Dux DN15DS Instruction Manual

Pre Boosted Gas Solar Water Heater MP15
Specications and materials may change without notice
Effective for Sunpro gas boosted solar water heaters manufactured and sold after 1 April 2011.
Owner’s Manual
For advice, repairs and service, call:
1300 365 115 (Australia)
0800 729 389 (New Zealand)
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
H4096 4096 Rev. F
Models: DN15DS
DL15DS
DN15CS
DL15CS

Owner’s Manual – Pre Boosted Gas Solar Water Heater MP15
H4096 4096 Rev. F
Welcome To Dux Hot Water 1
Installation of the Tank 2
Plumbing Connections 4
Specications 7
System Components 8
Installation of Collectors 10
Plumbing Connections to
Collectors 13
Gas Connection 15
Electrical Connections 16
Hotlogic Connections 17
Owner’s Information 18
System Maintenance 22
Troubleshooting 23
Warranty 25
Other Information 28
Contents
© Dux Manufacturing Limited 2012. All rights reserved.

Owner’s Manual – Pre Boosted Gas Solar Water Heater MP15
1
H4096 4096 Rev. F
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.

Owner’s Manual – Pre Boosted Gas Solar Water Heater MP15
2H4096 4096 Rev. F
Installer’s Guide
Full and detailed installation instructions
are in the Installer’s Guide, included
inside the water heater’s carton.
Outdoor Tank Installation
The water heater must be installed
outdoors, with the minimum clearances
as shown in the gure below.
We recommend a plinth be installed
under the water heater where the
water heater is subjected to wet
conditions. Please refer to AS/NZS
3500.4, clause 5.5.3.
Minimum clearance around the windows
and doors must be maintained – refer to
AS 5601.
Location
The water heater should be located as
close as possible to the most frequently
used hot water outlet. Ensure that the
data label is clearly visible and that there
is adequate access for servicing the unit.
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.
A properly drained overow tray must
be used where property damage could
occur from water spillage. (See AS/
NZS3500.4 for further details). 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.
C
B
A
A = 500mm B=300mm C=50mm min
For further details, refer to
AS5601 – Gas Installation Code
Installation of the Tank

Owner’s Manual – Pre Boosted Gas Solar Water Heater MP15
3
H4096 4096 Rev. F
Frost Protection
The areas in gray in the map below may
be vulnerable to frost. Solar hot water
heaters installed in these areas require
an approved antifrost protection device
to maximise system performance.
Note: The Gas Boosted Solar water
heater already has an in-built frost
protection device, so no further antifrost
protection is required.
Model Numbers
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
DN15CS 250 Litre, 45 MJ/h, Natural Gas
DL15CS 250 Litre, 45 MJ/h, LPG
Installation of the Tank
All locations highlighted in gray require an approved antifrost protection device to
maximise system performance. Call 133 326 for further information.
The EcoSmart®Hybrid Intelligent Solar water heater is fully assembled
with an in-built frost protection device so no further antifrost protection is required.
Wellington
Auckland
Christchurch
Installation of the Tank

Owner’s Manual – Pre Boosted Gas Solar Water Heater MP15
4H4096 4096 Rev. F
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”.
• AS5601/AG601 “Gas Installations”
• 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:
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.
Plumbing Connections

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H4096 4096 Rev. F
Pressure & Temperature Relief
Valve
The Pressure & Temperature Relief (PTR)
Valve is supplied loose with the water
heater. The valve rating is:
1000kPa
The specications and part numbers of
the PTR Valve provided are:
Part No: H0443
Description: PT VALVE ½" – HT55
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.
Warning: We recommend that you
open the PTR valve at least once every
six (6) months. Failure to do this may
result in problems with the water heater.
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.
Plumbing Connections

Owner’s Manual – Pre Boosted Gas Solar Water Heater MP15
6H4096 4096 Rev. F
Cold Water Connection
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.
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.
Hot Water Connection
The hot water line should be connected
to the “OUTLET” socket on the tank.
Insulation of Pipes
All hot water pipes must be insulated
with UV stabilized insulation suitable
for solar working temperatures, e.g.
Armaex Insulation.
Building Flow & Return
Never install a building circulated ow
and return line to the inlet connection
of a Dux (Electric solar or Gas solar
hot water heater) or (Heat Pump water
heater)
The solar water heater is not designed
to be installed on a circulated ow
and return line due to loss of thermal
efciency. Extensive pipe work will
cause efciency losses gained from
solar energy and will increase energy
consumption.
If a ow and return line is required, we
recommend that you install a backup
storage or continuous ow water heater
on the ow and return line and a time
control the building circulation loop to
help reduce energy usage.
Plumbing Connections

Owner’s Manual – Pre Boosted Gas Solar Water Heater MP15
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H4096 4096 Rev. F
Plumbing Connections
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 that
a suitably approved temperature control
device, such as a tempering valve, be
tted to the hot water supply to outlets
used primarily for personal hygiene.
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.

Owner’s Manual – Pre Boosted Gas Solar Water Heater MP15
8H4096 4096 Rev. F
Specifications
Front RHSLHS
A B
C
E
D
Wall See
Detail G
Detail G
Water
Heater
Hot
Water
Outlet
Return from
solar
collectors
Cold
Water
Inlet
Tank Alignment
To solar
collector
Gas inlet
Solar drain.
Plumb to
waste.
FSee
Detail G
Model
Number
Approximate
Weight Empty
(kg)
Dimensions
(mm)
Storage
Capacity
(L)
A B C D E F
DN15CS, DL15CS 98 1444 1231 215 750 617 648 259
DN15DS, DL15DS 112 1754 1541 215 750 617 1013 324
Note: Minor changes to specifications and materials may occur without notice. While these will not affect the
safety, reliability or performance of your Dux unit, they could impact on the installation procedures explained in
this manual – check with Dux on 1300 365 115 if you are uncertain about any aspect of installing this product.

Owner’s Manual – Pre Boosted Gas Solar Water Heater MP15
9
H4096 4096 Rev. F
3
9
7
8
2
1
4
6
5
System Components
1 PTR valve 6 To drain pipe
2 Hot water outlet to house 7 Cold Water Inlet
3 Solar collector return 8 Cold water outlet to solar collector
4 Gas inlet 9 Automatic Air Vent Valve
5 To solar collector pipe
DN15DS model shown
System Components

Owner’s Manual – Pre Boosted Gas Solar Water Heater MP15
10 H4096 4096 Rev. F
System Components
1 Burner unit 7 Backing plate
2 Fan 8 Diverter valve
3 Hotlogic controller 9 Solar drain pipe
4 Pump 10 Solar flow pipe (to collector)
5 Gas valve 11 Solar non return valve
6 Gas inlet pipe 12 PTR Valve (drain to waste)
1
4
3
2
5
6
7
11
12
8
9
10
DN15DS model shown
System Components

Owner’s Manual – Pre Boosted Gas Solar Water Heater MP15
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H4096 4096 Rev. F
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.
Where these installation instructions and
local regulations are in conict, local
regulations must prevail.
The Plumbing Regulations 2008 for
Victoria will be met by installing Dux
Solar Collectors as per orientation B on
the Collector Compass on page 12.
Location of Solar Collectors
There are several factors to consider in
selecting the collector(s) location:
• For best performance, the
collector(s) 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 12.
• If installing the collector(s) 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.
• Collector(s) should be installed with
a minimum inclination of 10°and
a maximum inclination of 45°.
See Collector Inclination Guide on
page 12.
• 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
collector(s) should be as close as
possible to the storage tank.
• For best performance, the
collector(s) should be located no
more than 20m from the storage
tank.
• Ensure that the roof structure is
suitable to support the weight of the
collector(s). The collectors weigh
approximately 40kg each when full.
Installation of Collector(s)

Owner’s Manual – Pre Boosted Gas Solar Water Heater MP15
12 H4096 4096 Rev. F
True North
NW NE
Surface Plate EastWest
45°
50° from
true north
60° 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. Complies with the Victorian Plumbing regulations when installed
with two panels
C.1. If A and B are not practical, an additional collector can be installed
at the home owner's discretion in range C.
C.2. Complies with the Victorian Plumbing regulations when installed
with three panels.

Owner’s Manual – Pre Boosted Gas Solar Water Heater MP15
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H4096 4096 Rev. F
Collector Rail Kit
The Collector Rail Kit that comes
with this water heater is designed
for mounting the collector(s) 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 collector(s) 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 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:
• 1 collector: 1.5m wide × 3m high
• 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 Collector(s)Installation of Collectors
Collector mounting rail
Collector mounting rail

Owner’s Manual – Pre Boosted Gas Solar Water Heater MP15
14 H4096 4096 Rev. F
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 Collector(s)
Connect the sealing ttings to the four
outer connections on the collector(s)
array:
1. Fit a brass conetite compression
tting to the top left and bottom
right corners of the array.
a. Tighten the assembly taking
care not to twist the copper
pipes of the collector.
b. Ensure you use correctly sized
spanners.
2. Fit the Automatic Air Vent Valve into
the top RC3⁄8" BSP tapered socket
and hand tighten.
3. Fit the conetite cone and 4 way
union to the top right hand socket
of the collector(s) array.
4. Tighten the Automatic Air Vent
Valve. (Note: It must be in a vertical
position and at the highest position
on the collectors).
5. Finally, insert a brass conetite
compression tting to the lower left
collector socket.
The collector(s) array is now completed
and ready for connection to the water
heater system.
Plumbing Connections to
Collectors

Owner’s Manual – Pre Boosted Gas Solar Water Heater MP15
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H4096 4096 Rev. F
To make the connection between the
solar collector array and the storage
tank, the following is required.
1. 2 × ½" (15 mm) copper pipes, run
from the collector(s) array down to
storage tank.
Note: Pipes must be insulated with
UV stabilized insulation suitable for
solar working temperatures, e.g.
Armaex DuoSolar/Solar insulation.
2. 1 × 20m collector sensor cable run
from the collector(s) array to the
storage tank.
To complete this connection:
1. Connect one ½" insulated copper
tube to the conetite compression
tting at the bottom left hand corner
of the array and run down to the
ground mounted storage tank
location.
2. Connect the second ½" insulated
copper tube to the Hot Connection
assembly at the top right hand
corner connection of the array and
run down to the ground mounted
storage tank location.
Note: Care must be taken to ensure
that all roof penetrations are sealed to
prevent leaks and to comply with all
local regulations.
Plumbing Connections to
Collectors

Owner’s Manual – Pre Boosted Gas Solar Water Heater MP15
16 H4096 4096 Rev. F
Refer to the Data Label for correct gas
type.
Maximum Gas Consumption
Maximum gas consumption of the water
is shown in the table below.
Gas Pipe Sizes
Gas pipe sizes must comply with
AS5601/AG601.
The gas inlet sizes are shown below:
Model No. Max. Gas
Consumption
Gas Pipe
Size
DN15DS 45 MJ/h* R½"/15mm
DL15DS 45 MJ/h* R½"/15mm
DN15CS 45 MJ/h* R½"/15mm
DL15CS 45 MJ/h* R½"/15mm
*±5%
Gas piping should be connected to
the provided female tting (see gure
below).
A union connection should be used.
Gas Connection
Gas inlet

Owner’s Manual – Pre Boosted Gas Solar Water Heater MP15
17
H4096 4096 Rev. F
Electrical Connection
Covers providing access to live electrical
parts should be removed only by an
electrician.
The electrical power supply switch must
be turned off and the fuse removed at
the main electrical supply switchboard
before any electrical cover is removed.
This water heater is designed for
connection to CONTINUOUS TARIFF
for the Solar-Gas Module.
The electrical connection must comply
with Local Supply Authority Regulations
and AS3000.
Note: All electrical work must comply
with local regulations and be conducted
by a licensed electrician.
Note: The water heater is tted with a
over-temperature Energy Cut-Out (ECO).
Under no circumstances should the
water heater be operated without this
device 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.
Power Failure
In case of power failure, the unit will
restart automatically once power is
restored.
Temperature Sensor Connection
1. Insert the collector temperature
sensor into the temperature sensor
well of the 4 Way Union Assembly.
Fix in place using cable clip and
seal using a small amount of silicon
adhesive/sealant.
2. Run the cable to the storage tank.
(It is important that the sensor cable
DOES NOT contact the hot return
pipe).
3. Connect the collector temperature
sensor to the 20m extension using
quick connect, then connect the
other end of the 20m extension
to the Hotlogic cable using quick
connect. Secure the connections
using the thumb screws on the plug
ends.
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.
Electrical Connections

Owner’s Manual – Pre Boosted Gas Solar Water Heater MP15
18 H4096 4096 Rev. F
Hotlogic®Controller
The Hotlogic controller should be
plugged in to a weatherproof approved
power outlet for 10amps, 230 to 250
volt, 50Hz supply.
Hotlogic Normal Operation Codes
Power LED Sensor LED Outputs LED Explanation
Green flash alternating with Red flash Off System initialisation on power up (8 secs)
Green Green Flash (slow) N/A Heater in Frost Protection Mode
Green Green Flash (fast) N/A Heater in Over Temperature Mode
Green Green Green Boosting with gas or boosting wth solar
Green Green Off Boosting not required
Hotlogic Diagnosis Codes
Power LED Sensor LED Outputs LED Explanation
Off Off Off Power Off
Red Flash Off Off Hotlogic Controller Error
Green N/A Red Flash Control Output Error – Valve or Burner
Green N/A Red Gas Burner Lockout Error†
Green Red Flash (once) N/A Sensor 1 Error – Burner Sensor
Green Red Flash (twice) N/A Sensor 2 Error – Tank Sensor Bottom
Green Red Flash (3 times ) N/A Sensor 3 Error – Tank Sensor Top
Green Red Flash (4 times) N/A Sensor 4 Error – Tank Sensor Middle
Green Red Flash (5 times) N/A Sensor 5 Error – Ambient Sensor
Green Red Flash (6 times) N/A Sensor 6 Error – Collector Sensor
Flash Sequence Definition: If 2 sensor errors occur at the same time, the higher number flash will show first
† This is caused when the system fails to ignite. It may be caused by low/no gas supply. Turn power off, then on. If fault
recurrs, please contact Dux.
Hotlogic Connections
Power LED
Outputs LED
All LEDs are
Bi Colour –
Green & Red 1
2
3
4
5
6
Sensors LED