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Index

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2 Index

3 Introduction to Solar

4 Hydraulic station specifications

5 Differential temperature controller specifications

6 Ancillary components

Expansion vessel

Solar heat transfer fluid

7 Cylinder specifications

Unvented

Cistern-fed vented

9 Safety information

11 Installation of hydraulic station

Parts list

Identification of components

Pipework installation - general

Installing the hydraulic station - positioning

Installing the wall brackets and hydraulic station

Installing the safety group

Connecting the solar expansion vessel

Connecting pipework

17 Commissioning of system

Air test

Flushing and filling the pipework

Installation of solar controller

Appliance installation

Opening the controller

Electrical connection overview

230/240V~ connections

Solar gain measurement

Connection of temperature sensors

Control of auxiliary heat input

Commissioning of hydraulic station

Ensure the solar primary system is free from air

Setting the system pressure

Commissioning of solar controller

Main menu

Control button

Menu “info”

Menu “programming”

Menu “Manual operation”

Menu “Basic adjustment”

Overview of display and operating elements

Controller functions

General controller functions

Cylinder heating by solar primary system

Systems with two storage cylinders

Rotational speed regulation

Thermostat (heating)

Thermostat (cooling)

Tube collector

Sensor monitoring

Flow monitoring

System protection function

Frost protection

Energy productivity measurement

Operating hours meter

Setting the system flow rate

Checking and adjusting the flow rate

Installation of the thermal insulation

Commissioning record

Maintenance

Check heat transfer fluid

Maintenance of the collector

Cylinder

Fault Finding

Failures with error message

Spares

Spare parts and accessories

Warranty

Standard warranty terms & conditions

Содержание 2nd Fix Solar

Страница 1: ...ad these instructions before installing or commissioning This Solar Thermal Domestic Hot Water System should only be installed by a competent person PLEASE LEAVE THESE INSTRUCTIONS WITH THE USER FOR SAFE KEEPING 2nd Fix Solar Manual ...

Страница 2: ...rk installation general Installing the hydraulic station positioning Installing the wall brackets and hydraulic station Installing the safety group Connecting the solar expansion vessel Connecting pipework 17 Commissioning of system Air test Flushing and filling the pipework 19 Installation of solar controller Appliance installation Opening the controller Electrical connection overview 230 240V co...

Страница 3: ...solar collector panels through which a special heat transfer fluid is pumped As the fluid passes through the collector panels its temperature is raised The heated fluid is circulated through a heat exchanger coil in the base of the solar storage cylinder transferring the heat gained to the stored water gradually raising its temperature The cooled fluid then returns to the collector panel to be hea...

Страница 4: ...n connections compression fittings 22mm Maximum working temperature 160 C Maximum working pressure 6 bar Pressure Relief Valve setting 6 bar Circulating Pump Baxi Circulating Pump voltage 230 240 V Power consumption Setting 1 45W 45W Setting 2 68W 65W Setting 3 90W 85W Maximum Pump Head 6 metres Maximum Pump Capacity 4 5 m3 h 3 5 m3 h Flow meter scale 2 to 15 l min Fig 3 System Module Fig 4 Cascad...

Страница 5: ...emperature sensor temperature range PTF6 25 C to 200 C PT1000 1 000 kΩ at 0 C Test voltage 4 kV 1 min according to VDE 0631 Switching voltage 230V 240V Capability per one switch output 1A ca 230VA for cos j 0 7 1 0 Total capability of all outputs 2A ca 460VA maximum Fuse protection fine wire fuse 5 x 20mm 2A T 2 amperes slow Features Self explanatory menu driven operation Adjustable control values...

Страница 6: ...her types 3 The use of chemical resistant gloves and suitable eye protection is required when handling 4 A full safety data sheet is available on request 5 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 6 Although the solar heat transfer fluid is non corrosive a...

Страница 7: ...ed control pocket suitable for insertion of solar controller temperature probe Factory fitted safety features Direct models Manually re settable cut out on heating element operates at 85 C Indirect models High limit thermal cut out operates at 85 C Wired in series with two port motorised valve supplied to provide primary over temperature protection when using auxiliary boiler coil All models Tempe...

Страница 8: ...face area for improved performance Thermostat Direct models Element thermostat adjustable from 10 C to 70 C Indirect models Factory fitted cylinder thermostat from 10 C to 70 C Solar Factory fitted control pocket suitable for insertion of solar controller temperature probe Safety features Thermostats with manually resettable thermal cut out High limit thermal cut out operating at 85 C at solar coi...

Страница 9: ...at height you are required to take suitable and sufficient steps to prevent the risk of a fall including selecting the most suitable work equipment in accordance with the regulations Mitigate the consequences of a fall where the risk of a person or object falling still remains take suitable and sufficient measures to minimise the distance and consequences of any fall 5 Collective protection measur...

