Solartech Solar Water Heater User & Installation Manual. Contents. 1 Owner s information

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1 Solartech Solar Water Heater User & Installation Manual Contents 1 Owner s information How does the system work? Safe Operating Procedures (How do I operate the system safely?) Roof location selection Transporting and handling Emergency Shut Down Procedures What should I do during holidays? Water discharge from the pressure valve Why? Troubleshooting System Maintenance including schematic Overview Installation record Warranty Owner s information Congratulations on your purchase of a Solartech solar water heater system! You may have some questions about the system and thermosyphon operation. This manual will help you understand your system better. What is a thermosyphon system? A thermosyphon system is a system where the heated water in the solar collectors rises up into the storage tank through natural thermosyphon action. Thermosyphon action occurs when water is heated in the collectors, expands and becomes lighter. The colder, heavier water falls to the bottom of the collector and pushes the hotter, lighter water back up into the storage tank. This natural action occurs without any moving parts or auxiliary electrical energy input to the system. What is a closed circuit system? A closed circuit system is a system where two separate water circuits are contained within the solar water heater, one for the heat exchange and the other containing the potable water. What is an open circuit system? An open circuit system is a system where the water to be used in the household (hot water) circulates through the solar collector panels transferring solar energy into the storage tank. This system type is used in locations where the ambient temperature never falls below freezing point (0 C or 32 F). What precautions are there for my system? Frost protection Open circuit systems do not have frost protection. Therefore, they must not be installed in any location where the temperature can be expected to fall below +2 C. Closed circuit systems have frost protection to -15 C. This protection is provided by the use of a Propylene glycol/water fluid in the collector circuit. Solar fluid used in Solartech solar water heaters must be approved by Solartech. Failure to comply with these conditions can result in system failure and loss of warranty. Overheating control The Solartech thermosyphon system has an automatic overheating control which will release some hot water from the system if it should reach 95 C. Please ensure that the discharge point is known and is clear of obstructions at all times. 1

2 Recommended system output For optimum solar performance of the system it is recommended that the daily usage be not more than 75 % of the storage tank volume. For example in a 300 litre system the optimum maximum daily usage would be 225 litres per day How does the system work? Short description Thermosyphon systems are complete on-roof hot water systems, in which the storage tank and solar collector are mounted on the roof as a unit. Solar radiation heats the water in the solar collectors, reducing its density. The lighter, heated water rises naturally from the solar collectors into the storage tank. The cold and heavier water from the storage falls down into the collectors replacing the heated water. The heated water flows from the storage tank into the hot water lines and can be used directly for cooking, washing or showering. If the sun does not shine for several days or the water consumption rate is abnormally high, the storage tank thermostat automatically activates an internal electric booster. The three main components of the solar water heater system are the potable water storage tank, the solar collector(s) and the internal automatic electric booster. Solartech Heat Transfer Fluid Use only USP food grade propylene glycol Storage tank The storage tank is used to store the heated water ready for household use. It is constructed using high quality vitreous enamel lined low carbon steel to provide a long life. The storage tank is insulated with a high density polyurethane material to ensure maximum heat retention and structural strength. Solar collector The solar collectors contain a multi-tube copper water way system bonded to a solar absorber plate. The collector enhances the absorption of solar energy and transfers it to the fluid within the collector circuit. The absorber plate system is enclosed in an insulated metal casing covered with a high strength toughened glass sheet that protects the absorber system from physical damage. Internal electric booster The internal automatic electric booster uses an electric element to heat part of the stored household water on those occasions, when there is reduced solar energy available, e. g. cloudy days. The internal electric booster within the storage tank is controlled by an internal thermostat. The thermostat will only allow the internal electric booster to operate if the storage tank water temperature falls below a predetermined level (normally 60 C), which can be set according to your needs. It will only consume electricity until the water temperature has increased to the predetermined level at which stage it turns off automatically. Specifications For further specifications, see the technical datasheet Solartech thermosyphon series. Storage Tank Solartech Solartech 200L 300L Storage Volume [l] Weight empty [kg] weight full [kg] Dimensions (W x H x L) [mm] 570x570x x570x1860 Connections cold water inlet Connections hot water outlet Supply Pressure Operating Pressure 3/4" BSP 3/4" BSP 1 to 5,5 bar 1 to 6 bar Internal electronic booster (standard) 220/240V, 50Hz, 2KW 220/240V, 50Hz, 3KW Solartech_SWH_User&Installations_manual_COMPACT_2012_ /04/05 02:49:00 PM 2

3 Solar Collector Solartech 2.5BC Solartech 2.5TN Weight empty 43 kg 43 kg Weight full 46.5 kg 46.5 kg Dimensions (W x H x L) 2002 x 1250 x 84 mm 2002 x 1250 x 84 mm Riser diameter 10 mm 10 mm Riser pitch 118 mm 118 mm Header diameter 22 mm 22 mm Connections 22 mm 22 mm Glass 4mm toughened, 90% 4mm toughened, 90% transmission transmission Hail resistant Yes Yes Absorber material Copper Copper Absorber surface Black Chrome Tinox TM Blue Heat Transfer Fluid propylene glycol propylene glycol Frost resistant Yes, if used with glycol Yes, if used with glycol Hail resistant Yes Yes 3 Safe Operating Procedures (How do I operate the system safely?) A Solartech thermosyphon solar water heater system is designed for fully automated operation so there is nothing you need to do for day-to-day system operation. If the internal automatic electric booster has been fitted with a remote isolator switch or time clock, you can decide when and if ancillary energy support is permitted. For example, you can isolate the internal automatic electric booster during the summer months, and you can use a time clock to permit boosting after sunset or any other combination that suits your usage habit. Careful use of these options can further reduce the amount of energy used to supply hot water to your household. Installations of timers, readily available in the market, together with a Solartech thermosyphon solar water heater system are possible and recommended as these may help you to operate your Solartech solar water heater safely. It is recommended that a temperature control valve be fitted to the hot water supply pipe work. This valve should be checked at regular intervals to ensure its operation and settings remain correct. Ensure that the pressure and temperature relief valve is not located where it can cause damage if hot water is discharged. Ensure that no children play with the hot water taps or the water heater. The following basic safety instructions form an essential part of this operating manual and are of fundamental importance when handling this product. Installation of the Solartech Thermosyphon must only be performed by qualified personnel in accordance with all the instructions given in this operating manual, the provisions of current law, the recommendation of national standards, any local regulations and the rules of competent workmanship. All work associated with the installation must comply with local authority regulations. When these installation instructions and local regulations are in conflict, local regulations must prevail. Ensure that the operating manual is available during installation. The operating manual is an integral part of the product. Keep a copy of the operating manual in the immediate vicinity of the system. Ensure that the operating manual, and in particular the safety instructions, are read and understood by the relevant personnel before installation. Do not remove or disable any safety devices. The presence of a second party who can provide help in the event of an accident is obligatory during the entire installation process. To reduce the risk of scald injury it is recommended that a temperature control valve be fitted to the hot water supply pipe work. This valve should be checked at regular intervals to ensure its operation and settings remain correct. The water heater is not intended for use by young children or infirm persons without supervision. Young children should always be supervised to ensure that they do not play with hot water taps or the water heater. Do not commence an installation until you have satisfied yourself that all safety issues associated with working on and lifting components onto a roof have been addressed. Do not turn on the power supply until the solar water heater has been filled with water and pressurised If installation and filling of the system is being carried out in sunlight, cover the collectors. Covering the collectors prevents pressure variation due to thermal activity in the collectors during installation. Solartech_SWH_User&Installations_manual_COMPACT_2012_ /04/05 02:49:00 PM 3

4 Every care must be taken to ensure that in installations where rain water is being collected from the same roof, any spilt transfer fluid is cleaned up immediately so that the transfer fluid does not contaminate the water in the rain water storage tank. The Solartech Heat Transfer Fluid is of food grade. Do not fill the closed circuit system with any toxic mixture. Only use Solartech Heat Transfer Fluid. There is a health risk in case of use of un-authorised fluid. 4 Roof location selection There are five major factors to consider when selecting the solar water heater installation location: For optimum performance, the solar collectors need to face the equator (north in the southern hemisphere). Consequently, roof locations which face less than 45 away from the equator are acceptable. If the collectors are installed with an east facing bias, the best solar input is achieved in the morning and if there is a west facing bias, the best solar input is achieved in the afternoon. Careful site inspection is required to ensure the selected location is not subject to shading from adjacent trees or buildings throughout the day, but particularly between 9 am and 3 pm, which are the highest solar input times. Shadows are longer in winter than in summer. As a result, a site that is free of shadows from adjacent objects in summer may be covered by shadows in winter. The solar water heater should be located as close as possible to the location which uses the most hot water, e. g. bathroom or kitchen. This reduces energy losses which may occur if the pipe work between the solar water heater and the usage point is too long. To achieve optimum performance in on-roof installations the solar water heater should be installed on a roof pitch of greater than 10 and less than 30. Installations on a roof, where the roof pitch is greater than 30, will require additional support at the storage tank to prevent it from moving downwards during and after installation. If the roof pitch is less than 10, the system will require a mounting frame to increase the pitch. Installations below 10 do not Thermosyphon effectively and the collector glass will not self-clean during rainy periods. The roof system structure must be carefully inspected to ensure it can support the system s weight once it is filled with water. Particular care must be taken with on-roof installations, where the front foot of the storage tank is located. Typically, the tank front foot should be located over a tile batten, purlin or similar for maximum strength. If the roof cannot support the load, additional bracing must be installed before the solar water heater is installed. 5 Transporting and handling The following instructions should be observed when handling the Solartech Thermosyphon: Consider the maximum weight of the storage tank (up to 124 kg) and of the collector (43 kg). Take the dimensions of the collector 2002 x 1250 x 84 mm (L x W x H) into consideration. Do not lift the collectors or the storage tank by the connections or push hard on the bottom. Avoid impact and other mechanical influences on the collector glass, the collector body or the storage tank. Storage tank cartons are designed for vertical or horizontal storage see carton printing for details. For horizontal storage, the maximum storage height is four pieces. Collector packaging is designed for horizontal storage. For horizontal storage, the maximum storage height is 5 pieces. See carton printing for complete details. Remove any obstacles or objects that could create a trip hazard. Do not scratch or damage the casing or paint work. Do not remove the transportation packaging until the storage tank is in installation position. Store all components in a dry location. If any item becomes wet, it must be dried completely before storage. DO NOT USE PLUMPING CONNECTIONS ON THE TANK TO CARRY THE WEIGHT OF THE TANK THIS INVALIDATES THE WARRANTY! 6 Emergency Shut Down Procedures Should an emergency occur and you need to shut down your Solartech solar water heater follow the following procedures: Shut off water supply to your Solartech Solar Water Heater Locate your water mains and close the water supply to your house. Now, locate the stop cock fitted to your Solartech solar water heater and close this. You may now re-open your water mains to ensure availability of water in your house. Solartech_SWH_User&Installations_manual_COMPACT_2012_ /04/05 02:49:00 PM 4

5 Shut off electricity supply to your Solartech Solar Water Heater Locate the circuit breaker marked as Geyser or Hot Water Cylinder or HWC or similar on your house s electricity distribution board and switch this off. Alternatively, you can switch off the electricity supply to your Solartech solar water heater at the circuit breaker fitted to it. Shut off the natural Thermosyphon Process Locate your solar collectors and cover them to avoid exposure to solar radiation. 7 What should I do during holidays? If you are going to be away for a week or longer during the summer months it is advisable to turn off the electricity supply to the internal automatic electric booster and, if appropriate, cover the solar collectors. If the solar collectors are not covered there is a possibility that the high temperature valve in the storage tank may open briefly to reduce the storage tank temperature while you are away. This is a normal function and does not harm the system. If the hot water system has not been in use for two weeks or more the hydrogen gas must be dissipated by turning on the hot water tap of a sink, basin or bath but not a dishwasher, washing machine or other appliance for several minutes. During this procedure, there must be no smoking or open flame and no other electrical appliance operating nearby. Do not put your hands or any other part of your body beneath the tap. If hydrogen gas is discharged through the tap, an unusual noise will probably occur, which sounds like air escaping. 8 Water discharge from the pressure valve Why? All Solartech thermosyphon solar water heaters are equipped with either one or two pressure valves in the potable water system. For solar water heaters that only have a pressure and temperature valve located on the storage tank it is normal that a small amount of water is discharged during the heating cycle of the system. Closed circuit systems have a collector circuit pressure control valve located at the top of the storage tank adjacent to the pressure and temperature valve. The collector circuit valve is typically rated at 100 kpa (1 bar) and will discharge fluid during the first heating cycles after installation. This is normal and will cease once the storage tank has reached its maximum temperature. 9 Troubleshooting If there is not enough hot water we recommend that the following points are considered: Low solar energy input If there have been prolonged periods of cloud or during long periods of cold weather it may be necessary to reconsider the permitted internal electric booster time for time-clock controlled systems or to turn on the internal electric booster for systems with an isolation switch. Solar collector shading Often trees or other buildings shade the solar collectors or dirt has built up on the glass cover. Trees should be cut back if possible. If the shading cannot be removed the system should be relocated. If the glass is dirty it should be cleaned with a common domestic glass cleaner. Internal electric booster not operating The fuse or circuit breaker supplying the internal electric booster should be checked. If the time clock (where fitted) and the fuse or circuit breaker are operational and the water is cold you can turn the booster isolator on and off to see if the electricity meter speed changes. If there is no change in speed this indicates a booster failure. In the case of gas systems, the gas and electric supplies to the gas heater should be checked to ensure they are both switched on. If the water temperature from the gas heater is below 60 C and both supplies are on and the gas heater does not ignite there may be a problem. Is excessive water being discharged from the valves? If there is a discharge of more than 10 litres per day from any of the system valves there may be a problem requiring attention. Do not open or adjust any electrical covers or devices yourself! A qualified installer/electrician should carry out all maintenance to maintain your warranty. Are you using more hot water than you think? Often the hot water consumption of showers, washing machines and dishwashers is underestimated. Check these appliances to determine if your daily usage of water is greater than the storage volume of your water heater. Check the system model number to determine the number of litres you system can store. When water usage is greater than the storage capacity of the geyser, there may be periods where the water temperature is slightly lower than normal. As a guidance level, a correctly dimensioned installation will, on average, use 80 % of this volume each day. It is also advisable to inspect tap washers, hot water piping etc. for leakage and repair/replace them if necessary. Solartech_SWH_User&Installations_manual_COMPACT_2012_ /04/05 02:49:00 PM 5

6 10 System Maintenance including schematic Overview The Solartech thermosyphon system is designed in such a way that little system maintenance is required. Personally inspecting or servicing the system is not recommended. Glass cleaning usually occurs through natural rainfall, however if system is installed in an industrial (or similar) area with high levels of airborne particles a qualified person can clean the collector glass with normal window cleaning agents and equipment. The release device on the T&P relief valve should be operated at least every six months. Failure to do so may lead to tank failure. If water does not discharge freely from the valve they should be checked by the local service agent. The relief valves and relief valve drain lines must not be blocked. Some water may discharge during each heating cycle. In major metropolitan areas, the water quality expected to be of such nature that the water contains an amount of Total Dissolved Solids (TDS) less than 600 ppm. You should receive guidance from your local authorities on the water quality in your area. It is recommended that a qualified and Solartech approved installer annually inspects and if necessary replace the sacrificial magnesium anode, safety valves and checks the solar fluid level and pressure. In locations where the potable water contains an amount of Total Dissolved Solids (TDS) greater than 600 ppm, this service is recommended more regularly depending on the water quality. Your local Solartech approved installer/technician will be able to recommend a suitable service interval depending on your local water quality and conditions. Schematic Overview of serviceable items The items shown in bold below are serviceable in terms of the above maintenance guidelines: (1) Enamelled inner tank with magnesium anode (2) Heat exchanger (only closed circuit system) (3) Polyurethane insulation (4) Solar collector (5) Collector water way (6) Cold water inlet (7) Internal automatic electric booster (8) Hot water outlet (normal location of safety valve) 11 Installation record Please register your installation on our website 12 Warranty Your Solartech Solar Water Heater offers a comprehensive 10 year warranty! The terms of the limited Warranty are set out below. 1. WARRANTY NATURE The Solartech Solar Water Heater and certain components thereof are warranted against defective factory parts/materials or factory workmanship as set out in this document. This warranty is subject to the water quality in the area being equivalent to that in major metropolitan areas (below 600ppm TDS). Damage resulting from improper installation and/or transport is not covered by this warranty. The warranty is only valid upon presentation of original proof of purchase and subject to compliance with the service plan set out below. Solartech reserves the right to test the Solartech Solar Water Heater prior to any repair/replacement under this warranty. Solartech reserves the right to repair before replacing tank, solar collector or any component thereof. 2. DATE OF COMMENCEMENT The warranty commences from the earlier of the date your Solartech Solar Water Heater is installed as shown in section 8 of the owner s manual or the date of purchase. Failure to provide the original proof of purchase will result in voiding of the warranty. 3. NOTIFICATION OF CLAIM Solartech_SWH_User&Installations_manual_COMPACT_2012_ /04/05 02:49:00 PM 6

7 Any claim under the warranty or replacement guarantee must include the full details of the defect and/or damage to the hot water unit and solar collector or components in the hot water unit and solar collector. All claims must be made within one month of the detection of the defect. Warranty claims shall only be valid if and once the Solartech warranty claim form has been duly completed, signed and returned to Solartech by the owner of the Solartech Solar Water Heater. The Solartech warranty claim form is available upon request. 4. NORMAL / INTENDED USE This warranty is subject to the normal use of the Solartech Solar Water Heater and does not apply where the Solar Water Heater or components thereof have not been used as intended by the manufacturer. 5. INSTALLATION OF THE SOLARTECH SOLAR WATER HEATER The installation of the Solartech Solar Water Heater must comply with SANS applicable to this type of product. These may change from time to time and for the purpose of this warranty, the SANS applicable at the date of purchase and/or date of installation shall apply. Any installation of the Solartech Solar Water Heater must be performed by a Solartech approved installer/technician. Failure to comply will void the warranty. The installation of your Solartech Solar Water Heater is not covered under this warranty and in cases of installation failure the original installation service provider is responsible for any warranty claims. 6. REPAIR AND MAINTENANCE OF THE SOLARTECH SOLAR WATER HEATER Any repair or maintenance work performed on the Solartech Solar Water Heater must be performed by a Solartech approved technician/installer. Failure to comply will void the warranty. In addition, fitment of parts or spares not approved by Solartech will void the entire warranty. 7. WARRANTY DURATION The following guarantee durations apply to the parts and component of the Solartech Solar Water Heater (items not shown below are not guaranteed): Component Year(s) Note Solartech TS Tank 10 Subject to compliance with service plan Solartech Flat Plate Collector 10 Subject to compliance with service plan Solartech Evacuator Tube 5 Collector Solartech Frame 1 Thermostat 1 Element 1 Safety Valve 1 Draincock 1 Any other component Manufacturer T&Cs apply. Where a tank, solar collector or a component of a Solartech Solar Water Heater is replaced by Solartech, the balance of any original warranty or replacement guarantee period will remain effective. The replacement part or Solartech Solar Water Heater does not carry any additional warranty. Where Solartech installs/sells any non-solartech tanks and collectors, the original manufacturer s warranty periods apply. 8. SERVICE PLAN The limited 10 year warranty applicable to the Solartech TS Tanks and Flat Plate Collectors is subject to compliance with the Solartech Service Plan. This requires a Solartech approved technician/installer to perform a minimum service of the Solartech Solar Water Heater including an inspection of the safety valve, thermostat, element and sacrificial magnesium anode (compulsory replacement if deteriorated more than 50%). In addition, the Solartech approved technician should inspect the level of heat exchange fluid and where necessary top this up and pressure test the system. Failure to comply with the requirements of the Solartech Service Plan will result in a reduced warranty period of the Solartech TS Tank and Flat Plate Collectors of 5 years, provided the water quality in the area being equivalent to that in major metropolitan areas (below 600ppm TDS). Any service work under this Service Plan needs to be certified by Solartech, by issuance of a Solartech Service Certificate. The following table should assist you in maintaining your Solartech Solar Water Heater: Solartech_SWH_User&Installations_manual_COMPACT_2012_ /04/05 02:49:00 PM 7

8 Event Installation Service 1 Service 2 Service 3 Service 4 Service 5 Service 6 Service 7 Service 8 Service 9 Service 10 Installation or Service Date Invoice Number Solartech Service Certificate Number Upon claiming under this warranty, you will be required to present the above information to qualify for performance under this warranty. 9. AREA COVERED The warranty is valid in South Africa and Namibia. Where the Solar Water Heater is located more than 25km away from a Solartech office or distribution centre the owner is responsible for the costs of transporting any component of the Solartech Solar Water Heater to and from an approved installer or the location of the system. 10. ACCESS FOR REPAIRS Where the warranty applies but the tank and solar collector is installed or located in a position that does not comply with the installation instructions or any relevant statutory requirements, the owner of the Solartech Solar Water Heater will be responsible for the costs of: The dismantling/removal & re-fitment of cupboards, doors, walls, roof structures and other special equipment; and Any labour required to gain access to and to bring the system/unit to a position that complies with the installation instructions or relevant statutory requirements. The following free access is required to perform any maintenance and/or repair work: 500mm unobstructed space around the safety valve; 500mm unobstructed space around the draincock; 1 000mm unobstructed space around the cover plate. 11. WARRANTY EXCLUSIONS The warranty does not apply to any defects or damage not due to defective factory parts/materials or factory workmanship, including but not limited to defects or damage caused by or resulting from: a. Acts of God (force majeure), crime and terrorism. b. Accidental damage, abuse, misuse, maltreatment, abnormal stress or strain, harsh or adverse water conditions, contamination or corrosion from particles in the water supply, excessive water pressure, excessive temperature or neglect of any kind to the hot water unit and solar collector or their components. c. Alteration or repair of the Solartech Solar Water Heater other than by an approved Solartech agent or a technician of a gas or electricity utility approved by Solartech. d. Attachment of any parts or accessories other than those manufactured or approved by Solartech. e. Faulty or improper installation of the Solartech Solar Water Heater, including installation otherwise than in accordance with the instructions contained in the Owner s Manual and Installation Manual supplied by Solartech. f. Usage of the plumbing connections to carry the tank will invalidate the warranty. g. Collector glass is not covered by this warranty. h. Where hot water temperature & pressure relief valve, cold water expansion valve, check valve and strainer is not fitted in areas where mains pressure is likely to exceed 400 kpa. i. Where a closed circuit heat exchanger is not filled with the correct concentration of ST-5 heat transfer fluid in accordance with instructions. j. In case of excessive pressure of closed circuit system beyond the 400kPa maximum working pressure. k. Any plumbing or associated parts such as pressure limiting valves, stop cocks, non return valves, electrical switches, pumps or fuses are not covered by this warranty. Solartech_SWH_User&Installations_manual_COMPACT_2012_ /04/05 02:49:00 PM 8

9 l. Damage through commissioning of the system without having filled the tank with water first or from exposure of the solar collectors to sunlight without being filled with water/heat exchange fluid. m. Burnt out elements due to inadequate electric connections. n. Where closed circuit has had water addition not in accordance with water quality specifications; and o. Frost damage to open circuit system if installed in frost affected areas. 12. LIMITATION OF LIABILITY Solartech s obligations under this warranty are limited to repairing or replacing the tank and solar collector or components thereof. To the extent permitted by law, Solartech will not be liable for any loss or damage to furniture, carpets, walls, foundations or any other consequential loss of any kind caused by a defect in the tank and solar collector or any component thereof. 13. WARRANTY CONTACT DETAILS Contact trading as Solartech on the following details: Contact Method Contact Details Telephone Facsimile Web These contact details may be subject to change from time to time without prior notice. If in doubt, consult our website for the most up to date contact details. Solartech_SWH_User&Installations_manual_COMPACT_2012_ /04/05 02:49:00 PM 9

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