Installation, Operation And Maintenance Guide

Transcription

1 Vision Solar Systems 100 L Gravity Fed Type Vision Solar Systems 100 L Gravity Fed Type Installation, Operation And Maintenance Guide 1

2 ! IMPORTANT NOTICE Please read this manual immediately on receipt of the equipment, before unpacking and installation. Failure to comply with these instructions can render warranties null and void. Care for your equipment and safety Read these instructions before preparing to install the solar water heating system. The instructions contain information that will assist you in your task, provide information about what is contained in the packaging, and information about the water heater s performance and characteristics. Position the system so that the Tubes are out of reach of children and children s play areas. If necessary, a guard can be purchased to protect the tubes from objects directed at them. Position the system and any overflow pipes will guide any runoff water into a safe area. If this is not possible, then a gutter must be fitted to guide any overflow water into a safe point of discharge If animals, particularly monkeys are a menace in the area, then additional protection measures will need to be taken to prevent damage or malfunction of the system. This protection should prevent access, but not affect the sun reaching the collector. Do not touch the inside of the tubes, if they have been subjected to solar irradiance, the inside can be extremely hot.. Do not fill the system with water if the tubes have been subjected to solar irradiance, the sudden contraction with the cold water will result in the tubes cracking The main storage water tank must always be vented to the atmosphere. Vent pipes must be open to the atmosphere Do not fit any pressure controlling devices on the overflow or vent pipes. Vent pipes must be open to the atmosphere Only use elements and thermostats approved by the manufacturer. 2

3 The Electrical Element should be connected by a qualified electrician registered with the Electrical Contractors Board. This will insure that a correct and safe installation is completed. Ensure that all electrical connections are kept dry and protected from the ingress of water and moisture. The installation should be performed or under the control of a qualified person in terms of The National Building Regulations and any additional regional requirements as set out by Local Building Regulations Try and use a plumber who is registered with the Plumbers Registration Board (PIRB) AND who has completed the elective course on Solar Installations, and who is familiar with the product. The installation must comply with the National Building Regulations, The National Water Regulations and the Local Water (Plumbing) Regulations in the area where the installation takes place. Avoid axial or twisting force on the pipes. Do not use a pipe wrench on the pipe to tighten the connection. Always hold the pipe when tightening the connection. It is important to the operation of the system to use balanced pressure to any mixing valves on the hot water outlet to prevent back feed into the system. We do not recommend connecting mixing valves to the system outlet. While these systems contain no hazardous materials, it is always good practice to recycle. Should you need further information, please contact your local agent. 3

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5 INDEX Care for your equipment and safety 2 Unpacking 6 Reporting Problems with This Guide 6 For Further Information and Technical Assistance 6 Principal of Operation 7 Performance 11 Specifications 13 Installation 14 Using a timer on the Electrical Heating 18 Cleaning 21 Routine Inspection and Maintenance 21 Trouble Shooting 23 Warranty Policy 24 5

6 Unpacking It is important when receiving the equipment that you confirm that all the components of the system are received and are in good order. Listed below is a table of some of the most common parts ordered with an indication of whether these parts are supplied as standard or as optional equipment. Please check any additional parts against the original delivery note or invoice. Description Qty Supplied as Kit System Frame (Flat Roof or Pitch Roof as per Order) 1 Main Tank 1 Electric Element (Supplied fitted if ordered with Tank) Thermostat (Supplied fitted if ordered with Tank) Isolator Switch and Weatherproof Box 24 hour Timer with spring reserve Reservoir Tank (with Ball Valve fitted) 1 58 x 2000 x 2 mm Vacuum Tubes 10 Cold Water Pipe Kit Hot Water Pipe Kit Overflow Pipe Kit Drain Valve 2 x 4 Weatherproof Electrical Box with Isolator Tempering Valve Tube Guard (Expanded Metal cover for tubes) Optional at additional cost Reporting Problems with This Guide Please use the fax or addresses below to report any problems you find in this guide. Enervision Technical Services FAX: info@enervision.co.za For Further Information and Technical Assistance Enervision (Pty) Ltd recognizes the need to keep you informed about the availability of current product information. For up-to-date product information and a complete listing of sales offices, visit the Enervision website at: For comprehensive product data sheets, Product Guides and application notes please contact your local Enervision representative or info@enervision.co.za For technical assistance, contact your local Enervision representative in the first instance, alternatively phone or or info@enervision.co.za 6

