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Table of Contents
Summary of Contents for Ozroll OZS251E
- Page 3 SUPPLY BY THE MANUFACTURER The following Standard items are supplier to the Installer with each Our Solar Hot Water System Storage tank Flat plate solar collector (s) Roof mounting system for Standard pitched roof installations Roof mounting brass fittings kit including temperature well and air valve Flow restrictor to suit either 1 collector or 2 collector system Booster heating element Either 2.4 kw (250,300 litre tank) or 3.6kw (400 litre tank) Thermostat...
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Page 4: Table Of Contents
INSTRUCTIONS FOR INSTALLERS Installation of Solar Hot Water Systems must be in accordance with: 1. AS/NZS 3500.4 - National Plumbing and Drainage Code 2. AS/NZS 3000 – Wiring Rules 3. Local plumbing regulations INDEX SECTION PART ITEM DESCRIPTION PAGE Section A Safety Information –... -
Page 5: Safety Information - Warnings
SAFETY INFORMATION WARNING – OCCUPATIONAL HEALTH & SAFETY INFORMATION Solar hot water systems can be heavy so always use approved lifting devices when installing a solar systems. You MUST adhere to all Occupational Health and Safety requirements WARNING – ONLY USE COPPER PIPES AND APPROVED COPPER FITTINGS. PLASTIC PIPES MUST NOT BE USED IN THE INSTALLATION OF THE SOLAR HOT WATER SYSTEM 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 6: Pre Inspection
• Is it possible to have the unit facing north or close to north? The panels should be located on a North facing roof. C. SYSTEM SIZING C1. SOLAR HOT WATER SYSTEMS OZS251E OZS252E OZS301E OZS302E OZS402E... -
Page 7: Types Of Systems - Open Loop Vs Closed Loop
D. TYPES OF SYSTEMS – OPEN LOOP vs CLOSED LOOP OPEN LOOP SYSTEM In areas of frost, water may freeze in the collectors causing the collectors to rupture, The OPEN LOOP system provides an AUTOMATIC FREEZE PROTECTION SYSTEM to prevent freezing and damage to the collectors. The pump control system is automatically activated when the temperature gets too low. -
Page 8: Tank Anodes
F3. TANK ANODES TWO cast magnesium sacrificial anodes are connected to the inside of a storage tank from the top of the tank. Magnesium is used because it is a more active metal than steel. The magnesium rod therefore acts as an anode, by supplying electrons, and therefore sacrificing itself to protect the steel from corrosion. -
Page 9: Heater Booster Element
F7. HEATER BOOSTER ELEMENT Our single element mains pressure hot water storage cylinders have the element midway up the cylinder. The element is required to boost the temperature of the water to a minimum of 60 degrees celsius. Our cylinders have an adjustable thermostat which can be adjusted with a flat head screwdriver. -
Page 10: Hot Water Storage Tank Connection
Step 6. Push bracket towards inner tank to tension bracket and clip thermostat under bracket in position. The element, bracket and thermostat mounting is complete Refer to G9 - Connection to Electricity for wiring diagram. G. HOT WATER STORAGE CYLINDER CONNECTION G1 . -
Page 11: Isolating , Non Return Valves Or Duo Valves
G2. ISOLATING / NON RETURN VALVES (OR DUO VALVES) As water is heated it expands, and a mains pressure cylinder must have a NON RETURN valve fitted to prevent water being forced into the cold inlet supply line. This is because when the water in the cylinder is heated it expands and this increases the pressure inside the cylinder. - Page 12 G5. EXPANSION CONTROL VALVE (ECV) Scale deposits in water can cause TPR valves to become blocked with carbonate deposits as the scaling water passes through the hot valve body. To prevent failure of the TPR valve, cylinders installed in areas of high scale must have an expansion control valve (ECV) fitted on the cold supply to the water heater.
- Page 13 G7. DRAIN COCK A drain cock assists draining of the cylinder to remove sludge. Some areas of Australia require a drain cock to be fitted in the cold water supply. Check with your local authorities G8. LINE STRAINER The line strainer filters out small particles. It is not a filter designed to hold back fine particles.
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Page 14: Insulation Of Pipes
G 10. INSULATION OF PIPES Insulation to pipework is required to reduce heat loss from hot pipes and in some localities cold pipes must be well insulated, too, to prevent them from freezing. The plastic insulation that comes on pre-lagged pipe does not provide adequate insulation for pipes that have hot water in them for much of the day. -
Page 15: Pipe Lengths And Bends
6. The collectors should be located as close as possible to the storage cylinder to reduce energy losses. For optimum performance the collectors should be no more than 20 m of pipe run from the cylinder, a total of 40 metres including return pipes. -
Page 16: Installation Of The Collectors
H5. INSTALLATION OF THE COLLECTORS The procedure for solar collector installation is as follows: 1. Corrugated Iron Roof Diagram of a Corrugated Iron roof... - Page 17 For a single panel system – Corrugated Iron Roof Attach the mounting straps onto the ends of the support angle. Lay the angle on the roof in the selected position and attach the straps to the roof purlins. Position the panel centrally on the angle and then attach a strap to the top edge of the panel and fasten it to the roof.
- Page 18 Select the most advantageous position for the panels on the roof that spaces the panels equally about roof raft- ers. Mark a point on the nose of a tile in line with the left hand rafter to represent the bottom of the left hand panel For single panel system.
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Page 19: Inlet / Outlet Connections To Collectors
Attach the panel to the support rail. Repeat the tile removal and strap attachment at the top of the panel. Note that on all installations the excess strap above the panels should be removed for a neat and professional appearance H6. - Page 20 ‘Cold Water Valve Train Connections to Storage Tank’ (FOR ILLUSTRATION PURPOSE ONLY)
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Page 21: Storage Tank Installation
H7. STORAGE TANK INSTALLATION IMPORTANT: Refer to Diagram – “Cold Water Valve Train Connections to Storage Tank” Select the location of the storage cylinder to suit the panel and most frequently used hot water taps. Connect the cold water supply to the cylinder inlet utilising a stop valve, non-return valve, pressure reducing valve and, if required (listed in AS 3500.4 and local regulations), a cold water expansion valve. -
Page 22: System Controller / Pump Installation
H8. SYSTEM CONTROLLER / PUMP INSTALLATION Diagram – System Controller / Pump Assembly for Open Loop System – 1 or 2 solar collectors The use of a pump and system controller requires that the pump, controller electrical inputs and outputs in- cluding the temperature sensors are all correctly installed. -
Page 23: Mount Pump Box Assembly
H9. Mount Pump Box Assembly Mount the Controller/Pump box on a wall at a convenient position for piping and wiring. Ensure 4 plastic spac- ers are installed behind the box so that it sits away from the wall and allows the lid to be fitted. Place the pump inside the box and attach copper pipes to both connections so that they project through the grommets. -
Page 24: System Piping Connections
H10. SYSTEM PIPING CONNECTIONS Connect the piping and fittings as shown in the diagram. Run DN 15 copper tube up to the collector’s cold inlet from the pump outlet. Run DN 15 copper pipe from the panel’s hot outlet to the cylinder’s solar return connec- tion. - Page 25 Disconnect the long sensor lead at the system controller. Apply power to the system. After 10 to 12 seconds the control output relay should click and switch the pump on. It can be difficult to detect if the pump is running, it can run quietly and with little vibration.
- Page 26 • the whole system should be checked for leaks. • the storage cylinder and collectors should be checked to ensure that they sit properly in place • Once these checks have been carried out and there appears to be no reason to drain the storage cylinder, the cardboard cover(s) can be removed from the collectors.
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Page 27: System Maintenance / Periodic Inspections
I. System Maintenance / Periodic Inspections I1. Valves / Fittings & Draining the tank - The Pressure / Temperature ( P / T ) safety relief valve is mounted on the top of the storage tank. This valve should be opened and checked every 6 months by releasing the valve ( see Caution information below ). This flushes any lime deposits out of the valve which can clog it and make it not function correctly. -
Page 28: Tank Anode Replacement
It is recommended that periodically, depending on dust / dirt which may have settled on the collectors, the collectors should be wiped down with a cloth and warm soapy water followed by rinsing with water. I6. Contact / Service information Ozroll Industries 174 Cavan Road Dry Creek SA 5094 Ph: (08) 8368 0263... - Page 29 We recommend the appearance to be of a neat and tidy installation shown above. THE INSTALLATION IS COMPLETE INSTALLER – PLEASE EXPLAIN TO THE CUSTOMER HOW THE SOLAR HOT WATER SYSTEM WORKS AND ANSWER ANY QUESTIONS THEY HAVE ABOUT THE OPERATION OR MAINTENANCE OF THEIR NEW PRODUCT THANK YOU...
- Page 30 WARRANTY / GUARANTEE TERMS AND CONDITIONS A SOLAR HOT WATER SYSTEM INCLUDES A COMPREHENSIVE 1 YEAR PARTS AND LABOUR WARRANTY ON THE SOLAR HOT WATER SYSTEM. IN ADDITION, OUR GUARANTEE TO RE- PLACE YOUR HOT WATER TANK IF THE INNER CYLINDER FAILS OR YOUR SOLAR COLLEC- TORS FAILS WITHIN A 5 YEAR PERIOD FROM THE DATE OF INSTALLATION.
- Page 31 WARRANTY / GUARANTEE TERMS AND CONDITIONS SCOPE OF WARRANTY AND GUARANTEE 7. The warranty and guarantee ONLY APPLY to defects or damage as a direct result of faulty factory parts or workmanship 8. The warranty and guarantee DO NOT APPLY to Collector glass 9.
- Page 32 WARRANTY / SERVICE CARD Refer to Our Warranty and Guarantee Terms & Conditions Please fill in the details on this warranty card and keep it in a secure place along with your original invoice as proof of purchase and installation date. OWNER’S DETAILS: Surname: Given Name(s):...
- Page 33 WARRANTY / SERVICE CARD Refer to Our Warranty and Guarantee Terms & Conditions SERVICE DETAILS Date of Service : Service carried out by : Details of work carried out : Date of Service : Service carried out by : Details of work carried out : Date of Service : Service carried out by : Details of work carried out :...
- Page 34 WARRANTY / SERVICE CARD Refer to Our Warranty and Guarantee Terms & Conditions SERVICE DETAILS Date of Service : Service carried out by : Details of work carried out : Date of Service : Service carried out by : Details of work carried out : Date of Service : Service carried out by : Details of work carried out :...