Dux 2F136S User manual

Owner’s Manual
Electric Boosted Solar Water Heater
Specications and materials may change without notice.
Effective for Dux electric boosted solar water heaters manufactured and sold after 1 January 2012.
Carefully remove all packaging and
transit protection from the heater before
installation. Dispose of the packaging
responsibly using re-cycling facilities
where they exist.
Installation Details
Owner’s Information
Warranty
H3161 025248 Rev. D
Models: 2F136S
2F136SD
3F136S
3F136SD
4F136S
4F136SD
For advice, repairs and service, call:
1300 365 115 (Australia)
0800 729 389 (New Zealand)

Owner’s Manual – Dux Electric Boosted Solar
H3161 025248 Rev. D
Welcome To Dux Hot Water 1
Installation of the Tank 2
Plumbing Connections 4
Specications 7
Installation of Collectors 8
Plumbing Connections to
Collectors 11
Temperature Sensor 13
Panel Management 15
Electrical Connections 17
Hotlogic Controller 19
Owner’s Information 21
Troubleshooting 25
Warranty 27
Other Information 30
Contents
© Dux Manufacturing Limited 2012. All rights reserved.

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H3161 025248 Rev. D
Welcome To Dux Hot Water
Your decision to purchase a Dux Hot
Water system will reward you for many
years to come.
Since 1915, the Dux range has seen
continuous research and development,
resulting in many breakthroughs in the
efciency, reliability and longevity of hot
water systems.
Dux water heaters are manufactured
in Australia in a state-of-the-art facility,
using a Quality Endorsed Company
production system.
This is your assurance that you have
purchased the highest quality water
heater available, one that will provide
continuous hot water for all your needs
– safely, economically, and for many
years to come.
To be upfront about it, we want Dux to
be your brand of choice. So you can
depend on us to provide more than just
a hot water system.
You can rely on Dux products and
choose them with condence. We’ll
make sure you have the information, the
quality and the innovation you’re looking
for, including the latest energy-saving
alternatives. If you should ever have a
problem – and we’ll bet you won’t –
you’ll nd that we’re easy to get hold of,
friendly to talk to and quick to act. Our
service is all about providing anything
you need as soon as you need it.
Go with Dux and you’ll have a
dependable, economical, efcient hot
water system designed to perform well,
year after year. And that’s a promise.

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Installer’s Guide
Full and detailed installation instructions
are in the Installer’s Guide, included
inside the water heater’s carton.
Location
The water heater should be located as
close as possible to the most frequently
used hot water outlet. Ensure that the
data plate is clearly visible and provide
adequate access for service to the
thermostat, relief valve and anode.
Note: All models are equipped with a
sacricial anode, accessible through the
top cover. Allow 50% of the height of
the water heater for clearance above to
replace the anode.
We recommend a plinth be installed
under the water heater where the
water heater is subjected to wet
conditions
A properly drained overow tray must
be used where property damage could
occur from water spillage. (See AS/
NZS3500.4 for further details.)
Note: Warranty does not cover
consequential damage due to heater
leakage.
Safety
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.
Children and animals should be
supervised to ensure that they do not
interfere with the appliance.
Model Numbers
Below is a list of model numbers and
their descriptions:
Tank
Model Description
2F136S 250 Litre tank
2F136SD 250 Litre tank with Panel Management
3F136S 315 Litre tank
3F136SD 315 Litre tank with Panel Management
4F136S 400 Litre tank
4F136SD 400 Litre tank with Panel Management
Installation of the Tank

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Frost Protection
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 anti-frost
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 seperately.
Installation of the Tank
Tank
Model
Anti-Frost Valve
Needed?
2F136S Yes
2F136SD No
3F136S Yes
3F136SD No
4F136S Yes
4F136SD No
Frost Protection Installation Map
Wellington
Auckland
Christchurch
Locations in grey may be
subject to frost.

