Solfex IRC 2.1 Guide

solar energy innovationwww.solfex.co.uk
IRC 2.1 Roof Integrated Solar Collector
Solar Keymark No. 011-75347F
System Installation,
Commissioning and
Maintenance Manual

Contents
Health and Safety• ...................................................... 3
Installing the collectors• .......................................4 - 24
Installing the pump station• ........................................ 25
System schematics• ................................................26 - 27
Installing the stainless steel pipe• ............................ 28
Flushing and filling the system• ................................ 29
Commissioning the pump station• ........................... 30
Commissioning the solar controller• ....................... 30
System maintenance and warranty• ........................ 31
Commissioning checklist & warranty form• ....32 - 34
Maintenance record• ..................................................... 35

Page 2 of 24
Installation instructions – Wooden frame collectors
In
-
roof installation
SAFETY INSTRUCTION!
The basic equipment
includes:
+ safety shoes
+ hard hat
+ cut-proof safety gloves
+ safety harness
Ladder
Lean ladders only on strong and secure support points. Before climbing, be sure that the
ladder can not exile, fall over or sink in. Circulation lanes next to the site should be blocked
in order to avoid any risk of accident due to fall of objects.
Damaged ladder should not be used (nor patched up).
Up on the roof
At heights of more than 3 metes and for works on roofs with inclination between 20 and 60
Must take protection and safety measures against risks of fall. This can be done by using
scaffold for roof works or safety harnesses.
Wind gusts
Solar collectors and their accessories, such as covering frames, are of large area
and can be subject to wind gusts. One must be very aware of this phenomenon and be
sure of one’s stability. In case of strong wind, installation should be interrupted.
Health and Safety
page 3 - Health and safety
Technical changes may be made without notice
Page 3 of 24
°
.
Installation instructions – Wooden frame collectors
In
-
roof installation
BE VERY CAUTIOUS WITH….
Roof’s stability
Before any installation, it is imperative to check the good state of the roof’s substructure and
its load-bearing capacity. Particular attention should be paid the timber substructure with
regard to the durability of screw connections.
The indications of this notice are only valid within the frame of the following restrictions:
- Roof inclination 20 ° - 45°
- Maximal building’s height 25 m.
- Wind speed inferior to 150 km/h
Ventilation
It is imperative to build a sufficient air circulation underneath the collectors. This ventilation
avoid the stagnation of water underneath the collector in case of heavy rains.
Contamination Prevention
During the installation phase, all ventilation holes and connections must be protected against
contamination and clogging.
Flushing and filling
For safety reasons, you should only fill the collectors when the sun is not shining (or cover
the collectors). You should use a mixture of antifreeze with water (40% antifreeze), Tyfocor
LS is recommended. Filling should always be done with the recommended heat transfer fluid.
It is recommended that the use of a solar filling pump is used in order to completely de-aerate
the panels and the system.
We recommend to fill the system with a pressure filling pump to eradicate any air bubbles
within the solar collector and pipework.
Operating pressure
The maximum operating pressure is 9 bar, recommended operating pressure is 3 bar with
pre charge pressure of expansion vessel set at 2.5 bar.
Check heat transfer fluid
The heat transfer fluid must be checked every 12 months with regard to its antifreeze and pH
value. We recommend to use Tyforcor LS fluid
Maintenance of the collector
The collector or the collector array must be inspected visually, once a year, for any damage,
leaks and contamination and also antifreeze level checked as the above recommendation.
avoids the stagnation of water underneath the collector in case of heavy rains.

solar energy innovation
IRC 2.1: Roof Integrated Solar Collector
Technical Specifications
Gross collector area 2.1m²
Absorber area 1.83m²
Height 2110mm
Width 1032mm
Depth 107mm
Empty weight 44kg
Fluid content 1.2 litres
Connections 15mm/½ inch
Collector glazing 4mm, Solar safety float glass
Absorber Laser welded aluminium absorber, highly selective
Vacuum coating / Copper harp
Housing Wooden frame with aluminium section
Insulation 50mm mineral wool
Max operating pressure 6 Bar (pressure tested to 9 bar)
Stagnation temperature 209°C
Flow rate recommendation Minimum 1 litre per min / m2
Minimum inclination 20°
Maximum collectors in series 8. (collectors can also be
mounted on top of each
other to form larger arrays)
Absorption 95%
Emission 5%
Minimum output 525 kwh/m2a
Features of IRC 2.1 roof integrated solar collector
Simple installation to both new build & existing housing/perfect integration
Easily portable & modular in design
A choice of flashing kits available dependant upon roof tile / slate type
Portrait or landscape collectors available
Excellent price/performance ratio
Solar Keymark approved product/10 year solar collector warranty / 25 year
life expectancy
Optional flashing kit, roof tile/ slate
The publication of a new DINplus
certification scheme for barbecue
charcoal and barbecue charcoal
briquettes has added a new pro-
duct range to the list of our certi-
fications schemes for the award of
the DINplus quality mark.
Barbecue charcoal and firelighters
for barbecuing have already been
successfully certified by DIN CERTCO
for more than ten years. As in
other comparable cases, a number
of requirements specified in the
national standard became less
stringent on publication of the
relevant European Standard (DIN
EN 1860-2). At the suggestion of
individual manufacturers and of
the responsible trade association,
DIN CERTCO decided to offer DINp-
lus certification to suppliers
whose barbecue charcoal continu-
ed to meet the requirements of
the superseded German standard.
The DINplus mark, beside the DIN-
Geprüft mark, now also enjoys
growing popularity in the barbe-
cue charcoal branch.
�
Systems-built houses in solid con-
struction quality, planned and
built according to DIN – that is
the quality approach of Viebrock-
haus AG in Harsefeld and its fran-
chisees.
The new certification scheme
“Systems-built houses in solid
construction quality” was develo-
ped by DIN CERTCO in 2004. Con-
struction is characterised by a
large number of DIN Standards
which regulate the manufacture of
building products and their use,
and thus ensure that buildings in
Germany attain a high level of
quality. As proof of conformity
with DIN Standards a certification
mark is already awarded for indivi-
dual building products.
Systems-built houses are con-
structed to the same plans and
with the same materials (with
industrial variations in appoint-
ments/fittings). All materials used
and the way they are processed
are documented. The certification
scheme “Systems-built houses in
solid construction quality” governs
the award of the certification
mark DIN-Geprüft. A systems-built
house in solid construction quali-
ty only receives the certification
mark DIN-Geprüft if all materials
and building products, as listed in
the certification scheme, conform
to the respective DIN Standards,
and if this conformity can be duly
verified in a proper process of cer-
tification.
Continuing compliance with the
requirements is ensured by an
annual inspection audit. Viebrock-
haus AG, as the first holder of
such a certificate, has meanwhile
successfully passed its first ins-
pection audit and is thus entitled
to continue using the coveted
DIN-Geprüft mark.
�
Exploiting the free energy from
the sun is currently very popular
with people building their own
homes. In particular, the high
costs of other energy sources, and
the attractive financial subsidies
available, have brought about a
regular boom in the solar power
sector. Yet it is not always easy,
given the variety of products from
different manufacturers and supp-
liers, to choose among the solar
collectors and factory made solar
systems the one that is both sui-
table and of high quality.
Help in making the right choice of
product has been provided for
the last two years or so by the
Solar KEYMARK, the European
quality mark. More than 70 types
of solar collector and factory
made solar systems now bear the
Solar KEYMARK. Over 35 compa-
nies in nine countries use this
mark to document that they sub-
ject their products voluntarily to
impartial, independent and quali-
fied testing certification and ins-
pection on the basis of the Euro-
pean Standards DIN EN 12975 and
DIN EN 12976. This comprises not
only the obligatory performance
test of the collectors. Their fitness
for purpose and durability are also
the subject of stringent testing.
After all, the solar system is to
“last a lifetime”, capturing the
heat of the sun. Regular third-
party inspection of products and
of the manufacturers’ factory pro-
duction cont
rol further ensures
constant product quality. That
creates confidence among users
and consumers – wherever they
are in Europe!
Yet the Solar KEYMARK offers a
real added value from the manu-
facturer’s viewpoint, as well. The
active support from DIN CERTCO,
its recognized testing partners,
other European certification
bodies and the European Solar
Thermal Industry Federation
(ESTIF) has succeeded in establi-
shing the Solar KEYMARK as the
single European certification sche-
me so that the mark now enjoys a
high reputation and its award
counts in almost all European
countries as the precondition for
the granting of financial subsidies.
The manufacturer thus saves con-
siderably on costs for testing and
certification because these are
everywhere based on the same
test procedures and standards.
That, after all, was and is the aim
of the KEYMARK: tested and certi-
fied once – recognized everywhere
in Europe!
Full speed ahead to Europe for the Solar KEYMARK!
DINplus for barbecue charcoal
“Solid houses – solid quality”
2
The KEYMARK is the European quality mark for products and services. It
documents the conformity – tested and inspected (at least every two
years) – of the product or service with the requirements specified in
EN Standards and certification schemes, including the annual audit of
the quality assurance system.
The mark can currently be awarded by DIN CERTCO for the following
products:
�Eye protection devices
�
Insulation materials for buildings
�Floor heating
�Radiators
�Heat cost allocators
�Plastic piping
�Gully/manhole tops
�
Solar collectors and
thermal solar systems
�Vitrified clay pipes
Austrian
manufactured
German Testing
Institute
laser welded absorber
page 4 - Installing the collectors
Technical changes may be made without notice

