Rinnai Prestige Installation manual

Operation / Installation
Manual
Rinnai Prestige® Close Coupled Systems
All Rinnai gas products
are A.G.A. certified.
NOT SUITABLE AS A POOL OR SPA HEATER.
W169
AS 2712
Lic No.1849
SAI Global
SAI Global
15401022
NOTE
The appliance must be installed, commissioned and serviced by
an authorised person in accordance with all applicable local rules
and regulations.
IMPORTANT INFORMATION
TABLE OF CONTENTS
IMPORTANT INFORMATION & WARNINGS ................................................................................................ 2
SAFETY & REGULATORY INFORMATION .................................................................................................................. 2
SCALDS HAZARDS ..................................................................................................................................................... 3
OPERATION PRINCIPLE.............................................................................................................................................. 4
SAFETY DEVICES........................................................................................................................................................ 5
EXCESSIVE DISCHARGE FROM SAFETY DEVICES ................................................................................................ 5
WATER TEMPERATURE .............................................................................................................................................. 6
TURNING ‘OFF’ THE WATER HEATING SYSTEM ...................................................................................................... 6
TURNING ‘ON’ THE WATER HEATING SYSTEM ........................................................................................................ 6
WATER QUALITY.......................................................................................................................................................... 6
DRAINING AND FILLING THE WATER HEATING SYSTEM........................................................................................ 6
MAINTENANCE AND REGULAR CARE ...................................................................................................................... 7
SERVICING AND REPAIR ............................................................................................................................................ 7
SAVE A SERVICE CALL ................................................................................................................................ 8
SPECIFICATIONS ........................................................................................................................................ 10
SYSTEM SPECIFICATIONS ....................................................................................................................................... 10
COLLECTOR SPECIFICATIONS ................................................................................................................................ 12
GAS BOOSTER SPECIFICATIONS............................................................................................................................ 12
INSTALLATION INFORMATION .................................................................................................................. 13
REGULATIONS AND OCCUPATIONAL HEALTH AND SAFETY (OH&S).................................................................. 13
LOCATION .................................................................................................................................................................. 13
WATER PIPES ............................................................................................................................................................ 13
WATER SUPPLY ......................................................................................................................................................... 14
HOT WATER DELIVERY TEMPERATURE................................................................................................................. 14
VALVES AND FITTINGS ............................................................................................................................................. 15
SYSTEM ORIENTATION AND INCLINATION............................................................................................................. 16
ROOF MOUNTING OPTIONS .................................................................................................................................... 17
INSTALLATION OF SOLAR COLLECTORS & CYLINDERS...................................................................... 19
STANDARD INSTALLATION ....................................................................................................................................... 19
ATTACHING MOUNTING RAIL TO CYLINDER.......................................................................................................... 22
STANDARD INSTALLATION CONTINUED................................................................................................................. 23
ROOF PITCH GREATER THAN 30° ........................................................................................................................... 24
FRAMED INSTALLATIONS - FLAT, REVERSE AND SIDE PITCH............................................................................. 25
INSTALLATION & MAINTENANCE - GAS BOOSTED SYSTEMS ............................................................. 34
GAS BOOSTER LOCATION ....................................................................................................................................... 34
GAS SUPPLY .............................................................................................................................................................. 34
HOT WATER DELIVERY TEMPERATURE................................................................................................................. 34
SMARTSTART® .......................................................................................................................................................... 34
CLEARANCES .................................................................................................................................................. 36
INSTALLATION PROCEDURE.................................................................................................................................... 37
FILLING THE SYSTEM ............................................................................................................................................... 38
PRE SOLAR HEATING CHECKS ............................................................................................................................... 38
SOLAR HEATING........................................................................................................................................................ 39
FINISHING THE INSTALLATION ................................................................................................................................ 39
DRAINING INSTRUCTIONS ....................................................................................................................................... 39
INSTALLATION & MAINTENANCE - ELECTRIC SYSTEMS...................................................................... 40
INSTALLATION PROCEDURE.................................................................................................................................... 40
FILLING THE SYSTEM .............................................................................................................................................. 41
PRE SOLAR HEATING CHECKS ............................................................................................................................... 42
SOLAR HEATING........................................................................................................................................................ 42
FINISHING THE INSTALLATION ................................................................................................................................ 42
DRAINING INSTRUCTIONS ....................................................................................................................................... 42
CONTACT INFORMATION........................................................................................................................... 45
Rinnai Australia
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Solar Close Coupled Operating / Installation Manual - Issue 7 - 16/9/10
IMPORTANT INFORMATION & WARNINGS
SAFETY & REGULATORY INFORMATION
DO NOT operate this system before reading the manufacturers instructions.
WARNING
This appliance must be installed, commissioned and serviced by an authorised person in
accordance with all applicable local rules and regulations.
Access covers of water heating system components will expose 240V wiring and MUST be
removed by an authorised person.
This appliance is not intended for use by persons (including children) with reduced physical,
sensory or mental capabilities, or lack of experience and knowledge, unless they have been given
supervision or instruction concerning use of the appliance by a person responsible for their safety.
For continued safety of this appliance it must be installed, operated and maintained in accordance
with the manufacturers instructions.
Children should be supervised to ensure they DO NOT play with the appliance.
Any power leads from the water heater system components MUST BE plugged into an external
weatherproof electrical outlet. If the power supply cord of any water heating components is
damaged, it MUST BE replaced by an authorised person in order to avoid a hazard, using genuine
replacement parts available from Rinnai. Take care not to touch the power plugs with wet hands.
Care should be taken not to touch the pipe work as it may be HOT! The pipes between the solar
collectors and storage cylinder MUST BE copper, or alternative material pipes that may be
supplied by Rinnai. Plastic pipe is NOT suited to the water temperatures and pressures that may
occur in the system.
DO NOT place articles on or against this appliance.
DO NOT store chemicals or flammable materials near this appliance.
DO NOT operate with collectors or covers removed from this appliance.
DO NOT activate pump unless cylinder is full of water.
NEVER use a flammable spray such as hair spray, lacquer, paint, etc near this unit as this may
cause a fire.
NOTICE TO VICTORIAN CONSUMERS
This appliance must be installed by a person licensed with the Plumbing Industry Commission.
Only a licensed person will have insurance protecting their workmanship.
So make sure you use a licensed person to install this appliance and ask for your Compliance Certificate.
For Further information contact the Plumbing Industry Commission on 1800 015 129.
Rinnai Australia
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Solar Close Coupled Operating / Installation Manual Issue 7 - 16/9/10
IMPORTANT INFORMATION & WARNINGS
SCALDS HAZARDS
HOT WATER CAN CAUSE SCALDS.
CHILDREN, DISABLED, ELDERLY AND THE INFIRM ARE AT THE HIGHEST RISK OF
BEING SCALDED.
FEEL WATER TEMPERATURE BEFORE BATHING OR SHOWERING.
SCALDS FROM HOT WATER TAPS CAN RESULT IN SEVERE INJURIES TO YOUNG
CHILDREN.
SCALDS OCCUR WHEN CHILDREN ARE EXPOSED DIRECTLY TO HOT WATER WHEN
THEY ARE PLACED INTO A BATH WHICH IS TOO HOT.
ALWAYS......
Test the temperature of the water with your elbow before placing your child in the bath, also carefully feel
water before bathing or showering yourself.
Supervise children whenever they are in the bathroom.
Make sure that the hot water tap is turned off tightly.
CONSIDER.....
Installing child proof tap covers or child resistant taps (both approaches will prevent a small hand being
able to turn on the tap).
Installing tempering valves or thermostatic mixing valves which reduce the hot water temperature
delivered to the taps. Your local plumbing authority may already require that these be fitted. Contact your
installer or local plumbing authority if in doubt.
NEVER…..
Leave a toddler in the care of another child. They may not understand the need to have the water
temperature set at a safe level.
Rinnai Australia
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Solar Close Coupled Operating / Installation Manual Issue 7 - 16/9/10
IMPORTANT INFORMATION & WARNINGS
OPERATION PRINCIPLE
Close Coupled systems are designed to have the solar collectors on the roof and the storage cylinder above the
collectors, all mounted using available mounting brackets. Electric and Gas boosted models are available. The
system comprises of a hot water storage cylinder and solar collectors. The Close Coupled Solar System uses
thermo-syphoning principle to circulate the water through the collectors and then to the storage cylinder without the
need for a pump.
Supplementary heating is provided if insufficient heat is available from sun (such as during cloudy or rainy weather
or during winter months) either via an electric heating element located inside the storage cylinder or via a Gas
booster located external to the storage cylinder. The following diagrams illustrates the Close Coupled Solar Hot
Water System set up for both the Electric and Gas boosting.
STORAGE CYLINDER
COLLECTORS
COLD WATER
SUPPLY
GAS BOOSTER
HOT WATER
DELIVERY
GAS SUPPLY
Figure 1. Close Coupled Gas Boosted Solar Hot Water Systems
STORAGE CYLINDER
COLLECTORS
COLD WATER
SUPPLY
HOT WATER
DELIVERY
Figure 2. Close Coupled Electric Boosted Solar Hot Water Systems
Rinnai Australia
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Solar Close Coupled Operating / Installation Manual Issue 7 - 16/9/10
IMPORTANT INFORMATION & WARNINGS
SAFETY DEVICES
The water heating system is supplied with various safety devices including temperature sensors, overheat sensors
and switches and a Pressure & Temperature Relief (PTR) valve. These devices must not be tampered with or
removed. The water heating system must not be operated unless each of these devices is fitted and is in working
order.
