solar system installation & owner’s operation manual · the most frequently used hot water...

Installer checklist .................................. Page 2

Water quality ........................................ Page 3

Solar storage heater options ................. Page 4

Plumbing connection - Cylinder ............ Page 5

Plumbing connection - Wetback ........... Page 8

Collector Panel - Installation ................. Page 9

Electrical ............................................. 3

Owners information ............................ Page 15

Troubleshooting .................................. Page 17

Metro Solar Warranty .......................... Page 18

Warranty Registration ......................... Page 20

Metro Solar Systems

Solar System Installation & Owner’s Operation Manual

M10

37 0

3/13

PO Box 11, Inglewood 4347, New Zealand

Ph (06) 756 6520 • Fax (06) 756 6540

[email protected] • www.metrofires.co.nz

• pLeaSe eNSURe YOU ReVIeW aLL INFORMaTION ON THIS page aND COMpLeTe aLL TaSKS aS ReQUIReD

• Take steps to identify possible water quality issues prior to installing

• To maximize efficiency’s, solar water pipes and fittings are smaller than normal. Tubes are imperial, outside diameter rated 1/2” and 1”

• Review check list below

WaRNINg! Important Information

Installers Quick Reference Guide

Collectors

1. Must be level or orientated towards inlet to enable release of water to achieve drain-down.

2. Inlet & outlet pipes must both penetrate the roof below the collector connections to prevent air locks & achieve drain-down.

3. Air bleed valve must be on vertical axis.

4. Air bleed vent set open to allow air flow.

5. Use correct dektites with sensor penetrations to keep sensors away from hot copper pipe.

6. Collector couplings installed with specified compound and tightened to ensure approximately one remaining thread of nipple is visible. (page 11 of installation manual).

7. Correctly insulated with UV protection where exposed to weather.

Solar Pipe Circuit

1. Copper pipe 12.7mm outside diameter (refrigeration tube).

2. Copper pipe feeding collector inlet must remain below bottom of collectors to achieve drain-down.

3. All copper pipes need to be as straight as possible to eliminate air/water pockets.

4. Use solar rated non return supplied at solar return to tank, do not install additional check valves or non returns. (There is a second non return incorporated within the solar pump union, output side).

5. Only use high temperature close cell insulation. (Black).

Sensors

1. Hotlogic™ only use 1000ohm sensors.

2. Metro Solar Frost and Over Temperature controllers only use 1200ohm thermistors (Senztek).

3. Sensor leads must not contact copper pipe or roofing iron.

4. Sensor connections must be dry, water proof when installed above roof line.

5. When sensor leads need to be extended, wires must be joined using a suitable connector. Twisting exposed wires together is not acceptable.

Collector Drain

1. Pipe work must not prevent collectors from draining.

2. No restrictions must prevent the water gravity feeding from the collectors in drain down mode.

3. Separation between waste sump and drain is preferably by use of an open ‘Tundish’ method.

Service Valves

1. A service valve is incorporated within the input coupling of the solar pump of some models.

2. Installation of additional service valves are recommended prior to the solar pump and at the solar return to the tank to enable service of the non-return.

Please Note:

• Discuss with home dweller methods of maximising solar gain.

• Please ensure all warranty information on the rear page is completed at time of installation.

Your decision to purchase a Metro Solar Hot Water system will reward you for many years to come. Metro Solar’s Ecosmart range has seen continuous research and development, resulting in many breakthroughs in the efficiency, reliability and longevity of hot water systems.

Ecosmart water heaters are manufactured in Australia in a state-of-the-art facility, using a Quality Endorsed Company production system.

This is your assurance that you have purchased the highest quality water heater available, one that will provide continuous hot water for all your needs - safely, economically, and for many years to come.

Welcome to Metro Solar hot water

Your Ecosmart/Metro Solar water heater has been manufactured to suit water conditions of most New Zealand metropolitan supplies. Please note that harsh water supplies can have a detrimental effect on the water heater and its life expectancy. If you are unsure about your water quality you can obtain information from your local water supply authority.

Normal town water has a Chloride content of approx 10-30 parts per million. As Metro Solar water storage cylinders are either vitreous enamel lined or duplex stainless steel, they are suitable for use with most town water supplies, however there are some locations in New Zealand where water is known to be of ‘harsh quality’ and this needs to be considered prior to purchasing product.

In general, if chloride levels are below 50ppm at normal operating temperatures and total dissolved solids are below 600ppm you should enjoy an extended life expectancy.

Acceptable water quality parameters for Storage Heater and Solar Collectors

Generally you would expect the following results in relation to Metro Solar “Direct solar heating systems”

4 Treated city/town water supply Acceptable

4 Rain collection water supply Acceptable (Although masonry tanks are preferable to

fiberglass tanks)

✘ Bore, River or stream water Usually unacceptable and requires a full mineral analysis to

determine what treatment will be required.

In areas where the Total Dissolved Solids (TDS) exceed 600ppm storage heaters with magnesium alloy anode must be replaced with an aluminum alloy anode.

Water can be both corrosive and saturated with mineral which can be detrimental to your solar system. The following parameters need to be maintained if you are not on already on a treated water supply.

