1. RHEEM COMMERCIAL WATER HEATING TRAINING

2. TRAINING COURSE OBJECTIVES
Introduction to Rheem Commercial Booklet
Range appreciation
Familiarise key design / installation criteria
Introduction to manifolding
Introduction to sizing
Value added service

3. Commercial Water Heating course contents
Chapter 1 - Range overview - Commercial Booklet
Chapter 2 - Heat Pump
Chapter 3 - Commercial Solar
Chapter 4 - Equaflow Manifolding
Chapter 5 - Commercial Continuous Flow
Chapter 6 - Commercial Storage Gas systems
Chapter 7 - Raypak Heating and Hot Water
Chapter 8 - Commercial Electric
Chapter 9 - Guardian Warm Water
Chapter 10 – Pump Sets
Chapter Sizing and Selecting
Chapter Commercial installation and design

4. Range Overview & Rheem Commercial Booklet
Chapter 1
Range Overview & Rheem Commercial Booklet

5. Chapter 2 - Commercial Heat Pump

6. COMMERCIAL HEAT PUMP LAYOUTS

7. COMMERCIAL HEAT PUMP LAYOUTS

8. Chapter 3 - Commercial Solar

9. Commercial Solar Terminology Split / Pumped / Loline
Close Coupled / Thermosiphon / Hiline
Direct / Indirect (Premier Hiline)

10. Commercial Solar Loline

11. Commercial Solar Loline
Pumped system
Collectors and tank are split
Fluid is pumped between collectors and tanks
Can be on same level or different levels
Direct system
Consumed water passes through the collectors
Partial frost protection
In series boost

13. Commercial Solar Loline
325L and 410L vitreous enamel storage tanks
Manifold tanks as required
NPT200 collector
Painted aluminium selective surface
7 riser tubes
Good performance in all regions

14. Commercial Solar Loline
Frost
Limited frost protection
Frost sensor strategy
Electric or gas frost heater
Secondary Solar Recirculation
Maximum solar energy use
reduces energy use
BMS output
Run and fail status

15. Commercial Solar Premier Hiline

16. Commercial Solar Premier Hiline
Thermosiphon system
Collectors and tank are close coupled
Fluid rises through collectors naturally to tank
Tank is always above collectors
Indirect system
Transfer fluid passes through the collectors and transfers heat to tank via heat exchanger
Full frost protection
In series or in- tank electric boost

17. Commercial Solar Premier Hiline
300L stainless steel tank
Manifold systems as required
8 systems per array, multiple arrays possible
S200 collector
Steel collector
Painted selective surface
Good performance in all regions

19. Flat Plate vs Evacuated Tube Collectors

20. EQUA-FLOW MANIFOLDING
Chapter 4
EQUA-FLOW MANIFOLDING

21. EQUA-FLOW BASICS Equa-Flow Basics
The purpose of Equa-flow manifolding is to ensure water is used or generated equally in all cylinders in the manifold.
Water will always take the path of least resistance, therefore ensuring equal resistance in the equaflow manifold is the key to equa-flow manifolding.
First Principle
Direction of flow must always be in the same direction through the manifold headers.
This is sometimes referred to as “first in, last out”, but this can be confusing and needs to be understood. Other terminology could also be “water must exit the manifold at the opposite end to which it enters”.

22. EQUA-FLOW BASICS In Line Header diameters for cold/hot to be equal
Branch diameters for cold/hot to be equal
Hydraulic water flow “In one side, out the opposite”
Balanced performance per unit. Full delivery capacity from system
Flow direction Out
In Line
Flow direction In
Header sizes need to be equal to the diameter of cold supply to the plant and branch sizes should be at least one pipe size diameter smaller; Bushing down at the inlet/outlet connections is permissable.

23. EQUA-FLOW BASICS
Flow direction Out
Back to Back
Flow direction In

24. EQUA-FLOW BASICS 1 B 0+1+1=2 AA B
0+1+1=2
Water enters the first cylinder at point A, and thus travels zero distance through the manifold.
Water exits the first cylinder and travels along the hot water manifold for a distance of 2 metres to point B, the end of the manifold.
Total distance, or lineal resistance, equals 2 metres.

25. PATH of LEAST RESISTANCE1 A B

26. MORE EQUA-FLOW PRINCIPLES2 1 B 1 2 =6 =6 =6
It follows, then, that the hot and cold water branches do not necessarily need to be identical.
All hot water branches must be identical, and all cold water branches must be identical, but the hot and cold branches can be different to each other.
In this true life example, the plant room door was in the middle of the room and the heaters had to be placed on both sides of the door. The cold water and hot water manifolds were run at high level, above the door, and long droppers were run for each cold water branch.
In this example, the cold branches could be 2m long, and the hot branches are 1m long, as well as the distance between tanks is different.
From Point A to Point B, including the branches:
The first heater has a resistance of = 6m.
The second heater has a resistance of = 6m
And the third heater has a resistance of = 6m

27. ANGLED MANIFOLD 1 3 + bend A B The same is true for angled manifolds.
The third heater is encumbered by a manifold length 2 metres longer than the manifold between heaters one and two, plus one bend. This applies to both the cold and hot water manifolds.
Following the manifold principles, each cylinders’ resistance is as follows:
Cylinder 1:
Cold manifold = zero
Hot manifold = bend
Total = bend
Cylinder 2:
Cold manifold = 1
Hot manifold = bend.
Cylinder 3:
Cold manifold = bend
Hot manifold = zero
The key principle is that direction of flow is maintained in the same direction

28. BACK TO BACK MANIFOLD 0.75 1 1 A B 1 1 0.75
H2:
= 2.75
H4:
= 2.75
H6:
= 2.75 A
H5:
= 2.75 B
H1:
= 2.75
H3:
= 2.75
Back to Back manifolds can be a little hard to follow, but the principles remain unchanged.
In the illustrated example, the distance between branches between heater 1 &2 and 5 &6 is shorter than the distance between other branches. The distance travelled in each header is identical for hot and cold.
Once again, the key principle is that direction of flow is maintained in the same direction. 1 1
0.75

29. EQUAFLOW PRINCIPLES IN PRACTICE

30. COMPLICATED EQUAFLOW PRINCIPLES IN PRACTICE
When designing/ inspecting complicated manifolds consideration must be given to primary loops as well as hot and cold headers

31. EQUAFLOW PRINCIPLES IN PRACTICE

32. COMPLICATED EQUAFLOW PRINCIPLES IN PRACTICE

33. TO WATER HEATER MANIFOLD
BRANCHES
NEVER use non-return valves or pressure limiting valves in the branch
These create imbalance in the branches
Non-return and pressure reducing valves must be in a train on the cold water inlet
COLD WATER SUPPLY
TO WATER HEATER MANIFOLD
Never use non-return valves or pressure limiting valves in branches.
These create pressure imbalances between the branches and will affect equaflow performance.
All control valves must be installed in a train on the cold water inlet.

34. BRANCHES Only an isolating valve and union must be in the branch
Full flow gate or ball valves must ONLY be used
NEVER use duo valves or loose jumper valves
These create imbalance in the branches
So far we have been concentrating on flow direction and balancing resistance in the headers.
Branch resistance is equally important.
Each branch must ONLY contain an isolating valve and union
Use ONLY gate valves or ball valves, both fully open.
Duo valves and loose jumper valves create imbalance in the branches. Further, both of these valves act as non return valves and can affect water flow in certain applications. This will be discussed in more detail further in the session.

35. BRANCHES
T PIECE
Last branch should be a T piece, not an elbow, to maintain equal resistance in all branches
Ideally, the last branch in a manifold should be a T piece, not an elbow, in order to maintain equal resistance in all branches.

36. Chapter 5 - Commercial CFWH

37. RHEEM INDOOR CFWH – FLUE SYSTEMS
USE MM AND FF ADAPTERS IF HORIZONTAL LENGTH OF HORIZONTAL TERMINATING FLUE EXCEEDS 2.7M
TRIM
RING
USE CONDENSATE DRAIN & TRAP IF VERTICAL SECTION OF HORIZONTAL TERMINATING FLUE EXCEEDS 2M

38. Rheem Multipak, Tankpak, Commpak and Commpak Plus Commercial Continuous Flow
Hot Water Solutions

40. Chapter 6 - Commercial Gas Storage

41. RHEEM Commercial Gas Storage
Work horse of the industry
3 input sizes – 50, 110, 200MJ/hr
Indoor and outdoor models
Multi-fin flue technology
Flue damper
Hot Surface Ignition
Up to 82oC
Room sealed flue

42. HD Gas Layout

43. 631275 Room Sealed Flue Converts outdoor model to indoor room sealed
Ideal where no ventilation, contaminated air supply or fluing to roof impractical
3m and 3 x 90o bends
Re-use flue terminal
Kit P/No

45. Chapter 7 – Raypak Heating and Hot Water

46. Raypak Layouts

47. Chapter 8 - Commercial Electric Storage

48. RHEEM Commercial Electric Storage
Work horse of the industry
2 x 3 element models – 50 & 315L
1 x 6 element model – 315L
Up to 36kW output
Indoor and outdoor installation
Heavy Duty enamel
Larger anode
Models up to 82oC

49. HD Electric Layout

50. Chapter 9 - Rheem Guardian Warm Water

51. Chapter 10 - Pump Sets

52. Deluxe Pump Sets Deluxe Models UPS 20-60N and 32-80N pumps
Individual Auto, Off, Manual switches
Individual Run and Fail indicators
Timer control
Isolation and check valves included
BMS output

53. Standard Pump Sets Standard Models UPS 20-60N and 32-80N pumps
Single Auto, Off, Manual switch
Timer control
Isolation and check valves included

54. Chapter 11
Sizing and selecting...

55. Energy Consumption
It takes 4.2kJ of heat energy to raise 1litre of water (or 1 kg) of water 1 degree E = L x 4.2 x dT Example : To raise 500 litres by 32 degrees (from 10C to 42C) Energy consumption = 500 x 4.2 x 32 = 67,200kJ or 67.2MJ Plant efficiency must also be considered. If the plant operates at 80% efficiency, then; Energy required = 67.2 / 0.8 = 84MJ
O/H 14 - Why You Should Recommend Rheem
TAB - Rheem leads the way with Hot Surface Ignition, the safest, simplest and smartest way to control water heaters.
TAB - We offer a full 5 year replacement warranty for commercial applications, 10 year for domestic.
TAB - With features, such as HSI, high thermal efficiency, polyurethane insulation and flue damper, we lead the way in energy conservation and reduced running costs.
TAB - Rheem incorporates the latest technology features into all of its designs.
TAB - At the end of the day, however, lots of hot water when you need it, is still the main criteria. Only Rheem mains pressure water heaters provide true multipoint operation.
TAB - And backing our first class products is a nationwide network of service to ensure your customers are never left out in the cold and the right technical advice from a professional and friendly sales team.

56. Typical Hot Water Usage Assumptions
Offices
Office peak period 60 minutes
Water per person litres
Area per person 10m2
Occupants
Gymnasium peak period 30 minutes
Water per person litres

57. Typical Hot Water Usage Assumptions
Food Service
Restaurant Peak Period – 2 hours
(temperature requirements)
Bistro per Meal 5.0 litres
Coffee Shop per Meal 3.5 litres
Auditorium per Meal 3.0 litres
Restaurant per Meal 5.5 litres
Takeaway Shop per Meal
Café per Meal litres
Hotel Kitchen per Meal 6.0 litres
Remember to consider commercial temperature requirements

58. Typical Hot Water Usage Assumptions
Apartments
Peak period 60 minutes
Bed-sitter litres
1 Bedroom litres
2 Bedroom litres
2 Bedroom w/en suite litres
3 Bedroom litres
3 Bedroom w/en suite litres
4 Bedroom litres
Penthouse litres

60. Typical Hot Water Usage Assumptions
Motel
Motel peak period 60 minutes
(Assume 2 people per room)
Shower 1 & 2 Star 20 litres /person
Shower 3 Star 25 litres /person
Shower 4 Star 30 litres /person
Shower 5 Star 45 litres /person
Shower Family/Spa 100 litres /person

61. Sizing example... Motel 100 rooms 5 star accommodation
Central electric plant
Moderate climate
Refer to commercial booklet...

62. Sizing example... Motel Showers = 50 x 2x 45 = 4,500L/1hr peak
Moderate climate = 50oC rise
Central electric plant:
5 x with 6 x 6kW elements

63. Hot Water Usage Assumptions
Nursing Home
Peak period 180 minutes
Bedpan 2.5 litres / bed
Shower 25 litres / bed
Cleaning water 10 litres / bed
Water per meal 5.5 litres
Laundry peak 300 minutes
Laundry (1.2kg per bed) 10 litres / kg

64. Selecting a water heating system
Usage profiles...Have they changed?
Peak Period in Litres/hr (e.g. 1hr)
Redundancy
Daily Load in Litres (Solar)...
Water delivery Temperatures
Plant Location - Indoor or Outdoor
Flue location & termination (room sealed?)
Circulation Systems...considerations

65. Sporting Facility Case Study Football Club - Tasmania

66. Sizing example... Local football club
15 shower 6 litres per minute (hot)
35 players inc umpires
Commercial heat pump system
Refer booklet...

67. Sizing example... Players and Umpires = 35 Shower time, say 10 mins
Peak duration = 30mins
Showers = 35 x 6L/min x 10 = 2,100 litres
Plant selection:
6 x storage tanks
1 x heat pump
ambient =244L/hr = 9hrs

68. SELECTION & SIZING... Diversity...
The difference between the maximum possible load on a water heating system if all outlets were in use at once and the “likely” load at any given time.
Example...
In a multi story accommodation building, only a predictable percentage of taps will be turned on at any given time, however it can be expected that all taps in a shower block of a sporting facility can be turned on at once and will require full heated water flow.

69. CFWH PLANT or STORAGE PLANT... What to consider?
SELECTION & SIZING
CFWH PLANT or STORAGE PLANT...
What to consider?
Footprint availability e.g. solar
Storage volume?
Maintenance/removal
Flow rates
Gas and water pressure
Fluing
Energy/fuel types

70. Commercial Installation and Design Requirements
Chapter 12
Commercial Installation and Design Requirements

71. 82oC Dead Leg Operation

72. Primary Pump Requirements
Used for Raypak, Solar and Heat Pump
Non return valve is not required after primary pump.
Spindle must be horizontal
Pump is not weather proof – must be covered
Isolation Valve
Primary Pump
Note: Pump shaft must be horizontal

73. NOT EQUA-FLOW PUMP SPINDLE VERTICAL
There were two main problems with the installation.
The pumps were installed with the spindle in the vertical orientation. This is a problem as these circulators are water cooled and rely on water to flow around the armature to keep the motor cool.
Installed as shown, an air pocket can exist which may lead to little or no flow and ultimately to pump failure.
This is often a hard message to get across, typically asking that the pump be installed with the shaft in the horizontal orientation. Most plumbers believe the pumps in this photo are installed horizontally. And whilst it is true the water flow is horizontal, the axis of the shaft is vertical.
As it turned out, the pump shaft was broken on one of the heat pumps which explains why the unit tripped out immediately - With no water flow, the heat pump cannot transfer the heat it generates, leading to high discharge pressure in the refrigerant.
2) Of more importance however is that the primary flow and return between the two banks was, in fact, not plumbed in equa-flow. The direction flow to the two branch headers is from bottom to top, or from closest tank to furthest tank.
The section of main header between the two branch headers is less than 300mm, yet, not plumbed in equaflow, is sufficient for water flow to favour one bank over the other. In this case, the closest bank.

74. Clearances

75. CASE STUDY #2 Rheem Commercial Water Heating Systems
Rheem Solar preheated, gas storage with a warm water system.

76. Commercial application – Large nursing home

77. Including a commercial laundry

78. Commercial kitchen

79. Commercial sinks

80. Electric boost on sink

81. Commercial dishwashing machine

82. Water must be at sanitizing temperature i.e. 77 degrees

83. The solar array
To achieve the energy rating for the building, solar has been chosen.
Often solar is a preferred method to achieve the energy reduction on site.
Note - north facing collectors
Note - the fall protection
The panels are set in two arrays of 8 collectors

84. 16 Rheem solar panels – ‘primary source of heat’ Each square meter(approx) of panel requires approx. 60 litres of solar storage tank capacity!

85. Collector connections

86. Primary flow and return to solar panels.

87. Temperature probe wired to solar controller and to the circulating pump. It works on a 8 degree C differential.

88. Automatic air eliminator on the return line out of the panels.

89. The return hot water line to storage tanks
Note the pipe insulation to reduce heat loss which is measured in ‘ watts ‘ per meter
Lagging must be UV resistant and meet AS3500.4

90. Four Rheem 430 litre solar storage cylinders ( 1720 litre capacity )

91. Rheem Gas boost mains pressure storage units.

92. Rheem Solar controller
Green light indication of system cycle.
Note - the solar return pipe work from the panels.

93. Primary flow and return from solar panels
Note – the isolation valves
Note – the pipe lagging

94. Commercial site assistance

95. THANK YOU FOR YOUR TIME TODAY
We trust you have enjoyed and benefited from this training course...