7 Principal of Operation Construction The system comprises an inner storage tank, an outer cladding and an insulation medium between the two. A cistern tank with a ball or float valve is attached to the main tank and acts as a control valve to keep the main tank full. The solar collector consists of vacuum tubes that collect the energy from the sun, and via thermo siphon, will heat the water in the tank. The tank should be fitted with a vent pipe connected to the side of the tank, and raised to above the level of the vent on the cistern tank. This will ensure that the tank is not subjected to any pressure. These solar water heating systems consist of four major parts as shown in the picture and detailed below: The Thermal Storage Tank The thermal storage tank is a stainless steel tank constructed from 304 stainless steel material and, being a low pressure tank, we can use a technology we term no-weld. This involves all the pipe connections to the tank using a long life silicon grommet type seal and the end caps using a pressed and rolled seal. This eliminates welding from the tank and increases the longevity of the tank as any weld points can act as points where corrosion will start. The tank holds the potable water, is maintained full of water by the cistern tank, and has the collector tubes connected to it. Water is drawn from the tank by gravity feed. The tank must be located above the water outlet, and the pressure of the water is determined by the height of the tank above the water outlet. 7

8 The Collector The collector consists of vacuum tubes that contain some of the thermal fluid (water) and are connected into the tank via a silicon grommet type seal. The vacuum tubes are constructed from two extremely strong Borosilicate glass tubes of different diameters and placed one inside the other. At the one end the tubes are joined together and sealed and at the other end the inner tube is supported. A vacuum is then drawn so that the space between them becomes a vacuum. The vacuum prevents heat loss from the tubes (much like a thermos flask) and ensures that while the inner tube can contain hot water the outer tube is cool to the touch. In order to maintain the vacuum between the two glass layers a barium getter is used (the same as in television tubes). During manufacture of the vacuum tube the getter is exposed to a high temperature which causes the bottom of the tube to be coated with a layer of pure barium. The barium layer actively absorbs any CO, CO², N², O², H²O and H² gasses from the vacuum tube during storage and operation thus helping to maintain the vacuum. The barium layer also provides a clear visual indicator of the vacuum status. It will turn white when the vacuum is lost. The inner tube is coated with a special multi-layer coating forming a selective absorption layer that assists with the collection of energy from the sun and transfers this energy into heat in the water. The number of tubes used is chosen to cope with the volume of water in the tank which needs to be heated on a standard solar day. The Cistern or Reserve tank The cistern or reserve tank is a small tank which feeds the main thermal tank. It contains a ball valve which ensures that that the reserve tank is always filled to a certain level. If the level in the main tank drops through the cooling (and reducing volume of the water) the ball valve will open and top up the system. The ball valve is the only moving part in the complete system. WARNING: Do not extend the pipe connecting the cistern tank to the main tank. This will increase the pressure of the main tank which is designed to be vented to the atmosphere at a height of less than 1m from the main tank. The Backup Heating In any heating system the time that hot water is not available must be limited. On cloudy days the solar energy able to be harvested could be limited and, though there is a degree of energy available, it may not be sufficient to heat the amount of water required. In this system a thermostatically controlled backup electrical heating element is used to heat the water in the tank. NOTE: The element is supplied as an optional extra, and if required, should be included in your order to your supplier. Operation Collecting the energy from the sun As the sun s rays fall on the collector or collector tubes the irradiance is transformed from the light energy to heat energy in the water in the tubes. The coating used on the inside assists in transforming the ultraviolet light from the sun into heat inside the tubes. This aids in collecting some solar (UV light energy) on cloudy days. The heated water inside the tube expands and become more buoyant. It moves up the collector tube and eventually enters the tank, and it is replaced by colder water from the tank which is, in turn, heated by the sun s energy. This process, known as thermo-siphon, happens continuously while the solar energy falls on the collector. 8

