Installer’s Guide IMPORTANT INFORMATION For an easier installation, please read this document before you begin. On completion, sign and leave with owner. Electric Boosted Solar Water Heater Models: 2F136S 2F136SD 3F136S 3F136SD 4F136S 4F136SD 2S136ED 3S136ED 4S136ED Installation by a licensed tradesperson and in accordance with: • AS/NZS 3500.
Electric Boosted Solar Installer’s Guide Rough In Diagram 1 Flashing 17 Model Numbers 2 Temperature Sensor 18 Safety Audit 3 Only if installing models 20 Removal of Existing Tank 4 Non Return Valve 21 Placement of New Tank 4 PTR Valve and Drain Down Line 22 Water Connections 5 GPO 23 Pipes – Important Points 6 Tempering Valve 24 Collectors – Alignment and Inclination Commissioning the System 24 8 Commissioning Checklist 25 Collectors – Important Points 9 Installation Dec
Electric Boosted Solar Rough In Diagram Hot Tempering Valve Return Drain to Waste Flow A B F E Cold C D 100 100 Approximate location of pipework. A tolerance of 25mm is acceptable to dimensions shown in table below. Note: Ensure pipes protrude horizontally from wall, and leave enough length of pipe to allow easy connections.
Electric Boosted Solar Installer’s Guide Model Numbers • Below is a list of model numbers: Model Capacity Number (L) Panel Management 2F136S 250 No 2F136SD 250 Yes 2S136ED 250 Yes 3F136S 315 No 3F136SD 315 Yes 3S136ED 315 Yes 4F136S 400 No 4F136SD 400 Yes 4S136ED 400 Yes Read This Document First Step 1 • This Installer’s Guide and the Owner’s Manual (also included in the product carton) contain important information about installation and use of this water heater.
Electric Boosted Solar Installer’s Guide Safety Audit Step 2 • Arrive at site, park vehicle as close as allowable to installation, and conduct a safety audit, also known as Work Method Statements (WMS) or Job Site Analysis (JSA). • Prior to working at heights, it is the responsibility of the installer to ensure that all practices are compliant with any relevant OH&S legislation. Note: Do not commence a job where the risks cannot be controlled. • Refer to local working at heights regulations.
Electric Boosted Solar Installer’s Guide Removal of Existing Tank Step 3 • The existing tank (if applicable) should be drained and removed in a responsible manner. Note: Do not drain on to grass or garden beds. Placement of New Tank Step 4 • Safely position new storage tank on a level surface in accordance with all plumbing and building regulations. Note: We recommend a plinth be installed under the water heater where the water heater is subjected to wet conditions.
Electric Boosted Solar Installer’s Guide Water Connections Step 5 • Using correct plumbing methods, connect the cold water pipe to the storage tank. • According to local regulations and the plumbing code, fit any and all valves that are necessary e.g. tempering valves, pressure limiting valves, line strainer, duo valves, cold water expansion valves etc. • We recommend the use of new valves for all Installation. Refer to plumbing code and/or local requirements.
Electric Boosted Solar Installer’s Guide Pipes – Important Points Step 6 Critical: Due to the high temperature imposed by solar heated water, all solar system pipes and fittings must be DR brass and copper, including collector compression fittings (as supplied). No plastic pipes or fittings. • Flow and return lines must be installed as direct as possible between tank and collector. • Pipes must be fully insulated with UV stabilized insulation suitable for solar working temperatures.
Electric Boosted Solar Installer’s Guide – flow and return pipes from the solar collectors to the water storage tank have a minimum of 5° continuous fall – pipes have no high points that allow air to be trapped – the minimum number of bends in the pipes are used. • Flow and return lines should be neatly installed and hidden inside the roof cavity if possible. • Take care when running flow and return lines through the roof, cladding and the eaves.
Electric Boosted Solar Installer’s Guide Collectors – Alignment and Inclination Step 7 Solar Collector Alignment • For the most efficient solar gain, the collectors must be aligned ±45° from true north (i.e. north west to north east). See Collector Orientation Compass below. Collector Orientation Compass Collector Orientation Compass True North True North A A NW NW 60° from true north 45° West West A. B.
Electric Boosted Solar Installer’s Guide Collectors – Important Points Step 8 • Inspect fittings after collectors are pressurized with water. Critical: Fittings must be as tight as possible. Warning: Only pressurize the the collectors for inspection and de-pressurize them immediately after inspection. Critical: Do not leave collectors pressurised for longer than 24 hours.
Electric Boosted Solar Installer’s Guide Collectors – Attaching to Roof Step 9 For Both Metal and Tiled Roofs • Locate the lower mounting rail a minimum of 500mm distance from the gutter, or greater if roof allows. 500mm or greater Note: Ensure that the rail is parallel with the gutter. Step 10 For Metal Roofs Only • Fix roofing screws through the mounting straps on both sides, using rubber grommets to prevent corrosion.
Electric Boosted Solar Installer’s Guide For Tiled Roofs Only • Carefully remove a roof tile and locate the nearest roof truss. • Attach the first (2 per mounting rail) stainless steel collector strap to the mounting rail. Collector Strap • Shape the collector strap over the tile and position over the roof truss. Note: A minimum of 3 roofing screws of 40mm length must be used to fix the collector strap to the truss. • Ensure collector strap is located on truss vertically.
Electric Boosted Solar Installer’s Guide Collectors – Attaching Fittings Step 12 All connections must be brass and all pipe work must be copper Hold fitting A while tightening nut B to prevent twisting the header pipe A B • Ensure fitting is fully engaged on to the header pipe. This is very important for correct connection. • To ensure leak proof installation, hold fitting A (see illustration in margin) while tightening nut B to prevent twisting the header pipe.
Electric Boosted Solar Installer’s Guide Step 13 • Secure the collectors to the mounting rail with the Z brackets, screws, nuts and bolts provided with the water heater. Step 14 • Repeat the process for the second collector. Note: Ensure this is done with full consideration to OH&S regulations. Care should be taken. Step 15 • Now position the top mounting rail and repeat the above steps for that rail.
Electric Boosted Solar Installer’s Guide Step 16 • Connect collector flow and return pipes to the collectors. ~40mm ~40mm • Ensure that you connect the solar flow (cold) and solar return (hot) pipes to the correct connections: – the solar flow (cold) pipe connects to the bottom of the collectors – the solar return (hot) pipe connects to the top of the collectors, diagonally opposite to the solar cold pipe connection.
Electric Boosted Solar Installer’s Guide 4 Way Union Assembly Step 17 • Using correct plumbing methods, install the 4 Way Union assembly and air bleed valve at the highest point in the system, at the top of the collector diagonally opposite the solar collector inlet pipe. Valve must be vertical and at highest point in system • The air bleed valve must stand vertically straight towards the sky. Note: If installed in top left/ bottom right of collector, then T should be reversed.
Electric Boosted Solar Installer’s Guide Anti-Frost Valve Step 18 • Consult the table right to determine if your system needs an anti-frost valve. • If your model does require frost protection, you must install an antifrost valve. • However, TWO anti-frost valves must be installed if you live in alpine areas or areas subject to extreme frost, such as the ACT and Snowy Mountain regions. • The anti-frost valve comes in kit form and must be ordered separately.
Electric Boosted Solar Installer’s Guide • Connect the anti-frost valve to the top collector connection, on the opposite collector to where the thermowell/air bleed valve is installed. Anti-Frost Valve • Ensure the valve is pointing down the collector towards the gutter, parallel to the collector.
Electric Boosted Solar Installer’s Guide Temperature Sensor Step 20 • Insert the end of the collector temperature sensor (supplied in collector rail kit) into the sensor dry well. • The sensor must be fully inserted and touch the end of the thermowell. Warning: Extreme care must be taken to not damage the sensor by pulling on collector temperature sensor. • Firmly secure the sensor cable using the cable securing clip.
Electric Boosted Solar Installer’s Guide Step 21 Only if installing models 2F136SD, 2S136ED 3F136SD, 3S136ED 4F136SD, 4S136ED • Align the pin positions carefully and press home the collector temperature sensor into the 20 metre collector temperature sensor cable. • Secure the connection by tightening the thumb screws. Warning: If the collector temperature sensor cable is exposed to atmosphere, you must insulate the cable from UV radiation damage. Warning: Sensor connector pins align one way only.
Electric Boosted Solar Installer’s Guide Only if installing models 2F136S 3F136S 4F136S • Connect collector sensor cable to a terminal block secured to the timber or metal truss inside the roof cavity. • If the terminal block cannot be located within the roof space, it must be enclosed within a waterproof junction box. Do not leave exposed. • Do not run collector sensor cable in contact with the copper pipes as it may melt and cause signal interference.
Electric Boosted Solar Installer’s Guide Non Return Valve Step 22 Cold Water Flow Direction • A non return valve is included with this water heater. Hot Water Flow Direction • We recommend fitting the non return valve at the solar return pipe connection. • Ensure the non return valve is installed so that the flow direction arrow faces the storage tank. Non return valve • All pipe work must be insulated. Storage tank FLOW RELIANCE Flow Direction Arrow H3163 025247 Rev.
Electric Boosted Solar Installer’s Guide PTR Valve and Drain Down Line Step 23 • Connect the PTR valve and plumb to waste to comply with AS/NZS 3500.4 and local plumbing codes. PTR valve • The pipe from the PTR valve must: – be easily seen Plumb to waste to comply with AS/NZS 3500.4 and local plumbing codes – pose no risk of damage to the building or injury to persons. • Plumb the drain down line to waste to comply with AS/NZS 3500.4 and local plumbing codes.
Electric Boosted Solar Installer’s Guide GPO Step 24 • Install a Weatherproof GPO for the system. • This water heater requires the following electrical connections: 1. Solar Pump Module – CONTINUOUS TARIFF must be used. 2. Supplementary Electrical Boost Element (3.6kW) – Off Peak recommended, single phase 240V A.C. supply. A 15 amp power supply is needed. • Separate continuous electrical power must be supplied to the Hotlogic controller. This ensures the protection features are enabled.
Electric Boosted Solar Installer’s Guide Tempering Valve Step 25 • Fit the solar tempering valve that is included with this water heater. Note: Any adjustment to the valve should be made according to the valve manufacturer’s recommendations. Hot Tempered Cold Commissioning the System Step 26 • When the power is turned on, the Hotlogic will go through initialisation: Sensors (red) and Power (green) status lights will alternate for 4 seconds.
Electric Boosted Solar Commissioning Checklist Tick Task See Step No.
Electric Boosted Solar Installation Declaration Location of Installation: ........................................................................................... ............................................................................................................................... ............................................................................................................................... Tank Serial Number: .............................................................. ......
Electric Boosted Solar Components a 2 5 3 6 4 1 7 8 System Components H3163 025247 Rev.
DETAIL C SCALE 1 : 10 10 DETAIL D Electric Boosted Solar Exploded Diagrams 13 14 12 11 15 16 DETAIL E A B C E D 1 1 System Components 8 8 2 2 6 6 3 3 4 4 5 5 3 3 7 7 DETAIL DETAIL A A DETAIL DETAIL B B 1 Automatic air vent valve 2 Bush 3 15mm female tee 4 Union 15mm M × 15mm C 5 Sensor dry well 6 Hex nipple 7 Union 1" C × ½" M 8 Union conetite 9 9 28 H3163 025247 Rev.
1 1 2 2 6 6 3 3 Electric Boosted DETAIL A 8 8 4 Solar 4 5 5 Exploded Diagrams 9 3 3 7 7 DETAIL A DETAIL A DETAIL B DETAIL B DETAIL C SCALE 1 : 10 13 9 9 DETAIL C DETAIL C SCALE 1 : 10 SCALE 1 : 10 13 13 11 12 12 10 10 DETAIL D DETAIL D 14 12 11 15 16 DETAIL E 11 System Components 14 15 14 16 DETAIL E 15 16 DETAIL E 9 End stop 1" conetite 10 Union 1" C × ½" C 11 24mm galvanised screw, self tapping 12 Bolt 13 Bracket - clamp 14 Solar heater rail 15
Electric Boosted Solar Installer’s Guide H3163 025247 Rev.
