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    Solar Installation Manual

    SOLAR PLUMBING & ELECTRICAL INSTALLATION MANUAL

    v03 Nu-Heat

    underfloor heating

    ground source heat pumps

    air source heat pumpssolar thermal

    rainwater harvesting

    Nu-HeatU N D E R F L O O R & R E N E W A B L E S

    INTEGRATED RENEWABLE & HEATING SOLUTIONS

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    It is a condition of the warranty that the Certificate of Installation and

    Commissioning application form is completed and returned to Nu-Heat

    once the system is fully commissioned.

    This manual gives the information needed to install your Nu-Heat solar thermal

    system. In order for the process to be achieved quickly and easily the principle

    of solar thermal should be understood. A useful reference is produced by the

    Energy Saving Trust, entitledSolar water heating systems - guidance for

    professionals, conventional indirect models (CE131).

    The following pages have comprehensive diagrams showing the purpose of

    each major system component and its position in the overall scheme. Parts shown

    in colour are supplied by Nu-Heat and those shown in outline are generally

    supplied by others.

    Attention to the advice given in this manual will help to ensure a trouble-free

    and effective installation. The requirements of the relevant British Standards,

    Water Bye-laws and other regulations should always be met.

    If there is any aspect of the installation that you do not understand, please contact

    Nu-Heat Technical Support, quoting your system reference number, for advice.

    In line with the company policy of product development, Nu-Heat reserves the

    right to supply different components to those shown.

    This manual is the copyright of Nu-Heat. All rights reserved. No part of this

    publication may be reproduced, stored in a retrieval system, or transmitted

    in any form or by any means electronic, mechanical, photocopying, recording

    or otherwise without prior written permission of Nu-Heat.

    INSTALLATION MANUAL FOR NU-HEAT SOLAR THERMAL FLAT PANEL SYSTEM

    System Ref:

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    Solar Installation Manual

    section contents

    1.1 Checklist

    2.0 Fitting the solar panel

    3.0 Panel Mounting On-roof

    4.0 Fitting the solar pumping station

    4.1 Connection of Solar Pumping Station to Panels and Cylinder

    5.0 Second fix wiring information5.1 Wiring the solar pump station

    6.0 Filling and flushing the solar circuit

    7.0 Setting up electrical equipment

    7.1 Cylinder thermostat & timeclock EnergyMaster Solar only

    7.2 Selecting the operating mode

    7.3 User controls immersion heater timer Preheat cylinder

    with NIBE 360P

    and 1240 only

    appendices

    1 Aquastar Hot Water loop

    2 Solar system maintenance requirements

    3 Solar de-commissioning schedule

    4 Roth Heliostar 218 and 252 EN 12975 conformity certificate

    5 Sample installation checklist

    6 Further reading

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    1.1 CHECKLISTMains water supply: Check that the performance of the mains supply matches the requirements of the household.

    Boiler: If using a Nu-Heat EnergyMaster cylinder in conjunction with underfloor heating then the heat loading is indicated

    on the A3System Information. Please refer to the boiler manufacturers recommendations for installing and commissioning

    the boiler. Check the boiler installation requirements with the manufacturer as in some cases a by-pass valve may be

    recommended between flow and return pipework.

    Insulation of pipework: It is necessary to insulate the solar pipework, as well as the primary system pipework. Domestic

    hot water pipework should also be insulated, particularly on a pumped loop. Ensure that the incoming cold main is separatedfrom any hot pipework to prevent heat transfer.

    Taking delivery: Please check your delivery against the delivery note and report any discrepancies within 7 days of receipt.

    Warranty: In order to validate the warranty the Commissioning Checklist & Warranty Application form in the Commissioning

    Packattached to this manual must be completed by the installer and returned to the customer.

    recommended installation sequence

    The general sequence of installation is as shown in this manual. Before starting check the positions of the main components

    such as the cylinder and pump station as discussed at quotation stage.

    Please note that if the position of the cylinder has changed with respect to the position of the panels then the length and

    diameter of the connecting pipe will change also. Full dimensions of the components supplied are given in this manual.

    1. Fit the panels to the roof as part of the roofing work to make the property weather-tight.Note: The panel must be

    covered during installation to prevent solar irradiation. Pass flexible hoses and sensor cable through the roof.

    2. Complete the first fix wiring in accordance with the diagrams in this manual.

    3. Fit the cylinder. The other major plumbing works will need to be completed in order to fill the cylinder with domestic

    water, and heating primary water if applicable.

    4. Fit solar pump station and expansion vessel.

    5. Complete the connection pipework between the cylinder and panel array.

    6. 2nd fix the wiring of the solar equipment.

    7. Fill and flush the solar circuit.

    8. Commission the system in order to allows heat to be drawn from the panels.

    Only uncover the panels once this has been done.

    Solar docking schematics must be read in conjunction with the system docking drawing which will show the

    boiler/heat pump mechanical pipework layout.

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    2.0 FITTING THE SOLAR PANEL cont.

    other important notes

    roof loading

    The weight of each Heliostar 218 panel is only 35kg and each Heliostar 252

    panel is only 36kg. However consideration of additional loads from wind and

    snow must also be taken. Consult a structural engineer if there is any doubt as to

    the ability of the roof to support the additional load of the solar panel.

    lightning protection

    The requirement for lightning protection is only necessary when the assessed

    risk is greater than 1 in 100,000 according to BS 6651.

    installation of sensor

    Before finishing work on the roof the solar panel temperature sensor must be

    installed. It should be located in the last panel before the return to the cylinder

    (i.e the hot outlet, which is the hottest part of the collector array).

    To install the sensor remove the rubber bung. Feed the sensor through the hole

    in the bung and, after applying some heat conduction paste, insert the sensor

    into the pocket and refit the bung.

    It is possible to extend the sensor up to 50m using a 0.75mm twin core cable

    such as is integrated into the flexible stainless steel flow and return pipe work

    (optional).

    Important: Prior to installation the collectors should be stored indoors taking

    care not to damage the glass. Do not unpack the collectors until just before fitting

    to avoid moisture entering into the collector through the holes in the frame.

    Flow from solarpump station

    Sensor position

    Returnto solar

    pumpstation

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    Solar Installation Manual

    3.0 HELIOSTAR

    SOLAR PANEL ON-ROOF INSTALLATION

    general requirements

    panel array dimensions

    If more than 5 panels are required then they should be arranged in equal banks

    of up to 5. This will be discussed at quote stage if more than 5 panels are necessary.

    800mm

    1200mm

    1360mm(

    218panel)

    1640mm(

    252panel)

    1820mm(

    218panel)

    2100mm(

    252panel)

    1360mm(

    218panel)

    1640mm(

    252panel)

    1820mm(

    218panel)

    2100mm(

    252panel)

    1360mm(

    218panel)

    1640mm(

    252panel)

    1820mm(

    218panel)

    2100mm(

    252panel)

    1360mm(

    218panel)

    1640mm(

    252panel)

    1820mm(

    218panel)

    2100mm(

    252panel)

    800mm 10001200mm

    2400mm

    800mm 10001200mm 10001200mm

    3600mm

    800mm 10001200mm 10001200mm 10001200mm

    4800mm

    800mm 10001200mm 10001200mm 10001200mm 10001200mm

    6000mm

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    4.0 FITTING THE SOLAR PUMPING STATION

    The solar flow control station comprises the following:

    1. Mounting holes

    2. Pressure relief valve

    3. Pressure gauge

    4. Filling and flushing valve

    5. Isolating valves with non-return valve and dial thermometer

    6. Filling and flushing valve

    7. Flow regulating valve

    8. De-aerator with air bleed

    9. Solar circulating pump

    10. Mounting bracket

    Also mounted on the control station is the solar controller, as well as the connection

    point for the solar expansion vessel.

    9

    1

    10

    1

    2

    3

    4

    5

    6

    7

    8

    5

    Solar circulating pump

    Mounting holes

    Pressure relief valve

    Pressure gauge

    Filling and flushing valve

    Isolating valves with non-returnvalve and dial thermometer

    Filling and flushing valve

    Flow regulating valve

    De-aerator with air bleed

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    Solar Installation Manual

    4.0 FITTING THE SOLAR PUMPING STATION cont.

    installation

    The pump station is supplied preassembled, and is designed to be fitted to the wall

    1. To remove the front of the insulated cover first remove the two dial

    thermometers these are just a press fit and pull out. The front will then

    lift off.

    2. When deciding on the position of the solar pump station enough room

    must be left to the right of the pump for the solar expansion vessel. There is

    a dedicated fitting for connecting this.

    3. Mark the position for the mounting screws (1) horizontally at 150mm centres.

    Drill two 8mm diameter holes and insert plastic screw plugs.

    4. Fix the back housing to the wall using the screws provided.

    5. The pressure gauge comes pre-fitted, however should it be removed at any

    point to refit it should be screwed in fully, and then unscrewed until it is the

    correct way up. It will self seal.

    6. All threaded connections are factory tested, however they must be checked

    for water-tightness during the system pressure test.

    7. Fix the expansion vessel to the wall using the bracket provided. Take care

    when identifying the solar expansion vessel as it is rated for higher

    temperatures than standard heating types. The solar expansion vessel

    can be identified by the sticker on the vessel itself.

    8. The solar expansion vessel should be mounted with the plumbing connection

    at the top. The connection is made using the 0.5m flexible hose provided.

    Make sure to use the fibre washers, as provided. This pipe must remain

    uninsulated, as the heat dissipated protects the vessel from extremely

    high temperatures.

    9. If desired the solar controller can be detached from the pump station and

    mounted in a more convenient location. For details on wiring see Wiring the

    solar pump station.

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    4.1 CONNECTING THE PUMP STATION TO THE PANELS AND CYLINDER

    The top connections of the solar pumping station comprise the flow and return to the panel array, whilst the bottom

    connections are a flow and return to the cylinder.

    flexible stainless steel flow and return pipework

    As part of the solar quote there will have been the option of being supplied stainless steel flexible pre-insulated pipe,

    complete with sensor cable. This will have been sized according to the length of run, and the required flow-rate, being

    available in 16 or 20mm nominal diameter. As part of the kit supplied with this there will be a set of fittings, which should

    be used as follows:

    Clips will be supplied to fasten the stainless steel flexible pipes, and these should run at approximately 1.5m intervals.

    Note:the pipe-work must be earth bonded with a conductor of cross section 6mm2 or more.

    12mm flexible stainless steel pipes with 1/2 captivenuts (pair) supplied with panel fixing basic set

    1/2 male iron x DN16 or DN20 flexible stainlesssteel fitting (x 2) supplied with (optional) flexiblestainless steel pipe assembly

    22mm compression x DN16 or DN20flexible stainless steel fitting (x 2) supplied with (optional) flexiblestainless steel pipe assembly

    3/4" male iron x DN16 or DN20 flexiblestainless steel fitting (x 4) suppliedwith (optional) flexible stainless steelpipe assembly

    Solar panel array

    Solar pumpingstation

    Cylinder solar coil

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    Solar Installation Manual

    4.1 CONNECTING THE PUMP STATION TO THE PANELS AND CYLINDER cont.

    double banked panels reverse return fitting

    If more than five panels are specified then they must be fitted in two banks. This is because the pressure drop across more

    than five panels is too great. If the stainless steel flexible pipe is purchased from Nu-Heat then the necessary additional pipe

    will supplied to connect the two banks in the roof.

    It is important that the pipe work connecting the two banks is configured in a reverse-return layout in order that the pressure

    drop across each bank is equal. This will ensure that the flow through each bank is equal, and that one bank doesnt have

    more heat stripped from it that the other.

    Note:that the pipe work will pass through the roof before being joined.

    If the banks of panels are one above the other then the pipe-work is as the following diagram (the additional components

    supplied with the optional stainless steel flexible pipe are shown in red).

    Short length ofpipe cut frommain length

    Short lengthof pipe cutfrom mainlength

    DN16 equal tee

    5mlength

    DN16equal tee

    Sensor

    Through Quickslate

    ThroughQuickslate

    ThroughQuickslate

    Outflow

    Outflow

    1/2 MI xDN16/DN20coupling

    1/2 MI x DN16/DN20 coupling

    1/2 MI x DN16/DN20 coupling

    1/2 MI x DN16/DN20 coupling

    Inflow

    Inflow

    5mlength

    ThroughQuickslate

    Note:that the pipes marked 5m length refer to the length of stainless steel pipe where this is supplied. If copper is used

    then these pipes need to be of equal length.

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    4.1 CONNECTING THE PUMP STATION TO THE PANELS AND CYLINDER cont.

    If the banks of panels are side by side then the pipe-work is as the following diagram (the additional components supplied

    with the optional stainless steel flexible pipe are shown in red).

    Note:that the pipes marked 5m length refer to the length of stainless steel pipe where this is supplied. If copper is used

    then these pipes need to be of equal length.

    It is important that all joints are insulated, and that any material used for this is capable of withstanding 150C. High temperature

    nitrile rubber (e.g. Armaflex) is a proven material in this application. This should only be done once the system has been

    pressure tested.

    making connections with the stainless steel flexible pipe

    cutting the pipe

    The stainless steel flexible pipe is supplied in standard lengths and can be cut with ordinary (copper) pipe cutters. The cut

    should be made in the trough of the corrugation (the minor diameter). The pipe should be left free from burrs to avoid injury.

    connecting the stainless steel flexible pipe

    In the assembly with the stainless steel pipe will be a connection kit. There are two different styles of connector; eitherMetalflex (assembly codes SPCKR1/16-A or SPCKR1/20-A for single banked systems), or Isiclick (assembly codes

    SPCK2/16-A or SPCK2/20-A for double banked systems).

    Please see the information overleaf as to how to assemble each of these.

    DN16equal tee

    5m length

    5m length

    Through Quickslate 1/2 MI x DN16/DN20 coupling1/2 MI x DN16/DN20 coupling

    1/2 MI x DN16/DN20 coupling

    1/2 MI x DN16/DN20 coupling

    Outflow Outflow

    Inflow Inflow

    SensorDN16 equal tee

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    Solar Installation Manual

    4.1 CONNECTING THE PUMP STATION TO THE PANELS AND CYLINDER cont.

    metalflex (spckr1/16-a or spckr1/20-a)

    1. Cut the pipe to length as described above

    2. Place one of the pipe nuts over the pipe

    3. Close one of the retaining clips (circlips) around the pipe in the first crease

    4. The first corrugation must be compressed to provide a flat sealing surface. To achieve this assemble the fitting without

    the fibre washer and tighten as far as possible.

    5. Once the first corrugation has been flattened undo the fitting and fit the fibre washer before finally doing the fitting up tightly.

    If a sealant is desired then high temperature liquid PTFE should be used (e.g. Rocol 28022 Pipeseal PTFE Liquid)

    alternatives to flexible stainless steel flow and return pipework

    If the optional flexible stainless steel pipe has not been chosen then copper may be used. Be aware that any solder joints

    must be made with high temperature solder on the solar circuit.

    Also, any threaded or compression joints should be sealed with a high temperature liquid PTFE sealant (such as Rocol 28022

    Pipeseal PTFE Liquid)

    The pipe runs must be insulated both to prevent heat-loss and risk of being burnt. Any material used for this must be

    capable of withstanding 150C. High temperature nitrile rubber (e.g. Armaflex) is a proven material in this application.

    Copper pipework should be sized as indicated in the following table.

    Note:the pipe-work must be earth bonded with a conductor of cross section 6mm2 or more.

    Minimum pipe diameter Panel Qty

    2 3 4 5 4 (2x2) 6 (2x3) 8 (2x4)

    10 15 15 15 15 15 15 22

    15 15 15 15 15 15 15 22

    20 15 15 15 22 15 22 22

    30 (i.e. 20+10) 15 15 15 22 15 22 22

    Panel to cylinderdistance (m)

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    5.0 SECOND FIX WIRING

    The following pages give information required for the second fix wiring. The

    requirements of the relevant British Standards and IEE Wiring Regulations

    should always be met.

    BS7671: 2001 (2004). Requirements for Electrical Installations, IEE Wiring

    Regulations, Building Regulations

    electrical safety (part p)

    Installation must be carried out by a Competent Person or, failing that, the

    local building control authority must be notified of the proposed work before

    commencement and the completed installation must be inspected by a

    Competent Person.

    safety

    Nu-Heat recommends the use of a number of 5A switched fused spurs to supply

    the boiler and other electrical items that make up the heating system. Where

    live conductors are sleeved in a colour other than brown, coloured marker

    sleeves should be fitted at the ends of the wires to identify them.

    optional additional equipment

    Where connections are shown to equipment that is not supplied by Nu-Heat,

    this is for guidance only. In all such cases the suppliers installation information

    should be checked before fixing and connecting the equipment.

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    Solar Installation Manual

    5.1 WIRING THE SOLAR PUMP STATION

    1. The standard three-pin plug fitted to the solar station must be removed, and a double pole switched fused spur provided

    to supply the pump station.

    EL SL EL NLNE

    1 2 3 4 5 6 7 8 9 10 12 13 14 15 16 17 18 19 20S1 S2 S3 S4 VBus N R2 N R1 N L

    Temp sensor

    Pt 1000

    R1 1 (1) A (220...240)V

    R2 1 (1) A (220...240)V

    2. There is a prewired plug to connect to the pump to thecontroller. To comply with current best practice this must

    be disconnected and rewired as shown in the diagram

    above. Please note that the cable used to the pump must

    be capable of withstanding 90C. The plug on the pump

    must still be used, and this will only fit in the correct

    orientation. If the solar controller is to be located

    remotely from the pump station then this cable must

    be extended as required.

    3. To wire in the temperature sensor first switch off the

    mains supply to the pump station. Then slide the plastic

    cover out, and undo the cover retaining screw.

    4. For all systems there are two temperature sensors:a. Sensor S1 is located in the panel (see Fitting the solar

    panel). This can be extended up to 50m using 0.75mm

    twin core cable. If the (optional) stainless steel flexible

    pipe has been chosen then the integral sensor cable

    should be use to extend the sensor.

    b. Sensor S2 is fitted into the lower sensor pocket on the

    cylinder to sense the temperature near to the solar coil.

    This can be extended if necessary with 0.75mm twin

    core cable.

    See solar docking drawings for further details. Note: The sensors are not sensitive to polarity.

    energymaster cylinder second fix wiring

    Please note that for detail of the second fix please see the dedicatedA3 Electrical Drawings produced with each job.

    Fuse Solar circuitpump

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    6.0 FILLING AND FLUSHING THE SOLAR CIRCUIT

    Before filling the solar circuit the cylinder should first be flushed (cleansed) and filled as per the instructions in the relevant

    section of the chapter Cylinder installation and filling.

    In order to fill and flush the solar system a specialist flushing pump will be necessary, this can be purchased from Nu-Heat.

    SAFETY: Please note that if there is any significant solar irradiation, or if the panel has been left uncovered then

    there is a scalding risk from the hot fluid. There is also the possibility that if the solar panel has been exposed for

    any amount of time that the fluid could flash to steam.

    Filling should only ever be done when the system is cold, and when the panel has been suitably covered.

    It is necessary to initially flush the system using water, which can also be used for pressure testing. This must then be

    drained down and the system filled with antifreeze, and purged of air. This is described below.

    1

    2

    3

    4

    5

    67

    Solar panelarray

    Hose connectingto mains

    Hose drainingto waste

    Solar pumpingstation

    Cylinder solar coil

    flushing the solar circuit

    1. First check that the solar expansion vessel has the correct air charge of 1 bar. This must be done before the system is

    filled with fluid.

    2. Connect a hose from the mains to the filling valve (1), and another hose from the flushing valve draining to waste as

    shown in the following diagram

    3. Open the filling valve (1) and flushing valve (7)

    Operation of Flow and return ball valves (2 and 3)

    Open

    Close

    Spring

    NRV

    Internal detail

    4. Turn the return ball valve (3) by 45

    in order to open the non-return valve.

    The flow ball valve (2) should be

    horizontal, i.e. in the closed position.

    5. Turn on the mains and allow the

    water to flow through the system

    until it appears clear and free from

    debris at the drain.

    14mm

    Note: on new versions of the solar

    controller the ball valves are

    opened and closed by rotating

    the dial thermostat.

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    Solar Installation Manual

    5

    123

    4

    67

    Solar panelarray

    Hose drainingto waste

    Hose draining to waste

    Solar pumpingstation

    Cylinder solar coil

    6.0 FILLING AND FLUSHING THE SOLAR CIRCUIT cont.

    WARNING if the panel has been left uncovered then there is a scalding risk

    from the hot fluid. There is also the possibility that if the solar panel has

    been exposed for any amount of time that the fluid could flash to steam.

    Filling should only ever be done when the system is cold, and when the

    panel has been suitably covered.

    draining the water

    6. Remove the hose from the flushing valve (7) and connect it to the drain valve (5)

    7. Put the outlet of both hoses to waste, as per the following diagram.

    8. Set the flow ball valve (2) and the return ball valve (3) to 45 in order to open

    the non-return valves

    9. Open the drain valve (5) and then the filling valve (1)

    10. Allow the solar fluid (water at this stage) to drain to waste. Be aware that

    there may be fluid left in the panel and the solar coil in the cylinder

    11. Close the filling valve (1) and drain valve (5).

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    6.0 FILLING AND FLUSHING THE SOLAR CIRCUIT cont.

    filling with solar antifreeze, pressure testing the solar circuit and purging

    12. With the system drained, set up the flushing pump with the antifreeze as in the diagram on the following page, with

    the hose removed from the drain valve (5) and replaced on the flushing valve (7).

    13. Close the flow ball valve (2) by turning it clockwise. The return ball valve (3) should remain at 45.

    14. The inlet to the flushing pump should be put into the antifreeze, as should the outflow hose.

    mixing the antifreeze

    The antifreeze is supplied in 25 litre drums, filled with 10 litres of antifreeze. The other 15 litres should be filled

    completely with water, giving a concentration of 40%.

    15. Switch on the filling pump, and open the filling valve (1) and flushing valve (7). Continue to run the pump until there

    are no air bubbles at the return to the antifreeze container.Hint: Flush at a pressure of between 3-4 bar. To aid

    purging pulse the pump on and off. Also closing the flushing valve (7) to allow pressure to build up, and then

    opening it again can help clear air pockets.

    5

    1

    23

    4

    67

    Solar panel array

    Solar pumpingstation

    Connect toflushing pump

    Flushing pump

    Cylinder solar coil

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    Solar Installation Manual

    6.0 FILLING AND FLUSHING THE SOLAR CIRCUIT cont.

    16. To vent the pump close the return ball valve (3) and set the flow ball valve to 45. Release the pump vent screw to

    make sure the pump rotor is purged. Flush the pump for about a minute.

    17. Close the flow ball valve (2) and re-set the return ball valve to 45, and make sure that there is no further air in the system.

    18. Once the air has been completely purged close the flushing valve (7) and allow the pressure to rise to 5 bar.

    19. Close the filling valve (1), and shut off the pump.

    20. Set the flow ball valve (2) to 45 to open the ball valve, and ensure that the return ball valve (3) is also set at 45. Also

    make sure that the flow regulating valve (6) is open (the slot in line with the pipe).

    21. The system should now be thoroughly checked for leaks at all the joints. The pump station is tested at manufacture,

    but should still have all joints inspected for signs of leakage. Leave the system overnight and repeat the inspection.

    Note: It is not possible to rely on the pressure gauge reading to indicate the presence of a leak as the expansion of the

    fluid may give erroneous indications.

    22. Once the pressure test is complete, open the flushing valve (7) to let the pressure down to 1.5 bar, then close the

    flushing valve (7).

    23. Open the air vent (4) to remove any air from the deaerator.

    24. The solar pump should be run to compete the air purging. To do this set both the flow and return ball valves (2&3) to open

    (vertical). Switch the power on to the solar pump station. The controller should come on, as indicated by a green LED.

    25. To manually bring on the pump press the right hand button until the display reads hP then hold it down. Further options

    will become available. Use the right hand button to scroll through these until HND1 is reached. Press the middle

    button, and the SET icon will flash.

    26. Use the right -hand button to change it from Auto to ON and press the middle button again to confirm the selection.

    The pump should start running. Make sure that it is set to speed III.

    27. After about half an hour the manual air vent on the de-aerator (4) should be checked again, and then several times

    within the first day of running. This will ensure any residual air is removed.

    28. After having been left to run in this way for a several hours then the controller should be commissioned so that the solarsystem can start to draw heat from the panels.

    29. The flow rate must be adjusted for the solar circuit by varying the pump speed, and using the flow adjusting valve (6).

    The flow can be measured on the flow gauge on the pump station. The flow rate should be set to 1 litre/minute per

    panel, e.g. 3 a three panel system requires 3 litres per minute.

    30. Only at this stage should the cover be removed from the solar panels in order that they can receive solar irradiation.

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    00:00C

    K

    Backward Forward

    Set

    7.0 SETTING UP THE ELECTRICAL EQUIPMENT

    setting up the solar controller all configurations

    The solar system is supplied with the Deltasol BS controller. As supplied this is

    attached to the pumping station. If required it can be removed for positioning in

    a more convenient location.

    There are three buttons for altering the settings on the controller, as shown in

    the diagram to the right.

    In running mode the backward and forward buttons can be used to scroll between

    the collector temperature (COL), the cylinder temperature (TST) and the running

    hours (h P). It is advisable to check the calibration of the temperature sensors

    by placing them in hot water, which should also be measured with an accurate

    digital thermometer.

    To access the setup functions press and hold the Forward button. The table

    below lists all of the functions available. See the notes below about any functions

    that need the settings to be altered.

    00:00CK

    !

    SET

    Cylinder coil temperature sensor Function Setting

    Cylinder limit temperature sensor

    SET mode(flashing)

    DegreesCelsius

    DegreesKelvin

    Relay 1 activeRelay 2 active

    Maximum store limitationachieved/exceeded

    Antifreeze function activated(not generally used)Solar panel temperature sensor

    Solar panel

    Solar pump

    !& = Sensor

    defect

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    Solar Installation Manual

    7.0 SETTING UP THE ELECTRICAL EQUIPMENT cont.

    setting up the solar controller

    Channel Arr Description

    1 2*

    COL x x Temperature collector 1

    TST x Temperature store

    TSTL x Temperature store 1 bottom

    TSTU x Temperature store 1 at the top

    S3 x Temperature sensor 3TRF 1 1 Temperature return sensor

    S4 2 2 Temperature sensor 4

    n% x Pump speed relay1

    n1% x Pump speed relay 1

    h P x Operating hours relay 1

    h P1 x Operating hours relay 1

    h P2 x Operating hours relay 2

    kWh 1 1 Heat quantity kWh

    MWh 1 1 Heat quantity MWh

    Arr 12 Arrangement

    DT O x x Switch-on temperature difference

    DT F x x Switch-off temperature difference

    DT S x x Set temperature difference

    RISx x x Rise

    S MX x x Maximum temperature store 1

    Channel Arr Description

    1 2

    EM x x Emergency temperature collector 1

    OCX x x Option collector cooling collector 1

    OCN x x Option minimum limitation collector1

    OCF x x Option antifreeze collector 1

    OREC x x Option recoolingO TC x x Option tube collector

    AH O x Switch-on temp. for thermostat 1

    AH F x Switch-off temp. for thermostat 1

    OHQM x Option heat quantity measurement

    FMAX 1 1 Maximum flowrate

    MEDT 1 1 Antifreeze type

    MED% MEDT MEDT Antifreeze concentration

    nMN x Minimum pump speed relay 1

    n1MN x Minimum pump speed relay 1

    HND1 x x Manual operation relay 1

    HND2 x x Manual operation relay 2

    LANG x x Language

    PROG XX.XX Program number

    VERS X.XX Version number

    Note: Not all functions are necessary see below for details of necessary alterations.

    Note: All current Nu-Heat systems are configured as Arrangement 1 (Arr.1)

    To alter any of the function settings hold the Forward button to enter function mode.

    Scroll through the functions using the Forward and Backward buttons.

    Once the desired function is located press the Set button then use the Forward and Backward buttons to select the

    different options, then Setto confirm the selection.

    Note: If Set isnt pressed then the previous selection will remain. The programmer will revert back to running mode if left

    for a few minutes.

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    7.0 SETTING UP THE ELECTRICAL EQUIPMENT cont.

    setting up the solar controller

    S MX Maximum store temperature:

    The default maximum store temperature is 60C. This may be increased to 70C

    in order to get more solar gain from the system.

    HND1 Relay 1 operating mode:

    Relay 1 controls the solar pump, and the operating mode would usually be

    Auto. If the pump is needed to run for maintenance purposes then it can be

    switched to ON.

    cylinder thermostat and timeclock

    (energymaster solar cylinder only)

    The EnergyMaster cylinder thermostat should be set to between 6570C.

    The boiler thermostat must be set to be 10C higher than the cylinder

    thermostat setting.

    timing the cylinder for maximum solar gain

    The cylinder timeclock should be set in accordance with water usage. If domestic

    water is not going to be drawn during the day and it is judged that the solar is

    able to heat the cylinder then the boiler can be timed to be off in order to getthe most out of the solar gain. Obviously this will entail different setting for

    summer and winter.

    If the domestic water capability of the cylinder is sufficient for the early evening

    then keeping the boiler timed off will allow further solar gain, with the boiler

    then being timed to heat up any deficit for the mornings water usage.

    For more information please see theSolar User Guide.

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    Solar Installation Manual

    programming day and time

    1. Open the cover. Press the R/S

    button using a non-metallic object

    such as a matchstick. This will reset

    the timeclock to factory settings,

    including time and date.

    2. Press PROGtwice until SET ON

    TIME appears at the top of the

    display and MOTUWETHFR

    appears at the bottom of the

    display (days of the week).

    3. Use the +/-to set the first ONtime.

    SELECT

    PROG

    NEXT ON/OFF

    +

    DAY/HOL

    COPY

    R/S

    12:00 PMMO

    ON

    OFF

    AUTO

    ALL DAY

    +1HR

    MAN

    SELECT

    PROG

    NEXT ON/OFF

    +

    DAY/HOL

    COPY

    R/S

    12:00 PMTU

    SET TIME+1HR

    MAN

    SELECT

    PROG

    NEXT ON/OFF

    +

    DAY/HOL

    COPY

    R/S

    12:02 PMMO

    SET TIME+1HR

    MAN

    SELECT

    PROG

    NEXT ON/OFF

    +

    DAY/HOL

    COPY

    R/S

    12:00 PMMO

    SET TIME+1HR

    MAN

    SELECT

    PROG

    NEXT ON/OFF

    +

    DAY/HOL

    COPY

    R/S

    4:30AM

    MO

    SET TIME

    1

    ON+1HR

    MAN

    SELECT

    PROG

    NEXT ON/OFF

    +

    DAY/HOL

    COPY

    R/S

    8:00AM

    MO

    SET TIME

    2

    OFF+1HR

    MAN

    SELECT

    PROG

    NEXT ON/OFF

    +

    DAY/HOL

    COPY

    R/S

    11:15MO

    SET TIME

    6

    OFF

    PM

    +1HR

    MAN

    SELECT

    PROG

    NEXT ON/OFF

    +

    DAY/HOL

    COPY

    R/S

    12:30 PMTU

    SET TIME

    4

    OFF+1HR

    MAN

    SELECT

    PROG

    NEXT ON/OFF

    +

    DAY/HOL

    COPY

    R/S

    11:15 PMFR

    SET TIME

    6

    OFF+1HR

    MAN

    programming on/off times

    4. Press NEXT ON/OFF once only. 5. Use the +/-to set the first off time. 6. Press next ON/OFF once again and

    repeat steps 3-6 to set subsequent

    ON and OFFtimes.

    7. Press DAY/HOL and SASU will

    appear at the bottom of the screen

    (weekend).

    8. Repeat steps 3-6 to set the

    weekend times.

    9. Press PROGto return to run mode.

    Note: The timeclock will automatically adjust between GMT and BST.

    7.1 TS715 SINGLE CHANNEL TIMECLOCK

    energymaster solar cylinder only

    Ensure that the timeclock is set to your requirements as follows:

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    SELECT

    PROG

    NEXT ON/OFF

    +

    DAY/HOL

    COPY

    R/S

    12:45 AMMO

    ON

    OFF

    AUTO

    ALL DAY

    +1HR

    MAN

    7.2 SELECTING THE OPERATING MODE

    Behind the flap is the red select button; each press changes the operating

    mode as follows:

    ON The output is constantly on.

    OFF The output is constantly off unless +1hr is pressed.

    AUTO The output switches on and off to the set programme.

    ALLDAY The output switches on at setting 1 and stays on until setting 6.

    operation

    If the colon is blinking the unit is in run mode. It will

    automatically switch the underfloor heating on and off

    at the times set. However, useful overrides are provided

    which enable the user to make temporary changes to the

    on/off times without re-programming the unit.

    manual overrides

    When in OFF, AUTO or ALLDAY modes the +1HR buttoncan be used to switch from OFFto ON for just one hour,

    or to extend an existing period by one hour. This will be

    cancelled by pressing the +1HR button again, pressing the

    MAN button or when the next ON programme is reached.

    When in AUTO or ALLDAY modes pressing the MAN

    (manual) button will switch from ONto OFF, and vice

    versa. This override will only last until the next programmed

    change, when the automatic programming will resume, or

    until the button is pressed again.

    When the above overrides are selected a bar appears inthe display against the appropriate legend.

    reset

    Should the timeswitch be disconnected from the mains a

    small battery symbol will blink on the left of the display.

    After the second midnight (between 24 and 48 hours) the

    display will go blank and settings will be lost. When mains

    power is restored it is recommended that the unit be reset

    by inserting a non-metallic object such as a matchstick in

    the R/S hole under the flap. This will restore the factory

    settings including the time and date. The output will beOFF. Note that the colon will be blinking, meaning that the

    unit is in RUN mode and will switch ON and OFF according

    to the factory programming until reset.

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    Solar Installation Manual

    7.2 SELECTING THE OPERATING MODE cont.

    choice of 12- or 24-hour clock

    At any time whilst in run mode the time displayed can be toggled between a

    12-hour clock with an am/pm indicator or a 24-hour clock by pressing and

    holding both DAY/HOL and next ON/OFF buttons for 2 seconds.

    g.m.t./b.s.t.

    The timeclock is programmed to automatically switch between GMT and BST.

    factory pre-set programme

    The unit will be pre-set to 7-day/24-hour mode; this can be altered by moving

    the pins under the backplate.

    Firstly remove the screws under the unit and remove the front face.

    There are three operating modes available:

    1. 24 hour operation; the same

    programme each day,

    2. 5-day/2-day operation; different

    programmes for weekdays and

    weekends,

    3. 7-day operation; different

    programmes for each day.

    Set the pins as shown for the operating mode required.

    The pre-set factory ON/OFFtimes can be reinstated by pressing the recessed

    R/S button with a non-metallic object such as a matchstick. Please remember

    that underfloor heating takes longer to warm up and cool down than conventional

    radiators and the heat settings should reflect this. The factory settings are

    unlikely to be appropriate.

    1 2 3 4

    1 2 3 4

    1 2 3 4

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    7.3 USER CONTROLS IMMERSION HEATER TIMER

    preheat cylinder with 360p exhaust air heat pump and 1240 ground source heat pump only

    The preheat cylinder has an immersion heater to provide legionella protection.

    protection from bacterial growth, e.g. legionella

    With a preheat solar cylinder feeding a Heat Pump the immersion heater at the bottom of the cylinder is designed to

    purge the preheat cylinder to protect it from potential legionella growth. The timer controls the immersion heater.

    The Heat Pump has an Extra Hot Water temperature boost which should be programmed to be on at the same time as

    the cylinder immersion so that the whole storage volume is purged by raising it to 60C.

    A purging cycle should be timed for at least once a week (depending on your assessment of risk). It is advised that this is

    done over-night so as not to detract from the period of solar gain. This will be set up during the heat pump

    commissioning process.

    Note: Heating the water will not be dangerous to users, as the blending valve protects users from high temperature water.

    For the 200 litre cylinder the purging cycle should be run for 4 hours in order to ensure that the cylinder reaches

    the desired temperature.

    For the 300 litre cylinder the purging cycle should be run for 6 hours in order to ensure that the cylinder reaches

    the desired temperature.

    This is the worst case timing. If the cylinder is already hot then the thermostat will switch the immersion heater off when

    temperature is reached. The thermostat will be set at 60C during the commissioning process.

    programming the immersion heater timer

    Refer to manufacturers instructions.

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    Solar Installation Manual

    APPENDIX 1 AQUASTAR HOT WATER LOOP

    The Aquastar2 instant hot water loop (or for larger systems, Aquastar3) may be

    used with many modern hot water cylinders to give hot water at the taps without

    delay. The hot water loop will remain hot as dictated by the timer settings. Hot water

    drawn outside of the set times will take time to flow hot, as if the hot water loop

    were not present. The Aquastar hot water loop provides the ideal basis for the

    connection of towel rails throughout the house as very little extra plumbing is

    required. Heat for the towel rails is drawn from the existing heat reservoir in

    the hot water cylinder, usually without the need to bring on the boiler.

    Notes:

    The Aquastar hot water loop is only suitable for mains pressure hot water cylinders.

    Check that the installation of a pumped hot water loop is consistent with local

    water bye-laws.

    As the towel rails are heated by mains water they must be non-ferrous to prevent

    corrosion. The total output from all towel rails connected to the hot water loop must

    not exceed 5000 watts. Please contact Nu-Heat if the total output will be greater.

    The temperature of the loop, and therefore of the towel rails, is thermostatically

    controlled to prevent scalding. On the side of the Aquastar2 circulating pump

    there is a thermostat or, on larger systems, there is a separate thermostat

    mounted on a nearby pipe.

    The return temperature of the hot water loop should be 50C or greater in

    accordance with BS6700 and the HSCs Legionnaires disease: The control of

    legionella bacteria in water systems Approved Code of Practice and Guidance.

    If the temperature of circulation necessary to achieve this poses a significant risk of

    scalding then the temperature should be blended as close to the outlet as possible.

    12:00

    Discharge

    Larger systems have Aquastar

    components supplied as separate items

    Pump

    Expansionvessel

    Timeclock

    Non-return

    valve

    Flush/drain

    Pipe stat

    Appearance ofpumps may vary

    The hot water loop should be run

    throughout the year. If it is inactive for

    more than a week there is a risk of bacterialgrowth, such as legionella.

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    Careful thought should be given to the layout of the hot

    water loop and the fittings used on it. Flow pipework to

    bathrooms should be sized according to the hot water

    requirements of the household. Typically a small to

    medium sized installation will require 22mm flow

    pipework, a large installation may require 28mm or greater.

    15mm pipe may be used for the last 2 metres where thepipe connects to the Aquastar2 pump (22mm for Aquastar3).

    Individual hot water outlets should be fitted with flow-limiting

    valves to prevent unnecessarily high water flow rates affecting

    the water pressure at critical points such as shower units.

    It is recommended that only lockshield valves are used

    with towel rails on a secondary hot water loop. Towel rails

    should not be isolated from the loop for any significant

    amount of time (more than a few days) or there is a risk of

    bacterial growth, such as legionella. Fit a balancing valve or

    towel rail at the farthest end of each loop. If bathrooms are

    to be connected to the hot water loop in parallel, balancing

    valves must be fitted on each leg so that balancing betweenbathrooms can be effective (see illustration). The hot

    water flow and return pipes should be insulated to prevent

    unwanted heatloss. This is particularly important where hot

    pipes run alongside the supply pipes to cold tap.

    APPENDIX 1 AQUASTAR HOT WATER LOOP cont.

    Radiatorlockshield

    valves

    Outlet balancingvalvesPump

    Flush/drain

    Discharge

    For cylinder connection details refer tocylinder manufacturer

    planning and installing

    the loopBathroom 1

    Bathroom 3 Kitchen Utility

    Bathroom 2

    Loopbalancingvalves

    Non-returnvalve

    (may be partof pump)

    out

    return

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    Solar Installation Manual

    E

    N

    L

    E

    N

    L

    N

    L

    N L 1 2 3 4

    N

    L

    N

    L

    SL

    E

    L

    SL

    E E E

    N L SL E

    90

    70

    50

    30C

    SL L E

    Switched Live

    Live

    Neutral

    Earth

    Live voltagemarker sleeve

    KEYNote: colour ofwires may varyfrom those shown.

    Earth whererequired.

    SL

    L

    N

    E

    aquastar 2 hot water loop

    aquastar 3 hot water loop

    Switched fused 5A spur

    Domestic hot water pumpwith integral timeclock

    and thermostat

    Switched fused 5A spur Single channel timeclockMP1CP-C (type TS715)

    Internal wiring

    Pipe thermostat

    Internal wiring

    Domestic hotwater pump

    APPENDIX 1 OPTIONAL HOT WATER LOOP PUMP

    second-fix: nu-heat aquastar hot water loops

    Notes: See introduction for wiring safety notes.

    These diagrams should be read in conjunction with any third party manufacturer

    documentation.

    Fit link betweenterminals L and 1

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    APPENDIX 2 SOLAR SYSTEM MAINTENANCE REQUIREMENTS

    The following checks should be carried out at the specified time intervals. A record

    should be kept that all checks items were found to be satisfactory. If possible,

    the installer should be engaged for maintenance work.

    Note: Collector checks will more than likely require access to the roof. This

    should not be attempted without a suitable risk assessment being completed.

    annually:

    collector

    Collector glazing is undamaged.

    Collector glazing is reasonably clean.

    There is no visible evidence of leakage on the roof

    Where visible, absorber paintwork or coating is sound.

    The roof fixings are firm and the roof covering satisfactory by visual inspection.

    solar circuit

    The solar system pressure is correct according to the pressure gauge

    (1.5 bar +/- 0.2 bar)

    There is no visible evidence of leakage

    Safety valve manually checked Antifreeze concentration checked. Should protect to -19C.

    Deaerator checked for air buildup

    Electrical controls and temperature sensors are operating correctly

    Flow rate remains at level stated on commissioning certificate

    The circulating pump is operating without due noise.

    Pipework insulation is firmly in place.

    There are no condensation or damp spots, particularly around the pipework

    and fixings in the roof space.

    All safety and information labels are in place.

    every 5 years:

    The system should be emptied, flushed and refilled with fresh antifreeze

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    Solar Installation Manual

    7

    APPENDIX 3 SOLAR DECOMMISSIONING SCHEDULE

    energymaster cylinder

    Should it be necessary to decommission for maintenance or in the case of a fault

    the system the panel will need to be covered to prevent further solar irradiation,

    the power supply switched off. The expansion volume of the system should be

    sufficient for the system to be left with fluid in it. An engineer should be called

    as soon as possible to enable the system to be brought back into normal operation.

    The panel covering must be robust enough to stay in place until it is possible

    to re-commission the system.

    Should it be necessary for any reason to drain the solar circuit this is done as follows:

    1. Connect hoses to the filling valve (1), and drain valve (5)

    2. Put the outlet of both hoses to waste, as per the following diagram.

    3. Set the flow ball valve (2) and the return ball valve (3) to 45 in order to open

    the ball valves.

    4. Open the drain valve (5) and then the filling valve (1)

    5. Allow the solar fluid to drain to waste. Be aware that there may be fluid left in

    the panel and the solar coil in the cylinder

    6. Close the filling valve (1) and drain valve (5).

    7. The panel covering must be robust enough to stay in place until it is possible

    to re-commission the system.

    Solar panel array

    Solar pumpingstation

    Hose drainingto waste

    Hose drainingto waste

    Cylinder solar coil

    5

    6

    123

    4

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    APPENDIX 4 ROTH HELIOSTAR 218 & 252

    en 12975 conformity certificate

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    Solar Installation Manual

    All voltages

    isolator

    All voltages

    supplementary

    All voltages pump

    All voltages

    support

    All voltages fuse

    All voltages

    sheath and wiring

    All voltages cable

    All voltages class 2

    ELV segregation

    A double pole isolation for the fitted solar equipment i.e. controller/

    pump/valves, typically with a switched fused spur either located adjacent

    to the pump or controller.

    Supplementary (equipotential) earth bonding to be replaced where already

    present. Usually required for simultaneously accessible exposed and

    extraneous conductive parts. This typically includes pipes and pump

    housings, etc.

    Solar pump or other similar solar primary item to be connected via heat

    resisting flex/cord (not fixed cable), marked at least to tolerate 85KC

    and cable sheath clamp to be correctly used.

    Fixed wiring clipped correctly with mechanical protection (trunking, etc.)

    if at risk of physical impact. Minimum clip spacing 250mm horizontal,

    400mm vertical. No PVC cable to be in contact with copper pipes. Externalcables greater than 30cm are to be supported. All cables to be protected

    from sharp edges, etc. by purpose guides or grommets.

    Over-current protection should be present of the correct capacity for

    cables and connected appliances.

    Conductor sheath to be continuous into joint enclosures, conductors to

    be securely fastened to terminals, conductor insulation to be within 2mm

    of terminals.

    All cable conductors external of joint enclosures to be insulated and

    sheathed. External cables to be UV stable.

    Class 2 double insulation marked on all appliances normally intended for

    user operation.

    The separation between cables of different voltage classes should be at

    least 50mm, or placed in a separate conduit/trunking, or both insulated

    for highest voltage present.

    APPENDIX 5 SAMPLE INSTALLATION CHECKLIST

    For solar sealed primary systems drainback and fully filled.

    Elec 1

    Elec 2

    Elec 3

    Elec 4

    Elec 5

    Elec 6

    Elec 7

    Elec 8

    Elec 9

    electrical wiring

    ref item description initials

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    All voltages

    enclosures

    ELV cable joints

    All voltages

    location

    All electrical enclosures, including existing outlets from which spurs have

    been taken, to be refitted so as to ensure touch-proof connections and

    durability in service. Elec 13 ELV cable joints. All cable joints to be

    touch-proof and in joint boxes suitable for the installed environment,

    e.g. IP20 indoor, IP56 outdoor.

    All cable joints to be touch-proof and in joint boxes suitable for the installed

    environment, e.g. IP20 indoor, IP56 outdoor.

    All controllers, pumps, etc. to be installed in suitable environments, not in

    bathrooms and not accessible to people using a bath or shower. Equipment

    mounts to be secure and durable for the life of the installation. Location to

    be accessible for service and user operation if intended (e.g. temperature

    displays to be visible where available).

    APPENDIX 5 SAMPLE INSTALLATION CHECKLIST cont.

    Elec 10

    Elec 11

    Elec 12

    electrical wiring

    ref item description initials

    The glazing seals

    are weather-tight

    and sound

    Collector sensor

    clamped, insulated

    from ambient

    External pipesinsulated

    Shading

    Roof fixings

    Requires roof inspection. Where suspect, tested by 1 Bar water spray

    perpendicular and horizontal, then visual for drips/condensation mist

    inside glass.

    If temperature sensor is present, it should be a good mechanical fix, insulated

    and not loose.

    Where insulated, protected from UV, weather and vermin.

    No significant daily shading for more than two hours between spring

    and autumn.

    Requires roof inspection and within loft (to see sarking felt, etc). Where

    suspect, further tested by 1 Bar water spray perpendicular and horizontal

    then visual for drips/condensation. Fixings to be firmly attached to the

    roof structure and visual inspection that the roof covering is weatherproof.

    Roof 1

    Roof 2

    Roof 3

    Roof 4

    Roof 5

    roof

    ref item description initials

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    Solar Installation Manual

    Indicator of

    circulation

    The recommended

    flow-rate is

    achieved through

    the primary circuit

    pipework

    System is at the

    correct operating

    pressure

    Reverse flow

    protection

    Initial 100 Celsius

    prevention

    Secondary 100

    Celsius prevention

    Tertiary 100

    Celsius prevention

    The safety devices

    are operatingcorrectly

    Gaseous bubbles

    expelled from the

    transmission liquid

    Safe means to verify the designed circulation to the end-user, i.e. two

    thermometers (Flow/return temperatures), flow-rate indicator or other

    fault indicator.

    Requires an indicative flow indicator to be fitted i.e. in-line meter or

    electronic monitor. Flow rate checked against manufacturers

    recommendation. Engage override switch to test if solar gain is not present

    or observe normal circulatory function.

    Pressure gauge dial to show at least greater than static head. Checked

    when pump on and off.

    A device to prevent heat loss from unintentional reverse circulation.

    Thermostatic control of secondary storage (i.e. shut off primary circulation

    with automatic restart or self-setting temperature relief valve to EN 1490).

    Additional to Operation 5: unless a dedicated cold water cistern feeds the

    DHW store (i.e. is also open vented), then a manual reset device to cut off

    thermal energy (i.e. where collector wholly above store, then switch off

    pump or otherwise motorised valve).

    In addition to Oper 5 & 6, heat dissipation to control secondary storage to

    below 100C (e.g. temperature/pressure relief valve).

    Open vent and/or safety valve terminate in safe positions with low risk of

    accidental steam escape.

    Assessed by noise and through excessive noise with maximum circulation.

    Requires override switch to test or observe normal function if solar gain is

    not present.

    APPENDIX 5 SAMPLE INSTALLATION CHECKLIST cont.

    Oper 1

    Oper 2

    Oper 3

    Oper 4

    Oper 5

    Oper 6

    Oper 7

    Oper 8

    Oper 9

    operation

    ref item description initials

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    Contamination

    Drain point

    Fittings in contact

    with utilitys water

    Vent termination

    Pressure Equipment

    Regulations (PED)

    Sound

    engineering practice

    or higher conformity

    Temperature of

    materials

    Indoor components

    freezing

    Anti-scald

    Pressure limit

    If fitted, temporary connection to sealed system should have double check valve

    (fitted to cold water side), control valves both sides and flexible hose

    disconnected. For cisterns, 20mm air break (or twice pipe diameter) to spill level

    at float valve.

    Accessibly fitted on all low points, including pre-heat store.

    All fittings in contact with original utility supply of water must be marked

    with certain third party approvals and suitable for attached solar collector

    stagnation temperatures and pressures. Non-metallic materials in contact

    with utility supplied water meet the relevant parts of BS 6920 and be

    suitable for the purpose to which they are intended to be subjected.

    Primary vent into primary cistern, secondary into secondary. Vent pipes to

    be no less than 19mm ID, no reduction in bore, no deformable material

    and be insulated.

    If collector is not EN 12975, then assembled system must protect collector

    to below maximum design temperature. If system and collector are not

    designed and built along traditional lines (i.e. the assembled products and

    materials do not have a history of long and safe use) with each pressure

    component labelled, then evidence left on site of higher conformity.

    Pipe clips and insulation should withstand collector stagnation temperatures if

    in direct contact with pipe work or where there is foreseeable risk of contact.

    Components subject to risk of freeze damage to be protected i.e. trace

    heated, antifreeze.

    If secondary system can be heated to more than 60C from the solar, theneither an adjustable automatic blend valve (anti-scald) to be fitted to the DHW

    distribution, or automatic pump control to be capable of l imiting to 60C.

    Route from collector to over-pressure safety via non-deformable pipe with

    no possibility of blocking, diameter reduction, valve closure, scaling or freezing

    to the point of discharge. Discharge constantly falling and unobstructed. No

    risk to people, materials or environment from termination location.

    APPENDIX 5 SAMPLE INSTALLATION CHECKLIST cont.

    Gen 1

    Gen 2

    Gen 3

    Gen 4

    Gen 5

    Gen 6

    Gen 7

    Gen 8

    Gen 9

    general

    ref item description initials

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    Solar Installation Manual

    Limescale

    prevention pipes

    Limescale

    prevention

    exchanger

    Insulation

    Pre-heat store

    sensor

    Legionella

    All unions andglands are free

    from leaks

    Pipework

    Pipework

    insulation

    Making good

    No possibility of lime deposit in circuits that would significantly affect

    performance within collector primary loop in the lifetime of the system.

    If limescale risk in secondary circuit is above 100mg/l (calcium carbonate

    equivalent) then store to have control to prevent secondary water being

    solar heated greater than 60C, or a cleaning facility to be provided for

    heat exchanger (i.e. plate exchanger or cylinder hatch).

    When replaced, non-solar pipes connecting to store to have minimum 1

    metre insulation to concealment point.

    Sensor clamped and insulated from ambient.

    Check presence and function of auxiliary heat source with control fitted to

    heat at least 60C.

    Evident from stains or by moisture on pipes and fittings.

    All pipework is adequately secured and insulated and components are

    adequately supported. Pipes and fittings should be securely fixed whilst

    allowing for thermal movement (overhead pipes must use clip-over type).

    Rigid pipe spacing horizontal 1.8m, vertical 2.4m; non-rigid pipe spacing

    horizontal 0.3m, vertical 0.5m.

    All pipe insulation is firmly in place, including on roof. No significant gaps

    on slits, clips and ends.

    Penetrations in building made good. Debris removed.

    APPENDIX 5 SAMPLE INSTALLATION CHECKLIST cont.

    Gen 10

    Gen 11

    Gen 12

    Gen 13

    Gen 14

    Gen 15

    Gen 16

    Gen 17

    Gen 18

    general

    ref item description initials

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    Method for assessing solar water heaters. Elastomeric materials for absorbers, connecting pipes

    and fittings.

    Code of practice for solar heating systems for swimming pools.

    Performance characterisation of stores for solar heating systems.

    Thermal solar systems and components. Custom built systems. Test methods.

    Thermal solar systems and components. Custom built systems. General requirements.

    Solar energy. Vocabulary.

    Thermal solar systems and components. Factory made systems. Test methods.

    Thermal solar systems and components. Factory made systems. General requirements.

    Thermal solar systems and components. Solar collectors. Test methods.

    Thermal solar systems and components. Solar collectors. General requirements.

    APPENDIX 6 FURTHER READING

    BS 7431

    BS 6785:1986

    prEN 12977-3

    prEN 12977-2

    prEN 12977-1

    BS EN ISO 9488

    BS EN 12976-2

    BS EN 12976-1

    BS EN 12975-2

    BS EN 12975-1

    solar standards

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    Solar Installation Manual

    APPENDIX 6 FURTHER READING cont.

    Workmanship on building sites.

    Specification for unvented hot water storage units and packages.

    Requirements for electrical installations.

    Copper indirect cylinders for domestic purposes.

    Specifications for expansion vessels using an internal diagraph for sealed hot water heating systems.

    Application, selection and installation of expansion vessels and ancillary equipment for sealed

    water systems.

    Methods of specifying thermal insulation materials on pipes, ductwork and equipment in the

    temperature range of -40C to 700C.

    Specification of forced circulation hot water central heating systems for domestic premises.

    Telecommunications equipment and telecommunications cabling.

    Code of practice for thermal insulation of pipes and equipment.

    Specification and design, installation, testing and maintenance of services supplying water for

    domestic uses within buildings and their curtilages.

    Lightning Protection Code of practice for protection of structures against lightning.

    Code of practice for roofing and tiling Design.

    Suitability of non-metallic products for use in contact with water intended for human consumption

    with regard to their effect on the quality of the water.

    BS 8000

    BS 7206

    BS 7671

    BS 1566

    BS 4814

    BS 7074

    BS 5422

    BS 5449

    BS EN 12831

    BS EN 12828

    BS 6701

    BS 5970

    BS 6700

    BS 6651

    BS 5534

    BS 6399

    BS 6399BS 6920

    other relevant standards

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    DESIGN | INNOVATION | EXPERTISE | SERVICE

    If there is any aspect of the installation that you do not understand, please

    contact Nu-Heat Technical Support for advice.

    All illustrations and diagrams in this manual are the property of Nu-Heat.

    All rights reserved. No part of this publication may be reproduced, stored

    in a retrieval system, or transmitted in any form or by any means electronic,

    mechanical, photocopying, recording or otherwise without prior written

    permission of Nu-Heat.

    Heathpark House, Devonshire Road,

    Honiton, Devon EX14 1SD

    Tel: 01404 549770

    Fax: 01404 549771

    Web: www.nu-heat.co.ukEmail: [email protected]

    Nu-HeatU N D E R F L O O R & R E N E W A B L E S