novasun installation manual v2.5 2015 - solar...

Copyright © 2014 Ikhwezi Solar (Pty) Ltd, Novatherm CC, Solar Assist (Pty) Ltd

Instruction Manual

for the Installation and Maintenance of

Novasun Direct Freeze Resistant

High Pressure Solar Hot Water Systems (April 2014)

For use by trained qualified personnel only. Applicable to the following models:

Novasun, Direct Freeze Resistant, 150l, 200l, 300l

We reserve the right to change the installation instructions.

Reproduction, even partial, is only allowed with written permission.

WE Geysers (Pty) Ltd ,7 Nelmapius Street,

Chamdor, Krugersdorp, 1754

[email protected]

www.Novasunsolar.co.za

Copyright © 2014

Ikhwezi Solar (Pty) Ltd, Novatherm CC, Solar Assist (Pty) Ltd

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Contents

1. Introduction ............................................................................................................................... 2

2. System description ..................................................................................................................... 2

2.1 Configurations .................................................................................................................. 2

3. Health and safety ....................................................................................................................... 2

3.1 General ............................................................................................................................ 2

3.2 Installation considerations ................................................................................................. 2

4. System configurations ................................................................................................................ 3

4.1 Novasun Thermosiphon System .................................................................................. 3

4.2 Novasun Split-pumped System .................................................................................... 3

5. Frost, scaling and hail resistance, stagnation................................................................................ 4

5.1 Hail resistance ............................................................................................................... 4

5.2 Freeze protection .......................................................................................................... 4

5.3 Direct systems – Freeze resistant & Stagnation ......................................................... 4

5.4 Scale resistance ............................................................................................................ 4

6. System placement and orientation............................................................................................... 4

6.1 Collector orientation .......................................................................................................... 4

6.2 Shading............................................................................................................................ 4

6.3 Tilt angle .......................................................................................................................... 5

6.4 Water supply / delivery ..................................................................................................... 5

6.5 Roof structural integrity .................................................................................................... 5

7. Mounting methods ..................................................................................................................... 5

7.1 Selection of appropriate mounting method ......................................................................... 5

7.2 System mounting methods ................................................................................................ 5

8. Mounting process ....................................................................................................................... 7

8.1 Suggested mounting method 1 .......................................................................................... 7

8.2 Suggested mounting method 2 .......................................................................................... 8

9. System Installation ..................................................................................................................... 8

9.1 General installation technique ............................................................................................ 8

9.2 Cylinder and System plumbing ........................................................................................... 8

9.3 Geysers ............................................................................................................................ 9

9.4 Electrical connection ......................................................................................................... 9

9.5 Installation Diagrams ........................................................................................................ 9

Pumped System – Installation Diagram........................................................................................ 9

10. System commissioning ............................................................................................................. 11

10.1 Commissioning direct systems ......................................................................................... 11

11. Installation checklist ................................................................................................................. 11

12. System Selection and Sizing ...................................................................................................... 12

12.1 Introduction ................................................................................................................... 12

12.2 System sizing ................................................................................................................. 12

12.3 System type ................................................................................................................... 12

13. Owners operating and maintenance instructions ........................................................................ 13

13.1 Introduction ................................................................................................................... 13

13.2 Operating and efficient use ............................................................................................. 13

13.3 Over-night temperature stabilisation ................................................................................ 14

13.4 High water temperature .................................................................................................. 14

13.5 Periods of reduced usage or holidays ............................................................................... 14

13.6 Freeze protection liquid .............................................................................................. 15

13.7 Setting the time clock ..................................................................................................... 15

13.8 Owner maintenance ........................................................................................................ 17

13.9 Troubleshooting .............................................................................................................. 18

14. Warranties ............................................................................................................................... 19

15. Contacts .................................................................................................................................. 19

16. Warranty Contact Centre .......................................................................................................... 19

17. Warranty Services: (log warranty services) ................................................................................ 20

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1. Introduction

All Novasun solar hot water systems are high quality thermal solar

systems, using advanced technology to convert light into heat. This

installation manual must be read and understood before undertaking the

installation of a Novasun solar hot water system. Should any aspect of the

installation process remain unclear a Novasun Solar representative should

be contacted for advice prior to installation.

This manual does not seek to provide comprehensive guidance in terms of

the general plumbing and electrical connection of geysers, which is

assumed knowledge and required of any registered installer, but rather

sets out to provide guidance in terms of the correct installation of the solar

thermal components of the system.

Systems must be installed by suitably qualified and registered plumbers

and electricians, in accordance with relevant South African Norms and

Standards, National Building Regulations, Law and Regulations, Local By-

Laws, including the following:

� SANS 198 - Functional control valves and safety valves for domestic

hot and cold water supply.

� SANS 10106 - The installation, maintenance, repair and replacement

of domestic solar water heating systems, edition three.

� SANS10252 - Water supply and drainage for Buildings. Part 1 - Water

supply installations for buildings.

� SANS 10254 - The installation, maintenance, replacement and repair

of fixed electric storage water heating systems.

� SANS 10142 - The wiring of premises. Part 1 - Low-voltage

installations.

� SANS 10400 - Parts A, B, L, XA.

� Occupational Health and Safety Act (Act 85 of 1993)

� National Buildings Regulations Act 103 of 1977

� Water Services Act (Act N0 108 of 1977)

It is the responsibility of the installer to ensure that they and their staff

are familiar with and competent in respect of the above. Responsibility for

the safe and proper installation of a system rests with the installer.

The solar hot water systems referred to herein must be installed in

accordance with these instructions, local and national plumbing

regulations, municipal building codes and any other relevant statutory

regulations.

All intellectual property in this design and/or registrations and/or copyright

including any patent, patent application are the property of Novatherm CC

and/or WE Geysers (Pty) Ltd.

Observation of these instructions is most important and failure to do so

could void the benefits of the warranty.

The connection, attachment, integration or general association of other

equipment or parts which either directly or indirectly affect the operation

or performance of the solar system could void the warranty. Other such

equipment or parts not supplied by WE Geysers (Pty) Ltd, which may

affect its operation/performance must first be authorised by WE Geysers

(Pty) Ltd in writing if the full benefits of the warranty are to remain valid.

