CMD Solar CMD272 User guide

Owner & Installer Manual
CMD ELECTRIC BOOST SOLAR WATER HEATERS
Models
CMD272 CMD273
CMD342 CMD343
CMD452 CMD453
This water heater must be installed and serviced by a qualified trades person.
This guide must be left with homeowner.

CMD ELECTRIC BOOST SOLAR WATER HEATERS
Owner & Installer Manual
Models:
CMD272
CMD273
CMD342
CMD343
CMD452
CMD453
Congratulations for purchasing a high quality CMD Solar Water Heater,
designed in Australia for Australian conditions.
This water heater must be installed and serviced by a qualified person.
WARRANTY / SERVICE – Contact CMD Solar, PO Box 14486, Cairns. QLD. 4868
Australia or Telephone [phone].
Note to Installer: Following Installation, please:
1. Complete the installer checklist (page 28) and return to CMD Solar; and
2. Hand this manual to the homeowner for future reference. Note – the Warranty
page requires your signature for future reference.
THIS UNIT IS NOT SUITABLE FOR USE AS A POOL OR SPA HEATER
WARNING: Plumber - Note Carefully: Plastic pipe must not be used on a solar water heater
installation due to the effects of high water temperatures and pressures. USE COPPER PIPE
ONLY. All compression fittings must use brass or copper olives.
Notice to Victorian Customers from the Victorian Plumbing Industry Commission
This water heater must be installed by a licensed person as required by the Victorian Building Act 1993.
Only a licensed person will give you a Compliance Certificate, showing that the work complies with all relevant
Standards. Only a licensed person will have insurance protecting their workmanship for six years. Make sure you
use a licensed person to install this water heater and ask for your Compliance Certificate.
Installation and service must be performed by an authorised and qualified person. This water heater
must be installed in accordance with:
1. Manufacturer’s Installation Instructions
2. AS/NZS 3500.4 “National Plumbing & Drainage Code”
3. AS/NZS 3000 “Wiring Rules”
4. Relevant Occupational Health & Safety Regulations
5. Municipal Building Codes (including NZ Building Code if installed in New Zealand)
6. Any other relevant Local, State or Federal Statutory Regulations
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WARNING: Plumber – Note Carefully
•This page of brief instruction is to
be read in conjunction with other
plumbing and electrical installation
requirements contained within this
Installation Instruction and
Owner’s Manual
•All installation work must be
carried out by an appropriately
qualified Tradesperson/s.
•The installation must be performed
by Qualified and Authorised Persons
and comply with the requirements of
AS/NZS 3500.4, AS/NZS 3000, and
all local codes and regulatory
authority requirements.
•It is recommended the solar
storage tank be installed at ground
or floor level. The water heater
must stand vertically upright.
•This Water Heater Is Not Suitable
For Pool Heating
•Section 4 “Solar Collector Installation”
must be read and understood prior to
installation of collectors to roof top.
•Plastic pipe must not be used on a
solar water heater installation due to
the effects of high water temperatures
and pressures. USE COPPER PIPE
ONLY. All compression fittings must
use brass or copper olives.
•Hot and cold copper pipes to and
from the collectors must be
completely insulated with a suitably
temperature rated insulation that is
UV rated and weatherproof with
minimum thickness of 19mm.
•Valves and fittings supplied with this
water heater are supplied with
insulation covers which must be fitted
as part of the solar installation.
Failure to fully insulate pipework and
fittings increases the risk of freeze
damage and will void warranty
•The maximum height of solar flow
and return pipes must be where
these pipes enter and exit the solar
collectors to avoid the possibility of
air locks in the solar installation.
•The maximum length of the copper
tube from the solar pump to the
collectors is reliant on mains pressure
(minimum 200kPa) and the number of
bends and fittings in the run. As a
guide, for DN15 copper pipe, the
maximum length should not exceed
20 metres for 2 collectors and 15
metres for 3 collectors. Note that
maximum pipe lengths are based
on minimal bends.
•Valves and fittings supplied with
this solar water heater form part of
the installation and must be fitted in
accordance with this manual.
•The pump and controller assembly
is fitted with an AVG Flow Meter
FM15-1.4. This flow meter is pre-
set to 1.0L/Min for optimal
performance and must not be
adjusted at time of installation.
•Working on roofs should always be
considered a hazardous activity; by
law you must observe certain
minimum safety precautions. These
safety precautions are outlined in the
Work Cover Code of practice “Safe
work on roofs” Part 1 and 2 and in
the Occupation Health and Safety
Act 2011.
•A 240V 50 Hz 10 Amp power
outlet, connected to continuous
tariff, is required for the pump and
controller and must be installed by
a licensed Electrician. This may be
a weatherproof outlet depending on
location.
•The responsibility for all OH&S
issues relating to the installation of
the system resides with the
installing tradesperson/s.
•The system should only be connected
to water supply of acceptable quality
otherwise the warranty provided for the
system may become void. Refer to
Warranty conditions and section
entitled “Water Supply” contained
within this manual.
•Frost Protection Kits (CMD -FRK)
are available from CMD Solar and
should be fitted in areas that
experience frost or freezing
conditions (below 5°C). See detail
herein entitled “Frost Protection Kits”.
•The PTR valves and the Cold Water
Expansion valve must be fitted with
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a drain to legal discharge points
where the water discharge will be
clear of any paved areas and will
not cause damage or injury. Do not
block or seal these drain lines.
•This water heater is intended to be
installed as a fixed appliance and
must be installed on a hard, level
surface. If installation is to be in a
wet area or a concrete floor, ensure
the water heater is mounted on a
suitable and substantial raised
base (eg: wood or concrete)
•The use of a self-draining safe-tray
may be required in accordance with
the provisions of AS/NZS 3500.4,
Clause 5.4.2.
•Please refer any queries relating to
the design and/or installation of
CMD Solar products or
components to the Technical
Services Department in writing.
•Rough-In Dimensions for CMD
Solar Tanks as follows:
CMD Series Model Number
Model
Units
CMD272
CMD273
CMD342
CMD343
CMD452
CMD453
Water Heater Stored
L
270
270
340
340
450
450
Capacity
Number of Solar Collectors
#
2
3
2
3
2
3
Tank Height
mm
1408
1408
1711
1711
1733
1733
Overall Diameter
mm
648
648
648
648
730
730
Height to Cold Water Inlet
mm
82
82
82
82
83
83
(from ground)
Height to Hot Water Outlet
mm
1169
1169
1472
1472
1473
1473
(from ground)
Tempered Water Outlet
mm
540
540
695
695
695
695
(midway between hot & cold))
Flow to Solar Collectors (from
mm
650
650
650
650
650
650
ground)
Drain to Waste (from ground)
mm
82
82
82
82
82
82
Return from Solar Collectors
mm
569
569
687
687
673
673
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DOCUMENT CONTENT
PART A - HOUSEHOLDER GUIDE
Operation
Important Information
5
Instructions and Maintenance
7
Electric Boost
Safety valves and Frost Protection valves
Maintenance
Householder fault finding
PART B - INSTALLERS GUIDE
Solar Tank Installation
10
Solar Controller and Pump operation
Mounting Kit
Solar Collector Installation
19
Frost Protection Kits (CMD-FRK)
Filling & commissioning the installed solar water heater
22
PART C – PRODUCT WARRANTY
25
Installation Check List (Please complete and return to CMD Solar)
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PART A – HOUSEHOLDER GUIDE
IMPORTANT INFORMATION
CMD Solar Water Heater Models have roof mounted solar panels connected to a ground mounted solar
storage tank and/or boosting heater. The solar input is harvested with a circulation pump controlled by an
electronic temperature differential controller.
1. It is important for the householder to become
familiar with the contents of this manual to
ensure safety and to optimise the performance
and longevity of this water heater.
2. This water heater is designed for use by a
single family domestic dwelling to provide
hot potable water.
3. Do not operate this water heater until all
operating instructions have been read and
understood by the homeowner.
4. These water heaters are NOT recommended
for connection to Bore Water Supplies and
warranty may be void in such installations.
5. A properly drained safe tray must be used
where property damage could occur from
water spillage (see AS3500.4.2). Ensure
this safe tray does not become blocked.
6. If you live in an area that experiences frost in
winter months or freezing occurs (below 5°C),
please ask your installer to install a CMD Solar
Frost Protection Kit (CMD-FRK) to assist with
preventing damage to panels. Note that this is a
secondary frost protection mechanism as the
solar water heater is equipped with an electronic
freeze control system that will pump water from
the storage tank through the collectors when the
temperature of the water in the collectors
reduces to 3° Celsius. This process will cease
when the water temperature in the collectors
rises to 5° Celsius and may repeat while the
temperature is low. It is imperative that the
power supply to the pump and controller is not
interrupted or turned off. Damage to the panels
caused by freeze conditions which occur below
5° Celsius when the power is interrupted or
turned off is not covered by warranty.
7. Do not activate the power supply to this
water heater unless the cylinder is filled with
water and a satisfactory Megger reading is
obtained by a qualified tradesperson.
8. Do not block or seal the Pressure &
Temperature Relief (PTR) safety valve or drain
pipe. Never fit a PTR or Expansion Control
Valve (ECV) with a pressure rating greater than
that indicated on the product-rating label.
9. The water heater warranty can become void
if relief valves or other safety devices are
tampered with or if the installation is not in
accordance with these instructions.
10. Do not place any articles, chemicals or
flammable materials on or near the water
heater
11. Removal of access covers will expose 240V
wiring. Do not remove the terminal box cover or
gain access to this water heater unless the
power supply has been effectively disconnected
by a qualified tradesperson only.
12. Do not operate this water heater with the
terminal box cover removed or loose.
13. This water heater is not intended to be
operated or adjusted by young children or
infirm persons. Young children must be
supervised to ensure they do not interfere
with the water heater.
14. This water heater can deliver water at
temperatures which can cause scolding.
Check the water temperature before use,
such as when entering a shower or filling
a bath or basin.
15. Take care not to touch copper pipes
connected to the water heater as high
temperatures in the pipework may be present.
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16. The water heater pump / controller must be
plugged into a 240V 50Hz 10Amp electrical
outlet which may be required to be weatherproof
depending on location. Take care not to touch
the power plug with wet hands.
17. If the power supply cord, plug or electrical
conduit to the water heater is damaged, it
must be replaced by a qualified
tradesperson in order to avoid a hazard.
The power supply cord and plug must be
replaced with a genuine replacement part
available from CMD Solar Pty Ltd.
18. In times of low solar energy contribution, water
stored in the solar tank can be heated by an
electric booster consisting of an element and an
automatic thermostat located on the tank. It is
recommended that the electric boost be
connected to a continuous electrical supply;
however, if connected to an Off Peak Tariff, a
night rate tariff is NOT RECOMMENDED. Note
that the thermostat must only be adjusted by a
qualified tradesperson.
19. DANGER: FAILURE TO OPERATE THE
RELIEF VALVE EASING GEAR AT LEAST
ONCE EVERY SIX MONTHS MAY RESULT
IN THE WATER HEATER RUPTURING. IT IS
IMPORTANT THAT THE EASING GEAR ON
THE VALVE BE RAISED AND LOWERED
VERY GENTLY. FAILURE TO DO SO MAY
RESULT IN THE WATER HEATER
CYLINDER FAILING, OR UNDER CERTAIN
CIRCUMSTANCES, RUPTURING
VIOLENTLY.
20. IT IS NORMAL FOR SMALL QUANTITIES
OF WATER (UP TO AROUND 15 LITRES IN
A 24 HOUR PERIOD) TO BE RELEASED BY
THE ECV OR PTR VALVE IN THE HEATING
CYCLE. CONTINUOUS LEAKAGE OF
WATER FROM THE VALVE MAY INDICATE
A PROBLEM. IF THE VALVE DOES NOT
DISCHARGE WATER WHEN THE
EASING GEAR IS OPERATED, OR DOES
NOT SEAL AGAIN, A SERVICE CALL
SHOULD BE MADE WITHOUT DELAY.
THE PTR VALVE IS NOT SERVICABLE.
21. THE THERMOSTAT IN THE ELECTRIC
BOOST IS EQUIPPED WITH AN OVER-
TEMPERATURE CUT-OUT. IF THE OVER
TEMPERATURE CUT-OUT ACTIVATES,
IT MUST NOT BE RESET AND THE
WATER HEATER MUST BE SERVICED
BY AN AUTHORISED PERSON.
