Dux Prodigy 4 135ZN User manual

Owner’s Manual
Models: 135ZN / 135ZL
170ZN / 170ZL
4 Star Gas Hot Water Heater
Specications and materials may change without notice.
Effective for all Prodigy 4 water heaters manufactured and sold after 1st December 2012.
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
H3071 3071 Rev. J

Owner’s Manual – Prodigy 4
H3071 3071 Rev. J
Contents
© Dux Manufacturing Limited 2012. All rights reserved.
Welcome To Dux Hot Water 1
Installation Details 2
Specications 3
Plumbing Connections 4
Gas Connections 7
Commissioning Adjustments 10
Owner's Information 11
SystemMaintenance 13
Troubleshooting 14
Warranty 16
Other Information 19

Owner’s Manual – Prodigy 4
1
H3071 3071 Rev. J
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 – Prodigy 4
2
H3071 3071 Rev. J
Installation Details
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.
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 = 500mm B=300mm min
For further details, refer to
AS 5601 – Gas Installation Code

Owner’s Manual – Prodigy 4
3
H3071 3071 Rev. J
Specifications
System Components
Component Description
1PTR Valve
2Hot Water Outlet To House
3Cold Water Inlet
Tank Specifications
Model Numbers 135ZN / 135ZL 170ZN / 170ZL
Capacity (L) 135 170
Net Weight Empty (kg) 72 86
Relief Valve Pressure (kPA) 1400 1400
Gas Consumption 135ZN: 23.5 MJ/h
135ZL: 22.5 MJ/h
170ZN: 27 MJ/h
170ZL: 26 MJ/h
Dimensions (mm)
A – Height 1600 1895
B – Hot Water Outlet 1325 1620
C – Cold Water Inlet 220 220

Owner’s Manual – Prodigy 4
4
H3071 3071 Rev. J
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, 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 – 1120kPa
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

Owner’s Manual – Prodigy 4
5
H3071 3071 Rev. J
Plumbing Connections
Pressure & Temperature Relief
Valve
The Pressure & Temperature Relief Valve
is supplied loose with the water heater.
The valve rating is:
All Models – 1400kPa
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).
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
either of the RP¾/20 sockets marked
“INLET” at the bottom of the water
heater. All ttings must be approved by
the relevant Authority. See the diagram
on page 5 for details.
Note: Brass plugs are supplied with
the water heater to plug off the unused
ttings. Ensure that a sealing material is
applied to the plugs to prevent leaking.
Note for S.A. and W.A.: It is a state
requirement that a Expansion Control
Valve be tted on the cold water supply
line between the non return valve and
the water heater. See the diagram on
page 6 for details.

Owner’s Manual – Prodigy 4
6
H3071 3071 Rev. J
Hot Water Connection
The hot water pipe should be connected
to either of the RP¾/20 sockets marked
"OUTLET" at the top of the unit. Please
check local regulations regarding the
use of hot water supply pipework that is
not made of copper.
Insulation of Pipes
For the most economical operation of
the water heater, it is recommended
that all hot water lines are insulated.
Where the hot water pipes are installed
outdoors, the insulation should be UV
stabilised.
Note: a combined isolating valve/non-return valve/line strainer may be used.
Expansion Control Valve only required where local regulations demand although it is
recommended in areas where the water saturation index is above 0.40 (see page 11).
Union
Connection
Non-return
Valve
Line
Strainer
Cold Water
Inlet
Drain
Expansion
Control Valve
Isolating Valve
(Spindle Vertical)
Inlet Connections
Temperature Protection
Water heaters can produce very hot
water. 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 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.
Plumbing Connections

