Nova NovaSun 150l, NovaSun 200l, NovaSun 300l Instruction Manual
Copyright © 2014 Ikhwezi Solar (Pty) Ltd, Novatherm CC, Solar Assist (Pty) Ltd
Instruction Manual
for the Installation and Maintenance of
NovaSun Direct Freeze Resistant
High Pressure Solar Hot Water Systems
(October 2013)
For use by trained qualified personnel only. Applicable to the following models:
Novasun, Direct Freeze Resistant, 150l, 200l, 300l
We reserve the right to change the installation instructions.
Reproduction, even partial, is only allowed with written permission.
WE Geysers (Pty) Ltd ,7 Nelmapius Street,
Chamdor, Krugersdorp, 1754
novasun@solarassist.co.za
www.novasunsolar.co.za
Copyright © 2014
Ikhwezi Solar (Pty) Ltd, Novatherm CC, Solar Assist (Pty) Ltd
1
Contents
1. Introduction ............................................................................................................................... 2
2. System description ..................................................................................................................... 2
2.1 Configurations .................................................................................................................. 2
3. Health and safety ....................................................................................................................... 2
3.1 General ............................................................................................................................ 2
3.2 Installation considerations ................................................................................................. 2
4. System configurations ................................................................................................................ 3
4.1 Novasun Thermosiphon System .................................................................................. 3
4.2 Novasun Split-pumped System .................................................................................... 3
5. Frost, scaling and hail resistance, stagnation................................................................................ 4
5.1 Hail resistance ............................................................................................................... 4
5.2 Freeze protection .......................................................................................................... 4
5.3 Direct systems – Freeze resistant ................................................................................ 4
5.4 Scale resistance ............................................................................................................ 4
6. System placement and orientation............................................................................................... 4
6.1 Collector orientation .......................................................................................................... 4
6.2 Shading............................................................................................................................ 4
6.3 Tilt angle .......................................................................................................................... 5
6.4 Water supply / delivery ..................................................................................................... 5
6.5 Roof structural integrity .................................................................................................... 5
7. Mounting methods ..................................................................................................................... 5
7.1 Selection of appropriate mounting method ......................................................................... 5
7.2 System mounting methods ................................................................................................ 5
8. Mounting process ....................................................................................................................... 7
8.1 Suggested mounting method 1 .......................................................................................... 7
8.2 Suggested mounting method 2 .......................................................................................... 8
9. System Installation ..................................................................................................................... 8
9.1 General installation technique ............................................................................................ 8
9.2 Cylinder and System plumbing ........................................................................................... 8
9.3 Geysers ............................................................................................................................ 9
9.4 Electrical connection ......................................................................................................... 9
9.5 Installation Diagrams ........................................................................................................ 9
Pumped System – Installation Diagram........................................................................................ 9
10. System commissioning ............................................................................................................. 11
10.1 Commissioning direct systems ......................................................................................... 11
11. Installation checklist ................................................................................................................. 11
12. System Selection and Sizing ...................................................................................................... 12
12.1 Introduction ................................................................................................................... 12
12.2 System sizing ................................................................................................................. 12
12.3 System type ................................................................................................................... 12
13. Owners operating and maintenance instructions ........................................................................ 13
13.1 Introduction ................................................................................................................... 13
13.2 Operating and efficient use ............................................................................................. 13
13.3 Over-night temperature stabilisation ................................................................................ 14
13.4 High water temperature .................................................................................................. 14
13.5 Periods of reduced usage or holidays ............................................................................... 14
13.6 Freeze protection liquid ................................................................................................... 15
13.7 Setting the time clock ..................................................................................................... 15
13.8 Owner maintenance ........................................................................................................ 17
13.9 Troubleshooting .............................................................................................................. 18
14. Warranties ............................................................................................................................... 18
15. Contacts .................................................................................................................................. 18
16. Warranty Contact Centre .......................................................................................................... 18
17. Warranty Services: (log warranty services) ................................................................................ 19
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Ikhwezi Solar (Pty) Ltd, Novatherm CC, Solar Assist (Pty) Ltd
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1. Introduction
All NovaSun solar hot water systems are high quality thermal solar
systems, using advanced technology to convert light into heat. This
installation manual must be read and understood before undertaking the
installation of a NovaSun solar hot water system. Should any aspect of the
installation process remain unclear a NovaSun Solar representative should
be contacted for advice prior to installation.
This manual does not seek to provide comprehensive guidance in terms of
the general plumbing and electrical connection of geysers, which is
assumed knowledge and required of any registered installer, but rather
sets out to provide guidance in terms of the correct installation of the solar
thermal components of the system.
Systems must be installed by suitably qualified and registered plumbers
and electricians, in accordance with relevant South African Norms and
Standards, National Building Regulations, Law and Regulations, Local ByLaws, including the following:
SANS 198 - Functional control valves and safety valves for domestic
hot and cold water supply.
SANS 10106 - The installation, maintenance, repair and replacement
of domestic solar water heating systems, edition three.
SANS10252 - Water supply and drainage for Buildings. Part 1 - Water
supply installations for buildings.
SANS 10254 - The installation, maintenance, replacement and repair
of fixed electric storage water heating systems.
SANS 10142 - The wiring of premises. Part 1 - Low-voltage
installations.
SANS 10400 - Parts A, B, L, XA.
Occupational Health and Safety Act (Act 85 of 1993)
National Buildings Regulations Act 103 of 1977
Water Services Act (Act N0 108 of 1977)
It is the responsibility of the installer to ensure that they and their staff
are familiar with and competent in respect of the above. Responsibility for
the safe and proper installation of a system rests with the installer.
The solar hot water systems referred to herein must be installed in
accordance with these instructions, local and national plumbing
regulations, municipal building codes and any other relevant statutory
regulations.
All intellectual property in this design and/or registrations and/or copyright
including any patent, patent application are the property of Novatherm CC
and/or WE Geysers (Pty) Ltd.
Observation of these instructions is most important and failure to do so
could void the benefits of the warranty.
The connection, attachment, integration or general association of other
equipment or parts which either directly or indirectly affect the operation
or performance of the solar system could void the warranty. Other such
equipment or parts not supplied by WE Geysers (Pty) Ltd, which may
affect its operation/performance must first be authorised by WE Geysers
(Pty) Ltd in writing if the full benefits of the warranty are to remain valid.
WE Geysers (Pty) Ltd does not accept liability or responsibility for the final
fitness of water for consumption from this water heater, as the water
quality is not affected by the system and is a function of the municipal
and/or other water supply.
This manual has been written with the intention of ensuring that the
system is correctly installed and that the owner/user is fully conversant
with the best methods of operation.
2. System description
2.1 Configurations
NovaSun solar hot water systems utilise state of the art technology and
perform with high efficiency in a wide range of weather conditions.
Collector output is directly related to the amount of incoming solar
radiation striking the collectors. This installation manual covers the
installation of the following systems:
Model Major System Components
NovaSun
150l
150 Litre Solartherm Direct Geyser
1 x 1.7sqm NovaSun Collector
NovaSun
200l
200 Litre Solartherm Direct Geyser
1 x 2 sqm NovaSun Collector
NovaSun
300l
300 Litre Solartherm Direct Geyser
2 x 2 sqm NovaSun Collectors
The models governed by this manual are pumped and thermo-siphon
systems. Thermisiphon systems may be installed in a close-coupled or split
system format whilst pumped systems are installed in split system format
and water is circulated using an applicable water circulation pump.
The NovaSun range of solar hot water systems are direct freeze resistant
systems.
System heating performance
Model Q-Factor*
Energy
Rating**
NovaSun 150l 11.8 TBA
NovaSun 200l 16.3 TBA
NovaSun 300l 27.5 TBA
*The thermal performance of the systems have been established by the South
African Bureau of Standards in terms of SANS 6211, at an incoming radiation of 16MJ
per m² per day, a temperature differential of 10°C and at an inclination of latitude
plus 10°.
**Q-factor is calculated in mega-joules whereas the energy rating is calculated in
kilo-watt hours. The energy rating is calculated by converting the q-factor into kwh.
The specific thermal capacity of the NovaSun collector is 4.39KJ/K m².
3. Health and safety
3.1 General
This appliance is not intended for use by young or infirmed persons
without supervision.
Scalding occurs at 50°C. This appliance is capable of providing hot water
over this temperature. In certain circumstances the system may expel hot
water and relieve pressure through the temperature pressure valve. Never
block this valve and always leave open to the atmosphere. Take care to
avoid contact with water when valve is in discharge.
This appliance is a water heating apparatus only and the final quality of
water and fitness for consumption is dependent on the quality of water
supplied to the system.
These systems are designed for the supply of hot water to domestic
household premises which have been constructed to the appropriate local
and national codes and regulations.
3.2 Installation considerations
All installations are to be carried out in accordance with the Occupational
Health and Safety Act (Act 85 of 1993) requirements and any relevant
local authority prescriptions. Some general points to take note of,
however, include the following:
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Ikhwezi Solar (Pty) Ltd, Novatherm CC, Solar Assist (Pty) Ltd
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Assess site specific risks and eliminate or reduced to an acceptable
level so as to satisfy health and safety requirements, prior to
installation.
Water temperature can reach boiling point and the collector can reach
stagnation temperatures of over 70°C. Shade collectors during
installation to prevent heating.
Take care when handling collectors to prevent breakage to glass and
injury. Safety goggles, work wear and gloves must be used to reduce
risk of injury.
Be aware of overhead power lines coming in through roofs, as well as
electrical wiring running through ceilings.
Assess weather and postpone roof work if unsafe (e.g. high winds,
rain, lightning, etc.).
Scaffolding and safety equipment must be installed by certified
personnel and signed-off accordingly. Inspect before use.
Inform home owners or building occupants of time and place of work
to be carried.
Ensure occupants are aware of site access constraints and all health
and safety implications relevant to them. Cordon off the area, if
applicable, to prevent personal injury and ensure any pets are
secured.
Ensure personnel working on installation are competent and in suitable
physical condition. Installers must be trained and conversant with the
assessment of height hazards, working at height safety procedures,
assessment of safety equipment (e.g. scaffolding, harnesses, etc.) and
the use and wearing of safety equipment (e.g. goggles, hard hats,
gloves, etc.).
All personnel working on the installation of a solar hot water system
must be issued with the appropriate safety equipment and be trained
in their use.
Failure to observe
safe practices may
result in:
scalding /
burns;
electrical
shock;
and/or falling,
which can cause
serious injury or
death.
4. System configurations
4.1 Novasun Thermosiphon System
For the purposes of the Eskom Rebate Program only thermo-siphon systems
can be installed and a rebate claimed.
A thermo-siphon system relies on the natural circulation of fluid between the
collector and the geyser. In order for the thermo-siphon process to occur
the geyser must be placed in a higher position than the solar collector. The
system operates according to the laws of thermal dynamics (i.e. a liquid,
when heated, becomes less dense and rises above the denser cooler liquid).
Heated water rises up through the collector and into the geyser, displacing
colder water therein, which sinks to the header pipe of the Novasun
collector. The process continues until the collector can add no more gain in
temperature or until the sun stops shining. Without sunlight the water in the
collector header pipe cools, becomes denser, preventing hotter liquid in the
geyser from being displaced.
A thermo-siphon can be close-coupled or split as illustrated below, provided
there is sufficient roof space.
4.2 Novasun Split-pumped System
• Where the solar water heater is installed in the roof, it must be
installed in compliance with SANS 10106 complete with a Safety Valve,
drain cock, Multi Pressure Control Valve 400kPa, Drip Tray and vacuum
breakers on the cold and hot water supply.
• When installed inside the roof minimum clearance must be allowed in
order to remove the element and thermostat.
• Roof structural integrity must be handled according to section 6.5.
• For Product warranty detail refer to the separate Warranty Agreement.
• Pump Circulation in the Novasun SWH system.
• When it is not convenient or possible to place the cylinder higher than
the collector, a circulating pump controlled by an electronic control unit
and two sensors is used to monitor the temperature of the manifold
and the cylinder, that enable the powering of the circulation pump
when the water in the panel manifold is hotter than the water in the
cylinder.
• When the temperature difference is less than the set point the pump
will stop
• When temperature of water in the cylinder reaches the highest set
point, the controller will stop the pump.
• The circulating pump used must be installed and maintained according
to the manufacturer’s instructions.
• A 12V circulating pump with a photovoltaic can also be used.
• A split-pumped system is illustrated below.
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5. Frost, scaling and hail resistance, stagnation
5.1 Hail resistance
NovaSun collectors are hail resistant with 4mm toughened glass and have
passed SABS hail tests.
