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Solar Hot Water
Installation and Owner Manual
About this Manual
This manual provides information relating to the following products:
LEDA solar hot water heater, split system with electric booster,
270, 340 & 450ltr
LEDA solar hot water heater, split system with gas booster,
270, 340 & 450ltr
The manual is split into three sections:
1. Installation instructions for the information of the authorised installer;
2. Technical and product maintenance information;
3. Owner operating instructions.
All interested persons, i.e. installers, service and maintenance personnel, and the owner/user are requested to carefully read and understand all installation, servicing and operating guidelines to ensure trouble-‐free operation and longevity of the appliance.
We congratulate and thank you for your decision to purchase our product. Should you have any questions, please contact us on 1800 697 652 or visit our website at www.ledaaustralia.com
ATTENTION!
Please read this manual thoroughly before installing and using this appliance.
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Index
Section 1 – Installation instructions
Pre-‐installation checklist
Installing the hot water storage tank
Installing the pump and solar controller
Installing the flow and return lines
Electrical connections
Installing the solar collector panels
Installing the gas booster (for gas boosted models only)
Filling and commissioning the system
Frost protection
Section 2 – Technical and product maintenance
The hot water storage tank
The electric booster element
The gas booster
The solar collector panels
The solar controller and circulating pump
Frost protection
Valves
Maintenance
Certifications and licenses
Section 3 – Owner operating instructions
Safety warnings
Correct booster use
Warranty
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Section 1 – Installation instructions
WARNING!
This water heater must be installed by suitably licensed and qualified personnel.
Pre-‐installation checklist
1. Ensure you are aware of all relevant Standards and Regulatory requirements.
All LEDA hot water products must be installed by an authorised plumber, electrician and gas-‐fitter (for gas boosted models). Installation work must comply with all local authority standards as well as Australian Standard AS/NZS 3500.4, the National
Plumbing Code, all local electrical regulations and Occupational Health and Safety
Regulations. In some areas, the plumbing and electrical work will require certification by
local regulatory authorities.
2. Determine if the water supply quality is suitable.
Town water supplies are generally acceptable however some water supplies, especially bore water, may have high mineral content which can cause clogging of pipes and fittings. LEDA solar water heaters are of an “open loop” design meaning that potable water flows through the storage tank and solar collector panels. Accordingly, water supplies with total dissolved solids (TDS) higher than 1,000 ppm and total calcium hardness (CaCO
3
) greater than 200 ppm with an alkalinity in excess of 150 ppm, are not suitable. Water with a saturation index of -‐1.0 is considered corrosive and may result in the early failure of copper parts. Scaling can occur where the saturation index is above
+0.4. Where the TDS is greater than 600mg/L or less than 40mg/L, the standard sacrificial anode may be unsuitable to protect your water heater. In these circumstances, a correct anode should be fitted by an authorised service person. If you are unsure of the chemical composition of the water supply, contact your local water authority. Water heaters installed with incorrect anodes fitted due to high or low TDS, or where the water is corrosive or considered scaling, will not be covered by warranty.
3. Determine if the water pressure is suitable
A minimum 200kPa water supply pressure is required otherwise a pressure pump must be installed. The gas booster (if applicable) requires a minimum flow rate of 3 litres per minute to operate. A 500kPa pressure limiting valve should always be fitted, especially if the supply pressure can rise above 500kPa.
4. Determine the best location for the hot water storage tank.
The storage tank (and gas booster if applicable) should be installed in close proximity to the most frequently used hot water tap. However, other important factors must be borne in mind including:
-‐ the distance between the tank and solar collector panels should be no more than
15 metres;
-‐ the tank should be located on a suitable base or plinth with sufficient drainage to prevent corrosion from rainwater ponding around the base;
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-‐ if installed indoors, a suitable drainage tray must be installed;
-‐ electrical supply requirements, i.e. suitable power point outlets for the circulating pump, solar controller and gas booster (if applicable) and a hard-‐ wired supply for the electric booster element (if applicable);
-‐ sufficient space must be provided for future servicing including electrical element and sacrificial anode removal and replacement, as well as eventual complete removal and replacement of the tank itself;
-‐ adequate provision to allow for safe drainage of water from the tank and fittings so as not to cause damage to property in the event of failure;
-‐ clearance distances required for the gas booster (if fitted).
5. Ensure the gas supply is adequate (for gas boosted systems only)
For the gas booster to operate correctly, it is important to ensure that the gas supply is adequate and that the correct type of gas, i.e. natural gas or LPG, is available. For further information, refer to the manual supplied separately with the gas boosting unit.
6. Determine the best location for the solar collector panels.
The solar collector panels should be installed facing the equator, i.e. North in the
Southern Hemisphere and South in the Northern Hemisphere. If this is not possible, a deviation within 45 o
in either direction will have little impact on solar performance.
