Solar Flat Collector Forced Circulation System
Installation and operation manual
MILLIONSUN ENERGY CO.,LTD
www . millionsun . com
1
List
System Introduction.....................................................................................................3
How it works..................................................................................................................4
Facts you should know about your Millionsun water heater...................................5
Solar thermal structure.................................................................................................6
Solar thermal parts form..............................................................................................7
System installation.......................................................................................................8
Installation instructions................................................................................................15
Maintenance..................................................................................................................16
2
System Introduction
Millionsun provides the latest technology in solar water heaters. Millionsun Collector, with
Germany coating technology, has higher performances than typical water heaters. Millionsun’s
collector has got Solar Keymark certificates.
Millionsun water heaters are so effective that they can save you money anywhere in the world.
How much you save depends on local conditions and your hot water usage patterns. Solar
thermal Series uses a direct heating collector, incorporating state-of-the-art manufacturing
technology to ensure the same quality and finish as the Closed Circuit Series. It is important that
you select the correct water heater for your local conditions and your family's needs.
1.
2.
3.
4.
Flat plate collector.
support, (Material: steel. Surface coating : hot-dip galvanization + UV coating)
Control system.
Solar storage Tank. outside material: paint steel (thickness: 0.5mm); insulation: polyurethane
(thickness: 50mm); inner material: SUS316 (thickness: 1.2mm).
3
How it works
The Closed Circuit Series uses a heat exchanger that operates under the Force Principle.
Solar thermal Series uses a direct heating method that relies upon the Force Principle, but
circulates potable water through the collectors.
The Millionsun collectors absorb solar energy. The low-iron content solar glass allows more
radiation to pass through and be retained than other traditional float glass systems.
Heat is collected directly by the water circulating through the collector. As the water heats
up, it rises by the control system, directly to the storage tank. As the heated water travels
through the storage tank, the cooler water returns to the collectors. This process repeats
until all water in the storage tank is heated.
Tank inner double copper coil work theory.
4
Facts you should know about your Millionsun water heater
Your Millionsun water heater will generate hot water quickly and efficiently. Under normal family
use, it will operate between 60ºC and 70ºC. However, the temperature can exceed them and
under certain circumstances may be as high as 85ºC. This can occur during prolonged periods
of direct sunlight and particularly in summer or long periods of reduced water usage. Extreme
care should be taken under these circumstances.
Check the water temperature before use, such as when entering a shower or filling a bath or
basin, to ensure it is suitable for the application and will not cause scald injury.
We recommend, and it may also be required by regulations, that an approved temperature
limiting device be fitted into the hot water pipe work to the bathroom and ensuite when this water
heater is installed. This will keep the water temperature below 50℃ at the bathroom and ensuite.
The risk of scald injury will be reduced and still allow hotter water to the kitchen and laundry.
WARNING
This water heater is not intended to be operated, adjusted or tampered with by young children or
infirm people. Young children should be supervised to ensure they do not interfere with the water
heater. The removal of the front cover will expose the wiring. It must only be removed by an
authorized or service person. Care should be taken not to touch the pipe work connecting the
solar storage tank and the solar collectors. Very high temperature hot water can be generated
within the solar collectors under certain conditions, and will flow through the pipe work from the
solar collectors to the solar storage tank.
Over- temperature Protection System
The Closed Circuit Series high performance system is able to control the maximum temperature
of the water in the storage tank. These systems contain an in-line ‘Millionsun’ valve, located
between the hot outlet of the collectors and the inlet to the tank heat exchanger. This valve
closes when the tank has reached a sufficiently high temperature, thereby preventing further
heat transfer to the tank, and thus limiting its temperature to more acceptable levels.
External pipe insulation
Where potable water piping is at an external location or attic space where the temperature can
be as low as -7°C (18°F), it must be insulated with a minimum ¾” Armaflex (or similar) flexible
elastomeric closed cell thermal insulation. Where the temperature can fall to -11°C (12°F), the
insulation thickness must be increased to 1 ½”. Insulation in external locations can deteriorate
through UV radiation. To prevent this, a layer of outdoor UV stable paint or other similar
protective coating must be applied to the insulation.
5
Solar thermal parts structure
FLAT PLATE COLLECTOR
1. Sealing gasket: EPDM
2. Frame material: Aluminum alloy
3. Glass sealing rubber (up): EPDM
4. Glass: Textured tempered glass with low iron content (Thickness: 4mm)
5. Glass sealing rubber (down): EPDM
6. Side Insulation material: rockwool (thickness: 50mm)
7. Copper pipe: TP2 (diameter: φ22mm; thickness: 1mm)
8. Absorber: blue (German bluetec, copper strip surface treatment: high selective titanium coating)
9. Insulation material: rockwool (thickness: 50mm)
10. Back Plate: Aluminum sheet (thickness 0.5mm)
11. Sensor install hole
SOLAR STORAGE TANK
12. T.P valve (temperature protect < 90 ℃; pressure protect <
0.4MPa)
13. Outlet pipe (from tank to home): G3/4”
14. Up Copper coil
15. Sensor install hole I
16. Sensor hole II
17. Electrical heater: 1.5Kw
18. Below Copper coil
19. Inlet pipe (from home to tank): G3/4”
20. Drainage
Type
A-FC500/8
A-FC400/6
A-FC300/4
A-FC200/3
A-FC150/2
system
Weight
tank
Dimension
Weight
Volume
(Kg)
(mm)
(Kg)
(L)
310
250
180
160
120
Φ 700 X 1950
Φ 700 X 1580
Φ 520 X 2230
Φ 520 X 1470
Φ 520 X 1180
96
83
63
56
43
500 L
400 L
300 L
200 L
150 L
quantity
1
1
1
1
1
collector
Dimension
Weight
Area
(mm)
(Kg)
(m2)
2000X1010X95
2000X1010X95
2000X1010X95
2000X1500X95
2000X1010X95
144
113
72
62
36
8.08
6.06
4.04
3
2.02
quantity
support
Weight
(Kg)
4
3
2
1
1
48
42
36
28
25
accessory
copper
fitting
1 sets
1 sets
1 sets
1 sets
1 sets
Control
system
Expansion
vessel
（24L）
1 sets
1 sets
1 sets
1 sets
1 sets
1 sets
1 sets
1 sets
1 sets
1 sets
Solar thermal parts form
Parts
Collector
Tank
T.P Valve
6
Control system
Expansion vessel (24L)
A-FC500/8
A-FC400/6
A-FC300/4
A-FC200/3
A-FC150/2
4 pcs
3 pcs
2 pcs
1 pcs
1 pcs
Parts
1 set
1 set
1 set
1 set
1 set
1 pcs
1 pcs
1 pcs
1 pcs
1 pcs
1 set
1 set
1 set
1 set
1 set
Support
1 set
1 set
1 set
1 set
1 set
Support bolts
Bolt
Rubber
Stainless
( M8 X 20 )
gasket
gasket
support feet
A-FC500/8
A-FC400/6
4 pcs
3 pcs
4 pcs
2 pcs
16 pcs
12 pcs
56
36
112
72
112
72
no
no
A-FC300/4
3 pcs
2 pcs
8 pcs
28
56
56
no
7
A-FC200/3
A-FC150/2
2 pcs
2 pcs
2 pcs
2 pcs
4 pcs
4 pcs
Parts
16
16
32
32
32
32
no
no
Copper pipe fitting
A-FC500/8
A-FC400/6
A-FC300/4
A-FC200/3
A-FC150/2
Fitting 1
Fitting 2
Fitting 3
Fitting 4
8
6
4
2
2
2
2
2
2
2
4
4
4
4
4
1
1
1
1
1
Valve 2
1
1
1
1
1
System installation
1.