WE Geysers (Pty) Ltd does not accept liability or responsibility for the final

fitness of water for consumption from this water heater, as the water

quality is not affected by the system and is a function of the municipal

and/or other water supply.

This manual has been written with the intention of ensuring that the

system is correctly installed and that the owner/user is fully conversant

with the best methods of operation.

2. System description

2.1 Configurations

Novasun solar hot water systems utilise state of the art technology and

perform with high efficiency in a wide range of weather conditions.

Collector output is directly related to the amount of incoming solar

radiation striking the collectors. This installation manual covers the

installation of the following systems:

Model Major System Components

Novasun 150l

150 Litre Solartherm Direct Geyser

1 x 1.7sqm Novasun Collector

Novasun

200l


1 x 2 sqm Novasun Collector

Novasun

300l


2 x 2 sqm Novasun Collectors

The models governed by this manual are pumped and thermo-siphon

systems. Thermisiphon systems may be installed in a close-coupled or split

system format whilst pumped systems are installed in split system format

and water is circulated using an applicable water circulation pump.

The Novasun range of solar hot water systems are using a direct cylinder in

conjunction with the Novasun collectors employing its unique heat transfer

technology, fully enclosed and insulated, with no direct heating of water,

preventing freezing or overheating of the system.

System heating performance

Model Q-Factor*

Novasun 150l - Termosiphon 11.8 MJ

Novasun 200l – Thermosiphon 16.3 MJ

Novasun 200l – Pumped 23.7 MJ

Novasun 300l - Thermosiphon 27.5 MJ

*The thermal performance of the systems have been established by the South

African Bureau of Standards in terms of SANS 6211, at an incoming radiation of 16MJ

per m² per day, a temperature differential of 10°C and at an inclination of latitude

plus 10°.

**Q-factor is calculated in mega-joules whereas the energy rating is calculated in

kilo-watt hours. The energy rating is calculated by converting the q-factor into kwh.

The specific thermal capacity of the Novasun collector is 4.39KJ/K m².

3. Health and safety

3.1 General

This appliance is not intended for use by young or infirmed persons

without supervision.

Scalding occurs at 50°C. This appliance is capable of providing hot water

over this temperature. In certain circumstances the system may expel hot

water and relieve pressure through the temperature pressure valve. Never

block this valve and always leave open to the atmosphere. Take care to

avoid contact with water when valve is in discharge.

This appliance is a water heating apparatus only and the final quality of

water and fitness for consumption is dependent on the quality of water

supplied to the system.

These systems are designed for the supply of hot water to domestic

household premises which have been constructed to the appropriate local

and national codes and regulations.

3.2 Installation considerations

All installations are to be carried out in accordance with the Occupational

Health and Safety Act (Act 85 of 1993) requirements and any relevant

local authority prescriptions. Some general points to take note of,

however, include the following:

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� Assess site specific risks and eliminate or reduced to an acceptable

level so as to satisfy health and safety requirements, prior to

installation.

� Water temperature can reach boiling point and the collector can reach

stagnation temperatures of over 70°C. Shade collectors during

installation to prevent heating.

� Take care when handling collectors to prevent breakage to glass and

injury. Safety goggles, work wear and gloves must be used to reduce

risk of injury.

� Be aware of overhead power lines coming in through roofs, as well as

electrical wiring running through ceilings.

� Assess weather and postpone roof work if unsafe (e.g. high winds,

rain, lightning, etc.).

� Scaffolding and safety equipment must be installed by certified

personnel and signed-off accordingly. Inspect before use.

� Inform home owners or building occupants of time and place of work

to be carried.

� Ensure occupants are aware of site access constraints and all health

and safety implications relevant to them. Cordon off the area, if

applicable, to prevent personal injury and ensure any pets are

secured.

� Ensure personnel working on installation are competent and in suitable

physical condition. Installers must be trained and conversant with the

assessment of height hazards, working at height safety procedures,

assessment of safety equipment (e.g. scaffolding, harnesses, etc.) and

the use and wearing of safety equipment (e.g. goggles, hard hats,

gloves, etc.).

� All personnel working on the installation of a solar hot water system

must be issued with the appropriate safety equipment and be trained

in their use.

Failure to observe safe practices may result in:

� scalding / burns;

� electrical shock;

� and/or falling,

which can cause serious injury or death.

4. System configurations

4.1 Novasun Thermosiphon System

A thermo-siphon system relies on the natural circulation of fluid between the

collector and the geyser. In order for the thermo-siphon process to occur

the geyser must be placed in a higher position than the solar collector.

The system operates according to the laws of thermal dynamics (i.e. a

liquid, when heated, becomes less dense and rises above the denser cooler

liquid). In the Novasun SWH system, a non-toxic, non-hazardous, food

grade heat transfer liquid, in hermitically sealed heat transfer pipes,

becomes a vapour/gas that rises up as the sun heats the pipes, and this in

turn heats the water indirectly through its contact with the fully insulated

heat exchanger in the collector top. The process continues until the collector

can add no more gain in temperature or until the sun stops shining.

Maximum system equilibrium temperature will reach

approximately 73° C, where after the heat transfer process will

automatically cease due to the water temperature equilibrium

between cylinder and heat exchanger.

A thermo-siphon can be close-coupled or split as illustrated below, provided

there is sufficient roof space.

4.2 Novasun Split-pumped System

• Where the solar water heater is installed in the roof, it must be

installed in compliance with SANS 10106 complete with a Safety Valve,

drain cock, Multi Pressure Control Valve 400kPa, Drip Tray and vacuum

breakers on the cold and hot water supply.

• When installed inside the roof minimum clearance must be allowed in

order to remove the element and thermostat.

• Roof structural integrity must be handled according to section 6.5.

• For Product warranty detail refer to the separate Warranty Agreement.

• Pump Circulation in the Novasun SWH system.

