Technical

Manual
 Chromagen is a world leader specializing in thermal solar energy systems.
Founded in 1962 in Israel, Chromagen has years of experience in harnessing the sun’s
unlimited energy for the purpose of water heating. Chromagen provides systems
designed for domestic use as well as more complex central systems for commercial
applications in hotels, hospitals, apartment houses and industrial plants.

Meeting today’s needs, while keeping tomorrow in mind, Chromagen, a major

player in the global alternative energy arena, develops a range of efficient and
reliable products. Chromagen provides clean, dependable solutions for your
water heating needs.

Solar Thermal ]Thermosiphon[

systems
]Open-Loop[ ]Closed-loop[

]Forced Circulation[

]Single Home[ ]Central System[

]Open-Loop[ ]Closed-Loop[ ]Open-Loop[ ]Closed-Loop[

Products Chromagen designs its solar energy systems and solutions to meet individual
needs, and is involved in the planning and installation at every stage along
the way. In addition to its systems, solar collectors and solar storage tanks,
Chromagen provides accessories, such as stands and connectivity kits.

Solar Collectors Chromagen manufactures solar collectors using state-of-the-art technology.

Coated copper or aluminum fins are ultrasonically or laser welded to copper tubes
encased in a frame and covered with tempered solar glass. Galvanized steel and
aluminum case options are offered and absorbers are available with a variety of
coating options: selective paint, black chrome and ultra-selective sputtering.

Solar Chromagen produces storage tanks in a range of sizes from 30 to 300 L that
include: solar storage tanks and solar storage tanks with a heat-exchanger. All
Storage Tanks tanks are available with an electrical back up and are enamel coated. Tanks can
be mounted either vertically or horizontally.
Table of
contents [1] Introduction
1.1 About this Manual
1.2 Systems introduction
6
6
1.3 Quality Assurance 6
1.4 Solar water heating - basics 7
1.5 Forced circulation system 7
1.6 Thermosiphon system 8
1.7 Closed-Loop and Open-Loop Systems 9
1.8 Water quality 9

[2] Flat-plate collectors

2.1 introduction
2.2 collector parts
14
15
2.3 Chromagen Collector’s Specifications 17
2.4 Collectors’ Data Sheets 18

[3] Storage tanks

3.1 Introduction
3.2 Storage tank parts
28
28
3.3 Chromagen tanks 30
3.4 Storage Tanks’ Data Sheets 31

[4] Installation: Getting Started

4 . 1 General Information
4 . 2 Thermosiphon system configuration
40
41
41
4 . 3 Forced circulation system configuration 42
4 . 4 Safety During Site Inspection 42
4 . 5 Review Local Codes 42
4 . 6 Required tools and equipment 43
4 . 7 Selecting system location 43
4 . 8 Roof Survey 46
4 . 9 Water Requirements 46
4.10 Customer Approval 47
4.11 Work Force 47
4.12 Propylene Glycol properties

2
 [5] Thermosiphon system installation
5.1 Inclined roof installation
5.2 Flat roof installation
50
52
5.3 Plumbing 54
5.4 Filling and Testing 57

[6] Forced circulation system installation

6.1 Introduction
6.2 Inclined roof installation
60
60
6.3 Flat roof installation 61
6.4 Installation of collectors field 63
6.5 Location of collectors, tank and system operation 63
6.6 Anti-freeze Protection 65
6.7 Plumbing 65
6.8 Electrical Connections 65
6.9 Additional Notes 65

[7] Troubleshooting and maintenance

7.1 Thermosiphon System troubleshooting
7.2 Forced Circulation Systems troubleshooting
68
68
7.3 Maintenance 70
7.4 Periodic maintenance 71
7.5 Replacement of Parts 71
7.6 Warnings 71

[8] Accessories
8.1 Solar station
8.2 Thermostatic control
76
77
8.3 Circulation pumps 78
8.4 Freeze Protection Valve 80
8.5 Thermostatic mixing valve 80
8.6 Anti-scale filter 81

Index 82
Warranty Back cover

3
1
Introduction
1.1
About
This manual provides the following information:
[a] Solar water heating systems’ principles
[b] Chromagen products - collectors and storage tanks
[c] Specifications, installation and maintenance of Chromagen’s residential solar
this Manual water heating systems
Chromagen uses the most advanced production techniques in order to ensure
durable products. Read this manual thoroughly before beginning work. If any
questions arise please contact your local dealer or Chromagen’s head office.

1.2
Systems
Chromagen products may be assembled into four different system types:
[.] Thermosiphon, closed-loop systems
[.] Thermosiphon, open-loop systems
[.] Forced circulation, closed-loop systems
introduction [.] Forced circulation, open-loop systems
The differences and working principles of the different systems are described
in clauses 1.5-1.7.

Thermosiphon systems are recommended whenever the tank may be located

on the roof and the average ambient temperature doesn’t go below 5˚c. These
systems’ operational features are simpler than forced systems’ features, as
they do not involve any moving parts or electrical pumps. In forced systems,
the water storage tank may be located anywhere, which is useful when there are
aesthetic considerations, or when the roof structural support cannot hold the
weight of a full tank.

1.3
Quality
Chromagen’s quality management scheme meets the ISO 9001 standards.
Our products are made from the highest quality raw materials, while modern
production lines ensure a consistency of precision and finish. Chromagen systems
and components are tested to comply with the European standard EN12975 for
Assurance solar collectors and EN12976 for solar thermal systems, International standard
Iso9806, Israeli standard, SRCC USA, Australian standard and more.

Numerous institutes worldwide have tested and approved Chromagen systems:

Cener Spain, FSEC Florida, ITW Germany, SPF Switzerland, CSTB France, ENEA
Italy, Bodycote Canada, SII Israel and others. Chromagen is proud to provide
its customers with high quality, efficient products and to be an integral part of the
worldwide quest for a cleaner environment by using renewable energy sources.

6
1.4
Solar Thermal
A solar water heating system is made up of several important elements:
[a] One or more solar collectors mounted on the roof
[b] A storage tank, with or without an inner heat-exchanger
[c] An electrical pump for circulating the heat transfer fluid (in Forced systems only)
basics
There are two solar water heating circulation types:
[a] Thermosiphon [TS]
[b] Forced circulation [FC]
Forced circulation systems use electricity to power pumps that move liquid
through the system. Thermosiphon systems rely on gravity to move liquid through
the system. In both systems, the absorber plate of the collector gathers the sun’s
heat energy, which in turn warms the water or the anti-freeze solution that flows
through an array of tubes. Once heated, the liquid flows through the tubes to the
storage tank. The heated liquid warms the cooler water in the storage tank directly
or through a heat-exchanger. A backup energy source, normally electricity or
gas, supplies the energy deficit.

1.5
Forced
FC systems use electrical pumps, valves, and controllers to circulate water or other
heat-transfer fluids through the collectors. FC systems are usually less efficient
and more expensive than TS systems however they enable high flexibility in the
positioning of the systems’ components: storage tanks do not need to be installed
Circulation above or close to the collectors. Since FC systems use electricity to operate the
System pump, these systems will not function in a power outage.

Forced circulation system - Schematic

7 Introduction
1.6
Thermosiphon
In general, TS systems do not use electric-powered pumps to move liquid
through tubes. Instead, they use the thermosiphon principal. These systems are
easier to maintain, less expensive to install and generally more efficient than FC
systems. However, they have installation limits since the storage tank must be
system placed above the lower part of the collector.

Thermosiphon systems use natural convection to circulate water through

the solar collectors. As water in the collectors warms, it naturally rises to
the upper part of the collector and from there to the storage tank. At this
stage, the thermosiphoning action causes the cooler water in the tank to
flow down the pipes to the bottom of the collector and naturally circulate
throughout the system. The tank may be placed partly below the collector in
a low profile configuration as shown in section 4.2. Low profile installation
requires an additional check valve to prevent reverse thermosiphon flow.

Thermosiphon open-loop system- Schematic

[.] Tank must be located above the collectors

[.] Low profile mounting requires additional check valve

8
 Thermosiphon closed-loop system-Schematic

[.] Tank must be located above the collectors

[.] Low profile mounting requires additional check valve

1.7
Closed-Loop
Closed-loop system; heat transfer fluid (water or anti-freeze solution) circulates
through the system’s tubes without mixing with the potable water inside the
water storage tank. Closed-loop systems are better-suited for colder climates,
since the anti-freeze solution keeps the system from freezing. In places with
and Open-Loop hard water, the system limits scale development inside the collector’s tubes.
Systems Closed-loop systems can operate as FC or TS systems.

Open-loop systems operate like closed-loop systems with one major difference:
anti-freeze fluid must not be used, since the hot water from the collector mixes
with the supply water in the storage tank. Open-loop systems are best suited for
warm climates; the water can freeze in colder climates and possibly destroy the
system. In addition, these systems cannot be used in areas where the water is very
“hard” or acidic, since this type of water is likely to corrode or block the system’s
tubes. Open-loop systems are commonly operated in a Thermosiphon mode.

1.8
Water quality
In regions where calcium carbonate content of water exceeds 250 mg/L (or 250
ppm) it is highly recommended that a closed-loop system is used. Collector
clogging from mineral deposits is likely to impair collectors’ functionality and
shorten systems’ life span wherever hard water is used in open-loop systems.
For additional information review section 4.9.

