Please read these instructions before installing or commissioning. Potterton Solar - Solar Thermal Domestic Hot Water System should only be installed by a competent person. Please leave these instructions with the user for safe keeping. Installation Guide Potterton Solar - Solar Thermal Domestic Hot Water System © Baxi Heating UK Ltd 2007.
Index 2 Index 3 Introduction to Solar 4 Solar collector specifications 5 Hydraulic station specifications 6 Differential temperature controller specifications 7 Ancillary components Expansion vessel Solar heat transfer fluid Thermostatic blending valve 8 Cylinder specifications Unvented Cistern-fed vented 10 General Safety information 12 Installation of collector panel sensor 13 Installation of hydraulic station Parts list Identification of components Pipework installation Positioning Installation
Introduction to Solar Thank you for purchasing a high quality Potterton Solar Solar Thermal Domestic Hot Water System. The sun is the ultimate source of most of our renewable energy supplies. Energy from the sun is clean and abundant. There is a widely held opinion that the UK does not have enough sun to make solar systems worthwhile. In fact parts of the UK have annual solar radiation levels equal to 60% of those experienced at the equator.
Fig. 2.1 Flow/return connections 83 1197 Temperature sensor pocket Ø8mm 117 70 1170 Technical data FK8200 “on roof” collector Gross area: Net area: Weight: Absorber capacity: Pressure: Absorption: Emission: Stagnation temp: Glass: 2,02m2 1,84m2 39 kg 1,40 litres 10 bar 95% + _ 2% 5% + _ 2% 184°C (Max) Low-iron solar glass, tempered 3.2mm thick Light transmittance: >90.8% + _ 2% Insulation: 40mm Rockwool with black facing. Heat conductivity 0.045W/mK.
Fig. 3 3.0 3.
Differential temperature controller 4.0 Fig. 4 4.1 Housing Material Technical data 100% recyclable ABS Dimensions L x W x D in mm weight 175 x 134 x 56 ca. 360 g Ingress protection IP40 according to VDE 0470 Electrical values Operating voltage 230/240V ~ 50 Hz Interference grade N according to VDE 0875 Max. conductor cross-section 240V-connections 2.
5.0 Fig. 5 Expansion vessel 5.1 Ø300mm Ancillary components Expansion vessel Membrane expansion tanks for solar primary heating circuit. Manufactured according to the Directive PED 97/23/CE (approved noZ-DDK-MUC-02-396876-04). 3/4” 392mm Butyl membrane suitable for solar primary heating fluid, DIN 4807-3 approval. Maximum working temperature +110°C. Maximum percentage of glycol 50%.
6.0 Fig. 7 Unvented system - schematic diagram 6.0 Cylinder specifications Unvented Nominal capacities 190, 210, 250 and 300 litre. Rating Immersion heater(s) 1 x 3 kW (indirect models), 2 x 3kW (direct models) @ 240V~. Outer casing White plastic coated corrosion proofed steel. Thermal insulation CFC/HCFC-free (ODP zero) flame-retardant expanded polyurethane (50mm thick). GWP 3.1 (Global Warming Potential). Water container Duplex 2304 (Grade 1.4362 EN 10088) stainless steel.
Fig. 8 Vented system - schematic diagram 6.0 6.1 Cylinder specifications Cistern-fed vented Nominal capacities 190, 210, 250 and 300 litre. Rating Immersion heater(s) 1 x 3 kW (indirect models), 2 x 3kW (direct models) @ 240V~. Outer casing White plastic coated corrosion proofed steel. Thermal insulation CFC/HCFC-free (ODP zero) flame-retardant expanded polyurethane (50mm thick). GWP 3.1 (Global Warming Potential). Water container Duplex 2304 (Grade 1.4362 EN 10088) stainless steel.
7.0 7.1 General Safety information In order to reduce the number of deaths and major accidents attributable to work at height, the Health and Safety Executive has introduced comprehensive regulations and guidance that should be followed by all businesses working at height. We consider in the following paragraphs some of the main features of the regulations and guidance.
7.0 General Risk Assessments The HSE has published a number of very useful free publications that advise how to undertake risk assessments. Two of these that you should obtain are: Five Steps to Risk Assessment. A Guide to Risk Assessment Requirements. The five steps outlined in the HSE leaflet are: Step 1: Look for the hazards This will mean looking at the site and identifying significant hazards.
8.0 Fig. 9 Installation of collector panel sensor The Collector panel temperature sensor should be installed in the sensor pocket nearest to the collector array flow. It should be secured in pocket by inserting through the rubber gland provided. All materials used for installing temperature sensors (sensor element, conducting compound, cables, sealing and insulating materials) must be suitably temperature resistant (up to 250°C). NOTE: “On-roof” type panel shown.
9.0 Fig. 10 (Diagrams not to scale) 9.1 Parts list Before commencing the installation check all listed components are contained in the following cartons. 3 1 Installation of hydraulic station Hydraulic Station carton: 1. Hydraulic pump station with insulation incorporating wall mounting bracket. 2 2. Solar differential temperature controller. 4 3. Safety group, comprisingPressure relief valve, pressure gauge and fill & drain valve. 4. 22mm compression fitting (4 off). 5 5. Re Heat sensor.
9.0 Fig. 11 9.2 Installation of hydraulic station Identification of components The main components of the hydraulic station are: 1 3 2 4 6 5 – Two isolating valves (Fig. 11, Item 1 & 2) with integral thermometers which display the solar primary flow and return temperatures. – A safety group (Fig. 11, Item 3, supplied unconnected), which protects the solar primary circuit.The pressure relief valve and pressure gauge are integrated in the safety group.
9.0 Fig. 12 9.3 See Fig. 12 5 4 3 2 Installation of hydraulic station 1 1 2 3 4 5 6 7 8 9 Solar cylinder Collector temperature sensor lead Solar primary flow (from collector) Solar collector panel(s) Solar primary return (to collector) Solar primary flow (to cylinder) Solar primary return (from cylinder) Solar differential temperature controller Cylinder temperature sensor lead 9.4 8 7 6 9 Pipework installation - general The collectors, the hydraulic station and the solar cylinder (Fig.
9.0 Installation of hydraulic station 9.4.2 Venting the pipework Fig. 13 The Potterton Solar hydraulic station the component includes an air collector/separator and bleed point so an automatic air vent is not necessary. Any section of solar pipework that falls and rises again should be fitted with an additional air vent valve to relieve any trapped air which may cause air locking in the system.The automatic air vent and isolating valve used must be compatible with solar primary systems, i.e.
9.0 Fig. 14 Installation of hydraulic station 9.5 Installing the hydraulic station - positioning 9.6 Installing the wall brackets and hydraulic station It is usual to install the hydraulic station and solar differential temperature controller near to the solar cylinder. However this does not have to be the case, the hydraulic station can be installed anywhere convenient on the solar primary pipework although adequate access will be necessary for commissioning and maintenance.
Fig. 16 1 3 9.0 2 4 5 3 1 2 Fig. 18 Return to panel 3 Connecting the solar expansion vessel Mount the solar expansion vessel (Fig 17 Item 1) adjacent to the hydraulic station (Fig 17 Item 2) so that the vessel can be connected to the vessel connection of the safety group (Fig 17 Item 3) using the flexible pipe (Fig 17 Item 4) supplied. (Note: Solar expansion vessel, mounting bracket, self sealing connection and flexible pipe are supplied in the Ancillary Components kit).
10.0 Fig. 20 Hydraulic Station Solar panel sensor Solar differential controller L N E 230V/240V~ Mains supply Pump pre-wired (mounted on hydraulic station) Appliance installation The solar differential temperature controller is designed to be mounted on the front of the hydraulic station. Alternatively it can be removed from the insulation and be wall mounted (see panel below). In the case of wall mounting the pump cable may need to be lengthened.
10.0 Fig. 21 General connection guidelines. WMM PE T1 T2 L N A1 N A2 N A3 N T3 T4 T6 low voltage area Earthed wire Mains supply live conductor Mains supply neutral conductor Switch output to solar pump Neutral wire to solar pump Live switch output 2 Neutral wire switch output 2 Live switch output 3 Neutral wire switch output 3 WMM T1 T2 T3 T4 T5 T6 For switch functions A2 and A3 see Fig. 23 Flow transmitter Temp.- sensor collector 1 Temp.- storage tank 1 Temp.
Fig. 23 T T Tcoll C Collector 10.5 Storage tank For solar gain (energy productivity) measurement it is necessary to fit the flowmeter and collector return sensor as shown in the diagram in Fig. 23.The collector return sensor must be securely attached to the return pipework using the securing tiles supplied and then covered by insulation.
Fig. 24 10.0 Block Wiring Schemes A. Potterton Solar in conjunction with auxiliary heating by boiler 10.6 - no reheat control by solar controller. 3A Fused Supply Boiler Terminal Strip L N E 1 2 3 1 2 3 7 10 1 2 3 L PL N 1 4 2 3 5 6 7 8 9 10 3 3 2 10 1 5 E G/Y BL BR GR OR 1 L N E 1 2 3 2 3 2 2 N G/Y BL Room Stat 9 1 5 4 BR GR OR L 3 2 2 11 12 PE L N A1 N See Fig.
10.0 D. Auxiliary heating by boiler with 3 port mid position valve system - no reheat control by solar controller. 3A Fused Supply Boiler Terminal Strip L N E L 1 2 3 1 2 3 4 8 5 7 1 2 3 PL N 1 1 4 2 3 5 6 7 8 9 3 3 2 10 NOT USED E G/Y BL BR GR 2 3 2 N G/Y L N E 1 2 3 2 11 12 N A1 N 1 3 1 2 E 8 7 6 OR 2 9 7 5 4 BL WH GR OR L See Fig.
All descriptions and illustrations provided in this leaflet have been carefully prepared but we reserve the right to make changes and improvements in our products which may affect the accuracy of the information contained in this leaflet. All goods are sold subject to our standard Conditions of Sale which are available on request. Potterton A Trading Division of Baxi Heating UK Ltd, a division of Baxi Group. Brooks House, Coventry Road,Warwick.
