Atmos EasySolar. Installation Instructions for. In-roof and flat roof installation with flat plate collectors

Transcription

1 Atmos EasySolar Installation Instructions for Atmos EasySolar In-roof and flat roof installation with flat plate collectors Atmos Heating Systems West March Daventry Northants, NN11 4SA Tel: Fax: internet: Issue

2 Atmos EasySolar Installation Instructions In-Roof and Flat Roof Table of Contents 1 Introduction System Components Siting & requirements Installation Safety & insulation Storage tank Domestic water connections Hard water Tank in unheated space Protection of plastic pipe and pipe insulation Vented hot water system Connection to combi boiler Connection to unvented hot water cylinder Collectors integrated in sloping roof Collectors on flat roof Filling the tank Flushing the pump Connecting the collector circuit Connecting the optional booster pump Maintenance Technical specifications Commissioning Checklists The Benchmark Scheme Benchmark places responsibilities on both manufacturers and installers. The purpose is to ensure that customers are provided with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with the manufacturer s instructions by competent persons and that it meets the requirements of the appropriate Building Regulations. The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the customer for future reference. Installers are required to carry out installation, commissioning and servicing work in accordance with the Benchmark Code of Practice which is available from the Heating and Hotwater Industry Council who manage and promote the Scheme. Visit for more information. 2

3 Atmos Heating Systems 1 Introduction Thank you for purchasing an Atmos EasySolar hot water system. This will provides you with free hot water for many years to come, provided that it is correctly installed and maintained. Most of us dislike reading installation manuals, and prefer to fit it and read later, so we have summarised some of the 7 most important installation requirements below, BUT, please do not use this as an excuse not to read the manual properly. Remember that the warranty will be invalidated if the installation is not correct. 1. LOCATION; Ideally the solar collectors should be facing directly south, and mounted on a slope of between 30 and 40 degrees to the horizontal. Any deviation from this will result in less energy being collected, although between south east and south west it will at most result in less than 10% loss of performance. 2. SHADING. If there are trees or buildings shading the location of the solar collectors, this will also reduce the performance. Ideally there should be no shading. 3. DO NOT fit the collectors on a slope of less than 15 degrees. If you do the system will not only lose performance, but the drain back action will be impaired. That means the collectors will freeze and break in the cold winter. In the summer it will cause boiling, which is dangerous. 4. The storage tank MUST be located below the base of the flat plate collectors, or below the header of the evacuated tube collectors. 5. The storage tank is fitted with a pump which has a 3m, 4m or 6m head. The vertical distance between the base of the tank and the top of the solar collector MUST NOT be greater than the pump head. If it is, the system will not work. A booster pump is available from Atmos to give additional pump head if you make a mistake, but they are not cheap. 6. The pipes from the collector to the storage tank MUST have a continuous slope down towards the tank, otherwise the drain back will not work. They must be properly fixed so that they cannot droop or sag, or be pulled down by someone. 7. PLEASE make sure you use the insulation provided on the red and blue pipes, and make sure it is neatly and correctly fitted. Up to 20% of the heat collected by the solar collector can be lost if the insulation is not fitted (or badly fitted). 3

4 Atmos EasySolar Installation Instructions In-Roof and Flat Roof 2 System Components Boxes and parts The system is packaged in several boxes. Check that the boxes are not damaged and that you have received the correct boxes for the system you have ordered. See table below. Inform your supplier if you have received incorrect or damaged boxes. Numbers of boxes per system Storage Tank 100L 3M Article Number Storage Tank 100L 4M Article Number Storage Tank 100L 6M Article Number Collector Blackine Heat H Article Number Collector EasySolar P Article Number Assembly Kit EasySolar 1.0H Article Number Assembly Kit EasySolar 2.0H Article Number Assembly Kit EasySolar 3.0H Article Number Assembly Kit EasySolar 1.0P Article Number Assembly Kit EasySolar 2.0P Article Number Assembly Kit EasySolar 3.0P Article Number EasySolar 1.0H 3M Article No EasySolar 2.0H 3M Article No EasySolar 3.0H 3M Article No EasySolar 1.0P 3M Article No EasySolar 2.0P 3M Article No EasySolar 3.0P 3M Article No EasySolar 1.0H 4M Article No EasySolar 2.0H 4M Article No EasySolar 3.0H 4M Article No EasySolar 1.0P 4M Article No EasySolar 2.0P 4M Article No EasySolar 3.0P 4M Article No EasySolar 1.0H 6M Article No EasySolar 2.0H 6M Article No EasySolar 3.0H 6M Article No EasySolar 1.0P 6M Article No EasySolar 2.0P 6M Article No EasySolar 3.0P 6M Article No

5 Atmos Heating Systems Components in assembly kits picture 1.0H 2.0H 3.0H 1.0P 2.0P 3.0P Installation and User Instructions Adaptor 12 Volt Stainless steel screw ring and cap Wakaflex Side fixing strip aluminium Connecting strip black

6 Atmos EasySolar Installation Instructions In-Roof and Flat Roof afbeelding 1.0H 2.0H 3.0H 1.0P 2.0P 3.0P Roll sealing tape Support strip Wakaflex L=54cm Support strip Wakaflex L=88cm Collector return pipe blue L=650cm Collector flow pipe red (insulation supplied loose) L=400cm Insulated flexible connecting pipes for domestic water L=90 cm incl. rings Flow restrictor Straight connector 10 mm

7 Atmos Heating Systems picture 1.0H 2.0H 3.0H 1.0P 2.0P 3.0P T-connector Cross connector Pipe gland Stainless steel selflocking nut M Stainless steel bolt M

8 Atmos EasySolar Installation Instructions In-Roof and Flat Roof picture 1.0H 2.0H 3.0H 1.0P 2.0P 3.0P Filling plug Overflow plug Overflow connector Yellow filling hose with connector ¾

9 Atmos Heating Systems 3 Siting & requirements When choosing the location for the storage tank the following needs to be considered: The vertical distance between the base of the tank and the top of the collectors should not exceed the combined capacity of the storage tank pump and any booster pump that may be added to provide extra pump height. The distance between the storage tank and the appliance (combi boiler or hot water cylinder) to which pre-heated water is supplied, needs to be kept as short as practical. The storage tank needs to be sited on a firm horizontal surface that is able to take the weight when the tank is filled with water (116kg). Atmos supply a brackets and shelf set for optional wall mounting of the storage tank. The following are needed in the vicinity of the storage tank: o 240V electrical socket within 1.5 meter distance o Water tap with ¾ bsp hose union connection within 2.5 meter distance It is preferable to locate the storage tank and the connecting domestic water pipes in a frost free room. If the tank is installed in an unheated space particular care must be taken to protect the domestic water pipes against freezing. See paragraph 4.5. The following tools and materials are needed to install the system: Sloping roof Roof tile fixings Spanner 24 mm Spanner 14 mm Tape measure HSS drill bit 5 mm Sharp knife Hole saw 30 mm Battery drill with pozi bit Flat roof Ballast (concrete blocks or slabs) Spanners 8, 14 en 24 mm Tape measure Hole saw or masonry drill 50 mm for flat roof Sharp knife Rubber mat or tiles for protection of the roof Roof sealant for the pipe gland 9

10 Atmos EasySolar Installation Instructions In-Roof and Flat Roof 4 Installation 4.1 Safety & insulation Before you start work consider your own safety and that of others. The EasySolar hot water system has electrical parts. Apart from the adaptor which plugs into the 240V socket, these parts are all low voltage (12V) and therefore perfectly safe. However it is advisable to take care not to damage any electrical insulation and to avoid electrical parts becoming wet. The heat exchanger and the flexible connecting pipes for domestic water are subject to mains water pressure and can become hot. For this reason the flexible connecting pipes for domestic water need to be insulated. Insulation for these pipes is included in the assembly kit. The insulation must extend over the connections to the tank. Secure the insulation with tape. Ensure that the tank and connecting pipes have cooled down before any maintenance work is undertaken. The tank and connecting pipes can be cooled down by drawing off hot water. The pipes connecting the storage tank and the collectors can also become hot. The red flow pipe needs to be insulated along its full length. Insulation for this pipe is included in the assembly kit. Ensure that the pipes have cooled down before any maintenance work is undertaken. Assemble all components according to the installation instructions and avoid components getting damaged during installation or subsequent use. Put in place sufficient safety measures when working on the roof. Use scaffolding if necessary. 10

11 Atmos Heating Systems 4.2 Storage tank Connections Filling Collector cold Collector hot Collector sensor Domestic water hot Domestic water cold Domestic water connections The flexible connecting pipes provided in the assembly kit are for the domestic water hot and cold connections. Use the washers for sealing the connection between the flexible pipes and the storage tank. The blue connecting point is for incoming cold water and the red connecting point is the outlet for pre-heated domestic water. The incoming mains water pressure should be at least 1 bar and no more than 8 bar. If the mains water pressure is likely to exceed 8 bar, a pressure reducing valve should be fitted before connection to the storage tank. 4.4 Hard water In areas of hard water (hardness in excess of 200ppm) an approved water conditioner device must be fitted in accordance with the Building Regulations. Atmos can supply a suitable conditioner for fitting to the cold feed to the storage tank. In areas of hard water, failure to fit a suitable conditioner will invalidate the warranty. 4.5 Tank in unheated space If the tank is installed in an unheated space particular care must be taken to protect the domestic water pipes against freezing. Insulation for the domestic water flexible connecting pipes is supplied with the assembly kit. It may be necessary to apply additional insulation to these pipes and to other domestic water pipes particularly if the unheated space is subject to draught. 11

12 Atmos EasySolar Installation Instructions In-Roof and Flat Roof 4.6 Protection of plastic pipe and pipe insulation The red and blue collector pipes are made of plastic. It can occur that plastic pipes or pipe insulation material is damaged by rodents such as mice, rats or squirrels. Take appropriate precautions to protect the pipes and insulation material from this kind of attack if considered necessary. 4.7 Vented hot water system The Atmos EasySolar system is not suitable for connection to a low pressure vented hot water system. The reason for this is that the pressure loss through the storage tank is too great. 4.8 Connection to combi boiler The Atmos EasySolar hot water system can provide pre-heated water to a combi boiler. The combi boiler needs to be of the type that can accept pre-heated water. It is important to check this with the boiler manufacturer. The Atmos InterCombi gas condensing boiler is able to accept pre-heated water up to a temperature of 85 C. The diagram on the next page shows how the Atmos EasySolar system is connected to a combi boiler. 12

13 Atmos Heating Systems Connection to combi boiler EXPLANATORY NOTES: 1) TMV1 is a non-adjustable thermostatic mixer valve. Connect as shown and ignore the arrows on the body of the valve. This is a diverter valve and works in reverse. The operation is that if the water from the solar storage tank is greater than 50 deg C, it goes straight to the taps. If it is lower it is diverted through the boiler and is heated up. 2) TMV2 is an adjustable thermostatic mixer valve with a black adjuster head. This should be fitted as shown, and the arrows on the body are correct. K means Cold (cold inlet), W means Warm (hot inlet), and M means Mixed (or blended) out to the taps. Adjust hot water to desired tap outlet temperature (clockwise gets colder, and anti-clockwise gets warmer). CONNECTIONS: 1) Heated water from solar store connects into M on TMV1 2) W on TMV1 connects into cold inlet on combi boiler 3) K on TMV1 connects to W on TMV2 with T-off from domestic hot water outlet on combi boiler. 4) Incoming cold water connects into K on TMV2 5) M on TMV2 connects to domestic hot water taps 13

14 Atmos EasySolar Installation Instructions In-Roof and Flat Roof 4.9 Connection to unvented hot water cylinder The Atmos EasySolar hot water system can also provide pre-heated water to a hot water cylinder. The diagram below shows how the EasySolar system is connected to an unvented hot water cylinder. EXPLANATORY NOTES: 1. The pressure reducing valve and the 6 bar pressure relief valve must be fitted before the solar storage tank and before the T-off to the cold connection on the thermostatic mixer valve. 2. No valve must be fitted between the unvented tank and the solar storage tank or between the solar storage tank and the pressure relief valve. 14

15 Atmos Heating Systems 4.10 Collectors integrated in sloping roof Connections: A B C D E F A = Bracket for Wakaflex B = Collector flow (red) C = Collector return (blue) D = Collector sensor wiring E = Fixing bracket F = Rain water chute 15

16 Atmos EasySolar Installation Instructions In-Roof and Flat Roof For the 2.0H system (two collectors) and the 3.0H system (three collectors) it is necessary to cut separate pieces of the blue pipe for connecting to the collectors. Use a sharp knife to cut the pipe. For the 2.0H system cut two pieces 60cm long. For the 3.0H system cut one piece 20cm long for the middle collector and two pieces 105cm long for the two outside collectors. Before connecting the blue pipe to each collector insert the flow restrictor to a depth of at least 3cm. Insert the blue pipe into the fitting on the collector and tighten the nut with a spanner or with pliers. See figure below. Remove the roof tiles where the collectors are to be located: 16

17 Atmos Heating Systems Drive the screws (supplied with the assembly kit) into the tile battens. Leave a few millimeters between the screw head and the batten. Use a spirit level to ensure that the screws are at the same height. The figure below is of a two collector installation: Place the collectors side by side on the screws: 17

18 Atmos EasySolar Installation Instructions In-Roof and Flat Roof Use the aluminum side fixing strips and the black connecting strip to fix the collectors in position. The black connecting strip is for fixing between collectors and the aluminum side fixing strips are for fixing the outside edge of the collectors. Drill 5mm holes through the strips at the correct locations for screwing into the battens. Don t screw through the strips below the bend at the bottom but ensure a good fit with no gap. Take care not to drill or screw through the plastic collector flashing. Use the plastic rings and caps supplied for the screw heads on the black connecting strip. 18

19 Atmos Heating Systems The red and blue collector pipes can now be connected to the short pipes already connected to the collectors. Use the T-connectors for a two collector installation and the cross connectors for a three collector installation. The sensor cable from one of the collectors together with the flow and return pipes should run underneath the roof tiles and be taken down to the storage tank. The flow and return pipes must at all points slope down towards the storage tank. This is essential in order for the water in the collectors and in the pipes to flow back to the storage tank when the pump is not running. Ensure that there is no tension on the flow and return pipes or leakage may occur. The red flow pipe should be insulated along the whole of its length, using the pipe insulation provided. The sensor cable can be extended if necessary using a two wire cable. 19

20 Atmos EasySolar Installation Instructions In-Roof and Flat Roof How not to install the collector flow and return pipes: The correct way to install the collector flow and return pipes: Important: The flow and return pipes must at all points slope down towards the storage tank. 20

21 Atmos Heating Systems Stick the sealing tape on top of the aluminium side fixing strips: Allow the sealing tape to extend about 5cm beyond the bottom end of each aluminium side fixing strip. Replace the tiles at the sides and at the top of the collector. If required use tile fixings or brackets to secure the tiles in position. It may also be necessary to cut the tiles to size. 21

22 Atmos EasySolar Installation Instructions In-Roof and Flat Roof The sealing tape is designed to swell up. When outside temperatures are low it may take several days before the joint underneath the tiles is fully sealed. Stick the support strips to the rear side of the Wakaflex. Ensure space is left between the strips as shown below: Fix the Wakaflex to the bottom of the collectors by means of the brackets (two brackets on each collector). The sealing tape at the bottom of the side fixing strips must extend over the top of the Wakaflex. 22

23 Atmos Heating Systems Replace the roof tiles at the bottom and mould and stick the Wakaflex onto these tiles. Roof with flat tiles or slates. In the case of a roof with flat tiles or slates it is possible to achieve a neat installation by making use of timber furrings which are available from Atmos. The furrings are fixed to the tile battens and butt up against the aluminium side fixing strip. The furrings enable the slates or tiles to pass over the aluminium side fixing strips. See figure below. 23

24 Atmos EasySolar Installation Instructions In-Roof and Flat Roof 4.11 Collectors on flat roof Connections: A = Collector flow red (hot) B = Collector return blue (cold) C = Collector sensor wiring D = Fixing bracket 24

25 Atmos Heating Systems Assemble the frame using the bolts and nuts supplied: Fix the collector to the frame using the bolts and nuts supplied: 25

26 Atmos EasySolar Installation Instructions In-Roof and Flat Roof Position the frame on the roof. If more than one collector is used position the frames side by side and closely against each other. Place the frame(s) on rubber mats or rubber tiles in order to protect the roof and avoid leaks. Put ballast on the four corners as shown below: The table on this page shows the minimum required ballast weight in kg needed to secure each collector. Area I is an area of the country prone to high winds. Area II is an area with medium high winds. Area III has normal or moderate winds. Minimum required ballast weight in kg. Built up area Open countryside Height above ground [m] Area I Area II Area III Area I Area II Area III

27 Atmos Heating Systems For the 2.0P system (two collectors) and the 3.0P system (three collectors) it is necessary to cut separate pieces of the blue pipe for connecting to the collectors. Use a sharp knife to cut the pipe. For the 2.0P system cut two pieces 60cm long. For the 3.0P system cut one piece 20cm long for the middle collector and two pieces 105cm long for the two outside collectors. Before connecting the blue pipe to each collector insert the flow restrictor to a depth of at least 3cm. Insert the blue return pipe into the fitting on the collector and tighten the nut with a spanner or with pliers. See figure below. Drill a hole with a diameter of 6cm in the roof. Take the blue and the red pipe through this hole together with the sensor cable from one of the collectors using the pipe gland provided. See figure below. The flow and return pipes must at all points slope down towards the storage tank. This is essential in order for the water in the collectors and in the pipes to flow back to the storage tank when the pump is not running. Ensure that there is no tension on the flow and return pipes or leakage may occur. Provide support for the pipes if needed. The red flow pipe should be insulated along the whole of its length, using the pipe insulation provided. The blue return pipe should be insulated only above roof level. The sensor cable can be extended if necessary using a two wire cable. The pipe gland must be stuck to the roof surface using a suitable sealant, making the joint water tight. Important: The flow and return pipes must at all points slope down towards the storage tank. 27

28 Atmos EasySolar Installation Instructions In-Roof and Flat Roof 4.12 Filling the tank The procedure for filling the storage tank with water is as follows: Remove the plug from the overflow outlet and insert the overflow connector. Put a tray or bucket underneath to catch any water coming out. Use the yellow hose provided for filling the tank. Insert this into the filling connection point on the tank. Fill the tank slowly with clean water. Make sure the yellow hose is held firmly in position whilst water is flowing into the tank. Stop filling as soon as water flows from the overflow outlet. Allow the surplus water to flow out before replacing the overflow plug and inserting the filling plug. 28

29 Atmos Heating Systems 4.13 Flushing the pump It is necessary to flush the pump in order to remove any air. The procedure for this is as follows: Connect the two connection points on the tank for the collector pipes with a short length of pipe (can be either red or blue). Connect the two terminals on the sensor cable connection point using a short piece of wire. Supply power to the storage tank through the 12V adaptor. The pump will start running. Leave it running for one minute before removing the short piece of wire and the short length of pipe Connecting the collector circuit Connect the collector flow and return pipes to the connectors on the tank. To avoid leaks ensure that the pipe ends have been cut square. Before connecting the blue pipe to the tank, insert the flow restrictor to a depth of at least 3cm. Connect the sensor cable from one of the collectors to the sensor cable connecting point on the tank. Fit the pipe insulation provided for this purpose to the red collector flow pipe along its full length. 29

30 Atmos EasySolar Installation Instructions In-Roof and Flat Roof 4.15 Connecting the optional booster pump A booster pump is a pressure activated pump which serves the purpose of increasing the total pump height of the system. It must be fitted to the wall with the pipe connections at the top. The booster pump must not be above the overflow level of the tank and not lower than 500mm below this level. It is connected to the blue collector return pipe and it has its own power supply through a 12V adaptor. Flow restrictor Note! The flow restrictor is not fitted at the connection to the tank but at the connection to the booster pump. 30

31 Atmos Heating Systems 5 Maintenance Storage tank Annually check the sensor wiring and top up the tank. See 4.12 Collectors Annually check the collectors. Remove any debris and check that the collectors are still firmly fixed. In the case of the roof integrated collectors check on the flashings and check that no water can leak through the roof. Pipes Do a yearly check on the pipes to ensure that the pipe insulation is still in place and properly secured and that the collector pipes are correctly sloping down towards the storage tank at all points. Faults The dial on the front of the tank gives an indication of the amount of heat stored in the tank. If the storage tank is not collecting heat even though the sun shines this indicates a fault. To check for any malfunction follow the following procedure. This will only work when the sun is shining. Ensure the storage tank is cold by drawing off hot water. This may take 10 minutes if the storage tank is very warm to start with. 1. Is there 240V on the socket? Yes=>2, No=>13 2. Is there 12V feed to the storage tank? Yes=>3. No=>4 3. Are the wires from the collector thermostat and the 12V feed to the tank connected correctly? Yes=>6. No=>5 4. The 12V adaptor is faulty. Atmos can supply a replacement. 5. Ensure the wires are connected correctly. The wires from the collector thermostat are interchangeable. Does the pump start up within 10 minutes? Yes=>6, No=>7 6. Does the red pipe become warm after a few minutes? No=>8 7. Disconnect the wires to the collector thermostat from the connector block on the tank and then connect the two terminals on this block with a short piece of wire. Does the pump start up? Yes=>9, No=>10 8. Unplug the 12V adaptor from the socket. Top up the tank with water. Plug the 12V adaptor back into the socket. Does warm water begin to flow into the tank after a few minutes? Yes=>12, No=>11 9. The collector thermostat is faulty or the wiring to the collector thermostat is interrupted. 10. There is a fault with the storage tank pump or the wiring to the pump is interrupted. 11. Are the red pipe and the blue pipe to the collectors sloping back towards the storage tank at all points? Yes=>14. No=> Check the system for leakage. 13. Ensure there is 240V on the socket. 14. Check the flow restrictors for blockages. There is one flow restrictor for each collector and one for the storage tank. 15. Ensure that the red pipe and the blue pipe to the collectors are sloping back towards the storage tank at all points. Flush the pump on the storage tank as described in

32 Atmos EasySolar Installation Instructions In-Roof and Flat Roof 6 Technical specifications Collector Flat Roof General Capacity 830 W Aperture area 1,2 m2 Absorber area 1,1 m2 Maximum pitch 80 Minimum pitch 20 Weight 18 kg Minimum temperature -20 C Dimensions Absorber Content 1,5L Flow 15 l/h Material copper Connections 10 mm dismountable push-fit Cover Glass low-iron Frame Aluminium black 32

33 Atmos Heating Systems Collector Integrated In Roof General Capacity 830 W Aperture area 1,2 m2 Absorber area 1,1 m2 Maximum pitch 80 Minimum pitch 20 Weight 18 kg Minimum temperature -20 C Dimensions Absorber Content 1,5L Flow 15 l/h Material copper Connections 10mm dismountable push-fit Cover Glass low-iron Frame Aluminium black 33

34 Atmos EasySolar Installation Instructions In-Roof and Flat Roof Storage Tank General Storage volume Weight empty Weight filled 100L 16 kg 116 kg Dimensions Domestic water sided Content 1,5 L Maximum pressure 800 kpa Maximum temperature 80 C Connections ½ BU Pressure drop: Drukval [bar] 0,5 0,4 0,3 0,2 0, Debiet [l/min] Collector sided Content 89,5L Medium clean drinking water Maximum pressure no pressure Maximum temperature 80 C Connections 10mm dismountable push-fit Electrical Power supply 12 V/DC 34

35 Atmos Heating Systems 7 Commissioning Checklists 35

36 Atmos EasySolar Installation Instructions In-Roof and Flat Roof 36