Kelvinator KCT45036A, KCT34036A, KCT27036A, KCT27000A, KKSSUA Installation Manual
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Solar Hot Water Systems
Installation Manual
2 contents Kelvinator solar hot water systems
Congratulations and thank you for choosing our solar hot
water system. Before you install the hot water system, we
recommend that you read through the entire installation
manual, which provides instructions on the safe installation
of the hot water system.
To avoid the risks that are always present when you install
a hot water system, it is important that you read the safety
instructions carefully to ensure that the hot water system is
installed correctly and safely.
After unpacking the hot water system please check that it is
not damaged. If in doubt, do not install the hot water system
but contact your local Electrolux Customer Care Centre.
Meanings of symbols used in this manual are shown below:
warning
This symbol indicates information concerning your
personal safety
caution
This symbol indicates information on how to avoid
damaging the hot water system
environmental tips
This symbol indicates tips and information about
economical and ecological use of the hot water system
environmental tips
Information on disposal for users
• Most of the packing materials are recyclable.
Please dispose of those materials through your local
recycling depot or by placing them in appropriate
collection containers.
• If you wish to discard this hot water system or an old one
that has been replaced, please contact your local
authorities for the correct method of disposal.
warning
• Contact an authorised installer for installation of this
hot water system.
• Contact an authorised service technician for repair
or maintenance of this hot water system.
• If a power cord is to be replaced, replacement work
must be performed by authorised personnel only.
• Installation work must be performed in accordance
with the national standards by authorised personnel
only. Wrong connection can cause over heating or fire.
• This hot water system should be installed in accordance
with AS/NZS 3000 and your local electrical wiring rules.
Important safety instructions ........................................... 3
Specifications .................................................................... 4
General installation ........................................................... 6
General installation of solar collectors ............................. 8
Components list ................................................................ 9
Roof installation – flat panel collectors........................... 10
Installation diagram –
electric boosted flat panel collectors ............................ 12
Installation diagram –
gas boosted flat panel collectors ................................... 13
Roof installation – evacuated tube collectors ................. 14
Installation diagram –
electric boosted evacuated tube collectors .................. 17
Installation diagram –
gas boosted evacuated tube collectors ......................... 18
Installation – storage tank and solar controller .............. 19
Electrical installation ....................................................... 23
Commissioning ................................................................ 25
Troubleshooting .............................................................. 28
Notes ............................................................................... 29
Warranty .......................................................................... 31
Conditions of use
This appliance is intended to be used in household and
similar applications such as:
• staff kitchen areas in shops, ofces and other working
environments.
• farm houses.
• by clients in hotels, motels and other residential type
environments.
• bed and breakfast type environments
Congratulations Contents
This Installation Manual has been prepared for qualied
installers of the hot water system. Please keep in a safe place for
future reference. Installation must be performed by a qualied
installer (for example, a licensed plumber or gas tter).
warning
For continued safety of this appliance it must be installed,
operated and maintained in accordance with the
manufacturers instructions.
For the installer
The installation must be done in accordance with the
information supplied in this Installation Manual.
For gas boosted installations, please refer to Warnings and
Cautions in the Gas Continuous Flow installation manual
supplied with the unit. All other relevant National, State or
Local regulations must also be conformed with and these
include (but are not limited to):
• Australian Standard AS3500.1 – Water Supply
• Australian Standard AS3500.4 – Hot Water Supply
• Australian Standard AS3000 – Electrical Installation
• Australian Gas Association Code AS5601 –
Gas Appliance Installation
• Local Water, Gas & Electrical Authority Regulations
Municipal Building Codes
Important safety instructions
Ensure the following safety instructions are read and
understood before commencing installation.
warning
If you do not follow these instructions exactly, a re or
explosion may result causing property damage, personal
injury or loss of life.
• This appliance is not intended for use by persons (including
children) with reduced physical, sensor y or mental
capabilities or lack of experience and knowledge, unless
they have been given supervision or instruction concerning
use of the appliance by a person responsible for their safety.
• Children should be supervised to ensure that they do not
play with the appliance.
• If the solar hot water system is gas boosted and you smell
gas or smoke coming from the system:
– Do not try to light the hot water system.
– Do not touch any electrical switch
– Do not use any phone in your building
– Isolate the power at the main switchboard
– Check and isolate the main gas valve
– Immediately call your gas supplier from a neighbour's
phone. Follow the gas supplier's instructions
– If you cannot reach the gas supplier, call the
re department
• The piping system of the solar circuit is to be electrically
connected in the lower part of the building according to
local standards. The connection of the solar system to
an existing or to be created lightning protection system
or potential equalization may be implemented only by
authorised specialists.
• If the solar hot water system is gas boosted, ensure there
is proper ventilation to avoid oxygen deciency.
• Ensure that any water drained during installation does
not cause damage to the building or property.
• Be sure that the hot water system is well earthed in
order to avoid electric shock.
• The solar hot and solar cold pipes between the hot water
storage tank and solar collectors MUST BE copper
and fully insulated with closed cell polymer insulation
or similar (minimum thickness of 20mm). Thicker insulation
may be required to comply with the requirements of
AS/NZS 3500.4. Plastic pipe MUST NOT be used, as it
will not withstand the temperature and pressure of the
water generated by the solar collectors under stagnation
conditions. The solar collectors can generate extremely
high water temperatures of up to 272°C. Plastic pipe can
not withstand these temperatures. Failure of plastic pipes
can lead to the release of high temperature water
and cause severe water damage and flooding.
• The insulation must be weatherproof and UV resistant if
exposed to sunlight.
• All compression ttings must use brass or copper olives.
• The collectors must be lled with water before the
protective cover is removed to prevent damage to the
hot water system and harm to the installer.
• Ensure that the roof has the load bearing capacity
to withstand the weight of installation, including the
installers and the full collectors.
• Installation must be carried out in accordance with
local Occupational Health and Safety laws.
• Ensure that appropriate safety measures are taken to
prevent objects falling from the roof during installation.
• The standard roof mounting kit for the collectors supplied
with this unit is NOT suitable for cyclone prone areas.
If you are installing in a cyclone prone area, please
consult your local building authority for advice regarding
appropriate mounting requirements.
• The minimum inlet water pressure must be 150kPa.
• If the hot water system supply pressure exceeds 600kPa, a
pressure limiting valve must be tted to limit the pressure
to 600kPa. A cold water 700kPa pressure relief valve may
also need to be installed in the water inlet to the storage
tank according to local regulations.
• A 99°C/850kPa temperature and pressure relief valve
(supplied) must be installed near the top of the storage tank.
• Ensure that the discharge pipes of the pressure relief
valves are left open to the atmosphere at all times.
• The pressure-relief devices are to be operated regularly to
remove lime deposits and to verify that they are not blocked.
• If a supply cord is damaged, it must be replaced by the
manufac turer, its service agent or qualied persons in
order to avoid a hazard.
• The operation of the thermal cut-out on the hot water
storage tank indicates a possibly dangerous situation
(electric boosted installations only). Do not reset the
thermal cut-out until the hot water system has been
serviced by a qualied person.
• Solar hot water systems with at panel type collectors
are not designed to be installed in heavy frost or high
altitude areas 400m above sea level.
• This hot water system delivers water above 50°C
and a tempering valve must be installed to limit the
temperature of hot water to sanitary xtures primarily
used for the purpose of personal hygiene as per the
AS 3500 requirements.
• The temperature settings for the hot water system are
factory pre-set to ensure optimum energy efciency
whilst providing Legionella bacteria protection. The
temperature settings are therefore not adjustable by
the customer or installer.
Important Important safety instructions
Kelvinator solar hot water systems impor tant safety instruc tions 3
4 specications Kelvinator solar hot water systems
Specifications
Collector Flat panel (KCPF20A)
Collector dimensions per panel (mm) length 2002 x width 1025 x depth 80
Gross surface area 2.05m
2
Aperture surface 1.81m
2
Net weight 34.5kg
Operating positive pressure. max. 1000kPa
Stagnation maximum temperature 199 °C
Header pipe outer diameter 22mm
Collector frame material Aluminium
Absorber material 0.12mm copper n with TiNOx selective coating
Glazing 4mm low iron tempered patterned glass
Insulation material 40mm glass wool
Collector Evacuated tube (KCPE12A)
Number of evacuated tubes per collector panel 12
Collector dimensions (mm) length 1390 x width 1640 x depth 100
Gross surface area 2.28m
2
Aperture surface 2.0m
2
Collector capacity 1.6L
Net weight 37kg
Operating positive pressure. max. 1000kPa
Stagnation maximum temperature 272°C
Collector header pipe outer diameter 15.0 mm
Collector piping connections 1/2"
Collector frame material Anodised aluminium
Material selective absorber layer Aluminium nitrite
Kelvinator solar hot water systems specications 5
Specifications
Solar controller (KKSSUA)
Dimensions (mm) length 365mm x width 205mm x depth 100mm
Protection rating IPX4
Net weight 2.3kg
Operating positive pressure. max. 850kPa
Maximum water temperature 95°C
Circulation pump type UP15 – 14B
Circulation pump power 25W
Rated voltage of circulation pump AC 220-240V
Frequency 50Hz
Model number
KCT27000A
KCT27036A
KCT34000A
KCT34 036A
KC T4 5 036A
Diameter (mm) 648 648 730
Height (mm) 139 0 1690 1715
Tank capacity (L) 270 340 450
Net Weight (kg) 95 110 140
Tank wall thickness (mm) 2.5 3 3
Element rating (if installed) 3.6kW 3.6kW 3.6kW
PTR valve pressure limit (kPa) 850 850 850
PTR valve temperature limit (°C) 99 99 99
PTR max energy release rate (kW) 10 10 10
6 gener al installation Kelvinator solar hot water systems
General installation
The collec tor rails, unions, straps, clamps, bolts, nuts and
washers required for the installation are included in the
collector kit(s). Suitable screws will be required to x the
collectors to the roof.
The collec tors and mounting kit are not designed to be
installed in cyclone prone areas. If installing in these areas or
other areas where a high level of windy and stormy conditions
exist, the collectors will need to be xed accordingly. Consult
the local authorities for advice regarding any additional
mounting instructions.
Use an appropriate amount of thread sealing tape or an
approved thread sealant in between all ttings.
Solar collector location
Consideration must be given to the position of the solar
collectors in relation to the hot water storage tank. The
maximum length of the solar hot and solar cold pipes must
be 10 metres one way (20 metres total) or less to full energy
efciency rating requirements.
• The solar collectors should be installed in a shade
free position.
• The solar collectors are to be installed facing toward
the equator (i.e. North). Where this orientation is not
practical, a system facing up to 45° from the equator will
have its efciency reduced by approximately 4%.
• Inclination of the solar collectors should be approximately
equal to 90% of the local latitude angle. Solar collectors
may be installed at the roof angle for simplicity of
installation and appearance, but must never be less than
10°. If the roof angle varies by 15° from the correct angle,
efciency will be reduced by 10%.
Latitudes of some Australian cities
Adelaide 35°S Port Hedland 20°S
Mildura 34°S Canberra 35°S
Brisbane 27°S Broken Hill 31°S
Darwin 12°S Geraldton 28°S
Rockhampton 24°S Cairns 17°S
Alice Springs 24°S Hobart 42°S
Melbourne 38°S Sydney 34°S
Townsville 19°S Perth 32°S
If the roof is flat or has a pitch less than or greater than the
recommended angle, a pitch stand may need to be installed
to allow the collectors to be mounted correctly. This stand
may need to be purchased from a local store or made
especially for the installation.
warning
PLUMBER BE AWARE!
• Water temperatures above 50°C can cause severe burns.
• All plumbing work must be carried out by a qualied
person and in accordance with the National Plumbing
Standard AS/NZS 3500.4 and local authority
requirements.
• Ensure the roof structure is suitable to carry the full
weight of the solar collectors. Each flat panel solar
collector and its ttings weigh approximately 45kg
when full of water. Each evacuated tube solar collector
and its ttings weigh approximately 47kg when full of
water. If in doubt the roof structure should be suitably
strengthened. Consult a structural engineer.
• Do not remove the solar collector packaging
completely, prior to the installation. Remove only
sufcient packaging material to enable the installation.
Upon completion of the installation it is necessary to
leave the solar collector packaging covering the glass
on the solar collector. The packaging should not be
removed until the solar hot water system has been
commissioned and is ready for use.
• Plastic pipe MUST NOT be used, as it will not withstand
the temperature and pressure of the water generated
by the solar collectors under stagnation conditions.
The solar collectors can generate extremely high
water temperatures up to 272°C. Plastic pipe cannot
withstand these temperatures and MUST NOT be used.
Failure of plastic pipe can lead to the release of high
temperature water and cause severe water damage
and flooding.
• There must be a continuous fall in the pipe work
between the solar collectors and the solar storage tank.
The highest point of the solar cold pipe and solar hot
pipe must be where they connect to the solar collectors,
to avoid the possibility of air locks occurring in the
system.
• Safety harnesses must be used when working at heights
and on the roof. If the roof is wet or dewy it will be very
slippery and installation work should not be carried out
until it has become dry.
The solar hot and solar cold pipes between the storage
tank and solar collectors MUST BE copper only and fully
insulated with closed cell polymer insulation or similar
(minimum thickness 20mm). Thicker insulation may be
required to comply with the requirements of AS/NZS 3500.4.
The insulation must be weatherproof and UV resistant. All
compression ttings must use brass or copper olives.
Note: Failure to observe this requirement may void the
warranty for freeze damage.
The insulation is essential to assist in providing freeze
protection. When installed on a metal roof, insulation will
ensure corrosion protection against water runoff over the
copper pipe, assist in avoiding accidental contact with the
pipe work and also reduce pipe heat loss.
Kelvinator solar hot water systems general installation 7
General installation
Pipe lengths
The solar hot and solar cold pipes between the hot water
storage tank and the solar collectors must:
• have a continuous fall from the solar collectors to the hot
water storage tank of 5 (1 in 10 grade).
• not exceed the maximum recommended length of 10
meters (20 meters total).
Notes:
• It is important not to cross connect the solar cold and
solar hot pipes to the incorrect connec tions.
• In the at panel solar hot water system, the solar cold
pipes connect to the bottom of the solar collectors
and the solar hot pipe connects to the top of the solar
collectors diagonally opposite to the solar cold pipe
connection.
• In the evacuated tube hot water system, both connections
are located at the top of the collector.
• The collector sensor must be located in the same end as
the collector array outlet connection on both flat panel
and evacuated tube collectors.
It is essential for these requirements to be followed for the
system to operate correc tly and efciently. Solar pipe work that
is undersized, does not have the correct fall or is too long can
result in the solar hot water system not operating effectively.
Maximum height to collectors
The solar collectors must be the highest point of the system.
The maximum height of the solar installation, from the
base of the hot water storage tank to the top of the solar
collectors, is 9m. The pump supplied will not circulate closed
circuit uid through heights greater than 9m and solar gain
will not be achieved.
For heights greater than 9m, an auxiliary pump must be
installed above and within 1 m of the hot water storage tank.
Water quality
Water quality can vary in different locations and affect the
performance and safe operation of the hot water system.
If the water supply is not within the acceptable limits as
indicated below, the hot water system should not be
installed, and will not be covered by warranty from the
manufac turer. A suitable solution is to implement a water
pre-treatment process to bring the water quality to within
acceptable limits to support the installation.
The saturation index (SI) is a measure of the corrosive or
scaling properties of the water supply. Corrosive water (SI<-
1.0) can corrode copper components. In these conditions
warranty will not apply. Scaling water (SI>0.5) can cause
build up of CaCO3 (Calcium carbonate) which can impact
to the correct operation of moving parts within the system,
including the temperature and pressure relief valve. In these
conditions warranty will not apply.
Total Dissolved Solids (TDS) and water hardness can also
impact the life of the hot water system, and warranty does
not apply outside the following limits:
• TDS exceeding 600 p.p.m
• Electrical conductivity exceeding 850us/cm
• Total hardness exceeding 200 p.p.m
• Chloride exceeding 250 p.p.m
• Magnesium exceeding 10 p.p.m
• Sodium exceeding 150 p.p.m
• Acidity/Alkalinity must also be within the limits of
pH 6.5 - 8.5
Protecting the solar collectors
The solar collectors are designed to withstand impact and
be hail resistant, so it is not necessar y to install any special
hail guards to protect these collectors. However, if it is
possible that the collectors could be damaged due to falling
branches, vandalism etc. it is recommended that guards are
made and installed to prevent damage to the collectors.
Note: The installation of protective guards will impact on the
performance of the collectors.
Frost protection and damage due to freezing
The solar hot water system has been approved to level 2 frost
protection and can therefore withstand frosty conditions.
However, it is not recommended to install at panel type
collectors in areas 400m above sea level. It is recommended
that evacuated tube type collectors are installed in high altitude
and frost prone areas. The warranty for frost damage will not
apply if the hot water system is damaged due to freezing when
using flat panel type collectors in high altitude areas. The
warranty for frost damage will also not apply to solar hot water
systems with either type of collectors installed if the pipe work
between the collectors and the hot water storage tank has
insufcient piping insulation.
8 gener al installation of solar collectors Kelvinator solar hot water systems
10 -15 mm
from horizontal
inlet
20-30mm
from horizontal
30-45mm
from horizontal
horizontal
collector rail
outlet
Note: The solar collectors (both flat panel and evacuated
tube) must be installed at an angle from the horizontal.
This is to ensure that any air in the system will travel to
the air vent valve located on the outlet connection of the
collectors.
The distance between the end of the collector rail at the
outlet side of the solar collectors and the horizontal must be:
10 - 15 mm (for one solar collector)
20 - 30 mm (for two solar collectors)
30 - 45 mm (for three solar collectors)
If the roof material is uneven where the collectors are to be
installed, then it may be necessary to add an additional 10
mm to the above distances for each collector.
Space requirements
A
B
C
C
D
Space and load bearing requirements for evacuated
tube collectors
No. of
collectors
Dimension
A (mm)
Dimension
B (mm)
Weight when
full (approx.)
1 14 0 0 164 0 47kg
2 2800 1640 94kg
3 4200 1640 141kg
Dimensions C and D
• when determining the location for the collector ensure
that there is adequate space available for the water
connections and the xing of the mounting kit.
A
B
C
C
D
Space and load bearing requirements for flat
panel collectors
No. of
collectors
Dimension
A (mm)
Dimension
B (mm)
Weight when
full (approx.)
1 1025 2050 45kg
2 2050 2050 90kg
3 3075 2050 135kg
General installation of solar collectors
components list Kelvinator solar hot water systems 9
Components list
Supplied in kit: KKSSF2MA –
flat panel double roof mounting kit
Item No. Qty. Description
1 1 rail bottom for 2x flat panel collector
2 2 strap rail bottom
3 4 clamp flat panel collector
4 4 bolt, nut and washer assembly
5 2 strap top flat panel collector
6 2 self tapping screw
7 2 connector flat panel collector
Supplied in kit: KKSSF1MA –
flat panel single roof mounting kit
Item No. Qty. Description
8 1 rail bottom for 1x at panel collector
9 1 rail joiner
2 2 strap rail bottom
3 2 clamp flat panel collector
4 2 bolt, nut and washer assembly
5 1 strap top flat panel collector
6 1 self tapping screw
7 2 connector flat panel collector
Supplied in kit: KKSSE1MA –
evacuated tube single roof mounting kit
Item No. Qty. Description
10 1 rail bottom for 1x evacuated tube
collector
2 2 strap rail bottom
11 2 clamp evacuated tube collector
4 2 bolt, nut and washer assembly
12 1 strap top left evacuated tube collector
13 1 strap top right evacuated tube collector
14 2 bracket top evacuated tube collector
6 2 self tapping screw
9 1 rail joiner
Supplied in kit: KCPF20A –
flat panel solar collector
Item No. Qty. Description
15 1 flat panel collector
Supplied in kit: KCPE12A –
evacuated tube solar collector
Item No. Qty. Description
16 1 evacuated tube collector
17 1 connector evacuated tube collector
18 2 connector sleeve support evacuated
tube collector
19 2 connector to 1/2" male for evacuated
tube collector
Supplied in kit: KKSSURA –
roof fittings kit
Item No. Qty. Description
20 2 connector to 1/2" male for at panel collector
21 2 stopper flat panel collec tor
22 2 union 1/2" female to copper
23 2 t-piece 1/2" female
24 2 nipple 1/2" to 1/2" male
25 1 bush 1/2" male to 3/8" female
26 1 air vent valve 3/8" male
27 1 sensor pocket 1/2" male
28 1 sensor collector with wire 15m
Supplied in kit: KKSSUGA –
ground fittings kit
Item No. Qty. Description
29 1 solar controller
30 4 screw xing solar controller
31 2 bush 3/4" male to 1/2" female
24 5 nipple 1/2" to 1/2" male
23 1 t-piece 1/2" Female
27 1 sensor pocket 1/2" male
32 1 exible tube 1/2" female to 1/2" female
33 1 check valve 1/2" male to 1/2" female
22 2 union 1/2" female to copper
34 1 tempering valve 50°C
Supplied with tank: KCT*****A –
tank and TP&R valve assembly
Item No. Qty. Description
35 1 temperature and pressure relief valve
1/2" male
31 1 bush 3/4" male to 1/2" female
36 1 of
KCT27036A -
270L tank with 3.6kW element
KCT34036A -
340L tank with 3.6kW element
KCT45036A -
450L tank with 3.6kW element
KCT27000A -
270L tank without element
KCT340 00A -
340L tank without element
Supplied with gas booster: KGC26S*A – gas booster
Item No. Qty. Description
37 4 screw gas booster xing
38 1 of
KGC26SNA -
26L/min solar gas booster - natural gas
KGC26SLA -
26L/min solar gas booster - LP gas
10 roof installation – at panel collectors Kelvinator solar hot water systems
Roof installation –
flat panel collectors
Fix the bottom straps using appropriate screws into the
roof struts or trusses making sure the bottom rail is inclining
towards the proposed outlet end of the collectors.
If installing on a tiled roof, place the tiles back into their
normal positions after xing the straps.
Preparing and xing the collectors
Unpack each collector and cut out the template on the back
of the cardboard packaging. Place the cut out template
on the front of each collector and x it with tape. This is
important as the collector connections will become very
hot once exposed to solar radiation and may cause a safety
hazard or prevent the installation of the pipe work to the
collectors. Carefully lift the collectors onto the roof and
place them in position, resting against the bottom rail of the
collector mounting kit already xed to the roof.
Before the collectors are xed to the roof and mounting kit, they
are to be connected together forming an array (two and three
collector installations only). Two compression union ttings are
used to join two collectors together (one for top and one for the
bottom) and are supplied in the mounting kit(s).
solar collectors
collector
manifold
pipes
compression
union
Slide the ttings onto one side of the collector manifold pipe
to be joined and then push both collec tors together. The
collector manifold pipes should be inserted as far as possible
into both sides of the compression union tting.
Using two spanners, tighten each nut on the compression
union tting one side at a time, with one spanner used to
brace the tting in the middle. Tighten both sides of the
compression union tting until the copper olives are rmly
sealed against both collector manifold pipes.
This standard roof mounting kit is not suitable for cyclone
prone regions. Refer to the warning in the Important Safety
Instructions section.
Unpack the collector mounting kit(s) and check that all
components are included (see mounting kit contents table).
If you are installing three collectors, join the two bottom rails
together using the rail joiner.
Slide the bottom straps onto the bottom rail so that they are
evenly spaced and place the bottom rail assembly on the roof
in the installation location decided. If installing on an iron roof,
line up the bottom straps to the existing roong screws that
are xing the iron roong membrane to the struts.
If installing on a tiled roof lift up the tiles and line up the
bottom straps with the roof struts or trusses.
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