FF Flue

Installation

Manual

Rinnai FF coaxial flue system, suitable for use with the following Rinnai internal continous flow water heater models:

INFINITY 26i – REU-VR2632FFUG

HD 200i – REU-VRM2632FFUC

UP

These components shall be installed in accordance with:

• Manufacturer’s Installation Instructions

• Current AS/NZS 3000, AS/NZS 3500 & AS 5601

• Local Regulations and Municipal Building Codes

These components must be installed, serviced and removed by an Authorised Person.

INSTALLATION GENERAL

This flue must be installed by an authorised person. The Installation must conform to local regulations.

Installation must comply with the instructions supplied by Rinnai.

Service and removal must be carried out by an authorised person.

TABLE OF CONTENTS

CERTIFICATION ....................................................................................... 1

GENERAL .................................................................................................. 1

FF FLUEING OPTIONS ............................................................................. 2

GENERAL INSTALLATION METHODS ................................................... 3

DIRECT HORIZONTAL FLUE ................................................................... 4

EXTENDED HORIZONTAL FLUE ............................................................. 4

VERTICAL FLUE ....................................................................................... 5

COMBINED VERTICAL & HORIZONTAL FLUE ...................................... 5

CONDENSATE DRAIN .............................................................................. 6

DIMENSIONS ............................................................................................ 8

CLEARANCES .......................................................................................... 9

CONTACT INFORMATION ..................................................................... 10

CERTIFICATION

Certified by the Australian Gas Association (AGA) For use only with Rinnai internal continuous flow water heaters.

GENERAL

1. These instructions only apply to the Rinnai FF water heater coaxial flueing system. This flue system utilises pipe components with an aluminium inner pipe and a white plastic outer pipe.

These instructions DO NOT apply to older Rinnai water heater flueing that has either a stainless steel single skin or stainless steel coaxial construction. If in doubt contact Rinnai.

2. Before commencing installation, please read the 'Installation Instructions - General', located inside a pouch behind the front cover of all Rinnai water heater models. The Rinnai internal water heater range must only be installed with Rinnai water heater flueing as referred to in these instructions.

3. The requirements of the current AS5601/AG601 and local authorities must be met, which is the installers responsibility.

4. The required clearances of Rinnai internal continuous flow water heater when installed as a single unit are shown in Fig.1A. The appliances are certified to be installed side by side as shown on page 7, allowing a minimum distance between flues as follows:

• 270mm between horizontal terminals.

• 160mm between vertical cowls.

5. Rinnai internal continuous flow water heaters fitted with FF flue systems are room sealed as defined in AS5601.

No ventilation in the space where the water heater is installed is required.

6. The outer plastic section of the coaxial flue complies with temperature hazard requirements and can be installed with zero clearance to combustible material.

Rinnai Australia 1 Installation Manual

FFSBEND

FFWPLATE or

FFWSEAL (Optional)

FF FLUEING OPTIONS

127mm Hole

FFWPLATE or

FFWSEAL (Optional)

FFSBEND

2° fall to terminal

FFWPLATE

127mm Hole

2° fall to terminal

FFWPLATE

FFWALLTERM

DIRECT HORIZONTAL (FIG. 1)

A horizontal flue installation that consists of a starter bend (FFSBEND) and a wall terminal

(FFWALLTERM) only. See page 4 for details.

HORIZONTAL EXTENDED (FIG. 2)

A horizontal flue installation that consists of a starter bend (FFSBEND), flue pipe(s)

(FFPIPE1000) and a wall terminal

(FFWALLTERM). See page 4 for details.

Fig. 1

FFROOFCOWL

Minimum

Clearance

500 mm

Flue pipe clip supplied with

FFPIPE1000

FFSBEND

Drain Tube Cap

FFPIPE1000

Fig. 3

Decktite or lead collar flushing

Flue pipe clip supplied with

FFROOFCOWL

Minimum

Clearance

500 mm

Flue pipe clip supplied with

FFPIPE1000

VERTICAL (FIG. 3)

A vertical installation that consists of flue pipe(s) (FFPIPE1000) and a roof terminal

(FFROOFCOWL). See page 5 for details.