When it is not convenient or possible to place the cylinder higher than

the collector, a circulating pump controlled by an electronic control unit

and two sensors is used to monitor the temperature of the manifold

and the cylinder, that enable the powering of the circulation pump

when the water in the panel manifold is hotter than the water in the

cylinder.

• When the temperature difference is less than the set point the pump

will stop. When temperature of water in the cylinder reaches the

highest set point, the controller will stop the pump.

• The circulating pump used must be installed and maintained according

to the manufacturer’s instructions. A 12V circulating pump with a

photovoltaic solar panel can also be used.

• The method of freeze resistance is by way of 8mm diameter

silicone tube inserts of length 60cm to 100cm into pipe

connectors pipework between the cylinder and panel, on both

sides from the panel, and as supplied by manufacturer or

other approved supplier.

• A split-pumped system is illustrated below.

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5. Frost, scaling and hail resistance, stagnation

5.1 Hail resistance

Novasun collectors are hail resistant with 4mm toughened glass and have

passed SABS hail tests.

5.2 Freeze protection

Solar hot water systems can be classified as (i) direct: freeze resistant, (ii)

direct: non freeze resistant or (iii) indirect.

5.3 Direct systems – Freeze resistant & Stagnation

In traditional direct systems the water to be used in the household circulates

through the collector, transferring solar energy into the solar geyser.

The Novasun SWH new technology panel however contains a fully insulated

indirect heat exchanger located in the collector that acts as a freeze

resistant mechanism. The pipework connecting the solar geyser with the

collector must be insulated with Insulflex insulation material.

When installed with a PEX-lined Solartherm Cylinder it can be used

in all SA climate locations (i.e in areas where frost occurs and

areas, where ambient temperature may fall below 5°C) and in

areas with very high ambient temperatures due to its built-in

overheating (stagnation) prevention technology.

Contact Solar Assist to discuss your water quality and conditions.

5.3.1Direct systems: non-Freeze Resistant

In direct systems the water to be used in the household circulates through

the collector, transferring solar energy into the solar geyser.

Direct systems are used in frost-free locations, where ambient

temperature never falls below 5°C and where water quality is good (i.e. less

than 600ppm total dissolved solids/minerals).

5.3.2Indirect systems

In indirect systems the potable water used in the household does not

circulate through the collectors, but remains in the geyser and is heated

indirectly by a heat exchanger.

There are two basic types of heat exchanger, namely a jacketed system

where an inner cylinder is surrounded by a secondary outer layer and an

internal heat exchanger where the solar geyser contains an internal copper

pipe structure.

In both cases the solar loop (i.e. the pipe work to and from the collectors)

contains a heat transfer medium (i.e. propylene glycol/water solution) which

is physically separated from the potable water.

Propylene glycol has a lower freezing point and prevents the liquid in the

collectors from freezing and damaging the collector through expansion that

occurs when ice forms. Only food grade glycol should be used.

Indirect systems are used in locations where frost occurs and the ambient

temperature drops below 5°C and/or where water quality is poor (i.e. more

than 600ppm total dissolved solids/minerals).

These collectors are resistant to freezing when installed with an indirect

geyser and the solar loop filled with a solution of propylene glycol and

water. Water alone must not be used as a transfer fluid. The glycol / water

solution should be mixed in a glycol to water ratio of 1:3 (i.e. 33% glycol).

5.4 Scale resistance

Indirect systems: containing a glycol solution also prevents scale build up

inside the collector in areas of poor water quality. It is important to note that

the geyser cylinder itself may still be affected by water quality by way of

build-up of scale on the outside of the heat exchangers.

Ensure you are familiar with the relevant tank manufacturer’s warranty

terms and conditions in respect of water quality, particularly as it relates to

anode replacement in case of enamel-lined tanks.

Direct systems: If a direct system is used in areas of poor water quality

the manifold inside the collector and solar loop may be subject to a build-up

of scale. This may be avoided through the use of a water softening system.

This is good practice regardless of type of system, as the water will affect

other household appliances in any event.

Novasun SWH System: In the event that the Novasun SWH collectors

experience scale build-up, the manifold can firstly be flushed with a mildly

acidic solution (e.g. vinegar water mix solution or Scale-away solvent) and

thereafter with fresh water prior to re-commissioning. We recommend that

your service provider perform visual checks every 18 to 24 months and flush

the collector as a preventative measure.

The fitment of an appropriate water softening device in the water feed to

your system is good practice.

6. System placement and orientation

A number of basic fundamentals need to be observed when installing any

solar hot water system.

6.1 Collector orientation

Optimum system performance is achieved when the collectors face directly

North (i.e. true North) when installing in the Southern Hemisphere. The

closer the collector is to directly facing the equator the greater the amount

of solar radiation the collector will be exposed to and the greater the

potential for heating.

Angles up to 45° either side of North will not have a major effect on the

system performance given the state of the art technology used in the

construction of the Novasun systems. Therefore, roofs that are orientated

away from North are also acceptable for installation.

Outside of the 45° range one could consider utilising more collector surface

area or using a mounting frame to adjust the orientation back to North.

6.2 Shading

With a system orientated to face North, the time period when the collector is

exposed to the most direct solar radiation is between 10h00 and 16h00.

Solar collectors with an East bias will achieve a greater gain in morning

hours and those with a West bias will do so in the afternoon.

Care should be taken to ensure that the collectors are not subjected to

excessive shading from trees or adjacent buildings, particularly between

09h00 and 16h00. Also bear in mind that tree growth could lead to future

shading issues.

If the installation takes place in summer, it is also important to take into

account the lower solar angles in winter, which result in longer shadows.

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6.3 Tilt angle

In respect of the optimum angle of inclination for a solar collector, the rule

of thumb provides that the latitude of the location is taken and then 10°

added thereto. Therefore, a location with latitude of 25° would indicate an

optimum collector tilt angle of 35°.

The angle of inclination, however, is also flexible and minimal loss of

performance occurs by installing at lower or higher angles of inclination.

The Novasun collector can be installed as low as 10°. Below this, however,

the thermo-siphon process does not function effectively. Also, angles lower

than this would result in build-up of dust, as it is not able to be washed

away effectively by rainfall.

