Solar Water Heating - Corrosion and Performance Issues in New Zealand

Here are some quick links to help you find your way around Rusty Panels

2010-10-22T18:29:00.001+13:00

Yes, I am doing the occasional update. Because of the minimal input, things are not laid out as slick as they could be, so here are a few quick links to help you find your way around:

Gary Moller's experience with rusting, corroding, fading solar water heating panels

2008-11-12T22:31:00.000+13:00

This Sola60 panel (above) on our house looks impressive doesn't it? This is saving our family money on water heating and it is great for the environment. We are responsible citizens in this clean and green land. That was what we thought.

We noticed a steady drop off of peak water temperatures over a one year period, so I decided to investigate.

Here is another view:

There is extensive corrosion of the collector's absorber surfaces of this year old panel and what appears to be bleaching so that the surface looks grey-blue.

Here are the replacement panels that were supplied to us under warranty:

They are very smart looking. Now, here they are after a year:

These panels are bleached and have extensive corrosion (looks like sprinkled talcum powder) of the collector surface. And they now look kind of grey-blue which is not the best colour for absorbing solar heat.

Thankfully, they were replaced under warranty.

Here are the replacement ones seven months after being installed. Look carefully:

They are corroding again and we currently (30/11/2206) have a request with Sola60 to remove the system entirely from our roof because the warranty has not long to run and plenty of failed attempts have been had at resolving the problem. They were removed 24 January 2007.

Is there a problem?

The first clue that something may be amiss comes from the Branz report of Research Commissions:

"BRANZ Ltd identified that one of the biggest uncertainties in the cost/benefit analysis of solar water heating systems is the lack of reliable field data for system performances. Anecdotal evidence suggests that most existing systems fall significantly short of the calculated values used during the system design."

Could this shortfall be due to corrosion of the collectors?

How big is the problem? This is the question that I set out to answer by spending a few weeks trying to locate solar water heating systems in Central and South Wellington. This was not an easy exercise. I found several (Ours included).

An example of a Beasley Centurion 315 (From Reid Technology) Installed May 2006

2007-09-06T17:18:00.000+12:00

"A" writes:
I photographed this on 01/04/2006 in mid morning as I was hauling the first panel up to the roof. It was new out of its cardboard box. The shadow on it is from the lines and pegs on the clothes dryer behind the camera. Note the orange cord. It was a loop across the protruding pipe ends at the top end. The loop provided an attachment for the hauling line which passed through a pulley which itself was slung on a cord looped around an access hatch on the roof. I was concerned that by applying strain to the pipe end I could have damaged the internal structure; it was your web site information that relieved me of this doubt. You can just see the pipes inside.

This is how it looked yesterday afternoon 25/08/2007. Comparing the two pics, the same digital camera and settings were used, there is a difference in colour. The earlier one was strong deep blue, this is middling strong brown. The angle to the horizontal is nearly the same and the time is roughly four hours later. The glass looks less opaque. The sun has traveled further west. I couldn’t see the ribs in the panel in 2006 as clearly as I can now. Allowing for small differences it looks as though there has been a change in the internal conditions in the panel.

Note from Gary: the left hand panel may be more affected because the frost protection function may be reducing the amount of condensation in the right panel more than the other.

Is that down to damp affecting the flexible mask overlying the pipes? I say flexible because after contacting the supplier he said that there are four holes on the underside, so I explored with a piece of stiff wire and poked it up and felt and saw the overlay material deflected up toward the glass. I did that to prove that there was a hole and that there was nothing blocking it. Before I drilled the half inch hole in the lower edge and corner to drain contained water, I went through a week or more of doubt. Would I penetrate the pipe work? Would I damage the glass?

It took sheer determination to first drill a 1/16 hole as a leader followed by the half inch bit. Then I realised that the 20mm dia pipe inside allowed a fair bit of space around it above and below, probably 25mm top and bottom. Then I drilled a half inch hole top side just under the glass. That way I realised that I could suck saturated air out and replace it with dry air through the top hole.

Code of Practice for manufacture and installation of solar water heating systems in New Zealand

2007-09-06T16:16:00.000+12:00

Code of Practice for Manufacture and Installation of Solar Water Heating Systems in New Zealand
Version: 1 October 2004 (Revision 3)
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Here are some key extracts from this document that are relevant to the issues raised on this website:

Photo: Beasley Centurion 315 (From Reid Technology) Installed May 2006. Note condensation inside glass.

4.6 COLLECTOR CONSTRUCTION:
Requirements:
The collector shall be made from materials which in their application to the collector shall meet with the requirements of the New Zealand Building Code Approved Document B2.

Materials exposed to the weather shall be capable of withstanding the commonly encountered conditions such as solar radiation at the intensities normally encountered at the installation site, maximum and minimum temperatures at the installation site, and rain. The collectors shall
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Page 20
16
withstand snow loadings likely to be encountered. Collectors shall be capable of withstanding impact by hail up to the sizes commonly encountered at the installation site.

Collector insulation shall not absorb moisture.

Materials of construction of the collector (including the absorber) shall not degrade under the
conditions met in normal operation. Nor should they become damaged or degraded under repeated stagnation.

For direct collectors, components of the absorber which come in contact with potable water
shall comply with the requirements of the NZ Building Code, Approved Document G12 and of AS/NZS 4020.

Collectors shall be constructed to meet the requirements of Section 4 of AS/NZS 2712.
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Gary Moller comments:
There are numerous examples of solar water heating systems on this website that do comply with AS/NZS 2712. It is time for a rewrite of the Standard and there should be a product recall.

Nats claim solar power subsidy 'has backfired'

2007-08-17T17:50:00.000+12:00

Nats claim solar power subsidy 'has backfired' 5:00AM Tuesday August 14, 2007
Changes to the solar water heating initiative have backfired, causing the first decline in the number of new installations in years, National's climate change spokesman Nick Smith said yesterday.Last November the Government announced a $15.5 million climate change initiative that included an increase from $300 to $500 in financial assistance to homeowners for loans.

Government spokeswoman Greens co-leader Jeanette Fitzsimons said the goal was to double the number of systems being installed.Figures from the New Zealand Solar Industries Association show that in the first six months of this year installations were down 5 per cent on the previous year.At June 2006, 2017 installations had been done, in comparison by June 2007 only 1923 had been completed. This compares with an average annual growth of 37 per cent before the Government announcement in November.

Dr Smith said the policy had backfired because Ms Fitzsimons believed she could regulate down the price of the solar water heater systems, when it was best left to the competitive market.

"A further problem is that the Government's new Building Act is adding hundreds of dollars in costs to solar heating systems by requiring building consents, when it would be far less costly to regulate standards through accredited installers," Dr Smith said.

Ms Fitzsimons said she did not think the pricing arrangement for solar systems was unreasonable."It has to be sold at a price which means it will pay for itself over its 20-year life," she said on TV3. "I don't want consumers to be conned into buying solar water heating that isn't cost effective for them."- NZPA
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Gary Moller comments:
I wonder when the politicians are going to acknowledge the real reasons why there have been no sign-ups. It is because the New Zealand public is not stupid and NZ is such a small place that the word gets around very quickly. The internet helps and when it comes to the internet, the average Kiwi is savvy. The drop in sales coincides with the launch of this website in December 2007.

A "20 year life" is highly assumptive to the point of being ridiculous. I have yet to find a solar water heating system that is lasting anywhere near that kind of time without showing significant signs of deterioration. 5-6 years would be more like it (For evidence, browse the dozens of posts on this website using the "labels" tab in the right hand column).

If there is to be a 20 year lifespan, or near to that, then we must place the emphasis on quality rather than price. I do not believe that it is possible to make cheaper solar water heating systems without the serious risk of compromising performance and durability.

A solution to the problem of cost-effectiveness, in the face of the need to improve quality, is to increase the price of oil and electricity - but what politician is going to recommend that!

Smith seeks handouts for non cost-effective products

2007-08-17T16:25:00.000+12:00

Press release: Jeanette Fitzsimons (Govt Spokesperson: Energy Efficiency)14th August 2007

Nick Smith’s proposal that the Government should subsidise solar water heaters that are not cost-effective for customers is astonishing, Government Spokesperson for Energy Efficiency Jeanette Fitzsimons says.

