Installation & Operating Instructions for Flat Plate
Contents
1. 1 screw M8 x 20 2 washer 3 serrated lock washer 4 M8 nut Strictly follow above sequence when locking Installation and operating instruction for flat plate solar collectors ES2DU0 amp ES3TRI range inclined tile roof Repeat for next row of roof fixing 2 then level the Profile Rail edges top and bottom and tighten up all locking screws 6 Te EE Heh M ih Wi an il Lil M Wit PAT he oii f N i PEL hh UT i Hue UT fyi il HT T ip j i j i i ponin appn oon Ht HA WL ff AT Hf bit HHN Ii HE ly j i gL Important Depending on the type of tiles some tile material may need to be removed in order to put the tiles back into position 4 4 Locking screws for Collector Clamp Put the locking screws 6 into the Profile Rail top and bottom to fix the Collector Clamp 3 Put the locking screws into the Profile Rail 1 as shown on the picture a eg E rE P PE n is ii F ae oe re PU eee ee ee ri u ir i Fe y PN fi Ei e a ee Hit F FI sit ae p i i Fi i td ffpef Uh viene ij i Ait ii Wit BME ATM UA aa EL D NT Hi There are two Clamps 3 between Collectors so two locking screws 6 must be fixed and only one Clamp 3 on the edge set At this stage you can put aside the locking screws 6 for Collector edges to fix them after you place the Collectors The screws for Clamp 3 between Collectors have to be located symmetrically toward the Profile2. Rail centre Space requirements approx 1130 mm om i as 11 Installation and operating instruction for flat plate solar collectors ES2DU0 amp ES3TRI range inclined tile roof 4 5 Assembly of Collector Graspers Fix Collector Graspers 4 onto bottom Profile Rail 1 Hook the Collector Grasper onto bottom Profile Rail 1 and push downward to the final position Locate the first Grasper 4 at B distance away from Profile edge For the other graspers keep the distance of 700mm and 440mm alternate LOL HATELY AT nT UT th i 4 oe Important The distance between Collector Graspers is maintained correctly when the last Grasper is at B distance away from opposite edge of Profile Rail Installation and operating instruction for flat plate solar collectors ES2DU0 amp ES3TRI range inclined tile roof 4 6 Assembly of Collector Check all connections before first Collector installation Important Protect Collector against potential damage slide and fall accidents that could occur when transporting solar Collectors on the roof Position the bottom edge of Collector against the Profile Rail 1 Slide the Collector carefully onto the two Graspers 4 then lean the Collector on the top Profile Rail 1 if f Ey p Fd 4 fh f a f A 4 d A f 4 i Mi Ji fp pf 7 da FF AA y A ei sf d d H A Plac
3. System in order to ensure a safe risk free installation and trouble free operation Following installation and commissioning of the system the operation of the system and associated controls should be explained to the customer and these instructions left with them for future reference EHC Thermal Solar System must be installed in accordance with the manufacturer s instructions and all relevant regulations in force at the time of installation The EHC Thermal Solar System is subject to Building Regulation G3 England and Wales Technical Standard P3 Scotland or Building Regulation P5 Northern Ireland Installation and must be carried out by a competent person Working at Height It is mandatory that the Working at Height Regulations WAHR is adhered to at all times A site Risk Assessment must be conducted before operations take place such that suitable precautions are put in place to eliminate or at the very least minimize risks of injury not only to installers but to also protect the general public Lightning Protection If the Solar Collector System is installed over a height of 20 M and the building is without a lightning protection system then couple the electrically conductive elements to the earth min earth section 16mm and the equipotent bonding elements of the installation If the Solar Collection System does not exceed a height of 20 meters then a lightning protection system is not necessary Where a building is equipped wi
4. and Renewable Energy in Warsaw 1 4 Efficiency graph Solar Collectors a efficiency graph is 2 related to the active surface area of absorber 30 for G 800 W m 40 50 60 70 80 90 100 tm ta K Installation and operating instruction for flat plate solar collectors ES2DU0 amp ES3TRI range inclined tile roof 1 5 Domestic hot water heating installation diagram A T1 l Solar pump group 2 Valves for filling emptying and flushing of Solar circuit 3 Hot water tank Ti Collector temperature sensor Ti Tank temperature sensor K Solar Collector NW Expansion vessel ZB Safety valve ZW Cold water inlet CW Hot water outlet LB 3 A cease Weiiaine P o e ee CW Qo M LC NW Qe 2 o ily Z N a Solar installation must be in compliance with the BS EN 12975 12976 norm 1 6 Identification labels An identification label is placed on the both sides of the Collector at the bottom Additionally the warning and information icons are placed on the left side of Collector User Be aware The user is obligated to replace the identification labels where these are unable to be read 2 Safety Instructions 2 1 2 2 2 3 2 4 2 6 General Please carefully read and understand these instructions before installing the EHC Thermal Solar
5. shaft Important Run the temperature sensor wire along with return flexible hose Consideration must be given to the diameter of solar tubes The proper diameter of tubes is determined by flow rate of heating medium O 4 0 7 m s1 The table below shows the diameter of tubes recommended according to quantity and type of solar Collectors ES Collector Number of Collector Arrays Diameter of collecting Collectors tube mm EO Installation and operating instruction for flat plate solar collectors ES 2 0 ES A 2 0 amp ES A 2 3 inclined tile roof 5 6 Final Commissioning 5 1Check Up 5 2 5 3 Once the installation has been completed the system must be flushed hydraulic tested and system filled with Solar Fluid In order to carry out these tasks a solar pump and expansion vessel need to be installed Please refer to the manufactures installation amp operating instructions for operation of these items The following steps require to be completed make sure all elements of solar installation are fixed correctly flush the pipe system perform hydraulic pressure testing fillthe system with solar fluid Venting Use charging de aerating station for filling and flushing solar installations When the automatic air vent opens you must turn off the shut off valve once the venting has been completed This shut off valve is located before the vent System protection Once th
6. Installation amp Operating Instructions for Flat Plate Solar Collectors on inclined tiled roofs Harp Copper Absorber Harp Aluminium Absorber ee a a T T ETRY ili Wik j fy Wh I yi bhi il ETI lij j i WA j f E Pil LT LLL LLL TLD EEL DEP NN lihi AAT OE ETEN TTI mace mel LALLA yi Unit 40 Block 5 Thi oad Blantyre Industrial Estate Blantyre Glasgow G72 OUP Tel 01698 820533 Fax 01698 825697 Email info ehc renewables co uk WWW ehc renewables co u Installation and operating instruction for flat plate solar collectors ES2DU0 amp ES3TRI range inclined tile roof Contents 1 General information 1 1 ES Solar Collector 1 2 Types of Solar Collectors 1 3 Technical data table 1 4 Efficiency graph 1 5 Domestic hot water heating installation diagram 1 6 Identification labels 2 Safety instructions 2 1 General 2 2 Working at height 2 3 Lightning protection 2 4 Installers 2 5 Mounting kits 2 6 Risk of burn injury 2 7 Transportation storage and handling 3 Pre Installation 3 1 Collector mounting kit 3 2 Technical documentation 3 3 Tools and additional equipment 3 4 Collector location 3 5 Key dimensions 4 Collector Installation 4 1 Roof fixing 4 2 Mounting Rails connection 4 3 Mounting Rails assembly 4 4 Locking screws for Collector Clamp 4 5 Assembly of Collector Graspers 4 6 Assembly of Collector 4 7 Assembly of additi
7. Please note that invoices for servicing may be requested to prove that the unit has been serviced annually by a competant MCS certified installer service person EXCLUSIONS THE GUARANTEE DOES NOT COVER the effects of scale build up any labour charges associated with replacing the unit or its parts nor any consequential losses caused by the failure or malfunction of the unit For advice support or further information on EHC s full range of heating products call now on 01698 820 533 ola The EHC Ltd Unit 40 Block 5 Third Road Blantyre Industrial Estate Blantyre Glasgow G72 OUP Tel 01698 820533 info electric heatingcompany co uk Fax 01698 825697 www electric heatingqcompany co uk 19
