IDEAL Solar Thermal, TS 8000, EC2, TS 8001, EC1 Installation And Servicing
INSTALLATION
AND SERVICING
SOLAR THERMAL
When replacing any part on this appliance, use only spare parts that you can be
assured conform to the safety and performance specification that we require.
Do not use reconditioned or copy parts that have not been clearly authorised by Ideal.
For the very latest copy of literature for specification and maintenance practices visit our
website www.idealheating.com where you can download the relevant information in PDF format.
For users guide see reverse of book
February 2012
UIN 207786 A02
2
Solar Thermal - Installation and Servicing
GENERAL
Max. working excess pressure 6 bar
Max. working temperature 120
o
C
Safety valve 6 bar
Circulation pump Wilo ST25/7-ECO-3P
Nominal voltage AC 230 V
Power consumption Pump speed 1 39 W
Pump speed 2 47 W
Pump speed 3 53 W
Max. pump head 7 m
Max. pump capacity 4.5 m
3
/hr
Flow measuring device 2 – 12 l/min
TABLE 2 - GENERAL DATA - SOLAR PUMP STATION SPECIFICATION
TABLE 1 - GENERAL DATA - SOLAR COLLECTOR SPECIFICATION
Operating voltage 230 Volt ( + 15%) 50Hz
Internal consumption
< 1W
3 inputs for recording temperatures PT1000
1 output Normally open relay, switching power max.800W, fuse:250V 4A MT
Output protected against overload and short circuits
Display Animated LCD display, 2 colour backlight
Appropriate protection IP 20/DIN 40050
Operation temperature range 0 to + 45
o
C
Installation Wall mounting
Weight 250 g
Housing Recyclable, 3 part plastic housing
Dimensions L x B x H (mm) 136 x 133 x 37
2 x PT1000 1.5m silicon cable, measuring range up to+ 180
o
C
TABLE 3 - GENERAL DATA - SOLAR CONTROLLER SPECIFICATION
Model
TS 8000 TS 8001
Size
Collector type Roof-mounted collector In Roof-mounted collector
Overall area (m2) 2.02 2.51
Absorber area (m2) 1.84 2.28
Aperture area (m2) 1.91 2.32
L x W x H (mm) 1730 x 1170 x 83 2058 x 1227 x 105
Weight (kg) 35 49
Performance and
Installation
Absorber capacity (l) 1.4 1.7
Housing Al-frame Wooden frame
Surface
Al, natural or anodized
(Improved corrosion resistance)
Back plate Al-sheet
Absorber sheet Al highly selectively coated Al, highly selective vacuum coating
Absorption* (%) 95 95
Emission* (%) 5 5
ø manifold (mm) 18 or 22 (¾ or 1") 22 (1")
ø risers (mm) 8 8
Connections
Blank (compression joint),
coupling nut with at seal
Coupling nut with at seal
Glass 3.2 mm tempered solar safety glass 3.2 mm tempered solar safety glass
Transmittance of glass (%) 95 90.2
Insulation 40 mm mineral wool plate 50 mm mineral wool plate
Max. stagnation temperature 234˚C under test conditions 234˚C under test conditions
Max. operating pressure 10 bar 10 bar
Aperture area 1.922m² 2.33m²
Conversion factor N
0
0.769 0.776
Heat loss coefcient a
1
3.847W/m²K 3.293W/m²K
Proper heat transfer medium Polypropylene glycol/water mixture Polypropylene glycol/water mixture
Approved installation angle min. 15˚, max. 75˚ 15˚, max. 75˚
Certificate EN 1 2975-1.2 SOLAR KEYMARK
Sap Data TS8000 - On Roof TS8001 - In Roof
Aperture area 1.922m
2
Aperture Area 2.33m
2
Conversion Factor No 0.769 Conversion Factor No 0.776
Heat Loss coefcient a1 3.847W/m2K Heat loss Coefcient a1 3.293W/m2K
Heat Loss coefcient a2 0.0103W/m2K Heat loss Coefcient a2 0.011W/m2K
3Solar Thermal - Installation and Servicing
GENERAL
SOLAR THERMAL
Destination Country: GB, IE
TS8000 (on roof)
TS8001 (in roof)
CONTENTS
Commissioning Notes .......................................... 54, 55
Cylinders ....................................................................... 4
Fault Finding ............................................................... 58
Handing Over .............................................................. 56
Installation ................................................................... 12
Installation & Maintenance Checklist ........................ 57
Installation of On Roof Collector .............................. 12
Installation of In Roof Collector ................................. 21
Installation of Flat Roof Kit ......................................... 36
List of Parts ................................................................. 60
Planning Permission .................................................... 5
Pump Station ........................................................ 44, 45
Safe Handling ................................................................. 5
Solar Controller ..................................................... 46-53
Water Circuit Diagrams ............................................. 6, 7
4
Solar Thermal - Installation and Servicing
GENERAL
INTRODUCTION
Ideal Solar is a range of solar water heating equipment for use
with twin coil storage cylinders only. The solar collectors come as
at plate type or evacuated tube and are suitable for use in new
and refurbishment installations.
A range of packs are available providing all equipment (except
cylinders, pipework and insulation) for a range of properties. The
pack includes solar collector(s), mounting brackets, controller,
pump station, expansion vessel and system uid.
The solar collector is copper tube ultrasonically welded to
selectively coated absorber plates. This is housed in a sealed
casing with mineral wool insulation to rear and sides. It is sealed
into the casing with EPDM seals and a robust tempered glass
cover. Mounting kits are available to suit tiles, slates both on or
inset to roofs. In addition at roof mounting is provided.
THE IDEAL SOLAR SYSTEM PACKAGE COMPRISES OF:
1. Ideal Solar Collector(s)
The TS800 solar collector panel(s) can be mounted directly
onto sloping roofs with a variety of xings for different roof
coverings or onto a support frame for at roofs.
The TS8001 is for inset applications only.
The Ideal Solar kit comprises of one, two or three high
performance at solar panel collectors.
Pressure loss (bends, valves, etc.)should be recognised when
specifying the pump arrangement.
2. Ideal Solar Twin Line Pump Station
The solar pump station is supplied with integrated pump
to provide circulation of the heat transfer uid, the main
components of the unit are:
A circulation pump.
A ow limiter with ll & drain valve shut-off valve.
Two ball valves with integral display thermometers and check
valves.
Safety relief valve/pressure gauge assembly.
Non-ow valve tted in both the ow and return circuit to
prevent the possibility of gravity circulation in the solar circuit.
3. Ideal Solar Controller EC1
The controller allows quick setting of functions and features
with LCD display to provide graphical information.
The controller allows the user to select the temperature
required at the hot water cylinder. The controller then
automatically determines when to run the pump to bring the
energy from the solar collector panel(s) to the cylinder.
The control uses a simple temperature difference to dene
when the pump runs. This ensures that the pump is running
only when the benet from the solar collectors is available.
OPERATION
The solar collector panel is mounted on a surface which is
selected for its exposure to sunlight and connected via pipe work,
to the lower coil of a twin-coil solar cylinder.
The solar controller monitors the temperature of the solar
collectors and the cylinder via its sensors.
The energy in the sun’s rays is absorbed by the solar collector’s
selective coated plate’s which is then transferred to the heat
transfer uid contained within the collector system pipe work.
When the solar collector sensor temperature is elevated 4
o
C
above the cylinder sensor temperature the controller activates the
circulating pump.
The pipe work is lled with a ready-mixed heat transfer uid
containing glycol and water, which is circulated by a pump to the
solar coil in the hot water cylinder. The heat is deposited in the
storage cylinder and the heat transfer uid returns to the collector
to absorb more free solar energy.
The circulation pump will continue to operate until the
cylinder sensor is satised (factory set 60
°
C) or the differential
temperature between the solar collector sensor and the cylinder
sensor reduces to 2°C.
With current recommendations to store water at 60
o
C it is
becoming more of a consideration to protect persons of reduced
physical, sensory or mental capabilities from scalding. A suitable
method to achieve this would be to t a Thermostatic Mixing
Valve (TMV) to the hot water outlet from the cylinder. If the TMV
is not tted with a line strainer, they must be tted on the hot and
cold supply lines.
IMPORTANT
Plastic Pipework is not suitable for the temperatures
possible in Solar circuits.
All connections and joints must be resistant to glycol and be
resistant to temperatures of up to 200°C.
OPTIONAL EXTRA KITS
• Flat Roof Frame Kit (1 and 2 collectors)
• Roof Fixing Kit (slates)
• Heat Transfer Fluid (10, 25 & 25 lt containers)
• Additional on roof and in roof at panel collectors
• Vacuum tube collectors
• Single line pump station
• First x kit - on roof
• First x kit - in roof
• Solar controller EC2 (controls East/West solar collector
orientation)
• Roof Inset Kit (1, 2, 3 and additional collectors) for tile roofs
• Roof Inset Kit (1, 2, 3 and additional collectors) for slate roofs
UNVENTED DHW CYLINDERS
When connecting the Ideal Solar System to an un-vented hot
water storage cylinder, it is recommended that the electrical
supply to the solar control system is taken via the thermal cut-out
device on the cylinder.
CYLINDERS
For your Ideal Solar System a dual coil hot water storage cylinder
must be used. Installation can be for both open vented and
sealed systems. If a sealed system is used then part G3 of the
Building Regulations must be observed.
When sizing the Dual Coil Hot Water Cylinder a minimum
dedicated solar volume must be either 25 litres per sq metre of
panel or 80% of the daily hot water used.
For reasonable efciency 35 litres per sq metre of panel should
be used.
For best practice a gure of 50 litres per square metre of
panel should be used. (These details are contained within the
Domestic Heating Compliance Guide).
5Solar Thermal - Installation and Servicing
GENERAL
STANDARDS AND SAFETY INSTRUCTIONS
OVERVIEW OF EU STANDARDS
Solar Systems in General
EN ISO 9488
Thermal solar systems and components, terminology
(ISO/DIS 9488; 1995)
EN 12975-1
Thermal solar systems and components - Collectors Part 1: General requirements
EN 12975-2
Thermal solar systems and components - Collectors Part 2: Test Methods
ENV 1991-2-3
Eurocode 1 - Basis of design and actions on structures Part 2-3: Actions on structures - Snow Loads
EN 12976-1
Thermal solar systems and components - Factory made systems Part 1: General requirements
EN 12976-2
Thermal solar systems and components - Factory made systems Part 2: Testing Methods
ENV 12977-1
Thermal solar systems and components - Custom built systems
- Part 1: General requirements
ENV 12977-2
Thermal solar systems and components - Factory made systems Part 2: Testing Methods
ISO 9459-1: 1993
Solar heating - Domestic Water heating systems - Part 1:
Performance rating procedure using indoor test methods
ISO/TR 10217
Solar energy - Water heating systems - Guide to material
selection with regard to internal corrosion
Collectors and Collector Assembly
ENV 1991-2-4
Eurocode 1 - Basics of design and actions on structures Part 2-4: Actions on structures - Wind actions
Lightning Protection
ENV 61024-1
Protection of structures against lightning – Part 1: General
principles (IEC 1024-1: 1990; modied)
Building Regulation, dating from 1991 (England and Wales)
Requirement G3, L1 and Regulation 7
BS 7671
Requirements for electrical installations
(IEE Wiring Regulations, 16
th
edition
SAFE HANDLING OF SUBSTANCES
Heat Transfer Fluid
Use undiluted only.
Keep out of reach of children.
Avoid contact with skin and eyes.
If swallowed, seek medical advice immediately and show the label
adhered to the container.
Disposal
Any packaging contaminated or not along with Ideal Solar uid
must be disposed of at an appropriate waste site, whilst observing
local regulations.
PLANNING PERMISSION
Planning permission for the Ideal Solar System is generally only
required if you are in a conservation area or you are installing a
solar system on a listed building.
However it is prudent to seek the opinion of the local authority on
planning matters prior to starting work on the solar installation.
INSTALLATION REQUIREMENTS
The installation of the Ideal solar system must be carried
out in accordance with the relevant requirements for safety,
current Wiring Regulations, local Building Regulations, Building
Standards (Scotland), (Consolidation) Regulations and Bylaws
of the local water company and Health and Safety document No.
63S (Electricity at Work Regulations 1989).
