SOLAR BLOCKS TRAINING

Central Heating
Swimming Pool Heating
DHW - LV

V3 1
Solar Panels Installation
The Panels should be oriented SOUTH (at north hemisphere).
But their orientation may be shifted from Northeast to Northwest.
They may have an inclination between 10 º to 90 º degrees.
Best 45º to 90º

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Solar Panels Installation
Each panel has six M8 holes on the side tabs for fixation. The distance
between holes in the installation place should have the following
dimensions:

Each panel must be secured at 6 points (minimum)

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Solar Panels Installation
There are two types of solar panels:
• Left Panels
• Right Panels

RIGHT

LEFT

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Solar Panels Installation

The Solar panel must be always installed on the landscape position.

Never on portrait.

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Solar Panels Installation
Fixing Examples
The solar panels may be fix in various ways, the following are two of the
most used ones.

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Solar Panels Installation
The distance from the panels to the Thermodynamic Group must be
less than 30 meters.
The flatness should not exceed 15 meters.

We recommend that the distance shall not exceed the following values:
SB 6 to SB 16 → 20 meters
SB 28 to SB 40 → 30 meters

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Solar Panels Installation

The minimum space between solar panels:

- On the connections side : 200mm (ideal: 500mm)
- On the opposite side: preferably it should be of > 10mm

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 Solar Panels Layout
The panels’ layout depends on the system to be installed, on the disposition of
the installation area, on the architectural integration, etc...
Always prefer symmetrical layouts!

a)
ENERGIE

ENERGIE

ENERGIE

ENERGIE
ENERGIE

ENERGIE

ENERGIE

ENERGIE
b)
ENERGIE

ENERGIE
ENERGIE

ENERGIE
ENERGIE

ENERGIE

ENERGIE

ENERGIE
c)
ENERGIE
ENERGIE
ENERGIE

ENERGIE
ENERGIE
ENERGIE
ENERGIE

ENERGIE

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Thermodynamic Group Installation
Place:
• Accessibility
• Proximity of the Boiler
• Possibility of vibrations transmission
• Position of the pipes coming from the panels
Location:
• Ground
• The console (supported on a wall)

If the thermodynamic group is placed in the attic, you must pay special attention
to the vibrations produced.

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Welding's
The type of welding recommended is:
• Oxyacetylene welding (oxygen/acetylene)
• Another type of gas (i.e. propane).

Always protect the thermo-retractable joint with a damp (wet) cloth!

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Liquid Distributor
The distributor shall be placed between the solar panels.
The tubes connecting the distributor to the solar panels must have exactly
the same.
The tubes endings must connect directly to the solar panels.

Install the distributor(s) vertically, facing downwards.

Never horizontally!

Thereby ensuring that the fluid reaches the panels in even way.

If a tube is too long for required length it must be rolled up, never cut it.

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Liquid Line
So all ∅1/4’’ liquid lines MUST have all the same length
The same applies to the main distribution lines

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Suction Line
According to the Solar Block model and the panel’s positioning, it is
necessary to do one or more suction/aspiration lines.
The main suction line collects the refrigerant fluid in a gaseous state,
and it must regroup all suction tubes (∅ 3/8’’) from the solar panel.

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Solar Block 12

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Thermodynamic Group Connections
Each unit has at least 4 connections:

Two Panel Connections

• To and from the solar panel

Two Heating Connections

• Output and return from the heating emitters

Two DHW-LV & Swimming Poll Connections

• Output an return from the heat exchanger

Note: Before doing the refrigeration connections

you must empty the nitrogen through the access
valve.
All units are supplied with 30 bar nitrogen loading.
Thermodynamic Group Dimensions:
SB6 to SB16 (A= 93, L= 56, P = 55)cm
SB28 to SB40 (A= 93, L= 66, P = 64)cm
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Thermodynamic Group Access Valves

Low Pressure High Pressure

Access Valve Access Valve

It’s on the suction line It’s on the liquid line

Rotalock opens clockwise
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Leakage Test - 1st Step

After performing all the welding's on the panels

you should make a tube cleaning, which we call
Nitrogen cleaning.
It is intended to remove any impurities that may
be inside the pipe.

Weld a access valve on the Liquid Line,

open the Nitrogen’s cylinder shifter and push
the tip of the Aspiration line with your finger.

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Leakage Test - 2nd Step

After performing the Nitrogen Cleaning make a

10 bar Nitrogen load.
The solar panels should be 2-3 days with the
nitrogen load to ensure that there is no
leakage.
If after that time the pressure doesn’t come
down, you have ensured that there are no
leaks.

Close the aspiration line (welding) and cut

the Nitrogen load.

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Leakage Test - 3ºrd Step

After doing the solar panels’ nitrogen load

withdraw the existing nitrogen and weld the
liquid line and the aspiration line to the
thermodynamic group.

Repeat the 10 bar nitrogen load to the

entire system through the aspiration
access valve (low pressure access valve).

Check all the welds with soap foam water

to detect any leakages.

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Vacuum
The vacuum is done to remove air and humidity from the circuit.
The vacuum time depends on the following factors:
• Vacuum Pump’s Capacity (vol. m3/h)
• Tubes Volume
• System Volume
• Humidity Content

This operation shall be made with the two hoses. One connected to the
low pressure access valve and the other to high pressure access valve.

Solar Block 6 12 16 28 40
Minimum vacuum time (hours) 5 8 9 11 12

Once the vacuum process finishes close the vacuum pump valves. The
vacuum gauge must maintain the same reading after the pump stops,
ensuring that the installation keeps the vacuum and that is ready for the
loading.
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Refrigerant Loading - R407C
Non destructive to the ozone layer
It is a ternary Zeotropic mix of R32, R125 and R134a and it is only
compatible with polyester oils.
These type of oils absorbs lots of moisture, so they disintegrate very
quickly. To avoid this to happen always keep the ends of the copper
tubes sealed. Leaving the system open the shortest amount of time
possible and do good vacuums!

R32 - 23% R32 - 32%

R125 – 25% R125 – 32%
R134a- 52% R134a- 36%

Liquid Phase Vapour Phase

THE CHARGE MUST BE MADE WITH THE FLUID ON LIQUID PHASE

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Temperature/Pressure Comparison Chart R407c – R22

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Refrigerant Loading

If the load is carried out with a Zeotropic fluid on a vapour state, there is a strong
chance that one of the fluid’s components to vaporize before the others.
Therefore, you must ensure that the loading is done with the fluid on a liquid
state.

Before starting the loading make sure the compressor is off.

The load of the refrigerant is conducted on the compression access valve
(on high pressure side).
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Refrigerant Loading

Bottle Bottle
with without
Siphon Siphon

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Refrigerant Loading
The amount of fluid that must be loaded depends on the:
• Model of Solar Block
• Distance between thermodynamic group and the solar panels
To ensure the basic operation of the thermodynamic solar system, one
must ensure a minimum charge of fluid.
After the minimum charge is done and after the HP and LP are
equalized (see pressure gauges), the compressor is ready to start.

Solar Block 6 12 16 28 40
Minimum load (kg) 1,6 2 2,5 3 5,5
It may be required to adjust the charge. This the extra load shall be
made, slowly through the low pressure access valve (suction line) until
you reach:
A difference of 20ºC between the
AMBIENT TEMPERATURE and EVAPORATION TEMPERATURE
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Panel Control Board

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Electrical Connections

The power supply must meet the following manufacturers

specifications:

Model Power Suply

SB 6 230/400V (50Hz)
SB 12 230/400V (50Hz)
SB 16 400V (50Hz)
SB 28 400V (50Hz)
SB 40 400V (50Hz)

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Electrical Wiring

Electrical wiring section:

Solar Block 6 12 16 28 40
Single Phase (mm²) 2,5 4 4 --- ---
Tri-phase (mm²) 2,5 2,5 2,5 4 6

Installation of a magneto-thermal circuit breaker:

Solar Block 6 12 16 28 40
Single Phase (A) 16 25 25 --- ---
Tri-phase ( A) 6 10 16 20 25

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Troubleshooting

Faults & Solutions!!!

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Troubleshooting

No information on the display

Power Failure (230V or 400V)

Safety Thermostat Activated
Phase Sequencer (i.e. three-phase)
Electronic board (fuse or connections damaged)

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Troubleshooting

LP Warning

Extremely low outside air temperatures

Leak in the circuit
Damaged expansion valve
Damaged pressure switch

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Troubleshooting

HP Warning

Poor Heat Exchange

Blocked Circuit
Circulating pump OFF
Water pipes with airlocks

Undersized heat emitters

Too much fluid

Damaged expansion valve

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Troubleshooting

Tn- Thermal Safety

(Thermal Relay)

Excessive Power Consumption

(MANUAL RESET)

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Troubleshooting

Failure in the temperature probe

- Disconnected Probe

- The probe is in short-circuit

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Troubleshooting

Solar Block Diagnosis

Model Serial n.º Panels Orientation (N;S;E;W) Fluid Charge g

Central Heating Swimming Pool Heating DHW-XL

Area to Heat m² Length m Total Volume l

Ceiling Height m Width m Cylinders (one or two)

Type of Heat Emitters Depth m Recirculation (Y/N)

House Temp. ºC Water Temp ºC Water Temp ºC

Expansion
Suction Super Electrical
Time Valve Sun in the Outside Air
LP (bar) HP (bar) Temp. Heating S1 (ºC) S2 (ºC) S3 (ºC)* S4 (ºC)* Consumption
(Δt ≥ 5min) Opening Panels (Y/N) Temp. (ºC)
(ºC)** (ºC)* (A)
(%)*

* - Reading require only for new models with electronic expansion valve. V2.1
** - Reading on the EVD display for new models. Or by a thermometer place on the aspiration pipe just before the compressor, for older models.

(a) All values shall be obtained with the compressor runnig.

(b) For new models is required for the installer to have the electronic expansion valve display.

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DHW - XL
Every step and assembly sequences are identical to those described for
the Central Heating, except the connections between the
thermodynamic group to the finned tube heat exchanger that is inside
the cylinder.

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DHW - XL

When welding the heat

exchanger tubes use a
No. Legend: damp (wet) cloth to prevent
1 Electrical Connections the rubber gaskets to melt!
4 H.Exch. outlet (Refrig.)
5 H. Exch. inlet (Refrig.)
6 Solar Panels Outlet
7 Solar Panels Return
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Swimming Pool
Every step and assembly sequences are identical to those described for
the Central Heating, except the connections between the
thermodynamic group to the titanium heat exchanger.
The heat exchanger for the swimming pool systems should be installed
by following the next steps:
a) Fulfill all the hydraulic circuit
b) Always place a wet cloth on the copper pipes, near the heat
exchanger to protect the components during the welding.
c) Weld the tubes on the correct place: outlet of the solar block to the
inlet of the heat exchanger; inlet of the solar block to the outlet of the
heat exchanger

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How not to do it!

Uneven Distribution

Uneven Distribution

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 How not to do it!

Too Much Nitrogen Pressure

No Gap Between the Solar Panels

Means bad Ventilation
Panel upside down
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Pictures

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 Concrete Blocks
(i.e. 10 cm X 15 cm) 69
MARK AND DRILL

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PLACE WASHER

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TIGHTEN SUPPORT

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PANEL PLACEMENT 74
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POINTING SCREWS

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TIGHTEN SCREWS

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 THE END
SOLAR BLOCKS
Central Heating
Swimming Pool Heating
DHW - Large Volumes

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