Rheem NPT 200 Installation Instructions Manual
WARNING: Plumber – Be Aware
Use copper pipe ONLY. Plastic pipe MUST NOT be used.
It is a requirement of a solar water heater installation that all
pipe work be in copper and not plastic, due to the effects of
high water temperatures and pressures.
Installation Instructions
Solar Collector Kit
Solar Collector Add On Kit
NPT 200 SOLAR COLLECTORS
This collector kit must be installed and serviced by a qualified person
Please leave this guide with the householder.
WARNING: Plumber – Be Aware
The solar hot and solar cold pipes between the solar storage tank and the
solar collectors MUST BE of copper. All compression fittings must use
brass or copper olives.
The full length of the solar hot and solar cold pipes MUST BE insulated.
The insulation must:
be of a closed cell type or equivalent, suitable for a solar water heating
application and capable of withstanding the temperature of the water
generated by the solar collectors under stagnation conditions
The specification of the chosen insulation material should be checked
with the insulation manufacturer prior to installation as different
materials may vary in temperature tolerance.
be at least 13 mm thick, however thicker insulation may be required to
comply with the requirements of either AS/NZS 3500.4 or
AS/NZS 3500.5:2012 Section 3 (for a Class 1a or Class 10 building) as
applicable under the Plumbing Code of Australia
be weatherproof and UV resistant if exposed
extend through any penetrations in the eaves, ceiling and roof
cover valves and fittings in the solar pipe work
be fitted up to and cover the connections on both the solar storage tank
and the solar collectors.
Note: Failure to observe these requirements also increases the risk
of freeze damage.
Uninsulated pipe work, including concealed in cavities and roof spaces or
where it may be in contact with a metal roof, may lead to freeze damage.
The system has NO WARRANTY for freeze damage if the solar hot and
solar cold pipes are not insulated in accordance with the installation
instructions.
The insulation is essential to assist in providing freeze protection, will offer
protection to a metal roof against corrosion due to water running off the
copper pipes, assist in avoiding accidental contact with the solar pipe work
as very high temperature water can flow from the solar collectors to the
solar storage tank, and also reduce pipe heat losses.
Plumber: It is important to refer to and read in full the complete
“Warning: Plumber – Be Aware” statement commencing on page 13.
2
CONTENTS
HOUSEHOLDER - This installation instruction booklet is
intended for the installer but you may find it of interest.
Notice to Victorian Customers from the
Victorian Plumbing Industry Commission.
This water heater must be installed by a licensed person
as required by the Victorian Building Act 1993.
Only a licensed person will give you a Compliance Certificate, showing that
the work complies with all the relevant Standards. Only a licensed person will
have insurance protecting their workmanship for 6 years. Make sure you use
a licensed person to install this water heater and ask for your Compliance
Certificate.
Components And Kit Contents .................................................. 4
System Installation ...................................................................... 5
Installation – Solar Storage Tank ............................................... 7
Installation – Solar Collectors .................................................... 8
Roof Assembly Of Solar Collectors ......................................... 17
Connection Details .................................................................... 25
Pipe Work Roughing In Dimensions ........................................ 29
Installation – Solar Collectors .................................................. 31
Warranty Note ............................................................................ 35
3
SOLAR COLLECTOR KIT AND COLLECTOR ADD ON KIT
For installation with a solar storage tank.
Your solar water heater is designed for the solar collectors to be roof mounted
and the solar storage tank to be installed at ground or floor level. The collector
kits are suitable for:
Collector Kit (1 or 2 solar collectors)
299139 NPT 200 solar collectors Screwed fittings
Collector Add On Kit (for each additional solar collector)
299140 NPT 200 solar collector Screwed fittings
Note: One Collector Add On Kit is required for each additional solar collector.
