Rinnai Demand Duo User manual

INFINITYHD200
INFINITYHD200
INFINITYHD200
INFINITYHD200
INFINITYHD200
Demand Duo
Continuous ow with storage backup
Installation guide
Customised hot water systems with 2-5
Rinnai INFINITY HD or EF commercial
continuous ow gas hot water heaters.

This system shall be installed in accordance with:
- Manufacturer’s installation instructions
- AS/NZS 5601 Gas Installations
- Current AS/NZS 3000, G12, AS/NZS 3500.4
- Local regulations and municipal building codes
Installation, servicing and repair shall be carried out only
by authorised personnel.
Warning
Improper installation, adjustment, alteration, service or
maintenance can cause property damage, personal injury
or loss of life.
For more information about buying, using,
and servicing of Rinnai appliances call: 0800
RINNAI (0800 746 624).
Rinnai New Zealand Limited
105 Pavilion Drive, Mangere, Auckland
PO Box 53177, Auckland Airport, Auckland 2150
Phone: [phone]
Email: [email protected].nz
Web: www.rinnai.co.nz
www.youtube.com/rinnainz
www.facebook.com/rinnainz
Important:

cnt:
Before you start............................................... 4
Models covered............................................... 5
Specification summary.................................... 6
Dimensions...................................................... 7
General layout of system................................. 8
Connections.................................................... 9
Individual flueing of internal units................... 10
Systems with EF models - condensate drain ... 11
About the AlphaStat-Plus thermostat ............. 12
AlphaStat-Plus display panel............................ 13
Filling and draining.......................................... 14
Commissioning ............................................... 15
Troubleshooting.............................................. 15

4 | Demand Duo CFHW with storage backup installation guide: 12583-B
Before you start
Unpack the system and components and check for damage. DO NOT install any
damaged items. Check all components have been supplied and that you have the
correct gas type.
Read these instructions to get an overview of the steps required before starting the
installation. Failure to follow these instructions could cause a malfunction of the
system. This could result in serious injury and/or property damage.
Models covered
Code/model Description
RCWDD400E315N/L 2 x HD200 external units with a 315 litre Demand Duo cylinder
RCWDD600E315N/L 3 x HD200 external units with a 315 litre Demand Duo cylinder
RCWDD800E315N/L 4 x HD200 external units with a 315 litre Demand Duo cylinder
RCWDD1000E315N/L 5 x HD200 external units with a 315 litre Demand Duo cylinder
RCWDD400FF315N/L 2 x HDi200 internal units with a 315 litre Demand Duo cylinder
RCWDD600FF315N/L 3 x HDi200 internal units with a 315 litre Demand Duo cylinder
RCWDD800FF315N/L 4 x HDi200 internal units with a 315 litre Demand Duo cylinder
RCWDD1000FF315N/L 5 x HDi200 internal units with a 315 litre Demand Duo cylinder
Customised systems
DD 420 external 2 x EF250 external units with a 315 litre Demand Duo cylinder
DD 630 external 3 x EF250 external units with a 315 litre Demand Duo cylinder
DD 840 external 4 x EF250 external units with a 315 litre Demand Duo cylinder
DD 500 external 2 x HD250 external units with a 315 litre Demand Duo cylinder
DD 750 external 3 x HD250 external units with a 315 litre Demand Duo cylinder
DD 420 internal 2 x EFi250 internal units with a 315 litre Demand Duo cylinder
DD 620 internal 3 x EFi250 internal units with a 315 litre Demand Duo cylinder
DD 840 internal 4 x EFi250 internal units with a 315 litre Demand Duo cylinder
N: Natural Gas
L: LPG
FF: Forced flue (internal units)

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Location
System should be installed in accordance with G12 and AS/NZS 3500.4. For servicing
and maintenance, please allow sufficient room for access of all components of the
system.
Ensure the hot water system is installed in a corrosive free environment and free from chemicals
as this could potentially create an atmosphere that attacks the Rinnai INFINITY water heaters.
Base requirements
System should be installed on a flat level surface of sufficient strength to support the weight of
the Demand Duo system when full of water.
The frame must be secured to the floor using anchor bolts (not supplied).
Access to system
All components of the system must be installed to ensure access can be gained without hazard
or undue difficulty for inspection, repair, renewal, or operational purposes. Sufficient clearances
shall allow access to removal of all serviceable components.
Where a system is not accessible for maintenance, servicing, or replacement, the Rinnai
warranty will not cover any additional costs caused by access difficulty. The system must be
accessible without the use of a ladder or scaffold.
Catch pan
It is important a suitably drained catch pan (or drain system) is fitted where damage could be
caused by discharge from the cylinder. This is a mandatory requirement of the installation. If
damage is caused by a leaking cylinder that has not been installed with a suitable drain system
the owner can seek compensation through the installer or consider claiming on insurance.
Rinnai INFINITY flue clearances
Flue clearances must comply with AS/NZS 5601.1.
Demand Duo systems with HDi200 and EFi250 internal units, where each unit is flued
individually, must use a Rinnai approved flue system.