9 Maintaining the energy in the thermal storage tank The tank is constructed of double shell much like the tubes. The inner shell is stainless steel and contains all the connections and seals for the pipes and tubes. This tank is open to the atmosphere and is not under any pressure. The outer tank or shell is a thin sheet that protects the system and between the two layers is a thick layer of thermal insulation that restricts the loss of heat from the water in the inner tank. Using a low pressure tank to contain the thermal mass of water has its advantages. Firstly, it limits the maximum temperature of the water in the tank as the water cannot rise above 100ºC the point at which water boils at sea level. Secondly, by not having a tank of hot water under pressure, there is no need for management to ensure the safety of people, animals and possessions near the tank. Supplying the Hot Water Water is supplied to the plumbing by gravity feed. This requires that the tank is mounted above the water outlet to ensure a supply of water. The higher the tank is mounted above the water outlet, the greater the pressure of the water at the outlet. Note that the tank is designed for zero pressure, to extend the height of the cistern would place the tank under pressure, and this will affect the safe operation of the system, and can be harmful to persons and property. The Backup Heating The need for backup heating is twofold firstly, to compensate when there is little or no sunshine, and, secondly, when water usage exceeds the daily solar heating capacity. In these situations the backup element acts as a substitute heat source to the sun. It is a good practice to fit the timer to the supply feed for the element. With electricity conservation being the objective, a timer with a reasonable reserve (time it will continue to maintain time without the mains available) and the ability to set up exclusion zones should be installed. This will prevent the use of the electrical element during peak electricity usage period and also during the sun s normal heating time. Considerations There are some considerations to take into account in a system like this as the performance of the system differs to that of a normal hot water system. 1) The supply of water is via a gravity feed. Do not expect high pressures from the system. Flow rates will depend on the height of the tank above the water outlet, and the restriction of the pipe work to the water outlet. 2) The temperature of the water is dependent on the solar energy collected, and the amount of water used. On sunny days with little water usage, the temperature can very high, and on cloudy days with lots of water used, you can run out of hot water. 3) As the hot water is drawn from the system the water in the tank cools. This means that the water temperature tapers off as the water is used. In other words, initially the water temperature may be 65ºC, after half the water is used it may drop to 55ºC and at the end it may be as low as 40ºC. This means you will initially use a low amount of hot water and mix with cold water to get the water to the desired temperature and at the end you may be using mostly hot water with very little cold water mixed in. Safety and Operation There are certain great safety features in this type of system; 1) The tank of hot water is at low pressure so the water cannot be superheated under pressure and will never exceed boiling point. If left unused for an extended period of time the excess solar energy collected each day will boil out into the cistern tank and, at worst, some water can be lost through the overflow. This provides inherent safety of overheating and possible bursting of the tank. 9

10 2) The tubes are cool on the outside; consequently there is no danger of being burnt should they be touched. 3) No pressure and temperature relief valve is needed provided that the system is correctly installed, with the vent pipes not extended more than 1 meter above the main tank. On the operational side there are also some great features; 1) The ball valve is the only moving part. High quality brass and stainless steel valves are used to ensure durability and consistent operation. 2) The system works naturally so it will not need any power to control or manage the hot water. Even overheating and freezing of the main tank parts are inherently controlled. 3) Inherently freeze resistant with the water in the main tank. (Excluding connecting pipe work) 4) Inherently protected against overheating by the low pressure vented tank design and the latent heat absorbed by boiling water. 5) No glycol or sacrificial anode maintenance required. 10

11 Performance The output of the solar water will depend on the amount of solar irradiation that reaches the collector throughout the day. On a good day, with 6-7 hours of sunlight, the glass tubes will collect enough energy to heat the water up to 60ºC - 70ºC. You may even spot steam coming from the vent pipe as the water reaches boiling point. This is quite normal if you have not been using water from the system. By setting the tilt less than the latitude the system will work better in summer and using a tilt of more than latitude will improve the performance in winter. By facing the system a few degrees east of true north the water will heat earlier in the day and, similarly, a little more west of north will mean the water will heat later in the day. Shown below is the average solar irradiance for various cities in South Africa for collectors positioned at true north and a tilt equal to the latitude: Solar Irradiance MJ/m²/day (figures from NASA 22 year average) Area Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Johannesburg Cape Town Durban Port Elizabeth East London Bloemfontein Based on the above average solar irradiance, the average daily temperature rise of the thermal storage water would be as shown in the table below. Note that these are average figures and, on any one day, depending on the cloud cover and temperature, different results will be obtained: Expected Average Temperature Rise of water in the Storage Tank from Solar Only Area Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Johannesburg Cape Town Durban Port Elizabeth East London Bloemfontein Note that one needs to consider the amount of hot water drawn from the tank each day (the energy used) and the residual temperature each day to determine what the actual storage tank temperature will be, and what the total available hot water from solar heating only will be. Based on at least this hot water input being used every day, in other words, that tank is in equilibrium, without boiling, or running out of hot water (the balance coming from electrical heating if this is required), the average daily saving in electricity is shown in the table below: 11

12 Water Temperature in the Tank Vision Solar Systems L Gravity Fed Type Average Energy Saving per Day (kwh) Area Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Johannesburg Cape Town Durban Port Elizabeth East London Bloemfontein Always remember that the solar performance will depend on the amount of sun on the collector. Cloudy weather will decrease performance and reduce the amount of energy harvested from the sun. In addition, shade from trees and other objects during the day will mean that less solar energy is harvested. There is a backup element that can be fitted to the system to cope with bad weather and lower solar irradiation and also for abnormally high hot water demand. The backup element is thermostatically controlled and is normally used in conjunction with a timer so that the use of electrical energy can be controlled and used only when there is no solar harvesting likely to take place. In order to heat the water in the tank with the electrical element some time is needed to attain the required temperature. Shown below is the graph of the time taken to heat water from 20ºC to 70ºC Reheat Time with Electric Element kw Element 20.0 Time in Hours If the tank is at a higher temperature the time for 20ºC to the starting tank temperature can be subtracted from the full reheating time. Note that you will need to take into account the timer exclusion zones if these are active in the electrical element reheat cycle or alternatively put the timer into the bypass mode. 12

13 Specifications Description System Type Storage Tank Capacity Inner Tank Material Inner Tank Diameter Insulation Material Insulation Thickness Insulation Density Outer Tank Material Optional Outer Tank Diameter Optimal Flow Rate Fluid Type Tank Maximum Pressure Collector Tubes Outer Tube Diameter Material Thickness Inner Tube Diameter Material Coating Aperture Area Absorber Area Performance Estimated Life Span System Output (16MJ) Specification TZ58/ l 0.6mm US mm Polyurethane 50mm 36kg/m² Zinc coated 0.4mm Painted Steel 475mm 7l/min Water 50kPA 58mm Lead Free Glass 2mm 47mm Lead Free Glass Multilayer SS-C/Cu 0.95m² 1.76m² 10 years MJ Note: In order to allow for continuous improvement, Enervision reserves the right to update and change specifications without prior notice E&OE. 13

14 Installation Tools Required It is essential that the installation is completed by an accredited plumber who has been trained in solar water installations and has completed an installation training course on this type of solar system. In order to complete the installation successfully the following tools are recommended: 3m Ladder (two recommended) Ropes and slings 10mm Ring Flat Spanner 13mm Ring Flat Spanner 19mm Flat Spanner 22mm Flat Spanner Small Flat Screw Driver Adjustable Spanner Copper Pipe Cutter Gas Solder Unit Solder Flux Solder System Location The location of the solar water heater should be on an even surface facing true north. A variation of 20 degrees either side of true north will have a negligible effect on the overall performance. The collector must be in full sun, free from shadows, between the hours of 9am to 4pm throughout all the seasons. The tilt angle recommended for the collector is latitude plus 15 degrees. Increasing the tilt angle will improve the winter performance while decreasing the tilt angle will increase summer performance. The lower the latitude, the more critical the tilt angle will be to the overall system performance. Cloud cover will affect performance, if cloud is predominantly in the mornings, then try to face the solar collector more west of north, and if cloud cover is in the afternoon, then facing the collector more east of north will assist the performance. The Solar input as indicated on page 11 will provide an indication of the worst performing months of the year. In winter rainfall areas it is recommended that the tilt angle is increased to improve winter performance. Tips on finding True North Satellite dishes point to PAS7/10. This is positioned 68 degrees East of North. Some GPS systems will have a compass. Please confirm the accuracy of this before using it as they will sometimes require movement to determine direction. Use of a sundial type compass with a vertical shadow and a time of day can also be used to find True North. 14

15 Frame Assembly Assemble the frame as indicated in the sketch below: Ensure that all the bolts and nuts are tight. Securing the System Ensure that the intended location is sufficient to support the full weight the system when it is filled with water, and that there will be negligible sag that can damage rigid materials such as tiles if there is any movement. The rear legs are attached to a spreader beam to spread the weight of the water in the tank across the roof area. The spreader contains holes that allow the frame to be secured to the structure on which it is mounted. Use suitable bolts and nuts to secure the feet to the structure. Ensure that all feet are secured to a ridged part of the mounting structure. Any penetration of the roof structure must be suitably repaired to maintain the waterproofing. Failing to adequately secure the system to the structure can result in the frame flexing when subjected to high winds. This can cause excessive stress on the frame, tubes and tank and can result in the tubes fracturing. Where extremely high winds are experienced, additional care must be taken in securing the system and additional stainless steel guys may also be required to ensure that the system is securely mounted. Mounting the Main Tank and Reservoir Tank Always secure the pipe connection to the tank with a spanner to prevent any axial or twisting forces on the pipe. Use the mounting support bracket for the reservoir tank and adjust the feet to ensure that there is no axial force on the pipe connection. Remove the thread protection caps and nuts from the tank mountings. Lift the main tank and position it on the frame curved tank mounting brackets, ensuring that the bolts are not pushed into the tank. The tube holes should be pointing towards the front of the frame and the pipe connections should be on the right hand side when looking at the collector from the front. Put the tank bolts into the slotted holes in the tank mounting bracket and lightly tighten the nuts onto the bolts. 15