FFWALLTERM

2° fall to terminal

Fig. 2

VERTICAL / HORIZONTAL (FIG. 4)

A combination of pipe(s) (FFPIPE1000) and bends (FFSBEND/FFBEND) that terminate with either a wall (FFWALLTERM) or roof

(FFROOFCOWL) terminal. See page 5 for details.

FFROOFCOWL

For condensation drain fitting requirements see the section “CONDENSATE DRAIN” on page 6.

Decktite or lead collar flushing

Flue pipe clip supplied with

FFROOFCOWL

FFPIPE1000

FFPIPE1000

U P

FFWSEAL

Flue pipe clip supplied with

FFPIPE1000

Drain Tube

(See Page 6)

FFPIPE1000

FFBEND

FFPIPE1000

UP

UP

FFPIPE1000

FFBEND

FFPIPE1000

FFSBEND

Drain Tube

(See Page 6)

FFBEND

FFWSEAL

FFPIPE1000

FFWALLTERM

2° fall to

Termina

2° fall to trap

Fig. 4

Flue pipe clip supplied with FFPIPE1000

Rinnai Australia 2 Installation Manual

GENERAL INSTALLATION METHODS

Lubricating Components

A container of "O ring" grease is provided with the flue terminal components (FFWALLTERM and FFROOFCOWL).

To ease assembly, lubricate the “O” ring on the inner pipes of each flue component prior to assembly.

Use only a silicone based "O" ring seal lubricant. DO NOT use petroleum based lubricants such as petroleum jelly, as such products may cause deterioration.

Means of disconnection

The appliance connection shall include a means of disconnection in accordance with AS5601.

Flue Length Dip switch Settings

FFU (Internal) Models Only

Short Flue: Total flue lentgh less than 1.5 metres

OFFON

FFU (Internal) Models Only

Extended Flue: Total flue length 1.5 metres or greater

OFFON

Setting Flue Length Dipswitch

Installations can consist of both horizontal and vertical runs to a maximum length of 9 metres and with a maximum of three 90° bends.

If flue length exceeds 1.5m, dipswitch 1 of SW1 is to be switched to the 'OFF' position (Fig. 6).

SW1

OFFON

This increases the combustion fan speed to overcome the additional friction losses.

Fig. 6

Cutting The Flue Components

Using the dimensions shown on page 8, calculate the required number and type of flue components that are needed to reach from the water heater and the flue terminal.

SW2

50

15

When cutting components the outer flue pipe should be cut to the required length plus 35 mm and the inner flue pipe should be cut to the required length plus 50 mm, this will ensure that the correct penetration is provided for joining of components.

Penetration

When inner and outer pipes are re-assembled after cutting the inner pipe should extend 15mm beyond the end outer pipe (Fig. 7).

35

Required length

SW1

SW2

Fig. 7

OFFON

The ONLY COMPONENTS that can be cut are as follows: FFPIPE1000, FFROOFCOWL and

FFWALLTERM.

Ensure all ends are cut square (the use of a mitre box will ensure a clean square cut).

Ensure all cut ends are free from debris and burrs.

Flue Terminals

The flue gases can reach temperatures up to 200°C. The flue terminal is to terminate in a location not to cause a nuisance, in accordance with AS5601.

Multiple Terminal Installations

The terminal clearances in AS5601 do not apply to the Rinnai internal continuous flow water heaters when installed side by side (Fig. 8).

AGA certification allows for a horizontal separation of 160 mm for roof terminals and 270 mm for wall terminals.

Each terminal is to be terminated at the same vertical height.

Fig. 8

Rinnai Australia 3 Installation Manual

DIRECT HORIZONTAL FLUE

The Rinnai water heater 'direct' flueing components (FFSBEND, FFWALLTERM, FFWSEAL and FFWPLATE) must be used for this purpose.

Mount the water heater in an appropriate location ensuring that there is enough space to install the flue assembly and pipe work. Also ensure that positioning of the flue terminal complies with the requirements of AS5601 (Fig.5.3

on page 9).

Installation method

1. Using the dimensions provided in Fig. 9, mark a point along the appliance centring that is 160mm from the top of the water heater. This mark forms the centre point for the

127mm diameter wall penetration.

Ø127 Wall penetration

FFSBEND

130

5

2. When installing the FFSBEND directly backwards from the appliance it is necessary to extend the adjustable mounting brackets of the water heater to a minimum of 45mm to allow for the flue component radius.

3. Make a 127mm wall penetration for the flue. Ensure that the flue spigot is covered to avoid debris entering the appliance flue connection.

Fig. 9

Min

45

If an accurate wall penetration is made then the FFSBEND will cover the hole and an internal wall plate will not be necessary.

Ensure the drain tube cap remains fitted in place (Fig. 10).

1. Measure the required length for the horizontal terminal to penetrate the wall and allow an extra 10mm protrusion from the wall outer surface as shown in

Fig. 10. See the section “Cutting The Flue Components” on page 3 for correct cutting requirements.

2. Connect the FFWALLTERM to FFSBEND (ensuring components are pushed 'fully home') and fit associated wall plates/seals as required.

3. To prevent rain water from entering the flue terminal ensure the required 2° fall to outside is achieved (Fig.2 page 2).

4. Seal the flue around the wall plate using silicon sealant.

Fig. 10

10 Drain

Tube

Cap

EXTENDED HORIZONTAL FLUE

This option can be used when the water heater is mounted against an internal wall and flueing needs to extend horizontally to exit an external wall.

As with the DIRECT HORIZONTAL FLUE option the Rinnai water heater 'direct' flueing components (FFSBEND,

FFWALLTERM, FFWSEAL and FFWPLATE) must be used for this purpose, together with extension pieces

(FFPIPE1000 and FFBEND) components as required.

Total flue length can be up to 9 metres long and a maximum of 3 bends can be used. Horizontal flue is to be installed with a 2° fall towards the wall terminal to prevent condensation running back into the water heater.

If this can not be achieved and the length of the flue system exceeds 1.5 metres the condensate drain pipe will require connection, refer to “CONNECTING CONDENSATE DRAIN” on page 6 for details.

Ensure there is enough space to install the water heater, flue assembly and pipe work. Also ensure that positioning of the flue terminal complies with the requirements of AS5601 (Fig.5.3 on page 9).

Installation method

1. Follow the installation method as described for the DIRECT HORIZONTAL FLUE option, using FFPIPE1000 and

FFBEND components to extend the installation as required.

Rinnai Australia 4 Installation Manual

VERTICAL FLUE

This option can be used when the water heater is to be flued vertically through the roof.

The Rinnai water heater 'Vertical Flueing Components' (FFROOFCOWL and FFPIPE1000) with extension pieces

(FFPIPE1000) and optional roof seal (FFSEAL) must be used for this purpose.

With vertical flue systems the condensate drain pipe will require connection if the total length of the flue system exceeds 2 metres. Refer to the section “CONDENSATE DRAIN” on page 6 for details. If the condensate drain tube is not required to be connected it is important to keep the drain tube cap in place on the appliance flue spigot. It is only to be removed if the condensate drain tube is connected. Appliances must not be operated with the drain tube cap removed and with no condensate drain tube connected.

Total flue length can be up to 9 metres long and have a maximum of 3 bends.

Mount the water heater in an appropriate location ensuring that there is enough space to install the flue assembly and pipe work. Also ensure that positioning of the flue terminal complies with the requirements of AS5601 (Fig.5.3

on page 9).

Installation method

1. Set plumb bob from the centre of the heater flue outlet to ceiling marking position. Cut 127mm hole in plasterboard (or a suitable 'oval' for pitched roof applications). Repeat this step for underside of roofing.

2. Calculate the required number and combination of FFPIPE1000 lengths and cut to size as required, see the section “Cutting The Flue Components” on page 3.

3. Install flue and terminal. Flue to terminate at least 500mm from the end of the flue to the nearest part of the roof, in accordance with AS5601(Fig. 3 page 2). Seal the roof penetration with an approved flashing.

4. Install roof seal. (Not supplied, if required Rinnai Part No. FFWSEAL).

5. Ensure the flue is fully supported independently of the appliance, by the use of suitable clips or brackets, in accordance with AS5601. Appropriate standoff brackets are supplied with each FFROOFCOWL and

FFPIPE1000 component.

