Solarland Evacuated Tube Solar Hot Water System Installation & User Manual

Transcription

1 - 1 Solarland Evacuated Tube Solar Hot Water System Installation & User Manual Rev: SERVICE

2 - 2 Table of Contents 1. INTRODUCTION KEY FEATURES & BENEFITS IMPORTANT INFORMATION INSTALLATION MAINTENANCE TROUBLESHOOTING WARRANTY SYSTEM DRAWINGS BILL OF MATERIALS... Error! Bookmark not defined.

3 INTRODUCTION Congratulations on your purchase of a Solarland Evacuated TubeSolar Hot Water System (SETSHWS). Your new water heater combines state-of-the-art evacuated tube solar collector technology, & ether long-lasting stainless steel or vitreous enamel water storage tanks & the choice of highly efficient gas or electric boosting. A SETSHWS is designed to provide years of reliable service by harnessing clean, thermal energy to heat your water, free from the sun! The result is big reductions on your water heating bills & your Greenhouse gas emissions. Installing for superior performance In order for the collector to operate reliably at optimal efficiency, it must be correctly installed. Please ensure that you employ the services of a certified installer who will ensure the installation follows the manufacturer s guidelines & meets all government & health regulations. Easier Installation The SETSHWS has been designed with ease of installation as one of the key design features. This manual includes a clear step-by-step installation guide. If you come across any issues not covered by this manual during the installation please contact your Solarland accredited installer or Representative Agent. This manual explains the operation & installation requirements for the Solarland evacuated tube electric & gas boosted systems, both which use a small wattage circulation pump for solar heating purposes. Recommendations from AS/NZS 3500 Part National Plumbing Code Solar Water Heaters Installation form the basis for this manual. Regulatory requirements which are additional must be complied with.

4 KEY FEATURES & BENEFITS * Solarland evacuated glass tubes provide superior daily heat output due to the cylindrical absorber shape always being perpendicular to the sun. * Insulation properties of the vacuum in the Solarland solar evacuated tube allow 94% of the heat from the sun to be retained. * Copper heat pipe & header rapidly transfer heat to the circulating water from the storage tank passing through a well insulated manifold ensuring maximum solar heat gain. * Fibreglass insulated collector manifold, sealed evacuated tubes & freeze protected heat pipes allow reliable in even the coldest areas & on cloudy or overcast days. * Solarland collectors need no glycol or chemicals in frost prone areas. Systems that use glycol lose up to 10% performance & need regular changing of the glycol which can be costly. * Solarland evacuated glass tubes are naturally self cleaning when it rains due to their cylindrical shape & thus do not lose performance from collector being coated in dirt & pollutants. * The internal copper manifold pipe in the Solarland collector is 35mm in diameter (larger diameter allows greater water flow) & therefore is also excellent for thermosiphon systems. * Anodised Aluminium collector frame provides both strength & long term corrosion resistance. * Super quiet, low energy solar circulation pump (<28 watts when on) *Automated pump operation. Lew temperature protection & pre-wiring sensor lead via the Solarland Controllers ensure easy installation & reliable operation. Solarland Storage Tanks & Boosting * Choice of either an Everlast stainless steel or Solarland vitreous storage tank, gives customers more choice & options. * For both gas & electric boosted systems, the Solarland collector, using advanced heat pipe technology, provides not only high solar conversion efficiency but protection against freezing & leaking of any water through the evacuated glass tubes. * Storage Tanks incorporate a high level of insulation (50mm thick) to keep solar hot water hotter longer as well as exceeding industry standards.

5 IMPORTANT INFORMATION Safety: Australian/New Zealand Standards Installation must be completed in accordance with the requirements of AS/NZS 3500 & Australian Standard AS/5601 for installation of the Rinnai Solar booster (in accordance with AG 601). Qualified Installers Installation must be completed &/or checked off by a qualified plumbing professional or as agreed by Solarland Australia. Plumbing Ensure all flow & return pipes are copper with no plastic connections ALWAYS WEAR PROTECTIVE GLOVES & EYEWEAR WHEN H&LING EVACUATED TUBES Always ensure the water pressure is limited to 500 Kpa Ensure non return valves are fitted on the pump outlet side. The installation of this solar water heater should not compromise the structural integrity of the building Should the collector be located where is could be vandalised it may be necessary to install protective guards that do not detract from the collectors performance. Collector and Tank specifications (* All height dimensions are from the ground) Tank Tank Tank Hot Water Return Flow Cold Water Element Dry Size Height Diameter Outlet* (to tank)* Inlet* KW Weight 250l Stainless 1610mm 566mm 1190mm 370mm 168mm kg 315l Stainless 1965mm 580mm 1495mm 425mm 168mm kg 250l Vitreous 1400mm 650mm 1170mm 380mm 170mm kg 315l Vitreous 1690mm 650mm 1470mm 574mm 75mm kg 30 Tube Collector 2350 x kg 20 Tube Collector 1670 x kg 10 Tube Box 880 x kg 300 x 250 x 2000

