Nobel Manual.pub

Transcript

Installation, Maintenance and User Manual XILINAKIS D. & Co SOLAR & ELECTRIC WATER HEATING SYSTEMS INDUSTRY EXPORT DEPARTMENT : 25 I. Nika Str., 136 73 charnes, Athens, Greece | -el.: +30 210 2478677 - Fax: +30 210 2407185 HEADQUARTERS: 23 Nerantzoulas Str., 136 77 charnes, Athens, Greece | -el.: +30 210 2404051 - Fax: +30 210 2443444 e-mail: [email protected] | web site: www.nobel.gr Indirect Flat Plate Thermosyphon Solar Water Heating Systems Notes:- Table of Contents All About DOMESTIC HOT WATER CONSUMPTION ...................................................... 3 SOLAR WATER HEATER OPERATION - WATER HEATING .................................... 3 NOBEL SOLAR WATER HEATERS ........................................................................ 4 PACKAGING ... ............................................................................................................. 4 LABELING ... ............................................................................................................. 5 System Specifications WATER STORAGE TANK SPECIFICATIONS ..................................................... 6 COLLECTOR SPECIFICATIONS ...................................................... 7 SUPPORT BASE .7 NOBEL SINGLE PANEL LAYOUT ........................................................................................ 8 NOBEL DOUBLE PANEL LAYOUT ................................................................................... 9 Installation GENERAL INSTALLATION RULES .......................................................................... 10 INSTALLATION POSITION ......................................................................... 11 SAFETY PRECATIONS .. .....................................................................12 SOLAR WATER HEATER SUPPORT BASE PARTS ... 13 SUPPORT BASE ASSEMBLY FOR FLAT SURFACES. ............................................. 14 SUPPORT BASE ASSEMBLY FOR INCLINED SURFACES ............................................. 17 HYDRAULIC CONNECTION ..................................................................................... 20 CLOSED LOOP FILLING ...................................................................................... 20 ELECTRICAL CONNECTION ................................................................................... 21 SPLIT SYSTEM INSTALLATION ................. 23 Service & Maintenance POSSIBLE PROBLEMS - SOLUTIONS .............................................................................. 24 SERVICE - MAINTENANCE ..................................................................................... 25 POST INSTALLATION INSTRUCTIONS .................................................................. 27 (Emergency Shut Down Procedures) CHECK LIST ............................................................................................................. 28 GUARANTEE .29 Page 2 NOBEL, Xilinakis D. & Co Industry have been active in the Solar Energy Field since 1975, always with high-tech equipment and design to ultra-modern facilities and certified products of high quality, to reliability and support. Our experience and know-how supports our co-operation with our partners with both before and after sales, in Greece and abroad. Among others, we are presenting our NOBEL Solar Water Heater range, a product of high performance, quality and innovative aesthetics. In this manual you will find all the necessary instructions with regard to the installation, operation and maintenance of the NOBEL Solar Water Heaters range. Nowadays, the necessity for production and saving of energy without at the same time polluting the environment has become common knowledge. The planet’s conventional energy resources are diminishing to a threatening level as our society’s energy requirements are increasing, generating pollutants that affect the climate’s balance. Renewable energy sources promise a solution to the energy problem as well as to pollution. Gradually, international legislation is changing and encouraging - or even imposing the use of alternative energy products, with the aim to satisfy energy requirements without endangering the environment. DOMESTIC HOT WATER CONSUMPTION Proudly Distributed by Enerjetic Distributors 718 James Crescent Halfway House Midrand South Africa tel: 0861-276527 fax: 0862-454781 email: [email protected] web: www.enerjetic.co.za Statistically, it is estimated that the average family’s consumption of hot water is 35 to 50 litres per person per day. If we add the consumption of other hot water consuming devices in and around the home (e.g. washing machine, dishwasher etc), then these add an additional load to the hot water requirement depending on the usage, it therefore becomes imperative to select the correct size solar solution to meet your requirement. As an example, a family of four, with a average hot water consumption of 40 litres per person per day will require a 160 liter solar water heater, but if household appliances are taken into account then it would be wiser to rather select a 200 liter solar solution, this is commonly known as over-sizing and is the wiser choice. In order to take full advantage of a solar water heater system maximum use of hot water should be made during daytime hours so that the system can recover during the later part of the day and continue to produce hot water during the evening, therefore maintaining its maximum efficiency. SOLAR WATER HEATER OPERATION - WATER HEATING The collecting surface absorbs solar energy and heats the liquid (water & antifreeze mixture) which then circulates in the solar collector/s. Seeing that this liquid when heated becomes lighter and is directed to the water storage tank where it indirectly heats the water in the tank through a heat transferring process resulting in hot water being present in the tank. The flow of the collector’s liquid is accomplished naturally known as the thermosiphonic flow. Factors that affect the temperature of the water supplied by a solar system are many and vary according to the season, the time of day and the location. Bearing in mind that the solar system is a system that is exposed to the weather conditions, basic aspects affecting its performance are the mains water temperature, the available solar energy and the ambient temperature. As