REMASOL 200SE-2S Manual

RemaSol EN
Solar hot water calorifer
200SE-2S - 300SE-2S
L000541-B
Installation and
Service Manual
7607575-001-03

Declaration of conformity [
The device complies with the standard type described in the EG
declaration of conformity. It was manufactured and commissioned in
accordance with European directives.
The original of the declaration of compliance is available from the
manufacturer.
M003220-A

Contents
1 Introduction ................................................................................................4
1.1 Symbols used .......................................................4
1.1.1 Symbols used in the manual ...................................4
1.1.2 Symbols used on the equipment .............................4
1.2 Abbreviations ........................................................4
1.3 General ..................................................................5
1.3.1 Manufacturer’s liability .............................................5
1.3.2 Installer’s liability .....................................................5
1.4 Homologations ......................................................5
1.4.1 Certifications ...........................................................5
1.4.2 Directive 97/23/EC ..................................................6
2Safety instructions and recommendations ..............................................7
2.1 Safety instructions ...............................................7
2.2 Recommendations ................................................7
3Technical description ................................................................................9
3.1 General description ..............................................9
3.2 Main parts ..............................................................9
3.2.1 Solar domestic hot water calorifier ..........................9
3.2.2 Solar station ..........................................................11
3.2.3 Solar regulator .......................................................11
3.3 Operating principle .............................................11
3.3.1 General principle ...................................................12
3.3.2 Protection against overheating on the solar
circuit .....................................................................13
3.4 Technical specifications ....................................13
3.4.1 Solar domestic hot water calorifier ........................13
3.4.2 Sensor characteristics ...........................................14
3.4.3 Solar regulator .......................................................14
3.4.4 Solar station ..........................................................15
4 Installation ................................................................................................16
4.1 Regulations governing installation ...................16
4.2 Package list .........................................................16
4.2.1 Standard delivery ..................................................16
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4.3 Choice of the location ........................................17
4.3.1 Type plate .............................................................17
4.3.2 Positioning of the appliance ..................................17
4.3.3 Main dimensions ...................................................18
4.4 Positioning the appliance ..................................19
4.5 Levelling ..............................................................19
4.6 Installing the temperature sensors ...................19
4.7 Hydraulic installation diagrams ........................20
4.7.1 Boiler for heating only (Output <45 kW) +
200/300SE-2S ......................................................20
4.7.2 Combi boiler + 200/300SE-2S .............................21
4.7.3 Combi boiler + Additional heating (Output <45 kW) +
200/300SE-2S ......................................................22
4.8 Safety unit ...........................................................23
4.9 Hydraulic connections .......................................24
4.9.1 Primary solar circuit ...............................................24
4.9.2 Primary heating circuit ...........................................28
4.9.3 Connecting the calorifer to the domestic water circuit
(secondary circuit) .................................................28
4.10 Electrical connections ........................................31
4.10.1 Recommendations ................................................31
4.10.2 Connecting the solar control system .....................31
4.10.3 Electrical diagram ..................................................32
4.10.4 Connecting the resistor .........................................33
4.10.5 Connecting the circulation pump ...........................33
4.11 Filling the DHW calorifer ....................................33
4.12 Filling the primary solar circuit .........................34
4.12.1 Flowmeter .............................................................34
4.12.2 Anti-thermosiphon valve ........................................35
4.12.3 Filling the primary solar circuit ...............................35
4.13 Filling the heating circuit ...................................39
5 Commissioning ........................................................................................40
5.1 Control panels .....................................................40
5.1.1 Description of the keys ..........................................40
5.1.2 Description of the display ......................................40
5.2 Check points before commissioning ................42
5.2.1 Domestic hot water calorifer ..................................42
5.2.2 Primary solar circuit ...............................................42
5.2.3 Primary heating circuit ...........................................42
5.2.4 Electrical connection .............................................42
5.3 Commissioning procedure ................................43
5.3.1 Secondary circuit (domestic water) .......................43
5.3.2 Primary solar circuit ...............................................43
Contents
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5.4 Reading out measured values ...........................44
5.4.1 Resetting the values to zero ..................................44
5.5 Installer parameters ............................................45
5.5.1 Modifying the installer parameters ........................45
5.5.2 List of the parameters ...........................................45
5.5.3 Description of the installer parameters ..................47
6 Checking and maintenance .....................................................................51
6.1 General instructions ...........................................51
6.2 Safety valve or safety unit .................................51
6.3 Cleaning the casing material .............................51
6.4 Checking the magnesium anode .......................51
6.5 Descaling .............................................................52
6.6 Removing and remounting the inspection
hatches ................................................................52
6.6.1 Removing the inspection hatches .........................52
6.6.2 Remounting the inspection hatches ......................53
6.7 Inspection and maintenance of the solar
circuit ...................................................................54
6.7.1 Maintenance operations to be performed .............54
6.7.2 Adding heat transporting fluid ...............................54
6.8 Maintenance form ...............................................55
6.9 Installation report ...............................................57
7 Troubleshooting .......................................................................................59
7.1 Electricity supply ................................................59
7.2 Sensor fault .........................................................59
7.3 Incidents and solutions ......................................60
8 Spare parts ................................................................................................61
8.1 General ................................................................61
8.2 Spare parts ..........................................................61
8.2.1 Domestic hot water tanks ......................................62
8.2.2 Solar station ..........................................................64
8.2.3 Electric heating resistance ....................................66
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1 Introduction
1.1 Symbols used
1.1.1. Symbols used in the manual
In these instructions, various danger levels are employed to draw the
user’s attention to particular information. In so doing, we wish to
safeguard the user’s safety, obviate hazards and guarantee correct
operation of the appliance.
DANGER
Risk of a dangerous situation causing serious physical
injury.
WARNING
Risk of a dangerous situation causing slight physical
injury.
CAUTION
Risk of material damage.
Signals important information.
¼Signals a referral to other instructions or other pages in the
instructions.
1.1.2. Symbols used on the equipment
Before installing and commissioning the device, read
carefully the instruction manuals provided.
Dispose of the used products in an appropriate recovery
and recycling structure.
1.2 Abbreviations
4CFC: Chlorofluorocarbon
4DHW: Domestic hot water
1. Introduction 200SE-2S - 300SE-2S
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1.3 General
1.3.1. Manufacturer’s liability
Our products are manufactured in compliance with the requirements
of the various applicable European Directives. They are therefore
delivered with [ marking and all relevant documentation.
In the interest of customers, we are continuously endeavouring to
make improvements in product quality. All the specifications stated in
this document are therefore subject to change without notice.
Our liability as the manufacturer may not be invoked in the following
cases:
4Failure to abide by the instructions on using the appliance.
4Faulty or insufficient maintenance of the appliance.
4Failure to abide by the instructions on installing the appliance.
1.3.2. Installer’s liability
The installer is responsible for the installation and inital start up of the
appliance. The installer must respect the following instructions:
4Read and follow the instructions given in the manuals provided
with the appliance.
4Carry out installation in compliance with the prevailing legislation
and standards.
4Perform the initial start up and carry out any checks necessary.
4Explain the installation to the user.
4If a maintenance is necessary, warn the user of the obligation to
check the appliance and maintain it in good working order.
4Give all the instruction manuals to the user.
1.4 Homologations
1.4.1. Certifications
This product complies to the requirements to the european directives
and following standards:
42006/95/EC Low Voltage Directive.
Reference Standard: EN 60.335.1.
42004/108/EC Electromagnetic Compatibility Directive.
Reference Standards: EN 50.081.1, EN 50.082.1, EN 55.014
200SE-2S - 300SE-2S 1. Introduction
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1.4.2. Directive 97/23/EC
This product conforms to the requirements of european directive 97 /
23 / EC, article 3, paragraph 3, on pressure equipment.
1. Introduction 200SE-2S - 300SE-2S
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2 Safety instructions and
recommendations
2.1 Safety instructions
CAUTION
Before any work, switch off the mains supply to the
appliance.
CAUTION
In order to limit the risk of being scalded, the installation of
a thermostatic mixing valve on the domestic hot water flow
piping is compulsory.
2.2 Recommendations
CAUTION
Do not neglect to service the appliance. Service the
appliance regularly to ensure that it operates correctly.
WARNING
Only qualified professionals are authorised to work on the
appliance and the installation.
WARNING
4The heating water and the water-propylene-glycol
mixture must not come into contact with the domestic
hot water.
4The domestic hot water must not circulate through an
exchanger.
4Solar installations can be protected against lighting
and must be earthed or connected to an equipotential
connection.
To take advantage of the guarantee, no modifications must be made
to the appliance. Only remove the covers for maintenance and
breakdown repair operations and put the covers back in place after
the maintenance and breakdown repair operations.
Instructions stickers
The instructions and warnings affixed to the appliance must never be
removed or covered and must remain legible during the entire lifespan
of the appliance. Immediately replace damaged or illegible
instructions and warning stickers.
200SE-2S - 300SE-2S 2. Safety instructions and recommendations
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WARNING
Never cut the power to the solar control system, even
during extended absences. The control system protects
the installation against overheating in summer when it is
running.
WARNING
Do not modify the control system parameters unless fully
conversant with them.
During extended absences, we recommend lowering the set point
temperature in the solar DHW calorifier to 45°C. When the user is
present, the set point must be set to 60°C.
2. Safety instructions and recommendations 200SE-2S - 300SE-2S
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3 Technical description
3.1 General description
200SE-2S - 300SE-2S domestic hot water calorifiers are connected
to solar collectors by a solar station.
The calorifiers 200SE-2S - 300SE-2S are fully equipped with a solar
technical station, consisting of a charge device for each zone, a safety
device, an expansion vessel, a pump, a solar control system Delta
Sol AEL etc.
Main parts:
4The tanks are made of high quality steel lined with food quality
standard enamel vitrified at 850°C, which protects the tank from
corrosion.
4The heat exchangers welded into the tank are made of smooth
piping, the external surface of which, in contact with the drinking
water, is enamelled.
4The appliance is highly insulated with CFC-free polyurethane
foam, which reduces thermal losses to a minimum.
4The external casing is made of ABS.
4The tanks are protected against corrosion by several magnesium
anodes.
3.2 Main parts
3.2.1. Solar domestic hot water calorifier
200SE-2S - 300SE-2S 3. Technical description
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200SE-2S - 300SE-2S: External view
AExpansion vessel
ZTop inspection trap
ESide inspection plate
RSolar station
TSolar regulator
YElectrical back-up (Option)
USafety control unit for the solar circuit
All components are checked for leaks and tested in the
factory. The control system, the pump and the electrical
back-up are pre-wired.
200SE-2S - 300SE-2S: Internal view
ASolar exchanger
ZBack-up exchanger
(Boiler or heat pump)
EAnode - Side inspection plate
RAnode - Top inspection trap
All components are checked for leaks and tested in the
factory. The control system, the pump and the electrical
back-up are pre-wired.
L000430-C
5
7
4
6
1
2
3
L000598-A
4
2
1
3
3. Technical description 200SE-2S - 300SE-2S
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3.2.2. Solar station
APressure gauge
ZSolar circulation pump
EFilling valve
RDraining valve
TSafety valve
YSolar circuit air vent
UFlowmeter
IClamping ring fitting
ORed flow thermometer
PBlue flow thermometer
3.2.3. Solar regulator
ACover
ZAlphanumeric LCD display
EControl keys
RFuse 4 AT backup
TConnectors
YRouting the cables
UCover screw
IHole for fixation screw
3.3 Operating principle
The solar control system optimises the collection of solar energy in
order to reheat the domestic hot water contained in the calorifier.
1
3
5
2
4
109
6
7
8
L000415-C
M002750-A
1
4
5
8
7
7
2
8
6
3
200SE-2S - 300SE-2S 3. Technical description
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3.3.1. General principle
TC Temperature of the solar collectors
TR Temperature of the lower part of the tank
DT Reference temperature difference
SX Set temperature of the solar calorifier
PC % Solar circulation pump mode
CMIN Minimum collector temperature triggering the pump
CMAX Maximum temperature of the solar collector
tu Self-calibration time
°C Temperature
tTime
¼See chapter: "Description of the installer parameters", page
47.
Live Operating description
1The sun’s irradiation heat the transfer fluid in the collector. To trigger the circulation pump, a minimum temperature of
30°C is necessary in the collectors (CMIN) as is a temperature difference of 6 K between the temperature of the collectors
and the DHW tank.
2In the automatic calibration phase (setting parameter tu, factory setting 3 minutes), the solar pump (relay 1) operates on
full (100%) in order to stabilise the temperature in the solar circuit.
3Subsequently, the rate at which the solar pump operates is calculated dynamically to maintain a reference temperature
difference (parameter DT, factory setting 20 K) between the collectors and the DHW tank.
4The system loads the DHW tank according to the heat available in the collectors and stops when the set point temperature
of the DHW tank is reached (setting parameter SX, factory setting 60).
TC
TR
DT
SX
PC %
CMIN
CMAX
M002751-C
1 2 3 4 5678
°C
t
tu
3. Technical description 200SE-2S - 300SE-2S
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Live Operating description
5When the temperature in the collectors reaches the maximum value (adjustment parameter CMAX, factory setting 110°C),
the solar pump is triggered to cool the collectors.
The pump continues to operate until the temperature in the collectors is lower than 5 K at parameter CMAX and/or the
maximum storage temperature (80°C) is reached in the hot water storage tank.
6When there is less available sunlight, the temperature in the collectors drops and the temperature in the DHW tank is
stable.
7As soon as the temperature in the collectors drops below the temperature in the calorifier, the calorifier is cooled down to
its set temperature.
8When the set point SX is reached, the circulation pump shuts down, the temperature in the collectors drops again and the
temperature in the DHW tank falls according to any draw-offs made.
The DHW tank cooling function is inactive if using tubular
collectors (function FT active).
3.3.2. Protection against overheating on the solar
circuit
The control system has various functions, which are easy to discern
for the user, which limit overheating of the installation’s components.
3.4 Technical specifications
3.4.1. Solar domestic hot water calorifier
200SE-2S 300SE-2S
Primary circuit: Solar exchanger
Maximum operating temperature °C 110 110
Maximum operating pressure bar (MPa) 10 10
Exchanger capacity litres 5.6 8.1
Exchange surface m20.84 1.2
Primary circuit: Back-up exchanger
Maximum operating temperature °C 110 110
Maximum operating pressure bar (MPa) 10 10
Exchanger capacity litres 5.1 5.1
Exchange surface m20.76 0.76
Pressure drop at 2 m3/Time kPa 4 4
Secondary circuit (domestic water)
Maximum operating temperature °C 95 95
Maximum operating pressure bar (MPa) 10 10
Water content litres 225 300
Top up volume litres 75 105
Solar volume litres 150 195
Weight
Gross weight kg 125 125
Net weight kg 109 111.5
(1) Primary temperature: 80 °C - Domestic cold water inlet: 10 °C - Domestic hot water outlet: 45 °C - Primary flow rate: 2 m3/h
(2) Primary temperature: 80 °C - Domestic cold water inlet: 10 °C - Domestic hot water outlet: 40 °C - Domestic hot water storage: 65 °C
(3) Satisfies the requirements of the EN 12977–1 standard
200SE-2S - 300SE-2S 3. Technical description
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200SE-2S 300SE-2S
Performance Primary circuit: Back-up exchanger
Power exchanged(1) kW 24 24
Performance
Flow per hour (∆T = 35 °C)(1) litres per hour 590 590
Transfer capacity over 10 minutes (∆T = 30°C)(2) litres per 10 min. 150 200
Cooling constant Cr Wh/24h·L·K 0.23 0.20
Maintenance consumption (ΔT=45K)(3) kWh/24h 1.8 2.2
Performance NL 0.7 1.2
(1) Primary temperature: 80 °C - Domestic cold water inlet: 10 °C - Domestic hot water outlet: 45 °C - Primary flow rate: 2 m3/h
(2) Primary temperature: 80 °C - Domestic cold water inlet: 10 °C - Domestic hot water outlet: 40 °C - Domestic hot water storage: 65 °C
(3) Satisfies the requirements of the EN 12977–1 standard
3.4.2. Sensor characteristics
Temperature in °C -10 0 10 20 30 40 50 60 70 80 90 100 110
Resistance in Ω
(Pt1000)
961 1000 1039 1078 1117 1155 1194 1232 1271 1309 1347 1385 1423
3.4.3. Solar regulator
nSpecifications
4ABS box
4Class of protection: IP 20 / EN 60529
4Ambient temperature: 0...35°C
4Dimensions: 144x208x43 mm
4Display: Alphanumeric LCD display
4Control: via 3 keys on the front panel
4Storage temperature: -20...+70°C
4Inputs: 3 Pt1000 temperature sensors
4Output: 1 inverter contact electromechanical relay and 2 high
output relays
4Max. current: 4 A - 250 V
4Power supply: 210...240 V(AC) - 50...60 Hz
4Consumption on standby: 0.7 W
4Total shutdown capacity: 4 (1) A (100...240)V
4Shutdown capacity of the electromechanical relay: 4 (1) A
(100...240)V
4Shutdown capacity of the high output relays: 14 (3) A (100...240)V
nFunction
4Hour run meter on the electrical back-up.
L000612-A
3. Technical description 200SE-2S - 300SE-2S
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4Hour run meter on the solar pump.
4Tubular solar collector function.
4Calorimetric balance.
4Hourly command thermostat.
43-position switch.
3.4.4. Solar station
Dimensions Spacer 100 mm
Connections for pipes DN18 clamping ring screw connections
Connection for expansion vessel 3/4 external thread (Sheet gasket)
Outflow safety valve 3/4 internal thread
Operating data Maximum admissible pressure PN 10
Maximum operating temperature 120 °C
Maximum short-term temperature 160 °C < 15 mn
Max. propylene glycol content 50%
Equipment Safety valve 6 bar (0.6 MPa)
Pressure gauge 0–6 bar (0.0–0.6 MPa)
Anti-thermosiphon valve 2 x 200 mmWG
Circulation pump Wilo ST 15 / 6
Materials used Valves Brass
Gaskets EPDM
Anti-thermosiphon valve Brass
nCirculation pump
HManometric height
QWater flow
0
1
2
3
4
5
6
0 0,5 1 1,5 2 2,5 3 3,5
Q (m3/h)
H (m)
ST 15/6-130 ECO
L000245-B
200SE-2S - 300SE-2S 3. Technical description
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4 Installation
4.1 Regulations governing installation
CAUTION
Installation of the appliance must be done by a qualified
engineer in accordance with prevailing local and national
regulations.
CAUTION
France: The installation must comply in all matters to the
standards and rules which govern the work and
interventions in individual and collective homes, and other
constructions.
4.2 Package list
4.2.1. Standard delivery
The delivery includes:
4Solar calorifier, with complete solar station, control system, etc..
4User Guide.
4Installation and Service Manual.
Description Pack no. Reference
200SE-2S ER453 7606322
300SE-2S ER454 7606323
4. Installation 200SE-2S - 300SE-2S
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4.3 Choice of the location
4.3.1. Type plate
The type plate must be accessible at all times.
The type plate identifies the product and provides the following
information:
4DHW calorifier type
4Manufacturing date (Year - Week)
4Serial number.
4.3.2. Positioning of the appliance
CAUTION
Put the appliance in a frost-free location.
4Place the appliance as close as possible to draw-off points in order
to minimise energy losses through the pipes.
4Place the appliance on a base frame to facilitate cleaning of the
premises.
4Install the appliance on a solid, stable structure able to bear its
weight.
M003151-A
200SE-2S - 300SE-2S 4. Installation
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4.3.3. Main dimensions
A
B
C
D
E
F
I
ØG
H
55°
1
3
2
4
5
6
8
7
L000601-A
9
ADomestic hot water outlet G1"
ZCirculation G¾"
EExchanger inlet G1"
RDomestic hot water sensor
TExchanger outlet G1"
YDomestic cold water inlet + Drain opening G1"
USolar exchanger inlet DN18
ISolar exchanger outlet DN18
OPosition solar sensor
200SE-2S 300SE-2S
A70.5 71
B912 1127
C1092 1307
D1182 1397
E1323.5 1694
F1422.5 1796
G (Ø) 604 604
H892 892
I1718 1898
G : Exterior cylindrical threading, sealed by sheet gasket
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