Solar Collector Manual

Solar Collector Manual
SOLARcomfort
Solar Hot Water
Systems
2 & 3 Collector
Sets
Country of Destination GB/IE
Installation Instructions
LEAVE THESE INSTRUCTIONS WITH THE
END USER
TABLE OF CONTENTS
1.
1.1
1.2
1.3
1.4
1.5
1.6
2.
GENERAL INFORMATION ............... 2
GUARANTEE ......................................... 2
SYSTEM CONTENTS ............................... 2
SYSTEM INSTRUCTION BOOKS .................. 2
SOLARCOMFORT ................................. 3
LIFESTYLE ............................................ 3
HOW THE SYSTEM WORKS ...................... 3
THREE COLLECTOR SCHEMATIC ............. 19
FIXING STRAPS ................................... 20
ROOF TYPES ...................................... 21
COLLECTOR FIXINGS ............................ 22
COLLECTOR FITTING PROCEDURE ........... 23
PLUMBING CONNECTIONS ...................... 28
6.
COMMISSIONING & SERVICING .. 28
7.
FLAT ROOF/GROUND MOUNTING
KIT .................................................. 29
COMPONENT LIST ................................ 29
ANGLE OF INCLINATION ......................... 29
COLLECTOR ORIENTATION ..................... 30
DIMENSIONS ....................................... 30
FLAT ROOF CONDITION ........................ 30
GROUND PREPARATION ......................... 31
ASSEMBLY .......................................... 31
SAFETY ............................................ 5
3.
TECHNICAL DATA ............................ 6
3.1 TEMPERATURE/PRESSURE ....................... 6
3.2 COMPONENT LIST FOR 2 COLLECTOR SYSTEM
7
3.3 COMPONENT LIST FOR 3 COLLECTOR SYSTEM
8
3.4 COLLECTOR DIMENSIONS ........................ 9
3.5 FIXING STRAPS DIMENSIONS ................. 10
4.
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
REGULATIONS & STANDARDS..... 11
WATER REGULATIONS .......................... 11
BUILDING REGULATIONS ........................ 11
GENERAL GUIDANCE ............................ 11
BRITISH & EUROPEAN STANDARDS ......... 12
UK REGULATIONS (WATER HEATING) ..... 12
UK REGULATIONS (CONSTRUCTION) ....... 12
EU DIRECTIVES .................................. 13
OTHER PUBLICATIONS .......................... 13
ELECTRICAL CONNECTION ..................... 13
THERMAL INSULATION ........................... 13
5.
5.1
5.2
5.3
5.4
5.5
5.6
INSTALLATION ............................... 14
TOWN & COUNTRY PLANNING ............... 14
HOUSE INSURANCE .............................. 14
RISK ASSESSMENT .............................. 14
ROOF CONDITION ................................ 14
POSITIONING COLLECTORS .................... 14
CONSIDERATIONS FOR POSITIONING
COLLECTORS ...................................... 14
COLLECTOR INCLINATION ....................... 15
PIPEWORK & FITTINGS ......................... 15
INSULATION ......................................... 15
SIZING OF PIPES ................................. 15
PIPEWORK .......................................... 16
COLLECTOR COUPLINGS ....................... 16
COLLECTOR CONFIGURATIONS ............... 17
TWO COLLECTOR SCHEMATIC ................ 18
5.7
5.8
5.9
5.10
5.11
5.12
5.13
5.14
5.15
5.16
5.17
5.18
5.19
5.20
7.1
7.2
7.3
7.4
7.5
7.6
7.7
1
1.
GENERAL
INFORMATION
This manual is an integral and essential part of the product. It should be
kept with the product.
Please read carefully the instructions and notes about SOLARcomfort
contained in this manual as they provide important information regarding
the safe installation of the Solar Collectors.
IMPORTANT
Failure to follow these instructions correctly may invalidate the
guarantee.
IMPORTANT
Solar domestic hot water heating systems must be installed to
comply with the current Building Regulations, British Standards
and any applicable local regulations.
1.1 GUARANTEE
The SOLARcomfort Collectors are guaranteed for 5 years against
manufacturing defect - see terms and conditions of guarantee on back
page.
1.2 SYSTEM CONTENTS
The complete SOLARcomfort solar water heating system is supplied in
the following consignments:-
1.3 SYSTEM INSTRUCTION BOOKS
2
1. 800201
Collector
1 per box
2. 3107024/5
3. 3820011/2
Roof Fittings Kit
System Components
1 cardboard tube
1 box
4. 3820001
Tyfocor antifreeze heat transfer fluid
1 x 20l container
The following instruction booklets are supplied with a complete
SOLARcomfort solar water heating system:1.
SOLARcomfort Solar Hot Water Systems Collectors 2 & 3 Collector
Set.
Covers collector installation and plumbing connection.
Supplied in System Components box.
2.
SOLARcomfort Solar Hot Water Systems Pump Group 40/60.
Covers installation, plumbing connection, system filling, flushing and
commissioning.
Supplied in System Components box.
3.
Solar Controller AST 100
Covers installation, wiring connection and User Instructions.
Supplied in System Components box.
