Solarbeam SB-300-D-HP User guide

Solar Beam Warranty Policy-Rev2_January 2016
SOL RBEAM
A MEMBER OF THE MSAT GROUP
est.1978
SOLARBEAM
300Litre HIGH PRESSURE
SOLAR WATER HEATER
OWNER’S HANDBOOK

Solar Beam Warranty Policy-Rev2_January 2016
Noce:
This document is the property of Solarbeam (PTY) Ltd. All rights of the copyright are reserved
by Solarbeam. This document should not be reproduced without the wrien consent of the
directors of Solarbeam. We also reserve the right to change any informaon on this document
without any prior warning. It is the user’s responsibility to ensure that the correct level of the
document is used.
Solarbeam does not accept any responsibility for any loss or damage suered arising from any
errors or omissions.
Solarbeam will ensure that the installaon is carried out by a representave of the company
and will be qualied and accredited as required by the authories. This hand book is wrien
as a guide line to the installaon and not a step by step installaon instrucon.
Liability Waiver:
Solarbeam reserves the right to cancel all warranes and guarantees, if the installaon or
any form of maintenance is not carried out by a competent person. Improper installaon can
cause damage to the Solar System and personal injury.
2
Prepared By: Vijay Naidoo
Date: 13/02/2016
Version: SBOM001

Solar Beam Warranty Policy-Rev2_January 2016
1. Introducon.......................................................................................................................4
2. Thermal Properes............................................................................................................5
3. Health and safety...............................................................................................................5
3.1. General...............................................................................................................................5
3.2. Installaon consideraons.................................................................................................5
3.3. Solarbeam Thermosiphon System ..................................................................................7
4. Indirect Systems: Freeze resistant: ..................................................................................7
5. Scale resistance.................................................................................................................7
6. System, placement and orientaon..................................................................................8
6.1. Collector orientaon..........................................................................................................8
6.2. Shading..............................................................................................................................8
6.3. Tilt Angle............................................................................................................................8
7. Water supply / delivery......................................................................................................9
8. Roof structural integrity.....................................................................................................9
9. Mounng methods...........................................................................................................10
9.1. Selecon of appropriate mounng method....................................................................10
10. System Installaon............................................................................................................10
10.1. General installaon technique.........................................................................................10
11. Systemplumbing..............................................................................................................11
11.1.General.............................................................................................................................12
12. System descripon...........................................................................................................12
12.1. Basic operaon.................................................................................................................12
12.2.Collector:..........................................................................................................................13
12.3. Main Tank........................................................................................................................14
12.4. Frame Error! Bookmark not dened...............................................................................14
12.5 Fings:.............................................................................................................................14
12.6. Draincock:.........................................................................................................................14
12.7 Electrical connecon:.......................................................................................................14
13. System commissioning.....................................................................................................15
13.1. Commissioning direct systems.........................................................................................15
14. Installaon checklist.........................................................................................................15
15. ContactDetails..................................................................................................................16
15.1. SOLARBEAM (Pty) Ltd......................................................................................................16
15.2. Warranty Contact Centre..................................................................................................16
16. Idencaon Plate............................................................................................................17
17. CustomerDetails..............................................................................................................17
Contents
3

