Baxi Potterton Solar User Manual

Please read these instructions before installing or commissioning.

Potterton Solar - Solar Thermal Domestic Hot Water System

should only be installed by a competent person.

Please leave these instructions with the user for safe keeping.

Commissioning, Maintenance & Servicing Guide

Potterton Solar - Solar Thermal Domestic Hot Water System

ndex

2 Index

3 Commissioning of system

General information Flushing and filling the system

5 Commissioning of hydraulic station

Checking/setting pressure

hecking/adjusting flow rate

C Installation of thermal insulation

Commissioning of solar controller

Overview of display Button function Operating menu Menu structure

"Info" "Programming" "Manual operation" "Basic adjustment"

Controller functions

21 Commissioning record

22 Servicing and maintenance record

24 Maintenance

Check heat transfer fluid Maintenance of the collector

25 Fault finding

Failures with error message Resistance table Flow charts

28 Spares

30 Warranty

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The Company Secretary,BAXI Heating UK Ltd,The Wyvern Business Park,Stanier Way,Derby DE21 6BF.

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Potterton Solar - Solar Thermal Domestic Hot Water System2

.0 Commissioning of system

1.1 Commissioning - General

The Potterton Solar system uses a sealed system indirect solar primary circuit which must be filled with the solar heat transfer fluid provided. This is pre-diluted to the appropriate strength (40% glycol/60%water) and should not be diluted further. Use only the fluid supplied. Additional canisters of solar fluid are available in 10 litre (5119550) and 20 litre (5119549) bottles.

DO NOT mix the fluid with other types.

The system should be filled when there is no direct radiation from the sun. If direct radiation occurs the collector panels should be shaded by covering them during filling and flushing. Although the solar heat transfer fluid is non corrosive and biodegradable appropriate precautions should be taken when handling.

- Wear protective gloves and goggles.

- Wash with soap and water if the fluid comes into contact with skin.

- If fluid gets into eyes, immediately rinse with large quantities of clear running water.

- A full safety and specification sheet can be obtained by request.

The solar heat transfer fluid must be pumped into the system.The pump can be electric or manual but must be capable of producing a pressure of at least 2 bar. The system should be thoroughly flushed to remove any contaminants in the solar primary circuit prior to filling with the heat transfer fluid

Potterton Solar - Solar Thermal Domestic Hot Water System 3

Fig. 1

.0 Commissioning of system

1.2 Flushing the pipework

Before the system is commissioned the pipework must be flushed to remove any contaminants. It is recommended that this is done using the solar heat transfer fluid as it will be impossible to fully drain all parts of the system.

Connect the flushing pipes to the fill & drain valve on the safety group (Fig. 1 Item 1) and to the fill & drain valve on the flow meter (Fig. 1 Item 2).

Fig. 2

Filling pump

Filter

Open the fill & drain valves.

Turn the slot of the adjusting screw (Fig. 1 Item 3) in the return so the slot is vertical to open the non-return valve.

Turn the left hand isolating valve with integral thermometer in the flow (Fig. 1 Item 4) in the direction indicated by the arrow (to a 45° position) to open the non-return valve.

Ensure that the right hand isolating valve with integral thermometer in the return (Fig. 1 Item 5) is open indicated by the dot on the thermometer bezel being at the top.

Turn the slot of the adjusting screw of the flow meter (Fig. 1 Item 6) in the return vertically to open the flow limiter (Fig. 1 Item 7).

Flush the solar primary pump by pumping the fluid into the system via the fill and drain valve on the safety group. Close right hand isolating valve (dot on thermometer bezel at 9 o’clock position). Flush solar primary pipework and panels via the fill and drain valve on the safety group.

If reusing flushed fluid ensure this is filtered before reintroducing into the system (see Fig. 2).

Fig. 3

Solar fluid Solar fluid

1.3 Filling the pipework

Close the fill and drain valve (Fig. 3 Item 2) on the flow meter. Open the righthand isolating valve (Fig. 3. Item 1) with integral thermometer by turning so that the dot on the bezel is at the top. Fill the solar primary system by pumping in fluid until the system pressure reads 1.5 to

2.0 bar. Close the fill and drain valve (Fig. 3. Item 3) on the safety group.

