Dux DN15DS Assembly instructions

Installer’s Guide
For advice, repairs and service, call:
1300 365 115 (Australia)
0800 729 389 (New Zealand)

Read This Document First
On completion, sign and leave with owner
Specications and materials may change without notice
Effective for Sunpro gas boosted solar water heaters manufactured and sold after 1 April 2011.
Models: DN15DS
DL15DS
Installation only by a licensed tradesperson
and in accordance with:
• AS/NZS 3500.4 “National Plumbing &
Drainage Code Hot Water Supply Systems
– Acceptable Solutions”
• AS5601/AG601 Gas Installation
• Adherence to local authority and OH&S
regulations
• Victorian PIC Requirements
Carefully remove all packaging and
transit protection from the heater before
installation. Dispose of the packaging
responsibly using re-cycling facilities
where they exist.
Pre Boosted Gas Solar Water Heater MP15
H4099 4099 Rev. D

Pre Boosted Gas Solar Water Heater MP15
H4099 4099 Rev. D
Installer’s Guide
Rough In Diagram 1
Parts Included With The Water
Heater 2
Model Numbers 2
Read This Document First 3
Safety Audit 3
Removal of Existing Tank 4
Placement of New Tank 4
Water Connections 5
Pipes – Important Points 5
Collectors – Alignment and
Inclination 7
Collectors – Important Points 8
Collectors – Attaching to Roof 9
Collectors – Attaching Fittings 11
4 Way Union Assembly 14
Flashing 15
Temperature Sensor 16
Non Return Valve 20
PTR Valve and Solar Drain 20
GPO 21
Tempering Valve 21
Gas Connection 22
Commissioning the System 23
Commissioning Checklist 24
Installation Declaration 25
Exploded Diagrams 28
Flue Clearances 29
© Dux Manufacturing Limited 2012. All rights reserved.

1
Pre Boosted Gas Solar Water Heater MP15
H4099 4099 Rev. D
Centre Line
of Tank
E2 E
D
E1
D1
B1
D2
B
B2
Notes
1. All pipe work must comply with AS/NZS 3500.4.
2. All solar system pipes must be ½" copper.
3. Pipes must be fully insulated with UV stabilized
insulation suitable for solar working temperatures,
e.g. Armaflex DuoSolar / Solar insulation.
4. Pipes from the solar collectors to the water storage tank
must have a minimum of 5° continuous fall, to allow the
water to easily drain out of the pipes.
5. A solar non return valve is supplied, and MUST be fitted
to the return from the collectors, as per the supplied
Installer’s Guide.
Min
500mm
Valve
Train
C1
C
A
Tempering
Valve
C2
Return from solar collectors
PTR valve
Collector temperature sensor.
See Installer’s Guide for sensor
installation instructions
To solar collector
Gas Inlet
Plumb to waste to comply with AS/NZS 3500.4
and local plumbing codes. Treat as a PTR valve.
Plumb to waste to comply with AS/NZS
3500.4 and local plumbing codes
Wall
Return from solar collectors
Flow to solar collectors
Gas pipe
Cold water inlet
450mm
Front of heater
350mm
C
B
D
E
PTR valve
Ensure pipes protrude
horizontally from wall, and
leave enough length of pipe to
allow easy connections
Approximate location of pipework (rounded to the nearest 10mm). A tolerance of 25mm is acceptable to dimensions shown in table.
Rough In Diagram
DN15DS,
DL15DS
Capacity 324 L
Tank Height 1754
Overall diameter 617
A Untempered hot water outlet from top of fireproof slab 1541
B Return from solar collectors from top of fireproof slab B1
Return from solar collectors from centre line of tank B2
1013
450
CCold water inlet from top of fireproof slab C1
Cold water inlet from centre line of tank (allowing space for valve train) C2
215
350
DFlow to solar collectors from top of fireproof slab D1
Flow to solar collectors from centre line of tank D2
640
450
EGas entry from top of fireproof slab E1
Gas entry from side of tank E2
540
450

Installer’s Guide
2
Pre Boosted Gas Solar Water Heater MP15
H4099 4099 Rev. D
Installer’s Guide


• Inside the water heater’s carton is a
box containing the following parts
required to complete installation:
Description Part No.
DN15 (½") Y LINE STRAINER H4323
VALVE – SOLAR NON RETURN SNR502 H4508
VALVE – MIX SOLAR ½" (MIX11116) H3566
PT VALVE ½" – HT55 1000kPa H0443
OWNER’S MANUAL H4096
INSTALLER’S GUIDE H4099

• Below is a list of model numbers and
their descriptions:
Model No. Description
DN15DS 315 Litre, 45 MJ/h, Natural Gas
DL15DS 315 Litre, 45 MJ/h, LPG

Installer’s Guide
3
Pre Boosted Gas Solar Water Heater MP15
H4099 4099 Rev. D
Installer’s Guide


• This Installer’s Guide and the
Owner’s Manual contain important
information about installation and use
of this water heater.
Note: For an easier
installation, please read this
document before you begin.


• 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. NSW Ref: “Safe Work on
Roofs – Part 2 Residential” Code of
Practice 2004, Work Cover NSW.

Installer’s Guide
4
Pre Boosted Gas Solar Water Heater MP15
H4099 4099 Rev. D
Installer’s Guide


• The existing tank (if applicable)
should be drained and removed in a
responsible manner.
Note: Do not drain on to grass
or garden beds.


• 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
• Refer to the section called “Rough
In Diagram” on page 1 for detailed
information on position of plumbing.
Note: Certain locations are
prohibited areas for ue
terminals. Refer to the section
called “Flue Clearances” on
page 29 for detailed information
on the ue clearances
required by AS 5601 Gas
Installations.
Front View
Wall
Water
Heater
Tank Alignment
Install a plinth under the water
heater where the water heater is
subjected to wet conditions

Installer’s Guide
5
Pre Boosted Gas Solar Water Heater MP15
H4099 4099 Rev. D


• Using correct plumbing methods,
connect the cold water pipe to the
storage tank.
• It is mandatory to t the following
items between the supply main and
the RP¾"/20mm socket in the water
heater: an isolating valve, a non
return valve, a line strainer, a union.
• All ttings must be approved by the
relevant Authority and in accordance
to the plumbing code.
• We recommend the use of new valves
for all Installation. Refer to plumbing
code and/or local requirements.
• The hot water line should be
connected to the hot water outlet.


Note: All solar system pipes
and ttings must be DR
brass and copper, including
collector compression ttings
(as supplied). No plastic pipes
or ttings.
• Flow and return lines must be
installed as direct as possible
between tank and collector.
Hot water outlet
Cold water inlet
Hot water outlet
Cold water inlet
Pipes must be DR
brass and copper.
Refer to AS/NZS
3500.4.
Installer’s Guide

Installer’s Guide
6
Pre Boosted Gas Solar Water Heater MP15
H4099 4099 Rev. D
Installer’s Guide
• Pipes must be fully insulated with
UV stabilized insulation suitable for
solar working temperatures. We
recommend Armaex DuoSolar /
Solar insulation, minimum 13mm
thick (or as per local regulations).
Note: Warranty will be void
if this minimum insulation
requirement is not used.
• It is critical to stop any chance of an
air lock developing, so ensure that:
– no pipework is higher than the air
bleed valve
– ow 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 ow
and return lines through the roof,
cladding and the eaves.
Note: Where roof and
the eaves are made from
asbestos, specialised handling
and advice is necessary.
Pipes must be fully
insulated with UV
stabilized insulation
suitable for solar working
temperatures, minimum
13mm thick (refer to local
regulations)
Minimum 5°
continuous fall
To collectors
Non continuous
fall
To collectors
Incorrect Correct
Ensure flow and return pipes from the solar collectors to the
water storage tank have a minimum of 5° continuous fall
Pipes must have no
high points that allow
air to be trapped
No pipes can be higher than
the automatic air vent valve

Installer’s Guide
7
Pre Boosted Gas Solar Water Heater MP15
H4099 4099 Rev. D
Installer’s Guide



Solar Collector Alignment
• For the most efcient solar gain, the
collectors must be aligned ±45° from
true north (i.e. north west to north
east). See Collector Orientation
Compass below.
Solar Collector Inclination
• For the most efcient solar gain, the
collectors must be inclined within
10° to 45° from horizontal. See
Collector Inclination Guide right.
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)
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)

Installer’s Guide
8
Pre Boosted Gas Solar Water Heater MP15
H4099 4099 Rev. D
Installer’s Guide


• Inspect ttings 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.
• To prevent damage, collectors
should be left pressurised only when
connected to the storage tank with
appropriate pressure relief valves.
• Collectors can be located a maximum
of 20 metres (with minimal bends)
from the storage tank if pipe layout is
simple.
Note: For more energy
efciency, locate the
collectors as close as
possible to the tank
• This system is suitable for 2 storey
homes.

Installer’s Guide
9
Pre Boosted Gas Solar Water Heater MP15
H4099 4099 Rev. D
Installer’s Guide


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.

For Metal Roofs Only
• Fix roong screws through the
mounting straps on both sides,
using rubber grommets to prevent
corrosion.
Note: A minimum of 3 roong
screws of 40mm length must
be used to x the collector
strap to the truss.
• Ensure that the rail is parallel with the
gutter.
500mm
or
greater
500mm
or
greater

Installer’s Guide
10
Pre Boosted Gas Solar Water Heater MP15
H4099 4099 Rev. D
Installer’s Guide
For Tiled Roofs Only
• Carefully remove a roof tile and
locate the nearest roof truss.
• Attach the rst (2 per mounting rail)
stainless steel collector strap to the
mounting rail.
• Shape the collector strap over the tile
and position over the roof truss.
Note: A minimum of 3 roong
screws of 40mm length must
be used to x the collector
strap to the truss.
• Ensure collector strap is located on
truss vertically.
• Repeat this process for the collector
strap at the other end of the
mounting rail.

• Once the bottom rail has been
secured, the collector can now be
lifted on to the roof.
Note: Ensure this is done with
full consideration to OH&S
regulations. Care should be
taken.
Collector Strap
Collector Strap
Use minimum
of 3 screws

Installer’s Guide
11
Pre Boosted Gas Solar Water Heater MP15
H4099 4099 Rev. D
Installer’s Guide


All connections must be brass and all
pipe work must be copper
• Ensure tting is fully engaged on to the
header pipe. This is very important for
correct connection.
• To ensure leak proof installation, hold
tting A (see illustration in margin)
while tightening nut B to prevent
twisting the header pipe.
Critical: Do not use multi
grips or similar tool, as you
will damage the brass ttings.
Ensure you use the correct
size spanner.
Critical: This is a compression
tting, and therefore must be
tightened to operate correctly.
• Blank off any unused collector
header piping with the ttings
provided.
Ensure the brass conetite compression
fitting is installed in the correct direction
Hold fitting A while tightening nut B
to prevent twisting the header pipe
AB

Installer’s Guide
12
Pre Boosted Gas Solar Water Heater MP15
H4099 4099 Rev. D
Installer’s Guide

• Secure the collectors to the
mounting rail with the Z brackets,
screws, nuts and bolts provided with
the water heater.

• Repeat the process for the second
collector.
Note: Ensure this is done with
full consideration to OH&S
regulations. Care should be
taken.

• Now position the top mounting rail and
repeat the above steps for that rail.
• Join the top connections with the
brass compression ttings supplied.
Collector
strap
Collector
clamp bracket
Collector
mounting
rail
24mm self tapping
galvanised screw

Installer’s Guide
13
Pre Boosted Gas Solar Water Heater MP15
H4099 4099 Rev. D
Installer’s Guide

• Connect collector ow and return
pipes to the collectors.
• Ensure that you connect the solar
ow (cold) and solar return (hot)
pipes to the correct connections:
– the solar ow (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.
• We suggest when you install pipes
through roof, that you consider
colour coding the pipe ends to show
ow and return.
Critical: During connection,
the header pipe can move in
the collectors. It is critical that
the header pipe is centred to
provide about 40mm of tube
on both sides of the collector.
~40mm~40mm

Installer’s Guide
14
Pre Boosted Gas Solar Water Heater MP15
H4099 4099 Rev. D
Installer’s Guide


• Using correct plumbing methods,
install the 4 Way Union assembly
and automatic air vent valve at the
highest point in the system, at
the top of the collector diagonally
opposite the solar collector inlet pipe.
• The automatic air vent valve must
stand vertically straight towards
the sky.
Note: If installed in top left/
bottom right of collector, then
T should be reversed.
• When tting the 4 Way Union
assembly, we recommend Loctite
577 Thread sealant and/or a good
quality pink teon tape to secure the
automatic air vent valve. Tighten by
hand. Do not use spanner.
• If the system is installed correctly,
air will automatically be purged from
the system through the automatic air
vent valve.
Valve must be
vertical and at
highest point in
system
Use Loctite 577
thread sealant or
pink teflon tape to
seal all threads

Installer’s Guide
15
Pre Boosted Gas Solar Water Heater MP15
H4099 4099 Rev. D


• As per local authority regulations,
use an approved method of ashing
on the ow and return lines, e.g.
Dektite or lead collars.
• Where ow and return lines penetrate
the roof surface, the penetration
must occur on the high side of the
roof prole, not in the valley.
• Seal the roof penetration with
a exible waterproof ashing.
We recommend the use of the
appropriate Dektite brand solar
ashing (available for either tile or
steel roofs).
Flexible
waterproof
flashing
Roof penetration must
be on high side of tile
Installer’s Guide

Installer’s Guide
16
Pre Boosted Gas Solar Water Heater MP15
H4099 4099 Rev. D
Installer’s Guide


• 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 cable using
the cable securing clip.
Cable
securing clip
Collector
temperature
sensor
Sensor secured
by clip
Critical: To ensure the
collector temperature sensor
functions properly, ensure
that the sensor cable is rmly
secured by the clip.
Warning: Install the sensor
cable such that it does not
touch the roong material
surface.
Warning: Conceal all
temperature sensor cables
in the roof cavity so that they
are not exposed to sunlight or
heat.
Warning: The collector sensor
cable is a silicon rubber that
may require additional conduit
protection in extreme UV
radiation conditions.

Installer’s Guide
17
Pre Boosted Gas Solar Water Heater MP15
H4099 4099 Rev. D

• Align the pin positions carefully and
press home the collector temperature
sensor (Part No. H0403) into the 20
metre collector temperature sensor
cable (Part No. H0402).
• 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. When
attaching sensors, carefully
align the connector pins with
the correct holes, taking care
not to bend or damage them.
Collector temperature
sensor (Part No. H0403)
Part No. H0402)
Caution: Sensor connector pins align one way only
12
33
21
20m collector temperature sensor cable (Part No. H0402)
(Male /male connectors).
If the collector temperature sensor cable is exposed to
atmosphere, you must insulate the cable from UV
radiation damage.
Thumb screw
Part No. H0403)
Installer’s Guide

18
Pre Boosted Gas Solar Water Heater MP15
H4099 4099 Rev. D

• Locate the pre-installed collector
temperature sensor cable (Part No.
H0401) coming out of the side of the
water heater’s cover (see illustration
below).
• Remove the protective cap from
the end of the collector temperature
sensor cable.
Remove protective cap
Pre-installed collector
temperature sensor cable
(Part No. H0401)
Installer’s Guide