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1

TABLE OF CONTENTS

1.

GENERAL INFORMATION ................ 2

1.1 G

UARANTEE

.......................................... 2

1.2 S

YSTEM

 C

ONTENTS

................................ 2

1.3 S

YSTEM

 I

NSTRUCTION

 B

OOKS

................... 2

1.4 SOLAR

COMFORT

.................................. 3

1.5 L

IFESTYLE

............................................. 3

1.6 H

OW THE

 S

YSTEM

 W

ORKS

....................... 3

2.

SAFETY ............................................. 6

3.

TECHNICAL DATA ............................. 7

3.1 T

EMPERATURE

/P

RESSURE

........................ 7

3.2 C

OMPONENT

 L

IST

................................... 8

3.3 P

UMP

 G

ROUP

 D

IMENSIONS

...................... 9

3.4 E

XPANSION

 V

ESSEL

 D

IMENSIONS

............... 9

4.

REGULATIONS & STANDARDS...... 10

4.1 W

ATER

 R

EGULATIONS

........................... 10

4.2 B

UILDING

 R

EGULATIONS

......................... 10

4.3 G

ENERAL

 G

UIDANCE

............................. 10

4.4 B

RITISH

 & E

UROPEAN

 S

TANDARDS

.......... 11

4.5 UK R

EGULATIONS

 (W

ATER

 H

EATING

) ...... 11

4.6 UK R

EGULATIONS

 (C

ONSTRUCTION

) ........ 11

4.7 EU D

IRECTIVES

................................... 12

4.8 O

THER

 P

UBLICATIONS

........................... 12

4.9 E

LECTRICAL

 C

ONNECTION

...................... 12

4.10 T

HERMAL

 I

NSULATION

............................ 12

5.

INSTALLATION ................................ 13

5.1 F

ITTING

 F

LOW

 L

IMITER

.......................... 13

5.2 P

OSITIONING

 P

UMP

 G

ROUP

.................... 13

5.3 C

ONSIDERATIONS FOR

 P

OSITIONING

 P

UMP

G

ROUP

............................................... 14

5.4 P

IPEWORK AND

 F

ITTINGS

....................... 14

5.5 I

NSULATION

.......................................... 14

5.6 S

IZING OF

 P

IPES

.................................. 15

5.7 P

IPEWORK

........................................... 15

5.8 E

LECTRICAL

 C

ONNECTIONS

.................... 15

5.9 T

WO

 C

OLLECTOR

 S

CHEMATIC

................. 17

5.10 T

HREE

 C

OLLECTOR

 S

CHEMATIC

.............. 17

5.11 W

ALL

 M

OUNTING

 M

ODULES

................... 18

5.12 C

ONNECTING

 P

IPEWORK

........................ 19

5.13 P

IPE

 R

EDUCERS

.................................. 20

5.14 E

XPANSION

 V

ESSEL

.............................. 20

5.15 P

RESSURE

 R

ELIEF

 V

ALVE

...................... 21

5.16 F

ILLING

 P

OINT

..................................... 22

5.17 F

LOW

 R

EGULATOR

................................ 22

6.

COMMISSIONING SYSTEM ........... 23

6.1 P

RE

-

FILL

 C

HECK

.................................. 23

6.2 F

LUSHING AND

 F

ILLING THE

 S

YSTEM USING

G

LYCOL

.............................................. 24

6.3 F

LUSHING THE

 S

YSTEM USING

 W

ATER

...... 26

6.4 F

ILLING AND

 T

OPPING UP THE

 S

YSTEM WITH

G

LYCOL

.............................................. 28

6.5 S

YSTEM

 P

RESSURE

.............................. 30

6.6 C

OMMISSIONING

 S

HEET

......................... 31

7.

MAINTENANCE SCHEDULE .......... 32

this will be page 1

Summary of Contents for SOLARcomfort

Page 1: ...SOLARcomfort Solar Hot Water Systems Pump Group Instructions for Installation and Servicing LEAVE THESE INSTRUCTIONS WITH THE END USER Country of Destination GB IE...

Page 2: ...4 10 THERMAL INSULATION 12 5 INSTALLATION 13 5 1 FITTING FLOW LIMITER 13 5 2 POSITIONING PUMP GROUP 13 5 3 CONSIDERATIONS FOR POSITIONING PUMP GROUP 14 5 4 PIPEWORK AND FITTINGS 14 5 5 INSULATION 14 5...

Page 3: ...e complete SOLARcomfort solar water heating system is supplied in the following consignments 1 Ref 800201 Collector 1 per box 2 Ref 3107024 5 Roof Fittings Kit 1 cardboard tube 3 3820011 2 System Comp...

Page 4: ...cylinder with the temperature of the solar collectors Whenever the solar collectors are hotter than the water within the cylinder the controller switches on the system s circulating pump The temperatu...

Page 5: ...level fill point Ariston ITSI 210 300 twin coil cylinder Upper coil heated by boiler or other heat source Lower coil heated by solar energy AST 100 Controller Air vent PR Valve Solar system drain poin...

Page 6: ...rn to Solar Collectors 8 Return Temperature Gauge 9 Return Shut Off Valve c w non return valve blue Knob 10 Circulating Pump 11 System Fill and Drain Point 12 Fill and Drain Shut Off Valve 13 Flow Lim...

Page 7: ...f scalding Never loosen fittings or open vents when the system is hot WARNING TYFOCOR LS Heat Transfer Fluid Although non toxic it should not be swallowed Refer to label on its container for storage a...

Page 8: ...type 15 40 Maximum operating pressure 0 6MPa Electrical Cable 1 0mm 3 core heat resistant flex 3093Y to 85 C Cover Moulded polystyrene AIR SEPARATOR MODULE Pipe connection 22mm Reducers supplied 15mm...

Page 9: ...all the components required to fit the pump group Item Description Qty 1 Pump Group 1 2 Flow Limiter Components see 5 1 1 set 3 Wall Mounting Bracket 1 4 Screw 1 5 Wall Plug 1 6 Expansion Vessel 25l s...

Page 10: ...GROUP DIMENSIONS FIG 3 4A EXPANSION VESSEL DIMENSIONS 25 Litre standard 35 Litre optional code 12002737 3 3 PUMP GROUP DIMENSIONS 3 4 EXPANSION VESSEL DIMENSIONS Maximum pressure 10 bar Pre charge pr...

Page 11: ...o provide a fail safe means of shutting off the solar input to the heat exchanger if the cylinder temperature should rise above the set temperature of the cylinder s energy cut out See Note 1 As with...

Page 12: ...05 www communities gov uk Control of Substances Hazardous to Health Regulations COSHH 1994 www hse gov uk Further details available from www hse gov uk Health Safety At Work Act HSW 1974 Work at Heigh...

Page 13: ...linders IP13 93 Heating systems in buildings design for water based heating systems PrEN 12828 Building log books GPG 348 Solar heating CIBSE DBSP WGG Sun in Action II ESTIF Sun in Action II Minimisin...

Page 14: ...100 Controller Cylinder PRV discharge vessel Fill point Expansion Vessel Pump Group S3 S2 A flow limiter set is supplied separately this must be fitted to the pump group on the suction side of the pu...

Page 15: ...e hose Pipe joints and connections with other system components should also be able to withstand the working temperatures and pressures Thought should be given to preventing corrosion due to dissimila...

Page 16: ...st point i e near the flow connection of the collectors 5 Adequate support and fixing should be provided for all pipework to ensure that inclines are maintained and sagging is prevented 6 Owing to the...

Page 17: ...n Return Valve 10 Pressure Relief Valve PRV 11 PRV Discharge Vessel 12 Return Temperature Gauge 13 Air Separator with Manual Air Vent 14 Expansion Vessel 15 Solar AST 100 Controller 16 Upper Cylinder...

Page 18: ...9 Non Return Valve 10 Pressure Relief Valve PRV 11 PRV Discharge Vessel 12 Return Temperature Gauge 13 Air Separator Manual Air Vent 14 Expansion Vessel 15 Solar AST 100 Controller 16 Upper Cylinder...

Page 19: ...into consideration the following i Access for fill and drain ii Position of the expansion vessel iii Position of the PR Valve iv Provision has to be made for the discharge of the PR Valve to be collec...

Page 20: ...WORK A B C D A B C D PR Valve PR Valve relief plumbed to low level 15mm PRV discharge vessel Expansion Vessel System Drain Automatic Air Vent Pipes 15mm or 22mm see 5 FIG 5 12A CONNECTING PIPEWORK Shu...

Page 21: ...002737 A flexible connection pipe is supplied for connection of the expansion vessel The pump group has a dedicated expansion vessel connection point see fig 5 14A Alternatively the expansion vessel c...

Page 22: ...a p x E f o e r u s s e r p e r P l e s s e V l 5 2 l e s s e V l 5 2 l e s s e V l 5 2 l e s s e V l 5 2 l e s s e V l 5 2 d r a d n a t s d r a d n a t s d r a d n a t s d r a d n a t s d r a d n a...

Page 23: ...Point Alternative Filling Point return FIG 5 17A FLOW ADJUSTMENT 5 17 FLOW REGULATOR The flow regulator controls the flow rate at which the heat transfer fluid is circulated in the system To adjust t...

Page 24: ...any valve or restriction 10 Check pressure relief valve is correctly fitted 11 Check PRV discharge is fitted correctly and that a suitable collecting vessel is in place 12 Check that the indirect cyl...

Page 25: ...and then return to the container 13 After a short period close the ball valve G by turning the blue thermometer housing CCW This will divert the flow in the normal direction of the system 14 When flu...

Page 26: ...25 PRV Discharge To Expansion Vessel System Pressure Gauge Pump 3 5 Bar minimum Heat Transfer Fluid FIG 6 2A PUMP GROUP FLUSHING GLYCOL AND FILLING Return Flow...

Page 27: ...ling loop or start pumping water through the system As the pumped water will take the route of less resistance it will flow through the pump and then return to the drain or container 13 After a short...

Page 28: ...27 Mains 3 5 Bar minimum Filling loop Pump 3 5 Bar minimum Water FIG 6 3A PUMP GROUP FLUSHING WATER AND FILLING To Expansion Vessel System Pressure Gauge PRV Discharge Return Flow...

Page 29: ...m pressure to 3 5 Bar to improve air removal and to check all connections are sound 12 Switch off filling pump close valve B and remove filling pipe 13 Check air bleed valve G for air 14 Check system...

Page 30: ...29 FIG 6 4A PUMP GROUP FILLING AND TOPPING UP To Expansion Vessel System Pressure Gauge Pump 3 5 Bar minimum Heat Transfer Fluid PRV Discharge Return Flow...

Page 31: ...l e s s e V n o i s n a p x E f o e r u s s e r p e r P s e r t e m r a B r a B r a B 0 1 o t 3 5 1 3 1 3 1 3 1 3 1 3 1 4 1 4 1 4 1 4 1 4 1 1 1 6 1 4 1 4 1 4 1 4 1 4 1 5 1 5 1 5 1 5 1 5 1 2 1 7 1 5 1...

Page 32: ...plained and handed over Installation and maintenance instructions left on site System schematic handed over De commissioning details handed over Collector 1 Serial Number Collector 2 Serial Number Col...

Page 33: ...by visual inspection 10 Check electrical controls and temperature sensors are operating sensibly 11 Check the circulating pump is operating without due noise 12 Check pipework insulation is firmly in...

Page 34: ...manufacturer s instructions 2 Your installer does not complete the necessary commissioning process and procedure as detailed in the Installation and Operating Instruction manuals 3 Your appliance is...

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