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Pleion EGO 220 Installation And User Manual

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1
Congratulations
You have purchased a top quality product.
"EGO"
solar collector with integrated storage was designed by an Italian company, and all
its components are produced 100% in Italy.
After its simple installation, you can enjoy the beauty of its design, the practicality of its
operation and the guarantee of its performances:
Smart. Solar. Box
Installation and user handbook – rev.0.4 of 23.02.2017

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Summary of Contents for Pleion EGO 220

  • Page 1 Congratulations You have purchased a top quality product. “EGO” solar collector with integrated storage was designed by an Italian company, and all its components are produced 100% in Italy. After its simple installation, you can enjoy the beauty of its design, the practicality of its operation and the guarantee of its performances: Smart.

  • Page 2: Table Of Contents

    STORAGE ........................18 Note on the integrated storage system ..................18 TECHNICAL DATA ..........................19 Model EGO 110 ..........................19 Model EGO 150 ..........................20 Model EGO 180 ..........................21 Model EGO 220 ..........................22 Model EGO 260 ..........................23 OPERATION PRINCIPLES ......................
  • Page 3 Structural check ..........................26 SAFETY PRECAUTIONS WHILE ASSEMBLING ..................27 INSTALLATION ON A FLAT ROOF ...................... 28 Place and position ........................28 Necessary items ........................... 29 Installation phases ........................30 Anchoring with ballasts ........................ 35 INSTALLATION ON A SLOPED ROOF ....................37 Place and position ........................
  • Page 4 ELECTRICAL INTEGRATION KIT ....................61 Types of electric resistor ........................61 Installing the electric resistors ......................62 Indications on using electric resistors ....................63 PROGRAMMED MAINTENANCE ......................64 GUARANTEE CONDITIONS ......................65 ENVIRONMENTAL PROTECTION ....................66 FINAL NOTES ..........................66 SOLAR KEYMARK CERTIFICATION ..................

  • Page 5: Inside The Box

    INSIDE THE BOX Components that are supplied standard … Installation and user handbook – rev.0.4 of 23.02.2017...
  • Page 6 Before starting to install the product, make sure all the components are present: quantity letter component [pieces] “EGO” solar collector with integrated storage 1 right + BASIC SUPPORT: pair of galvanised sheet supports for flat roof 1 left c d e hammer head screw, washer and nut for fixing ¾‟‟...

  • Page 7: Optional Accessories

    OPTIONAL ACCESSORIES Accessories that can be requested  DELIGHT SUPPORT: pair of AISI 304 electropolished supports for flat roof 4403XXXX00 Article code: for EGO 110 4404XXXX00 for EGO 150 4405XXXX00 for EGO 180 4406XXXX00 for EGO 220 4407XXXX00 for EGO 260...
  • Page 8  SAFETY AND ONE-WAY UNIT, with MF ¾‟‟ connections 4400223301 Article code:  PRESSURE REDUCER, with ¾‟‟ MF connections 4400223302 Article code:  THERMOSTATIC MIXER VALVE, with ¾‟‟ MF connections 4400224500 Article code: Installation and user handbook – rev.0.4 of 23.02.2017...
  • Page 9 Follow the component assembly instructions; if using accessories, follow their pertinent options and limits of use. Only use genuine components. Should it be discovered that non-genuine components have been installed, the manufacturer can refuse all guarantee rights. Installation and user handbook – rev.0.4 of 23.02.2017...

  • Page 10: Explanation Of The Symbols Used

    EXPLANATION OF THE SYMBOLS USED ABBREVIATED SIGNS connection material to be obtained important note to the water supply (not supplied) 2 people necessary qualified electrician qualified designer tighten/loosen manually tighten with spanner perforate with drill DANGER SIGNS Danger! Risk of falling Risk of burns Generic danger from a height...

  • Page 11: Warnings

    WARNINGS GENERAL INDICATIONS  This document is an integral and essential part of the product. It is to be used by the installer and the end user, who must keep it carefully after the system has been installed and started. ...

  • Page 12: Protection From Vacuum Overheating

     Before cleaning or carrying out maintenance, disconnect the power supply from any electric accessories that may be present.  Dispose of the various packaging elements in a suitable manner.  Check the pressure of the water transportation network: if the pressure is higher than the nominal pressure of the product (4 bar = 400 kPa), prepare the necessary reduction units before the connection and regulate the pressure (see STARTING chapter).

  • Page 13: Protection Against Lightning

    Always position a thermostatic mixer valve between the system outlet and the domestic water user (see HYDRAULIC CONNECTION chapter). In general, do not touch the transport pipes or the hydraulic connections and the internal accumulation tanks while the system is operating. Should it be necessary to empty the system while it contains hot water: - do not discharge directly onto the roof or into the ground;...

  • Page 14: Laws And Reference Standards

    LAWS AND REFERENCE STANDARDS Decree no. 37/2008 of 22 January 2008 UNI EN 12975-1:2006 UNI EN 12975-2:2006 UNI EN 12976-1:2006 UNI EN 12976-2:2006 UNI EN 9806:2014 UNI EN 1991:2004 PARTS 1-2,1-3,1-4 (Actions on structures) Directive 97/23/EC UNI EN 1717:2002 Legislative Decree no. 81 of 09 April 2008 Installation and user handbook –...

  • Page 15: Specifications On Water Quality

    SPECIFICATIONS ON WATER QUALITY REFERENCE VALUES The characteristics of the water used can notably influence how well the product works and how long it lasts. The supply water should respect the values given in the table below. parameter unit of reference value measurement ≥6.5 and ≤9.5...

  • Page 16: Limits Of Use

    Should the supply water have values that exceed the reference limits given, above all if the hardness is >26°F (15°T equal to 267 ppm of CaCO ), it is advisable to place suitable filtering, scaling and/or softening devices downstream of the collector. If you do not know the reference values of the water used, have a chemical analysis carried out before installing.

  • Page 17: System Description

    SYSTEM DESCRIPTION TECHNICAL CHARACTERISTICS “EGO” solar collector with integrated storage is used for producing domestic water that is heated by solar power, to temperatures below boiling at atmospheric pressure in places where ice does not form. The system is made up of two integrated units: A.

  • Page 18: The Storage

     The upper frame is made of heat-sealed PVC (3) that can be removed to access the accumulation tank. Light and UV-resistant, its design makes it suitable for any architectural context.  The lower thermal insulation is made of a polyurethane foam panel, 30 mm thick, that is coated with sheets of aluminium;...

  • Page 19: Technical Data

    TECHNICAL DATA 4400100301 Model EGO 110 Article code: parameter unit of measurement value external dimensions (L x P x H) [mm] 2,136 x 711 x 217 gross surface area 1.52 surface area when open 1.09 absorption surface area 0.85 effective ACS content [litres] cover requirements [people]...

  • Page 20: Model Ego 150

    4400100401 Model EGO 150 Article code: parameter unit of measurement value external dimensions (L x P x H) [mm] 2,136 x 906 x 217 gross surface area 1.93 surface area when open 1.48 absorption surface area 1.13 effective ACS content...

  • Page 21: Model Ego 180

    4400100501 Model EGO 180 Article code: parameter unit of measurement value external dimensions (L x P x H) [mm] 2,136 x 1,101 x 217 gross surface area 2.35 surface area when open 1.86 absorption surface area 1.41 effective ACS content [litres] cover requirements [people]...

  • Page 22: Model Ego 220

    4400100601 Model EGO 220 Article code: parameter unit of measurement value external dimensions (L x P x H) [mm] 2,136 x 1,296 x 217 gross surface area 2.77 surface area when open 2.25 absorption surface area 1.69 effective ACS content [litres] cover requirements [people]...

  • Page 23: Model Ego 260

    4400100701 Model EGO 260 Article code: parameter unit of measurement value external dimensions (L x P x H) [mm] 2,136 x 1,491 x 217 gross surface area 3.18 surface area when open 2.64 absorption surface area 1.98 effective ACS content [litres] cover requirements [people]...

  • Page 24: Operation Principles

    OPERATION PRINCIPLES “EGO” solar collector with integrated storage is a natural circulation solar heating system in which the accumulation tank also acts as an absorber (direct exchange). The accumulation system is struck directly by the sun's rays, which pass through the transparent cover and transfer their thermal energy directly to the domestic water, which is contained in special steel cylinders.

  • Page 25: Installation

    INSTALLATION GENERAL INDICATIONS AND MOVING  Assembly, maintenance and cleaning must only be carried out by companies and specialist staff.  The components indicated in this handbook must be used when assembling. The use of other material is under the responsibility of the installer, who assumes full responsibility, including the product guarantee.

  • Page 26: Structural Check

    STRUCTURAL CHECK “EGO” solar collector with integrated storage can be placed on the ground or on a structure (attic, covering, balcony, etc...) that can support the device weight and dynamic actions caused by variable things (e.g. wind, snow,...), considered with the presence of “EGO”...

  • Page 27: Safety Precautions While Assembling

    SAFETY PRECAUTIONS WHILE ASSEMBLING Danger caused by wind Install when the weather conditions are good, avoid rainy days and strong winds. Danger caused by things falling from a height Solar systems often need to be installed at a height. Operators must follow regulations and laws in force regarding safety. Danger caused by hanging loads and material falling from a height If material needs to be lifted using a crane or machinery, apply all the pertinent recommendations and regulations in order to carry out these operations safely.

  • Page 28: Installation On A Flat Roof

    INSTALLATION ON A FLAT ROOF Never remove the cover sheet if you have not finished installing the panel and “EGO” if the collector has not been filled. The solar collector with integrated storage was not designed to be exposed to sunlight when empty. Do not move or force the solar collector using the threaded connections or the caps.

  • Page 29: Necessary Items

    The longest side of the collector must always be supported by the surface. Do not install the collector with the short side (where the connections are) against the surface. Do not turn the collector upside down. The outflow should be positioned at the top, and can be identified by its red cap (inflow at the bottom, identified by a blue cap).

  • Page 30: Installation Phases

    Installation phases Installation and user handbook – rev.0.4 of 23.02.2017...
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  • Page 35: Anchoring With Ballasts

    Anchoring with ballasts “EGO” solar collector with integrated storage cannot be anchored to the roof structure because the supporting surface cannot be drilled (e.g. because of waterproof coating) and if the supporting structure is strong enough (ask a structural expert for confirmation), the system can be anchored to ballasts that are sized according to the wind and snow, as well as to the weight of the collector when both full and empty.
  • Page 36 Examples of ballast In particularly windy areas, an additional safety system should be added to the ballasts, with a suitably-sized steel cable anchored to a solid part of the building that can hold the system. The ballasts and cable must be sized by a structural technician who is authorised to work in the installation area, as indicated by Eurocodes (EN 1991) or NTC 2008 (Decree 14 February 2008) if in Italy.

  • Page 37: Installation On A Sloped Roof

    INSTALLATION ON A SLOPED ROOF Never remove the protective sheet if you have not finished installing the panel, and if the collector has not been filled. The “ ” solar collector with integrated storage was not designed to be exposed to sunlight when empty. Do not move or force the system using the threaded connections or the caps.

  • Page 38: Necessary Items

    Do not turn the collector upside down. The outflow side should be positioned at the top, and can be identified by its red cap (inflow at the bottom, identified by a blue cap). Correct operation cannot be guaranteed if the system is installed upside down. Necessary items ...

  • Page 39: Installation Phases

    Installation phases Installation and user handbook – rev.0.4 of 23.02.2017...
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  • Page 45: Hydraulic Connection

    HYDRAULIC CONNECTION “EGO” solar collector with integrated storage is equipped with 2 connections with 3⁄4“ M thread for connection to the line using flat gaskets (supplied). GENERAL LAYOUT With standard installation, follow the basic hydraulic connection layout. Key of the symbols used in the drawing and synopsis of the compulsoriness/supply. obligatory standard supply optional, can be...
  • Page 46 Installation and user handbook – rev.0.4 of 23.02.2017...

  • Page 47: Indications On Gaskets And Connections

    The components surrounded by a broken line, identified by this icon, make up a basic set that is always present in all possible system configurations. For simplicity, these components are not shown in other hydraulic drawings, but their presence is indicated by the relative icon.

  • Page 48: Other Indications

    This compensates the thermal expansion of the lines caused by temperature oscillations and makes disconnecting and repositioning the solar collector easier if it has to be removed. Make sure the connecting pipes, once installed, can move in order to guarantee suitable thermal expansion. It is advisable to use a connecting system that is not fixed (e.g.

  • Page 49: Assembling The Safety Unit (An Alternative To The Safety Valve)

    Assembling the safety unit (an alternative to the safety valve) For installations in Italy and in countries where a regulation similar to the one established by Ministerial Circular no. 829571 of 26 March 2003 regarding accumulation water heaters: "...these devices must be connected to the domestic water system using a hydraulic safety unit. This unit must include at least one interception tap, a one-way valve, a control device for the one-way valve, a safety valve, a hydraulic charge interrupting device, all accessories necessary for using the water heaters safely.

  • Page 50: Positioning And Fixing The Backflow Preventer

    POSITIONING AND FIXING THE BACKFLOW PREVENTER “EGO” solar collector with integrated storage is protected from negative pressures by a backflow preventer (or air feed valve) that is assembled on the outflow connection. This valve is supplied installed, but must be directed correctly by the installer and fixed in position.

  • Page 51: Pressure Reducer

    A maximum tightening force of 20 Nm can be applied to the plastic connections and the valve body (it is best to use a torque wrench to avoid exceeding this value). A valve that is not positioned correctly can easily become clogged or dirty, which results in loss of functionality and leaks.

  • Page 52: Thermostatic Mixer Valve

    Thermostatic mixer valve To keep the usage temperature below 60°C and to prevent problems occurring in the hydraulic systems downstream of the system caused by the high temperatures that the system can reach, install a THERMOSTATIC MIXER VALVE, available as an optional 4400224500 accessory upon request (code This solution "protects the user from scalding hot water flowing out after a period during...

  • Page 53: Connecting More Than One Collector

    CONNECTING MORE THAN ONE COLLECTOR If using more than one collector, they can only be connected in parallel. This means that a manifold must be used to connect the collectors to the supply water system and to the user‟s water system. “EGO”...

  • Page 54: Examples Of System Layouts

    EXAMPLES OF SYSTEM LAYOUTS “EGO” solar collector collectors with integrated storage can be connected in different ways. Some examples, which are not exhaustive, follow. Layout 1: hydraulic connection to a traditional boiler 5-way thermostatic , mixer and diverter valve Layout 2: hydraulic connection to a boiler prepared for operation with a solar power system Installation and user handbook –...
  • Page 55 Installation and user handbook – rev.0.4 of 23.02.2017...

  • Page 56: Expansion Vessel

    EXPANSION VESSEL “EGO” The water held in the accumulator of the solar collector is subjected to notable thermal excursions and, as a result, important variations in volume. The system is protected from the overpressure caused by these fluctuations by the safety and one-way valve which, if necessary, opens and allows the system to return to its correct working pressure.

  • Page 57: Starting

    STARTING USING THE COVER SHEET “EGO” solar collector with integrated storage is supplied with a PVC cover sheet which darkens the surface that receives the sun's rays, therefore protecting the product against overheating caused by direct exposure, above all in the case when the solar collector has been installed but is not connected to the water system (therefore no water present).

  • Page 58: Filling

    FILLING We recommend carrying out this operation within two weeks after installation. a) connect the cold water supply line (water works, well,...) to the inflow connection, as shown in the basic hydraulic connection layout. Note. The outflow connection must be free; if a discharge tap was installed before the backflow preventer, it must be opened.

  • Page 59: Working Pressure

    Before opening the water supply and starting the system, make sure that all the safety components have been installed as indicated in the basic hydraulic connection layout. f) Finally, open a hot water tap to check if the water is being supplied correctly, and to eliminate the residue air in the system water supply line.

  • Page 60: Non-Use For Short Periods Of Time

    NON-USE FOR SHORT PERIODS OF TIME “EGO” If the solar collector with integrated storage is not used for a period of up to 15 days (e.g. absence for holidays), the system can be left full and the solar collector uncovered. However, it is advisable to completely empty the tank and then refill it before using the hot water again.

  • Page 61: Electrical Integration Kit

    ELECTRICAL INTEGRATION KIT TYPES OF ELECTRIC RESISTOR Even though the system was designed to operate in temperate zones with good radiation, it has a greater range of uses if combined with ELECTRIC RESISTORS, available as optional accessories to be requested. There are 3 types of resistor available: ...

  • Page 62: Installing The Electric Resistors

    INSTALLING THE ELECTRIC RESISTORS If electric resistors are to be installed after the collector has been started, it must be covered previously with the supplied cover sheet (or with a suitable darkening system) and emptied completely.  The integration resistor (1 and 2 kW) must be installed in the upper part of the solar collector, opposite the side where the outflow connection is positioned (I).

  • Page 63: Indications On Using Electric Resistors

    These accessories can only be connected to the electric power supply by a qualified installer who is authorised to operate in the installation area. The installer must apply all precautions to respect standards, above all those regarding safety, and to eliminate any risk situation.

  • Page 64: Programmed Maintenance

    PROGRAMMED MAINTENANCE At least once a year, visually check the “EGO” solar collector with integrated storage to verify if there is any damage, leaks and dirt. Even programmed maintenance must be carried out by a qualified company; the manufacturer will not recognise any guarantee rights if done by other people. Have the correct operation of the safety and one-way valve and the backflow preventer checked periodically if the water is particularly hard and/or has a high level of impurities, which can cause seal loss.

  • Page 65: Guarantee Conditions

    GUARANTEE CONDITIONS  Object: this guarantee is limited to original material and production faults relative to the “EGO” solar collector with integrated storage.  Duration and validity date: the guarantee lasts for: o 5 years for the solar collector and the integrated storage; o 2 years for spare parts;...

  • Page 66: Environmental Protection

    The guarantee does not cover the control of heat and noise pollution. The guarantee does not cover problems deriving from component installation paid by the purchaser/user and carried out by people/independent companies who are not the manufacturer. The guarantee is not valid and operational if the components are not paid for as indicated in the contract.

  • Page 67: Solar Keymark Certification

    SOLAR KEYMARK CERTIFICATION “EGO” solar collector with integrated storage got the Solar Keymark certification according to test report n.xxx issued by ENEA and certification issued by Kiwa Cermet Italia. Installation and user handbook – rev.0.4 of 23.02.2017...

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