Interplast Green Line 801 Manual

Technical Bulletin - Solar water heaters installation and
maintenance manual
Interplast Green Line Interplast Green Line Interplast Green Line Plus
801 – Strip 1,25 m2
120 – Strip 1,5 m2
150 – Strip 2 m2
170 – Strip 2 m2
200 – Strip 2 m2
270 – Strip 2,5 m2
300 – Strip 2 x 2m2
170 – Full Face 2 m2
202 – Full Face 2,2 m2
205 – Full Face 2,5 m2
270 – Full Face 2,5 m2
300 – Full Face 2 x 2m2
100L
150L
200L
5 years Guarantee
The Fully Integrated – Certified Solar Proposal!

2
Technical bulletin - Solar water heaters installation and maintenance manual
- Interplast Green Line
Index
1. Solar water heaters Interplast Green line…………………….…………..……………………………….3
1.1. General Information.....……………………………………………………………………………………………..3
1.2. Solar water heaters models ……………………………………………………………………………………….3
2. Technical features of the components of the Solar Boiler…………………………………………4
2.1. Selective collector Strip………………………………………………………………………….………………….4
2.2. Selective collector Full Face……….……………………………………………………………………………...6
2.3. Vacuum Tube……………………………………………………………………………………………………………8
2.4. Hot water cylinder…..………………………………………………………………………………………………..9
2.5. Foldable Bracket for Terrace…..………………………………………………………………………………..10
2.6. Tile Roof Mounting System…….………………………………………………………………………..………12
3. Basic Manual for Solar Water Heater Installation…….…………………………………………….13
3.1. Foldable Bracket for Terrace (Interplast Green Line Strip & Full Face)…..………..……………14
3.2. Terrace base (Interplast Green Line Plus – Vacuum)…………………………………………………..16
3.3. Tile Roof base (Interplast Green Line Strip & Full Face)……..……………………….………………17
3.4. Tile Roof base (Interplast Green Line Plus - Κενού)…………………………….………………………18
4. Hydraulic connection……………………….………………………………………………………………………..20
5. Filling – Emptying of the Solar Boiler………………………………….…………………………………….21
6. Electrical Resistance………………………….………………………………………………………………………22
7. Possible Problems / Solutions…….……………………………………………………………………….……23
8. Solar Boiler Accessories…………………………….………………………………………………………………23

3
Technical bulletin - Solar water heaters installation and maintenance manual
- Interplast Green Line
1. Solar water heaters Interplast Green line
1.1 General Information
During the production, all the certified procedures are followed and are used superior quality materials. The
solar water heaters have Solar Keymark certifications, CE, TUV and EKEFE Democritus.
The solar water heaters are of the highest standards, ensuring the best operation. The innovative design of
the automatic base (patent No 2011011633) ensures quick, easy and safe installation and any mistakes are
easily avoided.
1.2 Solar water heaters models
Solar Water heater Collector Hot water cylinder
Interplast Green Line 801 Selective Collector 1,25 m2
(Strip) 80 L (79L*)
Interplast Green Line 120 Selective Collector 1,5 m2
(Strip) 120 L (107L*)
Interplast Green Line 150 Selective Collector 2 m2
(Strip) 150 L (132L*)
Interplast Green Line 170 Selective Collector 2 m2
(Strip) 170 L (152L*)
Interplast Green Line 200 Selective Collector 2 m2
(Strip) 200 L (194L*)
Interplast Green Line 270 Selective Collector 2,5 m2
(Strip) 270 L (255L*)
Interplast Green Line 300 Selective Collector 2 x 2 m2
(Strip) 300 L (294L*)
Solar Water heater Collector Hot water cylinder
Interplast Green Line 170 Selective Collector 2 m2
(Full Face) 170 L (152L*)
Interplast Green Line 202 Selective Collector 2,2 m2
(Full Face) 200 L (194L*)
Interplast Green Line 205 Selective Collector 2,5 m2
(Full Face) 200 L (194L*)
Interplast Green Line 270 Selective Collector 2,5 m2
(Full Face) 270 L (255L*)
Interplast Green Line 300 Selective Collector 2x 2 m2
(Full Face) 300 L (294L*)
Solar Water heater Collector Hot water cylinder
Interplast Green Line Plus
100L 10 Vacuum Tubes 100 L
Interplast Green Line Plus
150L 15 Vacuum Tubes 150 L
Interplast Green Line Plus
200L 20 Vacuum Tubes 200 L

