Installation and Owner s Manual Solar Water Heater SP and IM - Series Split System Models SP, SPS, SPE, IME Electric Boosted Solar Water Heaters This manual uses the following conventions and symbols to highlight points of note throughout the manual. Read this manual before you start to use this equipment. SAFETY WARNING! Important Safety instructions. WARNING! Failure to follow the instructions in this manual can cause serious injury and or equipment failure. GENERAL NOTICE WARNING INSTALLER PLEASE NOTE Plastic pipe must not be used on a solar water heater installation due to the effects of high water temperatures and pressures. USE COPPER PIPE ONLY. This water heater must be installed and serviced by an authorised person. WARRANTY / SERVICE Contact SolarPower Pty Ltd15 Suscatand Street, Rocklea, Brisbane 4106. or email service@solarpower.net.au. Please note: When making a service call, it is imperative that the 6-digit water heater serial number, located on the technical label, is quoted. This unit is not suitable for use as a pool or spa heater Note: The Trade Practises Act 1974 and similar laws in each State and Territory provide the owner under certain circumstances with certain minimum statutory rights in relation to this water heater. This user manual and warranty must be read subject to that legislation and nothing in the Installer Manual or Warranty has the effect of excluding, restricting r modifying those rights. Note: Whilst every care has been taken to ensure the accuracy in preparation of this document, no liability can be accepted for errors or omissions and any subsequent consequences that may arise. 1
INSTALLATION GUIDE FOR ONE TANK SOLAR ELECTRIC BOOSTED SOLAR WATER HEATERS ON THE GROUND Model No SP, SPS, SPE, IME Electric Boosted Solar Water Heaters CONTENTS PAGE/DRAWING Installation and Regulatory Authorities 4 Water Quality 6 General Installation Layout 6 Installation Solar Collectors 10 Water Heater Location 13 Pump and Controller Location 15 Pipework and Fittings 17 Safety Valves 17 Frost Protection Valves 18 Solar Controller and Pump Operation 19 Filling and Commissioning the System 20 Pressure Limiting Valves 21 Controller Function Explained 21 Fault Finding 23 Owners instructions and maintenance 25 Warranty & Conditions 28 Mandatory Report Form 33 2
REGULATORY INFORMATION Notice to Victorian Customers from the Victorian Plumbing Industry Commission This water heater must be installed by a licensed person as required by the Victorian Building Act 1993. Only a licensed person will give you a Compliance Certificate, showing that the work complies with all relevant Standards. Only a licensed person will have insurance protecting their workmanship for six years. Make sure you use a licensed person to install this water heater and ask for your Compliance Certificate. Installation and service must be performed by an authorised person. This water heater must be installed in accordance with: 1. Manufacturers Installation Instructions 2. AS/NZS 3500.4 National Plumbing & Drainage Code 3. AS/NZS 3000 Wiring Rules 4. Municipal Building Codes 5. Any other State or Federal Statutory Regulations WARNINGS GENERAL INFORMATION FOR HOMEOWNER 1. Do not operate this water heater until all operating instructions have been read and understood by the homeowner. 2. These water heaters are NOT recommended for connection to Bore Water Supplies and warranty may be void in such installations. 3. A properly drained safe tray must be used where property damage could occur from water spillage (see AS3500.4.2). Ensure this safe tray does not become blocked. 4. Do not activate this water heater unless the cylinder is filled with water and a satisfactory Megger reading is obtained by an authorised person. 5. Do not block or seal the P&T safety valve or drain pipe. 6. The water heater warranty can become void if relief valves or other safety devices are tampered with or if the installation is not in accordance with these instructions. 3
7. Do not place any articles, chemicals or flammable materials on or near the water heater 8. Removal of access covers will expose 240V wiring. Do not remove the terminal box cover or gain access to this water heater unless the power supply has been effectively disconnected by an authorised person only. 9. Do not operate this water heater with terminal box cover removed or loose. 10. This water heater is not intended to be operated or adjusted by young children or infirm persons. Young children must be supervised to ensure they do not interfere with the water heater. 11. This water heater can deliver water at temperatures which can cause scolding. Check the water temperature before use, such as when entering a shower or filling a bath or basin. 12. Take care not to touch copper pipes connected to the water heater as high temperatures in the pipework may be present. 13. This water heater is intended to be installed as a fixed appliance and must be installed on a hard, level surface. If installation is to be in a wet area or a concrete floor, ensure the water heater is mounted on a suitable and substantial raised base (eg: wood or concrete) 14. The Water heater pump / controller must be plugged into a weatherproof electrical outlet if installed outdoors. Take care not to touch the power plug with wet hands. 15. If the power supply cord, plug or electrical conduit to the water heater is damaged, it must be replaced by an authorised person in order to avoid a hazard. The power supply cord and plug must be replaced with a genuine replacement part available from SolarPower. Phone the SolarPower Service Department on (07) 32740774 or Accredited Service Agent to arrange for a service call. GENERAL All Solar Power system have roof mounted solar panels connected to a ground mounted solar storage tank and/or boosting heater. The solar input is harvested with a circulation pump controlled by an electronic temperature differential controller. INSTALLATION AND REGULATORY AUTHORITIES Recommendations from Australian Standard 2002/7: Solar water heaters-installation form the basis for the guide, however where there is conflict between the guide and the requirements of any regulatory authority the latter shall prevail. This guide is to be used in conjunction with all of : The Installation and Warranty instructions supplied with Solar Power Water Heater incorporated in the system the Australian Standard AS3000 and AS3500.4.2 National Plumbing and Drainage, Australian Standard AS3500.5 (This water heater must be installed in accordance with the provisions of this Standard) 4
