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Our company has designed the solar collector, ensuring the maximum

thermal output, durability ease of installation and maximum lifespan.

In order to achieve the above all the components of our solar collectors are made by top

quality material according to the European and National legislation as well as the ISO 9001

standard and SOLAR KEYMARK standard that our company applies.

As soon as its manufacture is complete, the collector will be placed in a special package in

order to enable its transfer. The collector’s transfer must be performed by qualified

personnel.

! Attention must also be given to the vehicle which is used for the collectors’ transfer

as they have to be protected by solar radiance in all times.

Moreover, during the transfer leading to the collectors’ installation, we must have in mind

that the assembly and the placement on their base must be done according to the

mechanical drawing which accompanies the report.

In order to do so, we have to take in consideration that, during the collectors’

transportation, all the pieces of the terrace stand as well as those of the collector’s

adjustments must always be with us. When it comes to lifting the collector on the roof a

special lift belt is used as well as a lifting vehicle. However, before the collector is lifted, a

preliminary check of the roof’s condition has to take place in order not only for the

responsible plumper to be able to work safely as well as to make sure that the roof can

stand the weight of the installation.

As shown at the figure 1.1, attention must

be given in not lifting the collector by using its

22mm joints

Figure 1.1

GENERAL INFORMATION

TRANSPORT AND HANDLING OF THE COLLECTOR


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The solar collectors must have South direction at an inclination of 45 degrees

(Europe Conditions ) .

The collectors must be installed using 8mm galvanized screws (not supplied), that

will be screwed on the Nuts installed on the Collector Frame.

The installation and connection must be performed by a professional plumber.

Keep the collectors covered while installing and before filling with water and

Antifreeze/Heat-transfer fluid chemical mixture,(Remove the cover only after you

connect them to the system and fill them with water and Antifreeze/Heat-transfer

fluid chemical mixture)

After all the plumbing works and connections have been done, fill the system with

water Antifreeze/Heat-transfer fluid chemical mixture and check for leaks. If you

see any leaks from the connections fix them immediately.

You must add the Antifreeze/Heat-transfer fluid chemical mixture through the

22mm copper pipes which are located at the top of the collectors.

As soon as you make sure that no leaks are present you can take off the collectors’

cove away.

The solar collectors initiate their function as soon as solar rays incident to the

surface.

In order to achieve the maximum performance the solar collectors need to be in full

sunshine.

All pipes connected to the collector must be insulated with proper pipe insulation.

In case the collectors must be emptied they should be covered.

It is recommended that the building should be adequately protected against

lightning and the collectors be properly earthen by a professional electrician.

These solar collectors must be used as a part of a closed solar thermal circuit system

and they should be filled with proper mixture of water and Antifreeze/Heat-transfer

fluid chemical.

Note: Use water and Antifreeze/Heat-transfer fluid Chemical mixture that is

compatible with copper pipes. (During filling/refilling take personal protective

measures according to the instructions of the chemical manufacture).

It is recommended to use Sentinel R100 – Ready-to-use heat transfer fluid for solar

heating systems

Sentinel R100 is supplied in 10 and 20 liter nonreturnable plastic containers

Sentinel R100 Solar Thermal Fluid is a clear blue liquid based on propylene glycol

solution. It has been designed for use as a thermal fluid in solar heating equipment

such as a flat plate.

GENERAL INSTALLATION INSTRUCTIONS

HEAT TRANSFER FLUID – ANTIFREEZE CHEMICAL MIXTURE


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Sentinel R100 is designed for use in solar heating equipment operating up to 200oC

and is also optimized to provide freeze protection of the circuit even to -25oC

Content of the liquid is not reduced in any case less than 25Vol% for corrosion

protection

Not considered hazardous to health

Avoid with skin and eyes

Keep out of reach of children and animals

Wash out empty container thoroughly with water before disposal

First Aid

Skin Exposure: Wash immediately with plenty of water. If irritation develops, seek

medical attention

Eye Exposure: Flush immediately with plenty of running water. Keep eyelids

apart. Seek medical advice

Ingestion: Rinse mouth with water. Do not induce vomiting!

