Duplex Stainless Steel Solar Hot Water Tank Installation ...€¦ · Duplex Stainless Steel Hot...

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Exegi Pty Ltd

4/3 Techno Park Drive Williamstown Victoria 3016 03 93973993 Exegi.com.au

Duplex Stainless Steel Solar Hot Water Tank

Installation Manual

Duplex Stainless Steel Hot Water Storage Tank

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Key Points for Installation • This product must be installed by a licenced installer and all plumbing and

electrical work must meet all relevant Australian standards and regulations, failure to do so may void the warranty

• 500KPA pressure limiting valve must be installed if supply water pressure is above 500KPA.

• 600KPA expansion control valve must be installed (regardless of supply pressure).

• 700KPA PTR valve must be installed (regardless of supply pressure). • Check sacrificial anode every 12 months. • Solar tempering valve must be installed on hot outlet relevant Australian standards

and regulations.

Contents

Summary 3 Safety 4 Technical Specifications 6 Structure of DX0 tank 7 Structure of DX1 tank 8 Structure of DX2 tank 9 Tank Ports 10 Installation 11 Installation Examples diagrams 11 Standard no coil example 11 Coil tank example 12 Installation details 13 Operation/Comissioning 15 Maintenance 15 Troubleshooting 16 Component List 16 Warranty Certificate 16


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Summary 1.1 Component List

No Description Qty

1 Hot Water Tank 1 pc

2 Manual 1 pc

3 PTR valve 1 pc

4 Barcode (affixed to tank) 1 pc

5 Installation Manual 1 pc

1.2 Stainless Steel Hot Water Tank Models

The Red Circle Solar stainless steel hot water tanks are available without, or with one or two heat exchange coils.

DXO Series (No Coils) DX1 Series (1 Coil) DX2 Series (2 Coils)

200L 200L 200L

300L 300L 300L

400L 400L 400L

500L 500L 500L

1.3 Hot water tank protection The inner tank is constructed of 2205 Duplex stainless steel. The tank also features a sacrificial

magnesium anode to prolong the life of the tank. It is recommended that the sacrificial anode be checked

annually. The tank should not be installed with any plumbing tape.

1.4 Insulation

The 50mm polyurethane foam insulation layer used in the Exegi tank preserves the heat in the tank for

maximum efficiency. The insulation does not contain CFC or HCFC

1.5 Outer Tank The outer tank is made of coloured steel plate.


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1.6 Features

• Made from 2205 Duplex stainless steel.

• Large corrugated coils for maximum heating efficiency (On DX1 and DX2 models only).

• Coil designed to operate with water pressure up to 800 KPA

• 3 sensor ports.

• Multiple ports for a wide variety of applications.

• Magnesium sacrificial anode to provide extra protection

1.7 Important Information: Read Prior to Installation

• This manual should be regarded as part of the tank, the owner needs to keep this manual for

future reference, safety information and maintenance information.

• The manual should be read thoroughly and fully understood prior to installation.

• The Exegi Duplex stainless steel hot water tank must be installed by a licensed plumber in

accordance with this manual and all relevant plumbing and electrical work must meet all relevant

Australian standards and regulations. Failure to install or use the tank in accordance with the

manual may void your warranty.

• Children should not operate the tank.

• Packaging should be disposed of in a responsible manner.

• The tank should be installed away from combustible materials.

• Electrical wiring should be done by a licenced installer in accordance with the instructions in the

manual and all relevant plumbing and electrical work must meet all relevant Australian standards

and regulations.

1. Safety The Exegi Duplex stainless steel hot water tank must be installed by a qualified tradesperson who holds the relevant industry licenses and/or certificates for the work needed to complete installation.

At all times the qualified tradesperson installing the hot water tank must adhere to the occupational health and safety guidelines as set out by Workcare/Workcover in your state, and any other relevant workplace regulations.

The qualified tradesperson is responsible for their own safety at all times. No person should attempt to install the hot water tank without reading and understanding the manual.

Safety Warnings:

Symbol Signification

Failure to observe this safety warning may result in injury or death.

Failure to observe this safety warning may result in injury, or damage to plants or animals.


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2.1 The tanks should not be operational during installation or maintenance. There is a danger or electric shock if the wires are live during installation or maintenance.

There is a risk of burns if there is hot water in the tank or pipes during installation or maintenance.

2.2 The tank should be drained prior to disconnecting components. Removing electrical connections while the tank is in operation may result in electrocution.

Removal of pipes while the tank is in operation may result in burns or scalding from water leakage

2.3 Do not connect the hot water tank to mains electricity via an electrical plug. Electric elements must be hard wired, and must be installed accordance with all relevant Australian

standards and regulations. Electric shocks and death can be caused by non-compliant connections.

2.4 Beware of electrical wiring Breaking or making contact with a live wire may result in electrocution.

2.5 Do not place objects on top of the tank Storing or installing objects on top of the tank may cause the tank to fall or be damaged.

2.6 Do not climb or stand on the tank.

Climbing or standing on the tank may result in a fall causing injury

Climbing or standing on the tank may cause the tank to fall or be damaged.

2.7 Care must be taken when using ladders.

There is a risk of injury or death if unstable footings are used when installing or cleaning the tank. Make sure ladders are in good condition and secure. When working at heights, appropriate safety precautions should be taken.

2.8 Turn off electricity to tank before cleaning.

Cleaning the tank without turning off the electric supply may result in electrocution.

2.9 Beware of pipes and wires during installation

Damage to electrical wiring may result in electrocution or fire.

Damage to underground pipelines may result in explosion, fire, or poisoning.

2.10 Mordant solvent, alcohol, corrosive cleaners and pesticides must not be used to clean the tank

Use of these chemicals may damage the paint, plastic components of the tank or cause injury.

2.11 Do not use the product for industrial applications without prior consultation.

The hot water tank is designed for domestic applications. Use for industrial applications may overload the tank and cause damage.

2.12 Tank must be used by an appropriate adult

Operation or installation of the tank by a child may result in damage, injury or death.

2.13 Wiring work must meet all relevant Australian standards and regulations

Use of wiring that is too thin may result in overload and poses a fire risk.


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2.14 Appropriate personal protective equipment should be worn.

Failure to wear appropriate personal protective equipment may result in injury.

2.15 Check the safety of the tank if not operated for a period.

When the tank has not been operated for a period the safety protocols above should be checked before the tank is refilled. Damage may be caused if the check is not performed.

2. Technical Specifications No Coil tanks (DX0 series)

Model DX0-200 DX0-300 DX0-400 DX0-500 Water tank rated

Capacity (L) 200L 300L 400L 500L

Coil type None None None None Outer tank diameter (mm) φ560±5 Φ600±5 Φ650±5 Φ700±5 Inner tank diameter (mm) φ470±5 Φ500±5 Φ550±5 Φ600±5

Material of inner tank SUS 2205 Duplex SUS 2205

Duplex SUS 2205

Duplex SUS 2205

Duplex Thickness of inner tank(mm) δ=1±0.16 δ=1±0.16 δ=1.5±0.16 δ=1.5±0.16 Thickness of inner tank cover

(mm) δ=1.2±0.16 δ=1.2±0.16 δ=1.5±0.16 δ=1.5±0.16

Water tank rated pressure of the tank (Mpa) 0.8 0.8 0.8 0.8

Material of outer water tank Colour steel plate Colour steel

plate Colour steel

plate Colour steel

plate Thickness of outer tank cover

(mm) δ=0.5±0.03 δ=0.5±0.03 δ=0.5±0.03 δ=0.5±0.03

Insulation thickness (foaming) 45±2 50±2 50±2 50±2

Foaming density (KG/Mtr2) 36±2 36±2 36±2 36±2 Net weight（Kg） 39 59 74 91

Gross weight （Kg） 42 64 80 98 Packing Dimensions

(L*W*H) (mm) 630*630*1440 670*670*1630 720*720*1920 770*700*1930


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Single Coil tanks (DX1 series)

Model DX1-200 DX1-300 DX1-400 DX1-500

Water tank rated Capacity (L) 200L 300L 400L 500L

Coil type (corrugated) 28mm x 10mtr. SUS 316L 28mm x 15mtr.

SUS 316L 28mm x 15mtr.


SUS 316L Outer tank diameter (mm) φ560±5 Φ600±5 Φ650±5 Φ700±5

Inner tank diameter (mm) φ470±5 Φ500±5 Φ550±5 Φ600±5


Duplex SUS 2205

Duplex SUS 2205

Duplex Thickness of inner tank(mm) δ=1±0.16 δ=1±0.16 δ=1.5±0.16 δ=1.5±0.16

Thickness of inner tank cover (mm) δ=1.2±0.16 δ=1.2±0.16 δ=1.5±0.16 δ=1.5±0.16

Water tank rated pressure of tank and coil (Mpa) 0.8 0.8 0.8 0.8

Material of outer water tank Colour steel plate Colour steel

plate Colour steel

plate Colour steel

plate

Thickness of outer tank cover (mm) δ=0.5±0.03 δ=0.5±0.03 δ=0.5±0.03 δ=0.5±0.03


Foaming density (KG/Mtr2) 36±2 36±2 36±2 36±2

Net weight（Kg） 42 62 77 95

Gross weight （Kg） 45 67 83 101

Packing Dimensions (L*W*H) (mm) 630*630*1440 670*670*1630 720*720*1920 770*700*1930


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Twin Coil tanks (DX2 series)

Model DX2-200 DX2-300 DX2-400 DX2-500

Water tank rated Capacity (L) 200L 300L 400L 500L

Bottom Coil type (corrugated) 28mm x 7.5mtr. SUS 316L 28mm x 7.5mtr.



SUS 316L

Top Coil type (corrugated) 28mm x 7.5mtr. SUS 316L 28mm x 15mtr.



SUS 316L Outer tank diameter (mm) φ560±5 Φ600±5 Φ650±5 Φ700±5

Inner tank diameter (mm) φ470±5 Φ500±5 Φ550±5 Φ600±5


Duplex SUS 2205

Duplex SUS 2205

Duplex Thickness of inner tank (mm) δ=1±0.16 δ=1±0.16 δ=1.5±0.16 δ=1.5±0.16

Thickness of inner tank cover (mm) δ=1.2±0.16 δ=1.2±0.16 δ=1.5±0.16 δ=1.5±0.16

Water tank rated pressure of tank and coil (Mpa) 0.8 0.8 0.8 0.8

Material of outer water tank Colour steel plate Colour steel plate Colour steel

plate Colour steel plate

Thickness of outer tank cover (mm) δ=0.5±0.03 δ=0.5±0.03 δ=0.5±0.03 δ=0.5±0.03


Foaming density (KG/Mtr2) 36±2 36±2 36±2 36±2

Net weight（Kg） 45 65 80 98

Gross weight （Kg） 47 70 86 105

Packing Dimensions (L*W*H) (mm) 630*630*1440 670*670*1630 720*720*1920 770*700*1930


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A B

C

E D

F

G H

I K J L M

N

BSP 32mm FM (400L + 500L) 25mm FM (200 +300L) hot water outlet

BSP 20mm FM PTR

Top temp. sensor BSP 25mm FM top coil inlet 20mm Anode

BSP 25mm FM top coil outlet

Mid temp. sensor

BSP 25mm FM bottom

BSP 20mm FM secondary Bottom temp. seonsor BSP 25mm FM bottom coil

Element Port BSP 32mm FM (400L + 500L) 25mm FM (200 +300L) cold water inlet

BSP 20mm FM secondary flow BSP 20mm FM drain

DX0 DX1 DX2 DX0 DX1 DX2 DX0 DX1 DX2 DX0 DX1 DX2A = WidthB = HeightC =Hot Outlet, PTR,Top SensorD = Top Coil 950 1240 1370 1390E = Anode 940 906 1005 1040 1040 1140 1170 1190 1270 1190 1210 1290F = Mid Sensor 780 795 825 920 920 880 1000 1000 1010 1080 1020 1030G = Top Coil 700 690 820 840H = Bottom Coil orSolar Return 830 745 600 880 880 590 910 910 686 930 930 705

I = Secondary Return 700 665 475 800 800 465 830 830 496 850 850 515J = Bottom Sensor 400 410 400 400 400 400 430 430 430 450 450 450K = Bottom Coil orSolar Flow 300 340 350 340 340 340 370 370 370 390 390 390

L = Element Port 300 300 310 300 300 300 330 330 330 350 350 350M = Cold Inlet andSecondary FlowN = Drain

