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This system shall be installed in accordance with:
• Manufacturer's Installation Instructions
• Current AS/NZS 3500
• All applicable local rules and regulations including local OH&S requirements
This system is fully certified in its own right. Given the unique nature of the
installation for this system it is reccomended to discuss any additional site
requirements with the site Building Inspector / Surveyor.
This system must be installed, commissioned and serviced by an Authorised Person.
The solar hot and solar cold pipes between the solar storage tank
and the solar collector(s) must be copper tube. Fittings used to
join these pipes must use metallic materials to acheive sealing.
Plastic pipe and fittings must not be used as they are not suitable
for the high temperatures and pressures that may occur.
IMPORTANT
Failure of plastic pipe and/or fittings can lead to the release of high
temperature water and can cause sever flooding and water damage.
Not suitable as a pool or spa heater.
Operation Installation Manual
Low Profile Roof Mounted
Solar Hot Water Systems
All Rinnai gas products
are A.G.A. certified.
W169
SAI Global
AS/NZS 2712
Lic No.1849
SAI Global
Issue
Issue
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Summary of Contents for Rinnai Enduro XL SP250B
- Page 1 This system is fully certified in its own right. Given the unique nature of the installation for this system it is reccomended to discuss any additional site requirements with the site Building Inspector / Surveyor. All Rinnai gas products W169 This system must be installed, commissioned and serviced by an Authorised Person.
- Page 2 Rinnai Low Profile Roof Mounted OIM...
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Page 3: Table Of Contents
Valves and Fittings ������������������������������������������������������������������������������������������������������������������������������������������� 15 Connecting Fittings to Collector ����������������������������������������������������������������������������������������������������������������������� 16 System Orientation and Inclination ������������������������������������������������������������������������������������������������������������������� 16 Roof Mounting Options ������������������������������������������������������������������������������������������������������������������������������������� 17 Installation Attaching Mounting Rail to Cylinder ����������������������������������������������������������������������������������������������������������������� 19 Kit Components - BIKV200CCP1XL ����������������������������������������������������������������������������������������������������������������� 20 Installation Procedure ��������������������������������������������������������������������������������������������������������������������������������������� 21 Filling the System ��������������������������������������������������������������������������������������������������������������������������������������������� 25 Checking Solar Pump Operation ���������������������������������������������������������������������������������������������������������������������� 25 Adjusting Flow Rate ����������������������������������������������������������������������������������������������������������������������������������������� 26 Pre Solar Heating Checks �������������������������������������������������������������������������������������������������������������������������������� 26 Solar Heating ���������������������������������������������������������������������������������������������������������������������������������������������������� 27 Finishing the Installation ����������������������������������������������������������������������������������������������������������������������������������� 27 Rinnai Low Profile Roof Mounted OIM... -
Page 4: Warnings And Important Information
Access covers of water heating system components will expose 240V wiring and MUST only 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 manufacturer’s 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 an equivalent metallic material specified 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. 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 Victorian Building Authority. -
Page 5: Scald Hazards
Installing tempering valves or thermostatic mixing valves which reduce the hot water temperatures deliveredtothetaps.Yourlocalplumbingauthoritymayalreadyrequirethatthesebefitted.Contactour 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 Low Profile Roof Mounted OIM... -
Page 6: Operation Principle
WARNINGS AND IMPORTANT INFORMATION OPERATION PRINCIPLE Rinnai pumped low profile roof mounted systems are designed to have all components mounted on a flat roof. The system comprises a hot water storage cylinder, solar collector(s), pump, controller, temperature sensors and a gas booster. Water is pumped from the storage tank to the solar collectors when there is enough energy available from the sun. The solar controller utilises information from the sensors to manage this process. Supplementary heating is provided using a gas booster if insufficient heat is available from sun (such as during cloudy or rainy weather or during winter months). The following diagram illustrates the operation principle. sensor hot water from collector to cylinder cool water from cylinder to collector cold sensor on cylinder cold water in warm water from tank heated water from... -
Page 7: Excessive Discharge From Safety Devices
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. GAS BOOSTERS • 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. -
Page 8: 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 the separate warranty 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 document. The system is not suitable as a pool or spa heater. MAINTENANCE AND REGULAR CARE Operate the easing gear of the PTR as described in the section ‘Safety Devices’ on page 6. 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 the supplied warranty booklet). It is recommended that the sacrificial anode be inspected every 5 years or more frequently in areas where there is a high incidence of water deposits. Anodes suited to hard and soft water, are available from Rinnai. 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 Low Profile Roof Mounted OIM... -
Page 9: Save A Service Call
SAVE A SERVICE CALL Before contacting Rinnai for service, please follow the fault finding guide. If the problem persists or this information doesn’t answer your questions, contact Rinnai on the phone number on the back of this manual Service call outs attending to any condition or fault that is not related to Rinnai product or components may be chargeable. INSUFFICIENT OR NO HOT WATER Excessive hot water 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. consumption Consider discussing with your installer, fitting water saving fixtures and/or flow control or pressure limiting valves to reduce consumption. Incorrect solar system size The system may not have been adequately sized to suit the household. Temperature and pressure PTR Valves & ECV Valves (if fitted) relief valve / expansion It is normal and desirable that these valves allows a small quantity of water to be discharged control valve discharging during the heating cycle. If they discharges more than a standard bucket of water during a 24 water continuously... -
Page 10: Specifications
SOLAR COLLECTORS Enduro XL SP250B Type Flat plate Waterways Copper Absorber Aluminium Selective Surface High Performance Maximum Operating Pressure 1000 kPa Casing Material Aluminium Overall Dimensions 1960 x 1290 x 80 (L x W x H) (mm) Weight empty (kg) Water volume (litres) 2�4 Number of risers Potential Solar Output at 1�4 PTR relief conditions (kW) The Rinnai solar hot water warranty booklet specifies the locations and conditions that apply for flat plate collectors to be warranted against frost damage. In locations where the warranty booklet specifies that frost valves must be Frost Protection used, they must be fitted for warranty to apply. Failure to fit frost valves will void any warranty against frost damage. For full warranty terms and conditions refer to the Rinnai solar hot water warranty booklet. This booklet is available from www.rinnai.com.au. Low Profile Roof Mounted OIM Rinnai... -
Page 11: System Dimensions
1290 Ø685 1140 (cylinder) 2200 1525 2500 STORAGE CYLINDER Connections Rp ¾ Weight Empty (kg) Weight Filled (kg) GAS BOOSTERS Model Name Boost capacity at 20°C rise (l/min) Boost capacity at 25°C rise (l/min) Maximum rated flow (l/min) Minimum water supply pressure for maximum rated flow (kPa) Frost protection Gas consumption maximum (MJ/h) Gas consumption minimum (MJ/h) Hot water delivery temperature (°C) Dimensions - height x width x depth (mm) 530 x 350 x 194 Weight (kg) 1 Units will operate at lower pressures but the rated flow will not be achieved. 2 Gas boosters for Solar hot water applications must be set by Rinnai to deliver a minimum temperature of 70°C. Solar Gas boosters will be marked as Solar. Units not marked ‘Solar’ MUST NOT be used, and will invalidate warranty. See warranty booklet for more details. Low Profile Roof Mounted OIM Rinnai... -
Page 12: InstallationInformation
elements have sufficient clearances and are accessible for service and removal. The information on any data plates must also be readable. This system is designed to have the gas booster mounted to the storage cylinder using the supplied mounting components. The location on the roof of the gas booster must meet the requirements of the gas installation code (AS/NZS 5601) Clause 6.3.12 and 6.3.13 of AS/NZS 5601 specify requirements for access to a gas appliance. It is the responsibility of the installer to ensure these requirements are followed. IMPORTANT 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/NZS 5601 should be used. Low Profile Roof Mounted OIM Rinnai... -
Page 13: Gas Booster Clearances
For appliance s not addressed above acceptance should be obtained from the Technical Regulator. Minimum clearances d and e also apply to any combustion air intake openings of appliances. FIGURE 6.2 (in-part) LOCATION OF FLUE TERMINALS OF BALANCED FLUE, ROOM SEALED, FAN-ASSISTED OR OUTDOOR APPLIANCES Low Profile Roof Mounted OIM Rinnai... -
Page 14: Water Pipes, Fittings And Insulation
WATER PIPES, FITTINGS AND INSULATION The solar hot and solar cold pipes between the solar storage tank and solar collector(s) must be copper tube. Fittings used to join these pipes must use metallic materials to achieve sealing. Plastic IMPORTANT pipe and fittings must not be used as they are not suitable for the high temperatures and pressures that may occur. Failure of plastic pipe and/or fittings can lead to the release of high temperature water and can cause severe flooding and water damage. All hot water pipework should be insulated with sealed polyethylene foamed or equivalent insulation to optimise performance and energy efficiency, and to protect against frost damage. Such insulation may also be mandatory under local regulations. Rinnai recommend insulation on all pipes to achieve at least R 1.0 K.m²/W. With the exception of solar collector flow and return pipes, water pipe sizing should be performed in accordance with AS/NZS 3500. All supplied insulation materials must be fitted as shown to minimise heat losses. In frost prone areas this insulation will also protect against frost damage. If frost valves are fitted they must remain free of any insulation materials. Frost valves must be exposed directly to ambient air conditions to ensure correct operation. FROST PROTECTION MODE The Solar Controller has two different temperature modes. Low temperature mode and standard operating mode. When the controller is in low temperature mode, the pump will circulate water to the collectors when the temperature on the roof drops low enough, to prevent freezing of the collectors. -
Page 15: Water Supply
• Elbow connections for the hot, cold and gas supply are fitted at the bottom of the gas booster. • Fittings as shown on page 20� 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. • An approved pressure limiting valve (supplied with some systems) is required if the maximum rated water supply pressure on page 10 is exceeded. Low Profile Roof Mounted OIM Rinnai... -
Page 16: Connecting Fittings To Collector
Canberra 35°S Melbourne 38°S Albany 35°S Darwin 12°S Perth 32°S Alice Springs 24°S Dubbo 32°S Port Hedland 20°S Brisbane 27°S Geraldton 28°S Rockhampton 24°S Broken Hill 31°S Hobart 42°S Sydney 34°S Cairns 17°S Mildura 34°S Townsville 19°S Latitudes of Australian Cities Low Profile Roof Mounted OIM Rinnai... -
Page 17: Roof Mounting Options
Broome Mareeba Exmouth Green Head Biloela Marble Bar Bundaberg Millstream Karratha Kununurra Brisbane Mullewa Burketown Moreton Onslow Lord Howe Island Christmas Island Norfolk Island Cairns Nhulunbuy Port Hedland Morawa Collinsville Torres Strait Islands Cocos Islands Normanton Toowoomba Corindi Wyndham Darwin Rockhampton Wittanoom Geraldton Derby Townsville Bourke Karumba Indicative selection of towns in Regions A,B,C &D Low Profile Roof Mounted OIM Rinnai... - Page 18 10 metres see AS/NZS1170.2 or consult a certified structural engineer. Some examples are shown below. Example1 Example2 Area 3 Area 2 Area 2 Area 1 Area 3 In both examples : A = min of 0.2 x 20.3 = 4.06 0�2 x 12�1 = 2�42 1 x 3�8 = 3�8 → A = 2.42 A/2 = 1.21 m Low Profile Roof Mounted OIM Rinnai...
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Page 19: Installation
INSTALLATION ATTACHING MOUNTING RAIL TO 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. Rail Washer Bolt Spring Washer Once the rail is attached and suitably tightened, continue the installation as shown on the next pages. Low Profile Roof Mounted OIM Rinnai... -
Page 20: Kit Components - Bikv200Ccp1Xl
INSTALLATION KIT COMPONENTS - BIKV200CCP1XL 200 Litre Glass Lined Cylinder with 1 SP250B Collector, Gas Boosted Low Profile Roof Mounted OIM Rinnai... -
Page 21: Installation Procedure
3� Place collector on cylinder and Collector overhangs rails� The collector should be cylinder on this side supported by the cutout in the rails until it is secured� 33 5 Collector and cylinder to sit flush on this side Low Profile Roof Mounted OIM Rinnai... - Page 22 Fasten in place with screws provided� 33 6 6� Place the gas booster onto the mounting bracket� The booster should be supported by the tongues on the brackets� Secure the booster in place using the screws supplied� 33 6 Low Profile Roof Mounted OIM Rinnai...
- Page 23 INSTALLATION Connect Components Connect all fittings and components as shown in the diagram below. Do not connect power to the pump at this stage. Low Profile Roof Mounted OIM Rinnai...
- Page 24 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 Low Profile Roof Mounted OIM Rinnai...
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Page 25: Filling The System
FILLING THE SYSTEM When filling the system with water, the installer must be careful as high temperature water and steam can be discharged from the system. Wear protective clothing such as long sleeves, gloves and safety glasses. CAUTION 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 electric power supplies to the water heater and pump kit are switched off. 1� Ensure the gas supply to the continuous flow water heater is isolated. 2� Turn on the hot water tap at the sink. Open the stop cock in the cold water mains supply line. 3� The entire system will now be filled with cold water. Most air will be dispelled through the tap. Air should be 4� bled by temporarily loosening a fitting at the collector outlet. Turn off the hot tap at the sink when water flows freely without air bubbles or air bursts. Check all connections 5� for leakage and tighten if necessary. This applies especially to fittings in positions not easily accessed 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. If leaks are detected the system must be drained and leaks repaired before the system is refilled. If this is necessary, cover the solar collectors with packaging cardboard or a tarp to prevent them from CAUTION heating which could result in steam or hot water being discharged from fittings.. Once the system is free from leaks, insulate all exposed pipework and fittings. 6� CHECKING SOLAR PUMP OPERATION Ensure hot and cold sensors are connected as shown on page 23 1� Activate power supply. 2� Pumps will operate when solar energy is available to be collected. 3� Low Profile Roof Mounted OIM Rinnai... -
Page 26: Adjusting Flow Rate
The purpose of controlling the water flow rate between the collectors and storage cylinder is to optimise the performance of the system. The optimum flow rate for the system is achieved by changing the setting on the pump as shown in the diagram below. PRE SOLAR HEATING CHECKS Before commencing solar heating of the water in the system ensure the following actions have been completed: Solar Collectors Is the solar collector installed with the correct orientation and inclination? 1� Is the installation finished neatly with the roof made good, all tiles and flashings in place? 2� Are the bolts tight on the roof framework? 3� If leak testing completed and successful, have any covers been removed from the solar collectors? 4� Has operation of the solar pump been checked? 5� Have the hot and cold sensors and leads been positioned and connected correctly? 6� Has all the pipework and exposed fittings been correctly insulated? 7� Gas Booster Ensure the gas supply is isolated. Remove the test point screw located on the gas inlet connection and attach 1� a pressure gauge. Turn on the electrical power to the gas booster only (not the solar pump kit) and turn on the gas supply. 2� Ensure the cold water inlet (‘trio’) valve on the storage cylinder inlet is open. Open all available hot water taps. 3� Operate ALL other gas appliances at their maximum gas rate, in accordance with manufacturers instructions. 4� Ensure building occupants do not have access to hot water outlets during this procedure. CAUTION Low Profile Roof Mounted OIM Rinnai... -
Page 27: Solar Heating
The hot water delivery temperature should not exceed 50°C or 45°C as detailed in the section ‘Hot Water Delivery Temperature’ on page 15. SOLAR HEATING Remove any cardboard or tarp covers that may have been placed over the solar collectors to prevent them 1� from heating water during installation and commissioning. Activate electrical power to both the gas booster and solar pump and controller. Solar heating of the water in 2� 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 1� components and the importance of carrying out maintenance. Complete the installation record at the back of the manual. 2� Leave this manual and the warranty booklet with the householder. 3� Low Profile Roof Mounted OIM Rinnai... - Page 28 P.O. Box 460 Braeside, Victoria 3195 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 service, please call our National Help Line. Rinnai recommends that this appliance be serviced every 3 years.
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