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Dear Friends,
This is our first attempt to communicate with you in this manner, where
writing becomes a friendly chat. Through the pages of our second
enriched publication now in your hands, we present to you our com-
pany.
A company offering sunny solutions, working with passion and dedica-
tion, for three decades now, to always offer you the best.
HELIOAKMI has been manufacturing and installing solar water heaters
since the 1970s making thousands of loyal friends like you along the
way. Our experience in producing highly efficient non-defective prod-
ucts economically, makes us justifiably proud of our contribution tosociety. Because a solar water heater isnt just a simple appliance that
makes our life easier. It is a whole philosophy. A philosophy that has
taken HELIOAKMI to the top of the worlds hot water technology from
the sun, in over 60 countries, in all climatic conditions and for all types
of water qualities.
A philosophy that leads the way and makes us, as professionals, feel the
weight of responsibility and obligation to offer products and services
that are in harmony with the environment and man. To hand over a better
world to our children.
Always true to our principle for excellence in design and continuous
advancements, HELIOAKMI today offers high standard solar water heat-ers.
Along with architects, engineers, installers and professionals in this
field we can all create together. Using the most economic and efficient
technologies available we produce hot water from the sun. For the com-
mon good.
We live in special times. The environment is sounding the alarm. The
whole world is looking towards other renewable energy sources.. The
international outcry is raising consciousness When the answer is
right next to us, should we still be searching for it?
Solar water heaters are not a luxury. They are a part of the future, today.
The future we promised our children.
Our goal is one. Quality of life. This is our philosophy.
Sincerely yours,
Christos Papadopoulos
General Manager
Dear Friends,
This is our first attempt to communicate with you in this manner, where
writing becomes a friendly chat. Through the pages of our second
enriched publication now in your hands, we present to you our com-
pany.
A company offering sunny solutions, working with passion and dedica-
tion, for three decades now, to always offer you the best.
HELIOAKMI has been manufacturing and installing solar water heaters
since the 1970s making thousands of loyal friends like you along the
way. Our experience in producing highly efficient non-defective prod-
ucts economically, makes us justifiably proud of our contribution tosociety. Because a solar water heater isnt just a simple appliance that
makes our life easier. It is a whole philosophy. A philosophy that has
taken HELIOAKMI to the top of the worlds hot water technology from
the sun, in over 60 countries, in all climatic conditions and for all types
of water qualities.
A philosophy that leads the way and makes us, as professionals, feel the
weight of responsibility and obligation to offer products and services
that are in harmony with the environment and man. To hand over a better
world to our children.
Always true to our principle for excellence in design and continuous
advancements, HELIOAKMI today offers high standard solar water heat-ers.
Along with architects, engineers, installers and professionals in this
field we can all create together. Using the most economic and efficient
technologies available we produce hot water from the sun. For the com-
mon good.
We live in special times. The environment is sounding the alarm. The
whole world is looking towards other renewable energy sources.. The
international outcry is raising consciousness When the answer is
right next to us, should we still be searching for it?
Solar water heaters are not a luxury. They are a part of the future, today.
The future we promised our children.
Our goal is one. Quality of life. This is our philosophy.
Sincerely yours,
Christos Papadopoulos
General Manager
Dear Friends,
This is our first attempt to communicate with you in this manner, where
writing becomes a friendly chat. Through the pages of our second
enriched publication now in your hands, we present to you our com-
pany.
A company offering sunny solutions, working with passion and dedica-
tion, for three decades now, to always offer you the best.
HELIOAKMIhas been manufacturing and installing solar water heaters
since the 1970s making thousands of loyal friends like you along the
way. Our experience in producing highly efficient non-defective prod-
ucts economically, makes us justifiably proud of our contribution tosociety. Because a solar water heater isnt just a simple appliance that
makes our life easier. It is a whole philosophy. A philosophy that has
taken HELIOAKMI to the top of the worlds hot water technology from
the sun, in over60 countries, in all climatic conditions and for all types
of water qualities.
A philosophy that leads the way and makes us, as professionals, feel the
weight of responsibility and obligation to offer products and services
that are in harmony with the environment and man. To hand over a better
world to our children.
Always true to our principle for excellence in design and continuous
advancements, HELIOAKMItoday offers high standard solar water heat-ers.
Along with architects, engineers, installers and professionals in this
field we can all create together. Using the most economic and efficient
technologies available we produce hot water from the sun. For the com-
mon good.
We live in special times. The environment is sounding the alarm. The
whole world is looking towards other renewable energy sources.. The
international outcry is raising consciousness When the answer is
right next to us, should we still be searching for it?
Solar water heaters are not a luxury.They are a part of the future, today.
The future we promised our children.
Our goal is one. Quality of life. This is our philosophy.
Sincerely yours,
Christos Papadopoulos
General Manager
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C O N T E N T S
TECHNICAL SPECIFICATIONS AND DIMENSIONS - ALL MODELS Page 4
PACKING OF THE SOLAR WATER HEATER Page 5
WHAT YOU SHOULD KNOW ABOUT THE MEGASUN SOLAR
WATER HEATER Page 6
INSTALLATION INSTRUCTIONS Page 7
ASSEMBLY DIAGRAM OF THE SUPPORT BASE ON A FLAT SURFACE Page 8
ASSEMBLY DIAGRAM OF THE SUPPORT BASE
ON A SURFACE WITH MAXIMUM INCLINATION OF 32 Page 9
ANALYTICAL DESCRIPTION OF THE STORAGE TANKS
AND COLLECTORS COMPONENTS Page 10
INSTALLATION INSTRUCTIONS OF THE STORAGE TANK
AND COLLECTOR ON THE SUPPORT BASE Page 12
CONNECTION INSTRUCTIONS OF THE STORAGE TANK,
COLLECTOR AND COMPONENTS Page 13
FILLING INSTRUCTIONS OF THE CLOSED CIRCUIT
WITH THERMAL FLUID Page 14
DESCRIPTION OF THE PARTS OF THE ELECTRIC RESISTANCE
AND THERMOSTAT - CONNECTION INSTRUCTIONS Page 16
SPECIAL CLIMATIC CONDITIONS Page 18
INSTRUCTIONS AFTER THE INSTALLATION Page 20
TROUBLESHOOTING
REPLACEMENT OF THE MAGNESIUM ROD
INSTALLER INSTRUCTIONS Page 21
InstallatIon InstructIons InstructIons
TO THE END USER AND INSTALLER Page 22
FROST PROTECTION, OvERHEATING,
SNOW AND WIND LOADS, LIGHTNING PROTECTION Page 23
CONNECTION OF MULTIPLE SYSTEMS - TYPICAL INSTALLATIONS Page 24
INSTRUCTIONS FOR STRUCTURAL INTEGRITY AND FIXINGS Page 26
COMMISSIONING FORM Page 27
DECOMMISSIONING & SAFETY Page 28
INSPECTION CHECKLIST Page 29
MEGASUN AROUND THE WORLD Page 30
30 YEARS OF HISTORY Page 31
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TECHNICAL SPECIFICATIONS OF THE COLLECTOR1. External frame : anodized aluminium profile2. Back side : galanized sheet - 0,6 mm3. Back insulation : rock wool 40 mm4. Side insulation : glass-wool of 20 mm5. Absorber : A unique sheet with selectie titanium coating or
with black selectie.6. Absorbers tubes : copper pipes 10 & 22 (risers and headers)7. Coer : solar tempered glass8. Water-tightness : EPDM rubber/transparent silicone
Exe ig : dized miim tk ii : pyehe fm 40-60 mm
cyide mei : w b ee 3mm
Jke mei : w b ee 1,5 mm
cyide ie Pei : g emeig
addii pei : mgeim d
Eei eie : ppe them : bip f f
Pwe e : vibe fm 0,8kw 4kw
TECHNICAL SPECIFICATIONSOF THE STORAGE TANK
HElIoaKMI s.a. eeve he igh hge he peifii f he pd d/ hei eie wih pi ie.