6 | Demand Duo CFHW with storage backup installation guide: 12583-B
Specication summary
RINNAI DEMAND DUO SYSTEMS Auckland and Northland BOP, Gisborne, &
Hawkes Bay
Wellington, Waikato, Taranaki, Manawatu, & South Island
Model INFINITY Input
(MJ/h)
Output (kW)
Approx. weight when full
1st hr delivery (L/hr) @ 50 ° rise
2nd hr delivery (L/hr) @ 50 ° rise
1st hr delivery (L/hr) @
55 ° rise
2nd hr delivery (L/hr) @ 55 ° rise
1st hr delivery (L/hr) @ 60 ° rise
2nd hr delivery (L/hr) @ 60 ° rise
DD 400 ext 2 x HD200 ext 398 94 510 kg 1812 1560 1670 1418 1552 1300 DD 600 ext 3 x HD200 ext 597 141 540 kg 2592 2340 2379 2127 2202 1950 DD 800 ext 4 x HD200 ext 796 188 590 kg 3372 3120 3088 2836 2852 2600 DD 1000 ext 5 x HD200 ext 995 235 620 kg 4152 3900 3797 3545 3502 3250 DD 420 ext 2 x EF250 ext 422 111.2 545 kg 2172 1920 1998 1746 1852 1600 DD 630 ext 3 x EF250 ext 633 166.8 590 kg 3132 2880 2871 2619 2652 2400 DD 840 ext 4 x EF250 ext 844 222.4 665 kg 4092 3840 3744 3492 3452 3200 DD 500 ext 2 x HD250 ext 500 119.8 530 kg 2172 1920 1998 1746 1852 1600 DD 750 ext 3 x HD250 ext 750 179.7 570 kg 3132 2880 2871 2619 2652 2400 DD 400 int 2 x HDi200 int 390 90.2 510 kg 1812 1560 1670 1418 1552 1300 DD 600 int 3 x HDi200 int 858 135.3 545 kg 2592 2340 2379 2127 2202 1950 DD 800 int 4 x HDi200 int 780 180.4 595 kg 3372 3120 3088 2836 2852 2600 DD 1000 int 5 x HDi200 int 975 225.5 630 kg 4152 3900 3797 3545 3502 3250 DD 420 int 2 x EFi250 int 422 111.2 545 kg 2172 1920 1998 1746 1852 1600 DD 620 int 3 x EFi250 int 633 166.8 590 kg 3132 2880 2871 2619 2652 2400 DD 840 int 4 x EFi250 int 844 222.4 665 kg 4092 3840 3744 3492 3452 3200 Connections: Gas - 32 mm Water - 32 mm TPR - 20 mm Supply pressures: Gas (NG) - 1.13-3.5 kPa Gas (LPG) - 2.75 kPa Water - 700 kPa max. Primary pump: Grundfos CM5-2, for more information refer to the Grunfos book supplied in the accessory pack Ingress protection rating
: IPX4 (cylinder, control box, and Rinnai INFINITY)
Delivery rates, first hour assumes the system has a full cylinder of hot water. Second hour delivery is the maximum output of the Rinnai INFINITY units. For static recovery rates contact Rinnai.
All of these systems are connected to a 315 L Demand Duo cylinder.

Demand Duo Demand Duo CFHW with storage backup installation guide: 12583-B | 7
Dimensions
All dimensions are in mm.
700
1655
1750
External Model
Flue Terminal
Internal Model
Flue Terminal
2130
334
Cold Inlet
Cold
Inlet
Gas Inlet
Gas Inlet
Hot Outlet Hot Outlet
430
300
425 631
540
1905
385
695
INFINITY
INFINITY INFINITY
INFINITY INFINITY
INFINITY
A
Cylinder skid 1000 mm
Model INFINITY ‘A’ dimension
(total width of system - mm)
DD 400 external and internal 2 x HD200/HDi200 1770
DD 600 external and internal 3 x HD200/HDi200 2240
DD 800 external and internal 4 x HD200/HDi200 2540
DD 1000 external and internal 5 x HD200/HDi200 2920
DD 420 external and internal 2 x EF250/EFi250 2140
DD 630 external and internal 3 x EF250/EFi250 2540
DD 840 external and internal 4 x EF250/EFi250 3280
DD 500 external 2 x HD250 2140
DD 750 external 3 x HD250 2540

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General layout of system
The system layout below, depicting the DD400 system, highlights components
provided by Rinnai and components that are required to be supplied by the installer.
CM5-2 SS316 pump
Pipe and fittings
by Rinnai
Pipe and fittings
by Rinnai
Pipe and fittings
by installer
Pipe and fittings
by Rinnai
Alphastat
controller
Cold water inlet
32 mm fitting on the left hand side of the cylinder, approximately 280 mm above the ground. For
ease of draining it is advisable to fit a ‘tee’ piece with a capped valve or drain line between the
cold water isolation valve and cold water inlet connection on the Demand Duo cylinder.
Hot water outlet
32 mm fitting on the left hand side of the cylinder. Ensure adequate insulation/lagging is fitted to
the hot water pipe to minimise heat loss. Pipe sizing must be sized to allow sufficient water flow
to the hot water fixtures.
Pressure limiting valve
500 kPa.
Cylinder thermostat setting
To meet the New Zealand Building code requirement1to disinfect water for legionella bacteria2,
the cylinder thermostat has been set to 65 °C.
1 Clause G12.3.9, Acceptable Solution G12/AS1 6.14.3
2 Legionella is a bacterium that can cause Legionnaires’ disease―a severe form of pneumonia

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Connections
Expansion control valve (ECV)
The Demand Duo cylinder comes with an Expansion Control Valve (HT575) set to 700 kPa. This
valve allows for expansion of the water in the flow and return during the initial heat-up period.
This should be fitted to the cold water supply line.
TPR valves
Two 850 kPa TPR valves are supplied and fitted to a 20 mm fitting near the top of the cylinder.
Relief valve drain lines
Connect an independent 20 mm copper tube relief valve drain line to the TPR valve outlets.
Drain should be installed with a continuous fall toward a visible discharge point over a drain or
gully in accordance with AS/NZS 3500.4 sections 5.8 and 5.9.
• Drain line should not exceed 9 m in length
• Valves or other restrictions should not be installed with the relief vent line
• TPR valve drain line should not be joined to other drain lines
Return pump
A secondary or building return pump may be installed in conjunction with the Demand Duo hot
water system. Return line from the building loop is connected to the 32 mm return connection.
This is located just above the cold water inlet connection on the left hand side of the Demand
Duo cylinder.
If the secondary pump is not used a 32 mm brass plug should be fitted to the 32 mm return
connection, located just above the cold water inlet connection.
Install an effective filter to the circulating loop return line.
Gas connection
Check gas type of the Rinnai INFINITY matches the gas supply available on site.
Ensure gas pipe sizing is adequate to deliver the required volume/pressure. The pipe size used
on the inlet fitting is no indication of the pipe size required. Refer to appropriate pipe sizing
chart in AS/NZS 5601.1.
Gas meter or LPG cylinders and regulator should also be of a suitable size to ensure sufficient gas
supply to the gas installation.
Purge gas line and ensure removal of debris prior to final connection. Check for gas leaks using
suitable methods as listed in AS/NZS 5601.1

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Individual ueing of internal units
Flue gases can reach temperatures up to 200 °C. The flue terminal is to terminate in
a location so as not to cause a nuisance, in accordance with AS/NZS 5601.1.
12
3
4
1. Direct flueing: For installations where the internal continuous flow unit is mounted directly
on the inside of an external wall.
2. Horizontal extension flueing: The same as direct flueing with additional pipe required due
to the longer horizontal distance.
3. Vertical straight flueing: Installations where the internal unit is flued vertically through the
roof.
4. Combination vertical and horizontal flueing: A combination of all the above.
Important
• All heaters need to be flued individually—refer separate installation guide for installing Rinnai
INFINITY gas hot water heater internal flueing
• A condensate drain tube must be fitted to HDi200* units if the vertical flue length exceeds 1.5 m
• Internal models MUST BE flued with a Rinnai approved flue system
* EFi units have an inbuilt system to drain condensate
The Rinnai INFINITY internal gas hot water heaters are room sealed appliances—sealed from
the room as it takes air for combustion from the outside, and expels products of combustion
outside. No ventilation in the space where the water heater is installed is required. Each Rinnai
INFINITY water heater is flued individually.
The flueing for internal water heaters is a coaxial design. It has a stainless steel inner pipe to
discharge products of combustion and a thermoplastic outer pipe for air supply to the appliance.
Flueing options

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Systems with EF models - condensate drain
The Rinnai INFINITY EF water heaters generate condensate continuously at a rate of
up to five litres per hour as a by-product of a highly efficient gas burner. Condensate
must be drained via a pipe to a suitable discharge point.
As condensate is a by-product
of gas combustion it is mildly
acidic. For this reason copper
tube and fittings MUST NOT be
used as it will corrode. Instead
Rinnai recommend plastic pipes
and fittings.
Condensate drain pipe
Content of AS3500.4.2003
section 5.12 ‘Temperature/
Pressure Relief and Expansion
Control Valve Drain Lines’ has
been used in preparing these
guidelines.
A. Water heater drain outlet
connection, ½ “ (15 mm) BSP
male.
B. PE ½ “BSP (15 mm) female
to barbed ignition system
connector (13-19 mm) or
equivalent plastic fitting.
C. Drain pipe and fittings to
match (B).
D. Continuous fall of at least
2° from water heater to
discharge point.
E. Suitable points of discharge
are deemed to be sewers
or pits. DO NOT discharge
onto electrical connections,
earth stakes, copper pipes,
concrete paths, or into a
pond.
Condensate drain installation
Point of discharge from each
drain line shall be located so
the release of condensate does
not cause a nuisance, is readily
discernible and incurs no risk
of building damage. There
shall be no tap, valve or other
restrictions in any line. Each line
shall fall continuously from the
valve to the approved point of
discharge.
Drain lines shall not discharge
into a storage water heater safe
tray. The end of the condensate
drain line shall be:
- Not lower than 200 mm, or
higher than 300 mm above
an unpaved surface; or
- Not lower than 75 mm, or
higher than 300 mm above
a gravel pit, and not less
than 100 mm in diameter in
a paved surface.
Where discharging over a
tundish or gully trap, drain lines
shall have an air gap of a size
at least twice the diameter of a
drain line.
Joining condensate drain
lines
Condensate drain lines from
multiple water heaters may be
joined together provided they
conform with the installation
requirements stated on this
page.
Common stack discharge
Where individual heaters
are installed in a multistory
building, the condensate drain
lines may discharge into a
common stack subject to the
following:
- Drained to a tundish having
a discharge line that is not
less than the common
stack, directly connected to
a fixture trap, and installed
in a connection with any
adjacent soil or waste stack.
- Discharge point of the
common stack is readily
visible and does not cause
any nuisance.
- Common stack is vented by
extending the pipe upwards,
above the roof level.

12 | Demand Duo CFHW with storage backup installation guide: 12583-B
About the AlphaStat-Plus thermostat
The Rinnai AlphaStat-Plus is a thermostat configured to switch primary pumps
on water heating systems where Rinnai INFINITY continuous flow gas hot water
heaters are combined with storage cylinders. It is preset when leaving Rinnai.
167 mm
142 mm
Depth: 40 mm
Weight: 1.2 kg
Principle of operation
• The hot water cylinder sensor
is called ‘TANK’.
• The upper temperature
threshold is called ‘SET OFF’.
• The lower temperature
threshold is called ‘SET ON’.
The Rinnai AlphaStat-Plus is a
thermostat. The thermostat
measures the temperature at the
‘TANK’ sensor and compares this
to the ‘SET ON’ threshold. If the
cylinder is below this threshold,
then the pump is turned on to
activate the Rinnai INFINITY
unit(s) to heat the water in the
cylinder. Once the cylinder has
reached the ‘SET OFF’ threshold,
the pump is switched off.
Important
The Rinnai INFINITY must
be set to produce water at a
temperature to at least 10 °C
higher than the SET OFF/SET ON
values on the controller. Failure
to observe this requirement can
cause premature system failure,
which is not covered by warranty.
Rinnai preset settings
Demand = 65 °C
Set off/on = 65 °C/60 °C
Biosafe = OFF
Locked = YES
If you need different settings to
those above please let us know at
the time of the order or contact
Rinnai to obtain the programming
sheet (also available online on the
Rinnai TradeSmart website).
Adjustable values range
Set off = 21~75 °C
Set on = 20~74 °C
Demand = 20~100 °C
Biosafe = 50~70°C or OFF
Features
• 20 mm soft green LED display
• External mounting holes
• UV resistant cables and
enclosure
• Stainless steel water resistant
temperature sensor
Power supply
230 V, 50 Hz AC. Maximum current
draw with standard mains cable
supplied - 10 A (at 230 VAC).
Maximum current draw with
permanent fixed wiring - 16 A (at
230 VAC).
Enclosure construction
Polycarbonate (impact resistant),
UL94 V-2 non-burning, UV
stabilised.
IP rating - IP54 (when gland is
fitted)

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AlphaStat-Plus display panel
PWR light indicates that power is being
applied to the unit.
The TANK,
SET OFF,
and SET ON
indicates which
temperature is
being displayed.
Only one of the
three can ever
be on.
The HWC will be on when the pump is on.
REHEAT
indicates the
cylinder has
dropped below
the SET ON
point and the
pump will be
on. Controller
will remain
in this mode
until the SET
OFF point is
reached.
Biosafe
The biosafe mode is to prevent the growth
of dangerous organisms within the cylinder.
The cylinder must reach a preset temperature
of 60 °C at least once every two hours. The
Rinnai AlphaStat-Plus controller is preset to
have BIOSAFE switched off as the demand
temperature of 65 °C ensures that the water
temperature in the cylinder is above the
threshold for bacterial growth.
If for some reason temperatures below 60 °C
are programmed into the controller BIOSAFE
will need to be set.
Away
The AWAY function is to allow for long periods
where hot water is not required. Pressing the
AWAY button will prevent the pump from
being switched on to activate the Rinnai
INFINITY units.
The AWAY light flashes to indicate the user has
placed the controller in a suspended state. No
power will be applied to the hot water system
until the AWAY button is pressed again to
cancel it. The AlphaStat-Plus will remember
AWAY mode even if the power goes off and
comes on again.
HWC puts the controller into
demand mode, initiating a
manual request to turn the
pump on. Only the HWC light
will come on in this mode. To
cancel press the HWC button.
AWAY puts the controller in
away mode. To cancel press
the AWAY button again.
If in programming mode NEXT
will step from TANK to SET OFF
to SET ON, and the display will
show the temperature in °C.
TEST will check the system, all lights will
flash, then displays the number of times
the pump has been on. The count will
reset and start again after 999.

14 | Demand Duo CFHW with storage backup installation guide: 12583-B
Filling and draining
Do not turn on the pump or system until the cylinder is completely full of
water. Damage to the system as a result of not following this instruction
will void any warranty.
IMPORTANT
Filling
1. Flush the cold water inlet pipe to remove any debris before final connection to the cold
water inlet of the Demand Duo cylinder.
2. Ease the TPR valve open to expel air while the cylinder is filling with cold water.
3. Slowly open cold water expansion valve on the cold water supply pipe.
4. Allow cylinder to fill.
5. Check all connections for water leaks and tighten as required.
6. Prime circulating pump before start up.
7. The thermostat on the Demand Duo cylinder is set to 65 °C and the Rinnai INFINITY is set
to 75 °C. If the cylinder thermostat does not appear to be set correctly the thermostat may
need to be reprogrammed—refer programming sheet available within the technical section
of the Demand Duo product on the Rinnai website or contact Rinnai for assistance.
If hotter water is required the cylinder and the Rinnai INFINITY dip switches will need to be
adjusted.
8. Plug 3-core flex into suitably earthed general power outlet (GPO). Turn on power supply. The
thermostat will display the current water temperature in the cylinder, the pump should start
and the Rinnai INFINITY units should ignite.
9. The Rinnai INFINITY units will continue to operate until the thermostat reaches 65 °C. Once
the set temperature has been reached the thermostat will turn off the primary circulating
pump.
Draining
1. Isolate power supply to the Demand Duo system.
2. Close the cold water isolation valve.
3. Ease the TPR valve open to expel air.
4. Remove cap on the cold water drain valve if no drain line is fitted.
5. Connect a hose or similar to allow water to drain to a safe location.
6. Open cold water drain valve and allow water to drain from the system.

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Commissioning
Fill cylinder as detailed on previous page and commission the Rinnai INFINITY
units in accordance with the commissioning sheet attached to the front cover
of each unit.
Troubleshooting
A full set of error codes for the Rinnai INFINITY units* and thermostat are available in the owner’s
manual—separate document that is provided with the system.
* Error codes are displayed in the status monitor of all commercial Rinnai INFINITY units except the HDi200
and HD250 models (no status window on these models).

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Demand Duo CFHW with storage backup installation guide: 12583-B