22. The amount of water heated by the electric
boost is as follows:
a. CMD270 – 121 Litres
b. CMD340 – 153 Litres
c. CMD450 – 202 litres
23. WARNING: IF THE SOLAR SYSTEM IS
NOT USED FOR TWO WEEKS OR MORE,
A QUANTITY OF HYDROGEN GAS,
WHICH IS HIGHLY FLAMMABLE, MAY
ACCUMULATE IN THE SYSTEM. THIS
MAY BE OBSERVED AS VIOLENT
'SPLUTTERING' WHEN A HOT TAP IS
OPENED INITIALLY. TO DISSIPATE THIS
GAS SAFELY, IT IS RECOMMENDED
THAT A HOT TAP BE TURNED ON FOR
SEVERAL MINUTES AT A SINK, BASIN
OR BATH BUT NOT AT A DISHWASHER,
CLOTHES WASHER OR OTHER
APPLIANCE. DURING THIS PROCEDURE
THERE MUST BE NO SMOKING, OPEN
FLAME, OR ANY ELECTRICAL
APPLIANCE OPERATING NEARBY. IF
HYDROGEN HAS FORMED AND IS
DISCHARGED THROUGH THE TAP IT
WILL PROBABLY MAKE A SOUND
SIMILAR TO AIR ESCAPING.
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INSTRUCTIONS AND MAINTENANCE
Warning: This appliance not intended for use
by persons (including children) with reduced
physical, sensory or mental capabilities, or lack
of experience and knowledge.
Children should be supervised by a person
responsible for their safety to ensure that they
do not play with the appliance.
Operation
Ensure that your solar hot water system is filled
with water at all times. If drained at any time
then the solar panels should be covered as
prolonged exposure to sun without a supply of
coolant water may cause damage.
DO NOT turn off the ELECTRICITY or
WATER SUPPLY to the Solar Controller and
Pump.
The pump and controller should be connected
to a 240V 50 Hz power supply at all times i.e.
throughout the entire year. Even in winter it is
important that the controller is able to turn the
pump ON during cold conditions to prevent
panel damage due to freezing.
The controller is a differential thermostat which
turns the pump on and off in response to
temperature signals received from a hot
sensor, located in the solar panels on the roof,
and a cold sensor located in a pocket at the
base of the solar storage tank. The sensor
cables must not be damaged or cut.
IS NOT RECOMMENDED as the available
power may not be sufficient during inclement
weather and you may run short of hot water
during these periods.
The electric booster heating element is
controlled by an automatic electric thermostat.
The thermostat and element are mounted on
the solar storage tank. The boosted water
temperature is automatically controlled to the
thermostat setting when the booster heating
element switch is in the on position.
The thermostat is tradesperson adjustable. It
has a minimum temperature setting of 60ºC
and a recommended maximum temperature
setting of 75ºC. It must only be adjusted by an
authorised person. Automatic safety controls
are fitted to the water heater to provide safe
and efficient operation.
The electric booster element will automatically
heat the water in the upper section of the tank.
An isolating switch can be installed which will
allow manual control however be aware that if
this switch is turned off, a shortage of hot water
can occur during periods of low solar radiation
and water temperatures below 600C can give
rise to bacterial breeding including Legionella
bacteria. Australian Standards therefore
stipulate that this switch be left continuously on
and the automatic thermostat be set to a
minimum temperature of 600C.
Electric Boost
Water stored in the storage tank is heated
automatically by an electric booster element which
is controlled by an automatic thermostat. The
booster element heats the water during very cloudy
or rainy weather, during the winter months, or
during periods of unusually high demand. Although
it is recommended to connect the electric element
to continuous power, it can be connected to an off
peak tariff but NIGHT RATE OFF PEAK
Safety Valves and Frost Protection
Valves
See Solar Layout Drawings to identify these
valves.
Never fit a Pressure and Temperature Relief
Valve (PTR) or Expansion Control Valve (ECV)
with a pressure rating greater than that
indicated on the product-rating label.
It is normal for the ECV fitted to the cold mains
water supply to dribble as either the solar panels
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or water heater heats water within the system.
The expansion valve releases water from the
system so that the system will be maintained at
its design pressure.
The PTR valve fitted to the solar storage tank
should not dribble during normal operation as
they are fitted as safety valves. If the PTR
valve dribbles, operate the easing mechanism
on the valve and allow water to discharge
through the drain pipe. Remember this water
may be HOT and ensure that the discharge
does not come in contact with anyone. Release
the easing lever SLOWLY and reseat the
valve. If the valve is still dribbling 24 hours after
reseating contact CMD Solar.
If no water is drawn from the system for
several days in hot weather conditions the ECV
on the solar storage tank may open and freely
discharge water in order to discard the excess
solar energy collected. This should happen
only infrequently but it is considered normal
operation.
If the PTR valve on the storage water heater
freely discharges hot water and steam, turn off
the electricity supply to the storage unit and
contact CMD Solar Service.
IMPORTANT: Relief valves should be checked
to be in sound working order in intervals not
exceeding 5 years, or more regularly in areas
subject to water deposits. Checking should
include operation of the relief valve to remove
any lime deposits. The PTR valve should be
replaced every 5 years.
Frost Protection Valves
Frost protection valve kits (Kit Code CMD-FRK)
are available from CMD Solar and should be
fitted to collectors where solar water heaters are
installed in frost prone areas. Where fitted in frost
areas, one frost protection valve is fitted to the
bottom of each panel (2 off per kit) and must be
pointing downwards towards the guttering. It is
normal for these valves to dribble during very
cold weather. Failure to install frost protection kits
in frost prone areas may void warranty should
damage to collectors occur.
Maintenance
Periodic - as needed (minimum six-
monthly) by Owner
•Prune or remove trees or shrubs that
shade the solar panels. For effective
operation the panels should be in full
sunlight between at least 9am and 3pm in
both summer and winter. Panels which
are shaded will not function correctly.
•Shading from newly erected buildings
also needs to be considered and panels
relocated if necessary.
•Check cleanliness of solar panel glass.
Clean if covered in dust, grime, leaves
or other build up. The panels may be
cleaned with water and detergent only
when the panels are cool, for example
at the beginning or end of the day or
during overcast conditions. If there has
been little rain or if the panel is located
in a dusty location it may be necessary
to clean the panels more frequently.
Note. CMD Solar does not cover
cracked or broken glass in collectors.
This may be covered by your household
insurance policy.
•Draining and flushing the water heaters
and panels must be undertaken by an
authorised service agent or plumber and
not by the householder due to possible
high water temperatures.
WARNING!
Working on roofs should always be
considered a hazardous activity; by law you
must observe certain minimum safety
precautions. These safety precautions are
outlined in the Work Cover Code of practice
"Safe work on roofs" Part 1 and 2 and in the
Occupation Health and Safety Act 2011.
•Flush and reseat the PTR valve and cold
water pressure ECV. This is done by
raising the release lever, allowing water to
flow freely and then lowering the lever
slowly and allowing the valve to reseat
(this is to remove lime deposits and to
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verify that the valve is not blocked).
Remember that the water discharging
from the valves may be HOT and should
not be permitted to come into contact
with anyone.
Annual Service – By authorised Serviceman
CMD Solar recommends that the Solar System
be serviced annually. The components or parts
may not be covered by CMD Solar warranty if
damage to the system or parts is caused by
the lack of regular maintenance.
•It is important that the PTR valves, the
cold water ECV and frost valves be
replaced every 5 years.
•The protective anode fitted to the solar
storage tank should be checked and
replaced if necessary at suitable intervals
depending on water quality, but no later
than every 5 years. It is recommended
that CMD Solar be contacted regarding a
suitable replacement anode.
•Changing the anode at regular intervals
should extend the working life of the
storage tank.
Householder Fault Finding
Prior to contacting CMD Solar for a service
call, there are some basic checks that can be
made by the householder. Please note that
you will be charged by a CMD Solar where
the fault is not related to manufacture or
failure of a part or out of warranty.
Not Enough or No Hot Water?
If the collectors are shade-free, the weather
is fine and warm and the solar storage tank
contents are definitely cold, the circulating
pump should operate and the return
connection become warm or hot. Please
note that the pump is almost silent and
vibration-free in operation. Check the
following:
1. Is there 240 volts at the power
outlet? Is there a blown circuit
breaker, RCD or fuse?
2. Is the pump plugged into the
controller? The pump and controller
are located under the plastic terminal
box cover on the storage tank.
3. Are the sensors plugged into the
correct sockets in the controller?
4. Are the sensors correctly fitted into
the sensor pockets on the tank and
collectors?
5. Has all air been purged from the
system?
6. Has your hot water usage changed?
7. Is the thermostat setting sufficient to
recover from hot water usage?
Pressure and Temperature Relief (PTR) Valve
Leaking?
It is usual for a pressure and temperature relief
valve to release a small quantity of water during
the heating cycle; up to around 15 litres over a 24
hour period is acceptable. If the discharge is
noticeably more than this, contact CMD Solar.
Cold Expansion Control Valve (ECV) Leaking?
The ECV may discharge a small amount of
cold water to prevent the PTR valve from
potentially discharging water that has been
heated, thereby saving energy. This is normal.
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PART B – INSTALLERS GUIDE
SOLAR TANK INSTALLATION
Installer – Please Note The Following
1. This Water Heater Is Not Suitable
For Pool Heating
2. All work associated with the installation
of this water heater must be carried out
by properly trained and accredited
tradespersons and be strictly in
accordance with relevant Australian
Standards including AS/NZS 3500.4 and
AS/NZS 3000, local, State and Federal
Regulations including, but not limited to,
Occupational Health, Safety and
Welfare Regulations (OH&S)
3. If this installation is taking place in an
area subject to frost conditions or
freezing conditions (below 5°
Celsius), the CMD Solar CMD-FRK
Frost protection Kit containing two
frost protection valves should be
installed on the panels.
The solar water heater tank should be
installed in close proximity to the most
frequently used hot water outlet and its
position chosen with safety and service in
mind. Other considerations include the
position of the solar tank with respect to the
solar collectors as heat loss can occur in the
pipes, and copper pipe length should not
exceed 20 metres (for 2 panel systems).
Also consider servicing (the water heater
must be accessible without the use of a
ladder or scaffold and the anode, PTR
valve, thermostat and booster element must
be able to be removed) and nameplate data
must be able to be read. Other
considerations include:
●Electrical supply requirements for the
pump and controller
●Weight of the heater filled with water
●Dimensions of the heater and size
and location of connection points
●Water supply pressure limitations
Clearance
Allow adequate room to work with tools. A
minimum of 25mm clearance around the
water heater is required. An additional
30mm is required for relief valve removal,
80mm for access cover removal and
400mm for element removal. You should
be able to read the information on the
rating plate and all informative labelling.
Adequate provision must be made to
dispose of any water escaping from
heater or adjacent plumbing that might
result in damage to property.
The water heater must be connected in
such a way that:
•Space is allowed for the removal of
the heating element.
•Space is allowed for the removal
and replacement of the anode.
•The pump is accessible for servicing.
•Complete removal of the unit can
be easily effected if necessary
Confined Spaces
If the thermostat fails the unit may
produce excessive steam.
It is strongly recommended that the heater
should be installed in a well-ventilated
space to avoid condensation build up.
If installed in confined areas, make
provision for Service Access.
Vent safely to open air and carry hot
water overflow pipework to drain.
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Foundation
To ensure adequate ventilation, position
the unit on an approved support base to
Attention is drawn to the weight of the
water heater tank when full (up to
approximately 600kg depending on
model) and the installer should ensure
the base and footings are substantial
enough to avoid subsidence etc.
Water Supply
If the water heater is installed to a tank
water supply, a minimum 200kPa water
supply pressure must be available or a
pressure pump must be installed to
allow operation of the system
This water heater has been constructed to
meet water quality conditions in most
Australian water supply locations.
However, harsh water quality does exist in
some locations and, if in doubt, contact
your local council or water supplier. Only
potable water should be used in this water
heater. If you are unsure of the water
chemistry in your area, you may find
additional information by contacting your
local water supply authority.
Anode: The anode in your water heater is
sacrificial, however it is designed to protect
the vitreous enamel lined cylinder in most
public reticulated water supplies for five
years after which time it should be
replaced as part of annual service.
However it is important to understand that
many water supplies can exhibit chemical
qualities that are not suitable for the
standard anode supplied with this water
heater. Where the Total Dissolved Solids
(TDS) is greater than 600mg/L or less than
40mg/L, the installed anode may be
unsuitable for use to protect your water
heater. In these circumstances, a plumber
or authorised service person should be
contacted to fit the correct anode.
prevent water ponding around the base
of the water heater tank.
Different anodes are available in these
situations to protect the vitreous
enamel lined tank. Please note that
warranty becomes void if the TDS
value exceeds 2500 mg/L.
The Saturation Index is a measure of the
water’s corrosiveness. Corrosion may
result in early failure of copper parts such
as solar collectors and copper sheathed
electric components. Water is considered
corrosive should the saturation index be
below -1.0. Scaling, which is the build-up
of calcium carbonate in the tank, can occur
where the Saturation Index is above +0.4.
In these instances where the Saturation
Index exceeds +0.4, ensure the expansion
control valve (ECV) is fitted according to
instructions contained within this manual.
Should the saturation Index exceed +0.8, a
low Watts density element must be fitted.
Water heaters installed in locations
where incorrect anodes are fitted due
to high or low TDS or where the water
is corrosive or considered scaling will
not be covered by this warranty.
Pipework, Valves and Fittings
Valves and fittings for connecting the
solar panels on the roof and the storage
tank are supplied.
The temperature of the water at the outlet
connection on the panels may reach
150°C or more and therefore only copper
pipe can be used between the panels,
storage tank and boosting heater.
Class B copper pipe should be used and
the runs should be as short as possible
to reduce heat losses.
The pipes MUST be lagged using thick-
walled foam of at least 19mm thickness,
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RO.6 and should be weather proofed
and UV stabilized.
If insulation is not UV stabilized, it must
be protected by a suitable UV resistant
paint.
Pre-formed insulation gloves and cable
ties are provided to insulate fittings. The
areas to be insulated are: inlet pipework
fittings to the panel, the outlet pipework
fittings, and on 2 & 3 panel systems the
joiners between the panels. These
fittings must be insulated to protect them
from freezing in cold areas. Warranty
may be void if not fitted. Refer to the
Solar Panel Layout drawings for location
and installation detail. Water may drip
from the pipe of the pressure-relief
device. This pipe must be left open to
the atmosphere
Solar Controller and Pump Operation
The Aestiva Solar Controller and Grundfos Pump supplied with this Solar Water Heater is
enclosed within a UV Resistant ABS plastic enclosure which is designed to house these
components and protect them from harmful UV radiation. This Pump/Controller assembly is
fitted onto the side of the tank directly above the Cold Water Inlet using stainless steel screws
provided in the CMD-Ground kit.
The control unit turns the pump on and off in response to temperature signals received from a
hot sensor located in the solar panel's hot water outlet fitting on the roof top, and a cold
sensor located at the entry to the storage tank. It is crucial that these sensors and leads are
not damaged or cut during or subsequent to installation.
Note that after 2 hours of operation of the pump, it will automatically switch off for five minutes
before resuming to prevent any possible cavitation of the pump.
The controller incorporates an LCD display that can easily be read to identify the various
sensor temperatures and error modes (shown in bold below).
Temperature Probe Turn On (Pump On Temp) and Turn Off (Pump Off Temp) temperatures
are as follows:
“Pump On Temp”: 8°C Differential (ΔT) between Panel Sensor temperature and Tank
Temperature Sensor (panel sensor hotter than tank sensor).
“Pump Off Temp”: 2°C Differential (ΔT) between Panel Sensor temperature and Tank
Temperature Sensor.
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The Controller will also prevent the pump from circulating water to the panels should the tank
temperature, measured at the Tank Temperature Sensor become too high. Temperature
setting to protect the tank is as follows:
“Top Out Temp”: 75°C measured at the tank mounted sensor will de-activate the pump to
protect the vitreous lining of the steel tank.
Freeze protection is also a standard function of the controller. Where the panel temperature
measured at the Panel Temperature Sensor approaches freezing, the pump will activate and
circulate heated tank water to the panels until the panel temperature rises and prevents
against frost damage. Temperature settings are as follows:
“Protect On Temp”: 3°C measured at the roof top sensor will activate the pump.
“Protect Off Temp”: 5°C measured at the roof top sensor will de-activate the pump
Note that when cold conditions prevail overnight, this frost protect mechanism may switch the
pump on and off several times to protect the panels, potentially resulting in reduced hot water
being available in the morning.
The sensor leads are extra low voltage conduit and secured with conduit saddles to ensure
they remain undamaged.
but must to be encased in 20mm PVC The hot sensor (long lead) should be dry and pushed
to the bottom of the long hot sensor pocket on the top left hand corner of the solar panel. A
clip on the sensor probe port is provided to secure the sensor lead.
The cold sensor (short lead) is to be fitted dry into the short cold water sensor pocket at the
cold water entry to the solar storage tank. Refer to the respective layout diagram supplied
with the Solar Storage Tank.
Controller Error Codes
The LCD display will normally display the Lower “L” tank sensor temperature and the Roof-
top “R” sensor temperature as follows:
¤
¤
◎
◎
Sensor'Temp:
L:001
R:001
◎
◎
¤
¤
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In event of a tank sensor failure, an error code will be shown on the display and 4 LED lights
(2 green and 2 red) will become visible as follows:
¤
¤
◎
◎
Sensor'Temp:
L:Err
R:001
◎
◎
¤
¤
Similarly, when errors occur on roof top or both sensors, the display will indicate as follows:
¤
¤
◎
◎
Sensor'Temp:
L:Err
R:Err
◎
◎
¤
¤
Basic Controller Functions
Indicator Pump On
Switch on Pump manually
and used in Program Mode
Program mode (see below)
and used in Program Mode
Indicator – Frost Protection On
Scroll Settings in Program
Mode
Used in Program Mode –
see below
Indicator - Top Out Temp
Reached
Indicator – Pump in Manual
Mode
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Programming the Controller
Note: the controller is pre-set at the factory to operate at optimal settings for most
situations. Any access to the program mode and change to factory settings must be
done by a qualified and authorised person. The range of settings available are as
follows:
Factory Setting
Minimum Setting
Maximum Setting
SETTING
(°C)
(°C)
(°C)
Pump On Temp
8
0
90
Pump Off Temp
2
0
90
Top Out Temp
75
0
90
Protect On Temp
3
0
90
Protect Off Temp
5
0
90
Access to the Program Mode is as follows:
1. Press and hold down “Next” and “Program” keys
2. Then, press and hold down “(Prog Mode)” key whilst holding down the “Next” and
“Program” keys for approximately 3 seconds. Red and Green LED’s will flash.
a. “Pump On Temp” appears – Value = 008 (factory pre-set). Remove fingers from
keys.
b. “Pump On Temp” can be increased or decreased using the “+” and “-“ buttons
c. Following any changes, the program may either be exited by pressing and holding
down the “Program” key for around 3 seconds or access next Setting “Pump Off
Temp” by pressing the “Next” key. The same method applies to accessing all five
settings available.
d. When all settings are set to desired level, press and hold the “Program” key for
around 3 seconds. All settings will be retained and “Set Finish Rebooting” will
briefly appear before returning to sensor temperatures.
MANUAL PUMP Key
When pressed (not in Program Mode), this key activates the pump manually, over-riding the
pre-set settings of the controller. “Pump” and “Manual Pump” LED’s will glow. If left on, the
pump will run for 2 hours and then switch back to PUMP AUTO.
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DO NOT turn off the ELECTRICITY or WATER SUPPLY to the Solar Controller and Pump.
Note: Panel warranty does not cover damage caused by frost or freezing where:
•the solar controller and or pump are not operating;
•frost protection valves have not been fitted;
•the mains water supply to the system has been turned off; or
•the mains cold water supply to the system freezes because it is not insulated.
Mounting Kits
Note: The copper pipework and specified insulation is to be supplied and fitted by the
installer. The solar water heater is equipped with two Plumbing Mounting Kits as follows:
1. CMD Ground Kit –Ground Mounting Kit supplied as part of the Solar Water Heater Tank
installation package.
2. CMD Roof Kit –Roof Mounting Kit supplied as part of the Solar Collector installation package.
Both kits are designed to provide the installing plumber with all parts required for a normal
installation. Additional components required for installation are to be supplied by the installing
plumber.
The following items are contained within the CMD Ground Kit. Refer to section below entitled
“Solar Collector Installation” regarding componentry for CMD Roof Kit.
The CMD Ground Kit Contains:
•Brassware and Valves (Excluding PTR Valve which is contained in the water heater
tank packaging)
•Installation Manual including commissioning check list to be completed and retained as
a record by CMD Solar.
•Pump and Controller.
•Stainless steel screws for mounting pump and controller.
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CMD Ground Kit – Ground Mounting Kit Components
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CMD-Ground Kit – Installation Diagram
SOLAR COLLECTOR INSTALLATION
To achieve maximum solar performance, the solar collectors should be installed facing as close to
North as possible. The following are guidelines for the installation of solar collectors:
•Solar collectors should be positioned to face the equator which is North facing in Australia.
The further away from North, the greater the loss in solar efficiency.
•The inclination of the solar collectors should be within 10% either side of the local latitude
angle. For example, the latitude of Brisbane is 270South so the inclination of the solar
collectors should be approximately 24 to 30 degrees.
•Solar collectors should be free from shading by trees (should be checked regularly) or
nearby buildings or other structures.
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