Installation and Operation Manual Tivok Energy Domestic Thermal Systems TABLE OF CONTENTS Introduction1 Water Safety 22 General Information 1 Hail Protection 22 Document Scope 1 Lightning Protection 22 Product Certifications 1 Freeze Protection 22 Proper Use 1 Stagnation and No-Load Conditions 22 Installer Requirements 1 Completing Installation 23 Warranty Information 1 Filling the Tank 23 System Overview 2 Piping Insulation 23 System Details 2 System Test and First Run 23 How Does the System Work? 2 T-T500AS Energy Bank 3 T-HP20AB Heat Pump 4 T-U5812AS Solar Collector 5 Controller26 Product Installation Guide 6 Circulation Pump 26 Installation Preparation 6 Heat Pump 26 Energy Bank Installation 6 Solar Collectors 26 2HP Heat Pump Installation 7 System Commissioning 27 Heat Pump Wiring 7 Installer Detail 27 Mounting Information 8 Commissioner Details 27 Mounting Installation 8 Owner Details 27 System Maintenance Evacuated Tube Replacement Troubleshooting 24 24 26 Collector Plumbing 13 System Description 27 Installing Circulation Pump 13 System Checklist 27 Installing Controller 13 Appendix28 14 Glossary28 14 Notes29 20 The information contained in this manual is correct as of the 1st System Installation Tivok Domestic Split System System Operation Modification Warning 20 Understanding the Digital Solar Loop Controller 20 Operational Logic 20 Temperature Display 21 Basic System Maintenance 21 System Precautions 22 Water Quality 22 of May 2014. Further modifcations may be made without notice. Please contact Tivok Energy if you wish to ensure you are using the latest documentation. INTRODUCTION GENERAL INFORMATION PROPER USE Thank you for choosing a Tivok Energy Thermal System. We Tivok Energy Thermal Systems are designed for outdoor use, appreciate your business and your contribution to a greener and depending on the component can be mounted on support tomorrow. frames, stands, or flat surfaces. This guide contains information regarding the installation and When installing the system, observe all local, regional and national safe operation of Tivok Energy Thermal Systems. statutory regulations, which may include obtaining a building Please follow these instructions carefully and observe all safety precautions. Before installing a solar thermal system, you should familiarise yourself with the mechanical and electrical requirements for such systems. permit and council approval. WARNING All instructions should be read and understood before attempting to install, wire, operate, and maintain the system. Failure to do so may result in system failure or installer injury. Installing solar thermal technology requires specialised skills and knowledge, therefore it should only be performed by qualified and licensed installers. CAUTION Please read all instructions carefully. Failure to read this guide completely before starting the installation process may result in component or system failure. INSTALLER REQUIREMENTS All Tivok Energy installations must be conducted by a licensed plumber and a licensed electrician, in accordance to all of the requirements of this manual, as well as local codes, regulatory authorities and occupational health and safety guidelines. All installations must be in accordance to: • AS/NZS 2712.2007 — Solar and Heat Pump Water Heaters: DOCUMENT SCOPE This installation and operation manual is designed to cater to the needs of end-users and installers and describe the correct installation and operation procedures of a Tivok Energy Thermal System. Design and Construction • AS/NZS 3500 — National Plumbing and Drainage Code • AS/NZS 4234.2008 — Heated Water Systems - Calculation of Energy Consumption • AS/NZS 3000:2007 — Electrical Installations WARRANTY INFORMATION PRODUCT CERTIFICATIONS Tivok Energy Solar Thermal Systems have a warranty of 2 years By complying to these Standards, Tivok Energy can guarantee the for heat pump components, with collectors warranted for 10 reliability and performance of our products. years and tank components warranted for 15 years. Tivok Energy ensures compliance with the following Australian and International Standards: • AS/NZS 2712:2007 — Solar and Heat Pump Water Heaters – Design and Construction. • AS 3498:2009 — Authorization requirements for plumbing products – Water heaters and hot-water storage tanks • AS/NZS 5125.1:2010 — Heat pump water heaters – Performance assessment — Air source heat pump water heaters • AS/NZS 1170.2:2011 — Structural design actions – Wind WARNING Any unauthorised modifications to the system, including parts, will void warranty and any liability claims against Tivok Energy. The Tivok Energy warranty terms may not be applicable in certain circumstances which void the warranty. Further information can be found in the warranty information provided with Tivok Energy products. actions • AS/NZS 16641:1997 — Aluminium structures limit state design • AS/NZS 4600:2005 — Cold-formed steel structures • RoHS — Restriction of Hazardous Substances directive Tivok Energy Domestic Thermal Installation Manual 1 of 29 SYSTEM OVERVIEW SYSTEM DETAILS The following section will detail the basic technical information about our system enabling both the installer and the end-user to have an understanding of system operation and installation. HOW DOES THE SYSTEM WORK? The heat pump works by extracting heat energy from the surrounding air to heat up water that is passed through by a small pump. The heat pump operating cycle also produces cold-air as a by-product, which can be ducted for air conditioning applications. The tank temperature is always maintained at approximately 60°C. This is done by heat contributions from both the solar The Tivok Thermal System is a non-pressurised, closed loop collector and the heat pump. In case of low or no solar irradiation, system. Potable water is heated via a heat exchange coil within when the temperature sensor in the tank reaches a low set the Energy Bank, thus avoiding contamination of the potable point temperature and senses that the solar collectors cannot mains water. This feature ensures that the Tivok Thermal System contribute heat, the heat pumps are automatically run to boost is suitable for a wider range of applications. The Thermal System the tank temperature. employs two sources of heat generation; Solar Thermal Collectors and Energy Efficient Heat Pumps, which operate as a booster during days of low irradiation. The hot water generated by the collectors is circulated in Energy Banks that store thermal energy safely in a highly insulated construction to ensure ideal heat retention. As incoming potable water absorbs energy from the energy bank, the energy bank heat is replenished by constant recirculation through the solar collectors and/or the heat pump. By implementing a heat exchange mechanism, there is never any cross contamination between the heating medium and the potable water entering from the mains source (15°C) and exiting The solar collectors are a series of highly insulated evacuated the system at a higher temperature (55°C). This enables the tubes that circulate water and absorb solar energy through direct system to be used for a wide range of applications. flow technology to ensure optimal heat transfer. 2 of 29 A heat pump and tank only system is also available. Tivok Energy Domestic Thermal Installation Manual T-T500AS ENERGY BANK MODEL DETAILS Tivok Energy Energy Banks are designed with aesthetic beauty as well as form and function in mind. Tivok Energy Energy Banks are floor standing, low pressure and utilise heat exchange technology making them safe, clean and easily integrated into any modern environment. The inner tank design guarantees against corrosion and leakage, while 27% thicker insulation means far less heat loss. The inner core is rotary moulded with high temperature food grade material to prevent leaking and corrosion. Together, this leads to a far greater level of thermal energy conservation. The biggest advantage of our heat exchanger type storage tanks is its ability to heat water for more than just one form of usage, Model T-T500AS Capacity 500 litres Height 1780mm Width 710mm Length 700mm Weight (empty) 150kg (empty) Weight (filled) 650kg (filled) Maximum coil pressure 800kPa Maximum tank pressure 16kPa ranging from showers, swimming pools and spas to hairdressers and beauty salons to potable drinking water. FITTING TYPE Potable Cold Front Fittings Male DN20 BSP ¾” Top Fittings Female DN25 BSP 1” Potable Water Fittings Male DN20 BSP ¾” Collector Return Fitting Female DN20 BSP ¾” Potable Hot T3 Collector return Tivok Energy Domestic Thermal Installation Manual Float Switch 3 of 29 T-HP20AB HEAT PUMP Through advanced design concepts based on the laws of thermal dynamics and physical changes in chemical states, Tivok Heat Pumps are able to absorb ambient air temperature in order to modify the temperature of water. Most of the energy used by the heat pump in producing hot water does not come from electricity, but rather from the energy derived from the ambient air temperature, energy that exists in nature and does not cost any money to purchase. Due to the low boiling point of the refrigerant that Tivok Heat Pumps use, our Heat Pumps are guaranteed to operate even in freezing conditions and have an extremely low cost of operation. Heat Pumps alone can generate energy savings of up to 80% compared to conventional water heating technologies, this can then be further improved when combined with Solar Collectors. MODEL DETAILS Model T-HP20AB Heating output 7.6kW Power input 1.77kW Max power input 2.60kW Max input current 12.4A Rated input current 8.23A Coefficient of performance 4.3 (subject to weather) Height 620mm Width 1002mm Length 302mm Weight 65kg Defined output quantity 163 litres/hour Outlet fittings DN20 HEAT EXCHANGER SPECIFICATIONS Pressure drop 60kPa Noise level <54dBa Refrigerant R410A Compressor quantity 1 Compressor make Panasonic Compressor type Rotary 4 of 29 Tivok Energy Domestic Thermal Installation Manual T-U5812AS SOLAR COLLECTOR Tivok Energy Evacuated U-Tube Solar Collectors are made of a series of modular tubes, operating in parallel configuration, whose number can be increased or reduced depending on hot water requirements. This type of collector consists of rows of parallel transparent glass tubes, each of which contains an absorber tube (in place of the absorber plate to which metal tubes are attached in a flat-plate collector). In our evacuated U-tube collector, sunlight passing through the outer glass tube heats the absorber tube contained within it, which consist of copper (glass-metal design). A heat transfer fluid (water) is pumped through a U-shaped copper tube placed in each of the glass collector tubes which is heated by the heat energy trapped immediately outside the copper tube. The heated liquid then circulates through a heat exchanger and gives off its heat to water in that tank. Evacuated U-Tube collectors heat to MODEL DETAILS Model T-U5812AS Tubes per collector 12 Aperture area 1.6m² Peak efficiency 75% Optimum flow 1.8 to 2.0 litres/minute Stagnation temperature 260°C Height 1960mm Width 960mm Length 138mm Weight 38kg higher temperatures, providing up to 30% more solar with some models providing considerably more solar yield per square metre than flat panels. Evacuated tube collectors perform better than flat plate collectors in cold climates because they only rely on the light they receive and not the outside temperature. For a given absorber area, LIQUID PASSAGEWAY Riser tubes diameter 8mm copper Header tubes diameter 19mm copper Maximum pressure 1200kPa evacuated tubes can maintain their efficiency over a wide range of ambient temperatures and heating requirements. Outlet 1 Outlet 2 Tivok Energy Domestic Thermal Installation Manual 5 of 29 PRODUCT INSTALLATION GUIDE INSTALLATION PREPARATION • Plan your installation. Analyse the safety of your site • Plan where all components and relevant pipe support are to be installed • Safety First – ensure that the equipment is installed in a safe location for installer and our customers • Where a permit is required to comply with local regulations, the system installer is responsible for ensuring that they are in possession of the required permit prior to installation • The licensed installer should analyse the site before ENERGY BANK INSTALLATION Important Information The Tivok Energy Bank will be used as the storage method for hot water used as the heating medium by the system, which gains heat from the solar array and heat pump. Inside the energy bank, the heating medium water heats potable water through a heat exchanger. The heating medium water and potable water do not have any contact during this process. The Energy Bank should be: proceeding with installation in order to foresee potential • Installed in a safe location, away from pedestrian traffic complications in the installation process • Kept on level ground and must stand vertically • It is best to install the Energy Bank close to the outlet that WARNING All instructions should be read and understood before attempting to install, wire, operate, and maintain the system. Failure to do so may result in system failure or installer injury. RECOMMENDATION All the pipes needs to be insulated except the potable cold uses the most hot water, such as the laundry or bathroom • A concrete slab may be required to create a level surface • Unused ports must be sealed with a cap. • Plumbing information can be read in the following sections of this manual. Fittings There are 6 fittings on top of the tank and 6 fittings on the side: feed and the refill pipes Potable Cold WARNING All the pipes used for Tivok Thermal Systems should be copper, all compression fittings must be brass or copper. All joints and fittings used to plumb solar thermal collectors Potable Hot T3 Collector return Float Switch should carry appropriate temperature ratings. CAUTION When fitting components for mains water, all components must be WaterMark certified in order to comply with regulations and to maintain product warranty. Failure to comply will void any manufacturer’s warranty provided by Tivok Energy. WARNING Do not seal or block the overflow port. 6 of 29 Tivok Energy Domestic Thermal Installation Manual 2HP HEAT PUMP INSTALLATION HEAT PUMP WIRING Important Information T-HP20 is designed for single phase 230~240V AC 50Hz For safety, the heat pump unit should be installed according to the following criteria: supply with a maximum load of 2500 watts. Australian Standard AS/NZS 3000 or AS/NZS 3006 Wiring Code 1. Installation should allow easy access for later work. and local supply authority regulations apply. A licensed electrician 2. If the unit is to be installed on a floor, its undercarriage must complete this work. should be heightened to avoid accumulating water. The recommended height is 200mm to 300mm. 3. In snowy areas it is important to prevent accumulated snow Wiring Power • Exterior wiring is not provided and must be wired by a licensed from blocking the air outlet. 