Sudarshan Saur ETC User manual

USER MANUAL
EVACUATED TUBE COLLECTOR
SOLAR WATER HEATER SYSTEM
ETC
210 MMX297MM
SOLAR WATER HEATER
Sudarshan Saur Shakti Pvt. Ltd.
K-240, M.I.D.C. Waluj, Aurangabad - 431 136, Maharashtra, India.
Toll-free: 1800-233-4545 | www.sudarshansaur.com | [e-mail]
SOLAR WATER HEATER

SOLAR WATER HEATER
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WELCOME
Dear Customer,
Congratulations!
You are now a proud owner of a world-class solar water heating system by
Sudarshan Saur.
You have purchased the Evacuated Tube Collector System (ETC). It is a
world-renowned product and has been introduced for the first time in India by
Sudarshan Saur with technical collaboration from abroad.
The ETC System (Wonder Series) has been created in our magnificently fitted out,
technically sound unit, under the strictest of quality control standards.
Before installing your solar water heater, kindly go through this user manual, so that
you get an idea as to how best to use your new product.
We at Sudarshan Saur have a variety of applications for a wide range of users. Be it
houses, hospitals, hotels, industries, or anywhere else, you’ll find that we are able to
provide you with the solar water heater that is ideal for your institution.
All important information regarding such applications has been covered in this
manual. Plus you can also get a clear idea of the principles and technologies that go
into creating our products.
If you still have any queries or would like to talk about any inconvenience to the
system, or our service, then please get in touch with us on our Customer Care number.
Yours sincerely,
Managing Director,
Sudarshan Saur

1. Introduction........................................................................................................... 01
2. Working Principle.................................................................................................. 02
3. Components .................................................................................................03 - 04
4. Site Requirements.................................................................................................05
5. Plumbing Connection: Automatic Mode.............................................................. 06
6. Plumbing Connection: Series Mode..................................................................... 07
7. Plumbing Connection: Dual Mode........................................................................08
8. Plumbing Connection: Heat Pipe Model.............................................................. 09
9. Hot Water Line: Automatic Mode......................................................................... 10
10. Hot Water Vent: Automatic Mode......................................................................... 11
11. Operational Hints............................................................................................12 - 13
12. Troubleshooting Guidelines.................................................................................. 14
13. Customer Feedback.............................................................................................. 15
Page No.
SOLAR WATER HEATER
INDEX

Our Mission
The Sun is the powerhouse of the universe. It is the ultimate source of energy for the
Earth and it is the only source of energy which can be harnessed completely, without
disturbing the natural cycle of life.
We at Sudarshan Saur have made it our mission to harness this divine source of
energy for the well-being of mankind.
Ideal for Indian Society
The Evacuated Tube Collector (ETC) systems from Sudarshan Saur are specially
designed to satisfy the needs of Indian households. They are highly economical,
require low maintenance, are cost-effective, and most importantly, they help to reduce
the increased load on traditional means of power such as electricity, LPG and
firewood. Since they can be installed in areas having minimum space requirements,
they are the perfect appliance for your home.
INTRODUCTION
USER MANUAL - ETC SYSTEM
1

The Sudarshan Saur ETC system works on a Black Body Heat Absorption Principle.
The principle states that black colour absorbs maximum heat, more than any
other colour.
The system uses vacuum tubes made of borosilicate glass with a special coating to
absorb solar energy.
Air inside the gap between two glass tubes is evacuated which results in a high level of
vacuum, which acts as th e best insulation to minimize heat loss from the inner tube.
The black coating transfers this heat to the water. The water on the upper side of the
vacuum tube becomes hot and thus lighter, and starts moving upwards in the tank.
At the same time, cold water, which is heavier, comes downward from the tank and is
stored at the bottom. This phenomenon is called as natural thermosyphon
circulation, which occurs in every tube.
2
Hot Water
Tank
Cold Water
Inner Glass Tube
Outer Glass Tube
Vaccum Tube
(Cross-sectional View)
SOLAR WATER HEATER
WORKING PRINCIPLE OF ETC SYSTEM