The electric system’s installation is allowed to be done only by a specialized

electrician

Attention! if the solar collector is installed at a height exceeding the 20m, lightning

arrestors have to be also installed in order for the electrical installations to be

protected

The grounding can be performed through the wire of the main installation’s

equipotential connections or alternatively through a grounding bar

If a lightning protection installation exists, the solar collectors must be included in it

Note: National Regulations should be considered

It is recommended that the collector glass is cleaned regularly, always depending on the

amount of dust in the area. The cleaning should be done when there is not much sunshine

during morning or evening hours clean water and a sponge.

At least every six months the user must visit the solar collectors’ area and check for:

Cleanliness of the collectors glass

Possible broken glass

Leakages

Pipe insulation

Lack of Antifreeze/Solar Thermal Fluid chemical mixture

During static conditions the solar collectors should be completely empty so that

the thermal fluid is not exposed to extreme temperatures

Any Leaks & Damages must be fixed immediately by professionals.

MAINTENANCE INSTRUCTIONS

RECOMMENDATIONS ABOUT LIGHTNING PROTECTION


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Table 1.1

MODEL DIMENSIONS mm

D1xD2

Thickness mm

B1 WEIGHT Kg

CAS1-F8 1490 x 990 85 21

CAS2-F8 1490 x 1225 85 27

CAS3-F8 1990 x 990 85 30

CAS4-F8 1990 x 1225 85 38

CAS1-F15 1490 x 990 85 23

CAS2-F15 1490 x 1225 85 31

CAS3-F15 1990 x 990 85 32

CAS4-F15 1990 x 1225 85 38

SOLAR COLLECTOR TECHNICAL DATA – COLLECTOR TYPES

Collector Direction: South

Collector Inclination: Min 30 degrees – Max 45 degrees

Max. Operating Pressure: 10 bar

Permissible Snow Load: 1124 Pa (114.68 kg/m2)

Permissible Wind Load: 500 Pa (50.98 kg/m2)

The collectors must be properly earthen

The collectors can be installed in an array using 22mm connectors


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During a laboratory test measures have been made alternating the water suppliance at the

solar collector’s entrance (kg/h).

PRESSURE DROP


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Figure 1.2

The collector’s adjustment with the boiler is being made at the Copper Coil Pipe’s entrance

as well as at it exit, as it can be seen at the figure 1.2, creating a separate system in order to

avoid the pressure drop. Wherever using a joint is necessary to connect copper pipes, we

use joints of the type F-M (Female and Male adapters), as it can be seen at the figure 1.10.

It is recommended that the pipes used for connecting the solar collectors with the boiler are

made of plastic HDPE 100 – NP 16bar material and have outside diameter of 25mm. The

connections between the plastic pipes and the copper pipes at the marks of figure 1.2 can

be made by using joints, as it can be seen at the figure 1.12.

After connecting the joins, the pipes must be covered with the insulation material

(Armaflex).

In case the solar collectors have an altitude which is different from the boiler, it is

necessary to install a specialized circulator. When a large number of solar collectors must

be installed, an engineering report written by a mechanical engineer is recommended.

ADJUSTING THE SOLAR COLLECTORS WITH THE BOILER

Connection of

copper pipe and

Plastic HDPE

pipe

HD PE – PN16

Plastic Pipe 25mm

HD PE – PN16

Plastic Pipe 25mm


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Figure 1.3

The Linear connection of two collectors must be done by using 22mm joints especially

made for copper pipes, as show at the figure 1.3.

Figure 1.4

In case of collectors being parallel connected, we must take into consideration the L

distance, as shown the figure 1.4.

Solar

radiance

LINEAN CONNECTION OF TWO COLLECTORS

PARALLEL CONNECTION OF COLLECTORS

φ

L

θ


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The distance changes according to the φ angle only when the solar radiance incident

perpendicularly on the collectors’ surface.