It should be in accordance with the relevant recommendations of
the following British Standards and Regulations:
· BS 5918:1989
· The Health and Safety at Work Act 1974
· The Management of Health and Safety at Work Regulations
1999
· The Construction (Health, Safety and Welfare) Regulations
1996
· The Construction (Design and Management) Regulations
1994
· The Lifting Operations and Lifting Equipment Regulations
1998
The manufacturer’s notes must not be taken in any way as
overriding statutory regulations.
ELECTRICITY SUPPLY
All wiring must be performed in accordance with BS7671:
Requirements for Electrical Installations (IEE Wiring Regulations,
16th Edition).
A 3 amp fused three pin plug and un-switched shuttered socket
outlet (both complying with BS 1363) or preferably a double pole
isolator with a contact separation of 3mm in all poles supplying
the controller should be used. The controller must be earthed.
Earth Bonding
Ensure that the primary ow and return circuit is electrically
cross-bonded in accordance with BS 7676.
WARRANTY
The Ideal Solar system is supplied with a Comprehensive
Warranty cover of 10 years for the solar collector(s) and 2 years
for the pump station and controller.
For one off installers - products are sold with materials only
warranty
For Developers - Materials only warrantly. If labour required, to
be arranged and priced with the installer.
Ideal Solar Technical Support Line: 01482 498307.
HEAT TRANSFER FLUID
Solar panel collectors and system components should be used only
with the recommended heat transfer uid as supplied in the kit.
Recommended uid is supplied as:
10 Lt Container - Part No. UIN 206536
20 Lt Container - Part No. UIN 206537
25 Lt Container - Part No. UIN 206538
The heat transfer uid uses a proven concentration of anti-
freeze and water to give protection against freezing and provide
optimum performance from the solar panel collectors and system
components. Additional uid can be obtained via Ideal Solar
stockists.
The uid is pre-mixed to 60% concentration and is suitable for at
plate and vacuum tube collectors.
6
Solar Thermal - Installation and Servicing
GENERAL
2
5
7
9
12
15
L/MIN
bar
6
0
2
4
?C
0
20
40
60
80
100
120120
100
80
60
40
20
0
?C
Drain
Sun
Solar
Cylinder
Twin Line
Pump
Station
Expansion
Vessel
*Solar
Cont-
ainer
Safety Relief
Valve / Pressure
Gauge Assembly
Solar
Collector
Panel
T1
Solar
Collector Sensor
T2 Solar
Cylinder Sensor
sol8618-1
Hot Water to Supply
Back Up
from Boiler or
Immersion Heater
Solar
Controller EC1
*Important: solar fluid container should be manufactured from a material
capable of withstanding the high temperatures at which solar fluid operates.
1A
INDIRECT PRESSURISED SOLAR CIRCUIT
The Ideal Solar System features high performance solar panel collectors with highly advanced features. The collector has been
awarded the Solar Keymark, the EUs quality mark for solar collectors. The collectors are mounted on a fast-to-t frame and a solar
pump station is also supplied to provide all the safety features required for a pressurised circuit. The Ideal Solar Controller EC1
ensures efcient use of the available solar energy at any given time and features several extra functions.
INSULATION
Exposed pipe work should be insulated according to the high temperatures that the collectors are able to generate. This should be high
temperature Armalfex or similar grade.
Suitable insulation is available from Armacell UK Ltd., Mars Street, Oldham, Lancashire OL9 6LY.
7
INSTALLATION
Solar Thermal - Installation and Servicing
2
5
7
9
12
15
L/MIN
bar
6
0
2
4
?C
0
20
40
60
80
100
120
2
5
7
9
12
15
L/MIN
?C
0
20
40
60
80
100
120120
100
80
60
40
20
0
?C
Drain
SunSun
Solar
Cylinder
Expansion
Vessel
*Solar
Cont-
ainer
Safety Relief
Valve / Pressure
Gauge Assembly
Solar
Collector
Panel
Solar
Collector
Panel
T2
Solar
Collector Sensor
T1
Solar
Collector Sensor
sol8618-1
Hot Water to Supply
Back Up
from Boiler or
Immersion Heater
Solar
Cylinder
Sensor
Single
Line
Pump
Station
Twin Line
Pump
Station
Solar
Controller EC2
T3
*Important: solar fluid container should be manufactured from a material
capable of withstanding the high temperatures at which solar fluid operates.
1B
EAST WEST SOLAR PANEL CIRCUIT
Solar panels can be located in an East - West orientation. In this conguration single line pump station (Ideal part No. UIN 207072)
in addition to the twin line pump station should be employed. Control between the panels located in different orientations can be
achieved by specifying the solar controller EC2, (Ideal Part No. UIN 207754), which has the capability to control panels located in
East - West conguration. Controller, installation and operating instructions are provided with the Solar controller EC2 kit.
8
INSTALLATION
Solar Thermal - Installation and Servicing
2
SOLAR PACK CONTENTS
PARTS NOT INCLUDED IN THE SOLAR PACK
You will have to provide all pipework, ttings and insulation. The following specications are required for items provided by the
installer:
Pipework: This should be 15 mm or 22mm copper or exible stainless on both ow and return, depending on number of solar
collectors and pipework (see Frame 4). Plastic pipework is not suitable for the temperature extremes possible in solar circuits. Pipe
clips must withstand the temperatures of up to 200°C. (We recomend annular twin pipes PART No’s. 206519 - DN16x15m long &
206520 - DN20x15m long). A rst x kit is provided with each solar pack. This comprises exible through roof hoses (insulated)
one metre in length, collector panel angle couplings with bre seals and a separate solar controller ow sensor.
Fittings: Brass olive compression ttings must be used . Unleaded solder is not designed for solar circuits. Alternatively, high
performance crimped ttings or similar performance ttings can be used. Teon or similar type tape is not to be used although
a proprietary liquid type suitable for solar conditions may be used. Any drain valves etc. must be capable of handling the
temperatures indicated above. Any ttings and pipework must be capable of withstanding 1.5 times the safety valve pressure.
Insulation: This should be High Temperature Armaex or similar grade insulation or above. Class O Armaex is not UV-resistant
or designed for the temperatures realised in the solar primary circuit. Polythene insulation will melt on a solar primary circuit. All
external items such as cable clips to hold the collector sensor must be UV-resistant.
Flexible stainless steel hose is available in pre-insulated form using suitable high temperature UV-resistant insulation and a suitable
two-core cable for the solar collector sensor. This hose is specically designed for solar applications.
1.
3.
4. 5.
2.
6.
Before starting any work check the solar pack contents. Please note, dependent upon specic solar pack, ordered contents may vary.
ON ROOF SOLAR PACK
1. On roof solar collector(s)
2. Twin line pump station with expansion vessel installation
hardware
3. Solar controller EC1
4. Solar expansion vessel
5. Solar uid
6. First x connection pack containing angle through roof
exi hoses, panel angle couplings and solar controller
ow sensor.
7. Basic on roof collector ;mounting set - see frame seven
for detail
8. collector support rails - see frame seven for details.
IN ROOF SOLAR PACK
1. In roof solar collector(s)
2. Twin line pump station with expansion vessel installation
hardware
3. Solar controller EC1
4. Solar expansion vessel
5. Solar uid
6. First x connection pack containing angle through roof
exi hoses, panel angle couplings and solar controller
ow sensor.
7. Basic on roof collector ;mounting set - see frame seven
for detail
8. Wooden wedges for collectors ashing - see Frame 16
for detail.
9. In roof ashing set - see Frame 16 for detail.
INSTALLATION
9
INSTALLATION
Solar Thermal - Installation and Servicing
3
COLLECTOR SIZING AND LOCATION
Typically, approximately 1 square meter of solar collector should be supplied for each house occupant. Each Ideal Solar
Collector panel has an external area of 2.02m2 (TS8000) and 2.51 m2 (TS8001). Therefore, the Ideal 2 collector array is ideal
for a 3 to 4 person household and the Ideal 3 collector array for a 5 to 6 person household. The collector array should be
located between 30o East and 40o West of South and at an inclination between 20o to 45o within these bands there is no more
than a 10% loss in efciency from the optimum south facing at an inclination of 35o. For an East-West roof, either an EastWest application can be installed with a collector on each pitch or additional collector(s) can be tted on either the East-West
roof. For example, a 3 collector array on an East facing roof would be ideal for 4 to 5 occupants where there is a 20 % loss in
performance as compared to the ideal South facing 30° pitch. There should be no signicant over-shading of buildings, trees or
other obstructions. Even obstructions to the north of the collector can block a signicant proportion of the diffuse solar radiation.
Signicant overshading can be compensated by over-sizing the solar system.
4
INSTALLATION OF THE COLLECTOR AND EXTERNAL COMPONENTS
The ow and return pipework can be passed
through the roof either with a proprietary
roof penetration tile or a Code 4 lead custom
made roof penetration tile. Ventilation tiles
can sometimes be adapted for this purpose.
Alternatively a silicon “dektite” can be used.
Optional lead pipe ashing tile kits which can be
adapted to suit most roof tiles are available. Any
exposed elements of the roof penetration must be
carefully sealed with exterior grade low modulus
silicone.
IMPORTANT
All connections and joints must be resistant to temperature of up to 200°C and resistant to glycol.
During installation and servicing means for covering the solar collectors will be required to avoid burns. In direct sunlight, the solar
collectors can reach temperatures of 200°C.
Note. It is recommended that you select the pipework in accordance with this table. If the system provides additional pressure loss
(bends, valves, etc.), you should consider selecting pipe with larger diameter.
The nal part of the roof installation is the insertion of the silicon PT1000 Collector Sensor into its mounting pocket in the Flow
Connector and feeding of the cable through or under the ow roof penetration and through the felt or timber sarking so that the
sensor cable is visible in the loft space.
Wiring run lengths and cross sectional areas for low voltage collector sensor wire:
Lengths up to 50m: 0.75mm
2
Lengths up to 100m: 1.5mm
2
Number of Single Pipe Length
Solar Collectors Up to 6m Up to 15m up to 20m up to 25m
to 5 Ø 15mm (DN12) Ø 22 mm Ø 22 mm
(DN 15) (DN 20)
to 9 Ø 22 mm Ø 22 mm Ø 28 mm Ø 28 mm
(DN15) (DN20) (DN25) (DN25)
INSTALLATION
10
INSTALLATION
Solar Thermal - Installation and Servicing
5
ASSEMBLY INSTRUCTIONS
General and Transport Instructions
The mounting system is suitable for tiled roofs only. Installation must only be carried out by qualied personnel. The entire
information in these instructions is intended exclusively for such qualied personnel. Only the supplied material should be used for
the installation. Prior to starting installation and operation of the solar collector system, please inform yourself about the applicable
local standards and regulations. The use of a carrying strap is recommended for transporting the collector. The collector must
not be lifted at the connections or on the threading. Avoid impacts and mechanical inuences on the collector, in particular on the
solar glass, the rear panel and pipe connections.
Statics - tiled roofs
The collectors may only be mounted on sufciently load-bearing roof surfaces and substructures. It is imperative that the static
load bearing capacity of the roof or substructure is checked in terms of local and regional conditions prior to installation of the
collectors by the customer, if necessary through the involvement of a structural engineer. Particular attention should be paid to the
quality of the (timber) substructure in terms of the stability of the screw connections necessary for fastening the collectors. The
checking of the entire collector structure by the customer as per DIN 1055 part 4 and 5 or as per the applicable country-specic
regulations is particularly important in areas with heavy snowfall (note: 1 m³ powder snow ~ 60 kg / 1 m³ wet snow ~ 200 kg) or
in areas exposed to high wind speeds. The assessment should also take into account any particular circumstances at the place
of installation (foehn wind, air jets or eddy formation etc.) which can lead to increased loads. When selecting the installation site
it should be ensured that the maximum load is not exceeded either by snow or wind forces. As a rule, collector arrays must be
installed such that any possible collection of snow is prevented from reaching the collectors by snow barriers (or through special
forms of installation). The distance to roof ridges/edges must be at least 1 m.
Note: Installing a collector array signies an intervention into an (existing) roof. Roof coverings, e.g. tiles, shingle and slate,
especially in the case of converted and inhabited loft spaces or roofs with less than the minimum slope (with regards to the
covering) require additional measures by the customer, e.g. sarking membranes, as security against water penetration caused by
wind pressure and driving snow.
Lightning protection / Equipotential bonding of the building
In accordance with the lightning protection standard ÖVE/ÖNORM EN 62305 Part 1-4 the collector array cannot be connected
to the building’s lightning protection. A safety distance of at least 1 m must be maintained from any possible adjacent conducting
object. For installations on metal substructures at the installation site, generally qualied electricians must be consulted. To carry
out a building potential equalisation, the metal tubes of the solar circuit and all collector cases or fastenings must be connected
to the main potential equalisation bus by a qualied electrician in accordance with ÖVE/ÖNORM E 8001-1 or the country-specic
standards.
Connections
Depending on the design, the collectors must be connected with one another and/or the connection pipes using screw
ttings (1” internal/external thread) with at-face sealing. Ensure correct placement of the at gaskets. If exible pipes are
not used as connectors, precautions must be taken to protect the connection pipes against temperature uctuations caused
by heat expansion, e.g. expansion bends and exible piping (see Connecting the collectors to one another/Operational
recommendations). Larger collector arrays must be assembled with expansion bends or exible members inserted in the links.
(IMPORTANT: check the pump design). When tightening the union nuts, always balance (counter) the torque with a pipe wrench
or another spanner to prevent damage to the absorber.
Collector inclination / General notes
The collector is suitable for angles between 20° (minimum) and 65° (maximum). The collector must be installed so that rear
ventilation for preventing the diffusion of moisture in the collector is guaranteed. The collector connections and the ventilation
openings must be protected against the penetration of water as well as contamination such as dust etc.
Cleaning
Clean the water courses of the sheet metal edging at least once per year (or more often if required).
Legal guarantee
Legal guarantee claims can only be made if the supplier’s own antifreeze has been used and maintenance has been carried out
correctly. Installation by qualied personnel with absolute adherence to the instructions is a prerequisite for the justication of
claims.
ASSEMBLY
11
INSTALLATION
Solar Thermal - Installation and Servicing
6
SUGGESTION FOR ATTACHMENT POINTS
Additional mounting structures must be provided in
areas with high snow and wind loads!
(Observe DIN 1055 or country-specific regulations)
•.....Atachment points
Collector Vertical
Collectors Total length
Atachment
points
2 239cm 6
3 361cm 8
4 482cm 10
5 603cm 12
6 724cm 14
ASSEMBLY
12
INSTALLATION
Solar Thermal - Installation and Servicing
7
OVERVIEW OF MATERIALS - ON ROOF
Roof bracket Roof bracket console Self-tapping screws 6*60
Cup square bolt 8*25 M8 hex self-securing nut Clamping piece
Clamping piece extension Mounting part, top Mounting part extension
M8 washer M8*30 hammer-head bolt M8 hex nut
Support rail Mounting jig Flat gasket
INSTALLATION
13
INSTALLATION
Solar Thermal - Installation and Servicing
INSTALLATION
8
MOUNTING SYSTEM, PARALLEL
General Note:
Points 8-11, 16 and 17 of these instructions only apply when mounting more than two collectors.
1. Measure distance between mounting bracket.
Distance should be between (125 - 155cm).
Remove appropriate roof tiles to t roof bracket
console.
2. A = 125 - 155cm - Distance between brackets
3. Fasten roof bracket console to rafters with provided self
tapping screws 6 x 60
4. Replace roof tile, cut tile to ensure correct t if necessary.
1
2
3
4
14
INSTALLATION
Solar Thermal - Installation and Servicing
9
MOUNTING SYSTEM, PARALLEL
INSTALLATION
5. Insert the hammer-head bolt into the roof bracket and hand tighten
for now
Order:
hammer-head bolt - mounting bracket - washer - nut
6. Attach lower mounting rails (6a, 6b)
Order:
mounting rail - hammer-head bolt - roof bracket - washer - nut
7. Attach upper mounting rail (7a, 7b)
Order:
mounting rail - hammer-head bolt - roof bracket - washer - nut
5
6a
6b
7a
15
INSTALLATION
Solar Thermal - Installation and Servicing
INSTALLATION
10
MOUNTING SYSTEM, PARALLEL
WARNING: Upper and lower mounting rails must be mounted
perfectly straight and parallel to one another!
8. Set addition mounting points as described in Points 1-4 if
additional collectors are to be tted.
9. Push the clamping piece extension halfway into the inner
groove of the mounting rails (upper and lower) and tighten
Order: mounting rail - clamping piece extension - washer - nut
10. insert the following mounting rails (upper and lower) and attach
them using the clamping piece extension
Order: mounting rail - clamping piece extension - washer - nut
7b
8
9
10
16
INSTALLATION
Solar Thermal - Installation and Servicing
11
MOUNTING SYSTEM, PARALLEL
INSTALLATION
Solar Collector
Mounting Rail
11. Attache the mounting rails (upper and lower) using the roof
bracket / clamping piece extension
Order:
mounting rail - hammer-head bolt - roof bracket - washer -nut
12. Hang the rst collector in the lower mounting rail and adjust
(12a + 12b)
Note: Distance between collector and end of moutning rails =
45mm. Measurement A = mesurement B.
11a
11b
12a
12b
17
INSTALLATION
Solar Thermal - Installation and Servicing
INSTALLATION
12
MOUNTING SYSTEM, PARALLEL
13. Place the clamping piece on the upper mounting rail and hand
tighten for now.
Order: upper mounting rail - hammer-head bolt - washer -
clamping piece - washer - nut
14. Attach the second collector (measurement A = measurement B as
shown in Figure 12b)
Please use the mounting jig (14b)
15. Rotate the clamping piece by 90º and screw it tight using a long
socket wrench
13
14a
14b
15
18
INSTALLATION
Solar Thermal - Installation and Servicing
13
MOUNTING SYSTEM, PARALLEL
INSTALLATION
16. With clashing mounting rails, insert and position the mounting part
in the upper moutning rail
17. Attach additional clamping pieces / collectors as described in
Points 12-16.
18. Attach the mounting part on the upper left and right end of the
collector eld
Order:
mounting rail - hammer-head bolt - mounting part - washer - nut
19. Screw the collectors into place.
16
17
18
19
19
INSTALLATION
Solar Thermal - Installation and Servicing
INSTALLATION
14
INFORMATION ABOUT THE COLLECTOR (TS 8000)
Technical Data
Gross area m
2
2,02 Weight (dry) kg 35
Net ara m
2
1,84 Contents 1 1, 4
Aperture m
2
1,91 Max. Pressure bar 10
1
2
2
1
38
611
70
1730
1
1
7
0
20
INSTALLATION
Solar Thermal - Installation and Servicing
15
OPERATING TIPS - SOLAR POWER SYSTEM (TS 8000)
INSTALLATION
Connecting the collectors to one another
The diagram below is an example of how the collectors can be connected to one another. However, the actual connection may
be different depending on structural conditions. A maximum of 6 collectors may be connected in a series. If a collector panel is
made up of more than 6 collectors, the panel must be connected several times in parallel.
Mass Flow Rate
To ensure the performance of the collector, a specic ow rate of 30 l/m
2
h is to be selected up to a collector panel size of approx.
25m2.
Pipe Diameters
Dimensions table with a specic ow rate of 30 l/m
2
h
Collector panel size [m2] approx. 5 approx. 7.5 approx. 12.5 approx. 25
Pipe diameter / copper [mm] 10 - 12 15 18 22
Pipe diameter / stainless steel corrugated pipe DN16 DN20
Pressure loss collctor for anti-freeze / water mixture (40% / 60%) at a thermal conducting temperature of 50ºC
Pressure loss curve: ∆p = 0,000128x
2
+ 0,022931x
Mass ow rate [kg/h] 0 50 100 150 200 250 300 350 400 450 500
Pressure loss [mbar] 0 1,5 3,6 6,3 9,7 13,7 18,4 23,7 29,7 36,2 43,5
Supply
Return
21
INSTALLATION
Solar Thermal - Installation and Servicing
16
OVERVIEW OF MATERIALS - IN ROOF (TS8001)
Installation batten 30x40x2450 Attachment bracket Self-trapping screws 5*60 / 5*40
Flat gasket
Front corner section right/left or middle
Connecting bend
Side piece right/left Side tin cover strip
Sealed plumping screw 4,5*35
Middle cover strip Sealed plumping screw 3,9*13 Wooden wedge
Self-trapping screws 6*120 Side piece connector right/left Middle cover right/left or middle
Rear corner section right/left or middle
Self-trapping screws 4*25 Metal retainer, roofing nail
Foam rubber wedge
INSTALLATION
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