Professional Documents
Culture Documents
Nu-Heat
System Ref:
section
1.1 2.0 3.0 4.0 4.1 5.0 5.1 6.0 7.0 7.1 7.2 7.3
contents
Checklist Fitting the solar panel Panel Mounting On-roof Fitting the solar pumping station Connection of Solar Pumping Station to Panels and Cylinder Second fix wiring information Wiring the solar pump station Filling and flushing the solar circuit Setting up electrical equipment Cylinder thermostat & timeclock EnergyMaster Solar only Selecting the operating mode User controls immersion heater timer Preheat cylinder with NIBE 360P and 1240 only appendices
1 2 3 4 5 6
Aquastar Hot Water loop Solar system maintenance requirements Solar de-commissioning schedule Roth Heliostar 218 and 252 EN 12975 conformity certificate Sample installation checklist Further reading
1.1 CHECKLIST
Mains water supply: Check that the performance of the mains supply matches the requirements of the household. Boiler: If using a Nu-Heat EnergyMaster cylinder in conjunction with underfloor heating then the heat loading is indicated on the A3 System Information. Please refer to the boiler manufacturers recommendations for installing and commissioning the boiler. Check the boiler installation requirements with the manufacturer as in some cases a by-pass valve may be recommended between flow and return pipework. Insulation of pipework: It is necessary to insulate the solar pipework, as well as the primary system pipework. Domestic hot water pipework should also be insulated, particularly on a pumped loop. Ensure that the incoming cold main is separated from any hot pipework to prevent heat transfer. Taking delivery: Please check your delivery against the delivery note and report any discrepancies within 7 days of receipt. Warranty: In order to validate the warranty the Commissioning Checklist & Warranty Application form in the Commissioning Pack attached to this manual must be completed by the installer and returned to the customer.
working at height
Working at height can be dangerous and must only be done with the correct equipment and after a Risk Assessment has been performed. For proper guidance on safe practice see the Health and Safety Executive information on Health and Safety in Construction, section entitled Working at Height. Other relevant standards are listed in appendix 6. The fitting of solar panels generally requires the use of scaffolding or at least a scaffold tower and eaves-level boards to provide a safe platform on the roof. Scaffolding must be erected by a Competent person. If work involves erection of scaffolding on a public highway then the Local Council and the Highways Agency must be consulted. Protection from falling should be provided either by the use of guard rails or fall arrest/fall restraint equipment. If the danger of falling material is considered a significant risk then the area beneath must be made safe either by being cordoned off, or if this is not possible then alternative safety provisions should be made. In order to get the panel up to roof height a crane or hoist may be necessary.
risk of burning
It should be borne in mind that the solar panel may reach temperatures of 150350C once on the roof but without circulation through it. A suitable cover should be arranged to protect anyone on the roof from being burnt. Only remove this once the system has been commissioned.
lightning protection The requirement for lightning protection is only necessary when the assessed risk is greater than 1 in 100,000 according to BS 6651. installation of sensor
Before finishing work on the roof the solar panel temperature sensor must be installed. It should be located in the last panel before the return to the cylinder (i.e the hot outlet, which is the hottest part of the collector array). To install the sensor remove the rubber bung. Feed the sensor through the hole in the bung and, after applying some heat conduction paste, insert the sensor into the pocket and refit the bung. It is possible to extend the sensor up to 50m using a 0.75mm twin core cable such as is integrated into the flexible stainless steel flow and return pipe work (optional). Important: Prior to installation the collectors should be stored indoors taking care not to damage the glass. Do not unpack the collectors until just before fitting to avoid moisture entering into the collector through the holes in the frame.
general requirements
panel array dimensions If more than 5 panels are required then they should be arranged in equal banks of up to 5. This will be discussed at quote stage if more than 5 panels are necessary.
800mm 1200mm
800mm
10001200mm 2400mm
800mm
10001200mm 3600mm
10001200mm
800mm
10001200mm
10001200mm 4800mm
10001200mm
800mm
10001200mm
10001200mm 6000mm
10001200mm
10001200mm
Also mounted on the control station is the solar controller, as well as the connection point for the solar expansion vessel.