9 Introduction
2
Flat-Plate Collectors
2.1
Introduction
Solar water heaters use solar collectors to capture the sun heat energy.
When water temperature below 80°C is required, flat-plate collectors are
commonly used. A flat-plate collector is an insulated, weatherproofed box
containing a dark absorber plate connected to an array of tubes and is covered
by a transparent or translucent cover. A collector is typically 1 m wide, 2 m long
and 10 cm in depth. The absorber plate gathers the sun’s heat energy, which in
turn warms the water (or anti-freeze solution) that flows through an array of
tubes. Once heated, the liquid is pumped or naturally flows through the tubes to
the storage tank. The heated liquid warms the cooler water in the storage tank
directly or through a heat-exchanger.

Thermal The instantaneous efficiency of a solar collector, h, operating under steady

state conditions, is defined as the ratio of the actual useful power extracted,
Efficiency , to the solar energy intercepted by the collector, G•A.

1 (or 100%)

Where G is the global solar irradiance on the collector plane and A is the collectors
aperture area:
is calculated from where - flow rate through the collector;
- fluid specific heat; Tin- collector inlet temp; Tout - collector outlet temperature.

Selective The simple black painted surface can be improved and become more efficient
by the use of selective coatings. Certain special coatings can reduce the
Surface re-radiation ability without markably reducing the energy-absorption ability.

Chromagen manufactures solar collectors using state-of-the-art technology.

Coated copper or aluminum fins are ultrasonically or laser welded to copper
tubes encased in a frame and covered with tempered solar glass. Absorbers
are available with a variety of coating options; selective paint, black chrome
and ultra selective sputtering. Coated galvanized steel and anodized aluminum
cases are available.

14
2.2
[7]

The Collector
Parts

[4] [5]

[3]

[1][2]
[9]

[3]

[8]

[6]

[1] Absorber Plate

Made of copper or aluminum sheet, laser or ultrasonically welded to copper
tubes, ensuring high efficiency and durability.
[2] Absorber Plate Coating
Selective black paint, black chrome or ultra selective sputtered coating with
excellent energy absorption and very low energy emission for high performance
even in cooler climates.
[3] Insulation
The absorber plate is encased in 23 mm rigid polyurethane foam, with an option
to additional layer of glass wool, retaining the collector’s heat.
[4] Solar Glass Glazing
The single-pane 3.2 mm patterned and tempered solar glass has high solar
transmittance of 91% and excellent durability.
[5] Casings
A. All anodized aluminum extrusion casings are made of solid construction
available in a natural or black color.
B. Galvanized steel casings are available in black, gray or white polyester paint finish.
[6] Tubing Grid
16 mm or 8 mm copper risers brazed to 28 mm or 22 mm copper manifolds with
optimal flow distribution.
[7] Piping Connection
Four 3/4” BSPP female brass adaptors or clear cut edge for connector brazing.
[8] Back Plate
The back plate is made of black polypropylene sheet.
[9] Aluminum Foil
The aluminum foil, integrated to the insulation, acts as a barrier against out-gassing.

15 Flat -Plate Collectors

2.3
Chromagen
Chromagen collectors are identified by the coating type, casing type and size.
Z series | black painted copper fins
S series | black chrome plated copper fins
A Series | black painted aluminum fins
Collectors P series | sputtered aluminum full plate absorber
Specifications Q series | black painted full plate aluminum absorber

Each series may be constructed with aluminum frame or painted galvanized steel frame.
A Frame | anodized aluminum black or natural aluminum color
R frame | galvanized steel frame-grey, black, white or un-painted
Each series is composed of four models or more, differing in dimension

K D E F
(CR-90) (CR-100) (CR-110) (CR-120 V)

Risers diameter 1 6 1 6
8 mm 8 mm 8 mm 16 mm 8 mm 16 mm
mm mm
Gross area [m2] 1.65 1.65 2.02 2.02 2.34 2.34 2.77 2.77
Net aperture area [m2] 1.52 1.52 1.85 1.85 2.15 2.15 2.56 2.56
Length [cm] 181 181 189 189 218 218 218 218
Width [cm] 91 91 107 107 107 107 127 127
Thickness [cm] 9 9 9 9 9 9 9 9
Weight (empty) [kg] 26 28 30 33 34 37 39 43
Fluid capacity [L] 1.0 2.7 1.2 3.2 1.3 3.6 1.5 4.1

G W Z U
(CR-120 H) (CR-130) (CR-135) (CR-140)

Risers diameter 1 6 1 6 1 6
8 mm 8 mm 8 mm 8 mm 16 mm
mm mm mm
Gross area [m2]
2.77 2.77 2.93 2.93 3.12 3.12 3.67 3.67
Net aperture area [m2]
2.56 2.56 2.73 2.73 2.93 2.93 3.44 3.44
Length [cm]
218 218 246 246 246 246 308 308
Width [cm]
127 127 119 119 127 127 119 119
Thickness [cm]
9 9 9 9 9 9 9 9
Weight (empty) [kg]
40 44 44 49 34 46 54 59
Fluid capacity [L]
2.0 5.1 1.7 5.3 2.1 7.1 2.6 6.3
Example | PA-D has sputtered aluminum absorber, aluminum frame & size D=189x107 cm
[.] Collectors test pressure: 12 bar [.] Max collector operation pressure: 8 bar

Coating Absorptance Emissivity Stagnation Temp

α ε
Specifications @1000W/m2 & ambient Temp 30 °C

Selective paint 0.9 0.45 170°C

Black chrome 0.95 0.12 180°C
Sputtering 0.95 0.05 205°C

Glass Emissivity
Transmittance Transmittance
Thickness
Heat
Conduction
Specifications (Visible light) (Solar Radiation)

ε
τD65 τSOL t [mm] K[W/mk]
Float 0.85 0.90 0.86 2.8-3 1.00
Solar tempered 0.85 0.916 0.91 3-4 1.04

[.] Due to on- going development, specifications are subject to change without notice

17 Flat -Plate Collectors

2.4
Collectors’
Data Sheets
Risers diameter 8 mm 5/8” (~16 mm)
Connections thread BSP (female) 3/4” 3/4”
Gross area [m2] 1.65 1.65
Net aperture area [m2] 1.52 1.52
Length [cm] 181 181
Width [cm] 91 91

K(CR90) Thickness [cm]

Weight (empty) [kg]
9
26
9
28
Fluid capacity [L] 1 2.7
Test pressure [bar] 12 12
Max. operating pressure [bar] 8 8
Efficiency curve (selective paint) η=0.69- 4.2X
95 cm Efficiency curve (black chrome) η=0.72 - 4.1X
91 cm
Efficiency curve (sputtering) η=0.74 - 4.2X

Efficiency Curve
80%
70%
172 cm
181 cm

60%
50%
40%
30%
20%
10%
0%
0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16
X = (Tm-Ta)/G
Sputtering
Black chrome
Selective paint
Tm= Water temp:(Tout + Tin)/2
Ta = Ambient temp
G = Instantaneous solar radiation

[.] The attached chart is for comparison purposes

[.] Efficiency curves based on aperture area

PRESS drop on Pressure drop on

Flow one 16 mm COL. one 8 mm COL.
[L / hr]
[cm of Water] [cm of Water]
50 0.1 0.3
100 0.3 1
150 0.9 2.1
200 1.4 3.5
250 2.5 6
300 3.7 8
350 5.3 10.2

18
 Risers diameter 8 mm 5/8” (~16 mm)
Connections thread BSP (female) 3/4” 3/4”
Gross area [m2] 2.03 2.03
Net aperture area [m2] 1.85 1.85
Length [cm] 189 189
Width [cm] 107 107

D(CR100) Thickness [cm]

Weight (empty) [kg]
9
30
9
33
Fluid capacity [L] 1.2 3.2
Test pressure [bar] 12 12
Max. operating pressure [bar] 8 8
Efficiency curve (selective paint) η=0.69- 4.7X
111 cm Efficiency curve (black chrome) η=0.73 - 4.2X
107 cm
Efficiency curve (sputtering) η=0.75 - 3.9X

Efficiency Curve
80%
70%
60%
218 cm
209 cm

50%
40%
30%
20%
10%
0%
0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16
X = (Tm-Ta)/G
Sputtering
Black chrome
Selective paint
Tm= Water temp:(Tout + Tin)/2
Ta = Ambient temp
G = Instantaneous solar radiation

[.] The attached chart is for comparison purposes

[.] Efficiency curves based on aperture area

PRESS drop on Pressure drop on

Flow one 16 mm COL. one 8 mm COL.
[L / hr]
[cm of Water] [cm of Water]
50 0.2 0.6
100 0.4 0.9
150 1.0 2.5
200 1.5 4
250 2.7 6.3
300 4.0 8.5
350 5.6 10.9

19 Flat -Plate Collectors

 Risers diameter 8 mm 5/8” (~16 mm)
Connections thread BSP (female) 3/4” 3/4”
Gross area [m2] 2.35 2.35
Net aperture area [m2] 2.15 2.15
Length [cm] 218 218
Width [cm] 107 107

E(CR110) Thickness [cm]

Weight (empty) [kg] 34
9 9
37
Fluid capacity [L] 1.3 3.6
Test pressure [bar] 12 12
Max. operating pressure [bar] 8 8
Efficiency curve (selective paint) η=0.73- 4.9X
111 cm Efficiency curve (black chrome) η=0.76 - 4.3X
107 cm
Efficiency curve (sputtering) η=0.75 - 3.9X

Efficiency Curve
80%
70%
60%
50%
218 cm
209 cm

40%
30%
20%
10%
0%
0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16
X = (Tm-Ta)/G
Sputtering
Black chrome
Selective paint
Tm= Water temp:(Tout + Tin)/2
Ta = Ambient temp
G = Instantaneous solar radiation

[.] The attached chart is for comparison purposes

[.] Efficiency curves based on aperture area

PRESS drop on Pressure drop on

Flow one 16 mm COL. one 8 mm COL.
[L / hr]
[cm of Water] [cm of Water]
50 0.25 0.75
100 0.50 1.6
150 1.25 2.6
200 2.00 5
250 3.00 7
300 4.25 8.5
350 5.75 12

20
 Risers diameter 8 mm 5/8” (~16 mm)
Connections thread BSP (female) 3/4” 3/4”
Gross area [m2] 2.77 2.77
Net aperture area [m2] 2.56 2.56

G(CR120) Length [cm]

Width [cm]
218
127
218
127
Horizontal Thickness [cm] 9 9
Weight (empty) [kg] 40 44
Fluid capacity [L] 2 5.1
Test pressure [bar] 12 12
Max. operating pressure [bar] 8 8
222 cm Efficiency curve (selective paint) η=0.72- 4.8X
218 cm
Efficiency curve (black chrome) η=0.75 - 4.1X

Efficiency Curve
127 cm
118 cm

80%
70%
60%
50%
40%
30%
20%
10%
0%
0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16
X = (Tm-Ta)/G

Black chrome
Selective paint
Tm= Water temp:(Tout + Tin)/2
Ta = Ambient temp
G = Instantaneous solar radiation

[.] The attached chart is for comparison purposes

[.] Efficiency curves based on aperture area

PRESS drop on Pressure drop on

Flow one 16 mm COL. one 8 mm COL.
[L / hr]
[cm of Water] [cm of Water]
50 0.4 1.5
100 1 3
150 1.8 4.3
200 3 7.2
250 4.8 9.8
300 6 12.6
350 9 18

21 Flat -Plate Collectors

 Risers diameter 8 mm 5/8” (~16 mm)
Connections thread BSP (female) 3/4” 3/4”
Gross area [m2] 2.77 2.77
Net aperture area [m2] 2.56 2.56

F(CR120)
Length [cm] 218 218
Width [cm] 127 127

Vertical Thickness [cm]

Weight (empty) [kg]
9
39
9
43
Fluid capacity [L] 1.45 4.13
Test pressure [bar] 12 12
Max. operating pressure [bar] 8 8
Efficiency curve (selective paint) η=0.72- 4.8X
Efficiency curve (black chrome) η=0.72 - 4.1X
131 cm
127 cm Efficiency curve (sputtering) η=0.75 - 3.9X

Efficiency Curve
80%
70%
60%
50%
40%
209 cm
218 cm

30%
20%
10%
0%
0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16
X = (Tm-Ta)/G
Sputtering
Black chrome
Selective paint

[.] The attached chart is for comparison purposes

[.] Efficiency curves based on aperture area

PRESS drop on Pressure drop on

Flow one 16 mm COL. one 8 mm COL.
[L / hr]
[cm of Water] [cm of Water]
50 0.4 1.5
100 1 3
150 1.8 4.3
200 3 7.2
250 4.8 9.8
300 6 12.6
350 9 18

22
 Risers diameter 8 mm 5/8” (~16 mm)
Connections thread BSP (female) 3/4” 3/4”
Gross area [m2] 2.96 2.96
Net aperture area [m2] 2.73 2.73
Ratio net/gross area 0.93 0.92
Length [cm] 246 246

W(CR130)
Width [cm] 119 119
Thickness [cm] 9 9
Weight (empty) [kg] 44 49
Fluid capacity [L] 1.7 5.3
Test pressure [bar] 12 12
Max. operating pressure [bar] 8 8
Efficiency curve (selective paint) η=0.73- 4.9X
127 cm Efficiency curve (black chrome) η=0.74 - 4.2X
119 cm
Efficiency curve (sputtering) η=0.75 - 3.9X

Efficiency Curve
80%
70%
60%
50%
40%
30%
237 cm

20%
246 cm

10%
0%
0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16
X = (Tm-Ta)/G
Sputtering
Black chrome
Selective paint
Tm= Water temp:(Tout + Tin)/2
Ta = Ambient temp
G = Instantaneous solar radiation

[.] The attached chart is for comparison purposes

[.] Efficiency curves based on aperture area

PRESS drop on Pressure drop on

Flow one 16 mm COL. one 8 mm COL.
[L / hr]
[cm of Water] [cm of Water]
50 0.3 1
100 0.9 2.8
150 1.6 4
200 2.8 7
250 4.5 9.5
300 5.8 12.3
350 7.6 16.7

23 Flat -Plate Collectors

 Risers diameter 8 mm 5/8” (~16 mm)
Connections thread BSP (female) 3/4” 3/4”
Gross area [m2] 3.12 3.12
Net aperture area [m2] 2.93 2.93
Length [cm] 246 246
Width [cm] 127 127

Z(CR135) Thickness [cm]

Weight (empty) [kg]
9
46
9
54
Fluid capacity [L] 2.1 6.8
Test pressure [bar] 12 12
Max. operating pressure [bar] 8 8
Efficiency curve (sputtering) η=0.76- 4.1X
131 cm Efficiency curve (selective paint) η=0.73 - 4.5X
127 cm

Efficiency Curve
80%
70%
60%
50%
40%
30%
246 cm
237 cm

20%
10%
0%
0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16
X = (Tm-Ta)/G
Black chrome
Selective paint
Tm= Water temp:(Tout + Tin)/2
Ta = Ambient temp
G = Instantaneous solar radiation

[.] The attached chart is for comparison purposes

[.] Efficiency curves based on aperture area

PRESS drop on Pressure drop on

Flow one 16 mm COL. one 8 mm COL.
[L / hr]
[cm of Water] [cm of Water]
50 0.6 1.8
100 1.4 3.8
150 2.5 6.3
200 4 8.1
250 6 12.3
300 9 17.7
350 14 25

24
 Risers diameter 8 mm 5/8” (~16 mm)
Connections thread BSP (female) 3/4” 3/4”
Gross area [m2] 3.67 3.67
Net aperture area [m2] 3.44 3.44
Length [cm] 308 308
Width [cm] 119 119

U(CR140) Thickness [cm]

Weight (empty) [kg]
9
53
9
59
Fluid capacity [L] 1.9 6.3
Test pressure [bar] 12 12
Max. operating pressure [bar] 8 8
Efficiency curve (black chrome) η=0.75- 4.3X
127 cm Efficiency curve (selective paint) η=0.73 - 5.0X
119 cm

Efficiency Curve
80%
70%
60%
50%
40%
30%
20%
308 cm
298 cm

10%
0%
0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16
X = (Tm-Ta)/G
Black chrome
Selective paint
Tm= Water temp:(Tout + Tin)/2
Ta = Ambient temp
G = Instantaneous solar radiation

[.] The attached chart is for comparison purposes

[.] Efficiency curves based on aperture area

PRESS drop on Pressure drop on

Flow one 16 mm COL. one 8 mm COL.
[L / hr]
[cm of Water] [cm of Water]
50 0.6 1.8
100 1.4 3.8
150 2.5 6.3
200 4 8.1
250 6 12.3
300 9 17.7
350 14 25

25 Flat -Plate Collectors

3
Storage tanks and heat-exchangers
3.1
introduction
Thermo tanks are designed to store hot water for domestic or industrial use. The
water inside the tank is heated through several options, as follows:
[.] Electrical heating | using an electric heating element dipped inside the tank
[.] Direct heating | hot water from a solar collector, mixed with tank water
[.] Indirect heating | using a special storage tank that includes a heat-exchanger
connected to a water heating source (for example, collector, gas or wood heater)

The storage tank is insulated from the ambient air by a layer of injected
polyurethane foam. Chromagen offers a wide selection of water storage tanks
with capacity of 30 to 300 L. There are seven different types of solar tanks as
shown in the following diagrams:
[.] The horizontal or vertical orientation options enable flexible installation
according to customer requirements

3.2
[9] [10]
[3] [2] [1]
[4]

Storage tank
parts

[5]
[7] [9] [6]
Optional
[8] [11]

[ 1 ] External coating | aluminum or polyester coated galvanized steel sheet providing

extreme durability and an attractive finish
[ 2 ] Insulation | thick polyurethane insulation layer ensuring optimal insulation and
heat retention
[ 3 ] Storage tank | constructed of thick steel, automatically welded, ensuring
precision and enabling working pressure of 8 bars
[ 4 ] Enamel coating | internal glass-enamel layer protecting against corrosion
[ 5 ] Electric element | energy-efficient electric element with rapid heating time
enabling the provision of hot water 24 hours a day, 365 days a year
[ 6 ] Sacrificial anode | anti-corrosion protection
[ 7 ] Thermostat | built-in thermostat ensuring that water inside the tank does not
exceed a preset temperature, while using the electric element
[ 8 ] Cold water supply
[ 9 ] Hot water from collector - inlet
[10] Hot water to user
[11] Cold water to collector - outlet

28
29 Storage Tanks and Heat Exchangers
3.3
Vertical and
]Vertical Tanks[

Horizontal
Tanks

Solar Solar Spiral /Serpentine

(Open-Loop system) Side Flange Heat-Exchanger
(Closed-Loop system)

