BBC Elettropompe ECOSOM 4/80 Manual

1
Via G. Di Vittorio, 9
61034 Fossombrone (PU) - Italy
Tel. [phone]
Fax [phone]
www.bbc.it
INSTRUCTION AND
INSTALLATION MANUAL
ECOSOM 4/80
For electric pump type
SRF 4/80 DC 24 V
ECOSOM 320 - 290 - 262 - 190
For electric pumps
type
SEMISOM DC 24 V
“Translation of the
Original
Instructions”
Photovoltaic pumping station ECOSOM
with facility for generating set and battery charger

2
Part
1
1.1
1.2
1.3
1.4
1.4.1
1.4.2
1.4.3
1.4.4
2
3
4
4.1
4.2
4.3
5
6
7
8
9
LIST OF THE REVIEWS OF THE
MANUAL
Code/Description Review No. Date
L17/3rd ISSUE B JULY 2018
L17/2nd ISSUE A APR. 2016
L17/1st ISSUE 00 SEPT. 2010
L17/4th ISSUE C OCT. 2021
L17/5th ISSUE D APRIL 2023
INDEX
WARRANTY
SOME NOTES ABOUT
THE USER’S MANUAL
INTRODUCTION
- MANUFACTURER’S STATEMENT
- IDENTIFICATION OF THE UNIT
- GENERAL NOTES AT DELIVERY
- DESCRIPTION OF THE PUMPING UNIT
ECOSOM
- USE
- IMPROPER USE
- APPLICATION
- MAIN COMPONENTS
OF THE PUMPING STATION
SAFETY PRESCRIPTIONS
- SYMBOLS AND THEIR
MEANING
- CONTENTS
TECHNICAL FEATURES
HANDLING, INSTALLATION AND
CONNECTION
- PRELIMINARY INFORMATION ABOUT
HANDLING, INSTALLATION AND
CONNECTION
- INSTALLATION
- ELECTRIC CONNECTION
START
STOPPING AND CLEANING
MAINTENANCE
DISPOSAL AND ENVIRONMEN-
TAL LABELLING OF PACKAGES
TROUBLES AND REMEDY
DECLARATIONS OF
CONFORMITY
Page
3
3
4
4
4
4
5
5
5
5
6
7
7
8
11
12
12
13
16
20
20
21
21
21
23

3
SOME COMMENTS ABOUT THE USER’S
MANUAL
The User’s Manual is not an accessory of the
Pumping station, but is an integral part of the
station itself and represents a SAFETY MEASURE.
In order to make usage of the Manual easier,
each subject has been divided into numbered
points, which, where required are supported on
drawings.
This manual has to be kept intact, near the elec-
tric pump and delivered to any operator, user or
owner.
The manual shall not be damaged; it must be kept
intact – do not tear any sheets –, be kept far from
humidity and heat sources. While consulting, try
not to damage its readability.
The most important sections are highlighted by
symbols and detailed explanations above the pic-
tures.
Giving these notices, the Manufacturer aims, in an
unequivocal way, to alert the operator of meas-
ures, dangers and warnings that should concern
him.
WARRANTY
The 24 months warranty against manufacturing
defects is valid for any fault that may occur within
24 months from the date of delivery to the user.
The date is determined by the Delivery Note or
Invoice issued by the Dealer/Distributor. Without
this relevant documentation, the term (24
months) shall be deemed to start from the date
the product has been manufactured (month/year)
which clearly is marked on the item itself. War-
ranty is limited to the replacement or repair, at our
premises, of the products or components recog-
nised as actually being defective and does not
imply the possibility of requiring any indemnity.
Warranty will not cover failures caused by: wrong
electric connection, lack of adequate protection,
wrong installation, lack of accuracy in the execu-
tion either of the system or of the plant, any type
of corrosion or abrasion caused by the liquid
pumped, a non-respect of the limitations of use in
the Service manual.
Warranty shall not be recognised as valid in case
the products are disassembled, repaired or al-
tered by persons not expressly authorised.

4
PART 1
PRELIMINARY INFORMATION
1.1
MANUFACTURER’S STATEMENT
The pumping station ECOSOM is manufactured in
accordance with regulations described on page
23.
BBC informs that any modifications or tampering to
pumping station ECOSOM and/or operations car-
ried out in non-compliance with the provisions of
this manual, especially the non-observance of the
Safety Regulations, imply the non-validity of the
Warranty.
Please, remember that:
The technical data are referred to the pumping
station ECOSOM 4/80 and ECOSOM 320 - 290 -
262 - 190 (SEE PART 3 — TECNICAL FEATURES), draw-
ings and any other documents are owned by BBC
who owns all relevant rights that can not be
placed at any third parties’ disposal without BBC
written authorization.
Consequently, any reproduction – even partial –
of text and illustrations is strictly prohibited.
1.2
IDENTIFICATION OF THE UNIT
Always remember to quote the model of the
pumping station ECOSOM in case you call BBC or
its customer service.
Transcribe the type of unit, so that a copy of the
manual can be requested, should this one be lost
and/or should the label be unreadable.
1.3
GENERAL INFORMATION AT DELIVERY
The pumping station ECOSOM is dispatched in-
side a rigid packaging.
When you receive them, always check that:
- the package is not damaged;
- the solar panels and their accessories have not
been damaged.
Should there be any damage or missing parts, in-
form the supplier, the forwarding agent or his in-
surance company immediately, providing him de-
tailed information.

5
1.4
DESCRIPTION OF THE PUMPING STATION
ECOSOM
1.4.1
USE
(PURPOSE - SPECIFIC USE)
The ECOSOM solar station, being delivered in a
stand-alone kit and being easy-to-install units, al-
low to pump liquids wherever there is a good so-
lar radiation. They produce 24V DC renewable
energy by using available solar light.
1.4.2
IMPROPER USE
CAUTION, DANGER OF
FIRE AND TOXICITY!
THE PUMPING STATION ECOSOM MUST
NOT BE USED TO PUMP DANGEROUS LIQ-
UIDS (either inflammable or toxic)
Any use, other than that specified by the manufac-
turer, has to be considered as improper use.
1.4.3
PLACE OF USE
CAUTION, DANGER
OF EXPLOSION!
THE PUMPING STATION ECOSOM MUST
NOT BE INSTALLED IN EXPLOSIVE PLACES.
CAUTION, DANGER
OF ELECTROCUTION!
THE PUMPING STATION ECOSOM MUST NOT
BE INSTALLED IN PLACES WHERE THERE ARE
PEOPLE IN CONTACT WITH LIQUIDS (i.e. swimming
pools).
Maximum pump installation depth 20 m
(ECOSOM 262, 265, 320, 190).
Maximum pump installation depth 30 m
(ECOSOM 4/80).
Minimum and maximum operating temperature of
the liquid pumped:
- 0 / 35°C for limited use S2 (60 minutes)
ECOSOM 262, 265, 320, 190);
- 0 / 45°C for limited use S2 (60 minutes)
ECOSOM 4/80
The pumping station ECOSOM has no vibrations
and its noise is below 70 db (A).
In case of applications different from those
specified in this manual, please contact
BBC Elettropompe.

6
1.4.4
MAIN COMPONENTS OF THE PUMPING
STATION ECOSOM
Position Description Q.ty Position Description Q.ty
1 Solar module 180W
(±3%) 2 11 L Flat 10
2 L Profile=75cm 2 12 Flat bracket 10
3 L Profile=1.1m 2 13 Middle Clip 2
4 L Profile=72cm 2 14 End Clip 4
5 L Profile=1.24m 2 15 Cabinet 1
6 L Profile=1.44m 1 16 Fixing nut M8 A4 4
7 L Profile=1.7m 2 17 Square fixing clamp 2
8 L Profile=1.5m 2
9 L Profile=1.2m 3
10 Triangular Plate 4
1
16
17
14
3
6
10
2
11
8
9
15
5
12
7
4
13

7
PART 2
SAFETY PRESCRIPTIONS
While consulting this user’s manual you will find
some symbols; each one has its precise meaning.
CONVENTIONAL SYMBOLS AND
THEIR DEFINITION
WARNING, DANGER OF ELECTROCUTION!
It shows the concerned personnel that the opera-
tion described presents risk of electric shock if not
carried out in compliance with the safety regula-
tions.
WARNING, GENERAL DANGER!
It shows the concerned personnel that the opera-
tion described presents risks to get physical ly
injured if not carried out in compliance with the
safety regulations.
Every time, risks are detailed, in TEXT AND SYM-
BOLS.
NOTE!
It shows the concerned personnel which subject is
to be taken into better consideration.
WARNING!
It shows the concerned personnel basic
information whose content, if not respected, can
determine, slight injuries to people or damages to
the machine.
OPERATION
Indicates that only qualified personnel with
specific skills should carry out the operation.
The operator cannot carry out any operation re-
served for MECHANICAL OR ELECTRIC MAINTE-
NANCE QUALIFIED PERSONNEL.
MECHANICAL MAINTENANCE OPERATOR
Qualified technician able to manage the machine
in normal conditions. He/she is able to operate on
all mechanical parts so to carry out all adjust-
ments, maintenance interventions and repairs
required.
He/she is not allowed to operate on electric sys-
tems with voltage presence.
ELECTRIC MAINTENANCE OPERATOR OR TRAINED
PERSON (See EN 60204-1 point 3.52)
Qualified technician able to manage the machine
in normal conditions. He/she is put in charge of
the interventions of electric adjustment, mainte-
nance and repairing.
He/she is able to operate with voltage presence
inside electric panels or control boxes.
PERSONAL PROTECTION
The operator is OBLIGED to use devices for per-
sonal protection in presence of one of these self
explanatory symbols.
RECOMMENDATION
It is referred to a method of work experienced in
our facilities. Please, consider that each operator
can develop his/her own way to carry it out.
SPECIAL INTERVENTIONS
Any special maintenance intervention, evidenced
by this symbol, are to be requested to BBC Elettro-
pompe.

8
CONTENTS
2.1
Before installing the pumping station, the cus-
tomer shall make sure that the site is sufficiently
levelled and can stand its weight (see Technical
Features, Section 3). Furthermore, he/she will ver-
ify the presence of technological devices and suffi-
cient room on all sides for any possible mainte-
nance.
2.2
For all electric wiring, refer to the electric drawing
(see 4.4.2).
2.3
The personnel chosen for the handling of the elec-
tric pump and its accessories will have to wear
gloves and proper shoes to prevent accidents.
2.4
For all handling operations of the machine,
once it is unpacked, See Section 4 - Han-
dling, Installation and Connection.
2.5
All necessary operations of assistance, mainte-
nance and repair must be carried out only by a
QUALIFIED ELECTRIC TECHNICIAN or by a ME-
CHANICAL MAINTENANCE OPERATOR who knows
the safety prescriptions and the content of this
manual.
2.6
ZERO POWER STATE
Before doing any operation, turn the switch on O
“ZERO”.
- Remove fuses;
- Indicate WORK IN PROGRESS;
- Lock the panel, remove the key and bring it with
you.
THE PUMPING STATION IS EQUIPPED
WITH RE-SWITCHING DEVICES THAT
MAY RESTART IT AUTOMATICALLY!
2.7
The trained personnel called to operate on the
pumping station must have the following IPD
(Individual Protection Devices) at disposal:
helmet, protection glasses, oxygen set, safety
sling, gloves, accident prevention shoes when re-
quired.
Said personnel must also:
 Wear overalls with closed cuffs;
 Tie hair if this is long;
 Never wear fluttering and/or torn objects and/or
clothing (i.e., necklaces, watches, rings, brace-
lets, scarves, neckerchiefs, ties, etc.).

9
2.8
CAUTION, DANGER OF INFECTIONS!
Before carrying out any intervention, the
personnel operating shall make sure to use all
hygiene and health measures.
2.9
NOTE!
Do not move nor handle any part of the
ECOSOM pumping station by using its wires.
2.10
CAUTION! DANGER OF SHEARING, CUTTING AND
ABRASION!
Be particularly careful while handling the alumin-
ium profiles.
2.11
Start the electric pump only when it is duly in-
stalled and fixed.
NEVER START IT WITHOUT LIQUID.
2.12
CAUTION! DANGER OF ELECTROCUTION!
Never run nor start the electric pump if somebody
is in contact with the liquid to be pumped.
2.13
IT IS FORBIDDEN TO CARRY OUT MAKESHIFT RE-
PAIRS.
2.14
Make sure that there are no tools, rags and other
material left inside the panel or where the pump
has been installed.
OK NO

10
2.15
The solar panels can reach high temperatures.
Consequently, handle them only once they are
cool.
2.16
Always ask for and use original spare parts.
2.17
When the machine has finished its life cycle,
please dispose of it in a responsible manner.

11
PART 3
TECHNICAL FEATURES

12
4.1.4
CAUTION! DANGER OF INTOXICATION OR
POISONING BEACAUSE OF TOXIC GAS!
Make sure that there is neither toxic nor inflam-
mable gas in the area where the pumping station
ECOSOM will be installed.
4.1.5
CAUTION, DANGER OF SLIPPING!
Make sure that the area where the pumping sta-
tion ECOSOM will be installed is not muddy.
4.1.6
Make sure to have sufficient room where the
pumping station ECOSOM will be installed.
4.1.7
Surround the installation area with suitable
barriers.
PART 4
HANDLING, INSTALLATION
AND CONNECTION
Read thoroughly Part 2 and Part 3 of this
manual before handling, installing or wiring
the pumping station.
4.1
SOME PRELIMINARY INFORMATION A-
BOUT HANDLING, INSTALLATION AND WI-
RING
4.1.1
CAUTION, DANGER OF CRUSH, SHOCK AND ABRA-
SION!
The personnel operating while handling and in-
stalling the solar pumping station shall always
wear gloves, accident prevention shoes and hel-
met.
4.1.2
Bring the package/s near the place of installation
by means of lifting equipment, fork lift or hand
pallet truck.
4.1.3
NEVER work alone during the installation of the
pumping station ECOSOM.
Always wear safety belts and Individual Protection
Devices (IPD

13
4.2
INSTALLATION
4.2.1
Necessary tools to assemble the station:
6 mm Allen key
13 mm wrench
4.2.2
Place the bars of 1.2 m (9), the bars of 1.5 m (8).
Fix them with L-plates (11).
4.1.8
It is advisable to install a NON-RETURN valve at
least 1 (one) metre from the delivery outlet of the
electric pump to avoid a possible flow-back of liq-
uid through the delivery pipe.
4.1.9
Make sure that the electric pump to be installed is
suitable for the system (see Ø of the pipes, flow of
the electric pump, length of the pipework , etc.).
You can also consult the table of BBC General
catalogue “pressure loss”.
NOTE!
4.1.10
Before the installation, read all paragraphs (4.2,
4.3 and 4.4) so to be ready for any circumstance.
4.1.11
The preliminary information about HANDLING, IN-
STALLATION AND WIRING, is now complete.
1.02m
17 cm
8
8
9
9
11
8
9

14
4.2.3
Mount the1.24 m (5) bar and the 1.44 m (6) bar
fixing them with flat brackets (12).
4.2.4
Mount the 72 cm (4) bars fixing them with triangu-
lar plates (10).
4.2.5
Mount the 1.2 m bars (9) and fix them with L
plates (11). Mount the 75 cm bars (2) fixing them
with flat brackets (12) and triangular plates (10).
4.2.6
Mount the 1.1 m bars (3) fixing them with flat
brackets (12).
4.2.7
Mount the 1.7 m bars (7) fixing them with L plates
(11). Slide the 6 retaining clips of the panel (13
and 14) paying attention to position of the spring.
4.2.8
Insert the panels and tighten their screws.
5
56
12
4
4
10 10
4
10
24cm
2
2
9
10
10
11
12
3
3
12
7
7
11
13
14
1

15
4.2.9
POSITIONING:
Place the solar pumping station facing SOUTH if it
is installed in the northern Hemisphere, NORTH if
in the southern Hemisphere.
4.2.10
ANCHORAGE
The best way to secure the pumping station is to
fix the frame, firmly, to a rigid base. Its dimensions
must be proportionate to the weight of the station
and to the average wind speed of the area where
the ECOSOM pumping station is to be installed.
Use the proper fixing spots (A).
4.2.11
HOW TO FIX THE ELECTRIC PANEL
Lay the panel (15) on the frame, slide the mount-
ing brackets (17) on the screws coming out from
the base of the panel itself.
Tighten the nuts (16).
4.2.12
THE ASSEMBLING OF THE FRAME IS FINISHED.
A
A
A
A
15
16
17

16
4.3
ELECTRIC CONNECTION
4.3.1
CAUTION!
During the operation of electric connection, there
is a high RISK OF ELECTRIC SHOCK.
This is why this operation must be carried out only
by trained personnel (see EN 60204.1 point
3.52).
4.3.2
Take the electric diagram (see 4.4.2).
4.3.3
ELECTRIC PANEL
TECHNICAL FEATURES
- 30 A Unipolar thermal protector switch;
- 80 A power relay;
- Predisposed to be connected with float switches
for dry running protection;
- Predisposed to be connected with pressure
switches, start and stop float switch, etc.;
- HAND-OFF-AUTO selector switch;
- Spy lamps for: Pump running, pump cut-out, low
battery cut-out;
- 20 A automatic charge controller to supply the
correct power to the batteries protecting them
from any possible damage;
- Fibreglass cabinet that can be fixed to the main
structure;
- Fuse holder with fuses on both main and auxil-
iary circuit;
- Rechargeable and easy-to-inspect batteries fit in
a slot on the frame.
4.3.4
SYMBOLS OF THE COMPONENTS OF THE PANEL
- QS1 40A Opening interlock
- SCM-N 20 20A Charge controller;
- FU1 Fuses for PUMP protection;
- FU2 Fuses for SCM-N 20 protection;
- FU3 1A fuse to protect commands from
batteries ;
- FU4 Fuse to protect commands from SCM-
N 20;
- RL1 Signal relay from SCM-N 20-FU4;
- RL2 Signal relay from G1-G2-FU1-FU3;
- RLA/B 80A Power relay for pump control;
- SW01 HAND-0FF-AUTO selector switch for
the pump ;
- HL1 Lamp for low battery cut-out / FU4
interrupted;
- HL2 Lamp for thermal cut-out / level cut-
out / FU1 - 3 interrupted;
- HL3 Lamp for pump running;
- G1 RUN float switch;
- G2 STOP float switch;
- AUT Automatic device: i.e.: float switch,
pressure switch etc.

17
4.3.5
ELECTRICAL DRAWING

18
4.3.6
POWER CABLE
The electric pump is supplied with 5 Mt. cable.
If an extra length is needed, choose the right
size according to the table ’CHOISE OF THE
CABLE’ on BBC CATALOGUE.
Cable joints must be ABSOLUTELY WATER-
TIGHT
Cable section mm2
Caratteristiche nominali Nominal
Characteristic
Hp A 2 x 6 2 x 10 2 x 16 2 x 25
Maximum cable length in meters
0,75 28 10 15 20 30
Note Notes
- Voltage drop: - Voltage drop:
4% 4%

19
NOTE!
 Make sure that the electric cables are always
in good conditions and that the terminals are
well-tightened to their own clamps.
 Check, frequently and periodically, that all
electric protections are duly working.
 In case of intervention of one of the protec-
tions, check the reason before resetting the
system.
 Install the control and protection devices in
an ambient according to their IP protection.

4.4.3
CONNECTION OF THE SOLAR
PANELS
Turn the MAIN SWITCH on “0” (zero).
Use the quick connectors to wire
the cables coming from the back
of the panel to those of the solar
panels. Be sure that polarities
and colours match each other.
4.4.4
HOW TO PLACE AND CONNECT THE BAT-
TERIES
- DO NOT PUT TOOLS NOR ANY OTHER METAL
OBJECT ON THE BATTERIES
- NEVER MAKE TEMPORARY CONNECTIONS
Turn the MAIN SWITCH on “0” (zero).
Open the upper part of the control
panel, remove the lower panel by
unscrewing the fixing nuts.
The pre-wired cables to connect to
the batteries are also supplied with
eyelet.
Connect the batteries in series ac-
cording to the electric drawing.
Connect the sensor of temperature
to the battery.
4.4.5
THE ELECTRIC CONNECTION is now complete.
4.4
WIRING
Turn the MAIN SWITCH on “0” (zero).
4.4.1 How to reach the terminal
board
Unscrew the fixing screws of the
panel where the ON-OFF switch is
placed and then take it out.
4.4.2
DRAWING OF THE TERMINAL BOARD
The electric pump is supplied with a two-wire
power cable.
Power cable (red - black):
- their section is 6 mm²;
- they must be wired to terminals 1 and 2 of the
control panel.
1 terminal ( + ) red wire;
2 terminal ( - ) black wire.
AUTOMATIC DEVICE:
- G1 Run float switch;
- G2 Stop float switch;
- AUT Automatic device (i.e. pressure switch);
- Srart Stop Generator.
+-
+-

20
PART 5
START-UP
5.1
The operator must have read and understood this
user’s manual, particularly Part 2, ‘Safety pre-
scriptions’.
5.2
Before starting the electric pump, make sure that
there is liquid inside the basin and that the elec-
tric pump is submersed.
5.3
Make sure that the basin or the pit are firmly and
properly closed.
5.4
Start the electric pump supplied with the pumping
station ECOSOM by turning the selector switch on
MAN.
The electric pump is started and the
liquid is pumped.
5.5
Stop the electric pump by turning the selector
switch on “0”.
5.6
The START-UP is now complete.
OK
5.7CHECK OF THE AUTOMATIC DEVICES
5.7.1
Turn the selector switch on “AUTO”.
The electric pump is started and
stopped according to the status of the
automatic devices (i.e. float switches,
pressure switches, etc.).
PART 6
STOPPING AND CLEANING
6.1
The operator must have read and understood this
user’s manual, particularly Part 2, ‘Safety pre-
scriptions’.
6.2
Stop the electric pump supplied with the pumping
station ECOSOM by turning the MAINS SWITCH on
“0”.
6.3
IN CASE OF LONG PERIODS OF STOP, IT IS NECES-
SARY:
a - To turn the MAINS SWITCH on “0”.
b - CAUTION, DANGER
OF ELECTRIC SHOCK!
This operation must be carried out by an ELEC-
TRIC MAINTENANCE OPERATOR.
Disconnect the power cable of the pump from
the terminal board of the MAINS SWITCH.