CALEFFI DeltaSol 268050 Guide

Circulation units
for solar thermal systems, with solar regulator DeltaSol® C+
28199
268-269 series
Function
Circulation units ar us d on th primary circuit of
solar th rmal syst ms to control th t mp ratur
in th hot wat r storag . Th pump insid th
units is activat d by th signal arriving from th
r gulator. Mor ov r, saf ty and functional d vic s
for optimum control of th circuit ar fitt d in th
units.
Th y ar availabl with flow and r turn conn ction
or with r turn conn ction only.
Som v rsions ar also compl t with th digital
r gulator D ltaSol®C+ for solar th rmal syst ms,
suitabl for th op ration and control of 9 diff r nt
typ s of solar th rmal syst ms.
1
INDEX
Function
Product range
Technical specifications
Characteristic components
Installation
Filling the system
Commissioning
1
2
3
4
5
6
Components 7
Application diagrams 8
INSTALLATION AND COMMISSIONING MANUAL

NOTICE
The followin instructions must be read and understood before installin , commissionin and
servicin the circulation unit.
Th saf ty symbol is us d in this manual to draw att ntion to th r sp ctiv saf ty instructions.
Th m aning of this symbol is as follows:
N.B! YOUR SAFETY IS INVOLVED. FAILURE IN FOLLOWING THESE INSTRUCTIONS MAY
RESULT IN INJURIES.
- Th circulation unit for solar th rmal syst ms must b install d by a qualifi d t chnician in complianc with
r l vant national and/or local r gulations.
- If th circulation unit is not install d, commission d and s rvic d corr ctly in accordanc with th instructions
giv n in this manual, it might not work prop rly and could put th us r in dang r.
- Mak sur that all conn ction fittings ar wat rtight.
- Wh n r alising hydraulic conn ctions, mak sur that thr ad d conn ctions ar not ov rstr ss d m chanically.
Ov r tim , xc ssiv str ss may caus br akag s with hydraulic l aks and damag to prop rty and/or p rsonal injury.
- Wat r t mp ratur s xc ding 50°C may caus s v r burns.
- Wh n installing, commissioning and s rvicing, tak th n c ssary pr cautions so that th s t mp ratur s will not
b hazardous for p opl .
CAUTION: Risk of electric shock. Remove the power supply before carryin out any work.
Failure in followin these instructions may result in personal injury or dama e to
property.
2
Product range
Cod 268050 Circulation unit with r turn conn ction 1–13 l/min siz 3/4”
Cod 269050 Circulation unit with flow and r turn conn ction 1–13 l/min siz 3/4”
Cod 268250 Circulation unit with r turn conn ction, with r gulator D ltaSol
®
C+ 1–13 l/min siz 3/4”
Cod 269250 Circulation uniti with flow and r turn conn ction, with r gulator D ltaSol
®
C+ 1–13 l/min siz 3/4”
Package content
Th packag contains:
Circulation units
• Th solar circulation unit compl t with front
and r ar insulation.
• Th wall fixing brack t.
Regulator (only for v rsions compl t with)
• Solar r gulator D ltaSol®C+.
• 4 t mp ratur prob s.
Accessories:
• Bag of 2 M5 scr ws, S6 scr w anchors and
wash rs.