Solar Beam Warranty Policy-Rev2_January 2016
4
1. Introducon
All Solarbeam solar hot water systems are high quality thermal solar systems, using advanced
technology to convert sunlight into heat. This installaon manual must be read and under-
stood before undertaking the installaon of a Solarbeam solar hot water system. Should any
aspect of the installaon process remain unclear a Solarbeam Solar representave should be
contacted for advice prior to installaon.
This manual does not seek to provide comprehensive guidance in terms of the general plumb-
ing and electrical connecon of SWH Tanks, which is assumed knowledge required of any reg-
istered installer, but rather sets out to provide guidance in terms of the correct installaon of
the solar thermal components of the system.
Systems must be installed by suitably qualied and registered plumbers and electricians, in
accordance with relevant South African Norms and Standards, Naonal Building Regulaons,
Laws and Regulaons, Local By- Laws, including the following:
SANS 198 - Funconal control valves and safety valves for domesc hot and cold water supply.
SANS 10106 - The installaon, maintenance, repair and replacement of domesc solar water
heang systems, edion three.
SANS10252 - Water supply and drainage for Buildings.
Part 1: Water supply installaons for buildings.
SANS 10254 - The installaon, maintenance, replacement and repair of xed electric storage
water heang systems.
SANS 10142 - The wiring of premises. Part 1:Low-voltage installaons.
SANS 10400 - Parts A, B, L, XA.
Occupaonal Health and Safety Act (Act 85 of 1993)
Naonal Buildings Regulaons 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 sta are familiar with and
competent in respect of the above. Responsibility for the safe and proper installaon of a sys-
tem rests with the installer.
The solar hot water systems referred to herein must be installed in accordance with these
instrucons, local and naonal plumbing regulaons, municipal building codes and any other
relevant statutory regulaons.
All intellectual property in this design and/or registraons and/or copyright including any pat-
ent, patent applicaon remains the property of Solarbeam (Pty) Ltd.

Solar Beam Warranty Policy-Rev2_January 2016
5
2. Thermal Properes
The thermal performance of the systems have been established by the South African Bureau
of Standards in terms of SANS 6211, at an incoming radiaon of 16MJ per m² per day, a tem-
perature dierenal of 10°C and at an inclinaon of latude plus 10°.
The Q-factor is calculated in mega-joules whereas the energy rang is calculated in kilo-wa
hours. The energy rang is calculated by converng the q-factor into kwh. The specic thermal
capacity of the Solarbeam collector is 4.39KJ/K m².
Product
Code
Capacity
(litres)
Element
Rang (Kw)
Operang
Pressure
(Kpa)
Solar Con-
nectors
Male (mm)
Q-Factor Energy Rat-
ing (KwH)
SB-300-
D-HP
300 2 400 22 12.3 >6.0 per m²
3. Health and Safety
3.1. General
This appliance is not intended for use by young or inrmed persons without supervision.
Scalding occurs at 50°C. This appliance is capable of providing hot water over this tempera-
ture. In certain circumstances the system may expel hot water and relieve pressure through
the temperature pressure valve. Never block this valve and always leave open to the atmo-
sphere. Take care to avoid contact with water when valve is in discharge.
This appliance is a water heang apparatus only and the nal quality of water and tness for
consumpon is dependent on the quality of water supplied to the system.
These systems are designed for the supply of hot water to domesc household premises which
have been constructed to the appropriate local and naonal codes and regulaons.
3.2. Installaon consideraons
All installaons are to be carried out in accordance with the Occupaonal Health and Safety
Act (Act 85 of 1993) requirements and any relevant local authority prescripons. Some gener-
al points to take note of, however, include the following:

Solar Beam Warranty Policy-Rev2_January 2016
6
• Assess site specic risks and eliminate or reduced to an acceptable level so as to sasfy
health and safety requirements, prior to installaon.
• Water temperature can reach boiling point and the collector can reach stagnaon tem-
peratures of over 70°C. Shade collectors during installaon to prevent heang.
• Take care when handling collectors to prevent breakage to glass and injury. Safety goggles,
work wear and gloves must be used to reduce risk of injury.
• Be aware of overhead power lines coming in through roofs, as well as electrical wiring run-
ning through ceilings.
• Assess weather and postpone roof work if unsafe (e.g. high winds, rain, lightning, etc.).
• Scaolding and safety equipment must be installed by cered personnel and signed-o
accordingly. Inspect before use.
• Inform home owners or building occupants of me and place of work to be carried out.
• Ensure occupants are aware of site access constraints and all health and safety implica-
ons relevant to them. Cordon o the area, if applicable, to prevent personal injury and
ensure any pets are secured.
• Ensure personnel working on installaon are competent and in suitable physical condion.
Installers must be trained and conversant with the assessment of height hazards, working
at height safety procedures, assessment of safety equipment (e.g. scaolding, harnesses,
etc.) and the use and wearing of safety equipment (e.g. goggles, hard hats, gloves, etc.).
• All personnel working on the installaon of a solar hot water system must be issued with
the appropriate safety equipment and be trained in their use.
Failure to observe safe pracces may result
in:
• scalding / burns;
• electrical shock;
• and/or falling,
which can cause serious injury or death.

Solar Beam Warranty Policy-Rev2_January 2016
7
3.3. Solarbeam Thermo-siphon System
A thermo-siphon can be close-coupled or split as illustrated
below, provided there is sucient roof space. A thermo-si-
phon system relies on the natural circulaon of uid between
the collector and the geyser. In order for the thermo-siphon
process to occur the geyser must be placed in a higher posi-
on than the solar collector. The system operates according
to the laws of thermal dynamics (i.e. a liquid, when heated,
becomes less dense and rises above the denser cooler liquid).
Heated water rises up through the collector and into the gey-
ser, displacing colder water therein, which sinks to the header
pipe of the Solarbeam collector. The process connues unl
the collector can add no more gain in temperature or unl
the sun stops shining. Without sunlight the water in the collector header pipe cools, becomes
denser, prevenng hoer liquid in the geyser from being displaced.
4. Direct Systems: non-freeze resistant:
In direct systems the water to be used in the household circulates through the collector, trans-
ferring solar energy into the solar geyser.
Direct systems are used in frost-free locaons, where ambient temperature never falls below
5°C and where water quality is good (i.e. less than 600ppm total dissolved solids/minerals).
5. Scale resistance
Indirect systems containing a glycol soluon also prevents scale build up inside the collector in
areas of poor water quality. It is important to note that the geyser itself may sll be aected
by water quality as would be the case with any convenonal enamel-lined geyser unless a So-
larbeam Epoxy-lined geyser is used.
If a direct system is used in areas of poor water quality the pipe work inside pracce regardless
of type of system, as the water will aect 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 ushed with a mildly acidic soluon (e.g. vinegar soluon)
and in the case of the Solarbeam collector, the Header Pipe should be ushed. The pipe work
should then be ushed with fresh water aer removal of scale prior to re-commissioning.
Ensure you are familiar with the relevant tank manufacturer’s warranty terms and condions
in respect of water quality, parcularly as it relates to anode replacement in case of enam-
el-lined tanks.

Solar Beam Warranty Policy-Rev2_January 2016
8
6. System, placement and orientaon
A number of basic fundamentals need to be observed when installing any solar hot water
system.
6.1. Collector orientaon
Opmum system performance is achieved when the col-
lectors face directly North (i.e. true North) when installing
in the Southern Hemisphere. The closer the collector is to
directly facing the equator the greater the amount of solar
radiaon the collector will be exposed to and the greater
the potenal for heang.
Angles up to 45° either side of North will not have a major
eect on the system performance given the state of the art
technology used in the construcon of the Solarbeam sys-
tems. Therefore, roofs that are orientated away from North
are also acceptable for installaon.
Outside of the 45° range one could consider ulizing more
collector surface area or using a mounng frame to adjust the orientaon back to North.
6.2. Shading
With a system orientated to face North, the me period when the collector is exposed to
the most direct solar radiaon is between 10h00 and 16h00.
Solar collectors with an East bias will achieve a greater gain in morning hours and those
with a west bias will do so in the aernoon.
Care should be taken to ensure that the collectors are not subjected to
excessive shading from trees or adjacent buildings, parcularly between 09h00 and
16h00.
Also bear in mind that tree growth could lead to future shading issues.
If the installaon takes place in summer, it is also important to take into account the lower
solar angles in winter, which result in longer shadows.
6.3. Tilt Angle
In respect of the opmum angle of inclinaon for a solar collector, the rule of thumb
provides that the latude of the locaon is taken and then 10° added thereto. Therefore,
a locaon with latude of 25° would indicate an opmum collector lt angle of 35°. The
angle of inclinaon, however, is also exible and minimal loss of performance occurs by
installing at lower or higher angles of inclinaon.
The Solarbeam collector can be installed as low as 10°. Below this, however, the ther-
mo-siphon process does not funcon eecvely. Also, angles lower than this would result
in build-up of dust, as it is not able to be washed away eecvely by rainfall.
It must also be noted that installaon angles over 30° will require addional strapping to
secure the geyser and collector during and aer installaon, as at this angle the system
will tend to move downward. Consideraon should be given to a split installaon in these
circumstances.

Solar Beam Warranty Policy-Rev2_January 2016
9
7. Water supply / Delivery/Quality
The locaon of the installaon should give as ecient a supply of hot water to all areas of the
residence as possible. If not possible, the system should be placed as close to its main point of
usage (e.g. master bathroom).
Discuss this with the client and conrm their understanding and requirements.
The quality of water varies from Municipality to Municipality and therefore it is recommended
to replace the sacricial anode as per the below table.
Total Dissolved Solids (PPM) Recommended Anode Replacement
100-600 3 years
601- 1000 2 years
over 1000 1 year
8. Roof structural integrity
The area chosen for installaon must be structurally capable of handling the loading. Check
load weights of applicable system and ensure that the weight can be borne by the roof struc-
ture. Specialist advice should be sought if required.
The system should be placed, such that the tank spans at least three main trusses. It is good
pracce to brace all truss work that supports the installaon.
Strengthen raers (or mbers or other structures) used for supporng the panel and tank, for
example by adding noggins between raers or adding thicker mbers alongside them or cross
bracing them or adding addional supporng struts to the truss to spread the addional load
to a load bearing point. Where ever possible the system should be installed over a supporng
wall of the building (i.e. on a truss resng on a supporng load bearing wall). Never install a
system on a roof with damaged or rong mbers.
To prevent cracking of certain ber cement and metal roof sheeng, a at mounng frame
designed to spread the load of the geyser and its contents should be designed by suitably
qualied personnel and installed below the geyser. Ensure that the roof covering material is
structurally sound to receive the weight of the system. In the case of a split system installaon
a wooden frame should be constructed which raises the tank above the level of the collectors.
Care should be taken in the design and construcon of this frame so as to ensure it meets all
relevant standards.

Solar Beam Warranty Policy-Rev2_January 2016
9. Mounng methods
9.1. Selecon of appropriate mounng method
Please note that it is the installer’s responsibility to ensure that the means of xing the system
to the roof such that it results in a safe and funconal installaon.
The methods suggested are generic and will not necessarily be suitable in all situaons.
*Straps are not included as lengths required will dier from installaon to installaon. These
should be galvanised steel, aluminium or stainless steel.
**Please note that two hanger brackets are required per collector. The 300L system using two
collectors require 4 hanger brackets (two per collector).ocedu
10. System Installaon
10.1. General installaon technique
During ng and prior to lling, the system must be protected against the entry of dirt and
water. Aer the system has been mounted, it must be ushed in order to remove any debris
(e.g. metal chips, packaging residue, sawdust, etc.).
Shade panels unl aer connecng plumbing and installaon is ready for commissioning in
order to prevent heang of empty collector.
Exercise cauon during the liing phase of installing the collector and tank onto the roof. En-
sure that adequate personnel are present to bear the weight and that they are assisted with
supporve liing tethers and safety rigging.
With reference to secon 6 above, measure the size of the collector, and use measurement
to locate the best posion on the roof to ax panels, matching measurements to supporng
roof trusses and purlins. Avoid interference with coping or guers.
A minimum distance between the top of the panel and the tank ow outlet is 300mm. In split
system installaons distances should be kept as short as possible and generally should not
exceed 3 metres.
For roof pitches above 30°, special and/or extra strapping or brackets may be required to pre-
vent downward movement of the tank and collector.
10
Flat Roof Installation Inclined Roof Installation

Solar Beam Warranty Policy-Rev2_January 2016
11. System plumbing
11.1. General
Plumbing must conform to IOPSA code, SANS, PIRB and local regulaons.
In a thermo-siphon system the geyser is installed above the panel, but kept as close as possi-
ble.
All piping runs should be kept as short as possible, both between the collector and tank, as
well as between the tank and the locaon of hot water usage (i.e. bathrooms).
All pipework must be properly insulated, including at least two metres of the cold feed to and
hot supply from the geyser. Insulaon material must be heat tolerant and UV resistant, nor
must it unduly compress or cause corrosion.
Piping from the ow of the tank to the inlet at the top of the collector must have a connuous
fall and from the top of the collector to the return must have connuous rise.
Only hard-soldered connecons or compression ngs are to be used in the assembly of the
solar heang circuit. No uxing agents containing chloride should be used.
Use copper pipe only. Plasc pipe must not be used due to the eects of high water tempera-
tures and pressures. The pipe work to and from the geyser must also be copper for at least two
meters below the hot water outlet.
A temperature mixing valve must be used to control the temperature of water delivered to
the points of use. This is important in the prevenon of accidental scalding and is a SANS re-
quirement.du
11
Measure the exact size of your tank and use this to locate the best posion on the roof at
which to ax tanks to supporng roof trusses and purlins.
If necessary, strengthen raers used for securing the panel and tank, for example by adding
noggins between raers or adding thicker mbers alongside them.

Solar Beam Warranty Policy-Rev2_January 2016
12. System descripon
12.1. Basic operaon
Solarbeam water heaters ulize state of the art materials to ensure high ecient heat trans-
fer from the sun to the water in a wide variety of weather condions. Heat generated by the
collector is directly related to the amount of sun energy onto the Collector. The Solarbeam
No Pressure solar water heaters are complete on the roof systems whereby the water storage
tank and solar collector are mounted on the roof as a complete system.
12.2. Collector:
Solarbeam Collector:
The Solarbeam Flat Plate Collector is 100% locally produced and patented.
Flat Plate
Copper Risers
Aluminium Housing
4mm Tempered Glass
(Hail Resistant)
12

Solar Beam Warranty Policy-Rev2_January 2016
12.3. Main Tank
The solar water tank is a high pressure tank and acts as storage and circulaon reservoir for
the water. The tank is placed above the at collector and the cold water enters the collector
and the hot water exits the collector through the process of thermos-siphon (hot water rises)
and enters the storage tank and is commonly known as the potable water. The hot water is
ready for use. In a low pressure system it is not recommended to connect to the household’s
hot water reculaon system, it should rather have one outlet for water collecon.
Size: 300 litre
Inner cylinder: welded stainless steel inner cylinder.
Insulaon: 45mm closed cellular, non-biodegradable Polystyrene moulded jacket (k-factor
0,036w/m²/cº)
Outer casing: Galvanized sheet metal.
Outer casing: Galvanized sheet metal.
Tank: Stainless Steel inner tank – Grade LDX 2101 Duplex
45mm Polystyrene Moulded Insulaon
Galvanised Casing
Flat boomed Tank for increased stability
Flat boomed Tank for increased stability
13

Solar Beam Warranty Policy-Rev2_January 2016
SOLARBEAM Geyser tanks are ed with SABS approved peripherals.
All pipes and ngs must comply to the applicable SANS standards.
12.4. Pipes, Fings, Pressure & Safety Valves
NO Descripon Make & Model Size Manufacturer SANS Standard
1Vaccum breakers KHN 4.200 CX 22MM Kwikot SANS 198
2 Non Return Valve INDN - 20 22MM Kwikot SANS 198
3 TPV 400kpa ML KHI . 404 CXM 22MM Kwikot SANS 198
4 PRV 400 kpa PA 4 - 332 22MM Cobra SANS 198
5 Gate Valve FI DN - 20 22MM Maksal SANS 198
6Expansion Relief KH2 . 206 22MM Kwikot SANS 198
7 Draincock Double
MI
KH 5.002 22MM Kwikot SANS 1808-53-2012
8Draincock Single
MI
KH 5.002 22MM Kwikot SANS 1808-53-2012
9Conex Elbow 90°
c/c
COX - ELB - 0100 22MM Maksal SANS 1067 -1/2:2005
10 C o n e x E l b o w F I COX - ELB - 0200 22MM Maksal SANS 1067 -1/2:2005
11 Str Coupler MI COX - STM - 0100 15MM Maksal SANS 1067 -1/2:2005
12 tr Coupler MI COX -STM - 0200 22MM Maksal SANS 1067-1/2:2005
13 Str Coupler FI COX - STF - 0200 22MM Maksal SANS 1067-1/2:2005
14 Conex Str.Coupler COX - STR - 0200 22MM Maksal SANS 1067-1/2:2005
15 Conex Str.Coupler COX - STR - 0100 15MM Maksal SANS 1067-1/2:2005
16 Conex Equal Tee COX - TEE - 0200 22MM Maksal SANS 1067-1/2:2005
17 Delcop elbow 45 004 - 22 - 0100 22MM Maksal SANS 1067-1/2:2005
18 Delcop elbows 90 005 - 22 - 0100 22MM Maksal SANS 1067-1/2:2005
19 Delcop tee's 007 - 22 - 0100 22MM Maksal SANS 1067-1/2:2005
20 Conex Reducing
end Tee
COX - RTE - 0400 22MM Maksal SANS 1067 - 1/2 :2005
21 Ball o stop DN - 20 22MM Maksal SANS 1240
22 Copper Tubes DOLO 460/0 22MM Maksal SANS 460
13

Solar Beam Warranty Policy-Rev2_January 2016
13. System commissioning
13.1. Commissioning of Indirect Systems
Make sure that the solar radiaon is low during lling. In strong radiaon it is possible for
steam to form in the collector. Keep the collector covered throughout installaon and com-
missioning.
Do not turn on the electric backup unl the tank has been lled with water.
Turn on at least one hot water outlet tap and open the mains water supply to allow the water
to ll the tank and collector, expelling air from the tank. As soon as water ows freely, without
air spuer, close the tap and allow the cylinder to pressurize.
Glycol soluon: The soluon must be (food grade) 30% Propylene Glycol. The Glycol soluon
protects against any risk of the panels freezing or bursng in inclement weather condions.
The Glycol soluon must be tested every 2 years for deterioraon and must be replaced if not
to specicaon.
Check all piping, joints and ngs for water leaks.
Check pressure relief valves to ensure correct operaon.
Turn on the electric backup element. Make sure the tank is completely lled before turning on
the element. Ensure power is available to the backup element.
14. Installaon checklist
The following checklist should be observed by the installer before handing the system over to
the owner/user.
• All air bled from taps
• System checked for water leaks
• Cold and hot water pipes checked for leaks
• Roof les back in posion
• Roof ashing waterght
• Drain pipes free of obstrucon
• Pipe work insulated
• Electrical element, mer switch, isolator and thermostat, controller and pump checked
• Any protecve plasc or packaging sckers removed from tanks and/or collectors
• Owner instructed on use
14

Solar Beam Warranty Policy-Rev2_January 2016
15. Contact Details
15.1. SOLARBEAM (Pty) Ltd
Physical Address:
480 Chris Hani Road
Briardene
Durban North
Postal Address:
PO Box 20228,
Durban North
4016
Tel: [phone]
Fax: [phone]
Email: [email protected]o.za
Email: [email protected]
Website: www.Solarbeam.co.za
15.2. Warranty Contact Centre
Telephone: [phone]
Website: www.solarbeam.co.za
Email: [email protected]o.za
15

Solar Beam Warranty Policy-Rev2_January 2016
16. Idencaon Plate
Manufacturer's Name Solarbeam (Pty) Ltd
e Working Pressure 400Kpa
Model Number SB-300-D-HP
Aperture Area 2.5m²
Fitted with Hail Cover No
Freeze Protection Non-Freeze
Material of Fluid Channels Copper
Material of Collector Cover 4mm Low Iron Tempered Glass
Heat Transfer Fluid None
Energy Rating > 4.5 KwH per m² per day
17. Customer Details
Name
Address
Telephone Numbers
Home
Business
Cell
Date of Installaon
Model
Serial Numbers
Panel No1
Panel No2
Storage Tank
Expansion Tank
Guarantees
Solar Panels 10 year
Storage Tank 10 year
16

Solar Beam Warranty Policy-Rev2_January 2016
SolarBeam (Pty) Ltd
Head Oce: 256 Kent Avenue
Randburg. Johannesburg, 2125
Factory: 480 Chris Hani Road
Briardene, Durban 4015
Call: 0860SOLARBEAM
OFFICE: 011 068 9300
EMAIL: [email protected]
WEBSITE: www.solarbeam.co.za
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