16 Rotate the tank so that the bolts are approximately in the middle of the slots. Place the reservoir tank mounting bracket over the pipe inlet on the right hand side of the tank near the pipe connections. Screw on the reservoir tank and turn until the thread is tight. You will need to use a spanner to hold the pipe from the main tank. Once the tank is tight use the plastic bolts on the bracket to support the tank and ensure that there is no axial force on the pipe connection and ensure that there is no movement on the mountings. Connect the drain valve that complies with SANS to the bottom outlet on the tank. Additional Overflow pipe Overflow pipe Cold Water Supply Hot Water Output Connect the cold water pipe, as shown, to the reservoir tank. Ensure that the shutoff valve is fitted to this pipe. Connect the hot water pipe to the hot water output at the bottom of the tank. Connect the overflow pipe to the reservoir tank as shown in the schematic. Connect an additional overflow pipe to the side of the main tank as shown in the schematic. For all these connections, again take care to support the pipe connection to the tank in order to ensure that no axial or twisting force is applied to the tank pipes. Connect the cold water shutoff valve to the cold water supply. Test all connections for leaks. The shutoff valve on the cold water feed can be used to control the water flow. Enervision recommends that the hot water pipe from the geyser to the point of use does not exceed 10m and that the pipe is lagged along the whole length. In frost areas, cold water pipe and overflow pipes must be suitably lagged to prevent freezing. 16

17 Inserting the Vacuum Tubes Do not fill any tubes with cold water if they have been exposed to the sun. The sudden contraction will cause them to fracture. Keep the tubes covered and in the packaging when not preparing them for insertion into the tank. Spray or dip the open end of the tube in a dilute soapy non-toxic water solution. Pull the dust cover over the tube to about 150mm from the open end of the tube. Ensure that it is placed the correct way round with the bevelled side away from the open end. If necessary, re-wet the open end of the tube. Insert the tube into the opening of the tank, working from the centre to the outside. The tubes should be inserted well into the tank and then pulled back into the boot on the back box mounted on the stand. Once the tube has been installed in the tank, move the dust cover into position. It is recommended that the supply and outlet pipework is completed before the tubes are incerted. This will allow for a slow trickle water into the main tank to fill the tubes as the tube is inserted fill with water. Alternatively cover the tubes with an opaque cover, such as canvas cloth or the cardboard box until the system is filled. Adequate precautions must be taken to prevent the tubes from heating in the sun. If this is not possible, wait until the early hours of the morning, before the sun has had time to heat the tubes, to fill the system with water. Fitting the Electric Element Any electrical work done on the system should be done by a qualified electrician. There are various safety and legal requirements that must be complied with. In order to comply with the safety requirements, only Enervision Approved elements and thermostats may be used in the system. Do Not fit an electric element without a thermostat. If the system was ordered with an electric element, the element will be pre-fitted to the system. The Code of Practice for electrical installations requires that a two pole isolator switch is fitted to the supply to the element. 17

18 Using a timer on the Electrical Heating (Optional) Fitting a Timer Enervision recommends that a timer is fitted to control the supply to the element. This should exclude the peak demand periods in the morning between 7am and 10am, in the evening between 6pm and 9pm, and also between 10am and 3pm when normal solar water heating is taking place. (On cloudy days this time zone can be overridden if hot water is required in the early evening.) MTD 2 Type Timer This timer is a 24 hour timer with 15 minute programme intervals and a 7 day reserve. Connect the electrical circuit as shown in the diagram below. Programming the Timer Each toggle in the programming dial corresponds to a period of 15 minutes. When the toggle is in the right hand position, the element is on and when the toggle is ion the left hand position then the element is off. To set the timer for Eskom DSM, switch all toggles over to the right. Turn the dial and set the toggles from 7am to 3pm to the left position. Repeat the above for the times from 6pm to 9pm. Turn the dial so that the current time corresponds with the actual time. Note that the timer has a 100 hour reserve. If the power is off for more than 100 hours the time will need to be reset. Note: there is a manual override on the timer which allows the timer function to be overridden. For normal timer operation the override should be in the upper position and to override must be moved down. The MTD8 or the TDDGT Type Timer This timer is a 7 day timer with 1 minute programme intervals and a 15 day reserve. Connect the electrical circuit as shown on the diagram below: 18

