Nova NovaSun 150l User manual

Copyright © 2014 Ikhwezi Solar (Pty) Ltd, Novather CC, Solar Assist (Pty) Ltd
Instruction Manual
for the Installation and Maintenance of
NovaSun Direct Freeze Resistant
High Pressure Solar Hot Water Systems
( ctober 2013)
For use by trained qualified personnel only. Applicable to the following models:
Novasun, Direct Freeze Resistant, 150l, 200l, 300l
We reserve the right to change the installation instructions.
Reproduction, even partial, is only allowed with written per ission.
WE Geysers (Pty) Ltd ,7 Nel apius Street,
Cha dor, Krugersdorp, 1754
[e-mail]
www.novasunsolar.co.za

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Ikhwezi Solar (Pty) Ltd, Novather CC, Solar Assist (Pty) Ltd
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Contents
1. Introduction ............................................................................................................................... 2
2. Syste description ..................................................................................................................... 2
2.1 Configurations .................................................................................................................. 2
3. Health and safety ....................................................................................................................... 2
3.1 General ............................................................................................................................ 2
3.2 Installation considerations ................................................................................................. 2
4. Syste configurations ................................................................................................................ 3
4.1 Novasun Thermosiphon System .................................................................................. 3
4.2 Novasun Split-pumped System .................................................................................... 3
5. Frost, scaling and hail resistance, stagnation................................................................................ 4
5.1 Hail resistance ............................................................................................................... 4
5.2 Freeze protection .......................................................................................................... 4
5.3 Direct systems – Freeze resistant ................................................................................ 4
5.4 Scale resistance ............................................................................................................ 4
6. Syste place ent and orientation............................................................................................... 4
6.1 Collector orientation .......................................................................................................... 4
6.2 Shading............................................................................................................................ 4
6.3 Tilt angle .......................................................................................................................... 5
6.4 Water supply / delivery ..................................................................................................... 5
6.5 Roof structural integrity .................................................................................................... 5
7. Mounting ethods ..................................................................................................................... 5
7.1 Selection of appropriate ounting ethod ......................................................................... 5
7.2 Syste ounting ethods ................................................................................................ 5
8. Mounting process ....................................................................................................................... 7
8.1 Suggested ounting ethod 1 .......................................................................................... 7
8.2 Suggested ounting ethod 2 .......................................................................................... 8
9. Syste Installation ..................................................................................................................... 8
9.1 General installation technique ............................................................................................ 8
9.2 Cylinder and Syste plu bing ........................................................................................... 8
9.3 Geysers ............................................................................................................................ 9
9.4 Electrical connection ......................................................................................................... 9
9.5 Installation Diagra s ........................................................................................................ 9
Pu ped Syste – Installation Diagra ........................................................................................ 9
10. Syste co issioning ............................................................................................................. 11
10.1 Co issioning direct syste s ......................................................................................... 11
11. Installation checklist ................................................................................................................. 11
12. Syste Selection and Sizing ...................................................................................................... 12
12.1 Introduction ................................................................................................................... 12
12.2 Syste sizing ................................................................................................................. 12
12.3 Syste type ................................................................................................................... 12
13. Owners operating and aintenance instructions ........................................................................ 13
13.1 Introduction ................................................................................................................... 13
13.2 Operating and efficient use ............................................................................................. 13
13.3 Over-night te perature stabilisation ................................................................................ 14
13.4 High water te perature .................................................................................................. 14
13.5 Periods of reduced usage or holidays ............................................................................... 14
13.6 Freeze protection liquid ................................................................................................... 15
13.7 Setting the ti e clock ..................................................................................................... 15
13.8 Owner aintenance ........................................................................................................ 17
13.9 Troubleshooting .............................................................................................................. 18
14. Warranties ............................................................................................................................... 18
15. Contacts .................................................................................................................................. 18
16. Warranty Contact Centre .......................................................................................................... 18
17. Warranty Services: (log warranty services) ................................................................................ 19