Owner’s Manual – Prodigy 4
7
H3071 3071 Rev. J
Gas Connections
Refer to the Data Label for correct gas
type. Gas piping should be connected
through the side of the case (see gure
below).
The plastic grommet must be installed
around the pipe and clipped into the
case.
The gas control is tted with a RC½"/15
socket. A union connection should be
used.
Gas pipe sizes should be in accordance
with AS5601/AG601.
Warning: This water heater should be
checked on installation and the test
point pressure set in accordance with
that marked on Data Label.
Adjust gas pressure as required
to achieve specied gas test point
pressure. If problems are encountered
in this process contact the Dux Service
Department.
Failure to accurately set the pressure
can result in damage to the water
heater, and automatically cancels the
Manufacturer’s Warranty. This water
heater is to be installed only by an
Authorised Person.
Gas entry

Owner’s Manual – Prodigy 4
8
H3071 3071 Rev. J
Gas Connections
Filling the Water Heater
The water heater must be lled with
water before lighting.
Open all hot water taps. Open isolating
valve at the cold water inlet slowly and
allow water heater to ll until water ows
through the system. Close each hot
water tap after the air is expelled from
its line.
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.
Thermostat and
gas control knob Igniter
Lighting the Water Heater
Instructions for lighting procedure are
on the inside of the access cover and
shown below:
1. Turn the knob fully clockwise to the
“•” (off) position.
2. Wait ve (5) minutes so any build-up
of unburnt gas can escape.
3. Turn the knob to the (pilot)
position.
4. Depress the knob fully (until
disappears below housing) and after
thirty (30) seconds, whilst keeping
the knob depressed, repeatedly
press the igniter button (for up to 40
seconds) until the pilot ame ignites.
Note: It is not possible to depress
the knob fully if the gas control has
activated its safety shut-off feature.
In this case, wait 60 seconds for the
gas control to reset.
5. Keep the knob depressed for
twenty (20) seconds after the pilot
ame lights. The pilot ame can
be observed if a mirror is placed
directly below the pilot assembly.
6. Release the knob and check if the
pilot is still alight.

Owner’s Manual – Prodigy 4
9
H3071 3071 Rev. J
Gas Connections
7. If pilot has failed to light or has not
remained alight, turn gas control
knob to “•” (off). Wait ve (5)
minutes for the escape of unburnt
gas, then begin again at step 3.
8. When the pilot ame remains alight
with the knob released, turn the
knob anticlockwise to one of the
number settings. A setting of “6” is
recommended and this will give a
water temperature of about 60ºC.
9. Turn the knob to a higher number
for higher water temperatures or
a lower number for lower water
temperatures.
10. Replace the access panel and
ensure that it is rmly in position
before operating the appliance.
11. If the burner does not light at
the selected setting, the water
may already be at the selected
temperature.
Warning: Do not attempt to light if the
pilot is out and the knob is in the “ON”
position (one of the number settings).
Follow steps above.
Shutting Down The Water Heater
1. Turn the knob to “•” (off) position.
2. Turn water off at water isolating
valve.
Turning Off Gas To The Appliance
1. Turn the knob to “•” (off) position.
2. Turn off the gas isolation valve.
To maintain safety and efciency this
heater should be serviced annually by
an authorised service agent.
Note: Instruct owner in water heater
operation before leaving.

Owner’s Manual – Prodigy 4
10
H3071 3071 Rev. J
Commissioning Adjustments
Note: Commissioning adjustments
can be done only by a licensed
tradesperson.
Main Gas Pressure Regulator
Adjustment
The main burner pressure must be
set at installation and should not need
readjustment.
The pressure is best checked by
connecting a water manometer or
equivalent to the test point nipple on the
gas control. The test point pressure must
comply with the value on the Data Label.
If adjustment is necessary, proceed as
follows:
1. Remove the securing screw (1) from
the top of the Gas Control and lift
the plastic cover (2) upwards.
2. Locate the regulator adjustment
screw on the lower left hand side of
the Gas Control (3).
3. Light the burner. Rotate adjustment
screw clockwise to increase, or anti-
clockwise to decrease pressure.
4. Replace the plastic cover and
securing screw.
Note: For propane water heaters,
the pressure adjustment is at the gas
cylinder regulator. Adjustment should be
conducted as required to ensure correct
supply pressure to water heater as per
AS/NZS 5601.1.
Ignition System (Spark Gap)
Check the gap between the spark
electrode and the pilot burner is 3 –
5mm and adjust as necessary. Push the
igniter button to test for a spark.
Warning: Test the spark gap only where
there is no build up of gas.
Test The Water Heater
Test operation by lighting the water
heater (see Lighting the Water
Heater, earlier in this manual).
1
3
2