8. afety harness for use with a safety rope e Scaffolding ladder or lift 3 4 Collector location The Solar Collector surface must be in perpendicular position to the sun s rays to obtain the most efficient radiation absorption and there fore must be installed on the south side of inclined roofs Recommended Collector position Angle to sun 40 45 all year round 30 approx Summer time 60 approx winter time e Maximum snow and wind load capacity 2 0 kN m7 e Do not install solar Collectors if the slope value is less then 15 and more then 75 e There should be no shading from trees chimneys and neighbouring tall buildings e For Collectors in a row the row to row solar panel shading has to be considered Note The information and drafts in this instruction refer to the vertical Collector assembly only 3 5 Key dimensions ooo y a G o Installation and operating instruction for flat plate solar collectors ES2DU0 amp ES3TRI range inclined tile roof 4 Collector Installation 4 1 Roof fixing Having decided on the location for the Collector locate the internal horizontal roof rafters Bear in mind that lower roof rafter must be located approx 600 mm above bottom edge of the Collector mounting position whereas the upper roof rafter must be located approx 1600 mm 200 above it Remove some roofing tiles to get access to the roof rafters Horizontal roof rafter 1600 Fix to the r
9. correct outlet connection sequence is use the Clamping piece to connect cross pipe 2 to Collector connector 1 lock flexible hose 3 onto cross pipe 2 connect flexible hose to solar installation system Standard Solar Mounting Kitincludes manual air vent however you can install an automatic vent instead For the automatic air vent install ball valve between cross pipe and air vent Important As solar systems reach high temperatures installation of the vents and valves must be made of metal only 4 12 Temperature sensor Solar system malfunctions Most solar system malfunctions are caused by faulty temperature sensor installation or damage to the signal cable To prevent damage to the signal cable by birds or rodents ensure the signal cable is encased by a corrugated pipe Install temperature sensor into immersion sleeve insert temperature sensor all the way down into immersion heater prevent Clamping spring from sliding out Installation and operating instruction for flat plate solar collectors ES2DU0 amp ES3TRI range inclined tile roof 4 13 Collecting pipes Use flexible insulated hoses to make hydraulic connection to collecting pipes Connection of flexible hoses with solar installation must be made below vent valve level Do not connect inflexible collecting tubes directly to Collector Important Run the solar tubes through the roof by universal pass through for roofing or air
10. e above system testing has been carried out the Thermal Solar Collectors must be protected from the heat of the sun amp potential damage from birds and rodents A waterproof amp heat resistant insulated cover must be fitted over the complete Thermal Solar installation i e including all electrical sensors amp control cables Maintenance and Service 18 Maintenance personnel should before starting work conduct risk assessments and take suitable precautions in order to prevent slips trips and fall accidents When moving the Collector to carry out maintenance work ensure these are secured prevent falling Use suitable tools and equipment Use personal protective equipment e g protective gloves overalls boots etc Check Collector temperature before executing any maintenance work do not attempt maintenance while Collector is hot Solar system inspection must be carried out according to warranty guide of any supplied components Annual routine maintenance checks are recommended to assure trouble free solar system operation Frost Protection Determine the frost resistance of solar fluid using the refractometer Refill and vent the solar circuit if the frost resistance of liquid drops below 20 C System Pressure Control the working pressure of solar circuit drop pressure should not occur Expansion Vessel control the initial pressure of expansion vessel Disconnect the expansion vessel from the system a
11. e the Collector symmetrically towards Graspers 4 then fix the four Clamps 3 Fixing the Clamps Put the Clamp 3 onto locking screw the screw 6 that was placed into the Profile Rails 1 earlier see sub clause 4 4 then bring two elements as close as possible to Collector and put the Clamp 3 onto Collector angle bar Next put a washer serrated lock washer into position and lock the nut lightly LPT Adjust the final position of Collector Installation and operating instruction for flat plate solar collectors ES2DU0 amp ES3TRI range inclined tile roof 4 7 Assembly of additional Collectors Additional Collectors included in the set fiji LJ LO excluding one piece Collector set must i WAN be fixed on the Profile Rail 1 follow the 4 F 3 installation work sequence described in HLT sub clause 4 6 and make a hydraulic connection of Collectors at the same time Vil according to sub clause 4 8 Ai Keep the distance between the Collectors relatively constant approx 64 mm 4 8 Hydraulic connection 1 Collector connector 2 Nut 3 Clamping ring 4 Expansion joint Important Maximum number of Collectors in one row is 5 pieces The correct Collector connection sequence is undo the nut 2 then put the nut onto connector 1 put the Clamping ring 3 onto connector lock the nut 2 into expansion joint 4 put the nut onto connector of second Collec
12. nd determine the rate of pressure The initial pressure should be 0 3 bar lower than filling pressure i e Normally 2 5 to 3 bar Cleaning the Collectors When necessary clean the Collector using a general cleaning solution i e mix the washing soda or soap liquid with water then apply and rinse with water Control and safety system Check the control and safety system as well as support structure of Collectors It is recommended that maintenance is carried out by a MCS Certified Installer to assure continued reliable performance of the system 7 Guarantee The EHC Thermal Solar System is guaranteed against faulty materials or manufacture provided that It has been correctly installed as per this e It has not been subjected to frost damage document and all the relevant standards regulations and codes of practice in force at the e The unit has been serviced annually time e The guarantee period starts from the date of It has not been modified in any way other than by purchase and no registration is required the manufacturer e The extended guarantee is not transferable and rests It has not been misused tampered with or with the original householder subjected to neglect e The system is fed from a public water supply e It has only been used for its intended purpose The following Guarantee periods apply from date of purchase Solar Collectors amp Mountings 10 years Electrical componnts amp equipment 2 years
13. onal Collectors 4 8 Hydraulic connection 4 9 Inspection after assembly 4 10 Inlet connection 4 11 Outlet connection 4 12 Temperature sensor 4 13 Collecting pipes 5 Final Installation amp Inspection 5 1 Check up 5 2 Venting 5 3 Insulation 6 Maintenance and service 7 Guarantee O DDAAAOAON VN DAAMVAGOGH M Saa rhp sh SL A Installation and operating instruction for flat plate solar collectors ES2DU0 amp ES3TRI range inclined tile roof 1 General information 1 1 ES Solar Collector ES range of solar Collectors are intended to heat water for domestic properties and public utility buildings The ES Collectors can also be used to support central heating systems and heat water for swimming pools 1 2 Types of Solar Collectors ES4210709 Harp Solar Collector copper absorber surface area 2 m ES4210808 Harp Solar Collector aluminium absorber surface area 2 m ES4210709 Harp double Solar Collector copper absorber surface area 2 m ES4210808 Harp double Solar Collector aluminium absorber surface area 2 m ES4211805 Harp Solar Collector aluminium absorber surface area 2 3 m 1 3 Technical data table Flat Plate Solar Collector ES4210709 ES4210808 oo ES4211805 i072 Deh mm POCO CC S C A E a 23 absorber Rete cote w a f o id Flow min max 1 4 1 Following parameters active surface area of absorber forG 800 W m on base of research carried out at Institute for Fuel
14. oof by using No 6 x 40 wood screws and maintain the A value distance between roof fixing points Important The roof fixing values distances are only approximate values Installation and operating instruction for flat plate solar collectors ES2DU0 amp ES3TRI range inclined tile roof 4 2 Mounting Rails connection For three or more Collector sets the mounting Profiles must be connected Put the half length of Profile Rail connector 5 into the one of the ends of the Profile Rail 1 and then secure it by fixing the self tapping screw 7 approx 50 mm from Profile Rail edge 1 Put the next Profile Rail 1 into the second end of the connector 5 and then secure it by fixing the self tapping screw 7 Make sure that the Profile Rail edges 1 are placed parallel to each other Repeat for all Profile Rail sets Important If installing 4 Collectors make sure that two fixed sets of Rails have the same length 4 3 Mounting Rails assembly Fix Profile Rail 1 into the double threaded bolts 2 using a locking screw 6 Fix the locking screws 6 into the Profile Rail 1 with as many screws as doubled threaded bolts 2 Spacing between the locking screws 7 must be the same as for the doubled threaded bolts 2 _ Fix the locking screws 6 into the double J threaded bolts 2 and then lock the nut lightly wi a locking screw 6 Important Elements of locking screw kit
15. th a lightning protection system then we strongly recommend that suitably qualified and competent lightning equipment installer is used to connect the EHC Solar Installation to the existing lightning protection system Installers It is strongly recommended that MCS Certified Installers are used in the installation or servicing of EHC Thermal Solar Systems Mounting Kits It is mandatory that only EHC Solar Collector Mounting Kits are used to support the EHC Solar Collectors and failure to carry this out may increase the risk of personal injury and or damage to the property Risk of burn injury The solar Collectors and assembly elements may be hot due to radiation and therefore there is a risk of a burn injury As a result the guidelines below should be followed in order to avoid burn injuries use personal clothing e g Overalls gloves etc put a canvas cover on the Collector housing wait for temperature to go down before starting work on the unit 2 Transportation storage and handling Transport the Collectors in original manufacturer s package amp according to package marking Carefully handle and do not overturn or stack unpacked Collectors Packed Collectors must be handled by forklifts or pallet jack Protect against inclement weather conditions if stored in the open air Keep dry at all times The unpacked Collector must be carried by at least two people Collector can be carried manually or by carry straps in either
16. the horizontal or vertical position Do not use tools that can scratch a Collector surface e g steel cords chains metal hooks etc Always use lifting equipment such a ladder hoists pulley swing hoists or truck mounted cranes conveyors to transport the Collector onto the roof Never touch connectors while holding carrying lifting solar Collectors Installation and operating instruction for flat plate solar collectors ES2DU0 amp ES3TRI range inclined tile roof 3 Pre Installation 3 1 Collector Mounting Kit Mounting Kit items Number of Collectors Ja 5 O femsa ooo fae e g a aea 2 Rone OO s cam SSS e 20 i 5 Profle connector Locking screw screw M8x20 nut M8 washer 8 set 14 set 20 set 26 set 32 set rae rated lock washer setttapping sew o o o aoe mt lelaia Ensure the Mounting Kit is assembled correctly as above any damaged items must be replaced by the Original items only Installation and operating instruction for flat plate solar collectors ES2DU0 amp ES3TRI range inclined tile roof 3 2 Technical documentation The EHC Thermal Solar Kit contains various types of components and it is therefore important that the relevant installation instructions of these items are carefully read before installation mounting e Solar Collector e Pump group e Solar controller e Solar hot water cylinder 3 3 Tools amp additional equipment e Sprit level e S
17. tor put Clamping ring onto connector of second Collector bring second Collector near to expansion joint lock the nut onto expansion joint Important Tighten the lock nut tight enough to ensure a seal that is sufficient to guard against leaks Do not tighten the nut with too much force to avoid damages of connector and expansion joint Installation and operating instruction for flat plate solar collectors ES2DU0 amp ES3TRI range inclined tile roof 4 9 Inspection after assembly After the hydraulic connection has been completed double check that all connections are tight and secure Make sure all Collectors are firmly fixed to the mounting structures 4 10 Inlet connection Important Hydraulic connection elements can be fitted to either the right or the left side of Collectors 1 Fflexible insulated hose 3 4 2 Clamping elbow 3 Collector connector The correct inlet connection sequence is put the elbow nut 2 onto Collector connector 3 put the Clamping ring onto Collector connector lock the nut onto elbow lock the flexible hose nut 1 onto elbow connect flexible hose to solar installation system 15 Installation and operating instruction for flat plate solar collectors ES2DU0 amp ES3TRI range inclined tile roof 4 11 Outlet connection 1 Collector connector 2 cross pipe with manual airvent and immersion sleeve 3 flexible insulated hose 3 4 The
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