RVR Solar Systems RVR.ie Installation Instructions

RVR Solar Systems RVR.ie Installation Instructions
RVR Solar Systems
Installation Instructions
RVR.ie
Ireland’s Online Heating Suppliers
Version 16052007
RVR Solar Systems
Table of Contents
System Schematics and Circuits . . . . . . . . . . . . . . . . . . . . . . . . . 3
Twin Coil Thermal Store System . . . . . . . . . . . . . .
Single Coil Preheat Cylinder . . . . . . . . . . . . . . . .
System 3 – Thermal Store with External Heat Exchanger
System 4 – PROCLEAN tank system . . . . . . . . . . . .
Equipment Specifications
Standards and Codes . . .
Safety information . . . .
Locating Solar Panels . .
Orientation . . . . . . . .
Tilt Angle . . . . . . . . .
Shade . . . . . . . . . . . .
Distance from Solar Store
Access for Maintenance .
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.3
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.4
.4
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5
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.6
.6
.6
.7
.7
Handling of Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Mounting of Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Flat Surface Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Sloped Roof Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Brackets for mounting Calpak solar panels on-roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Brackets for mounting TiSUN solar panels on-roof. . . . . . . . . . . . . .
Installation instructions for pipe flashing on flat tile or slate roof . . . .
Installation instructions for 2 in 1 piping . . . . . . . . . . . . . . . . . . . .
Installation instructions for pipe flashing on corrugated / profiled roof
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. 11
.13
.14
.14
Procedure for Tiled Roofs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Method for connecting solar metalflex pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Piping and Pipe Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Arrangement of Collectors . . .
Pipe Materials . . . . . . . . . . .
Thermal Insulation of Pipes . . .
Pre-insulated solar pipe system .
Pipe Sizing . . . . . . . . . . . . .
Installation of pipework . . . . .
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16
17
17
18
18
18
System Expansion and Safety . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Overheat Protection . . . . . . . . . .
Safety valve . . . . . . . . . . . . . . .
Installation of Expansion Vessel . . .
Setting of Expansion Vessel Pressure.
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18
19
19
19
Controls and Pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Thermal Store. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Flushing, Filling And Leak Testing . . . . . . . . . . . . . . . . . . . . . . 20
Solar Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Filling and flushing the solar circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Maintainance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Installation Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Notes
Installation Instructions
System Schematics and Circuits
Detailed information on the design of solar systems is available in the RVR publication, Solar System Design Guide. This
may be downloaded from www.RVR.ie and should be read carefully before designing a system.
Four basic system types are described below:
Twin Coil Thermal Store System
This type of system is suited to new or replacement installations where the water heater is to be replaced. A dual coil
water heating tank is used as a solar store with the solar circuit connected to the lower coil. The tank used should be tall and
narrow to ensure good stratification of the heated water. An oil or gas boiler is usually connected to the upper coil. In this
type of system the solar system will be able to provide a large percentage of the domestic hot water needs of the household.
Vacuum or flat panel type solar collectors may be used.
Fig. 1 – Twin Coil Thermal Store System
Single Coil Preheat Cylinder
This can be easier to install alongside existing installations and it is not necessary to replace the existing water heater.
In this type of system the solar system will be able to provide a large percentage of the domestic hot water needs of the
household. Vacuum or flat panel type solar collectors may be used.
Fig. 2 – Single Coil Preheat Cylinder
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System 3 – Thermal Store with External Heat Exchanger
The heat from the solar panels is fed to a plate heat exchanger which in turn is used to heat the domestic hot water. It
may be a good choice where it can be retro-fitted to an existing water heating tank. Vacuum or flat panel type solar collectors may be used.
Fig 3 – Thermal Store with External Heat Exchanger
System 4 – PROCLEAN tank system
The solar system is connected to the lower coil in the PROCLEAN tank. The PROCLEAN tank allows the output of the solar
system to make a contribution to central heating as well as providing hot water heating. Vacuum or flat panel type solar
collectors may be used.
