Plumbing and Electrical Installation Guide
Contents
1. ceeeeeeeeeees Be TOOS REQUIST aese aen aae EA EEES 4 3 Consumables Required ssssseiessserrrresrrrrrreereee AA Optional terms casone e 5 First Fix Plumbing eeren 5 1 Solar Circuit and CONNECH ON scere 5 2 Tile Connections and CheckS sceccerereen 5 3 Connecting the Flow Meters Roof void 5 4 Connecting the Tile Temperature Sensor Assembly Roof VOiIC ccceeeeeeeeeeeeeeeeeteeeeetes 5 5 Running the Pipe Work to the Cylinder Cupboard 5 6 Installing the Pressure Relief Valve Cylinder CUP GA A ieena Taaa 5 7 Installing the Pressure Testing Filling Assembly Cylind r CUDD OANA a eoa naese 5 8 Pressure Testing the Solar Array Cylinder CUP GATA iieo 6 First Fix Electrical ereere 6 1 Installing the 5A fused Spur ee eeeeeeteeeteeeeeees 6 2 Installing the collector temperature sensor SXTOMSION Kit its renien nase an geen Neen 7 Cylinder Installation 0 00c ee 8 Second Fix Plumbing eerren 8 1 Installing the Pump Station Cylinder cupboard 8 2 Installing the Pressure Relief Valve and Tundish Cylinder cupboard 0 eeceeeeeeeeteeeessstteeaaees 8 3 Installing the Expansion Vessel Cylinder c UpBOsrd ssc 24 8 4 Installing the Heat Quantity Meter Sensor Pocket Gylinder CUO ONG z es niee eei 25 8 5 Installing the Energy Cut out Valve esee 26 8 6 Installing the Drain Cock Cylinder cupboard 26 8 7 Ins2. 5 First Fix Plumbing continued 5 8 Pressure Testing the Solar Array Cylinder cupboard Check the tile circuit connections with either a dry air or wet solar fluid pressure testing kit The flow and return pipe work will need to be temporarily capped for the pressure testing the system kit does not include stop end couplings for this purpose The tile connection circuit should be pressure tested to 6 bar determined by the pressure relief valve If wet pressure testing e Ensure that only the supplied Glycol Antifreeze solar fluid is used This must be diluted in a 40 60 mix with water e Ensure that the whole solar circuit is drained after testing and left open Any connections that fail should be checked in detail to identify and then remedy the fault the most common fault is a poorly tightened fitting which can be easily rectified Diagram 10 WARNING All pressure testing MUST satisfy the local health and safety legislation gt WARNING Failure to undertake a pressure test or to take heed of a pressure test failure could result in failure of the system at a later stage gt Z TIP If wet pressure testing you may wish to save the diluted solar fluid when draining the system so that you can use it in the next phase of installation Part Number 10120 01 19 C21t solarthermalrooftilesystem 6 20 First Fix Electrical 6 1 Installing the 5A fused spur A 13A 2 5 m t
3. Components should be installed in accordance with the system schematic supplied and also with the relevant British Standards and Codes of Practice Installers should be trained in Safe Working at Height and Safe Ladder Use Plumbing solar controller components and cabling should be undertaken by a competent plumber or UK Registered SHW Installer Mains pressure unvented hot water cylinder installation must be undertaken by a plumber trained to the Part G3 regulations For the AC mains fuse spur installation the cabling and connection to the pump station must be undertaken by an electrician qualified to Part P regulations Final system commissioning should be undertaken by a UK Registered SHW Installer ideally trained to BPEC Corgi or IPHD b WARNING The internal parts of an SHW tile will get hot when the tile is exposed to direct sunlight During very hot weather the flexible steel hoses may get hot even before the system is fully connected PX When the SHW system is filled and pressurised the heat transfer liquid may be heated to its boiling point and vaporised Improper system design or installation could lead to discharges from pressure relief valves faulty couplings and pipe work leaks Severe burns may result from contact with the escaping liquid or vapour The standards for installation quoted in this guide are correct at the time of printing Always refer to the latest relevant standards C21t solarthermalroo
4. Switch on the solar control unit and set the system pump control to manual HND 1 ON Allow the system pump to operate for five minutes Check that there is system circulation at the pump station flow meter and through all the tile column flow meters Switch off the system control unit and vent the system pump by loosening the vent plug Replace and tighten the plug Solar circuit pressure tests with jet pump Diagram 23 Diagram 24 Checked System circulation confirmed C21t tile column circulation confirmed Manual air vents cleared and closed Pump vented and closed 37 C21t solarthermalrooftilesystem 10 Commissioning continued 10 2 8 Setting the System Flow Rates al Set the pump speed to minimum see the Pump Station guide for details Switch on the solar control unit in manual operation Check that the calculated flow rate through the tile column flow meters is reached or exceeded If the column flow rate is exceeded adjust the individual column flow meters to the calculated rate by partly closing the regulator screw If the column flow rate is not reached increase the pump speed to the next setting and repeat the procedure above Switch off the solar control unit Commissioning hydraulics Setting Checked Pump speed set to system flow rate range System flow rate recorded C21t tile column 1 flow rat
5. First Fix Plumbing continued 5 2 Tile Connections and Checks continued Leave the flow and return hoses at the top and bottom of each column un connected 2 2 2 2 Diagram 4 WARNING Avoid forming kinks or using excessive force to bend the hoses during connection and installation because it could strain a plumbing connection within the C21t tile or rip the roofing membrane or membrane collar both of which could cause a roof leak WARNING Care should be taken when manipulating the hoses to make connections There is a risk that the hoses may spring back and cause damage or injury Part Number 10120 01 13 C21t solarthermalrooftilesystem 5 First Fix Plumbing continued 5 3 Connecting the Flow Meters Roof void Within the roof void fit a flow meter on the return pipe work in an easily accessible position diagram 5 The flow meter may be connected directly to the tile hose Ensure that the flow direction arrow on the body of the flow meter points towards the tile diagram 5a Check that the flow meters are set to fully open setting Adjust if necessary Diagram 5 Diagram 5a TIP If the location of the lowest tile means that the flow meter cannot be easily read the tile hose can be extended with 15 mm pipe work so that the flow meter is located in a visible position The number of compression fittings supplied allows for this Diagram 5 14 Part Number 10120 01 Plumbing and E
6. Frost protection setting without anti freeze Option re cooling adjustment Tube Collector Special Function Pump speed factory default Relay one status solar pump Relay two status not used English Spanish Programme WARNING The maximum hot water temperature in the cylinder SMX must be set lower than Version the control thermostat setting 41 C21t solarthermalrooftilesystem 10 Commissioning continued 10 3 3 Set the Control Unit Parameters continued Commissioning electrics Checked Controller parameter settings checked Relays set ON HND 1 amp HND 2 Delta T operation checked Controller cables clipped and tidy 10 3 4 Check the Delta t Operation Observe the operation of the system in automatic mode Depending on the weather conditions it should switch on and off This test can be simulated by removing the collector or return sensor from its pocket Flow Meter Settings Recommended Installation Location Units Comments Flow Rate Flow Rate Pump station system flow rate itres minute Tile column 1 itres minute Tile column 2 itres minute Tile column 3 itres minute Tile column 4 itres minute Tile column 5 itres minute Tile column 6 itres minute Dual Thermostat Settings Recommended Installation Units Comments Setting
7. Number 10120 01 51 C2tt solarthermalroctftilesystem For Customer Service support please contact Solarcentury on 020 7803 0180 customerservices solarcentury com 91 94 Lower Marsh P L Waterloo 4 London SE1 7AB w w T 44 0 20 7803 0100 F 44 0 20 7803 0101 so arce ntu ry wwwisolarcehtury com Part Number 10120 01
8. Other Notes The commissioning procedure is now complete Complete sign and return the commissioning certification card in order to activate the Solarcentury warranty Part Number 10120 01 47 C21t solarthermalrooftilesystem Appendix A Basic System Troubleshooting Guide Problem Possible Cause Action No power to the controller Faulty blown fuse in mains supply Faulty blown fuse in control unit Circuit breakers fuses tripped in house Power cut Check wiring and replace fuse if required Check wiring and replace fuse if required Check wiring and reset breaker Wait until power is restored Sensor fault indicated by i X symbol ii 888 8 displayed for sensor iii Operating control lamp flashes RED Faulty sensor Loose connection on sensor leads Check Change sensor Check sensor wires for proper connection Pump will not run Mains pump wiring faulty Pump rotor jammed System parameters CL CX exceeded System parameters incorrectly set CN and DO not satisfied Check wiring at mains pump See pump manufacturer s instructions Reset from table Correctly set parameters No action required Pump runs continuously HND1 setting incorrect Reset HND1 to auto No circulation in system Pump isolating valves closed Air lock at pressure relief valve Air lock in the system Pump is not running No sun shining Open valves Twist cap at pressure relief valve and vent air Clear manual
9. Setting Control or SMX 5 High limit 90 42 Part Number 10120 01 Plumbing and Electrical Installation Guide 10 Commissioning continued 10 3 4 Check the Delta t Operation continued Pressure Component Settings Recommended Installation Setting Setting Comments Expansion vessel 15 pre charge Initial system 2 0 working System operating range Relief safety valves Solar Fluid Location DM tei Your Comments Setting Setting Water 40 0 Solar Fluid Concentrate 60 0 Solar Fluid Concentrate Manufacturer Product details Freezing point Total system volume Litres Calculated 10 4 System Testing Operate the system for several minutes and check for poor circulation and any potential weeping joints Check that the whole system is functioning correctly Part Number 10120 01 43 C21t solarthermalrooftilesystem 10 Commissioning continued 10 5 Insulate Pipe Work Check that e All pipe work is insulated using high temperature insulation e All pipe work is secured with metal clips e All loose cable is tied down and contained Other elements Earthing and equi bonding All heat carrying pipework insulated All insulation secured Heat meter installation System satisfies all statutory requirements regarding energy input to an unvented hot water storage vessel as described in Building Regula
10. air pressure testing Certification Plumber Signature Company Name and Address Name Date checked Part Number 10120 01 30 Plumbing and Electrical Installation Guide 9 Second Fix Electrical 9 1 Installing the Sensors and Connecting to the Solar Controller The four sensors need to be installed in the sensor pockets Diagram 20 and the cables run back to the solar controller on the pump station The four sensors are e Tile collector temperature sensor in the loft space S1 e Lower cylinder temperature sensor S2 e Upper cylinder temperature sensor S3 e Heat quantity meter sensor below the pump station S4 Wiring connections to the solar controller Diagram 21 should be made in accordance with the details provided in the control schematic Refer to the user manual provided with the pump station for the solar controller wiring instructions Diagram 20 2 Temp Sensor Pt1000 T s2 Fai s4 112 3 4 5 61718 OSJO vosy Diagram 21 Part Number 10120 01 31 C21t solarthermalrooftilesystem 9 Second Fix Electrical 9 2 Installing the Junction Box and Terminating the Connections A 10 way junction box is provided for mains connection of the solar controller pump and solar energy cut out valve M r0 Diagram 22 All connections should be made in acco
11. air vents See above Wait until sun is out Pressure drops in system Leak in system Drain down valve not closed Pressure relief valve not fully closed Check all joints and connections Close fully Close clean and replace if necessary 48 General leaks Various If a leak occurs from the system and quick action is necessary to prevent damage drain the system Switch off the electricity to the controller Connect a garden hose to the drain cock and lead to a suitable drain point not a toilet or bucket Open the drain cock and empty the system The leak can be repaired after the system has been drained and fluid disposed of following local regulations Part Number 10120 01 Part Number 10120 01 Plumbing and Electrical Installation Guide Appendix B Draining the System Draining the system will only be required during commissioning or maintenance 1 2 o OO N D Ob e Switch off the jet pump Open the system flow meter regulating screw by setting the screw slot to vertical Open the lower valve connection to the pump station and release the anti freeze water mixture from the system into the jet pump reservoir BEWARE OF THE JET PUMP RESERVOIR OVERFLOWING WHEN THE SYSTEM PRESSURE IS REDUCED Allow the system pressure to reduce to zero Open the upper valve connection to the pump station Fit a suitable hose to the system drain cock or position a container under the
12. at the lowest point closest to the cylinder in the pipe returning to the pump station This will enable the whole system to be drained down if necessary for maintenance see appendix B Diagram 17a Part Number 10120 01 Plumbing and Electrical Installation Guide 8 Second Fix Plumbing continued 8 7 Installing the Deaerator Cylinder cupboard The solar circuit will contain a small amount of gas in the form of air pockets and micro bubbles even after conventional air venting at commissioning The solar deaerator enables both free flowing air and micro bubbles to be vented from the diluted solar fluid during system operation By doing so it e Helps optimise system performance e Enables quieter operation e Lengthens system component life The deaerator is fitted close to the cylinder on a vertical section of the flow pipe The flow pipe from the tiles is 15 mm diameter Therefore a p S 22 mm to 15 mm reducing adaptor is supplied to connect to the 22 mm m inlet of the deaerator A 22 mm pipe J can then be used to connect from the outlet of the deaerator to the cylinder inlet Diagram 18a An end cap needs to be fitted to the vent at the top of the unit if the system is to be pressure tested with air This should be left in place until the whole solar circuit has been pressure tested and then removed before final commissioning with correctly diluted sol
13. by setting the valve at 45 On unvented cylinders set the solar energy cut out valve to manually open Check that all flow meters on the solar tile columns are fully open Fill the jet pump filling unit reservoir with 40 concentration anti freeze and 60 water Open both filling valves on the pump station TIP If possible fill the system on a cloudy day and or in the early morning This will reduce system temperatures and reduce the risk of scalding WARNING Wear gloves and goggles to protect against scalding when filling the system When the SHW system is filled and pressurised the heat transfer liquid may be heated to its boiling point and vaporised Discharges are possible from the pressure relief valves poorly connected couplings and joints Severe burns may result from contact with the escaping liquid or vapour Part Number 10120 01 Part Number 10120 01 Plumbing and Electrical Installation Guide 10 Commissioning continued 10 2 4 Wet Pressure Testing of the System at 6 Bar T 2 oN p gr Ff Switch on the jet pump filling unit Allow the jet pump filling unit to circulate through the system for 5 minutes Check that e There is a continuous return to the jet pump filling unit reservoir e The system flow meter indicator is at the maximum flow position top With the pump still running and solar fluid still circulating through the system close the lower valve connection to the pump station Allo
14. on the cylinder in the dual thermostat pocket e A 5A fuse has been fitted to the switched spur The Resol DeltaSol BS Controller is the priority control mechanism for C21t systems Switch on the solar control unit 10 3 1 Sensor Testing Sensor Function Position Collector High At DTO amp DTF Collector array flow coupling Lower store sensor Low At DTO amp DTF Pocket in lower section return Maximum store temperature of cylinder Upper store sensor Customer information EM Mid height cylinder pocket cylinder Heat quantity Heat quantity measurement Return pipe work measurement sensor OHQM below pump station In turn for each sensor 1 With clean hands take the sensor out of its pocket and hold it in your hand 2 Check that the temperature reading for the sensor on the control unit display is around 37 C this is the normal temperature of the human body Refer to the Resol manual for details of how to display sensor temperatures 8 Replace the sensor ensuring that it is properly fitted and retained in the correct sensor pocket Part Number 10120 01 39 C21t solarthermalrooftilesystem 10 Commissioning continued 10 3 2 Control Thermostat Testing 1 Check the operation of the energy cut out valves by switching the system off and on This will enable you to observe valve opening and closing 2 Check the operation of the control thermostat by setting it to the mini
15. the roof void if there is not enough room for it in the cupboard Additional fittings to those supplied with the system will be required to achieve this WARNING Mains pressure unvented cylinders must be installed by a plumber qualified to Part G3 regulations Fit the cylinder in accordance with the instructions provided in the user manual supplied with the unit Part Number 10120 01 Regulation quoted is correct at time of going to print 21 C21t solarthermalrooftilesystem 8 Second Fix Plumbing The remaining solar circuit is completed in stages 8 1 to 8 9 as described in the following pages This process will finish with you making the connections to the cylinder and flushing the system 8 1 Installing the Pump Station Cylinder cupboard Compression to threaded BSP fittings are supplied for connecting the pump station into the solar circuit e The 22 mm fitting allows connection from the cylinder e The 15 mm fitting allows connection to the 15 mm return pipe to the tiles Be sure to use the high temperature sealing ring with the fittings supplied for both connections Position the pump station close to the cylinder in the cupboard so that the sensor cables and power cable can be run into it without interfering with the cover when refitted Position the pump station to ensure that all the connections and the front face of the pump station are visible and easily accessible for future maintenance Mount according
16. Commissioning e Hydraulic commissioning e Electrical commissioning e System test e Pipe work insulation e Attach warning labels and notices e Return a copy of the Commissioning Certification to Solar Century Part Number 10120 01 Plumbing and Electrical Installation Guide 4 Installation Checklist Before proceeding with the installation e Check that you have all the required parts supplied by Solarcentury e Check that you have the necessary tools and consumables required for the installation Depending on the location of the cylinder cupboard you may need to order additional items from Solarcentury Solarcentury parts supplied The following items are supplied Pack C21t Loft Box Description Quantity Sensor pocket RESOL brass chromed 60 mm X 0 5 BSP Compression equal tee 15 mm Compression straight coupling 15 mm X 0 5 BSP female Pack C21t System Box SHW system fluid concentrate 10 L Exansion vessel wall bracket and hose for 10225 01 Expansion vessel 18 L 10 BAR 120 C Pumpstation RESOL flowcon A DeltaSol BS 3 Deaerator Sprirovent vertical 10 BAR 180 C 22 mm X 22 mm C21t Cylinder cupboard template C21t Laminated system schematic GB C21t Laminated wiring control schematic GB Home operation and maintenance guide GB C21t Plumbing installation guide GB Sensor grommet grey Junction box RESOL including ove
17. Plumbing and Electrical Installation Guide C2tt solarthermalroctftilesystem For new build only to commence after installation of the C21t tiles ey This guide must be left with the property owner after installation ta Issue 02 December 08 SO l a re e n t u ry Solarcentury 2008 Part Number 10120 01 Loft void Zt Th l i vA i A Boiler primary circuit 09 oO eeu Cylinder Cupboard Lower floor T l i l l heating i T PRV vented 1 to comply Sees ea ees with local plumbing regulations C21t Solar Thermal Roof Tile Compression Straight Coupling 15 mm x 15 mm Compression Equal Tee Coupling 15 mm Compression Straight Coupling 15 mm x 0 5 in BSP Female Sensor Pocket Brass chromed 60 mm x 0 5 in BSP Male Collector Temperature Sensor FRP6 Collector Temperature Sensor FKP6 Bl
18. SECTION FIRST Solar thermal collectors and systems are not always readily identifiable within a building structure or heating system and can represent a significant risk of burns and heat damage if not treated properly The collector array should be accessible to competent persons only Solar absorbers and their pipe connections are capable of reaching temperatures approaching 200 C Installation and operating instructions must be read and understood before conducting any work on the system Always take care If you have any queries ask an experienced solar installer or engineer for guidance Temperature Severe burns can result from contact with the surfaces of some elements of the C21t system e Metal parts left in direct sunlight can reach temperatures of up to 80 C e The absorber surface within a C21t tile can reach temperatures approaching 200 C e Conduction heat transfer will cause other parts of the C21t tile and pipe work to reach similar high temperatures Conversely in cold weather metal components can become very cold Pressure The C21t system should not pose a risk to users as long as it has been installed correctly However if it is installed incorrectly there is a risk that severe burns or scalds could result from contact with liquid and or vapour escaping from the system e When the solar hot water circuit is filled and pressurised the heat transfer liquid may be heated to its boiling point and vaporise e Improper syste
19. ack 8 Collector Sensor Connection Box with Over Voltage Protection 9 Flow Meter 0 6 2 4 Litres Per Minute Range 15 mm 10 Expansion Vessel 18 Litre 10 Bar 120 Degrees C 11 Compression Straight Coupling 15 mm x 0 75 in BSP Male with High Temperature Sealing Ring 12 Pre assembled Single Line Pump Station Flowcon A Deltasol BS 3 13 Pressure Gauge Supplied on Pump Station 14 Pressure Relief Safety Valve Supplied on Pump Station 15 Filling and Flushing Drain Valve Supplied on Pump Station 16 Solar Thermal Pump Supplied on Pump Station 17 Flow Meter Supplied on Pump Station 18 Integrated Differential Temperature Controller Deltasol BS 3 Supplied on Pump Station 19 Compression Straight Coupling 22 mm x 0 75 in BSP Male with High Temperature Sealing Ring Sensor Pocket Brass chromed 60 mm x 0 5 in BSP Male 20 Flexible Hose 21 Isolating Valve with Handle 15 mm x 15 mm 22 Compression Stop End 15 mm 23 Compression Reducing Set 22 mm to 15 mm 24 Vertical Solar Deaerator 10 Bar 180 C 22 mm x 22 mm 25 Pressure Relief Safety Valve High Temp 0 5 in x 0 75 in BSP 6 Bar 26 Compression Straight Coupling 15 mm x 0 5 in BSP Male 27 Compression Straight Coupling 22 mm x 0 75 in BSP Male 28 Tundish 0 75 in 29 Compression Reducing Tee 22 mm x 22 mm x 15 mm 30 Compression Straight Coupling 15 mm x 0 5 in BSP Female 31 Sensor pocket Brass chromed 60 mm x 0 5 in Male 32 Heat Quantity Temperatur
20. ar fluid Diagram 18 ra TIP If the end cap is removed before the dry pressure test the system will not hold pressurised air WARNING The solar deaerator weighs approximately 2 kg and is supported by the pipe work it is connected to Therefore the pipe work either side of the solar deaerator must be properly secured using metal clips to adequately support the deaerator s weight Part Number 10120 01 27 C21t solarthermalrooftilesystem 8 Second Fix Plumbing continued 8 8 Completing the Cylinder Connections Cylinder cupboard Complete the solar circuit by making the final pipe work connections to the cylinder Diagram 19 Part Number 10120 01 28 Plumbing and Electrical Installation Guide 8 Second Fix Plumbing continued 8 9 Flushing the System Cylinder cupboard It should not be necessary to flush the system providing that compression joints have been used throughout the solar circuit and that they have been sealed with PTFE tape The commissioning procedure involves an element of system flushing through the jet pump filter This will normally be adequate to remove small amounts of excess flux or jointing paste if they have been used in small quantities WARNING If numerous silver solder joints have been made or if jointing paste has been used the solar system below the C21t tile array must be thoroughly flushed before proceeding The flow a
21. dicator on the column flow meters is at the maximum flow position top of the flow meter window If there is a restricted or zero flow through a column then close the flow meters on all the other tile columns Allow the jet pump filling unit to circulate through this single column The column flow meter should indicate maximum flow Open the flow meters on all the other columns and re check the flow rate through the column under test All the column flow meters should now show maximum flow Continue to circulate the anti freeze water mixture through the system for a further five minutes Maintain the system pressure at approximately 3 bar by adjusting the lower valve connection to the pump station After five minutes close the lower valve connection to the pump station Immediately close the upper valve connection to the pump station Switch off the jet pump filling unit Part Number 10120 01 Part Number 10120 01 Plumbing and Electrical Installation Guide 10 Commissioning continued 10 2 7 Venting the System Pump l Restore the non return valve above the pump by setting the valve to vertical 90 see Diagram 23 Replace the control unit onto the pump station assembly Open the system flow meter regulating screw by setting the screw slot to vertical see Diagram 24 On unvented cylinders return the solar energy cut out valve to automatic operation Set the system pump speed to its maximum setting normally 3
22. drain cock Open the drain cock and drain the remaining anti freeze water mixture into the container 49 C21t solarthermalrooftilesy Appendix C System Schematics Collector Sensor Black Cable 1A 1B 3 Connection Box 9 with Over Voltage Protection i 2A 2B Loft Void ie Lower Store Cylinder Return Sensor Grey Cable Cylinder Cupboard i Upper Store Cylinder Sensor Grey Cable ij Hear Quantity Meter Sensor Grey Cable gt 0 5mm 2 core PVC twisted flex Pump Station in Switched TT TT Fused Spur Resol Control Unit ii it Li Pump s b bs be L1 N E S1 S2 S3 S4 E i E N L N L 12 19 20 13 7 8 E x Link Link only required with power open power closed energy cut out valve Wiring connections dependent I elo on safety components supplied T 10 Way Junction Box T ale with cylinder Request a i ina j cylinder specific control 1 2 3 4 5 6 7 8 9 10 schematic from Solarcentury The control thermostat and E E energy cut out valve may not be s included with thet cylinder BI Br Or Gr Ba LA Request a cylinder specific control schematic from High Limit Control Solarcentury Dual Thermostat Energy Cut Out Valve Part Number 10120 01 50 Plumbing and Electrical Installation Guide Part
23. e Sensor FKP6 Black 33 Drain Valve 15 mm Plain Shank MT Plug Type A 34 Upper Store Cylinder Temperature Sensor FRP6 35 Lower Store Cylinder Return Temperature Sensor FRP6 36 Junction Box x 10 way 87 Twin Coil Unvented Stainless Steel Cylinder Kit 38 Sensor Grommet Grey 39 Solar Hot Water System Fluid Concentrate 10L 40 Two Port Valve Solar Energy Cut Out Valve may be supplied in cylinder 41 Dual Thermostat may be supplied in cylinder 42 Switched Fused Spur 5A 43 Expansion vessel servicing coupling Part Number 10120 01 Part Number 10120 01 Plumbing and Electrical Installation Guide C2tt solarthermalroctftilesystem This guide provides a step by step overview for the installation and commissioning of the plumbing and electrical components of a standard C21t solar thermal roof tile Solar hot water SHW system It is intended for systems of up to 32 C21t tiles connected to an unvented mains pressure cylinder For other system configurations please consult Solarcentury Contents Symbols and Notification Used 1 Health and Safety Considerations 4 2 General Guidance 0 cc eesse rererrrrrsrrrrrr reren 2 1 System OVEViIOW eee ceececeecceeeceeeeecteeeeeetesttaatees 2 2 SKINS REGUE ernia AE 3 Quick Installation Guide 00 e 4 Installation Checklist eree 4 1 Solarcentury Parts Supplied
24. e checked set C21t tile column 2 flow rate checked set System pressure reduced to cold fill pressure 10 2 9 Setting the System Cold Fill Pressure 1 System commissioning Setting Reduce the system pressure to the cold fill pressure of 2 1 bar by opening the lower valve connection to the pump station and releasing anti freeze water from the system into the pump station reservoir Beware of the jet pump filling unit reservoir overflowing Disconnect the jet pump filling unit from the pump station and re place the screw caps onto the upper and lower pump station valves System pressure reduced to operating pressure 2 bar Fill and drain valves closed Jet pump disconnected and blanking caps replaced Energy cut out valve set to AUTOMATIC This completes the hydraulic commissioning 38 Part Number 10120 01 Plumbing and Electrical Installation Guide 10 Commissioning continued 10 3 Electrical Commissioning Procedure Create a configuration record by completing this section as each procedure is finished Ensure that the hydraulic commissioning has been completed Then check that e All electrical wiring conforms to the control schematic e The system control unit is set to manual e The control thermostat is set to maximum e The energy cut out valve is set to automatic e The pump speed has been set e The column flow meters have been set e The S2 sensor has been installed
25. er from the cylinder is supplied to the taps in the normal manner The system can be supported with other sources of heat such as a gas oil or an electrical immersion heater The system works independently alongside the existing heating hot water systems but uses the same vessel for heat storage The rooftop SHW tiles can be treated much like any other source of heat such as a boiler e The FLOW refers to the pipe work FROM the source Cok of the heat TO the cylinder il e The RETURN refers to the pipe work TO the source of heat FROM the cylinder A g Use the cylinder cupboard template to ensure there is sufficient space in the cylinder cupboard for all the components Diagram 1 Part Number 10120 01 Part Number 10120 01 Plumbing and Electrical Installation Guide A IMPORTANT All connections in the solar circuit MUST be made using compression fittings Solder connections are unsuitable because the solar circuit reaches temperatures significantly higher than traditional plumbing Silver solder does meet the temperature requirements However the use of flux necessitates additional thorough flushing of the system prior to commissioning Skills Required All components must be installed by competent persons suitably qualified and trained
26. ests with jet pump Setting Checked Anti freeze concentration checked 40 Anti freeze added 5 bar wet pressure test All collector couplings checked All system couplings checked Drain cocks closed and tightened Operation of pressure relief valves checked 35 C21t solarthermalrooftilesystem 10 Commissioning continued 10 2 5 Venting the System 36 al oa F UUN Open the system flow meter regulating screw by setting the screw slot to vertical and then returning the screw slot to horizontal This clears the air trapped in the flow meter Switch on the jet pump filling unit Open the upper valve connection to the pump station Immediately partially open the lower valve connection to the pump station Allow the system pressure to fall to approximately 3 bar With the jet pump filling unit circulating anti freeze water through the system adjust the lower valve connection to the pump station to maintain a system pressure of approximately 3 bar BEWARE OF THE JET PUMP FILLING UNIT RESERVOIR OVERFLOWING WHEN THE SYSTEM PRESSURE IS REDUCED Allow the jet pump filling unit to circulate through the system for five minutes Check that there is a continuous return to the jet pump filling unit reservoir and that the system flow meter indicator is at the maximum flow position top 10 2 6 Venting the Individual Tile Columns Check that the flow in
27. eted solar circuit see section 8 9 e Ensure that the pump rotating vane is not jammed and that the pump rotates freely To do this 1 Remove the pump vent plug 2 Rotate the pump vane with a flat screwdriver 3 Replace the vent plug Part Number 10120 01 e Be sure the drain cock is closed 33 C21t solarthermalrooftilesystem 10 Commissioning continued 10 2 2 Pre filling Checks continued Pre filling checks Checked Expansion vessel pressure set All pipe work secure 6 bar pressure test on C21t tile array BY OTH 6 bar pressure test on complete system BY OT 34 Confirm pump rotating vane not jammed 10 2 3 Connecting the Jet Pump Filling Unit ae e N o Go Oo NO aI FF amp Ensure the solar system control unit is switched off Connect the jet pump filling unit hoses to the pump station e FLOW from the jet pump filling unit to the TOP connection e RETURN to the jet pump filling unit to the LOWER connection Be sure the couplings are fully tightened Remove the jet pump filling unit reservoir screw cap Check that the system drain valve is closed Check that the expansion vessel gas pressure is 1 5 bar Close the system flow meter regulating screw within the pump station by setting the screw slot to horizontal Remove the control unit from the pump station assembly to access the non return valve Open the non return valve above the pump
28. fault the most common fault is a poorly tightened fitting which can be easily rectified AN WARNING All pressure testing must satisfy the relevant local health and safety legislation Part Number 10120 01 29 C21t solarthermalrooftilesystem 8 Second Fix Plumbing continued 8 11 Pre commissioning Checks Before beginning the full commissioning procedure confirm that the following requirements have been met Tick when Pre commissioning Checks confirmed All the system components and pipe work is complete and secure The system pipe work has been flushed and drained if paste or soldered fittings have been used Two hoses per C21t tile have been brought into the loft space The roof membrane penetrations have been checked and remain weathertight C21t solar tiles are installed in correct configuration visual check Insulation checked The collector sensor is secured in its pocket System components have been installed according to the system schematic The complete system has been pressure tested to 5 8 6 bar System pressure testing results have been recorded in writing The expansion vessel pressure has been checked at 1 5 bar The secondary system is filled The drain to waste pipe work has been completed the drain to waste vessel is in place The deaerator cap has been removed if fitted for
29. ftilesystem 3 Quick Installation Guide The installation process can be viewed as four stages e First Fix Plumber and Electrician e Cylinder Installation Plumber e Second Fix Plumber and Electrician e Commissioning Plumber and Electrician First Fix Plumber First Fix Electrician e Join the C21t tiles into columns e Run cable for the fused spur to the cylinder cupboard e Join the columns of tiles into the final array e Install the collector temperature sensor e Fit the column flow meters and sensor pocket extension kit assembly to complete the solar array e Bring flow and return pipe work to the cylinder cupboard e Fit the supplied pressure relief valve and pressure testing filling assembly e Pressure test the tile array using either air or solar fluid e Drain the system reclaiming the fluid for use at a later stage Second Fix Plumber Second Fix Electrician nstall the pump station e Install the four system sensors and run the collector sensor cable to the cylinder cupboard nstall the expansion vessel e Terminate the pump station and solar controller connections nstall the heat meter sensor pocket nstall the energy cut out valve e Terminate the 5A fused spur nstall the drain cock nstall the deaerator e Make the cylinder connections e Pressure test the complete circuit and drain down the system reclaiming the fluid for use at a later stage e Pre commissioning checks
30. iiieiisis 44 10 6 Attaching Warning Labels and Notices n 45 10 7 CeriliCation wise Wea teehee eae 46 Appendix A Basic System Troubleshooting Guide 48 Appendix B Draining the System ccceeceeeeeteeeeeetetees 49 Appendix C System Schematics ccccccceeeeeeeeeeenees 50 C21t solarthermalrooftilesystem Symbols and Notification Used The following symbols are used throughout this document contain important information relating to safety or refer to a procedure that should be followed to prevent risk of injury or damage to any part of the installation N A triangle with an exclamation mark indicates a general warning The text adjacent to the symbol will A triangle with the HEAT symbol indicates a warning relating to a heat hazard e g a risk of burn or scald A triangle with the FLASH symbol indicates a warning relating to an electrical hazard e g a risk of electrical shock This symbol indicates that a warning label should be applied at this stage A circle with an i indicates that further information is available in the manufacturers manuals or other documentation supplied with the system J h A tick indicates a tip that could make installation easier Sections 8 to 10 MUST be completed by the Installer Commissioning Engineer Part Number 10120 01 Plumbing and Electrical Installation Guide 1 Health and Safety Considerations IMPORTANT READ THIS
31. lectrical Installation Guide 5 First Fix Plumbing continued 5 4 Connecting the Tile Temperature Sensor Assembly Roof void Fit the collector temperature sensor assembly at the top of the first column of tiles using brass compression fittings The first column is the one on the far right or far left if this helps reduce the cable run to the solar controller when viewed from within the loft void 2 Diagram 6 Diagram 6a TIP Fit the assembly only The sensor will be fitted during the second fix electrical installation see 9 1 Refer to the Solarcentury system schematic provided for connection details WARNING Solder joints must NEVER be used in the loft void due to increased fire risk All joints in the loft void MUST be brass compression fittings Solder joints cannot withstand the high temperatures of the solar circuit Part Number 10120 01 15 C21t solarthermalrooftilesystem 5 First Fix Plumbing continued 5 5 Running the Pipe Work to the Cylinder Cupboard Connect the columns of tiles in parallel to a common flow and return It is recommended that all flow and return pipe work is 15 mm diameter copper Flow and return pipe work should fall steadily from the tiles back to the cylinder location If this is not possible ensure that manual air vents are fitted to vent any trapped air during commissioning 2 5 Diagram 7 WARNING All joints in the loft void MUST be brass com
32. lumn flow meters Hose couplings C x rows r lengths metres C t 1 c 12 2x6 24 2 is 16 2x8 32 2 17 20 4x5 40 4 23 24 4x6 48 4 27 28 A 7 56 4 Si 32 4x8 64 4 s6 Tools required e Standard set of plumbing tools e Air pump with Schrader valve connection a foot pump or cycle track pump is ideal e Either a dry test kit with Schrader valve and 15 mm push fit fitting or a wet pressure test kit e Jet pump filling unit Consumables required e 5A switched fused spur e 015 mm 22 mm copper pipe for fitting the connection between the roof and cylinder location e Metal pipe clips not plastic e PTFE Teflon tape e High temperature pipe insulation rated to at least 150 C for the pipe work between the roof pump station and cylinder e Suitably rated compression fittings for the pipe runs Optional items Depending on the location of the cylinder cupboard relative to the C21t tiles and the space available in the cylinder cupboard you may need to purchase the following additional items e Fittings for remote location of the expansion vessel e Additional sensor cable e Manual air vents e Additional high temperature pipe insulation Suitable twin coil cylinder this is only required if you have not purchased a hot water cylinder with the Solarcentury system Please contact Solarcentury if additional components or spares are required Part Number 10120 01 Plumbing and Electrical Installati
33. m design or installation may lead to discharges from pressure relief valves faulty couplings or joints System Fluid The system fluid is non toxic when diluted to its correct mix of 40 glycol antifreeze and 60 water AN WARNING Do not mix system fluids from different manufacturers Access A safe means of access and a safe working environment including protection from falls should be established before any work is carried out on the system 2 General Guidance About this Guide e Provides the information to enable a competent plumber or solar installer who is already familiar with the basic system components to undertake the installation of the plumbing and solar controller components e Provides a suitably qualified plumber with guidance for connecting to the mains pressure hot water cylinder e Provides a fully qualified electrician with guidance for connecting the AC mains supply WARNING Check that the C21t tiles already installed comply with the system design guide If they do not seek advice from the system designer before proceeding Part Number 10120 01 C21t solarthermalrooftilesystem System Overview The C21t solar thermal tiles and related system components form a solar hot water SHW system that collects thermal energy from sunlight and uses it to heat water in the hot water cylinder The system uses a heating coil in a similar way to a typical domestic boiler Hot wat
34. mum setting When you do this the energy cut out valve should close 3 Set the control thermostat to its maximum setting normally 65 C The energy cut out valve should open Commissioning electrics Checked Correct fuse fitted to switch spur to solar controller Sensor tested on controller Operation of cylinder energy cut out valve checked Operation of control thermostat checked and set Operation of high limit thermostat Part Number 10120 01 40 Part Number 10120 01 Plumbing and Electrical Installation Guide 10 Commissioning continued 10 3 3 Set the Control Unit Parameters Set the Resol DeltaSol BS controller settings as shown below Parameter Setting Function Setting Tick when completed TIME Time Hours amp Minutes SYSTEM Single coil cylinder setting ARR 1 OHQM Heat quantity meter set on ON VMAX System flow rate Heat transfer medium propylene glycol 0 15 L min tile Percentage anti freeze concentration Switch on differential Switch off differential Adjustment Default Adjustment Default Maximum hot water temperature in cylinder Collector limit temperature System cooling Collector maximum temperature Minimum switch on temperature activated Minimum switch on temperature setting
35. nd return pipe work to the C21t tile array must be disconnected from the solar circuit before flushing to prevent contaminants entering the array Drain the system completely after flushing and ensure that no liquid is left in any pipe work loops Reconnect the pipe work to the tile arrays Before filling the system ensure that all waste discharges are safely disposed of in accordance with local regulations WARNING Any contaminants that enter the C21t tile array can seriously reduce system performance and may invalidate the warranty 8 10 Pressure Testing the Complete Solar Circuit The whole solar circuit should now be connected Prior to filling with diluted solar fluid see section 10 2 use a dry or wet test kit to pressure test the system to 6 bar determined by the pressure relief valve rating A temporary end cap must be installed on the deaerator during air pressure testing WARNING Air pressure tests are potentially dangerous because of the forces created by the compressed air Personal protective equipment including goggles should be worn and the building should be cleared of all persons other than the solar installer Wet pressure tests must use correctly diluted solar fluid and the solar circuit must be drained after testing vf TIP You may wish to collect the solar fluid mix after testing and use it to fill the system at commissioning Any connections that fail should be checked in detail to identify and then remedy the
36. on Guide 5 First Fix Plumbing 5 1 Solar Circuit and Connection The C21t solar thermal roof tiles are connected together in series to form columns using pre fitted flexible hoses and suitably rated brass compression fittings All multiple columns installed are connected together in parallel The flow and return are connected back to the pump station and cylinder within the building If required PTFE tape is recommended instead of paste on fittings and connections Note that compression coupling manufacturers state that no tape or paste is required AN WARNING Failure to follow this guidance may cause damage to equipment or injury to installers or users Refer to the Solarcentury system schematic and wiring control schematic provided 5 2 Tile Connections and Checks When completing the C21t solar thermal roof top installation the roofer feeds the inlet and outlet hose from each C21t tile through membrane collar These hoses are left hanging in the roof void for connection by the plumber For further details about the roof installation processes refer to the C21t Solar Thermal Roof Tile On Roof Installation Guide A 2 Za AA as Sv KAN Blue go i A Blue Red SE JN A Blue i Bed IP JR ZE Blue i Red Blue i Red NI Part Number 10120 0 Diagram 2 11 C21t solarthermalrooftilesystem 5 First Fix Plumbing continued 5 2 Tile Connections and Checks continued There are
37. pression fittings Solder joints cannot withstand the high temperatures of the solar circuit Part Number 10120 01 16 Plumbing and Electrical Installation Guide 5 First Fix Plumbing continued 5 6 Installing the Pressure Relief Valve Cylinder cupboard A 6 bar pressure relief valve must be fitted from the flow pipe within the cylinder cupboard This will allow the pressure test to be completed and then vented to a drain as part of the first fix installation Compression connections to threaded BSP adaptors are supplied for connecting the valve into the solar circuit e The 15 mm fitting allows connection from the 15 mm flow pipe e The 22 mm fitting allows connection to the 22 mm vent pipe Diagram 8 Diagram 8a Part Number 10120 01 C21t solarthermalrooftilesystem 5 First Fix Plumbing continued 5 7 Installing the Pressure Testing Filling Assembly Install the pressure testing filling assembly within the cylinder cupboard Use the 15 mm equal tee isolating valve and end stop provided Diagram 9 All pipe work must be secured with metal pipe clips to avoid movement The clips should be spaced at approximately one meter intervals This leaves space for insulation to be fitted following commissioning Diagram 9a vA TIP Do not fit insulation to the flow and return pipe work at this stage 18 Part Number 10120 01 Plumbing and Electrical Installation Guide
38. r voltage protection Junction box Honeywell 10 way Temperature sensor RESOL FRP6 with 2 5 m cable Temperature sensor RESOL FKP6 with 2 5 m cable Cable temperature sensor extension 10 m Pressure relief valve high temperature 0 5 X 0 75 BSP 6 BAR Tundish 0 75 BSP Compression straight coupling 22 mm X 0 75 BSP male Compression straight coupling 15 mm X 0 5 BSP male Compression reducing tee 22 mm X 22 mm X 15 mm Drain valve 15 mm plain shank MT plug type A Sensor pocket RESOL brass chromed 60 mm X 0 5 BSP Compression straight coupling 15 mm X 0 5 BSP female Compression isolating valve 15 mm with handle Compression stop end 15 mm Compression reducing set 22 mm to 15 mm Compression equal tee 15 mm Compression straight coupling 22 mm X 0 75 BSP male with high temperature seal Compression straight coupling 15 mm X 0 75 BSP male with high temperature seal Part Number 10120 01 C21t solarthermalrooftilesystem 4 10 Installation Checklist continued The components listed above remain the same for all system configurations up to and including 32 C21t tiles The number of couplings that connect the tiles the amount of high temperature insulation and the number of flow meters supplied can be calculated as follows C21t tiles t Array columns c Tile hose insulation Co
39. rdance with the details in the control schematic provided see Appendix C WARNING Do not connect the 5A supply until the 5A fused spur has been correctly installed see section 9 3 WARNING All wiring must be completed before the AC mains supply connection is made by a suitably qualified electrician 9 3 Connecting the Mains Supply A 5A fused spur is required to supply the solar controller pump and solar energy cut out valve This should be installed at the cylinder location adjacent to the pump station Fit the 5A fused spur and connect the power supply to the 10 way junction box If the pump station is fitted with a 13A plug this should be removed and replaced with a cable from the junction box to the pump station Make sure all cabling is tidy and clipped where possible All power leads must be long enough to be neatly clipped and or contained Check that the pump station cover is fitted ensuring that no cabling is trapped or interfering with the cover Leave the supply isolated at the consumer unit WARNING All mains AC components and cabling must be installed by an electrician fully qualified to Part P regulations WARNING Once installed the supply should be isolated at the consumer unit until final system commissioning 32 Part Number 10120 01 Plumbing and Electrical Installation Guide 10 Commissioning This section will guide you through the commissioning procedure please fill in the relevant details
40. required as you pass through the procedure 10 1 Confirming Pre commissioning Checks Before beginning the full commissioning procedure confirm that the precommisiong checks in section 8 11 have been completed and certified by the plumber WARNING Before switching on the Resol control unit check that all electrical wiring conforms to the control schematic and that a permanent electrical supply is installed 10 2 Hydraulic Commissioning Procedure 10 2 1 Volume of Fluid and Flow Rates The table below shows the volume of liquid required to fill the system Figures are based on 40 m of 15 mm pipe work 3 L fill volume in the heat exchanger coil and a 40 glycol to 60 water system fluid mix WARNING Incorrect mixing could compromise the fluid s anti corrosion properties and or reduce system performance AN WARNING No other additives should ever be used in the solar fluid No of C21t Approximate Volume Approximate Approximate Total Flow Rate Tiles in of Concentrated Solar Volume of Volume of Diluted at Pump System Fluid Required Water Required Solar Fluid Station 12 4 4L 1 L IOL 1 8 L mi 16 4 2L 6 4L VIL 2 4 L mi 20 4 4L 6 6L VIL 3 0 L mi 24 4 6L 6 8L Vib 3 6 L mi 28 4 7L Goll IL WZ IL 4 2 L mi 32 4 9L To I2 4 8 L mi 10 2 2 Pre filling Checks Make the following checks before filling the system e Physical and visual checks of all the compression joints e Pressure test the compl
41. ring cupboard within the building Fix the supplied cylinder cupboard template to the wall of the installation area This will indicate the relevant position of all the components of the solar system that must be located in the cupboard in addition to the cylinder itself The system designer will have decided the suitability of the installation using the C21t System Design Guide however before proceeding with the cylinder installation you should confirm that e The proposed system design is indirect water is heated via a heat exchange coil within an unvented water heating cylinder e The vertical distance between the cylinder location and the top of the C21t tiles is less than 8 m e There is sufficient room to install the cylinder e There is sufficient room to make all the required connections once the cylinder is installed this will reduce complicated pipe runs e The cylinder contains two coils The solar flow and return must be connected to the lower coil The upper coil is used by the auxiliary heat source e g the boiler e If the coils in the cylinder have a single helix The flow enters the cylinder at the upper inlet of the lower coil The return exits at the lower outlet e There is a suitable vertical surface adjacent to the cylinder to mount the pump station and the 18L expansion vessel Contact your system designer if you cannot confirm any of the above points or if you have any queries The expansion vessel can be fitted in
42. t to the pump station Specific pump expansion vessel mounting requirements vary from one model to another The equipment must be secured in accordance with the instructions provided in the user manual supplied with the unit isi Diagram 14 24 Diagram 14b Diagram 14a Part Number 10120 01 Plumbing and Electrical Installation Guide 8 Second Fix Plumbing continued 8 4 Installing the Heat Quantity Meter Sensor Pocket Cylinder cupboard Fit a temperature sensor pocket assembly in the 22 mm return just below the pump station The actual sensor will be fitted at a later stage see section 9 1 Having a temperature sensor fitted to the return pipe work is necessary to enable the total thermal energy yield kWh to be recorded Diagram 15a Diagram 15 Part Number 10120 01 25 C21t solarthermalrooftilesystem 8 Second Fix Plumbing continued 8 5 Installing the Energy Cut out Valve Cylinder cupboard If required by your cylinder provider the cut out valve should be fitted on the 22 mm return pipe between the cylinder and the pump station The cut out valve should be supplied with the cylinder if required For installation instructions refer to the user manual supplied with the unit Diagram 17 26 Diagram 16 8 6 Installing the Drain Cock Cylinder cupboard The drain cock supplied should be fitted
43. talling the Deaerator Cylinder cupboard 27 8 8 Completing the Cylinder Connections Cylinder CUPDOAIC sreniennnngoi nenga 28 8 9 Flushing the SYSTCM cciteessecnssienseecths ita 29 8 10 Pressure Testing the Complete Solar Circuit 29 8 11 Pre commissioning CNECKS nicissarii 30 9 Second Fix Electrical eerren 31 9 1 Installing the Sensors and Connecting to the SOAK COMTE re Radvencauneadamens 31 9 2 Installing the Junction Box and Terminating th COMMECTIONS sieniin 32 9 3 Connecting the Mains Supply 32 10 Commissioning eerren rererere 33 10 1 Confirming Pre commissioning Checks 33 10 2 Hydraulic Commissioning Procedure 33 10 2 1 Volume of Fluid and Flow Rates 33 10 22 Pretiling CHECKS eirias aia 33 10 2 3 Connecting the Jet pump filling unit 34 10 2 4 Wet Pressure Testing the System at 6 Bar 35 10 2 5 Venting the SyStem simissioarnsiniisa 36 10 2 6 Venting the Individual Tile Columns 36 10 2 7 Venting the System PUM 00 eee 37 10 2 8 Setting the System Flow Ratess 38 10 2 9 Setting the System Cold Fill Pressure 38 10 3 Electrical Commissioning Procedure 39 TOST Sensor TESUNG naise pnas 39 10 3 2 Control Thermostat Testing eee 40 10 3 3 Setting the Control Unit Parameters 41 10 3 4 Checking the Delta t Operation 42 10 4 System TESSU sirriga T aas 43 10 5 Insulating the Pipe Work sisircsisrissiror
44. tions Approved Document G Section G3 Hot Water Storage 44 Controller parameter settings checked Part Number 10120 01 Plumbing and Electrical Installation Guide 10 Commissioning continued 10 6 Attach Warning Labels and Notices Solar thermal regulations do not require any warning labels or system schematics to be fitted adjacent to equipment However Solarcentury recommends that a system schematic and wiring control schematic is fitted at the cylinder location This installation guide correctly completed should be left for the home owner Place it in the supplied zipped A4 bag and attach it to the cylinder or pump station using the supplied cable tie Part Number 10120 01 45 C21t solarthermalrooftilesystem 10 Commissioning continued 10 7 Certification Installation Address Postcode System Details System Size _ 8 Tiles _ 12 Tiles _ 16 Tiles _ 20 Tiles 24 Tiles 28 Tiles 32 Tiles Other Tiles No of Columns No of Rows Cylinder Manufacturer Cylinder Model Cylinder Size Installed by Company Name Address Installer Name Installer Signature Telephone Commissioned by Company Name Address Commissioner Name Commissioner Signature Telephone Part Number 10120 01 46 Plumbing and Electrical Installation Guide 10 Commissioning continued 10 7 Certification continued
45. to the instructions supplied with the pump station i DNS Diagram 12 22 Diagram 12a Part Number 10120 01 Part Number 10120 01 Plumbing and Electrical Installation Guide 8 Second Fix Plumbing continued 8 2 Installing the Pressure Relief Valve and Tundish Cylinder cupboard There are two pressure relief valves One was installed in section 5 6 the other is integral to the pump station Both need to be vented to a 28 mm or adequate diameter drain via a tundish Diagram 13a Diagram 13b Diagram 13 Diagram 13c WARNING A 22 mm pipe should be fitted from the pressure relief safety valves to the vent pipe before the tundish to comply with UK plumbing regulations 23 C21t solarthermalrooftilesystem 8 Second Fix Plumbing continued 8 3 Installing the Expansion Vessel Cylinder cupboard Locate the position of the expansion vessel on the cylinder cupboard template to the right of the pump station Be sure that the pump station and the expansion vessel are close enough to allow for connection with the flexible hose supplied Confirm and or set the pressure in the expansion vessel to 1 5 bar before mounting the vessel The expansion vessel is normally pre charged to 2 5 bar Mount the expansion vessel and connec
46. two hoses for each tile one flow and one return The hoses are fitted with plastic end caps to protect the stub and prevent dirt or debris entering the end of the hose The end of each FLOW hose will be marked with a RED end cap The caps can now be removed For each column of tiles e The flow and return from each tile should be connected in series with the tile above and below e The flow from each tile should point upwards to connect with the return of the tile above e For each column of C21t tiles there should be an unconnected flow hose at the top and an unconnected return hose at the bottom For the system configurations included in this guide there are a maximum of eight and a minimum of five C21t tiles per column Before the hoses are connected check e That there are the correct number of hoses entering the loft void e Ensure the membrane collar is seated correctly The neck of the collar should point upwards to prevent penetration of water e Which are the flow and return for each C21t tile e That none of the hose ends have been damaged during installation do NOT proceed with installation until any damage has been remedied e Check that the high temperature insulation hoses are installed and pushed up far enough to meet the roof membrane Use the compression fittings supplied to connect the tiles in series 12 Diagram 3 Part Number 10120 01 Plumbing and Electrical Installation Guide 5
47. w the system pressure to increase to 6 bar on the pump station pressure gauge Close the top valve connection to the pump station when the system pressure reaches 6 bar Switch off the jet pump filling unit A minimum depth of 100 mm of anti freeze water MUST be maintained within the jet pump filling unit reservoir If the jet pump filling unit reservoir empties to the minimum depth of 100 mm close the upper valve connection to the pump station and switch off the jet pump filling unit Re fill the jet pump filling unit reservoir with the correct anti freeze water mixture Switch on the jet pump filling unit and then open the top valve connection to the pump station Close the top valve connection to the pump station when the system pressure reaches 6 bar Switch off the jet pump filling unit nspect all the system pipe work and couplings for any possible leaks Monitor the system pressure gauge for 15 minutes Check that there is no decrease in system pressure f the wet pressure test is successful the commissioning procedure can be continued f the system pressure falls during the pressure testing re check the system pipe work and couplings for leaks The system will need to be drained down if a leak cannot be sealed by tightening the coupling nstructions on draining the system are provided later see appendix B Manually operate each pressure relief valve in turn and confirm discharge to the waste pipe Solar circuit pressure t
48. win and earth cable needs to be spurred from the ring main to the cylinder cupboard This will feed the 5A fused spur installed during the second fix 6 2 Installing the collector temperature sensor extension kit The collector temperature sensor is supplied as standard with a 1 5 m cable On the assumption that the 1 5 m cable may not reach the solar controller on the pump station an extension kit has been supplied consisting of a junction box Diagram 11 which has integrated over voltage protection and a 10 m extension cable When installing the extension kit e The sensor cable should be fitted with and follow the same route as the flow and return pipe work back to the pump station location e The cable can be tied to the outside of the INSULATED return pipe work it must not be tied directly to non insulated pipe work e The junction box should be fixed at a convenient secure location on a rafter or joist in the loft void SENSOR PROTECTION DEVICE Diagram 11 Part Number 10120 01 Plumbing and Electrical Installation Guide 7 Cylinder Installation The following guidance provides a general overview for cylinder installation If your cylinder has not been provided by Solarcentury you must refer to the separate instructions provided by the cylinder manufacturer for specific details It is usual to locate the cylinder pump station and the expansion vessel together in a dedicated cylinder or ai
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