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1. Introduction
All NovaSun solar hot water syste s are high quality ther al solar
syste s, using advanced technology to convert light into heat. This
installation anual ust be read and understood before undertaking the
installation of a NovaSun solar hot water syste . Should any aspect of the
installation process re ain unclear a NovaSun Solar representative should
be contacted for advice prior to installation.
This anual does not seek to provide co prehensive guidance in ter s of
the general plu bing and electrical connection of geysers, which is
assu ed knowledge and required of any registered installer, but rather
sets out to provide guidance in ter s of the correct installation of the solar
ther al co ponents of the syste .
Syste s ust be installed by suitably qualified and registered plu bers
and electricians, in accordance with relevant South African Nor s and
Standards, National Building Regulations, Law and Regulations, Local By-
Laws, including the following:
SANS 198 - Functional control valves and safety valves for do estic
hot and cold water supply.
SANS 10106 - The installation, aintenance, repair and replace ent
of do estic solar water heating syste s, edition three.
SANS10252 - Water supply and drainage for Buildings. Part 1 - Water
supply installations for buildings.
SANS 10254 - The installation, aintenance, replace ent and repair
of fixed electric storage water heating syste s.
SANS 10142 - The wiring of pre ises. 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 fa iliar with and co petent in respect of the above. Responsibility for
the safe and proper installation of a syste rests with the installer.
The solar hot water syste s referred to herein ust be installed in
accordance with these instructions, local and national plu bing
regulations, unicipal building codes and any other relevant statutory
regulations.
All intellectual property in this design and/or registrations and/or copyright
including any patent, patent application are the property of Novather CC
and/or WE Geysers (Pty) Ltd.
Observation of these instructions is ost i portant and failure to do so
could void the benefits of the warranty.
The connection, attach ent, integration or general association of other
equip ent or parts which either directly or indirectly affect the operation
or perfor ance of the solar syste could void the warranty. Other such
equip ent or parts not supplied by WE Geysers (Pty) Ltd, which ay
affect its operation/perfor ance ust first be authorised by WE Geysers
(Pty) Ltd in writing if the full benefits of the warranty are to re ain valid.
WE Geysers (Pty) Ltd does not accept liability or responsibility for the final
fitness of water for consu ption fro this water heater, as the water
quality is not affected by the syste and is a function of the unicipal
and/or other water supply.
This anual has been written with the intention of ensuring that the
syste is correctly installed and that the owner/user is fully conversant
with the best ethods of operation.
2. System description
2.1 Configurations
NovaSun solar hot water syste s utilise state of the art technology and
perfor with high efficiency in a wide range of weather conditions.
Collector output is directly related to the a ount of inco ing solar
radiation striking the collectors. This installation anual covers the
installation of the following syste s:
Model Major System Components
NovaSun
150l
150 Litre Solarther Direct Geyser
1 x 1.7sq NovaSun Collector
NovaSun
200l
200 Litre Solarther Direct Geyser
1 x 2 sq NovaSun Collector
NovaSun
300l
300 Litre Solarther Direct Geyser
2 x 2 sq NovaSun Collectors
The odels governed by this anual are pu ped and ther o-siphon
syste s. Ther isiphon syste s ay be installed in a close-coupled or split
syste for at whilst pu ped syste s are installed in split syste for at
and water is circulated using an applicable water circulation pu p.
The NovaSun range of solar hot water syste s are direct freeze resistant
syste s.
Syste heating perfor ance
Model Q-Factor* Energy
Rating**
NovaSun 150l 11.8 TBA
NovaSun 200l 16.3 TBA
NovaSun 300l 27.5 TBA
*The ther al perfor ance of the syste s have been established by the South
African Bureau of Standards in ter s of SANS 6211, at an inco ing radiation of 16MJ
per ² per day, a te perature differential of 10°C and at an inclination of latitude
plus 10°.
**Q-factor is calculated in ega-joules whereas the energy rating is calculated in
kilo-watt hours. The energy rating is calculated by converting the q-factor into kwh.
The specific ther al capacity of the NovaSun collector is 4.39KJ/K ².
3. Health and safety
3.1 General
This appliance is not intended for use by young or infir ed persons
without supervision.
Scalding occurs at 50°C. This appliance is capable of providing hot water
over this te perature. In certain circu stances the syste ay expel hot
water and relieve pressure through the te perature pressure valve. Never
block this valve and always leave open to the at osphere. Take care to
avoid contact with water when valve is in discharge.
This appliance is a water heating apparatus only and the final quality of
water and fitness for consu ption is dependent on the quality of water
supplied to the syste .
These syste s are designed for the supply of hot water to do estic
household pre ises which have been constructed to the appropriate local
and national codes and regulations.
3.2 Installation considerations
All installations are to be carried out in accordance with the Occupational
Health and Safety Act (Act 85 of 1993) require ents and any relevant
local authority prescriptions. So e general points to take note of,
however, include the following:

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Assess site specific risks and eli inate or reduced to an acceptable
level so as to satisfy health and safety require ents, prior to
installation.
Water te perature can reach boiling point and the collector can reach
stagnation te peratures of over 70°C. Shade collectors during
installation to prevent heating.
Take care when handling collectors to prevent breakage to glass and
injury. Safety goggles, work wear and gloves ust be used to reduce
risk of injury.
Be aware of overhead power lines co ing in through roofs, as well as
electrical wiring running through ceilings.
Assess weather and postpone roof work if unsafe (e.g. high winds,
rain, lightning, etc.).
Scaffolding and safety equip ent ust be installed by certified
personnel and signed-off accordingly. Inspect before use.
Infor ho e owners or building occupants of ti e and place of work
to be carried.
Ensure occupants are aware of site access constraints and all health
and safety i plications relevant to the . Cordon off the area, if
applicable, to prevent personal injury and ensure any pets are
secured.
Ensure personnel working on installation are co petent and in suitable
physical condition. Installers ust be trained and conversant with the
assess ent of height hazards, working at height safety procedures,
assess ent of safety equip ent (e.g. scaffolding, harnesses, etc.) and
the use and wearing of safety equip ent (e.g. goggles, hard hats,
gloves, etc.).
All personnel working on the installation of a solar hot water syste
ust be issued with the appropriate safety equip ent and be trained
in their use.
Failure to observe
safe practices ay
result in:
scalding /
burns;
electrical
shock;
and/or falling,
which can cause
serious injury or
death.
4. System configurations
4.1 Novasun Thermosiphon System
For the purposes of the Esko Rebate Progra only ther o-siphon syste s
can be installed and a rebate clai ed.
A ther o-siphon syste relies on the natural circulation of fluid between the
collector and the geyser. In order for the ther o-siphon process to occur
the geyser ust be placed in a higher position than the solar collector. The
syste operates according to the laws of ther al dyna ics (i.e. a liquid,
when heated, beco es less dense and rises above the denser cooler liquid).
Heated water rises up through the collector and into the geyser, displacing
colder water therein, which sinks to the header pipe of the Novasun
collector. The process continues until the collector can add no ore gain in
te perature or until the sun stops shining. Without sunlight the water in the
collector header pipe cools, beco es denser, preventing hotter liquid in the
geyser fro being displaced.
A ther o-siphon can be close-coupled or split as illustrated below, provided
there is sufficient roof space.
4.2 Novasun Split-pumped System
•Where the solar water heater is installed in the roof, it ust be
installed in co pliance with SANS 10106 co plete with a Safety Valve,
drain cock, Multi Pressure Control Valve 400kPa, Drip Tray and vacuu
breakers on the cold and hot water supply.
•When installed inside the roof ini u clearance ust be allowed in
order to re ove the ele ent and ther ostat.
•Roof structural integrity ust be handled according to section 6.5.
•For Product warranty detail refer to the separate Warranty Agree ent.
•Pu p Circulation in the Novasun SWH syste .
•When it is not convenient or possible to place the cylinder higher than
the collector, a circulating pu p controlled by an electronic control unit
and two sensors is used to onitor the te perature of the anifold
and the cylinder, that enable the powering of the circulation pu p
when the water in the panel anifold is hotter than the water in the
cylinder.
•When the te perature difference is less than the set point the pu p
will stop
•When te perature of water in the cylinder reaches the highest set
point, the controller will stop the pu p.
•The circulating pu p used ust be installed and aintained according
to the anufacturer’s instructions.
•A 12V circulating pu p with a photovoltaic can also be used.
•A split-pu ped syste is illustrated below.