19 Programming the timer Setting the time If there is no display, press and hold the RESET button for a few seconds Press and hold down the clock button while pressing the D+ button to the desired day of the week. Press and hold down the clock button while pressing the H+ button to the desired hour. Press and hold down the clock button while pressing the M+ button to the desired minutes. Release the clock button when the time and day is set. Setting the Time Zones Press P, Display will show the Time Zone 1 On time. Use the H+ to set the hour. Use the M+ to set the minutes. Use the D+ to set the day of the week. Enervision recommends MTWTFSS as default. (cycles MTWTFSS, MTWTFS, MTWTF, SS, MTW, TFS, MWF, TTS, M, T, W, T, F, S, S) Press the P again. Display will show Time Zone 1 OFF time. Press the H+ to set the hour. Use the M+ to set the minutes. Use the D+ to set the day of the week. Enervision recommends MTWTFSS as default. Press P again to go to Next Zone and continue from the top, or Press Clock to stop setting Time zones. There are a possible 16 time Zones that can be set. 19

20 First Filling with Water and Commissioning Do not fill any tubes with cold water if they have been exposed to the sun. The sudden contraction will cause them to fracture. Two methods can be used for the first filling of the tank. Method 1 Filling while inserting the tubes; In this method the installation of the system needs to be complete with all the plumbing connections made except for the vacuum tubes. Open the inlet supply valve and allow the water to fill the tank up to the holes for the vacuum tubes. Adjust the water so that it just trickles out of the tube holes. Check that the water contains no gritty deposits. (If this is the case, Enervision recommends the fitting of a filter trap and implementation of a regular maintenance procedure to clean the filters). Prepare the first tube for fitting with the dust cover and soapy lubrication. Insert the tube into the hole and then secure into the tailstock. Continue with the next tube, all the time ensuring that the tubes immediately start filling with water once they are fitted. Once all the tubes are fitted open the inlet valve completely and allow the tank to fill via the ball valve and reservoir tank. Check that the ball valve closes once the tank is full and that no water is discharged from the overflow. Check all installed pipework to ensure that there are no leaks. Open the drain and drain off 10 litres of water into a clean bucket. Check for any gritty deposits and that the ball valve closes again. Repeat if necessary. Switch timer into the override mode and switch on the isolator. Monitor the current on the electrical element with a tong tester. (Do not confirm with voltage measurements.). The system is now ready for use and will require time to heat. See performance information on page 11 to gauge the time it will take to heat the water sufficiently. Method 2 Filling with the tubes fitted In this method the installation of the system is complete including the vacuum tubes. If the tubes have been exposed to the sun for an extended period, wait until the early morning before filling the system. If the tubes are fitted in the evening, less than 1 hour from sunset, the system can be filled. Open the inlet valve completely and allow the tank to fill via the ball valve and the reservoir tank. Check that the ball valve closes once the tank is full and no water is discharged from the overflow. Check all installed pipe work to ensure that there are no leaks. Open the drain and drain off 10 litres of water into a clean bucket. Check for any gritty deposits and that the ball valve closes again. Repeat if necessary. Switch timer into the override mode and switch on the isolator. 20

21 Monitor the current on the electrical element with a tong tester. (Do not confirm with voltage measurements.) The system is now ready for use and will require some time to heat. See performance information on page 11 to gauge the time it will take to heat the water sufficiently. Cleaning If your water contains gritty sold objects like sand, Enervision recommends the use of a filter on the cold water supply to the system. Grit in the tank (Not a procedure that is normally required) If the water quality is poor, purge the tank periodically to ensure that there are no concentrations of chlorides in the tank water. Use the procedure below if there is grit build-up in the tank. Cleaning deposits from the tank is best done by a professional installer to ensure that it is done safely and to avoid any damage to the system. Please ensure that you fully understand the safety considerations before any attempt is made to do this on your own. Switch off the water supply. Drain the main tank. Remove the electric element and drain valve. Using a high pressure cleaner, jet water into the tank and allow the grit build-up to flow out the other end. Reconnect and seal the electrical element and the drain valve. Switch on the water supply. Check for leaks on the tank and pipe work. Grit in the tubes (Not a procedure that is normally required) Use the procedure above before reconnecting the water supply. Remove each tube ensuring that the tube and seal are not damaged. Jet water into the tube and allow the grit to exit. Fill the system as detailed in First filling with water and commissioning. Use the same precautions if the sun has heated the tubes. Routine Inspection and Maintenance Maintenance will play a vital role in obtaining the best performance and the continued successful operation of your solar water heating system throughout its operational life. By diagnosing problems early, and taking the necessary remedial action, you can ensure cost effective operation and compliance with warranty requirements. The Programme begins with regular routine inspections on the system. The interval between inspections will depend largely on the environmental and water conditions in your area. We recommend that, for average conditions, an interval of at least once every 6 months be conducted. This inspection should include the following: Cleaning the tubes Tubes need to be cleaned periodically (at least every 6 months depending on the environment) to remove dirt and increase the solar efficiency. Use a hose to wash down the vacuum tubes. Using a soft cloth wipe down the tubes removing any caked-on dirt. 21

22 Inspection for leaks Inspect the cold water pipework from point of supply to the geyser for leaks. Look for wet marks below the pipe or markings on the pipe for indication of leaks. Inspect the pipework on the tank and the tank itself for signs of leaking pipes. Inspect the hot water pipe to the point of delivery for signs of leaks. Have any leaks repaired by a competent plumber. Note: Overflow pipes may show signs of water flow. This is normal but there should be no continuous flow from these pipes. Testing the ball valve operation Check that the main tank is full of water. If not, check the operation of the ball valve. Ensure that the ball is free to move and release water into the reservoir tank and that there is free flow between the reservoir and main tank. Draw a 20 litre bucket full of water from the drain valve. Ensure that the ball valve opens to refill the system and stops once the tank water is replenished. If not, check the operation of the ball valve and ensure that the ball is free to move and release water into the reservoir tank and that there is free flow between the reservoir and main tank. Note: Air inside the tank can speed up the corrosion inside the tank. Checking all vent and overflow pipes are not blocked Check for insects that may build nests in the vent or overflow pipes. Clean and treat with an insecticide. Check that there are no blockages in the vent or overflow pipes. Clean out blockages and treat as required to prevent re-occurrence. Note: Any blockage can result in the main tank being subjected to supply pressure. This will adversely affect the system and can result in burst seals or tubes on the system or even structural damage. Seals on the outer cladding Check the rubber seals on all the pipe entry points on the outer cladding to ensure that they are still intact and to prevent the ingress of water into the insulation material, pay particular attention to the points on top of the tank. Seal if necessary to prevent ingress of water. Note: Water in the insulation material can increase the thermal losses from the tank and can speed up the corrosion on the outside of the tank. Indication of rust or corrosion on the tank or frame Check the outside cladding of the tank for signs of corrosion. Check the frame for signs of corrosion. Remove corrosion, treat the metal primer and then repaint the affected areas. Electrical back-up heating circuits Check the timer is set to the correct periods of operation. Check the isolator is in the on position. Check the supply voltage to the back-up circuit. Bypass or override the timer circuit. 22

23 Measure the current into the element (1.5kW ± 6.5A) Switch off bypass. Purging the tank If the water quality is poor, it is recommended that the water in the tank is purged every 6 months to a year to reduce the concentration of salts. Confirm that no hot water will be required for a few hours. Shut off the water supply to the geyser. Fit hose to the drain valve and lead water to a drain point. Open the drain valve. When the tank is completely drained open the supply valve for a short period to wash out the tank. Close the drain valve. Note: if the tubes are in the sun for a significant period without filling the system, then follow the procedure s for filling given on page 20. Trouble Shooting No water Test a cold water tap to see that there is supply water. Check that the system supply valve is on. Check that there is water at the system supply valve. Check to see that the main supply valve is on. Check that the municipal water supply is available, Check to see if the PRV is not blocked. No hot water Check that the collectors are not shaded between 9am and 3pm every day. Check that you are not using excessive water. Check that the main tank is full of water. Check the electrical supply to the element is working. (Check the main DB Board, timer, isolator, thermostat and element.) 23

24 Warranty Policy This warranty is granted by Enervision to an end user of the system in respect of the 100 litre Solar Water Heater Thermo Siphon System ( the system). Enervision (Pty) Ltd warrants the system to be free from defects in material and workmanship when correctly installed according to Enervision s installation instructions. Enervision warrants the components for the periods of warranty stipulated in the table below. The warranty period will commence on the date that the end user takes delivery of the system from Enervision. COMPONENT PART Typical Lifespan Warranty Period Hot Water Cylinder Casing (Outer Cladding) 10 years 1 years Inner Tank (SS 304, 0.6mm) 10 years 1 years Solar Collectors Evacuated Tubes 10 years 1 years Reflectors 10 years 1 years Ancillary Equipment Frame 10 years 1 year Conditions Within the warranty period stipulated in the above table Enervision undertakes to repair or replace a component found to have defects in material of workmanship rendering the component unserviceable. No charge will be made for the repair of replacement of the component. However, repair or replacement on site will be charged at the prevailing rates charged by accredited installers of the system at the time of replacement. The sole obligation of Enervision is expressly limited to replacement or repair of the defective materials or workmanship. Enervision will either repair or replace the defective component and / or workmanship. The replacement of the entire system shall be in Enervision s discretion. Enervision shall, at its option, not be obliged to honour its warranty obligations if: it has not been properly notified of the installation and all material information relating to the installation provided to it including the receipt by the user of the operating manual; a warranty claim is not made within 10 (ten) business days of the discovery of the defect. (Business days exclude weekends and any public holidays proclaimed in South Africa); damage to the components of the system is as a result from installation being effected by persons not accredited by Enervision to install the system; after making proper and diligent investigation, Enervision is satisfied that the defects are due to improper use, negligence or modifications or alterations made to the system outside of the provisions contained in the Operating Manual; any alterations or repairs effected to the components of the system by a third party not accredited by Enervision; any damage caused to the system by way of accident, act of God or reasons beyond the control of Enervision including, but not limited to, hail damage where the hail exceeds the requirements of SANS 1307 applied by the SABS in testing the system, tornado or other natural calamity causing accidental damage to the system; any damage to the system as a result of the water supply being outside the specifications for domestic water supply as defined in SANS 241, and the South African Water Quality Guide. Any components of the system that may be replaced as result of a warranty claim shall be guaranteed only for the balance of the guarantee period stipulated in the Warranty. 24

25 Under this warranty Enervision accepts no responsibility for any consequential or special loss or special damages of whatever nature suffered by the end user. Enervision shall cause repairs or replacement, if any, to be carried out by accredited installers and in terms of its administrative procedures. The warranty claim shall be processed against receipt by Enervision of notice of the claim from the end user. Repairs or replacement of defective components shall be affected within a reasonable period of time, allowing for the procurement of components, transportation of material and instruction of an accredited installer to take the remedial action necessary to repair the defect or replace the component. The end user shall grant Enervision, or its authorised representative, access to the premises where the system is installed for the purposes of examination of the system in order to consider a warranty claim, as well as to take whatever remedial action is necessary in terms of this warranty. Installation and Maintenance The 100 litre solar water heater thermo siphon system requires minimum maintenance but the importance of proper installation and maintenance which will enhance its operational efficiency and longevity cannot be overemphasised. End users shall be supplied with an Operating Manual that describes how the system is to be operated and maintained. Without limitation the Operating Manual provides for: the periodic inspection of the system to ensure correct operation is essential to limit any consequential damages occurring; the periodic preventative measures which should be implemented to limit corrosion, particularly the areas where high levels of corrosion may be expected; and how the collector needs to be cleaned at appropriate intervals to ensure its on-going efficiency of the system. Where water quality is known to be poor, this may have an impact on this warrantee and, wherever possible, measures should be taken to improve water quality to acceptable levels. 25

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27 WARRANTY RETURN CARD Fill in Card, cut out and fax to (011) or post to: Enervision Warranty, Enervision (Pty) Ltd P.O. Box 14960, Farrarmere, 1518 Product Number TZ58/ Product Serial Number Name of end user Installation address Contact Telephone number address Date of installation System Supplier Name Installer Name Installer Contact Number Installer s stamp 27

28 Head Office Clear Water Office Park, Block E, Cnr Atlas and Park Rds, Boksburg PO Box 14960, Farrarmere, Benoni, 1518 South Africa Phone +27 (0) Fax +27 (0) Cape Town Unit F 19, Stellenberg Close, Millenium Park, Parow Industrial, Cape Town PO Box 21280, Parow, 7499 South Africa Phone +27 (0) Fax +27 (0) ashley@enervision.co.za 28