aggliko-megasun0713

7/30/2019 aggliko-megasun0713

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Dear Friends,

This is our first attempt to communicate with you in this manner, where

writing becomes a friendly chat. Through the pages of our second

enriched publication now in your hands, we present to you our com-

pany.

A company offering sunny solutions, working with passion and dedica-

tion, for three decades now, to always offer you the best.

HELIOAKMI has been manufacturing and installing solar water heaters

since the 1970s making thousands of loyal friends like you along the

way. Our experience in producing highly efficient non-defective prod-

ucts economically, makes us justifiably proud of our contribution tosociety. Because a solar water heater isnt just a simple appliance that

makes our life easier. It is a whole philosophy. A philosophy that has

taken HELIOAKMI to the top of the worlds hot water technology from

the sun, in over 60 countries, in all climatic conditions and for all types

of water qualities.

A philosophy that leads the way and makes us, as professionals, feel the

weight of responsibility and obligation to offer products and services

that are in harmony with the environment and man. To hand over a better

world to our children.

Always true to our principle for excellence in design and continuous

advancements, HELIOAKMI today offers high standard solar water heat-ers.

Along with architects, engineers, installers and professionals in this

field we can all create together. Using the most economic and efficient

technologies available we produce hot water from the sun. For the com-

mon good.

We live in special times. The environment is sounding the alarm. The

whole world is looking towards other renewable energy sources.. The

international outcry is raising consciousness When the answer is

right next to us, should we still be searching for it?

Solar water heaters are not a luxury. They are a part of the future, today.

The future we promised our children.

Our goal is one. Quality of life. This is our philosophy.

Sincerely yours,

Christos Papadopoulos

General Manager

Dear Friends,




pany.



HELIOAKMI has been manufacturing and installing solar water heaters






the sun, in over 60 countries, in all climatic conditions and for all types

of water qualities.






advancements, HELIOAKMI today offers high standard solar water heat-ers.




mon good.





Solar water heaters are not a luxury. They are a part of the future, today.



Sincerely yours,


General Manager

Dear Friends,




pany.



HELIOAKMIhas been manufacturing and installing solar water heaters






the sun, in over60 countries, in all climatic conditions and for all types

of water qualities.






advancements, HELIOAKMItoday offers high standard solar water heat-ers.




mon good.





Solar water heaters are not a luxury.They are a part of the future, today.



Sincerely yours,


General Manager


3/32

C O N T E N T S

TECHNICAL SPECIFICATIONS AND DIMENSIONS - ALL MODELS Page 4

PACKING OF THE SOLAR WATER HEATER Page 5

WHAT YOU SHOULD KNOW ABOUT THE MEGASUN SOLAR

WATER HEATER Page 6

INSTALLATION INSTRUCTIONS Page 7

ASSEMBLY DIAGRAM OF THE SUPPORT BASE ON A FLAT SURFACE Page 8

ASSEMBLY DIAGRAM OF THE SUPPORT BASE

ON A SURFACE WITH MAXIMUM INCLINATION OF 32 Page 9

ANALYTICAL DESCRIPTION OF THE STORAGE TANKS

AND COLLECTORS COMPONENTS Page 10

INSTALLATION INSTRUCTIONS OF THE STORAGE TANK

AND COLLECTOR ON THE SUPPORT BASE Page 12

CONNECTION INSTRUCTIONS OF THE STORAGE TANK,

COLLECTOR AND COMPONENTS Page 13

FILLING INSTRUCTIONS OF THE CLOSED CIRCUIT

WITH THERMAL FLUID Page 14

DESCRIPTION OF THE PARTS OF THE ELECTRIC RESISTANCE

AND THERMOSTAT - CONNECTION INSTRUCTIONS Page 16

SPECIAL CLIMATIC CONDITIONS Page 18

INSTRUCTIONS AFTER THE INSTALLATION Page 20

TROUBLESHOOTING

REPLACEMENT OF THE MAGNESIUM ROD

INSTALLER INSTRUCTIONS Page 21

InstallatIon InstructIons InstructIons

TO THE END USER AND INSTALLER Page 22

FROST PROTECTION, OvERHEATING,

SNOW AND WIND LOADS, LIGHTNING PROTECTION Page 23

CONNECTION OF MULTIPLE SYSTEMS - TYPICAL INSTALLATIONS Page 24

INSTRUCTIONS FOR STRUCTURAL INTEGRITY AND FIXINGS Page 26

COMMISSIONING FORM Page 27

DECOMMISSIONING & SAFETY Page 28

INSPECTION CHECKLIST Page 29

MEGASUN AROUND THE WORLD Page 30

30 YEARS OF HISTORY Page 31

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TECHNICAL SPECIFICATIONS OF THE COLLECTOR1. External frame : anodized aluminium profile2. Back side : galanized sheet - 0,6 mm3. Back insulation : rock wool 40 mm4. Side insulation : glass-wool of 20 mm5. Absorber : A unique sheet with selectie titanium coating or

with black selectie.6. Absorbers tubes : copper pipes 10 & 22 (risers and headers)7. Coer : solar tempered glass8. Water-tightness : EPDM rubber/transparent silicone

Exe ig : dized miim tk ii : pyehe fm 40-60 mm

cyide mei : w b ee 3mm

Jke mei : w b ee 1,5 mm

cyide ie Pei : g emeig

addii pei : mgeim d

Eei eie : ppe them : bip f f

Pwe e : vibe fm 0,8kw 4kw

TECHNICAL SPECIFICATIONSOF THE STORAGE TANK

HElIoaKMI s.a. eeve he igh hge he peifii f he pd d/ hei eie wih pi ie.

Collector

with titanium

selectie

absorber

Collector

with black

selectie

absorber

EXTERNAL DIMENSIONS - ALL MODELS

1010

120

1275

160

1275

200

2050

200E

2050

260

2050

300

2580

300E

1010

160

02

01A 01B

14

15

16

08

04

09

EXTERNAL DIMENSIONS - ALL MODELS

MEGASUNMODEL

STORAGE TANK COLLECTOR SUPPORT BASE TOTAL WEIGHTDimensions

mmWeight

kg

Dimensionsmm

Collectors SurfaceWeight kg

( )

Weightkg

EMPTYkg (+/-5%)

FULLkg

120 530x1100 52 10 BAR 2050x1010x90 1 2,10 43 10 BAR 26 121 231

160M 530x1320 62 10 BAR 2050x1010x90 1 2,10 43 10 BAR 26 131 281

160 530x1320 62 10 BAR 2050x1275x90 1 2,60 51 10 BAR 27 140 290

200 570x1320 70 10 BAR 2050x1275x90 1 2,60 51 10 BAR 27 148 338

200E 570x1320 70 10 BAR 2050x1010x90 2 4,20 43 10 BAR 28 184 376

260 530x2050 103 10 BAR 2050x1010x90 2 4,20 43 10 BAR 30 219 469

300 570x2050 114 10 BAR 2050x1010x90 2 4,20 43 10 BAR 30 230 520

300E 570x2050 114 10 BAR 2050x1275x90 2 5,20 51 10 BAR 30 246 536

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PACKING OF THE SOLAR WATER HEATER

All MEGASUN appliances (storage tank, collector, support base and connection acce-

sories), are deliered well packed to the customer.

the ge k i ped bewee w d yfm ve f 7 m eh, whih

are tightened on the storage tank with stretch film. Then it is placed in a hard carton

pk, whih he idii f eh mde e dipyed he ide.The collector is packed with 4 plastic protectie elbows, attached on each corner,

which are fast tightened around the collector with a plastic strap (upon special order,the collectors could be deliered in groups of 10 pcs on a wooden pallete).

All the parts of the support base, the plastic bag with the connection fittings, the ther-

mal fluid and other accessories are packed in a carton box, on which the indications ofeach model appear on the outside.

The plastic bag contains all the connection fittings of each appliance like, screws, nuts

f he pp be, bke, pipe i, my pg, ew-, fey vve,

plugs and filling funnel of the thermal fluid.

All the tubes of the storage tank and collectors are coered with plastic plugs, in order

to protect their turns from striking during the transportation.

Mehdie ve de bye epibiiy d ik the peifii f he pd d hei eie hge y ime wih pi ie seeme f y dipe e de he jidii f he f ahe i Geee.

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WHAT YOU SHOULD KNOW ABOUT THE MEGASUN SOLAR WATER HEATER

The advanced technologys MEGASUNSolar water heaters use a closed cir-

cuit of natural circulation. The spe-

cial thermal fluid, used in the closed

circuit, enhances the performance of

the heater, protects it from the freeze

and it prevents the salt scale deposi-

tion inside the tubes of the collector.The closed circuit (jacket) where the

thermal fluid is circulating, is inde-

pendent and does not communicate

with the water storage tank.

I i vey imp he wih he

local representatie of HELIOAKMI,

the right size of the solar water heater,

whih wi ffi y eed.

For a better choice of the appliance, the

local climate conditions must be takeninto a serious consideration, as well as

y eed f h we.

the eegy vig h y wi hve

with the MEGASUN solar water heater,

depends on the use of hot water, theuse of the electric resistance and the

local weather conditions. Under faou-

be wehe dii, he eegy

vig my eh p 100%. o

y dy, he pwe f di-

tion is greater between 10:30am to

15:30pm. For this reason it is better to

hede y hevy mpi fhot water (washing machines etc) in the

midde f he dy.

Dig dy wih w hie d w

mbie empee, we gge y

turn on the electric resistance, in orderto hae hot water all the time.

hot outlet

cold inlet

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INSTALLATION INSTRUCTIONS

Befe y iig he we hee, pee ed efy he i -

lation instructions stated and illustrated in this manual.

Befe he ii f he we hee, i i vey imp h me

and installer agree on all the details concerning the correct and safe installation of

the appliance, such as location, placement point, static resistance and control of the

surface on which the appliance will be placed, piping and wiring run etc.

the pii y wi he f he ii f he we hee, hd be hded by y be (ee, bidig e) d he ye.

the ii hd be de dig he eei d pmbig egi

ppibe i y e.

For optimum performance, the solar water heater must face the south, for countrieslocated in the Northern hemisphere and north for countries located in the Southern

hemiphee. I e h i i y pibe f he we hee fe he

eq, y i wd E p 30o if mj h we dw i befe 2pm,

or towards West up to 30o if mj h we dw i fe 2 pm. I bh e, he

e f he ibi, i me h 6%.

If he we hee m be ied f whee he iii i e h

15o or more than 32o, then a different than the standard equipment of the support

be m be ed, imi he e ed f egi wih yph, hied hevy wid.

F he fe ii f he we hee pig f, i i eeyto install the support base in such a position so that the storage tank to be placed

exy ve f imbe d i e wy bewee w imbe.

If he fe whih he we hee wi be ied (pig f) i

compatible with the standard equipment supplied with each appliance, then a differ-

ent equipment must be used. The installer has to choose, propose and install this

diffee eqipme, wy de he e pii f he me.

F ii pig f, he D pe m be ewed wih he pppie

screws and nuts on the roof timber, in order to secure the right and safe installation

of the solar water heater.

I egi bje hevy wf, i i vey imp ee, h mhsnow doesnt accumulate behind the storage tank, and to check if the supports ofthe standard equipment are good enough to withstand the weight of the expected

w. the me ei m be pid, f egi wih hevy wid d m. I

hee e, he ge k m be ped i be wy he f d m

be igheed wih he ddii me p. I i bey eey e he

yph e (pge 18-19).

the be f he we hee we he d/h we pipig m be veywell insulated.

spei ei m be ke f he fiig d ei f he ed ii.

oy expeieed ehii pvide y wih he ei d he fiig.

Befe fiig he ed ii wih hem fid, he ge k m be mpeey

filled with water.

Befe ig he ii f he we hee, y m ed efy

the instructions, described and illustrated in this manual.

afe y hve fiihed he ii e he e whee he wk k pe.

Fi i he wy wih he eqied dei d hve me ig i. advie

me mi immediey he p f he wy Heikmi s.a.

the ii m mpy wih he d i egi d w (pmb-

ig, eeiiy, hygiee, b d he) h e i fe i y y.

the beve f he ii ed hi m i vey imp d he

-beve my e he vidiy f he wy.

Heiki s.a. deie y epibiiy f y kid, h my ie fm defeedii fm ie mipi fm y eeme eie

that are integrated/fitted on the appliance.

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A

A

B

B

C

C

D

D

D

D

E

E

U

U

Z

Z

A

A

B

B C

C

D

DD

D

F

F

E

E

U

U Z

Z

ASSEMBLY

INSTRUCTIONS

Before choosing the location and the installa-

i pi, ee h i i hded by y

obstacle (trees, buildings etc, see obstacle

diagram page 9).

The same support base is used for either

sloping or flat surfaces.

ce he pe a, B, c, D, u d Z by

screwing them tight as shown in the draw-

ings.

For models 260 and 300, screw also thepe F. sew gey he bottom plate E on

the plates B.

attention

the p pe E i djed fe he pe-

ment of the collectors.

Plumb the support base on the flat surfaces

leel. Place the collector(s), on the support

be d he ew i wih he my pg

and the screw nuts on the concrete, accord-

ig y y egi.

Assembly diagram of

the support base on a flat surface

Support base for

200, 260 & 300

(with 2 collectors)

Support base for 120, 160

& 200 (with 1 collector)

A = 2015 mm

B = 2360 mm

C = 1150 mm

D = 930 mm

D = 1180 mm

E = 840 mm

E = 1150 mm

E = 1430 mm

Z + U

F = 930 mm

SAME FOR

ALL MODELS

FOR MODELS 120 and 160M

FOR MODELS

160-200-260-300

FOR MODELS 120 and 160M

FOR MODELS 160-200

with one collector

FOR MODELS 200-260-300

with two collectors

SAME FOR

ALL MODELS

ONLY FOR

MODELS 260-300

LENGTHS OF THE

SUPPORT BASE PLATES

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D

E

E

U Z

A

BC F

Assembly diagram of the support base

on a surface with maximum inclination of 32

ASSEMBLY INSTRUCTIONS

Before choosing the location and the installation point, ensure

h i i hded by y be (ee, bidig e, eeobstacle diagram here below).

The same support base is used for either slopping or flat

surfaces.

Connect the plates (A) and (C) so that to form a parallelogram

frame, as shown in the drawing.

Bend the four (D) plates as shown in the drawing. Remoe the

tiles, and place the bended plates (D) on the wooden timbers or

on the concrete of the roof.

sew ighy he pegm fme (a)+(c) he pe (D).

Plumb the support base and screw the plates (D) on the woodentimber of the roof (see drawing).

sew he pe (B) he pegm fme (a)+(c). Eeh he pe (B) e ighy ewed he he f he pe

(A).

sew gey he bottom plate E on the plates B.

attention: The top plate (E) is fixed after the placement of the

collector(s).

note: The standard support base can be used also for surfaces

with minimum inclination 15o and maximum 32o.

For smaller or greater inclinations, different equipment is offered.

A

CD

D

C

E

A

BB

E

Z

U

UZ

attention: Exivey d y f he we heeMEGASUN 120 and 160M and for its installation on a ti led rood,

w ddii pe E (840mm egh) e eqied. thee

ddii pe epe he pe c (1150mm egh).

aeivey, f he fmi f he pegm fme, y

e he exiig pe E (840mm egh) i he pe f

he pe c. the pe c (1150mm), by mkig w he

10 whee eqied, wi be ied i he pe f he pe E.

OBSTACLE

TABLE

Latitude Distance between

collector and obstacle

0- 25 A = 1,0 x B25- 35 A = 1,5 x B

35- 45 A = 2,0 x B

45- 50 A = 2,5 x B

50- or more A = 3,0 x B

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01

02A

02

11

12

03

04

13A

07

07

05A

01A01B

08

10

05

06

13

12

13

03

03

0307

19

07

Analytical description of the storage tanks

and collectors components

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16

07

18

20A

20

14A

15

09

0309

14

17A

17A

17

19

07

03

01 Storage tank

01A+B Storage tanks suspension point

(ed y i pdi pe,

ignore them)

02 Filling pipe (for the closed circuit)

02A sfey vve 3 Bar

03 Elbow raccord (4 pcs)

04 Thermal fluid inlet pipe (to the stor-

age tank from the collector) (indica-

i jke)

05 Small connection tube

05A Insulated coer of the small con-

nection tube

06 Raccord

07 Water-tight compression ring

(4 pcs).

08 Hot water outlet pipe

for home consumption

(idii: h e)

09 sfey / -e vve

10 Thermal fluid outlet pipe

(from the collector to the

storage tank)

11 Collector(s)

12 Pipe unions (collector connectors).

oy f mde

with two collectors

13 Bottom left hand collector pipe

13A Pg 1/2

14 Filling pipe for the closed circuit

14A Pg 1/2

15 Cold water inlet pipe

(idii: d ie)

16 Thermal fluid outlet pipe (from

the storage tank to the collector)

(Idii: jke)

17 Top right hand collector pipe

17A Pg 1/2

18 Large connection tube with insula-

tion coer

19 Thermal fluid inlet pipe

(return to the collector)

20 Protectie side coer

20A Face plate

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Before the placement of the collectors on

the support base, loose the screws of thebottom plate E, so that the bottom fin of

he e p ey bewee he

plates E and B.

The top plate (E) is fixed after the

placement of the collector(s).

Place and centralize the collector(s) on

the support base.

F mde wih w e, y me hem eh he by ig he

pipe unions (12), supplied with each appli-ance.

Secure the bottom part of the collector(s)

by screwing tightly the bottom plate E

on the plates B.

Screw tightly the top plate E, on the plates

B, securing the collector(s).

Place the face-plate (20A) on the U, and

secure it under the collector(s).

Then place the storage tank on the two U.

attention

a. Before placing the storage tank on the

w u, hek efy if he pe ud Z e ewed ighy he pe

B.

b. The electric resistance must be on the

right hand side, as we face the appli-

ance.

c. Ensure that the appliance does not tiltfrom one or the other side and that the

tubes (02) and (14) of the storage tank

are ertical on the highest point of the

ge k. ue eeeiy pmb.

E

E

Z

B

20A

Installation instructions of the storage tank

and collector on the support base

Z

B

E

U

U

20A

E

A

12

B

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Connection instructions of the storage tank,

collector and componentsFor models with two collectors, connect

hem by ig he e e(pipe unions) (12), supplied with each

appliance.

Put the plug (17A) on the pipe (17) which

is located on the top right hand side of

the collector (13) and the plug (13A) onthe pipe (13) which is located on the bot-

tom left hand side of the collector, and

use Teflon or oakum for their complete

water tightness.

Screw the elbow raccords (03) on the

pipes of the storage tank (04) and (16)

wih he idii jke d he

pipes of the collector(s) (10) and (19)

epeivey.

afewd ji he m eitube (05) onto (04) and (10) and the

big connection tube (18) onto (16) and

(19) epeivey. Before connecting

the tubes (05) and (18) ensure that

the compression rings (07) have been

placed on the tubes.

Screw the non-return ale (09) on the

inlet pipe (15) of the storage tank (indica-

i: d ie).

ce he d we ppy he

fey/-e vve d he d

we ppy i he ge k i

mpeey fied. Whe y e fiig he

storage tank with water, the outlet of hot

water (08) should be opened. Connecthe h we ppy he ge k

e pipe (08). (Idii: h e).

After connecting all the fittings, check

vey efy ei f hei

complete water tightness.

attention: In regions where the tem-

perature falls bellow zero, ensure that

the connection tubes of the storage tankand collector as well as the hot and

cold water piping to/from the solar water

heater are well insulated.

FOLLOW STEP BY STEP THEINSTALLATION INSTRUCTIONS OF

THIS MANUAL.

ALL THE PLUMBING INSTALLATIONSMUST BE MADE IN ACCORDANCE

WITH THE PLUMBING REGULATIONSAPPLICABLE IN YOUR AREA.

12

17

13A

17A

0307

05

04

10

03

1816

15

09

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1402A

14A02

For antifreeze protection of the

solar water heater, please follow

the ratio of antifreeze protection

stated in the table here below.

Mix well the thermal fluid with water.

Start filling the closed circuit with

the mixture, from the pipes (14)

and (02).

The filling must be done

eivey, fm bh

pipes (14) and (02).

During the filling, we

dvie y hke heyem, h ee

that no air is trapped inside

the storage tank and thecollector.

Continue this procedure until

he e ii i mpeey

full.

the epibiiy f he -

rect use of the antifreeze liquidqiy i f he f he

installer and in no case of Helioakmi

S.A.

the e f we y he iqid my

e he vidiy f he wy.

ANTIFREEZE PROTECTION RATIO TABLE FOR SOLAR WATER HEATERS

Please take into account also to the dilution table on the bottle of the antifreeze liquid.

Filling Instructions of the Closed Circuit with

MODELMEGASUN GASUN MEGASUN MEGASUN MEGASUN MEGASUN MEGASUN MEGASUN

120 x 2.10m2 160 x 2,10m2 160 x 2.60m2 200 x 2.60m2 200E x 4.20m2 260 x 4.20m2 300 x 4.20m2 300E x 5.20m2

CLOSED CIRCUIT

TOTAL CAPACITY9 lt 10 lt. 11 lt 13 lt 18 lt 21 lt 22 lt 23 lt

TEMPERATURE RATIO

- 5C

Water 8 lt 9 lt 10 lt 11,5 lt 16 lt 19 lt 19,5 lt 20,5 lt

Fluid 1 lt 1 lt 1 lt 1,5 lt 2 lt 2 lt 2,5 lt 2,5 lt

- 11C

Water 7 lt 8 lt 9 lt 10,5 lt 14,5 lt 16,5 lt 17,5 lt 18,5 lt

Fluid 2 lt 2 lt 2 lt 2,5 lt 3,5 lt 4,5 lt 4,5 lt 4,5 lt

- 18C

Water 6 lt 6,5 lt 7,5 lt 9 lt 12,5 lt 14,5 lt 15,5 lt 16 lt

Fluid 3 lt 3,5 lt 3,5 lt 4 lt 5,5 lt 6,5 lt 6,5 lt 7 lt

- 20C

Water 6 lt 6,5 lt 7,5 lt 9 lt 12 lt 14 lt 14,5 lt 15,5 lt

Fluid 3 lt 3,5 lt 3,5 lt 4 lt 6 lt 7 lt 7,5 lt 7,5 lt

- 27C

Water 5,5 lt 5,5 lt 6,5 lt 7,5 lt 10,5 lt 12,5 lt 13 lt 13,5 lt

Fluid 3,5 lt 4,5 lt 4,5 lt 5,5 lt 7,5 lt 8,5 lt 9 lt 9,5 lt

- 36C

Water 4,5 lt 5 lt 5,5 lt 6,5 lt 9 lt 10,5 lt 11 lt 11,5 lt

Fluid 4,5 lt 5 lt 5,5 lt 6,5 lt 9 lt 10,5 lt 11 lt 11,5 lt

14


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20

17A

After the filling of the closed circuit, it is

eey e he pg (17a)

the top right hand of the collector, until it

starts dripping thermal fluid (for models

with two collectors, loose also the toppipe union (12) in order to release the

air from the collector(s). Tighten back the

plug (17A) and the collector connection

(12) and check for their complete water

tightness.

Place the protectie side coer (20).

12

Add some more fluid in the closed circuit,

until it oerflows from the tubes (14) and

(02). Screw the plug (14A) onto the tube

(14) d fix he fey vve (02a)

the tube (02).

chek efy ei f m-

plete water tightness.

Thermal Fluid (for the solar water heaters of closed circuit)

14

02A 14A

02

151515


16/32

DESCRIPTION OF THE PARTS OF THE ELECTRIC RESISTANCE

AND THERMOSTAT21 Plastic coer22 Electric resistance

22A Thermostats socket

22B Resistances coer

23 Base of multiple plug (for the

electric lines)

24 Metal wires for the connections

of the resistance with the ther-mostat25 Rubber flange for water tight-

ness

26 Central nut

27 Tightening nuts

28 Grounding lug

29 Electric resistances lug30 Grounding wire

31 Power wire

32 Multiple plug for power lines

33 Thermostat

34 Temperature control

35 sfey hem wih (idi-

i F s)

CONNECTION OF THE CABLES1. t ff he pwe mi ppy.

2. The coer of the electric resistance is

on the right hand side of the storagetank. Unscrew the screws and remoe

the coer.

3. the hem i djed fm he

fy 60oc. Y dj i

he empee y wih, by ig he

temperature control (34). In that casewe dvie h he empee y wi

fix not to exceed 75oC.

4. chek he fey hem wih (idi-

i F s) he hem.

the fey wih i i pei whe

it is pushed in.

5.RESISTANCE TYPE OVAL:Connecthe g 2 f he hem he g n

of the power line connector (blue cable).

Connect the lug 3 of the thermostat to

he g l f he pwe ie e

(bk be) ee digm bve.

RESISTANCE TYPE ROUND:

Connect the lug 1 of the thermostat to

he g l f he pwe ie e

(black cable). Connect the lug 4 of the

hem he g n f he pwe

ie e (be be) ee di-

gram at page 17.

6. The grounding lug is connected fromthe manufacturer, as shown in the

diagram. Ensure that it is well screwed.

7. Pass the wire through the hole of the

coer (21) and connect the wires on

the power line connector. Screw the

coer (21) on the storage tank.

attention:

the gdig g ( ) on the

power line connector, must be con-

DIAGRAM OF ELECTRIC

CONNECTION OF THE

THERMOSTAT

230 VAC

1 2 3 4

rsIstancE

28

26

34 35

33

24

27

32

31

24

27

2929

23

31

30

1 2 3 4

30

5060

70

80

N L

29

22A

22B 22A

22

25

31

31

RESISTANCE TYPE OVAL

16


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nected with the grounding wire of the

building

the pwe be m be eed

a switchboard, of which the separatingdistance of the contacts is more than

3mm.

The standard power of the electric

resistance is 2000W for 230v. Upon

a special order, the electric resistance

can be offered with power from 800Wto 4000W. For power of 110v, the

electric resistance is aailable (upon

special order) with power from 800W

to 2000W.

note: a eified eeii m mke he

electric connections.

Ee h he eei ei

mpy wih he eei egi

ppibe i y e d y bid-ing.

D he eei eie,

whe he ge k i empy.

All models 120, 160, 200, 260 and 300

can be deliered, upon a special order,

with a tube heat exchange built-in to the

electric resistance.

The tube heat exchanger can be con-

eed wih he e heig yem f

me eegy vig.

The instructions of the electric connectionsare same to the ones of the electric resist-

ance without a tube heat exchanger.

ELECTRIC RESISTANCE WITH A BUILT-IN TUBE HEAT EXCHANGER

hot water inlet from

the central heating

cold water outlet to

the central heating

DIAGRAM OF ELECTRIC

CONNECTION OF THE

THERMOSTAT

230 VAC

1 2 3 4

rsIstancE

21

36

26

33

30

24

27

32

24

27

2929

23L

31

34 35

28

RESISTANCE TYPE ROUND

17


18/32

I egi whee hevy wid, yph,

hurricanes and storms are usual, it is

eey e he pei TYPHOON

SET, pvided by HELIOAKMI.

The typhoon set contains:

1. Pe (J) f 1150mm

2. Plates (D) of 930 mm

3. Short fixing plates (L)

4. Long screws - small step nuts

5. Tape of metal belt.

6. Rubber profile

7. My pg - ew

Befe y iig he ppie,

y hd hek he fwig:

F ii f fe, hek

he deiy, hde d egh f

the concrete.

F ii pig f, ddi-

tional rafters must be installed under thetiles, so that the distance between the

rafters doesnt exceed 50 cm, and their

strength must be good enough for the

safe installation of the appliance.

S p e c i a l c l i m a t i c c o n d i t i o n s

To assemble the support base

fw he me emby pede,

mentioned on pages8-9 (for flat or sloping

surfaces).

For the connection of

the plates U, Z and B,

use the long screws -small step nuts.

Befe y dj

the metal belts around

the storage tank, placethe rubber profile

between the storage

tank and the metal

belt.

afe y hve ped he ge k

he pp be, dj he me

belt connecting the one end of the belt

between the screw-nuts, which tightenthe plates U and Z and the other end of

the metal belt between the screw-nuts

which tighten the plates U and B. (see

detail a & b).

attention

Use the second nuts

(O) to tighten the metal

belts. Tighten well the

metal belts on the stor-

age tank.

ASSEMBLING INSTRUCTIONS

J

U

B

J

CD

b

U

B

J

L

a

U

Z

O

18


19/32

Whe y hve i he ppie

f f, y m e he w

pe J, ewig hem he pe c.

Screw the short plates L on the platesJ. t ew he pe J he pe c

use the long screws - small step nuts.

Screw the short fixing plates L and

pe a he f, ig he mypg f he yph e, we he

4 screw nuts included in the plastic bag

with the fittings. The plastic bag with the

connection fittings is packed in the sup-

port base carton.

F he fe ii f y ppi-

e, we emmed y ee hestorage tank on the support base using

more mettal belts than the ones illus-

trated in the photos.

All the parts and accessories of the

typhoon set are packaged in one car-

ton which carries on the outside the

description TYPHOON SET

For installation on a sloping roof, we

emmed y e me me be,

securing both the storage tank and the

pp be, by ewig hem hetimbers under the tiles. You can also

e he f D pe, by ewig hem

under the timbers.

INSURANCE OF THE

APPLIANCE

I egi whee yph, d,

hurricanes etc occur and hail is larger

than 20mm in diameter, we recommendy ie ie f y ppi-

ance.

When the TYPHOON SET is used, the face-plate (20A) is not placed

J

LA

DD

D

D

D

D

19


20/32

the we hee wi eh pi-mm pefme w dy fe heii. Dig hee w dy, i irecommended to aoid hot water con-sumption, een if there is sunshine.

chek evey ye he eve f he fid i

the closed circuit. I egi wih f d, we em-

med h y e he g f hee wih we, evey w mh iorder to remoe the dust from the glass,unless there is enough rain.

I e f g dmge, epe heg immediey vid fhe dm-age of the collector.

F we hee, he mi piipeand codes require that the function of thevve i heked e ye. We recommend that during the same periody hek he ew, , pe, my

plugs, screw nuts and support plates, foree y dmge, epeiywhen the appliance is installed near thee. I e f dmge, hey m beeped by we expee.

Dig g bee (h mmehidy), i i emmeded vethe collector(s) with an opaque coer.

oe he ge k i fied i wihwe, i m ge empy (eved)f my h, d y if hee i need for changing the magnesium rodor the electrical resistance for which it isrequired a short time, since there is the

pibiiy f eig k d deh-ments in the internal protection of thestorage tank.

I e whee he we ppy pe-e exeed 6 B i i eey fia pressure reducer.

TROUBLESHOOTING

A. IF THE SOLAR

HEATER DOESNT

SUPPLY HOT WATERWITH

THE SUN1. chek efy he ei f

the solar water heater for leaks.2. Check the fluid leel in the closed circuit

d fi i, if eey (ee ii,page 14).

3. Check the connection tubes (05) and(18) ee h hey e beedor twisted

4. Ensure that there is no air trapped

inside the collector and the storage tank

5. Ensure that the solar water heater isinstalled in horizontal position.

6. Ee h he ppy f h we i eed ppy f d we.

7. chek he pmbig pipig f yhouse as well as the taps for slow

leaks.8. Ensure that the storage tanks and col-

e ei e ppey mded hey e fy we igh.

9. Ensure that there is no obstacle (build-ing, tree etc) shading the solar waterhee, y p f i.

The following should be also taken intoconsideration:10. The consumption of hot water is big-

ge h he ppie piy.11. Weather conditions.12. Huge consumption of hot water during

the night.13. The customer didnt understand the

use of the electric resistance.14. Customers expectations about the

pefme f he yem.If y we hee ie ppy h we, y distributor.

B. IF THE SOLAR

WATER HEATER

DOESNT SUPPLYHOT WATER WITH

THE ELECTRIC

RESISTANCE

1. t ff he pwe ppy dremoe the resistances coer.

2. chek he fey hem wih Fon the thermostat, which has to bepushed in.

3. Check the wiring between the ther-mostat and the electric resistance.

4. chek if he hem i djed

in a lower temperature than thedesired one.

5. chek he eie f y dm-age

6. chek he mi pwe ppy.7. t he pwe ppy ON and

check if the electric wires are prop-ey eed he eev peof the resistance.

A certified electrician must doall the electrical connections and

checkings.

REPLACEMENT OF THE

MAGNESIUM ROD

epe he mgeim d:1.t he pwe ppy ff.

2.Empy he we fm he ge k.3. Remoe the electric resistance and

unbolt the old worn magnesium rodand fix the new one. Fix afterwardshe eei eie fe y hvechecked that the elastic flange is notworn-out. If the elastic flange is worn-out, replace it with a new one.

4. t he we ppy d hekh he k i mpeey we igh.

5. afe he k i mpeey fied,wih he mi pwe ppy.

note:An authorized distributor must do the

replacement of the magnesium rod.The time of the replacement, of themagnesium rod, depends on theqiy f he we.It is recommended that in areas wheretotal dissoled solids (TDS) is up to600ppm, the magnesium rod must beeped evey 5 ye.In regions where the TDS is more than600ppm, the magnesium rod must beeped evey 3 ye.In regions where the TDS is more than1000ppm, the magnesium rod must beeped evey 2 ye.

note: In areas where the total dis-soled solids (TDS) is more than600ppm i i eey i filter

Note:The specifications of the products, their acces-sories (e.g. electric resistances, thermostats,ales, liquid.etc) and their materials are inaccordance with the Greek standards . You mustbe informed and check if the specifications of theproducts and their accessories are in accordancewith the local and national standards and regula-i h ppy i y y. the impe/di -tributor is responsible for the importation, com-mercialization and installation of the products.

HElIoaKMI s.a. i e i ibe f y dm-

ge ed hid pie f y e, has wrong installation of the appliances and theiraccessories, from the non-obseration of theregulations and lows (electrical, urban planning,pmbig, iye) ppyig i y -y/e. I e f defeive pd ppy heem d dii f he wy.

Thank you for choosingour products. Both our distributors

and us assure you that you havemade the right choice.

If you have questions or you need

any further information, pleasecontact your local distributor or

our Headquarters in Greece.

INSTRUCTIONS AFTER THE INSTALLATION

20


21/32

Local Standards

All Installations must be completed inaccordance with the local regulations

(electrical, plumbing, urbanism and

he) d dd h ppy i y

area.

Ii i he eiy fai m mpy wih he

requirements of AS/NZS 3500.4 (AS/

nZs3500.4.2 ni Pmbig d

Drainage Code Hot Water

sppy syem aepbe si), we y eev dd

and regulations. It is a requirement of AS/

NZS 3500.4 that for a new installation, a

we hee be ied i fe y

whee i he eve f ek, ppey my

otherwise be damaged. Construction,

ii d diig f fe ym mpy wih he bve meied

Standard.

Authorized Person

1. Ii m be mpeed by qified depe ie,

wh hd eev idy iee

or certificates required for the work

completed during the installation

process.2. the em hized pe()

ie ed hgh hi

dme efe iby qified

professional.3. Unless otherwise specified, no part

f he HElIoaKMI yem mybe inspected, repaired or maintained

by ybdy he h hized

person.

Safety

1. At all times installers must adhere topei heh d fey gideie

ied by Wke, d he

eev idy ii.

2. At all times installer is responsible

f hei w fey whie mpeig

installations.3. ude ime hd y

person, qualified or otherwise, attempt

to install an HELIOAKMI solar water

heig yem wih hghy

READING and UNDERSTANDINGhi ii m. F y

qeie HElIoaKMI ff my be

contacted.

Provisions of Safe Tray

It is a requirement of AS/NZS 3500.4 thatfor a new installation, a water heater be

ied i fe y whee i he eve

f ek, ppey my hewie be

damaged. Construction, installation and

diig f fe y m mpy wih

the aboe mentioned Standard.

Instructions for Draining the system

Turn Off The Water Heater

If i i eey ff he we

heater on completion of the installation,

such as on a building site or where the

premises is acant, then:

-swih ff he eei ppy heisolating switch to the water heater.

-Close the cold water isolation ale at

the inlet to the water heater.

Solar Storage Tank Draining

To drain the solar storage tank:

-Close all hot water taps.

-Operate the relief ale release leer -

d e he eve p bk y wi

damage the ale seat.

-Operating the leer will release the

pressure in the water heater.-Undo the union at the cold water inlet to

the solar storage tank and attach a hose

to the water heater side of the union.

-Let the other end of the hose go to a

drain.-Operate the relief ale again.

This will let air into the water heater and

allow the water to drain through the hose.

Warning: the ii my be depressure. Take care when remoing the

solar circuit relief ale, as a sudden

dihge f peized h vp my

be experienced. This discharge will createa sharp sound of apor being released.

Open the heat exchanger drain ale andremoe the plug from the end of the hose.

the ed ii id wi d he he.

Place the end of the hose into a container

d di he ed ii id fm he

heat exchanger.

Note: The heat exchanger can contain

my ie f ed ii id. a

iby ized ie hd be ed

mmde hi m f id.

The closed circuit fluid contains foodgrade additives (rust inhibitor, anti-

freeze agent, colour) and is harmless

to the environment. However, it is

good practice to recover any excess

closed circuit fluid and remove from

site for appropriate disposal.

Instructions to check the Pressure

and Temperature Relief valve

1. F ed p yem, he p

must operate at


22/32

INSTALLATION INSTRUCTIONS

the pipig yem ed he yem i

resistant to rain and moisture. the h wer pipig yem i herm ied.

sk

maximum (snow load) is 2kN/m according toENv 01/03/1991, and v

m(mean wind speed) is

180 km/h.

Disclaimer: This equipment can be installed inareas with snow load alues under 2kN / m andthe wind speed aerage under 180 km/h.

or eqipme be y ied wih fey

ale on the inlet cold water to preent oerprere, d fey vve verheig. there

is oerheating circuit which uses metal pipes(copper, stainless steel or steel) to hot waterexri. thi pipe yem i eed he

exri yem f he eqipme. thi yem

hd e y prbem y her

building material. the yem hd be ed wih mixig vve

draw-off temperature limit of 60 C.

the ii f he yem hd be per-frmed y by hrized ier. cer

should be coered during installation, for exam-ple with the same coer used for transportation.the er wi be fied wih prpyee gy

+ wer, wih ir. afer h, he er

coer can be remoed. To start using the col-er, pe he wer. afer h, y e

the installation. To re-check, please perform thesame procedure.

the peri f he yem r ie eve-ryhig w heked d i rre.The end userhd firm h everyhig i rre.

chek he gke, vve, fiig d herm

ii (repig i if eery). Frhermre,it should check the general state of metallic struc-ture as well, screws and nuts, in order to detecty ype f wer r dmge. thi i epeiy

important in marine enironments. The chargesfrm hee repir wi be he repibiiy f

the owner. If he wer prere exeed 6 br, y m

install a pressure reducing ale. the MEGasun yem hd be ied

close as possible to the place of consumptionf h wer. I i very impr ifrm ed

user, of technical aspects of installation, to agreewih him he dei i hi wy, ere

installation and aesthetics possible, respectingthe appearance of the building where it will beperformed.

the MEGasun yem be ied he

roof, terrace or garden, on a firm surface andrdy, whih de reeive hde f erby

be i y e.

cmpy wih rre regi wer d

eeriiy ii. Keep i mid he dii f wid, epeiy drig emby.

the dmge reig frm fy ii re

vered der wrry.

the k m be f f wer befre fiig heprimry iri r fied wih he he rfer

fluid before connecting the electrical resistancebackup.

afer fiihed he yem ii, mke re

that all leftoer materials used on the installation,re eed, ie hey my e ijry r

damage to third parties. the redig f hi iri m i very

impr, ie i heked, my vid he

wrry.

the pipig yem ed i hi yem i wer-proof and moisture.

a pipe fr dig h wer re hermy

isolated. he m be ed fr h wer driig

the nearest gutter, to aoid damage in materialsor people.

WARNING: THE INSTALLATION SHOULD NOTCOMPROMISE THE STRUCTURAL INTEGRITYOF THE BUILDING ON WHICH IS INSTALLED.

IN THE CASE OF MALFUNCTION

(instructions to the installer)

Ensure that: the ime dii permi he fiig f

he r yem.

there i hdig f he er by y

be d h hey re e frm d. th here i ekge i he ed iri d

that all of the connections, raccords, and pipesre ighy rewed d wer-igh.

If here i mixig vve fr h / d wer i

the outlet of the boiler, please check that it is cor-rey djed d i i fiig.

there i egh iqid i he ed iri fer- k. Drig dy wih high rdii

and normal operation of the pump, the pipes intheir highest points (outlet of collectors) shouldbe warm (be careful with the high heating due tosolar radiation).

there i ir rpped iide he er.

Note: All the connections and the installationsmust be done according to the regulations (electri-, pmbig, rbim d her) h ppy iyr re.

INSTRUCTIONS TO THE END USER

AND INSTALLER

the MEGasun r yem d reqire

the interention of the user. It is recommendedhgh, h fer he fir 15 dy f fiig,

to check the pressure of the closed circuit (collec-tor - boiler) and that the temperatures are at nor-mal leels in relation with the time of the inspec-tion, the sunlight and the Installation Sheet.

afer w yer f fiig, i i remmeded

that a program of annual serice is begun. Themaintenance program is to replace the fluid loopiri d mii he prpri f prpyee

gy, repig he mgeim de d

check the operation of all existing ales If here i brekge f er g, i m

be reped immediey h he brber wii

not be damaged. I dy dii r m rif, i i rem-

mended to clean the glass with a damp cloth, if

he er re diry . I i remmededthat the glass of the collectors are washed ate wie yer wih wer, exep if i fe

rains. afer he ii i mpee, he ier wi

hae to inform the client about the functioning ofhe yem.

I he e f y mfi f he yem, we

recommend the client to contact the installer ashe knows all of the arious parameters and thepossible particular characteristics of the instal-lation.

the vve m be peridiy heked

assure their correct functioning .

the ier wh wi mke he diemby mbe a specialized and certified installor in accord-e wih he i regi h ppy iyr ry. Whe he ii i mpeed

he must leae the place in the same conditionsas before the installation.

Befre pig he yem i peri, he

installer must check all the ales and fittings,including also the loop circuit as well as the mainwater tank.

the fey vve m be heked peridiy

assure their proper functioning If here i dger f fr, pee hek he

loop circuit to confirm if the s antifreeze liquid

conforms with the rules. In case of oerheatingcheck the oerheating ale to assure that theiri i wrkig prpery.

D r he yem peri if he weher

conditions are around 0C. Check the loop circuitd he qiy f he ifreeze iqid. c

the standards of the builder. Deri: drig high rdii d e

he ppy f wer d d empy he yem

Deri: the wer mpi f he y-tem can be withdrawn during high radiations topreve he verheig f he yem.

the he rfer iqid i prpyee gy

Drig perid f prged bee i i rem-mended the collectors to be coered with anopaque coering so that to aoid working unnec-eriy. D e pi meri r g

material for their coer. the yem de e y eeri devie

for freeze protection, because it works with pro-pyee gy.

the verheig prei f hi yem i i

electrical dependent, howeer it should not bedieed frm he eeriiy r wer ppy

network.

INSTALLATION INSTRUCTIONS Instructions to the end user and installer

22


23/32

Frost Protection

Overheating Snow and Wind loads Lightning protection

I my ie i he wie mhtemperatures fall to well below freezing.

As water freezes, it expands. This can

happen in the copper tubes of the solar

h we e we i he -

lectors can freeze and stretch the tubes

a little. After repeated frosts the tubes

fiy pi, eig i beleaking collector.

There are a few options to consider regar-

ding frost protection:

Frost Dump vales:

F dmp e biy empeeoperated ale that opens when the tempe-

rature of water falls to below 4C allowing

cold water from the tap to replace it.

This cold water is still cold, at around

8C but it will be warm enough to preent

freezing.

For single panel collectors, the frost dumpale should be positioned on either of

the bottom outlets. This is because we

know that warm water rises and therefore

the coldest water will be at the bottom of

e. F ped yem, wfrost dump ales are needed. One for

each collector, positioned at the top and

bottom.

Furthermore, because the water lost

through the ale can become significant

depending on the temperature, it is a good

idea to harest this water rather than lettingit go to waste. This can be as simple as lea-

ding a pipe from the ale down to a bucket.

If y s ce wi be g i

the sun for an extended period of time,

y hd ve he e p-

tect against oerheating and damaginghe e d y s H We

syem. a he diipi devie my be

needed to protect against oerheating

Snow and wind loads are a significant

factor for structural planning. European

norms were established, albeit without

peifiy kig ii iaccount. Wind and snow loads affect the

e d he ii yem.

Depending on the conditions and height of

the installation site as well as the collector

inclination, the mechanical loads on theyem vy ideby. a ee

guidelines for the planning of structural

frameworks and standards EUROCODE

1, (European guidelines for structural

planning). With combined snow and wind

loads the maximum strain for the solarcollector is 1,000 N/m. Note that wind

i pike my f edge.

I i mdy fw be pie

e f i pig,epeiy e-

ted to snow and wind loads. Different

de d egi ppy i diffeecountries and regions. In case of doubt

and/or in absence of exact static calcula-i ( emmeded) wy w f

additional fixtures,weight, anchors, and

ew, epeiy i egi wih kwweather extremes.

If the solar heating equipment protrudes

aboe the roof ridge or the building height

(installation height) exceeds 20 m, and

there is no lightning grounding rod instal-ed, k y eei

e y mpe he f h

d eeiiy he eh bdig

with an electrical earth cable of at least

16 mm

2

.Special measures regarding lightning

protection are not required for building

heights (installation heights) of less 20 m.

Where there is a lightning grounding rod

yem ied, k y eei

contractor to check that the solar heatingyem i ided i he ighig pe-

i yem.

statEMEnt: the die w d fey wih egd f h be eved f he peifi imi dii f eh

y

23


24/32

PARALLEL CONNECTION OF MULTIPLE SYSTEMS

notes:

1.All the branch lines to the

storage tanks must hae

same length and geom-

ey (dimee f be,

cures etc)

2. Pressure drop (p) must

be almost the same in

hot and cold-water tubes

SERIAL CONNECTION OF MULTIPLE SYSTEMS(It is recommended the installation of maximum fie appliances)

20mm (3/4) 15mm (1/2) 20mm (3/4)

25mm (1)

25mm (1)

COLD WATERINLET

HOT

WATEROUTLET

COLDWATERINLET

HOTWATER

OUTLET

(

3/4)

(

3/4)

In multiple connections

where the electric resist-

e i ed, y hd

aoid connecting the

electric resistance in the

storage tanks of the firsttwo appliances. These

appliances will be used

to pre-heat the water for

the consumption.

For this kind of instal-

lation (or for more than

three solar water heaters

eed i w) y

hae to make a special

eqe f 3/4 ie--lets pipes on the storage

k. We emmed y

to use a maximum of fie

appliances.

All the piping in 20 mm diameter

PARALLEL CONNECTION OF MULTIPLE SYSTEMS IN SERIES

notes

1. All the piping in 20 mm diameter. For this kind of

installation (or for more than three solar water heat-

e eed i w) y hve mke peieqe f 3/4 ie/e pipe he ge

tank.

2. We emmed y e mximm f five ppi-

ances in a row.

COLD

WATERINLET

3

2mm(

11/4)

3

2mm(

11/4)

2

5mm(

1)

2

5mm(

1)

2

0mm(

3/4)

2

0mm(

3/4)

HOTWATER

OUTLET : he bve dwig e ypi dwig f bi piipe.

Y m wy peiized egiee f y w i -

lation.

24


25/32

TYPICAL INSTALLATION OF MULTIPLE UNITS

notes

1. All the branch lines to the storage

tanks must hae same length and geo-mey (dimee f be, ve e)

2. Pressure drop (p) must be almost the

same in hot and cold-water tubes

3. I e h y hve i e

more solar water heater, the diameter

of the piping must be increased to thenext size.

notes:1.All the branch lines to the storage tanks must hae

me egh d gemey (dimee f be, ve

etc)

2. Pressure drop (p) must be almost the same in hot and

cold-water tubes

COLD WATER

INLET 25mm (1)

25mm (1)

20mm (3/4)

2

0mm(

3/4)

1

5mm(

1/2)

15mm (1/2)

2

5mm(

1)

HOT

WATER

OUTLET

TYPICAL INSTALLATION OF MULTIPLE UNITS

- PARALLEL CONNECTIONCOLD

WATER

INLET

32mm (11/4)

2

5mm(

1)

20mm (3/4)20mm

(3/4)

2

0mm(

3/4)

15mm (1/2) 15mm (1/2)

2

0mm(

3/4)

2

5mm(

1)

3

2mm(

11/4)

HOT

WATEROUTLET

: he bve dwig e ypi dwig f

bi piipe. Y m wy pei-

ized egiee f y w ii.

25


26/32

INSTRUCTIONS FOR STRUCTURAL INTEGRITY AND FIXINGS

Structural support for solar heatingsystems

Support

Installation on roofs must not produce restrictions

to rainwater flow that enables water to accumulateor pond.

Solar collectors installed above metal roofs must

have clearance between the collector and metalroof to avoid the accumulation of water or organic

matter. On corrugated metal roofing the clearancebetween the collector and the top of thecorrugations must be no less than 25 mm.

In coastal zones, and in locations adjacent toindustrial areas clearance of 50 mm must be

provided to allow access from at least 50% of thesystems perimeter to wash the cladding undersolar collectors.

Clearances must be provided to allow access to

and replacement of, all serviceable components.

The only point of contact between a solar heating

system and metal roof cladding should be wherepenetrations are made.

The load of the solar system must be carried bythe buildingstructure. The solar collector must befixed directly to the building structure and not to the

cladding. Means of mounting are shown in Figures1, 2, 3 and 4.

COMMENT:

Care must be taken to avoid distortion of metalcladding material.

The susceptibility for concrete and clay tiles to

break means that special care must be taken whenworking on and attaching systems to these roofs.

Figure 1: Panel bolt fixing Figure 2: Panel screw fixing

Figure 3: Panel stud fixing Figure 4: Panel stud fixing

All solar collectors must be fixed at no less than 4points.

Solar collectors with an area of up to 4m2, may be

fixed with: 14 gauge screws in accordance with

Figure 2 into the centre of one of:

(a) 14 gauge screws in accordance with Figure2 into:

(i) purlins 70 x 45 mm or larger, that spanno more than 900mm, or

(ii) purlins 90 x 45 mm or larger, that span nomore than 1 100mm, or

(iii) rafters, or

(iv) truss top chords

(b) 10mm galvanised bolts in accordance withFigure 1 to purlins 90 x 45 mm or larger

that span no more than 1100mm

(c) 10mm galvanised bolts welded to 3mm

galvanised plate in accordance withFigures 3 or 4 to either:

(i) rafters, or

(ii) truss top chords.

Where solar collectors with an area of greater than

4m2

to be installed, each group of

panels with an area of up to 4m2

is to be separatedfrom other groups by:

(a) At least one rafter or truss spacing alongthe roof, and

(b) By at least one purlin space up the roofslope

Where collectors are mounted together orseparately on a frame, the frames must meet therequirements described in Paragraph 6.5.

Alteration of roof structure forinstallation

Rafters, purlins and truss members may not be

cut, drilled, notched or otherwise reduced instrength except for drilling for the attachment ofcollectors or tanks.

Mounting of solar systems

Where solar collector panels are mounted aboveroof cladding, they must be mounted so that the

weight of the panels is:

(a) transferred directly to underlying rafters ortrusses with connections conforming with

paragraphs 6.2.9 or 6.2.10, or

(b) transferred directly to underlying purlins

conforming to Paragraph 6.2.8, and

(c) carried by collector support battensconforming to Paragraph 6.5.

All fixings that pierce metal sheeting must beprovided with adequate sealing washers or boots toprevent leakage.

When used with steel roof cladding, fixings must

be zinc coated or galvanised.

COMMENT:

The fixing types and product must be in

accordance with the requirements for fixing usedon normal roofing installations.

Collector support battens

Collector support battens may either:(a) run horizontally across the slope of the roof

as provided for in Paragraph 6.5.3 andFigure 5, or

(b) run up the slope of the roof as provided forin Paragraph 6.5.4 and Figure 6.

Where the collector is mounted on collectorsupport battens the battens must be constructed ofone of the following:

(a) galvanised mild steel with a minimumsection moment of inertia of 0.45 cm

4, or

(b) stainless steel with a minimum section

moment of inertia of 0.45 cm4

, or

(c) aluminium with a minimum section momentof inertia of 1.3 cm

4.

COMMENT:

A steel angle section 30 x 30 x 3 mm or analuminium channel section 25 x 25 mm with 3 mm

wall thickness meets the minimum stiffnessrequirements of Paragraph 6.5.2.

Collector support battens running horizontallyacross the roof slope, as shown in Figure 5, mustbe in one piece and be at least long enough to

span each space between rafters or trusses thathave a collector panel above them. Battens may cantilever up to 200 mm beyond a rafter or truss.The collector support battens are to be fixed using

the details given in Figures 1, 2, 3 and 4 to either:(a) each rafter or truss that they cross, or

(b) To purlins provided the purlins are aminimum size of 90 x 45 mm on their flatand span a maximum of 1100mm.

Figure 5: Collector support battensacross roof slope

Where the collector is laid on collector supportbattens running up the slope of the roof those

collector support battens must be supported asshown by Figure 6 by either:

1) each purlin crossed of a minimum

size of 90 x 45 mm on their flatusing the connection details given

by Figure 1, or

2) by a rafter or truss top chord at notmore than 1500 mm centres and

within 300 mm of each end usingthe connection details given byFigure 2 or by Figures 3 and 4,

and be in one piece

Figure 6: Collector frame up slope ofroof

WARNING: THE INSTALLATION SHOULD NOT

COMPROMISE THE STRUCTURAL INTEGRITY OF

THE BUILDING ON WHICH IS INSTALLED.

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COMMISSIONING FORM

INSTRUCTION

Fr r primry eed yem fy-ed.

Eer key peii dei d djme vribe

1 User instructions explained and handed oer? Yes/No

2 Demmii hede fr er d yider ef ie? Yes/No3 speii miee hede (idig freqey, miee

and list of parts to be replaced during normal maintenance) left on site?

Yes/No

4 a dmei be kep viiby er re preed frm he,water and dust. Name of location where documentation is left.

5 Glazing format of solar collector. Flat

6 abrber ype.

7 Net absorber or aperture area. m2

8 cpy f En 12975 frmiy erie ef ie. Yes/No

9 Manufacturers name.10 Unique serial no.

11 Maximum stagnation temperature of collector. C

12 Maximum design pressure of collector. bar

13 Maximum design pressure of heat exchanger. Bar

14 Mximm deig prere imi f yem. bar

15 li f prere fey devie.

16 Location of electrical fused isolating switch.

17 Fuse rating. Amps

18 Electrical controls? Yes/No19 the he rfer id prvide freeze prei . C

20 type f rfer id.

21 Corrosion inhibitor used?

SYSTEM COMMISSIONING

22 sr primry he exhger ype. Steel Plain

23 sr primry he exhger re. m2

24 Diy sWH d mpi. lire per dy c

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DECOMMISSIONING & SAFETY

The solar system can operate at extremely high temperatures. Please do not attemptto decommission the system yourself, as there is a risk of serious injury.

There is also a risk of electrocution from 240VAC electricity.

1. awy wer pprprie Per PreiveEqipme h gve d eye prei.

2. Eve if he pipewrk er he yider eem

cool, the panels can be at high temperature.Demmiiig hd herefre y be

attempted when there is no solar inpu t, or thepanels should be coered with light proof coersand left for at least 5 hours.

3. Turn off the switched fused spur and remoethe fuse. Leae the fuse holder open and use

a padlock or similar to lock it open. Leae aconspicuous sign stating the power should notbe reconnected.

4. Connect a short length of hose to the drain pointied he we pi f he yem d

pe i iby ized ier d dri

i he pbi ewerge yem. aifreeze

iqid m be diped f rrey.

5. Open the check ale.6. swy pe he dri p. Whe he iii w

reed by prere h pped, pe he ir-ent at the top of the solar pane ls.7. Whe he id h ihed driig, die

the pipework starting at the upper part of theyem. ci here my i be id i he

pipework.8. Dipe f y meri rrey.

9. Pe hd y be remved by qied pr -fei ig pprprie e d fey

equipment.

the w reqire empyer ppi e r mre mpee per i hem i ideifyig d impemeig he preveive d preive me-sures required.

MAINTENANCE SCHEDULE

TO BE SIGNED ON COMPLETION OF COMMISSIONING

Date of site isits for bacterial, water

qiy d e ik eme.

cmmiied by.

Competent persons scheme unique

ideii mbe.

On behalf of.

De yem mmiied dhanded oer.

Signature of commissioning engineer.

sige f e m eeip

and understanding (optional).

MAINTENANCE LOG

Date: nme f egiee/mpy:



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GENERAL DATA

Yes No

Registration no. ..................................................Inspection installation/maintenance

ype f ipei ..................................................

date ..................................................

inspector name ..................................................

SWH user

name ..................................................

address ..................................................

p de, iy ..................................................

phone ..................................................

SWH

brd d ype ..................................................

kid f yem hermyph/fred

circulation

yer f

manufacture

..................................................

Collector

area (m2) ..................................................

number of

collectors

..................................................

ype f er ..................................................orientation ..................................................

slope (o) ..................................................

Backup heating

eergy re eeriiy / g / i

hot water storage iegred / epre k / w

through

brd d ype ..................................................

power in kW ..................................................

VISUAL INSPECTION

Yes No

not

appl.

un-

known

Supporting frame (strong, attached toroof/grouting)

Storage tank (location, no leaks, mate-

rial)

Storage tank insulation (tight, no gaps)

If known: oernight temperature drop

C

Connection of pipes from storage tank

to collector and user points (right posi-

tion, insulation, air release ale, proper

roof penetrations)

Non-return valve (right position)

Positioning of circulation pipes be-

tween collector and tank

(right slope, no sharp bends, air release

ale)

Insulation circulation pipes (complete

length, weather-resistant material, condi-

tion of insulation)

Position expansion tank, vent pipe or

safety valve

Backup heating

a. manual switch (location)

b. thermostat setting C, range C

c. proper electrical wiring

Collector glass cover(clean, no cracks,

water- tight, no condensation)

Absorber(no corrosion, no leaks, paint/

coating in good condition)

INSPECTION CHECKLIST SOLAR WATER HEATERS

TESTING AND MEASUREMENTS

Yes No

not

appl.

un-

known

Hot water outlet temperature C

Circulation with thermosyphon sys-

tems (temperature difference between

h d d ji)

ACTION LIST

P ai eqied By whm

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MEGASUN AROUND THE WORLD

Spain (Canary Isands) Itay (Sardinia) Tunisia

Brazi Kazakhstan Kra

Zimbabw Spain Mauritius

Argntina Nicaragua Jamaica

Rmania India Swdn

Csta Rica Snga Maaysia

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ary 70sDesign of the vertical storagetank with open circuit system

(100. 150 & 200 lt)

1978Vertical storage tank with bothopen and closed circuit system

(100. 150 & 200 lt)

1980Horizontal storage tank with closedcircuit system (160 lt)

1983Horizontal storage tank (made fromstainless steel) with closed circuit

system (120, 160 & 200 lt)

1985Horizontal storage tank with closedcircuit system (with sandwich type

solar collectors- 120 lt)

1988Integrated solar water heaterCompact, with open circuit system

(160 & 200 lt)

1990Horizontal storage tank with closedcircuit system (120, 160 & 200 lt)

1994Horizontal storage tank with closedcircuit system (120,160,200,260& 300 lt)

2000 Floor standing boilers with one ortwo heat exchangers (150, 200,

300, 420, 500, 600, 800, 1000 lt.)

Thirty years of manufacturing Solar Water Heaters,means thirty five years of innovating in the field,

and introducing new technologies.

Three and a half decades of continuous development,

combined with vast experience and extensive research,have established MEGASUN products as leadersin most world markets.

Thousands of MEGASUN Solar Water Heaters aresuccessfully in use in most countries of the world from

Athens to America and from Africa to Australia, to allAsia and Far East and Europe provide continuous and

abundant hot water.

Tday HelIoAKMI nt ny rprsnts highyspciaizd tchngy and th xprinc

f thirty fiv yars, but high quaity systms,which mt th highst dmands.

Some of the countries where MEGASUNSolar Water Heaters are exported.

Germany, Italy, France, Spain, Canaries Islands, Portugal,

Holland, Austria, Belgium, Sweden, Bulgaria, Slovenia, Albania,

Cyprus, Australia, N. Zealand, Oman, Bahrain, U.A.E., India,

Thailand, Malaysia, Indonesia, Philippines, Korea, Argentina,

Brazil, Chile, Bolivia, Venezuela, Aruba, Granada, Martinique,

Nevis, St. Lucia, Dominican Rep., El Salvador, Costa Rica,

Nicaragua, Panama, Malta, Morocco, Tunisia, Egypt, Libya,

Algeria, Senegal, Ghana, S. Africa, Kenya, Botswana, Namibia,

Zimbabwe, Tanzania, Zambia, St. Mauritius,

Reunion, Madagascar and others

WORLD LEADER IN

SOLAR WATER HEATERS

35 YEARS BEFORE

OTHERS DISCOVER

THE POWER OF THE SUN

2010 Solar water heater with closedcircuit.

OVERHEATING

VALVE

HOT

WATER

OUTLET

LATERAL

CROSS-SECTION

COLD

WATER

INLET

FRONT

SIDE

COLD

WATER

INLET

THERMAL

SWITCH

HOT

WATER

OUTLET

THREE-WAY VALVE

WITH THERMO-

STATIC HEADUNDERFLOOR

HEATING

COMPENSATION

ELECTRICAL

VALVE

HEAT

PUMP

Frm th xtnsiv rsarch& th dsign

t th fina prduct

Spac hating and DHW

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