ICMA S001, S003, S002, S004 Technical Data Sheet

TECHNICAL DATA SHEET 02/2018 - ENG

ICMA S.p.a. via Garavaglia, 4 20012 Cuggiono (MI) – ITALIA

www.icmaspa.it e-mail: [e-mail]

pag. 1

ART. S001-S002-S003-S004 SOLAR MODULE

S001

S002

S004

S003

FUNCTION

The solar modules are employed in the primary
circuits of solar systems to manage the
thermodynamic cycle of the heat-transfer fluid
between the solar panels and the hot water
storage tank.
The S003-S004 modules are also equipped with
electronic controllers which, through a
sophisticated monitoring system and safety
functions, ensure the total protection of the
system during its operation.

PRODUCT RANGE

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pag. 2

ART. S001-S002-S003-S004 SOLAR MODULE

PRINCIPLE OF OPERATION

ICMA solar modules art. S001-S002-S003-S004, as already
written above, are employed in the primary circuits of solar
systems to manage the thermodynamic cycle of the heat-transfer
fluid between the solar panels and the hot water storage tank.
In thermal solar panels the solar radiation increases the heat­transfer fluid temperature and therefore its thermal power.
In the storage tank, instead, the heat-transfer fluid car rie s thro ugh a
heat excha nger most of its heat to the water in the tank.
The hot water in the tank will be then used for space heating or
domestic use.
The solar modules manage this process and are equipped with a
circulator pump having proper performances (flow and head) as
well as several regulation and control devices that run the operation
of the circuit.

TECHNICAL SPECIFICATIONS

Performance

Fluids used: Water and glycol solutions
Maximum percentage of glycol: 50%
Maximum operating pressure: 10 bar
Calibration of safety valve: 6 bar
Permitted temperature range: -10 °C / +160°C
Max ambient temperature: +40°C
Safety valve temperature range: -30÷160°C
Minimum pressure on intake
opening with temperatur es of: +50 °C : 0,05 bar
+95 °C : 0.3 bar
+110 °C : 1 bar
Opening check valves
minimum pres sure: Δp: 2Kpa (200 mm c.a.)
Manometer scale: 0÷10 bar
Thermometers scale: 0÷160 °C
Circulators: See specifications pag.7/11

Connections

System connections: G3/4” M
Safety valve connections : G1/2" F
Connection with expansion tank: G3/4” M
Filling/emp t yi ng co nne c tions with hose: Ø13 mm

Materials

Brass components: Brass CW617N - EN 12165
Seals: PTFE
Sealing elements: EPDM Perox
Flat seals: Betaflex
Insulation she l l: PPE
Conductivity of isulation shell λ(ΔT): 0.041 (W/mK)

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TECHNICAL DATA SHEET 02/2018 - ENG

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pag. 3

ART. S001-S002-S003-S004 SOLAR MODULE

S004

S003

S002

S001

Tab. 1

COMPONENTS

1. Safety valve for solar energy systems

2. Instrument holder connection with manometer

3. Taps for filling, emptying and washing the system

4. Shut off valve with thermometer and built-in check valve

5. Circulator

6. Flowmeter

7. Shut off valve with thermometer and built-in check valve

8. Deaerator

9. Preformed insulating base

10. Hose connection

11. Preformed insulating cover

12. Inspection compartment insert

13. Pump connector

14. Cable duct groove

15. Electronic controller frame

16. Electronic controller S301/S302/S302PWM

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ART. S001-S002-S003-S004 SOLAR MODULE

S002

S001

S003

S004

Tab. 2

DIMENSIONS

CODE A B C D E F G H I L

S001 G ¾” M 100 140 325 480 420 260 60 60 170 7.0
S002 G ¾” M / 140 275 480 420 235 40 60 170 5.0
S003 G ¾” M 100 140 480 480 420 260 60 60 170 7.5
S004 G ¾” M / 140 360 480 420 235 40 60 170 5.5

WEIGHT

(KG)

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pag. 5

ART. S001-S002-S003-S004 SOLAR MODULE

Fig.1

TECHNICAL SPECIFICATIONS

The solar modules receive a signal from the external controller which, having at least two temperature sensors (one is
positioned on the panel outlet pipe and the other is an immersion sensor in the boiler), constantly reads the temperature
difference and keeps it within the established range, which normally varies between 5 and 8 °C. If the Δt between the panel and
the boiler is found to be over the established set point, the controller starts up the pump on the module to provide the lacking
thermal load. If, on the other hand, the Δt is narrower than the one set, the internal pump will be disabled.
For further clarification about the electronic controller functioning, consult the technical documentation about art. S301, S302 and S302PWM.

