Transcription

TECHNICAL MANUALSolar water heatersInstallation, maintenance & use instructions

SOLAR WATER HEATERSCONTENTSGENERAL INFORMATION. 4DOMESTIC HOT WATER CONSUMPTION. 4SOLAR WATER HEATER OPERATION - WATER HEATING. 4SOLAR WATER HEATERS AELIOS. 5PACKAGING. 5LABELING. 7WATER STORAGE TANK SPECIFICATIONS. 8COLLECTOR AELIOS SPECIFICATIONS. 9AELIOS 120lt/2m2 LAYOUT. 11AELIOS 160lt/2m2 LAYOUT. 12AELIOS 160lt/2.6m2 LAYOUT. 13AELIOS 160lt/3m2 LAYOUT. 14AELIOS 200lt/2m2 LAYOUT. 15AELIOS 200lt/2.6m2 LAYOUT. 16AELIOS 200lt/3m2 LAYOUT. 17AELIOS 200lt/4m2 LAYOUT. 18AELIOS 300lt/4m2 LAYOUT. 19AELIOS 300lt/6m2 LAYOUT. 20GENERAL INSTALLATION RULES. 21INSTALLATION POSITION. 22GENERAL PREVENTION MEASURES. 23SUPPORT BASE PARTS. 24SUPPORT BASE ASSEMBLY ON A FLAT SURFACE. 25SUPPORT BASE ASSEMBLY ON AN INCLINED SURFACE. 28HYDRAULIC CONNECTION. 31CLOSED LOOP FILLING. 31ELECTRICAL CONNECTION. 32SYSTEM INSTALLATION ON A TILED ROOF WITH THE WATER STORAGETANK UNDER THE ROOF (NATURAL CIRCULATION OPERATION). 33CONNECTING THE COIL HEAT EXCHANGER. 33POSSIBLE PROBLEMS - SOLUTIONS. 34SERVICE - MAINTENANCE. 35POST INSTALLATION INSTRUCTIONS. 36CHECK LIST. 37SWH/AE3

GENERAL INFORMATIONIn the present manual you will find all necessary instructions with regard to the installation, operation andmaintenance of the product.The company is active in the Solar Energy Field with high-tech equipment, ultra-modern facilities and certifiedproducts of high quality. Our experience and know-how support our co operations, before and after sales, both inEurope and internationally.Nowadays, the necessity for production and saving of energy without at the same time polluting the environment hasbecome common knowledge. The planetʼs conventional energy resources are diminishing to a threatening level asour societyʼs energy requirements are increasing, generating pollutants that affect the climateʼs balance. Renewableenergy sources promise a solution to the energy problem as well as to pollution. Gradually, the international legislationis changing and encouraging - or even imposing - the use of alternative energy products, with the aim to satisfyenergy requirements without endangering the environment.DOMESTIC HOT WATER CONSUMPTIONStatistically, it is estimated that the mean family consumption is 35 to 50 litres daily per person. If we add theconsumption of a washing machine and a dishwasher, when these are connected to the solar water storage tank, theneach requires 20 litres per day (per wash). Thus, a family of four, for example, with a mean hot water consumptionof 40 litres per person, needs an 160 litres solar water heater. If household appliances connected to the solar waterheater are added, then the demand increases by at least 40 litres daily. In order to take full advantage of the solarwater heater, maximum use of hot water should be made during daytime, so that the system can continuouslyproduce hot water during the daylight hours, maintaining thus its maximum efficiency.SOLAR WATER HEATER OPERATION - WATER HEATINGThe collecting surface absorbs solar energy and heats the liquid (water or antifreeze mixture) that circulates in thewater element. This liquid when heated becomes lighter and is directed to the water storage tank where it heats thewater. The flow of the collector’s liquid is accomplished naturally and not forced (thermosiphonic flow).The factors that affect the temperature of the water supplied by a solar system are many and their values vary accordingto the season, the time of day and the location. Keeping in mind that the solar system is a system that is exposed tothe weather conditions, basic parameters affecting its performance are the mains water temperature, the availablesolar energy and the ambient temperature. The mains water does not have a constant temperature throughout theyear, being much colder in winter compared to summer. Considering 45 C as a satisfactory temperature for thedomestic hot water (in order to fulfil the needs of a home) and based on statistic values, in winter the temperatureof the mains water has to be increased by approximately 35 C, whereas during the summer the increase is 20 C.Similarly, the available solar energy does not remain the same throughout the year, being much less in the wintermonths than in the summer months. During periods of reduced sunlight and low ambient temperatures, the solarwater storage tank assures the preheating of the water and is assisted by an electrical heating element or thecentral heating water storage tank (triple action solar water storage tanks). As far as night-time temperature lossesare concerned, these are limited as much as possible by the solar system’s powerful thermal insulation. They arenevertheless affected by ambient temperatures, which vary depending on the location and the weather.4SWH/AE

SOLAR WATER HEATERSSOLAR WATER HEATERS AELIOSRELIABILITY - HARMONY - AESTHETICSSolar KeymarkCeritfiedAELIOS Solar Systems constitute an ecological proposal and an effective energy solution, combining high output,autonomy, aesthetics, facility in the installation and money saving. They are made of excellent materials according tointernational specifications and have all the certifications and tests that confirm their quality.They are highly aesthetic systems, which can be simply and quickly installed to blend with the traditional or modernarchitecture of a building and to provide free hot water almost the whole year round. Even in regions with low sunlightthey achieve the preheating of the water, which contributes to a drastically reduced consumption of conventionalenergy.With the use of solar systems, thermosiphonic or forced circulation, is achieved energy saving of 70-100%. At thesame time the operation time of the boiler or electric resistance is decreased, depending on the sunlight of eachregion and the system’s size, with simultaneous reduction of emission of carbon dioxide.PACKAGING1PRODUCT RANGEAELIOS series thermosiphonic systems are available in aluminium and copperwater frame and in black painted and selective absorber.Each of them is also available in the following models:2MODELDESCRIPTIONAELIOS 120/2AELIOS 160/2AELIOS 160/2.6AELIOS 160/3AELIOS 200/2AELIOS 200/2.6AELIOS 200/3AELIOS 200/4AELIOS 300/4AELIOS 300/6120lt tank, 2m2 collector160lt tank, 2m2 collector160lt tank, 2.6m2 collector160lt tank, 2 x 1.5m2 collector200lt tank, 2m2 collector200lt tank, 2.6m2 collector200lt tank, 2 x 1.5m2 collector200lt tank, 2 x 2m2 collector300lt tank, 2 x 2m2 collector300lt tank, 3 x 2m2 collectorSWH/AE31. Boiler2. Collector(s)3. Support base, fittings& Accessories4. Palette45

Each model packaging contains all the necessary equipment:1. The water storage tank2. The collector (s).3. The support base system & fittings and accessories.The water storage tank is placed between two round styrofoam covers, which are tightened on the storage tank withstretch film. The collector is packed in a carton box. All the parts of the support base system, with the connectionfittings, the antifreeze liquid and the other accessories are packed in a carton box.The fittings and the accessories of each appliance appears in the following table:SOLAR WATER HEATERS AELIOS ALS & AELIOS CuS FITTINGS & ACCESSORIES1 COLLECTOR2 COLLECTORS3 antityDescription1 PCT-PIECE WITH THEFILLING VALVE1 PCT-PIECE WITH THEFILLING VALVE1 PCT-PIECE WITH THEFILLING VALVE1 PCELBOW 3/4’’ FEMALEDN16 INOX1 PCELBOW 3/4’’ FEMALEDN16 INOX1 PCELBOW 3/4’’ FEMALEDN16 INOX2 PCSELBOW Ø22 COPPERX DN16 INOX2 PCSCONNECTOR Ø22COPPER X Ø22 COPPER4 PCSCONNECTOR Ø22COPPER X Ø22 COPPER2 PCSEND CAP Ø22COPPER2 PCSELBOW Ø22 COPPERX DN16 INOX2 PCSELBOW Ø22 COPPERX DN16 INOX1 PCONE WAY SAFETYVALVE 10 bar **2 PCSEND CAP Ø22COPPER2 PCSEND CAP Ø22 COPPERONE WAY SAFETYVALVE 10 bar **1 PCONE WAY SAFETYVALVE 10 bar **SAFETY VALVE1 PC(1,5 bar for 250lt and aboveor 2,5 bar up to 200lt)1 PC2 PCSINOX TUBE DN161 PC(1,5 bar for 250lt and aboveor 2,5 bar up to 200lt)1 PC(1,5 bar for 250lt and aboveor 2,5 bar up to 200lt)1 PCINSULATION Ø22 X 92 PCSINOX TUBE DN162 PCSINOX TUBE DN16*ANTIFREEZE LIQUID 1lt1 PCINSULATION Ø22 X 91 PCINSULATION Ø22 X 9*ANTIFREEZE LIQUID 1lt*ANTIFREEZE LIQUID 1ltSAFETY VALVESAFETY VALVE* The volume of liquid depends on the configuration boiler/collector* * ½’’ BSP up to 200lit or ¾” for 250lit and above6SWH/AE

SOLAR WATER HEATERSLABELINGAELIOS solar water heaters are identified by two stickers, one of them on the tank and the other on the collector.On these stickers all the details of the system are written. The information provided on the stickers are important forthe future identification of the system.Solar water heaterAELIOSxxxlt/xm2· Absorber area:XXX m2· Aperture area:XXX m2· Nominal capacity:XXX lt· Design pressure:XXX KPa· Heat transfer medium:Propylene glycol / water mixture· Permissible operating pressure of thecollector heat transfer medium: XXX KPa· Electrical Power: XXX W· Storage Tank S/N: ?· Date of manufacture: ?MADE IN EUAELIOS XXXXType: Flatplate collectorDimensions: (L x W x H) (mm): XXXX x XXXX x XXOverall area (m2): XXXAbsorber area (m2): XXXTotal weight of collector (kg): XXXVolume of heat transfer fluid (lt): XXXAbsorber coating: XXXStandstill temperature: XXX CMax. operating pressure: 1MPa (10bar)Transparent cover: Tempered solar glassHeat transfer medium: Propylene glycol solution/water mixtureSWH/AELicence No: ΧΧΧS/N: ΧΧΧDate: ΧΧ/ΧΧΧMADE IN EU7

WATER STORAGE TANK SPECIFICATIONS14613 1071234161. Cylinder: 3 mm thickness cold rolled steelwith a double internal layer of enamel,baked at 860 C according to DIN 4753.The enameling is done in our own hightech industrial facilities. The water storagetanks are checked individually upon exitfrom the enameling unit, assuring the topquality of the enamel.2. Surrounding heat exchanger (Jacket):cold rolled steel, 1.8 mm thickness forthe operation of the closed loop, whichis compulsory at low temperatures andalso in areas with water with high mineralcontent. It is specially designed so as toabsorb the heat transfer medium pressure.121198517 153. Thermal insulation: ecological, highdensity, expanded polyurethane ensuresminimum heat loss, maintaining the hotwater temperature.4. External housing: prepainted galvanized steel.5. Cathode protection by magnesium anodes for effective protection against corrosion and mineral deposits causedby electrolytic reactions.6. Large round flange rubber protected: innovative, smart design for the quick cleaning of minerals,fast replacement of anode and immediate access to the electrical components.7. Complete sealing of EPDM, non toxic material, which does not permit water to contact the flange, thus protectingit against electrolysis and corrosion, specially made to withstand the generally accepted specifications with regardto the heat resistance.8. Heating element rated according to the country of destination local regulations. (Optional, for the use of electricityas an auxiliary power source). All electrical components carry a CE marking according to EN 60335-1 andEN60335-2-21 standards.9. Automatically regulated thermostat with bipolar protection and auxiliary fuse. All electrical components carrya CE marking according to EN 60335-1 and EN60335-2-21 standards.10. Protective cover: designed to ensure the proper ventilation of the electrical section and its protection fromthe environmental conditions.11. Cable gland: for sealing the passage of the heating element’s connection cable.12. Cold water inlet: ½” BSP male threaded pipe end for water stratification and 10 bar safety valvefor releasing pressure (¾” for 250lt and above).13. Hot water outlet: ½” BSP male threaded pipe end (¾” for 250lt and above).14. Jacket inlet: ¾” BSP male threaded pipe end.15. Jacket outlet: Closed loop circuit filling point: ¾” BSP male threaded pipe end.16. Safety valve connection location (1,5 bar for 300lt or 2,5 bar for 120- 200lt): ½” BSP male threaded pipe end17. Heat exchanger (optional) with ¾” BSP male threaded ends for use of the heating produced by central heatingsystems during the winter.8SWH/AE

SOLAR WATER HEATERSCOLLECTOR SPECIFICATIONSSolar KeymarkCeritfied1. Collector frame of aluminium profile (Al Mg Si 05).2. Rear cover of aluminium 0,4mm, tightly fitted with elastic EPDM seal.3. Water frame of suitable gauge and thickness: Headers are punched with upper expansion, for perfect manifoldsfitting, thus avoiding pressure drop in the collectors.Tube pitch 107mm (EN 1652).Copper water frame (Aelios CuS & Aelios CuB):Ø22 headers: solar collector feed and feed-back. Ø8 manifolds: solar collector thermal absorptionAluminium water frame (Aelios ALS & Aelios ALB):Ø22 headers: solar collector feed and feed-back. Ø10 manifolds: solar collector thermal absorption.4. Complete area absorber made of black painted aluminium 0.3mm thick, or selective aluminium 0.4mm thick,covers the complete window area as well as the headers, thus increasing the collector’s absorbency, LaserWelded to the water frame.5. High density, eco-friendly thermal insulation achieved with a 50mm and 20mm (back and lateral)thick layer of prepressed glasswool for the minimization of thermal losses.Glasswool insulation thermal conductivity: λ 0.032 W/m grd (DIN 56612, measured at 0 C).6. Tempered solar glass, with a stable coefficient of expansion and high light transmittance, can withstandadverse weather conditions (e.g. hail storm, extreme temperature changes, etc.). ANSI Z 97-1 (U.S.A.) BS 6206(G.BRITAIN) DIN 52337 (GERMANY).SWH/AE9

Normal absorber design with louvers.Air turbulence increases heat lossComplete area technologyThe uniform area prevents heat lossSUPPORT BASEFLAT SURFACEINCLINED SURFACESupporting base system, madeof galvanised steel, for installationon flat or inclined surfaces10SWH/AE

AELIOS 200lt/2.6m2 LAYOUTAELIOS 200lt/2.6m2FLAT SURFACE65942713AELIOS 200lt/2.6m2INCLINED SURFACE56394127PART ΝΑΜΕDIMΕΝSIONS1Beam L (Laminate section 60 x 2.5mm)2060 x 60mm22Beam L (Laminate section 60 x 2.5mm)1224 x 60mm23Beam L (Laminate section 60 x 2.5mm)2289 x 60mm24Beam L (Laminate section 60 x 2.5mm)925 x 60mm25Beam (Laminate section 33 x 2mm)6Boiler Support7Aluminium Fastener8Protective Cover9Plastic Cover for Supporting Strips (Slab)Hexagon Head Bolt M811Hex Nut M8Washer13Screw 8 x 60980mm4Ø5802420mm2M8x162841012QTY.228Ø84414Upat D10415Hexagon Head Screw with Washer4NOPART ΝΑΜΕDIMΕΝSIONS1Beam L (Laminate section 60 x 2.5mm)2060 x 60mm22Beam L (Laminate section 60 x 2.5mm)2289 x 60mm23Beam L (Laminate section 60 x 2.5mm)925 x 60mm24Beam L (Laminate section 33 x 2mm)980mm25Beam (Laminate section 33 x 2mm)980mm26Boiler SupportØ5802420mm2M8x16207Aluminium Fastener8Protective CoverQTY.49Plastic Cover for Supporting Strips (Slab)10Hexagon Head Bolt M811Hex Nut M812Washer13Hexagon Head Screw with Washer220Ø844INCLINED SURFACE1889628FLAT SURFACENO26109001403WATER STORAGE TANKDIMENSIONS (mm)20342150200lt580x13561410TOTAL SYSTEMAELIOS 200lt/2.6m2NUMBER OF COLLECTORS1WEIGHT EMPTY (kg) (without packaging)81.8SYSTEM WEIGHT EMPTY (packed) / FULL (kg)JACKET CAPACITY (lt)18.3MAX WATER TANK OPERATING PRESSURE (bar)10JACKET SURFACE (m2)1.28CLOSED CIRCUIT MAX OPERATING PRESSURE (bar)2.5MAX TEST PRESSURE (bar)15MAX OPERATING PRESSURE (bar)10COLLECTOR156/354MAX OPERATING TEMPERATURE95 CAELIOS ALS 2600AELIOS ALB 2600AELIOS CuS 26002.62.62.62.611 (Ø10)11 (Ø10)11 (Ø8)11 (Ø8)CAPACITY (lt)1.731.731.64ABSORBER SURFACE 280x802030x1280x80TOTAL AREA (m2)NUMBER OF MANIFOLDSHEAT TRANSFER MEDIUMTOTAL DIMENSIONS LxWxH (mm)COLLECTOR TOTAL WEIGHT (without liquid) (kg)ABSORBERABSORBENCY / RADIATION COEFFICIENTAELIOS CuB 2600PROPYLENE GLYCOL SOLUTION1.644443.54544.5SELECTIVE ALUMINIUMBLACK PAINTED ALUMINIUMSELECTIVE ALUMINIUMBLACK PAINTED ALUMINIUM95% 2% / 5% 2%90% 2% / 84% 2%95% 2% / 5% 2%90% 2% / 84% 2%Note: All dimensions measured in mm16SWH/AE

SOLAR WATER HEATERSAELIOS 200lt/3m2 LAYOUTAELIOS 200lt/3m2FLAT SURFACE7510943612AELIOS 200lt/3m2INCLINED SURFACE478451239PART ΝΑΜΕDIMΕΝSIONSQTY1Beam L (Laminate section 60 x 2.5mm)1560 x 60mm22Beam L (Laminate section 60 x 2.5mm)1809 x 60mm23Beam L (Laminate section 60 x 2.5mm)933 x 60mm24Beam L (Laminate section 60 x 2.5mm)725 x 60mm25Beam (Laminate section 33 x 2mm)980mm46Collector Support1500mm27Boiler SupportØ58028Protective cover420mm29Plastic Cover for Supporting Strips (Slab)210Αluminium Fastener (CO holder)811Hexagon Head Screw with Washer12Hexagon Head Bolt M813Hex Nut M814Washer15Screw 8 x 60416Upat D1044M8 x 163636Ø812NOPART ΝΑΜΕDIMΕΝSIONSQTY1Beam L (Laminate section 60 x 2.5mm)1560 x 60mm22Beam L (Laminate section 60 x 2.5mm)1809 x 60mm23Beam L (Laminate section 60 x 2.5mm)933 x 60mm24Beam (Laminate section 33 x 2mm)980mm25Collector Support1500mm26Protective Cover420mm27Boiler SupportØ58028Plastic Cover for Supporting Strips (Slab)29Aluminium Fastener810Hexagon Head Screw with Washer11Hexagon Head Bolt M812Hex Nut M813Washer4M8x162828Ø812INCLINED SURFACE1602628FLAT SURFACENO21109002189WATER STORAGE TANKDIMENSIONS (mm)15341699200lt580x13562189TOTAL SYSTEMAELIOS 200lt/3m2NUMBER OF COLLECTORS2WEIGHT EMPTY (kg) (without packaging)81.8SYSTEM WEIGHT EMPTY (packed) / FULL (kg)JACKET CAPACITY (lt)18.3MAX WATER TANK OPERATING PRESSURE (bar)10JACKET SURFACE (m2)1.28CLOSED CIRCUIT MAX OPERATING PRESSURE (bar)2.5MAX TEST PRESSURE (bar)15MAX OPERATING PRESSURE (bar)10COLLECTOR168/364MAX OPERATING TEMPERATURE95 CAELIOS ALS 1500AELIOS ALB 1500AELIOS CuS 15001.581.581.581.588 (Ø10)8 (Ø10)8 (Ø8)8 (Ø8)CAPACITY (lt)1.141.141.12ABSORBER SURFACE 030x801530x1030x80TOTAL AREA (m2)NUMBER OF MANIFOLDSHEAT TRANSFER MEDIUMTOTAL DIMENSIONS LxWxH (mm)COLLECTOR TOTAL WEIGHT (without liquid) (kg)ABSORBERABSORBENCY / RADIATION COEFFICIENTAELIOS CuB 1500PROPYLENE GLYCOL SOLUTION1.122726.52827.5SELECTIVE ALUMINIUMBLACK PAINTED ALUMINIUMSELECTIVE ALUMINIUMBLACK PAINTED ALUMINIUM95% 2% / 5% 2%90% 2% / 84% 2%95% 2% / 5% 2%90% 2% / 84% 2%Note: All dimensions measured in mmSWH/AE17

AELIOS 200lt/4m2 LAYOUTAELIOS 200lt/4m2FLAT SURFACE1075943612AELIOS 200lt/4m2INCLINED SURFACE463841529PART ΝΑΜΕDIMΕΝSIONS1Beam L (Laminate section 60 x 2.5mm)2060 x 60mmQTY22Beam L (Laminate section 60 x 2.5mm)2289 x 60mm23Beam L (Laminate section 60 x 2.5mm)1224 x 60mm24Beam L (Laminate section 60 x 2.5mm)925 x 60mm25Beam (Laminate section 33 x 2mm)980mm46Collector Support1500mm27Boiler Support8Protective coverØ5802420mm29Plastic Cover for Supporting Strips (Slab)210Αluminium Fastener (CO holder)811Hexagon Head Screw with Washer12Hexagon Head Bolt M813Hex Nut M814Washer4M8 x 1636Ø8123615Screw 8 x 60416Upat D104NOPART ΝΑΜΕDIMΕΝSIONS1Beam L (Laminate section 60 x 2.5m

of 40 litres per person, needs an 160 litres solar water heater. If household appliances connected to the solar water heater are added, then the demand increases by at least 40 litres daily. In order to take full advantage of the solar water heater, maximum use of hot water should be