5.2 Freeze protection
Solar hot water systems can be classified as (i) direct: freeze resistant, (ii)
direct: non freeze resistant or (iii) indirect.
5.3 Direct systems – Freeze resistant
In direct systems the water to be used in the household circulates through
the collector, transferring solar energy into the solar geyser.
The Novasun panel contains a fully insulated heat exchanger that acts as a
freeze resistant mechanism, as declared by the manufacturer. The pipework
connecting to the solar geyser must be insulated with Insulflex insulation
material.
When installed with a PEX-lined Solartherm Cylinder it can be used in all SA
climate locations (i.e in areas where frost occurs and areas, where ambient
temperature may fall below 5°C). Contact Solar Assist to discuss water
quality matters.
5.3.1Direct systems: non-Freeze Resistant
In direct systems the water to be used in the household circulates through
the collector, transferring solar energy into the solar geyser.
Direct systems are used in frost-free locations, where ambient
temperature never falls below 5°C and where water quality is good (i.e. less
than 600ppm total dissolved solids/minerals).
5.3.2Indirect systems
In indirect systems the potable water used in the household does not
circulate through the collectors, but remains in the geyser and is heated
indirectly by a heat exchanger.
There are two basic types of heat exchanger, namely a jacketed system
where an inner cylinder is surrounded by a secondary outer layer and an
internal heat exchanger where the solar geyser contains an internal copper
pipe structure.
In both cases the solar loop (i.e. the pipe work to and from the collectors)
contains a heat transfer medium (i.e. propylene glycol/water solution) which
is physically separated from the potable water.
Propylene glycol has a lower freezing point and prevents the liquid in the
collectors from freezing and damaging the collector through expansion that
occurs when ice forms. Only food grade glycol should be used.
Indirect systems are used in locations where frost occurs and the
ambient temperature drops below 5°C and/or where water quality is
poor (i.e. more than 600ppm total dissolved solids/minerals).
These collectors are resistant to freezing only when installed with an indirect
geyser and the solar loop filled with a solution of propylene glycol and
water. Water alone must not be used as a transfer fluid. The glycol / water
solution should be mixed in a glycol to water ratio of 1:3 (i.e. 33% glycol).
5.4 Scale resistance
Indirect systems containing a glycol solution also prevents scale build up
inside the collector in areas of poor water quality. It is important to note that
the geyser itself may still be affected by water quality as would be the case
with any conventional enamel-lined geyser unless a Solartherm PEX-lined
geyser is used.
If a direct system is used in areas of poor water quality the pipe work inside
the collector and solar loop may be subject to a build-up of scale. This may
be avoided through the use of a water softening system. This is good
practice regardless of type of system, as the water will affect other
household appliances in any event.
In the event collectors experience scale build-up the performance
of the system will decrease. Should this occur the system can be
flushed with a mildly acidic solution (e.g. vinegar solution) and in
the case of the Novasun collector, the Header Pipe should be
flushed. The pipe work should then be flushed with fresh water
after removal of scale prior to re-commissioning.
Ensure you are familiar with the relevant tank manufacturer’s warranty
terms and conditions in respect of water quality, particularly as it relates to
anode replacement in case of enamel-lined tanks.
6. System placement and orientation
A number of basic fundamentals need to be observed when installing any
solar hot water system.
6.1 Collector orientation
Optimum system performance is achieved when the collectors face directly
North (i.e. true North) when installing in the Southern Hemisphere. The
closer the collector is to directly facing the equator the greater the amount
of solar radiation the collector will be exposed to and the greater the
potential for heating.
Angles up to 45° either side of North will not have a major effect on the
system performance given the state of the art technology used in the
construction of the NovaSun systems. Therefore, roofs that are orientated
away from North are also acceptable for installation.
Outside of the 45° range one could consider utilising more collector surface
area or using a mounting frame to adjust the orientation back to North.
6.2 Shading
With a system orientated to face North, the time period when the collector is
exposed to the most direct solar radiation is between 10h00 and 16h00.
Solar collectors with an East bias will achieve a greater gain in morning
hours and those with a West bias will do so in the afternoon.
Care should be taken to ensure that the collectors are not subjected to
excessive shading from trees or adjacent buildings, particularly between
09h00 and 16h00.
Also bear in mind that tree growth could lead to future shading issues.
If the installation takes place in summer, it is also important to take into
account the lower solar angles in winter, which result in longer shadows.
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6.3 Tilt angle
In respect of the optimum angle of inclination for a solar collector, the rule
of thumb provides that the latitude of the location is taken and then 10°
added thereto. Therefore, a location with latitude of 25° would indicate an
optimum collector tilt angle of 35°.
The angle of inclination, however, is also flexible and minimal loss of
performance occurs by installing at lower or higher angles of inclination.
The NovaSun collector can be installed as low as 10°. Below this, however,
the thermo-siphon process does not function effectively. Also, angles lower
than this would result in build-up of dust, as it is not able to be washed
away effectively by rainfall.
It must also be noted that installation angles over 30° will require additional
strapping to secure the geyser and collector during and after installation, as
at this angle the system will tend to move downward. Consideration should
be given to a split installation in these circumstances.
6.4 Water supply / delivery
The location of the installation should give as efficient a supply of hot water
to all areas of the residence as possible. If not possible, the system should
be placed as close to its main point of usage (e.g. master bathroom).
Discuss this with the client and confirm their understanding and
requirements.
6.5 Roof structural integrity
The area chosen for installation must be structurally capable of handling the
loading. Check load weights of applicable system and ensure that the weight
can be borne by the roof structure. Specialist advice should be sought if
required.
The system should be placed, such that the tank spans at least three main
trusses. It is good practice to brace all truss work that supports the
installation.
Strengthen rafters (or timbers or other structures) used for supporting the
panel and tank, for example by adding noggins between rafters or adding
thicker timbers alongside them or cross bracing them or adding additional
supporting struts to the truss to spread the additional load to a load bearing
point. Where ever possible the system should be installed over a supporting
wall of the building (i.e. on a truss resting on a supporting load bearing
wall). Never install a system on a roof with damaged or rotting timbers.
To prevent cracking of certain fibre cement and metal roof sheeting, a flat
mounting frame designed to spread the load of the geyser and its contents
should be designed by suitably qualified personnel and installed below the
geyser. Ensure that the roof covering material is structurally sound to
receive the weight of the system. In the case of a split system installation a
wooden frame should be constructed which raises the tank above the level
of the collectors. Care should be taken in the design and construction of this
frame so as to ensure it meets all relevant standards.
7. Mounting methods
7.1 Selection of appropriate mounting method
Please note that it is the installer’s responsibility to ensure that the means of
fixing the system to the roof such that it results in a safe and functional
installation.
The methods suggested are generic and will not necessarily be suitable in all
situations.
7.2 System mounting methods
7.2.1Suggested method 1 - General purpose installation brackets
The image below depicts a typical bracketing system which could be used
with NovaSun solar hot water systems. This type of bracketing system is
suitable for tiled or corrugated roof structures with a pitch of less than 30
degrees. Typical kits would include the following pieces:
A (2 pieces) – Tank Cradle Bracket
B (2 pieces) – Collector Clamp
C (2 pieces) – Straps (not included*)
D (2 pieces) – Collector Hanger Bracket**
*Straps are not included as lengths required will differ from installation to installation.
These should be aluminium or stainless steel.
**Please note that two hanger brackets are required per collector. The 300 litre
system using two collectors require 4 hanger brackets (two per collector).
Please note that points of contact between the collector frame and mounting
brackets and between tank and mounting brackets are buffered by a foam
lining to prevent issues surrounding galvanic corrosion.
The installer must install the system in such a fashion to prevent long term
degradation of system materials through galvanic reaction.
7.2.2Suggested method 2 - Alternate installation brackets
As an alternative to the first bracketing system, straps could be used.
Collectors could be secured directly to the roof structure, at each of the four
corners of the collector, by means of aluminium strapping.
The straps should be securely fixed to the underside of the aluminium
collector frame using aluminium speed screws. The straps can then be
passed under the tiling and secured around the nearest truss and/or purlin.
In respect of the geyser, strapping can be hooped around the geyser, on
either end of the cylinder, using strap clamps available with commercially
available strapping systems, leaving enough length to pass the tail pieces
under the tiles and secured around the appropriate roof woodwork.
As indicated above the installer must install the system in such a manner so
as to prevent galvanic corrosion between system components and the
mounting brackets and/or straps.
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