“This is the party that wants low taxes and reduced government spending. Yet Dr. Smith wants to use taxpayers’ money to give grants to solar water heaters that are sold at a price so high that the energy savings will never pay back the initial price,” Ms Fitzsimons says.

“The solar water heating programme agreed between the Government and the Green Party, has focussed so far on improving the quality of products and installations. This package includes: a new quality standard ; performance modelling to establish energy savings ; training courses for installers and an information website for consumers that shows which systems have passed their tests, and the price at which they will be cost effective.

“We are totally committed to ensuring the consumer gets quality and value for money when they choose to invest in solar heating,” Ms Fitzsimons says.

“The new grants for volume builders, announced just a month ago, are already bearing fruit.

“Builders are teaming up with solar suppliers, and the first grant for a group of at least 20 homes has been signed off. The informal advice is that builders are putting together proposals for a further 1,300 systems.” Ms Fitzsimons says.

Ms Fitzsimons is confident that the temporary reduction in sales cited by Dr Smith is a short term effect while the solar industry gets its systems tested and modelled, and more installers are trained.

“In the short term, I expect that most grants will go into groups of new homes,” Ms Fitzsimons says.

“In the longer term, with a number of new entrants waiting to enter the market,. I expect retrofit installation to resume. And they will be high quality products and high quality installations - at a price that is cost effective for the householder and for the country,” Ms Fitzsimons says.
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Gary Moller comments:
This is probably as close as we are ever going to get in the way of an admission that there are serious quality issues to do with solar water heating systems.

While I have no doubt that the industry will eventually get its house in order, I still ask the question:

"What is Ms Fitzsimons and the others who have been actively encouraging the installation of these devices on rooftops, going to do to help the many thousands of families and small businesses who are lumbered with installation and performance problems?"

Why should they be left out in the cold to carry the inconvenience and costs of the mistakes and sloppy work of others who profited off them in the process?

Ms Fitzsimons has known for a long time that there were serious problems. I know because I told her so last year and she ignored the warnings. She went ahead and encouraged us to install products that may actually be damaging to the environment (Energy intense to produce, costly landfill material when dumped).

Further, how can a responsible environmentalist continue to encourage the installation of these devices when there is absolutely no evidence that the products of today are any better than those of yesterday? The NZ standard that Ms Ftizsimons places so much faith in for saving her scheme does not in any way address the quality issues that are profusely documented on this website. The Emperor has no clothes.

I would hope that the solar water heating systems that are being installed under the Government's grant scheme come with proof that they will last 20 years as the Government would have us all believe.

At the least, there should be some kind of product recall of the thousands of faulty systems known to already be out there.

Finally, I do tend to agree with her about Nick Smith. But both of them are skirting about the main issues - conveniently avoiding the inconvenient truth.

Zero subscribers to govt solar power scheme TV3 News

2007-08-14T12:51:00.000+12:00

A government scheme aimed getting more New Zealand home owners to use the sun to heat their waters has failed to attract a single taker.

$15 million was set aside last year to subsidise home solar panels – but no home-owners have taken the offer up.

Here is the link TV3 News video, including a cameo by Yours Truly!
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Gary Moller comments:
Again I take issue with statements by Janette Fitzsimmons. For a solar water heating system to be able to last more than a few years - let alone 20 - then the price paid has to be a factor. Solar panels are placed in the most exposed places - atop roofing, exposed to howling gales, salt-laden water, frost and baking heat - and intense UV in New Zealand.

I have heard this time and again from people within the solar industry that the only way the price will come down is by skimping on the quality of the materials. To date, the evidence of the New Zealand situation is that there are few solar water heating systems that are of a quality of materials and installation that will last more than a few years without showing signs of significant deterioration (This website is bountiful with examples and reports of the current shortfalls).

Incidentally, the Chromagen system that featured in the TV3 news item is quite expensive to purchase; but on close inspection, the quality of construction and attention to detail is obvious. Although it is still early days, no Chromagen units have yet been found with faults or signs of deterioration.

Go solar: But shop around and be prepared to pay more in order to get the quality necessary to get years of trouble-free performance.

Our family is reinstaling a new solar water heating system

2007-08-13T16:45:00.000+12:00

Despite our previous negative experiences with solar water heating, our family is about to install a new solar water heating system on our house. More about this soon.

Far from being negative about the future of solar water heating in New Zealand, I am all for solar water heating. I believe that every NZ house with a sunny disposition should be employing solar energy capture systems like solar water heaters to reduce expenditure on household energy while improving quality of living.

Having said this, there is nothing to be gained and much to be lost if householders install poor quality systems that do not go the distance. Even a quality system will not perform or last if the workmanship of the installation is poor. There are good systems and quality installers out there; It is just a matter of doing your research carefully and selecting the best system for your requirements.

Please peruse this website using the search functions to in the right hand column to find your way. I strongly recommend that you take time to read the BRANZ reports that are on this website and read the responses on this website.

It is clear that pressuring the industry to bring down prices has been counter-productive. Low cost items simply may not be of a quality sufficient to withstand half a dozen years of being battered, soaked, frozen and roasted in the typical NZ roof setting - let alone durable enough to keep working for 20 years!

Energy conservation in the home is a multi-factorial exercise, since it is total energy consumption that is the key to reducing a family's energy costs - and saving the planet - of course!

As part of our family's programme to reduce our carbon footprint, we have amped up the insulation of our house by filling the internal cavities of the walls of our old house with foam insulation. For more information about this energy conservation measure, go here. However; in recommending this energy conservation measure, our family does not recommend this firm. They were very good on the sales pitch, but very poor on the after sales handling of us. Why do so many NZ companies keep letting themselves down on their customer service?

Janette Fitzsimons launches Government Scheme

2007-07-31T16:23:00.000+12:00

"Some of you may be aware of concerns raised in the media recently about discolouration of solar heating panels from two suppliers.

This appears to be a fairly limited issue, but we are taking it seriously because it is important that consumer confidence in solar water heating is not undermined. We are advised by those two firms that there is no problem now with performance, but we have not had all the information that homeowners need from these suppliers to reassure them about the quality and longevity of those systems. At this point they are not participating in the Government solar water heating programme.

To provide further information for consumers on this issue, EECA expects to undertake independent testing of some discoloured solar panels to determine any impact on energy performance, and longevity.

My two key objectives in this programme are quality assurance and cost-effectiveness. We have taken a number of steps over the last year to improve these outcomes for consumers: there are now training courses available for solar installation at most polytechs, there is an NZ/Australian standard and we are performance modeling systems to be able to advise consumers how much energy they will save under standard conditions. Our new website provides a one stop shop for home owners wanting to know whether solar is right for their home and how to go about deciding what sort. It lists all suppliers who have been through the performance modeling process and qualify for the grants.

I believe we are on the way to ensuring a sustainable, larger scale solar water heating industry and well informed building professionals and home owners."

Excerpt from the Speech by Janette Fitzsimons at Launch of Solar Water Heating Volume Build Scheme, Parliament Buildings, 25/07/2007
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Gary Moller comments:
First of all, I do not think Janette is being entirely sincere when she says that the problem is a "fairly limited issue". I am sure she has read the Branz reports and she sure should be aware of this website (rustypanels) because I have been letting her office know about it.

I think it has been just a tad unfair as well and misleading to have singled out two players in the industry and to also do so without mentioning names because this reflects poorly on the ones out there that are doing OK. It would appear that the problems referred to, including poor installation as documented in the Branz reports (copies available for viewing on this website here) are widespread and not just limited to two operators. Why pick on just two?

Her comments conveniently avoid the issue of what is to be done, if anything for the thousands of New Zealand families and businesses who are now facing ongoing performance problems and costs with their solar water heating systems that they installed with the encouragement of the Green Party. So far, there have been no answers forthcoming. The good New Zealanders (including me) who voted her in have been left out in the cold.

While it is encouraging to learn that there will be some proper performance testing done, the results will be several months away. The question must be asked: "Where is the evidence that the solar water heating systems being installed between now and then are any better than the ones of yesterday?" There is none. Should the Government be spending public money on a technology that has yet to prove its durability? Is it not misleading the public?

Note: To be fair and responsible; responses by all to these articles are welcomed and will be published.

The rusty panels keep coming in!

2007-07-31T12:53:00.001+12:00

These photos are of a six year old Solahart. What can be seen is extensive areas of dirty white and considerable moisture buildup under the glass.

This is typical of the pattern seen across the board with flat panel solar water heating systems.

The family that owns this lives on an isolated island without mains electricity. Repairs and replacement are not as simple as calling in a tradesman. Fortunately, they have a wetback backup for water heating. They estimate that performance is at least 50% less than when it was new.

Sadly, there appears little or no political, bureaucratic, consumer organisation or industry motivation to draw these problems to public attention.

Sadly, there seems no motivation at all for any kind of product recall. It appears the thousands of affected New Zealand families and businesses are being left out in the cold to deal with these problems on their own.

Sadly, there is yet to be any evidence whatsoever that the replacement panels of today are any better than those of yesterday.

On a positive note: Our family is soon going to reinvest in solar water heating. We are and have always been committed to energy conservation measures. But these have to be measures that really do work in a way that they really do return much more energy into the "system" than they consume in their production from raw material to product.

Why even small amounts of corrosion, rusting, fading or bleaching may seriously affect the performance of solar water heating panels

2007-07-20T17:40:00.000+12:00

This video explains why even slight corrosion, bleaching, discolouration or fading of the collector surfaces of a solar water heating system may cause significant and unacceptable losses in performance.

Rusty Solar Water Heating Panels found in Austria

2007-07-18T09:13:00.000+12:00

Here are some photos from Austria. No details given about the age or brand.

This is further evidence that there is a widespread issue that is bigger than New Zealand or Australia.

More about the Building Consent and Certificate of Acceptance for Solar Water Heating Installations

2007-07-17T11:23:00.000+12:00

"Gary .....

Under the Building Act 1991 & 2004 Territorial Authorities and Councils are not and were not permitted to issue retrospective consents, in those days the work was classed as safe and sanitary (1991 Act)

Under the 2004 Act the same applies but no longer can Safe & Sanitary inspections be done, hence the introduction of The Certificate of Acceptance which is for Building work carried out without a building consent and is issued for the work that can be inspected and complies with the NZ building Code only and in no form is a Retrospective consent and never will be".

Rob.
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Gary Moller comments:
When reading the advice and information on this website, please bear this advice from Ron in mind. I will be progressively altering any terminology and details but this will take time.

If you suspect a possible warranty problem with your solar water heating system

2007-07-17T09:07:00.000+12:00

"Hi Gary

I was up on the roof yesterday inspecting my one year old Solarhart system.
I was less than impressed with what I saw, a lot of corrosion or discoloration appearing on the black panels.
Considering this has only been on the roof for a year I hate to think what it will be like after five when the warranty runs out.
Who do I contact in the first instance, XXXX Plumbing did the installation but I don’t expect they cover the warranty.
Any advice would be appreciated.
Regards"
"T"
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Gary Moller comments:
This is a typical letter that I receive daily and am sometimes unable to reply to because of work commitments, so I thought I would publish it as an article to guide others.

Read the safety information on this site before clambering up on the roof.

Consider hiring an expert to do the assessment
I am compiling a list of impartial experts which you can find on this site.

The first action is to take digital photos of the detail of the panel surfaces. This may be very important for warranty claims. Even if any discoloration is slight at present, the photos become a record for comparison of further deterioration later on.
Inspect every aspect of your installation, including lagging, the way the system is secured and the materials used. Take photos. Please refer to the BRANZ reports on this website that list the many installation faults to look for.
Check the papers that the installer gave you to confirm the warranty term.
Confirm that there is a Building Consent for the work (An estimated 80% of installations since 2003 do not have this requirement)

If you don't have a Consent, ring your house insurer and check what your insurance exposure might be.

Check with your Council what is involved with getting one if you don't have one, including all of the costs.

Write to whoever did the installation, including copied of all the information gathered and state clearly what you want to happen. This should include:

Replacement of any faulty/damaged parts and rectification of poor workmanship
Keep a paper trail record and limit any dealings over the phone - keep it in writing in case you end up in dispute over anything.

If the installer refuses to address your concerns, or has done something to avoid liability like changing company ownership, write to their professional body such as the

Solar Industries Association
Plumbers Guild and so on

If your installer did not obtain a Building Consent on your behalf and the installation was after 2003, then you should advise the installer's professional association.

Complain to your local Building Inspector and ask their advice about what to do.

When seeking redress from the installer you should not have to pay for anything. The professional who you relied upon to do a professional job should pay.
Where it is a warranty replacement such as a corroding panel, require an extension on the warranty covering the part replaced, since there is no guarantee that the same problem will not recur.
If you are dissatisfied with progress or outcomes, take the matter up with the national distributor of the system that you have. If you remain dissatisfied:

Take the matter up with the Solar Industries Association
Write to EECA
Write to the Consumer's Institute
Write to the "Nailed" Consumer TV programme
Write to Fair Go Consumer TV programme
As a last resort I recommend taking the matter to a Disputes Tribunal

If it looks like things are not working out at any stage, please consider hiring an independent expert to inspect your solar water heating system and provide a report. Keep receipts and seek eventual reimbursement of all costs from the installer.

Advise the installer beforehand that you intend doing this and give them several days to respond before proceeding.

Finally, make sure that you send me a brief history of your situation along with photos and I might publish them (anonymously) for the benefit of others who may be facing similar issues.

A six year old Solahart that has changed colour

2007-07-13T22:35:00.000+12:00

Let's have a look at a six year old Solahart panel (This system is owned by a young family):

Here's another angle, because it can be very hard to see what is beneath patternised glass:

As one installer jokingly said to me; "White is not a very good colour for solar panels".

The Government, the Green Party and environmental groups like Greenpeace are urging householders to be responsible and "invest" in solar water heating. A 15 million dollar Government campaign has been announced that will encourage approximately 15,000 to 20,000 extra systems to be installed by 2010. This could be a lot of landfill material if my experience proves to be the rule and not the exception.

"But surely these systems have improved over the last five years?" You respond.

You could be right; but I will counter this immediately by pointing out that the three different solar panel models that we have had on our roof are all less than five years old from today.

A very rusty Sola60 solar water heating panel

2007-07-13T22:34:00.000+12:00

Here is a selection of photos of some of the panels which the owners allowed me to inspect, and which I was able to get up close to without risking breaking my neck:

Look at this Sola60 panel: Just two and a half years old, with visibly faded strips and corroded in places. No building consent.

Will this panel last five years; let alone 10-15? Look closer:

More examples of wet and corroding Solahart sloar water heating panels

2007-07-13T22:25:00.000+12:00

Here are two photos of a Solahart installation that has significant visible deterioration to both collector surfaces. Again, please note the date on the photos (31/03/2007)

Solahart and Sola60 feature prominently. This is only because I have not found many other brands. My findings are not necessarily representative of the industry.

If you have an example of a good or bad solar water heating setup, then write to me here. Please include digital photos and contact details to verify the details.

Another example of something wrong with a Sola60 solar water heater

2007-07-13T22:24:00.001+12:00

Here is another Sola 60 installation that shows deterioration of the collector surfaces (Please note the dates of the photos (31/03/2007)

An example of condensation and corrosion in a Solahart solar water heater

2007-07-13T22:22:00.000+12:00

What might be the mechanism that causes some of these examples of "discoloration"? The next two photos of a two year old Solahart give an indication of one of the factors: condensation

Three Sola60 solar water heating panels 2.5 years old

2007-07-13T22:21:00.000+12:00

This 2.5 year old array of Sola60 panels appears to be barely working, despite the cloudless day (Refer next three photos):

More corroding Sola60 solar water heating panels

2007-07-13T22:20:00.001+12:00

When was the last time you looked closely?
The first two photos are of a Sola 60 installation which shows visible "discoloration" of the collector surface.

A really good exsample of why solar panels must be designed for servicing

2007-07-13T22:17:00.000+12:00

These panels are of unknown make and are from 10-15 yrs old. It has heavily corroded copper surfaces and you can see the leaking hot water from the pipe in the 3rd photo, leaking several liters of hot water per hour (Bottom right of picture) and probably for more than a few years. You will also note the absence of any lagging on the pipes.

Points: - Fortunately, this is of a thick copper design. It can presumably be stripped, cleaned and restored to as good as new.
- Where different metals meet (Such as galvanised steel fittings on copper pipe), corrosion is inevitable.

- No air vents to allow moisture to escape, so this needs to be recitfied and the glazing seals replaced.

These panels show that it may be misleading to give the impression that any solar panels can be "set and forget" other than needing the occasional wash. Few structures can be expected to last 20 years exposed on a rooftop for 20 years without requiring a decent service now and then. Design should be such that panels can be conveniently dismantled and serviced as required.

What is also shown here is the corrosion that is likely to occur when different metals are in contact, setting up galvanic corrosion. This includes metal on metal contact with a metal roof as well as differing plumbing fittings. Once started, the only practical remedy is full replacement of the corroding parts.

Solar tubes - are they really that good?

2007-07-13T22:16:00.000+12:00

Solar tubes, mostly imported from China look promising; but can anybody show evidence that these will last when subjected to years of NZ climatic conditions?

A two year old Solahart with corrosion and no building consent

2007-07-13T22:15:00.001+12:00

Here is a two year old Solarhart installation.

No building consent.

A lovingly installed and maintained Thermocell

2007-07-13T22:13:00.000+12:00

This Thermocell installation was promising with just the slightest hint of corrosion of one small part of the collector surfaces; but being only two years old, no judgement can be made as to durability. Can anybody provide evidence that this make will last the distance better than others?

No building consent; but installed by the owner.

A really well-built home made solar water heating system

2007-07-13T22:12:00.000+12:00

Wow! Look at this home made solar array! Made by a good Kiwi bloke in his shed. He obtains 80c water tank temperatures, enough to run pool parties with the neighbours invited!

Here is another example of this resourceful fellow's fine work:

A Solahart just one year old

2007-07-13T22:11:00.000+12:00

The Solahart panels in these two photos are one year old and corrosion can be seen on the collector surfaces.
Note the damage to the pipe lagging from birds.
No building consent.

A corroded, buckled Solahart just three years old

2007-07-13T22:09:00.000+12:00

The two Solahart panels in the next three pictures are three years old. Corrosion can be seen on the panel surfaces.

Note the strip of bright white corrosion along the borders.
No building consent.

This was inspected by a Branz official recently; but nothing said of the condition of the panels.

An ingenious home made solar water heating system

2007-07-13T22:07:00.000+12:00

Here is an ingenious home made solar water heating system. Unfortunately, it has no ventialtion/drain holes with the result that it is now flooded with condensation.

A leaky Solahart just 2.5 years old

2007-07-13T22:06:00.000+12:00

If you have an example of a good or bad solar water heating setup, then write to me here. Please include digital photos and contact details to verify the details.

The following two photos are of a pair of Solahart panels that 2.5 years old and visibly corroding.

No building consent.

A rusty Sola60 just one year old

2007-07-13T22:04:00.000+12:00

These two photos are of a Sola60 panel that is just one year old. The elderly couple spent precious savings with the intention of making a meagre pension for further.

No building consent.

This panel was inspected by a Branz researcher who said nothing of this corrosion, leaving this elderly couple with the impression that their system was in perfect condition.

Solahart and Sola60 feature prominently. This is only because I have not found many other brands. My findings are not necessarily representative of the industry.

Three Solahart panels that are only two years old

2007-07-13T22:02:00.000+12:00

These two are of a three panel Solarhart that is just over two years old. Purchased by a retired couple to reduce living costs.

No building consent.

A 30 year old solar water heater that is still working

2007-07-13T22:00:00.000+12:00

This one is over 30 years old and still working quite well. No idea of the make. Owned by a lovely elderly couple. No lagging.

A leaky Solahart

2007-07-13T21:59:00.000+12:00

The following two are Solahart panels in Tauranga on a fast food outlet's roof. These panels are visibly corroded with water inside the panels.

You will also note the lack of lagging, a common installation fault observed in the Tauranga region.

A corroding Sola60, just two years old, no building consent

2007-07-13T21:58:00.000+12:00

Here is a Sola60 panel that is just two years old.

No building consent.

A very corroded Solapak, no lagging

2007-07-13T21:56:00.000+12:00

The collector surface of this Solapak really is this off-grey colour. Note the extensive corrosion and general bleaching of the collector surface.

There is no lagging whatsoever on any of the pipes.

A corroding Edwards without a Building Consent

2007-07-13T21:55:00.000+12:00

This Edwards installation (2 photos) does not have a building consent. It has condensation inside. There is visible corrosion and the black surface has faded in large expanses to a greyish colour.

Note there is no lagging of the pipes.

A solahart that does not work

2007-07-13T21:53:00.000+12:00

This Solahart (2 photos) is about 18 years old, but no longer works according to the owner. Note the absence of any lagging. The surfaces are corroded making the corrosion stand out visibly. The black surfaces are a lightish grey. There is condensation inside the panels.

Some really rusty solar water heating panels

2007-07-13T21:51:00.000+12:00

These two shots of a set of panels of unknown age and brand confirm the view that solar panels must be regularly maintained otherwise seals fail, water gets in and corrosion happens, ruining the panels in next to no time.

Note again the lack of any insulating lagging of the pipes.

Sola60 - four years old

2007-07-13T21:49:00.000+12:00

If you have an example of a good or bad solar water heating setup, then write to me here. Please include digital photos and contact details to verify the details.

This Sola60 panel is a little over four years old and is covered by what looks like white talcum powder.

Here is another view of the panel above: This has no lagging at all. It faces west, so it is only getting full sun later in the day and very little at all during winter months. It should be facing north.

The panel temperature sensor was hanging loose. It is possible that this panel has never worked due to this loose sensor, the absence of lagging and because it is facing the wrong way to the sun.

Safety information - read this before you climb up on the roof!

2007-07-13T21:40:00.000+12:00

Think safe then act!

Do not even think about going onto your roof until you have read the rest of this page about what to do. You must read all of this. Do not risk breaking your neck clambering up a ladder onto your roof. Get an experienced professional, like a builder or plumber to do the inspection for you. If the pitch of your roof is steep, then keep off it. Special equipment may be required to prevent slipping and falling to your death. Do not take any unnecessary risks.

If you are going up on the roof:

If you are still going to climb up on your roof to inspect your solar panels:

Ensure that your ladder is long enough for the job and is a good state of repair.
Keep the ladder at least several meters away from overhead powerlines.
Place the ladder on firm even ground and ensure there is no slippage.
Angle it approximately one meter out for every four meters up.
In the picture to the right, the ladder is securely tied at the base and partway up.
Ensure that the top of the ladder extends about one meter higher than the roof.
Only one person is on the ladder at a time - the one person holds the ladder secure while the other person is on the ladder.
Always face towards the ladder when ascending and descending
Always keep three points of contact on the ladder when climbing and descending.
Keep off the ladder and the roof if there is any more than a gentle breeze.
Do not go up if there has been rain or if there is dew settling.
Wear practical, non-slip footwear.
Stay well away from the edge of the roof.
Stay away from power cables.
Do not walk backwards when on the roof.
When you have finished what you went up there for - get down - carefully!

Latest news about solar water heating

2007-07-13T21:37:00.000+12:00

Solar water heating is growing in popularity as householders attempt to save energy and money by reducing the cost of hot water heating. With global warming, peak oil and the need to reduce emissions of greenhouse gases, people are seeking clean, green ways to heat water and thus reduce their environmental footprint on the planet.

Solar water heating certainly is the way of the future - rising energy costs, pending fuel shortages and catastrophic climate changes will surely see to that! However; there is no point at all in investing in solar water heating sytems if their quality is poor, meaning that they will not last the distance.

These automated newsfeeders are designed to keep you up to date and informed of the latest developments as they relate to solar water heating systems, new technology, their reliability, their economics and related issues like global warming and peak oil.

Please book mark this page and visit regularly.

Back to main page

What to do if your panels appear corroded or if there is no Building Consent

2007-07-13T21:00:00.000+12:00

Don't be an idiot- Stay off the roof - Read the safety information first (search by labels _ "safety" and read).

Keep up to date with news about solar water heating in NZ. Bookmark this page.

Some things to consider before going solar
Installing solar is a technical job to be done by a trained technician. The plumbing must be done properly and the panels must be able to withstand exposure to the elements for at least 10 trouble free years. Go here to view these industry training videos to get a good idea of what is involved.

Here is a helpful handbook about solar water heating.

Here is an informative website by EECA called SolarSmarter. While it is full of information it does little to help those who have found themselves owning of a lemon that is out of warranty.

It is not a good move to install or buy a Solar Water Heater if you are not well informed about the different possibilities and systems . Every supplier offers “his best system with maximum efficiency and cheapest price ” so it’s difficult to compare the advantages and disadvantages of each system.

Here is a questionnaire to suppliers of SWH-systems by Eric Jansseune of Environmental Engineering to assist you with choosing the right system and installer.

Do you require a Building Consent?
Yes: Where a structure is being mounted upon a roof and alterations are being made to plumbing and electricity there would be few exceptions; your Council requires a building consent plus an inspection of the work upon completion.

Here is a copy of the regulations and the company quoting you for the job and the company doing the installation should, at the very least, advise you of the requirements.

"The installation of a solar water heating system requires a Building Consent because solar water heating systems interact with potable water supplies and can involve heavy loads on roof structures if the hot water cylinder is mounted on the roof. A Building Consent is also required where there is a change to the potable water supply system and to the heat source. Other permits may be required to cover electrical alterations, or where there is a building height restriction. All plumbing work will require certification by a craftsman plumber. A registered electrician will need to certify any electrical work that may be needed. Certifications may be in the form of a Producer Statement as required by the Building Consent. Solar water heating installers should ensure that any necessary Building Consents are obtained and adhered to. An installer must then be able to demonstrate to the Consent Authority that the installation meets the requirements of the New Zealand Building Code." Source: EECA Installers Handbook

Depending on the job, the consent application may require technical information about the product, including its durability and loadings. You may have to supply details of the structure of the roof and a schematic diagram of the plumbing and any electrical wiring. The firm that is quoting on your solar water heating installation should do this for you with the cost built into the quotation. The cost of the paper work is as little as $50 when the installer does it for you.

Getting a Certificate of Acceptance
The cost of getting a retrospective building consent (a Certificate of Acceptance) after the job has been completed is not cheap and it is time-consuming. Excluding the professional services with producing drawings and other documentation, the cost varies between Councils. I was quoted $700 plus $80 inpection fee by Hutt City Council. This cost must be included somewhere in your financial assessment of the payback period on your solar investment. Instead of the payback being 20 years, this unforeseen cost may extend the payback period to 25 or more years.

If your installer tells you that you do not require a building consent, it is recommended that you contact your Council's building inspector and have this confirmed.

If you do not have a Building Consent and if one is required

Act quickly because your house insurance may be compromised. Speak to your insurance company to establish any exposure.

You may have problems with selling your house, if it has unconsented roof structures and work such as plumbing and wiring.

Claiming for compensation if you feel you were misled
When you made the decision to place this structure on your roof and to alter your plumbing, you presumably relied on the advice of the company that provided the successful quotation. This advice should have included their professional knowledge of council building regulations. If they do not undertake to rectify the situation immediately, you may consider filing a claim with the Disputes Tribunal for compensation of the costs with obtaining a consent (in this case; a Certificate of Acceptance). Take it up with the Solar Industries Association as well.

If you have a Building Consent; but decide to remove your solar water heating installation - You must have a Building Consent before you can undertake the removal because you are making further alterations to plumbing and removing a structure from your roof. In some cases, a demolition consent is required.

Warranty Issues
(This is not legal advice: this is my interpretation of the law as a consumer)
The payback period on most hot water systems is 10-15 years- over 20 years in some cases. Under the Consumer Guarantees Act the manufacturer/supplier is obliged to supply goods that do the job expected. This should presumably be reflected in the length of the warranty. In this case, a solar water heating system should reasonably be expected to provide trouble-free operation for at least the calculated period for payback on your investment (10-15 years in most cases). Although the Consumer Guarantees Act still gives you some protection, be wary of warranties that are for lesser periods such as five years.

If you think you have a warranty issue with your solar system

Be prompt and clear: Contact the installer and seek prompt action from them.
Do not try to open the panels to look at them because doing so may void any warranty.
Keep a paper trail of every letter and transaction in case you need to take the matter to a Disputes Tribunal.

If you make phone calls, make diary notes and, if an action is agreed upon, send a memo to the other party summarising what was agreed.
Take plenty of photos that show the problem.

Insist on an extension of the warranty period on the parts replaced (bearing in mind that the warranty should really be 10 years or more).

If you are having difficulties resolving problems with the supplier or manufacturer of your system

Contact me because I am very interested in learning about your case and I might be able to help
If you have any concerns about the service you are receiving discuss this with the Solar Industries Association of NZ. (This is where the paper trail is important).
Join the Consumers' Institute, then discuss the matter with an advisor.
Talk to your local Citizen's Advice Bureau which can provide basic legal advice.
Contact your MP.

If you find that you have reached an impasse you may need to file a claim with the Disputes Tribunal.

If your warranty has expired

First of all, talk to the supplier or manufacturer and see if you can work out something reasonable with them. If you are unable to resolve matters satisfactorily, you may still have recourse under the Consumers' Guarantees Act.

If all else fails, consider filing a claim with the Disputes Tribunal.

If your dispute involves panels that have failed prematurely due to corrosion, you might also consider including the NZ Government in your claim because it is has been encouraging householders to install these systems without proper assessment of their durability under New Zealand conditions. Your case may be particularly strong if you financed the installation with a Government subsidised loan scheme.

Which system is best for New Zealand conditions?

Let us find out for ourselves. If you have a solar water heating system; especially if it is more than four or five years old and still in perfect working condition, I want to hear from you. Write in about your system. You must include photographic evidence and documentation of age that I can publish and include your contact details (Contact details will be kept confidential).

Build your own?

If you are a real enthusiast and have more than half a clue as a good resourceful Kiwi, here's where you can learn more about DIY . Seriously, though, building your own panels is a significant technical and time commitment and it must still comply with all building codes.

Why am I doing this?
I am an enthusiastic environmentalist, committed to energy conservation. We finally "invested" in a solar system after exhaustive research - I had to put my money where my mouth was.

unfortunately, we have discovered that there was a problem with corrosion that progressively degrades the efficiency of the collectors and that this could be widespread. This site is to assist consumers with making the right choices in the best interests of the environment - and possibly the survival of the planet as we know it.

Consumers Institute Buyer's Guide: Although it is too general and in my view an overly glowing report that does not assist directly with this pressing issue of solar panel corrosion, the Consumers Institute has this buyer's guide that is worth perusing.

If you want to add to this advice, offer corrections, or simply to comment, please do so by clicking on the "comment" tab at the bottom right below this message.

Solar systems to face more scrutiny

2007-07-13T06:27:00.000+12:00

"The government is addressing the poor state of solar hot water installations in many homes.
Parliament is concerned at growing evidence many system installations are substandard, with Energy Minister David Parker telling the Commerce Select Committee that about 80% of installations are done without building permits because consent fees are too high.
Parker says the government is to rectify the situation by standardising the consent process which will encourage councils to lower their fees.
He says a cash grant scheme will also be launched for solar water heating suppliers which meet quality standards.
National Party energy spokesman Gerry Brownlee says while the emphasis on encouraging solar water heating is laudable, steps must be taken to ensure the installations are of high quality.
Brownlee says there should be a body monitoring standards and he believes the Building Act should be looked at to ensure the problem is fixed."
Source: TV1 Business News
___________________________________
Gary Moller comments:
I tried to arrange a meeting with Nick Smith, the National Party Environmental Spokesman, early in December of last year. It was a frustrating exercise; there was little sign of interest and nothing since. I wondered why?

However; it is good to see that the National Party is finally sitting up and paying more attention than before.

The building consents matter will finally get sorted out. However; it looks like National along with the others is quite content to leave the thousands of early adopters high and dry. If you don't have a building consent, it looks like National is not going to help you out. The Government has been actively encouraging you to install these systems and it was the responsibility of the installers to at the very, very least to advise you that you must have a buliding consent before doing the installation.

