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System Manual
Incorporating:
Solar Thermal Systems
European Solar Keymark Approved
Products covered by this manual:
Solar
Heat pipe vacuum tube collectors and accessories
LEAVE THIS MANUAL WITH THE END USER
Installation Instructions
Commissioning Instructions
Maintenance Instructions
Guarantee Registration
SHP20 SHP30
Q12-027 rev 02 May '10
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Table of Contents
Related Manuals for WarmFlow Solar SHP20
Summary of Contents for WarmFlow Solar SHP20
- Page 1 System Manual Incorporating: Installation Instructions Commissioning Instructions Maintenance Instructions Guarantee Registration Solar Thermal Systems European Solar Keymark Approved Products covered by this manual: Solar SHP20 SHP30 Heat pipe vacuum tube collectors and accessories LEAVE THIS MANUAL WITH THE END USER Q12-027 rev 02 May ‘10...
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Page 3: Table Of Contents
CONTENTS General Information ..................... 2 1.1 Warnings ........................2 1.2 Information ........................3 1.3 Product Conformity ...................... 3 Technical Characteristics .................... 4 2.1 Technical Data ......................4 2.2 Key Components ......................5 2.3 Circuit Diagrams ......................7 2.4 Pipework and Expansion Vessel Sizing ............... 8 2.5 Collector Pressure Drop .................... -
Page 4: General Information
GENERAL INFORMATION 1.1 Warnings In order to qualify for the product guarantee the equipment MUST be correctly commissioned as described herein and the guarantee registration section at the back of this manual completed and returned. Failure to commission and register the product may invalidate ALL guarantees. This equipment must only be installed and commissioned by professionally qualified personnel in accordance with current laws and standards and in line with the manufacturer’s instructions. -
Page 5: Information
1.3 Product Conformity The manufacturer declares that this equipment is manufactured to a high specification and in compliance with the relevant standards. All Warmflow solar products are CE certified and possess technical characteristics that comply with the following directives and standards:... -
Page 6: Technical Characteristics
Max. flow rate per collector (litres/min) Max. operating pressure (bar) Test pressure (bar) Heat transfer fluid Warmflow Solar Fluid (water-glycol mix) Max. working temperature ( Permissible wind load (m/s) Permissible snow load (mm) Table 1: Technical data for Warmflow Solar heat pipe collectors... -
Page 7: Key Components
The getter has a mirror-like appearance when new and becomes white when spent, indicating that the vacuum tube needs to be replaced. Figure 1: Warmflow Solar heat pipe tubes 1400 (Solar SHP20) 2100 (Solar SHP30) Manifold Transfers heat from the heat pipes to the system fluid. - Page 8 Ball Valves Filling Point Bleed Point Circulating Pump Continuous Air Separator Flow Adjuster Pressure Gauge Flow Indicator Flow Temperature Gauge Expansion Vessel Connection Return Temperature Gauge Flow Return to Solar Coil from Solar Coil Figure 3: Warmflow Solar dual-line pump station...
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Page 9: Circuit Diagrams
2.3 Circuit Diagrams Solar Collector Solar Sensors refer to instructions for Solar System Controller Dual-line Storage Cylinder Pump Station Pressure Relief Discharge Boiler Coil (if applicable) Solar Expansion Vessel Solar Coil Motorised Valve (if required) Drain Cock (at lowest point) Figure 4: Typical domestic circuit diagram... -
Page 10: Pipework And Expansion Vessel Sizing
Table 2 provides general guidance on the sizing of the system pipework and expansion requirements. The expansion capacity is expressed as the number of Warmflow Solar SEV18 expansion vessels required, each vessel having a volume of 18 litres. No. of... -
Page 11: Collector Pressure Drop
2.5 Collector Pressure Drop Figure 6: SHP20 collector pressure drop Figure 7: SHP30 collector pressure drop... -
Page 12: Installation
INSTALLATION 3.1 General Requirements Select a suitable position for the collector. Ensure the section of roof to which the collector is being installed is capable of supporting its weight and any likely wind loads. The collector should face as close as practicably possible towards south and not be shaded by surrounding buildings, trees or other sections of the building to which it is being installed. -
Page 13: Install Pitched Roof Brackets
3.2.2 Install pitched roof brackets Remove as many tiles as necessary to gain access to the rafters and laths and to determine their location and spacing. It may be helpful to position the collector nearer the ridgeline and work down from the top, removing the ridge tiles first. Using suitable fasteners (not supplied) fix the pitched roof brackets to the most convenient rafters ensuring the bracket spacing is within the guidelines below. -
Page 14: Install Support Frame And Manifold
3.2.3 Install support frame and manifold Fit the clamps supplied with the heat pipe manifold (SHPM~) to each rail of the support frame (SSF~), placing a pair at the top and at the bottom of each rail as shown. Install the support frame fixing each rail to the pitched roof brackets by passing the fasteners supplied through the sides of the rail and the loop on the end of each pitched roof bracket. -
Page 15: Connect Manifold Pipework
3.2.4 Connect manifold pipework To the flow (outlet) from the heat pipe manifold, fit the temperature sensor pocket supplied, sealing the connection with PTFE tape (not supplied) and setting the pocket to a suitable angle to allow the sensor cable to be secured to the flexible pipework. Either end of the manifold can be used for the flow (whichever is most convenient) but the sensor pocket must be fitted on the flow (outlet) side. -
Page 16: Slate Roof Installation
3.3 Slate Roof Installation Slate roof installation is essentially the same as tiled roof installation, only that the pitched roof brackets (SPRB~) may not be suitable. Slate roof brackets are available, codes SSRB20 and SSRB30 (for 20-tube and 30-tube manifold installations respectively). 3.3.1 Install slate roof brackets Using suitable fasteners (not supplied) fix the brackets to the most convenient rafters ensuring the bracket spacing is within the guidelines below. -
Page 17: Install Support Frame
3.3.2 Install support frame Install the support frame as described in Section 3.2.3 bolting the brackets to the underside of the support frame rails using the same bolts that secure the manifold and bottom rail to the rails. 3.3.3 Connect manifold pipework Connect the manifold pipework as described in Section 3.2.4. -
Page 18: Dual-Line Pump Station Installation
3.4 Dual-line Pump Station Installation 3.4.1 Mount pump station Route the supply cable (not supplied) behind the dual-line pump station (SDPS~) and through the hole in the centre of the rear casing. Using the fasteners supplied (if suitable, otherwise use appropriate alternatives) mount the pump station on a flat vertical surface. -
Page 19: Electrical Installation
3.5 Electrical Installation If connecting to an unvented cylinder, the pump station MUST be connected via an external wiring centre and an energy cut-out devise MUST be installed in order to comply with the Building Regulations. This MUST take the form of a 2-port motorised valve (not supplied) wired through a manually-reset high limit thermostat (not supplied). -
Page 20: Connect Back-Up Heat Source
3.5.3 Connect back-up heat source The controller is equipped with a 3-period, 24-hour programmer with temperature control to control the back-up heat source, such as a boiler or immersion heater(s). The back-up heat source is powered / controlled via the H1 outputs of the control unit. Note: The maximum operating current on the H1 contacts is 5A. -
Page 21: Commissioning
COMMISSIONING In order to qualify for the product guarantee the equipment MUST be correctly commissioned as described herein and the guarantee registration section at the back of this manual completed and returned. Failure to commission and register the product may invalidate ALL guarantees. 4.1 System Filling &... -
Page 22: Flush System
Figure 20: Multifunction ball valve filling positions 4.1.5 Fill system The system may ONLY be filled with Warmflow Solar Fluid, which is a specially blended solution of propylene glycol with corrosion inhibitors designed specifically for use with solar collectors to provide effective heat transfer, anti-freeze and corrosion protection. -
Page 23: Pressure Testing
4.2 Pressure Testing 4.2.1 Pressurise and inspect system On completion of system filling, close the valve at bleed point B. This will cause the system pressure to rise as the filling station pump will now be dead-heading. Using the regulator on the filling station (if fitted) set the outlet pressure to 5.5 bar (or as high as possible if 5.5 bar cannot be achieved). -
Page 24: Heat Pipe Tube Installation
4.4 Heat Pipe Tube Installation Only unpack and install the heat pipe tubes after the rest of the system had been flushed, filled and pressure tested and the system is ready to be brought into operation i.e. the DHW storage cylinder is in use or the swimming pool has been filled. 4.4.1 Insert tube into manifold Apply a generous amount of heat conducting glue (supplied with the manifold kit) to the exposed copper heat exchanger on the end of the heat pipe tube. -
Page 25: Circuit Flow Commissioning
4.5 Circuit Flow Commissioning 4.5.1 Set pump speed Calculate the required flow rate based on the number of tubes. A flow rate of 1 litre per minute is required for every 10 tubes, so: If you have 20 tubes, you need 2 litres per minute If you have 50 tubes, you need 5 litres per minute. -
Page 26: Maintenance
Visually inspect the installation for any signs of leakage, particularly if the system pressure has fallen below 3 bar. Any leakage must be rectified and the system re-pressurised and bled using Warmflow Solar Fluid (SF~) and an appropriate filling station. 5.2.2 Check fluid health... -
Page 27: Annual Service Checklist
5.2.4 Annual service checklist For guidance only – NOT to be completed and returned Collector inspection Visual collector inspection Visual inspection of the collector fixings Visual inspection for potential leaks in the roof Visual inspection of the thermal insulation on pipework Solar circuit inspection Visual inspection for potential leaks in the solar circuit at all joints and valve seals Colour check of the heat transfer medium... -
Page 28: Product Guarantee
Warmflow within 2 weeks of written notice being given to Warmflow of the defect. Such replacement parts shall be covered under the terms of this guarantee to the unexpired period of the aforementioned 2 year period. -
Page 29: Installation Notes
INSTALLATION NOTES Please use this section to record any important notes relevant to the installation which may be required for future reference. - Page 30 WARMFLOW Engineering Company Limited Lissue Industrial Estate, Moira Road, Lisburn BT28 2RF Tel: 028 9262 1515 Fax: 028 9262 0869 WARMFLOW Customer Care Centre UK: 028 9262 1515 ROI: 048 9262 1515 Email: service@warmflow.co.uk THIS MANUAL IS ACCURATE AT THE DATE OF PRINTING (E&OE)
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Page 31: Guarantee Registration
Commissioning Expansion vessel bladder pressure checked (prior to system filling)? (tick) Bladder pressure System flushed then filled with Warmflow Solar Fluid (tick) System flushed of all air (filling station run for at least 45 minutes) (tick) System pressure tested and inspected for leaks at all joints and valve glands... - Page 32 Guarantee Registration Please complete the Guarantee Registration Section overleaf then either remove this page or copy / scan the form and return it to Warmflow using one of the 3 methods below: By Post: Using the prepaid envelope, or otherwise, to:...