It must also be noted that installation angles over 30° will require additional

strapping to secure the geyser and collector during and after installation, as

at this angle the system will tend to move downward. Consideration should

be given to a split installation in these circumstances.

6.4 Water supply / delivery

The location of the installation should give as efficient a supply of hot water

to all areas of the residence as possible. If not possible, the system should

be placed as close to its main point of usage (e.g. master bathroom).

Discuss this with the client and confirm their understanding and

requirements.

6.5 Roof structural integrity

The area chosen for installation must be structurally capable of handling the

loading. Check load weights of applicable system and ensure that the weight

can be borne by the roof structure. Specialist advice should be sought if

required.

The system should be placed, such that the tank spans at least three main

trusses. It is good practice to brace all truss work that supports the

installation.

Strengthen rafters (or timbers or other structures) used for supporting the

panel and tank, for example by adding noggins between rafters or adding

thicker timbers alongside them or cross bracing them or adding additional

supporting struts to the truss to spread the additional load to a load bearing

point. Where ever possible the system should be installed over a supporting

wall of the building (i.e. on a truss resting on a supporting load bearing

wall). Never install a system on a roof with damaged or rotting timbers.

To prevent cracking of certain fibre cement and metal roof sheeting, a flat

mounting frame designed to spread the load of the geyser and its contents

should be designed by suitably qualified personnel and installed below the

geyser. Ensure that the roof covering material is structurally sound to

receive the weight of the system. In the case of a split system installation a

wooden frame should be constructed which raises the tank above the level

of the collectors. Care should be taken in the design and construction of this

frame so as to ensure it meets all relevant standards.

7. Mounting methods

7.1 Selection of appropriate mounting method

Please note that it is the installer’s responsibility to ensure that the means of

fixing the system to the roof such that it results in a safe and functional

installation.

The methods suggested are generic and will not necessarily be suitable in all

situations.

7.2 System mounting methods

7.2.1Suggested method 1 - General purpose installation brackets

The image below depicts a typical bracketing system which could be used

with Novasun solar hot water systems. This type of bracketing system is

suitable for tiled or corrugated roof structures with a pitch of less than 30

degrees. Typical kits would include the following pieces:

A (2 pieces) – Tank Cradle Bracket

B (2 pieces) – Collector Clamp

C (2 pieces) – Straps (not included*)

D (2 pieces) – Collector Hanger Bracket**

*Straps are not included as lengths required will differ from installation to installation.

These should be aluminium or stainless steel.

**Please note that two hanger brackets are required per collector. The 300 litre

system using two collectors require 4 hanger brackets (two per collector).

Please note that points of contact between the collector frame and mounting

brackets and between tank and mounting brackets are buffered by a foam

lining to prevent issues surrounding galvanic corrosion.

The installer must install the system in such a fashion to prevent long term

degradation of system materials through galvanic reaction.

7.2.2Suggested method 2 - Alternate installation brackets

As an alternative to the first bracketing system, straps could be used.

Collectors could be secured directly to the roof structure, at each of the four

corners of the collector, by means of aluminium strapping.

The straps should be securely fixed to the underside of the aluminium

collector frame using aluminium speed screws. The straps can then be

passed under the tiling and secured around the nearest truss and/or purlin.

In respect of the geyser, strapping can be hooped around the geyser, on

either end of the cylinder, using strap clamps available with commercially

available strapping systems, leaving enough length to pass the tail pieces

under the tiles and secured around the appropriate roof woodwork.

As indicated above the installer must install the system in such a manner so

as to prevent galvanic corrosion between system components and the

mounting brackets and/or straps.

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7.2.3Suggested method 3 alternate installation brackets

Geyser Brackets

a) Description: Profiled aluminium plating providing a solid footing

distributing the weight of the unit over the roof covering. Positioning of

bolts on brackets are off centre in order to allow the foot plate of the

geyser to rest squarely in the centre of the bracket once installed.

Easy to use wing nuts are supplied to minimise effort on installation.

The foot plate of the geyser has to be fitted to the geyser before the

bracket is fitted onto the foot plate.

b) Once the roof covering is moved away, the stainless steel strapping

attached to the bracket is then wrapped around timber roof structure

for anchoring the bracket. Be sure to secure the strapping onto the

timber using tech screws or similar. Roof covering is then placed back

into original position.

c) The bracket is placed underneath the geyser foot plate with the bolt

sliding through the slotted hole and tightened using the wing nut as

supplied.

d) Note the correct use of “left hand” and “right hand” bracket.

Attached strapping is then tightened onto the timber structure in the

same way as above.

Novasun tanks are equipped with extra anchor points on the

tank in order for the tank to be installed on an angle of 31° if

so required on pitch roofs.

Panel Bracket

a) Description: Holding bracket attached to stainless steel strapping.

b) The holding bracket is positioned underneath the panel in order to

hook onto the bottom lip of the panel. The stainless steel strapping is

then fastened onto the roof structure in the same way as the strapping

of the tank.

The holding brackets should be placed in position first and properly

fastened to the roof structure using tech screws or similar. The roof

covering can then be placed back into position and the panel positioned

and secured into the holding bracket.

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8. Mounting process

8.1 Suggested mounting method 1

Connect hanger bracket (D) to strapping (C), allowing enough length

strapping for the flexible strapping to fit under the roof tile and wrap around

the purlin/truss. Remove roof tiles and position hanger brackets.

The bracket should be secured in place by fixing to the purlin. Fixings (i.e.

screws, bolts, etc.) must be appropriate for the type of timber. Hard woods

and soft woods require particular fixings. Fix the bracket in place as shown

in the next image.

Replace tiles once the bracket is fixed in place as shown in the next image. 2

brackets are required per collector.

The hanger bracket should be positioned on the peak of the tile and not in

the valley. This helps prevent pooling of water and degradation to the

brackets and possible leaks.

The collector is positioned into the collector bracket as demonstrated in the

image above. A slight kick of 25mm from the cold inlet side to the hot outlet

side of the collector is recommended (i.e. cold side lower than hot side by

25mm).

