Instruction Manual Issue 2 2
0. Contents General Information Health and Safety Information..................................................................................................Page 4 Important Installer Tips.............................................................................................................Page 5 Working With Panels................................................................................................................Page 5 The RM Solar S Class Panel..........................................
1. Health & Safety Information 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”. When fitting the panels installers should comply with all health and safety regulations and recommendations.
2. Important Installer Tips Always:• Use only solar quality O rings if you are using press fittings. • Do not install the panels upside down; they will only work the right way up. • Use support sleeves (pipes inserts). • Never use plastic pipes for the thermal circuit. • Join copper pipes by brazing, Compression fittings, or Press fittings, not with soft solder. • The glycol is ready mixed; do not add water or any other ingredient.
4.0 The RM Solar S-Class Panel RM Solar S-Class solar panel is a vertically mounted glazed collector with collection pipes, intended for applications in systems equipped with circulating pumps. The RM Solar S-Class 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. The RM Solar S-Class panel is not intended to be used in drain-back systems.
4.1 The RM Solar M-Class Panel The RM Solar M Class 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 M Class panels are also available as a horizontal variant allowing installation on roofs where space is a premium. The RM Solar M-Class panel is not intended to be used in drain-back systems. Technical Information • Floor Space : 2.
4.2 The RM Solar Econ Panel RM Solar’s new Econ range is supplied using the exact same equipment as the S Class and the M Class panels. When fitting the Econ panel please be aware that frame extenders are supplied in order to allow the panel to sit into the existing RM Solar Frame, instructions can be found on the fitting of these extenders in the on roof installation section. Technical Information • Floor Space : 2.01 m2 • Dimensions : 1005 x 2000 mm • Weight empty : 46 kg • Fluid Volume : 2.
5. Positioning the panels 5.1 Generally south facing roofs Positioning the collectors is important for optimum performance. Collectors should ideally be mounted 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 provides optimum performance in the Northern Hemisphere. 5.
5.3 East/West facing roofs Good results can be obtained by splitting the collector array on East/West elevations but this should only be used when it is not possible to have a mainly southerly position for the collectors. If you are installing a split East/West system you have to double the number of the panels, e.g. 2 panels system requires 2 panels on East and 2 panels on West; each set of panels will behave as an independent system. A split system is not suitable for every East/West facing roofs. 5.
6. Frame Mounting RM Solar offers three types of on – roof panel mounting and two types of in – roof panel mounting. On – roof installations • On – roof kit shark tail – suitable for most tiles. • On – roof kit hook – suitable for medium and large tiles. • On – roof kit slate – suitable for slate roofs. In – roof installations • Flashing kit for tile roof. • Flashing kit for slate roof. Flat Roof Installations or ground level installations • The “A” frame 6.
6.1.1 When you unpack the on-roof frame packaging please check if any piece is missing. The package should contain: No.
6.1.2 Check the roof battens for stability. The battens must not show any sign of deterioration. If the battens to be used are smaller than 30 x 50 mm you give them additional strength by adding additional battons (not supplied). 6.1.3 Place the roof hooks (1) as shown using 2 wood screws (4 x 30 mm). Fix the blade (2) under the lower roof batten.
6.1.4 WARNING: In areas of where heavy snowfalls are experienced you should replace each roof tile that covers a roof hook with a metal tile. If you do not do this the roof tile might break under heavy snow loads. 6.1.5 Use screw kit M8 x 20 to connect the L-rails to the roof hooks. BE CAREFUL that the frame rails are mounted with the five holes (8.5 mm) positioned at the highest part of the roof.
6.1.6 The Z-profile must next be fixed on to the L-rails, using the bolt kit M6. The maximum distance from a roof hook to the end of the Z-rail must not be more than 500 mm. If necessary, use an on- roof extension kit, following the same procedure. 6.1.7 Place the panels in position in the centre of the completed frame. In case of systems with more than two panels, mount the middle panel first. Mount the wind clamps to protect the panels using the nuts and bolts provided.
Option to raise the panel pitch 6.1.8 This option may be used to obtain a better incline for the panels than the roof allows. 6.1.9 Here are three different sizes of pitch extension frames: (a) 500 mm which raises the pitch by about 15° (b) 750 mm which raises the pitch by about 21° (c)1000 mm which raises the pitch by about 27° 6.1.11 (1) Remove the adjustable angle from the upper roof hooks. (2) Fit the extension rails on to the upper roof hooks using the nuts and bolts provided.
6.2 On – roof slate mounting kit The slate roof mounting kit is suitable for of slate roofs, concrete roofs, pan tile and in windy areas. It is also suitable for roofs which have the roof tiles cemented permanently on to the roof structure. 6.2.1 When you unpack the slate roof frame packaging please check if any piece is missing. The package should contain: No.
6.2.2 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 roof screw to the end of the Z-rail should not be more than 500 mm on each side.
6.2.3 Drill the holes on each marked position with a high quality 25 mm 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 tile/slates, use an 8 mm wood bit to make a hole through the rafters at each position. Bolt the bottom part of the self sealing bolt fitting into each drilled hole. 6.2.4 Use the bolt kit M6x 6 to connect the L-rails to the self sealing bolt fitting.
6.2.5 The Z-profile must be fitted to the L-rail using the bottom two holes that are below the long adjustable slot. Do not tighten fully. TAKE CARE: Make sure frame connector is fitted into the Z-profile properly if extending the frame to accomodate additonal panels. 6.2.6 Cross measure along the diagonals and check that they are equal. Once you are satisfied that each distance (A and B) on the drawing are equal, tighten fully.
6.2.7 After you place the panels into the frame and connect the panels together using the straight connectors and pipe inserts provided, fit the wind clamps to the frame using the nuts and bolts provided. Option to raise the pitch 6.2.8 There are three different sizes of pitch extension frames: (a) 500 mm which raises the pitch by about 15° (b) 750 mm which raises the pitch by about 21° (c) 1000 mm which raises the pitch by about 27° 6.2.
(3) Fit the L-rail to the top of the extension rail and to the bottom of the right angle connection.
6.3 On – roof shark tail The on – roof shark tail mounting is suitable for thick and thin tiled roofs. 6.3.1 When you unpack the shark tail on-roof frame packaging please check if any piece is missing. The package should contain: No.
6.3.2 Check the battens for stability. The battens must not show any signs of deterioration. Remove sufficient tiles to enable you to fit the shark tail. 6.3.3 Fit the lower fittings first. Screw the support pipe with help of the pipe clamps. The distance between support pipe and nearest batten below should be around 90mm.
6.3.4 Fit the U – bolt on the support pipe and on the top part of the shark tail. The shark tail should be placed no more than 500 mm from the end of the pipe. 6.3.5 Fit the L – rail on to the shark tail. Fit the top sharks tail to the L rail and lower on to roof, the top of the shark tail indicates where you should place the top support pipe.
6.3.6 Fit the support pipe to the top shark tails. The shark tail must be upright. Then fit the shark tails and support pipe together with U-Bolts. 6.3.7 After you placed the L – rails into position, fit the Z – rails on the L – rail. Do not tighten bolts fully. Cross measure along the diagonals and check that they are equal. Once you are satisfied that each diagonal (A and B on the drawing) are equal, tighten fully.
6.3.8 If you are installing more than two panels always install middle panel first. 6.3.9 Do not forget to fit the wind clamps in place. Option to raise the panel pitch 6.3.
6.3.11 (1) Fit the right angle connector on the top of the fitting on the upper side screw extension rails (2) Fit the right angle connector to the top of the fitting on the lower L-rail Note: All Econ installation kits come with the extension brackets and wind clamps to suit the frame type. Please apply as shown below. Frame Extender Secure in place with bolts supplied Original Frame Note: Must be installed at the top of the L - Rail. NOT the bottom of the L - Rail.
6.4 In – roof fittings The standard in roof mounting kit is designed to accommodate ‘S’ & ‘M’ class panel systems and is suitable for most types of roofs. There are two different kits, one for tiled roofs and one for slate roofs. 6.4.1 When you unpack the in-roof frame kit from its packaging, please check if any part is missing.
No.
6.4.2 Determine where the panels will be mounted and check the roof tile alignment. 6.4.3 Remove the tiles/slate from the roof according to the size of system you are fitting. For a two panel installation a tiled/slate area of 2600 x 2600 should be removed. For every additional panel remove a further tiled area of 1100 x 2600. 6.4.4 Attach a lower support batten. Screw the lower support batten to the rafter along where the panels are going to be placed. Use wood screws (4.5 x 80).
6.4.5 Attach the angle irons (1) to the lower support batten at equal distances using 3 screws, 4x30 (20). If more than two panels are to be installed, fit the first and the last angle, tighten a cord between them and place the rest of the angle irons along the cord. 6.4.6 Attach the lower wooden slat (2) with the cut off edge placed toward the panel as shown. Use 4x30 (20) screws. NOTE: The slats in the in – roof installation set are longer than the ones in the extension set.
6.4.7 Fitting of the lower left flashing: Starting from the left side, place the lower left flashing (3) onto the slat and screw it 4x30 (20) at the top left corner as shown. 6.4.8 Continuing from the left to the right side, place the middle flashings (4), (5) onto the slat and interlock with section (3). Place a screw 4x30 (20) on each connection (see below).
6.4.9 Place the upper support wedge so that the distance between the lower slat (2) and the upper wedge (7) is 1950 mm. The upper wedge must be supported by at least two battens (Only use one 110mm screw to hold the wedge in place at this point) 6.4.10 Seal strip: Stick the seal strip (6) along the whole edge of the lower flashing (3) (4) (5). Place the panels and align them. The distance on each side of the field should be 100mm. It is important to check diagonal measurements. A = B.
6.4.11 Panels should be 100mm from the edge of bottom flashing. 6.4.12 Mounting the upper wedge: now secure the upper wedge (7) in place using 6 x 110mm screws (In Total). 6.4.13 Connect the panels together and connect them with pipes (see chapter 5.) and pressure test the system using either compressed air, or the glycol solution NOT water. 6.4.14 Insert the panel temperature sensor (brown wire).
6.4.15. Mount the middle and side wooden rafters. Using 3 x 110mm screws in each 6.4.16. Paste the adhesive backed black strip to the side panel edge and fix the middle flashing kit on the middle wooden rafter using the coloured screws 6.4.17. Next fix the left and right hand edge flashing using the capped coloured screws as shown 37 6.4.18.
6.4.19. Using the nails and clips shown below (1), secure the side flashings to the tile battons by hooking the clips over the outside edge of the flashings and nailing into the batton as shown below (2) 6.4.20. Fix another timber rail (not supplied) across 6.4.21. Paste the adhesive backed the top of the array, 280mm above the bib black strip along the top of flashing support rail fixed earlier. panels and flashing. See figure below. 6.4.22.
6.4.23. Fix the top flashing kit – left part 6.4.24. The middle part of the flashing kit interlocks with the left part 6.4.25. Fix the right part of the top flashing kit. 6.4.26. When you have firmly fixed all flashing the roof tiles/slates can be replaced.
6.5 Flat roof and free standing The A – frame is suitable for any kind of flat roof and it is also is suitable for ground installation. 6.5.1 When you unpack the A-frame kit packaging please check if any piece is missing. The package should contain: No. 1 2 3 4 5 6 No.
6.5.2 Fit together the basic rail, support rail and L-rail using the nuts and bolts provided. You will create triangular structures as shown in the diagram. 6.5.
6.5.4 First option for frame mounting: If it is not possible to screw the A – frame into the roof directly without affecting the integrity and water tightness of the roof structure you must use a special concrete-metal sheet. The A – frame must be fixed to the sheet placed on the roof and the frame and the sheet must be weighed down for security.
6.5.6 If mounting on a flat roof RM Solar recommends consulting with a competent roofing contractor. 6.5.7 Fit the Z – rail on to the triangles as shown below. To extend a two panel kit extension, fit the frame connection (K1141) to the bottom and to the top of Z-rails.
6.5.8 When the Z – rail has been fitted to the triangle, bolt the cross rail on the back of the frame construction. NOTE: Drill Ø 8 mm holes into the support rail as necessary. 6.5.9 WARNING: If the installation is more than 2 collectors, install the middle collector first. 6.5.10 When you have finished building the frame and fitting the panels, do not forget to fit the wind clamps.
6.5.11 If the overall length of the A frame is to be more than 8 metres the frame construction must be secured with another support rail as shown below. 6.5.12 WARNING: In areas with strong wind you must take into account the possibility of wind resistance which may cause the whole frame and panel construction to vibrate. In these cases fit one more support triangles at the end of each side of the A frame as shown. This will make the whole construction stronger.
6.6 Gable/Wall Mounting/Exhibition A Frames This A frame has a steeper incline than the normal A Frame, making it suitable for mounting onto gable ends, wall mounting, and for on roof installation with a shallower incline. Z-Rail Cross bracing should be applied to the bottom of the A-Frame, this is however not supplied in the kit and should be sought seperately.
Joining Exhibition A Frames Together When you have constructed both frames you will connect them together by inserting the frame connector (FIX0302) into the Z-Rail. The frame connector will be inserted approximately 180mm into the Z-Rail at the top and bottom of the frame. There are no pre-drilled holes in these Z-Rails to insert the bolts so you will require a 6.5mm H.S.S. bit to affix them. (Two bolts for each Z-Rail).
7. Panel connections and Pressure Testing 7.1 There are two separate kits; the installation kit is used for connecting the panels to the heat exchange loop and the extension kit is used for connecting one panel to another. 7.2 Before you place the panels on the frame and connect them check the diagonals to make sure the top and bottom rails are square. 7.3 Place the panels in position in the centre of the completed frame.
7.4 7.5 7.6 The panels are connected in series. The inlet (return) is always on the top left side and the outlet (flow) is on the top right side. (S Class Only) Connect the panels together using extension kit Place the panels on the frame. Insert 7.7 the support sleeves into the copper pipe connections. 49 Insert the straight 12 mm compression fitting on the connection pipe.
7.8 Pull up the panels together, so that the connections are exactly opposite each other. Using pair of the spanners tight the compression fitting. 7.9 On both the flow and return connection attach the brass T-piece with air vent (supplied). Lubricate the O-rings with silicon or glycol before tightening airvent connection. 7.10 Connect the brass T-pieces with copper or flexible stainless steel pipe.
7.11 Finally the panels should be secured to the frame using the wind clamps. Position the wind clamps at the top and bottom in the centre of each panel. 7.12 When the panels are connected together and the pipe work is complete the system should be pressure tested to 6 bar using either compressed air or RM Solar glycol, vented, and checked for leaks, and filled with the water/glycol mix. If you are fitting an in roof system, do the pressure test before you fit the top and side flashings.
Piping up the Econ and M Class Panels Return Airvent 1st Row A Panel Panel Panel A Panel Panel Panel 2nd Row if applicable A A Flow A = Stop End 52
8. The 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. 8.
8.6 Flow settings: The flow regulator should be set to 0.5 to 1.0 litre per minute per panel. A three-panel installation is set to a flow rate of 1.5 to 3 litres per minute. How to read the flow setter: 8.7 Pressure settings: The maximum pressure is 6 bar. Once the system is pressurised keep the pressure between 3 – 4 bar. With higher pressure inside the system, the glycol/mix will not evaporate until temperatures of around 120°Celsius are reached.
9. Expansion vessel (also known as expansion tank or pressure vessel) 9.1 Function of the Expansion Vessel An expansion vessel protects the solar system during pressure changes and temperatures fluctuations. For example, in very hot conditions when energy is not being drawn off, the system may overheat causing the glycol to expand. 9.2 Technical information: Maximum pressure: 10 bar Working pressure: 3.0 – 4.0 bar (20°C) Gas pressure: 2.
10. Piping and pipes connections 10.1 Piping The copper heat exchange pipe in RM Solar panels contain glycol, pressurised and heated to temperatures in excess of 170ºC when exposed to direct sunlight where the rays are striking the absorber plate at roughly a right angle. This heating process takes place very quickly. Similar temperatures will be reached in winter, but more slowly due to the lower levels of insolation.
11. Insulation The use of the correct insulation is critical. Normal central heating insulation will melt and become brittle at the very high solar generated temperatures in the system. Insulation materials must endure the highest occurring temperature, which will be more than 170oC near the collector.
13. Filling the system with glycol When the solar heating system is filled with heat exchange liquid (Glycol), the heat transfer medium displaces any air. The correct system charging will ensure that the solar system will run without pressure losses and with high performance. However carefully you fill the system manually, small bubbles of air might be caught in ‘air locks’ inside the pipes and some of these air locks will be from air naturally dissolved in the water part of the glycol solution.
14. The digital controller DC12 The digital controller DC12 is able to control one hydraulic circuit on the solar system for example a hot domestic water system, or a swimming pool heating system or a heating system. It cannot control more than a single circuit, so that it cannot control an installation which heats water and a swimming pool at the same time. The controller has been designed for universal multi-language usage.
1. Operating Modes - The controller can be switched into the three different operating modes (ON,OFF, Manual) - Each operating mode is displayed on the display in the left top corner. • Automatic • Off • Manual How to change the values? When the controller is showing AUTOMATIC press the ENTER button. The sign will start flash and by pressing right/left arrow you can change the operating mode. When you have chosen right operating mode press the ENTER button key (marked with a tick). 2.
What the signs mean: This is the actual temperature at the panels A minimum temp requirement at the panels for system to next switch on This is only a reading - it cannot be adjusted It is minimum set temperature.
Key number: 8-85 - This value allows us to set speed of the double pump station in manual operation. - Manufacturer setting is 0 % and must be changed to 100% (see paragraph ‘How to change the values’).
Remember: After you made any change on the values you must press the ENTER button so controller can take the new settings. When you finished with above settings press the X button until you return to the main display. Your digital controller is now set properly and will control solar heating system correctly and more efficiently. PLEASE NOTE: Read the instruction manual properly. It contains lots of important information, at the back there is a fault finding section.
E 1 2 N N DC12 Solar Controller N N 3 ECO C ECO for Solar 3 4 4 5 5 6 6 7 7 8 8 9 10 9 10 Wiring centre Boiler Primary ECO in Duostat ECO For Solar LowerTank sensor E 2 3 2 1 2 C 1 1 Control 2 E N E C L N E Solar Pump L E Boiler primary duostat 2 Schematic wiring with Solar Controller (1 Hydraulic Circuit) L Lower Tank sensor B1 T B2 T Panel sensor N E Solar circuit Motorised valve If fitted L 64
Commissioning Certificate COLLECTORS Collector type ...………………………… Number of panels ………………………..….. MOUNTING (please tick) Separate modules on roof ……………….…..….. Roof integrated ……………………….................. “A” Frame ……………..…….….…. Above roof ………………..…......... STORAGE Number of cylinders …………………..... Nominal volume Dimensions: Height ….………...…..mm Diameter ……………………....litres ...………………….…..mm PRIMARY CIRCUIT Pipe size ………………………….......mm Pump c/w valves Type ………………..
RM SOLAR PRODUCT GUARANTEE RM Solar Products are guaranteed by RM Solar Ltd as follows: Thermal Solar Panels (Performance) (S-Class & M-Class ONLY) Thermal Solar Panels (Against corrosion) (S-Class & M-Class ONLY) Thermal Solar Panels (Manufacturers guarantee) (ECON) Pump Stations, Controllers & Heat Exchangers Other RM Solar products 20 years 20 years 8 years 2 years 1 year In all cases, from the day system was commissioned. The Guarantee is conditional upon: 1. 2. 3. 4.
Service Record SERVICE 1 SERVICE 2 DATE: ENGINEER NAME: ENGINEER NAME: COMPANY NAME: COMPANY NAME: TEL NO. TEL NO. COMMENTS: COMMENTS: SIGNATURE: SIGNATURE: SERVICE 3 SERVICE 4 DATE: ENGINEER NAME: ENGINEER NAME: COMPANY NAME: COMPANY NAME: TEL NO. TEL NO. COMMENTS: COMMENTS: SIGNATURE: SIGNATURE: SERVICE 5 SERVICE 6 DATE: ENGINEER NAME: ENGINEER NAME: COMPANY NAME: COMPANY NAME: TEL NO. TEL NO.
