Dux ReadyHot series Installation Manual

Page 1

This appliance shall be installed in accordance with:

• Manufacturer’s Installation Instructions

• Current AS/NZS 3000, AS/NZS 3500 & AS/NZS 5601

• Local Regulations and Municipal Building Codes including local OH&S requirements This appliance must be installed, maintained and removed by an Authorised Person. For continued safety of this appliance it must be installed operated and maintained

in accordance with the manufacturers instructions.

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DUX READYHOT (DEU-CUG1-AK) INSTALLATION MANUAL

Circulating Pump

Heating Loop Return Connection

Cold Water Inlet Connection

Cold Water Outlet Connection

PCB

Fig.1

Pump Bleed Valve

Cold Water Inlet Bleed Valve

Power Lead

Control Lead & Socket

You must install this appliance in accordance with these Instructions and all regulatory requirements which exist in your area. Applicable publications may include:

• AS/NZS 5601 - Gas Installations

• AS/NZS 3500 - National Plumbing and Drainage

• AS/NZS 3000 - Wiring Rules

• Building Codes of Australia

NOTICE TO VICTORIAN CONSUMERS

This appliance must be installed by a person licensed with the Plumbing Industry Commission.

Only a licensed person will have insurance protecting their workmanship.

So make sure you use a licensed person to install this appliance and ask for your Compliance Certificate.

For further information contact the Plumbing Industry Commission on 1800 015 129.

THE READYHOT SYSTEM MUST BE MOUNTED ON A VERTICAL WALL OR STRUCTURE. THE READYHOT SYSTEM CANNOT BE USED BY ITSELF OR WITH ANOTHER MANUFACTURERS WATER

HEATER OR WATER CONTROLLERS.

• The Dux Readyhot system is Certified and compatible only with the Dux Endurance water heaters.

• At least one Water Controller must be used in conjunction with the water heater and the Readyhot system. Alternatively, if Water Controllers cannot be used a manual activation switch is available from electrical wholesalers.

• The installation of the water heater and water controllers must be perfor med in a ccordance with the ' Operatio n / Installation manual' supplied with the water heater.

• The Readyhot system is designed for domestic installations. However, it may be suitable for certain non domestic installations. Contact Dux Manufacturing for more information.

READYHOT KIT CONTENTS (Fig.1)

The Dux Readyhot kit comprises an enclosure containing circulating pump, water connection s for cold water inlet, cold water outlet and heating loop return, control wiring and printed circuit board. It is fitted with an electr ic po wer cord with three pin plug suitable for connection to a 240 V 10 Amp GPO. It is also fitted with a control lead for connection to the Dux Endurance water heater.

A Switch Harness (U268-605) is also provided for connection to a Manual Activation Switch (if required).

The Dux Readyhot kit does not include:

• 10 AMP GPO

• Heating loop flow and return pipework

• Gas and water isolating valves

• Control valves (non return valve, pressure limiting valve, expansion relief valve)

• Plumbing Connections between the Readyhot enclosure and Dux Endurance water heater and Dux water Controllers

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PRINCIPLE OF OPERATION (Fig. 2)

H O T

C O L D

G A S

Cold Inlet Mains

Readyhot®

Module

Dux Endurance

Continuous

Flow Water Heater

Hot Water

Outlet

Hot Water

Outlet

Fig.2

Heating Loop Flow

Heating Loop Return

One or more

Controllers

Preheat Button

The "Readyhot" system heats the water in the pipework water connected between the water heater and the hot water outlets before any outlets are opened using the 'flow and return' pipework principle. This results in water savings and reduced waiting time for heated water delivery from the outlet when opened.

Traditional 'flow and return' systems usually keep the water in the pipework heated continuously. The Readyhot system however, only heats the water before the outlet is opened. This results in significant energy savings because water is not heated unnecessarily whilst retaining the benefits of traditional flow and return systems.

A schematic of the Readyhot system installed in conjunction with a Dux Endurance water heater and water controller as shown in Fig.2 below.

The Readyhot system works as follows:

1. Before hot water is required, the user activates the Readyhot system by pressing the 'preheat' button on the water controller or by pressing the Manual Activation Switch.

2. This activates the Readyhot system and the integral pump is switched on.

3. Water flows from the pump and passes through the water heater. This in turn activates the water heater burner and water in the flow and return heating loop begins to heat.

4. When the Readyhot control mo dule se nses that the water in the full length of the flow and return heating loop has been heated, the pump and water heater stop operating.

5. The user opens the desired hot water outlet. Preheated water will be delivered from the flow and return heating loop to the outlet.

LOCATION (Fig. 3)

• Location and clearance requirements for the Dux water heaters are detailed in the Installation Instructions supplied with it.

• The Readyhot module weighs 7.5 kg and the wall or structure on which it is to be mounted must be capable of supporting the combined weight of the Readyhot unit, water heater and any associated pipework.

• Both the water heater and Readyhot module must be in an accessible location. Sufficient clearance shall allow access to, and removal of, all serviceable components. Water heater and Readyhot modules must not be mounted higher than 3.5 metres from the ground or floor level unless the customer can arrange permanen t and safe access or can arrange another means of access, for example, by means of scissor or boom lifts.

• The Readyhot module is usually located below the Dux Endurance water heater. However, it can be mounted anywhere within a 1.0 metre distance from the water heater (length of communication cable is one metre).

• An 10 Amp, AC240V weatherproof external earthed power point shall be provided adjacent to the Readyhot module (the power cord is 1.5 metres long).

• Alternatively, the water heater and Readyhot module can share the same power point provided it is of the dual outlet type.

• Double adaptors and extension leads must not be used.

• The power point must be kept clear of pipework connections, relief valve discharge points and the water heater flue outlet.

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One or more

NOTE

Controllers

Dux

Water

Heater

Ensure location and clearances around the water heater conform with the installation instructions supplied with the appliance

Hot Water

Branch Line

Hot Water

Branch Line

Power Lead

1.5 m

Power Lead

1.5 m

Readyhot®

Module

GAS

67 5 4

Hot Water

Branch Line Furthest from Water Heater

LEGEND TO FIG. 3

1. Water heater cold water inlet connection R¾” (20mm).

2. Readyhot module cold water outlet connection R¾” (20mm).

3. Copper tube R¾” (20mm), length approximately 300mm (maximum length 1000mm).

4. Isolating valve.

5. Non Return valve.

6. Pressure limiting valve, 500 kPa rating. OTHER RATINGS ARE UNSUITABLE!

7. Expansion control valve, 700 kPa rating. OTHER RATINGS ARE UNSUITABLE! Ensure the drain line is installed in accordance with the requirements of AS/NZS 3500.

8. Readyhot module cold water inlet connection R ¾” (20mm).

9. Readyhot module heating return loo p inlet conn ection R½” (15mm).

10.Insulated heating loop 'Flow' pipework R¾” (20mm).

11.Insulated heating loop 'Return' pipework R¾” (20mm).

Cold Inlet

Mains

Fig.3

Total length of items 10 & 11 not to exceed 60 metres.

12.Pump bleed valve.

13.Cold water inlet bleed valve.

14.Readyhot water heater communication cable.

SERVICE CONNECTION POINTS

Positions and sizes of the connection points to the water heater and pipework are shown in Fig.3 and the Dimensional drawings.

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VALVES (Fig. 3)

WARNING

• Approved isolation and non return valves must be fitted to the cold water inlet.

• A combination isolating and non return valve may be used. Approved pressure limiting and expansion control valves must also be fitted. A combination pressure limiting and expansion control valve may be used. The pressure limiting valve must be rated at 500 kPa.

• The Expansion Control valve must be rated at 700 kPa. OTHER RATING COMBINATIONS ARE NOT

SUITABLE!

• Valves must not be connected directly to the Readyhot module or Dux Endurance water heater.

• It may be necessary to fit a temperature limiting device for delivery to areas used primarily for the purposes of personal hygiene. Refer to the ‘Heated Water Delivery Temperature’ section of this document.

PIPEWORK (Fig. 3)

• All hot water pipework should be insulated to optimise performance and minimise energy wastage. This may also be required by local regulations.

• The flow section of the pipework should be 20mm (¾") type B copper or equivalent. The return section of the pipework should be 20mm (¾") type B copper or equivalent. Total combined length of the flow and return pipe should not exceed 60 meters.

• The branch lines from the flow and return pipework to the hot water outlets should be sized in accordance with AS/NZS 3500.

MOUNTING THE READYHOT MODULE (Fig. 3)

The Readyhot module is usually located below the Dux Endurance water heater. However, it can be mounted anywhere within a 1.5 metre distance from the water heater. These instructions assume it is located below the water heater.

Do not remove the front cover of the Readyhot or the water heater unless the power supply is isolated. It is not necessary to remove the front cover of either appliances for the purposes of mounting the Readyhot module.

1. Draw a line vertically down from the cold water inlet connection of the Dux Endurance water heater.

2. Mount the Readyhot module so the top edge of the enclosure is approximately 300 mm below the Dux Endurance water heater with the water outlet connection of the Readyhot module in line with the water inlet connection of the Dux Endurance water heater as shown in (Fig. 3).

3. Fasten the Readyhot module to the wall or supp orting st ructur e. The top bracket has a keyhole slot so that the Readyhot module can be positioned by hanging it on one screw, then the other screws can be secured.

4. Connect a piece of 20mm (¾") type B copper or equivalent between the outlet of the Readyhot module and the cold water inlet of the Dux Endurance water heater.

5. Connect the isolating, non return, pressure limiting a nd expansion contro l valves and an adequa tely size d cold water supply pipe to the cold water inlet of the Readyhot module.

6. Plan the route of the 'flow and return' pipework to ensure the shortest distance between the pipework and the hot water outlets.

7. Connect the 'flow and return' pipework between the hot water outlet of the Dux Endurance water heater and the heating loop return connection on the Readyhot module. Insulate pipework. The 'return' section of the pipework should be connected after the branch line furthest away from the water heater.

8. Install branch lines from the pipework to hot water outlets.

Install temperature limiting device in accordance with the ‘Heated Water Delivery Temperature’ section of this document.

COMMUNICATION CABLE

• Electronic signals are communicated between the Readyhot module and the Dux Endurance water heater via the communications cable already connected to the Readyhot module.

• The communications cable is connected to the remote control connection terminals on the Dux Endurance water heater in the same way as cables from the remote controller(s). Refer to the ‘WATER CONTROLLERS’ section of the ‘Operation / Installation Manual’ supplied with the Dux Endurance water heater for details.

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MANUAL ACTIVATION SWITCH

NOTE

50º C

appliance

KITCHEN

Water

Controller(s)

(at least one

DMC-91Q-2A)

LAUNDRY

BATHROOM

ENSUITE

H O T

C O L D

G A S

Heating Loop Flow

Heating Loop Return

Cold Inlet

Mains

Readyhot®

Module

Fig.4. - 50°C Appliance

Minimum length of pipe from hot outlet

to nearest hot water tap 2 metres.

TLD

KITCHEN

Water

Controller(s)

(at least one

DMC-91Q-2A)

LAUNDRY

BATHROOM

ENSUITE

H O T

C O L D

G A S

Heating Loop Flow

Heating Loop Return

Cold Inlet

Mains

Readyhot®

Module

Fig.5. - Not a 50°C Appliance.

Note: TLD = Temperature Limiting Device

• To obtain the full benefits of the water heater and Readyhot system, water controllers should be used. Howe ver it is possible to use a manual activation switch to activate the Readyhot system if water controllers are not fitted.

Parts required:

• Two core sheathed (do uble insulated) flex with minimum cross sectional area of 0.5 mm

• Switch Harness (U268-605) this comes supplied with the Readyhot system.

• One or more manual activation switch(es). Suggested part is Clipsal 30PBL or equivalent.

Procedure:

• Install the manual activation switch(es) in the desired location in accordance with manufacturer instruction s. Run the cable between the manual activation switches and the Readyhot system.

If more than one manual activation switch is used then the cables will need to be connected in parallel before entering the Readyhot syst em. Only one cable can be connected to t he terminals of the Readyhot system.

• Run the cable into the Readyhot enclosure using the same entry point as the communication cable fitted between the Readyhot and the Dux Endurance Water heater.

• The switch harness is connection be tween the cable from the manual activation switch(es) and the Printed Circuit Board (PCB) of the Readyhot. Connect the two wires from the manual activation switch ca ble to the Blue and Black wires on the switch harness (polarity does not apply). If an LED indicator is used, connect the two wires from the LED indicator to the Red and Black wires on the switch harness. Note: that the Orange wire on

the switch harness is not used.

• Plug the switch harness into the PCB as shown in the Circuit Diagram on page 8.

WATER CONTROLLERS

• At least one controller must be fitted to enable activation of the Read yhot system. Up to three or four contro llers can be fitted depending on water heater model. Refer to the 'WATER CONTROLLERS' section of the 'Installation Instructions' supplied with the Dux Endurance water heater and the Instruction sheet supplied with the Dux water controller.

• Other types of Dux water controllers can be fitted but will not enable activation of the Readyhot system.

HEATED WATER DELIVERY TEMPERATURE

The maximum water temperature delivered at the hot water outlets is deter mined by the pre -set limit progra mmed into the water heater. Local regulations and/or the requirements of AS/NZS 3500 must be considered regarding the temperature limitations of hot water supplied to areas used pr imarily for pe rson al hyg ien e. The tem per atur e of water to these areas may be limited to 50°C or less. If you are unsure about local regulations, contact your regulating authority or Dux Manufacturing.

If the water heater is marked to state that it delivers water not exceeding 50°C, local regulations may permit installation without a Temperature Limiting Device shown in Fig. 4

If the appliance is NOT marked to state that it delivers water not exceeding 50°C, or your local regulations require installation with a Temperatur e Lim iting D evice, then the installation should be in accordance with Fig. 5.

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TESTING AND COMMISSIONING

CAUTION

NOTE

1. Ensure the power supply to the Readyhot unit is switched ‘off’.

2. Carry out steps 1-12 of the ‘Testing ' in the Commissioning section from the Operation / Installation manual supplied with the water heater.

3. Inspect and clean the strainer located on the cold water inlet connection of the Readyhot module. This procedure may need to be repeated to ensure the strainer remains clear, especially on new installations.

4. Turn ‘off’ the power supply to both the water heater and Readyhot units.

5. Open all available hot water taps, including the shower, again until water from all outlets is cold. Then close the hot water taps.

Ensure building occupants do not have access to hot water outlets during this procedure.

6. Open the Readyhot module Pump and Cold Water inlet bleed valves items & of Fig. 3 (actual position of 'bleed valves' is shown on dimensional drawing) until all air pockets are released and a steady stream of water is discharged.

7. Activate the power supply to both the water heater and Readyhot units.

8. If water controllers are fitted: Press the ‘on/off’ button on the water control panel. The ‘on’ indicator next to the transfer button will glow when the control panel has been switched ‘on’. Then press the ‘preheat’ button on the control panel. The ‘preheat’ indicator next to the preheat button will glow indicating that the preheat system has been activated. Then adjust the temperature to the hottest setting by pressing the ‘hotter’ button until the temperature displayed on the control panel cannot be increased any further .

If a manual activation switch is fitted: Press the switch once.

With the Readyhot unit now activated via the water cont roller or man ual activation switch, the pump should start running immediately afterwards which is indicated by the left LED on the Readyhot PCB glowing green continuously. Check that this is the case. If the left LED on the Readyhot PCB does not glow green the pump has not started. In this case there is probab ly an incor rect or missing wir ing connection between water controllers or manual activation switch and the water heater or Readyhot unit. Check all wiring and connections between these items.

If the pump activates as required, shortly afterwards the water heater should turn on also. Wait two minutes. This will allow the water in the pipework to be warmed. If the water heater does not turn on re check electrical connections and installation.

9. Open the heated water outlet furthest away from the water heater. The water should become war m in a matter of seconds.

The waiting time for heated water delivery will vary depending on the size and layout of the branch line.

10. Inspect and clean the strainer located on the heating return loop inlet connection of the Readyhot module. This procedure may need to be repeated to ensure the strainer remains clear, especially on new installations.

11.Confirm the temperature delivered at the outlet with a suitable thermometer or digital temperature indicator. It should not exceed the temperature displayed on the water controller or the pre-set limit programmed into the printed circuit boards of either the Readyhot module or water heater.

12.After testing is completed, explain to the householder the functions and operation of the water heater, Water controller(s) and the Readyhot module. Explain to the househ older that so me temperatur e fluctuations may be experienced some of the time as a result of installing Readyhot.

13.Ensure the customer record section of the 'Operation / Installation manual' is filled in and that the booklet is handed to the customer.

14.The preheat function is cancelled 5 minutes after activation and the ‘preheat’ indicator will go out. This is to conserve energy. To reactivate, simply repeat steps 7-10 above

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CIRCUIT DIAGRAM

Default position of all dipswitches is 'OFF' (to the left)

MANUAL ACTIVATION SWITCH

Location for Switch Harness (manual activation switch)

TRANSFORMER

BLEED

COLDWATERINLET

BLEEDVALVE

Head Office

Lackey Road Moss Vale NSW 2577 AUSTRALIA Tel: 1300 365 115 (Australia) Tel: 0800 729 389 (New Zealand)

Manufacturing Limited

ABN 19 077 879 844

DUX

Internet: www.dux.com.au

For advice, repairs and service, call: 1300 365 115 (Australia) 0800 729 389 (New Zealand)

DIMENSIONS DIAGRAM

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