User Guide Final 01

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PERFECTHEAT Solar Thermal Systems

User Guide1st Edition : October 2008

for systems with the

PERFECTHEAT heat exchangerand turbo boost function


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IntroductionYourPERFECTHEATSolar Thermal System is comprised of many separate components each of

which performs a vital role to ensure the safe and correct functioning of the water heating system.

The highest quality components have been built into thePERFECTHEAT

Solar Thermal System and,provided that it has been installed and maintained correctly, the system has an expected life well in

excess of the 20 year guarantee.

The PERFECTHEATSolar Thermal System incorporates many features and benefits not found in

many other systems. The mini-digital thermometer provides a direct reading of the water

temperature contained in your hot water cylinder. The turbo-boost auxiliary heater to provide a

quick boost when there is no solar gain. The thermostatic mixing valve to prevent scalding solar

heated water can be much hotter than that from your boiler when you run the hot water taps.

Special de-aeration valves in the solar circuit to automatically remove any build-up of microscopic

air bubbles which might otherwise necessitate a service call to bleed the system. In fact, everything

possible to ensure safe reliable operation from the day that it was installed.

The unique and innovative feature of the PERFECTHEATSolar heat exchanger is the way that it

delivers solar heated water directly to the top of the hot water storage cylinder where it stratifies

ready for use at useable temperatures.

In marginal or intermittent conditions that are common in the northern hemisphere, particularly in

autumn, winter and spring the PERFECTHEATSolar Thermal System will produce useable hot

water in a way that no other system can at present.

The installer should have identified the user controls to you and explained their use. He or she

should leave the installation manual with you too as it contains essential information regarding your

PERFECTHEAT

Solar Thermal System. Please keep it safe and readily available for use if required.

Please read through this User Guide to familiarise yourself with what your PERFECTHEATSolar

Thermal System will do.

Contents1.1 Town and country planning Page1.2 Introduction to the PERFECTHEATSolar Thermal System Page1.3 Normal operation Page1.4 The PERFECTHEAT turbo boost function Page1.5

The mini-digital thermometer Page1.6 The thermostatic mixing valve Page

1.7 Maintenance Page1.8 Trouble shooting Page


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1.1 Town and Country PlanningYour PERFECTHEATSolar Thermal System does not normally require planning permission if it is to be installed in a residential (non-commercial) dwelling house.

Statutory Instrument 2008 No. 675 : The Town and Country Planning (General Permitted

Development) Order came into force on 6th April 2008 allowing installation of domestic

microgeneration equipment as permitted development in England.

Please note that it is the property owner who is responsible for obtaining the necessary

permissions not PERFECTHEAT nor the installer. For your information, the Act says:

Permitted developmentA. The installation, alteration or replacement of solar PV or solar thermal equipment on(a) a dwelling house; or

(b) a building situated within the curtilage of a dwelling house.

Development not permittedA.1. Development is not permitted by Class A, in the case of solar PV or solar thermalequipment installed on an existing wall or roof of a dwelling house or a building within its

curtilage if:

(a) the solar PV or solar thermal equipment would protrude more than 200 millimetres

beyond the plane of the wall or the roof slope when measured from the perpendicular

with the external surface of the wall or roof slope;

(b) it would result in the highest part of the solar PV or solar thermal equipment being

higher than the highest part of the roof (excluding any chimney);

(c) in the case of land within a conservation area or which is a World Heritage Site, the

solar PV or solar thermal equipment would be installed

(i) on a wall or roof slope forming the principal or side elevation of the dwelling house andwould be visible from a highway; or

(ii) on a wall or roof slope of a building within the curtilage of the dwelling house and

would be visible from a highway; or

(d) the solar PV or solar thermal equipment would be installed on a building within the

curtilage of the dwelling house if the dwelling house is a listed building.

ConditionsA.2. Development is permitted by Class A subject to the following conditions:(a) solar PV or solar thermal equipment installed on a building shall, so far as practicable, be

sited so as to minimise its effect on the external appearance of the building;

(b) solar PV or solar thermal equipment shall, so far as practicable, be sited so as to

minimise its effect on the amenity of the area; and(c) solar PV or solar thermal equipment no longer needed for microgeneration shall be

removed as soon as reasonably practicable.

Permitted developmentB. The installation, alteration or replacement of standalone solar within the curtilage of adwelling house.Development not permitted


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1.3 Normal operationThe PERFECTHEAT solar thermal system normally uses your existing hot water cylinder

and there has usually been no significant change to the existing hot water system so it will

work just as it did previously. But additionally, it will provide lots of free hot water on

sunny days or days when solar radiation is high.

The temperature controller within the solar pump station measures the temperature of

the heat transfer fluid in the PERFECTHEAT solar collectors and in the hot water cylinder.

When the differential temperature exceeds the pre-set level (about 6C ~ 8C) the solar

pump is switched ON. Then, all the while that there is sufficient temperature differential

the pump circulates heat transfer fluid through the primary circuit of the PERFECTHEAT

heat exchanger. A thermosyphonic circulation quickly establishes itself in the secondary

circuit of the heat exchanger and the hot water storage cylinder. The thermosyphonic flow

takes hot water to the top of the hot water cylinder having drawn cold water (from the

bottom of the cylinder) through the heat exchanger.

How much you benefit from solar energy will depend on you. If you continue to use theHW programmer with your boiler to produce hot water at the temperature you want and

a time when you want it, you will not obtain the maximum benefit from solar energy.

To optimise your use of solar energy to produce hot water you need to switch your boiler

OFF as much as possible so that it doesnt automatically produce hot water (all the while

HW the programme is calling for heat) regardless of whether you need hot water.

We recommend that you switch the boiler OFF and maintain manual control of hot

water. You will have little to do during the summer when solar energy should produce all

of your hot water. Ideally, you would switch the boiler OFF in early April and leave it off

for about six months - until mid-October. During autumn, winter and spring you should

be able to take advantage of clear sunny days and even modestly overcast days to heat

your water using solar energy too. Switch your boiler OFF on these days too.

Obviously, on cloudy, rainy days when solar radiation cannot reach your PERFECTHEAT

solar collectors, you will need to use turbo boost or, switch your boiler ON to ensure that

you have hot water. But, during autumn, winter and spring be vigilant of the current

weather conditions and forecast weather conditions so that you can switch the boiler OFF

at the earliest opportunity.

Apart from being aware of what weather is being experienced or anticipated and taking

action to ensure that you optimise solar energy to heat your water, there is nothing to do

except enjoy free hot water.

1.4 The turbo boost functionThe turbo boost function is provided to rapidly heat some water for a short time using the

auxiliary electrical heater.


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Instead of switching your boiler or immersion heater ON for a few hours to heat a whole

cylinder-full of hot water on a rainy day or, if you have used all the water heated by the

sun, you can use the PERFECTHEATturbo boost function for just 15, 30 or 60 minutes.

Simply press the BOOST button in quick succession until the indicator light for the required

boost period is illuminated. #1 -> 15 min, #2-> 30 min and #3-> 60 min.

To cancel the turbo boost period press the BOOST button continuously until ALL theindicator lights are OFF.

Keeping the BOOST button depressed will cancel any turbo boost period.

When the turbo boost is activated the indicator light will countdown showing the

approximate duration of the turbo boost period remaining.

The turbo boost will produce hot water within minutes and set up a thermosyphonic

circulation that also pumps hot water to the top of the cylinder where it stratifies ready

for use at useable temperatures.

The turbo boost will not operate if the PERFECTHEAT solar thermal system is producingsolar gain. The system has an interlock to prevent the turbo boost from operating when

the solar pump is running.

1.5 The Mini- Digital Thermometer

The turbo boost will automatically switch

the auxiliary heater OFF after the set timeso that you dont have to remember to!

TIP Remember that youre trying to save

energy so check the water temperature

using the mini-digital thermometer with

sensor fitted to the hot water storage

cylinder and only use turbo boost if really

necessar .

The mini-digital thermometer will enable you to monitor the water temperature available

for use. You will quickly learn what temperature is acceptable for a shower or bath and so

when / when not to use the turbo boost. Some people are happy to shower with 30C.

Why not purchase another mini-digital

thermometer or even two (available as an

accessory) to install at mid-height so that you

have more information about the

temperature profile in the hot water cylinder?


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1.6 Thermostatic mixing valve (TMV)

Hot bath water is responsible for the highest number of fatal and severe scald injuries in

the home. Young children and older people are most at risk from bath water scalds. This

is because their skin is thinner and therefore less tolerant to higher water temperaturesthan other age groups. As a result, they sustain scalds more quickly, at lower water

temperatures. Often with a greater depth of burn.

People with a reduced ability to perceive risk or react to hazardous situations those with

mental or physical disabilities are also at greater risk of injury.

Every year around 20 people die as a result of scalds caused by hot bath water and 570

suffer serious scald injuries.

75% of severe scalds are suffered by children under five years.

75% of fatalities are people aged 65+.

Please refer to the instructions supplied with the TMV for details about how it should be

adjusted and maintained.

1.7 MaintenanceLittle periodic maintenance is required for the PERFECTHEAT solar thermal system but it

is good practice to do the following:

ANNUAL INSPECTION -(USUALLY BY OWNER)

Externally observed from the ground (possibly using binoculars). Look at the PERFECTHEAT solar collectors on the roof to check that they are still

secure and laying flat as they were when installed. Check that the roof fixing

brackets are secure and check that the cover glass isnt broken highly unlikely

during normal use. However, an act of vandalism could cause a glass breakage. A

replacement cover glass complete with mounting frame is available. It can be

replaced easily and without having to switch the system OFF.

The PERFECTHEAT solar thermal system is fitted

with a special solar rated TMV which regulates the

temperature of the water flowing to the hot taps at a

safe temperature. It comes pre-set to about 43C for

safety but can be adjusted as required to warmer orcooler temperatures.

The TMV will be located close to the top of the hot

water cylinder and blends hot water (stored at

temperatures high enough to kill bacteria) with cold

water to ensure constant, safe outlet temperatures

preventing scalding.


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Check that all insulation is still firmly attached. Check that the collector temperature sensor is secure in the pocket provided.

Internally Look inside the loft to check that nothing untoward has happened i.e. roof leak

or rodent damage etc.

Check that there is no damage to pipe work. Check that there is no evidence of leaks or corrosion residues at joints. Replace any damaged pipe insulation otherwise performance will be impaired. Check that there is no air in the system. You can observe air bubbles that pass

through the flow-meter window or you might hear noise from the circulating

pump. However, it is very unlikely that air will enter the system because it is fittedwith two independent means of automatically removing air. There is an air

separator to which an automatic air vent if fitted at the highest point in the pipe

work usually in the loft space. There is also a special de-aeration valve which

removes micro-bubbles from the heat transfer fluid. This valve is located between

the PERFECTHEAT heat exchanger and the Resol solar pump station. These two

devices will normally expel any air build-up automatically from the solar system .

Check that the pressure gauge indicating system operating pressure is reading atleast 1.0 bar. If less than this, please contact your installer or the PERFECTHEAT

helpdesk for advice about what to do.

Check the expansion vessel connection unions to ensure that there are no leaks.There is no routine maintenance for the expansion vessel which will last for an

indefinite time provided the system is installed correctly and operating normally.

Check that the temperature sensors are securely fitted into the pockets provided. Check that all components are securely fitted and that all covers, fixing screws etc

are present.

Under no circumstances should you change any settings or adjustments. Check that the pressure relief valve releases a small quantity of heat transfer fluid

when briefly twisted. Check that the blue container into which the pressure relief

valve discharges is fixed securely in the correct location.

Remember that the system operates at high temperatures so hot pipes arenormal. Some components, such as the solar circulation pump, are always hot.

Any points arising from the above should be dealt with by a competent person.


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It is essential that the thermostatic mixing valve (TMV) is lubricated / maintained regularly.

Frequency of maintenance depends upon the condition of the water passing through it.

In-service testing of the thermostatic mixing valve must be carried out at leastevery 12-months for soft water conditions. In hard water conditions the interval

may be less than 6-months. Experience of local conditions and in-service testing

record will dictate the frequency of in-service testing.

In-service testing must be carried out to check whether any deterioration hasoccurred in the performance of the TMV.

NOTE: A TMV in need of maintenance can be undetectable in normal use andonly become apparent when a disruption occurs in the hot or cold water supply

pressures or temperatures.

If a TMV does not operate properly, there is a risk of someone being scalded. Refer to the TMV manufacturers user guide (supplied with the information pack

left by the installer) for details of in-service testing and maintenance.

PRESSURE LOSSThe pressure in the system may show a slight fall after the initial period of operation. This

is normal as the aerated water gives off its dissolved gasses and the special de-aeration

valve will automatically vent the air build-up in its chamber. However, if there is a

significant drop in pressure suspect one or more of the following:

Overheating may occur during a period of hot weather if, for some reason, thepump isnt operating, and the heat transfer fluid is therefore not being circulated

(e.g. during an extended power cut, or during a period of absence, holiday etc.).

Thermal energy is not being removed from the collector so the heat transfer fluid

temperature will rise, hence heat transfer fluid volume and system pressure will

increase. This could result in the release of hot water or steam from the pressure

relief valve or the automatic air vent. When the system returns to normal

operating conditions the pressure may reduce due to the loss in fluid volume.

If heat transfer fluid is escaping from the system the volume of heat transfer fluid inthe system decreases and hence the pressure will drop if not compensated by the

expansion vessel. If there is a leak in the system it may require drain down and

repair / replacement of a faulty component.

It is unlikely that an expansion vessel will develop a fault. The vessels are normallyfactory charged to 1.5 bar and double checked prior to installation. The pressure

can be checked using a standard tyre pressure gauge after removing the black cap

on the end of the vessel. This test should only be carried out when the system is

cool and there is a danger of scalding should the vessel be faulty. Any fluid escaping

from the test valve indicates a leaking diaphragm and the vessel should be

replaced.


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EVERY 5 YEARS TEST HEAT TRANSFER FLUID (BY COMPETENT PERSON). The heat transfer fluid may be tested by placing a sample volume into a freezer

compartment and measuring the temperature at which the sample becomesslushy. This temperature must be lower than the normal low temperature

expected in the locality. A more accurate testing requires the use of a suitable

refractometer. Please contact your installer or the PERFECTHEAT

helpdesk foradvice.

Asample volume is easily taken using drain-point on the solar pump station.Remove the cap on the outlet and then crack open the valve very gently to allow

some fluid to be expelled. This sample can be mailed in a small clean screw-top

container for testing. Please ensure the surfaces near the sample point are clean

and dry and that the canister is filled to the brim and mailed without delay.

Remember to provide contact details when you send a sample for testing. Check

system pressure after the sample is taken.

Please note that except under fault conditions, the system should not needdraining down for up to 20 years. We know of one system that is still operating

after 30 years without a drain down.

1.8 Trouble shootingIf the PERFECTHEAT solar thermal system doesnt function correctly after it has been

working satisfactorily since it was commissioned:

First check that the electrical supply is ON no power cut or MCB tripped out? Check the water supply does water come out of the cold tap? Check that little fingers havent been at work changing settings and adjustments. Check all items listed under section 1.7 Maintenance above. Look on the PERFECTHEAT websitewww.perfectheat.co.uk FAQs tab for

the latest information available.

Contact your installer or the PERFECTHEAT helpdesk for advice about what todo if you discover a problem or need further help identifying a problem.


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Some interesting facts about solar energy

The suns radiation maximum radiation intensity is 1200 W/m2. Radiation energy is average

radiation intensity x time (kWh/m2). Takes into account sun position, cloud and season. Total

useable radiation energy -> global radiation and is the sum of direct and diffuse radiation.


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Documents

User Guide Final 01