Beretta CONNECT SOLAR R - 7,5m User manual

Installation Manual
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Solar | Solar station
CONNECT SOLAR R - 7.5m
Installation Manual
EN

This manual, Code 20123006 - Rev. 1 (05/17) comprises 12 pages.
2
GENERAL INFORMATION
RANGE
MODEL CODE
CONNECT SOLAR R - 7,5m 20116162
Dear heating engineer,
We would like to congratulate you on having recommended
a Bsolar station unit: a modern product that's capable
of ensuring a high degree of reliability, efciency, quality
and safety.
While your technical skills and knowledge will certainly be
more than sufcient, this booklet contains all the informa-
tion that we have deemed necessary for the device's cor-
rect and easy installation.
Thank you again, and keep up the good work,
Beretta
CONTENTS
ENGLISH
1 GENERAL SAFETY INFORMATION
b
Check that the product is complete, undamaged and
as ordered as soon as you receive it. Report any dis-
crepancies or damage to the Bdealer who sold
it.
b
This product must be installed by a legally qualied
heating engineer. On completion of the installation,
the installer must issue the owner with a declaration
of conformity conrming that the installation has been
completed to the highest standards in compliance
with the instructions provided by Bin this instruc-
tion manual, and that it conforms to all applicable
laws and standards.
b
This product must only be used for the purpose
for which it is designed and made, as specied by
B. Bdeclines all responsibility, contractual or
other, for damage to property or injury to persons or
animals caused by improper installation, adjustment,
maintenance or use.
b
The product must be serviced at least once a year.
Servicing must be arranged in advance with the
BTechnical Assistance Centre.
b
All servicing and repairs must be performed by a
qualied heating engineer.
b
This instruction manual is an integral part of the prod-
uct. It must be kept safe and must ALWAYS accom-
pany the product, even if it is sold to another owner or
transferred to another user or to another installation.
If you lose this manual, order a replacement immedi-
ately. Keep the product purchase documents to be
presented to the Bauthorised Technical Assis-
tance Centre to request a service call under warranty.
b
Size the solar expansion tank so as to ensure com-
plete absorption of the expansion of the uid con-
tained within the system, with reference to the prevail-
ing regulations on the matter. In particular, consider
uid characteristics, considerable uctuation of ser-
vice temperature and vapour that might be generated
during solar collector stagnation stage. Proper size
of expansion tank ensures setting off of all volume
changes of the heat transfer uid, avoiding excessive
pressure increase. Limited pressure changes avoid
reaching safety valve opening pressure and the con-
sequent uid drainage.
Generalinformation
The following symbols are used in this manual:
b
CAUTION! = Identies actions that require caution
and adequate preparation.
a
STOP! = Identies actions that you MUST NOT do.
Thismanual,Code
-Rev.
comprises
pages.
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2
1 General Safety Information . . . . . . . . . . . . . . . . . 2
2 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Description of the appliance . . . . . . . . . . . . . . . . 3
4 Safety and control devices . . . . . . . . . . . . . . . . . 3
5 Identication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
6 System layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
7 Technical specications . . . . . . . . . . . . . . . . . . . 4
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
8 Unpacking the product . . . . . . . . . . . . . . . . . . . . 5
9 Installation premises . . . . . . . . . . . . . . . . . . . . . . 5
10 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
11 Water connections . . . . . . . . . . . . . . . . . . . . . . . . 6
12 Pump controller . . . . . . . . . . . . . . . . . . . . . . . . . . 6
13 Electrical connections . . . . . . . . . . . . . . . . . . . . . 8
COMMISSIONING AND MAINTENANCE . . . . . . . . . . 9
14 System ushing . . . . . . . . . . . . . . . . . . . . . . . . . . 9
15 System lling cock . . . . . . . . . . . . . . . . . . . . . . . 10
16 Device cleaning and maintenance . . . . . . . . . . 11
17 Interventions on the hydraulic system . . . . . . . . 11
18 Recycling and disposal . . . . . . . . . . . . . . . . . . . 11

GENERAL INFORMATION
3
2 PRECAUTIONS
The operation of any appliance that uses electrical power
demands that a number of fundamental safety precautions
be respected. In particular:
a
Never attempt to install the system without using suit-
able personal protection equipment and without fol-
lowing all applicable occupational safety standards.
a
It is forbidden to touch the device while barefoot or
with wet or moist body parts.
a
It is forbidden to perform any technical or cleaning
operations before having disconnected the device
from its electrical power supply, by setting the sys-
tem's main switch to "off".
a
It is forbidden to pull, detach, or twist the electrical
cables protruding from the device, even if it is discon-
nected from its electrical power supply.
a
Do not expose the storage cylinder to the elements. It
is not designed for use outdoors.
a
If solar plant pressure decreases, it is forbidden to
top up with only water as there is a danger of freezing
and overheating.
a
Do not use connections or safety devices or ttings
(expansion vessels, pipes, insulation) that are not
specically designed and tested for use in solar wa-
ter heating systems.
a
Do not allow children or inrm persons to operate the
system unsupervised.
a
Do not dispose of packaging material into the envi-
ronment, or leave it within the reach of children, since
it can become a potential hazard. Dispose of packag-
ing material in compliance with applicable legislation.
3 DESCRIPTION OF THE
APPLIANCE
The solar station CONNECT SOLAR R allows transferring
sun power from collectors to a storage system.
The solar station Bis enclosed in an EPP (Polypropyl-
ene foam) insulating casing and is designed to perform:
- system ushing
- system lling and emptying
- circulator removal.
The key components are:
- high-efciency circulator running at xed or variable
speed
- non-return shut-off valve
- thermometer
- pressure gauge
- tting for connection to a solar expansion tank
- suitable safety device, as indicated in paragraph "
Safety and control devices"
- ow-meter with ow-rate regulator.
4 SAFETY AND CONTROL DEVICES
The solar station safety is ensured by a safety valve with
intervention pressure of 6 bar.
5 IDENTIFICATION
The solar stations by B can be identied by:
Serial number plate
This species the serial number and model.
Cod. :
TqelBR100
Serial N.° :
Mod. :
MAX W
IP
Made in Italy
Beretta Caldaie
Via Risorgimento, 13
23900 Lecco (LC)
[e-mail]
b
If these plates or any other means of clearly iden-
tifying the product are defaced, removed or lost,
proper installation and servicing may be rendered
difcult.
In case of loss, request a duplicate to BTechnical As-
sistance Centre.

GENERAL INFORMATION
4
6 SYSTEM LAYOUT
1
234
5
0 6
R
RB
7
8
6
SV
VE
10
9
11
1
2
4
5
3
1 Return Valve (solar plant return) with built-in non-re-
turn valve
2 Return temperature gauge
3 Insulation
4 Flow regulator
5 Flow-meter
6 Tap A for system lling/draining
7 Pump
8 Fixing bracket
9 Tap B for system lling/draining
10 Pressure gauge
11 Safety valve (6 bar)
R Solar circuit return. Outlet of heat transfer uid to-
wards solar collector.
RB Storage system return. Inlet of heat transfer uid
from solar storage system.
SV Safety valve drain
VE Expansion tank tting
7 TECHNICAL SPECIFICATIONS
DESCRIPTION Return solar
station
Maximum working pressure 6 bar
Maximum operating temper-
ature 110 °C
Dimensions LxHxP 264x362x215 mm
Net weight with insulation 3,8 kg
Power supply 230~50 V~Hz
Min/max electrical current
draw 0,04 ÷ 0,48 A
Min/Max power consumption 2 ÷ 45 W
Useful head available
Return solar station
USEFUL HEAD AVAILABLE (mbar)
800
700
600
0
500
400
300
200
100
0 200 400 600 800 1000
FLOW RATE (l/h)
Values referred to a mix of water and 30% glycol.
The circulator speed is controlled through PWM signal and
varies according to the thermal gradient between solar col-
lectors and storage.
Pay attention to the system overall ow resistance (ex-
changer, solar collectors and pipes) at the maximum ow
rate conditions provided.

5
INSTALLATION
8 UNPACKING THE PRODUCT
Package content
1
2
3
4
1 Solar Station
In a plastic bag, the following material is also supplied:
2 Instruction manual
3 Circulator cover with logo (to be mounted during instal-
lation)
4 Wirings.
b
The instruction manual is an integral part of the boiler.
Once located, read it thoroughly and keep it safe.
9 INSTALLATION PREMISES
b
When installing the boiler, allow sufcient space
around it to access all safety and control devices and
to permit easy maintenance.
9.1 Recommended minimum
distances
Recommended distances for assembly and maintenance
are 300 mm on each side (including expansion tank).
Put the solar station at a proper hight to allow thermometer
and pressure gauge reading.
≥ 0,3 m
≥ 0,3 m
≥ 0,3 m
Installation
10 ASSEMBLY
- Remove the front insulation (1)
- Mark mounting points (F) on the wall and drill
- Insert blocks (not supplied)
F
F
70mm
1
1
23
0
55mm
b
Use suitable wall-mounting bolts and blocks.
- Set solar station at the centre
- Fasten the solar station with the xing bracket (4), the
screws (2) and the washers (3) not supplied.
4
2
3 3

INSTALLATION
6
11 WATER CONNECTIONS
T
E
R
RB
SV
VE
60mm72mm
R Solar circuit return (3/4" M). Outlet of heat trans-
fer uid towards solar collector.
RB Storage system return (3/4" M). Inlet of heat
transfer uid from solar storage system.
SV Safety valve drain
VE Expansion tank tting
E Solar expansion tank (not supplied)
T Safety valve outlet pipe (not supplied)
- Connect the return tting (R) in the upper part of the
solar station to the solar plant
- Connect the return tting (RB) in the lower part of the
solar station to the accumulation system
- Connect the safety valve drain to a pipe (T) to avoid
burns from expelled uid and to permit the heat trans-
fer uid to be recovered
- Connect expansion tank (E), suitable for solar plant
applications, to 1/2” tting (VE).
b
Fasten expansion tank as explained in the instruction
sheet supplied with the accessory.
b
For hydraulic connections, use silicone seals having
a hardness of at least 80SH. If no seals can be used,
seal ttings with high-temperature sealant (>180°C)
suitable for solar applications.
12 PUMP CONTROLLER
The circulator is produced with maximum hydraulic head
conguration of 7,5 meter.
USER INTERFACE
The user interface consists of a push-button (1), a red/
green LED (2) and four yellow LEDs (3).
1 2 3
LED 1 LED 2 LED 3 LED 4 LED 5
When necessary, the user interface provides access to:
- Functioning (performance display) mode. Pump per-
formance is displayed during functioning as a % of
current draw with respect to rated load. Alarm condi-
tions can be seen from the colour of LED.
- Setting Mode: Press button (1) to enter setting mode
and select the type of pump curve.
FUNCTIONING MODE
Performance display
When the pump is running, LED no.1 is green. The four
yellow LEDs indicate the pump's instantaneous electrical
power consumption as shown in the table.
Nr. displayed Meaning % power
LED 1 ashing green Stand-by 0
LED 1 green and LED 2
yellow, both lit Low load 0-25
LED 1 green and LEDs 2, 3
yellow, all lit
Low-medium
load 25-50
LED 1 green, LEDs 2, 3, 4
yellow, all lit
Medium-high
load 50-75
LED 1 green, LEDs 2, 3, 4,
5 yellow, all lit High load 75-100

INSTALLATION
7
Alarm display
If the pump detects one or more alarm conditions, LED 1
changes from green to red. When an alarm is active, the
LEDs indicate the type of alarm as shown in the following
table. If more than one alarm is active at the same time, the
LEDs only show the alarm condition with the highest priori-
ty. Alarm priority follows the order of the table.
When no alarm is active, the user interface automatically
displays pump performance.
Nr. dis-
played Meaning Function Action
LED 1 red
and LED 5
yellow, both
lit
The pump
rotor is
blocked
The pump
automatically
attempts to
start every
1.5 seconds
Wait or
check that
the pump
rotor is free
to rotate
LED 1 red
and LED 4
yellow, both
lit
Supply volt-
age too low
Indica-
tion only.
The pump
continues to
function
Check the
voltage of
the power
supply
LED 1 red
and LED 3
yellow, both
lit
Electronic
controller
error
The pump
has stopped
because
supply
voltage is
too low or
because an
error has
occurred in
the internal
electronic
controller
Check the
voltage of
the power
supply or
replace the
pump
SETTING MODE
Setting display
To switch from performance display to setting display,
press button (1). The LEDs shows the current setting. See
the following table for the meaning of the LED display.
Setting display mode shows the type of pump control or
the currently selected pump curve. Settings cannot be
changed in performance display mode. After 2 seconds,
the display returns to performance display mode.
LED no.1: if red it reveals an alarm or an external control;
if green it indicates the circulator performance or internal
control possibility.
LEDs no. 2 and 3 indicate different control mode possibility
and LEDs no.4 and 5 indicate the curve type setting (1,2,3
or 4). These LEDs are yellow.
PWM mode
LED
1
LED
2
LED
3
LED
4
LED
5
Curve 1 (4.5m) Red - Yel-
low - -
Curve 2 (5.5m) Red - Yel-
low
Yel-
low -
Curve 3 (6.5m) Red - Yel-
low
Yel-
low
Yel-
low
Curve 4 (7.5m) (*) Red - Yel-
low -Yel- low
(*) Factory setting
Direct speed control function.
LED
1
LED
2
LED
3
LED
4
LED
5
Curve 1 (4.5m)
Green
Yel-
low
Yel-
low - -
Curve 2 (5.5m)
Green
Yel-
low
Yel-
low
Yel-
low -
Curve 3 (6.5m)
Green
Yel-
low
Yel-
low
Yel-
low
Yel-
low
Curve 4 (7.5m) (*)
Green
Yel-
low
Yel-
low -Yel- low
(*) Factory setting
Button lock/unlock function
The button lock function serves to prevent improper use or
accidental changes to pump settings.
When the button lock is active, pressing the button has no
effect. This prevents users from accidentally accessing set-
ting mode while allowing them to use setting display mode.
If the button (1) is pressed for more than 10 seconds, it can
be switched to enable / disable the lockout function. In do-
ing so, all the LEDs, with the exception of the red LED, are
ashing for one second to indicate that the lockout function
has been switched.
Setting mode
To modify settings, press the button (1) for 2 to 10 seconds.
The user can select new settings provided that the button
lock function is disabled.
Available settings are displayed in a pre-dened sequence
that is repeated every time the button is briey pressed and
released.
If the button is not pressed for over 10 seconds, the pump
exits setting mode and returns to performance display
mode.
See the table above for the meanings of the LED sequenc-
es.
> 10 s.
SETTING MENUPERFORMANCE
> 2 s.
X
10 s.
2 s.
SELECTED SETTING

INSTALLATION
8
13 ELECTRICAL CONNECTIONS
b
The following is mandatory:
- have an omnipolar magneto-thermal circuit breaker
and a disconnecting switch compliant with the pre-
vailing standards of the installation country
- respect the polarity of the L1 (Phase) - N (Neutral)
connections
- use cables with insulation and cross section con-
forming to applicable standards (minimum cross
section 1.5 mm2)
- refer to the wiring diagrams in this manual for all
electric operations
- make sure the appliance is connected to an efcient
ground (earth).
a
It is strictly forbidden to use pipes of any kind to
ground the appliance.
The manufacturer is not responsible for any damages
due to the missing device grounding.
Refer to the manual supplied with the solar controller
for details of all electrical connections, programming,
etc..
The power supply and PWM signal connections must be
arranged by the technician.
To carry out the electric connections:
- remove the frontal insulation (1).
- the cables must be inserted through the proper pas-
sages (F).
1
F
- connect the connectors as shown in the gure.
PWM CONNEC-
TOR
POWER SUP-
PLY
To control the circulator in on/off mode, the PWM cable is
not required.
To control the circulator in modulating mode by using a
solar regulator, verify the compatibility between the chosen
regulator and the PWM signal (see following paragraph "
CONTROL SIGNALS").
CONTROL SIGNALS
The circulator can be controlled with a low voltage PWM
digital signal (pulse width modulation). The speed changes
according to the input signal, as indicated in paragraph "
PWM input signal".
Here below are the main characteristics required of the
PWM signal output by the associated regulator.
b
Check the characteristics of your regulator PWM sig-
nal to ensure they comply with the features below.
Different signals could irreversibly damage the circu-
lator on-board electronics.
PWM low-voltage digital signal
The PWM square wave signal was designed for a frequen-
cy interval between 100 and 4000 Hz. The PWM signal is
used to set circulator speed.
Example of Duty cycle
T
U
iH
UiL
t
T Period
d Duty cycle (t/T)
UiH High voltage level of input signal
UiL Low voltage level of input signal
IiH Input signal current
Example Evaluation
T = 2 ms (500 Hz) UiH = 4-24 V
t = 0,6 ms UiL ≤ 1 V
d % = 100 x 0.6 / 2 = 30 % IiH ≤ 10 mA (depending
on UiH)

9
COMMISSIONING AND MAINTENANCE
PWM input signal
With a low input value (<5 % PWM), the pump cannot start.
The pump stops when input signal is 5 to 8% of PWM signal
or when PWM signal is not present, for safety reasons. If
the pump receives no input, due for instance to failure of
the signal cable, it will stop in order to avoid solar system
overheating.
Speed (%)
0 5 10
100
20 30 40 50 60 70 80 90 100
PWM input signal (%)
Electronic circuit
PWM output
PWM input
Reference
signal
Opto-isolator
Pump electronics
Technical specications
Maximum power Symbol Value
PWM input frequency f 100-4000 Hz
Consumption in stand-by < 1 W
High voltage level of input
signal UiH 4-24 V
Low voltage level of input
signal UiL < 1 V
Input signal current IiH < 10 mA
Input Duty cycle PWM 0-100%
14 SYSTEM FLUSHING
Before lling the system with mixture of water and glycol, it
is necessary to ush the pipes of the solar system to elimi-
nate all residues of uid or scale.
Proceed as follows.
- Verify the ow-meter (C) is completely open
- Turn handle on valve (VR) clockwise
- Open taps (A) and (B) on the return tube
- Flush water in through the cock (B) and wait for it to
come out of the cock (A)
- Allow water to come out for at least 30 seconds
- Turn handle on valve (VR) counter clockwise
- Close taps (A) and (B).
b
During system ushing, pay attention to water com-
ing out of the taps as vapour could be released with
risk of burns or scalds. Use suitable personal protec-
tive equipment.
A
VR
B
RC
90°
0°
R
Position of the knob
of the return valve VR
Flow in
single direction
(non-return
valve function)
Flow
stopped
Commissioningandmaintenance

COMMISSIONING AND MAINTENANCE
10
b
If copper piping has been used and joints have been
hot brazed, ush out the system to remove any braz-
ing residues. Seal test the system after you have
ushed it out.
b
The solar circuit must be immediately lled with a
mixture of water and glycol, that avoids freezing and
corrosion.
15 SYSTEM FILLING COCK
Before lling the system:
- Cut power off to the solar station and to the connect-
ed integration system, by setting the system's main
switch and the device's main switch to OFF
b
Always use a mixture of water and glycol suitable for
solar applications. Choose the mixture according to
the minimum temperature that can be reached at the
installation site and to the maximum service tempera-
ture of solar collectors. For further information, please
refer to the glycol safety data sheet.
When using glycol not pre-mixed:
- Do NOT part ll the circuit with pure glycol then add
water later.
- Ensure that lling water characteristics comply with
prevailing regulations; if that is not so, lling water
must be treated. Use portable treatment systems, for
instance. In particular, when chlorine content is very
high (> 50ppm) you must use distilled water for the
mixture.
VR
B
A
C
Mixture
of glycol
and water
PC
PC Heat transfer uid lling pump
To ll the system, proceed as follows:
- Verify the ow-meter (C) is completely open
- Connect the lling pump (PC) as shown
- Turn handle on valve (VR) clockwise
Open taps (A) and (B) on the return tube
- Open manual degassing tap and any bleeder valve,
located at the highest points of the system, and keep
them open throughout the lling procedure.
- Pump the heat transfer uid around the circuit with an
external lling pump until all air bubbles have been
eliminated. Close the manual bleed valve and any
vent valves opened previously.
- Turn handle on valve (VR) counter clockwise
- Temporarily raise the pressure in the system to 4 bar.
- Start up the system for about 20 minutes.
- Repeat air bleeding operation until system is com-
pletely free of air bubbles.
- set the system pressure.
- Close taps (A) and (B).
b
The set pressure must ensure that the one measured
at the solar collectors is positive with respect to the
ambient one (avoid depression in the solar eld) and
must be set considering both the safety valve open-
ing pressure (6) and the solar expansion reservoir
pre-charge pressure. To set the system pressure cor-
rectly, refer to the design manual.
a
Do not ll the system in bright, sunny conditions or if
the collectors are hot.
b
Use a manual bleed valve, which should be installed
at the highest point in the system, to ensure that all air
bubbles have been eliminated from the circuit.

COMMISSIONING AND MAINTENANCE
11
16 DEVICE CLEANING AND
MAINTENANCE
b
Service the system at least once a year and carry out
the inspections specied in the relevant manual.
The following operations must be exclusively performed by
Technical Assistance Centre.
16.1 Checking the seals
After commissioning, check hydraulic tting sealing. Make
sure there is no leakage close to electric components to
avoid short-circuits.
16.2 External cleaning
If dust accumulates on the insulation, clean it with a dry
cloth.
a
Do not use abrasive products, petrol or triethylene.
17 INTERVENTIONS ON THE
HYDRAULIC SYSTEM
17.1 Draining the system
- Connect a rubber hose to taps (A) and (B)
- Connect the opposite end to a vessel
- Open system drain taps and allow full drainage
- Close system drain taps and remove the rubber hose
- The exhausted heat transfer uid must be disposed
of according to the prevailing regulations, pursuant
to the instructions provided in the safety data sheet
supplied with the glycol.
17.2 Disassembling the circulator
b
Remove the circulator when system has cooled down.
Before removing circulator (C):
- Cut power off to the solar station and to the connect-
ed integration system, by setting the system's main
switch and the device's main switch to OFF
- Disconnect circulator power by removing connectors
(D) and (E)
- Move away any wiring and electric devices below to
protect them against any leakage of heat transfer uid
- Close the valve (VR) by turning the handle 90° clock-
wise
- Open taps (A) and (B) and drain the solar circuit
- Loosen ring nuts (H1) and (H2) and remove circulator
(C).
R
RB
VR
A
B
C
H2
H1
E
D
Reverse the above steps to t the new pump.
Fill the solar circuit as described in paragraph "System ll-
ing cock".
18 RECYCLING AND DISPOSAL
The device is primarily composed of:
Material Component
metal materials tubes, circulator
EPP (polypropylene foam) insulation
electrical and electronic
components cable and wiring, circulator
At the end of the device's useful life, these components
must be separated and disposed of according to current
regulations in the country of installation.

20123006 - Rev. 1 (05/17)
Via Risorgimento, 23 A
23900 - Lecco (LC)
www.berettaboilers.com
The manufacturer strives to continuously improve all products. Appearance, dimensions, technical
specications, standard equipment and accessories are therefore liable to modication without notice.