Home Owner Handbook Installation & Commissioning Manual: Energy Smart Water Solar PV Hot Water System ROSC20 Series
Home Owner Handbook Installation & Commissioning Manual: Energy Smart Water Solar PV Hot Water System ROSC20 Series
Home Owner Handbook Installation & Commissioning Manual: Energy Smart Water Solar PV Hot Water System ROSC20 Series
This manual is intended for licensed installers who have prior knowledge, experience, relevant
training and comply with relevant Plumber’s Code in the installation and maintenance of hot water
storage tanks.
Installation of solar array and electrical connection and commissioning to the ROSC20 PCE device is
to be carried out by licensed installers.
When commissioning is complete, please leave this document with the owner, drawing their
attention to the sections:” Maintenance and Periodic Inspection” and “Troubleshooting”.
Email: [email protected]
Website: www.esw.net.au
DANGER—SHOCK HAZARD: Do not set up this product or make any electrical or cabling connections,
such as the power cord, during a lightning storm.
DANGER—The electronic circuit contains capacitors that may keep voltage even if the unit is not
supplied with power. Authorised installer must wait a minimum of 10 minutes after isolating both DC
and AC supplies before opening the myPV SC20 enclosure or commencing work on this equipment.
CAUTION—This appliance is not intended for use by persons (including children) with reduced
physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been
given supervision of instruction concerning use of the appliance by a person responsible for their
safety.
CAUTION— Children should be supervised to ensure that they do not play with the appliance.
CAUTION— If the supply cord is damaged, it must be replaced by the manufacturer, its service agent
or similarly qualified person.
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CAUTION—To be installed and serviced only by an authorised person.
CAUTION — The storage tank should not be exposed to constant sun/weather conditions.
CAUTION — Avoid exposure and operation in extreme ambient heat (<0 °C) or (>50 °C) and protect
the my-PV SC20 housing from direct sunlight.
CAUTION – Do not touch the power plug on the water heater with wet hands
WARNING —This water heater is to be connected directly to the water mains and not by a hose set.
WARNING — For continued safety of this appliance it must be operated and maintained in accordance
with the manufacturer’s instructions.
WARNING — THIS APPLIANCE MAY DELIVER WATER AT HIGH TEMPERATURE, REFER TO THE
PLUMBING CODE OF AUSTRALIA (PCA), LOCAL REQUIREMENTS AND INSTALLATION INSTRUCTIONS TO
DETERMINE IF ADDITIONAL DELIVERY TEMPERATURE CONTROL IS REQUIRED.
In accordance with AS/NZS 3500.4 a temperature limiting device is required to be fitted by the
installing plumber
WARNING —Check the tank water level every three months and ensure that the water level is within
the range of the water level indicator.
WARNING — Ensure all sources of electricity are disconnected from the unit before removing any of
the electrical covers
WARNING — The storage tank plastic wall on the ENERMAX SMARTcube tank can melt under the
effects of external heat (>85 °C) and, in the extreme case, can catch fire.
WARNING — Do not expose to ammonia, chlorine or other hazardous chemicals.
Installers are to read the manual before assembly, installation, operation and maintenance of this
system.
This manual is split into several parts to guide you through the installation process:
• Introduction
• Key points before installation of the ROSC20 system
• Installation guide
• Commissioning Instructions
• Operation Procedures
• Maintenance and Inspection
• Warranty
STANDARDS
The ROSC20 Series complies with the following Standards:
• AS/NZS 60335.2.21:2013+A1
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• AS/NZS 60335.1:2011+A1+A2+A3
• IEC 62109-1:2010
2. The DC current from the PV panels is controlled with an MPP-tracker, for maximum power
output to the DC heating element located in the tank. NO GRID CONNECTION is required.
3. The solar DC heating element can heat the tank water to a maximum of 85°C at which point it
switches off. Once the temperature drops, the solar element will re-activate.
4. On occasions when the solar energy gain is insufficient to heat the water to its minimum
temperature of 55°C, an AC boost heating element, either powered by grid and/or battery
storage, simultaneously heats the tank water to 65°C. Alternatively a gas backup is available.
(Note: System model numbers ending in E indicate AC electric boost configuration, System
model numbers ending in A indicate gas boost configuration)
5. Mains pressure fresh cold potable water runs through the stainless steel heat exchange coil
inside the tank separated from the heated thermal storage water. The potable water absorbs
energy via the coil from the heated storage water which heats the usable water to its final
temperature.
6. To prevent scalding, a high performance thermostatic mixing valve, or tempering valve ensures
9 that water for your personal use is delivered at the required temperature. (To be supplied by
installing plumber in accordance with AS/NZS 3500.4)
ROSC20- ROSC20- ROSC20- ROSC20- ROSC20- ROSC20- ROSC20- ROSC20- ROSC20- ROSC20-
Model Numbers:
328E 343E 34319E 544E 54443E 328A 343A 34319A 544A 54443A
Electric Boosting
Water stored in the storage tank is heated automatically by an electric booster heating unit (or
alternate boost source such as a gas booster). The booster heats the water during very cloudy or
rainy weather, during the winter months, or during periods of unusually high demand. The booster
heating elements are controlled by an electric thermostat. The thermostat and heating elements are
mounted into the storage tank inside the IP54 water resistant enclosure. The boost water
temperature is automatically controlled by the thermostat setting when the booster heating unit is
energized.
The AC boost thermostat is not adjustable. It has a minimum temperature setting of 55ºC and a
maximum temperature setting of 65ºC. Automatic safety controls are fitted to the water heater to
provide safe and efficient operation.
11 Gas Boosting
Where gas boosting is used, the AC electric element of the tank is not connected. The water from the
tank is pumped through the booster, if the sensor inside the gas booster detects the water
temperature is lower than the preset temperature of the booster, the booster will turn on and heat
the water.
Water Temperature
For domestic use, the system outlet temperature is controlled by a high performance tempering
valve or high performance thermostatic mixing valve to be supplied and installed by your installing
plumber in accordance with AS/NZS 3400.4 to deliver 50°C. During periods of low solar energy gain,
the water temperature is boosted by the thermostatically controlled electric booster heating
element or the gas booster for gas boosted systems. An alternative boost heat source can also be
used.
The water heater features a non-adjustable thermostat which is located inside the tank (The tank
thermostat is factory set to a maximum tank temperature of 85°C for Solar and 65°C for Boost). Tank
temperatures above 55°C are required to protect your installation from the potential of Legionella.
Intended Use
The ROSC20 Solar PV Hot Water System is designed to operate using direct PV input, up to 2.5 kW, in
ENERMAX SMARTcube 300L and 500L heat exchange tanks. This system is designed to have the PV
connected directly to the SC20 heating device. It is not intended or approved to be connected to the
grid in any way. Any other use is not permitted as it could result in electrical short circuit, fire or
electrical shocks. The safety instructions, together with the handling and installation information
need to be strictly followed.
Not for pool heating.
Safety Check
WARNING!
• The storage tank plastic wall on the ENERMAX SMARTcube tank can melt under the effects of
external heat (>85 °C) and, in the extreme case, can catch fire.
• Locate the ENERMAX SMARTcube tank at a minimum distance of 1 m from other heat sources
12 (>85 °C) (e.g. electric heater, gas heater, chimney, flue) and flammable materials.
• Locate the ENERMAX SMARTcube tank on a firm level base. Where located indoors, ensure
adequate drainage is provided.
• This appliance may deliver water at high temperature, refer to the Plumbing Code of Australia
(PCA), local requirements and installation instructions to determine if additional delivery
temperature control is required.
• Hot water outlet can exceed 50°C. Tempering valve or thermostatic mixing valve needs to be
installed in accordance to AS 3500.4 by your installing plumber.
• Ensure all sources of electricity are disconnected from the unit before removing any of the
electrical covers
Electrical
• Electrical installation must be carried out by a qualified and licensed installer, observing the
technical electrical guidelines and regulations according to Australian Standards AS/NZ 3000,
AS/NZS 5033, AS 1768, AS/NZS 1170.2, AS 4509 and other regulatory authorities.
• The 2kW PV array when connected to this device may be eligible for STCs
• Main supply must be switched off and isolated before starting any work on ENERMAX
SMARTcube tank. Ensure no possibility of unintentional live electricity at work space.
• Compliant electrical devices, leads and power distribution equipment must be used with
intact labels and tamper-proof seals.
Bore Water
• The water heater is not recommended for connection to a bore water supply. Many such
sources contain contaminants harmful to the components of the hot water system.
• If the system is connected to bore supply against our recommendation, warranty does not
apply. See details on warranty page.
Water Quality
• To comply with warranty conditions and ensure long life of the unit, ensure the water
condition complies with water quality specified in warranty conditions.
• Domestic hot water flows through stainless steel heat exchange coils only
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15 Foundation
• To ensure adequate tank support, position the unit on an approved support base such as a
concrete slab (See figure below).
• Alternative forms of water heater bases are acceptable providing they allow for adequate
support.
• Ensure the base and footings installed can adequately carry the load of the filled tank
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Safe Tray
• It is a requirement of the National Plumbing Code AS/NZS3500.4.2 that new water heaters
be installed in a safe tray where in the event of a leak, property may be damaged (i.e.
internal installations).
• Installation of such trays must comply with Clause 4.4 and Sub-Clauses 1 to 5 of the
abovementioned Code.
• Safe tray should covers the foot print of the ENERMAX SMARTcube hot water system,
including all the attached equipment (pump, top up tank) on the tank.
PARTS LIST
Item
No. Qty Description
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19
20
21
NOTE: To avoid damage to internal coils – Fill coils first prior to filling tank
• Connect cold water pipework to 25mm ‘Cold Water’ connection marked on top of tank with
blue identifying ring.
o Your installer must supply and install appropriate isolation, pressure and backflow
control as per local regulations. Ring main / building return also connects to this
point, entering pipework after backflow control (check valve).
• Connect hot water pipework to 25mm ‘Hot Water’ connection marked on top of tank with
red identifying ring.
o At hot water outlet, your installer must supply and install appropriate isolation and
temperature control valves as per local regulation.
o Hot water outlet from ENERMAX SMARTcube tank can exceed 50°C. Tempering
valve or thermostatic mixing valve needs to be installed in accordance to AS 3500.4
by your installing plumber.
• To allow for disconnection of the water heater a mechanical union and ball/isolation valves
must always be provided at the cold water inlets and hot water outlets to allow for
disconnection. The pipe work must be cleared of foreign matter before connection. All pipe
fittings must be assembled using two spanners – do not exert excessive amounts of torque
22 on the pipes or water heater fittings.
• After all the plumbing fittings are installed as per AS 3500, open the ball/isolation valves to
fill the coil with mains pressure water
o Coil/s must be filled before storage/jacket of ENERMAX SMARTcube tank is filled.
o Mains pressurised water and domestic water flows through the internal heat
exchange coil/s.
o Above red float indicator needs to be visible and sits between max and min level
labelled on the glass.
Top Up Tank
• Top up tank maintains water level in storage water of ENERMAX SMARTcube tank and heat
source/s
23 • After mains pressure coil/s are filled and all primary pipework is complete, the jacket of the
ENERMAX SMARTcube tank can be filled with water.
• This is carried out through the top up tank.
• Ensure all pumps are OFF.
• Make up water will stop flowing when water reaches level of float. To set level, see
commissioning instructions later in this document.
• Connect overflow port to suitable tundish.
Drains
• Drain required for the following:
o Cold expansion valve
o Top op tank overflow
• ENERMAX SMARTcube tank is a non-pressurised vessel and should be manually filled upon
initial installation. Refer to ‘Installation’ steps above.
PTR Valve
• The storage water in the ENERMAX SMARTcube tank is unpressurised. Hence, no PTR
(Pressure, Temperature Relief) valve is needed for the water heater tank.
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Plumbing
Check for leaks
Ensure sufficient gas supply and pressure to gas boosters. Purge gas line
Drains for top up tank, cold expansion valve, gas booster
Gas Boosters
Installed to gas code by licensed personnel
Static and dynamic gas pressure set and regulated to range on appliance data plate
Measured gas pressure when gas boosters operating
Set to correct outlet temperature - usually in the range of 75- 83°C, depending on the brand and model
of heater
Water filters clean on start up
Water filters clean after running for a sufficient period of time
Flueing
Flueing is installed to gas code and manufacturers installation instructions
Ventilate plant room for gas boosters that draw combustion air from location of appliance
Start up
Commissioning must be completed by a qualified and licensed personnel in accordance with AS/NZS 3500.4, AS/NZS
3498, AS/NZS 3000; AS/NZS 5601.1, Municipal Building Codes, Occupational Health, Safety & Welfare Regulations, any
other States or Federal Statutory Regulations
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Note: A switch-disconnect must have: marked on/off; be lockable in the off position; be load
breaking.
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Alternate Boost
Gas Booster
This system supports Gas Boost by instantaneous units in lieu of the electrical boost. The system can
be ordered this way and setup for operation as a system ready for installation on site. Consult with
Energy Smart Water for a customized solution.
Pump
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The pump is connected to the ROSC20 control unit via a standard 3 pin plug connected directly to
the ROSC20 controller, when the thermostat calls for booster heat the pump is powered to pump
water from the tank through the gas booster and back into the tank again thus energising the tank
from 55 degrees to maximum 65 degrees.
Do not use any force when screwing the element into the lid until it touches the seal. Use a 60mm
spanner and apply up 80 Nm.
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Electrical connection myPV SC20
❖ This unit is to be installed in accordance with AS/NZS 3000 .
❖ SC20 housing must be earthed.
❖ The unit must be connected to a 10A RCD protected circuit.
❖ Make sure that the main switch of the PV plant is disconnected.
❖ DC cables to be connected with correct polarity, to the two MC4 connections. The system will
not work in the case of reverse polarity, but no damage is caused.
❖ Connect the AC cable for AC, gas or alternate boost support heat.
Wiring Diagrams
Wiring Diagram SC20 Electric Boost
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34
1. After connecting SC20 device to the PV plant the DC separator needs to be switched on and
it will take approximately 10 minutes for the system to operate. During this time the green
LED will blink (standby).
2. The set temperature of 85°C is fixed.
3. Normal operation Yellow LED on
4. After set temperature is reached System turns off, yellow LED off, green LED
on
The additional reheating using AC, Gas or Alternate support heat, ensures that the reheat
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temperature is reached, independent from the PV input.
The reheat temperature is factory set at 55°C cut-in and 65 °C cut-out.
1x flash Over temperature cut off (98°C) . System has to be checked by an authorized service
technician.
2x flash Water temperature above 90°C. System switches off and back on once temperature
decreases.
Remark: This temperature is close to the over temperature cut off (98°C). Ensure to set the
temperature of the external source below 85°C.
3x flash Electronic overheating. System switches off and back on after cooling off.
5x flash DC-insulation fault (PV collectors or electric heating element). System has to be
checked by an authorized service technician.
36
6x flash Faulty temperature sensor. System needs to be checked by an authorized service
technician.
Troubleshooting
The system does not contain components which can be repaired/replaced. In case of failure please
contact:
Energy Smart Water Pty. Ltd. | E [email protected] | T +61 3 9939 6722 | W esw.net.au
General data
Maximum pressure max. 10 bar (1MPa)
Total efficiency >99% power rating
IP rating IP54
Ambient Operating 0 °C to 50 °C
temperature
Operating status display 3 LED’s
Interface serial IR Interface
Dimensions (WxHxD) 175 x 265 x 1550 mm
incl. element
Length of element 140 cm
Heating rod thread 40mm
connection
Weight 4.5 kg incl. cable, without
package
Environmental rating
Environmental category outdoor
Pollution degree 2
37 Relative humidity rating 0-99%
(not condensing)
Cooling convection
Maximum altitude 1000 meters
above sea level
Overvoltage category for Category 2
each input
❖ The safety temperature limiter in myPV SC20 cuts out permanently at 98°C +/- 3°C.
❖ The myPV SC20 PV heating device does not contain components which can be
repaired/replaced. In case of failure please contact Energy Smart Water.
Subject to change
Disposal
Retain packaging materials or dispose properly. At end of service life, dispose according to local
disposal laws.
EU declaration of Conformity
SC20 complies with the following standards
EN60355-2-21, EN60730-2-3, EN61000-6-2
Only genuine replacement parts are to be used on this water heater. Major service and replacement
parts are not included in the warranty. A charge will be applicable.
38 CAUTION – Do not touch the power plug on the water heater with wet hands
Cause Remedy
ENERMAX SMARTcube tank overflowing
Isolate each tank to determine which tank is leaking.
Leaking mains pressure coil
Check coil for leakage. Replace as necessary.
Top up tank incorrectly set Bend float arm in top up tank to lower water level
Pump is not primed Purge air lock from pipe. Run pump till the line is full.
Check the items above before making a service call. You will be charged for attending to
any condition or fault that is not related to manufacture deflect or failure of a part.
40
FOR ASSISTANCE CALL Energy Smart Water Pty Ltd on 03 9939 6722
Terms of Warranty
This Warranty covers any defects in materials when the product is installed and operated according
to Energy Smart Water written installation instructions, subject to the terms within this Limited
Warranty document. Improper installation may void this Warranty. This Warranty extends to the
original purchaser and subsequent owners, but only while the product remains at the site of the
original installation. This Warranty only extends through the first installation of the product and
terminates if the product is moved or reinstalled at a new station.
Replacement of the product may be authorized by Energy Smart Water only. Energy Smart Water
does not authorize any person or company to assume for it any obligation or liability in connection
with the replacement of the product. If a component or product returned to Energy Smart Water is
found to be free of defects in material or workmanship, or damaged by improper installation or
damaged during return shipping, the warranty claim for product, parts and labour may be denied.
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Proof of purchase is required to obtain warranty service. You may show proof of purchase with a
dated sales receipt, credit card statement or other proof of purchase. In the first instance, you
should contact Energy Smart Water by email or telephone and point out the defect.
All Energy Smart Water water heating units are carefully checked, tested and subject to stringent
quality controls.
Energy Smart Water will repair or replace the covered product or any part or component that is
defective in materials or workmanship as set forth as follows:
Conditions of Warranty
• Supplied product must only be installed, commissioned or serviced by qualified personnel.
• The connection, attachment, integration or general association of other equipment or parts
that are not specified by Energy Smart Water which either directly or indirectly affect the
performance or operation of this equipment could void warranty.
Water Quality
It is important that the ROSC20 system is installed in water conditions that are suitable for its
42 efficient long-term use. Product warranty is limited to the following conditions:
Description Max allowable
pH 6.5 to 8.0
TDS (total dissolved solids) 600mg/L
Total Hardness 200mg/L
Chlorides 150mg/L
Magnesium 10mg/L
Calcium 20mg/L
Sodium 150mg/L
Iron 1mg/L
If there is no option but to use a poorer water quality that is outside the max allowable warranty
conditions, coil/s can be replaced at owner’s expense. Please contact Energy Smart Water Pty Ltd.
Water supply must be sourced from municipal water supply.
Please contact the local authority for more information regarding the quality of water in your area.
Water quality outside of the above recommendations will void warranty.
Note that heat sources are separated from mains water supply, however maximum allowable limits
are applicable for both applications.