Sferasol Energy SFERASOL SF-S User guide

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Use and maintenance manual
INTEGRATED STORAGE COLLECTOR SFERASOLTM

The development of continuous product improvement may result, without notice, any changes or
modifications as described in this manual.
INTEGRATED STORAGE COLLECTOR SFERASOLTM
USE AND MAINTENANCE MANUAL
SFERASOL ENERGY S.R.L.
VIAG. PASCOLI, 1
10060 SCALENGHE(TO) - ITALIA
TEL. [phone]
MOB. [phone]
[e-mail]
WWW.SFERASOLENERGY.COM

INDEX
SferasolTM...................................................4
Safety basic instructions. .............................5
Before starting SferasolTM. ............................5
Technical features. .......................................6
Transport and storage. .................................7
SferasolTM positioning. .................................8
SferasolTM installation. ................................11
Start-up.....................................................12
Maintenance. ..............................................13
Level Control...............................................14
Troubleshooting and spare parts. ...................15
SferasolTM without tank inside SF-A. ..............16
SferasolTM Data Sheet SF-S...........................17
SferasolTM Data Sheet SF-A...........................18
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2 .
3 .
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INTEGRATED STORAGE COLLECTOR SFERASOLTM
USE AND MAINTENANCE MANUAL

SferasolTM.
SFERASOLTM is planned to produce sanitary warm water with the aid of the direct
and diffused solar energy. Water temperature supplied by a SFERASOLTM panel
depends on several external factors, varying according to the season, the place
and the time of the day.
Depending on weather conditions, the main parameters influencing SFERASOLTM
efficiency parameters are feed water, solar energy and environmental tempera-
ture.
SFERASOLTM surface heats the thermal liquid by means of the solar energy that
circulates in the two hemispheres. The liquid is then conveyed to the internal
exchanger heating the water contained in the boiler.
Water temperature of mains supply is not constant during the year.
During seasons with few sun exposure and low environmental temperature,
SFERASOLTM ensures pre-heating of water and must be supported by the main
hot water heating system.
As far as heating losses during night hours, these are minimized by the thermal
insulation of the water accumulating tank.
In addition, the spherical shape of SFERASOLTM panel allows an air formation in
the captators which reduces any further thermal losses.
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INTEGRATED STORAGE COLLECTOR SFERASOLTM
USE AND MAINTENANCE MANUAL

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Before starting SferasolTM.
3
Before starting the machine, staffshould read the use and maintenance booklet,
in particular “safety basic instructions”.
Occasional users (especially for maintenance and repairing) should read the pre-
sent user manual before starting operations.
More than reading use and maintenance booklet, it is necessary to follow all stan-
dard rules connected to accident prevention and environment protection, like
safety clothes and accessories.
The use and maintenance booklet has to be stored in an easy to use position for
an easy consulting.
Each machine modification must be done only under manufacturer approval.
The present rule shall be applied also with the safety device installation.
Spare parts requirements shall be in accordance with the manufacturer specifi-
cations.
Safety basic instructions.
SFERASOLTM has been manufactured respecting safety rules and in accordance
with Machinery Directives:
2006/42CE
2006/95/CE
2004/108/CE
Final user could be in danger if the machine components are damaged or worn out
or if SFERASOLTM is improperly used.
Use SFERASOLTM exclusively when all the components and safety protections are
perfectly functioning.
Use the machine only in accordance with the present instructions.
Always remember safety rules and risks during the machine working and follow the
rules of the present user and maintenance booklet.
Each defect that should compromise safety should be immediately eliminated.
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INTEGRATED STORAGE COLLECTOR SFERASOLTM
USE AND MAINTENANCE MANUAL