Support feet installation on the tile roof
Remark: this part not include in the support system, customer need buy this part from local
market
Paint steel poof
installation
2. Installing
the
support on the
support feet
3.
Installing
the
collector
support
on
the
support
8
Warning: Don’t damage surface bracket parts coating during installation process
In order to protect coating of the bracket
surface, fix the part as shown below.
Paint steel poof installation
4. Put the collector on the support
Paint steel poof
installation
show
9
5. Installing the collector copper fitting
6. Installing the collector copper circulation pipe, air valve and sensor
Remark: air valve not include in the system, customer need buy this part from local market
10
7.Fix the flat plate collector
8. Putting the
tank on the
floor
9. Installing the T.P valve
T.P valve protects
thermal
system
working
under
pressure
and
temperature.
solar
from
high
high
Detailed information:
Temperature & Pressure Safety Valves can lower the temperature and
reduce pressure automatically, have temperature and pressure double safe protection function; it
is the security protector bearing the pressing type hot water device at present according to
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American National Standard ANSIZ21.22 and Australian standard ASI1357.1, LN938.
MODEL
MS--15
MS--20
Import / Export
(in)
R1/2*RP1/2
R3/4*RP3/4
A
(mm)
41
42
B
(mm)
82
83
D
(mm)
29
29
T
(mm)
101
100
Weight
(g)
237
258
Temp.steam
BTU/hr
15,000
100,000
Basic Parameter:
Exactly make the pressure: 0.4MPa
Exactly make temperature: 90ºC
Warning: for normal condition of work the Temperature & Pressure Safety Valves should
be installed on the water heater top or side
10. Installing the control system (please read the control system installation manual carefully)
11. Connecting the control system and the expansion
vessel
12. Connecting the circulation pipe with the tank
12
13.
Connecting the sensor and the electricity heater wire
13
14. Connecting the secondary pipe for tank, maxing valve and showers
1. Maxing valve; 3.Showers;
15. Copper fittings installation
14
Warning
1. Connecting the flat collector with the copper fitting
Warning:
Photo 5
Shows
wrong
installing
method
which will
make
collector
copper pipe
circumvolve
and will
break
collector
welding
2. Check your product is not inclined or poorly balanced. The tank should always be
leveled.
Installation instructions
For optimum performance, the heater should be installed facing the equator (South in the Northern
Hemisphere, North in the Southern Hemisphere). Deviation from the equator of up to 45º East or
West has little effect on total annual solar contribution (approximately 5 per cent). If it is not
possible to face the equator, the decision of either an easterly or westerly bias must be made. If
the majority of hot water usage is before 2 p.m. favor an easterly bias. If the majority of hot water
usage is after 2 p.m. favor a westerly bias.
Ideally, the heater should be installed on a pitch equal to the geographic latitude of the place of
installation. However, variation in the pitch to within 20° of the latitude will have little effect on the
total annual solar contribution (nominally around a 5 per cent reduction). The minimum allowable
angle of pitch of the heater is 10°, to ensure sufficient pitch for thermosyphon and glass cleaning. If
it is necessary to face the solar hot water heater 45° to either the East or the West, a lower pitch
installation will give better performance. In such cases, the addition of a third panel to the system
15
may be more aesthetically, economically and thermally beneficial than mounting the heater on roof
brackets to face the equator.
THE HEATER MUST BE INSTALLED ON AN ADEQUATELY SUPPORTED AREA OF ROOF, as
close as possible to the most frequently used hot water outlet, or existing water heater system in
retrofit installations. The heater must be installed in an area that is free of shade all year round.
Ensure that trees do not shade the heater, particularly in winter.
Maintenance
Should your Millionsun solar water system not provide hot water, please check the following
before requesting a service call:
1) Shading from trees is not excessive and is not covering the collectors for all or part of the day.
2) Hot water usage is not excessive.
3) Hot water is not leaking from within the plumbing system.
Contact your local Millionsun dealer if all of the above have been checked and there is still no hot
water.
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