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Ferroli AquaSol, Installation & User Manual

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Ferroli AquaSol Installation & User Manual Download Page 14

M 1261-06-X AquaSol Ferroli Installation Manual.doc 

July 2006  

Page 14 of 24 

L-N-PE  

Power 

Supply 

PE 1-2 

 

Pump Supply 

 

3-4 

 

Thermostat for boiler control if required, VOLT FREE 

 

5-6 

 

Auxiliary supply for combination boilers with secondary  

storage 

CYL GREY  

Cylinder sensor upper 

CYL BLACK 

Cylinder sensor lower 

COL  

Collector 

sensor 

COL 

CYL GREY 
CYL BLACK 

Optimax HE 
Combination Boiler 

7.8

 

Electrical Connections: 

 

The unit has a factory fitted cable. This cable should be connected to a 3 Amp 
switched fused spur.  
The collector sensor must be connected to the terminals marked COL.  Polarity is not 

important. 
The AquaSol will give a signal to the Ferroli boiler to prevent it starting up the after 

heating function if the solar water temperature is above a temperature level of 60°C.  
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
WARNING! Isolate the electrical mains supply before removing the outer 
cover! 

Fig f.  AquaSol Circuit board 

H=pump constant high power 

H/L= pump high -> max low power level 

Auto= pump speed optimised to system 

Boiler terminals 1 & 2 

Summary of Contents for AquaSol

Page 1: ...User Manual THIS MANUAL IS TO BE LEFT WITH THE HOUSEHOLDER AFTER INSTALLATION Férroli Ltd Lichfield Road Branston Industrial Estate Burton Upon Trent Staffordshire United Kingdom DE14 3HD Tel 08707 282 885 Fax 08707 282 886 E mail technical ferroli co uk ...

Page 2: ...er 18 8 2 Filling the Solar Circuit 18 8 3 Starting the System 19 8 4 System Failure 19 9 Maintaining the System 19 9 1 Annual Maintenance 19 9 2 Draining the System 20 9 3 Flushing the System 20 10 Differential Temperature Controller 21 10 1 Fault finding errors 21 10 2 Low priority codes 22 10 3 High priority codes 23 11 Service Log 24 All rights reserved Specifications and information contained...

Page 3: ... or physical injury for which the manufacturer declines any responsibility This appliance must be installed strictly in accordance with the following instructions and regulations The Local Building Regulations The Building Regulations Part L The Building Regulations for Discharge Pipes The Buildings Standards Scotland Consolidated Regulations British Standards Codes of Practice B S 5449 FORCED CIR...

Page 4: ...re 2 5 Bar Collector Flow connection 10 mm Collector Return connection 15 mm 3 System requirements For correct operation the AquaSol must only be installed in conjunction with Ferroli combination boilers capable of receiving pre heated water and which incorporate a heat exchanger in which the domestic hot water is maintained at a minimum temperature of 60 C at all times Ferroli solar collectors su...

Page 5: ... the unit using any of the pipe work or fittings 6 Positioning and Mounting the Unit 6 1 Locating the Unit When locating the unit consideration should be given to the following Access to the cold water mains inlet pipe work Access to the hot water pipe work Access to a 230v a c electrical 3amp switched fused spur Access to waste water system see paragraph 7 9 Suitability of the wall to support the...

Page 6: ...all at a minimum height of 1300mm from floor level and at 325mm centres Holes should be drilled at these points to accept the wall bolts directly or the supplied plugs depending on the wall type Fix the supplied mounting bracket using the wall bolts and ensure the bracket is horizontal level Note if the AquaSol is not mounted on a solid wall adequate precautions should be taken to ensure that the ...

Page 7: ...Hot Water Systems All registered installers should carry an identification card as issued by the Institute of Unvented Hot Water Systems the Construction Industry Training Board or the Institute of Plumbers Schematic layout of water connections for AquaSol and boiler Collector AquaSol Ferroli Optimax HE Boiler HW Hot water TMV Mains in Inlet kit To drain Water flow limiter T P valve CR CW HW CF Co...

Page 8: ...ess than 10 Bar This information may be obtained from the local water authority or by conducting a mains pressure flow test Excessive use of flux can damage this unit especially the check valves Avoid over use and ensure that the system and all pipe work is flushed to BS7593 thus removing all contaminants prior connecting to the AquaSol Ensure that the discharge pipe tundish and drain valve are po...

Page 9: ...valve on the filling manifold 2 Connect 5 to the pressure relief outlet on the AquaSol 6 hand tighten only Connect the pump assembly 3 to the collector return 4 Note that the 15mm copper pipe fits inside the 22mm stainless steel pipe Hand tighten only Ensure the pump assembly and main tundish tail are fully located then fully tighten the compression joints Figure 2 10mm 9 ...

Page 10: ... copper tube Return to Collector 15mmØ copper tube Drain back pump Thermostatic Blending Valve Gradient of 30mm mtr back towards the AquaSol unit Return to Collector OpenTherm Room Unit 1 5 Metres above floor level Solar flat plate collector For maximum exposure the collector should face Southeast to Southwest at an angle of 35 Minimum angle 25 maximum angle 60 Water flow limiter 3amp Switched fus...

Page 11: ... or the expansion vessel and the AquaSol unit Alternative connection via copper tube etc To AquaSol cold inlet Heated water from AquaSol unit Expansion vessel attached to expansion relief valve body Flow limiter assembly HTG Flow HTG Return Expansion relief piped through supplied Tundish Gas supply Hot water supply to property Thermostatic mixing valve Mains cold water supply Exploded view of cold...

Page 12: ...m top of the collector to the top CF connection on the AquaSol NOTE Both connections to the Ferroli solar collector are at the bottom of the unit and flow and return can not be mixed up The flow connection is 10mm the Return connection is 15mm Always keep in mind the drain back level of the Solar storage system Always install the collector in a level plain the flow return must be mounted with an a...

Page 13: ...lector will be more than 4m a separate drain back tank must be installed in the collector flow In this way The maximum height difference between collector and AquaSol is expanded to 15m 4m 19m For detailed installation instructions and filling procedure see also the Manual of the drain back tank Installation of an extra drain back tank in the flow of the collector circuit Optional drain back tank ...

Page 14: ...nections The unit has a factory fitted cable This cable should be connected to a 3 Amp switched fused spur The collector sensor must be connected to the terminals marked COL Polarity is not important The AquaSol will give a signal to the Ferroli boiler to prevent it starting up the after heating function if the solar water temperature is above a temperature level of 60 C WARNING Isolate the electr...

Page 15: ... these locations Examples of acceptance discharge arrangements are i Ideally below a fixed grating and above the water seal in a trapped gully ii Downward discharges at low level i e up to 100mm above external surfaces such as car parks hard standing grassed areas etc are discharges a wire cage or similar guard must be positioned to prevent contact whilst maintaining visibility iii Discharges at h...

Page 16: ...e fixed grating trapped gulley safety device e g temperature relief valve Valve Outlet Size Minimum size of Discharge pipe D1 Minimum size of discharge pipe D2 from tundish Maximum resistance allowed expressed as a length of straight pipe i e no bends or elbows Resistance created by each elbow or bend G 15mm 22mm 28mm 35mm Up to 9m Up to 18m Up to 27m 0 8m 1 0m 1 4m G 22mm 28mm 35mm 42mm Up to 9m ...

Page 17: ...ngth of 7m therefore calculate the next largest size From Table 1 Example 2 Maximum resistance allowed for a straight length of 28mm cooper discharge pipe D2 from G temperature relief valve is 18 0m Subtract the resistance for 4 No 28mm elbows at 1 0m each 4m Therefore the maximum permitted length equates to 14m As the actual length is 7m a 28mm D2 copper pipe will be satisfactory 7 10 Advice on u...

Page 18: ...ed N B Flush system before filling 8 2 Filling the Solar Circuit A Remove the expansion relief valve assembly by removing the M8 screw B Attach a clean water supply to the filler nozzle Turn the valve on the filling manifold through 90 and begin to fill the system A B C D C When water begins to flow from the fill level indicator at the bottom of the filling manifold turn the fill valve back throug...

Page 19: ... installer 9 Maintaining the System 9 1 Annual Maintenance It is recommended that the following checks be carried out at least once a year by a competent operative a Twist the cap of the Expansion Relief Valve and check that water is discharged and is visible running through the tundish and at the discharge drain Ensure that the valve re seats itself and that no further water is discharged b Lift ...

Page 20: ... open the mains water inlet to ensure there are no leaks close the hot water outlet i After the completion of the service it is advisable to check the temperature of the mixed water using a calibrated gauge this should be done at the boilers recommended flow rate See the boiler technical data page within the boiler installation manual On completion of the annual maintenance please complete the log...

Page 21: ... period of 400 seconds following which it will switch to solar radiation dependent lower speed The pump will be switched off as the AquaSol reaches a temperature of 85 C After this the collector circuit will drain and prevent the AquaSol from overheating 10 1 Fault finding errors In the event of a malfunction flashing error codes will be displayed Codes 71 73 inclusive are low priority Codes 74 77...

Page 22: ...ensor defect Go to Tabel 2 Check for faults in the PCB Code 73 Cylinder lower sensor malfunction a temperature of the cylinder is below 0 C or above 100 C b sensor cable is broken or short circuited c sensor defect Go to Tabel 2 Check for faults in the PCB Sensor checklist Resistance v Temperature C KΩ C KΩ C KΩ 0 5 10 15 20 25 30 32 150 26 310 19 860 15 890 12 490 10 000 8 060 35 40 45 50 55 60 6...

Page 23: ...utions within the following 6 days If after 30 minutes Code 74 appears again check the following a Check the operation of the lower cylinder sensor Tabel 2 b Check the height difference between the pump and the highest point of the collector maximum 4 0m c Check the primary circuit for blockages d Check the connections and operation of the pump Code 75 Collector temperature too high pump switched ...

Page 24: ...M 1261 06 X AquaSol Ferroli Installation Manual doc July 2006 Page 24 of 24 11 Service Log Date Serviced by Sign Print Name Remarks ...

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