PH 7.7 – 8.5Chloride Up to 50 ppmIron Up to 0.01 ppmMaganese Up to 0.01 ppmLangelier Saturation Index - 0.5 to +0.8Ryznar Stability Index 6 to 8

Water outside these parameters is considered of “Harsh Quality” and will void warranty. Such water will require either water treatment or alternatively an “indirect solar system”

Ecosmart/Metro Solar water quality

Ecosmart Cylinder

Mains pressure enamel lined carbon steel storage heaters. Complies to AS/NZS2712:2007, AS4234

• Moldedpolycarbonatetopandbottomwithpowdercoated zincalum outer shell.

• HighDensitycasturethane.

• Electricboostelement,3.6kWmidheight thermostatically controlled.

• TPRsafetyvalve,1000kpasupplied

• Solartemperingvalvesupplied

• ¾”bspfemalepipeconnections

Direct solar circuit. (No heat exchanger) The potable water within the storage heater is circulated through the solar collectors.

Water resistant tanks are suitable for placement outside, but it is still recommended to provide additional protection (rain cover) to maintain the condition of insulation, wiring and valves etc.

Storage heaters are equipped with a Magnesium Alloy sacrificial anode, accessible through the top cover. To enable replacement of this anode a clearance above the storage heater, equating to 50% of the storage cylinders height is required.

Solar Storage Heater Specifications

Combo Cylinder

Mains pressure Duplex stainless steel storage heater. Complies with AS/NZS 2712:2007, AS4234, NZS 4606

• Galvanisedsteeloutershell.

• HighDensitycasturethane.

• Electricboostelement,3.0kWmidheight thermostatically controlled.

• TPRsafetyvalve,850kpa,hmcHT575supplied

• WaterIn/Solarsupply&Solarreturnconnections, ¾”bspfemale

• Wetback9mcoil,connections,1”bspmale

• Hotwateroutconnection,¾”bspfemale

Direct solar circuit. (No heat exchanger) The potable water within the storage heater is circulated through the solar collectors.

Internal wet back coil (9m length) for connection to your woodfire.

CaUTION! Important Information• We recommend safe trays are utilized with all

water storage heaters when installed inside the home. Warranty does not cover consequential damage due to heater or equipment leakage.

Nominal Measurement Tank Height (A) Tank Diameter (B) Tank Width (C) Tare Weight Gross Weight Outlet (D) Inlet (E) Solar Return (F)

Ecosmart Solar Cylinder 315L 1754mm 617mm 712mm 111kg 426kg 1545mm 215mm 215mm

Ecosmart Solar Cylinder 400L 1703mm 705mm 801mm 123kg 523kg 1465mm 240mm 240mm

Combo Cylinder 300L 1760mm 575mm 670mm 80kg 380kg - 130mm 130mm

Combo Cylinder 400L 1730mm 650mm 745mm 90kg 490kg - 130mm 130mm

Ecosmart CYLINDeR

FRONT VIeW

C

B

TOp VIeW

E

ReaR VIeW

900mm Mid Element

COMBO CYLINDeR

FRONT VIeW

E

C

B

TOp VIeW

900mm Mid Element

730mm Wetback return

Wetback feed connections

130mm

Location

The water heater should be located as close as possible to the most frequently used hot water outlet. Ensure that the specification data is clearly visible and provide adequate access for service to the element, thermostat, relief valve, anode and solar valves.

Installation

This water heater must be installed by a certified/registered plumber, and in accordance with:

• AS/NZS3500.4“NationalPlumbingandDrainageCodeHot Water Supply Systems – Acceptable Solutions”.

• Localauthorityregulations.

NOTE: This water heater is not suitable for pool heating.

Supply Pressure

These water heaters are designed for direct connection to water supply pressures of no greater than:

• 250-400LitreModels-500kParecommended

Where the mains pressure can exceed or fluctuate beyond the pressure shown above a pressure limiting device must be fitted in the cold water inlet supply. This device must be installed after the isolating valve and set at or below the pressure shown above. Note during periods of lower demand water pressure may increase.

Temperature & Pressure Relief Valve (TPR)

The temperature and pressure release valve is supplied loose with the water heater. The valve rating is:

• 300-400LitreEcosmartModels-1000kPa

• 300-400LitreComboModels-850kPa

The relief valve must be installed directly into the top socket marked ‘Relief Valve’. The drain line from this valve must run in a continuously downward direction with the discharge end left permanently open to atmosphere.

Tempering Valves

These water heaters can deliver water exceeding safe temperatures and therefore tempering valves must be fitted to limit output temperature to 55ºC

Water Supply Valves

The following should be included.

•Isolationvalve •Pressurelimitingvalvenotexceeding500kpa •Nonreturn/Strainer •Coldwaterexpansions •Anadditionalservicevalvepriortosolarcirculationpump

Copper Pipe

The solar circuit flowing between the solar storage cylinder and the solar collectors is required to be 12.7mm outside diameter copper tube. This smaller diameter tube greatly increases efficiency during periods of partial sunshine.

Pipe Gradient

• collectorstothewaterstoragetankhaveaminimumof 5° continuous fall

• pipeshavenohighpointsthatallowairtobetrapped

• theminimumnumberofbendsinthepipesareused.

• Flowandreturnlinesshouldbeneatlyinstalledandhiddeninside the roof cavity if possible

• Takecarewhenrunningflowandreturnlinesthroughtheroof, cladding and the eaves.

Plumbing Connections – Water Storage Cylinder

Drain Connections

Secondary 12v Drain supplied in cold regions to protect system from power outage

Heat Trap

Ensure to include a heat trap in the hot water discharge from the storage heater to reduce heat loss through dissipation.

