For further assistance or information contact our service desk. Congratulations for choosing a Solahart GreenGlo water heater

Transcription

1 INSTALLATION CHECKLIST Air bled from taps System checked for glycol pressure drop or leaks Cold and hot water piping checked for water leaks Roof tiles put back into position Drain pipes free of any obstruction All pipe work clipped where necessary All hot pipes are lagged Operation of element checked Solar controller connected Operation of solar pump checked Thermal paste is used with sensor probes Solar circulation pump and flow meter speed set Solar circuit runs smoothly and air pocket is left in expansion chamber Owner instructed on use and controller and service sticker mounted USER MANUAL Solar Group Accredited Installer INSTALLATION INSTRUCTION OPERATION & REGULAR CARE SOLAR WATER HEATERS MODEL: Solarhart GreenGlo and GreenGlo Max 180S 180D 300S 300D 300DS 400D 500D 800D 1000D Customer / User Congratulations for choosing a Solahart GreenGlo water heater We recommend you read page 1 to 7 of this manual. It may save you time and trouble later. The other pages of the manual are intended for the installer. For further assistance or information contact our service desk info@slg.co.nz

2 IMPORTANT INFORMATION COMMISSINING AIR PURGING SCHEMATIC This manual refers to the Solahart GreenGlo and GreenGlo Max System with Glycol in the panels. If panels are to be filled with water, some of these instructions do not apply. The Solahart GreenGlo hot water systems are to be installed in accordance with the cylinders manufacturer s installation instructions, local and NZ national plumbing regulations, municipal building codes, NZBC G12 and any other relevant statutory regulations. Observation of these instructions and the associated component instructions is most important and failure to do so could void the benefits of warranty. All work is to be carried out by appropriately qualified trades people or to be suitably supervised for trade assistant duties, and to be carried out in accordance with Local and National Occupational Safety Guidelines. The information contained in this manual, and all other information or advice provided by Solar Group Limited in connection with the purchase, installation use and service of water heaters, is given in good faith. Solar Group Limited will not be liable for any person for any inaccuracy or omission in the information arising through the fault of Solar Group Limited directly or indirectly. A pressure-limiting valve of 500kPa max rating must be fitted. Failure to install a pressure limiting valve where required will void the warranty. SAFETY Ensure compliance with safety regulations of working at heights on roofs. Scalding occurs at 50 0 C. This appliance is capable of providing hot water above this temperature. All installers must advise customers of the potential hazard of scalding in accordance with the relevant National standards including NZ A solar-rated tempering valve must be fitted on the hot outlet of the tank Young children should not play with the appliance. Care must be taken when fixing or replacing broken glass. Collectors have toughened glass complies with NZS and NZS No other glass shall be used. Please refer to page 1 of the GreenGlo manual for further safety issues with the mains pressure water storage cylinder. 18 1

3 COMMISSINING AIR PURGING Step 1: Set up Turn the knob on the pump station to face the filling port All temp probes should be in pockets Step 2: Flush Connect water supply from a garden hose or mains pressure to the Filling Valve and flush it through the Service Valve. Continue until all the air has escaped. Push the pump button on the controller while flushing for a few seconds. Turn the drain screw 90 on the solar pump until it leaks and screw it back. Step 3: Seal & Check Shut down the Service Valve, let the loop pressurise to 2-3 bar and then shut down the water supply via the Filling Valve Check the entire loop and the panels for leaks Check the pressure gage for pressure drop Step 4: Glycol introduction Connect the mobile Commissioning Station to the Filling Valve flow side and the Service Valve to the return into the plastic bin. Fill the lastic bin with Glycol and add glycol mix from previous commissioning or water if required. Turn on the commissioning pump while opening the Filling Valve. Open the Service Valve shortly after. Repeat Step 2 and Step 3 Step 5: Final Check Watch the solar pump in operation for at list two cycles smoothly and quietly If weather conditions are not heating up the collectors, press the pump button on the solar controller. Repeat step 2 & step 3 if there are any air noises or visible bubbles seen through the flow meter. Bottom expansion tank: Pressure when cold should be steady 2 bar Top expansion chamber: Open the plug to ensure that the air pocket exists. 17 ABOUT YOUR WATER HEATER 1. The main goal of producing Solahart GreenGlo heaters is heating and storing potable hot water in a main pressure storage tank using solar energy and electricity. The unit also offers optional heating equipment such as gas, diesel and wetback. Potable hot water is stored in the main water storage tank separately from the heating liquids in the coils. 2. The heating fluid is blue glycol with anti-freeze qualities. The blue colour is a leakage indicator and if shows, call an approved installer immediately. 3. The glycol is heated in the solar panels and is circulated to the top of the bottom tank coil using a circulating pump. It is a closed loop solar heater. 4. A solar controller controls the pump to optimise energy collection. 5. The type of water heater to choose (single or double coil) depends on additional heating sources or/and if you are planning to extract heat. 2

