Solar thermal install manual sample

A ZZURO S OLAR

Closed-loop Installation Manual

Installation Manual Domestic Hot-Water Systems Closed Loop System AZZURO Solar Š November 2005

1. INTR OD UC T IO N/ D IAGRA MS

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2. CONNECTIONS

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Piping Cautions Sensor on Collector Sensors on Cylinder

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3. EXPANSION VESSEL

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4. INST AL L ING SOL AR CO NT ROL S YSTE M

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5. FIL L ING & R INS IN G

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6. COM MIS SIO NING

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THE

SYSTEM

SYSTEM

7. MA IN TENA NC E & T ROUBL ESHOOTING

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You should not attempt to install or repair an AZZURO Solar system unless you are an AZZURO Solar approved installer. The system components could cause you or other persons serious bodily harm if not properly installed or handled, and they require special procedures not used with other solar systems. Before working on a roof you should be familiar with and willing to follow OSH guidelines for safety when using a ladder and when working at heights. See also our GENERAL INSTALLATION MANUAL for suggestions on safety equipment and procedures which may apply to your installation situation. All installation work must follow the Code of Practice for Manufacturing and Installation of Solar Hot Water Systems in New Zealand.

Linuo (NZ) Ltd trading as A ZZURO S OLAR 5A Andrew Baxter Drive, Airport Oaks, Auckland Tel: 09 2570098 Fax: 09 2570038 www.Linuo.co.nz Email: support@azzurosolar.co.nz

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AZZURO Solar

1. I NTR OD UC T IO N

TO

Closed-Loop System Installation Manual

C L OS ED - LO OP SY ST E MS

AZZURO Solar Closed Loop Systems can be operated on either mains pressure or low pressure.

They are ideal for homes as well as larger-scale commercial hot water projects. There are internal heat exchange closed-loop system, and external heat exchange closed-loop systems, as below:

Mains pressure ( Hi-Flow) uses a flow rate of 0.4 to 1.0 litre/min/m2.

If the collector area is more than 9 m2, it must be custom designed. Contact Azzuro Solar.

Mains pressure (Low-Flow) uses a flow rate of 0.25 to 0.4 litre/min/m2.

If the collector area is more than 12 m2, it must be custom designed. Contact Azzuro Solar.

Linuo (NZ) Ltd trading as AZZURO Solar 5A Andrew Baxter Drive, Airport Oaks, Auckland Email: support@azzurosolar.co.nz Fax: 09 257 0038 www.Linuo.co.nz

Tel: 09 257 0098

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AZZURO Solar

2.

Closed-Loop System Installation Manual

CON NEC T IO NS

Piping Cautions

DO NOT REMOVE the White Sun Protection Film attached to the components before finishing the entire system installation !!!

: The vertical distance between the Pump and the manifold must be not less than 2 meters to avoid steam damage. If the distance is less then 2 meters, the installer needs to make a dual U pipe to create a vertical distance of 2 meters. If an expansion vessel is used, it must be connected to the side of the ‘U’ pipe nearest the collector.

Distances required unless system is custom designed Pump to collector manifold minimum of 2 meters Collector to Cylinder horizontal - maximum of 20 meters Collector to Cylinder vertical maximum of 10 meters

Linuo (NZ) Ltd trading as AZZURO Solar 5A Andrew Baxter Drive, Airport Oaks, Auckland Email: support@azzurosolar.co.nz Fax: 09 257 0038 www.Linuo.co.nz

Tel: 09 257 0098

3

AZZURO Solar

Closed-Loop System Installation Manual

Sensor on Collector (Install while connecting pipes) NOTE: The Collector Sensor should always be located on the highest temperature side (solar return side) of collector arrays, and be inserted into the sensor pocket.

The Sensor Pocket must be sealed by a …

Check the sensor before sealing the sensor.

….. Thermal Compound

There are two sensor pockets in each collector. They are beside the collector inlet/outlet fittings: refer to the Picture “The CPC Collector Outer Structure.” The sensor pocket is 100mm in depth and slopes slightly upward. The sensor head needs to be pushed carefully into the sensor pocket at the right angle, to avoid damaging the sensor head. It also needs to be pushed in as far as possible to give an accurate reading of the collector temperature. Try to keep the sensor cable away from possible exposed copper pipes in the solar circuits to avoid heat influencing an accurate temperature reading.

A 10-meter collector sensor lead is normally supplied. If the sensor lead is too short, it can be extended by joining an extra length of lead. Be careful running the leads around sharp edges such as roof flashings, nails or staples.

Sensors in Cylinder One or two sensors can be used for all vertical hot water cylinders, depending on the controller used: 1 for the SS1, and 2 for the SS2 controller. The lower sensor should go 100 mm above the cold inlet, attached to the wall of the inner tank. The upper sensor should be positioned to give enough hot water to meet individual customer’s requirement. See the below example for reference.

Ends of the sensor leads are connected to the controller, according to controller manual. Do not let sensor leads touch bare pipes, or the lead insulation will melt.

1 person uses 40-50 litres hot water per day at 65 A 4 person family may use 160-200 litres.

Position the upper tank sensor to give hot water capacity 160-200 litres.

See the drawing: Lower Tank sensor position: 100 mm above the cold inlet, attached to the wall of the inner tank.

Use Plumbers silicone 780 to glue the sensor to the inner side of the tank/ cylinder.

Linuo (NZ) Ltd trading as AZZURO Solar 5A Andrew Baxter Drive, Airport Oaks, Auckland Email: support@azzurosolar.co.nz Fax: 09 257 0038 www.Linuo.co.nz

Tel: 09 257 0098

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AZZURO Solar

Closed-Loop System Installation Manual

3. EXPANSIO N VESSEL The expansion vessel must be installed between the pump and the collector on all closed loop systems. It must be installed with the water connection on top, or the diaphragm could jam shut. If you put a “Down U Pipe’ in the circuit, you must add a release valve on the top of the ‘Down U Pipe’ to let air out when commissioning the system.

The purpose of the expansion tank is to regulate the pressure and release any steam or air that gets trapped in the system. This is essential for the safe operation of a closed-loop system. It must be installed lower than the upper fitting of the water cylinder. They come is various sizes, and you must calculate based on the collector size how big a vessel is needed.

Fix the expansion vessel on the wall The installation of the expansion vessel requires a fixing board, fixing belt, 2 M8 nuts, 2 bolts, 2 plastic expansion bolts and 2 screw nails. As the fixing board and the fixing belt have been pre-packaged with the expansion vessel, simply attach the fixing board on the wall at the right position to secure the expansion vessel.

4. I NST AL L ING

THE

S OL A R C ONT ROL S YSTEM

There are different kinds of controllers used for closed loop systems. For instructions on installation of the pump-circulating unit and controller box refer to the appendices; e.g. “Solar station”, “Controller xxx”, and “Pump xxx”, and see the controller manual packed with the controller.

The distance between the Controller Station and HW Cylinder should not be more than 5 meters. If it is farther away, the installer needs to contact AZZURO Solar for advice.

Linuo (NZ) Ltd trading as AZZURO Solar 5A Andrew Baxter Drive, Airport Oaks, Auckland Email: support@azzurosolar.co.nz Fax: 09 257 0038 www.Linuo.co.nz

Tel: 09 257 0098

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