4
Technical bulletin - Solar water heaters installation and maintenance manual
- Interplast Green Line
2. Technical features of the components of the Solar Water Heaters
2.1 Selective collector Strip
Selective absorber made from aluminum strip sheets for higher performance in low temperatures.
Frame from painted aluminum for high resistance to corrosion (wet climates, coastal areas).
Back from anodized aluminum sheet for high corrosion resistance (humid climates, coastal areas).
30 mm thick rock wool insulation on the back and 15mm thick on the sides for higher
performance at low temperatures.
Vertical copper pipes (risers) Ø10 x 0.4 mm
Horizontal copper pipes (headers) Ø22 x 0.7 mm
Collector’s glazing made of 4mm prismatic security glass (securit), mistlite solar, with high
transmittance and low reflectivity.
Dimensions – Weight – Collector’s Surface
Height Width Weight Surface
(m) (m) (kg) (m2)
0.95 1.25 24 1.25
1.50 1.00 27 1.5
2.00 1.00 36.5 2
2.00 1.25 41 2.5

5
Technical bulletin - Solar water heaters installation and maintenance manual
- Interplast Green Line
Green Line Collector
1,5 m2 2,0 m2 2,5 m2
Dimensions (Length x Width x
Height )mm 1501x1007x87 2006x1007x87 2008x1258x87
Aperture area (m2) 1,35 1,83 2,31
Absorber area (m2) 1,34 1,81 2,30
Absorber Selective aluminum Selective aluminum Selective aluminum
Absorbance 0,95±0,01 0,95±0,01 0,95±0,01
Emmitance 0,05±0,02 0,05±0,02 0,05±0,02
Coating Titanium oxides Titanium oxides Titanium oxides
Material, Width
Side insulation
15 mm
Rock Wool
15 mm
Rock Wool
15 mm
Rock Wool
Material, Width
Back insulation
30 mm
Rock Wool
30 mm
Rock Wool
30 mm
Rock Wool
Soldering Absorber – Copper pipes Laser Laser Laser
Weight (kg) 27 36,5 41
Min inclination (ο) 25 25 25
Max inclination (ο) 90 90 90
Total water volume collector (lt) 1,3 1,6 1,9
Operation pressure (bar) 6 6 6
Testing pressure (bar) 10 10 10
Horizontal piping diameter Ø22 Ø22 Ø22
Vertical piping diameter 8 8 11
Number of Vertical pipes Ø10 Ø10 Ø10
Piping material Copper Copper Copper
Impermeability Silicone Silicone Silicone
Cover material Securit Mistlite
Solar Glass
Securit Mistlite
Solar Glass
Securit Mistlite
Solar Glass

6
Technical bulletin - Solar water heaters installation and maintenance manual
- Interplast Green Line
2.2 Selective Collector Full Face
Selective absorber Full Face (absorbance α= 0,94) for greater efficiency in winter season.
Anodized aluminum frame and galvanized metal sheet back plate for high corrosion resistance for
installations in humid climates or near the sea (coastal areas and islands).
Insulation of the collector made of expanded polyurethane and further compressed at a
temperature to achieve uniform density (52 kg/m2) throughout the length and width.
Insulation thickness of 30 mm on the back and 15mm on the sides for higher performance
at low temperatures (more hot water during winter).
Vertical copper pipes (risers) Ø10 x 0,4 mm
Headers Ø22 x 0,7 mm
Sealed with black silicone IG type and double adhesive tape.
Collector’s glazing made of 4 mm prismatic security glass (security), mistlite solar, with high
transmittance and low reflectivity.
Dimensions - Weights – Collector’s Surface
Height Width Weight Surface
(m) (m) (kg) (m2)
1.6 1.30 40 2.0
1.7 1.30 42 2.2
2.00 1.29 47 2.55

7
Technical bulletin - Solar water heaters installation and maintenance manual
- Interplast Green Line
Green Line Full Face Collector
2,0 m2 2,2 m2 2,55 m2
Dimensions (Length x
Width x Height) mm 1605x1300x87 1705x1295x87 1985x1285x87
Aperture are (m2) 1,82 2,03 2,36
Absorber area (m2) 1,81 2,01 2,31
Absorber Selective aluminum
single surface
Selective aluminum
single surface
Selective aluminum
single surface
Absorbance 0,95±0,01 0,95±0,01 0,95±0,01
Emmitance 0,05±0,02 0,05±0,02 0,05±0,02
Coating Titanium oxides Titanium oxides Titanium oxides
Material, Width
Side insulation
15 mm Compressed
Polyurethane (52kg/m3)
15 mm Compressed
Polyurethane (52kg/m3)
15 mm Compressed
Polyurethane (52kg/m3)
Material, Width
Back insulation
30 mm Compressed
Polyurethane (52kg/m3)
30 mm Compressed
Polyurethane (52kg/m3)
30 mm Compressed
Polyurethane (52kg/m3)
Soldering Absorber –
Copper pipes Laser Laser Laser
Weight (kg) 40 42 47
Min inclination (ο) 25 25 25
Max inclination (ο) 90 90 90
Total water volume of
collector (lt) 1,8 1,9 2,0
Operation pressure
(bar) 6 6 6
Testing pressure (bar) 10 10 10
Horizontal piping
diameter Ø22 Ø22 Ø22
Vertical piping diameter Ø10 Ø10 Ø10
Number of pipes 11 11 11
Piping material Copper Copper Copper
Impermeability Silicone & Double
Adhesive tape
Silicone & Double
Adhesive tape
Silicone & Double
Adhesive tape
Cover material
Low Iron
Securit Mistlite
Solar Glass
Low Iron
Securit Mistlite
Solar Glass
Low Iron
Securit Mistlite
Solar Glass

8
Technical bulletin - Solar water heaters installation and maintenance manual
- Interplast Green Line
2.3 Green line Plus Vacuum Tube
Made of borosilicate glass 1,6 mm thick.
Coating of selective solar absorber made of
aluminum nitride.
The component of the absorber consists of double
coated glass tube.
Due to special geometry (shape) of the absorber,
maximal absorption of solar energy is achieved.
Vacuum Tube
Length of Vacuum tube
(Length of absorber)
1800 mm
(1720 mm)
Inner / outer vacuum
diameter 58 / 47 mm
Glass thickness 1,6 mm
Material Borosilicate glass 3,3
Absorbance coating Graded Al-N/Al
Absorbance ≥93,5% ( ΙΑM 1,5)
Emmitance ≤6,5% ( 80o C)
Vacuum P < 3x10-3 Pa
Stagnation Temperature 231o C
Max efficiency
(for 20/15 vacuum tubes)
Tm-Ta=0K & 1000W/m2
1383 W / 826 W

9
Technical bulletin - Solar water heaters installation and maintenance manual
- Interplast Green Line
2.4 Hot water cylinder
Inner Tank Material: Metal steel sheet DCP
2.5mm for the main tank (EN 10130/2006) DCP
1,5mm for the jacket (exchanger) (EN
10130/2006)
Internal Anticorrosion Protection: LIQUID
enamel (DIN 4753-3), totally safe for public
health (DIN 51032 & ΕΝ 1388-2) and magnesium
anode (EN 12438)
Welding: MIG
Insulation: Hard polyurethane foam of 48kg/m³
(DIN 53420), self-extinguishing (DIN 4102)
Maximum Working Pressure for the Main
Tank: 10 bar
Test Pressure for the Main Tank: 15 bar (EN
12976-1, ¶4.1.6)
Maximum Working Pressure for the Jacket
(Exchanger): 3,5 bar
Test Pressure for the Jacket (Exchanger): 5
bar (EN 12976-1/2006, ¶4.1.6)
Maximum Working Temperature of the
Main Tank: 95οC
Heating Element: Optional, upon request
External Cover: Pre-painted galvanized steel
sheet 0,5mm (EN 10204/2.2)
Extrenal Cover: Pre-painted galvanized steel
sheet 0,5mm (EN 10204/2.2)
Type 120L 150L 170L 200L 270L 300L
Effective Capacity (L) 107 132 153 192 248 292
A Tank’s Length (mm) 1050 1250 1250 1250 1590 1850
ΒMain Tank’s Diameter (mm) Ø400 Ø400 Ø430 Ø480 Ø480 Ø480
C External Diameter (mm) Ø500 Ø500 Ø540 Ø580 Ø580 Ø580
Jacket’s Surface (m2) 0,65 0,88 0,95 1,06 1,50 1,89
D Jacket’s Capacity (L) 7,76 10,56 11,33 12,61 18,17 22,80
Flange Diameter (mm) Ø140 Ø140 Ø140 Ø140 Ø140 Ø140

10
Technical bulletin - Solar water heaters installation and maintenance manual
- Interplast Green Line
2.5 Foldable Bracket for Terrace
Base Dimensions (for 1 collector)
Height Width Surface Weight
m m m2Kg
1,5 1,00 1,5 16
2,00 1,00 2,00 19
2,00 1,25 2,00 19
Base Dimensions (for 2 collectors)
Ύψος Width Surface Weight
m m m2Kg
2,00 1,00 2 x 2,00 22

11
Technical bulletin - Solar water heaters installation and maintenance manual
- Interplast Green Line
Dimensions of Foldable Bracket
Tank
Volume
(L)
Collector
Surface
(m2)
A B C D E
Collector
Height
(m)
Collector
Width
(m)
Distance
Between
Lateral –
Vertical Leg
(m)
Base
Height
(m)
Distance
Between
Vertical Legs
(m)
80 1,2 0,95 1,2 0,98 0,82 0,76
80 1,5 1,5 1,0 1,55 1,15 0,76
120 1,5 1,5 1,0 1,55 1,15 0,94
170 2,0 1,6 1,3 1,62 1,22 0,94
300 2 x 2,0=4,0 1,6 1,3 1,62 1,22 0,94
200 2,2 1,7 1,3 1,69 1,29 0,94
150 2,0 2,0 1,0 1,9 1,5 0,94
170 2,0 2,0 1,0 1,9 1,5 0,94
200 2,0 2,0 1,0 1,9 1,5 0,94
300 2 x 2,0=4,0 2,0 1,0 1,9 1,5 0,94
270 2,5 2,0 1,25 1,9 1,5 0,94
200 2,55 2,0 1,29 1,9 1,5 0,94
270 2,55 2,0 1,29 1,9 1,5 0,94

12
Technical bulletin - Solar water heaters installation and maintenance manual
- Interplast Green Line
Comments: a) If there are 2 collectors, we double the distance Band add about 0,1m, due to the
connection between the 2 collectors. b) For calculating the holes for the moly in the floor, we are adding in
the distance Cmore 0,04m.
2.6 Tile Roof base
Comments: a) If we have 2 collectors, then we multiply the Βfactor and add ca. 0.1m due to the
connection required for the 2 collectors.
Dimensions of base stand for tiled roof
Tank
Volume
(L)
Collector
Surface
(m2)
A B C D E
Collector
Height
(m)
Collector
Width
(m)
Base
Width
(m)
Base
Height
(m)
Distance of Side Stands
(m)
120 1,5 1,5 1,0 1,5 2,0 0,94
170 2,0 1,6 1,3 1,5 2,5 0,94
300 2 x 2,0=4,0 1,6 1,3 1,5 2,5 0,94
200 2,2 1,7 1,3 1,5 2,5 0,94
150 2,0 2,0 1,0 1,5 2,5 0,94
170 2,0 2,0 1,0 1,5 2,5 0,94
200 2,0 2,0 1,0 1,5 2,5 0,94
300 2 x 2,0=4,0 2,0 1,0 1,5 2,5 0,94
270 2,5 2,0 1,25 1,5 2,5 0,94
200 2,55 2,0 1,29 1,5 2,5 0,94
270 2,55 2,0 1,29 1,5 2,5 0,94

13
Technical bulletin - Solar water heaters installation and maintenance manual
- Interplast Green Line
3. Basic Instructions of Solar Water Heater installation
WARNING!: Before starting the installation of the solar water heater, be sure to have received
all material of the table 8 (accessories of solar system). Read carefully all the instructions.
1. The orientation of the solar system should be south.
2. Shade areas during the day should be avoided.
3. During storage and before installation, the solar collectors should not be exposed to sun light.
4. The closed circuit of the solar system should be filled with water and add the antifreeze liquid which is in
the package.
5. The connection of the electric resistance should be done by a licensed electrician.
6. The electric resistance should not be in operation if the solar tank is empty from water.
7. Be sure that the solar tank is filled with a solute of water - antifreeze before its first operation
For any clarification or problem, please contact the Technical Department of our company or
your supplier.

14
Technical bulletin - Solar water heaters installation and maintenance manual
- Interplast Green Line
3.1 Foldable Bracket for Terrace (Interplast Green line)
•Read carefully the instructions below, before starting the base installation
•Special care should be taken to the right ground support
1. Open the package and put
the collector in vertical position
as picture 1.
2. Pull the base as indicated until the
end.
3. The base opening should be to
the maximum.
4. Place the base to the ground 5. Pull the base from the indicated
point until the angle reaches 90ο.
6. The base should be locked right

15
Technical bulletin - Solar water heaters installation and maintenance manual
- Interplast Green Line
7. Place the tank on the base. The coating of the resistance should be at the right side as we are looking the
solar panels. Place the screws and tight the tank to the base. Place the two angle pairs which are anchoring
is the base as it is seen in the scheme. The vertical angles are placed in the legs whether the oblique in the
sides
•The vertical and oblique legs are fixed with plugs 10's and propoted moles
Warning! : The base must be installed firmly on the ground. In any other case the warranty is
not applied.

16
Technical bulletin - Solar water heaters installation and maintenance manual
- Interplast Green Line
3.2 Terrace base (Interplast Green line Plus – Vacuum Tube)
•Read carefully the instructions below, before starting the base installation
•Special care should be given to the right ground support

17
Technical bulletin - Solar water heaters installation and maintenance manual
- Interplast Green Line
3.3 Tile Roof Base (Interplast Green line Strip & Full face)
Collate the tile roof base as it is seen in pic 7. After, mark the tiles in order to make the holes, always in the
tile's hump. Fix the base with the special moles which are included in the connection material. Place the tank
and solar panels and make all works of filling and emptying which are described in the rest of models.

18
Technical bulletin - Solar water heaters installation and maintenance manual
- Interplast Green Line
3.4 Tile Roof Base (Interplast Green Plus Κενού)

19
Technical bulletin - Solar water heaters installation and maintenance manual
- Interplast Green Line

20
Technical bulletin - Solar water heaters installation and maintenance manual
- Interplast Green Line
4. Hydraulic connections
1. Having placed the tank on the base with the electric resistance being at the right side, connect the two
pipes of cold and hot water. Correspondingly, we tap the two others with collector tap Ø22.
2. After, fill the circuit with the water-glycol mixture from the upper side of the tank until is fully filled.
(Position 1) Next, screw the safety valve 1,5 bar in one place and in the other the brass cap 1/2"
3. Connect the blue pot waiting with the cold water intake interjecting a valve and a venting valve
8bar.
4. The connection of Interplast Solar System is over.