Manual 02 - Section 08







Non-Residential Solar Information Manual
SECTION 8: Commissioning

When commissioning the Solahart Non Residential Solar Hot Water System it is essential to pressure test the Heat Store and the Collector array separately.

8.1 THE POTABLE WATER CIRCUIT

Fill the potable circuit via the cold potable water inlet connection. Ease the lever of the cold water pressure relief valve to expel all the air from within the potable water storage vessels during the filling operation.

When full operational pressure is reached ensure that all connections on the potable circuit are free of leaks. The potable water circuit must be full and pressurised before any other tests are conducted.

8.2 THE CLOSED CIRCUIT

Connect a hose with an appropriate 20 mm fitting to the fill/drain valve, located at the bottom right hand side of the Heat Store. This connection should also be fitted with a temporary 20 mm isolation ball valve as a precautionary measure and for convenience of filling.

AT NO STAGE IN THE FILLING OF THE CLOSED CIRCUIT SHOULD MAINS PRESSURE BE APPLIED TO THE HEAT STORE CLOSED CIRCUIT SYSTEM.

TO PREVENT ANY PRESSURE GREATER THAN 90 kPa BEING APPLIED TO THE HEAT STORE THE FOLLOWING PROCEDURE SHOULD BE USED:

CAUTION IS ESSENTIAL AS THE HEAT STORE IS NOW READY FOR PRESSURISATION.

LEAVE THE HEAT STORE AT 90 kPa PRESSURE FOR AT LEAST 60 MINUTES.

This is the operating level of the closed circuit fluid.

8.3 COLLECTOR ARRAY

For best results, the pressure test of the collector array is conducted late in the evening when there is little solar radiation and the collector array can be under pressure overnight.

Strict adherence to the following steps will ensure a successful pressure test as accomplished.

INSPECT EVERY CONNECTION OF THE COLLECTOR ARRAY AND ALL PIPE WORK TO AND FROM THE ARRAY FOR LEAKS.

SHOULD A LEAK BE OBSERVED RELEASE THE PRESSURE IN THE COLLECTOR ARRAY BY LIFTING THE EASING GEAR ON THE 350 kPa PRESSURE RELIEF VALVE

ATTEND TO ANY LEAK AND REPEAT THE PRESSURE TEST UNTIL THE PRESSURE IN THE COLLECTOR ARRAY IS STEADY AT 350 kPa.

LEAVE THE COLLECTOR ARRAY UNDER PRESSURE OVERNIGHT.

INSPECT THE COLLECTOR ARRAY EARLY THE FOLLOWING MORNING BEFORE ANY SOLAR RADIATION REACHES THE COLLECTORS.

Note: It is normal for the collector array pressure to drop slightly overnight dependant upon the change in ambient temperature. A 5% reduction in pressure is possible.

REPEAT THE LEAK INSPECTION AND RECTIFY AS DESCRIBED PREVIOUSLY.

LEAVE THE FILL LEVEL VALVE OPEN UNTIL COMMISSIONING IS COMPLETED

8.4 TESTING THE SOLAR CIRCUIT.

The potable circuit and the closed circuit of the Heat Store are at ambient condition and the system is now ready for simulation and testing.

If there is sufficient solar radiation, the hot sensor will measure a higher temperature than the cold sensor, indicating that there is energy to be collected. The temperature differential thermostat will switch the closed circuit circulating pump ON. The differential between the hot sensor and the cold sensor must be greater than 90 C.

In order to establish full flow through the collector array, each bank of the collector array must be balanced. This is accomplished as follows:

If the temperature rise is not uniform across all the banks of collectors, it indicates that the flow is not uniform. A uniform flow across the banks can be achieved by adjusting the 20 mm isolation ball valves as follows:

For example, in a collector array of 32 collectors installed in 4 banks of 8 collectors, the following temperatures were recorded.

Bank 1 Bank 2

60º C 54º C

46º C 45º C

Bank 3 Bank 4

60º C 56º C

45º C 46º C

(Bank 1 = 14º C) (Bank 2 = 9º C) (Bank 3 = 15º C) (Bank 4 = 10º C)

(Bank 1 = 13º C) (Bank 2 = 11º C) (Bank 3 = 13º C) (Bank 4 = 11º C)

8.5 ELECTRIC BOOSTED SYSTEMS

8.6 OFF - PEAK ELECTRIC BOOSTED SYSTEMS

8.7 GAS BOOSTED SYSTEMS: (TYPE 1)

8.8 GAS BOOSTED SYSTEMS: (TYPE 2)

8.9 COMBINED ELECTRIC AND GAS BOOSTED SYSTEMS

These systems are normally designed with two configurations.

1) To operate with one energy source at a time depending on which source is available.

2) To operate on Solar energy and Gas Boost at the same time.

Both configurations are fitted with an override switch to operate on electric boost should it become necessary.

8.10 DOSING THE CLOSED CIRCUIT WITH DI POTASSIUM.

The required quantity of di potassium mono hydrogen phosphate is supplied with each Heat Store. This chemical is a food grade quality, harmless additive which readily dissolves in water.

Raise the container to a level higher than the Heat Store and siphon the liquid through the fill/drain valve. Repeat this until all the di potassium mono hydrogen phosphate supplied, is added to the Heat Store closed circuit reservoir.

8.11 INTRODUCING THE NITROGEN BLANKET.

SWITCH THE SELECTOR SWITCH TO "AUTO" AND ALLOW THE SYSTEM TO OPERATE.