Conergy Active System, F20LC, E20SB, E20BC, E25BC Owners & Installation Manual
www.conergy.com.au
Conergy Active System
Open and Closed Split Systems
Owner & Installation Manual
ENGLISH
Conergy AS
Owners Manual
2
Owners Information
The environmental benefits
Why Conergy?
What is a Split System?
System components
Your Conergy AS model number
System operation
Important safety information
What should I do during holidays?
Troubleshooting
What should I check before making a service call?
System Maintenance
Pressure limiting valve
Draining the storage tank
Important Installation Notes
Roof location selection
Supplementary heat sources
Collector Installation
Installing the collectors
Connections at the Storage Tank
Removing the hot scoop from the storage tank
Connections for open circuit systems with a PM-600
Connections for closed circuit systems
Electrical Connections to the System
Electrical connections to the system
Electrical connection for gas AES systems
Electrical installation for a PM-600
Comissioning & Customer Handover
Warranty
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
2
2.1
3
3.1
3.2
4
4.1
4.2
5
5.1
6
6.1
6.2
6.3
7
7.1
7.2
7.3
8
9
3
3
3
3
5
7
7
8
8
9
9
11
11
11
13
13
13
14
14
18
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23
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24
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Table of Contents
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1 Owners Information
Congratulations on buying one of the most advanced solar hot water heaters in the world. As the
owner of a Conergy solar water heater you may have some questions about the system and how
it operates. Your solar water heater model is commonly referred to as an Active, Split or Ground
Mounted open circuit or closed circuit system and is one of the most efficient solar water heater
types available.
The environmental benefits
A Conergy Solar Water heater is an excellent and economic energy solution as, by using the sun’s
heat for heating water, we cut down on the amount of fossil fuels burnt to supply electricity to do the
same thing.
Any time you use solar energy to offset the amount of fossil fuels that are burned, you contribute to
everyone’s health and welfare. Operating one solar water heater instead of an electric water heater
saves the equivalent of 1400 litres of oil every year and reduces carbon dioxide emissions by up to
3.4 tonnes per year and sulphur dioxide which contributes to acid rain emissions by more than 6kg.*
Multiply those emissions per household by all the homes in your neighbourhood, town and state and
the benefits of solar for our environment are enormous.
Why Conergy?
Conergy offers Australia’s largest range of renewable energy products and our company operates
in 25 countries on 5 continents. Our products are used in hundreds of thousands of homes for Hot
Water and Solar Electricity worldwide and we offer the leading products in these technologies.
To sell solar water heaters in Australia, or achieve any of the state or Federal Government rebates, the
products must comply with the rigorous Australian Standards for hot water and solar hot water. Our
products comply with all of these standards. The Federal Government Renewable Energy Certificate
program, called RECs, is an indication of solar efficiency. If you compare any of the Conergy products
with an equal competitor model, you will find that Conergy achieves more RECs than any of our
competitors.
What is a Split System?
A Split System (also referred to as an Active system) is a system where the heated water in the solar
collectors is circulated by a pump, drawing cold water from the storage tank or heat exchanger,
pushing it through the collectors and back to the tank or heat exchanger as heated water. The
location of the tank can be up to 20 meters from the collectors. The pump requires electricity, but
uses a very small proportion of power in comparison to the heat collected by the system. The power
consumed is no greater than 28 watts.
There are two types of Conergy active solar water heaters. The operating methods and instructions
are similar for both. The two types are; “Open Circuit System” & “Closed Circuit System”:
1 Owners Information
1.1
1.2
1.3
* Source: Australian Greenhouse Office
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What is an open circuit system?
An Open Circuit System is one where the water used in the household circulates through the solar
collector panels. The circulating pump draws colder water from the lower section of the container
and circulates this water through the collectors before returning it to the container at a point
higher than the point of draw-off thus transferring solar energy to the storage tank. This system
type is used in locations where the ambient temperature never falls below freezing point (0°C or
32°F) and where the water quality is good – less than 600 ppm Total Dissolved Solids (TDS).
What is a closed circuit system?
In this system the pump circulates the transfer fluid around the collector circuit. The water within the
tank circulates via thermosyphon, from the cold bottom of the tank, through the heat exchanger,
where it is heated before returning the container at a point higher than the point of the cold water
inlet.
Open Circuit System
Closed Circuit System
1.3.1
1.3.2
1 Owners Information
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System components
The main components of your solar water heater are the household water storage tank, the solar
collector(s), circulation pump module & controller, heat exchange module (closed circuit models only)
and the Ancillary Energy Support (AES) System.