Hot Water Connection

The hot water line should be connected to the 20mm female socket marked as OUTLET. For the most economical operation of the water heater, it is recommended that all hot water lines are insulated with high temperature, UV resistant closed cell insulation as per AS/NZS 3500.4.2003 and page 12 of this manual. Ensure to include a heat trap in the hot water discharge from the storage heater to reduce heat loss through dissipation.

Safety Information

For safe performance this water heater is fitted with:

• Anover-temperatureenergycut-outthermostat.

• Acombinationpressure&temperaturereliefvalve.

These devices must not be tampered with or removed. The water heater must not be operated unless both of these devices are fitted and in working order.

The element cover should only be removed by an electrician. The electrical power supply switch must be turned off and the fuse removed at the main electrical supply switchboard before the water heater electrical cover is removed.

Seismic restraints must be fitted to the solar storage cylinder as per AS/NZS 3500.4.2003

Drain connections

Additional to the TPR and cold water expansion there is either one or two drains from the collector circuit.

Firstly, the collector drain is pre fitted to the Hotlogic drain down valve.

Secondly, in colder areas a secondary drain valve is coupled to the first valve which activates during power outage. (This second valve is not required in warmer Auckland or Northland regions.)

Collector Drain

• Withraincollectionsystemspipethisdrainbacktoraincollection tanks

• Withtownsupplysystempipethisdraintowaste.

• Ideallythedrain/drainsshouldemptyintoanopen‘tundish’ with sufficient volume to contain the discharge

Please note: System can discharge up to 5 litres of high temperature water.

Secondary Drain valve

Hotlogic Drain valve

System Connections and components

Item Description

1 Solar Electric Tank Assy (315L/400L)

2 Solar Collector Panel

3 Solar Collector Inlet

4 Solar Collector Sensor Lead

5 Solar Circuit Pipework

6 Air Bleed Valve

Item Description

7 Power to the Element - 15 amp (Stainless steel - 10amp)

8 Tempering Valve

9 Cold Water Expansion Valve

10 Non Return/Strainer x2

11 Solar Rated Check Valve

On the Ecosmart storage heater these fittings need to be piped to an accessible location to ease service

Alternative outlet

Power to element

Solar return turned up

Inlet dip tube turned down

Plug in power to Hotlogic

Outlet to house

TPR valve

Heat trap 250 minimum

3

6

4

10 9

7

11

10

1

8

5

22

Must be plumb

Wood fire

Pressure Red v/v 3.6M

Tempering Valve fitted

to achieve heat trap

Open Vent to

highest point

Hot Service Out

Roof

Op

en V

ent

Dra

in

Dra

in

Cold Water Exp. V/v 700Kpa

Mains Cold Water inlet

Pressure Limit V/v 500Kpa

Tem

p/P

ress

. rel

ief v

alve

850K

pa

Wetback element

130m

m33

0mm

* Hot pipe must rise

in a positive gradient

of 1 in 10

Both flow and return

pipes must be insulated.

Not compatible to under/

over systems

Metro Solar stainless steel storage cylinders are manufactured from high quality Duplex stainless steel configured as multi energy systems designed to be heated by solar, electric and wetback.

Model Combo, 300 litre/400L, 3.0Kwh electric element, Solar compatible, Wetback compatible

Plumbing

Wetbacks can be set up with either a hot open vented header tank or a low-pressure 3.6m head pressure – reducing valve. Vent pipes must be at the highest point in the thermosyphon circuit. The easiest way to achieve this is to screw a Tee into the top wetback fitting. Failing to comply will cause air pocket and primary circuit not functioning – Result no heating and a banging sound in the pipes.

Do not use a higher rating reducing valve, than 3.6m or the primary circulation water will tend to take the less resistance and pass up through the open vent rather than go through the coil in the cylinder.

Wetback piping between cylinder and the fire should be installed with a 1-10 gradient falling towards the fire.

It is very important to set the wetback system up “correctly” as it works by thermosyphon. Try and maintain a minimum height of 330mm from the bottom of the cylinder to the centre line of the top outlet connection on the wetback element in the fire. Failure to achieve this will result in “back syphoning”

Pipes connecting the wetback to the unit must be copper and minimum 25 dia. Both lines are to be insulated from the cylinder to the fire. It is very important not to fit any non-return valves into the wetback system.

Inlet water pressure – High pressure may cause excessive discharge and possible premature failure of the operating relief valve. The maximum water pressure usually occurs during the night, at the time of lowest water usage.

In any mains pressure water heater installation, if the inlet water pressure exceeds 80% of the nominal set pressure of the operating relief valve a Pressure limiting Valve must be fitted to the cold inlet.

Standard Wetback System

Cylinders set up with a thermosyphon wetback should provide many years of effective heating if installed correctly. Dimensions set out below must be adhered to or the system may “BACK SYPHON”.

Metro Solar stainless steel water heaters

Cold in

Please ensure that sufficient roof space is available to install the solar collectors in the desired location.

Please allow the following roof space for collector installation

•2collectorpanels–3.0metreswidex3.0metreshigh •3collectorpanels–4.0metreswidex3.0metreshigh

Roof areas smaller than these minimum measurements will make installation, and later service work, difficult.

