Manual 01 - Section 01








Residential Solar Information Manual
Section 2 - Quality Systems and Approvals

ISO 9001 QUALITY SYSTEM

INTRODUCTION

Solahart Industries Pty Ltd has been assessed and registered by Standards Australia Quality Assurance Services Pty Limited as having the capacity to control the quality of its products and services in accordance with the requirements of ISO 9001:1995. Registration number QEC 0360 has been issued to Solahart Industries Pty Ltd covering the design, manufacture and testing of electric and solar hot water systems incorporating:

  1. Open and closed circuit solar hot water systems with storage capacities ranging from 100 to 300 litres and connected to one, two or three collector panels.

  2. Solar Gas Booster FD 15

  3. Integrated Collector System - ICS100

  4. Commercial Heat Store - 2500J system; 3500J system; 6500J system.

  5. Cardiffair - Natural Cooling System

Items 1 and 3 are supplied in accordance with the relevant Australian Standards AS 1056-1991 and AS 2712-1993. Processes accredited include design, research, metal fabrication, welding, enamelling, insulation foam injection and associated non-destructive pressure testing utilising an in-house NATA certified laboratory.




WHAT IS ISO?

ISO (the International Organisation for Standardisation) is a worldwide federation of national standards bodies (ISO member bodies). The work of preparing International Standards is normally carried out through ISO technical committees. Each member body interested in a subject for which a technical committee has been established has the right to be represented on that committee. International organisations, governmental and non-governmental, in liaison with ISO, also take part in the work. ISO collaborates closely with the International Electromechanical Commission (IEC) on all matters of electromechanical standardisation.

Draft International Standards adopted by the technical committees are circulated to the member bodies for voting. Publication as an International Standard requires approval by at least 75 % of the member bodies casting a vote.

International Standard ISO 9001 was prepared by Technical Committee ISO/TC 176, Quality management and quality assurance, Subcommittee SC 2, Quality systems.

WHAT IS ISO 9001?

This International Standard is one of three International Standards dealing with quality system requirements that can be used for external quality assurance purposes. The quality assurance models, set out in the three International Standards listed below, represent three distinctive forms of quality system requirements suitable for the purpose of a supplier demonstrating its capability, and for the assessment of the capability of a supplier by external parties.

  1. ISO9001, Quality systems - Model for quality assurance in design, development, production, installation and servicing
    - for use when conformance to specified requirements is to be assured by the supplier during design, development, production, installation and servicing.

  2. ISO9002, Quality systems - Model for quality assurance in production, installation and servicing
    - for use when conformance to specified requirements is to be assured by the supplier during production, installation and servicing.

  3. ISO9003, Quality systems - Model for quality assurance in final inspection and test
    - for use when conformance to specified requirements is to be assured by the supplier solely at final inspection and test.

It is emphasised that the quality system requirements specified in this International Standard, ISO9002 and ISO9003 are complementary (not alternative) to the technical (product) specified requirements. They specify requirements that determine what element's quality systems have to encompass, but it is not the purpose of these International Standards to enforce uniformity of quality systems. They are generic and independent of any specific industry or economic sector. The design and implementation of a quality system will be influenced by the varying needs of an organisation, its particular objectives, the products and services supplied, and the processes and specific practices employed.

It is intended that these International Standards will be adopted in their present form, but on occasions they may need to be tailored by adding or deleting certain quality system requirements for specific contractual situations. ISO9000-1 provides guidance on such tailoring as well as on selection of the appropriate quality assurance model, viz. ISO9001, ISO9002 or ISO9003.


SOLAHART QUALITY POLICY STATEMENT Our Primary Mission is:

To design, manufacture, market and support our solar heating products in Australia and other countries where market conditions are supportive of our products and marketing systems such that our position is sustainable and:

Our Leadership should support the achievement of the Primary Mission such that:

Our actions should be guided by our desire to have a sound relationship with:

Our Suppliers such that:

Our Shareholder such that:

Our Competitors such that:

Specifiers and Advocates such that:

Our Channels to Market such that:

Governments and Utilities such that:

The Community such that:

End-Users of our products such that we provide products which:

Our achievements should be measured against the following Core Success Factors:


NATA ACCREDITATION

The National Association of Testing Authorities (NATA), was originally created by the Australian Government in 1947 to provide a national laboratory accreditation system. It was the first such national system to be established and remains the world's largest and most diversified national laboratory accreditation body, serving as a model for many other countries.

Solahart attained NATA accreditation for its on-site testing facility in 1990 (Registration number 3021). The scope of registration covers the majority of tests required by the following standards:

AS 1056.1 .....1991
AS 1056.3 .....1991
AS 2712 ........1993
AS 3142 ........1994

Measurements and calibrations performed by NATA accredited laboratories are also traceable to Australia's national standards of measurements and thereby to international standards.



AUSTRALIAN STANDARD AS2712

All Solahart domestic solar hot water systems are approved to the Australian Standard AS2712 (Registration Number 1048). This standard specifies requirements for the design and construction of solar hot water supply systems, for domestic, commercial and industrial installations with a maximum storage capacity of 700 litres.

Approval to AS2712 also requires compliance to AS1056 (Storage Water Heaters) and AS3142 (Electric Water Heaters).



PRODUCT TEST REQUIREMENTS FOR AS2712 APPROVAL

PULSATION TEST

The storage tank is subjected to 250.000 pressure pulses from 0 to 700 kPa at rate of 40 per minute to test the weld strength and enamel lining adhesion. After the pulsation test the tank is inspected for external leakage then cut open and inspected for any damage to the enamel lining.

TORQUE TEST

All connection fittings on the solar hot water system are subjected to a radial torque of 34Nm to ensure connection strength.

STANDING HEAT LOSS TEST

The temperature in the storage tank is raised by the electrical booster to 75C and after a 24 hour stabilising period the power consumed by the electrical booster is monitored during a further 24 hour period whilst the ambient temperature is controlled to 20°C. The energy consumed over this 24 hour period is recorded as the standing tank heat loss. The heat loss should not be greater than the allowable heat loss specified in AS1056.1 - 1991 that is in the range of 2.8 kWh for a 160 litre storage volume to 3.8 kWh for a 315 litre storage volume.

HOT WATER DELIVERY TEST

The rated electrical hot water delivery stated on the Solahart storage tank name plate is determined by a draw off test performed in accordance with Australian Standard AS1056.1-1991. The following paragraph explains the Australian Standard test procedure used for electric storage hot water systems and is applicable to solar hot water storage tanks fitted with an electrical booster element.

The tank is filled with cold water and the electric booster element energised. After the first thermostat cycle the tank temperature is allowed to stabilise with the power available at the thermostat for 24 hours.

The hot water draw off is commenced between 20 and 30 minutes after the thermostat has opened at the set temperature. During the draw off the electric booster element is switched off and the water flow rate is maintained at a constant rate of 9-10 litres/minute for units up to 125 litres and 12-13 litres/minute for units above 125 litres in volume.

The temperature of the hot water flow is measured at intervals of 5 litres and stopped when the water temperature has reached a level that is 12°C below the temperature measured during the first 5 litres.

The quantity of water drawn before the 12°C temperature drop is the rated electrical hot water delivery.

OVER PRESSURE TEST

The storage tank is subjected to a hydrostatic over pressure test of 1,400 kPa (being twice the maximum working pressure) for a period not less than 30 minutes. Following this test the tank must not show any sign of water leakage.

OVER TEMPERATURE CUT-OUT AND PRESSURE & TEMPERATURE RELIEF VALVE TEST

This test is performed with the auxiliary booster "ON" and with the thermostat low temperature switch by-passed. The thermostat over temperature cut-out switch must operate before the Pressure & Temperature Relief Valve opens. Upon completion of this test the over temperature cut-out on the thermostat is also bypassed and the tank continues to heat until the Pressure & Temperature Relief Valve opens. The Pressure & Temperature Relief Valve must open at or below 99 °C.

