Solar Kit Installation Manual

SOLAR KIT INSTALLATION
MANUAL
2
3
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
4
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
WARNINGS AND SAFETY DEVICES 5
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 modifcations during assembly exclude any responsibility of Extrafame
S.p.A.
Follow the following Standards particularly:
DIN 4757, 1st part Solar heating systems with water and water mixtures as heat transfer medium;
Demands to the safety realisation.
DIN 4757, 2nd part Solar heating systems with organic heat transfer medium; Demands to safety
realisation.
DIN 4757, 3rd part Solar heating systems; solar collectors; Meanings; safety regulations; Testing of
standstill temperature.
DIN 4757, 4th part Solar thermal systems; solar collectors; determination of ef ciency, 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 ef ciency
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 fuid 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.
WARNINGS AND SAFETY DEVICES 6
Chapter 1
fgure 1
fgure 2
COMPONENT DESCRIPTION 7
Chapter 2
COMPONENT DESCRIPTION
All kits supplied by La Nordica & Extrafame are made up from the various combinations of the components
described above. The confguration of the kits and their features are described in the sales publications
and in the price lists.
EXTRAFLAME PS AS1: highly selective fat 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
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
impressed current) and prepared for additional electric resistance.
TPS 500: 500 litre storage pufer without instant domestic hot water coil.
TPS 1000: 1000 litre storage pufer without instant domestic hot water coil.
SRA 1.5: 1.53 m
2
fnned copper coil for the production of domestic hot water or additional heating.
SRA 3: 3.75 m
2
SRA 5: 5.26 m
2
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 complete with wall-fxing kit and special non-return valve for
maintenance and stainless steel pipe for connection to the pump unit.
VES 35 50 80: 35 50 80 litre solar expansion vessel complete with fxing kit and special non-
return valve for maintenance and stainless steel pipe for connection to the pump unit.
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.
Chapter 2
PS AS1
Highly selective fat solar panels
Dimensions LxHxP 1946 x 946 x 105 mm
Gross surface 1.84 m
2
Surfaces of the opening 1.65 m
2
Absorber surfaces 1.62 m
2
Empty weight with glass 36 kg
Glass Hardened prismatic with 4mm thickness with low iron content
Absorber Copper with highly selective Tinox covering
Type of construction Lyra (ultrasound welding)
Pipes material Copper
Connection dimension
Absorbance 95 %
Emission 3 %
o 0,732
a1 3,771 W/(m
2
K)
a2 0,011 W/(m
2
K
2
)
Maximum working pressure 10 bar
Standstill temperature 211 C
Fluid content ~ 1 l
Working fow rate 60 100 l/h
Insulation Mineral wool
Insulation thickness
Lower: 50 mm
Lateral: 20 mm
Structure Aluminium with electrostatic treatment
Gasket EPDM Silicone
fgure 3

0
0,1
0,2
0,3
0,4
0,5
0,6
0,7
0,8
0,9
1
0 0,01 0,02 0,03 0,04 0,05 0,06 0,07 0,08 0,09 0,1
Chapter 2
(Tm - Ta)/ l* (m
2
K/W)
fgure 4
fgure 5
fgure 6
Ef ciency curve (l* = 800W/m
2
)
1
4
5
2
4
5
5
5
5
6
8
5
7
9
5
4
0
5
7
1
5
9
1
0
1"AG
3/ 4"AG
3/ 4"AG
1"AG
17,2
1"1/ 4
es t .54
Tubo
26x2
4
4
5
1/ 2"I G*
3/ 4"AG
A
B
C
D
E
F
G
H
I
45
500
Chapter 2
BSV 150 ES
150l vitrifed single coil domestic hot water cylinder.
Diameter x Height 650 x 960 mm (with insulator)
Capacity 150 l
Weight 81 kg
Internal treatment Two-coat vitrifcation
Solar coil surfaces 0,75 m
2
Solar coil liquid volume 4,2 l
Insulation Rigid polyurethane 50 mm
External covering Sky
Coils hydraulic connections 3/4
Protection from corrosion
Magnesium anode as per series (fgure 10)
Titanium anode optional (fgure 11)
fgure 7
A Magnesium anode or electronic with titanium F Solar cold return
B Domestic hot water output G Domestic cold water input + exp. vessel
C Solar heat fow H Inspection fange
D 6 bar safety valve/circulation I Thermometer
E Temperature probe
1
5
5
2
5
5
7
8
0
8
8
0
9
8
0
1
2
4
5
1
3
3
5
4
1
5
8
3
5
1
2
5
5
1
4
8
0
1"AG
3/ 4"AG
3/ 4"AG
3/ 4"AG
3/ 4"AG
1"AG
Tubo 17,2
1"1/ 2I G
Liber o
1"1/ 4
es t .54
Rondella M6
Tubo
26x2
75
5
2
0
1/ 2"I G*
3/ 4"AG
35
1/ 2"I G*
1
0
8
0
mq. 1,21
mq. 0,9
A
B
C
D
L
E
F
G
H
I
M
N
O
550
Chapter 2
BSV 300
300 l vitrifed double coil domestic hot water cylinder.
Capacity 300 l
Weight 121 kg
2
Coil surfaces integration 0,9 m
2
fgure 8
A Magnesium anode or electronic with titanium H Temperature probe
B Domestic hot water output I Solar cold return
C Additional boiler fow L Domestic cold water input + exp. vessel
D Temperature probe M Inspection fange
E 6 bar safety valve/circulation N Electric resistance
F Additional boiler return O Thermometer
G Solar heat fow
1
5
5
2
5
5
7
8
0
9
8
0
1
3
3
5
4
1
5
8
3
5
1
2
5
5
1
4
8
0
1"AG
3/ 4"AG
3/ 4"AG
1"AG
Tubo 17,2
1"1/ 2I G
Liber o
1"1/ 4
es t .54
Rondella M6
Tubo
26x2
75
5
2
0
1/ 2"I G*
3/ 4"AG
35
A
B
C
D
E
F
G
H
I
L
550
Chapter 2
BSV 300 ES
300 l vitrifed single coil domestic hot water cylinder.
Capacity 300 l
Weight 106 kg
2
fgure 9
A Magnesium anode or electronic with titanium F Solar cold return
B Domestic hot water output G Domestic cold water input + exp. vessel
C 6 bar safety valve/circulation H Inspection fange
D Solar heat fow I Electric resistance
E Temperature probe L Thermometer
TR
F
230 V, 50 Hz
TE
F
Chapter 2
The 150 or 300 litre domestic hot water cylinder is supplied as per standard with a sacrifcial 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 Extrafame 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
frst 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.
Magnesium anode with tester (as per standard) Titanium anode with impressed current (optional)
Confguration as per standard with magnesium anode Optional confguration with titanium anode
The fgures 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 Description
F Band for equipotential connections
TE Magnesium anode tester
TR Titanium anode transformer
fgure 10 fgure 11
fgure 12 fgure 13
2
3
0
4
1
0
6
3
0
7
1
5
9
2
0
1
0
4
0 1
2
2
0
1
2
7
0
1
3
8
0
1
5
9
5
3
0
1
5
0
1
2
5
0
1
5
0
1
5
1/ 2"
1"1/ 2
1/ 2"
1/ 2"
1"1/ 2
1/ 2"
1"1/ 2
1/ 2"
1"1/ 2
1/ 2"
1/ 2"
1"1/ 2
1"1/ 2
1"1/ 2
1"1/ 2
1"
1"
5
0
0
Dis c o Separ at or e
Tipo "HP 650"
A
B
B
B
B
B
B
C C
D
E
F
D
E
F
G
H
I
L
650
Chapter 2
TPS 500
500l storage accumulator.
Diameter x Height 850 x 1,680 mm (with insulator)
Capacity 500 l
Storage tank material Very thick carbon steel
Solar coil material Carbon steel
Weight 135 kg
2
Solar coil liquid volume 10 l
Removable insulation Polyurethane 100 mm
Covering Soft PVC
Stratifcation device Yes
Solar coil hydraulic connections 1
fgure 14
A 3 bar safety valve + vent F
Low temperature heating return/wood boi-
ler return
B Temperature probe G Flange for domestic hot water coil
C Boiler fow H Flange for boiler coil
D Heating fow I Solar heat fow
E
High temperature heating return/pellet boi-
ler return
L Solar cold return
1
7
0
1
6
5
0
1
7
0
1
5
3
0
1/ 2"
2.5
2
.5
Fondo 790
TDB
1"1/ 2
1"
1"1/ 2
1"1/ 2
1"1/ 2
1/ 2"
1"1/ 2
1/ 2"
1"1/ 2
1/ 2"
Separ at or e
t ipo "HP790"
1/ 2"
1"1/ 2
1"1/ 2
1/ 2"
1/ 2"
8
0
0
1"
2
5
0
5
2
0
9
5
0
1
0
3
5
1
3
3
5
1
6
4
0
1
6
9
0
1
8
0
0
2
0
3
5
A
B
B
B
B
B
B
C
D
E
F
C
D
E
F
G
H
I
L
790
Chapter 2
TPS 1000
1,000 l storage accumulator.
Diameter x Height 990 x 2,120 mm (with insulator)
Capacity 1000 l
Storage tank material Very thick carbon steel
Solar coil material Carbon steel
Weight 186 kg
Solar coil surfaces 3 m
2
Solar coil liquid volume 18 l
Removable insulation Polyurethane 100 mm
Covering Soft PVC
Stratifcation device Yes
Solar coil hydraulic connections 1
fgure 15
A 3 bar safety valve + vent F
Low temperature heating return/wood boi-
ler return
B Temperature probe G Flange for domestic hot water coil
C Boiler fow H Flange for boiler coil
D Heating fow I Solar heat fow
E
High temperature heating return/pellet boi-
ler return
L Solar cold return
Chapter 2
SRA 1,5
1.53 m
2
fnned copper coil
SRA 3
3,17 m
2
fnned copper coil
SRA 5
5.26 m
2
fnned copper coil
SRA 1,5 SRA 3 SRA 5
Length 345 mm 565 mm 800 mm
Diameter 200 mm 200 mm 200 mm
Hydraulic connections 3/4 3/4 1 1/4
Surfaces 1,53 m
2
3,17 m
2
5,26 m
2
Power than can be exchanged* 30 kW 60 kW 105 kW
Domestic hot water maximum fow rate 12 l/min 23 l/min 45 l/min
* Storage temperature: 75C - Cold water temperature 10C - Hot water temperature 45C
fgure 16
Chapter 2
GSC1
Single, one-pipe, circulation pump unit without deaerator.
Model GSC 1
Dimensions LxHxD 400 x 230 x 150
Pump max. head 6 m
Pump max. power 82 W
Flow rate adjustment 2-12 l/min
Safety valve 6 bar
Hydraulic connections 3/4
Manometer yes
Excludable non-return valve and
thermometer in the return
yes
thermometer in the fow
no
Deaerator no
Valves for system load and unload yes
GSC 2
Double, two-pipe, circulation pump unit with deaerator.
Model GSC 2
Dimensions LxHxD 400 x 230 x 150
Pump max. head 6 m
Pump max. power 82 W
Flow rate adjustment 2-12 l/min
Safety valve 6 bar
Hydraulic connections 22 mm
Manometer yes
thermometer in the return
yes
thermometer in the fow
yes
Deaerator yes
Valves for system load and unload yes
fgure 17
fgure 18
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
Model CS 3.1 CS 3.2
Inputs per sensors 4 4
Temperature probes supplied Pt 1000 x 3 Pt 1000 x 3
Standard relay outputs 1 2
Additional heating no yes
Dimensions LxHxD 172 x 110 x 46 mm 172 x 110 x 46 mm
Room temperature 040 C 040 C
Casing material PC-ABS PMMA PC-ABS PMMA
Thermostat function no yes
Working hour counter yes yes
Disconnection safety device yes yes
Anti-freeze protection yes yes
Tank cooling yes yes
fgure 19
Chapter 2
VES 18
18 litre solar expansion vessel complete with wall-fxing kit and special non-return valve for maintenance
and stainless steel pipe for connection to the pump unit.
VES 35-50-80
35 50 80 litre foor-mounted solar expansion vessel complete and special non-return valve for
maintenance and stainless steel pipe for connection to the pump unit.
Model VES 18 VES 35 VES 50 VES 80
Positioning Wall Ground Ground Ground
Diameter x Height 270 x 350 mm 380 x 377 mm 380 x 525 mm 450 x 608 mm
Capacity 18 l 35 l 50 l 80 l
Max. working pressure 10 bar 10 bar 10 bar 10 bar
Pre-load 2,5 bar 2,5 bar 2,5 bar 2,5 bar
Hydraulic connection 3/4 3/4 3/4 1
Diaphragm max. working
temperature
100 C 100 C 100 C 100 C
System max. working tempe-
rature
120 C 120 C 120 C 120 C
fgure 20
Special diaphragm resistant up to 100C
Resistant to any mixture containing ethylene glycol and propylene glycol
Structure completely welded
Epoxy paint
Quick installation
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.
fgure 21
0
50
100
150
200
250
DIC NOV OTT SET AGO LUG GIU MAG APR MAR FEB GEN
= 30 = 45
= 0
= 60
= 90
DIMENSIONING 21
Chapter 3
DIMENSIONING
The dimensioning of the solar heating system starts initially from the identifcation 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/benefts
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 afecting every m
2
of collector on variation of the angle of inclination.
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 Type of intake of the solar system
30 maximum summer production
45 maximum yearly production
60 maximum winter production
90 minimum summer production
k
W
h
/
(
m
2

M
o
n
t
h
)
fgure 22
DIMENSIONING 22
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 identifcation 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 23 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
Reference values for the dimensioning of the
surfaces of the collectors
North 1.2 m
2
every 50 litres/day
Centre 1,0 m
2
every 50 litres/day
South 0,8 m
2
every 50 litres/day
fgure 23
G
E
N
F
E
B
M
A
R
A
P
R
M
A
G
G
I
U
L
U
G
A
G
O
S
E
T
O
T
T
N
O
V
D
I
C
DIMENSIONING 23
Chapter 3
For diferent orientations and inclinations the surface of the collectors is increased on the basis of the
following table:
Orientation
South: 0 East/West: 90
Angle of inclination
0 15 30 45 60 75 90
0 1,12 1,03 1 1,01 1,07 1,20 1,44
15 1,12 1,04 1 1,02 1,07 1,20 1,44
30 1,12 1,04 1,01 1,03 1,08 1,22 1,42
45 1,12 1,06 1,03 1,05 1,11 1,23 1,42
60 1,12 1,07 1,06 1,08 1,15 1,26 1,44
75 1,12 1,10 1,1 1,13 1,2 1,31 1,51
90 1,12 1,13 1,15 1,2 1,28 1,40 1,61
Once the surface of the collectors has been obtained the storage tank must be dimensioned. With good
approximation every m
2
of collector requires 70 litres of storage.
The amount of hot water not covered by the sun during the winter months (see fgure below) must be
satisfed with an integrated boiler.
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 m
2
.
Due to orientation towards west the value of the surface must be increased and results equal to 5.76x1.15
= 6.62 m
2
.
The volume of the storage tank must be equal to 6.62 x 70 = 463 litres.
Useful intake of the
solar system
Requirement for
domestic hot water
k
W
h
/
(
m
2