10
Mounting holes
1 1
Pressure gauge
4
6 7
12mm flexible stainless steel pipes with 1/2 captive nuts (pair) supplied with panel fixing basic set Solar panel array 1/2 male iron x DN16 or DN20 flexible stainless steel fitting (x 2) supplied with (optional) flexible stainless steel pipe assembly
3/4" male iron x DN16 or DN20 flexible stainless steel fitting (x 4) supplied with (optional) flexible stainless steel pipe assembly
Cylinder solar coil 22mm compression x DN16 or DN20 flexible stainless steel fitting (x 2) supplied with (optional) flexible stainless steel pipe assembly
Clips will be supplied to fasten the stainless steel flexible pipes, and these should run at approximately 1.5m intervals. Note: the pipe-work must be earth bonded with a conductor of cross section 6mm2 or more.
4.1 CONNECTING THE PUMP STATION TO THE PANELS AND CYLINDER cont.
double banked panels reverse return fitting If more than five panels are specified then they must be fitted in two banks. This is because the pressure drop across more than five panels is too great. If the stainless steel flexible pipe is purchased from Nu-Heat then the necessary additional pipe will supplied to connect the two banks in the roof. It is important that the pipe work connecting the two banks is configured in a reverse-return layout in order that the pressure drop across each bank is equal. This will ensure that the flow through each bank is equal, and that one bank doesnt have more heat stripped from it that the other. Note: that the pipe work will pass through the roof before being joined. If the banks of panels are one above the other then the pipe-work is as the following diagram (the additional components supplied with the optional stainless steel flexible pipe are shown in red).
1/2 MI x DN16/DN20 coupling Sensor 1/2 MI x DN16/DN20 coupling Outflow Through Quickslate Short length of pipe cut from main length
Inflow Through Quickslate 5m length Short length of pipe cut from main length
1/2 MI x DN16/DN20 coupling 5m length Outflow Through Quickslate 1/2 MI x DN16/DN20 coupling
Through Quickslate
Note: that the pipes marked 5m length refer to the length of stainless steel pipe where this is supplied. If copper is used then these pipes need to be of equal length.
4.1 CONNECTING THE PUMP STATION TO THE PANELS AND CYLINDER cont.
If the banks of panels are side by side then the pipe-work is as the following diagram (the additional components supplied with the optional stainless steel flexible pipe are shown in red). Note: that the pipes marked 5m length refer to the length of stainless steel pipe where this is supplied. If copper is used then these pipes need to be of equal length.
1/2 MI x DN16/DN20 coupling DN16 equal tee Sensor Outflow 5m length Outflow
Inflow
Inflow
It is important that all joints are insulated, and that any material used for this is capable of withstanding 150C. High temperature nitrile rubber (e.g. Armaflex) is a proven material in this application. This should only be done once the system has been pressure tested.
4.1 CONNECTING THE PUMP STATION TO THE PANELS AND CYLINDER cont.
metalflex (spckr1/16-a or spckr1/20-a)
1. Cut the pipe to length as described above 2. Place one of the pipe nuts over the pipe 3. Close one of the retaining clips (circlips) around the pipe in the first crease 4. The first corrugation must be compressed to provide a flat sealing surface. To achieve this assemble the fitting without the fibre washer and tighten as far as possible. 5. Once the first corrugation has been flattened undo the fitting and fit the fibre washer before finally doing the fitting up tightly. If a sealant is desired then high temperature liquid PTFE should be used (e.g. Rocol 28022 Pipeseal PTFE Liquid)
Note: the pipe-work must be earth bonded with a conductor of cross section 6mm2 or more.
safety
Nu-Heat recommends the use of a number of 5A switched fused spurs to supply the boiler and other electrical items that make up the heating system. Where live conductors are sleeved in a colour other than brown, coloured marker sleeves should be fitted at the ends of the wires to identify them.
Fuse
S1 S2 S3 S4 VBus 1 2 3 4 5 6 7 8 9 10
N R2 N R1 N L 12 13 14 15 16 17 18 19 20
N L
L E SL
L N E
2. There is a prewired plug to connect to the pump to the controller. To comply with current best practice this must be disconnected and rewired as shown in the diagram above. Please note that the cable used to the pump must be capable of withstanding 90C. The plug on the pump must still be used, and this will only fit in the correct orientation. If the solar controller is to be located remotely from the pump station then this cable must be extended as required. 3. To wire in the temperature sensor first switch off the mains supply to the pump station. Then slide the plastic cover out, and undo the cover retaining screw.
4. For all systems there are two temperature sensors: a. Sensor S1 is located in the panel (see Fitting the solar panel). This can be extended up to 50m using 0.75mm twin core cable. If the (optional) stainless steel flexible pipe has been chosen then the integral sensor cable should be use to extend the sensor. b. Sensor S2 is fitted into the lower sensor pocket on the cylinder to sense the temperature near to the solar coil. This can be extended if necessary with 0.75mm twin core cable.
See solar docking drawings for further details. Note: The sensors are not sensitive to polarity.
Internal detail
Spring
3 4 6
m 14
NRV
Note: on new versions of the solar controller the ball valves are opened and closed by rotating the dial thermostat.
Operation of Flow and return ball valves (2 and 3)
3 4
2 1
8. Set the flow ball valve (2) and the return ball valve (3) to 45 in order to open the non-return valves 9. Open the drain valve (5) and then the filling valve (1) 10. Allow the solar fluid (water at this stage) to drain to waste. Be aware that there may be fluid left in the panel and the solar coil in the cylinder 11. Close the filling valve (1) and drain valve (5).
mixing the antifreeze The antifreeze is supplied in 25 litre drums, filled with 10 litres of antifreeze. The other 15 litres should be filled completely with water, giving a concentration of 40%.
15. Switch on the filling pump, and open the filling valve (1) and flushing valve (7). Continue to run the pump until there are no air bubbles at the return to the antifreeze container. Hint: Flush at a pressure of between 3-4 bar. To aid purging pulse the pump on and off. Also closing the flushing valve (7) to allow pressure to build up, and then opening it again can help clear air pockets.
There are three buttons for altering the settings on the controller, as shown in the diagram to the right.
00:00 K
C
Backward
Forward
Set
In running mode the backward and forward buttons can be used to scroll between the collector temperature (COL), the cylinder temperature (TST) and the running hours (h P). It is advisable to check the calibration of the temperature sensors by placing them in hot water, which should also be measured with an accurate digital thermometer. To access the setup functions press and hold the Forward button. The table below lists all of the functions available. See the notes below about any functions that need the settings to be altered.
!
Maximum store limitation achieved/exceeded Solar panel temperature sensor Antifreeze function activated (not generally used)
&
= Sensor defect
Relay 2 active
Relay 1 active
!
Solar panel
SET
Solar pump
00:00
Cylinder coil temperature sensor Cylinder limit temperature sensor Function Setting
C K
Emergency temperature collector 1 Option collector cooling collector 1 Option minimum limitation collector1 Option antifreeze collector 1 Option recooling Option tube collector Switch-on temp. for thermostat 1 Switch-off temp. for thermostat 1 Option heat quantity measurement Maximum flowrate Antifreeze type MEDT MEDT Antifreeze concentration x Minimum pump speed relay 1 x Minimum pump speed relay 1 x x Manual operation relay 1 x x Manual operation relay 2 x x Language XX.XX Program number X.XX Version number
Note: Not all functions are necessary see below for details of necessary alterations. Note: All current Nu-Heat systems are configured as Arrangement 1 (Arr.1) To alter any of the function settings hold the Forward button to enter function mode. Scroll through the functions using the Forward and Backward buttons. Once the desired function is located press the Set button then use the Forward and Backward buttons to select the different options, then Set to confirm the selection. Note: If Set isnt pressed then the previous selection will remain. The programmer will revert back to running mode if left for a few minutes.
+1HR
MAN
MO
12:00
+
+1HR
SET
PM
MAN
DAY/HOL COPY
R/S
12:00
TU
+
TIME PM
+1HR
SET MO
12:02
+
TIME PM
MAN
DAY/HOL COPY
R/S
DAY/HOL COPY
R/S
programming day and time 1. Open the cover. Press the R/S button using a non-metallic object such as a matchstick. This will reset the timeclock to factory settings, including time and date. 2. Press PROG twice until SET ON TIME appears at the top of the display and MOTUWETHFR appears at the bottom of the display (days of the week). 3. Use the +/- to set the first ON time.
+1HR
SET
MAN
MO
12:00
+
TIME PM
+1HR
SET MO
4:30
+
ON
TIME AM
+1HR
SET
2
MAN
MAN
DAY/HOL SELECT COPY
R/S
MO
PROG SELECT
8:00
+
OFF
TIME AM
DAY/HOL COPY
R/S
DAY/HOL COPY
R/S
NEXT ON/OFF
programming on/off times 4. Press NEXT ON/OFF once only. 5. Use the +/- to set the first off time. 6. Press next ON/OFF once again and repeat steps 3-6 to set subsequent ON and OFF times.
+1HR
SET
MAN
MO
PROG SELECT
611:15 PM
+
OFF
TIME
+1HR
SET
4 12:30 PM
TU
+
OFF
TIME
+1HR
SET
MAN
6 11:15 PM
FR
+
OFF
TIME
MAN
DAY/HOL COPY
R/S
DAY/HOL COPY
R/S
NEXT ON/OFF
7. Press DAY/HOL and SASU will appear at the bottom of the screen (weekend).
Note: The timeclock will automatically adjust between GMT and BST.
MAN
MO
PROG SELECT
12:45
+
AM
DAY/HOL COPY
R/S
NEXT ON/OFF
operation
If the colon is blinking the unit is in run mode. It will automatically switch the underfloor heating on and off at the times set. However, useful overrides are provided which enable the user to make temporary changes to the on/off times without re-programming the unit.
reset Should the timeswitch be disconnected from the mains a small battery symbol will blink on the left of the display. After the second midnight (between 24 and 48 hours) the display will go blank and settings will be lost. When mains power is restored it is recommended that the unit be reset by inserting a non-metallic object such as a matchstick in the R/S hole under the flap. This will restore the factory settings including the time and date. The output will be OFF. Note that the colon will be blinking, meaning that the unit is in RUN mode and will switch ON and OFF according to the factory programming until reset.
manual overrides
When in OFF, AUTO or ALLDAY modes the +1HR button can be used to switch from OFF to ON for just one hour, or to extend an existing period by one hour. This will be cancelled by pressing the +1HR button again, pressing the MAN button or when the next ON programme is reached. When in AUTO or ALLDAY modes pressing the MAN (manual) button will switch from ON to OFF, and vice versa. This override will only last until the next programmed change, when the automatic programming will resume, or until the button is pressed again. When the above overrides are selected a bar appears in the display against the appropriate legend.
g.m.t./b.s.t.
The timeclock is programmed to automatically switch between GMT and BST.
1 4 1 2 3 4 1 4
The pre-set factory ON/OFF times can be reinstated by pressing the recessed R/S button with a non-metallic object such as a matchstick. Please remember that underfloor heating takes longer to warm up and cool down than conventional radiators and the heat settings should reflect this. The factory settings are unlikely to be appropriate.
Non-return valve
Pump
12:00
Timeclock
Pipe stat
Bathroom 1
Bathroom 2
out For cylinder connection details refer to cylinder manufacturer return Pump Outlet balancing valves Radiator lockshield valves Kitchen Utility
Flush/ drain
Bathroom 3 Discharge
Careful thought should be given to the layout of the hot water loop and the fittings used on it. Flow pipework to bathrooms should be sized according to the hot water requirements of the household. Typically a small to medium sized installation will require 22mm flow pipework, a large installation may require 28mm or greater. 15mm pipe may be used for the last 2 metres where the pipe connects to the Aquastar2 pump (22mm for Aquastar3). Individual hot water outlets should be fitted with flow-limiting valves to prevent unnecessarily high water flow rates affecting the water pressure at critical points such as shower units. It is recommended that only lockshield valves are used
with towel rails on a secondary hot water loop. Towel rails should not be isolated from the loop for any significant amount of time (more than a few days) or there is a risk of bacterial growth, such as legionella. Fit a balancing valve or towel rail at the farthest end of each loop. If bathrooms are to be connected to the hot water loop in parallel, balancing valves must be fitted on each leg so that balancing between bathrooms can be effective (see illustration). The hot water flow and return pipes should be insulated to prevent unwanted heatloss. This is particularly important where hot pipes run alongside the supply pipes to cold tap.
KEY
Note: colour of wires may vary from those shown. Earth where required.
SL L N E
L N E
Switched fused 5A spur
L N E
Domestic hot water pump with integral timeclock and thermostat
L N E
SL L N E
L SL E
L N E
30
C 90
N L SL E
N L 1 2 3 4
SL L E
50 70
annually:
collector Collector glazing is undamaged. Collector glazing is reasonably clean. There is no visible evidence of leakage on the roof Where visible, absorber paintwork or coating is sound. The roof fixings are firm and the roof covering satisfactory by visual inspection. solar circuit The solar system pressure is correct according to the pressure gauge (1.5 bar +/- 0.2 bar) There is no visible evidence of leakage Safety valve manually checked Antifreeze concentration checked. Should protect to -19C. Deaerator checked for air buildup Electrical controls and temperature sensors are operating correctly Flow rate remains at level stated on commissioning certificate The circulating pump is operating without due noise. Pipework insulation is firmly in place. There are no condensation or damp spots, particularly around the pipework and fixings in the roof space. All safety and information labels are in place. every 5 years: The system should be emptied, flushed and refilled with fresh antifreeze
3 4
3. Set the flow ball valve (2) and the return ball valve (3) to 45 in order to open the ball valves. 4. Open the drain valve (5) and then the filling valve (1) 5. Allow the solar fluid to drain to waste. Be aware that there may be fluid left in the panel and the solar coil in the cylinder 6. Close the filling valve (1) and drain valve (5). 7. The panel covering must be robust enough to stay in place until it is possible to re-commission the system.
Elec 2
Elec 3
All voltages pump Solar pump or other similar solar primary item to be connected via heat resisting flex/cord (not fixed cable), marked at least to tolerate 85KC and cable sheath clamp to be correctly used. All voltages support Fixed wiring clipped correctly with mechanical protection (trunking, etc.) if at risk of physical impact. Minimum clip spacing 250mm horizontal, 400mm vertical. No PVC cable to be in contact with copper pipes. External cables greater than 30cm are to be supported. All cables to be protected from sharp edges, etc. by purpose guides or grommets. Over-current protection should be present of the correct capacity for cables and connected appliances. Conductor sheath to be continuous into joint enclosures, conductors to be securely fastened to terminals, conductor insulation to be within 2mm of terminals.
Elec 4
Elec 5 Elec 6
All voltages cable All cable conductors external of joint enclosures to be insulated and sheathed. External cables to be UV stable. All voltages class 2 Class 2 double insulation marked on all appliances normally intended for user operation. ELV segregation The separation between cables of different voltage classes should be at least 50mm, or placed in a separate conduit/trunking, or both insulated for highest voltage present.
Elec 11 Elec 12
roof ref Roof 1 item The glazing seals are weather-tight and sound Collector sensor clamped, insulated from ambient External pipes insulated Shading Roof fixings description Requires roof inspection. Where suspect, tested by 1 Bar water spray perpendicular and horizontal, then visual for drips/condensation mist inside glass. If temperature sensor is present, it should be a good mechanical fix, insulated and not loose. Where insulated, protected from UV, weather and vermin. No significant daily shading for more than two hours between spring and autumn. Requires roof inspection and within loft (to see sarking felt, etc). Where suspect, further tested by 1 Bar water spray perpendicular and horizontal then visual for drips/condensation. Fixings to be firmly attached to the roof structure and visual inspection that the roof covering is weatherproof. initials
Roof 2
Oper 2
Oper 3
Oper 7 Oper 8
Tertiary 100 Celsius prevention The safety devices are operating correctly Gaseous bubbles expelled from the transmission liquid
Oper 9
Gen 2 Gen 3
Gen 4
Vent termination
Gen 5
Pressure Equipment Regulations (PED) Sound engineering practice or higher conformity Temperature of materials
Indoor components Components subject to risk of freeze damage to be protected i.e. trace heated, antifreeze. freezing Anti-scald If secondary system can be heated to more than 60C from the solar, then either an adjustable automatic blend valve (anti-scald) to be fitted to the DHW distribution, or automatic pump control to be capable of limiting to 60C. Route from collector to over-pressure safety via non-deformable pipe with no possibility of blocking, diameter reduction, valve closure, scaling or freezing to the point of discharge. Discharge constantly falling and unobstructed. No risk to people, materials or environment from termination location.
Gen 9
Pressure limit
Gen 16
All pipework is adequately secured and insulated and components are adequately supported. Pipes and fittings should be securely fixed whilst allowing for thermal movement (overhead pipes must use clip-over type). Rigid pipe spacing horizontal 1.8m, vertical 2.4m; non-rigid pipe spacing horizontal 0.3m, vertical 0.5m. All pipe insulation is firmly in place, including on roof. No significant gaps on slits, clips and ends. Penetrations in building made good. Debris removed.
Gen 17 Gen 18
BS 7431 BS 6785:1986 prEN 12977-3 prEN 12977-2 prEN 12977-1 BS EN ISO 9488 BS EN 12976-2 BS EN 12976-1 BS EN 12975-2 BS EN 12975-1
Method for assessing solar water heaters. Elastomeric materials for absorbers, connecting pipes and fittings. Code of practice for solar heating systems for swimming pools. Performance characterisation of stores for solar heating systems. Thermal solar systems and components. Custom built systems. Test methods. Thermal solar systems and components. Custom built systems. General requirements. Solar energy. Vocabulary. Thermal solar systems and components. Factory made systems. Test methods. Thermal solar systems and components. Factory made systems. General requirements. Thermal solar systems and components. Solar collectors. Test methods. Thermal solar systems and components. Solar collectors. General requirements.
BS 8000 BS 7206 BS 7671 BS 1566 BS 4814 BS 7074 BS 5422 BS 5449 BS EN 12831 BS EN 12828 BS 6701 BS 5970 BS 6700 BS 6651 BS 5534 BS 6399 BS 6399 BS 6920
Workmanship on building sites. Specification for unvented hot water storage units and packages. Requirements for electrical installations. Copper indirect cylinders for domestic purposes. Specifications for expansion vessels using an internal diagraph for sealed hot water heating systems. Application, selection and installation of expansion vessels and ancillary equipment for sealed water systems. Methods of specifying thermal insulation materials on pipes, ductwork and equipment in the temperature range of -40C to 700C. Specification of forced circulation hot water central heating systems for domestic premises.
Telecommunications equipment and telecommunications cabling. Code of practice for thermal insulation of pipes and equipment. Specification and design, installation, testing and maintenance of services supplying water for domestic uses within buildings and their curtilages. Lightning Protection Code of practice for protection of structures against lightning. Code of practice for roofing and tiling Design. Suitability of non-metallic products for use in contact with water intended for human consumption with regard to their effect on the quality of the water.
If there is any aspect of the installation that you do not understand, please contact Nu-Heat Technical Support for advice. All illustrations and diagrams in this manual are the property of Nu-Heat. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means electronic, mechanical, photocopying, recording or otherwise without prior written permission of Nu-Heat.
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