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5. Frost, scaling and hail resistance, stagnation
5.1 Hail resistance
NovaSun collectors are hail resistant with 4 toughened glass and have
passed SABS hail tests.
5.2 Freeze protection
Solar hot water syste s can be classified as (i) direct: freeze resistant, (ii)
direct: non freeze resistant or (iii) indirect.
5.3 Direct systems – Freeze resistant
In direct syste s the water to be used in the household circulates through
the collector, transferring solar energy into the solar geyser.
The Novasun panel contains a fully insulated heat exchanger that acts as a
freeze resistant echanis , as declared by the anufacturer. The pipework
connecting to the solar geyser ust be insulated with Insulflex insulation
aterial.
When installed with a PEX-lined Solarther Cylinder it can be used in all SA
cli ate locations (i.e in areas where frost occurs and areas, where a bient
te perature ay fall below 5°C). Contact Solar Assist to discuss water
quality atters.
5.3.1Direct syste s: non-Freeze Resistant
In direct syste s the water to be used in the household circulates through
the collector, transferring solar energy into the solar geyser.
Direct syste s are used in frost-free locations, where a bient
te perature never falls below 5°C and where water quality is good (i.e. less
than 600pp total dissolved solids/ inerals).
5.3.2Indirect syste s
In indirect syste s the potable water used in the household does not
circulate through the collectors, but re ains in the geyser and is heated
indirectly by a heat exchanger.
There are two basic types of heat exchanger, na ely a jacketed syste
where an inner cylinder is surrounded by a secondary outer layer and an
internal heat exchanger where the solar geyser contains an internal copper
pipe structure.
In both cases the solar loop (i.e. the pipe work to and fro the collectors)
contains a heat transfer ediu (i.e. propylene glycol/water solution) which
is physically separated fro the potable water.
Propylene glycol has a lower freezing point and prevents the liquid in the
collectors fro freezing and da aging the collector through expansion that
occurs when ice for s. Only food grade glycol should be used.
Indirect systems are used in locations where frost occurs and the
ambient temperature drops below 5°C and/or where water quality is
poor (i.e. ore than 600pp total dissolved solids/ inerals).
These collectors are resistant to freezing only when installed with an indirect
geyser and the solar loop filled with a solution of propylene glycol and
water. Water alone ust not be used as a transfer fluid. The glycol / water
solution should be ixed in a glycol to water ratio of 1:3 (i.e. 33% glycol).
5.4 Scale resistance
Indirect syste s containing a glycol solution also prevents scale build up
inside the collector in areas of poor water quality. It is i portant to note that
the geyser itself ay still be affected by water quality as would be the case
with any conventional ena el-lined geyser unless a Solarther PEX-lined
geyser is used.
If a direct syste is used in areas of poor water quality the pipe work inside
the collector and solar loop ay be subject to a build-up of scale. This ay
be avoided through the use of a water softening syste . This is good
practice regardless of type of syste , as the water will affect other
household appliances in any event.
In the event collectors experience scale build-up the performance
of the system will decrease. Should this occur the system can be
flushed with a mildly acidic solution (e.g. vinegar solution) and in
the case of the Novasun collector, the Header Pipe should be
flushed. The pipe work should then be flushed with fresh water
after removal of scale prior to re-commissioning.
Ensure you are fa iliar with the relevant tank anufacturer’s warranty
ter s and conditions in respect of water quality, particularly as it relates to
anode replace ent in case of ena el-lined tanks.
6. System placement and orientation
A nu ber of basic funda entals need to be observed when installing any
solar hot water syste .
6.1 Collector orientation
Opti u syste perfor ance is achieved when the collectors face directly
North (i.e. true North) when installing in the Southern He isphere. The
closer the collector is to directly facing the equator the greater the a ount
of solar radiation the collector will be exposed to and the greater the
potential for heating.
Angles up to 45° either side of North will not have a ajor effect on the
syste perfor ance given the state of the art technology used in the
construction of the NovaSun syste s. Therefore, roofs that are orientated
away fro North are also acceptable for installation.
Outside of the 45° range one could consider utilising ore collector surface
area or using a ounting fra e to adjust the orientation back to North.
6.2 Shading
With a syste orientated to face North, the ti e period when the collector is
exposed to the ost direct solar radiation is between 10h00 and 16h00.
Solar collectors with an East bias will achieve a greater gain in orning
hours and those with a West bias will do so in the afternoon.
Care should be taken to ensure that the collectors are not subjected to
excessive shading fro trees or adjacent buildings, particularly between
09h00 and 16h00.
Also bear in ind that tree growth could lead to future shading issues.
If the installation takes place in su er, it is also i portant to take into
account the lower solar angles in winter, which result in longer shadows.