Local Electrical and Water Supply Authorities regulations and, if installed in New Zealand, The New Zealand Building Code. Local Das Authority regulations where applicable as defined in Australian Standard AS5601. Relevant Occupational Health & Safety (OH&S) regulations. These safety precautions are outlined in the Work Cover Code of practice Safe work on roofs Part 1 and 2 and in the Occupation Health and Safety Act 1983. All installation work must be carried out by the appropriately authorized Tradesperson/s. The 240V 10 A weatherproof power outlet required for the pump and controller must be installed by a licensed Electrician. The responsibility for all OH&S issues relating to the installation of the system resides with the installing plumber. Please refer any queries relating to the design and/or installation of Solar Power products or components to the Technical Services Department in writing. WARNING! Working on roofs should always be considered a hazardous activity; by law you must observe certain minimum safety precautions. These safety precautions are outlined in the Work Cover Code of practice Safe work on roofs Part 1 and 2 and in the Occupation Health and Safety Act 1983. COMPLIANCE WITH STANDARDS The installation must be performed by an Authorised Persons and comply with the requirements of AS/NZS 3500.4, AS/NZS 3000, and all local codes and regulatory authority requirements. It is recommended the solar storage tank be installed at ground or floor level. The water heater must stand vertically upright. SUITABILITY FOR INSTALLATION IN FROST AREAS The system is suitable for installation in areas that experience sub-zero temperatures; it has an air bleed valve and electronic freeze protection system integrated into the controller to prevent damage in the event of a frost. Frost valve kits are also available as an accessory and should be installed at time of installation in areas that experience frost. Power supply to the tank & controller must never be switched off, severe damage to panels may occur and warranty will be void. 5
WATER QUALITY The system should only be connected to water supply of acceptable quality otherwise the warranty provided for the system may be affected. Refer to Warranty instructions supplied with heater. The water quality requirements for these solar systems are the same as for the Solar Power water heater used in the system. These are set out in the Installation and Warranty Instructions supplied with the Solar Power water heater. TANK WATER SUPPLY If the water heater is installed to a tank water supply, a minimum 200kPa water supply pressure must be available or a pressure pump must be installed to allow operation of the system GENERAL INSTALLATION LAYOUT Also refer to the relevant Installation and Owner s Manual supplied with the solar tank as well as Solar Panel Pipework Layout drawing supplied with the solar panel kit for your particular system. 6
GROUND INSTALLATION KIT (GLINKI) 7
ROOF INSTALLATION KIT (STAKITGL) 8
9
INSTALLATION SOLAR COLLECTORS PREFACE: Approximate roof area required: SP225 COLLECTORS (WHERE INSTALLED) 2 Collectors are 2.8m wide x 2.4m high. (88kgs total, filled with water) 3 Collectors are 4m wide x 2.4m high. (132kgs total, filled with water) IM200 COLLECTORS (WHERE INSTALLED) 2 Collectors are 2.2m wide x 2.0m high NOTE: Ensure the mounting surface is strong enough to support the collectors. Most roofs can support the panels, but if unsure consult a structural engineer. 10
SP225 AND IM200 COLLECTOR INSTALLATION ONLY QUALIFIED TRADESPERSONS SHOULD INSTALL THESE COLLECTORS. GLAZING CANNOT BE REPLACED ONSITE. 1) Select a suitable place to install the lower mounting rail on the roof, align panel location as high as possible on the roof. 2) Locate the lower rail and mark the lower 4 bolt positions on the rail. The bolts are positioned to line up with the peaks of the tin or tile profile. DO NOT drill in the troughs of the roofing material. 3) Drill the 4 bolt positons on the top of the rail using a 16-20mm metal cutting hole saw, leaving a 5mm pilot hole through the bottom of the rail. 4) Using the drilled rail as a guide mark and drill the roof material with a 5mm pilot hole. This may not be needed for tin roofs, as the screws supplied are self tapping. 5) For tile roofs drill the tiles using a 12-14mm concrete drill bit, paying careful attention for any cracking in the tiles. Replace any cracked tiles with a new tile before continuing. 6) Once the holes have been drilled,place a fill the hole with silicon sealant, and apply a 6mm bead around hole. 7) Apply Silicon into the drilled hole then insert the Aluminium spacer tube into the hole. This is not required for a tin roof. 8) Position the mounting rail and insert the screws through the rail and into the roof batten, place a rubber washer as a seal, then evenly tighten the screws. For Tile roofs the Aluminium spacer will act as a stop. Do not over tighten and break a tile. NOTE: ensure a rubber sealing washer is placed between the rail and the roof surface for each screw hole, to provide adequate sealing of the screw hole from water ingress. Use adequate amounts of silicon sealant in the holes before inserting the screws. 9) Using a 20mm screw for each bracket mount 4 of the 60mmx60mmx 35mm wide right angle brackets evenly along the lower section of the lower rail. This will leave a short tab 11
of the bracket protruding above the rail. Evenly space 2 brackets for each panel. The panels can now be lifted onto the rails and the brackets will stop the panels sliding. 9) Follow instructions 2-8 for the other rails. A total of two rails are required for non cyclone areas, and a total of 3 rails are required for cyclone rated areas. 10) Once the rails are mounted to the roof then the side brackets can be placed on the rails. 11) Attach an upper corner bracket to the top left of the upper mounting rail, using 2 x 20mm 12G self tapping metal screws. This bracket is a 60mm x 60mm x 35mm angle Aluminium bracket. 12) Position the solar panels on the lower and upper rail (rails). Connect them as shown in the diagram, remembering to use Teflon tape or approved liquid sealant on all plumbing joints. Always use two spanners to tighten panel fittings, and do not exert any torque on the panels. NOTE: WATER FLOW THROUGH PANELS - the water inlet from the pump must be connected to the lower header pipe of the array. Ensure that the water exits the panels from the top header pipe, diagonally opposite from the inlet and returns to the Solar Return on the tank. 13) Once the panels have been connected together attach the corner bracket (s) to the top right of the upper mounting rail, using 2 x 20mm 12G self tapping metal screws. This bracket is a 60mm x 60mm x 3mm angle aluminium bracket. 14) Next attach the centre brackets (120mm x 40mm x 6mm flat Aluminium Bar) using the 135mm self drilling metal thread screw, screwing into the top of the aluminium rail sections. This provides hold down of the centre sections of the panels. 15) Using 1 x 20mm 12G self drilling metal screws attach each panel to each of the bottom mounting brackets by drilling through the brackets and into the sides of the panels. 16) Using 1 x 20mm 12G self drilling metal screws attach each side bracket to the panels by drilling through the bracket and into the sides of the panels. 17) The system is now fully attached to the roof bracket system. 12
18) Cover the panels with scrap cardboard, shade cloth or similar when empty of water and in direct sunlight. Fit air bleed valve onto the outlet of panels at the top left corner of the panels. NOTE: The air bleed valve needs to be checked to ensure the valve top is opened and that when the pump operates the valve seals properly when the pump is operating. This can be done by listening to the valve to ensure air is not entering the pipe work. Let the pump run for 3-5 minutes if air is still bubbling into the tank at this stage the valve is not sealing. 19) Mount the panel temperature sensor to the Air bleed T piece. 20) Drill a 10mm hole in the roof near the sensor and run the sensor leads through the hole drilled in the roof, once this is done seal the hole with silicon. NOTE: Do not use the same hole as the pipe work as movement of the pipes may ca use the cable to break or short circuit. 21) Install the Solar Hot Pipe and Solar Cold Pipe to run between the storage tank and the collectors. Both pipes should be DN15 (1/2 ) copper pipe, with 13mm or thicker synthetic rubber insulation (Armaflex, Bradflex). All insulation should be protected from UV degradation by two thick coats of paint, or by covering with ductwork. Prelagged pipe (often green PVC or plastic insulation) is not suitable for thermal insulation purposes only use foamed synthetic rubber insulation. 22) Connect the Solar Hot Pipe and Solar Cold Pipe to the heater and to the panels. NOTE: ensure that the water inlet from the syste m pump flow is to the lower right edge of the array, and that the water exits the pa nels diagonally opposite and through the sensor outlet fitting located on the top left hand corner of the array, and returns to the solar return on the tank. 23) Upon completion of the water heater installation, check the panels and associated plumbing for leaks while the pump is operating. Leaks above the water line of the tank will suck air in, rather than leak water out. When checking for leaks, if you can hear air bubbling in the tank after the pump has been running for more than 5mins it is likely that air is leaking into the piping. 13
24) Remove the covers from the solar collectors once the system has been commissioned. NOTE: The kit bags come complete with screws and spacers for both corrugated and tile roofs, there will be spare parts leftover at the end of the installation. COLLECTOR INSTALLATION IN CYCLONE AREAS The SolarPower Panel Mounting Kit is SUITABLE for installation in cyclonic locations when installed with an additional rail mounting and brackets to provide the required additional fixing to the roof frame. This ensures conformance with AS1170.2. Three mounting rails meet the requirement for a C3 rated area. Roof Sensor Connection The roof sensor cable is to be installed along with the solar pipe work and is connected to the pump / controller box located adjacent to the water heater tank. The sensor cable simply enters the pump / controller box and plugs into the colour coded socket on the base of the controller. NOTE: DO NOT run the sensor wire through the same hole in the roof material as the pipe work, as this will lead to the cable being damaged from the pipe movement in the hole and will cause short circuits or failure of the temperature sensing. WATER HEATER LOCATION Refer to water heater installation instructions for the rules governing the location of the water heater. For gas heater this covers such things as proximity to windows, doors, building corners etc. The tank should be installed in close proximity to the most frequently used outlet and its position chosen with safety and service in mind. Other considerations include the position of the solar tank with respect to the solar collectors as heat loss in the pipes and combined pipe length (hot and cold combined) should not exceed 20 metres, servicing (the water heater must be accessible without the use of a ladder or scaffold and the PTR valve, thermostat and booster element must be able to be removed) and nameplate data must be able to be read. Other considerations include: 14
