K0020
Pumped (Split) Systems:
200/300 Litre Gas/Electric - Open Loop System
Tank & System Overview
CONTINOUS FLOW
GAS WATER HEATER
(GAS BOOSTED SYSTEMS ONLY)
OPEN LOOP
STORAGE TANK
200L / 300 L
OR
GAS
SUPPLY
ELECTRICAL SUPPLY
(ELECTRIC BOOSTED
SYSTEMS ONLY)
GAS BOOSTER
EVACUATED TUBES SOLAR COLLECTOR
P0032
FLAT PLATE SOLAR COLLECTOR
P0010
P0215
P0024
HOT RETURN LINE
(COLLECTOR TO TANK)
P0047
COLD FLOW
LINE
P0501
P0025
P0077*
P0039
TEMPERED
WATER SUPPLY
P0483
P0057
P1459
P1039
P0151
P0031
COLD FLOW LINE
(TANK TO COLLECTOR)
P0463
P0027
P1039
P0522
P0459
P0087*
P0444
COLD
WATER
SUPPLY
P0022
SOLAR PUMP STATION
(SEE INSERT FOR DETAIL)
P0201*
COLD WATER SUPPLY
PTR RELEASE PIPE
(TO SUITABLE DRAIN)
SOLAR PUMP STATION DETAIL
(WITH FRONT COVER REMOVED)
* TO BE SUPPLIED BY INSTALLER
NOTE: System schematic is indicative only
Part Kits & Components
Parts not included in standard kits:
Part#
Qty
P0087
-
Component Name
Duo valve (to be supplied by installer)
P0201
-
Pressure limiting valve (to be supplied by installer)
P0077
-
Tempering valve (to be supplied by installer)
Standard components / kits included with the solar thermal collector systems:
200L Gas Open Loop System
300L Gas Open Loop System
200L Electric Open Loop System
300L Electric Open Loop System
1 x 200L Tank
1 x 300L Tank
1 x 200L Tank
1 x 300L Tank
1 x Tank Connecting Kit (K0020)
1 x Tank Connecting Kit (K0020)
1 x Tank Connecting Kit (K0020)
1 x Tank Connecting Kit (K0020)
1 x Gas Booster
1 x Gas Booster
-
-
Tank Connecting Kit (K0020)
Part#
Qty
P0010
1
Component Name
Solar Controller Open Loop
P0151
1
Tank Sensor (Cold)
P0022
1
Elbow 15mm M&F Brass
P0215
1
PTR valve
P0024
1
Elbow 15mm MI-Conetite
P0444
1
Pump Grunfos 15-20CIL Solar
P0025
1
Union 15mm MI-Conetite
P0459
1
Pump Union 25mm Suit 15-20CIL
P0027
1
15mm Brass Tee
P0463
1
15mm Tank Sensor Probe
P0031
1
Adaptor 20-15mm Brass Bush
P0483
1
Valve Flow Control AW
P0032
1
Reducer 20-15mm Brass Bush
P0501
1
Pump Station Housing
P0039
1
Elbow 20mm MI-15mm Conetite
P0522
1
Pump Station Connection Hose
P0047
6
Self Tapping Screw
P1039
2
Elbow 20mm MI-15mm Conetite Non-Return#
P0057
1
240 V Lead for use with Grundfos Pump
P1459
1
Pump Union 25mm Suit 15-20CIL Non-Return
Tank Connecting Kit (Continued)
#
May be supplied as separate Elbows and Non Return Valves
Pumped
Systems:
200/300L OL
1
K0020
Solar Hot Water Storage Tank Positioning
To obtain maximum performance the solar storage tank should be
positioned as close as possible to the most commonly used outlets.
The solar storage tank may be installed:
||
Externally on a level concrete / suitable plinth, such as a
concrete ripple slab or a Polyslab (Fig 1)
||
Internally, provided the following is adhered to:
• Must not be installed in the roof space and must be
accessible without the use of a ladder or scaffold
• Must not be installed where property damage could occur
as a result of water leakage
• Must be installed with an approved safe tray, drained
in accordance with AS3500.4 and must adhere to any
additional local regulations
CONCRETE
RIPPLE SLAB
POLYSLAB
Fig 1
PREASSEMBLED
SOLAR PUMP
STATION
Solar Pump Station Installation (Open Loop)
1.
2.
Ensuring the controller is located at the
top and the base plate
PREASSEMBLED
is plumb, fix the base plate to the tank
usingPUMP
4 x tek screws
SOLAR
PREASSEMBLED
provided (Fig 3)
STATION
3.
Fit the brass tee followed by the brass plug of the tank sensor
SOLAR PUMP
STATION
lead (Fig 4) into the solar cold flow tank connection and plug it
STATION
COLD
INLET TANK
into the “Tank” socket under the controller (Fig 7)
4.
COLD INLET TANK
CONNECTION
Position the base plate including the pre-assembled solar pump
station which includes the solar controller, pump and flow
control valve onto the tank over the cold inlet tank connection
(Fig 2)
BASE PLATE
Fig 2
PREASSEMBLED
SOLAR
PUMP
CONNECTION
COLD
INLET TANK
Connect the flexihose from the pump
assembly
to the brass tee
COLD
CONNECTION
at the cold flow tank connection (Fig
5) INLET TANK
CONNECTION
BASE PLATE
5.
Connect the incoming cold water line to the cold water tank
BASE PLATE pipe is directed
connection (Fig 6) ensuring that the connecting
BASE
downward with sufficient allowance for
thePLATE
pump station cover
to be fitted
6.
Connect the collector sensor wire to the “Panel” socket under
the controller (Fig 7)
7.
Once tank is filled with water plug the pump power lead into
GPO outlet on the base of the controller (Fig 7)
8.
Plug the controller power lead into the mains GPO and turn ON
9.
If the temperature at the collector is 7°C or greater, the “Tank”
LED light on the controller will illuminate “green” (Fig 7)
Fig 3
POWER LEAD
FOR CONTROLLER
the temperature of the collector and tank is equal, no lights will
be ON but the system is connected
pump station cover.
NOTE: The solar controller is rated IP20 and must be protected
from environmental exposure with a cover
PREASSEMBLED
POWER LEAD
PUMP
NOTE: If the power
is LEAD
damaged the SOLAR
controller
should
POWER
FORcable
CONTROLLER
STATION
LED
FOR CONTROLLER
POWER LEAD
be replaced, not repaired.
LED
INDICATORS
GPO OUTLET
FOR
FOR CONTROLLER
INDICATORS
LED
GPO
OUTLET
FOR
COLD INLET TANK
PUMP POWER LEAD
INDICATORS
PUMP
GPOPOWER
OUTLETLEAD
FOR
CONNECTION
PUMP POWER LEAD
PANEL SENSOR
PANEL SENSOR
LEAD SOCKET
LEAD SENSOR
SOCKET
PANEL
LEAD SOCKET
BASE PLATE
TANK SENSOR
TANK SENSOR
LEAD SOCKET
LEAD
TANKSOCKET
SENSOR
LEAD SOCKET
LEDTANK
COLD INLET
INDICATORS
CONNECTION
GPO OUTLET FOR
PUMP POWER LEAD
10.If
11.Fit
PREASSEMBLED
SOLAR PUMP
STATION
PLATE
SENSORBASE
FITTING
SENSOR FITTING
SENSOR FITTING
TANK SENSOR
Fig 4
LEAD SOCKET
PANEL SENSOR
LEAD SOCKET
FLEXIHOSE
FLEXIHOSE
FLEXIHOSE
Fig 5
POWER LEAD
FOR CONTROLLER
LED
INDICATORS
WASHERS
GPO WASHERS
OUTLET
FOR
COLLECTOR MOUNTING RAIL
PUMP POWER LEAD
WASHERS
Pumped
Systems:
200/300L OL
2
PANEL SENSOR
LEAD SOCKET
Fig 6
STRAPS TANK SENSOR
SENSOR FITTING
LEAD SOCKET
Fig 7
K0020
Filling and Commissioning an Open Loop system
Do not turn on the gas booster / electrical element until system is full
Filling the storage tank cylinder & purging air (Fig 8)
1.
Ensure the tank has been positioned properly and the plumbing
connections are completed as per the relevant instructions
2.
OPEN the mains cold water valve (1) to the tank making sure the
pressure / temperature relief (PTR) valve (2) is OPEN
3.
When water flows from the PTR valve, CLOSE the PTR valve
4.
Draw water through the tank by OPENING a hot water tap in the
house and OPENING the cold water supply valve (1) to the tank
5.
Wait until water comes out of the hot water tap
6.
Leave water running until air is bled (i.e. no more bubbles or
spitting) then turn OFF the hot water tap in the house
7.
Plug pump power lead into the bottom of the solar controller (3)
8.
Plug the solar controller lead into the GPO (4), and switch ON
Filling the solar loop & purging the remaining air (Fig 8)
9.
2
3
5
4
1
Loosen the nut immediately before the non-return valve on the
collector return line (5). Note: Non return valve may be built in or
as a separate non return valve (Shown as separate).
10.Allow
water to drip until no further air is detected (i.e no bubbles)
11.Re-tighten
Fig 8
the nut on the non-return valve (5)
SLOTTED SCREW
12.Check
the system for leakage by pressure testing all fittings to
a minimum of 800 kPa. If any leaks are detected, rectify them
immediately, and then the tank is prepared for use
FLOW VALVE
2.5
At time of commissioning the flow meter should be set, when the
pump is running, to 0.75 l/min for single panels and 1.75 l/min for
2 - 3 panel systems. The flow rate can be adjusted using the slotted
screw at the top of the flow meter with a blade screwdriver (Fig 9)
NOTE: Ball valve must be open to allow flow. Failure to do so may
lead to pump failure.
2
1.5
1
PUMP STATION
Fig 9
Activating gas booster (Gas models only)
13.Plug
in the power lead for the gas booster into the GPO and
ensure it is switched ON (Fig 10)
14.OPEN
the gas supply valve to the gas booster (Fig 10)
15.Turn
ON the hot water tap inside the house to check if the
booster is working
16.Test
17.Set
GAS SUPPLY
VALVE
POWER
SUPPLY
the water temperature to ensure temperature is rising
the tempering valve as per local authority / regulations
Activating the electric element (Electric models only)
18.Ensure
all electrical wiring is properly configured and
thermostat is calibrated (refer to following page for instruction)
Fig 10
19.Locate
the switchboard and check that the hot water electric
isolating switch is set to the ‘ON’ position. (This is usually
indicated by the label ‘Hot water’ or ‘Water heater’)
20.At
the tank location turn the isolating switch to the ON position.
Solar Hot Water Commissioning Check List
Please be advised that it is the responsibility of the plumber installing the tank (stage two) to fully commission the
system as no water is supplied to roof top panels on collector (stage one) installation.
……
……
……
……
……
……
……
Bleed all air from tank by opening hot tap inside house
Bleed all air from panels by loosening nut on hot return line & turn on power to controller
Check pump and control box for correct operation
Turn on all power and gas (if applicable) and open tap inside house to check for operation
Set the tempering valve as per local authority
Check tank, panels and all pipe work for any leaks and repair if required
Perform final check of overall system for operation and complete 'reference details' section of owners guide
Pumped
Systems:
200/300L OL
3
K0020
Electrical Wiring & Cotherm Thermostat (Electric boosted systems only)
ELECTRICAL WARNING
All Electrical Connections must be made by a licensed Electrician
1
DP ECO
50
3
4
30
70
240V ACTIVE
240V NEUTRAL
240V
ACTIVE
2
THERMOSTAT
THERMOSTAT
240V
NEUTRAL
10
ELEMENT
EARTH
ELEMENT
Wiring Schematic (240 VAC Single Phase)
5
||
Electrically isolate thermostat from mains supply
before disconnection. Failure to do so may result in
an electric shock
||
Wiring penetration should be made through the
supplied grommet at the side of the thermostat
cover
||
All wiring must conform to AS3100 and must be
performed by a licensed electrical contractor in
accordance with all relevant standards
||
Ensure all wiring is clear of element terminals to
eliminate heat damage to wiring
||
Temperature calibration should be tested at time of
commissioning
Parts: 1-Earth / 2-Thermostat / 3-Active / 4-Neutral /
5-Anode / 6-Flange / 7-Element
Tank Electrical Connections
200 / 300 Litre Tanks (Top of Tank)
Calibration Instructions
||
Check temperature of probe – check as per sensor
testing procedure chart using multimeter or take
tank temperature from water released at PTR
(ensure thermostat is situated in tank)
||
Remove housing from thermostat – disconnect all
power to thermostat and remove black housing
cover from top of thermostat
||
Calibrate thermostat – adjust thumbscrew to the
middle of where thermostat clicks on and off
||
Replace housing – Set temperature dial to
temperature of probe and replace housing
||
Check calibration – turn dial past position to ensure
that thermostat clicks on and off
||
Set temperature – set tank temperature to 60-65°C
||
Reconnect power – Reconnect power supply to
thermostat and reseal cover
Troubleshooting Tips
||
No power to thermostat – check supply with
multimeter, check off peak supply is operating
correctly and time clock is set correctly
||
No power to element – check reset button to
right of dial, dial thermostat up until click is heard,
measure voltage at element terminals. If no click
is heard disconnect thermostat and remove from
tank. Change temperature dial on thermostat, click
should be heard at approximate air temperature. If
not re-calibrate
7
6
Thermostat Wiring
Note: All thermostats should be calibrated at time of installation to avoid repeat service calls.
CA-IN-S-K0020.2
082016
Pumped
Systems:
200/300L OL
4
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