Installer’s Guide Important INFORMATION Read This Document First On completion, sign and leave with owner (Gas Post-Boost) Solar Water Heater Models: D2FN26, D2FL26, D3FN26, D3FL26, D4FN26, D4FL26 D2FN20, D2FL20 Installation by a licensed tradesperson and in accordance with: • AS/NZS 3500.
Installer’s Guide – (Gas Post-Boost) Solar Water Heater Installer’s Guide Rough In Diagram 1 Temperature Sensor 17 Read This Document First 2 Heat Trap/Non Return Valve 19 Safety Audit 2 PTR Valve 20 Removal of Existing Tank 3 Gas Connection 20 Placement of New Tank 3 GPO 21 Water Connections 4 Tempering Valve 22 Pipes – Important Points 5 Testing the Gas 22 Collectors – Alignment and Inclination Burner Test Point Pressure 23 7 Setting the Low Burner Rate 23 Collectors – I
Installer’s Guide – (Gas Post-Boost) Solar Water Heater Rough In Diagram Hot Return Gas Tempering Valve A D Flow B E Cold F C 100 House rebate level 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.
Installer’s Guide – (Gas Post-Boost) Solar Water Heater Installer’s Guide 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. Note: For an easier installation, please read this document before you begin.
Installer’s Guide – (Gas Post-Boost) Solar Water Heater 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.
Installer’s Guide – (Gas Post-Boost) Solar Water Heater Installer’s Guide Water Connections Step 5 • Using correct plumbing methods, connect the cold water pipe to the storage tank. Outlet to the heat exchanger water inlet • 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.
Installer’s Guide – (Gas Post-Boost) Solar Water Heater 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. Pipes must be DR brass and copper. Refer to AS/NZS 3500.4. • Flow and return lines must be installed as direct as possible between tank and collector.
Installer’s Guide – (Gas Post-Boost) Solar Water Heater Installer’s Guide • It is critical to stop any chance of an air lock developing, so ensure that: No pipes can be higher than the air bleed valve – no pipework is higher than the automatic air vent valve – 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 Pipes must have no high points that allow air to be trapped – the minimum
Installer’s Guide – (Gas Post-Boost) Solar Water Heater 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.
Installer’s Guide – (Gas Post-Boost) Solar Water Heater 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.
Installer’s Guide – (Gas Post-Boost) Solar Water Heater 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. Note: Ensure that the rail is parallel with the gutter. 500mm or greater Step 10 For Metal Roofs Only • Fix roofing screws through the mounting straps on both sides, using rubber grommets to prevent corrosion.
Installer’s Guide – (Gas Post-Boost) Solar Water Heater 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.
Installer’s Guide – (Gas Post-Boost) Solar Water Heater 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.
Installer’s Guide – (Gas Post-Boost) Solar Water Heater 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.
Installer’s Guide – (Gas Post-Boost) Solar Water Heater 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.
Installer’s Guide – (Gas Post-Boost) Solar Water Heater 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.
Installer’s Guide – (Gas Post-Boost) Solar Water Heater Installer’s Guide • 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. Anti-Frost Valve • The anti-frost valve comes in kit form and must be ordered seperately. • Connect the anti-frost valve to the top collector connection, on the opposite collector to where the thermowell/air bleed valve is installed.
Installer’s Guide – (Gas Post-Boost) Solar Water Heater Installer’s Guide Flashing Step 19 • As per local authority regulations, use an approved method of flashing on the flow and return lines, e.g. Dektite or lead collars. • Where flow and return lines penetrate the roof surface, the penetration must occur on the high side of the roof profile, not in the valley. • Seal the roof penetration with a flexible waterproof flashing.
Installer’s Guide – (Gas Post-Boost) Solar Water Heater 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. • Firmly secure the sensor using the cable securing clip. Collector temperature sensor Cable securing clip Sensor secured by clip Warning: Install the sensor cable such that it does not touch the roofing material surface.
Installer’s Guide – (Gas Post-Boost) Solar Water Heater Installer’s Guide Step 21 • Connect collector sensor cable to terminal block and secure to the timber or metal truss inside the roof cavity. • Connect extension collector sensor cable to junction block. • Do not run collector sensor cable in contact with the copper pipes as it may melt and cause signal interference. Terminal block secured to timber or metal truss inside roof cavity • Connect collector sensor cables as shown in diagram.
Installer’s Guide – (Gas Post-Boost) Solar Water Heater Installer’s Guide Heat Trap/Non Return Valve Step 22 • The hot water return pipe from the solar collector must run horizontally to the tank, to allow for a heat trap to be installed where the pipe enters the tank. • The heat trap prevents heat loss due to thermo-siphoning. Warning: This uninsulated pipe is very hot. Please Do Not Touch. • Flow and return lines should be neatly installed.
Installer’s Guide – (Gas Post-Boost) Solar Water Heater PTR Valve 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 – pose no risk of damage to the building or injury to persons. Plumb to waste to comply with AS/NZS 3500.4 and local plumbing codes Gas Connection Step 24 • Pipe sizes should be in accordance with AS5601/AG601.
Installer’s Guide – (Gas Post-Boost) Solar Water Heater Installer’s Guide • Before connecting to the gas service, purge any debris or air. Venting of purged gas shall be an area free of sources of ignition. • Close the isolating gas cock prior to connection of the appliance. • After connection, check all joints for leaks with an approved leak tester. GPO Step 25 • Install a Weatherproof GPO for the system. • This water heater is designed for connection to the following: 1.
Installer’s Guide – (Gas Post-Boost) Solar Water Heater Installer’s Guide Tempering Valve Step 26 • 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 Testing the Gas Step 27 Gas Fitter: • Test operation by lighting the water heater. Check that the gas inlet and test point pressures comply with the Data Plate on the side of the gas water heater.
Installer’s Guide – (Gas Post-Boost) Solar Water Heater Installer’s Guide Burner Test Point Pressure Step 28 Adjustments – Burner Test Point Pressure • The high and low test point pressures can be adjusted by doing the following: – Unscrew the four front cover retaining screws and remove the front cover. – Unscrew the blanking screw from the manometer test point (label 1) and connect the manometer to the test point.
Installer’s Guide – (Gas Post-Boost) Solar Water Heater Installer’s Guide • Close the hot water outlet, then repeat the above sequence to confirm the setting. • Close the hot water outlet. Setting the High Burner Rate Step 30 Setting the High Burner Rate • Set the Lower Dip Switch Block (2) for maximum output setting as shown right. • Open a hot water outlet fully in order to start combustion.
Installer’s Guide – (Gas Post-Boost) Solar Water Heater Commissioning Checklist Tick Task See Step No.
Installer’s Guide – (Gas Post-Boost) Solar Water Heater Installation Declaration Location of Installation: ........................................................................................... ............................................................................................................................... ............................................................................................................................... Tank Serial Number: ....................................
Installer’s Guide – (Gas Post-Boost) Solar Water Heater Components 11 10 7 4 1 9 2 6 5 3 8 System Components 1 PTR valve 2 Hot water outlet to house 3 Cold water inlet 4 Solar collector return 5 Gas inlet 6 Cold water outlet to solar collector 7 Solar collector sensor lead 8 Power supply cord 9 Heat trap (300mm recommended) 10 Anti-frost valve (if fitted) 11 Air bleed valve H4110 4110 Rev.
DETAIL C SCALE 1 : 10 10 DETAIL D 13 12 Installer’s Guide – (Gas Post-Boost) Solar Water Heater 11 Components 14 15 16 DETAIL E A B C E D 1 1 8 8 2 2 6 6 3 3 4 4 5 5 7 7 3 3 DETAIL DETAIL A A DETAIL DETAIL B B System Components 1 Air bleed 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 DETAIL DETAIL C C H4110 4110 Rev.
1 1 2 2 6 6 DETAIL A 8 8 3 3 4 Installer’s 4 – (Gas Post-Boost) Solar Water Heater Guide 5 5 Components 7 3 7 DETAIL A 9 3 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 DETAIL E 16 9 End Stop 1" conetite 10 Union 1" C × ½" C 11 24mm galvanised screw, self tapping 12 Bolt 13 Bracket - clamp 14
Installer’s Guide – (Gas Post-Boost) Solar Water Heater (Gas Post-Boost) Solar Water Heater Models: D2FN26, D2FL26, D3FN26, D3FL26, D4FN26, D4FL26 D2FN20, D2FL20 For Advice, Repairs And Service, Call: 1300 365 115 (Australia) 0800 729 389 (New Zealand) H4110 4110 Rev.
