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Kelvinator KCT27036A, Installation Manual, Page: 19 / 32

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Kelvinator KCT27036A Installation Manual Download Page 19

Installation – storage tank  

and solar controller

Prepare the solar controller by installing a 1/2" nipple and 
the flexible tube on the bottom connection of the solar 
controller.

solar controller  

connection

1/2" nipple

flexible tube

Place the solar controller in position above the “flow” 
connection on the storage tank and line up the flexible 
tube with the nipple on the “flow” connection. Fix the solar 
controller to the storage tank using the screws provided. Do 
not use any screws with a length longer than 13mm and if pre 
drilling the holes is required, be very careful not to penetrate 
too far into the storage tank. Use a spanner to connect the 
flexible tubing to the nipple of the “flow” connection of the 
storage tank.
Install the check valve, nipple and 1/2” copper union to the 
top of the solar controller with an appropriate thread sealant. 

1/2" female to  

copper union

1/2" nipple

check valve

solar controller  

connection

Preparing the storage tank location

The storage tank shall be installed on a level surface, 
preferably on a concrete platform so that it is elevated 
slightly from the ground and has a uniform mounting surface 
to spread its load. The storage tank shall be checked with a 
spirit level to ensure it is level for a number of reasons:  
•  to ensure the correct positioning of the anode inside  

the tank 

•  to ensure that any hot water is drawn from the very top  

of the tank 

•  to assist air being dispelled during commissioning
Consideration should be given to any potential damage due 
to water drainage or leakage. If leakage of water from the 
hot water system has potential to cause property damage, a 
properly drained safe tray is to be installed under the storage 
tank. The relief valve drainage pipes will be required to be 
plumbed to an outside drainage point.

Solar controller mounting and connections

Open the fittings kit KKSSUGA and check that all 
components have been provided (refer to the components 
list). It is recommended that the storage tank “flow” 
connections be installed first in order to determine the exact 
location to mount the solar controller.
Install the tee piece, sensor pocket, 1/2" nipples and 3/4" to 
1/2" reducing bush on the “flow” connection of the storage 
tank using appropriate thread sealant

 (see diagram below). 

FLOW

storage tank 'flow' 

connection

sensor pocket

3/4" to 1/2"  

reducing bush

T-piece

1/2" nipple

Kelvinator solar hot water systems

  installation – storage tank and solar controller   19

Summary of Contents for KCT27036A

Page 1: ...Solar Hot Water Systems Installation Manual ...

Page 2: ...ed 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 wi...

Page 3: ...r 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 l...

Page 4: ... copper fin 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 28m2 Aperture surface 2 0m2 Collector capacity 1 6L Net weight 37kg Operating positive pressure max 1000kPa Stagn...

Page 5: ... pump type UP15 14B Circulation pump power 25W Rated voltage of circulation pump AC 220 240V Frequency 50Hz Model number KCT27000A KCT27036A KCT34000A KCT34036A KCT45036A Diameter mm 648 648 730 Height mm 1390 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...

Page 6: ... 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 fittings weigh approximately 45kg when full of water Each evacuated tube solar collector and its fittings weigh approximately 47kg when full of water If in doubt the roof structure should be sui...

Page 7: ...o 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 impac...

Page 8: ... 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 1400 1640 47kg 2 2800 1640 94kg 3 4...

Page 9: ...n 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 flat panel collector 21 2 stopper flat panel collector 22 2 union 1 2 female to copper 23 2 t piece 1 2 female 24 2 nipp...

Page 10: ...d one for the bottom and are supplied in the mounting kit s solarcollectors collector manifold pipes compression union Slide the fittings onto one side of the collector manifold pipe to be joined and then push both collectors together The collector manifold pipes should be inserted as far as possible into both sides of the compression union fitting Using two spanners tighten each nut on the compre...

Page 11: ...s Ensure the vent valve is installed so that its vent is pointing directly upwards perpendicular to the ground not the roof ventvalve 1 2 femaleto copperunion sensorpocket 1 2 maleto collectorunion 1 2 to3 8 reducingbush 1 2 nipple 1 2 femaleT piece Once all the collectors are joined together two or three collector installations only they should be correctly positioned so that they are evenly dist...

Page 12: ...gulations including AS3500 plumbing and drainage requirements and AS3000 electrical wiring standards Bottom rail connection viewed from above 10 15mm fromhorizontal bottomrail assembly 1 5m reliefvalve uncontrolled hotwateroutlet kitchen laundry tempered 50 C hotwateroutlet bathrooms tempering valve 20 30mm fromhorizontal 30 45mm fromhorizontal Connecting strap viewed from roof cavity Components s...

Page 13: ...ce with all local regulations including AS5601 gas installation requirements AS3500 plumbing and drainage requirements and AS3000 electrical wiring standards Bottom rail connection viewed from above 10 15mm fromhorizontal bottomrail assembly reliefvalve uncontrolled hotwateroutlet kitchen laundry tempered 50 C hotwater outlet bathrooms tempering valve 20 30mm fromhorizontal 30 45mm fromhorizontal ...

Page 14: ...nto the manifold pipes of each collector Slide the fittings onto one side of the manifold pipe to be joined and then push both collectors together The collector manifold pipes shall be inserted as far as possible into both sides of the compression union fitting solarcollectors coppersleeve support collector manifold pipes compression union Using two spanners tighten each nut on the compression uni...

Page 15: ... top brackets to the roof strut by either using an existing roofing screw or adding a new one Fix the top brackets to each side of the collector array with the supplied self tapping screws If installing on a tiled roof two twisted straps are to be fixed to the roof and each side of the collector array The twisted straps are to be fixed so that the twisted ends are flush with the sides of the colle...

Page 16: ...sealing the copper olive to the collector manifold pipes collector 1 2 male compression union Open the fittings kit KKSSURA and check that all components have been supplied see components list Since this kit is also used for flat panel type collectors there will be some pieces which will not be used On the collector array outlet install a tee piece 1 2 to 3 8 reducing bush vent valve 1 2 nipple an...

Page 17: ...Bottom rail connection viewed from above 10 15mm fromhorizontal bottomrail assembly 1 5m reliefvalve uncontrolled hotwater outlet kitchen laundry tempered 50 C hot wateroutlet bathrooms tempering valve 20 30mm fromhorizontal 30 45mm fromhorizontal Connecting strap viewed from roof cavity Components shown in grey are only used in 2 and 3 collector panel connections Secure with screws on top and bac...

Page 18: ...lumbing and drainage requirements and AS3000 electrical wiring standards Bottom rail connection viewed from above 10 15mm fromhorizontal bottomrail assembly reliefvalve uncontrolled hotwateroutlet kitchen laundry tempered 50 C hotwateroutlet bathrooms tempering valve 20 30mm fromhorizontal 30 45mm fromhorizontal Connecting strap viewed from roof cavity Components shown in grey are only used in 2 a...

Page 19: ...rm mounting surface to spread its load The storage tank shall be checked with a spirit level to ensure it is level for a number of reasons to ensure the correct positioning of the anode inside the tank to ensure that any hot water is drawn from the very top of the tank to assist air being dispelled during commissioning Consideration should be given to any potential damage due to water drainage or ...

Page 20: ...ot water system under local plumbing requirements If the hot water system is installed in a bad water quality area where regular flushing is required due to sediment build up a drain cock or valve is also to be installed on the inlet piping On the storage tank return connection install a 1 2 copper union 1 2 nipple and 3 4 to 1 2 reducing bush with appropriate thread sealant RETURN storagetankretu...

Page 21: ... e g bathroom or ensuite fixtures The water supplying these fixtures shall not exceed 50 C as required by AS 3500 4 heat trap uncontrolled hot water outlet kitchen laundry tempered hot water outlet 50 C bathrooms tempering valve Relief valve piping A temperature and pressure relief valve comes supplied with the storage tank and must be installed on the relief valve connection near the top of the t...

Page 22: ...e sensors should not be run alongside power supply cables as this may induce a false signal into the sensor cable Installing the collector array temperature sensor The collector sensor cable is provided in the kit KKSSURA and is 15m long It has a temperature sensor on one end that is required to be installed in the sensor pocket located on the outlet to the collector array and the connector at the...

Page 23: ...ing rules the local electrical authority regulations and any other applicable standards The pipe work storage tank and collectors are to be properly connected to the earthing system of the premises in accordance with AS NZS 3000 Means for disconnection must be incorporated in the fixed wiring in accordance with the wiring rules The insulation of the fixed wiring must be protected by insulating sle...

Page 24: ...of the storage tank be completed first before the cable is wired to the switchboard If you are replacing an existing electric hot water system and re using the existing cable ensure that the power supply to this cable is isolated or disconnected at the switchboard The 20mm conduit adapter is to be inserted into the 20mm cut out provided and the locking ring screwed down to hold the conduit firmly ...

Page 25: ...ling the hot water system with water and checking for leaks At this stage the power to the tank element and pump station should be isolated off Fully open the cold water isolation valve located on the inlet to the storage tank to allow the system to begin filling with water Activate the temperature and pressure relief valve on the storage tank in order to allow air to bleed out of the tank outlet ...

Page 26: ...k that the temperature sensors are installed correctly connected to the solar controller and that the cables have not been damaged If the red LED is emitting continuous flashes this indicates that water is not circulating through the collectors and the storage tank correctly and that the temperature difference between them has been greater than 40 C for ten minutes There may be air in the system t...

Page 27: ...se the isolation valve on the inlet piping Drain the water out of the system by activating the relief valve Remove the flow sensor from the circuit and re connect the collector array piping leaving the flow restrictor in place Open the isolation valve on the inlet piping and refill the system with water ensuring that all air is bled as per the instructions provided The solar hot water system is no...

Page 28: ...k with a thermometer if the water temperature in the bathroom is over 50 C if so the tempering valve may have an incorrect setting or be malfunctioning Please call a service technician Water is discharging from the relief valve drainage pipe It s normal for a small amount of water to discharge during heating to allow for hot water expansion However if the relief valve appears to be continually lea...

Page 29: ...Kelvinator solar hot water systems notes 29 Notes ...

Page 30: ...30 notes Kelvinator solar hot water systems Notes ...

Page 31: ...nsported at the owner s cost and risk while in transit to and from Electrolux or its ASC 6 Proof of purchase is required before you can make a claim under this warranty 7 You may not make a claim under this warranty unless the defect claimed is due to faulty or defective parts or workmanship Electrolux is not liable in the following situations which are not exhaustive a the Appliance is damaged by...

Page 32: ...her information about Kelvinator appliances please visit your retailer phone or email our Customer Care team or visit our website telephone 1300 363 640 fax 1800 350 067 email customercare electrolux com au web www kelvinator com au Kelvinator We are part of the Electrolux family Share more of our thinking at www electrolux com au ...

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