Страница 10: ...ndings if you have fewer than five employees you do not need to write anything down though it is useful to keep a written record of what you have done If you employ five or more people you must record the significant findings of your assessment You must also tell your employees about your findings You need to be able to show that a proper check was made that you considered who might be affected th...

Страница 11: ...g wall mounting bracket 2 Solar differential temperature controller 3 Safety group comprising Pressure relief valve pressure gauge and fill drain valve 4 22mm compression fitting nut and olive 4 off 5 Sensor extension cable 13m not shown Ancillary component carton 6 Solar expansion vessel complete with mounting bracket and strap assembly 7 Expansion vessel connecting hose 8 Expansion vessel self s...

Страница 12: ...essure gauge are integrated in the safety group A non return valve in both feed and return prevents the possibility of gravity circulation in the solar primary circuit A solar circulation pump Fig 10 Item 4 A flow meter with fill drain valve and shut off valve Fig 10 Item 5 An air separator 2 The heat transfer fluid is circulated by the solar circulation pump integrated in the hydraulic pump stati...

Страница 13: ... diameters of 22mm However for short pipe runs up to 10m flow and return the use of 15mm diameter pipe is acceptable 3 All connections and joints must be resistant to temperatures of up to 150 C and resistant to glycol 4 If any pipe sealants are used these should be resistant to glycol and be able to withstand temperatures of up to 150 C 5 The difference in height between the highest point in the ...

Страница 14: ...ystems i e be resistant to glycol and temperatures up to 180ºC 10 Insulating the pipework External pipework should be insulated with high temperature resistant materials and be protected against UV degradation The insulation must be peck proof and rodent proof Internal pipework especially through unheated spaces such as a loft space should also be insulated with high temperature resistant material...

Страница 15: ...or level for ease of access and operation of the controls see Fig 13 4 When choosing the site for the hydraulic station provision of a discharge pipe from the safety group and the location of the solar expansion vessel must be considered 7 6 Installing the wall brackets and hydraulic station 1 Remove the front insulation moulding Fig 14 Item 1 by pulling forward whilst holding the solar differenti...

Страница 16: ...arge pressure of the solar expansion vessel must be adjusted when the fluid circuit is empty or de pressurised to a pressure equal to the static head 0 4 bar or a minimum of 1 2 bar NOTE the static head is the height difference between the highest point in the pipework collector and the hydraulic station in metres x 0 1 bar The charge pressure should not normally exceed 1 9 bar see also Section 7 ...

Страница 17: ...solating valve with integral thermometer in the flow Fig 19 Item 4 in the direction indicated by the arrow to a 45 position to open the non return valve 6 Ensure that the right hand isolating valve with integral thermometer in the return Fig 19 Item 5 is open indicated by the dot on the thermometer bezel being at the top 7 Turn the slot of the flow meter adjusting screw Fig 19 Item 6 in the return...

Страница 18: ... fluid 15 Re pressurise the filling pump and repeat steps 3 and 4 above until fluid is seen discharging from the drain valve on the flow meter Fig 19 item 2 Close the drain valve 16 Continue filling at the fill and drain valve on the safety group Fig 19 item 1 until the system pressure reaches 2 bar 17 At this point the circulation pump should be vented If the system pressure drops repressurise us...

Страница 19: ...Drill installation holes according to the dimensions shown below Screw in two upper screws up to 6 mm distance Open the appliance as described in section 10 2 and hang it onto two screws Now two lower screws can be mounted Tighten all screws Do not overtighten to avoid damage to the controller backplate 9 2 Opening the controller 1 Always disconnect from the mains before opening the controller cov...

Страница 20: ...ransmitters The terminals on the left side of the terminal block are for 230 240 V connections General connection guidelines 3 In the case of all connecting wires the outer sheath should be stripped back to 80mm The individual conductor sleeving should be stripped approx 10mm 4 Cables are inserted in the controller through knockouts provided in the controller backplate 5 Flexible cables must be se...

Страница 21: ...rked T7 where fitted see Fig 23 Collector Type 0 1 collector 1 storage tank Storage tank Collector Type 2 1 collector 2 storage tanks with 2 pumps Storage tank1 Storage tank2 Key Description Tc1 Temperature Sensor Collector 1 Tc2 Temperature Sensor Collector 2 Tth Temperature Sensor Thermostat Ts1 Temperature Sensor Storage 1 Ts2 Temperature Sensor Storage 2 Tret Temperature Sensor Collector Retur...

Страница 22: ...e No 5122765 4 If using a boiler for auxiliary input the output from the reheat function should be integrated into the boiler control circuit 3A Fused Supply L 1 1 7 10 3 1 2 3 E 2 3 4 5 6 7 8 9 10 Terminal Box Not supplied 2 3 4 2 3 5 1 2 3 7 6 N E PL L N E SL L N E DHWON CHON Boiler Terminal Strip Programmer 1 Cylinder Auxiliary Controls 6 9 2 1 2 N Room Stat 1 L Solar Controller Boiler Immersio...