4 PRODUCT INFORMATION GreenGlo Mild Steel Double Enamelled Cylinder: 180S 300S 180D 300D 300DS 400D 500D 800D 1000D Single Coil S Series Double Coil & Element D Series Volume (litres) ,000 Height (mm) Diameter (mm) No. of panels Glycol (ltr) Expansion (ltr) / / Please refer to page 3 & 4 of the GreenGlo manual for more technical information GreenGlo Max Duplex Stainless Steel Cylinder: Volume (litres) T Height (mm) Diameter (mm) No. of panels Glycol (ltr) Panel (collectors): Dimensions (each): 1.94m x 1.03m x 0.083m Weight (full): 37.6Kg Insulation: 38mm Glass Wool Weight (dry): 35Kg Max Pressure: 1400kPa Ports: 20mm Surface Types: Black Carbon / BT Selective Coating Titanium Blue Circulation Pump / Flow Meter: Standard: Three speed max power of 90w Flow meter: 2-8 l/min For more technical information, refer to the specific pump manual Solar Controller: Smart controller: Power Pump Plus: 10m 3 temp probes; booster controller and digital display A relay for ripple power or load of 3kW or more is essential For more technical information, please refer to the controller manual 3 START-UP AND COMMISSIONING Filling the tank with water Follow the instructions of the GreenGlo Manual WARNING: Ensure that the tank is full before turning on the electric power, solar pump or any other heat source Filling the solar circuit with glycol mixture ENSURE THAT THE PANELS ARE COVERED AND NOT LEFT EXPOSED TO THE SUN WHEN NOT CHARGED WITH GLYCOL OR IF THE CYLINDER IS NOT FILLED WITH WATER FAILURE TO DO THIS WILL VOID THE WARRANTY Warning: Care must be taken and suitable safety measures employed when filling the solar circuit as any outflow from the filling can be in excess of 50 o C at which temperature scalding can occur NOTE: The glycol mixture is of food grade and non toxic. However, care must be taken when handling not to spill or accidentally consume. Only use glycol mixture as specified by Solar Group Limited. Filling the solar circuit requires connection to the filling valve. Note: A recheck / top up of the fluid level in the solar circuit must be performed after 15 minutes. This is done to ensure that the circuit has been filled to the correct level and any suspended bubbles of air have risen into the expansion chamber. Press pump on the controller to force the circulation. Inspect the flow meter or noises for evidence of air locks DRAINING THE SYSTEM Drain close circuit first: IMPORTANT: Ensure that the glycol is not hotter than 50 0 C, cool if necessary Drain the glycol via service and filling valves while both open Draining the tank: Turn off the element(s); shut down cold water inlet and lift the lever of the TPR to relieve partial vacuum while draining via the taps. 16

5 INSTALLATION - ELECTRICAL Electrical connections must be installed in accordance with New Zealand Wiring Regulations, local electrical and building codes. ELECTRICAL RATING (kw) Please refer to the GreenGlo user manual THERMOSTAT Increase the adjustable thermostat temperature setting to 65 C. CABLE Existing cable from any previous electrical hot water system may be used provided that it is in sound condition and is of the correct size SOLAR TIMER (not required with smart controller) It is recommended that a timer be installed and set to turn the booster element on at 4pm and off at 6pm, then on again at 4am and off at 6am. POWER PUMP PLUS CONTOLLER Whenever the element is wired to a ripple power or the element rating is higher than 2kW, a relay box must be installed. Install the Relay Box as per page 12 between the element and the ripple. INSTALLATION - PUMP & SOLAR CONTROLLER Mount pump; controller and pressure gage so it is in accessible position SOLAR CONTROLLER Ensure that probe pockets are dry; use Thermal Paste between probes and pockets and seal against moisture afterward. Panel sensor is marked Roof. Place it in the pocket on the last panel of the circuit before commissioning Placing Intel and Tank Sensors: The inlet probe should go into the lower sensor pocket. This sensor pocket should be close to the Cold Coil port. if not place the probe on the flow pipe The tank probe should go into the upper sensor pocket. This sensor pocket should be approx 2/3 of the cylinder height. If lower than the element push inside the element box, above the element, between the insulation and the tank core Having completed this; connect the controller to the power point, plug in the pump 3-pin plug into the controller, and connect the relay box to the controller Do not power up the controller until commissioning the storage tank and the glycol. The pump must only be active after the solar circuit has been filled with glycol and air has been expelled. Adjust of the controller settings may affect solar performance - discuss with owner 15 WATER QUALITY Solahart GreenGlo water heaters have been manufactured to deal with most qualities of New Zealand water supply. Desired water quality levels: ph Level between 6.5 and 8.5 Chlorides: up to 200 ppm Total Dissolved Solids (TDS) up to 1000 mg/l Saturation Index between -0.8 and +0.8 If your water quality or the heating liquids are outside the above range, you should fit appropriate water filtration. The final fitness of water delivered is depending upon the quality of water supplied to the system. REGULAR CARE Regularly: Check the pressure gauge for pressure drop below 1 bar If below 1 bar call the installer immediately Six Monthly: Near the top of the water heater you will find the TPR Valve (Temperature Pressure Relief Valve). Raise the lower lever and gently release some water into the relief pipe. Notes: If water does not flow down the relief pipe, or if water does not stop flowing once you released the lever, contact your plumber It is normal for the valve to release small amount of water during heating cycles Never block the relief drain pipe Yearly maintenance: Wash the glass cover of the collector with a household detergent. Inspect the collector glass seals and surface coating for deterioration Five yearly maintenance: As per the GreenGlo cylinder user manual page 5 It is recommended that an accredited Solahart installer carry out a regular checkup service and replaces the glycol. 4

6 PERFORMANCE EXPECTATIONS & OPTIMISATION EXPECTATIONS Solar radiation is greater on sunny clear days between 9am and 3pm. During clear sunny days the system will exceed approximately twice the maximum daily outside air temperature. During cloudy days the system will exceed the max. daily outside temperature. During non-use, a maximum temperature of 85 0 C may be achieved. TIPS Schedule heavy washing loads as close as possible to the middle of the day. Evening showers will improve efficiency comparing to morning showers. On low or no solar days you should avoid heavy usage of hot water and spread hot water usage evenly throughout the day. SHADING If shading over your solar panels is experienced between 9am and 3pm then: 1. Annually prune or cut trees or shrubs that shade the system. 2. Partial shading by chimneys, TV antennas, and roof erected fixtures, during these hours is acceptable provided that it does not exceed 10% of the area. POWER PUMP PLUS CONTROLLER SETTINGS 1. Lower the boost-on and the boost-off settings during summer. 2. During winter periods the human body generally prefers hot water above 40 0 C to bathe in, so increase boost-on and boost off setting is essential for comfort unless a wet back is fitted. 3. Restrict boosting to upper element to maximise savings TEMPERATURE RUN DOWN GUIDANCE The temperature run down occurs where heat is transferred from the top strata of the water in the cylinder to a lower cold water stratum. This heat is NOT lost to the system but is simply conducted from one strata level to another inside the storage tank. This will happen: 1. Shortly after the element is turned on (up to 30 minutes) 2. When the solar starts introducing heat while the bottom of the tank is cold 3. Overnight 5 INSTALLATION SETUP THREE to SIX PANELS WITH TDC CONTROLLER 14

7 INSTALLATION SETUP TWO PANELS GreenGlo 180D; 300D or 300DS Energy Star 13 WARRANTY REGISTRATION: WARRANTY CARD You should receive a registration card directly from your installer. If you haven t received a warranty card within 30 days of the installation date please contact Solar Group Ltd or warranty@slg.co.nz CLAIMS All claims must be reported via the installer not to Solar Group Ltd. TERMS AND CONDITIONS The panel and the GreenGlo storage cylinder warranty are for 5 years; the solar controller is 3 years from installation date per warranty card. All other parts and labour carry 12 months warranty GreenGlo 180 Two BT; 300 Two BT; 400 Three BT & 500 Three BT extended warranty programme of 6-year for the GreenGlo cylinder and 10-year for the Solahart BT collectors is subject to 5-year service. CHANGES OF OWNERS The warranty extends beyond the original purchaser to subsequent owners of the system during the original warranty period. CONSUMERS STATUTORY RIGHTS All benefits offered by this warranty are in addition to all other statutory rights ANCILLARY PARTS This warranty only applies to the water heater and original or genuine company components replacement parts. NOT covered, are any plumbing or electrical parts supplied by the installer EXCLUSIONS The product is misused, neglected, abused or operated without appropriate fluid; or systems are flushed by a cleaning agent or product not recommended by Solahart Ltd. Damage is caused by an act of God, fire, lightning, flood, earthquake, landslide, storm, hail, wind, or severe adverse weather conditions. Equipment supplied by Solar Group as part of the installation kit has not been installed. Water hammer occurs, or pressure fluctuates above the standard valve settings. Other such equipment and parts not supplied by Solar Group to this installation which may affect its operation/performance must be authorized in writing by Solar Group Ltd. NOTES Any replacement system or parts thereof provided under this warranty do not carry a new warranty. The unexpired warranty remains effective. Whenever it is not a standard installation; i.e. Limited access, excessive roof pitch or multiple storey, additional costs & excessive travel may be incurred at the expense of the consumer. Solar Group Ltd shall not be liable for any consequential damages; damage to furniture, walls, or any incidental expenses resulting from any defects of its products. The glass fitted to the solar panels is not covered by this warranty. This warranty is for domestic use only. For details on all other situations (commercial farming or industrial) contact Solar Group Ltd. 6

8 INSTALLATION - GENERAL PERMITS The owner shall obtain all relevant permits and building consents from all the regulatory authorities, before commencing work to install the solar hot water system. All plumbing and installation work shall comply with Local Body and National Standard NZ and NZBC G12. PRIOR TO COMMENCING INSTALLATION Location of solar panels: The contractor shall inspect the premises and roof structure to ensure: i) The solar panels are located in an area of the roof, which will be unshaded all year round. Check high buildings or trees in the vicinity for WINTER shade. Discuss with the client about trimming trees if shading is apparent. ii) The location of the storage tank should give an efficient hot water supply at the point of usage with equal distribution throughout the house. iii) The area chosen is structurally capable of accepting the solar panels. iv) Adequate roof drainage where the solar panels will be positioned so they do not act as collection points for leaves and debris. v) Advise the client of the optimum location and CONFIRM that location. Orientation of Solar Panels: For optimum performance the solar panels should be installed facing towards the equator. Always check the orientation and use a compass. Variation of up to 45 0 East or West have little effect on the solar contribution (less than 5%). Variations of more than 45 o can be acceptable for lower than average hot water usage, otherwise consider a side/reverse stand or upgrading the solar panels Inclination Angle: Minimum recommended inclination angle is latitude minus 20 Frost Prone Areas. The Solahart GreenGlo systems are designed for frost prone areas. The heat transfer system fluid is a mixture of glycol (25%) which has specific properties that prevent it from freezing to -10 C. Double the glycol concentration for deep frost area (-10 C to -28 C) COMMISSIONING NOTE: The storage cylinder must be connected and filled with water prior to solar or any other heat source commissioning. The commissioning of the installation and its handing over to the client is the responsibility of the installer. The installer shall instruct the client in the method of operation of the system and hand the client a copy of this manual. 7 INSTALLATION SETUP ONE PANEL GreenGlo180S; GreenGlo180D 12

9 Tile Roofs Metal Roofs INSTALLATION COLLECTOR FIXING 11 INSTALLATION CYLINDER; PIPEWORK & PUMP General All pipe work within the roof space must be securely clipped to prevent vibration. Drainpipes should be clear of any possible obstruction. Hot water pipes must be copper, use tight fittings or Teflon only. Pipes should be fully insulated with min. 13mm wall in the Zone 5 and 19mm in Zone 6. Use Isopipe lagging or similar when exposed to UV. Pipe run should be as short as possible. Cold and Hot water supply and cylinder drain The thermal discharge rating of all protection valves must be greater than 7kW mainly TPR Valve and Cold water relief valve Solar flow The solar flow line to the solar pump is connected to the cylinder at the bottom connection marked Coil Cold. Ensure that the pump is orientated so that it is drawing glycol from the cylinder and pushing it up to the panels, the direction of the flow is indicated with an arrow on the pump casing. Refer to page 9 for details. Solar return The solar return line from the solar collectors is connected to the cylinder at the top connection marked Coil Hot. It should be shorter than solar flow pipe. A Heat Trap is to be installed to minimise heat losses when system is idle. The drop below the normal piping line should be no less than 300mm and extend no less than 200mm in length before its return to the normal piping line. Pipe size guide and flow meter rates Flow rate should be 2-3 litre/min per panel. Adjust pump speed and if down to speed 1, adjust flow meter. Pipe Run = Pipe length of flow pipe + Pipe length of return pipe + 1 meter per bend + 10 meters if two storey up # Panels Pipe Run in meters Recommended Pipe Flow meter rate 1 Less than mm 2-3 litre/min 1 More than mm 2-3 litre/min 2 Less than mm 4-6 litre/min 2 More than mm 4-6 litre/min 3 Less than mm 6-8 litre/min 3 More than mm 6-8 litre/min 4-5 Less than mm 8-15 litre/min 4-5 More than mm 8-15 litre/min 6 Less than mm litre/min 6 More than mm litre/min Maximum head is 6 meters. Also refer to the pump installation instructions. 8

10 INSTALLATION TANK; PIPES & PUMP SETUP 9 INSTALLATION - SOLAR PANELS It is important that the installation of the panels will not compromise the integrity of the roof or the building as per G12 AS2. Always use neo-prime washers or other insulators, to prevent dissimilar metal corrosion. Before starting, peel off the protective plastic coating from the panels as it will bake onto the surface if exposed to the sunlight. Protect the gutter from damage caused by ladders etc. Lift the solar panels onto the roof one at a time. The best way is to rest each panel against the gutter while supporting it from the ground. Then pull up the panel onto the roof. Fixing Methods Tiled roofs 1. Allow for the top collector upper support angle being positioned 3 tiles down from the ridge cap, position the bottom collector support angle 2 meters below where the upper collector support angle will be. 2. Slide on the straps to the bottom collector support angle and fasten the straps using stainless tek screws to the rafters underneath the tiles. 3. Position panels into the bottom collector support angle and begin connecting them together using the inter-connectors. Connect all start pipes and other fittings supplied where required. IMPORTANT: Ensure that fibber washers are fitted to all L type panel connections lubricated with black graphite 4. Blank off the remaining solar panel connections using a blanking nut and sensor nut. 5. Do not place sensor cable if system remains dry for more than 24hrs 6. Position the upper collector support angle and fasten to the rafters. 7. Lock the bottom and top collector to support angles with clamps. Metal Roofs The procedure is the same as the above except that the top collector support angles should be fastened straight onto a roof purlin Use the same fastening for the bottom angle. Use neoprene washers. 10