Electrical supply requirement for gas continuous flow and electric storage heaters Weight of heater filled with water Dimensions of heater and size and location of connection points Water supply pressure limitations PUMP / CONTROLLER LOCATION - PUMP LIMITS The SolarPower Pump/Controller system has a head limit of 6 meters and flow should not exceed 20 metres. On split systems the Solar Controller/Pump Box should be mounted onto a vertical surface close to the solar storage tank. The connections to the pump are labelled on the pump in the Pump / Controller Box to indicate the direction of flow. An approved 240V 10A 3 pin weather proof power outlet is required to supply the controller. NOTE: THIS WATER HEATER IS NOT SUITABLE FOR POOL HEATING. CLEARANCES Allow adequate room to work with tools. A minimum of 25mm clearance around the water heater is required. An additional 30mm is required for relief valve removal, 80mm for access cover removal and 400mm for element removal. You should be able to read the information on the rating plate and all informative labelling. Adequate provision must be made to dispose of any water escaping from heater or adjacent plumbing that might result in damage to property. The water heater must be connected in such a way that: Space is allowed for the removal of the heating element. The pump is accessible for servicing. Complete removal of the unit can be easily effected if necessary. 15
CONFINED SPACES If the thermostat fails the unit may produce excessive steam. It is strongly recommended that the heater should be installed in a well-ventilated space to avoid condensation build up. If installed in confined areas, make provision for Service Access. Vent safely to open air and carry hot water overflow pipework to drain. FOUNDATION To ensure adequate ventilation, position the unit on an approved support base on a concrete slab or other approved foundation (See figure below). Alternative forms of water heater bases are acceptable providing they allow for adequate ventilation. Attention is drawn to the weight of the water heater tank when full (up to approximately 600kg depending on model) and installer should ensure that the base and footings are substantial enough to avoid subsidence etc. SAFE TRAY It is a requirement of the National Plumbing Code AS/NZS3500.4.2 that new water heaters be installed in a safe tray where in the event of a leak, property may be damaged. Installation of such trays must comply with Clause 4.4 and Sub-Clauses 1 to 5 of the abovementioned Code. 16
PIPEWORK AND FITTINGS Valves and fittings for connecting the solar Panels on the roof are supplied. Refer to box labelled QUICKIE KIT (Does not include the copper pipe and pipe insulation) The temperature of the water at the outlet connection on the panels may reach 150 C or more and therefore only copper pipe can be used between the panels, storage tank and boosting heater. Class B copper pipe should be used and the runs should be as short as possible to reduce heat losses. The pipes MUST be lagged using thick-walled foam of at least 15mm thickness, RO.6 and should be weather proofed and UV stabilized. (Examples: Armaflex Solar Tube 15mm thick). If insulation is not UV stabilized, it must be protected by a suitable UV resistant paint. Pre-cut pieces of insulation and cable ties are provided to insulate the pipework fittings. The areas to be insulated are: inlet pipework fittings to the panel, the outlet pipework fittings, and on 2 & 3 panel systems the joiners between the panels. These fittings must be insulated to protect them from freezing in cold areas. Warranty may be void if not fitted. Refer to the Solar Panel Layout drawings for location, and page 8 for illustrations. Water may drip from the pipe of the pressure-relief device. This pipe must be left open to the atmosphere Note: The copper pipework and specified insulation is to be supplied and fitted by the installer. SAFETY VALVES All valves shown in the Tank & Panel Assembly diagram must be fitted in the installation unless incorporated in the appliance. (AS/NZS 60335.2.21). PTR Valves and brass tank plugs are supplied with the tank. The safety valves included in the solar Quickie Kit are the - Air Bleed Valve. This valve must be upright with the air bleed cap open. PTR Valve for a solar storage tank. This is supplied with the solar tank. Cold Water Expansion Valve Tempering Valve Duo Valve Other brassware components 17
FROST PROTECTION VALVES Additional accessories available from SolarPower include the Frost Valve Kit. These valves are required to be installed in Frost areas and must be installed facing downwards (one per panel). The valve must not contact the roof. During frosty conditions these valves open and allow a slow flow of water through the panels. They will automatically close when the water temperature rises. They provide backup for the freeze protection facility on the controller in the event of power failure. Do not use thread sealants to connect the frost valves; they must be fitted using the sealing washer supplied with the valve. Note: Thread sealants may cause problems with the operation of the valve. The PTR valves and the Cold Water Expansion valve must be fitted with a drain to legal discharge points where the water discharge will be clear of any paved areas and will not cause damage or injury. Do not block or seal these drain lines. Never fit a PTR or ECV valve with a pressure rating greater than that indicated on the product-rating label. IMPORTANT: Relief valves should be checked to be in sound working order in intervals not exceeding 5 years or more regularly in areas subject to water deposits. Checking should include operation of the relief valve to remove any lime deposits. DANGER: FAILURE TO OPERATE THE RELIEF VALVE EASING GEAR AT LEAST ONCE EVERY SIX MONTHS MAY RESULT IN THE WATER HEATER EXPLODING. IT IS IMPORTANT THAT THE EASING GEAR ON THE VALVE BE RAISED AND LOWERED VERY GENTLY. FAILURE TO DO SO MAY RESULT IN THE WATER HEATER CYLINDER FAILING, OR UNDER CERTAIN CIRCUMSTANCES, EXPLODING. IT IS NORMAL THAT SMALL QUANTITIES OF WATER (UP TO AROUND 15 LITRES OF WATER IN A 24 HOUR PERIOD) ARE RELEASED BY THE VALVE IN THE HEATING CYCLE, CONTINUOUS LEAKAGE OF WATER FROM THE VALVE MAY INDICATE A PROBLEM WITH THE WATER HEATER. IF THE VALVE DOES NOT DISCHARGE WATER WHEN THE EASING GEAR IS OPERATED, OR DOES NOT SEAL AGAIN, A SERVICE CALL SHOULD BE MADE WITHOUT DELAY. THE P&T VALVE IS NOT SERVICABLE. DANGER: THE OPERATION OF THE THERMAL CUT-OUT INDICATES A POSSIBLY DANGEROUS SITUATION. DO NOT RESET THE THERMAL CUT-OUT UNTIL THE WATER HEATER HAS BEEN SERVICED BY A QUALIFIED PERSON. 18
