Solfex IRC 2.1 System Installation, Commissioning And Maintenance Manual Download Page 1

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solar energy innovation

www.solfex.co.uk

IRC 2.1

Roof Integrated Solar Collector

Solar Keymark No. 011-75347F

System Installation,

Commissioning and

Maintenance Manual

Summary of Contents for IRC 2.1

Page 1: ...solar energy innovation www solfex co uk IRC 2 1 Roof Integrated Solar Collector Solar Keymark No 011 75347F System Installation Commissioning and Maintenance Manual ...

Page 2: ...station 25 System schematics 26 27 Installing the stainless steel pipe 28 Flushing and filling the system 29 Commissioning the pump station 30 Commissioning the solar controller 30 System maintenance and warranty 31 Commissioning checklist warranty form 32 34 Maintenance record 35 ...

Page 3: ...may be made without notice Installation instructions Wooden frame collectors In roof installation BE VERY CAUTIOUS WITH Roof s stability Before any installation it is imperative to check the good state of the roof s substructure and its load bearing capacity Particular attention should be paid the timber substructure with regard to the durability of screw connections The indications of this notice...

Page 4: ...o the respective DIN Standards and if this conformity can be duly verified in a proper process of cer tification Continuing compliance with the requirements is ensured by an annual inspection audit Viebrock haus AG as the first holder of such a certificate has meanwhile successfully passed its first ins pection audit and is thus entitled to continue using the coveted DIN Geprüft mark Exploiting th...

Page 5: ...ame collectors In roof installation The glass cover lies directly on to the aluminium rail without any rubber gasket Reason Rubber gasket inside the hot collectors release various chemical which can fog up the glass cover Only the side of the field of collectors underneath the flushing a rubber gasket has to be inserted 4x40mm Mounting bracket 70 70mm ...

Page 6: ...5m right Height 2 5m for one row fields 2 Install a 70 70mm support bracket on every rafter Place this bracket below the lowest slat and screw into the rafter with 2 Torx 4 x 80mm screws 3 Place the first collector the left one up on the roof The collector must be parallel to the rafters Note in order to cut fewer tiles during the covering Phase it is recommended to make sure that the distance bet...

Page 7: ...y will be used later 6 Lay down a layer of silicon on the left collector s part which will be fixed to the right s collector aluminium profile about 2cm 7 Then make this second collector slide sideways up till its complete contact with the first installed collector The first collector s glass cover must rest on the tightness gasket and be in complete contact with it Installing the collectors page ...

Page 8: ...both collectors 9 Collector s 1 and 2 are now installed Installation instructions Wooden frame collectors In roof installation 10 The following collectors will be installed following the exact same procedure as the one described in stages 5 to 10 page 8 Installing the collectors Technical changes may be made without notice ...

Page 9: ...12 Fix the collectors to the lower support brackets by means of Torx 4x30mm screws 2 screws per bracket 13 In the same way install the 70 70mm bracket on the collectors upper faces and fix them to the rafters by means of Torx 4x80mm screws 2 screws per bracket 14 Then fix these brackets to the collectors using 4x30mm screws 2 screws per bracket Installing the collectors page 9 Technical changes ma...

Page 10: ...tion the slat correctly and fasten it to collector using 3 Torx 4x30mm screws These screws should be spread regularly all along the frame 17 Mount the right hand side collector s aluminium profile on its frame use 4 25mm head screws 3 units 18 As described in step 17 Mount the finishing slat but this time on the right hand side Place this slat into the correct position and fasten it using 3 Torx 4...

Page 11: ... by means of clamping ring bends If the collectors are being connected using Pre insulated flexible pipe work it is advisable to fix the pipe work in position first using suitable brackets or strap band before making final joint connection of the solar collectors this will prevent the joint being disturbed at a later stage causing leakage of solar fluid ALWAYS CHECK CONNECTION JOINTS FOR TIGHTNESS...

Page 12: ...tor readings on the solar controller 22 Place the aluminium profiles at the junctions between the collectors and firmly fasten with 4 2x19mm screws Both profiles for cover and support of the glass cover must be perfectly aligned 23 Each profile must be fastened by 6 4 2x19mm screws NB Do not over tight 24 The aluminium profiles at the group s ends must be taken off before the mounting of the integ...

Page 13: ... wooden wedge meant to shelter the hydraulic connections This wedge is located at the top of the collectors and is fastened by Torx 4x80mm screws Be very careful not to damage the connections while fastening 27 On the left hand side collector place the frame s lower corner It is inserted in the runner located all around the collectors and must be tucked up till it s complete contact with the slat ...

Page 14: ...es of the cover Start by inserting the new elements sideways into the ones previously installed before completely fitting them in 31 Nail these pieces to the frame using sealed plumbing nails at the juncture 32 On the right hand end install the lower corner of the frame following the same procedure as described in 30 page 14 Installing the collectors Technical changes may be made without notice ...

Page 15: ...ft corner The sheet must be meticulously inserted into the collector s upper profile 35 Fasten this piece of cover to the wooden wedge using sealed plumbing nails 36 As for the bottom elements the straight upper pieces must be first sideways inserted one into another The fitting into the collector s profile must be meticulous Installing the collectors page 15 Technical changes may be made without ...

Page 16: ...ealed plumbing nails at the juncture 38 Firmly fix the side left and right side pieces 39 Place the right hand side cover sheet on top of the side gasket Fasten with sealed plumbing screws 1 at the top 1 at mid length and 1x at the bottom 40 Sealed plumbing screw top right page 16 Installing the collectors Technical changes may be made without notice ...

Page 17: ...ength and 1 at the bottom 42 Sealed plumbing screw top left 43 On the left hand side mount the exterior cover profile and fasten it with a 2x19mm screws These cover profiles must be perfectly aligned with the glass cover Each profile must by fixed with a 4 2x19mm screws 44 In the same wax mount the right hand side exterior profile Installing the collectors page 17 Technical changes may be made wit...

Page 18: ...arts to the roof slats thanks to metal retainer and roofing nails minimum 3x per side 47 In the same way place similar retainers every meter along the upper cover sheet Indication If there is no roof slat at this exact place it is necessary to install one before the installation of the covering fame 48 Stick a rubber wedge all along the upper edge of the cover sheet page 18 Installing the collecto...

Page 19: ...rms or strong wind periods 50 Adjust the lead skirting to the tiles To do so we recommend that you use a soft rubber hammer 51 Roof cover The tiles must be installed upon the lateral pieces in order to insure waterproofness To do so you might have to cut the edges off in order to make sure that the tiles lie flat on the flushing 52 Finished integration of a 6m set of collectors Installing the coll...

Page 20: ...N THOSE PIECES SHOULD BE FIRMLY INSERTED INTO THE RUNNER IF NEEDED A WOODEN BATTEN OR A HAMMER CAN BE USED 55 Then start inserted the straight extension pieces sideways into the runner They should first fit the corners of the pieces previously installed and the be completely and firmly inserted into the collector s runner 56 The pieces should overlap each other by 25 to 50 mm 25 50 mm MULTIPLE ROW...

Page 21: ... 24 Installation instructions Wooded frame collectors In roof installation 57 Collectors installed on several rows the installation of such sets is done by following the instructions 1 to 28 Between rows a 70mm separation batten will be installed IRC 2 1 M e t a l E d g i n g 2 7 m m m a x ...

Page 22: ...nges may be made without notice Page 19 of 24 Installation instructions Wooden frame collectors In roof installation Bracket 7x40mm 1st Collector 2nd Collector 3rd Collector 4x80mm 4x40mm Mounting installation Horizontal installation view from below ...

Page 23: ...ht 2026 2030 2296 2630 3019 2030 3289 2630 4012 2030 4282 2630 5005 2030 5275 2630 5998 2030 6268 2630 699x 2030 7x61 2630 7984 2030 8254 2630 8x77 2030 9247 2630 9970 2030 10240 2630 Number Area Disposition SMK12 4 6 8 10 12 m2 gross 8 12 16 20 24 Without flushing With flushing Total length Total height Total length Total height 2026 4110 2296 4710 3019 4110 3289 4710 4012 4110 4282 4x10 5005 411...

Page 24: ... material hydraulic connection Art Nr Name 4 6 8 10 12 14 16 18 20 22 24 26 28 14148 Number of panels 2 3 4 5 6 7 8 9 10 11 12 13 14 24100 basic kit for 2 panels wooden wedges on the top 1 1 1 1 1 1 1 24101 basic kit for 3 panels wooden wedges on the top 1 1 1 1 1 1 24102 extension kit for 2 panels wooden wedges on the top 1 1 2 2 3 3 4 4 5 5 6 20001 hydraulic connection kit for 2 panels 2 3 4 5 6...

Page 25: ...nting material hydraulic connection Art Nr 8 12 16 20 24 28 32 36 40 44 48 52 56 60 64 68 72 76 14107 Number of panels 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 24100 basic kit for 2 panels wooden wedges on the top 1 1 1 1 1 1 1 1 1 24101 basic kit for 3 panels wooden wedges on the top 1 1 1 1 1 1 1 1 1 24102 extension kit for 3 panels wooden wedges on the top 1 1 2 2 3 3 4 4 5 5 6 6 7 7 ...

Page 26: ...he kind of system there can be glycol Materials and performance of the components must necessarily take into account these particular operating conditions Pressure pump filling points page 26 System Schematics Technical changes may be made without notice Optional AAV Not needed if using filling pump Optional Heat Metering Accessories System with one collector field ...

Page 27: ...filling points System Schematics page 27 Technical changes may be made without notice Optional Heat Metering Accessories Optional AAV Not needed if using filling pump System with two collector fields East West System ...

Page 28: ...valley of the corrugation using an adjustable pipe cutter Do not clamp the cutter on the pipe with great force or the pipe will flatten 4 Allow 1 additional valley on each cut of the pipe to produce the sealing joint An optional extra flanging tool is available which will create a perfect flange finish on both DN 16 and DN 20 stainless steel pipework Final Connection 1 Insert the washer into the n...

Page 29: ...he anti clockwise position to allow this non return valve to be open Pour solar heat transfer fluid into the filling machine ensure the isolation valve is open on the bottom of the machine then switch it on to allow the fluid to circulate through the system for 30 minutes to flush out the air and any possible debris To clear any air or debris from the flow setter and pump turn the right hand isola...

Page 30: ...eeds to be adjusted to give optimum performance This will depend on the number of collectors used in the installation Commissioning the solar controller The recommended settings for the solar controller are Switch on temperature difference 7 C Switch off temperature difference 3 C Minimum pump speed 40 Store max temperature 65 C For thermal stores or if the outlet temperature is controlled with a ...

Page 31: ...hould also be made on the mounting brackets bolts for any corrosion or damage Warranty The collectors are guaranteed for 10 years and have a life expectancy of 25 years The warranty will be invalid in the following cases Collectors that are installed damaged or damaged during installation Failure of the collector due to frost lightning strikes transient voltages or any act of misuse or any act of ...

Page 32: ...ng C Unvented Cylinders only Capacity of cylinder Litres What is the incoming water pressure BAR Has strainer been cleaned of installation debris Yes No Has a water treatment device been fitted Yes No If Yes to above what type Are T P and expansion valves fitted and discharged tested Yes No Is Primary solar energy cut out 2 port valves operational Yes No Pressure reducing valve setting BAR Has exp...

Page 33: ...f Not Flowsetter reading Litres min Antifreeze protection method used Concentrated Yes No Please state glycol water mix used in percentage Water Gylcol Has system been flushed filled and de aireated with correct filling pump Yes No What pressure has the primary solar circuit been set to Bar Has the system been explained to the householder Yes No Has the systems literature been left with the custom...

Page 34: ...stomers signature Please see web site for warranty details and manufactures instructions for system annual maintenance check SOLFEX SOLAR KEYMARK COLLECTORS COME WITH A TEN YEAR MANUFACTURES WARRANTY Please contact us directly in writing within 7 days of any warranty issues Installation Date page 34 System commissioning checklist and warranty form Technical changes may be made without notice ...

Page 35: ...Maintenance record page 35 Technical changes may be made without notice Date Engineer Company Details Findings Maintenance Record ...

Page 36: ...Energy Arena Bannister Hall Works off Shop Lane Higher Walton Preston Lancashire PR5 4DZ Tel 01772 312847 Fax 01772 335277 sales solfex co uk www solfex co uk ...

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Solfex IRC 2.1, System Installation, Commissioning And Maintenance Manual

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