SOLARcomfort Solar Hot Water Systems Pump Group Instructions for Installation and Servicing LEAVE THESE INSTRUCTIONS WITH THE END USER Country of Destination GB/IE
TABLE OF CONTENTS 1. 1.1 1.2 1.3 1.4 1.5 1.6 GENERAL INFORMATION ................ 2 GUARANTEE .......................................... 2 SYSTEM CONTENTS ................................ 2 SYSTEM INSTRUCTION BOOKS ................... 2 SOLARCOMFORT .................................. 3 LIFESTYLE ............................................. 3 HOW THE SYSTEM WORKS ....................... 3 2. SAFETY ............................................. 6 3. 3.1 3.2 3.3 3.4 TECHNICAL DATA .......................
1. GENERAL INFORMATION This manual is an integral and essential part of the product. It should be kept with the product. Please read carefully the instructions and notes about SOLARcomfort contained in this manual as they provide important information regarding the safe installation of the Pump Group. IMPORTANT Failure to follow these instructions correctly may invalidate the guarantee.
1.4 SOLARCOMFORT SOLARcomfort systems are highly efficient and provide cost savings on the energy used for heating hot water wherever they are used in the UK. However, the savings made will depend on local climate, installation characteristics and the households use of hot water. It is important that the SOLARcomfort system is correctly sized for the local climate condition and the household’s domestic hot water requirements. 1.
Roof mounted collectors (two collector system shown) Air vent Energy Monitoring Sensor S4 (option) Temperature Sensor S1 Ariston ITSI 210/300 twin coil cylinder AST 100 Controller PR Valve Pump group Temperature Sensor S3 Expansion vessel Upper coil heated by boiler or other heat source Temperature Sensor S2 PRV discharge vessel Solar system low level fill point Lower coil heated by solar energy FIG. 1.
Flow 1. 2. 3. 4. Insulated Cover Flow from Solar Collectors Flow Temperature Gauge Flow Shut Off Valve c/w non return valve -red Knob 5. 6. 7. 8. 9. Air Separator Manual Air Vent Return to Solar Collectors Return Temperature Gauge Return Shut Off Valve c/w non return valve -blue Knob Return 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
2. SAFETY WARNING The pump group must be correctly fitted to the wall using the bracket supplied. It should not be supported by the connecting pipework alone. WARNING During operation and commissioning the temperature of the heat transfer fluid within the system and collectors can reach temperatures high enough to present a risk of scalding. Never loosen fittings or open vents when the system is hot. WARNING TYFOCOR LS Heat Transfer Fluid. Although non-toxic it should not be swallowed.
3. TECHNICAL DATA PUMP MODULE Pipe connection 22mm Reducers supplied 15mm Pump type 15/40 Maximum operating pressure Electrical Cable 0.6MPa 1.0mm² 3 core heat resistant flex 3093Y to 85°C Cover Moulded polystyrene AIR SEPARATOR MODULE Pipe connection 22mm Reducers supplied 15mm Maximum operating pressure Cover 0.6MPa Moulded polystyrene EXPANSION VESSEL 2 & 3 collector systems 25l Optional size (code 12002737) 35l Maximum pressure 10 bar Pre-charge pressure 2.
3.2 COMPONENT LIST Listed below are all the components required to fit the pump group. Item Description 1 Pump Group 2 Flow Limiter Components (see 5.1) 3 Wall Mounting Bracket 1 4 Screw 1 5 Wall Plug 1 6 Expansion Vessel 25l standard (35l option) 1 7 Expansion Vessel Fixings 1 8 Flexible Connector 1 FIG. 3.
3.3 PUMP GROUP DIMENSIONS FIG. 3.3A PUMP GROUP DIMENSIONS 3.4 EXPANSION VESSEL DIMENSIONS Maximum pressure Pre-charge pressure 10 bar 2.5 bar 25 Litre (standard) 35 Litre (optional: code 12002737) FIG. 3.
4. REGULATIONS & STANDARDS SOLARcomfort hot water heating systems should be installed in compliance with the following standards and regulations. 4.1 WATER REGULATIONS Water Supply (Water Fittings) Regulations 1999 / www.wras.co.uk These regulations (bye-laws in Scotland) ensure a good supply of wholesome water and that only approved materials, pipes and fittings are used to convey water. 4.
