Aurore Aura User manual

Solar Water Heater
Owner’s Guide
Please
follow the
instructions in
this owners guide
carefully. Save this owners
guide for future reference.
From

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Dear Friends,
Greetings fromAurore. Congratulations on acquiring an ‘Aura’ solar water
heater. You have joined a growing family of conscious change-makers
who have started using renewable energy for their daily use. You are
saving precious electricity and contributing towards the reduction of
harmful carbon dioxide emitted in the production of electricity. Through
our network partners we will ensure that you are able to derive the
maximum benefit from your solar water heater.
Here is some background on our organization. Aurore is located within
Auroville International Township near Puducherry. Our goal is to provide
high quality products and services in the area of renewable energy and
energy-efficiency. Our aim is to work towards building a society which
derives its energy from renewable sources of energy. Sun, a gift of Mother
Nature, makes inexhaustible energy available to us. Any efforts towards
harnessing energy from the Sun is a contribution towards conserving life
on earth.
Our engineers and researchers are on the constant look-out for reliable
and affordable solar energy solutions for domestic and commercial usage.
Our aim is to provide high quality products at affordable prices. To ensure
long-lasting performance, we tie up with our network partners to provide
dependable service and after-care for your valuable asset.
We hope that you find using your solar water heater a satisfying
experience. We would be happy to receive your valuable feedback in our
efforts towards improving our products and services.
Wishing you a happy and sunny future.
-Aurore Team-
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1. Solar Water Heater Parts 4
2. Safety Guide 5
3. Working Principle 8
4. Performance 9
5. Installation Tips 10
6. Optimal Usage 13
7. After Care Do’s/Don’ts 15
8. Trouble Shooting 18
9. Technical Specifications 21
10. Accessories 22
11. Warranty 23
Contents
Chapter Page

Tube
bracket
Support
structure
Drain
Cold
water inlet
Outer
tank
Inner tank
Vent
For grouting
Glass tubes
Electrical
heater
Glass Tube Water Heater
( Evacuated Tube Collector “ETC” )
Horizontal stay channel
Vent support
Right hand, Cradle
Right hand, Upper tie channel
Right hand, Diagonal
stay channel
Right hand, Main load channel
Right hand, Lower tie channel
Right hand, Diagonal load channel
Vent
support
NRV

Do not touch or put cold water inside the glass
tube if the tube has been exposed to sun
without water.
Safety Guide
NOTE : Before installing the Solar Water Heater
If there is a risk of hailstorms in your locality,
additional protection should be provided to
the Evacuated Glass tubes by means of a
mesh.
Place the evacuated glass tube collector out of reach of
children and infants.
If monkeys or other animals are a
menace in your locality, additional
protection should be provided to the
glass tubes with a mesh and vent pipe
which is properly supported.

The back-up electrical element should be installed by a trained
electrician who should provide a proper earth connection and
protect the cable connections from water and moisture.
Kitec fitting
Do not use a pipe wrench for installation
of pipe lines.
Test water before bathing, Hot water above 50 oC can cause
severe burns
(
CAUTION !
Households with small children, disabled, or
elderly persons should use hot water only under
adult supervision
Use back-up electrical element only when required. It is
recommended to switch OFF the electrical element before taking
a bath.
NOTE : Before using the Solar Water Heater

Do not drop hard objects on the glass
tubes.
Blockage or damage to the vent pipe can
create severe damage to the solar water
heater. Should this occur, call the
authorized service provider immediately.
In case of emergency, like breakage of
tubes or leakage in tank, close the cold
water inlet and hot water outlet valves
immediately and call our authorized
service provider for rectification of
problem.
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JJ
J

Working Principle of a Solar Water heater
A solar water heating system consists of a vacuum glass tube collector, an insulated
storage tank and connecting stand parts (page 4). The evacuated glass tubes are
filled with water and exposed to sun, thus heating up the water in the glass tubes.
As the specific gravity of cold water is heavier than hot water, the hot water in the glass
tubes starts rising in the insulated water tank, and the cold water in the insulated water
tank sinks into the glass tubes. As this cycle is repeated, water in the solar water
heater gets heated. This process is known as thermosiphon and is based on natural
convection (Fig.3)
The storage tank is insulated so the water stays hot and can be used later in the day
or even the following day.
Cold water
inlet
Heat vent
Polyurethane
(50mm)
Hot water
outlet
Electrical
heater
Hot water
outlet pipe
inside tank
Cold water
Cold water inlet
pipe inside tank
2
Earthing
Inside View of Tank
Drain or cold
water inlet
Valve +
NRV
Hot water

Performance
The output of a solar water heater system will depend on the amount of solar radiation
available. On a good sunny day with 6 to 7 hours of sunlight, the glass tubes will
collect enough solar energy to heat water up to 600C. On a good sunny day the water
temperature can rise very high and you may spot steam coming from the vent (this is
perfectly normal).
Rainy days: These tubes perform very well in overcast conditions and in low
temperatures. With evacuated glass tube technology, the reliability of the system
increases, since the temperature inside the glass tube is independent of the surrounding
temperature.
However, there is a provision for electrical back-up, which can be used on overcast
days and on days when there is a need for additional hot water. (See Accessories,
pg.23)
Sunlight
Tube Main tank
Cold water
Hot water
3Thermosiphon

Installation Tips
It is essential that a certified/trained plumber and electrical technician carry
out this installation.
1. The location of the solar water heater should be south facing on an even surface
with plenty of sunlight and free of shadows between at least 9 am and 4 pm.(Fig.4).
2. The solar water heater is designed to be used with a maximum head of 4 meters of
water. It should be connected to an overhead water tank, the bottom of which should
be at least one meter above the top of the solar system and not more than 3 meters
high (Fig.5).
3. Wherever wind speed is high, the solar water heater should be grouted properly to
the roof of the building. (Fig.4) A lightning-conductor can be fitted if required.
4. Connect the cold water inlet port preferably by a dedicated pipeline from the overhead
water tank.
5. Connect a valve to the hot water outlet port (Fig.5,6) to shut off the flow of hot water
for maintenance, or in case of leakage or any other emergency.
6. The distance between usage points and the solar water heater should be
minimised as much as possible; the maximum recommended distance with insu-
lated hot water pipe line without substantial heat loss is 12 meters.
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South facing
Ground or roof hard surface
4
Grouting
JJ
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300
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6
Vent
Main tank
Cold water
Hot water Mixing valve
Electric
heater
Earthing
u
u
Pipeline Installation with Pressure Pump
Drain
NRV
Shower outlet
Cold water
u
Inlet inside tank 
Hot water
outlet inside
tank
Pressure pump
NRV
Overhead tank
Vent support
- - - - - - - - - - - - - - - - - - -
Cold water
Hot water
Vent
Overhead tank
Main tank
Shower outlet
Mixing valve
5Vent
Earthing
uu uu
u
uu uu
u
NRV
< 2.75 mts
Pipeline Installation with Vent grouting
Cold water
uu
uu
u
Grouted Vent support
Inlet/Drain
Valve

Hot water outlet
Kitec pipe
8
7. The recommended number of usage points are:
8. In case your solar water heater runs out of water due to non usage it is necessary to
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.
9. After the installation, let the solar water heater heat the water for a minimum of 6
hours of good sunlight before using the hot water.
From
overhead
tank
II
II
I
Insulation
Vent
Cold
water
inlet
valve
Main
tank
7
Support
100 & 125 Litres = 1 - 2 usage points
150 & 200 Litres = 3 - 4 usage points
250 & 300 Litres = 5 - 6 usage points

