Home

CombiSolar 150 Installation and Service Manual

Contents

1. Itho Solar System CombiSolar 150 Installation and service manual Pre heat drain back solar system with unvented hot water solar cylinder for use with combination boilers PRO DIN A SOLAR Key Mark Certificated Building Regulations Approved Certificate No ETC16211 lt gt itho Climate for life Leave this manual with the User for safe keeping Contents 1 IATODUCHON unsa 2 8 Component replacement 2 20 2 Technical data 0 0 0 eeeeeeeteeeeeeeree 3 9 Wiring diagram ece 23 3 General information 0 ceee 6 10 Diagnostics and fault codes 23 4 Installation anaa 12 11 Checklist for unvented storage 26 5 Commissioning 16 12 Pat SUS eie aaa 27 6 System operation ceeeeeee 18 13 Inspection history scorsi 28 7 Routine inspection 20 1 Introduction The Itho CombiSolar 150 system is a pre heat drain back solar collector system which includes a floor standing 150 litre unvented cylinder to store water heated by the solar collector It is recommended that the system is used in conjunction with a Solar compatible combination boiler but other alternatives may be used if deemed suitable Refer Fig 3 and to Section 4 7 1 The CombiSolar 150 system includes a 150 litre cylinder at least one flat plate drain back solar collector up to a maximum of three drain back unit and unvented kit The 150 litre unvented cylinder is supplied with a pump control box and temperatur
2. 4 4 1 The CombiSolar 150 system is supplied in three boxes as follows Installation Unpacking Box 1 Solar cylinder contents include Solar cylinder Inlet pipework assembly Temperature pressure relief valve with discharge pipe Cylinder pump Cylinder stand Control box 3 way diverter valve and fittings Fitting instructions Box 2 Drain back unit contents include Housing and drain back unit pump Screw pack Cable set for collector temperature sensor Box 3 Unvented kit contents include Cold fill manifold assembly L includes 3 0 bar pressure reducing valve inlet filter and 6 bar pressure relief valve check valve 12 litre expansion vessel pre charged to 3 0 bar Expansion vessel mounting bracket Tundish Fitting instructions The following items are also required to complete the installation 1 4 5 6 Solar collectors Portatori deze sch cee ateccsdtectesiectestueacdictscfisctadeiee aN r LAM AS CAPS iiss tesco teas a a EEE Solar collector mounting kits a Pitched roof collector flashing kits portrait 2 to 3 panels landscape 2 panels Portrait lett hand PL c ccsth icini Portraitright hand PR secs seczevensseceascbesseesesesstersscadisveeizeesaneectens Portrait middle PM sa cci sceseecieceaeeccetecessctenttesdecdbeecnenesseensetnd Landscape left hand LU ironiis eninin Landscape right hand LR eecceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees b Flat roo
3. 15 89 3 60 1 07 12 49 2 99 0 92 10 00 2 49 0 79 8 06 2 09 0 68 Itho CombiSolar 150 page 25 11 Checklist for unvented storage Ensure the following is completed after the unit has been installed and commissioned UNVENTED HOT WATER STORAGE SYSTEM Are combined temperature pressure relief valve and expansion valve fitted and discharge tested Yes No What is incoming static cold water pressure at the inlet to the pressure reducing valve bar Has strainer if fitted been cleaned of installation debris _ Yes No What is the pressure reducing valve setting if fitted bar Where is the pressure reducing valve situated eee eeeeeeeeeneeeeeeeeeeeneeeteeeeeeeaueeeesaeeeteeeesenneeeseeeess Has the expansion vessel or internal air space been checked Yes No FOR ALL INSTALLATIONS CONFIRM THE FOLLOWING The hot water system complies with current Building Regulations Yes The appliance and associated equipment has been installed and commissioned in accordance with the manufacturer s instructions Yes The operation of the appliance and system controls have been demonstrated to the customer L_ Yes The manufacturer s literature has been left with the customer Yes COMMISSIONING ENGINEER S NAME Itho CombiSolar 150 page 26 12 Parts list Control box Ref Description Cylinder pump PCB Housing cylinder Top cover cylinder Bo
4. 2 3 4 5 6 7 Brown wire z i Solar collector temperature sensor White wire ro P N L Brown wire o Connector blocks N Blue wire 3 way diverter valve N j Black wire Itho CombiSolar 150 page 4 2 8 CombiSolar schematic Solar cylinder DHW heat exchanger To boiler 6 E E Py aCe IE Aj l l l Solar collector S l Q pesiae a l 1 l 4 4 Drain back unit l L 5 l ag 2 l 4 v i l s l i pie l fe ae Cold water gt 7 8 to DBU Hot water Hot water from DBU To hot water taps 18 lt 19 11 A 4 Mains cold water f l To solar cylinder To items 4 6 amp 13 13 i 4 l 14 17 16 L 15 l Cold water inlet OMAN OU RON N e ee ee A A M d CoO ON OA fF WON CO Collector temperature sensor Drain back unit pump Drain back unit heat exchanger Control box Temperature sensors Temperature and pressure relief valve Solar cylinder pump Limit thermostat Drain point for cylinder Immersion heater boss Unvented kit Cold fill manifold assembly Pressure relief valve part of item 12 Non return valve part of item 12 Pressure reducing valve with filter part of item 12 Tundish Expansion vessel 3 way diverter valve Thermostatically controlled mixing valve not supplied Thermostatically controlled mixing valve not
5. To ensure efficient operation of the CombiSolar system it is recommended that it is inspected and checked by a competent person as necessary at regular intervals Warning Before removing any covers or working on the system isolate the electrical supply The data label for the cylinder is located on the side of the cylinder housing The data label for the drain back unit is located on the top of the front cover Refer to Figs 9 and 10 Always carry out electrical system checks i e earth continuity resistance to earth short circuit and polarity with a suitable meter after any electrical work has been carried out on the system Check the operation of the system before and after any servicing or replacement of parts 7 1 Important notes prior to routine inspection Run the system and check the operation Ensure that all system connections and fittings are sound Open the solar cylinder drain valve Fig 2 item 9 until the water from the bottom of the cylinder runs clear Inspect and clean if required the filter and cartridge in the pressure reducing valve fitted to the cold fill manifold see Fig 12 and 18 and Section 8 5 5 Check the operation of the pressure relief valve by turning the head anti clockwise until it clicks The click is the valve lifting off its seat allowing water to escape to the discharge pipe check that this is happening and that the valve is not leaking after it has been operated Oy 6 Check the charge
6. competent person in accordance with the instructions The installation is subject to Building Regulations approval and the Local Authority must be notified of the intention to install Discharge pipe The discharge pipes from the temperature pressure and expansion relief valves must be routed to the tundish supplied and in 15 mm pipe The discharge pipework from both relief valves may be joined together in the same sized pipe providing at least 22 mm pipework is connected downstream of the tundish Tundish The tundish must be positioned within 600 mm of the appliance so that it is visible to the User and away from electrical devices The minimum size of the discharge pipe downstream of the tundish is given in the following table Sizing of copper discharge pipe D2 refer also to Fig 4A and 4B Valve Minimum size of discharge Minimum size of discharge Maximum resistance allowed Resistance created outlet size pipe D1 to tundish pipe D2 from tundish expressed as a length of straight by each elbow pipe i e no elbows or bends or bend 22 mm up to9m 0 8m 28 mm up to 18m 1 0m 35 mm up to 27m 1 4m The discharge pipework from the tundish 1 Shall fall continuously through its length Shall be of a heat resistant material e g metal Shall not be fitted with any valves or taps Shall discharge to a safe visible position e g into a gulley Shall have a minimum of 300 mm straight pipework directly from the t
7. cylinder insulation 0 032 W mK Global warming potential Zero Ozone depletion potential Zero Insulation blowing agent Steam water 2 6 Location The DBU should be positioned as close as possible under the solar collector The pipework between the collector and DBU can be extended according to the tables in Fig 7 maintaining a maximum vertical distance of 4 m using compression fittings only The pipework between the solar cylinder and DBU can be extended to a maximum of 12 m maintaining a maximum vertical distance of 6 m All pipework should be installed using the minimum of bends and restrictions possible and insulated using high temperature lagging for the pipework between the collector and DBU All pipework between the solar collectors drain back unit and cylinder and all cylinder connections MUST be copper with compression fittings 2 7 Electrical connections Note This appliance must be earthed Do not connect any other controls Brown wire DBU pump Blue wire Brown we fa LZ Blue wire E Connector blocks S H Earth Green Yellow wire from electrical supply and DBU pump Live Brown wire 230 240V 50Hz Fuse supply 3A Neutral Blue wire Fig 1 Control Box PCB connections H oven Therm connections to compatible Open Therm condensing boiler i Open Therm compatible room thermostat or remote display
8. suggested methods of terminating the discharge pipe safely Where a single pipe serves a number of discharges such as in blocks of flats the number served should be limited to not more than 6 systems so that any installation can be traced reasonably easily The single common discharge pipe should be at least one pipe size larger than the largest individual discharge pipe to be connected If the system is installed where discharges from safety devices may not be apparent i e in dwellings occupied by blind infirm or disabled people consideration should be given to the installation of an electronically operated device to warn when discharge takes place a Low level termination Solar cylinder temperature pressure relief valve Metal discharge pipe D1 from relief valve to tundish 300 mm 7 minimum T Metal discharge pipe D2 from tundish with continuous fall Fig 4a D1 gt To pressure Tundish relief valve Pipe close to wall to i 4 allow water to fan 300 mm a out safely 600 mm max minimum 100 mm max aes mm min D2 Ground level a Gulley if available b High level termination At high level discharge onto a roof is acceptable providing the roof is capable of withstanding high temperatures and there is a distance of 3 m from any plastic guttering systems that would collect such discharge Note The discharge will consist of scalding water and steam Asphalt roofing felt and non metal
9. water less gas is required to heat the water to the set temperature of above 60 C thereby saving energy costs Note If the combination boiler is not solar compatible a thermostatically controlled mixing valve MUST BE fitted in the cold water inlet to the boiler Collector sensor Solar cylinder Combination boiler Upper cylinder sensor Solar collector Control box 4i Drain back unit DHW heat exchanger Lower cylinder sensor 1 i DBU pump 1 Thermostatically controlled mixing valve for non Solar compatible boiler DBU heat exchanger Cold water gt 4 To boiler to DBU System pump Hot water To hot Hot water water taps 3 way diverter valve from DBU lt 1 Cold water inlet Thermostatically from cold water fill manifold controlled mixing valve Fig 17 6 2 Operation of the CombiSolar system Fig 17 Conirol When the controls detect a collector sensor temperature that is at least 10 C higher than the lower cylinder sensor and the solar cylinder temperature is less than 65 C the drain back unit pump will start The pump will run at full speed for 400 seconds and then modulate between 30 and 50 of full speed to circulate water around the collector The speed of the pump is dependent upon the difference in the temperature between the collector se
10. 4 If there is enough solar gain at the collector the cylinder pump and the drain back unit pump will run The drain back unit pump runs at full speed for 400 seconds to purge any air from the collector s then it modulates to its optimum speed for the collector temperature 5 4 Control box display Fig 16 The controls of the solar cylinder are able to indicate working modes in the display The push button provides the means to operate the cylinder During normal operation the system can be turned on and off using the button When the button is held in for 5 seconds the diagnostic mode will be entered Refer to Section 10 2 If the button is not touched for 10 minutes or is held in for 5 seconds the last mode will become active Display Push button Itho CombiSolar 150 page 16 Display shown Display explained The control of the solar system is operating standard mode The control of the solar system is not operating The solar system will not be heating up now The control can be switched on off by pressing the button The control shall then switch from oN to oF Note Always leave the control at oN System is at rest no modes such as Pr Cr Ar or Sr yet it is still in the oN mode Pre running Any heat in the drain back unit is removed before the collector mode starts up Collector running The solar cylinder operates and the collector is heated by solar energy After running The drain back unit
11. Check the boiler and room thermostat are operating correctly thermostat Itho CombiSolar 150 page 24 10 2 Diagnostic menu To enter the diagnostic menu press the button beneath the display in for 5 seconds Each following press of the button will advance through the diagnostic sequence as shown in the following table The code for the item being diagnosed and its value will be alternately displayed When you reach the last item pressing the button again will return you to the first item If you press the button in for 5 seconds or do not touch it for 10 minutes the system will leave the diagnostic mode return to the normal operating display Item being diagnosed Display Value of item being diagnosed Software version 00 99 Frost protection Cb Collector protection 00 means collector protection is in off mode Mode oF or oN Collector temperature 00 99 C Above 99 C the value will flash i e flashing 05 indicates 105 C Upper cylinder temperature 00 99 Cc Lower cylinder temperature 00 99 C Aux heat source temperature or 00 99 C Drain back unit pump speed 00 99 Cylinder pump speed 00 99 Diverter valve or 0 not fitted 1 Solar collector 2 Aux heat source Fault history XX XX Fault code 10 3 Collector sensor Temperature and resistance data KQ Ohm KQ Ohm KQ Ohm 32 15 6 53 1 75 26 31 5 33 1 48 19 86 4 37 1 26
12. DBU description Fig 6 Positioning The DBU must be located within a height of 4 metres of the top of the solar collectors see Fig 8 The pipework from the collectors to the DBU must always fall by a minimum of 40 mm per metre and must be insulated with high temperature pipe insulation Note The DBU must be located within 6 metres in height from of the bottom of the solar cylinder Dimensions The dimensions of the DBU and clearances required for servicing are shown in Fig 6 Water connections All connections on the top of the DBU as shown in Fig 6 Water connections on top of DBU Flow to collector Kv LLELLI LILLE L 4 J Hot water out 15 mm Blue 15 mm _ 55 Connect to collector hose with BLUE clip 266 Return from collector Cold water in 15 mm Red 15 mm Connect to collector hose with RED clip N 10 430 10 lt le 1 gt 199 7 340 B no x A oF X x 572 SAAS m 7 NAINA 300 ROW Note 1 Use copper pipe and compression fittings only on the pipework between the DBU and solar collectors 2 The tubing from the solar collectors must always slope down towards the drain back unit at least 40 mm per metre 3 There must not be any part of the tubing that will allow water to collect Fig 6 3 6 Solar collector descriptio
13. Item 11 Cold fill manifold assembly includes a pressure reducing valve 3 0 bar and a pressure relief valve 6 bar Itho CombiSolar 150 page 27 15 16 Part No 106 1228 106 1229 106 0801 106 0799 106 0668 106 0800 106 0812 106 0796 106 0797 106 0491 106 1230 106 0966 106 0882 106 1231 13 Inspection history Details of CombiSolar installation It is recommended your CombiSolar system is inspected regularly and that you complete the inspection record below Note Always use the manufacturer s specified spare parts when replacing any parts Cylinder Serial Number ecceeeceseeeeesceeeeeeseeteaeesseeseaeeeeeeteaes DBU Serial Number ecceeceeeeeeeeeeeeeeseeeeeeeneeeeaes Details of system inspection history Date of Inspection Details of Inspection Engineer Company Tel No This manual has been carefully prepared but we reserve the right to alter the specification at any time in the interest of product improvement Itho 2011 E lt gt itho 0845 250 8091 info itho co uk wwithcouk Climate for life Itho UK Ltd 10 Faraday Court First Avenue Centrum 100 Burton on Trent Staffordshire DE14 2WX m T 10 11 D271
14. a connector block see paragraph 4 above Note Ensure that the length of the earth wire is such that if the supply cable is pulled out of its clamp the live and neutral wires become taut before the earth wire DO NOT SWITCH ON the electrical supply at this stage 6 Make the following connections to the control box PCB if applicable Connect terminals 4 and 5 to either an Open Therm room thermostat or Remote Display Connect terminals 6 and 7 to the Open Therm condensing boiler i e if the boiler is suitable for Open Therm connections Cylinder sensors EO o Cylinder pump eooo oe 1 212223 24 25 26 Collector sensor 6 ES Overheat thermostat 3 way diverter 4 valve Mains supply OJ LZ DBU pump 230 V 50 Hz E Fused 3 Amp Operating lever INNNJILELLY To earth screw on cylinder pump manifold Connector block 0468 6o9 Earth terminal Open Therm connections 4and5 Open Therm room thermostat or Remote Display 6 and 7 To Open Therm condensing boiler Note Do not connect any other external controls Fig 14b Itho CombiSolar 150 page 15 5 Commissioning 5 1 Fill th
15. agram Upper Cylinder Sensor Br Brown Bk Black BI Blue W White G Y Green Yellow Lower Cylinder Sensor Cylinder Pump Limit A Thermostat manual reset Open Therm connections 4 and 5 Open Therm room thermostat or Remote Display 6 and 7 To Open Therm condensing boiler Note Do not connect any other external controls 3 way Diverter Valve Mains supply 230 240 V 50 Hz Fused at 3 A Connector Blocks 10 Diagnostics and fault codes 10 1 Fault codes The solar system is fully controlled by the electronic control on the cylinder Fault codes 71 to 84 will be shown in the display Fig 15 together with a flashing dot in the right hand corner of the display The following codes can be displayed Itho CombiSolar 150 page 23 Codes 71 72 and 80 will stop the solar system working The cause must be rectified before the system will operate When the cause has been rectified the system will start by itself Code 71 Temperature of the collector is below 40 C or above 250 C Collector sensor fault Check the collector sensor does it operate check sensor resistance in table on next page Sensor cable damaged or short circuited Sensor is faulty Code 72 Temperature of the cylinder is below 0 C or above 100 C Upper cylinder sensor fault Check the upper cylinder sensor does it operate check sensor resistance in table on next pa
16. ance with the following recommendations All current Building Regulations issued by the Department of the Environment i e Approved Document L1 Building Standards Scotland Consolidation Regulations issued by the Scottish Development Department UK Water Regulations Byelaws Scotland Health amp Safety Document No 635 The Electricity At Work Regulations 1989 The installation should also be in accordance with the following British Standard Codes of Practice BS 5449 Forced circulation hot water systems BS 5546 Installation of hot water supplies for domestic purposes BS 5918 Solar heating systems for domestic hot water BS 6700 Design installation testing and maintenance of services supplying water Failure to install this appliance correctly could lead to prosecution and will invalidate the guarantee It is in your own interest and that of safety to ensure that the law is complied with Manufacturer s instructions must NOT be taken in anyway as over riding statutory obligations This appliance meets the requirements of IP42 i e degree of protection against moisture Reference should be made to Criteria for gas fired combination boilers used as after heaters in solar thermal systems and BRE Solar heating UK 1981 Proviso WRAS Approval Solar heating system components Compliance with the relevant requirements of the Water Supply Water Fittings Regulations 1999 has been assessed for this product only as a component of a heating syst
17. cal supply before removing the front cover of the unit it is a push fit Place a bucket under the drain point see Fig 19 open the valve to drain the unit contains just under 10 litres Disconnect the pump electrical lead and undo the two pump union nuts then withdraw the pump Fit a new pump and sealing washers and re assemble in reverse order To fill the drain back unit 1 Unscrew the level point cap from the fitting in the flow pipe above the pump Fig 19 2 Fill using standard domestic water via the level point with a funnel and hose 3 Carefully fill the drain back unit until water overflows from the fitting in the pipe above the pump This indicates the correct fill level has been reached Note Do not overfill 4 Replace the level point cap to the fitting in the pipe above the pump and ensure the area around the pump is dry Itho CombiSolar 150 page 21 5 Switch on the electrical supply and start up the CombiSolar system as described in Section 5 3 6 Check for any leaks and replace the front cover It is important to prime the drain back unit pump aoe pale Fill level unscrew the centre cap and rotate the spindle using a small screwdriver Replace the cap Fill Overflow point 8 11 Limit thermostat Isolate the electric supply The limit thermostat is located on a pipe at the bottom of the cylinder Pull the plug from the thermostat and unscrew the thermostat from the
18. ction DHW outlet connection 3 way diverter valve connections 15mm DHW cylinder capacity 152 L Expansion vessel size pre charge press 12 L at 3 0 bar Pressure reducing valve setting 3 0 bar Temperature and pressure relief valve 90 C 7 bar Pressure relief valve setting 6 bar Flow rate L min Max 18 0 Min 1 0 gal min Max 4 0 Min 0 22 Max outlet water temp approx 70 C Immersion heater boss 1 Drain back unit DBU DHW circuit Flow connection Return connection Max working pressure Collector circuit Flow connection Return connection Max working pressure Vessel size Max filled content 9 8L Heat transfer capacity 110 W K Note Copper pipe MUST be used between the cylinder drain back unit and collector Reference to WRC NSF Test Procedure 1 50 220 using a 30 kW boiler Time to reheat water store by 50 C 36 minutes Reheat time for 70 of store 30 minutes 2 2 Solar collector details per panel types Portrait Landscape Dimensions Total surface area 2 5 Aperture area 2 3 Length x width x thickness 2230 x 1120 x 92 1120 x 2230 x 92 Water content 1 16 1 10 Lift weight 44 Gross 41 Nett Profile of collector when fitted using flashing kit protrudes approximately 30 mm to 60 mm above the tiles depends upon type of tile used Hydraulics Maximum pressure bar Absorber Aluminium cover and copper pipe Length x
19. e sensors The drain back unit is fitted with a heat exchanger and pump A 3 way diverter valve is also supplied The unvented kit must be fitted in the mains water supply to the cylinder The kit includes a cold fill manifold assembly which includes a pressure relief valve pressure reducing valve check valve and filter expansion vessel and a tundish There is a connection on the manifold that may be used as a balanced cold water supply Note In the Northern hemisphere solar collectors should ideally face South For more information see Section 3 6 The solar collector is supplied in special packaging to protect it during transit The four corners are protected with polystyrene caps and the exposed edges are protected with cardboard The glass front and aluminium back panel are exposed The packaging is not intended to support the full lift weight of the collector When manually carrying the collector always hold the exposed edges and not the packaging alone The collector can be lifted both horizontally and vertically The collector can only be carried using the lifting forks when on the original wooden pallet base IMPORTANT This System has been approved to the Building Regulations for unvented hot water storage systems and the Local Authority must be notified of the intention to install Therefore the installation must be carried out by a person competent to install unvented hot water systems The installation must be carried out in accord
20. e solar cylinder 1 Check that all the mains water connections are tight and any drain valves are closed 2 Open the mains water inlet valve Thoroughly flush out the hot water system by turning on all the hot water taps and allow the water to flow until no air is present this will automatically vent the cylinder of air Turn off each tap 3 Itis important to vent the solar cylinder pump by unscrewing the centre cap from the pump head see Fig 15 until water runs from it and then replace the cap 4 Isolate the mains inlet and drain the cylinder to remove any debris that may have collected in the cylinder Refill and vent the system as described above 5 2 Drain back unit Pump vent The drain back unit is supplied pre filled with the correct quantity of water screw 5 3 Turn on the electrical supply 1 Check that all the wiring has been correctly installed and that all the terminal connections are tight Fig 15 2 Switch on the electrical supply and the display see Fig 16 will show A1 and start to countdown from eighty to zero During this countdown the PCB does a self diagnosis of all the sensors and pumps If the collector temperature is between 10 and 130 C the drain back unit pump will run for a short period to run a test program after which the system is ready for use 3 When all the self diagnostic procedures have been completed the display will flash between the solar cylinder temperature and the operation mode
21. em If it is to be installed as part of a system using solar energy or ground or air source heat pumps for pre heating water which is to be used as domestic hot water the Water Fittings Regulations place a legal duty on the installer and user to ensure that the installation and operation of the complete system prevents contamination of domestic hot water by Legionella bacteria which can grow in water stored at temperatures between 20 and 45 C Where disinfection by heating is relied on to meet this obligation information on minimum conditions for thermal disinfection of Legionella bacteria can be found on the WRAS website www wras co uk The Itho CombiSolar unvented hot water solar cylinder has been specifically designed to prevent the proliferation of legionella bacteria in this hot water system and disinfection by heating is not relied upon to meet this obligation Lightning Protection Refer to BS6651 for lightning protection however this does not give specific requirements for solar panels and generally collectors mounted on non metallic roof structures will not require lightning protection Advice should be sought if mounting on metallic roof structures or mounting in situations where the risk of strikes are high Itho CombiSolar 150 page 2 2 Technical data 2 1 DHW details Solar cylinder Max hot water working pressure Max mains inlet pPreSSure inlet of pressure reducing valve Min mains water pressure Mains inlet conne
22. ent IEE Wiring BS7671 Regulations and in Scotland the electrical provisions of the Building Regulations applicable in Scotland with respect to the installation of the cylinder in a room or internal space containing a bath or shower When the cylinder is installed in a room containing a bath or shower it must not be possible for a person using the bath or shower to touch any electrical switch or cylinder control utilising mains electricity Note The bottom of the solar cylinder must be located within 6 metres in height from of the top of the drain back unit Dimensions The dimensions of the cylinder and clearances required for servicing are shown in Fig 5 Water connections gt 100 700 Dia gt 100 Y gt 100 1002 325 Ss o i Cylinder Connections E i A Water outlet to boiler 15 mm aa D B Cold water inlet 15 mm C Return from DBU 15 mm i D Flow from cylinder to DBU 15 mm 35 2808 E Cylinder sensor A h F Cylinder drain point ZZ Tihs itt Fig 5 The connections at the bottom of the cylinder are shown in Fig 5 Note Use compression fittings only on the cylinder connections and copper pipe between the cylinder and drain back unit We also recommend a minimum of 1 metre of copper pipe from the cylinder for the water inlet and outlet connections Itho CombiSolar 150 page 9 3 5 Drain back unit
23. eration of the drain back unit pump and the cylinder pump Code 75 After 5 minutes the collector temperature is still too high above 130 C with the drain back unit pump operating Check the level of water in the drain back unit Refer to filling procedure in Section 8 10 Check the difference in height between the drain back unit pump and the upper most side of the collector This can be a maximum of 3 metres Check the collector sensor and the lower cylinder sensor do they operate check sensor resistance in Section 10 3 Check the collector tubes are they blocked with dirt Is the decline of the pipes within the 40 mm per metre requirement Check the electrical connection and operation of the drain back unit pump and the cylinder pump Collector temperature too high Codes 82 83 and 84 These are communication faults between Open Therm compatible boiler and room thermostat Code 82 Check the electrical connections between the solar control and the boiler No communication with Open Check the boiler is operating correctly Therm boiler Code 83 Check the electrical connections between the solar control and the boiler and between the No communication with Open boiler and room thermostat Therm room thermostat Check the room thermostat is operating correctly Code 84 Check the electrical connections between the solar control and the boiler and between the No communication with boiler and room thermostat Open Therm boiler and room
24. ess the spring and carefully remove the plastic cover using a suitable spanner Extract the cartridge using long nosed pliers to grip the head of the set screw then withdraw the filter Clean the filter and cartridge under clean running water If the filter or cartridge are damaged replace them Re assemble in reverse order Refill and check for leaks If it is necessary to recalibrate the pressure reducing valve use a suitable Allen key to turn the adjusting screw in the centre of the plastic cover Rotate it anti clockwise to reduce the pressure Cold fill manifold assembly The manifold assembly includes the pressure reducing valve and the Cartridge pressure relief valve Drain the cylinder as described in Section 8 1 Unscrew the two mains pipe connections and the discharge pipe connection then unscrew the manifold from the expansion vessel Fit the new manifold in the reverse order using a new washer Open a hot tap to vent any air from the cylinder Note The pressure reducing valve on a new manifold is set to 3 0 bar Filter Cylinder pump Drain the cylinder as described in Section 8 1 Remove the terminal cover on the pump and remove the supply lead from the terminals Unscrew the two 5 mm bolts and remove the pump head Fit the new head and reassemble in reverse order Cylinder temperature sensors Isolate the electrical supply before removing the casing Remove the four plastic pins securing the top cover and remove the co
25. essure relief valve discharge pipe must be routed clear of the boiler to a drain in such a manner that it may be seen but cannot cause injury to persons or property Refer to the boiler instruction manual Connect the discharge pipework to the temperature pressure relief and expansion relief valves via the tundish supplied This pipework must be installed as recommended in Unvented hot water storage system Section 3 3 Ensure that all the valves are closed spindle flats at right angles to valve and do not turn on the water supply at this stage Itho CombiSolar 150 page 14 4 9 Electrical connections See Figs 14 and refer to Wiring diagram Section 9 The cylinder sensors item 1 in Fig 14b cylinder pump iten 2 in Fig 14b and the limit thermostat item 3 in Fig 14b are supplied connected to the control box 1 Remove the screws securing the front of the control box hinge the bottom cover down and the top cover up to provide access to the terminals on the control board Refer to Section 2 7 for details of all electrical connections required 2 Connect the drain back unit pump item 7 in Fig 14b The drain back unit pump is fitted with a cable Route the cable to the solar cylinder control box Connect the wires as follows Brown wire to terminal 9 Blue wire to terminal 8 and Green Yellow wire to gt Ensure that the cable is secured in the cable clamp 7 in Fig 14a 3 Connect the collector sensor item 6 in Fig 14b The senso
26. f collector mounting kit landscape only 2 off On Roof mounting kits for either Portrait or Landscape panels are available as follows On Roof basic Kit ccccccccccccscccececeeceeeeecececeeeesesseessssssrsneeaees ONn ROOF Slate Kits acisskecceriscdeaseccaccsdeasasshacigdadbedtnseitienacncedeedscetde On Roof tile Kit cccceescecccecceeeececeeeeeeeeeeseesesesesseesersrsreneneaees The basic kit is always required whether a slate or tile kit is selected Combination boiler and flue Part No 602 0023 Part No 602 0024 Part No 604 0101 Part No 604 0103 Part No 604 0102 Part No 604 0105 Part No 604 0106 Part No 604 0110 Instructions Data label r S Solar cylinder Bao and stand 4 JJ Ht I Se J F f Sey Fig 9 Box 1 Part No 604 0111 Part No 604 0112 Part No 604 0113 NIL Drain back unit Fig 10 Box 2 Note If the boiler is not Solar compatible a thermostatically controlled mixing valve will be required Thermostatically controlled mixing valve for hot water outlet High temperature 15 mm pipe insulation 150 C plus 15 mm copper pipe and compression fittings with high temperature mounting brackets 4 2 Location and clearances required Refer to Section 3 4 3 5 and 3 6 before locating the solar cylinder drain back unit and solar collector 4 3 Fit the collector and m
27. ge Sensor cable damaged or short circuited Sensor is faulty Code 80 Temperature of the cylinder is below 0 C or above 100 C Lower cylinder sensor fault Check the lower cylinder sensor does it operate check sensor resistance in Section 10 3 Sensor cable damaged or short circuited Sensor is faulty Code 77 is the only code displayed that is not actually a fault The code will disappear if the button is pressed Code 77 The control has not been operating for 30 days The system is not turned on Check the collector sensor and the lower cylinder sensor do they operate check sensor resistance in Section 10 3 Codes 74 and 75 will lock the solar system The cause must be rectified before the system will operate When the cause has been rectified the system control can be reset by pressing the button Code 74 Check water level in drain back unit No circulation in the collector Check limit thermostat manually reset if required Check the difference in height between the drain back unit pump and the upper most side of the collector This can be a maximum of 3 metres Check that the pipework between the DBU and collector is no more than 2 m in length Check the collector sensor and the lower cylinder sensor do they operate check sensor resistance in Section 10 3 Check the collector tubes are they blocked with dirt Is the decline of the pipes within the 40 mm per metre requirement Check the electrical connection and op
28. in reverse order with a new vessel and washer 8 3 Temperature and pressure relief valve Isolate the electrical supply before removing the casing Drain the cylinder as described in Section 8 1 Remove the four plastic pins securing the top cover and remove the cover Remove the insulation around the valve to expose its connections Undo the 15 mm copper discharge pipe from the valve and undo the valve from the cylinder and remove Unscrew the adapter from the old valve and fit it to the new one using a suitable joint sealer Reassemble in reverse order 8 4 Cylinder manifold assembly Drain the cylinder as described in Section 8 1 Disconnect the power cable from the pump and the earth lead from the manifold assembly and unplug the limit thermostat Disconnect all pipe connection and remove the two retaining clips one either side at the top of the manifold It is now possible to pull down on the manifold and remove it from the cylinder taking care not to damage the plastic tubes connected to it With the manifold removed from the cylinder it is possible to replace or service the following parts hot water outlet pipe mains inlet strainer diffuser hot inlet pipe hot inlet diffuser and pump outlet pipe Re assemble in reverse order Itho CombiSolar 150 page 20 8 5 8 6 8 7 8 8 8 9 Pressure reducing valve and cartridge filter Drain the cylinder as described in Section 8 1 Unscrew the adjusting Adjusting screw screw to decompr
29. in the domestic hot water expansion vessel and re pressurise if necessary Note Only check the expansion vessel charge when the system pressure is zero 7 Record details of the inspection in the Inspection History Section 13 8 Component replacement It is recommended that any service work is carried out by a competent person Warning Before removing any covers or working on the system isolate the electrical supply The data label for the cylinder is located on the side of the cylinder housing The data label for the drain back unit is located on the top of the front cover Refer to Figs 9 and 10 Always carry out electrical system checks i e earth continuity resistance to earth short circuit and polarity with a suitable meter after any electrical work has been carried out on the system Check the operation of the system before and after any servicing or replacement of parts Refer to Section 12 for information on parts and their location 8 1 Drain the cylinder Isolate the mains water supply and open a hot tap to release the pressure in the cylinder Attach a hose to the drain valve located at the bottom of the cylinder and route the hose to a drain Open the drain valve to drain the cylinder 8 2 Expansion vessel Drain the cylinder as described in Section 8 1 Loosen the vessel clamp and unscrew the vessel from the cold fill manifold assembly while holding the manifold with a spanner to prevent damaging the mains pipe Reassemble
30. ing holes If the four fixings are to be used support the unit while fitting the bottom two screws 5 The DBU is pre filled with the exact amount of water required 6 Connect the pipework from the collector to the DBU connections as detailed in Section 3 5 Fig 6 Note All pipework from the collector must always slope down towards the drain back unit at least 40 mm per metre There must not be any part of the pipework that will allow water to collect 340 ae 290 Fa Fixing holes DBU centreline Use top two when fitted vertically and all four when fitted at an angle Position of drain back unit Ay 300 90 to be between 55 and 90 55 Fig 11 4 6 Fitthe unvented kit 1 Unpack the box and check the contents 2 Locate the expansion vessel mounting bracket in a suitable position as close to the cylinder as possible and secure in position with the screws and wall plugs provided It may be vertical or horizontal 3 Secure the expansion vessel to the mounting bracket using the metal band nut washers and bolt Note Ensure the pressure in the expansion vessel is 3 0 bar If it is not adjust the pressure to give 3 0 bar Check when the system is not pressurised 4 Unscrew the plug from the cold fill manifold connection for the expansion vessel see Fig 12 and connect it to the expansion vessel using the washer supplied The cold fill manifold can be installed either horizontal
31. lic rainwater goods may be damaged by such discharges c Termination into a hopper pi Worked example Tundish 300 mm oa minimum 22 an Type A J m air gap End of pipe to be clearly visible The example below is for a G2 temperature relief valve with a discharge pipe D2 having four elbows and a length of 7 m from the tundish to the point of discharge From the table on page 6 Maximum resistance allowed for a straight length of 22 mm copper discharge pipe D2 from a G 2 temperature relief valve is 9 m Subtract the resistance for four 22 mm elbows of 0 8 m each 3 2 m Therefore the maximum permitted length equates to 9 3 2 5 8 m 5 8 m is less than the actual length of 7 m therefore calculate the next largest size Maximum resistance allowed for a straight length of 28 mm pipe D2 from a G2 temperature relief valve equates to 18 m Subtract the resistance for four 28 mm elbows at 1 0 m each 4 m Therefore the maximum permitted length equates to 18 4 14 m As the actual length is 7 m a 28 mm D2 copper pipe will be satisfactory Fig 4b Itho CombiSolar 150 page 8 3 4 Solar cylinder description Fig 5 Positioning The solar cylinder must be installed on a flat horizontal surface which is capable of supporting the weight of the cylinder when full 185 kg The cylinder may be installed in any room or internal frost free space although particular attention is drawn to the requirements of the curr
32. located at the top left hand side and for portrait collectors the grommet will be located at the top right hand side 2 Access to the grommet may be possible from within the roof area by removing tiles from inside 8 14 Drain back unit heat exchanger Note Care must be taken when carrying out repairs to the drain back unit as it reaches very high temperatures and can emit steam from connections when being removed Isolate the electrical supply before removing the front cover of the unit it is only a push fit Place a bucket under the drain point see Fig 18 open the valve to drain the unit contains just under 10 litres Drain the water from the cylinder as described in Section 8 1 Undo the four pipe connections on the heat exchanger and remove the heat exchanger it may be necessary to cut the plastic retaining strap Reassemble in reverse order using new sealing washers and refill the drain back unit refer to Section 8 10 Close cylinder drain valve and refill cylinder and check for water tightness 8 15 3 way diverter valve motor Isolate the electrical supply Remove the screws securing the control box cover and remove the cover Disconnect the diverter valve motor cable connections and remove the cable Remove the motor from the diverter valve body Fit the new motor and reassemble in reverse order ensuring all electrical connections are made correctly Refer to wiring diagram in Section 9 Itho CombiSolar 150 page 22 9 Wiring di
33. ly or vertically An inverted orientation may allow debris deposits onto the valve seating and cause the valve to malfunction Note Ensure the arrow marking on the valve body is pointing in the direction of flow 5 Connect the mains water supply to the manifold inlet and complete the pipework Thoroughly flush the water pipework Refer to Domestic hot water system Sections 3 2 and 3 3 Note No isolation valve must be fitted between the manifold and the solar cylinder 6 Check the operation of the pressure relief valve see Fig 12 by turning the head anti clockwise until it clicks The click is the valve lifting off its seat allowing water to escape from the system check that this is actually happening Itho CombiSolar 150 page 13 4 7 1 4 8 Pressure reducing valve includes filter p lief ressure relie valve Discharge pipe Expansion vessel connection Outlet to cylinder Balanced cold water Pressure gauge connection supply connection if required if required Fig 12 Cold fill manifold Fit the boiler It is recommended that the system is used in conjunction with a Solar compatible combination boiler However if it is not Solar compatible a thermostatically controlled mixing valve MUST BE fitted in the cold water inlet pipework Note Solar compatible means the boiler is suitable for hot water above 28 C entering the cold water inlet Install the boiler as described in the instruction manual
34. n Fig 7 The solar energy supplied by a system varies with the orientation and tilt of the collector which will usually be determined by the existing roof However the predicted variation is slight For a collector facing anywhere between SE and SW and tilted up to 60 from the horizontal the annual solar energy supplied will be at least 90 of that obtained at the optimum collector position South at 30 It should be remembered that shading from trees buildings etc can produce a significant decrease in system performance and collectors should be positioned to minimise shading from the sun The solar collector can be installed using one of the following methods a Integration of the collector into the tiles of a pitched roof Using the flashing kit portrait or landscape landscape or portrait collectors can be integrated into the structure of a pitched roof as shown in Fig 7 The roof must have an inclination of more than 20 for portrait and 30 for landscape The tiles used with the flashing kit must be suitable to ensure that the installation is weatherproof Full details of this type of installation are provided in the instructions supplied with the kit Itho CombiSolar 150 page 10 Portrait Landscape Collectors inclined inclined Flat roof roof roof X 10m X 10m X 10m X 5m z Please note All maximum distances X are under the condition that the connecting pipework between the individual collec
35. nsor and the lower cylinder sensor At the same time that the drain back unit pump starts the cylinder pump will start at 16 of full speed to circulate the cylinder water through the drain back unit heat exchanger The drain back unit pump will stop when the temperature difference between the collector sensor and the lower cylinder sensor falls to 3 5 C or the cylinder temperature reaches 70 C The cylinder pump will continue to run for 120 seconds to collect any excess heat from the drain back unit then it will also stop If a fault occurs a fault code will be visible in the display Refer to Section 10 1 for a list of fault codes and possible solutions Temperature display During normal operation the display Fig 16 will alternate to show the temperature C of the domestic hot water in the cylinder for 4 seconds the operating mode oN oF for 2 seconds and the system mode Pr Cr Ar or Sr also for 2 seconds after which the sequence will be continually repeated Itho CombiSolar 150 page 18 Domestic hot water circuit When a hot tap is opened cold mains water enters the solar cylinder at the bottom forcing hot water out from the top to go to the diverter valve If the water from the cylinder is above 60 C the 3 way diverter valve diverts the flow directly to the taps If the temperature is less than 60 C the valve diverts the flow through the combination boiler for further heating and then onto the taps The cylinder pump pas
36. ounting structure flashing kits or flat roof frame Refer to installation instructions supplied with the solar collector mounting kit to install the collector 4 4 Fit the solar cylinder The cylinder must be installed on a flat surface which is capable of supporting the weight of the full cylinder see Sections 2 3 and 3 4 Decide on the position of the cylinder taking into consideration the clearances and the maximum allowed distances from the drain back unit and collector Refer to Section 2 6 Itho CombiSolar 150 page 12 4 5 Fit the drain back unit DBU Fig 11 The DBU may be fitted at an angle of 55 to 90 in relation to the horizontal If it is fitted vertically only the top two fixings need be used any other angle and all four fixings must be used Drilling template screws and plugs are supplied with the unit Using the template supplied will ensure the correct positioning of the fixing holes 1 Decide upon the position of the DBU taking into account the clearances required around the unit see Section 3 5 Positioning and Fig 6 2 Using the template supplied mark the position of the fixings then drill and plug the holes ensure they are level If using only the top fixings fit two of the screws supplied with the heads about 5 mm proud so that they will locate in the keyhole slots on the fixing bracket 3 Remove the front cover of the DBU it is a push fit 4 Offer the DBU into position and hang it on the two fix
37. pipe Reassemble in reverse order Pump vent screw in centre of pump 8 12 Limit thermostat plug and lead Drain point Isolate the electrical supply Remove the screws securing the control box cover and remove the cover Unplug the thermostat lead from terminal 12 on the PCB and the earth lead from its spade connection Unplug the lead from the thermostat located on the Fig 19 return pipe at the bottom of the cylinder Loosen the gland securing the lead and remove the lead then feed the new lead into the gland and reassemble in reverse order 8 13 Collector temperature sensor The collector sensor is sealed into the collector during manufacture If it fails a replacement sensor kit is available which comprises of a sensor with a lead and grommet attached and a clip for securing the sensor to the collector plate The collector will have a pre drilled hole on one side blanked by a rubber grommet which must be removed to fit the new sensor The sensor should be fitted to the clip and then inserted through the hole in the collector with the sensor at the back of the plate and the clip hooked over the front similar to a pen clipped in a pocket Slide the grommet along the lead and into the hole making a seal Route the lead neatly to the break through in the roof and plug it into its connecting lead Note 1 If a landscape collector is used the position of the grommet will be
38. pressure reducing valve in the manifold However all taps and mixing valves used with the hot water system must be suitable for operating at a pressure of up to 8 bar Note The hot water control thermostat on the combination boiler must always be set at maximum To ensure economic use the pipe runs to the combination boiler and taps should be in 15 mm copper pipe and be as short as possible Wherever possible the pipework should be insulated to reduce heat loss Thoroughly flush out the mains water supply pipe before connecting it to the boiler and solar cylinder to avoid the danger of dirt or foreign matter entering the system Ensure the filter in the cold fill valve assembly is clear The temperature of the water in the solar cylinder is restricted to a maximum of 70 C At this temperature the DBU pump is switched off until the cylinder temperature is reduced To prevent high temperatures at the hot water taps it is recommended that a thermostatically controlled mixing valve is fitted after the boiler as shown in Fig 3 3 3 Unvented domestic hot water storage system To comply with the Building Regulations for unvented hot water storage it is required that the unvented kit detailed in Fig 3 is fitted before the mains cold water inlet to the solar cylinder No isolating valves must be fitted between these components and the cylinder All these components are supplied with the CombiSolar system in a separate package and must be fitted by a
39. ptying shower hoses after use 5 To avoid scalding if a thermostatic blending valve is not fitted take due care and attention especially with children and older people when running a bath 6 Ensure the Checklist in Section 11 has been completed after the unit has been installed and commissioned 7 Leave the instruction manuals with the User for use on future calls and for recording details in the Inspection History Section 13 Itho CombiSolar 150 page 17 6 System operation 6 1 Working principal Fig 17 The solar collector uses the energy of the natural light to heat the water being circulated around the collector When the heated water enters the drain back unit heat is transfer into the stored water via a plate heat exchanger Stored domestic hot water is pumped from the bottom of the solar cylinder through the drain back unit plate heat exchanger where it is heated and returned to the cylinder When a hot water tap is turned on mains water flows into the bottom of the solar cylinder and hot water flows out of the top towards the diverter valve If the water from the cylinder is above 60 C the 3 way diverter valve diverts the flow directly to the tap if the temperature is less than 60 C the valve diverts the flow through the combination boiler When the flow is via the combination boiler the water temperature is maintained by the boiler As the temperature of the water entering the boiler is higher than the normal incoming mains
40. pump stops but the system pump will operate to remove the last amount of heat from the drain back unit transferring it to the solar cylinder Stagnation running When the solar cylinder is not operating the collector temperature can be very high the system pump will operate to cool down the drain back unit before starting the drain back unit pump Temperature of the domestic hot water in the cylinder During normal operation the display will alternate to show the temperature C of the domestic hot water in the cylinder for 4 seconds the operating mode oN oF for 2 seconds and the system mode Pr Cr Ar or Sr also for 2 seconds Interruption code An interruption code 71 to 84 may be displayed together with a flashing dot in the right hand corner with flashing dotin of the display Refer to Section 10 1 right hand corner of the display Complete the details of the boiler installation in the Checklist in Section 11 5 5 User information The User must be advised and demonstrated if necessary of the following important points 1 How to turn the CombiSolar system on and off It is recommended the system is always left on 2 Explain what information is shown in the display and in the unusual case of a fault occurring explain the fault codes that may be shown 3 How important it is for the combination boiler hot water thermostat to be left at the maximum position 4 Weekly cleaning of shower heads and em
41. r has a 7 metre cable Plug the white sensor cable into the blue connector sensor cable and route the cable to the solar cylinder control box Connect the White and Brown wires to terminals 2 and 3 Ensure that the cable is secured in the cable clamp 6 in Fig 14a Note When using two or more collectors only one sensor is connected to the control box Connect the sensor from the collector in the more shaded position 4 Connect the 3 way diverter valve motor item 4 in Fig 14b The motor cable is 1 5 metre long Connect the cable via the cable clamp as follows The Black wire to terminal 21 the Blue wire to the neutral connector block N and the Brown wire to live connector block L Ensure that the cable is secured in the cable clamp 4 in Fig 14a Note Fit a wire to a connector block as follows Lever up the coloured operating lever until it clicks into the open position insert the stripped end 9 10 mm of the wire and return the lever back to its closed position flush with the connector block housing 5 Connect the Mains Supply item 5 in Fig 14b Refer to Section 2 7 Note The solar cylinder has been fitted with a mains supply cable However if it is necessary to fit an alternative supply cable refer to Section 3 1 and release the cable clamp 5 in Fig 14a Connect the new lead as follows Brown wire to live connector block L Blue wire to neutral connector block N and Green Yellow to the earth terminal To fit a wire to
42. ses the cool water from the bottom of the cylinder through the drain back unit heat exchanger and warm water back to the centre of the cylinder Collector water circuit The drain back unit pump Fig 17 is controlled by the PCB in the control box The collector water is circulated in a closed loop through the collector panel s where it is heated then passes through the heat exchanger in the drain back unit where heat is transferred to the domestic water from the cylinder Frost protection If the collector sensor registers a temperature less than 3 C the temperature difference required to start the drain back unit pump normally 10 C will be increased by 15 to 25 C This will ensure that the unit will not operate in frosty conditions with the possibility of freezing When the temperature rises above 3 C this temperature difference of 25 C will remain for a further 24 hours when it returns to normal Pumps If the electrical supply is on and the solar system has not operated for 24 hours the pumps will operate automatically every 24 hours providing the collector temperature is above 10 C Limit thermostat In the unlikely event the temperature of the stored water in the solar cylinder reaches 90 C the limit thermostat see Fig 3 will operate and switch off the collector pump If this happens the limit thermostat will need to be manually reset by pushing its reset button Itho CombiSolar 150 page 19 7 Routine inspection
43. supplied Required when a solar compatible boiler is NOT used Fig 2 Itho CombiSolar 150 page 5 3 General information 3 1 Electricity supply The CombiSolar system requires a 230 240 V 50 Hz mains supply fused at 3 A The system must be earthed There must only be one common isolator providing complete electrical isolation for the complete CombiSolar system This system has been fitted with a supply cable however if it is necessary to fit a cable use PVC insulated cable not less than 0 75 mm 24 x 0 2 mm to BS 6500 Table 16 The system should be connected to a fused three pin plug and unswitched shuttered socket outlet both complying with BS 1363 or a fused double pole switch with a contact separation of at least 3 mm in both poles Note There is no electrical connections between the boiler and the CombiSolar system Therefore it is recommended that the CombiSolar system electrical isolation is completely separate to the boiler and any external controls isolation All wiring must be in accordance with the current IEE Wiring Regulations BS 7671 3 2 Domestic hot water system Ensure the cold mains and hot water pipes do not have any dead legs of pipework The mains water supply must be first connected to the cold fill manifold detailed in Section 3 3 before the solar cylinder No valves must be fitted between the manifold and the cylinder The incoming mains water pressure to the cylinder is regulated to 3 0 bar by the
44. supplied with the boiler Connect the outlet from the solar cylinder directly to the 3 way diverter valve and then on to the boiler cold water inlet connection See Figs 2 and 3 Note The diverter valve must be fitted within 1 metre of the cylinder control box It is recommended that a thermostatic mixing valve is fitted in the hot water outlet before the taps Note Ensure the pipework is connected correctly to the diverter From solar cylinder gt valve See Fig 13 The boiler hot water thermostat must be set to its maximum position This will ensure that the hot water temperature from the boiler will be approximately 60 C To hot water taps via thermastatically Note The User must be informed that the boiler hot water controlled mixing valve thermostat must remain at maximum Fig 13 Connect the pipework Thoroughly flush out all the water pipework Ensure that all the caps are removed from the connections Note If soldering union bends ensure that the bends are not connected to the valves etc otherwise the internal seals may be damaged Do not use soldered connections between the solar collector and DBU or at the cylinder connections Connect the pipework from the unvented kit to the solar cylinder Note No valves must be fitted between the cylinder and the unvented kit Connect the system pipework to the boiler and the discharge pipe to the heating system pressure relief valve Do not forget that the pr
45. tors does not exceed the 5 metres Note When fitted the collector must be level i e within 2 mm per metre Pipe inlet position Pipe inlet position Portrait Landscape Fig 7 Positioning of a landscape collector onto a flat roof Using the flat roof kit the collector is mounted on the framework supplied The collector is fixed at an inclination of 30 and ballast is used to secure the frame in the required position Refer to Fig 8 for details of location of the drain back unit in relation to the collector Full details of this type of installation are provided in the instructions supplied with the kit Two collectors required up to a maximum of three allowed Ensure that all external pipework is insulated with high temperature insulation Minimum decline of 40 mm per metre required eg Max 4m Roof ial The collector must always be able cn 4 to fully drain back therefore the fe Nee lowest part of the collector must be bog NA ry above pipes of the drain back unit l i T 3 Drain back unit DBU e AH A i 8 Max 1 I ee A Preheated solar water to boiler B Cold water inlet i Aly t C Warm solar heated water into the cylinder L gt a i D Cool water to DBU E me a E gt E Cylinder drain point wo 4 Fig 8 Itho CombiSolar 150 page 11
46. ttom cover cylinder Manifold seal kit Temp press relief valve 90 C 7 bar 3 way diverter valve motor Expansion vessel 12 litre Cold fill manifold assembly Tundish 3 way diverter valve body only Collector temperature sensor kit Drain back unit pump Drain back unit heat exchanger Drain back unit front cover Limit thermostat 3 way diverter valve 15mm fittings kit Manifold and pipework assembly SSBVSHESRVASOSCNOAAONA Set of 2 cylinder temp sensors amp plug Qty e Cee Cree Ces Ce Cre Crees Crees Ce Cll Cuno Cees Cen Cllrs Cuneo Cures Cares Cllrs Ce Career 3 way diverter valve Part No 106 0499 106 1237 106 0497 106 0737 106 0736 106 0738 106 0495 106 1221 106 1235 106 1245 106 1223 106 1224 106 1234 106 0719 106 0985 106 1199 106 1225 106 1226 106 1236 106 1227 y 14 Collector A Drain back unit Description Qty Collector temperature sensor lead 1 Plug and lead overheat thermostat 1 Collector hoses amp fittings DBU to collector 2 HT pipe insulation pack DBU to collector 1 Clips cylinder to manifold 10 Foam seal hose entry 1 Screw pack DBU 1 Screw pack flashing kit 1 Bolt washer pack collector to flashing kit 1 12 m collector temp sensor pump ext lead kit 1 Drain back unit pump lead 1 Floor standing frame assembly 1 Immersion boss plug and seal 1 Pressure reducing valve cartridge and filter 1 Note
47. undish akon Note Where children may play or otherwise come into contact with discharges a wire cage or similar guard must be positioned to prevent contact whilst maintaining visibility Itho CombiSolar 150 page 6 Thermostat sensor Solar collector Two required up to a maximum of 3 allowed 3 only when using portrait collectors Combination boiler Temperature pressure relief valve V Drain back LX unit Thermostat sensor 7 N Drain back gt Hot tap unit pump COS a Heat exchanger Thermostatically Unvented Outlet water controlled cylinder temperature mixing valve 60 C y if required H_ Thermostat ad sensor Water temperature less than 60 C van Cylinder J pump Ne Thermostatically 3 way diverter valve controlled mixing valve o lt y Limit thermostat Water temperature more than 60 C Cold water supply OLLAN Expansion Po I y vessel l l Pressure 5 i I reducing Check G Press re i Filter S valve relief valve l 1 Oma gt lt l l T l l i A Cold fill manifold assembly l I i Tundish I Unvented kit I KX Stop Discharge yalen a ee ed ee Te a pipe Mains water supply Fig 3 Note If the combination boiler is not Solar compatible a thermostatically controlled mixing valve MUST BE fitted in the cold water inlet to the boiler to ensure the water entering the boiler is less than 28 C Itho CombiSolar 150 page 7 Given below are
48. ver Remove the four plastic pins from the bottom cover to enable the centre cover to be unwrapped from the insulation the joint where the centre cover overlaps is stuck with double sided tape and will need to be peeled apart The sensors are located in two insulated pockets in the side of the Fig 18 insulation behind two polystyrene plugs Carefully cut the tape securing the plugs and remove them peel the sensors from the cylinder and feed them out through the bottom cover Undo the two screws on the control box cover to expose the PCB and unplug the sensor leads from their plugs loosen the gland nut and remove the wires Feed the new sensor leads through the gland and plug them into their corresponding coloured sockets and tighten the gland Feed the sensors up through the bottom casing and fit them to the cylinder with using the tape supplied making sure they are in the correct location Reassemble in reverse order Control box PCB refer to Section 9 Remove the screws securing the control cover and open the cover Remove all terminal connections and remove all plug in connections Pull back the two clips to the left of the PCB and pull the PCB forwards to remove Fit the new PCB and reassemble in reverse order 8 10 Drain back unit pump Fig 19 Note Care must be taken when carrying out repairs to the drain back unit as it reaches very high temperatures and can emit steam from connections when being removed Isolate the electri
49. width x depth 2140 x 1030 x 0 5 1030 x 2140 x 0 5 Spectral selective layer Absorption coefficient 95 Emission f 5 Glass Collector housing Insulation Thickness Thermal conduction coefficient awa atm cg cosa Material Aluminium black powder coated Temperature sensor Connections Pre mounted flexible hoses Return to DBU mm 15mm Flow from DBU mm 15mm Roof slope 20 Min 90 Max 30 Min 90 Max 80 Aperture to gross collector area ratio o9 Max wind and snow load Pitched roof Same as supporting roof structure Flat roof Wind speed 27 m s Snow load 1 9 kN m Maximum number of collectors m2 3 x 2 3 m 6 9 m2 Itho CombiSolar 150 page 3 2 3 Installation Solar cylinder min clearances for servicing DBU min clearances for servicing Lift weight cylinder assembly Lift weight DBU Weight full and operational cylinder assembly Weight full and operational DBU 2 4 General 2 5 Electrical Solar cylinder dimensions i Supply 230 240 V 50 Hz External fuse 3A DBU dimensions i Power consumption Max 197 W 430 mm Min 5W 266 mm 3 way valve Power consumption 4Ww Solar cylinder material Stainless steel Moisture protection IP44 DBU heat exchanger material Stainless steel Covers Insulation material EPS foam Solar cylinder insulation thickness 100 mm Standing energy loss of solar cylinder 0 96 kWh 24hr 0 27 Wilitre Heat coefficient of

Download Pdf Manuals

Related Search

Related Contents

Sandberg Print Cover iPh5 Cuddle Monkey  MANUAL LL-380 - L-Link  Affiche - Services  abbaye de royaumont  as a PDF - LOOSE Research Group      Sony SU-FW1 User's Manual  

Copyright © All rights reserved. Failed to retrieve file