Interplast Green Line 801 Manual

Technical Bulletin - Solar water heaters installation and

maintenance manual

Interplast Green Line Interplast Green Line

Interplast Green Line Plus

801 – Strip 1,25 m2

120 – Strip 1,5 m2

150 – Strip 2 m2

170 – Strip 2 m2

200 – Strip 2 m2

270 – Strip 2,5 m2

300 – Strip 2 x 2m2

170 – Full Face 2 m2

202 – Full Face 2,2 m2

205 – Full Face 2,5 m2

270 – Full Face 2,5 m2

300 – Full Face 2 x 2m2

100L

150L

200L

5 years Guarantee

The Fully Integrated – Certified Solar Proposal!

Technical bulletin - Solar water heaters installation and maintenance manual

- Interplast Green Line

Index

1. Solar water heaters Interplast Green line…………………….…………..……………………………….3

1.1. General Information.....……………………………………………………………………………………………..3

1.2. Solar water heaters models ……………………………………………………………………………………….3

2. Technical features of the components of the Solar Boiler…………………………………………4

2.1. Selective collector Strip………………………………………………………………………….………………….4

2.2. Selective collector Full Face……….……………………………………………………………………………...6

2.3. Vacuum Tube……………………………………………………………………………………………………………8

2.4. Hot water cylinder…..………………………………………………………………………………………………..9

2.5. Foldable Bracket for Terrace…..………………………………………………………………………………..10

2.6. Tile Roof Mounting System…….………………………………………………………………………..………12

3. Basic Manual for Solar Water Heater Installation…….…………………………………………….13

3.1. Foldable Bracket for Terrace (Interplast Green Line Strip & Full Face)…..………..……………14

3.2. Terrace base (Interplast Green Line Plus – Vacuum)…………………………………………………..16

3.3. Tile Roof base (Interplast Green Line Strip & Full Face)……..……………………….………………17

3.4. Tile Roof base (Interplast Green Line Plus - Κενού)…………………………….………………………18

4. Hydraulic connection……………………….………………………………………………………………………..20

5. Filling – Emptying of the Solar Boiler………………………………….…………………………………….21

6. Electrical Resistance………………………….………………………………………………………………………22

7. Possible Problems / Solutions…….……………………………………………………………………….……23

8. Solar Boiler Accessories…………………………….………………………………………………………………23

Technical bulletin - Solar water heaters installation and maintenance manual

- Interplast Green Line

1. Solar water heaters Interplast Green line

1.1 General Information

During the production, all the certified procedures are followed and are used superior quality materials. The

solar water heaters have Solar Keymark certifications, CE, TUV and EKEFE Democritus.

The solar water heaters are of the highest standards, ensuring the best operation. The innovative design of

the automatic base (patent No 2011011633) ensures quick, easy and safe installation and any mistakes are

easily avoided.

1.2 Solar water heaters models

Solar Water heater Collector Hot water cylinder

Interplast Green Line 801 Selective Collector 1,25 m2

(Strip) 80 L (79L*)

Interplast Green Line 120 Selective Collector 1,5 m2

(Strip) 120 L (107L*)

Interplast Green Line 150 Selective Collector 2 m2

(Strip) 150 L (132L*)

Interplast Green Line 170 Selective Collector 2 m2

(Strip) 170 L (152L*)

Interplast Green Line 200 Selective Collector 2 m2

(Strip) 200 L (194L*)

Interplast Green Line 270 Selective Collector 2,5 m2

(Strip) 270 L (255L*)

Interplast Green Line 300 Selective Collector 2 x 2 m2

(Strip) 300 L (294L*)

Solar Water heater Collector Hot water cylinder

Interplast Green Line 170 Selective Collector 2 m2

(Full Face) 170 L (152L*)

Interplast Green Line 202 Selective Collector 2,2 m2

(Full Face) 200 L (194L*)

Interplast Green Line 205 Selective Collector 2,5 m2

(Full Face) 200 L (194L*)

Interplast Green Line 270 Selective Collector 2,5 m2

(Full Face) 270 L (255L*)

Interplast Green Line 300 Selective Collector 2x 2 m2

(Full Face) 300 L (294L*)

Solar Water heater Collector Hot water cylinder

Interplast Green Line Plus

100L 10 Vacuum Tubes 100 L

Interplast Green Line Plus

150L 15 Vacuum Tubes 150 L

Interplast Green Line Plus

200L 20 Vacuum Tubes 200 L

Technical bulletin - Solar water heaters installation and maintenance manual

- Interplast Green Line

2. Technical features of the components of the Solar Water Heaters

2.1 Selective collector Strip

Selective absorber made from aluminum strip sheets for higher performance in low temperatures.

Frame from painted aluminum for high resistance to corrosion (wet climates, coastal areas).

Back from anodized aluminum sheet for high corrosion resistance (humid climates, coastal areas).

30 mm thick rock wool insulation on the back and 15mm thick on the sides for higher

performance at low temperatures.

Vertical copper pipes (risers) Ø10 x 0.4 mm

Horizontal copper pipes (headers) Ø22 x 0.7 mm

Collector’s glazing made of 4mm prismatic security glass (securit), mistlite solar, with high

transmittance and low reflectivity.

Dimensions – Weight – Collector’s Surface

Height Width Weight Surface

(m) (m) (kg) (m2)

0.95 1.25 24 1.25

1.50 1.00 27 1.5

2.00 1.00 36.5 2

2.00 1.25 41 2.5

Technical bulletin - Solar water heaters installation and maintenance manual

- Interplast Green Line

Green Line Collector

1,5 m2 2,0 m2 2,5 m2

Dimensions (Length x Width x

Height )mm 1501x1007x87 2006x1007x87 2008x1258x87

Aperture area (m2) 1,35 1,83 2,31

Absorber area (m2) 1,34 1,81 2,30

Absorber Selective aluminum Selective aluminum Selective aluminum

Absorbance 0,95±0,01 0,95±0,01 0,95±0,01

Emmitance 0,05±0,02 0,05±0,02 0,05±0,02

Coating Titanium oxides Titanium oxides Titanium oxides

Material, Width

Side insulation

15 mm

Rock Wool

15 mm

Rock Wool

15 mm

Rock Wool

Material, Width

Back insulation

30 mm

Rock Wool

30 mm

Rock Wool

30 mm

Rock Wool

Soldering Absorber – Copper pipes Laser Laser Laser

Weight (kg) 27 36,5 41

Min inclination (ο) 25 25 25

Max inclination (ο) 90 90 90

Total water volume collector (lt) 1,3 1,6 1,9

Operation pressure (bar) 6 6 6

Testing pressure (bar) 10 10 10

Horizontal piping diameter Ø22 Ø22 Ø22

Vertical piping diameter 8 8 11

Number of Vertical pipes Ø10 Ø10 Ø10

Piping material Copper Copper Copper

Impermeability Silicone Silicone Silicone

Cover material Securit Mistlite

Solar Glass

Securit Mistlite

Solar Glass

Securit Mistlite

Solar Glass

Technical bulletin - Solar water heaters installation and maintenance manual

- Interplast Green Line

2.2 Selective Collector Full Face

Selective absorber Full Face (absorbance α= 0,94) for greater efficiency in winter season.

Anodized aluminum frame and galvanized metal sheet back plate for high corrosion resistance for

installations in humid climates or near the sea (coastal areas and islands).

Insulation of the collector made of expanded polyurethane and further compressed at a

temperature to achieve uniform density (52 kg/m2) throughout the length and width.

Insulation thickness of 30 mm on the back and 15mm on the sides for higher performance

at low temperatures (more hot water during winter).

Vertical copper pipes (risers) Ø10 x 0,4 mm

Headers Ø22 x 0,7 mm

Sealed with black silicone IG type and double adhesive tape.

Collector’s glazing made of 4 mm prismatic security glass (security), mistlite solar, with high

transmittance and low reflectivity.

Dimensions - Weights – Collector’s Surface

Height Width Weight Surface

(m) (m) (kg) (m2)

1.6 1.30 40 2.0

1.7 1.30 42 2.2

2.00 1.29 47 2.55

Technical bulletin - Solar water heaters installation and maintenance manual

- Interplast Green Line

Green Line Full Face Collector

2,0 m2 2,2 m2 2,55 m2

Dimensions (Length x

Width x Height) mm 1605x1300x87 1705x1295x87 1985x1285x87

Aperture are (m2) 1,82 2,03 2,36

Absorber area (m2) 1,81 2,01 2,31

Absorber Selective aluminum

single surface

Selective aluminum

single surface

Selective aluminum

single surface

Absorbance 0,95±0,01 0,95±0,01 0,95±0,01

Emmitance 0,05±0,02 0,05±0,02 0,05±0,02

Coating Titanium oxides Titanium oxides Titanium oxides

Material, Width

Side insulation

15 mm Compressed

Polyurethane (52kg/m3)

15 mm Compressed

Polyurethane (52kg/m3)

15 mm Compressed

Polyurethane (52kg/m3)

Material, Width

Back insulation

30 mm Compressed

Polyurethane (52kg/m3)

30 mm Compressed

Polyurethane (52kg/m3)

30 mm Compressed

Polyurethane (52kg/m3)

Soldering Absorber –

Copper pipes Laser Laser Laser

Weight (kg) 40 42 47

Min inclination (ο) 25 25 25

Max inclination (ο) 90 90 90

Total water volume of

collector (lt) 1,8 1,9 2,0

Operation pressure

(bar) 6 6 6

Testing pressure (bar) 10 10 10

Horizontal piping

diameter Ø22 Ø22 Ø22

Vertical piping diameter Ø10 Ø10 Ø10

Number of pipes 11 11 11

Piping material Copper Copper Copper

Impermeability Silicone & Double

Adhesive tape

Silicone & Double

Adhesive tape

Silicone & Double

Adhesive tape

Cover material

Low Iron

Securit Mistlite

Solar Glass

Low Iron

Securit Mistlite

Solar Glass

Low Iron

Securit Mistlite

Solar Glass

Technical bulletin - Solar water heaters installation and maintenance manual

- Interplast Green Line

2.3 Green line Plus Vacuum Tube

Made of borosilicate glass 1,6 mm thick.

Coating of selective solar absorber made of

aluminum nitride.

The component of the absorber consists of double

coated glass tube.

Due to special geometry (shape) of the absorber,

maximal absorption of solar energy is achieved.

Vacuum Tube

Length of Vacuum tube

(Length of absorber)

1800 mm

(1720 mm)

Inner / outer vacuum

diameter 58 / 47 mm

Glass thickness 1,6 mm

Material Borosilicate glass 3,3

Absorbance coating Graded Al-N/Al

Absorbance ≥93,5% ( ΙΑM 1,5)

Emmitance ≤6,5% ( 80o C)

Vacuum P < 3x10-3 Pa

Stagnation Temperature 231o C

Max efficiency

(for 20/15 vacuum tubes)

Tm-Ta=0K & 1000W/m2

1383 W / 826 W

Technical bulletin - Solar water heaters installation and maintenance manual

- Interplast Green Line

2.4 Hot water cylinder

Inner Tank Material: Metal steel sheet DCP

2.5mm for the main tank (EN 10130/2006) DCP

1,5mm for the jacket (exchanger) (EN

10130/2006)

Internal Anticorrosion Protection: LIQUID

enamel (DIN 4753-3), totally safe for public

health (DIN 51032 & ΕΝ 1388-2) and magnesium

anode (EN 12438)

Welding: MIG

Insulation: Hard polyurethane foam of 48kg/m³

(DIN 53420), self-extinguishing (DIN 4102)

Maximum Working Pressure for the Main

Tank: 10 bar

Test Pressure for the Main Tank: 15 bar (EN

12976-1, ¶4.1.6)

Maximum Working Pressure for the Jacket

(Exchanger): 3,5 bar

Test Pressure for the Jacket (Exchanger): 5

bar (EN 12976-1/2006, ¶4.1.6)

Maximum Working Temperature of the

Main Tank: 95οC

Heating Element: Optional, upon request

External Cover: Pre-painted galvanized steel

sheet 0,5mm (EN 10204/2.2)

Extrenal Cover: Pre-painted galvanized steel

sheet 0,5mm (EN 10204/2.2)

Type 120L 150L 170L 200L 270L 300L

Effective Capacity (L) 107 132 153 192 248 292

A Tank’s Length (mm) 1050 1250 1250 1250 1590 1850

ΒMain Tank’s Diameter (mm) Ø400 Ø400 Ø430 Ø480 Ø480 Ø480

C External Diameter (mm) Ø500 Ø500 Ø540 Ø580 Ø580 Ø580

Jacket’s Surface (m2) 0,65 0,88 0,95 1,06 1,50 1,89

D Jacket’s Capacity (L) 7,76 10,56 11,33 12,61 18,17 22,80

Flange Diameter (mm) Ø140 Ø140 Ø140 Ø140 Ø140 Ø140

Technical bulletin - Solar water heaters installation and maintenance manual

- Interplast Green Line

2.5 Foldable Bracket for Terrace

Base Dimensions (for 1 collector)

Height Width Surface Weight

m m m2Kg

1,5 1,00 1,5 16

2,00 1,00 2,00 19

2,00 1,25 2,00 19

Base Dimensions (for 2 collectors)

Ύψος Width Surface Weight

m m m2Kg

2,00 1,00 2 x 2,00 22

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