SOLAR CONTROLLER AND PUMP OPERATION The control unit turns the pump on and off in response to temperature signals' received from a hot sensor, located in panel's hot water outlet fitting and a cold sensor located at the entry to the storage tank. It is crucial that these sensors and leads are not damaged or cut during installation. The sensor leads are extra low voltage but must to be encased in 20mm PVC conduit and secured with conduit saddles to ensure they remain undamaged. The hot sensor (long lead) should be dry and pushed to the bottom of the long hot sensor pocket on the solar panel. The cold sensor (short lead) is to be fitted dry into the short cold water sensor pocket at the cold water entry to the solar storage tank, refer to the respective layout diagram supplied with the Solar Storage Tank. DO NOT turn off the ELECTRICITY or WATER SUPPLY to the Solar Controller and Pump. Note: Panel warranty does not cover damage caused by frost or freezing where: the solar controller and or pump are not operating, the mains water supply to the system has been turned off, or the mains cold water supply to the system freezes because it is not insulated. ELECTRIC BOOSTING Water stored in the storage tank is heated automatically by an electric booster heating unit. The booster element heats the water during very cloudy or rainy weather, during the winter months, or during periods of unusually high demand, such as when friends or relatives visit. The SolarPower Solar water heater is suitable for the heating unit to be connected to continuous electricity supply. The booster heating unit is controlled by an electric thermostat. The thermostat and heating element are mounted on the solar storage tank. The boost water temperature is automatically controlled to the thermostat setting when the booster heating unit is energised. The thermostat is tradesperson adjustable. It has a minimum temperature setting of 60ºC and a recommended maximum temperature setting of 75ºC. It must only be adjusted 19
by an authorised person. Automatic safety controls are fitted to the water heater to provide safe and efficient operation. The SolarPower Solar electric booster element will automatically heat the water in the tank. An isolating switch can be installed in your electrical meter box for your solar water heater. This will allow manual control of the electrical booster circuit if desired. FILLING AND COMMISIONING THE SYSTEM Do not turn on electric power or gas until the whole system has been filled with water and a satisfactory Megger reading is obtained by a qualified person. Solar Storage Tank and Water Heater Turn on a hot water outlet tap, preferably the one furthest from the heater. DO NOT purge through the PTR valves. Open the mains cold water supply valve so that air is displaced from the water heater and replaced with water. The hot water outlet tap should be left on until the water flowing from it f lows steadily without spurts. Turn off the hot water tap and allow the system to pressurize. Check the system for leaks. Repair if required. Solar Panels The solar panels must only be filled when they are cold, so it is important to ensure that the panels are fully covered for a suitable time beforehand. Filling hot panels may cause injury by scalding. Ensure the water heater is full of water and all of the hot taps are turned off. Loosen fitting on top of the solar panel return pipe to the solar storage tank and then turn on the mains cold water supply. Covering loosened fitting with a heavy cloth to prevent water spraying from fitting. Allow water to flow from the loosened fittings until a steady flow free of spurting is achieved i.e. all air is displaced. Re-tighten fitting. Allow system to pressurise. Check for leaks and rectify if required. Note. It is important that all air be removed from the solar panel circuit to ensure the circulating pump will function effectively. Air in the system will prevent circulation. Remove covers from solar panels. 20
PRESSURE LIMITING VALVES The water heater is designed to operate at mains pressure by connecting directly to the mains water supply. If the mains supply pressure exceeds the rated pressure, a pressure-limiting valve must be fitted before the inlet to the water +heater within the installation process as per (AS/NZS 603355.2.21) SOLAR CONTROLLER AND PUMP. Ensure that the hot and cold sensors are plugged into the correct sockets. Ensure that the pump is correctly plugged into the Solar Controller power outlet. Plug the Solar Controller into the weatherproof mains power outlet and switch on. If the weather is fair, the return pipe from the panels will become warm. Please note that the pump is near silent and vibration free in operation. If the weather is cool and cloudy, it may be necessary to cool the cold sensor probe to make the pump run. Alternatively, temporary connection of the pump to mains power will enable a test run. Be sure to reconnect it to the Solar Controller after testing. Note: The pump is not capable of purging air from the system. Air must be purged manually from the highest point at the panels. Controller Function Explained. The SolarPower controller has been specifically designed for SolarPower Hot Water installations. Using a purpose built solar panel the controller will endeavour to heat the tank water to 75 o C, and hold it at this temperature. The controller does this by using sensors to sense both the solar panel and the tank water temperature. When the solar panel temperature raises 9 o C above the tank water the controller will turn the pump ON to circulate the water through the solar panel. If the tank water reaches 75 o C, or the solar panel temperature decreases to within 5 o C of the tank water, the pump will turn OFF. There is also a built in freeze protection which will turn the pump ON if the solar panel temperature decreases to 3 o C. The pump will turn OFF once the panel temperature has risen to 5 o C. This feature will avoid the solar panel and the pipe work freezing. 21
Additional features include, Lights that to indicate Power ON, Pump ON, Tank Sensor Error and Collector Sensor Error. Specifications: - Maximum tank temperature Maximum collector temperature Freeze protection Tank/Collector differential Maximum load 75 o C 250 o C 3 o C to turn ON 5 o C to turn OFF 9 o C to turn ON 5 o C to turn OFF 240Vac 10 Amp Water Heater. Roof and Tank Sensors. Follow instructions supplied with heater. Note that it is necessary to provide a properly drained safetray under heaters located where leakage may cause damage. When locating water heater, ensure that the installation does not compromise the structural integrity of the building. A "Cold Water Sensor brass Pocket" kit is included and must be fitted to the cold water entry to the heater. Refer to the pipework drawing attached. Note: A Tempering Valve must be fitted in accordance with Australian Standards and other State and Council regulations. 22
