FireBird CPK 7210 N, Manual

Page 1: ...GUIDE TO SOLAR THERMAL SYSTEMS Working towards a greener planet ...

Page 2: ...em Design 14 4 0 Stagnation 19 5 0 Safeguard Against Legionella 20 6 0 System Schematics 21 7 0 Health and Safety Information 25 8 0 Transport and Storage 26 9 0 Installation 27 10 0 Commissioning 38 11 0 Maintenance and Service 39 Spare Parts 40 Firebird Solar Warranty 43 2 ...

Page 3: ...rdance with building regulations and must comply with health safety requirements APPROVALS CERTIFICATIONS All components used on the Firebird solar thermal systems are approved to relevant standards Firebird solar collectors are tested to EN 12975 and are approved under the globally recognised Solar Keymark DIN Geprüft schemes Firebird solar systems are also approved under the Irish NSAI agrément ...

Page 4: ...o 90 in the summer and up to 30 in the winter on average this equates to approximately 50 70 reduction in your hot water heating costs annually Environment Households create almost 30 of all CO2 emitted in Ireland and the UK As a result of installing a Firebird solar collector the emission of CO2 into the earth s atmosphere is reduced by approximately 1 tonne Energy Independence With decreasing re...

Page 5: ...system could provide the total energy needs for heating all your water 1 3 Application of Solar Systems Solar Systems can be used for a number of applications which in turn have varying return periods Domestic hot water heating is the common use for solar energy Energy consumption for hot water demands accounts for 6 of the total national delivered energy use Space heating solar thermal systems ca...

Page 6: ...h Orientation The azimuth angle is the angular distance between due south and the point in the horizon directly below the sun Optimum performance is achieved when the azimuth is equal to 0 i e south Collectors installed with angles of 40 east and 40 west of south show little variation in their performance However when a system is installed outside the parameters above compensation factors need to ...

Page 7: ...or larger systems installed in series of parallel it is essential that sufficient distance is allowed between the collectors Wind Loads The collectors and fixing bracket systems are designed to cover all Irish and the UK wind zones However in high wind load areas e g at excessive heights or very exposed areas additional roof fixing brackets may be required To minimise the effect of wind load on th...

Page 8: ...45 W mK on the back of the absorber protects the heat collected and aids against heat loss A sheet of 3 2mm toughened glass covers the collector as it faces the sun and this helps to prevent most of the convection losses Furthermore it reduces heat radiation from the absorber into the environment in a similar way as a greenhouse does Figure 2 1 Cross section of Firebird CPK7210 N Flat Panel Collec...

Page 9: ...bar 10 Stagnation temperature C 216 Contents L 1 4 Angle of inclination permitted 15 to 75 Flow rate 0 5 to 1 5 l min per m2 of aperture Solar anti freeze fluid Tyfocor L or equivalent Performance Data Aperture Area Absorber Area Zero loss collector efficiency η0 74 1 81 8 Annual energy yield kW m2 525 579 Collector heat loss coefficient a1 W m2 K 3 29 Collector performance ratio a1 η0 W m2 K2 0 0...

Page 10: ...e a U shaped pipe within the inner tube absorber of each solar tube The selective coating on the inner tube converts solar energy into heat energy and transfers heat to the copper U tube by means of a close fitting aluminium plate The heat transfer fluid usually glycol water antifreeze mixture in the U tube is heated and conducts the heat energy to the water inside the storage tank through a plate...

Page 11: ...r 10 Stagnation temperature C 286 Contents L 1 63 Angle of inclination permitted 15 to 75 Flow rate 0 5 to 1 5 l min per m2 of aperture Solar anti freeze fluid Tyfocor LS or equivalent Performance Data Aperture Area Absorber Area Zero loss collector efficiency η0 60 5 60 5 Annual energy yield kW m2 529 Collector heat loss coefficient a1 W m2 K 0 850 Collector performance ratio a1 η0 W m2 K2 0 010 ...

