TECHNICAL INSTALLATION MANUAL FOR THE SOLAR SYSTEM
Nothing is hotter than DIMAS...
DIMAS SA is a leading industrial manufacturing company of high quality solar products, such as solar systems, solar collectors and absorbers of all kinds. Since 1979, due to continuous improvement of quality and state-ofthe-art technology, DIMAS SA has succeeded to be always a step ahead from the others. Based on an experienced product development division with an advanced know-how, certified according to ISO 9001:2000 and awarded by quality and efficiency certificates, become the leading industry of solar energy applications in Greece. DIMAS SA always contributes using the best efforts in the benefit of solar applications, by offering economic solutions with enormous advantages for all. Cooperating with the major wholesalers in Europe, is well known as the strongest Greek solar competiton n the European solar energy market. In the last years DIMAS SA has started to export its products in the Middle East and Southern Mediterranean countries, investing in associated partnerships and expanding in futures solar energy markets, with a vision of being always a step ahead. Nowadays where the intense ecological problems sound the alarm of warning and the natural resources are diminished, is required from us to take a turn in solutions friendlier to the environment. For this reason, all of us in DIMAS SA company as well as our collaborators we are working out the solar energy in order to offer qualitative solar systems that will give solutions into a lot of sectors of our daily life.
Let’s take advantage of it! It’s worthwhile!
TECHNICAL INSTALLATION MANUAL FOR THE SOLAR SYSTEM TABLE OF CONTENTS INSTRUCTIONS FOR THE MOUNTING OF THE SUPPORT BASE ON TILT ROOF
Page 4-5
DESCRIPTION OF THE PLUMBING ASSEMBLY BETWEEN THE WATER TANK AND COLLECTOR ON TILT ROOF
Page 6-7
INSTRUCTIONS FOR THE MOUNTING OF THE SUPPORT BASE ON FLAT ROOF
Page 8-9
DESCRIPTION OF THE PLUMBING ASSEMBLY BETWEEN THE WATER TANK AND COLLECTOR ON FLAT ROOF
Page 10-11
INSTRUCTIONS FOR THE MOUNTING OF THE SOLAR SYSTEM ON FLAT ROOF
Page 12-13
TECHNICAL CHARACTERISTICS – DIMENSIONS – WEIGHTS OF SOLAR SYSTEMS
Page 14
TYPES OF SOLAR SYSTEMS / PROPORTION OF ANTIFREEZE LIQUID – WATER
Page 14
TECHNICAL CHARACTERISTICS OF THE WATER TANK
Page 15
TECHNICAL CHARACTERISTICS OF THE COLLECTOR
Page 15
ELECTRICAL CONNECTION DIAGRAM OF AUXILIARY HEATING RESISTANCE (DOUBLE ENERGY)
Page 16
ELECTRICAL CONNECTION DIAGRAM OF AUXILIARY HEATING RESISTANCE AND COPPER TUBE COIL FOR EXTERNAL THERMAL SOURCE (TRIPLE ENERGY) ORIENTATION OF SOLAR SYSTEM
Page 17
INSTALLATION OF 6 SOLAR SYSTEMS ON LINE DIMENSIONS OF SOLAR SYSTEMS
Page 18
INSTALLATION OF SOLAR COLLECTORS ON LINE (20sq.m.)
Page 19
INSTRUCTIONS FOR THE MOUNTING OF THE
B F
A
3.800 mm minimum
photo 1
A
photo 2
A photo 3
DĂ…
We first check that the height of the pitch roof from the highest top until the lower part of the solar system is at least 3800mm-minimum. We begin from the lower part of the support base by raising the tiles and positioning the stainless steel straps (F) between and under the convex of tiles with a distance between them of a min. 900mm and max. 1080mm (D1-D2).
04
min 900mm -
We screw the stainless steel straps to the oblong wood or flooring as at (photo 1) and we leave the one side out of the tiles, at least 200mm in the same distance and length between them. We reposition again the tiles as they were and we screw the external side of the stainless steel straps (F) on the vertical long bracket supports (A-A) of the support base (photo 2) with the plastic hatch on the
SUPPORT BASE ON TILT ROOF
C photo 4
B
A photo 5
C max 1080mm
A DÇ
top side (photo 3) We repeat the same process on the upper side of the support base with the difference that: ATTENTION: We first screw the stainless steel straps (F) on the top of the vertical long bracket supports (A-A) as at (photo 6) after we have raised the tiles, then we screw the stainless steel straps (F) to the oblong wood or flooring as at (photo 1) and we
photo 6
reposition again the tiles as they were before. When we have finished with the vertical long bracket supports (A-A) we position and screw at their lower part the horizontal support angle (C) of collector as at (photo 4) and at their upper part the horizontal support angle (B) of water tank-collector (photo 5 ).
05
DESCRIPTION OF THE PLUMBING ASSEMBLY BETWEEN THE 05 06
01
07 09
11
12
10 02 02 13 14 24 03
13
15 17 04
14
13
06
18
16
13
15
13
15
WATER TANK AND COLLECTOR ON TILT ROOF 08
12 19
13 20
16
13
13 18
01 Solar water tank 02 Water tank’s support angle 03 Solar Collector(s) 04 Collector’s support angle 05 Hot water supply (outlet) 06 Brass Tee ó" 07 Pressure relief valve of hot water supply ó" 08 Pressure relief valve female ó" (closed circuit) 09 Cold water supply (inlet) 10 Cold water expansion control valve with non-return and pressure relief valve (7 bars) 11 Cold water outlet from water tank to collector (closed circuit) 12 Brass angle
/
3 4"
Male-Female
13 Permanite washer (fibre) 14 Long stainless steel tube with brass raccor 15 Brass nut male
16
13
22
23
/
/
34
"
17 Brass screw plug Male
/
3 4"
circuit)
3 4"
16 Brass nut female
18 Brass angle
/
3 4 (closed
/
3 4"
Male-Female
19 Inlet of hot water from collector to water tank (closed circuit) 20 Short stainless steel tube with brass raccor
/
34
(closed circuit)
21 Brass interconnector 3/ 4 "(only for the connection between 2 or 3 collectors) 22 Brass reducing hexagon bush
/
3 4 "-
ó"
23 Spherical switch with special nozzle for plastic pipe, for the filling of the closed circuit with thermal fluid. 24 Protection side cover of aluminium for the flow tube
04
07
INSTRUCTIONS FOR THE MOUNTING OF
A B D photo 1
E D
D
G
G A
photo 2
A
F photo 3 We place the metallic small plate (F) at the backside of the long bracket support (A) at the lower part as at (photo 3) and screw it tight. We screw well the metallic corners (G) at the side parts of the vertical shorter bracket support (D) as at (photo 2) using the (oval) longer hole. We insert the cutting bevel part of the vertical
08
shorter bracket support (D) in the slot of the back side of the long bracket support (A) as at (photo 1). We assemble the "X" diagonal braces (E) with screw and back nut at the middle hole and then we adjust them at the back side of the vertical shorter bracket support (D) with screw and back nut as at (photo 5).
THE SUPPORT BASE ON FLAT ROOF
B A photo 4
D E A photo 5
C C photo 6 We place the horizontal support angle (B) of the water tank-collector as at (photo 4), and screw it on the long bracket supports (A) being careful that the notch and the screw are the middle ones as at (photo 4). We apply the same procedure for the lower horizontal support angle (C) of collector as at (photo 6).
F
We have to take care that the solar support base has the correct orientation (see page 17) and when we have installed the collector/s and the water tank on it, we drill the holes at the flooring with twist drill of 10mm and we insert the plastic sockets and long screws with washers as at (photo 2) and (photo 3)
09
DESCRIPTION OF THE PLUMBING ASSEMBLY BETWEEN
05 07
01
06
02
11
03
12
13
09
10
14
24
25
17
13
15 04
14 13
18
10
16
13 15
13
15
THE WATER TANK AND COLLECTOR ON FLAT ROOF
08 19 13 12
13 16
13
20 13
01 02 03 04 05 06 07 08 09
18
Solar water tank Water tank’s support angle Solar Collector(s) Collector’s support angle Hot water supply (outlet) Brass Tee ó" Pressure relief valve of hot water supply ó" Pressure relief valve female ó" (closed circuit) Cold water supply (inlet)
10 Cold water expansion control valve with non-return and pressure relief valve (7 bars)
16
13
22
23
11 Cold water outlet from water tank to collector (closed circuit) 12 Brass angle 3/ 4 " Male-Female 13 Permanite washer (fibre) 14 Long stainless steel tube with brass raccor 3/ 4 “ (closed circuit) 15 Brass nut male 3/ 4 " 16 Brass nut female 3/ 4 " 17 Brass screw plug Male 3/ 4 " 18 Brass angle 3/ 4 " Male-Female 19 Inlet of hot water from collector to water tank (closed circuit) 20 Short stainless steel tube with brass raccor 3/ 4 “ (closed circuit) 21 Brass interconnector 3/ 4 "(only for the connection between 2 or 3 collectors) 22 Brass reducing hexagon bush 3/ 4 "- ó" 23 Spherical switch with special nozzle for plastic pipe, for the refilling of the closed circuit with thermal fluid. 24 Protection side cover of aluminium for the flow tube 25 Protection middle cover of aluminium between the collectors
11
INSTRUCTIONS FOR THE MOUNTING OF THE
N 08
H photo 1
Îź
∞
J photo 3
photo 2
12
K
We first position the water tank on the top of the support base of the solar system and then we install the collector(s) being careful that the index arrow of the sticker on the side of each collector points downwards, and when we finish we use properly the plump level in order to check that our collector(s) is/are aligned.
Afterwards we position the metallic corner supports of collector(s) (H) as at (photo 1) that we have to insert them first in the aluminium frame of the collector and then screw them in the jam nut M8 that is placed to the horizontal support angle. We place one edge of the transparent special plastic tube (L) at the refilling valve that is
THE SOLAR SYSTEM ON FLAT ROOF
M
L
photo 5
photo 4 installed at the lower side of the collector(s) and the other edge at the filler neck of the bottle, as long as we have already lifted the bottle and the plastic tube (L) at the same height with the water tank (photo 4). Then we start filling up the closed circuit (loop) with the thermal fluid of the bottle and when it will be finished we continue filling it up with water until the water tank will run over from the tube at the side (N-08), which means that all of the air has come out, the closed circuit is filled up and we can screw the security valve finally. At the end, as long as we have checked very
carefully all of the connections for any possible leakages, we position the protection side cover of aluminium (J) as at (photo 2) and the protection middle cover of aluminium (K) in case of 2-3 collectors as at (photo 3), and finally we place the boiler security straps (M) (photo 5) that we have to screw in the jam nut M8 at the front side of the horizontal B support angle and the back side of the long bracket support A-A.
13
TECHNICAL CHARACTERISTICS – DIMENSIONS – WEIGHTS OF SOLAR SYSTEMS
SOLAR TYPE
SOL+ 160
SOL+ 160
SOL+ 200
SOL+ 200
SOL+ 250
SOL+ 300
SOL+ 300
WATER TANK ((DIMENSIONS)
1320x530 mm
1320x530 mm
1320x580 mm
1320x580 mm
2050x530 mm
2050x580 mm
2050x580 mm
WATER TANK (EMPTY WEIGHT) π¡√Ã
48 kgr
48 kgr
56 kgr
56 kgr
68 kgr
76 kgr
76 kgr
CLOSED CIRCUIT - WEIGHT π¡√Ã
4.6 (lt)
4.6 (lt)
4.9 (lt)
4.9 (lt)
5.4 (lt)
6.2 (lt)
6.2 (lt)
WATER TANK (EMPTY WEIGHT) GLASS
57 kgr
57 kgr
65 kgr
65 kgr
76 kgr
83 kgr
83 kgr
CLOSED CIRCUIT WEIGHT GLASS
4.6 (lt)
4.6 (lt)
4.9 (lt)
4.9 (lt)
5.8 (lt)
6.2 (lt)
6.2 (lt)
TOTAL SURFACE AREA (m2)
2 mÇ
2.90 mÇ
2.90 mÇ
4 mÇ
4 mÇ
4 mÇ
6 mÇ
COLLECTOR TYPE
S+2000
S+2900
S+2900
S+2000
S+2000
S+2000
S+2000
No. OF COLLECTORS
1
1
1
2
2
2
3
SOLAR SUPPORT BASE WEIGHT
34 kgr
35 kgr
38 kgr
38 kgr
40 kgr
40 kgr
44 kgr
SOLAR SYSTEM TOTAL WEIGHT EMPTY
121 kgr
137 kgr
148 kgr
172 kgr
186 kgr
194 kgr
237 kgr
160
160
200
2 mÇ
2 . 9 0 mÇ
2 . 9 0 mÇ
1000 cm
1450 cm
1450 cm
200
2 mÇ
250
2 mÇ
2 mÇ
300
2 mÇ
2 mÇ
2150 cm
2150 cm
300
2 mÇ
2 mÇ
2150 cm
2 mÇ
2 mÇ
3300 cm
TYPES OF SOLAR SYSTEMS / PROPORTION OF ANTIFREEZE LIQUID – WATER MINIMUM TEMPERATURE ÆC
SOL+160 2mÇ
SOL+160 2.90mÇ
SOL+200 2mÇ
SOL+200 4mÇ
SOL+250 4mÇ
SOL+300 4mÇ
SOL+300 6mÇ
THERMAL FLUID Kg
WATER Kg
THERMAL FLUID Kg
WATER Kg
THERMAL FLUID Kg
WATER Kg
THERMAL FLUID Kg
WATER Kg
THERMAL FLUID Kg
WATER Kg
THERMAL FLUID Kg
WATER Kg
THERMAL FLUID Kg
WATER Kg
-5
1.00
5.00
1.00
5.70
1.50
5.50
1.50
6.20
2.00
8.20
2.00
8.20
2.00
9.00
-10
1.50
4.50
1.50
5.20
2.00
5.00
2.00
5.70
2.50
7.70
2.50
7.70
2.50
8.50
-15
2.00
4.00
2.00
4.70
2.50
4.50
2.50
5.20
3.00
7.20
3.00
7.20
3.00
8.00
-20
2.50
3.50
2.50
4.20
3.00
4.00
3.00
4.70
3.50
6.70
3.50
6.70
3.50
7.50
-25
2.75
3.25
2.75
3.95
3.50
3.50
3.50
4.20
3.75
6.45
3.75
6.45
3.75
7.25
NOTES: 1. ONE BOTTLE OF THERMAL FLUID CONTAINS 1 kg (0.965LIT). 2. DON’T USE MORE THERMAL FLUID THAN THE QUANTITY THAT IS REQUIRED The closed loop solar systems with a few modifications can be used as open loop solar systems.
14
TECHNICAL CHARACTERISTICS OF THE WATER TANK 1.EXTERNAL CASING: Stainless Steel cover AISI 304BA thickness 0.5mm or Anodized aluminium 2.INSULATION: Polyourethane thickness 60mm, density 40kg/m3 3.INNER TANK: Stainless Steel AISI 316L HiMo thickness 2mm or Steel UST 37.2 thickness 3mm enameled according to DIN 4753 Teil3. 4.HEAT EXCHANGER: Stainless Steel AISI 316L HiMo thickness 1mm or Steel UST 37.2 thickness 1.5mm enameled according to DIN 4753 Teil3. 5.HEATING ELEMENT: Electric resistance 4000W – 230V 6.CORROSION PROTECTION: Magnesium anode bar
01
03 05 02
06
04
TECHNICAL CHARACTERISTICS OF THE COLLECTOR 1.COLLECTOR FRAME: Anodized aluminium profile 2.BACK PLATE: Aluminium 0.50mm thickness 3.BACK INSULATION: Rockwool with aluminium foil 40mm thickness, density 50kg/sq.m 4.SIDE INSULATION: Rockwool 20mm thickness, density 50kg/sq.m. 5.ABSORBER PLATE: Copper strips 0.20mm (Selective or Painted treatment) 6.ABSORBER RISERS: Copper strips 10x0.5mm & Headers 22x0.70mm 7.GLASS COVER: Tempered prismatic glass (Mistlite) 8.WATER PROOFING: Black silicone IG, EPDM rubber & adhesive tape
08
07
08 01
Collector Type
04
S + 2000
S + 2500
S + 2900
1250x2000x100
1450x2000x100
2,0
2,5
2,9
39
46
52
1.47
1.79
2.1
Dimensions (mm) 1000x2000x100 Collecting surface m2
Collector Weight (kg) Thermal Fluid weight (kg)
06 06
08 08
07 03
03
05
02
Note: Due to continuous improvement of the products the manufacturer keep all the rights for any changes of the technical specifications without any prior notice.
04
01
15
ELECTRICAL CONNECTION DIAGRAM OF AUXILIARY HEATING RESISTANCE 28. Thermostat DOUBLE ENERGY 29. Thermal security switch 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44.
Temperature regulator Earth terminal Electricity conductors Electric resistance Conductor joint Metallic support for the electric joint Sealing flange of the electric resistance Hatch of the electric resistance Thermostat socket Copper tube coil for external thermal source Magnesium anode bar Electric wire Sealing rubber of the hatch Protection hatch of the electric resistance Sealing rubbers of the inlet-outlet copper tube coil
43
42 41
31
28 29
32
30 36 38 33
40 32
–
If we are 100% sure that the supply of electric power is off we unscrew the 34 37 screws on the hatch of the electric resistance (43). The thermostat (28) 35 which is connected to the electric resistance 36 33 (33) is already adjusted to 60ÆC. If you need you can change the temperature levels yourself by using the temperature regulator (30), but we recommend not setting it more than 75ÆC. The thermal security switch (29) in order to be activated the red button must be pressed. As long as we have inserted the electric cable (41) from the slot of the protection hutch for the electric resistance (43), we connect the cables on the conductor joint (34) and we place them at the correct position as shown at the electrical diagram. Then we screw the terminals of the electric cables very well in order to avoid any sparking such as L = power – N = Neutral -― –- = earth, and when we are sure that we have made the correct installation we place and screw the hutch (43) back to its position. Notes: ñThe power of the electric resistance is 4000W – 230V ñThe electric installation must be made only by a licensee electrician ñThe electric resistance can be delivered with copper tube coil for external thermal source upon request (39) ñDon’t ever use the electric resistance if the water tank is empty because it will be destroyed.
16
44 43
TRIPLE ENERGY 39
42
41
36 38 39 33
40
ORIENTATION OF SOLAR SYSTEM The thermal performance of the solar system is optimized when is mounted facing South (when we are in the Northern hemisphere). The actual performance however is minimal decreased when the system is oriented less than 45o degrees South East or South West. If we increase the surface of the solar system, by using larger collectors or adding one more collector, the solar system can be oriented up to 90o South East or South West, with minimal or no impact to the annual thermal performance. ATTENTION: We will exactly do the opposite when we are at the Southern hemisphere.
S SE
SW
E
W
N 17
INSTALLATION OF 6 SOLAR SYSTEMS ON LINE DN 20mm (3/4”)
DN 20mm (3/4”)
DN 20mm (3/4”)
DN 20mm (3/4”)
DN 25mm (1”)
DN 20mm (3/4”)
DN 20mm (3/4”)
DN 20mm (3/4”)
DN 32mm (1 1/4”)
DN 25mm (1”)
DN 32mm (1 1/4”)
INLET OF COLD WATER
1.All of the tubes that we will use for the installation must have the same length and geometry.
OUTLET OF HOT WATER
2.The diameter of tubes must be the same for the cold and hot water net in order to have the correct pressure drop.
DIMENSIONS OF SOLAR SYSTEMS ∏ (mm)
L (mm)
W (mm)
SOL+160 (2mÇ)
2120
2150
1000
SOL+160 (2.90mÇ)
2120
2150
1450
SOL+200 (2.90mÇ)
2120
2150
1450
SOL+200 (4mÇ)
2120
2150
2150
SOL+250 (4mÇ)
2160
2150
2150
SOL+300 (4mÇ)
2160
2150
2150
SOL+300 (6mÇ)
2160
2150
3300
TYPE
H
L
w 18
INSTALLATION OF SOLAR COLLECTORS ON LINE (20sq.m.)
3
4
4
2mÇ
2mÇ
2
2mÇ
2mÇ DN 25mm (1”)
3 1
DN 25mm (1”)
4
4
2mÇ
2mÇ
2
2mÇ
2mÇ DN 25mm (1”)
1 4 DN 20mm (3/4”)
DN 32mm (1 1/4”)
3
4
2mÇ
2mÇ
2
2mÇ
2mÇ DN 32mm (1 1/4”)
1 INLET OF COLD WATER
OUTLET OF HOT WATER
1. 2. 3. 4.
OBSTRUCTION GATE VALVE COLLECTOR SENSOR THERMOMETER AUTOMATIC RELIEF VALVE
19
... because SOLAR is our business.
GENERAL DISTIBUTOR: