Summary of Contents for Rinnai brivis StarPro SP5 Series
Page 1
Brivis Models: StarPro SP5 series StarPro SP6 series Ducted Gas Heater (NG-2A+/NG-2A Controller) Service Manual...
Page 2
This appliance must be installed, maintained and removed only 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. Models SP6 Series Heaters...
REVISIONS Issue Date Description August 2021 • Introduction of Service Manual for NG-2A+ & NG-2A Controller for SP5 and SP6 models StarPro SP5 & SP6 Series Issue 4 - Service Manual...
WARNINGS AND IMPORTANT INFORMATION READ ALL INSTRUCTIONS BEFORE USING THE APPLIANCE. Always comply with the following precautions to avoid dangerous situations and to ensure WARNING 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.
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.
TABLE OF CONTENTS Revisions Warnings and Important Information Scope Heater Operation Operation Overview ............................. 10 Heater Specifications ........................... 11 Thermistor Specifications ..........................11 Controller Operation ............................. 26 Installer Menu ............................... 27 Service Menu .............................. 29 Service Parameters ............................30 Component Operation Gas Valve Operation ............................
1. SCOPE This Service Manual contains information relevant to servicing a Brivis StarPro SP5 and SP6 heater incorporating the NG-2A+ and NG-2A Controller. It is intended for Service personnel who have received adequate training on Gas Fired Ducted Central Heaters, in particular Brivis StarPro series heaters. The main sections covered include: •...
2. HEATER OPERATION This section provides an operational overview of the StarPro SP series heaters. It is vital that an understanding of how StarPro SP heaters and their components operate, in order to service the StarPro SP Series heater effectively and efficiently.
OPERATION OVERVIEW The StarPro SP and BX5 series heater is an induced draught combustion system, consisting of direct spark ignition with electronic gas modulation to vary the heat output to the desired level. The supply air temperature (air leaving the heater) is monitored via a thermistor located in the duct near the heater outlet, and is continuously monitored by the heater control board.
HEATER SPECIFICATIONS For detailed information, refer to Technical Specifications in the following tables. THERMISTOR SPECIFICATIONS Thermistor Temperature °C Resistance Value Ohm Storage Temperature: -10°C to +100°C 55.350 Operational Temperature: 0°C to +100°C 32.660 Curve Tracking +/- 0.5°C over entire operational temperature range 19.990 Thermistor and Value Curve (see right) 12.490...
Page 12
Technical Information SP521EN Table 1. AGA Approval No. 7489 Energy Label Star Rating Dimensions (mm) Length Width Height Pop Size Weight (kg) Cabinet 1046 300/350 (XA) Gas Type Natural Gas Input (max) 90 MJ Output (max) 21 kW Burner Pressure Natural Gas Maximum 800 Pa...
Page 13
Technical Information SP521IN Table 2. AGA Approval No. 7489 Energy Label Star Rating Dimensions (mm) Length Width Height Pop Size Weight (kg) Cabinet 1021 300/350 (XA) Gas Type Natural Gas Input (max) 90 MJ Output (max) 21 kW Burner Pressure Natural Gas Maximum 800 Pa...
Page 14
Technical Information SP530EN Table 3. AGA Approval No. 7489 Energy Label Star Rating Dimensions (mm) Length Width Height Pop Size Weight (kg) Cabinet 1096 350/400 (XA) Gas Type Natural Gas Input (max) 130 MJ Output (max) 30 kW Burner Pressure Natural Gas Maximum 760 Pa...
Page 15
Technical Information SP530IN Table 4. AGA Approval No. 7489 Energy Label Star Rating Dimensions (mm) Length Width Height Pop Size Weight (kg) Cabinet 1070 350/400 (XA) Gas Type Natural Gas Input (max) 130 MJ Output (max) 30 kW Burner Pressure Natural Gas Maximum 760 Pa...
Page 16
Technical Information SP535IN Table 5. AGA Approval No. 7489 Energy Label Star Rating Dimensions (mm) Length Width Height Pop Size Weight (kg) Cabinet 1070 Gas Type Natural Gas Input (max) 150 MJ Output (max) 35 kW Burner Pressure Natural Gas Maximum 760 Pa Minimum Modulation...