6. Ensure that the appliance can be removed without causing movement or displacement of the flue, in accordance with AS5601.

7. Fit the condensate drain tube if required (see “CONDENSATE DRAIN” on page 6).

8. All external joints of the PVC pipe must be glued with approved PVC cement to prevent water entering the flue.

COMBINED VERTICAL & HORIZONTAL FLUE

This option allows the water heater to be installed virtually anywhere using a wall (FFWALLTERM) or roof

(FFROOFCOWL) terminal. Extension pieces (FFPIPE1000 and FFBEND) can be mounted horizontally or vertically as required.

With combined horizontal and vertical flue systems the condensate drain pipe will require connection if the total length of the flue system exceeds 1.5 metres. Refer to the section refer to

“CONNECTING CONDENSATE DRAIN” on page 6 for details. If the condensate drain tube is not required to be connected it is important to keep the drain tube cap in place on the appliance flue spigot. It is only to be removed if the condensate drain tube is connected. Appliances must not be operated with the drain tube cap removed and with no condensate drain tube connected.

Total flue length can be up to 9 metres long and have a maximum of 3 bends. Mount the water heater in an appropriate location ensuring that there is enough space to install the flue assembly and pipe work. Also ensure that positioning of the flue terminal complies with the requirements of AS5601 (Fig.5.3 on page 9).

Installation method

1. Using a combination of the installation procedures covered in the “EXTENDED HORIZONTAL FLUE” on page 4 and “VERTICAL FLUE” on page 5 determine and install the required components.

Rinnai Australia 5 Installation Manual

CONDENSATE DRAIN

The condensate trap and associated drain connection are integral with the appliance flue spigot. The condensate trap collects any condensate from the flue system, thereby preventing condensate from entering the water heater and causing damage.

A condensate drain tube kit is supplied with the terminals (FFWALLTERM and FFROOFCOWL) and will require connection to the condensate drain connection in flue systems where the total length exceeds 1.5 metres AND condensate cannot be drained via the flue terminal. Usually, the condensate drain tube requires connection in

‘vertical flue’ and ‘combined vertical & horizontal flue’ systems and does not require connection in ‘direct horizontal’ and ‘extended horizontal’ flue systems.

If the condensate drain tube is not required to be connected it is important to keep the drain tube cap in place on the appliance flue spigot. It is only to be removed if the condensate drain tube is connected (Fig. 11).

Appliances must not be operated with the drain tube cap removed and with no condensate drain tube connected.

Drain Tube Cap

Because the 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 such as Unplasticised

Polyvinyl Chloride (UPVC) or Polyethylene (PE) which is commonly used for irrigation piping.

Fig. 11

Important Considerations For The Condensate Drain Tube

The content of AS3500.4:2003 Section 5.12 ‘Temperature / Pressure Relief and Expansion Control

Valve Drain Lines’ has been used as a guide in preparing these considerations.

A B C

B D

2° fall

A

A B C

E

F

A

B

C

D

E

F

G

Fig. 12 G

Flue spigot with integral condensate trap. Water heater drain outlet connection is 16mm.

Aluminium condensate drain tube. (Supplied with flue terminals FFWALLTERM or FFROOFCOWL).

Silicone connection tube and retaining clips. (Supplied with flue terminals FFWALLTERM or FFROOFCOWL).

Continuous fall (of at least 2°) from water heater to discharge point. Lengths and bends in accordance with

‘length And Changes Of Direction’ table below.

16 mm UPVC conduit to terminate in accordance with

G

.

Drainage tube to be sealed to conduit with approved silicone.

Suitable points of discharge are deemed to be drains, sewers or pits. DO NOT discharge onto electrical connections, earth stakes, copper pipes, concrete paths or into a pond.

Lengths and changes of direction

Maximum length and changes of direction greater than 45 ° should be as follows:

Max length (Metres)

Max changes of direction >45°

9

3

8

4

7

5

6

6

Installation Method

(a) The drain line MUST NOT discharge onto electrical connections, earth stakes, copper pipes, concrete paths or into a pond.