a backup to assist the heating of water the vessel can accommodate an electrical element which will switch on and off based on the thermostat setting. Please bear in mind that if all the hot water heated by the sun is consumed in the evening it may take anything between 3 to 5 hours for the electrical element to recover the hot water to an acceptable temperature, this based on the size of storage tank and temperature of the water. Care needs to be taken when fitting a timer which governs the electrical element so as not to negatively affect the systems performance. Page 3 NOBEL SOLAR WATER HEATERS This guarantee does not entitle the owner of the system to any financial or other compensation from Enerjetic Distributors other than the replacement/repair of the damaged unit. RELIABILITY - HARMONY - AESTHETICS It is recommended that an annual service inspection is carried out to ensure optimum performance; particular attention needs to be given to the replacement of the magnesium anode especially in known hard water areas. All maintenance and inspection expenses are charged to the owner of the solar system. NOBEL Solar Systems constitute an ecological proposal and an effective energy All service and replacement costs not covered by the guarantee will be for the owner of the systems account (according to the appointed Service Company’s pricelist). In the event of a manufacturer fault the full cost of transport, repair, and replacement will be covered by the manufacturer. Under no circumstances does any repair imply an extension of the original guarantee period. GUARANTEE LIMITATIONS This guarantee does not cover damages due to defective or poor installation. This guarantee does not cover the operation of the system under conditions different to that for which it has been designed. Damages or failures due to the installation not being done in accordance with all regulatory (SANS) standards with regards to Solar Water Heating, Building, Electrical, Water and Safety. solution, combining high output, autonomy, aesthetics, facility in the installation and money saving. They are made of excellent materials according to international specifications and have all the certifications and tests that confirm their quality. They are highly aesthetic systems, which can be simply and quickly installed to blend in with traditional or modern architecture of a building and provide free hot water for almost the entire year. Even in regions with low sunlight they achieve the heating requirements of the water, which contributes to a drastically reduced consumption of conventional energy. With the use of solar systems, thermosiphonic (or forced circulation), high energy saving can be achieved. At the same time the operation time of the electric element can be reduced and depending on the sunlight of each region and the system’s size, simultaneous reduction of emissions of carbon dioxide are achieved therefore assisting in the caring of the environment. The guarantee will be invalid if the device has been misused or the installation has been worked on, altered, modified or disassembled, even partially, by any persons not authorised by Enerjetic Distributors to do so. Enerjetic Distributors accepts no responsibility for any direct or indirect damages sustained by the owner for the period needed for any repairs to be affected to the system. The current guarantee does not apply in case of damages due to: Wear of the hot and cold service water pipes. External factors (theft, fire etc). Natural disasters (fire, flood, disaster, accident, act of god, storm, gale force wind etc). Extreme hail conditions exceeding that as defined by SANS 6210. Any other cause which is not due to the manufacturer as well as damages which potentially can be caused to other property. Frost (for open circuit solar system) or if the system is not filled with the proper solution of PACKAGING The water storage tank is placed between two round styrofoam covers, which are tightened on the storage tank with stretch film. The collector is packed in a carton box. All the parts of the support base, system, connection fittings, the antifreeze liquid and the other accessories are packed in a carton box. Please unpack these boxes carefully so as to avoid damage and potential breakages. antifreeze liquid or the addition of parts or liquids that have not been approved by the manufacturer. System pressure exceeding 400kpa where a pressure reducing valve (PRV) has not been fitted. Non-connection of the electrical grounding cable. Omission of regular replacement of the magnesium anode in known hard water areas. Major change in the characteristics of the water, which should be of low or medium corrosivity, that is: 1. Langelier Saturation Index: LSI > 0,1 2. Corrosivity Index (C.I.)*: 0,5 < C.I. < 3 For Inoxidable water tanks (INOX): The warranty is valid only in the case that the used water has a chloride concentration of max. 200 mg/l, (c(CL-) < 200 mg/l). The contracting parties accept the terms of the agreement. Page 4 Page 33 LABELING (Info-plates) CERTIFICATE OF GUARANTEE FOR YEARS FIVE(5) YEARS NOBEL solar water heaters are identified by two stickers, one of them on the tank and the other on the collector. On these stickers all the details of the system are written. The information provided on these stickers are important for the identification of the system. Purchaser details First name, Last name: Address: Postal Code: City: Country: Tel. no.: Fax. no.: E-mail: Type of solar system: Boiler S/N: Collectors S/N: Sales document no: Purchase date: Sales company: There are also other cautionary and informative stickers (info-plates) placed at various points on the system, care needs to be taken to adhere to the information relayed on these information stickers as some indicate areas of potential danger. Certain stickers can be removed once the system has been commissioned and is active. Supplier Name and Signature Service Date 1st 2nd 3rd 4th 5th Notes Service Signature Service Date Signature 6th 7th 8th 9th 10th With this certificate Enerjetic Distributors guarantees the recorded Nobel Solar Water Heating System against any manufacturing defects. This guarantee is valid from the date of purchase and is limited to the replacement and/or repair of defective parts. For the guarantee to be