M
o
n
t
h
)
fgure 24
GEN FEB MAR APR MAG AGO GIU LUG SET OTT NOV DIC
DIMENSIONING 24
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 fgure 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 m
2
of 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 m
2
of collectors
installed.
Useful intake of the
solar system
Requirement for
domestic hot water
Requirement for
heating
k
W
h
/
(
m
2

M
o
n
t
h
)
Inclination of the collector
Reference values for the dimensioning of
the collectors
<40 Surface just for hot water in m
2
x 2
>40 e <70 Surface just for hot water in m
2
x 3
>70 and <90 or integration of the swimming pool 1,5 3 m
2
/kW
fgure 25
A
B
C
10 %
70 %
20 %
A
B
C
3 %
70 %
27 %
DIMENSIONING 25
Chapter 3
HEATING SWIMMING POOLS
Heating a swimming pool using solar collectors is advantageous especially if combined with the combi
system, as this allows ef cient 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 afected 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
diferent months.
The fgure below summarises the diferent percentages if heat loss from outdoor and indoor pools.
Heat loss in the outdoor swimming pool Heat loss in the indoor swimming pool
A = Evaporation
B = Radiation towards the sky
C = Loss towards the ground or other
A = Evaporation
B = Ventilation
C = Other
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 26C.
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
Indoor swimming pool with covered pool 1 m
2
of collector every 2.5 m
2
of swimming pool
Outdoor swimming pool with covered pool 1 m
2
of collector every 2 m
2
of swimming pool
Outdoor swimming pool with uncovered pool 1 m
2
of collector every 1-1.5 m
2
of swimming pool
fgure 26
RF
MC
SERIES/PARALLEL CONNECTION LAYOUTS AND PANEL ARRAYS 26
Chapter 4
SERIES/PARALLEL CONNECTION LAYOUTS AND PANEL ARRAYS
The Extrafame 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 fow and the system fow rate that passes through each
collector is the same. The temperature if the heat transfer fuid increases from the frst to the last collector
and this means that the last collectors work at a higher temperature and therefore with lower ef ciency. The
loss of head of each collector is also added and as a consequence in this confguration it results convenient
to work with low fow rates (low fow).
RF = Cold return
MC = Hot fow
fgure 27
The parallel connection according to the Tichelmann method allows to obtain the same fow for each
collector. In order to prevent dead areas and to guarantee a turbulent fow it is useful to adjust the
circulating fow rate on each collector to a value exceeding 60 l/h. The fuid fow rate of the system with
parallel connection is divided between the various collectors. If the collectors are n and the total fow
rate is x, in each collector there is a fow rate equal to x/n. Diferently from connection in series, the heat
drop between up and downstream is the same for all collectors and therefore they work with the same
ef ciency value.
The connection in parallel seems more ef cient with respect to connection in series; on the other hand it
can only be applied to felds 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 fow rate (see fgure 29). Pay attention to the direction of assembly of the panel,
which must be positioned with the down side below.
RF
MC
RF
MC
Chapter 4
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 fow and return pipes
must be the same. In this way identical head losses are guaranteed along all of the parallel connections
(see fgure below).
fgure 28
fgure 29
RF
MC
RF
MC
Chapter 4
However, with this system it is very dif cult to obtain a uniform fow in the various panels and the total fow
rate of the fuid 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 fow
circulation and at the same time uniformly distribute the fow rate into the various panels.
The collectors can be connected in series and the batteries in parallel as represented in the fgure below.
The most ef cient system envisions parallel connection of the panels and series connection of the arrays,
as represented in the fgure below.
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.
fgure 30
fgure 31
SLOPING ROOF 29
Chapter 5
SLOPING ROOF
DESCR5IPTION OF THE ASSEMBLY COMPONENTS FOR 1 OR 2 PANEL KIT
fgure 32
Element Quantity
1 collector 2 collectors
1 Support plate 4 6
2 Support Z 4 6
3 8 x 60 wood screw 8 12
4 M8 x 12 screws 8 12
5 M10 x 20 screws 6 10
6 M10 nut 6 10
7 Clips 2 4
8 Aluminium section 1 x 1050 mm 1 x 2100 mm
9 Aluminium section 1 x 1050 mm 1 x 2100 mm
LOADS DUE TO THE WIND OR SNOW
The load efects of snow and wind can afect the fxing 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 installers responsibility to realise a suitable anchorage system on the basis of the
R
=
a
/8
a
b
R
=
a
/
8
SLOPING ROOF 30
Chapter 5
ASSEMBLY INSTRUCTIONS
A suitable earth plant must be prepared by qualifed
staf according to standards in force before installation
of the panels.
The Extrafame 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
fgure 33
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 33 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.
fgure 34
SLOPING ROOF 31
Chapter 5
ASSEMBLY PHASE
Remove a few tiles and look for safe anchorage points on the 1.
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 diferent types of material (see fgures 35-36).
ATTENTION!!!
Pay great attention if the insulating sheath is present. Water may
infltrate if it is perforated. It is the installers responsibility to
guarantee perfect water-tightness of the covering.
The fxing system is made up of the plate 1, the bracket 2, the lower 2.
aluminium section 8 and upper section 9.
Once the structure has been well-fxed to the roof, adapt the tiles 3.
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 infltration of
water.
Then rest the panel on the lower section (fgure 38) blocking its 4.
edge in the aluminium section. When performing this operation make
sure the side of the panel marked DOWN SIDE (fgure 39) is actually
placed downwards.
Fix the upper part and laterally block the panel using the clips as 5.
per fgure (fgure 40).
When installing 2 or more collectors side by side, connect them 6.
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
fbre and they expand with humidity.
fgure 35
fgure 36
fgure 37
fgure 38 fgure 39
SLOPING ROOF 32
Chapter 5
fgure 40
fgure 41
fgure 42 fgure 43
fgure 44
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 fgure.
After having fushed 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.
100
754.6
2100
1729.2
754.6
100
974.6
974.6
974.6
1949.2
1
6
6
5
4
0
100
685
905
685
100
1
6
6
5
4
0
SLOPING ROOF 33
Chapter 5
Sloping roof drilling template kit
for 1 panel
Sloping roof drilling template kit
for 2 panels
fgure 45
fgure 46
Fix the plate (1) to the wooden roof using the screws (3). For roofs made of diferent material, use solid
fxing 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).
1
5
6
3

FLAT ROOF 34
Chapter 6
FLAT ROOF
PREMISE
Before installation, check that the roof structures as suitable capacity and has no defects. Realise suitable
fxing 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
roofng, they must be adequately waterproofed in order to prevent water infltrations.
The anchorage can also be made using double-T beams (see fgure below) and also in this case the installer
should provide a secure anchorage without damaging the roof.
COMPONENT DESCRIPTION
For installation of the collectors on the roof there are 2 types of: fat roof kits for 1 panel and fat roof kits
for 2 panels (see fgures below).
fgure 47
fgure 48 fgure 49
FLAT ROOF 35
Chapter 6
Flat roof kit for 1 panel elements table
Numbering Code Description Quantity Length (mm)
1 2167000 Aluminium section with groove for 1 panel kit 2 1050
2 2167002 Flat roof kit left base section 1 1190
3 2167003 Flat roof kit right base section 1 1190
4 2167004 Flat roof kit left vertical upright 1 980
5 2167005 Flat roof kit right vertical upright 1 980
6 2167006 Flat roof kit left inclined bar 1 1490
7 2167007 Flat roof kit right inclined bar 1 1490
8 2167008 Flat roof kit rear cross-member 2 980
9 2167403 Panel fxing lateral clip 2
10 6000441 TE M10X20 fanged screws 17
11 6000724 M10 fanged nut 17
Flat roof kit for 2 panels elements table
Numbering Code Description Quantity Length (mm)
1 2167001 Aluminium section with groove for 1 panel kit 2 2100
2 2167002 Flat roof kit left base section 1 1190
3 2167003 Flat roof kit right base section 1 1190
4 2167004 Flat roof kit left vertical upright 1 980
5 2167005 Flat roof kit right vertical upright 1 980
6 2167006 Flat roof kit left inclined bar 1 1490
7 2167007 Flat roof kit right inclined bar 1 1490
8 2167008 Flat roof kit rear cross-member 2 1670
9 2167403 Panel fxing lateral clip 4
10 6000441 TE M10X20 fanged screws 19
11 6000724 M10 fanged nut 19

2
3

2
3
1563
1563
FLAT ROOF 36
Chapter 6
ASSEMBLY INSTRUCTIONS
Lay the left (2) and right (3) base sections on the assembly surface as shown in fgures 58 and 59, 1.
which refer to the 1-panel kit and the 2-panel kit, respectively. The sections must not be fxed to the
ground but just rested on it.
Fix the left (6) and right (7) inclined bars to the respective left (4) and right (5) uprights using the 2.
screws (10) and nuts (11), as shown in fgure 52 and adjust the desired angle of inclination by changing
the fastening holes in the base sections, as shown in fgures 53, 54 and 55. 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.
fgure 50
fgure 51
3
0
7
9
5
.4
1
4
3
0
890
1
1
6
1190

1
3
3
0
9
5
4
940
4
5
9
1
.
5
9
5
4
1
0
0
7
890
1190
6
0
6
6
FLAT ROOF 37
Chapter 6
Fix the 2 rear cross-members (8) as indicated in the fgure below. For the 1 panel kit, refer to fgure 3.
57, while for the 2 panel kit refer to fgure 58.
fgure 52 fgure 53
fgure 54 fgure 55
fgure 56

FLAT ROOF 38
Chapter 6
Fix the aluminium sections with groove (1) as indicated in the fgure below, using the relative screws 4.
(10) and fanged 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.
fgure 57 fgure 58
Fix the panel using the 2 clips (9) and relative screws (10) and fanged nuts (11) frontly (fgure below). 5.
The 2-panel kit contains 4 clips (9) and the relative fanged screws (11) and nuts (12), as shown in fgure
61. In the last case it is convenient to realise hydraulic connections between the two panels using
compensating joints before fxing the clips (9).
fgure 59
fgure 60
PANEL
1
10
11
1
11
10
10
11
9

FLAT ROOF 39
Chapter 6
Fix the left (2) and right (3) base sections to the ground, align the frame and tighten all the screws 6.
and nuts.
fgure 61
11
9

802 377 1563
802 377 1563
3025
1563 517 1563
1563 517 1563
4065
FLAT ROOF 40
Chapter 6
MULTIPLE COMPOSITION OF THE KITS
If 3, 5, 6, 8 or 10 panels are to be installed, several fat roof kits must be used side by side. The frst 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 fanked, the aluminium profles must be made to run in a way to prevent
reciprocal interference (fgure below). If necessary, the installer may decide to trim the sections in order to
minimize interference.
fgure 62
3 PANELS: KIT 1 + KIT 2
fgure 63
fgure 64
4 PANELS: KIT 2 + KIT 2

802 377 1563 517 1563
802 377 1563 517 1563
5105

802 377 1563 802 1563
802 377 1563
3025
802 377 1563
802 377 1563
3025
FLAT ROOF 41
Chapter 6
5 PANELS: KIT 1 + 2 X KIT 2
fgure 65
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 fnally fx the left (2) and right (3) base profles 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 seriesparallel 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.
fgure 66

1563 517 1563
1563 517 1563
1563 517 1563
1563 517 1563
4065 4065

802 377 1563 517 1563
802 377 1563 770 1563
802 377 1563 517 1563
802 377 1563 517 1563
5105
5105
FLAT ROOF 42
Chapter 6
8 PANELS: 4 X KIT 2
Realise 2 arrays of four panels each and connect them in series.
fgure 67
10 PANELS: 2 X KIT 1 + 4 X KIT 2
Realise 2 arrays of fve panels each and connect them in series.
fgure 68

b
a
FLAT ROOF 43
Chapter 6
INCLINATION OF THE PANELS
Panel inclination must be adjusted on the basis of the latitude and aim of the solar system. Three diferent
inclinations can be obtained using the fat roof fxing 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 Type of use
34 DHW only, mostly for summer use
45 DHW only, year-round use
60 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 fgure 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.
fgure 69
Inclination of the collectors Distance b
34 4,6 m
45 5,3 m
60 6,2 m

a a
b
tan tan
5 , 23 90
+ =
= = latitude
1 m
1 m
FLAT ROOF 44
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
roofs edges, leave at least 1 metre between the supports and the roof edges as indicated in the fgure
below.
fgure 70
TEMPERATURE PROBE AND HYDRAULIC SUPPLY CONNECTION ASSEMBLY 45
Chapter 7
TEMPERATURE PROBE AND HYDRAULIC SUPPLY CONNECTION
ASSEMBLY
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. It must be positioned on the top part of the last collector of the series, in
correspondence with the fow.
The use of a 4-way joint is recommended in a way to insert the sump for the probe and connect the ball
valve to bleed the system.
For perfect solar system ef ciency, 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.
Earth the solar panels suitably.
fgure 71
fgure 72
TEMPERATURE PROBE AND HYDRAULIC SUPPLY CONNECTION ASSEMBLY 46
Chapter 7
The hydraulic connection to the supply pipes takes place using long fexible 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.
fgure 73

0
1
2
3
4
5
6
7
8
9
0 50 100 150 200 250 300 350
HYDRAULIC SYSTEM 47
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 150C inside the collector circuit up to the standstill temperature in proximity
of the collector
Compatibility with heat transfer fuid (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 fow 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 frst diagram, starting from the system
fow rate in l/h (see Setting the collector and system fow rate chapter), on the basis of the diameter
of the pipe it is possible to obtain fuid 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 fow 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 fow rate.
Regarding the solar collectors, the fgure below supplies the head loss curve on the basis of the fuid fow
rate.
fgure 74
Panel head loss
Flow rate l/h
p

(
m
b
a
r
)
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
0
1
2
3
4
5
6
7
8
9
10
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
0
100
200
300
400
500
600
700
800
900
1000
3
5

x

1
.
5
2
8

x

1
.
5
2
2

x

1
1
8

x

1
1
5
x
1
1
2
x
1
1
2

x

1
1
5

x

1
1
8

x

1
2
2

x

1
2
8

x

1
.
5
3
5

x

1
.
5
HYDRAULIC SYSTEM 48
Chapter 8
Flow
(l/h)
External diameter
for thickness (mm)
< 240 15 x 1
240 - 410 18 x 1
410 - 570 22 x 1
Speed m/s
Speed m/s
F
l
o
w

r
a
t
e

l
/
h
H
e
a
d

l
o
s
s

m
b
a
r
/
m
fgure 75
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500
0
10
20
30
40
50
60
70
80
90
100
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500
0
50
100
150
200
250
300
350
400
450
500
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500
0
100
200
300
400
500
600
700
800
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500
0
10
20
30
40
50
60
HYDRAULIC SYSTEM 49
Chapter 8
fgure 76
BSV300 solar coil head loss
Flow rate l/h
p

(
m
b
a
r
)
p

(
m
b
a
r
)
p

(
m
b
a
r
)
TPS500 solar coil head loss
TPS1000 solar coil head loss
Flow rate l/h
Flow rate l/h
fgure 77
fgure 78
fgure 79
BSV150 solar coil head loss
Flow rate l/h
p

(
m
b
a
r
)
HYDRAULIC SYSTEM 50
Chapter 8
The hydraulic connection between the pipes and the solar panels must be realised using fexible 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 ef cient 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 170C, away from the
collector at least 120C
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 infltration of humidity, insulation must be carried out using closed cell materials,
as not even accurate covering can prevent the infltration of humidity. This seriously undermines the
ef ciency 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.
In order to minimise heat loss it is good practice to insulate all hydraulic parts involved in the transport of
the heat transfer fuid: connections, branches, valves etc.
fgure 80
Closed cell elastome-
ric insulator
Drawn copper
without welding
Integrated
temperature
sensor cable
Black flm that pro-
tects from mecha-
nical wear and from
UV rays
HYDRAULIC SYSTEM 51
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
(A) Ball valve on the fow branch
(thermometer with red ring and
0-120C scale) with VNR Solar
(B) Ball valve on the return branch
(thermometer with blue ring and
0-120C scale) with VNR Solar
Solar non-return valve
Inserted into the ball valve both
on the fow 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.
(C) Safety device unit
The CE and TV certifed 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 fexible kit, illustrated at the side.
(D) Flow rate regulator
The regulator allows to
adapt the fow 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 fow rate is indicated
by the relevant cursor:
the acknowledgement is
immediate thanks to the
vicinity of the relief valve.
(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.
Flexible ft installation
for safety device unit
(optional):
Remove the cap and 1.
22mm hub from the
safety device unit
Mount the details in 2.
the order indicated:
insert the nipple on
the internal diameter of
the safety device unit;
place the gasket
between the nipple and
cap of the fexible;
tighten the fexible,
paying attention to fx
it to the safety device
unit by the end with the
yellow cap.
Yellow cap
Flow
Return
fgure 81
The GSC2 unit is complete with connection for the fow pipe with deaerated and return, while the GSC1
unit only has connections for the return pipe.
In the latter case it is the installers responsibility to realise a suitable connection of the fow pipe and the
desecration system.
It is fxed to the wall using the set supplied.
To realise a connection pipe between the safety valve and an empty can on the foor, in a way to recover
any leaking heat transfer fuid when the pressure of the system should exceed 6 bar (see fgure 82).
A
B
C
D E
0 500 1000 1500 2000 2500 3000 3500
0
1
2
3
4
5
6
7
HYDRAULIC SYSTEM 52
Chapter 8
Flow
Hot
Return
Cold
fgure 82
For the technical details relative to the two GSC1 and GSC2 units, consult the instructions contained in the
relative packaging.
fgure 83
Wilo - Star ST 25/6
Flow rate (l/h)
H
e
a
d

(
m
)
GC
V E
V S
M
T T
V R
R1
R2
RP
D
V MS
h
g
e
o

(
m
)
C
HYDRAULIC SYSTEM 53
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 diference existing between the expansion vessel and the highest point of the solar circuit (upper
point of the solar panels). The value of this level diference (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 diference of 15m.
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 fnal pressure of the system must not exceed 5.5 bar as the
safety valve is calibrated at 6 bar.
Pressure Recommended
p
I
(initial) = column of water + 0.5 bar 2 bar up to 15 m
p
VE
(pre-load ) = pI - 0.5 bar 1,5 bar
p
F
(fnal) < 5,5 bar 5 bar
p
VS
(safety valve) = p
F
+ 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:
V
FL
= V
C
(collector) + V
T
(pipes) + V
SC
(heat exchanger) + V
A
(other components)
The expansion of the fuid in the liquid phase is equal to:
V
FL
= e x V
FL
(e = expansion coef cient of the water + gycol mix)
fgure 84
HYDRAULIC SYSTEM 54
Chapter 8
% of glycol Expansion coef cient e
20% 0,050
30% 0,060
40% 0,065
50% 0,070
The volume of the collectors is added to the expansion volume:
V
U
= (V
FL
+ V
C
) x 1,1
The nominal volume of the expansion vessel is equal to:
V
N
= V
U
x (p
F
+ 1)/( p
F
- p
I
)
The Extrafame 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 fgure 85). The vessel is connected to the
pump unit by means of a supplied stainless steel pipe.
The automatic relief valve, supplied with the wall-fxing bracket, must be inserted into the end of the stain-
less steel fexible pipe (see fgure 88).
The automatic relief valve is used to block the fow of anti-freeze fuid 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 fexible pipe (see fgure 87).
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 qualifed staf 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 hydraulic attachments, while VES80 has a 1 hydraulic attachment.
HYDRAULIC SYSTEM 55
Chapter 8
fgure 85 fgure 86
fgure 87 fgure 88
HYDRAULIC SYSTEM 56
Chapter 8
fgure 89
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 pufer). The domestic hot water
cylinder solar coil has hydraulic attachments.
The hot fow 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 fgure 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.
Symbol Description Symbol Description
B Domestic hot water cylinder RP Flow rate adjuster
C Solar collector T Thermometer
CE Electronic control unit TS Domestic hot water terminals
D Deaerator VE Expansion vessel
G Generator VMS Domestic hot water mixing valve
GC Pump unit VMTA Automatic thermostatic mixer valve
M Manometer VS Safety valve
R1 Tap 1 VR Non-return valve
R2 Tap 2
Where requested connect the integrated thermo-product to the upper coil as indicated in fgure 98. Also in
this case the hot fow 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.lanordica-extrafame.com.
Connect the expansion vessel and safety valve, calibrated at 6 bar, to the domestic hot water cylinder.
GC
VE
VS
VR
R1
R2
RP
VMS
CE
VMTA
TS PR
HYDRAULIC SYSTEM 57
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 pufer solar coil has 1 hydraulic connections. The hot fow of the solar panels must be
connected onto the upper part of the solar coil as indicated in the fgure below. For the technical details of
the pufer, consult the chapter relative to the description of the components.
C Solar collector R2 Tap 2
CE Electronic control unit RP Flow rate adjuster
D Deaerator T Thermometer
G Generator TS Domestic hot water terminals
GC Pump unit VE Expansion vessel
M Manometer VMS Domestic hot water mixing valve
P Pufer VMTA Automatic thermostatic mixer valve
PR Radiant panels VS Safety valve
R Heating VR Non-return valve
R1 Tap 1
The fgure above represents an example of a hydraulic system composed of a solar kit with TPS pufer and
Extrafame biomass boiler. The heat supplied from the solar panels pufer 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 fgure, in
fgure 90
HYDRAULIC SYSTEM 58
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 pufer. 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
fnned 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 25F.
The excessive deposit of lime scale inside the copper coil can jeopardise functioning.
Install the expansion vessel in the lower part of the pufer 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 fanges, in particular those positioned in the lower part
(discharge sleeve) and upper part of the tank.
Connect the pufer to earth correctly according to the standards in force.
110 48
2
8
1
7
5
65
ELECTRONIC CONTROL UNIT 59
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.
Delivery volume:
1 x Extrafame CS
1 x accessory box
1 x spare T4A fuse
2 x screws and plug
4 x strain relief and screws
Additional objects in the complete pack:
1 x FKP6 probe
2 x FRP6 probes
Regulator variants
PG system
version
Relay
Semi-conductor
Relay
Standard
Working
hour
counter
Speed
adjustment
Thermostat
Function
Heat
quantity
balance
CS 3.1 0 1 yes no no no
CS 3.2 0 2 yes no yes no
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: diferential regulator
with additional and optional
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
Outputs: according to version, see
Regulator variants table
Power supply: 220 ... 240 V ~
Total current absorption: 4 (2) at
250V ~
Current absorption for relay:
Electromagnetic relay: 2 (2) A
220 .. 240 V ~
fgure 91
fgure 92
fgure 93
fgure 94
Standard solar system
Solar system with integrative
heating
1
2(1)A(220...240)V
2 7 8 18
N
19
R1
14 3
L
4
S1
17 13 20
N
Temp. Sensor
5
220...240V
6
S2
Pt 1000
S3
T 4A
S4
12
7
R2 2(1)A(220...240)V
T 4A
14 5
N
Temp. Sensor
13 1
S1
17
Pt 1000
N
20
R1
12 17
S3
R1 2(1)A(220...240)V
19 4 8
S4
2
S2
220...240V
15 16
N
6
R2 L
17 18 3
Chapter 9
INSTALLATION
ASSEMBLY
ATTENTION!
always make sure that the network voltage is
completely disconnected before opening the casing.
Assembly must be carried out exclusively in closed, dry
environments. To guarantee regular functioning, make sure
there are no strong electro-/magnetic felds in the place of
installation. The regulator must e able to be separated from
the electrical mains by means of an additional device with
a minimum disconnection distance on all poles of 3mm), or
by means of a disconnection device in compliance with the
laws in force. Pay attention in the installation phase that the
connection cable to the electric mains and the probe cable
remain separate.
Loosen the mask screws crosswise and detach this 1.
from the casing by removing it downwards.
Mark the upper fxing point for suspension and 2.
pre-assemble the plug using the corresponding screw
included in the supply.
Attach the casing in the upper fxing point and mark 3.
the lower fxing point (distance between holes: 130 mm);
insert the lower plug.
Attach the casing at the top and fx it using the lower 4.
screw.
The input of electric current to the regulator must pass
through an external switch (last stage of assembly!) and
the electric voltage must be 220 ...240 V~ (50 ...60 Hz). The
fexible cables must be fxed to the regulator lid using the
relative brackets and screws to allow strain relief or put into
the channel in the regulator box. Depending on the version
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
connected:
Relais 1
18 = wire R1
17 = neutral wire N
13 = earth clamp
Relais 2 (PG 68.30 und 69.30)
16 = wire R2
15 = neutral wire N
14 = earth clamp
The temperature probes (S1 to S4) must be connected with
indiferent polarities to the following clamps:
1 / 2 = probe 1 (e.g. collector probe 1)
Display
Mask
Cable passage with
strain relief
Buttons
Fuse
Suspension
Fixing
ELECTRIC ATTACHMENT
CS 3.1
CS 3.2
Fuse
Probe clamps
Earth clamps
User clamps
Clamps
for attachment to the
electric network
Fuse
Probe clamps
Earth clamps
User clamps
Clamps
for attachment to the
electric network
fgure 95
fgure 96
16 18 15 14 13 12 8 7 6 5 3
S3
4
S2
S4/TRIT
R1
S1
L N
1
R1 R2 N S4
2
S3 N S2 S1
20 19 17
L
7
N
16
S4 S1
12
R2
5 18
S1
2 8
R1 N
17
S2
13 3 19
R1
6
S3
N
15
R2
S2
S3
1 14 4 20
S4/TRL
Chapter 9
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.
Symbol Name
S1 Collector probe
S2 Lower tank probe
S3 Upper tank probe
(optional)
S4/TRIT Probe for heat quantity
balance (optional)
R1 Solar pump
Clamp assignment: system 2
(PG 68.30 e PG 69.30)
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.
Symbol Name
S1 Collector probe
S2 Lower tank probe
S3 Upper tank probe/
thermostat probe
S4/TRIT Probe for heat quantity
balance (optional)
R1 Solar pump
R2 Feed pump for additional
heating
fgure 97
fgure 98
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.
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 briefy, SET will fash (SET mode)
Set the value using keys 1 and 2
Press key 3 briefy, SET appears again (constant), the
value set has been memorised.
Reverse
Forward
SET
(selection/operation mode)
1
2
3
fgure 99
System Monitoring Display 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 feld with 16 segments. Channel
names/menu levels are mainly displayed here. The lower
line (fled of 7 segments) displays channel values and setting
parameters.
The temperatures and temperature diferences 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
Tank maximum limitation
inserted/tank maximum
temperature exceeded
Collector cooling function inserted
Tank cooling function inserted
Anti-freeze protection
option
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 modifed
Mode SET
fgure 100
Channels indicator
fgure 101
List of symbols
fgure 102
only channels indicator
only list of symbols
System Monitoring display complete
Chapter 9
Layouts and systems indicator
fgure 103
layouts and systems indicator only
The layouts and systems indicator (systems active layout)
indicates the layout selected by means of SIST channel. It is
composed of diferent system component symbols that fash,
appear permanently or disappear according tot the current
status of the system.
probes
collector 2
upper tank probe
central heating circuit
valve
probe
symbol
additional. burner
functioning
tank 2 or additional heating (with
additional symbol)
tank tank heat exchanger
pumps
valve
collector 2
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 fashing codes
the pumps fash during the initialisation phase
the probes fash when the display channel is selected of the respective probe
the probes fash quickly if the probe is faulty
The burner symbol fashes when the additional heating is inserted
fgure 104
Chapter 9
Flashing LED codes
Constant green: no fault (every thing functions correctly)
Red/green fashing: manual functioning initialisation phase
Red fashing: faulty probe (the probe symbol fashes quickly)
COMMISSIONING
Firstly, set the layout of the desired system!
Activate the electric connection. The regulator 1.
passes to an initialisation phase in which
the control indicator fashes red/green
intermittently. After the initialisation, the
regulator passes to the automatic functioning
mode with its factory settings. The layout of the
pre-set system is SIST 1*.
- select the SIST channel 2.
- 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).
fgure 105
1 2
3
Forward
Reverse
Functioning control
indicator light
SET
(selection/operation mode)
fgure
106
View of the systems:
SIST 1*: Standard solar system
SIST 2: Solar system with additional heating
(CS 3.2)
*In the CS 3.1 program versions the SIST channel is
cancelled.
Chapter 9
CONTROL PARAMETERS AND DISPLAY CHANNELS
View of the channels
Key:
Corresponding channel present.
X
X*
Corresponding channel present if the respective
option is inserted.
Corresponding channel present only when the heat
quantity balance option is inserted (OWMZ).
1
2
Corresponding channel present only when the heat
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 Page
1 2*
COL x x Collector 1 temperature 66
SER x Tank 1 temperature 66
SERI x Lower tank 1 temperature 66
SERS x Upper tank 1 temperature 66
S3 x Probe 3 temperature 66
TRIT 1 1 Return probe temperature 66
S4 2 2 Probe 4 temperature 66
n % x Relay 1 speed 66
n1 % x Relay 1 speed 66
h P x Relay 1 working time 66
h P1 x Relay 1 working time 66
h P2 x Relay 2 working time 66
kWh 1 1 Heat quantity kWh 67
MWh 1 1 Heat quantity MWh 67
SIST 1-2 System
DT I x x Insertion temperature diference 68
DT D x x Disconnection 1 temperature diference 68
DT N x x Nominal temperature diference 68
INN x x Raising 68
S MS x x Tank 1 maximum temperature 68
SIC x x Collector 1 safety temperature 69
Channel
SIST
Name Page
1 2*
OCR x x Collector 1 cooling opt. 69
CMS x* x* Collector 1 maximum temperature 69
OCN x x Collector 1 minimum limitation opt. 70
CMN x* x* Collector 1 minimum temperature 70
OCA x x Collector 1 anti-freeze option 70
CAG x* x* Collector 1 anti-freeze temperature 70
ORAF x x Tank cooling option 70
O CT x x Tubular collector option 71
TE I x Thermostat 1 insertion temperature 71
TE D x Thermostat 1 disconnection temperature 71
OWMZ x Heat quantity balance option 67
VMAS 1 1 Maximum fow 67
ANTT 1 1 Type of protection 67
ANT% ANTT ANTT Anti-freeze level of protection 67
nMN x Relay 1 minimum speed 72
n1MN x Relay 1 minimum speed 72
MAN x x Manual functioning 1 72
MAN2 x x Relay 2 manual functioning 72
LING x x Language 72
PROG xx.xx Program number
VERS x.xx Version number
* system 2 is only valid in the CS 3.2 version
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
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
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.
Indication of the other temperatures
TRIT:
Other measurement
temperatures
respective probe.
TRIT: return temperature.
Working hour counter
h P / h P1 / h P2:
Display channel working
hours counter
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
fashes 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.
Chapter 9
Heat quantity balance
OWMZ: Heat quantity balance
Setting area: OFF...ON
Factory setting: OFF
In the basic systems (SIST) 1, 2 it is possible
realise the heat quantity balances in
connection with the fow volume counter.
Therefore activate the Heat quantity
balance in the OWMZ channel.
VMAS: Flow volume l/min
Setting area: 0...20 in steps of 0.1
Factory setting: 1
The fow volume (l/min) displayed in the
fow 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.
ANTT: Type of anti-freeze
protection
Setting area: 0...3
Factory setting: 1
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 fow volume and the
TVL fow 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 fashes and the heat quantity value is reset at 0. To close the RESET operation, confrm
using the SET key (3).
Wait 5 seconds to interrupt the RESET operation. The regulator passes automatically to the initial display
mode.
Chapter 9
T adjustment
DT I: Insertion temperature
diference
Setting area: 1.0...20.0 K
Factory setting 6.0K
At the start the regulation device
acts as a standard diference regulation
device. On reaching
the insertion diference (DTI) the pump
is inserted. If the temperature diference
is lower than the set disconnection
temperature diference
(DTD), the regulator is disconnected.
DT D: Disconnection
temperature diference
Setting area: 0.5..0.19.5 K
Factory setting: 4.0 K
ATTENTION: the insertion temperature diference 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 95C.
Chapter 9
Collector temperature limit
Collector safety disconnection
SIC:
Collector temperature limit
Setting area: 110..0.200 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 140C but this
can be modifed in the range of 110...200C. When
the collector temperature limit is exceeded, the
display shows the symbol (fashing).
System cooling
OCR:
Opt. system cooling
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 95C (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 (fashing). 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 feld of the collector
and the heat source.
CMS:
Collector max. temp.
Chapter 9
Option: collector minimum limitation
OCN:
Collector minimum limitation
Setting area ON/OFF
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 (fashing).
CMN:
Collector minimum temperature
Factory setting: 10C
Option: anti-freeze protection function
OCA:
Anti-freeze protection function
Setting area: ON/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
protection temperature must be reached.
On exceeding this anti-freeze protection
temperature set at 1C, the solar circuit
disconnects.
CAG:
Anti-freeze temperature
Setting area: -10...10 C
Factory setting: 4.0 C
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
On reaching the maximum tank temperature
set (SMAS), 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.
Chapter 9
Tubular collector function
O CT:
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 diference between the
collector and the tank should be exceeded
during the solar pump working time or
during the systems 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.
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
TE D:
Thermostat disconnection
temperature
Setting area. 0.0...95.0 C
When the 2 output 2 is inserted the display
shows the symbol.
Chapter 9
MAN/MAN1/MAN2:
Operation mode
Setting area:
OFF,AUTO,ON
Factory setting: AUTO
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 (fashing) +
AUTO : relay in automatic functioning
ON : relay inserted (fashing)
Language (LANG)
LANG:
Setting the language
Possible settings: Ger, En, It
Factory setting: Ger
The menu language can be set in this channel.
Ger: German
En: English
It: Italian
7
R2 2(1)A(220...240)V
T 4A
14 5
N
Temp. Sensor
13 1
S1
17
Pt 1000
N
20
R1
12 17
S3
R1 2(1)A(220...240)V
19 4 8
S4
2
S2
220...240V
15 16
N
6
R2 L
17 18 3
Chapter 9
Troubleshooting
If there is interference inside the regulator, the display
will communicate it with the following warning:
T4A fuse
Warning symbols
Control indicator
indicator
Problem Reason Solution
The regulator control
indicator led is always
of.
The regulator is not powered.
Check the regulator power supply.
Check the fuse and replace it if
necessary.
The control indicator
fashes red intermittently.
The symbol appears on
the display (spanner)
and the symbol (triangle)
fashes.
Faulty probe. 888.8 appears in the
corresponding channel instead of a
temperature, meaning that the probe
is broken or disconnected.
Check the probe. The attached Pt
probes can be controlled using a
polimeter. Their temperatures can be
compared with the resistance values
stated in the following table.
Faulty probe. -88.8 appears in the
corresponding channel instead of a
temperature, meaning that the probe
is short circuited.
Check the probe. The attached Pt
probes can be controlled using a
polimeter. Their temperatures can be
compared with the resistance values
stated in the following table.
The solar circuit pump
does not work even if
the collector is much
hotter than the tank.
The regulator control indicator is of.
Check the regulator power supply and
the fuse.
The solar circuit pump
does not function even
in manual mode.
Voltage has not reached the pump.
Check the power supply of the
regulator, the pump and the fuse.
The pump is blocked.
Release the pump rotor using a
screwdriver.
fgure 107 fgure 108
Chapter 9
The pump is hot, but
there is no heat transfer
from the collector to
the tank; fow and
return same heat; some
bubbling in the pipes.
Air present in the system. Deaerate the system.
System pressure too low.
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.
Collector circuit flter blocked Clean the flter
The pump is inserted
late.
Diference of insertion temperature
Tins set too high.
Modify Tins and if necessary Tdis.
Collector probe positioned in not
optimal position.
Move the probe inside the last collector
of the coil in correspondence with the
hot fow.
The pump continues to
insert and disconnect
frequently.
Diference of insertion temperature
Tins set too low.
Modify Tins and if necessary Tdis.
Collector probe positioned in not
optimal position.
Move the probe inside the last collector
of the coil in correspondence with the
hot fow.
The temperature diference
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
exchanger.
Remove the lime scale from the heat
exchanger.
Heat exchanger blocked. Clean the heat exchanger
The tank cools down
during the night.
Collector circuit pump also functioning
at night. The temperature of the collector
is greater than the external temperature
during the night.
Check the OCR and ORAF functions.
Tank ftting insulation insuf cient. Increase insulation.
Tank ftting insulation not adherent. Change or increase the insulation.
Presence of domestic hot water
circulation circuit.
Use a timer for the circulation pump.
Install a non-return valve to prevent
natural circulation.
Presence of additional heating in the
storage tank.
Install a non-return valve in the
additional heating circuit.
Natural circulation could start
through additional heating.
Chapter 9
Resistance value of the PT1000 probes
C C
-10 961 55 1213
-5 980 60 1232
0 1000 65 1252
5 1019 70 1271
10 1039 75 1290
15 1058 80 1309
20 1078 85 1328
25 1097 90 1347
30 1117 95 1366
35 1136 100 1385
40 1155 105 1404
45 1175 110 1423
50 1194 115 1442
START-UP 76
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 fll the system:
the frst flling and the second discharging. A third shut-of valve VI is used to disconnect them from each
other. The taps must be positioned in the lowest point of the solar UNIT (fgure 109).
The system must be washed by allowing water to
circulate before flling it with the water and anti-
freeze 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-of valve VI (see fgure 110)
Open all shut-of 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.
fgure 109
fgure 110
Mains cold water
Unload
R1
R2
VI
R1
R2
VI
START-UP 77
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 diferent components). Close tap R1 and
then also close the water tap.
Open the shut-of valve VI, use the electronic control unit to activate the solar circuit pump and bleed all
air from the circuit (see fgure 111).
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 frst
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.
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 flling is
taking place (see following paragraph).
The colour and viscosity of the fuid 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 flled again
immediately.
fgure 111
VI
R1
R2
START-UP 78
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 specifc
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.
External diameter and thickness in mm
Dimensions of the pipe 12 x 1 15 x 1 18 x 1 22 x1 28x 1,5 35 x 1,5
Content (l/m) 0,079 0,133 0,201 0,314 0,491 0,804
A heat transfer fuid is used inside the solar circuit. This transfers the heat absorbed by the solar panel
inside the domestic hot water storage tank.
This fuid is made up from a mixture of neutral water and TYFOCOR L anti-freeze liquid, able to protect the
system from the winters 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 (fgure 112).
TYFOCOR L
[% v/v]
Freezing Density
[g/cm
3
]
25 -10C 1,023
30 -14C 1,029
35 -17C 1,033
40 -21C 1,038
45 -26C 1,042
50 -32C 1,045
55 -40C 1,048
The minimum concentration to keep protection against corrosion complete must be greater than 25%,
while the maximum allowed is 55%.
0 10 20 30 40 50 60 70
-50
-40
-30
-20
-10
0
START-UP 79
Chapter 10
Glycol %
T
e
m
p
e
r
a
t
u
r
e

