EXTREME HEAT SOLAR Geyser User manual

EXTREME HEAT SOLAR
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100lNO PRESSURE EVACUATED TUBE SYSTEM
Instruction manual for the safe and correct
installation and maintenance of the complete
No Pressure Solar Hot Water System
For use by qualified personnel
Applicable to the following models:
100lNo Pressure Evacuated Tube System
May 2015

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Contents
1 Introduction ....................................................................................................................................3
2 System description.......................................................................................................................... 4
2.1 Basic operation ....................................................................................................................... 4
2.1.1 Collector..........................................................................................................................4
2.1.2 Main Tank........................................................................................................................4
2.1.3 Cistern Tank ....................................................................................................................4
2.1.4 Frame .............................................................................................................................. 4
2.2 Frost Protection ......................................................................................................................4
2.3 System Specifications..............................................................................................................4
3 Health and Safety............................................................................................................................ 5
3.1 General.................................................................................................................................... 5
3.2 Transport and handling........................................................................................................... 5
3.3 Installation considerations...................................................................................................... 5
4 System placement and orientation................................................................................................. 6
4.1 General.................................................................................................................................... 6
4.2 Shading....................................................................................................................................6
4.3 Collector angle ........................................................................................................................6
4.4 Roof location...........................................................................................................................6
4.5 Structural strength..................................................................................................................6
4.6 Mounting methods .................................................................................................................6
4.6.1 Tile roofs ......................................................................................................................... 6
4.6.2 Metal roofs...................................................................................................................... 7
5 Installation ......................................................................................................................................7
6 System commissioning..................................................................................................................14
6.1 Installation checklist..............................................................................................................14
7 Emergency shutdown procedure.................................................................................................. 14
8 Troubleshooting............................................................................................................................15
9 Maintenance and cleaning............................................................................................................ 15
10 Warrantee.....................................................................................................................................15
10.1 Warrantee nature .................................................................................................................15
10.2 Date of commencement .......................................................................................................16
10.3 Notification of claim..............................................................................................................16
10.4 Normal intended use ............................................................................................................16
10.5 Installation of the EHS solar water heater............................................................................ 16
10.6 Repair and maintenance.......................................................................................................16
10.7 Warrantee duration ..............................................................................................................16
10.8 Service plan...........................................................................................................................17
10.9 Area covered......................................................................................................................... 17
10.10 Warrantee exclusions .......................................................................................................17
10.11 Limitation of liability .........................................................................................................17
11 Contact information......................................................................................................................17

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1Introduction
Thank you for obtaining an Extreme Heat Solar (EHS) Solar water heater.
WARNING: Please read the complete manual before attempting to install the Solar water heater.
Failure to do so can cause serious injury and/or damage.
All EHS solar water heaters are very efficient thermal solar systems using advanced materials to
convert sun energy into heat energy.
This manual describes the safe and correct installation procedure for EHS solar water heaters. It
assumes the general knowledge of a registered installer and provides guidance in terms of the
installation of the solar thermal components. Systems must be installed by qualified plumbers and
electricians, in accordance with relevant South Africa 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.
Observation of these instructions is most important and failure to do so could void 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 EHS, which may affect its
operation/performance, must first be authorised by EHS in writing to validate the full benefits of the
warranty.
EHS 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 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 informed.