Optimal Usage Tips / Maintenance
There our some recommendations and tips which if followed can go a long way to
improve the over all efficiency of the solar water heater.
1. 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.
2. Run the hot water slowly, this will avoid the mixing of hot and cold water in the
solar water heater main tank.
3. Do not withdraw more than the rated capacity of the system on a single day.
4. Use electrical backup occasionally when more hot water is required.
5. Set the thermostat of the electrical backup at 40 degree centigrade. This is
usually sufficient for a hot water shower. A higher setting will increase your electricity
bills.
Litres of water
Heating time for 1.5 / 3 Kw element in ETC
Hours of heating (for 150C rise in temperature)
3.5
3
2.5
2
1.5
1
0.5
75 100 125 150 175 200 225 250 275 300
0
1.5 Kw
3 Kw
6. Paint the MS support stand once in four – five years. Though the supporting
structure and other MS parts are powder coated for long rust-free life, inspect
occasionally and paint them if needed.

7. 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.
8. 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 (Fig.4).
9. If the water in your area is hard it is recommended to clean the solar water heater
main tank and glass tubes with fresh water once a year to flush out the settled scales.
In places where the hardness of water is very high, it is advised to clean the solar
water heater more frequently.
10. 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.
11. Ask your authorized service provider for an Annual Maintenance Contract
once the warranty period is over. Check with him for an updated version of the owners
guide.

Hot
open Cold open
Mixing
lever Mixing
lever
Hot
closed Cold
closed
✔
After use
After Care ( Do’s & Don’ts )
2. Do not connect any other
equipment to the cold water inlet line
of the solar water heater.
3. Do not use a pipe-wrench. If the
system has to be disassembled and
reassembled care should be taken not
to use a pipe-wrench to connect the cold
water, hot water and vent pipes to the
solar water heater. If you do, it may
cause severe damage to the tank and
result in water leakage.
4. If mixing valves are used it is
strongly advised to close the hot water
and cold water tap after use and to
keep the mixing lever in the middle
position.
✔
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✘✘
✘
✔
✘✘
✘✘
✘
✘✘
✘✘
✘
✔
✘✘
✘✘
✘
< 2.75 mts
- - - - - - - - - -
> 2.75 mts
1. This is a non-
pressurized solar water
heater and it should not be
connected directly to a
pressure pump or more
than four metres of water
pressure. Check with
Authorized Service
provider for more
information.

5. 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
advisable to cover the glass tubes
with a canvas cloth or a mat.
✔
✘✘
✘✘
✘
6. Ensure that there is always a cold water
supply to the solar water heater: Leave the valve
on the cold water inlet open and ensure that the
overhead water tank is filled with water.
7. 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.
8. Clean the glass tubes regularly:
If dust and dirt are allowed to settle
on the glass cover it will block the
sun’s rays and reduce the efficiency
ofthesystem.It is advisabletoclean
the glass tubes every two weeks
with fresh water or soft cloth. Do not
use coarse materials while clean-
ing the glass tubes. ✔
✘✘
✘✘
✘
Fill ‘er
up
now!

9. 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.
10. Regularly check the vent to ensure it is not bent and is firmly supported
using a vent support. Get it fixed immediately if any damage is noticed in the vent
pipe or the support structure. Do not close, bend or block the vent pipe. It is essen-
tial that the vent pipe be open to the atmosphere and that it is higher than the cold
water storage tank, otherwise it may badly damage the system.
✔
✘✘
✘✘
✘
✘✘
✘✘
✘
✔
Vent support

Problem Cause Remedy
Water is not
coming from
the tap.
Trouble shooting
If after using this trouble-shooting guide, you still cannot solve the problem, please
contact our Authorized Service provider.
a) Cold water inlet pipe from
overhead tank or hot water
outletpipe from thesolar water
heater is choked by sediment
or scales.
b) No cold water supply to
solar water heater from
overhead tank.
c) Cold water inlet valve is
shut.
d) Float valve in the make up
tank has jammed or chocked.
e) Non-return valve stuck.
f) Air is trapped in the cold or
hot water pipe line.
a) Clean the pipes & descale
sediment.
b) Fill the overhead cold water tank.
c) Open the valve.
d) Clean the float-valve or replace it.
e) Remove & clean NRV spring.
f) Open the hot water outlet pipe near
the valve and remove the air or drain
the water out of the tank and fill it
again.
a) The solar water heater is not
receiving enough sun light.
b)Excess water consumption
(Undersized).
c) Incorrect connection of cold
water and hot water pipes to
solar water heater storage
tank.
d) Cloudy day, not enough sun
light.
e) Cold water pressure due to
mixing valve preventing the hot
water coming through.
a) Relocate in unshaded area.
b) Plan your water usage as per
installed capacity. In case of high
consumptionuse the electric back-up.
c) Shorten the hot water plumbing line
or increase the capacity of the
system.
d) Use the electrical back-up.
e) 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.
Not getting hot
water.

Problem Cause Remedy
Hot water flow
irregular.
Large drop in
overnight tem-
perature
a) Air vents of overhead tank
and solar water heater is not
provided or blocked.
b) Air lock.
c) Cold water inlet pipe inside
tank choked by sediment or
scales.
a) Ineffective insulation.
b) The insulation is wet.
c) Excess heat loss in hot
water pipeline
a) Cloudy day.
b) Glass tubes not cleaned.
c) The monkey protection
mesh is dirty.
d) Solar water heater not
getting enough sun light.
e) Reverse flow of cold water
in to the solar water heater tank
(In case of mixing valve).
f) Hot water pipeline not
insulated properly.
g) Hard water scale deposits in
the glass tube and tank.
h) Excessive consumption of
hot water the previous night.
a) Provide suitable air vent for both
the tanks, clean the vent pipe and put
it back properly.
b) Remove hot water outlet pipe from
valve to clear air or drain and refill
water from the solar water heater.
c) Clean the pipe with long wirebrush
after removing makeup tank.
a) Check the insulation around the
storage tank.
b) Ensure that the insulation is dry. If
it is wet due to rain leaking through
the cladding, or due to a leak in the
tank, then it will not keep the water in
the system warm.
c) Install as per installation guide
lines.
a) Use electrical back-up, if provided.
b) Remove dust which has
accumulated on the glass tubes.
c) Clean the monkey protection mesh
regularly to avoid this problem.
d) Relocate in unshaded area.
e) Close cold & hot water tap of the
mixing valve after use.
f) Insulate the pipeline with suitable
insulation.
g) Clean the glass tubes and tank
with fresh water.
h) Plan your shower / bath according
to the system’s capacity, use
electrical back-up heater if required.
The water is
only luke-warm.

Water is boiling
and steam is
being released
from vent.
a) System not in use for a long
time.
b) Failure of thermostat.
a) Wrong wiring connections.
b) Inappropriate thermostat
temperature.
c) Lightning strike.
d) Short circuit.
e) Electrical heater thermostat
failure.
a) The solar water heater or
plumbing line has a leak.
a) Reverse flow of cold water
in to the solar water heater
tank (In case of mixing valve).
b) Inappropriate air vent
length.
c) Float Valve stuck in the
make up tank.
a) If the system is not being used,
cover the glass tubes with a shade or
install a steam trap on the air vent.
b) Change the thermostat.
a) Connect according to the wiring
diagram.
b) Set the thermostat for a
comfortable bath between 35 - 45
degrees centigrade.
c) Inspect / replace fuse, heater
element and thermostat.
d) Inspect / replace fuse, heater
element and thermostat.
e) Replace with a new one.
a) Try to determine the source of the
leakage. If it is not rainwater, fix the
leak. If the problem persists, call the
authorized service provider.
a) Close cold & hot water tap of the
mixing valve.
b) Increase the length of the air vent
as per installation guide lines.
c) Clean or replace the float valve in
the make up tank
Electrical
backup not
working.
The solar water
heater is leak-
ing.
Water over
flows from air
vent or make up
tank.
Problem Cause Remedy