Rinnai HD28E User manual

Commercial Manifold Pack
Operation & Installation Manual

Rinnai 2 Commercial Manifold Pack OIM
Congratulations on the purchase of your Rinnai Manifold Pack System. We trust you will have many years of
comfort and enjoyment from your appliances.
This manual applies to Manifold Pack Systems utilising HD model continuous ow water heaters.
IMPORTANT
BEFORE USING THIS APPLIANCE SYSTEM
Before proceeding with the operation or installation, read this manual thoroughly and gain a full
understanding of the appliance, to ensure safe and correct use.
IMPORTANT NOTICE FOR INSTALLERS
Please leave these instructions with the end user after commissioning of the system and alert the
end user of the content sections “Warnings” and “Periodic Inspection” and “Maintenance”.
Not suitable as a pool or spa heater.
This manual must be read and understood before
installation, commissioning and operation of water heaters
and flue systems are attempted. The information
contained in other Operating / Installation instructions
supplied with water heaters applies in full, unless
otherwise dictated in this manual.
This appliance must be installed in accordance with:
• Manufacturer’s Installation Instructions
• Current AS/NZS 3000, AS/NZS 3500 & AS/NZS 5601
• Plumbing Code of Australia (PCA)
• Local Regulations and Municipal Building Codes
including local OH&S requirements
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 manufacturer’s
instructions.
All Rinnai gas products
sold in Australia are
A.G.A. certified.

Rinnai 3 Commercial Manifold Pack OIM
TABLE OF CONTENTS
WARNINGS & IMPORTANT INFORMATION 4
Notice to Victorian Consumers ��������������������������������������������������������������������������������������������������������������������������� 5
Safety ����������������������������������������������������������������������������������������������������������������������������������������������������������������� 5
Hydrogen Gas ������������������������������������������������������������������������������������������������������������������������������������������������ 6
Water Temperature ����������������������������������������������������������������������������������������������������������������������������������������� 6
Warning About Hot Water ����������������������������������������������������������������������������������������������������������������������������������� 6
Scald Hazards ���������������������������������������������������������������������������������������������������������������������������������������������������� 6
Save A Service Call �������������������������������������������������������������������������������������������������������������������������������������������� 7
INSTALLATION 8
Location �������������������������������������������������������������������������������������������������������������������������������������������������������������� 8
HD28e, HD250e, HD210e (External Models) ����������������������������������������������������������������������������������������������������� 8
HD28I, HD210I (Internal models) ����������������������������������������������������������������������������������������������������������������������� 8
Horizontal Obstructions �������������������������������������������������������������������������������������������������������������������������������������� 9
Horizontal Flue Terminal Clearances (Extract from AS/NZS 5601) ������������������������������������������������������������������ 10
Co-Axial Flueing for Internal Models ���������������������������������������������������������������������������������������������������������������� 11
Multiple Flue Terminals ������������������������������������������������������������������������������������������������������������������������������������� 12
Installation Options ������������������������������������������������������������������������������������������������������������������������������������������� 13
Manifold Pack with no reticulation system �������������������������������������������������������������������������������������������������������� 16
Manifold Pack with reticulation system ������������������������������������������������������������������������������������������������������������� 16
Specications 17
Typical Rinnai Manifold Pack Installation ��������������������������������������������������������������������������������������������������������� 17
Appliance Dimensions ���������������������������������������������������������������������������������������������������������������������������������� 17
Installation Handover Manual 18
Cold Water Supply �������������������������������������������������������������������������������������������������������������������������������������������� 18
Hot Water Outlet ����������������������������������������������������������������������������������������������������������������������������������������������� 18
Ring Main Pump ������������������������������������������������������������������������������������������������������������������������������������������� 18
Gas Supply ��������������������������������������������������������������������������������������������������������������������������������������������������� 18
Electrical Supply ������������������������������������������������������������������������������������������������������������������������������������������� 18
Filling Instructions ��������������������������������������������������������������������������������������������������������������������������������������������� 18
Rinnai Manifold Electronic Control System - MECS and Cascade ������������������������������������������������������������������ 19
FAULT FINDING 20
Manifold Pack Preventative Maintenance �������������������������������������������������������������������������������������������������������� 20
Ring Main Pump ����������������������������������������������������������������������������������������������������������������������������������������������� 21
Service ������������������������������������������������������������������������������������������������������������������������������������������������������������� 21
Commercial Hot Water System Commissioning Check-List ����������������������������������������������������������������������������� 22
Commissioning 22
Contacts 24

Rinnai 4 Commercial Manifold Pack OIM
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 INFORMATION
This appliance shall be installed in accordance with these instructions and all regulatory
requirements which exist in your area including those in relation to manual lifting, working at
heights and on roofs. Applicable publications and regulations may include:
• AS/NZS 3500 National Plumbing and Drainage, AS/NZS 3000 Wiring rules, AS/NZ 5601 Gas
Installations & Building Codes of Australia (BCA)
• Local Occupational Health and Safety (OH&S) regulations
• Local Regulations and Municipal Building Codes
DO NOT operate this system before reading the manufacturers instructions.
This appliance must be installed, commissioned and serviced by an authorised person in
accordance with all applicable local rules and regulations.
For continued safety of this appliance it must be installed, operated and maintained in accordance
with the manufacturer’s instructions.
This appliance is heavy, use 2 people or mechanical lifting device. Improper lifting may result in
serious injury.
DO NOT modify the electrical wiring of this appliance. If the control power wiring is damaged or
deteriorated then it must be replaced only by an authorised person. Failure to do so may result
in electric shock, re, serious injury or product failure.
Care should be taken not to touch the pipe work as it may be HOT!
DO NOT place articles on or against this appliance.
DO NOT store chemicals or ammable materials near this appliance.
DO NOT operate with panels, covers or guards removed from this appliance.
DO NOT remove covers while power is on.
DO NOT enclose this appliance.
DO NOT activate pump unless cylinder is full of water.
Not suitable as a pool or spa heater.
All Rinnai Manifold Pack (MP) systems and components are Watermark Certied by SAI Global
as applicable.
All dimensions referred to in these instructions are in millimetres, unless otherwise specied.
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.
NOTE
WARNINGS & IMPORTANT INFORMATION

Rinnai 5 Commercial Manifold Pack OIM
WARNING
MANDATORY INSPECTION PRIOR TO INSTALLATION
Immediately report any damage or discrepancies to the Supplier of the appliance. This
appliance was 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 and electrical
supply, and/or other services it is intended to be connected to.
For safety and warranty purposes, appliances that may be damaged or incorrect must not be
installed or operated under any circumstances. Installation of damaged or incorrect appliances
may contravene local government regulations. Rinnai disclaims any liability or responsibility
whatsoever in relation to the installation or operation of damaged or incorrect appliances.
NOTICE TO VICTORIAN CONSUMERS
WARNING
This appliance MUST be installed by a person licensed with the Victorian Building Authority.
ONLY a licensed person will have insurance protecting their workmanship.
Make sure you use a licensed person to install this appliance and ask for your Compliance
Certicate.
For further information contact the Victorian Building Authority on 1300 815 127
SAFETY
WARNING
This appliance is NOT intended for use by persons (including children) with reduced physical,
sensory or mental capabilities, or lack of experience and knowledge unless they have been given
supervision or instruction concerning use of the appliance by a person responsible for their
safety.
Children should be supervised to ensure that they DO NOT play with the appliance.
Any power leads from the water heater system components MUST be plugged into an external
weatherproof electrical outlet. If the power supply cord of the system is damaged, it MUST be
replaced by an authorised person in order to avoid a hazard, using genuine replacement parts
available from Rinnai. Take care of not to touch the power plugs with wet hands.
If the supply cord is damaged, it must be replaced by the manufacturer, its service agent or
similarly qualied persons in order to avoid a hazard.
DO NOT touch the unit cover or the ue outlet.
DO NOT insert objects into the ue outlet.
DO NOT spray water directly into the ue outlet.
Keep, trees, shrubs, etc. well clear of the ue outlet.
On colder days steam may discharged from the ue
outlet. This condition is normal for high e󰀩ciency
appliances and does not indicate a fault.
DO NOT Spray aerosols in the vicinity of this appliance
while it is in operation.
DO NOT use or store ammable materials in or near
this appliance.
DO NOT place articles on or against this appliance.
DO NOT modify this appliance.
DO NOT store pool chemicals near this appliance.
HOT!
WARNINGS & IMPORTANT INFORMATION

Rinnai 6 Commercial Manifold Pack OIM
Hydrogen Gas
If the hot water heater is not used for two weeks or more, a quantity of hydrogen gas, which is highly ammable,
may accumulate in the water heater. To dissipate this safely, it is recommended that a non electrically operated
hot tap be turned on for several minutes at a sink, or bath, but not a dishwasher or other appliance. During this
procedure there must be no smoking, open ame or any electrical appliance operating nearby. If hydrogen gas is
discharged through the tap, it will probably make a sound like air escaping.
Water Temperature
The outlet temperature setting of the gas continuous ow heater is factory pre-set to 75°C.
WARNING ABOUT HOT WATER
WARNING
This appliance may deliver water at high temperature. Refer to the Plumbing Code of Australia
(PCA), local requirements and installation instructions to determine if additional delivery
temperature control is required.
SCALD HAZARDS
Hot Water can cause scalds.
Children, disabled, and the elderly are at the highest risk of
being scalded.
Feel water temperature before bathing or showering.
Scalds from hot water taps can result in severe injuries to
young children.
Scalds can occur when children are exposed directly to hot
water when they are placed into a bath which is too hot.
Always......
Test the temperature of the water with your elbow before placing your child in the bath, also carefully feel
water before bathing or showering yourself.
Supervise children whenever they are in the bathroom.
Make sure that the hot water tap is turned o󰀨 tightly.
Consider.....
Installing child proof tap covers or child resistant taps (both approaches will prevent a small hand being
able to turn on the tap).
Installing tempering valves or thermostatic mixing valves which reduce the hot water temperature delivered
to the taps. Your local plumbing authority may already require that these be tted. Contact your installer
or local plumbing authority if in doubt.
Never….
Leave a toddler in the care of another child. They may not understand the need to have the water
temperature set at a safe level.
DANGER BEWARE OF
SCALDING HAZARDS
WARNINGS & IMPORTANT INFORMATION

Rinnai 7 Commercial Manifold Pack OIM
SAVE A SERVICE CALL
Check the items below before requesting a service. Service and parts charges may be incurred where it is found
that there is no fault with the water heater and the issue is related to the plumbing installation or is due to the failure
of water or electric supplies.
Insu󰀩cient or no hot water
Is the electricity supply
connected?
Check that the isolating switch marked “HOT WATER” or “WATER HEATER” at the
meter box is switched on. Check also that any isolating switches installed near the
water heater are switched on.
Check the fuse or circuit breaker marked “HOT WATER” or “WATER HEATER” at
the meter box. Repeated failure of fuse or tripping of circuit breaker indicates a fault
which must be investigated by an authorised trades person.
Is there insu󰀩cient gas
supply for gas heater(s)?
Check gas is available and turned ‘ON’.
Check the isolation valve in the gas line is opened.
Refer to your plumber to ensure the gas line has been purged of air after installation.
Are you using more hot
water than you think?
Often end users are surprised at the amount of hot water used, especially when
showering. If the amount of hot water used during the day exceeds the capacity of
the hot water system, it is likely that there will be insu󰀩cient hot water. Have your
plumber install water saving xtures and/or ow control or pressure limiting valves to
reduce consumption.
Thermostat settings? Check the temperature of hot water delivered with a thermometer placed under the
closest outlet (usually the kitchen sink) on a non-tempered hot water line.
The temperature of the water delivered should be at least 55°C (allowing for heat
losses in pipe work).
If this is not the case, the temperature may need to be increased. Contact your
installer or Rinnai to discuss adjusting the temperature.
No water from the hot tap? Restriction in the hot tap or failure of the cold water supply to the heater.
Check for water ow at the other hot taps and that the cold water isolation valve is
fully open.
Are any of the heaters
displaying an error code?
Refer to fault nding section of this manual.
Are the cold water lters
clean on the gas water
heater(s)?
Isolate and remove the water lter at the cold water connection point. Refer to
separate manual for the gas continuous ow water heater operation.
CARE & MAINTENANCE

