WarmFlow Solar SHP20 User guide

System Manual
Incorporating: Installation Instructions
Commissioning Instructions
Maintenance Instructions
Guarantee Registration
Solar Thermal Systems
European Solar Keymark Approved
Products covered by this manual:
Solar SHP20 SHP30
Heat pipe vacuum tube collectors and accessories
LEAVE THIS MANUAL WITH THE END USER
Q12
-
027 rev 02 May ‘10

1
CONTENTS
1General Information ..................................................................................................... 2
1.1 Warnings ..................................................................................................................... 2
1.2 Information................................................................................................................... 3
1.3 Product Conformity ...................................................................................................... 3
2Technical Characteristics ............................................................................................ 4
2.1 Technical Data............................................................................................................. 4
2.2 Key Components ......................................................................................................... 5
2.3 Circuit Diagrams .......................................................................................................... 7
2.4 Pipework and Expansion Vessel Sizing ....................................................................... 8
2.5 Collector Pressure Drop............................................................................................... 9
3Installation ...................................................................................................................10
3.1 General Requirements................................................................................................10
3.2 Tiled Roof Installation .................................................................................................10
3.2.1 Assemble pitched roof brackets ........................................................................................... 10
3.2.2 Install pitched roof brackets.................................................................................................. 11
3.2.3 Install support frame and manifold ....................................................................................... 12
3.2.4 Connect manifold pipework .................................................................................................. 13
3.3 Slate Roof Installation .................................................................................................14
3.3.1 Install slate roof brackets...................................................................................................... 14
3.3.2 Install support frame............................................................................................................. 15
3.3.3 Connect manifold pipework .................................................................................................. 15
3.4 Dual-line Pump Station Installation .............................................................................16
3.4.1 Mount pump station .............................................................................................................. 16
3.4.2 Connect pump station pipework ........................................................................................... 16
3.5 Electrical Installation ...................................................................................................17
3.5.1 Mount controller.................................................................................................................... 17
3.5.2 Connect external wiring centre............................................................................................. 17
3.5.3 Connect back-up heat source .............................................................................................. 18
4Commissioning ...........................................................................................................19
4.1 System Filling & Flushing............................................................................................19
4.1.1 Check expansion vessel pre-charge .................................................................................... 19
4.1.2 Calculate system volume ..................................................................................................... 19
4.1.3 Connect filling station ........................................................................................................... 19
4.1.4 Flush system ........................................................................................................................ 20
4.1.5 Fill system............................................................................................................................. 20
4.2 Pressure Testing.........................................................................................................21
4.2.1 Pressurise and inspect system............................................................................................. 21
4.2.2 Set system pressure............................................................................................................. 21
4.3 Sensor Installation ......................................................................................................21
4.4 Heat Pipe Tube Installation .........................................................................................22
4.4.1 Insert tube into manifold ....................................................................................................... 22
4.5 Circuit Flow Commissioning........................................................................................23
4.5.1 Set pump speed ................................................................................................................... 23
4.5.2 Set flow adjuster ................................................................................................................... 23
5Maintenance ................................................................................................................24
5.1 Periodic System Check...............................................................................................24
5.2 Annual Maintenance ...................................................................................................24
5.2.1 Check installation ................................................................................................................. 24
5.2.2 Check fluid health ................................................................................................................. 24
5.2.3 Check performance .............................................................................................................. 24
5.2.4 Annual service checklist ....................................................................................................... 25
6Product Guarantee......................................................................................................26
7Installation Notes ........................................................................................................27
8Guarantee Registration...............................................................................................29

2
1 GENERAL INFORMATION
1.1 Warnings
In order to qualify for the product guarantee the equipment MUST be correctly
commissioned as described herein and the guarantee registration section at the back of
this manual completed and returned.
Failure to commission and register the product may invalidate ALL guarantees.
This equipment must only be installed and commissioned by professionally qualified
personnel in accordance with current laws and standards and in line with the manufacturer’s
instructions. It is recommended that the system is installed by a competent installer such as
those registered under the Microgeneration Certification Scheme (MCS) in the United
Kingdom or with Sustainable Energy Ireland (SEI) in the Republic of Ireland.
The installation must comply with the requirements of:
- the Building Regulations
- current IEE Wiring Regulations or ETCI rules for electrical installations
Where no specific instructions are given, reference should be made to the relevant European
Standards.
This equipment must be used solely for the purpose for which it was designed and
manufactured – indirect heating of stored water (e.g. domestic hot water production).
Any other use is deemed improper and as such dangerous. The manufacturer accepts no
liability for damage or injury to persons or animals caused as a result of errors in the
installation and/or use of the equipment, or through non-compliance with current local and
national standards and/or the manufacturer’s instructions.
This equipment is only suitable for use in a sealed solar thermal system filled with the system
fluid supplied or specifically recommended by the manufacturer. The means of heating
domestic hot water (DHW), a swimming pool or other medium must be via a suitable heat
exchanger, for example the coil of a DHW storage cylinder.
This instruction manual forms an integral and essential part of the equipment and must be
kept in a safe place, available for future reference. This manual, along with the
commissioning and service records and proof of purchase, must be left with the end user.
It is essential that the heat pipe tubes are protected from overheating prior to installation.
NEVER leave uninstalled heat pipe tubes exposed to the sun.
Only unpack and install the heat pipe tubes after the rest of the system had been flushed,
filled and pressure tested and the system is ready to be brought into operation i.e. the DHW
storage cylinder is in use or the swimming pool has been filled.
If for any long periods there will be no heat load on the system (e.g. property unoccupied or
swimming pool emptied) the solar collector must either be covered or the heat pipe tubes
removed. If installing the collector onto a new-build property, DO NOT install the tubes until
the property is, or is about to become, occupied.
Due to the high temperatures that may be generated by a solar installation it is
recommended that a mixing valve be fitted to the hot water outlet from a domestic hot water
storage cylinder in order to limit the domestic hot water temperature. A setting of 60ºC is
recommended.

3
1.2 Information
Suitable personal protective equipment (e.g. hand and eye protection) must be used when
handling glass tubes. Avoid scratching or knocking the tubes and take care to protect the
teat at the base of the tube.
After removing the packaging, check that the equipment has not been damaged. In case of
doubt, do not attempt to install the equipment. Contact the supplier immediately to report the
damage. Packaging materials must not be left within reach of children as these items may
constitute a hazard and should be disposed of responsibly.
In case of a fault and/or malfunction in the equipment, shut the system down and isolate the
electrical supply. Contact your installer for advice.
In order to maintain the efficient and safe operation of this equipment it must be serviced
annually by professionally trained personnel in line with the manufacturer’s instructions.
The equipment can be regarded as electrically safe when connected to an effective earthing
system installed in accordance with the requirements of current regulations. This
fundamental safety requirement must be checked and verified. In case of doubt, have the
electrical installation checked by a qualified electrician. The manufacturer accepts no liability
of damage or injury caused as a result of inadequate or ineffective earthing.
1.3 Product Conformity
The manufacturer declares that this equipment is manufactured to a high specification and in
compliance with the relevant standards. All Warmflow solar products are CE certified and
possess technical characteristics that comply with the following directives and standards:
- Low Voltage Directive 73/23 CEE
- Electromagnetic Compatibility Directive 89/336 CEE
- BS EN 12975 - Thermal solar systems and components – Solar collectors
Warmflow accepts no liability for the consequences of non-observance of the
instructions herein or where actions not specifically described are undertaken.

4
2 TECHNICAL CHARACTERISTICS
2.1 Technical Data
Model
Solar SHP20
Solar
SHP30
Absorber area (m
2
) (approx) 1.622 2.432
Aperture area (m
2
) (approx) 1.891 2.834
Fixed Parameter
Hydraulic connections G ¾” male
Gross size L x W x H (mm) 2050 x 1400 x 154 2050 x 2100 x 154
Weight empty (kg) 66.5 95.0
Fluid volume (litres) 1.2 1.7
Operating data
Rated flow rate per collector (litres/min) 2.0 3.0
Max. flow rate per collector (litres/min) 20
Max. operating pressure (bar) 6.0
Test pressure (bar) 9.0
Heat transfer fluid Warmflow Solar Fluid (water-glycol mix)
Max. working temperature (
0
C) 250
Permissible wind load (m/s) 25
Permissible snow load (mm) 500
Table 1: Technical data for Warmflow Solar heat pipe collectors

5
2.2 Key Components
Figure 1: Warmflow Solar heat pipe tubes
Figure 2: Warmflow Solar heat pipe collectors
Heat Pipe
Rapidly and efficiently transfers the sun’s energy from within the vacuum tube
into the manifold where it is transferred into the system fluid.
Tube Securing Nut
Locates and secures the vacuum tube into the manifold ensuring a positive
engagement.
Tube Seal
Seals the inner chamber of the vacuum tube to minimise convection losses
and protect the heat pipe and transfer fin from corrosion.
Transfer Fin
Conducts the sun’s energy from the vacuum tube’s absorber surface into the
heat pipe.
Vacuum Chamber
Insulates the heat pipe and transfer fin to minimise thermal losses, similar to a
vacuum flask.
Vacuum Tube
High efficiency twin-wall glass tube with 3600advanced Al-N/Al coated
absorber surface applied by Magnetron Sutter CVD for maximum absorption of
the sun’s rays from any angle.
Getter
Intelligent boron coating that maintains the vacuum within the vacuum
chamber by chemically absorbing any air. The getter has a mirror-like
appearance when new and becomes white when spent, indicating that the
vacuum tube needs to be replaced.
1
2
3
4
5
6
7
14
58
1945
1
2
3
4
5
6
7
1
1400 (Solar SHP20)
2100 (Solar SHP30)
154
2050
2
3
4
5
Manifold
Transfers heat from the heat
pipes to the system fluid.
Vacuum tube
See previous figure.
Support Frame
Is secured to the roof and
provides support for the
manifold and bottom rail.
Tube End Supports
Support the bottom of the
vacuum tubes.
Bottom Rail
Fixes the tube end supports.
1
2
3
4
5

6
Figure 3: Warmflow Solar dual-line pump station
Expansion Vessel
Connection
6 bar Pressure Relief Valve
Flow
from Collector
Return
to Collector
Flow
to Solar Coil
Return
from Solar Coil
Filling Point
Circulating Pump
Flow Adjuster
Flow Indicator
Pressure Gauge
Flow Temperature Gauge
Return Temperature Gauge
Bleed Point
Continuous Air Separator
Multifunction
Ball Valves

7
2.3 Circuit Diagrams
Figure 4: Typical domestic circuit diagram
Solar Collector
Dual
-
line
Pump Station
Pressure Relief
Discharge
Solar
Expansion Vessel
Motorised Valve
(if required)
Drain Cock
(at lowest point)
DHW
Storage Cylinder
Solar Coil
Boiler Coil
(if applicable)
T
3
T
2
T1
T1
T
2
T
3
Solar Sensors
refer to instructions for
Solar System Controller
M
FLOW
RETURN
FLOW
RETURN

8
Figure 5: Circuit layout for 20m2array (240 tubes)
2.4 Pipework and Expansion Vessel Sizing
Table 2 provides general guidance on the sizing of the system pipework and expansion
requirements. The expansion capacity is expressed as the number of Warmflow Solar
SEV18 expansion vessels required, each vessel having a volume of 18 litres.
No. of
vacuum tubes
Total length
of pipework
Minimum
pipe size
Minimum
expansion capacity
20 up to 70m 15mm 1 x SEV18
30 up to 45m 15mm 1 x SEV18
40
up to 30m 15mm 1 x SEV18
up to 40m 22mm 1 x SEV18
up to 75m 22mm 2 x SEV18
50 up to 10m 15mm 1 x SEV18
up to 45m 22mm 2 x SEV18
Table 2: Pipework and expansion vessel sizing
NOTE:
•The total length of pipework is the sum of both the flow and return runs from the cylinder
to the collector and back e.g. if the cylinder and collector were 5 metres apart, the total
length of pipework would be 10 metres (if piped directly).
•It is recommended that the minimum pipe size be used, otherwise expansion capacity
additional to that quoted may be required.
DN
32
DN
32
DN2
0
DN2
0
DN2
0
DN2
0
4 x SHP30 = 120 tubes
4 x SHP30 = 120 tubes
Note:
It is not recommended that more than
180 tubes be connected in series

9
2.5 Collector Pressure Drop
Figure 6: SHP20 collector pressure drop
Figure 7: SHP30 collector pressure drop

10
3 INSTALLATION
3.1 General Requirements
Select a suitable position for the collector. Ensure the section of roof to which the collector is
being installed is capable of supporting its weight and any likely wind loads.
The collector should face as close as practicably possible towards south and not be shaded
by surrounding buildings, trees or other sections of the building to which it is being installed.
The collector must be installed with the manifold at the top (not on its side) and on a section
of roof with a tilt of between 250and 600to the horizontal. Table 3 shows the effect of the
tilt and orientation of the collector on performance.
Tilt of
collector
Orientation of collector
South
South
-
east
South-west East / West
North
-
east
North-west North
30
0
Recommended 4.3% loss 15% loss 27% loss 32% loss
45
0
1.8% loss 7.1% loss 20% loss 36% loss 40% loss
60
0
7.8% loss 14% loss 28% loss 44% loss 53% loss
Data derived from SAP2005
Table 3: Loss of performance due to collector angle and orientation
The collector can be installed in 2 ways:
•tiled roof installation (refer to Section 3.2)
•slate roof installation (refer to Section 3.3)
3.2 Tiled Roof Installation
3.2.1 Assemble pitched roof brackets
Adjust the settings of the solar pitched roof brackets
(SPRB~) by varying the dimensions A and B to suit
the shape and thickness of the tiles. The dimensions
can be varied within the limits specified. Bolt the 3
sections of the brackets firmly together using the
fasteners supplied.
Figure 8: Adjustment of pitched roof bracket
Dimension
Minimum
Maximum
A 70 140
B 45 60
Table 4: Adjustment limits for pitched roof brackets

11
3.2.2 Install pitched roof brackets
Remove as many tiles as necessary to gain access to the rafters and laths and to determine
their location and spacing. It may be helpful to position the collector nearer the ridgeline and
work down from the top, removing the ridge tiles first.
Using suitable fasteners (not supplied) fix the pitched roof brackets to the most convenient
rafters ensuring the bracket spacing is within the guidelines below. As much as is possible,
space each set of brackets equally either side of each collector centreline.
In some instances, depending on the tile design, it may be necessary to notch the underside
of the overlapping tile to allow it to sit flush. If necessary the tiles can be cut and the roof
made watertight using suitable lead flashing (not supplied).
Figure 9: Pitched roof bracket layout for SHP20 collector
Figure 10: Pitched roof bracket layout for SHP30 collector
2100
800 – 1000 800 – 1000
1413 – 1705
SHPM30 Manifold
1400
1100 – 1300
1413 – 1705
SHPM20 Manifold

12
3.2.3 Install support frame and manifold
Fit the clamps supplied with the heat pipe manifold (SHPM~) to each rail of the support frame
(SSF~), placing a pair at the top and at the bottom of each rail as shown.
Install the support frame fixing each rail to the pitched roof brackets by passing the fasteners
supplied through the sides of the rail and the loop on the end of each pitched roof bracket.
Ensure the pair of clamps that are further apart are at the top, as these will secure the
manifold. The clamps closer together go at the bottom and secure the bottom rail.
Fit the bottom rail supplied with the manifold to the lower end of the support frame and
secure in place by tightening the clamps. Ensure the clamps either side of the bottom rail
face inwards towards it and that the edges of the clamps securely grip the lip on the rail.
Fit the manifold to the upper end of the support frame in a similar fashion, again ensuring the
clamps either side of the manifold face inwards towards it and that the edges of the clamps
securely grip the lip on the manifold.
Figure 11: Support frame and manifold installation
WARNING: Only unpack and install the heat pipe tubes after the rest of the system has been
flushed, filled and pressure tested and the system is ready to be brought into operation i.e.
just prior to commissioning, in order to prevent damage from excessive heat build-up.

13
3.2.4 Connect manifold pipework
To the flow (outlet) from the heat pipe manifold, fit the temperature sensor pocket supplied,
sealing the connection with PTFE tape (not supplied) and setting the pocket to a suitable
angle to allow the sensor cable to be secured to the flexible pipework. Either end of the
manifold can be used for the flow (whichever is most convenient) but the sensor pocket must
be fitted on the flow (outlet) side.
Liberally apply the heat conducting paste, supplied with the manifold (SHP~), to the PT1000
temperature sensor with the black cable, supplied with the system controller (SSC~), then
insert the sensor into the sensor pocket. Ensure the sensor is fully inserted in the pocket.
Once the pipework has been insulated, secure the cable to the outside of the insulation using
an appropriate cable tie to prevent the sensor from coming out of the pocket.
If installing multiple collectors, connect each pair using the manifold connector (SMC~) and
sealing washers supplied with the extension kit (Solar SHPX~).
Provide effective lightening protection by connecting a suitable conductor to either the flow or
return connection of EACH collector installed.
Connect the pre-insulated flexible hoses (SFH~) to the return connection of the manifold and
to the sensor pocket on the flow connection using the washers provided. Route the pipes
through appropriate flashing and into the roof space. The flashing should seal directly onto
the pipes, rather than onto the insulation, as the insulation could absorb water over time and
lead to water ingress to the property.
Use appropriate fittings and sealing (not supplied) to either extend the hoses or connect to
rigid pipework then plumb the flow and return pipework to the top connections of the dual-line
pump station (SDPS~).
ALL pipework must be fully insulated with high temperature insulation (such as Armacell
HT/Armaflex).
Solder ring fittings and standard solder joints must not be used, as the high temperatures
generated occasionally can melt the solder. Use only compression fittings, appropriate union
fittings or high temperature solder or braze suitable for up to 2500C.
Figure 12: Sensor pocket location
Figure 13: Connecting multiple collectors

14
3.3 Slate Roof Installation
Slate roof installation is essentially the same as tiled roof installation, only that the pitched
roof brackets (SPRB~) may not be suitable. Slate roof brackets are available, codes
SSRB20 and SSRB30 (for 20-tube and 30-tube manifold installations respectively).
3.3.1 Install slate roof brackets
Using suitable fasteners (not supplied) fix the brackets to the most convenient rafters
ensuring the bracket spacing is within the guidelines below. As much as is possible, space
each set of brackets equally either side of each collector centreline.
Figure 14: Bracket layout for SHP30 collector
Figure 15: Bracket layout for SHP30 collector
SHPM30 Manifold
SHPM20 Manifold

15
3.3.2 Install support frame
Install the support frame as described in Section 3.2.3 bolting the brackets to the underside
of the support frame rails using the same bolts that secure the manifold and bottom rail to the
rails.
3.3.3 Connect manifold pipework
Connect the manifold pipework as described in Section 3.2.4.

16
3.4 Dual-line Pump Station Installation
3.4.1 Mount pump station
Route the supply cable (not supplied) behind the dual-line pump station (SDPS~) and
through the hole in the centre of the rear casing.
Using the fasteners supplied (if suitable, otherwise use appropriate alternatives) mount the
pump station on a flat vertical surface. It must not be mounted horizontally or at an angle.
3.4.2 Connect pump station pipework
Fit the 1” x 22mm connection tails (supplied) to the four pipework connections A, B, C& Dof
the pump station using the sealing washers provided. Tighten firmly but do not over-tighten.
Alternatively, suitable flexible pipework with appropriate 1” union nuts and washers can be
used to connect the pump station.
Connect the pipework running from the collector to top connections A& Bof the pump
station as indicated. The pipe connected to Amust be the flow from the collector i.e. the end
of the collector with fitted with the temperature sensor pocket.
Connect the pipework running from the solar coil of the DHW storage cylinder (or swimming
pool heat exchanger) to the bottom connections C& Dof the pump station as indicated.
Pipe the pressure relief discharge Eto a safe visible discharge point.
Connect the solar expansion vessel (SEV~) to the expansion vessel connection Fvia the
flexible hose, using the sealing washers supplied with the vessel fitting kit (SVFK~). Mount
the vessel as instructed in the fitting kit instructions.
Note: Solder ring fittings and standard solder joints must not be used, as the high
temperatures generated occasionally can melt the solder. Use only compression fittings,
appropriate union fittings or high temperature solder or braze suitable for up to 2500C.
Figure 16: Dual-line pump station installation
Expansion Vessel Connection
(F)
Pressure Relief Discharge
(E)
Flow from
Collector
(A)
Return to
Collector
(B)
Flow to
Solar Coil
(C)
Return from
Solar Coil
(D)

17
3.5 Electrical Installation
If connecting to an unvented cylinder, the pump station MUST be connected via an external
wiring centre and an energy cut-out devise MUST be installed in order to comply with the
Building Regulations. This MUST take the form of a 2-port motorised valve (not supplied)
wired through a manually-reset high limit thermostat (not supplied). If in doubt, consult the
cylinder manufacturer.
Only if connecting to an open-vented cylinder can the pump station be connected directly
to the system controller as described in the controller instruction booklet.
3.5.1 Mount controller
Install the solar system controller (SSC~) in an appropriate location as described in the
instructions supplied. Connect the wiring centre and user interface as instructed. Connect a
permanent live supply to the wiring centre, via a fused spur isolator.
3.5.2 Connect external wiring centre
Specify an appropriate 5-wire motorised valve (not supplied) and connect it as shown.
Connect the high limit thermostat of the solar cylinder to the wiring centre, so that power to
the motorised valve would be interrupted should the high limit thermostat trip. Wire the pump
inside the pump station as shown.
Figure 17: Wiring layout with external wiring centre
Brown
Blue
Green/Yellow
Green/Yellow
Brown
Blue
Green/Yellow
Brown
Blue
Brown
Blue
Green/Yellow
Brown
Grey
Blue
Green/Yellow
Orange
Dual
-
line Pump
Station (SDPS~)
Pump
External Wiring Centre
(not supplied)
SSC~ Control Unit
P1
Perman
ent
Mains Supply
(via fused spur)
Cylinder
High Limit
Thermostat
(not supplied)
Motorised Valve
(on pipework to solar coil)
Diagram supplied for guidance only.
Detailed instructions on how to wire the high limit
thermostat of the solar cylinder should be sought
from the cylinder manufacturer’s instructions, as
differences may exist between products.

18
3.5.3 Connect back-up heat source
The controller is equipped with a 3-period, 24-hour programmer with temperature control to
control the back-up heat source, such as a boiler or immersion heater(s). The back-up heat
source is powered / controlled via the H1 outputs of the control unit.
Note: The maximum operating current on the H1 contacts is 5A. If immersion heaters are
used they MUST be powered via an external relay. Powering an immersion heater directly
will overload the control unit. Failure due to overloading is not covered by the guarantee.
If connecting to an unvented cylinder, the back-up heat source MUST be connected via an
external wiring centre and an energy cut-out devise MUST be installed in order to comply
with the Building Regulations. This MUST take the form of a 2-port motorised valve (not
supplied) wired through a manually-reset high limit thermostat (not supplied). If in doubt,
consult the cylinder manufacturer.
Only if connecting to an open-vented cylinder can the back-up heat source be connected
directly to the system controller without a motorised valve.
Figure 18 shows a typical single-heating-zone S-plan system with two 2-port motorised
valves. Additional heating zones can be added as required.
Figure 18: Wiring layout with external wiring centre
Grey
Orange
Brown
SSC~
Control Unit
H1
Permanent
Mains Supply
(via fused spur)
Heating
Zone Valve
Diagram supplied for guidance only.
Detailed instructions on how to wire the high limit thermostat of the solar cylinder should be sought from the cylinder
manufacturer’s instructions, as differences may exist between products.
L
N
E
CH OFF
COM
CH ON
CH Programmer
L
1
N
L2
CH Room Stat
E
N
External Wiring Centre
Brown
Blue
G/Y
Brown
Blue
G/Y
N
N
Brown
Blue
G/Y
N
N
Cylinder
Zone Valve
(on back-up coil)
Cylinder
High Limit
Thermostat
N
Grey
Orange
Brown
Back
-
up Heat Source
(e.g. Boiler)
Back
-
up Circuit
Circulating Pump
(if applicable)
Blue
G/Y
N
Blue
G/Y
N
Brown
Brown