Potterton Solar - Solar Thermal Domestic Hot Water System4

2.0 Commissioning of hydraulic station

2.1 Check pressure in the solar primary

pipework

After flushing and filling the solar primary system with

eat transfer fluid the pressure must be checked.

Pressure test the system (6 bar). Observe the maximum pressure ratings of all components concerned.

Check the solar heating system for leaks.

Close the fill and drain valve on the safety group.

Fig. 4

2.2 Ensure the solar primary system is free

from air

Switch on the power supply to the solar differential temperature controller.

Manually switch the circulation pump ON and OFF via the solar differential temperature controller (see section 3.1.7) to pump fluid around the solar primary system.

Turn the pump off and open the airbleed screw on the air separator (Fig. 4 Item 1). Bleed any air from the air separator. If the system pressure drops top up by opening the fill and drain valve (Fig. 4 Item 2) on the safety group and pumping in more solar fluid to restore the pressure. This must be repeated until the pressure remains stable.

2.3 Setting the system pressure

During commissioning, the system pressure should be

0.7 bar above the static pressure (1 metre height differential equals 0.1 bar). However, it must be at least

1.5 bar and no higher than 2.2 bar.

Determine the system pressure when the system is cold (20°C).This should be recorded on the Commissioning Record Sheet (page 21).

If the pressure is too low you should pump additional heat transfer fluid into the system; the fill & drain valve on the safety group (Fig. 4 Item 2) needs to be opened for this purpose.When system pressure is correctly set, ensure the fill and drain valve is closed and remove filling hose from safety group.

Potterton Solar - Solar Thermal Domestic Hot Water System 5

Fig. 5

.0 Commissioning of hydraulic station

Table 1

Flow rate

(when system is cold)

Collectors l/min

1 approx. 2 2 approx. 4 3 approx. 6

2.4 Checking and adjusting the flow rate

Adjust the flow rate when the system is cold (20°C) (see Fig. 5).

The flow rate should be adjusted to give the optimum flow rate depending on the number and type of collector panels connected.

Turn the slot of the adjusting screw (Fig. 5 Item 1) below the return temperature gauge horizontally to close the non-return valve.

Turn the l.h. isolating valve with integral thermometer in the flow (Fig. 5 Item 2) as far as it will go in the direction indicated by the arrow to close the non-return valve (dot on bezel on top).

Turn the slot of the adjusting screw (Fig. 5 Item 3) in the return vertically to open the flow limiter on the flow meter (Fig. 5 Item 4).

Manually operate the solar pump (see section 3.1.7).

Set the solar pump switch (Fig. 5 Item 5) so that the required flow rate is achieved or exceeded with the lowest possible setting.The flow limiter adjusting screw (Fig. 5 Item 3) can be used to fine-tune the flow rate.

Depending on the number and type of collectors installed, set the required flow rate from table (SeeTable 1).

Fig. 6

The float in the flow meter will indicate the circulation flow rate through the flow meter sight glass.

Adjust screw of the flow limiter (Fig. 5 Item 3) with a screwdriver, until the upper edge of the float in the sight glass indicates the required flow rate.

Set manual pump operation to off.

2.5 Installation of the thermal insulation

Refit the controller mounting moulding (Fig. 6 Item 1) onto the rear moulding.

Push the front thermal insulation (Fig. 6 Item 2) against the rear thermal insulation section (Fig. 6 Item 3) until it clips into place.

Potterton Solar - Solar Thermal Domestic Hot Water System6

Fig. 7

.0 Commissioning of solar controller

3.1 Overview of display and operating elements

(see Fig. 7).

Number Description

1 Display with graphic symbols

2 Control button scroll upwards / +

3 Control button exit / break-off

5 Control button choice / confirmation

3.1.1 Explanation of graphic symbols

Graphic symbol Description Indication in operation

Main Menu

Menu "Info"

Control button scroll downwards / –

Menu "Programming"

Menu "Manual operation"

Menu "Basic adjustment"

Graphic symbol Description Indication in operation

Indicator values

dT Temperature difference

min Min value Appears when minimum values are indicated

max Max value Appears when maximum values are indicated

min Timeframe 1 start Appears when the differential controller is active

0:00 (timeframe 1-3) or tube collector is active (timeframe 4)

Max Timeframe 1 stop Appears when the differential controller is active

23:59 (timeframe 1-3) or tube collector is active (timeframe 4)

5 x 7 segment display. Display of all values, display flashes when

Presentation of figures 00000 to 99999 a value is changed

When symbol flashes it is possible for it to be selected. If that symbol is chosen by pressing the button, the symbol remains static (not flashing).

ºC Temperature in Celsius

K Temperature difference in Kelvin

h Operating hours

kWh Productivity indication in kWh

Potterton Solar - Solar Thermal Domestic Hot Water System 7

.0 Commissioning of solar controller

ok?

Graphic symbol Description Indication in operation

Measuring points assignment

Temperature measuring point collector array 1

Temperature measuring point collector array 2

Temperature measuring point storage tank 1 lower

(storage tank 1 charging)

Temperature measuring point storage tank lower

(storage tank 2 charging)

Temperature measuring point collector - return

Temperature measuring point storage tank upper

(thermostat function)

Antifreezing sensor or universal temperatures

measuring point (T6) (no sensor monitoring)

2nd temperature differential controller

Operating hours, energy productivity measurement

Status indication

Solar circulation pump Symbol revolves when solar circulation pump is on

Switch output 1 is active Appears when switch output 1 is active (on)

Switch output 2 is active Appears when switch output 2 is active (on)

Switch output 3 is active Appears when switch output 3 is active (on)

Reference to system fault Display flashes when a fault occurs in the system

Safety query for value changes which are to be stored

Input value can be either

rejected or accepted

Potterton Solar - Solar Thermal Domestic Hot Water System8

ok?

Button Function Description

"Up" • Step up through menu

"+" • Value change: Increase of the indicated value by 1, holding the button down will

automatically increase values

"Call" • Call up of main menu, step down through menu

"Down" • Value change: Decrease of the indicated value by 1, holding the button down will

automatically decrease values

"Scroll left" • In main menu, scrolls to the left

"Exit" • Exit current menu

• Exit menu point

"Break-off" • Break-off value change without storing

"Scroll right" • In main menu, scrolls to the right

"Choice" • Choosing one menu point

"Confirmation" • Confirmation of value change, stores value change

3.1.2 Button function

Operation and programming of the Potterton Solar differential temperature controller is by means of 4 operating buttons.By means of pressing these buttons you can:

• recall display values

• carry out controller adjustments

The graphic symbols on the display step through the operating structure and show clearly the current menu

oints, display values or parameters.

p Operating buttons have the following functions:

Example of setting procedure

Button Function Icon after operation step Description

"Exit"

"Scroll right"

"Call"

"Down"

"Choice"

"Up"

"Confirm"

Max

65°C

dT min

Currently selected menu icon will flash

Exit menu's "Info"

Choosing menu "Programming"

Chosen menu icon will flash

Call up menu "Programming", the first menu

point appears

Repeated pressing up to menu point

"S1 dTmin" appears

Choosing presented character

When chosen, value to be changed will flash

Increase of parameter

Confirmation of the character

"ok?" icon will flash

"Confirm"

"Exit"

"Scroll left"

"Call"

Potterton Solar - Solar Thermal Domestic Hot Water System 9

60°C

dT min

Storing of the parameter

When stored, icon will stop flashing

Exit menu "Programming"

Currently selected menu icon will flash

Choosing menu "Info"

Chosen menu icon will flash

Call up menu "Info"

Menu Description

Info Main menu for automatic regulation of solar system

• Indication of current measured values

• Indication of system condition

• Indication of error messages

• Indication of operating hours and energy productivity (if installed)

Programming Changes to programmable values (parameters)

.0 Commissioning of solar controller

3.1.3 Operating menu

To make the operation of the controller clear, operating

nd display functions are divided into 4 main menus.

These are

• Info

• Programming

• Manual operation

• Basic adjustment

Each active menu is shown in the upper line of the display by its corresponding icon.

Note: Changes can affect systemfunctions!

Manual operation Switching on and off connected pumps / valves by hand. Overrides automatic regulation.

Basic adjustment Information about basic adjustment for system function

Important Adjustments and changes in this menu must be carried out only by a competent installer or service engineer.

Potterton Solar - Solar Thermal Domestic Hot Water System10

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