In the case of sheet roofing, as depicted in the following image, a roof screw

can be removed, the strap placed over the existing hole and the roof screw

reinserted thereby securing the strap. In instances of sheet roofs,

appropriate waterproofing needs to be effected to the roof surface after

straps have been secured to the roof material.

The tank cradle (A) is positioned up against the top edge of the collector,

with the foot of the cradle slid underneath the collector.

The collector clamp (B) is fixed to the tank cradle to lock down the top of

the collector as depicted in the next image.

The tank cradles should also be placed on the peak of the roof tile. Once the

tank cradles are in place and the collector clamp fixed in place the geyser

can then be positioned into the cradles as pictured in the next image.

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Make sure that the tank is rotated to a position where the drain cock is at

the lowest point on the geyser as pictured above. This will ensure that the

maximum volume of water in the tank is available to be heated by the

collector.

The image below depicts the completed mounting of the system.

Larger tank sizes may require additional tank cradle brackets depending on

the roof pitch.

8.2 Suggested mounting method 2

As an alternate to collector hanger brackets, aluminium straps could be used

to secure the collector. Aluminium friendly speed screws can be used to

secure the strap to the back of the collector frame. A strap needs to be fixed

to each corner of the collector frame (i.e. four straps).

Straps should be long enough to be fed underneath the roof tiles and then

folded around the timberwork of the roof. The straps should be positioned

on the peak of the tile and not the valley to prevent water from pooling and

degrading the strap. The straps used should be of sufficient gauge to

provide for a secure mounting of the collector.

The image below depicts the view from below, with a tile removed. This

demonstrates the strap fixed to the frame of the collector and then folded

around the purlin. Fixings appropriate for the type of timber should be used

(i.e. hard woods and soft woods require particular fixings).

In respect of the geyser, stainless steel strapping can be hooped around the

geyser, on either end of the cylinder, using commercially available strap

clamping ystems or other secure means of completing the hoop, leaving

enough length to pass the tail pieces under the tiles and secured around the

appropriate woodwork with appropriate fixings.

As shown in the image below, the strap should fit closely around the body of

the tank. Make sure that the tank is positioned in such a way that the drain

cock is at the lowest point of the tank. Once the tank is in place, fix the

hoop in place and replace tiles.

9. System Installation

9.1 General installation technique

During fitting and prior to filling, the system must be protected against the

entry of dirt and water. After the system has been mounted, it must be

flushed in order to remove any debris (e.g. metal chips, packaging residue,

sawdust, etc.).

Shade panels until after connecting plumbing and installation is ready for

commissioning in order to prevent heating of empty collector.

Exercise caution during the lifting phase of installing the collector and tank

onto the roof. Ensure that adequate personnel are present to bear the

weight and that they are assisted with supportive lifting tethers and safety

rigging.

With reference to section 6 above, measure the size of the collector, and use

measurement to locate the best position on the roof to affix panels,

matching measurements to supporting roof trusses and purlins. Avoid

interference with coping or gutters.

A minimum distance between the top of the panel and the tank flow outlet is

300mm. In split system installations distances should be kept as short as

possible and generally should not exceed 3 metres.

For roof pitches above 30°, special and/or extra strapping or brackets may

be required to prevent downward movement of the tank and collector.

Measure the exact size of your tank and use this to locate the best position

on the roof at which to affix tanks to supporting roof trusses and purlins.

If necessary, strengthen rafters used for securing the panel and tank, for

example by adding noggins between rafters or adding thicker timbers

alongside them (refer section 6.5 above).

9.2 Cylinder and System plumbing

9.2.1General

Plumbing must conform to IOPSA code, SANS, PIRB and local regulations.

In a thermo-siphon the geyser is installed above the panel, but kept as close

as possible.

All piping runs should be kept as short as possible, both between the

collector and tank, as well as between the tank and the location of hot water

usage (i.e. bathrooms).

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9

All pipework must be properly insulated, as per our requirements, the

cylinder & panel/collector insulated with 28x 25mm R-value 1 insulation, all

pipework including at least two metres of the cold feed to and hot supply

from the geyser. For Flat Roof installations insulation must also cover all

open pipework leading into the roof space. Insulation material must be heat

tolerant and UV resistant, nor must it unduly compress or cause corrosion.

Installation Tip: For increased weatherability in harsh climate areas insulation can further be wrapped with aluminium duct

tape or covered by a product such as Flash Harry membrane and coating.

Piping from the flow of the tank to the inlet at the top of the collector must

have a continuous fall and from the top of the collector to the return must

have continuous rise.

Only hard-soldered connections or compression fittings are to be used in the

assembly of the solar heating circuit. No fluxing agents containing chloride

should be used.

Use copper pipe only. Plastic pipe must not be used due to the effects of

high water temperatures and pressures. The pipe work to and from the

geyser must also be copper for at least two metres below the hot water

outlet.

A temperature mixing valve must be used to control the temperature of

water delivered to the points of use. This is important in the prevention of

accidental scalding and is a SANS requirement.

9.3 Geysers

The Novasun Solar Water Heating systems make use of WE Geysers (Pty)

Ltd’s Solartherm geysers cylinders, depending on the model selected. The

manufacturers’ installation requirements that accompany each of these

products must be observed in the installation process. Failure to do so may

result in the warranty of these products becoming null and void.

WE Geyser tanks are fitted with SABS approved peripherals.

Geysers installed inside must have sufficient space for servicing thermostats

and elements (Note: there are no anodes in Solartherm cylinders which

require regular servicing) , as well as allowing for the required SANS height

of vacuum breakers above the tank

9.4 Electrical connection

All electrical work must be carried out by properly qualified and registered

electricians.

Novasun recommends the installation of a time switch when undertaking a

solar installation. This optimises the performance of the system and is

specifically required when a rebate is to be claimed in respect of the Eskom

incentive program.

The time clock is fitted to the distribution board and is used to set the time

periods that the thermostat and element receive electrical input. Time

settings will be dictated by patterns of consumption, but for example could

be set to activate from 3am to 5am and from 4pm to 6pm, taking care that

the times do not fall within Eskom peak periods.

