6 MODELS ONLY)
A
BC
D
E
F
G I K
M
H J L
øSa
øRa
N
A
BC
D
E
F
G I K
M
H J L
øRa
øSa
N
BC
E

Rinnai 13 Ducted Gas Heater IM
Table 3. BX5 Heater Dimensions (mm)
MODEL A B C D E F G H J K L M N P
BX520 775 852 420 341 41 156 135 391 1145 715 1085 370 771 300
BX526 866 1028 582 387 41 238 135 557 1280 805 1220 415 951 350
3.3 SERVICE CLEARANCES –INTERNAL
3.3.1 Service Clearance Notes
All SP6 models, SP5 models, SP415 and SP421 models can be installed in accordance with 'Method 1',
'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 Cabinet
Platform
Side View Plan View
Fan
Cabinet
Heat
Exchanger
Cabinet
800 mm
Minimum
Platform
Service Clearance
Heat
Exchanger
Cabinet
Fan Cabinet
750mm
Minimum
Side View Plan View

Rinnai 14 Ducted Gas Heater IM
Method 3: Lay-down Option – In Ceiling
Diagram 6. Method 3 Clearances
Method 4: Lay-down Option – Under Floor
Diagram 7. Method Clearances
Note: Method 3 and Method 4 are not options for SP430 and SP435 models. These models may be installed to Method 1 or Method
2 only.
3.4 SERVICE CLEARANCES –EXTERNAL
3.4.1 Installation of Flashing
The flashing must be fitted to ensure the ductwork is adequately weather protected.
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.
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 surface area of the heater roof.
Fire resistant board
(refer to AS5601)
700 mm
750 mm
300 mm (refer to AS5601)
Side View
Service
Clearance
(Full length of heater)
Ground
750 mm
200 mm (refer to AS5601)
Lowest part of floor structure
Concrete Base 50mm
Service
Clearance
(Full length of heater)
700 mm
Side View

Rinnai 15 Ducted Gas Heater IM
Diagram 8. External Clearances
1000 mm min
Side View
Service
Clearance
500 mm
min
Service
Clearance
Plan View
Service Clearance
500 mm min
300 mm
min
300 mm
min
(Front)
(Top)
(Front)
(End)(End)
Flashing
3.4.3 BX5 Service 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 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
Service
Clearance
Service
Clearance
(Top)
(Front)
(Front)
(End) (End)
Flashing

Rinnai 16 Ducted Gas Heater IM
4. HEATER CONFIGURATION
4.1 HEATER DUCT POP INSTALLATION
On all SP series heaters, the duct connection pops need to be fastened to the heater cabinet as follows:
• Insert pops into the hole in the pop plate, ensuring the pop flange is placed over the prescribed wall of the
cabinet, refer to Table 4.
• Spread pop flange to fit tightly into the hole in the cabinet (the notch side overlapping the other).
• Secure pops with the rivets supplied.
Table 4. Pop Installation
Matrix
Return Air Supply Air
No. of Walls Install Pop No. of Walls Install Pop
Universal Model Cabinet
SP4 2 Inner Wall 2 Inner Wall
SP5 1 No Option 2 Inner Wall
SP6 1 No Option 2 Inner Wall
Internal Model Cabinet SP5 1 No Option 2 Inner Wall
SP6 1 No Option 2 Inner Wall
4.2 DUCT CONNECTION CONFIGURATION OPTIONS
(Not applicable BX5 Models)
For SP Series heaters, the return air and supply air duct connections can be reconfigured. That is, the heater panels
can be repositioned to move the duct outlet/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 Connection Options
Return Pop Position
from Factory
Supply Pop
Position
from
Factory
F1
HEATER CABINET FAN CABINET
RETURN AIR
SIDE
SUPPLY AIR
SIDE
F2
H1
H2
H3 F3
SP430U and SP435U: The pops can be configured to support any combination of the following options:
• Return air pop: Can be positioned at F1 or F2 (Diagram 10).
• Supply air pop: Can be positioned at H1, H2 or H3.
SP415U, SP421U, SP5U and SP6U: The pops can be configured to support any combination of the following
options:
• Return air pop: Can be positioned at F1, F2 or F3 (Diagram 10).
• Supply air pop: Can be positioned at H1, H2 or H3.
SP5 and SP6 Internal: The return air pop can be configured to support any combination of the following options:
• Return air pop: Can be positioned at F1 or F2 or F3 (Diagram 10).
• Supply air pop: Can be positioned at H3 only.

Rinnai 17 Ducted Gas Heater IM
Return Air Orientation
4.2.1 SP430U and SP435U Fan Cabinet: Swap F1 – F2
a. Remove the lid.
b. Remove F1 and F2 panels (Diagram 10).
c. Remove the internal blanking panel (four screws behind insulation).
d. Install the blanking panel in the required position.
e. Install F1 and F2 panels in the required positions.
f. Install the lid.
4.2.2 SP415U, SP421U Fan Cabinet: Swap F1/F2 – F3
(Not available for SP430U and SP435U)
a. Remove the lid (Diagram 10).
b. Remove the F3 handle and flue terminal, and then remove the panel.
c. Remove the flue hole blanking plate from F1 or F2 as required, then remove the panel.
d. Remove the internal blanking panel (four screws behind insulation).
e. Install the blanking panel in the required position.
f. Install the panels in the required positions.
g. Install the flue terminal and flue hole blanking plate.
h. Install the lid.
4.2.3 SP5U and SP6U Fan Cabinet: Swap F1 – F2
a. Remove the lid (Diagram 10).
b. Remove F3 handle and panel.
c. Remove F1 and 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 the flue is correctly installed.
f. Install the lid.
4.2.5 SP5 and SP6 Internal Fan Cabinet: Swap F1 – F2/F3
a. Remove the screws securing the side pop plate F1 and blanking plate F2/F3 and remove the plates.
b. Install the panels in the required positions
IMPORTANT: RETURN AIR CONNECTION AT THE END OF THE UNIT - REAR ENTRY (F3)
Connecting the return air duct to the end of the unit reduces the rated airflow by up to 30%. The total number of outlets normally permitted
for a heating system shall be reduced by 2 (predominantly when a unit is laid down). Refer to the outlet register chart on "Table 9. Outlet
Register Chart" on page 34
For ADD-ON cooling applications, MAKE SURE that the minimum recommended airflow is maintained. Refer to the
ADD-ON installation manual for more information.

Rinnai 18 Ducted Gas Heater IM
IMPORTANT: RETURN AIR CONNECTION AT THE END OF THE UNIT (F3)
Connecting the return air duct to the end of the unit reduces the rated airflow by up to 30%.
For ADD-ON cooling applications, MAKE SURE that the minimum recommended airflow is maintained. Refer to the
ADD-ON installation manual for more information.
Supply Air Orientation
4.2.6 SP4 Heater Cabinet: Swap H1/H2 – H3
a. Remove the lid (Diagram 10).
b. Remove the H3 handle, and then remove the panel.
c. Remove H1 or H2 panel as required.
d. Remove the internal blanking panel (four screws behind insulation).
e. Install the blanking panel in the required position.
f. Install the external panels in the required positions.
g. Install the lid.
4.2.7 SP5 and SP6 Heater Cabinet: Swap Any Combination of H1, H2 or H3
a. Remove the lid (Diagram 10).
b. Remove H3 panel.
Diagram 11. Overheat Switch
Overheat
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
All SP units leave the factory configured for an internal installation with the supply air pop at the heaters end, refer
to diagram 12A. When models detailed in Table 5 are reconfigured to an external installation the supply air overheat
switch assembly must remain secured to the internal supply air pop panel. The supply air overheat loom for external
installations must be rerouted and path is dependent on the nominated supply air side of heater, refer to diagrams
12B and 12C to identify the requirements. All other models within this manual not detailed in Table 5 have a fixed
supply air overheat switch position for internal and external configurations.

Rinnai 19 Ducted Gas Heater IM
Table 5. Models with variable supply air O/H switch location
SP6 Models SP5 Models
SP623U SP521U
SP623U XA SP521U XA
SP630U
SP630U XA
Diagram 12. Overheat switch position and loom route
Diagram 12A:
Internal configuration from factory
Diagram 12B:
External configuration.
Supply air fan side.
Diagram 12C:
External configuration.
Supply air motor side.
4.3 SP SERIES GAS FEED TUBE INSTALLATION
SP4, SP5 and SP6 model heaters are supplied 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 upper corner of the end panel near the gas valve
assembly.
c. Position the gas feed tube from the gas valve out through the hole.
d. Install the compression fitting to the valve assembly to connect the feed tube. Do not over-tighten the compression
fitting.
ABC

Rinnai 20 Ducted Gas Heater IM
5. CONDENSATE REMOVAL
All SP6 models have a condensate drain outlet. A fitting and clamp are provided loosely beneath the heater lid for
connection to the drain (refer to Diagram 13).
• The outlet is located in the bottom corner below the gas supply connection point.
• The condensate is mildly acidic, and shall be run via a PVC pressure pipe (to AS 1477), with an outside
diameter of approximately 27mm, away from the heater to a suitable area (i.e. to above a drain, sewer or pit)
• Use PVC cement on all joints to prevent any condensate leakage.
• Do not connect the condensate drain directly to the sewer or below ground level of a storm water drain. A
blockage in the drain system would cause the heater condensate tank to flood with water and shut down. Check
for any additional local drainage codes which may apply.
• Under no circumstances should it be allowed to run onto electrical connections, earth stakes, copper pipes or
concrete paths. It should also not discharge onto metallic roofs or guttering, however the condensate drain may
terminate into the vertical section of a downpipe above ground level.
• Tube length should be minimised and a continuous fall of 20mm per metre created. Maximum equivalent tube
length of 12m is recommended (or 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 the size of the heater.
Note: Ensure adherence to these instructions: Incorrect drainage can cause serious damage to the heater and/or its surroundings.
5.1 CONDENSATE DRAIN
Fitment of the 'BARBED CONNECTOR" and 'DN 20 PRESSURE PIPE' is identical for SP6U internal and external
installations.
5.1.1 Install a Condensate Drain to an SP6 Universal and Internal Units
a. Retrieve the barbed connector and hose clamp supplied loosely in the controls area beneath the lid.
b. Slide the hose clamp over the flexible hose.
c. Fit the barbed connector to the flexible condensate hose (refer to Diagram 13).
d. Fasten the hose to secure the barbed connector to the flexible hose.
e. Fit the DN20 pressure pipe drain to the barbed connector.
Note: Always use the correct PVC cement to bond the field supplied PVC pressure pipe to the barbed connector, following the
instructions as detailed for the PVC cement for proper bonding and curing.
Diagram 13. Condensate Drain Installation
BARBED CONNECTOR
(Supplied)
DN20 PRESSURE PIPE
(Field Supplied)
FLEXIBLE CONDENSATE HOSE
HOSE CLAMP
(Supplied)