Beretta Solar module 50 Operating Manual

Solar Module 50

Operating Manual

2

Table of contents

1. General 3

1.1. Use 3

1.2. Sample application 3

2. Description 4

3. Warnings 4

4. Structure of the solar module 4

5. Safety instructions 5

6. Assembly and commissioning 6

6.1. Assembly 6

6.2. Positioning the solar module 6

6.3. Hydraulic connection 10

6.4. Electrical connection 10

6.5. Commissioning 11

7. Technical data 13

7.1. Design 14

7.2. Pump characteristics 15

8. Warranty 16

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1. General

Before commissioning your new solar module, please read all chapters
thoroughly and, in particular, please note the warnings given in champter 3.
Improper handling or operation may lead to damage of the system.

1.1. Use

The solar module 50 enables the buffer tank to be loaded depending
]on the temperature. The solar module is speed controlled, energy
efficient and suitable for large buffer tanks.

1.2. Sample application

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2. Description

The solar module 50 is used to connect a solar collector plant up to

50 m² in

size to a buffer tank. The solar heat is transferred from the collector circuit to
the buffer circuit using highly efficient heat exchangers.
In the process, an intelligent system provides optimal interaction between the
solar pump and buffer loading pump depending on the solar radiation and
ensures a high efficiency level of heat transfer.
The module loads the buffer using speed control and the corresponding
temperature zone of the buffer depending on the temperature.

3. Warnings

The system must be installed and operated in accordance with the

locally applicable specifications and standard practices.

Only qualified technical personnel should carry out the assembly,

maintenance and cleaning of the shift layer module.

Unauthorised modifications or changes are not permitted on the

system for safety reasons and inevitably lead to the warranty becoming
null and void.

The operating pressures specified should not be exceeded!
If any errors occur – regardless of the type – please contact your

heating system installer. Please do not carry out any repairs to the
plant yourself, since this is not permitted by law and you could expose
yourself to hazards as a result.

4. Structure of the solar module

We reserve the right to make
constructional modifications on account
of advanced technical development. Each
of these modifications shall be taken into
consideration in the operating manual by
replacing the relevant pages or revising
the electronic media (CD ROM). The
module may sometimes vary from the
appearance given in the illustration!

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5. Safety instructions

The module must be connected taking the following standards, national guidelines

and the regulations of the local water utility company into consideration.

DIN EN 12828 VDE 0100

Heating systems in buildings Setting up electrical operating

equipment

DIN 1988 VDE 0185

Technical regulations for drinking water
supply installations

General information on setting up
lightning protection systems

DIN 4708 VDE 0190

Central hot water installations Main potential equalisation of

electrical installations

DIN 4751 ÖNORM EN ISO9488

Safety equipment of heating installations Solar energy – Terminology

(ISO 9488:1999)

DIN 4753 ÖNORM ENV 12977-1

Water heaters and water heating
installations for drinking water and
industrial water

Thermal solar plants and their
components – customised plants

DIN 4757 ÖNORM M7700

Solar heating and solar thermal plants Solar energy – Terms with definitions

DIN 18380 ÖNORM M7701

Central heating systems and process
water systems

Solar plants – Approximation
procedure for dimensioning flat
collectors in water heating
installations

DIN 18381

Gas, water and waste water installation
work

DIN 18382 ÖNORM M7731

Electrical cable and wiring systems in
buildings

Solar heating plants for heating water
– Requirements and tests

DIN EN 12975

Thermal solar systems and their
components

This appliance is not intended for use by persons (including children) with
limited physical, sensory or mental abilities or with a lack of experience
and/or knowledge, unless they are being supervised by a person who is
responsible for their safety, or have received instructions from such a
person regarding its use. If the mains connection line of this appliance is
damaged, it must be replaced by the manufacturer or their customer
service or a person having similar qualification, in order to avoid hazards.

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6. Assembly and commissioning

Before you start the assembly, please keep the following in mind:

Read the entire operating manual and pay particular attention to the section

on Warnings.

This appliance is not intended for operation by persons (including children)

with limited physical, sensory or mental abilities.

Uninformed or inexperienced persons are permitted to operate the

appliance only under the supervision or instruction of a person responsible
for the safety.

The installations must meet the respective official requirements.

6.1. Assembly

The erection and installation must be done by an approved technical agency.
This agency also takes over the responsibility for correct installation and
commissioning. A dry, frost-free room that provides sufficient space for
maintenance work is required as the installation site.
The solar module must be installed so that it is protected from splashing
water and should be run only at room temperatures below 40°C.

6.2. Positioning the solar module

Installation near the buffer tank is recommended to avoid heat losses. This
should be done on an even surface as far as possible and one that is statically
suitable, whereby adjustable legs have been provided for the purpose of levelling.

Tightening the mounting screws too tightly damages the insulation.

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Wall mounting

The appliance is mounted on the wall using the fixing material supplied (3 x M8
hanger bolts, M8 nuts and 3 flat washers M8) as follows:

1. As given in the Drilling jig enclosed, drill the boreholes marked with the 10 mm

dia. drill bit at least 8 cm deep.

2. Next, insert the dowels into the borehole and screw in the hanger bolts into

the brickwork until the dowel threads are no longer visible.

3. Now hang the solar module on the threaded bolts and mount it using the

flat washers and nuts.

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Drilling jig for wall mounting

9

Mounting the tank

Before mounting the module, the buffer sensors must be mounted in the terminal
strip of the buffer.

The installation on the tank takes place using the installation material in 3
steps as follows:

Step 1: (Figure above) Step 2: (Figure above)

Mount and tighten the
3 threaded rods and the
3 corrugated pipe hoses
including the gaskets at the
relevant connecting points on
the tank.

Push the shift layer module over the

corrugated pipe hoses and the threaded
rods and fix the module to the tank
using the flat washers and nuts.

Step 3: (Figure on the right)

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Tighten the 3 corrugated pipe
hoses with the gaskets on the
module.

6.3. Hydraulic connection

The pipelines are connected in accordance with the installation layout of this
manual. See 1.2. Sample application:

The path of the lines to the tank should be as short as possible!
We recommend steel or copper pipes as the material for the lines. The

installation sequence must be followed for all pipelines and fittings in order
to prevent electrochemical corrosion.

Installation in gravitational heating systems is not permissible!
The expansion tank of the collector circuit must be connected directly.
The installation of shut-off valves (except suitable maintenance units such as

cap valves) is not permitted!

Connections must be tightened only after the pipelines have been sealed.

Tightening torques or impact of forces on components and connections that
have already been pre-mounted must be avoided at all costs!

In addition, all flat seal connections must be checked for the right tightening
torque of the union nuts (screw connections may become loose during
transport!).

6.4. Electrical connection

The electrical components of the plant have been wired internally at the factory.
Connection to the mains supply (230 V/AC, 50 Hz) takes place using the power
supply line already connected to the terminals.
The buffer sensors supplied with the appliance are placed at the appropriate
measuring points of the buffer tank and connected to the corresponding
terminals of the controller in the same manner as the collector sensor included in
the scope of delivery. The controller manual contains comprehensive information
on the controller integrated in the module.

Work on live parts of the module is carried out only after following the respective
regulations of the electricity supply company and the relevant standards
applicable.

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6.5. Commissioning

Use only water that has been treated in accordance with the standards (e.g.,
ÖNORM H 5195-1:2010). All lines must be designed and executed to be
impermeable.

The filling and commissioning must be done by an approved technical agency.
Here, the function and tightness against leaks of the entire plant including the
parts assembled at the manufacturing works must be checked. The proper
working of the safety valve must be checked at regular intervals. It is
recommended to carry out annual maintenance by a technical and professional
agency.
Opening the ball valves slowly at the inlet and outlet of the module prevents
pressure shocks during the rinsing process. Use the rinsing connections
provided to fill up the collector circuit. See 7.1. Design.

The filling and rinsing must be carried out till it is ensured that the system is
completely de-aerated. Flow noises during operation of the buffer loading pump
indicate that there is still some air in the plant, which needs to be discharged via
the pump and the manual bleeding or venting device.

At the end of the filling process, close the return line of the collector and control
the system pressure to approx. 3 bar (this applies to expansion tanks with a
primary pressure of 2.5 bar, and the static height of the plant must be taken into
account).

Ensure disconnection from the mains supply before opening the control panel
housing!
Do not undertake filling with intense sunlight since this may lead to water hammer
effects!

Rinsing and filling the collector circuit:

The filling and rinsing must be carried out until it is ensured that the system is
completely de-aerated. Flow noises during operation of the buffer loading pump
indicate that there is still some air in the plant, which needs to be discharged via
the manual bleeding or venting device.

Please read the following points carefully before starting the rinsing or filling
procedure.

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Solar-side (Collector side)

See 7.1. Design.

1. Only an approved glycol-water mixture (frost-proof up to at least -25°) should

be used for heating to fill up in the solar circuit.

2. Before you begin with rinsing and filling, assure yourself that all connections

(solar inflow / return flow, etc.) have been properly provided with gaskets and
have been tightened.

3. Connect the filling pump inflow to the KFE valve A (filling nozzles).

4. Connect the filling pump return flow to the KFE valve B (drainage nozzles).

5. First open the KFE valve A (handle in the flow direction).

6. Now open the KFE valve B (handle in the flow direction).

7. Start the rinsing procedure for the solar circuit by switching the filling pump

on.

8. Allow the pump to operate until the glycol-water mixture flows back into the

tank without any bubbles.

9. Close the KFE valve B (handle in the direction opposite to the flow).

10. Now observe the pressure gauge.

11. When the pressure gauge indicates the desired operating pressure, close the

KFE valve A (handle in the direction opposite to the flow).

12. You can now switch the pump off and remove the connections of the filling

pump from the KFE valves A and B.

13. The solar circuit is now filled up completely and ready for use.

14. If any airborne noise occurs in the circuit, restart again with point 1.

Buffer-side

1. Only heating water in accordance with ÖNORM H 5195-1:2010 should be

used to fill up the buffer circuit and the buffer tank.

2. Before you start connecting the lines from the solar module to the buffer

tank, shut the ball valves C, D and E (handle in the direction opposite to the
flow) on the solar module.

3. Before you begin filling, assure yourself that all connections (solar inflow /

return flow, etc.) have been properly provided with gaskets and have been
tightened.

4. First open all the valves of the connecting lines at the buffer tank.

5. Now open valve C, then valve D and finally, valve E at the shift layer module.

6. When you do not hear any airborne noises, switch the buffer circuit pump on

manually.

7. Allow this to run for a few minutes. Thereafter, switch the pump off again.

8. Bleed the buffer tank and fill up heating water, if required.

9. The buffer circuit is now filled up completely and ready for use.

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7.

Technical data

Solar module 50

Dimensions Width 496 mm

Height 930 mm

Depth 325 mm

Cover EPP black RG 45 g/l

Solar piping Copper pipe ø 22mm * 0.8 mm

Buffer piping Ring corrugated hose, Niro steel 1.4404,

ø 26.2 mm * 0.18 mm

Weight ~ 25 kg

Connections A KFE valve filling nozzles G3/8", external thread

B KFE valve drainage nozzles G3/8",

external thread

C Buffer return flow, cold, ball valve G1",

external thread

D Buffer inflow, warm, ball valve G1",

external thread

E Buffer inflow, hot, ball valve G1", external thread

F Solar inflow, G1", external thread
G Solar return flow, G1", external thread
H Connection to the expansion tank,

G3/4", external thread

Maximum operating pressure

Collector circuit Max. 6 bar

Buffer circuit Max. 3 bar

Solar pump

WILO HU25/6-1

Nominal voltage 230 VAC / 50 Hz

Nominal output Max. 86 W

Max. pumping height Max. 6 m

Buffer loading -

pump

WILO HU25/4-1

Nominal voltage 230 V / 50 Hz

Nominal output Max. 63 W

Max. pumping height Max. 4 m

Plate heat

exchanger

(glycol / water)

Output ~ 26 kW

Inflow temperature 60°C (Glycol) / 29°C (Water)

Outflow temperature 35°C (Glycol) / 54°C (Water)

Flow rate 970 kg/hr.

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7.1. Design

15

7.2. Pump characteristics

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8. Warranty

The manufacturer provides a warranty of 2 years from the date of delivery for the
products and components supplied.

Unauthorised modifications or changes are not permitted on the system for
safety reasons and inevitably lead to the warranty becoming null and void.

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Notes

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Notes

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Rev. 1 05/12