OPERATING AND INSTALLATION MANUAL WATT VIP 504 CPC

OPERATING AND INSTALLATION MANUAL WATT VIP 504 CPC 1

1. FUNCTIONAL DIAGRAM AND COMPOSITIONS OF SOLAR SYSTEM WITH WATT CPC 9 +COLLECTORS... 4 1.1 GENERAL DIAGRAM OF WATT VIP 504 CPC... 4 1.2 COMPONENTS OF WATT VIP 504 CPC SYSTEM... 5 2. DESCRIPTION OF MAIN SYSTEM COMPONENTS... 6 2.1 WATT CPC9+ COLLECTOR... 6 2.2 DOUBLE-COIL HOT UTILITY WATER HEATER 500L.... 8 2.3 RESOLWATT PLUS CONTROLLER... 9 2.4 DOUBLE SOLAR GROUP... 11 2.5 ELBI EXTENSION VESSEL... 14 2.7 LIQUID FOR WATT CPC COLLECTORS... 16 3. SUPERVISION OF SOLAR SYSTEM... 17 3.1. CONTROL OF WORKING MEDIUM PARAMETERS... 17 3.2. CHECKING THE PRELIMINARY PRESSURE IN THE EXTENSION VESSEL... 17 3.3. VESSEL... 17 4. UPON COMPLETION OF THE INSTALLATION THE AUTHORIZED INSTALLER/CUSTOMER SHOULD CHECK IF THE FOLLOWING ACTIVITIES HAVE BEEN CARRIED OUT PROPERLY... 17 4.1 APPROPRIATE SELECTION OF PIPES AND THEIR CONNECTION:... 17 4.2 APPROPRIATE SYSTEM INSULATION... 17 4.3 SYSTEM TIGHTNESS... 17 4.4 SYSTEM VALVES... 17 4.5 FILLING AND VENTING EQUIPMENT... 18 4.6 PROTECTION OF COLLECTORS FROM SOLAR RADIATION DURING INSTALLATION... 18 4.7 CHECK FLOW ADJUSTMENT... 18 4.8 CHECK FLUID QUALITY... 18 4.9 CHECK IF ORIGINAL VESSELS HAVE BEEN USED... 18 2

Dear Customer, Thank you very much for your decision to purchase the special-offer WATT VIP 504 CPC solar system. WATT VIP 504 CPC vacuum-collector systems was designed with consideration to the climatic conditions present at our latitude. The vacuum collector included in the system shows high absorption and minimum heat loss to allow excellent energy efficiency of the system in any season. The collector is mountable on any roof. Where the installation is to be made on a flat surface a special free-standing structure must be ordered additionally. These operating instructions are intended to facilitate the proper use of your system. We recommend the system be installed by a specialized company, which will install the system according to your requirements. These instructions include only the basic elements of the set with a short description. Full fitting instructions are available at www.watt.pl and from your fitter. Please use the services of experienced fitting companies that will fit the set according to the design guidelines and your needs 3

1. Functional diagram and compositions of solar system with WATT CPC 9 +collectors 1.1 General diagram of WATT VIP 504 CPC 4

1.2 Components of WATT VIP 504 CPC system No. of Item no. Description pieces 01-8002 WATT CPC 9 + vacuum collector - painted 4 10-0203 Heater for warm usable water - double coil HT 500 ERR 1 03-1504 Roof aluminium fixing IV - painted 1 03-2504* Aluminium free standing construction IV painted* 1 05-0400 Solar collectors liquid WATT CPC 20 l 2 05-1010 15 mm collector clamp connector 6 06-0001 18/15 mm reducer 2 05-1011 15/15 mm side clamp hole plug 1 05-1020 Side protective hole plug 1 06-0031 ReSolWATT Plus controller 1 06-0111 Double solar group with rotameter and manometr 1 06-0146 Set for connecting double solar group with heater 1 06-2001 Solar covering 9x18mm 40 06-0205 Expansion vessel for collectors 80 l 1 06-2101 Isolation for coupling for collector 15 mm 6 06-0404 Connector for expansion vessel 1 1 * free standing construction is included In WATT VIP 504 KWS set 5

2. Description of main system components 2.1 WATT CPC9+ collector Heart of the WATT VIP 302 CPC system are vacuum collectors CPC 9+. The solar collectors are one of the most modern technical solutions in the field of solar technology. The vacuum in double walls glass tube guarantees excellent insulation in any weather conditions. The special absorber is put on the inner tube surface, the sun rays which get into the absorber have no possibility to get out of it. The accumulated heat energy is transferred to the freeze resistant working medium through the transferring elements and the copper tubes located inside the vacuum pipe. The glass tightness provides long life of tubes, which are also resistant to hailstorm. Use of parabolic mirrors provides optimal utilization of sun operation thanks to focusing on the vacuum tube the rays reflected from mirror. Such design of solar collectors lets to increase the system efficiency, especially in the periods of weak sun operation, thanks to significantly lower heat losses. The WATT CPC+ vacuum tube collectors, which use vacuum tubes manufactured for leading European companies and offer the best prices in the market, enable efficient utilization of solar energy all year long and reduce costs related to hot utility water heating (up to 80%) and central heating (up to 50%). 6

CPC parabolic mirror active and design 1. vacuum tube 2. absorber 3. CPC mirror Advantages of CPC 9+ collectors : certificate ISFH Z-W3205 high efficiency and energy output all-year-round perfect insulation through the use of vacuum covered with glass the use of corrosion-proof materials (aluminum, copper) warranty: 10 years CAUTION! Before the system is put into operation, the solar collector must be covered to protect the absorber from overheating. The system should be filled only when the collector hydraulic system is assembled and it cannot be put into operation until there is a possibility to carry away heat generated by the solar collector. It is obligatory to use the solar fluid (propylene glycol) provided by the manufacturer. Warranty is not valid, if the collector is filled with water or a medium whose parameters differ from those of glycol provided by WATT. The collector can be located according to the roof conditions available (on a flat or sloped roof) or at any location on a free-standing structure. Under no circumstances may the collector be placed so that the collector top faces upwards as it may result in permanent damage to the collector. 7

2.2 Double-coil hot utility water heater 500l. Quality you are going to feel. We present hereby a new generation of WATT sanitary hot water. The vessels were made to meet current demands of the heating system market and modern solar systems. WATT vessels can operate with all available gas boilers and other energy sources such as solar systems, heat pumps or fireplaces with water jacket. Wide selection of accessories allows the adaptation of the sanitary hot water system to user s needs. Characteristics of WATT reservoirs: Protection of the inner vessel side from corrosion through an anode and high quality double enamel coat according to DIN 4753. Advanced coil welding method (lime-resistant). Inspection flange adapted to install an electric heater. Specifications:!!! CAUTION!!! Due to two types of reservoirs being available in SU sets, the technical data is provided in the operation and maintenance manual for the reservoir and at www.watt.pl 8

2.3 ResolWATT Plus controller Principle of operation The system is equipped with ReSolWATT Plus controller, which controls the operation of P1 pump included, in the solar group. The controller turns the pump on when the preset temperature difference between T1 collector and T2 tank is detected. system monitoring display up to 4 temperature Pt1000 sensors heat balancing function control user-friendly operation by simple handling easy housing installation, outstanding design optional rotational speed control, solar operating hours counter and thermostat function 9

Scope of delivery: 1x ResolWATT Plus 1X accessory bag 1x spare T4A fuse 2x screws and dowels 4x strain relief and screws Additionally enclosed in the full set: 1x FKP6 sensor 2x FRP6 sensor Specifications: Description Power supply: Wymiar /ilość 210...250 V (50Hz...60Hz) -40...200 O C kolektor i zasobnik Mounting: Dimensions: Breaking capa city per relay Ambient temperature: Wall mounting, mounting into patch-panels is possible 172x110x46 mm Semi-conductor relay 1,6 (1) A 250V 0 O C - 40 O C Mode of operation: 67.30 Display System screen for system visualisation, 8 symbols for system status and operating control lamp 10

2.4 Double solar group Solar system WATT fittings allows connection of the solar collector to the sanitary hot water heater in the solar circuit. Where the supply pipes transferring heated medium from the collector to the vessel are routed directly alongside the return pipeline (carrying cooled collector medium in the opposite direction) a two-line Regusol pumping module can be installed. In order to effectively degas the medium used in solar systems the Regusol-L module was equipped with a venting tank installed in the supplying line. Filling of the solar system with collector fluid or draining of the solar system is possible through the filling/draining tap. In order to avoid excessive pressure build-up in the solar system Regusol modules were equipped with safety groups to which expansion vessels can be connected. market. Regusol fittings are adapted to use with all glycol-based collector fluids available in the Advantages: high functional efficiency warranty of a reputed manufacturer complete systems available material of high quality max. short-term starting temperature 160 C max. continuous working temperature 120 C aesthetic and close-fitting insulation 11

Two-riser Regusolwatt-130 module for vertical riser with safety group for connection with the solar circuit DN 25 by use of Regusolwatt compression fittings (to be ordered separately). Complete, pre-assembled and leak tested unit with safety group and connection to the expansion tank: with shut-off possibility with adjustable flow measuring device with shut-off facility for flow regulation in the solar circuit with wall mounting device and closely-fitting insulating shell with ball valve with integrated check valve Specifications: Continuous work temperature Short term starting temperature Max pressure(safety Valve): Opening pressure of the check valve: 120 C 160 C 6 bar 20 mbar Pump: Grundfos UPS 25/60 Power consumption -phase 1 34 44 W -phase 2 46 63W -phase 3 68 82 W Max pump head: Max pump capacity: Control ranges of flow measuring device: 6 m 3,5 m3 1-6 l/min 12

Operation: The one-riser Regusolwatt 130 module is equipped with a ball valve with an integrated check valve serving to avoid gravity circulation when the pump is switched off. The safety group is connected to the lateral connection piece of the ball valve and is equipped with a safety valve, filling/draining tap and a connection for the expansion tank. A drainage pipe leading to a collecting basin can be connected to the outlet pipe of the safety valve. The circulation pump is particularly suitable for use in solar circuits and is located in the return line between the ball valve and the flow rate measuring device (rotameter) at which the fine setting of the flow rate can be carried out. The required flow rate depends on the number of collectors or on the installation equipment itself. The flow rate measuring device can be shut off completely. The circulation pump can easily be removed after shutting off the flow measuring device and closing the pump ball valve. Functioning: The solar group pump forces the working fluid in a closed circuit from the collector to the two-coil vessel through the system of copper pipes. The fluid is heated as it is transferred through the pipe system of the collector. Heat transfer from the working fluid to the sanitary water is performed through the coil pipe located inside the vessel. Having given off heat the working fluid flows through the piping to the solar group, which forces it to the solar collector. This is how the circuit is closed. 13

2.5 Elbi extension vessel Heating of the working fluid in the collector to a high temperature results in the volume of the fluid being increased. To compensate for the increased working fluid volume a membrane vessel of the capacity of 50 litres was installed in the system. Specifications ELBI ER 50 CE: capacity 50 l max working pressure 8 bar pre-charge pressure 1,5bar H 410mm De 270mm Ø ¾'' Principle of operation To protect the system from excessive pressure build-up a safety valve was used in the system, set to the pressure of 6 bar. The valve is an integral part of the solar group. Should a release of the working fluid through the safety valve occur the system must be refilled with identical fluid. Instructions for installation and start-up of ELBI membrane vessels ELBI membrane vessels can be used in closed central heating systems protected according to PN- 99/B-02414. It must be assumed that the pre-pressure in the membrane expansion vessel connected to the suction side of the circulating pump is not less than: p = p st + 0.2 where p st : hydrostatic pressure (in bars) in the water heating system at the level of the pipe connected to the vessel expansion pipe, for the system water temperature of t 1 =10ºC. 14

Example: static pressure of the central heating system = 2.7 bar pre-pressure in the vessel = 2.9 bar The safety valve should be adjusted so that the initial opening pressure is equal to or lower than the admissible pressure in the expansion vessel, while accounting for the difference in levels between the expansion vessel and the safety valve. Closing pressure should not be less than 80% of the initial opening pressure. The safety valve should be sealed. It is recommended to install ELBI expansion vessel in the return line of the system. Mounting should be performed according to the design and standards and regulations in force. During installation water flows into the vessel. The system should be filled with cold water at the pressure, which is 0.1 bar higher than the pre-pressure (i.e. 3.0 bar in the example above). Once the a.m. conditions are met the system is ready for operation. Remarks: 1. It is forbidden to make any modifications in the design of and remodel ELBI pressure vessels. 2. While introducing any pressure changes ELBI pressure vessels must be disconnected from the system. 3. Check the pre-pressure in the vessels without manometers using a separate gauge e.g. tyre pressure gauge. 4. Where p x V 50 [bar litre] the expansion vessel must be approved for putting into operation by a locally relevant Inspectorate of Technical Inspection. 5. It is recommended to carry out an inspection of the expansion vessels at least once a year. 15

2.6 Set for connecting double solar group with heater 18mm installations 2.7 Liquid for WATT CPC collectors Ready-to-use reversibly evaporisable special heat-transfer fluid based on propylene glycol, for utilisation in solar heating installations Chemical composition - Propylene glycol, water, and inhibitors Technical data: Appearance clear, red-fluorescent liquid Density (20 C) 1.032 1.035 g/cm³ ASTM D 1122 Refraction index nd20 1.380 1.384 DIN 51757 ph value 9.0 10.5 ASTM D 1287 Alkali reserve min. 20 ml 0.1 n HCl ASTM D 1121 Viscosity (20 C) 4.5 5.5 mm²/s DIN 51562 Boiling point 102 105 C ASTM D 1120 Flash point none DIN 51376 Water content 55 58 % DIN 51777 Frost protection 28 C ASTM D 1177 16

3. Supervision of solar system 3.1. Control of working medium parameters Due to the working medium operating at high temperatures the fluid ageing may be accelerated and its parameters (in particular ph, density and freezing point) may be changed. It is recommended to check the working medium parameters at annual intervals. 3.2. Checking the preliminary pressure In the extension vessel Pressure check in the vessel by means of control manometer is recommended. 3.3. Vessel It is indispensable to carry out inspections of vessels used in solar systems at intervals not longer than two years. Attention must be paid to the fact that magnesium anodes used in enamelled vessels are subjected to natural wear and tear and they must be exchanged. 4. Upon completion of the installation the authorized installer/customer should check if the following activities have been carried out properly 4.1 Appropriate selection of pipes and their connection: a) The glycol system pipes should be made of copper or steel. Under no circumstances may PVC pipes be used. It is also possible to use pre-insulated stainless steel pipes however they may not form pipeline sections longer than 10m due to system venting problems. b) Solder to be used for the system must be of hard type (e.g.: PbCu). Compression fittings with rings may be used instead. Do not use couplings with rubber or plastic parts. Sealing of pipe joints must be made with hemp and sealing paste. It must be always noted that the temperature in the system may reach 280 C. 4.2 Appropriate system insulation The piping should be insulated along the whole length with coating. Attention must be paid to the coating method and the quality of joints. 4.3 System tightness Check if the system is tight and dry and if no significant pressure drops occur after longer time. 4.4 System valves Check if the collector vent valves were closed on the day after venting was performed. 17

4.5 Filling and venting equipment Attention must be paid to the venting method exercised by the fitter. The fitter should use professional equipment for filling, flushing and venting of the solar systems. It may resemble the station available in our offer. He may also use other devices equipped with pumps of suitable parameters, which are able to provide a pressure of 5 bar in the system. a) The best venting method is by the so-called pressure jumps consisting in turning off the pump return pipe to increase the pressure and then quick opening of the valve. If the system is properly vented the pressure should rise very quickly on the valve closing to reach the safety valve limit (6 bar). b) The system should be vented on both sides i.e. by removing air from both the collectors and the vessel. 4.6 Protection of collectors from solar radiation during installation It is of utmost importance to keep the collectors covered during installation on roof, filling, venting or adjusting. Where possible they should be covered with a film, tarpaulin or original cardboard boxes. 4.7 Check flow adjustment Once the system is fully vented check the flow on the rotameter. The flow should be adjusted on the rotameter during manual pump operation (100% speed). According to design values: 0,6 l/min per square meter for vacuum collectors. 4.8 Check fluid quality Check whether the fluid in the system is the one recommended by WATT and whether it is not diluted with water or mixed with other fluids, which do not meet the guidelines of the National Institute of Hygiene.!!! ATTENTION!!! ONLY THE FLUIDS OFFERED BY WATT ARE 100% NEUTRAL (NON-TOXIC); BY USING OTHER FLUIDS YOU LOSE THE WARRANTY FOR THE ENTIRE SOLAR ENERGY SYSTEM 4.9 Check if original vessels have been used Membrane vessel should be properly selected for the system according to the formula available at: www.watt.pl 18