Fault Finding If the collectors are shade-free, the weather is fine and warm and the solar storage tank contents are definitely cold, the circulating pump should operate and the return connection become warm/hot. Please note that the pump is almost silent and vibration-free in operation. Check the following: 1. Is there 240 volts at the power outlet? 2. Is the pump plugged into the controller? 3. Are the sensors plugged into the correct sockets in the controller? 4. Are the sensors correctly fitted into the sensor pockets? 5. Has all air been purged from the system? Switch power outlet off for 10 seconds, then back on. If no activity, contact Solarpower Service on 07 3726 2003. HOW TO TURN OFF THE WATER HEATER Should it be necessary to turn off the water heater following commissioning, then: Switch off or isolate the electrical supplies to the water heater AND the pump / controller Close the cold water valve at the water heater inlet Note: If the water heater is located in a frost area and freeze protection valves are not fitted, damage to the panels may result if the water heater is switched off. Damage to the panels where no power is available at the pump / controller and where no freeze protection valves have been fitted is not covered by warranty 23
DRAINING THE SOLAR COLLECTORS power is switched off Ensure power is switched off at both the water heater and controller Open a hot water tap and allow the hot water to run for a full 5 minutes immediately prior to draining the solar collectors. This will assist in draining high temperature water from the collectors back to the storage tank. After 5 minutes, the hot water tap may be closed. NOTE: Extreme care must be exercised as water discharged from the solar collectors may be at a very high temperature Turn off the water heater (see above) Loosen fitting on top of solar panel return pipe Disconnect the solar cold pipe and water will drain from the solar collectors When water stops flowing from the solar hot and cold pipes, reconnect the solar cold pipe and retighten fitting on top of solar panel return pipe. DRAINING THE WATER HEATER Ensure power is switched off at both the water heater and controller Open a hot water tap and allow the hot water to run for a full 5 minutes immediately prior to draining the solar water heater tank. This will assist in draining high temperature water from the collectors back to the storage tank. After 5 minutes, the hot water tap may be closed. NOTE: Extreme care must be exercised as water discharged from the solar collectors may be at a very high temperature Turn off the water heater (see above) Operate the relief valve release lever carefully to release the pressure in the water heater do not allow the lever to snap back or damage may result to the valve seat Undo the union at the cold water inlet and attach a hose to allow the water to drain from the tank Operate the relief valve again to allow air into the water heater which will allow the water in the water heater to drain away 24
OWNERS INSTRUCTIONS (INSTALLER PLEASE HAND TO OWNER) WATER HEATER OPERATION See instructions supplied with heater. Warning: Appliance not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge. Children should be supervised by a person responsible for their safety to ensure that they do not play with the appliance. (IEC 60335-1A2 : 2006) SOLAR SYSTEM OPERATION Ensure that your solar hot water system is filled with water at all times. If drained at any time then the solar panels should be covered as prolonged exposure to sun without a supply of coolant water may cause damage. DO NOT turn off the ELECTRICITY or WATER SUPPLY to the Solar Controller and Pump. The pump and controller should be connected to a 240V power supply at all times i.e. throughout the entire year. Even in winter it is important that the controller is able to turn the pump ON during cold conditions to prevent panel damage due to freezing. The controller is a differential thermostat which turns the pump on and off in response to temperature signals received from a hot sensor, located in the solar panels on the roof and a cold sensor located 25
in a pocket at the base of the solar storage tank. The sensor cables must not be damaged or cut. PRESSURE & TEMPERATURE RELIEF VALVES AND COLD WATER EXPANSION VALVE. See Solar Layout Drawings to identify these valves. Never fit a PTR or ECV valve with a pressure rating greater than that indicated on the product-rating label. It is normal for the cold water expansion valve fitted to the cold mains water supply to dribble as either the solar panels or water heater heats water within the system. The expansion valve releases water from the system so that the system will be maintained at its design pressure. The PTR valve fitted to the solar storage tank should not dribble during normal operation as they are fitted as safety valves. If the PTR valve dribbles, operate the easing mechanism on the valve and allow water to discharge through the drain pipe. Remember this water may be HOT and ensure that the discharge does not come in contact with anyone. Release the easing lever SLOWLY and reseat the valve. If the valve is still dribbling 24 hours after reseating contact Solar Power Service. If no water is drawn from the system for several days in hot weather conditions the ECV valve on the solar storage tank may open and freely discharge water in order to discard the excess solar energy collected. This should happen only infrequently but it is considered normal operation. If the PTR valve on the storage water heater freely discharges hot water and steam, turn off the gas or electricity supply to the storage unit and contact Solar Power Service. Frost Protection Valve(s) Where fitted in frost areas, one frost protection valve is fitted to the bottom of each panel and must be pointing downwards. It is normal for these valves to dribble during very cold weather. Warning: If the solar system is not used for two weeks or more, a quantity of hydrogen gas, which is highly inflammable, may accumulate in the system. This may be observed as violent 'spluttering' when a hot tap is opened initially. To dissipate this gas safely, it is recommended that a hot tap be turned on for several minutes at a sink, basin or bath but not at a dishwasher, clothes washer or other appliance. During this procedure there must be no smoking, open flame, or any electrical appliance operating nearby. If hydrogen has formed and is discharged through the tap it will probably make a sound similar to air escaping. 26