valid the customer must return the completed warranty slip (provided with the system) to the manufacturing company's central offices within two months from the purchase date, stamped by the accredited Sales and Installation Company and accompanied by a copy of the sales receipt. The customer should also keep all documents related to any repair, maintenance or replacement of the system and/or its components. TERMS OF THE GUARANTEE The installation must be carried out in accordance with the supplied technical manual and installed by an Enerjetic Distributors accredited installer. The electrical parts are covered by the manufacturers guarantee for one year. All couplings, valves, pipes etc are covered in terms of the manufacturer’s guarantee which is normally one year. In case of failure the customer should inform the company immediately by sending all necessary information (e.g. photos, reports etc) and record a service fault. In the event of a water tank or collector leakage due to a manufacturing defect, the company will replace the faulty part at it’s discretion with another or similar type which is currently available. Page 32 Page 5 WATER STORAGE TANK SPECIFICATIONS STEEL - ENAMEL 1. Cylinder: 2.5mm thickness cold rolled steel with a double internal layer of enamel, baked at 860ºC according to DIN 4753. The enameling is done in our own high tech industrial facilities. The water storage tanks are checked individually upon exit from the enameling unit assuring the top quality of the enamel coating. 2. Surrounding heat exchanger (Jacket) with internal expansion tank: cold rolled steel, 1.5mm thickness for the operation of the closed loop, which is compulsory at low temperatures and also in areas with water with high mineral content. 3. Thermal insulation: ecological, high-density, expanded polyurethane ensures minimum heat loss maintaining the hot water temperature. 4. External housing: naval aluminum alloy / pre painted galvanized steel. 5. Cathode protection by means of magnesium anodes Ø22x300mm/200gr and Ø26x500mm/500gr (tank size dependent) for effective protection against corrosion and mineral deposits caused by electrolytic reactions. 6. Large round flange rubber protected: innovative, smart design for the quick cleaning of minerals, fast replacement of anode/s and immediate access to the electrical components. 7. Complete sealing rubber of silicone, non toxic material, which does not permit water to contact the flange, thus protecting it against electrolysis and corrosion, specially made to withstand the generally accepted specifications with regard to the heat re- 8. Heating element rated according to the country of destination local regulations. (Optional, for the use of electricity as an auxiliary power source). All electrical components carry a SABS marking according to SANS 60335-1 and SANS 60335-2-21 standards. 9. Automatically regulated thermostat (with bipolar protection and/or auxiliary fuse). All electrical components carry a SABS marking according to SANS 60335-1 and SANS 60335-2-21 standards. 10. Protective cover: designed to ensure the proper ventilation of the electrical section and its protection from the environmental conditions (hole in the cover must always be at the bottom) Gland: for sealing the passage of the heating element’s connection cable. Page 6 Page 31 POST INSTALLATION INSTRUCTIONS Before using the system make a final check. Open all the valves and check for any kind of leakage. Repeat the inspection after 30 minutes. Check if the system is filled with water and antifreeze fluid according to the specified instructions. In case of any failure condition a specialized technician should be called in. Following its installation, the solar water storage tank needs about 2 days in order to achieve its maximum efficiency. For this reason it is recommended that there is no hot water consumption during the first two days following installation, even if there is ample sunshine. 11. Cold water inlet: brass 22mm BSP male threaded pipe end for water stratification and 8bar safety valve for releasing pressure. 12. Hot water outlet: 22mm BSP male threaded pipe end. 13. Jacket inlet: 22mm BSP male threaded pipe end. 14. Jacket outlet: Closed loop circuit filling point: 22mm BSP male threaded pipe end. 15. 3,5 bar safety valve connection location: 15mm BSP male threaded pipe end. A basic periodic maintenance will assure the long life and high efficiency of the solar water heater. COLLECTOR SPECIFICATIONS - It is recommended that the appliance is inspected in accordance to the instructions stated in the guarantee and checked for possible damage of the collectors’ glass, leaks in the connecting piping and the system, inspection of the pipe insulation and cleaning of the glass. 1. External one piece aluminium trough forged through a process for high aesthetics purposes. Shaped by a deep drawing method in a 400 ton capacity press, made of a naval aluminium alloy which is rich in magnesium. Robust construction for perfect tightness, fit and to reduce water penetration. 2. High density, eco-friendly thermal insulation achieved with a 60mm thick layer of pre-pressed rockwool with a covering of black glass fabric for the minimization of thermal loss. - If the collectors’ glass is broken, it should be replaced immediately. - It is recommended that the glass be washed at an hour of low sunlight to avoid damages due to expansion/contraction due to temperature changes. Rockwool insulation thermal conductivity: λ=0.035 W/m grd (DIN 56612, measured at 0°C) - If the fittings are worn (screws, plugs, piping, etc), these should be replaced. 