DO NOT tamper with or remove safety devices.
WARNING
DO NOT operate the water heater unless all safety devices are fitted and in working order.
DO NOT block or seal the PTR Valve and drain pipe.
Pressure & Temperature Relief (PTR) Valve
This valve is located near the top of the water heater
and is essential for safe operation. It is normal for the
valve to release a small quantity of water through the
drain line during heating.
However, continuous leakage of water from the
valve and its drain line may indicate a problem with
the water heater.
WARNING
Twist cap until water
flows from drain line
Lift lever until water
flows from drain line
(Lower lever gently!)
Never block the outlet of the PTR valve or it’s drain line for any reason. The easing gear must be
operated at least every 6 months to remove lime deposits and verify that it is not blocked. Failure
to do this may result in the water heater failing.
If the valve does not discharge water when the easing gear lever is opened, or does not seal again
when the easing gear is closed, attendance by an authorised person must be arranged without
delay. The PTR valve is not serviceable.
EXCESSIVE DISCHARGE FROM SAFETY DEVICES
Pressure & Temperature Relief (PTR) Valve
It is normal and desirable that this valve allows a small quantity of water to be discharged during the heating cycle.
If it discharges more than a bucket of water during a 24 hour period or discharges continuously there may be
another problem.
If the valve dribbles continuously, try easing the valve gear for a few seconds as described above. This may
dislodge any foreign matter and alleviate the problem.
If the valve discharges at high flows, especially at night, it may be as a result of the water pressure exceeding the
design pressure of the water heater. Ask your installer to fit a Pressure Limiting Valve (PLV).
NEVER replace the PTR valve with one which has a higher pressure rating than is specified for your
water heater.
WARNING
Expansion Control Valve (ECV) - if fitted
It is normal and desirable that this valve allows a small quantity of water to be discharged during the heating cycle.
If it discharges more than a bucket of water during a 24 hour period or discharges continuously there may be
another problem.
If the valve leaks continuously, try easing the valve gear for a few seconds. This may dislodge any foreign matter
and alleviate the problem. If this does not alleviate the problem contact Rinnai.
Operate the easing gear regularly to remove any lime deposits and to verify that it is not blocked.
Rinnai Australia
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Solar Close Coupled Operating / Installation Manual Issue 7 - 16/9/10
IMPORTANT INFORMATION & WARNINGS
Gas boosted models
•
•
•
•
Do not touch the flue outlet or do not insert any objects into the flue outlet.
Keep flammable materials, spray cans, fuel containers, trees, shrubs and pool
chemicals etc. well clear of the flue outlet.
Do not use the gas types other than those designated on the data plate. For
example, do not use Propane/Butane gas mixtures on appliances marked Propane
Gas.
Do not use Propane gas on appliances marked as Natural gas and vice versa.
H OT !
WATER TEMPERATURE
The water gets heated by the solar energy contributed from the sun and heats the water
until the water at the base of the storage cylinder reaches approximately 65°C. At this
time water at the hot outlet can be up to 88°C. Continued heating is prevented by the
‘No Load’ protection, a Thermo-arrestor (TA) valve that prevents water passing from the
cylinder to the collectors. During periods of low solar gain, supplementary heating
occurs to a minimum of 60°C as required.
To meet Australian regulatory requirements, supplementary heating temperature settings
must be at least 60°C.
IMPORTANT
TURNING ‘OFF’ THE WATER HEATING SYSTEM
If you plan to be away for only a few nights, we suggest you leave the water heating system switched on.
If it is necessary to switch off the water heater, do so as outlined below:
Electric Boosted systems
• Switch off the electric supply to the supplementary heating element. The switch is usually marked and
located in the electricity meter box of the dwelling.
• Switch off the electric supply to the solar controller and pump.
Gas Boosted systems
• Switch off the electric supply to the gas booster.
• Switch off the electric supply to the solar controller and pump.
TURNING ‘ON’ THE WATER HEATING SYSTEM
Electric Boosted system
• Switch on the electric supply to the supplementary heating element(s). The switch is usually marked and
located in the electricity meter box of the dwelling.
• Switch on the electric supply to the solar controller pump. Electric and solar water heating will now occur as
required. It may take a number of hours before hot water is available.
Gas Boosted systems
• Switch on the electric supply to the gas booster.
• Switch on the electric supply to the solar controller and pump. Solar water heating will now occur. Hot
water is available immediately from the gas booster when hot water tap is opened, irrespective of solar
heat gain.
WATER QUALITY
The water quality of most public supplies is suitable for the water heating system. The water quality from bore
wells is generally unsuitable for the water heating system. Refer to separate 'Warranty Terms and Conditions'
document for water quality parameters and how they affect the warranty conditions. If in doubt about the water
quality, have it checked against the parameters listed in the warranty conditions. The system is not suitable as a
pool or spa heater.
DRAINING AND FILLING THE WATER HEATING SYSTEM
• Draining or filling normally occur only during installation or servicing and must be carried out by an
authorised person.
Rinnai Australia
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Solar Close Coupled Operating / Installation Manual Issue 7 - 16/9/10
IMPORTANT INFORMATION & WARNINGS
MAINTENANCE AND REGULAR CARE
Operate the easing gear of the PTR as described under “SAFETY DEVICES” on page 5.
The overflow tray (supplied by installer) and drain underneath the storage cylinder (if fitted) should be periodically
checked to ensure there are no blockages.
SERVICING AND REPAIR
Our Servicing network personnel are fully trained and equipped to give the best service on your appliance. If your
appliance needs service, ring one of the service contact numbers on the back of this booklet.
It is recommended that the system be serviced at least every 5 years.
The pressure and temperature relief valve and expansion control valve must be checked for performance or
replaced by an authorised person at intervals not exceeding 5 years or more frequently in areas where the water
is classified as scaling water (refer to ‘Warranty Terms and Conditions’ document - ‘Water Quality’).
If the electric conduit, power supply cord or plug to the water heater is damaged, they must be replaced by an
authorised person in order to avoid a hazard. The power supply cord and plug (if fitted) must be replaced by a
genuine replacement part available from Rinnai.
Rinnai Australia
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Solar Close Coupled Operating / Installation Manual Issue 7 - 16/9/10
SAVE A SERVICE CALL
SAVE A SERVICE CALL
Before calling Rinnai for service, perform the fault finding steps in the Table 1. If the problem persists, contact
Rinnai.
Service calls attending to any condition or fault that is not related to the Rinnai product and components may
be chargeable.
Table 1 - Troubleshooting
Problem
Insufficient or no hot Water
Cause
Remedy
Booster heating not operating
Or
Insufficient gas supply for gas boosted heating
system
Excessive hot water
consumption
Electric Boosted Systems:
If the water goes cold, are you using more hot water than you think? Often end
users are surprised at the amount of hot water used, especially when showering. If
the amount of hot water used during the day exceeds the storage capacity of the
cylinder, it is likely that there will be insufficient hot water. Has your plumber install
water saving fixtures and/or flow control or pressure limiting valves to reduce
consumption.
Gas Boosted Systems:
Insufficient flow may occur if multiple outlets are in use at the same time and exceed
the rated flow capacity of the gas booster. If so, reduce the number of outlets in use.
Have your plumber install water saving fixtures and/or flow control or pressure
limiting valves to reduce consumption.
Check correct size gas booster is fitted.
Incorrect Solar system size
Do you have the correct system size and configuration for your requirements? Refer
to Rinnai literature for information.
Temperature and pressure relief valve /
Expansion Control valve
discharging water continuously
Pressure and Temperature Relief (PTR) valve
It is normal and desirable that this valve allows a small quantity of water to be
discharged during the heating cycle. If it discharges more than a bucket of water
during a 24 hour period or discharges continuously there may be another problem.
If the valve dribbles continuously, try easing the valve gear for a few seconds as
described under 'Regular Care'. This may dislodge any foreign matter and alleviate
the problem.
If the valve discharges at high flows, especially at night, it may be as a result of the
water pressure exceeding the design pressure of the water heater. Ask your installer
to fit a Pressure Limiting Valve (PLV).
•
WARNING
•
Never replace the PTR valve with one which has a higher pressure rating
than is specified for your water heater.
If the valve discharges hot water at high flows, (dumps) there may be a
serious problem. Switch off the power supply in the meter box (the switch
marked ‘WATER HEATER’ or ‘HOT WATER’) or the isolating switch installed
near the water heater and contact Rinnai.
Insufficient or no hot Water
Continued
Rinnai Australia
Electric boosted Systems:
Check to ensure the electric isolating switch(es) at the switchboard (usually marked
"Hot water" or "water heater") is switched 'ON'.
Check to ensure that the electric fuses for hot water at the switchboard are intact.
Gas Boosted Systems:
Check to ensure the power cord of the gas booster is plugged in and the power point
switched 'ON'.
Check gas is available and turned ON'.
Close the hot tap and wait for 10 seconds and open it again. The hot tap must be
opened enough to ensure that the flow rate is not less than 2.4
L/min. gas the gas booster burners will not light if it is less than 2.4 L/min. Check the
isolation valve in the gas line is opened.
If there is gas supply to other appliances in the rest of the house, try lighting another
gas appliance.
Refer to your plumber to ensure the gas line has been purged of air after installation.
Expansion Control Valve (ECV) - if fitted
It is normal and desirable that this valve allows a small quantity of water to be
discharged during the heating cycle. If it discharges more than a bucket of water
during a 24 hour period or discharges continuously there may be another problem.