Part No
Kit Components and Description
299139
Collector
kit
NPT 200
299140
Add on kit
NPT 200
129870
Installation instructions roof kit
1
-
191614
Collector angle 1 panel
-
1
191613
Collector angle 2 panel
1
-
191801
Collector straps
4
3
080022
Screws self tapper ½” x 8G ZP pan head
8
3
330695
Collector union assembly
2
2
063603
Connector M33
1
-
063604
Sensor connector M33 assembly – consisting of:
1 x 063605 fitting M33-15BSP for temp sensor
1 x 088062 sensor nipple solar loline
1 x 087026 O ring 5/16” ID x 1/16 BS011 silicone
1
-
088027
Compression olive copper ½”
2
-
080055
Compression nut brass ½”
2
-
063602
End plug collector M33
2
-
330606
Blanking disc
2
-
330171
O ring 25 ID x 3.2
8
4
056001
or
056029
Hot sensor assembly Loline
1
-
087025
O ring 5/32” ID x 1/16
2
-
123204
Label hot pipe / cold pipe
1
-
348071
Cable ties 150 mm long
3
-
COMPONENTS AND KIT CONTENTS
4
SYSTEM INSTALLATION
THIS WATER HEATER IS NOT SUITABLE FOR POOL HEATING.
The system is suitable for installation with NPT 200 solar collectors as part of an
open circuit system installation.
The system is not suitable for installation above 400 metres altitude.
IMPORTANT NOTES
Working on roofs is and should always be considered a hazardous activity,
particularly early in the morning, late in the evening, when the roof is wet and
during and after periods of rain.
All work must be carried out in accordance with Local, State and Federal
Occupational Safety, Health and Welfare Regulations. In particular, the
requirements for safety whilst manual lifting, working at heights and on roofs.
Installers must be competently trained in:
Height Hazard Assessment
Working at Height Procedures
Assessment / Use / Wearing of correct height safety equipment
(harnesses etc.)
All other relevant safety factors specific to the installation and
maintenance work to be compliant with suitable Occupational, Health and
Safety Regulations / Codes.
All relevant permits shall be obtained from the regulatory authorities before
commencing work to install the solar hot water system.
All work carried out must be performed by appropriately qualified
tradespeople or be suitably supervised for trades assistant duties.
Every care must be taken to protect and warn occupants of the building and
the public from personal injury which may occur from falling tools, roof
materials, fittings or any other hazards of a general nature.
Advise the occupants of any inconvenience which may occur due to
disconnection of existing water and electrical supplies.
The connection, attachment, integration or general association of other
equipment or parts which either directly or indirectly affect the operation or
performance of this equipment could void the warranty.
5
SYSTEM INSTALLATION
INSTALLATION STANDARDS
The water heater must be installed:
by a qualified person, and
in accordance with the installation instructions, and
in compliance with Standards AS/NZS 3500.4 or AS/NZS 3500.5:2012
Section 3 (for a Class 1a or Class 10 building) as applicable under the
Plumbing Code of Australia, AS/NZS 3000 and all local codes and regulatory
authority requirements.
In New Zealand, the installation must also conform to Clause G12 of the New
Zealand Building Code.
WATER HEATER APPLICATION
This water heater is designed for use in a single family domestic dwelling for the
purpose of heating potable water. Its use in an application other than this may
shorten its life.
If this water heater is to be used where an uninterrupted hot water supply is
necessary for the application or business, then there should be back-up
redundancy within the hot water system design. This should ensure the continuity
of hot water supply in the event that this water heater was to become inoperable
for any reason. We recommend you provide advice to the system owner about
their needs and building back-up redundancy into the hot water supply system.
OPEN CIRCUIT SYSTEM INSTALLATION
An open circuit system has a collector circuit which is directly connected to the
potable water in the solar storage tank. Potable water from the solar storage tank
circulates through and collects heat gained by the solar collectors and then
circulates back into the solar storage tank.
Freeze Protection
The system has a level of freeze protection designed to guard the system against
damage from freeze conditions. The system must be installed with the full length
of the solar hot and solar cold pipes insulated to offer protection against freeze
damage (refer to “Warning: Plumber Be Aware” on page 13). Freeze conditions
occur below 6°C.
The system has NO WARRANTY for freeze damage when installed above
400 metres altitude or if the solar hot and solar cold pipes are not insulated in
accordance with the installation instructions (refer to “Warranty Note” on
page 35).
Note: Warranty against freeze damage applies only to systems installed in
Australia.
6
INSTALLATION – SOLAR STORAGE TANK
SOLAR WATER HEATER STORAGE TANK LOCATION
The solar storage tank should be installed close to the most frequently used
outlet and its position chosen with safety and service in mind.
Consideration must also be given to the position of the solar storage tank in
relation to the solar collectors. There are limitations on the maximum length of
the solar hot and solar cold pipes between the solar storage tank and the solar
collectors. Refer to “Solar Collector Location” on page 8, to “Pipe Lengths” on
page 12 and to “Maximum Height to Collectors” on page 15.
Refer to the installation instructions supplied with the solar storage tank for
installation details of the solar storage tank.
7
INSTALLATION – SOLAR COLLECTORS
SOLAR COLLECTOR LOCATION
Consideration must be given to the position of the solar collectors in relation to
the solar storage tank. There are limitations on both the maximum length of the
solar hot and solar cold pipes and the maximum height between the solar storage
tank and the solar collectors. Refer to “Solar Collector Location” on page 8, to
“Pipe Lengths” on page 12 and to “Maximum Height to Collectors” on page 15.
The solar collectors must be installed in a shade free position. The surrounds
should be checked for higher buildings or trees which may cause shade at other
times of the year and for small trees which may grow and shade the solar
collectors in the future.
The installation must comply with the requirements of either AS/NZS 3500.4 or
AS/NZS 3500.5:2012 Section 3 (for a Class 1a or Class 10 building) as
applicable under the Plumbing Code of Australia, and all local codes and
regulatory authority requirements.
Refer to the installation instructions supplied with the solar storage tank for
details on the installation of the solar storage tank.
ROOF STRENGTH
The installer must ensure the structural integrity of the building is not
compromised by the solar water heater installation and the roof structure is
suitable to carry the full weight of the solar collectors and frame (if one is
installed). If in any doubt of the construction or the condition of the roof, the roof
should be suitably strengthened. Consult a structural engineer. Each solar
collector and its fittings weighs approximately 42 kg when full of water.
ROOF AREA FOR INSTALLATION
Roof area required for solar collectors:
4 solar collectors – 4.6 m wide x 2.0 m deep. Weight (full) 168 kg approx.
3 solar collectors – 3.5 m wide x 2.0 m deep. Weight (full) 126 kg approx.
2 solar collectors – 2.4 m wide x 2.0 m deep. Weight (full) 84 kg approx.
1 solar collector – 1.3 m wide x 2.0 m deep. Weight (full) 42 kg approx.
In addition to this area, a minimum of one (1) metre clearance is recommended
to be left around the solar collectors on all four sides for safe service access.
8
INSTALLATION – SOLAR COLLECTORS
Maximum Number of Collectors
The maximum recommended number of these non-selective collectors for each
tank size as part of an open circuit system is:
410 model tank – 4 x NPT200 collectors
325 model tank – 3 x NPT200 collectors
270 model tank – 3 x NPT200 collectors
ORIENTATION OF SOLAR COLLECTORS
To help maximise system performance, solar collectors should be installed with
an optimum orientation facing true north (in the southern hemisphere) or true
south (in the northern hemisphere). Always check for true north or true south
using a compass or other suitable device.
The solar performance of a system reduces as the orientation of the collectors
moves away from the optimum orientation, resulting in the need for increased
boosting to supply the same hot water load. Solar collectors facing up to 45° from
the optimum orientation will receive about 4% to 5% less total solar radiation.
