Dux Prodigy 5 330T User manual

Owner’s Manual
Models: 330T
360T
5 Star Gas Hot Water Heater
Specications and materials may change without notice.
Effective for all Prodigy 5 water heaters manufactured and sold after 1st December 2007.
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
H1651 1651 Rev. G

Owner’s Manual – Prodigy 5
H1651 1651 Rev. G
Welcome To Dux Hot Water 1
Installation Details 2
Plumbing Connections 4
Specications 6
Gas Connections 7
Owner’s Information 8
Troubleshooting 14
Service Information 16
Commissioning Adjustments 18
Warranty 19
Warranty Card 22
Contents
© Dux Manufacturing Limited 2011. All rights reserved.

Owner’s Manual – Prodigy 5
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H1651 1651 Rev. G
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 5
2H1651 1651 Rev. G
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 properly drained overow tray must
be used where property damage
could occur from water spillage. (See
AS/NZS3500.4.2 for further details).
Warranty does not cover consequential
damage due to heater leakage.
The water heater should be installed
OUTDOORS with the minimum
clearances as shown in the gure below.
The water heater should be installed
on a level, reproof plinth at least
50mm above the surrounding ground
level. Position the two wall brackets
25 mm below the lip of the lid and
secure them so that they are protruding
approximately 10mm beyond the back
of the heater. Position the unit in place
and secure the brackets to the wall (as
per gure below).
A = 500mm B=300mm min
For further details, refer to
AS 5601 – Gas Installation Code

Owner’s Manual – Prodigy 5
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Installation Details
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.
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.

Owner’s Manual – Prodigy 5
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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).
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.
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.
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.
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 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. See the diagram on page
5 for details.

Owner’s Manual – Prodigy 5
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H1651 1651 Rev. G
Plumbing Connections
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. For the
most economical operation of the water
heater, it is recommended that all hot
water lines are insulated. Please check
local regulations regarding the use of
hot water supply pipework that are not
made of copper.
Insulation of Pipes
All hot water pipes must be insulated
with UV stabilized insulation suitable
for solar working temperatures, e.g.
Armaex Insulation.
Note: a combined isolating valve/non-return valve/line strainer may be used.
Expansion valve only required where local regulations demand.
Union
Connection
Non-return
Valve
Line
Strainer
Cold Water
Inlet
Drain
Expansion
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/NZS3500.4.2
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.

Owner’s Manual – Prodigy 5
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Specifications
System Components
330T 360T
A Overall Height 1732 2045
B Outlet 1365 1675
Specifications
Nominal Capacity (Litres) 135 170
Water Capacity in First Hour* (Litres) 333 371
Net Weight Empty (kg) 100 118
Relief Valve Pressure (kPA) 1400 1400
Gas Consumption (MJ/hr) – Natural Gas 42 42
* Temperature rise at 45ºC and inlet temperature of 15ºC using natural gas

Owner’s Manual – Prodigy 5
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H1651 1651 Rev. G
Gas Connections
Gas piping should be connected to the
side of the case (see gure below).
The tting provided is an RC½/15
socket. A union connection should be
used.
Gas pipe sizes should be in accordance
with AS5601/AG601.
A second spanner should be used on
the brass tting provided to ensure that
no rotation of that tting can occur.

Owner’s Manual – Prodigy 5
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Owner’s Information
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 it is possible that the
magnesium alloy anodes (supplied in the
heater and colour coded orange) may
become over reactive. To alleviate this,
the magnesium alloy anodes should be
replaced with aluminium alloy anodes
(colour coded blue), available from your
local Dux supplier. Remove the lid,
which is secured by two (2) screws at
the rear and a clipping arrangement at
the front, to gain access to the anode
sockets.
Water can also be very corrosive. The
measure of this is the Saturation Index.
If the Saturation Index is greater than
0.40, an expansion control valve should
be tted and where the index is greater
than 0.80, the water heater installed
should be a Hard Water Model. Please
consult our Service Department for
advice if required.

Owner’s Manual – Prodigy 5
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H1651 1651 Rev. G
Owner’s Information
Warning
It is essential for the safe operation of
this gas heater that clothing or any other
ammable material should not be placed
against or on top of the water heater.
In addition, do not store ammable or
corrosive materials, such as dry cleaning
uids, pool chemicals, etc., in close
proximity to the heater.
The use of aerosol sprays in the vicinity
of the heater should be avoided. The
propellant gases used in these devices,
e.g. y-spray, hair-spray and laundry
aids, can break down in the ames
of the burner and produce corrosive
agents.
Caution
If this water heater is left in an operating
condition and unused for two weeks or
more, a quantity of hydrogen (which is
highly ammable) may accumulate in the
top of the water cylinder. 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 sound as with air escaping.

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Owner’s Information
The appliance is not intended for use by
young children or inrm persons without
supervision. Young children should be
supervised to ensure that they do not
play with the appliance.
Warning:
For safe performance this water heater
is tted with:
1. Thermostat.
2. Over-temperature energy cut-out.
3. Combination pressure and
temperature operated relief valve.
These devices must not be tampered
with or removed.
The water heater must not be operated
unless each of these devices is tted
and in working order.
Relief valves should be checked for
adequate performance or replaced at
intervals not exceeding 5 years, or less
in areas where there is a high incidence
of water deposits. The lever on the relief
valve must be pulled to operate the
valve at least once every 6 months.
Failure to operate the relief valve easing
gear at least once every six (6) months
may result in the water heater exploding.
Important
The relief valve and its drain outlet pipe
must not be sealed or blocked. It is
normal for the valve to overow during a
heating cycle.
Warning
Gas Fitter:
This water heater should be checked on
installation and the test point pressure
set in accordance with that marked
on Data Plate (see “Commissioning
Adjustments” on page 18).
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. This water heater
must be installed on a re-proof base.
User:
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.

Owner’s Manual – Prodigy 5
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H1651 1651 Rev. G
Owner’s Information
Filling The Water Heater
Open all hot water taps. Open stop
cock at the cold water inlet 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.
Lighting The Water Heater
The water heater must be lled with
water before lighting. Instructions for
lighting procedure are on the inside of
the access cover and discusses in the
section “Lighting Instructions for “Eurosit
Gas Control”.
The access cover is removed by easing
the cover up and away from the water
heater.
The unit is tted with a thermostat
that incorporates a Thermal Overload
Safety Cut-Out. In the event of
thermostat failure, the Safety Cut-Out
will automatically and permanently cut
off the supply of gas to the burner. If this
happens, your heater will not light and
you should call your local Dux agent.
It is important to t the drain cap
supplied to the unused drain (located
on either side of the lower edge of the
water heater.) A tube (e.g. standard
garden hose) should be connected to
the drain on the lower side of the unit
which is most suitable, so that water is
directed away from any concrete paths.
Precautions to be taken in freez-
ing conditions
If the household is to be left unoccupied
for a long period of time where the
heater may experience freezing
conditions then the thermostat should
be set to the minimum setting. If the
heater is turned off and isolated from
the gas supply then the tank should be
isolated from the mains water supply
and fully drained of water to prevent
frost damage.

Owner’s Manual – Prodigy 5
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Lighting Instructions for “Eurosit
Gas Control”
Warning: Do not light heater until it is
full of water.
4. Turn the knob fully clockwise to the
“•” (off) position.
5. Wait ve (5) minutes so that any
build-up of unburnt gas can escape.
6. Turn the knob to the (pilot)
position.
7. Depress the knob fully (until the
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 as
activated its safety shut-off feature.
In this case, wait for 60 seconds for
the gas control to reset.
8. Keep the knob depressed for
twenty (20) seconds after the pilot
ame lights. The pilot ame can
be observed in the mirror placed
directly below the pilot assembly.
9. Release the knob and check if the
pilot is still alight.
10. If the 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.
Thermostat and
gas control knob Igniter
11. When the pilot ame remains alight
with the knob released, turn the
knob anti-clockwise to one of the
number settings. A setting of “6” is
recommended and this will give a
water temperature of about 60°C.
Owner’s Information