Rinnai Australia 6 Installation Manual

CONDENSATE DRAIN

(b) The point of discharge from each drain line shall be located so that the release of condensate does not cause a nuisance, is readily discernible and incurs no risk of damage to the building.

In view of (a) and (b), suitable points of discharge are deemed to be drains, sewers or pits.

(c) There shall be no tap, valve or other restrictions in any line.

(d) Each line shall fall continuously from the valve to the approved point of discharge.

(e) Drain lines shall not discharge into a storage water heater safe tray.

(f) The end of the condensate drain line shall be:

(i) not lower than 200 mm or higher than 300 mm above an un-paved surface; or

(ii) not lower than 75 mm or higher than 300 mm above a gravel pit not less than 100 mm in diameter in a paved surface.

(g) Where discharging over a tundish or gully trap, drain lines shall have an air gap of a size at least twice the diameter of the drain line.

Interconnection Of Condensate Drain Lines

Condensate drain lines from multiple water heaters may be joined together provided they conform with the

‘INSTALLATION’ requirements on page 6.

Common Stack Discharge

Where individual water heaters are installed in a multistorey building, the condensate drain lines may discharge into a common stack, subject to the following:

(a) The discharge from the common stack is to a tundish, having a discharge line, that is not less than the size of the common stack, directly connected to a fixture trap, and installed in connection with any adjacent soil or waste stack.

(b) The discharge point of the common stack is such that any discharge is readily visible and not cause any nuisance.

(c) The common stack is vented by extending the pipe upwards, above the roof level.

Tundish Drain Lines

The drain line from any tundish shall be not less than DN 20 or less than one size larger than that of the largest drain line discharging into the tundish. Tundish drain lines shall comply with the ‘INSTALLATION’ requirements on page 6.

Areas Subject To Freezing

In areas where water pipes are prone to freezing, the drain pipe from any valve shall be insulated and not exceed

300 mm in length. It shall discharge into a tundish through an air gap of not less than 75 mm and not more than 150 mm measured from the outlet of the drain pipe to the rim of the tundish.

Rinnai Australia 7 Installation Manual

64.5

130 5

FFSBEND

FFWALLTERM

Includes:

Drain tube

Silcone lubricant

80

15

15

FFPIPE1000

Includes:

Wall bracket

DIMENSIONS

64.5

165 5

85

92

490

FFBEND

(2x 45° Bends)

75

80

(As a 90° OFFSET)

15

(As a 45° OFFSET)

80

975 5

FFWSEAL

125

Thickness 1mm

FFROOFCOWL

Includes:

Drain tube

Silcone lubricant

Wall bracket

FFWPLATE

20

Ø6 x 4

127

Thickness 1mm

80

125

DESCRIPTION

Starter Bend

Universal 45/90 Degree Bend

Horizontal Flue Terminal

Flue Pipe 1000mm length

Vertical Flue Terminal

Ceiling Ring

Wall Plate

Rinnai Australia

CODE NUMBER

FFSBEND

FFBEND

FFWALLTERM

FFPIPE1000

FFROOFCOWL

FFWSEAL

FFWPLATE

8

BAR CODE NUMBER

9314109158311

9314109143058

9314109107685

9314109107061

9314109107678

9314109107722

9314109107715

Installation Manual

CLEARANCES

Rinnai Australia 9 Installation Manual

CONTACT INFORMATION

Australia Pty. Ltd.

Head Office

10-11 Walker Street,

Braeside, Victoria 3195

P.O. Box 460

Tel: (03) 9271 6625

Fax: (03) 9271 6622

ABN 74 005 138 769

Rinnai has a Service and Spare Parts network with personnel who are fully trained and equipped to give the best service on your Rinnai appliance. If your appliance requires service, please call our Hot Water Service Line. Rinnai recommends that this appliance be serviced every 3 years.

10

Internet: www.rinnai.com.au E-mail: [email protected]

National Help Lines

Sales & Service

Tel: 1300 555 545* Fax: 1300 555 655*

Spare Parts & Technical Info

Tel: 1300 366 388* Fax: 1300 300 141*

*Cost of a local call Higher from mobile or public phones.

Hot Water Service Line

Tel: 1800 000 340

RA TSD01-011 Issue 4.0 12/06/08