3. Water frame of copper pipes of suitable gauge and thickness (headers: Ø22, manifolds: Ø8) Headers are punched with upper expansion, for perfect manifolds fitting, thus avoiding pressure drop in the collectors. Tube pitch = 93mm (EN 1652) - The level of antifreeze in the closed circuit must be checked annually (as it could need toping up), to ensure the efficient operation. - In cases where there is to be no use of hot water for long periods of time (e.g. on holidays), then there can be a build-up of high pressure in the thermal tank, it is possible that the safety valve will open and water will run out. This is a normal function that protects the water storage tank from high pressures. If the mains pressure often exceeds 4 bar, then it will be necessary to add a pressure reducer - expansion tank. - Switch off the electrical heating element in the following cases: a) when the mains water supply has been cut. b) When the connecting pipes have frozen and there is no water flow from the water storage tank to the taps! Attention: Fit taps with a thermostatic regulated valve for hot water use to prevent burns which may be caused by the high temperature of the water in the solar water heater. We remain at you disposal for any further information you may need. 4. Sun-Selective complete area absorber made of selective aluminium sheet with a special titan coating formed in a vacuum, of high absorbency and low radiation, covers the complete window area as well as the headers, thus increasing the collector’s absorbency, Laser Welded to the water frame. 5. Special plastic parts for supporting and sealing the water frame to the trough, specially designed for the collector’s ventilation, with sensor supporting option. Special silicone rubber seals allow fluctuation of the absorber’s length (contraction - expansion) in a -40°C to +200°C temperature range. 6. Tempered solar glass low iron, with a stable coefficient of expansion and high light transmittance, can withstand adverse weather conditions (e.g. hail storm, extreme temperature changes, etc.). 7. Solar glass rubber seal: UV proofed We can assure you that you have made the best choice. Thank you for choosing our product! 8. Aluminium profile electrostatically painted (Al Mg Si 05): for solar glass seating and supporting SUPPORT BASE One type of supporting base system, electrostatically painted, made of 2.5mm thick galvanized steel, with stainless steel screws and nuts. The support base can be used in two configurations to fit either a flat surface or an inclined surface by simply removing the leg supports. Page 30 Page 7 NOBEL Single Panel LAYOUT DRAINING THE GEYSER 1. Ensure that the electrical supply to the geyser is switched off. 2. Close off the mains water supply to the geyser either by shutting off the multivalve (if present) or the main supply stop cock. 3. Fit a discharge hose to the drain cock and lead off the hot water supply to a safe area for discharging. 4. Loosen and remove one of the vacuum breakers. 5. Open the drain cock by using a proper tool and allow the water to drain from the geyser. 6. Once empty do the necessary required repair/service work. 7. When done close the drain cock by using the proper tool and remove discharge hose. 8. Refit the vacuum breaker. 9. Open main water supply to the geyser and allow to fill. Once full check for leaks and correct if need be. 10. Switch on the local isolator. 11. Switch on the main circuit breaker to the geyser element. Attention! - Any intervention - work on the solar water heater must be carried out only by specialized technicians and where electrical components are concerned, only by qualified and licensed electricians. - All solar water heater service data must be entered on the respective chart on the warranty document (term of warranty). - In areas where extreme weather conditions are common (hail storms, storms, tornadoes, etc.) it is recommended that the appliance is insured. Emergency Shutdown Procedure In the unfortunate event that the system needs to be shut down follow these easy steps. Page 8 1) Ascertain if the failure is directly associated with the Solar System. 2) If so immediately switch of the electrical Safety Relay (circuit breaker) which should be installed in your Electric Distribution Board (DB board) located somewhere in the house. This should be identified by a tag marked “Geyser” 3) If your problem is water related then turn off the supply to the geyser, this can be done by locating the main supply to the home and by turning the stop-cock off and shutting down the water supply to the house. 4) If the problem is of an electrical nature then contact a qualified electrician. 5) If the problem is of a water supply nature then call a qualified plumber or the installer who originally installed your system. Page 29 table below:- MAINTENANCE SERVICE NOBEL Double Panel LAYOUT It is recommended that your solar water heater should be serviced every year by an authorized representative or a company technician. These periodic checks are necessary to ensure optimum performance of your solar water heating system. The inspection concerns the whole system and more specifically: 1) Secure fitting of flange - checks for leaks. 2) Safety valve - test for functionality and leaks 3) Heating element & thermostat - check for proper functioning 4) Connection fittings - visual check for secure fitting 5) Piping, Insulation, Seals - check for leaks 6) Transparent cover (solar glass) - clean regularly 7) Supporting system - check for secure fitting and support 8) Replacement of anode and checking the closed loop liquid - Check for excessive corrosion to the anode, replace if necessary. Top up or replace glycol mixture if required. REPLACING THE SACRIFICIAL ANODE BAR/s (two methods a or b): 1) Shut down the electrical supply. 2) Empty the water from the water storage tank. 3) Remove the electrical component’s cover. 4) Disconnect the three electrical wires. 5) (a) Remove the electrical heating element by removing the M8 screws. 6) Remove the old magnesium bar from the heating element’s flange (if present) 7) Screw in the new magnesium bar and replace the heating element tightening securely , or ... 8) (b) Unscrew the external magnesium cap located on the water storage tank’s opposite side (if present). Replace the sacrificial anode with a new Ø22x300mm / 200gr on the cap and screw back into place. 9) Open the water supply and a hot water tap until the water storage tank fills up. 10) Check for water leaks. 11) Reconnect the electrical components at their designated positions. 12) Check that the thermostat is securely clipped to the heating element. 