Страница 23: ... OR 3 2 9 7 G Y BL WH GR 3 Port Mid PositionValve 5 OR See Fig 23 A2 N A1 N PE 11 12 E Solar Pump 2 A2 N A1 N PE 11 12 E Solar Pump 2 D Auxiliary heating by boiler with 3 port mid position valve system no reheat control by solar controller E Auxiliary heating by boiler with 3 port mid position valve system reheat control by solar controller 9 0 Installation of solar controller 9 8 1 Key to abbrevi...

Страница 24: ... group and pumping in more solar fluid to restore the pressure This must be repeated until the pressure remains stable 10 2 Setting the system pressure 1 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 2 Determine the system pressure when the system is cold...

Страница 25: ...ction To carry out any changes to this menu it must be selected within the first minute after switching the appliance on IMPORTANT Adjustment and changes in this menu must only be carried out by a competent installer or service engineer Each active menu is shown in the upper line of the display by its corresponding icon 11 2 Control Button When in the Main Menu the control button functions are as ...

Страница 26: ... if temperature sensor fitted not supplied as standard No Displays current return temperature No 60 C Heating Cooling Temperature difference controller T1 T6 Only displayed when activated No Yes No Yes Indication of minimum temperature storage tank s Resettable to current temperature Antifreeze sensor Indication of universal temperature measuring points T6 Only displayed if temperature sensor fitt...

Страница 27: ...torage tank 1 or 2 Maximum permissible temperature 40 C Meaning dT 10 K 3 40K Temperature difference controller Hysteresis dT max Storage tank 1 or 2 switch off differential dToff 2 35K Adjustment of pump rotational speed 100 rotational speed regulation set to off 7K 1 30K Switch on temperature for Heating Cooling function Hysteresis for Heating Cooling function 10K 30 100 Value range 20 90 C Typi...

Страница 28: ...o Indication after approximately 8 hours and the automatic regulation is activated again NOTE Exiting this menu will automatically return the system to normal operation Press or to scroll up or down to the required sub function The icon will flash press to select the function Reset by pressing or for increase decrease values Press and appears press to confirm and disappears ok ok Switching on off ...

Страница 29: ...tion 110 150 C 120 C Recooling storage tank temperature 30 90 C 40 C Energy yield measurement Off 0 Energy yield measurement with flow meter 1 Energy yield measurement without flow meter 2 Energy yield measurement sets glycol type 0 11 11 0 100 5 steps No value shown when item 5 is set to 0 Adjustment value when item 5 is set to 1 0 5 25Litres per impulse Adjustment value when item 5 is set to 2 0...

Страница 30: ...reezing sensor or universal temperatures measuring point T6 no sensor monitoring Auxiliary heating temperature 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 ...

Страница 31: ...e 1 3 or tube collector is active timeframe 4 1 Max Time period 1 stop Appears when the differential controller is active 23 59 timeframe 1 3 or tube collector is active timeframe 4 1 5 x 7 segment display Display of all values display flashes when Presentation of figures 00000 to 99999 a value is changed ºC Temperature in Celsius K Temperature difference in Kelvin h Operating hours kWh Productivi...

Страница 32: ...Toff The solar cylinder is heated by operating the solar pump on output A1 up to the set maximum storage temperature 65 C Pump operation starts when the collector temperature exceeds the cylinder temperature by more than dTon and continues while the collector temperature is above cylinder temperature dToff as set in the programming menu dTon cannot be set lower than dToff 1K 11 12 Systems with two...

Страница 33: ...e pump power is adjusted by a controller so that switch on temperature difference Storage tank dTmax is kept constant as much as possible At lower deviation of Storage tank dTmax the pump is operated with the lowest power till the switch off wave is reached 11 14 Thermostat heating 1 The thermostat is an independent control circuit from the storage loading Thus auxiliary heating of the top area of...

Страница 34: ...can be switched off on in the Basic setting menu point 4 Timeframe 4 in the Program menu makes it possible to activate this function during certain periods of the day When activated the solar pump will be switched on every 30 minutes for a period of 30 seconds to check for any heat gain in the collector 11 17 Sensor monitoring 1 The sensors and their connecting cables are constantly monitored for ...

Страница 35: ...fter a short period of operation once normal flow temperature conditions are restored 11 19 System protection function 1 The system protection function switches the system off if the maximum collector temperature is exceeded by 10K As soon as the temperature drops below the maximum collector temperature the system restarts This function has priority and is always active regardless of whether the c...

