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RM Solar S Class 10 Instruction Manual

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Instruction Manual
Issue 4
Note: These Instructions Should Be Read Carefully Before
Install, And Before Calling Technical Support.

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Summary of Contents for RM Solar S Class 10

  • Page 1 Instruction Manual Issue 4 Note: These Instructions Should Be Read Carefully Before Install, And Before Calling Technical Support.

  • Page 2: Table Of Contents

    - Page 25 Section 4 - In Roof Frames - Page 34 S Class 20 In Roof Installation - Page 34 S Class 10 In Roof Installation - Page 52 Section 5 - Connections & Components - Page 77 System Piping...

  • Page 3: Introduction

    RM Solar panels are high quality thermal solar panels using selective coating technology to convert light into heat. RM Solar panels should only be fitted by authorised, trained and qualified personnel. They are not intended to be a “do it yourself” product. Panels are also sometimes called “solar collectors”.

  • Page 4: S Class 10 Specification

    S Class 10 Specification RM Solar’s new S Class 10 panel comes in a variety of arrangements, including standard vertical, oversized vertical, and horizontal panels. Technical Information Collector Casing: Material: Aluminium Profile Colour: Brown Back Plate: AlZn 0.5mm Transparent Cover:...

  • Page 5: S Class 20 Specification

    The RM Solar S Class 20 panel is constructed with a single meander system piping without using soldering or welding and is folded into the absorber plate; a single piece tray folded into the frame holding the glazing.

  • Page 6: S Class 20 Pro Specification

    S Class 20 Pro Specification The RM Solar S-Class Pro Panel has been specifically designed to meet the needs of large industrial applications. Suitable for both Commercial Buildings, and Private applications, such as large swimming pool installations. The S-Class Pro panels are also available as a horizontal variant allowing installation on roofs where space is a premium.

  • Page 7: Positioning The Panels

    Positioning the Panels South Facing Roofs Positioning the collectors is important for optimum performance. Collectors should ideally be mounting at an angle of between 30 degrees and 60 degrees on a south facing position that is not shaded by overhanging trees, buildings, or structures. Good results can be obtained by positioning the panels facing anywhere in an arc between south west and south east but due south facing pro- vides optimum performance.

  • Page 8: Piping Schematics For Panels

    Piping Schematics For Panels Typical S Class 10 (Parallel) (Maximum 10 Panels Per Bank) Airvent Stop End Sensor Cable Stop End Typical S Class 20 (Series) (Maximum 3 Panels Per Bank) (Maximum 10m Primary Circuit) Sensor Cable Typical S Class 20 (Parallel) (Maximum 10 Panels Per Bank)

  • Page 9: Section 3 - On Roof Frames

    Primarily suited to slate installs, but will fit most roof types. For installation of this frame please see page 18 Note: It is important to note that the S Class 10 Panel is bigger than the S Class 20 product, so when using on roof products remember to select the correct hole when locating the ‘Z’ rails.
  • Page 10 Roof Space Required This is the roof space approximately required to install the panels on roof in millimeters. 8320 9360 10400...
  • Page 11 On Roof Sharks Fin Before attempting to fit your equipment on the roof please ensure that you have all the equipment required to complete the installation. The table below will tell you what pieces are included in each of the packages. 1 Panel Frame Part...
  • Page 12 The instructions show the installation of a 3 panel kit, be sure to only make the connections, and holes in the roof that you require.
  • Page 13 Exploded View 3 Panel On Roof Tile Frame (Comprising 2 Panel Frame and 1 Extension)
  • Page 14 Search for the rafters at the position of the collector field. Push up or remove tiles on the total length of the collector field. Using the wood screws provided mount the support pipe using the pipe brackets. The distance between the lower batten and pipe centre should be 90mm. If more panels are added use the extension bolts to join the pipes.
  • Page 15 Screw the align screw [9] in the centre hole of the shark bracket. Now use the U-Bolt Bracket [6], washer [7], and nut [8] to fix the hooks to the pipes. Choose so that the brackets are placed under the centre of the panel. Note: The outside Sharks fin should not be more than 500mm from the outer panel edge.
  • Page 16 Use screw kit M6 x 16 [15] to connect L-Rails [10] to the Sharks Fin. The end with the most predrilled holes goes to the top of the roof frame.
  • Page 17 Screw the Z-Rail [11] [12] to the L-Rail [10] using two screws M6 and two washers [16] on each connection. Maximum Distance from sharks fin to the end of the Z-Rail must not be more than 500mm! If more than 2 panels are to be mounted use the frame connector as shown in fig. C. Before screws are tightened be sure that a cross measurement has been made.
  • Page 18 Place the panels in the correct position. In case of systems with more than two panels, mount the panels starting in the middle. Do not forget to secure the panels together with any straight connectors required (supplied in panel extension set) Mount the wind clamps [14] and connect the panels.
  • Page 19 On Roof Slate Bolt Before attempting to fit your equipment on the roof please ensure that you have all the equipment required to complete the installation. The table below will tell you what pieces are included in each of the packages. 1 Panel Frame Part...
  • Page 20 The instructions show the installation of a 3 panel kit, be sure to only make the connections, and holes in the roof that you require.
  • Page 21 Exploded View 3 Panel On Roof Tile Frame (Comprising 2 Panel Frame and 1 Extension)
  • Page 22 Locate the rafters under the slates. Mark the slates where the holes should be drilled so that the hole penetrates the centre of a rafter. Use the angle rail as a template. Note: The distance from the slate bolt to the end of the Z-Rail should not be more than 500mm on each side.
  • Page 23 Drill the holes on each marked position with a high quality 25mm masonry bit. Make sure the drill does not spin too fast or you may break the tile / slate. Do not penetrate beyond the tile / slate. After drilling the holes into the slates, use an 8mm wood bit to make a hole through the rafters at each position.
  • Page 24 Use the bolt kit M10 to connect the L-Rails to the self sealing bolt fitting. Note: The L-Rails must be mounted into the long adjustable slot.
  • Page 25 The Z-Rails have to be screwed on to the L-Rails using the M6 screws. Maximum distance from slate bolt to the end of the Z-Rail must not be more than 500mm max. 500 mm...

  • Page 26: A Frame Installation

    A Frame Installation Before attempting to fit your equipment on the roof please ensure that you have all the equipment required to complete the installation. The table below will tell you what pieces are included in each of the packages. Frame 1 Panel Part...
  • Page 27 Exploded View 3 Panel On Roof Tile Frame (Comprising 2 Panel Frame and 1 Extension)
  • Page 28 To protect the panels from getting affected by strong winds they have to be screwed tightly to the rood structure. If this is not possible, each panel must be attached to a minimum weight of 220kg/ panel. This can be done in two ways: 1.
  • Page 29 Screw the rails 1, 2, and 3 together using 6mm screws (9). The bottom rail has holes for ground or roof fixing. The holes for wall fixing have to be drilled on site.
  • Page 30 Mount the Z profile, the distance between the last triangle and the end of the Z rail must not be more than 500mm. Pay attention that the triangles are aligned to each other. Use a string to check this, the Z rails must be mounted without any tension. Check cross measurements (A=B). Mount frame connectors if required.
  • Page 31 Drill holes 8.5mm on the appropriate place of the back rails. Use the cross rail (D) as a template. Attach cross rail (D), using screws (12), washers (10) and nuts (13), to the back rail of the frame.
  • Page 32 Mount the panels starting in the middle, mount the wind clamp (8) using screw (9) to the top and bottom of the panel. 4 Wind clamps must be used per horizontal panel.
  • Page 33 Proceed with the next panel. Place extension kit on connection before you place the panel. Make the panel connections.
  • Page 34 Place the panels in the correct position. In case of systems with more than two panels, mount the panels starting in the middle. Do not forget to secure the panels together with any straight connectors required (supplied in panel extension set) Mount the wind clamps [14] and connect the panels.

  • Page 35: Section 4 - In Roof Frames

    In Roof Frames - S Class 20 The In roof frames from RM Solar come in the following two styles, choosing the correct frame for your installation is paramount to an effective install. Minimum roof pitch for installation is 28...
  • Page 36 Preparation The following is the area space required by a set of in roof panels, please ensure you have this area available to you before attempting installation of your equipment. 254 0m m 358 0m m 462 0m m 566 0m m 566 0m m 670 0m m 774 0m m...
  • Page 38 Important When unpacking the in-roof frame package please check if any pieces are missing using the list below. The pack should contain the following pieces: Item Single Frame Extension Angle Bracket Lower Wooden Slat Bottom L/H Flashing Bottom Center Flashing Bottom R/H Flashing 7/14 Seal Strip 20x20...
  • Page 39 Installation Remove the tiles / slates required for installation: 2 Panel Flashing Set = 260 x 260 110cm for every further panel in the same row Attach the lower support batten, screw the lower support batten to the rafter along where the collectors are going to be placed.
  • Page 40 Mount Angle Brackets Mount angle brackets (1) in equal distance with each 4 screws 4x30 (23) to the support batten. With more than 2 collectors, mount first and last angle bracket. Now use a string to level the rest of the brackets by stretching it from one to the other.
  • Page 41 Mounting Lower Flashings Starting from left side, screw lower left flashing (3) at left end to lower slat (2) with screws 4x30 (23). Mount rest of lower flashing (4/5/6) continuing left to right, push flashing together and fit with screw (23) to lower wooden slat (2) where the overlap and on right end.
  • Page 42 Mounting Upper Wooden Wedge The upper wooden wedge (no in set incl.) has to be mounted so that the distance between the lower wooden slat and the top angled timber wedge is 1950mm. The top angled timber wedge must sit on at least two battens.
  • Page 43 Place and Align Collectors Distance A = 10cm, Distance B = 10cm Place 2 high load support brackets (8) under each collector side.
  • Page 44 Mounting Top Angled Timber Wedge Place top timber wedge (9) under each collector, align them and secure each with 2 screws 5x110 (24). Connect collector connections as shown in the collector installation manual. Make sure to do a quick A = B measurements on the panels to ensure they are square. NOTE: Pressure test the panels and insert temperature sensor into R/H panel.
  • Page 45 Stick Side Seal Strip To Collector Stick side seal strip to the collector sides as shown. You should when applying keep to the external edge of that panel.
  • Page 46 Mount Center Flashings Place center flashing (11) on the lower collector edge and snap in starting from the bottom to the top. Ensure the flashing snaps in tight, if required adjust the gap on the underside of the flashing. Secure flashing into wooden block (26) using screws supplied (25).
  • Page 47 Mount Side Flashings Push the side flashing (12/13) from the side over the collector edge. Use sealing screws (25) to fix the flashings as shown. Be Careful! Do not bend the flashings. The 8” long slit on the side flashings goes at the bottom of the collectors and allows the flashing to flex onto the roof covering.
  • Page 48 Place Top Seal Strip Stick top seal strip (14) across the total length.
  • Page 49 Wind Protection Rail Place wind protection rail (15) and fix with wood screws 4x30 (23) each 4 times. Note that the buckle must be placed direct over the edge of the wooden wedge (9). Each end of the wind protection rail should overlap the vertical flashings and pin the top of the vertical flashings in place.
  • Page 50 Top Flashings Starting from the left side. Push top corner flashing (16) under the wind protection rail (15), when located correctly you should no be able to lift the leading edge. Fix with wood screw 5x30 (23) on the right joint and with sealing screw (22) from the left side. Continue with parts (17/18/19).
  • Page 51 Nail Straps Fix top flashings (16/17/18/19) with 2 nail strips and side flashing (12/13) with 4 nail strips (20) each. Stick wedge formed seal (21) across the total length. It must be placed so that after replacing the tiles it will be approximately 5cm under the bottom tile edge. NOTE: Seal (21) must be placed at least 10cm down the side flashings (16/19).
  • Page 52 Place Tiles If necessary, cut tiles to make them fit. Please use the diagram as a guide as to where to tile up to. min.
  • Page 53 In Roof Frames - S Class 10 The In roof frames from RM Solar for the S Class 10 Panel only come in one style which is suitable for all roof coverings regardless of whether they are tile or slate. Minimum roof pitch for installation is 28 This style comes complete with the flexible corrugated lead flashing for molding to a rolling tile.
  • Page 54 Preparation The following is the area space required by a set of in roof panels, please ensure you have this area available to you before attempting installation of your equipment. 261 5m m 370 0m m 478 5m m 587 0m m 587 0m m 695 5m m 804 0m m...
  • Page 55 Important When unpacking the in-roof frame package please check if any pieces are missing using the list below. The pack should contain the following pieces: Item Single Frame Extension Small Wood Screws (4x30) Large Wood Screws (5x110) Sealing Screws (4x80) Small Self Tapping Screws Side Seal Strip 4.3m...
  • Page 56 Installation Remove the tiles / slates required for installation: 2 Panel Flashing Set = 270 x 270 110cm for every further panel in the same row...
  • Page 57 Secure Battens Attach 2 battens using (4.5x80 - not supplied) 450mm and 350mm from the top of the batten beneath.
  • Page 58 Mounting The Flashings Starting from the left hand side, place the left hand apron flashing onto the top batton (450mm) and screw into position (just use the top screw holes to secure in place at this point). Note: Please remove the protective plastic coating from the pieces of flashing before it is installed.
  • Page 59 Mounting The Flashings Connect the right hand apron flashing to the left hand apron flashing as illustrated (below) ensuring that they interlock correctly.
  • Page 60 Mounting The Flashings Note: If the system is larger than 1 panel then the apron from the extension kit is placed between the right hand and left hand flashing of the 1 panel flashing frame.
  • Page 61 Mounting The Flashings Slide the colour coded flashings over the galvanized section of the apron, start with the middle sections first (the left hand and right hand corners are always found in the one panel kit box and not on the extension boxes).
  • Page 62 Mounting The Flashings These pieces also interlock.
  • Page 63 Mounting The Flashings When interlocking correctly the colour coded cover flashing will butt up to the galvanized fixing plates at each end.
  • Page 64 Mounting The Flashings Now insert the rest of the fixing screws into the galvanized fixing plates. (approx 100mm from the top). Place the left hand panel into the galvanised fixing plate so it is positioned as shown (below).
  • Page 65 Mounting The Flashings Insert the pipe reinforcers (supplied in the install and extension kits) into the panel connections, also put a capnut and olive on to the connection. Now put the neighboring panel (if 2 or more panels) in place, insert pipe reinforcers, capnuts and olives into the panel connections and join the 2 panels together using 2 x 22mm straight connections supplied.
  • Page 66 Mounting The Flashings At this point measure diagonally across the panels. The two measurements should be the same to ensure the panels are square. A must equal B. Mount the wooden latts supplied down the sides (and middle is using 2 or more panels) of the panels using the 3 x large wood screws supplied (5x110mm).
  • Page 67 Mounting The Flashings The panels can now be piped up and the pipework inserted through the roof felt. The panels should now be pressure tested to 6.5bar using either compressed air or glycol. Note: If using glycol cover the panels for at least an hour before and at all times during the test. The picture shown above assumes the panel doesn’t have an in built stat pocket.
  • Page 68 Mounting The Flashings For every panel there will be 1 x wedge shaped wooden section, this needs to be mounted on 2 battens directly above the panel, and secure in place using 2 x (5x110mm) wood screws.
  • Page 69 Mounting The Flashings Stick the weather seal (supplied on a roll) to the colour coded apron flashing at both corners and up the vertical edges of the panels. (This foam expands to 10mm deep).
  • Page 70 Mounting The Flashings Mount the left hand side flashings starting with the bottom screw, use 1 x small self tapping seal screw (4.5x35mm) at the bottom and 6 x larger sealing screws (4x80mm) up the length, ensure the flashing runs parallel to the panel. Mount the middle vertical flashing (for 2 or more panels) and the right hand side flashings in the same manner.
  • Page 71 Mounting The Flashings Stick the square seal along the top of the panels also over the face of the side and middle vertical flashings.
  • Page 72 Mounting The Flashings Screw the wind retaining rails into place, the angel should run parallel with the edge of the wooden wedge and should lap over the vertical flashings at either side using small wood screws (4x30).
  • Page 73 Mounting The Flashings Starting at the left hand side mount the top flashing ensuring that the leading edge hooks under the wind retaining rail. When located correctly you will not be able to lift the leading edge by hand. Secure in place using 1 x (4x30mm) wood screws (this screw needs to be located as indicated so as not to compromise the water tightness of the flashings.
  • Page 74 Mounting The Flashings The top flashings interlock in the same way the apron flashings interlock, continue from left to right. The clips and galvanized nails are used to secure the side flashings and the top flashings to the battens.
  • Page 75 Mounting The Flashings Stick the triangular seal along the top of the top flashings and down each side by at least 150mm (if required additional seal is available to order through your merchant from RM Solar).
  • Page 76 Mounting The Flashings A small seal screw (4.5x35mm) is used to secure the four corners of the flashings in place, you may need a 3mm HSS drill to pilot these holes.
  • Page 77 Mounting The Flashings The roof covering can now be installed at least to the ridge on the side flashings and to the angle on the top flashings.

  • Page 78: System Piping

    Resistance to pests, such as mice and birds that may eat it • Insulation should be externally sealed to prevent it carrying moisture. RM Solar carry a range of suitable insulation in stock that can be purchashed through your plumbers merchant. Glycol...

  • Page 79: Double Pump Station

    Double Pump Station The double pump station ensures a continuous circulation of the glycol inside the closed solar loop when useful energy is available in the solar panels. The double pump station recommended by RM Solar is constructed so as to be unaffected by the operating temperatures of the loop for many years, however it is always recommended that in order to protect the pump that the cooler glycol returning to the panel passes through the pump.

  • Page 80: Expansion Vessel

    RM Solar solar panels connected within the one solar heating system. Approximately for one collector 6 litres of expansion vessel volume is required. When fitting a system larger than 3 panels RM Solar should be consulted on expansion vessel sizing.

  • Page 81: Section 6 - Filling The System

    Filling The System This guide assumes the use of an RM Solar Filling Pump, no other methods are supported by RM Solar as they can often lead to excess air in the system. Prior To Filling The System Cover the panels 30 minutes before filling the system, and leave covered whilst filling. (If it is not possible to cover the panels, fill the system when there is little solar energy, e.g.
  • Page 82 Please check carefully to see which diagrams apply to the controllers being used. The Stelflow hot water cylinder as supplied by RM Solar is designed to work perfectly in conjunction with any RM Solar controller we supply, when using hot water cylinders other than those supplied by...

  • Page 83: Wiring Diagram

    Energy Cut L N E 1 C 2 9 10 9 10 Br Bl G O Gy 2 Port Valve (Fitted Below Pump) (If not required link 6 & 5 together) SHE-02 Solar Controller Wiring Diagram Energy Cut L N E 1 C 2 9 10 9 10...
  • Page 84 Energy Cut L N E L N E 1 C 2 9 10 9 10 12 13 14 15 16 17 Br Bl G O Gy Br Bl G O Gy 2 Port Valve 2 Port Valve (Fitted Below Pump 1) (Fitted Below Pump 2) (If not required link 4 &...
  • Page 85 2. Open the grub screw beneath the circulating pump fully by turning anti clockwise as far as possible. 3. Set the circulating pump on speed 1, power up the RM Solar Controller and adjust the settings if required. Never run the solar pump dry, doing so will invalidate any pump guarantees.

  • Page 86: Product Guarantees

    Customer completing the registration form available at the RM Solar website within 28 days of installation. • RM Solar being notified of any circumstance giving rise to a claim hereunder within 28 days of such circumstance arising. The Guarantee DOES NOT cover: •...

  • Page 87: Service Record

    Service Record SERVICE 1 SERVICE 2 DATE: DATE: ENGINEER NAME: ENGINEER NAME: COMPANY NAME: COMPANY NAME: TEL NO. TEL NO. COMMENTS: COMMENTS: SIGNATURE: SIGNATURE: SERVICE 3 SERVICE 4 DATE: DATE: ENGINEER NAME: ENGINEER NAME: COMPANY NAME: COMPANY NAME: TEL NO. TEL NO.

This manual is also suitable for:

S class 10 proS class 20

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