Double Jacket Double Spiral

Heat-exchanger Heat-exchanger
(Closed-Loop system) (Closed-Loop system)

[Horizontal Tanks]

Solar Spiral/Serpentine
(Open-Loop system) Heat-exchanger
(Closed-Loop system)

Double Jacket Double Jacket

Heat-exchanger Heat-exchanger
(Closed-loop system) (Closed-Loop system)

30
3.4
Storage Tanks’
Data

Solar [ 1 ] External coating

[ 2 ] Insulation
Vertical Tanks [ 3 ] Storage tank
[ 4 ] Enamel coating
[ 5 ] Electric element
[ 6 ] Sacrificial anode
C [ 7 ] Thermostat
[ 8 ] Cold water supply
[ 9 ] Hot water to user
[10] Hot water from collector- inlet
[11] Cold water to collector- outlet

B A

[9]
[1]
[5]
[2]
[6]
[3]
[7]
[4]
[10]

[8]
[11]

Capacity A B C Weight Electric Element

[L] [mm] [mm] [mm] [Kg] (kW)

150 1020 950 585 53 2.5

200 1270 1210 585 65 2.5
300 1420 1360 650 91 2.5 / 3.6

31 Storage Tanks and Heat Exchangers

Solar
Vertical Tanks [ 1 ] External coating
[ 2 ] Insulation
Side Flange
[ 3 ] Storage tank
[ 4 ] Enamel coating
[ 5 ] Electric element
[ 6 ] Sacrificial anode
C [ 7 ] Thermostat [1]

[ 8 ] Cold water supply

[2]
[ 9 ] Hot water to user
[12]
[10] Hot water from collector- inlet [9]
[11] Cold water to collector- outlet [3]

[12] PT valve - inlet [4]

B
[13] Sensor house - inlet
[5]

[6]

[5] [10]

[13]

[11]
[8]

Capacity B C Weight Electric Element

[L] [mm] [mm] [Kg] (kW)

400 1765 650 110 3.6

400 1765 645 105 None
Industrial

32
Solar
Horizontal Tanks [ 1 ] External coating
[ 2 ] Insulation
[ 3 ] Storage tank
[ 4 ] Enamel coating
A
B [ 5 ] Electric element [1] [2] [3] [4] [10] [9]

[ 6 ] Sacrificial anode
[ 7 ] Thermostat
C [ 8 ] Cold water supply
[ 9 ] Hot water to user
[10] Hot water from collector- inlet
[11] Cold water to collector- outlet

[11]
[8]

[5] [6] [7]

Capacity A B C Weight Electric Element

[L] [mm] [mm] [mm] [Kg] (kW)

120 860 800 560 46 2.5

150 1020 950 560 53 2.5
200 1270 1210 560 65 2.5
300 1420 1360 650 91 2.5 / 3.6
300 1809 1741 586 95 3.6

33 Storage Tanks and Heat Exchangers

Solar Tanks
with [ 1 ] External coating
Double-Jacket [ 2 ] Insulation
Heat-Exchanger [ 3 ] Storage tank
[ 4 ] Enamel coating
[ 5 ] Electric element
[ 6 ] Sacrificial anode
A [ 7 ] Thermostat
B
[ 8 ] Cold water supply
[ 9 ] Hot water from collector - inlet
C
[10] Hot water to user
[9] [10]
[11] Cold water to collector - outlet
[3] [2] [1]
[4]

[6] [5]
[7] [9]
Optional
[8] [11]

Electric Heat- Heat-

Capacity A B C Weight
Element exchanger exchanger
[L] [mm] [mm] [mm] [Kg]
(kW) Area [m2] Vol. [L]

120 1260 1185 477 74 2.5 0.9 7.5

150 1020 950 585 75 2.5 0.8 6.5
200 1270 1210 585 93 2.5 1.2 9.5
300 1420 1360 690 133 2.5/ 3.6 1.6 12.5
300 1814 1741 578 145 2.5 2.0 16

34
Solar
[ 1 ] External coating
Vertical Tanks [ 2 ] Insulation [6]
[6]
with Spiral [ 3 ] Storage tank
[4]
[4]
[7]
[7]
[10]
[10]

Heat-exchanger
[13]
[13]
[1]
[ 4 ] Enamel coating [1]
[14]
[14]
[ 5 ] Electric element [5]
[5] [11]
[11]
[ 6 ] Sacrificial anode
[3]
[3] [8]
[8]
[ 7 ] Thermostat [2]
[2]
C
[ 8 ] Spiral heat-exchanger [9]
[9]

[ 9 ] Cold water inlet [12]

[12]

[10] Hot water to user

Double Spiral
[11] Heat-exchanger inlet Double Spiral

[12] Heat-exchanger outlet

[13] Auxiliary heating inlet
B A [14] Auxiliary heating outlet

[10]
[5]
[6]
[7]
[11]
[4]
[3] [8]
[2]
[1] [9]
[12]

Single Spiral

Electric Main
Capacity A B C Weight Main HXG.
Element HXG.
[L] [mm] [mm] [mm] [Kg] Area [m2]
(kW) Vol. [L]

860/ 86/ 585/

120 74/76 2.5 0.6 0 3.3 0
1260 1185 477
1020/ 950/ 585/
150 75/78 2.5 0.6 0 3.3 0
1480 1415 477
200 1270 1210 585 93 2.5 0.6 0 3.3 0
200
Double 1270 1210 585 108 2.5 0.6 0.6 3.3 3
spiral
300 1420 1360 650 133 2.5/ 3.6 0.9 0 5 0
300
Double 1420 1360 650 145 2.5/ 3.6 1.2 0.6 6.5 3
spiral

35 Storage Tanks and Heat Exchangers

Horizontal Tank [10]

with Serpentine [ 1 ] External coating [9]

Heat-exchanger [ 2 ] Insulation
[ 3 ] Storage tank
[ 4 ] Enamel coating
[ 5 ] Electric element
A
B
[ 6 ] Sacrificial anode
[ 7 ] Thermostat
[1] [2] [3] [4]
[ 8 ] Cold water supply
C
[ 9 ] Hot water to user
[10] Hot water from collector- inlet
[11] [8]
[11] Cold water to collector- outlet

[6] [7]

Electric Heat- Heat-

Capacity A B C Weight
Element exchanger exchanger
[L] [mm] [mm] [mm] [Kg]
(Watt) Area [m2] Vol. [L]

300 1420 1360 650 133 2.5/ 3.6 0.8 4.5

36
37 Storage Tanks and Heat Exchangers
4
Installation: Getting Started
4.1
General
[1] Safety Precautions - Read carefully BEFORE installation. This manual contains
easy-to-follow instructions for the correct installation, activation and function of
Chromagen domestic solar water heating systems.

Information Please take your time to understand the system and its parts; it will ensure a
successful and trouble-free installation. If you have any questions regarding
this installation contact your Chromagen agent.

When working on, or around your roof, take care to avoid hazards such as
electrical wires and loose shingles/tiles. Use extreme caution when using a
ladder or when walking on the roof. Safety always comes first!

[2] The information provided in this manual is general. System installations in

different locations might require a different emphasis. Please consult with a
Chromagen representative if any doubt arises.

[3] Brass fittings must not be connected directly to the tank pipes to prevent
galvanic corrosion. Steel sacrificial adaptor or dielectric fitting must be used.

[4] Lightning protection is based on the connection of the system’s metal tubing
to common grounding in order to provide the easiest path for lightning to
pass to the ground.

[5] Remember that the system components may be damaged if not handled
properly. Take extreme care when loading, unloading, transporting or lifting
to the roof.

[6] for safety reasons a system shall be provided with blow-off lines wherever
steam or hot fluid can escape.

120 L system 150 L system 200 L system 300 L system

Tank: Tank: Tank: Tank:

120 L /32 GL 150 L /40 GL 200 L /53 GL 300 L /80 GL

Collector: Collector: Collector: Collector:

1xD (CR100) 1xE (CR110) 1xF (CR120) 2xE (CR110)
[1.85 m2] [2.15 m2] [2.56 m2] [4.3 m2]
Or 1xK (CR90) Or 1xD (CR100) Or 1xE (CR110) Or 2xD (CR100)
[1.52 m2] [1.85 m2] [2.15 m2] [3.7 m2]

40
4.2
Thermosiphon
System
Configuration

4.3
Forced
Circulation
System
Configuration

[.] Different configurations or different absorbers might be needed in different global locations

[.] For accessories, plumbing and mounting parts review chapters 5, 6 and 8

[.] Dimensions, weight and other properties of solar collectors can be found in chapter 2

[.] Dimensions and weight of solar, double jacket and spiral tanks can be found in chapter 3

[.] Supply line recommended pressure: 4-6 bars

[.] Thermostat maximum temperature setting: 60oC (140of)

41 Installation: Getting Started

4.4
Safety
[.] Always exercise extreme caution when working on or around a roof
[.] Be sure to secure ladders so that they do not slip or fall
[.] Wear shoes with proper tread to prevent slipping
[.] Disconnect all electric power when installing the control system and pumps
During Site [.] Always consult with the proper authorities or check with your local building
Inspection department for requirements and applicable codes before starting the job

4.5
Review
Review:
[a] Area requirements
[b] Plumping requirements
[c] Roof support stress load and modification requirements, (including engineering
Local Codes review, if necessary)

Obtain building plans, if possible, to help locate bearing walls /columns / beams,
and determine truss strength.

Record extreme weather conditions:

[a] Heavy snowfall areas require a roof-ridge mount
[b] High-wind areas require an additional bracing kit
[c] Installation sites subject to winds of more that 50 m.p.h. require a specially
engineered mounting rack

4.6
Tools and
Basic Plumbing Supplies
Standard tools: pliers, cutters, hammers, saw,
screwdrivers, metric and American wrenches
Carpentry Supplies

5x10x240 cm (2”x4”x96”) redwood or

treated wood runners as required

equipment 12” pipe wrench Masking/Duct tape

Adjustable - crescent wrenches Waterproof sealing compounds

M8 /5 /16” lag bolts ,

Water pressure gauge
length 2”,3”,4”,6” as required
Nails, 10 cm (16d -3.5”)
Copper tubing tools
or assorted as required

Caulking gun Silicone sealant

Wood/sheet metal
24” spirit level
screws and washers

Measuring tape

Extendable ladder

½’’electric drill with bits

Skill saw with standard

and masonry blades

42
 [.] system must face south when installed in

4.7
a northern hemisphere location
.
[ ] system must face north when installed in a
southern hemisphere location
Selecting .
[ ] deviation of 30 0 to each side is acceptable
[.] site must be shade -free all year round and
system location
clear of obstructions
Figure 6.5 Northern Hemisphere positioning

4.8
Roof Survey
Record the following on your pre-installation survey:
[.] Type of roofing material (tile, shingle, tar & gravel, metal, etc.)
[.] Roof condition. Note repair requirements
Note: Roofs in poor condition may need replacement before installation.

Using the following table, select the appropriate supporting structure:

Roof Type Supporting Structure

TS system inclined roof rack

Inclined roof
FC system collectors rack

TS system universal flat roof stand

Flat roof
FC system flat roof collectors rack

Tile roof structure

[.] Draw diagram (top view) of installation area. Mark the location of the system and stub-out (see figure 6.5)

43 Installation: Getting Started

45 Installation: Getting Started
Installation Flat solar collectors must be tilted at an angle (to the horizontal surface) that
is approximately equal in degrees to the local latitude. Since the sun is lower
Tilt-angle on the horizon during the winter months, tilting the collector at an angle of
up to 15 degrees greater than latitude increases winter performance, which is
desirable in most cases.

Roof Support The 300 L (80 GL) system weighs 475 kg (1140 lbs) when installed and filled,
therefore it might be necessary to provide additional roof support. You must
Requirements inspect the roof support system to determine if additional bracing is needed.

4.9
Water
Water quality | City water is a controlled water source and should not cause
any difficulty with the system. Some water may have elevated mineral content
and require more frequent system maintenance. For additional information
review section 1.8.
Requirements
Water pressure | water pressure range of 1 to 6 bars (15-87 psi) is required for a
correct operation. Pressure above 6 bars (87 psi) requires the installation of a
pressure regulator on the main supply.

Notes:
[.] All plumbing installation must conform to local codes
[.] All piping must be adequately supported: supports must conform to local codes
[.] All piping must be adequately insulated: insulation must conform to local codes
[.] All piping must slope towards a drain
[.] Plumbing must be installed in a manner that minimizes flow resistant

4.10
Customer
Suggested customer procedures:
[.] Review installation point with the customer
[.] Ensure that the customer signs job approval form

Approval

46
4.11
Work Force
The empty 300 L (80 GL) tank weighs 130 kg (290 lbs) and special provisions
are required to lift it to the roof. In some cases a crane is needed to place the
tank on its rack. Only a qualified electrician, should install all electrical wiring.
Professional installation is essential to the reliable operation of a solar system.
Installers should be specialists in the planning and installation of solar water
heating systems.

4.12
Propylene Glycol
For anti-freeze protection of closed-loop solar systems anti-freeze liquid is
filled, containing a certain percentage of propylene glycol solution according to
the lowest ambient temperature predicted.

properties Concentration by volume Propylene Glycol Freezing Point

55% -40oC (-40oF)

50% -33oC (-28oF)
40% -25oC (-13oF)
30% -16oC (+4oF)
20% -8oC (+17oF)

Notes:
[.] concentration of 40% to 50% glycol is accepted as a standard in central Europe
[.] Anti-freeze protection is essential, as a single freeze event can destroy a
collector. (Even in warm areas, collector tubes have frozen and burst during
hard winter freezes)
.
[ ] The Food and Drug Administration (FDA) has determined propylene glycol
to be “generally recognized as safe” for use in food, cosmetics, and medicines
.
[ ] Corrosion is usually minimized by using pH control and corrosion inhibitor use;
however corrosion problem are unlikely to occur in air-free closed circuit systems

47 Installation: Getting Started

5
Thermosiphon system installation
5.1
Inclined roof
[ 1] Mark supporting rafter/ truss and bearing-wall/column/beam locations on roof
[ 2 ] Mark the tank location on the roof
[ 3 ] Remove the tiles and place four metal bases on the roof truss with 8x60 M lag bolts
[ 4 ] Place the tiles back in place and seal holes, if any were made
installation [ 5 ] Place the system metal frame over the bases and secure the frame to the
bases with 10 M bolts
[6 ] Position and secure the tank to the cradle to the cradle, remember that the
tank is heavy and needs special care
[ 7 ] Position the collectors in place and secure them by using the supplied brackets
[ 8 ] Connect the solar collectors between them (if two or more are used), using
a ¾” brass union
[ 9 ] Connect the flexible pipes between the tank and the collectors to ensure
continuous slope toward the tank
[10] Fill the water tank with water and make sure there is no leakage
[11] Fill the closed-loop with anti-freeze, purge air and make sure there is no leakage

Inclined TS 150/200 L inclined roof stand parts

roof rack No. Description Quantity
parts MXMAMZV100 front leg TLSCPc 1 2
MXMAMZV105 front leg TLSCPc 2 2
MXMAMZV155 upper bar 200 1
MXMAMZV150 collector ruler 200 1
MXMAMZV120A tank support 1 2
MXMAMZV120B tank support 2 2
MXMAMZV122 COL. securer 45° 2
MXMAMZV145 Tension bar-diag 200 1
MXMAMZV100 Leg base 4
Bolt 8x15 M 18
Nut 8 M 16
Bolt DIN 7991 8x20 M 2

50
TS150 /200 L Install the system rack as shown in the drawings:

Inclined Roof
Stand Parts

Detail A

[.] Use a mold to set the location of the bases in accurate position

[120B][122] [155] [145]

[120A]

[100]

[105]

[150] [135]

51 Thermosiphon System Installation

5.2
Flat roof
[1] Mark supporting rafter/ truss and bearing-wall/column/beam locations on roof
[2] Mount and position the stand on provisions made for the stand in the flat roof
[3] Position and secure the tank on the cradle, remember that the tank is heavy
and needs special care
installation [4] Position the collectors on the stand and secure them by using the supplied brackets
[5] Connect the solar collectors between them (if two or more are used), using
a ¾” brass union
[6] Connect the flexible pipes between the tank and the collectors to ensure
continuous slope toward the tank
[7] Fill the water tank with water and make sure there is no leakage
[8] Fill the closed-loop with anti-freeze purge air and make sure there is no leakage

Flat roof
stand

Low Profile Installation

52
 parts for 150 L & 200 L stands 30° & 45° mounting:
MAXFH1F30 MAXFH1F45 MAXFH1D30 MAXFH1D45
Part no. Description 200L-30° 200L-45° 150L-30° 150L-45°
QTY. QTY. QTY. QTY.
MXMAMZV100 front leg TLSCPc 1 2 2 2 2
MXMAMZV105 front leg TLSCPc 2 2 2 2 2
MXMAMZV110 upper bar 150 0 0 1 1
MXMAMZV115 collector ruler 150 0 0 1 1
MXMAMZV120A & MXMAMZV120B 2 2 2 2
MXMAMZV122 COL. securer 45˚ 2 2 2 2
MXMAMZV125 rear leg 150-30 0 0 2 0
MXMAMZV126 rear leg 150-45 0 0 0 2
MXMAMZV130 tension bar 4 2 5 3
MXMAMZV131 tension bar short 0 2 0 2
MXMAMZV135 leg base 4 4 4 4
MXMAMZV140 rear leg 200 30˚ 2 0 0 0
MXMAMZV141 rear leg 200 45˚ 0 2 0 0
tension bar-diag.
MXMAMZV145 1 1 0 0
200
MXMAMZV150 collector ruler 200 1 1 0 0
MXMAMZV155 upper bar 200 1 1 0 0
steel frame COL.
MXMAMZV160 2 2 2 2
securer

[120B] [122]
[120A]
[150] [145]
[100]
B

[140]

[130]

[130]

[160] [155]
[105]
A

[135]

Detail A Detail B

[.] For detailed drawings of other models such as low profile stands, please contact your local Chromagen agent

53 Thermosiphon System Installation

5.3
Plumbing
Use the fittings and accessories supplied with the system. Install the system
according to one of the following installations possibilities:
5
4
3
2
1
HOT OUTLET

6
7

13
COLD INLET
18 8 9 10 12
11
After filling
the C\L, 21
close the valve
with plug (21) 13
14 11
FILLING VALVE
15
5 To col. 16mm insulated copper tube
From col. 16mm insulated copper tube 17 16
20
19 22 18
23
24

Only for
low profile
installations

22 20
18 19
[.] In a high profile installation there is no need for a “low profile check valve” since there is no risk of

reverse thermosiphon action

Description IKITCL0190 IKITCL0200

No.
Thermosiphon Closed loop system QTY. QTY.
1 Steel reducing nipple 1/2” - 3/4” 1 1
2 Brass T 1/2” 1 1
3 Ball valve 1/2” M-F 1 1
4 Air relief valve 1/2” 1 1
5 Brass copper tube 1/2” M-16 mm 2 2
6 Brass elbow 3/4” M-M 1 1
7 Brass check valve 1/2”-3/4” 1 1
8 Brass pressure relief valve 8 bar 1/2” 1 1
9 Galvanized nipple 3/4”x120 1 1
10 Brass cross 3/4” 1 1
11 Brass reducing nipple 3/4”-1/2” 2 2
12 Expansion vessel 8 L 1 1
13 Brass ball valve F-F 1/2” 2 2
14 Brass cross 1/2” 1 1
15 Pressure relief valve 3 bar 1 1
17 Manometer 1 1
18 Brass plug 3/4” M 3 3
19 Brass street elbow 3/4” F-M 2 2
20 Brass copper tube 3/4” M-16 mm 2 2
21 Brass plug 1/2” M 1 1
22 Brass bushing 1/4”-1/2” 1 1
22 Brass union 3/4” 2 -
23 Brass hex double nipple 3/4” 1 1
23* Brass hex double nipple 3/4” 1 1
24* Low profile valve 3/4” F-F 1 1
[.] (23,24) Only for low profile installations * IKITCL0190 kit for 2 collectors ** IKITCL0200 kit for 1 collectors

[.] for safety reasons a system shall be provided with blow-off lines wherever steam or hot fluid can escape

(parts 8,15)

54
Thermosiphon 1
2 BACK VIEW

Closed-loop
10
System HOT WATER OUTLET
3

insulated SS tube
5 insulated SS tube
COLD WATER INLET

6 6 10 9 10 6 7

10

8
9 6
6
10 10

[.] high profile installation

Description IKITCL0330 IKITCLO360

No.
Thermosiphon closed-loop system QTY. QTY.
9 Brass union 3/4” - 2
10 Brass street elbow 3/4” 6 6
2 Brass reduction nipple 1/2”-3/4” 1 1
3 Brass check valve 1/2”-3/4” 1 1
4 Brass pressure relief valve 8 bar 1 1
5 Brass ball valve 1/2” F-F 1 1
1 Safety valve 3 bar 1/2”x3/4” 1 1
8 Ball valve 1 1
7 Brass plug 3/4” M 1 1
6 Flat fiber seal 3/4” 5 5

* IKITCL0330 kit for 1 collectors ** IKITCL0360 kit for 2 collectors

[.] for safety reasons a system shall be provided with blow-off lines wherever steam or hot fluid can escape

(parts 1,4)

55 Thermosiphon System Installation

 7
6 8
4
20

21
To Exp. Vessel
20 2

14 8 21
5 22 23
24 4 10 21 3
25
24
21 15 19
21 4 11

14

19 15
21

14

[.] In a high profile installation there is no need for a “Low Profile check valve” since there is no risk of

reverse thermosiphon action

No. Description Qty.

2 Expansion vessel 8 L 1
3 Brass bushing 1/4”-1/2” 1
4 Brass bushing 1/2’’ x 3/4’’ 3
5 Brass check valve 1/2”-3/4” 1
6 Brass bushing 3/8”-1/2” 1
7 Automatic air relief valve 1
8 Galvanized nipple 3/4” 2
10 Brass cross 3/4” 1
11 Manometer 1
14 Brass street elbow 3/4” M-F 3
15 Brass union 3/4” M-M 2
19 Brass plug 3/4“ M 2
20 Brass T 3/4’’ 2
21 Brass hex double nipple 3/4” 6
22 Low profile valve 3/4” F-F 1
23 Brass plug 1/2” 1
24 Brass pressure relief valve 8 bar 2
25 Brass ball valve 1/2” F-F 1

[.] for safety reasons a system shall be provided with blow-off lines wherever steam or hot fluid can escape (parts

24 x two units)

56
5.4
Filling and Testing
Important: in a double - jacket tank, ensure that the solar storage tank is filled
and pressurized before filling the double mantle.

Filling Procedure [1] Make sure that all system connections are fastened and that the tank is leveled
[2] Connect the tank to the main water supply and fill with potable water
[3] Remove heat-exchanger air relief valve
[4] Connect the anti-freeze filling pipe to the filling valve
[5] Fill the closed-loop with anti-freeze solution until all the air is purged out
of the collector loop and it is completely filled
[6] Return to place the air relief valve
[7] Pressurize the closed loop to 3 bar and make sure all the air is purged
[8] Test for possible leaks and repair, if needed
[9] Lower the collector loop pressure to a working pressure of 2-3 bars by purging
water from the air relief valve

Additional Notes [.] Prepare 10-20 L of anti-freeze solution depending on the heat-exchanger type
and size. (See anti-freeze solution table in section 4.12 | See collector
volume in chapter 2 | See heat-exchanger volume in chapter 3)
.
[ ] The system operates properly only when the internal heat-exchanger is fully
filled with liquid. Air in the system might hinder the thermosiphon action.
Check carefully for leaks and tighten all fittings (re -checking is recommended
every 6 months)
.
[ ] Recommended closed loop working pressure is 2 - bar for Double-Jacket and
3 bars for spiral heat-exchanger
.
[ ] It is necessary to install a pressure reduction valve if the water supply pressure
exceeds 6 bars
.
[ ] There is no provision for the collection of water in case of leakage from the tank.
(Seal or fitting failure). Consider installing a pile with draining pipe under the tank
.
[ ] Local codes might require the installation of a tempering (mixing) valve
between the hot water outlet of the tank and the main hot water supply pipe
to the house. The tempering valve should be regulated to 50oC
[.] for safety reasons a system shall be provided with blow-off lines wherever
steam or hot fluid can escape
Filling Point 1
Pressure Relief Valve

Supply Water
Water to User

Solar Collectors

Filling Point 2

[.] Tank must be located above the collectors

[.] Low profile requires additional check valve

57 Thermosiphon System Installation

6
Forced circulation system installation
6.1
Introduction
Forced circulation systems are to be used whenever the storage tank cannot be
installed above the collectors as described in chapter 2. The circulating pump
is operated by a differential thermostatic control. The basic elements of this
system are:
[.] Solar collectors
[.] Storage tank
[.] Circulation pump
[.] Differential thermostat
[.] Sensors
[.] Expansion tank
[.] Valves and accessories
The elements in this system simulate the thermosiphon phenomena.

Description MXFH0030
No.
Inclined roof rack for 2 collectors QTY.
1 ALUM sima30 profile 2310 mm 2
2 Carriage bolt 8 M 20
3 8 galvanized nut M 20
4 Collector fastener alum 8
[1]5 Screw 2 pairs ofRack
bases to the
base [2] Connect 2 Aluminium bars4to the
roof base beams. 2 upper and 2 lower bases.
6 Collector support 99x30 x2 4
7 Lag bolt 8x60 M 12
[1]
[1] Screw
Screw 22 pairs
pairs of
of bases
bases to
to the
the [2]
[2] Connect
Connect 22 Aluminium
Aluminium bars
bars to
to the
the
roof
roof base
base beams.
beams. 22 upper
upper and
and 22 lower
lower bases.
bases.

6.2
[1] Screw 22 pairs
pairsof
ofbases
basestotothe [2] Connect 22 Aluminium
aluminiumbars
barstotothe
the
roofthe
base beams.
roof base beams 2 upper and and
2 upper 2 lower bases.
2 lower bases

Inclined roof Place the collectors over the 2 bars.

installation
Place
Place the
the collectors
collectors over
over the
the 22 bars.
bars.
[3] [4]

Place the collectors

Place the collectorsover
overthe
the22bars.
bars

[3]
[3] [4]
[4]
[3] [4] Secure the collectors to the bars

[3] [4]

[5]
[5]

[5]
[5]

[5]

60
 B [7]

[2] [6]

Detail B [8] [9]

[1]
[3]
[11]
A

Detail A

Single Collector steel rack

MXFH0030
No. Part number Description
QTY.
1 MXMAMZV105 Front leg TLSCPc 2 2
2 MXMAMZV130 Tension bar 1
3 MXMAMZV135 Leg base 4
4 PBRAGV060 Nut 8 M 16
5 PBRAGV040 Bolt 8x15 M 12
6 MXMAMZV240 front leg TLSCPc 1 2
7 MXMAMZV225 - a Collector upper securer 2
8 MXMAMZV200 Collector bottom clamp 2
9 MXMAMZV110 Lower/upper bar 150 2
10 PBRALN100 DIN 7991 8x20 M conic head 4
11 MXMAMD020 Slope roof stand base 4
12 PBRAGV030 Hex bolt 10x20 M 4
13 PBRAGV065 Hex nut 10 M 4

6.3
Flat roof
[.] Wind pressure requires binding the collector to the roof
[.] The wind pressure can be approximated by:
Pressure = ½ x (density of air) x (wind speed)2 x (shape factor)
[.] The density of air is about 1.25 kg /m3. The shape factor (drag coefficient)
installation depends on the shape of the body. It has order of magnitude 1 and it is
dimensionless; here it is approximated as 0.6
.
[ ] The wind speed must be expressed in m/s. In that case the pressure has units
of kg/m/s2, i.e. N/m2
[.] In case of 40 m/s wind speed=> wind pressure = 0.5x1.25x40x0.6=600
[N/m2]=600 [pa]
[.] This pressure requires a support of approximately 60 kg for every square meter
mounted in a 45° on a flat roof

61 Forced Circulation System Installation

 [11] [3]
B

[5]
[1]

[4] [5]

[8] [2] [7]

[6]

Detail A Detail B 4x 8 M Concrete Wedge Anchors

Detail B Detail A Detail B Detail method
[Optional A of securing the
stand to the roof]

Description MAXFHEF45
No.
Flat roof Collectors stand 1xE/F QTY.
1 Front leg TLSCPc 1 2
2 Front leg TLSCPc 2 2
3 Lower/Upper bar 2
4 Rear leg 2
5 Tension bar 3
6 Leg base 4
7 Collector bottom clamp 2
8 Long tension bar 2
9 NUT 8 M 23
10 Bolt 8 x15 M 19
11 Collector upper securer 2
12 Cone bolt and nut 8 x20 M 4

62
6.4
Installation of
Large forced circulation systems requires larger collectors field

collectors field

[3] [2] [1]

The collectors are regularly connected to each other with 3/4” brass unions

6.5
Location
The collectors should be placed facing south or north, depending on the earth’s
latitude and slope, as explained in section 4.7. The tank should be placed as
close as possible to the collectors, to avoid heat loss . The recommended pump
should match the hot water circulation and a flow of 50 -100 L per hour per 1 m2
of collectors, of collectors’ area.
tank and system
operation

63 Forced Circulation System Installation

Plumbing 17 10 11 12 15 21 16 Tank sensor

forced Hot water exit

circulation 2 13 14
From auxiliary

To auxiliary heater

System From COL. 16mm

insulated copper tube
2 1
From collector

To collector
2 20

COL. sensor
2 16 Cold water inlet

insulated copper tube

7

16mm
8 5 6 3
18
2
12
10 19
4
2
1
To COL. 16mm insulated copper tube

Description IKITCL0168
No.
Forced system with pump station QTY.
1 Steel adaptor 3/4’’ M-F 2
2 Brass copper tube 3/4” M-16 mm 6
3 Steel short nipple 3/4’’ 1
4 Brass street elbow 3/4’’ 2
5 Brass check valve 1/2-3/4’’ 1
6 Brass ball valve 1/2’’ F-F 1
7 Brass pressure relief valve 8 bar 1
8 Pump station 1
10 Brass union 3/4’’ 2
11 Brass hex double nipple 3/4’’ 1
12 Brass 3/4’’ T 2
13 Brass reduction nipple 1/2-3/4’’ 1
14 Brass 1/2’’ T 1
15 Air relief valve 1
16 Temperature sensor 20 cm sensor 1
17 Brass plug 3/4’’ M 2
18 Brass barrel nipple 3/4’’ 1
19 Expansion vessel 8 L 1
20 Brass plug 3/4’’ F 1
21 Ball valve 1/2’’ M-F 1

[.] for safety reasons a system shall be provided with blow-off lines wherever steam or hot fluid can escape

64
6.6
Anti-freeze
The system is double anti-freeze protected. The heat transfer liquid is a solution
of propylene glycol and water, and the pump circulates warmer heat transfer
liquid through the collector in freezing conditions. Anti-freeze protection
is essential for all solar systems as a single freeze can destroy a collector.
Protection

6.7
Plumbing
Follow the installations details as shown on Fig 6.4 and as explained in section 5.4.
Use the following guidelines:
[.] water feed to the tank should be through a ball valve and a check valve
[.] pump must be installed on the cold line, which runs between the lower part
of the tank to the lower inlet of the collector(s) and a check valve must be
installed next to the pump
.
[ ] To allow pump service, install ball valves before and after the pump
[.] All pipes in the circulation line should be 16/18 mm copper, water-quality pipes
[.] Pipes lengths shall be adjusted to the specific installation. Shortest pipes
should be used to minimize unwanted heat loss
.
[ ] Best performance achieved with well insulated pipes. The hot line from the
collectors must be insulated
.
[ ] for safety reasons a system shall be provided with blow-off lines wherever
steam or hot fluid can escape

6.8
Electrical
It is recommended to put the differential thermostat in an electrical box with
a switch and fuses. The box should be accessible for maintenance and easy to operate.
A qualified electrician should perform all wiring according to local codes.
The wiring from the differential thermostat to the sensors carries a very low
Connections voltage and is not dangerous when wired correctly.

6.9
Additional
[.] A discharge pipe may be connected in a continuously downward direction in

.
a frost free environment and open to the atmosphere
[ ] It is necessary to install a pressure reducing valve, if the water supply pressure
exceeds the rated pressure
Notes .
[ ] The recommended flow rate of the collector loop is 50-100 l/hr m2 of absorber surface

65 Forced Circulation System Installation

7
Troubleshooting and maintenance
7.1
Thermosiphon
Problem Probable Cause

[1] Shadow on the collectors

Corrective Action

[1] Remove obstruction

[2] Incorrect piping [2] Re-pipe
System [3] Clogging pipes [3] Clean pipes
troubleshooting Not enough hot water
[4] Tank blocked with sediment [4] Clean
[5] System not leveled [5] Level
[6] Ruptured tank jacket [6] Replace tank
[7] Air trapped in circulation pipes [7] Purge air
[8] Not enough liquid in the closed loop [8] Fix leaks and fill up

7.2
Forced Circulation
Problem Probable Cause

[1] Electrical fault

Corrective Action

[1] Check electrical connections

[2] Burnt motor or fuses [2] Replace
Systems [3] Cloudy weather, not enough [3] No action required.
troubleshooting Pump is not working temperature to operate thermostat
[4] Differential thermostat is not
The system is working

[4] Repair or replace

working
[5] Faulty sensor [5] Replace
[1] Working non-stop [1] Check differential thermostat
[2] Air trap [2] Purge air
Pump working
incorrectly [3] Faulty sensors [3] Replace
[4] Differential thermostat does not
[4] Repair or replace thermostat
begin to work.
[1] Water taps in circulation line
[1] Open
are closed
[2] Air trapped in circulation loop [2] Purge air
No water circulation
[3] Blockage in circulation loop piping [3] Clear blockage
[4] Piping diameter too small causing [4] Replace with wider
high pressure drop diameter piping
[1] Pump is not operating
[2] Air trapped in circulation loop Check all accessories, air vents,
No hot water one way valves, filling system of
[3] Frozen or leaking pipes
jacket
[4] Pump circulates during cloudy days
or night due to faulty sensors
[1] Set switch to automatic
[1] Control switch in manual position
position
[2] Release air via air vent valves
[2] Air trapped in solar circulation loop
installed in collectors array
Circulation Pump [3] Check the differential
operating non-stop [3] Defective differential thermostat thermostat. Replace if
necessary
[4] Check sensor(s) with
[4] Faulty sensor(s) Ohmmeter. Replace if
necessary
WARNING! These systems are electrically powered. Take necessary precautions to
avoid electrical shock.

68
 Problem Probable Cause Corrective Action

[1] Set control switch to

[1] Control switch in manual position
automatic mode
Pump operating
at night or when [2] Water not circulating in the solar
[2] See next section
there is lack of circulation loop
solar radiation [3] Check valve is stuck in open
during the day [3] Strike check valve lightly with a
position causing thermosiphon
due to cloudiness plastic hammer or wooden rod
flow in circulation loop
[4] Defective differential thermostat [4] Repair or replace
[1] Water taps in circulation loop are
[1] Open water taps
closed
[2] Air trapped in circulation loop [2] Purge air
[3] Check valve is stuck in closed [3] Strike valve with plastic
position hammer or wooden rod
Pump operating [4] Check valve installed in the wrong [4] Install valve in proper flow
but water does direction direction
not circulate in [5] Incorrect piping installation in
the circulation [5] Install piping correctly
circulation loop
loop
[6] Locate blockage and clean or
[6] Circulation loop pipe clogging
replace pipe
[7] Replace damaged section of
[7] Bent or dented pipes
pipe
[8] Main pipe with too small diameter
[8] Use larger pipe diameter
causes high pressure drop
[1] Control switch in OFF position [1] Set control switch to Automatic

[2] Check if fuse is suitable for pump

[2] Burnt fuse power, Change fuse, check that
pump shaft is not stuck

[3] Defective differential thermostat [3] Repair or replace

[4] Check sensors with ohmmeter.
Circulation pump [4] Faulty temperature sensors
Replace if necessary
does not operate
[5] Faulty pump motor [5] Replace pump motor
[6] Check if voltage supply is
[6] Pump receiving no power supply
reaching pump connections
[7] Change differential thermostat.
[7] Burnt transformer in the
Check that the voltage supply
differential thermostat
is not more than 110 V 20V
[8] Collectors are covered with dust [8] Wash the collectors
[1] Collector’s temperature sensor is
[1] Install sensor as deep as possible
installed outside the collector’s
inside the collector header
header
Pump operating
[2] Tank’s temperature sensor is [2] Install the sensor at the bottom
with long delay
installed too high in the tank of the tank
[3] Consult with Chromagen
[3] Wrong controller setting
technical staff
Pump repeatedly [1] Purge air out of system-ensure
[1] Air-bound system
starts and stops pipes slope
[1] Air bound pump [1] Purge air out of system
[2] Broken pump coupler [2] Replace; check alignment

No circulation [3] Clogged impeller or piping [3] Locate and remove obstruction
[4] System valve closed [4] Open
[5] Check all related low and line
[5] Incorrect pump electrical-circuit
voltage circuits

69 Troubleshooting & Maintenance

 Problem Probable Cause Corrective Action

[ 1 ]purge air out of system-

[ 1 ] Air-bound system
ensure pipes slope
[ 2 ] Air-bound pump [ 2 ] purge air out of system

[ 3 ] Clogged impeller or piping [ 3 ] Locate and remove obstruction

[ 4 ] Clogged strainer [ 4 ] Remove and clean screen

[ 5 ] Pump impeller damaged or
[ 5 ] Replace or re-assemble
Inadequate backwards
Circulation [ 6 ] Lower pump, raise pressure
[ 6 ] Insufficient NPSH
or relocate
[ 7 ] Pump too small [ 7 ] Replace pump

[ 8 ] Partially air-bound pump [ 8 ] Purge air out of system

[ 9 ] Pump running backwards
[ 9 ] Reverse any two motor leads
(three-phase)
[10] Improper motor speed [10] Check wiring and voltage

[ 1 ] Trapped air [ 1 ] Vent system

[ 2 ] Lower pump or raise
[ 2 ] Pump cavitation
pressure or relocate
Pump or [ 3 ] Install balancing cocks or
[ 3 ] Excessive water velocity
system noise parallel piping
[ 4 ] Provide rigid foundation
[ 4 ] Poor foundation
with adequate grouting
[ 5 ] Provide adequate pipe
[ 5 ] Pipe vibration support or change pipe
length
[ 1 ] Improper pump (size/ type) [ 1 ]Replace

[ 2 ] Improper pump location [ 2 ] Relocate

Premature
[ 3 ] Check manufacturers
failure of pump [ 3 ] Excessive water treatment
instructions
components
[ 4 ] Pump operating close
[ 4 ] Balance system
to or beyond
[ 5 ] Excessive piping load [ 5 ] Provide proper pipe support

If troubleshooting fails, please contact your local dealer or Chromagen’s head office

7.3
Maintenance
This section covers scheduled inspections, maintenance, and detailed
procedures for dismantling and repair of the system. Only qualified personnel
should perform periodic maintenance.

70
7.4
Periodic
[.] Check the system pressure every 6 months. Pressure reduction might indicate

.
a leak. The pressure should remain above 1 bar. If necessary, pressurize again
and check for leaks
[ ] Every 3-6 months clean the collectors’ glazing and trim any surrounding
maintenance trees that might cast a shadow on the collectors
.
[ ] Every 12 months flush all safety valves. Pressure relief device failure may
result in excessive pressure and system damage. Continuous leakage from
the valve may indicate excessive heat or defective valve
.
[ ] Flush and refill collectors in open-loop systems every 12 - 18 months
[.] Drain tank if necessary: the cold water inlet is generally the lowest pipe in the
tank. Close the main supply, disconnect pipe, and open the tanks’ hot water
outlet for air to come in while draining
.
[ ] Replace anodes and safety valves every 3 years
[.] Every three to five years qualified personnel must check electrical connections
(pumps, thermostats, switches and wiring)
.
[ ] Every three to five years replace anti-freeze

7.5
Parts
When replacing parts, which are supplied by Chromagen: for example, collector
glass, complete collector, tank flange etc., always use Chromagen original parts
in order to keep the warranty valid.

Replacement

7.6
Warnings
A thermal cut-out might indicate a dangerous situation. Do not reset the
“Bipolar Safety” of the thermostat until the water heater has been serviced by
a qualified person.

WARNING! If the hot water system is not used for two weeks or more, a quantity
of hydrogen gas, which is highly flammable, may accumulate in the water heater.
To dissipate this gas safely, it is recommended that a hot tap be turned on for
several minutes at a sink, basin or bath, but not at a dishwasher, clothes washer
or other appliance. During this procedure, there must be no smoking, open
flame or any electrical appliance operating nearby. If hydrogen is discharged
through the tap, it will probably make an unusual sound like escaping air.
for safety reasons a system shall be provided with blow-off lines wherever steam or hot
fluid can escape.

71 Troubleshooting & Maintenance

73 Troubleshooting & Maintenance
8
Accessories
8.1
Solar station
In a closed-loop installation a pump and thermostatic control are required.
These accessories may be installed separately or combined in a complete kit
referred to as a SOLAR STATION. Chromagen supplies solar stations, which
include the RESOL thermostatic control and a WILO pump.

The standard two-line solar pump station, for integration of the controller
RESOL DeltaSol® BS is on the left side of this page (with and without cover). The
most important hydraulic components for the operation of a solar system are
already mounted for an easy and quick installation:
[.] Controller DeltaSol® BS
[.] Solar thermal pump WILO Star ST20/4 or ST20/6 or ST20/7
[.] Pointer thermometers for feed flow and return flow
[.] Return flow line with ball valve and adjustable non-return valve
[.] Flowmeter with scale
[.] Security bracket with security valve and manometer
[.] KFE-cock for filling and flushing of the system
[.] Wall mounting with screws and dowels
[.] Heat insulation

76
8.2
Thermostatic
RESOL | Chromagen supplies solar systems which includes RESOL DeltaSol BS
thermostatic control. English, Italian, French and Dutch versions of RESOL
Thermostatic control manual can be found in RESOL website: http://www.resol.de/

control STECA | Chromagen tested and approved the use of STECA thermostatic control
http://www.stecasolar.com/ The English manual version can downloaded from
steca web site.

77 Accessories
8.3
Circulation
Example | Pump Performance chart

pumps

[.] A Forced circulation system uses a pump to move hot water or propylene glycol
from the collector down to the tank
.
[ ] The water or glycol circulation through the collectors can reach temperatures
as high as 130°C, therefore only pumps that are designed to operate with hot
water may be used
.
[ ] Selecting a pump is based on the calculated head loss of the collectors loop
measured in meters of water and the required flow rate. A nominal flow rate
of 50 L/hr per square meter of collectors aperture area may be taken
.
[ ] For example, a system with two Chromagen CR110 collectors with aperture
area of 2.15 m2, each one requiring a flow rate of 4.3x50=215 L/hr. the losses
over the collectors may be taken as 2x7=14 cm and the losses through 20 m of
16 mm copper tube at 250 L/hr is approximately 60 cm. Taking into account
the loss over an internal heat-exchanger and the minor losses over the
plumbing accessories, we can assume 1 m head loss over the collectors loop
a Wilo star ST20/4 at its lowest speed should easily generate the required
flow rate for this system, see the above pump performance chart

78
79 Accessories
8.4
Freeze
The freeze protection valve can protect collectors from freezing damage at mild
low temperatures, and is suitable for open-loop systems installed at locations
with short periods of sub-zero temperatures. The 3/4” external thread valve
should be screwed into the lower collector’s manifold as a plug. The valve opens
Protection and drips when the valve’s actuator, dipped in the lower manifold, drops to 1.7°C.
Valve The valve’s opening enables the storage tank’s water to enter the collector. The
valve closes at 4.4°C, when hotter water reaches the actuator.
Remember not to insulate the valves body!

8.5
Thermostatic
Thermostatic mixing valve is fitted between the solar water heaters hot water outlet
pipe and the home hot water piping system. Its purpose is to ensure that water
temperature does not exceed 50 °C in order to avoid burns and piping damage.

mixing valve ]1[ ]2[

]4[ ]3[

[1] Tank’s hot water outlet

[2] Tank’s cold water inlet
[3] Cold water supply
[4] Controlled hot water to user

80
8.6
Anti-scale
The anti-scale filter protects open-loop systems from scale build up. This anti-
scale filter is a plastic filter containing polyphosphate (siliphos) crystals.
Siliphos reduces the amount of scale deposits by keeping the minerals, which
cause scale, in a dissolved and suspended state at higher temperatures. As a
filter result most scale-causing minerals pass through the system instead of forming
scale deposits near the heating element or in the collector.

Siliphos is classed as a ‘food grade’ additive which conforms to EN1208 and WHO
standards as a safe additive for drinking water. Therefore it can be installed
directly on the cold water supply to the tank, and the customer can safely bath
in or even drink the water that has passed through the filter.

Siliphos reduces its volume in proportion to the amount of water passing

through the anti-scale filter which will vary according to specific domestic
circumstances. The siliphos fill should be changed every 1.5 years.

siliphos crystals

81 Accessories
Index Index: Glossary of Terms

Abbreviation Corrective Action

ALUM Aluminum

COL. Collector

cm Centimeter

D.J. Double-Jacket

DIAG Diagonal

DIAM. Diameter

F Female

GL Gallon

hr Hour

L Liter

M Male

mm Millimeter

N Narrow

P Page

PRESS Pressure

QTY. Quantity

TEMP Temperature

TLSCPc Telescopic

Vol. Volume

W Wide

v2.0 | ©2011, Chromagen, Ltd. Subject to change without notice.

82
Sha’ar Ha’amakim 36588, Israel | Telephone +972.4.953.8888 | Fax +972.4.953.8872 | www.chromagen.com