Gerry Brownlee's laudable statement also fails to make any mention of the widespread problem of corrosion and fading. Is this a convenient oversight of the inconvenient truth, or simply failure to properly read the reports? Why is there no product recall?

So, you discovered that you do not have a Building Consent foryour solar water heating system!

2007-07-13T06:21:00.000+12:00

So you do not have a Building Consent, your house insurance is compromised, it is going to take you months and the cost of getting a Certificate of Compliance is months away and already well over $1,000 in costs! Furthermore; the company that did the installation is taking cover and hiding from its responsibilities - playing smoke and mirrors by cunningly changing ownership between husband/wife/son. Other companies are using the aggressive direct approach and simply tellling their customers to go away!

Advisory and regulatory gencies and politicians are telling you that getting a building consent is your responsibility. There is no sign of there ever being a coordinated rescue package, let alone a product recall. This is an unconscionable exercise in damage control by those who helped make the mess. How dare they offer no help while shifting the blame onto the victim. My advice to the thousands of affected consumers is not to let them off the hook - make those responsible for this mess pay for the clean-up.

I have been receiving about three inquiries per day about this matter and I wonder when the agencies who should be showing leadership are going to step up to the plate?

The word is getting out

2007-07-13T06:20:00.001+12:00

Check this out:
www.grownups.co.nz - Rusty panels

Does fading really affect performance of your solar water heating system?

2007-07-13T06:15:00.000+12:00

Some experts claim there is no evidence that a change of colour of the collector surface has an adverse effect on performance. To make such claims flies in the face of the most basic rules of the physics of light. In this video I go back to school to give a lesson:

Gary Moller's response to Janette Fitzsimons interview with Paul Henry

2007-07-13T06:11:00.000+12:00

(Click on the image above to see the Closeup Video. You have to wait for the ad to run before viewing the programme.)

Here is my response to some of the things that Jeanette Fitzsimons said in her interview with Paul Henry:

It is time for politicians to stop playing politics, including stopping obfuscating the facts. It is time for leadership. It is time for solutions that are in the best interests of the consumer and the environment. The Branz reports here are ample evidence on their own that there are numerous warrantable issues, including the matter of discolouration of panel surfaces. These reports present a compelling case for some kind of product recall, probably dating back to 2003 when building consents became mandatory for most SWH installations.

you are welcome to leave a message in the "Comments" below.

I am working on a new page for solar water heating systems that appear to be going the distance. This is to assist consumers with making good choices because the Government's guide, http://www.solarsmarter.org.nz/ is of little real help when it comes to the crunch of making a really informed decision.

So, come back this way now and then and please tell people you know who are into solar to do the same. Thank you.

Reports commissioned by EECA outline the problems

2007-07-13T06:07:00.000+12:00

Here they are; hot off the press along with analysis and commentary:

Branz report about seven Wellington installations

Branz report about solar water heating systems

Reponse from Solahart

Response of Sola60

Reponse of Gary Moller

Response of Gary Moller to Solahart letter

NB: I have used the wrong terminology in places: Where I refer to a "Certificate of Compliance", this should read " Certificate of Acceptance" . As a matter of interest, applications for a Certificate of Acceptance are made as per Building Act 2004 Sections 96,97,98 & 99.

Post your comments
You are invited to post your comments by clicking on the "comments" tab at the foot of this or any other posting

Solar water-heating alert issued by Consumer's Institute

2007-07-13T06:03:00.000+12:00

"Flat panel" solar water-heating system owners beware. If you have one of these solar water-heating systems, we advise having the panel checked for deterioration.
Gary Moller noticed a steady drop in the peak temperatures of the water from his Sola60 system.
He checked the panels on his roof, and discovered what looked like corrosion. The panels were replaced - twice - but the problem returned. Gary has since had his system removed, and received a refund. But this was only after he created a website documenting the problems."
Consumer's Institute Alert 31/05/2007
___________________________________
Gary Moller comments:
At last the story is finally out and now let's hope that the media will pick up this story and run with it.

As one industry insider commented to me yesterday: "this news is absolutely huge". So, why is it not huge news yet?

What I do take issue with is that the Consumer's Institute is focussing only on Sola60 when it is obvious that this is a problem that affects other makes and models.

The question must be asked: Why has Consumer not demanded a product recall when there is overwhelming evidence (As detailed on this site) of there being a serious and widespread problem? And why have there not been calls for a proper investigation to determine the extent?

Sola60 Promises to stand by its products and to look after its customers

2007-07-13T05:58:00.000+12:00

29 May 2007
"Dear Mr Moller
Further to our earlier conversations, I confirm the panel discolouration issue identified on your web site relates to a limited historical issue.

To put this issue into perspective, Sola6O has installed over 10,000 panels throughout New Zealand and the number of warranty claims relating to any deterioration of the panel surface is around one percent.Sola6O has a continuous focus on research, development and product testing. This testing has confirmed the high performance of the current Sola6O product range and random audits of Sola6O installations provide an additional quality control measure.

I’d also like to confirm that SoIa6O stands behind the quality of its products and encourage any Sola6O customer that may have a concern about their panel to contact us on 0800 765 260, by emailing customercare@sola60.co.nz or by writing directly to:The Management TeamSola6O NZP0 Box 2310Tauranga

I would appreciate it if you would include these details on your web site to make it simple for customers to contact us should they have any questions or concerns about their Sola6O system.
Yours sincerely"
Sandra Bell
Business Manager
_______________________
Gary Moller comments:
While it could be argued that Sandra is tactfully down-playing the full extent of the problem, this is wonderful news for Sola60 customers. So, congratulations to the management of Sola60 for taking a positive position for its customers!

It must be emphasised that Sola60 is not the only brand that is identified as having problems. These problems (as detailed on this website) include shoddy installation, inadequate lagging and no building consents as well as corrosion/discoloration or whatever one wants to call it.

Even if you are outside of your warranty, still raise the issue with Sola60 and please do let us know how you get on.If your installation does not have a building consent; but one is required (Check with your local Council), you should not have to pay the extra costs. Talk to the people who installed your system and who should have been responsible for obtaining the necessary consents.

Which solar water heating system is best for New Zealand conditions?

2007-07-13T05:54:00.000+12:00

"Although the value of COP (Co-efficient of Performance). effectively determines the overall performance of the tested systems and allows comparisons to be made, it is of more use to potential buyers of solar and heat pump systems to compare financial figures which incorporate both performance and the costs of the systems. For Dunedin the evacuated tube system gives an attractive Internal Rate of Return (IRR) of 9.0% and a positive Net Present Value (NPV) of $936 using a discount rate of 5% (after tax). The heat pump system in Dunedin also gives a positive NPV of $263, while both flat-plate models give negative NPV’s.

For the Auckland estimation the evacuated tube system still yields the most favourable economic result with an IRR of 10.3% due to its low capital cost, despite having a slightly lower COP than both the heat pump or flat-plate thermosyphon systems. In the Auckland location all systems except the flat-plate pumped circulation system give attractive economic results. "

"The main conclusion from this study is that it is important to test actual systems before making any assumptions about energy savings and or economic performance. In particular it can be seen that the high cost of installed systems in NZ makes it difficult for them to achieve good economic return on capital. It is also clear that evacuated tube systems need to be taken into serious consideration as a preferred system type, especially for the cooler parts of the country.

The performance of the flat-plate pumped circulation system has proved to be highly suspect and possibly dependant on the fact that it was a ‘retrofit’ installation to an existing domestic hot water cylinder.

This is an important finding, as there are no on site performance tests for solar hot water systems undertaken and many New Zealand systems may be seriously underperforming, perhaps unbeknown to the house owner."

Source:
Experimental and Simulated Performance of Commercially available Solar and Heat-pump Water Heaters in New Zealand - S.E. Thomas and C.R. (Bob) Lloyd, Energy Management Department, University of Otago

________________________________________

Commentary:

This report indicates that there may be serious performance issues with flat plate panels; especially with those that are retrofitted to existing hot water cylinders. This report does not take account the almost universal and progressive corrosion of flat panel surfaces that begins to become visible and within months of installation in some cases.

There is also a further progressive loss of performance over the years on non-heat exchange flat panel systems caused by internal corrosion and buldup of deposits on the internals of the system. Heat exchange systems that use liquids like glycol in them are more expensive and this must be taken account when comparing performance to initial cost and return on investment over the years.

From a straight dollar return on investment, it is difficult to recommend any kind of flat panel system at this stage. As the report indicates, more research is required because "many New Zealand systems may be seriously underperforming".

Evacuated Solar Tubes

The evacuated solar tube systems look very promising and I met a number of very satified owners. While their durability in the NZ setting still needs to be confirmed, inspection of existing setups in the Wellington Region show that they are promising. As the study referred to above indicates, these systems crank out the heat and do so in poor light conditions.

In their favour is their relative low initial cost and ease of installation. However; I am very cautious to make a recommendation as to which brand to go with and caution that cheaper is not necessarily best - And not all evacuated tube systems have the same performance as the best of them. So I have been advised by industry experts.

Not all evacuated tubes are the same, as is the case with flat panel systems. You get very much get what you pay for and that there are any number of cheap Chinese made systems available that should be treated with caution, although not discounted outright. Similarly, you should be wary that there may be brands passing themselves off as European when in fact they are Chinese made components and may not be of the same quality as those European made systems. You are seeking a system that will last as long as two decades, so take care.

Ensure that the tubes meet the NZ and Australian standards for roof mounted structures with regards to resistance to hail damage.

Because each tube is independent of the other, the owner can easily remove and replace a damaged tube. These tubes are delicate but light weight. This amounts to being able to provide ongoing onsite maintenance; whereas replacement of a heavy flat panel that is faulty is quite an exercise and each unit is costly. This ease of servicing makes sense for a roof mounted system that has to last for decades.

Damaged tubes are recyclable which is a huge plus for the green household.

My recommendation is to look closely and carefully at the emerging evacuated tube technology when shopping around for a solar water heating system.

Here is an interesting TV3 video item worth looking at. Of course, what it is telling you, the viewer, is based on the assumption that all panels will still be working effficiently 5 years later! Take care when selecting what is best for you.

Corroding solar water heating panels discovered in Sydney Australia

2007-07-13T05:49:00.000+12:00

As we suspected dry Australia - the "land of fire" is equally affected. Here are examples from two Sydney installations which are the first and only ones inspected at random to date. The person who took these photos did so by walking down a Sydney street and selecting the first two he randomly came across.

The first photo is of a Solahart that is estimated, by the manufacturer, to be over 23 years old. What is significant is that the white corrosion is visible from the ground.

The following two photos are of a Solahart installation that is a little over three years old and visibly corroded.

What these and the many other photos on this website show is that there is a progressive deterioration of flat panel collector surfaces over their lifetime. Depending on make this process is beginning as early as 6 months after installation.

According to EECA of NZ a 20 year pay back period is required for a Solahart installation and that assumes near 100% performance over that period. It is assumed that this will be a shorter period in Australia.

Please ask your friends and neighbours with solar water heating to check their systems and ask them to send me digital photos of what they find.

We are seeking to identify systems that do not have signs of discoloration. Please help
Thank you.
For more information go here.

What does it really cost to get a certificate of compliance?

2007-07-13T05:44:00.000+12:00

In my advice about what to do if your solar water system's installer did not obtain a Building Consent before proceeding, I stated that the cost for getting a Certificate of Compliance was $700-plus as compared to about $80 if the the job had been done right.

Here is a quotation from a letter from Wellington City Council to an elderly couple who have a new Solahart installation that did not have a building consent. With the help of the Installer, an application for a Certificate of Compliance was submitted:

"Your documentation is being returned because the Council does not accept incomplete applicationsThe following information is needed....:
Provide the application fee of $690
Confirm the system has compliance with NZS 2718
Provide a roof plan showing the proposed location of the panels
Provide fixing details of the panels and the method of making the pipe penetrations through the roofing cladding watertight
Provide two copies of documentations and drawings"

The letter also states that the cost of inspections is $120 per hour.

This elderly couple can not provide this detailed information without the assistance of a plumber and an architect. They estimate the cost will be about $1,500 all up and will take some months to be completed.

In the meantime, their house insurance is compromised by having unconsented work on their house.

Did Branz and EECA know there might be a performance problem early 2006?

2007-07-13T05:37:00.000+12:00

You be the judge.....
"One of the biggest uncertainties in the cost/benefit analysis of solar water heating systems is the lack of reliable field data for system performances. Anecdotal evidence suggests that most existing systems fall significantly short of the calculated values used during the system design. This information gap needs to be urgently addressed by conducting a representative field study of existing solar water systems in New Zealand. "

The main conclusion from this study is that it is important to test actual systems before making any assumptions about energy savings and or economic performance. In particular it can be seen that the high cost of installed systems in NZ makes it difficult for them to achieve good economic return on capital. It is also clear that evacuated tube systems need to be taken into serious consideration as a preferred system type, especially for the cooler parts of the country.

"The performance of the flat-plate pumped circulation system has proved to be highly suspect and possibly dependant on the fact that it was a ‘retrofit’ installation to an existing domestic hot water cylinder. This is an important finding, as there are no on site performance tests for solar hot water systems undertaken and many New Zealand systems may be seriously underperforming, perhaps unbeknown to the house owner. "Go here for to read the full report.

Corroding solar water heating panels "A serious failure"

2007-07-13T05:34:00.000+12:00

"Hi Gary,
I just discovered your web-site over the the weekend and decided to take a look at my solar panel.
Thanks for the publicity on the issue and advice!
Like many others I may have been oblivious to what I consider a serious failure."
Anon.
_________________________
Gary Moller comments:
If you know of people who have solar water heating panels installed please urge them to carry out their own inspection independent of who did the installation. Solar panels are the perfect product - out of sight - out of mind until well out of the warranty period.

Notes about these Wellington panels:

Installed about 16 months ago with a required payback period of over 10yrs
All of the panel is seriously faded or corroded
No building consent obtained by the installer
Cost of a building consent would have been about $50: Is now about $700 to get a Certificate of Acceptance
The same problems with rusty solar water heating panels exists in Australia

Refer here for more information about rusty solar panels.

Corroding/fading panels found in Auckland

2007-07-13T05:17:00.001+12:00

"Hi,
Panel itself has a white oxidised coating almost all over. It was installed only a year ago.
Cheers"

Dave
_____________________________
Gary Moller comments:
This problem is a nationwide one that potentially affects thousands of unsusupecting householders.

Readers, I need your assistance:

This is an installation on a refurbished South Auckland Housing Corp property. Apparently, Housing NZ has invested heavily in these systems. Dave tells me this is typical of the ones he has seen on Housing Corp rooftops.

The photograph, while a little blurred, clearly shows a whitish panel surface that should be a dark grey-black. White is not a good colour for collecting solar energy!

This is a very significant photo because it shows that the near 100% corrosion rate that I have demonstrated is happening to solar water heating panels in Wellington is not a regional freak happening. I am awaiting information about whether the same pattern is showing in Australia.

These systems are being sold to the unsuspecting public on the promise that they are good for the environment and will save the householder money. They will do neither if they progressively lose function and are as good as junk by five years. We are contributing to global warming and creating a landfill problem by installing these sub-standard systems.

Readers, If you know of any solar water heating panels sitting on a roof nearby, please can you assist by arranging with the owner to take a look at the state of the panels. Please take digital photos and send them to me with a description of the system, including brand, age and location. If they are in perfect conditioin, I want to know because these are a rarity. What's the situation in other places like the US?

A Solahart that is just one year old

2007-07-12T22:37:00.000+12:00

Here is a Solahart system that is just one year old and doesn't it look really smart?

Look carefully through the heavily patternised glass and you can just see a lots of white patches dotted about the panel:

Here's another angle and another section of panel: No building consent

As you would gather, the owner (A family with two young children) was concerned that this could happen so quickly. To make matters worse; the installer had told him that a building consent was not required for the installation. The building inspector thought otherwise. This owner is now facing a costly and lengthy bureaucratic procedure to get retrospective approval.

Are there any systems that will reliably last 10+ years?

I cannot answer this. I found several brands; but some I could not get access to for various reasons (Mostly lack of safe access) and other installations were far too recent to be able to make any kind of judgement.

The Solar Industry and the Government need to certify which solar panels are of sufficient durability to provide at least 10-15 years of reliable service under New Zealand conditions.

Some notes and commentrary about what I think is going on

2007-07-11T22:42:00.000+12:00

Comments about what might be going on here:

Notes:

The following pages do not purport to be an authoritative study by a qualified expert. This site does not endorse or favour any product over another. Solar water heating installations are presented as they were found. They are in no particular order and may only represent those brands that have sold the most in a region.
Any information is that from one interested consumer being passed to another. Anybody may offer corrections and add further information by the comments function of this blog, or by writing direct to the owner.
Modern solar water heating systems are very efficient and a technology that is sensible to embrace. However; they must work at close to peak, trouble-free seasonal efficiency year after year for 15-20 years to provide payback on the investment.
The difficulty for the consumer is on deciding which make and model will go the distance when most of the modern systems on NZ roofs are only a few years old. These web pages and the feedback from readers via the blog comments may assist the consumer wiht making an informed choice.
Even if a system is replaced under an extended warranty, this runs counter to "green" sentiments by creating expensive landfill materials.
This page was first loaded November 26, 2006 and is updated regularly. By the date of this page's latest update (25 Feb 2007) over thirty faulty setups have been identified and this number grows by the day.

Quick Summary

Our family home had solar water heating for just over four years.
In that time, we had the collector panels replaced three times.
The third set has visibly corroded in just seven months and needed replacement.
Our warranty was due to run out out in less than a year and the company (Sola60) refused to warranty the replacement panels beyond that time.
We then sought a refund and removal of the system. Sola60 refused.
Our only option was to take the matter to a Disputes Tribunal hearing.
Dissatisfied with the Tribunal option, I decided to see if other consumers had similar problems.
Of those solar water heating panels that were able to be examined, all Solahart and all but one of the Sola60 panels were visibly corroding meaning that in excess of 80% of the total of all flat panel systems older than one year showed discoloration. Photos of many of these are published on this website to give consumers a good idea of the extent of the problem and to know what to look for.
The problem is not restricted to Sola60 or Solahart as is evident from the photos on this website.
None of the householders contacted were aware of the problem.
The same pattern of discoloration, whatever the cause may be, is reported and documented for other parts of New Zealand and similar results are found in Australia.
Many of the installations, including ours, did not have the required building consents despite this being a requirement in most cases if not all. According to our insurance company our house insurance has been compromised for the last four years.
Many of the installations lacked the required insulation lagging on pipes as is required for peak performance.
Many were poorly sited and improperly angled to the sun and thus compromised in terms of performance.
As a result of this website going live in November 2007, we have now received a refund and the panels on our roof have been removed.
This website is being maintained as an information resource for the consumer.

While Although I am not an expert on these matters, I have studied physics and chemistry at tertiary level and I probably have a better than average technical knowledge. One can not assume that what works well in the relatively hot, dry conditions of continental Australia, the USA or the Middle East can be transferred to New Zealand's climatic conditions.. New Zealand is a long and narrow country. It is typically very windy with lots of rain and humid coastal air that is salt laden (Since writing this, the same patterns have been documented in Australia).

Solar Solar water heating panels are intentionally sited in exposed locations, typically on the top of buildings. They are therefore exposed to the worst local conditions of heat, cold, wind and water. In Wellington solar panels are subjected to salt-laden rain that is horizontally driven by wind gusts that can exceed 160km/hr. Unless the panel is exceptionally well sealed and built from corrosion-resistant materials, it is inevitable that water will get inside and materials will eventually degrade (It should be noted that similar problems are seen in central North Island locations that are well away from the ocean).

Another factor that may be at work is the circadian expansion and contraction of the inner air space. Heated air is forced out during the day; then cool moist air is sucked back in during the night to condense on the glass and collector surfaces. The next day the moisture is evaporated, leaving a slight salt deposit that steadily builds over time. If you look carefully at the first photo of the Solahart panel you can see what appears to be salt streaking left by condensation on the innerside of the glass. The same can be seen on the collectors of the Sola60 panels

Once the metal is wet and with a buildup of salt and the cyclical application of heat and cold the conditions are ripe for some exciting chemistry: namely corrosion - the conversion of metal into powdery whitish metal salt crystals. Corrosion is also rampant where Galvanic processes are at work. Galvanising happens where different metals, like copper and aluminium, aided by moisture and salt, are able to exchange electrons in a redox reaction like what happens between the cathode and anode partitions of a standard battery. Once these destructive processes have begun, the solar panel is probably doomed.

Fading may be due to the black coating surface on the collector being of poor resistance and even too thin to resist the baking under high UV sunlight.

These corrosive processes are very gradual and may go unnoticed until after the warranty has run out. From my survey of Wellington and other parts of New Zealand, this would appear to be what is happening: Not a single householder that I contacted had any idea of what was happening. For those with patternised glass panels, being able to see what is happening underneath is especially difficult.

Access problems means that many panels are inaccessible for householders; particularly the elderly. In some cases, scaffolding, ropes and harnesses are necessary to safely gain access to rooftop panels.
The general inaccessibility of the panels, plus the very gradual deterioration in heat absorption is such that few people will notice. This gradual deterioration is further hidden by the daily and seasonal fluctuations of sunlight (In Wellington we often get all four seasons in a week!).

Power bills fluctuate for all kinds of reasons and the electric booster heater on a single tank system may hide the deterioration by quietly working a little harder as the years pass. The consequent increase in power bills is understandably attributed fully to price increases. We insisted on a double tank setup which was fortunate. We have one tank that is entirely solar heated. It feeds into another tank which is then boosted before being used by the household. We are therefore able to closely monitor the daily solar performance as the months and years go by without being confused by power bills.

Which system is best for New Zealand conditions?
Let us find out for ourselves. If you have a solar water heating system; especially if it is more than four or five years old and still in perfect working condition, I want to hear from you. Write in about your system. You must include photographic evidence and documentation of age that I can publish and include your contact details (Contact details will be kept confidential).

Warning:

Unless you really know what you are doing, you must stay off your roof. Please read the safety information on this website

Keep up to date with news about this story as it develops by bookmarking this website

You are most welcome to post your comments, observations, corrections and advice in the "Comments" Section below for the benefit of all our readers. Just click on the "comments" tab and type away!

Find an Expert in Solar Water Heating Systems

2007-07-11T19:22:00.000+12:00

Consumers:
If you require the services of a technical expert in the solar water heating sector that is able to give you independent advice about your solar water heating system, I am compiling a list of experts who may be able to help you. Bookmark this page so that you are alerted each time it is updated.

Independent Experts Urgently Needed!

Experts:
If you are trained in areas like building, roofing, plumbing and engineering with an expertise in Solar Water Heating systems and able to provide impartial advice and guidance, please contact Gary Moller if you would like to have your contact details listed on this page. I need to know your name, qualifications, area of expertise, region and contact details. If you are selling or are an agent, or in the employ of a solar heating provider, please give us those details as well, thanks

Rob Koppers.
Building Control Officer

Work Email: rob.koppers@waidc.govt.nz
Home Email: rob.koppers@xtra.co.nz

My Qualifications are as follows.

Branz CITE Certificate in Building Compliance for IQP / BLP Branz CITE Certificate in Acess,Egress & Barriers.
Branz CITE Certificate in Plumbing and Drainage.
Branz CITE Certificate in Building Controls.
Trade Certificate in Carpentry

In brief I have been in the Building industry for 25 + years and have been a Building Control Officer for Three & 1/2 years.

An example of a Chromagen solar water heating system

2007-07-02T22:40:00.000+12:00

Here is a photo of the oldest Chromagen installation of the three I found in Wellington. This one has been in place for almost five years. Of all the solar panels that I inspected, this is the only installation over a few years old that did not show any corrosion of the absorber surfaces:

Warning!

Do not even think about going onto your roof until you have read the safety information on this website.

You must read and heed the safety advice. Do not risk breaking your neck clambering onto your roof.

Get an experienced professional, like a builder or plumber to do the inspection for you.