Potterton Solar, Maintenance & Service Manual

Page 1: ...stic Hot Water System Baxi Heating UK Ltd 2007 Please read these instructions before installing or commissioning Potterton Solar Solar Thermal Domestic Hot Water System should only be installed by a competent person Please leave these instructions with the user for safe keeping ...

Page 2: ...y BAXI Heating UK Ltd TheWyvern Business Park StanierWay Derby DE21 6BF Full acknowledgement of author and source must be given WARNING Any person who does any unauthorised act in relation to a copyright work may be liable to criminal prosecution and civil claims for damages 2 Index 3 Commissioning of system General information Flushing and filling the system 5 Commissioning of hydraulic station C...

Page 3: ...sun If direct radiation occurs the collector panels should be shaded by covering them during filling and flushing Although the solar heat transfer fluid is non corrosive and biodegradable appropriate precautions should be taken when handling Wear protective gloves and goggles Wash with soap and water if the fluid comes into contact with skin If fluid gets into eyes immediately rinse with large qua...

Page 4: ...in the return Fig 1 Item 5 is open indicated by the dot on the thermometer bezel being at the top Turn the slot of the adjusting screw of the flow meter Fig 1 Item 6 in the return vertically to open the flow limiter Fig 1 Item 7 Flush the solar primary pump by pumping the fluid into the system via the fill and drain valve on the safety group Close right hand isolating valve dot on thermometer beze...

Page 5: ... airbleed screw on the air separator Fig 4 Item 1 Bleed any air from the air separator If the system pressure drops top up by opening the fill and drain valve Fig 4 Item 2 on the safety group and pumping in more solar fluid to restore the pressure This must be repeated until the pressure remains stable 2 3 Setting the system pressure During commissioning the system pressure should be 0 7 bar above...

Page 6: ...olar pump see section 3 1 7 Set the solar pump switch Fig 5 Item 5 so that the required flow rate is achieved or exceeded with the lowest possible setting The flow limiter adjusting screw Fig 5 Item 3 can be used to fine tune the flow rate Depending on the number and type of collectors installed set the required flow rate from table See Table 1 The float in the flow meter will indicate the circula...

Page 7: ...hes when Presentation of figures 00000 to 99999 a value is changed ºC Temperature in Celsius K Temperature difference in Kelvin h Operating hours kWh Productivity indication in kWh 3 0 Commissioning of solar controller 3 1 Overview of display and operating elements Number Description 1 Display with graphic symbols 2 Control button scroll upwards 3 Control button exit break off 4 Control button scr...

Page 8: ...torage tank upper thermostat function Antifreezing sensor or universal temperatures measuring point T6 no sensor monitoring 2nd temperature differential controller Operating hours energy productivity measurement Status indication Solar circulation pump Symbol revolves when solar circulation pump is on Switch output 1 is active Appears when switch output 1 is active on Switch output 2 is active App...

Page 9: ...ure Button Function Description Up Step up through menu Value change Increase of the indicated value by 1 holding the button down will automatically increase values Call Call up of main menu step down through menu Down Value change Decrease of the indicated value by 1 holding the button down will automatically decrease values Scroll left In main menu scrolls to the left Exit Exit current menu Exit...

Page 10: ...ain menu for automatic regulation of solar system Indication of current measured values Indication of system condition Indication of error messages Indication of operating hours and energy productivity if installed Programming Changes to programmable values parameters Note Changes can affect systemfunctions Manual operation Switching on and off connected pumps valves by hand Overrides automatic re...

Page 11: ...nimum storage cylinder temp Start temperature Glycol percentage storage2 at bottom collector 2 Heating cooling Maximum storage cylinder temp Hysteresis temperature Volume flow storage2 at bottom collector 2 heating cooling Td Current collector Temperature differential Controlling time in temperature return line controller seconds Maximum temperature of the heating target Tmax Current temperature T...

Page 12: ...or temperature yes Re settable to current temperature 52ºC Indication of current temperature storage tank lower no min 40ºC Indication of minimum temperature storage tank lower yes Re settable to current temperature max 67ºC Indication of maximum temperature storage tank lower yes Re settable to current temperature 25ºC Indication of universal temperature measuring points T3 no 55ºC Indication of ...

Page 13: ... control of the pump 30 100 100 100 100 speed control off 13 21 Clock 0 00 23 59 12 00 min Temperature start for the function 20 90ºC 40ºC 40ºC heating cooling dT Hysteresis heating cooling 1 30K 10K 10K max Differential controller Maximum 15 95ºC 65ºC 65ºC temperature of heat target Tmax min Differential controller Maximum 0 95ºC 15ºC 15ºC temperature of heat source Tmin dTmax Temperature differe...

Page 14: ...peration there is no automatic regulation of the system To avoid inadmissible operating states this mode of operation changes into Indication after ca 8 hours and the automatic regulation is activated again Indication Description Value range Switching on off switch output A1 solar circulation pump by hand 0 off 1 on Switching on off switch output A2 pump2 valve1 by hand 0 off 1 on Switching on off...

Page 15: ...Re cooling function only when collector 0 off 0 off protection is on 1 on 3 40ºC Target temperature for the storage after 30 90ºC 40ºC collector protection activity 4 0 Time controlled circulation with 0 off 0 off tube collectors 1 on 5 0 Yield estimation off on 0 off 0 off 1 on 6 0 Glycol types see table below 0 10 0 7 50 Glycol percentage 0 100 50 5 steps 8 1 0 Volume flow Litre per impulse flow...

Page 16: ...e solar pump on output A1 up to the set maximum storage temperature Pump operation is allowed as long as the collector panel temperature exceeds the cylinder temperature by a set amount 3 1 12 Systems with two storage cylinders For systems with more than one storage cylinder System Types 1 and 2 the cylinder heating can be optimised depending on the energy supply Usually the cylinder with lower pr...

Page 17: ...ference Storage tank dTmax is kept constant as much as possible At lower deviation of Storage tank dTmax the pump is operated with the lowest power till the switch off wave is reached 3 1 14Thermostat heating The thermostat is a control circuit that s independent from the storage loading Thus an auxiliary heating in the top area of the storage cylinder is made possible The output A3 will be Switch...

Page 18: ... time 3 2 1 Sensor monitoring The sensors necessary for control functions and their connecting cables are monitored regarding break and short circuit If a faulty sensor is recognised by the software the symbol is shown By scrolling up and down you can find an error source The use of tem perature sensors of the wrongtype can also lead to an error m essage Basic Setting Programming 14 3 Maximum temp...

Page 19: ...ps by 10K Part of the energy is lost in the pipes the rest is loaded in the storage which results in increasing the storage temperature above the adjusted maximum storage temperature For security reasons the function will be interrupted if the storage reaches 95ºC If the storage temperature is bigger TStmax 2K and the collector temperature is 10K below TSt then the re cooling function is activated...

Page 20: ... minimum runtime of the pump is 5 minutes For security reasons the function is deactivated if the temperature of the priority storage falls below 5ºC 3 2 6 Energy productivity measurement For the purposes of energy productivity measurement solar gain a sensor on the collector return line and a flow meter are required The yield value is calculated from the values of the temperature difference betwe...

Page 21: ...djustment adjustment Storage tank1 65 C Maximum storage temperature Storage tank1 7 K switch on difference dTon Storage tank1 3 K switch off difference dToff Storage tank2 90 C Maximum storage temperature Storage tank2 7 K switch on difference dTon Storage tank2 3 K switch off difference dToff Minimum pump power on 100 rotational speed regulation Switch on temperature of 40 C thermostat function H...

Page 22: ...primary system flow rate l min l min l min l min l min l min l min l min l min l min l min l min l min Check operation of PRV Check sensor operation use resistance temperature table See page 22 Check solar cylinder in accordance with manufacturer s instructions Ensure system is free of air Visually check condition of solar collector panels Visually check condition of collector panel brackets and f...

Page 23: ...ar bar bar bar bar bar bar bar bar bar Check solar primary system pressure cold bar bar bar bar bar bar bar bar bar bar bar bar bar Check solar primary system flow rate l min l min l min l min l min l min l min l min l min l min l min l min l min Check operation of PRV Check sensor operation use resistance temperature table See page 22 Check solar cylinder in accordance with manufacturer s instruc...

Page 24: ... the solar heat transfer fluid Check pH value with a pH indicator rod target value approx pH 7 5 If the limit pH value is less than pH 7 replace the heat transfer fluid 4 2 Maintenance of the collector The collector or the collector array must be inspected visually once a year for any damage leaks and contamination 4 3 Cylinder Refer to manufacturers documentation volume Density at 20 C g cu cm Re...

Page 25: ...Measures flashing Sensor wire broken Check wire Sensor defect Check sensor resistance if necessary exchange sensor flashing Short circuit in sensor wire Check wire Sensor defect Check sensor resistance if necessary exchange sensor Error in pump connection Check cabling Pump defect Exchange pump Air in the system Check the float of the flow meter moves when the system runs if visible Connection wit...

Page 26: ...1 80 1309 90 1347 100 1385 120 1461 140 1535 200 1758 YES No display at solar differential temperature controller Controller fault Replace controller Is the 230 240V power supply switched on YES Has thermal cutout on cylinder operated unvented systems only NO NO Is internal fuse operational YES NO Replace internal fuse Check wiring and rectify Reset thermal cutout Investigate cause of operation an...

Page 27: ... Check connections and rectify as necessary YES Displayed temperatures on controller vary greatly over short time intervals Controller fault Replace controller Are sensor cables laid alongside mains voltage cables NO Have sensor cables been lengthened with unshielded cable NO NO Do sensors give correct temperature v resistance readings YES YES NO Are sensor connections correctly made YES Sensor fa...

Page 28: ...Potterton Solar Solar Thermal Domestic Hot Water System 28 6 0 Spares A B C D E F G H I J K L Diagrams not to scale 10 20 LITRE O M N P Q R ...

Page 29: ...ion washer On roof panels comprising 2 off flat sealing washer 5119535 E Temperature sensor 5119536 F Solar differential temperature controller complete 5122978 G Pressure relief valve 5119538 H Pressure Gauge 5119539 I Safety Group complete 5119540 J Solar primary circulating pump 5119541 K Flow meter assembly 5119542 L Temperature gauge 5119543 M Solar heat transfer fluid 10 litre drum 5119544 N...

Page 30: ...nty will affect your statutory consumer rights What you need to do if you experience a problemwith your Potterton Solar system You should always contact your installer first because the fault may not be related to the Potterton Solar system If your installer confirms that the fault is within the Potterton Solar system itself and he she decides they cannot repair it our friendly customer service te...

Page 31: ...ied locations Potterton Solar collector s can be installed Baxi Heating UK Ltd will only carry out warranty repair replacement to Potterton Solar collectors which have safe access provided that meets current Health Safety working at heights requirements Heateam will cover the cost of any safety equipment required to meet this standard after the first 30 days of installation up to 2 years and will ...

Page 32: ...et All goods are sold subject to our standard Conditions of Sale which are available on request Potterton A Trading Division of Baxi Heating UK Ltd a division of Baxi Group Brooks House Coventry Road Warwick CV34 4LL After Sales Service and Technical Enquiries 08700 603261 Our contact centre is open Monday to Friday 8am to 6pm Weekends and Bank Holidays 8 30am to 2pm We are closed Christmas Day an...