Extraflame PS AS1 User manual

SOLAR KIT INSTALLATION
MANUAL

2

3
Index
Chapter 1
WARNINGS AND SAFETY DEVICES......................................................................................................5
Chapter 2
COMPONENT DESCRIPTION ................................................................................................................7
PS AS1..................................................................................................................................................................................... 8
BSV 150 ES ..........................................................................................................................................................................10
BSV 300 ................................................................................................................................................................................11
BSV 300 ES ..........................................................................................................................................................................12
TPS 500.................................................................................................................................................................................14
TPS 1000 ..............................................................................................................................................................................15
SRA 1,5 .................................................................................................................................................................................16
SRA 3.....................................................................................................................................................................................16
SRA 5.....................................................................................................................................................................................16
GSC1......................................................................................................................................................................................17
GSC 2.....................................................................................................................................................................................17
CS 3.1 ....................................................................................................................................................................................18
CS 3.2 ....................................................................................................................................................................................18
VES 18...................................................................................................................................................................................19
VES 355080......................................................................................................................................................................19
GAG 20 .................................................................................................................................................................................20
Chapter 3
DIMENSIONING...................................................................................................................................21
INCLINATION OF THE COLLECTORS.........................................................................................................................21
PRODUCTION OF JUST DOMESTIC HOT WATER .................................................................................................22
PRODUCTION OF HOT WATER AND INTEGRATION TO HEATING .................................................................24
HEATING SWIMMING POOLS......................................................................................................................................25
Chapter 4
SERIES/PARALLEL CONNECTION LAYOUTS AND PANEL ARRAYS .................................................26
Chapter 5
SLOPING ROOF....................................................................................................................................29
DESCR5IPTION OF THE ASSEMBLY COMPONENTS FOR 1 OR 2 PANEL KIT..............................................29
LOADS DUE TO THE WIND OR SNOW......................................................................................................................29
ASSEMBLY PHASE............................................................................................................................................................31
Chapter 6
FLAT ROOF ...........................................................................................................................................34
PREMISE...............................................................................................................................................................................34
COMPONENT DESCRIPTION........................................................................................................................................34
ASSEMBLY INSTRUCTIONS ..........................................................................................................................................36
MULTIPLE COMPOSITION OF THE KITS...................................................................................................................40
3 PANELS: KIT 1 + KIT 2 ..................................................................................................................................................40
4 PANELS: KIT 2 + KIT 2 ..................................................................................................................................................40
5 PANELS: KIT 1 + 2 X KIT 2...........................................................................................................................................41
FIXING THE MULTIPLE KITS..........................................................................................................................................41
FIXING THE ARRAYS........................................................................................................................................................41
6 PANELS: 2 X KIT 1 + 2 X KIT 2....................................................................................................................................41
8 PANELS: 4 X KIT 2..........................................................................................................................................................42

4
10 PANELS: 2 X KIT 1 + 4 X KIT 2.................................................................................................................................42
INCLINATION OF THE PANELS ....................................................................................................................................43
SHADOWING .....................................................................................................................................................................43
DISTANCE FROM THE EDGE OF THE ROOF............................................................................................................44
Chapter 7
TEMPERATURE PROBE AND HYDRAULIC SUPPLY CONNECTION ASSEMBLY ..............................45
Chapter 8
HYDRAULIC SYSTEM...........................................................................................................................47
INDICATIONS OF THE TYPE AND DIAMETERS OF THE PIPES .........................................................................47
CONNECTION OF THE PUMP UNIT...........................................................................................................................51
DIMENSIONING AND CONNECTION OF THE EXPANSION VESSEL...............................................................53
CONNECTION TO THE STORAGE TANK....................................................................................................................56
CONNECTION OF THE BSV 300, BSV 150 ES CYLINDER....................................................................................56
CONNECTION OF THE PUFFER...................................................................................................................................57
Chapter 9
ELECTRONIC CONTROL UNIT.............................................................................................................59
ELECTRIC ATTACHMENT...............................................................................................................................................60
INSTALLATION...................................................................................................................................................................60
ASSEMBLY...........................................................................................................................................................................60
USE AND FUNCTIONING...............................................................................................................................................62
COMMISSIONING.............................................................................................................................................................64
CONTROL PARAMETERS AND DISPLAY CHANNELS..........................................................................................65
Chapter 10
STARTUP.............................................................................................................................................76
WASHING THE SOALER CIRCUIT................................................................................................................................76
SEALING CHECK ...............................................................................................................................................................77
WASHING THE SOLAR CIRCUIT ..................................................................................................................................77
DILUTING THE GLYCOL TO THE DESIRED CONCENTRATION..........................................................................78
FILLING THE SOLAR CIRCUIT.......................................................................................................................................80
SETTING THE COLLECTOR AND SYSTEM FLOW RATE.......................................................................................81
CHECKING THE SETTINGS OF THE ADJUSTMENT CONTROL UNIT..............................................................82
SETTING THE DOMESTIC HOT WATER MIXER.......................................................................................................82
FILING THE BSV 300, BSV 300 ES AND BSV 150 ES TANK ................................................................................82
Chapter 11
MAINTENANCE....................................................................................................................................83
Chapter 12
WARRANTY TERMS .............................................................................................................................85
Chapter 13
WARRANTY DOCUMENT ....................................................................................................................87

5
WARNINGS AND SAFETY DEVICES
Chapter 1
WARNINGS AND SAFETY DEVICES
Read the assembly and commissioning instructions carefully. Make sure that assembly takes place in
compliance with recognised technical standards. Also comply with the insurance accident-prevention
standards against injury in the work place. Use that does not comply with the Standards as well as the
implementation of unallowed modications during assembly exclude any responsibility of Extraame
S.p.A.
Follow the following Standards particularly:
DIN 4757, 1st part DSolar heating systems with water and water mixtures as heat transfer medium;
Demands to the safety realisation.
DIN 4757, 2nd part DSolar heating systems with organic heat transfer medium; Demands to safety
realisation.
DIN 4757, 3rd part DSolar heating systems; solar collectors; Meanings; safety regulations; Testing of
standstill temperature.
DIN 4757, 4th part DSolar thermal systems; solar collectors; determination of eciency, heat capacity
and pressure loss.
Also comply with the following European CE Standards:
UNI-EN 12975-1 Thermal solar systems and components, 1st part: general requirements.
UNI-EN 12975-2 Solar heating systems and their components; collectors, 2nd part: test methods.
UNI-EN 12976-1 Thermal solar systems and components; factory made systems, 1st part: general
requirements.
UNI-EN 12976-2 Thermal solar systems and components; factory made systems, 2nd part: test methods.
UNI-EN 12977-1 Thermal solar custom build systems and components, 1st part: general requirements.
UNI-EN 12977-2 Thermal solar custom build systems and components, 2nd part: test methods.
UNI-EN 12977-3 Thermal solar custom build systems and components, 3rd part: hot water tank eciency
check.
The Standards and Directives of the place of installation regarding assembly and operation of the
plant must be complied with.
General precautions
The work position must be clean and free from objects that could be an obstruction.
The work place must be well-lit.
Keep children, pets and persons not in charge of works out of the reach of tools and work positions.
Keep heat transfer uid out of the reach of children.
If the work position is changed, disconnect all electrical appliances from the sockets or make sure
they cannot be switched on accidentally.
Wear suitable work clothes: accident-prevention shoes, helmet and protective goggles.
Arrange anti-fall guards as requested by the Standards.
If high voltage cables are present in the vicinity, remove the current for the entire duration of the
work and respect safety distances in compliance with national standards.
If the solar collectors are installed temporarily without heat carrying uid inside, they must be
protected from the sun’s rays in order to prevent them overheating

6
Chapter 1
WARNINGS AND SAFETY DEVICES
gure 1.1
gure 1.2

7
COMPONENT DESCRIPTION
Chapter 2
COMPONENT DESCRIPTION
All kits supplied by La Nordica & Extraame are made up from the various combinations of the components
described above. The conguration of the kits and their features are described in the sales publications
and in the price lists.
EXTRAFLAME PS AS1:highly selective at solar panels 1946 x 946 x 105 mm.
BSV 150 ES:150 litre domestic hot water cylinder with single coil, with magnesium anode as per
series and external tester (replaceable alternatively with an optional electronic electrode with titanium
impressed current).
BSV 300:300 litre domestic hot water cylinder with double coil, with magnesium anode as per
series and external tester (replaceable alternatively with an optional electronic electrode with titanium
impressed current) and prepared for additional electric resistance.
BSV – ES 300:300 litre domestic hot water cylinder with single coil, with magnesium anode as per
series and external tester (replaceable alternatively with an optional electronic electrode with titanium
impressed current) and prepared for additional electric resistance.
TPS 500:500 litre storage puer without instant domestic hot water coil.
TPS 1000:1000 litre storage puer without instant domestic hot water coil.
SRA 1.5:1.53 m2nned copper coil for the production of domestic hot water or additional heating.
SRA 3:3.17 m2nned copper coil for the production of domestic hot water or additional heating.
SRA 5:5.26 m2nned copper coil for the production of domestic hot water or additional heating.
GSC 1:Single, one-pipe, circulation pump unit without deaerator.
GSC 2:Double, two-pipe, circulation pump unit with deaerator.
CS 3.1:electronic control unit with 3 probes and one relay output for the solar pump.
CS 3.2:electronic control unit with 3 probes and two output relays for the solar pump and aux.
boiler.
VES 18:18 litre solar expansion vessel.
VES 35 – 50 – 80:35 – 50 – 80 litre solar expansion vessel.
GAG 20:20 l / 21 kg can of concentrated glycol anti-freeze to be diluted in relation to the freezing
limit temperature of the area of installation.

8
Chapter 2
COMPONENT DESCRIPTION
PS AS1
Highly selective at solar panels
Dimensions LxHxP 1946 x 946 x 105 mm
Gross surface 1.84 m2
Surfaces of the opening 1.65 m2
Absorber surfaces 1.62 m2
Empty weight with glass 36 kg
Glass Hardened prismatic with 4mm thickness with low iron content
Absorber Copper with highly selective Tinox covering
Type of construction Lyra (ultrasound welding)
Pipes material Copper
Connection dimension ¾”
Absorbance 95 %
Emission 3 %
ηo 0,732
a1 3,771 W/(m2K)
a2 0,011 W/(m2K2)
Maximum working pressure 10 bar
Standstill temperature 211 °C
Fluid content ~ 1 l
Working ow rate 60 – 100 l/h
Insulation Mineral wool
Insulation thickness Lower: 50 mm
Lateral: 20 mm
Structure Aluminium with electrostatic treatment
Gasket EPDM – Silicone
gure 2.1

0
0,1
0,2
0,3
0,4
0,5
0,6
0,7
0,8
0,9
1
0 0,01 0,02 0,03 0,04 0,05 0,06 0,07 0,08 0,09 0,1
9
COMPONENT DESCRIPTION
Chapter 2
η
(Tm - Ta)/ l* (m2K/W)
Eciency curve (l* = 800W/m2)
gure 2.2
gure 2.3
gure 2.4

127
245
555
685
813
405
715
910
1"AG
3/4"AG
3/4"AG
1"AG
ø17,2
1"1/4
øest.54
Tubo
26x2
445
1/2"IG*
3/4"AG
A
B
C
D
E
F
G
H
I
45
500
10
Chapter 2
COMPONENT DESCRIPTION
BSV 150 ES
150l vitried single coil domestic hot water cylinder.
Diameter x Height 650 x 960 mm (with insulator)
Capacity 150 l
Weight 81 kg
Internal treatment Two-coat vitrication
Solar coil surfaces 0,75 m2
Solar coil liquid volume 4,2 l
Maximum working pressure 6 bar
Insulation Rigid polyurethane 50 mm
External covering Sky
Coils hydraulic connections 3/4”
Protection from corrosion Magnesium anode – as per series (gure 2.8)
Titanium anode – optional (gure 2.9)
AMagnesium anode or electronic with titanium FSolar cold return
BDomestic hot water output GDomestic cold water input + exp. vessel
CSolar heat ow HInspection ange
D6 bar safety valve/circulation IThermometer
ETemperature probe
gure 2.5

155
255
780
880
980
1245
1335
415
835
1255
1480
1"AG
3/4"AG
3/4"AG
3/4"AG
3/4"AG
1"AG
ø17,2
1"1/2IG
1"1/4
øest.54
26x2
65
520
1/2"IG*
3/4"AG
45
1/2"IG*
1080
mq. 1,21
mq. 0,9
AB
C
D
L
E
F
G
H
I
M
N
O
550
11
COMPONENT DESCRIPTION
Chapter 2
BSV 300
300 l vitried double coil domestic hot water cylinder.
Diameter x Height 650 x 1515 mm (with insulator)
Capacity 300 l
Weight 121 kg
Internal treatment Two-coat vitrication
Solar coil surfaces 1,21 m2
Solar coil liquid volume 6,7 l
Coil surfaces integration 0,9 m2
Maximum working pressure 6 bar
Insulation Rigid polyurethane 50 mm
External covering Sky
Coils hydraulic connections 3/4”
Protection from corrosion Magnesium anode – as per series (gure 2.8)
Titanium anode – optional (gure 2.9)
AMagnesium anode or electronic with titanium HTemperature probe
BDomestic hot water output ISolar cold return
CAdditional boiler ow LDomestic cold water input + exp. vessel
DTemperature probe MInspection ange
E6 bar safety valve/circulation NElectric resistance
FAdditional boiler return OThermometer
GSolar heat ow
gure 2.6

155
255
780
980
1335
415
835
1255
1480
1"AG
3/4"AG
3/4"AG
1"AG
ø17,2
1"1/2IG
1"1/4
øest.54
26x2
65
520
1/2"IG*
3/4"AG
45
AB
C
D
E
F
G
H
I
L
550
12
Chapter 2
COMPONENT DESCRIPTION
BSV 300 ES
300 l vitried single coil domestic hot water cylinder.
Diameter x Height 650 x 1515 mm (with insulator)
Capacity 300 l
Weight 106 kg
Internal treatment Two-coat vitrication
Solar coil surfaces 1,21 m2
Solar coil liquid volume 6,7 l
Maximum working pressure 6 bar
Insulation Rigid polyurethane 50 mm
External covering Sky
Coils hydraulic connections 3/4”
Protection from corrosion Magnesium anode – as per series (gure 2.8)
Titanium anode – optional (gure 2.9)
AMagnesium anode or electronic with titanium FSolar cold return
BDomestic hot water output GDomestic cold water input + exp. vessel
C6 bar safety valve/circulation HInspection ange
DSolar heat ow IElectric resistance
ETemperature probe LThermometer
gure 2.7

TR
F
23
0 V, 50 Hz
TE
F
13
COMPONENT DESCRIPTION
Chapter 2
The150or300litredomestichotwatercylinderissuppliedasperstandardwitha sacricialmagnesiumanode
with duration tester. This detail is subject to natural wear and is consumed in variable times depending on
the features of the water It must therefore be checked periodically in order to protect the cylinder suitably.
The alternative solution proposed by Extraame in order to have a constant protection through time,
independently from the controls, and therefore to obtain the extension of the warranty period up to 5 years,
is the replacement of the magnesium anode with a titanium anode.
This electronicaccessory automaticallydistributestheimpressedcurrentsina waytopreventcorrosioninside
the tank. Replacement of the standard anode with the optional electronic one takes place by removing the
rst from the upper part of the cylinder (after having disconnected the connection wire to the tester that
remains in its position), inserting and connecting the new accessory according to the methods described in
the “Assembly and Use instructions” attached to the detail.
Magnesium anode with tester (as per standard) Titanium anode with impressed current (optional)
Conguration as per standard with magnesium anode Optional conguration with titanium anode
The gures above indicate the earth of the anodes and tanks. The yellow-green cable exiting the tank is
relative to the tester (TE). The tank must be connected to earth by means of an equipotential band applied
onto a pipe.
Symbol Description
FBand for equipotential connections
TE Magnesium anode tester
TR Titanium anode transformer
gure 2.8 gure 2.9
gure 2.10 gure 2.11

230
410
630
715
920
1040
1220
1270
1380
1595
30 150 1250 150
15
1/2"
1"1/2
1/2"
1/2"
1"1/2
1/2"
1"1/2
1/2"
1"1/2
1/2"
1/2"
1"1/2
1"1/2
1"1/2
1"1/2
1"
1"
500
Disco Separatore
Tipo "HP 650"
A
B
B
B
B
B
B
C
C
D
E
F
D
E
F
G
H
I
L
650
14
Chapter 2
COMPONENT DESCRIPTION
TPS 500
500l storage accumulator.
Diameter x Height 850 x 1,680 mm (with insulator)
Capacity 500 l
Storage tank material Very thick carbon steel
Solar coil material Carbon steel
Weight 135 kg
Solar coil surfaces 2,3 m2
Solar coil liquid volume 10 l
Maximum working pressure 3 bar
Removable insulation Polyurethane 100 mm
Covering Soft PVC
Stratication device Yes
Solar coil hydraulic connections 1”
A3 bar safety valve + vent FLow temperature heating return/wood boiler
return
BTemperature probe GFlange for domestic hot water coil
CBoiler ow HFlange for boiler coil
DHeating ow ISolar heat ow
EHigh temperature heating return/pellet boi-
ler return LSolar cold return
gura 2.12

170 1650 170 1530
1/2"
2.5
2.5
Fondo Ø790
TDB
1"1/2
1"
1"1/2
1"1/2
1"1/2
1/2"
1"1/2
1/2"
1"1/2
1/2"
Separatore
tipo "HP790"
1/2"
1"1/2 1"1/2
1/2"
1/2"
800
1"
250
520
950
1035
1335
1640
1690
1800
2035
A
B
B
B
B
B
B
C
D
E
F
C
D
E
F
G
H
I
L
790
15
COMPONENT DESCRIPTION
Chapter 2
TPS 1000
1,000 l storage accumulator.
Diameter x Height 990 x 2,120 mm (with insulator)
Capacity 1000 l
Storage tank material Very thick carbon steel
Solar coil material Carbon steel
Weight 186 kg
Solar coil surfaces 3 m2
Solar coil liquid volume 18 l
Maximum working pressure 3 bar
Removable insulation Polyurethane 100 mm
Covering Soft PVC
Stratication device Yes
Solar coil hydraulic connections 1”
A3 bar safety valve + vent FLow temperature heating return/wood boiler
return
BTemperature probe GFlange for domestic hot water coil
CBoiler ow HFlange for boiler coil
DHeating ow ISolar heat ow
EHigh temperature heating return/pellet boi-
ler return LSolar cold return
gura 2.13

16
Chapter 2
COMPONENT DESCRIPTION
SRA 1,5
1.53 m2 nned copper coil
SRA 3
3,17 m2 nned copper coil
SRA 5
5.26 m2 nned copper coil
SRA 1,5 SRA 3 SRA 5
Length 345 mm 565 mm 800 mm
Diameter 200 mm 200 mm 200 mm
Hydraulic connections 3/4” 3/4” 1” 1/4
Surfaces 1,53 m23,17 m25,26 m2
Power than can be exchanged* 30 kW 60 kW 105 kW
Domestic hot water maximum ow rate 12 l/min 23 l/min 45 l/min
* Storage temperature: 75°C - Cold water temperature 10°C - Hot water temperature 45°C
gure 2.14

17
COMPONENT DESCRIPTION
Chapter 2
GSC1
Single, one-pipe, circulation pump unit without deaerator including stainless steel exible pipe, wall xing
bracket and non-return valve for expansion vessel.
Model GSC 1
Dimensions LxHxD 400 x 230 x 150
Pump max. head 6 m
Pump max. power 82 W
Flow rate adjustment 2-12 l/min
Safety valve 6 bar
Hydraulic connections 3/4“
Manometer yes
Excludable non-return valve and
thermometer in the return yes
Excludable non-return valve and
thermometer in the ow no
Deaerator no
Valves for system load and unload yes
GSC 2
Double, two-pipe, circulation pump unit with deaerator including stainless steel exible pipe, wall xing
bracket and non-return valve for expansion vessel.
Model GSC 2
Dimensions LxHxD 400 x 230 x 150
Pump max. head 6 m
Pump max. power 82 W
Flow rate adjustment 2-12 l/min
Safety valve 6 bar
Hydraulic connections 22 mm
Manometer yes
Excludable non-return valve and
thermometer in the return yes
Excludable non-return valve and
thermometer in the ow yes
Deaerator yes
Valves for system load and unload yes
gure 2.15
gure 2.16

18
Chapter 2
COMPONENT DESCRIPTION
CS 3.1
Electronic control unit with 3 probes and one relay output for the solar pump.
CS 3.2
Electronic control unit with 3 probes and 2 relay outputs: 1 for the solar pump and 1 for the boiler
3 TEMPERATURE PROBES
1 OR 2 RELAY OUTPUTS
FUNCTIONS CONTROL
MODERN DESIGN
EASY INSTALLATION
Model CS 3.1 CS 3.2
Inputs per sensors 44
Temperature probes supplied Pt 1000 x 3 Pt 1000 x 3
Standard relay outputs 12
Additional heating no yes
Dimensions LxHxD 172 x 110 x 46 mm 172 x 110 x 46 mm
Room temperature 0…40 °C 0…40 °C
Casing material PC-ABS PMMA PC-ABS PMMA
Thermostat function no yes
Working hour counter yes yes
Disconnection safety device yes yes
Anti-freeze protection yes yes
Tank cooling yes yes
gure 2.17

19
COMPONENT DESCRIPTION
Chapter 2
VES 18
18 litre solar expansion vessel.
VES 355080
35 – 50 – 80 litre oor-mounted solar expansion vessel.
Model VES 18 VES 35 VES 50 VES 80
Positioning Wall Ground Ground Ground
Diameter x Height 270 x 350 mm 380 x 377 mm 380 x 525 mm 450 x 608 mm
Capacity 18 l 35 l 50 l 80 l
Max. working pressure 10 bar 10 bar 10 bar 10 bar
Pre-load 2,5 bar 2,5 bar 2,5 bar 2,5 bar
Hydraulic connection 3/4“ 3/4“ 3/4“ 1”
Diaphragm max. working
temperature 100 °C 100 °C 100 °C 100 °C
System max. working tempe-
rature 120 °C 120 °C 120 °C 120 °C
Special diaphragm resistant up to 100°C
Resistant to any mixture containing ethylene glycol and propylene glycol
Structure completely welded
Epoxy paint
Quick installation
gure 2.18

20
Chapter 2
COMPONENT DESCRIPTION
GAG 20
20 l / 21 kg can of concentrated glycol anti-freeze to be diluted in relation to the freezing limit temperaturea
of the area of installation.
TYFOCOR® L
Concentrated anti-freeze liquid with corrosion inhibitors: contains propylene glycol, not damaging for the
health.
It is normally diluted in water for applications in solar plants, for the production of domestic hot water or
to heat rooms. The mixture can be obtained using drinkable water from 25 to 55 % v/v (volume/volume) in
relation to the danger of system freezing.
gure 2.19