Page 12: ...aporate at temperatures as low as 25 C Solar energy is absorbed onto the absorber surface on the glass tube and then transfers to the heat pipe causing the alcohol type fluid to heat up and turn to vapour As the fluid evaporates it rises to the top of the heat pipe known as the condenser section Here it condenses back to a fluid state and releases latent heat which is transferred to the heat excha...

Page 13: ...sure bar 6 6 Stagnation temperature C 200 200 Content L 1 6 2 3 Angle of inclination permitted 15 to 75 15 to 75 Flow rate 0 5 to 1 5 l min 0 5 to 1 5 l min per m2 of aperture per m2 of aperture Solar anti freeze fluid Tyfocor LS Tyfocor LS or equivalent or equivalent Performance Data Aperture Area Absorber Area Zero loss collector efficiency η0 73 4 85 0 Annual energy yield kW m2 525 529 Collecto...

Page 14: ...g installations are also acceptable and will only incur minor losses Avoid shadowing of the collectors from trees or nearby buildings Make sure that there is enough free space on the roof to fit the intended collector area bearing in mind position of roof windows chimneys etc 3 1 Overview of System Sizing To design a solar system the following steps should be followed 1 Calculate the Domestic Hot ...

Page 15: ...hlights a generic method of calculating hot water storage requirements and a more accurate calculation based on water temperatures Basic Rule of Thumb Typical sizing 5 People 40 litres person day 5 x 40 200 litres Daily Hot Water demand 200 litres x 2 400 litres storage volume Ref CIBSE Advanced Calculation Method To accurately size the required storage volume the following calculation can be used...

Page 16: ...ware Guidance values The table below outlines guidance on number of persons to recommended collector areas and DHW tank sizes No of persons Number of collectors Tank size litres 2 x CPK7210 N Flat Panel collectors 2 4 2 x CVSKC 10 Vacuum Tube collectors 200 30 or 40 TZ58 1800 heat pipes 3 x CPK7210 N Flat Panel collectors 5 6 3 x CVSKC 10 Vacuum Tube collectors 300 40 or 60 TZ58 1800 heat pipes Ir...

Page 17: ...ase note the following in relation to solar pipe insulation Avoid leaving pipes or connections un insulated except for the spur line to the expansion vessel For outdoor pipe work the insulation must stand up to environmental degradation air pollution UV radiation rain snow etc and degradation by animals birds mice etc To prevent moistening the insulation should be made of a closed cell material se...

Page 18: ...it and the pipe should be un insulated A guideline calculation for solar expansion vessel is as follows Basic Rule of Thumb Expansion vessel m2 collector x 1 litre solar fluid x 4 FETAC Guidelines Advanced Calculation Method Expansion vessel Total system volume x 25 Intermediate vessel The Eurpoean VDI 6002 directive recommends that an intermediate cooling vessel is installed when the contents of ...

Page 19: ...tion These include a 6 bar pressure release valve and a pressure vessel These should be installed as per the instructions on the return line off the pump station Also supplied is a solar fluid which is an anti freeze and inhibitor withstanding temperatures of up to 200 C and temperatures as low as 25 C Additional options available to an installer with a Firebird solar system A holiday function in ...

Page 20: ...ses are unoccupied for any length of time before using any hot water The water system should be flushed out on a regular basis to prevent the water from stagnating The Firebird differential controller has an anti Legionella function built in This function must be connected to a Second Relay R2 to enable it to operate by means of motorised value or immersion The function enables the controller to r...

Page 21: ...temp sensor 7 Pump station 7A Pressure relief valve 7B Expansion vessel 7C Intermediate vessel if needed 8 Controller 9 DHW tank sensors Please Note The following system schematics are concept designs and are only intended as a guide to installers They are NOT full system design drawings Installers must always calculate and design the system requirements for each individual installation SYSTEM SCH...

Page 22: ...en vented cylinder 3 Temp sensor after heating 4 Cold water tank 5 Solar collector 6 Collector temp sensor 7 Pump station 7A Pressure relief valve 7B Expansion vessel 7C Intermediate vessel if needed 8 Controller 9 DHW tank sensors 10 Isolating valve 11 Air vent SYSTEM SCHEMATICS ...

