SolarEast FPC270-2D,FPC270-3D,FPC340-2D,FPC340-3D,FPC450-2D,FPC450-3D,TZ250E-25R250L,TZ250E-30R250L,TZ315E-25R315L,TZ315E-30R315L,TZ315E-40R315L,TZ400E-30R400L,TZ400E-40R400L, FPC340-2D, FPC450-2D, FPC340-3D, FPC450-3D Owners & Installation Manual

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Version 12.0 OCTOBER 2015 Page 1

OWNER & INSTALLER MANUAL

ELECTRIC BOOST SOLAR WATER HEATERS

Version 12.0 OCTOBER 2015 Page 2

Models:

Flate Plate Collector Models

FPC270-2D

FPC270-3D

FPC340-2D

FPC340-3D

FPC450-2D

FPC450-3D

Evacuated Tube Collector Models

TZ250E-25R-

250L

TZ250E-30R-

250L

TZ315E-25R315L

TZ315E-30R315L

TZ315E-40R-

315L

TZ400E-30R400L

TZ400E-40R400L

Congratulations for purchasing a high quality Solar Water Heater, designed in Australia for Australian conditions.

This water heater must be installed and serviced by a qualified person.

WARRANTY / SERVICE – Contact SolarEast Australasia Pty Ltd (“SolarEast”) by email on

service@solareast.com.au.

Note to Installer: Following Installation, please:

1. Complete the installer checklist (page 28) and return to SolarEast; and

2. Hand this manual to the homeowner for future reference. Note – the Warranty page requires your signature for future reference.

THIS UNIT IS NOT SUITABLE FOR USE AS A POOL OR SPA HEATER

WARNING: Plumber - Note Carefully: Plastic pipe must not be used on a solar water heater

installation due to the effects of high water temperatures and pressures. USE COPPER PIPE ONLY. All compression fittings must use brass or copper olives.

Notice to Victorian Customers from the Victorian Plumbing Industry Commission

This water heater must be installed by a licensed person as required by the Victorian Building Act 1993. Only a licensed person will give you a Compliance Certificate, showing that the work complies with all relevant Standards. Only a licensed person will have insurance protecting their workmanship for six years. Make sure you use a licensed person to install this water heater and ask for your Compliance Certificate.

Installation and service must be performed by an authorised and qualified person. This water heater must be installed in accordance with:

1. Manufacturer’s Installation Instructions

2. AS/NZS 3500.4 “National Plumbing & Drainage Code”

3. AS/NZS 3000 “Wiring Rules”

4. Relevant Occupational Health & Safety Regulations

5. Municipal Building Codes (including NZ Building Code if installed in New Zealand)

6. Any other relevant Local, State or Federal Statutory Regulations

Version 12.0 OCTOBER 2015 Page 3

WARNING: Plumber – Note Carefully

 This page of brief instruction is to be read in

conjunction with other plumbing and electrical installation requirements contained within this Installation Instruction and Owner’s Manual

 All installation work must be carried out by an

appropriately qualified Tradesperson/s.

 The installation must be performed by Qualified and

Authorised Persons and comply with the requirements of AS/NZS 3500.4, AS/NZS 3000, and all local codes and regulatory authority requirements.

 It is recommended the solar storage tank be installed at

ground or floor level. The water heater must stand vertically upright.

 This Water Heater Is Not Suitable For Pool Heating  Section 4 “Solar Collector Installation” must be read and

understood prior to installation of collectors to roof top.

 Plastic pipe must not be used on a solar water heater

installation due to the effects of high water temperatures and pressures. USE COPPER PIPE ONLY. All compression fittings must use brass or copper olives.

 Hot and cold copper pipes to and from the collectors

must be completely insulated with a suitably temperature rated insulation that is UV rated and weatherproof with minimum thickness of 19mm.

 Valves and fittings supplied with this water heater are

supplied with insulation covers which must be fitted as part of the solar installation. Failure to fully insulate pipework and fittings increases the risk of freeze damage and will void warranty

 The maximum height of solar flow and return pipes must

be where these pipes enter and exit the solar collectors to avoid the possibility of air locks in the solar installation.

 The maximum length of the copper tube from the solar

pump to the collectors is reliant on mains pressure (minimum 200kPa) and the number of bends and fittings in the run. As a guide, for DN15 copper pipe, the maximum length should not exceed 20 metres for 2 collectors and 15 metres for 3 collectors. Note that maximum pipe lengths are based on minimal bends.

 Valves and fittings supplied with this solar water heater

form part of the installation and must be fitted in accordance with this manual.

 The pump and controller assembly is fitted with an AVG

Flow Meter FM15-1.4. This flow meter is pre-set to

1.0L/Min for optimal performance and must not be adjusted at time of installation.

 Working on roofs should always be considered a

hazardous activity; by law you must observe certain minimum safety precautions. These safety precautions

are outlined in the Work Cover Code of practice “Safe work on roofs” Part 1 and 2 and in the Occupation Health

and Safety Act 2011.

 A 240V 50 Hz 10 Amp power outlet, connected to

continuous tariff, is required for the pump and controller and must be installed by a licensed Electrician. This may be a weatherproof outlet depending on location.

 The responsibility for all OH&S issues relating to the

installation of the system resides with the installing tradesperson/s.

 The system should only be connected to water supply of

acceptable quality otherwise the warranty provided for the system may become void. Refer to Warranty conditions and section entitled “Water Supply” contained within this manual.

 Frost Protection Kits (AVFPK) are available from

SolarEast and should be fitted in areas that experience frost or freezing conditions (below 5°C). See detail herein entitled “Frost Protection Kits”.

 The PTR valves and the Cold Water Expansion valve

must be fitted with a drain to legal discharge points where the water discharge will be clear of any paved areas and will not cause damage or injury. Do not block or seal these drain lines.

 This water heater is intended to be installed as a fixed

appliance and must be installed on a hard, level surface. If installation is to be in a wet area or a concrete floor, ensure the water heater is mounted on a suitable and substantial raised base (eg: wood or concrete)

 The use of a self-draining safe-tray may be required in

accordance with the provisions of AS/NZS 3500.4, Clause 5.4.2.

 Please refer any queries relating to the design and/or

installation of SolarEast products or components to the Technical Services Department in writing.

 Rough-In Dimensions for SolarEast Tanks as

follows:

Version 12.0 OCTOBER 2015 Page 4

Model Number – Flat Plate Collector Models

Model

Units

FPC270-

FPC340-

FPC450-

Water Heater Stored Capacity

270

340

450

Number of Solar Collectors

# 2 3 2 3 2 3

Panel Inlet / Outlet Diameter

Tank Height

1408

1711

1733

Overall Diameter

648

730

Height to Cold Water Inlet (from ground)

Height to Hot Water Outlet (from ground)

1169

1472

1473

Tempered Water Outlet (midway between hot & cold))

540

695

Flow to Solar Collectors (from ground)

650

Drain to Waste (from ground)

Return from Solar Collectors

569

687

673

Model Number – Evacuated Tube Collector Models

Model

Units

TZ250E-

25R-250L

TZ250E-

30R-250L

TZ315E-

25R-315L

TZ315E30R-315L

TZ315E-

40R-315L

TZ400E30R-400L

TZ400E-

40R-400L

Water Heater Stored Capacity

270

340

450

Number of Solar Collectors

# 1 1 1 1 2 1

Number of Tubes per Collector

Tank Height

1408

1711

1733

Overall Diameter

648

730

Height to Cold Water Inlet (from ground)

Height to Hot Water Outlet (from ground)

1169

1472

1473

Tempered Water Outlet (midway between hot & cold))

540

695

695 Flow to Solar Collectors (from ground)

650

Drain to Waste (from ground)

Return from Solar Collectors

569

687

673

Version 12.0 OCTOBER 2015 Page 5

DOCUMENT CONTENT

PART A - HOUSEHOLDER GUIDE Operation Important Information 6 Instructions and Maintenance 8

Electric Boost Safety valves and Frost Protection valves Maintenance Householder fault finding

PART B - INSTALLERS GUIDE Solar Tank Installation 11

Solar Controller and Pump operation

Mounting Kit

Solar Collector Installation 20

Filling & commissioning the installed solar water heater 23

PART C – PRODUCT WARRANTY 29 Installation Check List (Please complete and return to SolarEast)

Version 12.0 OCTOBER 2015 Page 6

PART A – HOUSEHOLDER GUIDE

IMPORTANT INFORMATION

These Water Heater Models have roof mounted solar panels connected to a ground mounted solar storage tank and/or boosting heater. The solar input is harvested with a circulation pump controlled by an electronic temperature differential controller.

1. It is important for the householder to become familiar with the contents of this manual to ensure safety and to optimise the performance and longevity of this water heater.

2. This water heater is designed for use by a single family domestic dwelling to provide hot potable water.

3. Do not operate this water heater until all operating instructions have been read and understood by the homeowner.

4. These water heaters are NOT recommended for connection to Bore Water Supplies and warranty may be void in such installations.

5. A properly drained safe tray must be used where property damage could occur from water spillage (see AS3500.4.2). Ensure this safe tray does not become blocked.

6. If you live in an area that experiences frost in winter months or freezing occurs (below 5°C), models using evacuated tube technology should be installed for maximum protection against frost conditions. Damage to flat plate panels caused by freeze conditions which occur below 5° Celsius is not covered by warranty.

7. Do not activate the power supply to this water heater unless the cylinder is filled with water and a satisfactory Megger reading is obtained by a qualified tradesperson.

8. Do not block or seal the Pressure & Temperature Relief (PTR) safety valve or drain pipe. Never fit a PTR or Expansion Control Valve (ECV) with a pressure rating greater than that indicated on the product-rating label.

9. The water heater warranty can become void if relief valves or other safety devices are tampered with or if the installation is not in accordance with these instructions.

10. Do not place any articles, chemicals or flammable materials on or near the water heater

11. Removal of access covers will expose 240V wiring. Do not remove the terminal box cover or gain access to this water heater unless the power supply has been effectively disconnected by a qualified tradesperson only.

12. Do not operate this water heater with the terminal box cover removed or loose.

13. This water heater is not intended to be operated or adjusted by young children or infirm persons. Young children must be supervised to ensure they do not interfere with the water heater.

14. This water heater can deliver water at temperatures which can cause scolding. Check the water temperature before use, such as when entering a shower or filling a bath or basin.

15. Take care not to touch copper pipes connected to the water heater as high temperatures in the pipework may be present.

16. The water heater pump / controller must be plugged into a 240V 50Hz 10Amp electrical outlet which may be required to be weatherproof depending on location. Take care not to touch the power plug with wet hands.

17. If the power supply cord, plug or electrical conduit to the water heater is damaged, it must be replaced by a qualified tradesperson in order to avoid a hazard. The power supply cord and plug must be replaced with a genuine replacement part available from SolarEast Pty Ltd.

18. In times of low solar energy contribution, water stored in the solar tank can be heated by an electric booster consisting of an element and an automatic thermostat located on the tank. It

Version 12.0 OCTOBER 2015 Page 7

is recommended that the electric boost be connected to a continuous electrical supply; however, if connected to an Off Peak Tariff, a night rate tariff is NOT RECOMMENDED. Note that the thermostat must only be adjusted by a qualified tradesperson.

19. DANGER: FAILURE TO OPERATE THE RELIEF VALVE EASING GEAR AT LEAST ONCE EVERY SIX MONTHS MAY RESULT IN THE WATER HEATER RUPTURING. IT IS IMPORTANT THAT THE EASING GEAR ON THE VALVE BE RAISED AND LOWERED VERY GENTLY. FAILURE TO DO SO MAY RESULT IN THE WATER HEATER CYLINDER FAILING, OR UNDER CERTAIN CIRCUMSTANCES, EXPLODING.

20. IT IS NORMAL FOR SMALL QUANTITIES OF WATER (UP TO AROUND 15 LITRES IN A 24 HOUR PERIOD) TO BE RELEASED BY THE ECV OR PTR VALVE IN THE HEATING CYCLE. CONTINUOUS LEAKAGE OF WATER FROM THE VALVE MAY INDICATE A PROBLEM. IF THE VALVE DOES NOT DISCHARGE WATER WHEN THE EASING GEAR IS OPERATED, OR DOES NOT SEAL AGAIN, A SERVICE CALL SHOULD BE MADE WITHOUT DELAY. THE PTR VALVE IS NOT SERVICABLE.

21. THE THERMOSTAT IN THE ELECTRIC BOOST IS EQUIPPED WITH AN OVERTEMPERATURE CUT-OUT. IF THE OVER

TEMPERATURE CUT-OUT ACTIVATES, IT MUST NOT BE RESET AND THE WATER HEATER MUST BE SERVICED BY AN AUTHORISED PERSON.

22. The amount of water heated by the electric boost is as follows:

a. 270 L– 121 Litres b. 340L – 153 Litres c. 450L – 202 litres

23. WARNING: IF THE SOLAR SYSTEM IS NOT USED FOR TWO WEEKS OR MORE, A QUANTITY OF HYDROGEN GAS, WHICH IS HIGHLY FLAMMABLE, MAY ACCUMULATE IN THE SYSTEM. THIS MAY BE OBSERVED AS VIOLENT 'SPLUTTERING' WHEN A HOT TAP IS OPENED INITIALLY. 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 AT A DISHWASHER, CLOTHES WASHER OR OTHER APPLIANCE. DURING THIS PROCEDURE THERE MUST BE NO SMOKING, OPEN FLAME, OR ANY ELECTRICAL APPLIANCE OPERATING NEARBY. IF HYDROGEN HAS FORMED AND IS DISCHARGED THROUGH THE TAP IT WILL PROBABLY MAKE A SOUND SIMILAR TO AIR ESCAPING.

Version 12.0 OCTOBER 2015 Page 8

INSTRUCTIONS AND MAINTENANCE

Warning: This appliance not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge.

Children should be supervised by a person responsible for their safety to ensure that they do not play with the appliance.

Operation

Ensure that your solar hot water system is filled with water at all times. If drained at any time then the solar panels should be covered as prolonged exposure to sun without a supply of coolant water may cause damage.

DO NOT turn off the ELECTRICITY or WATER SUPPLY to the Solar Controller and Pump.

The pump and controller should be connected to a 240V 50 Hz power supply at all times i.e. throughout the entire year. Even in winter it is important that the controller is able to turn the pump ON during cold conditions to prevent panel damage due to freezing.

The controller is a differential thermostat which turns the pump on and off in response to temperature signals received from a hot sensor, located in the solar panels on the roof, and a cold sensor located in a pocket at the base of the solar storage tank. The sensor cables must not be damaged or cut.

Electric Boost

Water stored in the storage tank is heated automatically by an electric booster element which is controlled by an automatic thermostat. The booster element heats the water during very cloudy or rainy weather, during the winter months, or during periods of unusually high demand. Although it is recommended to connect the electric element to continuous power, it can be connected to an off peak tariff but NIGHT RATE OFF PEAK IS NOT RECOMMENDED as the available power may not be sufficient during inclement weather and you may run short of hot water during these periods.

The electric booster heating element is controlled by an automatic electric thermostat. The thermostat and element are mounted on the solar

storage tank. The boosted water temperature is automatically controlled to the thermostat setting when the booster heating element switch is in the on position.

The thermostat is tradesperson adjustable. It has a minimum temperature setting of 60ºC and a recommended maximum temperature setting of 75ºC. It must only be adjusted by an authorised person. Automatic safety controls are fitted to the water heater to provide safe and efficient operation.

The electric booster element will automatically heat the water in the upper section of the tank. An isolating switch can be installed which will allow manual control however be aware that if this switch is turned off, a shortage of hot water can occur during periods of low solar radiation and water temperatures below 600C can give rise to bacterial breeding including Legionella bacteria. Australian Standards therefore stipulate that this switch be left continuously on and the automatic thermostat be set to a minimum temperature of 600C.