If the valve leaks continuously, try easing the valve gear for a few seconds as
described under 'Regular Care'. This may dislodge any foreign matter and alleviate
the problem. If this does not alleviate the problem contact Rinnai.
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Solar Close Coupled Operating / Installation Manual Issue 7 - 16/9/10
SAVE A SERVICE CALL
Problem
Cause
Remedy
Insufficient or no hot Water
continued
Booster element Thermostat Settings
Electric Boosted Systems:
The end user can check the temperature of hot water delivered with a
thermometer placed under the closest non tempered outlet (usually the kitchen
sink).
CAUTION: Take care to avoid scalding. This test should be done early in
the morning after overnight electrical boosting before any hot water is
used. The temperature of the water delivered should be at least 55° C
(allowing for heat losses in pipe work).
If this is not the case or the temperature needs to be increased contact Rinnai.
The thermostat settings of the heating element thermostat can also be confirmed
directly by a qualified person as described under 'hot water storage & delivery
temperature'. The settings can be increased if required. Contact Rinnai.
Gas Boosted Systems:
The delivery temperature of gas boosted systems is normally 60 or 65°C. Iff
temperatures are higher than this, the flow of water through the gas booster will
reduce and may result in insufficient flow rate.
The end user can check the temperature of hot water delivered with a
thermometer placed under the closest outlet (usually the kitchen sink).
CAUTION: Take care to avoid scalding. If the temperature is higher than
65°C the gas booster may be preset incorrectly. Contact Rinnai.
No Water from the hot tap
Restriction in the hot tap or failure of the cold water
supply to the water heater.
Check for water flow at the other taps and that the cold water isolation is fully
open.
Gas Booster operating too
frequently
Insufficient Sunlight - Collectors shaded
Ensure the trees or other objects are not shading onto the collector surface (Trim
the trees or relocate the solar collector if the obstruction is permanent).
Make sure the glass on the collector is not dirty.
High electricity or gas bill
Excessive hot water consumption
See entry under 'Insufficient hot water'.
Solar Control unit switched off
If the solar control unit is switched off there will be no solar pre-heating of water
resulting in the water being heated entirely by electricity or gas' boosting'. Check
the power outlet for the solar control unit is switched on.
Temperature and pressure relief valve / Expansion
Control valve discharging water continuously
See entry under 'Insufficient hot water'.
Lack of solar gain
Reduced sunlight:
Reduced sunlight due to overcast weather in summer or low solar contribution in
winter will result in an increased dependence on electricity or gas boosting.
Higher electricity or gas bills under these conditions, especially in winter, are
normal.
Collectors shaded:
If the solar collectors are shaded by trees or other objects, or the glass is dirty,
the effectiveness of the collectors is greatly reduced. Arrange for trimming of the
trees or relocation of the solar collectors if the obstruction is permanent. Arrange
for cleaning of the collector glass.
Solar collectors incorrectly positioned
Check that positioning and alignment of solar collectors is in accordance with the
section 'Location and alignment of solar collectors'.
WARNING: Persons working from elevated surfaces such as roofs must be
adequately trained an qualified in accordance with local OHS requirements.
High Electricity Tariffs (electric boosted systems only) Electric Boosted Systems
The electricity tariff will determine the running costs of the system. It is important
the end user is aware of the applicable tariffs. Contact your electricity supplier to
confirm what these tariffs are.
Little or no water circulation in the solar 'flow and
return' loop
There are numerous causes of little or no circulation in the solar flow and return
circuit the circulation of water through the collectors. These causes must be
investigated by a qualified person. Contact Rinnai.
Water flow fluctuations
One or more hot taps opened at the same time
More than one or two hot taps in use at the same time may cause a decrease in
the hot water flow from the taps.
Is there more than one or two hot taps open, or are appliances such as a
dishwasher or washing machine, in use at the same time?
Ensure only one or two hot taps are on at one time.
Check the flow of the water from one tap, eg. the shower. The shower should be
adjusted so the hot tap is fully open.
Water Hammer
Hot and cold water plumbing in the premises
Have a plumber check clipping of hot and cold water pipework and install a
pressure limiting valve and water hammer arrestor as required.
Rinnai Australia
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Solar Close Coupled Operating / Installation Manual Issue 7 - 16/9/10
SPECIFICATIONS
SYSTEM SPECIFICATIONS
Close Coupled hot water systems are specified according to the cylinder capacity, number of solar
collectors and boost type and capacity. Boost capacity for gas boosted system depends on the gas
booster model selected. Boost capacity for electrically boosted systems depends on the power rating
of the electric heating element.
Specifications and principal dimensions for the various systems are shown below.
Table 2 - Systems Specifications
Connections
- Solar flow and return
3/4”
- PTR Valve
3/4”
- Cold Inlet
3/4”
- Hot Outlet
3/4”
PTR Valve setting (kPa)
850
Rating of PTR Valve supplied (kW)
10
Expansion Control Valve (ECV) setting (kPa) - Supplied by
Installer if required
700
Max supply pressure with ECV (kPa)
500
Max supply pressure without ECV (kPa)
700
Pressure limiting valve rating (kPa) - Supplied by Installer if
required
500
Electric Element Power Rating for Electric Systems (kW)
Gas Booster
Rinnai Australia
24, or 3.6 standard
1.8 or 4.8 available separately
S20, S26 or other Rinnai Infinity
Models converted to Solar.
* (Refer section on gas booster
specification)
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Solar Close Coupled Operating / Installation Manual - Issue 7 - 16/9/10
SYSTEM SPECIFICATIONS
SYSTEM DIMENSIONS
1540
2275
1200
1200
1025
(1050)
2120
(2165)
2390
2090
3385
2090
2120
(2165)
3215
(3290)
610
600
1940
(1965)
Dimsensions shown for
Enduro and Equinox collectors
Dimensions in brackets “(__)” for
Excelsior collectors
2535
(2560)
Figure 3 - System Dimensions
Rinnai Australia
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Solar Close Coupled Operating / Installation Manual - Issue 7 - 16/9/10
SPECIFICATIONS
COLLECTOR SPECIFICATIONS
Table 4 - Collectors Specifications
MODEL NUMBERS AND SPECIFICATIONS
CHARACTERISTICS
Enduro / Equinox
(SP200A) or
(SP200A FTC)
Excelsior
(EXT OR EXT FTC)
TYPE
Flat plate
Flat plate
- Waterways
Copper
Copper
- Absorber
Aluminium
Copper
- Selective Surface
High Performance
Sputtered Titanium Oxide
CONSTRUCTION
Maximum Operating Pressure
850 kPa
Casing Material
Aluminium
Overall Dimensions
(L x W x H) (mm)
1940 x
1025 x
80
1964 x
1047 x
81
Weight empty
(STD/FTC) (kg).
33 / 35
35 / 38
Water volume (Litres)
1.3
1.5
Number risers
8
10
Potential Solar Output at
PTR relief conditions (kW)
1.25
Frost Protection
* Standard version - no frost protection
FTC Version - Frost Protection to -5°C
* FOR MORE INFORMATION ON FROST PROTECTION
REFER TO WARRANTY BOOKLET
GAS BOOSTER SPECIFICATIONS
* Table 5 - Gas Boosters Specifications
Model Name
S20
S26
20
16
26
24
20
26
Minimum Supply Pressure for Maximum rated flow: (1) (kPa)
120
200
Minimum Flow for Operation:
2.4
2.4
Yes
Yes
125 - 18
188 - 23
5.5
5.0
60°C
60°C
Boost Capacity:
- L/min. @ 20°C rise
- L/min @ 25°C rise
(L/min)
Maximum Rated Flow:
(L/min)
(L/min)
Frost Protection:
Gas Consumption (Maximum / Minimum):
(MJ/Hr.)
Star Rating (AS 4552 - 1998):
Hot Water Delivery Temperature:
(2)
Dimensions: Height x Width x Depth:
(mm)
530 x 350 x 194
530 x 350 x 194
Weight:
(kg)
15
21
(1) - Units will operate at lower pressures but the rated flow with not be achieved.
(2) - Gas boosters for Solar hot water applications should be preset to deliver a minimum temperature of 60°C.Gas boosters factory pre
set to 60°C or 65°C will be marked as such. If there are no temperature markings on the water heater, on site conversion is required.
Other models of Rinnai Infinity Water Heaters (including internal units) can be converted to solar gas boosters. Contact Rinnai for details.
Rinnai Australia
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Solar Close Coupled Operating / Installation Manual - Issue 7 - 16/9/10
INSTALLATION INFORMATION
REGULATIONS AND OCCUPATIONAL HEALTH AND SAFETY (OH&S)
Installation and commissioning must be performed by authorised persons.
Rinnai solar systems must be installed in accordance with these instructions
and all regulatory requirements which exist in your area including those in
relation to manual lifting, working at heights and on roofs. Applicable
publications and regulations may include:
WARNING
• AS 5601 Gas Installations
• AS/NZS 3500 National Plumbing and Drainage
• AS/NZS 3000 Wiring rules
• Building Codes of Australia (BCA)
• Local Occupational Health and Safety (OH&S) regulations
This appliance is not suitable for use as a domestic spa pool or swimming pool
heater.
Solar collectors and cylinders are heavy and bulky items and are usually
positioned on the roofs of buildings. Australian State and Territories have a
principal Occupational Health and Safety (OH&S) Act which contains
requirements relating to the handling of large, bulky or awkward items and the
prevention of falls from elevated surfaces. Persons installing solar collectors
must be aware of their responsibilities and be adequately trained and qualified,
in accordance with local OH&S requirements.
LOCATION
System Location
Select suitable areas of roof on which to install the solar collectors and cylinder. It is essential that
the roof structure is suitable for the solar collector/cylinder combination and can support the weight
of these items when full of water. It is the installers responsibility to ensure the roof can safely
support the system and to visually check the roof, and if there is any damage that requires attention
(such as cracked tiles etc.), to inform the owner. If this affects the safe installation of any part of the
system, installation should not proceed until the damage has been rectified. Collectors should be
positioned for optimum solar benefit. Refer to section “SYSTEM ORIENTATION AND
INCLINATION” on page 16 for more information.
All system components must be in an accessible location. Sufficient clearances shall allow access
to, and removal of, all serviceable parts. Ensure the PTR valve, drain lines, thermostat and elements
for electric systems have sufficient clearances and are accessible for service and removal. The
information on any data plates must also be readable.
All electrically boosted solar hot water heating elements must be connected to an independent,
fused, AC 240V 50 Hz power supply with an isolating switch installed at the switch board.
Gas Booster Location (where applicable)
The S20 & S26 gas booster are designed for 'Outdoor' Installation only. As such, it must be located
in an above ground open air situation with natural ventilation, without stagnant areas, where gas
leakage and products of combustion are rapidly dispersed by wind and natural convection.
If an internal model which has been converted to a solar gas booster follow information supplied with
the unit for location, mounting and flueing requirements.
WATER PIPES
All hot water pipework should be insulated with sealed Polyethylene foamed or equivalent insulation
to optimise performance and energy efficiency. Such insulation may also be mandatory under local
regulations. With the exception of solar collector flow and return pipes, water pipe sizing should be
performed in accordance with AS/NZS 3500.
•
WARNING
Rinnai Australia
The collector flow and return pipes must be a minimum of 1/2” copper tube or
alternative material pipe supplied by Rinnai. Plastic pipe must not be used
between collectors and cylinder or booster. Plastic pipe is not suited to the
high water temperatures and pressures that may occur in the collector flow
and return system.
- 13 -
Solar Close Coupled Operating / Installation Manual Issue 7 - 16/9/10
INSTALLATION INFORMATION
WATER SUPPLY
The minimum and maximum water pressures for the various systems are listed in Table 5.
Approved pressure limiting valves may be required if the 'Maximum' rated water supply pressures
are exceeded. For gas boosted systems to achieve the rated flow through the outlet of the
continuous flow water heater, the minimum water supply pressures must be supplied.
The systems will operate at lower pressures but the rated flow will not be achieved.
Water chemistry and impurity limits are detailed in the separate 'Warranty conditions' document.
Most metropolitan water supplies fall within these requirements. If you are unsure about water
quality, contact your water authority. If sludge or foreign matter is present in the water supply, a
suitable filter should be incorporated in the water supply to the storage cylinder.
HOT WATER DELIVERY TEMPERATURE
Local regulations and/or the requirements of AS/NZS 3500.4 must be considered regarding the
temperature limitations of hot water supplied to areas used primarily for personal hygiene. The
temperature of water to these areas is limited to 45°C for early childhood centres, primary and
secondary schools and nursing homes or similar facilities for young, aged, sick or people with
disabilities and 50°C for all other buildings. To comply with these requirements, a temperature
limiting device, such as a thermostatic mixing or tempering valve, will be required on all solar hot
water systems as detailed in Figures 4 and 5.
COLD WATER
SUPPLY
LAUNDRY
HEATED WATER
FROM STORAGE
CYLINDER
GAS SUPPLY
KITCHEN
BATHROOM
ENSUITE
TEMPERATURE
LIMITING
DEVICE
Figure 4 - Tempered Gas hot water systems
LAUNDRY
COLD WATER
SUPPLY
HEATED WATER
FROM STORAGE
CYLINDER
KITCHEN
BATHROOM
ENSUITE
TEMPERATURE
LIMITING
DEVICE
Figure 5 - Tempered Electric hot water systems
Rinnai Australia
- 14 -
Solar Close Coupled Operating / Installation Manual Issue 7 - 16/9/10
INSTALLATION INFORMATION
VALVES AND FITTINGS
Components Supplied by Installer
The following valves & fittings are to be supplied by the installer:
• A cold water expansion control valve (ECV). An ECV must be fitted in Western Australia and
South Australia to the cold water supply to the storage cylinder to comply with local regulations.
An ECV is recommended in all other geographical areas where the water supply has a
tendency to cause scaling. This will reduce hot water discharge from the Pressure and
Temperature Relief (PTR) valve which minimises wear on this valve.
• A stop cock, non return valve and line strainer. Combination valves incorporating two or more
of these functions (such as 'Trio' valves) are suitable. These are fitted to the cold water supply
to the storage cylinder by the installer.
• Cold water supply and hot water discharge pipework to and from the storage cylinder.
• An isolating valve and connection union for the gas supply to the gas booster.
• A approved pressure limiting valve is required if the maximum rated water supply pressure in
Table 2 is exceeded.
Components Supplied with System
The following valves are supplied with your solar hot water system:
• A combined pressure and temperature (PTR) relief valve, capacity 10 kW.
Relief valve pressure settings vary with models. This valve is fitted at the top of the storage
cylinder. The PTR valve is a safety device and it is mandatory that it is fitted by the installer in all
installations.
• Thermo-Arrestor (TA) valve. This valve is fitted on the inlet pipe to the Solar Collectors.
• For gas boosted systems, elbow connections for the hot, cold and gas supply are fitted at the
bottom of the gas booster.
• Fittings as shown in Figures 24 to 27.
Rinnai Australia
- 15 -
Solar Close Coupled Operating / Installation Manual Issue 7 - 16/9/10
INSTALLATION INFORMATION
SYSTEM ORIENTATION AND INCLINATION
The performance of any solar hot water system is determined by the way that the system is installed.
In Australia, the solar collectors should face the equator (North) as shown below. Where this
orientation is not practical, collectors facing within 45 degrees from North (between North-East and
North-West) area acceptable, with a reduction in efficiency of approximately 5%. If the bulk of hot
water consumption occurs before 2 pm face the collectors in a North - Easterly direction. If the bulk of
hot water consumption occurs after 2 pm face the collectors in a North Westerly direction.
(Ideal gives 3 hours either side of noon day sun)
North
45o
45o
West
East
South
Figure 6 - Orientation angle of Collectors
The inclination of the solar collectors should ideally be the same as the latitude angle of the site.
Inclinations within 20 degrees of the latitude angle of the site are acceptable, with a reduction in
efficiency of approximately 5%. Most roofs within Australia have a slope of between 20° and 25° and
provide an appropriately angled mounting surface.
To ensure operation of the system the inclination MUST NOT be less than 10°.
North
City Latitude +/- 20o
Figure 7 - Inclination of Collector
Table 7: Latitudes of Australian Cities
City
Adelaide
Alice Springs
Brisbane
Broken Hill
Rinnai Australia
Latitude
35°S
24°S
27°S
31°S
City
Cairns
Canberra
Darwin
Geraldton
Latitude
17°S
35°S
12°S
28°S
City
Hobart
Mildura
Melbourne
Perth
- 16 -
Latitude
42°S
34°S
38°S
32°S
City
Port Hedland
Rockhampton
Sydney
Townsville
Latitude
20°S
24°S
34°S
19°S
Solar Close Coupled Operating / Installation Manual Issue 7 - 16/9/10
INSTALLATION INFORMATION
For all installations the collector bank must slope upwards approximately 8 mm per collector from inlet
to outlet as shown below:
HOT CONNECTION
BLANKED OFF
CONNECTION
BLANKED OFF
CONNECTION
COLD
CONNECTION
COLLECTOR BANK MUST SLOPE
UPWARDS APPROX 8 mm PER COLLECTOR
Figure 8 - Collector Banks
ROOF MOUNTING OPTIONS
For mounting options not shown in Figure 9, for example in areas where the cyclone frame can not
be used, consult your nearest Rinnai Branch or Rinnai Representative.
For roofs with a slope of 10° or less a flat roof frame must be used.
Rinnai do not recommend installing Close Coupled systems on roofs with a pitch greater than 30°.
An additional strap should be used to prevent the cylinder from tipping over if a system is installed in
this manner. Refer page 24.
It is normal to mount the solar collectors down close to the gutter. Roof construction must be checked
to ensure that the roof timbers are capable of supporting the additional load. (Refer to AS 3500.4
Appendix H).
For tiled roof installations. Check for cracked or damaged tiles in the area of proposed installation.
Replace any faulty tiles.
If spare tiles are not available, swap damaged tiles with good ones from along the gutter line.
