Rheem NPT 200 Installation Instructions Manual

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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.

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

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

191614

Collector angle 1 panel

191613

Collector angle 2 panel

191801

Collector straps

080022

Screws self tapper ½” x 8G ZP pan head

330695

Collector union assembly

063603

Connector M33

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

088027

Compression olive copper ½”

080055

Compression nut brass ½”

063602

End plug collector M33

330606

Blanking disc

330171

O ring 25 ID x 3.2

056001

056029

Hot sensor assembly Loline

087025

O ring 5/32” ID x 1/16

123204

Label hot pipe / cold pipe

348071

Cable ties 150 mm long

COMPONENTS AND KIT CONTENTS

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.

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.

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.

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.

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.

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.

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

INSTALLATION – SOLAR COLLECTORS

Maximum recommended total combined pipe length (solar hot + solar cold)

and number of 90° bends

Pipe Size

1 or 2 Collectors

3 Collectors

4 Collectors

Pipe Length

90°

Bends

Pipe Length

90°

Bends

Pipe Length

90°

Bends

DN15

40 metres

30 metres

15 metres

DN20

40 metres

For each additional 90° bend, reduce the maximum total pipe length by 0.5 metres. For each additional metre of pipe length, reduce the number of 90° bends by two. Note: One 90° elbow is equal to two 90° bends. NR – not recommended.

PIPE LENGTHS

The solar hot and solar cold pipes between the solar storage tank and the solar collectors shall:

 be of bendable grade or hard drawn copper tube.

Annealed or soft copper shall not to be used.

 have a continuous fall from the solar collectors to the solar storage tank.

Horizontal runs of pipe work are acceptable and may be installed as part of an open circuit system.

Care must be taken to ensure the pipe work maintains a continuous fall or horizontal runs over the life of the installation. Pipe work should be fixed at regular intervals to assist in maintaining this requirement.

 not exceed the maximum recommended combined lengths as specified in

the table.

Notes:

 It is important to connect the solar hot and solar cold pipes to the correct

connections at the solar collectors and at the solar storage tank.

 The solar cold pipe connects to the bottom of the solar collector array and

may connect to either the left or right hand side. The solar hot pipe must connect to the top of the solar collector array diagonally opposite to the solar cold pipe connection. The solar hot outlet connection is to be the highest point of the system.

 The hot sensor connection is at the solar hot outlet where the solar hot pipe

connects to the solar collector for this open circuit system.

 Refer to “Warning: Plumber – Be Aware” on page 13.

It is essential for these requirements to be followed for the system to operate correctly and efficiently. Solar pipe work which is oversized, or is too long, or does not have a continuous fall can result in a reduction in performance or the system not operating effectively.

INSTALLATION – SOLAR COLLECTORS

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 temperatures of up to 150°C, which may be 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

and the solar collectors.

Note: Failure to observe these requirements also increases the risk of freeze damage.

INSTALLATION – SOLAR COLLECTORS

WARNING: Plumber – Be Aware

 The insulated copper pipe work:

 should be fixed at suitable locations to prevent or reduce the possibility

of noise from water hammer and vibration from occurring

 is not to be placed or installed in contact with plastic pipe work.

Likewise, plastic pipe work is not to be placed or installed in contact with the insulated copper pipe work after the collector circuit is installed.

 The solar hot outlet and hot sensor connection is to be the highest point of

the system. The highest point of the solar hot and solar cold pipes must be where they connect to the solar collectors, to avoid the possibility of air locks occurring in the system. There MUST BE a continuous fall in the pipe work from the solar collectors to the solar storage tank. Horizontal runs of pipe work are acceptable and may be installed as part of an open circuit system.

 Plastic pipe MUST NOT be used, as it will not withstand the temperature

and pressure of the water generated by the solar collectors under stagnation conditions. Extremely high water temperatures up to 150°C for non-selective surface collectors and greater than 200°C for selective surface collectors and extremely high water pressures can be generated under these conditions. Plastic pipe cannot withstand these temperatures and pressures and MUST NOT be used. Failure of plastic pipe can lead to the release of high temperature water and cause severe water damage and flooding.

