GreenGLo GG20T User manual

Solar Group Limited – 0800 447 336 | Page 1
Installation Instructions
Evacuated Tube Solar Water Heaters
GreenGlo water heaters are AS/NZ 2712:2007 cert f ed. They are known for the r except onal performance and
longev ty. Please read the follow ng nstruct ons carefully to ensure the r correct nstallat on for opt mum results.
If you have any questions please call us on 0800 447 336
Th s document was pr nted as per March 2013 requ rements and may not be the latest document.

Solar Group Limited – 0800 447 336 | Page 2
GreenGlo Evacuated tube solar system – installation manual
Th s assembly manual covers assembly of the frame ( f needed), roof mount ng of the 20 and 30 tube evacuated solar
tube collectors and nstallat on to the cyl nder.
Contents
age
3 Section 1
Spec f cat ons and caut ons
7 Section 2
General gu del nes for roof-mount ng of the solar collectors
8 Section 3
Collector assembly
10 Section 4
Frame assembly when collector angle needs to be greater than the roof p tch
11 Section 5
Roof f x ngs
12 Section 6
Roof Support
13 Section 7
Plumb ng
14 Section 8
Electr cal
14 Section 9
F n sh ng off
16 Section 10
Common Issues
17 Section 11
L m tat ons and Clauses
18 Section 12
Installer checkl st
Commissioning with Customer
Ask customer to be ava lable at the end of the day/est mated
complet on t me for comm ss on ng and to go through the
paperwork.
Otherw se th s can be d scussed by phone or f another
appo ntment s necessary a call out fee may be appl ed.
Please make sure you have the appropr ate Counc l spec f c PS3
and any other paperwork requ red by the local counc l to leave
on s te w th the consent documents.

Solar Group Limited – 0800 447 336 | Page 3
Section 1: Specifications and cautions
Dimensions of the solar collectors: GG20T (20 tube) and GG30T (30 tube).

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Specifications
Model
GG
20
T
GG
30
T
Number of Tubes
20
30
D mens ons （ L×W×H ）
2050×1400×153
2050×2100×153
Effectual Absorb Area
1.62m
2
2.42m
2
We ght （ Empty ）
63kgs
94kgs
Man fold’s Capac ty
1.15L
1.7L
Connect ons
G3/4" male thread
G3/4"male thread
Components
1. Heat P pe
Transfers the thermal energy from w th n the vacuum tube to the condenser eff c ently and
rap dly ；
2. Glass tube top holder
The Part to hold the glass tubes to the man fold box
3. Cover
Stab l ses the heat p pe and m n m ses the thermal energy loss from the glass tube ；
4. Conduct ve Alum n um f ns
Transfer the thermal energy from the glass nner wall to the heat p pe more eff c ently;
5. Vacuum layer between the glass sk ns;
6. Solar glass tube
H gh eff c ency solar glass tube w th max mum rad at on absorpt on, m n mum thermal
rad at on losses and h gh nsulat on performance ；
7. Base / tube seal
Th s sect on has a m rror f n sh to m n m se heat loss n the vacuum layer seal zone.
arameters
Solar collector tube parameters
Absorpt v ty Em ss v ty Glass
transm ss on Vacuum T ptop temp. Low temp. durab l ty
W nd
durab l ty
≥92 ％ ≤10 ％ ≥92 ％ ≤5×10
-2
Pa 250
℃ —35 ℃ 30m/s
Cautions
1.1 Gloves and Eye protect on must be used when handl ng glass tubes. Avo d scratch ng or any sudden blow
to tubes;
1.2 Under no c rcumstances are the tubes to be left exposed to the sun over a long per od w thout heat
extract on from the system;

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1.3 Unpack and nstall tubes after the man fold un t has been nstalled and all p pe work has been completed and
the system s f lled. （ Avo d h gh temperature of empty man fold to affect system eff c ency);
1.4 Dur ng nstallat on of the tubes, the pump should be sw tched on;
1.5 If the system s out of use for a long t me, the solar collector must be covered over / shaded w th a su table
screen;
1.6 Apply locally appl cable Health and Safety gu del nes at all t me;
1.7 The solar collector should be nstalled w th n 22° ～
～～
～ 50
0
angle.
1.8 The we ght bear ng capac ty of the roof MUST be calculated for the max mum collector we ght, the load-
bear ng po nts and the rafter s ze / strength;
1.9 When heat ng a sw mm ng pool or spa, a heat exchanger should be used between the pool and the collector.
1.10 GreenGlo man folds are des gned to operate at a max mum pressure of 6 Bar (90ps ). It’s strongly
recommended to use a su table pressure rel ef valve.
1.11 To extend the serv ce l fe of your system, the vacuum tubes should not be nstalled unt l the system s fully
connected and ready for use.
System diagrams
Mains pressure, open loop solar system with electricity – Retrofit by 5-way port

