Thermo Solar ECO2 160 Technical document

TABLE OF CONTENTS
INSTRUCTIONS FOR THE MOUNTING
OF THE SUPPORT BASE ON TILT ROOF Page 4-5
DESCRIPTION OF THE PLUMBING ASSEMBLY BETWEEN THE WATER TANK
AND COLLECTOR ON TILT ROOF Page 6-7
INSTRUCTIONS FOR THE MOUNTING
OF THE SUPPORT BASE ON FLAT ROOF Page 8-9
DESCRIPTION OF THE PLUMBING ASSEMBLY BETWEEN THE WATER TANK
AND COLLECTOR ON FLAT ROOF Page 10-11
INSTRUCTIONS FOR THE MOUNTING
OF THE SOLAR SYSTEM ON FLAT ROOF Page 12-13
TECHNICAL CHARACTERISTICS – DIMENSIONS –
WEIGHTS OF SOLAR SYSTEMS Page 14
TYPES OF SOLAR SYSTEMS / PROPORTION OF ANTIFREEZE LIQUID – WATER Page 14
TECHNICAL CHARACTERISTICS OF THE WATER TANK Page 15
TECHNICAL CHARACTERISTICS OF THE COLLECTOR Page 15
ELECTRICAL CONNECTION DIAGRAM
OF AUXILIARY HEATING RESISTANCE (DOUBLE ENERGY) Page 16
ELECTRICAL CONNECTION DIAGRAM OF AUXILIARY HEATING RESISTANCE
AND COPPER TUBE COIL FOR EXTERNAL THERMAL SOURCE (TRIPLE ENERGY)
ORIENTATION OF SOLAR SYSTEM Page 17
INSTALLATION OF 6 SOLAR SYSTEMS ON LINE
DIMENSIONS OF SOLAR SYSTEMS Page 18
INSTALLATION OF SOLAR COLLECTORS ON LINE (20sq.m.) Page 19
TECHNICAL INSTALLATION
MANUAL FOR THE
SOLAR SYSTEM
TABLE OF CONTENTS
INSTRUCTIONS FOR THE MOUNTING
OF THE SUPPORT BASE ON TILT ROOF Page 4-5
DESCRIPTION OF THE PLUMBING ASSEMBLY BETWEEN THE WATER TANK
AND COLLECTOR ON TILT ROOF Page 6-7
INSTRUCTIONS FOR THE MOUNTING
OF THE SUPPORT BASE ON FLAT ROOF Page 8-9
DESCRIPTION OF THE PLUMBING ASSEMBLY BETWEEN THE WATER TANK
AND COLLECTOR ON FLAT ROOF Page 10-11
INSTRUCTIONS FOR THE MOUNTING
OF THE SOLAR SYSTEM ON FLAT ROOF Page 12-13
TECHNICAL CHARACTERISTICS – DIMENSIONS –
WEIGHTS OF SOLAR SYSTEMS Page 14
TYPES OF SOLAR SYSTEMS / PROPORTION OF ANTIFREEZE LIQUID – WATER Page 14
TECHNICAL CHARACTERISTICS OF THE WATER TANK Page 15
TECHNICAL CHARACTERISTICS OF THE COLLECTOR Page 15
ELECTRICAL CONNECTION DIAGRAM
OF AUXILIARY HEATING RESISTANCE (DOUBLE ENERGY) Page 16
ELECTRICAL CONNECTION DIAGRAM OF AUXILIARY HEATING RESISTANCE
AND COPPER TUBE COIL FOR EXTERNAL THERMAL SOURCE (TRIPLE ENERGY)
ORIENTATION OF SOLAR SYSTEM Page 17
INSTALLATION OF 6 SOLAR SYSTEMS ON LINE
DIMENSIONS OF SOLAR SYSTEMS Page 18
INSTALLATION OF SOLAR COLLECTORS ON LINE (20sq.m.) Page 19
TECHNICAL INSTALLATION
MANUAL FOR THE
SOLAR SYSTEM
18
19
20
21
22-23
16-17
Page
PageCOLLECTOR’S DATA SHEET
TRANSPORTATION AND HANDLING

04
We first check that the height of the pitch roof from the
highest top until the lower part of the solar system is at
least 3800mm-minimum.
We begin from the lower part of the support base by
raising the tiles and positioning the stainless steel
straps (F) between and under the convex of tiles with a
distance between them of a min. 900mm and max.
1080mm (D1-D2).
We screw the stainless steel straps to the oblong wood
or flooring as at (photo 1) and we leave the one side
out of the tiles, at least 200mm in the same distance
and length between them.
We reposition again the tiles as they were and we
screw the external side of the stainless steel straps (F)
on the vertical long bracket supports (A-A) of the
support base (photo 2) with the plastic hatch on the
min 900mm -
3.800 mm minimum
A
F
A
A
B
DÅ
photo 1
photo 2
photo 3
INSTRUCTIONS FOR THE MOUNTING OF THE

05
top side (photo 3)
We repeat the same process on the upper side of the
support base with the difference that:
ATTENTION: We first screw the stainless steel
straps (F) on the top of the vertical long bracket
supports (A-A) as at (photo 6) after we have raised
the tiles, then we screw the stainless steel straps (F) to
the oblong wood or flooring as at (photo 1) and we
reposition again the tiles as they were before.
When we have finished with the vertical long bracket
supports (A-A) we position and screw at their lower
part the horizontal support angle (C) of collector as at
(photo 4) and at their upper part the horizontal
support angle (B) of water tank-collector (photo 5 ).
SUPPORT BASE ON TILT ROOF
max 1080mm
C
B
A
A
C
DÇ
photo 4
photo 5
photo 6

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02
03
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05
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09
10
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24
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13 18 13 15
16 13 15
02
06
DESCRIPTION OF THE PLUMBING ASSEMBLY BETWEEN THE

08
19
22 23
12
13
20
13 13
18
16 13
04
16
07
01 Solar water tank
02 Water tank’s support angle
03Solar Collector(s)
04 Collector’s support angle
05 Hot water supply (outlet)
06 Brass Tee ó"
07 Pressure relief valve of hot water supply ó"
08 Pressure relief valve female ó" (closed circuit)
09 Cold water supply (inlet)
10 Cold water expansion control valve with non-return and
pressure relief valve (7 bars)
11 Cold water outlet from water tank to collector
(closed circuit)
12 Brass angle " Male-Female
13 Permanite washer (fibre)
14 Long stainless steel tube with brass raccor (closed circuit)
15 Brass nut male "
16 Brass nut female "
17 Brass screw plug Male "
18 Brass angle " Male-Female
19 Inlet of hot water from collector to water tank
(closed circuit)
20 Short stainless steel tube with brass raccor (closed circuit)
21 Brass interconnector "(only for the connection
between 2 or 3 collectors)
22 Brass reducing hexagon bush "- ó"
23 Spherical switch with special nozzle for plastic pipe,
for the filling of the closed circuit with thermal fluid.
24 Protection side cover of aluminium for the flow tube
WATER TANK AND COLLECTOR ON TILT ROOF
34
/
34
/
34
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34
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34
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34
/

08
We place the metallic small plate (F) at the
backside of the long bracket support (A) at the
lower part as at (photo 3) and screw it tight. We
screw well the metallic corners (G) at the side parts
of the vertical shorter bracket support (D) as at
(photo 2) using the (oval) longer hole.
We insert the cutting bevel part of the vertical
shorter bracket support (D) in the slot of the back
side of the long bracket support (A) as at ( photo 1 ).
We assemble the "X" diagonal braces (E) with
screw and back nut at the middle hole and then we
adjust them at the back side of the vertical shorter
bracket support (D) with screw and back nut as at
(photo 5).
INSTRUCTIONS FOR THE MOUNTING OF
photo 1
photo 2
photo 3
A
D
D
GG
B
E
D
A
A
F

09
We place the horizontal support angle (B) of the
water tank-collector as at (photo 4), and screw it
on the long bracket supports (A) being careful that
the notch and the screw are the middle ones as at
(photo 4). We apply the same procedure for the
lower horizontal support angle (C) of collector as at
(photo 6).
We have to take care that the solar support base
has the correct orientation (see page 17) and when
we have installed the collector/s and the water tank
on it, we drill the holes at the flooring with twist drill
of 10mm and we insert the plastic sockets and
long screws with washers as at (photo 2) and
(photo 3)
THE SUPPORT BASE ON FLAT ROOF
photo 4
photo 5
photo 6
D
A
C
A
B
E
F
C

10
DESCRIPTION OF THE PLUMBING ASSEMBLY BETWEEN
01
02
03
04
05
06
07
09
10
12 13 14
15
13
17
24
18
14
13
13 15
25
13
16 15
11

11
01 Solar water tank
02 Water tank’s support angle
03 Solar Collector(s)
04 Collector’s support angle
05 Hot water supply (outlet)
06 Brass Tee ó"
07 Pressure relief valve of hot water supply ó"
08 Pressure relief valve female ó" (closed circuit)
09 Cold water supply (inlet)
10 Cold water expansion control valve with non-return
and pressure relief valve (7 bars)
11 Cold water outlet from water tank
to collector (closed circuit)
12 Brass angle " Male-Female
13 Permanite washer (fibre)
14 Long stainless steel tube with brass raccor “
(closed circuit)
15 Brass nut male "
16 Brass nut female "
17 Brass screw plug Male "
18 Brass angle " Male-Female
19 Inlet of hot water from collector to water tank
(closed circuit)
20 Short stainless steel tube with brass raccor “
(closed circuit)
21 Brass interconnector "(only for the connection
between 2 or 3 collectors)
22 Brass reducing hexagon bush "- ó"
23 Spherical switch with special nozzle for plastic
pipe, for the refilling of the closed circuit
with thermal fluid.
24 Protection side cover of aluminium for the flow tube
25 Protection middle cover of aluminium
between the collectors
THE WATER TANK AND COLLECTOR ON FLAT ROOF
34
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34
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34
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13
16 22 23
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13
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/

12
We first position the water tank
on the top of the support base
of the solar system and then we
install the collector(s) being
careful that the index arrow of
the sticker on the side of each
collector points downwards,
and when we finish we use
properly the plump level in
order to check that our
collector(s) is/are aligned.
Afterwards we position the
metallic corner supports of
collector(s) (H) as at (photo 1)
that we have to insert them first
in the aluminium frame of the
collector and then screw them
in the jam nut M8 that is placed
to the horizontal support angle.
We place one edge of the
transparent special plastic tube
(L) at the refilling valve that is
photo 1
H
N
J
K
photo 2
photo 3
INSTRUCTIONS FOR THE MOUNTING OF THE
μ
∞
08

13
installed at the lower side of the collector(s) and the
other edge at the filler neck of the bottle, as long as we
have already lifted the bottle and the plastic tube (L) at
the same height with the water tank (photo 4). Then
we start filling up the closed circuit (loop) with the
thermal fluid of the bottle and when it will be finished
we continue filling it up with water until the water tank
will run over from the tube at the side (N-08), which
means that all of the air has come out, the closed
circuit is filled up and we can screw the security valve
finally. At the end, as long as we have checked very
carefully all of the connections for any possible
leakages, we position the protection side cover of
aluminium (J) as at (photo 2) and the protection
middle cover of aluminium (K) in case of 2-3 collectors
as at (photo 3), and finally we place the boiler
security straps (M) (photo 5) that we have to screw
in the jam nut M8 at the front side of the horizontal B
support angle and the back side of the long bracket
support A-A.
THE SOLAR SYSTEM ON FLAT ROOF
ML
photo 5
photo 4

300
14
SOLAR
TYPE
WATER TANK
((DIMENSION S)
ECO2
160
1320x530
mm
48 kgr 48 kgr 56 kgr 56 kgr 68 kgr 76 kgr 76 kgr
4.6 (lt) 4.6 (lt) 4.9 (lt) 4.9 (lt) 5.4 (lt) 6.2 (lt) 6.2 (lt)
57 kgr 57 kgr 65 kgr 65 kgr 76 kgr 83 kgr 83 kgr
4.6 (lt) 4.6 (lt) 4.9 (lt) 4.9 (lt) 5.8 (lt) 6.2 (lt) 6.2 (lt)
2 mÇ 2.90 mÇ 2.90 mÇ 4 mÇ 4 mÇ 4 mÇ 6 mÇ
S+2000 S+2900 S+2900 S+2000 S+2000 S+2000 S+2000
111222 3
34 kgr 35 kgr 38 kgr 38 kgr 40 kgr 40 kgr 44 kgr
121 kgr 137 kgr 148 kgr 172 kgr 186 kgr 194 kgr 237 kgr
1320x530
mm
1320x580
mm
1320x580
mm
2050x530
mm
2050x580
mm
2050x580
mm
ECO2
160
ECO2
200
ECO2
200
ECO2
250
ECO2
300
ECO2
300
WATER TANK
(EMPTY WEIGHT) π¡√Ã
CLOSED
CIRCUIT - WEIGHT
π¡√Ã
WATER TANK (EMPTY
WEIGHT) GLASS
CLOSED
CIRCUIT -
WEIGHT
GLASS
TOTAL
SURFACE
AREA (m2)
COLLECTOR
TYPE
No. OF
COLLECTORS
SOLAR
SUPPORT BASE
WEIGHT
SOLAR SYSTEM
TOTAL WEIGHT
EMPTY
TYPES OF SOLAR SYSTEMS / PROPORTION OF ANTIFREEZE LIQUID – WATER
ECO2 160
2mÇ
ECO2 160
2.90mÇ
ECO2 200
2mÇ
ECO2 200
4mÇ
ECO2 250
4mÇ
ECO2 300
4mÇ
ECO2 300
6mÇ
MINIMUM
TEMPERATURE
ÆC
THERMAL
FLUID Kg
WATER
Kg
THERMAL
FLUID Kg
WATER
Kg
THERMAL
FLUID Kg
WATER
Kg
THERMAL
FLUID Kg
WATER
Kg
THERMAL
FLUID Kg
WATER
Kg
THERMAL
FLUID Kg
WATER
Kg
THERMAL
FLUID Kg
WATER
Kg
1.00 5.00 1.00 5.70 1.50 5.50 1.50 6.20 2.00 8.20 2.00 8.20 2.00 9.00
-5
1.50 4.50 1.50 5.20 2.00 5.00 2.00 5.70 2.50 7.70 2.50 7.70 2.50 8.50
-10
2.00 4.00 2.00 4.70 2.50 4.50 2.50 5.20 3.00 7.20 3.00 7.20 3.00 8.00
-15
2.50 3.50 2.50 4.20 3.00 4.00 3.00 4.70 3.50 6.70 3.50 6.70 3.50 7.50
-20
2.75 3.25 2.75 3.95 3.50 3.50 3.50 4.20 3.75 6.45 3.75 6.45 3.75 7.25
-25
NOTES: 1. ONE BOTTLE OF THERMAL FLUID CONTAINS 1 kg (0.965LIT).
2. DON’T USE MORE THERMAL FLUID THAN THE QUANTITY THAT IS REQUIRED
TECHNICAL CHARACTERISTICS – DIMENSIONS – WEIGHTS OF SOLAR SYSTEMS
1450 cm
1000 cm
2mÇ
250
160
2mÇ 2 mÇ 2 mÇ 2 mÇ 2 mÇ
300
200
2.90mÇ
2.90mÇ
160
2mÇ 2 mÇ
200
2mÇ 2 mÇ
1450 cm 2150 cm 2150 cm 2150 cm 3300 cm
The closed loop solar systems with a few modifications can be used as open loop solar systems.
The table above shows the ECO2 solar systems .

15
1.EXTERNAL CASING: Stainless Steel cover AISI 304BA thickness 0.5mm or Anodized aluminium
2.INSULATION: Polyourethane thickness 60mm, density 40kg/m3
3.INNER TANK: Stainless Steel AISI 316L HiMo thickness 2mm or Steel UST 37.2
thickness 3mm enameled according to DIN 4753 Teil3.
4.HEAT EXCHANGER: Stainless Steel AISI 316L HiMo thickness 1mm
or Steel UST 37.2 thickness 1.5mm enameled according to DIN 4753 Teil3.
5.HEATING ELEMENT: Electric resistance 4000W – 230V
6.CORROSION PROTECTION: Magnesium anode bar
TECHNICAL CHARACTERISTICS OF THE WATER TANK
1.COLLECTOR FRAME: Anodized aluminium profile
2.BACK PLATE: Aluminium 0.50mm thickness
3.BACK INSULATION: Rockwool with aluminium foil 40mm thickness, density 50kg/sq.m
4.SIDE INSULATION: Rockwool 20mm thickness, density 50kg/sq.m.
5.ABSORBER PLATE: Copper strips 0.20mm (Selective or Painted treatment)
6.ABSORBER RISERS: Copper strips 10x0.5mm & Headers 22x0.70mm
7.GLASS COVER: Tempered prismatic glass (Mistlite)
8.WATER PROOFING: Black silicone IG, EPDM rubber & adhesive tape
TECHNICAL CHARACTERISTICS OF THE COLLECTOR
Collector Type S+2000 S+2900
Dimensions (mm)
1000x2000x100
1450x2000x100
Collecting
surface m22,0
39
1.47
52
2.1
2,9
Collector
Weight (kg)
Thermal Fluid
weight (kg)
08
04
08
01
07
08
02
06
03
04
05
01
07
08
06
03
Note: Due to continuous improvement of the products the manufacturer keep all the rights
for any changes of the technical specifications without any prior notice.
01
06
05
04
03
02
S+2500
1250x2000x100
46
1.79
2,5
Rockwool, density 50kg/sq.m
Rockwool or glasswool thickness, density 50kg/sq.m
Aluminium (Selective or Painted treatment)
Copper strips & Headers

16
ELECTRICAL CONNECTION DIAGRAM OF AUXILIARY
HEATING RESISTANCE
28. Thermostat
29. Thermal security switch
30. Temperature regulator
31. Earth terminal
32. Electricity conductors
33. Electric resistance
34. Conductor joint
35. Metallic support for the electric joint
36. Sealing flange of the electric resistance
37. Hatch of the electric resistance
38. Thermostat socket
39. Copper tube coil for external thermal source
40. Magnesium anode bar
41. Electric wire
42. Sealing rubber of the hatch
43. Protection hatch of the electric resistance
44. Sealing rubbers of the inlet-outlet copper tube coil
DOUBLE ENERGY
If we are 100% sure that the supply of
electric power is off we unscrew the
screws on the hatch of the electric
resistance (43). The thermostat (28)
which is connected to the electric resistance
(33) is already adjusted to 60ÆC. If you need
you can change the temperature levels yourself by
using the temperature regulator (30), but we
recommend not setting it more than 75ÆC. The thermal security
switch (29) in order to be activated the red button must be pressed.
As long as we have inserted the electric cable (41) from the slot of the protection hutch for the electric resistance (43), we
connect the cables on the conductor joint (34) and we place them at the correct position as shown at the electrical diagram.
Then we screw the terminals of the electric cables very well in order to avoid any sparking such as L = power – N = Neutral
= earth, and when we are sure that we have made the correct installation we place and screw the hutch (43) back to its
position.
Notes:
ñThe power of the electric resistance is 4000W – 230V
ñThe electric installation must be made only by a licensee electrician
ñThe electric resistance can be delivered with copper tube coil for external thermal source upon request (39)
ñDon’t ever use the electric resistance if the water tank is empty because it will be destroyed.
40
38
33
36
41
42
43
36
37
32
33
35
34
31
32
30
29
28
-
-
―
–
–

17
TRIPLE ENERGY
40
38
33
36
41
42
43
39
44
39
N
EW
S
SE SW
The thermal performance of the
solar system is optimized when
is mounted facing South
(when we are in the
Northern hemisphere). The
actual performance however is
minimal decreased when the
system is oriented less than 45o
degrees South East or South
West.
If we increase the surface of the
solar system, by using larger
collectors or adding one more
collector, the solar system can
be oriented up to 90o South
East or South West, with
minimal or no impact to the
annual thermal performance.
ATTENTION: We will exactly do
the opposite when we are at the
Southern hemisphere.
ORIENTATION OF SOLAR SYSTEM

18
INSTALLATION OF 6 SOLAR SYSTEMS ON LINE
1.All of the tubes that we will use for the installation must have
the same length and geometry.
2.The diameter of tubes must be the same for the cold and hot water
net in order to have the correct pressure drop.
INLET OF
COLD WATER
OUTLET OF HOT
WATER
DIMENSIONS OF SOLAR SYSTEMS
TYPE
ECO2 160 (2mÇ)
ECO2 160 (2.90mÇ)
ECO2 200 (2.90mÇ)
ECO2 200 (4mÇ)
ECO2 250 (4mÇ)
ECO2 300 (4mÇ)
ECO2 300 (6mÇ)
∏ (mm)
2120 2150
2150
2150
2150
2150
2150
2150
2120
2120
2120
2160
2160
2160
L (mm)
H
w
1000
1450
1450
2150
2150
2150
3300
W (mm)
L
DN 32mm (1 1/4”)
DN 20mm (3/4”) DN 20mm (3/4”) DN 20mm (3/4”)
DN 32mm (1 1/4”)
DN 25mm (1”)
DN 25mm (1”)
DN 20mm (3/4”)
DN 20mm (3/4”)
DN 20mm (3/4”)
DN 20mm (3/4”)

19
INSTALLATION OF SOLAR COLLECTORS ON LINE (20sq.m.)
1. OBSTRUCTION GATE VALVE
2. COLLECTOR SENSOR
3. THERMOMETER
4. AUTOMATIC RELIEF VALVE
INLET OF
COLD WATER
OUTLET OF HOT
WATER
4
4
4
4
4
4
1
1
1
2
2
2
3
3
3
DN 32mm (1 1/4”)
DN 20mm (3/4”) DN 25mm (1”)
2mÇ 2mÇ 2mÇ 2mÇ
2mÇ 2mÇ 2mÇ 2mÇ
2mÇ 2mÇ 2mÇ 2mÇ
DN 32mm (1 1/4”)
DN 25mm (1”) DN 25mm (1”)