SOLE 125-1-S150, 125-1-S200, 150-1-S200, 150-1-S230, 150-2-S150, 200-1-S200, 200-1-S230, 200-1-S260, 200-2-S200, 300-2-S200, 300-2-S230 Installation & User Manual

INSTALLATION

USERS MANUAL

DOMESTIC SOLAR WATER HEATER

THERMOSIPHON SYSTEM

CLOSED CIRCUIT

MODELS EUROSTAR ECO :

125-1-S150, 125-1-S200, 150-1-S200, 150-1-S230, 150-2-S150, 200-1-S200, 200-1-S230, 200-1-S260, 200-2-S200, 300-2-S200, 300-2-S230

INDEX

INDEX .............................................................................................................................................................................. 1

1. Observance of the instructions and standards........................................................................................................... 2

2. Description of solar system and components ............................................................................................................ 2

2.1 General Description.................................................................................................................................................. 2

2.2. Collector................................................................................................................................................................... 3

2.3. Accumulation tank (cylinder)................................................................................................................................... 3

2.4 Support system......................................................................................................................................................... 4

2.5. Thermo convention liquid ....................................................................................................................................... 6

2.6. Packaging, Transport and Storage........................................................................................................................... 6

3. Warnings..................................................................................................................................................................... 7

4. Recommendations...................................................................................................................................................... 6

5. Flat Roof.................................................................................................................................................................... 15

Assembly instructions for systems with 1 collector: .................................................................................................... 15

Models: 125-1-S150, 125-1-S200, 150-1-S200, 150-1-S230, 200-1-S200, 200-1-S230, 200-1-S260............................ 15

Assembly instructions for systems with 2 collectors:................................................................................................... 17

Models: 150-2-S150, 200-2-S200, 300-2-S200, 300-2-S230.........................................................................................17

7. Inclined roof - Tiles ................................................................................................................................................... 19

Assembly instructions for systems with 1 collector : ................................................................................................... 19

Models: 125-1-S150, 125-1-S200, 150-1-S200, 150-1-S230, 200-1-S200, 200-1-S230, 200-1-S260............................ 19

Assembly instructions for systems with 2 collectors:................................................................................................... 21

Models: 150-2-S150, 200-2-S200, 300-2-S200, 300-2-S230.........................................................................................21

9. Check list for installer ............................................................................................................................................... 23

10. Operation instructions............................................................................................................................................ 24

11. Maintenance instructions.......................................................................................................................................24

12. Decommissioning of the system…………………..………………………….. …………………………..…………………….……………….….24

1. Observance of the instructions and standards.

1.1. It is very important to follow these installation, operating and maintenance instructions, in order to avoid

danger of death, injury, property damages, and to have your device functioning properly in the long run. The company that manufactured and/or supplied this solar system has no liability for the installer and/or the user in case these instructions have not been followed carefully.

1.2. Whether further information or clarifications are needed, please contact the supplier of the product.

1.3. These solar systems have been manufactured and tested under the European standards:

ISO 9806:2013: Energy – Solar Thermal Collectors – Test methods EN 12975-1: Thermal solar systems and components – Solar collectors -part 1: General requirements. EN 12975-2: Thermal solar systems and components – Solar collectors – part 2 : Test methods. 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: Test methods.

1.4. These systems are in conformity with the applicable requirements of the following documents:

Ref. No.

Title

EN 60335-1:2012 +A11:2014 (IEC 60335-1:2010)

Household and similar electrical appliances — Safety — Part 1: General requirement

EN 60335-2-21:2003 +A2:2008 (IEC 60335-2-21:2002 +A2:2008)

Household and similar electrical appliances — Safety — Part 2-21: Particular requirements for storage water heaters

EN 60529:1991 +Α1:2000 +Α2:2013 (IEC 60529:1989 +Α1:1999 +Α2:2013)

Degrees of protection provided by enclosures (IP code)

ENV 61024-1:1995

(IEC 61024-1:1990)

Protection of structures against lightning Part 1: General principles

The manufacturer declares that the equipment named in this document have been designed to comply with the relevant sections of the above referenced specifications.

2. Description of solar system and components

2.1 General Description

This solar system is a closed loop thermosiphon unit which delivers hot water for domestic use. It consists from the collector, the accumulation tank, the support system, the hydraulic accessories and the thermoconvention liquid. Four nominal sizes of accumulation tanks are combined with four different sizes of collectors as the table

below:

MODEL

TANK NOMINAL SIZES

COLLECTOR NOMINAL

SIZES

125 ltrs

150 ltrs

200 ltrs

300 ltrs

1,50m

2,00m

2,30m

2,60m

125-1-150

125-1-200

150-1-200

150-1-230

150-2-150

200-1-200

200-1-230

200-1-260

200-2-200

300-2-200

12300-2-230

Other combinations are available upon request

2.2. Collector

The collectors are manufactured in 4 sizes with nominal area of 1,50m2-2, 00m2-2.30m2-2,60m2. The absorbers of the collectors are made by copper tubes and the fins area by selective aluminum fins. The fins are welded to the tubes by laser welding. The frame of the collector is made by extruded aluminum epoxy oven painted to resist ambient conditions. The glass cover is a “prismatic securit” glass of 3.2mm thickness for maximum penetration of solar irradiation. At the back and sides of the absorber there is sufficient insulation of rock wool and glass wool to minimize heat loses and to resist stagnation temperatures.

Technical data of collector as the table below:

Nominal size (m2)

1,50

2,00

2,30

2,60

Length (mm)

1540

1960

2135

Width (mm)

960

1165

1238

Depth (mm)

818181

Weight (kg)

27,3

32,0

38,8

Stagnation temperature: about 150oC Test pressure: 1500 kPa Operating pressure: 1000 kPa

2.3. Accumulation tank (cylinder)

The solar accumulation tank is an indirect (double circuit) hot water horizontal cylinder. The inner surface is enameled at 850oC to guarantee potable sanitary water for long life. Additionally it is protected against rusting with a large magnesium anode. The ecologic polyurethane foam insulation guaranties minimum thermal loses even at very low ambient temperatures. The external cover of the tank can resist any extreme weather conditions for life. The internal heat exchanger with large surface guaranties the energy transfer to the domestic hot water. The hot water exits from the hottest zone (level) of the tank. At the same time equal quantity of cold water enters the tank at the coldest zone (level). The solar tank can be optionally (accessory) equipped with immersion electric heater (electric element) for use only for emergency situations. The immersion electric heater is available in 2 kW or 3kW or 4 kW at 230 Volt. It is equipped with control thermostat set at 60oC and safety thermostat (thermal cut out) manually reset. The safety valve only opens to discharge when the system pressure exceeds 10bar in the form of water. Technical Data of tanks as table below:

Nominal size

125

150

200

300

Length (mm)

1130

1185

1215

1915

Diameter (mm)

440

500

530

Weight (kg)

46,7

50,8

Capacity (ltr) (Incl. h.exchanger)

115

142

170

276

Test pressure (kPa)

1500

Operating pressure (kPa)

1000

Max temperature (oC)

90oC

Cold & hot water connectors (male)

½˝½˝½˝

½˝

2.4 Support system

The support system is made from galvanized pressed steel. It is designed for flat roof installation as well as for inclined tiled roof. It can be installed at 3 different inclinations. 20o-30o-40o, so it can meet any roof slope. The support system can withstand wind velocity up to 97,2 km/hr. and weight of snow up to 64cm height.

In order to assembly the support system the following tools are needed.

 Spanner 10mm 1 X

 Spanner 13mm 1 X

 2 Spanners 17mm 2 X

 Screwdriver 1 X

 Drill Ø10 (for fastening the system on the roof)

The material list for each set of support system is:

(*)

Required quantities for: flat roof / inclined roof (tiles)

(All the other quantities arethe same for flat roof or inclined roof installation)

Part

MODEL

125-1-150

125-1-200

150-1-200

150-1-230

150-2-150

200-1-200

200-1-230

200-1-260

200-2-200

300-2-200

300-2-230

SET OF SUPPORT FRAME PARTS

A1 profile in Π section 1465mm

(*)

---------

-/1

A125 profile in Π section 1107mm

(*)

2/1---2/1------

A150 profile in Π section 1377mm

(*)

2/1

2/1-2/1

2/1

A200 profile in Π section 1489mm

(*)

---

----2/1--

A12 profile in Π section 240mm

(*)

-/2

D125 profile in Π section 1671mm

2---2------

D150 profile in Π section 2091mm

-22

2-22-22

D200 profile in Π section 2266mm

---

----2--

H/H2:bracket in Π section 850mm

(*)

1/1

1/1--

H11/H12:bracket Π section1400mm(*

)

---

------1/1

1/1

I : angle bracket 173mm

22222222222

T : support bracket 160mm

44444444444

E1 :angle Z shape 2000mm

----2---22-

E2 :angle Z shape 2310mm

----------2

Stainless steel strips 833mm

(*)

