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IDEAL Solar Thermal Installation And Servicing

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INSTALLATION
AND SERVICING
SOLAR THERMAL
For users guide see reverse of book
When replacing any part on this appliance, use only spare parts that you can be
assured conform to the safety and performance specification that we require.
Do not use reconditioned or copy parts that have not been clearly authorised by Ideal.
For the very latest copy of literature for specification and maintenance practices visit our
website www.idealheating.com where you can download the relevant information in PDF format.
February 2012
UIN 207786 A02

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Summary of Contents for IDEAL Solar Thermal

  • Page 1 Do not use reconditioned or copy parts that have not been clearly authorised by Ideal. For the very latest copy of literature for specification and maintenance practices visit our website www.idealheating.com where you can download the relevant information in PDF format.
  • Page 2 Wall mounting Weight 250 g Housing Recyclable, 3 part plastic housing Dimensions L x B x H (mm) 136 x 133 x 37 2 x PT1000 1.5m silicon cable, measuring range up to+ 180 Solar Thermal - Installation and Servicing...

  • Page 3: Table Of Contents

    Kit ......... 36 list of parts ..............60 planning permission ............ 5 pump station ............44, 45 safe Handling ..............5 solar controller ............. 46-53 Water circuit Diagrams ..........6, 7 Ts8001 (in roof) Solar Thermal - Installation and Servicing...

  • Page 4: Cylinders

    The pipe work is filled with a ready-mixed heat transfer fluid Ideal Solar is a range of solar water heating equipment for use containing glycol and water, which is circulated by a pump to the with twin coil storage cylinders only. The solar collectors come as solar coil in the hot water cylinder.

  • Page 5: Planning Permission

    OVERVIEW OF EU STANDARDS The installation of the Ideal solar system must be carried solar systems in general out in accordance with the relevant requirements for safety, current Wiring Regulations, local Building Regulations, Building...

  • Page 6: Water Circuit Diagrams

    Solar Keymark, the EUs quality mark for solar collectors. The collectors are mounted on a fast-to-fit frame and a solar pump station is also supplied to provide all the safety features required for a pressurised circuit. The Ideal Solar Controller EC1 ensures efficient use of the available solar energy at any given time and features several extra functions.
  • Page 7 1b easT WesT solar panel circuiT Solar panels can be located in an East - West orientation. In this configuration single line pump station (Ideal part No. UIN 207072) in addition to the twin line pump station should be employed. Control between the panels located in different orientations can be achieved by specifying the solar controller EC2, (Ideal Part No.
  • Page 8 UV-resistant. Flexible stainless steel hose is available in pre-insulated form using suitable high temperature UV-resistant insulation and a suitable two-core cable for the solar collector sensor. This hose is specifically designed for solar applications. Solar Thermal - Installation and Servicing...
  • Page 9 West application can be installed with a collector on each pitch or additional collector(s) can be fitted on either the East-West roof. For example, a 3 collector array on an East facing roof would be ideal for 4 to 5 occupants where there is a 20 % loss in performance as compared to the ideal South facing 30°...
  • Page 10 Legal guarantee claims can only be made if the supplier’s own antifreeze has been used and maintenance has been carried out correctly. Installation by qualified personnel with absolute adherence to the instructions is a prerequisite for the justification of claims. Solar Thermal - Installation and Servicing...
  • Page 11 Collector Vertical Atachment Collectors Total length points 239cm 361cm 482cm 603cm 724cm Additional mounting structures must be provided in areas with high snow and wind loads! (Observe DIN 1055 or country-specific regulations) •..Atachment points Solar Thermal - Installation and Servicing...

  • Page 12: Installation

    Self-tapping screws 6*60 Cup square bolt 8*25 M8 hex self-securing nut Clamping piece Clamping piece extension Mounting part, top Mounting part extension M8 washer M8*30 hammer-head bolt M8 hex nut Support rail Mounting jig Flat gasket Solar Thermal - Installation and Servicing...
  • Page 13 2. A = 125 - 155cm - Distance between brackets 3. Fasten roof bracket console to rafters with provided self tapping screws 6 x 60 4. Replace roof tile, cut tile to ensure correct fit if necessary. Solar Thermal - Installation and Servicing...
  • Page 14 6. Attach lower mounting rails (6a, 6b) Order: mounting rail - hammer-head bolt - roof bracket - washer - nut 7. Attach upper mounting rail (7a, 7b) Order: mounting rail - hammer-head bolt - roof bracket - washer - nut Solar Thermal - Installation and Servicing...
  • Page 15 Order: mounting rail - clamping piece extension - washer - nut 10. insert the following mounting rails (upper and lower) and attach them using the clamping piece extension Order: mounting rail - clamping piece extension - washer - nut Solar Thermal - Installation and Servicing...
  • Page 16 12. Hang the first collector in the lower mounting rail and adjust (12a + 12b) Note: Distance between collector and end of moutning rails = 45mm. Measurement A = mesurement B. Solar Collector Mounting Rail Solar Thermal - Installation and Servicing...
  • Page 17 14. Attach the second collector (measurement A = measurement B as shown in Figure 12b) Please use the mounting jig (14b) 15. Rotate the clamping piece by 90º and screw it tight using a long socket wrench Solar Thermal - Installation and Servicing...
  • Page 18 18. Attach the mounting part on the upper left and right end of the collector field Order: mounting rail - hammer-head bolt - mounting part - washer - nut 19. Screw the collectors into place. Solar Thermal - Installation and Servicing...
  • Page 19 14 informaTion abouT THe collecTor (Ts 8000) Technical Data Gross area 2,02 Weight (dry) Net ara 1,84 Contents 1, 4 Aperture 1,91 Max. Pressure Solar Thermal - Installation and Servicing...
  • Page 20 / water mixture (40% / 60%) at a thermal conducting temperature of 50ºc Pressure loss curve: ∆p = 0,000128x + 0,022931x Mass flow rate [kg/h] Pressure loss [mbar] 13,7 18,4 23,7 29,7 36,2 43,5 Solar Thermal - Installation and Servicing...

  • Page 21: Installation Of In Roof Collector

    Sealed plumping screw 3,9*13 Wooden wedge Self-trapping screws 6*120 Side piece connector right/left Middle cover right/left or middle Rear corner section right/left or middle Self-trapping screws 4*25 Metal retainer, roofing nail Foam rubber wedge Solar Thermal - Installation and Servicing...
  • Page 22 2a. Attach the installation batten below, self-taping screws 5*60 2b. Measurement A = 80mm for tile sheet metal edging Measurement A = 50mm for shingle and crown tile sheet metal edging 2c. Measurement B = 200mm or tile width + 50mm Solar Thermal - Installation and Servicing...
  • Page 23 5. Fasten the collectors to the attachment bracket, self-tapping screws 5*40. 6. Secure the collectors to the upper attachment bracket, 1 bracket in the centre of each collector glass, self-tapping screws 5*40.If necessary, install upper installation batten, self- tapping screws 5*60. Solar Thermal - Installation and Servicing...
  • Page 24 9. If installing a second row install the installtion batton for the second row of collectors using the provided 5 x 60 self tapping screws. The distance between the upper and lower rows should be 200mm. Solar Thermal - Installation and Servicing...
  • Page 25 11. Slide the front section into the middle. 12. Slide the front corner section to the right. 13. Secure the front section on the required positions (stampings) using sealed plumbing screws 4.5*35. Solar Thermal - Installation and Servicing...
  • Page 26 16. Place the metal wedge in the middle between the collector rows and tighten it on the roof structure using self-tapping screws 6*120. Install the side piece connector on the right and left. Solar Thermal - Installation and Servicing...
  • Page 27 20. Tighten the middle cover strips using two self-drilling sealed plumbing screws and the lateral tin cover strip using one self- drilling sealed plumbing screw 3.9*13. Solar Thermal - Installation and Servicing...
  • Page 28 23. Slide in the middle cover on the right 24. Tighten the left and right middle cover to the side tin cover strip and the collector on the required position using a self-drilling sealed plumbing screw 4.5*35 Solar Thermal - Installation and Servicing...
  • Page 29 4*25 27. Hang the middle rear section in the collector and connect the rear left corner section. Tighten the sheet metal outside of the rein-forcing seam using a self-tapping screw 4*25. Solar Thermal - Installation and Servicing...
  • Page 30 30. Laterally secure the right and left rear corner section to the roof batten using metal retainers and roofing nails 31. Glue the foam rubber wedge on the side and the top (applies to sheet metal edgings for tile roofs only!) Solar Thermal - Installation and Servicing...
  • Page 31 33. Finally, adjust the lead skirting (for sheet metal edging with tile roofs only) to the contour of the tile. 34. Note: When installing the side sections of the plain-tile metal casing, the tiles and metal parts must always be alternately co-vered! Solar Thermal - Installation and Servicing...
  • Page 32 27 informaTion abouT THe collecTor (Ts 8001) Technical Data Gross area 2,52 Weight Net ara 2,32 Contents 1, 7 Aperture 2,28 Max. Pressure 1130 1227 Solar Thermal - Installation and Servicing...
  • Page 33 28 in roof mounTing (Ts 8001) Connecting bend Installation batten Attachment bracket Solar Thermal - Installation and Servicing...
  • Page 34 / water mixture (40% / 60%) at a thermal conducting temperature of 50ºc Pressure loss curve: ∆p = 0,0001579x + 0,0274717x Mass flow rate [kg/h] Pressure loss [mbar] 11,8 16,7 22,5 29,0 36,3 44,3 53,3 Solar Thermal - Installation and Servicing...
  • Page 35 Clamping piece Clamping piece extension Mounting part, top Mounting part extension M8 washer M8*30 hex bolt M8*30 hammer-head bolt M8 hex nut Attachment bracket Base bracket Support bracket Support rail Mounting jig Flat gasket Solar Thermal - Installation and Servicing...

  • Page 36: Installation Of Flat Roof Kit

    (minimum screw depth ≥ 100mm) Order: rubber seal – washer – nut 4. Align the attachment brackets at the same height and fasten Order: nut – washer – attachment bracket – washer – nut Solar Thermal - Installation and Servicing...
  • Page 37 Order: screw – base bracket – support bracket - washer – nut 6b. Screw the base bracket to the attachment bracket on the front (B) Order: screw – attachment bracket – base bracket – washer – nut Solar Thermal - Installation and Servicing...
  • Page 38 - hammer-head bolt - mounting part - washer - nut 8. Attach upper mounting rail as described in Point 7 Warning: Upper and lower mounting rails must be mounted perfectly straight and parallel to one another! Solar Thermal - Installation and Servicing...
  • Page 39 Order: mounting rail – clamping piece extension – washer – 11. Attach the mounting rails (upper and lower) using the base brak-kets Order: support rail – hammer-head bolt – base bracket – washer – nut Solar Thermal - Installation and Servicing...
  • Page 40 Order: upper mounting rail – hammer-head bolt – clamp – washer – nut 14. Attach the second collector. (measurement A = measurement B as shown in Figure 12b) Please use the mounting jig (14b). Solar Thermal - Installation and Servicing...
  • Page 41 15. Rotate the clamping piece by 90° (see figure 13) and screw it tight using a long socket wrench 16. With clashing mounting rails, insert and position the mounting part in the upper mounting rail 17. Attach additional clamping pieces / collectors as described in Points 12–16 Solar Thermal - Installation and Servicing...
  • Page 42 18. Attach the mounting part on the upper left and right end of the collector field Order: mounting rail – hammer-head bolt – mounting part – washer – nut 19. Screw the collectors into place with the proper torque Ideal Solar - Installation and Servicing...
  • Page 43 Especially in regions exposed to frost, for flat plate collectors you should use a mixture of (FS) antifreeze with water (40% antifreeze). The solar thermal system should be filled and commissioned within one week of installation, because heat build- up in the collector (array) can damage the flat gaskets in empty systems. If this is not possible, the flat gaskets should be replaced before commissioning to prevent leakage.

  • Page 44: Pump Station

    (see picture). the close position, as shown here aside. Solar Thermal - Installation and Servicing...
  • Page 45 / pressure gauge assembly The Hydraulic solar pump station in the Ideal solar package is equipped with a 6 bar pressure relief valve which should be connected via 22mm pipe work terminating in a suitable container. An empty canister of heat transfer fluid can be used for this purpose Drain valve It is good practice to install a suitable drain valve at the lowest point in the system to facilitate draining of the solar system if required.

  • Page 46: Solar Controller

    41 iDeal solar conTroller - safeTy insTrucTions 1. Please see that fire safety cable systems and similar systems nominal currents must not be exceeded. If there is a are not impaired. grounded conductor planned or laid down for pump or reversing valve it MUST also be connected.
  • Page 47 43 iDeal solar conTroller - connecTions 1. The cable can be fed through the underside of the controller Warning. THe connecTion WorK DescribeD or back panel of the housing depending on the installation. Here is only possible WHen THe conTroller’s fronT cover is open.
  • Page 48 44 iDeal solar conTroller - opening anD closing THe conTroller 1. The front cover is secured by two holding bars on the top 3. Now, the front cover can be folded down and the push edge of the controller and a screw on the housing.
  • Page 49 46 iDeal solar conTroller - Display overvieW sol8580 Symbols for temperature sensors Display for temperature values and error symbols e.g. short circuit, open circuit or ‘SYS‘ = system error (see Section A ) Holiday function (see section B) Antifreeze function (not applicable see section C) Change-over °C / °F (see section D)
  • Page 50 47 iDeal solar conTroller - operaTing THe conTroller secTion a During normal operation the keys are used to browse through the recorded temperature values. The (T1,T2,T3) sensor symbols in the system diagram, show which measurement value is currently being displayed.
  • Page 51 The vacuum collector function is only applicable for systems using Evacuated tube collector type systems. This is not applicable with the ideal solar system. sol8589 continued ..Solar Thermal -...
  • Page 52 49 iDeal solar conTroller - operaTing THe conTroller continued secTion f Press the ‘SET’ button for 2 seconds to open the settings menu. At first, the current valid maximum storing temperature value is displayed. To illustrate which value is referred to, the ‘max’ indicator in the storage tank symbol and the T2 sensor flash.
  • Page 53 50 iDeal solar conTroller - noTes on TroublesHooTing Warning. before opening THe fronT cover, THe poWer musT be DisconnecTeD from THe Device. The controller was designed to be continually used for several years. Nevertheless, faults may occur. Most of the time, the fault’s cause is not sought in the controller, rather in the peripheral system elements.

  • Page 54: Commissioning Notes

    3. Using a screwdriver esnure the adjustment screw below the pump is in the veritcal position. The Ideal Solar System is supplied with heat transfer fluid and 4. Turn the left gauge thermometer dial anti clockwise by 45° is pre-mixed and ready to use. The heat transfer fluid ensures reliable operation, high vapour reliability and protects against to manually open the non return valve.

  • Page 55: Commissioning The System

    7. The system is now commissioned and available for normal operation. Circulation Pump Adjustment Screw Fill and Drain Valve Flow Measure Display corresponding flow rates for ideal solar collectors (cold) of collectors l/min Solar Thermal - Installation and Servicing...

  • Page 56: 53 Handing Over

    8 and 9 pm. This setting will make •...

  • Page 57: Installation & Maintenance Checklist

    2. Roof tiles replaced and secure 3. For flat roof installation: the supporting frame is secure or weighted Ideal recommend that the above maintenance procedure is 4. Automatic air vent is open with cap in place followed annually, preferably when the boiler and/or cylinder 5.

  • Page 58: Fault Finding

    No LCD display No power supply, check fuse and 230 V LCD says short circuit T1/T2 Check relevant sensor for short circuit LCD says interruption T1/T2 Check relevant sensor for circuit break Solar Thermal - Installation and Servicing...
  • Page 59 Solar Thermal - Installation and Servicing...

  • Page 60: List Of Parts

    When replacing any part on this appliance use only spare parts that you can be assured conform to the safety and performance specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Ideal.
  • Page 61 Double line solar sTaTion single line solar sTaTion sensor Solar Thermal - Installation and Servicing...
  • Page 62 Solar Thermal - Installation and Servicing...
  • Page 63 Solar Thermal - Installation and Servicing...
  • Page 64 & servicing of central heating systems Manufactured under a BS EN ISO 9001: 2000 Quality System accepted by BSI ideal boilers ltd, P.O. Box 103, National Ave, Kingston upon Hull, HU5 4JN. Telephone: 01482 492 251 Fax: 01482 448 858. Registration No. London 322 137.
  • Page 65 When replacing any part on this appliance, use only spare parts that you can be assured conform to the safety and performance specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Ideal.
  • Page 66 “ “ is displayed in the upper right hand LCD display for 5 seconds. Your Ideal Solar EC 1 Controller is now fully automated and will operate correctly. Switch in central position means automatic mode. The backlight display is yellow.
  • Page 67 The Holiday Function is a storage re-cool function. If the user does not use hot water from the solar cylinder over a number of days the storage cylinder may reach its maximum temperature. In this case vaporisation may occur within the Ideal Solar Collector panel which is normal.

  • Page 68: Troubleshooting

    TroublesHooTing If for any reason your Ideal Solar EC 1 Controller does not seem to be operating, check the fault finding chart below before contacting a Solar Qualified Engineer. WARNING. DO NOT OPEN THE HOUSING controller shows no function secondary condition: possible cause: The controller’s display is blank...

This manual is also suitable for:

Ts 8000Ec2Ts 8001Ec1

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