Page 17
Technical Information SP615IN Table 6. AGA Approval No. 7489 Energy Label Star Rating Dimensions (mm) Length Width Height Pop Size Weight (kg) Cabinet 1021 Gas Type Natural Gas Input (max) 58 MJ Output (max) 15 kW Burner Pressure Natural Gas Maximum 800 Pa Minimum Modulation...
Page 18
Technical Information SP623EN Table 7. AGA Approval No. 7489 Energy Label Star Rating Dimensions (mm) Length Width Height Pop Size Weight (kg) Cabinet 1052 300/350 (XA) Gas Type Natural Gas Input (max) 86 MJ Output (max) 23 kW Burner Pressure Natural Gas Maximum 700 Pa...
Page 19
Technical Information SP623IN Table 8. AGA Approval No. 7489 Energy Label Star Rating Dimensions (mm) Length Width Height Pop Size Weight (kg) Cabinet 1052 300/350 (XA) Gas Type Natural Gas Input (max) 86 MJ Output (max) 23 kW Burner Pressure Natural Gas Maximum 700 Pa...
Page 20
Technical Information SP630EN Table 9. AGA Approval No. 7489 Energy Label Star Rating Dimensions (mm) Length Width Height Pop Size Weight (kg) Cabinet 1102 350/400 (XA) Gas Type Natural Gas Input (max) 110 MJ Output (max) 29 kW Burner Pressure Natural Gas Maximum 730 Pa...
Page 21
Technical Information SP630IN Table 10. AGA Approval No. 7489 Energy Label Star Rating Dimensions (mm) Length Width Height Pop Size Weight (kg) Cabinet 1070 350/400 (XA) Gas Type Natural Gas Input (max) 110 MJ Output (max) 29 kW Burner Pressure Natural Gas Maximum 730 Pa...
Page 22
Technical Information SP635IN Table 11. AGA Approval No. 7489 Energy Label Star Rating Dimensions (mm) Length Width Height Pop Size Weight (kg) Cabinet 1070 Gas Type Natural Gas Input (max) 129 MJ Output (max) 35 kW Burner Pressure Natural Gas Maximum 750 Pa Minimum Modulation...
Page 23
Diagram 2. StarPro Wiring Diagram StarPro SP5 & SP6 Series Issue 1 - Service Manual...
Page 24
Diagram 3. Motor Wiring Diagrams Table 12. Main Fan Motor table Fasco 315W - Fasco 650W - Model 80855BNVA-A20 80855BPVA-A12 Power 315 W 650 W Maximum Current 4.2 A 4.3 A Capacitor 15±1.5 µF 25±2.5 µF Main Fan Motor Start Winding Resistance @ 20ºC 37.5 - 43.2 Ω...
CONTROLLER OPERATION The controller has an LCD display and 3 buttons to access information and change parameters. DOWN The controller has two menus that limit access to relevant personnel. These being the Installer menu and Service Menu. ** NG-2A+’s Ignition Cable has a 6.3mm Spade terminal instead of 2.8mm terminal on the NG-2A. y EN298 compliant Automatic Burner Control System NG-2A+ Features: y Combustion air proving circuit (pressure switch)
INSTALLER MENU Networker Parameter The Installer menu provides information and has parameters that can be controlled by the installer. On power up of the heater, the display will show “HTG_OFF nG”, if a Brivis Networker wall control is connected, and show “SEARCH_nG”...
Page 28
DISPLAY DESCRIPTION COOLING: MINIMUM FAN SPEED SETTING For zoned cooling systems this setting defines the minimum main fan speed. H01 ID08 NET516/506 settings Installer Setting Primary Display Description Number 7 Value No zoning or add-on refrigeration control is enabled. Either the internal or external relays are configured for zone control only. Either the internal or external relays are configured for both zone control and Add-On refrigeration control.
SERVICE MENU The service menu can be accessed by following the instructions below: Ensure the LCD displays one of the following before commencing to the next sequence: Heat_##-# - when the heater is running, (where ##- # is the measured supply air temperature in °C to one decimal place). HTG_OFF NG –...
SERVICE PARAMETERS Table 14. NG-2A+ Parameter List Parameter Default Description Range Number Value NG modulating coil minimum current level (mA) 0 - 160 NG modulating coil maximum current level (mA) 0 - 160 Factory NG modulating coil ignition current level (mA) 0 - 150 Heating warm up cut off temperature (°C) 30 - 55...
3. COMPONENT OPERATION GAS VALVE OPERATION The gas valves function is to provide gas for combustion. The gas valve is a Honeywell VK8105M gas valve, with electronic modulation, to vary the gas flow rate. It consists of two primary main solenoids which open and shut the gas valve, and an electronic modulating solenoid, to vary the gas flow rate.
PRESSURE SWITCH OPERATION PRESSURE SWITCH: The pressure switch is a Cleveland NS2 series diaphragm pressure differential activated switch. StarPro SP5 models have one pressure switch and SP6 models have two. For the location of these pressure switches refer below. Combustion Airflow Proving Switch (All models) The pressure switch for proving sufficient combustion airflow is located in the vicinity of the combustion fan and measures the vacuum pressure in the heat exchanger outlet box prior to the combustion fan.
OPERATION FLOW CHARTS – START UP Diagram 6. Heater “Start up” Flow Chart Heater switched on Combustion fan hold off (2 sec) Retry Pressure Switches Check Fail Combustion Fan Pre-purge (15 sec) Ignition Ignition retry phase activated Flame detect time Has flame been detected within 4.5 seconds?
3.10 OPERATION FLOW CHARTS – SHUT DOWN Diagram 7. Heater “Shut down” Flow Chart Heater switched off Gas valve closes Initiate cooldown at constant fan speed Combustion fan post-purge (5 sec) Is supply air temperature below 50°C? (Service parameter S9) Ramp down fan speed by 10 rpm every 0.5 seconds (Service parameter S8) until minimum fan...
5. TROUBLESHOOTING Most failure modes will result in a fault code being logged in the NG-2A+ control. These faults can be viewed by entering the Service Menu. A brief description of each fault code is shown below, followed by detailed troubleshooting for each fault code.
Page 36
Fault Code LCD Message Description No Flame on Ignition During an ignition attempt within the “FLAMEDETECT” state the flame signal is Error 46 not detected within the flame detect time interval and the maximum attempts at flame detection during ignition have not been made. The heating cycle will be forced to its “OFF”...
Page 37
Fault Code LCD Message Description Board Failure On energising the primary valve control relay its contact is not detected as Error 61 closed within the primary valve control relay contact closed verification time indicating that it is “stuck off”. Board Failure Error 62 With the primary valve control relay not being energised its contact is detected as closed indicating it is “stuck on”.
ERROR 30 – FAN_LIMP Description: The NG-2A+ has not received the fan motor speed sensor signal required for normal operation. Limp Mode Operation The heater still operates with this error present, though the operation may not give the maximum or best performance.
ERROR 33 – MDGV_LIMP Description: The feedback current from the gas valve modulating coil is not detected for at least the gas valve modulating coil fault delay time interval of 5 seconds even though a drive level is being applied to the coil. Limp Mode Operation The gas valve modulating coil control reverts to open loop mode where the current level supplied to the modulating coil is fixed at 60 mA.
ERROR 36 – Bad SA_THM Description: BAdSA_THM means, the supply air thermistor has a circuit, but has not reached 30oC. Within 2 minutes of the fan operation commencing, in a normal heating cycle. Operation Mode: The user still has some heating, until the problem can be rectified by a service technician, though the operation does not give the maximum or best performance.
Page 41
Description: These errors will appear whilst an over temperature is current, the Over Heat Switch circuit is open, or the thermistor is measuring a temperature greater than 90ºC. The heater’s fan will be forced to operate at maximum speed and the combustion fan will also be operating. All StarPro models have a supply air over heat switch located near the supply air discharge and is activated before the supply air reaches 90°C.
5.10 ERROR 43 – OHCooLDwn Description: This error will be displayed during the 60 second maximum fan operation but is always logged following an over temperature error. Service Check List: y Check the error log to determine what over heat error has occurred. y Refer to Check List of the following error code for diagnosis: i.e.
5.12 ERROR 45 – LOW 24VOLT Description: The 24 volt circuit has been subjected to low voltage, resulting in insufficient 24 Volt output for reliable ignition or operation. This low voltage condition is usually only temporary and may be the result of a power loss or brown out. Service Check List: y Check incoming power supply voltage (minimum 200 V).
y Check the flame sensor rod is located in the correct location as specified in “Diagram 9. Flame Sense / Ignitor Gap” on page 61. Check for sufficient ignition burner pressure and adjust if required. y Check power supply polarity is correct. y Check the voltage to the gas valve is maintained (i.e.
y During ignition, measure the ignition burner pressure and ensure it is within specification. Check that the correct injectors have been fitted and the gas type is correct. Too much gas flow during ignition can cause violent flame behaviour. y Check that the vacuum pressure switch is the correct switch and functioning correctly. y Check that the inlet gas pressure is sufficient during ignition (at least 800 Pa for ignition).
5.16 ERROR 49 – LOST_FLME / PS_FM_FLT Description (NG-2A): During normal operation after ignition has been validated, if the flame sensor signal has unexpectedly been lost, the heating cycle is forced into its “OFF” state with a restart initiated and an Error 49 logged. Description (NG-2A+): Condition 1: Pressure switches error detected during pre-purge and ignition starting sequence.
5.18 ERROR 51 – RLT_NOGAS Description: This error indicates that the AFRO circuit has detected a flame rollout while the gas valve is not energised, and flame is not expected. Service Check List: y Check that the pilot AFRO bar or wiring is not shorted to Earth. y Check if a flame is present with the unit turned OFF.
Service Check List: y Check if the unit has been operating on a hot day following a power up. y Check if the unit is ceiling mounted with a high level return air grille. y Check that the fan speed is sufficient for the system so that over heating will not result. y Check the fan motor is functioning correctly, and is not blocked or obstructed.
5.23 ERROR 56 – PRES_STOF Description: With the combustion fan forced on the combustion chamber pressure switch is detected as open after the combustion fan delay time of 15 Seconds has expired indicating that the switch is “stuck off” and did not close when it should.
Description: With the combustion fan forced off, the pressure switch is detected as closed indicating that the switch is “stuck on” and is not open when it should be. This error will occur prior to pre-purge when the NG-2A+ control checks to ensure that the pressure switch/switches are open before operating the combustion fan.
Fasco 315W – Fasco 650W – 80855BNVA-A20 80855BPVA-A12 Start Winding resistance @ 20°C 37.5 – 43.2 Ω 10.0 – 11.5 Ω Main Winding resistance @ 20°C 9.8 – 11.3 Ω 6.2 – 7.1 Ω y Check if the motor casing is HOT, indicating the motor’s thermal over temperature switch may be tripped. If the motor is hot: y Check motor bearings for wear and stiffness.
4. The state of the flame signal is monitored and if flame is detected as available this would suggest that the flame sensing circuitry has failed as no flame should be available at this stage (gas valve main coil not energised). Subsequently, a lockout condition (Code#52) is registered forcing the heating cycle back to its “OFF”...
5.31 ERROR 65 – MTR_LKOUT Description: The unit is locked out due to fan motor open circuit (Error 60), and the fan motor speed sensor signal has not been received by the NG-2A+ (Error 30). The unit was operating in FAN_LIMP mode (Error 30), and an over temperature condition has occurred (Error 40, 41, or 42).
5.34 ERROR 68 – SVCR_FAIL Description: While the secondary valve control relay should be energised its contact is detected as opened by the primary microcontroller. Once the “FLAMEDETECT” state is entered the secondary valve control relay contact state is continuously monitored by the primary microcontroller until the “OFF”...
Page 55
Service Check List: y Check the transformer y Check if the 24 Volt internal wiring circuit to the over temperature switches, pressure switch/s and gas valve is not shorted to Earth. y Check that any wiring connected to the On-Board relays is not shorted to Earth. y Check that any wiring connected to the 24V terminal is not shorted to Earth (i.e.
6. MAIN COMPONENTS SERVICING This section contains the procedures for checking and adjusting (if necessary) the main components of the heater. This may be required due to a failure or a routine service. GAS VALVE SERVICING The diagram below indicates the measurement and adjustment locations. If adjustment to the gas valve is required, an 8 mm and 5 mm spanner, or small size adjustable wrench will be required.
GAS VALVE CHECKING AND ADJUSTMENT ( ONLY IF REQUIRED ) To check for correct gas valve settings and operation, the following should be performed, and adjustments made when necessary. Inlet Pressure Measurement Loosen the gas inlet test point screw, located on the gas valve as shown in the diagram, and connect a suitable manometer to the test point.
Page 58
The minimum burner pressure can now be checked. If the burner pressure is within specifications (Refer to “2.2 Heater Specifications” on page 11), no adjustment is required. If adjustment is required, adjust the minimum burner pressure setting screw on the gas valve (clockwise increases pressure). Note: If operating at the minimum burner pressure for greater than x minutes, then temporarily set the “Heat”...
COMBUSTION FAN SERVICING General Service 1. Check that the motor’s shaft spins freely. 2. While in operation during a pre-purge, check for any unusual noise, such as bearing or scraping noise. Note: The presence of a “tinkling” sound can be caused by the impellor removing water particles out of the fan housing, which is normal. If there is any suspicion of an underperforming combustion fan or that the entire system is resulting in low vacuum pressure, the following should be performed: 1.
Combustion Fan Speed and Supply Voltage. FAN SPEED VOLTAGE COMBUSTION FAN SPEED UNIT HIGH RESISTOR (Ohm) HIGH SP521 2800 2500 SP623 2800 2500 SPARK IGNITER SERVICING Isolate the heater power and gas supply from the unit. Checking the Spark Igniter y Unscrew the spark igniter away from the burner y Check Spark Igniter electrode, lead and plug connection y Clean igniter probe and make sure there is a spark gap of approximately 4 mm.
FLAME SENSOR SERVICING Isolate the heater power and gas supply from the unit. Checking the Flame Sensor y Check that the Flame Sensor rod is clean, located correctly and the lead and plug connection is in good condition. y Reassemble. Checking Flame Sensor location relative to burner face y Remove the burner assembly as described in 7.1 on page 66.
PRESSURE SWITCH SERVICING y Make sure the vent hole and bleed hole are clear of any foreign material. y Make sure the hoses are free of condensation. y Check the hoses leading to the pressure switch are not split or damaged y Reassemble.
MAIN FAN ASSEMBLY SERVICING External Models y Turn the unit OFF and isolate the power supply. y Remove the main fan assembly as described in Section 7.10 on page 70. y Check for any signs of wear. y Rotate the fan wheel and check for any irregular noise such as scraping or worn bearings. y Clean impellor and motor.
Unit Operation y Check power supply lead is in good condition. y Check all gas connections are good and do not leak. y Check condensate drain and discharge (SP6 models only). y Check the Networker wiring connection at the unit is in good condition. y Check the burner’s maximum and minimum operating gas pressure on the test point provided on the gas valve.
7. REMOVAL PROCEDURES REFER TO MODEL SPECIFIC SERVICE MANUAL FOR MORE DETAILS ON REMOVAL PROCEDURES. Before any of the following assemblies or components can be removed, it is important to isolate the heater’s power and gas supply. The heaters roof will also have to be removed by removing 2 screws at each end of the roof. Internal heaters have a top wrap around the service chamber that can be removed for easier access, if required by simply removing the 10 screws off the top wrap.
Installation is a reversal of the removal procedure with attention to the following points: y When re-inserting the assembly, ensure that the injectors are inserted into the ring on the top of the burners correctly. y Ensure that the gas inlet feed-tube is retightened and checked for leaks. y Ensure that the gas valve loom is not damaged along its length and at the connector.