6 - 6 Pressure A pressure limiting valve of 500kPa maximum (PLV15/500), must be fitted as the cold water mains pressure frequently exceed 500kPa. A pressure limiting valve can protect your hot water tank & other appliances that use water such as washing machine or dishwasher by limiting the water pressure that goes into them & hence prolonging their working life. Failure to install a pressure limiting valve will void the warranty. This system will not operate efficiently with less than 300kPa (see attached Appendix 1). Note: In SA, WA (& some other areas of other states subject to local authority regulations) it is a requirement that an expansion control valve be fitted between the non-return isolating valve & the water heater. Pressure Temperature Relief Valve (PTR) a) The Solarland storage tank is fitted with an 850kPa PTR Valve, which is located on the side of the cylinder & is essential for its safe operation. We recommend you operate the easing knob or lever on the PTR valve once every 6 months. It is important you rotate the knob or lift the lever gently & don t let the valve snap back to its seat as this can cause damage to seat & potential leakage. b) The PTR Valve is designed to allow small quantities of hot water to discharge during heating to allow for hot water expansion. Water Quality Water in direct flow through the manifold header must meet the following requirements: Total dissolved solids < 600 mg/litre or p.p.m. Total hardness < 200 mg/litre or p.p.m. Chloride < 250 mg/litre or p.p.m. Sodium < 150 mg/litre or p.p.m. Magnesium < 10 mg /litre or p.p.m. ph Levels In areas with hard water (<200ppm), lime scale may form inside the collector header pipe. In such regions, it is advisable to install a water softening device to ensure the long term efficient operation of the solar collector, &/or use a close loop for the Solarland collector. Corrosion Both copper & stainless steel are susceptible to corrosion when high concentrations of chloride are present, & therefore use of this system to heat chlorinated pool or spa water will void the Warranty. Chloride levels present in most recirculated public potable water supply are safe for use in the solar collector provided there is no use of bore waters in the recirculated supply. To use Solarland collectors in heating swimming pools a plate heat exchanger will be required. Refer to Warranty. Freeze Protection Freeze protection is incorporated into the Solarland Controller with a Low Manifold Temperature pump circulation feature, which turns the pump on if the manifold temperature, drops 4 C & turns off again when the temperature rises to 5 C. The collector does not need integrated manifold freeze protection as the Solarland evacuated tubes & manifold are not susceptible to damage in cold weather. In areas of sub zero temperature & known power outages, it is recommended to install a UPS (Uninterrupted Power Supply) power supply to ensure continued power supply to the controller & pump should the power be interrupted.

7 - 7 Stagnation & Excess Heat Stagnation of the water in the manifold occurs when the recirculation pump stops to prevent the storage tank from overheating during periods of high sun load. The recirculation pump stops when the storage tank reaches 80 C however the collector will continue draw heat from the sun & potentially boil the water within. Due to the small amount of water within the collector the effect of the boiled water should have little effect on the overall system & in worst case the TP or cold water expansion valve may trickle discharge a small amount of water during heating or hot weather. Wind Stress When installing the Solarland collector please consider the issue of wind resistance & the resultant stress on attachment points. The standard frame, Low Pitched roof frames or A-frame for flat roofs are designed to withstand wind speeds of up to 180km/h 112 mph without damage, but roof attachment points may not be as strong. In areas in high wind load (cyclone areas) the collector mounting frames should be mounted within 100mm of the roof truss. When installing collectors other than the standard frame in high wind load areas you should obtain design approval by an authorized engineer. Hail Resistance Testing has proven the Solarland evacuated tubes are able to withstand impact from hail up to 25mm (1 ) however if the collector is to be installed in areas of know hail storms with hail larger than 25mm it suggested the collector be mounted at an angle of 40 degree or greater. 4. INSTALLATION Unpack & Inspect Component List Please familiarise yourself with the components listed on the packing list which is included in the manifold box. If components from any package are missing please contact your supplier who will have spares in stock. Tube Inspection Open the tube box(s), which contain both evacuated tubes & heat pipes combined. See Picture to the left. Check to make sure the evacuated tubes are all intact, & the bottom of each is still silver. If a tube has a white or clear bottom, it is damaged & should be replaced. Each evacuated tube contains alloy heat transfer fins which hold the heat pipe in place in the centre of the evacuated tube. Do not remove &/or expose the tubes to sunlight until you are ready to install them, otherwise the inner tube & heat transfer fin will become very hot. The outer glass surface does not become hot under normal operating conditions.

8 - 8 Heat Pipes Solarland heat pipes are centrally located & pre-inserted into the evacuated tubes to reduce the installation time. Due to the Solarland heat pipes being pre-inserted & sealed at the top of the evacuated tubes as well as having tapered ends on the bottom of the heat pipes they are naturally frost protected down to -15 C. This makes them the natural choice in cold climates & frosty climates. Frame Unpack the frame that is packed together with the manifold. If an adjustable angle frame (Aframe) is also being used, it will be packed separately. It may be necessary to purchase bolts or other fasteners to suit the installation surface. The attachment plates & bolt required to attach the manifold & bottom track are already in place on the frame front tracks. For each frame front track, there are two extra sets of bolts that can be used for securing the roof attachment straps. Positioning Collector Direction Facing the collector in the correct direction & at the correct angle is important to ensure optimal heat output form the collector. Where possible the collector face due north in Australia for best performance. Note: The Solarland collectors if angled NNE or NNW will have reduced sun exposure than true north. If true north is not achievable it s better to have the collector facing NNW rather than NNE in order to gain the afternoon sun which generally has more intensity. See below. Collector Angle Solarland evacuated tubes perform best when installed at an angle of between 20 & 70. Where possible the Solarland collectors should be installed at an angle equal to the location s latitude unless the latitude is less than 20. In the table below are suggested ranges if pith for major cities. If a roof has an angle less than 20, it is advisable to use a pitched roof frame be installed to ensure optimal heat pipe operation. The heat pipes operate best when set to a minimum angle of not less then 20. Note: Angling the collector greater then the Optimum Pitch for Performance will give better performance in winter whilst decreasing performance in summer. This might be needed in areas where there is more heat generated in summer than is required. Optimum Winter Angle is obtained by multiplying the latitude for a given area by 0.9 & then adding This angle may avoid any potential overheating in summer but will conversely decrease summer performance. Location Latitude Acceptable Range of Pitch Optimum Pitch for Annual Performance Optimum Winter Angle Adelaide Alice Springs Brisbane Canberra Darwin Hobart Melbourne Perth Sydney Avoid Shading Collectors should be located so that shading does not occur for at least 3 hours either side of 12 noon standard time. Partial shading due to small objects such as antennas or a small flue is not of concern.

9 - 9 Location of the Solarland Collector & storage tank. Solarland evacuated tube solar collectors should be positioned as close as possible to the storage cylinder. Storage cylinders should be located as close as possible to where the hot water demand is within the house to prevent water wastage. The location of the tank often ends being a compromise between proximity to collector & service & this should be considered carefully. If possible always have the longer section of pipe run as the flow line (tank>collector) Note: When installing this solar hot water system it s very important that you DO NOT compromise or alter the building structural integrity in any way Storage Tank Solarland offers a range of storage tanks including electric & or gas boosted systems stainless steel & vitreous enamel & vitreous enamel gas storage cylinders. WARNING! VITREOUS ENAMEL TANKS: IF THE HOT WATER SYSTEM IS NOT USED FOR TWO WEEKS OR MORE, A QUANTITY OF HIGHLY FLAMMABLE HYDROGEN GAS TO ACCUMULATE IN THE WATER HEATER. TO DISSIPATE THE GAS SAFELY, IT IS RECOMMENDED THAT A HOT TAP BE TURNED ON FOR SEVERAL MINUTES OR UNTIL DISCHARGE OF GAS CEASES. USE A SINK, BASIN OR BATH OUTLET BUT NOT THE DISHWASHER, CLOTHES WASHER OR OTHER APPLIENCE DURING THIS PROCEDURE, THERE MUST BE NO SMOKING, OPEN FLAME, OR ANY ELECTRICAL APPLIENCE OPERATING NEARBY. IF HYDROGEN IS DISCHAGED THROUGH THE TAP, IT WILL PROBABLY MAKE AN UNUSUAL SOUND AS WITH AIR ESCAPING. Where tanks are installed in areas where leakage may cause damage, a properly drained safe tray under the heater must be installed. For external installation of the storage tank a plinth or concrete base pad is recommended in accordance with Australian Standard AS clause A concrete base pad simply provides uniform even support. Where tanks are mounted indoors it is requirement to install an under tray in accordance with AS where leakage may cause damage. Gas Booster Two gas boosting systems are available; Rinnai (20s & 26s). Both Rinnai Solar Boosted systems are for external installation only in accordance with AG 601 (Now covered by Australian Standards AS 5601). Installation location must meet the prescribed requirements in respect to clearances for the flue terminal for Gas Boosted systems. The Rinnai S26I can be mounted indoors when installed with the Rinnai internal flue kit. Solarland Controller Settings The delta T (Turn-On & Turn-Off differential settings) of the Solarland Controllers are designed to ensure optimum pump cycling as the Evacuated Tubes are heating. When the collector is 8 C hotter than the tank then the Controller turns the Solar Pump on & it turns off again when the difference decreases to 1 C. There is also a freeze protection setting programmed into the Controller that turns the Solar Pump on when the temperature drops to just 4 C for added safety. Please note that the frost protection is factory activated on the Solarland Controller. Another feature built into the controller is a maximum tank temperature feature which turns the pump off when the tank reaches 80 protecting against overheating of the storage tank. Note: In the unlikely event that you need to move the tank or drain the tank during the day you will need to ensure the power supply to pump & controller is disconnected during this time.

10 - 10 Mounting Frame All Solarland collectors come with a standard anodised alloy frame that can be attached directly to metal roofs or tiled roofs where the pitch is greater than 20. Where the roof is flat or the angle is less that 20 it is recommended the use of a additional pitching frame which to increase the mounting angle as close as possible equal the latitude of the installation. Frame Material All frame components are made up of 2.8mm thick marine grade extruded alloy making them frame both strong & corrosion resistant. It is important that frame attachment points & fasteners are also of suitable structural strength & corrosion resistant. Galvanic Reaction between Aluminium & Zinc Galvanised Steel or Colorbond Zinc or Zn/Al galvanised components should NOT be installed in direct contact with Alloy, as galvanic reaction between the two metals can cause premature corrosion of the zinc coating & the steel underneath. Galvanic corrosion potential between common construction metals METAL Alum. Brass Bronze Coppe r Galva n Steel Iron/ Steel Lea d Stainless Steel Zinc Aluminum n/a Copper n/a Galvanized Steel n/a 2 3 n/a 3 Lead n/a 2 3 Stainless Steel* n/a 1 Zinc n/a 1. Galvanic action will occur with direct contact 2. Galvanic action may occur 3. Galvanic action is insignificant between these metals *Active stainless Steel Roof Installation Three types of roof installation are outlined in this guide: 1. Installation on a pitch tiled or corrugated roof. 2. Installing on a low angle pitched roof. 3. Installing on a flat surface. Frame & Bottom Track Attachment Both the manifold & frame bottom track are secured to the frame front tracks using special attachment plates. They are designed such that when loose, the manifold & bottom track are able to slide left & right. This allows the front tracks to easily be adjusted to suit the roofing surface, for a Low Pitched frame or Adjustable A-frame. Once the frame is correctly aligned the nuts should be tightened using a spanner, locking the manifold & bottom track in place. It is a good idea to only finger tighten the bolts that hold the

11 - 11 manifold in place until after you have inserted all the evacuated tubes at that way when you have a bit of play in case the tubes are a tight fit. Note: The bolt is up-side-down with the nut on top. This allows the thread to be viewed & as such prevents the installer from loosening the bolt so much that the nut drops off. Next click all the Locking Caps into the Bottom Track so that they are all flush. After all the tubes have been inserted into the manifold you can then fully tighten the locking bolts at the back of the manifold. Customising the Frame The standard frame, Low pitched frame & A-frame kit components can be used creatively to suit a range of different installation situations. Additional holes may be drilled in the frame as required (9mm fits the supplied bolts), but ensure that frame structural integrity is not compromised (i.e. drilling holes to close together). Flush Pitched Roof Installation When the angle of the roof pitch is close to the desired installation angle, the collector may be flush mounted onto the roof. Installation Planning In order to minimise the number of tiles that need robe removed (& returned in place), please carefully plan the location of the manifold, & frame front tracks & plumbing pipes. Positioning Manifold The manifold & bottom track can slide left & right in relation to the frame front tracks, so there is some flexibility when selecting the location for the frame front tracks. Generally the frame front tracks should be located such that they lay flat & even on the roof ( match the tiles) & also line up with the roof frames timbers, if possible try to locate then under the 1 st & 2 nd tube from each end. Roof Attachment For tiled roofs the 600mm long roof attachment straps should first be secured under the tiles using the 80mm roof screws & then to the underside of the frame front tracks using the M8-20 stainless steel bolts & nut assemblies. The picture to the right show a strap at the top of one of the front tracks. Another strap should also be attached lower down each front track to provide an additional attachment point. Attachment to the roof should be completed with the 50mm roofing screws through the roof truss. Note: You might need to drill a small pilot hole if the wood you are screwing into is very hard. Please ensure that roof- anchoring points are very sturdy. You can even use two 75mm roof screws per steel strap to give a more secure hold if needed. Once the upper straps are attached & tightened, adjust the bottom straps to ensure that they are too providing support to the frame. In effect the frame hangs off the roof. The rubber blocks that are supplied that fit under the frame can be used on tiled roofs by using a dab of silicon & sliding the rubber blocks under uniformly appropriate areas of the frame. Note: The steel straps should be positioned so that they go down the trough of the tiles. If you find that the rafter does not exactly line up with the trough in the tiles then you can bend the steel strap after connecting it to the rafter so that it will be in the correct position.