Collector
with titanium
selectie
absorber
Collector
with black
selectie
absorber
EXTERNAL DIMENSIONS - ALL MODELS
1010
120
1275
160
1275
200
2050
200E
2050
260
2050
300
2580
300E
1010
160
02
01A 01B
14
15
16
08
04
09
EXTERNAL DIMENSIONS - ALL MODELS
MEGASUNMODEL
STORAGE TANK COLLECTOR SUPPORT BASE TOTAL WEIGHTDimensions
mmWeight
kg
Dimensionsmm
Collectors SurfaceWeight kg
( )
Weightkg
EMPTYkg (+/-5%)
FULLkg
120 530x1100 52 10 BAR 2050x1010x90 1 2,10 43 10 BAR 26 121 231
160M 530x1320 62 10 BAR 2050x1010x90 1 2,10 43 10 BAR 26 131 281
160 530x1320 62 10 BAR 2050x1275x90 1 2,60 51 10 BAR 27 140 290
200 570x1320 70 10 BAR 2050x1275x90 1 2,60 51 10 BAR 27 148 338
200E 570x1320 70 10 BAR 2050x1010x90 2 4,20 43 10 BAR 28 184 376
260 530x2050 103 10 BAR 2050x1010x90 2 4,20 43 10 BAR 30 219 469
300 570x2050 114 10 BAR 2050x1010x90 2 4,20 43 10 BAR 30 230 520
300E 570x2050 114 10 BAR 2050x1275x90 2 5,20 51 10 BAR 30 246 536
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PACKING OF THE SOLAR WATER HEATER
All MEGASUN appliances (storage tank, collector, support base and connection acce-
sories), are deliered well packed to the customer.
the ge k i ped bewee w d yfm ve f 7 m eh, whih
are tightened on the storage tank with stretch film. Then it is placed in a hard carton
pk, whih he idii f eh mde e dipyed he ide.The collector is packed with 4 plastic protectie elbows, attached on each corner,
which are fast tightened around the collector with a plastic strap (upon special order,the collectors could be deliered in groups of 10 pcs on a wooden pallete).
All the parts of the support base, the plastic bag with the connection fittings, the ther-
mal fluid and other accessories are packed in a carton box, on which the indications ofeach model appear on the outside.
The plastic bag contains all the connection fittings of each appliance like, screws, nuts
f he pp be, bke, pipe i, my pg, ew-, fey vve,
plugs and filling funnel of the thermal fluid.
All the tubes of the storage tank and collectors are coered with plastic plugs, in order
to protect their turns from striking during the transportation.
Mehdie ve de bye epibiiy d ik the peifii f he pd d hei eie hge y ime wih pi ie seeme f y dipe e de he jidii f he f ahe i Geee.
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WHAT YOU SHOULD KNOW ABOUT THE MEGASUN SOLAR WATER HEATER
The advanced technologys MEGASUNSolar water heaters use a closed cir-
cuit of natural circulation. The spe-
cial thermal fluid, used in the closed
circuit, enhances the performance of
the heater, protects it from the freeze
and it prevents the salt scale deposi-
tion inside the tubes of the collector.The closed circuit (jacket) where the
thermal fluid is circulating, is inde-
pendent and does not communicate
with the water storage tank.
I i vey imp he wih he
local representatie of HELIOAKMI,
the right size of the solar water heater,
whih wi ffi y eed.
For a better choice of the appliance, the
local climate conditions must be takeninto a serious consideration, as well as
y eed f h we.
the eegy vig h y wi hve
with the MEGASUN solar water heater,
depends on the use of hot water, theuse of the electric resistance and the
local weather conditions. Under faou-
be wehe dii, he eegy
vig my eh p 100%. o
y dy, he pwe f di-
tion is greater between 10:30am to
15:30pm. For this reason it is better to
hede y hevy mpi fhot water (washing machines etc) in the
midde f he dy.
Dig dy wih w hie d w
mbie empee, we gge y
turn on the electric resistance, in orderto hae hot water all the time.
hot outlet
cold inlet
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INSTALLATION INSTRUCTIONS
Befe y iig he we hee, pee ed efy he i -
lation instructions stated and illustrated in this manual.
Befe he ii f he we hee, i i vey imp h me
and installer agree on all the details concerning the correct and safe installation of
the appliance, such as location, placement point, static resistance and control of the
surface on which the appliance will be placed, piping and wiring run etc.
the pii y wi he f he ii f he we hee, hd be hded by y be (ee, bidig e) d he ye.
the ii hd be de dig he eei d pmbig egi
ppibe i y e.
For optimum performance, the solar water heater must face the south, for countrieslocated in the Northern hemisphere and north for countries located in the Southern
hemiphee. I e h i i y pibe f he we hee fe he
eq, y i wd E p 30o if mj h we dw i befe 2pm,
or towards West up to 30o if mj h we dw i fe 2 pm. I bh e, he
e f he ibi, i me h 6%.
If he we hee m be ied f whee he iii i e h
15o or more than 32o, then a different than the standard equipment of the support
be m be ed, imi he e ed f egi wih yph, hied hevy wid.
F he fe ii f he we hee pig f, i i eeyto install the support base in such a position so that the storage tank to be placed
exy ve f imbe d i e wy bewee w imbe.
If he fe whih he we hee wi be ied (pig f) i
compatible with the standard equipment supplied with each appliance, then a differ-
ent equipment must be used. The installer has to choose, propose and install this
diffee eqipme, wy de he e pii f he me.
F ii pig f, he D pe m be ewed wih he pppie
screws and nuts on the roof timber, in order to secure the right and safe installation
of the solar water heater.
I egi bje hevy wf, i i vey imp ee, h mhsnow doesnt accumulate behind the storage tank, and to check if the supports ofthe standard equipment are good enough to withstand the weight of the expected
w. the me ei m be pid, f egi wih hevy wid d m. I
hee e, he ge k m be ped i be wy he f d m
be igheed wih he ddii me p. I i bey eey e he
yph e (pge 18-19).
the be f he we hee we he d/h we pipig m be veywell insulated.
spei ei m be ke f he fiig d ei f he ed ii.
oy expeieed ehii pvide y wih he ei d he fiig.
Befe fiig he ed ii wih hem fid, he ge k m be mpeey
filled with water.
Befe ig he ii f he we hee, y m ed efy
the instructions, described and illustrated in this manual.
afe y hve fiihed he ii e he e whee he wk k pe.
Fi i he wy wih he eqied dei d hve me ig i. advie
me mi immediey he p f he wy Heikmi s.a.
the ii m mpy wih he d i egi d w (pmb-
ig, eeiiy, hygiee, b d he) h e i fe i y y.
the beve f he ii ed hi m i vey imp d he
-beve my e he vidiy f he wy.
Heiki s.a. deie y epibiiy f y kid, h my ie fm defeedii fm ie mipi fm y eeme eie
that are integrated/fitted on the appliance.
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A
A
B
B
C
C
D
D
D
D
E
E
U
U
Z
Z
A
A
B
B C
C
D
DD
D
F
F
E
E
U
U Z
Z
ASSEMBLY
INSTRUCTIONS
Before choosing the location and the installa-
i pi, ee h i i hded by y
obstacle (trees, buildings etc, see obstacle
diagram page 9).
The same support base is used for either
sloping or flat surfaces.
ce he pe a, B, c, D, u d Z by
screwing them tight as shown in the draw-
ings.
For models 260 and 300, screw also thepe F. sew gey he bottom plate E on
the plates B.
attention
the p pe E i djed fe he pe-
ment of the collectors.
Plumb the support base on the flat surfaces
leel. Place the collector(s), on the support
be d he ew i wih he my pg
and the screw nuts on the concrete, accord-
ig y y egi.
Assembly diagram of
the support base on a flat surface
Support base for
200, 260 & 300
(with 2 collectors)
Support base for 120, 160
& 200 (with 1 collector)
A = 2015 mm
B = 2360 mm
C = 1150 mm
D = 930 mm
D = 1180 mm
E = 840 mm
E = 1150 mm
E = 1430 mm
Z + U
F = 930 mm
SAME FOR
ALL MODELS
FOR MODELS 120 and 160M
FOR MODELS
160-200-260-300
FOR MODELS 120 and 160M
FOR MODELS 160-200
with one collector
FOR MODELS 200-260-300
with two collectors
SAME FOR
ALL MODELS
ONLY FOR
MODELS 260-300
LENGTHS OF THE
SUPPORT BASE PLATES
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D
E
E
U Z
A
BC F
Assembly diagram of the support base
on a surface with maximum inclination of 32
ASSEMBLY INSTRUCTIONS
Before choosing the location and the installation point, ensure
h i i hded by y be (ee, bidig e, eeobstacle diagram here below).
The same support base is used for either slopping or flat
surfaces.
Connect the plates (A) and (C) so that to form a parallelogram
frame, as shown in the drawing.
Bend the four (D) plates as shown in the drawing. Remoe the
tiles, and place the bended plates (D) on the wooden timbers or
on the concrete of the roof.
sew ighy he pegm fme (a)+(c) he pe (D).
Plumb the support base and screw the plates (D) on the woodentimber of the roof (see drawing).
sew he pe (B) he pegm fme (a)+(c). Eeh he pe (B) e ighy ewed he he f he pe
(A).
sew gey he bottom plate E on the plates B.
attention: The top plate (E) is fixed after the placement of the
collector(s).
note: The standard support base can be used also for surfaces
with minimum inclination 15o and maximum 32o.
For smaller or greater inclinations, different equipment is offered.
A
CD
D
C
E
A
BB
E
Z
U
UZ
attention: Exivey d y f he we heeMEGASUN 120 and 160M and for its installation on a ti led rood,
w ddii pe E (840mm egh) e eqied. thee
ddii pe epe he pe c (1150mm egh).
aeivey, f he fmi f he pegm fme, y
e he exiig pe E (840mm egh) i he pe f
he pe c. the pe c (1150mm), by mkig w he
10 whee eqied, wi be ied i he pe f he pe E.
OBSTACLE
TABLE
Latitude Distance between
collector and obstacle
0- 25 A = 1,0 x B25- 35 A = 1,5 x B
35- 45 A = 2,0 x B
45- 50 A = 2,5 x B
50- or more A = 3,0 x B
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01
02A
02
11
12
03
04
13A
07
07
05A
01A01B
08
10
05
06
13
12
13
03
03
0307
19
07
Analytical description of the storage tanks
and collectors components
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16
07
18
20A
20
14A
15
09
0309
14
17A
17A
17
19
07
03
01 Storage tank
01A+B Storage tanks suspension point
(ed y i pdi pe,
ignore them)
02 Filling pipe (for the closed circuit)
02A sfey vve 3 Bar
03 Elbow raccord (4 pcs)
04 Thermal fluid inlet pipe (to the stor-
age tank from the collector) (indica-
i jke)
05 Small connection tube
05A Insulated coer of the small con-
nection tube
06 Raccord
07 Water-tight compression ring
(4 pcs).
08 Hot water outlet pipe
for home consumption
(idii: h e)
09 sfey / -e vve
10 Thermal fluid outlet pipe
(from the collector to the
storage tank)
11 Collector(s)
12 Pipe unions (collector connectors).
oy f mde
with two collectors
13 Bottom left hand collector pipe
13A Pg 1/2
14 Filling pipe for the closed circuit
14A Pg 1/2
15 Cold water inlet pipe
(idii: d ie)
16 Thermal fluid outlet pipe (from
the storage tank to the collector)
(Idii: jke)
17 Top right hand collector pipe
17A Pg 1/2
18 Large connection tube with insula-
tion coer
19 Thermal fluid inlet pipe
(return to the collector)
20 Protectie side coer
20A Face plate
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Before the placement of the collectors on
the support base, loose the screws of thebottom plate E, so that the bottom fin of
he e p ey bewee he
plates E and B.
The top plate (E) is fixed after the
placement of the collector(s).
Place and centralize the collector(s) on
the support base.
F mde wih w e, y me hem eh he by ig he
pipe unions (12), supplied with each appli-ance.
Secure the bottom part of the collector(s)
by screwing tightly the bottom plate E
on the plates B.
Screw tightly the top plate E, on the plates
B, securing the collector(s).
Place the face-plate (20A) on the U, and
secure it under the collector(s).
Then place the storage tank on the two U.
attention
a. Before placing the storage tank on the
w u, hek efy if he pe ud Z e ewed ighy he pe
B.
b. The electric resistance must be on the
right hand side, as we face the appli-
ance.
c. Ensure that the appliance does not tiltfrom one or the other side and that the
tubes (02) and (14) of the storage tank
are ertical on the highest point of the
ge k. ue eeeiy pmb.
E
E
Z
B
20A
Installation instructions of the storage tank
and collector on the support base
Z
B
E
U
U
20A
E
A
12
B
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Connection instructions of the storage tank,
collector and componentsFor models with two collectors, connect
hem by ig he e e(pipe unions) (12), supplied with each
appliance.
Put the plug (17A) on the pipe (17) which
is located on the top right hand side of
the collector (13) and the plug (13A) onthe pipe (13) which is located on the bot-
tom left hand side of the collector, and
use Teflon or oakum for their complete
water tightness.
Screw the elbow raccords (03) on the
pipes of the storage tank (04) and (16)
wih he idii jke d he
pipes of the collector(s) (10) and (19)
epeivey.
afewd ji he m eitube (05) onto (04) and (10) and the
big connection tube (18) onto (16) and
(19) epeivey. Before connecting
the tubes (05) and (18) ensure that
the compression rings (07) have been
placed on the tubes.
Screw the non-return ale (09) on the
inlet pipe (15) of the storage tank (indica-
i: d ie).
ce he d we ppy he
fey/-e vve d he d
we ppy i he ge k i
mpeey fied. Whe y e fiig he
storage tank with water, the outlet of hot
water (08) should be opened. Connecthe h we ppy he ge k
e pipe (08). (Idii: h e).
After connecting all the fittings, check
vey efy ei f hei
complete water tightness.
attention: In regions where the tem-
perature falls bellow zero, ensure that
the connection tubes of the storage tankand collector as well as the hot and
cold water piping to/from the solar water
heater are well insulated.
FOLLOW STEP BY STEP THEINSTALLATION INSTRUCTIONS OF
THIS MANUAL.
ALL THE PLUMBING INSTALLATIONSMUST BE MADE IN ACCORDANCE
WITH THE PLUMBING REGULATIONSAPPLICABLE IN YOUR AREA.
12
17
13A
17A
0307
05
04
10
03
1816
15
09
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1402A
14A02
For antifreeze protection of the
solar water heater, please follow
the ratio of antifreeze protection
stated in the table here below.
Mix well the thermal fluid with water.
Start filling the closed circuit with
the mixture, from the pipes (14)
and (02).
The filling must be done
eivey, fm bh
pipes (14) and (02).
During the filling, we
dvie y hke heyem, h ee
that no air is trapped inside
the storage tank and thecollector.
Continue this procedure until
he e ii i mpeey
full.
the epibiiy f he -
rect use of the antifreeze liquidqiy i f he f he
installer and in no case of Helioakmi
S.A.
the e f we y he iqid my
e he vidiy f he wy.
ANTIFREEZE PROTECTION RATIO TABLE FOR SOLAR WATER HEATERS
Please take into account also to the dilution table on the bottle of the antifreeze liquid.
Filling Instructions of the Closed Circuit with
MODELMEGASUN GASUN MEGASUN MEGASUN MEGASUN MEGASUN MEGASUN MEGASUN
120 x 2.10m2 160 x 2,10m2 160 x 2.60m2 200 x 2.60m2 200E x 4.20m2 260 x 4.20m2 300 x 4.20m2 300E x 5.20m2
CLOSED CIRCUIT
TOTAL CAPACITY9 lt 10 lt. 11 lt 13 lt 18 lt 21 lt 22 lt 23 lt
TEMPERATURE RATIO
- 5C
Water 8 lt 9 lt 10 lt 11,5 lt 16 lt 19 lt 19,5 lt 20,5 lt
Fluid 1 lt 1 lt 1 lt 1,5 lt 2 lt 2 lt 2,5 lt 2,5 lt
- 11C
Water 7 lt 8 lt 9 lt 10,5 lt 14,5 lt 16,5 lt 17,5 lt 18,5 lt
Fluid 2 lt 2 lt 2 lt 2,5 lt 3,5 lt 4,5 lt 4,5 lt 4,5 lt
- 18C
Water 6 lt 6,5 lt 7,5 lt 9 lt 12,5 lt 14,5 lt 15,5 lt 16 lt
Fluid 3 lt 3,5 lt 3,5 lt 4 lt 5,5 lt 6,5 lt 6,5 lt 7 lt
- 20C
Water 6 lt 6,5 lt 7,5 lt 9 lt 12 lt 14 lt 14,5 lt 15,5 lt
Fluid 3 lt 3,5 lt 3,5 lt 4 lt 6 lt 7 lt 7,5 lt 7,5 lt
- 27C
Water 5,5 lt 5,5 lt 6,5 lt 7,5 lt 10,5 lt 12,5 lt 13 lt 13,5 lt
Fluid 3,5 lt 4,5 lt 4,5 lt 5,5 lt 7,5 lt 8,5 lt 9 lt 9,5 lt
- 36C
Water 4,5 lt 5 lt 5,5 lt 6,5 lt 9 lt 10,5 lt 11 lt 11,5 lt
Fluid 4,5 lt 5 lt 5,5 lt 6,5 lt 9 lt 10,5 lt 11 lt 11,5 lt
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20
17A
After the filling of the closed circuit, it is
eey e he pg (17a)
the top right hand of the collector, until it
starts dripping thermal fluid (for models
with two collectors, loose also the toppipe union (12) in order to release the
air from the collector(s). Tighten back the
plug (17A) and the collector connection
(12) and check for their complete water
tightness.
Place the protectie side coer (20).
12
Add some more fluid in the closed circuit,
until it oerflows from the tubes (14) and
(02). Screw the plug (14A) onto the tube
(14) d fix he fey vve (02a)
the tube (02).
chek efy ei f m-
plete water tightness.
Thermal Fluid (for the solar water heaters of closed circuit)
14
02A 14A
02
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DESCRIPTION OF THE PARTS OF THE ELECTRIC RESISTANCE
AND THERMOSTAT21 Plastic coer22 Electric resistance
22A Thermostats socket
22B Resistances coer
23 Base of multiple plug (for the
electric lines)
24 Metal wires for the connections
of the resistance with the ther-mostat25 Rubber flange for water tight-
ness
26 Central nut
27 Tightening nuts
28 Grounding lug
29 Electric resistances lug30 Grounding wire
31 Power wire
32 Multiple plug for power lines
33 Thermostat
34 Temperature control
35 sfey hem wih (idi-
i F s)
CONNECTION OF THE CABLES1. t ff he pwe mi ppy.
2. The coer of the electric resistance is
on the right hand side of the storagetank. Unscrew the screws and remoe
the coer.
3. the hem i djed fm he
fy 60oc. Y dj i
he empee y wih, by ig he
temperature control (34). In that casewe dvie h he empee y wi
fix not to exceed 75oC.
4. chek he fey hem wih (idi-
i F s) he hem.
the fey wih i i pei whe
it is pushed in.
5.RESISTANCE TYPE OVAL:Connecthe g 2 f he hem he g n
of the power line connector (blue cable).
Connect the lug 3 of the thermostat to
he g l f he pwe ie e
(bk be) ee digm bve.
RESISTANCE TYPE ROUND:
Connect the lug 1 of the thermostat to
he g l f he pwe ie e
(black cable). Connect the lug 4 of the
hem he g n f he pwe
ie e (be be) ee di-
gram at page 17.
6. The grounding lug is connected fromthe manufacturer, as shown in the
diagram. Ensure that it is well screwed.
7. Pass the wire through the hole of the
coer (21) and connect the wires on
the power line connector. Screw the
coer (21) on the storage tank.
attention:
the gdig g ( ) on the
power line connector, must be con-
DIAGRAM OF ELECTRIC
CONNECTION OF THE
THERMOSTAT
230 VAC
1 2 3 4
rsIstancE
28
26
34 35
33
24
27
32
31
24
27
2929
23
31
30
1 2 3 4
30
5060
70
80
N L
29
22A
22B 22A
22
25
31
31
RESISTANCE TYPE OVAL
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nected with the grounding wire of the
building
the pwe be m be eed
a switchboard, of which the separatingdistance of the contacts is more than
3mm.
The standard power of the electric
resistance is 2000W for 230v. Upon
a special order, the electric resistance
can be offered with power from 800Wto 4000W. For power of 110v, the
electric resistance is aailable (upon
special order) with power from 800W
to 2000W.
note: a eified eeii m mke he
electric connections.
Ee h he eei ei
mpy wih he eei egi
ppibe i y e d y bid-ing.
D he eei eie,
whe he ge k i empy.
All models 120, 160, 200, 260 and 300
can be deliered, upon a special order,
with a tube heat exchange built-in to the
electric resistance.
The tube heat exchanger can be con-
eed wih he e heig yem f
me eegy vig.
The instructions of the electric connectionsare same to the ones of the electric resist-
ance without a tube heat exchanger.
ELECTRIC RESISTANCE WITH A BUILT-IN TUBE HEAT EXCHANGER
hot water inlet from
the central heating
cold water outlet to
the central heating
DIAGRAM OF ELECTRIC
CONNECTION OF THE
THERMOSTAT
230 VAC
1 2 3 4
rsIstancE
21
36
26
33
30
24
27
32
24
27
2929
23L
31
34 35
28
RESISTANCE TYPE ROUND
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I egi whee hevy wid, yph,
hurricanes and storms are usual, it is
eey e he pei TYPHOON
SET, pvided by HELIOAKMI.
The typhoon set contains:
1. Pe (J) f 1150mm
2. Plates (D) of 930 mm
3. Short fixing plates (L)
4. Long screws - small step nuts
5. Tape of metal belt.
6. Rubber profile
7. My pg - ew
Befe y iig he ppie,
y hd hek he fwig:
F ii f fe, hek
he deiy, hde d egh f
the concrete.
F ii pig f, ddi-
tional rafters must be installed under thetiles, so that the distance between the
rafters doesnt exceed 50 cm, and their
strength must be good enough for the
safe installation of the appliance.
S p e c i a l c l i m a t i c c o n d i t i o n s
To assemble the support base
fw he me emby pede,
mentioned on pages8-9 (for flat or sloping
surfaces).
For the connection of
the plates U, Z and B,
use the long screws -small step nuts.
Befe y dj
the metal belts around
the storage tank, placethe rubber profile
between the storage
tank and the metal
belt.
afe y hve ped he ge k
he pp be, dj he me
belt connecting the one end of the belt
between the screw-nuts, which tightenthe plates U and Z and the other end of
the metal belt between the screw-nuts
which tighten the plates U and B. (see
detail a & b).
attention
Use the second nuts
(O) to tighten the metal
belts. Tighten well the
metal belts on the stor-
age tank.
ASSEMBLING INSTRUCTIONS
J
U
B
J
CD
b
U
B
J
L
a
U
Z
O
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Whe y hve i he ppie
f f, y m e he w
pe J, ewig hem he pe c.
Screw the short plates L on the platesJ. t ew he pe J he pe c
use the long screws - small step nuts.
Screw the short fixing plates L and
pe a he f, ig he mypg f he yph e, we he
4 screw nuts included in the plastic bag
with the fittings. The plastic bag with the
connection fittings is packed in the sup-
port base carton.
F he fe ii f y ppi-
e, we emmed y ee hestorage tank on the support base using
more mettal belts than the ones illus-
trated in the photos.
All the parts and accessories of the
typhoon set are packaged in one car-
ton which carries on the outside the
description TYPHOON SET
For installation on a sloping roof, we
emmed y e me me be,
securing both the storage tank and the
pp be, by ewig hem hetimbers under the tiles. You can also
e he f D pe, by ewig hem
under the timbers.
INSURANCE OF THE
APPLIANCE
I egi whee yph, d,
hurricanes etc occur and hail is larger
than 20mm in diameter, we recommendy ie ie f y ppi-
ance.
When the TYPHOON SET is used, the face-plate (20A) is not placed
J
LA
DD
D
D
D
D
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the we hee wi eh pi-mm pefme w dy fe heii. Dig hee w dy, i irecommended to aoid hot water con-sumption, een if there is sunshine.
chek evey ye he eve f he fid i
the closed circuit. I egi wih f d, we em-
med h y e he g f hee wih we, evey w mh iorder to remoe the dust from the glass,unless there is enough rain.
I e f g dmge, epe heg immediey vid fhe dm-age of the collector.
F we hee, he mi piipeand codes require that the function of thevve i heked e ye. We recommend that during the same periody hek he ew, , pe, my
plugs, screw nuts and support plates, foree y dmge, epeiywhen the appliance is installed near thee. I e f dmge, hey m beeped by we expee.
Dig g bee (h mmehidy), i i emmeded vethe collector(s) with an opaque coer.
oe he ge k i fied i wihwe, i m ge empy (eved)f my h, d y if hee i need for changing the magnesium rodor the electrical resistance for which it isrequired a short time, since there is the
pibiiy f eig k d deh-ments in the internal protection of thestorage tank.
I e whee he we ppy pe-e exeed 6 B i i eey fia pressure reducer.
TROUBLESHOOTING
A. IF THE SOLAR
HEATER DOESNT
SUPPLY HOT WATERWITH
THE SUN1. chek efy he ei f
the solar water heater for leaks.2. Check the fluid leel in the closed circuit
d fi i, if eey (ee ii,page 14).
3. Check the connection tubes (05) and(18) ee h hey e beedor twisted
4. Ensure that there is no air trapped
inside the collector and the storage tank
5. Ensure that the solar water heater isinstalled in horizontal position.
6. Ee h he ppy f h we i eed ppy f d we.
7. chek he pmbig pipig f yhouse as well as the taps for slow
leaks.8. Ensure that the storage tanks and col-
e ei e ppey mded hey e fy we igh.
9. Ensure that there is no obstacle (build-ing, tree etc) shading the solar waterhee, y p f i.
The following should be also taken intoconsideration:10. The consumption of hot water is big-
ge h he ppie piy.11. Weather conditions.12. Huge consumption of hot water during
the night.13. The customer didnt understand the
use of the electric resistance.14. Customers expectations about the
pefme f he yem.If y we hee ie ppy h we, y distributor.
B. IF THE SOLAR
WATER HEATER
DOESNT SUPPLYHOT WATER WITH
THE ELECTRIC
RESISTANCE
1. t ff he pwe ppy dremoe the resistances coer.
2. chek he fey hem wih Fon the thermostat, which has to bepushed in.
3. Check the wiring between the ther-mostat and the electric resistance.
4. chek if he hem i djed
in a lower temperature than thedesired one.
5. chek he eie f y dm-age
6. chek he mi pwe ppy.7. t he pwe ppy ON and
check if the electric wires are prop-ey eed he eev peof the resistance.
A certified electrician must doall the electrical connections and
checkings.
REPLACEMENT OF THE
MAGNESIUM ROD
epe he mgeim d:1.t he pwe ppy ff.
2.Empy he we fm he ge k.3. Remoe the electric resistance and
unbolt the old worn magnesium rodand fix the new one. Fix afterwardshe eei eie fe y hvechecked that the elastic flange is notworn-out. If the elastic flange is worn-out, replace it with a new one.
4. t he we ppy d hekh he k i mpeey we igh.
5. afe he k i mpeey fied,wih he mi pwe ppy.
note:An authorized distributor must do the
replacement of the magnesium rod.The time of the replacement, of themagnesium rod, depends on theqiy f he we.It is recommended that in areas wheretotal dissoled solids (TDS) is up to600ppm, the magnesium rod must beeped evey 5 ye.In regions where the TDS is more than600ppm, the magnesium rod must beeped evey 3 ye.In regions where the TDS is more than1000ppm, the magnesium rod must beeped evey 2 ye.
note: In areas where the total dis-soled solids (TDS) is more than600ppm i i eey i filter
Note:The specifications of the products, their acces-sories (e.g. electric resistances, thermostats,ales, liquid.etc) and their materials are inaccordance with the Greek standards . You mustbe informed and check if the specifications of theproducts and their accessories are in accordancewith the local and national standards and regula-i h ppy i y y. the impe/di -tributor is responsible for the importation, com-mercialization and installation of the products.
HElIoaKMI s.a. i e i ibe f y dm-
ge ed hid pie f y e, has wrong installation of the appliances and theiraccessories, from the non-obseration of theregulations and lows (electrical, urban planning,pmbig, iye) ppyig i y -y/e. I e f defeive pd ppy heem d dii f he wy.
Thank you for choosingour products. Both our distributors
and us assure you that you havemade the right choice.
If you have questions or you need
any further information, pleasecontact your local distributor or
our Headquarters in Greece.
INSTRUCTIONS AFTER THE INSTALLATION
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Local Standards
All Installations must be completed inaccordance with the local regulations
(electrical, plumbing, urbanism and
he) d dd h ppy i y
area.
Ii i he eiy fai m mpy wih he
requirements of AS/NZS 3500.4 (AS/
nZs3500.4.2 ni Pmbig d
Drainage Code Hot Water
sppy syem aepbe si), we y eev dd
and regulations. It is a requirement of AS/
NZS 3500.4 that for a new installation, a
we hee be ied i fe y
whee i he eve f ek, ppey my
otherwise be damaged. Construction,
ii d diig f fe ym mpy wih he bve meied
Standard.
Authorized Person
1. Ii m be mpeed by qified depe ie,
wh hd eev idy iee
or certificates required for the work
completed during the installation
process.2. the em hized pe()
ie ed hgh hi
dme efe iby qified
professional.3. Unless otherwise specified, no part
f he HElIoaKMI yem mybe inspected, repaired or maintained
by ybdy he h hized
person.
Safety
1. At all times installers must adhere topei heh d fey gideie
ied by Wke, d he
eev idy ii.
2. At all times installer is responsible
f hei w fey whie mpeig
installations.3. ude ime hd y
person, qualified or otherwise, attempt
to install an HELIOAKMI solar water
heig yem wih hghy
READING and UNDERSTANDINGhi ii m. F y
qeie HElIoaKMI ff my be
contacted.
Provisions of Safe Tray
It is a requirement of AS/NZS 3500.4 thatfor a new installation, a water heater be
ied i fe y whee i he eve
f ek, ppey my hewie be
damaged. Construction, installation and
diig f fe y m mpy wih
the aboe mentioned Standard.
Instructions for Draining the system
Turn Off The Water Heater
If i i eey ff he we
heater on completion of the installation,
such as on a building site or where the
premises is acant, then:
-swih ff he eei ppy heisolating switch to the water heater.
-Close the cold water isolation ale at
the inlet to the water heater.
Solar Storage Tank Draining
To drain the solar storage tank:
-Close all hot water taps.
-Operate the relief ale release leer -
d e he eve p bk y wi
damage the ale seat.
-Operating the leer will release the
pressure in the water heater.-Undo the union at the cold water inlet to
the solar storage tank and attach a hose
to the water heater side of the union.
-Let the other end of the hose go to a
drain.-Operate the relief ale again.
This will let air into the water heater and
allow the water to drain through the hose.
Warning: the ii my be depressure. Take care when remoing the
solar circuit relief ale, as a sudden
dihge f peized h vp my
be experienced. This discharge will createa sharp sound of apor being released.
Open the heat exchanger drain ale andremoe the plug from the end of the hose.
the ed ii id wi d he he.
Place the end of the hose into a container
d di he ed ii id fm he
heat exchanger.
Note: The heat exchanger can contain
my ie f ed ii id. a
iby ized ie hd be ed
mmde hi m f id.
The closed circuit fluid contains foodgrade additives (rust inhibitor, anti-
freeze agent, colour) and is harmless
to the environment. However, it is
good practice to recover any excess
closed circuit fluid and remove from
site for appropriate disposal.
Instructions to check the Pressure
and Temperature Relief valve
1. F ed p yem, he p
must operate at
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INSTALLATION INSTRUCTIONS
the pipig yem ed he yem i
resistant to rain and moisture. the h wer pipig yem i herm ied.
sk
maximum (snow load) is 2kN/m according toENv 01/03/1991, and v
m(mean wind speed) is
180 km/h.
Disclaimer: This equipment can be installed inareas with snow load alues under 2kN / m andthe wind speed aerage under 180 km/h.
or eqipme be y ied wih fey
ale on the inlet cold water to preent oerprere, d fey vve verheig. there
is oerheating circuit which uses metal pipes(copper, stainless steel or steel) to hot waterexri. thi pipe yem i eed he
exri yem f he eqipme. thi yem
hd e y prbem y her
building material. the yem hd be ed wih mixig vve
draw-off temperature limit of 60 C.
the ii f he yem hd be per-frmed y by hrized ier. cer
should be coered during installation, for exam-ple with the same coer used for transportation.the er wi be fied wih prpyee gy
+ wer, wih ir. afer h, he er
coer can be remoed. To start using the col-er, pe he wer. afer h, y e
the installation. To re-check, please perform thesame procedure.
the peri f he yem r ie eve-ryhig w heked d i rre.The end userhd firm h everyhig i rre.
chek he gke, vve, fiig d herm
ii (repig i if eery). Frhermre,it should check the general state of metallic struc-ture as well, screws and nuts, in order to detecty ype f wer r dmge. thi i epeiy
important in marine enironments. The chargesfrm hee repir wi be he repibiiy f
the owner. If he wer prere exeed 6 br, y m
install a pressure reducing ale. the MEGasun yem hd be ied
close as possible to the place of consumptionf h wer. I i very impr ifrm ed
user, of technical aspects of installation, to agreewih him he dei i hi wy, ere
installation and aesthetics possible, respectingthe appearance of the building where it will beperformed.
the MEGasun yem be ied he
roof, terrace or garden, on a firm surface andrdy, whih de reeive hde f erby
be i y e.
cmpy wih rre regi wer d
eeriiy ii. Keep i mid he dii f wid, epeiy drig emby.
the dmge reig frm fy ii re
vered der wrry.
the k m be f f wer befre fiig heprimry iri r fied wih he he rfer
fluid before connecting the electrical resistancebackup.
afer fiihed he yem ii, mke re
that all leftoer materials used on the installation,re eed, ie hey my e ijry r
damage to third parties. the redig f hi iri m i very
impr, ie i heked, my vid he
wrry.
the pipig yem ed i hi yem i wer-proof and moisture.
a pipe fr dig h wer re hermy
isolated. he m be ed fr h wer driig
the nearest gutter, to aoid damage in materialsor people.
WARNING: THE INSTALLATION SHOULD NOTCOMPROMISE THE STRUCTURAL INTEGRITYOF THE BUILDING ON WHICH IS INSTALLED.
IN THE CASE OF MALFUNCTION
(instructions to the installer)
Ensure that: the ime dii permi he fiig f
he r yem.
there i hdig f he er by y
be d h hey re e frm d. th here i ekge i he ed iri d
that all of the connections, raccords, and pipesre ighy rewed d wer-igh.
If here i mixig vve fr h / d wer i
the outlet of the boiler, please check that it is cor-rey djed d i i fiig.
there i egh iqid i he ed iri fer- k. Drig dy wih high rdii
and normal operation of the pump, the pipes intheir highest points (outlet of collectors) shouldbe warm (be careful with the high heating due tosolar radiation).
there i ir rpped iide he er.
Note: All the connections and the installationsmust be done according to the regulations (electri-, pmbig, rbim d her) h ppy iyr re.
INSTRUCTIONS TO THE END USER
AND INSTALLER
the MEGasun r yem d reqire
the interention of the user. It is recommendedhgh, h fer he fir 15 dy f fiig,
to check the pressure of the closed circuit (collec-tor - boiler) and that the temperatures are at nor-mal leels in relation with the time of the inspec-tion, the sunlight and the Installation Sheet.
afer w yer f fiig, i i remmeded
that a program of annual serice is begun. Themaintenance program is to replace the fluid loopiri d mii he prpri f prpyee
gy, repig he mgeim de d
check the operation of all existing ales If here i brekge f er g, i m
be reped immediey h he brber wii
not be damaged. I dy dii r m rif, i i rem-
mended to clean the glass with a damp cloth, if
he er re diry . I i remmededthat the glass of the collectors are washed ate wie yer wih wer, exep if i fe
rains. afer he ii i mpee, he ier wi
hae to inform the client about the functioning ofhe yem.
I he e f y mfi f he yem, we
recommend the client to contact the installer ashe knows all of the arious parameters and thepossible particular characteristics of the instal-lation.
the vve m be peridiy heked
assure their correct functioning .
the ier wh wi mke he diemby mbe a specialized and certified installor in accord-e wih he i regi h ppy iyr ry. Whe he ii i mpeed
he must leae the place in the same conditionsas before the installation.
Befre pig he yem i peri, he
installer must check all the ales and fittings,including also the loop circuit as well as the mainwater tank.
the fey vve m be heked peridiy
assure their proper functioning If here i dger f fr, pee hek he
loop circuit to confirm if the s antifreeze liquid
conforms with the rules. In case of oerheatingcheck the oerheating ale to assure that theiri i wrkig prpery.
D r he yem peri if he weher
conditions are around 0C. Check the loop circuitd he qiy f he ifreeze iqid. c
the standards of the builder. Deri: drig high rdii d e
he ppy f wer d d empy he yem
Deri: the wer mpi f he y-tem can be withdrawn during high radiations topreve he verheig f he yem.
the he rfer iqid i prpyee gy
Drig perid f prged bee i i rem-mended the collectors to be coered with anopaque coering so that to aoid working unnec-eriy. D e pi meri r g
material for their coer. the yem de e y eeri devie
for freeze protection, because it works with pro-pyee gy.
the verheig prei f hi yem i i
electrical dependent, howeer it should not bedieed frm he eeriiy r wer ppy
network.
INSTALLATION INSTRUCTIONS Instructions to the end user and installer
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Frost Protection
Overheating Snow and Wind loads Lightning protection
I my ie i he wie mhtemperatures fall to well below freezing.
As water freezes, it expands. This can
happen in the copper tubes of the solar
h we e we i he -
lectors can freeze and stretch the tubes
a little. After repeated frosts the tubes
fiy pi, eig i beleaking collector.
There are a few options to consider regar-
ding frost protection:
Frost Dump vales:
F dmp e biy empeeoperated ale that opens when the tempe-
rature of water falls to below 4C allowing
cold water from the tap to replace it.
This cold water is still cold, at around
8C but it will be warm enough to preent
freezing.
For single panel collectors, the frost dumpale should be positioned on either of
the bottom outlets. This is because we
know that warm water rises and therefore
the coldest water will be at the bottom of
e. F ped yem, wfrost dump ales are needed. One for
each collector, positioned at the top and
bottom.
Furthermore, because the water lost
through the ale can become significant
depending on the temperature, it is a good
idea to harest this water rather than lettingit go to waste. This can be as simple as lea-
ding a pipe from the ale down to a bucket.
If y s ce wi be g i
the sun for an extended period of time,
y hd ve he e p-
tect against oerheating and damaginghe e d y s H We
syem. a he diipi devie my be
needed to protect against oerheating
Snow and wind loads are a significant
factor for structural planning. European
norms were established, albeit without
peifiy kig ii iaccount. Wind and snow loads affect the
e d he ii yem.
Depending on the conditions and height of
the installation site as well as the collector
inclination, the mechanical loads on theyem vy ideby. a ee
guidelines for the planning of structural
frameworks and standards EUROCODE
1, (European guidelines for structural
planning). With combined snow and wind
loads the maximum strain for the solarcollector is 1,000 N/m. Note that wind
i pike my f edge.
I i mdy fw be pie
e f i pig,epeiy e-
ted to snow and wind loads. Different
de d egi ppy i diffeecountries and regions. In case of doubt
and/or in absence of exact static calcula-i ( emmeded) wy w f
additional fixtures,weight, anchors, and
ew, epeiy i egi wih kwweather extremes.
If the solar heating equipment protrudes
aboe the roof ridge or the building height
(installation height) exceeds 20 m, and
there is no lightning grounding rod instal-ed, k y eei
e y mpe he f h
d eeiiy he eh bdig
with an electrical earth cable of at least
16 mm
2
.Special measures regarding lightning
protection are not required for building
heights (installation heights) of less 20 m.
Where there is a lightning grounding rod
yem ied, k y eei
contractor to check that the solar heatingyem i ided i he ighig pe-
i yem.
statEMEnt: the die w d fey wih egd f h be eved f he peifi imi dii f eh
y
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PARALLEL CONNECTION OF MULTIPLE SYSTEMS
notes:
1.All the branch lines to the
storage tanks must hae
same length and geom-
ey (dimee f be,
cures etc)
2. Pressure drop (p) must
be almost the same in
hot and cold-water tubes
SERIAL CONNECTION OF MULTIPLE SYSTEMS(It is recommended the installation of maximum fie appliances)
20mm (3/4) 15mm (1/2) 20mm (3/4)
25mm (1)
25mm (1)
COLD WATERINLET
HOT
WATEROUTLET
COLDWATERINLET
HOTWATER
OUTLET
(
3/4)
(
3/4)
In multiple connections
where the electric resist-
e i ed, y hd
aoid connecting the
electric resistance in the
storage tanks of the firsttwo appliances. These
appliances will be used
to pre-heat the water for
the consumption.
For this kind of instal-
lation (or for more than
three solar water heaters
eed i w) y
hae to make a special
eqe f 3/4 ie--lets pipes on the storage
k. We emmed y
to use a maximum of fie
appliances.
All the piping in 20 mm diameter
PARALLEL CONNECTION OF MULTIPLE SYSTEMS IN SERIES
notes
1. All the piping in 20 mm diameter. For this kind of
installation (or for more than three solar water heat-
e eed i w) y hve mke peieqe f 3/4 ie/e pipe he ge
tank.
2. We emmed y e mximm f five ppi-
ances in a row.
COLD
WATERINLET
3
2mm(
11/4)
3
2mm(
11/4)
2
5mm(
1)
2
5mm(
1)
2
0mm(
3/4)
2
0mm(
3/4)
HOTWATER
OUTLET : he bve dwig e ypi dwig f bi piipe.
Y m wy peiized egiee f y w i -
lation.
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TYPICAL INSTALLATION OF MULTIPLE UNITS
notes
1. All the branch lines to the storage
tanks must hae same length and geo-mey (dimee f be, ve e)
2. Pressure drop (p) must be almost the
same in hot and cold-water tubes
3. I e h y hve i e
more solar water heater, the diameter
of the piping must be increased to thenext size.
notes:1.All the branch lines to the storage tanks must hae
me egh d gemey (dimee f be, ve
etc)
2. Pressure drop (p) must be almost the same in hot and
cold-water tubes
COLD WATER
INLET 25mm (1)
25mm (1)
20mm (3/4)
2
0mm(
3/4)
1
5mm(
1/2)
15mm (1/2)
2
5mm(
1)
HOT
WATER
OUTLET
TYPICAL INSTALLATION OF MULTIPLE UNITS
- PARALLEL CONNECTIONCOLD
WATER
INLET
32mm (11/4)
2
5mm(
1)
20mm (3/4)20mm
(3/4)
2
0mm(
3/4)
15mm (1/2) 15mm (1/2)
2
0mm(
3/4)
2
5mm(
1)
3
2mm(
11/4)
HOT
WATEROUTLET
: he bve dwig e ypi dwig f
bi piipe. Y m wy pei-
ized egiee f y w ii.
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INSTRUCTIONS FOR STRUCTURAL INTEGRITY AND FIXINGS
Structural support for solar heatingsystems
Support
Installation on roofs must not produce restrictions
to rainwater flow that enables water to accumulateor pond.
Solar collectors installed above metal roofs must
have clearance between the collector and metalroof to avoid the accumulation of water or organic
matter. On corrugated metal roofing the clearancebetween the collector and the top of thecorrugations must be no less than 25 mm.
In coastal zones, and in locations adjacent toindustrial areas clearance of 50 mm must be
provided to allow access from at least 50% of thesystems perimeter to wash the cladding undersolar collectors.
Clearances must be provided to allow access to
and replacement of, all serviceable components.
The only point of contact between a solar heating
system and metal roof cladding should be wherepenetrations are made.
The load of the solar system must be carried bythe buildingstructure. The solar collector must befixed directly to the building structure and not to the
cladding. Means of mounting are shown in Figures1, 2, 3 and 4.
COMMENT:
Care must be taken to avoid distortion of metalcladding material.
The susceptibility for concrete and clay tiles to
break means that special care must be taken whenworking on and attaching systems to these roofs.
Figure 1: Panel bolt fixing Figure 2: Panel screw fixing
Figure 3: Panel stud fixing Figure 4: Panel stud fixing
All solar collectors must be fixed at no less than 4points.
Solar collectors with an area of up to 4m2, may be
fixed with: 14 gauge screws in accordance with
Figure 2 into the centre of one of:
(a) 14 gauge screws in accordance with Figure2 into:
(i) purlins 70 x 45 mm or larger, that spanno more than 900mm, or
(ii) purlins 90 x 45 mm or larger, that span nomore than 1 100mm, or
(iii) rafters, or
(iv) truss top chords
(b) 10mm galvanised bolts in accordance withFigure 1 to purlins 90 x 45 mm or larger
that span no more than 1100mm
(c) 10mm galvanised bolts welded to 3mm
galvanised plate in accordance withFigures 3 or 4 to either:
(i) rafters, or
(ii) truss top chords.
Where solar collectors with an area of greater than
4m2
to be installed, each group of
panels with an area of up to 4m2
is to be separatedfrom other groups by:
(a) At least one rafter or truss spacing alongthe roof, and
(b) By at least one purlin space up the roofslope
Where collectors are mounted together orseparately on a frame, the frames must meet therequirements described in Paragraph 6.5.
Alteration of roof structure forinstallation
Rafters, purlins and truss members may not be
cut, drilled, notched or otherwise reduced instrength except for drilling for the attachment ofcollectors or tanks.
Mounting of solar systems
Where solar collector panels are mounted aboveroof cladding, they must be mounted so that the
weight of the panels is:
(a) transferred directly to underlying rafters ortrusses with connections conforming with
paragraphs 6.2.9 or 6.2.10, or
(b) transferred directly to underlying purlins
conforming to Paragraph 6.2.8, and
(c) carried by collector support battensconforming to Paragraph 6.5.
All fixings that pierce metal sheeting must beprovided with adequate sealing washers or boots toprevent leakage.
When used with steel roof cladding, fixings must
be zinc coated or galvanised.
COMMENT:
The fixing types and product must be in
accordance with the requirements for fixing usedon normal roofing installations.
Collector support battens
Collector support battens may either:(a) run horizontally across the slope of the roof
as provided for in Paragraph 6.5.3 andFigure 5, or
(b) run up the slope of the roof as provided forin Paragraph 6.5.4 and Figure 6.
Where the collector is mounted on collectorsupport battens the battens must be constructed ofone of the following:
(a) galvanised mild steel with a minimumsection moment of inertia of 0.45 cm
4, or
(b) stainless steel with a minimum section
moment of inertia of 0.45 cm4
, or
(c) aluminium with a minimum section momentof inertia of 1.3 cm
4.
COMMENT:
A steel angle section 30 x 30 x 3 mm or analuminium channel section 25 x 25 mm with 3 mm
wall thickness meets the minimum stiffnessrequirements of Paragraph 6.5.2.
Collector support battens running horizontallyacross the roof slope, as shown in Figure 5, mustbe in one piece and be at least long enough to
span each space between rafters or trusses thathave a collector panel above them. Battens may cantilever up to 200 mm beyond a rafter or truss.The collector support battens are to be fixed using
the details given in Figures 1, 2, 3 and 4 to either:(a) each rafter or truss that they cross, or
(b) To purlins provided the purlins are aminimum size of 90 x 45 mm on their flatand span a maximum of 1100mm.
Figure 5: Collector support battensacross roof slope
Where the collector is laid on collector supportbattens running up the slope of the roof those
collector support battens must be supported asshown by Figure 6 by either:
1) each purlin crossed of a minimum
size of 90 x 45 mm on their flatusing the connection details given
by Figure 1, or
2) by a rafter or truss top chord at notmore than 1500 mm centres and
within 300 mm of each end usingthe connection details given byFigure 2 or by Figures 3 and 4,
and be in one piece
Figure 6: Collector frame up slope ofroof
WARNING: THE INSTALLATION SHOULD NOT
COMPROMISE THE STRUCTURAL INTEGRITY OF
THE BUILDING ON WHICH IS INSTALLED.
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COMMISSIONING FORM
INSTRUCTION
Fr r primry eed yem fy-ed.
Eer key peii dei d djme vribe
1 User instructions explained and handed oer? Yes/No
2 Demmii hede fr er d yider ef ie? Yes/No3 speii miee hede (idig freqey, miee
and list of parts to be replaced during normal maintenance) left on site?
Yes/No
4 a dmei be kep viiby er re preed frm he,water and dust. Name of location where documentation is left.
5 Glazing format of solar collector. Flat
6 abrber ype.
7 Net absorber or aperture area. m2
8 cpy f En 12975 frmiy erie ef ie. Yes/No
9 Manufacturers name.10 Unique serial no.
11 Maximum stagnation temperature of collector. C
12 Maximum design pressure of collector. bar
13 Maximum design pressure of heat exchanger. Bar
14 Mximm deig prere imi f yem. bar
15 li f prere fey devie.
16 Location of electrical fused isolating switch.
17 Fuse rating. Amps
18 Electrical controls? Yes/No19 the he rfer id prvide freeze prei . C
20 type f rfer id.
21 Corrosion inhibitor used?
SYSTEM COMMISSIONING
22 sr primry he exhger ype. Steel Plain
23 sr primry he exhger re. m2
24 Diy sWH d mpi. lire per dy c
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DECOMMISSIONING & SAFETY
The solar system can operate at extremely high temperatures. Please do not attemptto decommission the system yourself, as there is a risk of serious injury.
There is also a risk of electrocution from 240VAC electricity.
1. awy wer pprprie Per PreiveEqipme h gve d eye prei.
2. Eve if he pipewrk er he yider eem
cool, the panels can be at high temperature.Demmiiig hd herefre y be
attempted when there is no solar inpu t, or thepanels should be coered with light proof coersand left for at least 5 hours.
3. Turn off the switched fused spur and remoethe fuse. Leae the fuse holder open and use
a padlock or similar to lock it open. Leae aconspicuous sign stating the power should notbe reconnected.
4. Connect a short length of hose to the drain pointied he we pi f he yem d
pe i iby ized ier d dri
i he pbi ewerge yem. aifreeze
iqid m be diped f rrey.
5. Open the check ale.6. swy pe he dri p. Whe he iii w
reed by prere h pped, pe he ir-ent at the top of the solar pane ls.7. Whe he id h ihed driig, die
the pipework starting at the upper part of theyem. ci here my i be id i he
pipework.8. Dipe f y meri rrey.
9. Pe hd y be remved by qied pr -fei ig pprprie e d fey
equipment.
the w reqire empyer ppi e r mre mpee per i hem i ideifyig d impemeig he preveive d preive me-sures required.
MAINTENANCE SCHEDULE
TO BE SIGNED ON COMPLETION OF COMMISSIONING
Date of site isits for bacterial, water
qiy d e ik eme.
cmmiied by.
Competent persons scheme unique
ideii mbe.
On behalf of.
De yem mmiied dhanded oer.
Signature of commissioning engineer.
sige f e m eeip
and understanding (optional).
MAINTENANCE LOG
Date: nme f egiee/mpy:
Date: nme f egiee/mpy:
Date: nme f egiee/mpy:
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GENERAL DATA
Yes No
Registration no. ..................................................Inspection installation/maintenance
ype f ipei ..................................................
date ..................................................
inspector name ..................................................
SWH user
name ..................................................
address ..................................................
p de, iy ..................................................
phone ..................................................
SWH
brd d ype ..................................................
kid f yem hermyph/fred
circulation
yer f
manufacture
..................................................
Collector
area (m2) ..................................................
number of
collectors
..................................................
ype f er ..................................................orientation ..................................................
slope (o) ..................................................
Backup heating
eergy re eeriiy / g / i
hot water storage iegred / epre k / w
through
brd d ype ..................................................
power in kW ..................................................
VISUAL INSPECTION
Yes No
not
appl.
un-
known
Supporting frame (strong, attached toroof/grouting)
Storage tank (location, no leaks, mate-
rial)
Storage tank insulation (tight, no gaps)
If known: oernight temperature drop
C
Connection of pipes from storage tank
to collector and user points (right posi-
tion, insulation, air release ale, proper
roof penetrations)
Non-return valve (right position)
Positioning of circulation pipes be-
tween collector and tank
(right slope, no sharp bends, air release
ale)
Insulation circulation pipes (complete
length, weather-resistant material, condi-
tion of insulation)
Position expansion tank, vent pipe or
safety valve
Backup heating
a. manual switch (location)
b. thermostat setting C, range C
c. proper electrical wiring
Collector glass cover(clean, no cracks,
water- tight, no condensation)
Absorber(no corrosion, no leaks, paint/
coating in good condition)
INSPECTION CHECKLIST SOLAR WATER HEATERS
TESTING AND MEASUREMENTS
Yes No
not
appl.
un-
known
Hot water outlet temperature C
Circulation with thermosyphon sys-
tems (temperature difference between
h d d ji)
ACTION LIST
P ai eqied By whm
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MEGASUN AROUND THE WORLD
Spain (Canary Isands) Itay (Sardinia) Tunisia
Brazi Kazakhstan Kra
Zimbabw Spain Mauritius
Argntina Nicaragua Jamaica
Rmania India Swdn
Csta Rica Snga Maaysia
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ary 70sDesign of the vertical storagetank with open circuit system
(100. 150 & 200 lt)
1978Vertical storage tank with bothopen and closed circuit system
(100. 150 & 200 lt)
1980Horizontal storage tank with closedcircuit system (160 lt)
1983Horizontal storage tank (made fromstainless steel) with closed circuit
system (120, 160 & 200 lt)
1985Horizontal storage tank with closedcircuit system (with sandwich type
solar collectors- 120 lt)
1988Integrated solar water heaterCompact, with open circuit system
(160 & 200 lt)
1990Horizontal storage tank with closedcircuit system (120, 160 & 200 lt)
1994Horizontal storage tank with closedcircuit system (120,160,200,260& 300 lt)
2000 Floor standing boilers with one ortwo heat exchangers (150, 200,
300, 420, 500, 600, 800, 1000 lt.)
Thirty years of manufacturing Solar Water Heaters,means thirty five years of innovating in the field,
and introducing new technologies.
Three and a half decades of continuous development,
combined with vast experience and extensive research,have established MEGASUN products as leadersin most world markets.
Thousands of MEGASUN Solar Water Heaters aresuccessfully in use in most countries of the world from
Athens to America and from Africa to Australia, to allAsia and Far East and Europe provide continuous and
abundant hot water.
Tday HelIoAKMI nt ny rprsnts highyspciaizd tchngy and th xprinc
f thirty fiv yars, but high quaity systms,which mt th highst dmands.
Some of the countries where MEGASUNSolar Water Heaters are exported.
Germany, Italy, France, Spain, Canaries Islands, Portugal,
Holland, Austria, Belgium, Sweden, Bulgaria, Slovenia, Albania,
Cyprus, Australia, N. Zealand, Oman, Bahrain, U.A.E., India,
Thailand, Malaysia, Indonesia, Philippines, Korea, Argentina,
Brazil, Chile, Bolivia, Venezuela, Aruba, Granada, Martinique,
Nevis, St. Lucia, Dominican Rep., El Salvador, Costa Rica,
Nicaragua, Panama, Malta, Morocco, Tunisia, Egypt, Libya,
Algeria, Senegal, Ghana, S. Africa, Kenya, Botswana, Namibia,
Zimbabwe, Tanzania, Zambia, St. Mauritius,
Reunion, Madagascar and others
WORLD LEADER IN
SOLAR WATER HEATERS
35 YEARS BEFORE
OTHERS DISCOVER
THE POWER OF THE SUN
2010 Solar water heater with closedcircuit.
OVERHEATING
VALVE
HOT
WATER
OUTLET
LATERAL
CROSS-SECTION
COLD
WATER
INLET
FRONT
SIDE
COLD
WATER
INLET
THERMAL
SWITCH
HOT
WATER
OUTLET
THREE-WAY VALVE
WITH THERMO-
STATIC HEADUNDERFLOOR
HEATING
COMPENSATION
ELECTRICAL
VALVE
HEAT
PUMP
Frm th xtnsiv rsarch& th dsign
t th fina prduct
Spac hating and DHW
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