Electric water heaters use 220 Volt AC power. The circuit breaker and

isolator should be switched off before working on the geyser.

Verify that power is off with a volt meter and ensure that load shedding or

existing timers are not active, which may cause the electrics to become live

whilst working on the system.

Power should not be applied to an empty electric water heater as heating

elements will be damaged. Tank warranties would be void in these

circumstances.

9.5 Installation Diagrams

Various installation diagrams are illustrated below in order to assist

installers with installation services. Approved installers must

contact Solar Assist for system specific training and

instructions prior to installing the Novasun SWH range.

Thermosiphon System – Installation diagram

Acknowledgement: www.solarassist.co.za Note: For purpose of installation demonstration no insulation

has been shown here but insulation must be installed according to standard on all open copper piping as

per paragraph 9.2.1

Pumped System – Installation Diagram

Note: For purpose of Pump controller installation and wiring instruction refer to the Geyserwise Installation

manual or go to www.geyserwise.co.za

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Pumped Controller – Geyserwise System

Acknowledgment: Geyserwise Installation Manual: For purpose of Pump controller installation and wiring

instruction refer to the Geyserwise Installation manual or go to www.geyserwise.co.za

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10. System commissioning

10.1 Commissioning direct systems

Make sure that the solar radiation is low during

filling. In strong radiation it is possible for steam

to form in the collector. Keep the collector

covered throughout installation and

commissioning.

Do not turn on the electric backup until the tank

has been filled with water.

Turn on at least one hot water outlet tap and

open the mains water supply to allow the water

to fill the tank and collector, expelling air from the

tank. As soon as water flows freely, without air

sputter, close the tap and allow the cylinder to

pressurise.

Check all piping, joints and fittings for water

leaks.

Check pressure relief valves to ensure correct

operation.

Turn on the electric backup element. Make sure

the tank is completely filled before turning on the

element. Ensure power is available to the backup

element.

Ensure the time clock has been correctly set.

11. Installation checklist

The following checklist should be observed by the

installer before handing the system over to the

owner/user.

� All air bled from taps

� System checked for water leaks

� Cold and hot water pipes checked for leaks

� Roof tiles back in position

� Roof flashing watertight

� Drain pipes free of obstruction

� Pipework insulated

� Electrical element, timer switch, isolator

and thermostat, controller and pump

checked

� Any protective plastic or packaging stickers

removed from tanks and/or collectors

� Owner instructed on use

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12. System Selection and Sizing

12.1 Introduction

Individuals purchase solar hot water systems for

many reasons. Some buy to realise savings on

their energy spend, others out of concern for the

environment, others as they have no other means

of heating water or it could be a combination of

the above. Whatever the motivating factor is it is

important that the type and size of the system

selected are going to best meet the consumers’

needs and expectations.

12.2 System sizing

In deciding on the system required, apart from

conducting a site visit to ascertain the proposed

installation site and associated mounting,

plumbing and wiring considerations, the sales

representative should also consult with the

prospective customer as to their hot water

requirements.

It is critically important that the prospective buyer

provide accurate information in this regard, as

the results of providing incorrect information can

result in a system that either over or under

performs, given the specific needs of the

customer.

The onus is on the prospective buyer to provide

the sales consultant with an accurate disclosure

of the hot water requirements and usage patterns

in order that a load profile can be formulated.

A load profile would include information such as

how many showers are taken per day and how

many litres are used, how many baths are taken

and size of baths, how much hot water goes

towards washing dishes and doing laundry, etc.

Only once this information is analysed can a final

recommendation be made on system size.

12.3 System type

System type can relate to a number of system

characteristics as follows:

� Direct vs. Indirect (refer section 5 above)

� Close-coupled vs. Split (refer section 4

above)

The decision between direct versus indirect is

described in section 5 above, but basically this is

determined by whether or not frost or poor water

quality dictate an indirect system.

NOTE: THE DIRECT NOVASUN

(THERMOSIPHON/PUMPED) SOLAR

WATER HEATING SYSTEMS CAN BE

USED IN ALL CLIMATE AREAS OF

SOUTH AFRICA

The decision between close-coupled and split

system is largely an aesthetic decision based on

customer preference, but there is a cost

implication in that split system requires additional

plumbing, system controller, circulation pump and

mounting structures which translate into a

greater installed cost.

As the Novasun systems have been SABS tested

in a thermo-siphon and pumped configuration

and registered with Eskom accordingly, a split

system installation can be claimed for on the

rebate programme if the system is a thermo-

siphon or pumped system. That is, even though

the tank is installed inside the roof there is

enough space that the tank is above the level of

the collector/s, allowing a thermo-siphon to

operate or a pump to force the circulation.

NOTE: Please visit www.Novasunsolar.co.za for

more information on system.

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13

13. Owners operating and maintenance

instructions

13.1 Introduction

Dear Customer,

Thank you and congratulations on your purchase.

Your system is one of the most advanced

available and is proudly produced in South Africa.

It will provide years of service and savings. The

information below is provided to give guidance in

the effective use and maintenance of your system

and should be retained for future reference.

Yours sincerely,

WE Geysers (Pty) Ltd

13.2 Operating and efficient use

Savings in energy costs achieved is dependent

upon usage patterns and the extent to which

electrical backup is used. The following will assist

in understanding system performance:

� Solar radiation is greater on clear, sunny

days, between 9am and 3pm. During

periods of use the system operates at

approximately twice the maximum ambient

temperature and during periods of non-use,

it is possible to achieve well over 70°C.

� On days of high radiation schedule washing

loads as close as possible to mid-day.

� On low solar radiation days avoid heavy hot

water usage.

� Electrical backup, which is thermostatically

controlled and governed by a time-clock,

should be set at 55°C. The time-clock has

battery backup in order to prevent settings

being lost during general power failures. In

order to claim an Eskom rebate, a time-

clock is mandatory. We would advise the

use of a time-clock in any event, as this is

the most efficient method of operating a

solar system.

� Time-clock settings should, generally

speaking, be set for two hours in the

morning and two hours in the evening. For

example, if you bath at 06h30 and 18h00,

set your time-clock for 04h00 to 06h00 and

again for 15h00 to 17h00. Ensure backup

time periods do not coincide with localised

load shifting by municipalities employing

ripple relay devices. This will ensure that if

there was not sufficient solar gain during

the day, you will still have hot water in the

evening and early morning.

� Solar systems without time-clocks rely on

thermostats to control when the element

switches on and off. This is not efficient or

cost-effective. An example of this would be,

using hot water in the morning which

causes the thermostat to automatically

activate the element to heat your water.

However, this is when the sun will start to

heat your water. Therefore, if you do not

have a time-clock or it is not programmed

properly, you will not save as much energy

as you will use both electricity and solar

energy to heat your water simultaneously.

� An override function is provided on the time

clock so you can over-ride programmed

heating times and heat up your water

electrically. This should only be used when

strictly necessary (e.g. during periods of

more than normal usage when guests are

in the residence) and remembering to

revert to pre-programmed settings. This will

save you the optimum amount of electricity

and provide the necessary reduction in

peak-period use.

� If you wish to set your timer differently,

you should discuss this with the dealer.

However, your timer must not come on

during Eskom’s peak electricity use periods.

These may change from time to time so

please check with your installer.

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14

� Once you get used to the system and its

optimum performance pattern, you may

eventually completely switch the electrical

backup off, particularly in summer months.

An additional benefit of this is that it is the

fastest way to reduce the system’s payback

period.

� Savings can be further maximised by using

hot water in the evening rather than in the

morning, maximising the free energy

harvested during the day.

Additional tips to enhance savings include:

� To further optimise energy and hot water

savings, install aerated shower heads and

aerators in taps to reduce hot water

consumption.

� Insulate hot water piping to minimise heat

losses.

� Showering generally uses less water than

bathing.

� For health reasons your hot water system

should provide water at 55ºC, but not much

warmer than that. Do not set your

thermostat backup temperature control for

temperatures in excess of this.

� If shading of collectors is experienced

between 9am and 3pm then corrective

action should be taken. Annually prune or

cut trees that shade the system.

� Partial shading by chimneys, TV antennas,

roof erected fixtures, etc. on buildings

during these hours is acceptable provided

that it does not exceed 10% of the area.

Shading from newly erected buildings

should be checked and if system

performance is affected, relocation of the

system may be necessary.

13.3 Over-night temperature stabilisation

� Over-night temperature stabilisation is the

reduction in water temperature, as the hot

water at the top of the storage cylinder

transfers some of its heat to the cooler

water in the lower section of the cylinder.

� This effect is often perceived as heat loss,

but is actually the redistribution of stored

heat more evenly over the entire contents

of the storage tank. This may make it

necessary to use the electric element to

raise the water in the top section of the

cylinder back to an acceptable temperature.

� Over-night temperature stabilisation is most

evident in the morning if the time clock is

left off overnight.

13.4 High water temperature

� Your solar water heater will generate hot

water quickly and efficiently. Under normal

family use, it will operate between 60ºC

and 70ºC. However, the temperature can

exceed this and under certain

circumstances may be as high as 75ºC. This

can occur during prolonged periods of

direct sunlight and particularly in summer

or long periods of reduced water usage.

Extreme care should be taken in these

circumstances.

� Although every system is fitted with a

mixing valve that regulates temperature at

points of water use, check the water

temperature before use, such as when

entering a shower or filling a bath or basin,

to ensure it is suitable for the application

and will not cause scalding. It is required by

SANS regulations, that a temperature

limiting device / mixing valve be fitted to

the system. This will limit the water

temperature to 50°C at the point of use.

The risk of scalding will be reduced, but

water should always be tested prior to use

to prevent injury in the case of a tempering

valve failure.

13.5 Periods of reduced usage or holidays

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15

If the water heater is left unused for two weeks

or more a small quantity of hydrogen gas,

which is highly flammable may accumulate in

the top of the water cylinder. This is true of

both conventional electric geysers and solar

systems. To dissipate this gas safely, it is

recommended that a sink hot tap be turned on

for several minutes. Do not use a dishwasher,

clothes washer or other appliance for this

purpose. During this procedure there must be

no smoking, open flames or any electrical

appliance operating nearby. If hydrogen is

discharged through the tap it will make an

unusual sound like air escaping.

It is recommended that if the system is going

to be left unused for long periods of time, that

the backup element switched off at the

distribution board. Remember that when the

geyser breaker is reactivated the time clock

may have to be reset as it has a limited settings

memory when switched off (i.e. approximately

72 hours depending on the model).

13.6 Freeze protection liquid

No freeze protection liquid is used in the

Novasun system as the system inherently

is protected against freezing conditions.

(Passed SABS Freeze Test -20°C)

13.7 Setting the time clock

WE Geysers (Pty) Ltd recommends that an SABS

approved time clock, with battery backup, be

installed on the distribution board. There are

many such time clocks on the market and the

operation of which are all relatively similar. A

Samite QAT-R-DM time clock has been selected

to illustrate how to program the time clock.

This time clock has four different screens. When

it is powered up screen 1 (main screen) appears.

SCREEN 1: Actual Time Indicator

This ON/OFF indicator indicates whether the time

clock is currently active or not. This screen also

displays the current actual time.

Press the green function button to cycle forward

to the next screen.

SCREEN 2: Set Actual Time

Press the Hour and Minute buttons to set the

actual time. Once the time is set press the

function button to advance to the next screen.

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16

SCREEN 3: Program Timer On/Off

To program the desired timer settings press the

off button to move the flashing segment to the

time at which power is made available to the

geyser thermostat/element. Once the segment is

at the desired time, press the on button

repeatedly to insert 30 minute backup segments

until the time is reached when you want the

backup period to end. These steps can be

repeated if further backup periods are required.

For effective operation an afternoon and an early

morning backup period are recommended.

EXAMPLE: Backup period from 3PM to 6PM

Press the Off button until the program time

indicates 15h00, then press the On button until

the program time indicates 18h00. As shown

below.

