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
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
• 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
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
• 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
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
• 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
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

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.