RM Solar S Class 10, S Class 10 Pro, S Class 20, S Class 20 Pro Instruction Manual

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Instruction Manual

Issue 4

Note: These Instructions Should Be Read Carefully Before

Install, And Before Calling Technical Support.

Contents

Table Of Contents:

Introduction - Page 2

Health & Safety Information - Page 2 Post Installation - Page 2

Section 1 - Product Specications - Page 3

S Class 10 Specication - Page 3 S Class 20 Specication - Page 4 S Class 20 Pro Specication - Page 5

Section 2 - Positioning & Piping - Page 6

Positioning The Panels - Page 6 Piping Schematics For Panels - Page 7

Section 3 - On Roof Frames - Page 8

Sharks Fin Frame - Page 10 Slate Bolt Frame - Page 18

A Frame Installation - Page 25

Section 4 - In Roof Frames - Page 34

S Class 20 In Roof Installation - Page 34 S Class 10 In Roof Installation - Page 52

Section 5 - Connections & Components - Page 77

System Piping - Page 77 Insulation - Page 77 Glycol - Page 77 Double Pump Station - Page 78 Expansion Vessel - Page 79

Section 6 - Filling The System - Page 80

Filling The System - Page 80

Section 7 - Controller Setup - Page 81

Setting Up The SHE-02 - Page 82 Setting Up The Solastat - Page 82

Setting Up The Resol (East/West Split) - Page 83 Setting Up The Resol (2 Store System) - Page 83

Section 8 - Commissioning & Maintenance - Page 84

Commissioning Certicate - Page 84 Product Guarantees - Page 85 Maintenance - Page 85

Section 9 - Service Log - Page 86

Service Log - Page 86

Introduction, Health & Safety, & Post Installation

Introduction

This installation manual contains essential information for the effective and safe installation of RM

Solar products. It is essential that this kit is tted by someone with relevant training or previous experience in the eld of Solar Thermal, if this kit is installed without prior training or qualication

your guaranteed may be void and your help limited.

This technical documentation should be available with you at all times during the installation, but prior to installation please read these instructions as in many cases it will prevent problems from

occurring during the installation process.

Health & Safety Information

RM Solar panels are high quality thermal solar panels using selective coating technology to convert light into heat. RM Solar panels should only be tted by authorised, trained and qualied personnel.

They are not intended to be a “do it yourself” product. Panels are also sometimes called “solar collectors”.

When tting the panels installers shall comply with all relevant health and safety regulations and shall carry out a suitable and sufcient risk assessment before any work commences.

Post Installation

After the correct and full installation and commissioning of the RM Solar system please make sure

you take the following steps:

In The Manual Please:

• Complete the product guarantee form included with the solar kit.

• Complete the product commissioning certicate.

Ensure that you:

• Explain how the system works and how to get the best from the system to the customer.

• Make sure these instructions are left with the customer.

• Service the system in accordance with recommended guidance, and complete the log as

appropriate.

Pre Installation

• Please ensure all equipment is on site, and no parts are damaged.

• Please make a note of any solar panel serial numbers.

Section 1 - Product Specications

S Class 10 Specication

RM Solar’s new S Class 10 panel comes in a variety of arrangements, including standard vertical,

oversized vertical, and horizontal panels.

Technical Information Collector Casing:

Material: Aluminium Prole Colour: Brown Back Plate: AlZn 0.5mm

Transparent Cover:

Type: Temperated Glass, 4mm

Standards: prEN 12150, BS6206 Class A

Dimensions: 1000 x 2000 / 1200 x 2000 Young Factor: E=70Gpa

Poisson Factor: μ=0.22

Expansion Factor: 0.000009m/mok

Light Transmittance: >89% +/-0.5%

Glass Sealing: Silicone

Insulation:

Type: Rockwool With Black Fleece

Thickness: 40mm (back) 20mm (side) Density: 40kgr/m

Thermal Conductivity: 0.044W/mK (100oC)

S Class 10 S Class 10 Horizontal S Class 10 Pro

Overall Area (m2) 2.09 2.09 2.49

Absorber Area (m2) 1.92 1.92 2.31

Aperture Area (m2) 1.92 1.92 2.31

Length (mm) 2030 1030 2030

Width (mm) 1030 2030 1230

Height (mm) 87 87 87

Overall Weight (kg) 48.20 49.60 50.50

Collectors Installation Vertical Horizontal Vertical

Absorber Type Grid Grid Grid

Absorber Capacity (l) 1.97 1.97 2.23

Coating Selective Selective Selective

Thickness (mm) 0.50 0.50 0.50

Absorption 95% +/-2% 95% +/-2% 95% +/-2%

Emission 5% +/-2% 5% +/-2% 5% +/-2%

Welding Process Laser Laser Laser

Stagnation Temperature 191 191 193

Certications Keymark Keymark Keymark

Max Working Pressure (Bar) 10 10 10

Heat Transfer Medium Glycol Glycol Glycol

Type S Class 10 S Class 10 Horizontal S Class 10 Pro

Efciency (%) 78.6 75.9 74.5

a1 (W/m2K) 3.62 3.038 3.556

a2 (W/m2k2) 0.028 0.042 0.017

Section 1 - Product Specications

S Class 20 Specication

RM Solar S Class 20 solar panel is a vertically mounted glazed collector with collection pipes, intended for applications in systems equipped with circulating pumps.

The RM Solar S Class 20 panel is constructed with a single meander system piping without using soldering or welding and is folded into the absorber plate; a single piece tray folded into the frame

holding the glazing.

The RM Solar S Class 20 panel is not intended to be used in drain-back systems.

Technical Information

• Floor Space : 2.03 m2

• Dimensions : 1010 x 2010 mm

• Weight empty : 36.5 kg

• Fluid Volume : 1.3 litres

• Recommended ow of heat transfer uid : 30 L/h/m2 collector

• Stagnation temperature : 170°C

• Panel connection : in series

• Maximum number of panels that can be linked in a series : 3

• Maximum number of series : 1

• Maximum number of panels in parallel: 10 - Please see page 20.

• Glazing : 4mm low iron hailstone resistant

Tested to EN 12975 (parts 1 & 2) and to Solar Rating & Certication Corporation Standards for the

United States of America and to all applicable Canadian test standards

Maintenance

The panels have been designed to withstand high temperatures; the glass does not require cleaning.

There are no user serviceable parts inside and due to the heat exchange process the panel does not

contact potable water or water to be heated.

Important

The panels must be covered for a minimum of 1 hour before lling the system with glycol.

Section 1 - Product Specications

S Class 20 Pro Specication

The RM Solar S-Class Pro Panel has been specically designed to meet the needs of large

industrial applications. Suitable for both Commercial Buildings, and Private applications, such as

large swimming pool installations.

The S-Class Pro panels are also available as a horizontal variant allowing installation on roofs where

space is a premium.

The RM Solar S-Class Pro panel is not intended to be used in drain-back systems.

Technical Information

• Floor Space : 2.03 m2

• Dimensions : 1010 x 2010 mm

• Weight empty : 36.5 kg

• Fluid Volume : 1.3 litres

• Recommended ow of heat transfer uid : 30 L/h/m2 collector

• Stagnation temperature : 170°C

• Panel connection : in parallel

• Maximum number of panels that can be linked : 10

• Maximum number of series : Innite

• Glazing : 4mm low iron hailstone resistant

Tested to EN 12975 (parts 1 & 2) and to Solar Rating & Certication Corporation Standards for the

United States of America and to all applicable Canadian test standards

Maintenance

The panels have been designed to withstand high temperatures; the glass does not require cleaning.

There are no user serviceable parts inside and due to the heat exchange process the panel does not

contact potable water or water to be heated.

Important

The panels must be covered for a minimum of 1 hour before lling the system with glycol.

Section 2 - Panel Positioning

Positioning the Panels

South Facing Roofs

Positioning the collectors is important for optimum performance. Collectors should ideally be

mounting at an angle of between 30 degrees and 60 degrees on a south facing position that is not

shaded by overhanging trees, buildings, or structures. Good results can be obtained by positioning the panels facing anywhere in an arc between south west and south east but due south facing provides optimum performance.

North Facing Roofs

It is not generally recommended that you install the panels on North facing roofs in the Northern

Hemisphere. South of the equator, north will provide the optimum performance and south facing the worst performance.

East / West Facing Roofs

Good results can be obtained by splitting the collector array on East / West elevations but this should

only be used when it is not possible to have a mainly southernly position for the collectors. If you are installing an East / West split system you have to double the number of panels that would normally be required, e.g. a 2 panel system would require 2 panels on the east and 2 panels on the west.

East / West Facing Roofs (Alternate Conguration)

Another option is to oversize the collector area on the side of the roof chosen to mount the collec-

tors. E.g. If 2 panels would have been adequate had the roof orientation been south, then 3 collectors would be required on either the east side or the west side depending on which recieved the most

sunlight.

Section 2 - Piping Congurations

Piping Schematics For Panels

Typical S Class 10 (Parallel) (Maximum 10 Panels Per Bank)

Typical S Class 20 (Series) (Maximum 3 Panels Per Bank) (Maximum 10m Primary Circuit)

Typical S Class 20 (Parallel) (Maximum 10 Panels Per Bank)

Typical S Class Pro (Parallel) (Maximum 10 Panels Per Bank)

Sensor Cable

Stop End

Airvent

In Out

Stop End

Section 3 - On Roof Frames

On Roof Frames

The on roof frames from RM Solar come in the following two styles, choosing the correct frame for

your installation is paramount to an effective install.

Sharks Fin

Primarily suited to tile installs. For installation of this frame please see page 10

Slate Bolt

Primarily suited to slate installs, but will t most roof types. For installation of this frame please see

page 18

Note: It is important to note that the S Class 10 Panel is bigger than the S Class 20 product, so

when using on roof products remember to select the correct hole when locating the ‘Z’ rails.

Section 3 - On Roof Frames

Roof Space Required

This is the roof space approximately required to install the panels on roof in millimeters.

8320

9360

10400

Section 3 - Sharks Fin Installation

On Roof Sharks Fin

Before attempting to t your equipment on the roof please ensure that you have all the equipment required to complete the installation. The table below will tell you what pieces are included in each of

the packages.

Part Name 1 Panel

1 Panel

Extension

2 Panel

Frame

Connector

1 Steel Pipe = 2000mm - - 2 -

2 Steel Pipe = 1000mm 2 2 - -

3 Connection Bolt - - - 2

4 Pipe Bracket 4 4 6 -

5 Shark Tail 4 2 4 -

6 U-Bolt Bracket M8 4 2 4 -

7 Washer M8 8 4 8 -

8 Nut M8 8 4 8 -

9 Adjustment Screw M8 5 2 5 -

10 L-Rail 2 1 2 -

11 Z-Rail Long - 2080mm - - 2 -

12 Z-Rail Short - 1040mm 2 2 - -

13 Frame Connector - - - 2

14 Wind Clamp 2 2 4 -

15 Screw M6 x 16 17 9 17 4

16 Wood Screw 14 8 14 -

Section 3 - Sharks Fin Installation

The instructions show the installation of a 3 panel kit, be sure to only make the connections, and holes in the roof that you require.

Section 3 - Sharks Fin Installation

Exploded View

3 Panel On Roof Tile Frame

(Comprising 2 Panel Frame and 1 Extension)

Section 3 - Sharks Fin Installation

ca. 1040 mm

ca.1040 mm

1780 - 1980 mm

Search for the rafters at the position of the collector eld. Push up or remove tiles on the total length of the collector eld.

Using the wood screws provided mount the support pipe using the pipe brackets. The distance between the lower batten and pipe centre should be 90mm. If more panels are added use the extension bolts to join the pipes. Extensions must be mounted with 2 pipe brackets [4]. The end brackets should not be more than 500mm from the end of the support pipe.

max 500mm

90 mm

Section 3 - Sharks Fin Installation

Screw the align screw [9] in the centre hole of the shark bracket. Now use the U-Bolt Bracket [6], washer [7], and nut [8] to x the hooks to the pipes. Choose so that the brackets are placed under

the centre of the panel. Note: The outside Sharks n should not be more than 500mm from the outer panel edge.

Warning: In areas of heavy snow: please replace roof tile with a metal tile, otherwise the roof tile might break under heavy snow loads, or use the slate screw installation kit.

500mm Max

Section 3 - Sharks Fin Installation

Use screw kit M6 x 16 [15] to connect L-Rails [10] to the Sharks Fin. The end with the most predrilled

holes goes to the top of the roof frame.

Section 3 - Sharks Fin Installation

max. 500 mm

Screw the Z-Rail [11] [12] to the L-Rail [10] using two screws M6 and two washers [16] on each

connection. Maximum Distance from sharks n to the end of the Z-Rail must not be more than 500mm! If more than 2 panels are to be mounted use the frame connector as shown in g. C. Before

screws are tightened be sure that a cross measurement has been made. A = B.

Section 3 - Sharks Fin Installation

Place the panels in the correct position. In case of systems with more than two panels, mount the panels starting in the middle. Do not forget to secure the panels together with any straight connectors required (supplied in panel extension set) Mount the wind clamps [14] and connect the

panels.

Design of the wind clamps may vary - this will not effect the performance of the roof frame.

Section 3 - Slate Bolt Installation

On Roof Slate Bolt

the packages.

Part Name 1 Panel

1 Panel

Extension

2 Panel

Frame

Connector

1 Slate Bolt 4 2 4 -

2 L-Rail 2 1 2 -

3 Z-Rail Long - 2080mm - - 2 -

4 Z-Rail Short - 1040mm 2 2 - -

5 Frame Connector - - - 2

6 Wind Clamp 2 2 4 -

7 Screw M6 x 16 13 7 25 -

M10 Bolt

2 x M10 Washers

M10 Spacer Nut

M10 Nut

Seal Cap

Weather Seal (Sponge)

Stainless Bolt

Section 3 - Slate Bolt Installation

The instructions show the installation of a 3 panel kit, be sure to only make the connections, and holes in the roof that you require.

Section 3 - Slate Bolt Installation

Exploded View

3 Panel On Roof Tile Frame

(Comprising 2 Panel Frame and 1 Extension)

ca. 1040 mm

- 1

- 8

)

Locate the rafters under the slates. Mark the slates where the holes should be drilled so that the

hole penetrates the centre of a rafter. Use the angle rail as a template. Note: The distance from the slate bolt to the end of the Z-Rail should not be more than 500mm on each side.

Section 3 - Slate Bolt Installation

Drill the holes on each marked position with a high quality 25mm masonry bit. Make sure the drill

does not spin too fast or you may break the tile / slate. Do not penetrate beyond the tile / slate. After

drilling the holes into the slates, use an 8mm wood bit to make a hole through the rafters at each

position. Bolt the bottom part of the slate bolt into each hole. Note: The angle between rafter and drill bit must be 90o.

90°

Section 3 - Slate Bolt Installation

Use the bolt kit M10 to connect the L-Rails to the self sealing bolt tting. Note: The L-Rails must be mounted into the long adjustable slot.

1.3m to 1.8 Max

Section 3 - Slate Bolt Installation

max. 500 mm

The Z-Rails have to be screwed on to the L-Rails using the M6 screws. Maximum distance from slate bolt to the end of the Z-Rail must not be more than 500mm

Section 3 - A Frame Installation

the packages.

Part Name 1 Panel 2 Panel

Frame

Connector

1 Panel

Horizontsl

1 Rail A 1 2 - 2

2 Rail B 1 2 - 2

3 Rail C 1 2 - 2

4 Z-Rail Long - 2 - 2

5 Z-Rail Short 1 - - -

6 Frame Connector - - 2 -

7 Rail D - 1 - 1

8 Wind Clamp 2 4 4 4

9 Screw M6x16 10 19 - 19

10 Washer 8,4 5 9 - 9

11 Washer 6,4 - 2 - 2

12 Screw M8 x 20 - 2 - -

13 Nut M8 - 2 - -

A Frame Installation

Section 3 - A Frame Installation

Exploded View

3 Panel On Roof Tile Frame

(Comprising 2 Panel Frame and 1 Extension)

Section 3 - A Frame Installation

To protect the panels from getting affected by strong winds they have to be screwed tightly to the rood structure. If this is not possible, each panel must be attached to a minimum weight of 220kg/ panel. This can be done in two ways:

1. Screw the A frame to an aluminium trapeze plate and cover it with gravel.

2. Use concrete blocks as a foundation and screw the A frame to it.

Section 3 - A Frame Installation

Screw the rails 1, 2, and 3 together using 6mm screws (9). The bottom rail has holes for ground or roof xing. The holes for wall xing have to be drilled on site.

Section 3 - A Frame Installation

Mount the Z prole, the distance between the last triangle and the end of the Z rail must not be more than 500mm. Pay attention that the triangles are aligned to each other. Use a string to check this, the Z rails must be mounted without any tension. Check cross measurements (A=B). Mount frame connectors if required.

max 500 m

Section 3 - A Frame Installation

Drill holes 8.5mm on the appropriate place of the back rails. Use the cross rail (D) as a template. Attach cross rail (D), using screws (12), washers (10) and nuts (13), to the back rail of the frame.

Section 3 - A Frame Installation

Mount the panels starting in the middle, mount the wind clamp (8) using screw (9) to the top and

bottom of the panel. 4 Wind clamps must be used per horizontal panel.

Section 3 - A Frame Installation

Proceed with the next panel. Place extension kit on connection before you place the panel. Make the

panel connections.

Section 3 - Slate Bolt Installation

panels.

Design of the wind clamps may vary - this will not effect the performance of the roof frame.

Section 4 - In Roof Frame Installation

In Roof Frames - S Class 20

The In roof frames from RM Solar come in the following two styles, choosing the correct frame for

your installation is paramount to an effective install. Minimum roof pitch for installation is 28

Tile In Roof

The tile in roof has a shallower prole to accommodate the panels with the thicker roof covering, a exible corrugated lead ashing is also present to allow moulding to a rolling tile.

Slate In Roof

The slate in roof has a deeper prole to accommodate the panels with the thinner roof covering.

Currently the S Class 20 Panel can only be installed In Roof up to 3 panels, and cannot be installed

using the “parallel” method.

Section 4 - In Roof Frame Installation

Preparation

The following is the area space required by a set of in roof panels, please ensure you have this area available to you before attempting installation of your equipment.

Note: Additional materials and tools necessary and not included in the equipment supplied:

• Minimum of 3 battens in the same size as the ones used in the roof, it can be possible to use battens from the area under where the collector will be mounted.

• Wood Screws 4 x 80 to x the battens to the roof.

• Battery drill with 2.5mm HSS drill bit, hammer, measuring tape, wood saw, grinder with stone blade, plumbers tools, ladder, and rope with lashings.

2540m m

mm0552

3580m m

4620m m

5660m m

6700m m

7740m m

8780m m

mm0552

Section 4 - In Roof Frame Installation

Important

When unpacking the in-roof frame package please check if any pieces are missing using the list

below. The pack should contain the following pieces:

No. Item Single Frame Extension

1 Angle Bracket 2 2 2 Lower Wooden Slat 1 1

3 Bottom L/H Flashing 1 N/A 4/5 Bottom Center Flashing N/A 1

6 Bottom R/H Flashing 1 N/A 7/14 Seal Strip 20x20 2.8m 2.2m 8 High Load Support Brackets 4 2 9 Wood Wedge 1 1 10 Side Seal Strip 4m 4m 11 Center Flashing N/A 1

12/13 Side Flashing 2 N/A 15 Wind Protection Rail 1 1

16 Top L/H Flashing 1 N/A 17/18 Top Center Flashing N/A 1 19 Top R/H Flashing 1 N/A 20 Nail Strips 10 2 21 Triangular Seal 1.8m 1.2m 22 Sealed Screws (4.5x35) 4 N/A

23 Wood Screws (4x30) 36 15 24 Wood Screws (5x110) 3 3 25 Sealed Screws (4x80) 2 2 26 Wood Block with Hole 2 1

Section 4 - In Roof Frame Installation

Installation

Remove the tiles / slates required for installation:

2 Panel Flashing Set = 260 x 260

110cm for every further panel in the same row

Attach the lower support batten, screw the lower support batten to the rafter along where the collectors are going to be placed. Use screws (4.5x80)

Note: These battens and screws are not included.

A = 8,5 - 12 cm

Section 4 - In Roof Frame Installation

Mount Angle Brackets

Mount angle brackets (1) in equal distance with each 4 screws 4x30 (23) to the support batten. With more than 2 collectors, mount rst and last angle bracket. Now use a string to level the rest of the brackets by stretching it from one to the other. Now place the lower wooden slat (2) with the cut edge showing upward and screw to angle brackets with each 4 screws 4x30 (23). If the battons are narrow

please use 2 battons to mount the brackets.

B = 0,5 cm

Section 4 - In Roof Frame Installation

Mounting Lower Flashings

Starting from left side, screw lower left ashing (3) at left end to lower slat (2) with screws 4x30 (23). Mount rest of lower ashing (4/5/6) continuing left to right, push ashing together and t with screw (23) to lower wooden slat (2) where the overlap and on right end. (The ashings must interlock with each other). When nished stick the seal strip at top of ashing edge (7) (covering the screw heads)

across total length.

Section 4 - In Roof Frame Installation

Mounting Upper Wooden Wedge

The upper wooden wedge (no in set incl.) has to be mounted so that the distance between the lower wooden slat and the top angled timber wedge is 1950mm. The top angled timber wedge must sit on at least two battens. Mount a second support batten if necessary.

195 cm

1950 mm

mind. 2

Section 4 - In Roof Frame Installation

Place and Align Collectors

Distance A = 10cm, Distance B = 10cm Place 2 high load support brackets (8) under each collector side.

Section 4 - In Roof Frame Installation

Mounting Top Angled Timber Wedge

Place top timber wedge (9) under each collector, align them and secure each with 2 screws 5x110 (24). Connect collector connections as shown in the collector installation manual. Make sure to do a quick A = B measurements on the panels to ensure they are square.

NOTE: Pressure test the panels and insert temperature sensor into R/H panel. The panels should

be pressure tested to 6.5 bar using either compressed air, or glycol, DO NOT USE WATER. If using

glycol cover the panels for the duration of the test.

Section 4 - In Roof Frame Installation

Stick Side Seal Strip To Collector

Stick side seal strip to the collector sides as shown. You should when applying keep to the external

edge of that panel.

10 mm

Section 4 - In Roof Frame Installation

Mount Center Flashings

Place center ashing (11) on the lower collector edge and snap in starting from the bottom to the top. Ensure the ashing snaps in tight, if required adjust the gap on the underside of the ashing. Secure ashing into wooden block (26) using screws supplied (25). N.B. Do not over tighten screw (25) this will deform the ashing.

Section 4 - In Roof Frame Installation

Mount Side Flashings

Push the side ashing (12/13) from the side over the collector edge. Use sealing screws (25) to x the ashings as shown. Be Careful! Do not bend the ashings. The 8” long slit on the side ashings goes at the bottom of the collectors and allows the ashing to ex onto the roof covering.

Section 4 - In Roof Frame Installation

Place Top Seal Strip

Stick top seal strip (14) across the total length.

Section 4 - In Roof Frame Installation

Wind Protection Rail

Place wind protection rail (15) and x with wood screws 4x30 (23) each 4 times. Note that the buckle must be placed direct over the edge of the wooden wedge (9). Each end of the wind protection rail should overlap the vertical ashings and pin the top of the vertical ashings in place.

Section 4 - In Roof Frame Installation

Top Flashings

Starting from the left side. Push top corner ashing (16) under the wind protection rail (15), when located correctly you should no be able to lift the leading edge. Fix with wood screw 5x30 (23) on the right joint and with sealing screw (22) from the left side. Continue with parts (17/18/19).

Leading Edge

Section 4 - In Roof Frame Installation

Nail Straps

Fix top ashings (16/17/18/19) with 2 nail strips and side ashing (12/13) with 4 nail strips (20) each. Stick wedge formed seal (21) across the total length. It must be placed so that after replacing the tiles it will be approximately 5cm under the bottom tile edge.

NOTE: Seal (21) must be placed at least 10cm down the side ashings (16/19).

Additional seal can be ordered from the outlet where the kit was purchased.

min. 10 cm

Section 4 - In Roof Frame Installation

Place Tiles

If necessary, cut tiles to make them t. Please use the diagram as a guide as to where to tile up to.

min.

Section 4 - In Roof Frame Installation

In Roof Frames - S Class 10

The In roof frames from RM Solar for the S Class 10 Panel only come in one style which is suitable for all roof coverings regardless of whether they are tile or slate. Minimum roof pitch for

installation is 28o.

This style comes complete with the exible corrugated lead ashing for molding to a rolling tile.

Section 4 - In Roof Frame Installation

Preparation

The following is the area space required by a set of in roof panels, please ensure you have this area available to you before attempting installation of your equipment.

Note: Additional materials and tools necessary and not included in the equipment supplied:

• Minimum of 3 battens in the same size as the ones used in the roof, it can be possible to use battens from the area under where the collector will be mounted.

• Wood Screws 4 x 80 to x the battens to the roof.

• Battery drill with 2.5mm HSS drill bit, hammer, measuring tape, wood saw, grinder with stone blade, plumbers tools, ladder, and rope with lashings.

2615m m

mm0162

3700m m

4785m m

5870m m

6955m m

8040m m

9125m m

mm0162

Section 4 - In Roof Frame Installation

Important

When unpacking the in-roof frame package please check if any pieces are missing using the list

below. The pack should contain the following pieces:

Item Single Frame Extension

Small Wood Screws (4x30) 20 15 Large Wood Screws (5x110) 10 7 Sealing Screws (4x80) 14 7 Small Self Tapping Screws 7 1 Side Seal Strip 4.3m 4 Top Square Seal 1.5m 1.2

Triangular Seal 1.8m 1.2 Bottom L/H Flashing 1 N/A Bottom R/H Flashing 1 N/A Bottom Centre Flashing N/A 1 Colour Coded Bottom L/H 1 N/A Colour Coded Bottom R/H 1 N/A Colour Coded Bottom Centre N/A 1 Middle Flashing N/A 1 L/H Side Flashing 1 N/A R/H Side Flashing 1 N/A Top L/H Flashing 1 N/A Top R/H Flashing 1 N/A Top Centre Flashing N/A 1 Wind Retaining Rail 1 1 Nail Strips & Nails 10 2 Top Wooden Wedge 1 1 Wood Side Section 2 1

Section 4 - In Roof Frame Installation

Installation

Remove the tiles / slates required for installation:

2 Panel Flashing Set = 270 x 270

110cm for every further panel in the same row

Section 4 - In Roof Frame Installation

Secure Battens

Attach 2 battens using (4.5x80 - not supplied) 450mm and 350mm from the top of the batten

beneath.

Section 4 - In Roof Frame Installation

Mounting The Flashings

Starting from the left hand side, place the left hand apron ashing onto the top batton (450mm) and screw into position (just use the top screw holes to secure in place at this point).

Note: Please remove the protective plastic coating from the pieces of ashing before it is installed.

Section 4 - In Roof Frame Installation

Mounting The Flashings

Connect the right hand apron ashing to the left hand apron ashing as illustrated (below) ensuring

that they interlock correctly.

Section 4 - In Roof Frame Installation

Mounting The Flashings Note: If the system is larger than 1 panel then the apron from the extension kit is placed between the

right hand and left hand ashing of the 1 panel ashing frame.

Section 4 - In Roof Frame Installation

Mounting The Flashings

Slide the colour coded ashings over the galvanized section of the apron, start with the middle sections rst (the left hand and right hand corners are always found in the one panel kit box and not

on the extension boxes).

Section 4 - In Roof Frame Installation

Mounting The Flashings

These pieces also interlock.

Section 4 - In Roof Frame Installation

Mounting The Flashings

When interlocking correctly the colour coded cover ashing will butt up to the galvanized xing plates

at each end.

Section 4 - In Roof Frame Installation

Mounting The Flashings

Now insert the rest of the xing screws into the galvanized xing plates. (approx 100mm from the

top).

Place the left hand panel into the galvanised xing plate so it is positioned as shown (below).

Section 4 - In Roof Frame Installation

Mounting The Flashings

Insert the pipe reinforcers (supplied in the install and extension kits) into the panel connections, also put a capnut and olive on to the connection.

Now put the neighboring panel (if 2 or more panels) in place, insert pipe reinforcers, capnuts and

olives into the panel connections and join the 2 panels together using 2 x 22mm straight connections supplied.

The panels at both ends of the collector array should be just lapped by the apron ashing at the bottom when sighted correctly.

Section 4 - In Roof Frame Installation

Mounting The Flashings

At this point measure diagonally across the panels. The two measurements should be the same to ensure the panels are square. A must equal B.

Mount the wooden latts supplied down the sides (and middle is using 2 or more panels) of the panels using the 3 x large wood screws supplied (5x110mm). The wooden latts should be positioned 200mm from the bottom of the panels and should screw to the battens with a screw at the top middle and bottom. The latts require pilot holes to prevent splitting.

The latts are tapered and the 90mm end goes to the top of collector array with the 95mm end going

to the bottom.

Section 4 - In Roof Frame Installation

Mounting The Flashings

The panels can now be piped up and the pipework inserted through the roof felt.

The panels should now be pressure tested to 6.5bar using either compressed air or glycol.

Note: If using glycol cover the panels for at least an hour before and at all times during the test.

The picture shown above assumes the panel doesn’t have an in built stat pocket. RM are gradually

introducing them across the range. If your panel doesn’t have a stat pocket please attach as photo

above. If there is a pocket in the panel please insert the probe into this and secure, the above tting is then replaced with a T-Piece complete with airvent.

Section 4 - In Roof Frame Installation

Mounting The Flashings

For every panel there will be 1 x wedge shaped wooden section, this needs to be mounted on 2 battens directly above the panel, and secure in place using 2 x (5x110mm) wood screws.

Section 4 - In Roof Frame Installation

Mounting The Flashings

Stick the weather seal (supplied on a roll) to the colour coded apron ashing at both corners and up

the vertical edges of the panels. (This foam expands to 10mm deep).

Mounting The Flashings

Mount the left hand side ashings starting with the bottom screw, use 1 x small self tapping seal screw (4.5x35mm) at the bottom and 6 x larger sealing screws (4x80mm) up the length, ensure the ashing runs parallel to the panel.

Mount the middle vertical ashing (for 2 or more panels) and the right hand side ashings in the

same manner.

Note: the middle apron ashing will need a 3mm pilot hole drilling on the upstand to enable the small self tapping seal screws (5x35mm) to be tted.

Section 4 - In Roof Frame Installation

Mounting The Flashings

Stick the square seal along the top of the panels also over the face of the side and middle vertical ashings.

Section 4 - In Roof Frame Installation

Mounting The Flashings

Screw the wind retaining rails into place, the angel should run parallel with the edge of the wooden wedge and should lap over the vertical ashings at either side using small wood screws (4x30).

Section 4 - In Roof Frame Installation

Mounting The Flashings

Starting at the left hand side mount the top ashing ensuring that the leading edge hooks under the wind retaining rail. When located correctly you will not be able to lift the leading edge by hand. Secure in place using 1 x (4x30mm) wood screws (this screw needs to be located as indicated so as not to compromise the water tightness of the ashings.

Leading Edge

Section 4 - In Roof Frame Installation

Mounting The Flashings

The top ashings interlock in the same way the apron ashings interlock, continue from left to right.

The clips and galvanized nails are used to secure the side ashings and the top ashings to the

battens.

Section 4 - In Roof Frame Installation

Mounting The Flashings

Stick the triangular seal along the top of the top ashings and down each side by at least 150mm (if required additional seal is available to order through your merchant from RM Solar).

Section 4 - In Roof Frame Installation

Mounting The Flashings

A small seal screw (4.5x35mm) is used to secure the four corners of the ashings in place, you may need a 3mm HSS drill to pilot these holes.

Section 4 - In Roof Frame Installation

Mounting The Flashings

The roof covering can now be installed at least to the ridge on the side ashings and to the angle on the top ashings.

Once you have made the connections in accordance with page 7 be sure to seal and pressure test to at least 1 and a half times the proposed working pressure of the system (suggested working pressure 3 - 4 Bar), normal testing pressure will be 6.5 Bar. Once the system has been tested

connections can be taken from the roof space to the proposed location of the double pump station.

Be sure to use 22mm Copper Pipe, and Compression ttings. If required using a small amount of

sealing compound on the outside of the olive is suggested in order to give a good seal for glycol.

Important: Plastic pipe should NEVER be used.

The use of the correct insulation is critical. Normal central heating insulation will melt and become

brittle at the very high solar generated temperatures in the system. Insulation materials must endure

the highest occurring temperature, which will be more than 170oC near the collector.

When the insulation is to be used outside it must be:

• Resistant to temperatures up to 170oC

• Must have a exibility in - 30oC conditions

• Resistant to air pollution

• Resistance to UV radiation

• Resistance to pests, such as mice and birds that may eat it

• Insulation should be externally sealed to prevent it carrying moisture.

RM Solar carry a range of suitable insulation in stock that can be purchashed through your plumbers merchant.

The glycol is used as heat exchange uid with a very low freezing point, already pre-mixed to allow

give a freezing point of -20oC. RM Solar only recommend using the glycol supplied by ourselves and

that comes as part of the kit purchased. RM Solar glycol has the following properties:

• Premixed to give protection down to -20oC (Do not dilute further).

• Contains anti-corrosion inhibitors for pipe protection

• Glycol is a low toxic polypropylene product approved for use in solar systems by all major

countries including the USA & EU

• The glycol has a notably more intensive creeping property than water

• Glycol is not compatible with Zinc, so pipes with internal zinc galvanising should not be used

• As with all chemicals, normal precautions should be taken in handling the glycol to prevent ingestion and delivery into the water system.

Important

Under no circumstances should any ethylene based glycol be used in solar systems. The material

safety data sheet for the RM Solar glycol is available from RM Solar on request.

Section 5 - Piping System, Insulation & Glycol

System Piping

Insulation

Glycol

The double pump station ensures a continuous circulation of the glycol inside the closed solar loop

when useful energy is available in the solar panels. The double pump station recommended by RM

Solar is constructed so as to be unaffected by the operating temperatures of the loop for many years,

however it is always recommended that in order to protect the pump that the cooler glycol returning

to the panel passes through the pump.

Double Pump Station - Technical Data

Maximum working excess pressure: 6 bar

Safety valve: 6 bar Circulation pump: Solar Circulating Pump

Nominal voltage: AC 230V Power consumption: Speed 1 - 45w Speed 2 - 65w Speed 3 - 90w

Maximum pump head: 6m Maximum pump capacity: 6Ltr/Min

Location Of Double Pump

The double pump station must always be mounted at a level that is lower than the panels so that no steam may penetrate the expansion vessel in case of stagnation. Stagnation occurs when the solar panels have heat energy which is not needed by the system and the panels stagnate at around

180oC. If the expansion vessel is mounted at the same level or at a higher level than the panels, an

anti-gravity loop must be installed. To install an anti gravity loop the pipe work from the double pump to the expansion vessel should be hard piped in 22mm copper pipe, the pipe should be allowed to

fall for approximately 1m from the pump, before rising 1m to enter the expansion vessel.

Important

1. Never ush the solar system with water.

2. The double pump station is not suitable for direct contact with swimming pool water.

Section 5 - Double Pump Station

Double Pump Station

Temp.

Gauge 1

Temp.

Gauge 2

Pump

Pressure

Gauge

Pressure

Relief Valve

Expansion

Hose

(Do Not

Insulate)

Flow Gauge

Filling Point 1

Filling Point 2

Expansion

Vessel

Connection

Vessel

Bracket

The expansion vessel protects the solar system during pressure changes and temperature

uctuations. For example, in very hot conditions when energy is not being drawn off, the system may

overheat causing the glycol to expand.

Technical information (Standard 18L Vessel):

Maximum pressure: 10 bar

Working pressure: 3.0 - 4.0 bar (20oC) Gas pressure: 2.5 bar Maximum working temperature: 130oC

Membrane: Nytril (butyl) rubber Resistance: 40% glycol

Sizing

It is of critical importance to have the correct size of expansion vessel in your solar system. The volume of the expansion vessel is determined by the number of RM Solar solar panels connected

within the one solar heating system. Approximately for one collector 6 litres of expansion vessel volume is required. When tting a system larger than 3 panels RM Solar should be consulted on

expansion vessel sizing.

Location

The pressure vessel should be located in a position where it can be easily accessed. It should be tted with isolating valve for ease of replacement. The isolating valve should not be accessible without a tool so that an unqualied person cannot shut it off. The expansion vessel should be tted

on the return run of the system.

Where the expansion vessel is sited at the same level as the panels or above, a thermal loop should be present.

Maintenance

Once an expansion vessel is pressurised correctly it will require yearly maintenance and a visual inspection by a qualied person. Monthly checking of the pressure gauge on a double pump station is also very important, as well as pressure testing the expansion vessel at each maintenance

inspection. A pressure drop might indicate:

• A leak on the pipes connections or

• A leak on the panels connections or

• A faulty expansion vessel or loss of pressure in the expansion vessel

In the case of any unexpected changes, the customer must contact the installer immediately and the

installer should inform the customer of this when explaining the system.

Important

When installing your expansion vessel ensure that you have not mixed the expansion vessel with another one from somewhere else. The solar expansion vessel has been carefully designed to work with glycol without corrosion. The solar expansion vessel should be clearly marked as being a solar

expansion vessel.

Section 5 - Expansion Vessel

Expansion Vessel

This guide assumes the use of an RM Solar Filling Pump, no other methods are supported by RM Solar as they can often lead to excess air in the system.

Prior To Filling The System

Cover the panels 30 minutes before lling the system, and leave covered whilst lling. (If it is not possible to cover the panels, ll the system when there is little solar energy, e.g. early morning, late

evening.

Ensure the expansion vessel pressure has been set correctly at 2.5 bar.

Connecting The Filling Pump

At the Pump Station:

1. Connect the right hand hose (Side with the pressure gauge) of the pumping station to the top

lling pump connection of the lling pump.

2. Connect the left hand hose of the lling pump to the bottom lling connection on the solar pumping station.

3. Twist the red and blue temperature gauges on the solar pump station 45o clockwise.

4. Close the grub screw (twist all the way in) on the solar pump station, this is between the pump and the ow gauge.

5. Open the buttery valves on the pump station where the lling pump hoses are connected, manually open any zone valves ect on the solar primary pipe work.

At the Filling Pump:

1. Open the right hand isolation valve, close the left hand isolation valve and open the isolation

valve beneath the white tank.

2. Fill the white tank at least half full.

Running The Filling Pump

1. Switch on the lling pump - keep the tank topped up to half full.

2. The pressure can be adjusted using the ll pressure regulator on the lling pump.

Whilst Filling:

1. Whilst lling open the bleed screw on the solar circulating pump, expel all the air and then re- close.

2. Allow the lling pump to circulate for approximately 1 hour.

3. Check in the lling tank that no air bubbles are returning with the glycol.

4. Close the isolating valve on the solar pump station beneath the circulating pump.

5. Allow the system to pressurise to between 3-4 bar.

6. Close the isolation valve beneath the pressure gauge beneath the pressure gauge on the solar pump station.

7. Switch off the lling pump and close the isolation valves.

8. Remove and drain the hoses from the solar pump station.

Section 6 - Filling The System

Filling The System

RM Solar provide the original instruction book from the manufacturer for each of the solar controllers

supplied, however provided are the recommended wiring details for the controllers most scenarios available. Please check carefully to see which diagrams apply to the controllers being used.

The Stelow hot water cylinder as supplied by RM Solar is designed to work perfectly in conjunction with any RM Solar controller we supply, when using hot water cylinders other than those supplied by RM Solar a pipestat/control stat may be required to enable the solar controller to function correctly.

Section 7 - Controller Setup

Control Setup

Section 7 - Controller Setup

P1T1

COM

T2N L ALAL

1 2 3 4 5 6 7 8 9 10

2 3 4 5 6 7 8 9 10

Br Bl G O Gy

L N E 1 C 2 E

L N E

1 526 3

5 3

Solar Controller

Solar Pump 1

Stat

Energy Cut

Out

2 Port Valve

(Fitted Below Pump)

(If not required link 6 & 5

together)

SHE-02 Solar Controller

Wiring Diagram

4 3

+N E PL -+

1 2 3 4 5 6 7 8 9 10

2 3 4 5 6 7 8 9 10

Br Bl G O Gy

L N E 1 C 2 E

L N E

2 3 41

1 526 3

5 32

Solar Controller

Solar Pump 1

Stat

Energy Cut

Out

2 Port Valve

(Fitted Below Pump)

(If not required link 6 & 5

together)

Solastat Controller

Wiring Diagram

4 3

Roof Cyl

Section 7 - Controller Setup

1 2 3 4 5 6 7 8 9 10

2 3 4 5 6 7 8 9 10

Br Bl G O Gy Br Bl G O Gy

L N E L N E 1 C 2 E

2015 16 1712 13 14

1 2 3 4 5 6

S1 S2 S3

L N E

23 6

1 1 7 35 6 224 3

5 337

Solar Controller

Solar Pump 1

Tank Sensor 1

Panel Sensor 1

Panel Sensor 2

Solar Pump 2

Stat

Energy Cut

Out

2 Port Valve

(Fitted Below Pump 1)

(If not required link 4 & 5

together)

2 Port Valve

(Fitted Below Pump 2)

(If not required link 6 & 7

together)

Resol BS Plus - East / West Split

Wiring Diagram

N L

2015 16 1712 13 14 1918

1 2 3 4 5 6 7 8 9 10

2 3 4 5 6 7 8 9 10

Br Bl G O Gy Br Bl G O Gy

L N E 1 C 2 E

1 2 3 4 5 6

S1 S2 S3

L N E

103 4 1

1 1 9 37 226 3

9 3

L N E

10 15 3

Solar Controller

Solar Pump 1

Stat

Store 1

Energy Cut

Out

C1 2 E

Stat

Store 2

Energy Cut

Out

2 Port Valve

(Fitted Below Pump)

(If not required link 6 & 7

together)

2 Port Valve

Resol BS Plus - 2 Store Priority

Wiring Diagram

4 3

3 Port Valve

Store 1 Store 2

Tank Sensor 1

Panel Sensor 1

Tank Sensor 2

Section 8 - Commissioning & Maintenance

The following steps are important when ensuring the system has been installed correctly and has

been setup to run correctly under normal operating circumstances.

1. Ensure the red and blue valves on the solar pumping station are twisted as far anti clockwise as

possible (usually inline with the pipework).

2. Open the grub screw beneath the circulating pump fully by turning anti clockwise as far as possible.

3. Set the circulating pump on speed 1, power up the RM Solar Controller and adjust the settings if required. Never run the solar pump dry, doing so will invalidate any pump guarantees.

4. Put the RM Controller into manual operation (ensure any motorised valves ect. on the solar

primary pipework have opened).

5. Set the ow rate between 0.5-1L/m per panel, e.g. a 2 panel system requires a owrate of between 1-2L/m.

6. To slow the owrate slowly close the grub screw beneath the solar pump by twisting clockwise.

7. To increase the owrate switch the circulating pump speed setting up at the pump.

8. When the desired ow rate has been achieved put the controller into automatic mode.

The system has now been correctly commissioned.

Commissioning

Product Guarantee

RM Solar Products are guaranteed by RM Solar Ltd as follows:

Thermal Solar Panels (Performance) - S Class 20 Only 20 Years Thermal Solar Panels (Manufacture & Corrosion) - S Class 20 Only 20 Years Thermal Solar Panels (Manufacture & Corrosion) - S Class 10 Only 10 Years Pump Station, Controller & Heat Exchanger 1 Years Other RM Solar Products 1 Years

In all cases from the day the system was installed & commissioned.

The Guarantee is conditional upon:

• The solar system is installed by an approved RM Solar installer in accordance with recommended RM Solar techniques & practices, and is serviced in line with our recommendations, and a full

service history is recorded.

• The installation is paid for in full.

• Customer completing the registration form available at the RM Solar website within 28 days of

installation.

• RM Solar being notied of any circumstance giving rise to a claim hereunder within 28 days of

such circumstance arising.

The Guarantee DOES NOT cover:

• Hot water cylinders and thermal stores, which are separately guaranteed by their own

manufacturers.

• Workmanship which is separately guaranteed by the installer.

All statutory rights are not effected by this guarantee and every subsequent owner of the property at which the thermal solar installation is installed will be recognised hereunder RM Solar Ltd.

Maintenance

These requirements are recommended by RM Solar Ltd and must be adhered to and must be logged in the service records. Any failure to do so will nullify any manufacturers guarantees, and possibly installer guarantees. In addition these requirements are separate from any regime for the prevention

of legionella.

The following checks should be carried out at least once every 12 months:

• Visual inspection for weeps, leaks, and uid escapes

• Manually operate all valves and pumps to ensure they are working correctly

• Visual inspection that system pressure has not dropped into the red zone

• Visual inspection that ow gauges indicate correct ow levels

• Visual inspection that there is no damage to panels or xings, this can be done from ground level

• If there is pre heating used, regular checks of the heating system for the nal heated cylinder

should be made

• Check the pre-charge of the expansion vessel(s)

• Check the whole system for signs of corrosion

• Test glycol with approved testing kit

• Visual inspection that all insulation is in good condition and not becoming brittle or cracked

• If vacuum panels are used, check that the vacuum guage shows that there is still sufcient

vacuum, the pointer should be in the green zone.

Storage vessels should be checked in accordance with manufacturers recommendations.

Section 8 - Commissioning & Maintenance

SERVICE 1

DATE:

SERVICE 2

DATE:

ENGINEER NAME: ENGINEER NAME:

COMPANY NAME: COMPANY NAME:

TEL NO. TEL NO.

COMMENTS: COMMENTS:

SIGNATURE: SIGNATURE:

SERVICE 3

DATE:

SERVICE 4

DATE:

ENGINEER NAME: ENGINEER NAME:

COMPANY NAME: COMPANY NAME:

TEL NO. TEL NO.

COMMENTS: COMMENTS:

SIGNATURE: SIGNATURE:

SERVICE 5

DATE:

SERVICE 6

DATE:

ENGINEER NAME: ENGINEER NAME:

COMPANY NAME: COMPANY NAME:

TEL NO. TEL NO.

COMMENTS: COMMENTS:

SIGNATURE: SIGNATURE:

SERVICE 7

DATE:

SERVICE 8

DATE:

ENGINEER NAME: ENGINEER NAME:

COMPANY NAME: COMPANY NAME:

TEL NO. TEL NO.

COMMENTS: COMMENTS:

SIGNATURE: SIGNATURE:

SERVICE 9

DATE:

SERVICE 10

DATE:

ENGINEER NAME: ENGINEER NAME:

COMPANY NAME: COMPANY NAME:

TEL NO. TEL NO.

COMMENTS: COMMENTS:

SIGNATURE: SIGNATURE:

SERVICE 11

DATE:

SERVICE 12

DATE:

ENGINEER NAME: ENGINEER NAME:

COMPANY NAME: COMPANY NAME:

TEL NO. TEL NO.

COMMENTS: COMMENTS:

SIGNATURE: SIGNATURE:

Service Record

Section 9 - Service Record

RM Solar S Class 10, S Class 10 Pro, S Class 20, S Class 20 Pro Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual