Classic SWH Technical Manual
Classic SWH Technical Manual
CONTENTS
GENERAL INFORMATION........................................................................................................................................... 4
DOMESTIC HOT WATER CONSUMPTION................................................................................................................ 4
SOLAR WATER HEATER OPERATION - WATER HEATING...................................................................................... 4
SOLAR WATER HEATERS.......................................................................................................................................... 5
LABELING.................................................................................................................................................................... 5
PACKAGING................................................................................................................................................................ 6
WATER STORAGE TANK SPECIFICATIONS............................................................................................................. 7
COLLECTOR APOLLON AL SPECIFICATIONS ......................................................................................................... 8
SOLAR WATER HEATER 120lt/2m2 LAYOUT........................................................................................................... 10
SOLAR WATER HEATER 160lt/2.6m2 LAYOUT........................................................................................................ 11
SOLAR WATER HEATER 160lt/3m2 LAYOUT........................................................................................................... 12
SOLAR WATER HEATER 200lt/2.6m2 LAYOUT........................................................................................................ 13
SOLAR WATER HEATER 200lt/3m2 LAYOUT........................................................................................................... 14
SOLAR WATER HEATER 200lt/4m2 LAYOUT........................................................................................................... 15
SOLAR WATER HEATER 300lt/4m2 LAYOUT........................................................................................................... 16
SOLAR WATER HEATER 300lt/5.2m2 LAYOUT........................................................................................................ 17
GENERAL INSTALLATION RULES........................................................................................................................... 18
INSTALLATION POSITION........................................................................................................................................ 19
GENERAL PREVENTION MEASURES..................................................................................................................... 20
SUPPORT BASE PARTS FOR INSTALLATION ON FLAT SURFACE ..................................................................... 21
SUPPORT BASE ASSEMBLY ON A FLAT SURFACE (System with 1 collector)...................................................... 22
SUPPORT BASE ASSEMBLY ON A FLAT SURFACE (System with 2 collectors)..................................................... 25
SUPPORT BASE PARTS FOR INSTALLATION ON INCLINED SURFACE.............................................................. 28
SUPPORT BASE ASSEMBLY ON AN INCLINED SURFACE (System with 1 collector)........................................... 29
SUPPORT BASE ASSEMBLY ON AN INCLINED SURFACE (System with 1 collector)........................................... 32
HYDRAULIC CONNECTION...................................................................................................................................... 35
CLOSED LOOP FILLING........................................................................................................................................... 35
ELECTRICAL CONNECTION.................................................................................................................................... 36
SYSTEM INSTALLATION ON A TILED ROOF WITH THE WATER STORAGE
TANK UNDER THE ROOF (NATURAL CIRCULATION OPERATION)...................................................................... 37
CONNECTING THE HEAT EXCHANGER................................................................................................................. 37
POSSIBLE PROBLEMS - SOLUTIONS..................................................................................................................... 38
SERVICE - MAINTENANCE...................................................................................................................................... 39
POST INSTALLATION INSTRUCTIONS.................................................................................................................... 40
CHECK LIST.............................................................................................................................................................. 41
SWH/CL 3
GENERAL INFORMATION
In the present manual you will find all necessary instructions with regard to the installation, operation and
maintenance of the product.
The company is active in the Solar Energy Field with high-tech equipment, ultra-modern facilities and certified
products of high quality. Our experience and know-how support our co operations, before and after sales, both in
Europe and internationally.
Nowadays, the necessity for production and saving of energy without at the same time polluting the environment has
become common knowledge. The planetʼs conventional energy resources are diminishing to a threatening level as
our societyʼs energy requirements are increasing, generating pollutants that affect the climateʼs balance. Renewable
energy sources promise a solution to the energy problem as well as to pollution. Gradually, the international legislation
is changing and encouraging - or even imposing - the use of alternative energy products, with the aim to satisfy
energy requirements without endangering the environment.
4 SWH/CL
SOLAR WATER HEATERS
With the use of solar systems, thermosiphonic or forced circulation, is achieved energy saving of 70-100%. At the
same time the operation time of the water tank or electric resistance is decreased, depending on the sunlight of each
region and the system’s size, with simultaneous reduction of emission of carbon dioxide.
LABELING
CLASSIC solar water heaters are identified by two labels, one of them on the tank and the other on the collector.
On these one can find all the details of the system. The information provided is important for the future identification
of the system.
