pressure series solar water heater with heat pipe install...
TRANSCRIPT
Pressure Series Solar Water Heater With
Heat Pipe install instruction
Version number 1.2
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1 Table of Contents
1 Table of Contents ................................................................................................................................................ 1
2 Warranty ............................................................................................................................................................ 2
3 Warning ............................................................................................................................................................. 2
4 Principle of Operation ........................................................................................................................................ 4
4.1 Vacuum Tube ................................................................................................................................................ 4
4.2 Heat Pipe ...................................................................................................................................................... 4
5 Installation .......................................................................................................................................................... 5
5.1 Solar System Location ................................................................................................................................. 5
5.2 Structure ...................................................................................................................................................... 5
5.3 Solar Water Heater Installation .................................................................................................................... 6
5.3.1 Installation Overview ............................................................................................................................. 6
5.3.2 Frame Assembly .................................................................................................................................... 6
5.3.3 Tank Assembly ....................................................................................................................................... 9
5.3.4 Vacuum Tube Installation ...................................................................................................................... 9
5.3.5 Important Notice .................................................................................................................................. 10
6 Pipeline Installation .......................................................................................................................................... 11
6.1 Pipeline Installation Drawing ..................................................................................................................... 11
6.2 Pipeline Installation Tips ............................................................................................................................ 11
7 Using Hot Water ............................................................................................................................................... 12
7.1 Filling Water............................................................................................................................................... 12
7.2 Using Water ................................................................................................................................................ 12
7.3 Auxiliary Heating ....................................................................................................................................... 13
7.4 Commissioning the System ........................................................................................................................ 13
8 Routine Maintenance Tips ................................................................................................................................ 14
9 Troubleshooting ................................................................................................................................................ 15
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2 Warranty Upon installation of the solar water heater, the dealer responsible for the sale will fill out the warranty card
and the customer will complete a record of it and retain it for future service.
This limited warranty covers the glass evacuated tubes, hot water tank and tank support frame for tube-
breakage, leakage or any other malfunction caused by defects in the materials and/or workmanship. It
extends to the first buyer and to any subsequent owner as long as the water heater has been installed by
trained and qualified authorized technicians approved by the local dealer.
On glass tubes the limited warranty is for a period of 5 years from the date of purchase. This warranty
excludes loss of vacuum in a tube or tubes due to breakage during transport, handing or after installation,
when caused by personnel, other than those appointed by or approved to by dealer. A gradual reduction in
vacuum levels over time is normal and accordingly is not a defect in terms of this warranty.
The limited warranty on the hot water tank and support frame is for a total period of 3 years from the date
of purchase.
This warranty does not cover:
1. Cover leakage or breakage of tubes or other malfunctions caused by defective installation, misuse,
operation and maintenance contrary to the written instructions in the user manual.
2. Odoriferous, discoloring or rusty water coming from the system.
3. Damage to surrounding area or property caused by leakage or malfunction of the system.
4. Costs associated with the replacement and repair of the unit. Associated costs including freight,
shipping or delivery charges, removal, installation or re-installation charges; any material, and
permits required for installation, re-installation or repair.
All legal disputes shall be settled in Dealer Country of operation.
To facilitate warranty service, you should:
Follow all instructions enclosed with the product.
Retain all bills of sale or receipts for proof of installation. Etc.
Contact your installer or dealer as soon as any problem or defect is noticed.
When necessary, allow our chosen representative, to inspect the unit.
Attention
High exhaust pipe must be fixed, and not suitable for too high, our products are not bearing products
High water tank water level difference below 3 meters.
If you use small tank,please add relief valve on the inlet water pipe of small tank,and the pressure of the
relief valve is less than 0.3MPa
3 Warning
Before using and installing the water heater, please read through the manual carefully. Keep
the manual for reference in the future.
1. Installation should be carried out by professional workers approved by us or our dealer. We will not
be responsible for any damage or loss caused by users’ incorrect installation.
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2. Prevent from burn injury, touching the heat pipes in the glass tubes is strictly prohibited. The
evacuated tubes are not allowed to expose under the sunshine directly before installation.
3. For continued safety of this appliance it must be installed, operated and maintained in accordance
with the manufacturers’ instructions
4. Test water temperature before bathing. Hot water from solar water heater may cause burns.
Children, disabled or elderly persons should not operate solar water heater without adults.
5. Do not expose solar water heater under sunshine long time without water, this may cause damage
to the system. In case of no usage for long time, cut off power supply and ensure solar water
heater is full of water.
6. Electrical heater should be installed with leakage protection plug and used only when required.
Ensure enough water before opening electrical heater. Do not use hot water from solar water heater
when electrical heater is running.
7. Air vent is very important to non-pressure solar water heater. Keep the air vent unblocked and
connect to ambient atmosphere directly.
8. Fill solar water heater tank to increase its weight to ensure its safety against heavy wind. Lightning
rod is advised for lightning and thunder area usage.
9. Vacuum tube is fragile, appropriate protection is advised for its safety.
10.Piping to and from the solar water heater should be insulated.
11.Do not change the structure of solar water heater optionally. Do not climb on solar water heater.
12.Water inside solar water heater is not suitable for drinking.
13.Place the vacuum tube out of reach of children.
14.The water temperature can be very high in the summer months and steam can be observed coming
out of the vent pipe. If the solar water heater is not in use in the summer or for a long period of
time, it is advised to cover the glass tubes with a canvas cloth or a mat.
15.If the solar water heater tank has become empty due to non-supply of cold water for long periods,
it should be refilled only during early morning hours when the temperature within the tubes is at a
minimum.
16.Clean the glass tubes regularly. If dust and dirt are allowed to settle on the glass cover it will block
the sun rays and reduce the efficiency of the system. It is advised to clean the glass tubes every
two weeks with fresh water or soft cloth. Do not use coarse material that might scratch the glass
surface while cleaning the glass tubes.
17.Prevent any shade falling on the glass tubes. Regularly trim back the branches of trees in the
vicinity of the glass tubes to allow as much as possible sunlight to fall on them.
18.Do not throw stones or any hard objects on the glass tubes which may cause breakage of the tubes.
19.In case of any problem during usage of this solar water heater, please contact your nearest dealer.
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4 Principle of Operation
4.1 Vacuum Tube
A vacuum tube drawing
A Vacuum Tube (a.k.a. evacuated Tube) consists of two glass tubes made from borosilicate glass, with a
partial vacuum in between. The borosilicate glass adds strength and durability to the vacuum tube. Sunlight
traverses the glass tubes to heat water inside the inner tube. The vacuum is important in that it acts as an
insulator to keep heat inside the tube. When the heat inside the tube is high (~150℃), the outer tube will
remain only few degrees from ambient temperature; which is an advantage over flat plate collectors.
The selective absorption layer coating of the inner tube is excellent at absorbing incident solar radiation
while minimizing reflection.
In order to maintain the vacuum between the two glass layers, a barium getter is used (the same as in
television tubes). While manufacturing the tube, and through special treatment, a Barium layer forms at the
bottom of the evacuated tube. Called a "getter", this barium layer actively absorbs escaping gaseous
particles from the evacuated tube and increases the longevity of the vacuum. It also provides a clear visual
indication of the vacuum status; the silver-colored barium layer turns white if the vacuum is lost making it
easy to identify.
4.2 Heat Pipe
An evacuated-tube collector contains several individual glass tubes, each containing an aluminum fin and a
heat pipe. The heat pipe transfers the heat efficiently to the water in the tank.
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5 Installation
5.1 Solar System Location
The solar system must be installed in a non-shaded place. High buildings or trees may cause shade to solar
water heater and reduce its performance.
For optimum performance, solar water heater should be installed facing towards the equator. For South
Hemisphere solar water heater should be installed facing north, while for North Hemisphere should be
facing south. Diverting for this north/south orientation is possible, given installation site conditions, and is
best considered by your dealer’s appointed professional installers.
5.2 Structure
Solar Water Heater Structure Diagram
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5.3 Solar Water Heater Installation
5.3.1 Installation Overview
(Frame assembly drawing)
5.3.2Frame Assembly
1. Open the packing case and check the accessories, sort out the front legs, rear legs, assistant bars,
cross bars, reflectors, tail stocks, tank brackets.
2. Take out the front legs and put them horizontally on the ground.Then take the horizontal bars out
and connect them with the front legs in turn.Then, Take the front assistant bars out and connect
them with front leg and horizontal bars.
3. Take the tank bracket out and connect them with each front leg in turn.
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4. After the connection of tank brackets and front legs, take the rear side legs out and connect them
with the corresponding connecting holes of the tank brackets by bolts and nuts.
5. Take out the side above bars and connect them with the front and rear legs according to
the corresponding connecting holes.
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6. Then connect the front legs with the rear legs by side below bars.
7. Take the cross bars out and connect them with the two rear legs.
8. Connect the front and rear legs with the cousins.
9. Turn the frame over and put it on the ground at the installation angle between the front legs and
rear legs.
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5.3.3 Tank Assembly
1. Open the water tank package and screw the nuts from the connection bolts at bottom of tank.
2. Put the water tank on the tank brackets slowly and lightly according to the corresponding
connecting holes. Screw the nuts tightly to adjust the angle of tank to ensure vacuum tube holes
and tail stocks are on the same level.
3. See photos below for reference.
5.3.4 Vacuum Tube Installation
1. Prepare a small basin of water mixed with little dish washing soap. This will ease inserting
vacuum tubes to solar water heater tank holes.
2. Open the pack of the vacuum tubes and takes out a vacuum tube at a time.
a. Install the anti-dust seal on top of vacuum tube.
b. Soak the header of vacuum tube with water,
c. Insert the vacuum tubes into the water tank slowly, while turning the tube.
3. Pull down the vacuum tube and place it on the right tail stock hole.
4. Connect the tail stock with the corresponding holes of the front legs.
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5. The bottom nipple on the vacuum tube is extremely fragile, so pay extra attention to fitting the
tube properly without hitting the nipple. If nipple or tube breaks, this causes vacuum leakage thus
damaging the tube.
5.3.5 Important Notice
1. Solar water heater should face the sun, with 10° to 20° variation southwest. Be sure there is no
shade on both sides of solar water heater.
2. Solar water heater should be fixed with roof firmly with expanding screw and/or steel wire to
avoid potential danger against heavy wind.
3. Be sure that no leakage in pipeline, joints, valves and so on.
4. Pipeline should be insulated to avoid heat loss. For cold area usage, use electrical heating cable to
protect against freezing.
5. If the area is prone to lightning strikes, with no existing protection then, user should add the
lightning conductor fixture for protection against lightning.
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6 Pipeline Installation
6.1 Pipeline Installation Drawing
6.2 Pipeline Installation Tips
1. Connect the hot water outlet port after the valve with insulated pipeline to the usage points. It is
advised to use either Kitec (polyethylene-laminated aluminum pipe) or CPVC (N 20 Grade) for
the hot water pipe.
2. It is advised to use compression fitting plumbing pipes which can be installed without tools (Kitec
or CPVC) for cold and hot water usage for ease of installation and maintenance. They provide
better insulation than manually-insulated metal pipes, and need no insulation of the hot water
plumbing pipe that does not exceed 12 meters. Do not use a pipe wrench.
3. The distance between usage points and the solar water heater should be minimized as much as
possible; the maximum recommended distance without heat loss is 12 meters using Kitec or
CPVC pipes. For longer distances, proper insulating material should be used to prevent heat loss
(like special insulating rubber sleeve, PUF sleeve or rock wool with chicken mesh).
4. In case the usage points are many or the water line is quite long, it is recommended to expand the
capacity of the solar water heater.
5. The standard diameter of inlet/outlet points of the solar water heater is half inch (3/4 inch is
optional one). Half inch pipes should be connected depending on the number of usage points and
the results of the pre-installation survey.
6. In places where the hot and cold water pressure is not equal and mixing valves are used at the
usage point, care should be taken to install either non-return valve (NRV) based mixer or a NRV
on the hot water pipe of each usage point so as to prevent the reverse flow of hot water. The
temperature adjustment of the thermostatic mixing valve range: 20~60℃.
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7. Use soap-oil on glass tubes then insert them into solar water heater tank. Cover glass tubes with
materials like canvas, cloth or cardboard till the proper plumbing connections are made and the
solar water heater is supplied with regular cold water. This is to avoid the glass tubes overheating
without water, which could lead to breakage of tubes.
8. The system has a feeding tank normally, and the feeding tank has an air went .User can fix a long
pipe with the air went ,and the pipe shall be connected to a safe position to drain water. Because
when the water in store is boiling, the steam can exit from the air went.
9. Ensure the first filling of cold water is done in the early morning hours when the temperature
within the tubes is low to avoid damage to the glass tubes.
10. After the installation, let the solar water heater heat the water for a day of sunlight before using the
hot water.
11. The solar water heater has a provision for back-up electrical heater. It should ideally by a trained
electrician providing a proper earth and protecting the cable connections from water and moisture.
12. The water heater is non-pressure, the rated pressure is 0.2 bar.
7 Using Hot Water
7.1 Filling Water
Turn on V1 and V3; the tap water will fill the tank.
If the solar tank has become empty due to non-supply of cold water for long periods, it is better be refilled
only during early morning(before sunrise) or late evening (after sunset) when the temperature in the
vacuum tubes is low. Do not fill cold water at the hot noon, especially after vacuum tube is heated without
water inside.
Do not touch or put cold water inside the vacuum tubes if the tubes have been exposed to sun without
water inside. The collector transfer medium is water.
7.2 Using Water
Turn on and adjust the mixing valve, to mix the cold water and the hot water to get suitable
temperature hot water. The hot water inside the tank may be over 60℃, it is advised to open
the cold water at first and adjust the hot water to suitable temperature.
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7.3 Auxiliary Heating
When water in the tank are not hot enough, then you can use auxiliary electric heater to heat the water, Do
remember to cut off the power before using hot water.
Electrical circuit of the electrical heater
Electric heater, heating curves
7.4 Commissioning the System
After installation, fill the tank in the early morning, late afternoon, or when the tubes have not been
exposed to sun radiation while empty.
1. Fill and turn on the solar water heater.
2. Open all of the hot water taps in the house.
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3. Open the isolation valves fully on the cold and hot water branches to the solar water heater.
4. Open the cold water isolation valve fully on the cold water line to the solar water heater.
5. Close each tap after confirming water flows freely from it.
6. Check all pipelines to see any leakage.
7. Switch on the electrical supply at the isolating switch to the solar storage tank.
To turn off the water heater:
1. Switch off the electrical supply at the isolating switch to the solar storage tank.
2. Close the cold water isolation valve at the inlet to the solar water heater to shut down the system,
or close the isolation valves on the cold and hot water branches to shut down solar water heater.
Cover the tubes to shade them if necessary.
8 Routine Maintenance Tips
There are some recommendations and tips which if followed can go a long way to improve the overall
efficiency of the solar water heater.
1. Hot water will flow from usage point only after unheated water in pipeline flow out first.
2. Plan the consumption of hot water in quick intervals at one time (either in the morning or evening)
to minimize heat loss in the pipeline.
3. Run the hot water slowly, this will avoid the mixing of hot and cold water in the solar water heater
tank.
4. Do not withdraw more than the rated capacity of the system on a single day.
5. Use electrical backup occasionally when more hot water is required.
6. If you use a controller to turn on the electrical heater automatically, please set it at 45°C. This is
usually sufficient for a hot water shower. A higher setting will increase your electricity bills.
7. Paint the MS support stand once in five years. Though the supporting structure and other MS parts
are powder coated for long rust-free life, inspect occasionally and paint them if need.
8. Regularly inspect the solar water heater tank to make sure it’s not damaged and that no rainwater
runs into the tank insulation. Also check for any rusting in the plumbing lines. Do necessary
repairs using the authorized service provider.
9. To drain the water from solar water heater (for cleaning or repair). Disconnect the cold water inlet
pipe line and open the cold water inlet valve; If a makeup tank is used, close the cold water inlet
valve and remove the drain pipe dummy to drain the water from the solar water heater tank.
10. If the water in your area is hard, it is recommended to clean the solar water heater tank and glass
tubes with fresh water once a year to flush out the settled scales.
11. Do not to carry out any repairs or replacement of parts of the solar water heater on your own.
Consult your authorized service provider for help.
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9 Troubleshooting
Problem Possible Cause Solution
Water is not coming from
the tap.
Cold water inlet pipe or hot
water outlet pipe from the
solar water heater is choked
by sediment or scales
Clean the pipes and descale
sediment
Cold water inlet valve is
shut. Open the valve.
Float valve in the makeup
tank has jammed or
chocked.
Clean the float-valve or replace it.
Non-return valve is stuck Clean the NRV or replace it.
Air is trapped in the cold or
hot water pipe line.
Open the hot water outlet pipe
near the valve and remove the air
or drain the water out of the tank
and fill the solar water heater
again.
Not getting hot water
The solar water heater
is not receiving enough
sun light.
Excess water
consumption.(undersiz
ed)
Incorrect connection of
cold water and hot
water pipes to solar
water heater storage
tank.
Cloudy day, not
enough sun light.
Cold water pressure
due to mixing valve
preventing the hot
water coming through.
Relocate in un-shaded area.
Plan your water usage as per
installed capacity. In case of
high consumption use the
electric back-up.
Shorten the hot water
plumbing line or increase the
capacity of the system.
Use the electrical back-up.
Run hot water slowly at first
and then gradually open up
the cold water tap for optimal
mixing of hot and cold water
at the point of use.
Electrical backup not
working.
Wrong wiring
connections.
Inappropriate set up
temperature.
Lightning strike.
Connect according to the
wiring diagram.
Inspect/replace fuse, heater
element and/or thermostat.
The solar water heater is
leaking.
The solar water heater or
plumbing line has a leak.
Determine the source of the
leakage; if it is not rainwater,
fix the leak.
If the problem persists, call
the authorized service
provider.
Water over flows from air
vent or make up tank.
Reverse flow of cold
water into the solar
water heater tank (in
case of mixing valve).
Inappropriate air vent
length.
Close cold and hot water tap
of the mixing valve.
Increase the length of the air
vent as per installation guide
lines.
Hot water flow irregular. Air vent of makeup
tank and solar water
heater is not provided
Provide suitable air vent for
main or makeup tank, clean
the vent pipe and put it back
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or blocked.
Locked air in the
system
Cold water inlet pipe
inside tank choked by
sediment of scale.
properly.
Remove hot water outlet pipe
from valve to clear air or drain
and refill water from the solar
water heater.
Clean the pipe with long wire
brush after removing make up
tank.