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Table of Contents
Summary of Contents for Ecosolar Solar Hot Water System
- Page 1 Solar Hot Water System Installation Guide...
- Page 2 E C O S O L A R Solar Hot Water Heating Installation Guide Energy Conscious Design Limited / EcoSolar 15B Saturn Place, Albany, Auckland, Postal PO Box 81049 • Whenuapai • Auckland • New Zealand Phone 09 442 0996 • Fax 09 442 0997 E info@ecosolar.co.nz •...
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Page 3: Table Of Contents
Inclination Horizontal versus vertical cylinders Solar Collector Mounting 31 Pumped/thermosyphon systems Corrugated / iron sheet roofing Tiled roofing Pumped systems Flat roof or to increase or decrease collector Thermosyphon systems inclination from roof pitch EcoSolar Energy Conscious Design Limited... - Page 4 Initial wiring Programming System Control Controller user guides System control overview Pumped systems System control using EcoSolar ESR21 solar Temperature sensor installation controller and One Shot backup heating Variable speed drives controller System control using EcoSolar ESR21 solar Over heating...
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Page 5: Thank You
G U I D E Thank you Thank you for choosing an EcoSolar hot water system. You may look forward to many years of monetary savings as well as knowing that you are helping provide a sustainable future for generations to come. -
Page 6: Selecting The Most Appropriate System
Type of system The types of solar hot water system include, thermosyphon systems, pumped systems, drainback systems, indirect and direct systems. Each of these systems has advantages and disadvantages that should be understood so that by the most appropriate system is recommended to the customer. For... - Page 7 Figure 1 Thermosyphon system Figure 2 Indirect pumped drainback system EcoSolar Energy Conscious Design Limited...
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Page 8: Basics Of System Sizing
Figure 3. EcoSolar 12Volt UVR61 controller Basics of system sizing As a rule of thumb solar hot water systems are often sized on the basis of 1m2 of collector area per 50 to 75 litres of water storage or per person. For instance, based upon 75litres of water storage per person a two person house hold should be able to comfortably utilise an existing 135 or 180 litre cylinder. - Page 9 The installation of the EcoSolar “One shot” controller makes this control method much more user friendly and eliminates the problem of the electric element being left on.
- Page 10 Figure 3 above, are able to not only control the solar system, but are also able to control the wetback circulating pump. The solar controller monitors the temperatures in the wetback EcoSolar Energy Conscious Design Limited...
- Page 11 The boosting cylinder may be heated by electric elements, gas boiler or another heat source. Figure 6 below shows an EcoSolar drainback system operating as a solar preheating system with a boiler heated booster cylinder.
- Page 12 Figure 6. EcoSolar drainback solar preheat system c/w boiler heated booster cylinder EcoSolar Energy Conscious Design Limited...
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Page 13: Caution - Issues
Building consent and Code Compliance You will be required to submit a building consent for the installation of a solar hot water system. An owner occupier can undertake some of the installation however, in order for the building consent... -
Page 14: Freeze Protection
If Propylene Glycol does enter a rainwater tank used for drinking water, it will have an adverse effect upon the taste of the water and it may be necessary to EcoSolar Energy Conscious Design Limited... - Page 15 This system effectively manages the risks of freezing and overheating. Controller The EcoSolar solar controllers have functions to start the pump and allow warm water to enter the collector when low temperatures are recorded by its sensor in the collector, thereby reducing the risk of the water in the collector freezing.
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Page 16: Water Quality
Such failures are out of acceptable limits and are not covered by the warranty. Systems operating under such conditions should have their periodic maintenance increased to suit. Collectors For reference the collector specifications are available from the EcoSolar website. EcoSolar Energy Conscious Design Limited... -
Page 17: Cylinders
Cylinders with / without heat exchangers Cylinders can be fabricated with or without internal heat exchangers and there are several configurations available. Unless a heat exchanger is installed, the solar water heating system will EcoSolar Energy Conscious Design Limited... -
Page 18: Cylinder Capacity
20 to 30 Watts depending upon system characteristics. These systems offer increased reliability on sites susceptible to mains power failure. These systems are often installed in remote sites where thermosyphon systems cannot be suitably installed. EcoSolar Energy Conscious Design Limited... -
Page 19: Thermosyphon Systems
The systems with horizontal cylinders, such as the case with close coupled systems, have reduced efficiency due to thermal mixing within the cylinder. EcoSolar Energy Conscious Design Limited... -
Page 20: System Types
At EcoSolar we tend to specify duplex grade stainless steel cylinders, due to their resilience to temperatures and pressures and have found them to be a reliable option. -
Page 21: Low Pressure System
These cylinders will either have connections just made into the hot water cylinder and allow the stored water to circulate through the solar collector, direct system, or have a heat exchanger installed within or encompassing the cylinder, indirect system. EcoSolar Energy Conscious Design Limited... -
Page 22: Solar Water Heating System Types And Schematics
However, they are prone to overheating and freezing and so these need to be effectively managed to ensure a cost effective and resilient system. EcoSolar Energy Conscious Design Limited... - Page 23 Figure 8 above shows an open loop solar hot water installation retrofitted on to a cylinder with only bottom entry fittings, no bottom dispersion plate. This installation uses the 4 way inlet fitting. EcoSolar Energy Conscious Design Limited...
- Page 24 Figure 9 Mains pressure open loop solar hot water installation, using side entry connections and retrofit 4-way connection. EcoSolar Energy Conscious Design Limited...
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Page 25: Indirect Or Closed Loop Systems
Propylene glycol are becoming understood. An indirect Glycol based system is shown in Figure 10 below. These systems are resilient to frost however they have a higher installed cost than direct systems, can be exposed to overheating and have increased levels of maintenance. EcoSolar Energy Conscious Design Limited... - Page 26 Figure10 Closed loop glycol based system with single pump and heat exchanger in the DHW cylinder. EcoSolar Energy Conscious Design Limited...
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Page 27: Indirect Drainback System
NZ. As well as the conventional drainback system as shown in Figure 11 below, options are available to retrofit a drainback system on to an existing cylinder or a cylinder without an internal heat exchange coil, see Figure 12. EcoSolar Energy Conscious Design Limited... - Page 28 Figure 11 Closed loop drainback system with single pump and heat exchanger in the DHW cylinder. EcoSolar Energy Conscious Design Limited...
- Page 29 Figure 12 Retrofit indirect drainback system with twin pumps. EcoSolar Energy Conscious Design Limited...
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Page 30: Thermosyphon Systems
As the separation distance increases so the resistance to flow also increases and it is advantageous to increase the pipe size from ¾” as per many close coupled systems to 1” and greater to increase the system performance. Figure 13. Close coupled thermosyphon system EcoSolar Energy Conscious Design Limited... -
Page 31: General Installation
• The return, warmer water, from the solar collector is connected from the top of the solar collector to the top of the hot water cylinder or dispersion tube. EcoSolar Energy Conscious Design Limited... -
Page 32: Roof Penetrations
A safe tray c/w drain to a suitable drain shall be installed on all new and if at all possible under existing hot water cylinders to capture water from leaks. Controller Please reference the controller installation manual included with the kitset for details including installing the sensors and programming of the controller. EcoSolar Energy Conscious Design Limited... -
Page 33: Solar Collector Location
The latitudes for New Zealand are shown below; The collector shall be installed with a slight (10mm) slope upwards to the air vent. This will allow the air to automatically vent rather than airlock. EcoSolar Energy Conscious Design Limited... - Page 34 (X for locations in NZ are shown below) Cape Reinga Kaitia 17.5 Whangerei Auckland 18.5 Hamilton Taupo 19.5 Palmerston North Wellington and Nelson 20.5 Kaikoura 21.5 Christchurch Duneden Invercargil Stewart Island EcoSolar Energy Conscious Design Limited...
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Page 35: Solar Collector Mounting
There are several methods of installing the collectors flat on to an iron roof, Figure 14 shows the EcoSolar aluminium profile system. Short lengths of aluminium angle are used to bolt into the roof and the aluminium profile to maintain a separation between the collector and the roof. - Page 36 Figure 14 Fixing method to corrugated iron and long run, pan or deep trough roofing. EcoSolar Energy Conscious Design Limited...
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Page 37: Tiled Roofing
The collector is then bolted on to the angle brackets using M8 bolts. Rubber separators are to be installed between the angle brackets and the solar collector. See Figure 15 below. EcoSolar Energy Conscious Design Limited... - Page 38 Figure 15 Fixing method to tiled roofing EcoSolar Energy Conscious Design Limited...
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Page 39: Inclination From Roof Pitch
The concept for increasing the collector pitch off of a pitched roof is shown below. The pitch required shall be stated when ordering the fixing kits from EcoSolar. Figure 16 Fixing method pitching collector off of a flat, corrugated iron or shallow trough roof... -
Page 40: Collectors Inclined Across Roof Pitch
Figure 16 above. Figure 17 presents a potential system. Please contact us for details. Figure 17 Fixing method pitching collector off of a corrugated iron or shallow trough roof EcoSolar Energy Conscious Design Limited... -
Page 41: Maximising The Benefit From Solar Hot Water
Maximising the benefit from solar hot water Following these recommendations will further enhance the benefit from your solar hot water system. • Install low flow shower heads, taps, install flow restrictors and generally conserve water • Heavy washing or hot water consumption maximised during the middle of the day •... - Page 42 UVR-61R3, having all the functions of the ESR21-R3, this controller is able to monitor 6 temperature sensors and can also monitor an EcoSolar solar radiation sensor. This controller can control up to 3 solar systems allowing the solar collectors to heat up to 3 hot water cylinders, swimming or spa pools.
- Page 43 Figure 19 EcoSolar UVR61R3 controller • Ecosolar “OneShot”, this backup heating controller is installed with the above controllers. The user is able to manually turn on the backup heating and the controller will automatically turn the heating off once the water is up to temperature. The user can choose if the heating should only be turned on once, i.e.
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Page 44: Pumped Systems
Variable speed drives The EcoSolar ESR21D and UVR61R3 controllers both come standard with a variable speed drive. Utilising this speed drive will considerably increase the system performance and its reliability. EcoSolar Energy Conscious Design Limited... -
Page 45: Overheating
Water boils at lower temperatures as the pressure decreases, at the inlet of the pump, there is potential, depending upon EcoSolar Energy Conscious Design Limited... -
Page 46: Expansion Vessels
Once the hot water cylinder temperature reduces or there is another heating demand, the solar heated water is redirected back to the hot water cylinder or other heating demand until again satisfied. EcoSolar Energy Conscious Design Limited... - Page 47 Figure 21 Latest generation EcoSolar controller is able to automatically control a solar system to prioritise heat to several heating demands and then dump excess heat so to avoid system overheating. Figure 22 Closed loop solar water heating system with automated heat dump system...
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Page 48: Drainback
Care should be taken when selecting pumps for these systems to ensure, sufficient pump head to prime the circuit and not too much flow that could result in mixing within the cylinder. EcoSolar Energy Conscious Design Limited... - Page 49 A sightglass on the outside of the cylinder indicates the water level which should be periodically checked. EcoSolar Energy Conscious Design Limited...
- Page 50 See the next article on options for boosting the water temperature for details of installing an instantaneous water heater. EcoSolar Energy Conscious Design Limited...
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Page 51: Reliability
Existing hot water cylinder heating Source Once the solar hot water system is installed the existing hot water heating source needs to be managed to minimise the energy consumed heating water, maximise the use of the solar heating system and minimise the risk of Legionella forming within the hot water cylinder and system. - Page 52 The EcoSolar UVR61-3 controller is able to automate the above process by determining if there is sufficient hot water in the cylinder at the end of the day and automatically turning on and off the heating as required.
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Page 53: Legionella
Legionella establishing itself in the hot water cylinder. In order to minimize this risk the water should be heated to 60 C for 6 hours once a week. This function can be manually managed or EcoSolar are able to supply controllers or timers that take care of this function for you. If you are managing this yourself we recommend that the water is heated at the same time each week this way the management will hopefully become habitual. -
Page 54: Periodic Maintenance
Check temperature sensor displayed temperatures • Check electrical system and water booster heater • Check pump and differential controller operation 3 years • Check system and connections for leaks • Replace pressure and thermal relief valves EcoSolar Energy Conscious Design Limited... -
Page 55: Glazing Maintenance
The owner shall also be provided with copies of; • Installation sizing / survey • Installation inspection report • Operating and maintenance instructions • Manufacturers information • Recommended maintenance check list EcoSolar Energy Conscious Design Limited... -
Page 56: Structural
Here follows instructions that should be read in conjunction with the instructions supplied with the controller. The controller must be wired correctly and programmed as follows. PLEASE NOTE Ensure that the controller cables do not come into contact with the pipework between the solar collector and cylinder. EcoSolar Energy Conscious Design Limited... -
Page 57: Initial Wiring
Once the correct value is showing, a single press of the up arrow will select and confirm the value, the value will now stop flashing. EcoSolar Energy Conscious Design Limited... - Page 58 2 is the temperature at high level in the cylinder at which the heating turns off. max 2 is the temperature at high level in the cylinder at which the heating turns on again. The max 2 and max 2 temperatures shall be the maximum operating EcoSolar Energy Conscious Design Limited...
- Page 59 If ON is selected with a hand at low level the pump is switched on permanently, if the OFF is selected the pump is switched off permanently. EcoSolar Energy Conscious Design Limited...
- Page 60 Now press the right hand arrow Start f is displayed, this is factory set to off and should normally remain off Now press the right hand arrow ART is displayed, this is the after run time for the pump and is normally is left at 0. EcoSolar Energy Conscious Design Limited...
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Page 61: Controller User Guides
The user guides for the ESR21 and the UVR61 are shown below, copies of these are available from the website for inclusion in the operation and maintenance manual. Solar System Control Using EcoSolar ESR 21 and One Shot Back up Heating Controller... - Page 62 Legionella establishing itself in the hot water cylinder. In order to minimize this risk the water should be heated to 60 C for 6 hours once a week. This function can be manually managed or EcoSolar are able to supply controllers or timers that take care of this function for you. If you are managing this yourself we recommend that the water is heated at the same time each week this way the management will hopefully become habitual.
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Page 63: Controller
45 C which is an optimum temperature for Legionella growth. Solar System Control Using EcoSolar UVR 61 Solar Controller and One Shot Back up Heating Controller Overview The UVR 61 Solar Controller is a multi function controller which automates the solar water heating system. - Page 64 ( T3 ), over a short period of time they will determine the temperature below which additional hot water is required, this temperature will vary from household to household and depend upon hot water consumption. If the water does need to be heated the user should press the boost EcoSolar Energy Conscious Design Limited...
- Page 65 In order to minimize this risk the water should be heated to C for 6 hours once a week. This function can be manually managed or EcoSolar are able to supply controllers or timers that take care of this function for you.
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