Ozroll OZS251E Installation Manual Download

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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 – WARNINGS

Section B

Pre – inspection

Section C

System Sizing

Solar Hot Water Systems

Storage tanks

Collectors

Section D

Types of Systems – Open Loop vs Closed Loop

Section E

Hot Water Usage Patterns

Section F

Tanks

Tank Types

Tank Sizes

Tank Anodes

Anode Replacement

Tanks – How do they work

Tank Position

Heater Booster Element

Section G

Hot Water Storage Tank Connection

System Connection Requirements

Isolating , Non Return valves or Duo Valves

Temperature – Pressure Relief ( TPR ) Valve

Pressure Limiting Valve

Expansion Control Valve ( ECV )

Tempering Valve

Drain Cock

Line Strainer

Connection to Electricity

G10

Insulation of Pipes

Section H

Installation

Collectors – Installation Requirements

Pipe Lengths and Bends

Roof Area Required and Weights of Collectors

Collector Size and Packaging

Installation of the collectors

Inlet / Outlet Connections to Collectors

Storage Tank Installation

System Controller / Pump installation

Mount Pump Box Assembly

H10

System Piping Connections

H11

Temperature Sensor Fitment

H12

Preliminary System Test

H13

Commissioning System

Section I

System Maintenance / Periodic Inspections

Valves and Fittings and Draining Tank

Tank Anode replacement

Replacement of the Electric Booster Element

Replacement of Collector Glazing 26

General Maintenance Tasks

Contact Information

Warranty Information

Summary of Contents for OZS251E

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Page 3: ...em controller and pump assembly 12 Pressure Temperature Relief P T valve 13 Additional valves may be provided by the manufacturer Specific to client 14 Polyslab base SUPPLY BY THE INSTALLER The following items are to be supplied by the installer 1 All labour required to fully install test and commission the system 2 Copper piping DN15 to complete the installation 3 Thermal UV resistant insulation ...

Page 4: ...Pressure Relief TPR Valve 9 G4 Pressure Limiting Valve 9 G5 Expansion Control Valve ECV 10 G6 Tempering Valve 10 G7 Drain Cock 11 G8 Line Strainer 11 G9 Connection to Electricity 11 G10 Insulation of Pipes 12 Section H Installation 12 H1 Collectors Installation Requirements 12 H2 Pipe Lengths and Bends 13 H3 Roof Area Required and Weights of Collectors 13 H4 Collector Size and Packaging 13 H5 Inst...

Page 5: ...RS MUST exercise extreme care when installing or working on solar systems Our recommend solar panels are ALWAYS covered during installation WARNING It is a mandatory requirement of Australian Standard AS NZS3500 4 2 that a suitably approved temperature control device be fitted to the hot water supply for outlets used primarily for personal hygiene This valve should be checked regularly to ensure i...

Page 6: ...enor mously from family to family a good estimate is 60 to 80 litres of hot water per person per day HOUSE NUMBER SUGGESTED SUGGESTED SIZE PEOPLE TANK SIZE TANK P N 1 2 bedrooms 1 2 250 litres 31 100 100 3 bedrooms 3 4 300 litres 31 100 101 4 6 bedrooms up to 6 400 litres 31 100 102 C2 COLLECTORS Our Collectors have been specifically designed for optimal performance Our Collectors are manufactured...

Page 7: ...t electricity will bring the entire contents of the tank up to temperature If the hot water is used in the morning or during the day and it is a sunny day the solar input is likely to heat the water so that little or no night boosting is required This maximizes the efficiency of the system and minimizes the requirement of additional heating from the booster F TANKS F1 TANK TYPES Basically there ar...

Page 8: ...ressure or operating pressure If the working pressure is reached eg due to thermal expansion the valve releases some water to maintain the pressure at acceptable levels F6 CYLINDER POSITION By locating the cylinder as close as possible to points of use you can minimize heat loss and hot water wasted Choose a position close to the most often used tap if possible In most cases this position would be...

Page 9: ...h in the metre box during installation WARNING The element cover must only be removed by an electrician The electrical power supply must be de activated at the main switchboard before the water heater electrical cover is removed BOOSTER ELEMENT THERMOSTAT THERMOSTAT BRACKET FITTING 7 Step 1 Remove the housing cover by removing 2 screws Step 2 Open housing with views of 4 mounting studs Step 3 Inse...

Page 10: ...pipe size and specifications Note that only dezincification resistant DR brass fittings can be used for potable water plumbing Note for some States and local council areas It is a local requirement that an expansion control valve be fitted on the cold water supply line between the non return valve and the water heater Check with your local authori ties to see if this is required and fit according ...

Page 11: ...spring holds the valve on its seat and the pressure of water forces it to stay there The isolating valve effectively turns off the hot water system It is installed on the cold supply therefore will pre vent hot water from leaving the storage cylinder of a mains pressure hot water system no cold in no hot out G3 TPR VALVE A TEMPERATURE PRESSURE RELIEF TPR valve MUST be fitted in all cases to the to...

Page 12: ...a A solar hot water system will not always reach 60 C without some form of boost heating Having heated the water to 60 C it is too hot to be safe for bathrooms etc so it must be reduced in temperature using a tempering thermal mixing valve The location of the tempering valve is an issue It is probably easiest to install it right at the hot water storage cylinder or continuous unit This has the dis...

Page 13: ...onnections to electricity MUST either be carried out by a licensed electrician OR depending on the electrical connections required may be undertaken by a Licensed plumber with a limited electrical license Any electrical work MUST always be carried out by properly licensed persons Booster Heating elements require a 15 A service The tanks have 2 green yellow striped earth wires 1 connected from the ...

Page 14: ... North is possible However it must be understood the efficiency of the system may be reduced 2 The collectors must be installed in a shade free position particularly between 9am and 3pm the highest solar input times For maximum efficiency the collectors should be installed at a similar angle to the latitude of the installation location This will vary from place to place around Australia Ideally th...

Page 15: ... each extra metre of pipe length reduce the number of 90 bends by two For each additional 90 bend reduce the maximum total pipe length by 0 5 metres One 90 elbow equivalent to two 90 bends H3 ROOF AREA REQUIRED AND APPROXIMATE WEIGHT OF COLLECTORS 1 Collector 1 3 m wide x 2 0 m deep Weight approximately 40 kg 2 Collectors 2 4 m wide x 2 0 m deep Weight approximately 80 kg H4 COLLECTOR SIZE AND PAC...

Page 16: ...H5 INSTALLATION OF THE COLLECTORS The procedure for solar collector installation is as follows 1 Corrugated Iron Roof Diagram of a Corrugated Iron roof 14 ...

Page 17: ...ting on the left of the mounting strap Slide a mounting strap 50mm onto right end of the angle and maintaining a 15mm rise along the angle fasten the mounting strap down through top of a sheet ridge into the purlin Locate the left hand panel into its selected position Slide the second panel along the support angle from the right until its compression fittings register with those on the first panel...

Page 18: ...iles at the same height as the first two from above the rafter which is 1800mm to the right Slide a mounting strap onto each end of the support angle and attach them to the exposed rafters so that there is a 15mm rise along the angle Note that the straps may need to be twisted below the level of the tiles and be attached to the side of the rafter if there is insufficient room on top of the rafter ...

Page 19: ...semble and install the Hot Connection Thermocouple Well assembly to the hot water outlet of the last panel in the array as follows Hot Thermocouple Well Assembly with Air Bleed valve a Take the temperature well and slide it onto the copper spigot at the top right of the collector array with its tee pointing upwards Screw nipple into the tee and then another tee facing out with another nipple Screw...

Page 20: ... FOR ILLUSTRATION PURPOSE ONLY Cold Water Valve Train Connections to Storage Tank 18 ...

Page 21: ...inder and run a copper drain line from the valve to a safe discharge point angled downwards The drain line MUST be permanently open to the atmosphere and MUST be unobstructed at all times The Pressure relief valve MUST be operated every 6 months to remove lime deposits and verify no blockages NOTE that water may drip from the pipe during normal operation if an ECV Expansion Control Valve is not fi...

Page 22: ...ine where it would be pulling sucking the water from the collectors On the return line it would be likely to cavitate causing noise and damaging the pump The rate of circulation should not be too high Approx 0 2 l min m otherwise there will be excessive tur bulence stirring up of the hot and cold layers of water within the storage cylinder This reduces the efficiency of the solar collectors A rest...

Page 23: ...r 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 Diagram System Piping and Fittings 21 ...

Page 24: ...er ensure that the short lead with the white end uses the con nector with the white band The long sensor lead is used to sense the temperature at the top of the collector The short lead with the black end is used to sense the temperature at the bottom of the storage tank The short lead with the white end is used to sense the temperature at the middle of the tank Install all sensor leads carefully ...

Page 25: ... CONNECTING ANY ELECTRICAL WIRING Open some convenient hot taps in the house and then open the cold water valve to allow the cylinder to fill When air free water is discharging from the taps and NRV then close them and allow the pressure in the cylinder to stabilise Check for leaks throughout the system and correct as required H13 COMMISSIONING THE SYSTEM Follow the procedures for installation of ...

Page 26: ...ce block might be cold enough to simu late frosty conditions the pump should again come on to provide frost protection Frost protection commences through operation of the pump at 4 degrees celcius the sensor associated with the bottom of the storage cylinder can similarly be tested if it is heated it should turn the pump off the manual override knobs on the TPR temperature pressure relief on the s...

Page 27: ...he P T valve Check all other valves and copper fittings to ensure there are no leaks NOTE It is normal for water to drip from time to time from the discharge pipe connected to the Expansion Control Valve ECV This drip is due to expansion of hot water in the system which may exceed the setting on the ECV Draining the tank The tank may need to be drained from time to time for maintenance reasons CAU...

Page 28: ... NOT ATTEMPT to replace the electric element The system must be COMPLETELY electrically isolated and drained of water before replacing the element On 250 litres and 300 litres storage tanks the booster element must be replaced with a 2 400 watt booster ele ment On 400 litre storage tanks the booster element must be replaced with a 3 600 watt booster element Section F7 explains how the booster elem...

Page 29: ...SE 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 We recommend the appearance to be of a neat and tidy installation shown above 27 ...

Page 30: ... to faulty mate rials or workmanship including installation 4 The warranty covers either repair AND OR replacement of failed components and the deci sion is made entirely at our discretion GUARANTEE 5 YEARS 5 If the inner cylinder of the storage tank fails after the 1 year warranty period but within 5 years of the installation date then we will provide a replacement storage tank All costs associ a...

Page 31: ...on valve check valve and strainer is not fitted in areas where mains pressure is likely to exceed 1100 kPa 10 The guarantee does not cover any removal or disassembly costs transport costs installa tion costs plumbing costs or any other associated part costs 11 If a failed component is replaced or repaired under the warranty or guarantee period the balance of any original warranty or guarantee peri...

Page 32: ...urchase and installation date OWNER S DETAILS Surname Given Name s Address State Postcode Date of Purchase Model Serial Number Date of Manufacture see plate on storage tank INSTALLER S DETAILS Date of Installation Installer s Name Installer s Signature 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 o...

Page 33: ...VICE 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 Date of Service Service carried out by Details of work carried out ...

Page 34: ...VICE 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 Date of Service Service carried out by Details of work carried out ...

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