Conergy TS Owners & Installation Manual

Conergy TS

Open and Closed Circuit Systems

Owner & Installation Manual

www.conergy.com.au

ENGLISH

Conergy TS

Owner & Installation Manual

1

Table of Contents

Table of Contents

Customer Information

The environmental benefits

Why Conergy?

How does the system work?

Installation Information

Conergy TS model number explained

Important safety information

If the customer is away for a period of time

Water discharge through the pressure valve

Troubleshooting

Low solar energy input

Solar collector shading

Booster system not operating

Excessive water discharge from the valves?

Using more hot water than anticipated?

Water discharge from frost valve

System Maintenance

Installation Instructions

Typical open circuit assembly diagram

Typical system assembly

Connection and mounting part kits

Roof location selection

Supplementary heat sources

Common installation procedure

System installation

System diagrams and components

Plumbing connections - Open Circuit models

Plumbing connections – Closed Circuit models

Draining the storage tank

Filling the Closed Circuit jacket

Electrical installation instructions

Gas (AES) installation instructions

Commissioning & Customer Hand Over

ANNEX - Mounting frame for flat roof

Warranty

1

1.1

1.2

1.3

2

2.1

2.2

2.3

2.4

3

3.1

3.2

3.3

3.4

3.5

3.6

4

5

5.1

5.2

5.3

5.4

5.5

5.6

5.7

5.8

5.9

5.10

5.11

5.12

5.13

5.14

6

7

8

2

2

2

2

5

5

5

6

6

7

7

7

7

7

7

8

9

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Conergy TS

Owner & Installation Manual

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1 Customer Information

You are installing one of the most advanced solar water heaters in the world. This manual provides
you with the essential information needed to install the Conergy Thermosiphon System correctly.
Please read it carefully and follow all the instructions. We hope you find the following information
useful.

The environmental benefits

A Conergy solar water heater is an excellent and economic energy solution. By using the sun’s heat
to heat our water, we cut down on the amount of fossil fuels needed to be burnt to supply electricity
to do the same.

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 100 000’s of Solar Home Systems for Hot
Water and Solar Electricity worldwide and we offer the leading products in this technology.

Before you can sell in Australia, or achieve any of the State or Federal Government rebates, your
product must comply with the rigorous Australian Standards for solar water heaters. Our products
comply with all 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 systems often achieve more RECs than our
competitors.

How does the system work?

Under normal operating conditions the potable water within the potable storage tank is heated by
the solar collectors. For example, in an open circuit system where the household hot water is in the
collector circuit, cold water is pushed downwards via the long external pipe from the storage tank to
the bottom of the solar collector. As the water is heated in the absorber by the sun, it rises to the top
of the collector then travels through the short external pipe into the storage tank.

The Conergy TS solar water heater is supplied in kit form so that the installer can assemble and
connect the solar water heater in various configurations to suit the installation location and user
requirements. Typically the kit contains the four main components of your solar water heater system
which are the potable water storage tank, the solar collector(s), the Ancillary Energy Support (AES)
System and the parts box, containing pipes fittings and mounting rails to interconnect and mount the
system. Please note the AES system can be either electric or gas operated dependent on the model
purchased.

1 Customer Information

1.1

1.2

1.3

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Conergy TS

Owner & Installation Manual

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1 Customer Information

Storage Tank & Solar Collectors

The potable water storage tank is used to store the heated water ready for household use. It is
constructed using high quality vitreous enamel lined low carbon steel to provide long life. The
tank is insulated with a high density polyurethane material to ensure minimal heat losses and
maximmum structural strength.

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 insulated metal casing covered with a high
strength toughened glass sheet that protects the absorber system from physical damage.

Ancillary Energy Support (AES) - Booster System

Electricity and gas are the two options for the AES system. An electric Ancillary Energy Support
(AES) system uses an electric element to heat part of the stored household water on those
occasions when there is reduced solar energy available e.g. cloudy days.

The electricity supply to the electric AES, located within the storage tank, is automatically
controlled by an internal thermostat. This thermostat will only allow the electric element to operate
if the storage tank water temperature falls below 60oC. It will only consume electricity until the
water temperature is increased to 60oC. At this stage, it will turn off automatically.

1.3.1

1.3.2

Conergy TS 300 litre vitreous enamel tank

LC collector

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Conergy TS

Owner & Installation Manual

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For gas AES systems the electric element in the storage tank is not connected to an electricity
supply. Instead a continuous flow gas water heater is fitted in series with the hot water supply from
the storage tank and the household hot water pipe system. As the hot water from the solar storage
tank passes through the gas heater its temperature is automatically monitored. If the temperature
is below 60°C, the gas heater will add the heat required to deliver hot water of at least 60 °C. If the
water temperature is above 60°C, the gas heater is programmed not to ignite.

1 Customer Information

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Conergy TS

Owner & Installation Manual

5

2 Installation Information

Conergy TS model number explained

Important safety information

| 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 every 6 months to ensure its operation and settings remain
correct. Please check that the pressure & temperature relief valve relief 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, infirm persons, or persons lacking
relevant skill or experience, without suitable supervision. Children should be supervised to
ensure they do not play with hot water taps or the water heater.

| For closed circuit systems, if the water seems red in appearance it could mean that there is
a leakage of glycol from the jacket into the main water tank. Please contact your authorised
Conergy dealer or installation service provider as soon as possible.

2 Installation Information

2.1

2.2

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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Owner & Installation Manual

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Hydrogen gas can accumulate!

If the hot water system is not used for two weeks or more, a quantity of hydrogen gas, which is highly
flammable, 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 but not 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.

If the customer is 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 high temperature valve in the storage tank
may open and disperse small amounts of hot water for a short period 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 have two pressure valves located within the system configuration.
The cold water expansion valve, located in the cold water supply pipe, may release a small amount
of water from time to time during the heating cycle of the system. The water discharge is water
expanding due to the heating process. Normally the discharge will be less than 10 litres per day.
The pressure & temperature valve, located on the storage tank, may also release a small expansion
discharge.

2 Installation Information

2.3

2.4

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Owner & Installation Manual

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3 Troubleshooting

3 Troubleshooting

What to check for during service calls

If there is not enough hot water we recommend that the following points are considered as part of the
service call. The most obvious reasons for a lack of hot water could be one of the following:

Low solar energy input

If there have been prolonged periods of cloud or winter is approaching, it may be necessary to
reconsider the permitted boosting time for time-clock controlled systems or to turn on the booster
for systems with a booster isolation switch.

Solar collector shading

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 standard
domestic glass cleaner. If rainwater collection occurs from the same roof on which the solar water
heater is located, do not use chemical cleaning agents to clean the collectors. Any spillage of these
onto the roof could cause contamination of water in the rainwater tank.

Booster system not operating

For electric systems the fuse or 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. Contact your authorised Conergy dealer or
installation service provider as soon as possible.

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. Contact your authorised Conergy dealer or
installation service provider as soon as possible.

Excessive water discharge from the valves?

If there is a discharge of more than 10 litres per day from any of the systems valves, it indicates there
may be a problem with the valve or an increased water supply pressure. Contact your authorised
Conergy dealer or installation service provider as soon as possible.

Using more hot water than anticipated?

Often the hot water usage of showers, washing machines and dishwashers is underestimated by
the customer. Review these appliances to determine if the daily usage is greater than the storage
volume of the water heater. Depending on the model, our TS system tanks contain 180 or 300 litres
of hot water therefore if the customer’s usage is greater than 300 litres within a short period of time,
there may be periods where the water temperature is slightly lower than normal. It is also advisable
to inspect hot water tap washers etc. for leakage and replace if necessary.

3.1

3.2

3.3

3.4

3.5

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Conergy TS

Owner & Installation Manual

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Water discharge from frost valve

If your system has a frost valve fitted it will be located at the bottom corner of the collector. In
temperatures that cause frost or freezing the valve will open and some water will discharge from this
valve. There is nothing that needs to be done to the valve or the system, it is operating correctly. The
water will stop discharging once the valve has warmed enough to close again, usually as the frost
clears.

3.6

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Conergy TS

Owner & Installation Manual

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The Conergy system is designed such that there is little to do regarding system maintenance. Should
you decide that you want to inspect the roof mounted system it is essential that you use all safety
devices required to ensure your personal safety.

Glass cleaning usually occurs by natural rainfall, however if the installation is in an industrial (or
similar) area with high levels of airborne particles then a qualified person can clean the collector
glass with normal window cleaning chemicals and equipment. If rainwater collection occurs from the
same roof on which the solar water heater is located, do not use chemical cleaning agents to clean
the collectors. Any spillage of these onto the roof could cause contamination of water in the rainwater
tank.

In the unusual case that the toughened glass collector covers are broken, Conergy does not advise
replacement of the glass. The entire panel should be replaced to maintain the performance and
integrity of the water heater. Replacement panels should be installed by a qualified person.

The lever on the relief valves should be operated at least every six months. Failure to do so may result
in failure of the tank. If water does not discharge freely from the valves they should be checked and
possibly replaced. The relief valves and relief valve drain lines must not be blocked. Some water may
discharge during each heating cycle.

Every five years all safety valves should be replaced to ensure continued life and operational safety
of the system. In locations where the potable water has a Total Dissolved Solids (TDS) of greater than
600 ppm it is recommended to replace all safety valves every 3 years.

The high quality vitreous enamel lined low carbon steel tanks have a sacrificial anode for long tank
life. This anode should be inspected every few years and be replaced when it has worn out. As a
minimum it is recommended that the anode be changed every 5 years.

4 System Maintenance

4 System Maintenance