12 - 12 Colorbond/Zincalume/Galvanized/Corrugated Roof For installation on a corrugated iron roof, use heavy duty roofing screws (14-gauge 90mm long with plastic washer) in combination with the rubber frame mounting blocks that are also supplied. The rubber frame mounting blocks fit perfectly under the frame allowing the roofing screw to go through the centre hole. The 14- gauge 90mm roofing screws need a 5/16 th inch drill socket. Standard roofing screws can be removed using a 5/16 th inch drill socket. Check your roofing screws to be certain which drill socket(s) you will require when installing the Solarland collector. Note 1: If you find that your current roofing screws do not line up with the pre-cut holes in the Solarland alloy frame you can drill an extra 9mm hole using a standard twist drill for drilling steel. Alternatively you can also use the steel roofing straps supplied to secure to the frame & connect to a roofing screw using one of the runner frame blocks to stop the strap & the roof touching. Note 2: The collector frame must be fastened to the roofing battens using 9 X 90mm screws for 20 & 30 tube collectors & 6X 90 mm for a 10 tube collectors. The rubber blocks are used on both metal & tiled roofs Correctly Align Frame Please make sure that the front tracks are both parallel & level. An uneven frame may result in damage to the system in particular the evacuated tubes. Flat Roof Installation (A-Frame) The adjustable angle frame (A-frame) is appropriate for installation on flat surfaces, or roofs that have a reverse slope, & provides adjustment from The A-frame kit provides the additional components required to assemble the complete A-frame. Note: The standard frame that comes with every system consists of the front tracks & bottom track & these components are also used in the A-frame. Number of Legs A 10 tube collector A-frame uses two side Tracks & one rear cross brace. The 20 & 30tube collector A-frames utilise three tracks & rear legs, as well as two rear cross braces. Front Track Positioning For the A-frame, the position of each front track is fixed, as dictated by the rear X braces & front braces. If the location of the front tracks need to be adjusted, these two components can have additional holes drilled & be cut to length. The standard location of the left & right Front Tracks is directly beneath the second tube from each end. For 30 tube collectors which have a third set of Front Track & Rear Leg, the centre Front Track is approximately located between the 11 th & 12 th, or 15 th & 16 th tubes respectively. Adjusting Frame Angle

13 - 13 The rear legs of the A-frame comprise two interlocking pieces (top & bottom leg), which allow the length of the rear leg to be adjusted, thus changing the collector angle from between If an angle less than 35 is required the top legs may be cut short allowing a lesser angle; in such cases the bottom leg component is not required remember though that the collector requires a minimum angle of 20 for optimal operation. If the top leg is cut short, the rear X brace holes will not match the rear leg s holes, in which case additional hole in the rear X-brace must be drilled. The rear X-brace must always be installed as it provides lateral rigidity to the Frame. Plumbing Plumbing Connection Once the frame has been mounted & the manifold attached, the manifold header may be connected to the system plumbing. Do not use plastic olives on any compression fittings on the solar flow & return lines as they will not stand up to the heat that the Solarland collector produces. Please use only copper olives as they are designed to withstand higher temperatures. Solarland systems are delivered complete with a Pump station including the Solarland Controller and Grundfos pump to ensure correct pump orientation. Note: The Solarland evacuated tubes should be inserted last after the system has been commissioned, if you wish to install them all at the same time then cover them up until the pump is on & the system commissioned. No water actually enters the evacuated tubes themselves as the heat pipes conduct the heat to the manifold so therefore no water can ever leak for the evacuated tubes.

14 - 14 Choice of Piping Material. AS 1432 approved copper pipe should be used for the system & be properly insulated using high level thermal lagging such as UV stable Armaflex or simular etc. Keep pipe runs short as possible to reduce any possible heat losses. Do not under any circumstance use plastic piping for the solar flow & return lines. Pressure Levels Regardless of the installation configuration a pressure & temperature relief valve rated at 850kpa must be installed in the storage tanks unless using a non pressurized gravity feed storage tank. The cold water supply should be limited to 500kpa using a pressure limiting valve. It area of know high solids & cold water expansion valve should installed to prolong the life of the temperature pressure relief valve. Tempering Valve (Solar Hot Water Systems) It is recommended, & may be required by regulations that a tempering valve be installed into the hot water supply line incorporating all sanitary household hot water outlets such as bathrooms, ensuites & wash basins as this will reduce the risk of scalding. The tempering valve recommended for solar hot water systems is the orange cap valve as it has been specially designed to work with the higher temperatures that solar hot water systems can produce. Standard tempering valves are only rated up to 90 C but the orange top one is rated up to 99 C. The tempering valve controls the temperature of the hot water coming form the storage tank to a maximum of 50 C thus preventing serious burns in sanitary outlets in the house. In new home installations, this is a requirement of the national Plumbing Code AS Note: It is a recommendation of AVG that tempering valves should be checked every year for correct temperature delivery & replaced every five years. The AVG valve is now included as part of the system and should be installed as part of warranty. Inlet & Outlet Connection to the Collector There are two 22mm ports at each end of the collector that can be interchanged & used as either inlet or outlet ports. Both ports have a corresponding 10mm temperature sensor socket next to them, however, the 10mm sensor socket next to the port used as the outlet is where the temperature sensor should be placed. Using the sensor well next to the inlet port can result in the pump cycling incorrectly. Two 22mm (C) compression to 15mm (M) male thread connectors are supplied if low water pressure is encountered or if the manifold is to be used for thermo syphoning. No Brazing Permitted Do not braze copper pipe directly onto the manifold ports as the rubber seal could melt. Only use the supplied DR Brass compression fittings (or locally available equivalent) which provides a male ½ or ¾ BSP thread. Always use two opposing spanners when tightening the compression fitting. DO NOT twist the copper pipe as the header may be damaged. Plumbing Check Once plumbing is confirmed as running correctly, leak free & with all air having been purged, the evacuated tubes containing the heat pipes may be inserted into the manifold. To Remove the air form the system, turn the power on to circulating pump & crack the solar return pipe at the tank (care needs to be taken as this water can be extremely hot). Once all the air has escaped from the pipes, tighten the pipe & check for leaks.