 The pressure applied to the collector circuit and solar collectors during a

pressure test of an open circuit system MUST NOT exceed 1000 kPa where NPT200 solar collectors are installed, otherwise damage may result.

Refer to “Pressure Testing” on page 16.

 Upon completion of the installation of the NPT200 solar collectors the

packaging material may be removed, whether or not the collector circuit is connected to the solar storage tank and / or the solar water heater is commissioned.

INSTALLATION – SOLAR COLLECTORS

Maximum Height to Collectors

The maximum height of a pumped open circuit solar installation, from the solar controller (circulator) to the top of the solar collectors, is determined by the maximum recommended total pipe length for the system and the water supply pressure.

The maximum recommended total pipe length of the collector circuit should not be exceeded and a minimum water supply pressure of 200 kPa should be available at the inlet to the system, otherwise the system performance may be reduced or the collector circuit may not be purged of air during the commissioning of the system.

Open Circuit System

Pipe Work Installation Requirements

INSTALLATION – SOLAR COLLECTORS

Pressure Testing

The solar water heater, including the collector circuit, is to be isolated during the testing and commissioning of the heated water reticulation system in a building in accordance with Clause 9.3 (a) of AS/NZS 3500.4:2015 or Clause 3.34.2 (a) of AS/NZS 3500.5:2012 for a Class 1a or Class 10 building as applicable under the Plumbing Code of Australia. The collector circuit includes the solar hot and solar cold pipes and solar collectors.

It may be necessary to pressure test the collector circuit to comply with codes and regulatory authority requirements or on other occasions where the solar collectors and solar hot and solar cold pipes are installed prior to the solar storage tank, such as on a building site.

Collector Circuit

Warning: The pressure applied to the collector circuit during a pressure test of an open circuit system MUST NOT exceed 1000 kPa where NPT200 solar collectors are installed, otherwise damage may result to the solar collectors.

Open Circuit System

If the solar collectors, solar pipe work and solar storage tank are installed and commissioned together, then the flooding of the collector circuit with water under mains pressure for an open circuit system and checking the pipe work for leaks during the commissioning procedure can be substituted for the pressure testing of the collector circuit.

ROOF ASSEMBLY OF SOLAR COLLECTORS

Notes:

 These solar collectors have passed the AS/NZS 2712 requirements for

resistance to hailstone damage, so it is not normally necessary to fit a guard to a collector. Stone Guards are available to provide a level of protection to the collectors against vandalism or accidental damage. Refer to your local Solar Distributor for details.

 Warranty DOES NOT cover breakage of solar collector glass. Check your

insurance policy covers collector glass breakage.

Warning: No attempt should be made to remove or replace broken

collector glass. The collector glass is not offered as a replacement part. Should the solar

collector require replacement, contact your local Solar Distributor for details.

 Warning: Do not remove the solar collector packaging completely, prior

to the installation as the solar collector surface can become very hot. Remove only sufficient packaging material to enable the installation of the solar collectors.

Upon completion of the installation of the NPT200 solar collectors, such as on a building site, the packaging material may be removed whether or not the collector circuit is connected to the solar storage tank and / or the solar water heater is commissioned.

The solar collector packaging must be removed completely prior to the permanent operation of the water heater.

 All connectors, end plugs, ‘O’ rings, brass fittings, collector straps and

collector angle required for the installation are included with the collector kit. Suitable screws or anchors will be required to fix the collector straps to the rafters for a pitched roof installation.

 Screws to secure the collector straps and collector angle to the solar

collectors must not be longer than 15 mm. Suitable screws are provided in the collector kit.

 All olive compression fittings must use brass or copper olives.

Use an approved thread sealant such as Teflon tape on all other threaded joints. Fittings with an O-ring do not require a thread sealant.

 Roof Condition: Check the condition of the roof and advise the client of any

broken tiles or damaged roof sheeting before commencing the installation.

ROOF ASSEMBLY OF SOLAR COLLECTORS

Numbers in parentheses refer to items in the diagrams on pages 31 (two solar

collector installation) and 32 (three or four solar collector installation).

