SolarArk Solar Hot Water Systems Installation Manual

Evacuated tube solar hot water system

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Providing Insight into hot water, solar systems and various components used

within a SolarArk Solar Hot Water System. This is a confidential document for

July 2012

SolarArk representative use only. This document is to be taken as a

comprehensive introduction into solar heating. This document is for the use

of SolarArk accredited installers only.

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Page 1 Solar Hot Water Installation Manual Systems Providing Insight into hot water, solar systems and various components used within a SolarArk Solar Hot Water System. This is a confidential document for July 2012 SolarArk representative use only. This document is to be taken as a comprehensive introduction into solar heating.
Page 2: Table Of Contents
Table of Contents Introduction to Solar Water Heating ........................5 Key Features .................................6 Tempering Your Water Supply ..........................7 Boosting Options ..............................7 Gas Boosting .................................8 Water Flow ................................9 Electric Boosting ..............................9 Water Delivery & Recovery Rates ........................9 Local Standards ..............................10 SolarArk Accreditations ............................. 10 SolarArk System Compliance ..........................
Page 3 Basic System schematic ............................. 22 Collector Positioning ............................23 Storage Tank Location ............................24 Pipe Insulation ..............................24 Installation Procedure ............................24 Mounting frame ..............................24 Manifold and Bottom Track Attachment ......................25 Manifold and Bottom Track Attachment Process ..................... 25 Installation Planning ............................
Page 4 Installation Instructions ............................. 45 Flat Roof Frame Assembly Guide-30 Tube Collector ..................49 Standard Tubes Assembly Guide -30 Tube Collector ..................53 Flat Roof Frame Assembly Guide-10 and 20 Tube Collector ................55 Standard Tube Assembly Guide -10 and 20 Tube Collector ................58 Bill of Materials ..............................
Page 5: Introduction To Solar Water Heating
Thank you for your decision to purchase a SolarArk Evacuated Tube Solar Hot Water System. The content of this manual provides detailed information on maintenance, troubleshooting, safety precautions and warranty that should be thoroughly read and adhered to following installation. Should you have any questions regarding the information contained, please contact SolarArk on Ph: 1300 760 966 for support.
Page 6: Key Features
Key Features SolarArk utilizes copper, aluminium and titanium as part of a three target film technology. This provides excellent heat retention that exceeds other standard tubes by more than 12%. The diameter of the heat exchanger has been specifically designed to maintain low pressure drop. High density Rockwool insulation is used to ensure maximum solar heat gain by minimising the amount of heat loss even in cold temperatures.
Page 7: Tempering Your Water Supply
Tempering Your Water Supply Tempering valves are mandatory throughout Australia. They are to comply with local regulations as a safety device to reduce hot water supply to a maximum of 50°C. AS/NZS 3500.4:2003 details the requirements of the tempering valve. The function of the tempering valve is to reduce the 65-75 degree water leaving your hot water storage tank and blending it with cold water to achieve 50°C .To reduce the possibility of scalding the tempering valve must be installed to the hot water supply line incorporating all sanitary...
Page 8: Gas Boosting
During periods of low solar contribution, gas or electric boosting is required to maintain 60° temperature. Gas Boosting The instantaneous gas booster is activated if the water passing through is less than 55°C. The gas booster will automatically turn off when boosting is not required, therefore increases energy efficiency.
Page 9: Water Flow
Water Flow S21 or S26 hot water gas boosters have limited hot water flow due to the flow rate of the gas booster (21 or 26 litres per minute). To ensure that your instantaneous unit functions effectively, it is advisable to use a AAA rated showerhead with a minimum flow of 9 l/m.
Page 10: Local Standards
Local Standards Installation must be completed in accordance with the requirements of AS/NZS 3500.4 (AS/NZS3500.4.2 “National Plumbing and Drainage Code Hot Water Supply Systems – Acceptable Solutions”), or in New Zealand, Clause G12 of the New Zealand Building Code, as well as any relevant local standards and regulations.
Page 11: Authorised Installers
Authorised Installers All installation of SolarArk solar hot water systems must be installed and checked by a SolarArk authorised licensed plumber who holds all relevant qualifications. Any installation, inspections, repairs or maintenance that is required should only be carried out by a person authorised by SolarArk Pty Ltd.
Page 12: Pressure And Temperature Control And Relief
Pressure and Temperature Control and Relief The pressure & temperature Relief Valve is supplied with the water heater from the manufacturer. The valve must be installed into the socket marked “RELIEF VALVE”. No hot water storage tank should be operated without the PTRV fitted and functional.
Page 13: Corrosion
To alleviate this, the magnesium alloy anode should be replaced with an aluminium alloy anode, available from your local plumbing supplier. Water can also be very corrosive, the measure of this is the saturation index, if the water saturation index is greater than 0.40 an expansion control valve should be fitted and where the index is greater than 0.80 the water heater installed should be a Hard Water Model.
Page 14: Lightning Protection
pitched roof frame and angle frame are designed to withstand high wind speeds without damage. However the roof attachment points may not be as strong. For areas with the possibility of high winds, additional arrangements for reinforcing attachment points should be considered. Lightning Protection Where the solar collector is installed in an area that is prone to lightning it is recommended to earth the solar collector copper circulation loop to aid in avoiding lightning related damage and safety issues,...
Page 15 required at these times, the controller will turn off the pump to prevent the tank from overheating and the hot water tank temperature will not increase further, when water is no longer circulating through the solar collector that would cause stagnation due to the energy still getting absorbed and not getting used, the temperature will rise in the manifold there for pressure will start to build-up.
Page 16: Water Boiling Point
Water Boiling Point When operating a hot water system under pressure the boiling point at which the water will turn to steam will change as per the following chart. Gauge Pressure KPa Boiling Point °C Automatic Air Eliminator An automatic air eliminator should be installed on the solar collector to provide an escape point for any air that may be trapped in the solar loop supply and return lines.
Page 17 There are two compression fittings supplied with the solar collector manifold 22mm compression to ½ inch flare connection if connecting multiple collectors for commercial applications a 22mm compression to ¾ BSP brass fittings may be used. Only Australian standard approved brass fittings should be used.
Page 18 For closed loop system an expansion vessel/tank should always be used to prevent the system from dumping the heat transfer fluid. For domestic use of up to 90 tubes a 10-12L expansion vessel should be used. The expansion vessel will accept system pressure increase; refer to expansion vessel manufactures for correct sizing on large systems.
Page 19: Storage Tanks
• Solar pipes and fittings can reach temperatures of over 100°C extreme care should be taken when installing or servicing SolarArk solar hot water systems • If hot water system is not used for two weeks or more, a quantity of highly flammable hydrogen gas may accumulate in the water heater.
Page 20: Tanks - Stainless Steel
WASHER.DRYER OR ANY OTHER APPLIANCE. During this procedure there must be no, SMOKING OPEN FLAMES OR ANY ELECTRICAL APPIANCES OPERATING NEARBY. If hydrogen is discharged through a tap similar to air escaping noise will be herd. • All safety percussion should be taken before any parts of the installation are started. Tanks –...
Page 21: Safety Drip Tray
Safety Drip Tray The safety tray is a requirement for all water heaters to protect property from damage. As per The National Plumbing Code AS/NZS 3500.4:2003. The safety tray must comply with Clause 4.4 and Sub Clauses 1 to 5 of the Code. Gas Boosted Storage Tank The gas boosted hot water storage tank is a standard tank with an instantaneous gas booster that can be attached to the tank or mounted on the wall close by the gas booster is a Type-A appliance.
Page 22: Basic System Schematic
Basic System schematic System Schematic-Electric Boosted Stainless Steel Tank Parts Schematic – Not all components are Provided by SolarArk Component Name Supplier: Part Code Notes Non-Return Isolating Valve Australian Standards Approved 1. Optional Inclusion, compulsory in some states Line Strainer Australian Standards Approved 2.
Page 23: Collector Positioning
Collector Positioning Some major factors need to be considered when installing the evacuated tube collector Location Latitude Acceptable Pitch Angle Optimum Angle Adelaide 35˚ 20-55˚ 55˚ 23˚ 20-43˚ 43˚ Alice Springs Brisbane 27˚ 20-47˚ 47˚ Canberra 35˚ 20-55˚ 55˚ 12˚ 20-32˚...
Page 24: Storage Tank Location
Storage Tank Location The hot water storage tank should be installed as close as possible to the most frequently used hot water outlet point. Electrically boosted hot water storage tank can be installed indoor or outdoor. The ideal location of the solar collector should be around the 10m range away from the hot water storage tank.
Page 25: Manifold And Bottom Track Attachment
Manifold and Bottom Track Attachment The manifold and the bottom frame tube holders track are secured to the frame front track using special holding attachment plates. The plates are design in such a way that when loosed it allows the front frame tracks to slide left and right to simplify adjustment process for rafter locating. Manifold and Bottom Track Attachment Process 1.
Page 26: Installation Planning
Installation Planning The location of the manifold should be carefully planned for tiled roofs in order to minimize the The location of the manifold should be carefully planned for tiled roofs in order to minimize the The location of the manifold should be carefully planned for tiled roofs in order to minimize the number of tiles that needs to be removed and number of tiles that needs to be removed and returned into place for the correct pipe and frame returned into place for the correct pipe and frame...
Page 27: Wind Loading
Wind Loading Wind loading and wind resistance issue should always be considered during the planning stage of the collector installation process. The local Building codes and regulation should always be followed in regarding to installation of such objects. The SolarArk standard frame kits are designed to withstand high wind speeds of up to 220km/h, as per frame kit assembly diagram contained within this document.
Page 28: Snow Load
Snow Load In heavy snow fall areas the solar collector should ideally be installed at an angle of 50° or greater to help promote snow sliding off the tubes. Always install the collector with a raised front tube holder frame. A distance of 20-25cm should be allowed off the roof surface, allowing snow to settle beneath the collector so it can be easily cleared away.
Page 29: Colorbond/Zincalume/Galvanised Corrugated Roof
FRONT FRAME STRAP Once the upper straps are attached and secured adjust the bottom straps to provide support to the bottom end of the collector. Attach, adjust and tighten the bottom straps to ensure that they too are providing adequate support. The rubber blocks should be fitted to the underside off the front track, secure with a small amount of silicon.
Page 30: Asphalt Tiled Roof
Asphalt Tiled Roof For installation on an asphalt tiled roof the standard frame can be directly mounted to the roof surface. Alternatively the round feet and rubber feet can also be used; round feet and rubber are an optional extra to be purchased separately. Flat Roof Installation (Adjustable Frame) The adjustable angle frame to be used for flat roofs or with roofs under 20˚...
Page 31: Adjusting Frame Angle
Adjusting Frame Angle The rear legs of the flat roof frame comprise two interlocking pieces. The top and bottom legs slide into each other to allow the length of the rear leg to be adjusted, thus changes the collector angle from between 27˚-67˚.if an angle of less than 27˚...
Page 32: System Filling And Air Purging
Braze copper piping directly to manifold ports is not recommended as brazing may damage rubber components on solar collector header .do not over tighten or twist the copper piping on manifold that could also cause damage only use brass compression fittings supplied. There are two compression fittings supplied with the solar collector manifold •...
Page 33: Draining Solar Collector
Draining Solar Collector Draining the solar collector may be required to service, repair or remove. Such work should be carried out by appropriately qualified personnel only to avoid injury and collector damage. Turn of the water supply to the hot water storage tank. Isolate the power supply to the hot water storage tank, pump and controller before any water is drained.
Page 34: Flow Control Valve
Flow Control Valve For optimum solar collector performance a flow control valve should be installed and set to the right water flow as nominated by SolarArk. The water flow valve should be installed on the water flow side of the solar loop after the pump outlet pointing toward the solar collector as indicated on the water flow valve directional arrow.
Page 35: Circulating Pump
Circulating Pump The circulating pump supplied with the SolarArk system is a 3 speed pump to provide The circulating pump supplied with the SolarArk system is a 3 speed pump to provide The circulating pump supplied with the SolarArk system is a 3 speed pump to provide adequate pressure and flow to circulate water pressure and flow to circulate water through the solar loop.
Page 36 The return line should be around 5-10°C hotter than the supply. If the return line temperature is to hot that would indicate that the water flow is too low, if the water return is similar in temperature to supply that would indicate no water flow. That could be due to an air lock or pump head pressure is insufficient.
Page 37: Controller Function & Operation
Controller Function & operation The solar hot water system works by extracting heat from the solar collector and storing it in the hot water storage tank. The controller works by means of cycling the pump on and off through a temperature differential control.
Page 38: Controller Temperature Sensors
The following is the pre-set program settings: PUMP ON: 8°C PUMP OFF: 2°C TOPOUT: 70° FROST: 4°C The standard controller that is supplied with the SolarArk system does not have a digital screen display it is factory set and cannot be reprogrammed on site. There are four indicator lights on the front of the controllers which indicate the functions.
Page 39: Pump And Controller Box
Pump and Controller Box The pump and controller can be supplied in one box to assist in installation and provide wether protection to the circulating pump. The pump is not water proof and should always be installed avoiding direct water contact. Pump warranty will be void if fault occurred due to water damaged. System Start Up Once the cold water supply is opened and all the air expelled from the system allow the main water supply pressure to completely fill and pressurise the system, check the piping for water leaks.
Page 40: Installation Reference Guide
Installation Reference Guide 1. Read and understand this manual for installation process. 2. Ensure all safety precautions are followed for a safe system installation. 3. Unpack all parts and check against packing slip. 4. Select collector position (NORTH FACING ROOF). 5.
Page 41: Troubleshooting
Troubleshooting Any system adjustments, repairs or maintenance should only be carried out by a qualified technician. Insufficient hot water If the gas booster is not turned on before sending water through, it may default to 40°C. To reset the system, turn the gas booster off via the power point or take the plug out of the controller and wait two minutes before turning the system back on.
Page 42: Troubleshooting Guide
Troubleshooting Guide System Troubles Possible Fault Solution Check power supply from distribution board and to the storage tank. Boosting not working Check tank thermostat if manual reset is triggered. (Electric) Check electric element for fault. Change to full tariff and install a timer set to run depending on your water usage pattern.
Page 43 Pump cavitation could cause a lack of water flow loosen the union on the pump outlet be care full very hot water or steam will come out. Ensure there is 20cm of straight pipe both sides of the pump prior to any bends or elbows installation. Insufficient or no flow Inspect the check valve for correct operation.
Page 44 Steam forming in the Install an air eliminator on collector outlet. manifold due to Increase cold water supply pressure to 400 kpa +. stagnation more so in Install collector for winter sun performance. low pressure water supply. Rattling/banging noise in pipes when hot water is used.
Page 45: Installation Instructions
Installation Instructions Copyright © SolarArk Installation Manual version 4.6 July 2012 P a g e | 45...
Page 46 Safety – Before you Start Step 3 Slide front of manifold into slots on frame, followed by Important Note: inserting clip into grove on rear of manifold and tighten. Do not commence an installation until you have satisfied Finish manifold assembly by coating O-rings with solid soap yourself that all Safety issues associated with working on or oil to aid with insertion of evacuated tubes.
Page 47 Connect power cord off pump to socket on copper pipe prior to any bends • controller Connect flow out from Solar Ark control box using • Always bleed air from solar loop by disconnecting 1/2” insulated copper tube to ½” flare fitting on solar loop return from tank and running pump on Solar Ark collector provided.
Page 48: Evacuated Tube Installation
Use sponge or spray bottle DONT SPRAY WATER INSIDE TUBE • Final Solar Ark commissioning Guide the heat pipe up into the header port - push in full depth • Wipe and clean tubes using soft clean cloth.
Page 49: Flat Roof Frame Assembly Guide-30 Tube Collector
Flat Roof Frame Assembly Guide-30 Tube Collector 30 Tube Collector Pages 1of 4 Copyright © SolarArk Installation Manual version 4.6 July 2012 P a g e | 49...
Page 53: Standard Tubes Assembly Guide -30 Tube Collector
Standard Tubes Assembly Guide -30 Tube Collector 30 Tube Collector Pages 1 of 2 Copyright © SolarArk Installation Manual version 4.6 July 2012 P a g e | 53...
Page 55: Flat Roof Frame Assembly Guide-10 And 20 Tube Collector
Flat Roof Frame Assembly Guide-10 and 20 Tube Collector 10 and 20 Tube Collector Pages 1of 3 Copyright © SolarArk Installation Manual version 4.6 July 2012 P a g e | 55...
Page 56 10 and 20 Tube Collector Pages 2of 3 Copyright © SolarArk Installation Manual version 4.6 July 2012 P a g e | 56...
Page 57 10 and 20 Tube Collector Pages 3of 3 Copyright © SolarArk Installation Manual version 4.6 July 2012 P a g e | 57...
Page 58: Standard Tube Assembly Guide -10 And 20 Tube Collector
Standard Tube Assembly Guide -10 and 20 Tube Collector 10 and 20 Tube Collector Pages 1of 2 Copyright © SolarArk Installation Manual version 4.6 July 2012 P a g e | 58...
Page 59 10 and 20 Tube Collector Pages 2of 2 Copyright © SolarArk Installation Manual version 4.6 July 2012 P a g e | 59...
Page 60: Bill Of Materials
Bill of Materials Glass Line Tank Electric Boost Solar Water Heater Parts Schematic – Not all components are Provided by SolarArk Component Name Supplier: Part Code Notes Non-Return Isolating Valve Australian Standards Approved 1. Optional Inclusion, compulsory in some states Line Strainer Australian Standards Approved 2.
Page 61: Glass Line Gas Boost
Glass Line Tank Gas Boost Solar Water Heater Parts Schematic – Not all components are Provided by SolarArk Component Name Supplier: Part Code Notes Non-Return Isolating Valve Australian Standards Approved 1. Optional Inclusion, compulsory in some states Line Strainer Australian Standards Approved 2.
Page 62: Stainless Steel Electric Boost
Stainless Steel Tank Electric Boost Solar Water Heater Parts Schematic – Not all components are Provided by SolarArk Component Name Supplier: Part Code Notes Non-Return Isolating Valve Australian Standards Approved 1. Optional Inclusion, compulsory in some states Line Strainer Australian Standards Approved 2.
Page 63: Stainless Steel Gas Boost
Stainless Steel Tank Gas Boost Solar Water Heater Parts Schematic – Not all components are Provided by SolarArk Component Name Supplier: Part Code Notes Non-Return Isolating Valve Australian Standards Approved 1. Optional Inclusion, compulsory in some states Line Strainer Australian Standards Approved 2.
Page 64: Installation Checklist
Installation Checklist Inspection report to be completed and returned to SolarArk along with installation photographic evident for future reference Please tick Installation Checklist YES NO 1. Collector orientation (North Facing) if NOT what aspect is the collector facing ________ 2. Collectors angle 20˚ or more if NOT what angle ______________________________ 3.
Page 65: Installation Report Form
Installation Report Form After completing the installation the following information must be completed by the installer and returned to SolarArk. Failing to complete and return may void warranty. Customer Details Customer Name: Customer phone Number: Installation Address: Invoice number: System Model & Serial Number: Tank Model &...
Page 66 Warranty Form Customer Reference No: SOLARARK WARRANTY FORM CUSTOMER Last Name: First Name: Address: Suburb: State: Postcode: SITE INSTALLATION Address: Suburb: State: Postcode: INSTALLER Last Name: First Name: Address: Suburb: State: Postcode: License Number: Date of Installation: SYSTEM DETAILS System Installed Model Number: SA Solar Tube Collector Serial Number: - Hot Water Tank Model and Serial Number: PLEASE RETURN TO SOLARARK PTY LTD WITHING TEN (10) WORKING DAYS OF PRODUCT...
Page 67: Solarark Maintenance
SolarArk Maintenance PTRV It is recommended that the lever on the pressure and temperature relief valve (PTRV) on the side of the hot water tank be operated once every 6 months to ensure reliable operation and replaced every five years. It is important to raise and lower the lever smoothly. Please be careful as the water released from the drain pipe will be HOT.
Page 68 Tube with Loss of Evacuated Air Tube with Evacuation intact Copyright © SolarArk Installation Manual version 4.6 July 2012 P a g e | 68...
Page 69: Evacuated Tube Installation
Evacuated Tube Installation Pull out each heat pipe by 15cm. Coat each pipe tip with therma Pull out each heat pipe by 15cm. Coat each pipe tip with therma Pull out each heat pipe by 15cm. Coat each pipe tip with thermal paste by squirting thermal paste into a short piece of insula thermal paste into a short piece of insulation.
Page 70: Other System Components
Other System Components The pump, storage tanks and gas/electric boosters should be inspected by a qualified technician according to the manufacturer’s maintenance guidelines. Precautions and Warnings VITREOUS ENAMAL TANKS: For solar collector systems using a vitreous enamel/glass lined storage tank the following precaution applies: IF THE HOT WATER SYSTEM IS NOT USED FOR TWO WEEKS OR MORE, A QUANTITY OF HIGHLY FLAMMABLE HYDROGEN GAS MAY ACCUMULATE IN THE WATER HEATER TO DISSIPATE THIS GAS SAFELY, IT IS RECOMMENDED THAT A HOT TAP BE TURNED ON FOR...
Page 71: Warranty Warranty Conditions
Warranty Warranty Conditions The solar water heating system must be installed in accordance with the manufacturer’s installation instructions, the local, State and National authorities and all relevant statutory requirements - AS3500.4 & 5, AS5601, AS3000, AS2712 etc. This warranty applies only to those components provided as part of the SolarArk solar water heating product and does not apply to any electrical or plumbing parts provided by the installer.
Page 72: Warranty Exclusions
Warranty Exclusions The following exclusions shall cause the warranty to become void, and may incur a service charge and cost of parts that may be required. Accidental damage, acts of God, failure due to misuse, incorrect installation including but not limited to, as per owner’s manual, installation guide, installation instruction and any other requirements set by SolarArk and or lack of maintenance.
Page 73 The changing or alternating from one water supply to another can have a detrimental effect on the operation and/or life expectation of water heaters storage cylinder, pressure temperature relief valve, heating unit and solar collector. SolarArk will not cover resulting faults to the storage cylinder and solar collector if this system is connected at any time to a water supply where the TDS contents of the water exceeds 600 mg/l.
Page 74: Component Warranty
Component Warranty Replacement of major components, including gas heater, evacuated tube solar collector, storage tanks, solar circulating pump, electric tank heating element, electric tank thermostat that fail due to faulty manufacturing or workmanship will be provided at no charge to the customer for replacement.
Page 75 Domestic Use Commercial Use Major Component Part Parts Labour Parts Labour Warranty Warranty Warranty Warranty 15 Years 1 Year 5 Years 1 Year Evacuated Tubes Evacuated Tube Solar 15 Years 1 Year 5 Years 1 Year Manifold Collector 15 Years 1 Year 7 Years 1 Year...
Page 76: Solarark Warranty Claim Procedure
SolarArk Warranty Claim Procedure For all warranty claims on SolarArk Solar Hot Water Systems, please contact your SolarArk Representative. Have all information regarding the warranty claim available including: Copy of Warranty Card Installer & Customer Details Installation Compliance Certificate System Details Information on Faulty Components An authorised agent will be allocated to your warranty claim.
Page 77: Disclaimer
Disclaimer This manual contains an overview of the SolarArk Solar Hot Water System, all instructions/recommendations must be followed exactly as stated herein. SolarArk Pty Ltd is not responsible for any loss of damage to any person or property of any type, whether direct or consequential, arising from the operation of the solar hot water system or any of its components.
Page 78: Solarark Frequently Asked Questions
SolarArk Frequently Asked Questions Why Choose a SolarArk Hot Water System? SolarArk is the only system in the Australian market that is backed by a 15 year manufacturing warranty for all major components. As SolarArk is an Australian owned company with its own manufacturing facility, you can be assured of the highest quality, ongoing support and service.
Page 79 What is the optimum angle to install the Solar Collector? The solar collector should be installed for optimum winter performance. The tubes perform best when installed at an angle of between 20° and 60° from the horizontal. If a roof has an angle less than 20°, it is advisable to use an adjustable pitched roof frame to ensure optimal heat pipe operation.

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