Grant GSD1 Installation & User'S Instructions Download

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Solar Thermal

Grant Solar Thermal Systems

On-Roof, Flat Roof and In-Roof Systems

Installation & User Instructions

Part No. DOC 73. Rev. 02 June 2010

For latest prices and delivery to your door visit MyTub Ltd - www.mytub.co.uk - [email protected] 0844 556 1818

Summary of Contents for GSD1

Page 1: ...r Thermal Systems On Roof Flat Roof and In Roof Systems Installation User Instructions Part No DOC 73 Rev 02 June 2010 For latest prices and delivery to your door visit MyTub Ltd www mytub co uk info mytub co uk 0844 556 1818 ...

Page 2: ... to accentuate the property and looks great on dark roof coverings such as slate Grant solar collectors are slender in appearance and are extremely durable with an extruded Aluminium frame and 4mm thick low iron glass Grant Sahara with a Bronze anodized frame this blends with most domestic roof types providing an aesthetically pleasing appearance Landscape one above other For latest prices and del...

Page 3: ...ructure 26 6 3 Installation of In Roof kit 28 6 4 Installation of collectors 33 6 5 Fitting top cover flashing 35 6 6 Closing the roof 35 7 Installation of Solar Collectors 36 7 1 Installation sequence of solar collectors 36 7 2 Installation of solar collectors On Roof and Flat Roof 37 8 Hydraulic Connections 39 8 1 Compression connection straight 39 8 2 Compression connection landscape systems on...

Page 4: ...t If the packaging is damaged during transit this must be immediately reported to the supplier delivery driver Before starting installation check the kit supplied contains all the required components Refer to Section 2 1 All packing materials must be disposed of appropriately after installation 1 3 Format of installation instructions These instructions describe the installation of collectors in bo...

Page 5: ...eded under any circumstances and if necessary a structural engineer must be consulted beforehand If the substructure has been penetrated it must be carefully re sealed in accordance with technical standards In roof Installation Fixing screws for mounting battens 1 8 Tools Required On roof and Flat roof installations Screwdriver 6mm hexagon socket Pencil Tape measure or folding rule 17 19mm open ja...

Page 6: ...late solar collectors conform to the requirements of BS EN 12975 Thermal solar systems and components Solar collectors and have the Solar Keymark approval For latest prices and delivery to your door visit MyTub Ltd www mytub co uk info mytub co uk 0844 556 1818 ...

Page 7: ...or to collector connector c w insulation 0 1 2 3 4 Cylinder bolt 4 8 12 16 20 Side gutter LH 1 1 1 1 1 Side gutter RH 1 1 1 1 1 Base tray lower section 1 2 3 4 5 Base tray upper section 1 2 3 4 5 Cover strip 2 3 4 5 6 Bottom apron flashing 1 piece 1 0 0 0 0 Bottom apron flashing LH 0 1 1 1 1 Bottom apron flashing RH 0 1 1 1 1 Bottom apron flashing Intermediate 0 0 1 2 3 Bottom flashing 1 piece 1 0...

Page 8: ... max 500mm max 500mm max 500mm max 500mm max 500mm max 500mm max 500mm max 500mm 200mm 1800mm 1800mm 1800mm 1800mm 60mm 60mm 60mm 900mm 60mm 60mm 1800mm 60mm 2042mm 2042mm 2042mm 2042mm 2042mm Figure 1 1 collector portrait Figure 2 2 collectors portrait Figure 3 3 collectors portrait Figure 5 5 collectors portrait Figure 6 2 collectors landscape Figure 4 4 collectors portrait 1142mm For latest pri...

Page 9: ...00mm 500mm 250mm 250mm 1770mm 1770mm 1770mm 1770mm 60 1770mm 2042mm 2042mm 2042mm 2042mm 1320mm 54mm 1318mm 1316mm 1334mm 2042mm Figure 7 1 collector portrait Figure 8 2 collectors portrait Figure 9 3 collectors portrait Figure 11 5 collectors portrait Figure 10 4 collectors portrait 60mm 60mm 60mm This is a fixed dimension and must be as shown above For latest prices and delivery to your door vis...