VITREOUS ENAMEL SOLUBILITY

Two specimens are cut from the wall of a tank, weighed and subjected to a boiling mild alkaline solution for 24 hours. The mixture is drained after 24 hours and replaced with a fresh solution. This cycle occurs a total of six times. The specimens are then cooled, dried and weighed again to determine the enamel lost during the test. The weight loss must not exceed 0.015 mg/ mm2 of sample area.

COLLECTOR STAGNATION TEST

This test is designed to assess the ability of a solar collector to withstand temperatures close to the maximum temperatures that will be encounter during service life. Such temperatures can occur when there is little heat removal from the collector during periods of high solar radiation and high ambient temperatures.

The collector is placed into an insulated container and oil at 170C is pumped through it for a period of at least 10 days. At the end of this 10 day period there must be no structural failure, burning, heat shrinkage or degradation of performance.

COLLECTOR INSTANTANEOUS EFFICIENCY TEST

A collector instantaneous efficiency test is taken over a thirty minute period when the solar radiation and water flow through the collector is stable. The following paragraph explains the Australian Standard AS2535 test method for calculating collector instantaneous efficiency.

The collector to be tested is fitted to a sun tracking device to ensure that the collector is facing directly at the sun for the duration of the test.

When collector inlet temperature is at 80°C six readings of collector output temperature, water flow rate, solar radiation and wind speed are taken over a one minute period. This information is fed into a computer that will calculate the collector efficiency at that particular moment. The readings are then repeated 4 minutes later, should the difference in data calculated from the first and the second batch of measurements be greater than 2% the test is rejected and conducted again.

The collector inlet temperature is lowered to preset points (usually 10°C intervals) and tests repeated to provide collector instantaneous efficiency ratings at the various inlet temperatures. From this information the collector instantaneous efficiency curves are drawn.

The Solahart collector instantaneous efficiency curves are included in the section "Product Performance"

COLLECTOR WATER INGRESS TEST

The collector is weighed and placed on a purpose-built test rig with 6 water spray nozzles and sprayed for 10 minutes through water jet nozzles with a water supply pressure of 300 kPa. After a 10 minute standing period the collector is covered with an opaque cover for 4 hours. At the completion of the 4 hour stabilisation period the drain holes are blocked and the collector weighed to determine if there is an increase in weight. The collector must not gain any weight during the test period.

HAIL RESISTANCE TEST

The hail resistance test is performed by dropping a 25.4 mm steel ball from a height of 2.9 metres on to the glass surface of the collector. This impact test is performed on 4 points of the collector 150 mm from the corner edges. The collector glass must not shatter during the test.


SUMMARY OF APPROVALS

      TYPE OF APPROVAL             APPROVAL. AUTHORITY         APPR. No.      DATE OF ISSUE

Gas booster FD15 and FD15-12     Australian Gas Association       4766         06-12-1991

Cyclone frame approval           Dept. of Lands, Housing         M/507/1       17-08-1994
                                 Darwin NT.

Electrical approval solar        Office of Energy West            W2281        20-01-1995
storage tanks                    Australia  

Australian solar systems         Australian Standards             1048         01-05-1995  
approval AS2712                                                                           

Product approval Germany to      TÜV BAYERN SACHSEN            02-228-515      13-04-1993  
TRD509                                                                                     

Product approval Spain           ATISAE    
Valencia                                        

Product approval Austria         BT                            319/1112-463    30-03-1990  

Product approval USA to OG300    SRCC   Washington DC                          181K/ Jan. 1986
                                                                               302L/ Dec. 1993
                                                                               303L/ Dec. 1993
                                                                               302J/ Oct. 1984
                                                                               302K/ Oct. 1983
                                                                               303K/ Dec. 1993

Plumbing authority approval      IAPMO 
USA

Product/ manufacturing           JIS                             AU8501        10-05-1994  
approval Japan

Appraisal certificate New        BTL(BRANZ)                        287         July 1988   

Performance test  Holland        TNO                               N/A         02-11-1993