APOLLON XXXX
Type: Flatplate collector
MADE IN EU
Dimensions: (L x W x H) (mm): XXXX x XXXX x XX
Overall area (m2): XXX
Absorber area w: XXX
Total weight of collector (kg): XXX
Volume of heat transfer fluid (lt): XXX
Absorber coating: XXX Licence No: ΧΧΧ
Standstill temperature: XXX°C S/N: ΧΧΧ
Max. operating pressure: 1.0 MPa (10 bar) Date: ΧΧ/ΧΧΧ
Transparent cover: Tempered solar glass
Heat transfer medium: Propylene glycol solution/water mixture MADE IN EU
SWH/CL 5
PACKAGING 1
PRODUCT RANGE
CLASSIC series thermosiphon systems
are available in the following models:
MODEL DESCRIPTION 2
CLASSIC 120/2 120lt tank, 2m2 collector
160lt tank, 2m2 collector 1. Boiler
CLASSIC 160/2
2. Collector(s)
CLASSIC 160/2.6 160lt tank, 2.6m2 collector 3. Support base, fittings
CLASSIC 160/3 160lt tank, 2 x 1.5m2 collector & Accessories
CLASSIC 200/2.6 200lt tank, 2.6m2 collector 4. Palette 3
CLASSIC 200/3 200lt tank, 2 x 1.5m2 collector
CLASSIC 200/4 200lt tank, 2 x 2m2 collector
CLASSIC 300/4 300lt tank, 2 x 2m2 collector
CLASSIC 300/5.2 300lt tank, 2 x 2.6m2 collector
The water storage tank is placed between two round styrofoam covers, which are tightened on the storage tank with
stretch film. The collector is packed in a carton box. All the parts of the support base system, with the connection
fittings, the antifreeze liquid and the other accessories are packed in a carton box. The fittings and the accessories
of each appliance appears in the following table:
1 COLLECTOR 2 COLLECTORS
Quantity Description Quantity Description
T-PIECE Ø22 COPPER X DN16 INOX
2 PCS ELBOW Ø22 COPPER X DN16 INOX 2 PCS
X Ø22 COPPER
1 PC FEMALE CONNECTOR ¾" X DN16 INOX 2 PCS FEMALE CONNECTOR ¾" X DN16 INOX
SAFETY VALVE
2 PCS END CAP Ø22 1 PC
(1,5 bar for 250lt and above or 2,5 bar up to 200lt)
1 PC ONE WAY SAFETY VALVE 10 bar 2 PCS INOX TUBE DN16 INOX
SAFETY VALVE
1 PC 1 PC INSULATION ARMAFLEX Ø22
(1,5 bar for 250lt and above or 2,5 bar up to 200lt)
6 SWH/CL
SOLAR WATER HEATERS
16. Closed loop circuit filling point: brass ½” BSP male threaded pipe end.
17. Heat exchanger (optional) with ¾” BSP male threaded ends for use of the heating produced by central heating
systems during the winter.
SWH/CL 7
COLLECTOR APOLLON AL SPECIFICATIONS
Solar Keymark
Certified
1. External one piece aluminium trough of high aesthetics, shaped by deep drawing method in 400 tn capacity
press, made of naval aluminium alloy, rich in magnesium. Robust construction for perfect tightness.
2. High density, eco-friendly thermal insulation achieved with a 60mm thick layer of prepressed rockwool with
a covering of black glass fabric for the minimization of thermal losses.
Rockwool insulation thermal conductivity: λ=0.035 W/m grd (DIN 56612, measured at 0°C)
3. Water frame of copper pipes of suitable gauge and thickness (headers: Ø22, manifolds: Ø8) Headers are
punched with upper expansion, for perfect manifolds fitting, thus avoiding pressure drop in the collectors.
(tube pitch) = 93mm (EN 1652).
4. Sun-Selective complete area absorber made of selective aluminium sheet with a special titan coating formed
in vacuum,of high absorbency and low radiation, covers the complete window area as well as the headers, thus
increasing the collector’s absorbency, Laser Welded to the water frame.
5. Special plastic parts for supporting and sealing the water frame to the trough, specially designed for the
collector’s ventilation, with sensor supporting option.
Special silicone rubber seals allow fluctuation of the absorber’s length (contraction - expansion) in a -40°C
to +200°C temperature range.
6. Tempered solar glass low iron, with a stable coefficient of expansion and high light transmittance, can withstand
adverse weather conditions (e.g. hail storm, extreme temperature changes, etc.).
7. Solar glass rubber seal: UV proofed
8. Alluminium profile electrostatically painted (Al Mg Si 05): for solar glass seating and supporting.
8 SWH/CL
SOLAR WATER HEATERS
SUPPORT BASE
SUPPORT BASE
One type of supporting base
system, electrostatically painted,
made of 2.5mm thick galvanised
steel, with stainless steel screws
and nuts for installation on flat
or inclined surfaces
SWH/CL 9
CLASSIC SOLAR WATER HEATER 120lt/2m2
CLASSIC 120lt/2m2
FLAT SURFACE 8 PART ΝΑΜΕ
No DIMΕΝSIONS QTY.