Inlet
Vacuum
Tubes
South
Stand
Outlet Tank
A) 3 T Evacuated Glass Tubes:Evacuated glass tubes are the main component of the
ETC system. They are made by assembling two concentric borosilicate glass
tubes. The outer surface of the inner tube is coated with Cu/SS-ALN by an
innovative coating technology called ‘magnetron sputtering technique’. A special
selective black coating absorbs maximum energy from the sun and loses
minimum energy. Since the evacuated tubes are round, sun rays fall on them at
an angle, and they are able to absorb solar radiations all day long.
B) Water Storage Tank: The storage tank is designed on the basis of different system
capacities. It is made from special grade stainless steel (SS-304) or special grade
anti-corrosive thick metal sheet with special non-stick food grade coating or glass
coating. The tank is covered with high-density PUF or Rockwool insulation, which
keeps the water hot overnight. This insulation is again laden with an outer
pre-coated G.I. cover.
The ETC system has the following components:
3
USER MANUAL - ETC SYSTEM
COMPONENTS

C) Manifold (for bigger systems): Manifold is used to hold the array of vacuum
tubes on either side, for systems of higher capacity (from 500 LPD upwards).
The assembly of tubes is covered with high quality PUF insulation, ensuring low
conduction and convection loss to the atmosphere. This insulation is again
laden with pre-coated G.I. cover to protect the in-built structure from the external
atmosphere. This makes the system compatible, efficient and economical.
D) Stand: The Stand is made of sturdy steel sections and G.I. powder coated (pure
Polyester) folded angles, so as to support all components of the system. It is
designed to take the load of the hot water storage tank (especially during
storms). The stand is supplied in various parts, which need to be
assembled on site.
E) Other Components: There are various components like seals, grommets, Tube
Bottom Support and other fasteners required, before the entire system can be
assembled.
Tank
Hot Water
Outlet
Cold Water
Outlet
Stand
Manifold
4
SOLAR WATER HEATER

a. Cold Water Head: You would require a cold water supply from the level above the
tank of your system i.e. the bottom of the cold water tank should be at least
4.5 feet (for systems up to 300 LPD) above the installation platform of ETC system.
b. Water Hardness: There are two different systems for soft water and hard water. And
depending on your system type, it will work differently according to your
requirement.
c. Area: This varies for systems with different capacities e.g. a 100 litre system
requires approximately 6’x 6’ area.
d. Orientation: System should face the south direction. If there is any limitation on
site, a variation of + or - 10° from south can be allowed, as it has minimal effect
on system performance.
e. Minimum Hot Water Line: The solar water heater must be installed at a place which
is easily accessible to the point in the home where hot water is to be used.
f. Place of Installation: The system can be installed directly on an RCC slab or on a
tapered roof, facing south. It can also be done on an open ground with a proper
foundation, a balcony or on a wall with proper structural support.
g. Shadow-free Place: The selected place should be free of shadows, as much as
possible, so as to receive clear sunshine from all angles, all through the day.
USER MANUAL - ETC SYSTEM
5
SITE REQUIREMENTS

This method of plumbing will work when there is a drop in temperature, due to mixing
of cold water in the tank. The ETC system needs to be of a sufficient capacity to hold
this water. The best part is, you won’t have to operate the gate valve every day to fill
the system to use hot water.
Air Vent
Outlet
Air Vent
Gate Valve
Inlet /Cold Water Line
Cold Water
Storage Tank
Hot Water
Storage Tank
6
SOLAR WATER HEATER
PLUMBING CONNECTION:
AUTOMATIC MODE

Gate
Valve
Air Vent Air Vent Air Vent
Hot Water
Storage Tank
Cold Water
Storage Tank
Hot Water
Storage Tank
This is suitable if you are residing in a cold region or if you have a large number of
family members utilizing hot water facilities at home.
Two systems of equal capacities are connected in a series, e.g. if your hot water
requirement is 150 LPD, then two systems of 150 LPD (150 x 2 = 300 LPD) would
vbe installed. The operation for this system is similar to the automatic mode type of
plumbing connection.
Water in a system gets heated for a couple of days. As you use the hot water from the
main system which has an outlet that is connected to your hot water tap, pre-heated
hot water from the other system moves into the main system and again gets heated
for one whole day.
Since water gets heated twice, you have the twice the amount of hot water during
winter season or in cold regions.
7
USER MANUAL - ETC SYSTEM
PLUMBING CONNECTION:
SERIES MODE

This is an alternate arrangement of plumbing, if you want to operate the valve in winter
or on cloudy days. You must close the cold inlet gate valve 1 and open gate valve 2
of the optional pipeline. After hot water has been utilized, make sure to fill water in the
storage tank.
This plumbing connection is highly recommended if you have purchased the
Wonder Standard (SS) model or Wonder Ultimate Glass Lining (GL) model.
Gate Valve 2
Air Vent
Over Flow Piping
Air Vent
Hot Water
Storage Tank
Cold Water
Storage Tank
Gate
Valve 1
Spray Outlet
Hot Water Outlet
Basin
Check Valve
Ball Valve
Cold Inlet
8
PLUMBING CONNECTION:
DUAL MODE
SOLAR WATER HEATER

This plumbing connection is only recommended for the Heat Pipe Model, also called
Wonder Ultimate: Pressurized Series.
This system is designed for bungalows and homes that use pressure pumps for high
water pressure requirements.
PLUMBING CONNECTION:
HEAT PIPE MODEL
USER MANUAL - ETC SYSTEM
9
Hex Ripple
T
Pressure Release Valve
Air Release Valve
Gate Valve
Gate
Valve
Pressure Pump
Mixing Valve
Mixing Valve
Spray Outlet
Other Applications
Water Inlet

a) This table must be strictly followed to know about the size and length of the hot
water line:
b) Insulation of Hot Water Line: Insulation may not be needed if the line size and
length are kept minimal, as stated in this table. This is applicable because, in most
parts of India, the temperature generally does not go below 10°C. However, it is
recommended to insulate the hot water line as per standard procedure.
c) Gate Valve: This must be provided in the hot water line, immediately after the
system outlet port, to help during system maintenance. Separate cold water Iine
must be laid down for the solar water heating system.
Cold Water Line:
If the cold water line is not separate and tapped from the main line going to other
points, the hot water which comes back might mix with the cold water and the system
will not function properly. Even a non-return valve should not be used while
establishing such connections. Gate valve must be provided in inlet line to help during
system maintenance. Size of cold water line should be equal to the main port of the
hot water line.
100 ETC 10 1/2” 1
150 ETC 10 1/2” 1
200 ETC 10 1/2” 2
250 ETC 10 1/2” 2
300 ETC 10 3/4” 2
500 ETC 20 3/4” 2
ETC System
Ratings
Max
Length Mtr. Line size Using Points
10
SOLAR WATER HEATER
HOT WATER LINE: AUTOMATIC MODE

Duly insulated vent pipe must be provided immediately after the outlet port of your
solar water heating system. The height of the vent pipe must be at least one foot
above the top level of the cold water supply tank.
The outlet line must be brought downward up to floor level and must be clamped or
grounded with the floor, so that the vertical load of vent pipe is transferred to the
ground. This will eliminate any chances of damage to system tank due to vent
pipe load.
11
USER MANUAL - ETC SYSTEM
HOT WATER VENT: AUTOMATIC MODE
Clamped to
Ground

1) Always ll cold water in your tank: Especially do this in the
morning, because doing so during afternoons might cause
the glass tubes to crack, due to a sudden change in
temperature. Although the tubes have been designed to
take this pressure, yet it is a point to be careful about.
2) Cleaning of Tubes: Outer surface of glass tubes must be
kept clean by frequently removing any kind of dust that
accumulates on it (twice a month is ideal).
3) Shadow-free Place: Remove any objects obstructing the
sun's rays in reaching the absorber panel by forming
shadows. Make sure you consider these obstructions
before installing your solar water heating system.
4) Dry Running of System: It is vital for you to have a consistent
supply of cold water to replace the hot water in the tube. In
case the system is not going to be used for a long period, we
advise you to cover the absorber tubes with a thick sheet.
12
SOLAR WATER HEATER
OPERATIONAL HINTS

5) Time gap between hot water removal: The water present in
the pipeline is usually cooler than the water in your storage
tank. So, do wait while the cold water goes out of the
pipeline and hot water has filled up again. This hot water
loses its heat, and the best way to reduce this heat loss is
to minimize the time gaps between water usage.
6) Cleaning of scales in vacuum tubes: If hard water creates a
scale formation in your tube then you should clean the tube
with a round wire brush. However, it is advised that a
trained plumber or technician do this kind of servicing. This
kind of deposition usually occurs in areas of hard water.
The effectiveness of heating may be reduced if the scale
removal is not done at proper time.
7) Long-lasting eectiveness of the stand: To make the stand
more stable, for a longer period of time, prop it up by using
a cement block.
8) High temperature due to non-usage: If hot water is
not utilized for more than 2-3 days, the temperature of
the water in the system can go up to 80-90°C. This
temperature would be too hig for hot water usage so do
mix an appropriate amount of cold water with it.
USER MANUAL - ETC SYSTEM
13

Disclaimer
All the information in this manual is based on the product range, design and models available as on the date of printing. At
Sudarshan Saur, our products continuously undergo the process of improvement and innovation, thus the parameters of your
product may vary from the information given in this manual. The company reserves the right to change/alter any part of its
system/product without prior notice.
14
Problem: Water is not sufficiently hot.
Reason: Supply valve may have remained open, which led
to mixing of cold water in the ETC tank.
Solution: Close the supply valve before you take a bath.
Problem: Water is not sufficiently hot.
Reason: There might be some obstacle or obstruction that
does not allow sunrays to fall on the vacuum tube
of your system.
Solution: Remove the obstacle and make sure that sunrays
do fall on the system through the day.
Problem: Water is not sufficiently hot.
Reason: There may be some scaling inside the vacuum
tube due to hard water impurities.
Solution: Call a trained plumber or technician and have
them remove the impurities by servicing the
system.
Problem: Water is not flowing out of the outlet.
Reason: The ETC system tank may be empty as the water
may not have been filled, the previous morning.
Solution: Open the supply valve and make sure water gets
filled first thing next morning.
SOLAR WATER HEATER
TROUBLESHOOTING GUIDELINES

CUSTOMER FEEDBACK
Name
Address
Contact Number
E-mail
How did you find out about Sudarshan Saur Solar Water Heater?
Please tick () as applicable.
Referral
Friends/Relatives
Advertisements/Communication
Internet
Comments
15

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GUARANTEE CERTIFICATE
Dealer Stamp
*Conditions apply.
We hereby confirm that your Sudarshan Saur Solar Water Heating System
is guaranteed for the period mentioned, from the date of the invoice.
Client Name
Address
System Model/Rating
Sr. No. Date
Invoice No.
7 Years’ Guarantee - Wonder Ultimate Glass Lining
5 Years’ Guarantee - Wonder Ultimate Special Lining
Wonder Ultimate Pressurized
Wonder Standard SS
Wonder Standard G.I.


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
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1. We agree to repair or replace any part found defective, without any charges to the user.
2. The Company reserves the right to decide whether the defective part is to be repaired or
replaced but in no case do we guarantee to replace the total system.
3. This guarantee does not cover:
a. Breakage of Vacuum Tube due to any reason
b. Minor scratches or distortion occurred during transport, loading, unloading or
installation of system
c. Various components like rubber parts, plastic parts, air relief valve, electrical heater etc.
that are bought from outside
d. Damages occurred due to natural calamities like cyclone, heavy winds, hail stones,
heavy rainfall, or earthquakes
e. If inlet water pressure increases more than 4 kg/cm2in case of Pressurized model
4. a. Chloride hardness should be less than 600 ppm and TDS must be less than 1500 ppm
for Wonder Ultimate Glass Lining series
b. Chloride hardness should be less than 300 ppm and TDS must be less than 800 ppm
for Wonder Ultimate Special Lining series
c. In case of Wonder Standard SS and Wonder Standard G.I. series, chlorde hardness must
be less than 200 ppm and TDS must be less than 500 ppm
5. The guarantee certificate shall not be valid in the following situations:
a. If the system is not purchased from our authorized dealer
b. If the system is not installed, operated, maintained, as per the guidelines given in the
user manual
c. If the system parts are repaired, altered or shifted from other unauthorized agencies
without company's official permission
d. Normal wear and tear of various parts
e. Effect on exterior surface coating due to weathering, rain or sunshine etc.
f. Improper performance of system, or any other damage due to salts and scaling occurred
because of hard water
6. The guarantee does not include transport, delivery, handling charges of defective and
replaced items.
7. In no event shall the company be liable to a user for any special, incidental or consequential
loss or damage. Any such claims are specifically excluded under this guarantee certificate.
Other Terms and Conditions applicable to this guarantee certificate are as follows: