thermital BPS Series User guide

BPS
INSTRUCTIONS FOR THE INSTALLER AND
FOR THE TECHNICAL ASSISTANCE CENTRE
SOLAR STORAGE CYLINDER

2
Dear Installer,
Thank you for having chosen a BPS solar storage cylinder, a modern high quality product, providing
you with the utmost wellbeing and with a high level of reliability and safety. And this is particularly
the case if the storage cylinder is entrusted to a THERMITAL Technical Assistance Centre which is
specifically capable of carrying out routine maintenance, to keep it running at maximum efficiency,
with low running costs and which has original spare parts if required.
This instruction booklet contains important information and suggestions that should be observed for
easy installation and better use of the solar storage cylinder BPS.
Thank you once again.
THERMITAL
MODEL CODE
BPS SOL 1500 HT 20136245
BPS SOL 2000 HT 20136246
RANGE

3
GENERAL
GENERAL WARNINGS
In some parts of the booklet, some symbols areused:
b WARNING = for actions that require par-
ticular caution and adequate preparation
aFORBIDDEN = for actions that absolutely
SHOULD NOT be carried out
GENERAL
General warnings page 4
Basic safety rules “ 4
Description of the appliance “ 5
Identification “ 5
Structure “ 6
Water circuit “ 6
Technical data “ 7
INSTALLER
Receiving the product page 9
Handling “ 9
Assembly of the insulation (BPS 2000 e 3000) “ 10
Installation room of the storage cylinder “ 10
Installation on appliances that are old
or that need to be updated
“ 10
Hydraulic connections “ 11
TECHNICAL ASSISTANCE CENTRE
First commissioning preparation page 12
First commissioning “ 12
Checks during and after
the first commissioning “ 12
Deactivation for long periods “ 13
Maintenance “ 13
Cleaning of the storage cylinder and dismantling
of the internal components “ 14

4
CONTENTS
CONTENTS
b Check that the product is complete, undamaged
and as ordered as soon as you receive it. Report
any discrepancies or damage to the THERMITAL
dealer who sold it.
b This product must be installed by a legally quali-
fied heating engineer. On completion of the instal-
lation, the installer must issue the owner with a
declaration of conformity confirming that the instal-
lation has been completed to the highest standards
in compliance with the instructions provided by
THERMITAL in this instruction manual, and that it
conforms to all applicable laws and standards.
b This product must only be used for the purpose
for which it is designed and made, as specified by
THERMITAL.THERMITAL declines all responsibi-
lity, contractual or other, for damage to property or
injury to persons or animals caused by improper
installation, adjustment, maintenance or use.
b The product must be serviced at least once a year.
Servicing must be arranged in advance with the
THERMITAL Technical Assistance Centre.
b All servicing and repairs must be performed by a
qualified heating engineer.
b If water leaks from the storage cylinder, turn off the
water supply and contact THERMITAL’s Technical
Assistance Centre or a qualified heating engineer
immediately.
b If the product is not going to be used for an exten-
ded period of time, contact the manufacturer’s
Technical Assistance Centre to have at least the fol-
lowing operations performed:
- Close the shut-off cocks for the domestic hot
water circuit
- Shut down the boiler connected to the storage
cylinder as instructed in its own manual
- Switch the storage cylinder OFF at the control
panel (if fitted) and at the mains power switch
- Drain the central heating circuit and domestic hot
water circuit if there is any risk of freezing.
b This instruction manual is an integral part of the
product. It must be kept safe and must ALWAYS
accompany the product, even if it is sold to another
owner or transferred to another user or to another
installation. If you lose this manual, order a repla-
cement immediately. Keep the product purchase
documents to be presented to the THERMITAL
authorised Technical Assistance Centre to request
a service call under warranty.
b Size the solar expansion tank so as to ensure com-
plete absorption of the expansion of the fluid con-
tained within the system, with reference to the pre-
vailing regulations on the matter. In particular, con-
sider fluid characteristics, considerable fluctuation
of service temperature and vapour that might be
generated during solar collector stagnation stage.
Proper size of expansion tank ensures setting off of
all volume changes of the heat transfer fluid, avoi-
ding excessive pressure increase. Limited pressure
changes avoid reaching safety valve opening pres-
sure and the consequent fluid drainage.
a Never attempt to install the system without using
suitable personal protection equipment and without
following all applicable occupational safety stan-
dards.
a Do not touch the product when barefoot or wet if it
has any electrical accessories installed in it.
a Never clean or service the storage cylinder without
first turning the mains power switch OFF to discon-
nect all electrical accessories (if fitted) from the
mains electricity supply.
a Never pull, disconnect, or twist any electrical cables
coming from the appliance even if it is discon-
nected from the mains electricity supply.
a Do not expose the storage cylinder to the elements.
It is not designed for use outdoors.
a If solar plant pressure decreases, it is forbidden to
top up with only water as there is a danger of free-
zing and overheating.
a Do not use connections or safety devices or fittings
(expansion vessels, pipes, insulation) that are not
specifically designed and tested for use in solar
water heating systems.
a Do not allow children or infirm persons to operate
the system unsupervised.
a Do not dispose of packaging material into the envi-
ronment, or leave it within the reach of children,
since it can become a potential hazard. Dispose of
packaging material in compliance with applicable
legislation.
Please remember that the use of products using electric power and water involves respect for a few basic safety rules
such as:
BASIC SAFETY RULES
GENERAL WARNINGS

5
GENERAL
GENERAL WARNINGS
The solar storage cylinders with a double coil and a
capacity of 1500 and 2000 litres, can be integrated into
solar systems for producing domestic hot water.
The main technical elements of the design of the solar
storage cylinder are:
- the careful study of the geometries of the tank and the
coils that allow you to obtain the best performance in
terms of stratification, heat exchange and reactivation
times
- the inner covering, bacteriologically inert, to ensure
maximum hygiene of the water processed, to reduce
the possibility of limestone deposit and make cleaning
easier
- the regulation of the connections to various heights for
employing various types of heat generators, without
influencing the stratification
- the polyurethane insulation without any CFC and the
elegant outer covering to limit dispersion and to impro-
ve efficiency
- the use of the flange to facilitate cleaning and mainte-
nance
- the use of the magnesium anode with an "anti-corro-
sion" function
The boilers can be equipped with a specific solar regula-
tor and they can easily be inserted into solar equipment
where the boilers or thermal systems act as auxiliary
producers of heat.
The BPS solar storage cylinders can be identified by:
b Tampering, removal, lack of identification labels or anything else which does not permit the safe
identification of the product, makes any installation and maintenance operation difficult.
– Technical Label
Lists the technical and performance data of the
storage cylinder.
– Product Label
Lists the name of the product.
RIELLO S.p.A. Via Ing. Pilade Riello, 7 - 37045 Legnago (VR)
RIELLO S.p.A. Via Ing. Pilade Riello, 7 - 37045 Legnago (VR)
RIELLO S.p.A. Via Ing. Pilade Riello, 7 - 37045 Legnago (VR)
RIELLO S.p.A. Via Ing. Pilade Riello, 7 - 37045 Legnago (VR)
– Serial Number
Lists the serial number, the model, the power con-
sumption and the capacity.
IDENTIFICATION
DESCRIPTION OF THE APPLIANCE

6
1
3
13
2
6
5
7
9
4
8
10
11
12
EAF
UAC
MC
RC
RL
M
R
SB
1 - First magnesium anode
2 - Probe socket
3 - Auxiliary socket (for models 1500)
4 - Auxiliary socket (for models 2000)
5 - Flange for tank inspection
6 - Flange cover
7 - Lower coil
8 - Polyurethane insulation
9 - Upper coil
10 - Tank
11 - Second magnesium anode
12 - Electric heater socket (not supplied)
13 - Solar regulator probe socket
STRUCTURE
GENERAL
WATER CIRCUIT
b The BPS solar storage cylinder is not equipped
with load circulators which should be appro-
priately sized and installed on the system. For
the recommended flow rate of the solar heating
circuit, see the instructions for assembling the
solar collector and the THERMITAL operation
and maintenance manual of the storage system.
UAC - DHW outlet
MC - Flow
RC - Return
M - Flow
R - Return
RL - DHW recirculation
EAF - Domestic cold water inlet
SB - Cylinder drain
BOILER
SOLAR

7
GENERAL
GENERAL WARNINGS
(*) In accordance with DIN 4708 with a ΔT of 20°C (80°/60°C) at the coil.
(**) Electrical heating element (not supplied)
TECHNICAL DATA
DESCRIPTION BPS SOL 1500 HT BPS SOL 2000 HT
Type of storage cylinder Vitrified
Storage cylinder layout Vertical
Heat exchanger layout Vertical
Storage cylinder capacity 1390 1950 l
Useful non-solar volume (Vbu) 525 800 l
Diameter with insulation 1200 1300 mm
Diameter of storage cylinder without insulation 1000 1100 mm
Height without insulation 2120 2370 mm
Height with insulation 2185 2470 mm
Insulation thickness 100 100 mm
Total net weight 325 540 kg
First magnesium anode (Ø x length) 32x700 mm
Second magnesium anode (Ø x length) 32x400 mm
Flange diameter (external/internal) 290/220 mm
Diameter/length of sensor socket 8/200 mm
Sleeve for electric heating element (**) 1" 1/2
Coil water capacity 19,4 28,1 L
Coil heat exchange surface area 3,4 4,6 m2
Power absorbed by coil (*) 88 120 kW
Domestic hot water production (*) 2200 2900 l/h
Flow required at coil (*) 3,8 5,2 m3/h
Top coil water capacity 10,4 16,9 l
Top coil heat exchange surface area 1,8 2,8 m2
Power absorbed by top coil (*) 47 73 kW
Hot water production – top coil (*) 1200 1800 l/h
Flow required at top coil (*) 2 3,1 m3/h
Maximum operating pressure 8 bar
Maximum operating temperature 99 °C
Discharges according to EN 12897:2006
(∆T=45 °C, ambient 20°C and storage at 65°C)
162 186 W
3,89 4,46 kWh/24h
Insulation type Soft PU
Maximum operating pressure of coil 10 bar
Maximum working temperature of coil 110 °C
NL performance factor 55 84

8
GENERAL
Pressure drop TOP COIL
Pressure drops BOTTOM COIL
PERDITA DI CARICO (mbar)
PORTATA (l/h)
500
550
600
450
400
350
300
250
200
150
100
50
0
0 500 1000 1500 20002500 3000 3500 4000 4500 5000 5500 6000
Mod. 1500
Mod. 2000
PERDITA DI CARICO (mbar)
PORTATA (l/h)
600
650
700
550
500
450
400
350
300
250
200
150
100
50
0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000
800
850
900
850
750
Mod. 1500
Mod. 2000
FLOW RATE (l/h)
PRESSURE DROP (mbar)
FLOW RATE (l/h)
PRESSURE DROP (mbar)

9
INSTALLER
The solar storage cylinders BPS are supplied in a single
package, protected by a nylon bag and put on wood
pallets.
The BPS SOL 1500 HT model is provided with a foam
rubber shock absorbent protective band.
The two magnesium anodes are supplied in a cardboard
box on the pallet.
RECEIVING THE PRODUCT
The BPS SOL 2000 HT models are supplied in two sepa-
rate packages:
- the first package is composed of the painted tank, pro-
tected by a nylon bag and put on wooden pallets.
- the second package, also protected by a nylon bag,
is composed of the polyurethane insulation with an
elegant outer covering, the outer trim rings of the pipe
coupling, the top cover, the flange covers, the identifi-
cation labels and the documentation.
HANDLING
Once the packaging is removed, the handling of the sto-
rage cylinder is carried out manually with equipment that
is suitable for the weight of the appliance.
To separate the BPS SOL 1500 HT storage cylinder from
the pallet cut the band (1) located under the insulation
near the hinges.
To lift the BPS SOL 2000 HT, storage cylinders, after
removing the insulation, bind the high part of the storage
cylinder with a cord that can bear the weight and care-
fully lift it.
b Use suitable accident-prevention protections.
a It is forbidden to dispose of the packaging material
and keep it within children's reach, as it may be a
potential source of danger.
1
1
Model 1500
Models 2000
Model 1500 Models 2000
The following material is supplied in a plastic envelope
inside the package:
- Instruction booklet
- Label with bar code
- Hydraulic test certificate.
The two magnesium anodes are supplied in a cardboard
box on the pallet.
b The instruction booklet is an integral part of the sto-
rage cylinder and it is recommended that it be read
and kept safe.
INSTALLING THE MAGNESIUM ANODES
Proceed as follows to install the magnesium anodes:
- Remove the protective plugs
- Fit the two magnesium anodes in the fittings (1) and
(2)
- Screw in the magnesium anodes using a suitable
spanner.
NOTE: Tighten to a torque of 25 Nm.
1
2
2

10
INSTALLER
Once the tank is positioned in its place in the installation
room, the insulation and the elements completing the
solar storage cylinder can be assembled.
To do this:
- Remove all the material supplied in the second packa-
ge.
- Assemble the two magnesium anodes on the connec-
tions (1) and (2),.
- Wind the insulation around the tank (3) following the
direction of the holes already present on the inside of
the insulation and secure it with the special zippers (4)
located at the ends.
- Pierce the insulation near the holes for the attachments
and attach the outer trim rings (5)
- Attach the flange cover (6).
- Lastly apply the upper part (7) of the insulation and in
turn place the cover (8) on it
3
3
4
4
4
1
2
5
7
8
6
ASSEMBLY OF THE INSULATION (BPS SOL 2000 HT)
The BPS solar storage cylinders can be installed in all rooms where a level of electrical protection of the appliance
above IP X0D is not required.
b The room where it is installed should be dry, to prevent rust forming.
b In order to make the installation, assembly, inspection and ordinary and extraordinary maintenance operations
easy, the minimum distances must be maintained and the installation room of the storage cylinder must be easily
accessible. In particular, access to the room must allow, among other things, the possible total removal and re-
installation at the end of the storage cylinder's useful life. The user is, therefore, responsible for any costs for remo-
val of masonry work or anything else making it impossible or hard to access the installation room of the storage
cylinder.
When the BPS solar storage cylinders are installed on
appliances that are old or that need to be updated, make
sure that:
- The installation comes with the safety and control com-
ponents in compliance with the specific regulations
- The appliance has been washed, cleaned of mud and
grime, de-aerated and the water seals have been che-
cked
- There is a treatment system for when the supply/make-
up water is particular (the values in the table can be
used as reference values).
REFERENCE VALUES
pH 6-8
Electric conductivity less than 200 μS/cm (25°C)
Chlorine ions less than 50 ppm
Sulphuric acid ions less than 50 ppm
Total iron less than 0.3 ppm
M alkalinity less than 50 ppm
Total hardness less than 35°F
Sulphur ions none
Ammonia ions none
Silicon ions less than 30 ppm
INSTALLATION ON OLD APPLIANCES OR APPLIANCES THAT NEED TO BE UPDATED
PLACE OF INSTALLATION
b Having completed the assembly, attach the serial
number, the technical data label and the product
label which enable a secure identification of the
storage unit (see positions on page 6).

11
INSTALLER
The BPS solar storage cylin-
ders can be connected to heat
generators, even those alre-
ady installed, provided they
have adequate heat output
and comply with the direction
of the water flow. Moreover,
they can be easily integra-
ted into THERMITAL solar
equipment which include
solar collectors, the fastening
system, the hydraulic unit, the
expansion tank and the ther-
mostatic mixer valve.
Installation on appliances that
are old or that need to be upda-
ted
The BPS storage cylinders
include probe holder wells to insert
possible probes.
We recommend isolating valves in the outlet and return lines.
HYDRAULIC CONNECTIONS
DESCRIPTION
BPS MODEL
1500 HT 2000 HT
UAC Domestic hot water outlet 1"1/2 F Ø
MC Outlet from boiler 1"1/4 F Ø
RC Return to boiler 1"1/4 F Ø
M Outlet from solar collector 1"1/4 F Ø
R Return to solar collector 1"1/4 F Ø
RL DHW recirculation 1" F Ø
EAF (SB) Domestic cold water inlet (storage cylinder drain) 1"1/2 F Ø
Psc1 Diameter/length of boiler sensor socket 8/200 - mm
Psc2 Diameter/length of boiler sensor socket - 8/200 mm
Psr Diameter/length of solar controller sensor socket 8/200 mm
RE Sleeve for electric heating element (not supplied) 1"1/2 F Ø
AD1 Diameter/length of first magnesium anode 32/700 Ø/mm
AD2 Diameter/length of second magnesium anode 32/400 Ø/mm
TR Temperature gauge 1/2" F Ø
A 1230 1340 mm
B - 1487 mm
C 1775 2000 mm
D 280 250 mm
E 415 400 mm
F 525 662 mm
G 1125 1205 mm
H 1225 1315 mm
I 1325 1425 mm
L 1420 - mm
M 1730 1870 mm
N 1890 1990 mm
O 2120 2045 mm
P 1200 1300 mm
EAF
R
UAC
RC
RL
M
MC
SB
RE
G
H
I
M
N
D
E
C
B
A
AD1
AD2
TR
Psc1
Psr
F
L
O
Psc2
P
The characteristics of the hydraulic connections are as follows:

12
INSTALLER
Before the start-up and before testing the boiler, it is
absolutely necessary to check that:
- The water supply taps of the domestic water circuit are
open
- The water connections to the respective boiler and to the
water unit of the solar equipment have been carried out
correctly
- The procedure for washing and filling up of the solar
heating circuit with the water-glycol has been carried
out correctly, and the equipment has been de-aerated
at the same time.
The transfer of heat into the solar heating circuit takes
place when the temperature of the solar collector is
higher than that of the storage cylinder. Therefore in
managing the solar equipment the exact temperature is
not important, but rather the temperature difference.
- Set the temperature difference between the collector
and the storage cylinder (see the instruction manual of
the control box).
- Commission the boiler for the auxiliary heating of the
storage cylinder.
Basic solar control box (accessory)
prog
A1
prog
FIRST COMMISSIONING PREPARATION
FIRST COMMISSIONING
CHECKS DURING AND AFTER THE FIRST COMMISSIONING
At the start-up make sure that:
- The flow rate of the solar heating circuit is 30 l/h per m2
of collector surface
- The solar heating circuit is completely vented
- The cold pressure of the equipment is about 3 bar
- The safety valves intervenes at 6 bar
- The piping of the hydraulic supply are insulated in full
respect of current regulations.
If all conditions have been met, restart the boiler and
storage cylinder and check the regulated temperature
and the amount of DHW that can be taken.
1
2
3
4
5
06

13
TECHNICAL ASSISTANCE CENTRE
Periodic maintenance, which is essential for safety purposes, the efficiency and the life of the solar storage cylinder, pro-
vides reduced consumption and keeps the product reliable over time. Remember that the maintenance of the storage
cylinder, can be carried out by the THERMITAL Technical Assistance Centre or else by qualified professional personnel
and should take place at least once a year.
Before doing any maintenance work:
- Disconnect the storage cylinder's hydraulic unit and
the respective generator from the electrical supply,
positioning the main switch and that of the control
panel to "off"
- Close the intercept devices of the sanitary system
- Empty the storage cylinder's secondary circuit.
Not using the solar storage cylinder for a long period of
time requires that the following operations be carried out:
- Empty the solar heating circuit
-
Close the intercept devices of the sanitary system
- Switch off the boiler in the manner described in the
appliance's instruction booklet
- Position the system's master switch to off.
b Drain the heating and domestic hot water
systems if there is any risk of freezing.
The THERMITAL Technical Assistance Centre is availa-
ble if the procedure reported above is difficult to do.
MAINTENANCE
DEACTIVATION FOR LONG PERIODS

14
TECHNICAL ASSISTANCE CENTRE
12
OUTSIDE
Cleaning the cover of the storage cylinder should be
carried out with damp cloths and water and soap. In the
case of stubborn stains dampen the cloth with a mixture
of 50% water and methylated spirit or with specific pro-
ducts for the marks. Once the cleaning is finished, dry
the storage cylinder.
a Do not use abrasive products, gasoline or trichloro-
ethylene.
INSIDE
Removing and checking the magnesium anode
- Remove the plug (1), the cover (2) and the central
insulating disc that covers the anode
- With a 45 mm spanner unscrew the anode holder plug
(3).
- Check the state of wear of the magnesium anode and
replace it if necessary.
Perform the same operation on the second magnesium
anode, using a box wrench.
Once the cleaning operations are finished, reassemble
all the components, following the above instructions in
the reverse order.
Cleaning the parts inside the storage cylinder
- Remove the flange cover (4).
- Unscrew the fastening nuts (5) of the flange (6) and
remove it together with the gasket
- Clean the inside surfaces and remove the residues
through the opening.
Once the cleaning operations are finished, reassemble
all the components, following the above instructions in
the reverse order.
b Tighten the bolts (5) of the flange fastening (6) with
a “cross-head” system to uniformly distribute pres-
sure on the gasket.
- Load the storage cylinder's secondary circuit and
check the seal of the gaskets.
- Carry out a performance test.
3
4
6
5
CLEANING THE STORAGE CYLINDER AND DISMANTLING THE INTERN AL COMPONENTS

15
NOTE

Cod. Doc-0071229 - Rev. 4 (08/17)
RIELLO S.p.A.
Via Ing. Pilade Riello, 7
37045 - Legnago (VR)
www.thermital.it
The manufacturer strives to continuously improve all products. Appearance, dimensions, technical
specifications, standard equipment and accessories are therefore liable to modification without
notice.