4. Ensure the heat pump is located in an area with adequate electrician • Interior wiring can be seen below: drainage for condensed water discharge 5. If the unit is installed on a balcony or on a rooftop, the installation site must meet the allowable loading capacity of building structure without affecting the structural safety. 6. Ensure the unit is well ventilated, and the outlet faces away from windows and has adequate space away from walls and other obstacles (as shown in the diagram below). 7. The unit should not be installed near highly flammable or corrosive components 8. The unit must be installed on a reliable base or framework. The weight capacity of the base should be at least 180kg. 9. If required, ensure that the heat pump is secured to the • L is active from power (from power plug) • N is neutral from power (from power plug) • is earth WARNING All instructions should be read and understood before base or framework to comply with regulatory requirements, attempting to wire the system. Contact with electrically active particularly in high wind regions. parts of the system such as terminals can result in burns, Clearance Below are minimum recommended spacing requirements between the closest obstruction, and each heat pump face: sparks, or lethal shock. Connect Heat Pump to Controller • Connect the male plug from the Controller to the female • At least 200mm from the back and sides socket inside the Heat Pump. Detailed connections can be • At least 200mm from the top seen in the electrical connection schematic on page 19.. • At least 1000mm from the front Connect Sensor to Energy Bank • Connect the temperature probe according to the instructions shown in the System Installation section on page 14. Heat Pump Plumbing • Connect the Heat Pump to the Energy Bank as displayed in the System Installation section on page 14. • Minimise elbow bends to increase flow. • Use braze welding if required. Refill System • The automatic refil system comprises of a float switch, a solenoid valve and a 12VDC power supply. • The float swtich detects the water level in the Energy Bank. If WARNING If there is inadequate space between the heat pump and the water level drops below the float switch level, the solenoid valve operates, refilling the tank until the water level in the tank is above the float switch level. surrounding objects, or if there are obstacles in front of the outlet, it may present a severe fire hazard. Tivok Energy Domestic Thermal Installation Manual 7 of 29 MOUNTING INFORMATION These mounting components are designed for compatibility with Roof Space Required Tivok Energy T-U5812 Solar Collectors Each collector requires approximately 1.4 metres of width and Please ensure spacing between triangle fames remains as 2 metres of length in order to be safely mounted and minimise specified in this manual to ensure the ability of the mounting to shading losses. sustain a continuous load and compliance with standards. It is recommended to inspect the roof beforehand in order to Tivok Energy’s mounting system is compliant with the following gauge the safest method of installation and if there is sufficient Australian standards: roof space. It is the installers responsibility to ensure the structural adequacy of the roof or any other structure on which the thermal system is to be installed. CAUTION When inspecting or working on components on a rooftop or other elevated structure, please utilise the appropriate safety equipment, tools and ensure that appropriate certification is current and up to date. • AS/NZS 1170.2 – Structural Design Actions: Wind Actions • AS/NZS 1664.1 – Aluminium Structures: Limit State Design • AS/NZS 4600 – Cold Formed Steel Structures Climate In compliance with AS/NZS 1170.2, the mounting components are designed to withstand the wind loading requirements in the following wind regions: 50km 100km 150km Mounting Positioning • Where possible, Tivok mounting should be positioned so as to 20° maximise the exposure of the solar thermal collectors to solar irradiation. • It is recommended that the piping from the collectors to the system is less than 25 metres in order to reduce heat loss and maximise system efficiency. 25° 25° 27° 30° 30° Pre-Installation Inspection Before installing mounting and collectors make sure to check: • The structural integrity of the structure to which the mounting will be fixed has been checked and is in compliance with the Building Code of Australia and other relevant standards. • All evacuated tubes and their end-caps are intact • The collector is not exposed to sunlight prior to installation • A risk assessment is performed to address and control risks associated with the installation REGION A REGION C REGION B REGION D Roof Footing Due to certain regulations on roof mounting for the range of roof materials, the following options are available to secure the mounting hardware onto the roof. Corrugated Steel: • Kliplok roof clamps WARNING Do not expose the solar collector to prolonged sunlight before • Self-driving screws Concrete: installation, severe injury or burns may result through contact • Sleeve anchors with temperature components • Other expanding anchor bolts (e.g. Dynabolt) MOUNTING INSTALLATION Make sure you inspect the site before installation in order to source components that fit the roofing at the installation site. Tivok Energy provides a customised mounting system that is able If direct roof penetration is not possible a ballast system is to provide an incline in order to maximise efficiency on flat or required, however in Australia these systems are limited to wind low-angle roofing. region A. Please refer to AS 1170.2 Structural Design Actions: Compliance The rail is manufactured from code 6061 T5 aluminium, and Wind Actions in order to calculate the appropriate weight for the ballasts. It is recommended that a structural engineer is consulted prior to the installation of a ballasted roof mounted system. certain components such as bolts and screws are stainless steel. 8 of 29 Tivok Energy Domestic Thermal Installation Manual Mounting Component List TE-TR001FR Frame-Rail Interface 57 40 6 40 4 17 56 TE-TR002EC End Clamp 20 6 90 TE-TR003L Support Bracket 56 TE-TR004R Railing 47 3450 32 30 TE-TR005BS Strut 3 30 1750 TE-TR006TF Triangular Frame Includes: ground bar mounting bar rear bar Tivok Energy Domestic Thermal Installation Manual 9 of 29 Mounting Installation Steps Step 1 Locate and ensure components are in an adequate and usable condition, please check against components list. Contact Tivok Energy if there are any damaged or missing parts. Step 2 Take out collapsed Triangle Frames (#TE-TR006TF), the connection between ground bar, mounting bar and rear bar should already pre-screwed. If not, follow instructions for connecting ground bar and suspension bar Step 3 Connect the mounting bar and rear bar using hex bolt and nut. The tilt of the kit can be changed by selecting different pre-drilled holes. Step 4 Attach the frame-rail interface (TE-TR001FR) to the vertical bar, by unscrewing the two hex nuts provided and aligning the hex bolts with the pre-drilled holes at the bottom of the frame. Ensure the rail nut is facing upwards. Step 5 Repeat above step for the top of the frame. 10 of 29 Tivok Energy Domestic Thermal Installation Manual Step 6 Once all the triangle frames are assembled slide one rail onto the triangle frames at the bottom frame-rail interface points. Step 7 Secure the rail by tightening the hex bolt on the frame-rail interface on all triangle frame interfaces. Step 8 Repeat steps 6 and 7 for the top frame-rail interface points. Step 9 Locate pre-drilled holes at the back of the rear bars in the triangle frame, there will be two per bar; one upper and one lower. Step 10 Attach the back struts (TE-TR005BS) to two vertical bars on adjacent triangular frames by unscrewing the two hex nuts provided and aligning with one upper and one lower pre-drilled hole on the suspension bar. Step 11 Slide the support bracket into the rail, with the rail nut interfacing with the rail groves. Make sure the long side of the support bracket against the rail with the short side facing outwards at the bottom of the rail. Tivok Energy Domestic Thermal Installation Manual 11 of 29 Step 12 Position the support bracket along the bottom rail 800mm apart with more than 100mm margin to the edge. Make sure the support bracket are in the interval between two triangle frames. 100mm 800mm 100mm Step 13 Tighten hex bolt to secure the support bracket to the rail. Step 14 Before adding collectors to the mounting system check all bolts are secured tightly! Do not apply excessive torque when fastening bolts to avoid deformation of components. Step 15 Add collectors onto the mounting system, with the lower end resting on the support bracket of the bottom rail. Step 16 Un-screw end clamp rail nut and add aluminium mat, re-screw end rail nut on top. 12 of 29 Tivok Energy Domestic Thermal Installation Manual Step 17 Slide end clamps into the rail with the rail nut interfacing with the rail grooves. Make sure the lip of the clamp faces towards the collector. Step 18 Slide end clamps towards the collector so that they press against both its sides, with the aluminium mat beneath the collector. Secure the end clamps in position by tightening the hex bolt, make sure the end clamp lip is flush with the collector. Step 19 100mm 100mm Repeat steps 11-16 again for other collectors as required. COLLECTOR PLUMBING • Please refer to the schedules in the system installation section for proper system plumbing. INSTALLING CONTROLLER Using a screwdriver you will need to wire the interior of the controller (as seen below) as the following instructions: CAUTION Do not circulate water through the system until the system installation is complete. Do not circulate water for the first • T1 – is for thermocouple lead from the output top of collector time under hot solar collector condition. The system may • T2 – is for the thermocouple lead at the BOTTOM of the energy bank become damaged. • T3 – is for the thermocouple lead at the TOP of the energy INSTALLING CIRCULATION PUMP • Always follow circulation pump manufacturer’s instructions • Do not turn on the pump until system is fully installed and commissioned. • The flow rate of the pump should be set as close to 2 litres per second as possible. • The circulation pump should be placed on the ground with adequate clearance in order to prevent rainwater entering Tivok Energy Domestic Thermal Installation Manual bank • F – For flow switch if applicable • H – Float switch • V – DC value controller, not used in this controller version • PUMP L – Active power for Circulation Pump • PUMP N– Neutral for Circulation Pump • – earth slot from power (from power plug) • POWER L is active from power (from power plug) • POWER N is neutral from power (from power plug) 13 of 29 SYSTEM INSTALLATION TIVOK DOMESTIC SPLIT SYSTEM The split domestic system takes advantage of two heat sources to ensure continuous hot water and ensuring maximum energy savings to meet household requirements of small to medium size Solar Circulation Piping Solar circulation piping connects the energy bank and solar thermal collector array accompanied with a solar circulation pump. households. The 2HP heat pump operates during low or no solar The pump is controlled by the control box based on the isolation periods at above 300% efficiency. temperature difference between the solar array output In addition to this, the solar collectors convert free sunlight to produce hot water during the day, which is stored in the highly insulated energy bank. Control systems ensure that the tank is temperature and the temperature at the bottom of the energy bank. A union is used to connect the pump and the circulation loop to ensure easy maintenance. storing adequate heat at all times. Two separate hot water loops It is recommended that the hot side of the solar array should are circulating cooler water out of the tank to circulate through be positioned higher than the cold inlet to ensure any air in the the solar collector array loop (during the day when there is system is vented out of the collector array during commissioning enough sun) and through the heat pump loop (during the night or unfavourable weather). This is done automatically through the control box which activates the solar pump and/or the heat pump according to temperature signals from probes in the energy bank. By maintaining the hot water temperature in the tank, it ensures that potable water going through it will always be heated to the specified temperature needed by the household (~55°C). System Overview This hot water system could be divided to 3 main components, namely: solar thermal collector array, energy bank array and heat pump array. Based on the domestic thermal system schematic diagram, piping between them are outlined in the following sections. Be aware that in most systems, each Energy Bank is usually connected to one Heat Pump, however this could be modified in special circumstances. Details can be seen in each schedule diagram in the following pages. Potable Water Piping Heat Pump Circulation Piping The heat pump array is used as the secondary heat source for the water heater system in case of low solar irradiation conditions, and it is controlled by its own controller via reading the water temperature from the sensor installed in the middle port of the Energy Bank. Please consult the Energy Bank specifications on page 8 for further details. When the heat pump is on, cold water flows into the heat pump via the front bottom left port, and hot water returns to the Energy Bank via the front top left port. General Attention CAUTION Please read carefully over the following section, failure to do so may result in a non-operational or damaged system. • A high temperature nylon washer is required between the collector flexi-joints • If Teflon tape is used, pink/high temperature tape is required Potable water input (represented by dark blue line) takes water Tivok Supplied Components mains through the energy bank to be heated, then exits out of the Primary Components: energy bank through Potable water return (dark red line), passing • Collectors through a mixing valve to the end user. • Energy Banks Water Refill Piping It should be noted, at the end of the potable water feed, a pipe • Heat Pump (including controller and temperature sensor) • Mounting Equipment (not including Kliplok) Accessories: branch is extended for water filling system. This system is • Controller accompanied with a solenoid valve which is controlled by the float • Collector Flexi Joints switch based on water levels in the tank. Water is refilled into the • High Temperature Nylon Washers tank from the top port of the tank. • Solenoid Valve • Float Switch • Temperature Sensors (T1, T2, T3) 3 metres in length • Sensor Pocket (T1, T2, T3 + Heat Pump Sensor) 14 of 29 Tivok Energy Domestic Thermal Installation Manual Split System Schematic T1 HOT WATER OUT REFILL 12VDC/240VAC COLD WATER IN T3 FLOAT OVERFLOW HEAT PUMP SENSOR POCKET T2 LEGEND Signal Line Non-return valve 3/4 Cap Cold Line Pump Solenoid Valve Hot Line Ball valve Mixing Valve Power Cable 240V Power Source Auto Vent Drain Out More collectors AC/DC Transformer Tivok Energy Domestic Thermal Installation Manual 15 of 29 A REFILL B T2 C RAW POTABLE HOT Reducing nipple (3/4” to 1/2”) POTABLE COLD IN POTABLE HOT OUT Needs to be bent Immerse this copper pipe halway into tank FLOAT SWITCH HEAT PUMP OUT HEAT PUMP IN HEAT PUMP SENSOR Please note that the materials used are indicative only, actual installation may vary due to local material availability and site circumstances T3 Reducing nipple (3/4” to 1/2”) REFILL 1. A mixing valve is used as shown in the diagram at the ‘Potable out’ end to limit the Schedule 1: Tank Connection Instructions temperature so that water is suitable for domestic usage. This valve mixes the water from “Potable in” and potable hot water (could be up to 80 °C) from the energy bank. Tee A is used to split the cold water flow for the mixing valve input and energy bank input. If necessary a reducing nipple is used to change the fitting of the mixing valve. 2. Tee B is installed to split the energy bank input for refill and heating purposes. After a reducing nipple and kinco nut set, use ½ inch pipe to connect the “To refill” and “refill” port in the diagram, the “refill” port is followed by solenoid valve. Directly connect the solenoid valve to the tank as shown on the diagram 3. Connect the solar array to the “Solar return” port. A ball valve is used to control the flow of the return solar hot water. For connection between solar return line and top tank, the copper tube between two kinco nuts must immerse halfway into tank to minimize heat loss. 4. Connect ball valve to the side of the tank, which will later connect to the heat pump 5. Put a cap on the aircon/commercial refill fitting on the side of the tank 6. Connect Tee C to the bottom of the energy bank, screw the male sensor pocket to the energy bank via this tee first valve for drain purposes while the other port is connected to circulation pump. 7. Connect the middle fitting of the Tee C to Tee D. The middle Tee D is connected to a ball TANK WITH 8. Put the Sensor T2,T3, into male sensor pocket and heat pump sensor to the female • Tighten the float switch to the plug with the nuts float come out of the hole • Insert the float switch into the hole through the end of the plug, letting the threaded of the • Take off the threaded nut of the float switch • Predrill a hole of 1cm on top of the plug 10. The Float Switch comes with a special vented plug. Installer should: Tee3 into tank, and heat pump sensor pocket to the lower middle port of the energy bank. sensor pocket. The installation is illustrated in the diagram. CAN BE REPLACED BY SOLAR FEED WELDED CAPILLA RY 9. Plug in the sensor pocket as shown in the diagram. T3 at top of the tank, T2 through SOLENOID VALVE Reserved Drain D • Screw the plug into the tank as shown in the diagram 11. Connect the sensors and float switch to appropriate terminals in the solar controller. Tivok Energy Domestic Thermal Installation Manual 16 of 29 SOLAR RETURN Schedule 1: Tank Connection Schedule 2: Collector Array Please note that the materials used are indicative only, actual installation may vary due to local material availability and site circumstances 17 of 29 Tivok Energy Domestic Thermal Installation Manual Schedule 2: Collector Array Instructions 1. Install the solar racking on the roof as described in the racking installation section on page 8. 2. Place the solar collector on the roof first, leave 15cm between 3. Connect the solar collector with Tivok flexible joints, two on each collector. 4. Connect two threaded tees at the end of the array row, the outer one is pointed upward to connect to automatic air vent Schedule 3: Heat Pump Instructions 1. Connect the upper water fitting to the “heat pump out” from tank via an elbow. The lower water fitting is connected to the “heat pump in” from the tank. 2. Connect the controller for the heat pump as described in the heat pump installation section on page 7. 3. Place the sensor to the “heat pump sensor” fitting of the tank 4. Connect power to 240V AC General Power Outlet. while the inner one is connected to the solar return pipe. The Example Balance of Materials male sensor pocket will go through these two tees with T1 Tank Connections sensor inside. Component Quantity ¾” check valve 1 ¾” ball valve 6 ¾” nipple 9 ¾” adapter MF 1 Threaded copper tee 4 ¾” kinco nut and olive 8 ½” kinco nut and olive 2 ½” to ¾” reducing nipple 2 1 threaded pipe plug cap 1 ¾ threaded pipe plug cap 1 Male sensor pocket 2 Female sensor pocket 1 Solenoid valve 1 Float switch 1 Solar Collector (to Solar Return on Energy Bank) Component Quantity ¾” kinco nut and olive 3 ¾” threaded nipple 3 ¾” Cap 1 ¾” Ball valve 1 ¾” threaded tee 1 ¾” male sensor pocket 1 Collector joints 2 Solar Collector (Solar Feed from Energy Bank) Component Quantity ¾” Cap 1 ¾” kinconut and olive 1 Solar Circulation Pump Solar Circulation Pump 1 Additional components According to pump brand Heat Pump ¾” nipple 2 ¾” kinco nut and olive 2 1 elbow 1 Piping Component Distance Copper pipe Depending on system ¾” copper pipe 10 metres Insulation 10 metres ½” copper pipe 0.6 metres 5. Connect the tees set to the upper thread of the manifold via ¾” kinco nut and pipe set, so the solar return line can be pointed vertically downward. 6. Use a ¾” cap to cover the lower port in the collector manifold. 7. Install the solar return line with ball valve, as shown in the diagram. The middle ¾” copper pipe is used to adjust the position of ball valve. Connect the solar return line to the tank fittings. 8. On the other side of the collector array, install the solar feed line. 9. Bend the tube to 90 degree and connect to a ball valve, as shown on the schedule. This ball valve is used for maintenance purpose. Connect the other side of the ball valve to the one way valve (usually placed near the solar circulation pump) via certain length of copper pipe. The length and path of the copper pipe depends on the site specifications. 10. Connect the tank solar feed to the inlet of the circulation pump via a ball valve and union. Connect the outlet of the pump to another union, followed by ball valve and one way valve. Schedule 3: Heat Pump HEAT PUMP OUT GAUGE POWER CONNECTION TO SENSOR HEAT PUMP IN (COLD) 18 of 29 Tivok Energy Domestic Thermal Installation Manual Electrical Connection Diagram Float switch to be sccrewed into tank top as indicated Housing Enclosures Electric wires (ELECTRICIAN ONLY) Electric wires (Plumber may install) LEGEND Collector Heat Pump Isolator / GPO Circulation Pump Heat Pump Circuit Breaker at Switchboard T1 (TO COLLECTOR) T2 (TO TANK BOTTOM) Hottest Collector at Array Return FLOW SWITCH SHORT CIRCUIT FLOAT SWITCH SOLENOID VALVE Controller Schematic Main Switch Board T3 (TO TANK TOP) Pump Power GPO Controller Includes a Flexiplug Solar Array Circulation Pump 19 of 29 Tivok Energy Domestic Thermal Installation Manual SYSTEM OPERATION MODIFICATION WARNING Once your system is installed you should not attempt to modify the system in any way. If any modification is required please contact the licensed installer that installed your system or contact Tivok Energy for a list of authorised service providers. WARNING Any unauthorised modifications to the system, including parts, will void warranty and any liability claims against Tivok Energy. Protection against Freezing Controller will turn on circulation pump when T1 ≤ 5°C, the pump will keep running for 10 minutes Protection against Overheating Controller will turn OFF circulation pump when T3 ≥ 95°C and will resume normal functionality when T3 ≤ 75°C, this is in place to protect the circulation pump and prevent loss of water through evaporation. Manually Controlling Pump Power The circulation p ump can be turned on or off via the “LOOP” UNDERSTANDING THE DIGITAL SOLAR LOOP CONTROLLER Tivok’s Solar Loop Controller is to be used as an informational button, this will override the controller functionality to turn pump on or off and will resume normal controller functionality after 10 minutes display for the system performance and to drive the water flow in Auto Refill Functionality the solar loop based on programmed functioning logic, ensuring Water refill solenoid valve will be open to fill up tank when water the reliability and safety of your system. level is low and float switch is engaged. The solenoid valve will be closed and stop filling tank when water level is up and float switch is open. Fault Detection Controller can run a search to detect any faulty thermocouples or open loop, when an error is detected the blue “faulty” will flash. See error codes table on page 26 for more information. The digital solar controller functions based on the temperatures sensed at three parts of the system: T1 – Temperature at the output of solar collector T2 – Temperature at the bottom of the tank T3 – Temperature at the top of the tank OPERATIONAL LOGIC Temperature Differential The controller triggers the circulation pump power state based on these fixed values: • On: If T1 – T2 ≥ 7°C • Off: If T1 – T2 ≤ 2°C 20 of 29 Tivok Energy Domestic Thermal Installation Manual TEMPERATURE DISPLAY BASIC SYSTEM MAINTENANCE Tivok Energy Solar Thermal Systems require basic system maintenance every six months, and it is recommended that you contact your installer or Tivok Energy to perform system service every two years from date of installation to maintain optimal output. Every six months: • Ensure that there are no objects obstructing the heat pump Buttons • LOOP is used to manually turn pump on and off. It is not recommended that you use this function as it overrides the controller functionality for about 10 minutes. It should only be used to check if pump is functioning • SEARCH is used to check temperature of T1 (at the output of collector) and T2 (bottom of the tank) Display units, as proper ventilation is required for optimal efficiency. • Ensure that the solar collectors are not obstructed by leaves, branches or other debris. Please ensure your own safety first when inspecting collectors. If you need to trim trees, make sure to consult your council. • Visually inspect the collectors, energy bank and pipework for any weather damage, if there are broken tubes please contact Tivok Energy or your installer in order to get a replacement. Extra care must be taken as components may be hot. • The default temperature displayed is the temperature at the • Manual tank refill: open the refill valve at the top of the tank top of the heat exchanger (T3). When the search button is to refill, close the valve when water is coming out of the pressed you can see T1 and T2, however after a few seconds overflow. it will default back to T3. • PUMP light is on when solar pump is functioning. i.e. When the pump is turned on during the conditions explained in the logic section on the previous page. • If FAULTY light is flashing and/or the system is beeping you • Do not attempt to open or service any components as doing so will void warranty and certifications. • Check temperature on the controller panel, if under sunny conditions and the temperature is below 50 you may want to contact your installer or Tivok Energy for inspection. must turn the system OFF at the power plug and contact your licensed installer or Tivok Energy to arrange a service call. • Note that if the controller is unplugged or not working, the system will still provide hot water via the heat pump CAUTION When inspecting or working on components on a rooftop or other elevated structure, please utilise the appropriate safety equipment, tools and, if required, possess a ‘Work Safely at Heights’ certificate. WARNING Any unauthorised modifications to the system, including parts, will void warranty and any liability claims against the manufacturer. If your system requires servicing, please contact your licensed intaller or Tivok Energy. Tivok Energy Domestic Thermal Installation Manual 21 of 29 SYSTEM PRECAUTIONS WATER QUALITY Poor water quality may compromise system lifetime and cause damage to the components over time, particularly to circulation STAGNATION AND NO-LOAD CONDITIONS pumps. It is strongly advised that the system inlet is connected Stagnation to a drinking water outlet, which meets Australian Drinking Water Stagnation occurs when the circulation pump stops running and Guidelines at all times. For areas with hard water, a water softener there is no water flow between collector and tank. This is normally device prior to system main inlet is recommended (contact local caused by tank temperature protection mechanism, which water authorities for more information). Rainwater or recycled prevents tank water from overheating. Other reasons may include water should not be used under any circumstances. circulation pump failure or power failure. The collector and its WATER SAFETY accessories are designed and tested to cope with such condition when temperature could reach as high as 260°C. The system will By complying with AS 3498, Tivok adheres to the WaterMark resume normal working conditions automatically after satisfying certificate, which proves to supply clean potable water from the certain parameters measured by the controller. system. In addition, different from a traditional water heater, the potable water loop is completely separate from tank water by No-Load Conditions using heat-exchange technology. No-load conditions occurs when the system has no output for HAIL PROTECTION a period of time. With the maximum temperature of tank water set to 95°C through the controller, the system can adjust itself The low-iron glass of Tivok Energy Solar Collectors has been to prevent overheating. Moreover, the vented tank design avoids tested in accordance to AS/NZS 2712:2007 to be capable of building up tank pressure during no-load periods. withstanding hailstones of up to 25mm diameter. In case one or more evacuated glass tubes (12 tubes in each collector) are broken due to extreme weather conditions or other causes, the system will still function but at a reduced total output. Broken tubes can be easily replaced by a trained installer without replacing the entire solar collector. LIGHTNING PROTECTION Lightning protection is advised particularly in the areas where lightning is common. Earthing the system and its mounting is the primary way of avoiding electrical faults and damage caused by lightning strikes. FREEZE PROTECTION In accordance to AS/NZS 2712:2007, freeze protection is built into Tivok Energy Thermal Products via the Thermal Controller and Circulation Pump. If temperatures fall below 5°C at the collector outlet, hot water will be circulated through the system until temperatures reach higher levels. Tivok Energy Thermal Systems have passed Frost Level 2 protection to -15°C. It is important to note that the frost protection relies on the operation of the Circulation Pump and Thermal Controller, which require power to operate. 22 of 29 Tivok Energy Domestic Thermal Installation Manual COMPLETING INSTALLATION FILLING THE TANK SYSTEM TEST AND FIRST RUN Domestic System Prior to running the system ensure that all components are Refill the energy bank by normal garden hose via the overflow outlet in the front of the Energy Bank or by the automatic refill system. PIPING INSULATION The system must be insulated to minimise heat loss and to maximise the efficiency of the system. RECOMMENDATION All the pipes needs to be insulated except the potable cold feed and the refill pipes installed and connected correctly, and the tanks have been filled. WARNING If further work on the system is required, the entire system may need t be shut down. See the Troubleshooting section in System Maintenance for possible faults. • Plug in the electrical components • Turn on heat pump: −− Ensure the temperature is set to 57°C (number shown on left side of heat pump controller display) −− Ensure mode is set to heating • The heat pump should start working after 2 to 3 minutes • After the heat pump is running place your hand on the cold in line to the heat pump −− The water should be flowing −− There should be minimal vibration −− The system should not produce any loud noises • While the pump is running, inspect all fittings and welding to ensure there is no leakage, if there is shut down the system to rectify and repeat the above procedure. • Inspect the LED display on the controller to ensure the temperature is rising. • The system will take several hours to initially heat up the energy bank. • If weather conditions do not trigger solar circulation pump , press “LOOP” on the controller to force water flow through the solar array to check for proper operation. Please ensure that this is done during low solar irradiation to avoid thermal shock in the solar array. CAUTION Do not circulate water for the first time under hot solar collector condition. The system may become damaged. Tivok Energy Domestic Thermal Installation Manual 23 of 29 SYSTEM MAINTENANCE EVACUATED TUBE REPLACEMENT In the event of broken or damaged tubes, please follow these instructions to safely replace without damaging installer or equipment. Step 1 Make sure the end cap is screwed on adequately Step 2 Wear protective eye wear and gloves at all times Step 3 Squeeze the bottom side placeholders while gently pulling the cap up and out Step 4 The end cap will dislodge with a pop Step 5 Slide the glass tube out while ensuring that the aluminium tube is held straight, to dislodge the tube from the rubber fitting at the manifold, apply gentle twisting motion to the glass tube to ease it out of the rubber holder Step 6 Inspect the manifold and the collector frame for any remaining pieces of glass. Shards are commonly stuck in the manifold and rubber fitting, use caution when cleaning out these parts using tools. 24 of 29 Tivok Energy Domestic Thermal Installation Manual Step 7 Wipe down the aluminium fins to remove excess glass shards Step 8 Take new unbroken glass tube and slide in, while ensuring that the aluminium tube is held straight at all times. Ease in the glass tube into the rubber holder using a gentle twisting motion. Ensure the fins are aligned with each other before inserting the new glass tube. Step 9 Put on the end cap, and fix onto bottom rail by pressing on the side placeholders and using a gentle downward force onto the rail Step 10 If difficulty is experienced in Step 9, and the slots on the end cap aren’t yet aligned, try pushing the tube further into manifold. Step 11 Inspect for any air infiltration and structural integrity of the tube CAUTION If you hear a hissing sound, it is likely that the vacuum seal has been compromised. This can also be indicated by a milky appearance on the inner surface of the glass tube. Most commonly, this is caused by a crack in the pointed end of the glass tube. This tube will need to be replaced with a new one. Tivok Energy Domestic Thermal Installation Manual 25 of 29 TROUBLESHOOTING Heat Pump Circulation Pump Test CONTROLLER Move the heat pump sensor out of the unit, this will pick up a Error Codes lower temperature and will trigger the heat pump unit to start. When controller is beeping it will give an error code. See the index below for a list of errors. You may have to wait up to 5 minutes before the unit startsv. If it does not run, you will need to do a power reset on the unit. 01 T1 Fault Check thermocouple wiring or change thermocouple 02 T2 Fault Check thermocouple wiring or change thermocouple 03 T2, T3 Fault Check thermocouple wiring or change thermocouples 04 T3 Fault Check thermocouple wiring or change thermocouple 05 T1, T3 Fault Check thermocouple wiring or change thermocouples Energy to arrange for a replacement unit. 06 T2, T3 Fault Check thermocouple wiring or change thermocouples Defrosting 07 T1, T2, T3 Fault Check thermocouple wiring or change thermocouples For low ambient temperature, when ice is sensed in the 08 Flow Switch Fault Check flow switch wiring or change flow switch temperature of hot water may reduce due to decreased recovery 09 T1 and Flow Switch Fault Check thermocouple & flow switch wiring or change both of them 10 T2 and Flow Switch Fault Check thermocouple & flow switch wiring or change both of them 11 T1, T2 and Flow Switch Fault Check thermocouple & flow switch wiring or change both of them 12 T3 and Flow Switch Fault Check thermocouple & flow switch wiring or change both of them maintenance. 