Outside of these parameters, consideration should be given to adding an additional panel, however under no circumstances should panels face in a direction greater than
90 o
from the equator. When using a compass, be aware of magnetic variation in your locality. In addition, the following factors must be considered:
-‐ the panels should be installed no further than 15 metres from the hot water storage tank;
-‐ the location should be free of shade all day with an area large enough to accommodate the panels (each collector is 1.2m x 2.04m but refer to “Installing the solar collector panels” for more detailed information);
-‐ the location should be strong enough to support the weight of the panels when full of water (44 kgs each);
-‐ pitch should be a minimum of 10 o
and a maximum of 30 o
-‐ a minimum of 500mm of roof space must be left between the bottom of the solar panels and roof guttering to prevent rainwater cascading over guttering.
7. Determine if the location is in a frost prone area.
If the location experiences frost, even on rare occasions, the appliance will require frost protection equipment. Please refer to the section entitled “Frost Protection”.
SAFETY WARNING!
Do not use plastic pipe for the flow and return lines connecting the
storage tank and solar collector panels. To do so will have catastrophic consequences.
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Installing the hot water storage tank
Remove the hot water storage tank from its packaging and place it in the predetermined location (please refer to Item 4 in the “Pre-‐installation checklist”). Note that the Pressure
and Temperature Relief (PTR) valve is located in the tank packaging.
Rough-‐in dimensions are shown in the following diagram:
LEDA SOLAR HOT WATER ELECTRIC BOOST WATER HEATER PIPEWORK
ROUGH IN DIMENSIONS (MM)
B
F A
C
E
D
ROUGH IN PIPEWORK DIMENSIONS
MODELS A -‐ HEIGHT
B -‐
DIAMETER
LEDA 270
LEDA 340
LEDA 450
1408
1711
1733
648
648
732
C -‐
ELEMENT
748
912
903
D -‐ COLD
INLET
82
82
83
E -‐ SOLAR
RETURN
500
680
658
F -‐
OUTLET &
PTRV
1169
1472
1473
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Assemble the plumbing fittings (see the Tank Parts Kit components on the following pages) in accordance with the following illustration:
Note: If the water heater is an electric boosted solar system, the hot water supply feeds directly to the tempering valve as there is no gas booster. Also note that gas boosted tanks have no provision for an electric booster element.
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The pump and solar controller should be installed in conjunction with the above (please refer to “Installing the pump and controller” section on Page
10 for further information).
Pipework must be insulated with approved UV protected and weatherproof insulation of 19mm minimum thickness. Fittings must be insulated with insulation covers supplied with the appliance.
The Tank Parts Kit contains the following (note that the PTR valve is located in the tank
carton):
Part Code Part Description Quantity Instructions
STP525
STP530
STP550
Pump/Controller Cover
(Grey)
Solar Circulation Pump
Solar Controller
1
1
1
Item 1. Grey plastic cover used to house the solar pump and controller on the side of the tank
Item 2. Solar Pump. See diagram
STP515
AVP400
AVP420
AVP410
AVP041
AVP051
AVP045
Tank Sensor Wire
15mm High
Performance
Tempering Valve
15mm High
Temperature Non-‐
Return Check Valve
15mm 700kpa Cold
Water Expansion Valve
Loose Nut FI x 15mm
Compression Pump
Union
15mm MI x 15mm
Compression Union
(Straight)
Pump Flow Meter
1
1
3
1
2
3
1
Item 3. Installed in grey cover. Pump plugs into controller, controller into
GPO
Item 4. To be connected to solar controller and inserted into solar sensor fitting at the base of tank
Item 5. To be connected at the hot
outlet of the tank on the supply to the home
Item 6. To be installed on solar flow, solar return and cold supply. See installation diagram
Item 7. See diagram
Item 8. To be installed on inlet/outlet of pump
Item 9. See diagram
AVP049
15mm FI Flexible
Connector 175mm
Long
1
Item 10. To be installed on pump.
See diagram
Item 11. To connect pump assembly to 5-‐way tee at the base of the tank
AVP025
AVP005
AVP012
5 Way Cold Inlet Tee
20mm x 15mm
Reducing Bush
15mm Brass Plug
1
1
1
Item 12. For cold inlet and solar flow connection at the base of the tank
Item 13. To be used on solar return connection to tank
Item 14. For unused point on 5-‐way tee at base of the tank
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AVP015
AVP020
15mm Brass Hex
Nipple
15mm FI Tee
2
2
Item 15.
Item 16. For connecting to cold expansion valve and cold supply to tempering valve.
Item 17. AVP021
AVP031
AVP065
AVP066
15mm Compression
Tee
15mm FI Brass Hex
Socket
15mm MI x 15mm
Compression Elbow
20mm MI x 15mm
Compression Elbow
15mm Sensor Fitting
90mm Long
SS M4 x 15mm Screw
1
1
1
1
Item 18.
Item 19.
Item 20.
AVP080
STP580
AVP591 15mm Red Fibre
Washer
1
8
3
Item 21. To be installed in 5-‐way tee at base of tank. See diagram
To attach pump/controller cover to tank
To be used on the loose nut connections on the 5-‐way tee at base of tank.
Installing the pump and controller
The electronic solar controller and water circulating pump are supplied with the storage tank. They are enclosed in a weatherproof UV resistant housing and the whole assembly is fitted to the side of the storage tank directly above the cold water inlet using 8 screws
provided in the Tank Parts Kit. Nut-‐serts are provided in the tank casing for this purpose.
Sensor wires connect the controller to sensors in the storage tank and the solar collector panels. These sensors detect temperature differentials between the solar panels and the tank and cause the pump to turn on and off. It is therefore critical to ensure they are protected from possible damage and the use of protective conduit is recommended for all external areas of exposure. Care should be taken to ensure the sensor wire from the solar
panels does not come into contact with the solar flow or return lines as the excessive temperatures that can be generated will interfere with the sensors and cause the
controller to malfunction. If a wire is cut or broken, it must be completely replaced.
The pump and controller assembly includes a Flow Meter which should be checked and adjusted, if necessary, during installation to a flow rate of one litre per minute.
The illustration on the below shows the pump and controller assembly installed in situ on
the side of the storage tank:
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Installing the flow and return lines
SAFETY WARNING!
Do not use plastic pipe for the flow and return lines connecting the storage tank and solar collector panels. To do so will have catastrophic consequences. Also use only brass and copper compression fittings.
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As water temperatures in the solar collector panels and pipework connecting them to the hot water storage tank can reach extreme temperatures during stagnation conditions
(>150 o
C) USE ONLY COPPER PIPE and ensure it is insulated with suitable UV resistant and weather proof insulation of 19mm minimum thickness.
Run the flow and return pipes with a continuous rise and fall to eliminate air locks, and with a minimum of bends to minimise resistance. The maximum distance between the hot water storage tank and the solar collector panels should be no more than 15 metres.
SAFETY WARNING!
Under stagnation conditions, water in the solar collector panels,
and the flow and return lines can become super-‐heated and will cause immediate scalding and possible death. Take care when opening fittings and ensure other persons or animals are kept safe.
Electrical connections
All electrical work must be carried out by a licensed electrician who will adhere to all local codes and regulations. The following electrical connections will be required:
-‐ A general power outlet to run the pump and controller (weatherproof if outdoors);
-‐ A general power outlet to run the gas booster if the system is a gas boosted system
(weatherproof if outdoors);
-‐ A hard-‐wired connection to the electric element if the system is an electric boosted system. The electrical supply should be connected to the terminal block provided and should not be wired directly to the thermostat or element itself.
When connecting the electric element, the power supply must be protected by an individual circuit breaker at the main electrical switchboard. As various element sizes are available, it is important to ensure the wiring and circuit breaker are rated to suit the particular element
size fitted to the storage tank.
Electric boosted systems can be connected to an
Off Peak Tariff
if desired however a
“Night Rate Only” tariff is not recommended. “Night Rate Only” tariffs do not supply electricity during daylight hours and solar water heaters connected to these tariffs can run
short of hot water during periods of inclement weather.
WARNING!
Do not switch on the electric element until the storage tank is full of water. If you do, you will burn out the element.
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Installing the solar collector panels
SAFETY WARNING!
Working at heights can be dangerous. When working on rooftops ensure that you comply with all Workplace Health and Safety requirements and regulations.
The solar collector panels should be installed facing as close to North as possible (please refer to Item 6 in the “Pre-‐installation checklist”).
The Collector Parts Kit contains the following:
Part Code Description
STP511 Collector Sensor Wire
AVP011
AVP013
AVP026
10mm Brass Plug
20mm Brass Plug
Solar Sensor Tee
Quantity Instructions
1 To connect to the sensor fitting in the collector and the solar controller at talk location
1
2
1
To plug connection point for automatic air bleed valve in solar sensor tee.
(connection point not used)
To plug unused connection to solar collectors
To be installed at outlet of solar collectors. Solar sensor wire to be fitted to this connection
2
1
To connect solar collectors
For flow connection to collectors
AVP056
AVP066
STP560
STP565
STP565
20mm MI Barrel Union
20mm MI x 15mm Comp
Elbow
1.8m Black Anodised Collector
Rail
SS Collector Mounting Strap
(Bottom Strap)
SS Collector Mounting Strap
(Top Strap)
20mm screw
1
2
2
To mount collectors to roof
To mount collector rail to roof
To hold top of collectors to roof
MAP581 6 To attach straps to collector rail
On a tile roof ensure there is sufficient roof space to allow the removal of tiles to fix the mounting rails and stainless steel mounting straps to the underlying roof rafters at the top
and bottom of each panel. In this regard, note that the length of each panel is 2.04 metres.
Connect the bottom mounting rail to the stainless steel mounting straps. To secure the mounting straps to the roof rafters, remove sufficient tiles to expose the underlying rafters and secure the straps to the rafters with roofing screws. Make sure the mounting rail is level and that a space of at least 500mm is left between the mounting rail and the roof guttering. This will prevent water cascading over the guttering from the panels during heavy rain. Then replace the roof tiles ensuring there is no breakage.
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Lay each panel with the bottom fitting snugly into the bottom mounting rail. Secure the panels together by fitting the panel connector unions into each. Do not tighten at this stage. Secure the bottom of each panel to the bottom mounting rail using the 20mm screws provided.