Installing the Collectors
Installing the collectors - page 5
Technical changes may be made without notice
Page 4 of 24
Installation instructions
–
Wooden frame collectors
In-roof installation
The glass cover lies directly on to the aluminium rail, without any rubber gasket. Reason: Rubber gasket inside the hot collectors release various chemical, which can fog up the glass cover. Only the side of the field of collectors, underneath the flushing, a rubber gasket has to be inserted.
4x40mm
Mounting bracket 70/70mm

Page 5 of 24
Installation instructions
–
Wooden frame collectors
In-roof installation
(4)
Fix the collector on the left side with 2 Torx 4 x 80mm
screw.
Screw slanting through the frame beam all the way
through to the slat.
ROOF INTEGRATION:
(1)
Uncover the area needed for the installation of the
collectors.
Width: width of a collector group + 0,5m (left) + 0,5m
(right)
Height: 2,5m (for one-row fields)
(2)
Install a 70/70mm support bracket on every rafter.
Place this bracket below the lowest slat and screw into
the rafter with 2 Torx 4 x 80mm screws.
(3)
Place the first collector (the left one) up on the roof.
The collector must be parallel to the rafters.
* Note: in order to cut fewer tiles during the covering
Phase, it is recommended to make sure that the
distance between the collector and edge of the tiles is
55 mm (see picture besides)
*
page 6 - Installing the collectors
Technical changes may be made without notice

Page 6 of 24
Installation instructions
–
Wooden frame collectors
In-roof installation
(5)
Haul up the second collector on the roof.
Unscrew the covering aluminium profile.
To do so, you have to unscrew 6 4, 2 x 19 mm screws.
Caution: keep those screws. They will be used later.
(6)
Lay down a layer of silicon on the left collector’s part,
which will be fixed to the right’s collector aluminium
profile. (about 2cm).
(7)
Then, make this second collector slide sideways up till
its complete contact with the first installed collector.
The first collector’s glass cover must rest on the
tightness gasket and be in complete contact with it.
Installing the collectors - page 7
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Page 7 of 24
(8
)
Firmly screw the two collectors with a Torx 4x80mm
screw that you will screw sideways through the frames
of both collectors.
(9)
Collector’s 1 and 2 are now installed.
Installation instructions
–
Wooden frame collectors
In-roof installation
(10)
The following collectors will be installed following
the exact same procedure as the one described
in stages
(5) to (10).
page 8 - Installing the collectors
Technical changes may be made without notice

Page 8 of 24
Installation instructions
–
Wooden frame collectors
In-roof installation
(1
1
)
the collectors will be fastened to the roof’s structure
only after they are all placed on the roof in a correct
way.
See stages (14) to (17)
(12)
Fix the collectors to the lower support brackets by
means of Torx 4x30mm screws. 2 screws per bracket.
(13)
In the same way, install the 70/70mm bracket on the
collectors’ upper faces and fix them to the rafters by
means of Torx 4x80mm screws. 2 screws per bracket.
(14)
Then fix these brackets to the collectors using
4x30mm screws. 2 screws per bracket.
Installing the collectors - page 9
Technical changes may be made without notice

Page 9 of 24
Installation instructions
–
Wooden frame collectors
In-roof installation
(1
5
)
On the right hand side of the collector field:
As for the left hand side, fasten the collector to the
slats. To do so, use Torx 4x80mm screws and screw
sideways through the frame all the way through to the
slat.
(16)
On the right hand side, mount the finishing slat:
Position the slat correctly and fasten it to collector
using 3 Torx 4x30mm screws. These screws should be
spread regularly all along the frame.
(17)
Mount the right hand side collector’s aluminium profile
on its frame.
use 4×25mm head screws (3 units)
(18)
As described in step (17):
Mount the finishing slat but this time on the right hand
side:
Place this slat into the correct position and fasten it
using 3 Torx 4x30mm screw. These screws should be
spread regularly all along the frame.
page 10 - Installing the collectors
Technical changes may be made without notice

Page 10 of 24
Installation instructions
–
Wooden frame collectors
In
-
roof installation
(19)
Place the linings, mounds the junctions and
secure using a hex spanner.
Do NOT fasten too strongly. This might damage
the collector’s connections.
(20)
Make the group’s inlet and outlet connections run
through the attic space by means of clamping ring
bends.
If the collectors are being connected using Pre-insulated flexible pipe work, it is advisable to
fix the pipe work in position first using suitable brackets or strap band before making final joint
connection of the solar collectors, this will prevent the joint being disturbed at a later stage
causing leakage of solar fluid.
ALWAYS CHECK CONNECTION JOINTS FOR TIGHTNESS PRIOR TO
FIXING FLASHING KIT!
Installing the collectors - page 11
Technical changes may be made without notice

Page 11 of 24
Installation instructions
–
Wooden frame collectors
In-roof installation
(21
)
The sensor tube and collector sensor should be inserted
in the last solar collector with the flow of hot solar transfer
fluid down to the solar cylinder / store, this will give
accurate temperature collector readings on the solar
controller.
(22)
Place the aluminium profiles at the junctions between
the collectors and firmly fasten with 4,2x19mm screws.
Both profiles, for cover and support of the glass cover,
must be perfectly aligned
(23)
Each profile must be fastened by 6 4,2x19mm screws.
NB: Do not over tight
(24)
The aluminium profiles at the group’s ends must be
taken off before the mounting of the integration cover.
page 12 - Installing the collectors
Technical changes may be made without notice

Page 12 of 24
Installation instructions
–
Wooden frame collectors
In-roof installation
INSTALLATION OF THE
INTEGRATION COVER:
(25)
At the bottom of each collector, by the centre of the
collector, mount the wooden slats with 2 4x80mm
screws for each one of them.
Advice:
The slat’s upper face must be, at the highest, at the
level of the upper edge of the collector’s frame.
(26)
Mount the wooden wedge meant to shelter the
hydraulic connections. This wedge is located at the top
of the collectors and is fastened by Torx 4x80mm
screws.
Be very careful not to damage the connections while
fastening.
(27)
On the left hand side collector, place the frame’s lower
corner. It is inserted in the runner located all around
the collectors and must be tucked up till it’s complete
contact with the slat previously installed.
(28)
Fasten this front corner section to the slat using sealed
plumbing nails.
Installing the collectors - page 13
Technical changes may be made without notice

Page 13 of 24
Installation instructions
–
Wooden frame collectors
In-roof installation
(29
)
In the same way, on the side, fix this cover section to
the collector.
(30)
As the bottom, place the straight pieces of the cover:
Start by inserting the new elements sideways into the
ones previously installed before completely fitting them
in.
(31)
Nail these pieces to the frame using sealed plumbing
nails, at the juncture.
(32)
On the right hand end, install the lower corner of the
frame following the same procedure as described in
(30).
page 14 - Installing the collectors
Technical changes may be made without notice

Page 14 of 24
Installation instructions
–
Wooden frame collectors
In-roof installation
(3
3
)
As in stage (32), nail the covers to the wooden frame
using sealed plumbing nails.
(34)
Mounting of the cover’s superior left corner:
The sheet must be meticulously inserted into the
collector’s upper profile.
(35)
Fasten this piece of cover to the wooden wedge using
sealed plumbing nails.
(36)
As for the bottom elements, the straight upper pieces
must be first sideways inserted one into another. The
fitting into the collector’s profile must be meticulous.
Installing the collectors - page 15
Technical changes may be made without notice

Page 15 of 24
Installation instructio
n
s
–
Wooden frame co
l
lectors
In
-
roof installati
o
n
(37
)
As for the corner part, nail these elements to the
wedge using sealed plumbing nails, at the juncture.
(38)
Firmly fix the side left and right side pieces.
(39)
Place the right hand side cover sheet on top of the side
gasket.
Fasten with sealed plumbing screws: 1× at the top, 1×
at mid-length and 1x at the bottom.
(40)
Sealed plumbing screw, top right.
page 16 - Installing the collectors
Technical changes may be made without notice

Page 16 of 24
Installation instructions
-
Wooden frame collectors
In
-
roof installation
(4
1
)
Place the left hand side cover sheet on top of the side
gasket.
Fasten with sealed plumbing screws: 1× at the top, 1×
at mid-length and 1× at the bottom.
(42)
Sealed plumbing screw, top left.
(43)
On the left hand side, mount the exterior cover profile
and fasten it with a, 2x19mm screws.
These cover profiles must be perfectly aligned with the
glass cover.
Each profile must by fixed with a 4,2x19mm screws.
(44)
In the same wax, mount the right hand side exterior
p
rofile.
Installing the collectors - page 17
Technical changes may be made without notice

Page 17 of 24
Installation instructions
-
Wooden frame collectors
In
-
roof installatio
n
(45
)
At the bottom sheets and by the mix-collector,
underneath the glass cover, add a sealed plumbing
screw (into the wooden slat installed in (29)).
(46)
Fasten the side parts to the roof slats thanks to metal
retainer and roofing nails. (minimum 3x per side).
(47)
In the same way, place similar retainers every meter
along the upper cover sheet.
Indication:
If there is no roof slat at this exact place, it is
necessary to install one before the installation of the
covering fame.
(48)
Stick a rubber wedge all along the upper edge of the
cover sheet.
page 18 - Installing the collectors
Technical changes may be made without notice

Page 18 of 24
Installation
instruction
–
Wooden frame collectors
I
n
-
roof installation
(49
)
Glue the lead skirting to the tile with silicon gel or PU
foam.
In case this stage is not well carried out, the collector
field’s lower edge can be seriously damaged in storms
or strong wind periods.
(50)
Adjust the lead skirting to the tiles.
To do so, we recommend that you use a soft rubber
hammer.
(51)
Roof cover:
The tiles must be installed upon the lateral pieces in
order to insure waterproofness. To do so, you might
have to cut the edges off in order to make sure that the
tiles lie flat on the flushing.
(52)
Finished integration of a 6m² set of collectors.
Installing the collectors - page 19
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Page 21 of 24
Installation
instructions
–
Wooden
frame collectors
In
-
roof
installation
(53
)
Insert the left hand cover strip and only fix it first with a
sealed plumbing screw on the side.
Then, drill the collector’s rail with a 4,5mm bit and
secure with a sealed plumbing screw.
(54)
Put the left hand side corner in place and secure it to
the collector.
This step will be repeated for the right hand side corner
at the suitable time.
CAUTION:
THOSE PIECES SHOULD BE FIRMLY INSERTED
INTO THE RUNNER. IF NEEDED, A WOODEN
BATTEN OR A HAMMER CAN BE USED.
(55)
Then, start inserted the straight extension pieces
sideways into the runner. They should first fit the
corners of the pieces previously installed and the be
completely and firmly inserted into the collector’s
runner
.
(5
6
)
The pieces
should
overlap
each
other
by 25 to 50 mm.
25
–
50 mm
MULTIPLE
ROW
INSTALLATION
:
To
cover
and
protect
horizontal
junctures
between
rows,
covering
pieces are provided. They should be inserted into the upper collectors’ runner.
page 20 - Installing the collectors
Technical changes may be made without notice