Instruction Manual for the Installation and Maintenance of Novasun Direct Freeze Resistant High Pressure Solar Hot Water Systems

Transcription

1 Instruction Manual for the Installation and Maintenance of Novasun Direct Freeze Resistant High Pressure Solar Hot Water Systems (April 2014) For use by trained qualified personnel only. Applicable to the following models: Novasun, Direct Freeze Resistant, 150l, 200l, 300l We reserve the right to change the installation instructions. Reproduction, even partial, is only allowed with written permission. WE Geysers (Pty) Ltd,7 Nelmapius Street, Chamdor, Krugersdorp,

2 Contents 1. Introduction System description Configurations Health and safety General Installation considerations System configurations Novasun Thermosiphon System Novasun Split-pumped System Frost, scaling and hail resistance, stagnation Hail resistance Freeze protection Direct systems Freeze resistant & Stagnation Scale resistance System placement and orientation Collector orientation Shading Tilt angle Water supply / delivery Roof structural integrity Mounting methods Selection of appropriate mounting method System mounting methods Mounting process Suggested mounting method Suggested mounting method System Installation General installation technique Cylinder and System plumbing Geysers Electrical connection Installation Diagrams... 9 Pumped System Installation Diagram System commissioning Commissioning direct systems Installation checklist System Selection and Sizing Introduction System sizing System type Owners operating and maintenance instructions Introduction Operating and efficient use Over-night temperature stabilisation High water temperature Periods of reduced usage or holidays Freeze protection liquid Setting the time clock Owner maintenance Troubleshooting Warranties Contacts Warranty Contact Centre Warranty Services: (log warranty services)

3 1. Introduction All Novasun solar hot water systems are high quality thermal solar systems, using advanced technology to convert light into heat. This installation manual must be read and understood before undertaking the installation of a Novasun solar hot water system. Should any aspect of the installation process remain unclear a Novasun Solar representative should be contacted for advice prior to installation. This manual does not seek to provide comprehensive guidance in terms of the general plumbing and electrical connection of geysers, which is assumed knowledge and required of any registered installer, but rather sets out to provide guidance in terms of the correct installation of the solar thermal components of the system. Systems must be installed by suitably qualified and registered plumbers and electricians, in accordance with relevant South African Norms and Standards, National Building Regulations, Law and Regulations, Local By- Laws, including the following: SANS Functional control valves and safety valves for domestic hot and cold water supply. SANS The installation, maintenance, repair and replacement of domestic solar water heating systems, edition three. SANS Water supply and drainage for Buildings. Part 1 - Water supply installations for buildings. SANS The installation, maintenance, replacement and repair of fixed electric storage water heating systems. SANS The wiring of premises. Part 1 - Low-voltage installations. SANS Parts A, B, L, XA. Occupational Health and Safety Act (Act 85 of 1993) National Buildings Regulations Act 103 of 1977 Water Services Act (Act N0 108 of 1977) It is the responsibility of the installer to ensure that they and their staff are familiar with and competent in respect of the above. Responsibility for the safe and proper installation of a system rests with the installer. The solar hot water systems referred to herein must be installed in accordance with these instructions, local and national plumbing regulations, municipal building codes and any other relevant statutory regulations. All intellectual property in this design and/or registrations and/or copyright including any patent, patent application are the property of Novatherm CC and/or WE Geysers (Pty) Ltd. Observation of these instructions is most important and failure to do so could void the benefits of the warranty. The connection, attachment, integration or general association of other equipment or parts which either directly or indirectly affect the operation or performance of the solar system could void the warranty. Other such equipment or parts not supplied by WE Geysers (Pty) Ltd, which may affect its operation/performance must first be authorised by WE Geysers (Pty) Ltd in writing if the full benefits of the warranty are to remain valid. WE Geysers (Pty) Ltd does not accept liability or responsibility for the final fitness of water for consumption from this water heater, as the water quality is not affected by the system and is a function of the municipal and/or other water supply. This manual has been written with the intention of ensuring that the system is correctly installed and that the owner/user is fully conversant with the best methods of operation. 2. System description 2.1 Configurations Novasun solar hot water systems utilise state of the art technology and perform with high efficiency in a wide range of weather conditions. Collector output is directly related to the amount of incoming solar radiation striking the collectors. This installation manual covers the installation of the following systems: Model Major System Components Novasun 150l Novasun 200l Novasun 300l 150 Litre Solartherm Direct Geyser 1 x 1.7sqm Novasun Collector 200 Litre Solartherm Direct Geyser 1 x 2 sqm Novasun Collector 300 Litre Solartherm Direct Geyser 2 x 2 sqm Novasun Collectors The models governed by this manual are pumped and thermo-siphon systems. Thermisiphon systems may be installed in a close-coupled or split system format whilst pumped systems are installed in split system format and water is circulated using an applicable water circulation pump. The Novasun range of solar hot water systems are using a direct cylinder in conjunction with the Novasun collectors employing its unique heat transfer technology, fully enclosed and insulated, with no direct heating of water, preventing freezing or overheating of the system. System heating performance Model Novasun 150l - Termosiphon Q-Factor* 11.8 MJ Novasun 200l Thermosiphon 16.3 MJ Novasun 200l Pumped Novasun 300l - Thermosiphon 23.7 MJ 27.5 MJ *The thermal performance of the systems have been established by the South African Bureau of Standards in terms of SANS 6211, at an incoming radiation of 16MJ per m² per day, a temperature differential of 10 C and at an inclination of latitude plus 10. **Q-factor is calculated in mega-joules whereas the energy rating is calculated in kilo-watt hours. The energy rating is calculated by converting the q-factor into kwh. The specific thermal capacity of the Novasun collector is 4.39KJ/K m². 3. Health and safety 3.1 General This appliance is not intended for use by young or infirmed persons without supervision. Scalding occurs at 50 C. This appliance is capable of providing hot water over this temperature. In certain circumstances the system may expel hot water and relieve pressure through the temperature pressure valve. Never block this valve and always leave open to the atmosphere. Take care to avoid contact with water when valve is in discharge. This appliance is a water heating apparatus only and the final quality of water and fitness for consumption is dependent on the quality of water supplied to the system. These systems are designed for the supply of hot water to domestic household premises which have been constructed to the appropriate local and national codes and regulations. 3.2 Installation considerations All installations are to be carried out in accordance with the Occupational Health and Safety Act (Act 85 of 1993) requirements and any relevant local authority prescriptions. Some general points to take note of, however, include the following: 2