DO NOT MODIFY THESE PARTS IN ANY WAY.

1. Solar Frame: If a solar frame is to be installed, determine the location of the

frame(s). Refer to “Solar Collector Location” on page 8 and the installation instructions provided with the frame(s).

Assemble and fix the frame(s) to the roof in accordance with the installation instructions provided with the frame.

Depending upon the positioning of the frame on the roof and any minor fall the roof may have, ensure the collector rail is either horizontal or is higher on the hot outlet side of the solar collectors. If in doubt use a spirit level.

Proceed to step 4.

2. Solar Collector Location: If a solar frame is not installed, select a suitable

position for the solar collectors. Refer to “Solar Collector Location” on page 8.

3. Collector Angle – Pitched Roof Installation: Determine the location of the

collector angle(s) (1). If more than two solar collectors (17) are installed, locate the collector angle(s) (1) from the Collector Add On kit(s) adjacent to the first collector angle (1).

Hook two collector straps (2) to each bottom collector angle (1). When positioned, the collector angle is to be either horizontal or have a rise

across the solar collectors from the solar cold connection side up to the solar hot connection side for an open circuit system. The solar hot outlet and hot sensor connection is to be the highest point of the system.

Note: Refer also to “Tile Roof with a flat tile profile” on page 18 if the installation is on a tile roof where the tile has a flat profile. Additional requirements for the positioning of the collector rail and installation of the solar collectors apply.

Tile Roof with a flat tile profile: If the installation is on a tile roof with a flat tile profile, the solar collectors (17) must be installed at an angle from the horizontal to assist in rainwater runoff. The solar hot outlet side must be on the left hand side and the solar cold inlet must be on the right hand side of the collector array.

The top end of the solar collector on the solar cold inlet side must sit atop the lower end of a tile lap. Measure down the roof approximately 1940 mm from this point to determine the position of the bottom collector rail.

Horizontal

Solar Hot

Outlet

Position top of collector as low as practical on roof tile

Solar Hot

Outlet

Horizontal

Position top of collector as low as practical on roof tile

FOLDED TRAY COLLECTORS

EXTRUDED RAIL

ENVELOPE COLLECTORS

EXTRUDED RAIL

30-40mm

from

horizontal

15-20mm

from horizontal

30-40mm

from

horizontal

Solar Cold Inlet

15-20mm

from horizontal

Solar Cold Inlet

15-20mm

from horizontal

Solar Cold Inlet

30-40mm

from

horizontal

Position top of collector as low as practical on roof tile

ROOF ASSEMBLY OF SOLAR COLLECTORS

Ensure the end of the collector angle (1) at the outlet side (left hand side) of the solar collectors is higher up the roof than the end of the collector angle at the inlet side (right hand side) of the solar collectors by:

 15 – 20 mm for one solar collector, or  30 – 40 mm for two solar collectors, or  45 – 60 mm for three solar collectors.

This is to provide a downward angle along the top end of the collectors to assist in rainwater runoff in order to prevent pooling.

Flat Tile Profile – Collector Angle From Horizontal

Failure to adhere to this requirement may result in pooling of rainwater at the top of the collectors. If the top end of the collector array is too close to the lap of the tiles, there is a risk of pooling water seeping up and under the tile lap. The rainwater runoff is to flow from left to right to reduce the risk of water working through the joints between tiles.

Tile Roof: Remove the tiles on the next row above the position of the collector angle (1) to expose the rafters. Position the collector angle (1) and fix the collector straps (2) directly to the rafters, using suitable screws or anchors. Replace the tiles.

Metal Roof: Once the collector angle (1) is in position, fix the collector straps (2) to the rafters, through the metal roofing material, using suitable screws or anchors. Care should be taken not to mark Colorbond or other metal roof sheet with a marking pen and to remove all swarf from the metal roof as these can cause deterioration of the metal roofing material.

ROOF ASSEMBLY OF SOLAR COLLECTORS

Note: Fixings must penetrate only through the high point in the roof material profile. AS/NZS 3500.4 states a minimum of three (3) screws 40 mm long be used per fixing strap. Longer screws or anchors may be required to achieve a 40 mm minimum embedment into rafters for a metal roof. Additional screws or anchors may be required.

4. Solar Collectors: Using a lifting device, lift the first solar collector (17) onto

the roof and place it carefully with the lower end seated in the collector angel (1) and prior to positioning the next solar collector, screw the collector angle (1) to the solar collector (17) using one of the screws (13) provided.

Repeat this procedure for additional collectors (17), screwing the collector angle (1) to the solar collector (17) using one of the screws (13) provided.

Solar Frame Installation: Using a lifting device, lift the first solar collector (17) onto the roof and place it carefully with the lower end seated in the collector rail (1) and prior to positioning the next solar collector, firmly clamp (two clamps per collector) to the collector rail using the clamps, hex screws, washers and nuts provided.

Repeat this procedure for additional collectors (17), firmly clamping each collector to the collector rail (1) with two clamps (13) prior to positioning a subsequent collector.

Note: Screwing or firmly clamping each solar collector to the collector rail as it is placed in position reduces the possibly of the collector(s) accidently moving or sliding off the collector rail.

Remove the red transit plugs from the collector sockets.

5. Collector Unions: Couple the solar collectors (17) together using the

collector unions (3) and ‘O’ rings (6) supplied in the collector kit. Refer to “Coupling Collector to Collector – Screwed Fittings” on page 25. Note: It will be necessary to remove the screw or loosen the clamps on a

collector prior to it being coupled to its adjacent collector. Secure the screw or the clamps again on each collector after it is coupled to the adjacent collector.

6. Fixing Collector (bottom): Ensure the solar collectors (17) are correctly

positioned, centred and well seated in the collector angle (1). Pitched Roof Installation: Screw the collector angle (1) to the solar

collectors (17) (two screws per collector), using the screws (13) provided. Solar Frame Installation: Tighten the clamps (13) on each solar

collector (17).

ROOF ASSEMBLY OF SOLAR COLLECTORS

7. Collector Strap (top) – Pitched Roof Installation: Position a collector

strap (2) against the top end of each solar collector (17). Tile Roof: Remove the tiles on the next row above the top edge of the solar

collectors (17) to expose the rafters. Once in position, fix the collector straps (2) directly to the rafters, using suitable screws or anchors. Replace the tiles.

Metal Roof: Once in position, fix the collector straps (2) to the rafters, through the metal roofing material, using suitable screws or anchors. The collector straps (2) may be cut to a length of approximately 100 mm to retain the aesthetics of the installation.

Screw the collector straps (2) to the solar collectors (17) using the screws (13) provided.

Solar Frame Installation: Ensure the solar collectors are correctly positioned, centred and well seated in the top collector rail. Clamp the solar collectors (two clamps per collector) to the collector rail, using the clamps, hex screws, washers and nuts provided with the frame.

8. Connector: Fit a connector (10) to the inlet of the solar collector array using

an ‘O’ ring (6) provided. Refer to “Coupling Cold and Hot Pipes to Collector – Screwed Fittings” on

page 27.

9. Sensor Connector: Fit the sensor connector (4) (with hot sensor port) to

the outlet of the solar collector array using an ‘O’ ring (6) provided. Note: If the installation is on a tiled roof, the orientation of the hot sensor

port and hot sensor probe (when installed) must be angled between the perpendicular (90°) to the roof to a maximum 30° off perpendicular down the roof. Refer to Detail E on page 28.

Refer to “Coupling Cold and Hot Pipes to Collector – Screwed Fittings” on page 27.

10. End Plugs: Fit the end plugs (5) to the two remaining solar collector

connections using the ‘O’ rings (6) and blanking discs (7) provided. Refer to “End Plug Assembly – Screwed Fittings” on page 26.

ROOF ASSEMBLY OF SOLAR COLLECTORS

11. Solar Hot and Solar Cold Pipes: Install the solar cold pipe from the solar

storage tank to the solar collectors (17) and the solar hot pipe from the solar collectors (17) to the solar storage tank.

The solar hot and solar cold pipes should be a minimum DN15, but sized to suit the installation for an open circuit system. Refer to “Pipe Lengths” on page 12.

The solar hot and solar cold pipes must have a continuous fall from the solar collectors to the solar storage tank. Horizontal runs of pipe work are acceptable and may be installed for an open circuit system.

The full length of the solar hot and solar cold pipes must be insulated. The insulation must be capable of withstanding the temperatures generated by the solar collectors under stagnation conditions.

Warning: Plumber – Be Aware: It is important you refer to “Warning:

Plumber – Be Aware” on page 13 for important information relating to the

installation of the solar hot and solar cold pipes. Refer also to installation diagrams on pages 31 and 32 and to “Pipe Work

Roughing In Dimensions” on page 29.

Notes:

 Penetrations through the roofing material must be:

■ at the high point of the roof tile or metal sheet;

■ made neatly and kept as small as practicable;

■ waterproofed upon installation of the solar hot and solar cold pipes.

 Exposed insulated pipe work between the solar collectors and the

penetration through the roofing material should be kept to a minimum to maintain the aesthetics of the installation.

12. Connecting the Solar Hot and Solar Cold Pipes to Collectors: Connect the solar cold pipe to the connector (10) at the inlet of the solar collectors (17) and the solar hot pipe to the sensor connector (4) at the outlet of the solar collectors (17) using the compression nuts and olives provided.

Refer to “Coupling Cold and Hot Pipes to Collector – Screwed Fittings” on page 27 and the installation diagrams on pages 31 and 32.

ROOF ASSEMBLY OF SOLAR COLLECTORS

13. Hot Sensor Lead – Collector Connection: Insert the sensor probe of the hot sensor lead assembly (9) into the sensor connector (4), ensuring the ‘O’ ring is in position on the probe. Lock it into position with the locking washer and clip provided.

Hot Sensor Lead – Solar Storage Tank Connection: Run the hot sensor lead down to the solar storage tank. An extension sensor lead is available if the hot sensor lead is not long enough to reach the solar control unit.

Connect the hot sensor lead to the hot sensor cable connecting socket located at the underside of the solar control unit screwed to the side of the solar storage tank.

14. Cable Ties: Secure the hot sensor lead at appropriate locations with the cable ties (14) provided.

Notes:

 The hot sensor lead may be cable tied to the outside of the insulation

on the solar pipe work.

 Ensure the hot sensor lead is not in direct contact with the solar pipe

work at any point of the collector circuit, otherwise damage to the sensor lead can occur due to the high temperatures which can be experienced within the pipe work.

 Damage to the hot sensor lead can result in solar gain not being

achieved and the freeze protection system being rendered inoperative.

15. Labels: At ground or floor level, adjacent to the location of the solar storage

tank, attach the ‘Solar Cold Pipe’ label (16) to the insulation on the solar cold pipe to the solar collectors and the ‘Solar Hot Pipe’ label (15) to the

insulation on the solar hot pipe from the solar collectors. Ensure the arrows on the labels are pointing in the correct direction of water

flow.

16. Pressure Testing the Collector Circuit: Upon completion of the solar collector and solar hot and solar cold pipe installation, it may be required to pressure test the collector circuit. Refer to “Pressure Testing” on page 16.

17. Connecting the Solar Hot and Solar Cold Pipes to the Solar Storage

Tank: Refer to “Connections – Plumbing” and “Installation – Solar Control Unit” in the Owner’s Guide and Installation Instructions supplied with the

solar storage tank for details on the solar hot and solar cold pipe connections to the solar storage tank.

18. Commissioning: Upon completion of the installation, refer to the Owners Guide and Installation instructions supplied with the solar storage tank for the commissioning procedure of the solar water heater.

ROOF ASSEMBLY OF SOLAR COLLECTORS

INSTALLATION CHECK LIST

Once the installation is complete, it is important to check the following:

 Maximum recommended total combined solar hot and solar cold pipe length

is not exceeded.

 Solar hot and solar cold pipes are insulated in accordance with the

installation instructions.

 The solar hot and solar cold pipes have a continuous fall from the solar

collectors to the solar storage tank. Horizontal runs of pipe work are acceptable.

 Ensure the collector angle is either horizontal or is higher on the hot outlet

side of the solar collectors. If in doubt use a spirit level. Or if the installation is on a tile roof with a flat profile tile, then the end of the

collector angle at the outlet side (left hand side) of the solar collectors is higher up the roof than the end of the collector angle at the inlet side (right hand side) of the solar collectors by:

 15 – 20 mm for one solar collector, or  30 – 40 mm for two solar collectors, or  45 – 60 mm for three solar collectors.

CONNECTION DETAILS

P/No: 33-0171

O-Ring 25mm ID x 3.2 Thk

Solar Collector Solar Collector

P/No: 33-0171

O-Ring 25mm ID x 3.2 Thk

P/No: 33-0695

Collector Union

Solar Collector

COUPLING COLLECTOR TO COLLECTOR – SCREWED FITTING

Refer to installation diagrams on pages 31 and 32 for position and Detail A on page 25.

1. Seat an ‘O’ ring (6) into each of the collector connections to be joined.

2. Fit a collector union (3) to each collector connection of the first solar collector (17) to receive the second solar collector and screw in the unions until they seat firmly against their ‘O’ ring (6). Hand tighten only so the solar collectors can be shifted and centred.

3. Place the collector unions (3) into the collector connections on the second solar collector and screw in the unions until they seat firmly against their ‘O’ ring (6). Hand tighten only so the solar collectors can be shifted and centred.

4. Repeat steps 1 and 2 for a third and fourth solar collector (if installed).

5. After the solar collectors are centred on the collector rail(s), tighten each collector union (3) with a spanner applying medium pressure.

DETAIL A – COLLECTOR UNION ASSEMBLY – SCREWED FITTING

CONNECTION DETAILS

P/No: 33-0606

Blanking Disc

P/No: 33-0171

O-Ring 25mm ID x 3.2 Thk

P/No: 063602

Collector M33 End Plug

Solar Collector

END PLUG ASSEMBLY – SCREWED FITTING

Refer to installation diagram on page 31 for position and Detail B on page 26.

1. Seat an ‘O’ ring (6) into the collector connection.

2. Place a blanking disc (7) over the seated ‘O’ ring (6).

3. Place the end plug (5) into the collector connection and screw in until it seats firmly against the blanking disc (7), applying medium pressure with a spanner to tighten.

DETAIL B – END PLUG ASSEMBLY – SCREWED FITTING

CONNECTION DETAILS

Solar Collector

Solar Collector Solar Collector

O-Ring 25mm ID x 3.2 Thk

Connector M33 - NPT

P/No: 063603

Copper Compression

Olive 1/2"

P/No: 088027

Brass Compression

Nut 1/2" x 15

P/No: 080055

P/No: 33-0171

O-Ring 25mm ID x 3.2 Thk

COUPLING COLD AND HOT PIPES TO COLLECTOR – SCREWED FITTING

Refer to installation diagram on page 31 for position and Detail C on page 27,

Detail D on page 28 and Detail E on page 28.

1. Seat an ‘O’ ring (6) into the collector connection.

2. Place the connector (10) into the collector connection and screw in the union until it seats firmly against the ‘O’ ring (6), applying medium pressure with a spanner to tighten.

3. Place the compression nut (11) and olive (12) over the end of the solar cold pipe. Position the cold pipe into the connector (10), seat the olive (12) and tighten the compression nut (11).

4. Repeat this procedure with the sensor connector (4) to couple the solar hot pipe to the solar collector (17).

Note: If the installation is on a tiled roof, the orientation of the hot sensor port and hot sensor probe (when installed) must be angled between the perpendicular (90°) to the roof to a maximum 30° off perpendicular down the roof. Refer to Detail E on page 28.

DETAIL C – CONNECTOR ASSEMBLY – SCREWED FITTING

(WATER CONNECTION TO SOLAR COLLECTOR)

CONNECTION DETAILS

Solar Collector

DETAIL B

CONNECTOR

(BETWEEN COLLECTORS)

(LOLINE AND HILINE)

Brass Compression Nut 1/2" x 15 P/No: 080055

Solar Collector

Copper Compression Olive 1/2" P/No: 088027

Sensor Lead, Thermister sensor head & clip assbly P/No: 056001

O-Ring 5/32" ID x 1/16" Thk P/N 087025

Solar Collector Solar Collector

P/No: 33-0171

O-Ring 25mm ID x 3.2 Thk

P/No: 33-0695

Collector Union

P/No: 33-0171

O-Ring 25mm ID x 3.2 Thk

Connector M33 Assbly for

Temp Sensor - NPT

P/No: 063604

DETAIL A

CONNECTOR

(WATER CONNECTION TO COLLECTOR)

(LOLINE)

Connector M33 - NPT

P/No: 063603

Copper Compression

Olive 1/2"

P/No: 088027

P/No: 33-0171

O-Ring 25mm ID x 3.2 Thk

Tiled roof

30°

Down roof

Hot sensor & connector

assembly range is from

perpendicular to maximum

30° off perpendicular

"down" roof

Perpendicular

to roof

30°

DETAIL D – SENSOR CONNECTOR ASSEMBLY – SCREWED FITTING

DETAIL E – SENSOR CONNECTOR ORIENTATION – TILED ROOF

PIPE WORK ROUGHING IN DIMENSIONS

Pipe Work to Solar

Storage Tank

A B C

Hot

Outlet

Solar Hot

Flow

Solar

Cold

Return

Cold Inlet

Electric Boost

270 litre tank

1190

685

635

325 litre tank

1430

754

635

410 litre tank

1600

820

643

Refer to the diagrams for roughing in dimensions for pipe work to the solar collectors and to the solar storage tank.

Note: * the roughing in dimensions for B and C are 200 mm above fitting to allow room for bends and valve installation.

Electric Boost Solar Storage Tank

PIPE WORK ROUGHING IN DIMENSIONS

Pipe Work to

Solar Collectors

1 Collector

1240

1880

2 Collectors

2360

1880

3 Collectors

3480

1880

4 Collectors

4600

1880

Solar Pipe Work Roughing In Dimensions

INSTALLATION – SOLAR COLLECTORS

SOLAR COLD PIPE

SOLAR HOT PIPE

Note: Although the drawings illustrate the solar cold pipe connecting the bottom left hand corner of the solar collector array, the solar cold pipe may be connected to either the bottom right or the bottom left hand corner. The solar hot pipe must connect to the top of the solar collector array diagonally opposite to the solar cold pipe connection.

INSTALLATION WITH SCREWED FITTING SOLAR COLLECTORS

SUPPLIED IN COLLECTOR KIT (SCREWED FITTINGS) (299139)

1. Collector angle

2. Collector strap

3. Collector union

4. Sensor connector

5. End plug

6. ‘O’ ring

7. Blanking disc

9. Hot sensor lead assembly

10. Connector

11. Compression nut

12. Compression olive

13. Screws

14. Cable tie

15. Label – solar hot pipe

16. Label – solar cold pipe (Supplied separately)

17. Solar collector

INSTALLATION – SOLAR COLLECTORS

Solar Loline Collector Installation - Additional Collector (Exploded View)

with NPT 200 Solar Collectors

Supplied In Additional

Collector Kit (299140)

INSTALLATION – ADDITIONAL SOLAR COLLECTOR – SCREWED FITTING

SUPPLIED IN COLLECTOR ADD ON KIT (SCREWED FITTINGS) (299140)

1. Collector angle

2. Collector strap

3. Collector union

6. ‘O’ ring

13. Screws (Supplied separately)

17. Solar collector

This page is intentionally blank.

WARRANTY NOTE

The solar water heater and its components are covered by a manufacturer’s warranty. For full details, refer to the Owners Guide and Installation Instructions supplied with the solar storage tank.

The part extracts from the “Terms Of The Warranty And The Exclusions To It” of the water heater Warranty should be noted before commencing the installation of the solar collectors.

TERMS OF THE WARRANTY AND EXCLUSIONS TO IT

2.5 Where the water heater is installed in a position that does not allow safe or ready access,

the cost of that access, including the cost of additional materials handling and/or safety

equipment, shall be the owner’s responsibility. In other words, the cost of dismantling or

removing cupboards, doors or walls and the cost of any special equipment to bring the water heater to floor or ground level or to a serviceable position is not covered by this warranty.

2.7 The warranty does not cover faults that are a result of: c) Installation not in accordance with the Owner’s Guide and Installation Instructions or with

relevant statutory and local requirements in the State or Territory in which the water heater is installed.

d) Connection at any time to a water supply that does not comply with the water supply

guidelines as outlined in the Owner’s Guide and Installation Instructions.

k) Breakage of collector glass for any reason including hail damage (we suggest that the

collector glass be covered by the home insurance policy).

l) Ice formation in the waterways of a water heater system incorporating a freeze protection

system where the electricity supply has been switched off or has failed or where it is installed at an altitude more than 400 metres above sea level.

2.8 Subject to any statutory provisions to the contrary, this warranty excludes any and all claims

for damage to furniture, carpet, walls, foundations or any other consequential loss either directly or indirectly due to leakage from the water heater, or due to leakage from fittings and/ or pipe work of metal, plastic or other materials caused by water temperature, workmanship or other modes of failure.

Revision Date: 2016 August 129870N

RHEEM AUSTRALIA PTY LTD - ABN 21 098 823 511

1 Alan Street Rydalmere NSW 2116 Australia

(PO Box 7508 Silverwater NSW 2128 Australia)

PATENTS

This water heater may be protected by one or more patents or registered designs

in the name of Rheem Australia Pty Ltd.

Registered trademark of Rheem Australia Pty Ltd.

Trademark of Rheem Australia Pty Ltd.

TRADEMARKS

Note: Every care has been taken to ensure the accuracy in preparation of this

publication. No liability can be accepted for any consequences,

which may arise as a result of its application.

Rheem NPT 200 Installation Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

CONTENTS

COMPONENTS AND KIT CONTENTS

SYSTEM INSTALLATION

IMPORTANT NOTES

INSTALLATION STANDARDS

WATER HEATER APPLICATION

OPEN CIRCUIT SYSTEM INSTALLATION

Freeze Protection

INSTALLATION – SOLAR STORAGE TANK

SOLAR WATER HEATER STORAGE TANK LOCATION

INSTALLATION – SOLAR COLLECTORS

SOLAR COLLECTOR LOCATION

ROOF STRENGTH

ROOF AREA FOR INSTALLATION

Maximum Number of Collectors

ORIENTATION OF SOLAR COLLECTORS

INCLINATION OF SOLAR COLLECTORS

CYCLONIC OR HIGH WIND AREAS

LATITUDE OF SOME AUSTRALIAN CITIES

PIPE LENGTHS

Maximum Height to Collectors

Pressure Testing

Collector Circuit

Open Circuit System

ROOF ASSEMBLY OF SOLAR COLLECTORS

INSTALLATION CHECK LIST

CONNECTION DETAILS

COUPLING COLLECTOR TO COLLECTOR – SCREWED FITTING

END PLUG ASSEMBLY – SCREWED FITTING

COUPLING COLD AND HOT PIPES TO COLLECTOR – SCREWED FITTING

PIPE WORK ROUGHING IN DIMENSIONS

INSTALLATION – SOLAR COLLECTORS

INSTALLATION WITH SCREWED FITTING SOLAR COLLECTORS

SUPPLIED IN COLLECTOR KIT (SCREWED FITTINGS) (299139)

INSTALLATION – ADDITIONAL SOLAR COLLECTOR – SCREWED FITTING

SUPPLIED IN COLLECTOR ADD ON KIT (SCREWED FITTINGS) (299140)

WARRANTY NOTE

TERMS OF THE WARRANTY AND EXCLUSIONS TO IT