5 7 1 Beam Π 100x2x1800mm 2
2 Beam Π 90x2x2550mm 2
1 3 Beam Π 80x2x500mm 2
4
4 Collector Support 870mm 2
5 Beam (Lam. section 33x2mm) 1400mm 2
6 Screw Rod M8x1770mm 2
7 Hexagon Head Bolt M8 M8x20 13
8 Hexagon Head Bolt M8 M8x25 4
9 Hex Nut M8 25
22 10 Hexagon Head Bolt M6 M6x50 4
11 Hex Nut M6 4
12 Washer Ø8 12
66 13 Washer Ø10 4
10 14 Screw 8x60 4
3 15 Upat D10 4
260
1
285
3
820 2084
1252
1128 2130
10 SWH/CL
SOLAR WATER HEATERS
260
1
285
3
1050 2084 1252
1401 2130
1401
SWH/CL 11
CLASSIC SOLAR WATER HEATER 160lt/3m2
CLASSIC 160lt/3m2
No PART ΝΑΜΕ DIMΕΝSIONS QTY.
FLAT SURFACE 8 1 Beam Π 100x2x1600mm 2
7
5 2 Beam Π 90x2x2050mm 2
3 Beam Π 80x2x500mm 2
4 4 Collector Support 1600mm 2
1 5 Beam (Lam. section 33x2mm) 1400mm 2
6 Screw Rod M8x1290mm 2
7 Hexagon Head Bolt M8 M8x20 17
8 Hexagon Head Bolt M8 M8x25 4
9 Hex Nut M8 25
2 10 Hexagon Head Bolt M6 M6x50 4
11 Hex Nut M6 4
6 12 Washer Ø8 16
13 Washer Ø10 4
10 14 Screw 8x60 4
3
15 Upat D10 4
208
7
233
4
1050 1252
1533
2154 2154
1599
12 SWH/CL
SOLAR WATER HEATERS
260
1
285
3
1050 2084 1252
1475 2130 1475
SWH/CL 13
CLASSIC SOLAR WATER HEATER 200lt/3m2
CLASSIC 200lt/3m2
No PART ΝΑΜΕ DIMΕΝSIONS QTY.
FLAT SURFACE 8 1 Beam Π 100x2x1600mm 2
7
5 2 Beam Π 90x2x2050mm 2
3 Beam Π 80x2x500mm 2
4 4 Collector Support 1600mm 2
1 5 Beam (Lam. section 33x2mm) 1400mm 2
6 Screw Rod M8x1290mm 2
7 Hexagon Head Bolt M8 M8x20 17
8 Hexagon Head Bolt M8 M8x25 4
9 Hex Nut M8 25
2
10 Hexagon Head Bolt M6 M6x50 4
11 Hex Nut M6 4
6 12 Washer Ø8 16
13 Washer Ø10 4
10
3 14 Screw 8x60 4
15 Upat D10 4
208
233 7
4
1050 1533 1252
2154 1599 2154
14 SWH/CL
SOLAR WATER HEATERS
260
1
285
3
SWH/CL 15
CLASSIC SOLAR WATER HEATER 300lt/4m2
260
1
285
3
1050 2084 1252
2154 2130 2154
16 SWH/CL
SOLAR WATER HEATERS
CLASSIC 300lt/5.2m2
FLAT SURFACE Αρ. ΌΝΟΜΑ ΔΙΑΣΤΑΣΕΙΣ ΤΕΜ.
9 1 Beam Π 100x2x1800mm 2
6
2 Beam Π 90x2x2550mm 2
11 8 3 Beam Π 80x2x1465mm 2
4 Beam Π 80x2x500mm 2
1 5 Collector Support 2070mm 2
5
6 Beam (Lam. section 33x2mm) 1400mm 2
7 Screw Rod M8x1770mm 2
3 8 Hexagon Head Bolt M8 M8x20 13
9 Hexagon Head Bolt M8 M8x25 4
10 Hex Nut M8 25
11 Hexagon Head Bolt M6 M6x50 6
2 12 Hex Nut M6 6
13 Washer Ø8 12
7 14 Washer Ø10 4
4 15 Screw 8x60 4
18 Upat D10 4
260
1
285
3
1050 2084
1252
2678 2130
2678
SWH/CL 17
GENERAL INSTALLATION RULES
ATTENTION! Installation must be in compliance with local & national rules concerning water and electrical
installations (plumbing, electricity, hygiene, urban and others).
The solar system’s packaging must be removed at the site of installation in order to protect the device from shocks
during its transportation, making sure that the collectors are not supported on their pipe joints. Until installation is
completed, the collector’s glass must remain covered until the water storage tank is filled with domestic water, so as
to avoid the boiling of the filling liquid or the breaking of the glass. The plastic protective caps must be removed from
the water storage tank’s and the collectors’ pipe joints.
Installation location - shading: Prior to installation, a proper selection of the location must be made by the installer
(in agreement with the customer), and the surface must be checked (taking into consideration its static resistance),
so that it can bear the weight of the system.
On inclined roofs the system should not be placed between two beams but above a single one.