Solar Collector Installation

Note: Do not commence an installation until you have satisfied yourself that all Safety issues associated with working on and lifting components onto a roof have been addressed. Important: All work associated with the installation must comply with local authority regulations including AS/NZS 3500.4.2. Where these installation instructions and local regulations are in conflict, local regulations must prevail.

Solar Collector Location Selection

There are five major factors to consider in selecting the solar collector location site.

1. For optimum performance, the solar collectors need to face the equator (in New Zealand this is north). Collector orientation can be within 45º of north if necessary but solar gain will be reduced. To recover lost solar gain, installation of an additional collector will boost efficiency. If the collectors are installed with an east facing bias, the best solar input is achieved in the morning and if there is a west facing bias, the best solar input is in the afternoon.

2. Careful site inspection is required to ensure the selected location is not subjected to shading from adjacent trees or buildings at any time of the day, but particularly between 9am and 3pm, the highest solar input times. You must remember that 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.

3. For optimum performance the collectors should be located no more than 20m from the solar storage cylinder. To optimise efficiency, the collectors should be as close as possible to the solar storage cylinder. Irrespective of the pipe length, it is important that both the solar flow and return lines are insulated with high temperature, UV resistant closed cell insulation to minimise heat loss.

4. Ensure that the roof structure is suitable to support the weight of the collectors. The Ecosmart collectors weigh approximately 40 kg each when filled with water or heat exchange fluid.

5. The collectors should be installed at an inclination equal to that of the local latitude. When this is not possible the minimum inclination should not be less than 10 degrees, and a maximum inclination should not be more than 45 degrees.

6. Ecosmart collectors and aluminium mounting cross rails cannot be installed onto an unpainted galvanised steel roof, as water run-off from the aluminium onto the exposed galvanising will cause galvanic attack, and the roof will quickly rust. Painting the roof prior to installation will resolve this issue.

Installation Details - Collector Panel

Figure X: Latitudes for New Zealand

35º

36º

37º

38º

39º

40º

41º

42º

43º

44º

45º

47º

46º

Collectors mount onto lower and upper aluminum cross rails which are directly fixed into purlins. These cross rails support the solar collectors 24mm above the roof cladding.

On new builds it is beneficial if an additional roof purlin (90 x 45) is specified 2000mm above the lower support purlin to allow the cross rails to be directly fixed to these purlins.

If timber can not be positioned for direct fixing the cross rails, stainless steel straps are available that secure to existing timber from which the rails are suspended creating a “floating

mount” This rail and strap system is required for both clay & masonry tile situations.

In situations where local authorities require the collectors to be elevated 100mm above the roof cladding the rails can be fixed to the roof truss by means of “Hanger Bolts” that elevate the collector to the height required.

Collector Connection & Mounting Kits

Steel profile cladding

• Itisbeneficialtofixthecollectorcrossrailsdirectlyontopurlins positioned to allow this. A minimum of four fixings are required for each cross rail.

• Iftimbercannotbeplacedtoallowthecrossrailtofixdirectly to the purlin, then stainless steel straps can be used to suspend the cross rail from the suitable fixing available. When stainless steel straps are used to fix the upper cross rail it is also acceptable to invert these (on steel cladding profiles) so they run down the cladding under the collector, to effectively hide the stainless steel straps.

• EnsureEPDMrubberisalwaysusedtoseparaterailsandstraps from any steel cladding.

• Ensuretherailsareparallelwiththerooflinesowaterisfree to drain from the supply pipe when the system is in “drain down” function.

Clay or Masonry tile cladding Collector rail fixed by stainless steel straps.• Carefullyremovearooftiletolocatethenearesttrussand

consider the position of all cross rail straps in relation to truss position/spacing to distribute an even weight loading.

• Atwocollectorarrayrequirestwostrapspercrossrail,while a three collector array requires three straps per cross rail.

Collector mounting rail

Collector mounting rail

Note: A minimum of 3 roofing screws of 40mm length must be used to fix the collector strap to the truss.

Collector strap

Collector strap

Use a minimum of 3 roofing screws of 40mm length

• Positionthefirststraptothelowercrossrailandfixtothetruss while shaping the strap over the tile and purlin. The lower rail would usually rest near the front of a roof tile above the purlin support.

• Repeatthisprocessattheotherendofthecrossrailwhile ensuring the rail is level and parallel to the roof line and rivet the straps to the cross rail. EPDM tape should be placed at the connection of this strap to the rail to protect roof cladding.

• Oncethelowerrailhasbeensecuredtheupperrailshould be positioned using 2000mm spacing poles to ensure correct spacing to receive the solar collector.

• Afterthecollectorshavebeenplacedandonlyafterthe brass connectors have been fully lubricated and tightened can the cross rails be screwed to the ends of each collector.

•4xEPDMspacers/crossrail •4x14gx60Tekscrew/crossrail •4x14gx25Tekscrew/collector

Cold connection Inlet x 1

Connectors x 2

Plugs x 2

Hot connection outlet x 1

Connector OutletPlug

Connector PlugInlet

Cone & nut coupling

Currently all brass unions consist of a tapered cone olive type fitting.

When installing these fittings owing to their large diameter they tend to bind and give the false impression of being tight, with heat expansion and contraction these later leak and cause issues.

To prevent these leaks it is essential to follow the procedure below:

Coupling installation procedure

1. The collector manifolds are free to move from side to side within the collector, so ensure the manifold is centralized prior to tightening fittings.