Once the panels are in place, to secure the top of each panel, screw the top mounting straps to the top of each collector using the screws provided. Then secure the mounting straps to the exposed roof rafters using roofing screws. Then replace the roof tiles ensuring there is
no breakage.
On a metal roof follow the same procedure as for a tile roof except the stainless steel mounting straps can be secured to the roof battens using existing roofing screws.
Once the solar collector panels are secured into position, connect the plumbing fittings in accordance with the following illustration noting that the plumbing configuration can be reversed if desired:
Tighten all fittings but do not over-‐tighten. USE TWO SPANNERS for each fitting; one for the fitting itself and one for the panel header nut which will ensure no damage is done to the internal copper header pipe during the tightening process.
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Insert the temperature sensor leading from the solar controller into the sensor well at the top of the panels and secure with the fastener (Refer to the section entitled “Sensor wires”
on Page 10 and ensure the sensor wires are adequately protected from damage).
Connect the copper flow and return lines to the alternate top and bottom corner fittings of the collector panels ensuring the flow line is connected to the bottom of one panel and the return line is connected to the opposite top outlet of the other panel.
ENSURE THAT ALL ROOF PENETRATIONS ARE SEALED FROM POSSIBLE LEAKS
BY USING APPROPRIATE ROOF FLASHING.
SAFETY WARNING!
Do not use plastic pipe for the flow and return lines connecting the
storage tank and solar collector panels. To do so will have catastrophic consequences. Also use only brass and copper compression fittings.
Installing the gas booster (for gas boosted models
only)
LEDA solar hot water systems designed for gas boosting utilise a hot water storage tank without any electric heating element fitted. The storage tank stores solar pre-‐heated water only and the hot outlet is connected to the cold inlet of the gas booster which is factory-‐set at 75 o
C to comply with Australian Standard AS 3498-‐2009. Under no circumstances should this temperature setting be altered.
The hot outlet of the gas booster is then connected to the tempering valve as shown in the
illustration on Page 8
For all other installation instructions, please refer to the separate manual provided with the continuous flow gas booster unit. Pay particular attention to the required clearances.
SAFETY WARNING!
Do not connect an LPG model to natural gas, or a natural gas model to LPG. Check that you have the right system for the gas supply as they cannot be changed in the field after installation.
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Filling and commissioning the system
WARNING!
Do not switch on the electric element, or the gas booster, or the solar controller until the following steps are completed. To do so may cause damage that is not covered by warranty.
1. Turn on a tap inside the home, preferably one that is furthest away from the storage tank;
2. Turn on the cold water supply to the storage tank;
3. Allow the system to fill with cold water until water flows freely from the internal tap with no evidence of air spurts (do not open the PTR valve for this purpose);
4. Turn off the internal tap and allow the system to pressurise;
5. Turn on the electricity supply to the solar controller and circulating pump;
6. Ensure that the circulating pump is operating; if not, turn it on manually (refer to 20 for instructions);
TAKE EXTREME CARE BEFORE THE NEXT STEP. REFER TO THE SAFETY WARNING BELOW!
7. Open the fitting above the non-‐return valve on the solar return line and allow all air to purge from the solar collector circuit; when water flows freely, close the fitting and ensure no leaks;
8. If the system is electric boosted, turn on the electricity supply at the main switchboard.
The electrical supply should be connected to the terminal block provided and should not be wired directly to the thermostat or element itself;
9. If the system is gas boosted, turn on the electricity supply to the gas booster at the power point; then turn on an internal tap and check that the gas booster is working;
10. Check the complete system for leaks and rectify if necessary.
SAFETY WARNING!
If the solar collector panels have not been covered on a sunny day,
they can generate pressurised steam which can cause instant scalding and possible death. Extreme care should therefore be taken to perform Step 7 and it is strongly recommended that the solar collector panels be covered beforehand.
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Do of
Frost protection
Although the solar controller and circulating pump have an automatic frost protection function (refer to Section 2 for full technical details), if the installation is located in a frost prone area, even if frost only occurs on rare occasions, a frost protection kit must be
installed as a backup because damage caused by freezing is not covered by warranty.
A LEDA Frost Protection Kit contains the following:
Frost Protection
Kit Model No.
Product Code
AVP440
AVP005
AVK091
Description
Solar Frost Valve
20mm x 15mm Reducing Bush
Qty.
1
1
Frost Protection Valve
Fit one Frost Protection Valve to each of the bottom corner fittings of the collector array ensuring the valves do not touch the roof and face downwards (as shown above). Do not use thread sealants as this can interfere with the correct operation of the valves. Use the
sealing washers provided.
When the water temperature in the solar collector panels approaches freezing the optional frost protection valve will open and allow a flow of water through the panels and out onto the roof to prevent freezing, this is normal operation for the frost protection valve. The circulating pump will switch on and circulate warmer water from the storage tank to the
panels. On sensing the warmer water, the valves will close and the pump switches off. This process repeats until the danger of freezing passes.