(for inclined roof)

-/4

Insulated long pipe Ø15mm (for close loop cold water)

1.56m

2.07m

1.85m

2.07m

2.25m

2.10m

2.22m

Insulated short pipe Ø 15mm (for close loop hot water)

0.42m

0.48m

0.38m

0.69m

0.50m

0.40m

0,71m

0.40m

0.58m

SET OF FITTINGS

Compression Elbow Ø15 x 18x2.5 PE-X

11111111111

Compression Elbow Ø18 x 18x2.5 PE-X

11111111111

Compression Elbow Ø18 x Ø15

---

1-11111

Compression Union Ø18 x Ø15

111

-1-----

Tee connector female ½

˝ x Ø15 x Ø15

11111111111

End Cap male ½

11111111111

Copper Ring ½

11111111111

Compression End Cap Ø18

----2---222

Compression Connector Ø18 x Ø18

----2---222

Pressure Safety Valve 10 bar (for open loop)

11111111111

SET OF BOLTS AND NUTS

Bolt Μ10x16 (DIN 933/8.8)

(*)

18/26

Nut Μ10 (DIN 934/8)

(*)

18/26

Bolt Μ6x20 (DIN 933/8.8)

44448444888

Washer Ø6 (DIN 9021)

44448444888

Anchored Bolt Μ8x60 (DIN 571)

44444444444

Washer Ø8 (DIN 9021)

44448444888

Plastic Rawlplugs D10

(*)

4/-

Cross Recess Counter Sunk Head Bolt Μ8x20 (DIN 7969)

----4---444

Nut Μ8 (DIN 934/8)

----4---444

2.5. Thermo convention liquid

The thermal energy collected from the solar irradiation by the collector is transferred to the heat – exchanger of the tank by the thermo convention liquid, which is naturally re circulated by the thermosiphonic principle in the closed loop system. The heat exchanger is heating the domestic consumption water. The solution contains inhibitors for antirust protection and propylenoglycol for antifreeze protection up to -15oC. If lower temperature protection is needed please consult your supplier. The solution is a non toxic, non-flammable chemical liquid; however normal protection measures should be taken during handling. Keep it away from children. Eyes protection: Protective glasses must be used. Skin protection: PVC or rubber gloves must be used.

 In case of contact with eyes, wash eyes with plenty of water for 15 minutes (with open eyelids)  In case of contact with skin simply wash with water and soap.

Physical Properties:

Phase: liquid Color: Light red Odor: nearly odorless Specific gravity at 20oC : 1,03g/cm

Freezing point: -15oC Boiling point: 106oC Packing: Containers of 2ltr. & 4ltr. ready for usage.

2.6. Packaging, Transport and Storage

The solar collectors and the solar tanks are supplied individually packaged, the collectors in carton boxes and the tanks with stretch film and expanding polystyrene. The collector model is indicated on the outside of each box and the tank model is indicated outside of each package. Depending on the number of units ordered, collectors can be supplied palletised in groups of up to 12 units. Collectors should always be during transport and storage placed in horizontal position with the glass facing on top, otherwise there is danger of water entering in the collectors from the ventilation holes at the back of the collector. They should not be stored or transported in piles of more than 12 units. The tanks can be supplied palletised in groups of up to 10 units. Alternatively, under request, the whole system can be palletised in individual pallets. The tanks should be always in vertical position during transportation and should not be stored or transported in piles of more than 2 units. It is recommended to use special safety belts during transportation in order to avoid movements and/or falling. The support system, the hydraulic accessories and the thermo-convention liquid are delivered in one pallet, the exact content and models are indicated on the outside of each pallet.

2.7. Placement of the System

The choice of location, inclination and orientation of the solar system has to be determined at the design stage of the installation. The installation of the solar system in the building should be carried out respecting the instructions of the person in charge of the project, who should have taken into consideration the effect of the orientation, inclination and possible shadows in the calculation of benefits of the solar system.

Particular attention should be paid to the minimum distance maintained between a wall or obstacle in front of a system and it. During the calculation of this distance one should take into consideration the latitude of the place, the inclination of the terrain and the period of use of the facility. Failure to have a more detailed specification by the designer of the facility, the distance should not be less than the indicated below.

3. Warnings

Before starting installation, the installer should read and observe carefully the following warnings in order to avoid danger of death, injury or property damages.

3.1. You may elevate on roof the parts of the solar system, ONLY when an internal staircase of enough width, exists in the building reaching the roof. Otherwise you must use a proper CRANE to elevate the parts. It is not allowed to stand at the edge of any roof (flat or inclined) and pull by ropes any part. DANGER OF DEATH.

3.2 The collectors have a large surface exposed to wind. NEVER install a system with strong winds. Choose a calm day. DANGER OF DEATH or heavy injury.

3.3. If the installation will be on an inclined roof (tiles), there is danger of slipping. Use always SAFETY BELTS (securely fastened) from a higher position of roof. DANGER OF DEATH.

3.4. After completion of the installation make sure that all bolts and nuts are fastened well and the whole system is securely fastened to the roof. The support system can withstand air velocities up to 97,2 km/hr. Make sure that the fastening on roof can withstand as well at least same air velocity. DANGER OF DEATH.

3.5. Frequently some parts of the support systems have sharp edges. Use always gloves when you are handling the support system, in order to avoid danger of injuring the hands. DANGER OF INJURY.

3.6. The collectors when exposed to solar irradiation during installation get very hot; above 120oC in 2-3 minutes. There is danger of burning the hands when touching the copper piping outlets. You must leave the carton package cover ON the glass until completion of the installation, or you must use thermo resistance gloves. DANGER OF INJURY.

3.7. If you are using hands to position the tank on the support system at least 2 people are needed for systems 120-150. It is preferred to use a crane. In this case make sure that the pulling belts are on each side between the piping outlets of the boiler so that it cannot slip.

3.8. In cases where the solar system is large and the hot water consumption is low, the hot water in the solar tank may reach temperatures up to 90oC. In this case there is danger of burns for the user, especially for children. It is strongly recommended to install a thermostatic mixing valve set at 55oC anywhere at the hot supply piping and before the hot outlets of the building (before taps, showers, e.t.c.)

3.9. If the solar system is equipped with the (optional) electric immersion heater, the electrical connection should be done by a fully licensed electrician following the national rules for electric installation. The immersion heater is single phase 230 Volt of 2kW or 3 kW or 4 kW power. There is an “earth point” on the flange of the heater which must be connected to the central “earth” of the building. In any case the support of the solar system must be “earthed” with copper wire of 16 mm2to the earthing grid of the building. This will also serve as lightning protection.

3.10 In a solar system equipped with the optional electric heater, after completion of electrical and plumbing installation test the operation of the electric heater and thermostat, ONLY AFTER FILLING the tank with city water. Otherwise the electric heater will be fused out. (destroyed)

3.11 Make sure that before filling the tank with city water the pressure safety non-return valve has been installed on the cold water inlet with the arrow pointing to the tank. This valve will open and release the pressure when by overheating or other reason it has exceeded 10 bar.

3.12. When handling the thermo-convention liquid make sure that you wear protective glasses for the eyes and gloves for the skin.

3.13. When temporarily leave the collectors on the roof during installation ALWAYS position them with glass facing the sky. Otherwise there is danger that water from rain may enter the collector from the back side through the ventilation holes. If this happens the insulation will be wet and the glass will have humidity on inside surface. Drying will take a very long time.

4. Recommendations

4.1 The cold water piping should withstand pressure of 1000 kPa. The hot water piping should withstand temperature of 95oC at pressure 1000 kPa.

4.2. The cold and hot water piping should be well insulated to eliminate heat losses and prevent as possible freezing. The insulation material should withstand weather conditions like rains, snow and solar irradiation.

4.3. The system should be protected always with antifreeze liquid as supplied by the company to prevent from frost.

4.4. On the hot water supply piping, install a reliable thermostatic mixing valve set at 55oC to prevent higher temperature hot water to reach the consumption points.

4.5. The system may only be installed in locations with lower values of sK(snow load) 0.64m and vm(average wind velocity) 97.2km/h

4.6. The required solar irradiation for which overheating will happen is shown on the table below. The system should not be used in climate zones with higher irradiation values than these.

SWH 200-2-S200

H (MJm-2)

Tsn (°C)

15.20

31.72

25.01

32.13

19.42

28.69

24.16

30.98

26.42

31.48

26.88

31.62

27.42

32.88

27.94

35.07

27.40

33.82

26.59

35.01

27.21

35.75

+ 18 hidden pages

SOLE 125-1-S150, 125-1-S200, 150-1-S200, 150-1-S230, 150-2-S150, 200-1-S200, 200-1-S230, 200-1-S260, 200-2-S200, 300-2-S200, 300-2-S230 Installation & User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual