Installation Manual and Service Log for Twin Flow Important. Read these instructions carefully before attempting installation or use of this appliance. All work must be carried out by competent persons.
WARNINGS Persons carrying out installation work on the Rinnai Twin Flow require the following certificates For any gas work carried out: Registration in proof of competence scheme. At time of writing CORGI is the only acceptable body. ACS certification must also be up to date. The Twin Flow hot water system is not covered by Building Regulations Part G3 unless it is a closed system such as one piped with a secondary return system.
CONTENTS Warnings..............................................................................................................2 Contents................................................................................................................3 Property Owners Responsibility..................... .......................................................4 Twin Flow Package Parts......................................................................................5 Basic Operating Principle................
PROPERTY OWNER’S RESPONSIBILITY Twin Flow in Domestic Properties. Any domestic heating and hot water system must be subject to an annual service. All gas appliances must be serviced by a competent person. Twin Flow in Commercial and Rented Properties. If the property is to be used as a commercial premise, including landlord’s rented accommodation, then there is a duty of care to protect employees, tenants, and the public from the possible dangers of hot water systems including scalding and Legionella.
TWIN FLOW PACKAGE PARTS The Rinnai Twin Flow is supplied with the following.
BASIC OPERATING PRINCIPLE The boiler and water heater are installed together to supply the property with heating and hot water. Boiler. The boiler can be controlled by a wireless room stat or an Opentherm controller. When the room is below temperature the boiler will come on to heat it up. The boiler is fully modulating so as the return water temperature increases and the room warms up the unit will reduce the gas input.
PLANNING OUT THE SITE When choosing the location of the Twin Flow the following should be taken into account:1. The Twin Flow has a necessary clearance of 100mm to the side with the isolator switches and 60 mm on the other side. It also requires 250mm above, 600mm to the front, and enough space below for the pipework. 2. The Twin Flow should mount on a wall or suitable framework that can hold the total weight of the system.
PREPARING WALL Open the box with the backplate in it. Along with the backplate are the expansion vessel, template and mountings. Remove the template and fix it to the wall in the chosen location. Make sure it is the right way up as the same template is used for left and right handed installations. The template is marked WATER HEATER and BOILER; make sure the letters that are written right side up show the two appliances as they are to be laid out.
PREPARING BACKPLATE When the backplate is removed from the box the 16L expansion vessel for the heating circuit may not be fixed into position. Place a foam pad (supplied) on each side of the expansion vessel to prevent any vibration noise. The vessel should be installed to the back of the backplate through the bracket and held in with the spring band. This is attached the same way regardless of left or right handed installation.
INSTALLATION BACKPLATE Now hang the backplate over the six bolts in the wall and then tighten them up using a ratcheting spanner or socket driver. PRIOR TO MOUNTING THE TWIN FLOW APPLIANCES THE HOLES FOR THE FLUES MUST BE CORE DRILLED.
INSTALLATION WATER HEATER The water heater must be installed to the requirements of the Installation Manual supplied with the heater. These instructions do not supersede those instructions, but are to be followed in conjunction with that manual. 1. Siting the Water Heater. The water heater should be located on the studded back plate. The necessary clearance between the boiler and water heater flues is achieved with the backplate used in a left hand or right hand configuration.
INSTALLATION BOILER The boiler must be installed to the requirements of the Installation Manual supplied with the boiler. These instructions do not supersede those instructions, but are to be followed in conjunction with that manual. 1. Siting the boiler. The boiler is supplied with a bracket which can be located on the predrilled backplate. The necessary clearance between the boiler and water heater flues is achieved with the backplate used in a left hand or right hand configuration.
TWIN FLOW GAS PIPEWORK The gas pipe work for the Twin Flow should be sized for the total system gas consumption in accordance with British Standards. Due to the flow switch the maximum gas consumption of the standard Twin Flow system is 54 kW (5.05 m3/hr.) This is based on the E32S 32kW boiler and a 26i water heater. If a larger or smaller water heater is used it will alter this gas rate. The correctly sized gas supply pipe should be run to the Twin Flow.
TWIN FLOW MAINS COLD WATER PIPEWORK The mains cold water pipework for the water heater of the Twin Flow should be sized based on the maximum flow rate through it. If a high temperature set point is to be used such as 55 or 60C then the maximum flow rate through the heater (based on a summer incoming temperature of 20C, which is the maximum allowable in the UK) is around 20 L/min. For lower setpoints the maximum flow rate through the heater could be as high as 32 L/min.
TWIN FLOW HOT WATER PIPEWORK The hot water supply pipe work from the water heater of the Twin Flow should be the same size as the mains supply to the heater. The water heater must have an isolating valve (supplied with the Twin Flow) and union connection for removal of the appliance on the hot water supply.