Technical features.
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4
• Storage water tank in AISI 304 S.S., thickness 2,0 mm. Capacity 150 litres.
Our boilers are duly checked after assembly and welding, in order to ensure
tightness and quality.
• Heat exchanger made in AISI 304 S.S.
• Thermal insulation in high density Ecological Polyurethane CFC free.
• Cathode protection with magnesium anode, to be replaced periodically to
prevent corrosion and scale deposits due to electromechanical reactions.
• Electrical heating element ( optional supplied on request only).
• Expansion pot.
• Re-circulating pump for the thermal fluid in the SFERASOL.
• Thermostat sets at 3° Delta T.
• Absorbers in metal coated with black mat heat-resistant paint.
• Transparent covering made in shockproof plastic material (methacrylate),
ultraviolet-rays resistant and it optimizes the effect greenhouse.
• Inlet - outlet water AISI 304 S.S. connections.
• Inlet - outlet water copper connections.
• Safety valve.
• Base made in AISI 304 S.S., 20 mm. thickness. Pre-bored for floor fixing.
• Inspection door in AISI 304 S.S., for electronic board and pump inspection.
To enable installation, always keep it “SOUTH” oriented. .
• Thermal fluid, mix of mono propylene glycol, non toxic, ensures anti-free-
zing and anti-scale protection.
INTEGRATED STORAGE COLLECTOR SFERASOLTM
USE AND MAINTENANCE MANUAL

Transport and storage.
7
Follow basic rules for operation with cranes and fork lifts, loading charges ma-
chineries, etc.
Each lifting operation must be done with machineries with a sufficient loading
power.
Move or lift SFERASOLTM panel with maximum care ensuring lifting systems to
the apposite hook on the top of SFERASOLTM panel and follow the instructions
below.
Check that lifting powers are suitable for the machine weight.
Take care during lifting and be sure that no unbalancing is present.
SFERASOLTM unit net weight with water storage tank SF-S (empty): 130 Kg.
During transport ensure that SFERASOLTM panel is always vertically positioned.
SFERASOLTM panel should be slippering protected during transport to avoid
damages.
If SFERASOLTM panel has already worked, disconnect all connections before mo-
ving the machine.
In case a fork lift or crane are not available, SFERASOLTM panel should be hand-
led considering the weight of the appliance.
Use the special white plastic cover supplied for the appliance storage.
SFERASOLTM can be stored following the same conditions for transport. No par-
ticular care is necessary, but storage place must be clean and the appliance
should be covered in case of a quite long non working period, protecting it from
shocks or tumbles.
N.B.: Do not leave packaging material in the environment.
They must be disposed in accordance to local environmental rules currently in
force.
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INTEGRATED STORAGE COLLECTOR SFERASOLTM
USE AND MAINTENANCE MANUAL

SferasolTM positioning.
Installation area requirements.
Follow carefully instructions below before connecting and starting SFERASOLTM
panel.
Manufacturer will not be responsible for damages caused by the failure in re-
specting the following requirements
Packing removal.
SFERASOLTM packing must be removed in the installation place to avoid shocks
during transport. Keep the appliance covered until the boiler is filled with sanitary
water, in order to avoid filling liquid boiling
Installation place and base.
Choose carefully installation place and base before installation.
Basement on which the machine will be positioned must be planned so that is su-
itable to hold the machine weight. Before machine positioning the area must be
cleaned and planarity must be checked by a level device. Each difference from
optimal condition should be modified by the use of thickness sheets.
Connections.
Customer shall agree with the Installation Service all necessary plumbing and electri-
cal connections to ensure correct installation in accordance with Electrical and Plum-
bing Regulations currently in force.
Grounding.
SFERASOLTM must be connected to the general ground network.
Orienting and shading.
Correct installation is fundamental for maximum efficiency of the solar system.
During installation follow the indications below in order to ensure maximum efficiency
of the solar system.
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INTEGRATED STORAGE COLLECTOR SFERASOLTM
USE AND MAINTENANCE MANUAL

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• SFERASOLTM must be installed in a place with total daytime sunlight. If not possible,
sunlight should be at least from 11 a.m. to sunset.
• When installed, SFERASOLTM inspection door must be always SOUTH-side oriented
• In order to avoid temperature losses due to piping length, SFERASOLTM panel should
be positioned next to the Storage tank and/or to the collection point.
• After installation, ensure that SFERASOLTM is protected against wind which reduces
the greenhouse effect obtained by the spherical shape of the system.
• Any changes to the optimal orientation would reduce SFERASOLTM efficiency, with no
responsibility of SFERASOLTM panel.
• In case optimal installation is not possible, the number of SFERASOLTM panels requi-
red would increase to compensate efficiency losses.
• Shading (due to trees, buildings or any other obstacles) should be avoided in order to
ensure at least 4-6 hours of complete sunshine exposure during maximum sun thermal
radiation.
• Basement on which the machine will be positioned must be planned so that is sui-
table to hold the machine weight
• A well corresponding to the appliance base should be advisable and lay underground
a piping connection for water and electrical connection (min. diam. 100 mm.).
• Fix SFERASOLTM to the support foot through 4 wedges diam. 8 mm in the apposite
holes on the base, ensuring that 3 mm. washers are fitted with the wedges.
This operation avoids any condensate stagnancy inside the support foot.
To this purpose, do not seal the support foot to the base with mortar or silicon.
SFERASOLTM efficiency can be further improved by following previous suggestions,
thanks to its innovative shape, exploiting also the shaded part of the appliance.
Exploiting diffused energy, it is advisable to use light colors for any walls next to
the appliance, and to create a 1,5 diam.white gravel circle in case of installation
on lawn.
The above advices enable a reflection phenomenon of sunlight which optimizes
the appliance efficiency.
INTEGRATED STORAGE COLLECTOR SFERASOLTM
USE AND MAINTENANCE MANUAL

Connection requirements.
Electrical connections must be done by specialized electrician or by instructed staff
only.
Plumbing connections must be done by specialized thermohydraulic staffor by in-
structed staffonly.
Plumbing connections.
Place the connection lines so that they will be safe for the operating staffand avoiding
any voltage risk.
Ensure that cold water pressure is less than 6 bar.
Electrical connections.
Electrical connections must be done by specialized electrician or by instructed staff
only.
All operations on electrical devices (connections, maintenance, etc.)., must be done
with electrical supply excluded through apposite switches.
Warning:
During all installation and connection operations, the appliance must be cove-
red by the special white polyethilene packaging to avoid damages during these
operations.
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INTEGRATED STORAGE COLLECTOR SFERASOLTM
USE AND MAINTENANCE MANUAL

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Installation and connections
SFERASOLTM installation is very easy and and can be carried out by specialized staff
following the instructions below:
• Make cold water piping and heated water suction piping connections in the apposite
well located in the support base. Piping can be made in hot-dip zinc coated carbon ste-
el. sanitary copper or polypropilene and must be duly insulated. Piping diameter shall
be in compliance with the technical data sheet enclosed. Piping insulation is vital in
areas where cold emperatures in winter season are particularly severe.
• Arrange an electrical supply cable with adequate section for the installed power.
• Connect the cold water piping to the non-return valve fitted in the inlet cold
water circuit to Sferasol.
• Fill in SFERASOLTM with cold water (complete filling is reached when water is
out coming without air bubbles).
• Connect warm water piping to the outlet heated water circuit connection to
SFERASOLTM.
• An apposite pressure gear must be fitted if pressure is exceeding 6 bar.
• Remove the plug from the board.
• Pass the end of the cable through the cable fastening and bring it to the
electrical part.
• Fit a bipolar power supply sectionalising switch.
• Connect 220V-50 Hz power supply to the socket placed on the side of the
control board: connect the black cable (phase) to clamp 1, the neutral cable to
clamp 3 and the ground cable to the relevant clamp .
• Close the pin cover.
• Ensure that the socket is firmly fastened.
• After installation and connection operations, remove the apposite plastic cover
and start SFERASOLTM panel.
WARNING:
When installing the appliance on the base, the inspection door placed on the sup-
port must “South” oriented
WARNING:
Circulator functioning is assured by electrical power supply
SferasolTM installation.
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INTEGRATED STORAGE COLLECTOR SFERASOLTM
USE AND MAINTENANCE MANUAL

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Start-up.
Staffin charge.
Start up operations must be done by allowed staffafter the complete reading of
the present use and maintenance booklet.
All the electrical connections must be done by specialized operators.
Ensure that water flow can be stopped by means of a manual device (for example
a spherical valve).
Start-up operation must be reported. Such report shall be duly filled in and signed
by Customer and operating staffin charge. Always keep start-up report together
with the instruction booklet.
Start-up.
For SFERASOLTM start-up follow the indications below:
• Set the thermostat of the control board at 3 °C
• Give power tension to the board.
• Open inlet cold water valve.
Note: circulator rotation speed is set by Manufacturer at first speed (950
RPM); such setting must not be change.
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Working principles.
A soon as a temperature difference between thermal liquid and storage tank wa-
ter, the control board activates circulating pump, which moves thermal liquid until
same storage tank temperature is reached with minimum power consumption.
Thermal re-balancing is then obtained.
The whole system can be switched offthrough the apposite switch fitted by the
installer.
Instructions after installation.
Maximum efficiency of SFERASOLTM panel is reached after half day full sunshine from
installation. For this reason, we suggest to avoid warm water consumption during the
first two days after installation, even if sunlight exposure conditions are optimum.
INTEGRATED STORAGE COLLECTOR SFERASOLTM
USE AND MAINTENANCE MANUAL

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Maintenance.
Maintenance operations enable to keep the machine in perfect working con-
ditions.
The most important components of the machine must be kept clean for in-
spection.
Inspections must be done in order to keep the machine in perfect functioning.
Inspections are split in monthly or annual inspections.
During inspections safety advices must be carefully followed.
Safety advices.
Monthly inspection.
Annual inspection.
Other controls.
• Check that re circulating pump is working properly.
• Check that no electrical cable is damaged.
• In case of damage, cables must be replaced by specialized staff.
• Check tightness of connections (no losses) and ensure that no damages are
present (flexible hoses, etc.)
• In case of damage, connections must be replaced by specialized staff.
• Magnesium anode must be carefully checked by Authorized Service Cen-
tre. Any relevant labour costs and component expenses shall be at Custo-
mer’s charge.
• Thermal liquid of the closed circuit must be carefully checked by Authori-
zed Service Centre. Any relevant re-filling or replacement shall be done by
Authorized Centre and any labour costs or component expenses shall be at
Customer’s charge.
Methachrylate spherical bowls must be periodically cleaned with a damp
soft mop (NOT ABRASIVE). Do not use cleaning solvents or acid substances,
use neutral cleaning detergents only.
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WARNING:
Lesion risk!
Check
Ensure that power is switched off before opening inspection doors.
Always check that the machine is maintained switched off during operation
(main switch position “0”)
INTEGRATED STORAGE COLLECTOR SFERASOLTM
USE AND MAINTENANCE MANUAL

Extra-ordinary maintenance.
In case of breakings or damages to the appliance or to any other components,
revert to the Authorized Service Centre.
Storage.
No particular care is necessary but storage place must be clean and the
machine should be covered in case of a quite long non working period.
• In case of quite long non working period of the appliance, this one must be
covered with the white plastic cover supplied, without disconnecting power
supply.
• To re-start the appliance after a long non working period, follow instructions
indicated in relevant paragraph.
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INTEGRATED STORAGE COLLECTOR SFERASOLTM
USE AND MAINTENANCE MANUAL
Level Control.
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You will find a plug with dipstick to measure the glycol level in the Sferasol™
Set the Sferasol ™ SF -S, as required by the O & M manual, unscrew the eyebolt
and remove the brass cap [ Key 27] .
Insert and tighten plug with dipstick .
NOTE: measurement of the level of glycol in the expansion vase should always be
made with Sferasol ™ SF -S turned off.
Keep the brass cap and the lifting eye for future transit.

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Troubleshooting and spare parts.
Spare parts must be in compliance with Manufacturer specifications requirements.
Original spare parts satisfy such requirement.
TROUBLESHOOTING.
In case a satisfying warm water quantity is not assured, follow instructions below:
1. Consider weather conditions .
2. Consider domestic water .
3. Check carefully tightness of all connections of the system and fasten or replace
any loose connections.
4. Check thermal liquid level and tap up if necessary.
If efficiency is not enough, contact the Reseller.
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Replace Control Unit.
Replace Circulation Pump.
Replace Sensor.
Replace Sensor.
Replace Sensor.
Replace Sensors.
Replace Sensor.
Replace Sensor.
Replace Control Unit.
Circulation
pump does not
run
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POSSIBLE ROOT CAUSE WHAT TO DO
Circulation
pump always on
Control Unit out of order
Circulation Pump out of order.
Temp sensor interrupted.
(infinite resistance)
Outer temp sensor short circuited.
(resistance = 0)
Inner or outer temp sensors interrupted or
unplugged. (infinite resistance)
Inner or outer temp sensors short circuited
Outer sensor interrupted
(infinite resistance)
Inner temp sensor short circuited. (res.= 0)
Control Unit out of order
INTEGRATED STORAGE COLLECTOR SFERASOLTM
USE AND MAINTENANCE MANUAL

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INTEGRATED STORAGE COLLECTOR SFERASOLTM
USE AND MAINTENANCE MANUAL
SFERASOLTM can be supplied without storage tank also. This is an ideal solution for
swimming-pools systems, systems with centralized storage and solutions in which
only primary circuit is needed.
The appliance without storage tank is supplied without the following:
- Water storage tank
- Heat exchanger
- Expansion pot
- Circulating pump
- Differential thermostat (SFERASOLTM panel is supplied with two sensors, one al-
ready
connected the panel and the other to be connected inside the tank, which will be
fitted in case of swimming-pools systems, inside the thermal exchanger)
- Thermal fluid. (Primary circuit will be closed and will be charged, but regarding
TOTAL primary circuit , necessary quantity of thermal liquid shall be quantified de-
pending on the realized system).
Regarding SFERASOLTM without storage tank, always consider that dimensioning is
not made by Sferasol S.r.l., so any damages occurred or any malfunctioning to the
final system shall not be attributable to Sferasol Energy S.r.l.
All missing components can be supplied by Sferasol Energy S.r.l. excepting the storage tank.
WARNING:
During installation of the system primary circuit must not be higher than
0,5 bar. Captators would be seriously damaged if the above value has over-
come.
During installation of a SFERASOLTM panel without storage tank, follow instructions
relevant to SFERASOLTM with storage water tank
SferasolTM without tank inside SF-A.

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INTEGRATED STORAGE COLLECTOR SFERASOLTM
USE AND MAINTENANCE MANUAL
SferasolTM Data Sheet SF-S
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Integrated Storage Collector SFERASOLTM made by:
2 external metachrylate hemispheres
2 internal steel 09/10 P06 hemispheres
1 water tank in INOX AISI 304 stainless steel
1 heat exchanger in INOX AISI 304 stainless steel, length 8,20 m
1 INOX AISI 304 stainless steel basement
1 30W – 1.300 rpm Circulation Pump
1 Electronic Control Unit
System Classification
System Model: .........................................................................................................................................................................SFERASOLTM
System Code:............................................................................................................................................................................................ SF-S
Classification:........................................................................................forced circulation, integrated with storage tank
Collector System
Nr. of Collectors:................................................................................................................................................................................................1
Gross Collector Surface:...........................................................................................................................................................4,524 m2
Collector Data
Type: ................................................................................................................................................................................................... Spherical
Gross total surface:.......................................................................................................................................................................4,524 m2
Aperture surface:............................................................................................................................................................................ 1,130 m2
Net total surface:...........................................................................................................................................................................0,891 m2
Nr. of coverages:...............................................................................................................................................................................................1
Coverage Material:..........................................................................................................................................................Merthacrylate
Coverage thickness:...........................................................................................................................................................................3 mm
Structure material:.......................................................................................................................INOX AISI 304 Stainless Steel
Net mass: ................................................................................................................................................................................................. 130 kg
Outer dimensions:.............................................................................................................................................1200*1200*1600 mm
Absorber
Material:..............................................................................................................................................................................09/10 P06 steel
Surface treatment: ......................................................................................................black selective paint - high opacity
Connections:...................................................................................................................................................... copper pipes Ø 8mm
Thermalconvector fluid
Type:mixture of monopropylene glycol + water
Antifreeze protection: ...........................................................................................................................................................................YES
Storage
Capacity: ............................................................................................................................................................................................. 150 liters
Storage material: ................................................................................................................................................. INOX AISI 304 steel
Dimensions:.................................................................................................................................................... Ø 600mm – H 850mm
Isolation............................................................................................................................................................ polyurethane 45 kg/m3
Isolation thickness:...........................................................................................................................................................................50 mm
Heat Exchanger:.......................................................................................................................................Ø 27mm - INOX AISI 304
Length: ............................................................................................................................................................................................... 8200 mm
Operating pressure:....................................................................................................................system pressure – max 6 bar
Protection against Corrosion:............................................................................................Magnesium anode, L 600mm
Electric REsistance (optional) ..............................................................................................................................400W – 1200W
Connections
Hot water:.................................................................................................................................................................................................Ø ½” R
Cold water:..............................................................................................................................................................................................Ø ½” R

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INTEGRATED STORAGE COLLECTOR SFERASOLTM
USE AND MAINTENANCE MANUAL
SferasolTM Data Sheet SF-A
Product
Integrated Storage Collector SFERASOLTM made by:
2 external metachrylate hemispheres
2 internal steel 09/10 P06 hemispheres
1 INOX AISI 304 stainless steel basement
1 INOX AISI 304 stainless steel structure
System Classification
System Model: .........................................................................................................................................................................SFERASOLTM
System Code:............................................................................................................................................................................................ SF-A
Classification:...............................................................................................................................................................forced circulation
Collector System
Nr. of Collectors:................................................................................................................................................................................................1
Gross Collector Surface:...........................................................................................................................................................4,524 m2
Collector Data
Type: ................................................................................................................................................................................................... Spherical
Gross total surface:.......................................................................................................................................................................4,524 m2
Aperture surface:............................................................................................................................................................................ 1,130 m2
Net total surface:...........................................................................................................................................................................0,891 m2
Nr. of coverages:...............................................................................................................................................................................................1
Coverage Material:..........................................................................................................................................................Merthacrylate
Coverage thickness:...........................................................................................................................................................................3 mm
Structure material:.......................................................................................................................INOX AISI 304 Stainless Steel
Net mass: ................................................................................................................................................................................................... 80 kg
Outer dimensions:.............................................................................................................................................1200*1200*1600 mm
Absorber
Material:..............................................................................................................................................................................09/10 P06 steel
Surface treatment: ......................................................................................................black selective paint - high opacity
Connections:...................................................................................................................................................... copper pipes Ø 8mm
Thermalconvector fluid
Type: ...................................................................................................................... mixture of monopropylene glycol + water
Antifreeze protection: ...........................................................................................................................................................................YES
Connections
Inlet glycol:............................................................................................................................................................................................Ø 1/4”R
Outlet glycol:.......................................................................................................................................................................................Ø 1/4”R
Operating pressure
Maximum:................................................................................................................................................................0.5 Bar

Thank you for choosing SFERASOLTM
INTEGRATED STORAGE COLLECTOR SFERASOLTM
USE AND MAINTENANCE MANUAL

Via G. Pascoli, 1 - 10060 Scalenghe (TO) - ITALIA
Tel + 39.011.194.577.34 - MOB. + 39.335.18.93.453
[e-mail]
www.sferasolenergy.com
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