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Owner's Guide
and
Installation Instructions
Domestic Mains Pressure
Gas Boosted Solar Water Heater
SG165 to SG415 Series
Warning: Use copper pipe ONLY. Plastic pipe MUST NOT be used.
It is a requirement of a solar water heater installation that all pipe work be in copper and not plastic, due to
the effects of high water temperatures and pressures.
Warning: Important notes for plumber.
For installation requirements critical for correct operation of the solar water heater, refer to "Warning:
Important Notes for Plumber" on page 25.
This solar water heater must be installed and serviced by a qualified person.
Please leave this guide with the householder.
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Summary of Contents for Aqua MAX SG165 Series
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Page 1: Installation Instructions
Owner’s Guide Installation Instructions Domestic Mains Pressure Gas Boosted Solar Water Heater SG165 to SG415 Series Warning: Use copper pipe ONLY. Plastic pipe MUST NOT be used. It is a requirement of a solar water heater installation that all pipe work be in copper and not plastic, due to the effects of high water temperatures and pressures. - Page 2 Warning: Upon completion of the installation and commissioning of the solar water heater, leave this guide with the householder or responsible officer. DO NOT leave this guide inside the cover of the solar control unit or gas booster, as it may interfere with the safe operation of the solar water heater or ignite when the solar water heater is turned on.
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Page 3: Table Of Contents
CONTENTS Householder: Read the section “About Your Solar Water Heater” (pages 3 to 13). The “Installation” section is intended for the installer but may be of interest. ABOUT YOUR SOLAR WATER HEATER ......................3 Model Type ..............................3 Pipe Work, Insulation & Freeze Protection ....................4 Turning On the Solar Water Heater ....................... -
Page 4: About Your Solar Water Heater
ABOUT YOUR SOLAR WATER HEATER Product Application This solar water heater is designed for use in a single family domestic dwelling for the purpose of heating potable water. Its use in an application other than this may shorten its life. Warning: This solar water heater is only intended to be operated by persons who have the experience or the knowledge and the capabilities to do so. -
Page 5: Pipe Work, Insulation & Freeze Protection
Gas Booster Operation During periods of low solar energy (low solar gain), the gas booster will boost the water temperature automatically to its preset outlet temperature setting (refer to “Hot Water Temperature” on page 4). Mains Pressure Operation This solar water heater is designed to operate at mains pressure by connecting directly to the mains water supply. -
Page 6: Turning On The Solar Water Heater
It is essential the electrical circuit to the solar control unit is continually turned on if there is a risk of freezing. The Aquamax warranty does not cover damage caused by freeze conditions when the electrical circuit or electrical supply to the solar control unit is turned off or interrupted. Warning: If it is necessary to switch the power off to the solar control unit and there is a risk of freezing, then it is necessary to have your plumber drain the solar collectors and solar flow and return pipe work. -
Page 7: Periodic Maintenance
If it is necessary to turn off the solar water heater for any reason, follow the “Shut Down Procedure” on page Note: When switched back on, the solar water heater will take some time to reheat the water by solar gain. The time to reheat the water in the solar storage cylinder will depend upon time of year, time of day and prevailing weather conditions;... - Page 8 Operate easing lever on expansion control valve (if ECV fitted) (refer to “Expansion Control Valve” on page 8). If a safety tray is installed, check to ensure the safety tray drain pipe is not blocked. Clean solar collector glass if required (refer to “Cleaning the Solar Collector Glass” on page 8). Major Five Year Service It is recommended a major five year service be conducted on the solar water heater including the gas booster (for gas booster major five year service actions, refer to the Owner‟s Guide and Installation...
- Page 9 Expansion Control Valve (ECV) In many areas, including South Australia, Western Australia and scaling water areas, an ECV is fitted to the cold water supply line to the solar water heater (refer to the “Cold Water Supply Plumbing Arrangement” diagram on page 21). The ECV may discharge a small quantity of water from its drain line during the heating period instead of the PTR valve on the solar water heater.
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Page 10: Water Chemistry
Purging the Solar Collectors It is necessary to purge air from the solar collector circuit: After installation. When the solar system is to be turned on and the solar collectors and solar hot and solar cold pipes have been drained. After maintenance has been conducted on the solar collectors or pipe work and air has entered the system. - Page 11 colour code „Black‟) should be replaced with an aluminium alloy anode (cap colour code „Blue‟). For more information refer to “Water Chemistry & Anode Type” on page 10. In locations where TDS approaches 600 mg/L, e.g. due to sediment, we strongly recommend fitting an appropriate filter to ensure water entering or in the solar water heater does not exceed this level at any time i.e.
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Page 12: Troubleshooting
filters/conditioners etc to reduce the saturation index and total hardness of the water. Refer to your Local Water Authority for information on water in your area. A build up of white sediment on hot water taps or shower roses can be indicative of scaling water. Contact Aquamax if this condition is observed. Spring, Dam, Bore &... - Page 13 Pressure Temperature Relief Valve Running Normal Operation It is normal and desirable for the PTR valve to allow a small quantity of water to escape during the heating cycle, however there may be a problem if the valve continuously dribbles more than a bucket full of water in a normal 24 hour cycle.
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Page 14: Solar Monitor Led Indication
Is there a leaking hot water pipe, dripping hot water tap, etc? Even a small leak will waste a surprising quantity of hot water and energy. Replace faulty tap washers and have your plumber rectify any leaks. Is the booster operating too frequently? Refer to “Gas Booster Operating Too Frequently”... -
Page 15: Installation
INSTALLATION Installation Overview This solar water heater must be installed by a qualified person in accordance with the installation instructions. The installation must comply with the requirements of AS/NZS 3500.4, AS/NZS 3000 and all local codes and regulatory authority requirements. This solar water heater is comprised of the following components: Solar storage cylinder. -
Page 16: Water Supplies
Hot Water Redundancy If this solar water heater is to be used where an uninterrupted hot water supply is necessary for the application or business, then there should be redundancy within the hot water system design. This should ensure the continuity of hot water supply in the event that this solar water heater was to become inoperable for any reason. -
Page 17: Installation - Components
INSTALLATION – COMPONENTS This section details the installation of the solar storage cylinder, gas booster, solar controller kit and solar collector kit. To install the plumbing for these components refer to the “Installation – Plumbing & Plumbing Connections” section on page 20. Solar Storage Cylinder Installation Solar Storage Cylinder Location The solar storage cylinder is suitable for either outdoor or indoor installation, however if the gas booster is... -
Page 18: Gas Booster Installation
Gas Booster Installation Gas Booster Location The gas booster must not be installed indoors or in a confined space. The gas booster may be remotely located or mounted on the solar storage cylinder. If the gas booster is mounted on the solar storage cylinder, the solar water heater is suitable for outdoor installation only. -
Page 19: Solar Controller Kit Installation
Mounting the Gas Booster to the Solar Storage Cylinder A mounting bracket has been installed on the solar storage cylinder to support the gas booster. To mount an Aquamax CF20-60 or CF26-60 model continuous flow in-series gas booster to the storage cylinder: Remove two screws retaining gas booster top bracket (located on rear of gas booster) and remove bracket. - Page 20 For optimum performance, inclination of solar collectors should be approximately equal to 90% of the local latitude angle. The latitudes of some Australian cities are shown in the “Latitude of Some Australian Cities Table” on page 19. Solar collectors may be installed at the roof angle for simplicity of installation and appearance, but must never be flat.
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Page 21: Installation - Plumbing & Plumbing Connections
INSTALLATION – PLUMBING & PLUMBING CONNECTIONS This section details plumbing, plumbing connections and plumbing diagrams for the solar storage cylinder, gas booster, solar controller kit and solar collector kit. To install these components refer to the “Installation – Components” section on page 16. Solar Storage Cylinder Plumbing &... - Page 22 heaters, an additional effective back-flow prevention device also should be fitted as an extra safeguard. Valve manufacturer RMC recommends Dual Check Valve No N7150, as being suitable for this application. A pressure limiting valve and expansion control valve may also be required (for PLV requirements refer to “Water Supplies”...
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Page 23: Gas Booster Plumbing & Plumbing Connections
Relief Valve Drain(s) DN15 copper drain lines must be fitted to the pressure temperature relief valve and expansion control valve (if one is installed) to carry the discharge clear of the solar water heater. Connect the drain lines to the valves using disconnection unions. -
Page 24: Solar Controller Kit Plumbing & Plumbing Connections
The components supplied in the „Flexible Hose Kit‟ are: 1 x Nipple R20 X R20 Brass DR 1 x Elbow R20 x RP20 Brass DR 1 x Flexible Hose Ø12 RP20 x RP20 x 800 To connect the flexible hose to the solar storage cylinder and gas booster: Fit elbow to hot water outlet of solar storage cylinder, orientating elbow downwards. - Page 25 The solar hot water return plumbing connection is located at the mid left hand side of the solar storage cylinder and is marked “Connection for Solar Return Pipe”. The bleed valve solar hot pipe is connected to this inlet which allows hot water from the collector(s) to enter the solar storage cylinder. It is important not to cross connect solar cold and solar hot pipes to incorrect connections.
- Page 26 WARNING: Important Notes for Plumber The solar hot and solar cold pipe work between the storage cylinder and the solar collectors and the pipe work between this solar water heater and a temperature limiting device, or this solar water heater and a hot water outlet if a temperature limiting device is not installed MUST BE of copper. All compression fittings must use brass or copper olives.
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Page 27: General Plumbing Arrangement & Plumbing Diagrams
General Plumbing Arrangement & Plumbing Diagrams Two Temperature Zones Using a Temperature Limiting Device This solar water heater can deliver water at temperatures which can cause scalding. It is necessary and we recommend that a temperature limiting device be fitted between the solar water heater and the hot water outlets in any ablution area such as a bathroom or ensuite, to reduce the risk of scalding. - Page 28 Two Temperature Zone Plumbing Diagrams Two Temperature Zone Plumbing Diagram – Gas Boosted Solar System with Integrated Gas Booster Two Temperature Zone Plumbing Diagram – Gas Boosted Solar System with Remote Gas Booster...
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Page 29: Circulated Hot Water Flow & Return Systems
Circulated Hot Water Flow & Return Systems The solar storage cylinder of a solar water heater should not be installed as part of a circulated hot water flow and return system in a building. The benefits of solar gain will be significantly reduced and energy gained from the sun lost through the pipe work. - Page 30 Circulated Flow & Return Plumbing Diagram – Gas Boosted Solar System with Remote Gas Booster...
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Page 31: Installation - Electrical & Electrical Connections
INSTALLATION – ELECTRICAL & ELECTRICAL CONNECTIONS Warning: The power supply to the solar water heater must not be switched on until the solar water heater is filled with water and a satisfactory megger reading is obtained. All electrical work and permanent wiring must be carried out by a qualified person and in accordance with the Wiring Rules AS/NZS 3000 and all local codes and regulatory authority requirements. - Page 32 If there is solar gain, the circulator activates and the green LED will emit a series of three (3) flashes. The three (3) flashes indicate the circulator is operating and power to the solar control unit has been on for less than 48 hours. The circulator will operate at full speed for approximately fifteen (15) seconds.
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Page 33: Draining The Solar Collectors
Draining the Solar Collectors To drain the solar collectors and the solar hot and solar cold pipes: Warning: Exercise care when performing the following procedure as water discharged from the solar collectors and solar circuit may be of a very high temperature. Wear personal protective equipment to reduce the risk of scalding. - Page 34 Switch off the electrical supply at the power outlet to the solar control unit. Close the cold water isolation valve at the inlet to the solar storage cylinder. Close all hot water taps in premises. Operate PTR valve lever for a period of five seconds to release pressure in solar storage tank. Note: Operate lever gently and do not let lever snap back or you will damage relief valve seat.
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Page 35: Dimensions And Technical Data
Dimensions and Technical Data Solar Water Heater SG415 ~ SG165 Models with Remote Gas Booster (booster not shown) Model SG415 SG325 SG260 SG165 Capacity (L) Empty Weight (kg) Full Dimensions A (mm) 1525 1535 1215 1410 B (mm) C (mm) D (mm) H (mm) 1760... - Page 36 Solar Water Heater SG415 ~ SG165 Models with Integrated Gas Booster Model SG415 SG325 SG260 SG165 Capacity (L) Empty Weight (kg) Full Dimensions A (mm) 1525 1535 1215 1410 B (mm) C (mm) D (mm) 20L Booster 1170 1020 E (mm) 26L Booster 1135 1130...
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Page 38: Warranty
WARRANTY AQUAMAX SOLAR WATER HEATER SG415, SG325, SG260 & SG165 THE AQUAMAX WARRANTY – GENERAL This warranty is given by Aquamax Australia Pty Limited ABN 37 138 189 689 of 463-467 Warrigal Road, Moorabbin Victoria. Aquamax offer a trained and qualified service network who will repair or replace components at the address of the water heater subject to the terms of the Aquamax warranty. - Page 39 Subject to any statutory provisions to the contrary, this warranty excludes any and all claims for damage to furniture, carpet, walls, foundations or any other consequential loss either directly or indirectly due to leakage from the water heater, or due to leakage from fittings and/ or pipe work of metal, plastic or other materials caused by water temperature, workmanship or other modes of failure.
- Page 40 INSTALLER INFORMATION DEAR INSTALLER, Please provide the following information upon completion of the installation. This information should be provided to assist the customer in the event that a claim is made under the Aquamax warranty. Plumber (Name & Company): Plumber’s licence number: Compliance Certificate: (if applicable in your state) Installation date:...
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