Saxon COPPERFLOW User manual

MAINS PRESSURE ELECTRIC WATER HEATER
INDOOR/OUTDOOR MODEL
OWNER &
INSTALLER
MANUAL
AND
WARRANTY
INFORMATION.
PLEASE READ THIS MANUAL
CAREFULLY BEFORE
INSTALLING AND OPERATING.
THIS WATER HEATER MUST
BE INSTALLED BY
A QUALIFIED PERSON.
COPPERFLOW SERIES
Manufactured in Australia by Peter Sachs Industries Pty Ltd
A.C.N. 010 792 051 A.B.N. 69 010 792 051
Marketed by SAXON SALES
FOR SERVICE - CALL 1300 363 959
OR EMAIL [email protected]

1
CONTENTS
Page No.
ABOUT YOUR HEATER & SERVICE .......................................................2
HOW YOUR HEATER WORKS ................................................................5
INSTALLATION DIAGRAMS ..................................................................8/9
INSTALLATION .......................................................................................10
CONNECTIONS - PLUMBING................................................................13
CONNECTIONS - ELECTRICAL.............................................................15
SERVICE FAULT CHECK LIST...............................................................17
Copyright Peter Sachs Industries Pty. Ltd.
© 2009 Document: B710 Issue: 09
Date: July 2009
Certificate of Suitability CS/57/Q (Degree of Protection IP23)
Standards Australia Watermark AS3498 LIcense No. W191C
Tick License No. N1136
AUTHORISATIONS:

2
ABOUTYOUR WATER HEATER
AND HOW TO SERVICE IT.
Congratulations for choosing a SAXON Electric Mains Pressure Heat Exchange
Water Heater. With over 70 years of water heater manufacturing experience,
SAXON produces high quality innovative products at affordable prices and is
committed to providing excellent sales and service back up.
Helpful advice is only a Phone Call away.
FOR SERVICE - CALL 1300 363 959
Please quote your Serial Number and Date of Manufacture when telephoning for
Service. These are situated on the large decal on the water heater.
(SEE FIGURE 1 BELOW)
WHAT IS THE LIFE OF A WATER HEATER?
The factors which determine water heater life include water quality, water
pressure and temperature at which the unit operates and water usage. Your
SAXON heater is supported by the Comprehensive Warranty enclosed.
DATE OF
MANUFACTURE
SERIAL
NUMBER
FIG. 1

3
HOW TO SAVE UNNECESSARY
SERVICE COSTS
Follow the Check List below before Calling 1300 363 959.
You will be charged for attending to any condition or fault not related to the
manufacture of failure of a component part (See Warranty included).
SERVICE CHECK LIST FOR ITEMS NOT UNDER WARRANTY
1. Excessive Discharge from Overflow caused by water pressure rising above
the pressure designated for your heater. (See ‘Water Pressure’, Page 11)
2. If the Discharge is caused by a faulty valve or a Leak in the heat exchange
coil call 1300 363 959 for an inspection.
3. Not enough hot water or no hot water.
Check if electricity is switched on at Switchboard and isolating switch if
installed at heater. (Look for marking on Switch Board ‘Water Heater’)
4. (a) Adjusting thermostat.
(b) Adjusting tempering valve.
(c) Checking system controlling relay.
(d) Replacing blown fuses - Power not connected.
(e) Other unrelated complaints.
5. It is now current practice for most Electricity Supply Authorities to fit a relay
in the meter box of new dwellings and frequently in existing dwelling, to
control the supply of electricity to the water heater. This is a switch which the
Electrical Authority is able to turn on and off by remote control.
These relays sometimes malfunction, resulting in a loss of electricity to heat
sufficient water to meet household requirements.
Relays in new installations are often set for times on and off, which do
not suit the occupants and it is possible to have these times altered and
malfunctions rectified by contacting your Local Electricity Supply Authority.
6. Is your water heater too small for your requirements?
SAXON Sizing Guide literature is available or check website www.saxon.net.au
which will help you decide if your water heater is big enough or talk to your
Installing Plumber.

4
HOW TO IMPROVE PERFORMANCE
7. If your installation is Borderline, enquire from your plumber about fitting
inexpensive flow control valves, water efficient shower roses, low flow tap
aerators which will help reduce water usage. Replace leaky tap washers.
8. An option is to adjust the Thermostat upwards to gain additional hot
water capacity for limited periods. Avoid setting above 80ºC to reduce the
possibility of scalding and reduction of the life of your heater.
9. You may adjust the Flow Rate of the heater. (See ‘Adjusting the Flow Rate’,
Page 12).
HIGH ELECTRICITY BILLS
• Check for excessive flow from Overflow - (See ‘Water Pressure’, Page11)
• Check for leaking pipe or dripping tap. A dripping tap at one drip per second
wastes over 14,000 litres of water per year, which have paid to heat.
• Ask your Plumber to replace any leaking tap washers or other leaks.
• Is an outlet such as the shower using more hot water than is necessary?
Fit an inexpensive flow control valve.
EXCESSIVE STEAM DISCHARGING FROM THE
WATER HEATER VENT
Adjust thermostat down. If the water heater is boiling, turn off the power to
the unit and phone [phone] or an Accredited Service Agent to arrange for
inspection.

5
HOWYOUR WATER HEATER WORKS
A VERY SAFE SYSTEM
Water is stored in a copper tank containing a copper heat exchange coil. Water in
the tank is heated by an electric heating element. As cold water passes through
the heat exchange coil it is heated by the transfer of heat from the hot water in
the tank to the cold water in the coil. The mains pressure water in the coil, now
hot, is then delivered to taps in the home.
Water delivered from a heat exchange system gradually reduces in
temperature during the course of prolonged draw off and you will find the
need to make small adjustment to the hot and cold taps or your lever mixer to
maintain an even flow at the temperature which suits you. After a short time
this will become an automatic and unconscious response. This does not mean
you are running out of hot water.
MAINS PRESSURE
The internal copper coil heat exchanger is designed to operate at mains pressure
for connection to the mains water supply. If the mains supply pressure in your
area exceeds that shown on Page 11 ‘Water Pressure’, a pressure limiting valve
must be fitted.
ELECTRICAL SUPPLY
• Continuous electricity supply.
This type of supply is required where the unit is operating at maximum
capacity.
• Off peak or controlled electricity supply.
This type of connection will only allow heating to occur during certain set
hours and requires larger capacity units. A volume of water sufficient for the
day’s total use is heated and stored. This type of supply is more economical.
THERMOSTAT
The thermostat automatically controls the electricity supply to the heating
element, maintaining a constant temperature. The thermostat is mounted inside
the junction box cover of the water heaters.
Do not switch off the water heater when it is not in use, except for extended
periods. The thermostat is fully automatic and only uses power when heating is
required.

6
PRESSURE RELIEF & NON-RETURN VALVE
Situated near the top of the water heater, the pressure relief valve is combined
with a non-return valve and is set at 1400kPa. During periods after hot water has
been drawn off, water in the coil is trapped between the tap and the non-return
valve. This water heats up through the transfer of heat from water in the tank and
expands. The relief valve redirects this excess into the tank, assisting with topping
non-restricted to provide different flow rates.
The pressure relief valve should be checked for performance or replaced at
intervals not exceeding 5 years, or more often in areas where water contains
hard water deposits (See ‘Topping Up’, Page 7)
VENT PIPE
The vent pipe must not become blocked or obstructed. It should be checked
regularly to ensure it is not blocked.
SAFETY
This water heater is protected by a thermostat and a pressure relief valve.
Hot water increases the risk of injury by scalding.
The water heater is thermostat should be set at the lowest possible temperature
which will provide sufficient hot water. The thermostat can be adjusted within the
range shown below –
Minimum Thermostat Setting of 60ºC
Maximum Allowable Thermostat Setting of 80ºC
We recommend, and it may also be required by some Councils, that an approved
temperature limiting device be fitted into the hot water piping to bathrooms. This
will keep the water temperature below 50ºC at the bathrooms. Risk of scald injury
will be reduced, whilst providing hotter water to the kitchen and laundry.

7
TOPPING UP
Once every six months the pressure relief valve must be checked by the owner.
To top up the tank and check the valve, lift the valve lever against the spring
pressure until water flows from the overflow pipe. When water flows from the
overflow, restore the lever to its original position. (Do not let the lever snap back,
as this may damage the valve seat). As cold water is introduced into the tank, it
will expand and continue to flow for some time. It is good idea to do this check
whenever you receive your electricity bill. If water does not flow freely call the
SAXON Service Number or the local SAXON Accredited Service Agent.
FIG. 2
LIFT THE LEVER UPWARDLY
AGAINST THE SPRING TENSION
COMBINATION
EXPANSION RELIEF,
NON-RETURN, FILLER VALVE

8
INTERNAL TEMPERATURE CONTROL
The internally adjustable thermostat may be altered by removing the junction box
cover. This adjustment must be made by a qualified service person.
ADJUSTING FLOW RATE
If you need to adjust the flow rate of the water heater see Page 12 for more
detail. Correcting the flow rate will provide best possible performance.
INSTALLATION DIAGRAMS

9
INSTALLATION DIAGRAMS
Use to adjust flow rate as
per SAXON installation
instructions
Isolating Stopcock
Cold Water Supply Downward
Heat Trap
(advisory)
Junction
Box Cover
Adjustment of Tempering
Valve Temperature
See valve manufacturer’s
instructions for details.
Line Strainer
(advisory)
Pressure Limiting Valve
(if required)
Tempered Water Outlet
(to Bathrooms)
Full Hot Water Outlet
(to Kitchen)
Use this outlet to measure flow rate
When fitting Tempering Valve at the water heater, ensure the cold
supply to the Tempering Valve is teed off the cold supply to the water
heater down stream from the isolating stopcock and any pressure
limiting valve (if fitted)
NOTE:
For optimum performance or when fitting Tempering Valve remote from water heater, use RMC Heatguard
HP Tempering Valve (green knob) or similar.

10
INSTALLATION
INSTALLATION
Installation of this water heater must be performed by an Authorised Person and
in accordance with both Local Authority Regulations and AS/NZS 3500.4 “National
Plumbing and Drainage Code and AS/NZS 3000. Wiring Rules.
LOCATION
Install as close as practicable to the kitchen or most frequently used hot water
outlet in an accessible position, and with adequate access to thermostat and
element at front of heater. Do not completely enclose unit – it is essential that it
be readily removable for servicing.
CLEARANCES
Allow adequate room to work with tools. A minimum of 25mm clearance all
around the water heater including the top is required. An additional 30mm is
required for relief valve removal, 80mm for access cover removal and 400mm for
element removal. You should be able to read the information on the rating plate.
Adequate provision must be made to dispose of any escape of water from
heater or adjacent plumbing which might result in damage to property.
The water heater must be connected in such a way that the electrical junction
box is accessible to a service agent allowing the removal of the heating element
and for complete removal of the unit when necessary.
CONFINED SPACES
If the thermostat fails the unit may produce excessive steam.
It is strongly recommended that heater should be installed in well ventilated
spaces to avoid condensation build up.
If installed in confined areas, make provision for Service Access.
Vent safely to open air and carry overflow to drain.
FIG. 4

11
FOUNDATION
To ensure adequate ventilation, position unit on a timber support base on a
concrete slab. (SEE FIGURE 5)
Alternative forms of water heater bases are acceptable providing they allow for
adequate ventilation.
Attention is drawn to the weight of the water heater when full and installer
should ensure that the base and footings are substantial enough to avoid
subsidence etc.
SAFE TRAY
It is a requirement of the National Plumbing Code AS/NZS 3500.4 that all water
heaters be installed in a safe tray, where in the event of a leak, property may
otherwise be damaged. Installation of safe trays must comply with clause 4.4 and
sub clause 1 to 5 of the abovementioned Code.
WATER PRESSURE
Test Incoming Water Pressure with a gauge. If pressure exceeds 1100kPa, an
approved pressure limiting valve is required and should be fitted as shown in the
installation diagram. (Page 9)
Pressure limiting Valves are not supplied with Water Heaters.
TANK SUPPLY
Not recommended without a pressure pump, minimum supply pressure should
be no less than 350kPa.
A non-restricted HPNR valve may be required to be fitted for supply less than
350kPa.
FIG. 5

12
BORE WATER SUPPLY
NOT RECOMMENDED FOR CONNECTION.
For further information contact SAXON Service. If the heater is connected to bore
supply against SAXON recommendation, warranty does not apply.
VENT PIPE
This Pipe Must Not Become Blocked or Obstructed.
It should be checked periodically to ensure it remains clear. To prevent accidental
discharge of hot water through the vent pipe whilst checking the valve, the vent
pipe may be extended downwardly. (See Connections Plumbing ‘Vent Pipe’, Page 13)
ADJUSTING FLOW RATE
Failure to operate the water heater at the correct recommended flow rate could
result in unsatisfactory hot water delivery.
The best flow rate to heat water to the required temperature is 9 litres/minute
for the 140 litre model. For the 70 litre, 90 litre and 140 litre model, a flow rate in
excess of 9 litres/minute is not recommended. A flow rate up to 12 litres/minute
can be set for the 180, 280 and 400 litre units if desired.
To adjust the flow rate:
• The cold water supply should be turned off at the stopcock which is situated
on the cold water inlet side of the unit.
• Position an average household bucket of 9 litres under the laundry hot tap.
• Turn the tap fully on and note how long it takes to fill the bucket.
• A 9 litre bucket should fill in 1 minute for 9 litre/minute or 45 seconds for
12 litres/minute. Should the bucket not be filled or overflow in this time, the
flow rate can be adjusted by adjusting the water heater isolating the stopcock.
• Repeat this procedure until the desired rate is achieved.
HOT WATER DELIVERY
As this water heater delivers water hotter than 50ºC, a temperature control device
is recommended to be fitted, at the water heater (See illustration, tempering valve,
Page 9) between the water heater and outlets in bathrooms and en suites.
REDUCING HEAT LOSSES
To reduce heat loss, it is recommended weatherproof insulation be applied to the
first 1.5 to 2m of the hot water line out of the water heater.
HEAT TRAP
A heat trap should be inserted in the hot water supply line. See diagram on Page 8.
Refer to National Plumbing Code AS/NZS 3500.4.

13
CONNECTIONS - PLUMBING
All Plumbing Connections should be made in accordance with appropriate
Local Authority Regulations.
Flush out pipes before connecting unit to ensure that no foreign matter blocks
the valve seating.
Use Line strainers where required by Local Authority.
It is recommended that Connections should be made with compression fittings
– under no circumstances should any connections in the installation be welded,
brazed or soldered. Provided flare annealing and the use of hammer type
flaring tools are not used, crox or flare connections may be used.
CONNECTION SIZES
• Hot Water Connection: DN115 Copper Tube
• Cold Water Connection: BSP Male suitable for compression joint.
• Vent Pipe: 12.7mm Copper Tube DN15 Copper Tube.
• Overflow 19.1mm Copper Tube DN20 Copper Tube.
PRIZE SIZES
For best results, choose the most suitable pipe size for each application. Allow
for the cold water piping to the water heater to be the same size or larger than
the hot water line from the water heater.
INLET/OUTLET CONNECTION
On the cold water inlet connection, carefully follow the installation diagram
(See Page 8 and 9). Always provide a union connection at the inlet and outlet on
the water heater to allow for disconnection of the water heater.
VENT PIPE
The vent pipe must not become blocked or obstructed. It should be checked
regularly to ensure it remains clear. The vent pipe may be extended downwardly
a distance not exceeding 1 metre, in the event of accidental discharge of hot
water through the vent pipe whilst checking the relief valve. To prevent the
possibility of collapsing the tank by creating a vacuum, a 3mm hole should be
drilled into the top of the elbow attached to the vent pipe. The vent pipe should
discharge at a visible point where water flow will not cause damage to property
or injury to persons.
Note: Thermostats above 80ºC will cause normal wafting steam which will condense
and drip from the vent pipe. (See Installation in ‘Confined Spaces’, Page 10)

14
OVERFLOW PIPE
Overflow pipes may be extended from the water heater, but must not be less
than 19.1mm (¾”) O.D. copper tube – not more than 10 metres in length. Right
angled bends must be limited to no more than three. The extension must fall
from the overflow outlet, should not be looped, and shall discharge at a visible
point where water flow will not cause damage to property or injury to persons.
This Pipe Must Not Become Blocked Or Obstructed.
FILLING THE WATER HEATER BY LIFTING THE VALVE LEVER
N.B. – Turning on the Stopcock or Duo Valve alone does not fill the heater.
Power must not be turned on until the water heater is filled with water, and a
satisfactory megger reading is obtained.
Open the cold water isolating stopcock to the water heater.
Operate the lever on the combination pressure relief and non-return valve. This
allows the water to bypass the valve and fill the main tank. Water will flow from
the overflow when the tank is full.
DRAINING THE WATER HEATER
Turn the power off.
Turn off the cold water supply to the heater.
Check that vent and overflow pipes are unobstructed to avoid collapsing the
tank.
To drain the tank, remove the drain plug and attach a hose to the water heater.
Rake the other end of the hose to a Drain.

15
CONNECTIONS – ELECTRICAL
Power must not be turned on until the water heater is filled with water, and a
satisfactory megger reading is obtained. (See ‘Filling the Heater’, Page 14)
All water heaters are designed for 230-240V a.c. mains operation.
Electrical connections are made at the terminal block (access to which is made
by removing the junction box cover from the front of the heater).
1. Check all connections for wires which may have worked loose in transit.
2. Check thermostat setting before replacing junction Box Cover.
Normal thermostat setting is 80ºC.
Caution: Take care when drilling into external case for saddles or clips used to
mount plumbing and electrical fittings. Do not penetrate more than 12mm.
HEATING ELEMENT
The water heater is fitted with an incoloy bolt-on immersion type element. There
are several different element ratings used throughout the SAXON range of water
heaters.
The rating of your element is shown on the main decal (SEE FIG. 1) and will be
one of the following:-
(i) 1.8kW (ii) 2.4kW (iii) 3.6kW (iv) 4.8 kW
The standard element will make a rumbling sound under normal operating
conditions, similar to the sound of an electric jug heating water. This sound in
itself does not indicate that the unit is boiling. If you consider this noise to be
unacceptable, some possible solutions are:-
(1) Changeover existing element with non-standard lower density heating
element of the same wattage.
(2) Relocate Water Heater.

16
PLASTIC PIPINGAND HOT WATER
Under normal operating conditions, electric water heaters may heat water to
around 80ºC. Mains pressure varies from location to location and from time to
time and SAXON electric water heaters are fitted with an expansion relief valve
rated at 1400kPa. Under certain circumstances such as component malfunction,
temperatures of water may exceed 80ºC at pressures up to 1400kPa.
Tradesmen must ensure that the plastic pipe they are using complies with
relevant standards and can handle both the temperatures and the pressures
associated with water heaters in both normal operating conditions and in times
of component malfunction for the life of the installation within the property.
Tradesmen should reference AS/NZS 3500.4 to ensure that they use the correct
plastic pipe for the particular task. Pipe manufacturers may also provide
additional information.
WATER QUALITY
SAXON water heaters have been manufactured to suit most Australian water
supplies. However, some water supplies can have a detrimental effect on the
copper inside the SAXON water heater. Water chemistry from some water
authorities and in some shires may, from time to time, result in pitting corrosion
of the copper coil and ultimate failure of the water heater. Some SAXON water
heaters are fitted with a small anode to assist in the prevention of pitting
corrosion due to water which is corrosive to copper.
Key know contributors to pitting corrosion include pH levels below 7 and/or
bicarbonate to sulphate ratios in the water of less than 2:1 ratio. If you are unsure
of your water quality, you can obtain information from your local council or
local laboratories. Installing a SAXON water heater in areas where water that is
corrosive to copper exists may void your warranty.

17
SERVICE
FAULT CHECKLIST
COMPLAINT SUSPECTED CAUSE TO CORRECT PROBLEM
Poor Water Pressure Blockage at the inlet connection Re-adjust isolating valve Disconnect
the water supply at the valve to remove
blockage Fit unrestricted HPNR valve
Not Heating (a) Tripped Circuit Breaker
(b) Faulty thermostat or
heating element
(c) Fuse Wire broken
(d) Unit switched off
(e) Faulty control relay
Reset Circuit Breaker
Call SAXON Service to replace parts if in
warranty period - if out of warranty, call
electrician
Call Electrician
Switch unit on
Contact Locate Electricity Authority
Insufficient Hot Water (a) Unit connected to wrong
electricity tariff
(b) Unit leaking
(c) Water passing through too quickly
(d) Water level in storage cylinder
below desired level
(e) Tempering valve setting on low
(f) Thermostat setting too low
Phone Electrical Authority to change tariff
Call SAXON Service to repair unit if under
warranty
Adjust flow rates to recommended setting
(See Page 12)
Refer Valve Maintenance
(See Page 6)
Call Plumber
Call Electrician
Overflowing
(if in excess of 250ml
per day)
(a) Faulty Valve
(b) Mains water supply in excess
of 1100kPa
(c) Leaking coil
If under warranty-contact SAXON service
Outside of warranty contact local plumber
Install pressure limiting valve in cold water
line before HPNR valve (500-600 kPa)
Call SAXON service or local plumber/
electrician
Steam issuing
from unit
Unit boiling (a) Adjust thermostat down
(b) Replace thermostat - if under
warranty call SAXON service
(c) Contact local electrician
Rumbling Sound Heating (element) Rumbling sound occurs during normal
heating cycle. If noise is excessive
(See ‘Heating Element’, Page 15)
Loud banging noise in
or near heater
Water hammer (a) Adjust flow rate to recommended
settings
(b) Call SAXON service
Electricity account
too high
Leaking pipe or dripping tap boiling Check for leaks
See above (Unit Boiling)
SAXON SERVICE - PHONE [phone]

SERVICE 1300 363 959
MANUFACTURED IN AUSTRALIA BY PETER SACHS INDUSTRIES PTY LTD MARKETED BY SAXON SALES
Peter Sachs Industries Pty Ltd Zillmere Brisbane 4034 Phone [phone] Fax [phone] A.C.N. 010 792 051
NOTE: Every care has been taken to ensure the accuracy in preparing this publication. No liability can be accepted
for any consequences which may arise as a result of its application.