SUNPRO D2FN26 Assembly instructions

H4110 4110 Rev. F
Specications and materials may change without notice
Effective for Sunpro gas post-boosted solar water heaters manufactured and sold after 1st Sept 2006.
Installation by a licensed tradesperson and in
accordance with:
• AS/NZS 3500.4 “National Plumbing &
Drainage Code Hot Water Supply Systems
– Acceptable Solutions”
• AS5601/AG601 Gas Installation
• Adherence to local authority and OH&S
regulations
• Victorian PIC Requirements
Installer’s Guide
For advice, repairs and service, call:
1300 365 115 (Australia)
0800 729 389 (New Zealand)

Read This Document First
On completion, sign and leave with owner
(Gas Post-Boost) Solar Water Heater
Models: D2FN26, D2FL26,
D3FN26, D3FL26,
D4FN26, D4FL26
D2FN20, D2FL20
Carefully remove all packaging and
transit protection from the heater before
installation. Dispose of the packaging
responsibly using re-cycling facilities
where they exist.

Installer’s Guide – (Gas Post-Boost) Solar Water Heater
H4110 4110 Rev. F
Installer’s Guide
Rough In Diagram 1
Read This Document First 2
Safety Audit 2
Removal of Existing Tank 3
Placement of New Tank 3
Water Connections 4
Pipes – Important Points 5
Collectors – Alignment
and Inclination 7
Collectors – Important Points 8
Collectors – Attaching to Roof 9
Collectors – Attaching Fittings 11
4 Way Union Assembly 14
Anti-Frost Valve 15
Flashing 16
Temperature Sensor 17
Heat Trap/Non Return Valve 19
PTR Valve 20
Gas Connection 20
GPO 21
Tempering Valve 22
Testing the Gas 22
Burner Test Point Pressure 23
Setting the Low Burner Rate 23
Setting the High Burner Rate 24
Commissioning Checklist 25
Installation Declaration 26
Components 27
© Dux Manufacturing Limited 2011. All rights reserved.

Installer’s Guide – (Gas Post-Boost) Solar Water Heater
1
H4110 4110 Rev. F
Rough In Diagram
Approximate location of pipework. A tolerance of 25mm is acceptable to dimensions shown in table below.
Note: Ensure pipes protrude horizontally from wall, and leave enough length of pipe to allow easy
connections.
250 L 315 L 400 L
Tank Height 1444 1754 1703
Overall diameter 617 617 705
A Hot water outlet 1230 1300 1450
B Tempered water outlet (mid-way between A and C) 505 540 615
C Cold water inlet 220 220 220
D Return from solar collectors 1231 1541 1466
E Gas entry 770 820 820
F Flow to solar collectors 600 600 600
House rebate level
100
A
B
F
C
D
E
Hot Return
Gas
Flow
Cold
Tempering
Valve
100

Installer’s Guide – (Gas Post-Boost) Solar Water Heater
2H4110 4110 Rev. F
Installer’s Guide


• This Installer’s Guide and the
Owner’s Manual (also included in the
product carton) contain important
information about installation and use
of this water heater.
Note: For an easier
installation, please read this
document before you begin.


• Arrive at site, park vehicle as close as
allowable to installation, and conduct
a safety audit, also known as Work
Method Statements (WMS) or Job
Site Analysis (JSA).
• Prior to working at heights, it is the
responsibility of the installer to ensure
that all practices are compliant with
any relevant OH&S legislation.
Note: Do not commence a
job where the risks cannot be
controlled.
• Refer to local working at heights
regulations. NSW Ref: “Safe Work on
Roofs – Part 2 Residential” Code of
Practice 2004, Work Cover NSW.

Installer’s Guide – (Gas Post-Boost) Solar Water Heater
3
H4110 4110 Rev. F
Installer’s Guide


• The existing tank (if applicable)
should be drained and removed in a
responsible manner.
Note: Do not drain on to grass
or garden beds.


