MAZDON. Table of Contents. Cautions. MAZDON Collector Tube Figure 1 Figure 2

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1 Table of Contents MAZDON Cautions MAZDON Collector Tube Figure 1 Figure 2 Installation Procedure for MAZDON Sloping Roof (M) system Figure 3-6 Figure 7 Installation Procedure for MAZDON Sloping Roof (K) system Figure 8-11 Figure 12 Installation Procedure for MAZDON Flat Roof (F) system Figure Figure 17 Connections Figure 18 Pipework and Plumbing Figure Expansion Vessel Figure 21 Series Tank Installation Figure Parallel Tank Installation Figure 24 Calculating Pump Size Figure Pressure Drop of MAZ 30 Under Various Flow Rates Table Series Installation Figure 27 Figure Figure 30 Cont d

2 Table of Contents - cont d. Calcium Deposits and Aggressive Water Collector Efficiency and Sizing Figure Figure 33 Domestic and Commercial Energy Requirements - Tables Table 1) Table 2) Table 3) Table 4) Table 5) Table 6) Table 7) Table 8) Average Domestic Hot Water Utilization Hotel/Restaurant/Guest House Outdoor Pool Energy Requirement Outdoor Pool Specific Heat Loss Average Space Heating Requirements Typical Requirements for a Middle European House Latent Heat System Sizing Periodic Checks Parts List

3 CAUTIONS 1. Gloves and Eye Protection must be used when handling glass tubes Avoid scratching or any sudden shock to tubes. Unpack and install tubes after the manifold unit has been installed and all pipe work has been completed and the system is filled. During installation of the tubes, the pump should be switched on. In hot water applications, a heat exchanger should be used between the collector and the hot water storage tank to ensure a long and trouble free service life (calcium deposition). When heating a swimming pool or spa, a heat exchanger should be used between the pool and the collector. Mazdon manifold systems are designed to operate at a maximum pressure of 6 bar (90psi). It is strongly recommended to use a suitable pressure relief valve. To extend the service life of your system, the vacuum tubes shall not be installed until the system is fully connected and ready for use. Under no circumstances are the tubes to be left exposed to the sun over a long period without heat extraction from the system

4 COLLECTOR TUBE MAZDON 4 Fig. 1 The ABSORBER PLATE (1) is coated with a special high efficiency SELECTIVE COATING which ensures maximum radiation absorption and minimum thermal radiation losses. The coating undergoes stringent quality control tests with only the materials meeting our required levels of absorption and emittance standards being used in production. The plate is bonded to a HEAT PIPE (2) and the assembly is then sealed within an EVACUATED GLASS TUBE (3). This results in an almost total elimination of convection and conduction losses from the absorber. The heat pipe is coupled to a high efficiency CONDENSER (4). Radiation striking the collector plate is absorbed then transferred as thermal energy to the condenser. The condenser transfers heat to the water pipe via a chamber, which is housed in an insulated protection box. (Fig 1)

5 Fig. 2 System MAZDON 20 MAZDON 30 Number of Tubes Dimensions (W x L x D) 59" x 80" x 6 1/4" 87" x 80" x 6 1/4" Weight (Empty) 135 lbs. 196 lbs. 's Capacity 0.12 US Gallons 0.18 US Gallons Connections 3/4" NB 3/4" NB

6 INSTALLATION PROCEDURE FOR MAZDON, SLOPING ROOF (M) SYSTEM See Fig Select a suitable position for the collector. It should face due south. Recommended angle of tilt is the same as your geographical latitude. Distances between perforated bands are given in mm. 2. Remove tiles. 3. Secure the LOWER band (Pt. No. B0290) to rafter using coach screws (Pt. No. A0168) and washers (A0170) 4. Replace tiles. 5. Locate and secure bottom end of side rail (Pt. No. B0282) to LOWER band. Use captive washer (Pt No. A0330) to hold the bolt of the lowest hole in place for later use. 6. Locate one support rail (Pt. No. B0177 or B0178) in tab on side rail (Pt. No. B0282), bolt both to UPPER band. Distance from side rails to ends of support rail should be equal. 7. Secure the UPPER band to rafter. 8. Locate the other support rail (Pt. No. B0177 or B0178) in tab on side rail (Pt. No. B0282), bolt both to LOWER band. Distance from side rails to ends of support rail should be equal. 9. Locate manifold (Pt. No. B0832 or B0833) in tab at top of side sails and bold as shown. The distance from the side rails to the ends of the manifold should be equal. 10. Ensure that both support rails and manifold are in line. Tighten all bolts. 11. Locate manifold fittings to manifold inlet and outlet. Note that the air vent should be installed vertically. Check all plumbing and pipework between collector and hot water storage tank. Fill system and then turn the circulating pump on. 12. Remove self-tapping screws and remove manifold lid Remove top layer of insulation from manifold - Apply heat transfer paste, thinly and evenly to the condenser location seats of the manifold chamber. - Unpack first tube, push one rubber disc gently over the condenser end of the tube with flange facing glass, and onto rubber grommet. Starting at one end of the manifold, insert condenser through hole in front of manifold and into manifold chamber, resting tube body on rubber of the support rails. Rubber disc should seal up against front of manifold. ENSURE SELECTIVE COATING SURFACE IS UPPERMOST - Make sure condenser sits evenly through hole in manifold chamber. - Using a pair of pliers, squeeze the retaining clip tightly together, making sure there are no air gaps. - Fit clips over tube to both support rails. Note: Push clips only where shown repeat for all tubes - Replace top layer of insulation into manifold. 14. Replace manifold lid and secure with self-tapping screws. 15. Switch pump control unit to automatic.

7 Sloping Roof (M) MAZDON Fig. 3 Fig. 4 Fig. 5. Fig. 6

8 Fig. 7 Sloping Roof (M) MAZDON Ground Points For Lightening Conduction

9 INSTALLATION PROCEDURE FOR MAZDON, SLOPING ROOF (K) SYSTEM See Fig Select a suitable position for the collector. It should face due south. Recommended angle of tilt is the same as your geographical latitude. Distances between perforated bands are given in mm. 2. Remove tiles. Secure the LOWER leg of UPPER bracket (Pt. No. B0249) to rafter replace tile between bracket legs. 3. Secure UPPER bracket of leg to rafter and replace remaining tiles. 4. Locate and secure LOWER bracket to bottom end of side rail (Pt. No. B0282) 5. Locate one support rail (Pt. No. B0177 or B0178) in tab on side rail (Pt. No. B0282), bolt both to UPPER bracket. 6. Secure lower leg of LOWER bracket to rafter. 7. Secure upper leg of bracket to rafter. Replace remaining tiles 8. Locate manifold (Pt. No. B0832 or B0833) in tab at top of side sails and bold as shown. The distance from the side rails to the ends of the manifold should be equal. 9. Locate support rail (Pt. No. B0177 or B0178) in tab on side rail (Pt. No. B0282), bolt both to LOWER bracket. 10. Ensure that both support rails and manifold are in line. Tighten all bolts. 11. Locate manifold fittings to manifold inlet and outlet. Note that the air vent should be installed vertically. Check all plumbing and pipework between collector and hot water storage tank. Fill system and then turn the circulating pump on. 12. Remove self-tapping screws and remove manifold lid Remove top layer of insulation from manifold - Apply heat transfer paste, thinly and evenly to the condenser location seats of the manifold chamber. - Unpack first tube, push one rubber disc gently over the condenser end of the tube with flange facing glass, and onto rubber grommet. Starting at one end of the manifold, insert condenser through hole in front of manifold and into manifold chamber, resting tube body on rubber of the support rails. Rubber disc should seal up against front of manifold. ENSURE SELECTIVE COATING SURFACE IS UPPERMOST - Make sure condenser sits evenly through hole in manifold chamber. - Using a pair of pliers, squeeze the retaining clip tightly together, making sure there are no air gaps. - Fit clips over tube to both support rails. Note: Push clips only where shown repeat for all tubes - Replace top layer of insulation into manifold. 14. Replace manifold lid and secure with self-tapping screws. 15. Switch pump control unit to automatic.

10 Sloping Roof (K) MAZDON

11 Fig. 12 Sloping Roof (K) Ground Points For Lightening Conduction

12 INSTALLATION PROCEDURE FOR MAZDON FLAT ROOF (F) SYSTEM See Fig Select a suitable position for the collector. It should face due south. Recommended angle of tilt is the same as your geographical latitude. Distances between perforated bands are given in mm. 2. Position and bolt front brackets (Pt. No. A0327) and rear brackets (Pt. No. A0328) to the flat roof or surface using coach screws (Pt. No. A0168). Use raw plugs (Pt. No. A0886) 3. Fix rear strut assembly (Pt. No. B0356) to rear bracket (Pt. No. A0328). 4. Bolt side rail (Pt. No. B0282) to front bracket (Pt. No. A0327) using bottom hole in side rail. 5. Locate one support rail (Pt. No. B0177 or B0178) in tab on side rail (Pt. No. B0282), bolt both to rear strut (Pt. No. B0356). Distance from side rails to ends of support rail should be equal. 6. Locate the other support rail (Pt. No. B0177 or B0178) in tab on side rail (Pt. No. B0282) bolt as shown. 7. Locate and secure side brace (Pt. No. B0005) using the single hole in the front bracket. Secure the other end using slots to rear in either position shown. Locate a second side brace to the other side of frame. 8. Locate the universal brace (Pt. No. B0006) diagonally between rear struts and cut off any excess length. 9. Locate manifold (Pt. No. B0832 or B0833) in tab at top of side rails and bolt as shown. The distance from the side rails to the ends of the manifold should be equal. 10. Ensure that both support rails and manifold are in line. Tighten all bolts. 11. Locate manifold fittings to manifold inlet and outlet. Note that the air vent should be installed vertically. Check all plumbing and pipework between collector and hot water storage tank. Fill system and then turn the circulating pump on. 12. Remove self-tapping screws and remove manifold lid Remove top layer of insulation from manifold - Apply heat transfer paste, thinly and evenly to the condenser location seats of the manifold chamber. - Unpack first tube, push one rubber disc gently over the condenser end of the tube with flange facing glass, and onto rubber grommet. Starting at one end of the manifold, insert condenser through hole in front of manifold and into manifold chamber, resting tube body on rubber of the support rails. Rubber disc should seal up against front of manifold. ENSURE SELECTIVE COATING SURFACE IS UPPERMOST - Make sure condenser sits evenly through hole in manifold chamber. - Using a pair of pliers, squeeze the retaining clip tightly together, making sure there are no air gaps. - Fit clips over tube to both support rails. Note: Push clips only where shown repeat for all tubes - Replace top layer of insulation into manifold. 14. Replace manifold lid and secure with self-tapping screws. 15. Switch pump control unit to automatic.

13 Flat Roof (F) Fig. 13 Fig (30-Tube) (ZO-Tube) Fig. 15 Fig. 16

14 Fig. 17 Flat Roof (F) MAZDON Ground Points for Lightening Conduction X = 12lOmm α = 40 X = 1094mm α = 38 X = 976mm α = 30 X = 862mm α = 25 X = 746mm α = 20 α X

15 MANIFOLD CONNECTIONS The manifold flow and return connections are 22mm in diameter and are designed for use with compression couplings. The recommended manifold connections for installations are given in Fig 18 below. For multiple manifold installations, the following is a recommended maximum number of manifolds that should be connected in series: 4 of 20 tube manifolds 3 of 30 tube manifolds Part Numbers Fig A Al l22 3. A A PIPEWORK AND PLUMBING For a solar installation with pipework of total length metres, the following dimensions are recommended for the flow and return pipework: System Tubing Dimensions 30 tubes 15mm by 1mm or l/2 NB 60/90 tubes 22mm by l mm or 3 /4 NB 120 tubes I28mm by l mm or 1 NB Installed within the flow and return circuits of the system should be (see Fig 19.): PUMP (7), with flow meter attached to monitor flow of water within the system. NON-RETURN VALVE (2), to prevent gravitational flow of water in flow circuit from the collector when the storage tank temperature may be greater than the collector temperature (i.e. at night). Be sure to install correctly. MANUAL and AUTOMATIC AIRVENTS (l) fitted to the highest part of the system to facilitate removal of air pockets from the system. Air vents should be open when filling the system. cont d

16 AN EXPANSION VESSEL (9), to contain increased water volume in the system due to rise in temperature and hence increased pressure of water. A combined PRESSURE RELIEF VALVE and PRESSURE GAUGE (11) to monitor the pressure of the system and to serve as a safety mechanism to avoid over pressuring of the system (e.g. 3 bar 45 psi.) DOUBLE CHECK VALVE (10),to stop back-syphonage of water into cold mains water supply. FILLING LOOP, consisting of a flexible hose and stop valve that connects from water mains supply to hose connector and filler valve. PIPES SHOULD ALWAYS BE INSTALLED RISING SLIGHTLY TO AVOID THE CREATION OF AIR POCKETS NOTE THAT WHEN INSTALLING THE COLLECTOR AND PIPEWORK IT IS IMPORTANT THAT ALL LOCAL AUTHORITY REGULATIONS AND RELEVANT STANDARDS ARE ADHERED TO. WHEN FILLING THE SYSTEM ALL VALVES SHOULD BE OPEN i.e. PUMP BALL VALVES, CHECK VALVES ETC. 1a 1b Fig. 19 Fig. 20 1a Manual Air Vent 6 Coil (Solar System) 1 Electric Element (immersion heater) 1b Automatic Air Vent 7 Pump 2 Non Return Valve 8 Flow Meter 3 Storage Tank 9 Expansion Vessel 4 Coil Central Heating) 10 Filling Loop 5 Drain 11 Pressure Relief Valve

17 EXPANSION VESSEL (see Fig. 21 next page) If the water temperature in the system rises, water volume will increase resulting in a rise in pressure and the possibility of damage to the system if the expansion is not absorbed. By incorporating an expansion vessel into the system, the increase in water volume may be contained until the water temperature has reduced and the water volume returns to its initial level. The vessel consists of two halves. One half connects directly to the water system. The second, separated by a special diaphragm, contains nitrogen or air. As pressure rises and volume increases, the diaphragm is displaced. The size of the expansion vessel required depends on the volume of water in the solar collector circuit, maximum working temperature, maximum working pressure and the vessel pre-charge pressure. The size can be calculated as follows: First calculate the required expansion volume. Vu = Required expansion volume of vessel Vi = Volume of water in the solar collector circuit a = Expansion of water at the maximum working temperature, as a percentage of its volume at 0 C a = 3.2% at 90 C, 6.0% at 120 C, 9.0% at 150 C. Vu = Vi x a (1) 100 Next calculate the expansion efficiency of the vessel. c = Expansion efficiency Pw = Maximum working pressure, typically 3.5 bar (52.5 psi) Pi = Initial system pressure (expansion vessel pre-charge pressure), typically 1.5 bar (22.5 psi). c = Pw-Pi Pw +1 (2) Finally calculate the total volume, Vv, of the expansion vessel. Vv = Vu c Example: Find the required capacity of a vessel for a system pre-charged to 1.5 bar (22.5 psi), solar collector circuit volume 80 litres, max temperature 90 C and maximum working pressure 3.5 bar (52.5 psi) Equation (1) gives (3) Vu = 80 x 3.2 = 2.56 litres 100 (2) gives c = = (3) gives Vv = 2.56 = 5.8 litres 0.44 Therefore select an expansion vessel of at least 6.0 litres.

18 Fig. 21 EXPANSION VESSEL Connection to System

19 SERIES TANK INSTALLATION MAZDON For large installations two or more tanks may be connected to the solar system in series (preheat).fig 22, Fig 23. Fig Storage Tank 2. Reheat Fig way valve (short circuit) 2. 3 way valve (preheat 1) 3. 3 way valve (preheat 2) 4. Storage Tank 5. Preheat 1 6. Preheat 2 Applications: Hotels, Hospitals, Multi-storey Buildings

20 PARALLEL TANK INSTALLATIONS MAZDON A number of storage tanks may be connected in parallel to the collector system. Applications: Hotels, Hospitals, Multi-storey buildings When the water temperature in Tank 1 reaches a set temperature, the water from the collector is directed via a motorized 3-way valve, controlled by a temperature sensor at Tank 1, to Tank 2. If the temperature in Tank 1 falls below set temperature, the water from the collector is redirected through its heating coil. See Fig 24. Fig Motorized 3-way switch 2. Tank 1 3. Tank 2 4. Tank 3

21 CALCULATING PUMP SIZE When sizing a pump it is often necessary to calculate the system flow rate and the system pressure drop. Water Flow Rate: The recommended water flow rates are in the range of 0.1 to 0.25 litres/min per collector tube. Increased flow rates will not increase system performance; they will however increase the system pressure drop. Example: If we select a flow rate of 0.1 l/min per collector tube then: Flow rate in each branch is 90 tubes x 0.1 l/min/tube = 9 l/min. System flow rate is 180 tubes x 0.1 l/min/tube = 18 l/min. Fig tube 30 tube 30 tube 30 tube 30 tube 30 tube Pressure Drop As explained above, if manifolds are connected in series a higher flow rate is necessary. Since pressure drop increases with a higher flow, the pressure drop in each manifold will increase also. The graph below gives the approximate pressure drop for a single manifold at various flow rates: Fig. 26 Pressure drop for single manifold. Pressure Drop in kpascals Flow litres/min

22 Specific Flow Rate [litre/min/tube] MAZDON PRESSURE DROP OF MAZ30 UNDER VARIOUS FLOW RATES (Approximate guideline only) Number of s in series Total flow rate [litre/min] Total pressure drop of 4 Maz30 manifolds [kpa] Specific Flow Rate [litre/min/tube] Number of s in series Total flow rate [litre/min] Total pressure drop of 3 Maz30 manifolds [kpa] Specific Flow Rate [litre/min/tube] Number of s in series Total flow rate [litre/min] Total pressure drop of 2 Maz30 manifolds [kpa] Series Installations: To obtain a pressure drop through manifolds connected in series add the pressure drops for each manifold. Ps = Pm1 + Pm2 + etc. Ps = Pressure drop across system Pm1 = Pressure drop across manifold 1 (from graph) Pm2 = Pressure drop across manifold 2 (from graph) Fig. 27

23 Parallel Installations For larger installations where manifolds are connected in parallel, the system pressure drop is equal to the pressure drop in a single branch, as calculated above, irrespective of the number of branches. Fig. 28 Flow Rate And Pressure Drop Examples Examples below are manifold and connection pressure drops, pipework losses are not included. Example 1: Three manifolds in series Fig tube 30 tube 20 tube Typical flow rate = 80 tubes x 0.1 1/min/tube = 8/1min From Graph: pressure drop at 8 1/min for 30 tube manifold = 4.8 kpa pressure drop at 8 1/min for 20 tube manifold = 3.2 kpa Therefore total pressure drop = = 12.8 kpa Example 2: next page

24 Example 2: Previous (Fig. 29) example in parallel Fig tube 30 tube 20 tube 30 tube 30 tube 20 tube Typical branch flow rate = 80 tubes x 0.1 1/min/tube = 8 1/min Typical system flow rate = 160 tubes x 0.1 1/min/tube = 16 1/min Branch pressure drop (as example 1) = 12.8 kpa System pressure drop = branch pressure drop = 12.8 kpa CALCIUM DEPOSIT AND AGGRESSIVE WATER In areas where local water is known to be hard or aggressive, a heat exchanger MUST be used and the use of water softener is recommended, otherwise regular cleaning of the system will be required. IN ANY CASE A HEAT EXCHANGER IS STRONGLY RECOMMENDED. Chloride Ion Presence In areas where chloride ion concentration is greater than 40 ppm a heat exchanger MUST be used in hot water storage tank. The solar system should be filled with distilled or de-chlorinated water.

25 Collector Efficiency and Sizing MAZDON Fig. 31 Figure 31 (at left) gives details of collector efficiency for various insolation levels, installations and ambient temperatures. Figure 32 (below left) shows the measured efficiency curve of the collector system vs. solar insolation. Information on the sizing of a system can be obtained from the chart given in Figure 33 and by following steps 1 through 11 below. Fig. 32 Step 1 Determine the number of people using solar water heating system. Step 2 Using local data, find hot water consumption per day, per person. (ASHRAE recommends 20 gallons per day, per person.) Step 3 Select the Solar Water Heater tank size. Step 4 Find solar insolation and hours of sunshine per year. Step 5 Select the solar collector installation location. Step 6 Calculate deviation from true North/South line. Step 7 Find local latitude Step 8 Find roof angle or installation tilt angle. Step 9 Calculate the difference between local latitude and roof angle. Step 10 Estimate Thermomax tubes required. Step 11 Contact your local dealer for delivery and pricing information

26 Fig. 33 MAZDON A: Consumption = Litres of Hot (50 C) Water Per Day Per Person B: Insolation = Hours of Sunshine Per Year C: Orientation = Deviation from North/South Line (Shown as 0 ) D: Inclination = Difference Between Local Latitude And Roof Angle Example: 5 people with a requirement of 50 litres per day, per person, with a local Annual Insolation of 1400 hours. Orientation of the roof is 30 West of South. The local latitude is 45 and the roof angle is 35 (inclination difference 10 ). This, as can be seen from the plotted line on the chart, indicates a requirement for 45 tubes with a storage capacity of 375 litres.

27 Domestic and Commercial Energy Requirements MAZDON Tables given on the following pages give a brief guide to some domestic and commercial energy requirements for hot water and space heating. PLEASE NOTE THAT THESE SHOULD ONLY BE USED AS A VERY ROUGH GUIDE. Table 1) Table 2) Table 3) Table 4) Table 5) Table 6) Table 7) Table 8) Average Domestic Hot Water Utilization Hotel/Restaurant/Guest House Outdoor Pool Energy Requirement Outdoor Pool Specific Heat Loss Average Space Heating Requirements Typical Requirements for a Middle European House Latent Heat System Sizing Table 1 AVERAGE DOMESTIC HOT WATER UTILIZATION PER HOUSEHOLD APPLICATIONS Sink Wash Basin Bath Shower Bidet Washing m cold Washing m hot Total Consumption Low Average High APPLICATIONS Table 2 WATER TEMP. C CONSUMPTION lit/day HOTEL/RESTAURANT/GUEST HOUSE WATER TEMP. C CONSUMPTION lit/day Restaurant per menu per guest Hotel per room Room + wash basin Room + shower Room + bath Guest house NOTE: ALL ABOVE DATA VARIES ACCORDING TO METHODS OF INSULATION, AGE AND SIZE OF DWELLING, EXTERNAL AND TARGET TEMPERATURES.

28 Table 3. OUTDOOR POOL ENERGY REQUIREMENTS (kwh) MAZDON WATER TEMP C SWIMMING SEASON/YEAR 4 mths 5 mths 6 mths UNITS KWh/m 2 season Example: Energy requirement to heat pool for 4-month season to 22 C Assume solar insolation of 5 KWh/m 2 /day 4 month season = 120 days Therefore: 5 kwh x 120 days = 600 kwh/m 2 /season Collector efficiency = 0.7 Therefore: 600/0.7 = 420 kwh/m 2 /season, energy available during a 4 month period from collector. Energy required to heat pool to 22 C from Table 3 is 150 kwh/m 2 /season 150/450 = 1/3 i.e.: require a ratio of collector surface area to pool surface area of 1:3 Target Temp C Table 4 SPECIFIC HEAT LOSS (kwh) FOR OUTDOOR POOL Swimming Period in Months/Annum Pool A Pool B Pool C Pool D Units: kwh/ m 2 Pool A : Pool with two sides well-protected (trees, building or wall) wind speed 1 m/s. Pool B : Pool with two sides partially protected wind speed 2 m/s. Pool C : Pool with no protection, wind speed 4 m/s. Pool D : Pool with a cover of coefficient of conductivity of 8.12 W/m K. NOTE: ALL ABOVE DATA VARIES ACCORDING TO METHODS OF INSULATION, AGE AND SIZE OF POOL, EXTERNAL AND TARGET TEMPERATURES.

29 Table 5 AVERAGE SPACE HEATING REQUIREMENTS TARGET TEMP 20 C BUILDING TYPE Small detached Large detached Bungalow Large semi Small semi Semi bungalow Terrace End terrace FLOOR SPACE sq m Loft only INSULATION Loft & Walls UNITS kwh/ m 2 /annum Example: Energy requirement to heat large detached house, floor space 150m 2 Assume solar insolation of 3 kwh/ m 2 /day Therefore: 3 kwh x 180 days = 540 kwh/ m 2 /annum Energy required to heat a large detached house with good loft and wall insulation, floor space 150 m 2, to a target temperature of 20 C, is 110 kwh/ m 2 /annum. 110/378 = approx 0.3. i.e. require a ratio of collector area to floor space of 30%, giving a collector area of 50 m 2 House type Table 6 Terrace TYPICAL REQUIREMENTS FOR A MIDDLE EUROPEAN LOCATION Corner terrace house Detached house Small apartment Block (2x) Apartments (4x) Apartments (8x) Apartments (16x) A B C D E F G H Solar heat exchanger: approx. 0.3 m 2 /10 tubes Specifications: A. Approximate storage capacity m 2 B. Number of people C. Approximate hot water requirement in litres/day D. Hot water losses in litres/day Flow Rate: approx /h per 10 tubes E. Hot water production in litres/day F. Heat output new building (kw) G. Heat output old building good H. Heat output old building bad

30 Latent Heat Table 7 1 m 2 of collector area, with insolation of 1000 W/m 2 can approximately in one hour: i) increase temperature of 7.8kg of water from 25 C to 100 C or ii) produce 1 kg of vapour at 100 C from water at 100 C or iii) produce 0.9 kg of vapour at 100 C form water at 25 C or iv) produce 0.8 kg of vapour at 140 C from water at 25 C System Sizing Table 8 Number of persons Number of tubes Application tank size in litres PLEASE NOTE THAT THESE SHOULD ONLY BE USED AS A VERY ROUGH GUIDE.

31 Periodic Checks 1. Ensure that no physical damage has occurred to the tubes and remove any debris that may have accumulated. 2. Check the flow and return pipework between the collector and the storage tank. Check all connections for leaks and ensure that all components are operating correctly. 3. Check that the system pressure is maintained at 15 psi. If the pressure continually drops below 5psi then check the system for leaks. Five Yearly Checks 1. Every five years the Antifreeze in the collector loop should be checked. Good quality antifreezes like DowFrost HD can last up to 20 years. If necessary the system should be completely drained and flushed then refilled with new antifreeze. 2. Check the pipework insulation for deterioration. 3. Check the seals where the flow and return connections pass through the roof. Pressure Loss Periodically check the pressure gauge. If pressure loss in the system is apparent it may be due to one of the following: 1. Faulty pressure relief valve. - If pressure setting is wrong - correct it. If the relief valve fails to operate, drain the system and replace the valve. 2. Leakage. - If water is escaping from the system the volume of water in the system, and therefore the system pressure will decrease. Check all pipework and plumbing for the possibility of leads. If they do occur, drain the system and repair. 3. Overheating. - Overheating may occur if the pump isn t operating during a period of sunshine and water is not being circulated (i.e. power cut). Thermal energy is not being removed from the collector so the water temperature will rise, hence the water volume and the system pressure will increase. This can result in the release of steam or hot water from the air vent or pressure relief valve. When the system returns to normal operating conditions the system pressure will be reduced due to the loss of water. Top up the system to a pressure of 15 psi. Replacement of Tubes Due to the Thermal diode operation of the collector tube, damaged or broken tubes do not negatively affect the operation of the system, but merely reduce the efficiency of that tube. It is possible, therefore, to delay replacement of tubes to a suitable time. Pumps and Controls Thermomax Collectors can be installed with a variety of different pumps and controllers. The logic behind different makes of controller varies greatly. If you have a controller problem refer to the manual that came with the controller. If unable to solve it contact the installer or Thermomax at the address below. Thank you for purchasing a THERMOMAX collector. We know you will enjoy years of hot water from your system!

32 PARTS LIST C0132 SMT100 C0126 SMT300 C0128 SMT 400 C0031 MAZDON 20M MANIFOLD C0034 MAZDON 30M MANIFOLD C0045 TMA 400 TUBES (10 X) C0213 TMA 600 S (10 X) MAZDON B0005 ELEVATION KIT BRACE B0006 UNIVERSAL BRACE B0007 REAR STRUT (F) A0168 REAR BRACKET (F) A0167 FRONT BRACKET A0174 HINGE ASSEMBLY FOR REAR BRACKET B0177 BOTTOM SUPPORT RAIL (20) B0178 BOTTOM SUPPORT RAIL (30) B0282 SIDE RAIL B0249 ROOF BRACKET (K) B0290 ROOF BRACKET (M) A0064 SUPPORT CLIPS (type 1) A0087 RUBBER WASHERS A0169 HEX NUTS S/S A0170 M8 PLAIN WASHERS A0172 M8 SPRING WASHERS A0173 FORMED WASHER A0175 M8 X 20 BOLT A0176 CLAMPING PLATE WASHER A0330 FIBRE WASHER A mm LONG HINGE TUBING A0759 TOP SUPPORT RAIL CONNECTING SET A0921 SUPPORT CLIPS (type 2) COMPRESSION FITTINGS A0188 A0332 A0351 A0477 A0683 A0740 A0741 A0742 A1121 A1122 A1123 A1196 A mm x ½ BSP (F) x 22mm T PIECE TANK SENSOR POCKET COACH SCREW KIT COLLECTOR SENSOR POCKET RETURN SENSOR POCKET RETURN SENSOR COLLECTOR SENSOR TANK SENSOR ½ BSP PLUG MANUAL AIR VENT (½ BSP) COUPLING SET (2 x tees, manual air vent, connecting tube, plug) AUTOMATIC AIR VENT (½ BSP) 22mm x 56mm CONNECTION TUBE