Safety Valves and Frost Protection Valves

See Solar Layout Drawings to identify these valves. Never fit a Pressure and Temperature Relief Valve

(PTR) or Expansion Control Valve (ECV) with a pressure rating greater than that indicated on the product-rating label.

It is normal for the ECV fitted to the cold mains water supply to dribble as either the solar panels or water heater heats water within the system. The expansion valve releases water from the system so that the system will be maintained at its design pressure.

The PTR valve fitted to the solar storage tank should not dribble during normal operation as they are fitted as safety valves. If the PTR valve dribbles, operate the easing mechanism on the valve and allow water to discharge through the drain pipe. Remember this water may be HOT and ensure that the discharge does not come in contact with anyone. Release the easing lever SLOWLY and reseat the valve. If the valve is still dribbling 24 hours after reseating contact SolarEast.

If no water is drawn from the system for several days in hot weather conditions the ECV on the solar storage tank may open and freely discharge water in order to discard the excess solar energy collected. This should happen only infrequently but it is considered normal operation.

If the PTR valve on the storage water heater freely discharges hot water and steam, turn off the electricity supply to the storage unit and contact SolarEast Service.

Version 12.0 OCTOBER 2015 Page 9

IMPORTANT: Relief valves should be checked to be in sound working order in intervals not exceeding 5 years, or more regularly in areas subject to water deposits. Checking should include operation of the relief valve to remove any lime deposits. The PTR valve should be replaced every 5 years.

Frost Protection Valves

Frost protection valve kits (Kit Code AVFPK) are available and should be fitted to flat plate collectors where solar water heaters are installed in frost prone areas. Where fitted in frost areas, one frost protection valve is fitted to the bottom of each panel (2 off per kit) and must be pointing downwards towards the guttering. It is normal for these valves to dribble during very cold weather. Failure to install frost protection kits in frost prone areas may void warranty should damage to collectors occur.

The use of flat plate collectors in frost prone areas is not recommended and warranty may be void. It is recommended that evacuated tube models only be installed in frost prove areas.

Maintenance

Periodic - as needed (minimum six-monthly) by Owner

 Prune or remove trees or shrubs that shade

the solar panels. For effective operation the panels should be in full sunlight between at least 9am and 3pm in both summer and winter. Panels which are shaded will not function correctly.

 Shading from newly erected buildings also

needs to be considered and panels relocated if necessary.

 Check cleanliness of solar panel glass.

Clean if covered in dust, grime, leaves or other build up. The panels may be cleaned with water and detergent only when the panels are cool, for example at the beginning or end of the day or during overcast conditions. If there has been little rain or if the panel is located in a dusty location it may be necessary to clean the panels more frequently. Note. SolarEast does not cover cracked or broken glass in collectors. This may be covered by your household insurance policy.

 Draining and flushing the water heaters and

panels must be undertaken by an authorised service agent or plumber and not by the householder due to possible high water temperatures.

WARNING!

Working on roofs should always be considered a hazardous activity; by law you must observe certain minimum safety precautions. These safety precautions are outlined in the Work Cover Code of practice "Safe work on roofs" Part 1 and 2 and in the Occupation Health and Safety Act 2011.

 Flush and reseat the PTR valve and cold

water pressure ECV. This is done by raising the release lever, allowing water to flow freely and then lowering the lever slowly and allowing the valve to reseat (this is to remove lime deposits and to verify that the valve is not blocked). Remember that the water discharging from the valves may be HOT and should not be permitted to come into contact with anyone.

Annual Service – By authorised Serviceman

It is strongly recommended that the Solar System be serviced annually. The components or parts may not be covered by SolarEast warranty if damage to the system or parts is caused by the lack of regular maintenance.

 It is important that the PTR valves, the cold

water ECV and frost valves be replaced every 5 years.

 The protective anode fitted to the solar

storage tank should be checked and replaced if necessary at suitable intervals depending on water quality, but no later than every 5 years. It is recommended that SolarEast be contacted regarding a suitable replacement anode.

 Changing the anode at regular intervals

should extend the working life of the storage tank.

Version 12.0 OCTOBER 2015 Page 10

Householder Fault Finding

Prior to contacting SolarEast for a service call, there are some basic checks that can be made by the householder. Please note that you will be liable for all charges where the fault is not related to manufacture or failure of a part or out of warranty.

Not Enough or No Hot Water?

If the collectors are shade-free, the weather is fine and warm and the solar storage tank contents are definitely cold, the circulating pump should operate and the return connection become warm or hot. Please note that the pump is almost silent and vibration-free in operation. Check the following:

1. Is there 240 volts at the power outlet? Is there a blown circuit breaker, RCD or fuse?

2. Is the pump plugged into the controller? The pump and controller are located under the plastic terminal box cover on the storage tank.

3. Are the sensors plugged into the correct sockets in the controller?

4. Are the sensors correctly fitted into the

sensor pockets on the tank and collectors?

5. Has all air been purged from the system?

6. Has your hot water usage changed?

7. Is the thermostat setting sufficient to

recover from hot water usage?

8. Scale formation in the tank and collector can limit the heating ability of the solar collectors.

Pressure and Temperature Relief (PTR) Valve Leaking?

It is usual for a pressure and temperature relief valve to release a small quantity of water during the heating cycle; up to around 15 litres over a 24 hour period is acceptable. If the discharge is noticeably more than this, a service call may be required.

Cold Expansion Control Valve (ECV) Leaking?

The ECV may discharge a small amount of cold water to prevent the PTR valve from potentially discharging water that has been heated, thereby saving energy. This is normal.

Version 12.0 OCTOBER 2015 Page 11

PART B – INSTALLERS GUIDE

SOLAR TANK INSTALLATION

Installer – Please Note The Following

1. This Water Heater Is Not Suitable For Pool Heating

2. All work associated with the installation of this water heater must be carried out by properly trained and accredited tradespersons and be strictly in accordance with relevant Australian Standards including AS/NZS 3500.4 and AS/NZS 3000, local, State and Federal Regulations including, but not limited to, Occupational Health, Safety and Welfare Regulations (OH&S)

3. If this installation is taking place in an area subject to frost conditions or freezing conditions (below 5° Celsius), it is recommended that only evacuated tube models be installed.

The solar water heater tank should be installed in close proximity to the most frequently used hot water outlet and its position chosen with safety and service in mind. Other considerations include the position of the solar tank with respect to the solar collectors as heat loss can occur in the pipes, and copper pipe length should not exceed 20 metres (for 2 panel systems). Also consider servicing (the water heater must be accessible without the use of a ladder or scaffold and the anode, PTR valve, thermostat and booster element must be able to be removed) and nameplate data must be able to be read. Other considerations include:

● Electrical supply requirements for the pump and controller

● Weight of the heater filled with water

● Dimensions of the heater and size and

location of connection points

● Water supply pressure limitations

Clearance

Allow adequate room to work with tools. A minimum of 25mm clearance around the water heater is required. An additional 30mm is required for relief valve removal, 80mm for access cover removal and 400mm for element removal. You should be able to read the information on the rating plate and all informative labelling.

Adequate provision must be made to dispose of any water escaping from heater or adjacent plumbing that might result in damage to property.

The water heater must be connected in such a way that:

 Space is allowed for the removal of the

heating element.

 Space is allowed for the removal and

replacement of the anode.

 The pump is accessible for servicing.  Complete removal of the unit can be

easily effected if necessary

Confined Spaces

If the thermostat fails the unit may produce excessive steam.

It is strongly recommended that the heater should be installed in a well-ventilated space to avoid condensation build up. If installed in confined areas, make provision for Service Access. Vent safely to open air and carry hot water overflow pipework to drain.

Foundation

To ensure adequate ventilation, position the unit on an approved support base to prevent water ponding around the base of the water

heater tank. Attention is drawn to the weight of the water heater tank when full (up to approximately 600kg depending on model) and the installer should ensure the base and footings are substantial enough to avoid subsidence etc.

Water Supply

If the water heater is installed to a tank water supply, a minimum 200kPa water supply pressure must be available or a pressure

Version 12.0 OCTOBER 2015 Page 12

pump must be installed to allow operation of the system

This water heater has been constructed to meet water quality conditions in most Australian water supply locations. However, harsh water quality does exist in some locations and, if in doubt, contact your local council or water supplier. Only potable water should be used in this water heater. If you are unsure of the water chemistry in your area, you may find additional information by contacting your local water supply authority.