REVERSE PITCH FRAME
FLAT ROOF FRAME
STANDARD
N
N
CYCLONE FRAME
SIDE PITCH FRAME
N
N
N
Figure 9 - Solar Collector Roof Mounting Options
Rinnai Australia
- 17 -
Solar Close Coupled Operating / Installation Manual Issue 7 - 16/9/10
INSTALLATION OF SOLAR COLLECTORS & CYLINDERS
TABLE 8 - MOUNTING COMPONENTS
02817,1*&20321(176VXSSOLHGLQWKH,QVWDOODWLRQ.LW
Size of Cylinder / Number of Collectors
Part Name / Number
180 / 1
180 / 2
330 / 2
330 / 3
2
-
-
-
Mounting Rail Small
14201196
-
2
2
Mounting Rail Medium
14201197
-
-
-
2
Mounting Rail Large
2*
+
2#
4*
4*
14201198
6*
Collector Mounting Strap
* supplied with collectors,
# supplied in collector installation kit
4
4
4
4
M8 Bolt, Washer and Nut
(used to bolt collector mounting
strap to mounting rail)
4
8
8
12401012
BOLT
WASHER
NUT
12
Collector Retainer
4
8
8
26601706
12
M6 Bolt, Washer and Nut
(used with collector retainers)
Rinnai Australia
22601052
17401072
16801062
- 18 -
BOLT
WASHER
NUT
22601073
17401073
16801007
Solar Close Coupled Operating / Installation Manual Issue 7 - 16/9/10
INSTALLATION OF SOLAR COLLECTORS & CYLINDERS
STANDARD INSTALLATION
Cylinder Mounting Component Pre Assembly for a Standard Installation
This installation is not suitable for use in cyclonic areas. For further details, please
contact your local Rinnai Solar distributor.
NOTE
• Assemble the cylinder cradle components and the lower collector rail components as shown in
Figure 10.
• Only loosely attach the collector retainers to the rails.
COLLECTOR SUPPORT STRAPS
MOUNTING RAIL
COLLECTOR RETAINERS
M6 BOLT, NUT &WASHER
COLLECTOR SUPPORT STRAPS
MOUNTING RAIL
COLLECTOR RETAINERS
M6 BOLT, NUT &WASHER
Figure 10 - Cylinder Mounting
Rinnai Australia
- 19 -
Solar Close Coupled Operating / Installation Manual Issue 7 - 16/9/10
INSTALLATION OF SOLAR COLLECTORS & CYLINDERS
STANDARD INSTALLATION CONTINUED
Fastening (Collectors to a Tiled Roof)
This installation is not suitable for in cyclonic areas. For further details, please
contact your local Rinnai Solar distributor.
NOTE
• Position the lower collector mounting rail
assembly so that the rail is angled to ensure
the collectors have an 8 mm / collector rise.
Tiles removed
• Attach the collector mounting straps to the
rafter or truss under the tiles as shown in
Figure 11.
Nail strap to rafter
Figure 11 - Mount Lower Collector Rail
• Place the collector(s) onto the roof above the
lower rail. If more than one collector is being
installed then join them together using the
compression fittings supplied.
• Push down on the collector retainers to clamp
the collector and tighten the nuts as shown in
Figure 12.
Figure 12 - Mount collector on Roof
• Position the upper collector rail above the
collectors. Push down on the retainers to
clamp the collector and tighten the nuts.
Tiles removed
• Attach the collector mounting straps to the
rafter or truss under the tiles as shown in
Figure 13.
Nail strap
to rafter
Figure 13 - Attach Mounting Straps
• Replace the tiles and ensure the collector is
secure as shown in Figure 14.
Figure 14 - Replace Tiles
Rinnai Australia
- 20 -
Solar Close Coupled Operating / Installation Manual Issue 7 - 16/9/10
INSTALLATION OF SOLAR COLLECTORS & CYLINDERS
STANDARD INSTALLATION CONTINUED
Fastening (Collectors to a Metal Roof)
This installation is not suitable for use in cyclonic areas. For further details, please
contact your local Rinnai Solar distributor.
NOTE
• Position the lower collector mounting rail
assembly so that the rail is over the roof
purlin and the rail is angled ensure the
collectors have an 8 mm / collector rise.
Bolt lower
mounting rail
to roof purlin
using a suitable
fastener
• Drill through the roof iron and purlin using
the holes in the rail as a guide. Apply
some silicone sealant down the holes to
ensure no water leakage.
• Bolt the rail to the roof purlin using a
suitable fastener as shown in Figure 15.
Figure 15 - Mount Lower Collector Rail
• Position the collector(s) onto the roof
above the lower rail. If more than one
collector is being installed, join them
together using the compression fittings
supplied.
• Push down on the collector retainers to
clamp the collector and tighten the nuts.
• Place the upper collector mounting rail
above the collectors. Push down on the
collector retainers to clamp the collector
and tighten the nuts.
• Drill through the roof iron and purlin using
the upper mounting rail as a guide. Apply
some silicone sealant down the holes to
ensure no water leakage and secure with
suitable fasteners as shown in Figure 16.
Alternatively the rail can be attached to
the roof using the collector mounting
straps.
Figure 16 - Mount Collector on Roof
Bolt upper mounting
rail to roof purlin using
a suitable fastener
Figure 17 - Attach Upper Rail
Rinnai Australia
- 21 -
Solar Close Coupled Operating / Installation Manual Issue 7 - 16/9/10
INSTALLATION OF SOLAR COLLECTORS & CYLINDERS
ATTACHING MOUNTING RAIL TO CYLINDER
Depending on the packaging, either one or two rails are attached to the cylinder.
•
The extra rail and fastenings are packed with
the cylinder. They are screwed into the rail
mounting holes in the cylinder.
•
Attach the rail using the bolts, washers and
spring washers in the order shown.
•
Ensure the feet on the rails face outwards
•
Ensure that the bolt is tightened sufficiently to
flatten the spring washer. This ensures that the
bolt is adequately tightened.
•
Once the rail is attached and suitably tightened,
continue the cylinder installation as shown on
the next page.
Figure 18 - Cylinder with one rail
Rail
Washer
Bolt
Spring
Washer
Figure 19 - Attachment of rail
Figure 20 - Cylinder with both rails
Rinnai Australia
- 22 -
Solar Close Coupled Operating / Installation Manual Issue 7 - 16/9/10
STANDARD
INSTALLATION
CONTINUED
INSTALLATION
OF SOLAR
COLLECTORS
& CYLINDERS
STANDARD INSTALLATION CONTINUED
•
•
Fastening Cylinder to a Tiled Roof
Lift the storage cylinder onto the roof and
locate it above the collector bank. The
cylinder’s position should be as central as
possible to the collector bank. The lower
rail must be on a load bearing surface.
Slide the cylinder support strap into the
slots located in the uppermost cylinder
support bracket (shown in Figure 21) so
that the strap are in line with the rafter or
as close as possible to them.
Figure 21 - Cylinder Support Strap
•
•
Remove tiles one row up from the storage
cylinder. Apply tension to the straps and
attach them to the rafters using a suitable
fastener.
TILE
REMOVED
Replace the tiles
LOWER CYLINDER RAIL
MUST BE ON A LOAD
BEARING SURFACE
FASTEN STRAP
TO RAFTER
Figure 22 - Cylinder Installation Tiled Roof
Fastening Cylinder to a Metal Roof
Lift the storage cylinder onto the roof and
locate it above the collector bank. The
cylinder’s position should be as central as
possible to the collector bank. The lower
rail must be on a load bearing surface.
• Slide the cylinder support strap into the
slots located in the uppermost cylinder
support bracket (shown in Figure 21) so
that the strap are in line with a suitable
fastening point.
• Bolt the lower support rail to the roof using
a suitable fastener.
• Apply tension to the cylinder support
straps and attach them to the rafters using
a suitable fastener.
• Seal any holes in roof using a suitable
sealant to ensure roof is water tight.
•
BOLT STRAP TO ROOF USING
A SUITABLE FASTENER
BOLT RAIL TO ROOF USING
A SUITABLE FASTENER
LOWER CYLINDER RAIL MUST BE
ON A LOAD BEARING SURFACE
Figure 23 - Cylinder Installation Metal Roof
Rinnai Australia
- 23 -
Solar Close Coupled Operating / Installation Manual Issue 7 - 16/9/10
INSTALLATION OF SOLAR COLLECTORS & CYLINDERS
ROOF PITCH GREATER THAN 30°
In situations where a Close Coupled System is installed onto a roof with a pitch of 30° or greater, an
additional strap must be used to prevent the cylinder tipping over. Builders strapping available from
hardware stores is suitable for this. The strapping is attached through the slots in the front cylinder
rail, goes over the tank and is then fastened to the roof behind the cylinder.
Tiled Roof
Metal Roof
Securely fasten
strap to roof using
a suitable fastener
Securely fasten
strap to roof using
a suitable fastener
Attach strap through
slot in cylinder rail.
Attach straps through
slot in cylinder rail.
Ensure straps are on
main section of tank as
plastic endcaps are not
loadbearing
Securely fasten
straps to roof
using a suitable
fastener
Ensure straps are on
main section of tank as
plastic endcaps are not
loadbearing
Securely fasten
strap using a
suitable fastener
Rinnai Australia
- 24 -
Solar Close Coupled Operating / Installation Manual Issue 7 - 16/9/10
INSTALLATION OF SOLAR COLLECTORS & CYLINDERS
FRAMED INSTALLATIONS - FLAT, REVERSE AND SIDE PITCH
NOTE
This installation is not suitable in cyclonic areas. For the correct frame for use in
cyclone areas, contact your local Rinnai Solar distributor.
Table 9 - Framed Installations
• For use on a flat roof or where the roof pitch
is too low.
• This frame allows the system to be installed
at a suitable inclination.
• Installations instructions are provided in the
Rinnai Frame Installation Manual.
FLAT ROOF FRAME
• These comprise of a Close Coupled system
flat roof frame and a side/reverse pitch kit.
• They can be used when the system need to
•
•
be installed in the reverse direction to the
direction the roof is facing.
For example, using a reverse pitch frame on
a South facing roof enables the system to be
oriented to the North.
Installations instructions are provided in the
Rinnai Frame Installation Manual.
REVERSE PITCH FRAME
• These comprise of a Close Coupled system
flat roof frame and a side/reverse pitch kit.
• They can be used when the system need to
•
•
be installed side on to the direction the roof
is facing.
For example, using a side pitch frame on an
East or West facing roof to enables the
system to be oriented to the North.
Installations instructions are provided in the
Rinnai Frame Installation Manual.
SIDE PITCH FRAME
FRAMED INSTALLATIONS - CYCLONE FRAME
• Assemble cyclone frame and mount
components as described in instructions
provide with cyclone frame kit.
Rinnai Australia
- 25 -
Solar Close Coupled Operating / Installation Manual Issue 7 - 16/9/10
INSTALLATION OF SOLAR COLLECTORS & CYLINDERS
9
20
9
8
7
6
16
4
3
1
2
20
10
14
9
11 12 13 9
16
21
180 Litre Cylinder with 1 Collector
Figure 24 - 180 Litre Cylinder with 1 Collector
Rinnai Australia
- 26 -
Solar Close Coupled Operating / Installation Manual Issue 7 - 16/9/10
Rinnai Australia
- 27 -
1
1
1
1
1
1
Qty
TA Valve
Reducing Nipple
R1 x R ¾
Elbow Rp ¾ x Rp ¾
R ¾ Nipple (long)
*supplied with cylinder
T adaptor hot outlet
*supplied with cylinder
P&TR Valve
11007711
17201036
21201004
17201011
19001018
11004784
Item / Part Number
1
1
1
1
4
1
Qty
1 x Elbow G ¾ (Flexi) x G ¾
(Kinco)
1 x Kinco nut and olive ¾
Adapting Nipple
G ¾ (Flexi) x G ¾ (Kinco)
Kinco olive ¾
Kinco nut ¾
-
-
Elbow assembly
Fibre washer ¾
Adaptor
M33 x G ¾ (Flexi)
17201007
33001011
16801018
21201013
17401008
16601065
Item / Part Number
180 litre cylinder with 1 collector
Installation Kit IK180CCT01
1
1
2
1
Qty
17201006
Flexi Pipe 600 mm
with Insulation
11601097
11601099
28801025
1 G ¾ plug
1 ¾ Kinco nut + 1 ¾ Kinco olive)
Flexi pipe 1930 mm
with insulation
-
Stop end assembly
Adapting Nipple
R ¾ x G ¾ (Flexi)
Item / Part Number
INSTALLATION OF SOLAR COLLECTORS & CYLINDERS
Solar Close Coupled Operating / Installation Manual Issue 7 - 16/9/10
INSTALLATION OF SOLAR COLLECTORS & CYLINDERS
9
16
23 9
8
7 6
1
2
23
10
17
17
14 9
10
16
9
24
180 Litre Cylinder with 2 Collectors
Figure 25 - 180 Litre Cylinder with 2 Collectors
Rinnai Australia
- 28 -
Solar Close Coupled Operating / Installation Manual Issue 7 - 16/9/10
Rinnai Australia
- 29 -
1
1
1
1
Qty
TA Valve
Reducing Nipple
R1 x R ¾
*supplied with cylinder
T adaptor hot outlet
*supplied with cylinder
P&TR Valve
11007711
17201036
19001018
11004784
Item / Part Number
1
2
4
1
Qty
1 x Elbow G ¾ (Flexi) x G ¾
(Kinco)
1 x Kinco nut and olive ¾
Adapting Nipple
R ¾ x G ¾ (Flexi)
-
-
Elbow assembly
Fibre washer ¾
Adaptor
M33 x G ¾ (Flexi)
17201006
21201013
17401008
16601065
Item / Part Number
180 litre cylinder with 2 collectors
Installation Kit IK180CCT02A
1
1
2
2
Qty
1 x nipple G3/4
2 x Kinco nut and olive ¾
Flexi Pipe 670 mm
with Insulation
Flexi Pipe 2450 mm
with Insulation
-
-
11601098
11601095
32201709
28801025
1 G ¾ plug
1 ¾ Kinco nut + 1 ¾ Kinco olive)
Union compression ¾
-
Stop end assembly
Item / Part Number
INSTALLATION OF SOLAR COLLECTORS & CYLINDERS
Solar Close Coupled Operating / Installation Manual Issue 7 - 16/9/10
INSTALLATION OF SOLAR COLLECTORS & CYLINDERS
9
20
9
8
7
6
16
4
3
1
2
20
10
17
17
14 9
11 12 13 9
16
22
330 Litre Cylinder with 2 Collectors
Figure 26 - 330 Litre Cylinder with 2 Collectors
Rinnai Australia
- 30 -
Solar Close Coupled Operating / Installation Manual Issue 7 - 16/9/10
Rinnai Australia
- 31 -
1
1
1
1
1
1
Qty
TA Valve
Reducing Nipple
R1 x R ¾
Elbow Rp ¾ x Rp ¾
R ¾ Nipple (long)
*supplied with cylinder
T adaptor hot outlet
*supplied with cylinder
P&TR Valve
11007711
17201036
21201004
17201011
19001018
11004784
Item / Part Number
1
1
1
1
4
1
Qty
1 x Elbow G ¾ (Flexi) x G ¾
(Kinco)
1 x Kinco nut and olive ¾
Adapting Nipple
G ¾ (Flexi) x G ¾ (Kinco)
Kinco olive ¾
Kinco nut ¾
-
-
Elbow assembly
Fibre washer ¾
Adaptor
M33 x G ¾ (Flexi)
17201007
33001011
16801018
21201013
17401008
16601065
Item / Part Number
330 litre cylinder with 2 collectors
Installation Kit IK330CCT02A
1
1
2
2
1
Qty
1 x nipple G 3/4
2 x Kinco nut and olive ¾
Flexi Pipe 480 mm
with Insulation
Flexi pipe 1930 mm
with insulation
-
17201006
11601064
11601099
32201709
28801025
1 G ¾ plug
1 ¾ Kinco nut + 1 ¾ Kinco olive)
Union compression ¾
-
Stop end assembly
Adapting Nipple
R ¾ x G ¾ (Flexi)
Item / Part Number
INSTALLATION OF SOLAR COLLECTORS & CYLINDERS
Solar Close Coupled Operating / Installation Manual Issue 7 - 16/9/10
INSTALLATION OF SOLAR COLLECTORS & CYLINDERS
23 9
9
16
8
7 6
1
2
23
10
17
17
17
14 9
17
10
16
9
25
330 Litre Cylinder with 3 Collectors
Figure 27 - 330 Litre Cylinder with 3 Collectors
Rinnai Australia
- 32 -
Solar Close Coupled Operating / Installation Manual Issue 7 - 16/9/10
Rinnai Australia
- 33 -
1
1
1
1
Qty
TA Valve
Reducing Nipple
R1 x R ¾
*supplied with cylinder
T adaptor hot outlet
*supplied with cylinder
P&TR Valve
11007711
17201036
19001018
11004784
Item / Part Number
1
2
4
1
Qty
1 x Elbow G ¾ (Flexi) x G ¾
(Kinco)
1 x Kinco nut and olive ¾
Adapting Nipple
R ¾ x G ¾ (Flexi)
-
-
Elbow assembly
Fibre washer ¾
Adaptor
M33 x G ¾ (Flexi)
17201006
21201013
17401008
16601065
Item / Part Number
330 litre cylinder with 3 collectors
Installation Kit IK330CCT03A
1
1
4
2
Qty
1 x nipple G 3/4
2 x Kinco nut and olive ¾
Flexi Pipe 770 mm
with Insulation
Flexi Pipe 2450 mm
with Insulation
-
11601096
11601095
32201709
28801025
1 G ¾ plug
1 ¾ Kinco nut + 1 ¾ Kinco olive)
Union compression ¾
-
Stop end assembly
Item / Part Number
INSTALLATION OF SOLAR COLLECTORS & CYLINDERS
Solar Close Coupled Operating / Installation Manual Issue 7 - 16/9/10
INSTALLATION & MAINTENANCE - GAS BOOSTED SYSTEMS
GAS BOOSTER LOCATION
The gas booster is designed for ‘Outdoor” Installation only. As such, it must be located in an above
ground open air situation with natural ventilation, without stagnant areas, where gas leakage and
products of combustion are rapidly dispersed by wind and natural convection. The location must
comply with the clearances specified in AS 5601.
The gas booster must be mounted on a vertical structure with the water and gas connections on the
underside pointing downwards. The heated outlet of the cylinder is connected to cold water inlet of
the gas booster.
Ensure that the wall or structure on which it is to be mounted are capable of supporting the weight
of the appliance and associated pipe work. See Table 5 for individual gas booster weights. For gas
boosters installed on elevated structures or under floors specific requirements apply.
Refer to AS 5601 for details.
• Attach the gas booster to the wall using screws.
• Location of the gas booster flue terminal must be in accordance with Figure 5.3 of
AS 5601.
• If an internal model which has been converted to a solar gas booster follow information
supplied with the unit for location, mounting and flueing requirements.
GAS SUPPLY
The maximum gas consumption of the gas booster and the required gas pressure are shown on the
appliance data plate. If the gas pipe sizing is insufficient the customer will not get the full performance
benefit. Gas pipe sizing must consider the gas input to the gas booster as well as all the other gas
appliances on the premises. The gas meter and regulator must be specified for this gas rate. An
approved sizing chart such as the one in AS 5601 should be used. An approved full flow isolation
valve and disconnection union must be fitted to the gas supply inlet of the gas booster. Isolation
valves must not be fitted directly.
HOT WATER DELIVERY TEMPERATURE
Gas boosters for use in solar hot water systems are preset to deliver a fixed temperature of 60°C in
accordance with plumbing regulations. In addition, they contain the warning stating “Rinnai Water
Controllers are NOT compatible with solar hot water installations and MUST NOT BE USED” in the
vicinity of the temperature controller connections inside the appliance.
•
NOTE
•
Gas Boosters other than models designated “S20”, S26”or “Solar” must not be
used.
Gas Boosters marked with the text: “THIS APPLIANCE DELIVERS WATER NOT
EXCEEDING 50°C IN ACCORDANCE WITH AS 3498" are incompatible with
solar hot water systems and must not be used.
SMARTSTART®
Smartstart® Function
The Smartstart® is a separate system that works in conjunction with the Rinnai solar hot water
system.
When activated by the manual activation switch, water in the pipework connected between the solar
hot water system and the hot water outlets is warmed before any outlets are opened. This results in
water savings and added convenience. Refer the Figure 28 for installation details.
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Solar Close Coupled Operating / Installation Manual Issue 7 - 16/9/10
Rinnai Australia
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Supply from solar storage cylinder
Installations MUST conform to local
regulataions.
Refer to Rinnai manuals supplied
with appliances for important
installation information.
Outlets to Personal Hygiene areas
to be tempered to 50°C as per
AS3500.4
IMPORTANT
Rinnai Smartstart Unit
Rinnai Continuous Flow Water
Heater - Gas Booster
Gas Supply
Manual Activation
Switch ONLY
(not supplied)
Water controllers
MUST NOT
be used!
Return Line
INSTALLATION & MAINTENANCE - GAS BOOSTED SYSTEMS
Figure 28 - Smartstart® Schematic
Solar Close Coupled Operating / Installation Manual Issue 7 - 16/9/10
INSTALLATION MAINTENANCE - GAS BOOSTED SYSTEMS
CLEARANCES
Figure 5.3 is reproduced below. Note that AS 5601-2004 was current at time of printing but may
have been superseded. It is the installer’s responsibility to ensure current requirements are met.
AS 5601 - Figure 5.3 ‘Clearances’ - Gas Booster Flue Terminal
Rinnai Australia
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Solar Close Coupled Operating / Installation Manual Issue 7 - 16/9/10
INSTALLATION MAINTENANCE - GAS BOOSTED SYSTEMS
INSTALLATION PROCEDURE
1.
Install Solar Collectors and cylinders
2.
• Position and install the solar collectors and cylinder in accordance with the section
‘INSTALLATION OF SOLAR COLLECTORS AND CYLINDERS”.
Connect PTR Valve
3.
• Connect the PTR Valve in the location shown in the relevant diagram of Figures 24 to 27.
Leave the valve outlet pointing down. Tighten the valve using the spanner flats - never use
the valve body.
• The PTR Valve must be adequate for the thermal loading applied to the storage cylinder. In
the case of gas boosted systems, the thermal load is applied only by the solar collectors.
The continuous flow hot water heater does not apply thermal load to the storage cylinder.
The potential solar output for the solar collectors at PTR Valve relief conditions is listed in
Table 3.
• The PTR Valve pressure ratings vary according the cylinder specifications. The maximum
heater input rating is 10.0 kW. The PTR valve rating MUST EXCEED the total input from the
solar collectors. If it does not, the PTR valve MUST be exchanged for a model of higher
capacity.
• For example, for a gas boosted solar system with 3 x SP200A collectors, the thermal load is
3 x 1.25 = 3.75 kW. This is less than 10.0 kW, hence the supplied PTR valve is of sufficient
capacity.
• Use Teflon thread tape on the valve, never use hemp or other sealing materials. Ensure the
tape does not protrude past the end of the thread, which could result in it hanging over the
end of the thread and blocking the water passage through the valve.
Mount Gas Booster
4.
• Mount the gas booster in accordance with the section ‘GAS BOOSTER LOCATION &
MOUNTING’.
Connect Water to Gas Booster
5.
• Connect the outlet of the storage cylinder to the water inlet of the gas booster.
Connect Fittings
6.
• Connect fittings and pipe work as shown in the relevant diagram in Figures 24 to 27.
Cold Water Supply
7.
• Connect cold water supply to the inlet ‘T’. Ensure that the relevant valves as described in
the section “VALVES AND FITTINGS” are fitted.
• Purge the cold water supply lines to remove air and swarf before final connection.
Relief Drain Lines
• Independent 15 mm copper pipes must be fitted to the drain outlets of the PTR and ECV.
Each pipe must be open to atmosphere and run with a continual downward grade in a frost
free environment to a visible discharge point. Drain lines must not exceed 9 metres in
length.
• Valves or other restrictions must not be placed in the relief valve drain outlet line.
Some water will drip from the drain lines during heating of the water in the storage
cylinder. It is recommended to discharge directly above a drain.
NOTE
8.
Hot Water Discharge
• Connect the hot water outlet of the gas booster to the pipe work supplying hot water to the
premises.
A temperature limiting device may be required as detailed in the section “HOT
WATER DELIVERY TEMPERATURE”.
WARNING
9.
Connect Gas to Booster
• Connect a suitable gas supply and isolating valve to the gas booster. Follow instructions
supplied with gas booster. Keep gas booster isolated at this stage.
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Solar Close Coupled Operating / Installation Manual Issue 7 - 16/9/10
INSTALLATION MAINTENANCE - GAS BOOSTED SYSTEMS
FILLING THE SYSTEM
CAUTION
1.
2.
3.
Ensure building occupants are warned to stay clear of the solar system
components, building perimeter and roof since hot water or steam may be
discharged from pipes or components.
Ensure the gas supply to the continuous flow water heater is isolated.
Turn on one or more hot water taps at the sink. Open the stop cock in the cold water mains
supply line. The entire system will now be filled with cold water.
Turn off the hot tap at the sink when water flows freely without air bubbles or air bursts. Check
all connections for leakage and tighten if necessary. This applies especially to fittings in
positions not easily assessed such as near the solar collectors. Operate the easing gear of both
the PTR and ECV valves at the storage cylinder to ensure these valves are functional.
CAUTION
If leaks are detected the system must be drained and leaks repaired before the
system is refilled. If this is necessary, temporarily cover the solar collectors with
packaging cardboard or a tarp to prevent them from heating which could result in
steam or hot water being discharged from fittings.
PRE SOLAR HEATING CHECKS
Before commencing solar heating of the water in the system ensure the following actions have been
completed:
Solar Collectors
1.
2.
3.
4.
5.
Are the solar collectors installed with the correct slope and orientation to the sun?
Is the installation finished neatly with the roof made good, all tiles and flashings in place?
Are the bolts tight on the roof framework?
Are all solar collector straps fitted and correctly anchored to the roof structure?
If leak testing completed & successful, have any covers been removed from the solar
collectors?
Gas Booster
1.
2.
3.
4.
Ensure the gas supply is isolated. Remove the test point screw located on the gas inlet
connection and attach a pressure gauge.
Turn on the electrical power to the gas booster and turn on the gas supply.
Ensure the cold water inlet ('trio') valve on the storage cylinder inlet is open. Open all available
hot water taps.
Operate ALL other gas appliances at their maximum gas rate, in accordance with
manufacturers instructions.
Ensure building occupants do not have access to hot water outlets during this
procedure.
CAUTION
5.
6.
With all gas appliances in operation at the maximum gas rate, the pressure should read
between 1.13 - 3.0 kPa on Natural Gas. On LPG the pressure should be 2.75 - 3.0 kPa. If the
pressure is lower, the gas supply is inadequate and the appliance will not operate to
specification. It is the installers responsibility to check the gas meter, service regulator and pipe
work for correct operation/ sizing & rectify as required. Note that the gas regulator on the
appliance is electronically controlled and factory pre-set. Under normal circumstances it DOES
NOT need adjustment during installation. Make adjustments only if the gas booster is not
operating correctly and all other possible causes for incorrect operation have been eliminated.
Instructions for gas pressure setting are located in the pocket behind the front cover of the gas
booster.
Close the hot water taps including the shower.
Rinnai Australia
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Solar Close Coupled Operating / Installation Manual Issue 7 - 16/9/10
INSTALLATION MAINTENANCE - GAS BOOSTED SYSTEMS
7.
Check the hot water delivery temperature by placing a suitable thermometer at the hot water
outlet closest to the gas booster. This is usually the hot water outlet in the kitchen. The delivery
temperature should be greater than 55°C (this temperature allows for heat losses in pipe work).
If the delivery temperature at the hot water outlet is lower than 55°C, check the delivery
temperature at the outlet of the gas booster. It should be within 2°C of the set point, usually
60°C. If not, refer to the section 'Hot Water Delivery temperature' refer to page 34.
8. Close the cold water inlet ('trio') valve on the storage cylinder inlet and inspect and clean the
strainer. Repeat for the strainer connected at the inlet of the gas booster. This procedure may
need to be repeated to ensure the strainers remains clear, especially on new installations.
9. Confirm the hot water delivery temperature from the gas booster. This is done by checking the
hot water delivery temperature at an untempered outlet close to the water heater. This is
usually the hot water outlet in the kitchen.The untempered hot water delivery should be
between 55°C & 60°C.
Temperature Limiting Devices
1.
2.
Commission any temperature limiting devices in accordance with the instructions supplied by
the manufacturer.
Confirm the hot water delivery temperature at a tempered water outlet. Tempered water outlets
should be those supplying areas primarily used for the purposes of personal hygiene such as
bathrooms. The hot water delivery temperature should not exceed 50°C or 45°C as detailed in
the section 'Hot Water Delivery temperature' refer to page 34.
SOLAR HEATING
1.
2.
Remove any cardboard or tarp covers that may have been placed over the solar collectors to
prevent them from heating water during installation and commissioning.
Activate electrical power to the Rinnai gas booster. Solar heating of the water in the cylinder will
now commence when sufficient solar radiation is available.
FINISHING THE INSTALLATION
• After testing is completed explain to the householder the functions and operation of solar water
heater components. Also explain to the householder the importance of carrying out
Maintenance as per separate ‘Warranty Terms and Conditions’ document.
• Leave this Manual with the householder.
• Remind the householder to complete the 'Warranty Certificate' provided in the separate
‘Warranty Terms and Conditions’ document.
DRAINING INSTRUCTIONS
1.
2.
3.
4.
5.
6.
7.
The power supply to the gas booster must be switched off.
Close the cold water mains supply stop cock.
Open a hot tap to relieve pressure.
Disconnect the cold water connection to the Thermo-arrest (T/A) valve.
Remove the brass plug on the bottom right hand side of the collector bank.
Disconnect the ‘water inlet’ and ‘water outlet’ connections at the gas booster.
The system will now drain all water.
Rinnai Australia
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Solar Close Coupled Operating / Installation Manual Issue 7 - 16/9/10
INSTALLATION & MAINTENANCE - ELECTRIC SYSTEMS
INSTALLATION PROCEDURE
1. Install Solar Collectors and Cylinders
Position and install the solar collectors and cylinder in accordance with the section
“INSTALLATION OF SOLAR COLLECTORS AND CYLINDER”.
2. Connect PTR Valve
•
Connect the PTR Valve in the location shown in the relevant diagram of Figures 24 to 27.
Leave the valve outlet pointing down. Tighten the valve using the spanner flats - never use
the valve body.
•
The PTR Valve must be adequate for the thermal loading applied to the storage cylinder. In the
case of gas boosted systems, the thermal load is applied only by the solar collectors. The
continuous flow hot water heater does not apply thermal load to the storage cylinder. The potential
solar output for the solar collectors at PTR Valve relief conditions is listed in Table 3.
•
The PTR Valve pressure ratings vary according the cylinder specifications. The maximum heater
input rating is 10.0 kW. The PTR valve rating MUST EXCEED the total input from the solar
collectors. If it does not, the PTR valve MUST be exchanged for a model of higher capacity.
•
For example, for a gas boosted solar system with 3 x SP200A collectors, the thermal load is 3 x
1.25 = 3.75 kW. This is less than 10.0 kW, hence the supplied PTR valve is of sufficient capacity.
•
Use Teflon thread tape on the valve, never use hemp or other sealing materials. Ensure the tape
does not protrude past the end of the thread, which could result in it hanging over the end of the
thread and blocking the water passage through the valve.
3. Connect Fittings
•
Connect fittings and pipe work as shown in the relevant diagram in Figures 24 to 27.
4. Cold Water Supply
•
Connect cold water supply to the inlet ‘T’. Ensure that the relevant valves as described in the
section “VALVES AND FITTINGS” are fitted.
•
Purge the cold water supply lines to remove air and swarf before final connection.
5. Relief Drain Lines
•
Independent 15 mm copper pipes must be fitted to the drain outlets of the PTR and ECV. Each
pipe must be open to atmosphere and run with a continual downward grade in a frost free
environment to a visible discharge point. Drain lines must not exceed 9 metres in length.
•
Valves or other restrictions must not be placed in the relief valve drain outlet line.
Some water will drip from the drain lines during heating of the water in the storage
cylinder. It is recommended to discharge directly above a drain.
NOTE
6. Hot Water Discharge
•
Connect the hot water outlet of the storage cylinder to the pipe work supplying hot water to the
premises.
A temperature limiting device may be required as detailed in the section “HOT
WATER DELIVERY TEMPERATURE”.
WARNING
Rinnai Australia
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Solar Close Coupled Operating / Installation Manual Issue 7 - 16/9/10
INSTALLATION & MAINTENANCE - ELECTRIC SYSTEMS
7. ELECTRIC SUPPLY
The power supply to the heating elements must not be activated until the system is
filled with water.
WARNING
•
The power supply can be either Off-Peak
(overnight), Extended Off-Peak (overnight and day)
or continuous, depending on the tariffs available
from the local electricity supply authority. The OffPeak (overnight) power supply minimises the cost
of any required electric boosting. Discuss power
supply requirements with the end user and
electricity supply authority as required.
•
Connections for elements Figure 29 shows the
wiring detail for the water heater.
•
A flexible 20 mm conduit is required for the
electrical cable to the storage cylinder. The conduit
is to be connected to the unit with a 20 mm
terminator. Connect the power supply wires directly
to the terminal block and earth tab connections
ensuring there are no excess wire loops inside the
front cover.
Figure 29 - Wiring detail
Heating Element Thermostat Temperature Settings
Australian Standards require a minimum thermostat set point of 60°C to inhibit the growth of
Legionella Pneumophilia bacteria.
FILLING THE SYSTEM
WARNING
Ensure building occupants are warned to stay clear of the solar system
components, building perimeter and roof since hot water or steam may be
discharged from pipes or components.
1. Ensure the electric power supply to the heating element is switched off and fuses removed.
2. Turn ON one or more hot water taps at the sink. Open the stop cock in the cold water mains supply
line. The entire system will now be filled with cold water.
3. Turn OFF the hot tap at the sink when water flows freely without air bubbles or air bursts. Check all
connections for leakage and tighten if necessary. This applies especially to fittings in positions not
easily assessed such as near the solar collectors. Operate the easing gear of both the PTR and
ECV valves at the storage cylinder to ensure these valves are functional.
WARNING
Rinnai Australia
If leaks are detected the system must be drained and leaks repaired before the
system is refilled. If this is necessary, temporarily cover the solar collectors with
packaging cardboard or a tarp to prevent them from heating which could result in
steam or hot water being discharged from fittings.
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Solar Close Coupled Operating / Installation Manual Issue 7 - 16/9/10
INSTALLATION & MAINTENANCE - ELECTRIC SYSTEMS
PRE SOLAR HEATING CHECKS
Before commencing solar heating of the water in the system ensure the following actions have been
completed:
Solar Collectors
1. Are the solar collectors installed with the correct slope and orientation to the sun?
2. Is the installation finished neatly with the roof made good, all tiles and flashings in place?
3. Are the bolts tight on the roof framework?
4. Are all solar collector straps fitted and correctly anchored to the roof structure?
5. If leak testing completed and successful, have any covers been removed from the solar collectors?
Electric Heating Element
1. Has the thermostat set point been set to at least 60°C and no greater than 70°C?
Temperature Limiting Devices
1. Commission any temperature limiting devices in accordance with the instructions supplied by the
manufacturer.
2. Confirm the hot water delivery temperature at a tempered water outlet. Tempered water outlets
should be those supplying areas primarily used for the purposes of personal hygiene such as
bathrooms. The hot water delivery temperature should not exceed 50°C or 45°C as detailed in the
section "Hot water delivery temperature" of these instructions.
SOLAR HEATING
1. Remove any cardboard or tarp covers that may have been placed over the solar collectors to
prevent them from heating water during installation and commissioning.
Auxiliary Energy Supply
1. Connect the electrical element to the power supply (off peak if available).
2. When the system is fully of water turn on electrical supply to element.
FINISHING THE INSTALLATION
• After testing is completed explain to the householder the functions and operation of solar water
heater components. Also explain to the householder the importance of carrying out
Maintenance as per separate ‘Warranty Terms and Conditions’ document.
• Leave this Manual with the householder.
• Remind the householder to complete the 'Warranty Certificate' provided in the separate
‘Warranty Terms and Conditions’ document.
DRAINING INSTRUCTIONS
1. The power supply to the element must be switched off.
2. Close the cold water mains supply stock cock.
3. Open a hot tap to relieve pressure.
4. Disconnect ‘cold water inlet’ connection to the T/A valve.
5. Remove the brass plug on the bottom right hand side of the collector bank.
6. The system will now drain all water.
Rinnai Australia
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Solar Close Coupled Operating / Installation Manual Issue 7 - 16/9/10
Rinnai Australia
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Solar Close Coupled Operating / Installation Manual Issue 7 - 16/9/10
IMPORTANT INFORMATION
CONTACT INFORMATION
Australia Pty. Ltd.
Internet: www.rinnai.com.au
E-mail: [email protected]
ABN 74 005 138 769
Head Office
10-11 Walker Street,
Braeside, Victoria 3195
P.O. Box 460
Tel: (03) 9271 6625
Fax: (03) 9271 6622
Spare Parts & Technical Info
Tel: 1300 555 545*
Fax: 1300 300 141*
Rinnai has a Service and Spare Parts network with personnel who are fully trained
and equipped to give the best service on your Rinnai appliance. If your appliance
requires a service, please call our National Help Line.
*Cost of a local call Higher from mobile or public phones.
Hot Water Service Line
Tel: 1800 000 340
123 45678 90123 4
Rinnai Australia
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Solar Close Coupled Operating / Installation Manual Issue 7, 16/9/10
15401022
National Help Line