203418-1.pmd

Ideal Solar -

Installation and Servicing

GENERAL

Dimensions

1945 x 945 x 105 mm

Weight

37.5 kg

Liquid Volume

2.36 litres

Flow Volume

100 lt/hr

Test Pressure

20 bar

Maximum Working Pressure

10 bar

Pressure loss

1.6 mbar

Absorber plate

Selective coating

Absorption level

95 %

Thermal emission level

3 %

Absorber plate

Copper sheet

Header/Absorber riser

24mm dia / 12.7mm dia

Glass

Low ironed, tempered glass

Glass transmittance

91 %

Insulation

CE Certificated High Density Rock wool

Weather proofing

EDPM / Silicon

Case

Painted Aluminium

Heat Endurance

232

Back Plate

Embossed aluminium case

Riser to absorber fixing

Ultrasonic

Number of Risers

TABLE 1 - GENERAL DATA - SOLAR COLLECTOR SPECIFICATION

Max. working excess pressure

6 bar

Max. working temperature

120

Safety valve

6 bar

Circulation pump

Grundfos UPS 25-60

Nominal voltage

AC 230 V

Power consumption Pump speed 1

45 W

Pump speed 2

65 W

Pump speed 3

90 W

Max. pump head

6 m

Max. pump capacity

4.5 m

/hr

Flow measuring device

1 6 l/min

TABLE 2 - GENERAL DATA - SOLAR PUMP STATION SPECIFICATION

Operating voltage

230 Volt ( + 15%) 50Hz

Internal consumption

< 1W

3 inputs for recording temperatures

PT1000

1 output

Normally open relay, switching power max. 800W,
fuse: 250V 4A MT

Output protected against overload and short circuits
Display

Animated LCD display, 2 colour backlight

Appropriate protection

IP 20/DIN 40050

Operation temperature range

0 to + 45

Installation

Wall mounting

Weight

250 g

Housing

Recyclable, 3 part plastic housing

Dimensions

L x B x H (mm) 136 x 133 x 37

2 x PT1000

1.5m silicon cable, measuring range up to+ 180

TABLE 3 - GENERAL DATA - SOLAR CONTROLLER SPECIFICATION

Ideal Solar -

Installation and Servicing

GENERAL

ideal solar

Destination Country: GB, IE

CONTENTS

Commissioning Notes .......................................... 34,35

Cylinders ........................................................................ 4

Fault Finding ............................................................... 38

Handing Over .............................................................. 36

Installation ..................................................................... 7

Installation of the Collector ......................................... 8

Installation on a Slate Roof ....................................... 10

Installation on a Tiled Roof ....................................... 12

Installation on a Flat Roof ......................................... 14

Installation with an Inset Kit ...................................... 18

List of Parts ................................................................. 39

Planning Permission .................................................... 5

Pump Station ............................................................... 24

Safe Handling ................................................................ 5

Servicing Schedule .................................................... 37

Solar Controller .......................................................... 26

Water Circuit Diagram .................................................. 6

Ideal Solar -

Installation and Servicing

GENERAL

INTRODUCTION

Ideal Solar is a range of solar water heating equipment for use
with twin coil storage cylinders only. The solar collectors are of
flat plate type and are suitable for use in new and refurbishment
installations.
A range of packs are available providing all equipment (except
cylinders, pipework and insulation) for a range of properties. The
pack includes solar collector(s), mounting brackets, controller,
pump station, expansion vessel and system fluid.
The solar collector is copper tube ultrasonically welded to
selectively coated absorber plates. This is housed in an
aluminium casing with dense rockwool insulation to rear and
sides. It is sealed into the casing with EPDM seals and a robust
tempered glass cover. Mounting kits are available to suit tiles,
slates both on or inset to roofs. In addition flat roof mounting is
provided.

THE IDEAL SOLAR SYSTEM PACKAGE COMPRISES OF:

1. Ideal Solar Collector(s) SC1

The solar collector panel(s) can be mounted directly onto
sloping roofs with a variety of fixings for different roof
coverings or onto a support frame for flat roofs.
The Ideal Solar kit comprises of one, two or three high
performance flat solar panel collectors.
A maximum of 9 solar collector panels may be installed.
Pressure loss (bends, valves, etc.)should be recognised when
specifying the pump arrangement.

2. Ideal Solar Pump Station PU1

The solar pump station is supplied with integrated pump to
provide circulation of the heat transfer fluid, the main
components of the unit are:
A circulation pump.
A flow limiter with fill & drain valve shut-off valve.
Two ball valves with integral display thermometers and check
valves.
Safety relief valve/pressure gauge assembly.
Non-flow valve fitted in both the flow and return circuit to
prevent the possibility of gravity circulation in the solar circuit.

3. Ideal Solar Controller EC1

The controller allows quick setting of functions and features
with LCD display to provide graphical information.
The controller allows the user to select the temperature
required at the hot water cylinder. The controller then
automatically determines when to run the pump to bring the
energy from the solar collector panel(s) to the cylinder.
The control uses a simple temperature difference to define
when the pump runs. This ensures that the pump is running
only when the benefit from the solar collectors is available.

OPERATION

The solar collector panel is mounted on a surface which is
selected for its exposure to sunlight and connected via pipe
work, to the lower coil of a twin-coil solar cylinder.
The solar controller monitors the temperature of the solar
collectors and the cylinder via its sensors.
The energy in the sun's rays is absorbed by the solar collector's
selective coated plate's which is then transferred to the heat
transfer fluid contained within the collector system pipe work.
When the solar collector sensor temperature is elevated 4

above the cylinder sensor temperature the controller activates
the circulating pump.
The pipe work is filled with a ready-mixed heat transfer fluid
containing glycol and water, which is circulated by a pump to
the solar coil in the hot water cylinder. The heat is deposited in
the storage cylinder and the heat transfer fluid returns to the
collector to absorb more free solar energy.
The circulation pump will continue to operate until the cylinder
sensor is satisfied (factory set 60

C) or the differential

temperature between the solar collector sensor and the cylinder
sensor reduces to 2

With current recommendations to store water at 60

C it is

becoming more of a consideration to protect persons of reduced
physical, sensory or mental capabilities from scalding. A suitable
method to achieve this would be to fit a Thermostatic Mixing
Valve (TMV) to the hot water outlet from the cylinder. If the TMV
is not fitted with a line strainer, they must be fitted on the hot and
cold supply lines.

IMPORTANT
Plastic Pipework is not suitable for the temperatures
possible in Solar circuits.
All connections and joints must be resistant to glycol and be
resistant to temperatures of up to 200°

OPTIONAL EXTRA KITS

Flat Roof Frame Kit

Roof Fixing Kit (slates)

10 Litre Heat Transfer Fluid

System Filling Hand Pump

Additional Solar Panel Collectors

Roof Inset Kit (1, 2, 3 and additional collectors) for tile roofs

Roof Inset Kit (1, 2, 3 and additional collectors) for slate roofs

UNVENTED DHW CYLINDERS

When connecting the Ideal Solar System to an un-vented hot
water storage cylinder, it is recommended that the electrical
supply to the solar control system is taken via the thermal cut-out
device on the cylinder.

CYLINDERS

For your Ideal Solar System a dual coil hot water storage
cylinder must be used. Installation can be for both open vented
and sealed systems. If a sealed system is used then part G3 of
the Building Regulations must be observed.
When sizing the Dual Coil Hot Water Cylinder a minimum
dedicated solar volume must be either 25 litres per sq metre of
panel or 80% of the daily hot water used.
For reasonable efficiency 35 litres per sq metre of panel should
be used.
For best practice a figure of 50 litres per square metre of panel
should be used. (These details are contained within the
Domestic Heating Compliance Guide).
There are many suitable hot water storage cylinders available
from manufacturers such as:
Albion, Shelah Road, Halesowen, West Midlands B63 3PG
Tel: 0121 585 5151
Range, Tadman Street, Wakefield, West Yorkshire WF1 5QU
Tel: 01924 234514

Ideal Solar -

Installation and Servicing

GENERAL

STANDARDS AND SAFETY INSTRUCTIONS

OVERVIEW OF EU STANDARDS

Solar Systems in General

EN ISO 9488

Thermal solar systems and components, terminology
(ISO/DIS 9488; 1995)

EN 12975-1

Thermal solar systems and components - Collectors -
Part 1: General requirements

EN 12975-2

Thermal solar systems and components - Collectors -
Part 2: Test Methods

ENV 1991-2-3

Eurocode 1 - Basis of design and actions on structures -
Part 2-3: Actions on structures - Snow Loads

EN 12976-1

Thermal solar systems and components - Factory made systems
- Part 1: General requirements

EN 12976-2

Thermal solar systems and components - Factory made systems -
Part 2: Testing Methods

ENV 12977-1

Thermal solar systems and components - Custom built systems
- Part 1: General requirements

ENV 12977-2

Thermal solar systems and components - Factory made systems -
Part 2: Testing Methods

ISO 9459-1: 1993

Solar heating - Domestic Water heating systems - Part 1:
Performance rating procedure using indoor test methods

ISO/TR 10217

Solar energy - Water heating systems - Guide to material
selection with regard to internal corrosion

Collectors and collector assembly

ENV 1991-2-4

Eurocode 1 - Basics of design and actions on structures -
Part 2-4: Actions on structures - Wind actions

Lightning Protection

ENV 61024-1

Protection of structures against lightning Part 1: General
principles (IEC 1024-1: 1990; modified)
Building Regulation, dating from 1991 (England and Wales)
Requirement G3, L1 and Regulation 7

BS 7671

Requirements for electrical installations
(IEE Wiring Regulations, 16

edition

SAFE HANDLING OF SUBSTANCES

Heat Transfer Fluid
Use undiluted only.

Keep out of reach of children.
Avoid contact with skin and eyes.
If swallowed, seek medical advice immediately and show the label
adhered to the container.

Disposal
Any packaging contaminated or not along with Ideal Solar fluid
must be disposed of at an appropriate waste site, whilst observing
local regulations.

PLANNING PERMISSION

Planning permission for the Ideal Solar System is generally only
required if you are in a conservation area or you are installing a
solar system on a listed building.
However it is prudent to seek the opinion of the local authority
on planning matters prior to starting work on the solar
installation.

INSTALLATION REQUIREMENTS

The installation of the Ideal solar system must be carried out in
accordance with the relevant requirements for safety, current
Wiring Regulations, local Building Regulations, Building
Standards (Scotland), (Consolidation) Regulations and Bylaws of
the local water company and Health and Safety document No.
63S (Electricity at Work Regulations 1989).
It should be in accordance with the relevant recommendations of
the following British Standards and Regulations:

BS 5918:1989

The Health and Safety at Work Act 1974

The Management of Health and Safety at Work Regulations
1999

The Construction (Health, Safety and Welfare) Regulations
1996

The Construction (Design and Management) Regulations
1994

The Lifting Operations and Lifting Equipment Regulations
1998

The manufacturer's notes must not be taken in any way as
overriding statutory regulations.

ELECTRICITY SUPPLY

All wiring must be performed in accordance with BS7671:
Requirements for Electrical Installations (IEE Wiring Regulations,
16

Edition).

A 3 amp fused three pin plug and un-switched shuttered socket
outlet (both complying with BS 1363) or preferably a double pole
isolator with a contact separation of 3mm in all poles supplying
the controller should be used. The controller must be earthed.

Earth Bonding

Ensure that the primary flow and return circuit is electrically
cross-bonded in accordance with BS 7676.

WARRANTY

The Ideal Solar system is supplied with a Comprehensive
Warranty cover of 10 years for the solar collector(s) and 2 years
for the pump station and controller.
For one off installers - products are sold with materials only
warranty
For Developers - Materials only warrantly. If labour required, to
be arranged and priced with the installer.
Ideal Solar Technical Suppoort Line: 01482 498307.

Ideal Solar -

Installation and Servicing

GENERAL

L/MIN

bar

100

120

100

Drain

Sun

Solar

Cylinder

Solar

Controller

Pump

Station

Expansion

Vessel

Solar

Cont-

ainer

Safety Relief
Valve / Pressure
Gauge Assembly

Solar

Collector

Panel

Auto

Air Vent

Solar

Collector Sensor

Solar

Cylinder Sensor

sol8618-1

Hot Water to Supply

Back Up

from Boiler or

Immersion Heater

INDIRECT PRESSURISED SOLAR CIRCUIT

The Ideal Solar System features high performance solar panel collectors with highly advanced features. The collector has been
awarded the Solar Keymark, the EUs quality mark for solar collectors. The collectors are mounted on a fast-to-fit frame and a solar
pump station is also supplied to provide all the safety features required for a pressurised circuit. The Ideal Solar Controller ensures
efficient use of the available solar energy at any given time and features several extra functions.

IDEAL HEAT TRANSFER FLUID

Ideal solar panel collectors and system components should be
used only with the recommended Ideal heat transfer fluid.

The heat transfer fluid uses a proven concentration of anti-freeze
and water to give protection against freezing and provide
optimum performance from the solar panel collectors and system
components. Additional fluid can be obtained via Ideal Solar
stockists.

INSULATION

Exposed pipe work should be insulated according to the high
temperatures that the collectors are able to generate.
This should be high temperature Armalfex or similar grade.
Suitable insulation is available from Armacell UK Ltd., Mars
Street, Oldham, Lancashire OL9 6LY.

INSTALLATION

Ideal Solar -

Installation and Servicing

SOLAR PACK CONTENTS

Before starting any work check the solar pack contents. Your Ideal Solar Pack comprises of the following:

10. Flow connection cross over fitting
11. Stat pockets (cylinder pocket) - 1 off
12. Solar automatic air vent isolation valve and fibre washer
13. Expansion vessel bracket + fastening
14. Collector panel blanking caps and washers - 2 off
15. Pump station nuts and olives
16. 3/8" brass plug
17. 3/4" x 3/4" elbow
18. Mounting brackets (single collector shown)

PARTS NOT INCLUDED IN THE SOLAR PACK

You will have to provide all pipework, fittings and insulation. The following specifications are required for items provided by the
installer:
Pipework: This should be 15 mm or 22mm copper or flexible stainless on both flow and return, depending on number of
solar collectors and pipework (see Frame 4). Plastic pipework is not suitable for the temperature extremes possible in solar
circuits. Pipe clips must withstand the temperatures of up to 200°C.
Fittings: Brass olive compression fittings must be used . Unleaded solder is not designed for solar circuits. Alternatively, high
performance crimped fittings or similar performance fittings can be used. Teflon or similar type tape is not to be used although a
proprietary liquid type suitable for solar conditions may be used. Any drain valves etc. must be capable of handling the
temperatures indicated above. Any fittings and pipework must be capable of withstanding 1.5 times the safety valve pressure.
Insulation: This should be High Temperature Armaflex or similar grade insulation or above. Class O Armaflex is not UV-resistant
or designed for the temperatures realised in the solar primary circuit. Polythene insulation will melt on a solar primary circuit. All
external items such as cable clips to hold the collector sensor must be UV-resistant.
Flexible stainless steel hose is available in pre-insulated form using suitable high temperature UV-resistant insulation and a
suitable two-core cable for the solar collector sensor. This hose is specifically designed for solar applications.

1. Solar collector (s)
2. Collector panel connectors with washers - 2 per panel
3. Controller with two temperature sensors & fittings
4. Pump station and safety assembly
5. 25 litre solar expansion vessel
6. Connector hose
7. Connector hose washers - 2 off
8. 20 ltrs of solar heat transfer fluid
9. Solar automatic air vent

11.

12.

13.

14.

15.

16.

17.

18.

10.

3.1

4.2

4.3

4.1

pump

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Ideal Solar -

Installation and Servicing

COLLECTOR SIZING AND LOCATION

Typically, approximately 0.75 square metre of solar collector should be supplied for each house occupant. Each Ideal Solar
Collector panel has an external area of 1.85 sq. m. Therefore, the Ideal 2 collector array is ideal for a 3 to 4 person household and
the Ideal 3 collector array for a 5 to 6 person household. The collector array should be located between 30

East and 40

West of

South and at an inclination between 20

to 45

within these bands there is no more than a 10% loss in efficiency from the

optimum south facing at an inclination of 35

. For an East-West roof, either an East-West application can be installed with a

collector on each pitch or additional collector(s) can be fitted on either the East-West roof. For example, a 3 collector array on an
East facing roof would be ideal for 4 to 5 occupants where there is a 20 % loss in performance as compared to the ideal South
facing 30° pitch. There should be no significant over-shading of buildings, trees or other obstructions. Even obstructions to the north
of the collector can block a significant proportion of the diffuse solar radiation. Significant overshading can be compensated by
over-sizing the solar system.

INSTALLATION OF THE COLLECTOR AND EXTERNAL COMPONENTS

The flow and return pipework can be passed
through the roof either with a proprietary roof
penetration tile or a Code 4 lead custom made
roof penetration tiles. Ventilation tiles can
sometimes be adapted for this purpose.
Alternatively a silicon "dektite" can be used.
Optional lead pipe flashing tile kits which can be
adapted to suit most roof tiles are available. Any
exposed elements of the roof penetration must
be carefully sealed with exterior grade low
modulus silicone.

IMPORTANT

All connections and joints must be resistant to temperature of up to 200°C and resistant to glycol.
During installation and servicing means for covering the solar collectors will be required to avoid burns. In direct sunlight, the solar
collectors can reach temperatures of 200°C.
Note. It is recommended that you select the pipework in accordance with this table. If the system provides additional pressure
loss (bends, valves, etc.), you should consider selecting pipe with larger diameter.

For Pitched Roof Only: The Automatic Air Vent must be installed internally at a level above that of the collectors
(i.e. within the pitch of the roof) to allow access for manual venting from within the roof space.
The final part of the roof installation is the insertion of the silicon PT1000 Collector Sensor into its mounting pocket in the Flow
Connector and feeding of the cable through or under the flow roof penetration and through the felt or timber sarking so that the
sensor cable is visible in the loft space.
Wiring run lengths and cross sectional areas for low voltage collector sensor wire:
Lengths up to 50m: 0.75mm

Lengths up to 100m: 1.5mm

The collectors should be piped
diagonally opposite corners as
shown.

Note. The flow outlet can be
either left or right exiting but
ensure that the return is
diagonally opposite).

Number of

Single Pipe Length

Solar Collectors

Up to 6m

Up to 15m

up to 20m

up to 25m

to 5

Ø 15mm (DN12)

Ø 22 mm

(DN 15)

(DN 20)

to 9

Ø 22 mm

Ø 28 mm

(DN15)

(DN20)

(DN25)

A Solar automatic air vent
B Air vent fibre sealing

washer

C Isolation valve
D Brass plug

(fitted if air vent is

located remote from the
connector)

E Flow manifold incl. stat

pocket

F Collector fibre sealing

washer

G Collector panel

connections

H Return connection fitting

sol8687(1)

Solar panel collectors

Flow Connector Assembly

(to be fitted directly
to the collector)

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INSTALLATION

Ideal Solar -

Installation and Servicing

INSTALLATION OF THE COLLECTOR AND EXTERNAL COMPONENTS

It is the installer's responsibility to make sure the roof is water tight and secure.

The Ideal Solar System is designed for operation in standard UK geographic applications. For high wind exposure
applications, it is the installer's responsibility to make sure the collectors are suitably fixed to the roof. It is also the
installer's responsibility to maintain the necessary Health and Safety standards. Ideal recommend the use of either
scaffolding and/or custom made solar installation access equipment for the safe lifting and installation of the solar
collectors. If in doubt, please use a competent roofer to install the collectors.

IMPORTANT.
Ensure safe working practices and handling are observed at all times.

Do not lift the solar collector panels by the connections.

The National Federation of Roofing Contractors (NFRC) offers a solar panel roof mounting service via its network of
approved members. The NFRC can be contacted on 020 7436 0387 or via www.nfrc.co.uk

The mounting plate and roof brackets are designed for use with both flat and profiled concrete pantiles. For Rosemary clay tiles or
slate, the top and bottom mounting rails are to be secured via 4 galvanised brackets for a single collector or 6 brackets for a 2
collector installation. The brackets are shaped to fit behind the tiles and must be fixed to either the rafters or noggins between the
rafters with coach screws. See below.

Any holes in the roof (which should be avoided if possible) must be sealed with an external grade low modulus silicon sealant or
proprietary `O' rings.

Side profile shape of galvanised bracket
for a rosemary tile roof.

continued . . . . .

Mounting
Bar

Profile of Galvanised

Location of
coach screws

Bracket

sol8602_1

N.B. Galvanised brackets can be
shortened to suit depth of particular tile as
appropriate.

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Ideal Solar -

Installation and Servicing

10 INSTALLATION OF THE COLLECTOR FOR FLAT ROOFS

IMPORTANT.
It is the installer's responsibility to ensure the roof is water tight and secure.

Ensure safe working practices and handling are observed at all times.

Do not lift the solar collector panels by the connections.

Consideration must be given to conditions that may lead to an increase in the
wind load stresses on the installation. These conditions may include: location of
surrounding buildings, specific roof designs or an exposed location. Ballast and
(or) fittings must be used to secure the frame and collectors to the roof, ensuring
they are not susceptible to lift.

Legend
1 Angle iron 40 x 40 x 1900mm
2 Angle iron 40 x 40 x 1330mm
3 Angle iron 40 x 40 x 2180mm
4 Angle iron 25 x 25 x 1440mm
5 Top and bottom rails
For 2 collectors 30 x 30 x 2760mm as
supplied
For 1 collector cut to 30 x 30 x 1335mm

a Clamps - 4 off
b M6 x 20mm screws - 8 off
c M6 shouldered nuts - 8 off
d M10 x 25mm shouldered

screws - 10 off

e M10 shouldered nuts - 10 off

1L & 1 R

2L & 2R

3L & 3 R

4E & 4S

5D & 5U

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Ideal Solar -

Installation and Servicing

12 INSTALLATION OF THE COLLECTOR FOR FLAT ROOFS ... continued

1. Connect the base angle No.1 to

the rear angle No.2 with the M10
screws and nuts provided.

Bring together the front angle
No.3 to connect to angles 1 and
2 to form a triangle.

2. Repeat to form the second

triangle.

4. Fit the bottom rail using the

M6 x 20mm screws and nuts.

5. Ensure the capture lip is in the

correct orientation.

3. Using angle iron No.4, connect

the two triangles via the upper
and lower holes in angle No.2
(for a single collector) to create a
diagonal brace. Repeat for the
second triangle.

(For a 2 collector system use the
middle set of holes).

6. The `A' frame is now complete and

ready for the solar collector to be
located.

IMPORTANT.
ENSURE THE SOLAR
COLLECTOR(S) ARE
CORRECTLY ORIENTATED.
THE BOTTOM OF THE
COLLECTOR IS IDENTIFIED
WITH A LABEL.

7. Observing correct manual handling

techniques, locate the bottom of the
collector (labelled `Down Side') in to
the cature lip on the bottom rail.

The top rail can now be moved to
locate the lip on the top of the
collector.

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Ideal Solar -

Installation and Servicing

15 INSTRUCTION FOR THE SOLAR COLLECTOR INSTALLATION

WITH AN INSET KIT

16 READY MOUNTED DIMENSIONS

Before you start mounting the flashings please check the dimensions, which show the mounted dimensions of the flashing. You
have to add the dimensions of the flashing to the dimensions of the solar collector so you will get the mounted dimension of the
whole solar system.

The roof inset kits are suitable for use with the Ideal Solar collector panel, ref SC1.

The variants of roof inset kits available are listed below. These allow collector inset fitment onto either corrugated tiles or flat roof slates.
Dedicated kits allowing installation of up to three collectors are provided. Furthermore, by specifying the appropriate matching
additional collector kits as appropriate installation of more than three collectors can be undertaken.

The following instructions show the installation method to 1, 2, or 3 collector kits.

This mounting
instruction is valid for
corrugated and flat
roof tiles (for roof tiles
the foreparts are
fabricated without lead
apron).

Ideal Solar -
Roof Inset Kits:

Roof inset kit (1 Collector)
fitted within corrugated tiles.
Product code 203623
Roof inset kit (2 Collectors)
fitted within corrugated tiles.
Product code 203398
Roof inset kit (3 Collectors)
fitted within corrugated tiles.
Product code 203624
Roof inset kit (Additional
Collector) fitted within
corrugated tiles.
Product code 203399
Roof inset kit (1 Collector)
fitted within roof slates.
Product code 203625
Roof inset kit (2 Collectors)
fitted within roof slates.
Product code 203626
Roof inset kit (3 Collectors)
fitted within roof slates.
Product code 203627
Roof inset kit (Addtional
Collector) fitted within roof
slates.
Product code 203628

for slate roof without

lead apron

for slate roof without

lead apron

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Ideal Solar -

Installation and Servicing

17 FITTING THE FOREPARTS

1. Before mounting the foreparts you must add an

additional roof baton to stabilise the foreparts.
The distance for this additional roof baton is
displayed in Frame 1.

2. Start the mounting of the foreparts with the left one.

Hook the forepart in the roof baton above the baton
added in Frame1. Fix the forepart with the 4 screws
through the pre-drilled holes.

3. The middle forepart (only necessary in the case of

more than 2 collectors) must be hooked on the same
roof baton as the left one. Then slide into the left
forepart until the marked signs on the part.

4. Please note that the foreparts must be joined and aligned

before you fix the middle forepart with 4 screws through
the pre-drilled holes.

5. Slide the right forepart in the middle part (or left part in

the case of 2 collectors) in the same way as mentioned
in pic no. 4. Also fix it with 4 screws.

Take care to align with mark provided before fitting
screws.

alignment
mark

KEY TO MAIN INSET COMPONENTS

1. Left forepart
2. Middle forepart
3. Right forepart
4. Lower left lateral part
5. Upper left lateral part
6. Lower right lateral part
7. Upper right lateral part

8. Lower connection part
9. Upper connection part
10. Support plate
11. Left back part
12. Middle back part
13. Right back part
14.Support plate cover

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Ideal Solar -

Installation and Servicing

18 FIXING THE SOLAR COLLECTORS

1. You must begin with the left collector and hook it in the

flaps of the left forepart. Align the collector with the marks
provided on the forepart. (see Pic No.2)

2. The left collector has to be hooked into the flaps of the

forepart as shown in pic. No. 2. The collector must be
moved until the left edge reaches the marked sign on the
forepart.

3. Before placing the second collector, fix the left collector

with three small flat fixation brackets on the left side.

The flat brackets and screws are provided with the inset
kit. Locate the bracket in the groove provided along the
side of the collector. When secured the bracket clamps
the collector downward onto the batten. Do not fix the
right side of the collector at this stage.

4. Now fit the second collector in the middle forepart (or in

the case of only 2 collectors, in the right forepart). The
second collector must be fitted in the same way like the
first one.

4a. Now fit the second collector in the middle forepart (or in

the case of only 2 collectors in the right forepart). The
second collector must be fitted in the same way like the
first one. Clamp down the collectors with the remaining

flat brackets. Note longer brackets for clamping in
between collectors (see Frame 4a) are provided.

4b. The mounting of a 3rd or further collectors works in the

same way as explained in the last points.

location mark

location
mark

flap
hooks

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Ideal Solar -

Installation and Servicing

19 MOUNTING THE LATERAL PARTS

1. Take the lower left lateral part, hook it on the front edge of

the collector and fit to the left forepart as shown in pic. no. 1.

After fitting the lower lateral part you MUST bend the small
flap from the left forepart upwards, until it is closed with the
lower lateral part.

2. After fixing the lower lateral part you MUST fit the upper

lateral part. The upper lateral part must be fitted on the
collector and also fitted in the lower lateral part. The upper
part must cover the lower one, so that any water cannot leak
through into the roof. You must slide down the upper part
until it hooks on the upper edge of the collector.

3. After fitting the lateral parts they must be fixed with 5 fixation

clips and nails as shown in pic. no. 3.

4. Repeat steps 1-3 to fit the right lateral parts.

20 MOUNTING THE CONNECTION PARTS

1. Hook the lower connection parts into the panel

edge and push them down until they fit with the
panel surface.

2. Hook the upper connection parts into the panel

edge and push them down until they fit with the
panel surface, ensuring they are covering the
lower connection part.

INST

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INSTALLATION

Ideal Solar -

Installation and Servicing

22 FITTING THE COVER PLATES AND SUPPORT PLATES

1. After all the backparts are fitted, they must then be

fixed with the cover plates and support plates. You will
find 3 holes in them.

2. Each cover plate incorporates three screw holes. The

upper hole accepts a wood screw provided in the inset
kit hardware pack, screwed into the upper baton. The
lower two holes incorporate a tapped thread. Fit the

two threaded screws provided into these holes ensuring
the sealing washer is in place beneath the screw head.
See Pic 2 for detail.

3. After fixing the cover plates the left and the right back-

parts must be fixed on the sides with 2 fixation clips and
nails (2 left and 2 right).

1. The backparts have to be fixed finally with 3 screws

through every back-part and the roof batons as in
the picture shown. The holes for this fixation must
be drilled through the backparts.

2. Fix the single parts with rivets as shown in the

picture.

3. Around the lateral and the back parts place foam

gaskets as shown in the picture.

This is only necessary in the case of corrugated
roof material.

23 SECURING

INST

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INSTALLATION

Ideal Solar -

Installation and Servicing

PUMP

TION

24 PUMP STATION

Installation, initial operation, maintenance and repairs must to be
carried out by authorised and qualified trade persons.

The transmission unit/pump circuit must always be mounted at a
lower level than the collectors so that no steam may penetrate the
expansion tank in case of solar collector panel stagnation.

If the expansion tank is mounted at the same or higher level than the
transmission unit, a thermal insulation loop or buffer is required.

Install the solar pump station and the solar collectors as close as
possible to the solar storage cylinder, this will aid the connection of
the temperature sensors (see Frame 4 for extending wire lengths).

When installing the solar pump station the space for mounting the
expansion vessel should be taken into account.

LEGEND

A. Pump Legs

B. Safety relief valve / Pressure gauge assembly

C. Front thermal insulation shell cover

D. Rear thermal insulation shell cover

E. Rear thermal insulation shell cover

F. Plastic mounting brackets

MOUNTING THE PUMP STATIOIN

1. Remove the front thermal insulation shell (C) cover by

pulling forward.

2. Remove the rear thermal insulation shells (D, E) by

sliding the two halves outwards.

3. Remove the two pump legs (A) by unclipping them from

the plastic mounting brackets (F), noting the position and
orientation.

4. Drill an 8mm hole for each of the two plastic mounting

brackets (F), with a secure hole centre distance of
262mm. Secure with plugs, washers and screws
provided.

5. Mount the pump legs into the plastic brackets. Do not

replace the thermal insulation shells.

6. Connect the solar circuit pipework to the upper and lower

connections of the unit using the compression fittings
provided.

Note. When connecting the pipes to the pump station,
collectors and cylinder coil, ensure correct direction of
flow. Refer to Frame 1.

When using soft and thin walled pipes, reinforcing
sleeves are to be used. The ends of the pipe must be cut
at right angles and have to be free from burrs. Introduce
the pipe until stop and firmly tighten the compression
fittings using a spanner, hold firm while tightening.