Solar Lord hot water system User manual

1
SL/CEO/version6






     H HO OT T W WA AT TE ER R S SY YS ST TE EM M



            
T
Th he e S So ol la ar r W Wa at te er r H He ea at te er r o of f N Ne ew w G Ge en ne er ra at ti io on n





                               

 I In ns st ta al ll la at ti io on n 

 O Op pe er ra at ti io on n 

 M Ma ai in nt te en na an nc ce e 

 O Ow wn ne er rs s G
Gu ui id de e 

 W Wa ar rr ra an nt ty y 












2
SolarLordHotWater


  Instructionsforinstallation
  Pleaseforwardthemanualtotheowners

       





           
E E‐ ‐m ma ai il l: :     i in nf fo o@ @s so ol la ar rl lo or rd d. .c co om m. .a au u 

          W We eb bs si it te e: : h ht tt tp p: :/ // /w ww ww w. .s so ol la ar rl lo or rd d. .c co om m. .a au u






         
S Sa al le es s: :             1 13 30 00 0 1 13 33 3 7 78 82 2                          

           S Se er rv vi ic ce e: :          1 13 30 00 0 1 13 33 3 7 78 82 2  
                      




ThankyouforchoosingaSolarLordhotwatersystem.Youmaylookforwardtomany
yearsofmonetarysavingsaswellasknowingthatyouarehelpingprovideasustain‐
ablefutureforgenerationstocome.




THISSOLARWATERHEATERMUSTBEININSTALLEDBY
ALICENSEDPLUMBER&ELECTRICIAN


        









3
I
IM MP PO OR RT TA AN NT T 


Pleasereadtheseinstructionscarefullyandmakesureyouunderstandthembeforetheinstallation;
itwillensureasuccessfulandtrouble‐freeinstallation.

THISAPPLIANCESHALLBEINSTALLEDINACCORDANCEWITHTHEMANUFACTURER’SINSTALLATION
INSTRUCTIONS,LOCALANDAS3500.4NATIONALPLUMBINGREGULATIONS,MUNICIPALBUILDING
CODESANDANYOTHERRELEVANTSTATUTORYREGULATIONS.

Allworkcarriedoutmustbeperformedbytheappropriatequalifiedtradespeopleorbesuitablysu‐
pervisedfortradeassistantduties.

Thisisawaterheatingapparatusonlyandthefinalfitnessofwaterdeliveredisdependentuponthe
qualityofwatersuppliedtothissystem.SolarLorddoesnotacceptliabilityorresponsibilityforthe
finalfitnessofwaterforconsumptionfromthissystem.

Thisapplianceisnotsuitableforpools.

Materialsandspecificationsaresubjecttochangeduetoongoingproductionimprovement.The
productsasoutlinedinthismanualmaydifferslightlyfromsystemspurchased.

SAFEGUARDS

Scaldingoccursat50°C.Thisapplianceiscapableofprovidinghotwaterabovethistemperature.Un‐
derstagnationconditionsthesolarcollectorshavetheabilitytogeneratetemperaturesofuptoand
exceeding270°C.Caremustbetakenwhenhandlingorotheractivitieswhereskincontactcouldoc‐
curandscaldingwouldresult.

Watermaydripfromthedischargepipeofthepressurereliefvalvedevice.Thispipemustbeleft
opentotheatmosphere.Childrenshouldbesupervisedtoensurethattheydonotplaywiththeap‐
plianceandnearbydrainage.

Thisapplianceisnotintendedforusebyyoungchildrenorinfirmpersonsunlesstheyhavebeen
adequatelysupervisedbyaresponsiblepersontoensurethattheycanusetheappliancesafely.

SolarLordwaterheatersaredesignedforthesupplyofhotwatertoadomestichouseholdpremises
whichhavebeenconstructedtoandcompliedwiththeappropriatelocal,nationalcodesandregula‐
tionsandhasbeenmaintainedingoodcondition.

Wherebraces,bracket,framesetcaresecuredtorooftimbersallfittingsmustbeofanappropriate
typetosuitthetypeoftimber.Wherethecollectorismountedonametalroof,thebraces,frames
etcmustbefastenedtotherafterunderneaththemetalsheet.Inadequateorinappropriatefixings
mayresultinbracesbecomingunsecuredandtheinstallationofthesolarcollectorsbecomingdan‐
gerous.

Solarhotwatercollectorscanbeheavyandfragilesoalwaysuseapprovedliftingdevicestoassist
installing.AllworkmustbecarriedoutinaccordancewithLocal,StateandFederalOccupational

4
Safety,HealthandWelfareRegulations.Inparticulartherequirementsforsafetywhilstmanufactur‐
ing,workingatheights

SOLARLORDDOESNOTACCEPTLIABILITYORRESPONSIBILITYFORANYACCIDENTORPER‐
SONALINJURYDURINGTHEINSTALLATIONOFTHISSYSTEM

Installersmustbequalifiedthetrainingin:

1.HeightHazardAssessment
2.WorkingatHeightProcedures
3.Assessment/Use/Wearingofcorrectheightsafetyequipment(harnessesetc.)
4.AllotherrelevantsafetyfactorsspecifictotheworktobesuitabletoOccupational,Healthand
SafetyRegulations/Codes.

