CONERGY PTY LTD Conergy TS Owner & Installation Manual
Table of Contents 1 2 3 4 5 6 7 8 9 Customer Information ................................................................................................................ 2 1.1 Installing your new Conergy TS System ........................................................................... 2 1.2 Conergy quality ................................................................................................................. 2 1.3 How does the system work? ..............................................
1 Customer Information 1 CUSTOMER INFORMATION 1.1 Installing your new Conergy TS System You are installing one of the most advanced solar water heaters in the world. This manual provides you with the essential information needed to install the Conergy Thermosiphon System correctly. Please read it carefully and follow all the instructions. We hope you find the following information useful. 1.
1 Customer Information 1.3.1 Storage Tank & Solar Collectors Figure 1.1 Typical System Layout (Cut-away) Figure 1.2 System Layout Detail (Cut-away) The potable water storage tank is used to store the heated water ready for household use. The TS Plus is manufactured using high quality 444 grade stainless steel and the TS model is constructed with vitreous enamel lined mild steel to provide a long life.
1 Customer Information The solar collectors contain a multi tube copper water way system bonded to a solar absorber plate, the combination of which collects solar energy and transfers it to the fluid within the collector circuit. The absorber plate system is enclosed in an insulated metal casing covered with a high strength toughened glass sheet that protects the absorber system from physical damage. 1.3.
1 Customer Information 1.4 Conergy model numbers explained XX NNN / XX / X / XNN / X / XNNXX System Type – Nom.
1 Customer Information 1.6 Important safety information All water heaters have the ability to produce hot water very quickly. To reduce the risk of scald injury it is recommended that a temperature control valve be fitted to the hot water supply pipe work. This valve should be checked every 6 months to ensure its operation and settings remain correct. Check that the pressure & temperature relief valve drain pipe is not located where it can cause damage if hot water is discharged.
2 Troubleshooting 2 TROUBLESHOOTING If there is not enough hot water we recommend that the following points are considered as part of the service call. The most obvious reasons for a lack of hot water could be one of the following. 2.1 Low solar energy input If there have been prolonged periods of cloud or winter is approaching, it may be necessary to reconsider the permitted boosting time for time-clock controlled systems or to turn on the booster for systems with a booster isolation switch. 2.
2 Troubleshooting 2.6 Water discharge from the frost valve If your system has a frost valve fitted it will be located at the bottom corner of the collector. In temperatures that cause frost or freezing the valve will open and some water will discharge from this valve. There is nothing that needs to be done to the valve or the system, it is operating correctly. The water will stop discharging once the valve has warmed enough to close again, usually as the frost clears. Refer to section 1.
3 System Maintenance 3 SYSTEM MAINTENANCE The Conergy solar water heater is designed so that there is little to do in the way of system maintenance. Personally inspecting or servicing any part of the system is not recommended. Should you decide that you want to inspect the roof mounted system it is essential that you use all safety devices required to ensure your personal safety. Most importantly the electricity supply must be turned OFF. 3.
3 System Maintenance 3.4 Relief valves The lever on the relief valves should be operated at least every six months. Failure to do so may result in failure of the tank. If water does not discharge freely from the valves they should be checked and possibly replaced. The relief valves and relief valve drain lines must not be blocked. Some water may discharge during each heating cycle Every five year’s all safety valves should be replaced to ensure continued life and operational safety of the system.
4 Important Installation Information 4 IMPORTANT INSTALLATION INFORMATION 4.1 Local Standards The following standards and regulations must be taken into account when planning the installation of the Conergy TS solar water heater system. AS/NZS 3500.4.2 National plumbing and drainage code hot water supply systems – acceptable solutions. HB 263-2004 heated water systems plumbing industry commission. AS/NZS 3000 Electrical installations (known as the Australian/New Zealand wiring rules).
4 Important Installation Information 4.4 Pressure Reducing Valve Where the mains water supply pressure is likely to exceed 550 kPa at any time, a 500kPa pressure reducing valve that complies with AS1357 must be fitted to the inlet of the hot water system. This is essential to safeguard the appliance and ensure correct operation. A breach of this requirement may void the warranty in the event of damage caused by excessive pressure. 4.
4 Important Installation Information Any supplementary heat source must be limited such that the maximum tank temperature is 80 °C. 4.9 Legionella requirements The Australian Standards require that a water heater system provide a means to inhibit the growth of the Legionella bacteria in potable water. If the system is installed with an approved Gas AES, with the outlet temperature set to 70°C, then this requirement is satisfied.
4 Important Installation Information 4.10.2 Shading Careful site inspection is required to ensure the selected location is not subjected to shading from adjacent trees or buildings throughout the day, but particularly between 9am and 3pm, the highest solar input times. Shadows are longer in winter than in summer so a site that is free of shadows from adjacent objects in summer may have some shadows in winter. 4.10.
5 Dimensions and Technical Data 5 DIMENSIONS AND TECHNICAL DATA 5.1 System Overall Dimensions Figure 5.1 300L System overall dimensions Figure 5.2 180L System overall dimensions Envirosun TS Installation Manual Rev5b PVNW.
5 Dimensions and Technical Data Model Number Dimensions (mm) A B C D E F TS180/20/C///E20 2600 1370 1226 2000 1000 82 TS180/20/O///E20 2600 1370 1226 2000 1000 82 TS180/25/C///E25 2600 1370 1226 2000 1235 82 TS180/25/O///E25 2600 1370 1226 2000 1235 82 TS300/25/C///E25 2600 1370 2010 2000 1235 82 TS300/25/O///E25 2600 1370 2010 2000 1235 82 TS300/40/C///E20 2600 2238 2010 2000 1000 82 TS300/40/O///E20 2600 2238 2010 2000 1000 82 TS300/50/C///E
5 Dimensions and Technical Data 5.3 System Weights Tank Material Weight – Empty (kg) Weight – Full (kg) TS180/C/E24/V Vitreous Enamel Mild Steel 64 239 TS180/O/E24/V Vitreous Enamel Mild Steel 54 229 TS300/C/E24/V Vitreous Enamel Mild Steel 101 399 TS300/O/E24/V Vitreous Enamel Mild Steel 87 385 TS300/O/E24/S 444 Stainless Steel 71 369 Table 5.3 TS Tank Weights Collector Weight – Empty (kg) Weight – Full (kg) E20BC 29.5 31.2 E25BC 36.0 38.0 E20AA 39.0 40.7 Table 5.
6 Installation Instructions 6 INSTALLATION INSTRUCTIONS Before commencing the installation of the solar water heater system, please ensure you have familiarised yourself with the requirements of Section 4 Important Installation Information. Remove all packaging and protective coatings and dispose of them in an appropriate manner. This includes the plastic core-strip from the back of the collector and the plugs from the collector and storage tank connection pipes. 6.
6 Installation Instructions 13. 14. 15. 16. 17. 18. 19. 20. 21. Using the self-drilling screws supplied, screw fix the collector rail to the collectors as shown in Figure 6.3. Use two (2) per collector. Finally, using two (2) of the self-drilling screws supplied, screw fix the collector straps to the collector rail and collector/s. The collector/s are now mounted. Continuing, slide a Compression Plug assembly (Figure 6.4) to the top left and bottom right corners of the collector array.
6 Installation Instructions 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. Now it is time to fit the cold connection pipe. This procedure will differ between models, so refer to the appropriate picture. Slide a compression elbow to the bottom left corner of the collector array. For closed circuit systems this will be an integral fill fitting elbow. Tighten the assembly taking care not to twist the copper tubes on the collector. Insert one end of the flexible connection pipe to the elbow.
6 Installation Instructions 6.3 Flat roof installations For flat roof installations a special mounting frame is required. mounted, follow the instructions as outlined above. 6.4 System diagrams and components 6.4.1 TS300/TS300 Plus Open Circuit Once the frame is Figure 6.13 Typical TS300/TS300 Plus Open Circuit Installation 6.4.2 TS180/TS180 Plus Open Circuit Figure 6.14 Typical TS180/TS180 Plus Open Circuit Installation Envirosun TS Installation Manual Rev5b PVNW.
6 Installation Instructions 6.4.3 TS300 Closed Circuit Figure 6.15 Typical TS300 Closed Circuit Installation 6.4.4 TS180 Closed Circuit Figure 6.16 Typical TS180 Closed Circuit Installation Envirosun TS Installation Manual Rev5b PVNW.
6 Installation Instructions 6.5 Plumbing Connections 6.5.1 Cold water connection A check valve and a stop cock must be fitted to the cold water supply pipe work. 1. 2. The cold water connection is made at the blue disc. Connect the cold water supply to the end of the ¾” BSP female thread of the Tee piece in the cold down pipe assembly (Detail A).
6 Installation Instructions Electrical entry for the electric AES is achieved via a 20mm opening adjacent the element surround. Thermostat Electrical element 5mm Earth stud Terminal block 20mm entry Figure 6.17 Electrical entry A cable gland with orange circular cable, or 19mm conduit with 3 core TPS cable must be used to make electrical supply to the unit. The power supply must be protected by an individual fuse or circuit breaker rated to suit the booster size.
6 Installation Instructions 6.6.1 Electrical circuit diagram Figure 6.18 Electrical circuit diagram 6.7 Gas AES installation instructions All gas work must comply with local regulations including AS5701/AG601 and AS/NZ 3500.4 All gas work must be conducted by a suitability licensed gas fitter. Installation of the gas heater must be installed in accordance with the installation instructions supplied with it. Conergy systems only use approved Gas Heaters.
7 Commissioning & Customer Hand Over 7 COMMISSIONING & CUSTOMER HAND OVER 7.1 Commissioning When all connections have been completed the solar water heater can be filled with water. 1. 2. 3. 4. 5. 6. 7. 7.2 Before turning on the cold water supply to the system, open one hot tap within the household to release air from the system during the filling process. Do not leave the open tap unattended during the filling process. Turn on the cold water supply and wait for the system to fill.
7 Commissioning & Customer Hand Over 7.2.3 Procedure Ensure the Collectors are fully covered for this procedure to prevent pressure variation occurring due to thermal activity in the collectors. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 7.3 Remove the 100 kPa jacket relief valve from the tank socket. Refer to Figure 6.11 on page 20 for the location of this valve. Connect the ½” (15 mm) flexible hose to the fill tap located at the bottom left side of the collector array. Refer to Figure 6.
8 Warranty 8 WARRANTY Component Warranty coverage Parts Warranty Labour Warranty TS & TS Plus Tank (roof mounted) 5 year 5 year AS Tank (ground mounted) 5 year 1 year Element Flange subassembly TS Systems 5 year 5 year Collector 5 year 5 year Seal, Neck Ring 5 year 5 year Mounting Frame 5 year 5 year Element 1 year 1 year Anode (TS Range only) 1 year 1 year Thermostat, Solar 1 year 1 year Valves and plumbing accessories 1 year 1 year Heat Exchanger 1 year 1 year Vesse