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Section 2 – Technical and product maintenance
The hot water storage tank
The storage cylinder is constructed of 3mm mild carbon steel and has a maximum pressure rating of 850kPa although a lower operating pressure is recommended to achieve maximum product longevity (refer to “Valves” below). The interior is coated with Class Y vitreous enamel with a maximum temperature rating of 75 o
C and the exterior is coated with an anti-‐ corrosive coating. Although the 3mm gauge steel is greater than most hot water cylinders in
Australia and provides greater product longevity, it is also heavier and care must be taken during installation and removal. Occupational Health and Safety Regulations must be adhered to.
The tank is fitted with a replaceable magnesium sacrificial anode designed to provide protection against corrosion in most town water supplies in Australia. The anode attracts corrosive forces and sacrifices itself while protecting the tank. To achieve maximum tank longevity, the sacrificial anode should be replaced at regular intervals not exceeding 5 years
(refer to “Maintenance” below).
In areas with harsh water, the anode should be replaced at more regular intervals or an
aluminium anode should be fitted. Please contact your LEDA representative in such cases.
Note that cathodic protection against corrosion using sacrificial anodes is the most common protective method employed by hot water system manufacturers worldwide. It is also
commonly used in marine environments for shipping, oil rigs, and underground steel pipes.
The cylinder is encased in a pressure-‐injected flame retardant and fluoride free high density foam insulation which minimises heat loss and maximises overall efficiency which is evidenced by the high number of Small Technology Renewable Energy Certificates (STCs) awarded by Government testing.
The outer casing is constructed of powder-‐coated steel.
Dimensions and weights are set out in the following table:
SHW Tanks
Tank Storage Capacity
Tank Dimensions (Height/Diameter)
270ltr
1408mm/
648mm
340ltr
1711mm/
648mm
450ltr
1733mm/
732mm
Cold Water inlet Height
Solar Return Height
82mm
582mm
82mm
762mm
83mm
741mm
Hot Water Outlet and PTR Valve
Height 1169mm 1472mm 1473mm
Electrical booster height (if applicable) 748mm 912mm 903mm
Tank Weight (empty) 84kg 98kg 131kg
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The electric booster element
If your model is electrically boosted, the tank is fitted with a standard 3.6 kWh Kawai or
Backer element. Other sized elements are available. Please contact your LEDA representative for further information.
The element is fitted at roughly the mid-‐point of the storage tank and is connected to an automatic thermostat which is factory set at 60 o
C to comply with Australian Standard AS
3498-‐2009. When connected to an electricity supply, the automatic thermostat will maintain the water temperature in the upper part of the tank at 60 o
C leaving the cooler water in the lower part to be heated by free solar energy. The electrical supply should be connected to the terminal block provided and should not be wired directly to the thermostat or element itself.
Australian Standard AS 3498-‐2009 stipulates that solar water heaters will ensure that at least 45 per cent of the water contained within the storage tank is heated to a minimum of 60 o
C daily to inhibit the growth of Legionella bacteria in potable water.
For this reason it is important to understand that the switch for the electric booster element should be left continuously in the ‘On’ position so the automatic thermostat can control the water temperature in the upper portion of the tank leaving the lower portion available for solar heating. Not only does this comply with the Australian Standard, it also ensures a reliable supply of hot water.
Electric boosted systems can be connected to an Off Peak Tariff if desired however a “Night
Rate Only” tariff is not recommended. “Night Rate Only” tariffs do not supply electricity during daylight hours and solar water heaters connected to these tariffs can run short of hot water during periods of inclement weather. For systems connected to a continuous tariff, it is possible to install a time switch provided the availability of electrical power is sufficient to
comply with the provisions of AS 3498-‐2009 as outlined above.
The gas booster
The LEDA 6 Star rated continuous flow gas boosters come in two sizes, i.e. 20 litres per minute and 26 litres per minute, and also in two models, i.e. Natural Gas and LP Gas. Please contact your LEDA representative for further information.
The gas booster comes with its own separate manual. Please consult that manual for technical specifications and maintenance requirements. Take particular notice of required clearances and ventilation requirements.
A gas boosted storage tank does not have provision for an electric heating element so the water in the storage tank is pre-‐heated by solar energy. Consequently, the minimum water temperature in the storage tank is not controlled so, to comply with the provisions of
Australian Standard AS 3498-‐2009, the thermostat of the gas booster is factory-‐set at 60 o and must not be adjusted from that setting.
C
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When a hot tap is turned on in the home, solar pre-‐heated water flows to the cold inlet of the gas booster. A series of sensors measure the incoming water temperature and if the incoming water is up to temperature, the gas booster does not ignite and the hot water
flows through to the tempering valve (refer to “Valves” below for further details).
If the incoming water is below the thermostat setting, the sensors cause the gas booster to ignite and the water is heated to 60 o
C, instantly killing any bacteria that may be present.
This type of system also provides an endless supply of hot water.
The solar collector panels
LEDA solar collector panels are 2.44 m
2
in area with the following specifications:
Dimensions:
Absorber fins:
2040 x 1200 x 100 MM
0.14 copper plate
Absorber surface: Selective paint
Risers:
Headers:
Casing:
Backing sheet:
Glass:
Insulation:
Coupling:
Weight:
Copper tube
Copper tube
1.2mm black anodized aluminium
0.4mm aluminium
2000 x 1160 x 4 MM low iron prismatic tempered
High density glass wool
¾” brass
40kg (Approx)
The absorber fins, headers and risers, are ultrasonically welded together which provides maximum solar absorption and transfer of heat energy to the potable water. The design of the solar collector panels and the hot water storage tank play a large role in the very high
solar performance achieved as evidenced by the number of Small Technology Renewable
Energy Certificates (STCs) awarded by government testing.
The solar controller and circulating pump
The electronic solar controller works in conjunction with the circulating pump. They are housed in a weatherproof UV resistant housing on the side of the storage tank and are connected to sensors located in the bottom of the tank and the top of the solar collector
panels.
The controller turns the pump on and off in response to temperature differentiations between the two sensors. When the temperature at the solar panels is 8 sensors falls to 2 o
C, the pump is switched off. In effect, the pump is switched on when solar energy is available and switched off when it is not. o
C higher than the tank sensor, the pump is switched on. When the temperature differential between the two
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The controller also features an automatic over temperature switch-‐off function. When the water temperature at the tank sensor reaches temperature, the pump is switched off which
prevents the tank from over-‐heating and prolongs tank life.
There is also an automatic freeze protection feature. If the water temperature in the solar panels falls to 3
O
C, the pump is turned on and warm water from the tank is pumped up through the solar panels. When the temperature in the panels reaches a higher set temperature, the pump is turned off. This process is repeated until the danger of freezing from a low ambient temperature passes. Note that in severely cold locations, hot water supply in the storage tank can run low as a result of these repeated processes.
Also note that the pump will turn off for 5 minutes after two hours of operation and then turn on again automatically to prevent possible cavitation. The pump uses a very low 20-‐30 watts of power during operation and is silent during operation.
It is important to understand that the pump and controller will only operate with a continuous supply of electricity. For normal operation it should therefore be connected to a continuous supply and not turned off.
Basic Controller Functions
Indicator Pump On
Indicator – Frost Protection On
Switch on Pump manually and used in Program Mode
Scroll Settings in Program Mode
Program mode (see below) and used in Program Mode
Used in Program Mode – see below
Indicator -‐ Top Out Temp Indicator – Pump in Manual
Reached Mode
Note – the controller is factory pre-‐set to operate at optimal settings and should not require programming. In this regard, contact your LEDA representative if necessary.
To turn on the pump manually, first ensure the control panel is not in “Program” mode.
Then press the “-‐“ key as shown above. If left on, the pump will run for two hours before switching back to automatic mode.
The LCD display of the solar controller displays the following error codes:
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L:001 R:001
L:Err R:001
L:001 R:Err
L:Err R:Err
Normal (Note L=lower sensor and R=roof sensor)
Tank sensor failure (LED lights also illuminate)
Roof sensor failure (LED lights also illuminate)
Both sensor failure (LED lights also illuminate)
Frost protection
In areas where frost occurs, even on rare occasions, it is important to protect your solar
collector panels from freezing as the resultant damage is not covered by warranty.
Even though the solar controller and circulating pump incorporate an automatic freeze protection feature (refer to “The solar controller and circulating pump” section above),
backup protection is needed in case of power outages.
You should ensure therefore that a Frost Protection Kit is installed. When the water temperature in the solar collector panels approaches freezing the optional frost protection valve will open and allow a flow of water through the panels and out onto the roof to prevent freezing, this is normal operation for the frost protection valve. The circulating
pump will switch on and circulate warmer water from the storage tank to the panels. On sensing the warmer water, the valves will close and the pump switches off. This process
repeats until the danger of freezing passes.
Valves
Regulations require that hot water supplied to bathrooms and bathing areas be supplied at temperatures no greater than 50 fitted and set to 50 o o
C. A high performance tempering valve must therefore be
C. The tempering valve mixes incoming hot water from the water heater with cold water from the cold water supply and delivers 50 degree water to the outlets.
Although the hot water system is rated to a maximum of 850 kPA, a 500kPa pressure limiting valve should be fitted to the cold water supply. If not fitted at the mains water supply this should be fitted before the cold line to the tempering valve so as to equalise both the hot and cold line pressure. Reducing the hot water pressure to this level will protect your household appliances including dishwashers, etc., as well as prolonging the life
expectancy of your hot water system.
A 700kPa expansion control valve (ECV) should be fitted. As water is heated it expands and increases pressure. During the heating cycle (either from solar or electricity) the ECV will drip water to relieve the build-‐up of pressure. This can be many litres in a 24 hour period and should be drained to a convenient location. Water dripping from this valve is
considered normal.
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An 850kpa pressure and temperature relief (PTR) valve is supplied with the storage tank and is fitted to the top of the tank. This valve has two functions. The first is to relieve pressure build-‐up through expansion should the thermostat fail to turn off the electric element. The second is to relieve pressure build up should the ECV fail. The temperature setting for this
valve is just below boiling point, and the pressure setting is 850kPa.
During the heating cycle (either from solar or electricity) the PTR will drip water to relieve the build-‐up of pressure. This can be many litres in a 24 hour period and should be drained
to a convenient location. Water dripping from this valve is considered normal.
NOTE THAT THIS IS A HOT WATER VALVE AND EXTREME CARE IS NEEDED TO PREVENT
SCALDING OR INJURY.
Maintenance
Proper maintenance of your solar hot water system will ensure its correct operation and
performance as well as extend its life.
The relief valve easing gear on the PTR valve and ECV should be opened and closed at least once every six months. Gently pull the easing gear lever open and then gently close it again so that it reseals. Water will be expelled when the easing gear is opened.
WARNING – Water at the PTR valve can be very hot and can cause scalding.
Take extreme care when opening the easing gear and keep other persons or animals well clear.
DANGER – Failure to operate the relief valve easing gear at least once every six months may result in the water heater exploding. Continuous leaking
from the PTR valve may indicate a problem with the valve.
A major service should be carried out at least every five years, or more often in areas with poor water quality. This major service will involve the following:
-‐ Replacing the PTR valve in line with regulations
-‐ Replacing the sacrificial anode
-‐ Cleaning the solar collector glass
-‐ Checking the system for leaks or other abnormalities and reporting these to the owner
Normal rain events should keep the solar collector glass sufficiently clean, however if the glass becomes dirty the glass can be hosed from ground level. Anyone climbing on to roof
tops must comply with all Occupational Health and Safety regulations.
WARNING – If the solar hot water system is not used for two weeks or more, a quantity of hydrogen gas can accumulate in the top of the tank. This may be indicated by significant spluttering when a hot tap is opened. HYDROGEN
GAS IS HIGHLY FLAMMABLE. To dissipate the gas, choose a hot tap that is
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remote from any appliances such as dishwashers, clothes dryers, or other appliances that can create a spark and ignite the gas. While allowing the gas to dissipate through the remote tap, there must be no smoking, open flame or electrical appliance operating nearby. Allow the gas to escape until water
flows freely with no sound of gas or air escaping.
Certifications and licenses
Section 3 – Owner operating instructions
SAFETY WARNING!
HOT WATER CAN BE DANGEROUS!
Please read the following warning statements carefully and take all due care when operating your solar hot water system.
• Hot water temperatures over 50 o
C can cause scalding and all due care must be taken
to prevent injuries to yourself as well as others, especially children and the elderly.
• Solar water heaters can generate water temperatures in the hot water storage tank in excess of 85 o
C and regulations require that a high-‐performance solar tempering valve be fitted by an authorised plumber (please refer to “Valves” in Section 2 for an explanation of how this valve works).
• DANGER: Failure to operate the easing gear of the relief valves at least once every six months may result in the water heater exploding. Take extreme care when operating the easing gear of the Pressure and Temperature Relief (PTR) valve as very hot and untempered water will flow from this valve. Keep people and animals well away during this operation.
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• During periods of stagnation (when the circulating pump is not pumping water through the solar collector panels) the water in the collector circuit can become super-‐heated and can cause instant scalding and perhaps death. Do not, under any circumstances disconnect the flow and return lines to and from the solar collector panels unless you are an authorised and licensed plumber.
• Your solar hot water system should not be operated by persons with reduced physical or mental capabilities, or lack of experience and knowledge. This includes young children and the elderly. Always ensure that such people are adequately supervised.
• If the solar hot water system is not used for two weeks or more, a quantity of hydrogen gas can accumulate in the top of the tank. This may be indicated by significant spluttering when a hot tap is opened. HYDROGEN GAS IS HIGHLY
FLAMMABLE. To dissipate the gas, choose a hot tap that is remote from any appliances such as dishwashers, clothes dryers, or other appliances that can create a spark and ignite the gas. While allowing the gas to dissipate through the remote tap, there must be no smoking, open flame or electrical appliance operating nearby.
Allow the gas to escape until water flows freely with no sound of gas or air escaping.
• Legionella bacteria can breed in hot water systems where the stored water temperature is low enough to create ideal conditions and there have been cases of people contracting Legionnaire’s Disease. Make sure you operate your back-‐up booster in accordance with Australian Standard AS 3498-‐2009. DO NOT TURN OFF
YOUR BOOSTER SWITCH. Please read and fully understand the sections entitled
“The electric booster element” and “The gas booster” on Page 18 for a full explanation. Note that these requirements apply to all solar hot water systems in
Australia no matter what brand or model.
• Your LEDA solar hot water system is one of the most efficient, highest performing, solar hot water systems on the market today and, as such, attracts amongst the highest Small Technology Renewable Energy Certificates (STCs) as a result of government testing. Note that this testing is carried out at government approved laboratories following set procedures that include the booster being connected to continuous electrical power in accordance with Australian Standard AS 3498-‐2009.
The greater the number of STCs awarded, the higher the solar performance. Please take care of your LEDA solar hot water system by maintaining and operating it in accordance with the guidelines outlined herein. You will then enjoy reliable and safe hot water for years to come.