2. Slide the nut onto the collector manifold and then apply 567 loctite sparingly onto both the copper pipe and all surfaces of the taped cone to lubricate and fill any defects on the surface of the tube allowing the cone to clamp down onto the tube securely without distortion. Apply graphite paste to the 1” thread of the nipple to prevent binding during tightening.

3. Hold the brass union stationary and tighten the nut securely. You will feel the nut first tighten against the cone, then more tension will compress the cone securely onto the copper tube. Once tightened only one thread of the nipple should be visible at the end on the nut.

Flared fitting couplings

In time to come current collector fittings will be replaced with “Flared fittings” If your collector is supplied with flared fittings ensure to apply graphite lubricant to both the flare and thread to prevent binding.

Air Bleed assembly

When tightening the “hot connection” outlet ensure the air bleed valve finishes in a plumb position. Check this with a spirit level as the internal float needs to be plumb to operate correctly, and ensure drain-down function is successful

Roof penetrations and sensor

Ensure to use dektites that have cable penetration points as only these or the use of separate dektites for the sensor cable is an acceptable method.

The sensor must be protected from sharp edges of roofing and be separated from the copper pipe due to electrical interference effecting the electronics ability to interpret the temperature reading.

Insulation

Only fit final insulation after the system has been commissioned to insure it is free of leaks.

The insulation section thickness is specified in the following table and climate zone map.

The tubular closed cell insulation shrinks under temperature and so should be compressed during installation to allow for this shrinkage.

Where insulation is exposed to the weather it must be protected from UV

Solar circuit piping

The solar circuit running between the solar storage cylinder and the solar collectors is required to be 12.7mm outside diameter copper tube. This smaller diameter tube greatly increases efficiency during periods of partial sunshine.

Solar circuit copper pipe must be installed to ensure there are no high points where air locks can form and water is free to flow away during drain down function.

Solar circuit copper pipe between the solar collectors & storage heater should be limited to not more than 20m each way. Any vertical rise is best limited to 3m per section of run.

Solar Collector Manifold Fittings

Water piping insulation

New Zealand climate zones for frost protection

WaTeR pIpINg INSULaTION TO aCHIeVe MINIMUM THeRMaL INSULaTION

System Location of piping to be insulatedClosed cell insulation wall thickness

Climate Zone 1

Climate Zone 2

Climate Zone 3

Circulating heated water piping

All heated water piping within a conduit encased within a concrete floor slab (except for piping which is part of a floor heating system)

13 13 13

All external flow and return piping including 500mm along any branch from the flow and return piping.

13 25 38

All internal flow and return piping including 500mm along any branch from the flow and return piping.

13 13 13

Where insulation is exposed to the weather, it shall be made weather resistant by painting or by covering with a weatherproof encloser.

This water heater is designed for connection to a CONTINUOUS TARIFF, single phase 240V A.C supply.

The electrical connection must comply with New Zealand electrical standards.

For the electrician the access cover may be removed by undoing the two screws on the cover and sliding the cover downward to disengage it from the case. Ensure that the conduit entry is well sealed to achieve correct weatherproofing.

Pump Module Electrical Connection (All Models)

Note:

1. All electrical work must comply with local regulations

2. All electrical work must be conducted by a licensed electrician.

3. 10amp 230V plug in supply for Hotlogic control and solar pump.

4. Additional 230V supply for a plug in transformer which powers a secondary drain valve to protect system from power outages. This secondary drain valve incorporates a capacitor that opens the collector circuit to waste should power loss occur. This secondary protection is supplied with solar systems installed south of the Bombay Hills.

5. The Ecosmart enamel lined storage heater has a 3.6kW element requiring a 15amp supply while the Combo wetback storage heater has a 3.0kW element requiring only a 10amp supply.

Sensor Cables

• Allsensorcablesarerated1000ohm.

• Thecollectsensorrequiresextendingintheceilingspace with the 20m of twin core wire and terminal block supplied.

• Whenthereisnoceilingcavityandthesensorextensionconnection has to be made above the roof line, it is necessary to use crimp fittings and water proof with heat shrink.

• Sensorwiringmustnotcomeincontactwithcopperwater pipes as this will cause interference.

• Looselycable-tiesensorcablealongtheinsulatedpipe.

• TanksensorsarepreinstalledinenameledEcosmartstorage heaters.

• Tanksensorsrequiretobefittedintothesensorpocketsprovided on Combo wetback storage heaters. These must be fully inserted and locked into position with plumbers putty to prevent movement and retain latent heat.

• SensorconnectiontotheHotlogicisasshownoverpage.

Temperature Panel

A battery operated temperature panel is supplied with the stainless steel Combo Storage Heater to read the temperatures as indicated.

Insert the lower and upper temperature probes into corresponding pockets located on the side of the tank and hold in place with plumbers putty.

The solar return temperature probe should be taped to the solar return pipe in a convenient location under the insulation with the wire directed through the wall of the insulation away from the hot pipe.

Electrical Connections

WaRNINg! Important Information• The water heater is fitted with a thermostat

and over-temperature energy cut-out. Under no circumstances should the water heater be operated without both these devices being in the circuit. Replacement must only be carried out by a qualified electrician or the manufacturer.

• The operation of the thermal cut-out indicates a possibly dangerous situation. Do NOT reset the thermal cutout until the water heater has been serviced by a qualified person.

CaUTION! Important Information• The water heater must be filled with water

before turning on the electricity supply.

Ecosmart has now integrated the Metro Solar Drain Down System within the Hotlogic controller, resulting with this compact assembly all in one water resistant enclosure.

Hotlogic H3795/10305 with integrated Drain Down

Collector sensor 1000 ohm

Lower Tank sensor 1000 ohm

Upper Tank sensor 1000 ohm

Ambient sensor 1000 ohm

Drain Down valve/actuator

Hotlogic Solar Controller

Solar Pump

230 volt supply

Supply to Solar Collector

Power Status LED

Sensor Status LED

Drain valve/Pump LED

Drain Down, pipe to waste

Cold Water Supply

K

L

M

N

Solar operating parameters

• Solarpumprunswhensolargainavailable,ie.>10°differentialbetweenLowerTankandCollector.• Solarpumpstopswhensolargaindifferentialreducesto2°CorwhenUpperTankreaches80°C

1. Over-temp events:

• SolarstopspumpingwhenUpperTank>80°C,thendrainsCollectors.• RefillcollectorsifCollectorTemp<80°C,UpperTank<75°andsolargainisavailable.

ie.>10°differentialbetweenLowerTankandCollector.

2. Frost events:

• CollectorsdrainwhenCollectorTemp<8°C• CollectorsrefillwhensolargainavailableandCollectorTemp>12°C

LED STATUS TABLE - NOTE: LED will flash during valve switching (<60 sec) SeNSOR FaULT INDICaTORS

LED Status Solar gain available No solar gain Cylinder over temp Frost condition Centre LED Fault Indicator

Power Status Solid Green Solid Green Solid Green Solid Green Collector Sensor Single red flash

Sensor Status Solid Green Solid Green Rapid Flash Slow Flash Lower Tank Sensor Double red flash

Output Status Pump on Pump off Open-waste Open-waste Upper Tank Sensor Triple red flash

Drain Valve/Pump Solid Green OFF OFF OFF Ambient Sensor Quad red flash

Supply to solar collector

Flare fitting for 12.7mmOD copper.

(In frost regions an additional drain valve is fitted to provide freeze protection during “power outage”)

K

L

M

N

K

L

How does my system work?

The main components of your solar system are the water storage heater, the solar collectors, the Hotlogic™, solar pump, drain down control valve, and electric boost element.

The storage cylinder

1. The Ecosmart storage tank is used to store the heated water ready for household use. It is a specific solar electric storage tank, incorporating a high temperature vitreous enamel lining to provide long life, and high density polyurethane insulation to ensure minimal heat loss.

2. The MetroSolar storage tank is used to store the heated water ready for household use. It is a specific solar electric storage tank made from Duplex stainless steel, with internal heat exchanger coils for wet back or specialized applications. It has high density polyurethane insulation to ensure minimal heat loss.

Electric Boosting

Our tanks may seem large but that is due to our mid height boost element. This reduces your volume of hot water to half a tank when the sun does not shine. But when solar energy is produced the result is ample of hot water with capacity for the following day. All this free energy raises the tank temperature saturating the mid height element thermostat in heat up to 80 degrees Celsius which prevents it from switching on. When the reserve of hot water reduces to half a tank at 60 degrees, the element will switch on as required to maintain this temperature in the top half of the tank leaving the lower half cold, ready for the sun and/or wetback to heat.

Gas Boosting

For those who prefer Natural gas for boosting the Ecosmart Premium Instantaneous heater will ensure you never run short of hot water. The electric element in your storage heater will need to be switched off or isolated. As water is drawn from the storage heater and passes through the Ecosmart Premium Instantaneous heater, the system sensors the water temperature and only when the temperature is below 70 degrees the burner will start and raise the temperature to the 70 degree threshold, as required with solar systems using gas boost.

Wetback

To maximise free energy gain, a wetback heat exchanger from your solid fuel heater can be connected to the MetroSolar water storage cylinder. Because the water flowing from the wetback will circulate through a stainless steel coil within the water cylinder, the cylinder can be configured as either a low or mains pressure system.

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 casing covered with a high strength, low iron glass sheet that protects the absorber system from physical damage.

In an Open Circuit system, the pump draws cold water from the bottom of the tank and pushes it up into the solar collectors. The water is heated in the collector by absorbing heat from the sun and continues on its pumped circulation path back to the lower solar section of the storage cylinder.

Pump and drain down operation

The Circulation Pump is a simple device used to circulate the water in the collector circuit. This, in turn, enables solar energy from the collectors to be transferred to the storage cylinder. The pump consumes only a very small amount of electrical energy to perform this task. The circulation pump has an integral ‘non-return valve’ to prevent solar energy from reverse cycling back through the storage cylinder to the collectors at night.

The electronic control device used to control the circulation pump has a complex set of activities. It is the brain of the system and ensures optimum system efficiency and safety. The basic functions are:

1. Detecting availability of useful solar energy in the solar collectors. When the temperature of the solar collector is 10°C higher than the storage cylinder temperature, the circulation pump is initiated. If the temperature differential falls to less than 2°C the circulation pump is stopped.

2. When the storage cylinder is fully heated and it’s upper temperature reaches 80ºC the circulation pump will stop and the collectors will drain down. This function prevents excessive temperatures within the solar storage heater. These parameters are detailed on page 14.

3. To protect from frosts, the system will drain down once the fluid temperature within the collector drops to 8ºC. Do not be concerned when your outside temperature is less than this temperature as once the sun shines the internal collector temperature will rise dramatically and the system will refill and achieve solar gain. The operating parameters are detailed on page 14.

How long will the heater run each day?

The length of time that the solar heater will run each day will vary dependent upon the amount of hot water being used by the household and the availability of sunlight to heat the solar collectors.

Owners Information - How does my system work?

CaUTION! Important Information• All water heaters have the ability to produce

hot water in a surprisingly short time. To reduce the risk of scald injury, it is mandatory under the requirements of New Zealand Standards AS/NZS3500 that an approved temperature control valve be fitted to the hot water supply pipe work. This valve should be checked at regular intervals to ensure its operation and settings remain correct.

What should I do during holidays?

This is personal choice and we suggest leaving the power on, as without your usual hot water consumption the system will easily heat the storage heater to it’s upper limit, then drain the collectors down costing just a few cents per day and the heater will be hot and ready on your return.

You should only shut the power off to your system if you have the ability to empty the solar collectors such as when a secondary drain down is installed as detailed on page 13.

The power supply to the solar controller Hotlogic pump module must be left ON

• Whensecondarydrainvalvesareinstalledasshownonpage 13, it is important the transformer is permanently switched on to safeguard the solar system.

Durability and system maintenance

Metro Solar systems have excellent durability and will continue to operate efficiently far beyond the 15 year durability period required by the Department of Building and Housing subject to normal inspection and maintenance.

6 Monthly Inspections

Should you decide to personally inspect the roof mounted equipment, it is essential that you use all safety devices required to ensure your safety.

• OperateTPR(TemperaturePressureRelief)valvedischarge on water heater to flush contaminate from valve by slowly extending valve lever for 10 seconds. Check to ensure the valve closes correctly.

• Manuallytest“DrainDownSystem”.Thisisonlypossiblewhen a secondary drain valve is installed. Test by switching off the transformer to ensure the valve actuates at which time you will hear water discharge, then re-initiate power to the transformer to return to normal operation.

• Checkandremoveanydebrisfromandaroundsolarcollector panels.

• Checkoperationanddoseasnecessaryanywatertreatment purification equipment installed.

• Checkforshadingfromanytreesthatmaybeovergrown.

5 Yearly Service by authorised contractor

Water heater

• Checkoperationandservice/replacevalvesasnecessary.

• Drain&flushstoragecylinder.

• Replacesacrificialanodesiffitted.

• Checkconditionofinsulationandrepair/replaceasnecessary.

Water purification equipment

• Inspectoperationofanywaterpurificationequipmentandservice as required.

Solar collectors, fittings and penetrations

• Inspectconditionofsolarcollectorsandclearanydebrisfrom and surrounding collectors.

• Inspectbothconditionandwatertightnessofseals,flashings and fixings.

• Inspectandcleardebrisfromventsandoperationofairbleed vent while ensuring it is level.

• Inspectconditionofbothinsulation,ultravioletprotection,and maintain or replace as necessary.

• Inspectconditionandrigidityofmounting.

• Checkforshadingpossibilitiesfromtreesandsurroundingbuildings, ensure to allow for lowest annual sun angle.

What should I check before making a service call?

If there is not enough hot water, it is recommended that the following points be considered before making a service call. If after checking the following points the problem has not been identified, please contact your nearest Metro Solar supplier or contact Pioneer Manufacturing Ltd.

Owners Information - Durability and system maintenance

WaRNINg! Important InformationEnamel lined storage heater with sacrificial anode

• If the hot water system is not used, for two weeks or more, a quantity of hydrogen gas, which is highly flammable, may accumulate in the water heater. To dissipate this gas safely, it is recommended that a hot tap be turned on for several minutes at a sink, basin or bath but not a dishwasher, clothes washer, or other appliance. During this procedure there must be no smoking, open flame or any other electrical appliance operating nearby. If hydrogen is discharged through the tap, it will probably make an unusual noise similar to air escaping.

CaUTION! Important Information• It is important to know that there are no user

serviceable components in the system, and as such, it is recommended that no covers be removed and no adjustments made to the system settings by anyone other than an authorised representative. Do not open or adjust any electrical covers or devices yourself.

Leaking from the TPR (Temperature Pressure Relief) Valve

Continuous trickle (TPR)

This is most likely due to a build up of foreign matter. In this case try gently raising the easing lever on the pressure & temperature relief valve for a few seconds then release gently. This may dislodge a small particle of foreign matter and rectify the fault.

Steady flow (TPR) - more than 20L per day

This may be caused by excessive water supply pressure, a faulty pressure & temperature relief valve or a faulty thermostat. Turn off the electricity supply and contact your Metro Solar agent.

Leaking from the cold water expansion valve

It is not unusual for this valve to allow a small quantity of water to escape during the heating cycle. The amount of discharge will depend on hot water usage.

No Hot Water

• IsthePressure&Temperaturereliefvalvedischargingtoomuch water?

• Ifyouhaveasecondarydrainvalve,checkthatitisenergised

• Doyouhavethecorrectsizewaterheaterforyourrequirements? Sizing details are available from your supplier.

• Isoneoutlet(suchastheshower)usingmorehotwaterthan you think?

• Carefullyreviewthefamily’shotwaterusageandifnecessary check the shower flow rates with a bucket, measuring the amount of water used over that period of time. If it is not possible to adjust water usage patterns, an inexpensive flow control valve can easily be fitted to the shower outlet.

• Considerthatoftenthehotwaterusageofshowers,washing machines and dishwashers can be under estimated. Review these appliances to determine if your daily usage is greater than the storage volume of your water heater. If for example you have a 315 litre storage tank and you are using 450 litres of water it is possible that there will be certain times of the day where there is insufficient hot water.

• Istherealeakinghotwaterpipeordrippinghotwatertap? A small leak can waste a large quantity of hot water.

• Replacefaultytapwashersandhaveyourplumberrectifyany leaking pipe work.

Solar Collector shading

Often trees or other buildings can shade the solar collectors, or there can be dirt build up on the glass cover. Trees should be cut back if possible, or the system relocated if removal of the shading is not possible, in the present location. If the glass is dirty, this should be cleaned with any normal domestic glass cleaner – recommended to be done by an authorised tradesperson.

Troubleshooting

1 Solar Panels within 45 degrees of north with an incline between 10 and 45 degrees. Page 9

2 Brass collector unions but be assembled with lubricant to ensure correct tightening. Page 11

3 Air Bleed Valve must be level/plumb, Check with spirit level. Page 11

4 Solar circuit copper pipe must be 12.7mm outside diameter and installed to ensure there are no high points where air locks can form and water is free to flow away during drain down function. Page 5

5 Copper pipe between the solar collectors & storage heater should be limited to not more than 20m each way. Any vertical rise is best limited to 3m per section of run. Page 13

6 Sensor wires correctly fitted to controller and panel. Ensure 20m sensor wire from panel does not come in contact with the copper flow and return pipes as it causes interference. Page 13

7 Continuous electrical power MUST be used for the electric booster element and the pump must be connected to a separate supply. Page 13

8 Heat traps installed. Page 6

9 Tempering valve must be commissioned not fully opened as this would exceed the required 55º maximum limit. Page 5

10 Check operation of Hotlogic controller. Page 14

10 Point Installation & Commissioning Checklist

The solar system has a one year parts warranty from date of purchase, including solar controller, pump and drain valves.

The Ecosmart™ hot water storage cylinder has a limited 5 year warranty commencing from date of purchase.

The Metro Solar stainless steel storage cylinder has a limited 7 year warranty commencing from date of purchase.

The Ecosmart™ solar collector has a 5 year limited warranty commencing from date of purchase.

Warranty Conditions

• Thesolarstorageheatermustbeinstalled,operatedandmaintained strictly in accordance with the building code, Plumbing & Drainage standard AS/NZS 3500 and the manufacturers “Operation & Installation Manual”

• Waterqualitythatdoesnotmeetthespecificationasdescribed in the“Operation & Installation Manual” may void the warranty

• Attachmentofanypartsoraccessoriesotherthanthoseapproved by Metro Solar may void this warranty.

• ThiswarrantyonlyappliestoequipmentsuppliedbyMetroSolar and not associated parts as supplied by agents or installers.

• Collectorglassisnotcoveredbythewarranty

• Thiswarrantyexcludesanybuildingmodificationthatmaybe required to access or replace equipment.

• Thiswarrantycoversthereplacementorrepairatthemanufacturer’s discretion, but excludes freight, labour and/or travel costs.

• Themanufacturerortheiragentarenotliableforany loss or expense directly or indirectly arising from the failure of any part or operation of the heating and/or control system.

A claim under this warranty should be directed to the retailer who supplied the Metro Solar equipment, or if this is not possible, write direct to Metro Solar at Pioneer Manufacturing stating details of the fault, retailer where purchased and when installed.

Information for Owner

Retailer purchased from ........................................................

Installer ..................................................................................

Date Installed .........................................................................

Storage cylinder type .............................................................

Your decision to purchase Metro Solar water heating will reward you for many years to come. We appreciate your feedback and encourage you to forward your comments to us by submitting on our web page or write to Metro Solar at Pioneer Manufacturing.

Metro Solar Warranty

Firstly Call your supplier

Secondly Metro Solar www.metrosolar.co.nz Phone 06 756 6520 Fax 06 756 6540

• ATTACH METRO SOLAR STICKER TO THE SOLAR STORAGE CYLINDER & COMPLETE THE TWO SECTIONS OF THE INSTALLATION DETAIL ON PAGE 18 & THIS PAGE. TEAR OFF & RETURN LOWER SECTION TO METRO SOLAR

WaRNINg! Important Information for the Metro Solar System Installer

Installer to complete and return the following details to Metro Solar.

Owners Name ..................................................................................................................................................................................

Installation address ...........................................................................................................................................................................

Phone Hm ................................................................ Mobile ...................................... Work ...........................................................

Retailer purchased from ...................................................................................................................................................................

Installer ........................................................................................................... Date Installed ...........................................................

Storage tank type .............................................................................................................................................................................

Recirc. pump/controller ....................................................................................................................................................................

Collector type & quantity ...................................................................................................................................................................

Instantaneous booster ......................................................................................................................................................................

Comments .......................................................................................................................................................................................

Advice, repairs and service

PO Box 11, Inglewood 4347, New Zealand

Ph (06) 756 6520 • Fax (06) 756 6540

[email protected] • www.metrofires.co.nz

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