WARNING

Ifcoldwaterpressurelikelyexceeds550kPaapressurereductionvalvemustbefitted.Failuretoin‐
stallapressurereductionvalvewhererequiredwillvoidthewarranty(refertopg.42).Insomeloca‐
tionsregulationsrequireapressurereliefvalvetobefittedtothecoldwatersupply.

ThisinstallationmustcomplywithrequirementofAS3500.4andmanufacturer’sinstallationinstruc‐
tions,localwaterregulations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benefitsof
SOLARLORDwarrantyprotection.

Theconnection,attachment,integrationorgeneralassociationofotherequipmentorpartswhich
eitherdirectlyorindirectlyaffecttheoperationorperformanceofthisequipmentassuppliedbySo‐
larLordcouldvoidthewarranty.

OthersuchequipmentorpartsnotsuppliedbySolarLordtothisinstallationwhichmayaffectitsop‐
eration/performancemustfirstbeauthorisedbySolarLordinwritingifthefullbenefitsofthiswar‐
rantyaretoremainvalid.

Safety

Inadditiontothenormalconventionsforsafety,wheninstallingorworkingonthesystem,please
takenoteofthefollowing;

•Isolateelectricalsupplytocontroller,pumpandelectricwaterheaterbooster
•Waitforthesystemtocooldown
•Wearprotectiveclothingduetosharpedgesandhotcomponents.
•Turnoffthewatersupply
•Releasethewaterpressureusingthereliefvalves
•Coverthecollectorswithcardboardorsheetstolimitheatgainfromthesun


5
TABLEOFCONTENTS


General ----------------------------------------------------------------------------------------------- 6
The Principal of Operation ------------------------------------------------------------------- 6
Contractor’s Responsibilities -------------------------------------------------------------- 9
Installation ------------------------------------------------------------------------------------------------- 10
SYSTEM LOCATION -------------------------------------------------------------------------- 10
INSTALLATION INFORMATION ----------------------------------------------------------------- 11
OPEN (DIRECT) CIRCUIT ------------------------------------------------------------------- 12
HEAT PIPE SYSTEM OPEN (DIRECT) CIRCUIT -------------------------------------------- 12
U TUBE SYSTEM OPEN (DIRECT) CIRCUIT -------------------------------------------- 13
Installation Diagrams ---------------------------------------------------------------------- 14
CLOSED (INDIRECT) CIRCUIT ------------------------------------------------------------------ 16
Installation Diagrams ------------------------------------------------------------------------- 16
General Installation --------------------------------------------------------------------------- 17
Piping ---------------------------------------------------------------------------------------- 17
SOLAR COLLECTOR CONNECTIONS ------------------------------------------------------------ 17
TANK CONNECTIONS ------------------------------------------------------------------------------- 18
SOLAR CONTROLLER ------------------------------------------------------------------------------- 18
Electrical Connections ------------------------------------------------------------------------------------ 19
Gas Connections ------------------------------------------------------------------------------------------ 20
The Solar Collector Installation ------------------------------------------------------------------- 21
Set-up Circuits & Commissioning ------------------------------------------------------------------ 26
Checking the System Operation -------------------------------------------------------------------------- 27
Maintenance and Service --------------------------------------------------------------------------------- 28
Owner’s Manual ---------------------------------------------------------------------------------------------- 30
Appendices -------------------------------------------------------------------------------------------- 35
Warranty Conditions ------------------------------------------------------------------------------------------ 39




6

GENERAL

ThisinstructionisthemanualforinstallationanduseofSolarLordwaterHeaters.Itstateshowtoinstall,set‐
upandcheckthesystem.Italsoprovidesnecessarytechnicaldataandknowledgeofsolarhotwatersystem.

THEPRINCIPALOFOPERATION

Sinceevacuatedglasstubetechnologywasinverted,solarenergycanbechangedtoheatenergyefficientlyin
fourseasons.Solarexposurecanbeturnedtoheatregardlessambienttemperatureofthecollectors.Solar
LordcollectorsusingGermandesignforthetubingandSydneyUniversitycoatingtechnologyfortheabsorbing
surface.

Theinsideandoutsidetubesaremadefromextremelystrongborosilicateglasswhichareevacuatedand
fusedtogether.Thevacuumspacebetweentwoglasslayersformsexcellentinsulationtostoptheheatloss
fromtheinsidetotheoutside.Theoutsideoftheinnertubeiscoatedasurfacetoabsorbmaximumsolaren‐
ergy.

Whensunlightstrikesthecollector,thesolarradiationgoesthroughtheclearglassoftheoutsidetubesandis
absorbedbythecoatingontheoutsideoftheinnertubes.Thesolarenergyischangedintoheatenergybythe
coatingsurfaceandheatstheinnertube.

Eitheraheat‐transferfluidortheactualpotablewatertobeusedflowsthroughtubesattachedtotheab‐
sorberandtransferstheheatfromit.Theheatedwaterisstoredinastoragetankuntilneeded.Ifadditional
heatisneeded,itisprovidedbyelectricityorgasenergy.

TheSolarLordhotwatersystemyouareinstallingisa‘pump’solarsystemthathascirculationofwater(direct
loop)orglycolmixture(indirectloop)aroundthesolarcollector.
Thesmallcirculatingpumpcirculatesthewaterbetweenthecollectorsandthehotwatercylinder.Thepump
isusuallyoperatedbyasolarcontrollerthatonlyturnsthepumponwhenthewaterinthecollectoriswarmer
thanthewaterinthetank.Thesepumpsareveryquiet,offeringnonoisedisturbanceandonlydrawaround
23watts.

Wecanalsooffer12voltpumpswhicharecoupledtoaphotovoltaiccellofapproximatelyupto20wattsde‐
pendinguponsystemcharacteristics.Thesesystemsofferautomaticcontrol,i.e.whenthereissolargain,the
collectorwarmsupandalsothepumpoperates.Thesesystemsareofteninstalledinremotesiteswhere
thermosyphonsystemsarenotsuitable.
InaHeatPipecollector,theSun’senergythatisabsorbedbythetubesisthentransferredtoyourwatervia
specialheatpipeslocatedinsideeachtube.Asmallamountofnon‐toxicliquidisinsideeachheatpipe.This
liquidisturnedtogasbytheSun.Thisgasrisestothetipsofthepipeswhichareinsertedintoaheattransfer
manifoldlocatedonyourroof.Wateristhenpumpedthroughthismanifoldabsorbingtheheatandstoredina
waterstoragetanklocatedbelow.
InaUTubecollector,thecoppertubeisbentintoaUShape(calledUtube)andinlaidintoheattransferring
fins.Bothcoppertubesandapairoffinssitinsideoftheevacuatedglasstube.Whensunlightstrikesthecol‐
lectorthesolarradiationgoesthroughtheclearglassoftheoutsidetubesisabsorbedbythecoatingonthe
outsideoftheinnertubes.Thesolarenergyischangedintoheatenergybythecoatingsurfaceandheatsthe
innertube.Encircledbytheinnerglasstubethefinstransfertheheatfromtheabsorbingsurfaceoftheinner
tubetothecopperUtube.WaterflowsinsidetheUcoppertubeandisheatedandpipedtothestoragetank
whereitiskeptuntilneeded.

7
TheresultisanincrediblyefficientsystemtoharnesstheheatoftheSuneveninextremelycoldareas.Be‐
causethesystemissoefficientitdoesnotrequirefullsunandcanworkincloudyorevenrainydays.
HeatPipe


Insideofthecopperheatpipehasbeenevacuatedandfilledwithnot‐toxicheattransferliquid.Whensunrays
striketheevacuatedtube,theliquidwillbeheatedandmelttoahotvapour.Thehotvapourrisesuptocon‐
denserattopoftheheatpipeandheatsupthemanifoldwheretheheatpipeispluggedin.Whenwaterflows
throughinsideofthemanifold,thewaterisheatedandflowsintostoragetank.Oncethevapourreleasethe
heattomanifolditturnsintoliquidagain,thenflowsdowntothebaseoftheheatpipe.Thiscyclecontinu‐
ouslyrepeatswhensolarradiationisbeingabsorbedbytheheatpipe.Everycirculationofliquid‐gaswillcom‐
pletetheheattransfer.
Inthiswaythesolarenergyistransferredfromtheheatpipetothemanifoldwherethecoldwaterisheated.
Duringtheday,wateriscirculatedthroughthemanifoldheader,viaintermittentpumpcycling.Eachtimethe
watercirculatesthroughtheheaderthetemperaturesisraisedby5‐10°C.Throughouttheday,thewaterin
thestoragetankisgraduallyheated.
Theevacuatedtubularcollectorwithheatpipescanbequasi‐trackinginfourseasons,thecollectorwillbein
operationaslongasthesunshines.Withintheheatpipecollectortheheattransfersisinonedirectiononly.
Heatpipewaterheaterscanbeinserviceallyearroundevenincoldclimateareaswhereexperiencebelowto
‐9°Cinwinter.

CopperUTube
Theinsideandoutsidetubesaremadefromextremelystrongborosilicateglasswhichareevacuatedandfused
together.Thevacuumspacebetweentwoglasslayersformsexcellentinsulationtostoptheheatlossfrom
insidetotheoutside.Theoutsideoftheinnertubeiscoatedwiththe“NovelSputtering”coatingtoabsorb
maximumsolarenergy.ThiscoatingwasdevelopedandpatentedatSydneyUniversity.


8



ThecoppertubeisbentintoaUShape(calledUtube)andinlaidintoheattransferringfins.Bothcoppertubes
andapairoffinssitinsideoftheevacuatedglasstube.Whensunlightstrikesthecollectorthesolarradiation
goesthroughtheclearglassoftheoutsidetubesisabsorbedbythecoatingontheoutsideoftheinnertubes.
Thesolarenergyischangedintoheatenergybythecoatingsurfaceandheatstheinnertube.Encircledbythe
innerglasstubethefinstransfertheheatfromtheabsorbingsurfaceoftheinnertubetothecopperUtube.
WaterflowsinsidetheUcoppertubeandisheatedandpipedtothestoragetankwhereitiskeptuntilneeded.

TheUtubecollectorsmaximizesolarheatgainandminimizeheatloss.Ithasbeentestedandproventobethe
highestefficiencycollectoravailableglobally.ThetestingwasperformedbyGermanlaboratoryFraunhofer‐
thetoplaboratoryofsolarenergyintheworld.