Warranty
In addition to the guarantees under the Australian Consumer Law (ACL), LEDA provides consumers a warranty that all products in its product range will be free from defects in materials and workmanship under normal use for the period of time applicable to particular components of each product as set out in the table below.
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The warranty periods listed in the table below commence from the date of original purchase by the original owner.
If a product fails to conform to this warranty during the applicable warranty period, LEDA will either replace any failed component part of the product excluding the labour or replace the product free of charge if within the warranty labour period (which LEDA will determine
in its absolute discretion).
Table of Applicable Warranty Periods
COMPONENT
Hot water storage tank
WARRANTY PERIOD
PARTS ONLY
5 years
5 years
WARRANTY PERIOD
LABOUR
1 year
1 year Solar collector panels
All electrical components including element, thermostat, solar controller, solar sensor, etc..
1 year 1 year
Circulating pump 1 year 1 year
Valves supplied by LEDA
Gas booster -‐ heat exchanger only
Gas booster -‐ all other components
Installation
1 year
10 years
3 years n/a
1 year
1 year
1 year
1 year
Where a labour warranty period has expired the customer is liable to pay the labour
required to replace or fix the component.
Terms Of Warranty And Exclusions
To the extent permitted by Australian Consumer Law (ACL), this warranty does not cover the following:
1. If you request a call out and it is found that the fault is not covered by the warranty, you are responsible for our standard call out charge. If you choose to have the non-‐warranty component repaired it will be at your cost;
2. Defects or faults caused during the installation of the appliance;
3. Defects or faults caused by misuse, abnormal strain, or accidental damage;
4. Damage to the solar collector glass by hail, frost, storm, tempest or any other means.
We suggest that the collector glass be covered by your home insurance policy;
5. Damage by Acts of God such as floods, storms, fire, lightening strikes and alike, or other circumstances outside the control of LEDA;
6. Corrosion caused by lack of maintenance, including anode replacement, as recommended in this manual;
7. Scale formation or corrosion where the appliance has been connected to water qualities that are outside the recommendations outlined in this manual;
8. Frost damage where the product has been installed without approved optional frost protection valve or where the electricity supply has been switched off or has failed to
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the freeze protection system. Warranty will not apply to frost damaged collectors if the pump or controller are determined to be faulty for any reason;
9. Damage to any roofing materials or property due to the operation of a frost protection valve;
10. Faulty water plumbing including excessive water pressure, blocked pipework or water strainers, and inappropriate water flow restricting devices. Please note the minimum flow rate in the installation instructions. If the minimum flow rate cannot be achieved due to inappropriate water flow restricting devices the product should not be installed.
11. Faulty gas plumbing including undersized gas lines and incorrect gas type selection;
12. Any parts not supplied by LEDA;
13. External labour or equipment costs, e.g. cranes and lifting devices, including costs to bring the water heater components down to ground level;
14. All consequential loss, property damage, personal injury or economic loss;
15. Where the appliance is installed on premises other than residential;
16. Freight and travelling costs outside a radius of 30 kilometres from the point of purchase or the nearest authorised service agent;
17. Out of normal business hours call-‐out fees.
Where a component is replaced or repaired under warranty, the balance of the original warranty remains effective. The replaced or repaired part does not carry a new warranty.
Australian Consumer Law (ACL)
In addition to this warranty, certain legislation (including the ACL) may give you rights which cannot be excluded, restricted or modified. This warranty must be read subject to such legislation and nothing in this warranty has the effect of excluding, restricting or modifying
those rights.
If LEDA fails to meet a guarantee under the ACL, your remedy for such failure may be limited to any one or more of the following:
• replacement of the product;
• repair of the product;
• refunding the cost of the product;
• payment of reasonable costs of having the product repaired;
• payment in respect of the reduced value of the product.
As required by legislation, including the ACL, any claims for damage, or any consequential loss either directly or indirectly due to defects of any kind in a product will only be met by
LEDA where the damage or loss was reasonably foreseeable by LEDA.
Our goods come with guarantees that cannot be excluded under the Australian Consumer
Law. You are entitled to a replacement or refund for a major failure and for compensation for any other loss or damage. You are also entitled to have the goods repaired or replaced if
the goods fail to be of acceptable quality and the failure does not amount to a major failure.
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Register for Warranty
Warranty registration can be done by going to website www.ledaaustralia.com
HOW TO MAKE A WARRANTY CLAIM
At the time of purchasing your water heater, you should ensure you receive an owner’s manual and that details of your purchase, including the date of purchase and the serial number of the storage tank, are recorded therein. You should keep those documents in a safe place in case of a warranty claim as documentary proof of purchase or other tangible evidence will be required to make your claim. If the date of installation is unknown the warranty period commences one month after the date of manufacture of the component.
Claims can be made at the point of sale or by posting, faxing, or emailing a written claim to
LEDA (contact details listed below) within 3 months of the appearance of a defect. Claims
must include the following details:
• Date of purchase;
• Location of purchase;
• Proof of purchase; and
• Contact details including name, address, telephone numbers, and email address.
LEDA’s contact details are as follows:
Leda
Ph: 1800 697 652
E: [email protected]
www.ledaaustralia.com
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