MAINTENANCE Periodically as needed (minimum six Monthly) by Owner Prune or remove trees or shrubs that shade the solar panels. For effective operation the panels should be in full sunlight between at least 9am and 3pm in both summer and winter. Panels which are shaded will not function. Shading from newly erected buildings also needs to be considered and panels re-iocated if necessary. Check cleanliness of solar panel glass. Clean if covered in dust, grime, leaves or other build up. The panels may be cleaned with water and detergent only when the panels are cool. For example at the beginning or end of the day or during overcast conditions, if there has been little rain or if the panel is located in a dusty location it may be necessary to clean the panels more frequently. Note. If collector glass is broken or cracked contact Solar Power service department. Draining and flushing the water heaters and panels must be undertaken by an authorised service agent or plumber and not by the householder due to possible high water temperatures. WARNING! Working on roofs should always be considered a hazardous activity; by law you must observe certain minimum safety precautions. These safety precautions are outlined in the Work Cover Code of practice "Safe work on roofs" Part 1 and 2 and in the Occupation Health and Safety Act 1983. Flush and reseat the PTR and Cold water pressure relief valve. This is done by raising the release lever, allowing water to flow freely and then lowering the lever and letting the valve to reseat (this is to remove lime deposits and to verify that the valve is not blocked). Remember that the water discharging from the valves may be HOT and should not be permitted to come into contact with anyone. 27
Annual Service Solar Power recommends that the Solar System be serviced annually by a Solar Power accredited serviceman. The components or parts may not be covered by Solar Power warranty if damage to the system or parts is caused as a result lack of regular maintenance. Contact Solar Power service. It is important that the PTR valves, the cold water expansion and frost valves be replaced every 5 years. The protective anode fitted to the Solar Storage Tank should be checked and replaced if necessary at suitable intervals depending on water quality. It is recommended that Solarpower be contacted regarding a suitable replacement anode. Changing the anode should extend the working life of the storage tank. 28
WARRANTIES PRODUCT WARRANTY All benefits associated with this warranty are in addition to all other rights regarding this product contained within the Trade Practices Act, ACL and other State and Territory laws. The warranty for this product specifically relates to remedies as a result of defects due to faulty materials and/or workmanship Parts and labour repair or replacement warranty for this water heater is offered in accordance with the following table and Warranty Conditions: Tank Only (Steel Cylinder) Parts SP - 5 Years SPS 5 Years IME 5 Years 1 Year Labour Solar Collectors Parts SP225 5 Years IM200 5 Years Labour 1 Year All other parts (inc Parts 2 Years Valves, Labour 1 Year Thermostats, pump, controller) Commercial applications: the cylinder is covered by a 12 month materials and labour warranty. Warranty Conditions - Effective For Products manufactured after January 1, 2012 1. Water heater must be installed in a single family domestic dwelling. 2. All terms of this warranty are effective from the date of manufacture of the water heater except where the date of installation can be clearly verified with a Certificate of Compliance where the installation date is within 6 months of date of manufacture. 3. Water heaters must be installed in accordance with manufacturer s installation instructions (including installation of a safe tray), AS3500.4, AS3000, AS5601 in addition to all local regulations and municipal building codes. 29
4. Where a failed water heater or component is replaced under warranty, the balance of the original warranty period will remain effective. The replaced water heater or component does not carry a full warranty. 5. Where a water heater is installed outside of the boundaries of a metropolitan area or further than 25km from a registered SolarPower service agent, the cost of transport, insurance and travelling costs to the installed site shall be the owner s responsibility. 6. Where the water heater is installed in a position that does not allow easy safe access, the cost of accessing the water heater safely, including the cost of additional materials handling and/or safety equipment, shall be the owners responsibility. 7. This water heater warranty applies only to the installed water heater and does not apply to installation work undertaken by the installer or any parts including valves, fuses, switches etc that were supplied by the installer. 8. The water heater must be correctly sized to meet the requirements of the household in accordance with the guidelines in the water heater instruction manuals and printed materials. Warranty Exclusions 1. THE FOLLOWING WARRANTY EXCLUSIONS MAY VOID THE WATER HEATER WARRANTY AND/OR MAY INCUR ADDITIONAL SERVICE CHARGES AND/OR COSTS OF PARTS. a) Accidental damage to the water heater or any component including: Acts of God, failure due to misuse, incorrect installation and attempts to repair the water heater other than by a TPS registered service agent. b) Where it is found that there is nothing wrong with the water heater or the electricity supply is turned off or disconnected c) Where the complaint is related to excessive discharge of the pressure and temperature liming valve due to high water pressure d) Where excessive electricity or water usage which occurs as a consequence of failure of the water heater or components or workmanship e) Where the water heater has failed directly or indirectly as a result of the attachment of accessories other than those approved by the manufacturer, excessive water pressure, excessive temperature or blocked pipework including overflow/vent drain f) Where faulty plumbing has affected the performance of the water heater and/or the installation including plumbing pipes and fittings or restricted flow g) Where the water heater is located in a position such that it requires major dismantling of cupboards, walls or doors or use of special equipment to bring the water heater to a serviceable position or return to the manufacturer h) Repair and/or replacement of the water heater due to scale formation and the effects of corrosive water when the water heater has been connected to a scaling or corrosive water supply or a water supply with a high chloride or low ph level in the Installation Manual under Important Information i) Where it is found that the sensor cable has been damaged or cut resulting in an open circuit or a short circuit sensor. 30
Warranty Exclusions - Solar Panels The Warranty period for the panels is 5 years (IM200) or 5 years (SP225). The Warranty Conditions and Warranty Exclusions are the same as those applying to the Solar Power water heater or components, except when damage to the panels is caused by frost or freezing where: j) the solar controller and or pump are not operating, k) the mains water supply to the system has been turned off, l) or the mains cold water supply to the system freezes because it is not insulated, m) the anti frost valves are not fitted or fitted incorrectly or have been installed for more than 5 years. WATER QUALITY This water heater has been constructed to meet water quality conditions in most Australian water supply locations. However, harsh water quality does exist in some locations and, if in doubt, contact your local council or water supplier. Only potable water should be used in this water heater. Anode: Where the Total Dissolved Solids (TDS) is greater than 600mg/L or less than 40mg/L, the anode may be unsuitable for use to protect your water heater. In these circumstances, a plumber or authorised service person should be contacted to fit the correct anode. The Saturation Index is a measure of the water s corrosiveness. Corrosion may result in early failure of copper parts. Water is considered corrosive should the saturation index be below -1.0. Scaling can occur where the Saturation Index is above +0.4. Water heaters installed where incorrect anodes are fitted due to high or low TDS or where the water is corrosive or considered scaling will not be covered by this warranty The warranty only applies where the complete water heater system (the System) has been installed and commissioned according to SolarPower installation instructions and by an authorised SolarPower installer or licensed plumber. 1. Free repair or replacement is provided within the metropolitan area of Australian capital cities as defined by SolarPower within 25km of the city centre or a branch, office or accredited service agent. In other areas defective parts or Systems must be returned to the point of sale before replacement can be considered under the terms of the warranty. Freight and insurance charges for the transport of a defective and replacement System or parts are payable by the owner. 2. Where a failed component or System is replaced under warranty, the balance of the original warranty period shall remain effective. The replaced part or System does not carry a new warranty. 3. The warranty only applies to the System and does not cover any plumbing or electrical parts. The electrical element, the circulator pump and pump controller warranty is detailed above. 4. Warranty claims must include all details listed overleaf and should be made to the point of sale or to the company address listed below within one (1) month of the appearance of the defect. 31
5. This warranty does not cover the System where it is found that the System does not suffer a defect; where the complaint is related to solid matter lodging under valve seats; where there is a failure of water supplies, electrical supplies or the result of extreme water pressure or thermal input. 6. This warranty does not cover the System where the System is located in a position that does not comply with either the SolarPower installation instructions or the relevant statutory requirements and as a consequence there is a need for major dismantling or removal of doors, walls etc, or the use of special equipment to bring the System to ground level. 7. This Warranty excludes the removal of scale formation in the waterways where the System has been connected to a harsh water supply. 8. Subject to any statutory provisions to the contrary, this warranty excludes claims for damage to furniture, carpets, walls, foundations, or any other consequential loss either directly or indirectly due to leakage from the System. 9. The collector glass cover-plate is not covered by this Warranty. Your household insurance policy should be extended to include breakage of the collector cover-plate glass. 10. This warranty excludes damage resulting from acts of God, fire, lightning, flood, earthquake, landslide, storm, hail, frost, wind or other adverse weather conditions 11. The warranty excludes damage resulting from misuse, faulty installation or repairs carried out by persons other than a SolarPower accredited service agent or technician. 12. Water Quality, must meet the detailed description of the requirements for water quality as listed in the installation manual. 2. Subject to any statutory provisions to the contrary, this warranty excludes any and all claims for damage to furniture, carpets, walls, foundations or any other consequential loss, either directly or indirectly due to leakage from the water heater, or due to leakage from fittings and/or pipework of metal, plastic or other materials caused by water temperature, workmanship or other modes of failure. 3. Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure. 32