FILLING THE SYSTEM

1. Open the shut off valve s con nected with the a ir vent va lves A (Fi g.1). These va lves must be located at the highest p oint

of the system to optimize their function of air expulsion from the circuit.

2. Open both the shut off valves 4 (Tab.1) and 7 (when present) turning their handles to 45° (see the operating specifications

of these valves on page 11 of this data sheet).

3. Fully open the flow meter 6 (Tab. 1) carrying the reference mark of the flow meter in vertical position (see operating

specifications on page 10). Check that the drain tap 3 is closed.

4. Connect an external pump to the tap 3 of the instrument holder connection 2 (Tab.1) with a rubber pipe. This pump will

get the heat-transfer fluid, previously prepared, from an external container.

5. Open the tap 3 of the instrument holder c onnection 2 (Tab.1) and start the external pump to fill the system.

6. Fill the system until air stops coming out of the air vent valves A (Fig.1).

7. Close the tap 3 and disconnect the external pump.

8. Close the shut off valves connected with the air vent valves A (Fig.1).

WASHING THE SYSTEM

1. Open both the sh ut o ff va lve s 4 (T ab.1) and 7 ( when p re sent ) tur nin g the ir handle s t o 45° (see the operating specifications

of these valves on page 11 of this data sheet).

2. Close the flow meter 6 (Tab. 1) carrying the reference mark of the flowmeter in horizontal position (see operating

specifications on page 10).

3. Connect the drain cock 3 of the flow meter 6 (Tab. 1) to a point of discharge using a rubber pipe.

4. Connect an external pump to the tap 3 of the instrument holder connection 2 (Tab.1) with a rubber pipe. This pump will

get the was hi ng liquid (or the new heat-transfer fluid) from an external container.

5. Start the external pump and op en both taps 3, the washing fluid will enter into the system while the o ne inside will be

discharged through the lower tap 3 of the flow meter 6 (Tab. 1).

6. Open slightly and for a short time the flow meter 6 (Tab. 1) to let the washing fluid running also through the system pump.

7. For a proper washing let the pump running for a few minutes, then close the taps, switch off the pump and disconne ct t he

rubber pipes.

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ART. S001-S002-S003-S004 SOLAR MODULE

A

B

F

E

C

D

G

Fig. 2

START-UP

1. Connect an external pump to the tap 3 of the instrument holder connection 2 (Tab.1). The pump is used to increase the

pressure in the system.

2. Start the pump, open the tap 3 and increase the pressure in the system up to the maximum value. Read the pressure value

on the manometer 2 (Tab. 1), then close the tap 3 and stop the pump.

3. Open the shut off valves 4 (Tab.1) and 7 (when pre s ent) by turni ng them counter-clockwise until they stop.

4. Fully open the flowmeter 6 (Tab. 1) carrying the reference mark of the flowmeter in vertical position (see operating

specifications on page 10). Check that the drain cock 3 is closed.

5. Start the circulator 5 (Tab.1) .

6. Let the system running for a while, check the hydraulic seals of the system.

7. Open both the shut off valves 4 (Fig.1) and let drain a ny remaining a ir in the system, then c l ose the valves.

8. Stop the circulator 5 (Tab.1)

9. Restore the pressure to the desired operating value as described above in step 2.

10. The system flow can be regulated by using the flowmeter 6 (Tab. 1) and reading the flow value on the scale "flow

indicator" (see operating specificatio ns on page 10). During this operation, the circulator 5 has to run at its maximum
power. To choose the flow rate suitable to the system follow the instructions of the solar panels manufacturer.

11. After a few hours of operation, remove air from the solar system once again with the air vent valves A (Fig.1) and the

deaerator 8 (Tab. 1) when present. After all air has been removed, check once again the pressure in the syste m with the
manometer 2 (Tab.1) and, if necessary, restore the desired operating value as described above in step 2.

EMPTYING THE SYSTEM

The system must be emptied if it has b e e n filled with water only and will be exposed to a risk of freezing.

1. Open the shut off valves connected with the air ve nt valves A (Fig.1).

2. Open both the shut off valves 4 (Tab.1) and 7 (when present) turning their handles to 45° (see the operating specifications

of these valves on page 11 of this data sheet)

3. Open the drain cock of the flowmeter 6 (Tab. 1) or the tap located at the lo west point in the system.

INSTALLATION AND WALL MOUNTING

The fixing of the delivery part (A) and return part (B) to the insulation shell (C) is made in the factory by two screws
M8x35mm and two washers (D).
The suppo rting plate (E ) and the do wels for the wall fixing (F) a re optional.

To install the solar module please proceed as follows:

1. Lay the pipes inside the solar system, leaving enough space for the solar module as shown in Table N. 2 (page 4).

2. Define the positioning of the module on the wall and mark the position of the 4 holes for the fixing (G) .

3. Drill the wall and insert the dowels (dowels are not included).

4. Fix the solar module to the wall and connect it to the system pipes.

5. Check that a l l unions are properly tig ht.

6. Proceed with the electrical wiring.

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TECHNICAL DATA SHEET 02/2018 - ENG

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pag. 7

ART. S001-S002-S003-S004 SOLAR MODULE

Technical specifications

Technical specifications

CIRCULATORS RANGE

ARTICLE: S160

Synchronous circulation pump with 3 speeds

Brand: Wilo
Model: Solar ST20/6
Centre to centre distance: 130 mm
Connections: G1” M
Electrical power supply: 230V – 50/60Hz
Operating temperature: 2÷110°C.
Max temperature: 140°C per brevi periodi
Max operating pressure: 10 bar
Protection level: IP44
Energy class (EEI): C

Hydraulic characteristics

ARTICLE: S160G

Synchronous circulation pump with 3 speeds

Brand: Grundfos
Model: Solar 15/65
Centre to centre distance: 130 mm
Connections: G1” M
Electrical power supply: 230V – 50/60Hz
Operating temperature: 2÷110°C.
Max temperature: 140°C per brevi periodi
Max operating pressure: 10 bar
Protection level: IP44
Energy class (EEI): C

Hydraulic characteristics

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TECHNICAL DATA SHEET 02/2018 - ENG

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ART. S001-S002-S003-S004 SOLAR MODULE

Technical specifications

Technical specifications

ARTICLE: S163

Circulator with 4 constant curves, 4 PWM curves profile C

Brand: Grundfos
Model: UPM3 SOLAR 15-75 130
Centre to centre distance: 130 mm
Connections: G1” M
Electrical power supply: 230V – 50Hz
Operating temperature: 2÷110°C.
Max temperature: 130°C per brevi periodi
Max operating pressure: 10 bar
Protection level: IPX4D
Energy class (EEI): ≤0.20
PWM signal cab le code: C64P3280153

Hydraulic characteristics

(NOT INCLUDED)

ARTICLE: S165

Circulator wit h 3 constant curves, ΔP variable

Brand: Wilo
Model: Yonos PARA ST 15/6 RKC
Centre to centre distance: 130 mm
Connections: G1” M
Electrical power supply: 230V – 50/60Hz
Operating temperature: 2÷110°C.
Max temperature: 130°C per brevi periodi
Max operating pressure: 10 bar
Protection level: IPX4D
Energy class (EEI): ≤0.21

Hydraulic characteristics

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TECHNICAL DATA SHEET 02/2018 - ENG

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ART. S001-S002-S003-S004 SOLAR MODULE

Technical specifications

ARTICLE: S164

Circulator wit h 3 constant curves, ΔP variable, 2 PWM curves

Brand: Wilo
Model: Yonos PARA RSTG 15/7.5 RK
Centre to centre distance: 130 mm
Connections: G1” M
Electrical power supply: 230V – 50/60Hz
Operating temperature: 2÷110°C.
Max temperature: 130°C per brevi periodi
Max operating pressure: 10 bar
Protection level: IPX4D
Energy class (EEI): ≤0.21

Hydraulic characteristics

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ART. S001-S002-S003-S004 SOLAR MODULE

CONTROLLER

Open position

Vertical

screwdriver cut

CONTROLLER

Close position

Horizontal

screwdriver cut

Fig.3

FLOW
CONTROLLER

DRAIN

FLOW
INDICATOR

GRADUATED RATE OF

FLOW SCALE (L/MIN)

LEVEL

INDICATOR

Fig.4

FLOW METER

The flowmeter (6 in Tab.1) is an instrument to measure the flow of the heat-transfer fluid circulating in the system.
It is possible to read in real time the value of the flo w in the circuit with the flow indicator ( Fig.3). This device is equipped
with a glass having a graduated rate of flow scale, with a calibration spring and with a movable indicator that varies its position
according to the flow inside the glass. The flow rate reading are explained the paragraph below.
The flow meter is also equipped with a manual flow regulator, adjustable with a screwdriver.
For proper operation, the flow meter must be installed in a vertical positio n.
The scale range is 0-12 l/min.

COOK

FLOW RATE READING

Example of reading: 5 l/min

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ART. S001-S002-S003-S004 SOLAR MODULE

Fig.7

Reference
notches

Fig.5

Reference
notches

Thermometer holder

Fig.6

45°

Reference

Open

45° Rotation

Fig.8

Normal

functioning

SHUT/OFF VALVE AND CHECK VALVE

The group is equipped with shut-off valves wit h ther mometer and built -in check valve 4 e 7 (Tab.1). The valves intercept the
delivery and return flow to let fill, wash and discharge the system. They also enable a quick and easy replacement of the pump
without emptying the system.
The shut-off valves are also equipped with check valves which ensure the proper flow of the heat-transfer fluid inside the solar
circuit preventing undesired refluxing when the pump is not working

1) To fully close the shut-off valves turn the regulatig handles clockwise until they stop (Fig.5).

2) T o allo w the fluid to pass thro ugh t he valves in bot h directi ons and op en the check valve , turn the regulati ng ha ndl es

to 45° (Fig.6).

3) During the normal operating cycle instead, the valves must be in the position shown in Fig.7 by turning the

regulating handles counter-clockwise until they stop.

(closed position)

notches

passage

DEAERATOR

(Present only in the solar modules art. S001 and S003)

The solar modules art. S001 and S003 are equipped with a deaerator 8 (Tab. 1).
During the normal functioning of the solar circuit, the air present in the heat-transfer
fluid is separated and collected in the upper part of the deaerator.
During the star t -up, the air collected in the deaerator has to be periodically discharged
by the manual air vent located in the upper part of the deaerator by turning its spindle
counter-clockwise with a screwdriver. After discharging all the air in the deaerator,
close the vent by turning its spindle cloc kwise until it stops.
Once the star-up is completed, for the first few months this operation must be
repeated every week or every month.
When the system is working, instead, it is necessary to repeat such operation just
every 6 months to mantain the solar system efficient.

Risk of burns!

When bleeding the system, depending on the pressure and temperature of the heat­transfer flu id in the syste m, opening the ai r vent may cause a high-speed jet of hi gh­temperature liquid or water vapour, dangerous for the operator.
To prevent any accidents, please follow these ins tructions:

- Carefull y t urn the air ve nt protecting your hands with suitabl e gloves.

- Keep your face away from the deaerator.

- Protect all components and electrical connections from water.

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ART. S001-S002-S003-S004 SOLAR MODULE

SAFETY

Safety warnin gs

Read assembly and operating instructions carefully before starting up the system in order to prevent accidents and
damage to the system caused by improper use. Remember that your rights under the warranty will be forfeited if
you make an y changes to the syst em or ta mper wit h it duri ng assemb ly and co nstruct ion witho ut aut horisatio n. In
addition, you must follow the r e quirements of the regulations listed below:

DIN 4751
Water heating systems

DIN 4757
Solar heating systems

DIN 18380
Heating systems and hot water heatin g systems

DIN 18382
Electrical systems and pipes in buildings

DIN 12975
Thermal solar systems and components

OPERATING CONDITIONS

The limits on operating values specified must not be exceeded under any circumstances. Safe operation is guaranteed if you
comply with the general conditions and limits on operating valves described in this information sheet.

SAFETY STANDARDS FOR ASSEMBLY AND INSPECTION

Assembly and inspection operations must always be performed by qualified, authorised personnel familiar with the
instructions contained herein. Make sure the system is shut down before performing any work on it.

ELECTRICAL CONNECTIONS

Electrical connections must be made by qualified personnel. Connecting cables must be positioned in the cavity provided for
the purpose in the insulating shell 1 4 (Tab.1) so as to avoid contact with the body of the pump motor and with pipes.
Check that the power supply voltage is as specified on the plate before turning on the pump. All connections must be made as
required by law.

MAINTENANCE

Maintenance work must always be performed by qualified, authorised personnel familiar with the instructions contained
herein. Make sure t he s yste m is s hut do wn befo re per for ming a ny work on it . W hen r epla ci ng the pu mp, t ur n the on/o ff va lve ,
return connection 4 (Tab.1) and flow control valve 6 (Tab.1) to the off position.

Warning! Depending on operating conditions in the pump and the system, the
surface temperature could be very high. Touching the pump directly comports
a risk of burning!

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