Owner’s Manual – Prodigy 5
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H1651 1651 Rev. G
12. Turn the knob to a higher number
for higher water temperatures or
a lower number for lower water
temperatures.
13. Replace the access panel and
ensure that it is rmly in position
before operating the appliance.
14. 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.
Close-Down Procedure
1. Turn the knob to the “•” (off)
position.
2. Turn water off at the isolating valve.
To Turn Off Gas To The Appliance
1. Turn the knob to the “•” (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.
Owner’s Information

Owner’s Manual – Prodigy 5
14 H1651 1651 Rev. G
Pressure And Temperature Relief
Valve Running
It is not unusual for the valve to allow
a small quantity of water to escape
during the heating cycle. The amount
of discharge will depend on hot water
usage. As a guide, if it discharges more
than 20 litres of water in 24 hours there
may be a problem.
Continuous trickle
Likely build up of foreign matter. Try
gently raising the easing lever on the
relief valve for a few seconds. This
may dislodge a small particle of foreign
matter and rectify the fault. Release lever
gently.
Steady ow emitted
Likely causes are excessive water
supply pressure or a faulty pressure
valve.
No Hot Water
Is the relief valve discharging too much
water? See “Pressure and Temperature
Relief Valve Running”.
Do you have the correct size water
heater for your requirements? Sizing
details are available from your Dux
supplier.
Is one outlet (especially 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 and
a watch. If it is not possible to adjust
water usage patterns, an inexpensive
ow control valve can easily be tted to
the shower outlet.
High Gas Bills
Is the relief valve discharging too much
water? See “Pressure and Temperature
Relief Valve Running”.
Is one outlet (especially the shower)
using more hot water than you think?
See “No 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
pipework.
Troubleshooting

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Six Monthly Service (By Owner)
Operate the Pressure and Temperature
Relief Valve for approximately 10
seconds by raising the easing lever on
the top of the valve to ensure water is
able to be relieved through the relief
drain pipe. Check to ensure the valve
closes correctly.
Annual Service (By Authorised
Personnel Only)
Clean and service the gas burner and
pilot.
Five Year Service (By Authorised
Personnel Only)
The ve yearly service should be carried
out by a licensed Tradesperson. It is
recommended that this service be
carried out by your local Dux agent. The
service should include the following:
• Replace the Pressure and
Temperature Relief Valve.
• Replace the anode. In areas of
harsh or adverse water conditions,
it is recommended that you carry
out a more frequent check of your
anode's condition. Refer to “Water
Quality”.
• Clean and service the gas burner
and pilot.
• Flush the cylinder.
Removal And Replacement Of Baf-
e (By Authorised Personnel Only)
There may be some instances where
the bafe may need to be accessed
for cleaning, repairs or replacement. To
access the bafe, the following steps
need to be followed:
• Make sure the gas controller is
turned to pilot or off position before
commencing.
• Remove the plastic lid from the top
of the heater. There are screws at
either side of the lid towards the
rear and a clipping arrangement
at the front which can be popped
using a screwdriver, taking care to
not scratch the heater case.
• Remove the rockwool insulation
blanket. The top of the down duct
will now be present, wrapped in foil-
backed glass insulation.
Caution: Metal surfaces in this
region, including the bafe, may
be hot. Use appropriate protection
when performing the following
procedures.
Service Information

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Service Information
• Cut the foil-backed insulation as
outlined in the gure below and peel
back the aps to enable access to
the top cover and the screws that
secure it.
• Remove the screws (standard tip,
short blade length screwdriver
required) and tilt the top cover
towards the rear of heater until there
is enough clearance to remove bafe.
• Remove the bafe and replace with
either a new bafe of same type
(ie for a 330TN, 360TN, 330TL or
360TL) or the same bafe that has
been cleaned or repaired.
• Ensure bafe is hanging correctly
and replace top cover and screws.
• Replace the folds of insulation and
seal the cuts with aluminium tape (do
not use any other type of tape due to
the heat that occurs in this region).
• Replace rockwool and plastic
lid and turn gas controller to
appropriate setting (ignite, if
required, using the instructions
outlined in the section “Lighting
Instructions for “Eurosit Gas
Control”). If the bafe is new and
has a surface coating of oil, there
may be a pungent odour as the oil
burns off. Do not be alarmed, as
this will only last for a few minutes.

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Service Information
(a) Burner Aeration
The aeration is self adjusting. There is no
facility or requirement for you to adjust
aeration.
(b) Main Gas Pressure Regulator
Adjustment
The main burner pressure must be
set at installation and should not need
readjustment. If adjustment is necessary,
proceed as follows: (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 Plate).
EUROSIT Gas Control:
i. Loosen the plastic cover from the
top of the gas control and ensure
pressure adjustment screw on left
hand side is accessible.
ii. Remove test point screw from upper
nipple on the right hand side of the
gas control and attach manometer.
iii. Light the burner. Rotate adjustment
screw clockwise to increase
pressure, or anti-clockwise to
decrease pressure.
iv. Once pressure is set, rotate
thermostat adjustment knob on
gas control to pilot setting (see
“Operating Instructions”). Remove
manometer and replace the test
point screw.
v. Replace the plastic cover.
vi. Ensure pilot is still lit (if not, relight
as per the “Operating Instructions”).
Rotate thermostat adjustment knob
to desired setting.
Note: Pressure adjustments at gas
cylinder regulator should be conducted
as required to ensure correct supply
pressure to water heater as per
AS5601/AG601.
(c) Ignition System (Spark Gap)
Check that 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: Only test the spark gap
where there is no build up of gas).
(d) Pilot Flame
Check that the pilot ame plays on
the last 4mm of the Thermocouple. If
necessary, the direction of the ame can
be corrected by careful manipulation of
the pilot burner hood.

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18 H1651 1651 Rev. G
Warranty
Dux Hot Water Unit
Manufactured by Dux Manufactur-
ing Limited (“Dux”)
Terms of Warranty and Replace-
ment Guarantee
All Prodigy 5 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 5 tank
includes a guarantee to replace your
hot water unit or ue if the inner cylinder
or ue fails within ten (10) years,
including labour for the rst ve (5) years
(conditions apply – see below).
The terms of the Warranty and
replacement guarantee are set out
below.
1 Year Comprehensive Warranty
Your Prodigy 5 hot water system and
its components are covered by a one
(1) year (parts and labour) warranty
against defective factory materials or
workmanship from the date your hot
water unit is installed or two (2) years
from date of manufacture, whichever
occurs rst.
10 Year Replacement Guarantee
a. If an inner cylinder or ue fails on a
Dux hot water unit within a further
four (4) years after the end of the
initial one (1) year warranty period,
Dux will provide a free replacement
hot water unit or ue at the nearest
approved Dux agent or Dux ofce to
the owner’s home (including labour).
b. If an inner cylinder or ue fails on
a Dux hot water unit fails within a
further ve (5) years after the end
of the rst ve (5) year warranty
period, Dux will provide a free
replacement hot water unit or ue
at the nearest approved Dux agent
or Dux ofce to the owner’s home
(not including labour).
During the 10 Year 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 respon-sibility of
the owner of the existing hot water unit.
Scope of Warranty and Replace-
ment Guarantee
In addition to the guarantees implied
by the Australian Consumer Law
(“ACL”), Dux provides a warranty for the
periods of time set out above (1 year
plus a further 9 years), after the date of
installation (or manufacture) of the hot
water heater (“the Unit”), that the Unit is
free from all defects in factory materials
or workmanship under normal use.
If the Unit fails to conform to this
warranty during the applicable period,