• Safely position new storage tank on
a level surface in accordance with all
plumbing and building regulations.
Note: We recommend a plinth
be installed under the water
heater where the water heater
is subjected to wet conditions.
• Refer to the section called “Rough
In Diagram” on page 1 for detailed
information on position of plumbing.
Install a plinth under the
water heater where the
water heater is subjected
to wet conditions

Installer’s Guide – (Gas Post-Boost) Solar Water Heater
4H4110 4110 Rev. F


• Using correct plumbing methods,
connect the cold water pipe to the
storage tank.
• According to local regulations and
the plumbing code, t any and
all valves that are necessary e.g.
tempering valves, pressure limiting
valves, line strainer, duo valves, cold
water expansion valves etc.
• We recommend the use of new valves
for all Installation. Refer to plumbing
code and/or local requirements.
• Connect the supplied hose from
the top left tank outlet to the heat
exchanger water inlet.
Cold
water
inlet
Outlet to the heat
exchanger water inlet
Installer’s Guide

Installer’s Guide – (Gas Post-Boost) Solar Water Heater
5
H4110 4110 Rev. F
Installer’s Guide


Critical: Due to the high
temperature imposed by solar
heated water, all solar system
pipes and ttings must be DR
brass and copper, including
collector compression ttings
(as supplied). No plastic pipes
or ttings.
• Flow and return lines must be
installed as direct as possible
between tank and collector.
• Pipes must be fully insulated with
UV stabilized insulation suitable for
solar working temperatures. We
recommend Armaex DuoSolar /
Solar insulation, minimum 13mm
thick (refer to local regulations).
Note: Warranty will be void
if this minimum insulation
requirement is not used.
Pipes must be DR
brass and copper.
Refer to AS/NZS
3500.4.
Pipes must be fully
insulated with UV
stabilized insulation
suitable for solar working
temperatures, minimum
13mm thick (refer to local
regulations)

Installer’s Guide – (Gas Post-Boost) Solar Water Heater
6H4110 4110 Rev. F
Installer’s Guide
• It is critical to stop any chance of an
air lock developing, so ensure that:
– no pipework is higher than the
automatic air vent valve
– ow and return pipes from the solar
collectors to the water storage tank
have a minimum of 5° continuous fall
– pipes have no high points that
allow air to be trapped
– the minimum number of bends in
the pipes are used.
• Flow and return lines should be
neatly installed and hidden inside the
roof cavity if possible.
• Take care when running ow
and return lines through the roof,
cladding and the eaves.
Note: Where roof and
the eaves are made from
asbestos, specialised handling
and advice is necessary.
Pipes must have no
high points that allow
air to be trapped
No pipes can be higher than
the air bleed valve
Minimum 5°
continuous fall
To collectors
Use minimum
number of bends
Must fully
insulate flow
and return
pipes
Minimum 5°
continuous fall
To collectors
Non continuous
fall
To collectors
Incorrect Correct
Ensure flow and return pipes from the solar collectors to the
water storage tank have a minimum of 5° continuous fall

Installer’s Guide – (Gas Post-Boost) Solar Water Heater
7
H4110 4110 Rev. F
Installer’s Guide



Solar Collector Alignment
• For the most efcient solar gain, the
collectors must be aligned ±45° from
true north (i.e. north west to north
east). See Collector Orientation
Compass below.
Solar Collector Inclination
• For the most efcient solar gain, the
collectors must be inclined within
10° to 45° from horizontal. See
Collector Inclination Guide right.
True North
NW NE
Surface Plate EastWest
45°
50° from
true north
70° from
true north 45°
B
Collector Orientation Compass
True North
A
A = 500mm, or greater if roof allows
B = Between 10° and 45°
B
Note: When establishing the correct Collector Orientation, please account
for the Magnetic Declination of your geographic location
Collector Inclination Guide
C
A
C
A. Dux preferred range
B. Industry accepted range
C. If orientations A or B are not practical, an additional collector can be
installed at the home owner’s discretion in range C (not required north
of Tropic of Capricorn)
True North
NW NE
Surface Plate EastWest
45°
50° from
true north
70° from
true north 45°
B
Collector Orientation Compass
True North
A
A = 500mm, or greater if roof allows
B = Between 10° and 45°
B
Note: When establishing the correct Collector Orientation, please account
for the Magnetic Declination of your geographic location
Collector Inclination Guide
C
A
C
A. Preferred range
B. Industry accepted range
C. If orientations A or B are not practical, an additional collector can be
installed at the home owner’s discretion in range C (not required north
of Tropic of Capricorn)

Installer’s Guide – (Gas Post-Boost) Solar Water Heater
8H4110 4110 Rev. F
Installer’s Guide


• Inspect ttings after collectors are
pressurized with water.
Critical: Fittings must be as
tight as possible.
Warning: Only pressurize the
the collectors for inspection
and de-pressurize them
immediately after inspection.
Critical: Do not leave
collectors pressurised for
longer than 24 hours.
• To prevent damage, collectors
should be left pressurised only when
connected to the storage tank with
appropriate pressure relief valves.
• Collectors can be located a maximum
of 20 metres (with minimal bends)
from the storage tank if pipe layout is
simple.
Note: For more energy
efciency, locate the
collectors as close as
possible to the tank
• This system is suitable for 2 storey
homes.

Installer’s Guide – (Gas Post-Boost) Solar Water Heater
9
H4110 4110 Rev. F
Installer’s Guide


For Both Metal and Tiled Roofs
• Locate the lower mounting rail a
minimum of 500mm distance from
the gutter, or greater if roof allows.
Note: Ensure that the rail is
parallel with the gutter.

For Metal Roofs Only
• Fix roong screws through the
mounting straps on both sides,
using rubber grommets to prevent
corrosion.
Note: A minimum of 3 roong
screws of 40mm length must
be used to x the collector
strap to the truss.
• Ensure that the rail is parallel with the
gutter.
500mm
or
greater
500mm
or
greater

Installer’s Guide – (Gas Post-Boost) Solar Water Heater
10 H4110 4110 Rev. F
Installer’s Guide
For Tiled Roofs Only
• Carefully remove a roof tile and
locate the nearest roof truss.
• Attach the rst (2 per mounting rail)
stainless steel collector strap to the
mounting rail.
• Shape the collector strap over the tile
and position over the roof truss.
Note: A minimum of 3 roong
screws of 40mm length must
be used to x the collector
strap to the truss.
• Ensure collector strap is located on
truss vertically.
• Repeat this process for the collector
strap at the other end of the
mounting rail.

• Once the bottom rail has been
secured, the collector can now be
lifted on to the roof.
Note: Ensure this is done with
full consideration to OH&S
regulations. Care should be
taken.
Collector Strap
Collector Strap
Use minimum
of 3 screws

Installer’s Guide – (Gas Post-Boost) Solar Water Heater
11
H4110 4110 Rev. F
Installer’s Guide


All connections must be brass and all
pipe work must be copper
• Ensure tting is fully engaged on to the
header pipe. This is very important for
correct connection.
• To ensure leak proof installation, hold
tting A (see illustration in margin)
while tightening nut B to prevent
twisting the header pipe.
Critical: Do not use multi
grips or similar tool, as you
will damage the brass ttings.
Ensure you use the correct
size spanner.
Critical: The tting must be as
tight as possible on the barrel
union to prevent the tting
coming loose.
Ensure the brass conetite compression
fitting is installed in the correct direction
Hold fitting A while tightening nut B
to prevent twisting the header pipe
AB

Installer’s Guide – (Gas Post-Boost) Solar Water Heater
12 H4110 4110 Rev. F
Installer’s Guide

• Secure the collectors to the
mounting rail with the Z brackets,
screws, nuts and bolts provided with
the water heater.

• Repeat the process for the second
collector.
Note: Ensure this is done with
full consideration to OH&S
regulations. Care should be
taken.

• Now position the top mounting rail and
repeat the above steps for that rail.
• Join the top connections with the
brass compression ttings supplied.
Collector
strap
Collector
clamp bracket
Collector
mounting
rail
24mm self tapping
galvanised screw

Installer’s Guide – (Gas Post-Boost) Solar Water Heater
13
H4110 4110 Rev. F
Installer’s Guide

• Connect collector ow and return
pipes to the collectors.
• Ensure that you connect the solar
ow (cold) and solar return (hot)
pipes to the correct connections:
– the solar ow (cold) pipe connects
to the bottom of the collectors
– the solar return (hot) pipe connects
to the top of the collectors,
diagonally opposite to the solar
cold pipe connection.
• We suggest when you install pipes
through roof, that you consider
colour coding the pipe ends to show
ow and return.
Critical: During connection,
the header pipe can move in
the collectors. It is critical that
the header pipe is centred to
provide about 40mm of tube
on both sides of the collector.
~40mm~40mm

Installer’s Guide – (Gas Post-Boost) Solar Water Heater
14 H4110 4110 Rev. F


• Using correct plumbing methods,
install the 4 Way Union assembly
and air bleed valve at the highest
point in the system, at the top of
the collector diagonally opposite the
solar collector inlet pipe.
• The air bleed valve must stand
vertically straight towards the sky.
Note: If installed in top left/
bottom right of collector, then
T should be reversed.
• When tting the 4 Way Union
assembly, we recommend Loctite
577 Thread sealant and/or a good
quality pink teon tape to secure the
air bleed valve. Tighten by hand. Do
not use spanner.


• The areas in gray in the map on the
next page may be vulnerable to frost.
• In these areas, you must install an
anti-frost valve.
Valve must be
vertical and at
highest point in
system
Use Loctite 577
thread sealant or
pink teflon tape to
seal all threads
Installer’s Guide

Installer’s Guide
Installer’s Guide – (Gas Post-Boost) Solar Water Heater
15
H4110 4110 Rev. F
• However, TWO anti-frost valves
must be installed if you live in alpine
areas or areas subject to extreme
frost, such as the ACT and Snowy
Mountain regions.
• The anti-frost valve comes in kit form
and must be ordered seperately.
• Connect the anti-frost valve to the
top collector connection, on the
opposite collector to where the
thermowell/air bleed valve is installed.
• Ensure the valve is pointing down the
collector towards the gutter, parallel
to the collector.
Anti-Frost Valve
Anti-Frost Valve must
point towards the gutter,
parallel to the collector
Frost Protection Installation Map
Wellington
Auckland
Christchurch
Locations in grey may be
subject to frost.

Installer’s Guide
Installer’s Guide – (Gas Post-Boost) Solar Water Heater
16 H4110 4110 Rev. F


• As per local authority regulations,
use an approved method of ashing
on the ow and return lines, e.g.
Dektite or lead collars.
• Where ow and return lines penetrate
the roof surface, the penetration
must occur on the high side of the
roof prole, not in the valley.
• Seal the roof penetration with
a exible waterproof ashing.
We recommend the use of the
appropriate Dektite brand solar
ashing (available for either tile or
steel roofs).
Flexible
waterproof
flashing
Roof penetration must
be on high side of tile

Installer’s Guide
Installer’s Guide – (Gas Post-Boost) Solar Water Heater
17
H4110 4110 Rev. F


• Insert the end of the collector
temperature sensor (supplied in
collector rail kit) into the sensor dry
well.
• The sensor must be fully inserted
and touch the end of the thermowell.
• Firmly secure the sensor using the
cable securing clip.
Cable
securing clip
Collector
temperature
sensor
Sensor secured
by clip
Warning: Install the sensor
cable such that it does not
touch the roong material
surface.
Warning: Conceal all
temperature sensor cables
in the roof cavity so that they
are not exposed to sunlight or
heat.
Warning: The collector sensor
cable is a silicon rubber that
may require additional conduit
protection in extreme UV
radiation conditions.

Installer’s Guide
Installer’s Guide – (Gas Post-Boost) Solar Water Heater
18 H4110 4110 Rev. F

• Connect collector sensor cable to
terminal block and secure to the
timber or metal truss inside the roof
cavity.
• Connect extension collector sensor
cable to junction block.
• Do not run collector sensor cable
in contact with the copper pipes
as it may melt and cause signal
interference.
• Connect collector sensor cables as
shown in diagram.
• There is no polarity for which
collector sensor cable goes into
which terminal block connection.
• Ensure terminal block is covered,
ideally installed within the roof space
and secured to a truss. Do not
leave exposed.
• If the terminal block cannot be
located within the roof space, it must
be enclosed within a waterproof
junction box.
Warning: If sensor cable is on
top of a steel roof, the heat
produced from the roof may
cause the sensor wire to melt
and cause signal interference
or failure.
Terminal block secured
to timber or metal truss
inside roof cavity
Collector
Sensor
Cables
S1 & S2
S1
12345678 12 13 14 15 16 17 18 19 20
DeltaSol BS/3
DeltaSol® BS
S2 S3 S4 N R2 N R1 N L