TWIN FLOW CENTRAL HEATING PIPEWORK The central heating pump within the boiler has an available external head of 17kPa. The water heater must have an isolating valve (supplied with the Twin Flow) and union connection for removal of the appliance on the hot water supply.
TWIN FLOW FLUEING For standard horizontal flueing the Twin Flow is supplied with a flue kit including: 2 x wall terminal 600mm long, concentric, 80/125. 2 x white gasket (internal) 2 x black gasket (external) 1 x straight F/F adapter 2 x 90 bend M/F The flue connection on the top of the water heater is a male connection. When flueing directly through the wall behind the Twin Flow the water heater must have a straight Female/Female adapter, then a male/female 90 degree bend and then the wall terminal.
TWIN FLOW ELECTRICS All of the mains electrics has been prewired. The only mains voltage electrical installation that needs to be done is to plug the Twin Flow in. This has been done so that the installer does not require any special certification such as Part P, and to make it as easy as possible. The side of the unit has two isolator switches that isolate the appliances on both poles with at least a 3mm gap.
TWIN FLOW ELECTRICS SOLAR CONECTIONS N2 L1 Solar pump EARTH EXT 444 EXT 443 N 24 L 14 Time and temp RF controller EARTH Keypad DHW EXT 32 EXT 31 N 23 L 13 Water heater EARTH S L 442 SL441 SL44 SL43 SL42 SL41 N 22 L12 DHW Flow switch Boiler EARTH DHW Switch Heating switch Neutral 2 Live 1 EARTH Wiring Loom Schematic 19 3 pin plug
TWIN FLOW ELECTRICS Mains L1 N2 E Htg Control L12 N22 E 443 444 Htg Boiler Switch L1 L12 N2 N22 E Keypad x3 31 32 DHW Flow Switch 441 442 W Htg switch L1 L13 N2 N23 E W Htg L13 N23 E 31 32 Boiler L12 N22 E Electrical Backplate Layout 41 42 43 44 240volts 3Amp Fused Controls 0 volt Contacts 20
TWIN FLOW CONTROLS There are three controls that must be plugged into the control box of the unit. These are the water heater remote, flow switch, and the boiler wireless room stat receiver. Correct location and locking of the three plugs must be observed before power is applied to the unit. Control Connection Points Opentherm / Weather Compensation If chosen the Opentherm controller is wired directly to the boiler connections within the boiler casing.
TWIN FLOW CONDENSATE DISPOSAL The boiler condensate drain combines the pressure relief and condensate drain together. The condensate side has an internal trap to prevent by-products of combustion entering the room. Condensate and Pressure Relief Discharge Disposal. Disposal of the condensate/pressure relief water must be done in accordance with BS 6798:2000, the Building Regulations Part H, Building Regulation G3, and any local building controls. These rules should be followed when piping the discharge.
TWIN FLOW CONDENSATE DISPOSAL 23
TWIN FLOW CONDENSATE DISPOSAL 24
COMMISSIONING PROCEDURE Following installation of the Twin Flow the following must be done to commission the system. This is to include the commissioning of the Twin Flow system only. Commissioning procedures for the water heater and boiler are found in the Installation Instructions with each appliance. 1. After installation of the Twin Flow all pipework, valves, and radiators must be flushed out. 2. Connect the Twin Flow to the building pipe work. 3. Check all connections for tightness. 4.
COMMISSIONING RECORD NOTES Please make note of all commissioning figures here for future references Attach Flue Gas Analyzer printout to this page.
MAINTAINING TWIN FLOW All gas appliances must be serviced at least annually by a CORGI registered engineer. This should include : Water Heater • • • • • • • • • • • • Isolate electrics and valve off hot, cold, and gas to unit. Check the water filter and strainer to be sure there are no blockages. Remove the combustion fan and clean the impeller. Check the burner for wear or water damage. Vacuum out any debris. Wipe out chamber.
SERVICE RECORD SERVICE 1 DATE____________ Company______________________ Address ______________________ _____________________________ TEL __________________________ Engineer ______________________ Serviced..
SERVICE RECORD SERVICE 9 DATE____________ Company______________________ Address ______________________ _____________________________ TEL __________________________ Engineer ______________________ Serviced..
Serial Number if applicable Part Replaced Reason If any parts require to be replaced on a Twin Flow Appliance please note it here so future engineers are aware of what work has been carried out date.
SERVICE CONTACT Rinnai UK LTD. 9 Christleton Court Manor Park Runcorn Cheshire WA7 1ST Tel. 01928 531870 Fax. 01928 531880 E-mail. info@rinnaiuk.com Web. www.rinnaiuk.