Page 23: ... DHW tank 3 Temp sensor after heating 4 Cold water tank 5 Solar collector 6 Collector temp sensor 7 Pump station 7A Pressure relief valve 7B Expansion vessel 7C Intermediate vessel if needed 8 Controller 9 DHW tank sensors 10 Isolating valve 11 Air vent East West SYSTEM SCHEMATICS ...

Page 24: ... 2 DHW tank for boiler 3 Temp sensor after heating 4 DHW tank for solar 5 Solar collector 6 Collector temp sensor 7 Pump station 7A Pressure relief valve 7B Expansion vessel 7C Intermediate vessel if needed 8 Controller 9 DHW tank sensors 10 Isolating valve 11 Air vent SYSTEM SCHEMATICS ...

Page 25: ...Do not open or attempt to service the panels There are no user serviceable parts inside All solar packaging is recyclable so please dispose of it in an environmentally friendly way Firebird site risk assessment documents are to be used in conjunction with all other safety documents and relevant standards Wear safety shoes when carrying out installation work If no mechanical fall protection or fall...

Page 26: ...Heat Pipe Solar collectors should remain in their respective boxes in normal storage position during transport and storage Cylinders should be transported and stored vertically All other solar system components should be stored in a clean dry frost free environment until ready for installation Heavy goods should never be loaded on top of solar collectors or kit boxes Parts should be inspected for ...

Page 27: ...or into last collector on the flow side Locate and install solar tank Install pump station Wire solar controller Complete all pipe work on the solar circuit and back up heating circuit using all the necessary components such as air vent anti scald mixing valve lightning diodes etc Complete all electrical connections including collector sensor Fill and purge system If using TZ58 1800 install heat p...

Page 28: ... sure that you have suitable lifting equipment and safety harnesses Please note the following Never lift the collectors by the connections or the screw threads A special kit is available for carrying and lifting flat plate collectors please contact the Firebird sales office for more details Do not expose the collectors to direct sunlight until the installation is complete Firebird provide special ...

Page 29: ...des so a 3 4 brass union is required to connect the manifolds together 3 4 brass union for connecting TZ58 1800 manifolds Collectors can be connected in series of up to a maximum of Six collectors in series for the CPK7210 N Flat Panel Collector Eight collectors in the case of the CVSKC 10 Vacuum Tube Collector Up to a total of 100 tubes for the TZ58 1800 Heat Pipe Solar collectors As shown on the...

Page 30: ...n birds rain snow etc High temperature insulation must be used on all solar pipe installations Sensor pocket locations The following outlines the location of sensor pockets with respect to each Firebird solar system Collector sensors should always be inserted to the flow side of the manifold TZ58 1800 Heat Pipe Solar Collector sensor pocket located on left hand side of manifold CPK7210 N Flat Pane...

Page 31: ...elt When penetrating through the roof felt care must be taken to maintain the weather tightness of the membrane Use only tried and tested products as shown below Glidevale G1 roof vent NSAI BBA approved Roof flashing for slate roof Roof flashing for tiled roof When passing a solar pipe through the felt membrane use a sealing collar Example KLOBER Outlet Sealing Collar IAB approved Make right any d...

Page 32: ...olar cylinders have a purpose designed solar heating coil at the base of the cylinder which ensures maximum heat input and efficiency from the solar energy while the back up heating system boiler will heat the hot water via the upper coil The cylinder is fitted with bosses to accommodate solar sensor pockets to enable correct heat control on the solar system The solar tank should be sized accordin...

Page 33: ...lve for filling and flushing the system Pressure relief valve PRV Pressure gauge Connection for expansion vessel Wall mounting bracket with screws and dowels The following connections need to be made to the solar pump station Flow and return lines linking the solar collector and storage tank Expansion vessel connection An optional kit is available which includes a flexi pipe wall bracket and check...

Page 34: ...the water in the bottom of the storage tank and the fluid in the solar collectors When the fluid in the collectors is 6 C factory set warmer than the coolest water in the storage tank there is usable heat to be collected The controller starts the pump and when the temperature difference drops to within 4 C factory set the controller stops the pump The pump remains off until a useful temperature di...

Page 35: ... safety shut off Drainback options Additional anti freeze functions Easy to use holiday function Anti legionella control In addition the controller has a second available relay that facilitates features such as Back up heat source available for central heating or immersion connection Timer set up for back up heat source heating Surplus energy usage More advanced controllers are available including...

Page 36: ...on vessel As with any sealed system the pumped circulation solar system has to have an expansion capability to cope with fluid expanding as the temperature increases A suitably sized expansion vessel must be selected large enough to accommodate the content of the collector when steam forms stagnation This is to ensure that no heat transfer medium can escape from the safety valve Installation of ex...

Page 37: ...ational phases 9 9 2 Intermediate expansion vessel High temperature fluid in the expansion vessel for long periods of time has the effect of shortening its useful life ultimately causing premature failure of the diaphragm To avoid this situation an additional flow through expansion vessel is recommended when the fluid volume between the collector and the expansion vessel is approx 50 or less than ...

Page 38: ...approx 15 minutes When the filling pump is running the flushing valve is closed and the system pressure is set to around 4 bar Pressurising the system to 4 bar will force solar fluid into the expansion vessel this lines the walls of the expansion vessel and the membrane of the vessel that separates the pressurised air from the solar fluid The solar fluid inhibitor properties will protect and prolo...

Page 39: ...the scale the glycol should be changed Frequent overheating of the solar fluid stagnation causes the glycol to disintegrate into acids leading to corrosion of the solar collector pipework 11 0 MAINTENANCE AND SERVICE Firebird householder installation manuals should be completed on commissioning and left adjacent to the pump station This document facilitates warranty and service record completion s...

Page 40: ...In Roof Mounting Kit Tile Roof 2 CPK7210 N Flat Plate collectors SOL512TRF In Roof Mounting Kit Tile Roof 1 extra CPK7210 N Flat Plate Collector SOL513SRS In Roof Mounting Kit Slate Roof 1 extra CPK7210 N Flat Plate Collector Sales Code DESCRIPTION SOL102FMT Flat Roof Kit 2 CPK7210 N Flat Plate collectors SOL104FMT Flat Roof Kit 1 extra CPK7210 N Flat Plate Collector SOL152VMT Flat Roof Kit 2 CVSK...

Page 41: ...lexible pre insulated twin pipe with UV protection sheath for linking collectors to solar tank Saves considerable installation time and money Sales Code DESCRIPTION SOL010TWP Insulated Twin Pipe DIN16 10m SOL015TWP Insulated Twin Pipe DIN16 15m SOL025TWP Insulated Twin Pipe DIN16 25m STAINLESS STEEL INSULATED TWIN PIPE Sales Code DESCRIPTION SOL505EXP Intermediatory Vessel 5 litre SOL512EXP Interm...

Page 42: ...ors SOL170BLT Coach bolts for TZ58 1800 Heat Pipe Solar Collector SOL163VHP Single TZ58 1800 Heat Pipe SOL155VTC Single CVSKC 10 Vacuum Tube Sales Code DESCRIPTION SOL001ELB 1 Male to 22mm Compression Fitting for CPK7210 N Flat Plate Collector SOL001FEM 1 Female to 22mm Compression Fitting for CPK7210 N Flat Plate Collector SOL075ELB 3 4 Male to 22mm Compression Fitting for CVSKC 10 Vacuum Tube Co...

Page 43: ...laims must be made within the above stated time limits The solar system must be installed in accordance with the Firebird installation instructions and all relevant standards and codes of practice The solar system must be commissioned by qualified person s The Firebird warranty commissioning card must have been completed and returned to the Firebird service department immediately after the system i...

Page 44: ...ed and described in this publication at any time Whilst every care has been exercised in the production of this catalogue Firebird cannot accept any liability for errors or omissions For the latest details always consult Firebird Revision 3 18 09 2011 Print Date 18 09 2011 United Kingdom FIREBIRD UK Central Avenue Lee Mill Industrial Estate Nr Ivybridge Devon PL21 9PE t 44 0 1752 691177 f 44 0 175...