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6.3 Tilt angle
In respect of the opti u angle of inclination for a solar collector, the rule
of thu b provides that the latitude of the location is taken and then 10°
added thereto. Therefore, a location with latitude of 25° would indicate an
opti u collector tilt angle of 35°.
The angle of inclination, however, is also flexible and ini al loss of
perfor ance occurs by installing at lower or higher angles of inclination.
The NovaSun collector can be installed as low as 10°. Below this, however,
the ther o-siphon process does not function effectively. Also, angles lower
than this would result in build-up of dust, as it is not able to be washed
away effectively by rainfall.
It ust also be noted that installation angles over 30° will require additional
strapping to secure the geyser and collector during and after installation, as
at this angle the syste will tend to ove downward. Consideration should
be given to a split installation in these circu stances.
6.4 Water supply / delivery
The location of the installation should give as efficient a supply of hot water
to all areas of the residence as possible. If not possible, the syste should
be placed as close to its ain point of usage (e.g. aster bathroo ).
Discuss this with the client and confir their understanding and
require ents.
6.5 Roof structural integrity
The area chosen for installation ust be structurally capable of handling the
loading. Check load weights of applicable syste and ensure that the weight
can be borne by the roof structure. Specialist advice should be sought if
required.
The syste should be placed, such that the tank spans at least three ain
trusses. It is good practice to brace all truss work that supports the
installation.
Strengthen rafters (or ti bers or other structures) used for supporting the
panel and tank, for exa ple by adding noggins between rafters or adding
thicker ti bers alongside the or cross bracing the or adding additional
supporting struts to the truss to spread the additional load to a load bearing
point. Where ever possible the syste should be installed over a supporting
wall of the building (i.e. on a truss resting on a supporting load bearing
wall). Never install a syste on a roof with da aged or rotting ti bers.
To prevent cracking of certain fibre ce ent and etal roof sheeting, a flat
ounting fra e designed to spread the load of the geyser and its contents
should be designed by suitably qualified personnel and installed below the
geyser. Ensure that the roof covering aterial is structurally sound to
receive the weight of the syste . In the case of a split syste installation a
wooden fra e should be constructed which raises the tank above the level
of the collectors. Care should be taken in the design and construction of this
fra e so as to ensure it eets all relevant standards.
7. Mounting methods
7.1 Selection of appropriate ounting ethod
Please note that it is the installer’s responsibility to ensure that the eans of
fixing the syste to the roof such that it results in a safe and functional
installation.
The ethods suggested are generic and will not necessarily be suitable in all
situations.
7.2 Syste ounting ethods
7.2.1Suggested method 1 - General purpose installation brackets
The i age below depicts a typical bracketing syste which could be used
with NovaSun solar hot water syste s. This type of bracketing syste is
suitable for tiled or corrugated roof structures with a pitch of less than 30
degrees. Typical kits would include the following pieces:
A (2 pieces) – Tank Cradle Bracket
B (2 pieces) – Collector Cla p
C (2 pieces) – Straps (not included*)
D (2 pieces) – Collector Hanger Bracket**
*Straps are not included as lengths required will differ fro installation to installation.
These should be alu iniu or stainless steel.
**Please note that two hanger brackets are required per collector. The 300 litre
syste using two collectors require 4 hanger brackets (two per collector).
Please note that points of contact between the collector fra e and ounting
brackets and between tank and ounting brackets are buffered by a foa
lining to prevent issues surrounding galvanic corrosion.
The installer ust install the syste in such a fashion to prevent long ter
degradation of syste aterials through galvanic reaction.
7.2.2Suggested method 2 - Alternate installation brackets
As an alternative to the first bracketing syste , straps could be used.
Collectors could be secured directly to the roof structure, at each of the four
corners of the collector, by eans of alu iniu strapping.
The straps should be securely fixed to the underside of the alu iniu
collector fra e using alu iniu speed screws. The straps can then be
passed under the tiling and secured around the nearest truss and/or purlin.
In respect of the geyser, strapping can be hooped around the geyser, on
either end of the cylinder, using strap cla ps available with co ercially
available strapping syste s, leaving enough length to pass the tail pieces
under the tiles and secured around the appropriate roof woodwork.
As indicated above the installer ust install the syste in such a anner so
as to prevent galvanic corrosion between syste co ponents and the
ounting brackets and/or straps.

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7.2.3Suggested method 3 alternate installation brackets
Geyser Brackets
a) Description: Profiled alu iniu plating providing a solid footing
distributing the weight of the unit over the roof covering. Positioning of
bolts on brackets are off centre in order to allow the foot plate of the
geyser to rest squarely in the centre of the bracket once installed.
Easy to use wing nuts are supplied to ini ise effort on installation.
The foot plate of the geyser has to be fitted to the geyser before the
bracket is fitted onto the foot plate.
b) Once the roof covering is oved away, the stainless steel strapping
attached to the bracket is then wrapped around ti ber roof structure
for anchoring the bracket. Be sure to secure the strapping onto the
ti ber using tech screws or si ilar. Roof covering is then placed back
into original position.
c) The bracket is placed underneath the geyser foot plate with the bolt
sliding through the slotted hole and tightened using the wing nut as
supplied.
d) Note the correct use of “left hand” and “right hand” bracket.
Attached strapping is then tightened onto the ti ber structure in the
sa e way as above.
NovaSun tanks are equipped with extra anchor points on the
tank in order for the tank to be installed on an angle of 31° if
so required on pitch roofs.
Panel Bracket
a) Description: Holding bracket attached to stainless steel strapping .
b) The holding bracket is positioned underneath the panel in order to
hook onto the botto lip of the panel. The stainless steel strapping is
then fastened onto the roof structure in the sa e way as the strapping
of the tank.
The holding brackets should be placed in position first and properly
fastened to the roof structure using tech screws or si ilar. The roof
covering can then be placed back into position and the panel positioned
and secured into the holding bracket.

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8. Mounting process
8.1 Suggested ounting ethod 1
Connect hanger bracket (D) to strapping (C), allowing enough length
strapping for the flexible strapping to fit under the roof tile and wrap around
the purlin/truss. Re ove roof tiles and position hanger brackets.
The bracket should be secured in place by fixing to the purlin. Fixings (i.e.
screws, bolts, etc.) ust be appropriate for the type of ti ber. Hard woods
and soft woods require particular fixings. Fix the bracket in place as shown
in the next i age.
Replace tiles once the bracket is fixed in place as shown in the next i age. 2
brackets are required per collector.
The hanger bracket should be positioned on the peak of the tile and not in
the valley. This helps prevent pooling of water and degradation to the
brackets and possible leaks.
The collector is positioned into the collector bracket as de onstrated in the
i age above. A slight kick of 25 fro the cold inlet side to the hot outlet
side of the collector is reco ended (i.e. cold side lower than hot side by
25 ).
In the case of sheet roofing, as depicted in the following i age, a roof screw
can be re oved, the strap placed over the existing hole and the roof screw
reinserted thereby securing the strap. In instances of sheet roofs,
appropriate waterproofing needs to be effected to the roof surface after
straps have been secured to the roof aterial.
The tank cradle (A) is positioned up against the top edge of the collector,
with the foot of the cradle slid underneath the collector.
The collector cla p (B) is fixed to the tank cradle to lock down the top of
the collector as depicted in the next i age.
The tank cradles should also be placed on the peak of the roof tile. Once the
tank cradles are in place and the collector cla p fixed in place the geyser
can then be positioned into the cradles as pictured in the next i age.

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Make sure that the tank is rotated to a position where the drain cock is at
the lowest point on the geyser as pictured above. This will ensure that the
axi u volu e of water in the tank is available to be heated by the
collector.
The i age below depicts the co pleted ounting of the syste .
Larger tank sizes ay require additional tank cradle brackets depending on
the roof pitch.
8.2 Suggested ounting ethod 2
As an alternate to collector hanger brackets, alu iniu straps could be used
to secure the collector. Alu iniu friendly speed screws can be used to
secure the strap to the back of the collector fra e. A strap needs to be fixed
to each corner of the collector fra e (i.e. four straps).
Straps should be long enough to be fed underneath the roof tiles and then
folded around the ti berwork of the roof. The straps should be positioned
on the peak of the tile and not the valley to prevent water fro pooling and
degrading the strap. The straps used should be of sufficient gauge to
provide for a secure ounting of the collector.
The i age below depicts the view fro below, with a tile re oved. This
de onstrates the strap fixed to the fra e of the collector and then folded
around the purlin. Fixings appropriate for the type of ti ber should be used
(i.e. hard woods and soft woods require particular fixings).
In respect of the geyser, stainless steel strapping can be hooped around the
geyser, on either end of the cylinder, using co ercially available strap
cla ping yste s or other secure eans of co pleting the hoop, leaving
enough length to pass the tail pieces under the tiles and secured around the
appropriate woodwork with appropriate fixings.
As shown in the i age below, the strap should fit closely around the body of
the tank. Make sure that the tank is positioned in such a way that the drain
cock is at the lowest point of the tank. Once the tank is in place, fix the
hoop in place and replace tiles.
9. System Installation
9.1 General installation technique
During fitting and prior to filling, the syste ust be protected against the
entry of dirt and water. After the syste has been ounted, it ust be
flushed in order to re ove any debris (e.g. etal chips, packaging residue,
sawdust, etc.).
Shade panels until after connecting plu bing and installation is ready for
co issioning in order to prevent heating of e pty collector.
Exercise caution during the lifting phase of installing the collector and tank
onto the roof. Ensure that adequate personnel are present to bear the
weight and that they are assisted with supportive lifting tethers and safety
rigging.
With reference to section 6 above, easure the size of the collector, and use
easure ent to locate the best position on the roof to affix panels,
atching easure ents to supporting roof trusses and purlins. Avoid
interference with coping or gutters.
A ini u distance between the top of the panel and the tank flow outlet is
300 . In split syste installations distances should be kept as short as
possible and generally should not exceed 3 etres.
For roof pitches above 30°, special and/or extra strapping or brackets ay
be required to prevent downward ove ent of the tank and collector.
Measure the exact size of your tank and use this to locate the best position
on the roof at which to affix tanks to supporting roof trusses and purlins.
If necessary, strengthen rafters used for securing the panel and tank, for
exa ple by adding noggins between rafters or adding thicker ti bers
alongside the (refer section 6.5 above).
9.2 Cylinder and Syste plu bing
9.2.1General
Plu bing ust confor to IOPSA code, SANS, PIRB and local regulations.
In a ther o-siphon the geyser is installed above the panel, but kept as close
as possible.
All piping runs should be kept as short as possible, both between the
collector and tank, as well as between the tank and the location of hot water
usage (i.e. bathroo s).

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All pipework ust be properly insulated, including at least two etres of the
cold feed to and hot supply fro the geyser. Insulation aterial ust be
heat tolerant and UV resistant, nor ust it unduly co press or cause
corrosion.
Installation Tip: For increased weatherability in harsh cli ate areas insulation can further be wrapped with alu iniu duct
tape or covered by a product such as Flash Harry e brane and coating.
Piping fro the flow of the tank to the inlet at the top of the collector ust
have a continuous fall and fro the top of the collector to the return ust
have continuous rise.
Only hard-soldered connections or co pression fittings are to be used in the
asse bly of the solar heating circuit. No fluxing agents containing chloride
should be used.
Use copper pipe only. Plastic pipe ust not be used due to the effects of
high water te peratures and pressures. The pipe work to and fro the
geyser ust also be copper for at least two etres below the hot water
outlet.
A te perature ixing valve ust be used to control the te perature of
water delivered to the points of use. This is i portant in the prevention of
accidental scalding and is a SANS require ent.
9.3 Geysers
The Novasun Solar Water Heating syste s ake use of WE Geysers (Pty)
Ltd’s Solarther geysers cylinders, depending on the odel selected. The
anufacturers’ installation require ents that acco pany each of these
products ust be observed in the installation process. Failure to do so ay
result in the warranty of these products beco ing null and void.
WE Geyser tanks are fitted with SABS approved peripherals.
Geysers installed inside ust have sufficient space for servicing ther ostats
and ele ents (Note: there are no anodes in Solarther cylinders which
require regular servicing) , as well as allowing for the required SANS height
of vacuu breakers above the tank
9.4 Electrical connection
All electrical work ust be carried out by properly qualified and registered
electricians.
Novasun reco ends the installation of a ti e switch when undertaking a
solar installation. This opti ises the perfor ance of the syste and is
specifically required when a rebate is to be clai ed in respect of the Esko
incentive progra .
The ti e clock is fitted to the distribution board and is used to set the ti e
periods that the ther ostat and ele ent receive electrical input. Ti e
settings will be dictated by patterns of consu ption, but for exa ple could
be set to activate fro 3a to 5a and fro 4p to 6p , taking care that
the ti es do not fall within Esko peak periods.
Electric water heaters use 220 Volt AC power. The circuit breaker and
isolator should be switched off before working on the geyser. Verify that
power is off with a volt eter and ensure that load shedding or existing
ti ers are not active, which ay cause the electrics to beco e live whilst
working on the syste .
Power should not be applied to an e pty electric water heater as heating
ele ents will be da aged. Tank warranties would be void in these
circu stances.
9.5 Installation Diagra s
Various installation diagra s are illustrated below in order to assist
installers with installation services. Prospective installers ust
contact Solar Assist for syste specific training and instructions
prior to installing the Novasun SWH range.
Ther osiphon Syste – Installation diagra
Acknowledge ent: www.solarassist.co.za Note: For purpose of installation de onstration no insulation
has been shown here but Insulflex insulation ust be installed according to standard on all open copper
piping as per paragraph 9.3.1
Pu ped Syste – Installation Diagra
Note: For purpose of Pu p controller installation and wiring instruction refer to the Geyserwise Installation
anual or go to www.geyserwise.co.za

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Pu ped Controller – Geyserwise Syste
Acknowledg ent: Geyserwise Installation Manual: For purpose of Pu p controller installation and wiring
instruction refer to the Geyserwise Installation anual or go to www.geyserwise.co.za

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10. System commissioning
10.1 Co issioning direct syste s
Make sure that the solar radiation is low during
filling. In strong radiation it is possible for stea to
for in the collector. Keep the collector covered
throughout installation and co issioning.
Do not turn on the electric backup until the tank
has been filled with water.
Turn on at least one hot water outlet tap and open
the ains water supply to allow the water to fill the
tank and collector, expelling air fro the tank. As
soon as water flows freely, without air sputter,
close the tap and allow the cylinder to pressurise.
Check all piping, joints and fittings for water leaks.
Check pressure relief valves to ensure correct
operation.
Turn on the electric backup ele ent. Make sure the
tank is co pletely filled before turning on the
ele ent. Ensure power is available to the backup
ele ent.
Ensure the ti e clock has been correctly set.
11. Installation checklist
The following checklist should be observed by the
installer before handing the syste over to the
owner/user.
All air bled fro taps
Syste checked for water leaks
Cold and hot water pipes checked for leaks
Roof tiles back in position
Roof flashing watertight
Drain pipes free of obstruction
Pipework insulated
Electrical ele ent, ti er switch, isolator and
ther ostat, controller and pu p checked
Any protective plastic or packaging stickers
re oved fro tanks and/or collectors
Owner instructed on use

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12. System Selection and Sizing
12.1 Introduction
Individuals purchase solar hot water syste s for
any reasons. So e buy to realise savings on their
energy spend, others out of concern for the
environ ent, others as they have no other eans
of heating water or it could be a co bination of the
above. Whatever the otivating factor is it is
i portant that the type and size of the syste
selected are going to best eet the consu ers’
needs and expectations.
12.2 Syste sizing
In deciding on the syste required, apart fro
conducting a site visit to ascertain the proposed
installation site and associated ounting, plu bing
and wiring considerations, the sales representative
should also consult with the prospective custo er
as to their hot water require ents.
It is critically i portant that the prospective buyer
provide accurate infor ation in this regard, as the
results of providing incorrect infor ation can result
in a syste that either over or under perfor s,
given the specific needs of the custo er.
The onus is on the prospective buyer to provide the
sales consultant with an accurate disclosure of the
hot water require ents and usage patterns in order
that a load profile can be for ulated.
A load profile would include infor ation such as
how any showers are taken per day and how
any litres are used, how any baths are taken
and size of baths, how uch hot water goes
towards washing dishes and doing laundry, etc.
Only once this infor ation is analysed can a final
reco endation be ade on syste size.
12.3 Syste type
Syste type can relate to a nu ber of syste
characteristics as follows:
Direct vs. Indirect (refer section 5 above)
Close-coupled vs. Split (refer section 4 above)
The decision between direct versus indirect is
described in section 5 above, but basically this is
deter ined by whether or not frost or poor water
quality dictate an indirect syste .
N TE: THE DIRECT N VASUN
(THERM SIPH N/PUMPED) S LAR
WATER HEATING SYSTEMS CAN BE
USED IN ALL CLIMATE AREAS F S UTH
AFRICA
The decision between close-coupled and split
syste is largely an aesthetic decision based on
custo er preference, but there is a cost i plication
in that split syste requires additional plu bing,
syste controller, circulation pu p and ounting
structures which translate into a greater installed
cost.
As the NovaSun syste s have been SABS tested in
a ther o-siphon and pu ped configuration and
registered with Esko accordingly, a split syste
installation can be clai ed for on the rebate
progra e if the syste is a ther o-siphon or
pu ped syste . That is, even though the tank is
installed inside the roof there is enough space that
the tank is above the level of the collector/s,
allowing a ther o-siphon to operate or a pu p to
force the circulation.
NOTE: Please visit www.novasunsolar.co.za for
ore infor ation on syste .

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13. wners operating and maintenance
instructions
13.1 Introduction
Dear Customer,
Thank you and congratulations on your purchase.
Your syste is one of the ost advanced available
and is proudly produced in South Africa.
It will provide years of service and savings. The
infor ation below is provided to give guidance in
the effective use and aintenance of your syste
and should be retained for future reference.
Yours sincerely,
WE Geysers (Pty) Ltd
13.2 Operating and efficient use
Savings in energy costs achieved is dependent
upon usage patterns and the extent to which
electrical backup is used. The following will assist in
understanding syste perfor ance:
Solar radiation is greater on clear, sunny
days, between 9a and 3p . During periods
of use the syste operates at approxi ately
twice the axi u a bient te perature and
during periods of non-use, it is possible to
achieve well over 90°C.
On days of high radiation schedule washing
loads as close as possible to id-day.
On low solar radiation days avoid heavy hot
water usage.
Electrical backup, which is ther ostatically
controlled and governed by a ti e-clock,
should be set at 55°C. The ti e-clock has
battery backup in order to prevent settings
being lost during general power failures. In
order to clai an Esko rebate, a ti e-clock
is andatory. We would advise the use of a
ti e-clock in any event, as this is the ost
efficient ethod of operating a solar syste .
Ti e-clock settings should, generally
speaking, be set for two hours in the orning
and two hours in the evening. For exa ple, if
you bath at 06h30 and 18h00, set your ti e-
clock for 04h00 to 06h00 and again for 15h00
to 17h00. Ensure backup ti e periods do not
coincide with localised load shifting by
unicipalities e ploying ripple relay devices.
This will ensure that if there was not
sufficient solar gain during the day, you will
still have hot water in the evening and early
orning.
Solar syste s without ti e-clocks rely on
ther ostats to control when the ele ent
switches on and off. This is not efficient or
cost-effective. An exa ple of this would be,
using hot water in the orning which causes
the ther ostat to auto atically activate the
ele ent to heat your water. However, this is
when the sun will start to heat your water.
Therefore, if you do not have a ti e-clock or
it is not progra ed properly, you will not
save as uch energy as you will use both
electricity and solar energy to heat your
water si ultaneously.
An override function is provided on the ti e
clock so you can over-ride progra ed
heating ti es and heat up your water
electrically. This should only be used when
strictly necessary (e.g. during periods of ore
than nor al usage when guests are in the
residence) and re e bering to revert to pre-
progra ed settings. This will save you the
opti u a ount of electricity and provide
the necessary reduction in peak-period use.
If you wish to set your ti er differently, you
should discuss this with the dealer. However,
your ti er ust not co e on during Esko ’s
peak electricity use periods. These ay
change fro ti e to ti e so please check
with your installer.

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Once you get used to the syste and its
opti u perfor ance pattern, you ay
eventually co pletely switch the electrical
backup off, particularly in su er onths.
An additional benefit of this is that it is the
fastest way to reduce the syste ’s payback
period.
Savings can be further axi ised by using
hot water in the evening rather than in the
orning, axi ising the free energy
harvested during the day.
Additional tips to enhance savings include:
To further opti ise energy and hot water
savings, install aerated shower heads and
aerators in taps to reduce hot water
consu ption.
Insulate hot water piping to ini ise heat
losses.
Showering generally uses less water than
bathing.
For health reasons your hot water syste
should provide water at 55ºC, but not uch
war er than that. Do not set your ther ostat
backup te perature control for te peratures
in excess of this.
If shading of collectors is experienced
between 9a and 3p then corrective action
should be taken. Annually prune or cut trees
that shade the syste .
Partial shading by chi neys, TV antennas,
roof erected fixtures, etc. on buildings during
these hours is acceptable provided that it
does not exceed 10% of the area. Shading
fro newly erected buildings should be
checked and if syste perfor ance is
affected, relocation of the syste ay be
necessary.
13.3 Over-night te perature stabilisation
Over-night te perature stabilisation is the
reduction in water te perature, as the hot
water at the top of the storage cylinder
transfers so e of its heat to the cooler water
in the lower section of the cylinder.
This effect is often perceived as heat loss, but
is actually the redistribution of stored heat
ore evenly over the entire contents of the
storage tank. This ay ake it necessary to
use the electric ele ent to raise the water in
the top section of the cylinder back to an
acceptable te perature.
Over-night te perature stabilisation is ost
evident in the orning if the ti e clock is left
off overnight.
13.4 High water te perature
Your solar water heater will generate hot
water quickly and efficiently. Under nor al
fa ily use, it will operate between 60ºC and
70ºC. However, the te perature can exceed
this and under certain circu stances ay be
as high as 95ºC. This can occur during
prolonged periods of direct sunlight and
particularly in su er or long periods of
reduced water usage. Extre e care should be
taken in these circu stances.
Although every syste is fitted with a ixing
valve that regulates te perature at points of
water use, check the water te perature
before use, such as when entering a shower
or filling a bath or basin, to ensure it is
suitable for the application and will not cause
scalding. It is required by SANS regulations,
that a te perature li iting device / ixing
valve be fitted to the syste . This will li it
the water te perature to 50°C at the point of
use. The risk of scalding will be reduced, but
water should always be tested prior to use to
prevent injury in the case of a te pering
valve failure.
13.5 Periods of reduced usage or holidays
If the water heater is left unused for two weeks
or ore a s all quantity of hydrogen gas, which
is highly fla able ay accu ulate in the top of
the water cylinder. This is true of both

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conventional electric geysers and solar syste s.
To dissipate this gas safely, it is reco ended
that a sink hot tap be turned on for several
inutes. Do not use a dishwasher, clothes
washer or other appliance for this purpose.
During this procedure there ust be no s oking,
open fla es or any electrical appliance operating
nearby. If hydrogen is discharged through the tap
it will ake an unusual sound like air escaping.
It is reco ended that if the syste is going to
be left unused for long periods of ti e, that the
backup ele ent switched off at the distribution
board. Re e ber that when the geyser breaker
is reactivated the ti e clock ay have to be reset
as it has a li ited settings e ory when
switched off (i.e. approxi ately 72 hours
depending on the odel).
13.6 Freeze protection liquid
No freeze protection liquid is used in the Novasun
syste .
13.7 Setting the ti e clock
WE Geysers (Pty) Ltd reco ends that an SABS
approved ti e clock, with battery backup, be
installed on the distribution board. There are any
such ti e clocks on the arket and the operation
of which are all relatively si ilar. A Sa ite QAT-R-
DM ti e clock has been selected to illustrate how
to progra the ti e clock.
This ti e clock has four different screens. When it
is powered up screen 1 ( ain screen) appears.
SCREEN 1: Actual Ti e Indicator
This ON/OFF indicator indicates whether the ti e
clock is currently active or not. This screen also
displays the current actual ti e.
Press the green function button to cycle forward to
the next screen.
SCREEN 2: Set Actual Ti e
Press the Hour and Minute buttons to set the actual
ti e. Once the ti e is set press the function button
to advance to the next screen.

