Atmos EasySolar Series User manual

Atmos EasySolar
Installation Instructions
for
Atmos EasySolar
Sloping roof and flat roof installation with evacuated tube
collector
Atmos Heating Systems
TBS Building Supplies Ltd
Hackwood oad
Daventry
Northants, NN11 4ES
Tel: [phone]
Fax: [phone]
e-mail: [email protected]
internet: www.atmos.co.uk
Issue 1.6.13

Atmos EasySolar Installation Instructions Evacuated Tube Collector
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Table of Contents
1 Introduction ................................................................................................................. 3
2 System Components ................................................................................................... 4
3 Sitin & requirements .................................................................................................. 7
4 Installation ................................................................................................................... 8
4.1 Safety & insulation ................................................................................................ 8
4.2 Stora e tank ......................................................................................................... 9
4.3 Domestic water connections ................................................................................. 9
4.4 Hard water ............................................................................................................ 9
4.5 Tank in unheated space ....................................................................................... 9
4.6 Protection of plastic pipe and pipe insulation ...................................................... 10
4.7 Vented hot water systems .................................................................................. 10
4.8 Unvented hot water systems .............................................................................. 10
4.9 Connection to combi boiler ................................................................................. 10
4.10 Connection to an unvented hot water cylinder ................................................ 12
4.11 Connection to a vented hot water cylinder ...................................................... 13
4.12 Evacuated tube collector on slopin roof ......................................................... 14
4.13 Evacuated tube collector on flat roof ............................................................... 20
4.14 Fillin the tank ................................................................................................. 24
4.15 Flushin the pump ........................................................................................... 25
4.16 Connectin the collector circuit........................................................................ 25
4.17 Connectin the optional booster pump ............................................................ 26
5 Maintenance.............................................................................................................. 27
6 Technical specifications ............................................................................................ 28
7 Commissionin checklists ......................................................................................... 30

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1 Introduction
Thank you for purchasin an Atmos EasySolar hot water system. This will provides you
with free hot water for many years to come, provided that it is correctly installed and
maintained.
Most of us dislike readin installation manuals, and prefer to fit it and read later, so we
have summarised some of the 7 most important installation requirements below,
BUT, please do not use this as an excuse not to read the manual properly. Remember
that the warranty will be invalidated if the installation is not correct.
1. LOCATION; Ideally the solar collectors should be facin directly south, and mounted
on a slope of between 30 and 40 de rees to the horizontal. Any deviation from this
will result in less ener y bein collected, althou h between south east and south west
it will at most result in less than 10% loss of performance.
2. SHADING. If there are trees or buildin s shadin the location of the solar collectors,
this will also reduce the performance. Ideally there should be no shadin .
3. DO NOT fit the collector on a slope of less than 20 de rees. If you do the system will
not only lose performance, but the drain back action will be impaired. That means the
collectors will freeze and break in the cold winter. In the summer it will cause boilin ,
which is dan erous.
4. The stora e tank MUST be located below the header of the evacuated tube collector.
5. The stora e tank is fitted with a pump which has a 3m or 4m head. The vertical
distance between the base of the tank and the top of the solar collector MUST NOT
be reater than the pump head. If it is, the system will not work. A booster pump is
available from Atmos to ive additional pump head if you make a mistake, but they
are not cheap.
6. The pipes from the collector to the stora e tank MUST have a continuous slope down
towards the tank, otherwise the drain back will not work. They must be properly fixed
so that they cannot droop or sa , or be pulled down by someone.
7. PLEASE make sure you use the insulation provided on the red and blue pipes, and
make sure it is neatly and correctly fitted. Up to 20% of the heat collected by the solar
collector can be lost if the insulation is not fitted (or badly fitted).

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*1] *2] *3]
2 System Components
Boxes and parts
The system is packa ed in several boxes. Check that the boxes are not dama ed and
that you have received the correct boxes for the system you have ordered. See table
below. Inform your supplier if you have received incorrect or dama ed boxes.
Numbers of boxes per system
For sloping roof installations specify which roof bracket is required
*1]Standard (roof bracket 30-3 mm)
*1]Medium (roof bracket k 40-50 mm)
*1]Wide (roof bracket 51-63 mm)
*2]Slate
*3]Bitumen/wall
TC = tube collector
S = slopin roof
F = flat roof
Stora e tank 100L 3M
Article No. 000574
Stora e tank 100L 4M
Article No. 000667
15 Tube collector
Article No. 0008 3
20 Tube collector
Article No.0008 4
24 Tube collector
Article No. 000874
Installation kit slopin roof
Article No. 000 42
Installation kit flat roof
Article No. 000876
EasySolar 15TC S 3M Article No. 0008 2 1 1 1
EasySolar 20TC S 3M Article No. 0008 5 1 1 1
EasySolar 24TC S 3M Article No. 000877 1 1 1
EasySolar 15TC S 4M Article No. 0008 6 1 1 1
EasySolar 20TC S 4M Article No. 0008 7 1 1 1
EasySolar 24TC S 4M Article No. 000878 1 1 1
EasySolar 15TC F 3M Article No. 000 00 1 1 1
EasySolar 20TC F 3M Article No. 000 01 1 1 1
EasySolar 24TC F 3M Article No. 000 02 1 1 1
EasySolar 15TC F 4M Article No. 000 03 1 1 1
EasySolar 20TC F 4M Article No. 000 04 1 1 1
EasySolar 24TC F 4M Article No. 000 05 1 1 1

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Components in installation kits
picture
Slopin roof Flat roof
Installation and User
Instructions

1 1
Adaptor 12 Volt 1 1
Wakaflex 1 0
Collector return pipe blue
L=650cm 1 1
Collector flow pipe red
(insulation supplied loose)
L=650cm
1 1
Insulated flexible
connectin pipes for
domestic water L=90 cm
incl. rin s
2 2
Flow restrictor 1 1
Elbow
2 2
Compression elbow 2 2

Atmos EasySolar Installation Instructions Evacuated Tube Collector
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Pipe land 0 1
Fillin plu 1 1
Overflow plu 1 1
Overflow connector 1 1
Yellow fillin hose with
connector ¾”
1 1

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3 Siting & requirements
When choosin the location for the stora e tank the followin needs to be considered:
• The vertical distance between the base of the tank and the top of the collectors
should not exceed the combined capacity of the stora e tank pump and any booster
pump that may be added to provide extra pump hei ht.
• The distance between the stora e tank and the appliance (combi boiler or hot water
cylinder) to which pre-heated water is supplied, needs to be kept as short as practical.
• The stora e tank needs to be sited on a firm horizontal surface that is able to take the
wei ht when the tank is filled with water (116k ). Atmos supply a brackets and shelf
set for optional wall mountin of the stora e tank.
• The followin are needed in the vicinity of the stora e tank:
o 240V electrical socket within 1.5 meter distance
o Water tap with ¾”bsp hose union connection within 2.5 meter distance
• It is preferable to locate the stora e tank and the connectin domestic water pipes in
a frost free room. If the tank is installed in an unheated space particular care must be
taken to protect the domestic water pipes a ainst freezin . See para raph 4.5.
The followin tools are needed to install the system:
Sloping roof
Flat roof
Spanner 24 mm
Spanner 8 mm
Tape measure
HSS drill bit 5 mm
Sharp knife
Hole saw 30 mm
Battery drill with pozi bit
Ductin tape
Ballast (pavin slabs)
Spanner 24 mm
Spanner 8 mm
Tape measure
Hole saw 50 mm
Sharp knife
Rubber tiles for roof protection
Roof sealant for roof penetration
Ductin tape

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4 Installation
4.1 Safety & insulation
Before you start work consider your own safety and that of others.
• The EasySolar hot water system has electrical parts. Apart from the adaptor which
plu s into the 240V socket, these parts are all low volta e (12V) and therefore
perfectly safe. However it is advisable to take care not to dama e any electrical
insulation and to avoid electrical parts becomin wet.
• The heat exchan er and the flexible connectin pipes for domestic water are subject
to mains water pressure and can become hot. For this reason the flexible connectin
pipes for domestic water need to be insulated. Insulation for these pipes is included in
the assembly kit. The insulation must extend over the connections to the tank. Secure
the insulation with tape. Ensure that the tank and connectin pipes have cooled down
before any maintenance work is undertaken. The tank and connectin pipes can be
cooled down by drawin off hot water.
• The pipes connectin the stora e tank and the collectors can also become hot. The
red flow pipe needs to be insulated alon its full len th. Insulation for this pipe is
included in the assembly kit. Ensure that the pipes have cooled down before any
maintenance work is undertaken.
• Assemble all components accordin to the installation instructions and avoid
components ettin dama ed durin installation or subsequent use.
• Put in place sufficient safety measures when workin on the roof. Use scaffoldin if
necessary.

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4.2 Storage tank
Connections
4.3 Domestic water connections
The flexible connectin pipes provided in the assembly kit are for the domestic water hot
and cold connections. Use the washers for sealin the connection between the flexible
pipes and the stora e tank. The blue connectin point is for incomin cold water and the
red connectin point is the outlet for pre-heated domestic water. The mains water
pressure should be no more than 8 bar. If the mains water pressure is likely to exceed 8
bar, a pressure reducin valve should be fitted before connection to the stora e tank.
4.4 Hard water
In areas of hard water (hardness in excess of 200ppm) an approved water conditioner
device must be fitted in accordance with the Buildin Re ulations. Atmos can supply a
suitable conditioner for fittin to the cold feed to the stora e tank. In areas of hard water,
failure to fit a suitable conditioner will invalidate the warranty.
4.5 Tank in unheated s ace
If the tank is installed in an unheated space particular care must be taken to protect the
domestic water pipes a ainst freezin . Insulation for the domestic water flexible
connectin pipes is supplied with the assembly kit. It may be necessary to apply
additional insulation to these pipes and to other domestic water pipes particularly if the
unheated space is subject to drau ht.
- - - - - -
Fillin
Collector cold
Collector hot
Collector sensor
Domestic water hot
Domestic water
cold

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4.6 Protection of lastic i e and i e insulation
The red and blue collector pipes are made of plastic. It can occur that plastic pipes or
pipe insulation material is dama ed by rodents such as mice, rats or squirrels. Take
appropriate precautions to protect the pipes and insulation material from this kind of
attack if considered necessary.
4.7 Vented hot water systems
The Atmos EasySolar system can be used as a preheat tank with a vented hot water
system. The base of the cold water feed tank must be at least 1m above the base of the
EasySolar tank, and the cold feed to the hot water cylinder passes throu h the cold/hot
connections of the EasySolar tank. In most cases where the cold tank is in the roof
space, a platform will be required of stron construction in accordance with the current
standards.
4.8 Unvented hot water systems
The Atmos EasySolar system can be used to provide preheated water to an unvented
hot water cylinder. However the pressure reducin valve assembly as fitted on the cold
water inlet feed of an unvented cylinder must be fitted before the EasySolar tank, and
then the warm outlet from the EasySolar tank is connected to the cold inlet on the hot
water cylinder (see pa e 12)
4.9 Connection to combi boiler
The Atmos EasySolar hot water system can be used provide preheated water to a combi
boiler. However the followin points must be noted;
a) If the boiler is solar compatible (e Atmos HE32 InterCombi) it can be connected
directly to the cold water inlet as per the dia ram on pa e 11.
b) If the boiler is not solar compatible, but can accept cold water at 28 de C, a
Combisol valve must be fitted (available from Atmos)
c) In all cases for combi boilers which are not solar compatible, the installer should
check with the manufacturers that the boiler is able to accept cold water at 28 de C
inlet. If this is not acceptable, then an EasySolar system should not be fitted, or the
boiler should be chan ed to a solar compatible type.

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Connection to combi boiler
EXPLANATO Y NOTES:
1) TMV1 is a non-adjustable thermostatic mixer valve. Connect as shown and i nore the
arrows on the body of the valve. This is a diverter valve and works in reverse. The
operation is that if the water from the solar stora e tank is reater than 45 de C, it oes
strai ht to the taps. If it is lower it is diverted throu h the boiler and is heated up.
2) TMV2 is an adjustable thermostatic mixer valve with a black adjuster head. This should
be fitted as shown, and the arrows on the body are correct. K means Cold (cold inlet) , W
means Warm (hot inlet), and M means Mixed (or blended) out to the taps. Adjust hot
water to desired tap outlet temperature (clockwise ets colder, and anti-clockwise ets
warmer).
CONNECTIONS:
1) Heated water from solar store connects into M on TMV1
2) W on TMV1 connects into cold inlet on combi boiler
3) K on TMV1 connects to W on TMV2 with T-off from domestic hot water outlet on combi
boiler.
4) Incomin cold water connects into K on TMV2
5) M on TMV2 connects to domestic hot water taps

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4.10 Connection to an unvented hot water cylinder
The Atmos EasySolar hot water system can provide pre-heated water to an unvented hot
water cylinder. The dia ram below shows how the EasySolar system is connected to an
unvented hot water cylinder.
EXPLANATO Y NOTES:
1. The pressure reducin valve and the 6 bar pressure relief valve must be fitted before
the solar stora e tank and before the T-off to the cold connection on the thermostatic
mixer valve.
2. No valve must be fitted between the unvented cylinder and the solar stora e tank or
between the solar stora e tank and the pressure relief valve.

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4.11 Connection to a vented hot water cylinder
The Atmos EasySolar hot water system can provide pre-heated water to a vented hot
water cylinder. The dia ram below shows how the EasySolar system is connected to a
vented hot water cylinder.

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4.12 Evacuated tube collector on slo ing roof
Fixing profiles:
The len th of the fixin profiles various accordin to the number of evacuated tubes.
The ima e below shows the flow and return connections on the rear side of the collector
header.
return flow

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Assemble the frame as shown:
Remove the tiles where the roof hooks are to be located. Place the roof hooks in the
valley of the tile and hook behind the roof batten.
The width of the frame can be adjusted to fit the position of the roof hooks. Determine the
location of the remainin 4 roof hooks and drill 8.5mm holes in the profiles A to fix the
roof hooks to the profiles A. After this the tiles can be replaced.

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Once the frame and the roof hooks have been fixed to the roof the header can be fitted to
the frame.
It is important that the header is fitted level, so that the water in the header drains
back correctly.
• Use an an le rinder to cut a section out of a roof tile.
• Cut two pieces of wakaflex each 50cm lon .
• Use a hollow punch to make two 20mm holes in one of the two pieces of Wakaflex.
Fix the pipe land to the holes. If the correct size hollow punch is not available it is
possible to use a 22mm compression rin instead.
• Place the wakaflex with the pipe land over the tile with the section cut out and
underneath the tile hi her up. Do not stick the wakaflex down till after the red and blue
collector pipes have been taken throu h the pipe land.
• Place the second piece of wakaflex on top and above the first piece and underneath
the tiles hi her up.

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•
hot cold

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• Fit the compression elbows to the pipes comin out at the rear of the header.
• Connect the red and blue collector pipes and take these throu h the pipe land.
Ensure that AT ALL POINTS THE PIPES SLOPE DOWN away from the collector
header.
• Fit the pipe insulation to the red and blue collector pipes.
• Ensure that there is enou h slack in the pipes for thermal contraction (max 5%).
• Stick the wakaflex to the tiles.
• Fit the evacuated tubes and the fixin cups. Apply the heat transfer paste to the metal
ends of the lass tubes. Usin soapy liquid on the ends of the lass tubes will make it
easier to slide them in.
Fixin cup:

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End result:
The sensor cable from the collector header should be taken underneath the roof tiles and
down to the stora e tank. The flow and return pipes must at all points slope down
towards the stora e tank. This is essential in order for the water in the collectors and in
the pipes to flow back to the stora e tank when the pump is not runnin . Ensure that
there is no tension on the flow and return pipes or leaka e may occur. The red flow pipe
should be insulated alon the whole of its len th, usin the pipe insulation provided. The
blue return pipe should be insulated only above roof level. The sensor cable can be
extended if necessary usin a two wire cable.

Atmos EasySolar Installation Instructions Evacuated Tube Collector
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4.13 Evacuated tube collector on flat roof
• Assemble the frame. There are different options with re ard to the an le of the
collector. The lowest possible an le is 35°.
• Place rubber tiles for roof protection underneath the frame.
• The horizontal L profiles for the ballast are needed when ballast is used. Ensure that
the L profiles are secured under the ballast and cannot slide free.
Fit the header to the frame and insert the lass tubes. Ensure that the header is level.
This is necessary so that the water in the header drains back correctly. Apply the contact
paste to the metal ends of the lass tubes. Soapy water can be used to make it easier to
slide the lass tubes into the sockets on the header.