4 Assess site specific risks and eliminate or reduced to an acceptable level so as to satisfy health and safety requirements, prior to installation. Water temperature can reach boiling point and the collector can reach stagnation temperatures of over 70 C. Shade collectors during installation to prevent heating. Take care when handling collectors to prevent breakage to glass and injury. Safety goggles, work wear and gloves must be used to reduce risk of injury. Be aware of overhead power lines coming in through roofs, as well as electrical wiring running through ceilings. Assess weather and postpone roof work if unsafe (e.g. high winds, rain, lightning, etc.). Scaffolding and safety equipment must be installed by certified personnel and signed-off accordingly. Inspect before use. Inform home owners or building occupants of time and place of work to be carried. Ensure occupants are aware of site access constraints and all health and safety implications relevant to them. Cordon off the area, if applicable, to prevent personal injury and ensure any pets are secured. Ensure personnel working on installation are competent and in suitable physical condition. Installers must be trained and conversant with the assessment of height hazards, working at height safety procedures, assessment of safety equipment (e.g. scaffolding, harnesses, etc.) and the use and wearing of safety equipment (e.g. goggles, hard hats, gloves, etc.). All personnel working on the installation of a solar hot water system must be issued with the appropriate safety equipment and be trained in their use. Failure to observe safe practices may result in: scalding / burns; electrical shock; and/or falling, which can cause serious injury or death. Maximum system equilibrium temperature will reach approximately 73 C, where after the heat transfer process will automatically cease due to the water temperature equilibrium between cylinder and heat exchanger. A thermo-siphon can be close-coupled or split as illustrated below, provided there is sufficient roof space. 4.2 Novasun Split-pumped System Where the solar water heater is installed in the roof, it must be installed in compliance with SANS complete with a Safety Valve, drain cock, Multi Pressure Control Valve 400kPa, Drip Tray and vacuum breakers on the cold and hot water supply. When installed inside the roof minimum clearance must be allowed in order to remove the element and thermostat. Roof structural integrity must be handled according to section 6.5. For Product warranty detail refer to the separate Warranty Agreement. Pump Circulation in the Novasun SWH system. When it is not convenient or possible to place the cylinder higher than the collector, a circulating pump controlled by an electronic control unit and two sensors is used to monitor the temperature of the manifold and the cylinder, that enable the powering of the circulation pump when the water in the panel manifold is hotter than the water in the cylinder. 4. System configurations 4.1 Novasun Thermosiphon System A thermo-siphon system relies on the natural circulation of fluid between the collector and the geyser. In order for the thermo-siphon process to occur the geyser must be placed in a higher position than the solar collector. The system operates according to the laws of thermal dynamics (i.e. a liquid, when heated, becomes less dense and rises above the denser cooler liquid). In the Novasun SWH system, a non-toxic, non-hazardous, food grade heat transfer liquid, in hermitically sealed heat transfer pipes, becomes a vapour/gas that rises up as the sun heats the pipes, and this in turn heats the water indirectly through its contact with the fully insulated heat exchanger in the collector top. The process continues until the collector can add no more gain in temperature or until the sun stops shining. When the temperature difference is less than the set point the pump will stop. When temperature of water in the cylinder reaches the highest set point, the controller will stop the pump. The circulating pump used must be installed and maintained according to the manufacturer s instructions. A 12V circulating pump with a photovoltaic solar panel can also be used. The method of freeze resistance is by way of 8mm diameter silicone tube inserts of length 60cm to 100cm into pipe connectors pipework between the cylinder and panel, on both sides from the panel, and as supplied by manufacturer or other approved supplier. A split-pumped system is illustrated below. 3