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2System description
2.1 Basic operation
EHS Solar water heaters utilize state of the art materials to ensure high efficient heat transfer from
the sun to the water in a wide variety of weather conditions. Heat generated by the collector is
directly related to the amount of sun energy onto the vacuum tubes.
EHS No Pressure solar water heaters are complete on the roof systems whereby the water storage
tank and solar collector are mounted on the roof as a complete system.
2.1.1 Collector
The solar collector consists of various evacuated tubes or vacuum tubes. These glass tubes are
constructed by creating 1 glass tube inside a second glass tube. The area between the 2 glass tubes is
a vacuum, forming a theoretical perfect temperature isolator. The inner glass tube is coated with a
highly absorbent material collecting the sun’s energy and transferring it to the water inside the inner
glass tube. The UV energy from the sun passes through both glass tubes heating the water in the
inner tube. Since the vacuum between the 2 tubes forms a near perfect isolator, heat from the inner
glass tube cannot escape back into the atmosphere - even in cold conditions. The heated water
inside the vacuum tube rises to the tank causing the colder water in the tank to lower into the
vacuum tubes. This process is referred to as the thermosyphon effect. This process results in a very
efficient solar water heating system for a wide variety of weather conditions.
2.1.2 Main Tank
The Solar water tank is a no pressure tank and acts as storage and circulation reservoir for the water.
The vacuum tubes of the solar collector enter the tank close to the bottom at an angle creating a
way for the water in the vacuum tube to enter and exit the storage tank. The main tank has provision
for an electrical element to boost the water temperature when needed.
2.1.3 Cistern Tank
The cistern tank is installed on top of the no pressure main tank. This tank acts as an additional
reservoir to the main tank. This is needed since heated water is less dense compared to colder water
and needs a larger storage area. The extra volume needed for the hot water is provided by the
cistern tank. The cistern tank controls the flow of water into the main tank from the main water
supply. This flow is regulated by a mechanical float valve.
2.1.4 Frame
The frame of the solar water heater mounts the tank and collector onto the roof. Since the angle of
the solar collector influence the efficiency of the heat collection, the frame is reconfigurable to fit a
flat and pitched roof.
2.2 Frost Protection
The EHS No Pressure systems are freeze resistant systems when correctly installed. The correct
thermal isolation material must be used to isolate the supply and return pipes of the solar water
heater.
2.3 System Specifications
System heat performance:
Model
Q Factor*
Energy Rating **
EHS 100 l No Pressure
TBA
12.6 Mj per day

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*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 kw/h. The specific thermal capacity of
the EHS No Pressure collector is 12.6MJ/D.
Storage Tank
EHS 100 lNo Pressure
Storage Volume [l]
100 l
Weight empty [kg]
17 kg
Dimensions [w] x [H] x [L]
470 x 470 x 1160
Cold water inlet connection
¾ “
Hot water outlet connection
¾ “
Supply pressure
2 bar
Operating pressure
0 bar
Internal electrical element
2 kW
3Health and Safety
3.1 General
This system is capable of heating water above 90 degrees Celsius. Water above 50 degrees can cause
scaling and serious burns. Under certain conditions the system can expel excess hot water above 90
degrees as a safety measure to avoid overheating and over pressurizing. This water is expelled
through the overflow port on the main tank and/or cistern tank. Never close off these overflow
ports. Take care not to come in contact with water expelled from these ports.
3.2 Transport and handling
The following instructions should be considered when transporting and handling the solar water
heater:
Consider the maximum weight of the solar tank and vacuum tubes.
Take the dimensions of the total system into consideration
Do not lift the vacuum tube carton by the straps since they can break.
Avoid impact or mechanical forces on the vacuum tubes. When lose glass is detected, take
extreme care when opening the vacuum tube boxes. Use the required safety protection gear.
Remove any obstacles that could pose a trip hazard.
Do not damage the main tank or frame, since exposed parts will corrode easy.
3.3 Installation considerations
All installations need to be carried out in accordance with the Occupational Health and Safety Act.
Please take note of the following during installation:
Installation of the Solar water heater must only be performed by qualified installers.
Installation must comply with local authority regulations.
Ensure that the installation manual is available during installation.
Asses site specific risks and eliminate or reduce risk to an acceptable level to satisfy the health
and safety requirements.
Postpone roof work when weather creates unsafe working environment on the roof.
Do not remove or disable any safety devices.
Glass vacuum tubes can reach boiling point in a matter of minutes when exposed. Shade vacuum
tubes and fill with water before installing as part of the system.

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Take care to use safety gloves and safety goggles to prevent injury due to the risk of breaking
glass tubes during installation.
Be aware of overhead power lines connected through roofs.
Asses safety issues related to lifting and working on the roof are in place and adequate before
commencing installation.
Inform building occupants to when installation will take place.
Install necessary safety barrier to keep unauthorised persons from entering unsafe area.
Ensure installation personal are trained, well equipped and fit for the installation.
4System placement and orientation
The following points needs to be considered when selecting a suitable installation location for a solar
water heater system.
4.1 General
For optimum performance the solar collector needs to face the equator (north in the southern
hemisphere). The closer the collector faces true north, the more efficient the total system will
perform. Roof locations which face less than 45 degrees from the equator are acceptable.
4.2 Shading
Proper site inspection is needed to ensure that minimal shading is cast onto the collector. More
shadows during winter time needs to be considered as well as shadows from fast growing trees.
4.3 Collector angle
The angle of the collector needs to be installed between 25 and 45 degrees to ensure optimum solar
heating and thermosyphon effect of the water in the vacuum tubes. A collector angle of more than
45 degrees will result in less sun exposed to the collector during summer and a collector angle of less
than 25 degrees will reduce the thermosyphon effect resulting in a less efficient heat transfer
between the water in the vacuum tube and the water in the storage tank.
The collector angle can be adjusted by adjusting the rear legs (legs under the main tank) of the frame
as described in the Installation section.
4.4 Roof location
The location on the roof where the solar water heater needs to be installed should be as close as
possible to the location where the most hot water is needed. A large distance between the solar
water heater and the location where the water is needed will result in heat loss, especially during
colder seasons.
4.5 Structural strength
The roof structure where the solar water heater needs to be installed needs to be inspected for
structural integrity. The structure needs to be able to carry the total system weight when filled with
water. Special care needs to be taken for on roof installations where the system connects with the
roof. The necessary support needs to be installed to ensure a safe installation.
4.6 Mounting methods
4.6.1 Tile roofs
To fix the solar water heater to a tile roof, install hoop iron to the nearest purlin/support brace
above where the top frame feed is situated on the roof. The hoop iron passes between tiles to
connect with the frame of the solar water heater. Ensure that the heaviest part of the frame is

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supported by a purlin. If necessary install additional purlins under the tiles to avoid the tiles from
cracking and support the weight of the solar water heater. Use this method for all frame mounting
points.
Figure 1 Hoop iron fixed to brandering. Figure 2 Hoop iron protruding between tiles.
4.6.2 Metal roofs
To fit the solar water heater onto a metal roof, locate the nearest point of a purlin where the top
feet of the frame needs to be installed. Secure the top feet of the frame on the purlin. If no purlin is
available, support the inside of the metal roof sufficient to be able to carry the weight of the solar
water heater. Use the correct roof mounting screws and matching sealing washers to secure the
frame to the roof.
5Installation
During installation and fitting care must be taken that no debris enters the system and pipes. This
will cause obstruction in the water supply. All plumbing pipes needs to be flushed before connecting
the solar water heater.
1. Open the long narrow box that contains the geyser frame. The frame should consist of the
following:
Picture 1.1 Geyser frame elements










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1) 1 x Bag of bolts, nuts and washers
2) 4 x Foot pieces
3) 1 x Bottom horizontal frame (81 cm)
4) 2 x Horizontal frame (81 cm)
5) 2 x Side cross support (38 cm)
6) 4 x Long cross support (54.5 cm)
7) 2 x Side frame (204 cm)
8) 1 x Tube base (82 cm)
9) 2 x Leg (78.7 cm)
2. Attach the one side frame section (7) to
the tube base segment (8) using bolts,
washers and nuts from the supplied bag
(1).
3. Attach the second frame section (7)
to the tube base segment (8).
4. Attach the horizontal frame section
(4). Note the positions of the centre
holes in section (4).
5. Attach the two cross support
parts (6) between the horizontal
frame section and the side
frames.
NOTE: If the geyser will be mounted flat on a roof without the leg sections, skip to step 12.
Picture 1.2 Side frame element attached to tube base element
Picture 1.3 Side frame elements attached to tube base element
Picture 1.4 Horizontal frame element attached to frame
Picture 1.5 Cross support elements added

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6. Attach two foot pieces (2) to the legs (9).
Picture 1.6 Foot pieces attached to the legs
7. Attach the legs to the frame.
8. Attach the second horizontal frame
section (4) between the legs.
9. Attach the side cross support sections (5).
Picture 1.8 Horizontal frame
element fitted
Picture 1.9 Side cross support sections (5) fitted
Picture 1.7 Leg segments
attached to the frame

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10. Attach the long horizontal cross support sections
(6).
11. Attach the bottom horizontal frame section (3).
Picture 1.11 Bottom horizontal section fitted
12. Attach the frame feet to the roof using appropriate roofing screws.
13. Open the box that contains the geyser tank.
Picture 1.12 Tank and isolation material in box
14. Remove the thread protecting rubbers from the bolts.
15. Remove the nuts from the mounting bolts.
Picture 1.13 Thread protecting
rubbers are being removed
Picture 1.14 Remove the nuts
from the mounting bolts
Picture 1.10 Attach cross
support

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16. Install the tank on top of the frame. Make sure that
the four tank mounting bolts fit through the two
openings in the frame.
17. Install one of the stainless steel pipes at the cold
water inlet at the top of the tank.
Picture 1.16 Stainless steel pipe installed at
the cold water inlet of the geyser tank
18. Fit the rubber collar around the geyser’s cold water inlet.
Picture 1.17 Collar installed around cold water inlet
19. Apply hem to the thread of the cold water inlet before
installing the reservoir tank.
20. Rotate the geyser tank until the reservoir tank is entirely
vertical before fitting and tightening the four tank bolts
to the frame. (These are located at the bottom of the
tank.)
Picture 1.15 Geyser tank
installed on the frame
Picture 1.18 Reservoir tank installed

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21. Open the box that contains the vacuum tubes. Handle the tubes with care –especially the
bottom end since it contains a vacuum. If a tube is damaged, air will be forced in and the bottom
end of the tube will change to a milky colour. A faulty tube needs to be replaced.
22. Before inserting a tube into the geyser, fill the tube with water (if a tube is installed without
water, it will be hot by the time the cold water is added, and crack). Install the black cover rubber
around the open edge of the tube and lubricate the open edge with a dishwashing liquid or
window cleaner. This will ease the task of inserting the tube into the geyser.
Picture 1.19 Fill the tube with water, install the rubber and lubricate the open end of the tube
23. Push the open end of the tube carefully into the first hole of the geyser until the bottom of the
tube is just over the tube base section (8). Pull the tube a little bit back until the bottom is
settled firmly in the base of the frame.
Picture 1.20 Installing the vacuum tube
24. Install the remainder of the vacuum tubes.
25. Cut two pieces of 15mm copper piping:
approximately 14cm and 19cm. Use these
piping to connect the geyser overflow to the
reservoir using the appropriate couplers (not
supplied).
Picture 1.21 Connect the geyser overflow to the reservoir

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26. Install the isolation material before fastening
the pipes.
Picture 1.22 Install the pipe isolation.
27. If a backup element will be used, install the
element and thermostat in the holes on the
side of the geyser. Position the seal for the
element cover.
28. Close the element with the element cover and
supplied self-tapping screws.
29. Install a stainless steel pipe into the hot water outlet
before connecting the hot water from the geyser to the
house.
30. Connect the cold water supply from the house to the
cold water inlet on the reservoir.
Picture 1.26 Connect the cold water supply to the inlet on the reservoir
Picture 1.23 Install the backup element and
thermostat and the seal for the element cover
Picture 1.25 Install a stainless steel pipe in the
hot water outlet.
Picture 1.24 Close the element with the cover

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31. Isolate all piping with the supplied pipe isolation.
32. Open the water supply to the geyser and test for any leaks.
33. Congratulations, you have successfully installed a solar geyser!
6System commissioning
Ensure that all vacuum tubes have been filled with water before they were inserted into the main
water tank. If this was not the case, make sure that all vacuum tubes are completely covered to
avoid heat build-up. When confident that the vacuum tube temperature is below 40 degrees, the
main water supply to the solar water heater can be opened.
Keep electrical power to the backup element switched off at all times.
Flush all plumbing pipes before connecting the solar water heater.
The cold water will fill the tank and all excess air will exit through the safety overflow port. The
cistern tank valve will close when the main tank is full.
Check all piping and joints for water leaks.
Turn on the backup element and check if water is heating up after 10 or more minutes. Make sure
the main tank is filled before turning on the backup element.
6.1 Installation checklist
The following checklist should be verified before handing over to the client:
System has been checked for water leaks.
Working of the backup element has been checked.
All air has been bled from the taps.
Roof tiles are back in position and roof waterproofing has been applied.
All pipes have been thermally isolated.
Overflow valves are unobstructed.
The owner has been instructed on the use of the system.
7Emergency shutdown procedure
Should an emergency occur and you need to shut down the solar water heater follow the following
steps:
Switch off the electrical supply to the backup element on the distribution board marketed
“Geyser”.
Turn off the main water supply to the house if the stop valve supplying the geyser is not in reach.
Close off the supply valve to the solar water heater and open the main water supply to the
house.

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8Troubleshooting
Not sufficient hot water:
During cloudy or rainy days, there is not sufficient sun energy to heat the water of the solar
water heater. Switch on the backup element till the water has reached the required
temperature.
Water dripping from the overflow port:
During extreme temperature variation, the water in the main tank expand and can even exit
from the overflow valve. This happens especially when very little or no hot water is used for a
few days. This is normal and will stop when hot water is being used.
When water is being used and excess water is released through the overflow port, it could be
due to dirt in the float valve located in the cistern tank. The cistern tank can be opened and the
seal be cleaned by a qualified installer.
Pressure valve towards the solar water heater faulty. The pressure regulator valve supplying
water to the solar water heater can become faulty and allow high pressure water to pass to the
inlet of the solar water heater, This usually happens during night time when the water pressure
is at its highest level.
9Maintenance and cleaning
The EHS solar water heater is designed in a way that very little maintenance is needed. Natural rain
normally cleans the collector from any dust. When heavy bird life is present close to where the solar
water heater is installed, more regular cleaning of the collector is required.
Maintenance that should be done once every 3 - 6 months:
Check all pipes and fittings for leaks and corrosion of the thermal isolation material
Check if overflow port is properly connected to overflow pipe to avoid water from dripping on
the cistern or main storage tank.
Inspect for any leaks between the cistern tank and main tank.
Check for any cracks in the vacuum tubes
Clean the vacuum tubes with a wet cloth when needed.
Clean the filter at the inlet of the cistern tank only when water flow into the tank is not
adequate.
10 Warrantee
The EHS solar water heater has a 2 year warrantee. The conditions of the warrantee are as follow:
10.1 Warrantee nature
The EHS solar water heater and components thereof are warranted against defective factory
parts or factory workmanship. This warrantee is subjected to the water quality supplied to the
solar water heater equivalent to water quality in major metropolitan areas classified for
domestic water use (and below 600 ppm TDS)
Damage resulting from improper transportation or installation is not covered by this warrantee.
The warrantee is only valid upon presentation of the proof of purchase and subject to
compliance with the installation, maintenance and service plan as described in this document.
EHS reserves the right to test the solar water heater and installation prior to any
repair/replacement claimed under this warrantee.

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EHS has the right to repair before replacement of any part of the solar water heater.
Whenever the claim submitted is not covered by the warrantee, EHS has the right to invoice a
call out fee for investigating the claim submitted, if needed.
10.2 Date of commencement
The warrantee commences from the date that the installation has been completed and signed off by
the end user or the date of purchase. Failing to provide a signed of document (signed the day of
commissioning of the solar water heater) or purchase document, voids the warrantee of the system.
10.3 Notification of claim
Any claim under the warrantee must include a detailed description of the defect or abnormality and
need to be submitted within 30 days after the defect has been discovered. Failure in submitting the
claim within 30 days will void the warrantee. Warrantee claims will only be valid when a warrantee
claim form has been completed and submitted by the owner of the solar water heater. A Warrantee
claim form can be obtained from EHS upon request.
10.4 Normal intended use
This warrantee is subjected to the normal intended use of the solar water heater and does not apply
where the solar water heater or components has been used for a different application or in a
different manner.
10.5 Installation of the EHS solar water heater
The installation of this solar water heater needs to comply with the South African National Standards
as set by the South African Burro of standards. The standards may change and it is the duty of the
installer to ensure that the installation complies with the newest SABS standards. The installation
needs to be performed by an EHS approved installer.
The installation cost is not covered under this warrantee. In case of non-complaint installation or
installation failure, the original installation service provider is responsible for any warrantee claims.
10.6 Repair and maintenance
Any repair or maintenance work on an EHS solar water heater needs to be conducted by an EHS
approved installer. Fitting of any spares or parts not approved by EHS will void the warrantee.
10.7 Warrantee duration
Warrantee duration of solar water heater components are as per below table:
Component
Warrantee time
Main water tank
2 years
Cistern tank
2 years
Frame
2 years
Vacuum tubes
2 years
Element and thermostat
No warrantee
When any solar water heater components are being replaced under warrantee the original
warrantee term remains. The replacement part does not carry any additional warrantee.

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10.8 Service plan
A limited 2 year warrantee applies to all EHS solar water heater components, subjected to the
compliance of the EHS service plan. An EHS approved installer should conduct the inspection of the
solar water heater according to the service and maintenance described in this document.
10.9 Area covered
The warrantee is valid in South Africa. Where the solar water heater is located at a distance of more
than 20 km from the EHS offices, the owner is responsible for the cost of transportation of any part
or components to and from the EHS office and site where the solar water heater is installed.
10.10 Warrantee exclusions
Warrantee to any parts or components of the solar water heater do are not covered during the
following instances:
Acts of God (force majeure), crime and terrorism.
Accidental damage, abuse, misuse, maltreatment, abnormal stress or strain, harsh or adverse
water conditions, contamination or corrosion from particles in the water supply, excessive water
pressure, excessive temperature or neglections of any kind to the hot water unit and solar
collector or their components.
Modifications, alterations or repairs not approved by EHS or not conducted by an EHS approved
installer.
Faulty or improper installation as described in this manual.
Vacuum tube glass is not covered by this warrantee.
Where the correct pressure valve is not installed on the cold water supply line feeding the
cistern tank.
When the overflow ports are being blocked off.
Any plumbing or electrical and associated parts are not covered by this warrantee.
Damage to any parts from incorrect installation or commissioning of the system.
Electrical elements.
Damage due to frost when inadequate thermal protection has been used.
10.11 Limitation of liability
EHS’s obligation is towards the solar water heater and its components and therefore will not be
responsible for loss or damage to furniture, ceilings, carpets, walls, foundation or any other
structural damage caused by malfunction of any of the solar water heater components or parts.
11 Contact information
For any queries or information please contact us at:
432 Asetileen Street, Silvertondale Extension 2, Pretoria
www.extremeheatsolar.co.za
[e-mail]
Phone: [phone]
Fax: [phone]