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SCREEN 3: Progra Ti er On/Off
To progra the desired ti er settings press the off
button to ove the flashing seg ent to the ti e at
which power is ade available to the geyser
ther ostat/ele ent. Once the seg ent is at the
desired ti e, press the on button repeatedly to
insert 30 inute backup seg ents until the ti e is
reached when you want the backup period to end.
These steps can be repeated if further backup
periods are required. For effective operation an
afternoon and an early orning backup period are
reco ended.
EXAMPLE: Backup period fro 3PM to 6PM
Press the Off button until the progra ti e
indicates 15h00, then press the On button until the
progra ti e indicates 18h00. As shown below.
SCREEN 4: Bypass on or off
The ti er progra e is bypassed using this
screen. Press the “Bypass On’’ button to bypass the
ti er and provide the geyser with a constant
supply. The Bypass on display flashes.
Press the “Bypass Off” button for power to be
controlled by the ti er and switch on according to
the set ti es.
Press the function button to return to screen one.
Note: When in “Bypass On” ode the display will
not revert to screen one after 60 seconds.
Should you be away fro ho e for any extended
period and you wish to switch the geyser off at the
breaker on the distribution board, please re e ber
that you would have to re-progra e the ti e
clock on your return as the on-board e ory is
only stored for approxi ately 72 hours without
being connected.
The use of the electrical backup is very uch
dependent on personal usage patterns of hot
water. The following, however, are a few tips:
During days with te peratures below 20°C,
water te perature ay only reach 40°C to
50°C. It could be lower if these colder days
are coupled with overcast and rainy
conditions.
The hu an body generally prefers
te peratures of between 35°C to 40°C for
bathing during winter and therefore boosting
ay be required at certain ti es.

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Backup heating is generally preferable during
late afternoon and early orning, so that
axi u use of solar energy during the day
is taken advantage of.
The backup should not be set that it is on
during periods when the water is being used.
This because an ele ent cannot heat the
water with any efficiency when water is being
used.
If hot water use is heavy during the evening
then it is vital that a backup heating period
be set for the early orning if one desires hot
water first thing in the orning.
13.8 Owner aintenance
To ensure that the syste will perfor reliably,
so e preventative aintenance should be
perfor ed by the ho e owner/user. If the syste
is in a position which is not easily accessible or the
owner is not in a position to effect the points
below, a service technician should be e ployed to
carry out the aintenance.
The following should be perfor ed annually by the
owner/user or his appointed technician:
Wash the glass cover of the collector with a
ild household detergent. The collector glass
and seals should be inspected.
Mounting brackets and straps should be
checked for signs of wear.
Pipe insulation should be checked for signs of
degradation and/or da age. Please note that
although UV resistant insulation is used, the
harshness of the South African cli ate eans
that the insulation will not last indefinitely.
There is no warranty on pipe insulation.
Visually inspect pipework for signs of leaks.
A periodic inspection of pressure reducing
valves, expansion valves, vacuu breakers,
te perature pressure valves and te pering
valves should be conducted on a solar geyser,
just as it should be done on any conventional
electrical geyser. These valves allow for the
safe operation of the geyser and should be
inspected twice yearly.
The te perature pressure (TP) valve is near
the top of the water heater and is essential
that this valve operates safely. It is possible
for the valve to release a little water through
the drain line during each heating period.
This occurs as heated water expands by
approxi ately 1L out of 50L of its volu e. If
continuous leaking occurs this ay indicate a
proble with the valve - please report this to
your installer i ediately. WARNING - Never
block the outlet of this valve. TP valves
should be checked for perfor ance at
intervals not exceeding 6 onths, or ore
frequently in areas of high incidents of water
deposits (such as Calciu or Magnesiu ).Be
advised that in areas or periods of high solar
radiation there will be greater frequency of
this valve opening. In order to check the TP
valve the easing gear should be operated.
This is a black knob on the TP valve that
needs to be turned in an anti-clockwise
direction and so e water allowed to escape.
Be aware that this water ay be at a high
te perature. Before opening the valve ake
sure you are well clear and be advised that
the geyser will be under pressure so water
ay be expelled at a high rate. Guard
carefully against exposure to the water
whether through direct contact or through
back splash. Be careful not to confuse the TP
valve with the solar relief valve fitted on
so e indirect syste s. Please contact your
installer for advice if unsure.
If at any point the te perature at point of
use (e.g. bathroo ) appears to be increasing
or decreasing, the te perature ixing valve
ay need to be set or adjusted accordingly.

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Warning
When inspecting your syste please bear the
following in ind:
The re oval of the electrical cover plate on the
solar geyser will expose 220 V wiring. It ust
only be re oved by an authorised electrician or
service person.
Care should be taken not to touch the pipe work
connecting the solar storage tank and the solar
collectors. Very high te perature hot water can be
generated by the solar collectors under certain
conditions, and will flow through the pipe work
fro the solar collectors to the solar storage tank.
Working at heights should only be undertaken by
suitably qualified personnel, using the proper safety
equip ent.
Failure to observe safe
practices ay result
in:
scalding / burns;
electrical shock;
and/or falling,
which can cause
serious injury or
death.
13.9 Troubleshooting
Should your syste not provide hot water please
check the following before requesting a service call:
Shading fro trees is not excessive and is not
covering the collectors for all or part of the
day.
Hot water usage has not been excessive.
Hot water is not leaking fro within the
plu bing syste that feeds hot water to the
points of use.
The ti e clock is operational and has been
progra ed correctly.
The electric eter and/or display light on the
ti e clock speeds up when the ti e clock is
active.
Power has been provided to the ain board
(i.e. no electrical faults or load shedding).
The ripple relay has not beco e ja ed in
the open position.
The water supply to the ho e has not been
interrupted (i.e. unicipal shut-off)
Please contact your local dealer and/or installer if
all of the above have been checked and there is still
no hot water. A charge out fee ay apply if the
syste is found to be functioning correctly and the
atter relates to one of the above issues.
14. Warranties
Please refer to the NovaSun SWH Warranty
Docu ent.
15. Contacts
WE Geysers (Pty) Ltd (Pty) Ltd
Physical Address 7 Nell apius Road, Cha dor,
Krugersdorp, 1754
Postal Address PO Box 4060, Luipaardsvlei,
1743
Tel [phone]
Fax [phone]
e ail [e-mail]
e ail [e-mail]
Website www.novasunsolar.co.za
16. Warranty Contact Centre
SolarAssist 0861 106 618 (24/7)
Website: www.solarassist.co.za
E ail: [e-mail]

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17. Warranty Services: (log warranty services)
Important Notice: Making use of a non-accredited Solar Installer to perfor warranty work on your
Novasun SWH syste will void your Warranty Agree ent.
Date: Service Provider/Contact detail Services/Job performed.
wner Notes: