Refu sol AE PV User manual

REFUsol –Solarwechselrichter
REFUsol<Gerätetyp>
Installationsanleitung
Version 01
AE PV Heating Element
Screwing in Heating Unit
Installation Manual
Version 01.6

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2
Title
AE PV Heating Element Warm Water Generation
Type of Documentation
Installation Manual
Purpose of the
Documentation
In this document the use of AE PV Heating element is described.
Publisher
REFUsol GmbH
Uracher Straße 91 D-72555 Metzingen
Telephone: [phone]

Fax [phone]
www.refusol.com
Legal Reservation
All the specifications in this document are created and checked very
carefully. However, errors or deviations cannot be totally excluded due to
the technical progress.
Any responsibility is not assumed for completeness.
The current version can be found under www.refusol.com.
Copyrights
The specifications in this documentation are the assets of REFUsol
GmbH. The evaluation as well as publishing of this documentation is
done after the written approval of REFUsol GmbH.
Trademark
REFUsol®is a Registered Brand.
Identification Version Number
Comments
IA_AE_PV_Heating_element_V01.6_EN
01/2014

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Table of Content
1About this Installation Manual..............................................................................................4
1.1 Symbols and Markups ................................................................................................4
1.2 Warnings....................................................................................................................4
1.2.1 Structure of a Warning Message.................................................................................4
1.2.2 Class of Warnings.......................................................................................................4
1.3 Note ...........................................................................................................................5
2Security Note.........................................................................................................................5
2.1 Introduction.................................................................................................................5
2.2 Usage as Per Determination.......................................................................................5
2.3 Qualification of the Personnel .....................................................................................6
2.4 Operating Temperature...............................................................................................6
2.5 Structure of Hot Water Storage...................................................................................6
2.6 Disclaimer...................................................................................................................6
3Scope of Delivery..................................................................................................................7
3.1 Packaging Content .....................................................................................................7
3.2 Unpacking and Checking the Delivered Material .........................................................7
4Installation.............................................................................................................................8
4.1 Tools Required...........................................................................................................8
4.2 Installation Instructions ...............................................................................................8
4.3 AE PV Install Screw-in Heater at the HotWater Tank..................................................8
5Maintenance..........................................................................................................................9
6Dismantling and Returning...................................................................................................9
7Disposal.................................................................................................................................9
8Technical Data.....................................................................................................................10
9Spare Parts..........................................................................................................................10
10 Contact ................................................................................................................................10
11 Certificates ..........................................................................................................................10
12 Warranty ..............................................................................................................................11

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1 About this Installation Manual
This installation manual is a part of the product
Read the installation manual before the installation of the device.
Keep the installation manual available near the device for the whole life time of the product.
Make the installation manual available for all the future users of the device.
1.1 Symbols and Markups

Prerequisite

One step user Instruction
1.
Multi step user Instruction

List
Highlighting
Highlighting within a text

Result
1.2 Warnings
1.2.1 Structure of a Warning Message
WARNING
Type and source of the danger are described here.
Here are the measures to avoid the danger.
Example
DANGER
Death or severe personal injury due to high leakage current while
opening the device.
It is necessary to generate earthling before connecting to power supply
circuit.
1.2.2 Class of Warnings
There are three classes of warnings.
DANGER
“DANGER” indicates a security note, whose violation immediately leads to
death or severe personal injury!
WARNING
“WARNING” indicates a security note, whose violation can lead to death or
severe personal injury!

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CAUTION
“CAUTION”indicated a security note, whose violation can lead to material
damage or minor personal injuries!
1.3 Note
2 Security Note
2.1 Introduction
The following notes are should be considered before the installation of a device for avoiding personal
damage and/or material damage. The security notes should be considered every time.
Before the installation and start up of this device, all the subsequent documents should be read.
In case of sale, loan or other transmission of the device the product documentation should also be
attached.
2.2 Usage as Per Determination
AE PV Heating element should be used only with the provided AE PV Heater DCLV.
WARNING
Danger of infection due to water, which is not enough disinfected.
The thermal disinfection should be guaranteed by the existing heating
system.
The screwing in heating element is part of AE PV Heater DCLV and is used for the heating of water in
the house equipment. By its structure the screwing in heating element is suitable for the operation in
the warm water storage as well as in enameled drinking water storage, which are designed with a 1.5
inch screwed connection and this screwed connection has been provided with the help of an adaptor
for revision opening. The screwing in heating element is available for the operation in the
unpressurised and pressurized hydraulic systems from 80 liters capacity till a maximum operation
pressure of 10 bars.
The screwing in heating element should be used only with the AE PV Heater DCLV. Each usage
except this is not valid as per the approval.
The AE PV Heater DCLV serves as an Additional Heating System in warm water storage or in
drinking water storage in case of central heating system with primary heat generator (oil, gas or solid
fuel heaters). Both the types are described as warm water saving. The heating requirement exceeding
from the available solar capacity is covered by the primary heat generators. The system linking
ensures temperature sensitivity, this means as long as the maximum permitted storage temperature is
allowed and solar radiation is available, the AE PV Heater delivers the heat. If the maximum permitted
storage temperature is exceeded on the central heat sensor of AE PV Heater then the heat supply is
interrupted. If the storage temperature for comfort is exceeded, then the primary heat generator is
responsible for the delivery of heat energy. Also weekly disinfection of the drinking water (Legionella
protection) takes over the primary heat generator.
However, the AE PV Heater DCLV can be set as solar island system for heating water generation e.g.
Note: A Note describes information, which is important for the optimal and
economical operation of the system.

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in a mountain shelter or in a garden house. In this case it is to be considered that the dimensioning of
the system or the hot water usage behavior should be aligned in such a way that the storage water
temperature of 60°C will be achieved once in a week for the Legionella protection.
The pipes of screwing in heating element consist of a high corrosion resistant of special alloy. In order
to guarantee the possibly long life, we recommend the usage of processed, softened heating water as
per VDI2035.
While operating the screwing in heating element in drinking water storage, it is to be calculated as per
the hardness grade of the drinking water with the strong lime deposits on the heater rod. So that the
life of the screwing in heating element can be considerably shorten. In order to avoid this, we
recommend the following in case of drinking water storage:
Never configure the maximum temperature of AE PV Heater DCLV above 60°C.
Clean the warm water storage every two years using the revision opening of depositions and
sediments.
2.3 Qualification of the Personnel
The screwing in heating element should be installed only by qualified heating engineers. The heating
engineer should be enough familiar with the fitting, installation and operation of the product as well as
all the warnings and security measures as per this operation manual. They should have proper
security equipments and should be the first one to help.
2.4 Operating Temperature
The Messing-Nipple can increase the temperature of the storage water. The maximum water
temperature for the screwing in heating element is 85°C.
The primary heating system (especially important in case of solid boilers) should not heat up the
water above the maximum temperature of 85°C on screwing in heating element of AE PV Heater
DCLV at any point of time. Temperature more than 85°C can lead to the safety shutdown of the
device.
After the safety shutdown the device is switched off for the remaining day. If the safety shutdown
takes place for 7 consecutive days, then the device can be start up again only by the customer
service.
2.5 Structure of Hot Water Storage
The maximum operating pressure for the screwing in heating element includes 10 bars.
An exceeding of the maximum pressure by obstacles in the flowing system should be closed
immediately.
The screwed coupling should be shorter than the unheated zones of heating rod, in order to prevent
the overheating and corrosion of the screw-in heating element.
2.6 Disclaimer
There are general conditions for the deliveries and services of REFUsol GmbH.
REFUsol GmbH does not take the responsibility of the damage in terms of not following the
warnings in this installation manual or usage beyond the approved usage.
The PV Heaters have water as well as the electrical contact. Any changes with exception of
the allowed exchange of heating rod with an original REFUsol- additional heating rod
(subsequent: changes) on the PV Heaters are endangered, therefore their secured function
and possible damages are covered. Especially it threatens the life risk in case of changes on

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the PV heaters.
Therefore, it is recommended not to undertake any changes or repairs on the PV heaters.
REFUsol is not responsible, if damage takes place due to a change or repair on a PV heater.
Changes on the PV Heaters lead to the termination of guaranty claims, if the changes are not
covered under guaranty conditions.
Before the installation, the operational, warnings and security notes should be read.
The perfect and secured operation of this device implies proper and competent transport,
storage, fitting and installation as well as careful handling and maintenance.
Accessories - spare parts provided by the manufacturer are acceptable.
The security measures and clauses of the county, in which the system is used, should be
considered.
The environment conditions given in the product documentation should be maintained.
For the European countries the EG-policy 2004/108/EG (EMV-Policy) should be considered
while operating the device.
The technical data, the measuring, connection and installation conditions are to be read from
the product documentation and to be adhered to.
For damages in relation to the high violence and disaster situation no liability is assumed.
3 Scope of Delivery
3.1 Packaging Content
PCs.
Name
Item No.
1
AE PV heating element for AE PV Heater DCLV –Set including Double-
Temperature sensor
0034480
1
Gasket for AE PV Heating element
0034478
1
Installation manual
0034479
The AE PV heater used in addition is delivered in a special packing.
3.2 Unpacking and Checking the Delivered Material
Check the complete packaging content as per 3.1.
In case of incomplete delivery or damage the installation and operation is not recommended. In this
case contact REFUsol Service.

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4 Installation
WARNING
Risk of injury or Property Damage due to Improper Installation.
The immersion heater must be installed only by trained and qualified
heating installers.
The low-impedance grounding of the immersion heater on the local
potential equalization for the purpose of the insulation monitoring is to
ensure and document.
Note safety instructions in chapter 2, page Fehler! Textmarke nicht
definiert.
4.1 Tools Required
Standard tool and key SW 60.
4.2 Installation Instructions
For the utilization of the maximum energy storage capacity, a installation position is as low as
possible makes sense in the heating water tank or drinking water storage. For many drinking water
storage is an enameled connection flange for the inspection opening 1.5 "internal thread available to
achieve a deep position. The energy storage capacity of water is 0.116 kWh per degree per 100 litres
water volume.
Figure dimensions in mm
4.3 AE PV Install Screw-in Heater at the Hot Water Tank
WARNING
Risk of injury or Property Damage due to Incorrect Installation Position or
Overheating.
Install horizontal screw-in heaters.
Make sure that the heating rods of the screw-in heater are surrounded in
the operation by water and the water level is at least 20 mm above the
heater rods.
The sealing is done with the supplied sealing ring.

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1. Install seal ring (arrow).
2. Screw Immersion heater in the screw socket.
3. Tighten Immersion heater with key SW 60, without damaging the sealing ring by squeezing
(Recommended torque 60 Nm).
4. Fill with enough water.
5. Check tightness.
5 Maintenance
A special maintenance of the immersion heater is not required. Check once in a year:
Connection cable on fixed connection
Cable damage
Fragility of cables
Remove deposits on the immersion heater, such as E.g. calcification if necessary.
The reliability of the hot water tank must be ensured within the framework of regular maintenance
and inspection by a specialist.
6 Dismantling and Returning
The dismantling takes place in reverse order as the Assembly.
Carefully pack the screw-in heater for returns under warranty.
7 Disposal
Dispose of the packaging and parts replaced in accordance with the
regulations of the country where the immersion heater has been
installed.
Do not dispose of the appliance with the household waste!
The device is RoHS - compliant. Thus the device can only be delivered
to local sites for the disposal of household appliances.
REFUsol GmbH take back the device completely. Please contact for
the service!

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8 Technical Data
Technical Data
AE PV Heating Element
MECHANICAL DATA REFUsol Screw-in Heater
Material Heating Rod
high-quality nickel-iron-chromium alloy
Maximum Operating Pressure, bar
10
Unheated Area, mm
100
Dimension Length / Diameter, mm
400 / 40
Connection Thread
1 ½”
Fitting Length, mm
14
Use
Drinking water, deionized heating water to VDI
2035
Weight, kg
1,0
9 Spare Parts
Spare parts can be ordered from the AE REFUsol service hotline.
PCs.
Name
Item No.
1
AE PV heating element for AE PV heater DCLV - Set including Double
Temperature sensor
0034480
1
Double- Temperature sensor PT1000 for AE PV Heating element
0034473
1
Seal for AE PV Heating element
0034478
10 Contact
Questions regarding errors or technical problems please contact:
Service-Hotline: [phone] (on working days from 8:00 –17:00 O‘clock)
Fax: [phone]
Email: [e-mail]
11 Certificates
The EG declaration of conformity is available on the homepage of the REFUsol GmbH
www.refusol.com available for download.
The AE PV heating element has been successfully tested according to the following test basics of the
DVGW (German Association of gas and water compartment):
UBA KTW: UBA “KTW Leitlinie”from 07.10.2008
UBA BESCH-LL: UBA (Coating guideline) from 30.11.2010
UBA ELASTOM: UBA (Elastomer guideline) from 22.12.2011

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12 Warranty WARRANTY CERTIFICATE
for PV Heater
We hereby provide a warranty that, if the PV heater breaks down or suffers from a malfunction, we will exchange it on the terms outlined below:
Duration of the Warranty:
2 Years
1. The REFUsol manufacturer's warranty shall commence upon the PV heater first being commissioned. The
warranty shall end upon the expiry of the warranty period.
2. We guarantee that, if the PV heater should break down or malfunction should occur during the warranty
period we will send the holder of the warranty a replacement device on the following terms, either
ourselves or through a company instructed by us. REFUsol shall be entitled to supply a replacement
product, either of identical construction or otherwise a compatible device from a successive series in the
same performance category.
3. In order to assert the warranty claim, the failure or malfunction of the device is to be notified to the
REFUsol helpline by e-mail, telefax or letter, presenting a copy of the sales receipt.
4. Once a guarantee case has been filed, REFUsol will, either itself or through a company instructed, send
the warranty holder a replacement product together with a return delivery note. The replacement product
will be free of charge for the holder of the warranty if a warranty claim actually exists (breakdown of the
device or malfunction that does not fall under Clause 7), and the holder of the warranty sends the device
complained about, with a legible model identification plate, together with a copy of the sales receipt, in the
container in which the replacement product was delivered, to the address given on the return delivery
note, no later than 10 business days after delivery of the replacement product.
5. The costs of sending the equipment back and forth from/to the site of the product complained of are to be
borne by the warranty holder.
6. This warranty does not cover any claims not expressly mentioned in this certificate of warranty.
7. The warranty does not cover any defects caused by modifications to or intervention with the device
undertaken by individuals not authorised by REFUsol in this respect, defective installation or
commissioning by the holder of the warranty or a third party, not adhering to the instructions given in the
operating manual (e.g. the rules in regard to shipping, packaging, storage, protection from corrosion,
handling, installing, commissioning and use), technical specifications and any pertinent safety regulations,
improper use or Acts of God (e.g. being struck by lightning, excess voltage, storm, fire, being nibbled by
rodents, etc.). Also excluded from the warranty are any defects in construction based on instructions given
by REFUsol's customer if REFUsol had pointed the risks out to the customer in writing, as well as the
usual wear and tear of the heating element. The usual wear and tear of the heating element shall primarily
also depend upon the water hardness, and shall, for technical reasons, be increased with increased or
decreased water hardness.
8. The holder of the manufacturer's warranty may transfer its rights and obligations arising from this warranty
to third parties. REFUsol shall likewise be entitled to assign any rights and obligations arising from this
manufacturer's warranty to third parties.
9. Should it transpire that no warranty claim exists, or should the warranty holder making a claim not fulfil its
obligations, REFUsol shall be entitled to charge the warranty holder for any expenditure incurred to
REFUsol through the warranty claim being asserted, including the costs of the replacement product.
10.This manufacturer's warranty is governed by German law, with the exception of German international
private law. It does not limit the warranty claims of REFUsol's customer, and is given in addition to the
customer's warranty claims.

All information without guarantee.
Technical changes and errors
excepted.
REFUsol GmbH
Uracherstraße 91
D-72555 Metzingen / Deutschland
Tel: [phone]
Fax: [phone]
[email protected]
www.refusol.com
Item No.: 0034957