3
Technical specifications
Materials
Shut-off valves
Body: brass EN 12165 CW617N
Ch ck valv : brass EN 12164 CW614N
T mp ratur gaug : st l / aluminium
Air se arator device
Body: brass EN 12165 CW617N
Instrument holder
Body: brass EN 12165 CW617N
S als: EPDM
O-Rings: EPDM
Flow meter
Body: brass EN 12165 CW617N
Transpar nt l v l gaug : PSU
Flow indicator: brass EN 12164 CW614N
Hydraulic s als: EPDM
Insulation
Mat rial: EPP
Av rag thickn ss: 30 mm
D nsity: 45 kg/m3
Working t mp ratur rang : -5 – 120°C
Th rmal conductivity: 0,037 W/(m·K) at 10°C
R action to fir (UL 94): class HBF
Performance
M dium: wat r, glycol solutions
Max. p rc ntag of glycol: 50%
Max. working t mp ratur : - d a rator sid flow: 160°C
- pump sid r turn: 110°C
Max. working pr ssur : 10 bar
Saf ty r li f valv working t mp ratur rang : -30–160°C
Saf ty r li f valv s tting: 6 bar (for oth r s ttings, s 253 s ri s)
Ch ck valv min. op ning pr ssur (∆p): 2 kPa (200 mm w.g.)
Working t mp ratur rang of shut-off and ch ck valv : -30 – 160°C
Working t mp ratur rang of flow m t r : -10 – 110°C
Flow rat adjustm nt: 1–13 l/min
Flow rat indicator accuracy: ±10%
Pr ssur gaug scal : 0–10 bar
T mp ratur gaug scal : 0-160°C
Conn ctions: 3/4” F
Hos conn ction: 3/4” M
Fill/drain conn ctions: with Ø 15 mm hos conn ction
Grundfos Solar 15-65 um
Body: cast iron GG 15/20
El ctric supply: 230 V - 50 Hz
Max. pr ssur : 10 bar
Max. t mp ratur : 110°C
Prot ction class: IP 42
Digital regulator
El ctric supply: 230 V - 50 Hz
Nominal pow r consumption: 1,5 VA (12 V (ac))
4 Pt1000 prob inputs
2 r lay outputs with s miconductor with contact rating: 1 A
2 t mp ratur prob s with working rang : -50
– 200°C
Prob cabl working t mp ratur rang : -50 – 70°C
2 t mp ratur prob s with working rang : -50 – 200°C
Prob cabl working t mp ratur rang : -50 – 180°C
Ambi nt t mp ratur rang : 0 – 40°C
Prot ction class: IP 20
Dim nsions: 172 x 111 x 49 mm
Head available at the circulation unit connections
00
H (mm w.g.)
G (m3/h)
H (kPa)
0
1
2
3
UPS 15-65
6
5
4
3
2
1
60
50
40
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10
0,2 0,4 0,6 0,8 1,0 1,2 1,4 00
H (mm w.g.)
G (m3/h)
H (kPa)
0
1
2
3
UPS 15-65
6
5
4
3
2
1
60
50
40
30
20
10
0,2 0,4 0,6 0,8 1,0 1,2 1,4
Power consum tion
0
P (W)
G (m3/h)
20
30
40
50
60
70
80
0,2 0,4 0,6 0,8 1,0 1,2 1,4
1
2
3
UPS 15-65
268 series Flow rat adjustm nt rang 1 – 13 l/min 269 series Flow rat adjustm nt rang 1 – 13 l/min

4
Characteristic components
1) Grundfos Solar 15-65 circulation pump
2)
Saf ty valv with adjustabl outl t typ 253 s ri s
3) Fill/drain cock with control k y
4) Instrum nt hold r fitting with pr ssur gaug
5) Flow m t r
6) D a rator with air v nt
7) Flow t mp ratur gaug
8) R turn t mp ratur gaug
9) Pr -form d sh ll insulation
10) Shut-off valv with built-in ch ck valv
11) Conn ction kit for xpansion v ss l (optional)
12) Display with synoptic diagram and t mp ratur indication*
13) R gulating k ys*
14) T mp ratur prob *
15) Stainl ss st l prob pock t cod 257004 (optional)
16) Hos conn ction
* only for v rsions with D ltaSol®C+ r gulator
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75°65°
12°
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5
Installation
• Fix th wall support brack t, using th fixing scr ws suppli d in th pack (1).
• Ins rt th r ar insulation, through th notch provid d (2).
• Ins rt th unit compon nts in th insulation using th sp cial notch s mad in th brack t and th slots in th compon nts. Block th
compon nts on th brack t, pulling th m downwards to that th y click into th ir housing (3).
• Establish th position for installing th xpansion v ss l at a distanc allow d by th l ngth of th fl xibl pip , using th brack t provid d.
Th latt r allows th us of xpansion v ss ls with a maximum capacity of 24 l, s th instructions conc rning th acc ssori s (4).
• Install th pip s of th whol syst m and conn ct th solar unit. S cur th compon nts and th pip s to th r ar insulation.
Fully tight n all th fittings.
• Th unit’s thr ad d fittings ar tight n d and t st d in th ass mbly phas at th factory. How v r, wh n commissioning it is n c ssary to
ch ck th s al of th fittings, p rforming a pr ssur t st.
• Mak th l ctrical conn ctions of th syst m, as sp cifi d in th r gulator instruction manual. Apply th front part of th insulation.
Fillin the system
• Op n th shut-off valv coupl d with th automatic air v nt, install d in th high st point of th solar th rmal syst m (1).
• Op n th shut-off and ch ck valv s, turning th control st ms (2) through 45° (do not r mov th t mp ratur gaug s).
• Fill by m ans of a pump, using th cock (A) locat d at th low st point of th syst m, until air no long r com s out of th air v nt (1). If th
solar th rmal syst m is mad using wat r pr mix d with antifr z , any top-ups must b carri d out using a mixtur with th sam
proportions.
• Clos th shut-off valv of th air v nt (3).
• Clos th cock (A).
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1234
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3

Commissioning
• Clos th flow m t r fil/drain cock (1) and incr as th syst m pr ssur up to th maximum d sign pr ssur , by m ans of th xt rnal filling
pump appli d to th fill/drain cock of th saf ty unit. Wh n this pr ssur is r ach d (2), clos th fill/drain cock of th saf ty unit using th cap
quipp d with control k y.
• Op n th valv s of th unit (3) and switch on th pump of th solar circulation unit (do not r mov th t mp ratur gaug s).
• L t th wat r circulat for a c rtain tim , th n ch ck th wat r tightn ss.
• Op n th air v nt again, install d in th high st point of th solar th rmal syst m, r p ating th d a ration phas , bri fly activating th
circulation pump.
• R stor th d sir d working pr ssur with th filling pump.
• Th syst m flow rat may b chang d by m ans of th flow m t r (4). This modulation is p rform d by th ball valv with which it is
quipp d (s r sp ctiv charact ristics). To r gulat /limit th flow rat it is r comm nd d to follow th indications of th solar pan l
manufactur r.
• Aft r th first op rating hours, th solar th rmal syst m must b d a rat d again, both in th high st point and on th air s parator (on th
v rsions wh r this is cont mplat d).
Onc d a ration has b n compl t d, ch ck th syst m pr ssur and if n c ssary r stor to th d sir d working pr ssur .
Draining the s stem
• Th draining op ration is n c ssary if th syst m has b n fill d only with wat r and th r is a risk of frost.
• Op n th shut-off and ch ck valv s, turning th ball valv through 45°. Op n th air v nts in th high st point.
• Op n th drain cock at th low st point of th syst m.
Flushing the s stem
•
Clos th flow m t r r gulating ball valv (1). Th n op n th fill/drain cock, by turning it count r-clockwis using th cap with control k y (2).
• By m ans of a (s parat ) xt rnal pump appli d on th fill/drain cock of th saf ty unit (3), l t th m dium flow through th solar pan ls and
th h at xchang circuit until th m dium com s out of th fill/drain cock (4) of th flow m t r.
• Bri fly op n th flow m t r ball valv (4) to xp l all th air from th syst m.
• L av th xt rnal pump running on th syst m for a f w minut s to nsur corr ct flushing.
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6

Shut-off and check valves
Th shut-off valv s ar quipp d with a built-in ch ck valv ,
position d insid th ball.
1. To allow th passag of th fluid
in both dir ctions, th ball valv s
must b op n d at 45°, using a
9 mm fix d wr nch.
Th ch ck valv is op n d by th
ball, s figur (A).
2. In normal syst m op ration, th
ball valv s must b compl t ly
op n.
Air separator device
Th solar circulation units with flow and r turn conn ction ar
quipp d with an air s parator d vic on th flow lin . Th gas s
s parat d from th th rmal carri r m dium coll ct at th top of th
d a rator.
Th coll ct d gas s must b vacuat d from tim to tim ( v ry
day aft r commissioning and aft rwards, d p nding on th
quantity of air, onc a w k or onc a month) using th manual air
v nt with a suitably siz d scr wdriv r.
To maintain optimal ffici ncy of th solar th rmal syst m,
aft rwards, it is n c ssary to
v nt th syst m v ry six
months by using th d a rator.
A
Full closing and opening of the valve
Th valv can b
compl t ly op n d or
clos d.
A slot on th obturator
st m indicat s th
status of th valv .
Correction for liquids with different density
Th variation in th flow rat r ading r mains within th rang of
accuracy indicat d (±10%), for glycol p rc ntag s up to 50%.
Fully closed Fully o en
7
Captiv nut
Flow rat adjustm nt
Fitting 1/2” F
Graduation
Fitting 3/4” F
Flow meter
Th flow m t r is a floating gaug flow rat m asurator with a
built-in r gulating ball valv .
It works within th rang of 1–13 l/min.
The flow meter must be fitted in a vertical osition only.
A th rmom tric lab l is plac d on th back of th flow m t r to
signal if th maximum p rmitt d t mp ratur (110°C) has b n
xc d d:
whit color = t mp ratur not xc d d;
dark color = maximum t mp ratur xc d d.
Th lab l r moval mak s th manifactur r warranty on th d vic
xpir .
Th l v l is tak n from th
top dg of th float.
N.B! Us only a
9mm fix d
wr nch to r gulat th flow
m t r.
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➜
➜
open closed
2
3
0
°
F
1
1
0
°
C
Thermometric
label
AB

Application diagrams
Shut-off valve
Pump
Air vent
Expansion vessel
Temperature gauge
Safety relief valve
Automatic
filling
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Shut-off valve
Pump
Air vent
Expansion vessel
Temperature gauge
Safety relief valve
Automatic
filling
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