4.4 BRITISH & EUROPEAN STANDARDS Connection of thermal solar heating systems EN 12976: Thermal solar heating systems and their components (prefabricated systems). ENV 12977: Thermal solar heating system and their components (bespoke systems). BS5918: Latest version: Solar heating systems for domestic hot water. Installation and equipment of DHW cylinders BS5546: 2000 Specification for installation of hot water supplies for domestic purposes, using gas-fired appliances of rated input not exceeding 70 kW.
4.7 EU DIRECTIVES Further details available from: www.europa.eu.int Construction Directive: 89/106/EEC Electromagnetic: 89/336/EEC Low voltage: 73/23/EEC Machinery Directive: 98/37/EC 4.8 OTHER Preventing hot water scalding in bathrooms: using TMVs (IP 14/03). DTI testing of solar systems (SP300275 1-3). Review of issues related to active solar heating systems (SP300246). Active solar performance and data review (SP300270). Solar heating systems for hot water (BS 5918).
5. INSTALLATION 5.1 FITTING FLOW LIMITER A flow limiter set is supplied separately, this must be fitted to the pump group on the suction side of the pump as shown in fig. 5.1a. Note: The flow limiter is supplied with fittings for 15Ø pipe. 15Ø FIG. 5.1A FITTING FLOW LIMITER 5.2 POSITIONING PUMP GROUP To Collector Temperature Sensor S1 From Collectors To Collectors AST 100 Controller Expansion Vessel Cylinder S3 Fill point Pump Group S2 PRV discharge vessel FIG. 5.
5.3 CONSIDERATIONS FOR POSITIONING PUMP GROUP The pump group and should normally be wall mounted in close proximity to the cylinder. Fig. 5.2A gives a typical layout. The AST100 Solar Controller should be positioned so that the householder has easy access with good visibility of the display. Also, consideration has to be given to routing for connection to the pump group, cylinder and collector temperature sensors.
5.6 SIZING OF PIPES The flow rate in the circuit is between 0.5 and 1.5 litres/min for each collector. The flow velocity in the circuit should not exceed 1.5m/sec otherwise the the system may be noisy during operation. As a guide only: systems with total pipework of less than 50 metres, 15mm diameter pipe should allow flow conditions to be met for systems with up to four collectors. When the total pipework is over 50 metres, then 22mm pipe should be used.
5.9 TWO COLLECTOR SCHEMATIC Cylinder 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Collector System Pressure Guage Pump Group Automatic Air Vent Flow Temperature Gauge Shut Off Valve Circulating Pump Flow Limiter Non-Return Valve Pressure Relief Valve (PRV) PRV Discharge Vessel Return Temperature Gauge FIG. 5.9A TWO COLLECTOR FLOW DIAGRAM 16 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.
5.10 THREE COLLECTOR SCHEMATIC Cylinder 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Collector System Pressure Guage Pump Group Automatic Air Vent Flow Temperature Gauge Shut Off Valve Circulating Pump Flow Limiter Non-Return Valve Pressure Relief Valve (PRV) PRV Discharge Vessel Return Temperature Gauge 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.
5.11 WALL MOUNTING MODULES See fig. 5.11A The pump module is supplied with a wall bracket. The pump group must be correctly fitted to the wall using the bracket supplied. It should not be supported by the connecting pipework alone. FITTING PROCEDURE 1. Determine the best location for the pump group, take into consideration the following:i Access for fill and drain. ii Position of the expansion vessel. iii Position of the PR Valve.
5.12 CONNECTING PIPEWORK Automatic Air Vent Shut Off valve Pipes Ø15mm or Ø22mm see 5.% C PR Valve A Expansion Vessel D B PR Valve relief plumbed to low level Ø15mm PRV discharge vessel Flow C Return A System Drain D FIG. 5.
5.13 PIPE REDUCERS The basic pipe size for the system is either Ø22mm or Ø15mm see section 5.5. The collectors connections and three of the four pump group connections are supplied for Ø22mm pipe. The flow limiter has a Ø15mm connection. Compression fittings Ø22 to Ø15 will need to be fitted as required to suit system pipe size. Ø15mm Pipe Ø22mm Pipe FIG. 5.13A PIPE REDUCERS 5.
The chart below gives the initial pressure charge that the expansion vessel will require for a given system height (static system head). The expansion vessel should be charged to this pressure prior to filling the system. The factory set pressure of vessels is 2.5 bar. System height 5.15 PRESSURE RELIEF VALVE (metres) System filling pressure (metres) 3 to 1 0 Pre-pressure of Expansion Vessel 2 5 l Ve s s e l 3 5 l Ve s s e l 1 .5 1 .3 1 .4 11 1 .6 1 .4 1 .5 12 1 .7 1 .5 1 .6 13 1 .8 1 .
5.16 FILLING POINT The system is filled with heat transfer fluid, this is pumped into the system via a filling point. The pump group has dedicated filling points - see fig. 5.16A. Alternatively a filling point can be created at any low level part of the system using an appropriate non return valve and shut-off valve arrangement. Filling Point Alternative Filling Point (return) FIG. 5.16A PRESSURE RELIEF VALVE 5.
6. COMMISSIONING SYSTEM 6.1 PRE-FILL CHECK IMPORTANT All fittings used must be suitable for temperatures in excess of 150°C. Flushing and commissioning should only be carried out when:1. No sun is shining on the collectors e.g. early in the morning, evening or when the collectors are covered. 2. Temperatures are not near freezing or there no is risk of frost. Before filling the system carry out the following pre-fill check. 1. Check collectors have been fitted correctly. 2.
6.2 FLUSHING AND FILLING THE SYSTEM USING GLYCOL To remove any contaminants, the solar system has to be flushed with heat transfer fluid or water prior to final filling, for water flush see 6:3. Flushing and filling with glycol is done using a suitable electric pump or hand pump which should be able to provide pressure up to 3.5 bar. Flushing Procedure using glycol - refer fig. 6.2A IMPORTANT The indirect cylinder MUST be fully filled before filling the solar circuit.
Flow Return System Pressure Gauge PRV Discharge To Expansion Vessel Pump 3.5 Bar minimum Heat Transfer Fluid FIG. 6.
6.3 FLUSHING THE SYSTEM USING WATER IMPORTANT The indirect cylinder MUST be fully filled before filling the solar circuit. Failure to do so may result in irreparable damage to the cylinder. To remove any contaminants, the solar system has to be flushed with heat transfer fluid or water prior to final filling, for glycol flushing and filling see 6:2. Flushing and filling with water can be done using a conventional filling loop from the mains supply.
Flow Return System Pressure Gauge PRV Discharge To Expansion Vessel Filling loop Mains 3.5 Bar minimum Pump 3.5 Bar minimum Water FIG. 6.
6.4 FILLING AND TOPPING UP THE SYSTEM WITH GLYCOL To remove any contaminants the solar system must be flushed with heat transfer fluid (glycol) or water prior to final filling. For glycol flushing and filling see 6:2, for water flushing see 6.3. Filling with glycol is done using a suitable electric pump or hand pump which should be able to provide pressure up to 3.5 bar. IMPORTANT The indirect cylinder MUST be fully filled before filling the solar circuit.
Flow Return System Pressure Gauge PRV Discharge To Expansion Vessel Pump 3.5 Bar minimum Heat Transfer Fluid FIG. 6.
6.5 SYSTEM PRESSURE System geodetic 30 2 Collector 3 Collector 2 5 l Vessel 3 5 l Vessel height System filling pressure metres Bar Bar Bar 3 to 1 0 1 .5 1 .3 1 .4 11 1 .6 1 .4 1 .5 12 1 .7 1 .5 1 .6 13 1 .8 1 .6 1 .6 14 1 .9 1 .7 1 .7 15 2 .0 1 .8 1 .
✓ 6.
7. MAINTENANCE SCHEDULE SOLARCOMFORT - ANNUAL MAINTENANCE SCHEDULE ✓ 1. Check the system pressure when cold against commissioned tolerances. 2. Check the expansion vessel pressure against commissioned tolerances. 3. Check the pH level of the heat transfer liquid. Tyfocor LS must be in the range 9 -10.5 4. Check the refraction index. Tyfocor LS must be in the range 1.380 – 1.384 5. Check using refractometer that heat transfer fluid is of sufficient concentration for -28°C 6.
TERMS AND CONDITIONS OF GUARANTEE The SOLARcomfort Pump Group is guaranteed for 2 years. Please read these terms and conditions which are in addition to any terms and conditions detailed in this book or any registration card supplied with your appliance. SOLARcomfort solar thermal systems must only be installed and commissioned by Ariston trained and approved installers. Failure to comply with this requirement will invalidate the warranty. A charge will be made to the owner of the appliance if:1.