C
To select the correct dilution, refer to the table assuming a freezing point equal to
Minimum temperature detected on average in the area - 10C
Example:
Average minimum winter temperature in the area = - 11 C
Critical freezing point = - 11C 10C = - 21C
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
fgure 112
GC
V E
V S
M
T T
V R
R1
R2
RP
D
V MS
B
GP
TS
C
CE
START-UP 80
Chapter 10
FILLING THE SOLAR CIRCUIT
Water/glycol
mixture
B Domestic hot water cylinder R1 Tap 1
C Solar collector R2 Tap 2
CE Electronic control unit RP Flow rate adjuster
D Deaerator T Thermometer
GC Pump unit VE Expansion vessel
GP Loading the pump unit VS Safety valve
M Manometer VR Non-return valve
Before flling 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-of valve VI must be closed (see fgure 110).
Open all shut-of taps upstream from the automatic relief valves or all of the manual air-bleed valves.
Use the pump to fll the collector circuit with the water and glycol mixture until the fuid starts to
escape from tap R2.
fgure 113
START-UP 81
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 of.
Open the shut of 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 of 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-of valves upstream from the automatic air-bleed valves.
Once again check the initial pressure inside the solar circuit when cold (early morning) and add fuid,
if necessary.
With the system cold, periodically deaerate the system using the deaerator positioned on the fow 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 fow rate inside each collector is between 60 and 100 l/h. Connecting the panels in parallel
results in a total fow rate equal to the optimal fow rate multiplied by the number of panels. If, for example,
4 panels are installed a total fow rate equal to 240 400 l/h (4 6.7 l/min) results.
To set the desired fow rate:
Open the shut of valve VI completely.
Set the pump at the lowest regular working conditions.
By means of the fow rate measuring device inserted at the base of the GSC1 and GSC2 pump units
(fgure 114), 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 fow 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 efective control of the fow rate can be performed using the temperature diference control
START-UP 82
Chapter 10
fgure 114
between fow and return thanks to two thermometers present in the GSC2 pump unit. If during
summer days with strong insulation a temperature diference between fow and return of 10 and 20C
is measure, it means that the fow rate is set correctly. For diferences exceeding 20C the fow must be
increased, while for diferences below 10C the fow 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 flled as follows:
Open the shut-of 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.
MAINTENANCE 83
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 diference between fow and return, during the summer days with
strong insolation is between 10C and 20C.
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 fow 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 fow 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 feld.
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 fuid as
described in the system flling chapter.
MAINTENANCE 84
Chapter 11
Troubleshooting table
FAULTS POSSIBLE CAUSES
Pressure loss in the collectors circuit when the
system is cold
Loss of fuid 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
dimensioning, a fault or incorrect pressure pre-set
on the expansion vessel and fuid has escaped from
the circuit.
Damage caused by freezing after a period of intense
cold.
The pump is not inserted automatically
An ignition temperature diference that is too high
has been set.
There is no current therefore the control unit is of.
The maximum temperature inside the tank has
been reached.
The temperature probes are broken.
The pump is blocked or broken.
The pump is working but heat is not reaching the
collector
Presence of air inside the collector circuit.
Formation of vapour because the pump started too
late or the fow rate is too low.
Collector glass dirty.
The tank cools down quickly
The insulation has been performed unsuitably.
Cooling caused by the collector pump working
during the night.
Presence of the circulation pump in the domestic
hot water circuit.
The pump changes over continuously between on
and of
An ignition temperature diference that is too low
has been set.
Incorrect position of the probes or their
connection.
Faulty pump.
WARRANTY TERMS 85
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 of ces in Montecchio Precalcino (VI), via dellArtigianato 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 certifed EXTRAFLAME PS AS 1 model
Domestic hot water cylinder enamelled glass BSV 150 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 fll in the asseveration, by a skilled technician,
which certifes 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:
The solar kit has been installed, inspected and serviced perfectly in compliance with the regulations 1.
in force on this subject and the provisions contained in the installation, user and maintenance manual
relative to the product, by qualifed staf with the requisites required by the law (Law n 46 dated 5
March 1990);
For the systems in which the following components are mounted: 2.
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.
The WARRANTY DOCUMENT has been flled in completely and is kept with the fscal documentation 3.
relative to the product purchased.
WARRANTY TERMS 86
Chapter 12
The warranty is not considered valid in the following cases:
The conditions for the implementation of the warranty have not been respected. 1.
Installation has not been performed with respect to the standards in force regarding the provisions 2.
described in the user and maintenance manual.
Negligence of the customer due to lack of or incorrect maintenance. 3.
Presence of electric and hydraulic plants that do not comply with the standards in force. 4.
Damage deriving from atmospheric agents, chemicals, electro-chemicals, improper use of the 5.
product, modifcations or tampering of the product and/or other causes not deriving from the
manufacture of the product.
Damage caused by normal corrosion or typical deposits of the hydraulic plants. 6.
Damage caused to the system owing to the use on non-original spare parts or consequences of 7.
interventions carried out by unqualifed technical staf.
Improper or negligent use. 8.
All damage caused by transport. It is therefore recommended to carefully check the goods on 9.
receipt, informing the dealer of any damage immediately, making a note on the transport document
and on the carriers copy.
Atmospheric events of greater intensity to those envisioned by certifcation tests and such to 10.
break the collector glass.
Wear of the magnesium anode or malfunctioning of the titanium electronic anode 11.
Breakdown of the solar control unit caused by over-voltages. 12.
Malfunctioning of coils SRA 1,5 , SRA 3 , SRA 5 caused by the deposit of lime scale. 13.
Extrafame S.p.A. is not liable for any damage/injury that can, directly or indirectly, afect 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.
WARRANTY DOCUMENT 87
Chapter 13
WARRANTY DOCUMENT
Product identifcation 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
Date of Purchase
IMPORTANT: accept do not accept
Information note for the purpose and efect 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 fulfl all legal requirements as well as
to ef ciently 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 specifc
obligations of the law. The afected body has the faculty to exert the rights recognised in art.7 of the stated decree
Stamp
Manuale installazione kit solare
REV 003 27.06.2008
Stufe a Pel l et
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 specifed:
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 users risk.
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Solar Kit Installation Manual

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SOLAR KIT INSTALLATION

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