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Mains pressure, open loop solar system with electricity – Full system

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Section 2: General guidelines for roof-mounting of the solar collectors
The deal locat on for the Solar Collectors s on a roof fac ng the m d-day / early afternoon sun.
(North / NNW n New Zealand).
The panel angle to the sun should be approx mately the same as the geograph cal lat tude
(e.g. 36° for Auckland, 45° for Duned n).
If the roof p tch s s gn f cantly less than th s value, we recommend that the panel s elevated on a frame to
max m se the collector eff c ency.
Cl ents w ll have a v ew on the use of a frame; t s mportant to expla n to them ( n wr t ng) that Solar Group
does recommend a frame n these c rcumstances to max m se eff c ency, espec ally n h gher value lat tudes
(eg Duned n).
It s mportant also that the panels w ll not be shaded for any of the day n summer or w nter by trees or bu ld ngs etc.
P tch roof – elevated P tch roof – flat to roof Flat roof – elevated
Sta nless steel f tt ngs of an appropr ate grade must be used, nclud ng roof mount ng screws.
Roof cladd ng penetrat ons must be appropr ately sealed accord ng to local bu ld ng code standards and must
follow good pract ce at all t mes.

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Section 3: Collector assembly
Before beg nn ng, make sure you have all the p eces requ red;
•2-3 boxes of 10 evacuated tubes (depend ng f t s a GG20T or GG30T).
•1 box conta n ng the man fold, bottom track, end cups, sta nless steel cl ps and a small brass f tt ng.
•1 box conta n ng the vert cal tracks.
•Flat roof stand f requ red – refer to page 9 for d agram.
Assembling the frame
Put frame together as per d agram.
1. Take apart the sta nless steel f x ng
brackets and thread them through the
holes n the frame p eces as shown n the
p cture.
The brackets s t w th the project ng edges
'fac ng each other'.
GG30T only – For the central vert cal frame
p ece, ONLY place the top cl p at th s
stage.
1a. Vert cal tracks—the man fold end has
the holes for the brackets further apart—
p cture show ng man fold end w th
brackets.
1b. Vert cal tracks—Lower end, p cture
show ng tops de of brackets.
Note – GG20T frame s m lar to GG30T, w thout m ddle bar.
2. To f t the man fold onto the frame, l ft the
man fold and pos t on t between the
outer pa rs of sta nless steel f x ng cl ps.
Then sl de the cl ps nwards to clamp the
man fold.
2b. At th s stage ONLY do up the nuts f nger
t ght - you may need to adjust the pos t on
later.
GG30T only - See that the lower central
man fold cl p s NOT yet f tted n the frame.
3. Repeat the f x ng process for the bottom
ra l. All the pa rs of brackets can be
located as the bottom track s not
adjustable.
Note – make sure t s the r ght way round!

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Finalising position
1. To f nal se the pos t on of the Man fold, and t ghten the f x ngs, the two end
evacuated tubes must be f tted. An ncorrect spac ng between the man fold and
the bottom ra l w ll mean that the tube end caps w ll not cl ck securely nto
place.
2. To f t the f rst tube, the heat p pe must be pulled out from the tube as shown.
(Do not use the thermal conduct on glue as the tube s only be ng temporar ly
nstalled).
3. Then nsert the end f rmly and completely nto the man fold.
4. Next sl de the loose copper collar up, followed by the black plast c tube mount
wh ch screws onto the man fold.
5. Then, ease the evacuated tube gently but f rmly nto the black plast c tube
mount unt l you feel t come to a stop.
6. Cl p the plast c end-cap nto place on the bottom ra l.
7. NOTE f the end-cap has NOT cl pped n securely (as n the photo), the
man fold w ll have to be adjusted up to allow the end cap to cl ck nto place.
8. Now the man fold cl ps can be t ghtened ON THIS SIDE ONLY because the
tube end cap has cl pped securely over the evacuated tube; n other words the
man fold s correctly pos t oned on the frame.
GG30T only – At th s stage, the last central man fold cl p can be added, and
the pa r t ghtened up. Make sure the central frame p ece s st ll n the m ddle of
the man fold!
9. Now the two evacuated tubes can be removed and re-packed.
Fitting the feet to the Collector unit;
10. If the un t s to be f tted flat to a roof, the feet w ll all be bolted to the frame
that has just been completed.
11. If the un t s to be elevated, then the front feet w ll be f tted to the collector
frame as above but the rear feet w ll be f tted to the elevat on frame.
12. The feet are bolted to the frame sect ons as shown. Note the rubber spacer /
gr p that s glued to each foot.
13. Sta nless steel f x ng screws of the appropr ate grade must be used to f x the
un ts to the roof.

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Section 4: Pitched frame assembly
The GG20T and GG30T collectors can be elevated to the requ red angle on both flat and p tched roofs us ng the
spec al sed frame p eces suppl ed.
Adjustable angle range: 22
0
-50
0
Making up the frame
The cross braces (6) and angled brac ng sect on (3) should be cut to the des red length.
Both sect ons must be f tted to the collector frame us ng the sta nless steel M8 bolts prov ded. The bolt holes should
be dr lled carefully to avo d scarr ng the powder-coated surface of the sect on.
The vert cal parts (5) can be pulled out to the r ght angle of cho ce and bolted up w th the bolts prov ded n the k t.
The feet should be f tted as shown n Sect on 3.
Notes:
•The above d agram shows a GG30T frame, the GG20T s s m lar, w thout the m ddle bars.
•Use the U-channel to ensure that all penetrat ons through the roof be through the crests of the roof cladd ng and
to spread the pressure load.
•Use neoprene washer or butanol or s m lar methods for solat on of d ss m lar metals

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Section : Roof fixings
Note: These f x ngs are for parallel to roof nstalls only. For roof stands see prev ous page.

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Section : Roof Support
NOTE: Locate solar collectors away from h gh w nd pressure areas n accordance w th NZBC G12/AS2 cl. 4.1 and f gure 2.
Rafter spacing
Use the table below as a gu de to determ ne f the ex st ng rafters are able to span the d stance requ red w th the
add t onal load ng from the solar collector un t.
Rafter Span (Reproduced from NZS 3604:2011)
Rafter Spacing (mm)
480
600
900
Rafter Size
(mm) Rafter Span (mm)
90 x 45
1300
1300
1200
140 x 45
2500
2400
2100
190 x 45
3400
3200
2800
240 x 45
3800
3500
3100
290 x 45
4100
3800
3300
Rafter spans for flush mounted collectors nstalled n all W nd Zones, l ght and heavy roofs, and up to 1.5 kPa snow load.
Purlin strengt ening not needed for flus
collectors unless needed according to details
s eet S3 & S4 (pages 11 & 12).

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Section 7: Plumbing
1.
For a new nstall
—
please follow 1. NZS3606
nstallat on gu de, ensure
there s room for thermostat and that rel ef valves have suff c ent room
for ma ntenance and potent al removal.
2. For a retrof t—turn off and unplug / d sconnect cyl nder.
3. Dra n cyl nder.
4. Add r ser to return end of 5-way valve (retrof t) 1/3 up the tank.
5. Connect 5 way valve (retrof t).
6. Connect and close ball valve, non-return valve and pump to the cold s de
of the cyl nder, see d agram.
7. Ensure the pump stat on has enough support and s nstalled n a vert cal
pos t on access ble for replacement and adjustment of sett ngs.
8. Connect Temper ng valve f requ red to hot and cold sources on cyl nder
hot supply as per standard.
9. Connect and close ball valves.
10. F ll cyl nder and turn on.
11. Connect p pes from roof.
12. Open ball valves and check for leaks.
13. System to be nstalled to the follow ng plumb ng standards;
ASNZS3500.4, G12 of bu ld ng code; copper to NZS3501.
14. Ensure all p pes out of cyl nder are lagged!
Note: All f tt ngs shown above (exclud ng roof flash ng, copper p pe & f tt ngs) are part of the solar k ts.
See pr cel st or call us on 0800 447 336.

Solar Group Limited – 0800 447 336 | Page 14
Section 8: Electrical
Use controller manual suppl ed for deta led
nstruct ons;
also refer to
plumb ng & electr cal schemat c on pages 2&3 of th s gu de.
1. Mount controller (and relay for retrof ts).
2. Attach probes S3 at top and S2 at bottom of cyl nder(s) (top connect
beh nd nsulat on ½ way from top of cyl nder, bottom thermocouple
often s best beh nd nsulat on touch ng copper by thermostat / element)
– New systems w ll have spec f c probe pockets.
3. Ensure probe pockets are free of mo sture. Use probe grommet or
s l cone to stop water gett ng nto pocket.
4. Ensure good connect on between probe and ns de of cyl nder.
5. Connect pump us ng 3-p n plug.
6. (Electr c an) Connect controller to element v a s ngle pole relay f not a
solar cyl nder – supply must not be subject to r pple control.
7. Connect power to controller – relay s a sw tch, do NOT connect an
outs de l ve to relay.
8. Sw tch on and test.
9. For overheat dump opt on connect p pe thermostat, (l ve comes from P1
connect on) and 3-way valve.
10. Program controller – see system controller booklet
11. For a solar cyl nder use only the top element and connect d rect to the
ma ns (not through the controller) on all day rate / r pple power
Section 9: Finishing Off
1.
Purge p pe and pump of a r.
2. Set the flow speed 2.5 l tre/m n per 10 tubes.
3. Pressure test for leaks by open ng to operat ng pressure and runn ng the
pump.
4. Install tubes nto man fold use the wh te heat transfer paste suppl ed.
5. F t exter or nsulat on – so that no bare copper or brass s show ng.
6. UV protect the nsulat on f not already protected by us ng PVC tape,
cover red dekt te.
7. Program the controller. Full descr pt on for setup opt ons and
ma ntenance g ven n the controller manual suppl ed. Also see the next
page.
8. Debr ef and rev ew sett ngs w th customer.
9. F ll out paper work, CoC’s and PS3’s for counc l.
10. Clean up the s te from boxes, w res, etc.
11. Complete Installer Checkl st. (Append x 2/Page 14)
Ensure cups are open

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Installation of the tubes and end-caps
1. To f t the tubes, the heat p pe must be pulled out from the tube
as shown. Coat the end of the heat p pe w th the thermal
conduct on glue
2. Then nsert the end of the heat p pe f rmly and completely nto
the man fold.
3. Next sl de the loose copper collar up,
4. Sl de up the black plast c tube mount wh ch then screws f rmly
onto the man fold.
5. Then, ease the evacuated tube gently but f rmly nto the black
plast c tube mount unt l you feel t come to a stop.
NOTE - When the collector s on a roof, the tube can sl de out aga n.
Keep up gentle pressure unt l the end cap s n place
6. Cl p the plast c end-cap nto place on the bottom ra l, push ng
stead ly unt l t cl cks nto place.

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Section 10: Common Issues
1. No hot water:
a. Check element s sw tched on at the wall.
b. Check f power company turned the r pple power off
c. Check that the fuse n the thermostat has not popped – may need to replace w th auto-reset thermostat, reduce SMX by 5˚C.
d. Check the t m ng for the element s on for long enough – most cyl nders requ re 6 hours of heat ng.
e. Check shower flow rate s not too h gh – may requ re flow meter.
2. System not performing as well as expected
a. Check non-return valve s nstalled and work ng, check not thermos phon ng at n ght. (Temp at n ght should be
s m lar to amb ent) – may requ re a second NRV.
3. Boiling on the roof but not heating cylinder
a. Check the flow meter rate
b. No flow - bleed pump f mak ng loud no se, s pump connected vert cally?
c. Check there s no h gh spots above the solar (w ll create a steam block) – use steam vent. (AAV).
d. Check steam vent s work ng.
e. Check pump s on fast enough speed.
4. System flooding through house (not that common)
a. Th s has mostly happened where heat has got through to Polypropylene p pe and melted t. Ensure that copper
s used where th s can occur. (NB heat can travel up the cold supply p pe when the whole cyl nder s HOT.)
May requ re thermal trap on the cold supply (bare copper p pe n a loop).
b. Check that the heat dump at the TPR valve can dra n away w thout back ng up and flood ng – may requ re flow restr ctor
n heat dump loop.
5. Cylinder making banging noise
a. Due to cyl nder expans on through heat. Ensure that a cold water expans on valve and a hot water TPR valve are
f tted and work ng. Reduce CWE valve to 6 bar.
6. Sensor Error.
a. Check that the screw nto the w re at the control box s screwed nto the w re and not the plast c.
b. To check f a w re fault, sw tch w th a dummy sensor.
7. Funny temperature readings
a. Check the r ght sensor s used n the r ght pos t on. PT1000 (grey) for TDC and SolaStat for Plus2 controllers (black)
8. Element not coming up to 60C
a. Check probe contact w th cyl nder and allow 8°C for losses.
b. Check t m ng and temp of heat ng program.
c. Check clock t me, check n ght rate and r pple control potent al confl cts w th t mers.
9. Night circulation from cylinder to panel—due to controller not reach ng pump off Temp d fferent al
a. Improve connect on w th Inlet Probe.
b. Check f the Recool ng funct on s ON
10. Too much hot water—system is always boiling
a. Remove tubes.
b. Install heat dump loop.
c. Turn ON Recool ng funct on.
d. Look at heat ng t m ng.

Solar Group Limited – 0800 447 336 | Page 17
Section 11: Liitations and clauses — requ red for AS2712:2007 2.9.1
A. The solar water heater, parts and f tt ngs are usable up to 10 bar pressure / 1000kPA.
The system s made of copper so pool levels of chlor ne are not acceptable for use.
For levels of h gh l me content please check the element n cyl nder s ncalloy otherw se GreenGlo
panels are capable of handl ng poor water qual ty.
B. I The water heater w ll be nstalled n accordance w th AS/NZS3500.4 nclud ng nsulat on and p p ng.
Copper p p ng should be used only, throughout nstall as per attached nstruct ons.
II Cyl nders to be nstalled so to allow for dra n ng of system, water expans on and rel ef of vacuum
as per AS/NZS3500.4.
III Dra n trays to be nstalled as per AS/NZS3500.4, where requ red.
IV N/a.
V In case of hard water bu ldup of l me may occur on hot areas, ensure element type s su table for
the water type otherw se soften ng of water may be requ red.
C. The system s des gned for level 1 and 2 frost protect on, f n areas of long term below zero temperatures
a closed loop system s adv sed.
D. Guards to the collectors may be requ red n areas of vandal sm or large ha l zones.
E. In areas of cyclon c cond t ons spec f c eng neer ng des gn s requ red; refer to Installat on Handbook rev B
for l m tat ons. Panels we gh 18.8kg/m2 when f ll of water.
F. For full nstallat on nclud ng roof structure spac ng please refer to Eng neer ng Installat on manual, purl n
tables etc. Solar to be nstalled as to not comprom se the structural ntegr ty of the bu ld ng.
G. Ensure appropr ate f x ngs per roof type as conta ned n th s manual, for roof types outs de of these then
refer to eng neer ng manual otherw se spec f c eng neer des gn requ red.
H. Controller manual to be suppl ed to customer (wh ch has a boost nstruct on h ghl ghted).
I. Controller manual to be suppl ed w th the default (pr nted sett ngs of the thermostats).
J. Follow the f n sh ng off nstruct ons conta ned for comm ss on ng of the system.
K. Ensure that all systems have an appropr ately solar capable temper ng valve and th s s set to 55C or 45C
for elderly, schools and preschools appl cat ons. We recommend a 20mm + temper ng valve for all low
pressure appl cat ons.

Solar Group Limited – 0800 447 336 | Page 18
Section 12: Important Checklist for Installer
To complete and tick before leaving site
Please ask customer to be ava lable at the end of the day/est mated complet on t me for comm ss on ng and
to go through the paperwork.
Otherw se th s can be d scussed by phone or f another appo ntment s necessary a call out fee may be appl ed.
Important Checks
 Check for leaks
 Ensure probes have good contact
 Ensure pump works
 Check heat ng element sw tches on and off
 Controller programmed
 System debr ef w th customer and rev ew controller sett ngs
 Clean up the s te from boxes, w res, etc.
Important aperwork
 Complete Code of Compl ance for counc l
 Complete Counc l spec f c PS3 documentat on
 F ll out EECA Grant Cla m form and go through w th customer
 Complete warrantee deta ls n Owner’s Manual
 Leave system manuals for customer
 Electr cal CoC form left w th customer documents
If comm ss on ng s not poss ble because the customer s absent please leave your contact deta ls to make
another t me or d scuss v a a phone call.
Dear Customer
Unfortunately n your absence we were unable to go over some of the paperwork and comm ss on your system w th
you. If you would l ke to d scuss anyth ng further please call me to make a t me or go over these on the phone. Please
note f another appo ntment s necessary a call out fee may be appl ed.
Installer: Date:
Notes: Phone: