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Envirosun AS Installation Manual Rev1a PVNW.docx

Page 1

Table of Contents

Customer Information ................................................................................................................ 2

1.1

Installing your new Conergy AS System .......................................................................... 2

1.2

Conergy quality ................................................................................................................. 2

1.3

System Components ........................................................................................................ 2

1.4

Conergy model numbers explained .................................................................................. 4

1.5

Is the system suitable for extremely cold climates? ......................................................... 4

1.6

Important safety information ............................................................................................. 5

1.7

If the customer is away for a long period of time .............................................................. 5

1.8

Water discharge through the pressure valve .................................................................... 5

1.9

Hydrogen gas can accumulate! ........................................................................................ 5

Troubleshooting ......................................................................................................................... 6

2.1

Low solar energy input ..................................................................................................... 6

2.2

Solar collector shading ..................................................................................................... 6

2.3

AES (Booster) system not operating ................................................................................ 6

2.4

Excessive water discharge from the valves ..................................................................... 6

2.5

Hot water use higher than anticipated .............................................................................. 6

2.6

Water discharge from the frost valve ................................................................................ 7

System Maintenance ................................................................................................................. 8

3.1

Draining and flushing the system ..................................................................................... 8

3.2

Collector glass cleaning .................................................................................................... 8

3.3

Hail damage or broken collector glass ............................................................................. 8

3.4

Relief valves ..................................................................................................................... 9

Important Installation Information ............................................................................................ 10

4.1

Local Standards .............................................................................................................. 10

4.2

Safety .............................................................................................................................. 10

4.3

Water Quality .................................................................................................................. 10

4.4

Pressure Reducing Valve ............................................................................................... 11

4.5

High wind or cyclonic areas ............................................................................................ 11

4.6

Piping material ................................................................................................................ 11

4.7

Supplementary heat sources .......................................................................................... 11

4.8

Legionella requirements ................................................................................................. 12

4.9

Roof location selection ................................................................................................... 12

Dimensions and Technical Data ............................................................................................. 14

5.1

Collector Installation Area ............................................................................................... 14

5.2

Parts Kit Details .............................................................................................................. 15

5.3

System Weights .............................................................................................................. 16

Installation Instructions ............................................................................................................ 17

6.1

Installing the collectors ................................................................................................... 17

6.2

Flat roof installations ....................................................................................................... 19

6.3

Solar Flow and Return Lines .......................................................................................... 19

Connections at the Storage Tank ............................................................................................ 21

7.1

Connections for the PM-600 ........................................................................................... 21

7.2

Plumbing Connections .................................................................................................... 22

Electrical Connections ............................................................................................................. 23

8.1

Electrical connection for Electric AES (Booster) ............................................................ 23

8.2

Electrical Installation for the PM-600 .............................................................................. 24

8.3

Gas AES installation instructions .................................................................................... 26

Commissioning & Customer Hand Over ................................................................................. 27

9.1

Commissioning ............................................................................................................... 27

9.2

Customer Hand Over ...................................................................................................... 27

Warranty .................................................................................................................................. 28

Contact Details ........................................................................................................................ 28

Содержание Conergy AS System

Страница 1: ...CONERGY PTY LTD Conergy AS Owner Installation Manual ...

Страница 2: ...cleaning 8 3 3 Hail damage or broken collector glass 8 3 4 Relief valves 9 4 Important Installation Information 10 4 1 Local Standards 10 4 2 Safety 10 4 3 Water Quality 10 4 4 Pressure Reducing Valve 11 4 5 High wind or cyclonic areas 11 4 6 Piping material 11 4 7 Supplementary heat sources 11 4 8 Legionella requirements 12 4 9 Roof location selection 12 5 Dimensions and Technical Data 14 5 1 Col...

Страница 3: ...tains the five main components of your solar water heater system These are 1 Potable Water Storage Tank 2 Solar Controller Module 3 Solar Collector s 4 Ancillary Energy Support AES System Please note the AES system can be either electric or gas operated dependent on the model purchased 5 Parts Box which includes pipes fittings and mounting rails to interconnect and mount the system 1 3 1 Storage T...

Страница 4: ...omatically Figure 1 3 1 Electric AES Schematic For gas AES systems the electric element in the storage tank is not connected to an electricity supply Instead a continuous flow gas water heater is fitted adjacent the storage tank in series with the hot water supply from the storage tank and the household hot water pipe work As the hot water from the solar storage tank passes through the gas heater ...

Страница 5: ...Table 1 4 1 System Model Number For example AS315 40 0 E36 V E20AA AS Active System 315 315 litre storage tank 40 4 m of collector area E36 an electric AES with 3 6 kW rating V Vitreous enamel tank E20AA 2 m selective surface solar collector model E20AA 1 5 Is the system suitable for extremely cold climates The open circuit system is not suitable for frost prone or freeze areas If you are in a fro...

Страница 6: ...tical cover the solar collectors If the solar collectors are not covered there is a possibility that the high temperature valve in the storage tank may open and disperse small amounts of hot water for a short period to reduce the storage tank temperature while you are away This is a normal function and does not harm the system 1 8 Water discharge through the pressure valve All Conergy solar water ...

Страница 7: ...the booster isolator on and off to see if the electricity meter speed changes If there is no change in speed it indicates there may be a booster problem Contact your authorised Conergy dealer or installation service provider as soon as possible For gas systems the gas and electric supplies to the gas heater should be checked to ensure they are both on If water temperature from the gas heater is be...

Страница 8: ... the collector In temperatures that cause frost or freezing the valve will open and some water will discharge from this valve There is nothing that needs to be done to the valve or the system it is operating correctly The water will stop discharging once the valve has warmed enough to close again usually as the frost clears Refer to section 1 5 on page 4 for more information on frost protection ...

Страница 9: ...e drain pipe to the cold connection at the tank Place the open end of the drain hose in a location where it is safe for the hot water to drain away from the tank 6 Manually open the pressure temperature relief valve which will allow air into the tank and the water within the tank will ﬂow out via the ﬂexible drain pipe ﬁtted to the cold inlet connection Hold the valve open until the tank is empty ...

Страница 10: ...eely from the valves they should be checked and possibly replaced The relief valves and relief valve drain lines must not be blocked Some water may discharge during each heating cycle Every ﬁve year s all safety valves should be replaced to ensure continued life and operational safety of the system In locations where the potable water has a Total Dissolved Solids TDS of greater than 600 ppm it is ...

Страница 11: ...pproved professional with suitable experience and licenses authorised by Conergy to conduct the work It is imperative that installers adhere to Occupational Health and Safety Guidelines at all times The installer is responsible for their safety and the safety of those around them 4 3 Water Quality Water supply from an unfiltered water source that may be highly conductive or have a high mineral con...

Страница 12: ...allation is on a roof with a pitch greater than 30 If the solar water heater is installed in an area classed as Cyclone Region C or D according to AS 1170 2 2002 the standard mounting systems must not be used Please consult a structural engineer for advice on ensuring the installation will comply with local building codes and regulations 4 6 Piping material Conergy recommends the use of copper pip...

Страница 13: ... for 32 minutes in each 7 day period This will require any timing device or manual control to be adequately set up or operated 4 9 Roof location selection There are six major factors to consider when selecting the solar collector installation location 4 9 1 Collector orientation For optimum performance the solar collectors need to face the equator in southern hemisphere this is north and in the no...

Страница 14: ... is greater than 30 will require additional support at the storage tank to prevent it moving downward during and after installation If the roof pitch is less than 10 the system will require a mounting frame to increase the pitch above 10 Air can accumulate in installations below 10 and may not circulate effectively Additionally the collector glass will not self clean during rainy periods 4 9 5 Roo...

Страница 15: ...20 2600 1370 1226 2000 1000 82 TS180 25 C E25 2600 1370 1226 2000 1235 82 TS180 25 O E25 2600 1370 1226 2000 1235 82 TS300 25 C E25 2600 1370 2010 2000 1235 82 TS300 25 O E25 2600 1370 2010 2000 1235 82 TS300 40 C E20 2600 2238 2010 2000 1000 82 TS300 40 O E20 2600 2238 2010 2000 1000 82 TS300 50 C E25 2600 2645 2010 2000 1235 82 TS300 50 O E25 2600 2645 2010 2000 1235 82 TS300 60 C E20 2600 3260 ...

Страница 16: ...204 TS300 25 C E25 TS300 C E24 E25BC PK 2101 PK 1204 TS300 25 O E25 TS300 O E24 E25BC PK 2100 PK 1204 TS300 40 C E20 TS300 C E24 E20BC PK 2103 PK 1205 TS300 40 O E20 TS300 O E24 E20BC PK 2102 PK 1205 TS300 50 C E25 TS300 C E24 E25BC PK 2101 PK 1206 TS300 50 O E25 TS300 O E24 E25BC PK 2100 PK 1206 TS300 60 C E20 TS300 C E24 E20BC PK 2103 PK 2104 PK 1205 PK 1207 TS300 60 O E20 TS300 O E24 E20BC PK 2...

Страница 17: ... Vitreous Enamel Mild Steel 64 239 TS180 O E24 V Vitreous Enamel Mild Steel 54 229 TS300 C E24 V Vitreous Enamel Mild Steel 101 399 TS300 O E24 V Vitreous Enamel Mild Steel 87 385 TS300 O E24 S 444 Stainless Steel 71 369 Table 5 3 1 TS Tank Weights Collector Weight Empty kg Weight Full kg E20BC 29 5 31 2 E25BC 36 0 38 0 E20AA 39 0 40 7 Table 5 3 2 Collector Weights ...

Страница 18: ...of the collector mounting rail Error Reference source not found adjacent the location marked in step 1 and laid horizontally across the roof to the right 3 Locate two roof trusses which are under the collector mounting rail as near as possible to the outer edges of the rail Clip two collector straps Detail E item 16 to the collector mounting rail where the trusses pass under the mounting rail 4 Ad...

Страница 19: ...ide of the second collector 15 Locate a roof truss which is under the third panel extension rail detail XX itemXX as near as possible to the outer edge of the rail Clip one collector strap Detail E item 16 to the extension rail where the truss will pass under the extension rail 16 Screw fix the extension rail to the two panel collector rail that is already installed using the self drilling screws ...

Страница 20: ...embly Detail D item 4 to the bottom left hand corner connection of the array Tighten the assembly taking care not to twist the copper tubes of the collector Make sure you use correctly sized spanners and that the nut is held steady whilst the compressing union is tightened The collector array is now completed and ready for connection to the water heater system 6 2 Flat roof installations For flat ...

Страница 21: ...or supplied with the Pump Module PM 600 Fully insert the temperature sensor into the temperature sensor well of the hot connection union assembly Secure in place with the P Clip and screw provided Run the cable down to the ground mounted storage tank location This sensor is known as the Collector Temperature Sensor Care must be taken to ensure that all roof penetrations are sealed to prevent water...

Страница 22: ...fitting 4 Apply thread tape or a suitable sealant to one end of the BSP brass union P No 60 5065 and fasten it into the lower Gland Union attached to the Ball Valve 5 Loosely attach one end of the 225mm Flexible Connector P No 60 1115 to the brass nipple on the PM 600 module Loosely attach the other end to the bottom inlet fitting of the storage tank 6 With the flexible connector loosely fitted mo...

Страница 23: ...be ﬁtted to the cold water supply pipe work 1 The cold water connection is made at the connection marked Cold Water Inlet 2 Where the water supply pressure is greater than or likely to exceed 550 kPa at any time a 500 kPa pressure reducing valve must be ﬁtted to limit the supply pressure A breach of this requirement may void the warranty in the event of damage caused by excessive pressure 7 2 2 Co...

Страница 24: ...lid surface like concrete 1 Fit the pressure temperature relief valve supplied with the tank into the tank socket marked Valve 2 Ensure that the drain line from the pressure and temperature relief has a continuous downslope and falls away from the valve and towards the ground level to a safe location terminating above the ground level Please ensure that the drain is installed in a place where it c...

Страница 25: ...djacent the element surround A cable gland with orange circular cable or 19mm conduit with 3 core TPS cable must be used to make electrical supply to the unit The power supply must be protected by an individual fuse or circuit breaker rated to suit the booster size The supply to the solar water heater can be operated directly from the switchboard or via a remotely mounted switch or time clock as r...

Страница 26: ... in direct contact with fluid Always use immersion sleeves Take the collector temperature sensor cable assembly and attach to the panel mounted 2 way connector This plug will only fit one way The tank temperature sensor cable is hard wired to the module and exits the case through an M12 cable gland Should extra cable length be required there is slack inside the module Remove the cover loosen the c...

Страница 27: ...splay screen 3 Using Buttons 1 2 to scroll move up and down the channels until you reach the one requiring amendment 4 Change the channel a Press Button 3 The SEt on the display will start to flash b Using Buttons 1 2 to scroll adjust the channel to the desired value c Save the channel setting by pressing Button 3 The SEt will return to the steady state 5 Check all channels for conformity to the t...

Страница 28: ...lar attention must be given to the gas supply system to ensure the there is a sufﬁcient gas supply available to the gas heater when operating at full output burner rate 8 3 1 Approved Gas AES models Gas heater models used with Conergy solar water heater systems must be certiﬁed to all local requirements be automatic ignition and have full ﬂame modulation The temperature setting of the gas AES must...

Страница 29: ...em is proven water tight power and or gas can be applied to the AES system 6 To test that the element is operational turn the circuit breaker in the switch board on and off you should see the power meters speed change during this action 7 For gas AES systems turn on a hot water tap and the gas heater will ignite provided the water temperature is less than 70 C 9 2 Customer Hand Over The solar wate...

Страница 30: ...r Pump 1 2 1 year 1 year Sensors 1 year 1 year Controller 1 year 1 year Heat Pump 2 years 1 year Table 9 2 1 Warranty Terms 11 CONTACT DETAILS For further information please call one of the following phone numbers from anywhere in Australia For service installation information or warranty 1300 137 602 For sales or new product information 1300 724 516 Head Office Conergy Pty Ltd 460 Victoria Road M...

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