SCREEN 4: Bypass on or off

The timer programme is bypassed using this

screen. Press the “Bypass On’’ button to bypass

the timer and provide the geyser with a constant

supply. The Bypass on display flashes.

Press the “Bypass Off” button for power to be

controlled by the timer and switch on according

to the set times.

Press the function button to return to screen one.

Note: When in “Bypass On” mode the display will

not revert to screen one after 60 seconds.

Should you be away from home for any extended

period and you wish to switch the geyser off at

the breaker on the distribution board, please

remember that you would have to re-programme

the time clock on your return as the on-board

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17

memory is only stored for approximately 72 hours

without being connected.

The use of the electrical backup is very much

dependent on personal usage patterns of hot

water. The following, however, are a few tips:

� During days with temperatures below 20°C,

water temperature may only reach 40°C to

50°C. It could be lower if these colder days

are coupled with overcast and rainy

conditions.

� The human body generally prefers

temperatures of between 35°C to 40°C for

bathing during winter and therefore

boosting may be required at certain times.

� Backup heating is generally preferable

during late afternoon and early morning, so

that maximum use of solar energy during

the day is taken advantage of.

� The backup should not be set that it is on

during periods when the water is being

used. This because an element cannot heat

the water with any efficiency when water is

being used.

� If hot water use is heavy during the

evening then it is vital that a backup

heating period be set for the early morning

if one desires hot water first thing in the

morning.

13.8 Owner maintenance

To ensure that the system will perform reliably,

some preventative maintenance should be

performed by the home owner/user. If the

system is in a position which is not easily

accessible or the owner is not in a position to

effect the points below, a service technician

should be employed to carry out the

maintenance.

The following should be performed annually by

the owner/user appointed technician:

� Wash the glass cover of the collector with a

mild household detergent. The collector

glass and seals should be inspected.

� Mounting brackets and straps should be

checked for signs of wear.

� Pipe insulation should be checked for signs

of degradation and/or damage. Please note

that although UV resistant insulation is

used, the harshness of the South African

climate means that the insulation will not

last indefinitely. There is no warranty on

pipe insulation.

� Visually inspect pipework for signs of leaks,

scale build-up.

� A periodic inspection of pressure reducing

valves, expansion valves, vacuum breakers,

temperature pressure valves and tempering

valves should be conducted on a solar

geyser, just as it should be done on any

conventional electrical geyser. These valves

allow for the safe operation of the geyser

and should be inspected twice yearly.

� The temperature pressure (TP) valve is

near the top of the water heater and is

essential that this valve operates safely. It

is possible for the valve to release a little

water through the drain line during each

heating period. This occurs as heated water

expands by approximately 1L out of 50L of

its volume. If continuous leaking occurs this

may indicate a problem with the valve -

please report this to your installer

immediately. WARNING - Never block the

outlet of this valve. TP valves should be

checked for performance at intervals not

exceeding 6 months, or more frequently in

areas of high incidents of water deposits

(such as Calcium or Magnesium).Be advised

that in areas or periods of high solar

radiation there will be greater frequency of

this valve opening. In order to check the TP

valve the easing gear should be operated.

This is a black knob on the TP valve that

needs to be turned in an anti-clockwise

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18

direction and some water allowed to

escape. Be aware that this water may be at

a high temperature. Before opening the

valve make sure you are well clear and be

advised that the geyser will be under

pressure so water may be expelled at a

high rate. Guard carefully against exposure

to the water whether through direct contact

or through back splash. Be careful not to

confuse the TP valve with the solar relief

valve fitted on some indirect systems.

Please contact your installer for advice if

unsure.

� If at any point the temperature at point of

use (e.g. bathroom) appears to be

increasing or decreasing, the temperature

mixing valve may need to be set or

adjusted accordingly.

Warning

When inspecting your system please bear the

following in mind:

The removal of the electrical cover plate on the

solar geyser will expose 220 V wiring. It must

only be removed by an authorised electrician or

service person.

Care should be taken not to touch the pipe work

connecting the solar storage tank and the solar

collectors. Very high temperature hot water can

be generated by the solar collectors under certain

conditions, and will flow through the pipe work

from the solar collectors to the solar storage tank.

Working at heights should only be undertaken by

suitably qualified personnel, using the proper

safety equipment.

Failure to observe safe practices may result in:

� scalding / burns; � electrical shock; � and/or falling,

which can cause serious injury or death.

13.9 Troubleshooting

Should your system not provide hot water please

check the following before requesting a service

call:

� Shading from trees is not excessive and is

not covering the collectors for all or part of

the day.

� Hot water usage has not been excessive.

� Hot water is not leaking from within the

plumbing system that feeds hot water to

the points of use.

� The time clock/cntroller is operational and

has been programmed correctly.

� The electric meter and/or display light on

the time clock speeds up when the time

clock is active.

� Power has been provided to the main board

(i.e. no electrical faults or load shedding).

� The ripple relay has not become jammed in

the open position.

� The water supply to the home has not been

interrupted (i.e. municipal shut-off)

Please contact your local dealer and/or installer if

all of the above have been checked and there is

still no hot water. A charge out fee may apply if

the system is found to be functioning correctly

and the matter relates to one of the above issues.

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14. Warranties

Please refer to the Novasun SWH Warranty

Document.

15. Contacts

WE Geysers (Pty) Ltd (Pty) Ltd

Physical Address 7 Nellmapius Road, Chamdor,

Krugersdorp, 1754

Postal Address PO Box 4060, Luipaardsvlei,

1743

Tel +27 11 769 1387

Fax +27 11 762 2200

email [email protected]

email [email protected]

Website www.Novasunsolar.co.za

16. Warranty Contact Centre

SolarAssist 0861 106 618 (24/7)

Website: www.solarassist.co.za

Email: [email protected]

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17. Warranty Services: (log warranty services)

Important Notice: Making use of a non-accredited Solar Installer to perform warranty work on your

Novasun SWH system will void your Warranty Agreement.

Date: Service Provider/Contact detail Services/Job performed.

Owner Notes:

novasun installation manual v2.5 2015 - solar...

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