Owner’s Manual – Prodigy 4
11
H3071 3071 Rev. J
Owner's Information
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.
DO NOT place articles on or against
this appliance.
DO NOT use store chemicals or
ammable materials, or spray aerosols
near this appliance.
DO NOT operate with panels or covers
removed from the appliance.
Water Quality
Your Dux water heater has been
manufactured to suit water conditions of
most Australian metropolitan supplies.
Please note that harsh water supplies
can have a detrimental effect on the
water heater and its life expectancy. If
you are unsure about your water quality
you can obtain information from your
local water supply authority.
The water heater is designed for use in
areas where the Total Dissolved Solids
(TDS) content of the water supply is less
than 2500 mg/L. In areas where the
TDS exceeds 600mg/L the magnesium
alloy anode (supplied in the heater) may
become over reactive. To alleviate this,
the anode should be replaced with an
aluminium alloy anode, available from
your local Dux supplier.
The saturation index (SI) is a measure of
the corrosiveness or carbonate scaling
potential of water. Negative SI indicates
corrosive water that is non-scaling. The
more negative the SI the more corrosive
the water. Conversely, a more positive
SI indicates a greater potential for
scaling. If the SI is greater than 0.40 an
expansion control valve should be tted
as shown in the diagram on page 6.

Owner’s Manual – Prodigy 4
12
H3071 3071 Rev. J
How Long Will The Heater Run
Each Day?
The length of time that the heater will run
each day will vary dependent upon the
amount of hot water being used by the
household.
Caution: All water heaters have
the ability to produce hot water in a
surprisingly short time. To reduce the
risk of scald injury, it is mandatory
under the requirements of Australian
Standards AS3500 that an Australian
Standards approved temperature
control valve be tted to the hot water
supply pipe work. This valve should be
checked at regular intervals to ensure its
operation and settings remain correct.
What Should I Do During Holidays?
If the hot water system is not used,
for two weeks or more, a quantity
of hydrogen gas, which is highly
ammable, may accumulate in the water
heater. 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 a dishwasher, clothes
washer, or other appliance. During this
procedure there must be no smoking,
open ame or any other electrical
appliance operating nearby. If hydrogen
is discharged through the tap, it will
probably make an unusual noise similar
to air escaping.
Note: There are no user serviceable
components in the system.
How Does My System Work?
The Dux water storage tank is used
to store the heated water ready
for household use. It has a high
temperature vitreous enamel lining to
provide long life, and a high density
polyurethane insulation to ensure
minimal heat loss.
Never turn the gas supply off during
normal use.
Owner’s Information

Owner’s Manual – Prodigy 4
13
H3071 3071 Rev. J
Six Monthly Service – By Owner
Open the Pressure & Temperature Relief
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.
Other than this, personally inspecting or
servicing any part of the system is not
recommended.
Five Year Service – By Authorised
Personnel Only
After each 5 years of operation you
should contact the local service agent
to replace all safety valves and anodes
to ensure continued system life and
operational safety. In locations where the
water has a TDS greater than 600 mg/L
(see Water Quality on page 11), this
service is recommended every 3 years.
This service must be carried out by a
licensed tradesperson and we would
recommend that this service be carried
out by your local Dux Service Agent.
The service should include the following:
• Replace the Pressure &
Temperature Relief Valve.
• Replace the anode.
• Flush the water heater by doing the
following:
i. Turn off gas and electricity
supply.
ii. Turn off the cold water supply to
the water heater at the isolating
valve.
iii. Gently operate the easing lever
on the Pressure & Temperature
Relief Valve to release the
pressure in the water heater.
iv. Disconnect the cold water inlet
union to the heater and attach a
drain hose.
v. Gently operate the Pressure
& Temperature Relief Valve to
let air into the heater and allow
water to escape through the
hose.
vi. Flush the heater until clear water
appears then reconnect all
ttings,lltheheaterandrestore
the gas and electricity supply.
System Maintenance

Owner’s Manual – Prodigy 4
14
H3071 3071 Rev. J
What Should I Check Before
Making A Service Call?
If there is not enough hot water, it is
recommended that the following points
be considered before making a service
call. If after checking the following points
the problem has not been identied,
please contact Dux on 1300 365 115.
No Hot Water
• Is the Pressure & Temperature Relief
Valve discharging too much water?
• Do you have the correct size water
heater for your requirements? Sizing
details are available from your Dux
supplier.
• Is one outlet (such as the shower)
using more hot water than you
think?
• Carefully review the family's hot
water usage and if necessary
check the shower ow rates with a
bucket, measuring the amount of
water used over that period of time.
If it is not possible to adjust water
usage patterns, an inexpensive ow
control valve can easily be tted to
the shower outlet.
• Consider that often the hot water
usage of showers, washing
machines and dishwashers can
be under estimated. Review these
appliances to determine if your daily
usage is greater than the storage
volume of your water heater. For
example, if you have a 170 litre
storage tank and you are using
300 litres of water it is possible that
there will be certain times of the day
where there is insufcient hot water.
• Is there a leaking hot water pipe or
dripping hot water tap? A small leak
can waste a large quantity of hot
water.
• Replace faulty tap washers and
have your plumber rectify any
leaking pipe work.
Troubleshooting

Owner’s Manual – Prodigy 4
15
H3071 3071 Rev. J
Water Discharge from the PTR
Valve
Pressure & Temperature Relief Valve
(PTR)
It is normal for the PTR to allow a small
quantity of water to escape during the
heating cycle. The amount of discharge
will depend on hot water usage.
Continuous trickle (PTR)
This is most likely due to a build up of
foreign matter. In this case try gently
raising the easing lever on the Pressure
& Temperature Relief Valve for a few
seconds then release gently. This may
dislodge a small particle of foreign
matter and rectify the fault.
Steady ow (PTR) – more than 20L per
day
This may be caused by excessive water
supply pressure, a faulty Pressure &
Temperature Relief Valve or a faulty
thermostat. Turn off the gas supply and
contact your Dux Hot Water.
Troubleshooting

Owner’s Manual – Prodigy 4
16
H3071 3071 Rev. J
Dux Hot Water Unit
Manufactured by Dux Manufactur-
ing Limited (“Dux”)
Terms of Warranty and Replace-
ment Guarantee
All Prodigy 4 water heaters
manufactured and sold after 1 January
2011 are backed by a comprehensive
one (1) year full parts and labour
warranty (conditions apply – see below).
Furthermore, the Prodigy 4 tank includes
a guarantee to replace your hot water
unit if the inner cylinder fails within seven
(7) years (conditions apply – see below).
The terms of the Warranty and
replacement guarantee are set out
below.
1 Year Comprehensive Warranty
Your hot water system and its compo-
nents (“Unit”) are covered by 1 year (parts
and labour) warranty against defective
factory materials or workmanship.
This warranty period commences from
the date of installation of the Unit pro-
viding you have proof of this installation
date. Where the date of completion of
installation is not known or cannot be
proven, then this warranty will commence
one (1) month after the date of manufac-
ture (refer to the data label on the unit).
7 Year Replacement Guarantee
If an inner cylinder fails on a Dux hot
water unit within a further six (6) years
after the end of the initial one (1) year
warranty period, Dux will provide a
free replacement hot water unit at the
nearest approved Dux agent or Dux
ofce to the owner’s home. Under this
replacement guarantee, the transport,
installation and labour costs of delivering
the replacement hot water unit and
removing and replacing the existing
hot water unit with the replacement hot
water unit will be the responsibility of the
owner of the existing hot water unit.
Conditions of Warranty and Re-
placement Guarantee
The benets provided to you by the
warranty and replacement guarantee
(collectively “Warranty”) are in addition
to the guarantees and other rights and
remedies available to you under the
Australian Consumer Law (“ACL”).
If the Unit fails to conform to this
Warranty during the applicable period,
Dux will replace any failed component
or where necessary, in the absolute
discretion of Dux, replace the Unit free
of charge including reasonable labour
costs incurred in normal business
working hours.
This Warranty only applies to defects
which have arisen solely from faulty
materials or workmanship in the Unit
and does not apply to other defects
which may have arisen as a result
of, without limitation, the following:
accidental damage, abuse, misuse,
Warranty

Owner’s Manual – Prodigy 4
17
H3071 3071 Rev. J
Warranty
maltreatment, abnormal stress or strain,
harsh or adverse water conditions
including excessive water pressure or
temperature, neglect of any kind or
otherwise as a result of any use of the
Unit contrary to the product manual
or other instructions provided by Dux.
Alterations or repair of the Unit other
than by an accredited and licensed
service agent or technician are not
covered. Attachment of accessories
or use of non genuine replacement
parts other than those manufactured
or approved by Dux are not covered by
this Warranty.
This Warranty applies only to the Unit and
does not cover any ancillary plumbing
or electrical parts supplied by the
installer such as pressure limiting valve,
tempering valve, line strainer, stop cocks,
non-return valve, electrical switches,
pumps or fuses, or faulty installation.
The Unit must be installed by a licensed
plumber in accordance with information
set out in the Owner’s Manual and/
or Installer’s Guide supplied with the
Unit and/or any relevant statutory
requirements.
In addition to this Warranty, certain
legislation (including the ACL) may give
you rights which cannot be excluded,
restricted or modied. This Warranty
must be read subject to such legislation
and nothing in this Warranty has
the effect of excluding, restricting or
modifying those rights.
If Dux fails to meet a guarantee under
the ACL, your remedy for such failure
may be limited to any one or more of the
following:
• replacement of the Unit;
• repair of the Unit;
• refunding the cost of the Unit;
• payment of reasonable costs of
having the Unit repaired;
• payment in respect of the reduced
value of the Unit.
Any defective part of the Unit must be
returned to the point of sale before
replacement can be considered under
the terms of this Warranty. If the costs
of returning any defective parts are
unreasonable, please contact Dux on
1300 365 115 (Australia) or 0800 729
389 (New Zealand) so that we can
arrange a collection if appropriate.
Warranty claims can be made at the
point of sale or by posting or faxing a
warranty claim to Dux (contact details
listed below) within one (1) month of the
appearance of a defect. Warranty claims
under this extended warranty must
include the following details:
• Date of Purchase;
• Location of Purchase;
• Proof of Purchase;
• Date of Installation;
• Contact Details

Owner’s Manual – Prodigy 4
18
H3071 3071 Rev. J
Warranty
• Product Serial Number
Contact details
Dux’s contact details are as follows:
Business Address:
Dux Manufacturing Limited
Lackey Road
Moss Vale, NSW, 2577
Australia
Telephone:
1300 365 115 (Australia)
0800 729 389 (New Zealand)
Facsimile:
(61 2) 4868 0257
Email:
[email protected]
Note: If the Unit is located in a position
that does not comply with the installation
instructions or relevant statutory
requirements, then this Warranty does
not cover major dismantling or removal
of cupboards, doors, walls or special
equipment and/or excessive labour, at
the determination of Dux, to make the
Unit accessible for repair or replacement.
As required by legislation, including
under the ACL, any claims for damage
to furniture, carpets, walls, foundations
or any other consequential loss either
directly or indirectly due to defects
of any kind in a Unit will only be met
by Dux where the damage could be
considered reasonably foreseeable.
Our goods come with guarantees that
cannot be excluded under the Australian
Consumer Law. You are entitled to a
replacement or refund for a major failure
and for compensation for any other
reasonably foreseeable loss or damage.
You are also entitled to have the goods
repaired or replaced if the goods fail to
be of acceptable quality and the failure
does not amount to a major failure.