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Installation Requirements
This water heater must be installed
by a licensed tradesperson, and in
accordance with:
• AS/NZS3500.4 “National Plumbing
and Drainage Code Hot Water
Supply Systems – Acceptable
Solutions”.
• Clause G12 of the New Zealand
building code.
• Local authority regulations.
• Outside Australia and New Zealand,
please refer to local plumbing and
building codes and regulations.
• 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 certicate,
showing that the work complies with
all the relevant Standards and only a
licensed person will have insurance
protecting their workmanship for 6
years.
Water Supply Pressure
This water heater is designed for direct
connection to water supply pressures of
no greater than:
All Models – 800kPa
Where the mains pressure can exceed
or uctuate beyond the pressure shown
above, a pressure limiting device
(complying with AS1357) must be tted
in the cold water inlet supply. This device
must be installed after the isolating
valve and set below the pressure shown
above. Note during periods of lower
demand water pressure may increase.
Pool Heating
This water heater must not be used for
pool heating.
Pressure & Temperature Relief
Valve
The Pressure & Temperature Relief Valve
is supplied loose with the water heater.
The valve rating is:
All Models – 1000kPa
The PTR valve must be installed directly
into the top socket marked “RELIEF
VALVE”. The drain line from this valve
must run in a continuously downward
direction in a frost-free ambient position
with the discharge end left open to
atmosphere permanently.
The PTR Valve is not intended to enable
connection of the water heater to
supplementary energy sources such as
solar panels or slow combustion stoves
(refer AS/NZS 3500.4 for guidance on
these types of installations).
Open the PTR Valve for approximately
10 seconds by lifting the lever on the
valve to ensure water is relieved to waste
through the relief drain pipe. Lower lever
gently and check that it closes correctly.
Plumbing Connections

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The PTR Valve must not be tampered
with or removed. The water heater must
not be operated unless this valve is
tted and in working order.
The PTR Valve should be checked for
adequate performance or replaced at
intervals not exceeding 5 years, or less
in areas where local regulations apply.
Important: The PTR Valve and its
drain outlet pipe must not be sealed or
blocked. It is normal for the PTR valve
to leak a small amount of water during
heating cycles.
Danger
Failure to operate the relief valve easing
lever at least once every six (6) months
may result in a problem with the water
heater and in some cases the tank may
explode.
Warning: A separate drain line must be
run for this relief valve. It is not permitted
to couple drain lines from relief valves
into a single common drain line.
Cold Water Connection
An approved isolating valve, non
return valve, line strainer (optional but
recommended), and union must be
tted between the supply main and the
RP¾"/20mm T tting connected to the
socket in the water heater.
All ttings must be approved by the
relevant Authority and in accordance to
the plumbing code.
Union
Connection
Non-return
Valve
Line
Strainer
Cold Water
Inlet
Expansion
Valve
Isolating Valve
(Spindle Vertical)
Note: a combined isolating valve/non-
return valve/line strainer may be used.
Expansion valve only required where local
regulations demand.
Note for S.A. and W.A.: It is a state
requirement that a pressure relief valve
be tted on the cold water supply line
between the non return valve and the
water heater.
PTR valve
Plumb to waste
to comply with
AS/NZS 3500.4
and local plumbing
codes
Plumbing Connections

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Hot Water Connection
The hot water line should be connected
to the “OUTLET” socket on the tank.
Note: Once all connections have been
properly made, ll tank by opening
the cold water inlet and bleed all lines
according to appropriate plumbing code.
Safety Information
For safe performance this water heater
is tted with:
• an over-temperature energy cut-out
thermostat
• a combination Pressure &
Temperature Relief Valve.
These devices must not be tampered
with or removed. The water heater must
not be operated unless both of these
devices are tted and in working order.
The element cover should be removed
only by a qualied electrician. The
electrical power supply must be
isolated at the main electrical supply
switchboard before the water heater
electrical cover is removed.
Insulation of Pipes
All hot water pipes must be insulated
with UV stabilized insulation suitable
for solar working temperatures, e.g.
Armaex Insulation. Please check local
regulations regarding the use of hot
water supply pipework other than pipes
made of copper.
Temperature Protection
All solar water heaters have the
ability to produce hot water very
quickly. To reduce the risk of scald
injury, it is mandatory under the
requirements of Australian Standard
AS/NZS3500.4:2003 that a suitably
approved temperature control device be
tted to the hot water supply to outlets
used primarily for personal hygiene.
This valve should be checked at regular
intervals to ensure its operation and
settings remain correct.
Note: This water heater is supplied
with a tempering valve. Install the
valve according to the manufacturer’s
recommendations. Any adustments to
the valve should be made according to
the manufacturer’s recommendations.
The tempering valve should be checked
at regular intervals to ensure its
operation and settings remain correct.
Plumbing Connections

