thermital TSOL 20 N BLU User manual

TSOL 20 N BLU
INSTALLATION INSTRUCTIONS

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CONFORMITY
RANGE
MODEL CODE
TSOL 20 N BLU 20005823
Kit of 7 collectors TSOL 20 N BLU 20005825
Solar collectors conform to EN 12975 standard
and to Solar Keymark certification standard.

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Dear Customer,
We thank you for playing your part in saving the environment and for choosing a top quality solar
collector. You have purchased a modern product that is easy to install and use, and is designed to
give you dependable and safe energy savings for many years to come. You can keep your new solar
collector in peak condition by having it serviced regularly by an authorised THERMITAL Technical
Assistance Centre.
This instruction manual contains important instructions and precautions that must be observed to
ensure the trouble-free installation and efficient functioning of your solar collector.
Please accept our thanks and our congratulations on your choice of product.
Riello S.p.A.

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INDEX
CONTENTS
GENERAL
General safety information and precautions page 5
Description of the solar collector “ 6
Identification “ 6
Design “ 7
Technical specifications “ 8
Accessories “ 8
Water circuit “ 9
Location of probes “ 10
FOR THE INSTALLER
Unpacking the collector page11
Dimensions and weight “ 12
Handling the collector “ 12
Installation “ 13
Filling the circuit “ 14
Checks “ 15
The following symbols are used in this manual:
b CAUTION! = Indicates actions that require cau-
tion and adequate preparation.
a STOP! = Identifies actions that your MUST NOT do.
This manual, Code 20007790 - Rev. 0 (10/08) is made
up of 16 pages.

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GENERAL
GENERAL SAFETY INFORMATION AND PRECAUTIONS
b As soon as you open the packaging, check imme-
diately that the contents are all present and undam-
aged. Contact the reseller from whom you pur-
chased the solar collector if you notice any prob-
lems.
b This solar collector must be used only for the proper
purpose for which it is designed and made. The
manufacturer declines all responsibility, contractual
or other, for damage to property or injury to persons
or animals caused by improper installation, adjust-
ment, maintenance or use.
b The solar collector must be serviced every two
years.
b Work near uncovered and live electrical wires, with
which it is possible to come into contact, is only
permitted under the following conditions:
- Wires must be free from voltage for the entire dura-
tion of the work.
- Parts remaining live must be covered or accidental
contact prevented.
- The following minimum safety distances must be
respected:
1 m for voltages of up to 1000 Volts
3 m for voltages from 1000 to 11000 Volts
4 m for voltages from 11000 to 22000 Volts
5 m for voltages from 22000 to 38000 Volts
over 5 m if the voltage is not known.
Contact with open, live electrical wires may lead to
electrocution and may even be fatal.
b Always wear safety goggles when drilling. Always
wear safety shoes, cut-proof protective gloves and
a safety helmet when performing installation work.
b Before beginning installation work on roofs, install
the necessary fall prevention and fall arrest devices
and ensure that all applicable safety standards are
applied.
Use only tools and materials that conform to the
safety standards that are applicable in the place of
work.
b Only wear overalls that have a safety harness (with a
suitable safety or fall-arrest belt, ropes or slings, fall
dampers or dissipaters). In the absence of adequate
fall prevention and security devices, failure to use a
proper safety harness may lead to falls from great
heights with serious or even fatal consequences.
b The use of ladders leaned against walls can lead to
serious falls if the ladder slips, slides of falls. When
using ladders, always ensure that they are stable,
and that suitable ladder stops are present. If pos-
sible secure the ladder with hooks. Make sure that
there are no live electrical wires near the ladder.
b Especially when installing the solar collector as part
of a domestic hot water system, follow the orienta-
tion and angle of the roof to ensure that the collector
blends in with the architecture of the building.
b This instruction manual is an integral part of the solar
collector. It must be kept safe and must ALWAYS
accompany the solar collector, even if it is sold
to another owner or transferred to another user or
to another installation. If you damage or lose this
manual, order a replacement immediately from your
local Technical Assistance Centre.

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GENERAL
These panel type solar collectors have four water fittings
and consist of an aluminium frame to which a single-pie-
ce copper absorber plate is secured. This has a highly
selective finish obtained by a special vacuum treatment
called “TiNOX” that guarantees excellent collector per-
formance. The absorber plate is ultrasonically welded
to 10 copper pipes through which the heat transfer fluid
flows. The two main pipe connection manifolds are also
in copper. The heat transfer fluid runs through the 10
parallel pipes of the absorber plate.
Each panel is protected by solar, hail-proof, tempered
glass with low iron oxide content and a high energy
transmission factor. The bottom of the tray is lined with
3 cm of rock wool insulation. The temperature probe is
installed in a special copper socket.
These solar collectors are easy to install. Provided they
are properly installed, they provide reliable, long lasting
and extremely efficient service.
DESCRIPTION OF THE SOLAR COLLECTOR
IDENTIFICATION
The solar collectors are identified by two plates:
b If these plates or any other means of clearly identifying the product are defaced, removed or lost, proper installa-
tion and servicing may be rendered difficult.
- Data plate
This lists the technical specifications and performance of the product.
- Serial number plate
This bears the collector’s code number, model and serial number.
Serial Number
Model
Code
Via Mussa, 20 Z.I. 35017 Piombino Dese (PD) - Italia
CODE : 0500201
MADE IN ITALY by Riello S.p.A.
DESCRIPTION : CP20TS
S/N :
PLATE SOLAR COLLECTOR
DIMENSIONS : 1856X1086X90 mm
GROSS AREA : 2,02m2MAXIMUM TEMPERATURE : 210 °C
EXPOSED AREA : 1,81 m2LIQUID CONTENT : 1,35 l
ABSORBER AREA : 1,77 m2MAX GLYCOL CONTECENTRATION : 50 %
EMPTY WEIGHT : 32 kg HEAT TRANSFER FLUID : WATER +
PROPYLENE GLYCOL
UP TO MAX 6 COLLECTORS CAN BE CONNECTED
MAXIMUM OPERATING PRESSURE : 10 bars

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GENERAL
DESIGN
(*)
(**)
(*) Alternative collector return
(**) Alternative collector outlet
bThe outlet and the return must be connected to opposite sides.
Collector
probe
socket
Collector
outlet
Collector
return
Direction of flow of
heat transfer liquid
Collector Ø 22 mm.
3,2 mm anti-reflection glass

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GENERAL
TECHNICAL SPECIFICATIONS
ACCESSORIES
The following accessories are available, to be ordered separately.
DESCRIPTION
Total area 2,02 m2
Exposed area 1,81 m2
Effective absorption area 1,77 m2
Connections (copper tube) 4 x Ø22 mm
Empty weight 32 kg
Liquid content 1,35 l
Recommended flow rate per m2of panel 30 l/h
Glass type - thickness safety glass with anti-reflective surface - 3,2 mm
Absorption (α) 95 %
Emissions (ε)5%
Maximum permitted pressure 10 bar
Maximum temperature 210 °C
Maximum number of collectors connectable in series 6 n°
WIND AND SNOW LOADS ON COLLECTORS
Installation height
above ground
Mass in kg to secure collector against
lifting by wind
Load on roof from wind, snow, and
collector weight
Wind speed
0 - 8 m
8 - 20 m
20 - 100 m
100 km/h
130 km/h
150 km/h
80 kg
180 kg
280 kg
At angle of 45° At angle of 20° At angle of 45° At angle of 20°
40 kg
90 kg
150 kg
320 kg
470 kg
624 kg
345 kg
430 kg
525 kg
Diameter of connection pipes for a specific flow rate of 30 lt/m2h
Total surface area (m2) ca 5 ca 7,5 ca 12,5
Diameter of copper pipe (mm) 10-12 15 18
Diameter of steel pipe DN16 DN20
1
0,8
0,6
0,4
0,2
00 0,02 0,04 0,06 0,08 0,1 0,12
Tm[m2K/W]
*
Efficiency curve
Tested according to EN 12975, referred to
a 33.3% water-glycol mix, flow rate of 75 l/h
and irradiation G = 800W/m2.
Tm = (Coll._inlet _temp.+Coll._outlet_temp.)/2
T*m = (Tm - ambient_temp)/G
Optical effi-
ciency of
absorber
(ηο)
0,77 3,93 0,0104
Thermal dispersion factor
of absorber
a1
W/(m2K)
a2
W/(m2K2)
ACCESSORY CODE
Threaded straight union kit for Ø 22 mm pipes 20007285
Threaded end union kit for Ø 22 mm pipes 20007286
Threaded curve union kit for Ø 22 mm pipes 20007278
Manual bleed valve 4383056
Thermostatic mixer valve 4383076
Glycol anti-freeze (5 kg) 4383085
Glycol anti-freeze (10 kg) 4383059

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GENERAL
WATER CIRCUIT
The diagram below illustrates the water connections between solar collectors and a storage heater.
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R
M
°C
M
4
4
4
9
8
11
10
13
14
2
6
12
Water control system
5
7
15
16
17
17
18
1 - Solar collector
2 - Storage heater
3 - Collector probe
4 - Disconnect valves
5 - Non-return valve
6 - Temperature gauge
7 - Vent valve
8 - Safety valve
9 - Pressure gauge
10 - Drain
11 - Expansion vessel
12 - Pump
13 - Flow regulator
14 - Flow meter
15 - Vent cock
16 - Manual bleed valve (accessory)
17 - Plugs
18 - Heat transfer fluid recovery
M - Collector outlet
R - Collector return
b Connect no more than 6 collectors in series.
b If copper pipes are used, joints must be hot brazed.
b We recommend the use of stainless steel pipes
specially made for solar collectors for the outlet,
return and probe pipes. The probe cable should be
of the shielded type.
b Do not use plastic or multistrate pipes. Operating
temperature can exceed 180°C.
b Pipe lagging must be able to resist high tempera-
tures (180°C).
60
50
30
10
40
20
0
0 100 200 300 400 500 600 700 800 900 1000
Pressure drop (mbar)
Flow rate (kg/h)
Pressure drop in solar collectors (*)
(*) With antifreeze-water mix of 33,3% / 67,7% and heat transfer medium temperature = 20°C.

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GENERAL
LOCATION OF PROBES
M
°C
M
4
4
4
9
8
11
10
13
14
2
6
12
Water control system
SOLAR
REGULATOR
17
7
5
15
16
18
3
R
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19
19
20
1 - Solar collector
2 - Storage heater
3 - Collector probe
4 - Disconnect valves
5 - Non-return valve
6 - Temperature gauge
7 - Vent valve
8 - Safety valve
9 - Pressure gauge
10 - Drain
11 - Expansion vessel
12 - Pump
13 - Flow regulator
14 - Flow meter
15 - Vent cock
16 - Manual bleed valve (accessory)
17 - Storage heater bottom probe
18 - Storage heater top probe
19 - Plugs
20 - Heat transfer fluid recovery
M - Collector outlet
R - Collector return
The temperature sensor must be installed in the nearest socket to the collector outlet. Make sure that the sensor makes
good contact with the socket. Materials (sensor, cables, seals and insulation) used to install the temperature sensor
must be able to withstand high temperatures (up to 250°C).

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INSTALLER
UNPACKING THE COLLECTOR
The solar collectors are packed in various ways depend-
ing on the number of units supplied.
A - Individually packaged collectors
Pallet contents:
- collector
- Documentation envelope containing:
- certificate of warranty and label with bar code.
B - Packages of 7 collectors
Pallet contents:
- 7 collectors
- Documentation envelope containing:
- certificate of warranty and label with bar code.
b Take care not to lose the flat seal strapped to the
fittings of the solar collector.
b The instruction manual is an integral part of the solar
collector. Once located, read it thoroughly and keep
it safe.
Case A
Case B

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INSTALLER
DIMENSIONS AND WEIGHT
HANDLING THE COLLECTOR
1120
1086
1856
68
90
Net weight 32 kg
A
A
A
A
Once you have removed the outer packaging, proceed
as follows to unpack and handle the solar collector:
- Remove the PVC wrapping to free the solar collector
from the pallet.
- Tilt the solar collector slightly and grip it at the four
points shown (A) to lift it.
- Use a hoist or other suitable lifting equipment to hoist
the solar collector on to the roof.
b Wear suitable personal protective equipment and
use suitable safety devices.
aDo not dispose of the packaging material into the
environment where it can become a potential haz-
ard. Dispose of the packaging material in compli-
ance with applicable legislation.
aDo not lift the collector by means of its outlet or
return pipes.

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INSTALLER
INSTALLATION
Assembly
The solar collector must be fitted by specialist personnel. Use
only the assembly material supplied with the solar collector.
The supporting framework and all masonry or brickwork fixing
points must be checked by a person expert in static loading,
and must be suitable for the nature of the installation site.
Static load
The solar collector must only be installed on roofs or frames
that are strong enough to support its weight. The strength
of the roof or frame must be verified on site by a person
expert in static loading before the solar collector is installed.
During this process, it is important to verify the suitability of
the supporting frame to hold the screw fasteners that fix
the solar collector in place. An expert in static loading must
verify that the entire frame complies with relevant stand-
ards, especially in areas liable to snow and areas exposed
to high winds. Conditions (gusts of wind, formation of wind
vortices, etc.) at the point where the solar collector is to
be installed must be carefully considered since these can
increase the loads on the supporting structure.
Lightning protection
The metal piping of the solar heating circuit must be connect-
ed to the main potential compensation bar by a (yellow-green)
copper wire (H07 V-U or R) of at least 16 mm2. If a lightning
conductor system is already installed, the solar collectors may
be connected to the existing system. Alternatively, the solar
collector piping may be connected to ground via a ground
wire sunk into the earth. Ground wires must be sunk outside
the house. The ground wire must be connected to the potential
compensation bar through a wire of the same diameter.
Water connections
If flexible pipes are not used to connect the solar col-
lectors, the piping must be fitted with expansion joints
(U-type expansion joints, flexible hoses) to absorb ther-
mal expansion. Provided adequate expansion joints are
used, up to 6 solar collectors may be connected in series.
Make sure that the seal rings are correctly positioned in
their seats. When tightening a fitting with a pipe wrench
or spanner, always hold the opposite fitting steady with a
second tool to avoid damaging the absorber.
b All pipes in the water circuit must be insulated in
conformity to relevant standards.
Lagging and insulation must be protected against
damage by the weather and birds and animals.
Angle of collectors / General
Solar collectors are designed to be installed at angles of
between 15° (minimum) and 75° (maximum).
Make sure that the bleed and vent valves of the collec-
GENERAL INSTRUCTIONS
tors remain open while the collectors are being installed.
Take care to protect all fittings, connections, bleed and
vent valves against dirt and dust etc.
In installations which serve primarily to produce domestic hot water
in the summer, install the collectors facing from east to west at an
angle of between 20 and 60°. The ideal orientation is southwards,
at an angle equal to the latitude of the location minus 10°.
If the system sustains the greatest thermal load in the
winter (as in systems that combine domestic hot water
production with central heating), install the collectors
facing south (or south-east or south-west) at an angle
greater than 35°. The ideal orientation is southwards, at
an angle equal to the latitude of the location plus 10°.
Flushing and filling
For safety reasons, only fill the system when the sun is not
shining. In areas liable to frost, fill the circuit with a 40%
glycol solution for solar panels.
b The anti-freeze solution must be mixed with water
prior to filling the system.
b Take care if you flush the system out, because any
trapped water may freeze if the circuit is not filled
immediately with anti-freeze.
Bleeding
Bleed the circuit:
- On start-up (after initial filling) (see the figure on page 10).
- Whenever necessary, as in the event of system mal-
functioning.
Make quite sure that all air has been bled out of the sys-
tem.
b Risk of burns from hot fluid inside the collectors!
b Only open the vent valve if the temperature of the
fluid in the circuit is below 60°C.
Make sure that the collectors are not hot before you
start bleeding the circuit. Always cover the solar col-
lectors before bleeding the circuit. Always perform
bleeding in the morning.
Checking the heat transfer liquid
Check the anti-freeze effect and the pH level of the heat
transfer liquid every 2 years.
-
Use an instrument like a refractometer or densimeter to check
the anti-freeze effect (which must have a nominal protection
value of approx. -30°C). If the protection threshold is higher
than -26°C, replace the mix, or add anti-freeze as required.
- Use litmus paper to check the pH (nominal value approx.
7.5). If the measured value is below 7, change the mix.

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INSTALLER
FILLING THE CIRCUIT
b Do not fill the system in bright, sunny conditions or if
the collectors are hot.
b Make sure that you have bled all the air out of the
system, using the water control system vent too.
Perform the following steps before starting up the sys-
tem.
1 - FLUSHING AND SEAL TESTING THE SYSTEM
If copper piping has been used and joints have been hot
brazed, flush out the system to remove any brazing resi-
dues. Seal test the system after you have flushed it out.
b Fill the solar collector with glycol/water mix imme-
diately after flushing it out, because flushing water
may remain trapped in the circuit (with a conse-
quent risk of freezing).
2 - PREMIXING WATER + GLYCOL
Glycol anti-freeze is supplied separately in standard vol-
umes and must be premixed with water in a suitable con-
tainer before being used to fill the system. For example,
a mix of 40% glycol and 60% water provides anti-freeze
protection down to a temperature of -21°C.
b The propylene glycol supplied is specially formulat-
ed for solar collector applications and remains fully
efficient throughout the -32 to +180°C temperature
range.
It is also non-toxic, biodegradable and biocompat-
ible.
b Do NOT part fill the circuit with pure glycol then
add water later.
b Do not use automatic or manual filling systems.
b If the water supply is highly chlorinated, use dis-
tilled water to prepare the glycol/water mix.
3 - FILLING
1 - Open the non-return valve (A).
2 - Open the air vent at the highest point in the system
(see figure alongside) and keep it open throughout
the filling operation.
3 - Open the vent valve (7).
4 - Pump the heat transfer fluid around the circuit with an
external filling pump until all air bubbles have been
eliminated. Close the manual bleed valve.
5 - Temporarily raise the pressure in the system to 4
bar.
6 - Start up the system for about 20 minutes.
7 - Bleed the system again from step 2 until all the air has
been removed.
8 - Set the pressure in the system to 3 bar.
9 - Close the non-return valve (A) and any open vent
valves to prevent the heat transfer fluid from evapo-
rating.
Anti-freeze Temperature Density
50% -32°C 1,045 kg/dm3
40% -21°C 1,037 kg/dm3
30% -13°C 1,029 kg/dm3
°C
M
A
R
M
7
Anti-freeze mix
Water control system
Heat
transfer fluid
filling pump
Solar collector
Manual
bleed valve
(accessory)
Heat exchanger
of solar
Heat transfer fluid filling pump (accessory). A manual
bleed valve is not required if this pump is used.

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INSTALLER
CHECKS
On completion of the installation, perform the checks listed in the table below.
DESCRIPTION OK
Collector circuit
Cold pressure 3 bar
Collector circuit seal test
Safety valve check
Anti-freeze checked to - ___ °C
pH of heat transfer fluid = ____
Collector circuit bled
Flow rate of 30l/h per m2checked
Non-return valve functioning
DESCRIPTION OK
Solar collectors
Visual check of collectors
Collectors cleaned if necessary
Visual check of collector fixing points
Visual check of roof impermeability
Visual check of insulation/lagging

Via Mussa, 20 Z.I. - 35017 Piombino Dese (PD) - Italia
Tel. [phone] - Fax [phone] - www.thermital.com - email: [email protected]
The manufacturer strives to continuously improve all products.
Appearance, dimensions, technical specifications, standard equipment
and accessories are therefore liable to modification without notice.
Cod. 20007790