Compact Solar Drainback System SECUSOL

Transcription

1 TECHNICAL INFORMATION / INSTALLATION INSTRUCTIONS Compact Solar Drainback System SECUSOL Operational Safety and Low Maintenance When the pump is not operating, there is no solar fluid present in the collectors. Therefore the solar fluid and any downstream system components are protected against detrimental effects from overheat. Unwanted gravitational forces as well as operational faults due to air pockets are eliminated. A service intensive membrane expansion vessel, air bleeds and check valves are not required. Operation with common anti-freeze solar fluid prevents potential frost damage. High Yield Thanks To: High transparency anti reflection glass Single surface absorber with selective vacuum coating Solid insulation of individual components Simplified Installation and Start-Up Pre-assembled unit of storage tank, solar controller and solar circulator, including all safety components. Flexible copper double-pipe with only mm cross section, for simple and time saving piping (supplied by Wagner & Co). No expansion vessel and hence no setting of pre-pressure required. Very simple flushing and filling No venting of solar circuit required Installation, startup and maintenance of the SECUSOL solar thermal installation are intended to be carried out by trained professionals only, e.g. in line with SRCC Standard OG-300 installation guidelines or NABCEP certification. They have to be licensed, must be familiar with the IAPMO Uniform Solar Energy Code and must conform to applicable federal, state and local regulations, codes, standards and meet all legal requirements related to the installation of solar hot water systems as well as plumbing, electrical wiring and roof works. Content Technical Information. Technical Data. Scope of Supply 8.3 Accessories 4 General Safety Notes 6. Symbols 6. Standards and Codes 6.3 Qualification of the Installer 7.4 Intended Use and Application 7.5 Pre Installation Notes 8.6 Function of the SECUSOL system 8 Figure SECUSOL-System 3 Installation 9 3. Preparation 9 3. On-Roof Installation Free Standing Installation General Notes about Storage Installation Setting up the Storage Tank Connection to Domestic Water Supply Laying the Solar Circuit Installing the Controller 35 4 Startup DHW System Backup Heating Circuit Solar Circuit 36 5 Connecting the storage Insulation 38 6 Advice for the User 38 7 Maintenance and Care 39 8 Troubleshooting 40 Solar thermal / Collectors EN-USA_SECUSOL_TI-MA-03-R800

2 Technical Information. Technical Data Table Technical Data Features SECUSOL 50- SECUSOL 50- Solar collectors Type EURO C0 AR-M EURO L4 or EURO C0 AR-M Gross area / aperture area sq ft (m²) EURO C0 AR-M 8. sq ft (.6 m²) / 5.7 sq ft (.39 m²) EURO L4 4. sq ft (.5 m²) /.6 sq ft (.0 m² Collector racking Orientation of collector On roof or free standing Horizontal installation only (pitch of 0 85 ), max. permitted diversion from horizontal orientation: No. of collectors (cannot be extended) SECUSOL 350- Solar circuit Collector circuit material (on site) Cu mm, order as needed from Wagner Solar, see material requirements in table 8 Insulation material (accessory) see material requirements in table 8 Length of solar circuit (sum of flow and return legs) Minimum 6.4 ft (5 m) / maximum 98.4 ft (30 m) Maximum operating pressure Installation height ) 87 psi (6 bar) Minimum 3.3 ft ( m), from the bottom of the tank to the bottom of the collector Maximum 8 ft (approx. 8.5 m), from the bottom of the tank to the top of the collector Minimum temperature Frost resistant up to.4 F (-7 C), if correctly filled ) Heat transfer fluid in collector loop Water/propylene glycol mix only with 33 % glycol ), filling capacity:.9 to.95 Gal ( liters) Solar controller Name SUNGO US plus Pump control Speed controlled Overheat protection 80 F temperature limitation for the tank Storage Nominal content 66 Gal (50 l) 9. Gal (350 l) Stand by heating volume approx. 3 Gal (0 l) approx. 4 Gal (60 l) Total height (including insulation) 6.83 in (596 mm) 7.64 in (845 mm) Diameter (including insulation) 9.53 in (750 mm) Permissible operation pressure / Permissible operating temperature 45 psi / 03 F (0 bar / 95 C) Corrosion protection of the storage cylinder Cathodic corrosion protection Cold/hot water connections Sensor connection Solar heat exchanger Enamel coating according to DIN 4753 T3 Mg sacrificial anode acc. to DIN 4753 T6 " NPT (M) Clip in lower tank area approx..39 sq ft (.5 m²) Backup heating coil none / approx. 6.0 sq ft (0.65 m²), depending on type approx. 8.6 sq ft (0.8) m² Socket for electrical immersion heater, Position: Heat insulation (PU foam, polystyrene jacket) " NPSM (F) Cylinder and lid approx..5 in (75 mm) Base.57 in (40 mm) Weight 85.5 lb (9.5 kg) lb (39.5 kg) ) See Figure 8 page3. ) Lower edge of storage cylinder to lower edge of collector (Figure 8 page3). 3) In order to achieve higher frost protection, the glycol content needs to be increased to over 33 %. However, this results in increased pressure drop and hence a reduced maximum installation height and length of solar circuit. Please also observe the technical information of the solar liquid. If required feel free to contact our technical support. EN-USA_SECUSOL_TI-MA-03-R800

3 76.0 in/933 mm 3.5 in 80 mm EURO L4 HTF in/035 mm in/63 mm in/5 mm 4.33 in 0 mm EURO C0 AR M 4.79 in/087 mm in/5 mm Figure Dimensions of solar collectors EURO L4 (upper image) and EURO C0 AR-M (lower image). Throughout this document and all other Wagner & Co documentation the term flow refers to the hot, outgoing pipe leg, while the term return refers to the the colder, incoming leg of the heating or solar circuit (the one returning to the heat generating device). EN-USA_SECUSOL_TI-MA-03-R800 3

4 Table Storage dimensions in inch (mm) Pos. Dimension SECUSOL 50 SECUSOL 350 Total height (without insulation) 55.9 in (40 mm) in (797 mm) 4 Socket ("NPSM(F)), height above ground 34.3 in (867 mm) 44.7 in (36 mm) 7 Hot water connection (stainless steel and brass, NPT(M)) ), height above groand Cold water connection (stainless steel and brass, NPT(M)) ), height above ground 5.3 in (303 mm) 66.6 in (683 mm) 8.78 in (477 mm) 3 Solar flow / hot side (G ¾) ), height 3.7in (87 mm) 5 6 Backup heating flow / hot side ) (¾ NPTM(M)) ), height Backup heating return (¾ NPTM(M)) ) /colder side, height Diameter (without insulation) Base ring openings Solar return / colder side, pump flange height above ground Legend: ) Dimension position numbers from figures 3 and 4 ) Pipe thread DIN ISO 8- (cyl.), flat sealing If present: 36.0 in (97 mm) in (86 mm) If present: in (7 mm) 57.0 in (448 mm) 3.6 in (600 mm) Ø.8 in (300 mm) 3.8 in (350) mm 3/4" NPT(F) 7 " NPT(M) SECUSOL /4" NPT(M) 4 " NPSM (F).8 in 300 mm 5 3/4" NPT(M) 3 3/4" G " NPT(M) 8.78 in (477 mm) 3.7in (87 mm) 36.0 in (97 mm) in (7 mm) 5.3 in (303 mm) 55.9 in (40 mm) 3.6 in (600 mm) Figure 3 Dimensions SECUSOL 50 solar storage tank; () Flange with sacrificial anode; Dimensions of cylinders are without insulation. SECUSOL 50 is available with and without backup heat exchanger (upper coil). The image shows the version with upper coil. The version without upper coil does not feature the connections 5 and 6. 4 EN-USA_SECUSOL_TI-MA-03-R800

5 3/4" NPT(F) 7 " NPT(M) 6 3/4" NPT(M) " NPSM (F) in / 06 mm SECUSOL in 300 mm 5 3/4" NPT(M) 3 3/4" G " NPT(M) 8.78 in (477 mm) 3.7in (87 mm) in (86) 57.0 in (448 mm) 66.6 in (683 mm) in (797 mm) 3.6 in (600 mm) Figure 4 Dimensions of SECUSOL 350 solar cylinder (without insulation). () Flange with sacrificial anode EN-USA_SECUSOL_TI-MA-03-R800 5

6 On roof 76. in / 933 mm 3 EURO L in 63mm 9.57 in 36 mm >60 in / 4060 mm in 63mm Free standing setup 76. in / 933 mm >60 in / 4060 mm 4 EURO L in 63mm in 63mm Figure 5 Connection options for the EURO L4 for on-roof and free-standing installation, with sensor positions, dimensions of the collector field and racking system. The absorber connections can point to the left or to the right. () Solar sensor; () Rail; (3) Rafter bracket or roof anchor; (4) Racking triangle. 6 EN-USA_SECUSOL_TI-MA-03-R800

7 On roof in / 5 mm 3 EURO C0 AR-M in 5mm in 433 mm >77.7 in / 4500 mm in 5mm Free standing setup in / 5 mm >77.7 in / 4500 mm 4 EURO C0 AR-M in 5mm in 5mm Figure 6 Connection options for the EURO C0 AR-M for on-roof and free-standing installation, with sensor positions, dimensions of the collector field and racking system. The absorber connections can point to the left or to the right. () Solar sensor; () Rail; (3) Rafter bracket or roof anchor; (4) Racking triangle System air Solar liquid Collector Storage Storage System air Heat exchanger Solar liquid Pump System idle System in operation Figure 7 Design principle of the SECUSOL system. Left hand side: When in idle state, the collector loop and the collctor are filled with air (light-coloured lines). The solar fluid (darker lines) is located in the heat exchanger. Right hand side: When the system is in operation the air is pushed into the upper loops of the heat exchanger by the rising solar fluid. EN-USA_SECUSOL_TI-MA-03-R800 7

8 . Scope of Supply The complete system is delivered with the following components: Table 3 Components Qty. Collector EURO L4 or Collector EURO C0 AR-M or Solar storage, nominal content 50 l or 350 l, respectively (screwed onto pallet), incl. solar flow and return group with circulator and solar controller SUNGO US plus ) plug " NPSM (fixed to pallet), for closing the storage socket ) For details see Table 5 and Figure 8 Table 4 Scope of Supply Boxed components Customer information folder with instructions and system documentation Solar liquid DC0 F.5 l in 5 l canisters Collector adapter set coll. US Secusol serial connection set System with coll. side by side coll. one above the other US Secusol parallel connection set Roof anchor / rafter bracket (only for on-roof installation) ) ) Minimum no., actual no. depends on structural and geographical situation. Table 5 Scope of supply, storage SECUSOL 50 / SECUSOL 350 Position ) Components Quantity Jacket insulation Cover insulation 3 Ground insulation 4 Storage cylinder lid 5 Solar controller 6 Container 7 Socket cover with integrated protective anode 8 Solar return subassembly 9 Ventilation opening 0 Plug " NPSM Compression olive fitting mm 3 Storage cylinder connection nozzle 5 f Collector sensor k Collector sensor cable n Mains cable p Pump cable s Storage cylinder temperature sensor ) Position numbers from Figure 8. 8 EN-USA_SECUSOL_TI-MA-03-R800

9 4 7 5 f k p n s Figure 8 Scope of supply of the SECUSOL storage cylinder shown for the 50 l- (see table 5 for a position number legend). EN-USA_SECUSOL_TI-MA-03-R800 9

10 Set for single collector Figure 9 Single basic set for on-roof installation with collector EURO C0 AR-M Note The roof brackets shown throughout this document are of the type A Pro+, specifically developed for common North-American asphalt shingle roofs. For installation details refer to the separate instructions coming with the roof brackets. Other roofing types require different roof anchors. Table 6 On roof racking, set for single collector, scope of supply Single collector Pos. ) Components Quantity Part no. Rafter bracket or roof anchor (recommended)² ) (4) Collector rail 49.5 in / 57 mm (EURO C0 AR-M) with two collector clamps wire strip 4 Collector EURO C0 AR-M 5 Compression olive connection ½" - mm Gasket ½" ) Position no. from Figure 0 ) Not included in the set, to be ordered separately 0 EN-USA_SECUSOL_TI-MA-03-R800

11 Collector installation set for horizontal installation, one above the other Note The roof brackets shown throughout this document are of the type A Pro+, specifically developed for common North-American asphalt shingle roofs. For installation details refer to the separate instructions coming with the roof brackets. Other roofing types require different roof anchors. Figure 0 Set for on-roof installation of collectors installed one above the other Table 7 On roof racking, set of collectors installed one above the other, scope of supply Part no. Pos. ) Components Quantity for EURO C0 for EURO L4 Rafter bracket or roof anchor (recommended)² ) (8) 3 Collector rail 49.5 in / 57 mm (EURO C0 AR-M) or 47.3 in / 0 mm (EURO L4), respectively, with two collector clamps Collector rail 48. / 3 mm (EURO C0 AR-M) or in / 68 mm (EURO L4) with one collector clamp 4 Rail connector 5 Wire strap 6 Collector EURO C0 AR-M or L4 7 Collector interconnection hose with insulation pieces and flat seals 8 Compression olive connection ½" - mm 9 Gasket ½" 4 ) Position no. from Figure 0 ) Not included in the set, to be ordered separately EN-USA_SECUSOL_TI-MA-03-R800 EN-USA_SECUSOL_TI-MA-03-R800

12 Collector installation set for horizontal installation, next to each other Figure Set for installation of collectors next to each other Note The roof brackets shown throughout this document are of the type A Pro+, specifically developed for common North-American asphalt shingle roofs. For installation details refer to the separate instructions coming with the roof brackets. Other roofing types require different roof anchors. Table 8 On roof racking, set of collectors installed next to each other, scope of supply Part no. Pos. ) Components Quantity For EURO C0 For EURO L4 Rafter bracket or roof anchor (recommended)² ) (8) Collector rail 49.5 in / 57 mm (EURO C0 AR-M) or 47.3 in / 0 mm (EURO L4), respectively, with two collector clamps 3 Wire strap 4 Collector EURO C0 AR-M or EURO L4 5 Compression olive connection ½" - mm 4 6 Gasket ½" 4 7 Compression T-fitting mm 8 Copper tube mm 4 9 Foam insulation 4 ) Position no. from Figure ) Not included in the set, to be ordered separately EN-USA_SECUSOL_TI-MA-03-R800

13 Set for free standing rackets 8 3 Figure Set for free standing setup Table 9 Free standing racks, scope of supply Single collector; order no Position ) Components Quantity Pre-assembled racking triangle 4 Hexagonal head screw M8 x Nut M8 with locking teeth 4 4 Collector clamp lower part Collector clamp upper part Washer Ø 8.4 mm Hexagonal head screw M8 x Collector EURO C0 AR-M or EURO L4 ) ) Position numbers from Figure. ) Not included in the set Collectors next to each other; order x no EN-USA_SECUSOL_TI-MA-03-R800 3

14 .3 Accessories Table 0 Accessories Description Part no. Euro collector carrying handles ( pieces) Thermostatic Mixing Valve ¾" Twin Cu solar circuit pipe comprised of insulated double copper pipe mm with integrated temperature sensor line, 5 m coil Oval clamp set for for Twin-Cu Solar circuit insulation: flexible foam insulation 3x for single pipes (Aeroflex), 6.56 ft / m length, Flange cover gasket Magnesium sacrificial anode Temperature sensor Pt Storage cylinder height adjustment (always order 3!) Earthing clamps (order!) 0 00 US Sensor connection box SP EN-USA_SECUSOL_TI-MA-03-R800

15 Table 0 Accessories Description Part no. US Secusol parallel connection set US Secusol serial connection set Collector adapter set / -mm US_Secusol Cx-threaded elbow connection set mm x straight compression fitting mm EN-USA_SECUSOL_TI-MA-03-R800 5

16 General Safety Notes. Symbols The following symbols are used throughout these instructions and must be adhered to. READ ALL INSTRUC- TIONS CAREFULLY BEFORE BEGINNING INSTALLATION WORK: Immediate DANGER of serious personal injury, including risk of death and lifelong disability. WARNING against situations leading to possibly severe injuries and death. CAUTION against situations leading to minor injury and material damage.. Inspect for and remove frost and other slipping hazards before getting onto roof surfaces.. Cover and secure all skylights and openings, or install guardrails to keep workers from falling through the openings. 3. When the roof pitch is over 4: and up to 6:, install slide guards along the roof eave after the first 3 rows of roofing material. 4. When the pitch exceeds a 6: pitch, install slide guards along the roof eave 5. Use a safety harness system with a solid anchor point on steep roofs with a pitch greater than 8: or if the ground-to-eave height exceeds 5 feet. 6. Stop all operations on roofs when storms, high winds or other adverse weather conditions create unsafe conditions. 7. Remove or properly guard any impalement hazards. 8. Wear shoes with slip-resistant soles. Make sure to observe all federal, state, county and city regulations related to roof works and roof sealing standards as well as professional codes for plumbing work. Installers must be qualified and - where applicable - licensed to work on roofs. NOTICE of situations which may lead to property damage if no precaution is taken. Notes with additional important or useful information.. Standards and Codes Building and plumbing permits and/or inspections may be required for installation. Comply with all code requirements and applicable standards and regulations. Snow and wind loads - risk of injury from falling objects or collapsing structures Comply with federal, state, county and city regulations and standards related to snow and wind load as well as structural planning in general. Only install the installation set on roofs that can structurally support the additonal load. In case of doubt, always consult a structural engineer or a roofer. Follow the Solar Rating and Certification Organisation SRCC OG 300 guidelines for safe collector installation. Work on roofs - risk of fall and falling objects resulting in potentially serious injury and death We strongly recommend to follow the NAHB-OSHA Jobsite Safety Handbook, especially: Risk of injury and material damage resulting from improper handling of collector and storage Use soft crane straps for lifting collectors with crane (observe secure overhead transport!). Alternatively loop rope around the frame and pull collector up a secured ladder. We also recommend the use of two ladders and our special collector handles. Never attach ropes to collector connections and never use connection pipes as handles! Only use the crane hoisting lugs on top of the storage tank for crane transport. Observe good practice standards for construction sites. Object is heavy and can cause severe injuries and damage upon falling. Uniform Solar Energy Code The installation has to be carried out by a licensed professional in accordance with all professional standards, in particular all safety, health and environmental standards, as given by the IAPMO Uniform Solar Energy Code. For detailed information and to obtain the full text of the code contact IAPMO: International Association of Plumbing and Mechanical Officials 500 E. Philadelphia Street Ontario, CA USA System Integration During integration of the storage tank into the domestic water supply and connection of the solar controller, all national and local health and safety regulations must be complied with, including relevant lightning protection regulations. When installing a backup heating device please follow the manufacturer s guidelines. Follow the Uniform Solar Energy Code. 6 EN-USA_SECUSOL_TI-MA-03-R800

17 Conformity The SECUSOL solar energy system and its components were designed and manufactured in accordance with current European Union and United States laws and regulations. The system and its components are in compliance with SRCC OG 00, IAPMO and NSF testing and/or certification standards, where applicable. EN 806- and pren 77:999 Provided the system is installed correctly, the requirements of EN 806- and pren 77:999 are met. EN 976 and EN 977 The entire system was designed and manufactured according to the regulations in EN 976 and EN Qualification of the Installer Risk of injuries resulting from insufficient qualification Setup, installation and commissioning of the SECUSOL compact solar heating system must be carried out by authorized professionals (e.g. NABCEP or Wagner Academy certified or equivalent combination of knowledge and experience). The installation should be carried out following the guidelines established by the Solar Rating & Certification Corporation (SRCC). See SRCC OG 300: SOLAR WATER HEATING SYSTEM DE- SIGN AND INSTALLATION GUIDELINES, available on the SRCC website at Please note that in case of a warranty complaint the warranty is only valid if the correct start-up has been certified in a commissioning report. Contact us for further information..4 Intended Use and Application Collectors should be stored inside in a dry place. Outdoor storage can result in damage. For proper outdoor storage, remove PE film, and lay down collectors with glass pane up. Avoid direct ground contact (e.g. underlay square timber). Avoid scratches on glass panes by using spacers between collectors (e.g. wooden laths). When leaning collectors against walls or similar, use a minimum inclination of 5 and apply spacers. Do not use cardboard as underliner. If incorrectly stored, humidity can enter the collectors through the air vents. Storing collectors in foil package can damage the glass surface (Figure 3). Figure 3 Do not expose PE-film covered collector to rain mage, health risks and renders all warranty void. As operating mediums water (attention risk of freezing!) or an appropriate water-glycol mixture can be used in a closed circuit. Prolonged operation of the collector at conditions below the dew point temperature within the collector is not permitted! This can occur, for example, when collectors are integrated in the brine circuit of a heat pump. Preventing frost damage After pressure testing and flushing, collectors cannot always be completely emptied. Make sure that no pure water remains in collector during risk of frost! Unfilled collector on roof After being installed on the roof, unfilled collectors should not be exposed to the sun for more than a few days. Otherwise thermal stress on gaskets can result in damage. Alternatively postpone the installation of gaskets to just before filling the solar circuit. Maintenance only by trained professionals! Under normal operating conditions we recommend annual check and maintenance intervals. All testing, repair and maintenance work must be carried out by qualified and licensed professionals. For maintenance notes and additional information about setup and operation of the collector field, please refer to the technical information Solar Thermal Systems - Setup, Commissioning and Maintenance. Collectors: Scope and limitations of application The collector is intended for the application in solar thermal installations for hot water preparation and space heating support. ANY OTHER TYPE OF APPLICATION IS NOT PERMITTED unless explicitly permitted in writing by the manufacturer. Non compliance can lead to serious da- EN-USA_SECUSOL_TI-MA-03-R800 7

18 .5 Pre Installation Notes Risk of burns at collector connections! Collector connections can get very hot as soon as uncovered collector is exposed to the sun (figure 3). Wear gloves! Danger of open injuries! Always wear gloves to avoid severe cuts and lacerations when working with sharp edged metal sheets and components! Risk of damage to absorber! Remove protective plastic caps from connections before collector is exposed to the sun. Risk of molten plastic entering and damaging the absorber! Risk of suffocation! Remove glass protection PE-LD film before commencing installation work! (Figure 4) Keep plastic film out of reach of children! Figure 4 Remove glass protection film before installing collector!.6 Function of the SECUSOL system Function The SECUSOL solar thermal system is designed for domestic hot water (DHW) preparation. The solar fluid is pumped from the solar heat exchanger to the solar collector where it is heated. The thermal energy carried by the solar fluid is then transferred to the domestic water in the storage tank. Backup heating of domestic water in the upper part of the storage tank can be done via a suitable downstream continuous flow heater, an optional electrical immersion heater or via the integrated backup heating coil (not with SECUSOL 50 monovalent, i.e. only one heat exchanger), when connected to central heating. The included SUNGO US plus solar controller controls the circulation pump speed depending on the temperature difference between collector and storage. It also monitors the max. storage temperature. If the system is in stagnation, the entire solar fluid is moved to the heat exchanger, while collector field and collector circuit are filled with system air (figure 7, left hand side). When the circulation pump is switched on, the collector and the collector circuit are filled with solar fluid and the system air is pushed into the upper coils of the heat exchanger (figure 7, right hand side). Once the storage tank is heated up to the maximum temperature, the controller switches off the circulation pump. Normally the solar fluid automatically flows back to the heat exchanger. Otherwise if irradiation continues, the solar fluid vaporizes in the collector field and the system is emptied this way. As the fluid retreats, the air within the system flows into the collectors which quickly reach their stagnation temperature. The heat transport to the tank stops and the solar fluid, which is temperaturesensitive, then is safely stored in the storage tank area. Using a solar fluid with 33 % glycol content ensures permanent protection against frost damage, in addition to corrosion protection. By design heat loss from the storage tank due to overnight convective recirculation or thermosyphonic flows are impossible. Thus the installation of check valves is not required. The installation of venting equipment and a service-intensive membrane expansion vessel are unnecessary due to the special -phase operating system. Operational Limits Note that the storage tank and solar controller must not be installed outdoors and that the system may only be operated within the permitted operating conditions (Chapter : Technical Information). Due to the special system design a maximum of collectors can be integrated. Retroactive extension of the collector area is not possible. The maximum system height is 8 ft / 8.5 m, the maximum length of the solar circuit is 98 ft / 30 m (sum of flow and return legs, according to (Figure 8 page3). Other Documents that have to be Observed The following documents must be observed during installation and operation: 8 EN-USA_SECUSOL_TI-MA-03-R800

19 Operation instructions of the respective solar Controller SUNGO US plus. Technical information Solar Liquid DC0 F, the respective material safety data sheet and label on the canister. Technical information of the respective collectors Material Specifications Table Material specifications Component Parameters Requirements Solar circuit piping Pipe insulation Material Dimension Outside Inside Temperature resistance Dimensions and measurements Copper only 0.47 in / mm Cu UV-resistant No special requirements Up to 347 F /75 C for a short time Dimensions usually are indicated in both: metric and US customary units. In case of doubt the metric dimensions must be considered more precise. The required screws are included in the package and conform to ISO metric standards. For some of the components included in the delivery no exact US pendants exist. In these cases only metric dimensions are indicated. 3 Installation 3. Preparation Scope of Supply Before commencing the installation, please ensure that all components listed in table 3 and 4 are present. Material Required on Site In order to complete the installation and commissioning of the SECUSOL solar energy system, the following is required on site: Piping (copper pipe Cu) for the collector loop pipes Insulation material for the collector loop pipes (for outside use, UV-resistant), available as accessory Electric extension cable for the collector sensors ( threads with cross section of 8/ AWG.) Thermostatic DHW mixer, available as accessory Storage cylinder safety subassembly for cold water connection, available as an accessory, For reasons of corrosion protection the collector loop must be made of materials meeting the requirements of table 8. Other materials are not permitted. Suitable connecting methods are soldering, press fittings or clamp ring connectors. When installing the flat sealing connections please only use the original soft fiber sealants included in the delivery. These sealants have been specially tested for this purpose. Required Tools The following tools are required for the installation and fixing of the collector loop system: Combined wrench 3 mm / / inch (for hexagonal screw M8) Combined wrench 7 mm / /6 inch (for hexagonal screw M0) Pipe wrench 3/4" open-end ratcheting wrench (for collector connection) Electric power screw driver with star bit (e.g. TorxTM) set (for roof bracket fixation) water hoses of m / 6.56 ft length each, both with ½" hose connector on one side Water bucket with a minimum capacity of.64 gal / 0 liters Safety Note Before installing the collectors, please read the information leaflet Safety Precautions for the Installation of Collectors. Observe local statutory accident regulations as well as the technical installation rules described in these instructions. The SECUSOL system is suitable for on-roof and free standing installation. The collectors have to be mounted horizontally to allow them to empty in idle state and during stagnation. EN-USA_SECUSOL_TI-MA-03-R800 9

20 3. On-Roof Installation The on-roof racking system allows fast installation of the collectors on a pitched roof without having to open larger parts of the roof. This is achieved by positioning rafter brackets on the roof. Rafter brackets of type Apro+ for example are suitable for composition shingle roofs, as they are used in much of the north-eastern United States. There are also other bracket and roof anchor types available for a variety of roofings, including industrial metal sheet roofs. Two vertical mounting rails are fixed to the rafter brackets, and the collectors are installed horizontally on these brackets. All individual components are shown in figure 9 (see following page). 3 Fixing of the Roof-Brackets The roof brackets of the type A Pro+ shown in this manual are given as examples only. The actual type and required tools depend on the roofing. For more information refer to the installation instructions included with the roof brackets. Figure 5 Correct fixing of roof bracket type A Pro+ on rafter 0 EN-USA_SECUSOL_TI-MA-03-R800

21 Installation of the Rails C B A B.5 lb-ft (7 Nm) C. lb-ft (30 Nm) Already connect the rails while still on the ground Figure 6 Overview of rail installation (upper image; collector clamps are pre-assembled). () supporting rail fixed with two roof brackets and holding two collector clamps () supporting rail fixed with rail connector to upper rail and one roof bracket; rail holds one collector clamp. Table Distance in inch / mm Segment EURO C0 AR-M EURO L4 A 63 in in 600 mm 900 mm 59 in in 500 mm 700 mm B max. 47. in / 00 mm max. 47. in / 00 mm C max. 8 in / 00 mm max. 8 in / 00 mm For the side by side installation of two collectors the four supporting rails of type (see figure 4) must be aligned at the given distance (see figures 5 and 6). EN-USA_SECUSOL_TI-MA-03-R800

22 Installation of the Collectors Install the upper collector first!.0 lb-ft (7 Nm) Figure 7 Installation of first collector RISK of falling objects and structural damage Improperly positioned collectors can lead to insufficient fixation! Loosen collector clamp slightly, then push tightly against collector and tighten screw (.5 lb-ft / 7 Nm). After installation check for proper position. EN-USA_SECUSOL_TI-MA-03-R800

23 X Figure 8 Installation of the following collector when two collectors are installed, with one above the other RISK of falling objects and structural damage Improperly positioned collectors can lead to insufficient fixation! Loosen collector clamp slightly, then push tightly against collector and tighten screw (.5 lb-ft / 7 Nm). After installation check for proper position. EN-USA_SECUSOL_TI-MA-03-R800 3

24 3.3 Free Standing Installation inch (57 mm) inch (490 mm) 0-00 mm inch 0-00 mm inch Figure 9 EURO TRIC F horizontal for Determining the pitch Table 3 Racking pitch a [ ] A C in 863 mm 0.39 in 0 mm A EURO TRIC F in 940 mm 39.7 in 009 mm 5.79 in 47 mm.4 in 3 mm C in 070 mm 0.5 in 5 mm Figure 0 Installation pitch and setup dimensions for ground- or flat-roof installation (left) or facade installation (right) 4 EN-USA_SECUSOL_TI-MA-03-R800

25 Installation of Racking Triangles.5 lb-ft (7 Nm) M8 x 40.5 lb-ft (7 Nm) 3 Use appropriate wrench, e.g. combined wrench 3 mm / / inch, such as Metrinch MET-3, or adjustable spanner. Figure Unfold racking triangle, set correct angle and lock in position EN-USA_SECUSOL_TI-MA-03-R800 5

26 Fixing of Racking Triangles Fixing the racking triangles on different surfaces is depicted below. Local building standards and codes and structural guidelines must be observed. Assure sufficient carrying capacity of the installation surface. In case of doubt feel free to consult our technical department. max. 7.9 in (00 mm) max. 7.9 in ( 00 mm) Figure Maximum rail projections Ø 0.5 mm 0.43 in (gauge Z) Figure 3 Fixing the racking triangles on steel beams 6 EN-USA_SECUSOL_TI-MA-03-R800

27 Ø mm 0.47 in Use appropriate wrench, e.g. combined wrench 7 mm / /6 inch, such as Metrinch MET-7. or adjustable spanner. Figure 4 Fixing the racking triangles with concrete-slab installation kit (part no ) EN-USA_SECUSOL_TI-MA-03-R800 7

28 Installation of the Collectors on the Racking Triangles X For the C0 AR-M use the lowest rivet nut and for L4 the one above the lowest. X Risk of injury from collapsing collector racks! Make sure that the collector racks are properly set up and all screws are fastened before placing the collectors. Improperly set up racking triangles could collapse and lead to injuries of limbs. Wear appropriate protective workwear! RISK of falling objects and structural damage Improperly positioned collectors can lead to insufficient fixation! Loosen collector clamp slightly, then push tightly against collector and tighten screw (.5 lb-ft / 7 Nm). After installation check for proper position. Use appropriate wrench, e.g. combined wrench 7 mm / /6 inch, such as Metrinch MET-7. or adjustable spanner. Figure 5 Connecting collector and racking triangle 8 EN-USA_SECUSOL_TI-MA-03-R800

29 3.4 General Notes about Storage Installation The pre-assembled return flow sub-assembly has a mm pipe nozzle on the solar circuit side (➊) --> Numbers in black circles refer to Figure Setting up the Storage Tank Please observe the following when setting up the storage tank (Figure 8 page9): The tank insulation consists of 3 parts, the tank insulation (), the cover insulation () and the pre-installed ground insulation (3). Remove the tank insulation, the storage cylinder lid (4) as well as the cover insulation and put safely aside. Unscrew cylinder (6) from the pallet and carry to its final position. Note that the enamel coating of the storage tank can be damaged if jolted. Remove NPSM plug (0) from the pallet and put aside. Place the storage cylinder so that the connections will face the wall. During transport a cable binder is used to secure the pre-wired controller at the cylinders hoisting lug. Cylinder temperature sensor and pump control cable also are pre-wired. 3.6 Connection to Domestic Water Supply Hot and Cold Domestic Water Cold and hot water connections must be done according to the rules and regulations of your local water supplier. We recommend the connection as shown in Figure 6 Connect a safety subassembly () with a safety valve and a non-return valve according to DIN 988 to the cold water inlet of the tank (➋). Within the United States the installation of an IAPMO compliant backflow preventer is mandatory for all installations connected to the drinking water supply. Risk of serious scalding for the end user! Water temperatures at hot water taps can reach up to 03 F / 95 C! A thermostatic mixing valve must be installed to avoid injuries to end customers! It is absolutely necessary to install a thermostatic mixing valve (3) since temperatures during the summer months can reach up to 03 F / 95 C at the hot water outlet. ➐ Without thermostatic mixing valve there is a considerable risk of scalding. The thermostatic mixing valve can be connected between safety subassembly () and the cold water connection at the storage tank ➋ using a T-piece. Close the " NPSM socket ➍ with the plug and seal thoroughly. Alternatively an electrical immersion heater is available which can be installed in this socket, as outlined in the chapter Backup Heating. Re-tighten bolts around flange cover (6) to ensure leakage-free operation. Re-Circulation The return leg (8) should be led away just before the tapping point (0). The circulation pump (9) should be controlled according to the hot water temperature at the most distant tap (sensor ). We recommend that the circulation should be returned to the cold water inlet (4) of the thermostatic mixer (3). A check valve should be installed in the circulation pipe. Please note that circulation can cause significant loss of heat. Hint: use a time, temperature or tap-event controlled circulator. EN-USA_SECUSOL_TI-MA-03-R800 9

30 Cold water supply Storage cylinder safety sub assembly 3 Thermostatic mixer 4 Cold water return 5 DHW distribution pipe 6 Socket lid 7 Protective anode 8 Re-circulation return 9 Re-circulator pump 0 DHW tap Temperature sensor Sensor clamp 3 Solar circuit pump 4 Safety valvel 5 Filling/emptying cock 6 Solar circuit flow sub -assembly 9 Backup heat exchanger 0 Solar heat exchanger Storage cylinder connections: ➊ Solar circuit return ➋ Cold water feed ➌ Solar circuit flow ➍ Electric immersion heater ➎ Backup heating flow/feed (not with SECUSOL 50 mono) ➏ Backup heating return (not with SECUSOL 50 mono) ➐ Hot water connections Figure 6 Connection example for SECUSOL storage cylinder 30 EN-USA_SECUSOL_TI-MA-03-R800

31 3.7 Laying the Solar Circuit Connecting the Solar Sub Assemblies Please note: when the pipes of the solar circuit are soldered, they must be flushed before connecting them to the storage cylinder (see chapter 4, Start-Up). Connect the inlet subassembly to the solar flow inlet of the storage tank (6) using the locking nut (5). Don t forget the flat seal (). Align the filling tap horizontally or upwards (Figure 7). Information: Here flow and return refer to the hot and cold sides at the solar collector. As a result the solar flow is the incoming leg at the solar storage heat exchanger. The return sub-assembly with solar circulation, safety sub-assembly and filling/emptying cock is pre-assembled. (Figure 6 pos. 3 5). If necessary, the screw fittings of the return and the inlet subassemblies should be re-tightened to ensure leak tightness. Operational faults can lead to a discharge of fluids from the safety valve. To avoid soaking of the cylinder insulation we recommend discharging the fluid with a " Cu pipe or similar via the back ventilation opening at the bottom of the insulation (to be provided on site) Connecting the Solar Circuit Observe the operational limits of the SECUSOL system in terms of system height and solar circuit length (Figure 8 and table ) as well as the permitted connection schemes (Figure 5 and Figure 6). Only mm copper pipes may be used for the solar circuit (included in the delivery). The collector loop pipes (figure 7) should be installed with down-grade slope from the collector connections to allow for fast emptying during times of inactivity. The collector loop can be installed without using elbow pieces. The solar circuit can be layed without penetrating the roof see Figure 9. If pipes have to be led through the roofing, ventilation tiles or other safe roof penetrations complying with local building codes are required on site (Figure 30). Place the ventilation tile or pipe duct at the lower edge of the collector, below the collector connection. The upper rim of the elbow pipe under the roof must be installed lower than the collector connection (detail A). When installing a single collector or two collectors one above the other, the upper ventilation tile or duct has to be placed higher than the upper edge of the collector (detail B). Use the included mm coupling to connect the solar circuit return and flow legs (Figure 7 for the example of the solar flow sub-assembly) to the respective subassembly. Saw off the pipe ends, deburr the ridges and fully insert into the coupling. Then tighten nuts. 6 L Figure 7 Solar circuit with flow sub-assembly Copper-Tpiece; Flat sealing gaskets; 3 Filling/emptying cock; 4 Straight compression coupling, mm; 5 Swivel nut; 6 Solar circuit pipe; 7 Storage cylinder connection nozzle of solar flow leg. H L 0 Figure 8 Solar circuit and definition of system length/height L = length of the flow pipe; L0 = length of the return pipe; H = system height (from the bottom of the tank to the top of the collector). EN-USA_SECUSOL_TI-MA-03-R800 3

32 hh B hh A Figure 9 Laying of solar circuit pipe along the outside wall. Figure 30 Laying the solar circuit with penetration of the roof; detail A: Lower collector edge, detail B: Upper collector edge; Collector connection; Venting roof-tile. 3 EN-USA_SECUSOL_TI-MA-03-R800

33 Connecting the Collectors Depending on the type of connection, solar circuit and collectors are connected according to Figure 5 and Figure 6). NOTE: When tightening the joints at the collector connections there is a risk of damaging the absorber. The absorber should not be subjected to torque forces, therefore the connection at the collector side should be secured with an open spanner when tightening! Connection variant with two collectors next to each other (Figure 3 below): Attach a compression fitting () to each of the levelled connections facing each other, and connect them with flat sealing gaskets to the collector connection nozzle ). Connect included short pieces of mm copper pipe (4) to the compression fittings (). Cut to length as needed. To avoid damage to the absorber, no pressure must be exerted onto the absorber pipe during the following insertion of the compression fitting T-piece (3). The collector therefore must be loosened for a moment at its four connection clamps and then pushed outwards. Insert compression fitting T-piece (3), return loosened collector to its previous position, and re-tighten the collector clamp screws. Tighten the lateral compression fitting nuts of the T piece and the inserted pipes (4). Connect mm copper pipe (5) of the solar circuit to the unconnected middle connection of the T-piece (3). Check all connections for tightness after completing all installation works Connection variant with two collectors one above the other (Figure 3): Slip insulation pieces (7) onto the adjacent collector connection nozzles. Then connect one connection of the collector connection hose (6) to a collector connection nozzle (flat sealing). Bend connection hose and connect it in the same fashion to the connection nozzle of the adjacent collector. Pull the ends of the connection hose rubber bellow over both connection nozzle insulation pieces (7). The connections to the solar circuit are carried out in the same fashion (see below). 6 Figure 3 Connection of two collectors, one above the other: Collector connection; 6 Collector connection with flat sealing gaskets and 7 Insulation pieces. 7 Variant with single collector (Figure 33): Connect compression fitting () to collector connection nozzle (, flat sealing). Connect mm copper pipe (5) to compression fitting (); secure with open spanner during tightening to avoid damage to the absorber. Check all connections for tightness after completing the installation work. 4 Figure 3 Connecting two collectors placed next to each other: Collector connection; Compression fitting ½" mm with flat sealing gasket; 3 Compression-fitting T-piece, mm; 4 Connecting pipes with insulation and 5 Solar circuit connections (copper pipe pieces, not part of the package). 5 Figure 33 Solar circuit connection of a single collector or of two collectors placed one above the other: Collector connection; Compression fitting ½" mm with flat sealing gasket; 5 Solar circuit copper pipe (not part of the package). EN-USA_SECUSOL_TI-MA-03-R800 33

34 Installing the Collector Sensor Insert the temperature sensor into the respective sensor sleeve, depending on collector positioning. (see Figure 5 and Figure 6) according to Figure 34. Pull rubber grommet (5) out of the sensor sleeve (7), remove from collector frame and slide onto the temperature sensor cable (6). Clear sensor sleeve from insulation material, if required (Figure 34 details), insert sensor into sensor sleeve and screw in the rubber grommet again. To avoid mechanical load on the sensor, use a wire strap to attach the sensor cable to the insulated collector connection. Extend the sensor cable with a cable to the solar controller, if required (minimum cross section 8/ AWG). Use the sensor connection box SP 0 for the extension on the collector side (accessory, see Table 0) Figure 34 Installing the collector sensor 5 Rubber grommet of sensor sleeve; 6 Collector sensor; 7 Sensor sleeve. 34 EN-USA_SECUSOL_TI-MA-03-R800

35 3.8 Installing the Controller Install the controller to the storage cylinder as follows (fig- Figure 35): Only work on the controller when it is not connected to mains! Do not start-up the system if the controller, the cables or the connected 0 V consumers are visibly damaged! Before connecting the solar controller, place the tank insulation () around the cylinder without closing it, as shown in Figure 35. To affix the controller, break out one of the half-moon shaped perforated sections at the upper end of the insulation mantle; hook controller into the insulation Place the lid insulation () in the tank insulation () and loosely place the tank cover (3) on the cylinder. The mains connection for the controller is preassembled. Since the cable is temperature resistant, it can be passed between the tank insulation and the cylinder and led out along the solar return. Mains power has to be connected from outside the controller via an ON/OFF switch. If a protective connector plug is used for mains connection, the switch is not a must. If the cable needs to be extended, use a cable with a minimum cross section of 5/3 AWG. Local regulations must be complied with. Installing the Sensor (Figure 36) Pass the collector sensor connection cable (k) under the insulation to the solar flow and connect to sensor cable via luster terminal. If extending the sensor cable is required we recommend to use our sensor connection box SP (see accessories tabletable 0 page4) as protection against current surges. Note that only the cables included in the delivery or cables temperature resistant up to 0 C may be used! The temperature sensor cables must not be bent or placed under tension. The minimum bending radius is 50 mm. The SUNGO US plus controller features an additional mains terminal (e.g. for controlling an additional pump) as well as an additional temperature sensor (s). It can be used to control a backup heating circulator pump or to measure the temperature of the cylinder s standbysection (Figure 34). 3 p k s s n 4 Figure 35 Connecting the sensors: () Insulation jacket; () Insulation lid; (3) Storage cover; (4) Ventilation opening; (s) Storage temperature sensor; (p) Pump connection cable; (k) Connection cable for collector sensor; (n) main cable EN-USA_SECUSOL_TI-MA-03-R800 35

36 4 Startup k System Check After fitting all components please carry out the following checks: Are all components fitted correctly? Are all fittings and connections safe and tight and fitted with the original flat seals? Were the bolts on the flange cover re-tightened? Are all electrical connections installed correctly and according to regulations? Are the temperature sensors in the right position? Does the controller show plausible values? s 4. DHW System p Figure 36 Wiring scheme of the SUNGO US plus controller: (s) storage temperature sensor; (p) Pump connection cable; (k) Connection cable for collector sensor; (n) Mains connection cable with on/off switch. n Rinsing the DHW Storage Cylinder Appropriate retainers are to be used when rising the storage cylinder in order to remove remaining particles from the piping. We also recommend to install a dirt retainer at an appropriate place of the heating circuit. Filling and Venting the DHW System To fill the storage cylinder with domestic water, open the shutoff of the safety sub-assembly at the cold-water feed and the up-stream water tap. (Figure 37). Close all water taps after the pipework was successfully vented. Check for tightness of all connections and sockets, retighten, if required, and monitor the system pressure (Figure 38). Pressure Testing of the DHW System Cary out a pressure test of the system after successful installation. : Connect the hot water taps and check all connections and welding points. Afterwards vent cylinder once again. 4. Backup Heating Circuit If a heat generator is connected to the upper heat exchanger coil, the bachup heating circuit has to be rinsed upon startup in order to remove production residues from the coil. 4.3 Solar Circuit Rinsing the Solar Circuit To avoid damage to the system or malfunctions, possible residues from production or installation have to be flushed out of the system before startup (Figure 39): Connect a suitable hose () to the cold water filling tap of the solar return sub-assembly (3) and a domestic water tap (). With a second hose (4) connect the cold water filling and emptying tap of the solar flow (feed) subassembly (5) to a waste water discharge or a container (6). Open filling and rinsing cocks (3 and 5). Open domestic water tap (). Due to the higher pressure loss in the collector loop only the heat exchanger 36 EN-USA_SECUSOL_TI-MA-03-R800