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H3161 025248 Rev. D
1
7
5
2
3
4
8
6
FRONT VIEW
E
F
D
A
RIGHT VIEW
E
D
LEFT VIEW
59.5°
C
B
TOP VIEW
Specifications 250L 315L 400L
Storage Capacity (L) 259 324 416
Hot Water Delivery (L) 250 315 400
Net Weight Empty (kg) 81 94 114
Relief Valve Pressure (kPa) 1000 1000 1000
Dimensions (mm) 250L 315L 400L
Tank Height (A) 1444 1754 1704
Tank Diameter (B) 617 617 705
Tank Width (C) 712 712 801
Outlet (D) 1211 1521 1445
Inlet (E) 195 195 219
Solar Return (F) 628 838 642
System Components
Item
Number
Description
1 Solar electric tank assembly
2 Solar collector
3 Solar collector flow connection
4 Solar collector flow pipe
5 Automatic air vent valve
6 Solar collector return pipe
7 Non return valve
8 Solar module
Specifications

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Installer’s Guide
Full installation instructions for the
collectors are in the Installer’s Guide,
included inside the water heater’s carton.
Safety
Do not commence an installation until
you have satised yourself that all safety
issues associated with working on and
lifting components onto a roof have
been addressed.
Local Authority Regulations
All work associated with the installation
must comply with local authority
regulations, including AS/NZS 3500.4.2.
Where these installation instructions and
local regulations are in conict, local
regulations must prevail.
Location of Collectors
There are several factors to consider in
selecting the collector location site:
• For best performance, the collectors
need to face true north. Due to the
high solar energy levels experienced
in Australia, installations on angles
of up to 45° away from true
north should not have a major
effect on the annual solar output.
Consequently, installations up
to 45° away from true north
are acceptable. See Collector
Orientation Compass on page 9.
• If the collectors are installed with an
east facing bias, the best solar input
is achieved in the morning and if
there is a west facing bias, the best
solar input is in the afternoon.
• The collectors should be installed
with a minimum inclination of 10°
and a maximum inclination of
45°. See Collector Inclination Guide
on page 9.
• Careful site inspection is required to
ensure the selected location is not
subjected to shading from adjacent
trees or buildings at any time of the
day, but particularly between 9am
and 3pm, the highest solar input
times.
• Remember that shadows are longer
in winter than in summer, so a
site that is free of shadows from
adjacent objects in summer may
have some shadows in winter.
• To optimise efciency, the collectors
should be as close as possible to
the storage tank.
• For best performance, the collectors
should be located no more than
20m from the storage tank.
• Ensure that the roof structure is
suitable to support the weight of
the collectors. The collectors weigh
approximately 40kg each when full.
Installation of Collectors

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Installation of Collectors
True North
NW NE
Surface Plate EastWest
45°
50° from
true north
70° from
true north 45°
B
Collector Orientation Compass
True North
A
A = 500mm, or greater if roof allows
B = Between 10° and 45°
B
Note: When establishing the correct Collector Orientation, please account
for the Magnetic Declination of your geographic location
Collector Inclination Guide
C
A
C
A. Dux preferred range
B. Industry accepted range
C. If orientations A or B are not practical, an additional collector can be
installed at the home owner’s discretion in range C (not required north
of Tropic of Capricorn)

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Collector Rail Kit
The Collector Rail Kit that comes
with this water heater is designed
for mounting the collectors to most
common Australian roof types.
All kits consist of specially designed
rails, clamps and bolts etc. that are used
to x the collectors to the roof structure.
With the exception of the copper tube
and roong bolts, these kits contain all
of the plumbing components required
to connect the collectors to the ground
mounted water heater.
Refer to the collector rail kit instructions
located in the rail kit box. The rail kit
instructions can also be obtained from
Dux Service on 1300 365 115.
For installations requiring three
collectors, an additional Collector
Rail Kit is required as an extension to
increase the mounting capacity from
two to three collectors.
Roof Space
It is not advisable to install collectors
on roof spaces that are smaller than
described below:
• 2 collectors: 3m wide × 3m high
• 3 collectors: 4.5m wide × 3m high
Roof areas smaller than these minimum
measurements will make installation and
later service work difcult.
Installation of Collectors
Collector mounting rail
Collector mounting rail

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Insulation
Irrespective of the pipe length, both
the solar ow and return lines must be
insulated with UV stabilized insulation
suitable for solar working temperatures,
e.g. Armaex DuoSolar/Solar insulation.
No Plastic Fittings
Only DR brass and copper pipes and
ttings must be used. Plastic ttings and
PVC pipes are not able to withstand
the high temperatures >200ºC that the
system can create. Failure to use ttings
with a high temperature rating will void
the warranty.
Connections To The Collectors
Connect the sealing ttings to the four
outer connections on the collector array:
1. Fit a sealing washer and plug
assembly to the top left and bottom
right corners of the array.
a. Tighten the assembly taking
care not to twist the copper
tubes of the collector.
b. Ensure you use correctly sized
spanners.
2. Screw t the Air Bleed Valve into
the top 3⁄8" BSP socket and hand
tighten until the nylon ring seals
against the socket face.
Important: Please open the knob
on top of the valve two turns anti
clockwise.
3. Fit the sealing washer and union
base tting to the top right hand
socket of the collector array.
4. Place the Hot Connection Union
assembly onto the union base then
tighten with the air bleed valve
vertical. (NB: The air bleed valve
should be at the highest position on
the collectors).
5. Finally insert a washer and ¾" to
½" conetite union to the lower left
collector socket.
The collector array is now completed
and ready for connection to the water
heater system.
Plumbing Connections to
Collectors

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Connections To The Collectors
Supplied with the water heater are the
following:
• an Automatic Air Vent Valve
• a 4 way union assembly.
Full installation instructions for these
items are in the Installer’s Guide,
included inside the water heater’s carton.
4 way union
assembly
Automatic Air
Vent Valve
Non Return Valve
A non return valve is supplied with this
water heater.
The non return valve must be tted at
the solar collector return pipe, where the
pipe enters the middle of the storage
tank.
Ensure the non return valve is installed
so that the ow direction arrow faces the
storage tank.
All pipe work must be insulated.
Insulation
Pipes must be insulated with UV
stabilized insulation suitable for solar
working temperatures, e.g. Armaex
DuoSolar/Solar insulation.
No Plastic Fittings
Only DR brass and copper pipes and
ttings must be used. Plastic ttings and
PVC pipes are not able to withstand
the high temperatures >200ºC that the
system can create.
Failure to use ttings with a high
temperature rating will void the warranty.
Plumbing Connections to
Collectors
RELIANCE
FLOW
Flow Direction Arrow
Storage tank
Cold Water
Flow Direction
Hot Water
Flow
Direction
Non return
valve

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Connections To The Tank
Supplied in the collector rail kit are the
following:
• a collector sensor
• a 20m collector sensor cable.
Full installation instructions for the
temperature sensor are in the Installer’s
Guide, included inside the water heater’s
carton.
Note: Ensure that the temperature
sensor cable does not come in contact
with the hot collector return pipe.
Note: Care must be taken to ensure
that all roof penetrations are sealed to
prevent water ingress and to comply
with all local regulations.
Temperature Sensor
Collector sensor connection for
models 2F136SD, 3F136SD, 4F136SD
Collector temperature sensor
(supplied in collector rail kit)
Caution: Sensor connector pins
align one way only
12
33
21
Collector temperature sensor cableCollector temperature sensor cable
20m collector temperature sensor
cable (supplied in collector rail kit)

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COLLECTOR
SENSOR
BOTTOM
SENSOR
TOP
SENSOR
MODULE
SENSOR
Attach collector
sensor cable to
terminal block
COLLECTOR
SENSOR
BOTTOM
SENSOR
TOP
SENSOR
MODULE
SENSOR
Terminal block secured
to timber or metal truss
inside roof cavity
Collector sensor connection for
models 2F136S, 3F136S, 4F136S

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The Solar Module
The solar module provides protection
against both cold and hot temperature
extremes. The solar module includes
the Hotlogic controller, which continually
monitors temperature conditions.
Freeze Protection
When temperatures approach freezing,
the Hotlogic controller removes the
water from the collectors to prevent the
water freezing and causing damage.
The Hotlogic controller rells the
collectors when temperatures improve.
Hot Temperature Protection
The water in the collectors can reach
dangerously high temperatures, which
may cause steaming, expansion and
over-pressure problems. When the
tank approaches its thermal maximum
(maximum energy storage limit), the
Hotlogic controller removes the water
from the collectors when it is safe to do
so, then rells them when conditions
improve.
Installation of the Solar Module
• The solar module’s drain line must be
safely plumbed to waste to comply
with AS3500.4 and local plumbing
codes. This line must not be con-
nected to the the PTR drain line.
• The water heater should be installed
to allow easy access and removal of
the solar module cover.
• The pipe extensions to the valve are
designed to provide a compression
connection, so soldering should not
be necessary. If soldering is required,
the pipe extensions should be re-
moved from the body of the valve to
avoid damaging the valve.
• It is critical that the solar non return
valve is installed on the solar collec-
tor return pipe, where the pipe enters
the middle of the storage tank.
• The solar module system satises
Level 2 test for severe frost condi-
tions (AS/NZS 2712:2007).
Panel Management
(Available only for models 2F136SD, 3F136SD and 4F136SD)

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Panel Management
(Available only for models 2F136SD, 3F136SD and 4F136SD)
Warning: The point of discharge from each drain
line shall be located so that the release of steam
or hot water does not cause a nuisance, is readily
discernible and incurs no risk of damage to the
building or injury to persons.
Install water
heater to
allow easy
access and
removal of the
solar module
cover
Pipes with
flared fittings.
Remove pipes
from valve if
soldering is
required.
Plumb to waste as per AS3500.4
Do not connect to the the PTR
drain line.
The electrical supply to the
pump module must be continu-
ously available. Off Peak power
must not be used.

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This water heater requires the following
electrical connections:
1. Solar Pump Module –
CONTINUOUS SUPPLY GPO 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.
Note: This water heater is designed to
allow the tank boost to be connected
to continuous or off peak power supply.
Large daytime users of hot water
that exceed the capacity of the off
peak boost option should connect to
continuous supply.
Element
The booster element is located midway
up the tank, so it heats up the top half of
the tank only. Thus, in a 400L tank, only
200L of water is heated. This booster
element is turned on only in times of low
solar gain (e.g. in winter or on cloudy
days), or when hot water is being used
faster than the solar heating can recover.
Once the top half of the tank is
sufciently hot, the booster element is
switched off.
This set up helps minimise electricity
costs, while still providing a reliable
back-up hot water supply.
Regulations
All electrical work must:
• comply with local regulations and
AS3000
• be conducted by a licensed
electrician.
Connections
For models not pre-wired with a exible
lead, connections are made at the
terminal block under the element cover.
Entry to the connection area is through
the hole below the element cover,
designed to accept a 20mm conduit.
For the electrician, the access cover
may be removed by undoing the two
screws on the cover and sliding the cover
downward to disengage it from the case.
Ensure that the conduit entry is well sealed
to achieve complete weatherproong.
Note: The water heater is tted with
a thermostat and over-temperature
energy cut-out. Under no circumstances
should the water heater be operated
without both these devices being in the
circuit. Replacement must be carried
out only by a qualied electrician or the
manufacturer.
Danger: The operation of the thermal
cut-out indicates a possibly dangerous
situation. Do NOT reset the thermal
cutout until the water heater has been
serviced by a qualied person.
Electrical Connections

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Electrician: Press the reset button
on thermostat(s) to ensure over-
temperature cut-out is set.
Power Cables
Power cables should be routed away
from any hot water pipes. If this is not
practical, insulate the hot water pipes
to avoid direct contact with the power
cables.
If the power cable is damaged, it should
be replaced by a lead assembly available
only from Dux service agents.
Solar Module Electrical Connec-
tion
The electrical supply to the pump
module must be continuously available.
Off Peak power must not be used.
Caution: The water heater must be
lled with water before turning on the
electricity supply.
Electrical Connections