duco installation manual soliorfl150 english

Installation manual Solior FL150 solar water heater

Installatiehandleiding Solior FL150 zonneboiler 23-05-2008 2

Solior BV I Kanaalweg 16-G I 3526 KL I Utrecht I Postbus 8408 I 3503 RK I Utrecht

T: +31 30 28 08 321 I F: +31 30 28 08 301 I E: [email protected] I W: www.solior.com


Inhoudsopgave

1 Introduction 4

2 Regulat ions 5

3 Check this f i rst 7

4 Instal lat ion instruct ions 9

5 Maintenance 24

6 Faults and service 26

7 Operation and technical detai ls 29

8 Notes 37


1 Introduction

The Solior FL150 is an integrated solar

hot water system with a combined hot

water cylinder and collector. The system

is installed on the roof and connected to

the hot and cold water pipes. The

protective system is fully assembled and

includes an inlet combination valve and

thermostatic mixer valve.

The unit is supplied complete with a

support frame for installation on flat

roofs. This ensures a quick and

straightforward installation. Compared

with other solar hot water systems the

Solior is practically maintenance-free. All

it requires is a functional inspection once

a year.

The unit can reduce the energy

consumption for providing hot water to a

single family dwelling by 40% (in the

Netherlands) to 70% (in Spain).


2 Regulat ions

The local building regulations should be observed when installing the Solior FL150.

• In each case the version and supplements in force at the time of installation of the

unit should be observed.

• This unit may only be installed by qualified personnel. Qualifications are granted by

the electricity and water supply companies.

• This installation manual should be considered as a complement to the above

regulations, and the regulations always take priority over the information in this

document.

• Check the manual of the water heating appliance used for post-heating the water

from the Solior unit to check if this appliance is compatible with an inlet temperature

(cold water supply) of 65 oC.


Safety

• This unit should be installed by qualified personnel.

• Carefully read the instructions in this manual before starting the installation

work.

• Ensure compliance with all relevant installation requirements, national

legislation, standards and the requirements of the electricity and water

suppliers.

• The protective system requires 230 VAC. This voltage is also used inside the

Solior FL150. Hence, be sure to remove the mains plug from the outlet before

starting work on the system.

• The pipe connections can reach a temperature of 85oC, or even higher when the

tank is empty. You are advised to cover the Solior FL150 with a tarpaulin to

prevent the risk of burns when you accidentally touch the couplings.

• The box is designed to facilitate transport and handling. It is recommended that

you only remove the Solior FL150 from the box once you are ready to install it on

the roof. Keep the marked side up.

• Comply with the relevant legislation and regulations when working on the roof.

• Throughout the installation process, the hot water appliance used for

supplementary heating should be switched off and its mains plug removed from

the outlet.

• Check if the hot water appliance used for supplementary heating is compatible

with solar hot water systems.

Liability

• This manual was written with the utmost care. However, the installer is

responsible for the quality of the installation work. Solior shall not be held liable

for any omission or mistake in this manual.

Conformity

• This solar hot water system is compatible with drinking water systems (to EN

806-1).

• The electrical components comply with EN 60335-1 and EN 60335-2-21.

• The system has been tested to EN12975-2/EN12976-2.


3 Check this f irst

Before installing the unit it’s important to consider a number of issues.

• Weight

When installing the Solior unit you have to consider the weight of the filled unit,

which is 210 kg. The weight of the unit including the maximum snow load is 400

kg.

• Piping

To ensure that hot water is supplied with minimum delays it is advisable to

minimise the length of the piping between the unit and the draw off point. Solior

recommends that hot water draw off pipes have a minimum diameter of 15 mm,

this also depends on the pipe resistance and water pressure.

• Roof penetration

After completion of the installation there should not be an open connection

between the dwelling and the exterior. Use glass wool, mineral wool or an

equivalent product and seal any holes with appropriate materials.

• Electrical supply

The Solior SL150 requires a 230 V supply.

• Drain connection

When the solar hot water system heats up some water will be discharged from

the relief valve integrated in the inlet combination valve. If the Solior SL150 is

combined with a condensing hot water appliance then this will also drain some

condensate. It is essential that the Solior's inlet combination valve and the hot

water appliance have unrestricted drain connections. Ensure that the water is

discharged to the sewer as required.

Scope of supply

Note:

• If possible, keep the box indoors and with the marked side up.

• The box is specially designed for the safe and convenient handling and transport

of the Solior unit.

Keep the Solior unit in the box until you have reached the place where it is to be

installed.

8

The Solior FL150 system is packed in a box which contains:

• the Solior FL150 system;

• the fully assembled protective system;

• 2 electrical junction boxes;

• 1 support frame;

• 4 feet;

• 4 screws, 2 bolts, 2 nuts and 2 washers;

• insulating sleeve, aluminium cover plate and cable tie.

Required materials which are not included:

• Pipes to connect Solior FL150 installed on the roof to the protective system

installed inside the dwelling, and to connect the protective system to the hot

water appliance;

• Pipe insulation;

• Pipes and fittings to connect the protective system to the drain;

• Four-conductor 230 VAC electrical cable (green/yellow, brown, blue and black

conductors) to connect the Solior FL150 installed on the roof to the protective

system;

• Adhesive for the feet; silicone caulk is compatible with most roofing materials.

9

4 Instal lation instructions

Step 1: Select the most appropriate place for the Solior FL150 on the roof and make a

hole in the roof (roof penetration).

Step 2: Install the Solior FL150 on the roof.

Step 3: Install the protective system indoors.

Step 4: Install the piping between the protective system and the Solior FL150

Step 5: Install the electrical cable between the system on the roof and the protective

system.

Step 6: Install the piping between the protective system and the hot water appliance.

Commissioning

Step 7: Fill the tank

Step 8: Put the mains plug into an electrical outlet

Step 9: Starting-up

10

Step 1: Select the most appropriate place for the Solior FL150 on

the roof and install the roof penetration

1. Select the most appropriate place for the Solior FL150. The figure shows the outline

of the feet of the Solior system (to within a few centimetres), measured from the

pipe couplings (all dimensions in millimetres).

Figure 1

Note:

To find the best place for the Solior on the roof:

• The installer should determine if the Solior FL150 might be too heavy for the roof

where system is installed (see Solior FL150 specifications).

Roof penetration to be made

under the Solior

11

• The Solior FL150 should be installed on the roof such that dome is aligned with the

south (indicated by the arrow). A minor misalignment is acceptable, as long as the

unit is installed between south west and south east.

• The location should have a minimum of shading by other buildings or trees,

throughout the day and throughout the year. Bear in mind that the sun is much

lower in the sky in winter.

• The piping between the Solior FL150 and hot water appliance used for

supplementary heating should be as short as possible. The shorter the pipes are, the

higher the output will be.

• If a roof penetration is used then you should determine the best position for the

pipes to enter the dwelling, as the roof penetration should be installed directly

below the pipe couplings.

• The system should be installed towards the centre of the roof, where the wind load

is lower than at the edge.

2. Cut a hole in the roof. The hole should have a diameter of at least 120 mm to

accommodate the pipes and their insulation (see Figure 2; see also Section 7A

"Roof penetration").

3. Fix the roof flashing (usually aluminium) on the roof, aligned with hole in the roof.

Note:

The roof flashing should be carefully bonded to the roof to get a durable and waterproof

joint. As the roof flashing is a standard component (widely used for flues) it is a routine

job, but should be undertaken by a qualified roofer.

12

Figure 2

Part Description Part Description

A 4-core cable G Junction box

B Solior solar hot water system H Fill with PUR foam

C Cable tie I Roof

D Aluminium cover plate J Roof flashing

E Pipe (15*13) K Pipe (15*13 or 22*20)

F Standard pipe insulation L Insulating sleeve

Alternative installation options

In areas which are guaranteed frost-free the pipes need not be taken directly into the

building but can run some distance across the roof. In that case the roof penetration

may not be required.

13

Step 2: Install the Solior FL150 on the roof

Figure 3

Part Description Quantity Part Description Quantity

A Solior solar hot water

system

1 G feet 4

B Nut 2 H Protective system 1

C Washers 2 I Junction box 2

D Support frame 1 J Caulk

E Bolt 2 K Roof flashing

F Screw 4

1. After installing the roof penetration, install two pipes with 1/2" and 3/4" external

(male) threads through the penetration and fix them temporarily with self-adhesive

tape.

2. Bring the Solior FL150 onto the roof. Open the box and take the components out. The

Solior FL150 may only be laid down on the back (black side), not on the clear front or

sides.

Note:

It may be possible to carry the box up the stairs, or it may have to be lifted onto the

roof by crane. In either case, it is advisable to leave the system in the box to prevent

damage. The box is specially designed for this.

14

3. Install the tubular support frame and the four feet. The tubular support frame fits

onto the pins on the rear frame of the unit (Figure 4).

The four feet fit onto the two ends of the tubular frame and the two tubes at the

front of the steel frame (all four feet are identical).

4. Position the Solior FL150 with the pipe couplings directly over the roof flashing.

5. The four feet need to be secured with one screw each, and there are also two sets of

nuts and bolts for securing the tubular frame.

Figure 4

6. Put some caulk under the four feet to ensure that the system does not slide across

the roof, silicone caulk is likely to be suitable.

Figure 5

15

7. Connect the pipes, use Teflon tape or another sealant suitable for temperatures up to

120oC.

8. Feed the electrical cable through the roof, into the building.

9. From inside the building, slide the pipe insulation across the pipes, to within a few

centimetres of the couplings. The special insulating sleeve and aluminium cover plate

are installed after filling the system with water and testing it for leaks (Step 7).

Note:

• If the tank of Solior FL150 is empty, the couplings can reach temperatures over

100oC. This means that you should avoid touching them when installing the unit.

Alternatively, you can cover the dome with a tarpaulin to reduce the

temperature.

• In most cases the Solior FL150 can be placed on the roof without the need for

mechanical fixing to the roof. The weight of the filled system (210 kg) and the

caulk under feet (to stop it sliding across a slippery roof) are normally enough to

keep it in place. However, in areas where extreme storms occur, the unit will

need to be mechanically fixed to the roof. The Solior FL150 can be fixed to the

roof by screwing through the feet. Please ensure that this does not result in

leaks through the roofing.

• The feet have rounded edges to prevent damage to the roofing.

This design is suitable for most common roofing materials, including insulating

slabs covered with plastic or bitumen roofing.

• Please note that the tubular frame and the tubes at the front have sharp edges.

To prevent damage to the roofing the system should not be placed on the roof

without the feet.

• The transparent cover should not be removed as this will reduce the efficiency of

the optical surfaces.

• The inlet connection has an internal (female) thread of 3/4" and the flow

(outlet) connection an internal thread of 1/2". The different sizes are used to

clearly indicate the inlet and outlet.

• The roof penetration should meet the following requirements:

o It should prevent the ingress of water and snow.

o It should provide a vapour seal, inside the building.

o The pipes should be insulated and the ambient air should not flow along

the pipes (see also the section 7 "Roof penetration").

16

Step 3: Install the protective system indoors

For the installation diagram see Chapter 7 “Piping diagram 1”.

1. Fix the protective system on a wall,

• near the hot water appliance used for supplementary heating;

• near a mains outlet;

• near a connection to the sewer;

• between the Solior FL150 and the hot water appliance (where possible).

Figure 5

Note:

The protective system may be installed in any orientation, as long as the drain

connection points downward (this connection can be rotated a full turn) and the thin

hose from the solenoid-operated valve also drains into the sewer connection. The dial of

the temperature gauge should be clearly visible. It can be rotated after loosening the

small screw.


A Temperature gauge H Inlet combination valve (green knob)

B Temperature adjustment I Check valve

C Thermostatic mixer valve J Adjusting screw

D Junction box W1 To hot water appliance

E Solenoid-operated valve W2 Cold water inlet

F Mains plug (230 V) W3 To the solar hot water system on the roof

G Drain to sewer W4 From the solar hot water system on the roof

17

Alternative installation options

• In areas where there is never any frost, the protective system may be installed

outdoors but will need protection against heavy rain, such as a cover or cabinet. It

will also need to be protected against freezing. • If the hot water appliance used for supplementary heating can accept a cold water

inlet temperature of 85 oC and it is an instantaneous (flow-through) unit, then you

have the option of installing the hot water appliance between the Solior FL150 and

the thermostatic mixer valve (see section 7, Piping diagram 3).

This has the following advantage: If the hot water appliance is an instantaneous unit

then the temperature of the water leaving it may vary by a few degrees as the unit

cycles on and off. The temperature swings will largely be suppressed by the

thermostatic mixer valve. Hot water appliances with a storage tank (hot water

cylinder) do not suffer from these temperature swings.

• An expansion vessel may be installed in the circuit to reduce the volume of water

drained due to expansion (see section 7 Piping diagram 2). As the water in the

Solior FL150 heats up it will expand. Normally this expansion will be drained by the

relief valve in the inlet combination valve (H). This is perfectly normal, and affects

most hot water appliances with a hot water cylinder. The volume of water drained

can be reduced significantly by including an expansion vessel in the circuit. The

expansion vessel should have a capacity of 4 to 5 l. The expansion vessel should be

certified for use in drinking water systems.

• In some countries it is recommended to install an additional thermostat close to the

hot water cylinder of the solar hot water unit. This thermostat disables the hot water

appliance used for supplementary heating when the water in the cylinder of the solar

hot water system is hot enough not to need supplementary heating.

This can save energy, especially if the pipe runs are long. The disadvantage is that

the delay time before the hot water reaches the tap will be longer. For the position

of the additional thermostat, see section 7 "Roof penetration", under "Additional

thermostat".

18

Step 4: Install the piping between the protective system and the

Solior FL150 150

1. Determining the pipe diameters. The required pipe diameters depend on the

maximum flow and the length of the pipe runs. The pipes should be suitable for

drinking water systems with temperatures up to 85oC.

Section 7 discusses the hydraulic resistance of the Solior FL150 cylinder and that

of standard 15*13 mm pipe. Generally, in single-family dwellings, with pipe runs

up to 10 m (5 m flow and 5 m return), a 15*13 mm pipe will suffice. If the flow

rate is higher or the pipe work is longer, a larger flow (inlet) pipe may be used,

e.g. 22 mm, to reduce the pressure losses in the system.

2. Install the pipes between the protective system (W3 and W4) and the solar hot

water system on the roof.

Note:

• All pipes need to be adequately fixed.

• Within the building there is no need for pipe insulation.

19

Step 5: Install the electrical cable between the system on the roof

and the protective system

The electrical connection between the Solior FL150 on the roof and the protective

system indoors is made with a 4-core cable (see section 7 "Wiring diagram).

1. Install the electrical junction box close to the protective system and connect the

solenoid-operated valve.

2. Install the second junction box inside the building, next to the roof penetration.

3. Install the 4-core cable between the two junction boxes.

Note:

• Before working on the electrical system, check that the mains plug is removed

from the outlet.

• The four conductors should be connected to the junction box by the Solior and

the junction box by the protective system. The normal colour code for a 4-core

cable is:

• Green/yellow: Earth

• Brown: Live (L)

• Blue: Neutral (N)

• Black: Switched (S)

• If you do not use a standard roof penetration then the junction box may be fixed

to the steel frame of the Solior (look below the black cover on the rear to locate

the steel frame). The junction box may be fixed with a self-drilling screw, or by

drilling a hole and then using a self-tapping screw.

• If the cable runs across the roof and is exposed to the weather then it should be

of a suitable type to resist the effects of the weather.

• The cable may be secured to the cold water pipe.

20

Step 6: Install the piping between the protective system and the

hot water appliance

1. Connect the hot water outlet (W1) of the protective system to the cold water inlet

of the hot water appliance.

2. Connect the cold water inlet (W2) to the cold water supply.

3. Connect the outflow of the relief valve to the drain.

4. Commissioning

Note:

• The hot water appliance used for supplementary heating (electrical

instantaneous heater, electrical hot water cylinder, gas instantaneous heater or

gas hot water cylinder) should be compatible with an inlet temperature of 65oC.

There should be a certificate confirming that the hot water appliance is suitable

for use downstream of a solar hot water system.

• There is a relief valve integrated in inlet combination valve of the protective

system of the Solior FL150, so there is normally no need for an expansion valve

upstream of the hot water appliance. However, such a valve may be required by

local regulations. It is also required if a stop valve is fitted between the

protective system and the hot water appliance.

• The drain connection should be suitable for water at 85oC.

21

Step 7: Fill the tank

1. Fill the tank by opening the main valve and or the stop valve on the inlet

combination valve.

Open a hot water tap inside the building to vent the air from the system.

Once water runs from the tap the tank has been filled.

2 Wait until the water flowing from the hot water tap no longer includes any air

bubbles and then close the tap.

3. Check all the piping on the roof and inside the building for leaks.

4. Install the insulating sleeve between the roof penetration and the pipe couplings.

Slide the pipe insulation upwards so that it butts against the insulating sleeve.

Note:

• Check if the insulating sleeve meets:

• The pipe couplings;

• The top of the lower tray of the Solior unit;

• The pipe insulation, at the bottom.

5. If everything is installed correctly the aluminium cover plate can be fixed around

the insulating sleeve with a cable tie. Fill the gaps between the pipes and the hole

in the roof with insulating foam (e.g. PUR foam), working from inside the building.

22

Step 8: Plug the mains plug into the outlet

1 Once the system is filled with water the mains plug can be plugged into the outlet.

Normally, the solenoid-operated valve of the protective system will remain closed

when the system is plugged in.

2 Where applicable, connect the hot water appliance to the mains and switch it on.

23

Step 9: Starting up

1. Check the operation of the solenoid-operated valve of the protective system by

shorting connections L and S. Repeat this several times to flush any dirt (possibly

introduced during installation) from the valve.

Check that the adjusting screw on the body of the solenoid-operated valve is set

to 0. Turn the adjusting screw to 1, water should now be flow from the valve. Turn

the adjusting screw back to 0.

2. Check if the pressure relief valve of the inlet combination valve operates correctly,

by turning the green knob (see arrows) until some water is flows out.

3. Check if the drain connection leaks.

4. Turn the thermostatic mixer valve (black knob) anticlockwise (towards the W)

until it stops. This selects the maximum temperature of 65oC.

5. Check that the hot water appliance is set to a hot water temperature which is a

few degrees lower than the setting of the protective system of the Solior FL150

(e.g. 60oC). These temperatures may need to be changed, depending on the local

regulations concerning scalding and Legionella.

6. Open a hot water tap and check if the hot water flow rate from system is

sufficient. (Note that the hot water appliance may be fitted with a flow restrictor).

7. Check the operation of the hot water appliance.

24

5 Maintenance

Local regulations

Some countries have mandatory maintenance schedules which should be observed.

Maintenance

The Solior FL150 is practically maintenance-free. However, the proper operation of the

unit should be checked once a year. This is best done on a sunny day (strong solar

radiation) when the water in the system is hot.

• Check if there is any damage to the Solior FL150 and if there is excessive dust

on the dome. Dust can be washed off with water.

• Check if there is any water leaking from the pipes and connections of the

system.

• Check the operation of the solenoid-operated valve of the protective system by

turning the adjusting screw on the brass valve body from 0 to 1. Water should

now drain from the valve. Turn the knob back to 0; the valve should now close.

If the solenoid-operated valve does not operate correctly then it should be

removed for cleaning or replacement (consult your supplier).

• Check if the protective system is still plugged into the mains.

• Check the operation of the system. Open a hot water tap and check if preheated

water flows from the Solior FL150 to the hot water appliance. You can read the

temperature of water out on the temperature gauge of the protective system. If

you turn the black knob of the mixer valve from hot (W) to cold (K) the

temperature should fall.

Then turn the knob back to hot (W).

Cleaning the dome

In most climates there is regular heavy rain which cleans the dome. In some climates

(extremely dry or extremely wet), the dome may be covered by dust or algae, which

reduces its light transmission. As this absorbs some of the light of the sun and reduces

the output, it is recommended to remove this occasionally. In Spain it is recommended

to do this twice per year.

25

Draining system

The system can be drained of water:

1. Shut the cold water supply off;

2. Open a hot water tap in the system to admit air;

3. Open the relief valve of the inlet combination valve by turning the green knob as

indicated by the arrows. The system will take some time to drain as the tank

contains 150 l of water.

Warning • If the system is left on the roof for extended periods without containing water then

it should be securely fixed to the roof.

• The hot water tap should be left open as long as the system is dry.

Condensation

Occasionally, condensation may occur on the internal surface of the dome or on the blue

coating with spectral selectivity.

This is perfectly normal and will disappear when there is more solar radiation.

26

6 Faults and service

a. Faults and trouble-shooting

b. Wind load

c. Decommissioning

A Faults

Fault 1: the Solior FL150 produces no hot water at all, or not enough

• Check that the Solior FL150 was correctly connected. The cold water should

enter the tank through the 3/4" connection (large) and the hot water should

leave the tank through the 1/2" connection (small).

• Check if the protective system was correctly connected (see section 7 "Piping

diagram").

• Check if the dome of the Solior FL150 is cracked.

• Check if the dome of the Solior FL150 is covered by dust or algae.

• Check if the thermostatic mixer valve is operating correctly (you can feel this

with your hand; on a sunny day the Solior FL150 should be producing hot water

and as long as the temperature does not exceed 65oC, the temperature of the

mixed water should be about the same).

• Check if the thermostatic mixer valve is set to the highest temperature (turn it

anticlockwise, towards the W).

• Check if the hot water appliance used for supplementary heating is working

correctly.

• Check if the protective system is working correctly. The solenoid-operated valve

should be closed (and not drain water to the sewer) as long as the temperature

in the Solior FL150 is in the normal range from 10 to 75 oC.

Fault 2: Water drains frequently or constantly from the discharge

• Check if the water is discharged from the solenoid-operated valve or from the

pressure relief valve. During normal operation, water will regularly drain from

the pressure relief valve as this valve will open while the Solior FL150 is warming

up.

• If the Solior FL150 is not warming up (i.e. there is no sun) and water is still

flowing from the pressure relief valve then the mains pressure of the water may

be higher than 8 bar. If this is not the case, then the inlet combination valve will

27

need to be replaced by a qualified installer. The maximum operating pressure of

the system is 8 bar.

• If the water is draining from the solenoid-operated valve then pull the plug out

off the socket. The flow of water should stop. You can operate the solenoid-

operated valve by bridging connections L and S once you have put the plug back

into the outlet. Repeat this a few times to remove any contamination from the

solenoid-operated valve.

• If the water continues to drain even when the plug is pulled, then check if the

adjusting screw of the brass valve body is set to 0.

• If the water continues to drain then the solenoid-operated valve will need to be

replaced by a qualified installer (please refer to the technical specifications of the

Solior FL150).

• If the flow of water stops when the plug is pulled then check if the temperature

of the Solior FL150 is between 10oC and 75oC (you can check this by measuring

the temperature of the water being drained). If the temperature is below 10oC or

above 75oC then the system may well be operating normally. If the temperature

is between these two limits, then check if the electrical wiring is correctly

connected (see Section 9 "Wiring diagram"). If the wiring is correct, then the

bimetal thermostats in the Solior FL150 and the resistor need to be checked and

may require replacement. Please consult the supplier for further information.

28

B Wind load

Note:

• It is the responsibility of the installer to check if a freestanding Solior FL150 unit

meets the local regulations.

• If the tank of the Solior FL150 is left empty for any length of time then the

system will have to be fixed to the roof.

The Solior FL150 is suitable for freestanding installation on a roof in areas with an

average wind pressure below 0.7 kN/m2 (equivalent to a wind speed vm of

approximately 33 m/s). The system should be installed towards the centre of the roof,

and not at the edge where the wind load is higher.

The regulations are different for each country, so Solior cannot provide information

about this. Generally speaking, the system does not require mechanical fixing to the

roof, except in areas affected by violent storms.

C Decommissioning

The Solior FL150 is designed for easy disassembly and recycling of its components.

Some parts are actually made of recycled material: the black HDPE base (up to 100%),

the steel components (up to 50%) and the aluminium components (up to 60%).

Note:

• Remove the mains plug from the outlet before decommissioning the Solior

FL150.

• Drain the tank before decommissioning the Solior FL150.

• Observe the relevant safety measures when working on the roof.

The solar hot water system can easily be disassembled by removing all the screws and

bolts. Practically all components can be recycled; hardly any components are made of

mixed materials. The only mixed material components are the feet which are made of

glass fibre reinforced nylon. This material can be reused as a structural filler.

29

7 Operation and technical details

A Operation of the unit and electrical connection

B Drawings

C Technical details

A Operation of the Solior and electrical connection

Hydraulic (flow) resistance of the Solior FL150 tank

Graph 1

0.00

0.50

1.00

1.50

2.00

2.50

0 5 10 15 20 25 30

Flow rate [litre/minute]

Flo

w r

es

ista

nc

e [

m w

ate

rco

lum

n]

30

Hydraulic resistance of a 15*13 mm pipe (per metre of pipe)

• Remember to add the flow resistance of bends and fittings used in the circuit.

0.00

0.20

0.40

0.60

0.80

1.00

0 5 10 15 20 25 30

Flow rate [litre/minute]

Flo

w r

esis

tan

ce

per

m p

ipe

[m

wate

rco

lum

n]

Graph 2

31

B Drawings

External dimensions (in mm)

32

Piping diagram

1: Standard system

2: System with expansion vessel

3: System with the hot water appliance installed between the tank (hot water cylinder)

and the protective system


A Cold water inlet F Hot water appliance

B To hot water appliance* W1 To hot water appliance*

C Protective system W2 Cold water inlet

D Solar hot water system W3 To solar hot water system

E Expansion vessel W4 From solar hot water system

*Except when using piping diagram 3

33

Wiring diagram (230 V)


A Bottom of the tank G Mains plug

B Top of the tank H Solenoid-operated valve

C Cold sensor L Live = brown

D Hot sensor S Switched = black

E Resistor, 15 kOhm N Neutral = blue

F Junction box Earth = green/yellow

34

Roof penetration


A 4-core cable H Fill with PUR foam

B Solar hot water system I Roof

C Cable tie J Roof flashing, approx. 150 mm high

D Aluminium cover plate K Pipe (15*13 or 22*20)

E Pipe (15*13) L Insulating sleeve

F Standard pipe insulation M Position of the additional thermostat, if

used

G Junction box

35

C Technical details • Collector (aperture) area: 1.85 m2

• External dimensions (length, width, height): 1962*1282*527 mm

• Mass, empty: 60 kg • Mass, full: 210 kg

• Capacity of the hot water tank: 150 l

• Maximum water pressure: 8 bar

• Test pressure of the tank: 8 bar

• Maximum temperature, full: 85oC

• Maximum temperature, empty: 200oC

• Cold water connection: ¾” internal

• Hot water connection: ½” internal

• Tank: stainless steel

(+ 50% recycled)

• Mirror: Miro 27 on aluminium

substrate (60% recycled

aluminium)

• Selective spectral absorption layer: Mirotherm on aluminium

(60% recycled aluminium)

• Absorption 94%

• Infrared emission 5%

• Dome: PMMA

• Convection suppressor: PC

• Lower shell: HDPE

(up to 100% recycled)

• Optical efficiency 72%

• Frame and support: galvanised steel

(+ 50% recycled)

• Pressure on the roof (inc. maximum snow load): 0.03 N/mm2

• Mass on the roof (inc. maximum snow load): 400 kg

• Average annual heat loss factor (aperture area) 2 W/m2 K

• Overheating protection: water is discharged when a temperature of 85oC is reached

and the hot water pipe is fitted with a thermostatic mixer valve.

• Frost protection: when the pipes pass straight through the roof (installation in

colder climates): frost protection of the inlet and outlet pipes by heat transferred

from the building and by discharging some water if the temperature of the outlet

pipe falls below 3oC.

• Frost protection: of the pipes are installed on the roof (installation in warmer

climates):

frost protection of the inlet and outlet pipes by electrical tracing (heater tape) and by discharging some water if the temperature of the outlet pipe falls below 3oC.

• The water in the tank will never freeze completely in western and southern Europe.

The tank will only reach the freezing point during extreme winters and the tank is

protected by discharging some water if the temperature falls below 3oC.

• The temperature resistance of the system was tested with an empty tank at a

maximum insolation of 1113 W/m2 during 1 hour over a total period of 24 days (to

EN 12975-2 section 5.4).

• Electrical connection: 230 V (AC)

• Maximum electrical power consumption when the

overheating protection operates: 15 W

36

• Maximum electrical power consumption when the frost

protection operates: 15 W

• Average annual electrical power consumption: < 1 kWh

• Minimum permissible ambient temperature: -30oC

• Maximum snow load (Sk, flat roof, FL model) 1000 N/m2

• Maximum wind load, freestanding (vm, flat roof, FL model): 33 m/s (wind pressure

0.7 kN/m2), when filled with water. If the system is drained for longer periods then it

should be fixed to the roof.

• The volume of water drained due to overheating and frost protection is approximately 100 l/year

(assuming three weeks summer holidays, southern and western Europe).

• Average overnight drop in temperature of the water in the tank 3oC (western Europe)

to 4oC (southern Europe).

• The system should be connected to the cold water supply and hot water appliance

used for supplementary heating using the pre-assembled protective system which

includes the following components:

o relief valve (Pentec UBIC).

o check valve (Pentec UBIC).

o stop valve (Pentec UBIC).

o thermostatic mixer valve (DUCO).

o solenoid-operated (230 VAC) drain valve for frost and overheating protection (ASCO

valve, consult Solior for the type).

o temperature gauge (Pentec).

o electrical junction box, IP54.

o mains plug for connection to 230 VAC mains.

System output to EN 12976-2

Qd = hot water demand Ql = system output Fsol = solar fraction of the system (Ql/Qd)

Stockholm Davos

Demand

Qd

(MJ/year)

Ql (MJ/

year)

Fsol

(%) Demand

Qd

(MJ/year)

Ql (MJ/

year)

Fsol

(%)

80 l/day 4478 2305 51.5 80 l/day 4857 3658 75.3

110 l/day 6150 2810 45.7 110 l/day 6654 4415 66.4

140 l/day 7821 3081 39.4 140 l/day 8483 4762 56.1

170 l/day 9492 3185 33.6 170 l/day 10281 4857 47.2

200 l/day 11164 3217 28.8 200 l/day 12110 4920 40.6

Würzburg Athens

Demand

Qd

(MJ/year)

Ql (MJ/

year)

Fsol

(%) Demand

Qd

(MJ/year)

Ql (MJ/

year)

Fsol

(%)

80 l/day 4289 2044 47.7 80 l/day 3343 2460 73.6

110 l/day 5897 2463 41.8 110 l/day 4573 3094 67.7

140 l/day 7506 2640 35.2 140 l/day 5834 3564 61.1

170 l/day 9114 2693 29.5 170 l/day 7064 3847 54.5

200 l/day 10691 2725 25.5 200 l/day 8326 3974 47.7

37

8 Notes

duco installation manual soliorfl150 english

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