Rinnai 8 Commercial Manifold Pack OIM
NOTE
INSTALLATION, SERVICE AND REMOVAL MUST BE BY AN AUTHORISED PERSON ONLY.
Remove transit protection lm. Check for damage, if any is found DO NOT install and contact
supplier.
These instructions apply to the Manifold Pack range of Rinnai hot water systems using multiple Heavy Duty
continuous ow water heaters to provide large ow rates of hot water.
Rinnai Commercial Manifold Pack hot water systems must only be installed, commissioned, service and removed
by an authorised person in accordance with these instructions, AS/NZS 5601, AS/NZS 3000, AS/NZS 3500 and
local regulations and municipal building codes including local OH&S requirements.
Rinnai Manifold Pack hot water systems are not suitable or approved as a pool heater.
Read these instructions carefully before proceeding with the installation.
LOCATION
Ensure reasonable access for installation, servicing and removal. All valves, controls and pumps etc must be
easily accessible.
When using free standing frames the system must be mounted on a solid level base, capable of supporting the
weight of the appliance when full of water. Ensure components are not allowed to stand in water.
Manifold Pack can be plumbed “left handed”, “right handed” or “equal ow” as staging determines operating
sequence of heaters, not the plumbing. Stage-less or larger systems may need to be “equal ow”. Contact Rinnai
Commercial for assistance.
Gas booster ue terminals must be located in accordance with AS/NZS 5601 Fig 6.2 “Location of balanced ue
terminals”.
Rinnai HD units are fan assisted appliances and thus have lower clearances than a natural draft appliance of the
same MJ rating.
HD28E, HD250E, HD210E (EXTERNAL MODELS)
These appliances are designed for 'Outdoor' Installation only. As such, each must be located in an above ground
open air situation with natural ventilation, without stagnant areas, where gas leakage and products of combustion
are rapidly dispersed by wind and natural convection.
The appliance must be mounted on a vertical structure with the water and gas connections on the underside
pointing downwards. For appliances installed on elevated structures or under oors specic requirements apply.
Refer to AS/NZS 5601 Section 6 for details.
This appliance must not be used as a domestic spa or swimming pool heater.
Location of the appliance ue terminal must be in accordance with Section 6 and Figure 6.2 of AS/NZS 5601.
Figure 6.2 is reproduced in the 'Horizontal Flue Terminal Clearances' section of these instructions.
NOTE
AS/NZS 5601 is current at the time of printing. It is the installers’ responsibility to ensure current
requirements are met.
HD28I, HD210I (INTERNAL MODELS)
These appliances are designed for ‘Indoor’ installation only. They may be installed ‘Outdoors’ in an enclosure if the
requirements of AS/NZS 5601 Section 6 are satised. An enclosure is dened as a compartment, enclosed area
of partitioned o󰀨 space primarily used for the installing of the appliance.
If installed in an enclosure either Internally or Externally, the location should be ventilated to allow gas to dissipate
and provision must be made for the safe disposal of any leaking water to a visible location.
This appliance must not be used as a domestic spa or swimming pool heater.
Two types of ue systems are available:
• The Rinnai Commercial Common Flue System.
• The Rinnai Co-Axial FFU ue system.
The use of non Rinnai ue components may result in a dangerous situation and violates regulations.
INSTALLATION

Rinnai 9 Commercial Manifold Pack OIM
The appliance(s) must be located so that the ue terminal exits the building at a suitable point.
For detailed information refer to "Co-Axial Flueing for Internal Models" on page 11.
If a horizontal (wall) terminal is used, the location must be in accordance with Section 6 and Figure 6.2 of AS/
NZS 5601. Figure 6.2 is reproduced under ‘HORIZONTAL FLUE TERMINAL CLEARANCES’ on page 10 of this
manual.
If a vertical (roof) terminal is used, the location must be in accordance with Section 6 of AS/NZS 5601 and the
‘FLUEING FOR INTERNAL MODELS’ on page 11.
HORIZONTAL OBSTRUCTIONS
AS/NZS 5601-2010 ‘Gas Installations’ stipulates a minimum horizontal clearance of 500mm between a building
structure and obstruction facing the terminal.
For Rinnai External continuous ow water heaters such a building structure must ‘obstruct’ the full front cover
height of the appliance, or extend vertically above and below the front cover.
There must be no partial obstructions to the front cover of the appliance or any other parts of the appliance casing.
This will avoid the appliance failing to operate under windy conditions.
500mm
INSTALLATION INSTRUCTIONS

Rinnai 10 Commercial Manifold Pack OIM
HORIZONTAL FLUE TERMINAL CLEARANCES (EXTRACT FROM AS/NZS 5601)
Min. Clearances (mm)
For appliances up to 50 MJ/h input 200300
For appliances over 50 MJ/h input 300500
300300*ecafrusrehtoroynoclabaevoba,dnuorgehtmorFb
300500*renroclanretxerollawnruteratnorFc
d
From a gas meter (M) (see Note 5)
(see Clause 5.11.5.9 for vent terminal location of regulator)
(see Table 6.7 for New Zealand requirements)
10001000
eFrom an electricity meter or fuse box (P) † (see Note 5) 500500
epipliosroepipniardamorFf
gHorizontally from any building structure* = or obstruction facing a terminal 500500
hFrom any other flue terminal , cowl, or combustion air intake * 300500
Appliances up to 150 MJ/h input * 300500
Appliances over 150 MJ/h input up to 200 MJ/h input * 3001500
Appliances over 200 MJ/h input up to 250 MJ/h input * 5001500
Appliances over 250 MJ/h input * 15001500
All fan-assisted flue appliances, in the direction of discharge 1500-
10001500rewolbapsagnidulcni,telnirialacinahcemamorFk
Space heaters up to 50 MJ/hr input
Other appliances up to 50 MJ/hr input 500500
Appliances over 50 MJ/h input and up to 150 MJ/h input 10001000
Appliances over 150 MJ/h input 15001500
metI.feR
a
Below eaves, balconies and other projections:
FIGURE 6.2 (in-part) LOCATION OF FLUE TERMINALS OF BALANCED FLUE,
ROOM-SEALED, FAN-ASSISTED OR OUTDOOR APPLIANCES
n
j
Horizontally from an openable window, door, non-mechanical air inlet, or any other opening into a building with the
exception of sub-floor ventilation:
Vertically below an openable window, non-mechanical air inlet, or any other opening into a building with the
exception of sub-floor ventilation:
Where dimensions c, j or k cannot be achieved an equivalent horizontal distance measured
diagonally from the nearest discharge point of the terminal to the opening may be deemed by
the Technical Regulator to comply.
See Clause 6.9.4 for restrictions on a flue terminal under a covered area.
See Figure J3 for clearances required from a flue terminal to an LP Gas cylinder. A
flue terminal is considered to be a source of ignition.
For minimum clearances not addressed above acceptance should be obtained from the
Technical Regulator.
Minimum clearances d and e also apply to any combustion air intake openings of appliances.
1
2
3
4
5
* Unless appliance is certified for closer installation.
† Prohibited area below electricity meter or fuse box extends to ground level.
NOTES:
75150
Sha d ing ind i c ates p r ohibite d
ar e a for flue term inal s
LEGEN D:
I= Mechan i c al air i n let
S= Str u c ture
M= Ga s m ete r
T= Fl ue ter m inal
P= El e c tr i c it y meter or fu s e box
Z= Fan-assis ted appl i ance only
Dir e ction of
discharge
See N o te 1
See N o te 1
Opening into
a building
T
T
T
T
T
T
T
C
M
d
d
e
e
h
j
j
j
n
b
f
a
h
P
Z
S
k
k
g
g
g
I
T
Door
Fan assistedNatural draft
150150
INSTALLATION INSTRUCTIONS

Rinnai 11 Commercial Manifold Pack OIM
CO-AXIAL FLUEING FOR INTERNAL MODELS
This system is certied and suitable for use with Rinnai internal commercial continuous ow water heaters.
The Rinnai ueing system must be installed in accordance with the instructions supplied with the ue terminal. Non
Rinnai ueing systems MUST NOT be used.
The Rinnai internal ueing system is highly versatile and makes installation of an internal water heater simple and
convenient.
The ueing for internal water heaters is a Co-Axial design. It consists of an aluminium or polypropylene inner ue
pipe to discharge products of combustion and a plastic outer pipe for air supply to the appliance. The water heater
is a room sealed appliance.
NOTE: Each Rinnai water heater is ued individually.
Horizontal ueing can be used as a direct wall ue or extended from another internal wall.
Vertical ueing is used when the water heater
needs to be ued vertically through the roof.
A condensate trap may be required for
extended ue runs depending on the type of
water heater and ue system used. Details
are provided in the separate ue installation
instructions and MUST be adhered to.
Rinnai HD internal water heaters are
classied as ‘room sealed’ appliances. Flue
systems must be installed in accordance with
Rinnai Installation Instructions (supplied with
ue terminals), local gas tting regulations,
municipal building codes, AS/NZS 5601 and
all other relevant statutory regulations.
All these internal and external model heaters
are AGA certied to be installed side by
side. The default ue terminal clearances in
AS/NZS 5601 do not apply for the HD28e,
HD250e and HD210e external model heaters
when installed in this conguration.
MP6 Direct Wall Flue
Manifold Pack 5 internal
INSTALLATION INSTRUCTIONS

Rinnai 12 Commercial Manifold Pack OIM
NOTE
Only Rinnai Flueing systems can be used with Internal Water Heaters. Non-Rinnai Flueing
systems are not certied and will not be covered under warranty.
For all further information on internal ueing, please refer to separate Flueing Manual supplied with ueing
components.
MULTIPLE FLUE TERMINALS
Dimension 'H' in AS/NZS 5601 Figure 6.2 does not apply when multiple Rinnai external water heaters of the same
model are installed on the same vertical face with ue terminals at the same height (i.e. side by side). Under these
conditions appliances can abut each other as shown below:
Before commencing installation, ensure you refer to the content of all other Operation / Installation manuals
supplied with the appropriate model Rinnai Continuous Flow Water Heater or Rinnai Flueing Systems.
INSTALLATION INSTRUCTIONS

Rinnai 13 Commercial Manifold Pack OIM
INSTALLATION OPTIONS
The Rinnai Commercial Common Flue System is suitable for the Rinnai Internal Commercial Gas Continuous
Flow Water Heaters (listed on the cover of this manual) in accordance with the ue design options outlined in the
AS/NZS 5601.1 Appendix titled ‘Flue Design'. Figure 1 & Figure 2 below, illustrate typical application principles.
Figure 1. Typical Natural Draft Flue Installation - VRM/VCM-Series ONLY
Figure 2. Typical Power Flue Installation - Both N-Series & VRM/VCM-Series
For more information on the ue system, please refer to the Rinnai Commercial Common Flue System Operation
& Installation Manual.
RINNAI FLUE HEADER(S)
NATURAL DRAFT FLUE PIPE
SUPPLIED BY OTHERS/
ALREADY INSTALLED
CERTIFIED FLUE COWL
CONDENSATE DRAIN
WHERE NECESSARY
RINNAI ADJUSTABLE SLEEVE/OR EQUIVALENT
MULTIPLE RINNAI
WATER HEATERS
ROOF
RINNAI COMMON FLUE
INSERT TERMINAL
ENDCAP
A FALL TOWARDS THE
DRAIN IS REQUIRED
FAN FAILURE SENSING
DEVICE INTERLOCKED WITH
GAS SUPPLY TO APPLIANCES
FAN
DAMPER ADJUSTING
DILUTION AIR
MULTIPLE RINNAI CONTINUOUS
FLOW WATER HEATERS
EXTERNAL WALL
EXTERNAL WALL
FLUE PIPE SUPPLIED BY
OTHERS / ALREADY INSTALLED
RINNAI FLUE HEADER(S)
EXHAUST OF DILUTED
COMBUSTION AIR.
INTAKE OF FRESH AIR
PLANT ROOM VENTILATION
AND COMBUSTION AIR
RINNAI COMMON
FLUE INSERT TERMINAL
RINNAI ADJUSTABLE
SLEEVE / BEND
OR EQUIVALENT
(Note 1) A FALL TOWARDS THE
DRAIN IS REQUIRED
CONDENSATE DRAIN
WHERE NECESSARY
INSTALLATION INSTRUCTIONS

Rinnai 14 Commercial Manifold Pack OIM
Unpacking
Manifold Packs are supplied in cardboard packaging in separate modules of MP2 and MP3. Systems are packed
upside down. When turning over to correctly orient heaters beware that system is top heavy.
Assembly:
A Rinnai Manifold Pack is supplied in modules of either 2 or 3 HD continuous ow units plumbed in parallel
and mounted on a dedicated and lightweight frame. Standard systems can be installed together in any order by
coupling the barrel unions supplied with the copper header pipes. Specically engineered systems (generally for
larger projects or restrictive plant areas) will be marked up accordingly to aid the on site assembly process.
1
2
3
1
2
3
Gas
Hot Water
Cold Water
INSTALLATION INSTRUCTIONS

Rinnai 15 Commercial Manifold Pack OIM
Wall mounting or oor mounting of the heat source is possible.
Wall mounting - drill holes in the wall in the desired location and mount the frame to the wall using suitable xings.
A useful nominal height is 1500mm (height of the frame) from oor level. This is subject to site requirements, the
desired location of the ue terminal in reference to AS/NZS5601 (refer to page 10) and service accessibility. If
you are installing an internal plant, ue design and the associated wall or roof penetrations need to be considered
as the centre distance between the heaters varies depending on which heater is being installed. Refer to the
drawings and specications section on page 17 for dimensional information.
Floor mounting - you will require the appropriate number of DDBASE supports to enable suitable oor mounting.
DDBASE requires some minor assembly using the brackets and xings provided. Every module of either 2 or 3
heaters requires one DDBASE and it is recommended to assemble the DDBASE to the heat source module(s) prior
to joining the pipework. The heat source can also be installed in a back to back conguration using DDFJOINKIT.
Again if you are installing an internal plant, ue design and the associated wall or roof penetrations need to be
considered as the centre distance between the heaters varies depending on which heater is being installed. Refer
to the drawings and specications section on page 17 for dimensional information.
NOTE
When passing the ues through the mounting wall, it may be necessary to attach them to the
water heater before securing the water heater to the wall.
Specically engineered systems mounted on a skid base do not require any assembly of the heat source unless it
has been split purely for transport purposes. If this is the case the pipe connections will be marked up accordingly
to aid the assembly process.
Manifold Packs have a staging system consisting of either a Manifold Electronic Control System (MECS) or
Cascade System. MECS and Cascade are sophisticated electronic control systems that are supplied pre-wired
except for the module connections. Refer to the separate installation booklet supplied for full details on how to
connect each heater control.
Optional Base
(DDBASE)
INSTALLATION INSTRUCTIONS

Rinnai 16 Commercial Manifold Pack OIM
Starting instructions
These are specic to the Manifold Pack and installation conguration:
MANIFOLD PACK WITH NO RETICULATION SYSTEM
• Turn on power to each heater via the Socket Outlets
• Open one or more outlets to generate water ow through the heaters. The outlet temperature should appear
in the maintenance monitor window on each heater. This is factory preset at 75°C but can be adjusted if
required, refer to relevant temperature settings for heaters. This indicates the units are operational.
• Not all heaters may will re up as this is ow rate dependent. To verify all heaters are operational either open
more outlets or, if this is not practical, close the cold water valve underneath the currently operating heaters
to restrict the ow. Other heaters should then re up.
• Clean all lters on completion
MANIFOLD PACK WITH RETICULATION SYSTEM
• Turn on power to each heater via the Socket Outlets
• Turn on the Ring Main pump to generate water ow through the heaters. The outlet temperature should
appear in the maintenance monitor window on each heater. This is factory preset at 75°C but can be adjusted
if required, refer to relevant temperature settings for heaters. This indicates the units are operational.
• Not all heaters may re up as its ow rate dependent. To verify all heaters are operational either open some
outlets or, if this is not practical, close the cold water valve underneath the currently operating heaters to
restrict the ow. Other heaters should then re up.
• Clean all lters on completion
INSTALLATION INSTRUCTIONS

Rinnai 17 Commercial Manifold Pack OIM
TYPICAL RINNAI MANIFOLD PACK INSTALLATION
Appliance Dimensions
Model A B C D E FG H Dry
Weight
HD200 Manifold Packs
MP2 28
375
750
280 340 440 540 1500 850
60 Kg
MP3 28 1125 90 Kg
MP4 28 1500 120 Kg
MP5 28 1875 150 Kg
MP6 28 2250 180 Kg
HD210 Manifold Packs
MP2 210
500
1000
310 340 440 540 1500 850
75 Kg
MP3 210 1500 110 Kg
MP4 210 2000 150 Kg
MP5 210 2500 185 Kg
MP6 210 3000 225 Kg
C
A A
B
H
ED F G
SPECIFICATIONS

Rinnai 18 Commercial Manifold Pack OIM
COLD WATER SUPPLY
• Cold water pipe work to inlet of MP, including required valves as shown above to comply with AS/NZS 3500
and local regulations. Non return valve not required for dead-leg installations.
• Maximum cold water inlet pressure to Manifold Pack is 1000kPa. Fit pressure limiting valve if required.
• Minimum water pressure requirement is 300kPa.
• When a Ring Main pump is included, ensure cold water inlet pressure does not exceed maximum pump
rating. This is usually mains pressure plus pump head pressure (eg: 750 kPa mains +250 kPa pump head
pressure =1000kPa).
HOT WATER OUTLET
• Connect hot water outlet pipe on the other side of the manifold pack that the cold supply is connected. For
example, if the cold water supply is connected to the left hand side, then connect the hot water building
supply to the right hand side.
• Ensure adequate insulation / lagging is tted to hot water pipe to minimise heat loss.
Ring Main Pump
• A secondary or building return pump may be installed in conjunction with the Rinnai Manifold Pack hot water
system. Pump should be sized for minimal temperature loss around the ringmain. Pump must have a check
valve on the discharge.
• Return line from building loop is connected to the cold water supply pipe after the check valve. From that
point onwards the cold pipe should be insulated.
Gas Supply
• Check gas type of Rinnai HD water heater matches gas supply available (LPG or Natural) on job site.
• Gas inlet connection is the top pipe on a MP manifold.
• Manifold Packs have gas isolation valves per water heater.
• Ensure gas pipe sizing is adequate to deliver the required volume / pressure. Pipe size used on inlet tting
is no indication of pipe size required.
• Refer to appropriate pipe sizing chart in Appendix “F” AS/NZS 5601 for appropriate sized gas pipe that
should be used to ensure adequate gas supply.
• Gas meter / LPG cylinder and regulator should also be of suitable size to ensure su󰀩cient gas supply to the
gas installation.
• Purge gas pipe to ensure removal of debris etc prior to nal connection.
• Check for gas escapes using suitable methods as listed in Appendix “E” AS/NZS 5601.
Electrical Supply
• Each water heater consumes approximately 100 Watts when in operation. It is recommended not to exceed
24 heaters on one electric supply circuit. Refer to the manual supplied with the specic water heater for
exact requirements..
FILLING INSTRUCTIONS
• Flush pipe work to remove any debris before nal connection.
• Turn on hot water tap to allow air to be expelled from system.
• Check all connections for water leakage. Tighten as required.
• Purge gas lines until gas is available at water heaters.
• Prime circulating pump(s) before start up by removing chrome screw
and allowing water to drip out the end of the pump shaft (as illustrated).
INSTALLATION HANDOVER MANUAL

Rinnai 19 Commercial Manifold Pack OIM
Manifold Pack Principle Of Operation
Cold water enters system through cold inlet pipe is heated by water heater(s) and exits through hot pipe. Dead-leg
systems will deliver preset temperature as per dipswitch or controller settings.
Rinnai Heavy Duty Units require a minimum of either 1.5 l/min or 2.4l/min (depending on which water heater is
used) per heater before they can operate. If this is not achieved they will not re. When there is an expected
scenario that results in a lower ow per heater a staging system is required. Rinnai Manifold Packs come as
standard with either MECS (Manifold Electronic Control System) or Cascade staging systems. Staging will control
the ow through each water heater, increasing the chance of minimum ow rate being achieved. It does this by
measuring the ow rate passing through the turbine of each heater. It will drive the geared motor inside the HD
unit shut in heaters that are not required to operate, therefore increasing the ow rate through the remaining
heaters. Extra heaters are red as the ow rate increases. The staging control system also rotates the sequence
of operation to share the load across all heaters to maximise life expectancy.
RINNAI MANIFOLD ELECTRONIC CONTROL SYSTEM - MECS AND CASCADE
Rinnai Heavy Duty Gas Fired Continuous Flow Water Heaters can be manifolded together, (up to 25 individual
water heaters), by connecting them in parallel to enable a far greater hot water ow rate than is possible with a
single unit.
MECS and Cascade are integrated control systems unique to Rinnai linking each water heater. Their primary
function is to monitor demand and activate water heaters accordingly.
The key advantages to using a staging control system are as follows:
• Very high ow rates/volumes made possible by linking individual heaters in parallel.
• Load shared across linked heaters ensuring even wear rates.
• Inherent redundancy in the event of a failed water heater(s).
• Reduced gas consumption resulting in increased economy.
• Unsurpassed water temperature consistency.
Refer to the separate installation instructions provided with the control system.
INSTALLATION HANDOVER MANUAL

Rinnai 20 Commercial Manifold Pack OIM
MANIFOLD PACK PREVENTATIVE MAINTENANCE
Your Rinnai Continuous Flow water heaters have self diagnostic capability. If a fault occurs, an Error Code will ash
on the status monitor or inbuilt controller. If you have Water Controllers, this assists with diagnosing the fault and
may enable you to overcome a problem without a service call. Please quote the code displayed when enquiring
about service.
HD Fault Codes
Code
Description Remedy
-Noticeable reduction in water ow Inlet water lter needs to be cleaned - Service Call
03
Power interruption during Bath ll
(Water will not ow on power reinstatement) Turn o󰀨 all hot water taps Press On/O󰀨 twice
05
By-Pass Flow Control Failure Service Call
10
Air Supply or Exhaust Blockage
or Condensate Pipe Blockage Service Call
11
No ignition / No gas supply Check gas is turned on at water heater and gas
meter or cylinder
12
Flame Failure / Low gas ow
Check gas is turned on at water heater and gas
meter or cylinder. Check there are no obstructions
to the ue outlet
14
Heat Exchanger Overheat Failure Service Call
15
Venturi Control Failure Service Call
16
Over Temperature Warning Service Call
17
Venturi Blockage Service Call
19
Electrical Earthing Failure Service Call
21
Data Transfer Error Service Call
32
Outgoing Water Temperature Sensor Failure Service Call
33
Heat Exchanger Thermistor Failure Service Call
34
Combustion Air Temperature Sensor Failure Service Call
38
Exhaust Thermistor Failure Service Call
41
Freeze Protection Thermistor Failure Service Call
51
Inlet Thermistor Failure Service Call
52
Gas Valve Failure Service Call
54
High Exhaust Gas Temperature Failure Service Call
S5
Scheduled Service Reminder Service Call
Se
Cascade Connection Failure Service Call
61
Combustion Fan Failure Service Call
65
Water Flow Control Failure
(Does not stop ow properly) Service Call
70
PCB Failure Service Call
71
Solenoid Valve Circuit Failure Service Call
72
Flame Rod Failure Service Call
Wireless water controller (when tted) is ‘Out of
Range’ due to the distance from transceiver or an
obstruction.
Move wireless water controller or transceiver or
remove the obstruction.
FAULT FINDING