CONERGY PTY LTD Conergy AS Owner & Installation Manual
Table of Contents 1 Customer Information ................................................................................................................ 2 1.1 Installing your new Conergy AS System .......................................................................... 2 1.2 Conergy quality ................................................................................................................. 2 1.3 System Components ..............................................................................
1 Customer Information 1 CUSTOMER INFORMATION 1.1 Installing your new Conergy AS 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 Active System correctly. Please read it carefully and follow all the instructions. We hope you find the following information useful. 1.
1 Customer Information The electric element within the storage tank is used for the electric AES. This element is automatically controlled by an internal thermostat which only allows the electric element to operate if the water temperature in the storage tank falls below 60 °C. Even then, it will only consume electricity until the water temperature is increased to 60 °C. At this stage it turns off automatically. Figure 1.3.
1 Customer Information 1.4 Conergy model numbers explained XX NNN / XX / X / XNN / X / XNNXX System Type – Nom.
1 Customer Information If the unit is to be fitted in areas prone to frost and freezing the unit must be installed in accordance with any relevant sustainability programme (such as the Sustainability Victoria program). A breach of this requirement may void the warranty in the event of damage caused by leaking due to frost or freezing. 1.6 Important safety information All water heaters have the ability to produce hot water very quickly.
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 collectors, 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 AS 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 4.8 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. If the system is installed with an Electric AES, then one of the following requirements must be met: 1. 2. 4.
4 Important Installation Information 4.9.2 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. 4.9.
5 Dimensions and Technical Data 5 DIMENSIONS AND TECHNICAL DATA 5.1 Collector Installation Area Figure 5.1.
5 Dimensions and Technical Data 5.
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 5.3.1 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 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. tube spigots of that collector slide fully home into the collector connectors already fitted to collector. Tighten the compression nuts of the collector connector fittings (Detail B – item 3), taking care not to twist the copper tubes of the collector. Make sure you use correctly sized spanners and that the centre nut is held steady whilst the compressing nuts are tightened.
6 Installation Instructions 21. 22. 23. 24. 25. 26. 27. 28. Assemble and install the Hot Connection Union assembly (Detail A) as follows; Take the temperature well (Detail A – item 10) and slide it onto the copper spigot at the top right of the collector array. Tighten the assembly taking care not to twist the copper tubes of the collector. Make sure you use correctly sized spanners and that the nut is held steady whilst the compressing plug is tightened.
6 Installation Instructions 3. mounted storage tank location. This tube is known as the Collector Hot Connection. Connect a 2 core cable to the two wires of the black insulated temperature sensor supplied with the Pump Module (PM-600). Fully insert the temperature sensor into the temperature sensor well of the hot connection union assembly. Secure in place with the P-Clip and screw provided. Run the cable down to the ground mounted storage tank location.
7 Connections at the Storage Tank 7 CONNECTIONS AT THE STORAGE TANK 7.1 Connections for the PM-600 1. 2. 3. 4. 5. 6. 7. 8. 9. Apply thread tape or a suitable sealant to the thread of the ¾” BSP to ½” compression union (P/No 60-1029). Screw the union into the top (outlet) socket on the right side of the storage tank. Fasten the Collector Hot Connection (Section Error! Reference source not found., Step 2) into the compression union.
7 Connections at the Storage Tank 60-1032 35-8009 35-8008 60-1032 60-5065 60-5066 Figure 7.1.1 Connection for the PM-600 7.2 Plumbing Connections The Storage Tank is installed and connected to the plumbing installation as normal and detailed in the Conergy installation instructions supplied with the water heater. The household plumbing connections should be made to the tank socket fittings on the left side of the storage tank.
7 Connections at the Storage Tank 7.2.4 Pressure & temperature relief valve (P&T valve) Remember this valve can discharge very hot water, so carefully consider its location. Never discharge onto a solid surface like concrete. 1. 2. Fit the pressure & temperature relief valve supplied with the tank into the tank socket, marked “Valve”.
8 Electrical Connections 8 ELECTRICAL CONNECTIONS 8.1 Electrical connection for Electric AES (Booster) For safe performance this water heater is fitted with a thermostat and an over temperature cut-out. These devices should not be tampered with or removed. Do not operate this water heater without the electrical thermostat and over temperature cut-out in the circuit. The electric element is only connected in models using an electric AES system.
8 Electrical Connections 8.1.1 Electrical circuit diagram Figure 8.1.1 Electrical circuit diagram 8.2 Electrical Installation for the PM-600 From the mains electrical connection, install a permanent 230 to 250 volt, 50 Hz external GPO in a suitable position near the pump module. The pump module draws a maximum 50 watts at full load. The temperature sensors should not be in direct contact with fluid. Always use immersion sleeves.
8 Electrical Connections Figure 8.2.2 PM-600 Wiring Diagram 8.2.1 Controller Setting It is not recommended that you alter the optimal factory settings or run the system in manual for extended periods. If there is a need to change a field you have noticed to be incorrect: 1. 2. 3. 4. 5. 6. Turn on the power supply and wait 15 seconds. Press and hold down Button 1 until “SEt” appears on the display screen.
8 Electrical Connections Figure 8.2.3 Controller functions 8.3 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.
9 Commissioning & Customer Hand Over 9 COMMISSIONING & CUSTOMER HAND OVER 9.1 Commissioning When all connections have been completed the solar water heater can be filled with water. 1. 2. 3. 4. 5. 6. 7. 9.2 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.
10 Warranty 10 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 Ves