1.4 SOLARCOMFORT
SOLARcomfort systems are highly efficient and provide cost savings on
the energy used for heating hot water wherever they are used in the UK.
However, the savings made will depend on local climate, installation
characteristics and the household’s domestic hot water requirements.
It is important that the SOLARcomfort system is correctly sized for the
local climate condition and the householders requirements.
1.5 LIFESTYLE
After installation of the SOLARcomfort system, changes to the
householders use of hot water will be beneficial. Simple changes such as
bathing in the evening instead of the morning and putting automatic washing
machines on when free hot water is available by solar energy.
In addition, the timing of the dwelling’s boiler controls must be modified to
ensure the ‘hot water ON’ time is set so that the water temperature in the
cylinder is at a minimum by the start of the ‘solar day’.
1.6 HOW THE SYSTEM WORKS
See fig. 1.6A
The solar collectors are heated by the sun’s rays. The heat generated is
stored in a hot water storage cylinder e.g. Ariston Primo twin coil stainless
steel cylinder. The system controller continually compares the temperature
of the water within the cylinder with the temperature of the solar collectors.
Whenever the solar collectors are hotter than the water within the cylinder,
the controller switches on the system’s circulating pump. The temperature
differential between the collectors and the cylinder is set via the AST 100
Solar Controller. The heat transfer fluid within the solar system is then
circulated through the collectors and the cylinder’s heat exchanger, heating
the cylinder in just the same way as a central heating boiler.
The cylinder typically has two coils (heat exchangers), the lower coil is
heated by the solar system, therefore solar is the primary heat source.
The upper cylinder is heated by an auxiliary heat source, typically a central
heating boiler, which is used to heat water when there is insufficient heat
generated by the solar system. The Ariston Primo Twin cylinder also has
two immersion heaters making it suitable for electric only heating systems.
The SOLARcomfort system is a forced circulation sealed system and
therefore requires an expansion vessel and a pressure relief valve (PRV),
both supplied with SOLARcomfort.
The air separator with an integral manual air vent together with an automatic
air vent positioned at the highest point on the system ensures that the
sealed system remains free of air.
3
Roof mounted collectors
(two collector system shown)
Air vent
Energy
Monitoring
Sensor S4
(option)
Temperature
Sensor S1
Ariston ITSI 210/300
twin coil cylinder
AST 100
Controller
PR Valve
Pump group
Temperature
Sensor S3
Expansion
vessel
Upper coil
heated by boiler
or other heat
source
Temperature
Sensor S2
PRV discharge
vessel
Solar system
low level fill
point
Lower coil heated by
solar energy
FIG. 1.6A SOLAR BASIC PRINCIPLES
4
Solar system
drain point
2.
SAFETY
WARNING - RISK TO LIFE
Correct procedures must be followed when lifting the collectors.
To satisfy Health and Safety requirements relating to the construction
industry, the use of a crane or other lifting device may be required.
Note:
Optional lifting handles are available
from Ariston (code 3107023).
Take appropriate precautions to prevent accidents and falls when
working on roofs.
Ensure correct personal protective clothing and safety equipment
are used when working on roofs.
Ensure that collectors lifted onto the roof or scaffold are always
secured to prevent them slipping and falling off the roof. Serious
injury or death may result from collectors falling.
WARNING
The collectors must be correctly secured to the roof. The roof must
be of adequate structure to support the collectors.
WARNING
During operation and commissioning the temperature of the heat
transfer fluid within the system and collectors can reach temperatures
high enough to present a risk of scalding. Never loosen fittings or
open vents when the system is hot.
WARNING
TYFOCOR LS Heat Transfer Fluid.
Although non-toxic it should not be swallowed.
Refer to label on its container for storage and safety information.
A detailed technical specification is available from Ariston on request.
Caution
SOLARcomfort should be installed and commissioned by approved
contractors. Failure to do so may invalidate the warranty.
Caution - Risk of damage to collectors
IMPORTANT! Always keep the glass side of the collectors fully
covered until the system is filled and ready for operation.
Always transport the collectors in an upright position. Never position the
collectors with the glass side facing down.
Leave collectors in their packaging until the time of installation. Do not
allow the bottom side of the collectors to be damaged by sharp objects.
Never leave the collectors with the glass side down when they could be
exposed to the weather, as rainwater could infiltrate the collector and cause
condensation within the collector.
5
3.
TECHNICAL DATA
COLLECTORS
Weight - each - empty
38kgs
Total surface area - each
2m²
Aperture area - each
1.83m²
Absorber area - each (evaluated according to EN12975:2001)
1.76m²
Capacity - each
1.5l
Maximum operating pressure
*The stagnation temperature was calculated
for:Insolation level of 1000W/m²
Atmospheric temperature value 30°
6Bar
Pressure loss
10mbar
Output - each
100l/h
Plate absorption
95%
Plate emission
5%
*Stagnation temperature
167°C
Inlets/Outlets - copper
Frame
Ø22mm
Grey aluminium UV resistant
EXPANSION VESSEL
2 collector system
25l
3 collector system
25l
HEAT TRANSFER FLUID
Type
Tyfocor LS
Use undiluted
100%
Weight
1.04kg/l
Frost Protection
to -28°C
3.1 TEMPERATURE / PRESSURE
Operating pressure and
temperature must be within
the limits depicted by the
hatched area
Operating temperatures above
100°C as depicted by the
shaded area must be avoided
for continuous operation
FIG. 3.1A TEMPERATURE PRESSURE DIAGRAM
6
3.2 COMPONENT LIST FOR 2
COLLECTOR SYSTEM
Listed below are all the components required to fit the collectors for the
SOLARcomfort 2 collector system.
Roof Fixing Kit (cardboard tube)
Flexible connecting kit
Collector brass fitting kit
Ref
Des cription
Qty
Cons ignment
Pa cked
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Collectors 1 0 0 0 mm x 2 0 0 0 mm
Support Ra ils length 2 2 0 0 mm
Short fixing s tra ps
Long fixing s tra ps
Stra p fixing s crews Ø6 x 5 0 (No.1 2 x 2 ")
Outer cla mps (s hort)
Inner cla mps (long)
Collector bottom bra ckets
M8 x 2 5 hex s ta inles s s teel bolts
M8 hex s ta inles s s teel nuts (inc 6 spare)
M8 s ta inles s s teel wa s hers (inc 12 for wood screws)
Compres s ion coupling 2 2 mm
Compres s ion s top end 2 2 mm
Compres s ion T 2 2 mm x ½" x 2 2 mm
½" to 3 /8 " Reducer bus h
Ins ula ted flexible pipe 2 2 mm x 1 m
Compres s ion coupling 2 2 mm
Automa tic a ir vent
Is ola ting va lve 3 /8 "F x 3 /8 "M
2
2
4
4
12
4
2
4
12
18
24
3
2
2
1
2
2
1
1
1 per box
Individua l
Roof fixing kit
1 Ca rdboa rd tube
Collector bra s s
fittings kit
Pa cked in Sy s tem
Components box
Flexible connection
kit
Pa cked in Sy s tem
Components box
20
Collector Ins tructions
1
21
½" Thermos ta t pocket
1
Pa cked in Sy s tem
Components box
Pa cked in with AST 1 0 0 Controller
FIG. 3.2A 2 COLLECTOR SYSTEM COMPONENT LIST
7
3.3 COMPONENT LIST FOR 3
COLLECTOR SYSTEM
Listed below are all the components required to fit the collectors for the
SOLARcomfort 3 collector system.
Roof Fixing Kit (cardboard tube)
Flexible connecting kit
Ref
Description
Qt y
Consignment
Packed
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Collectors 1000mm x 2000mm
Support Rails length 3300mm
Short fixing straps
Long fixing straps
Strap fixing screws Ø6 x 50 (No.12 x 2")
Outer clamps (short)
Inner clamps (long)
Collector bottom brackets
M8 x 25 hex stainless steel bolts
M8 hex stainless steel nuts (inc 8 spare)
M8 stainless steel washers (inc 18 for wood screws)
Compression coupling 22mm
Compression stop end 22mm
Compression T 22mm x ½" x 22mm
½" to 3/8" Reducer bush
Insulated flexible pipe 22mm x 1m
Compression coupling 22mm
Automatic air vent
Isolating valve 3/8"F x 3/8"M
Collector Instructions
½" Thermostat pocket
3
2
6
6
18
4
4
6
24
24
34
5
2
2
1
2
2
1
1
1
1
1 per box
Individual
Roof fixing kit
1 Cardboard tube
Collector brass
fittings kit
Packed in System
Components box
Flexible connection
ki t
Packed in System
Components box
FIG. 3.3A 3 COLLECTOR SYSTEM COMPONENT LIST
8
Collector brass fitting kit
Packed in System
Components box
Packed in with AST 100 Controller
3.4 COLLECTOR DIMENSIONS
FIG. 3.4A COLLECTOR DIMENSIONS
9
3.5 FIXING STRAPS DIMENSIONS
LONG
SHORT
FIG. 3.5A FIXING STRAP DIMENSIONS
10
4.
REGULATIONS &
STANDARDS
SOLARcomfort hot water heating systems should be installed in
compliance with the following standards and regulations.
4.1 WATER REGULATIONS
Water Supply (Water Fittings) Regulations 1999 / www.wras.co.uk
These regulations (bye-laws in Scotland) ensure a good supply of
wholesome water and that only approved materials, pipes and fittings are
used to convey water.
4.2 BUILDING REGULATIONS
These are statutory documents and take priority over all other regulations
and recommendations. The installation of an unvented hot water storage
cylinder is classified as a “Controlled Service” and Regulation G3 applies.
To meet the requirements of the Regulations, installation of an unvented
system should be undertaken by a “competent installer”.
All installations of unvented hot water storage systems having a capacity
of more than 15 litres should be notified to the relevant Local Authority by
means of a building notice or by the submission of full plans. It is important
to note that it is a criminal offence to install an unvented hot water storage
system without notifying the Local Authority. The installation of the unvented
cylinder and hot water system must comply with BS 6700 and the HSE
Legionella Code of Practice.
4.3 GENERAL GUIDANCE
Current guidance notes do not cover the connection of a solar thermal
circuit to an unvented storage vessel (cylinder). However, if guidance is
sought for compliance with current regulations the fundamental principle
is to provide a fail-safe means of shutting off the solar input to the heat
exchanger if the cylinder temperature should rise above the set temperature
of the cylinder’s energy cut out. (See Note 1).
As with all unvented hot water systems, notification of intention to install
should be given to your local building control.
Option A. A non self-resetting mechanical shut-off should be installed on
the solar primary flow to the cylinder. The mechanical shut-off should be
suitable for use with a solar primary circuit (i.e. high temperature and glycol
resistant). The mechanical shut-off should be integrated electrically with
the cylinder energy cut out/s and if necessary the solar circuit temperature
control, please refer to the solar controller manufacturer for further
information.
Option B. Where the solar controller and hydraulic system demonstrate
that by no lesser means the requirement in Option A is satisfied by other
means; certification by an approvals body is required to demonstrate that
in the event of the stored water going over temperature, the heat input to
the cylinder is isolated by physical means and is non self-resetting.
These systems should be clearly identified with reference to the approvals
body. (See Note 2).
Note 1 : Whilst most solar cylinders use a coil type heat exchanger other
options such as external plate to plate devices, external annulars or ‘tank
in tank’ systems may be used but the same control options always apply.
Note 2 : Current approved bodies include the British Board of Agrèment
(BBA), WRc-NSF Limited, or KIWA.
11
4.4 BRITISH & EUROPEAN
STANDARDS
Connection of thermal solar heating systems
EN 12976: Thermal solar heating systems and their components
(prefabricated systems).
ENV 12977: Thermal solar heating system and their components (bespoke
systems).
BS5918: Latest version: Solar heating systems for domestic hot water.
Installation and equipment of DHW cylinders
BS5546: 2000 Specification for installation of hot water supplies for domestic
purposes, using gas-fired appliances of rated input not exceeding 70 kW.
BS6700: 1997 Specification for design, installation, testing and
maintenance, of servicing, supplying water for domestic use within buildings
and their curtilages.
The local water company by-laws.
Electrical connection
Current IEE wiring regulations.
Health and Safety document No 635 (Electricity at Work Regulations)
4.5 UK REGULATIONS
PARTICULARLY RELEVANT FOR
WATER HEATING EQUIPMENT
4.6 UK REGULATIONS
PARTICULARLY RELEVANT FOR
CONSTRUCTION
The Pressure Equipment Regulations (PED) 1999 - www.eurodyn.com
The Building Regulations (L1 A&B) 2006 and Domestic Heating Compliance
Guide - www.communities.gov.uk
The Building Regulations (P) 2005 - www.communities.gov.uk
Control of Substances Hazardous to Health Regulations (COSHH) 1994 www.hse.gov.uk
Further details available from: www.hse.gov.uk
Health & Safety At Work Act (HSW) 1974
Work at Height Regulations 2005.
Reporting of Injuries, Diseases and Dangerous Occurrences Regulations
(RIDDOR) 1995.
Management Health & Safety at Work Regulations (MHSWR) 1999.
Noise at Work Regulations 1989.
Construction (Health, Safety & Welfare) Regulations (CHSWA) 1996.
Electricity at Work Regulations 1989.
Construction Regulations (Head Protection) 1989.
Control of Substances Hazardous to Health Regulations (COSHH) 1994.
Construction (Design and Management) Regulations (CDM) 1994.
Personal Protective Equipment at Work Regulations 1992.
Lifting Operations and Lifting Equipment Regulations (LOLER) 1998.
Confined Spaces Regulations 1997.
Manual Handling Operations Regulations 1992.
The Workplace (Health, Safety and Welfare) Regulations 1992 (WHSWA).
Provision and Use of Work Equipment Regulations (PUWER) 1998.
Health and Safety (First Aid) Regulations 1981.
LZC - Low or zero carbon energy sources: strategic guide.
12
4.7 EU DIRECTIVES
Further details available from: www.europa.eu.int
Construction Directive: 89/106/EEC
Electromagnetic: 89/336/EEC
Low voltage: 73/23/EEC
Machinery Directive: 98/37/EC
4.8 OTHER
Preventing hot water scalding in bathrooms: using TMVs (IP 14/03).
DTI testing of solar systems (SP300275 1-3).
Review of issues related to active solar heating systems (SP300246).
Active solar performance and data review (SP300270).
Solar heating systems for hot water (BS 5918).
Hard water scale in hot water storage cylinders (IP13/93).
Heating systems in buildings – design for water-based heating systems
(PrEN 12828).
Building log books (GPG 348).
Solar heating (CIBSE DBSP WGG).
Sun in Action II (ESTIF – Sun in Action II).
Minimising the risk of legionnaires’ disease (TM 13).
BRE Digest 489.
Energy Saving Trust - www.est.org.uk
CE131 Solar Water Heating Systems - Guidance for professionals,
conventional indirect models.
PUBLICATIONS
4.9 ELECTRICAL CONNECTION
BS7671 2001 Amended 2004
APD P:
P1 - Design, Installation, Inspection and Testing
P2 - Provision of information
4.10 THERMAL INSULATION
Thermal Insulation Standard TIMSA (Thermal Insulation Manufacturers
and Suppliers Association).
13
5.
INSTALLATION
5.1 TOWN & COUNTRY PLANNING
The following topics should be considered prior to installing the
SOLARcomfort system.
In general Solar Thermal Systems tend to be looked upon favourably by
Local Authority Planning Departments, although there are implications for
listed buildings and sensitive front elevations in some conservation areas.
Some Local Authorities may consider solar panels as ‘Permitted
Development’ and therefore not requiring formal Planning Permission.
This may not be the case in all circumstances and contact with the local
Planning Authority is vital to determine the authority’s policy.
Permitted development rights do not necessarily apply in Areas of
Outstanding Natural Beauty, Conservation Areas, Sites of Special Scientific
Interest and National Parks.
5:2 HOUSE INSURANCE
The householder should ensure that they are covered for the modifications.
The Home Information Pack (HIP) may have specific requirements
regarding the installation of solar panels.
5.3 RISK ASSESSMENT
A risk assessment covering construction, water quality and bacterial risks
must be made before work starts. A site visit is required to assess the
risks to workers, householders, members of the public and animals.
5.4 ROOF CONDITION
Prior to installation, the current condition of the roof must be assessed to
ensure that it is capable of withstanding the additional weight of the solar
collectors and roof mounting system. Where necessary, specialist
personnel should be contacted to verify the suitability of the roof structure.
5.5 POSITIONING COLLECTORS
The solar collectors offer maximum energy performance when the glass
surface faces directly south. The angle of the dwelling in relation to the
sun and site restrictions may lead to variations to this optimum south
position, a maximum recommended variation is 30° from due south.
A collector facing east side of south will give better performance in the
morning than in the afternoon.
A collector facing west side of south will give better performance in the
afternoon than in the morning.
5.6 CONSIDERATIONS FOR
POSITIONING COLLECTORS
14
Consideration should be given to the following when selecting a position
for collectors.
1.
The collectors must not be in the shade during daylight hours.
The trimming or felling of trees may be advised.
2.
In positions where exposure to high winds are likely, extra or alternative
collector mountings should be considered.
3.
The collectors should be placed as close as possible to the storage
cylinder to keep pipe runs to a minimum.
4.
Collectors and the in loft pipework must be accessible for all necessary
maintenance work.
5.
The possibility of bird or animal droppings fouling the surface of the
collectors e.g. overhead cables or branches.
5.7 COLLECTOR INCLINATION
Collectors mounted on a pitched roof should always be parallel to the tiles
i.e. at the same angle as the roof. There is no exception to this rule.
Collectors can be mounted on a flat roof or the ground, for such applications
a special inclined angle fixing set is available - see section 7.
5.8 PIPEWORK AND FITTINGS
Taking into account that the heat transfer fluid within the system may reach
high temperatures, the primary circuit should be copper, stainless steel
(rigid and flexible) or carbon steel braided high temperature hose. Pipe
joints and connections with other system components should also be able
to withstand the working temperatures and pressures. Thought should be
given to preventing corrosion due to dissimilar metals in contact.
All copper pipework must be Kite Marked BS EN1057 1996 Table X half
hard copper tube.
All fittings must be quality brass BS864-2 compression type.
Brass olives are recommended as they produce a better seal.
Brazed or silver soldered joints are acceptable.
The use of joint compounds such as ‘Fernox White’ is recommended for
compression joints.
Owing to the high temperatures of the solar system, plastic pipe and
fittings must not be used.
All fittings and components fitted must be able to withstand
temperatures in excess of 150°
Soldered and push fit fittings should not be used.
Galvanised steel pipe should not be used.
5.9 INSULATION
All external pipework, connections and fittings must be insulated with
suitable high temperature, vermin resistant and UV resistant insulating
materials.
All internal pipework (excluding pipework to the expansion vessel) must
be insulated with suitable high temperature insulating materials.
Insulation of the pipework must only be undertaken after tightening
of the compression fittings and completion of a pressure test - see
Pump Group Manual.
5.10 SIZING OF PIPES
The flow rate in the circuit is between 0.5 and 1.5 litres/min. for each
collector.
The flow velocity in the circuit should not exceed 1.5m/sec otherwise the
system may be noisy during operation.
As a guide only: for systems with total pipework of less than 50 metres,
15mm diameter pipe should allow flow conditions to be met for systems
with up to four collectors.
When the total pipework is over 50 metres, then 22mm pipe should be
used.
An assessment of the specific installation requirements must be
undertaken.
15
5.11 PIPEWORK
5.12 COLLECTOR COUPLINGS
The installation of pipework must be made in accordance with good
plumbing practice, the following points should be considered when installing
pipework.
1.
Pipe runs should be chosen to give the shortest most direct route to
the storage cylinder, with minimum bends. Tight bends should be
avoided.
2.
The falls of pipes should be arranged to allow the system to be drained
and vented.
Low points, when unavoidable, should be fitted with a drain.
High points, when unavoidable, should be fitted with a vent.
3.
Where possible, all pipe runs should have a continuous slight incline
up to the highest point in the system to allow for natural venting of air
from the system.
4.
The automatic air vent supplied with the system should be fitted to
the highest point i.e. near the flow connection of the collectors.
5.
Adequate support and fixing should be provided for all pipework to
ensure that inclines are maintained and sagging is prevented.
6.
Owing to the high temperature differentials within the solar circuit
consideration should be given to the expansion of the pipework, expect
up to 12mm on a 5 metre run. Pipes should be fitted with brackets
and devices that allow for expansion and contraction, rigid fixings
should be avoided.
7.
A drain point must be fitted at the lowest point of the solar circuit. It
must be positioned at the down side of the non-return valve to ensure
the system can be fully drained.
Collectors are jointed together and connected to the pipework by 22mm
compression fittings.
These fittings connect to the 22mm spigots projecting each side of the
collector. The spigots are not fixed and can move in and out in relation to
the side panel of the collector to allow for alignment of the collectors. Owing
to this movement it is important to ensure each spigot penetrates the fitting
fully so that a correct join is made.
It is advised to make a pencil mark on each spigot 22mm from the end.
When the fittings are in position, these marks will show that the spigots
have fully penetrated the fitting - see fig. 5.12A.
This also applies to the two stop ends fitted to the collectors.
FIG. 5.12A COLLECTOR COUPLINGS
16
5.13 COLLECTOR
CONFIGURATIONS
Two to seven collectors can be connected in series. When more than
seven are installed we recommend the panels are installed in a parallel
configuration. Connection in series is recommended when a limited output
and high domestic hot water temperature is required.
SERIES
Flow
Return
Auxiliary heat
source
Twin Coil
Indirect Cylinder
FIG. 5.13A COLLECTOR SERIES CONFIGURATION
PARALLEL
Flow
Return
Auxiliary heat
source
Twin Coil
Indirect Cylinder
FIG. 5.13B COLLECTOR PARALLEL CONFIGURATION
17
5.14 TWO COLLECTOR SCHEMATIC
Cylinder
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Collector
System Pressure Guage
Pump Module
Automatic Air Vent
Flow Temperature Gauge
Shut Off Valve
Circulating Pump
Flow Limiter
Non-Return Valve
Pressure Relief Valve (PRV)
PRV Discharge Vessel
Return Temperature Gauge
FIG. 5.14A TWO COLLECTOR FLOW DIAGRAM
18
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
Air Separator with manual air vent
Expansion Vessel
Solar AST 100 Controller
Upper Cylinder Temperature Sensor (S3)
Lower Cylinder Temperature Sensor (S2)
Collector Temperature Sensor (S1)
System Fill Point (flow)
System Fill Point (return)
System Drain
Cylinder - twin coil shown
Boiler (auxiliary heat source)
5.15 THREE COLLECTOR SCHEMATIC
Cylinder
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Collector
System Pressure Guage
Pump Module
Automatic Air Vent
Flow Temperature Gauge
Shut Off Valve
Circulating Pump
Flow Limiter
Non-Return Valve
Pressure Relief Valve (PRV)
PRV Discharge Vessel
Return Temperature Gauge
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
Air Separator with manual air vent
Expansion Vessel
Solar AST 100 Controller
Upper Cylinder Temperature Sensor (S3)
Lower Cylinder Temperature Sensor (S2)
Collector Temperature Sensor (S1)
System Fill Point (flow)
System Fill Point (return)
System Drain
Cylinder - twin coil shown
Boiler (auxiliary heat source)
FIG. 5.15A THREE COLLECTOR FLOW DIAGRAM
19
5.16 FIXING STRAPS
Two types of Fixing Strap are supplied, long and short - for dimensions
see fig. 3.5A.
The construction of the roof, batten spacing and type of tile will determine
which of the fixing straps is most suitable for the installation.
Where appropriate, an optional rafter bar is available (code:
). The
rafter bar allows the fixing strap to penetrate the roof and be attached to a
bar affixed between the rafters (see separate data sheet).
Long Fixing Straps
These are generally suitable for roofs with tiles up to a maximum length of
500mm e.g. large slate tiles.
Short Fixing Straps
These are generally suitable for roofs with small clay tiles.
The fixing straps are made of stainless steel and are pliable enough to be
bent to shape around the fixed tiles, so that their top end lays flat on the
felt/membrane directly over rafters.
Rafters should be in sound condition. Rafters that have deteriorated due
to age and decay should be made sound, reinforced or replaced.
It is important that each strap is secured to a sound rafter with at least
three screws which have at least 45mm length in the rafter, washers are
supplied for the screws.
Always pre-drill the rafter before screwing to prevent splitting.
Wood Screws
3 qty Ø6 x 50
+ washer
Fixing Strap
A
Bend Fixing Strap
around tiles
FIG. 5.16A FIXING STRAP
For best appearance the collectors should be fitted so that they are square
with the tiles.
To achieve this ensure that the bottom pair of fixing straps are positioned
using the edge of the tiles as a datum - dimension ‘A’ in fig. 5.16A.
WARNING
The collectors must be correctly secured to the roof. The roof must
be of adequate structure to support the collectors.
20
5.17 ROOF TYPES
INTERLOCKING PROFILED TILES
For all profiled tiles, straps should be
fixed to align with the troughs in the tiles
as opposed to the peaks, as shown.
FLAT TILE / SLATES
Bend the fixing strap to ensure a secure
fixing on the rafter. The exposed part
of the strap must be beyond the edge
of the tile.
CLAY PLAIN TILED
For shorter tiles the tile battens can be
too close together and bending the roof
brackets to suit will be difficult.
Wood spacers can be fitted as shown.
Screws must be passed through
spacers and penetrate at least 45mm
into the rafter.
An alternative method is to loosen the
battens and slide the fixing straps under
the battens. Care must be taken to
ensure the resulting roof structure is
sound.
FIG. 5.17A ROOF TYPES FIXING
21
The two aluminium collector support rails are bolted directly to the roof
fixing straps.
5.18 COLLECTOR FIXINGS
Collector bottom brackets hook over the rails on the front edge of the
collectors to prevent the collectors sliding down.
IMPORTANT
After installation check all clamp nuts
are tight.
The extruded section of the support rails is designed to accept M8 hexagon
bolt heads, these are slid in from the end and will remain captive.
The collectors are clamped to the top of the support rails with clamp plates.
Captive Bolts
Support Bar
M8 Bolt
Centre Clamp
Outer Clamp
Collector
Support Bar
Bottom Stop
FIG. 5.18A COLLECTOR FIXINGS
22
Fixing Strap
5.19 COLLECTOR FITTING
PROCEDURE
CAUTION
EXTREME care must be taken NOT
to puncture the under side of the
collectors.
1.
Fix lower fixing straps to rafters using the Ø6 x 50 screws provided,
three screws minimum per strap. Rafters must be sound and screws
must penetrate the rafters by at least 45mm.
Two straps for 2 Collectors, three straps 3 Collectors.
2.
Slide bolts along one of the support rails to align with lower fixing
straps.
3.
Locate bolts in the holes in the fixing straps, fit nuts with washers,
align bar in required position and tighten nuts.
4.
Measure for top rail.
5.
Fit top fixing straps to rafter.
Two straps for 2 Collectors, three straps 3 Collectors.
6.
Fit top support rail.
7.
Slide on two bottom support brackets for first collector.
8.
Unpack both collectors and cover glass side.
9.
Lower first collector and locate the two bottom support brackets in
the bottom edge of the collector.
10. Slide in 1 bolt into outer end of each rail approx. 75mm.
11. Fix collector outer edge using one outer (short) clamp on each rail.
12. Slide 1 bolt from the other end of each rail to 50mm of the collector.
13. Attach 22mm compression coupling to both collector inner pipes.
Ensure that the pipes enter the couplings by 22mm - see 5.12.
IMPORTANT
After installation check all clamp nuts
are tight.
14. Slide on two bottom support brackets for next collector.
15. Lower next collector on – take care not to damage under side of
collector.
Ensure that the pipes enter the couplings by 22mm - see 5.12.
16. Fit two inner (long) clamps between the collectors.
17. Fully tighten both centre pipe couplings.
For three collector system repeat No.11 to No. 17.
18. Slide 1 bolt from the end of each rail.
19. Fix second collector outer edge using one outer (short) clamp on
each rail.
20. Tighten all clamps.
Note:Sensor S1 and ½” pocket are packed
in with the AST 100 Controller.
21. Fit stop ends to the two connecting pipes not required.
22. Fit 22mm compression T to collector flow (top of collector). Fit collector
sensor S1 with ½” thermostat pocket, then fit flexible pipe to open
end of T - also see fig. 5.20A.
23. Connect the remaining insulated flexible pipe to the return spigot using
22mm compression coupling.
24. Make suitable weatherproof flashing where the pipes enter the roof
space.
23
24
Approximate
positions
25
For three collector system
repeat No.11 to No. 17.
IMPORTANT
Tighten all bolts
26
Flow shown
27
5.20 PLUMBING CONNECTIONS
1.
2.
3.
4.
5.
6.
7.
Automatic Air Vent
22mm x ½” Compression ‘T’
½” to 3/8” Reducer
½” Thermostat Pocket
Isolating Valve
Collector Temperature Sensor (S1) and Cable
Flexible Pipe
FIG. 5.20A COLLECTOR FLOW CONNECTION - TYPICAL
6.
28
COMMISSIONING
AND SERVICING
Commissioning and servicing instructions are detailed in the associated
SOLARcomfort Pump Group Instructions.
7. FLAT ROOF/GROUND
MOUNTING KIT
7.1 COMPONENT LIST
Ref
1
2
3
4
5
6
7
8
9
Collectors can be mounted on a flat roof or on any prepared flat surface
using the Flat Roof/Ground mounting kit.
Product Code 3820011 - 2 Collector Kit
Product Code 3820012 - 3 Collector Kit
Descri pti on
Upri ght
Cross Braci ng
Collector Bottom Bracket
Bottom clamp
M8 x 25 Grub Screw
M8 Nut
M8 x 25 Hexagon Bolt
M8 Washer
Connecti ng Plate
Qt y
2 COLLECTOR
KIT
Qt y
3 COLLECTOR
KIT
4
4
4
4
4
18
14
8
2
6
6
6
6
6
27
21
12
4
FIG. 7.1A FLAT ROOF / GROUND MOUNTING KIT COMPONENT LIST
7.2 ANGLE OF INCLINATION
Note:Section 7.2 only applies to flat roof
and level ground applications, for
pitched roofs the collectors are
always at the same angle as the roof
pitch.
The inclination of the collectors in relation to the horizontal surface will
depend on the season in which the collectors will be used, the type of use
intended and the latitude of installation..
It is generally believed that to obtain optimum performance from solar panels
the angle of inclination should be equal to the latitude of the location. When
this is so the solar panels will directly face the sun at noon on 21st March
and 21st September.
This is correct for lower latitudes, however given that the UK has large
variations in radiation levels between summer and winter this is not strictly
correct. In practice it has been found that optimum performance in Southern
England has been achieved by an angle of 35° to the horizontal.
29
In the unlikely event that peak winter operation (October – March) is
required, the inclination should be equal to the latitude of the location,
increased by up to 10°, this will encourage absorption when the sun is low
over the horizon. In the UK this could result in an angle of 50° - 75°,
however it is not practical to install the collector at an angle greater than
60°.
Latitudes for the UK
7.3 COLLECTOR ORIENTATION
City
Latitude
City
Latitude
Plymouth
50°
Southamton
51°
London
51.5°
Birmingham
52.5°
Liverpool
53.5
Leeds
54°
Edinburgh
56
Inverness
57.5°
Dublin
53
Faroe
62°
The solar collectors offer maximum energy performance when the glass
surface faces directly south. It is recommended not to vary more than 30°
from the optimum due south position.
A collector facing east side of south will give better performance in the
morning than in the afternoon.
A collector facing west side of south will give better performance in the
afternoon than in the morning.
7.4 DIMENSIONS
Angle
'L'
30
782
35
935
40
1117
45
1340
50
1628
FIG. 7.4A FLAT ROOF / GROUND MOUNTING DIMENSIONS
7.5 FLAT ROOF CONDITION
Prior to installation, the current condition of the roof must be assessed to
ensure that it is capable of withstanding the additional weight of the solar
collectors and roof mounting system. Where necessary, specialist
personnel should be contacted to verify the suitability of the roof structure.
The frame should be fixed to the floor with M10 Bolts (not supplied).
It is essential that the fixing points are 100% waterproof.
30
7.6 GROUND PREPARATION
When the collectors are to be mounted on the ground a suitable base
should be provided. A suggested construction is shown in Fig. 7.5a.
The frame should be fixed to the base with M10 Bolts (not supplied).
On very exposed sites further bracing is recommended.
Concrete
300 wide x 100 thick
Concrete
200 wide x 100 thick
Stone or slab infill
FIG. 7.6A GROUND MOUNTING BASE
7.7 ASSEMBLY
M8 grub screw used to lock sliding
block to collector at correct position
- see fig 7.3A
1st
2nd
3rd
FIG. 7.7A FLAT ROOF / GROUND FRAME ASSEMBLY
31
NOTES
32
TERMS AND CONDITIONS OF GUARANTEE
The SOLARcomfort Collectors are guaranteed for 5 years against
manufacturing defect.
Please read these terms and conditions which are in addition to any terms and
conditions detailed in this book or any registration card supplied with your
appliance.
SOLARcomfort solar thermal systems must only be installed and
commissioned by Ariston trained and approved installers. Failure to comply
with this requirement will invalidate the warranty.
A charge will be made to the owner of the appliance if:1.
The reason for any service visit is as a direct result of a failure to install the
appliance in accordance with the manufacturer’s instructions.
2.
Your installer does not complete the necessary commissioning process
and procedure as detailed in the Installation and Operating Instruction manuals.
3.
Your appliance is not serviced on or before the 12 month anniversary of
installation.
4.
Our service engineer calls as requested and the failure is a nonmanufacturing defect.
Failure to pay an invoice for any such occurrence will be assumed by MTS that
you accept that your appliance has not been installed correctly and understand
that any manufacturer’s guarantee has been withdrawn.
On the 12 month anniversary of the appliance installation, you must have it serviced
to continue any guarantee offered into the following year. Failure to do so will
invalidate your guarantee and should an MTS engineer be required to attend and
no proof of service documentation is made available, then MTS will charge.
MTS (GB) Limited
MTS Building
Hughenden Avenue
High Wycombe
Bucks HP13 5FT
Tel.:- 01494 755600
Fax:- 01494 759775
www.mtsgroup.com/uk
email: [email protected]
Technical Service Hot Line 0870 241 8180
Customer Service Help Desk 0870 600 9888
Solar Hot Water Systems
2 and 3 Collector Sets Manual 06/02/2007
If you have a problem with commissioning on installation, please contact our
Technical Department on 0870 241 8180.
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