13) Replace the electrical component’s cover. Page 28 Page 9 GENERAL INSTALLATION RULES POSSIBLE PROBLEMS - SOLUTIONS Attention! Installation must be in compliance with local & national rules concerning water and electrical installations (plumbing, electricity, hygiene, urban and others). This product must be installed to the requirements as stipulated in SANS 10254 & SANS 10106 THE SOLAR WATER STORAGE TANK DOES NOT SUPPLY A SATISFACTORY AMOUNT OF HOT WATER BY SOLAR POWER The solar system’s packaging must be removed at the site of installation in order to protect the device from damage during its transportation, making sure that the collectors are not supported on their pipe ends. Until installation is completed, the collector’s glass must remain covered until the water storage tank is filled with domestic water, so as to avoid the boiling of the filling liquid or the breaking of the glass. The plastic protective caps must be removed from the water storage tank’s and the collectors’ pipe joints. 1) Take the weather conditions into consideration. 2) Avoid large hot water consumption during the night. 3) Check if your needs in hot water have increased and cannot be covered by the system’s capacity. 4) Make sure your solar water heater is not shaded by any kind of obstacles. 5) Check that the system is leveled. 6) Check carefully all connections for tightness and tighten or replace any connections that are not tight. 7) Check the building’s piping and taps for the possibility of leakage. 8) Make sure the hot water supply is not mixing with a cold water supply. 9) Make sure the connecting pipes are not kinked. 10) Check the level of the antifreeze liquid and top up if necessary. 11) Make sure there is no trapped air in the water storage tank or the collectors. If after all the above checks you are still not satisfied with your solar system’s performance, then please contact your local representative or the company’s technical department. Installation location - shading: Prior to installation, a proper selection of the location must be made by the installer (in agreement with the customer), and the surface must be checked (taking into consideration its static resistance), so that it can bear the weight of the system when filled. On inclined roofs the system should not be placed between two beams but above a single one. Roof truss support and bracing needs to be done where required. The position chosen for the solar water heater installation should not be shaded by any obstacles such as trees, buildings etc (all year round), so as to ensure at least 4 hours of Orientation - optimum angle: a basic factor for the system’s optimum performance is the selection of its angle and orientation for its particular location and the time during which the maximum gain is required The solar system should preferably be positioned so that the collector’s surface faces geographical North, or if needed from East to West and equal to the latitude of the site +10°. Any deviation means a reduction in the system’s performance. If a deviation from the proper orientation cannot be avoided, then the system’s performance should be corrected by increasing the collector surface, following a study and evaluation of the specific conditions that apply. As the sun ray’s angle of attack varies with time but also depending on the system’s location, the collector’s angle should be approximately equal to the installation location’s latitude plus 10°. At this angle the maximum energy gain on an annual basis is achieved. Installation peculiarities: In instances where there is no compatibility between the surface where the solar water heater will be installed (inclined or flat) and the standard equipment provided with the system, a different solution needs to be sought. The responsibility for this selection of alternate equipment lies with the installer. It is up to the installer to propose and agree with the client and to install using the alternate equipment whilst still adhering to all OHS and Installation Standards. If in doubt the installer needs to contact the supplier for guidance and advice. Special weather conditions: In regions with heavy snowfalls, please make sure that the snow is always removed as soon as possible to expose the collector/s. For regions subjected to heavy storms, high wind velocity, heavy rainfall, cyclones, tornadoes etc, the system must be placed on the roof and secured firmly using extra metal strips. In areas where hail-storm conditions of more than 20mm in diameter occur, it is recommended to install a hail-stone protector frame and sheet over the collector/s to protect them. Page 10 In this case follow these steps: THE SOLAR Water storage tank DOES NOT SUPPLY HOT WATER WHEN USING THE ELECTRICAL HEATING ELEMENT Attention! The following tasks must be carried out only by a qualified electrician! 1) Shut down the electrical supply and open the electrical components’ cover. 2) Check the cable connection between the thermostat and the heating element. 3) Check the temperature at which the thermostat is set, so that it is not lower than that needed for consumption. 4) Check the heating element. 5) Check the central electrical connection. 6) Switch on the electrical current and measure the voltage at the heating element’s terminals. 7) Check the thermostat’s thermoelectric fuse F (if applicable), which must be pressed in. If it is not, rotate the thermostat’s regulator until the button of the thermoelectric fuse F appears. Press this. Once it has been reset, the thermostat can operate once again. Page 27 Panel Truss Bracing Piping: the routing of the piping and cabling must be agreed upon between the installer and the client, so as to ensure the proper installation of the solar system in compliance with local rules concerning water and electrical installations. Make sure that the tubes connecting the storage tank with the collector and the piping to/ from the water heater are insulated in such a way that they can withstand temperatures covering the range of: -30°C to 120°C. Anti-UV protection must be used for the insulation. Antifreeze Liquid: The special heat transfer medium used in the closed circuit protects the system from freezing and from salt accumulation inside the collector tubes. The jacket in which the heat transfer fluid circulates, does not come into contact with the potable water in the water tank. The thermal fluid must be well mixed with water in a percentage that is necessary to protect the system (see table, page 21). The responsibility for the appropriate heat transfer medium quantity as well as for the use of other liquid other than the one accompanying the solar water heater lies with the installer and in no case on the company. The use of water or inappropriate liquid may annul the warranty validity. Geyser Truss Bracing After the installation is completed, the area where the work was executed should be clean & tidy. The warranty card should be filled in and signed and the customer should immediately mail it to the company. The customer should fill in the check list provided by the company and check the installation in accordance with this check list. The company is not responsible for an inappropriate installation and/or incorrect parts used, this is the responsibility of the installer. INSTALLATION POSITION The installation is only allowed on roofs and flat surfaces of adequate bearing capacity. Before you proceed with the installation, make sure that the roof and/or the construction is of adequate bearing capacity and always according to the expected maximum loads at the installation point. If the installation is in a place with an extremely big wind and snow load, the system as a whole should be statically checked by a skilled person, e.g. a specialized engineer. In special cases, strengthening or more solid constructions may be required. Truss work - All truss work to be adequately supported with appropriate materials of acceptable dimensions and braced to spread the load of the unit accordingly. Piping - The piping must be installed in a manner that ensures correct thermosiphonic action and must at all times be in a upward gradient. Care must be taken to ensure that the piping does not create heat traps or air-locks as this will restrict flow. Note:- All pipes must be fully insulated. Panel Position - The collector panel/s must be positioned at least 300mm below the bottom of the water tank (geyser). Space requirements for installation on the roof Drip Tray - A suitable size drip tray needs to be installed at all times and must be angled towards the drain outlet to ensure free flow of discharged water. TILED ROOF - For the installation on the roof the following points must be taken care of: The minimum distances from the ends of the roof should be: Water-proofing - Ensure that all roof penetrations are adequately waterproofed and sealed to prevent leakages. From the sides: distance equal to the width of two tiles and from the top and bottom of the roof: distance equal to three rows of tiles. Page 26 Page 11 Space requirements for free standing installation (SPLIT PUMPED SYSTEM) continued... FLAT ROOF The system should be installed at least 1.5m away from the edges of the roof so as for: PV Pumped System explained. The systems to be accessible for maintenance reasons. During the day and with the lowest possible solar irradiaon the photovoltaic generator produces direct current with which it supplies the electric pump. The pump allows the circulaon of the heat transfer medium (water-propylene glycol soluon) between the solar collector and the heat exchanger of the water tank. In this way, the heat transfer medium is heated within the solar collector, which absorbs the solar irradiaon and is transferred within the storage tank. This constant recirculaon of the heat transfer medium between the solar collector and the storage tank leads to the gradual heang of the liquid within the storage tank. The systems and the fixing system not to be exposed to strong winds which are developed at the ends and edges of the roof. Snow to be removed. SAFETY PRECATIONS Please adhere to all OHS standards in respect to the installation of a solar thermal systems as well as the piping. Please keep the work place clear and free of objects obstructing the execution of works. When there is no adequate sunlight or during the night the photovoltaic generator does not produce electric current and thus the pump immediately stops its operaon avoiding the aimless recirculaon of the heat transfer medium. Do not let children, pets and other people come into the installation area and demark this as a place of work. Be mindful of falling objects at all times. The pump is provided with the necessary electrical power in order to operate through a photovoltaic generator, and eliminates all the drawbacks of the forced circulaon systems. Store the antifreeze liquid in a safe place and away from children. This system is extremely simple and economical since there is no need of many components of the convenonal systems (differenal thermostat, regulator, non return valves, temperature sensors, expansion tank or safety valve) for its operaon, and that is why no maintenance or regulaon works are required. During the execution of maintenance, service, modification or installation works, please ensure that the unit is switched off at the electrical distribution board as well as the locallised isolator—check the device for electrical charge before commencing of work. Use only suitable tools intended to be used for this specific solar system. The use of other components or inappropriate tools may cause damage. Requirements related to personnel Moreover, there are no delay phenomena (like the ones that occur in the convenonal forced circulaon systems), since when there is sunlight the photovoltaic generator produces the volume of current needed and the pump operates exchanging the heat transfer medium between the storage tank and the solar collector. The installation of the NOBEL Solar Thermal systems can only be undertaken by authorized specialized companies and trained/qualified personnel. Work on electrical installations or conductors have to be executed by trained & specialized qualified electricians only. Labour uniforms Use protection glasses as well as an appropriate work uniform, protection shoes, protection helmet and height harness. If, despite the use of protection glasses antifreeze liquid comes into contact with your eyes, wash out your eyes with plenty of water and if need be seek medical assistance. Use only shoes meant for this type of work, avoid shoes that are slippery and do not grip. Installation of the water storage tank For the transportation, mounting & installation of the tank use forklifts suitable for the dimension and weight of the tank. Please protect the enameling surface from damage during transportation and installation. Due to the tank’s weight, there is a risk of accidents. Please make sure that the