Installation is a reversal of the removal procedure with attention to the following points: y Fasten both halves together with correctly sized cir-clips or e-clips, if the original spring clips are too difficult to fit. Method 2 – Complete Fan Removal 1.
COMBUSTION FAN LOOM REMOVAL. 1. Isolate the heater power supply. 2. Disconnect the loom from the combustion fan and from the NG-2A+, including earth points. 3. Remove the screws holding the ballast resistors in place. 4. Remove the loom assembly from the appliance. FLUE PIPE REMOVAL External Models y Remove the flue terminal and then slowly remove the flue pipe away from the combustion fan and away from...
Internal Models The flue should be fitted to the flue pipe spigot via a bolted flue sleeve connection. y Loosen these bolts sufficiently to allow the flue pipe to be removed from the spigot. y Ensure that the flue pipe seal exiting the roof is not damaged. y Once reconnected ensure that there are no potential gas leaks from the flue pipe.
Motor and Plate Removal 1. Remove the screws that attach motor plate to the fan scroll then remove the motor plate, motor and fan wheel assembly from the fan scroll. 2. Remove the fan from the motor by loosening the grub screw from the motor shaft. If the fan wheel is ceased onto the motor shaft then WD-40 and a puller may be required.
8. BRIVIS ACC NETWORK 516 MODULE LOW - VOLTAGE y Suitable for all Brivis StarPro SP5 and SP6 Internal / External Ducted Gas Heaters y This module CANNOT be used on any other model. y The Network 516 Zone Module is required to be used on StarPro units with software higher than Version 50 on the NG-2A+ Control Board.
Page 73
Connect the 6 pin plug to the terminal marked “Option Board” at the NG-2A+. Programming Network 516 modes The Network 516 setting is selected through the heaters Installer parameters, in the same way other heater adjustments are made. y Press the SET button on the NG-2A+ module to scroll through the displays. y To make changes press the up/down buttons.
NET 516 CONTROL BOARD SETTING NET506 Description Setting Heating Add-on Cooling ZoneRelay 1 Not Enabled ZoneRelay 2 Not Enabled ZoneRelay 3 Not Enabled Enabled ZoneRelay 4 Not Enabled Heating Add-on Cooling ZoneRelay 1 Enabled as Zone A ZoneRelay 2 Enabled as Zone B ZoneRelay 3 Enabled as Zone C Enabled...
9. FLUEING REQUIREMENTS REFER TO MODEL SPECIFIC SERVICE MANUAL FOR MORE DETAILS ON FLUEING REQUIREMENTS. Internal – SP Series General y All flues shall be installed in accordance with AS/NZS 5601. y Horizontal flues shall have a minimum rise of 20mm per 1m run. y Horizontal flues terminating on a wall shall be at least 300mm above ground level.
EXTERNAL – SP SERIES FLUE TERMINAL CLEARANCES Installation of Flue Terminal The flue outlet socket can be found behind an installer instruction label. The flue terminal must be ordered separately when SP5 or SP6 is installed externally (Part No. B021385). Remove the label and insert the flue terminal firmly into the flue outlet socket in the correct orientation to ensure the flue gases are expelled away from the house (refer to Diagram 12).
Page 77
1000mm y Measured vertically, from an opening window, door, non-mechanical air inlet or any other opening into the building (except sub floor ventilation). y From a gas meter. y From a mechanical air inlet, including a spa blower, measured both vertically and horizontally. y A flue terminal of this type shall not be located under a roofed area, unless the roofed area is fully open on at least two sides, and a free flow of air at the appliance is achieved.
Page 78
NOTES StarPro SP5 & SP6 Series Issue 1 - Service Manual...
Page 79
NOTES StarPro SP5 & SP6 Series Issue 1 - Service Manual...
Tel: 1300 555 545* Fax: 1300 555 655 Monday to Friday, 8.00 am to 5.00 pm EST. *Cost of a local call higher from mobile or public phones. For further information visit www.rinnai.com.au or email enquiry@rinnai.com.au innai New Zealand Ltd...
Need help?
Do you have a question about the brivis StarPro SP5 Series and is the answer not in the manual?
Questions and answers