However, the optimum orientation of solar collectors is not always practical or
achievable. Solar collectors may be installed up to 90° from the optimum
orientation. Where the orientation is greater than 60° from the optimum, it may
be possible for an additional solar collector to be installed or to install selective
surface collectors in lieu of non-selective surface collectors to help make up for
the reduction in solar performance compared to the optimum orientation. Each
option should be discussed with the system owner.
If neither of these options are possible nor acceptable to the system owner, then
the system owner needs to be made aware of, understand and accept that
increased boosting may be required to meet their hot water requirements.
9
INSTALLATION – SOLAR COLLECTORS
INCLINATION OF SOLAR COLLECTORS
To help maximise system performance, solar collectors should be installed with
an optimum inclination. This is equal to 90% to 100% of the local latitude angle
when collectors are oriented within 60° of true north or true south, and between
10° and 20° when the collectors are oriented between 60° and 90° from the
optimum orientation.
Generally, improved summer performance is obtained from an angle of
inclination less than the optimum angle and improved winter performance is
obtained by an angle of inclination greater than the optimum angle. If the angle
of inclination varies by 20° from the optimum angle, the solar collectors will
receive about 10% less total annual solar radiation. The latitude of some
Australian cities are listed on page 11.
However, the optimum inclination of solar collectors is not always practical or
achievable. Solar collectors may be installed at the roof angle for simplicity of
installation and appearance, but must never be flat for a pumped solar open
circuit water heater installation. Although the solar collectors can be installed with
an inclination of less than 10°, this is not advised. The risks include:
the collector glass not 'self-cleaning', leading to dirty collector glass reducing
solar performance, and
condensation on the underside of the glass taking longer to clear, and
condensation droplets falling onto the absorber plate potentially causing
discolouration.
The collector kit is suitable for installations with an inclination of up to 30°. Where
the solar collectors are installed at inclinations greater than 30°, a With Pitch
frame is necessary. Refer to your local Solar Distributor for details.
A Variable Pitch frame can be installed to increase the angle of inclination of the
collectors used in a solar pumped water heater installation. This type of frame
should be used if the roof pitch either varies by more than 20° from the optimum
angle or is less than 10°.
The use of a Variable Pitch frame should be discussed with the system owner. If
this option is neither possible nor acceptable to the system owner, it may be
possible for an additional solar collector to be installed or to install selective
surface collectors in lieu of non-selective surface collectors to help make up for
the reduction in solar performance compared to the optimum inclination. Each
option should be discussed with the system owner.
If these options are neither possible nor acceptable to the system owner, then
the system owner needs to be made aware of, understand and accept that
increased boosting may be required to meet their hot water requirements.
10
INSTALLATION – SOLAR COLLECTORS
Adelaide
35°S
Cairns
17°S
Hobart
42°S
Port Hedland
20°S
Alice Springs
24°S
Canberra
35°S
Mildura
34°S
Rockhampton
24°S
Brisbane
27°S
Darwin
12°S
Melbourne
38°S
Sydney
34°S
Broken Hill
31°S
Geraldton
28°S
Perth
32°S
Townsville
19°S
CYCLONIC OR HIGH WIND AREAS
For an installation of solar collectors on a pitched roof in a cyclonic or high wind
area, a suitable With Pitch frame is required. Refer to your local Solar Distributor
for details.
The installation of these solar collectors on a suitable frame, subject to the
frame’s design criteria not being exceeded:
may be suitable for installation in geographic locations up to and within Wind
Region D (With Pitch frame) or up to and within Wind Region C (Variable
Pitch frame), as defined in the Building Code of Australia, Australian
Standard AS 4055 and the Australian / New Zealand Standard
AS/NZS 1170.2, or equivalent locations, and
may provide an acceptable method of installation where it is necessary to
satisfy the requirements of the Building Code of Australia for high wind
areas, or equivalent requirements.
LATITUDE OF SOME AUSTRALIAN CITIES
11
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