thermital BPS SOL 1500 HT User guide

BPS
INSTRUCTIONS FOR THE INSTALLER AND
FOR THE TECHNICAL ASSISTANCE CENTRE
Code 20055741_EN rev. 2 - 05/16
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
The BPS solar boiler has a SPECIFIC GUARANTEE starting from the date of validation by the
THERMITAL in your area.
We would invite you, then, to promptly contact the above-mentioned THERMITAL Technical
Assistance Centre which will, FREE OF CHARGE carry out the commissioning of the solar boiler
under the conditions specified in the WARRANTY CERTIFICATE supplied with solar boiler, which
we suggest you read carefully.
The Technical Assistance Centre, at your request, can provide you with good advice on how to use the solar boiler
correctly.
MODEL CODE
BPS SOL 1500 HT 20052815
BPS SOL 2000 HT 20052816
RANGE
WARRANTY

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 13
First commissioning “ 13
Checks during and after
the first commissioning “ 13
Deactivation for long periods “ 14
Maintenance “ 14
Cleaning of the storage cylinder and dismantling
of the internal components “ 15

4
CONTENTS
CONTENTS
b After removing the packaging make sure that
everything is there and undamaged, if not contact
the THERMITAL Agency that sold you the applian-
ce.
b The installation of the solar storage cylinder BPS
should be carried out by a company certified which
when the work is finished will issue the owner with
a declaration of conformity that the installation is up
to standard, i.e. in compliance with regulations in
force and with the recommendations provided by
the THERMITAL instruction booklet.
b The solar storage cylinder BPS should only be
used for the purposes for which it was made by
THERMITAL.
N o contractual or extracontractual liability is accep-
ted by THERMITAL for damage caused to people,
animals, or objects due to errors in installation,
adjustment, or maintenance or by improper use.
b If necessary, use a pressure reducer for the water
input.
b Use a safety valve alibrated in the manner shown
on the technical data label on the storage cylinder.
b Use an expansion tank of a suitable size for the
dimensions of the storage cylinder (it is recommen-
ded that this calculation be done by a heating engi-
neer).
b Before start-up it would be good to check the tight-
ness of the flange screws.
b Maintenance of the storage cylinder should be car-
ried out at least once a year.
b In the event of a water leak, disconnect the stora-
ge cylinder from the main power supply, shut off
the water supply and promptly notify the Technical
Assistance Centre THERMITAL or else professio-
nally qualified personnel.
b Maintenance of the storage cylinder should be car-
ried out at least once a year.
b Not using the solar storage cylinder for a long
period of time requires that at least 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 Mix the anti-freeze (propylene glycol), availa-
ble separately, with water in a variable percen-
tage (30÷50%) following the instructions in the
THERMITAL operating and maintenance manual.
b Always fill the solar system with the water/
glycol mixture in the percentage reported in the
THERMITAL operating and maintenance manual.
b This booklet is an integral part of the appliance
and so should be carefully preserved and should
ALWAYS accompany the storage cylinder even
when it is sold to another owner or user or when
transferred to another system. In case of loss or
damage, please contact your local THERMITAL
Technical Assistance Service for a new copy.
a Children and non-assisted disabled people are not
allowed to use the storage cylinder.
a It is forbidden to touch the storage cylinder while
barefoot or if parts of your body are wet.
a Any cleaning operation is forbidden before discon-
necting the storage cylinder from the main power
supply by turning off the system's main switch as
well as the main switch of the control panel.
a Do not modify adjustment devices without the manu-
facturer's permission and relative instructions.
a It is forbidden to pull, disconnect or twist the electric
cables coming out of the storage cylinder even if it
is disconnected from the main power supply.
a It is forbidden to expose the storage cylinder to
the elements because it is not designed to function
outdoors.
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.
a It is forbidden, in the event of a drop in pressure of
the solar system, to top up only with water as there
is a risk of freezing.
a It is forbidden to use connection and safety devices
that have not been tested or that are not suitable for
use in solar equipment (expansion tanks, piping,
insulation) .
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 BPS 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 with
collectors.
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, and the magnesium anode with an "anti-corro-
sion" function
The BPS boilers can be equipped with a specific solar
regulator and they can easily be inserted into solar
equipment where the THERMITAL 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.
– Serial Number
Lists the serial number, the model, the power con-
sumption and the capacity.
IDENTIFICATION
DESCRIPTION OF THE APPLIANCE

6
1
3
4
2
6
5
7
9
8
10
11
12
3
4
2
6
5
7
9
8
10
11
12
1
1 - First magnesium anode
2 - Probe socket
3 - Auxiliary socket
4 - Solar regulator probe socket
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)
STRUCTURE
GENERAL
WATER CIRCUIT
EAF
UAC
MC
RC
RL
M
R
SB
EAF
UAC
MC
RC
RL
M
R
SB
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
(*) According to DIN 4708, to get domestic hot water with ΔT 20°C (80°/60°C) on the heat-exchanger, please observe the values show-
ed in the datasheet concerning absorbed power and necessary capacity heat-exchanger.
(**) With average boiler temperature = 60°C and ambient temperature = 20°C
TECHNICAL DATA
DESCRIPTION BPS SOL 1500 HT BPS SOL 2000 HT
Cylinder type Vitrified
Cylinder layout Vertical
Heat exchangers layout Vertical
Cylinder diameter with insulation 1200 1300 mm
Cylinder diameter without insulation 1000 1100 mm
Height with insulation 2185 2470 mm
Insulation thickness 100 mm
First magnesium anode (Ø x length) 32 x 700 mm
Second magnesium anode (Ø x length) 32 x 400 mm
Flange diameter 290/220 mm
Probe socket diameter 8 8 mm
Electric resistor socket (not supplied) 1"1/2 1"1/2 Ø
Lower coil water content 19,4 28,1 l
Upper coil water content 10,4 16,9 l
Lower coil heat exchange surface 3,4 4,6 m2
Upper coil heat exchange surface 1,8 2,8 m2
Lower coil absorbed power (*) 88 120 kW
Upper coil absorbed power (*) 47 73 kW
DHW (*) - bottom coil 2200 2900 l/h
DHW (*) - top coil 1200 1800 l/h
Necessary capacity heat exchanger – lower coil (*) 3,8 5,2 m3/h
Necessary capacity heat exchanger – upper coil (*) 2,0 3,1 m3/h
Storage cylinder maximum operating pressure 8 8 bar
Coils maximum operating pressure 6 6 bar
Maximum operating temperature 99 99 °C
Heat loss (**) 3,93 4,77 kWh/24h
Net weight with insulation 330 544 kg
Useful volume 1390 1950 I
Dispersion 250 305 W
6 7,32 kWh/24h
Insulation type Soft PU shells
Useful non-solar volume (Vbu) 525 800 l

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 BPSare 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 - DHW outlet 1”1/2 F 1”1/2 F Ø
MC - Boiler outlet 1”1/4 F 1”1/4 F Ø
RC - Boiler return 1”1/4 F 1”1/4 F Ø
M - Solar flow 1”1/4 F 1”1/4 F Ø
R - Solar return 1”1/4 F 1”1/4 F Ø
RL - DHW recirculation 1” F 1” F Ø
EAF (SB) - Domestic cold water inlet (cylinder drain) 1”1/2 F 1”1/2 F Ø
Psc - Diameter/length boiler probe socket 1/2" F 1/2" F Ø/mm
Psr - Diameter/length solar regulator probe socket 1/2" F 1/2" F Ø/mm
RE - Electric resistor socket (not supplied) 1”1/2 F 1”1/2 F Ø
AD1 - Diameter/length magnesium anode 32 x 700 Ø/mm
AD2 - Diameter/length magnesium anode 32 x 400 Ø/mm
TR - Thermometer 1/2" F 1/2" F Ø
A 1230 1340 mm
B 1820 2000 mm
C 280 260 mm
D 415 400 mm
E 525 660 mm
F 1125 1205 mm
G 1220 1315 mm
H 1315 1425 mm
I 1410 1485 mm
L 1720 1870 mm
M 1870 1990 mm
N 2185 2470 mm
O 1200 1300 mm
Net weight with insulation 330 544 kg
EAF
R
UAC
RC
RL
M
MC
SB
E
F
G
H
L
M
C
D
B
A
AD1
AD2
TR
Psc
Psr
E
I
N
O
The characteristics of the hydraulic connections are as follows:

12
INSTALLER
3
2
R
M
°C
M
4
4
4
9
8
11
10
13
14
6
5
12
Gruppo idraulico
15
16
7
UAC
EAF
PRIMARIO
MC
RC
RL
SB
11
4
4
11
12
5
10
4
4
44
8
17
18
19
Uscita
4
4
11
10
Ingresso
4
4
12
5
Schematic diagram
b When using unsoftened water, it is recommended
that the maximum temperature of the storage cylin-
der be set at 60°C, since at higher temperature
limestone will deposit with the resulting deteriora-
tion of the heat exchange.
b Before commissioning the solar equipment, the boi-
ler must be filled with water.
b If a solar storage unit is being used with network
pressure greater than 4 bar, plan to use a pressure
reducer.
b Be careful not to get burned when opening the vent
valves of the solar equipment.
b The expansion tank must resist high temperatures
and the membrane must not come into contact with
the water-glycol mixture.
b IT IS OBLIGATORY that the sanitary system include
the expansion tank, the safety valve, the automatic
vent valve and the storage cylinder discharge tap.
b The safety valve outlet must be connected to a sui-
table collection and venting system. The manufac-
turer of the storage cylinder waives all liability for
any flooding caused by the intervention of the safe-
ty valve.
b To limit the temperature of the domestic hot water
use a thermostatic mixer valve (19).
b If there is a drop of pressure in the solar equipment
DO NOT fill with water but with water-glycol mixture:
risk of freezing.
b All the piping installed including the collectors, the
exchangers and the hydraulic devices, must under-
go seal tests.
b The selection and the installation of the compo-
nents of the system is referred to the expertise of
the installer, who must operate according to the
rules of good technique and current Legislation.
1 - Solar collector
2 - Storage cylinder
3 - Collector probe
4 - Isolating valves
5 - Non-return valve
6 - Thermometer
7 - Drain valve
8 - Safety valve
9 - Pressure gauge
10 - Discharge
11 - Expansion tank
12 - Circulator pump
13 - Flow regulator
14 - Flow meter
15 - Drain tap
16 - Manual bleed valve (accessory)
17 - Softener filter
18 - Pressure reducer
19 - Mixer valve
UAC- DHW outlet
MC - Boiler outlet
RC - Boiler return
M - Flow collector
R - Return collector
RL - DHW recirculation
EAF - Domestic cold water inlet
SB - Cylinder drain

13
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

14
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

15
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

Via Mussa, 20 Z.I. - 35017 Piombino Dese (PD) - Italy
Tel. [phone] - Fax [phone] - www.thermital.com - email: [email protected]
Since the Company is constantly improving its range of products,
the appearance and dimensions, the technical data, the equipment and accessories,
can be subject to variation.
Code 20055741_EN rev. 2 - 05/16