15 - 15 Insulation It s important to insulate the flow & return lines completely with good quality insulation such as Armaflex or equivalent. External & internal piping that is subject to low temperatures should have an appropriate insulation thickness of either 19mm dependant on the relevant plumbing codes. Where possible use a high grade UV stable product where it s exposed the sun light, if unsure of its UV rating the insulation should be shielded with a suitable UV stable product such as foil. It should be noted that up to 60% heat loss can occur due to poor or non insulation of pipes carrying hot water. Solar Circulation Pump & Controller The Solarland circulation pump should be connected on the solar flow line as close as possible to the bottom of the tank. The Solarland Controller units may be mounted on any vertical surface adjacent to the water heater, or attached to the storage tank outer casing. Arrows embossed on the pump body indicate the direction of water flow. Arrows on the pump should wherever possible point upwards as this ensures that air will not lodge in the pump & that the motor shaft axis is horizontal. If using the larger 3-speed pump you will generally use either speed 1 or 2. When using the larger Grundfos ECO, the pump should also be in the horizontal plane. Note: Pumps must be protected from severe weather to prevent water ingress. The circulation pump controller should be fitted & connected in an accessible position. Controllers have an extended use IP rating IP54. The power supply to the circulation pump shall be from circuits that are not subject to switching by the electrical supplier for the purpose of load management. In areas that are subject to frost, the power supply must not be turned off as per the instructions on the power supply lead. In frost or power out areas use a UPS. The Solarland Controller unit is a differential thermostat which turns the pump on & off in response to temperature signals received for the sensor located in the Solarland Collector. A tank sensor is also located at the Storage Tank. It is crucial that the sensor leads are installed with care in order that they are not cut or damaged. Note 1: If the Collector Sensor wire needs to be extended then this is a good indicator that the larger pump might be needed to pump the extra distance. Pipe runs longer than 15 meters (from the tank to the collector) low water pressure & more than 6m head pressure the 3 speed recirculation option should be selected. Note 2: If the system is supplied from tank water & pressure pump, you should select the three speed recirculating pump option the system may not work as intended and prohibit optimum results. Insert the probe into the sensor well on the solar tube collector so that the end of the brass probe sits just inside the copper sensor well & the wires are showing only. Do not push the sensor probe all the way down in the sensor well. Seal the sensor well with a dab of high temperature silicon sealant to prevent the ingress of moisture & dirt. Install the tank sensors into top & bottom sensor ports on tank as labelled. Collector sensor located on the outlet port

16 - 16 The Solarland Controller has two main functions: 1) When the collector temperature is 8 hotter than the bottom of the tank, the controller will activate the pump (delta T). 2) Freeze protection mode- When the temperatures in the Collector Panels drops to 4 C, the pump switches on to recirculate a small amount of hot water around the system. When the temperature rises to 5 C, the pump switches off. This ensures that any part of the system that is not insulated will not freeze. If you live in an area that is frost prone & regularly experiences power failures you might also consider installing a low cost UPS (Uninterrupted Power Supply) to ensure the pump & controller continue to work even if there has been a power failure. The controller & pump will resume normal operation after a power failure with no need to reset. In the event the pipe work or collector does freeze & damages the pipe work, you should isolate the water supply to the solar system & turn off the power & gas supply to the booster & solar controller until the problem is rectified. Gas Connections & Gas Piping (Gas Boosted Units Only) The Solarland Evacuated Tube Solar Hot Water System incorporates a Rinnai Gas Booster which is a Type A Appliance in accordance with AG The Gas Installation Code, applies to all general work & safety requirements, materials & gas piping, installation of gas piping, appliance installation & commissioning. The gas booster can be mounted either on an adjacent wall or externally if the storage tank is inside. Start-Up Procedure Step 1 Fill the water heater by opening all hot water taps & operating the cold water inlet to allow the heater to fill up & air in the system to be expelled. Close each hot water tap, as the flow becomes free of air. Step 2 Check the pipe connections for leaks. It will be necessary to loosen the top fittings on the Evacuated Tube Solar Collector & allow all air to be expelled from, relying on the mains water pressure to ensure that no airlocks remain. Power to the pump should not be turned on until the water heater is completely filled with water. Step 3 After verifying the system to be leak free, turn the pump & collector on at the power outlet. Correct controller operation can be determined to determine the green light comes on the controller face. The operation can be tested by placing the bottom tank sensor in hot water until which should turn the controller light to red. Step 4 Gas supply & power to the Rinnai Gas booster may be turned on & the unit checked for the presence of leaks. The Gas Boosted operation of the heater should be checked. Evacuated Tube/ Heat Pipe Installation The Solarland evacuated tube solar collector is a simple plug in system. The heat pipes & evacuated tubes just need to be plugged into the manifold after applying thermal paste to the head of the heat pipes. The contact between the heat pipe condenser (top of the heat pipe) & heat pipe header port in the manifold needs to be tight in order to ensure good heat transfer. Applying the supplied thermal paste ensures that both the heat pipe & header port to be in close contact.

17 - 17 DO NOT INSTALL THE HEAT PIPES & EVACUATED TUBES UNTIL SYSTEM PLUMBING IS COMPLETED & SOLAR PUMP & CONTROLLER OPERATIONAL Unpacking The heat pipes & evacuated tubes are pre inserted & are packed in the same box. a) Ensure that the heat pipe is snugly inserted into the evacuated tube & the top of the heat pipe is straight. b) Check the evacuated tube is silver at the bottom ensuring the vacuum is good. Evacuated Tube/Heat Pipe Insertion into Manifold a) Coat the tip of the heat pipe with a thin layer of thermal paste supplied & lubricates the top outer surface of the evacuated tube with a wet rag. The water will allow the tube to easily slip through the manifold rubber ring seal. You should always use gloves so as not to dirty the evacuated tube & protect your hands in the event of breakage. DO NOT ALLOW ANY WATER TO ENTER THE TUBE b) Whilst firmly holding the evacuated tube about mid length, pull the heat pipe out of the tube by 30-40cm; guide the heat pipe tip in past the manifold rubber seal, & into the heat pipe port. Push the heat pipe up to the manifold ensuring the bulb in hard up into the port. c) Using a slight left & right twisting action, push the evacuated tube up into the manifold. To alleviate the evacuated tube sticking to the outer rubber ring on the manifold, lubricate the rubber ring or top of tube with a small amount of water. The evacuated tube will push against the heat pipe condenser pushing the heat pipe fully into the manifold port. The heat pipe & evacuated tube are fully inserted once the black coating of the evacuated tube has disappeared up into the manifold (no clear glass visible) & the bottom of the tube sits correctly in the bottom locking cap. d) After insertion of each tube, secure the tube in the locking cap & tighten carefully the screw located at the base of the locking cap until the tube doesn t move. Note: Minimal pressure is required & care should be taken not to over tighten as the screw only needs to be up against the protective cap on the base of the evacuated tube to stop it from moving. Post Installation Cleaning Clean each tube with a liquid glass cleaner & cloth/paper. A sponge with clean water is also very effective. System Operation Solar radiation is greatest between 9am & 3pm & on clear sunny days. The controller will monitor the temperature of the water in the Solarland collector, returning it to the storage cylinder once the temperature rises by a set amount of 12 C above the storage tank. The Collector then turns off the pump when there is only a 6 C difference between the collector temperature & storage tank temperature. Note: The Solarland collector can remain quite hot even when the sun has disappeared & therefore still retains enough heat to continue heating water. The pump therefore can still be going up to an hour or so after the sun has gone down. This is quite normal.

18 - 18 Gas Boosted Systems (Instantaneous) The Solarland Storage Tank is highly insulated to a level exceeding that required MEPS specification, thus minimising heat loss from the tank throughout both day & night. The cylinder is simply a storage vessel for the solar heated water. When solar gain is high the water may be of suitable temperature for direct use. During such periods the Rinnai Gas Booster is automatically OFF, with no standby or pilot heating losses. For periods when solar contributions insufficient to reach required temperatures, or as the tank temperature drops due to hot water usage, the Rinnai Gas Booster will automatically boost the water to the required level. Points to Note: 1. The gas booster operates when there is a minimum of 3L of hot flowing water. The use of water saving tap fittings that have less than 7.5L/mm flow rate or that have restrictors in them rather than a straight through reduced flow can interfere with the operation. To check operation, open the hot tap fully to see if the gas booster comes on. 2. The Electronic range of Rinnai gas boosters (20S & 26S) need a minimum of 150kPa water pressure (15.3m head pressure) in order to function properly. If the pressure is less than 150kPa then a water pressure pump can be installed (9.789kPa=1m of head pressure). 3. If the water pressure is very high & a pressure limiting valve has not been installed then this can cause the solenoid valve in the gas booster to shut down temporarily & not let any water through the system. 4.When upgrading from a gas storage tank to a gas-solar system using an instantaneous gas booster check that the Gas Regulator has been upgraded from 1.375kPa (1.38kPa) to 2.75kPa otherwise you might experience low water pressure &/or water that does not get heated by the gas booster to the required temperature. Your plumber needs to organise through your local gas provider to obtain a replacement upgrade Gas Regulator. Also, as a matter of precaution, replace the two rubber washes if the old ones look worn. Depending on your gas appliances you might (but generally not) have to also upgrade your gas meter. This can be determined by your local energy company. 5. If you turn on the gas booster at the power point before water is flowing through the unit it will go into default mode & allow no more than 40 C temperatures to flow. To reset the gas booster simply turn it off at the power point for 1 minute & then turn back on. Leave another 1 minute before turning the water on. 6. It is not recommended to use Electronic Temperature Controllers with an instantaneous gas boosted solar system as their operation is limited due to the stored solar hot water often being hotter than the temperature selected. 7. The Rinnai gas booster is factory preset to boost the water temperature to 60 C & no adjustment is required. Electronic Boosted Systems The Solarland electric boosted water heater cylinder is fitted standard with a 3.6Kw booster element which is actuated via the off-peak (preferred option) this ensures that if water has not been fully heated by solar radiation during the day then it heated overnight but only by the difference between what the tank & temperature is through solar heating an the thermostat set temperature on the tank. The two heating periods are complimentary. If the tank is at a sufficient temperature through solar heating then the electric booster element doesn t come on. You will generally require it to be set to come on in the night to allow the Solarland collectors to heat during the day & take advantage of reduced tariff electricity if available form your electricity provider.

19 - 19 Continuous Tariff If off-peak Tariff is not available then Continuous Tariff can be used in conjunction with an electric timer. If the hot water falls below & acceptable temperature i.e. you have used all the hot water up & need more then the Boost Button on your timer may be pressed to activate the electric element at any tine. Boost switches are series current actuation locked & will turn off when the thermostat reaches the set temperature. Older homes may have a day-night switch which must be manually reset once your hot water needs are satisfied. Do not leave the switch on day in daylight hours, unless necessary, as solar savings will be adversely affected. Draining & Refilling Storage Tank Step 1 Ensure the power is turned off at the mains to isolate the Pump/Controller & the Gas Heater Step 2 Turn OFF the gas supply to the Rinnai Gas Booster or isolate supply to the electric element Step 3 Turn OFF the cold water supply to the storage tank Step 4 Open the lever on the Pressure & Temperature Relief Valve (care should be taken to ensure that the lever does not snap back as this could damage the valve set) Step 5 If a drain cock is fitted to the water inlet, attach a hose to it, taking the other end of the hose to the drain & open up the drain cock. If there isn t a drain cock undo the union at the cold water inlet & attach a hose to the storage tank side of the union. Step 6 Following complete draining of the system, the closest hot water taps may be opened fully & the PT&R valve closed with care. The union on the cold water inlet is reconnected (or the drain cock is closed) & the cold water inlet stop valve (Duo Valve) opened & the storage tank totally filled with water until the hot taps are tunning free of air. The hot water taps are closed & the power supply & gas supply turned on. The solar loop needs to be air-free & this is achieved automatically by the Air Vent on the Collector. To flush the heater Flushing the storage tank at regular intervals is recommended in areas that have high sediment levels in the water. To assist this process, the heater has been designed to fully flush out any built up solids. To make flushing easy we recommend that a drain cock be fitted at the cold water inlet pipe. When flushing out the storage tank follow steps 1 to 6 in draining & refilling above then repeat the operations until all sediment is flushed from the storage tank. The system is clear of sediments when clear water is observed going down the drain. Post Installation Collector Operation After installing all the Solarland evacuated tubes, & given good sunlight, the solar collector will begin to produce heat after an initial 5-10 min warm-up period. Check to ensure that he pump is working by checking the PUMP light on the Controller is on. If the weather is particularly poor the pump may not come on, or may only cycle once every minutes depending on the solar radiation available. If the solar radiation is particularly good the pump could stay on continuously to return heated water to the storage tank.

20 - 20 Precautions Evacuated Tubes The Solarland evacuated tubes are made form toughened borosilic glass (similar to Pyrex) & are resilient to hail (up to 25mm) & other small foreign objects hitting them such as small tree branches. Be careful though when handling the evacuated tubes as they will break if knocked heavily or dropped onto hard surfaces. If you happen to break a tube wear appropriate protective gloves when handling any broken glass. High Temperatures With the heat pipe installed in the evacuate tube, & good sunlight, the heat pipe condenser can reach temperatures in excess of 200 C (392 F) At this temperature touching the heat pipe will result in serious burns, so please take care when experimenting with, or demonstrating the evacuated tube & heat pipes. If the system is turned off for maintenance, or due to power outage, the collector header (internal copper piping in the collector) & plumbing pipes close to the manifold will be extremely hot & will cause serious burns if touched. If extended maintenance is planned it is advisable to cover the Solarland collector to prevent continued heat production. 5. MAINTENANCE Maintenance of the system is very easy & includes the following tasks: Temperature & Pressure Relief valve PTV (all tanks) The Solarland storage tank is fitted with an 850kPa PTR Valve, which is located on the side of the cylinder & is essential for its safe operation. It is important that you operate the easing knob or lift the lever on the PTR valve once every 6 months. It is important you rotate the knob or lever gently so seat is not damaged Vitreous enamel tanks The five yearly service should be carried out by a licensed tradesperson. It is recommended that this service be carried out by your local Solarland agents. The service should include the following: 1. Replace the Pressure & temperature relief valve 2. Replace the anode (anodes should be replaced more frequently if subjected to hard water conditions, refer table in the warranty exclusions, Solarland should be consulted regarding the replacement anode if not a genuine Solarland anode) 3. Flush the water heater Cleaning Regular rain should keep the evacuated tubes clean, but if particularly dirty then may be washed with a soft cloth & warm soapy water or glass cleaning solution. If the tubes are not easily & safely accessible, high pressure water spray is also effective. Be aware a soapy wet roof will be very slippery! Leaves During autumn leaves may accumulate between or beneath the tubes. Please remove these leaves regularly to ensure optimal performance & to prevent a fire hazard. Note: The solar collector will not cause the ignition of flammable materials.

21 - 21 Broken Tube If a tube is broken it should be replaced as soon as possible to maintain maximum collector performance. The system will still operate normally even with a tube broken. Any broken glass should be cleared away to prevent injury. Care should be taken by using protective gloves & safety glasses when handling broken tubes. Broken tubes should be disposed of in a proper manner. To replace a Tube: Insulation a) Open the locking cap at the base of the solar tube, slide existing tube out & carefully pick up any glass pieces. Please wear protective gloves when handling the broken glass. When removing the tube, the rubber ring in the manifold casing may pop out. Just return this ring into place before inserting the new tube. b) Avoid touching the Rockwool insulation with bare hands, as it can cause mild skin irritation. c) New tubes already have hest transfer fins inserted, so place the heat pipe into the new tube taking care to guide the heat pipe into the slot between the heat fins. The Plumbing pipes running to & from the collector should be heavily insulated. This insulation foam should be checked annually for damage. If available, UV stabilised foam (or metallic wrap) should be used, otherwise deterioration can occur over time. Note: Up to 60% heat loss can occur if the insulation is non existent or sub standard. Therefore please pay particular attention to making sure the system is properly insulated & any external insulation is UV Protected. Other Components Other parts of the system such as the pump & storage tank (electric or gas water heater) should be serviced/inspected according to the manufacturer s own maintenance guidelines. 6. TROUBLESHOOTING No Hot Water If there is no hot water, it will generally be related to the gas or electric heating system, & not the solar tube collector. The solar tube collector pre-heats water, with final boosting completed by the electric element or gas booster system. Please contact your local Solarland Agent. Reduced Solar Contribution Solar contribution to your heating is directly related to the amount of solar radiation & the volume of hot water used. During the winter, & periods of rainy, or particularly overcast weather, the amount of energy produced by the solar collector will be greatly reduced. As a general rule, the solar collector will have been sized to provide close to 100% of your summer hot water needs, which depending on your location, angle of collector & hot water usage patterns, may result in up to 80% or more of your annual hot water energy needs. During the winter, due to increased cloud cover & reduced solar radiation levels, solar contribution may also be as low as 50%. This is normal. If, given similar environmental conditions, you feel that the solar contribution (as indicated by energy savings) has considerably reduced there may be a problem with your solar heating system. This may be due to an incorrectly configured or damaged Controller, pump

22 - 22 malfunction or problem with the boosting system. In such cases please contact your Solarland Agent. Step 1 Does the circulation pump appear to be operating? In good sunny weather the circulation pump should come on as can be seen by the PUMP light on the Controller. The pump may run very quietly & so you may need to touch the pump or piping running to & from it to feel for motor operation (slight vibration). Careful it might be hot!! The controller has a green light to indicate the pump has power going to it. Step 2 Are all the tubes intact? If a tube has been damaged (broken) it will reduce the systems overall performance only marginally but should be replaced. If a tube is damaged, do not attempt to remove it without wearing protective gloves. Note: No water will escape from the manifold due to a broken evacuated tube as the tubes do not have any water entering them. Step 3 Are there any apparent leaks in the plumbing to & from the collector? Any water trails down the roof, or around the storage tank? Have installer tighten fittings when necessary. Regular Releasing of Hot Water If during normal daily hot water use, the PTR valve (Pressure Temperature Release valve) on the tank is regularly releasing hot water, it indicates there may be a problem. A few litres a day is normal. Possible Causes: The system might have been oversized. This will be most apparent in the summer months, when solar radiation levels are high. Solution: Remove some of the heat pipes from the evacuated tubes & replace in the manifold. A problem exists with the electric heating thermostat (Electric boosting only). Solution: Contact your local Solarland Agent Incorrect, faulty or missing Pressure Limiting Valve (PSV50-500kPa) Solution: Contact your local Solarland Agent. Note: if the PTR valve is less than one year old then it is covered under warranty. To test the system, run the hot water tap in the bathroom or kitchen for five minutes to release some heat form the system (the water will be hot so be careful). If after this period, the tank is still regularly releasing hot water it indicated a definite problem. Please contact your local Solarland Agent. Safety Precautions For any problems that involve plumbing or electrical connections the services of a qualified professional must be employed. 7. WARRANTY PLEASE RETAIN PROOF OF PURCHASE AS THIS IS YOUR WARRANTY. Warranty Conditions The system must be installed by a licensed gasfitter/plumber &/or electrician in accordance with all installation instructions & all relevant statutory & local requirements of the state in which the system is installed.

23 - 23 This warranty only applies to the solar system/gas water heater/electric water heater product & does not apply to any additional electrical &/or plumbing parts supplied by the installer. The system is covered for the indicated period form the date of the original purchase. Should a part of the complete solar system/water heater product be replaced during this period, only the balance of the original warranty will continue to remain effective. The system is installed in a domestic household with the pump & controller connected to a 240V power supply at all times throughout the year. Should this system be installed in a regional location where regular flushing is required due to sediment build-up, the drain cock for flushing must be fitted at the time of installation. If in doubt consult your installer/plumber. Component manufacturers are at liberty to alter the design or construction for the products not withstanding that the product may have been sold by description or sample, even though alterations may have been introduced from the date of Contract & the date of delivery provided that the products are of the same or similar quality & are fit for purposes for which they are purchased. Such alterations shall not constitute a defect in design or construction under this Warranty. The Warranty shall be limited to the replacement or repair, at the option of Solarland of any defective products & of such parts as have been damaged in consequence of defect. Solarland is excluded to the extent allowable by Law from responsibility for any consequential loss including: Injury to persons Economic loss Injury to property Pain & suffering Any legal or other damages flowing from any manufacturing fault/defect Solarland shall be under no obligation to return parts replaced at its option pursuant to this Warranty. Warranty Exclusions The following warranty exclusions shall cause the system warranty to become void. This may incur a service charge & costs for parts should they be necessary. Where service is required to reconnect the water heater operation due to problems related abnormal water supply (i.e. high water pressure), faulty gas fitting, plumbing &/or electrical wiring, or major variations in gas or electrical energy supply. If the system is sold & repaired & altered by any third party without the consent of Solarland. Claims for damage to walls foundations (outside), furnishings (inside), roofs or other losses, directly or indirectly due to leakage from the water heater. Where the system has been drained for a period without solar tube collector being covered, resulting in damage to the collector. Accidental breakage is not covered by this warranty, & should be added separately to your general household insurance policy. This warranty does not cover the effects of sludge/sediment as a result of connection to water supply from unfiltered sources i.e. spring, dam, bore, river or other.

24 - 24 This warranty does not cover the effects of the connection of the appliance to bore waters & highly mineralized waters. Where water stored in the cylinder exceeds the following levels: Total dissolved solids 600mg/litre or p.p.m Total hardness 200mg/litre or p.p.m Chloride 250mg/litre or p.p.m Sodium 150mg/litre or p.p.m Magnesium 10mg/litre or p.p.m ph Levels The benefits conferred by this warranty are in addition to all other rights & remedies in respect of the product, which the purchaser has under the Trade Practices Act (Commonwealth) 1975, & similar State or Territory Laws. Warranty Coverage Details Coverage Details Solarland Solar Collector Header Solarland Solar Collector Heat pipes and tubes Solarland Solar Collector Mounting Frame Solar Circulating pump. Solarland Solar controllers Coverage Period One year parts and labour Fifteen years parts only One year parts and labour Ten years parts only One year parts and labour Fifteen years parts only One year parts and labour (all states) Two years parts only (all states)ŧ One year parts and labour (all states) Rinnai Gas Booster Booster Heat exchange Everlast Stainless steel tanks Solarland Vitreous Enamel tanks Three years parts and labour Ten years parts only One year parts and labour Fifteen years parts only One year parts and labour Seven years parts only *Please note: Where the heater is installed outside the boundaries of a Capital Cities Metropolitan area i.e. those area on STD, the cost of transport, insurance and travelling will be charged by Solarland to the owner. Ŧ A Warranty of two (2) years from the date of Installation or twenty seven (27) months from the date of Invoice applies if the Installation Date is not established. Where the failed Pump is replaced or repaired under Warranty, the original Warranty Period remains effective. This means the replaced or repaired Pump does not carry a new Warranty.

25 - 25 OH&S Disclaimer Solarland and Solarland Australia Pty Ltd work with & recommend various installation & plumbing companies to install, test & certify correct operation of solar hot water systems. Solarland is a supplier of systems only. Each installation must be covered by the installer s insurances, commercial terms & conditions & by the applicable OH&S legislation. Each person that installs assembles or services must comply with all OH&S requirements relevant to the type of work being conducted including, but not limited to, plumbing work, work on roofs & electrical work. Solarland Australia Pty LTD do not accept any responsibility for any loss or damage to any person or property of any type, whether direct or consequential arising form the installation, maintenance or operation of the solar hot water system or any of its components. NOTES:

26 8. SYSTEM DRAWINGS - 26

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