Anode: The anode in your water heater is sacrificial, however it is designed to protect the vitreous enamel lined cylinder in most public reticulated water supplies for five years after which time it should be replaced as part of annual service. However it is important to understand that many water supplies can exhibit chemical qualities that are not suitable for the standard anode supplied with this water heater. Where the Total Dissolved Solids (TDS) is greater than 600mg/L or less than 40mg/L, the installed anode may be unsuitable for use to protect your water heater. In these circumstances, a plumber or authorised service person should be contacted to fit the correct anode. Different anodes are available in these situations to protect the vitreous enamel lined tank. Please note that warranty becomes void if the TDS value exceeds 2500 mg/L.

The Saturation Index is a measure of the

water’s corrosiveness. Corrosion may result

in early failure of copper parts such as solar collectors and copper sheathed electric components. Water is considered corrosive should the saturation index be below -1.0. Scaling, which is the build-up of calcium carbonate in the tank, can occur where the Saturation Index is above +0.4. In these instances where the Saturation Index

exceeds +0.4, ensure the expansion control valve (ECV) is fitted according to instructions contained within this manual. Should the saturation Index exceed +0.8, a low Watts density element must be fitted.

Water heaters installed in locations where incorrect anodes are fitted due to high or low TDS or where the water is corrosive or considered scaling will not be covered by this warranty.

Pipework, Valves and Fittings

Valves and fittings for connecting the solar panels on the roof and the storage tank are supplied.

The temperature of the water at the outlet connection on the panels may reach 150°C or more and therefore only copper pipe can be used between the panels, storage tank and boosting heater.

Class B copper pipe should be used and the runs should be as short as possible to reduce heat losses.

The pipes MUST be lagged using thickwalled foam of at least 19mm thickness, RO.6 and should be weather proofed and UV stabilized.

If insulation is not UV stabilized, it must be protected by a suitable UV resistant paint.

Pre-formed insulation gloves and cable ties are provided to insulate fittings. The areas to be insulated are: inlet pipework fittings to the panel, the outlet pipework fittings, and on 2 & 3 panel systems the joiners between the panels. These fittings must be insulated to protect them from freezing in cold areas. Warranty may be void if not fitted. Refer to the Solar Panel Layout drawings for location and installation detail. Water may drip from the pipe of the pressure-relief device. This pipe must be left open to the atmosphere

Version 12.0 OCTOBER 2015 Page 13

Solar Controller and Pump Operation

The Aestiva Solar Controller and Grundfos Pump supplied with this Solar Water Heater is enclosed within a UV Resistant ABS plastic enclosure which is designed to house these components and protect them from harmful UV radiation. This Pump/Controller assembly is fitted onto the side of the tank directly above the Cold Water Inlet using stainless steel screws provided in the Ground kit.

The control unit turns the pump on and off in response to temperature signals received from a hot sensor located in the solar panel's hot water outlet fitting on the roof top, and a cold sensor located at the entry to the storage tank. It is crucial that these sensors and leads are not damaged or cut during or subsequent to installation.

NOTE: Run the power cord for the pump behind the controller before mounting the controller in position on the pump housing base frame.

Note that after 2 hours of operation of the pump, it will automatically switch off for five minutes before resuming to prevent any possible cavitation of the pump.

The controller incorporates an LCD display that can easily be read to identify the various sensor temperatures and error modes (shown in bold below).

Temperature Probe Turn On (Pump On Temp) and Turn Off (Pump Off Temp) temperatures are as follows:

“Pump On Temp”: 8°C Differential (ΔT) between Panel Sensor temperature and Tank Temperature Sensor (panel sensor hotter than tank sensor).

“Pump Off Temp”: 2°C Differential (ΔT) between Panel Sensor temperature and Tank Temperature Sensor.

The Controller will also prevent the pump from circulating water to the panels should the tank temperature, measured at the Tank Temperature Sensor become too high. Temperature setting to protect the tank is as follows:

“Top Out Temp”: 65°C measured at the tank mounted sensor will de-activate the pump to protect the vitreous lining of the steel tank.

Freeze protection is also a standard function of the controller. Where the panel temperature measured at the Panel Temperature Sensor approaches freezing, the pump will activate and circulate heated tank water to the panels until the panel temperature rises and prevents against frost damage. Temperature settings are as follows:

Version 12.0 OCTOBER 2015 Page 14

“Protect On Temp”: 3°C measured at the roof top sensor will activate the pump. “Protect Off Temp”: 5°C measured at the roof top sensor will de-activate the pump

Note that when cold conditions prevail overnight, this frost protect mechanism may switch the pump on and off several times to protect the panels, potentially resulting in reduced hot water being available in the morning.

The sensor leads are extra low voltage but must to be encased in 20mm PVC conduit and secured with conduit saddles to ensure they remain undamaged.

The hot sensor (long lead) should be dry and pushed to the bottom of the long hot sensor pocket on the top left hand corner of the solar panel. A clip on the sensor probe port is provided to secure the sensor lead.

The cold sensor (short lead) is to be fitted dry into the short cold water sensor pocket at the cold water entry to the solar storage tank. Refer to the respective layout diagram supplied with the Solar Storage Tank.

Controller Error Codes

The LCD display will normally display the Lower “L” tank sensor temperature and the Roof-top “R” sensor temperature as follows:

In event of a tank sensor failure, an error code will be shown on the display and 4 LED lights (2 green and 2 red) will become visible as follows:

¤ ¤

◎

Sensor Temp:

L:Err R:001

◎

¤ ¤

◎

Sensor Temp:

L:001 R:001

◎

¤ ¤

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Similarly, when errors occur on roof top or both sensors, the display will indicate as follows:

¤ ¤

◎

Sensor Temp:

L:Err R:Err

◎

¤ ¤

Basic Controller Functions

Programming the Controller Note: the controller is pre-set at the factory to operate at optimal settings for most situations.

Any access to the program mode and change to factory settings must be done by a qualified and authorised person. The range of settings available are as follows:

SETTING

Factory Setting

(°C)

Minimum Setting

(°C)

Maximum Setting

(°C)

Pump On Temp

8 0 90

Pump Off Temp

2 0 90

Top Out Temp

65 0 90

Protect On Temp

3 0 90

Protect Off Temp

5 0 90

Indicator Pump On

Indicator – Frost Protection On

Switch on Pump manually and used in Program Mode

Program mode (see below) and used in Program Mode

Indicator - Top Out Temp Reached

Indicator – Pump in Manual Mode

Scroll Settings in Program Mode

Used in Program Mode – see below

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Access to the Program Mode is as follows:

1. Press and hold down “Next” and “Program” keys

2. Then, press and hold down “(Prog Mode)” key whilst holding down the “Next” and “Program” keys for approximately 3 seconds. Red and Green LED’s will flash.

a. “Pump On Temp” appears – Value = 008 (factory pre-set). Remove fingers from keys. b. “Pump On Temp” can be increased or decreased using the “+” and “-“ buttons c. Following any changes, the program may either be exited by pressing and holding down the

“Program” key for around 3 seconds or access next Setting “Pump Off Temp” by pressing the “Next” key. The same method applies to accessing all five settings available.

d. When all settings are set to desired level, press and hold the “Program” key for around 3

seconds. All settings will be retained and “Set Finish Rebooting” will briefly appear before

returning to sensor temperatures.

MANUAL PUMP Key

When pressed (not in Program Mode), this key activates the pump manually, over-riding the pre-set settings of the controller. “Pump” and “Manual Pump” LED’s will glow. If left on, the pump will run for 2 hours and then switch back to PUMP AUTO.

DO NOT turn off the ELECTRICITY or WATER SUPPLY to the Solar Controller and Pump.

Note: Panel warranty does not cover damage caused by frost or freezing where:

 the solar controller and or pump are not operating;  frost protection valves have not been fitted;  the mains water supply to the system has been turned off; or  the mains cold water supply to the system freezes because it is not insulated.

Mounting Kits

Depending on the model of water heater supplied and the requirements of the installer, mounting kits may be supplied to assist the installer. These kits are not supplied unless requested.

Note: The copper pipework and specified insulation is to be supplied and fitted by the installer. The solar water heater may be supplied with a selection of some valves or Plumbing Mounting Kits as follows:

1. Ground Kit – Ground Mounting Kit supplied as part of the Solar Water Heater Tank installation package.

2. Roof Kit – Roof Mounting Kit supplied as part of the Solar Collector installation package.

Should Ground and Roof Kite be supplied, these kits are designed to provide the installing plumber with all parts required for a normal installation. Additional components required for installation are to be supplied by the installing plumber.

The following items are contained within the Ground Kit where it is supplied. Refer to section below entitled “Solar Collector Installation” regarding componentry for Roof Kit.

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The Standard Ground Kit Consists Of the Following Components:

 Brassware and Valves (Excluding PTR Valve which is contained in the water heater tank packaging)  Installation Manual including commissioning check list to be completed and retained as a record by

SolarEast.

 Pump and Controller.  Stainless steel screws for mounting pump and controller.

Ground Kit – Ground Mounting Kit Components

Codes:

Image

Quantity

Instructions

BFEQuickie15*

Diagram item 10

Used for Hot Water Outlet BFP15MI *

Used for connection to unused port on 4-Way Tee

BFS15*

Diagram Item 3

4 required

1. Connection of Item 7 – ECV Valve

2. Connection of Item 11 – Flow Valve

3. Connection of Item 2 PLV

4. Connection of Item 10 – Solar Return

BFT15C15C15C w 1 Nut & Olive*

Diagram item 4

Connection of 500kPa PLV to 4-Way Tee

BFT15C15C15C w 2 Nuts and Olives

Diagram items 4/6

Tee off for ECV Valve Refer to installation diagram for positions

601074 – 15MI Thermowell

15mm Thermowell Sensor Port on 4-Way Tee (Item

BFTQuickie15*

Diagram item 5

4-Way Tee for connection to Cold Water Inlet (Flow)

BFU15MI15C

Diagram item 8

Drain Line unions for ECV Valve, PTR Valve and Solar Return Pipe from Collectors

BFU25Q15C

Diagram item 12

Pair of Pump Connection Unions

ECV15-700

Diagram item 7

750kPa Expansion Control Valve (ECV)

Version 12.0 OCTOBER 2015 Page 18

FC15FL – 175mm*

Diagram Item 14

175mm Stainless Steel Semi-Flexible Coupling. Note the second FC15FL not supplied as standard and can be replaced with copper pipe.

FM15-1.4

Diagram item 11

Flow Meter 1.4L/Min (Installer - Set to 1.0L/Min on installation). Install on line side of pump between stainless steel flexible coupling and pump coupling. Note direction of flow.

NRIBVS – 15C*

Diagram item 1

Non-Return Isolating Trio-Valve with Strainer and Insulation

NVHT-15F-15C w Nut and Olive

Diagram item 13

15mm High Temperature Non-Return Check Valve. Install on load side of Pump & Controller. (Note direction of Flow)

PLV15-500FM*

Diagram item 2

500kPa Pressure Limiting Valve installed after TrioValve (Item 1)

TVA15CHP*

Diagram item 9

High Performance Tempering Valve 15mm with Insulation

MSKM15MM

1 4 off M4 and 4 off M6 304 Grade S/Steel Screws and washers for mounting of Base Plate and Cover of Pump and Controller Assembly to Tank Outer Casing. (Note Nut-serts provided on Tank Case for ease of mounting).

Note: Valves and fittings marked with * are supplied with standard product however are not included in Builder Pack offers These items may can be purchased separately from the water heater supplier if required.

Version 12.0 OCTOBER 2015 Page 19

Ground Kit – Installation Diagram

Note: the above representation is typical for the standard Ground Kit however table above details which fittings are not supplied with Builder Pack.

SOLAR COLLECTOR INSTALLATION

To achieve maximum solar performance, the solar collectors should be installed facing as close to North as possible. The following are guidelines for the installation of solar collectors:

 Solar collectors should be positioned to face the equator which is North facing in Australia. The further away

from North, the greater the loss in solar efficiency.

 The inclination of the solar collectors should be within 10% either side of the local latitude angle. For

example, the latitude of Brisbane is 270 South so the inclination of the solar collectors should be approximately 24 to 30 degrees.

 Solar collectors should be free from shading by trees (should be checked regularly) or nearby buildings or

other structures.

Installing FPC1200 Flat Plate Collectors

Before placing panels on roof:

1. Repair or replace any damaged roof iron or tiles

2. Roof kit can be fitted to panels including all brass fittings and air eliminator

3. Bend 4 TOP straps through 90º and fasten to panels using only the 25mm Roof Zips supplied in the roof kit. No other screws are to be used.

Version 12.0 OCTOBER 2015 Page 20

4. Bend the other four stainless steel straps through 180º approximately 30mm from the end of the strap with the largest hole and slide through the purpose made slots in the rail with suitable spacing. The strap must be placed in the slots so that the 30mm bent over section of the strap finally sits between the rail and the panel.

5. Fit the powder-coated annodised aluminium rail to the roof trusses / battens. Locate the

horizontal rail provided onto the roof with the stainless steel straps permanently fasted to the roof supporting frame-work using the 65mm roof zips provided.

6. For metal roof tops, remove the screws along the batten line where the stainless steel strap is to be

fastened. Ensure the rail will be at least 500mm up from the gutter.

7. For tiled roofs, the bottom collector rail should be positioned on the front edge of a tile ensuring no

less than 500mm from the gutter.

8. Remove the tiles above the rail strap and secure the rail strap to the trusses / battens using the 65mm Roof Zip screws provided and replace tiles.

Note: If the above guidelines cannot be achieved, consideration should be given to increasing the solar collection area by adding an extra solar panel, particularly if the direction is further than 450 either side of North. In any case, no direction should be chosen that has any inclination towards South.

1. FPC1200-D FLAT PLATE SOLAR COLLECTOR PLUMBING INSTALLATION

2-Panel Roof Kit – Collector Plumbing Roof Mount Kit

The 2 Panel Roof Mounting Kit is supplied with the solar collectors for installation when the collectors are installed. The kit does not include Frost Protection Valves as standard. The Frost Protection Kit (AVFPK) is available as an accessory for use in frost prone areas HOWEVER evacuated tube collectors should be installed in these areas.

Version 12.0 OCTOBER 2015 Page 21

Components contained within the 2 Panel Roof Kit include:

Codes

Image

Quantity

Instructions

BFAVT22C-Short (22c not shown)

AVG Custom Sensor Fitting. Insert Roof Top Sensor to end of pipe when installed. Comes with Insulation Glove. Fit hot water return to tank.

AEHT-10

Air Eliminator. Fix to BFA Fitting BFE20MI15CQIK

(22C not shown)

20Mlx 15C Elbow. Cold Water Inlet to bottom RHS of Collector with Insulation Glove

BFU15MI22C

22mm Copper to 15mm MI Fittings for blocking unused ports of Collectors with 15mm plugs below

BFC15 2

15mm Female Brass Plugs for unused ports on Hot Water Collectors

BFU22C22C

20MI x 20MI Brass Barrel Union with Insulation Glove for connection of the solar collectors

NOTE: Details of Roof Kit components shown above are for two-panel configurations. Three panel kits (AVRK3) are also available on request.

2 Panel Roof Installation Diagram

FROST PROTECTION KITS (AVFPK)

Version 12.0 OCTOBER 2015 Page 22

Additional accessories available from SolarEast include the Frost Valve Kit for use with flat plate panels models. Note that, for frost prone areas, it is recommended that evacuated tube models only be installed to eliminate issues that may arise with damage to panels due to frost conditions. These valves are required to be installed in frost prone areas or areas subject to freezing (below 5°C) and must be installed facing downwards (one per panel). The valve must not contact the roof. During frosty conditions these valves open and allow a slow flow of water through the panels. They will automatically close when the water temperature rises. They provide backup for the freeze protection facility on the controller in the event of power failure. Do not use thread sealants to connect the frost valves; they must be fitted using the sealing washer supplied with the valve. Note: Thread sealants may cause problems with the operation of the valve.

The following items are contained within these kits for installation.

2. TZ58/1800 EVACUATED TUBE SOLAR COLLECTOR INSTALLATION

Heat pipe working theory

Heat pipe is not a new concept, it was initially used in aviation to transfer

high temperature and keep the aircraft safe.

Now heat pipe technology is commonly used in computers and airconditioning. Laptop computers usually use small heat pipe to conduct heat away from the CPU, and in air-conditioning, people use heat pipe for

heat conduction.

As we know, at sea level water’s boiling point is 100oC, however as altitude increases, the boiling point of water reduces. Heat pipe technology uses the principle of water boiling at a lower temperature with decreased air pressure.

A small volume of purified water in the heat pipe inside the evacuated tube will boil at temperatures as low as 30o C. When the vacuum tube absorbs solar energy and heats the heat pipe to 30oC, the water vaporizes and rises to the top of the heat pipe condenser. As the heat pipe condenser meets cold water and cools down, the water will return to a fluid state and return to the bottom of the heat pipe and the process can begin again.

Transportation of evacuated tube collectors

Solar Collectors must be secured during transportation. It is imperative that each collector be secured from falling out of the packaging, and that they be secured from scratching each other, as this may damage the collectors and lessen their performance. You should always follow these simple precautions:

Frost Protection Kit Model No.

AVFPK

Product Code

Description

Qty.

BFT20FI

3/4" Brass Tee Female

BFN20MI15MI

20MI x 15MI Reducing Hex Nipple

BFN20MI20MI

20MI Brass Hex Nipple

FPV

Frost Protection Valve

TEF-ROL

Roll of Teflon

Version 12.0 OCTOBER 2015 Page 23

- Use of a carrying strap is recommended

- Do not lift the collector by the connection ports or header tube

- Avoid impacts and vibration on the collector as much as possible

- Please lift the collector by the lifting lugs (if included)

Heat pipe solar collector installation

Step 1. Check solar collector parts One whole heat pipe solar collector is generally packed in three or four cartons; manifold and tail stock as one carton, frame as one carton and vacuum tubes in one or two cartons.

Before installing the solar collector, it is most important to open the vacuum tube carton(s), which contain both vacuum tubes and heat pipes combined. Check to make sure the vacuum tubes are all intact, and the bottom of each tube is still silver. If a tube has a white or clear bottom, it is damaged and should be replaced. Each vacuum tube contains aluminium heat transfer fins which hold the heat pipe in place in the centre of the vacuum tube. Sunrain heat pipes are centrally located and pre-inserted into the vacuum tubes to reduce your installation time and costs.

Do not remove and/or expose the tubes to sunlight until you are ready to install them, otherwise the inner tube and heat transfer fin will become very hot quickly. The outer glass surface does not become hot under normal operating conditions. If you wish to install the vacuum tubes into the manifold before commissioning the system, you can place a cover over the whole collector so as not to attract the sun and cause very high temperatures in the manifold. This can then be removed when you are ready to commission the system.

The orientation and inclination of the evacuated tube array is similar to the flat plate information provided above.

Evacuated Tube Solar Collector Parts

Manifold (1pcs)

Tail stock (1pcs)

Optional silicon grease (1pcs/collector)

Vertical support bar (2pcs for 10 and 15 tubes, 3 pcs for 20, 25 and 30 tubes)

Vacuum tube (10 or 15pcs/carton)

Anti-dust circle (Same as tube quantity)

L-Feet (10 off) – Stainless steel 4mm thick – for mounting rail to rail (Method 1 below) or rail to roof using EPDM Isolation pads provided (Method 2 below)

Version 12.0 OCTOBER 2015 Page 24

T-Bolts and Nuts (16 off)

Stainless Steel Straps (4 off)

Screw Kits (8 off 65mm and 8 off 25mm RoofZips)

Horizontal support bar (2 pcs/collector, the length will be determined by how many collector installed in series). Also included are s/steel straps, roof mounting screws, L-Brackets for mounting horizontal rail to vertical rail and T-Bolts and nuts.

Method 1: Using Stainless Steel Straps Provided - Evacuated Tube Mounting on Pitched Roofs

Steps:

1. Bend the 4 off stainless steel straps through 90º 30mm from the strap end with the largest hole.

2. Locate under the horizontal rail and use 4 off 15mm T-Bolts provided to fasten the straps to the rail.

3. Locate the 2 off horizontal rails provided onto the roof with the stainless steel straps permanently fasted to the roof supporting frame-work using the 65mm roof zips provided. All fixing straps must be fastened to rafter/battens through roof sheeting or under tiles.

4. Fasten the vertical rail to the horizontal rail using 6 off L-Feet and additional 12 off T-Bolts provided. 6 sets of L-Feet and T-Bolts are provided for the 3 vertical rails. All must be used and nuts tightened.

5. Locate the header manifold on the vertical rail using the black annodised z-feet and T-Bolts provided. 6 Z-feet are required to be fitted, 3 to the top of the manifold and 3 at the bottom.

6. Locate the foot of the tube array using the same method as for the header manifold

7. Refer to the diagrams below for instruction on tube insertion

8. Tighten the black plastic screw in fitting at the bottom of the evacuated tube to firmly position the tube.

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Method 2: Mounting Horizontal Rails to Roof (For Metal Roofs Only)

1. Fasten 6 off Stainless Steel L-Feet to the metal roof replacing existing rood screws with 65mm RoofZips provided. The L-Foot must be effectively isolated from the metal roof using the EPDM rubber isolation pads provided. Ensure the slotted hole is left for mounting of the vertical rail.

2. Fasten the three vertical rails to the slotted holes in the L-Feet using 6 off T-Bolts and nuts provided.

3. By lifting the three vertical rails to the tops of the slotted holes prior to tightening, the rails are clear

of the metal roof to allow clear passage for any foreign matter such as leaves.

4. Locate the header manifold on the vertical rail using the black annodised z-feet and T-Bolts provided. 6 Z-feet are required to be fitted, 3 to the top of the manifold and 3 at the bottom.

5. Locate the foot of the tube array using the same method as for the header manifold

6. Refer to the diagrams below for instruction on tube insertion

7. Tighten the black plastic screw in fitting at the bottom of the evacuated tube to firmly position the tube.

INSTALLER PLEASE READ - IMPORTANT NOTES FOR FLAT PLATE COLLECTOR AND EVACUATED TUBLE COLLECTOR MOUNTING SYSTEMS:

1. WARNING: Do not mount vertical rails to roofline using the stainless steel straps and tee-bolt provided. They may loosen and slide out of the rail which may cause a dangerous situation to occur or result in serious physical injury.

2. Ensure only 65mm roof-zips provided are used to fasten the mounting rails to the roof structure. The 25mm roof zips are only required to mount the stainless steel straps to the flat

7 Steps to installing racking system for Evacuated Tube panels. Note – for metal roofs, align straps to roof screws and use 65mm roofzips provided.

Version 12.0 OCTOBER 2015 Page 26

plate collectors and to fasten the annodised aluminium bottom rail of the flat plate mounting system to the collectors being installed.

3. Ensure T-Bolts are tightened correctly to prevent any loosening over time.

Inserting the heat pipe into the manifold

Evacuated Tube Maintenance Requirements

1. Cleaning

Regular rain should keep the evacuated tubes clean, but if particularly dirty they may be washed with a soft cloth and warm, soapy water or glass cleaning solution. If the tubes are not easily and safety accessible, high pressure water spray is also effective.

2. Leaves

During autumn days, leaves may accumulate between or beneath the tubes. Please remove these leaves regularly to ensure optimal performance and to prevent a fire hazard.

3. Broken tube

If a tube is broken it should be replaced as soon as possible to maintain maximum collector performance. The system will still operate normally even with a tube broken. Any broken glass should be cleared away to prevent injury. To replace a tube: Remove the tube clip, slide broken tube out and carefully pick up any glass pieces. Please wear protective gloves and glasses when handling the broken glass. When removing the tubes, the rubber ring in the manifold casing may pop out. Just return the ring into place before inserting the new tube. Avoid touching the glass wool insulation with bare hands, as it can cause mild skin irritation.

The new tubes should already have heat transfer fins inserted, so slide the new tube into place taking care to guide the heat pipe into the slot between the fin and the glass wall. Normally the heat pipe does not need to be removed from the manifold.

Filling and Commissioning the System

Do not turn on electric power until the whole system has been filled with water and a satisfactory Megger reading is obtained by a qualified person.

Solar Storage Tank and Water Heater

Follow instructions supplied with the heater. Note that it is necessary to provide a properly drained safetray under heaters located where leakage may cause damage.

When locating the water heater, ensure the installation does not compromise the structural integrity of the building.

Note: A Tempering Valve must be fitted in accordance with Australian Standards and other State and Council regulations.

Version 12.0 OCTOBER 2015 Page 27

Turn on a hot water outlet tap, preferably the one furthest from the heater. DO NOT purge through the PTR valves. Open the mains cold water supply valve so that air is displaced from the water heater and replaced with water. The hot water outlet tap should be left on until the water flowing from it flows steadily without spurts. Turn off the hot water tap and allow the system to pressurize. Check the system for leaks. Repair if required.

Solar Panels

The solar panels must only be filled when they are cold, so it is important to ensure that the panels are fully covered for a suitable time beforehand. Filling hot panels may cause injury by scalding.

Turn on the mains water supply and ensure the water heater is full of water and all of the hot taps are turned off. Turn on the circulating pump either by the manual override or by plugging it directly into a power point.

Depending on the model, the water heater will either be fitted with an air eliminator at the highest point in the collector circuit or an air bleed valve fitted on the solar return.

For models incorporating an air eliminator, please proceed as follows: Ensure the water heater is full of water and all of the hot taps are turned off. Loosen fitting on top of the solar panel return pipe to the solar storage tank and then turn on the mains cold water supply. Covering loosened fitting with a heavy cloth to prevent water spraying from fitting. Allow water to flow from the loosened fittings until a steady flow free of spurting is achieved i.e. all air is displaced. Re-tighten fitting. Allow system to pressurise. Check for leaks and rectify if required.

Note. It is important that all air be removed from the solar panel circuit to ensure the circulating pump will function effectively. Air in the system will prevent circulation.

For models incorporating the air bleed valve, please proceed as follows: Open the air bleed valve (HWP

875) at the tank and allow all air to purge from the system. When water flows freely from the air bleed

valve without air spurting, close off the valve. Allow the system to pressurise. Check for leaks and rectify if required.

Note. It is important that all air be removed from the solar panel circuit to ensure the circulating pump will function effectively. Air in the system will prevent circulation. If difficulty is experienced in purging all air from the system, it may need bleeding from the highest point of the panels by loosening a fitting and allowing air to be bled at that point.

Remove covers from solar panels.

WARNING – on a sunny day, if the solar panels are not covered during this operation, the water flowing from the air bleed valve can be extremely hot causing steam and possible scalding. Ensure sufficient precautions are taken to prevent injury to nearby persons.

Solar Pump and Controller

Ensure that the hot and cold sensors are plugged into the correct sockets at the tank inlet connection and the top hot outlet of the solar collectors..

Ensure that the pump is correctly plugged into the Solar Controller power outlet. Plug the Solar Controller into the weatherproof (where required) mains power outlet and switch on. If the weather is fair, the return pipe from the panels will become warm. Please note that the pump is

very quiet and vibration free in operation.

Version 12.0 OCTOBER 2015 Page 28

If the weather is cool and cloudy, it may be necessary to cool the cold sensor probe to make the pump run. Alternatively, temporary connection of the pump to mains power will enable a test run. Be sure to reconnect it to the Solar Controller after testing.

Note: If the pump is not capable of purging air from the system, all air must be purged manually from the highest point at the panels.

How to Turn Off the Water Heater

Should it be necessary to turn off the water heater following commissioning, then:

 Switch off or isolate the electrical supplies to the water heater AND the pump / controller  Close the cold water valve at the water heater inlet

Note: If the water heater is located in a frost area and freeze protection valves are not fitted, damage to the panels may result if the water heater is switched off. Damage to the panels where no power is available at the pump / controller and where no freeze protection valves have been fitted is not covered by warranty

Draining the Solar Collectors

 Ensure power is switched off at both the water heater and controller  Open a hot water tap and allow the hot water to run for a full 5 minutes immediately prior to draining

the solar collectors. This will assist in draining high temperature water from the collectors back to the storage tank. After 5 minutes, the hot water tap may be closed.

NOTE: Extreme care must be exercised as water discharged from the solar collectors may be at a very high temperature

 Turn off the water heater (see above)  Loosen fitting on top of solar panel return pipe  Disconnect the solar cold pipe and water will drain from the solar collectors  When water stops flowing from the solar hot and cold pipes, reconnect the solar cold pipe and

retighten fitting on top of solar panel return pipe.

Draining the Water Heater

 Ensure power is switched off at both the water heater and controller  Open a hot water tap and allow the hot water to run for a full 5 minutes immediately prior to draining

the solar water heater tank. This will assist in draining high temperature water from the collectors back to the storage tank. After 5 minutes, the hot water tap may be closed.

NOTE: Extreme care must be exercised as water discharged from the solar collectors may be at a very high temperature

 Turn off the water heater (see above)  Operate the relief valve release lever carefully to release the pressure in the water heater – do not

allow the lever to snap back or damage may result to the valve seat

 Undo the union at the cold water inlet and attach a hose to allow the water to drain from the tank  Operate the relief valve again to allow air into the water heater which will allow the water in the water

heater to drain away

Version 12.0 OCTOBER 2015 Page 29

Troubleshooting Guide

Problem

Cause

Remedy

Pump not cycling during good weather and collector is hot.

Tank sensor not inserted properly into controller

Check plug for sensor is connected at pump controller, contact supplier if sensor plug connected and fault light still flashes

Pump always ON even during minimal solar radiation conditions

Possible air lock in manifold

Contact your supplier.

Not enough hot water

Electric booster not connected to mains power

Ensure mains breaker (remote internal booster switch also if installed) is turned on for electric booster. Check if connected to off peak tariff, if connected to off peak tariff ensure that it is connected to tariff 33. If once all of the above is checked and booster still does not operate, please contact your supplier.

Banging noise in pipes when hot water tap is opened.

Steam formation in collector when hot water tap is opened after a period of collector stagnation. Often occurs when inlet cold pressure is low (<400kPa).

Check cold supply water pressure. Install pressure pump to raise cold supply pressure above 400kPa.

Hot water leaking from pressure temperature relief valve

Water temperature stored in tank is nominal

It is normal operation for the system to discharge up to 5 litres per day from the pressure temperature relief valve.

Heat pipe solar collector low working performance

Solar collector is covered by shade so can’t receive enough sunlight

Relocated in unshaded area Vacuum tube broken

Replace a new fine vacuum tube

Heat pipe does not install correctly

Pull out the heat pipe and daub some silicon grease on the heat pipe’s condenser then reinsert it into the manifold

Solar collector installed by a wrong angle

Adjust the solar collector and make sure the installation angle is from 15 to 75 degree

Pipe line don’t seal and insulated very well, so there is more energy loss

Check and seal the pipe line and keep the pipeline insulated very well.

Version 12.0 OCTOBER 2015 Page 30

PART C – PRODUCT WARRANTY

This warranty is offered by SolarEast and full contact details are shown at the end of this document.

In addition to the guarantees under the Australian Consumer Law (ACL), SolarEast provides consumers (i.e. retail customers, not trade customers) a warranty that all products in its product range (products) will be free from defects in materials and workmanship under normal use for the period of time applicable to particular components of each product as set out in the table below.

If a product fails to conform to this warranty during the applicable warranty period, SolarEast will either replace any failed component of the product or replace the product free of charge (which SolarEast will determine at its absolute discretion).

Table of Applicable Warranty Periods

Hot Water Storage Cylinder

7 years

Solar Collectors (Flat Plate and Evacuated Tube)

7 Years

All electrical parts, e.g. element, thermostat, pump, controller

2 years

Associated valves supplied by SolarEast including Frost Valves

2 years Labour to replace or repair defect

1 year

 The original storage tank must have undergone a 5 year maintenance service no earlier than 2 years before the expiration

of the original 5 year warranty period and no later than one month after the expiration of the original warranty period in accordance with the maintenance instructions published in the owner’s manual.

 The failure of the original storage tank or solar collector panel must be certified by SolarEast.

Exclusions

1. This warranty only applies to defects which have arisen solely from faulty materials or workmanship in the product and does

not apply to other defects which may have arisen as a result of, without limitation, the following:

 Installation by a non-authorised person or installation that is not strictly in accordance with the manufacturer’s

installation instructions as described in the Installation and Owner’s Manual;

 Accidental damage, abuse, misuse, maltreatment, abnormal stress or strain of the products;

 Tarnishing and damage to or deterioration of finishes as a result of harsh or adverse conditions (including corrosive

environments such as coastal locations, and inadequate ventilation and drainage of installation locations);

 Fair wear and tear;

 Excessive water pressure, blocked pipework, faulty plumbing, restricted flow or excessive temperature;

 Scale formation or the effects of corrosive water where the product has been connected to a water supply that is outside

the parameters outlined in the Installation and Owner’s Manual;

2. Alterations or repair of the product other than approved by SolarEast are not covered (for the avoidance of doubt, the

attachment of accessories or use of non-genuine replacement parts other than those manufactured or approved by SolarEast are not covered).

3. Where the water heater is installed in a position that does not allow easy and safe access, the cost of accessing the water

heater safely, including the cost of additional materials, handling and/or safety equipment, is not covered.

4. Personal injury, property damage or economic loss, howsoever caused, will not be covered.

Version 12.0 OCTOBER 2015 Page 31

5. The warranty is restricted to residential installations only. A separate warranty applies to commercial installations.

6. Freight and travelling costs associated with the repair or replacement of the product in accordance with this warranty is not

covered except where the product is installed inside a 50 kilometre radius of the business premises of SolarEast or its appointed Distributor.

7. Where a failed component or system is replaced under warranty, the balance of the original warranty period shall remain

effective. The replaced part or system does not carry a new warranty.

8. Solar collector glass damage or breakage is not covered under this warranty. Your household insurance policy should be

extended to include damage or breakage of the solar collector glass.

9. Freezing and frost damage is not covered under this warranty except where adequate precautions are taken in accordance

with the instructions contained in this “Installation Instructions and Owner’s Manual” and then only in accordance with the

separate warranty coverage provided for any frost protection devices fitted.

Australian Consumer Law (ACL)

In addition to this warranty, certain legislation (including the ACL) may give you rights which cannot be excluded, restricted or modified. This warranty must be read subject to such legislation and nothing in this warranty has the effect of excluding, restricting or modifying those rights.

If SolarEast fails to meet a guarantee under the ACL, your remedy for such failure may be limited to any one or more of the following:

 replacement of the product;  repair of the product;  refunding the cost of the product;  payment of reasonable costs of having the product repaired;  payment in respect of the reduced value of the product.

As required by legislation, including the ACL, any claims for damage, or any consequential loss either directly or indirectly due to defects of any kind in a product will only be met by SolarEast where the damage or loss was reasonably foreseeable by SolarEast.

Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and for compensation for any other loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure.

HOW TO MAKE A WARRANTY CLAIM

At the time of purchasing your water heater, you should ensure you receive an owner’s manual and that details of your

purchase, including the date of purchase and the serial number of the storage tank, are recorded therein. You should keep those documents in a safe place in case of a warranty claim as documentary proof of purchase or other tangible evidence will be required to make your claim. Claims can be made at the point of sale or by posting, faxing, or emailing a written claim to SolarEast (contact details listed below) within 3 months of the appearance of a defect. Claims must include the following details:

 Date of purchase;  Location of purchase;  Proof of purchase; and  Contact details including name, address, telephone numbers, and email address.

Please note: When making a service call, it is imperative that the 6-digit water heater serial number, located on the technical label, is quoted.

Version 12.0 OCTOBER 2015 Page 32

SolarEast contact details are as follows:

SolarEast Australasia Pty Ltd

Unit 2, 10-12 Cerium Street

Narangba QLD 4504

P: 1300 668 886 E: service@solareast.com.au

Note: Whilst every care has been taken to ensure the accuracy in preparation of this document, no liability can be accepted for errors or omissions and any subsequent consequences that may arise. Specifications and materials may change without notice.

Version 12.0 OCTOBER 2015 Page 33

WARRANTY FORM

Model – SolarEast Water Heater

Manufactured and distributed by:

SolarEast Australasia Pty Ltd

Unit 2, 10-12 Cerium Street

Narangba QLD 4504

P: 1300 668 886 E: service@solareast.com.au

PLEASE FILL IN THE DETAILS HEREUNDER AND RETAIN THIS WARRANTY TOGETHER WITH YOUR PURCHASE INVOICE, WHICH MUST BE PRESENTED WHEN MAKING A WARRANTY CLAIM.

Homeowner Name: Installation Address:

City:

State: Post Code: Date of installation:

System Model Number: Number of Collectors / Tubes:

Collector Type: (Flat Plate or Evacuated Tube)

Serial Number of Tank: Plumber Name:

License no: Plumber Signature:

This warranty does not exclude, limit or modify any warranty, condition or liability which is or may be implied or imposed on the Company by virtue of the Trade Practices Act, 1974, or any other statute, law, rule or regulation except for the extent to which the Company is lawfully entitled. Note that SolarEast is not liable for any expenses associated with making a warranty claim.

Version 12.0 OCTOBER 2015 Page 34

SOLAR WATER HEATER – INSTALLER CHECKLIST

Attention: Installer - upon Commissioning; This Form must be completed and returned to SolarEast. Failure to do so can void homeowner warranty.

The Installer is responsible for Commissioning & Testing -  For “Yes”, x for “No”.

Has the installation been installed in accordance with Workplace Health & Safety regulations? Is the Contractor Solar accredited? Has this system been installed to Australian standards AS3500.4 –1994, AS/NZS 2712 including water

tightness test and Wiring Rules AS/NZS 3000?

Has the contractor located solar collectors where site drawing / order nominates. (Collectors should be

facing North for optimum efficiency). If not, indicate direction

Has the system been installed as per this Owner & Installer Manual? Have the tempering valve, cold water expansion valve, pressure reducing valve and high temperature non-

return valves been installed?

Has both Solar Collector sensor & Tank sensor leads been installed and TESTED to ensure are functioning

correctly

Has both the Flow & Return COPPER pipes been correctly insulated; Armorflex 13mm (or similar) Does the pump light switch on when operating? Are Solar Flow & Return lines installed using Copper pipe (Plastic Pipe or similar not acceptable)? In areas where frost or freezing (below 5°C) is prevalent are AVFPK Frost protection kit fitted (Note –

SolarEast recommends the use of evacuated tube collectors in frost areas and warranty may be void where Frost Protection kits have been incorrectly installed or inadequately maintained?

Has the air been purged from system? Has the circulation pump been tested and ensure water is circulating to collectors?

I certify that the solar hot water system is installed at the address shown below and has been installed to the manufacturer's requirements and in accordance with this installation manual.

Homeowner Name: Installation Address: City: State: Post Code: Date of installation: System Model Number: Number of Collectors / Tubes: Serial Number of Tank: Plumber Name: License no: Plumber Signature:

SolarEast FPC270-2D,FPC270-3D,FPC340-2D,FPC340-3D,FPC450-2D,FPC450-3D,TZ250E-25R250L,TZ250E-30R250L,TZ315E-25R315L,TZ315E-30R315L,TZ315E-40R315L,TZ400E-30R400L,TZ400E-40R400L, FPC340-2D, FPC450-2D, FPC340-3D, FPC450-3D Owners & Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual