CoolSky FK8203 Installation Manual

Flat plate collectors

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FK8203 Flat Plate Collectors

Installation Manual

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Summary of Contents for CoolSky FK8203

Page 1 FK8203 Flat Plate Collectors Installation Manual...
Page 2: Table Of Contents
CoolSky FK8203 Flat Plate Installation Manual TABLE OF CONTENTS Important Safety Information : Solar Thermal Introduction FK8203 Technical Specification Sizing Accessory Components Solar Pumping Station Pump Sizing Solar Expansion Vessels Sizing & Designing your Solar System System Sizing Sizing the Solar Cylinder Pipe Type and Size Stagnation &...
Page 3: Important Safety Information
Important Safety Information :...
Page 4: Solar Thermal Introduction
CoolSky FK8203 Flat Plate Installation Manual Solar Thermal Introduction Introduction The CoolSky FK8203 Flat Plate Collectors are high quality, high performance, European Manufactured Solar Thermal Collectors that are certified under both the European SolarKeymark Certification and the UK Microgeneration Certification Scheme (MCS)
Page 5 Solar Thermal System Key Components CoolSky FK8203 Collectors The CoolSky FK8203 Collector is available in Solar Energy is collected when the sunlight one standard size that offers complete strikes the selective absorber contained inside flexibility and adaptability for various the Collector Housing.
Page 6: Fk8203 Technical Specification
CoolSky FK8203 Flat Plate Installation Manual FK8203 Technical Specification Model : FK8203 Key Features Aperture Area : 1.84 m Housing : Aluminium Frame Gross Area : 2.02 m Aluminium Backing Sheet Weight (Dry) : 35 kg Fluid Capacity : 1.56 litres...
Page 7 Solar Systems, comply with UK 600 mm – Twin or Triple Coil regulations, and are fully compatible with the CoolSky FK8203 Solar Collectors. Options are Nominal Heights : available for both vented and unvented 1050 mm, 1200 mm, 1300 mm systems.
Page 8 CoolSky FK8203 Flat Plate Installation Manual Pressure & Temperature Relief Valve (PTRV) Building Regulations The installation of unvented hot water cylinder The storage tank must be fitted with a PTRV. for domestic applications is regulated under All tanks should be supplied as standard with Building Regulation G3 for England and Wales, an approved valve.
Page 9: Sizing Accessory Components
Sizing Accessory Components The CoolSky Technical Design Team provide a free sizing service to our customers to advise on the recommended Diameter of Pipework, Pump Head, Expansion Vessel Size and Quantity of Fluid that will be required for your installation.
Page 10: Pump Sizing
If the pipe run is very long or there are more CoolSky offer a range of different sizes of than 8 FK8203 Panels in the collector array, a Zilmet Solar Expansion vessels. These should larger pump may be needed. For these...
Page 11 Mounting the Expansion Vessel Expansion Vessel Connection Kit Always mount solar vessels in a vertical CoolSky also provide, as standard, with each position and recognised best practice is to of our standard expansion vessels an connect to the provided connection port on expansion vessel connection kit to connect the pump station.
Page 12 CoolSky FK8203 Flat Plate Installation Manual Avoid mounting the expansion vessel in close proximity to the solar collector where temperatures can reach temperatures approaching 200°C. In cases where this cannot be avoided, it is highly recommended that the expansion vessel be installed in conjunction with a heat protecting ‘intermediate’...
Page 13 = 1.56 Litres per Panel = Number of Collectors The above are based upon a system using the CoolSky FK8203 in Portrait Installation with 20 = Pressure Relief Valve Setting meters of DN16 Flexible S/S Pipework and a = 6 Bar as CoolSky Ltd Standard Heat Exchanger with 2 litre capacity.
Page 14 PRV the Solar Pumping additional corrosion inhibitors for use with the Station and to allow its recovery during regular FK8203 Collectors. The fluid is supplied in 20 maintenance - neatly avoiding the issues of litre drums.
Page 15: Sizing & Designing Your Solar System
West is considered acceptable and complies Collector Orientation with the requirements of BS5918. The FK8203 Collectors can be installed in either a Portrait or a Landscape orientation. For installations where there is not a suitable southerly facing aspect consideration may then be given to installing an East-West System (i.e.