DIRECTHEATINGSYSTEM(OPENLOOP):
E450U45‐O,E450U30‐O,E340U15‐O,E270U15‐O,E450SH48‐O,E450SH40‐O,E340SH32‐O,E270SH24‐O
&E180SH16
G450U45‐O,G450U30‐O,G340U15‐OandG270U15‐O,G450SH48‐O,G450SH40‐O,G340SH32‐O,
G270SH24‐O,G2001‐OandG180SH16‐O

Intheopenloopsystemthepotablewaterisdirectlyheatedasitcirculatesbyapumpthroughsolarcollectors
mountedontheroof.Theheatedwateristhenstoredinaground‐mountedstoragecylinderandrisesupthe
cylinderbynaturalconvectiontothetopofthetankwherethehotletis.

INDIRECTHEATINGSYSTEM(CLOSEDLOOP):
E3002‐C,E3001‐C,G3002‐C&G3002‐C

Indirectheatingsystemsuseaheatexchangerinthestoragetanktocompleteheattransfer.Byusinganindi‐
rectsolarcircuitthatcontainsaglycolmixturecirculatedtosolarcollectorsbyapump,theheatenergypro‐
ducedfromtheabsorbingsurfaceofthecollectoristransferredtothepotablewaterinthestoragetankasthe
glycolpassesthroughtheheatexchanger.Theindirect(closed)circuitprotectsthecollectorsfromfreezingand
isrecommendedforareasthataresusceptibletofrostbelow‐7°Corharshwaterconditions.

Anauxiliaryheaterisalsoincludedinthesystemtoboostwatertemperatureduringperiodsofcontinuousrain
orlowsunradiationdays.Boostersmayrunoncontinuous/off‐peakelectricityorpostgas.

Thesystemmodelrepresentssourceofbooster,storagecapacity,typeofcollector,numberofevacuatedglass
tubesandkindofsystemindicatedinorderasfollows,

9
   

CONTRACTOR’SRESPONSIBILITIES
1.STANDARDS

AllSolarLordHotWatersystemsmustbeinstalledbyanauthorisedPlumberandelectricitysuppliedbyareg‐
isteredelectrician.Theentireworkswillneedtomeetlocalauthoritystandards,AustraliaStandard(AS3500.4)
andtheNationalPlumbingCodealongwithlocalElectricalregulations.

2.PREPARATIONS

(a)Installersmusthavebeencompletelytrainedinthecorrectsafetyproceduresforworkingatheightsof
roofsandmakesurethatallworkiscarriedoutinaccordancewithlocal,stateandfederaloccupationalsafety,
healthandwelfareregulationsinparticulartherequirementsforsafetywhilstmanuallifting,workingat
heightsandonroofs.

(b)Useanapprovedliftingdeviceasthesolartanksandcollectorscanbeveryheavy(reftospecification).The
evacuatedglasstubesarefragile.Takecarewhenliftingandinstallingthecollector(s).Wearglovestoavoid
cutbybrokenglassandscaldedhotcomponents.

(c)Takeallconsiderationstoprotectandwarnoccupantsofthebuildingandthepublicfrompersonalinjury
whichmayoccurfromfallingtools,brokenglass,roofmaterials,fittingsoranyotherhazardsofageneralna‐
ture.

(d)Advisetheoccupantsofthepropertyaboutanyinconveniencecausebytemperatedisconnectionofexist‐
ingwater,electricalandgassuppliesduringtheinstallation.

3. COMMISSIONING

Thecommissioningoftheinstallationanditshandingovertotheclientshallbetheresponsibilityofthecon‐
tractor.Thecontractorshallinstructinthemethodoperationandhandtheclientacopyofthismanual.Itis
thecontractor’sresponsibilitytoadviseownersofthepotentialhazardscaldinginaccordancewithAS3500.4
andotherrelatedstandards.

Calltheclientandcheckifsystemfunctionswellandsuppliesenoughhotwaterthreedaysaftertheinstalla‐
tion.





10
INSTALLATION

SYSTEMLOCATION
Solarcollectors

Orientation

Thesolarcollectormustbemountedontheroofandorientatedtogeographicnorthforoptimumsolargain.
Geographicnorthisbetween17and24degreeswestofmagneticnorthasshownbyacompass.Foroptimum
performance,thesolarcollector/sshouldbepositionedonanorth‐facingroof(nomorethan45°eastorwest
ofnorth)atananglebetween15°and50°.Useacompasstocheckorientation.Variationgreaterthan
60°East/Westwillrequireanadditionalcollector,whilebetween45°‐60°canbeacceptableundercertaincir‐
cumstancesoflessthanaveragehotwaterusage.

Thecollectorshouldbeinashadowfreepositionallyearround.Carefullycheckforhighbuildingsortreesin
thevicinityforWINTERshade.Adeviationof45°toeast/westhaslittleeffectonannualsolargain.

Inclination

Inclinationofthesolarcollectorshouldbeapproximatelyequaltothelocallatitudeangleforreceivingmax
annualsolargain.Iftheroofanglevariesby±15°fromthecorrectangle,annualefficiencywillbereducedby
5%.Ingeneralvariationabout±10°isacceptable.Traditionalflatcollectorsrequesttheidealinclinationofthe
solarcollectoratanangleequaltothelatitudeofthesiteduetoitssignificantlossontheannualsolargainsif
collectordeviationsgreaterthan20°.

SolarLordUtubeCollectorcanbeinstalledonanyroofpitchfrom10°‐90°duetoitshighefficiency.Solar
LordHeatPipecollectorneedsaroofpitchgreaterthan20°toachievethebestperformance.Standardroof
pitchisusuallysufficient.
Aninclinationlessthanthelatitudewillresultinincreasedsummerperformanceandinclinationsgreaterthan
thelatitudeofthesitewillincreasesolargainduringwinter.BecausethelowestSunrays,shortestsunshine
durationandcoldestwatertemperaturefromthemainsinwinter,weencourageyoutoinstallcollectorsincli‐
nationashighaspossibletocapturemaxsolarenergyinwinter.ThelatitudesofthemaincitiesofAustralia
arelistedbelow;

CITYLATITUTECITYLATITUTECITYLATITUTECITYLATITUTE
Adelaide35°Cairns17
°
Hobart 42
°
PortHedland20
°
Alicesprings24°Canberra35
°
Mildura 34
°
Rockhampton24
°
Brisbane27°Darwin12
°
Melbourne 38
°
Sydney34
°

Location

Solarcollectorshouldbeinstalledascloseaspossibletothestoragetank.Thepipinglengthbetweensolarcol‐
lector/sandtankwillaffectthesystemefficiency.Longerpipewillincreaseheatlossofthesolarhotwater
unit.Thesolarcollectormustbenomorethan15metresawayfromthestoragetank.Thesolarwaterstorage
tankshouldbeinstalledclosetothemostfrequentlyusedoutletanditspositionchosenwithsafetyandeffi‐
ciency.


Roofstructure

Thesolarcollectorsneedtoinstallontheroofwherechoseniswellstructurallycapableofsupportingthe

11
weightandsize(refertoSOLARCOLLECTORLOCATIONPG.17).Thebuildingshallbecompliedwithnational
buildingregulationsandassociatedAustralianStandardsorequivalent.Itistheinstaller’sresponsibilitytoen‐
surethatthenecessarystructuralassessmentshavebeenmade.

Specialconditionareas

a) CYCLONICAREAS

Thecylindricalshapeoftheevacuatedglasstubesandthegapsbetweenthetubesletwindeasilyget
through.Thecollector/scanstanduptoBeaufortWindForce11.SolarLordmountingframehascom‐
pletedthetestandpasttothetestofAustraliaStandards(AS4040.03:1992andAS1170.2:2002).Thistest
includesthecollectorandinstallationkidsforWindResistance.Itisstronglyrecommendedthatthesys‐
temisfittedontothemountingframeandtobesecuredandfastenedenoughtoresisttheseconditions.

b)FROSTANDPOORWATERQUALITYAREAS
(E3001‐C,E3002‐C,G3001‐C&G3002‐C)
TheClosedLoop(indirectcircuit)shouldapplytotheseareas.Theclosedsolarcircuitsystemisdesignedfor
frost‐proneandpoorqualityareas.Anti‐freezecontrolisincorporatedinthedesignbyusingaglycolmixture
inthesolarcircuit.Theheattransferfluidis’Glycol’whichhasspecificpropertiesthatpreventitfromfreezing
andthereforeeliminatingtheriskoffrostdamagetothecollectors.SolarLordGlycolisafood‐gradefluid.De‐
pendinguponitsconcentration,itenablesthesystemtooperateatenvironmenttemperaturesdownto‐40°C.
PleasecontactSolarLordforfurtherdetails.

StorageTank
Toobtainmaximumperformancethesolartankshouldbepositionedascloseaspossibletothemostused
outletsandtosolarcollectorsaswell.Thetankcanbeinstalledinternallyonanapprovedspilltraywithdrain
orexternallyonalevelconcreteplinth.

MakesurePressureandTemperatureReliefvalveisaccessible.Itisrecommendedthesolarstoragetankbe
installedatgroundorfloorlevelandshallbeplacedverticalupright.Noblockageabovethetankandelectric
elementbush(electricbackupmodels)foreasyaccessformaintainandservicepurposes.

Boosting
Systemsthatuseelectricalboostingshouldbeconnectedtodaytariff(power)oroffpeaktariff(ifapplicable)
accordinglyinrespectofthemodeltoclaimtheORERrebates.
Whenusinggasboosting,thecontinuousgasunitshouldbeinstalledascloseaspossibletothemostuseout‐
letsandtankaswelltoreducetheheatlossfromthepipe.

Electricconnection
Localcodesmustbeadheredtoforallelectricalworkandbeundertakenbyaqualifiedelectrician.Allpumped
solarhotwatersystemrequireapoweroutlettorunthepump.Whenusingthegasboosteranadditionalwa‐
terproofpoweroutletwillbeneeded.A15AMPpowerconnectionwillbeneededforelectricbackupsystem.

Pre‐approvedbyowner
Pleaseadvisetheowneroftheoptimumlocationtoapproveandconfirmpriortotheinstallation.

INSTALLATIONKIT
AninstallationKitshouldbedeliveredwiththesystem.Checkwiththepackinglistifyouhavethenecessary
componentsbeforetheinstallation.