The position chosen for the solar water heater installation should not be shaded by any obstacles such as trees,
buildings and other all year round, so as to ensure at least 4 hours of uninhibited exposure of the collector to the sun
during the midday hours.
H
46° - 50° 2.5 x H
> 50o 3.0 x H
N S
Orientation - optimum angle: a basic factor for the system’s optimum
performance is the selection of its angle and orientation for its particular
location and the time during which the maximum gain is required.
The solar system should be positioned so that the collector’s surface
faces the geographical south, if the installation takes place in the
S N
Northern Hemisphere (and the geographical north for the Southern
Hemisphere), i.e. it should always face the Equator.
Northern Hemisphere Southern Hemisphere
Any deviation means a reduction in the system’s performance. If a deviation from the proper orientation cannot
be avoided, then the system’s performance should be corrected by increasing the collector surface, following a
study and evaluation of the specific conditions that apply. As the sun ray’s angle of attack varies with time but also
depending on the system’s location, the collector’s angle should be approximately equal to the installation location’s
latitude. At this angle the maximum energy gain on an annual basis is achieved.
Installation particularities: In case there is no compatibility between the surface where the solar water heater will be
installed (inclined or flat) and the standard equipment provided with the system, a different kind of equipment should
be used. The responsibility for the equipment chosen lies on the installer and in no case on the company. It is up to
the installer to propose & install the different equipment required, who must previously agree it with the customer.
Special weather conditions: In regions suffering from heavy snowfalls, please make sure that the snow is always
timely removed. For this case and cases of regions with storms, high wind velocity, rainfall, cyclones, tornadoes, the
system must be placed on the roof as firmly as possible and must be tightened with extra metal stripes. In areas
where these conditions occur and hail of more than 20mm in diameter is to be observed, it is recommended that
insurance for the solar water heater is issued. In every case, it is recommended to secure your solar water heater on
the support base system with more metal belts than those provided.
18 SWH/CL
SOLAR WATER HEATERS
Piping: the routing of the piping and cabling must be agreed upon between the installer and the client, so as to ensure
the proper installation of the solar system in compliance with local rules concerning water and electrical installations.
Make sure that the tubes connecting the storage tank with the collector and the piping to/from the water heater
are insulated in such a way that they can withstand temperatures covering the range of: -30°C to 120°C. Anti-UV
protection must be used for the insulation.
Antifreeze Liquid: The special heat transfer medium used in the closed circuit protects the system from freezing and
from salt accumulation inside the collector tubes. The jacket in which the heat transfer medium’s circulation takes
place, does not communicate with the water tank. The thermal fluid must be well mixed with water in a percentage
that is necessary to protect the system. The responsibility for the appropriate heat transfer medium quantity as well
as for the use of other liquid than the one accompanying the solar water heater lies on the installer and in no case
on the company.
The use of water or inappropriate liquid may annul the warranty validity.
After the installation is completed, the area where the work was executed should be clean & tidy. The warranty
should be filled in and the customer should sign it and immediately mail it to the company. The customer should fill
in the check list provided by the company. The company does not hold any responsibility that may be the result of an
inappropriate installation or incorrect use of components used for the solar water heater installation.
INSTALLATION POSITION
The installation is only allowed on roofs and flat surfaces of adequate bearing capacity. Before you proceed with the
installation, make sure that the roof and/or the construction is of adequate bearing capacity in terms of statics, always
according to the expected maximum loads at the installation point. If the installation is in a place with an extremely
big wind and snow load, the system as a whole should be statically checked by a skilled person, e.g a specialized
engineer. In special cases, strengthening or more solid constructions may be required.
For the proper operation of the system, the minimum recommended inclination angle of the collectors is 20 °
APOLLON AL COLLECTOR
WIND LOAD SNOW LOAD
INSTALLATION MODE [km/h] / [kΝ/m2] [kΝ/m2]
Τhe system may only be installed in locations with lower wind and snow load values than the ones mentioned above.
yy The minimum distances from the ends of the roof should be:
- From the sides: distance equal to the width of two tiles
- From the top of the roof: distance equal to three rows of tiles
yy The minimum distance limit of 0.8 m should necessarily be respected, in order for the collectors and the mounting
accessories not to be exposed to winds the power of which increases on the perimetrical edges of the roof.
Space requirements for free standing installation (FLAT ROOF)
The system should be installed at least 1.5 m away from the edges of the roof so as for:
Labour uniforms
yy Have protection glasses on, as well as appropriate work uniform, protection shoes, protection helmet and special
long hair net.
yy Do not wear baggy clothes or jewelry, as they me be trapped in movable parts.
yy If, despite the use of protection glasses, antifreeze liquid comes in contact with your eyes, wash off your eyes with
plenty of water and with the eyes wide open.
yy Please wear protection helmet during the installation works executed at the level of or above the head.
LIGHTNING PROTECTION
The metal construction conforms to the general requirements of the ELOT 1197 Standard and the special lightning
protection requirements of the ELOT 1412 Standard which takes into account the environmental conditions as well
as the altitude.