1 Owners Information
1.4
Storage tank & solar collectors
The solar collectors contain a multi tube copper water way system bonded to a solar absorber
plate, the combination of which collects solar energy and transfers it to the fluid within the collector
circuit. The absorber plate system is enclosed in an aluminium or zincalume casing covered with
a high strength, low iron toughened glass sheet that protects the absorber system from physical
damage. Conergy offers 4 collector models with your system. They are:
Ancillary Energy Support (AES) - booster systems
Electricity and gas are the two options for the AES system. The selection of the most suitable AES
system type is made at the time of purchase from the Conergy dealer.
For electric AES systems the electric element within the storage tank is automatically controlled
by an internal thermostat which will only allow the electric element to operate if the storage tank
1.4.1
1.4.2
Open circuit tank, closed circuit tank, solar collectors
Electric AES System
The Conergy water storage tank is
used to store the heated water ready for
household use. It is a standard water
heater storage tank, incorporating
a high temperature vitreous enamel
lining to provide long life, and a high
density polyurethane insulation to
ensure minimal heat loss.
| F20LC - Selective surface guarantees maximum performance in high solar radiation areas
| E20SB - Semi selective surface on copper substrate for maximum performance in high solar
radiation areas, aluminium tray for corrosive environments
| E20BC - Black chrome surface on copper substrate guarantees maximum efficiency, aluminium
tray for corrosive environments
| E25BC - 2.5 m
2
surface area black chrome surface on copper substrate guarantees higher efficiency,
aluminium tray for corrosive environments
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1 Owners Information
Detecting availability of useful solar energy in the solar collectors. When the temperature of the
solar collector is 6°C higher than the storage tank temperature, the circulation pump is initiated.
If the difference in temperature falls to less than 4°C the circulation pump is stopped.
Controlling maximum storage tank temperature. If the storage tank temperature reaches 70°C,
the circulation pump is stopped to prevent excessive temperatures in the storage tank.
Collector maximum temperature limiting. If for any reason the collector temperature reaches
200°C, circulation is stopped to prevent potential damage to the system components.
Collector Temperature control. During periods when the circulation pump is idle, and if the
water temperature falls below 60°C and will only consume electricity until the water temperature
is increased to 60°C then turns off again.
For gas AES systems a continuous flow gas water heater is fitted adjacent the storage tank in
series with the hot water supply from the storage tank and the household hot water pipe work
system. As the hot water from the solar storage tank passes through the gas heater its temperature
is automatically monitored by the gas heater. If the temperature is below 60°C the gas heater
will add the energy required to deliver hot water of at least 60°C. When the water storage tank
temperature is above 60°C the gas heater will not ignite.
Circulation pump
The circulation pump is a simple device used to circulate the water in the collector circuit. This, in
turn, enables solar energy from the collectors to be transferred to the storage tank location. The
pump consumes only a very small amount of electrical energy (less than 28 watts) to perform this
task. The circulation pump has an integral ‘non-return valve’ to prevent solar energy from reverse
cycling back through the storage tank to the collectors at night.
The electronic control device used to control the circulation pump has a complex set of activities.
It is the brain of the system and ensures optimum system efficiency and safety. The basic functions
are:
1.4.3
1.
2.
3.
4.
Gas AES System
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Your Conergy Split System model number
System operation
A Conergy solar water heater is designed for fully automatic operation, so there is nothing you need
to do for day to day system operation. If the AES System has been fitted with a remote isolator switch
or time-clock, you may make the decision when and if Ancillary Energy Support is permitted. As a
guide you may like to isolate the AES System during the summer months and you may use a time clock
to permit boosting after sunset or any other combination, which suits your usage pattern. Careful use
of these options can further reduce your energy use for hot water supply to the household.
collector temperature rises above 190°C, the circulation pump will be initiated to reduce the
collector temperature to below 185°C. This is to protect the collector from prolonged periods
of extreme temperature.
System Cooling. During the collector circuit temperature control operation, if the storage tank
water temperature has risen above the set 70°C maximum, the controller will initiate the pump
to reduce the excess tank temperature back to the set point of 70°C. This function is to ensure
water temperatures above 70°C are not stored for prolonged periods in the storage tank.
5.
1.5
1.6
1 Owners Information
XX NNN / N / X / XNN / X / XNNXX
System Type - Nominal Volume - Collector Area - Tank Type - Booster - Tank Material - Collector Type
Variable Categories
System Type AS Active Systems (pumped)
HP Heat Pump System Type
TS Thermosiphon, TS
Nominal Volume Nominal Storage Volume
Collector Area 2, 2.5, 4, 5, 6 Nominal Collector Area
Tank Type O Open Circuit
C Closed Circuit
Booster E Electric
G Gas
XX Booster Rating (kWx10 or Lpm)
Tank Material /
Designation
V Vitreous Enamel
S Stainless Steel
M Millenium Tank
Collector Type E20SB, E20BC, E25BC or F20LC
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1 Owners Information
Important safety information
1.
2.
3.
1.7
All water heaters have the ability to produce hot water very quickly. To reduce the risk of scald
injury, it is recommended that a temperature control valve be fitted to the hot water supply pipe
work. This valve should be checked at regular intervals to ensure its operation and settings
remain correct.
Please check that the pressure & temperature relief valve drain pipe is not located where it can
cause damage if hot water is discharged.
This water heater is not intended for use by young children or infirm persons without supervision.
Young children should always be supervised to ensure that they do not play with hot water taps
or the water heater.
If you are away for a period of time
If the system is not to be used for a period of a week or more during the summer months,
it is advisable to turn off the electricity supply to the booster and if practical cover the solar
collectors. If the solar collectors are not covered, there is a possibility that the pressure &
temperature relief valve in the storage tank may open and disperse small amounts of hot water
to reduce the storage tank temperature while you are away. This is a normal function and does
not harm the system.
Water discharge through the pressure valve
All Conergy solar water heaters will have either one or two pressure valves in the water pipe
work:
1. A Pressure & Temperature Relief Valve attached to the tank, and possibly;
2. A Cold Water Expansion Valve located in the cold water supply pipe work.
For solar water heaters that only have a Pressure & Temperature Relief Valve, it is normal for
a small water discharge to occur during the heating cycle of the system. This discharge is
water expanding due to the heating process. Normally the discharge will be less than 10 litres
per day. For systems that have both valves, the expansion discharge will occur from the Cold
Water Expansion Valve.
Hydrogen gas can accumulate!
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 several minutes at a sink, basin or bath. Do not use a dishwasher,
clothes washer or other appliance. During this procedure there must be no smoking, open
flame or any other electrical appliance operating nearby. If hydrogen is discharged through the
tap, it will probably make an unusual noise as with air escaping. Do not place hands or any part
of your body beneath the tap during this procedure.
1.7.1
1.7.2
1.7.3
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What should I check before making a service call?
If there is not enough hot water, it is recommended that the following points are considered before
making a service call. If after checking the following points the problem has not been identified,
please contact the Conergy distributor from whom you purchased the system.
2.1
2 Troubleshooting
2 Troubleshooting
It is important to know that there are no user serviceable components in the system, and as such,
it is recommended that no covers be removed and no adjustments made to the system settings by
anyone other than an authorised Conergy representative.
Low Solar Energy Input / Shading
If there have been prolonged periods of cloudy weather, or winter is approaching, it may be
necessary to reconsider the permitted AES allowance for time-clock controlled systems, turn
on the AES for systems with a booster isolation switch or turn on the gas supply to gas AES
models.
Often trees or other buildings can shade the solar collectors, or there can be a dirt build up on
the glass cover. Trees should be cut back if possible, or the system relocated if removal of the
shading is not possible, in the present location. If the glass is dirty, this should be cleaned with
any normal domestic glass cleaner.
Ancillary Energy Support (Booster System) not operating
For electric systems, the fuse, circuit breaker supplying the AES System should be checked.
If the time clock (where fitted) and the fuse or circuit breaker are operational and the water is
cold, you can turn the booster isolator on and off to see if the electricity meter speed changes. If
there is no change in speed, it indicates there may be a booster problem and a service call will be
necessary. It is important to remember – Do not open or adjust any electrical covers or devices
yourself.
For gas systems the gas and electric supplies to the gas heater should be checked to ensure they
are both on. If water temperature from the gas heater is below 60°C and both supplies are on and
the gas heater does not ignite there may be a problem and a service call will be necessary.
Excessive water discharge from the Valves?
If there is a discharge of more than 10 litres per day from any of the system’s valves, it indicates
there is a problem that requires a service call.
Are you using more hot water than you think?
Often the hot water usage of showers, washing machines and dishwashers is under estimated.
Review these appliances to determine if your daily usage is greater than the storage volume of
your water heater. Refer to the section “What system do I have?” to determine the storage volume
of your water heater. It is also advisable to inspect tap washers etc. for leakage and replace if
necessary.
2.1.1
2.1.2
2.1.3
2.1.4
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