Sunsystem PK SL AL Series User manual

TECHNICAL PASSPORT
INSTALLATION and OPERATION MANUAL
For SOLAR COLLECTORS - РК SL AL
With full plate aluminum absorber
model: ............................
serial number: .....................................
version 01/SRCC-2-2011/

TECHNICAL PASSPORT INSTALLATION and OPERATION MANUAL
2 - EN
Table of contents
#
page
1
S
afety instructions
3
1.1
Requirements to solar collector installation place
3
1.1.1
Instructions to collector installer
3
1.1.2.
Instructions to installation user
4
2
MAIN
TECHNICAL
SPECIFICATIONS
5
3
Description
5
4
Transport. Handling
6
5
Collector protection against lightning
6
6
COLLECTORS INTERCONNECTING IN A FIELD WITH 20m²
6
7
Pressure loss
7
8
Recommended angle of installation of the collector
7
9
Collector protection against frost
8
10
Maintenance
8
10.1
Installation of collectors
PK
SL
AL
AS PART OF A FORCED
CIRCULATION CENTRAL SOLAR SYSTEM
8
10.2
Selection of installation area
8
11
Maximum limit of snow load and wind speed
9
12
Installation
9
13
Important
recommendations
when instal
ling the
collector
10
14
Warranty terms
11
15
Technical features
12
16
Recycling and waste disposal
14

TECHNICAL PASSPORT INSTALLATION and OPERATION MANUAL
3 - EN
1. Safety instructions
1.1. Requirements to solar collector installation place
This manual contains important information for the safe and correct installation, start-up and
trouble-free operation and maintenance of the solar collector.
The solar collector can be used to produce domestic hot water and support of space heating system
only in the manner described in this manual.
The application and any other was the area of operation is not recommended by the manufacturer
and is not responsible for the occurrence of defects or failures.
Note the collector type data on the factory rating label and the technical data provided in this
manual in order to ensure proper operation of the product.
1.1.1. Instructions to collector installer
During installation and operation, the country-specific requirements and regulations must be
observed:
• local construction regulations on installation on building – mass of the system to comply
with the building structure.


Fixation
of
support
must
be
in
compliance
with
local
regulations
and
requirements
regarding
wind/snow load resistance (if necessary take measures to make them compliant)
• regulations and norms concerning safety installation and operation of solar collectors -
protective gloves, eyewear should be used; make sure collector is securely attached to the
building.


Use only original parts
 
DANGER of structure damage / injury from fall.
The weight of collector/collectors must
comply with the building structure, namely the distribution of weight; strong and secure
fixation of collector support to the roof/façade of building. We recommend the securing
of the area during installation and the construction of roof barriers protecting against
downslide of snow mass. Failure to comply with these recommendations can lead to fatal
consequences.

Risk of injury, burn
upon installation and maintenance of solar collectors:
- On contact with broken glass/vacuum tube
- On contact with collector in function because of its high temperature.
We recommend the use of protective equipment, gloves, eyewear (goggles), clothing.
Installation and maintenance of collectors must be carried out in the early morning hours.
When the collector is still cold you can cover it with tarpaulin to avoid its heating by direct
sunlight.

FIRE HAZARD
through contact of accumulated waste (dry leaves, plastic bags, paper) with
the hot parts of the collectors. We recommend the regular inspection and cleaning of
collector installation sites.

TECHNICAL PASSPORT INSTALLATION and OPERATION MANUAL
4 - EN

DANGER of slipping, fall. In most cases, collectors are installed in hardly accessible and
dangerous places. We recommend that installation and service maintenance be carried
out by authorized service technicians observing all safety measures.
1.1.2. Instructions to installation user
 
CAUTION! Danger of injury / damage of system due to incompetent operation.
- The solar collector must be serviced only by persons familiar with the operation
manual.
- Structural changes to collector by user can cause damage to equipment or injury.
Safety rules for user operation:
- The solar collector can be used to produce hot water and support the heating system only in the
manner described in this manual.
- Installation and maintenance must be performed by a technician / service shop authorized for such
operations.

TECHNICAL PASSPORT INSTALLATION and OPERATION MANUAL
5 - EN
2. MAIN TECHNICAL SPECIFICATIONS
Table. 1
Model
ABSORBING
SURFACE
DIMENSIONS
AxBxC (mm)
WEIGHT OF
EMPTY
COLLECTOR
(kg)
THERMAL
LIQUID
CAPACITY (Lt)
MAXIMUM
WORKING
PRESSURE
(bar)
PK SL AL
2,00 м²
ALUMIN
UM
SELECTIVE
1010x1980x86 34 1,75 10.
PK SL AL
-2,4 м²
ALUMINUM
SELECTIVE
1230x1930x86 43 2,03 10.
This manual is also valid for all collectors in the a/m dimension with standard casing profile with
thickness 86mm and 100mm.
Scheme 1
3. Description
The solar collectors PK SL AL are designed to function as part of thermosiphonic solar systems or as
part of forced circulation central system for heating sanitary water, space heating, air conditioning
and pool heating.
The collectors PK SL AL are flat solar collectors with Aluminum high selective absorbing surface,
copper risers and header tubes, clear tempered glass, rock mineral wool insulation and aluminum
frame.
For all flat solar collectors including Ultra series, there is the possibility to include other type of
absorbing surfaces like copper full plate selective, copper fins black paint, copper fins black paint,
aluminum full plate black paint and other solutions according to customers’ demands.
Flat solar collectors with selective absorbing surface perform higher efficiency under diffuse solar
radiation weather conditions.

TECHNICAL PASSPORT INSTALLATION and OPERATION MANUAL
6 - EN
Antifreeze liquid mixture is absolutely necessary in any case.
4. Transport. Handling.
Collectors are packed in cardboard or with stretch film, carton on glass surface and hard polystyrene
on the corners and must always be transported in vertical position.
Palletizing of collectors. Upon request special pallets for horizontal packaging are available.
Scheme 2
During installation, keep the upper carton or plastic film in place up to the moment the circuit is filled
with thermal fluid.
5. Collector protection against lightning
Use a copper wire 16 mm² to connect the collectors (metal parts) with lightning protection system if
existing or earth them to an earth rod using wire of the same size. The route of this wire should be
always outdoors. Ask specialist for more information.
6. COLLECTORS INTERCONNECTING IN A FIELD WITH 20m²
For collectors PK SL AL -2,00 m² and PK SL AL -2,4m ², the optimal arrangement is in five arrays
connected in parallel with maximum two collectors in each array connected in series. For
Mediterranean countries, all collectors must be connected in parallel to prevent over heating as
much as possible during summer. Use brass joints for copper tube Ø 22 and copper tubing
properly insulated to make all connections.
Collectors are delivered bare copper tube Ø 22 without any threading or union nuts.
Scheme 3
Scheme 4
ATTENTION: When screwing the connection fittings of the collectors (plugs, raccords, connectors,
etc.) use divert force to avoid damaging the header tube connections inside the collector.

TECHNICAL PASSPORT INSTALLATION and OPERATION MANUAL
7 - EN
7. Pressure loss
For the dimensioning of the circulating pump, the following tables which show the pressure drop
against flow of thermal fluid through the collector must be taken under consideration:
Scheme 5. Pressure loss of collectors PK SL AL 2,0 и 2,4
8. Recommended angle of installation of the collector
The angle of the collector referred to the horizon must be the latitude of the place plus 5°. At this
angle the maximum of the year around efficiency is achieved.
In case of difficulty to follow the above rule, try to keep the inclination between 30° and 50° in order
to benefit a minimum year around efficiency (for places with latitude 40°).
9. Collector protection against frost
To protect the collector against frost (closed loop) Propylene Glycol PG heat-carrier fluid is
recommended:
Table. 2
PG
/ Propylene Glycol /
:
Water
Freezing point
20% : 80% - 7
℃
30% : 70%
-
13
℃
40% : 60% - 23
℃
50% : 50%
-
34
℃
If you choose water as heat carrier, it is recommended to connect to the system a controller unit
supporting antifreeze function working with water as heat-carrier.

TECHNICAL PASSPORT INSTALLATION and OPERATION MANUAL
8 - EN
10. Maintenance
Our collectors require the minimum maintenance and attendance such as summarized below.
Every two years the following actions must be taken:
I. Check that all the fastening screws of the supports and the screws of the collectors’ holders
are well tightened. If not, fix them properly or change them if necessary.
II. Clean the glass of the flat plate collectors from dust to increase efficiency.
III. Check the level of the thermal fluid and fill the system if necessary using the upper point
(venting point) of it or use any other convenient method.
IV. Check for any leakage in the collectors and joints.
V. Check again the slope of the collectors to avoid any formation of air traps.
10.1. Installation of collectors PK SL AL AS PART OF A FORCED CIRCULATION CENTRAL
SOLAR SYSTEM
Safety instructions:
1. In case of using ladders, check them in order not to be damaged, and place them on
secure surfaces in inclination ≈70°. For maximum protection use safety belts.
2. We suggest the installer to wear protective gloves, safety shoes and helmet. Also
protective glasses are necessary in some cases.
3. In case that the place of installation is near electrical wires, keep safety distance
(minimum 5 meters) and pay maximum attention when handing long parts of the support
structures or tools for the installation.
10.2. Selection of installation area
Check with the constructor of the building that the roof can withstand the load of the collectors
full of water and ask for a written confirmation. Check the same with the local technical
authorities if needed.
Our collectors can be installed on flat roofs or on the ground or on sloped roofs with defined
orientation and slope.
For optimum performance, the collectors must face the south, for counties located in the
Northern hemisphere and north for counties located in the Southern hemisphere. In case that it
is not totally possible for the collectors to face the equator, you can turn it towards East up to
30° if major hot water draw is before 2 p.m. or towards West u p to 30° if major hot water draw
is after 2 pm. In both cases, the losses of the total annual solar contribution, is no more than 6%.
To compensate energy losses there is the option to increase the number and surface of the
collectors’ that are going to be installed.
The following points must be considered when selecting the installation area:
The position you will choose for the installation of the solar water heater, should not be shaded
by any obstacles (trees, buildings, etc.) all around the year.

TECHNICAL PASSPORT INSTALLATION and OPERATION MANUAL
9 - EN
The distance from an obstacle being at East, South or West must be :
- at least 1,5 time the height of the obstacle for countries with latitude 30°
- at least 2 times the height of the obstacle for countries with latitude 40°
- at least 2,5 times the height of the obstacle for countries with latitude 50°
For optimum performance the collectors must have inclination to the horizon of 45° (countries
with latitude 40°). In general the inclination of the collectors should be 5° higher than the
latitude of the place. Any change of the above mentioned condition causes a reduction to the
average annual gain of usage that must be considered.
The distance between the collectors and the boiler or other heat exchanger must be the shorter
possible.
The area of collector’s installation should have an easy and safe access for maintenance.
The static resistance of the surface that the installation will take place must be considered in
relation with the total weight of the collectors and other parts that will be installed.
The installation should be done according to the electric, plumbing and town planning
regulations applicable in the installation area.
11. Maximum limit of snow load and wind speed
It is admitted that our collectors can resist without any failure to a snow load of up to 500 Pa. The
support systems may only be installed in locations with a value of possible snow load lower than
500 Pa. According to the characteristics of their support frame and the standard ENV 1991, Solar
Flame systems may not be installed in locations where the maximal mean wind velocity exceeds
55 m/s (value for islands exposed to high winds).
12. Installation
Installation, connections and starting of the system should be made by specialized,
experienced and authorized technicians as necessary.
As soon as the support structure is ready to fix the collector/s we have to use the M8 screws
and flat washers M8. Each collector has 4 receptions for M8 screws (2 on the upper side and 2 on
the down side) as indicated in the following drawing. After placing the collector on the support
structure these receptions have to align with the oval holes of the collectors holders.

TECHNICAL PASSPORT INSTALLATION and OPERATION MANUAL
10 - EN
13. Important recommendations when installing the collector
- It is very critical to keep the front cover on until the whole circuit is full of thermal fluid
otherwise very high temperatures may appear on the collectors which can damage them.
- Verify again that the inclination towards the outlet of about 1-2% exists. The inclination is
imperative for the air venting of the closed circuit through a venting valve installed at the
highest point of the system.
- If more than one is installed, connect the collectors with appropriate joints thermally
insulated. The distance between them must be kept at the minimum. The system of collectors
should be connected to the hot water tank (heat exchanger of the tank) with tubing properly
insulated. When installing collectors in parallel, it is more practical to use the four outlets
available for the middle ones, connect the lower inlet of the first one on the left to the
discharge of the circulating pump and on the right close with a cap its upper inlet. Then
connect the upper outlet of the last one to the heat exchanger of the tank and close the lower
outlet with a cap.
A circulation pump with appropriate automatism must be used for the circulation of the
thermal liquid in the closed circuits.
Attention must be given so that all collectors have an interrupted slope.
- Prepare the mixture using the thermal fluid and water - please see the PG label

TECHNICAL PASSPORT INSTALLATION and OPERATION MANUAL
11 - EN
- Start pouring the anti-freezing and anti-corrosive brine in the system using the venting upper point
of the system or other appropriate method. A good air venting of the system is critical for any solar
installation.
- Check again inclination and tightness of the system.
14. Warranty terms.
  Failure to observe the installation and operating requirements described in the manual
and the service booklet voids the warranty.
14.1. Manufacturing defects and materials guarantee
The manufacturer expressly guarantees that the products it manufactures shall be free from defects
in materials and workmanship which can prevent from normal operation under proper and normal
use, installation and maintenance for the intended functions of the products for a period set out in
the warranty certificate of the respective model of the collector you have bought.
The warranty period begins from the date indicated in the purchase invoice. If a product or any
component thereof is determined to be defective in manufacture or materials, manufacturer will
repair or replace the defective component or product.
14.2. Exclusions and Limitations of Warranty Coverage
14.2.1. The customer can claim warranty during warranty period of respective product immediately
after any defects have been determined, except for in case of noticeable defects at the moment of
purchase, in which case the customer must make the claim at the shop immediately after noticing
the defect, as it is provided for in the general conditions of sale.
14.2.2. This warranty certificate is considered void in cases when defects and errors in functioning of
products are caused by:
- Accidents as a result of improper storage, transportation, unsuitable or incorrect use.
- Failure to observe the installation, use, and maintenance instructions set forth in the
installation manual of respective product.
- Improper installation or use as well as changes especially if they are not made by authorized after-
sale service personnel of manufacturer.
- Testing and operation pressures greater than the values established by manufacturer and set forth
in product manuals.
Freeze, flood, natural disasters or third party actions as well as any interventions into normal
functioning conditions of collectors and the control of manufacturer.
14.2.3. The warranty certificate is considered void as well for collectors whose serial identification
number has been modified, removed or blurred, or cannot be expressly attested.
14.2.4. Damages in the appearance of products shall not be considered as defects giving right for
laying claim except for those ones which cause problems in functioning or change technical
characteristics of collectors.
14.2.5. The manufacturer preserves the right, in case of replacement, to deliver another model of
collector in order to fulfill approved warranty claims in case the original model is not being
manufactured.

TECHNICAL PASSPORT INSTALLATION and OPERATION MANUAL
12 - EN
14.3. Claiming warranty
Every customer who has purchased a collector from manufacturer, and who has good reasons to lay
a warranty claim, shall proceed as follows:
14.3.1. Immediately notify in writing:
- The installer, or the company that has sold the collector to him;
- The distributor firm;
- The commercial representative of manufacturer in the region.
For this purpose the claimant shall fill out a claim form; the latter shall be accompanied by the
document proving the purchase of the collector (invoice) with the date of purchase in it.
14.3.2. After receiving the claim form, manufacturer considers it and makes decision whether the
claim has grounds or not, and whether the defect is within the scope of the warranty set forth in this
certificate for limited warranty; after which informs the customer as to its decision.
14.3.3. The return of a product cannot be done without written authorization issued by the Claim
Department.
14.3.4. If on customer's request, and when there is reason for urgency, the customer demands
immediate replacement of the product he has claimed warranty for, before receiving the decision as
to the claim, said request shall be accompanied by a Purchase requisition from the Commercial
Department. After decision for satisfaction of the claim has been made, the Purchase requisition
mentioned above will be annulled by issuing a receipt for returned goods; with this receipt the
customer can purchase another product with the same price in case the claim has proved grounded.

TECHNICAL PASSPORT INSTALLATION and OPERATION MANUAL
13 - EN
15. Technical features of collectors PK SL AL
Табл 3
PK SL AL 2.0
PK SL AL 2.4
Overall dimensions
Width L mm 1010 1230
Height
H
mm
1980
1930
Thickness D mm 86 86
Overall surface
m
2
2.00 2.37
Aperture/Absorber surface
m
2
1.86/1.86
2.23/2.23
Volume of heat carrier
L
1.40
1.70
Test pres
sure
Bar
15
15
Max. Operating pressure
Bar 10 10
Weight
(
empty collector
)
kg
35
43
Thickness of solar glass
mm 4 4
Material of solar glass
K
Heat tempered prismatic glass
Material of pipes F Copper
Absorber pipes
,
pcs
/
diameter
G
9
x ø8
11
x ø8
Manifold pipes, pcs/diameter 2 x ø22
Inlet / Outlet
P/N
ø22
Material of absorber
S Aluminum, thickness 0,5mm
Coating of absorber
PVD
high efficient
(
α
=95%,
ε
=5%).
Thermal loss coefficient -к1 W/m
2
K 5.140
Thermal loss coefficient
-
к
2
W/m
2
K
2
0.017
Efficiency factor -η
0
η
0
0.788
Insulation
Black mineral wool
g
=50
kg
/
m
3
δ
=30
mm
Heat carrier fluid
Propylene Glycol PG 50% (freezing point
-
34 ° C)
Stag
nation temperature
°C
152
Resistance to
hail
snow mass
wind
Size up to
25 mm
Load up to 1,25 kN/m2
Speed up to 150 km/h
Certificates
EN 12975:2006; OEM 9949/2/2

TECHNICAL PASSPORT INSTALLATION and OPERATION MANUAL
14 - EN
16. RECYCLING AND WASTE DISPOSAL
16.1. Recycling of collector packaging
Parts of the packaging made of wood or paper can be used as combustible for the boiler. Submit the
rest of the packaging material for recycling according to the local regulations and requirements.
Replaced heating installation components must be submitted for processing to an authorized factory
which complies with the environmental protection regulation.
16.2. RECYCLING AND WASTE DISPOSAL
At the end of life cycle of each product its components are due to be disposed of in conformity with
regulatory prescriptions.
According to Directive 2002/96/EC on waste electrical and electronic equipment (WEEE) they are to
be disposed of outside the normal flow of solid domestic waste.
Obsolete equipment shall be collected separately from other recyclable waste containing materials
with adverse effect on health and environment.
Metal details, as well as non-metal ones shall be sold to licensed recyclable metal or non-metal waste
collection organizations. Those should not be treated as domestic waste.

TECHNICAL PASSPORT INSTALLATION and OPERATION MANUAL
15 - EN
Notes

TECHNICAL PASSPORT INSTALLATION and OPERATION MANUAL
16 - EN