INSTALLATIONINFORMATIONOPEN(DIRECT)CIRCUIT

12
HEATPIPESYSTEMOPEN(DIRECT)CIRCUIT




MODEL(HeatPipe)
E180SH16‐OE270SH24‐OE340SH32‐OE450SH40‐OE450SH48‐OG180SH16‐OG270SH24‐OG340SH32‐OG450SH40‐OG450SH48‐O
TANK
StorageCapac‐
ity(litres)
180270 340450 450 180 270 340450 450
HotWaterDeliv‐
ery(litres)
166250 315400 400 166 250 315400 400
BoosterElectricGas
Dimensions(mm)
Diameter A 
540648 648730730540 648 648730730
Height B 
13411387 16901703 1703 1341 1387 16901703 1703
Coldwaterinlet C 
8282 8282 82 82 82 8282 82
Hotwateroutlet D 
11481175 1478148214821148 1175 147814821482
Collectorhotreturn E 
462582 582582582462 582 582582582
Collectorcoldflow F 
8282 82828282 82 828282
Connectionspace G 
652760 760842842652 760 760842842
NetWeightempty(Kg)
56841021501505684102150150
NetWeightfull(Kg)
236354442600600236354442600600
Cold/tocollector
3/4”BSP3/4”BSP
Hot/solarreturn
3/4”BSP3/4”BSP
COLLETOR

No.ofTubes
16243240481624324048
Dimensions(mm)

ManifoldLength H  1280

1920

12801280+1920128012801920

12801280+19201280
CollectorHeight196019601960
19601960196019601960 19601960
ConnectionspaceI128019202710
33504140128019202710 33504140
NetWeight
empty(Kg)5170
102
1211535170
102
121153
Pipeconnection3/4”BSP3/4”BSP
FlowRate(L/min)0.750.75 11.3 2.2 0.75 0.75 11.3 2.2

13

UTUBESYSTEMOPEN(DIRECT)CIRCUIT


MODEL(Utube)E270U15‐OE340U15‐OE450U30‐OE450U45‐OG270U15‐OG340U15‐OG450U30‐OG450U45‐O
TANK
StorageCapac‐
ity(litres)
270340450 450 270 340 450450
HotWaterDeliv‐
ery(litres)
250315400 400 250 315 400400
BoosterElectricGas
Dimensions(mm)

DiameterA648648730730648 648730730
HeightB138716901703 1703 1387 169017031703
ColdwaterinletC7474828274 748282
HotwateroutletD11751478148214821175 147814821482
Collectorhotreturn
E
574
574582582
574
574582582
CollectorcoldflowF7474828274 748282
ConnectionspaceG760760842842760 760842842
NetWeightempty
(Kg)8410215015084102150150
NetWeightfull(Kg)354442600600354442600600
Cold/tocollector3/4”BSP3/4”BSP
Hot/solarreturn 3/4”BSP3/4”BSP
COLLETOR

No.ofTubes151530451515 3045
Dimensions(mm)
ManifoldLeighH112811281128x21128x3112811281128x21128x3
CollectorHeight22302230
2230223022302230 22302230
ConnectionspaceI12501250265040501250125026504050
NetWeight
empty(Kg)67
67
13420167
67
134201
PipeconnectionDN15DN15
FlowRate(L/min)0.750.751.302.00.750.751.302.0

14
HORIZONTALTANKSYSTEM


MODEL(Utube)E200U15‐OH E300U15‐OH G200U15‐OHG300U15‐OH
TANK(Horizontal)
StorageCapacity(litres)200 300 200300
HotWaterDelivery(litres)199 295 199295
BoosterElectricGas
Dimensions(mm)

DiameterA568568 568 568
LeighB1534 2186 15342186
ColdwaterinletC137137137137
HotwateroutletD442442 442 442
CollectorhotreturnE291291 291 291
CollectorcoldflowF137137137137
ConnectionspaceG1734238617342386
NetWeightempty(Kg)64856485
NetWeightfull(Kg)264385264385
Cold/tocollector3/4”BSP 3/4”BSP
Hot/solarreturn 3/4”BSP 3/4”BSP
COLLETOR

No.ofTubes1515 1515
Dimensions(mm)
ManifoldLeighH11281128 11281128
CollectorHeight22302230 22302230
ConnectionspaceI12501250 12501250
NetWeightempty(Kg)6767 6767
PipeconnectionDN15DN15
FlowRate(L/min)0.7510.751

15

INSTALLATIONDIAGRAMS

OPEN(DIRECT)CIRCUIT
THEELECTRICBOOSTERSYSTEM
ModelE450U45‐O,E450U30‐O,E340U15‐OandE270U15‐O
E450SH48‐O,E450SH40‐O,E340SH32‐O,E270SH24‐OandE180SH16‐O







16
THEGASBOOSTERSYSTEM

ModelG450U45‐O,G450U30‐O,G340U15‐O,G270U15‐OandG2001‐O
G450SH48‐O,G450SH40‐O,G340SH32‐O,G270SH24‐OandG180SH16‐O




17
GeneralInstallation

PIPING

Plumbingconnectionsandpipearrangementmustbeinaccordancewiththeinstallationdiagramsasnotedin
thismanualandcomplywiththeAS3500.4(inAustralia)andlocalwaterauthorityandbuildingregulations.

Allpipeworkshallbecopperandcompletedinaneatandeconomicallayout,usinglongradiusbendsandless
bendstoensurethattheresistancetoflowratethroughthepipeworkisminimised.Pipeworkshallrun
straightataconstantgrade.

Toreducetheheatlossfromthepipingallhotwaterpipeworkshouldbeasshortaspossibleandneedstobe
insulatedbyArmstrong,Armaflexorsimilarinthicknessof13mm.Theseshouldincludesolarflow‐fromtank
tocollector,solarreturn‐fromcollectortotankandhotoutletfromtankservicetotheend‐user.

Pipeworkshallbeflushedouttoensurenoforeignmatterremainsinandpurgedbeforeattemptingtooper‐
atethewaterheater.Tochecktheleakagefromthejointsthepipeworkshallbepressuretestedto1.5times
theworkingpressureofthesystemor1000kPa,whicheverisgreater.

Approvedflushmustbekeptwhenpipepenetratingtherooftowaterproof.Allpipeworkwithintheroof
spaceshouldbesecurelyclippedtopreventvibration.Drainpipesshouldbeclearofanypossibleobstruction.

Undernocircumstancesshouldplasticpipingbeusedandwillvoidwarrantyiffitted.

Donotpowerupthecontrolleruntilcommissioningasitcontrolsthepump.Thepumpmustonlybeactive
afterthesolarcircuithasbeenfilledwithwater/fluidandairhasbeenexpelled.Thepumpchamberwill
automaticallybleedtheairourafterashortperiodofoperation.

ForindirectsystemtheLongpiperunsshallincorporateexpansionloopsorbendstoallowforthermalexpan‐
sion.Theseshallbeinstalledhorizontallytoavoidformingairlocks.

SOLARCOLLECTORCONNECTIONS

SOLARFLOW–fromtanktocollector/s

Thesolarflowline(fromtanktocollector)shouldbeconnectedfromthebottomofthestoragetankwhere
marked“tocollector”tothe“inlet”ofthecollector/sontheroof.Viaa20mmbrassteepiecethecirculation
pumpfittothetank.Anarrowonthepumpindicatesthewayofwater/fluidflow.Orientthepumpupwardto
ensurethepumpdrawswaterfromthetankandforcesituptothecollectors.Onewayvalve(nonreturnvalve)
shallbefitafterthepumpwiththearrowpointingthesamedirectionasthepumptostopbackcirculation.

Fitthetanksensorintotheteeformeasuringfluidtemperatureatbottomofthetank.Pleaserefertopage15.

SOLARRETURN‐fromcollectortotank

Thesolarreturnline(fromcollectortotank)shouldbeconnectedfromoutletofthecollector/stothemiddle
ofthestoragetankwheremarked“FROMCOLLECTOR”.

Fitthecollectorsensorintothesensorpocketneartheoutletofthecollectorsformeasuringcollector’stem‐
perature.Securethesensorwirebycabletieattachedtothecollector(refertoinstallationdiagram)thesen‐
sorshallbefittedintothelastcollectoroftheflowifafewcollectorsarelinkedinseries.

18

BothsolarflowandreturnlinesshouldbeusedcopperpipeinsulatedbysolarratedArmflexwithminim
13mmwallthickness.

Inlowwaterpressureareas(<350kPa),anairbleedvalveshouldbeinstalledviateeatthehotoutletofthe
collectorinthehighestpointofthesystemtoavoidairblockage.Theairreleasevalvesshallbeleftonthe
openpositiontoensurealltheaircanescapefromthesystem.Toopenthevalve:turnthevalveclockwisetill
tighttoclosethenturnanti‐clockwise3600.Usehandtotunethevalveonly,donotusetools.

TANKCONNECTIONS

Coldwatersupply
Thestoragetankhasapressure/temperaturereliefvalvesetat850kPa.Thecoldwaterinletpressureshould
notexceed650kPa.Apressurereductionvalvemustbefittedadjacenttothecoldwaterinletifthisisnotthe
case.Insomelocationsregulationsrequireapressurereliefvalvebefittedtothecoldwatersupply.Thecold
waterinletis20mmFIandlocatedatthebottomofthetankmarked"coldinlet".Thecoldwaterinletrequires
anapprovedisolating/nonreturnvalve.Asshownintheconnectiondiagrams,thedrainconnectionisincorpo‐
ratedinthecoldwaterexpansioncontrolvalvelocatedatthecoldwaterinletforallthemodels.

Thereliefvalvewilldischargeasmallamountofwaterwhenthesystemisheatingandshouldbechecked
everysixmonths.

Hotwatersupply
Thehotwateroutletfromthetankislocatedatthetopofthetankwith20mmFIwherelabelled“Hotoutlet”.
Allthehotwaterpipesneedtobeinsulatedtopreventheatloss.

AsrequiredbytheNationalPlumbingCode,aninstaller/plumberMUSTfitatemperingvalvetotheheaterto
preventthewatertemperaturegoingtothehomeexceedingapresetsafemaximum.Thetemperingvalve
shouldbeconnectedtothehotwateroutletlines.Thevalvemustbefittedatthetimeofsysteminstallation
orinretrofittingtoexistingsystems.

SOLARCONTROLLER

Thesolarcontrolleroperatesonadifferenceoftemperaturewhichismeasuredbythetwotemperaturesen‐
sors;tanksensor(fittedintobottomofthetank)andcollectorsensor(fittedintocollector).TheSolarcontrol‐
lerturnsthecirculatingpumponoroffaccordingtothe
differenceoftemperaturethathasbeenpreset.The
pumpisautomaticallyturnedonwhenthecollector/s
temperatureisapproximately9°Chigherthanthetank.It
thenisturnedoffwhenthetemperaturedifferentialis
4°C.

Theredifferentialsarepresetat;
Operation9°C=pumpon
4°C=pumpoff
Overheatedprotection;thetanksensorhasbeenpre‐settostopthepumpcirculationwhenitstemperature
gets70°C.
Thesolarcontrollerintegratedwithpumpstationwhichcanbemountedonawallnearthetankoronthe
tank.Caremustbetakentoprotecttheroofsensorwirefromdamagewhereitpenetratestheroof.Please
matchthecolourofplugtothesocketonthecontrollerbox.

Sensorwire

19

PLEASEDON’TWRAPTHEWIREATTACHEDTOTHECOPPERPIPEWITHINTHEINSULATION(ARMFLEX)

Thesolarsensorwirewillneedtoberunwithreturnlinesfromcollectorstotank.Makesurethesensorprobe
isinsertedintothesensorpocketandfixedthepositionbytightenthesensorflange.Makesurethesensor
wireisprotectedfromdamage.Ifthiswireiscutorbrokenitwillneedtoberejoinedsolderedandshrink
sealed.Ensurethesensorwiredoesnotcomeintocontactwithsolarcirculationcopperpipes,asveryhigh
temperaturescanmelttheinsulationofthewirecausingashort‐circuitandcontrollermalfunction.


SystemTemperatures
Solarsystemsareabletoheatthewatertoveryhightemperatures.Thisleadstothefollowingconcerns,

•temperatureofwaterdeliveredfromtaps
Atemperingvalvemustbeinstalledtolimitthewatertemperaturedeliveredatthetaps.Ifthereisalready
oneinstalled,itscorrectoperationshouldbeconfirmedandthevalvereplacedifthereisanydoubtoverits
operationandcorrectfunction.Thefunctionofthisvalveshallberegularlycheckedandbeappropriately
maintained.

•damagetosystemcomponents
Somecomponentsinstalledinconventionalhotwatersystemsarenotcompatiblewiththehightemperatures
experiencedinsolarhotwatersystems.Ofparticularconcernare;

1. Mainspressurehotwatercylinderswhich,unlessmanufacturedspecificallyforuseinhightempera‐
turesystems,havearecommendedtemperaturelimit.Inmanycasesthiswillbebetween70°Cto
80°C.
2.Thespecificationoftheinstalledcylindershouldbecheckedandatemperaturelimitationdevicein‐
stalledtolimitthetemperaturewithinthecylindertowithinacceptablelimits.Thesolarcontrollerhasthis
functionandshouldbeprogrammedtosuit.


PressureandTemperatureReliefValve
Pressureandtemperaturereliefvalve(850kPa,10kw)andOutletteemustbescrewedtoP&Tvalveofthetank.
Adrainpipemustbefittedtothereliefvalvetolettheexcesspressureandtemperatureescapewhenthesys‐
temisheated.Thepipeworkfromthereliefvalvetothedrainshouldbeasshortaspossible,andfallallthe
wayfromthewaterheaterwithnorestrictionsandfrost‐free.Itshouldhavenomorethanthreerightangles
bendinit.Theoutlineofthedrainpipemustbeinsuchapositionthatflowoutofthepipecanbeeasilyseen
butthedischargewillnotcauseinjury,damageornuisance(refertoAS3500.4).

ELECTRICALCONNECTIONS

ElectricalconnectionsmustbeinstalledinaccordancewithAS3000SAA
wiringrules(inAustralia)andlocalcodes.Alltheelectricalworkmustbe
undertakenbyaqualifiedelectrician.Allsolarhotwatersystemsrequire
apoweroutlettorunthepump.Whenusingthegasboosteranaddi‐
tionalpoweroutletwillbeneeded.

ElectricBooster(forEseriesonly)
Alltheelectricboostersystemsarefitthesameelements 
3.6kW15AMP
Elementsareboltontype:


20
Theaboveisaguideonlyandsubjecttolocalelectricalauthorityandcustomerrequirements.

THERMOSTAT
Anadjustablethermostatisfittedandpresetat600C.Thiscanbeadjustedtosuitindividualrequirements.Ifa
highertempisrequiredboththethermostatandthecontrollerboostprofilemustbechangedaccordinglyand
pre‐approvedbySolarLord.

CABLE
Connectiontotheelementisviatheentryholeoftheelectricalboxatbottomofthecover.Removethein‐
spectioncoverandconnectactive,neutralandearthwiresasmarked.Theconnectiondiagramprovidedinside
ofthecover.Electricalcablesshouldbeclosedinweatherproofconduitandfittings,whererequired.Asepa‐
ratesupplycablefromtheelectricalmeterboxtotheboosterelementandoffpeakelementsshouldbein‐
stalled.Onlyuseelectricalcable/wiringwithatemperatureratingof>106°Ctoinsidetheappliancebox.

SWITCHES
Anon‐offswitchforthesolarsystemshouldbeinstalledinthemeterbox.Anexistingunusedon‐offswitch
maybeusedprovideditisofthecorrectcurrentratingandisinsoundcondition.

GASCONNECTIONS

GasBooster(forGseriesonly)

SolarLordgasboosterisaninstantaneousgasheaterdesignedforexternaluseonly.Thecoldinletof
thegasheatershouldbeconnectedtohotoutletofthesolarstoragetankDetailsshowatpage15.

