Pleion X-RAY R Series User manual

TECHNICAL MANUAL
INSTALLATION INSTRUCTIONS AND START-UP
SOLAR VACUUM COLLECTORS
- NEW RANGE -
www.pleion.it
100% MADE IN PLEION
EN

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Technical manual – Installation instructions and start-up X-RAY R - ver. 1.0 del 07/11/2018

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Technical manual – Installation instructions and start-up X-RAY R - ver. 1.0 del 07/11/2018
INDICE
SAFETY WARNINGS 4
INSTALLATION INSTRUCTIONS 6
START UP 7
TRANSPORT INSTRUCTIONS 8
COLLECTOR INFORMATION 9
BRACKET TYPES 12
SLOPING ROOF (TRACK SYSTEM) 13
FLAT ROOF (TRACK SYSTEM) 14
DISTANCE BETWEEN ANCHORAGE POINTS 20
COMPLETING BRACKET SYSTEM 23
EASY SYSTEM (VERTICAL) 24
SLOPING ROOF (VERTICAL) 25
DISTANCE BETWEEN ANCHORAGE POINTS (VERTICAL) 27
FLAT ROOF (VERTICAL) 29
COMPLETING BRACKET SYSTEM (VERTICAL) 31
INSTALLATION ON FLAT ROOF WITH BALLAST 32
OVERALL DIMENSIONS 34
HYDRAULIC CONNECTION 35
PRESSURE DROP 37
PUMBLING CONNECTIONS 38
WARRANTY AND CONDITIONS 44
MAINTENANCE 45

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Technical manual – Installation instructions and start-up X-RAY R - ver. 1.0 del 07/11/2018
Regulation-compliant, non-personal fall protection or safety netting or other catch equipment, in accordance with DIN
18338 Rooof Covering and Roof Sealing Work and DIN 18451 Scaffolding Work with Safety Net, must be installed
before starting work.
Safety harnesses must be secured above the user if possible. Only secure safety harnesses to building elements or
connection points with sufcient load – bearing capacity.
If no personal fall protection or fall arrest system or equipment has been installed for technical reasons, safety
harnesses must be worn.
When using lean-to ladders, there is a risk of dangerous falls if the ladder sinks, slips or falls over.
Do not use damaged ladders e.g. splintered stringers and rungs on wooden ladders, bent or kinked metal ladders. Do
not patch up splintered oor broken stringers, step and rungs of wooden ladders.
Contact with live overhead electrical cables and wiring can lead to fatal injury.
Only use safety herness equipment (harnesses or belts, ropes and straps, fall arresters, reope shorteners) that havev
been approved by authorised testing authorities.
Work in the vicinity of live, electrical cables and wiring, where contact is possible, can only be carried out if safety
distances and precautions are observed.
Make sure that lean-to ladders are propped securely. Apply the correct leaning angle (68° - 75°). Secure lean-to
ladders against slipping, falling over and sinking into the ground e.g. by using wider feet, adjusting the ladder feet to
the ground surface, securing/hook xtures.
The manufacturer declines any responsibility for failure to abserve safety. Regulations and/or information contained in
this manual which may cause serious accidents/damage.
If no personal fall protection or fall arrest system is used there is a risk of falling from a great height which can lead to
serious or fatal injury if no safety harness or equipment in used.
Wear protective goggles when drilling or handling collectors.
Only lean ladders against secure supporting surfaces. Cordon off ladders in trafc areas.
Wear safety shoes when carrying out installation work.
Wear cut-proof safety gloves when carrying out installation work or handling collectors due to sharp edges.
Wear a safety helmet when carrying out installation work.
SAFETY WARNING

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Technical manual – Installation instructions and start-up X-RAY R - ver. 1.0 del 07/11/2018
SUN BOX
PARAFFINED CARDBOARD BOX FOR OUTDOOR USE TO COVER THE
SOLAR PANEL AND TO PROTECT AGAINST SUNLIGHT.
Remove only after the system
has started functioning.
A - Cut the cover along the dotted line and fold upwards.
B - Place on top of the installed solar panel.
C - Fix to the panel with an elastic cord or with adhesive tape.
AA
C
B
Either the base or the top of the box can be used.

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Technical manual – Installation instructions and start-up X-RAY R - ver. 1.0 del 07/11/2018
GENERAL INFORMATION
Read carefully all the instructions for assembly and for rst activation. Assembly and rst activation must be carried out
only by authorised installers. The guarantee shall not be valid if the indications of Pleion are not followed.
Installation must be carried out only by qualied personnel and in full respect of safety regulations and of the indications
contained in this document. We recommend that only original components, specically designed for the series of solar
thermal vacuum panels, be used.
Before the installation and start-up of the system, knowledge of the standards, laws and provisions of the locality in
which the systems are situated must be obtained. Suitable belts should be used to transport the solar panels. Do not lift
the solar panels using the threaded hydraulic connections. Do not allow the solar panels to sustain blows or mechanical
action; special care must be paid to protect the glass tubes which, for their nature, can be shattered.
STATIC
Solar collectors must be installed on a sufciently sturdy surface. Static capacity must be checked by a structural engineer
prior to any installation. Check suitability for xing systems. For installation in particularly snowy and/or windy sites
please contact manufacturer.
LIGHTNING PROTECTION / EQUIPOTENTIAL BONDING OF THE BUILDING
In accordance with the lightning protection standard ÖVE/ÖNORM EN 62305 Part 1-4 the collector array cannot be
connected to the building’s lightning protection. A safety distance of at least 1 m must be maintained from any possible
adjacent conducting object.
For installations on metal substructures at the installation site, qualied electricians must be consulted.
To carry out a building potential equalization, the metal tubes of the solar circuit and all collector cases or fastenings
must be connected to the main potential equalization bus by a qualied electrician in accordance with ÖVE/ÖNORM E
8001-1 or the country-specic standards.
CONNECTIONS
Connect the collectors together with the exible connectors supplied which regulate any linear thermal expansion in the
pipes and collector. Irreparable damage may occur if such connectors are not used.
COLLETTOR ANGLE / GENERAL NOTES
The solar collector and xing systems have been designed for angles between 15° and 70°. Please contact manufacturer
for authorization under different installation conditions.
COVER THE PANELS
During installation, it is essential to cover the area of the panels that is sensitive to sunlight, immediately and during
the entire preparation of the system. The panels must remain covered also during the successive loading and start-up
steps; they will be uncovered by the installer only when said steps have been completed. The solar panels, if left empty
and under the rays of the sun, in any season and condition, can undergo irremediable damage not ascribable to the
products but to said exposure.
INTRODUCTION

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Technical manual – Installation instructions and start-up X-RAY R - ver. 1.0 del 07/11/2018
FLUSHING AND FILLING
Flushing and lling must be carried out only when the collectors are covered (see the paragraph “Covering the
collectors” above). Fill the collectors with anti-freeze/water mixture supplied by manufacturer.
Anti-freeze recommended by manufacturer:
After the rst lling the collectors cannot be emptied completely, so to avoid any “risk of freezing” this anti-freeze/water
mixture must be used to test working operations and wet sealing.
Any damage caused by freezing is not covered by warranty.
INSTALLATION OF TEMPERATURE SENSOR
The temperature sensor must be installed in the specic holder on the collector head (hot side) to ensure optimal
contact for accurate readings, sensor holder should be lled with conducting compound. Sensor must be temperature
resistant up to 250°C.
OPERATING PRESSURE
The normal operating pressure is 2-3 bar.
The maximum test pressure is 10 bar.
START UP
SOLAR LIQUID FAST G28
Premixed solar liquid ready for use in solar thermal vacuum
panels, blue in colour based on monopropylene glycol, suitable
for temperatures as low as -28°C. The chemical formula which
includes corrosion inhibitors prevents the corrosion of the
metals with which it comes into contact, and thus protects
metals like aluminium and copper of which the main parts of a
solar system are made.
Insoluble metal oxides, which can develop if the system is not
bled and which cannot be removed, will form mud which over
time can deposit on the heat exchange surfaces thus decreasing
the yield, and therefore the mixture includes additives with a
dispersing action so that any deposits are kept in suspension.
Available in drums of 10 and 20 litres.
CHEMICAL AND PHYSICAL
CHARACTERISTICS
Appearance Blue liquid
Smell Not offensive
PH as is 8,5-9
Freezing point -28°C
Boiling point From 103 to 172°C
(1 bar - 8 bar)

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Technical manual – Installation instructions and start-up X-RAY R - ver. 1.0 del 07/11/2018
In the system installation and loading phase, the solar panels must be transported and handled in their original
packaging, which must not be removed until they are positioned on the roof, or any other structure on which they
are to be installed, in accordance with the paragraph “Cover the panels”.
When handling and lifting the solar panels, personal protective equipment suitable for the handling should always be
worn. The panels should be transported with the aid of ropes passed through the eyebolts provided (see the gure
below). The eyebolts must be screwed to the bolts provided on the rear part of the panel head prole.
It is obligatory to use certied karabiners (spring catches) and ropes that have a breakage point above 2000 kg.
Non sollevare il collettore utilizzando gli attacchi idraulici filettati, non sollevare il collettore gravando
o tirando sui tubi di vetro.
Evitare che il collettore subisca colpi o azioni meccaniche, proteggete soprattutto
i tubi in vetro che per la loro natura sono particolarmente fragili.
Fissare accuratamente le funi per il sollevamento: Attenzione pericolo di incidenti anche gravi!
TRANSPORT INSTRUCTIONS
Do not lift the manifolds by connecting to the threaded hydraulic connections.
Do not lift the collectors by putting on or pulling on the glass tubes.
Prevent collectors from being struck or mechanically damaged, especially protect glass pipes
which by their nature are particularly fragile.
Attach any lifting belts carefully to avoid serious accidents!

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Technical manual – Installation instructions and start-up X-RAY R - ver. 1.0 del 07/11/2018
DESCRIPTION
The panels with X-RAY R tubes have three main pre-assembled components:
~ Vacuum tubes;
~ Curved CPC mirrors;
~ A collector with a heat distribution unit and integrated return tubing
Each vacuum tube is composed of two concentric glass tubes; every single tube is closed at one end by a hemisphere,
and is connected with another tube at the other end. The vacuum is created in the space between the tubes. The
recipient which is thus formed can be considered a heat recipient. To more effectively store the solar energy, the
internal glass tubes (protected by the hollow space containing the vacuum) are coated with aluminium nitrite, which
allows the tubes to capture the heat very efciently.
Highly reecting CPC (compound parabolic concentrator) mirrors, resistant to atmospheric agents, have been placed
behind the vacuum tubes to further increase their efciency. The geometry of the mirrors allows both direct and
diffused sunlight to hit the captivating surface even when the rays of the sun strike them at an unfavourable angle.
The input and return tubes are located in the upper part of the panels. The input tubes branch into heat absorption
units; these are U shaped copper ducts provided with heat deectors in sheet aluminium, which transfer the heat
from the glass tubes to the U shaped tubes through which the vector liquid ows. The hot liquid ows through the
tubes and reaches the heat exchange unit for the production of hot water for domestic use or to supplement the
central heating system.
The vacuum collectors are supplied completely pre-assembled and therefore they are fast and easy to install.
They are a reference point for the solar market thanks to their physical resistance, energy performance and exclusive
design. The exclusive hydraulics of the X-RAY R collectors with a built-in third tube allow for connecting up to 6 solar
panels in cascade mode, with the extraordinary advantage that an external return line is not required.
This drastically reduces the installation cost and time, and guarantees a hydraulically balanced system with a
clean and elegant line. Installation is possible thanks to the anchorage system which allows for installation on any type
of surface. The third lateral connection allows for integrated hydraulic connection, with parallel hydraulic distribution
which improves the energy performance compared with normal panels connected in series.
INFORMATION
length
height
width width
PERFORMA
BASIC

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Technical manual – Installation instructions and start-up X-RAY R - ver. 1.0 del 07/11/2018
TECHNICAL DATA
THE BENEFITS REFER TO THE GROSS SURFACE ACCORDING TO EN ISO 9806: 2013
modelli X-RAY R 10 R X-RAY R 11 R X-RAY R 12 R X-RAY R 13 R X-RAY R 14 R X-RAY R 15 R
TECHNICAL DATA
Evacuated tubes [ N ] 10 11 12 13 14 15
Measurements
(length x width x
height)
[ mm ] 1106 x 1921 x 114 1216 x 1921 x 114 1326 x 1921 x 114 1436 x 1921 x 114 1546 x 1921 x 114 1656 x 1921 x 114
Gross surface area [ m² ] 2,12 2,34 2,55 2,76 2,97 3,18
Aperture Area [ m² ] 1,91 2,11 2,29 2,48 2,65 2,87
Absorber
surface 360°
[ m² ] 2,57 2,82 3,09 3,34 3,59 3,85
Weight when empty [ kg ] 40,0 43,6 48,2 52,8 54,5 58,2
Fluid content [ lt ] 1,78 1,96 2,15 2,35 2,5 2,68
Max test pressure [ bar ] 10 10 10 10 10 10
Recommended
capacity
[ l/min ] 1,50 1,65 1,80 1,95 2,10 2,25
Peak Power [ W ] 1272 1404 1530 1656 1826 1955
Optical eciency [ % ] 60,0 60,0 60,0 60,0 61,5 61,5
Tramittance
coecient a1
[ W/m²K ] 0,910 0,910 0,910 0,910 0,850 0,850
Tramittance
coecient a2
[W/m²K² ] 0,013 0,013 0,013 0,013 0,009 0,009
Absorber
coecient
[ % ] 92 92 92 92 92 92
Emission
coecient
[ % ] 6,5 6,5 6,5 6,5 6,5 6,5
Coecinet transfer
of the glass
[ % ] 92 92 92 92 92 92
Connections [ Ø ] 4-6 x 3/4 " M 4-6 x 3/4 " M 4-6 x 3/4 " M 4-6 x 3/4 " M 4-6 x 3/4 " M 4-6 x 3/4 " M
Stagnation
temperature
[ °C ] 176 176 176 176 176 176
Head insulation
thickness
[ mm ] 30 30 30 30 30 30
Diameter - vacuum
pipe length
[ mm ] 58/47 - 1800 58/47 - 1800 58/47 - 1800 58/47 - 1800 58/47 - 1800 58/47 - 1800
Recommended
inclination
[ ° ] 15 - 75 15 - 75 15 - 75 15 - 75 15 - 75 15 - 75
Incidence angle
correction factor
[ K50° ] 1,05 1,05 1,05 1,05 1,05 1,05
Energy produced
annually EN 12975 -
Wurzburg - Tempe-
rature 50°C
[ kWh ] 1231 1359 1481 1603 1844 1974
Test report EN
12975-2
[ - ] RP.2018.
COL.202a.1
RP.2018.
COL.202a.1
RP.2018.
COL.202a.1
RP.2018.
COL.202a.1
RP.2018.
COL.202b.1
RP.2018.
COL.202b.1
DIN CERTCO number
of registration
[ - ] 16084 Rev.0 KIWA 16084 Rev.0 KIWA 16084 Rev.0 KIWA 16084 Rev.0 KIWA 16083 Rev.0 KIWA 16083 Rev.0 KIWA