220

32.5

250

32.5

270

32.532.5

Port

All measurements are in MM

560

1340

N/A N/A N/A

N/A

700

1105

N/A

N/A

230

N/AN/A

1565 1585

200 L 300L 400L 500L

1325 1560 1810 1828600 650


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Tank Ports

Hot outlet

Coil or Secondary heat

source port

port

Solar return port

port Coil or Secondary heat

source port

port

Solar flow port

port

Bottom sensor port

port

Cold inlet port

port

Drain port

port

Element cover and port

port

Rubber feet x 4

Top sensor port

PTR port

Sacrificial Anode

port Middle sensor port

port


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3. Installation For Installation examples (See below)

Installation example of a standard (DX0) tank to a solar collector

THESE ARE EXAMPLES ONLY, SYSTEMS SHOULD ALWAYS BE DESIGNED AND INSTALLED BY A LICENSED PROFESSIONAL


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Installation example of a DX2 twin coil tank to a solar collector and alternative heat sources This example is of a DX2 tank to a solar collector – please note a DX1 is the same, but ignore the notes for the top coil)



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Installation example of standard (DX0) Tank with Instantaneous Gas Booster The solar rated natural gas or LPG booster can be fed directly from the solar hot out. Please refer to manufacturers specifications.


Sensor for solar. (Tank)

Sensor for solar. (Collector)


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INSTALLATION DETAILS

4.1.1 Location of Tank The tank must be level and secured on a solid base. The tank should be installed as close as possible to the

other hot water system components (manifold, pump, controller etc.). The location of installation must be

able to bear the weight of the tank when full (see specifications in part 3 of manual).

4.1.2 Test the pressure of the system after the pipes are connected to ensure there are no leaks and insulate the hot water pipes. Insulate cold pipes also if in a frost prone area.

4.2 Water Quality

4.2.1 Please note that Stainless steel tanks are not suitable for all locations. Some areas have poor water

quality (e.g. hard water and bore water). This can affect the lifespan of stainless steel and will void the

warranty.

4.2.2 The water quality must be within the following parameters. Operation of the tank with water with higher

particulate counts will void the warranty.

Total Dissolved Solids Total Hardness Chloride PH level

600 mg/L or ppm 200 mg/L or ppm 250 mg/L or ppm Minimum 6.5–Maximum 8.5

If you are unsure of the water quality in your local area, you can contact your local water authority. Local water authorities regularly conduct water quality tests, and should be able to give you information so that you can check whether your water exceeds the particulate count above. Where your local water supply is low quality, installing a water filter or water treatment system may help to improve the quality of the water. We recommend consulting a supplier/plumber to determine the filter or system that is right for you. If the filter or treatment system does not improve water quality to within the specified standards your warranty will be void.

Important: Safety Warnings

• The hot water tank must be installed with a PTR valve suitable for a system with a maximum working

pressure of 700 KPA and comply with Australian standards.

• The PTR valve must be connected directly to the tank. There must not be any valves or obstructions

placed between the tank and the relief valve.

• The discharge pipe from the PTR valve must be unobstructed and in a frost-free location.

• A 600 KPA expansion control valve must be installed on the cold inlet pipe that supplies the storage

tank.

• A 600 KPA expansion control valve must be installed in the closed loop when connecting the coil heat

exchanger with other heat source.


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• The PTR valves and expansion control valves should be manually activated at least every 6 months to

prevent blockages and to ensure the valve is working properly.

4.3 Connecting the Electric Booster element.

Attention: All electrical work must be carried out by a licensed professional and must meet all relevant

Australian standards and regulations.

Open the element enclosure on the side of the tank. Thread the wire through the waterproof cable gland of

the tank and connect the element as shown in the diagram on the next page, then cover the element

enclosure and tighten the screws. The connecting wire of the element should use 60227IEC53(RVV)300/500

chlorine rubber thread, with a diameter of 3×2.5mm2. The electric heater temperature also can be set by

adjusting the thermostat control knob.

It is recommended that the Electric element (if used) to be set to 60-65 degrees Celsius for maximum

efficiency.

Important: Safety Warning Electric components must be properly grounded.

4.3.1 Wiring connection drawing:

A N

E

Element

Thermostat


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4.4 The tank must be installed in accordance with the relevant regulations and standards in your state.

4.5 The temperature for thermostat should be set to 60-65 degrees Celsius.

5. Operation/Commissioning 5.1 Open the cold water inlet tap to fill the pressurised tank with while ensuring any air can escape. This can be done through the vent port located on the top of the tank. 5.2 Fully fill the flow and return pipes to the solar collector and vent out any air. 5.3 Check the PTR valve, the expansion control valve, the pump/controller, and electric heater regularly to make sure they are working properly 5.4 Solar controller: The solar controller comes pre-set but can be manually adjusted to suit the application.


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Aestiva Split System solar controller

(If used, or similar differential controller)

The controllers interface consists of 4 buttons and 4 indicator lights and a white back lit LCD screen.

To help explain, the buttons can be named as below: Button A (manual Pump) Button B (Next) Button C (Prog Mode) Button D (Program)

The controller is in automatic mode with the factory settings when it is turned on first. The screen will display the 2 sensors’ temperatures as below. L = Tank, R = Solar collector.

By pressing and holding buttons “B”, “C” and “D” at the same time for 5 seconds, the controller will enter programming mode. During the programming mode, all 4 LED lights will be flashing. The screen will display “Pump On Temp: 008” first in the programming interface. By pressing “Button B” (Labelled “Next”), the controller will go through the following setting menus in sequence and repeat this in cycles: To adjust the settings, press the A (-) or C (+) buttons.

Sensor’s Temp : L: 01 R: 01


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In each setting menu, by using “Button A” and “Button C” (Labeled “+” and “—“), the setting parameters can be increased and decreased until the desired figures are achieved. When programming is completed, holding the “Button D” (18abelled “Program”) will exit the program mode and save all the changes made. The controller will reboot itself and display the following messages.

Hold B, C and D down for 5 Seconds

Pump on Temp: 08 Pump will turn on when Solar temp sensor (R) is 8 Deg C higher than Tank sensor (L)

Pump off temp: 02

Press next (Button B)

Pump will turn off when Solar temp sensor (R) is 2 Deg C higher or less than Tank


Top out Temp: 75


Pump will turn off when Tank (L) temp reaches 75 Deg C or more.

Protect on Temp: 03


Pump will turn on when solar collector (R) temp reaches 3 Deg C or less. Frost protection.

Protect off Temp:05


Pump will turn off when solar collector (R) temp reaches 5 Deg C or more. Frost protection.


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If by accident, the parameter settings have been messed up, the controller can be returned back to factory default setting by pressing and holding “Button B” and “Button D” for 5 seconds. The factory settings are listed below with references: • Circulation pump differential control – The circulation pump will only be activated when

there is sufficient solar energy present on the roof to contribute to the heat gain in the water cylinder. This is achieved by sensing the temperature difference between the roof collector and inlet water temperature. The water circulation will stop when the roof collector temperature falls and not sufficiently higher than the water cylinder inlet temperature.

“Pump Differential On Temp”: 8oC “Pump Differential Off Temp”: 2oC

• Top out protection – In good solar conditions, the solar collector could harvest the solar energy extremely sufficiently and quickly raise the storage water cylinder temperature. The storage water cylinder internal lining may be damaged by the high temperature water, which can exceed the designed operating temperature range by the tank manufacturer. The top out function prevents the water cylinder reaching dangerously high temperature by stopping the pump circulation to the collector, so that the water is not heated further. A solar rated high temperature non-return valve must be used in the solar loop in conjunction for maximum protection.

“Top Out Temp”: 75oC “Top Out Reset Temp”: 73oC

• Anti-freeze protection – In frost conditions, the risers in flat plate collector or the heat exchangers in evacuated tube collector may freeze and cause damages. Anti-freeze protection can sense the roof temperature and activate the pump circulation for short period before the water may freeze inside. “Anti-freeze on Temp”: 3oC “Anti-freeze off Temp”: 5oC

• SHM (Smart Heat Management days) – In this mode, the user can set the number of days

they wish the controller be at SHM mode. The default figure is 60 days. It can be set to a maximum 90 days.


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Summer mode: Smart heat management. (SHM) During SHM mode, the controller actively detects and monitors the tank and collector temperatures. When the tank experiences top out condition for 4 hours continuously, it will deem the system in an overheating stagnation condition. The controller will circulate the pump during night time to cool the lower half tank in a reverse differential control (i.e. when the roof is 10 deg cooler than the tank to allow actual cooling effect). During the SHM period, if a day has overcast and the system is not in overheating situation, the controller will not activate the night circulation, as the tank top out condition is not met. The solar return port is about half way of the tank. This means the cooling will apply the bottom half of the tank. The upper half of the tank is not affected. This means there will be no loss of hot water for morning applications such as showers, as the hot water is drawn from the top of the tank.

SHM (smart heat management) mode activation and deactivation • How to activate SHM mode By pressing and holding buttons “A” and “B” at the same time for 5 seconds. The controller will enter SHM mode. “SHM” will appear on top of the temperature setting. The controller will automatically exit “SHM” mode after 60 days of operation by default or the number of days can be programmed in the program mode described above. • How to manually exit SHM mode By pressing and holding buttons “C” and “D” at the same time for 5 seconds. The controller will exit SHM mode and “SHM” will disappear from the screen


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6. Maintenance 6.1 Prior to performing any maintenance on the hot water tank the power must be turned off.

6.2 The outer tank should not be cleaned with alcohol or corrosive cleaners.

6.3 The sacrificial anode should be checked at regular intervals (we recommend annual checks) and the tank descaled if necessary. To descale the tank, close the cold water inlet valve and open the hot water valve, then open the drainage valve to drain the deposit in the tank. A professional descaling solution may be needed.

6.4 Once the tank has been descaled, close the drainage valve and fully fill the tank as instructed in part 5 (operation) of the manual and check that there is no leakage.

6.5 If there are issues with the tank seek assistance from a qualified plumber or contact Exegi Pty Ltd.

7. Troubleshooting Guide

Please contact Exegi Pty Ltd for any further information.

Problem Cause Solutions

No hot water

No water supply, the water inlet and outlet valve is closed or blocked.

Open the cold water inlet valve and hot water valve. Check for blockages in all relevant valves.

The cold water pipe is frozen Wait for the thawing of the pipe and ensure pipe is properly insulated

The water temperature is

low

Blocked tempering valve. Check filters in tempering valve for blockages.

Circulation pump malfunctioning due to air in the heat exchange coils or solar collector manifold.

Vent the air in the pump and circulation pipe.

Incorrect system control, pipe linkage or setting Refer the manual, or consult the installer/manufacturer

The coil heat exchanger is scaling due to long-term high temperature operation

Clean the tank and consider adding water treatment to remove the scale.

Leakage of the water tank

Aging of the electric element or magnesium rod seals

Replace the electric element or the magnesium rod seals

Long term overvoltage operation of the tank Replace the tank

Water that is low quality causing a hole or split (outside parameters set in the manual). Replace the tank


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Warranty Certificate Exegi Duplex Stainless Steel Hot Water Tank

Please keep a copy of this document and proof of purchase.

Warranty Period: Important Information:

Please keep a record of the following information.

Invoice number:

Date of Installation:

Product serial number (can be found on tank and also on tank box)

Installer’s name:

Installer’s plumbing certificate number:

Location of installation:

The warranty does not cover:

1. The tank is outside of the 5 year warranty period. 2. The electrical components including the element outside of the 1 year warranty period. 3. Damage arising from incorrect installation or use, including but not limited to failure to follow the

directions in the manual provided by Exegi Pty Ltd (“the manual”). 4. Damage caused in transport once the customer has taken possession of the tank. 5. Damage caused by use of the tank with low quality water that exceeds the maximum particulate

count specified in the manual.

Claim Procedure: Claims under the warranty should be lodged with:

Exegi Pty Ltd (ABN: 41621313620). (03) 9397 3993 4/3 Techno Park Drive [email protected] Williamstown, Vic 3016

Please provide the following to support your claim:

1. Photos of the installed unit, and all safety and isolation valves. 2. The information requested in the above table.

Please note that additional information may be requested to confirm the nature of the fault. There may be freight charges payable.

Main Tank 5 years from date of sale Electrical Components 1 year from date of sale

Duplex Stainless Steel Solar Hot Water Tank Installation ...€¦ · Duplex Stainless Steel Hot...

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