MAZDON ‘2’ TYPE SYSTEM
Installation Notes for the
Thermomax Mazdon System
Revision 6
THERMOMAX DIVISION
THERMO TECHNOLOGIES
E-mail: info@thermotechs.com
Internet Site http://www.thermotechs.com
Phone (410) 997-0778 o fax (410) 997-0779
January 2004
5560 Sterrett Place, Suite 115
Columbia, MD 21044
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MAZDON ‘2’ TYPE SYSTEM
CAUTIONS
We advise you to read through this guide for technical details and
installation data before commencing with the installation.
1. Gloves and eye protection must be used when handling glass tubes.
2. Avoid scratching or sudden shock to tubes.
3. Unpack and install tubes only after the manifold unit has been installed and all the
pipe work has been completed.
4. The Chloride content of the water pas sing through the manifold should not exceed
40ppm.
5. In hot water applications a heat exchanger should be used between the collector and
the hot water storage tank to ensure a long and trouble free service life.
6. When heating a swimming pool or spa a heat exc hanger must be used between the
pool and the collector.
7. Thermomax manifold systems are designed to operate at a maximum pressure of
5bar (75psi) it is strongly recommended to use a relief valve (set at 4.5bar).
8. To prevent corrosion and scaling we would recommend using a corrosion inhibitor
in the system.
9. The circulating pump should under no circumstances be switched off during a sunny
day. If switched off, there will be a high temperature and as a result, high pressure
in the system. When not in use for extended periods, the circulating pump must be
left switched on and a by-pass should divert the heat from the storage tank.
10. The Thermomax tubes should under no circumstances be exposed to the sun for
extended periods (maximum one day) if the system has not been filled.
11. ALL LOCAL AUTHOURITIES REGULATIONS AND REVELANT
STANDARDS SHOULD BE FOLLOWED.
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MAZDON ‘2’ TYPE SYSTEM
M SYSTEM INSTALLATION GUIDE
1. Select a suitable position for the collector. It should face due south. Recommended
angle of tilt is the same as the geographical latitude. Distances between the perforated
bands are given in Table 1.
2. Remove tiles as per FIG.1(M) (2).
3. Secure the LOWER band (Pt. No. B0290) to rafter using coach screws (Pt. No. A0168
/ A0170). [FIG.1(M) (3)]
System Type
4. Replace tiles. [FIG.1(M) (4)] .
MAZ 20 - 2
MAZ 30 - 2
A 35” – 48” 48” – 55”
Table 1: Distance between the side rails
B
Measurement
55”
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MAZDON ‘2’ TYPE SYSTEM
eps 2 to 7) should be repeated for the opposite side of the
5. Locate and secure the UPPER band to the top end of the side rail (Pt. No. B0282)
using the lower hole. Use the Nylon washer (Pt. No. A2158) to hold the bolt of the
lowest hole in place for later use. Remove upper tiles.
6. Locate and secure end of the side rail (Pt. No. B0282) to the LOWER band using the
middle hole in the side rail. Use the Nylon washer (Pt. No. A2158) to hold the bolt in
place for later use.
7. Secure UPPER band to rafter. [FIG.2(M) (7)]
8. Locate and secure support rails (Pt. No. B0177 (20) / B0178 (30)) to the side rails
[FIG.2(M) (6)] and [FIG.2(M) (8)]
Note: This process (st
frame.
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MAZDON ‘2’ TYPE SYSTEM
9. Locate manifold (Pt. No. B0832 (20) / B0833 (30)) in tab at top of side rails and bolt
as shown. The distance from the side rails to the ends of the manifold should be
equal. [FIG.3(M) (9)]
10. Ensure that both support rails and manifold are in line (centre line of rubber support
pads with centre line of holes in manifold) [FIG.3(M) (10)]. Tighten all bolts.
11. Locate manifold fittings to manifold inlet and outlet. Note that the air vent should be
installed vertically. Check all plumbing and pipe work between collector and hot
water storage tank. Fill the system, switch the circulating pump on and vent the
installation.
12. Remove the self -tapping screws [FIG.3(M) (11)] and remove the manifold lid.
[FIG.3(M) (12)]
13. Switch on circulating pump .
14. Make sure there is no leak in piping system.
15. Check system pressure and flow rate.
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MAZDON ‘2’ TYPE SYSTEM
(A) With the supplied Stainless steel tube (Key Lever) open the pocket in the
manifold chamber "B" by turning the Key Level "C" through 90o. Unpack the
first tube; insert condenser "A" gently through grommet in front of the manifold.
Resting the tube body on the rubber pads of the top and bottom support rails,
slide the condenser "A" into the open pocket. ENSURE BLACK SURFACE
OF ABSORBER FACES UPPERMOST AND TOWARDS THE SOUTH.
(B) Make sure the tube condenser is exactly between the two copper blocks and sits
evenly through hole in manifold chamber.
(C) Repeat stages (A) and (B) for all tubes. Secure tubes by turning the Key Lever to
original position.
16. Replace manifold's lid and secure with self -tapping screws.
17. Make the final inspection on each tube.
18. Set clips over tubes to both top and bottom support rails.
19. Ground manifold installation as per local government regulations and switch pump
control unit to automatic
The manifold flows and return connections are 3/4" copper pipes. Two compression
couplings are included in each manifold system. These couplings are to be used. Manifold
inlet and outlet should not be soldered.
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MAZDON ‘2’ TYPE SYSTEM
System Operation and Plumbing Details
The interconnections of the manifolds, pumps, valves, and pipes shall meet the recommendations required
by manufacturer's installation manual books. Great care must be taken to ensure long-term durability and
leak tightness of the interconnection and piping. The typical closed loop interconnection for the
Thermomax solar collectors is shown in the following diagram:
1. Collector
2. Collector Sensor
3. Manual Air Valve
4. Hot Water to Existing Tank
5. Tempering Valve
6. Solenoid Valve (Optional)
7. Check Valve (Optional)
8. Hose Bibs for Filling and Flushing
9. Expansion Tank
10. Air Purge and Air Vent
11. Circulating Pump
12. Pressure Relief Valve
13. Pressure Gauge
14. Collector Supply
15. Heat Exchange Coil
16. Solar Hot Water Tank
17. Immersion Heater
18. Solar Controller
a) The Control System will switch on the pump when the temperature at the collector sensor TC is
higher than the return temperature TR by at least the pre-selected amount.
b) The pump circulates heat transfer liquid around the loop.
c) Heat from the collector is transferred to the storage tank.
d) Solenoid valve (6) discharges hot water if the tank temperature is reached at T
(vacation or
MAX
low hot water usage system protection).
When a pre-set tank temperature is reached at T
, the solar controller system switches off the pump.
MAX
The check valve (non-return valve) prevents heat from the tank rising towards the collector should the
tank be warmer (e.g. at night).
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