®

PERFECTHEAT
Solar Thermal Systems

User Guide
1st Edition : October 2008

for systems with the

PERFECTHEAT ® heat exchanger
and turbo boost function

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Introduction

Your PERFECTHEAT® Solar 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 the PERFECTHEAT® 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 PERFECTHEAT® Solar 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 PERFECTHEAT® Solar 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 PERFECTHEAT ® Solar 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 PERFECTHEAT ® Solar
Thermal System will do.

Contents

1.1 Town and country planning Page

1.2 Introduction to the PERFECTHEAT® Solar Thermal System Page
1.3 Normal operation Page
1.4 The PERFECTHEAT® turbo boost function Page
1.5 The mini-digital thermometer Page
1.6 The thermostatic mixing valve Page
1.7 Maintenance Page
1.8 Trouble shooting Page

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1.1 Town and Country Planning

Your PERFECTHEAT ® Solar 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 development
A. 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 permitted

A.1. Development is not permitted by Class A, in the case of solar PV or solar thermal
equipment 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 and
would 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.

Conditions
A.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 development
B. The installation, alteration or replacement of standalone solar within the curtilage of a
dwelling house.
Development not permitted

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 B.1. Development is not permitted by Class B if:
(a) there would be more than one stand alone solar within the curtilage; or
(b) any part of the stand alone solar:
(i) would exceed four metres in height above ground level;
(ii) would, in the case of land within a conservation area or which is a World Heritage Site,
be situated within any part of the curtilage of the dwelling house and would be visible from
the highway;
(iii) would be situated within five metres of the boundary of the curtilage;
(iv) would be situated within the curtilage of a listed building; or
(c) the surface area of the solar panels forming part of the stand alone solar would exceed
nine square metres or any dimension of its array (including any housing) would exceed
three metres.

Conditions
B.2. Development is permitted by Class B subject to the following conditions—
(a) stand alone solar shall, so far as practicable, be sited so as to minimise its effect on the
amenity of the area; and
(b) stand alone solar which is no longer needed for microgeneration shall be removed as
soon as reasonably practicable.

1.2 Introduction to the PERFECTHEAT® solar thermal system

The PERFECTHEAT® solar thermal system works in a different way to conventional solar
hot water systems. The PERFECTHEAT® solar heat exchanger will deliver solar heated
water directly to the top of the hot water cylinder where it stratifies ready for use at
useable temperatures. Hot water will start to accumulate at the top of the hot water
cylinder within minutes of the sun starting to shine strongly. Background solar radiation
during daylight hours on even overcast days will produce a constant and prolonged heating
effect.

Independent testing at the Centre for Sustainable Technologies of the Ulster University
School for the Built Environment shows that the PERFECTHEAT® solar thermal system
consistently outperformed existing twin coil solar technology across a range of tests.

Conventional Indirect Hot Water Cylinder

The hot water from the boiler is pumped through

the coil at the bottom of the cylinder.

Water in the cylinder starts to heat up from the

bottom and gradually (some hours later) water at
the top of the cylinder is hot enough to use.

PERFECTHEAT® solar thermal system

The hot water produced in the heat exchanger

(shown as the green item in the diagram) becomes
so hot that it causes a thermosyphonic circulation
to start. This means that hot water is pushed into
the top of the hot water cylinder and cold water is
taken from the bottom of the cylinder. You start to
get hot water build up within minutes and usable
quantities very quickly afterwards.

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1.3 Normal operation

The 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 6°C ~ 8°C) 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 the
HW 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 doesn’t 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 function

The 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 PERFECTHEAT® turbo 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 the
indicator 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 automatically switch
the auxiliary heater OFF after the set time
so that you don’t have to remember to!
TIP – Remember that you’re 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
necessary.

The turbo boost will not operate if the PERFECTHEAT® solar thermal system is producing
solar 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 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 30°C.

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)
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 43°C for
safety but can be adjusted as required to warmer or
cooler 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.

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 temperatures
than 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 Maintenance

Little 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 isn’t 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.

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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 fitted
with 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 at
least 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’ are
normal. 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 least
every 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 has
occurred in the performance of the TMV.

• NOTE: A TMV in need of maintenance can be undetectable in normal use and

only 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 manufacturer’s user guide (supplied with the information pack
left by the installer) for details of in-service testing and maintenance.

PRESSURE LOSS

The 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, the
pump isn’t 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 in
the 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 normally
factory 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 becomes
‘slushy’. 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 for
advice.

• A sample 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 need
draining 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 shooting

If the PERFECTHEAT® solar thermal system doesn’t 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’ haven’t been at work changing settings and adjustments.

• Check all items listed under section 1.7 Maintenance above.

• Look on the PERFECTHEAT® website www.perfectheat.co.uk – FAQ’s tab for

the latest information available.

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

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 Some interesting facts about solar energy

The sun’s 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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