Страница 36: ...flow meter are required The yield value is calculated from the values of the temperature difference between the collector and collector return line and the value measured by the flow meter This function is switched on and off in the Basic settings menu 11 22 Operating hours meter 1 When the storage tank is being charged by a pump the operating hours meter records for each separate pump The number ...

Страница 37: ...ate from table See Table 1 6 The float in the flow meter will indicate the circulation flow rate through the flow meter sight glass Fig 36 Item 4 7 Adjust screw of the flow limiter Fig 36 Item 3 with a screwdriver until the upper edge of the float in the sight glass indicates the required flow rate Fig 36 Item 4 Turn the screw anticlockwise to increase the flow 8 Ensure that the float is stable wh...

Страница 38: ...ence dTon Storage tank1 3 K switch off difference dToff Storage tank2 90 C Maximum storage temperature Storage tank2 7 K switch on difference dTon Storage tank2 3 K switch off difference dToff Minimum pump power on 100 rotational speed regulation Switch on temperature of 40 C thermostat function Hysteresis of thermostat function 10 K 2nd temperature differential 65 C controller maximum temperature...

Страница 39: ...bar bar bar bar bar bar Check solar primary system flow rate l min l min l min l min l min l min l min l min l min l min l min l min l min Check operation of PRV Check discharge vessel fluid level Check sensor operation use resistance temperature table See page 43 Check solar cylinder in accordance with manufacturer s instructions Ensure system is free of air Visually check condition of solar coll...

Страница 40: ...essel charge pressure bar bar bar bar bar bar bar bar bar bar bar bar bar Check solar primary system pressure cold bar bar bar bar bar bar bar bar bar bar bar bar bar Check solar primary system flow rate l min l min l min l min l min l min l min l min l min l min l min l min l min Check operation of PRV Check discharge vessel fluid level Check sensor operation use resistance temperature table See ...

Страница 41: ...y 21 deg C 40 concentration Replace fluid if necessary 13 2 Maintenance of the collector 1 The collector or the collector array must be checked serviced annually to check for any damage leaks or contamination 2 In areas where there may be a build up of dirt on the collector only non abrasive cleaning materials and methods should be used to clean the collectors and mounting system components 13 3 C...

Страница 42: ... Measures Sensor wire broken Check wire Sensor defect Check sensor resistance if necessary exchange sensor Sensor missing Check parameter settings and sensor installation requirements Short circuit in sensor wire Check wire Sensor defect Check sensor resistance if necessary exchange sensor Error in pump connection Check cabling Pump defect Exchange pump Air in the system Check the float of the flo...

Страница 43: ...ES No display at solar differential temperature controller Controller fault Replace controller Is the 230 240V power supply switched on YES Has thermal cutout on cylinder operated unvented systems only NO NO Is internal fuse operational YES NO Replace internal fuse Check wiring and rectify Reset thermal cutout Investigate cause of operation and rectify Note Allow the cylinder to cool or draw off t...

Страница 44: ...s and rectify as necessary YES Displayed temperatures on controller vary greatly over short time intervals Controller fault Replace controller Are sensor cables laid alongside mains voltage cables NO Have sensor cables been lengthened with unshielded cable NO NO Do sensors give correct temperature v resistance readings YES YES NO Are sensor connections correctly made YES Sensor fault Replace senso...

Страница 45: ...ried out by a competent installer or authorised service engineer or agent 1 C1 E1 L1 K1 Short Parts List Key Description Manufacturer s No No Part No A1 Connection Washer 5119535 B1 Temperature Sensor 720224801 C1 Solar Differential Temperature Controller 720709001 D1 Insulation 720689701 E1 Insulation Insert 720689901 F1 Safety Group 720690901 G1 Solar Primary Circulating Pump 720688101 J1 Temper...

Страница 46: ...lp or assist with booking an engineer visit if required Our contact centre is open Monday to Friday 8am 5pm excluding Christmas Day and New Years Day When calling heateam you must have the following information to hand Solarflo serial number Affixed to Solar controller Solarflo system model number Affixed to Solar controller Your Postcode and House Number Your installer name address details and co...

Страница 47: ...ty repair or replacement costs that we haven t been told about and agreed with you in advance 15 Compensation for consequential losses e g loss of earnings business losses stress and inconvenience arising from a product breakdown including repair delays caused by factors outside our reasonable control 16 heateam will not be liable for failures resulting from fair wear and tear willful or accidenta...

Страница 48: ...of the information contained in this leaflet All goods are sold subject to our standard Conditions of Sale which are available on request BAXI A Trading Division of Baxi Heating UK Ltd 3879156 Brooks House Coventry Road Warwick CV34 4LL Technical Enquiries 0844 871 1568 Our contact centre is open Monday to Friday 8am to 6pm Weekends and Bank Holidays 8 30am to 2pm We are closed Christmas Day and N...

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