Table 1.2

MODEL L1 (θ=30ο , φ=60

ο) L2 (θ=45

ο , φ=45

ο)

CAS1-F8 & CAS1-F15 430mm 1054mm

CAS2-F8 & CAS2-F15 430mm 1054mm

CAS3-F8 & CAS3-F15 575mm 1408mm

CAS4-F8 & CAS4-F15 575mm 1408mm

When the solar collectors are installed on the special stands

Front View

Figure 1.5

Top View

Figure 1.6

SURFACE BEING OCCUPIED BY THE COLLECTORS’ ASSEMBLY

W1 C1

H1

H1

L1 , L2

Cold

Water

In

Hot

Water

Out

Assembly Area

1st Line

2nd Line


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When the solar collectors are installed on the special stands, then the area that will be used

during the compartment can be calculated according to the figure 1.6. The L1,L2 distances,

which are featured at this figure, are calculated according to the table 1.2 . For an area of

20m2, the largest number of solar collectors that can be installed on it is given at the

following table.

Table 1.3

Type of collector

C1 (mm)

W1

(mm) L2

(mm) H1

(mm) Number of Lines

Max Collectors

(20 m2)

CAS1-F8 &

CAS1-F15 80 990 1054 1054

1 18

2 12

3 6

CAS2-F8 &

CAS2-F15 80 1225 1054 1054

1 10

2 8

3 6

CAS3-F8 &

CAS3-F15 80 990 1408 1408

1 18

2 12

3 6

CAS4-F8 &

CAS4-F15 80 1225 1408 1408

1 10

2 8

3 6

Solar Collectors are installed on a flat surface

Figure 1.7

Assembly Area

W1 C1

Y1


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In case the solar collectors are installed on a flat surface then the amount of the surface use

for that reason can be calculated according the figure 1.7. At the following table is

described the maximum number of solar collectors than can be installed in an area of 20m2

Table 1.4

Type of collector

C1 (mm)

W1

(mm) Y1

(mm)

Max Collectors

(20 m2)

CAS1-F8 &

CAS1-F15 80 990 1490 13

CAS2-F8 &

CAS2-F15 80 1225 1490 9

CAS3-F8 &

CAS3-F15 80 990 1990 9

CAS4-F8 &

CAS4-F15 80 1225 1990 7

Connecting Copper Pipes

In order to connect the copper pipes we use joints of: Flared Joints by using adapters of the

type Double M Adapter-Type M and F Adapter – Type F as it appears at the figure 1.8 and

figure 1.9. The connection procedure must be done by a qualified person and the standard

NFPA54/ANSI.Z223.1 must be followed.

Figure 1.8 - Double M adapter – Type M

CONNECTIONS

22mm


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Figure 1.9 - F Adapter – Type F

Figure 1.10 – Connecting copper pipes

Figure 1.11

22mm


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Connection of copper pipe and plastic pipe

Figure 1.12

Figure 1.13

The connection of the copper pipes with the plastic ones is being done by using M and F

adapter as well as washer ring, as it appears in figure 1.12.

In all connections Teflon must always be used in order to ensure tightness.

Washer Plastic

Adapter

Type F

Plastic Pipe – Type

HDPE – PN 16

23.2mm 25mm

HDPE – Pipe

25mm


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Figure 1.6

Heat transfer in parallel connection

Heat transfer in line connection

HEAT TRANSFER

When the collector is fully loaded, the

heating is being transferred as shown

at the figure 1.6 Collector

Cold water

Hot water

Cold water

Hot water

Cold water

Hot water


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SAFETY PRECAUTIONS;

INSTALLATIONS & CONNECTION MUST BE PERFORMED BY

PROFESSIONALS

MIND YOUR SAFETY…. USE PERSONAL PROTECTIVE EQUIPMENT!

PLEASES HANDLE WITH CARE!

For further information & instruction please contact our technical support department

at +0357-25576031

VELPA SOLAR HEATERS

25A OPTIKOU NIKOLIDE

3045 Limassol,

CYPRUS

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