20 SWH/CL
SOLAR WATER HEATERS
1 2 6
4 5
SWH/CL 21
SUPPORT BASE ASSEMBLY ON A FLAT SURFACE
SYSTEM WITH 1 COLLECTOR
2
1. Part 1 is screwed and tightened to part 2 2
using the M8x25 screws, the nuts and the
washers contained in the packaging.
Part 6 (if contained in the packaging) 6
1 1
is joined to part 2 with the M8x50 screws. 6
The procedure is repeated for the other
pair of 1 and 2 parts.
4
3. Parts 4 are placed crosswise,
but not tightened.
22 SWH/CL
SOLAR WATER HEATERS
STEP 9
STEP 11
STEP 12
STEP 16
STEP 10
SWH/CL 23
9. The DN16 INOX corner female union ¾", screwed horizontally and to the left to the water tank at the point
marked “JACKET INLET”.
10. The Ø22 x DN16 INOX corner union, is screwed on to the collector’s bottom right inlet with an upward direction
and an angle equal to the collector’s.
11. The second Ø22 x DN16 INOX corner union, is screwed on to the collector’s top left outlet with an upward
direction and according to the inclination angle of the collector.
12. The DN16 INOX female union ¾", is placed at the point marked “JACKET OUTLET” on the water tank.
13. Using the DN16 INOX flexible connecting pipe the “JACKET OUTLET” at the bottom of the water tank is joined
to the bottom right inlet of the collector, after first having placed the relevant insulation on the plastic pipe.
14. The DN16 INOX flexible connecting pipe is then connected to the “JACKET INLET” of the water tank and to the
upper left outlet of the collector, after first placing the relevant insulation on the pipe.
NOTE: Make sure the length of the insulation is bigger that the pipe’s so that when the fittings are tightened in,
all the components will be covered.
15. Now all the fittings can be tightened.
16. The whole system then has to be properly oriented (See paragraph “GENERAL INSTALLATION RULES”).
N S
S N
Northern Hemisphere Southern Hemisphere
17. Τhe base is secured using four Upat D10 and bolts (M8x60).
24 SWH/CL
SOLAR WATER HEATERS
4
3. Parts 4 are placed crosswise,
but not tightened.
SWH/CL 25
6. In case of two collectors, first place the left one to the
bottom part 5 lifting the upper one. Place the screws
M8x20 with the support washers of the collector (4 for each
collector) without tightening them. Place the T-pieces Ø22 x
DN16 INOX x Ø22 unions at the edges of the collector.
STEP 11 STEP 12
STEP 14
26 SWH/CL
SOLAR WATER HEATERS
9. Center the collectors and tighten the screws to parts 5, as well as all other screws on the base. Make sure the
appliance is level and not at an angle using a spirit level.
10. The female unions ¾" x DN16 INOX are placed on the water tank at the points marked “JACKET INLET” (STEP
10a) and “JACKET OUTLET” (STEP 10b).
11. Using the flexible connecting pipe DN16 INOX, the “JACKET OUTLET” (at the bottom of the water tank) is joined
to the T-piece at bottom inlet of the collectors, after first having placed the relevant insulation.
12. The flexible connecting pipe DN16 INOX, is then connected to the “JACKET INLET” of the water tank and to the
T-piece at the top outlet of the collectors, after first placing the relevant insulation.
NOTE: Make sure the bottom T-piece is angled in the same way as the collectors, the top T-piece is vertical and
the length of the insulation is greater than that of the respective pipes’ so that when the fittings are tightened in,
all the components will be covered.
13. All the fittings are tightened.
14. The whole system then has to be properly oriented (See paragraph “GENERAL INSTALLATION RULES”).
N S
S N
Northern Hemisphere Southern Hemisphere
15. Τhe base is secured using four Upat D10 and bolts (M8x60).
During the installation of the collector, make sure that the arrow points up.
SWH/CL 27
SUPPORT BASE PARTS FOR INSTALLATION ON INCLINED SURFACE
28 SWH/CL
SOLAR WATER HEATERS
1. Parts 1 are screwed and tightened to parts A using the M8x20 screws, and the nuts contained in the packaging.
Α
1
Α
4. The four studs 3 are screwed to the respective appropriate holes of your convenience (s. 4.1 ή 4.2) in parts 1
and onto a solid internal beam of the tilled roof. After angling as desired, the base is tightened onto studs 3 with
the M12 nuts and washers.
4
4
3 3
4.1 4.2 4.3
SWH/CL 29
5. The collector is placed on the base with
the arrows pointing up, on lower part
2, lifting upper part 2 and screwed with
the M8x20 screws onto parts 2 without
tightening.
6. Using a spirit level the water tank bases 4 are leveled and the M8x60 screws are tightened.
STEP 9 STEP 12
STEP 11 STEP 10
30 SWH/CL
SOLAR WATER HEATERS
SWH/CL 31
SUPPORT BASE ASSEMBLY ΟΝ ΑΝ INCLINED SURFACE
ATTENTION! After the installation check that the collectors surface has a tilt angle to the horizontal position of
geographical latitude ±5°.
1. Parts 1 are screwed and tightened to parts A using the M8x20 screws, and the nuts contained in the packaging.
Α
1
Α
2
2. One of the parts 2 is placed at the bottom
and tightened with M8x20 screws.
4. The four studs 3 are screwed to the respective appropriate holes in parts 1 and onto a solid internal beam of the
tilled roof. After angling as desired the base is tightened onto studs 3 with the M12 nuts and washers (4.3).
4
4
3 3
4.1 4.2 4.3
32 SWH/CL
SOLAR WATER HEATERS
5. In case of two collectors, first place the left one to the bottom
part 5 lifting the upper one. Place the screws with the support
washers of the collector (4 for each collector) without tightening
them. Place the T-pieces Ø22 x DN16 INOX x Ø22 unions at the
edges of the collector.
6. Join the second collector without tightening the union. Screw the collectors using the screws and washers onto
parts 5 without tightening.
7. Using a spirit level the water tank bases 4 are leveled and the M8x60 screws are tightened.
SWH/CL 33
STEP 13 STEP 10 STEP 11
STEP 12
9. Center the collector and tighten the screws as well as all the screws of the support base to parts 5. Make sure
that the device is straight and lies in horizontal position. Make sure the appliance is level and not at an angle
using a spirit level.
10. A female union ¾" x DN16 INOX is screwed to the water tank at the point marked “JACKET INLET”.
11. A corner union ¾" x DN16 INOX is placed at the point marked “JACKET OUTLET”.
12. Using the flexible connecting pipe x DN16 INOX, the “JACKET OUTLET” at the bottom of the water tank is joined
to the T-piece at the bottom inlet of the collectors, after first having placed the relevant insulation.
13. The flexible connecting pipe x DN16 INOX is then connected to the “JACKET INLET” of the water tank and to the
T-piece at the upper outlet of the collectors after first placing the relevant insulation.
NOTE: Make sure the bottom T-piece is angled the same as the collectors, the top T-piece is vertical and the
length of the insulation is greater that the respective pipe’s so that when the fittings are tightened in will cover all
the components.
14. All the fittings are tightened.
34 SWH/CL
SOLAR WATER HEATERS
HYDRAULIC CONNECTION
CONNECTING THE SYSTEM WITH THE COLD AND HOT WATER MAINS
The “COLD WATER INLET” and “HOT WATER OUTLET” sockets colored blue and red respectively are located on
the side of the water storage tank.
ATTENTION! The connections to the hot and cold water pipes should be made with union nuts and not by soldering.
1. Onto the “COLD WATER INLET” the hot water safety valve is screwed first, followed by a mini ball valve. The
cold water pipe is then connected to the ball valve with an insulated plastic pipe Ø15.
2. The “HOT WATER OUTLET” is then connected to the hot water pipe of the consumer network through an
insulated plastic pipe (Plastic pipes are recommended to minimize electro-corrosion).
3. Filling the water storage tank WITH WATER: With the ball valve and a hot water tap open, the water storage tank
is allowed to be filled with cold water. When water starts to run out of the tap, the water storage tank is full and
the hot water tap can be closed.
1. The antifreeze is diluted with clean water in a container and mixed until it is fully dissolved. The closed circuit
cannot be filled with antifreeze unless it is first diluted with water to a ratio of 1:1.
1 2
2. The solution is fed into the water tank from the top “CLOSED CIRCUIT
FILLING POINT” (2). Τhe “CLOSED CIRCUIT SAFETY VALVE
CONNECTION” (1) is kept open to ease the bleeding of the closed circuit
and is filled with water until full. Τhe filling should be done slowly (so as to
allow air bubbles to escape), and should continue until liquid overflows at
the filling inlet.
3. The female ½" plug is placed on one pipe joint at point (2) and the 3.5 bar
safety valve on the other at point (1).
4. The female ½" plug and the 3.5 bar safety valve are secured on the
respective water tank filling points.
5. The collectors are uncovered and the glass cleaned.
6. Following the completion of the installation, the appliance should be left for
24 hours without any hot water being used so that the closed circuit can
go into operation.
7. Joint sealing. Check for leaks and make sure that all pipe joints to the
collectors and the water tank, as well as the cold and hot water pipes
towards the system are properly insulated, in order to avoid thermal loss and protect them from frost.
ANTI FREEZE LIQUID is an advanced, propylene glycol based special product, designed and formulated in order
to ensure effective heat transfer properties at high or low temperatures. It is non-toxic and provides protection up
to -37°C (solution 55% v/v with water). It is especially designed to provide excellent anticorrosion properties. In
aquacius solutions anti freeze liquid offers protection according to the extent of dilution as per in the table below:
PERCENTAGE % 5 10 15 20 25 30 40 45 50 55
TEMPERATURE °C -2 -4 -6 -8 -11 -15 -19 -24 -30 -37
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ELECTRICAL CONNECTION
DESCRIPTION OF ELECTRICAL COMPONENTS (heating element - thermostat - accessories)
ELECTRICAL DIAGRAM - General rules
The electrical installation of the solar water heater should be carried out by a qualified electrician and in accordance
with the national regulations in force and the rules and conditions that apply to the building where the installation is
taking place. The heating element must not be switched on when there is no water in the water storage tank. In such
case the heating element warranty does not apply.
B1 B2 B3
NOTE: The heating element’s rating depends on local regulations of the country of destination.
1. Remove the screws from the protection flap which covers the electrical components (Image B1).
2. A 3x4mm2 section electrical cable (for a 4kW heating element) is required to connect the heating element to the
mains.
3. Pass the end of the cable through the gland and towards the electrical components (Image B2).
4. Connect the black wire (phase) to the connector L and the blue wire (neutral) to the connector N on the thermostat.
Connect the yellow wire (earthing) to the small M4 screw on the heating element marked with the ground symbol
(Drawing 1).
5. The thermostat has been connected to the heating element at the factory. Adjust the thermostat to 60°C.
ATTENTION! The thermostat should be well fitted at the heating element (Drawing 1).
6. Close the cover of the electrical components (Image B3).
7. Switch off the central mains switch.
8. Connect the other end of the cable to the electrical board using a bipolar disconnection switch with a minimum
distance between contacts of at least 3mm. The circuit breaker’s rating must be suitable for the heating element
in use.
36 SWH/CL
SOLAR WATER HEATERS
Drawing 1
ELECTRICAL COMPONENTS (Heating Element - Thermostat)
Thermostat
THERMOSTAT AUTOMATIC HEATING
AUXILIARY THERMOELECTRIC ELEMENT
FUSE
This is tripped when the water storage
tank’s internal temperature exceeds
95°C and shuts down the thermostat, to Temperature
protect the appliance form overheating. 3 Regulator
4 2
Safety
5
1 B
RESETTING THE EN 15
EC
THERMOELECTRIC FUSE 1 2
A
~
R
0V
Rotate the temperature regulator until B
25
0
A
52
T 11
the button of the thermoelectric fuse A Neutral
appears and press it. Once the fuse
has been reset to its normal operating
position (pressed in), the thermostat
can operate again.
Earthing Phase
the collector outlet and the water storage tank inlet must not 8°
exceed 3m. The angle of the pipe joining these 2 points must
not be less than 8°.
MIN. ANGLE 8°
HYDRAULIC CONNECTION
The central heating system to which the solar system is to be connected must be equipped with:
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Specifically: To connect the coil heat exchangers of the D D
20cm
min
the steps below:
ζ
5. Adjust the automatic filling valve AF, ½ bar above the
static height H (e.g. for a height of 15m, it should be set
to 2 bar).
6. Fill the system with water and check for leaks.
A. Circulator
AF
C. Expansion tank
1. Take the weather conditions into consideration. 7. Check the building’s piping and taps for the
possibility of slow leakage.
2. Avoid large hot water consumption during the night.
8. Make sure the hot water supply is not mixing with a
cold water supply.
3. Check if your needs in hot water have increased
and cannot be covered by the system’s capacity. 9. Make sure the connecting pipes are not kinked.
4. Make sure your solar water heater is not shaded by 10. Check the level of the antifreeze liquid and top up if
any kind of obstacles, necessary.
5. Check that the system is leveled. 11. Make sure there is no trapped air in the water
storage tank or the collectors.
6. Check carefully all connections for tightness and
tighten or replace any connections that are not
tight.
If after all the above checks you are still not satisfied with your solar system’s performance, then please contact your
local representative or the company’s technical department.
38 SWH/CL
SOLAR WATER HEATERS
THE SOLAR WATER STORAGE TANK DOES NOT SUPPLY HOT WATER WHEN USING
THE ELECTRICAL HEATING ELEMENT
The following tasks must be carried out only by a qualified electrician.
1. Shut down the electrical supply and open the 5. Check the central electrical connection.
electrical components’ cover.
6. Switch on the electrical current and measure the
2. Check the cable connection between the thermostat voltage at the heating element’s terminals.
and the heating element.
7. Check the thermostat’s thermoelectric fuse F, which
3. Check the temperature at which the thermostat must be pressed in. If it is not, rotate the thermostat’s
is set, so that it is not lower than that needed for regulator until the button of the thermoelectric fuse
consumption. F appears. Press this. Once it has been reset, the
thermostat can operate once again.
4. Check the heating element.
SERVICE - MAINTENANCE
Your solar water heater should be serviced every two years by an authorized representative or a company technician.
These periodic checks are necessary for the solar water heater’ s warranty to apply. The inspection concerns the
whole system and more specifically:
1. Flange 5. Piping
2. Safety valve 6. Insulation - seals
3. Heating element - thermostat 7. Transparent cover (solar glass)
4. Connection fittings 8. Supporting system
9. Replacement of anode and
checking the closed loop’s liquid.
It is recommended that the water
storage tank is cleaned of mineral
deposits and sludge every five
years.
Especially for the replacement of the anode bar follow these steps:
1. Shut down the electrical supply. 10. Replace the sacrificial anode with a new
Ø22x300mm on the cap and screw back into place.
2. Empty the water from the water storage tank.
11. Open the water supply and a hot water tap until the
3. Remove the electrical component’s cover.
water storage tank fills up.
4. Disconnect the three electrical wires.
12. Check for water leaks.
5. Remove the electrical heating element by removing
13. Reconnect the electrical components at their
the M8 screws.
designated positions.
6. Remove the old magnesium bar from the heating
14. Check that the thermostat is securely clipped to the
element’s flange.
heating element.
7. Screw in the new magnesium.
15. Replace the electrical component’s cover.
8. Replace the heating element with the rubber seal.
16. Reconnect the electrical supply.
9. Unscrew the external magnesium cap located on
the water storage tank’s right side.
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ATTENTION!
yy Any intervention - work on the solar water heater must be carried out only by specialized technicians and where
electrical components are concerned, only by qualified and licensed electricians.
yy All solar water heater service data must be entered on the respective chart on the warranty document (term of
warranty).
yy In areas where extreme weather conditions are common (hail storms, storms, tornadoes, etc.) it is recommended
that the appliance is insured.
Following its installation, the solar water storage tank needs about 2 days in order to achieve its maximum efficiency.
For this reason it is recommended that there is no hot water consumption during the first two days following installation,
even if there is ample sunshine.
A basic periodic maintenance will assure the long life and high efficiency of the solar water heater.
yy It is recommended that the appliance is inspected in situ according to the instructions stated in the guarantee
twice a year and checked for possible damage (breaking) of the collectors’ glass, leaks in the connecting piping to
the mains and to the consumption system, inspection of the pipe insulation and cleaning of the glass.
yy If the collectors’ glass is broken, it should be replaced immediately.
yy It is recommended that the glass is washed at an hour of low sunlight to avoid damages due to expansion-
contraction, due to temperature changes.
yy If the fittings are worn (screws, pugs, piping, etc), these should be replaced at the owner’s cost.
yy The level of antifreeze in the closed circuit must be checked annually (as it could need toping up), to ensure the
efficient operation.
yy In cases where there is to be no use of hot water for long periods of time (e.g. during the summer holidays), it
is recommended that the collector surface is covered with an opaque cover in order to avoid the building up of
high temperatures, which could trip the thermoelectric fuse of the thermostat and cut the electrical circuit. (See
paragraph “RESETTING THE THERMOELECTRIC FUSE F”).
yy During the build-up of high pressure in the thermal tank, it is possible that the safety valve will open and water will
run out. This is a normal function that protects the water storage tank from high pressures. If the mains pressure
exceeds 4 atm., it is necessary to add a pressure reducer - expansion tank.
yy Do not switch on the electrical heating element in the following cases:
Α) When the mains water supply has been cut
Β) When the connecting pipes have frozen and there is no water flow from the water storage tank to the taps.
Caution! Place taps with thermostatic regulation up to 38°C for hot water use to prevent burns which may be caused
by the high temperature water in the solar water heater.
40 SWH/CL
SOLAR WATER HEATERS
CHECK LIST
INSTRUCTIONS FOR THE INSTALLER
After the installation is complete, the installer, with the help of the check list below has to check all of the points which
are noted and mark in the relevant column with a √.
LIST CHECK
HYDRAULIC CONNECTIONS
Are there any leaks in the closed circuit, the connections, or in the tube heat exchanger ?
Are the safety valves installed properly?
Does a mixing valve of hot / cold water exist?
ELECTRICAL CONNECTION
Is the electric resistance connected properly? (if it exists)
Has the electric connection been done according to the local regulations? (insulation, grounding, etc...)
GENERAL
Was the guarantee properly filled in and given to the client?
Were the instructions of use given to the client?
Was the proper selection of the model made according to the needs of the client?
Was the client informed of other options for the production of hot water?
Address........................................................................ Address........................................................................
Telephone..................................................................... Telephone.....................................................................
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NOTES
42 SWH/CL
05-18
Headquarters: 315, Acharnon Str. - 11145, Athens - Greece / Tel.: +30 210 2112591
Branch: 4, Slavianska Str. FL 3-2850, Petrich - Bulgaria / Tel.: +359 88 777 2092
Website: www.economysolarsolutions.com
Email: [email protected]