5 5. Frost, scaling and hail resistance, stagnation 5.1 Hail resistance Novasun collectors are hail resistant with 4mm toughened glass and have passed SABS hail tests. 5.2 Freeze protection Solar hot water systems can be classified as (i) direct: freeze resistant, (ii) direct: non freeze resistant or (iii) indirect. 5.3 Direct systems Freeze resistant & Stagnation In traditional direct systems the water to be used in the household circulates through the collector, transferring solar energy into the solar geyser. The Novasun SWH new technology panel however contains a fully insulated indirect heat exchanger located in the collector that acts as a freeze resistant mechanism. The pipework connecting the solar geyser with the collector must be insulated with Insulflex insulation material. When installed with a PEX-lined Solartherm Cylinder it can be used in all SA climate locations (i.e in areas where frost occurs and areas, where ambient temperature may fall below 5 C) and in areas with very high ambient temperatures due to its built-in overheating (stagnation) prevention technology. Contact Solar Assist to discuss your water quality and conditions Direct systems: non-freeze Resistant In direct systems the water to be used in the household circulates through the collector, transferring solar energy into the solar geyser. Direct systems are used in frost-free locations, where ambient temperature never falls below 5 C and where water quality is good (i.e. less than 600ppm total dissolved solids/minerals) Indirect systems In indirect systems the potable water used in the household does not circulate through the collectors, but remains in the geyser and is heated indirectly by a heat exchanger. There are two basic types of heat exchanger, namely a jacketed system where an inner cylinder is surrounded by a secondary outer layer and an internal heat exchanger where the solar geyser contains an internal copper pipe structure. Ensure you are familiar with the relevant tank manufacturer s warranty terms and conditions in respect of water quality, particularly as it relates to anode replacement in case of enamel-lined tanks. Direct systems: If a direct system is used in areas of poor water quality the manifold inside the collector and solar loop may be subject to a build-up of scale. This may be avoided through the use of a water softening system. This is good practice regardless of type of system, as the water will affect other household appliances in any event. Novasun SWH System: In the event that the Novasun SWH collectors experience scale build-up, the manifold can firstly be flushed with a mildly acidic solution (e.g. vinegar water mix solution or Scale-away solvent) and thereafter with fresh water prior to re-commissioning. We recommend that your service provider perform visual checks every 18 to 24 months and flush the collector as a preventative measure. The fitment of an appropriate water softening device in the water feed to your system is good practice. 6. System placement and orientation A number of basic fundamentals need to be observed when installing any solar hot water system. 6.1 Collector orientation Optimum system performance is achieved when the collectors face directly North (i.e. true North) when installing in the Southern Hemisphere. The closer the collector is to directly facing the equator the greater the amount of solar radiation the collector will be exposed to and the greater the potential for heating. In both cases the solar loop (i.e. the pipe work to and from the collectors) contains a heat transfer medium (i.e. propylene glycol/water solution) which is physically separated from the potable water. Propylene glycol has a lower freezing point and prevents the liquid in the collectors from freezing and damaging the collector through expansion that occurs when ice forms. Only food grade glycol should be used. Angles up to 45 either side of North will not have a major effect on the system performance given the state of the art technology used in the construction of the Novasun systems. Therefore, roofs that are orientated away from North are also acceptable for installation. Indirect systems are used in locations where frost occurs and the ambient temperature drops below 5 C and/or where water quality is poor (i.e. more than 600ppm total dissolved solids/minerals). These collectors are resistant to freezing when installed with an indirect geyser and the solar loop filled with a solution of propylene glycol and water. Water alone must not be used as a transfer fluid. The glycol / water solution should be mixed in a glycol to water ratio of 1:3 (i.e. 33% glycol). 5.4 Scale resistance Indirect systems: containing a glycol solution also prevents scale build up inside the collector in areas of poor water quality. It is important to note that the geyser cylinder itself may still be affected by water quality by way of build-up of scale on the outside of the heat exchangers. Outside of the 45 range one could consider utilising more collector surface area or using a mounting frame to adjust the orientation back to North. 6.2 Shading With a system orientated to face North, the time period when the collector is exposed to the most direct solar radiation is between 10h00 and 16h00. Solar collectors with an East bias will achieve a greater gain in morning hours and those with a West bias will do so in the afternoon. Care should be taken to ensure that the collectors are not subjected to excessive shading from trees or adjacent buildings, particularly between 09h00 and 16h00. Also bear in mind that tree growth could lead to future shading issues. If the installation takes place in summer, it is also important to take into account the lower solar angles in winter, which result in longer shadows. 4

6 6.3 Tilt angle In respect of the optimum angle of inclination for a solar collector, the rule of thumb provides that the latitude of the location is taken and then 10 added thereto. Therefore, a location with latitude of 25 would indicate an optimum collector tilt angle of 35. The angle of inclination, however, is also flexible and minimal loss of performance occurs by installing at lower or higher angles of inclination. The Novasun collector can be installed as low as 10. Below this, however, the thermo-siphon process does not function effectively. Also, angles lower than this would result in build-up of dust, as it is not able to be washed away effectively by rainfall. 7.2 System mounting methods 7.2.1Suggested method 1 - General purpose installation brackets The image below depicts a typical bracketing system which could be used with Novasun solar hot water systems. This type of bracketing system is suitable for tiled or corrugated roof structures with a pitch of less than 30 degrees. Typical kits would include the following pieces: It must also be noted that installation angles over 30 will require additional strapping to secure the geyser and collector during and after installation, as at this angle the system will tend to move downward. Consideration should be given to a split installation in these circumstances. 6.4 Water supply / delivery The location of the installation should give as efficient a supply of hot water to all areas of the residence as possible. If not possible, the system should be placed as close to its main point of usage (e.g. master bathroom). Discuss this with the client and confirm their understanding and requirements. 6.5 Roof structural integrity The area chosen for installation must be structurally capable of handling the loading. Check load weights of applicable system and ensure that the weight can be borne by the roof structure. Specialist advice should be sought if required. The system should be placed, such that the tank spans at least three main trusses. It is good practice to brace all truss work that supports the installation. Strengthen rafters (or timbers or other structures) used for supporting the panel and tank, for example by adding noggins between rafters or adding thicker timbers alongside them or cross bracing them or adding additional supporting struts to the truss to spread the additional load to a load bearing point. Where ever possible the system should be installed over a supporting wall of the building (i.e. on a truss resting on a supporting load bearing wall). Never install a system on a roof with damaged or rotting timbers. To prevent cracking of certain fibre cement and metal roof sheeting, a flat mounting frame designed to spread the load of the geyser and its contents should be designed by suitably qualified personnel and installed below the geyser. Ensure that the roof covering material is structurally sound to receive the weight of the system. In the case of a split system installation a wooden frame should be constructed which raises the tank above the level of the collectors. Care should be taken in the design and construction of this frame so as to ensure it meets all relevant standards. 7. Mounting methods 7.1 Selection of appropriate mounting method A (2 pieces) Tank Cradle Bracket B (2 pieces) Collector Clamp C (2 pieces) Straps (not included*) D (2 pieces) Collector Hanger Bracket** *Straps are not included as lengths required will differ from installation to installation. These should be aluminium or stainless steel. **Please note that two hanger brackets are required per collector. The 300 litre system using two collectors require 4 hanger brackets (two per collector). Please note that points of contact between the collector frame and mounting brackets and between tank and mounting brackets are buffered by a foam lining to prevent issues surrounding galvanic corrosion. The installer must install the system in such a fashion to prevent long term degradation of system materials through galvanic reaction Suggested method 2 - Alternate installation brackets As an alternative to the first bracketing system, straps could be used. Collectors could be secured directly to the roof structure, at each of the four corners of the collector, by means of aluminium strapping. The straps should be securely fixed to the underside of the aluminium collector frame using aluminium speed screws. The straps can then be passed under the tiling and secured around the nearest truss and/or purlin. In respect of the geyser, strapping can be hooped around the geyser, on either end of the cylinder, using strap clamps available with commercially available strapping systems, leaving enough length to pass the tail pieces under the tiles and secured around the appropriate roof woodwork. As indicated above the installer must install the system in such a manner so as to prevent galvanic corrosion between system components and the mounting brackets and/or straps. Please note that it is the installer s responsibility to ensure that the means of fixing the system to the roof such that it results in a safe and functional installation. The methods suggested are generic and will not necessarily be suitable in all situations. 5

7 7.2.3Suggested method 3 alternate installation brackets Geyser Brackets d) Note the correct use of left hand and right hand bracket. Attached strapping is then tightened onto the timber structure in the same way as above. a) Description: Profiled aluminium plating providing a solid footing distributing the weight of the unit over the roof covering. Positioning of bolts on brackets are off centre in order to allow the foot plate of the geyser to rest squarely in the centre of the bracket once installed. Easy to use wing nuts are supplied to minimise effort on installation. The foot plate of the geyser has to be fitted to the geyser before the bracket is fitted onto the foot plate. Novasun tanks are equipped with extra anchor points on the tank in order for the tank to be installed on an angle of 31 if so required on pitch roofs. Panel Bracket a) Description: Holding bracket attached to stainless steel strapping. b) Once the roof covering is moved away, the stainless steel strapping attached to the bracket is then wrapped around timber roof structure for anchoring the bracket. Be sure to secure the strapping onto the timber using tech screws or similar. Roof covering is then placed back into original position. b) The holding bracket is positioned underneath the panel in order to hook onto the bottom lip of the panel. The stainless steel strapping is then fastened onto the roof structure in the same way as the strapping of the tank. c) The bracket is placed underneath the geyser foot plate with the bolt sliding through the slotted hole and tightened using the wing nut as supplied. The holding brackets should be placed in position first and properly fastened to the roof structure using tech screws or similar. The roof covering can then be placed back into position and the panel positioned and secured into the holding bracket. 6

8 8. Mounting process 8.1 Suggested mounting method 1 Connect hanger bracket (D) to strapping (C), allowing enough length strapping for the flexible strapping to fit under the roof tile and wrap around the purlin/truss. Remove roof tiles and position hanger brackets. The collector is positioned into the collector bracket as demonstrated in the image above. A slight kick of 25mm from the cold inlet side to the hot outlet side of the collector is recommended (i.e. cold side lower than hot side by 25mm). In the case of sheet roofing, as depicted in the following image, a roof screw can be removed, the strap placed over the existing hole and the roof screw reinserted thereby securing the strap. In instances of sheet roofs, appropriate waterproofing needs to be effected to the roof surface after straps have been secured to the roof material. The bracket should be secured in place by fixing to the purlin. Fixings (i.e. screws, bolts, etc.) must be appropriate for the type of timber. Hard woods and soft woods require particular fixings. Fix the bracket in place as shown in the next image. The tank cradle (A) is positioned up against the top edge of the collector, with the foot of the cradle slid underneath the collector. Replace tiles once the bracket is fixed in place as shown in the next image. 2 brackets are required per collector. The collector clamp (B) is fixed to the tank cradle to lock down the top of the collector as depicted in the next image. The hanger bracket should be positioned on the peak of the tile and not in the valley. This helps prevent pooling of water and degradation to the brackets and possible leaks. The tank cradles should also be placed on the peak of the roof tile. Once the tank cradles are in place and the collector clamp fixed in place the geyser can then be positioned into the cradles as pictured in the next image. 7

9 In respect of the geyser, stainless steel strapping can be hooped around the geyser, on either end of the cylinder, using commercially available strap clamping ystems or other secure means of completing the hoop, leaving enough length to pass the tail pieces under the tiles and secured around the appropriate woodwork with appropriate fixings. As shown in the image below, the strap should fit closely around the body of the tank. Make sure that the tank is positioned in such a way that the drain cock is at the lowest point of the tank. Once the tank is in place, fix the hoop in place and replace tiles. Make sure that the tank is rotated to a position where the drain cock is at the lowest point on the geyser as pictured above. This will ensure that the maximum volume of water in the tank is available to be heated by the collector. The image below depicts the completed mounting of the system. 9. System Installation 9.1 General installation technique During fitting and prior to filling, the system must be protected against the entry of dirt and water. After the system has been mounted, it must be flushed in order to remove any debris (e.g. metal chips, packaging residue, sawdust, etc.). Larger tank sizes may require additional tank cradle brackets depending on the roof pitch. 8.2 Suggested mounting method 2 As an alternate to collector hanger brackets, aluminium straps could be used to secure the collector. Aluminium friendly speed screws can be used to secure the strap to the back of the collector frame. A strap needs to be fixed to each corner of the collector frame (i.e. four straps). Straps should be long enough to be fed underneath the roof tiles and then folded around the timberwork of the roof. The straps should be positioned on the peak of the tile and not the valley to prevent water from pooling and degrading the strap. The straps used should be of sufficient gauge to provide for a secure mounting of the collector. The image below depicts the view from below, with a tile removed. This demonstrates the strap fixed to the frame of the collector and then folded around the purlin. Fixings appropriate for the type of timber should be used (i.e. hard woods and soft woods require particular fixings). Shade panels until after connecting plumbing and installation is ready for commissioning in order to prevent heating of empty collector. Exercise caution during the lifting phase of installing the collector and tank onto the roof. Ensure that adequate personnel are present to bear the weight and that they are assisted with supportive lifting tethers and safety rigging. With reference to section 6 above, measure the size of the collector, and use measurement to locate the best position on the roof to affix panels, matching measurements to supporting roof trusses and purlins. Avoid interference with coping or gutters. A minimum distance between the top of the panel and the tank flow outlet is 300mm. In split system installations distances should be kept as short as possible and generally should not exceed 3 metres. For roof pitches above 30, special and/or extra strapping or brackets may be required to prevent downward movement of the tank and collector. Measure the exact size of your tank and use this to locate the best position on the roof at which to affix tanks to supporting roof trusses and purlins. If necessary, strengthen rafters used for securing the panel and tank, for example by adding noggins between rafters or adding thicker timbers alongside them (refer section 6.5 above). 9.2 Cylinder and System plumbing 9.2.1General Plumbing must conform to IOPSA code, SANS, PIRB and local regulations. In a thermo-siphon the geyser is installed above the panel, but kept as close as possible. All piping runs should be kept as short as possible, both between the collector and tank, as well as between the tank and the location of hot water usage (i.e. bathrooms). 8

10 All pipework must be properly insulated, as per our requirements, the cylinder & panel/collector insulated with 28x 25mm R-value 1 insulation, all pipework including at least two metres of the cold feed to and hot supply from the geyser. For Flat Roof installations insulation must also cover all open pipework leading into the roof space. Insulation material must be heat tolerant and UV resistant, nor must it unduly compress or cause corrosion. Verify that power is off with a volt meter and ensure that load shedding or existing timers are not active, which may cause the electrics to become live whilst working on the system. Power should not be applied to an empty electric water heater as heating elements will be damaged. Tank warranties would be void in these circumstances. 9.5 Installation Diagrams Various installation diagrams are illustrated below in order to assist installers with installation services. Approved installers must contact Solar Assist for system specific training and instructions prior to installing the Novasun SWH range. Thermosiphon System Installation diagram Installation Tip: For increased weatherability in harsh climate areas insulation can further be wrapped with aluminium duct tape or covered by a product such as Flash Harry membrane and coating. Piping from the flow of the tank to the inlet at the top of the collector must have a continuous fall and from the top of the collector to the return must have continuous rise. Only hard-soldered connections or compression fittings are to be used in the assembly of the solar heating circuit. No fluxing agents containing chloride should be used. Use copper pipe only. Plastic pipe must not be used due to the effects of high water temperatures and pressures. The pipe work to and from the geyser must also be copper for at least two metres below the hot water outlet. A temperature mixing valve must be used to control the temperature of water delivered to the points of use. This is important in the prevention of accidental scalding and is a SANS requirement. 9.3 Geysers Acknowledgement: Note: For purpose of installation demonstration no insulation has been shown here but insulation must be installed according to standard on all open copper piping as per paragraph Pumped System Installation Diagram The Novasun Solar Water Heating systems make use of WE Geysers (Pty) Ltd s Solartherm geysers cylinders, depending on the model selected. The manufacturers installation requirements that accompany each of these products must be observed in the installation process. Failure to do so may result in the warranty of these products becoming null and void. WE Geyser tanks are fitted with SABS approved peripherals. Geysers installed inside must have sufficient space for servicing thermostats and elements (Note: there are no anodes in Solartherm cylinders which require regular servicing), as well as allowing for the required SANS height of vacuum breakers above the tank 9.4 Electrical connection All electrical work must be carried out by properly qualified and registered electricians. Novasun recommends the installation of a time switch when undertaking a solar installation. This optimises the performance of the system and is specifically required when a rebate is to be claimed in respect of the Eskom incentive program. Note: For purpose of Pump controller installation and wiring instruction refer to the Geyserwise Installation manual or go to The time clock is fitted to the distribution board and is used to set the time periods that the thermostat and element receive electrical input. Time settings will be dictated by patterns of consumption, but for example could be set to activate from 3am to 5am and from 4pm to 6pm, taking care that the times do not fall within Eskom peak periods. Electric water heaters use 220 Volt AC power. The circuit breaker and isolator should be switched off before working on the geyser. 9

11 Pumped Controller Geyserwise System Acknowledgment: Geyserwise Installation Manual: For purpose of Pump controller installation and wiring instruction refer to the Geyserwise Installation manual or go to 10

12 10. System commissioning 10.1 Commissioning direct systems Make sure that the solar radiation is low during filling. In strong radiation it is possible for steam to form in the collector. Keep the collector covered throughout installation and commissioning. Do not turn on the electric backup until the tank has been filled with water. Turn on at least one hot water outlet tap and open the mains water supply to allow the water to fill the tank and collector, expelling air from the tank. As soon as water flows freely, without air sputter, close the tap and allow the cylinder to pressurise. Check all piping, joints and fittings for water leaks. Check pressure relief valves to ensure correct operation. Turn on the electric backup element. Make sure the tank is completely filled before turning on the element. Ensure power is available to the backup element. Ensure the time clock has been correctly set. 11. Installation checklist The following checklist should be observed by the installer before handing the system over to the owner/user. Any protective plastic or packaging stickers removed from tanks and/or collectors Owner instructed on use All air bled from taps System checked for water leaks Cold and hot water pipes checked for leaks Roof tiles back in position Roof flashing watertight Drain pipes free of obstruction Pipework insulated Electrical element, timer switch, isolator and thermostat, controller and pump checked 11

13 12. System Selection and Sizing 12.1 Introduction Individuals purchase solar hot water systems for many reasons. Some buy to realise savings on their energy spend, others out of concern for the environment, others as they have no other means of heating water or it could be a combination of the above. Whatever the motivating factor is it is important that the type and size of the system selected are going to best meet the consumers needs and expectations System sizing In deciding on the system required, apart from conducting a site visit to ascertain the proposed installation site and associated mounting, plumbing and wiring considerations, the sales representative should also consult with the prospective customer as to their hot water requirements. It is critically important that the prospective buyer provide accurate information in this regard, as the results of providing incorrect information can result in a system that either over or under performs, given the specific needs of the customer. The onus is on the prospective buyer to provide the sales consultant with an accurate disclosure of the hot water requirements and usage patterns in order that a load profile can be formulated. A load profile would include information such as how many showers are taken per day and how many litres are used, how many baths are taken and size of baths, how much hot water goes towards washing dishes and doing laundry, etc. Only once this information is analysed can a final recommendation be made on system size System type System type can relate to a number of system characteristics as follows: Direct vs. Indirect (refer section 5 above) Close-coupled vs. Split (refer section 4 above) The decision between direct versus indirect is described in section 5 above, but basically this is determined by whether or not frost or poor water quality dictate an indirect system. NOTE: THE DIRECT NOVASUN (THERMOSIPHON/PUMPED) SOLAR WATER HEATING SYSTEMS CAN BE USED IN ALL CLIMATE AREAS OF SOUTH AFRICA The decision between close-coupled and split system is largely an aesthetic decision based on customer preference, but there is a cost implication in that split system requires additional plumbing, system controller, circulation pump and mounting structures which translate into a greater installed cost. As the Novasun systems have been SABS tested in a thermo-siphon and pumped configuration and registered with Eskom accordingly, a split system installation can be claimed for on the rebate programme if the system is a thermosiphon or pumped system. That is, even though the tank is installed inside the roof there is enough space that the tank is above the level of the collector/s, allowing a thermo-siphon to operate or a pump to force the circulation. NOTE: Please visit for more information on system. 12

14 13. Owners operating and maintenance instructions 13.1 Introduction Dear Customer, Thank you and congratulations on your purchase. Your system is one of the most advanced available and is proudly produced in South Africa. It will provide years of service and savings. The information below is provided to give guidance in the effective use and maintenance of your system and should be retained for future reference. Yours sincerely, WE Geysers (Pty) Ltd 13.2 Operating and efficient use Savings in energy costs achieved is dependent upon usage patterns and the extent to which electrical backup is used. The following will assist in understanding system performance: Solar radiation is greater on clear, sunny days, between 9am and 3pm. During periods of use the system operates at approximately twice the maximum ambient temperature and during periods of non-use, it is possible to achieve well over 70 C. On days of high radiation schedule washing loads as close as possible to mid-day. On low solar radiation days avoid heavy hot water usage. Electrical backup, which is thermostatically controlled and governed by a time-clock, should be set at 55 C. The time-clock has battery backup in order to prevent settings being lost during general power failures. In order to claim an Eskom rebate, a timeclock is mandatory. We would advise the use of a time-clock in any event, as this is the most efficient method of operating a solar system. Time-clock settings should, generally speaking, be set for two hours in the morning and two hours in the evening. For example, if you bath at 06h30 and 18h00, set your time-clock for 04h00 to 06h00 and again for 15h00 to 17h00. Ensure backup time periods do not coincide with localised load shifting by municipalities employing ripple relay devices. This will ensure that if there was not sufficient solar gain during the day, you will still have hot water in the evening and early morning. Solar systems without time-clocks rely on thermostats to control when the element switches on and off. This is not efficient or cost-effective. An example of this would be, using hot water in the morning which causes the thermostat to automatically activate the element to heat your water. However, this is when the sun will start to heat your water. Therefore, if you do not have a time-clock or it is not programmed properly, you will not save as much energy as you will use both electricity and solar energy to heat your water simultaneously. An override function is provided on the time clock so you can over-ride programmed heating times and heat up your water electrically. This should only be used when strictly necessary (e.g. during periods of more than normal usage when guests are in the residence) and remembering to revert to pre-programmed settings. This will save you the optimum amount of electricity and provide the necessary reduction in peak-period use. If you wish to set your timer differently, you should discuss this with the dealer. However, your timer must not come on during Eskom s peak electricity use periods. These may change from time to time so please check with your installer. 13

15 Once you get used to the system and its optimum performance pattern, you may eventually completely switch the electrical backup off, particularly in summer months. An additional benefit of this is that it is the fastest way to reduce the system s payback period. Savings can be further maximised by using hot water in the evening rather than in the morning, maximising the free energy harvested during the day. water at the top of the storage cylinder transfers some of its heat to the cooler water in the lower section of the cylinder. This effect is often perceived as heat loss, but is actually the redistribution of stored heat more evenly over the entire contents of the storage tank. This may make it necessary to use the electric element to raise the water in the top section of the cylinder back to an acceptable temperature. Over-night temperature stabilisation is most evident in the morning if the time clock is left off overnight. Additional tips to enhance savings include: 13.4 High water temperature To further optimise energy and hot water savings, install aerated shower heads and aerators in taps to reduce hot water consumption. Insulate hot water piping to minimise heat losses. Showering generally uses less water than bathing. For health reasons your hot water system should provide water at 55ºC, but not much warmer than that. Do not set your thermostat backup temperature control for temperatures in excess of this. If shading of collectors is experienced between 9am and 3pm then corrective action should be taken. Annually prune or cut trees that shade the system. Partial shading by chimneys, TV antennas, roof erected fixtures, etc. on buildings during these hours is acceptable provided that it does not exceed 10% of the area. Shading from newly erected buildings should be checked and if system performance is affected, relocation of the system may be necessary Over-night temperature stabilisation Over-night temperature stabilisation is the reduction in water temperature, as the hot Your solar water heater will generate hot water quickly and efficiently. Under normal family use, it will operate between 60ºC and 70ºC. However, the temperature can exceed this and under certain circumstances may be as high as 75ºC. This can occur during prolonged periods of direct sunlight and particularly in summer or long periods of reduced water usage. Extreme care should be taken in these circumstances. Although every system is fitted with a mixing valve that regulates temperature at points of water use, check the water temperature before use, such as when entering a shower or filling a bath or basin, to ensure it is suitable for the application and will not cause scalding. It is required by SANS regulations, that a temperature limiting device / mixing valve be fitted to the system. This will limit the water temperature to 50 C at the point of use. The risk of scalding will be reduced, but water should always be tested prior to use to prevent injury in the case of a tempering valve failure Periods of reduced usage or holidays 14

16 If the water heater is left unused for two weeks or more a small quantity of hydrogen gas, which is highly flammable may accumulate in the top of the water cylinder. This is true of both conventional electric geysers and solar systems. To dissipate this gas safely, it is recommended that a sink hot tap be turned on for several minutes. Do not use a dishwasher, clothes washer or other appliance for this purpose. During this procedure there must be no smoking, open flames or any electrical appliance operating nearby. If hydrogen is discharged through the tap it will make an unusual sound like air escaping. It is recommended that if the system is going to be left unused for long periods of time, that the backup element switched off at the distribution board. Remember that when the geyser breaker is reactivated the time clock may have to be reset as it has a limited settings memory when switched off (i.e. approximately 72 hours depending on the model). This ON/OFF indicator indicates whether the time clock is currently active or not. This screen also displays the current actual time. Press the green function button to cycle forward to the next screen. SCREEN 2: Set Actual Time 13.6 Freeze protection liquid No freeze protection liquid is used in the Novasun system as the system inherently is protected against freezing conditions. (Passed SABS Freeze Test -20 C) 13.7 Setting the time clock WE Geysers (Pty) Ltd recommends that an SABS approved time clock, with battery backup, be installed on the distribution board. There are many such time clocks on the market and the operation of which are all relatively similar. A Samite QAT-R-DM time clock has been selected to illustrate how to program the time clock. Press the Hour and Minute buttons to set the actual time. Once the time is set press the function button to advance to the next screen. This time clock has four different screens. When it is powered up screen 1 (main screen) appears. SCREEN 1: Actual Time Indicator 15

17 SCREEN 3: Program Timer On/Off To program the desired timer settings press the off button to move the flashing segment to the time at which power is made available to the geyser thermostat/element. Once the segment is at the desired time, press the on button repeatedly to insert 30 minute backup segments until the time is reached when you want the backup period to end. These steps can be repeated if further backup periods are required. For effective operation an afternoon and an early morning backup period are recommended. EXAMPLE: Backup period from 3PM to 6PM Press the Off button until the program time indicates 15h00, then press the On button until the program time indicates 18h00. As shown below. SCREEN 4: Bypass on or off The timer programme is bypassed using this screen. Press the Bypass On button to bypass the timer and provide the geyser with a constant supply. The Bypass on display flashes. Press the Bypass Off button for power to be controlled by the timer and switch on according to the set times. Press the function button to return to screen one. Note: When in Bypass On mode the display will not revert to screen one after 60 seconds. Should you be away from home for any extended period and you wish to switch the geyser off at the breaker on the distribution board, please remember that you would have to re-programme the time clock on your return as the on-board 16

18 memory is only stored for approximately 72 hours without being connected. The use of the electrical backup is very much dependent on personal usage patterns of hot water. The following, however, are a few tips: During days with temperatures below 20 C, water temperature may only reach 40 C to 50 C. It could be lower if these colder days are coupled with overcast and rainy conditions. The human body generally prefers temperatures of between 35 C to 40 C for bathing during winter and therefore boosting may be required at certain times. Backup heating is generally preferable during late afternoon and early morning, so that maximum use of solar energy during the day is taken advantage of. The backup should not be set that it is on during periods when the water is being used. This because an element cannot heat the water with any efficiency when water is being used. If hot water use is heavy during the evening then it is vital that a backup heating period be set for the early morning if one desires hot water first thing in the morning Owner maintenance To ensure that the system will perform reliably, some preventative maintenance should be performed by the home owner/user. If the system is in a position which is not easily accessible or the owner is not in a position to effect the points below, a service technician should be employed to carry out the maintenance. The following should be performed annually by the owner/user appointed technician: Wash the glass cover of the collector with a mild household detergent. The collector glass and seals should be inspected. Mounting brackets and straps should be checked for signs of wear. Pipe insulation should be checked for signs of degradation and/or damage. Please note that although UV resistant insulation is used, the harshness of the South African climate means that the insulation will not last indefinitely. There is no warranty on pipe insulation. Visually inspect pipework for signs of leaks, scale build-up. A periodic inspection of pressure reducing valves, expansion valves, vacuum breakers, temperature pressure valves and tempering valves should be conducted on a solar geyser, just as it should be done on any conventional electrical geyser. These valves allow for the safe operation of the geyser and should be inspected twice yearly. The temperature pressure (TP) valve is near the top of the water heater and is essential that this valve operates safely. It is possible for the valve to release a little water through the drain line during each heating period. This occurs as heated water expands by approximately 1L out of 50L of its volume. If continuous leaking occurs this may indicate a problem with the valve - please report this to your installer immediately. WARNING - Never block the outlet of this valve. TP valves should be checked for performance at intervals not exceeding 6 months, or more frequently in areas of high incidents of water deposits (such as Calcium or Magnesium).Be advised that in areas or periods of high solar radiation there will be greater frequency of this valve opening. In order to check the TP valve the easing gear should be operated. This is a black knob on the TP valve that needs to be turned in an anti-clockwise 17

19 direction and some water allowed to escape. Be aware that this water may be at a high temperature. Before opening the valve make sure you are well clear and be advised that the geyser will be under pressure so water may be expelled at a high rate. Guard carefully against exposure to the water whether through direct contact or through back splash. Be careful not to confuse the TP valve with the solar relief valve fitted on some indirect systems. Please contact your installer for advice if unsure. If at any point the temperature at point of use (e.g. bathroom) appears to be increasing or decreasing, the temperature mixing valve may need to be set or adjusted accordingly Troubleshooting Failure to observe safe practices may result in: scalding / burns; electrical shock; and/or falling, which can cause serious injury or death. Should your system not provide hot water please check the following before requesting a service call: Warning When inspecting your system please bear the following in mind: The removal of the electrical cover plate on the solar geyser will expose 220 V wiring. It must only be removed by an authorised electrician or service person. Care should be taken not to touch the pipe work connecting the solar storage tank and the solar collectors. Very high temperature hot water can be generated by the solar collectors under certain conditions, and will flow through the pipe work from the solar collectors to the solar storage tank. Working at heights should only be undertaken by suitably qualified personnel, using the proper safety equipment. Shading from trees is not excessive and is not covering the collectors for all or part of the day. Hot water usage has not been excessive. Hot water is not leaking from within the plumbing system that feeds hot water to the points of use. The time clock/cntroller is operational and has been programmed correctly. The electric meter and/or display light on the time clock speeds up when the time clock is active. Power has been provided to the main board (i.e. no electrical faults or load shedding). The ripple relay has not become jammed in the open position. The water supply to the home has not been interrupted (i.e. municipal shut-off) Please contact your local dealer and/or installer if all of the above have been checked and there is still no hot water. A charge out fee may apply if the system is found to be functioning correctly and the matter relates to one of the above issues. 18