Page 10: ... 100 340 190 50 160 160 50 100 100 340 190 50 160 160 50 100 100 340 190 50 160 160 50 100 100 340 190 50 160 160 2450mm 2450mm 2450mm 2450mm Figure 13 2 collectors portrait Figure 14 3 collectors portrait Figure 16 5 collectors portrait Figure 15 4 collectors portrait Note Dimensions include cover frame Figure 12 1 collector portrait For latest prices and delivery to your door visit MyTub Ltd www...

Page 11: ...0 100 340 190 50 160 160 50 100 100 340 190 50 160 160 6525mm 8615mm 10700mm 1550mm 1550mm 1550mm 1550mm 2355mm 4440mm Figure 17 1 collector landscape Figure 18 2 collectors landscape Note Dimensions include cover frame Figure 20 4 collectors landscape Figure 19 3 collectors landscape Figure 21 5 collectors landscape 1550mm For latest prices and delivery to your door visit MyTub Ltd www mytub co u...

Page 12: ...oof System Installation 12 On Roof System Installation See Section 9 for details of roof penetrations For latest prices and delivery to your door visit MyTub Ltd www mytub co uk info mytub co uk 0844 556 1818 ...

Page 13: ...he roof covering e g slates flat tiles or profile tiles Item Description 01 Collector 02 Mounting rail set 03 Roof Anchors A profile tile B flat tile C slate roof 04 Rail profile 05 Anchor block 06 Collector connection kit 07 Collector to Collector connection kit 08 Cylinder anchor bolt 09 Fixing Bracket 10 Interlocking bolt 11 Hydraulic connection 12 Insulation 13 Temperature sensor 14 Mounting h...

Page 14: ... the tile valleys 3 Place roof anchor 03 A in line with the top edge of the roof tile in the tile valley Fix the base plate of the roof anchor to the rafter with screws 16 4 Fix all further roof anchors in the same way For roof anchor intervals see Page 8 3 1 On Roof System installation Note Roof anchors must be horizontally and vertically aligned follow roof tile valleys 65mm 70mm 40mm 150mm 120m...

Page 15: ...ent Horizontal positioning of roof anchors is dependent on the rafters and the tile valleys 3 Place roof anchor 03 B in line with the top edge of the roof tile Fix the roof anchor to the rafter with screws 16 4 Fix all further roof anchors in the same way For roof anchor intervals see Page 8 3 1 On Roof System installation Note Roof anchors must be horizontally and vertically aligned follow roof t...

Page 16: ...ote The distance of 185mm is dependent on the roof anchor and type of roofing and must be modified if necessary 4 Place the roof anchor 17 on to the slate tile and mounting battens and fix with screws 16 5 Fix all further roof anchors in the same way For roof anchor intervals see Page 8 3 1 On Roof System installation Note Roof anchors must be horizontally and vertically aligned 65mm 250mm 30mm 50...

Page 17: ...he sections of rail using the screws and fishplates supplied in the fixing kit provided as follows Fit the fishplate into the rectangular opening at the end of the one section of mounting rail Refer to Figure 36 Align the threaded hole in the fishplate with the hole in the rail 50mm from the rail end fit the cylinder bolt provided and tighten to secure Refer to Figure 37 Fit the exposed end of the...

Page 18: ...5 Flat Roof System Installation 18 Flat Roof System Installation For latest prices and delivery to your door visit MyTub Ltd www mytub co uk info mytub co uk 0844 556 1818 ...

Page 19: ...ock 06 Collector connection kit 07 Collector to collector connection kit 08 Cylinder anchor bolt 09 Fixing Bracket 11 Hydraulic connection 12 Insulation 13 Temperature sensor 14 Mounting hooks 15 Cruciform 07 A 12 06 13 11 01 04 03 C 08 09 05 04 14 02 Figure 39 Installation Summary Vertical Solar Collector Layout Flat Roof System Installation 19 For latest prices and delivery to your door visit My...

Page 20: ... bracket to the mounting rail using the interlocking bolts serrated washers and nuts provided Note Interlocking bolts must be secured to the mounting rail using a 90 turn 4 Place the next flat roof mounting bracket on the mounting rail and fix using the interlocking bolts Do not tighten the bolts too tightly as final adjustment may be required For interval b see Page 9 3 2 Flat roof installation D...

Page 21: ... legs of the flat roof mounting bracket and the mounting rail Place the angled long ends of the securing cruciform between the flat roof mounting bracket and fix with bolts M8x18 washers and nuts Note Always fit the stays of the securing cruciform to the right hand side of the flat roof mounting angles See detail views A and B 6 Tighten the nuts on the interlocking bolts If necessary modify the po...

Page 22: ...adequately weighted down or bolted If the supporting frame is secured by weights rather than being screwed down the weights must conform to the following specifications for a wind pressure zone up to 8 m building height and a snow load zone up to 0 75 kN m2 according to the table Permissible roof load must not be exceeded under any circumstances and if necessary a structural engineer must be consu...

Page 23: ...In Roof System Installation 23 6 In Roof System Installation For latest prices and delivery to your door visit MyTub Ltd www mytub co uk info mytub co uk 0844 556 1818 ...

Page 24: ...and for slates Item Description 16 A Bottom apron Left hand flashing for tiles 16 B Bottom apron Right hand flashing for tiles 17 A Top cover Left hand flashing 17 B Top cover Right hand flashing 18 Fixing screw not shown 19 Clip with nail not shown 20 Foam draught seal wedge 21 Foam draught seal block 22 Closure strip Figure 48 Installation Summary Vertical Collector Installation 6 1 Installation...

Page 25: ...s Item Description 16 A Bottom apron Left hand flashing for tiles 16 B Bottom apron Right hand flashing for tiles 17 A Top cover Left hand flashing 17 B Top cover Right hand flashing 18 Fixing screw not shown 19 Clip with nail not shown 20 Foam draught seal wedge 21 Foam draught seal block 22 Closure strip 23 Collector to collector connection kit landscape collectors only Figure 49 Installation Su...

Page 26: ...0mm up from the existing roof batten below such that the fold in the bottom flashing sits exactly on the top edge of the tiles see Figure 52 and 53 Secure the bottom batten to the rafters with screws supplied by installer Note The specified thickness for the battens is 30mm If the existing roof battens are thicker then it will be necessary to either pack out the battens or use thicker ones so the ...

Page 27: ...y installer A C B 180 230mm 01 02 B 02 A 03 Figure 53 Top Upper middle Lower middle and Bottom Horizontal Fixing Battens Table 4 Fixing Batten Spacing In Roof System Installation 27 Intervals between fixing battens mm for In roof installation portrait landscape Dimension side by side side by side A 2025 1125 B 260 260 C 1110 N A For latest prices and delivery to your door visit MyTub Ltd www mytub...

Page 28: ...the right in the centre Adjust width of the bottom flashing to suit see Table 5 Adjust the position of the bottom flashing as required to centre it in the opening in the roof tiles slates or to avoid the need to cut tiles on one or both sides Mark position of both ends of bottom flashing on batten Remove left hand flashing and fix right hand flashing to batten using suitable small screws not suppl...

Page 29: ...f the sealing screws provided in the installation kit for this fixing Fit first upper base tray 10 B Locate the lower edge of upper base tray into top of lower base tray until the side channels touch Fix to upper middle batten 02 B using one of the self drilling sealing screws provided in the installation kit at the centre of the upper edge see Figure 56b Dimension C Portrait 145mm Landscape 165mm...

Page 30: ...e batten as before using a single screw see Figure 57a Fit second upper base tray locating it into top of lower tray and fixing to upper middle batten using one of the self drilling sealing screws provided in the installation kit at the centre of the upper edge see Figure 57b For installations using more than two collectors repeat the above procedure to fit further lower and upper base trays as ne...

Page 31: ...vided in the installation kit at the centre of the upper edge see Figure 58b 6 Fit second RH half base tray As with the first tray position it with the lower edge along the fold line of the bottom flashing Ensure gap between trays does not exceed 4mm see Figure 57c Fix to middle batten using one of the self drilling sealing screws provided in the installation kit at the centre of the upper edge se...

Page 32: ...dges of each side gutter is located INSIDE the return edge on the bottom flashing 8 Secure side gutters in place using the clips provided Hook the clips over the outer edge of the side gutters and fix to battens using the nails provided 9 Fit cover strip on the joint between the base tray and side gutter Fit the end of the strip onto the two outward facing flanges see Figure 64 Slide cover strip u...

Page 33: ...refully mark their position on the base tray with a pencil Important Ensure brackets are correctly positioned with the two holes at the top Remove protective film from underside of brackets and press them into place in the correct position Fix in place with the self drilling screws supplied in the kit using the Torx 25 screwdriver bit provided in the kit Refer to Figure 67 16 04 100 10 100 100 10 ...

Page 34: ...the two anchor blocks in top collector profile to align with the hole in the two mounting brackets Fit the two cylinder bolts through the top mounting brackets into the anchor blocks and tighten Repeat for bottom mounting brackets 5 Repeat procedure for second collector and so on as required 6 5 Fitting Top Cover Flashing Note Flow and return system pipework and connections between collectors shou...

Page 35: ... Press down the end of the left hand flashing to seal Fix the left hand flashing to the batten beneath using the self drilling screws provided in the kit 6 6 Closing the Roof 1 If necessary the right roof tile row must be cut It may also be necessary to remove the upstands fitted to the roof tiles on the sheet side side cover sheet Note To improve the weather tightness of the roof covering optiona...

Page 36: ...troller in the sensor pocket next to the outlet flow connection of the collector array Figure 76 Connections for Portrait Format Collectors Mounted Side by Side Figure 77 Connections for Landscape Format Collectors Mounted one Above the Other Figure 78 Connections for Two Landscape Format Collectors Mounted Side by Side B A A 19 B B A 19 A B 19 Figure 80 Connections for Three Landscape Format Coll...

Page 37: ... c For portrait collector format approx 800mm 3 Place the first solar collector on the mounting rail mounting hook and align Distance to left hand mounting rail edge 39mm 4 Remove carry handles from the first solar collector and attach them to the next solar collector 5 Install anchor blocks 05 at the end of the mounting rail 04 and place them so that the fixing brackets 09 can be screwed flush to...

Page 38: ...so that the fixing brackets can be fixed finally side by side 12 Install fixing brackets into the solar collector profile and push them down onto the mounting rails 13 Push the second solar collector up to the first solar collector until the ends of the fixing brackets touch using cylinder bolts M8x14 Note Take care with compression fitting Guide the second solar collector s connector into the com...

Page 39: ...et next to the Outlet flow connection of the collector array 5 Push back the thermal insulation on the solar collector connection kits place the compression connections onto the connectors and secure 6 Take the temperature sensor seal 13 out of the solar collector hole next to the outlet flow connection pierce the centre and push it over the temperature sensor Finally guide the temperature sensor ...

Page 40: ...hem to the collector connectors 4 Tighten the compression elbows Caution Apply opposite force when tightening the compression connections otherwise the pipes on the solar collector can be damaged 5 After successfully checking the seal of the solar collectors fit the thermal insulation on the pipe and elbows 6 Continue in the same way to install additional solar collectors Figure 92 Hydraulic Conne...

Page 41: ...o the collector connections Drill a 25mm hole in the tile using a diamond tipped bit Locate the flashing below the drilled tiles with the copper pipe passing through the drilled hole SolarDek Flashings These have a coated lead base with a silicone centre section that is cut off to suit the diameter of the pipe These can replace the tiles adjacent to the collector connections Figure 94 Ventilation ...

Page 42: ...ection inside the roof space For SolarDek Flashings Cut the insulation to fit on to the silicone seal Cut the silicone seal to give the required diameter hole for the pipe Pass the pipe through the silicone seal for connection inside the roof space 3 If the substructure is punctured the roof covering must be re sealed afterwards Guide the connection pipes into the correct position through the wate...

Page 43: ...Controller see page 42 Safety Information Declaration of Conformity This device corresponds to the requirements of the relevant guidelines and standards if the corresponding regulations and the manufacturer s instructions are complied with Function This controller enables the regulation of various types of system 1 Solar regulation 2 Solid fuel boiler regulation The device is simple to operate and...

Page 44: ...000 10 1 039 20 1 078 30 1 118 40 1 155 50 1 194 60 1 232 70 1 270 80 1 309 90 1 347 100 1 385 110 1 422 120 1 460 If an error occurs the symbol appears in the display and the associated error number appears flashing On pressing the three operating keys simultaneously the parameters are reset to their default factory settings Sensor fault No Designation Significance E71 Collector The collector sen...

Page 45: ... pump Control Limit E 1 2 c 1 2 c 3 Amp fused supply L N E 4 not supplied Pump Station Figure 104 System Schematic Diagram 11 12 13 14 15 16 17 18 19 20 10 9 8 7 6 5 4 3 2 1 E Important ensure that 1 the collector sensor F1 is correctly located next to the flow connection of the collector refer to page 36 2 the storage tank sensor F4 is correctly located in bottom sensor pocket of the hot water st...

Page 46: ...he display required with the rotary knob at the front B Display the selected temperature or time C Weekday 1 Monday 7 Sunday here Saturday D Pump operation indicator Arrow Pump ON a Pump A1 is ON see connection diagram E Operation indicator OFF ON Hand Pumps ON max duration 30 min F When the total solar production in display C2 exceeds 10 MW the three arrows appear above the text x 1000 A Designat...

Page 47: ...the set value Right set value Use the Plus Minus keys to select the number of the set value required Display left A list of all the set values is provided on the following pages Press the Prog key Select the set value The LED beside the Prog key lights up This means that the set value can now be modified with the Plus Minus keys Change the set value using the Plus Minus keys Press the Prog key The...

Page 48: ...d for difference 1 1K 30K 3 31 Hysteresis to switching threshold for 1 1K 10K 3 Special Functions 40 Enable temperature collector s 20 C 90 C 35 C 41 Maximum collector temperature 80 C 180 C 110 C 50 Maximum storage tank temperature 10 C 130 C 60 C Pump Kick Function Temperature Test Function 60 Kick duration 0 2s 59s 0 OFF 61 Kick pause 10 min 60 min 30 min 62 Measuring time for 0 5K increase 1 m...

Page 49: ...nally the switch on conditions for the collector pump are checked 05 Pump Kick Function Switch On Time Refer to Pump kick function section 05 Pump Kick Function Switch Off Time Refer to Pump kick function section Fitter Set Values 20 Enter Code No After entering the code number the set values assigned to the fitter level can be modified Standard value 0000 21 Valid Code No The code number currentl...

Page 50: ...ed in the system glycol type P79 and the mixture ratio with water P78 must be set The day s production and total production are displayed in kWh in the case of values in excess of 10 MW the display of the total production changes to MWh The change is indicated in the display by means of three arrows The total production is updated on the same day The day s production is reset to zero at midnight B...

Page 51: ...ure gauge Connector expansion vessel Filling and flushing connector Features Benefits Flow meter volume flow rate setting Solar pump tailored to solar installation low volume flow rate high pressure difference Compact insulation Efficient and attractive prevents heat loss Stop valves with gravity breaking 6 bar safety valve low vapour build up Long service life of component Connection to expansion...

Page 52: ...m Description 42 Flow ball valve with thermometer integrated gravity brake 43 Return ball valve with thermometer integrated gravity brake 44 Pressure gauge 45 Solar safety valve 6 bar 46 Circulating pump 47 Flush fill gate valve 48 Flow meter 49 Air collector 50 Bleed valve 51 Connection supports G 1 2 IG closed off with plastic plugs 52 Expansion vessel connector 49 45 Rp 3 4 Rp 3 4 Rp 3 4 ca 548...

Page 53: ...the handles are at an angle of 45 Figure 113 Ball Valve Opened To prevent the circulation of gravity pressure the gravity brake must be in the operating position closed This means that the slots in the handles are in the vertical position Function of Gravity Brakes Opening pressure of gravity brakes 20 mbar each The gravity brakes are incorporated into both the flow and return ball valve assemblie...

Page 54: ...all through the rear insulation jacket Important The solar pump station must only be installed vertically as shown Note These Instructions are to be left with the Solar System Operator Building Owner 13 Solar Pump Station Important All system pipe connections must use compression fittings with brass olives Soft soldered joints must NOT be used on the solar primary circuit Plastic pipe must NOT be ...

Page 55: ...rmometer intergrated gravity break 44 Pressure gauge 45 Solar safety valve 6 bar 46 Circulating pump 47 Flush fill gate valve 47a Filling valve 47b Flushing valve 48 Flow meter 49 Air collector 50 Bleed valve 52 Expansion vessel connector 53 Filling station tank 54 Filling hose 55 Flushing hose 56 Filling station frame 57 Filling pump Twin coil cylinder Solar collectors Filling station Solar pump ...

Page 56: ...e there should be a suitable flat surface on which to stand the filling station eg floor loft boarding or similar 14 1 Heat Transporting Fluid In order to prevent frost and corrosion damage to the solar collectors and connections the system may only be filled with a high quality heat transporting fluid propylene glycol and water mix If the recommended ready mixed fluid is used this provides adequa...

Page 57: ...filling station fill the solar circuit and then flush for approx 15 minutes When the filling pump is running close the flushing valve and set the system pressure to around 4 5 bar When the pressure is reached close the filling valve and immediately switch off the filling pump Check that the device is leak free If the pressure gauge shows a significant drop in pressure this points to a leakage in t...

Page 58: ...trictor in the flush fill panel The flow indicator displays the volume flow set The display range is between 1 and 13 litres per minute Note For larger installations please contact Grant Technical Department for assistance Read off the volume flow values on the top edge of the rotameter Figure 122 Flow Indicator Releasing Trapped Air The residual air from the heat transfer fluid is collected in th...

Page 59: ...ure setting adjusted when cold 2 Bar Minimum allowable primary system pressure level before user action required 0 5 Bar Procedure for user to follow if primary pressure level is below limit Location of primary system pressure gauge Frequency of regular test of pressure safety device Yearly Location of pressure safety device Pumpstation Location of electrical fused isolating switch Fuse rating 3 A...

Page 60: ...r Low Medium High Limescale control in heat exchanger Cleaning hatch Thermostat on primary circulation Expected annual delivered solar energy to taps kWh Expected annual solar fraction of DHW per cent Method of performance calculation SAP2005 Other Daily DHW load assumption Litres per day at ºC Date of site visits for bacterial water quality and access risk assessments Commissioned by On behalf of...

Page 61: ...ing guidance 16 2 Solar fluid Using the small amount of solar fluid removed from the expansion vessel carry out the following tests a Using a Refractometer check antifreeze concentration and level of protection b Using suitable litmus indicator strips check Acidity ph value Replace solar fluid as required if either test indicates the fluid is unsuitable Safety If the replacement of solar fluid is ...

Page 62: ...eat thermostats and heat source controls temperature controls and programmers Switch on the heat source s gas or oil boiler heat pump etc to put the cylinder back into operation 17 2 Disposal of Solar fluid The propylene glycol used in the Grant pre mixed solar thermal system fluid is non toxic and does not contain any nitrates phosphates or ammonia Refer to Section 14 3 for details of the Grant s...

Page 63: ...ided upon request Chargeable Repairs A charge will be made if the cause of the breakdown is due to any of the following Faults caused by the plumbing or heating system external electrics or any external components The Grant Solar Thermal System has not been commissioned or serviced in accordance with the Installation User manual supplied with the system The system has been installed for over five ...

Page 64: ...ton Industrial Estate Devizes Wiltshire SN10 2EU Telephone 01380 736920 Fax 01380 736991 Email info grantuk com Website www grantuk com For latest prices and delivery to your door visit MyTub Ltd www mytub co uk info mytub co uk 0844 556 1818 ...

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