Page 16: System Sizing
CoolSky FK8203 Flat Plate Installation Manual Installation Angle System Sizing The FK8203 Solar Panel must be installed at an angle of between 15-75 from horizontal to Domestic System Sizing ensure optimal heat pipe operation. For For residential domestic water heating optimum summer performance for Domestic applications basic “rules of thumb”...
Page 17: Sizing The Solar Cylinder
Commercial Collector Sizing ~75 litres per Panel Sizing a commercial system usually requires the use of professional modelling software. CoolSky can offer a free technical support and design service to our customers for these applications. The following table gives guidelines to typical...
Page 18: Pipe Type And Size
CoolSky FK8203 Flat Plate Installation Manual Using a smaller capacity tank will lead to the taken into account: flow rate and pressure system reaching maximum temperature drop sooner, which will often result in wasted These two factors are closely related; a higher and/or uncollected energy.
Page 19: Stagnation & Overheating
Pressure Loss with Height Even though a system might be a closed loop CoolSky supply a 1.3 kW air to water heat and pressurized, there is always some dissipation unit designed to dissipate the pressure loss caused by height. This is energy produced by solar collectors.
Page 20 CoolSky FK8203 Flat Plate Installation Manual seasons, or for systems where there is an The unit is a finned fluid to air style unit that irregular or low summer demand, for example, can be used to dissipate heat from the system schools, holiday homes and sports clubs.
Page 21: Connection Of Multiple Panels
Connection of Multiple Panels Hydraulic Connections for Portrait Installations in a Single Row of Collector Panels The CoolSky FK8203 Panel can be connected up to a maximum of 10 in series. When more than 6 panels are connected in series it is...
Page 22 CoolSky FK8203 Flat Plate Installation Manual Hydraulic Connections for Portrait Installations in a Double-Row of Collector Panels Hydraulic Connections for Portrait Installations in a Triple-Row of Collector Panels...
Page 23 Installations in a Single Row with expansion bends or flexible members inserted in the links. When tightening the The FK8203 Collectors can also be installed in union nuts, always balance (counter) the a Landscape (or horizontal) orientation. The torque with a pipe wrench or another spanner hydraulic connection requirements for to prevent damage to the absorber.
Page 24 ~pH 7, replace the heat conducting compound. transfer fluid. All materials used for installing temperature CoolSky can supply an Installer Test Kit for sensors (sensor element, conducting testing the Heat Transfer Fluid antifreeze compound, cables, sealing and insulating content and pH values.
Page 25: Balancing Flow Through Collectors
Balancing Flow through Collectors Wind & Structural Loading When connecting multiple banks of collectors The collectors may only be mounted on in parallel, the flow rate through each bank sufficiently load-bearing roof surfaces and MUST be equal. Otherwise, some collectors substructures.
Page 26 CoolSky FK8203 Flat Plate Installation Manual For flat roof installations, if using concrete Hail Resistance blocks under the feet, connecting the blocks The UK and Ireland are not considered to be together, particularly front and rear, is areas subject to extreme hail conditions.
Page 27 Coastal Regions should comply with the local building regulations and be fitted with the appropriate The FK8203 Collector is manufactured from safety features for over-temperature and over- 6060 Grade Aluminium and has good pressure protection. corrosion properties to salt water, and therefore, installation of the collectors in coastal regions is not normally an issue.
Page 28: Electrical Supply
CoolSky FK8203 Flat Plate Installation Manual Roof Penetration (PRV) – therefore when using these pump stations the maximum allowable pressure is Depending on the location and local codes, 5.5 Bar (or lower as specified by local building there may be various acceptable means of regulations).
Page 29: Health & Safety Considerations
Health & Safety Considerations minimise the distance and consequences should a fall occur Anyone undertaking solar heating installations Under the regulations you are required to should obtain an up-to-date copy of the ensure : relevant UK HSE (Health & Safety Executive) All work at height is properly planned and Regulations and / or the Irish HSA (Health &...
Page 30 CoolSky FK8203 Flat Plate Installation Manual - Safety on the roof is always an important consideration. Avoid roof work if it is raining and ensure that the inside of the manifold does not get wet. Do not let rain enter the pipework of the panels.
Page 31: Installation Guidelines
CoolSky FK8203 Collectors. skin burns. The outer glass surface should not Several of the more common types of become excessively hot.
Page 32: Installing The Collector Panels
Fixing to the Roof within the roof cladding and is protected from rain ingress by a flashing kit that surrounds the All the CoolSky FK8203 Support Frames may panels. be secured to the roof using either Roof Hanger Bolts or Roof Hooks.
Page 33: Collector Attachment Points
Portrait Installation Fixing Points The tables below provide details on the (Observe DIN 1055, Eurocodes or country- recommended attachment points for the specific regulations) installation of the FK8203 Collector in Portrait Orientation...
Page 34 CoolSky FK8203 Flat Plate Installation Manual Landscape Installation Fixing Points Additional mounting structures must be provided in areas with high snow and wind The tables below provide details on the loads! recommended attachment points for the installation of the FK8203 Collector in...
Page 35: Other System Components
Statics - tiled roofs against water penetration caused by wind The collectors may only be mounted on pressure and driving snow. sufficiently load-bearing roof surfaces and substructures. It is imperative that the static Other System Components load bearing capacity of the roof or substructure is checked in terms of local and regional conditions prior to installation of the For a typical domestic installation, due...
Page 36: Collector Installation
Securing to Roof The Standard FK8203 Collector Fitting Kit is suitable for attaching the collector to Tiled, Slate or Metal roofs that consists of Hanger Bolt fittings. An alternative fitting kit consisting of Roof Hooks is also available.
Page 37 The installer should also ensure that a water- tight and durable seal is made using the provided Rubber Seal. In addition, and where appropriate a suitable constructional sealant in accord with the British Standard BS5918 that specifies flexible sealant should conform to BS EN ISO 11600 or BS 6213.
Page 38 CoolSky FK8203 Flat Plate Installation Manual (identified as part 1.7) can also be used to assist with the accurate spacing of subsequent panels that will be added to the array series. The next panel in the series can then be...
Page 39 Proprietary roof flashing tiles are available from CoolSky that are suitable for the pipe and sensor feed-through.
Page 40: Flat Roof Installation
CoolSky upon request. Flat Roof Installation The versatile CoolSky In-Roof Flashing kits allow a collector array of up to 6 x FK8203 Panels in a single series to be installed in-roof. For installations onto Flat Roofs an A-Frame kit for the FK8203 Collectors is also available.
Page 41: Connection To Plumbing
Connection to Plumbing Plumbing Connection Once the frame has been mounted and the collectors attached, the collector array may be connected to the system plumbing. Delayed Commissioning If the collector is to be installed prior to plumbing connection (e.g. on new house), WARNING: high temperature resistant covers (aluminum foil) should be placed over the header inlet and...
Page 42: Insulation
CoolSky FK8203 Flat Plate Installation Manual Insulation Insulate Piping Ensure all piping running to and from the collector array is appropriately insulated with a high quality insulation that complies with local building regulations in terms of its thermal conductivity and thickness required. Heat loss...
Page 43: Commissioning The System
Ensure Expansion Vessel Pressure has been that any accumulation of air in the system can re-set correctly before filling the system. be regularly vented. The standard CoolSky Pumping stations are supplied with a ready- fitted manual air-scoop to allow for further air bleeding of the solar loop if required.
Page 44: Post Installation
CoolSky FK8203 Flat Plate Installation Manual aerated. During this operation it is good practice to momentarily open the Restrictor Cool Tip Flow Valve (3) to ensure any trapped air in this region is cleared. Set Flow Rate through the collector array : 0.75 litre / minute / panel...
Page 45: Maintenance & Repair
Check pH, should be within the range specified by the manufacturer. Periodic inspections by an authorised CoolSky installer is recommended to ensure optimum Use an Anti-Freeze tester to check freeze system operation.
Page 46 CoolSky FK8203 Flat Plate Installation Manual Draining the Collector During system maintenance draining of the collector may be required. If the building is going to be vacant for longer than 45 days at a time, the system must be drained and the collectors covered with a tarpaulin.
Page 47: Maintenance Schedule
Maintenance Schedule It is recommended that as a minimum the following maintenance schedule is followed: Other Components Other parts of the system such as the storage tank and the back-up heating / boiler should be serviced and inspected according to their specific manufacturer’s maintenance guidelines.
Page 48: Troubleshooting Guide
Troubleshooting Guide : Problem Possible Cause Suggested Solution Pump not Temperature Check that sensors are installed correctly : ● coming ON Sensors not - Are they wired to the correct terminal blocks in the solar controller during good working properly - Ensure wires are secure solar radiation conditions...
Page 49 Troubleshooting Guide (continued) : Problem Possible Suggested Solution Cause Poor Solar Increased hot Check if hot water demand from the property has increased which would ● Heating water reduce the % of contribution from the solar collector even with the same Contribution demand level of output...
Page 50 CoolSky FK8203 Flat Plate Installation Manual Troubleshooting Guide (continued) : Problem Possible Suggested Solution Cause Poor Solar Pump Cycling dTMin value set too low ● Heating too Long and Contribution Dissipating T2 Sensor (Bottom Tank) too low in tank and always reading cold water –...
Page 51 Troubleshooting Guide (continued) : Problem Possible Cause Suggested Solution System Air in System Release air from air vent on Pumping Station ● Operation is Piping generating Purge system of air – run on maximum pump speed for a period of ●...
Page 52: Home-Owner Maintenance
CoolSky FK8203 Flat Plate Installation Manual The following basic maintenance or inspection MAY be completed by the HOMEOWNER Home-Owner Maintenance Inspection Cleaning If there is any problem with the system, the In most cases, periodic rain will keep the glass installer will, generally, ask the homeowner to of the panels clean.
Page 53: Decommissioning Instructions
Decommissioning Instructions End of Life Recycling Decommissioning of the Solar System MUST Once the Solar Collector has reached the end only be undertaken by a competent and of its usable life, it can be efficiently recycled. trained person due to the high temperatures Below are the main materials used in the solar (>150 ºC) and high pressures (>...
Page 54 The information provided herein is provided ‘as is’ without warranty or guarantee of any kind. CoolSky Ltd disclaims all warranties and conditions with regard to this information, including all implied warranties and conditions of merchantability, fitness for a particular purpose, title and non-infringement.
Page 55: Glossary Of Terms
Glossary of Terms pressure limit is reached, thus preventing damage to the system components. Temperature Mixing Valve (TMV) Pressure & Temperature Relief Valve (PTRV) A valve installed between the solar water The Pressure & temperature relief valve heating system and the fixtures to combines a pressure relief valve with a automatically mix the hot water with cold temperature sensitive core which will open to...
Page 56: Important Information
CoolSky FK8203 Flat Plate Installation Manual Important Information INTRODUCTION The information contained herein is for guidance only with regard to the safe use and operation of domestic hot water and heating systems. The installer / user should reference the applicable National Standards in force that take precedence over any guidance contained in this document.
Page 57: Risk Assessment
If the installation is not intended for a domestic house and is intended for a commercial or industrial use (e.g. hospital, nursing home, factory, hotel, guest house, leisure centre etc.) then contact CoolSky Ltd Technical Support Office for guidance and advice on correct design solutions...
Page 58: Limit Of Liability
WARRANTY PERIOD The Warranty Periods for Products supplied by CoolSky Ltd is limited to the benefit of any such warranty that is provided to CoolSky Ltd by the manufacturer of the Products. Where, the Manufacturer Warranty differs from that stated herein, the Manufacturer warranty takes precedence.
Page 59 Evidence that the Products were installed in accordance with the applicable Products Installation Manuals and any special written design or installation guidelines by CoolSky Ltd for this project. Evidence that the Products were installed in accordance with all applicable local and national building, plumbing and...
Page 60 Collector Model : FK 8203 N4A SolarKeymark Licence : 011-7S1323 F Collector Model : FK 8203 N4A MCS Certificate No : MCS BBA 0128 CoolSky Ltd, 42 Milecross Road, Newtownards, BT23 4SR, Northern Ireland, U.K. Tel : 028 9182 9470 Email : info@cool-sky.co.uk Web : www.cool-sky.co.uk...