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SOL 25 Plus Flat Plate Collector Installation Manual

1. LC ME in 24 in 24 in 48 1 in 96 3 in 144 4 in Figure 9 Multiple collector framing arrangement with frame connectors and cross bracing M10 nuts M10 bolts Frame Connectors O SES Figure 10 SFC001 Frame Connector Splice Kit Frame Connector splice to join two profile rails Profile rails Figure 11 SFC001 Frame Connector Splice Kit 15 ENGLISH Fastening To Structures The type of roof or wall is a crucial factor in the choice of fasteners Remember to take the static and dynamic live load forces into account The 45 vertical mounting racks can develop significant pull out forces under heavy wind conditions therefore it is important to take wind loads into account Force data for each collector Mounting Ht Shear Force Tensile Force Up to 26 ft 470 165 250 Ibs 8m 2 1 kN 1 1 kN Up to 65 ft 790 165 700 Ibs 20m 3 5 KN 3 1 KN To handle shear forces along the fastening surface 6 fasteners over which the shear force is distributed are recommended To handle tensile forces perpendicular to the fastening surface 6 fasteners over which the tensile force Is distributed are recommended For anchoring in concrete use six M8 UPAT Multicones or SM M10 anchors both of stainless steel per collector
2. dick wie SOLAR RATING amp CERTIFICATION CORPORATION 3 d t P rs S xm m u SA CH Na ee Zr AWARD OF COLLECTOR CERTIFICATION TS dr ie lt i The solar collector listed below has heen evaluated by the Solar Rating and Certification Comoration 8RCC in accordance WERTET EN Fr with SROC Document OG 100 Operating Givideliner and M nimam Standards for Certifring Solar Collectors and has been ames ar certified by the zs specified in SECC Scandant 100 94 Text Methods and Minimum Standards for Cerrifeing Solar ij gt ae Collectors Certifieutiem and thermal periormanee ratings are based on the successful durstility and per ormunce testing af a Oy sample unit where tests have been conducted by an independent laboratory accredited by the SRCC HRS Su D ins Collector Certification Number 100 2005016 LE i f E Date Certified June 26 2006 Expiration Date June 26 2011 Eos W Test Laboratory PSEC Report Number 00201 Report Date June 20 2006 SE i itty i Product Glazed Flat Plate Certified Model Sol 25 Plus Model Tested Sol 25 Plus iy Supplier Stiebel Eltron St ee 17 West Street Dd p West Harfleld 01088 USA GI 413 241 3380 ue ed eL eU o En E ry YT it Set ec Deaenptior Aluminum Extrusion frame Low Iron Tempered Glass glazing Copper absorber with Sputtered titanium nitride coating Min
3. Has the solar storage system tank been installed to the domestic water pipes according to Stiebel Eltron instructions and all local regulations Has the temperature sensor in the solar storage system tank been mounted and electrically connected to the controller according to Stiebel Eltron instructions and all local regulations Has the backup water heater afterheating or reheating been tested and properly installed for re heating If so specify the equipment connected and its temperature settings Is the SOM controller properly grounded electrically Was the lightning protection equipment connected by authorized skilled personnel Is the solar controller set according to the assembly and operating instructions Has the test run of the circulation pump been performed Checked for excessive unusual noise Checked for proper heat collection and storage during insolation Place Date Inspected by Company name 64 Specialists should carry out an annual inspection of the solar heating system to ensure proper functioning of the system and its components including the control unit safety equipment and tank System components fittings thermal insulation mounting hardware fasteners etc exposed to the weather must also be checked periodically for their condition Look for signs of abrasion wear corrosion contamination or damage Check the pH value gt 7 and frost protection level lt 20 F of the heat transfer medium a
4. can develop significant wind forces in certain locales Pre drill holes through the roof and mounting blocks The spacer blocks should be sized to fit snugly between the underside of the roof decking sheathing and the spanner block Apply liberal amounts of silicone sealant to the bolt hole and underneath the mounting block to prevent leaks It is extremely important to use galvanically compatible fasteners Stiebel Eltron mounting hardware L brackets frames etc are made of aluminum therefore stainless steel fasteners are strongly recommended to provide the required strength and protection from corrosion in harsh rooftop environments roof cement 7 mounting L bracket G Stainless steel nut N bolt amp washer mounting block E neoprene washer p silicone sealant NIE E shingles FD IIIIITIIIIIS NS spanner wood blocks 2 stainless steel sized to fit nuts amp washer WW Figure 1 Roof Attachment Using Spanner Block And Carriage Bolt 1 ENGLISH If the roof deck is inaccessible from below the collector mounting hardware may be fastened using lag bolts through the roof sheathing and into rafters from above as shown in Figure A 2 Lag bolts must solidly penetrate rafters or other structural members to provide solid anchoring strength The location of these may be determined by tapping the roof with a hammer Drill holes through the roof several sizes smaller than the b
5. E in 48 1 NM 96 3 in 144 4 in Figure 18 Multiple collector framing arrangement with frame connectors and cross bracing M10 nuts M10 bolts Frame Connectors Figure 19 SFC001 Frame Connector Splice Kit Frame Connector splice to join two profile rails Profile rails Figure 20 SFC001 Frame Connector Splice Kit 50 If multiple arrays of collectors are being installed on a flat roof one behind another the recommended spacing between them should be at least 30 ft 9 3 m for 60 vertical installation as shown in Figure 21 or at least 18 ft 5 3 m for 30 vertical installation as shown in Figure 22 This spacing prevents excessive shading from adjacent rows for latitudes of up to 50 For latitudes significantly higher than 50 multiple rows of collectors may not be practical due to low sun altitude angles Fastening To Structures The type of roof or wall is a crucial factor in the choice of fasteners Remember to take the static and dynamic live load forces into account The 30 60 vertical mounting racks can develop significant pull out forces under heavy wind conditions particularly in the 60 tilt orientation therefore it is important to take wind loads into account Mounting Ht Shear Force Tensile Force Up to 26 ft 470 165 250 165 8m 2 1 kN 1 1 kN Up to 65 ft 790 Ibs 700 Ibs 20m
6. For anchoring in wood use six wood screws in accordance with DIN 571 at least 10 x 80 of stainless steel per collector 5 1 2 45 Mounting On A Wall Procedures described above for mounting of collectors upon a flat roof apply to wall mounting except for the following 1 If multiple wall mounting frames are being set up next to one another use frame connector splice kits SFC001 to join them Line up the mounting supports with a string so that the mounting frames will be aligned properly 2 Fasten the wall mounting supports to the wall in a suitable manner using the holes in support riser SE45 110R then tighten all bolts and screws 3 Maintain the spacing between connection points as specified by the manufacturer 4 Low elevation mounting configurations may be prone to damage from falling 16 Array spacing for 45 Vertical Mounting on a flat roof or ground At least 25 ft 7 6 m Figure 12 Recommended row spacing for 45 vertical arrays for latitudes up to 50 Array spacing for 45 Horizontal Mounting on a flat roof or ground At least 14 ft 4 0 Figure 13 Recommended row spacing for 45 horizontal arrays for latitudes up to 50 ice or nearby vehicles or other hazards Appropriate precautions should be taken to mitigate these hazards 5 1 3 45 Mounting On The Ground Procedures descr
7. R2 frame for one collector horizontal installation or two collectors vertical installation In combination with the mounting hardware sets permits installation on sloped roofs flat roofs or walls Frame Connector kit for SOL 25 Plus Connects two collector frames together Flush mounting kit for vertical installation on a roof or a wall for SOL 25 Plus Collector Flush mounting kit for horizontal installation on a roof or a wall for SOL 25 Plus Collector Frame tilt mounting kit for vertical installation of SOL 25 Plus TWO NEEDED PER FRAME Frame tilt mounting kit for horizontal installation of SOL 25 Plus TWO NEEDED PER FRAME 45 mounting frame for vertical installation of SOL 25 Plus TWO NEEDED PER FRAME 45 mounting frame for horizontal installation of SOL 25 Plus TWO NEEDED PER FRAME 60 mounting frame for vertical installation of SOL 25 Plus TWO NEEDED PER FRAME Aluminum Clamp for metal roof arrangements of SOL 25 PLUS collectors Parts Included 2 profile rails 8 anchor brackets 8 sets M10 20 nuts and bolts 2 profile rails 16 anchor brackets 16 sets M10 20 nuts and bolts 1 compensator flexible stainless steel tube 170804 with vent screw and 2 seals 2 113 frame connectors 8 sets M10 20 bolts and nuts 2 S101 collector rails vertical 4 102 L brackets 8 sets M10 20 nuts and bolts 2 5201 collector rails horizontal 4 102 L brackets 8 sets M10 20 nuts and bolts 1
8. brackets to be installed during the subsequent steps ENGLISH Step 19 Prepare to install the bottom right rear L bracket Step 20 Prepare to install the bottom right rear L bracket WWW STIEBEL ELTRON USA COM SOL 25 PLUS 53 Step 21 Install an M10 serrated flange nut Repeat this procedure for the other side Step 22 Align the bottom front L brackets as shown Step 23 Prepare to install the front left L bracket Note that the side of the L bracket with the hole closer to the edge is aligned parallel to the support rails 54 SOL 25 PLUS WWW STIEBEL ELTRON USA COM Step 24 Installan M10 x 30 bolt and an M10 serrated flange nut ENGLISH Step 25 Prepare to install the front right L bracket Note that the side of the L bracket with the hole closer to the edge is aligned parallel to the support rails Step 26 Install an M10 x 30 bolt and an M10 serrated flange nut WWW STIEBEL ELTRON USA COM SOL 25 PLUS 55 E si P Step 27 Diagonal view of front right Step 28 At this point the entire assembly may be flipped over and stood up as shown d D i EFSF 7 d E Step 28a Measure the angle of the assembly to make sure that it is at the required angle If it is not then it is necessary to adjust the riser struts The illustrated assembly is adjusted to 30 56 PLUS WWW STIEBEL EL
9. support does not protrude past the edge of the profile rail WWW STIEBEL ELTRON USA COM SOL 25 PLUS 37 Step 18 Attach the other end of the right angle assembly to the bottom of the rectangular assembly using the same fasteners Repeat these steps for the remaining right angle assembly Step 19 Rotate the assembly so that it is resting on the base WWW STIEBEL ELTRON USA COM WWW STIEBEL ELTRON USA COM Step 20 Install one ofthe cross braces to the riser support using two 1 nuts bolts and washers Ifthe collectors are being mounted on a wall it is usually preferable to install the cross braces between the two base supports Step 21 Align the remaining cross brace to the oppisite attachment slots and fasten it to the riser support using the same fasteners and attattach the two cross braces together in the middle using one 1 nut bolts and washer The assembly is now ready to be installed at the installation site SOL 25 PLUS 59 ENGLISH 5 3 Flush Mounting On A Pitched Roof The collector mounting frames p n 185545 and or 185546 may be used as templates for locating the support rails and L brackets The Stiebel Eltron provides flush mounting kits for both vertical and locations of fasteners may be determined from these templates horizontal collector layouts part numbers SFM001 and SFM001H After the mounting L brackets are installed assemble the frame respectively Figure 24 shows th
10. yeW 0 8ing AV SS AW 9A EA euuoosiq 9A EA Jo ainssald 9 EA Joy aJnjeJadua 3 juan 9JnssaJd AV DATA Pay d Jajaw MO J 14 AeA 8 Uu jud 0 1 T JUOA jenuew pue SS sumy uoiun peasy 4459 H E 1 5 1 e qix9 J AW Jasueyoxq JeaH yuel Ul 10 s umu edid e 3 128 paso 3 8 AEM OML yay 2 aw 1938 Wwow Jay 3 Pay 8 129 T 58 931 Collector Temperature Sensor Well Figure 3 11 Mounting hardware for Stiebel Eltron SOL 25 PLUS solar collectors is available in the following configurations 45 fixed mount vertical orientation 45 fixed mount horizontal orientation 30 60 fixed mount vertical orientation flush mount vertical orientation flush mount horizontal orientation e 15 30 tilt mount vertical orientation e 15 30 tilt mount horizontal orientation Select the collector mounting kit that is capable of providing the required tilt and azimuth in a mounting location that is not subject to excessive shading of the solar collectors The mounting kit must be securely attached to a structure capable of supporting and maintaining its integrity under the static and dynamic e g high wind loading conditions The type of mounting system that is best suited to the installation must be determined by the designer an
11. 029 psi 2 0 mbar Pressure drop of collector 52 gal hr and 68 F fluid temp 0 087 psi 6 0 mbar G 3 4 male BSPP British Standard Pipe Parallel Thread Propylene Glycol ready mixed Connection Heat transfer medium Heat transfer medium fluid content incl manifold 0 43 gal 1 6 Total area 29 sq ft 2 7 m Effective collector aperture area 27 sq ft 2 5 m Absorber area 27 sq ft 2 5 m Installation angle 20 90 Housing aluminum saltwater proof Cover low iron tempered 0 16 safety glass super transparent Absorber copper highly selectively vacuum coated Pipe copper header pipe 3 4 pot pipe 5 16 Thermal insulation rear wall mineral wool 1 57 inches 40 mm thick ENGLISH Thermal insulation side wall Seal EPDM Connection fittings pipe bend stainless steel with union nut brass G 3 4 Thermal power generated per collector 0 to 6830 BTU hr 0 to 2000 W Conversion factor ho 0 781 Heat loss value ao 0 500 BTU hreft2 F 2 838 W m 2 K Heat loss value 0 0027 BTU hreft2 F 0 0154 W m 2 K mineral wool 0 39 inches 10mm thick 4 1 Accessories Table 4 1 1 shows the mounting accessories available for several common NOTE All fasteners in these kits are of stainless steel Item R1 frame for one SOL 25 plus collector vertical installation In combination with the mounting hardware sets permits installation on pantile roofs corrugated sheet roofs flat roofs or walls
12. 3 5 KN 3 1 KN To handle shear forces along the fastening surface 6 fasteners over which the shear force is distributed are recommended To handle tensile forces perpendicular to the fastening surface 6 fasteners over which the tensile force is distributed are recommended For anchoring in concrete use six M8 UPAT Multicones or SM M10 anchors both of stainless steel per collector For anchoring in wood use six wood screws in accordance with DIN 571 at least 10 x 80 of stainless steel per collector 5 2 2 30 60 Mounting on a Wall It is not generally advisable to use the 30 mounting orientation on a wall unless additional supporting structures are installed to bear the loads Installers should consult with a structural engineer Procedures described above for mounting 21 Array spacing for 60 Vertical Mounting on a flat roof or ground At least 30 ft 9 3 m Figure 21 Recommended row spacing for 60 vertical arrays for latitudes up to 50 Array spacing for 30 Vertical Mounting on a flat roof or ground At least 18 ft 5 3 m Figure 22 Recommended row spacing for 30 vertical arrays for latitudes up to 50 ase Figure 23 Typical wall mount installation of a 60 collector array WWW STIEBEL ELTRON USA COM of collectors upon a flat roof apply to wall mounting except for the following 1 If
13. 4 washers M10 nuts MV iinan 1 4 20 nuts I bolts 1 4 20 x M10 bolts 2 1 2 bolts N u Support Riser 545286 Support Base S4518B Support Diagonal 5107 ___ Brace 5109 ___ Figure 7 45 degree Horizontal Mounting Kit p n 074324 Proceedure 1 Choose attachment site allowing for subsequent pipe penetration 2 Boltthe support base SE45 110B support riser SE45 110R and transverse support SE45 111 collector rail together to form a triangle truss as shown in Figure 8 Support Diagonal Figure 8 Assembled triangle trusses with cross braces 3 Bolt the resulting truss es to the upper and lower profile frame rails 4 If installing one collector the triangle trusses must be set up at intervals of 82 in 210 cm for horizontal installation or lt 43 in 110 cm for vertical installation 5 If installing two or more collectors the triangle trusses are to be positioned at the midpoint behind the collectors 6 Whenever two or more triangle trusses are installed brace the center span with a cross brace as shown in Figure 8 7 When installing four or five trusses brace both end spans with crossbraces as shown in Figure 9 For six or more trusses cross braces should also be placed in an inside Span 8 If multiple flat roof mounting frames are being set up next to one another use frame connector splice kits SFC001 shown in Figure 10 to join th
14. 400 Plus 400 liter 110 gal solar storage tank double HX includes STAK 002 connection kit 187874 SBB 600 Plus 600 liter 163 gal solar storage tank double HX includes STAK 002 connection kit 187875 Red indicator anode rod for SBB tanks 140919 Anode rod for SBB 300 400 tanks 249041 Anode rod for SBB 600 tank 249042 Segmented flexible replacement anode for SBB tanks 143499 Gasket for anode rod 036770 Thermometer for SBB Tanks 165967 ENGLISH 4 2 Planning and Installation System Schematic A schematic diagram of components and pipe arrangements for a typical Stiebel Eltron SOLKIT system is shown in Figure 1 A ddns Ja eM 5 a adAj y ue JO ssajyue 19jeau MHa Je1usurs ddns 0 enuew uonejjejsui suoiyesijddy Jejos 10 SyUe a8eJ01S GgS 0 12481 aseajd yuez 8 10 5 pue ay uo 104 AJLA 8 E 19 NU SUNY uoiun T J9UlEJUO MO0 JJ9AO Sulweays ijue pue 1uaA 0jne 1ew Q 8Jng 8T ccc OU sod Z Das UOI IBUUOD YUE 591 uie SI 071 1 N 2 sajddiu T JajawW MO X Ale qr 3 119 uol ejos 0 pue epioJur paads esum dung wv uieJq 3 1115 qr asaydsowje u do uaym painseaw o nssa d poSJeup aJd ISd 11 21V k uoisuedx3 V N Deuuoo
15. 7 66 9 69 8 72 5 75 0 5 2 5 Detailed Assembly Instructions for 60 Mounting Kit 52 SOL 25 PLUS 64 8 69 5 74 0 78 4 not recommended not recommended not recommended not recommended not recommended not recommended not recommended not recommended Step 01 Major components for assembly of the Stiebel Eltron 30 60 mounting kit single panel vertical version displayed WWW STIEBEL ELTRON USA COM Step 02 Place the profile rail upside down as shown The longer cutout surface approx 1 should be facing toward the center ofthe rectangle and be parallel to the ground This is the surface on which the back of the collector will rest ENGLISH Step 03 Slide one ofthe M10 bolts into the slot ofthe profile rail as shown Step 04 Prepare to assemble the top left corner of the rectangle The end of the support rail with the hole closer to the edge is the top side of the rail Note If assembling a mounting system using the longer profile rails p n 185546 the support rails should not be fastened to the ends of the profile rails but should be assembled such that the supports are approximately 2 from each side of the profile rail and are therefore approximately 4 feet from each other WWW STIEBEL ELTRON USA COM SOL 25 PLUS 33 Step 05 Insert the threads of the M10 bolt through the hole in the support rail Step 06 Install M10 nut Repeat the preceding 4 steps for the top right corner
16. a horizontal flush mounting system the holes on either end of the support rail are equidistant from each end Note 2 If assembling a mounting system using the longer profile rails p n 185546 the support rails should not be fastened to the ends of the profile rails but should be assembled such that the supports are approximately 2 from each side of the profile rail and are therefore approximately 4 feet from each other SOL 25 PLUS 41 ENGLISH Step 05 Insert the threads of the M10 bolt through the hole in the support rail Step 06 Install M10 nut Repeat the preceding 4 steps for the top right corner of the rectangle Step 07 Align the profile rail in the same manner as the top The longer cutout surface should be facing toward the center of the rectangle and be parallel to the ground 42 SOL 25 PLUS WWW STIEBEL ELTRON USA COM EIS Lh WWW STIEBEL ELTRON USA COM Step 08 Prepare to assemble the bottom right corner Step 09 Slide one ofthe M10 bolts into the slot ofthe profile rail as shown Step 10 Insert the threads of the M10 bolt through the hole in the support rail SOL 25 PLUS 43 ENGLISH Step 11 Install M10 nut Repeat the preceding 4 steps for the bottom left corner of the rectangle Step 12 The resulting assembly Turn this assembly over so that the support rails are on the ground and the and the profile rails are slightly elevated before proceeding to the next
17. all required relays of the solar control unit are connected according to the controller s operating instructions Then set the control unit back to automatic mode The system should then start automatically subject to all starting conditions being met If that is not the case check in Section 10 0 Troubleshooting for a possible cause for this fault See that the solar system places no excessive temperature or pressure on auxiliary system Have owner check the system daily to observe pressure temperature and flow rate while the pump is on and to look for evidence of overflows from pressure relief valves It is also wise to continue checking for leaks periodically Any deviation from normal should prompt immediate corrective action by the installer 65 ENGLISH 8 6 Checklist for Start up Of Solar Installations CAUTION IT IS MANDATORY TO PERFORM THE WORK IN COMPLIANCE WITH THE SAFETY REGULATIONS FOR WORK ON AND INVOLVING ROOFS AND THE INSTRUCTIONS SAFETY AND RESCUE HARNESSES PUBLISHED BY THE TRADE ASSOCIATION THESE ASSEMBLY AND OPERATING INSTRUCTIONS AND THE ASSEMBLY AND OPERATING INSTRUCTIONS FOR THE SOM CONTROLLER AND THE STORAGE SYSTEM ARE TO BE FOLLOWED DILIGENTLY DURING THE ASSEMBLY WORK Upon the start up of solar installations provided with Stiebel Eltron Flat Plate Collectors the following checklist should be reviewed to help ensure successful completion of the installation Installation Operator F
18. inputs SOM 8 SI differential temperature controller a sophisticated solar system controller providing up to nine control functions pumps valves etc and 15 sensor inputs They are typically used for larger more complex and or commercial systems STAK storage tank accessory kit temperature pressure gauge a special mechanical gauge that integrates both temperature and pressure indicators tensile force force acting in line with a fastener or member placing it in tension which would pull it apart if sufficiently high above its tensile strength Tensile force acts in opposite direction than compressive force which would buckle or crush the member thermal conductivity the ability of a material to conduct heat typically in units of W m K it is the inverse of thermal resistance thermo siphoning the passive convection or flow of a fluid through a conduit that is caused by density changes due to differences in temperature from one point in the conduit to another Thermosiphons are particularly prevalent in vertical loops of pipe carrying liquids where one side of the loop is exposed to a warmer 69 ENGLISH temperature than the other In some cases thermo siphoning is undesirable when it causes heat to be transported away from Storage truss a triangular shaped structure used to tilt incline solar collectors at an angle relative to the structure inclination angle on which they are mounted Units of Measu
19. multiple wall mounting frames are being set up next to one another use frame connector splice kits SFC001 to join them Line up the mounting supports with a string so that the mounting frames will be aligned properly 2 Connect the wall mounting supports to the wall in a suitable manner using the holes in support riser SE60 110 then tighten all bolts and screws or support base SE60 108 if installing as a 30 system and transverse support S101 collector rail 3 Maintain the spacing between connection points as specified by the manufacturer Low elevation mounting configurations may be prone to damage from falling ice or nearby vehicles or other hazards Appropriate precautions should be taken to mitigate these hazards Figure 23 shows a typical wall mount installation of a 60 collector array 5 2 3 30 60 Mounting on the Ground Procedures described above for mounting of collectors upon a flat roof apply to ground mounting except for the following 1 Installer must ensure that the mounting foundation for the system is not subject to movement such as frost heaves Therefore it is necessary to install footings below the frost line in locations subject to freezing weather If it is not possible or practicable to avoid movement due to frost etc it will be necessary to provide a floating frame that does not flex or warp the collectors mounting frames if the ground shifts or heaves 2 G
20. not attempt to twist or readjust the connections once they have been installed The return piping can now be connected to the unoccupied external thread of the R 3 4 adapter on the collector immersion sleeve sensor well Immediately after installation run a pressure leak test fill and flush the system with propylene glycol mixture heat transfer medium and place the system into service as described in Section 8 0 61 ENGLISH WARNING PRESSURE TEST SYSTEM ONLY WITH COMPRESSED AIR NEVER FILL AND PRESSURE TEST THE SYSTEM WITH WATER WHERE THERE IS A RISK OF FROST COLLECTORS CAN FREEZE AT TEMPERATURES SIGNIFICANTLY ABOVE AIR TEMPERATURE IF RADIATIONAL COOLING IS STRONG SUCH AS WITH CLEAR SKIES After the installation is complete the system may be commissioned for service Commissioning involves the following procedures which are explained in detail in this section Pressure and Leak Test Section 8 1 Setting The Expansion Tank Pre charge Pressure Section 8 2 e Flushing The System Section 8 3 Final Charging and Venting The System Section 8 4 Start up Section 8 5 8 1 Pressure and Leak Test After the pipework has been installed and the collectors have been connected it will be necessary to pressure test the system to detect leaks before filling the solar loop with heat transfer fluid Propylene glycol solutions can leak from much smaller gaps than can water so such testing is critical to assuring
21. of the rectangle Step 07 Align the profile rail in the same manner as the top The longer cutout surface should be facing toward the center of the rectangle and be parallel to the ground 54 SOL 25 PLUS WWW STIEBEL ELTRON USA COM EIS Lh WWW STIEBEL ELTRON USA COM Step 08 Prepare to assemble the bottom right corner Step 09 Slide one ofthe M10 bolts into the slot ofthe profile rail as shown Step 10 Insert the threads of the M10 bolt through the hole in the support rail SOL 25 PLUS 35 ENGLISH Step 11 Install M10 nut Repeat the preceding 4 steps for the bottom left corner of the rectangle Step 12 Resulting assembly to which the remaining components will be attached to form a 60 mounting system Step 13 Align the base support and the riser support in the manner shown Note that the end of the riser which is attached in this step is the end without the cutout 56 SOL 25 PLUS WWW STIEBEL ELTRON USA COM Step 14 Align the holes and insert one of the 3 8 16 x 3 bolts and install a 3 8 serrated flange nut Repeat these steps for the remaining riser and base supports ENGLISH Step 16 Close up view of assembly Step 17 Attach the riser support of one of the right angle assemblies which were just assembled to the top of the rectanglular assembly using of the 3 8 16 x 3 bolts and a 3 8 serrated flange nut Note that the top is the part in which the diagonal
22. pressure should be set to 5 7 psi less than the sys tem start up cold pressure check it when the system has not been filled This pressure must not be reduced ENGLISH WARNING NEITHER DROP THE COLLECTOR NOR ANYTHING ONTO THE COLLECTOR NEVER STEP ONTO OR STAND ON THE COLLECTOR NEVER LEAVE THE COLLECTOR UNSUPPORTED OR UNSECURED THE GLASS COULD BREAK IF THE COLLECTOR FALLS OVER CAUSING SERIOUS INJURY OR DEATH WARNING SETTING THE MAXIMUM TANK TEMPERATURE HIGHER THAN 140 F AT THE CONTROL UNIT IS PERMISSIBLE ONLY IN CONJUNCTION WITH A THERMOSTATICALLY CONTROLLED DHW MIXING VALVE OTHERWISE THERE CAN BE A RISK OF SCALDING AT THE DRAWOFF POINT IMPORTANT ALL SENSOR WIRING SHOULD BE RATED FOR EXPECTED TEMPERATURES AND MUST BE PROTECTED FROM DEGRADATION AND ELECTRICAL INTERFERENCE Solar Loop Use only a mixture of 50 GRAS food grade Propylene Glycol and de ionized water Heat Exchanger type SW AWWA Fluid Class II see MSDS for handling instructions WARNING FLUID MAY BE DISCHARGED AT HIGH TEMPERATURE AND OR PRESSURE NO OTHER FLUID SHALL BE USED THAT WOULD CHANGE THE ORIGINAL CLASSIFICATION OF THIS SYSTEM UNAUTHORIZED ALTERATIONS TO THIS SYSTEM COULD RESULT IN A HAZARDOUS CONDITION Shut Down Use only a mixture of 50 GRAS food grade Propylene Glycol and de ionized water Heat Exchanger type SW AWWA Fluid Class II see MSDS for handling instructions Except for repair and or emergency the control unit
23. step Step 13 Prepare to install the lower right hand L bracket The vertical portion should contain the hole which is closest to the edge of the bracket 44 SOL 25 PLUS WWW STIEBEL ELTRON USA COM WWW STIEBEL ELTRON USA COM Step 14 Slide one ofthe M10 bolts into the slot ofthe profile rail as shown Step 15 Insert the threads of the M10 bolt through the hole in the vertical portion of the L bracket SOL 25 PLUS 45 ENGLISH Step 16 Install M10 nut Repeat the preceding 3 steps for the remaining 3 L brackets Step 17 Finished product top view 46 SOL 25 PLUS WWW STIEBEL ELTRON USA COM 5 4 15 30 Tilt Mounting on a Pitched Roof N IMPORTANT INSTALLED HEIGHT MUST NOT EXCEED 60 FEET Stiebel Eltron provides tilting frame mounting kits for both vertical and horizontal collector layouts part numbers SFT004 and SFTOO4H respectively Figure 26 shows the SFT004 kit and Figure 27 shows the SFTOO4H kit The SFT004 frame tilt kit SFTOOAH in the case of horizontal mounting provides adjustment of the collector array from 15 to 30 For mounting on a roof two 2 tilt kits are needed per collector frame for either vertical or horizontal configurations Stiebel Eltron tilt mount kits are generally not recommended for mounting upon flat roofs walls or the ground Instead the 45 or 30 60 mounting systems are more appropriate for mounting to structures other than pitched r
24. that an anti freeze solution provides reheating the addition of more heat to the outlet domestic hot water of a solar storage tank to raise it to the desired temperature for final use by a building s occupants RTD resistance temperature detector or resistance thermometer a temperature sensor that exploits the predictable change in electrical resistance of some materials with changing temperature They are most often made of platinum Pt is the symbol for platinum Stiebel Eltron s SOM 6 7 and 8 use RTD temperature sensors to measure temperatures of solar collectors heat exchangers and storage tanks RTDs are manufactured to achieve a particular resistance curve vs temperature R value insulation a measure of thermal resistance used in the building and construction industry The bigger the number the better the insulation s effectiveness R value is the reciprocal of U value In the U S the units of measure of R value are degrees Fahrenheit square feet hours per BTU ft2 F h BTU Converting to from SI units 1 ft F h BTU 0 1761t K m W or 1 K m W 5 67446 ft2 F h BTU SBB Stiebel Eltron solar storage tank models Schrader valve most often found on tube type and tubeless tires Schrader valves are used on many refrigeration and air conditioning systems to allow servicing including recharging with refrigerant They are also used to conduct leak down pressure tests on pipe installations Stiebel
25. the loss of pressure of a fluid as it flows through pipes and other components caused by its viscosity or friction Pressure drops must be taken into account when determining pump sizes system pressures and other design factors profile frame rails extruded aluminum members that form the frame in which to hold collectors and that provide slots for bolt attachments propylene glycol a non toxic type of heat transfer medium and anti freeze solution that is often used in closed loop solar collector systems to prevent freezing of the liquid and related damage to components in very cold temperatures The correct percentage of propylene glycol in a mixture with water Is critical to the proper functioning and safe operation of solar thermal systems psi psia psig pounds force per square inch typically for pressure or stress measurement psia is absolute pressure psig is gauge pressure Sea level atmospheric pressure is approximately 14 7 psia or 0 psig as read by a gauge Purgomat air vent an automatic float type air vent that is used to purge a hydronic system or solar loop of air and allow efficient heat transfer to take place PVC polyvinyl chloride a thermoplastic polymer It is often used as a Jacket or cover for solar loop piping and other components refractometer a device used to measure of an index of refraction For solar thermal systems the index of refraction is translated to degrees of freeze protection
26. to the to fill amp drain valve in the pumping station 2 Connect a hose to the boiler drain at the bottom of the loop bottom fill amp drain valve at the outlet side of the storage tank s heat exchanger 3 Use a clean dry pail or catch basin and fill it with sufficient Dowfrost medium propylene glycol mixture to fill the entire system s volume plus some extra 4 Keep all other vents and valves closed during the flushing operation 5 Close the flow meter adjusting screw at the pump assembly horizontal position 6 Start charging the system and observe the loop fluid draining back into the pail Make sure that the fluid level in the container always remains higher than the intake hose 7 The flushing process should continue until the fluid draining back appears clean and free of contaminants The screens filters may require cleaning during this process 8 When the system is fully flushed proceed to the final charging phase described below 8 amp Final Charging and Venting The System The solar heating system must be filled exclusively with the premixed propylene glycol heat transfer medium The bottles have been premixed and require no further treatment Never admix water or alternative process media otherwise the essential characteristics and corrosion protection can no longer be guaranteed For this reason the system must not be topped off with water Follow these steps to complete the final charging and vent
27. use pressurized nitrogen to a final pressure of 5 psi less than the target system pressure For example if the final target system solar loop pressure is to be 50 psig fill the expansion tank to 45 psig which is the recommended default value When complete cap the Schrader valve fitting and re attach the tank to the pump station Make sure the expansion tank always faces up the Schrader valve must be pointed down 8 3 Flushing the System The next step of the commissioning process involves flushing the solar loop to purge contaminants and air Preparations Use only 50 50 Dowfrost propylene glycol solution for flushing the system Use of water or any other fluid may adversely affect the operation of the system Wear protective gloves and goggles when handling propylene glycol mixtures Never fill the system when it is subject to strong solar irradiation This could lead to steam hammer inside the collectors and possible burns from escaping steam If the sun shines during start up cover the collectors or wait until there is some shade The following procedure makes use of a charging pump screen filter and large pail or trough to circulate fluid through the system The sump can have a coarse mesh screen to prevent large particles from entering the pump The outlet of the pump should be fitted with 5 micron sediment filter The intake sump should be set near the bottom of the pail 1 Connect the charging pump s outlet
28. water piping requires insulation of at least R 2 6 All exterior piping also requires UV and moisture protection Insulation must be resistant to temperatures up to 356 F Use the following recommended temperature and UV resistant thermal insulation to insulate the external pipework Polyiscocyanurate PVC cover Armaflex Mineral wool backed by aluminum mesh foil Flexible EPDM hose e g type Aeroflex A rigid aluminum sheath is recommended as protection for the mineral wool The EPDM hose can be finished with UV resistant paint Where required protect the thermal insulation against bird or rodent attack Insulate all lines of the solar loop Apply the thermal insulation after pressure testing and checking the system for leaks see Section 8 Extremely cold climates that experience nighttime winter temperatures below 30 F may need thicker than standard pipe insulation to prevent freeze ups or slushing of the anti freeze mixture Minimum Insulation Thickness Min thickness of insulation layer based on thermal conductivity of 0 035 W meK Normal Diameter of Pipes Less than 3 4 3 4 3 4 to 1 1 4 1 1 1 4 to 4 identical to pipe diameter Greater than 4 Collector Temperature Sensor Well The collector sensor well is threaded onto the outlet pipe of the collector array i e positioned at the hot side The outlet can be the upper left or right side of the collector depending o
29. 6 2 185546 2 185546 N A 1 SFC001 1 SFC001 1 SFC001 2 SFM001H 4 SFTOO4H 4 074324 Vertical 1 185546 1 185546 1 185546 1 185546 1 185545 1 185545 1 185545 1 185545 1 SFCoo1 1 SFCoo1 1 SFCoo1 1 SFCoo1 1 170804 1 170804 1 170804 1 170804 2 SFMoo1 3 SFTOO4 3 185543 3 SE60 1 104 1 109 1 S109 Horizontal 3 185546 3 185546 3 185546 N A 2 SFCoo1 2 SFCoo1 2 SFCoo1 3 SFMOO1H 6 SFTOO4H 6 074324 4 No kit available requires custom design If mounting horizontally in one row 1 Peak altitude angle of the sun at noon at 45 north latitude at summer solstice is about 68 Maximum gain occurs with panels normal perpendicular to this angle or tilted 22 from horizontal facing true south Overall gain is not reduced significantly if collectors are within 10 of the optimum tilt angle and within 15 of true south 12 Recommended mounting kits for installation sites and corresponding section numbers Flush Mount 15 30 Tilt Mount 45 Mount 30 60 Mount Flat Roof NR e e SE Sec 5 1 1 Sec 5 2 1 Wall NR e 2 _ ______________ ___ Sec 5 1 2 Sec 5 2 2 Ground NR e e Sec 5 1 3 5 2 3 Pitched Roof e e e Sec 5 3 Sec 5 4 Sec 5 1 4 Sec 5 2 4 Table 5 2 Mounting Configurations Available NR not recommended for most applications 5 1 Installation of 45 Mounts on Roofs Walls or Ground N IMPORTANT INSTALLED
30. Austria Stiebel Eltron Ges m b H Eferdinger Str 73 A 4600 Wels Tel 072 42 47367 0 Fax 07242 47367 42 E Mail info stiebel eltron at Internet www stiebel eltron at Czech Republic Stiebel Eltron spol s r o K H jum 946 CZ 15500 Praha 5 Stodulky Tel 02 5111 6111 Fax 02 355 12122 E Mail info stiebel eltron cz Internet www stiebel eltron cz Hungary Magyarorsz g Stiebel Eltron Kft Pacsirtamezo u 41 H 1036 Budapest Tel 012 50 6055 Fax 013 68 8097 E Mail info stiebel eltron hu Internet www stiebel eltron hu Poland Stiebel Eltron sp z o o ul Instalator w 9 PL 02 237 Warszawa Tel 022 8 4648 20 Fax 022 8 466703 E Mail stiebel Qstiebel eltron com pl Internet www stiebel eltron com pl Switzerland Stiebel Eltron AG Netzibodenstr 23c CH 4133 Pratteln Tel 061 8 169333 Fax 061 8 169344 E Mail info stiebel eltron ch Sweden Sverige Stiebel Eltron AB Box 206 SE 641 22 Katrineholm Tel 0150 487900 Fax 0150 487901 E Mail info stiebel eltron se Internet www stiebel eltron se Thailand Stiebel Eltron Ltd 469 Building 77 Bond Street Tambon Bangpood Ampur Pakkred Nonthaburi 11120 Tel 02 960 1602 4 Fax 02 960 1605 E Mail stiebel loxinfo co th Internet www stiebeleltronasia com 5 ENGLISH WARRANTY STIEBEL ELTRON WARRANTS TO THE ORIGINAL OWNER THAT THE SOL 25 PLUS FLAT PLATE SOLAR COLLECTOR WILL BE FREE FROM DEFECTS IN WORKMANSHIP AND MAT
31. Building materials adjacent to solar components must not be exposed to the elevated temperatures that the collectors can generate Exposed components that can readily be reached must be maintained below 140 F or otherwise be insulated isolated All other exposed surfaces that can exceed 140 F should be labeled with appropriate burn hazard warnings 30 mounting is not recommended for wall mounting without additional supporting structures Tools Needed 1 Power drill with 1 4 drill bit Bits of other sizes are recommended as well 11 16 drill bit for corrugated sheet roof installations Two 17mm wrenches and or sockets for M10 bolts Two 15mm wrenches and or sockets for M10 nuts Two 7 16 wrenches sockets for 7 16 and 1 4 nuts bolts Two 9 16 wrenches sockets for 3 8 nuts bolts One 2 adjustable wrench for collector fittings Oo uU E WM 5 1 1 Mounting on a Flat Roof Two mounting frames are available for fixed 45 degree collector tilt R1 for one collector installed vertically 185545 See Figure 4 R2 for two collectors installed vertically or one collector installed horizontally 185546 See Figure 5 Anchor brackets panel clips M10 nuts M10 bolts Profile rails Figure 4 R1 Mounting Frame for Vertical Collector Arrangement For 45 vertical mounting on a flat roof two sets of 185543 flat roof wall mounting hardware are needed for two collectors or more the number of sets requir
32. CES OR APPLICABLE MANUALS DIAGRAMS TECHNICAL BULLETINS OR WRITTEN INSTALLATION INSTRUCTIONS AND TO APPLICATIONS OTHER THAN MEDIUM TEMPERATURE TO OBTAIN SERVICE UNDER THIS WARRANTY THE OWNER MUST FIRST SECURE WRITTEN AUTHORIZATION FROM STIEBEL ELTRON INC THE OWNER SHALL BE REQUIRED TO SHOW PROOF OF PURCHASE DATE AND TO PAY ALL TRANSPORTATION COSTS TO RETURN THE DEFECTIVE PART S FOR REPAIR OR REPLACEMENT f 6 STIEBEL ELTRON INC 17 West Street West Hatfield MA 01088 USA PHONE 800 582 8423 or 413 247 3380 FAX 413 247 3369 E Mail info stiebel eltron usa com www stiebel eltron usa com WWW STIEBEL ELTRON USA COM SOL 25 PLUS 77 ENGLISH
33. E al 90 Chien EA A E b UL z3 Pee ee PUER P ON SRCC COLLECTOR CERTIFICATION NE Solar Rating and Certification Corporation c o FSEC 1679 Clearlake Road Cocoa FL 32922 517 WWW STIEBEL ELTRON USA COM SOL 25 PLUS 73 ENGLISH USA Stiebel Eltron Inc 17 West Street West Hatfield MA 01088 Tel 413 247 3380 Fax 413 247 3369 E Mail info stiebel eltron usa com Internet www stiebel eltron usa com Germany Stiebel Eltron International GmbH Dr Stiebel Str 37603 Holzminden Tel 0 5531 702 0 Fax 0 5531 702 479 E Mail info stiebel eltron com Internet www stiebel eltron com Great Britain Stiebel Eltron Ltd Lyveden Road Brackmills GB Northampton NN4 7ED Tel 016 04 766421 Fax 016 04 765283 E Mail info stiebel eltron co uk Internet www stiebel eltron co uk France Stiebel Eltron SAS 7 9 rue des Selliers BP 85107 F 57073 Metz C dex 3 Tel 03 87 74 3888x Fax 03 87 74 6826 E Mail secretcom stiebel eltron fr Internet www stiebel eltron fr Belgium Stiebel Eltron Sprl Pvba Rue Mitoyenne 897 B 4840 Welkenraedt Tel 087 88 1465 Fax 087 88 1597 E Mail stiebel skynet be Internet www stiebel eltron com 4 Netherlands Stiebel Eltron Nederland B V Daviottenweg 36 Postbus 2020 NL 5202 CA s Hertogenbosch Tel 073 6 2300 00 Fax 073 6 23 1141 E Mail stiebel stiebel eltron nl Internet www stiebel eltron nl
34. ERIALS FOR A PERIOD OF TEN 10 YEARS FROM THE DATE OF PURCHASE SHOULD THE PART S PROVE TO BE DEFECTIVE UNDER NORMAL USE DURING THIS PERIOD STIEBEL ELTRON INC WILL BE RESPONSIBLE FOR REPLACEMENT OF THE DEFECTIVE PART S ONLY STIEBEL ELTRON INC WILL NOT BE LIABLE FOR ANY COSTS OF TRANSPORTATION REMOVAL REINSTALLATION OR ANY OTHER LABOR OR FREIGHT CHARGES THAT MAY ARISE IN CONNECTION WITH A WARRANTY CLAIM OR ANY INCIDENTAL OR CONSEQUENTIAL EXPENSES THIS WARRANTY DOES NOT APPLY 1 ST m M M TO CONDITIONS RESULTING FROM A FAILED COMPONENT OR PART THAT IS NOT PART OF THE SOLAR COLLECTOR OR ABSORBER PLATE TO FREEZE DAMAGE TO CONDITIONS RESULTING FROM MISUSE ABUSE NEGLECT ACCIDENT OR ALTERATION TO MINOR DISCOLORATION OF THE COLLECTOR FRAMEWALL OR ABSORBER PLATE TO GLASS BREAKAGE TO CONDITIONS RESULTING FROM THE INTRODUCTION OF HARMFUL CHEMICALS CAUSTIC FLUIDS OR LIQUIDS DELETERIOUS TO COPPER TUBING INCLUDING IMPROPERLY APPLIED OR MAINTAINED HEAT TRANSFER FLUIDS TO PROPYLENE GLYCOL PH LEVELS ABOVE 10 OR BELOW 8 TO PERIODS OF STAGNATION IN EXCESS OF 60 DAYS TO EXCESSIVE PRESSURE TO CLOUDING OR SIMILAR OCCURRENCE RESULTING FROM THE NORMAL INTRUSION OF MOISTURE INTO TO CONDITIONS RESULTING FROM FLOODS EARTHQUAKES WINDS FIRE LIGHTNING OR CIRCUMSTANCES BEYOND THE MANUFACTURER S CONTROL TO INSTALLATION METHODS WHICH DO NOT CONFORM TO RELEVANT NATIONAL STATE OR LOCAL CODES AND ORDINANCES GOOD INDUSTRY PRACTI
35. Eltron expansion tanks are fitted with Schrader valves to permit easy charging with pressurized air or nitrogen sensor well a cylindrical bore made in a component to allow insertion of a cylindrical temperature sensor that is to measure the component s temperature An external sensor well is integrated with pipe fittings to attach to the Stiebel Eltron SOL 25 PLUS solar collector shear force force acting perpendicular to a fastener or member which would shear it off if sufficiently high above the member s or fastener s shear strength smooth tube heat exchanger a type of immersed tube HX that does not employ fins to help conduct heat Stiebel Eltron s SBB storage tanks employ smooth tube heat exchangers solar loop the fluidic loop that closed loop solar systems employ to transport solar heated liquid from solar collectors to solar storage tanks and or other devices The loop may also be used to shed heat if temperatures in the system exceed safe limits SOLKIT Stiebel Eltron solar hot water system kit which includes one or more solar collectors a solar storage tank a pumping station a controller and related accessories SOM 6 SI differential temperature controller a solar system controller providing one control function e g one pump and 3 sensor inputs SOM 7 SI differential temperature controller a solar system controller providing two control functions e g two pumps or one pump and one valve and 4 sensor
36. G SUNSHINE System Pressure Regularly check the pressure gauge of the heat transfer circuit at the SE Flowstar pump station it should indicate 50 psi when the system is cold below 86 F A 2 tank system should include bypass valves to bypass the solar storage tanks All valves should be labeled with operating position indicated After heating Backup The backup heater should be of adequate capacity to provide suf ficient hot water The backup water heater must be certified listed and labeled by an accredited safety certification organization Expansion Tank The standard 1 5 gallon expansion tank for the solar loop is sized for up to 10 gallons of total system fluid volume and up to 60 feet in overall system height 3 3 Technical Data amp Specifications Model SOL 25 Plus Part no 185541 English Units Unit Dim SI Units Unit Dim Height 87 15 16 inches 2233 mm Width 48 1 8 inches 1223 mm Depth 3 1 16 inches 78 mm Grid dimension incl fitting 48 1 8 x 91 46 inches 1223 x 2327 mm Weight empty 108 Ibs 49 kg Standing temperature at 1000 W m 410 F 210 C Operating pressure min 50 psi 3 5 bar Permissible operating overpressure 87 psi 6 0 bar Tested pressure absorber ex factory 160 psi 11 0 bar Test medium ex factory water Pressure test of complete solar system with Tyfocor LS 115 psi 7 8 bar Flow rate rated capacity 13 80 gal hr 50 300 ihr Pressure drop of collector 26 gal hr and 68 F fluid temp 0
37. HEIGHT MUST NOT EXCEED 60 FEET CHECK THE ROOF STRUCTURE TO ENSURE PROPER SUPPORT FOR COLLECTORS MOUNTING HARDWARE WIND LOADS ETC STATIC CALCULATION REQUIRED IF NECESSARY CONTACT THE BUILDER ALL ROOFING WORK MUST BE CARRIED OUT BY A PROFESSIONAL ROOFING CONTRACTOR WHEN WORKING ON ROOFS OBSERVE ALL RELEVANT SAFETY REGULATIONS IN PARTICULAR SAFETY REGULATIONS FOR WORK ON ROOFS AND SAFETY AND RECOVERY HARNESSES V OR LOCAL REGULATIONS INSTALLERS MUST COMPLY WITH ALL LOCAL STATE AND NATIONAL CODES ROPE MAY BE USED TO HOIST COLLECTORS BUT MUST NEVER BE ATTACHED TO THE COLLECTORS PIPES WHEN WORKING ON ROOFS ALL RELEVANT SAFETY REGULATIONS MUST BE OBSERVED Designers and installers should consider how rainwater snow and ice accumulation is affected by the installation of the collectors and mounting hardware Collectors affect the flow of rainwater around them so appropriate means for conducting the water away from the vicinity of the collectors must be provided Collectors and mounting hardware are also subject to accumulation of snow and ice in cold climates Installations must provide protection to people and structures below the solar collectors to avoid hazards due to falling snow and ice as it melts or is blown off by winds Installers must also consider the possibility of snow and ice falling onto collectors from any structures located above them and provide appropriate means of protecting them
38. IEBEL ELTRON USA COM SOL 25 PLUS 21 ENGLISH Step 13 Prepare to assemble one of the 90 joints Step 14 Align the holes of the two supports and insert one of the 3 8 16 x 3 bolts ve NN 1 Step 15 Install one of the 3 8 16 nuts 22 SOL 25 PLUS WWW STIEBEL ELTRON USA COM WWW STIEBEL ELTRON USA COM Step 16 Install the base support to the to the bottom of the assembled rectangle by repeating the two previous steps Remember that the bottom is the end in which the diagonal support is attached to the profile rail using the hole furthest from the end vertical kit only Step 17 Repeat this process for the top of the rectangle SOL 25 PLUS 23 ENGLISH Step 18 Resulting assembly M as 1 BUS Iu E ZELLE Lid Zeg e pt fe Step 19 Repeat these processes for the other half of the rectangle 24 SOL 25 PLUS WWW STIEBEL ELTRON USA COM WWW STIEBEL ELTRON USA COM C A Step 20 Rotate the assembly so that it is resting on the base Step 21 Align the cross braces and fasteners as shown and loosely attach the 2 cross braces SOL 25 PLUS 25 ENGLISH Step 22 Loosely attach one of the corners of the X to one of the upper slots of the kit s vertical support using a Ya nut bolt and washer The preferable slot to use is dependent upon the distance between the two triangles which in turn is dependent upon the specificities of each install
39. OPERATING AND INSTALLATION INSTRUCTIONS FLAT PLATE SOLAR COLLECTOR SOL 25 PLUS STIEBEL ELTRON ENGLISH SECTION 1 Contents 2 Safety Instructions 3 Assembly Instructions for the Professional 3 1 Equipment Description 3 2 Important Information 3 3 Technical Data amp Specifications Installation Instructions 4 1 Accessories 4 2 Planning and Installation 5 Mounting Systems 5 1 Installation of 45 Mounts on Roofs Walls or Ground 5 1 1 45 Mounting on a Flat Roof 5 1 2 45 Mounting on a Wall 5 1 3 45 Mounting on the Ground 5 1 4 145 Mounting on a Pitched Roof 5 1 5 Detailed Assembly Instructions for 45 Mounting kit 5 2 Installation of 30 60 Mounts on Roofs Walls or Ground __ 5 2 1 30 60 Mounting on a Flat Roof 5 2 2 30 60 Mounting on a Wall 5 2 3 30 60 Mounting on the Ground 5 2 amp 30 60 Mounting on a Pitched Roof 5 2 5 Detailed Assembly Instructions for 60 Mounting kit 5 3 Flush Mounting on a Pitched Roof 5 3 1 Detailed Assembly Instructions for Flush Mounting kit 5 4 15 30 Tilt Mounting on a Pitched Roof 5 4 1 Detailed Assembly Instructions for Tilt Mounting kit 6 Lightning Protection and Bonding 7 Setting Up and Interconnecting the Collectors 8 Commissioning the System 8 1 Pressure and Leak Test 8 2 Setting the Expansion Tank Pre charge Pressure 8 3 Flushing the System 8 4 Final Charging and Venting The System 8 5 Start up 8 6 Checklist for start up of Solar Ins
40. SAFETY ALERT SYMBOL IT IS USED TO ALERT YOU TO POTENTIAL PERSONAL INJURY HAZARD OBEYALLSAFETY MESSAGES THAT FOLLOW THIS SYMBOL TO AVOID POSSIBLE INJURY OR DEATH COLLECTOR WARNING A SOLAR COLLECTOR GENERATES HEAT FROM SUNLIGHT AND ALL OTHER TYPES OF LIGHT THIS LEADS TO COLLECTOR CONNECTORS GETTING VERY HOT EVEN WHEN THEY ARE NOT FILLED WHICH CREATES A RISK OF BURN INJURY COVER THE COLLECTORS WITH OPAQUE MATERIAL UNTIL THE INSTALLATION HAS BEEN COMPLETED IT IS RECOMMENDED THAT YOU LEAVE THE COLLECTOR INSIDE ITS PACKAGING UNTIL IT IS INSTALLED SAFETY VALVE WARNING NEVER INSTALL ANY VALVES OR SHUT OFF DEVICES IN THE PIPING BETWEEN THE COLLECTORS AND THE SAFETY VALVE THE SAFETY VALVE IS ACTUATED AT 87 PSI PRESSURE NEVER SET THE SOLAR LOOP PRESSURE GREATER THAN POTABLE DOMESTIC WATER SUPPLY PRESSURE IF THE POTABLE WATER PRESSURE IS TOO LOW A BOOSTER PUMP MAY BE NEEDED TO ASSURE THAT IT EXCEEDS THE REQUIRED SOLAR LOOP PRESSURE The solar system must not bypass auxiliary system safety devices Check Valve The Flowstar pump station is equipped with two check valves to prevent heat loss from thermo siphoning between the storage tanks and the solar loop and collectors Drain Facility Install a drain valve at the lowest point of the system Expansion Tanks The diaphragm type expansion tanks are designed for an operating pressure of 87 psi and are resistant to deterioration from propylene glycol mixtures The air side inlet
41. SE Flowstar Pump Station kit including circulator expansion tank pressure relief valve 2 boiler 221339 drains temperature pressure gauge flowmeter check valve return line thermometer air vent SOM 6 SI differential temperature controller for one control function and 3 sensor inputs 2 222140 FKP6 temperature sensors included SOM 7 SI differential temperature controller for two control functions and 4 sensor inputs V bus 222141 4 FKP6 temperature sensors included SOM 8 SI temperature differential controller for nine control functions and 15 sensor inputs 227535 V bus 6 FKP6 temperature sensors included Collector sensor well use one per control unit 185307 Pt1000 1K RTD type temperature sensor for SOM controllers 165818 Purgomat air vent 510043 Flexible stainless steel tube for 501 25 PLUS panels 170804 Dowfrost 50 ready mixed propylene glycol heat transfer medium 5 0 U S gallons 19 liters 074200 contains 50 propylene glycol jug Expansion tank diaphragm type 2 0 gal ST116 SB 150 S 150 liter 40 gal solar storage tank single HX 221220 SB 200 S 200 liter 52 gal solar storage tank single HX 221221 SBB 300 S 300 liter 82 gal solar storage tank single HX includes STAK 003 connection kit 221219 SBB 400 S 400 liter 110 gal solar storage tank single HX includes STAK 003 connection kit 221222 SBB 300 Plus 300 liter 82 gal solar storage tank double HX includes STAK 002 connection kit 187873 SBB
42. TRON USA COM Step 29 Front view Step 30 Install one ofthe cross braces using two 1 4 nuts bolts and washers SOL 25 PLUS 57 ENGLISH Step 31 Loosely attach the two cross braces together using 1 4 fasteners The small part of the L shapes should be facing away from each other Step 32 Align and attach the two ends of this cross brace to the risers 58 SOL 25 PLUS WWW STIEBEL ELTRON USA COM WWW STIEBEL ELTRON USA COM Step 33 Stiebel Eltron tilt mounting system SOL 25 PLUS 59 ENGLISH WARNING HAVE LIGHTNING PROTECTION MEASURES CARRIED OUT BY PROFESSIONALS If there is an existing lightning protection system the collector casing their mounting frames and the piping must be tied into the lightning protection measures by professionals Collector Casing Pan Drill into each collector from the bottom and use screw type devices to tie it into the lightning protection measures Use two 1 4 6 3 mm diameter stainless steel sheet metal screws for each collector The drill holes should be predrilled to a diameter of 3 16 5 mm See Figure 29 for locations of holes On each collector drill two 3 16 diameter holes in the hatched area and make the connection to the lightning protection equipment with two 1 4 diameter stainless steel sheet metal screws Figure 29 Attachment of bonding wire for lightning protection 60 Piping Make the piping connection by means of pipe clam
43. a successful installation Recommended test pressure is 80 psi The thermal insulation should be installed only after the leak test has been successfully completed It is recommended that compressed air be used to test the system for leaks as it is very easy to make repairs and it will prevent loss of solar medium spills property damage and messy clean up problems Air is also capable of revealing very small leaks that water may not reveal through which propylene glycol will often leak Leaks will be evident from the sound of escaping air observation of bubbles emanating from fittings and other leak prone components that are coated with soapy water and watching the pressure gauge over time Bear in mind that the pressure gauge will vary based on temperature of the air so one must try to read the pressure on successive nights when the system cools down to ambient temperature The following procedure is recommended 1 Isolate the Purg O Mat and expansion tank by shutting their isolation valves 2 Turn check valves in the pumping station to their 45 position to allow two way flow 3 Close the bottom fill amp drain valve 4 Connect hose with a Schrader valve to the upper fill amp drain valve 5 Connect an air compressor and raise the solar loop system pressure to 80 psi 6 The first phase of the leak test which detects gross leaks or inadvertently open valves involves listening for leaks or observing if pressure does not i
44. adjustable riser strut set S103U S103L 4 102 L brackets 1 5109 cross brace 1 101 collector rail vertical 5 sets M10 30 nuts and bolts 5 sets 1 4 20 x 3 4 bolts nuts and washers 1 adjustable riser strut set S103HU S103HL 4 102 L brackets 1 S109 cross brace 1 S201 collector rail horizontal 5 sets M10 30 nuts and bolts 5 sets 1 4 20 x 3 4 bolts nuts and washers 1 SE45 110R support riser 1 SE45 110B support base 1 SE45 111 collector rail vertical 1 5109 cross brace 2 sets M10 20 nuts and bolts 3 sets 1 4 20 x 3 4 bolts nuts and washers 3 sets 3 8 16 x 3 flange bolts and nuts 1 S4528R support riser 1 S4518B support base 1 S107H collector rail horizontal 1 5109 cross brace 2 sets M10 20 nuts and bolts 3 sets 1 4 20 x 3 4 bolts nuts and washers 3 sets 1 4 20 x 2 1 2 bolts nuts and washers 1 SE60 110 support riser 1 SE60 108 support base 1 5101 collector rail vertical 1 5109 cross brace 2 sets M10 20 nuts and bolts 3 sets 1 4 20 x 3 4 bolts nuts and washers 3 sets 3 8 16 x 3 flange bolts and nuts 1 clamp 2 3 8 bullet nosed setscrews 1 M10 bolt with washer Part No 185545 185546 SFC001 SFM001 SFM001H SFTOO4 SFTOOAH 185543 074324 SE60 550 Table 4 1 2 shows the mounting accessories available for several common arrangements of SOL 25 PLUS collectors Item Parts No
45. al electrolytic anode An anode rod must be replaced when it is depleted otherwise the tank and or its internal components will start to corrode boiler drains drain cocks installed in solar and hydronic heating systems to allow portions or all of the system to be drained of their working fluids heat transfer media curves Note The variable speed pump does not stop immediately but only after it reaches its lowest speed BSPP British Standard Pipe Parallel Thread for tubes and fittings where the threads do not provide pressure tight sealing bypass valves valves that are installed in solar heating and afterheating systems to allow portions of the system to be bypassed for maintenance and repair Bypass valves are typically installed in 2 tank systems to allow flow to bypass the solar storage tanks charging of system the process of filling the solar loop with heat transfer medium fluid charging pump a pump used to fill charge or recharge the solar loop with heat transfer medium check valve a special type of valve that permits fluid to flow in one direction but not the other It is typically used in solar heating systems to prevent undesired thermosiphoning of heat transfer medium when the collector pump is switched off compensator a flexible stainless steel tube that is installed between solar collectors and used to connect them to solar loop piping The compensator allows piping to expand and contract and mo
46. and mounting hardware Collectors affect the flow of rainwater around them so appropriate means for conducting the water away from the vicinity of the collectors must be provided Collectors and mounting hardware are also subject to accumulation of snow and ice in cold climates Installations must provide protection to people and structures below the solar collectors to avoid hazards due to falling snow and ice as it melts or is blown off by winds Installers must also consider the possibility of snow and ice falling onto collectors from any structures located above them and provide appropriate means of protecting them Building materials adjacent to solar components must not be exposed to the elevated temperatures that the collectors can generate Exposed components that can readily be reached must be maintained below 140 F or otherwise be insulated isolated All other exposed surfaces that can exceed 140 F should be labeled with appropriate burn hazard warnings Tools Needed 1 Power drill with 1 4 drill bit Bits of other sizes are recommended as well 11 16 drill bit for corrugated sheet roof installations Two 17mm wrenches and or sockets for M10 bolts Two 15mm wrenches and or sockets for M10 nuts Two 7 16 wrenches sockets for 7 16 and 1 4 nuts bolts Two 9 16 wrenches sockets for 3 8 nuts bolts One 2 adjustable wrench for collector fittings dE Stiebel Eltron provides a 30 60 fixed
47. and the pump must remain powered and activated in order to avoid overheating the collectors Prior to shutting down the system for repairs cover the solar collectors or work at night If EMERGENCY SHUT DOWN is needed the system should be placed in manual operating mode set HND OFF see SOM controller manual then call for service There are three isolation valves on the Flowstar pump unit see Flowstar manual 3 1 Equipment Description The SOL 25 Plus flat plate collector converts sunlight radiation into heat Light penetrates the glass cover which Is pre stressed highly transparent single pane safety glass As the light strikes the absorber plate it is converted into heat The highly selective vacuum coating of the absorber and the thermal insulation on the back of the absorber reduce heat losses to the environment to a minimum The thermal energy produced by the collector is transported by the heat transfer medium solar loop fluid via a circulating pump to the storage tank s The inside of the collector can mist up under certain operating conditions e g large tank with low temperature compared to the outdoor temperature and or high relative humidity Vent holes are provided in the collectors for venting humidity and equalizing air pressure 3 2 Important Information WARNING RISK OF SCALDING TO PREVENT THE SOLAR FLUID FROM BOILING IN THE COLLECTORS THE SYSTEM SHOULD NOT BE FLUSHED OR FILLED DURING PERIODS OF STRON
48. aphragm for leaks Check the vessel size and precharge pressure Check the antifreeze level and the pH value Vent the pump Increase the system pressure Increase the system pressure Change to a lower pump rate and check the flow rate at the flow meter with balancing valve Fault The tank cools down excessively overnight After the pump has stopped the flow and return operate at different temperatures the collector temperature is higher at night than the outside temperature Re heating does not work The boiler runs for a short while stops and restarts again This repeats frequently until the tank has reached its setpoint temperature The tank cools down excessively The pump does not stop Cause The check valve is not closed or not closing thereby causing thermosiphoning and heat loss from the tank to the solar loop Single pipe thermosiphoning circulation occurs in short pipework with low pressure drop Air in the re heat heat exchanger Heat exchanger area is too small Insulation faulty or incorrectly fitted Re heating controller setting is incorrect DHW circulation runs too frequently and or at night Sensor faulty or sensor position incorrect Remedy Check the position of the check valve handle which should be set for one way flow Inspect the check valve gravity brake for leaks jammed swarf dirt particle in the sealing surface Make sure the tank s heat exchange
49. arge The solar irradiation is insufficient to heat up the entire pipework The flow rate is excessive pump set too high The switching temperature differential of the controller is set too low Pipework not fully insulated The tank and collector sensor wiring Is reversed problem occurs after commissioning A drop in pressure seen shortly after the system is filled is normal as air is still being vented from the system A subsequent pressure drop can be caused by an air pocket that has shifted later on In standard operation the pressure can fluctuate by 3 to 4 psi subject to system temperature If the pressure falls continuously a leak exists at some point in the system Fluid loss occurs via operation of the safety valve The expansion vessel is too small and or without pressure or is faulty Collectors have been damaged by icing frost as a result of insufficient frost protection and have developed leaks Air in the pump Insufficient system pressure causes voids and cavitation This is normal in the first few days after filling the system If this occurs later two possible causes System pressure too low The pump draws in air via the air vent valve The pump rate is set too high Remedy Check the system pressure Operate the pump in intervals at maximum pump rate Open the air vent valves at the collector at the pump and at the solar tank and vent these items Should this fail to provide any impro
50. ation If the collectors are being mounted on a wall it is usually preferable to install the cross braces between the two base supports Step 23 Loosely attach the X to the same slot on the other vertical support base support If performing a wall mount 26 SOL 25 PLUS WWW STIEBEL ELTRON USA COM WWW STIEBEL ELTRON USA COM Step 24 Attach the bottom of the X to the requisite lower slots and tighten all nuts and bolts The unit is now assembled and ready for mounting SOL 25 PLUS 27 ENGLISH 5 2 Installation of 30 60 Mounts on Roofs Walls or Ground N IMPORTANT INSTALLED HEIGHT MUST NOT EXCEED 60 FEET CHECK THE ROOF STRUCTURE TO ENSURE PROPER SUPPORT FOR COLLECTORS MOUNTING HARDWARE WIND LOADS ETC STATIC CALCULATION REQUIRED IF NECESSARY CONTACT THE BUILDER ALL ROOFING WORK MUST BE CARRIED OUT BY A PROFESSIONAL ROOFING CONTRACTOR WHEN WORKING ON ROOFS OBSERVE ALL RELEVANT SAFETY REGULATIONS IN PARTICULAR SAFETY REGULATIONS FOR WORK ON ROOFS AND SAFETY AND RECOVERY HARNESSES V OR LOCAL REGULATIONS INSTALLERS MUST COMPLY WITH ALL LOCAL STATE AND NATIONAL CODES ROPE MAY BE USED TO HOIST COLLECTORS BUT MUST NEVER BE ATTACHED TO THE COLLECTORS PIPES WHEN WORKING ON ROOFS ALL RELEVANT SAFETY REGULATIONS MUST BE OBSERVED Designers and installers should consider how rainwater snow and ice accumulation Is affected by the installation of the collectors
51. d must take into consideration the details of the roof wall or ground upon which the collectors are to be placed the latitude and orientation of the site the space available for the collectors possible shading from nearby structures or vegetation etc The intended use of the system should also be an important consideration For example if the house is a summer residence that requires only domestic hot water during summer months and it is located near 45 north latitude the best performance can be gained by mounting the collectors tilted between 10 and 30 from horizontal as the best solar gain will be obtained for summertime use In contrast if most of the water heating and some space heating is required during winter months the best angle for collectors would be approximately 60 from horizontal thus maximizing wintertime solar gain Stiebel Eltron furnishes mounting kits for each of the above arrangements and for each SOLKIT system Table 5 1 below gives details of the kits and their components Table 5 1 Mounting Hardware Kits For SOLKIT Systems No of Panels in Array Vertical Horizontal FLush Mount 15 50 Tilt Mount 45 Mount 30 60 Mount Vertical 1 185545 1 185545 1 185545 1 185545 1 SFM001 2 SFTOO4 2 185543 2 SE60 Horizontal 1 185546 1 185546 1 185546 N A 1 SFM001H 2 SFTOO4H 2 074324 Vertical 1 185546 1 185546 1 185546 1 185546 1 SFM001 2 SFTOO4 2 185543 2 SE60 Horizontal 2 18554
52. d with every SFC001 frame splice kit if connectors are to be connected in a row The compensator allows thermal expansion of the collectors support frames and piping to occur without over stressing the fittings and seals The collector pipe nipples may also be connected to field supplied piping with either 7 8 UFT 3 4 G European or 3 4 BSPP thread See Figure 31 Installation of the compensator tube is followed by placement of thermal insulation supplied by the customer Air Vent S S Tube with 3 4 G Union Seals Collector Nipple e 3 4 BSPP male thread A Mating threads include 3 4 G European e 3 4 BSPP e 7 8 UFT Figure 31 Interconnection of collectors using flexible compensator tube p n 170804 Install the collector immersion sleeve sensor well at the outlet of the collector array as shown in Figure 2 Itis imperative that the sensor be placed at the collector array outlet not inlet so that the collector temperature can be properly detected by the controller The system will not work properly without the correct location of the sensor IMPORTANT THE SENSOR MUST BE PLACED AT THE COLLECTOR ARRAY OUTLET NOT INLET SO THAT THE COLLECTOR TEMPERATURE CAN BE PROPERLY DETECTED BY THE CONTROLLER Coat the collector sensor with thermally conductive paste and push it into the immersion sleeve as far as it will go Do
53. e SFM001 kit and Figure 25 shows profile rails to the support rails S101 with the included fasteners the SFM001H kit Stiebel Eltron flush mount kits are generally not then bolt the assembly to the L brackets recommended for mounting upon flat roofs walls or the ground Instead the 45 or 30 60 mounting systems are more appropriate for mounting to structures other than pitched roofs Mounting L bracket S102 Mounting L bracket S102 M10 nuts M10 nuts M10 bolts M10 bolts Support Rail S101 Support Rail S201 Figure 25 Horizontal Flush Mount Kit p n SFM001H gt Figure 24 Vertical Flush Mount Kit p n SFM001 5 3 1 Detailed Assembly Instructions for Flush Mounting Kit Step 01 Major components for assembly of the Stiebel Eltron flush mounting kit single panel vertical version displayed 40 SOL 25 PLUS WWW STIEBEL ELTRON USA COM WWW STIEBEL ELTRON USA COM Step 02 Place the profile rail upside down as shown The longer cutout surface approx 1 should be facing toward the center ofthe rectangle and be parallel to the ground This is the surface on which the back of the collector will rest Step 03 Slide one ofthe M10 bolts into the slot ofthe profile rail as shown Step 04 Prepare to assemble the top left corner of the rectangle The end of the support rail with the hole closer to the edge is the top side of the rail Note 1 If assembling
54. e both end spans with crossbraces as shown in Figure 18 For six or more trusses cross braces should also be placed in an inside span Support Diagonal Figure 17 Assembled triangle trusses with cross braces 8 If multiple flat roof mounting frames are being set up next to one another use frame connector splice kits SFC001 shown in Figure 19 to join them as shown in Figures 18 and 20 Line up the mounting supports with a string so that the mounting frames will be aligned properly 9 Fasten the flat roof mounting racks to the roof in an appropriate manner or weight them down with at least 400 Ibs 180 kg of solid dead weight e g concrete slab per collector if the installed height is less than 25 ft 8 m Remember to take the static and dynamic e g wind loading into account for the roof structure 10 For installed heights above 25 ft 8 m weighting is not advisable due to the higher wind loading conditions In this case the holes in the horizontal support base SE60 108 or SE60 110 if flipped for 30 degree tilt should be used to fasten the mounting hardware to the roof six M6 bolts per horizontal support 29 ENGLISH R2 Profile Rail R1 Profile Rail Frame 1 collector width 2 collect idth R2 Profile Rail 2 collector wi M Splice x 2 collector width BE L 71 L NN 24 in 24
55. e profile rails but should be assembled such that the supports are approximately 2 from each side of the profile rail and are therefore approximately 4 feet from each other Step 08 Displayed is the completed rectangle top view WWW STIEBEL ELTRON USA COM E be LE WWW STIEBEL ELTRON USA COM Step 09 Align an S103U and an 51031 Displayed is the proper alignment rear view Step 10 Proper alignment side view Step 11 Prepare to assemble 51030 and S103L with displayed fasteners Step 12 Slide the 2 components together as shown Step 13 Slide 2 of the 1 4 bolts though the slots of one component and the holes of the other Step 14 Install two 1 4 nuts and washers Repeat this procedure for the remaining two riser struts SOL 25 PLUS 51 ENGLISH Step 15 Align the two riser assemblies with the top side of the assembled support rectangle as shown Note that the slotted sides of the risers are adjacent to the sides of the rectangle the sides with the circular holes are flat on the ground and the bottom of the L of the risers are both facing away from the rectangle Step 16 Install an M10 x 30 bolt through the holes one of the L brackets and one of the riser assemblies Step 17 Install an M10 serrated flange nut Repeat this procedure for the other side 92 SOL 25 PLUS WWW STIEBEL ELTRON USA COM Step 18 Assembly thus far including L
56. ed is the same as the number of collectors See Figure 6 For 45 horizontal mounting on a flat roof or a wall the number of BF W 074324 flat roof wall mounting hardware sets needed is twice the number of collectors See Figure 7 13 ENGLISH NOTICE TO PREVENT EXCESSIVE PRESSURE DROP IN THE SOLAR LOOP NEVER LINK UP MORE THAN 5 COLLECTORS IN SERIES ARRANGE THE INDIVIDUAL LINEAR ARRAYS PARALLEL TO EACH OTHER Building penetrations for plumbing and mounting must not impair enclosure integrity or functionality and must not allow rodent or vermin intrusion They must meet applicable codes and National Roofing Contractors Assoc practices Structural members penetrated by solar system components must not be compromised and penetrations must meet code particularly penetrations through fire rated construction Do not reduce fire resistance below code Protect control sensor wiring Anchor brackets panel clips M10 nuts M10 bolts M6 nuts KH K y Flexible Stainless Steel Pipe Seals Figure 5 R2 Mounting Frame for Single Horizontal or Two Vertical Collector Arrangement 1 4 washers 1 4 20 nuts M10 nuts 1 4 20x3 4 3 8 16 x 3 bolts SCH M10 bolts K pons b e 3 8 16 flange nuts Ne Support Riser SE45 110R un Support Base SE45 110B Support Diagonal SE45 111 __ Brace S109 Figure 6 45 degree Vertical Mounting Kit p n 185543 14 1 4 washers 1 4 20 nuts 1
57. ed with air or nitrogen that provides a cushion against which the system liquid may expand this chamber Is typically isolated fluidically by a rubber membrane diaphragm that is chemically compatible with the system liquid and capable of withstanding the temperatures of that liquid flowmeter a device used to measure or display fluid flow rates in a fluidic system They may be electronic or mechanical Mechanical flowmeters often use an annular orifice venturi float system for measuring flow rates Flowstar brand of pump station used in Stiebel Eltron SOLKIT solar systems The contain a circulator pump expansion tank pressure relief valve 2 boiler drains temperature pressure gauge flowmeter check valve return line thermometer and air vent frame connector splice a set of hardware that allows the collector profile frame rails to be connected end to end to form a row array of solar collectors GPH gallons per hour GPM gallons per minute GRAS Generally recognized as safe GRAS is an American Food and Drug Administration FDA designation that a chemical or substance added to food is considered safe by experts and so is exempted from the usual Federal Food Drug and Cosmetic Act FFDCA food additive tolerance requirements For solar thermal systems the GRAS non toxic food grade designation is often required of the propylene glycol heat transfer medium if there is a possibility of the medium s being introduced in
58. ells walls Secure the sensor and its lead e g cable tie Installation Example A general system schematic diagram of components and pipe arrangements for a typical Stiebel Eltron SOLKIT domestic hot water DHW heating system with both solar heating and alternative afterheating or reheating with a boiler is shown in Figure 3 10 HST ISNA enuew uonejjejsui suone ijddy 10 syUe a pioie ggs 0 13484 aseajd yuez a piois pue uoneijs duind y UO uoneuuojul 104 STccc OU Hed asaydsouje oj uado uaym sod c jas painseaw ainssaid peSJeu aJd UOIP3UUOI jue en mu T Ge P E jdans Sumy O SS SS SS m Jayem volun N p uuos q H 3 1113 qi 121a Mou A LA H cs c sajddiu SE isd uonejos E J3U1e U0 ds c m paads E V M0 JJ8 0 d d Cen 1 98e10 S i D Tod uo suedx3 L d AJLeA V NEA 4 SEN lt o asne S ee DC us LL e 6EETCC OU Hed lt NY ped 10 29 0 05 E 4 ww 2 doo jeaysayy v I A ag Y Mi SQ and wa sAs LN 8 9A EA 8 HP IK a 55 ga se I w Ta s uoz duNNeay SS r 9 AW juaA 0jne
59. em as shown in Figures 9 and 11 Line up the mounting supports with a string so that the mounting frames will be aligned properly 9 Fasten the flat roof mounting racks to the roof in an appropriate manner or weight them down with at least 400 Ibs 180 kg of solid dead weight e g concrete slab per collector if the installed height is less than 25 ft 8 m Remember to take the static and dynamic e g wind loading into account for the roof structure 10 For installed heights above 25 ft 8 m weighting is not advisable due to the higher wind loading conditions In this case the holes in the horizontal support base SE45 110B should be used to fasten the mounting hardware to the roof six M6 bolts per horizontal support Multiple Rows of Collectors If multiple arrays of collectors are being installed on a flat roof one behind another the recommended spacing between them should be at least 25 ft 7 6 m for vertical installation as shown in Figure 12 or atleast 14 ft 4 0 m for horizontal installation as shown in Figure 13 This spacing prevents excessive shading from adjacent rows for latitudes of up to 50 For latitudes significantly higher than 50 multiple rows of collectors may not be practical due to low sun altitude angles R2 Profile Rail R1 Profile Rail Frame 1 collector width 2 collect idth R2 Profile Rail 2 collector wi Ba Splice a 2 collector width 1
60. emperature sensor Make sure sensor has been mounted to the outlet pipe of the collector s Reduce the temperature differential Briefly switch over to max speed or insert a screwdriver into the slot and turn manually Dismantle and clean the pump Close the throughput limiter and pump ball valve Make sure sensor has been mounted on the hot outlet not inlet pipe of the collector Check the sensor position installation and resistance curves the collector sensor must be securely and fully inserted into the sensor well 65 ENGLISH Fault The pump is running but no flow rate is discernible at the flow meter with balancing valve The flow and return temperatures are identical or the tank temperature does not rise or rises only slowly The pump is running but no flow rate is discernible at the flow meter with balancing valve Pump appears to start late and stop early The pump starts and switches itself off again shortly afterwards short cycling This is repeated a few times until the system runs correctly The same happens in the evening The pressure gauge indicates a loss of pressure The pump runs noisily System is noisy 66 Cause There is air in the pipework System pressure too low System contaminated Flow meter with balancing valve stuck or faulty Clog in system Shut off valve closed The temperature differential between the collector and the tank is too l
61. eral Wool side insulation and Mineral Wool back insulation C SEES 2 RE AR bd ew d Re Water was the fluid for performance tests Gross Area 2 73 m 2443 ft Aperture Arca 2 60 m 27 94 al Lat his Ks E DE lA KW 3 V Een PET m 13 dk ie L iE is ae F TSS Me f Ce om eS AT TERT ETI SE po a r Dom 3 13 BE PEE Ce a 08 im e RET a us T A Ponl Heating Wann Clinme B Pool Heating Cool Climate C Winer Heating Warn Clima D Water Heating Cool Rep iw Climate E Air Camdllibianm ssl n d A sie Se Efficiency Equation NOTE P TI Ta Interet Sin Ge Be E pe TE PA 0660 429 Wi n ms wy Unis ne 649 05529 IM LOOM PY 0660 0755 d i TT d E Incident Angie Modifier NOTE 5 1 cos 8 1 K 10 02324 5 Doll sy 10 5027 S Fit zi p zr This award of certificate rm oo oll fees amd Dit of Ge Programs amp de drun ane pa DEN therein b reference Jr be renzwed anally Am change im collector design materials specilscutices parts or constuction must be r eporied tr SEC far exaliumtinn of comtimied certifican Dir Pe ee eee gt WESER TEST FESTES AS L i ZLIE E fy re HTC AC A E July 6 2006 E _ LAE EE ALE ENON SUE ULF NN AL LE
62. he diagonal support Note 2 If assembling a mounting system using the longer profile rails p n 185546 the diagonal supports should not be fas tened to the ends of the profile rails but should be assembled such that the supports are approximately 2 from each side of the profile rail and are therefore approximately 4 feet from each other 18 SOL 25 PLUS WWW STIEBEL ELTRON USA COM Step 06 Install M10 nut Repeat the last 4 steps for the top right corner Step 07 Prepare to assemble the bottom 2 corners Remember to double check that the longer cutout surface approx 1 is facing toward the center of the rectangle and is parallel to the ground Step 08 Prepare to assemble the bottom left corner WWW STIEBEL ELTRON USA COM SOL 25 PLUS 19 ENGLISH Step 09 Slide M10 bolt into slot of profile rail Step 10 Position the diagonal support such that the M10 bolt protrudes through the hole furthest from the end Step 11 Install M10 nut Repeat the last 4 steps for the bottom right corner 20 SOL 25 PLUS WWW STIEBEL ELTRON USA COM Step 12 Resulting assembly Step 13 When performing assembly steps involving the base support make sure to use the same end of said supports for analogous parts of each half of the assembly as they appear to be symmetrical but are not To check line them up as shown This is the correct orientation NOTE This is the incorrect orientation WWW ST
63. he height above surrounding grade usually in reference to the height of the solar collectors isolation valve a valve used to cut off and isolate a device e g a vent valve or an expansion tank from the rest of a fluidic system lightning protection equipment and measures used to ensure that particular equipment and attached structures are protected from lightning strikes and induced charges these often include special grounding cables and clamps to safely conduct current to earth ground MSDS material safety data sheet a data sheet that usually accompanies many chemicals and other materials to allow users to take appropriate measures to ensure their safe use mounting frame an assembly of hardware that forms a frame in which solar collectors are held in place on a roof or other structure pipe run the piping in a solar loop circuit that connects the collector s pump station and heat exchanger s in storage tank s polyisocyanurate foam typically used as rigid thermal insulation Its thermal conductivity has a typical value of 0 16 BTU in hr ft2 F 0 023 W mK It has superior resistance to breakdown at high temperatures which is necessary for solar loops pre charge pressure of expansion tank the pressure of the gas typically air or nitrogen cushion on the dry side of an expansion tank s diaphragm It helps to regulate the system pressure and must be set according to the instructions pressure drop
64. her as illustrated in Figure 28 For angles between 15 and 30 the struts may be bolted together through the intermediate holes 7 The upwards facing short side of the pivot bracket attached to the upper roof hook U profile is now bolted to the bottom of the riser strut Pivot Bracket Figure 28 Tilt Strut Assembly 4 ENGLISH 8 As illustrated another pivot bracket is connected to the top of the standoff strip 9 When installing two or more collectors brace the center span When setting up four or more collectors brace both end spans With six or more collectors braces S109 should also be placed in an inside span 10 The frame created from the support rails S101 and collector profile rails is now bolted to the pivot brackets 34 The bolt located in the channel of the profile rails is bolted into the middle hole of the pivot bracket Before bolting together the support rails and profile rails two bolts must be inserted into the channel of each profile rail 11 If more than one rooftop frame is used mount the frames to one another using frame connector splice kits SFC001 shown in Figure 19 to join them as shown in Figures 18 and 20 Line up the mounting supports with a string so that the mounting frames will be aligned properly 12 Then tighten all bolts and screws 5 4 1 Detailed Assembly Instructions for Tilt Mounting Kit 48 SOL 25 PLUS Step 01 Major components of the Stiebel Eltro
65. ibed above for mounting of collectors upon a flat roof apply to ground mounting except for the following 1 Installer must ensure that the mounting foundation for the system is not subject to movement such as frost heaves Therefore it is necessary to install footings below the frost line in locations subject to freezing weather If it is not possible or practicable to avoid movement due to frost etc it will be necessary to provide a floating frame that does not flex or warp the collectors mounting frames ifthe ground shifts or heaves 2 Ground mounting configurations may be prone to damage from falling ice or nearby vehicles or other hazards Appropriate precautions should be taken to mitigate these hazards 3 Ground mounting often requires longer outside piping runs so proper insulation and protection of collector piping essential Installers should consider laying pipe runs below grade to avoid damage and to mark the location of these runs to avoid damage from digging operations 5 1 4 45 Mounting On A Pitched Roof Procedures described above for mounting of collectors upon a flat roof apply to mounting on a pitched sloped roof except for the following 1 Use of weights to secure collectors and mounting hardware is not advisable Collector mounting frames should be fastened to all pitched roofs in an appropriate manner 2 The 45 mounting kits add 45 to an existing roof pitch as shown in the table bel
66. ing purging of air of the system 1 Energize the pump station to activate the electric pump to circulate the solar medium through the system 2 Open the air vent valves and Purg O Mat at the highest point of the system and open the ball valve for the flow meter 3 To purge air from the system the size of the air bubbles can be reduced as the system loop pressure increases by slowly constricting the return flow to the drain bucket via partially closing the lower drain amp fill valve while the pump is operating Also open the bleed screw on the circulator pump 4 Continue purging the system until no more bubbles are expelled from the drain hose Allow system pressure to build up to approx 20 44 psi This process usually takes 20 30 minutes Continue looking for leaks 5 Tighten the anti steaming valve fully and then back off 1 4 turn 6 Close the bottom fill amp drain valve after completing this ventilation step but before shutting off the pump 7 Keep the circulator pump running and then close the top fill amp drain valve 8 Open the air vent valve at the highest point until only solar medium is expelled 9 Shut off the circulating pump 10 Open the valve to the expansion tank to connect it to the solar loop The system pressure will drop slightly 11 Use the charging pump to raise the system pressure in a cold state to its operating pressure of 50 psi or other target pressure As there is sometimes sti
67. itting Company Name Name Street Street City City Solar Circuit Yes No Are the collectors installed in their mounting frames in the proper position and secured tightly free of play with the top and the bottom screws Has the installation of the pipework between the collectors and the pumping station been performed according to Stiebel Eltron installation instructions Has all the pipework in the solar collector loop been hard soldered Has all the pipework been insulated Is the pressure relief safety valve 87 psi and the vent installed according to Stiebel Eltron installation instructions Was the pressure and leak test performed Is the solar loop filled using only the premixed 50 GRAS Propylene Glycol and deionized water heat transfer medium Have labels been installed on all valves tank and pipework Are the shut off valves open and is the check valve set per pumping station assembly instructions Is the collector temperature sensor mounted at the specified position at the outlet pipe of the collector s and electrically connected to the controller Has the electrical wiring been performed in accordance with the Stiebel Eltron controller wiring diagram Is the solar controller set according to the assembly and operating instructions Has the test run of the circulation pump been performed Checked for excessive unusual noise Checked for proper heat collection and storage during insolation Hot Water Circuit Yes No
68. ll a little air remaining in the system which will eventually be purged via the Purg O Mat it is recommended that this pressure be a few psi higher than the target 12 Use a permanent marker to record the pressure and the date time on the expansion tank 13 It is further recommended that the installer measure and record the glycol water mixture using a refractometer or hydrometer It is critically important that the mixture be correct before turning the system over to the final customer 14 Set the red dial on the pressure gauge to the expansion tank s precharge pressure This should be the lowest pressure that the system ever reaches in normal operation 15 Let the solar heating system rest overnight and vent again in the morning via the air vent valve before solar radiation warms the collectors Close the air vent valve again 16 Turn check valves in the pumping station to their normal 90 position to allow one way flow 17 Make sure the controller and pumping station are energized and that the proper settings for the controller have been entered 18 Cover both fill amp drain valves with the caps supplied 19 If the system does not start automatically there may still be air in the system Repeat the venting process if required 8 5 Start up Re tighten all fittings prior to start up Complete the Start up report Section 8 6 after the first Start up Set the integral controller to manual mode to check whether
69. mmediately reach 80 psi Repair any such gross leaks 62 7 The second phase of the leak test detects smaller leaks and requires a wait time Pressurize the system to 80 psi and watch the pressure gauge over a period of 15 60 minutes to see if any pressure loss occurs 8 After any leaks have been repaired repeat this test If pressure appears steady line up the red dial of the pressure gauge with the needle indication Check again to see if the pressure holds relative to the lowest pressure previously indicated by the red dial Small leaks may be detected by covering suspected locations with soapy water and looking for bubbles 9 After all known leaks have been repaired the final phase of the leak test requires waiting a day or more to see if pressure is holding steady Use the red dial to mark the pressure and see that the gauge returns to the same indication each evening Remember that the air pressure will vary based on the temperature of the loop so it will be necessary to read the pressure at night after the system cools down At the conclusion of the leak test check all fittings and vent the system 8 2 Setting the Expansion Tank Pre charge Pressure While the leak testing described above is being performed the installer should set the expansion tank s precharge pressure Make sure that the wet side of the expansion tank pipe connection is vented to atmosphere Using a compressor pre charge the tank with air or
70. mounting kit p n SE60 for 28 vertical arrangement of collectors The truss that the kit forms can be flipped to provide either tilt angle 5 2 1 30 60 Mounting On A Flat Roof Two mounting frames are available for fixed 30 and 60 degree collector tilt e R1 for one collector installed vertically 185545 See Figure 14 R2 for two collectors installed vertically or one collector installed horizontally 185546 See Figure 15 S Anchor brackets panel clips _ M10 SCH M10 Ss M6 e Profile rails M Figure 14 R1 Mounting Frame for Vertical Collector Arrangement For 30 60 vertical mounting on a flat roof two sets of SE60 flat roof wall mounting hardware are needed for two collectors or more the number of sets required is the same as the number of collectors See Figure 16 NOTICE TO PREVENT EXCESSIVE PRESSURE DROP IN THE SOLAR LOOP NEVER LINK UP MORE THAN 5 COLLECTORS IN SERIES ARRANGE THE INDIVIDUAL LINEAR ARRAYS PARALLEL TO EACH OTHER Building penetrations for plumbing and mounting must not impair enclosure integrity or functionality and must not allow rodent or vermin intrusion They must meet applicable codes and National Roofing Contractors Assoc practices Structural members pen etrated by solar system components must not be compromised and penetrations must meet code particularly penetrations through fire rated construction Do not reduce fire resistance below code Protect control senso
71. n how the array is plumbed to the pump station After installing the sensor well on the collector coat the sensor probe with heat conducting paste and insert it into the sensor well until it bottoms out Secure the lead to the outside of the insulation to avoid melting under high temperature operation and under a protective cover Cover the collector sensor well and the roof outlet with thermal insulation which must be tightly sealed and must be temperature and UV resistant Also protect the thermal insulation against bird attack See Figure 2 for details ENGLISH Temperature sensor with heat conducting paste Thermal insulation Roof outlet duct corrugated hose Heat transfer medium flow direction Collector sensor well Fitting Figure 2 Collector Temperature Sensor Well Storage Tank In a standard residential solar heating system one to three collectors are connected in series to a solar storage tank of 80 163 gallons capacity Refer to the tank installation instructions for details Storage Tank Temperature Sensor The temperature sensor for the SBB tanks is inserted into the sensor well of the lower internal smooth tube heat exchanger only the SBB Plus tanks have an upper heat exchanger Coat the collector sensor with heat conducting paste and insert it into the sensor well until it bottoms out It is very important that the sensor make full contact without gaps or voids to the inside of the sensor w
72. n Tilt Mounting System single panel vertical version displayed Step 02 Align the mounting system components upside down as shown The longer cutout surface approx 1 should be facing toward the center of the rectangle and be parallel to the ground on both the top and bottom This is the surface on which the back of the collector will rest The end of the support rail with the hole closer to the edge is the top side of the rail WWW STIEBEL ELTRON USA COM WWW STIEBEL ELTRON USA COM Step 03 Prepare to assemble top left corner with illustrated components Step 04 Slide M10 x 30 bolt into the groove of the profile rail as shown Step 05 Slide the threads of the bolt through the hole of the L bracket Note that the hole which is closer to the edge is installed on the vertical side of said bracket SOL 25 PLUS 49 ENGLISH Step 06 Slide the threads of the bolt through the hole in the top side of the of the support rail Step 07 Install the M10 serrated flange nut Repeat this procedure for the remaining three corners of the rectangle making sure that the top sides of the profile rails are each attached to the same profile rail Note 1 If assembling a horizontal tilt mounting system there is only one hole on either end of the diagonal support Note 2 If assembling a mounting system using the longer profile rails p n 185546 the diagonal supports should not be fastened to the ends of th
73. nnually Refer to the table below for general fault identification troubleshooting Fault Fault error message at the controller Pressure fluctuations in the system immediately after commissioning Collectors mist up The pump does not run even though the collector is warmer than the tank neither motor noise nor vibrations are discernible Cause System fault sensor faulty or incorrectly connected Air pockets in the solar circuit Moisture ingress during storage Overnight condensation of humidity during certain weather conditions Maximum tank or collector temperature exceeded Indicator lamp or display at the controller activated No electrical power Excessive temperature differential gt 30 F selected or the controller does not work Pump shaft blocked Pump contaminated Sensor faulty or incorrectly installed Remedy See installation and operating instructions for the controller Vent the system again The internal mist will evaporate after a few weeks in operation by moisture progressively escaping through the integral ventilation slots Moisture will usually evaporate persistent misting may require the addition of weep holes in the bottoms of collector pans The controller has shut down correctly and restarts again automatically when the actual temperatures drop below their selected maximum temperatures Check cables and fuses Check the controller Check the t
74. olt to assure a tight fit The threads of the lag bolt should penetrate at least two inches 2 into the structural member itself below the roof sheathing It is therefore critical that the installer determine the length of bolt necessary to give the depth of penetration required Apply liberal amounts of silicone sealant to the bolt hole and underneath the mounting block to prevent leaks After tightening the bolt apply more sealant over the entire assembly roof cement mounting L bracket stainless steel lag bolt N amp washer mounting block WS neoprene washer silicone sealant mE sung NL EK sheathing AL 2 min rafter Figure A 2 Roof Attachment Using Lag Bolt Into Rafter There are other well engineered roof fastening systems available that the installer may wish to consider In all cases it is prudent to contact the local code enforcement office to determine the appropriate means of attachment to roofs or other structures NOTE Installers must ensure that no deterioration e g rot or water damage has occurred to the underlying members if the roof structure is compromised by deterioration or cracking it will be necessary to repair it before mounting the solar equipment 2 APPENDIX B CERTIFICATION S MAU ed Fk Pe AL SL te LT EE EE cee ADU UU DSSS is 1 rug gc OU E a Pa Pr a Ta a Ta Tr TUA TCU RR NE Bo bet m ZT T V TA 1 X d
75. oofs Mounting L bracket S102 M10 nuts M10x30 bolts D y Support Rail S101 1 4 washers 1 4 20 nuts 1 4 20x3 4 bolts Brace S109 10 nuts M10x30 bolts x KS 9 Support Rail S201 EM 1 4 washers 1 4 20 nuts 1 4 20x3 4 bolts Brace S109 es u Upper Riser Strut S103HU Lower Riser Strut S103HL Figure 27 Horizontal Frame Tilt Kit p n SFTOO4H Procedure 1 Choose attachment site allowing for subsequent pipe penetration 2 Ensure that two bolts are inserted into the channel of the upper and lower profile rails before the upper and lower riser struts are bolted to the profile rails 3 The distance between the collector support rails should be slightly larger than the distance between the upper roof hooks U strips which have already been installed on the roof 4 On the roof hooks U strips the long sides of the pivot brackets are screwed into the middle drill holes The short side should be at the top 5 On the lower roof hooks U strips the short side of the second pivot bracket is bolted to the first pivot bracket 6 Cut the riser struts of the standoff to the proper length for the required angle For 15 tilt in the case of vertical installation or 30 in the case of horizontal installation only one strut is needed for each pivot point For 30 vertical installation the riser struts are bolted toget
76. or shall be supplied by the installer Vent tiles are recommended for the roof penetrations on steeply pitched tile roofs for flat roofs corrugated sheet roofs and roofs with shallow pitch passing the pipes through an external wall is recommended to avoid water leaks Pipe hangers must provide correct support and pitch and must meet building codes Hangers must not compress insulation and should allow for thermal contraction and expansion of the pipework Installers must comply with all Local State and National Codes We recommend trimming pipes with pipe cutters to avoid creating metal filings Electrically ground the pipework in accordance with electrical codes Connect all pipework to the building s ground over the shortest possible distance Soldered Pipe Soldered pipe must be hard soldered using 95 5 lead free solder Alternative Piping Piping made with locking ring fittings press fittings and corrugated hoses must be sealed using suitable sealants Seals must be resistant to propylene glycol and temperatures up to 356 F Rated Volumetric Flow Rate The rated volumetric flow rate for a collector array max 5 collectors is 27 80 gallons hour or 0 45 1 33 GPM All collector arrays must be connected in parallel The flow rate for every additional collector array is added to the total so in a system with 3 x 3 collectors the flow rate would be 80 240 gallons hour Thermal Insulation All hot water and final 5 feet of cold
77. ow Roofs with pitches above 9 in 12 generally should not use this mounting kit as the resulting collector tilt angle will be too steep for almost any location Roof Pitch rise to run Roof Pitch Angle 1 in 12 4 8 2 in 12 9 5 3 in 12 14 0 4 in 12 18 4 5 in 12 22 6 6 in 12 26 6 7 in 12 30 3 8 in 12 33 7 9 in 12 36 9 10 in 12 39 8 11 in 12 42 5 12 in 12 145 0 5 1 5 Detailed Assembly Instructions for 45 Mounting Kit Resulting Collector Tilt Angle with 45 Mount 49 8 54 5 59 0 63 4 67 6 71 6 75 3 78 7 not recommended not recommended not recommended not recommended Step 01 Major components for assembly of the Stiebel Eltron 45 mounting kit single panel vertical version displayed Step 02 Align the mounting system components upside down as shown The longer cutout surface approx 1 should be facing toward the center of the rectangle and be parallel to the ground on both the top and bottom This is the surface on which the back of the collector will rest WWW STIEBEL ELTRON USA COM SOL 25 PLUS 17 ENGLISH Step 03 Prepare to assemble the top left corner Step 04 Slide M10 bolt into slot of profile rail F ia Fr MS CR WY Step 05 Position the diagonal support such that the M10 bolt protrudes through the hole closest to the end Note 1 If assembling a 45 horizontal mounting system there is only one hole on either end of t
78. ps in the immediate vicinity of the collectors above the roof Note possibility of corrosion Use only compatible metals for fastening to the aluminum collector pans and mounting hardware Mounting Frame Connect the mounting frame to the lightning protection equipment separately via screw type or clamp connections Connect the forward and return piping to the building s equipotential bonding system ground at frequent intervals in 4 inches WARNING HAVE LIGHTNING PROTECTION MEASURES CARRIED OUT BY PROFESSIONALS Secure each collector at the top and bottom with eight 8 angle brackets four along the top profile frame and four along the bottom by inserting M10 bolts from kit 185545 or kit 185546 into the profile rail s bolt channel placing the angle brackets into position and tightening the bolts See Figure 30 For horizontal mounting systems secure each collector at the top and bottom with sixteen 16 angle brackets eight along the top profile frame and eight along the bottom Angle Brackets Figure 30 Securing Collectors To Frame Using Angle Brackets The collector pipe nipple connections are located on the top of the collector in the case of vertical mounting or on the sides with horizontal mounting It is recommended that collectors be interconnected by means of a compensator flexible stainless steel tube p n 170804 which comes with every R2 185546 mounting frame One should also be ordere
79. r s supply lines are configured in a U downwards shape to prevent thermosiphoning f required install a two way valve that is switched off simultaneously with the pump to block thermosiphoning in the solar loop Install a check valve gravity brake in the flow or a heat insulating loop Vent the re heat heat exchanger Compare the details supplied by the boiler manufacturer and those of the tank manufacturer The problem may be resolved by selecting a higher flow temperature at the boiler Check the insulation insulate the tank connections Check the boiler controller setting Check the switching times and interval operation Check the sensor position installation and resistance Control unit not OK The following is a glossary of terms definitions of abbreviations and acronyms which appear in this manual absorber plate a metal plate typically made of copper which has a selective coating to efficiently convert sunlight into heat and transfer this heat to liquid that circulates through copper pipes attached to the plate after heating a method to add heat from a non solar source such as a fuel fired boiler to raise the temperature of water in a storage tank to the minimum required for end use altitude angle angle of sun above the horizontal plane anode rod a metallic rod that is installed in a water storage tank in order to reduce corrosion of the tank and its internal components by serving as a sacrifici
80. r wiring ID Anchor brackets panel clips M10 nuts M10 bolts M6 nuts N Ss on NT 7 Profile rails Compensator Flexible Stainless Steel Pipe 77 WE ipe Figure 15 R2 Mounting Frame for Single Horizontal or Two Vertical Collector Arrangement 3 8 16 flange nuts M10 nuts M10 bolts N N B 3 8 16 x 3 bolts 1 4 washers 1 4 20 nuts IM 1 4 20x3 4 K bolts a Support Riser SE60 110 Support Base SE60 108 Support Diagonal S101 __ Brace S109 NOTE Riser and Base interchange for 30 degree tilt Figure 16 Vertical 30 60 Mounting Kit p n SE60 Procedure 1 Choose attachment site allowing for subsequent pipe penetration 2 Bolt the support base SE60 108 support riser SE60 110 and transverse support S101 collector rail together to form a triangle truss as shown in Figure 17 3 Bolt the resulting truss es to the upper and lower profile frame rails 4 f installing one collector the triangle trusses must be set up at intervals of 82 in 210 cm for horizontal installation or s 43 in 110 cm for vertical installation 5 If installing two or more collectors the triangle trusses are to be positioned at the midpoint behind the collectors 6 Whenever two or more triangle trusses are installed brace the center span with a cross brace as shown in Figure 17 7 When installing four or five trusses brac
81. re BTU British thermal unit C degrees Celsius F degrees Fahrenheit ft foot feet of distance K Kelvin degree of absolute temperature kg kilogram kN kiloNewton thousand Newtons of force Ib pound force or weight m meter mm millimeter psi pounds per square inch psia pounds per square Inch absolute psig pounds per square inch gauge W watt UV ultraviolet radiation typically a component sunlight venting the process of purging air from the solar loop or other parts of a heating system vertical collector mounting a mounting arrangement in which the long dimension of each collector is oriented up down the collector s pipe fittings nipples typically point upward wind loads forces generated by winds impinging upon solar collectors and related components 70 If the roof attic is accessible we recommend fastening the solar collector mounting hardware using carriage bolts through the roof sheathing and a spanner block that spans across rafters as shown in Figure A 1 It is important to provide adequate support for the spanner to keep it from buckling as shown in the diagram with two spacer blocks to allow the carriage bolt to clamp tightly to the structure Choose large enough carriage screws to allow adequate load bearing for the snow ice and wind conditions likely to be present at the site Keep in mind that solar collectors that are not flush to the roof particularly those that are inclined steeply
82. round mounting configurations may be prone to damage from falling ice or nearby vehicles or other hazards Appropriate precautions should be taken to mitigate these hazards SOL 25 PLUS 31 ENGLISH 3 Ground mounting often requires longer outside piping runs so proper insulation and protection of collector piping essential Installers should consider laying pipe runs below grade to avoid damage and to mark the location of these runs to avoid damage from digging operations 5 2 4 30 60 Mounting On A Pitched Roof Procedures described above for mounting of collectors upon a flat roof apply to mounting on a pitched sloped roof except for the following 1 Use of weights to secure collectors and mounting hardware Is not advisable Collector mounting frames should be fastened to all pitched roofs in an appropriate manner 2 The 30 mounting kits add 30 to an existing roof pitch as shown in the table below Roofs with pitches above 12 in 12 generally should not use this mounting kit as the resulting collector tilt angle will be too steep for almost any location Roof Pitch rise to run Roof Pitch Angle Resulting Collector Tilt Angle w 30 Mount Resulting Collector Tilt Angle w 60 Mount 1 in 12 4 8 2 in 12 9 5 3 in 12 14 0 4 in 12 18 4 5 in 12 22 6 6 in 12 26 6 7 in 12 30 3 8 in 12 33 7 9 in 12 36 9 10 in 12 39 8 11 in 12 42 5 12 in 12 45 0 34 8 39 5 44 0 48 4 52 6 56 6 60 3 63
83. siq sd 06 Wi 3 a neg ainssad aunssald 6EETCC OU Jed duing 40 23 0 Je OS AW AW IAEA peuuoosiq NEA joy 3JnssaJd ONE Jo 3 U3A 3JnsSaJd 14 witi F paads g L dung 9 _ 7 IO jenuew pue SS suy uoiun ddSg H E aqn 3215 ssajuleys 2 q X2 4 AW 8 jeaH 10 Sale 29U d Jaa Mo J s8umiJ 3 1128 3 20 pesop MO J anjea em oM yay 9M 1 3 pu 8 T 58 E QN4941 iagram ic D SOLKIT System Schemat Figure 1 IMPORTANT TO PROTECT THE SYSTEM AGAINST FROST AND CORROSION FILL THE SOLAR HEATING SYSTEM EXCLUSIVELY WITH THE RECOMMENDED PROPYLENE GLYCOL MIXTURE SECTION 2 1 2 THESE INSTRUCTIONS ARE APPLICABLE ONLY TO SINGLE HYDRAULIC ASSEMBLIES OF NO MORE THAN 30 INDIVIDUAL COLLECTORS LARGER SYSTEMS REQUIRE INDIVIDUAL APPROVAL COMMERCIAL SYSTEMS MUST ADHERE TO LOCAL REGULATIONS Pipework Installation Use copper or stainless steel pipes or corrugated stainless steel hoses for the supply and return lines Pipe diameter is dependent on length of run and expected flow rates Recommended pipe diameter for systems of up to 10 collectors is 3 4 Ifthe pipe run is longer than 60 feet a larger pipe diameter may be needed All pipe runs to the building interi
84. tallations 9 Maintenance and Care 10 Troubleshooting 11 Glossary of Terms APP A Roof Mounting Detials APP B Certification APP C Contact 12 Warranty PAGE co oc mn E FF N pi NJ 13 13 16 16 17 17 28 28 30 31 32 32 40 40 4 _ A8 60 61 62 62 62 62 63 63 64 65 65 67 71 73 74 76 General Information Read this entire manual Failure to follow all the guides instructions and rules could cause personal injury or property damage Improper installation adjustment alteration service and use of this unit can result in serious injury This unit must be installed by a professional installer The installation must comply with all national state and local plumbing and electric codes Proper installation is the responsibility of the installer Failure to comply with the installation and operating instructions or improper use voids the warranty Save these instructions for future reference Installer should leave these instructions with the consumer If you have any questions regarding the installation use or operation of this water heater or if you need any additional installation manuals please call our technical service line at 800 582 8423 USA and Canada only If you are calling from outside the USA or Canada please call USA 413 247 3380 and we will refer you to a qualified Stiebel Eltron service representative in your area Safety Instructions THIS IS THE
85. to the potable water 68 hard solder 95 5 lead free solder used to join piping in the solar loop It is capable of withstanding the elevated temperatures that solar collectors are capable of generating heat conducting paste a thermally conductive paste that aids in transferring heat between components This paste is typically used in solar thermal systems to allow temperature sensors to read temperatures of components more accurately heat exchanger a device used to efficiently transfer heat between one component and another In heating systems heat exchangers are most often used to transfer heat between two separate fluids There are liquid to liquid liquid to gas and other types of HX heat transfer medium fluid that is used to collect and transport heat energy between solar collectors and storage tanks or other devices in a solar loop horizontal collector mounting a mounting arrangement in which the short dimension of each collector is oriented up down the collector s pipe fittings nipples point horizontally to the sides HX heat exchanger hydrometer an instrument used to measure the specific gravity or relative density of liquids that is the ratio of the density of the liquid to the density of water In solar thermal systems it is often used to test the composition of the heat transfer medium insolation incoming solar radiation that impinges upon a solar collector or other surface installed height t
86. unting hardware to move slightly under loads and thermal expansion without placing undue stress on collector fittings It is very important to avoid repeated stress cycles upon fittings as leaks may 6f ENGLISH develop which would cause the system to stop working properly controller an electronic device that senses temperatures and uses control algorithms rules to determine when to activate pumps and relays and various warnings and alarms The controller serves as the brain of a solar thermal system and controls how and when the system collects heat sheds excessive heat and shuts down to protect various components DHW domestic hot water DHW mixing valve a temperature sensitive regulating valve that mixes cold water with incoming hot water to limit its temperature to prevent scalding and other problems for end users Dowfrost 50 ready mixed propylene glycol heat transfer medium that contains approximately 50 propylene glycol anti freeze fluid EPDM ethylene propylene diene monomer M class rubber a synthetic rubber that exhibits outstanding heat ozone and weather resistance and is often used for sealing components in heating systems expansion tank a tank that is attached to heating systems to allow normal expansion of liquids that undergo heating and cooling cycles in order to prevent undue stress on and failure of piping tanks fittings and other vessels Most modern expansion tanks have a chamber fill
87. vement Flush the system in both directions clean fittings such as flow meters with balancing valve and dirt traps Check the line routing in case of up and down e g at balcony protrusions or around water pipes change the line routing if required or insert additional air vent valves Check the function of the automatic air vent valve For this remove the protective cap and check the float movement with a blunt needle If necessary replace the air vent valve Check the function of the flow meter with balancing valve A jammed ring can block the display in the sight glass even if the flow rate is correctly adjusted Start the pump in manual mode the pump piston movement should be discernible Release the piston through tapping it lightly in emergencies replace the flow meter with balancing valve Open the shut off valve Check for faults again when there is strong solar irradiation Check for faults again when there is strong solar irradiation Reduce the pump rate Increase the switching temperature differential at the controller Insulate the pipework Connect the temperature sensors to the correct sensor terminals see the control unit installation and operating instructions Check to be sure that the automatic shut off valve is closed First check the fittings glands at shut off valves and all threaded connections then all solder fittings Check the expansion vessel inlet pressure and the di

SOL 25 Plus Flat Plate Collector Installation Manual

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