13 T1, T3 and Flow Switch Fault Check thermocouple & flow switch wiring or change both of them Broken Evacuated Tubes 14 T2, T3 and Flow Switch Fault Check thermocouple & flow switch wiring or change both of them 15 T1, T2, T3 and Flow Switch Fault Check thermocouple & flow switch wiring or change all of them CIRCULATION PUMP • On the Controller, press the Loop button, the pump light should now be green. • Place your hand on the Circulation Pump, and feel it for any vibration. • If there is no operation, perform a power reset and try again. If there is still no vibration, replace the circulation pump. HEAT PUMP Unit Pressure Noisy Fan Check if there are any objects obstructing the fan, if fan is broken or faulty contact Tivok Energy for fan replacement Unit not Operational Where the unit is not operational you will need to contact Tivok evaporation coil, defrost mode would be active. Output rate. SOLAR COLLECTORS Draining Draining the Solar Collector is required before service and If tubes are broken, contact Tivok Energy for a replacement. Tubes are easily replaceable and the system can continue to run with broken tubes at a lower level of efficiency. Please see the system maintenance section on page 24 for instructions how to replace broken tubes. Water Overflowing from Tubes This means there is a leak or multiple leaks on the copper manifold. Inspect the leaking and replace the collector if required. Contact Tivok Energy for a replacement. Collector Insulation Insulation foam at inlet and outlet plumbing pipes and protective cover/foil should be in good condition. Ensure that there is sufficient pressure on the gauge (side of unit). If there is not sufficient pressure a refrigerant recharge maybe required. The refrigerant used is R410A. You may need to call an authorised refrigerant recharge technician. 26 of 29 Tivok Energy Domestic Thermal Installation Manual SYSTEM COMMISSIONING INSTALLER DETAIL COMMISSIONER DETAILS Name: Name: License Number: License Number: Company: Company: Contact Number: Contact Number: OWNER DETAILS Name: Company (If applicable): Address: State: Name: Phone Number: Email: SYSTEM DESCRIPTION Tivok Energy Reference Code: Solar Collectors: Model Number: Aperture Area: m² Heat Pumps: × HP Energy Banks: × L SYSTEM CHECKLIST Checklist Complete Comments 1 Check security of collector fixings 2 Check weather sealing of roof/wall penetrations 3 Check pipework arrangement complies with specification 4 Check that all insulation is in place 5 Check location and function of automatic air vents 6 Check flowrate litres/min Litres/minute 7 Check pump speed Speed 8 Check primary circuit volume litres Litres Check system operating pressure bar bar 10 11 Check operation of pressure safety valve 12 Check operation and direction of non return valve 13 14 Differential temperature controller Check Δt setting: switch on °C Check Δt setting: switch off °C Check setting of high temperature limit °C Ancillary controls (where applicable) Check setting of auto pump changeover 15 Check that all electrical controls are operating correctly to the manufacturers specifications I hereby undertake that the Tivok Energy Thermal System Name: referenced above has been commissioned by me, in accordance License Number: with the prescribed commissioning report above and that I am satisfied that all of the installation points specified have been Date: µµµ / µµµ / µµµ Signature: correctly followed and satisfied. Tivok Energy Domestic Thermal Installation Manual 27 of 29 APPENDIX GLOSSARY • Stagnation — a condition that occurs when the circulation pump stops running and there is no water flow. • Collector — a typically roof mounted device that consists of the evacuated tubes inserted into a manifold. • Booster — an additional heat source component, such as a heat pump, that provides additional heating when the solar thermal collector is not providing enough heat. • Manifold — the top metal part of a solar collector which contains copper pipes through which water flows. • Thermal Controller – an electronic control module that automates pump switching and monitors tank temperatures. • Circulation Pump — a pump which circulates water through the solar collector array, it is contained within the Energy Banks. • Collector Outlets — outlets which come out from the side of a collector at the manifold, one is a cold water inlet the other a hot water outlet. • Refrigerant — a chemical substance used in the refrigeration cycle within Tivok Energy Heat Pumps. • Evacuated Tubes — a double walled glass tube which is part of the collector, the air between the two walls of glass is evacuated creating a vacuum between them. • Heat Exchanger — a device located within our Energy Banks which transfers thermal energy from the solar or heat pump loop to the mains water loop. • Solar Loop — the closed loop of plumbing that runs through the collectors and Energy Bank • Mains Loop — the loop of plumbing the runs through the main water line and the Energy Bank. • Bracket — a mounting component that links the roof and the frame. • Frame — the mounting component supporting the collector • Mounting — the entire collector support system that holds the frame securely in place on rooftops. • Rail — a horizontal aluminium weight bearing mounting component which is in direct contact with the collector and frame. This allows adjustable horizontal positioning. • Clip Lock — a type of specialised bracket mounting component that allows mounting of the frame to corrugated metal roofing. • DynaBolt — a specialised bolting mounting component that allows secure anchoring of the bracket to a flat concrete roof. • Potable water — water that is drinkable straight from the tap 28 of 29 Tivok Energy Domestic Thermal Installation Manual NOTES Tivok Energy Domestic Thermal Installation Manual 29 of 29 Tivok Energy 4/51-53 Bourke Road, Alexandria NSW 2015 Australia +612 8084 7905 tivok.com.au 30 of 29 Tivok Energy Domestic Thermal Installation Manual
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