bearing capacity of the area where the tank is to be installed is adequate when the tank is full of water. Brace and support the system securely to as to avoid the system from moving or being blown out of position by strong winds. Page 12 Page 25 SYSTEM INSTALLATION ON A TILED ROOF WITH THE WATER SOLAR WATER HEATER SUPPORT BASE PARTS STORAGE TANK UNDER THE ROOF (SPLIT PUMPED SYSTEM) For the system’s optimum operation using pumped circulation the maximum and minimum distances and angles for the pipes must be respected. The maximum distance between the collector outlet and the water storage tank inlet must not exceed 5m. Air-relief valve Attention! To be installed in accordance with SANS 10254 , SANS 10106, SANS 10400 and SANS 10252. Closed Loop Filling Procedure Ensure the geyser tank is full of water before you start. First open Air-relief valve, start filling glycol from the bottom most point of the system until all air is removed from the closed-loop. Shut off filling valve and then close off air-relief valve. Notes: A suitable controller must be fitted for the correct operation of the system. Choice of circulation pump can be 220v or 12v PV with a minimum rating of 95° C Isolation valves must be installed both before and after the pump to allow for maintenance. A Air-relief valve must be fitted at the highest point of the system. Please ensure that a drip tray of adequate sizing is installed when the geyser is positioned in-roof. The drip tray drain pipe must lead directly out of the building to ensure discharge takes place externally. Safety valve discharge pipe must be routed externally and not into the drip tray. Page 24 Page 13 SUPPORT BASE ASSEMBLY ON A FLAT SURFACE SYSTEM INSTALLATION ON A TILED ROOF WITH THE WATER Attention! After the installation check that the collectors surface has a tilt angle of 35° to the horizontal position. STORAGE TANK UNDER THE ROOF (SPLIT SYSTEM) SYSTEMS WITH 1 OR 2 COLLECTORS For the system’s optimum operation using natural circulation, the maximum and minimum distances and angles for the pipes must be respected. The maximum distance between the collector outlet and the water storage tank inlet must not exceed 3m. The angle of the pipe joining these 2 points must not be less than 8º. Attention! To be installed in accordance with SANS 10254 , SANS 10106, SANS 10400 and SANS 10252. Notes: Please ensure that a drip tray of adequate sizing is installed when the geyser is positioned in-roof. The drip tray drain pipe must lead directly out of the building to ensure discharge takes place externally. Safety valve discharge pipe must be routed externally and not into the drip tray. In certain instances a pumped circuit may be required if the natural thermosyphon flow is not achievable. In-Roof Installation Page 14 Page 23 6. Repeat for the top part 7. In case of two collectors, first place the left one, lifting the collector’s upper supporting part. When the collector is placed under, we slightly tighten the M8 screws and nuts with the collector’s supporting parts in order to temporarily restrain it and easily center it with the system. Place the mechanically tightened unions Ø22 at the collector’s edges. 8. Join the second collector and tighten the unions.* Heating Element Please ensure that the replacement element is of the same rating as that originally supplied with the system. Thermostat Ensure that the thermostat is replaced with one that controls the temperature and which is compatible with the element. L= Phase 9. Screw on the two supports of the tank. Tighten all screws on the base. Properly orientate the base with the collector. Firmly attach the base using the 4 Upad D10 and bolts (M8x60) This is the Live Phase and the RED wire is connected to this. N= Neutral This is the Neutral Phase and the BLACK wire is connected to this. Earthing (Earth) Connect the UNSHIELDED or GREEN & YELLOW wire to this. Isolator Always ensure that there is an ISOLATOR installed within easy reach of the geyser. Safety Relay (Circuit Breaker) Always connect the geyser supply to a adequately rated Safety Relay (circuit breaker) 10. Place and tighten the Ø22 mechanically tightened plug on the top right and on the bottom left of the collector/collectors.* Place the water storage tank on the base with its electrical components to the left, when viewing the water storage tank from the front. 11. Centre the water storage tank’s position on the collector/s. Rotate the water storage tank (if necessary) in order for the cold and hot domestic water sockets to remain vertical to the horizontal surface. Screw the water storage tank onto the base using the screws provided in the packaging. Ensure the appliance is not tilted and is properly leveled. 12. Place the small flexible tube on the special connection at the water storage tank’s side where the heating element is located and to the socket marked “collector intake”. 13. Join the other end to the top left socket of the collector using the corner fitting, having firstly passed the tube through the insulation pipe. Page 22 Page 15 6. Following the completion of the installation, the appliance should be left for 24 hours without any hot water being used so that the closed loop can go into operation. ANTI FREEZE LIQUID is an advanced, propylene glycol based special product, designed and formulated in order to ensure effective heat transfer properties at high or low temperatures. It is non-toxic and provides protection up to -37°C (solution 55% v/v with water). It is especially designed to provide excellent anticorrosion properties. In aquacius solutions anti freeze liquid offers protection according to the extent of dilution as per the ELECTRICAL CONNECTION DESCRIPTION OF ELECTRICAL COMPONENTS (HEATING ELEMENT - THERMOSTAT - ACCESSORIES) Τhe back-up element shall only be used for sporadic heating purposes The electrical installation of the heating element should be carried out by a qualified electrician and in accordance with the national regulations. The heating element must not be switched on when there is no water in the water storage tank. In such case the heating element warranty does not apply! 14. Place the t- piece with the filling valve to the socket on the right side of the water storage tank marked “collector return”. NOTE: The heating element’s rating depends on local regulations of the country. 15. Place the big flexible tube with the special connection to the t- piece on the right side of the water storage tank. 1. Remove the screws from the protection covers (Drw.1). 16. Place the other end at the bottom right socket of the collector using the Ø22x corner fitting*, having firstly passed the tube through the insulation tube. 2. A 3x4mm² section electrical cable (for a 4kW heating element) is required to connect the heating element to the mains (Drw. 2). Tighten all unions in the system as well as all the screws on the base. 3. Pass the end of the cable through the gland and towards the electrical components. Do the hydraulic connection , fill the closed loop and do the electrical connection as described in the relevant sections. Check for leaks. 4. Connect the Red wire (live phase) to the connector L and the Black wire (neutral) to the connector N on the thermostat. Connect the earth wire (earthing) to the small M4 screw on the heating element marked with the ground symbol (Drw. 3). 17. After having placed the collectors at a parallel to each other position, fasten them to the support base. 5. The thermostat has been connected to the heating element at the factory. Adjust the thermostat to 60°C. 18. Fit the water storage tank supporting base covers. Attention! the thermostat should be firmly fitted to the heating element. *Use lock nuts in order to avoid the copper tube mechanical strain. 6. Close the cover of the electrical components (Drw.4) 7. Switch off the central mains switch. 8. Connect the other end of the cable to the electrical board. The circuit breaker’s rating must be suitable for the heating element in use. Caution! A safety relay against electrical shock is absolutely necessary and a dedicated isolator needs to be installed within easy reach of the geyser. Page 16 Page 21 HYDRAULIC CONNECTION (Hot and Cold Connection) SUPPORT BASE ASSEMBLY FOR INCLINED SURFACES Attention! To be installed in accordance with SANS 10254 and SANS 10106 Attention! CONNECTING THE SYSTEM WITH THE COLD AND HOT WATER MAINS After the installation check that the collectors surface has a tilt angle of 35° to the horizontal position. The “COLD WATER INLET - Blue” and “HOT WATER OUTLET - Red” sockets are located on the side of the water storage tank. SYSTEMS WITH 1 OR 2 COLLECTORS Attention! The connections to the hot and cold water pipes should be made with union nuts and not by soldering. 1. Turn off main water supply if required. 2. Install a 400kPa multivalve (if required), drain cock and vacuum breaker on the Cold Line leading to geyser. 3. Install a banjo/safety valve and vacuum breaker to Hot Line coming from the geyser. 4. Ensure that adequate insulation is installed. NOTE: The safety valve should have a drain pipe connected to its outlet. This pipe should run to an area that is safe to discharge hot water. Do not seal or block the ends of this drain pipe or the valve outlet. Potable water may be discharged from this pipe during extreme temperatures and must be left open to the atmosphere. The drain pipe must be of metal and must be installed in a continuously downward direction. 5. Install a mixing valve at the solar water heater tank and set to a temperature that will reduce the risk of scalding. 6. Filling the water storage tank with water: With the shut off valve open and any hot water tap open, turn on the mains water supply again. The water storage tank will now fill with cold water. When water starts to run out of the hot tap, the water storage tank is full and the hot water tap can be closed. 7. Check for leaks and correct any if need be. CLOSED LOOP FILLING Attention! Before starting to fill the closed loop with anti freeze liquid, the water storage tank has to be completely filled with water. 1. Remove the expansion valve from the top of the geyser and leave this open to the atmosphere. (Drw.3) 2. Mix glycol and water as per the table below and fill the glycol loop through the specially designed fitting (Drw.2) to the point where the mixture flows freely from the exposed expansion valve port. Shut off the filling valve and refit the expansion valve closing the glycol loop circuit. The Closed Loop circuit is now primed. 3. Uncover the collectors and clean the glass removing all the information stickers. 4. Check for leaks and correct any if need be. 5. Ensure all hot & cold water pipes are properly insulated in order to avoid thermal loss and protection against frost. Page 20 Page 17 9. Place and tighten the Ø22 mechanically tightened plug on the top right and the bottom left of the collector/collectors. Place the water storage tank on the base with its electrical components to the left, when viewing the water storage tank from the front. 10. Centre the water storage tank’s position on the collector/s. 13. Place the t- piece with the filling valve to the socket on the right side of the water storage tank marked “collector return”. 14. Place the big flexible tube with the special connection to the t- piece on the right side of the water storage tank. 15. Place the other end at the bottom right socket of the collector using the Ø22x corner fitting*, having firstly passed the tube through the insulation tube. Tighten all unions in the system as well as all the screws on the base. Rotate the water storage tank (if necessary) in order for the cold and hot domestic water sockets to be vertical to the horizontal level. Screw the water storage tank onto the base using the screws provided in the packaging. Do the hydraulic connection , fill the closed loop and do the electrical connection as described in the relevant sections. Make sure the appliance is not tilted and is properly leveled. If necessary use a level. Check for leaks. 11. Place the small flexible tube on the special connection at the water storage tank’s side where the heating element is located and to the socket marked “collector intake”. 16. Place the collectors at a parallel to each other position, fasten them to the support base. 12. Join the other end to the top left socket of the collector using the Ø22x corner fitting,* having firstly passed the tube through the insulation pipe. 17. Fit the water storage tank supporting base covers. Page 18 *Use lock nuts in order to avoid the copper tube mechanical strain. Page 19