Fig 4 – PROCLEAN tank system
4
Installation Instructions
Equipment Specifications
$
$
"
"
#
#
Fig 5 – GS Type Collector
Fig 6 – VTN Type Collector
FM-S
FM-W
Dimensions
Α × B × C (mm)
2160 × 1180 × 100
1180 × 2160 × 100
Area
(m2 )
2.55
2.55
Empty Weight
(Kg)
49
49
240GS
2350 × 1070 × 95
2.5
12 VTN
1600 × 1330 × 100
2.13
Model
51
51
Maximum Working
Pressure (Bar)
15
15
Flat Surface Support
Bracket Kit
334401
335401
38
40
13
SOL230
35
38
13
SOL225
Full Weight (Kg)
Sloped Roof Support
Bracket Kit
334511
335511
ASB015 (single)
ASB020 (double)
ASB005 (single)
ASB010 (double)
Table 1
The TISUN FM models are flat plate collectors with a selective type absorber, tempered glass, rockwool insulation and an
aluminium casing.
The CALPAK GS are flat plate collectors with a selective type absorber, tempered glass, expanded polyurethane insulation
and an aluminium casing.
CALPAK VTN vacuum collector consists of vacuum tubes, 1.5 m long, with external diameter of 47 mm. A special CPC
reflector is used to concentrate all solar rays onto the tubes thus minimising the number of tubes required.
Vacuum tube collectors have higher efficiency in diffuse radiation (cloudy weather and winter), compared to flat plate
collectors. The vacuum produced between the two glass tubes provides excellent insulation which protects the collector
from freezing when ambient temperatures are as low as -18 °C (without anti-freeze).
Standards and Codes
The installation of the solar system should only be carried out by suitably qualified and certified personnel.
All applicable standards and codes of practice should be complied with. These include but are not limited to :
•
•
•
•
•
•
•
Safety, Health and Welfare at Work Act 2005
Any requirements of the Health and Safety Authority
The Building Regulations
Local Authority Requirements
EN 12975 and EN 12976 which deal with Solar Systems and Collectors
lEE Regulations
Any other applicable local national or European codes or standards
All solar panel should be certified and carry the Solar Keymark which is the official quality mark of the European
Committee for Standardization (CEN). It guarantees the quality of solar heating products, both panels and complete
systems.
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Safety information
• Use safe access methods and install anti-fall protection. Do not use damaged ladders or equipment and ensure that
they are placed safely and secured against falls and slippage.
• Use safety harnesses and belts.
• When working near electrical wires or cables, disconnect the electrical supply or maintain a safety distance of:
1 m with voltages up to 1000 V
more than 5 m when the voltage is not known.
• Wear protective goggles, safety shoes, gloves and helmet of approved quality.
Locating Solar Panels
The following five important factors should be considered when locating the panels:
Orientation
The collectors ideally should be oriented to face South (use compass to find South). However a variation of up to 15° from
South does not have a significant effect on the efficiency. Orientation between SE and SW will typically affect efficiency by
less than 5%.
By compensating with more collector area, it is possible to orient the collectors anywhere between east and west as the
loss of efficiency at these extreme orientations is about 25%.
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Fig 7 – Collector orientation and tilt
Tilt Angle
The tilt angle at which you mount the collector should roughly correspond to the latitude of the location. The optimum
tilt angle is about 50° for installations in Ireland or the UK although any angle between 30° and 60° will give good results.
Angles greater than 60° result in a significant loss of efficiency in summer. The loss of efficiency at a tilt angle of 80° will be
about 20%. This may be compensated for by installing additional collector area.
Shade
)
)NJO
Fig 8 – Collector shading
Try to avoid significant shading of more than 2 hours per spring or autumn day. Ideally, the distance from an obstacle to
the East, South or West should be at least 2.5 times the height of the obstacle.
6
Installation Instructions
Distance from Solar Store
The collectors should be as close to the solar store tank as possible in order to minimise heat and pressure loss.
Access for Maintenance
The area where the collectors are installed should have easy and safe access for maintenance.
Handling of Panels
During installation, keep the upper carton or plastic film in place up to the moment the circuit is filled with thermal fluid.
Glass is better protected in this way from thermal or mechanical shocks.
The VTN collectors are packed in wooden or cardboard crates and must always be transported in a vertical position with
big warnings that the tubes are made of glass (FRAGILE – GLASS TUBES). When quantities of more than one are transported,
use pallets and use strapping and stretch film to ensure quality of packaging and protect against damage.
When mounting on the roof, remove the packing crate, and use appropriate straps and handling equipment to place
the panels in position.
Do not remove the plastic cover before filling up the system with solar liquid.
