SOLAR KIT INSTALLATION MANUAL
SOLAR KIT INSTALLATION
MANUAL
2
Index
Chapter 1
WARNINGS AND SAFETY DEVICES...................................................................................................... 5
Chapter 2
COMPONENT DESCRIPTION ................................................................................................................ 7
PS AS1..................................................................................................................................................................................... 8
BSV 150 ES ..........................................................................................................................................................................10
BSV 300 ................................................................................................................................................................................11
BSV 300 ES ..........................................................................................................................................................................12
TPS 500.................................................................................................................................................................................14
TPS 1000 ..............................................................................................................................................................................15
SRA 1,5 .................................................................................................................................................................................16
SRA 3 .....................................................................................................................................................................................16
SRA 5 .....................................................................................................................................................................................16
GSC1......................................................................................................................................................................................17
GSC 2.....................................................................................................................................................................................17
CS 3.1 ....................................................................................................................................................................................18
CS 3.2 ....................................................................................................................................................................................18
VES 18 ...................................................................................................................................................................................19
VES 35-50-80 ......................................................................................................................................................................19
GAG 20 .................................................................................................................................................................................20
Chapter 3
DIMENSIONING ...................................................................................................................................21
INCLINATION OF THE COLLECTORS .........................................................................................................................21
PRODUCTION OF JUST DOMESTIC HOT WATER .................................................................................................22
PRODUCTION OF HOT WATER AND INTEGRATION TO HEATING .................................................................24
HEATING SWIMMING POOLS ......................................................................................................................................25
Chapter 4
SERIES/PARALLEL CONNECTION LAYOUTS AND PANEL ARRAYS .................................................26
Chapter 5
SLOPING ROOF ....................................................................................................................................29
DESCR5IPTION OF THE ASSEMBLY COMPONENTS FOR 1 OR 2 PANEL KIT ..............................................29
LOADS DUE TO THE WIND OR SNOW ......................................................................................................................29
ASSEMBLY PHASE ............................................................................................................................................................31
Chapter 6
FLAT ROOF ...........................................................................................................................................34
PREMISE ...............................................................................................................................................................................34
COMPONENT DESCRIPTION........................................................................................................................................34
ASSEMBLY INSTRUCTIONS ..........................................................................................................................................36
MULTIPLE COMPOSITION OF THE KITS ...................................................................................................................40
3 PANELS: KIT 1 + KIT 2 ..................................................................................................................................................40
4 PANELS: KIT 2 + KIT 2 ..................................................................................................................................................40
5 PANELS: KIT 1 + 2 X KIT 2 ...........................................................................................................................................41
FIXING THE MULTIPLE KITS ..........................................................................................................................................41
FIXING THE ARRAYS ........................................................................................................................................................41
6 PANELS: 2 X KIT 1 + 2 X KIT 2....................................................................................................................................41
8 PANELS: 4 X KIT 2 ..........................................................................................................................................................42
3
10 PANELS: 2 X KIT 1 + 4 X KIT 2 .................................................................................................................................42
INCLINATION OF THE PANELS ....................................................................................................................................43
SHADOWING .....................................................................................................................................................................43
DISTANCE FROM THE EDGE OF THE ROOF ............................................................................................................44
Chapter 7
TEMPERATURE PROBE AND HYDRAULIC SUPPLY CONNECTION ASSEMBLY ..............................45
Chapter 8
HYDRAULIC SYSTEM ...........................................................................................................................47
INDICATIONS OF THE TYPE AND DIAMETERS OF THE PIPES .........................................................................47
CONNECTION OF THE PUMP UNIT ...........................................................................................................................51
DIMENSIONING AND CONNECTION OF THE EXPANSION VESSEL...............................................................53
CONNECTION TO THE STORAGE TANK....................................................................................................................56
CONNECTION OF THE BSV 300, BSV 150 ES CYLINDER ....................................................................................56
CONNECTION OF THE PUFFER ...................................................................................................................................57
Chapter 9
ELECTRONIC CONTROL UNIT .............................................................................................................59
ELECTRIC ATTACHMENT ...............................................................................................................................................60
INSTALLATION...................................................................................................................................................................60
ASSEMBLY ...........................................................................................................................................................................60
USE AND FUNCTIONING ...............................................................................................................................................62
COMMISSIONING.............................................................................................................................................................64
CONTROL PARAMETERS AND DISPLAY CHANNELS ..........................................................................................65
Chapter 10
START-UP .............................................................................................................................................76
WASHING THE SOALER CIRCUIT ................................................................................................................................76
SEALING CHECK ...............................................................................................................................................................77
WASHING THE SOLAR CIRCUIT ..................................................................................................................................77
DILUTING THE GLYCOL TO THE DESIRED CONCENTRATION ..........................................................................78
FILLING THE SOLAR CIRCUIT .......................................................................................................................................80
SETTING THE COLLECTOR AND SYSTEM FLOW RATE .......................................................................................81
CHECKING THE SETTINGS OF THE ADJUSTMENT CONTROL UNIT ..............................................................82
SETTING THE DOMESTIC HOT WATER MIXER .......................................................................................................82
FILING THE BSV 300, BSV 300 ES AND BSV 150 ES TANK ................................................................................82
Chapter 11
MAINTENANCE ....................................................................................................................................83
Chapter 12
WARRANTY TERMS .............................................................................................................................85
Chapter 13
WARRANTY DOCUMENT ....................................................................................................................87
4
Chapter 1
WARNINGS AND SAFETY DEVICES
Read the assembly and commissioning instructions carefully. Make sure that assembly takes place in
compliance with recognised technical standards. Also comply with the insurance accident-prevention
standards against injury in the work place. Use that does not comply with the Standards as well as the
implementation of unallowed modifications during assembly exclude any responsibility of Extraflame
S.p.A.
Follow the following Standards particularly:
DIN 4757, 1st part D Solar heating systems with water and water mixtures as heat transfer medium;
Demands to the safety realisation.
DIN 4757, 2nd part D Solar heating systems with organic heat transfer medium; Demands to safety
realisation.
DIN 4757, 3rd part D Solar heating systems; solar collectors; Meanings; safety regulations; Testing of
standstill temperature.
DIN 4757, 4th part D Solar thermal systems; solar collectors; determination of efficiency, heat capacity
and pressure loss.
Also comply with the following European CE Standards:
UNI-EN 12975-1 Thermal solar systems and components, 1st part: general requirements.
UNI-EN 12975-2 Solar heating systems and their components; collectors, 2nd part: test methods.
UNI-EN 12976-1 Thermal solar systems and components; factory made systems, 1st part: general
requirements.
UNI-EN 12976-2 Thermal solar systems and components; factory made systems, 2nd part: test methods.
UNI-EN 12977-1 Thermal solar custom build systems and components, 1st part: general requirements.
UNI-EN 12977-2 Thermal solar custom build systems and components, 2nd part: test methods.
UNI-EN 12977-3 Thermal solar custom build systems and components, 3rd part: hot water tank efficiency
check.
The Standards and Directives of the place of installation regarding assembly and operation of the
plant must be complied with.
General precautions
™ The work position must be clean and free from objects that could be an obstruction.
™ The work place must be well-lit.
™ Keep children, pets and persons not in charge of works out of the reach of tools and work positions.
™ Keep heat transfer fluid out of the reach of children.
™ If the work position is changed, disconnect all electrical appliances from the sockets or make sure
they cannot be switched on accidentally.
™ Wear suitable work clothes: accident-prevention shoes, helmet and protective goggles.
™ Arrange anti-fall guards as requested by the Standards.
™ If high voltage cables are present in the vicinity, remove the current for the entire duration of the
work and respect safety distances in compliance with national standards.
™ If the solar collectors are installed temporarily without heat carrying fluid inside, they must be
protected from the sun’s rays in order to prevent them overheating
WARNINGS AND SAFETY DEVICES
5
Chapter 1
figure 1.1
figure 1.2
6
WARNINGS AND SAFETY DEVICES
Chapter 2
COMPONENT DESCRIPTION
All kits supplied by La Nordica & Extraflame are made up from the various combinations of the components
described above. The configuration of the kits and their features are described in the sales publications
and in the price lists.
™ EXTRAFLAME PS AS1: highly selective flat solar panels 1946 x 946 x 105 mm.
™ BSV 150 ES: 150 litre domestic hot water cylinder with single coil, with magnesium anode as per
series and external tester (replaceable alternatively with an optional electronic electrode with titanium
impressed current).
™ BSV 300: 300 litre domestic hot water cylinder with double coil, with magnesium anode as per
series and external tester (replaceable alternatively with an optional electronic electrode with titanium
impressed current) and prepared for additional electric resistance.
™ BSV – ES 300: 300 litre domestic hot water cylinder with single coil, with magnesium anode as per
series and external tester (replaceable alternatively with an optional electronic electrode with titanium
impressed current) and prepared for additional electric resistance.
™ TPS 500: 500 litre storage puffer without instant domestic hot water coil.
™ TPS 1000: 1000 litre storage puffer without instant domestic hot water coil.
™ SRA 1.5: 1.53 m2 finned copper coil for the production of domestic hot water or additional heating.
™ SRA 3: 3.17 m2 finned copper coil for the production of domestic hot water or additional heating.
™ SRA 5: 5.26 m2 finned copper coil for the production of domestic hot water or additional heating.
™ GSC 1: Single, one-pipe, circulation pump unit without deaerator.
™ GSC 2: Double, two-pipe, circulation pump unit with deaerator.
™ CS 3.1: electronic control unit with 3 probes and one relay output for the solar pump.
™ CS 3.2: electronic control unit with 3 probes and two output relays for the solar pump and aux.
boiler.
™ VES 18: 18 litre solar expansion vessel.
™ VES 35 – 50 – 80: 35 – 50 – 80 litre solar expansion vessel.
™ GAG 20: 20 l / 21 kg can of concentrated glycol anti-freeze to be diluted in relation to the freezing
limit temperature of the area of installation.
COMPONENT DESCRIPTION
7
Chapter 2
PS AS1
Highly selective flat solar panels
Dimensions LxHxP
Gross surface
Surfaces of the opening
Absorber surfaces
Empty weight with glass
Glass
Absorber
Type of construction
Pipes material
Connection dimension
Absorbance
Emission
ηo
a1
a2
Maximum working pressure
Standstill temperature
Fluid content
Working flow rate
Insulation
Insulation thickness
Structure
Gasket
1946 x 946 x 105 mm
1.84 m2
1.65 m2
1.62 m2
36 kg
Hardened prismatic with 4mm thickness with low iron content
Copper with highly selective Tinox covering
Lyra (ultrasound welding)
Copper
¾”
95 %
3%
0,732
3,771 W/(m2K)
0,011 W/(m2K2)
10 bar
211 °C
~1l
60 – 100 l/h
Mineral wool
Lower: 50 mm
Lateral: 20 mm
Aluminium with electrostatic treatment
EPDM – Silicone
figure 2.1
8
COMPONENT DESCRIPTION
Chapter 2
Efficiency curve (l* = 800W/m2)
1
0,9
0,8
0,7
0,6
η
0,5
0,4
0,3
0,2
0,1
0
0
0,01
0,02
0,03
0,04
0,05
0,06
0,07
0,08
0,09
0,1
(Tm - Ta)/ l* (m2K/W)
figure 2.2
figure 2.3
figure 2.4
COMPONENT DESCRIPTION
9
Chapter 2
BSV 150 ES
150l vitrified single coil domestic hot water cylinder.
Diameter x Height
Capacity
Weight
Internal treatment
Solar coil surfaces
Solar coil liquid volume
Maximum working pressure
Insulation
External covering
Coils hydraulic connections
650 x 960 mm (with insulator)
150 l
81 kg
Two-coat vitrification
0,75 m2
4,2 l
6 bar
Rigid polyurethane 50 mm
Sky
3/4”
Magnesium anode – as per series (figure 2.8)
Titanium anode – optional (figure 2.9)
Protection from corrosion
1"1/4
øest.54
A
45
3/4"AG
D
3/4"AG
E
715
910
H
C
405
F
G
1/2"IG*
Tubo
26x2
3/4"AG
1"AG
813
I
1"AG
127
245
445
555
685
ø17,2
B
500
figure 2.5
A
B
C
D
E
10
Magnesium anode or electronic with titanium
Domestic hot water output
Solar heat flow
6 bar safety valve/circulation
Temperature probe
F
G
H
I
Solar cold return
Domestic cold water input + exp. vessel
Inspection flange
Thermometer
COMPONENT DESCRIPTION
Chapter 2
BSV 300
300 l vitrified double coil domestic hot water cylinder.
Diameter x Height
Capacity
Weight
Internal treatment
Solar coil surfaces
Solar coil liquid volume
Coil surfaces integration
Maximum working pressure
Insulation
External covering
Coils hydraulic connections
650 x 1515 mm (with insulator)
300 l
121 kg
Two-coat vitrification
1,21 m2
6,7 l
0,9 m2
6 bar
Rigid polyurethane 50 mm
Sky
3/4”
Magnesium anode – as per series (figure 2.8)
Titanium anode – optional (figure 2.9)
Protection from corrosion
1"1/4
øest.54
A
O
45
mq. 0,9
1480
1255
1"1/2IG
B
C
1"AG
3/4"AG
65
D
E
F
G
N
1/2"IG*
3/4"AG
3/4"AG
3/4"AG
780
880
980
1080
1245
1335
ø17,2
mq. 1,21
H
835
M
1/2"IG*
3/4"AG
1"AG
155
255
415
I
L
520
26x2
550
figure 2.6
A
B
C
D
E
F
G
Magnesium anode or electronic with titanium
Domestic hot water output
Additional boiler flow
Temperature probe
6 bar safety valve/circulation
Additional boiler return
Solar heat flow
COMPONENT DESCRIPTION
H
I
L
M
N
O
Temperature probe
Solar cold return
Domestic cold water input + exp. vessel
Inspection flange
Electric resistance
Thermometer
11
Chapter 2
BSV 300 ES
300 l vitrified single coil domestic hot water cylinder.
Diameter x Height
Capacity
Weight
Internal treatment
Solar coil surfaces
Solar coil liquid volume
Maximum working pressure
Insulation
External covering
Coils hydraulic connections
650 x 1515 mm (with insulator)
300 l
106 kg
Two-coat vitrification
1,21 m2
6,7 l
6 bar
Rigid polyurethane 50 mm
Sky
3/4”
Magnesium anode – as per series (figure 2.8)
Titanium anode – optional (figure 2.9)
Protection from corrosion
1"1/4
øest.54
A
L
45
1"AG
C
3/4"AG
D
3/4"AG
65
I
E
835
H
1335
1480
1255
1"1/2IG
B
1/2"IG*
780
980
ø17,2
3/4"AG
1"AG
155
255
415
F
G
520
26x2
550
figure 2.7
A
B
C
D
E
12
Magnesium anode or electronic with titanium
Domestic hot water output
6 bar safety valve/circulation
Solar heat flow
Temperature probe
F
G
H
I
L
Solar cold return
Domestic cold water input + exp. vessel
Inspection flange
Electric resistance
Thermometer
COMPONENT DESCRIPTION
Chapter 2
Magnesium anode with tester (as per standard)
Titanium anode with impressed current (optional)
figure 2.8
figure 2.9
The 150 or 300 litre domestic hot water cylinder is supplied as per standard with a sacrificial magnesium anode
with duration tester. This detail is subject to natural wear and is consumed in variable times depending on
the features of the water It must therefore be checked periodically in order to protect the cylinder suitably.
The alternative solution proposed by Extraflame in order to have a constant protection through time,
independently from the controls, and therefore to obtain the extension of the warranty period up to 5 years,
is the replacement of the magnesium anode with a titanium anode.
This electronic accessory automatically distributes the impressed currents in a way to prevent corrosion inside
the tank. Replacement of the standard anode with the optional electronic one takes place by removing the
first from the upper part of the cylinder (after having disconnected the connection wire to the tester that
remains in its position), inserting and connecting the new accessory according to the methods described in
the “Assembly and Use instructions” attached to the detail.
230 V, 50 Hz
TE
TR
F
F
figure 2.10
figure 2.11
Configuration as per standard with magnesium anode
Optional configuration with titanium anode
The figures above indicate the earth of the anodes and tanks. The yellow-green cable exiting the tank is
relative to the tester (TE). The tank must be connected to earth by means of an equipotential band applied
onto a pipe.
Symbol
F
TE
TR
COMPONENT DESCRIPTION
Description
Band for equipotential connections
Magnesium anode tester
Titanium anode transformer
13
Chapter 2
TPS 500
500l storage accumulator.
Diameter x Height
Capacity
Storage tank material
Solar coil material
Weight
Solar coil surfaces
Solar coil liquid volume
Maximum working pressure
Removable insulation
Covering
Stratification device
Solar coil hydraulic connections
850 x 1,680 mm (with insulator)
500 l
Very thick carbon steel
Carbon steel
135 kg
2,3 m2
10 l
3 bar
Polyurethane 100 mm
Soft PVC
Yes
1”
1/2"
B
G
1"1/2
D
1/2"
B
B
1595
1380
1270
1220
1040
920
H
1"1/2
E
C
150
C
1/2"
1"1/2
D
1/2"
1"1/2
Disco Separatore
Tipo "HP 650"
B
E
1/2"
1"1/2
1250
1"1/2
15
A
1"
1/2"
L
B
F
150
F
1/2"
1"1/2
650
30
1"
1"1/2
500
B
410
230
715
630
I
figura 2.12
A
3 bar safety valve + vent
F
B
C
D
Temperature probe
Boiler flow
Heating flow
High temperature heating return/pellet boiler return
G
H
I
Low temperature heating return/wood boiler
return
Flange for domestic hot water coil
Flange for boiler coil
Solar heat flow
L
Solar cold return
E
14
COMPONENT DESCRIPTION
Chapter 2
TPS 1000
1,000 l storage accumulator.
990 x 2,120 mm (with insulator)
1000 l
Very thick carbon steel
Carbon steel
186 kg
3 m2
18 l
3 bar
Polyurethane 100 mm
Soft PVC
Yes
1”
15
1/2"
Fondo Ø790
TDB
A
2.
5
1"1/2
1/2"
C
B
G
2.5
C
B
170
Diameter x Height
Capacity
Storage tank material
Solar coil material
Weight
Solar coil surfaces
Solar coil liquid volume
Maximum working pressure
Removable insulation
Covering
Stratification device
Solar coil hydraulic connections
1"1/2
1/2"
1/2"
2035
1800
1690
1640
1"1/2
D
H
B
Separatore
tipo "HP790"
E
B
D
1"1/2
1/2"
E
1"1/2
1650
1"1/2
I
1335
1"
800
1/2"
1"1/2
1/2"
F L
B
F
1"1/2
170
250
520
1"
790
30
1035
950
B
figura 2.13
A
3 bar safety valve + vent
F
B
C
D
Temperature probe
Boiler flow
Heating flow
High temperature heating return/pellet boiler return
G
H
I
Low temperature heating return/wood boiler
return
Flange for domestic hot water coil
Flange for boiler coil
Solar heat flow
L
Solar cold return
E
COMPONENT DESCRIPTION
15
Chapter 2
SRA 1,5
1.53 m2 finned copper coil
SRA 3
3,17 m2 finned copper coil
SRA 5
5.26 m2 finned copper coil
figure 2.14
Length
Diameter
Hydraulic connections
Surfaces
Power than can be exchanged*
Domestic hot water maximum flow rate
SRA 1,5
345 mm
200 mm
3/4”
1,53 m2
30 kW
12 l/min
SRA 3
565 mm
200 mm
3/4”
3,17 m2
60 kW
23 l/min
SRA 5
800 mm
200 mm
1” 1/4
5,26 m2
105 kW
45 l/min
* Storage temperature: 75°C - Cold water temperature 10°C - Hot water temperature 45°C
16
COMPONENT DESCRIPTION
Chapter 2
GSC1
Single, one-pipe, circulation pump unit without deaerator including stainless steel flexible pipe, wall fixing
bracket and non-return valve for expansion vessel.
Model
Dimensions LxHxD
Pump max. head
Pump max. power
Flow rate adjustment
Safety valve
Hydraulic connections
Manometer
Excludable non-return valve and
thermometer in the return
Excludable non-return valve and
thermometer in the flow
Deaerator
Valves for system load and unload
GSC 1
400 x 230 x 150
6m
82 W
2-12 l/min
6 bar
3/4“
yes
yes
no
no
yes
figure 2.15
GSC 2
Double, two-pipe, circulation pump unit with deaerator including stainless steel flexible pipe, wall fixing
bracket and non-return valve for expansion vessel.
Model
Dimensions LxHxD
Pump max. head
Pump max. power
Flow rate adjustment
Safety valve
Hydraulic connections
Manometer
Excludable non-return valve and
thermometer in the return
Excludable non-return valve and
thermometer in the flow
Deaerator
Valves for system load and unload
GSC 2
400 x 230 x 150
6m
82 W
2-12 l/min
6 bar
22 mm
yes
yes
yes
yes
yes
figure 2.16
COMPONENT DESCRIPTION
17
Chapter 2
CS 3.1
Electronic control unit with 3 probes and one relay output for the solar pump.
CS 3.2
Electronic control unit with 3 probes and 2 relay outputs: 1 for the solar pump and 1 for the boiler
™ 3 TEMPERATURE PROBES
™ 1 OR 2 RELAY OUTPUTS
™ FUNCTIONS CONTROL
™ MODERN DESIGN
™ EASY INSTALLATION
figure 2.17
Model
Inputs per sensors
Temperature probes supplied
Standard relay outputs
Additional heating
Dimensions LxHxD
Room temperature
Casing material
Thermostat function
Working hour counter
Disconnection safety device
Anti-freeze protection
Tank cooling
18
CS 3.1
4
Pt 1000 x 3
1
no
172 x 110 x 46 mm
0…40 °C
PC-ABS PMMA
no
yes
yes
yes
yes
CS 3.2
4
Pt 1000 x 3
2
yes
172 x 110 x 46 mm
0…40 °C
PC-ABS PMMA
yes
yes
yes
yes
yes
COMPONENT DESCRIPTION
Chapter 2
VES 18
18 litre solar expansion vessel.
VES 35-50-80
35 – 50 – 80 litre floor-mounted solar expansion vessel.
Model
Positioning
Diameter x Height
Capacity
Max. working pressure
Pre-load
Hydraulic connection
Diaphragm max. working
temperature
System max. working temperature
VES 18
Wall
270 x 350 mm
18 l
10 bar
2,5 bar
3/4“
VES 35
Ground
380 x 377 mm
35 l
10 bar
2,5 bar
3/4“
VES 50
Ground
380 x 525 mm
50 l
10 bar
2,5 bar
3/4“
VES 80
Ground
450 x 608 mm
80 l
10 bar
2,5 bar
1”
100 °C
100 °C
100 °C
100 °C
120 °C
120 °C
120 °C
120 °C
figure 2.18
™ Special diaphragm resistant up to 100°C
™ Resistant to any mixture containing ethylene glycol and propylene glycol
™ Structure completely welded
™ Epoxy paint
™ Quick installation
COMPONENT DESCRIPTION
19
Chapter 2
GAG 20
20 l / 21 kg can of concentrated glycol anti-freeze to be diluted in relation to the freezing limit temperaturea
of the area of installation.
TYFOCOR® L
Concentrated anti-freeze liquid with corrosion inhibitors: contains propylene glycol, not damaging for the
health.
It is normally diluted in water for applications in solar plants, for the production of domestic hot water or
to heat rooms. The mixture can be obtained using drinkable water from 25 to 55 % v/v (volume/volume) in
relation to the danger of system freezing.
figure 2.19
20
COMPONENT DESCRIPTION
Chapter 3
DIMENSIONING
The dimensioning of the solar heating system starts initially from the identification of its use: only the
production of domestic hot water or the production of domestic hot water and integration of heating.
An inspection of the building is of fundamental importance in order to identify the availability of an
appropriate slope, with suitable surfaces and inclination.
Some general indications for the correct dimensioning of the solar heat system will be described. The
fundamental rule to be respected in order to guarantee good functioning is the suitable costs/benefits
ration and not over/dimensioning. There must always be equilibrium between the energy produced by
the collectors and the consumption of the user.
INCLINATION OF THE COLLECTORS
The solar energy that can be caught by the collectors during the entire year varies on the basis of the
inclination on which they are installed. The diagram shown below represents the variation of monthly
energy affecting every m2 of collector on variation of the angle of inclination.
250
α = 0°
200
kWh/(m2 Month)
α = 30°
α = 45°
α = 60°
150
100
α = 90°
50
0
GEN
FEB
MAR
APR
MAG
GIU
LUG
AGO
SET
OTT
NOV
DIC
figure 3.1
If the aim of the solar heating system is just the production of domestic hot water small inclinations will be
favoured, while in the case of integration to heating inclinations exceeding 45° will be opted for.
The table supplies the general indications for the choice of the most appropriate inclination on the basis
of the type of intake.
Inclination
30°
45°
60°
90°
DIMENSIONING
Type of intake of the solar system
maximum summer production
maximum yearly production
maximum winter production
minimum summer production
21
Chapter 3
PRODUCTION OF JUST DOMESTIC HOT WATER
The basic calculation for the dimensioning of the solar system for the production of domestic hot water
starts from the identification of the total consumption of the family in question.
On the basis of habits, consumption of hot water can be low, medium or high. Table supplies the indicative
values of daily consumption per person at the various comfort levels and for the household appliances
prepared for direct use with hot water.
Low Comfort: 30 l
Average Comfort: 50 l
High Comfort: 70 l
Washing machine: 20 - 40 l (1 wash)
Dishwasher: 20 l (1 wash)
The surface of the collectors must be dimensioned on the basis of the latitude, inclination of the roof and
orientation of the pitch. Maximum production is obtained with the collector facing perfectly south and
inclined from 30° to 45°.
The following table supplied an indication of the collector surfaces necessary on the basis of latitude.
Area in Italy
North
Centre
South
Reference values for the dimensioning of the
surfaces of the collectors
1.2 m2 every 50 litres/day
1,0 m2 every 50 litres/day
0,8 m2 every 50 litres/day
figure 3.2
22
DIMENSIONING
Chapter 3
For different orientations and inclinations the surface of the collectors is increased on the basis of the
following table:
Orientation
South: 0° East/West: 90°
0°
15°
30°
45°
60°
75°
90°
0°
1,12
1,12
1,12
1,12
1,12
1,12
1,12
Angle of inclination
30°
45°
60°
1
1,01
1,07
1
1,02
1,07
1,01
1,03
1,08
1,03
1,05
1,11
1,06
1,08
1,15
1,1
1,13
1,2
1,15
1,2
1,28
15°
1,03
1,04
1,04
1,06
1,07
1,10
1,13
75°
1,20
1,20
1,22
1,23
1,26
1,31
1,40
90°
1,44
1,44
1,42
1,42
1,44
1,51
1,61
Once the surface of the collectors has been obtained the storage tank must be dimensioned. With good
approximation every m2 of collector requires 70 litres of storage.
The amount of hot water not covered by the sun during the winter months (see figure below) must be
satisfied with an integrated boiler.
kWh/(m2 Month)
Useful intake of the
solar system
DIC
NOV
OTT
SET
AGO
LUG
GIU
MAG
APR
MAR
FEB
GEN
Requirement for
domestic hot water
figure 3.3
Example:
Home situated in Northern Italy with 4 persons with medium consumption and one wash using the
washing machine, roof facing west with inclination of 30°.
The total daily consumption of hot water results equal to 4x50 + 40 = 240 litres.
The surface of the correctly orientated surfaces results equal to (240x1.2)/50 = 5.76 m2.
Due to orientation towards west the value of the surface must be increased and results equal to 5.76x1.15
= 6.62 m2.
The volume of the storage tank must be equal to 6.62 x 70 = 463 litres.
DIMENSIONING
23
Chapter 3
PRODUCTION OF HOT WATER AND INTEGRATION TO HEATING
The dimensioning of the solar system combined for the production of domestic hot water and integration
with heating is much more complex with respect to that just for the production of hot water and must
always be supported by a dedicated calculation and simulation program. Large over-dimensioning of the
system must only be carried out when there is large consumption of water in the summer period, the
presence of a swimming pool to heat and the possibility to install the collectors with high inclination. It
can be deduced from the figure below that great covering of the heating requirement inevitably leads
to an intake of the solar system in the summer period. It is for this reason that the solar system is usually
dimensioned to cover 30% of the requirement for heating at a maximum.
A general indication can be obtained starting from the consumption of domestic hot water and calculating
the surface of the collectors necessary. This value can be doubled or tripled on the basis of the inclination
with which the collectors are installed. Only in the case of installation with inclination exceeding 70° or
the presence of a swimming pool allows the installation of 1.5 – 3 m2of collector every kW required by
the building for heating. The table summarises the indications for the dimensioning of a combi system.
Remember that the fact that the exact calculation of the collector surface necessary must be carried out
by an expert heating technician, supported by a calculation program.
Also in this case the volume of the storage tank necessary is equal to 70 litres every m2 of collectors
installed.
Requirement for
heating
Requirement for
domestic hot water
kWh/(m2 Month)
Useful intake of the
solar system
GEN
FEB MAR APR MAG GIU
LUG AGO
SET
OTT NOV
DIC
figure 3.4
Reference values for the dimensioning of
the collectors
<40°
Surface just for hot water in m2 x 2
>40° e <70°
Surface just for hot water in m2 x 3
>70° and <90° or integration of the swimming pool
1,5 – 3 m2/kW
Inclination of the collector
24
DIMENSIONING
Chapter 3
HEATING SWIMMING POOLS
Heating a swimming pool using solar collectors is advantageous especially if combined with the combi
system, as this allows efficient disposal of the excess summer heat captured by the solar panels. The
dimensioning of these systems, however, is not trivial due to the many factors that cause heat losses from
the swimming pool. Both in indoor and outdoor swimming pools the main cause of heat loss is evaporation.
This is affected by the temperature of the water and humidity of the air and wind speed on the surface.
It is therefore clear that heat loss in outdoor pools depends greatly on the geographical area where they
are installed. It is also not possible to guarantee a determined constant temperature of the water for the
different months.
The figure below summarises the different percentages if heat loss from outdoor and indoor pools.
Heat loss in the outdoor swimming pool
Heat loss in the indoor swimming pool
3%
10 %
A
A
B
20 %
B
27 %
C
C
70 %
70 %
A = Evaporation
B = Radiation towards the sky
C = Loss towards the ground or other
A = Evaporation
B = Ventilation
C = Other
figure 3.5
The use of a cover on the pool, when it is not being used, greatly reduces heat loss due to evaporation.
Regarding the dimensioning of the solar collectors, this can only be carried out approximately and on the
basis of the surface of the pool.
The following table supplies the indications for dimensioning of the collectors on the basis of the type of
swimming pool, with water temperature of 26°C.
However, the exact calculation must always be carried out by a heating technician and the swimming pool
must be heated with the aid of a boiler in order to be used not only in the summer months.
Type of swimming pool
Collector surfaces necessary
2
Indoor swimming pool with covered pool
1 m of collector every 2.5 m2 of swimming pool
Outdoor swimming pool with covered pool
1 m2 of collector every 2 m2 of swimming pool
Outdoor swimming pool with uncovered pool 1 m2 of collector every 1-1.5 m2 of swimming pool
DIMENSIONING
25
Chapter 4
SERIES/PARALLEL CONNECTION LAYOUTS AND PANEL ARRAYS
The Extraflame solar kits are made up from two or more panels that must be connected to each other. There
are three possible connections: in series, in parallel, and mixed in series – parallel. When the collectors are
connected in series, they are passed by the same flow and the system flow rate that passes through each
collector is the same. The temperature if the heat transfer fluid increases from the first to the last collector
and this means that the last collectors work at a higher temperature and therefore with lower efficiency. The
loss of head of each collector is also added and as a consequence in this configuration it results convenient
to work with low flow rates (low flow).
RF = Cold return
MC = Hot flow
MC
RF
figure 4.1
The parallel connection according to the Tichelmann method allows to obtain the same flow for each
collector. In order to prevent dead areas and to guarantee a turbulent flow it is useful to adjust the
circulating flow rate on each collector to a value exceeding 60 l/h. The fluid flow rate of the system with
parallel connection is divided between the various collectors. If the collectors are n and the total flow
rate is x, in each collector there is a flow rate equal to x/n. Differently from connection in series, the heat
drop between up and downstream is the same for all collectors and therefore they work with the same
efficiency value.
The connection in parallel seems more efficient with respect to connection in series; on the other hand it
can only be applied to fields formed by a small number of collectors (about 5).
Particular connection must be given to the connection of the pipes to the panels in order to guarantee
uniform distribution of the flow rate (see figure 4.3). Pay attention to the direction of assembly of the panel,
which must be positioned with the down side below.
26
SERIES/PARALLEL CONNECTION LAYOUTS AND PANEL ARRAYS
Chapter 4
MC
RF
figure 4.2
When more than 5 panels are to be installed, several arrays must be set up and connected to each other.
In arrays connected in parallel using the Tichelmann system, the total length of the flow and return pipes
must be the same. In this way identical head losses are guaranteed along all of the parallel connections
(see figure below).
MC
RF
figure 4.3
SERIES/PARALLEL CONNECTION LAYOUTS AND PANEL ARRAYS
27
Chapter 4
However, with this system it is very difficult to obtain a uniform flow in the various panels and the total flow
rate of the fluid in the system is high, with consequent increase of head losses.
It is therefore recommended to adopt a mixed series - parallel connection in a way to use a low flow
circulation and at the same time uniformly distribute the flow rate into the various panels.
The collectors can be connected in series and the batteries in parallel as represented in the figure below.
MC
RF
figure 4.4
The most efficient system envisions parallel connection of the panels and series connection of the arrays,
as represented in the figure below.
MC
RF
figure 4.5
In the case of 6 panels, 2 arrays of 3 collectors must be realised, connected in parallel to each other. The 2
arrays will be connected in series.
For 8 panels, 2 arrays of 4 collectors must be realised, connected in parallel to each other.
The 2 arrays will be connected in series.
In the case of 10 panels, 2 arrays of 5 collectors must be realised, connected in parallel to each other. The
2 arrays will be connected in series.
28
SERIES/PARALLEL CONNECTION LAYOUTS AND PANEL ARRAYS
Chapter 5
SLOPING ROOF
DESCR5IPTION OF THE ASSEMBLY COMPONENTS FOR 1 OR 2 PANEL KIT
figure 5.1
Element
1
2
3
4
5
6
7
8
9
Support plate
Support “Z”
8 x 60 wood screw
M8 x 12 screws
M10 x 20 screws
M10 nut
Clips
Aluminium section
Aluminium section
Quantity
1 collector
4
4
8
8
6
6
2
1 x 1050 mm
1 x 1050 mm
2 collectors
6
6
12
12
10
10
4
1 x 2100 mm
1 x 2100 mm
LOADS DUE TO THE WIND OR SNOW
The load effects of snow and wind can affect the fixing systems, causing possible mechanical problems. In
order to have an indication of the maximum operational altitude of the collectors in relation to the snow
load area and the slope of the roof with building height up to 20 metres, reference can be made to the DIN
1055 Standard.
The solar collectors must be fastened tot he covering well in order to prevent damage caused by strong
gusts of wind. It will be the installer’s responsibility to realise a suitable anchorage system on the basis of the
SLOPING ROOF
29
Chapter 5
type of roof and the climatic area where installation is carried out. The installation company is responsible
for respecting the standards in force and carrying out the job perfectly.
In the case of roofs with slopes less than 35°, particular attention must be paid to the currents that develop
at the ends and in the corners. Figure 5.2 supplies an indication of the lateral areas of the roof with slope
less than 35° where the panels must not be installed. The length a represents the smaller side of the roof
plan given by the length of the building plus the eaves, while b is the long side of the roof plan equal to the
length of the building plus the eaves. R is the lateral width on which the panels must not be installed.
For closed building, R must be greater than or equal to a/8.
The panels must also be positioned at a distance of at least 0.5 m from the ridge of the roof.
R=a/
ASSEMBLY INSTRUCTIONS
R=a
/
8
8
A suitable earth plant must be prepared by qualified
staff according to standards in force before installation
of the panels.
The Extraflame PS AS1 collectors can be mounted on
the pitch of the roof facing south by simply removing
some tiles.
The collectors are mounted vertically and positioned
in arrays made up from 2 or more panels (see
“series/parallel connection layouts and panel arrays”
chapter).
All additional elements that are not envisioned in the
kit and supplied by the installer must be:
™ Perfectly insulated
™ Weather resistant (wind and water) and to the
penetration of humidity into the heat insulation
™ Resistant to UV rays
™ Resistant to the pecking of birds
b
a
figure 5.2
figure 5.3
30
SLOPING ROOF
Chapter 5
ASSEMBLY PHASE
1. Remove a few tiles and look for safe anchorage points on the wooden
beams or on the cement structure present under the tiles. Use the
screws supplied or alternatively use solid plugs, which can be found
for different types of material (see figures 5.4-5.5).
ATTENTION!!!
Pay great attention if the insulating sheath is present.
Water may infiltrate if it is perforated. It is the installer’s
responsibility to guarantee perfect water-tightness of the
covering.
2. The fixing system is made up of the plate 1, the bracket 2, the lower
aluminium section 8 and upper section 9.
3. Once the structure has been well-fixed to the roof, adapt the tiles
to the shape of the bracket. Any adjustment in order not to create
interference with the tiles can be obtained by placing spacers or by
cutting them to shape with a diamond disk. The adjustments made
must be protected using water/proof sheaths to prevent infiltration of
water.
4. Then rest the panel on the lower section (figure 5.7) blocking its edge
in the aluminium section. When performing this operation make
sure the side of the panel marked “DOWN SIDE” (figure 5.8) is actually
placed downwards.
5. Fix the upper part and laterally block the panel using the clips as per
figure (figure 5.9).
6. When installing 2 or more collectors side by side, connect them
through the coupling joints (all panels are provided with 2 joints
each).
The coupling joints are elastic and compressible in order to absorb any
thermal expansions that might cause deformations in the case of arrays
formed from several panels.
Attention: the gaskets supplied inside the joints are in
vegetable fibre and they expand with humidity.
figure 5.7
SLOPING ROOF
figure 5.4
figure 5.5
figure 5.6
figure 5.8
31
Chapter 5
Pay great attention not to ruin the gaskets on tightening and not to
create twists in the collector copper pipe: it is recommended to tighten
the joint manually and then slightly using the spanners as indicated in
the figure.
After having flushed the system, let a few drops of liquid leak out of
the joints, which have not yet been completely tightened. Then screw
the connections tight, holding the 30 mm nut blocked and turning
the 22 mm locknut until the joint is perfectly sealed. Once the plant is
pressurised, periodically check the pump unit manometer to make sure
the pressure remains stable through time.
figure 5.9
figure 5.10
figure 5.11
figure 5.12
figure 5.13
32
SLOPING ROOF
Chapter 5
Sloping roof drilling template kit
for 1 panel
Sloping roof drilling template kit
for 2 panels
685
1729.2
754.6
1665
1665
40
40
974.6
1949.2
974.6
974.6
754.6
905
100
100
685
100
100
2100
figure 5.14
figure 5.15
™ Fix the plate (1) to the wooden roof using the screws (3). For roofs made of different material, use solid
fixing plugs that can be found on the market.
™ Fix the “Z”-shaped support to the plate (1) using the screws (4).
™ Fix the aluminium section (8), (9) to the “Z”-shaped support (2) using the screw (5) and the nut (6).
™ Position the panel on the aluminium section in a way that it is perfectly coupled to the edge of the
section (8).
™ Make the hydraulic connection between the collectors using the supplied coupling joints.
™ Fix the clips (6) onto the aluminium section (9) using the screws (5) and the nuts (6).
SLOPING ROOF
33
Chapter 6
FLAT ROOF
PREMISE
Before installation, check that the roof structures as suitable capacity and has no defects. Realise suitable
fixing on the basis of the height of the building and the wind. Make sure there are no shadowed areas
owing to obstructions such as trees, buildings etc. The panel will be facing south.
Refer to the DIN 1055 Standard for information on the load resistance of constructions. The panel supports
can be fastened directly on the roof using the 3 holes in each base section. In this case the installer must
realise suitable anchorage that is able to resist the loads due to snow and wind. If any holes are made in the
roofing, they must be adequately waterproofed in order to prevent water infiltrations.
The anchorage can also be made using double-T beams (see figure below) and also in this case the installer
should provide a secure anchorage without damaging the roof.
figure 6.1
COMPONENT DESCRIPTION
For installation of the collectors on the roof there are 2 types of: flat roof kits for 1 panel and flat roof kits
for 2 panels (see figures below).
15
63
figure 6.2
34
figure 6.3
FLAT ROOF
Chapter 6
Flat roof kit for 1 panel elements table
Description
Quantity
Aluminium section with groove for 1 panel kit
2
Flat roof kit left base section
1
Flat roof kit right base section
1
Flat roof kit left vertical upright
1
Flat roof kit right vertical upright
1
Flat roof kit left inclined bar
1
Flat roof kit right inclined bar
1
Flat roof kit rear cross-member
2
Panel fixing lateral clip
2
TE M10X20 flanged screws
17
M10 flanged nut
17
Numbering
1
2
3
4
5
6
7
8
9
10
11
Code
2167000
2167002
2167003
2167004
2167005
2167006
2167007
2167008
2167403
6000441
6000724
Numbering
1
2
3
4
5
6
7
8
9
10
11
Flat roof kit for 2 panels elements table
Code
Description
Quantity
2167001 Aluminium section with groove for 1 panel kit
2
2167002 Flat roof kit left base section
1
2167003 Flat roof kit right base section
1
2167004 Flat roof kit left vertical upright
1
2167005 Flat roof kit right vertical upright
1
2167006 Flat roof kit left inclined bar
1
2167007 Flat roof kit right inclined bar
1
2167008 Flat roof kit rear cross-member
2
2167403 Panel fixing lateral clip
4
6000441 TE M10X20 flanged screws
19
6000724 M10 flanged nut
19
FLAT ROOF
Length (mm)
1050
1190
1190
980
980
1490
1490
980
Length (mm)
2100
1190
1190
980
980
1490
1490
1670
35
Chapter 6
ASSEMBLY INSTRUCTIONS
1. Lay the left (2) and right (3) base sections on the assembly surface as shown in figures 6.4 and 6.5,
which refer to the 1-panel kit and the 2-panel kit, respectively. The sections must not be fixed to the
ground but just rested on it.
3
2
figure 6.4
1563
2
3
1563
figure 6.5
2. Fix the left (6) and right (7) inclined bars to the respective left (4) and right (5) uprights using the screws
(10) and nuts (11), as shown in figure 6.6 and adjust the desired angle of inclination by changing the
fastening holes in the base sections, as shown in figures 6.7, 6.8 and 6.9. Set the angle of inclination
according to the intended use of the solar system (see “Angle of panels” chapter). If inclination is equal
to 30° the two vertical uprights 5 and 6 must be trimmed.
36
FLAT ROOF
Chapter 6
0
30°
795
.4
143
6°
11
890
1190
figure 6.7
954
100
954
7
13
30
figure 6.6
91
.5
66
°
°
°
60
45°
890
940
1190
figure 6.8
figure 6.9
3. Fix the 2 rear cross-members (8) as indicated in the figure below. For the 1 panel kit, refer to figure 6.11,
while for the 2 panel kit refer to figure 6.12.
figure 6.10
FLAT ROOF
37
Chapter 6
figure 6.11
figure 6.12
4. Fix the aluminium sections with groove (1) as indicated in the figure below, using the relative screws
(10) and flanged nuts (11) supplied. The aluminium section relative to the 1 panel kit measures 1048
mm, while that relative to the 2 panel kit measures 2100 mm.
1
10
1
11
11
10
figure 6.13
5. Fix the panel using the 2 clips (9) and relative screws (10) and flanged nuts (11) frontally and from
the rear (figure below). The 2-panel kit contains 4 clips (9) and the relative flanged screws (11) and nuts
(12), as shown in figure 6.15. In the last case it is convenient to realise hydraulic connections between
the two panels using compensating joints before fixing the clips (9).
11
PANEL
10
9
figure 6.14
38
FLAT ROOF
Chapter 6
11
9
figure 6.15
6. Fix the left (2) and right (3) base sections to the ground, align the frame and tighten all the screws and
nuts.
FLAT ROOF
39
Chapter 6
MULTIPLE COMPOSITION OF THE KITS
If 3, 5, 6, 8 or 10 panels are to be installed, several flat roof kits must be used side by side. The first thing to
do is to draw a line indicating the front alignment along which the frames will be arranged at the intervals
given below.
When 3 or more panels are flanked, the aluminium profiles must be made to run in a way to prevent
reciprocal interference (figure below). If necessary, the installer may decide to trim the sections in order to
minimize interference.
figure 6.16
3 PANELS: KIT 1 + KIT 2
802
377
1563
802
377
1563
3025
figure 6.17
4 PANELS: KIT 2 + KIT 2
1563
517
1563
1563
517
1563
4065
figure 6.18
40
FLAT ROOF
Chapter 6
5 PANELS: KIT 1 + 2 X KIT 2
802
377
1563
517
1563
5105
802
377
1563
1563
517
figure 6.19
FIXING THE MULTIPLE KITS
In this case too, the most convenient procedure is to hydraulically connect the panels, then adjust and
align the frames and finally fix the left (2) and right (3) base profiles to the ground and then tighten all the
screws and nuts. After the above steps, the panels should be perfectly aligned with each other so that
there are no strains on the hydraulic compensating joints.
FIXING THE ARRAYS
If 6, 8 or 10 panels are to be installed, a combined series–parallel connection must be realised (see “Series/
parallel connections and panel arrays” chapter).
6 PANELS: 2 X KIT 1 + 2 X KIT 2
Realise 2 arrays of three panels each and connect them in series.
802
377
1563
802
377
1563
802
377
1563
802
377
1563
3025
3025
figure 6.20
FLAT ROOF
41
Chapter 6
8 PANELS: 4 X KIT 2
Realise 2 arrays of four panels each and connect them in series.
1563
517
1563
1563
517
1563
1563
517
1563
1563
517
1563
4065
4065
figure 6.21
10 PANELS: 2 X KIT 1 + 4 X KIT 2
Realise 2 arrays of five panels each and connect them in series.
802
377
1563
517
1563
802 377
1563
517
1563
802
377
1563
770
1563
802 377
1563
517
1563
5105
5105
figure 6.22
42
FLAT ROOF
Chapter 6
INCLINATION OF THE PANELS
Panel inclination must be adjusted on the basis of the latitude and aim of the solar system. Three different
inclinations can be obtained using the flat roof fixing kit: 34°, 45° and 60°.
The following table supplied the optimal inclination angle of the panel on the basis of the type of use.
Panel inclination
34°
45°
60°
Type of use
DHW only, mostly for summer use
DHW only, year-round use
DHW and integration to heating system
SHADOWING
The minimum distance between panel arrays to prevent reciprocal shading depends on the collectors’
angle of inclination and on the local characteristics (e.g., the lowest position of the sun during the year).
The figure below and the relative table supply the indications of the minimum distance of the arrays for
installations in Italy. For installations at other latitudes the system designer shall have to determine the
correct values to apply.
a
b
figure 6.23
Inclination of the collectors
34°
45°
60°
= 90° − − 23,5
b=
FLAT ROOF
Distance b
4,6 m
5,3 m
6,2 m
δ = latitude
a
a
+
tan
tan
43
Chapter 6
DISTANCE FROM THE EDGE OF THE ROOF
To prevent the panel from being subjected to stress caused by the wind turbulence that forms near the
roof’s edges, leave at least 1 metre between the supports and the roof edges as indicated in the figure
below.
1m
1m
figure 6.24
44
FLAT ROOF
Chapter 7
TEMPERATURE PROBE AND HYDRAULIC SUPPLY CONNECTION
ASSEMBLY
For hydraulic supply connections it is recommended to use the accessories indicated below (supplied on
request).
The collector probe is supplied with the control unit CS3.1 or CS3.2 and has a black silicone sheath able to
resist atmospheric agents. This must be positioned inside the sump in the top part of the first collector of
the last coil (collectors in parallel as per figure below).
In the top part of the last collector of the last coil, it is recommended to use a 3-way joint in a way to
connect the ball valve for plant bleeding and the flow pipe.
For perfect solar system efficiency, the probe must be completely inserted into the sump until fully home.
The sump must be embedded inside the panel.
Where necessary protect the cable from any damage (e.g. nibbling by rodents).
The probe cable carries signal voltage and must not be laid with the other power supply cables.
Protect the solar control unit from lightening, conveyed towards the probe cable, using the relevant devices
normally supplied by electrical companies.
1
5
2
3
2
4
figure 7.1
Reference
1
2
3
4
5
Code
5168002
5168001
6167402
5168000
2167602
Q.ty
1
2
1
1
x
Description
Sump for solar probe 3/4” female connection and gaskets
3/4” male/female joint and gasket
3/4” female 3-way fitting
3/4” female blind plug and gasket
3/4” flexible fitting joint for solar with 2 gaskets
Attention: the flexible fitting joints (5) with the respective gaskets, are supplied as per standard
in twos for each solar panel PSAS1.
TEMPERATURE PROBE AND HYDRAULIC SUPPLY CONNECTION ASSEMBLY
45
Chapter 7
figure 7.3
Earth the solar panels suitably.
The hydraulic connection to the supply pipes takes place using long flexible pipes (usually in stainless
steel). The direct connection of the collector to a rigid supply pipe is not allowed.
To lay the attachment pipes under the roof, use ventilation tiles or antenna passages.
Where necessary, contact a specialised company to pass the supply pipes under the roof.
Also pass the temperature probe with the pipes under the roof inside a protection sheath.
figure 7.2
46
TEMPERATURE PROBE AND HYDRAULIC SUPPLY CONNECTION ASSEMBLY
Chapter 8
HYDRAULIC SYSTEM
INDICATIONS OF THE TYPE AND DIAMETERS OF THE PIPES
For correct functioning the pipes must satisfy the following criteria:
™ Resistance to heat up to 150°C inside the collector circuit up to the standstill temperature in proximity
of the collector
™ Compatibility with heat transfer fluid (water and glycol mix)
™ The features of the materials and the installation techniques must guarantee the total tolerance of the
heat expansion in the envisioned temperature range (from about -20 to 150 °C)
™ Stability of the connections in the presence of heat and mechanical stress owing to expansion
™ Ideal piping: strong brazed copper
™ To prevent galvanic corrosions, do not use galvanised steel piping
The diameter of the pipes must be selected on the basis of the optimal flow rate of the system in a way
not to create excessive load losses. Figure 75 supplies an indication of the loss of head per metre of pipe
for several pipe diameters with a 40% gycol mix at 40 °C. In the first diagram, starting from the system
flow rate in l/h (see “Setting the collector and system flow rate” chapter), on the basis of the diameter
of the pipe it is possible to obtain fluid speed. In the second diagram, on the basis of the speed and the
diameter of the piping, it is possible to obtain the unit head loss in mbar/m. The total head loss is obtained
by multiplying this last value by the total length of the piping. For example, with a flow rate of 240 l/h and
a pipe measuring 15 x 1 mm a unit head loss of 4.5 mbar/m is obtained.
As well as the distributed head losses the concentrated ones due to valves, bends etc. must also be
calculated. The table below supplied the indicative values for the choice of appropriate diameter of the
pipes in relation to flow rate.
Regarding the solar collectors, the figure below supplies the head loss curve on the basis of the fluid flow
rate.
Panel head loss
9
8
7
Δp (mbar)
6
5
4
3
2
1
0
0
50
100
150
200
250
300
350
Flow rate l/h
figure 8.1
HYDRAULIC SYSTEM
47
Chapter 8
1000
35
700
Flow rate l/h
28
x
x1
800
1.5
.5
900
22
x1
600
18
500
x1
15 x
400
1
12 x 1
300
200
100
0
0,0
0,1
0,2
0,3
0,4
0,5
0,6
0,7
0,8
0,9
1,0
1,1
1,2
Head loss mbar/m
22
8
x1
1
18
x
12
9
15
x1
10
x1
Speed m/s
28
7
x1
.5
.5
x1
5
3
6
5
4
3
2
1
0
0,0
0,1
0,2
0,3
0,4
0,5
0,6
0,7
0,8
0,9
1,0
1,1
1,2
Speed m/s
figure 8.2
Flow
(l/h)
< 240
240 - 410
410 - 570
48
External diameter
for thickness (mm)
15 x 1
18 x 1
22 x 1
HYDRAULIC SYSTEM
Chapter 8
BSV150 solar coil head loss
60
Δp (mbar)
50
40
30
20
10
0
0
100
200
300
400
500
600
700
800
900
1000 1100 1200 1300 1400 1500
Flow rate l/h
figure 8.3
BSV300 solar coil head loss
100
90
Δp (mbar)
80
70
60
50
40
30
20
10
0
0
100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500
Flow rate l/h
figure 8.4
TPS500 solar coil head loss
500
450
Δp (mbar)
400
350
300
250
200
150
100
50
0
0
100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500
Flow rate l/h
figure 8.5
TPS1000 solar coil head loss
800
700
Δp (mbar)
600
500
400
300
200
100
0
0
100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500
Flow rate l/h
figure 8.6
HYDRAULIC SYSTEM
49
Chapter 8
The hydraulic connection between the pipes and the solar panels must be realised using flexible stainless
steel pipes. Direct connection of the panels tot he rigid pipes is not allowed.
The piping insulation must be suitable and without faults in a way to guarantee efficient transport of the
heat collected from the collector towards the tank. For pipe width up to 22 mm and insulation with heat
conductivity of 0.035 W/(m K) the minimum thickness of the insulator must be 20 mm. For diameters from
22 to 35 mm the minimum insulation thickness value must be 30 mm.
The following indications must be respected for pipes positioned inside:
™ The insulation must resist high temperatures (in proximity of the collector about 170°C, away from the
collector at least 120°C
™ The materials used must have low thermal conductivity
™ Only use open cell materials if there is no risk of humidity
The following indications must be respected for pipes positioned outside:
™ The insulation must resist environmental impact (atmospheric pollution, UV rays) and the action of
animals (pecking of birds, rodents, etc.) otherwise further coverings are required.
™ To prevent the risk of infiltration of humidity, insulation must be carried out using closed cell materials,
as not even accurate covering can prevent the infiltration of humidity. This seriously undermines the
efficiency of the insulation.
The following coverings for the insulators are available on the market:
™ Synthetic materials (to be used preferably on pipes located inside)
™ Galvanised steel
™ Aluminium 99.5
™ Salt-resistant aluminium
™ Stainless steel and aluminium-zinc alloy (special goods)
Single or double stainless steel or copper pipes complete with insulation, insulator covering and temperature
probe cable can be found on the market.
Closed cell elastomeric insulator
Drawn copper
without welding
Integrated
temperature
sensor cable
Black film that protects from mechanical wear and from
UV rays
figure 8.7
In order to minimise heat loss it is good practice to insulate all hydraulic parts involved in the transport of
the heat transfer fluid: connections, branches, valves etc.
50
HYDRAULIC SYSTEM
Chapter 8
CONNECTION OF THE PUMP UNIT
Regarding the one-pipe GSC1 and two-pipe GSC2 pump units, the hydraulic connections are the
following:
™ One-pipe unit GSC1: 3/4”
™ Two-pipe unit GSC2: 22 mm
(C) Safety device unit
The CE and TÜV certified safety unit protects the plant from over-voltages. It is calibrated at 6 bar, above which
the unit intervenes.
It is also supplied with a manometer and connection towards the expansion vessel by means of a 22mm pipe
or flexible kit, illustrated at the side.
Flow
A
Flexible fit installation
for safety device unit
(optional):
1. Remove the cap and
22mm hub from the
safety device unit
Return
C
B
2. Mountthedetailsinthe
order indicated:
™ insert the nipple on
the internal diameter of
the safety device unit;
™ place the gasket
between the nipple and
cap of the flexible;
™ tighten the flexible,
paying attention to fix
it to the safety device
unit by the end with the
yellow cap.
(A) Ball valve on the flow branch
(thermometer with red ring and
0-120°C scale) with VNR “Solar”
(B) Ball valve on the return branch
(thermometer with blue ring and
0-120°C scale) with VNR “Solar”
“Solar” non-return valve
Inserted into the ball valve both
on the flow and return branch.
Guarantees sealing and low head
losses.
To exclude the non-return valve,
e.g. if the system is to be emptied,
turn the knob 45° in a clockwise
direction.
E
D
(E) Pump
Manually-adjustable
three-speed
pump.
Thanks to the sealing of the ball
valves up and downstream from the
pump, it can be removed without
emptying the system.
(D) Flow rate regulator
The regulator allows to
adapt the flow rate to system
requirements by means of a
3-way valve. When the valve
is in the closed position
the normal circulation is
interrupted and it is possible
to use the lateral tap to load
the system.
A second lateral tap is present
for discharge.
The vicinity of the two
taps eases the operations
minimising the tract between
loading and unloading.
The flow rate is indicated Yellow cap
by the relevant cursor:
the acknowledgement is
immediate thanks to the
vicinity of the relief valve.
figure 8.8
The GSC2 unit is complete with connection for the flow pipe with deaerated and return, while the GSC1
unit only has connections for the return pipe.
In the latter case it is the installer’s responsibility to realise a suitable connection of the flow pipe and the
desecration system.
It is fixed to the wall using the set supplied.
To realise a connection pipe between the safety valve and an empty can on the floor, in a way to recover
any leaking heat transfer fluid when the pressure of the system should exceed 6 bar (see figure 8.9).
HYDRAULIC SYSTEM
51
Chapter 8
Flow
Hot
Return
Cold
figure 8.9
For the technical details relative to the two GSC1 and GSC2 units, consult the instructions contained in the
relative packaging.
Wilo - Star ST 25/6
7
6
Head (m)
5
4
3
2
1
0
0
500
1000
1500
2000
2500
3000
3500
Flow rate (l/h)
figure 8.10
52
HYDRAULIC SYSTEM
Chapter 8
DIMENSIONING AND CONNECTION OF THE EXPANSION VESSEL
The correct dimensioning of the expansion valve is of fundamental importance for the correct functioning
of the system and to guarantee the duration of the anti-freeze glycol.
The expansion vessels are supplied with a pre-load of 2.5 bar. This value must be set on the basis of the
level difference existing between the expansion vessel and the highest point of the solar circuit (upper
point of the solar panels). The value of this level difference (1 bar is equal to 10 m of the water column) is
equal to the pre-load pressure to be set. It is recommended to set a pre-load value equal to 1.5 bar up to a
level difference of 15m.
hgeo (m)
C
VS
VMS
M
T
VR
VE
T
D
R1
RP
GC
R2
figure 8.11
The initial pressure of the cold system must be greater by 0.5 bar with respect to the pre-load pressure, in
a way to keep the diaphragm of the expansion vessel taught. With a pre-load value of 1.5 bar there is an
initial pressure with cold system of 2 bar. The final pressure of the system must not exceed 5.5 bar as the
safety valve is calibrated at 6 bar.
Pressure
Recommended
pI (initial) = column of water + 0.5 bar
2 bar up to 15 m
pVE (pre-load ) = pI - 0.5 bar
1,5 bar
pF (final) < 5,5 bar
5 bar
pVS (safety valve) = pF + 1
6 bar
The total volume of the liquid contained in the system must be known in order to calculate the volume of
the expansion vessel:
VFL = VC (collector) + V T (pipes) + VSC (heat exchanger) + VA (other components)
The expansion of the fluid in the liquid phase is equal to:
ΔVFL = e x VFL (e = expansion coefficient of the water + gycol mix)
HYDRAULIC SYSTEM
53
Chapter 8
% of glycol
20%
30%
40%
50%
Expansion coefficient e
0,050
0,060
0,065
0,070
The volume of the collectors is added to the expansion volume:
VU = (ΔVFL + VC) x 1,1
The nominal volume of the expansion vessel is equal to:
ΔVN = VU x (pF + 1)/( pF - pI)
The Extraflame solar kits are supplied with an expansion vessel dimensioned on the basis of the number
of panels present. In the STAR PLUS 2-3 kits the 18 l VES18 expansion vessel must be wall-mounted using
the bracket supplied inside the packaging of the pump unit (see figure 8.12). The vessel is connected to the
pump unit by means of a supplied stainless steel pipe.
The automatic relief valve, supplied with the wall-fixing bracket, must be inserted into the end of the stainless steel flexible pipe (see figure 88).
The automatic relief valve is used to block the flow of anti-freeze fluid if the expansion vessel must be
removed for maintenance or must be replaced. If an expansion vessel is mounted on the ground, it must
always be placed at the end of the flexible pipe (see figure 8.14).
ATTENTION!!!
When the expansion vessel is removed by loosening the 38 mm locknut of the relief valve,
the valve itself closes automatically. Pay great attention in this phase as the solar hydraulic
circuit is deprived of the possibility to release the pressure in the expansion vessel. This
maintenance must be performed by qualified staff and without insulation, so as not to
cause dangerous pressure increases in the solar circuit.
The VES35, VES50 and VES80 vessels must be positioned on the ground and connected to the pump unit.
The VES35 and VES50 models have ¾’’ hydraulic attachments, while VES80 has a 1’’ hydraulic attachment.
54
HYDRAULIC SYSTEM
Chapter 8
HYDRAULIC SYSTEM
figure 8.12
figure 8.13
figure 8.14
figure 8.15
55
Chapter 8
CONNECTION TO THE STORAGE TANK
CONNECTION OF THE BSV 300, BSV 150 ES CYLINDER
The pump unit must be connected to the storage tank solar coil (cylinder or puffer). The domestic hot water
cylinder solar coil has ¾’’ hydraulic attachments.
The hot flow coming from the solar panels must be connected onto the upper part of the solar coil, while
the cold return is connected onto the lower part of the coil as indicated in the figure below. For the technical
details relative to the BSV 300, BSV 300 ES and BSV 150 ES cylinders, consult the chapter relative to the
components description.
figure 8.16
Symbol
B
C
CE
D
G
GC
M
R1
R2
Description
Domestic hot water cylinder
Solar collector
Electronic control unit
Deaerator
Generator
Pump unit
Manometer
Tap 1
Tap 2
Symbol
RP
T
TS
VE
VMS
VMTA
VS
VR
Description
Flow rate adjuster
Thermometer
Domestic hot water terminals
Expansion vessel
Domestic hot water mixing valve
Automatic thermostatic mixer valve
Safety valve
Non-return valve
Where requested connect the integration thermoproduct to the upper coil as indicated in figure 8.16 (solo
BSV300). Also in this case the hot flow must be connected in the upper part of the coil, while the cold
return in the lower part. The automatic thermostatic 3-way mixer valve is indicated in the layout. This allows
optimal functioning of the thermo-product. For further hydraulic layouts and information relative tot he
thermo-products consult www.extraflame.it/support .
Connect the expansion vessel and safety valve, calibrated at 6 bar, to the domestic hot water cylinder.
56
HYDRAULIC SYSTEM
Chapter 8
In order to prevent unpleasant burns due to very hot domestic hot water a thermostatic mixer valve must
be installed in the domestic hot water circuit so as to obtain distribution at a constant temperature. This is
thanks to mixing the water coming from the cylinder with cold network water.
CONNECTION OF THE PUFFER
The 500-1000 litre puffer solar coil has 1” hydraulic connections. The hot flow of the solar panels must be
connected onto the upper part of the solar coil as indicated in the figure below. For the technical details of
the puffer, consult the chapter relative to the description of the components.
R
TS
C
PR
P
VMS
VS
M
T
VE
D
VR
R1
T
GC
RP
G
R2
CE
VMTA
figure 8.17
Symbol
C
CE
D
G
GC
M
P
PR
R
R1
Description
Solar collector
Electronic control unit
Deaerator
Generator
Pump unit
Manometer
Puffer
Radiant panels
Heating
Tap 1
Symbol
R2
RP
T
TS
VE
VMS
VMTA
VS
VR
Description
Tap 2
Flow rate adjuster
Thermometer
Domestic hot water terminals
Expansion vessel
Domestic hot water mixing valve
Automatic thermostatic mixer valve
Safety valve
Non-return valve
The figure above represents an example of a hydraulic system composed of a solar kit with TPS puffer and
Extraflame biomass boiler. The heat supplied from the solar panels puffer is integrated by the biomass
boiler and ca be used to satisfy the heating areas.
Connect the high temperature heating system cold return above the solar coil as indicated in the figure, in
HYDRAULIC SYSTEM
57
Chapter 8
a way not to heat the lower part of the storage tank. Only in the case of cold return from the radiant panels
is connection possible in the lower part of the puffer. The mixing of the lower part of the storage tank with
the hot water in the system can jeopardise the solar intake to heating in the cold season.
In the TPS 500 and TPS 1000 storage tanks, the domestic hot water is produced through the large surface
finned copper coil. This guarantees maximum hygiene and prevents the formation of legionella. To
compensate the dilations caused by the temperature range of the water inside the coil and minimise the
ramming it is necessary to install a small expansion vessel (4 litre) and a safety valve calibrated at 6 bar.
In order to prevent unpleasant burns due to very hot domestic hot water a thermostatic mixer valve must
be installed in the domestic hot water circuit so as to obtain distribution at a constant temperature. This is
thanks to mixing the water coming from the cylinder with cold network water. Carry out water softening
treatment if water hardness exceeds 25°F.
The excessive deposit of lime scale inside the copper coil can jeopardise functioning.
Install the expansion vessel in the lower part of the puffer able to absorb the volume increase of the water
in the storage tank and install the safety valve, calibrated at 3 bar, in the highest part.
ATTENTION!!!
Check the closure of all sleeves and flanges, in particular those positioned in the lower
part (discharge sleeve) and upper part of the tank.
Connect the puffer to earth correctly according to the standards in force.
58
HYDRAULIC SYSTEM
Chapter 9
ELECTRONIC CONTROL UNIT
™ System Monitoring Display
™ Up to 4 Pt temperature probes
™ Heat quantity balance
™ Functions control
™ Easy handling
™ Casing with exceptional and easy to mount
design
™ Options: solar working time counter and
thermostat function.
figure 9.1
Delivery volume:
1 x Extraflame CS
1 x accessory box
1 x spare T4A fuse
2 x screws and plug
4 x strain relief and screws
175
28
65
Additional objects in the complete pack:
1 x FKP6 probe
2 x FRP6 probes
110
48
figure 9.2
Regulator variants
PG system
version
Relay
Semi-conductor
CS 3.1
0
CS 3.2
0
Technical data:
Casing: in plastic, PC- ABS and
PMMA
Type of protection: IP 20 / DIN
40050
Room temp.: 0 ... 40 °C
Dimensions: 172x110x46 mm
Assembly: wall, possibility of
mounting in an electric control
panel
Display: Monitor System for
system display, display with
16 segments, display with 7
segments, 8 symbols to check the
system status and a functioning
control speed.
Control: by means of three
buttons on the front
Functions: differential regulator
ELECTRONIC CONTROL UNIT
Working
Heat
Speed
Thermostat
hour
quantity
adjustment
Function
balance
counter
1
yes
no
no
yes
2
yes
no
yes
yes
with additional and optional
Standard solar system
functions. Functions control in
compliance with BAW directives,
solar pump working hour counter,
tubular collector function and
heat quantity balance.
Inputs: for 4 pt1000 temperature
probes
figure 9.3
Outputs: according to version, see
“Regulator variants” table
Solar system with integrative
Power supply: 220 ... 240 V ~
heating
Total current absorption: 4 (2) at
250V ~
Current absorption for relay:
Electromagnetic relay: 2 (2) A
220 .. 240 V ~
Relay
Standard
figure 9.4
59
Chapter 9
INSTALLATION
ASSEMBLY
ATTENTION!
always make sure that the network voltage is
completely disconnected before opening the
casing.
Display
Mask
Assembly must be carried out exclusively in closed, dry
environments. To guarantee regular functioning, make sure
Buttons there are no strong electromagnetic fields in the place of
installation. The regulator must e able to be separated from
the electrical mains by means of an additional device with
Fuse
a minimum disconnection distance on all poles of 3mm), or
by means of a disconnection device in compliance with the
Suspension
laws in force. Pay attention in the installation phase that the
connection cable to the electric mains and the probe cable
remain separate.
Cable passage with
strain relief
1. Loosen the mask screws crosswise and detach this
from the casing by removing it downwards.
2. Mark the upper fixing point for suspension and
pre-assemble the plug using the corresponding screw
included in the supply.
3. Attach the casing in the upper fixing point and mark
the lower fixing point (distance between holes: 130 mm);
insert the lower plug.
4. Attach the casing at the top and fix it using the lower
screw.
Fixing
figure 9.5
ELECTRIC ATTACHMENT
CS 3.1
Fuse
T 4A
220...240V
The input of electric current to the regulator must pass
through an external switch (last stage of assembly!) and
S1
S2
S3
S4
N R1 N L
the electric voltage must be 220 ...240 V~ (50 ...60 Hz). The
flexible cables must be fixed to the regulator lid using the
relative brackets and screws to allow strain relief or put into
Probe clamps Earth clamps
the channel in the regulator box. Depending on the version
Clamps
User clamps
for attachment to the the regulator is equipped with 1 relay (CS 3.1) or 2 relays
(CS 3.2), to which utilities such as pumps, valves etc. can be
electric network
CS 3.2
connected:
Fuse
™ Relais 1
18 = wire R1
Temp. Sensor
17 = neutral wire N
Pt 1000
13 = earth clamp
S1
S2
S3
S4
N R2 N R1 N L
™ Relais 2 (only CS 3.2)
16 = wire R2
Earth
clamps
15 = neutral wire N
Probe clamps
Clamps
14 = earth clamp
User clamps
for attachment to the The temperature probes (S1 to S4) must be connected with
electric network
indifferent polarities to the following clamps:
figure 9.6
2(1)A(220...240)V
Temp. Sensor
Pt 1000
1
2
3
4
5
6
7
8
12
13
14
17
18
19
20
T 4A
220...240V
R1 2(1)A(220...240)V
R2 2(1)A(220...240)V
1
60
2
3
4
5
6
7
8
12
13
14
15
16
17
18
19
20
ELECTRONIC CONTROL UNIT
Chapter 9
1 / 2 = probe 1 (e.g. collector probe 1)
3 / 4 = probe 2 (e.g. tank probe 1)
5 / 6 = probe 3 (e.g. TSPO probe 1)
7 / 8 = probe 4 (e.g. TRL probe TRL)
The connection to the network takes place using the following clamps:
19 = neutral wire N
20 = wire L
12 = earth clamp
Clamp assignment: system 1
Standard solar system with 1 tank, 1 pump and 3 probes. The S4/TRIT probe can be optionally used to
make heat quality balances.
S1
1
S2
2
3
S3
4
5
S4
6
7
N R2 N R1 N L
8
12 13 14
15 16 17 18 19
20
S1
Symbol
S1
S2
S3
S4/TRIT
R1
Name
Collector probe
Lower tank probe
Upper tank probe
(optional)
Probe for heat quantity
balance (optional)
Solar pump
S3
R1
S2
S4/TRIT
figure 9.7
Clamp assignment: system 2
(only CS 3.2)
S1
1
S2
2
3
S3
4
5
S4
6
7
N R2 N R1 N L
8
12 13 14
Solar and additional heating system with
1 tank, 3 probes and additional heating.
The S4/TRIT probe can be optionally used to
realise heat quantity balances.
15 16 17 18 19 20
S1
Symbol
S1
S2
S3
S3
R1
S4/TRIT
R2
S4/TRL
S2
R1
R2
Name
Collector probe
Lower tank probe
Upper tank probe/
thermostat probe
Probe for heat quantity
balance (optional)
Solar pump
Feed pump for additional
heating
figure 9.8
ELECTRONIC CONTROL UNIT
61
Chapter 9
USE AND FUNCTIONING
Adjustment keys
The regulator is controlled by 3 buttons placed under
the display. Key 1 is used to scroll (forward) in the display
menu or to increase setting values.
Key 2 corresponds to the contrary function.
Forward
Reverse
2
3
1
To set values press key 1 for 2 seconds. If
a value to be set appears on the display, SET
is displayed. In this case it is possible to pass to the operation
mode by pressing key 3.
Set the channel using keys 1 and 2
™ Press key 3 briefly, SET will flash (SET mode)
™ Set the value using keys 1 and 2
™ Press key 3 briefly, SET appears again (constant), the
value set has been memorised.
SET
(selection/operation mode)
figure 9.9
System Monitoring Display
System Monitoring display complete
figure 9.10
Channels indicator
The System Monitoring display is made up of 3 areas
the channels indicator, the list of symbols and the systems
layout indicator (systems active layout).
The channels indicator is composed of two lines. The upper
line is and alphanumerical field with 16 segments. Channel
names/menu levels are mainly displayed here. The lower
line (filed of 7 segments) displays channel values and setting
parameters.
The temperatures and temperature differences are displayed
by setting °C o K.
The additional symbols in the symbols list indicate the current
status of the system.
Symbol Normal
Flashing
Relay 1 inserted
Relay 2 inserted
only channels indicator
figure 9.11
List of symbols
Tank maximum limitation Collector cooling function inserted
inserted/tank maximum Tank cooling function inserted
temperature exceeded
Anti-freeze
option
protection Collector minimum limitation inserted
Anti-freeze protection function inserted
Collector safety device disconnection
inserted or tank safety device
disconnection
Faulty probe
Manual functioning inserted
A setting channel is modified
Mode – SET
only list of symbols
figure 9.12
62
ELECTRONIC CONTROL UNIT
Chapter 9
Layouts and systems indicator
layouts and systems indicator only
figure 9.13
probes
The layouts and systems indicator (systems active layout)
indicates the layout selected by means of SIST channel. It is
composed of different system component symbols that flash,
appear permanently or disappear according tot the current
status of the system.
upper tank probe
collector 2
central heating circuit
collector 2
valve
valve
pumps
probe
symbol
additional. burner
functioning
tank heat exchanger
tank
tank 2 or additional heating (with
additional symbol)
figure 9.14
Collectors
with collector probe
Temperature probes
Tanks 1 and 2
with heat exchanger
Central heating circuit
3-way valve
Only the actual direction of
the current or the current
operational
mode
are
indicated.
Pump
Additional heating
with burner symbol
Flashing codes
System layouts flashing codes
™ the pumps flash during the initialisation phase
™ the probes flash when the display channel is selected of the respective probe
™ the probes flash quickly if the probe is faulty
™ The burner symbol flashes when the additional heating is inserted
ELECTRONIC CONTROL UNIT
63
Chapter 9
Flashing LED codes
™ Constant green: no fault (every thing functions correctly)
™ Red/green flashing: manual functioning initialisation phase
™ Red flashing: faulty probe (the probe symbol flashes quickly)
COMMISSIONING
Firstly, set the layout of the desired system!
Functioning control
indicator light
Reverse
2
3
1
1. Activate the electric connection. The regulator
passes to an initialisation phase in which
the control indicator flashes red/green
intermittently. After the initialisation, the
regulator passes to the automatic functioning
mode with its factory settings. The layout of the
Forward
pre-set system is SIST 1*.
2. - select the SIST channel
- pass to the SET mode
- select the system layout by means of the SIST
reference code
- save the setting by pressing the key
Now the regulator is ready for use (with factory
settings).
SET
(selection/operation mode)
figure 9.15
View of the systems:
SIST 1*: Standard solar system
SIST 2: Solar system with additional heating
(CS 3.2)
figure 9.16
64
*In the CS 3.1 program versions the SIST channel is
cancelled.
ELECTRONIC CONTROL UNIT
Chapter 9
CONTROL PARAMETERS AND DISPLAY CHANNELS
View of the channels
Key:
X
Corresponding channel present.
1
Corresponding channel present only when the heat
quantity balance option is inserted (OWMZ).
X*
2
Corresponding channel present if the respective Corresponding channel present only when the heat
option is inserted.
quantity balance option (OWMZ) is disconnected.
ANTT
The anti-freeze level of protection channel (ANT%)
only appears if the type of protection (ANTT) is not
water or Tyfocor LS/G-LS (MEDT 0 or 3).
Note:
S3 and S4 are displayed only when the temperature probes are attached.
Channel
SIST
Name
1
2*
COL
x
x
Collector 1 temperature
SER
x
SERI
x
SERS
x
Page
Channel
SIST
1
2*
Name
Page
66
OCR
x
x
Collector 1 cooling opt.
69
Tank 1 temperature
66
CMS
x*
x*
Collector 1 maximum temperature
69
Lower tank 1 temperature
66
OCN
x
x
Collector 1 minimum limitation opt.
70
Upper tank 1 temperature
66
CMN
x*
x*
Collector 1 minimum temperature
70
Probe 3 temperature
66
OCA
x
x
Collector 1 anti-freeze option
70
S3
x
TRIT
1
1
Return probe temperature
66
CAG
x*
x*
Collector 1 anti-freeze temperature
70
S4
2
2
Probe 4 temperature
66
ORAF
x
x
Tank cooling option
70
n%
x
Relay 1 speed
66
O CT
x
x
Tubular collector option
71
Relay 1 speed
66
TE I
x
Thermostat 1 insertion temperature
71
Relay 1 working time
66
TE D
x
Thermostat 1 disconnection temperature
71
x
Heat quantity balance option
67
n1 %
hP
x
x
h P1
x
Relay 1 working time
66
OWMZ
h P2
x
Relay 2 working time
66
VMAS
1
1
Maximum flow
67
1
1
Type of protection
67
kWh
1
1
Heat quantity kWh
67
ANTT
MWh
1
1
Heat quantity MWh
67
ANT%
SIST
1-2
System
nMN
ANTT ANTT Anti-freeze level of protection
x
67
Relay 1 minimum speed
72
x
Relay 1 minimum speed
72
DT I
x
x
Insertion temperature difference
68
n1MN
DT D
x
x
Disconnection 1 temperature difference
68
MAN
x
x
Manual functioning 1
72
DT N
x
x
Nominal temperature difference
68
MAN2
x
x
Relay 2 manual functioning
72
INN
x
x
Raising
68
LING
x
x
Language
72
S MS
x
x
Tank 1 maximum temperature
68
PROG
xx.xx
Program number
SIC
x
x
Collector 1 safety temperature
69
VERS
x.xx
Version number
* system 2 is only valid in the CS 3.2 version
ELECTRONIC CONTROL UNIT
65
Chapter 9
Collector temperature indication
COL:
Collector temperature
Setting area: -40 ... +250 °C
Indicates the current temperature of the
collector
™ COL: collector temperature
Tank temperature indication
SER, SERI, SERS:
Tank temperature
Setting area: -40 ... +250 °C
Indicates the current temperature of the tank.
™ SER: tank temperature
™ SERI: lower tank temperature
™ SERS: upper tank temperature
Indications of probes 3 and 4
S3, S4:
Temperature probe
Setting area: -40 ... +250 °C
Indication of the other temperatures
TRIT:
Other
measurement
temperatures
Setting area: -40 ... +250 °C
Indicates the current temperature of the
respective additional probe (without
function in the regulator).
™ S3: temperature probe 3
™ S4: temperature probe 4
Note: S3 and S4 are displayed only if the
temperature probes are attached.
Indicates the current temperature of the
respective probe.
™ TRIT: return temperature.
Working hour counter
h P / h P1 / h P2:
Display channel
hours counter
66
working
The working hours counter adds the solar
working hours of the respective relay (h P/h
P1/h P2). The display indicates complete
hours.
The summed working hours can be reset
at zero. Once a working hours channel has
been selected, SET appears constantly on
the screen. To pass to the counter RESET
mode, press the SET key for 2 seconds. SET
flashes and the working hours are reset at
0. To end the RESET operation, do not press
any keys for 5 seconds. The regulator passes
automatically to the initial display mode.
ELECTRONIC CONTROL UNIT
Chapter 9
Heat quantity balance
OWMZ: Heat quantity balance
Setting area: OFF...ON
Factory setting: OFF
VMAS: Flow volume l/min
Setting area: 0...20 in steps of 0.1
Factory setting: 1
ANTT: Type of anti-freeze
protection
Setting area: 0...3
Factory setting: 1
In the basic systems (SIST) 1, 2 it is possible
realise the heat quantity balances in
connection with the flow volume counter.
Therefore activate the Heat quantity
balance in the OWMZ channel.
The flow volume (l/min) displayed in the
flow volume counter must be
set in the VMAS channel. The type and level
of anti-freeze of the heat carrier are displayed
in the ANTT and ANT% carriers.
Type of protection:
0 : water 1: propylene glycol 2: ethylene
glycol 3: Tyfocor® LS / G-LS
ANT%: Anti-freeze level of
protection as % (Vol)
Med% disappears with MEDT
0 and 3
Setting area: 20...70
Factory setting: 45
kWh/MWh: Heat quantity in
kWh/MWh
Display channel
The heat quantity transported is measured
by means of the flow volume and the
TVL flow reference (S1) and TRIT return reference
(S4). The heat quantity measured is displayed in
contents of kWh in the
kWh display channel and in contents of
MWh in the MWh channel. The sum of the two
channels forms the total heat yield.
The summed heat quantity can be reset at zero. As soon as one of the heat quantity display channels is
selected, SET appears on the display (constant). To pass to the counter RESET mode, press the SET key (3)
for 2 seconds. SET flashes and the heat quantity value is reset at 0. To close the RESET operation, confirm
using the SET key (3).
Wait 5 seconds to interrupt the RESET operation. The regulator passes automatically to the initial display
mode.
ELECTRONIC CONTROL UNIT
67
Chapter 9
ΔT adjustment
DT I: Insertion temperature
difference
Setting area: 1.0...20.0 K
Factory setting 6.0K
At the start the regulation device
acts as a standard difference regulation
device. On reaching
the insertion difference (DTI) the pump
is inserted. If the temperature difference
is lower than the set disconnection
temperature difference
(DTD), the regulator is disconnected.
DT D:
Disconnection
temperature difference
Setting area: 0.5..0.19.5 K
Factory setting: 4.0 K
ATTENTION: the insertion temperature difference must be minimum 1K greater than the
disconnection temperature.
Maximum temperature of the tank
SMS:
Tank maximum temp.
Setting area: 2...95 °C
Factory setting: 60 °C
When the maximum temperature of the tank
is exceeded, tank loading is interrupted, so
as to prevent dangerous overheating. When
the maximum temperature of the tank has
been exceeded, the display shows the
symbol.
ATTENTION: Te regulator has a safety disconnection device for the tank that prevents new tank
loading in the case of temperatures around 95°C.
68
ELECTRONIC CONTROL UNIT
Chapter 9
Collector temperature limit
Collector safety disconnection
SIC:
Collector temperature limit
Setting area: 110..0.200 °C
Factory setting: 140 °C
When the collector set limit temperature is
exceeded (SIC), the solar pump (R1) disconnects so
as to prevent dangerous overheating of the solar
components (collector safety disconnection). The
factory setting of the temperature is 140°C but this
can be modified in the range of 110...200°C. When
the collector temperature limit is exceeded, the
display shows the
symbol (flashing).
System cooling
OCR:
Opt. system cooling
Setting area: OFF...ON
Factory setting: OFF
CMS:
Collector max. temp.
Setting area: 100..0.190 °C
Factory setting: 120 °C
ELECTRONIC CONTROL UNIT
The solar system is disconnected when the
tank maximum temperature set is reached.
If the temperature of the collector increases
until reaching the collector set maximum
temperature (CMS), the solar pump is
inserted until the temperature is lower than
this limit value. In the meantime, the tank
temperature can continue to increase (tank
maximum temperature activated lastly) but
only to 95°C (tank safety disconnection).
If the temperature of the tank exceeds the
maximum set (SMS) and the temperature
of the collector is lower by a minimum of
5K to that of the tank, the solar plant will
remain inserted until the tank has cooled
again (-2K) by means of the collector and
the pipes and has a temperature lower than
the maximum set (SMS). When the system
cooling device is inserted the display shows
the symbol (flashing). By the mans of this
device, the solar system functions for a long
time even on hot summer days and keeps a
heat equilibrium in the field of the collector
and the heat source.
69
Chapter 9
Option: collector minimum limitation
OCN:
Collector minimum limitation
Setting area ON/OFF
Factory setting: OFF
CMN:
Collector minimum temperature
Setting area: 10..0.90 °C
Factory setting: 10°C
The collector minimum temperature is a
minimum insertion temperature that must
be exceeded in order to insert the solar
pump (R1). The minimum temperature
prevents the solar pump from inserting
too frequently in the case of collector low
temperature. In the case of temperatures
lower than the minimum temperature, the
display shows the
symbol (flashing).
Option: anti-freeze protection function
OCA:
Anti-freeze protection function
Setting area: ON/OFF
Factory setting: OFF
The anti-freeze protection function
inserts the heating circuit between the
collector and the tank to prevent freezing
or the thickening of the carrier; therefore
temperatures lower than the set anti-freeze
CAG:
protection temperature must be reached.
Anti-freeze temperature
On exceeding this anti-freeze protection
Setting area: -10...10 ° C
temperature set at 1°C, the solar circuit
Factory setting: 4.0 °C
disconnects.
ATTENTION: Given that the anti-freeze protection function only uses the tank limited heat quantity,
it is advised to use it in regions with only a few days of freezing per year.
Tank cooling function
ORAF:
Tank cooling option
Setting area: OFF...ON
Factory setting: OFF
70
On reaching the maximum tank temperature
set (SMS), the solar pump remains inserted
to prevent collector overheating. In the
meantime the tank temperature can continue
to increase, but only up to 95 °C (tank safety
disconnection). The solar pump is inserted
as quickly as possible (according to weather
conditions) so that the tank does not cool
by means of the collector and the pipes and
reaches its maximum temperature.
ELECTRONIC CONTROL UNIT
Chapter 9
Tubular collector function
If the regulator detects a raise of 2 K with
respect to the temperature of the collector
memorised last, the solar pump is inserted at
100% during the 30 seconds to determine the
current average temperature. After running
of the solar pump working time, the current
collector temperature is memorised as a
new reference. If the temperature detected
(new reference) has exceeded 2 K, the solar
pump is inserted again for 30 seconds. If
the temperature difference between the
collector and the tank should be exceeded
during the solar pump working time or
during the system’s period of inactivity,
the regulator passes automatically to the
solar load. If, during the inactive period, the
collector temperature should decrease by
2 K, the moment of insertion of the tubular
collector is calculated again.
O CT:
Tubular collector function
Setting area: OFF...ON
Thermostat function
(SIST = 2)
Additional heating
Using surplus heat
The thermostat function works independently
from the solar working and can be used, for
example, to make the most of the surplus
heat or for additional heating.
™ TE I < TE D
Using the thermostat function for additional
heating
™ TE I > TE D
Using the thermostat function to take
advantage of the surplus heat
TE I:
Thermostat
insertion
temperature
Setting area: 0.0...95.0 °C
Factory setting: 40 °C
ELECTRONIC CONTROL UNIT
TE D:
Thermostat disconnection When the 2 output 2 is inserted the display
temperature
shows the
symbol.
Setting area. 0.0...95.0 °C
Factory setting: 45 °C
71
Chapter 9
MAN/MAN1/MAN2:
Operation mode
Setting area:
OFF,AUTO,ON
Factory setting: AUTO
Language (LANG)
LANG:
Setting the language
Possible settings: Ger, En, It
Factory setting: Ger
72
The operational mode can be activated
manually for the control or maintenance
operations. Therefore select the setting value
MAN / MAN1 / MAN2. This value allows the
following settings:
™ MAN / MAN1 / MAN2
operational mode
OFF : relay disconnected (flashing) +
AUTO : relay in automatic functioning
(flashing)
ON : relay inserted
The menu language can be set in this channel.
™ Ger: German
™ En: English
™ It: Italian
ELECTRONIC CONTROL UNIT
Chapter 9
Troubleshooting
If there is interference inside the regulator, the display
will communicate it with the following warning:
Warning symbols
T4A fuse
Control indicator
indicator
T 4A
220...240V
R1 2(1)A(220...240)V
R2 2(1)A(220...240)V
Temp. Sensor
Pt 1000
S1
1
S2
2
3
S3
4
5
S4
6
7
N R2
8
12
13
14
15
16
N R1 N
17
18
19
L
20
figure 9.17
Problem
figure 9.18
Reason
The regulator control
indicator led is always The regulator is not powered.
off.
Solution
Check the regulator power supply.
Check the fuse and replace it if
necessary.
Check the probe. The attached Pt
Faulty probe. 888.8 appears in the
probes can be controlled using a
corresponding channel instead of a
The control indicator temperature, meaning that the probe polimeter. Their temperatures can be
compared with the resistance values
flashes red intermittently. is broken or disconnected.
stated in the following table.
The symbol appears on
the display (spanner)
Check the probe. The attached Pt
and the symbol (triangle) Faulty probe. -88.8 appears in the probes can be controlled using a
corresponding channel instead of a
flashes.
polimeter. Their temperatures can be
temperature, meaning that the probe
compared with the resistance values
is short circuited.
stated in the following table.
The solar circuit pump
does not work even if
Check the regulator power supply and
The regulator control indicator is off.
the collector is much
the fuse.
hotter than the tank.
The solar circuit pump Voltage has not reached the pump.
does not function even
in manual mode.
The pump is blocked.
ELECTRONIC CONTROL UNIT
Check the power supply of the
regulator, the pump and the fuse.
Release the pump rotor using a
screwdriver.
73
Chapter 9
Air present in the system.
The pump is hot, but
there is no heat transfer
from the collector to System pressure too low.
the tank; flow and
return same heat; some
bubbling in the pipes.
Collector circuit filter blocked
Deaerate the system.
Increase the system pressure by a
minimum of + 0.5 bar with respect to
the primary static pressure; continue
to increase it if necessary; insert and
disconnect the pump manually.
Clean the filter
Difference of insertion temperature
Modify “ΔTins and if necessary “ΔTdis.
ΔTins set too high.
The pump is inserted
late.
Collector probe positioned in not
Move the probe inside the collector.
optimal position.
Difference of insertion temperature
Modify “ΔTins and if necessary “ΔTdis.
The pump continues to ΔTins set too low.
insert and disconnect
Collector probe positioned in not
frequently.
Move the probe inside the collector.
optimal position.
The temperaturedifference
between the tank and the
collector increases a lot;
the collector circuit does
not lead the heat away.
Collector circuit pump faulty.
Check the pump.
Presence of lime-scale on the heat Remove the lime scale from the heat
exchanger.
exchanger.
Heat exchanger blocked.
Clean the heat exchanger
Collector circuit pump also functioning
at night. The temperature of the collector
Check the OCR and ORAF functions.
is greater than the external temperature
during the night.
The tank cools down
during the night.
74
Tank fitting insulation insufficient.
Increase insulation.
Tank fitting insulation not adherent.
Change or increase the insulation.
Use a timer for the circulation pump.
Presence of domestic hot water
circulation circuit.
Install a non-return valve to prevent
natural circulation.
Presence of additional heating in the
storage tank.
Install a non-return valve in the
Natural circulation could start additional heating circuit.
through additional heating.
ELECTRONIC CONTROL UNIT
Chapter 9
Resistance value of the PT1000 probes
°C
Ω
-10
-5
0
5
10
15
20
25
30
35
40
45
50
ELECTRONIC CONTROL UNIT
961
980
1000
1019
1039
1058
1078
1097
1117
1136
1155
1175
1194
°C
55
60
65
70
75
80
85
90
95
100
105
110
115
Ω
1213
1232
1252
1271
1290
1309
1328
1347
1366
1385
1404
1423
1442
75
Chapter 10
START-UP
WASHING THE SOALER CIRCUIT
Two taps R1 and R2, present in the GSC1 and GSC2 pump units must be used to clean and fill the system:
the first filling and the second discharging. A third shut-off valve VI is used to disconnect them from each
other. The taps must be positioned in the lowest point of the solar UNIT (figure 10.1).
The system must be washed by allowing water to
circulate before filling it with the water and antifreeze mix. All dirt and remains of the fondant paste
are removed from the solar circuit in this way.
Open tap R1 and connect it using a rubber pipe to
the cold water tap.
Open tap R2 and connect it using a rubber pipe to
the water discharge.
Close the shut-off valve VI (see figure 10.2)
Open all shut-off taps before the automatic relief
valves or all of the manual air-bleed valves.
Open the tap and allow water to run into the solar
circuit for a few minutes under force.
ATTENTION!!!
Only perform this operation if the
temperature is not rigid, otherwise the
system might freeze.
If the collectors are not used for long
periods of time and are therefore
disconnected from the rest of the
system, they must be protected, using a
cap, from the humidity that could enter.
In rigid conditions the condensate water
can freeze the collectors.
R1
VI
R2
figure 10.1
Mains cold water
VI
R1
Unload
R2
figure 10.2
76
START-UP
Chapter 10
SEALING CHECK
Conclude the rinsing phase by closing tap R2 and raise the pressure inside the solar circuit to at least 4 bar
(as long as this does not exceed the pressure accepted for the different components). Close tap R1 and
then also close the water tap.
Open the shut-off valve VI, use the electronic control unit to activate the solar circuit pump and bleed all
air from the circuit (see figure 10.3).
Carefully visually check the sealing of all pipes and
connections.
If desired and weather conditions permitting, the
system can be made to run for a test period using
just water.
This can only be performed if there is no risk of
freezing.
Unfortunately it continuously occurs that new
systems freeze because the owner has bought the
anti-freeze but has not yet introduced it into the
system. Instead of being caught out by the first
critical autumn day it is a good idea to add the
anti-freeze immediately, after having checked
that functioning takes place without problems
for a few days.
As an alternative the sealing check can be performed
with compressed air before the rinsing process. If a
loss of pressure is noted it is advised to check the
sealing of all critical connections using soapy water.
VI
R1
R2
figure 10.3
WASHING THE SOLAR CIRCUIT
Connect both taps to the discharge using rubber pipes, open them and empty the system. The quantity of
water can be measured and used for the preparation of the water and glycol mix. The real amount of water
contained in the system is greater because a small amount of water always remains inside the collector.
If the collector circuit cannot be completely emptied, it is possible to “push the water out” while filling is
taking place (see following paragraph).
The colour and viscosity of the fluid helps to recognise when not only water escapes from tap R2 but the
water and glycol mixture.
The water remaining inside the circuit puts the system in danger of freezing if the latter is not filled again
immediately.
START-UP
77
Chapter 10
DILUTING THE GLYCOL TO THE DESIRED CONCENTRATION
If the use of anti-freeze is envisioned, the water and glycol must be mixed in a container following the
data indicated by the producer and in a way that anti-freeze safety is guaranteed to a temperature of 10 °C
below the average minimum winter temperature. This data must be obtained on the basis of the specific
geographical area and is the same used to calculate the design of the heating system.
The volume of water contained inside the system can be measured directly after the washing phase and
sealing check or it can be calculated. The liquid contained inside each panel is equal to 1 litre. The liquid
contained inside the piping can be calculated on the basis of the following table, multiplying the values
by the total length of the pipes.
Dimensions of the pipe
Content (l/m)
12 x 1
0,079
External diameter and thickness in mm
15 x 1
18 x 1
22 x1
28x 1,5
0,133
0,201
0,314
0,491
35 x 1,5
0,804
A heat transfer fluid is used inside the solar circuit. This transfers the heat absorbed by the solar panel
inside the domestic hot water storage tank.
This fluid is made up from a mixture of neutral water and TYFOCOR® L anti-freeze liquid, able to protect the
system from the winter’s freezing.
The water used is normal drinking water or de-mineralised water (MAX chlorides 100 mg/kg).
The corresponding concentration and density is stated in the following table and the freezing-resistance
values are indicated in the graphics (figure 10.4).
TYFOCOR L
[% v/v]
25
30
35
40
45
50
55
Freezing
-10°C
-14°C
-17°C
-21°C
-26°C
-32°C
-40°C
Density
[g/cm3]
1,023
1,029
1,033
1,038
1,042
1,045
1,048
The minimum concentration to keep protection against corrosion complete must be greater than 25%,
while the maximum allowed is 55%.
78
START-UP
Chapter 10
0
Temperature °C
-10
-20
-30
-40
-50
0
10
20
30
40
50
60
70
Glycol %
figure 10.4
To select the correct dilution, refer to the table assuming a freezing point equal to
Minimum temperature detected on average in the area - 10°C
Example:
Average minimum winter temperature in the area = - 11 °C
Critical freezing point = - 11°C – 10°C = - 21°C
from which the following is obtained: dilution = 40% v/v
Preparation:
If 20 litres of diluted are necessary, it results:
8 litres of TYFOCOR L + 12 litres of water
START-UP
79
Chapter 10
FILLING THE SOLAR CIRCUIT
C
TS
B
VS
VMS
M
T
VE
VR
T
D
R1
GC
RP
R2
GP
CE
Water/glycol
mixture
figure 10.5
Symbol
B
C
CE
D
GC
GP
M
Description
Domestic hot water cylinder
Solar collector
Electronic control unit
Deaerator
Pump unit
Loading the pump unit
Manometer
Symbol
R1
R2
RP
T
VE
VS
VR
Description
Tap 1
Tap 2
Flow rate adjuster
Thermometer
Expansion vessel
Safety valve
Non-return valve
Before filling the pre-set pressure must be checked of the expansion vessel using a manometer.
Filling is performed as described below:
™ Connect a GP feed pump using a rubber pipe (e.g. manual or drill pump) to the container and tap R1.
On request the installer is supplied with the high head mobile pump for system loading (accessory - code
002160627).
™ Take a rubber pipe from tap R2 to the container.
™ The taps must be open and the shut-off valve VI must be closed (see figure 10.2).
™ Open all shut-off taps upstream from the automatic relief valves or all of the manual air-bleed valves.
™ Use the pump to fill the collector circuit with the water and glycol mixture until the fluid starts to
escape from tap R2.
80
START-UP
Chapter 10
™ Close tap R2. The pressure inside the solar circuit must rise up to the desired initial pressure (see
“Connection of the expansion vessel and pre-load adjustment” chapter). Then close the tap R1 and switch
the feed pump off.
™ Open the shut off valve VI.
™ Power the solar circuit pump by setting it in continuous working mode, in a way to remove the air
from the circuit. Manually open the manual air-bleed valve several times. Make the air escape by opening
the large brass screw on the front of the pump. If all of the air cannot be removed from the circuit, switch
the pump on and off again several times at a distance of 10 minutes.
™ After a few days and after having extracted all air completely (noises can no longer be heard inside the
system) close the shut-off valves upstream from the automatic air-bleed valves.
™ Once again check the initial pressure inside the solar circuit when cold (early morning) and add fluid,
if necessary.
™ With the system cold, periodically deaerate the system using the deaerator positioned on the flow of
the GSC2 pump unit. Connect a small pipe to the deaerator in order to recover the liquid and prevent
scalding. Successively, loosen the deaerator locknut until complete escape of the air and then tighten.
™ If not yet carried out, apply insulation to the solar circuit, joining it in all points without leaving leaks
or by gluing it.
™ Periodically check the pressure of the hydraulic circuit. If it should fall below the initial loading value it
means leaks are present, while if it should exceed 5 bar it means that the expansion vessel is not working
correctly.
SETTING THE COLLECTOR AND SYSTEM FLOW RATE
The optimal flow rate inside each collector is between 60 and 100 l/h. Connecting the panels in parallel
results in a total flow rate equal to the optimal flow rate multiplied by the number of panels. If, for example,
4 panels are installed a total flow rate equal to 240 – 400 l/h (4 – 6.7 l/min) results.
To set the desired flow rate:
™ Open the shut off valve VI completely.
™ Set the pump at the lowest regular working conditions.
™ By means of the flow rate measuring device inserted at the base of the GSC1 and GSC2 pump units
(figure 10.6), check that the desired value has been reached or exceeded. If this is the case, this working
order can be maintained. Only if it is greatly exceeded (1.7 times higher), the flow rate must be reduced
by throttling using valve VI. If the desired value is not reached, then the pump rotation must be increased.
Further checks and increases in regular working follow.
™ An effective control of the flow rate can be performed using the temperature difference control
START-UP
81
Chapter 10
figure 10.6
between flow and return thanks to two thermometers present in the GSC2 pump unit. If during summer
days with strong insulation a temperature difference between flow and return of 10 and 20°C is measure,
it means that the flow rate is set correctly. For differences exceeding 20°C the flow must be increased,
while for differences below 10°C the flow rate must be reduced.
CHECKING THE SETTINGS OF THE ADJUSTMENT CONTROL UNIT
The adjustment control unit settings must be checked following the user instructions. Set a storage tank
temperature that is not too high (< 85 °C), to prevent heat stress and the deposit of lime scale.
SETTING THE DOMESTIC HOT WATER MIXER
A mixer valve must be installed in the domestic hot water circuit to prevent unpleasant scalding.
The domestic hot water mixer must be set at the desired temperature.
FILING THE BSV 300, BSV 300 ES AND BSV 150 ES TANK
The tank must be filled as follows:
™ Open the shut-off cock in the cold water inlet line and a hot water tap in the house. Fill the tank until
water escapes from the tap.
™ If present, manually start the circulation pump.
™ Visually check the sealing of all pipes and connections.
Check the correct installation of the tank expansion vessel and the safety valve. With the cylinder hot
he domestic hot water side pressure must not exceed 6 bar, otherwise it means that there is a system
execution error or, for example, that the expansion vessel is not working correctly.
82
START-UP
Chapter 11
MAINTENANCE
Correct maintenance of the system, performed regularly by the user and periodically by skilled technicians,
is the essential condition for good functioning and duration of the entire system.
Regular checks by the user
The customer must regularly check the controls described below and inform the technicians in the case of
anomaly.
™ Check that the pressure on the pump unit manometer with system cold is constantly the same as the
value set.
™ Check that the temperature difference between flow and return, during the summer days with strong
insolation is between 10°C and 20°C.
™ Check that the collector temperature, read on the control unit display and detected by the probe
positioned on the collector is almost the same as the flow temperature read on the pump unit red
thermometer. On the contrary it means that the pipes have not been insulated suitably.
™ Check that the pump starts to function when there is strong solar radiation.
™ Check that during the night in when the sky is very cloudy that the pump is at a standstill and that
both system flow and return (red and blue thermometers) are cold.
™ Check there is no noise inside the pipe caused by the presence of air bubbles.
™ If the boiler has a magnesium anode, check the value indicated by the tester by pressing the integrated
button: the pointer must be positioned inside the green field.
Periodical maintenance by skilled technicians
™ Clean the collectors glass whenever this is very dirty.
™ Check the concentration of the anti-freeze using the relevant instrument (refractometer) at least once
every 2 years.
™ Check the level of acidity (PH) of the water and glycol mix inside the system at least once every 2 years:
if PH < 6.6 replace the liquid as it is corrosive.
™ If the cylinder has a magnesium anode, replace it when the tester indicates its wear (red range).
™ Check the pressure when the system is cold. If it should be lower than that set integrate fluid as
described in the “system filling” chapter.
MAINTENANCE
83
Chapter 11
Troubleshooting table
FAULTS
POSSIBLE CAUSES
Loss of fluid from the system: from the connections
or from the automatic deaerators.
Presence of air in the system.
The safety valve has intervened due to incorrect
Pressure loss in the collectors circuit when the
dimensioning, a fault or incorrect pressure pre-set
system is cold
on the expansion vessel and fluid has escaped from
the circuit.
Damage caused by freezing after a period of intense
cold.
An ignition temperature difference that is too high
has been set.
There is no current therefore the control unit is off.
The pump is not inserted automatically
The maximum temperature inside the tank has
been reached.
The temperature probes are broken.
The pump is blocked or broken.
Presence of air inside the collector circuit.
The pump is working but heat is not reaching the Formation of vapour because the pump started too
collector
late or the flow rate is too low.
Collector glass dirty.
The insulation has been performed unsuitably.
Cooling caused by the collector pump working
The tank cools down quickly
during the night.
Presence of the circulation pump in the domestic
hot water circuit.
An ignition temperature difference that is too low
has been set.
The pump changes over continuously between on
Incorrect position of the probes or their
and off
connection.
Faulty pump.
84
MAINTENANCE
Chapter 12
WARRANTY TERMS
EXTRAFLAME S.p.A. reminds you that the manufacturer is the owner of the rights envisioned by the
Legislative Decree dated 2 February 2002, n. 24 and the following warranty does jeopardise these
rights.
EXTRAFLAME S.p.A. with head offices in Montecchio Precalcino (VI), via dell’Artigianato 10, declares the
following WARRANTY conditions, relative to the components making up the SOLAR KITS:
ECO STAR
STAR PLUS
STAR COMBI
5 YEARS WARRANTY for following elements:
™ Flat solar collectors DIN SOLAR KEYMARK certified EXTRAFLAME PS AS 1 model
™ Domestic hot water cylinder enamelled glass BSV 150 ES with electronic titanium anode
™ Domestic hot water cylinder enamelled glass BSV 300 ES with electronic titanium anode
™ Domestic hot water cylinder enamelled glass BSV 300 ES with electronic titanium anode
™ TPS 500 solar storage tank
™ TPS 1000 solar storage tank
2 YEAR WARRANTY for accessories, electric and electronic components.
This declaration is supplied in compliance with the necessity to fill in the asseveration, by a skilled technician,
which certifies that the intervention complies with the requisites requested in articles 6, 7, 8 and 9 of the
Interministerial Decree dated 19/02/2007 in order to obtain tax relief of 55%.
WARRANTY CONDITIONS
The warranty is considered valid on the condition that:
1. The solar kit has been installed, inspected and serviced perfectly in compliance with the regulations
in force on this subject and the provisions contained in the installation, user and maintenance manual
relative to the product, by qualified staff with the requisites required by the law (Law n° 46 dated 5
March 1990);
2. For the systems in which the following components are mounted:
™ Domestic hot water cylinder enamelled glass BSV 300
™ Domestic hot water cylinder enamelled glass BSV 150 ES and BSV 300 ES
for validity of the warranty it is mandatory to install the titanium electronic anode for the continuous
prevention of corrosion and check the correct functioning.
3. The “WARRANTY DOCUMENT” has been filled in completely and is kept with the fiscal documentation
relative to the product purchased.
WARRANTY TERMS
85
Chapter 12
The warranty is not considered valid in the following cases:
1. The conditions for the implementation of the warranty have not been respected.
2. Installation has not been performed with respect to the standards in force regarding the provisions
described in the user and maintenance manual.
3. Negligence of the customer due to lack of or incorrect maintenance.
4. Presence of electric and hydraulic plants that do not comply with the standards in force.
5. Damage deriving from atmospheric agents, chemicals, electro-chemicals, improper use of the product,
modifications or tampering of the product and/or other causes not deriving from the manufacture of
the product.
6. Damage caused by normal corrosion or typical deposits of the hydraulic plants.
7. Damage caused to the system owing to the use on non-original spare parts or consequences of
interventions carried out by unqualified technical staff.
8. Improper or negligent use.
9. All damage caused by transport. It is therefore recommended to carefully check the goods on receipt,
informing the dealer of any damage immediately, making a note on the transport document and on
the carrier’s copy.
10. Atmospheric events of greater intensity to those envisioned by certification tests and such to break the
collector glass.
11. Wear of the magnesium anode or malfunctioning of the titanium electronic anode
12. Breakdown of the solar control unit caused by over-voltages.
13. Malfunctioning of coils SRA 1,5 , SRA 3 , SRA 5 caused by the deposit of lime scale
14. Formation of condensate inside the solar collector: the formation of condensate on the internal
glass surface is a normal phenomenon of all high-efficiency solar collectors, which does not jeopardise
functioning, it depends on the climatic conditions of the room in which the panels are installed and the
season.
Extraflame S.p.A. is not liable for any damage/injury that can, directly or indirectly, affect persons, objects
and pets as a consequence of failure to comply with the provisions indicated in the installation, user and
maintenance manual and the standards in force regarding installation and maintenance of the appliance.
The following are excluded from the warranty:
™ The collector glass due to breakage taking place after delivery or due to the atmospheric events
described above.
™ The gaskets, the coatings, painted details
™ Masonry work.
™ The system details not supplied by EXTRAFLAME S.p.A.
™ Any calibration or product adjustments are excluded from the warranty.
LAW COURT
The Vicenza Law Court is elected as the competent court for any disputes.
86
WARRANTY TERMS
Chapter 13
WARRANTY DOCUMENT
Product identification label
Attach here
Document to be kept and produced if an intervention is requested under warranty
Name
Surname
Address
Post code
Municipality of residence
Province
Telephone
Model
Serial N°.
Dealer
Stamp
Date of Purchase
IMPORTANT: ‰ accept ‰ do not accept
Information note for the purpose and effect of Legislative Decree 196/2003 - Your personal data is processed by the company with full respect
of the Legislative Decree 196/2003 for the entire duration of the contractual relationship in order to fulfil all legal requirements as well as
to efficiently manage the commercial relationships. The data can only be communicated to other external subjects to protect credit and
for better management of our rights relative to individual commercial relations, as well as communication to third parties due to specific
obligations of the law. The affected body has the faculty to exert the rights recognised in art.7 of the stated decree
WARRANTY DOCUMENT
87
Stufe a Pellet
EXTRAFLAME S.p.A.
Via Dell’Artigianato, 10
36030 MONTECCHIO PRECALCINO
Vicenza - ITALY
Tel. 0445/865911
Fax 0445/865912
http://www.lanordica-extraflame.com
E-mail: [email protected]
Important note
The texts and graphics in this manual have been realised with the greatest care and knowledge possible.
However, as it is impossible to exclude all errors the following must be specified:
The basis of your designs must be made up exclusively of calculations and designs on the basis of laws and
standards in force. We exclude any liability due to texts and illustrations published in this manual, as they
are just examples.
It contents taken from this manual are used; it is expressly under the user’s risk.
Any liability of the editor is excluded due to incompetent, incomplete or inexact information, as well as any
damage deriving from it.
This document is available at www.extraflame.it/support
004165101 - INGLESE
Manuale installazione kit solare
REV 004 12.03.2009
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