IDEAL Solar Thermal Installation And Servicing Download

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INSTALLATION

AND SERVICING

SOLAR THERMAL

When replacing any part on this appliance, use only spare parts that you can be
assured conform to the safety and performance specification that we require.
Do not use reconditioned or copy parts that have not been clearly authorised by Ideal.

For the very latest copy of literature for specification and maintenance practices visit our

website www.idealheating.com where you can download the relevant information in PDF format.

For users guide see reverse of book

February 2012
UIN 207786 A02

207786-2.indd 1

16/02/2012 11:25:35

Summary of Contents for Solar Thermal

Page 1: ...e specification that we require Do not use reconditioned or copy parts that have not been clearly authorised by Ideal For the very latest copy of literature for specification and maintenance practices visit our website www idealheating com where you can download the relevant information in PDF format For users guide see reverse of book February 2012 UIN 207786 A02 ...

Page 2: ...8 Aperture area m2 1 91 2 32 L x W x H mm 1730 x 1170 x 83 2058 x 1227 x 105 Weight kg 35 49 Performance and Installation Absorber capacity l 1 4 1 7 Housing Al frame Wooden frame Surface Al natural or anodized Improved corrosion resistance Back plate Al sheet Absorber sheet Al highly selectively coated Al highly selective vacuum coating Absorption 95 95 Emission 5 5 ø manifold mm 18 or 22 or 1 22...

Page 3: ...g Notes 54 55 Cylinders 4 Fault Finding 58 Handing Over 56 Installation 12 Installation Maintenance Checklist 57 Installation of On Roof Collector 12 Installation of In Roof Collector 21 Installation of Flat Roof Kit 36 List of Parts 60 Planning Permission 5 Pump Station 44 45 Safe Handling 5 Solar Controller 46 53 Water Circuit Diagrams 6 7 ...

Page 4: ...temperature of the solar collectors and the cylinder via its sensors The energy in the sun s rays is absorbed by the solar collector s selective coated plate s which is then transferred to the heat transfer fluid contained within the collector system pipe work When the solar collector sensor temperature is elevated 4o C above the cylinder sensor temperature the controller activates the circulating...

Page 5: ...ar installation Installation requirements The installation of the Ideal solar system must be carried out in accordance with the relevant requirements for safety current Wiring Regulations local Building Regulations Building Standards Scotland Consolidation Regulations and Bylaws of the local water company and Health and Safety document No 63S Electricity at Work Regulations 1989 It should be in ac...

Page 6: ...rised solar circuit The Ideal Solar System features high performance solar panel collectors with highly advanced features The collector has been awarded the Solar Keymark the EUs quality mark for solar collectors The collectors are mounted on a fast to fit frame and a solar pump station is also supplied to provide all the safety features required for a pressurised circuit The Ideal Solar Controlle...

Page 7: ...Station Solar Controller EC2 T3 Important solar fluid container should be manufactured from a material capable of withstanding the high temperatures at which solar fluid operates 1B east West solar panel circuit Solar panels can be located in an East West orientation In this configuration single line pump station Ideal part No UIN 207072 in addition to the twin line pump station should be employed...

Page 8: ... Armaflex or similar grade insulation or above Class O Armaflex is not UV resistant or designed for the temperatures realised in the solar primary circuit Polythene insulation will melt on a solar primary circuit All external items such as cable clips to hold the collector sensor must be UV resistant Flexible stainless steel hose is available in pre insulated form using suitable high temperature U...

Page 9: ...n be passed through the roof either with a proprietary roof penetration tile or a Code 4 lead custom made roof penetration tile Ventilation tiles can sometimes be adapted for this purpose Alternatively a silicon dektite can be used Optional lead pipe flashing tile kits which can be adapted to suit most roof tiles are available Any exposed elements of the roof penetration must be carefully sealed w...

Page 10: ... case of converted and inhabited loft spaces or roofs with less than the minimum slope with regards to the covering require additional measures by the customer e g sarking membranes as security against water penetration caused by wind pressure and driving snow Lightning protection Equipotential bonding of the building In accordance with the lightning protection standard ÖVE ÖNORM EN 62305 Part 1 4...

Page 11: ...nt points Additional mounting structures must be provided in areas with high snow and wind loads Observe DIN 1055 or country specific regulations Atachment points Collector Vertical Collectors Total length Atachment points 2 239cm 6 3 361cm 8 4 482cm 10 5 603cm 12 6 724cm 14 ASSEMBLY ...

Page 12: ...Roof Roof bracket Roof bracket console Self tapping screws 6 60 Cup square bolt 8 25 M8 hex self securing nut Clamping piece Clamping piece extension Mounting part top Mounting part extension M8 washer M8 30 hammer head bolt M8 hex nut Support rail Mounting jig Flat gasket INSTALLATION ...

Page 13: ...en mounting more than two collectors 1 Measure distance between mounting bracket Distance should be between 125 155cm Remove appropriate roof tiles to fit roof bracket console 2 A 125 155cm Distance between brackets 3 Fasten roof bracket console to rafters with provided self tapping screws 6 x 60 4 Replace roof tile cut tile to ensure correct fit if necessary 1 2 3 4 ...

Page 14: ...mer head bolt into the roof bracket and hand tighten for now Order hammer head bolt mounting bracket washer nut 6 Attach lower mounting rails 6a 6b Order mounting rail hammer head bolt roof bracket washer nut 7 Attach upper mounting rail 7a 7b Order mounting rail hammer head bolt roof bracket washer nut 5 6a 6b 7a ...

Page 15: ...ng points as described in Points 1 4 if additional collectors are to be fitted 9 Push the clamping piece extension halfway into the inner groove of the mounting rails upper and lower and tighten Order mounting rail clamping piece extension washer nut 10 insert the following mounting rails upper and lower and attach them using the clamping piece extension Order mounting rail clamping piece extensio...

Page 16: ... Attache the mounting rails upper and lower using the roof bracket clamping piece extension Order mounting rail hammer head bolt roof bracket washer nut 12 Hang the first collector in the lower mounting rail and adjust 12a 12b Note Distance between collector and end of moutning rails 45mm Measurement A mesurement B 11a 11b 12a 12b ...

Page 17: ...e upper mounting rail and hand tighten for now Order upper mounting rail hammer head bolt washer clamping piece washer nut 14 Attach the second collector measurement A measurement B as shown in Figure 12b Please use the mounting jig 14b 15 Rotate the clamping piece by 90º and screw it tight using a long socket wrench 13 14a 14b 15 ...

Page 18: ...nsert and position the mounting part in the upper moutning rail 17 Attach additional clamping pieces collectors as described in Points 12 16 18 Attach the mounting part on the upper left and right end of the collector field Order mounting rail hammer head bolt mounting part washer nut 19 Screw the collectors into place 16 17 18 19 ...

Page 19: ... Installation and Servicing INSTALLATION 14 Information about the collector TS 8000 Technical Data Gross area m2 2 02 Weight dry kg 35 Net ara m2 1 84 Contents 1 1 4 Aperture m2 1 91 Max Pressure bar 10 1221 3 8 6 1 1 70 1730 1170 ...

Page 20: ... parallel Mass Flow Rate To ensure the performance of the collector a specific flow rate of 30 l m2 h is to be selected up to a collector panel size of approx 25m2 Pipe Diameters Dimensions table with a specific flow rate of 30 l m2 h Collector panel size m2 approx 5 approx 7 5 approx 12 5 approx 25 Pipe diameter copper mm 10 12 15 18 22 Pipe diameter stainless steel corrugated pipe DN16 DN20 Pres...

Page 21: ...ner section right left or middle Connecting bend Side piece right left Side tin cover strip Sealed plumping screw 4 5 35 Middle cover strip Sealed plumping screw 3 9 13 Wooden wedge Self trapping screws 6 120 Side piece connector right left Middle cover right left or middle Rear corner section right left or middle Self trapping screws 4 25 Metal retainer roofing nail Foam rubber wedge INSTALLATION...

Page 22: ...m per collector 1 5m Height approx 3 0m for single row installation Height approx 5 0 6 0m for double row installation 2a Attach the installation batten below self taping screws 5 60 2b Measurement A 80mm for tile sheet metal edging Measurement A 50mm for shingle and crown tile sheet metal edging 2c Measurement B 200mm or tile width 50mm 1 2a 2b 2c INSTALLATION ...

Page 23: ...tachment diagram see Frame 28 self tapping screws 5 40 4 Set and align collectors on the roof 5 Fasten the collectors to the attachment bracket self tapping screws 5 40 6 Secure the collectors to the upper attachment bracket 1 bracket in the centre of each collector glass self tapping screws 5 40 If necessary install upper installation batten self tapping screws 5 60 3 4 5 6 ...

Page 24: ... roof integrated connection set 8a 8b Alternative Create a CU connection using a soldered connection Install the sensor with the sensor tube extension at the forward flow 9 If installing a second row install the installtion batton for the second row of collectors using the provided 5 x 60 self tapping screws The distance between the upper and lower rows should be 200mm 7 8a 8b 9 ...

Page 25: ...Slide the front corner section to the left into the required nut of the glass lower bar Note Before installing the underside of the metal casing remove the collectors lower protection piece 11 Slide the front section into the middle 13 Secure the front section on the required positions stampings using sealed plumbing screws 4 5 35 12 Slide the front corner section to the right 10 11 12 13 ...

Page 26: ... the upper edge of the collector Repeat steps 14 15 17 18 19 and 20 for second collector row accordingly 15 Secure the side pieces to the roof batten using metal retainers and roofing nails 16 Place the metal wedge in the middle between the collector rows and tighten it on the roof structure using self tapping screws 6 120 Install the side piece connector on the right and left 14 15 16 ...

Page 27: ... front corner section on the right and left at the collector using sealed plumbing screws 4 5 35 20 Tighten the middle cover strips using two self drilling sealed plumbing screws and the lateral tin cover strip using one self drilling sealed plumbing screw 3 9 13 19 Push the middle cover strip between adjacent collectors from the bottom as far as it can go 17 18 19 20 INSTALLATION ...

Page 28: ...e middle cover on the left 22 Slide in the middle cover to the centre 23 Slide in the middle cover on the right 24 Tighten the left and right middle cover to the side tin cover strip and the collector on the required position using a self drilling sealed plumbing screw 4 5 35 21 22 23 24 INSTALLATION ...

Page 29: ...re self tapping screws 5 120 Hang the left rear corner section 27b in the collector 27 Hang the middle rear section in the collector and connect the rear left corner section Tighten the sheet metal outside of the rein forcing seam using a self tapping screw 4 25 26 Tighten the left rear corner section outside of the reinforcing seam on the wooden wedge self tapping screws 4 25 25a 25b 26 27 ...

Page 30: ...ar section 29 Tighten the rear section on the left and right side to the cover strip and the collector using a sealed plumbing screw 4 5 35 30 Laterally secure the right and left rear corner section to the roof batten using metal retainers and roofing nails 31 Glue the foam rubber wedge on the side and the top applies to sheet metal edgings for tile roofs only 28 29 30 31a 31b ...

Page 31: ...sing the tiles and metal parts must always be alternately co vered 32 Cover the collector field If necessary the tile must be cut to the appropriate size using an angle grinder The top projecting end of the tile must be 80 and 140mm over the metal edge 33 Finally adjust the lead skirting for sheet metal edging with tile roofs only to the contour of the tile 32 33 34 ...

Page 32: ...rmal Installation and Servicing INSTALLATION 27 Information about the collector TS 8001 Technical Data Gross area m2 2 52 Weight kg 47 Net ara m2 2 32 Contents 1 1 7 Aperture m2 2 28 Max Pressure bar 10 1130 2058 2104 1227 105 ...

Page 33: ...33 INSTALLATION Solar Thermal Installation and Servicing INSTALLATION 28 In roof Mounting TS 8001 Connecting bend Installation batten Attachment bracket ...

Page 34: ...ance of the collector a specific flow rate of 30 l m2 h is to be selected up to a collector panel size of approx 25m2 Pipe Diameters Dimensions table with a specific flow rate of 30 l m2 h Collector panel size m2 approx 5 approx 7 5 approx 12 5 approx 25 Pipe diameter copper mm 10 12 15 18 22 Pipe diameter stainless steel corrugated pipe DN16 DN20 Pressure loss collctor for anti freeze water mixtu...

Page 35: ...8000 Bench screw M12 350 Rubber seal M12 washer M12 hex nut Clamping piece Clamping piece extension Mounting part top Mounting part extension M8 washer M8 30 hex bolt M8 30 hammer head bolt M8 hex nut Attachment bracket Base bracket Support bracket Support rail Mounting jig Flat gasket INSTALLATION ...

Page 36: ...tion wood Ø 8mm concrete as required 3 Attach the rubber seal screw it in and then fasten minimum screw depth 100mm Order rubber seal washer nut 4 Align the attachment brackets at the same height and fasten Order nut washer attachment bracket washer nut 1 2 3 4 INSTALLATION General Note Points 9 10 11 16 and 17 of these instructions only apply when mounting more than two collectors ...

Page 37: ...ss length from the bench screw Measurement D max 45mm 6 Attach the first mounting triangle as described in 6a 6c 6a Screw the base bracket to the support bracket A Order screw base bracket support bracket washer nut 6b Screw the base bracket to the attachment bracket on the front B Order screw attachment bracket base bracket washer nut 5 6 6a 6b ...

Page 38: ...her nut 6d Attach the second mounting triangle as described in 6a 6c 7 Slit T head bolt into the lower groove of the mounting rail and screw it to the mounting part using a washer and hexagon nut Order mounting rail hammer head bolt mounting part washer nut 8 Attach upper mounting rail as described in Point 7 Warning Upper and lower mounting rails must be mounted perfectly straight and parallel to...

Page 39: ... mounting rails upper and lower and tighten Order mounting rail clamping piece extension washer nut 10 Insert the following mounting rails upper and lower and attach them using the clamping piece extension Order mounting rail clamping piece extension washer nut 11 Attach the mounting rails upper and lower using the base brak kets Order support rail hammer head bolt base bracket washer nut 9a 9b 10...

Page 40: ...ail and adjust 12a 12b Note Distance between collector and end of mounting rails 45mm 13 Place the clamping piece on the upper mounting rail and hand tighten for now Order upper mounting rail hammer head bolt clamp washer nut 14 Attach the second collector measurement A measurement B as shown in Figure 12b Please use the mounting jig 14b 12a 12b 13 14a INSTALLATION ...

Page 41: ... elevation INSTALLATION 15 Rotate the clamping piece by 90 see figure 13 and screw it tight using a long socket wrench 16 With clashing mounting rails insert and position the mounting part in the upper mounting rail 17 Attach additional clamping pieces collectors as described in Points 12 16 14b 15 16 17 ...

Page 42: ...Mounting TS 8001 mounting system 45o elevation 18 Attach the mounting part on the upper left and right end of the collector field Order mounting rail hammer head bolt mounting part washer nut 19 Screw the collectors into place with the proper torque 18 19 INSTALLATION ...

Page 43: ...the collector array flow To ensure optimal contact between the sensor and the surrounding environment the gap between the sensor sleeve and the sensor element should be filled with a suitable conducting compound All materials used for installing temperature sensors sensor element conducting compound cables sealing and insulating materials must be suitably temperature resistant up to 250 C Operatin...

Page 44: ...ll the installation 2 Starting the installtion working Open the ball valve and close the side filling and draining valves Remove the hose unions and screw again the plugs to avoid any casual opening of the side valves it is better to stop the levers in the close position as shown here aside 3 Regulate the flow rate using the regulation rod until the right flow rate is shown N B The flow rate is sh...

Page 45: ...ingle line pump station Tee Connection 40 Bracket and Connection Kit for the Expansion Vessel A 3 4 flexible pipe connected to the security unit of the solar pumping station not included B Fibre sealing joint inlcuded C Connector with double check valve to disconnect the expansion vessel in a reliable and fast way without any leakage D Expansion vessel with 3 4 threaded connection available on req...

Page 46: ...e not permanently connected with the building have to be equipped with a strain relief clamp outside the controller The controller is only for the prescribed applications No liability is taken over for other utilization All operations on an open controller are only to be conducted cleared from the power supply All safety regulations for working on the power supply are valid Connecting and or all o...

Page 47: ...ductor is intended or required for the pump the Earth conductor must be connected The corresponding Earth conductor wire terminals are provided Ensure that the ground contact is also connected to the controller s mains supply side sol8573 Cut out cable entry 2 1 5 sol8574 Actuating the terminal clamp sol8575 Each clamp may only be allocated one connecting cable up to 2 5mm2 Connector sleeves must ...

Page 48: ... a mode switch on the left side of the housing Note Every change of the switching position is followed by a 3 sec lasting display of the current control mode on Automatic off 45 Ideal sOLAR cONTROLLER Commissioning sol8577 1 2 4 3 3 Now the front cover can be folded down and the push buttons can be threaded through 4 A fastening screw is used to securely close the housing sol8578 2 Switch in centr...

Page 49: ...ction see section B 4 Antifreeze function not applicable see section C 5 Change over C F see section D 6 Pipe collector function not applicable see section E 7 Setting of storage tank max temperature see section F 8 Symbols for solar circuit pump and circulation 9 Symbol for storage tank max temperature is reached see section G 10 Error icon e g short circuit open circuit see section A or SYS syst...

Page 50: ...ature early in the day In this case vaporization may occur within the solar unit and thus subjecting the unit to a higher thermal load Note This function should only be used if you are not at home for an extended period of time Please deactivate this function after returning back home to prevent unnecessary loses of energy If while the holiday function is activated a temperature 10K below the maxi...

Page 51: ...ts without anti freezing agents This is not applicable to the Ideal Solar System sol8591 section c section d sol8588 Changing the temperature display s unit of measurement Press and hold the set button for 2 seconds Use the and button to scroll to the temperature unit function Press and hold the set button to change Press the button to reach the next setting section e sol8589 The vacuum collector ...

Page 52: ...nimated pump operation now begins to move in the display If the temperature difference drops below 4K the pump operation is deactivated and the sun disappears If in the lower part of the storage tank T2 the set maximum storing temperature is reached factory setting 60 C the charging stops Pumps are stationary A new charging procedure is first possible at a temperature of 4K under the maximum stori...

Page 53: ...mum temperature 130 C has been exceeded Details see Frame 46 Pump symbol does not rotate Backlight display is red OFF blinks in display Mode switch is on manual operating position Pump Off Details see Frame 42 Pump symbol does not rotate Backlight display flashes red and green alternately One of the T1 T2 temperatures displays a sensor fault There is a sensor fault short circuit or interruption ch...

Page 54: ...efore commissioning Use a suitable filling pump capable of producing 2 bar with filter such as an electric solar pump manual hand pump or an attachment to a power tool 1 connect flushing pipes to the fill and drain valves on the side of the flow limiter by replacing the caps with the hose connectors 2 Open the fill and drain valves 3 Using a screwdriver esnure the adjustment screw below the pump i...

Page 55: ...o 1 bar NOTE DO NOT USE THE SAFETY ASSEMBLY PRESSURE RELIEF VALVE FOR THIS PURPOSE m2 of Collectors l min 1 1 0 2 2 0 3 3 0 4 4 0 5 5 0 6 6 0 7 7 0 8 8 0 9 9 0 Corresponding Flow Rates for Ideal Solar Collectors cold 3 Turn the solar controller to the ON position on the slider switch refer to Frame 45 4 Set the flow rate see table below using the speed setting on the circulation pump and adjustmen...

Page 56: ...r The lower section of the cylinder is available for the solar circuit the upper section of the cylinder is available to the boiler circuit The solar heating circuit operates most effectively when it has the largest volume of water to heat Therefore especially during the summer months Ideal strongly recommends that the boiler control circuit is left off during the solar day when the sun is likely ...

Page 57: ...d and free from leaks 7 Check valve bleed screw closed 8 Pump orientation correct and operating without undue noise or vibration 9 Pump isolation valves fully open 10 Pump and flow meter setting correct 11 Filling loop closed and disconnected 12 Pressure relief valve cleared and free from leaks 13 No isolation valve between collectors and safety valve 14 All non return valves solenoids and motoris...

Page 58: ...aulty DTC system settings Check delta Ton and delta Toff settings flowrate and pump speed control Also check functions ON OFF and DTC on auto Faulty PT1000 sensors Check sensor location and check electrical resistance to temperature see table in Frame 50 Faulty pump Check pump is rotating Check valves open and pump speed correctly set Restriction in circuit Check circuit components and for old ant...

Page 59: ...59 Solar Thermal Installation and Servicing ...

Page 60: ...ly authorised by Ideal Key No Description Qty Product Number SENSOR THERMOMETER HANDLE THERMOMETER PIT NUT Not shown RED RING THERMOMETER SUPPLY BALL VALVE AIR SEPERATOR BRV SHORT COPPER PIPE BRV THERMOMETER CONNECTION PIECE BLUE RING THERMOMETER RETURN BALL VALVE 1 1 2 NUT GASKET SAFETY GROUP SOLAR PRESSURE GAUGE WILO PUMP FLOW METER 2 12 l 2 LINE INSULATING BOX IDEAL BADGE EXPANSION VESSEL BRACK...

Page 61: ...61 List of parts Solar Thermal Installation and Servicing 2 4 9 5 6 7 8 10 12 13 14 15 16 17 19 20 11 2 9 10 14 15 11 21 22 SINGLE LINE SOLAR STATION Sensor DOUBLE LINE SOLAR STATION 1 ...

Page 62: ...62 Notes Solar Thermal Installation and Servicing ...

Page 63: ...63 Notes Solar Thermal Installation and Servicing ...

Page 64: ... specification without notice The Ideal Technical Training Centre offers a series of first class training courses for domestic commercial and industrial heating installers engineers and system specifiers For details of courses please ring 01482 498 432 CERTIFIED PRODUCT Manufactured under a BS EN ISO 9001 2000 Quality System accepted by BSI The code of practice for the installation commissioning s...

Page 65: ...his appliance use only spare parts that you can be assured conform to the safety and performance specification that we require Do not use reconditioned or copy parts that have not been clearly authorised by Ideal For installation guide see reverse of book ...

Page 66: ...ash Press repeatedly until the controller returns to normal operation mode WARNING It is recommended that the solar store temperature set point is not set below 60 C as this temperature facilitates the eradication of Legionella bacteria Risk of scalding from the solar storage tank if set above 60 C It is recommended that a thermostatic mixer is set to 60 C or below and is fitted local to the solar...

Page 67: ...ce the cylinder temperature over night by using the solar collectors as a radiator Enter the parameters mode as described in Frame 1 Use the buttons to select the symbol press and hold the SET button for 5 seconds until a tick appears in the holiday symbol Once the unit is set press repeatedly until the controller returns to normal operation mode Repeat in reverse order once the property is occupi...

Page 68: ...ded Pump symbol rotates in the display Pump s connecting line is not connected interrupted or fuse in the controller is burnt out replacement fuses provided in the housing Only use fuses of type 250V 4A MT Pump symbol does not rotate There is a sensor fault short circuit or interruption check the Backlight display flashes red and green alternately sensor supply lines and its connect connection on ...

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