Mounting of Panels
Support bracket kits are available to allow mounting of collectors on flat surfaces and sloped roofs. Before commencing
installation on any roof or surface, obtain written confirmation from the designer, builder or owner that the roof is strong
enough to support the weight of the solar installation.
Flat Surface Installation
A support bracket kit is available for each model of collector. Please see table 1 for bracket models.
Fig 9
• The components of the bracket kit are shown in the picture above. The angle pieces must be screwed together to
form two triangles. The vertical angle is marked 45Y2, the horizontal one 45L2 and the sloped one 45K2.
• Once the triangles have been formed, assemble the two reinforcing pieces to form the X configuration. These are
attached to the two vertical angles 45Y2. Finally screw the two blades together at the crossing point.
D
D
T
Y
E
E
D
D
E
E
_DPMMFDUPSXJEUI
Fig 10
Fig 11
• Fasten the triangles on the flat surface parallel to each other using special fixing bolts and check stability. Ensure that
the installation has sufficient stability to endure wind pressure.
• Mount the fixing pads “s” loosely on the sloped angle at points “c” and “d” by selecting one of the three available holes
at each point so that the collector will have an inclination upwards to the left as seen from the front.
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• Mount the collectors on the sloped angles and slide the fixing pad “s” at point “d” into the groove of the collector’ s
frame, then do the same with pads “s” at point “c” and finally screw it firmly.
• Verify that an inclination towards the outlet on the left of about 1-2° exists. This is imperative for air purging of the
solar circuit.
Sloped Roof Installation
Before mounting solar panels on a roof, check with a qualified person that the roof is strong enough to support the additional weight and wind loading.
Brackets for mounting Calpak solar panels on-roof
These brackets have been designed specifically for Irish roof systems and the harsh Irish weather.
They are professionally manufactured from high quality 304 grade stainless steel. They will have an almost unlimited life
in all normal environments. When installing solar panels in areas exposed to salt water spray or in heavily polluted atmospheric conditions, some corrosion may be experienced. If this is not acceptable, please contact RVR for technical advice
prior to installation.
All roof kits are mounted using hanger bolts as shown in the photograph below. This type of fastener has a wood screw
at one end and a threaded machine screw at the other end. All kits are complete with stainless steel hanger bolts and all
other fasteners required to assemble the brackets.
An installed roof bracket for a single solar panel is shown in figure 13.
Figure 12 – Hanger Bolt
Installation Procedure
Figure 13 – Installed Roof Bracket
First determine the approximate location of the roof bracket.
If the inside of the roof can be accessed, then go into the attic and mark the location of the lower mounting holes for
the bracket.
Figure 14
8
Installation Instructions
Now drill out through the rafter and slate with a long
6mm masonry bit making sure that the drill is perpendicular to the rafter.
Leave the drill bit protruding through the slate, to the outside, and place the bracket upright over it. Take a measurement
to determine a good location for the upper hanger bolt.
Figure 16
Figure 15
Now transfer the measurements which you have taken
onto the inside of the rafters and drill out again.
If the attic has been converted the location of the exact
centre of the rafter can be difficult to find. You can use an
electronic stud finder to locate the rafters internally.
Then drill out through the center of the rafters and repair
the holes inside.
Alternatively reference your location from a window and
triangulate your measurements. Then transfer them to the
outside and drill in through the slate.
Figure 17
See the following diagrams for spacing of rafter and hanger bolts in relation to the different types of mounting brackets.
Figure 18a
– Drill the centre
in these locations for 1-12VTN
bracket
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Figure 18b – Drill the
centre in these locations
for 1-240GS bracket
Figure 18c – Drill the centre in
these locations for 2-12VTN bracket
Figure 18d
– Drill the centre in
these locations for 2-240GS bracket
9
RVR Solar Systems
When all the holes are drilled, you now drill an 11mm clearance hole in the slate.
Next lock two SS nuts together as shown and twist in the hanger bolt until 50mm of threaded bolt protrudes above the
slate or flat tile.
Figure 19a
Apply some of the special purpose sealant (supplied) to
the surface around the bolt. Fit the 5mm thick neoprene
washer followed by the 40mm SS washer and SS nut. Tighten the nut by hand until you cannot turn it any more and
then give it one full turn to form a watertight seal. Do not
over tighten or you may break the slate!
Figure 20
Now put on another SS nut on the protruding bolts and
leave an even space between the first and second nut to ensure the bracket sits evenly off the roof. Don’t forget to put on
the 25mm SS washer which gives support to the SS bracket.
Figure 22
10
Figure 19b
We recommend the application of some more adhesive
sealant around the washer to give extra protection against
the Irish weather.
Figure 21
Next you fit the SS uprights making sure you put on the
25mm SS washer and the M10 SS nyloc nuts provided.
Figure 23
Installation Instructions
See completed mounting in figure 24.
Proceed to fit the crossmembers using the M8 bolts and nuts.
Figure 24
Figure 25
You can rest one side of the upper crossmember inside
the upright temporarily while you move to the other side
Figure 26
Loosely fit the clamps to the lower crossmember.
Figure 27
Then slide down the solar panel into the clamps.
Fit the upper clamps and tighten them ensuring the solar panel has a 1 to 2 degree rise towards the outlet connection.
Brackets for mounting TiSUN solar panels on-roof
Follow the same procedure for installation of hangar bolts as described for the vacuum collector installation. The TiSUN
panel has an extruded aluminium type mounting bracket.
There are two kits available, these are:
• Mounting kit for 1 panel and
• Mounting kit for each additional panel.
Figure 28
Figure 29
For more detailed installation instructions, please see the document supplied with the mounting kit or download it from
www.rvr.ie.
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Brackets for mounting TiSUN solar panels in-roof
There are flashing kits available for tile roofs and slate roofs. These are not interchangeable as the bottom part of the
flashing for tiled roofs has a greater offset angle and a flexible skirt.. There is also a triangular adhesive foam backed strip
provided for tiles. These foam strips are not used on slate roof installations.
There are 3 different kits available for each roof type, they are:
• Flashing kit for 1 panel.
• Flashing kit for 2 panels
• Flashing kit for each additional panel
Figure 30
It is also necessary to modify the roof by fitting three extra battens under the flashing for support.
The minimum unfinished roof area (mm) for installing the flashing is provided in table 2.
Panel quantity
1
W
1750
2
H
2850
W
3000
3
H
2850
W
4250
4
H
2850
W
5500
5
H
2850
W
6750
6
H
2850
W
8000
H
2850
Table 2 – minimum unfinished roof area (mm)
The flashing kits contain all the components required to install the panels. When the installation is completed, two insulated flexible pipes with 18mm copper pipe ends are inside the attic. Take care when fitting compression fittings to these
and to the panels. Use a 24mm and a 27mm open spanner to tighten the fittings. Do not use large adjustable spanners.
WARNING!
Be careful not to turn the pipe in the panel because it may create a leak internally.
When installing the fittings be sure to fit the brass inserts provided.
It is not necessary to apply sealant to the fittings because compression fittings create their own tapered seal.
Figure 31
Figure 32
For more detailed installation instructions, please see the document supplied with the mounting kit or download it from
www.rvr.ie.
12
Installation Instructions
Installation instructions for pipe flashing on flat tile or slate roof
A specially designed sloped roof flashing is available for sealing the insulated solar pipe, providing
a watertight seal. This flashing will seal a 1 ½" pipe, it can also be modified to 3" by tearing off the
inner sealing ring.
Determine the position of the pipe location, ensuring
that the hole is clear of the rafters and battens. Drill a pilot
hole in the position shown in the picture (fig. 33)
Figure 33
On slate roofs there may be copper retaining pins installed. Remove the pin which is located immediately above
the hole as shown (fig. 35)
Figure 35
If required install some copper pins on the upper corners
and on the centre bottom, liberally apply the mastic (which
is provided with the roof bracket kit) onto the area of slate
which will be covered (fig. 37)
Figure 37
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Now bore a hole with a core bit of approximately 65mm
to provide clearance for the insulated pipe (fig. 34)
Figure 34
Pre fit the roof flashing and measure the distance which
protrudes below the slate lip, then cut off the excess as
shown (fig. 36)
Figure 36
Drill a small hole for the pin on the bottom centre of the
flashing, then slide the flashing upwards and under the slate
located above the 65mm hole. Push down firmly and bend
the copper pins over.
Extra mastic may be applied around the flashing for a
watertight seal (fig. 38)
Figure 38
13
RVR Solar Systems
Installation instructions for 2 in 1 piping
It will be necessary to drill a larger hole in the slate.(fig. 39)
Figure 39
Push the piping through the flashing and ensure that
there is enough to reach the furthest away connection, then
notch the insulation and cut the pipe closest to the panel
connection. (fig. 41)
Figure 41
The hole in the flashing can be enlarged by tearing off the
inner ring of rubber. (fig. 40)
Figure 40
Install the fittings and secure the pipe along the top of
the mounting brackets. Cover the fittings with high temperature adhesive tape. (fig. 42)
Figure 42
Secure the pipe internally to the roof battens so there is no movement in the pipe.
Expanding foam can be applied inside the flashing; this will also provide rigidity and a good seal.
Installation instructions for pipe flashing on corrugated / profiled roof
A specially designed sloped roof flashing is available for sealing the insulated solar pipe, providing a watertight seal. The
base of these flashings has a soft aluminium base molded onto an EPDM rubber grommet, which can be cut for pipe sizes
from ¼" to 4" in diameter.
The flexible base can be shaped to match the profile shape.
Determine the position of the pipe location, ensuring
Liberally apply the mastic on the base and fit the top part unthat the hole is clear of the rafters and battens. Drill a 65mm
der the upper tile (if applicable). Screws or rivets can be used
(approx.) hole in the position shown in the picture (fig. 43)
to secure the flashing while the mastic is curing, see (fig. 44)
Figure 43
14
Figure 44
Installation Instructions
Method for connecting solar metalflex pipe
1. Cut the pipe with a tube cutter as shown in figure 42
(Warning: the pipe end can be very sharp!)
Figure 45
3. Tighten the connection using the threaded nipple
and nut to create a flat end on the pipe as shown in
figure 44.
Figure 47
2. Put the backnut on the pipe, then place the segment
ring in the first groove back from the end and squeeze
it tightly around the pipe as shown in figure 43.
Figure 46
4. Finally insert the fiber washer to create a leak proof
seal as shown in figure 45 (Do not use for any type of
sealant.)
Figure 48
Procedure for Tiled Roofs
The mounting procedure for flat tiled roofs is very similar to that described above except that it will usually be possible
to directly access the rafters from outside by pushing up the tiles as only every third row is fastened on a typical roof. In this
case, it will be easy to locate the rafter and drill through the tile from outside if desired.
When installing on curved tiles, it is important that the hangar bolt is located at the high point of the tile corrugation.
This may not coincide with a rafter position. In this case, it will be necessary to install an extra wooden batten between
adjacent rafters and screw the hangar bolt through this. Suitable treated batten kits are available from RVR Energy Technology Limited.
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RVR Solar Systems
Mounting of FlowCon Solar Station
The Flowcon Solar station contains the system pump, safety valve, flowmeter, service valves, expansion valve connection
and connections for filling and topping up the system.
Figure 49 – Solar Station
•
•
•
•
•
Select a suitable position for mounting the solar station.
Unpack the solar station and remove the front insulation jacket.
Let the solar station screwed to the back part of the insulation jacket.
Mark the mounting hole positions through the insulation and drill with an 8 mm drill. Insert the plugs into the holes.
Mount the solar station with the screws provided.
Piping and Pipe Sizing
Arrangement of Collectors
Tisun FM-S and FM-W Flat panel collectors
No more than seven Tisun flat panel collectors should be connected in series.
Figure 50 – Max seven Tisun collectors connected in series
Calpak GS Flat panel collectors
No more than three Calpak flat panel collectors should be connected in series.
Calpak VTN Vacuum tube collectors
When using vacuum tube collectors, the maximum number of tubes which should be connected in series is 36. ie 3 × 12
VTN collectors.
Figure 51 – Max three GS collectors connected in series
16
Figure 52 – Max three vacuum collectors connected in series
Installation Instructions
Connection of collectors in parallel
When larger numbers of collectors are installed, additional units should be piped in parallel.
Figure 53 – Collectors connected in parallel
Pipe Materials
The temperatures encountered in solar systems are far higher than those encountered in conventional heating systems.
For this reason metal pipe and tubing is used for the piping between collectors and the thermal store. Plastic tubing must
not be used.
Copper is normally used and flexible corrugated stainless steel pipes are often used. Steel pipes may be used in larger
systems. Galvanised pipes should not be used as they are not compatible with antifreeze fluids.
Suitable joining methods include releasable compression fittings using a metal clamping ring, hard soldering and non
releasable press fittings. Soft soldering has a usage limit of 110°C and is not recommended.
Thermal Insulation of Pipes
)
¤NNń
¤NNń
%
%
Figure 54 – Pre-insulated
Solar Pipe System
)
Figure 55b – Pipe Section (2 in 2 “Break Apart”)
Figure 55a – Pipe Section (2 in 1)
Stock №
Type
mm
inch
Coil length
Insulation type
SOL359
SOL360
SOL363
SOL365
SOL368
SOL369
DN12
DN16
DN16
DN20
DN20
DN25
12
16
16
20
20
25
5⁄16"
5⁄8"
5⁄8"
¾"
¾"
1"
10m
15m
25m
15m
25m
25m
2 in 1
2 in 2 ”Break Apart”
2 in 2 ”Break Apart”
2 in 2 ”Break Apart”
2 in 2 ”Break Apart”
2 in 1
Cross sectional
dimensions
75 × 45
96 × 48
96 × 48
104 × 52
104 × 52
105 × 55
Table 3 – Pipe sizes for RVR solar pipe system
The solar heat has to be delivered to the thermal store with the lowest possible losses. An insulation thickness of at least 12mm
should be used for pipes up to 22mm diameter. For larger diameters the insulation thickness should equal the pipe diameter.
There should be no gaps in the insulation. All fittings and connections should be insulated. The pipe insulation should be
resistant to the temperatures found in solar systems. It should also be UV and weather resistant.
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RVR Solar Systems
Pre-insulated solar pipe system
A special flexible pre-insulated solar piping system is available from RVR Energy Technology Limited. It is coated with a
UV resistant film and greatly simplifies the installation of solar system piping. It is available in several sizes and also incorporates a sensor cable.
Figure 56 – Pipe Sizing distance
Number of Solar
panels (up to)
3
6
9
12
15
18
21
24
27
Pipe Sizing
10
DN12
DN16
DN20
DN20
DN25
DN25
DN25
DN25
DN25
15
DN12
DN20
DN20
DN20
DN25
DN25
DN25
DN25
•
Distance (m)
20
DN12
DN20
DN20
DN20
DN25
DN25
DN25
DN25
•
25
DN16
DN20
DN20
DN25
DN25
DN25
DN25
DN25
•
30
DN16
DN20
DN20
DN25
DN25
DN25
DN25
•
•
Table 4 – Pipe sizes for RVR solar pipe system
The pipe diameters required for the solar circuit may calculated once the collector surface area and the length of the pipes
is known. The table above gives recommended pipe sizes for the RVR pre-insulated flexible solar piping system. Note: the distances are the total pipe route distance between the collectors and store. For more complex systems, please consult RVR.
Installation of pipework
Select the correct pipe size and install the piping between the collectors and solar station and between the solar station
and the thermal store.
System Expansion and Safety
Overheat Protection
European Standard EN 12976 requires that solar heating systems are safe and do not require any special measures on the
part of the user when exposed to prolonged high levels of solar radiation without heat consumption.
The worst case situation will occur when the electrical supply is interrupted or the system circulation pump fails. In this
case, the collector, which is filled with antifreeze fluid will boil dry and heat up to it’s stagnation temperature. The pressure
in the system will rise.
Collector Area
5
7.5
10
12.5
15
17.5
20
25
30
Approx System
Volume
18.50
23.25
28.00
32.75
37.50
42.25
48.00
58.50
69.00
Expansion Vessel Size
19.00
40.00
40.00
60.00
60.00
80.00
80.00
100.00
120.00
Table 5 – Recommended Expansion Vessel Sizes (based on an expansion
vessel pre-charge of 2.5 bar and a maximum system pressure of 5.75 bar)
– commercially available sizes
18
Installation Instructions
An expansion vessel of sufficient size is required to contain the displaced collector fluid. The volume of the expansion
vessel can be obtained from the table above and depends on the collector surface area and the system height between
the expansion vessel and the bottom of the collector. A special expansion vessel suitable for solar applications is required.
Suitable expansion vessels are available from RVR Limited.
It is important that the evaporated solar fluid cannot escape from any automatic air vents. If automatic air vents are
installed close to the collectors, they should be fitted with ball valves to allow shut off after commissioning.
Fig. 57 – Solar Station Components
Safety valve
A safety valve is required by law to be fitted in each section of the collector system which can be shut off. The safety valve
must be carefully chosen to cater for the temperature to which it will be exposed. The Safety valve should be piped to a
drain. The safety valve is incorporated into the Flocon S solar station.
Installation of Expansion Vessel
The expansion vessel is connected to the expansion vessel connection on the Flocon S solar station. A flexible metal hose
is supplied for this purpose, and comes with a wall bracket and connector for ease of servicing.
Setting of Expansion Vessel Pressure
The expansion vessel pre-charge pressure should be checked and set to the correct pressure.
Controls and Pumping
A solar station is a standard part of every RVR solar system.
It contains most of the essential control, pumping and safety devices required for satisfactory operation of the solar system.
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RVR Solar Systems
Thermal Store
Fig. 58 – Filling and Flushing the S
The thermal store should be well insulated.
If an unvented domestic hot water system is used, it is important that all of the required safety devices are fitted to ensure
the domestic hot water system complies with the requirements of standards and Building regulations.
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Fig. 59 – Ball Valve
The following safety components must be fitted in the DHW circuit
• Safety valve (release pressure setting = 6bar)
• Expansion vessel (see table 4 for sizes)
Flushing, Filling And Leak Testing
Solar Fluid
The lowest recorded temperature in Ireland is almost -20°C. The solar fluid needs to have a freezing point below this temperature. The addition of 40% propylene glycol to water will produce a solution with a freezing point of -28°C. As propylene
glycol is non-toxic and is not an irritant, it is very suitable for use in solar systems. Ready mixed non toxic food grade anti
freeze is also commercially available.
Do not use car anti-freeze !!
After mixing the antifreeze concentrate with water to achieve the desired level of frost protection (or using pre-mixed
antifreeze) the solar liquid is pumped into the solar circuit through the filling valve on the solar station.
Filling and flushing the solar circuit
• Connect flexible hose to the filling valve under the manometer and open the valve.
• Connect flexible hose to the drain valve and open the valve.
• The slit of the Flow Regulating Valve has to be adjusted horizontally. This closes the integrated ball valve. Open the
non-return valve over the pump by adjusting the ball valve with the aid of a combination-or flat-wrench to a position
of 45° (half opened, half closed).
• Add sufficient solar fluid for the system into the container of a filling station. Start the pump and fill the solar system.
• Using the filling station flush the solar circuit at least 15 minutes. To get the air completely out of the system, open
the Flow Regulation Valve after five minutes and then close it again.
• Do not use water to flush the system as it may present a danger of frost damage if it is not completely purged from
the system.
• Close the Drain Valve while the filling pump is running and increase the system pressure to about 3 to 4 bar. The
system pressure can be read off at the manometer.
• Close the Filling Valve and switch-off the pump. Open the Flow Regulating Valve (slit vertical).
20
Installation Instructions
Please note:
• Start the circulation pump with its maximum pump speed and let it pump for at least 15 minutes.
• To bleed the circulating pump, unscrew the brass screw on the face.
• Afterwards adjust the pump speed to the required speed.
• Adjust the volume flow at the flowmeter using the Flow Regulating Valve according to the values given in the table
below.
• Disconnect the hoses from the filling and drain valves and screw the caps onto the valves.
• Recheck the system once again for leaks.
• Open the ball valve above the pump completely.
• Mount the front insulation jacket to the solar station.
• Allow the system to run for several hours to clear further air from the system.
• The system is now ready for use.
• Refer to the controller instructions for further system settings.
Electrical Wiring
• The following are the wiring requirements for the solar system:
• The Solar Station requires a 220V, 50 Hz power supply. Fuse at 5 amps.
• A temperature sensor (PT 1000) should be fitted near to the bottom of the thermal store. This should be wired to the
S2 connection on the solar station via a 2 core cable.
• A temperature sensor (PT 1000) should be fitted to the outlet of the collector. This should be wired to the S1 connection on the solar station via a 2 core cable. Please see diagram below.
• When the solar station is used to control the supplementary heat source, a second sensor will need to be fitted to
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Fig. 60a – Electrical Wiring
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Fig. 60b – Electrical Wiring
the upper third of the thermal store. This should be wired to the S3 connection on the solar station (where available)
via a 2 core cable. Please see diagram below.
Maintainance
The RVR solar heating system requires minimum maintenance to ensure continued efficient operation.
The following maintenance should be carried out periodically. Every two years would normally be sufficient as a maintenance interval.
• Check that all the fastening screws of the collector supports and the screws of the fixing pads are secure and well
tightened. If not, fix them properly or change them if necessary.
• Clean the glass of the flat plate collectors or the vacuum tubes to increase efficiency.
• For vacuum collector models change any broken vacuum tubes. To change a tube, loosen the screws of the retaining
bracket on the lower part of the collector and slide out the broken tube.
• Slide the new one in place and re-mount the bracket.
• A broken vacuum tube does not prevent the system from running, but it will cause the loss of efficiency and will be
liable to frost.
• A vacuum tube that contains a white dust at the lower end of the tube has lost its vacuum and must be replaced.
• Check the level of the thermal fluid and fill the system if necessary using the filling method described in the previous
section. The PH level and freezing point of the thermal fluid should also be checked.
• Check for any leakage in the collectors and joints.
• For any other queries about maintenance and troubleshooting, please contact RVR.
21
RVR Solar Systems
Installation Tips
• Remember that the solar fluid can reach temperatures as high as 200°C under certain circumstances.
• On the Calpak 12-VTN vacuum panel, there is a dry pocket built into the top left of the panel close to the 22mm copper
pipe header. This is the position where the temperature sensor must be installed.
• Always fit the PT-1000 sensor which has black heat resistant silicone cable to the outlet side of the solar panel. This
is the hottest place in the circuit.
• On the Calpak 12-VTN vacuum panel the flow (hot) connection to the solar coil is on the top left, and the return (cold)
from the solar pump outlet goes to the top right of the panel (anti-clockwise circuit).
• If the collector sensor is on the return side of the circuit the system will not work properly because it will be cooled
too fast.
• Always fit the sensor for the solar heating as close to the bottom of the storage tank as possible to maximise the
volume of hot water.
• The solar coil in the heating tank is generally the lowest one available.
• For efficiency reasons the flow (hot) solar connection is the highest of the solar coil connections. (Some TiSUN tanks
have a different configuration see diagrams)
• Always use pipe thread sealant where you have male to female threaded connections (Check with your sealant supplier
for compatibility i.e. Propylene glycol@200°C)
• Compression fittings and flat seal connections do not require any sealant or tape as they are designed to be fitted dry.
(In fact some sealants can be deposited on the threads and stiffen the nut resulting in an under compressed connection.)
• Invest in proper tools for the job e.g. use two tight fitting open spanners on compression fittings.
• If the installation is in an awkward location the panels could be laid out at ground level and all the connections can
be pre-made, then take them apart and re-do the arrangement on the roof.
• Do not fully tighten the mounting clamps on the brackets until you have all your compression fittings fully tightened.
• Hold the body of the compression fitting still, and tighten the back-nut, this ensures that you don’t twist the copper
pipe causing a leak somewhere else.
• The Calpak 12-VTN vacuum panel comes with a white plastic wrapping; ideally this should be left on until they are
commissioned.
• Never fill solar panels when they are hot, the solar fluid will get very hot and may even vaporise suddenly, causing
burns and/or broken vacuum tubes.
• An air compressor is very useful for pre-checking the circuit for leaks. Pressurise the system to 4 bar, close the valves
and observe the pressure gauge for a while.
• The air compressor can also be used to cool down the panels if they are not covered.
• Solar Fluid gets thinner and the flowrate rises as the temperature rises so the system should be commissioned when
cold ≤ 30°C approx.
• The ends of the exterior pipe insulation should be properly sealed to prevent water running down along the metal pipe
to the tank/controller
• The simplest and best way to install a collector array is to have them on the same orientation i.e. the same roof surface.
If you have them in different orientations e.g east/west you will need a controller that can sense the temperature in
both arrays and be able to mechanically pump the fluid around the first/second or both arrays at a time.
22
Notes
23
RVR Energy Technology Limited, Kenmare, Co. Kerry, Ireland
Telephone: +353 64 41344 • Fax: +353 64 89520
www.RVR.ie
This publication is issued subject to alteration or withdrawal without notice. The illustrations and specifications are not binding in detail. All offers and sales are subject to the Company’s current terms and conditions
of sale which are available on www.rvr.ie
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