System: Installation and Maintenance Manual

SYSTEM
CS25
FOR DOMESTIC HOT WATER PRODUCTION
INSTALLATION AND MAINTENANCE MANUAL
THE RIGHT CLIMATE IN ALL WEATHER

CONFORMITY
CS25 water heating systems conform to EN 12976 standard
RANGE
DESCRIPTION CODE
CS 25 300 COND 4383022.3

CS 25 400 COND 4383023.3
CS 25 200 RESIDENCE 4383025.4

CS 25 300 RESIDENCE 4383022.4
CS 25 400 RESIDENCE 4383023.4
CS 25 200 4383025.0
CS 25 300 4383022.0
CS 25 400 4383023.0
CS 25 500
CS 25 200 REG 4383025.1

CS 25 300 REG 4383022.1
CS 25 400 REG 4383023.1
CS 25 500 REG 4383024.1
2
Dear Customer,
We thank you for playing your part in saving the environment and for choosing a top quality solar
water heating system. You have purchased a modern product that is easy to install and use, and is
designed to give you dependable and safe energy savings for many years to come. You can keep
your new solar water heating system in peak condition by having it serviced regularly by ’s
Technical Assistance Service.
This instruction manual contains important instructions and precautions that must be observed to
ensure the trouble-free installation and efficient functioning of your solar water heating system.
Please accept our thanks and our congratulations on your choice of product.
RIELLO S.p.A.
WARRANTY
WARRANTY
All parts of your new CS25 water heating system are covered by a SPECIAL WARRANTY that
comes into force from the date of validation by ’s Technical Assistance Service.
Contact RIELLO’s Technical Assistance Service for further information on ’s special
maintenance contract for solar heating systems.
3
CONTENTS
GENERAL
General safety information page 5
Safety precautions “ 5
Description of the system “ 6
Safety devices “ 6
Product identification “ 6
System layout “ 7
Accessories “ 8
INSTALLER
Unpacking the product page 9
Description and assembly
of system components “ 11
- fitting system (accessory) “ 11
- solar collector “ 12
- collector connections “ 16
- manual bleed valve (accessory) “ 17
- solar storage cylinder “ 18
- water return group “ 19
- thermostatic mixer valve “ 20
- SUN differential controller (SD2) “ 20
Preparing for initial start-up “ 21
Initial start-up “ 22
Typical connection schemes “ 24
TECHNICAL ASSISTANCE SERVICE:

Checks page 42
Maintenance “ 45
Troubleshooting “ 46
Appendix 1 “ 48
Appendix 2 “ 55
The following symbols are used in this manual:
CAUTION = Indicates actions that require

caution and adequate preparation
STOP! = Identifies actions that you MUST NOT do.
This manual, Code 068017GB - Rev. 7 (04/06) is made

up of 60 pages.
4 CONTENTS
GENERAL SAFETY INFORMATION
The system is delivered in separate crates. Check The liquid in the solar heating circuit can reach
that it is complete, undamaged and as ordered as VERY HIGH TEMPERATURES, in excess of 150°C.
soon as you receive it. Report any discrepancies Beware of burns.
or damage to the dealer who sold it.
Only use the anti-freeze liquid provided by
The system must be installed by a legally RIELLO to fill and top up the system. anti-
qualified installer. (In Italy, the law regulating freeze contains non-toxic, biodegradable and
professional installers is Law 46 of the 5th March environmentally friendly propylene glycol, and is
1990.) On completion of the installation, the specially designed for use in solar water heating
installer must issue the owner with a declaration systems.
of conformity confirming that the installation has
been completed to the highest standards. Periodically check that operating pressure in the
solar heating circuit is over 2.5 bar but below the
The system must only be used for the purpose maximum limit specified for the appliance. If this
specified by and for which it is designed. is not the case, contact ’s Technical
The manufacturer declines all responsibility, Assistance Service or a professionally qualified
contractual or other, for damage to property or technician.
injury to persons or animals caused by improper
installation, adjustment, maintenance or use. Make sure that the water-glycol mix in the primary
circuit is able to resist the minimum temperatures
likely to occur in the place of installation (e.g.:
If you notice any water or other liquid leaking from 40% glycol resists freezing down to -20°C).
the solar heating circuit, disconnect the system
immediately from the mains electricity supply, The system must be serviced at least once a
shut off the water supply, and notify ’s year.
Technical Assistance Service or a qualified
technician immediately.
SAFETY PRECAUTIONS
Never attempt to install solar collectors on roofs Do not tamper with or adjust the safety or control
without ensuring that all applicable standards devices without prior authorisation and instructions
governing safety at work are met first. from the manufacturer.
Never install solar collectors on roofs without an Do not expose the storage cylinder or the controller
adequate lightning protection system. to the elements. They are not designed for use
outdoors.
Never install the system without providing a
suitable drain for the solar heating circuit’s safety Never stop circulation in the solar heating by
valve. means of valves or cocks.
Never clean or service the system without first Do not dispose of packaging material into the
disconnecting it from the mains electricity supply environment, or leave it within the reach of children,
by turning the main power switch and the control since it can become a potential hazard. Dispose of
panel switch OFF. packaging material in compliance with applicable
legislation.
GENERAL 5
DESCRIPTION OF THE SYSTEM
The CS 25 system is a forced circulation system A roof fitting system and manual bleed valve for
for producing domestic hot water in single homes. installation at the highest point in the circuit for quick and
easy bleeding, are available separately.
It comes with all the parts necessary for a complete
installation, including all the accessories required for a A differential solar controller is also available to control
quick start-up: the entire system including any boilers used as
- solar collectors auxiliary heating sources.
- connections between the solar collectors and the solar
storage cylinder, complete with non-return valve
- water return group with flow regulator and safety
system complete with safety valve, expansion vessel
and automatic vent valve with manual closing
- anti-freeze for mixing with water
- solar storage cylinder.
SAFETY DEVICES
The system is equipped with the following safety The operation of a safety device indicates a
devices: potentially dangerous malfunction in the system,
- A safety valve that opens if pressure in the circuit rises and means that you must contact ’s
above the 6 bar threshold. Technical Assistance Service immediately.
The solar controller also prevents over-temperature by Safety devices must only be replaced by ’s
stopping heat exchange if the temperature in the solar Technical Assistance Service using original spare
collectors and storage cylinder exceeds a certain parts.
(programmable) threshold.
To recover any heat transfer liquid losses and
reduce the risk of burns, the safety valve drain must
be connected to a suitable recovery tank via a high
temperature resistant hose.
PRODUCT IDENTIFICATION
Serial number plate
The CS 25 solar water heating system

is identified by a serial number plate marked
with the code, description and serial number
of the product. This plate is supplied in the
documentation envelope delivered with the
system and must be applied to the solar
storage cylinder on completion of installation.
6 GENERAL
SYSTEM LAYOUT
The figure below illustrates the layout of the CS 25, water heating system on completion of installation.
2 1 1
M R
A1
prog
prog
5 6
9 7
12
13 15 14
10
11 TO SAFETY DRAIN
1 - Solar collector 10 - Flow regulator

2 - Manual bleed valve (accessory) 11 - Flow meter
3 - 7200/2 solar storage cylinder 12 - Solar circuit filling and drain cocks
4 - SUN differential controller (SD2) (required for 13 - Non return valve
‘REG’ versions) 14 - Expansion vessel
5 - Automatic vent valve with manual closing 15 - Flexible hose to expansion vessel
6 - Safety valve
7 - Pressure gauge M - Collector outlet
8 - Temperature gauge R - Collector return
9 - Solar circuit pump
GENERAL 7
ACCESSORIES
The following accessories are available, to be ordered separately.
ACCESSORIES CODE
Manual bleed valve kit (*) 4383056
Parallel roof fitting kit for 1 collector 4383060.1
Parallel roof fitting kit for 2 collectors 4383060.2
45° fitting kit for 1 collector 4383061.1
45° fitting kit for 2 collectors 4383061.2
Under tile roof fitting kit for 1 collector 4383070
Under tile roof fitting kit for 2 collectors 4383070.2
Recessed flashing kit for 1 or 2 collectors 4383090.2
Recessed flashing kit for 3 collectors 4383090.3
Stainless steel flexible pipe kit (15 metres) 4383068
(*) Required if no automatic filling pump is available.
8 GENERAL
UNPACKING THE PRODUCT
The CS 25 system is delivered on two pallets. The actual contents of the pallets differ according to the number
of collectors in the system, the type of fitting (parallel to roof or at 45°), the capacity of the solar storage cylinder and
expansion vessel, the head of the water return pump and the volume of anti-freeze.
Contents of FIRST pallet:

- Individually packaged collectors with data plate
- One or two cans of anti-freeze
- Box containing the water return group and safety group
and the brackets for fitting them to the solar storage
cylinder
- A bag containing:
Weld-on unions for the collectors and fittings for the
solar storage cylinder
Insulated solar storage cylinder connection pipe,
complete with non-return valve
- Expansion vessel and flexible hose to connect it to the
safety group
- Thermostatic mixer valve.
The following items are delivered in a plastic bag:
- Instruction manual
- Certificate of warranty and label with bar code
- Serial number plate.
The instruction manual is an integral part of the

CS 25 solar water heating system. Once
located, read it thoroughly and keep it safe.
Contents of SECOND pallet:

- The solar twin coil vitrified storage cylinder, complete
with instruction manual, certificate of warranty, spare
parts catalogue and hydraulic test certificate.
The parallel to roof or 45° collector fitting system

(accessory) is delivered in cardboard boxes marked
“SSPN1R” or “SSA45N1R” together with the “TRPNR”
support beams, the length of which depends on the
number of collectors in the system.
CS 25 systems with denominations ending

in “REG” are delivered with a box containing the
SUN differential controller (SD2) and the bracket
for fitting it to the solar storage cylinder.
GENERAL 9
DESCRIPTION CS 25 200 CS 25 300
Parallel to roof fitting 45° fitting Parallel to roof fitting 45° fitting
Solar collectors 1 1 2 2 nr.
Fitting system (accessory) 1 x SSPN1R 1 x SSPN1R 2 x SSPN1R 2 x SSA45N1R n° x type
Anti freeze liquid 10 10 10 10 l
Water return group 1 1 1 1 nr.
Expansion vessel 18 18 18 18 l
Expansion vessel connection hose 1 1 1 1 nr.
Thermostatic mixer valve 1 1 1 1 nr.
Connecting joints - - - - nr.
Solar storage tank capacity 200 200 300 300 l
DESCRIPTION CS 25 400 CS 25 500

Parallel to roof fitting 45° fitting Parallel to roof fitting 45° fitting
Solar collectors 3 3 4 4 nr.
Fitting system (accessory) 3 x SSPN1R 3 x SSPN1R 5 x SSPN1R 5 x SSA45N1R n° x type
Anti freeze liquid 15 15 20 20 l
Water return group 1 1 1 1 nr.
Expansion vessel 24 24 35 35 l
Expansion vessel connection hose 1 1 1 1 nr.
Thermostatic mixer valve 1 1 1 1 nr.
Connecting joints - - 2 2 nr.
Solar storage tank capacity 400 400 500 500 l
10 INSTALLER
DESCRIPTION AND ASSEMBLY OF SYSTEM COMPONENTS
FITTING SYSTEM (accessory)

The solar collectors can be installed parallel to sloping roofs or installed at 45° on flat roofs or the ground. Systems
incorporating more than three collectors require a connecting joint (B) between the support rails. The fitting system is
simple yet strong and creates a rigid structure that resists both wind and snow.
Refer to the instructions provided with the fitting system for details on how to install it.
‘P’ TYPE FITTING SYSTEM

(parallel to roof)
45° TYPE
A FITTING
A SYSTEM
C D E
INSTALLER 11
SOLAR COLLECTOR
These panel type solar collectors have two water fittings Once you have removed the outer packaging, proceed
and consist of a pressed aluminium tray covered with a as follows to unpack and handle the solar collector:
single-piece copper absorber plate. This has a highly - Remove the PVC wrapping to free the solar collector
selective finish obtained by a special vacuum treatment from the pallet.
called “SUN-SELECT”, which guarantees excellent - Tilt the solar collector slightly and grip it at the four
collector performance. points shown (T) to lift it.
The outlet pipe from each collector is fitted with a ring nut - Use a hoist or other suitable lifting equipment to hoist
(G) that can be connected directly to the next collector in the solar collector on to the roof.
the series. The seal ring (H) for the ring nut is strapped
on to the collector’s return pipe.
Collector tube, 22 mm
Ring nut (G)

T
T
COLLECTOR
RETURN
COLLECTOR
OUTLET
Seal ring (H)
Heat exchange
pipe, Ø 8 mm
Collector probe
socket (P) Bottom insulation
4 mm anti- Frame for glass

reflection glass
Aluminium tray
T
T
12 INSTALLER
Collector Collector
outlet return
Collector probe
socket
Direction of flow of
heat transfer liquid
Top frame for glass 4 mm anti-reflection glass

Rubber seal Heat exchange pipe, Ø 8 mm
Bottom frame for
glass
Connection ring nut 1"
Collector tube, 22 mm
Flange plate
Side insulation
Bottom insulation Aluminium tray
INSTALLER 13
Technical data
DESCRIPTION
Total area 2,57 m2
Exposed area 2,2 m2
Effective absorption area 2,17 m2
Connections (M) -(F) 1”
Empty weight 49 kg
Liquid content 1,66 l
Recommended flow rate per m2 of panel 30 l/h
Glass type thickness safety glass with anti reflective surface – 4 mm
Absorption ( α) ~ 0,95 %
Emissions (ε) ~ 0,05 %
Maximum permitted pressure 10 bar
Maximum temperature 230 °C
Maximum number of collectors connectable in series 6 Nr.
Efficiency curve
1
Optical Thermal dispersion factor of
efficiency of absorber
0,8 absorber
(ηο) a1 a2
W/(m2K) W/(m2K2)
0,6
0,806 3,68 0.0072
0,4
Tested according to EN 12975, referred to a
0,2 33.3% water-glycol mix, flow rate of 300 l/h, and
irradiation G G = 800W/ m2.
0 Tm=(Coll._inlet _temp. + Coll._outlet_temp.)/2
0 0,02 0,04 0,06 0,08 0,1 0,12
T*m = (Tm - ambient_temp)/G
*
Tm[m 2
K/W]
Wind and snow loads on collectors
Installation height Wind speed Mass in kg to secure collector against Load on roof from wind, snow, and
above ground lifting by wind collector weight
At angle of 45° At angle of 20° At angle of 45° At angle of 20°
0-8m 100 km/h 80 kg 40 kg 320 kg 345 kg
8 - 20 m 130 km/h 180 kg 90 kg 470 kg 430 kg
20 - 100 m 150 km/h 280 kg 150 kg 624 kg 525 kg
14 INSTALLER
Pressure drop in solar collectors
200
180
160
Pressure drop (mbar)
140
120
100
80
60
40
20
0
0 100 200 300 400 500 600 700 800 900 1000
Flow rate (kg/h)
Connect no more than 6 collectors in series. Do not use plastic or multistrate pipes. Operating
temperature can exceed 180°C.
If copper pipes are used, joints must be hot
brazed. Pipe lagging must be able to resist high
temperatures (180°C).
We recommend the use of stainless steel pipes
specially made for solar collectors for the outlet, A non-return valve must be fitted to the outlet of
return and probe pipes. The probe cable should the solar heating coil.
be of the shielded type.
General instructions
Assembly Lightning protection

The solar collector must be fitted by specialist personnel. The metal piping of the solar heating circuit must be
Use only the assembly material supplied with the solar connected to the main potential compensation bar by a
collector. The supporting framework and all masonry or (yellow-green) copper wire (H07 V-U or R) of at least 16
brickwork fixing points must be checked by a person mm2. If a lightning conductor system is already installed,
expert in static loading, and must be suitable for the the solar collectors may be connected to the existing
nature of the installation site. system. Alternatively, the solar collector piping may be
connected to ground via a ground wire sunk into the
earth. Ground wires must be sunk outside the house. The
Static load ground wire must be connected to the potential
The solar collector must only be installed on roofs or compensation bar through a wire of the same diameter.
frames that are strong enough to support its weight. The
strength of the roof or frame must be verified on site by a
person expert in static loading before the solar collector Connecting support rails
is installed. During this process, it is important to verify If a number of support rails are to be connected in series,
the suitability of the supporting frame to hold the screw fit a joint (KWSR) at the bottom and the top.).
fasteners that fix the solar collector in place. An expert in
static loading must verify that the entire frame complies
with relevant standards, especially in areas liable to
snow and areas exposed to high winds. Conditions
(gusts of wind, formation of wind vortices, etc.) at the
point where the solar collector is to be installed must be
carefully considered since these can increase the loads
on the supporting structure.
INSTALLER 15
Connections Angle of collectors / General
Solar collectors must be connected in series using the Solar collectors are designed to be installed at angles of
fittings and seal rings provided. between 15° (minimum) and 75° (maximum).
If flexible pipes are not used to connect the solar Make sure that the bleed and vent valves of the
collectors, the piping must be fitted with expansion joints collectors remain open while the collectors are being
(U-type expansion joints, flexible hoses) to absorb installed.
thermal expansion. Provided adequate expansion joints Take care to protect all fittings, connections, bleed and
are used, up to 6 solar collectors may be connected in vent valves against dirt and dust etc..
series. Make sure that the seal rings are correctly In installations which serve primarily to produce
positioned in their seats. When tightening a fitting with a domestic hot water in the summer, install the collectors
pipe wrench or spanner, always hold the opposite fitting facing from east to west at an angle of between 20 and
steady with a second tool to avoid damaging the 60°. The ideal orientation is southwards, at an angle
absorber. equal to the latitude of the location minus 10°.
Bleeding
All pipes in the water circuit must be insulated in Bleed the circuit:
conformity to relevant standards. Lagging and - On start-up (after initial filling)
insulation must be protected against damage by - Whenever necessary (e.g. in the event of system
the weather and birds and animals. malfunctioning).
Make quite sure that all air has been bled out of the
system.
Risk of burns from hot fluid inside the collectors!
Only open the vent valve if the temperature of the

fluid in the circuit is below 60°C.
Make sure that the collectors are not hot before
you start bleeding the circuit. Always cover the
solar collectors before bleeding the circuit. Always
perform bleeding in the morning.
COLLECTOR CONNECTIONS
Braze the unions provided to the outlet and return pipes

to connect the collectors to the rest of the system. The 1
unions are provided in a bag containing: 4
3
- Ring nut (1) 2
- Half union for brazing (2)
- Male union (3)
- Seal ring (4)
When you have fitted the unions, hot braze the

system connecting pipes to them.
16 INSTALLER
Proceed as follows to fit the unions:
- Fit the male union (3) with the seal ring (4) behind it to - Fit the half union (2) with the seal ring (G) behind it to
the outlet pipe of the collector. the return connector and tighten it in place with the ring
nut (1).
Outlet Return
M R
4
2
3
1
OUTLET RETURN
PIPE PIPE
MANUAL BLEED VALVE (accessory code 4383056)
The manual bleed valve is designed to bleed air quickly

from the system, and must be installed together with the
brazing union on the collector outlet pipe at the highest
point in the circuit.
Make sure that you close the manual bleed valve

after all air has been bled from the circuit.
Refer to the instructions provided with the bleed

valve for details on how to install it.
The manual bleed valve is not necessary

if an automatic filling pump is available.
INSTALLER 17
SOLAR STORAGE CYLINDER
7200/2 solar storage cylinders are twin coil units of 200, 300, 400 or 500 litre capacity. The storage cylinder is
delivered on the second pallet.
The 300 litre model differs from the 200, 400 and 500 litre models in the position of the recirculation fitting.
7200/2 storage cylinders can be equipped with the SUN (SD2) differential controller and can easily be
integrated in solar heating systems in which boilers serve as auxiliary heat generators.
Model 300/2 Models 200/2 - 400/2 - 500/2
1 1
UAC UAC
10 10
2
2
MC
9 MC 9
RC 8 RC 8
3
RL
M
3
RL M
7 7
4 6
6 4
5
R 5
R
EAF EAF
SB SB
1 - Magnesium anode
2 - Boiler / solar controller probe well
UAC - Domestic hot water outlet 3 - Auxiliary probe well
MC - Outlet from boiler BOILER 4 - Solar controller probe well
RC - Boiler return 5 - Cylinder inspection flange
M - Outlet SOLAR 6 - Flange cover
R - Return 7 - Bottom coil
RL - DHW recirculation 8 - Polyurethane insulation (51.5 mm)
EAF - Domestic cold water inlet 9 - Top coil
SB - Storage cylinder drain 10 - Cylinder
Refer to the instructions provided with the storage cylinder for all relevant technical specifications, water fitting
heights and other dimensions, coil pressure drops, and for all maintenance instructions.
18 INSTALLER
WATER RETURN GROUP
The water return group is delivered together with the

connection pipe and fittings for the solar storage
cylinder.
WALL MOUNTING for 18 and
The 18 to 24 litre expansion vessels come complete with 24 litre expansion vessels
a wall mounting bracket. The 35 litre model is fitted with
feet and is designed as a floor standing unit.
All expansion vessels come pre-charged to a

pressure of 2.5 bar.
L
The connecting hose (L) is supplied.
A non-return valve (N) is fitted at the outlet from the
bottom coil. This valve serves to prevent natural TO SAFETY DRAIN
circulation developing between the coil and the
collectors.
FLOOR
MOUNTING for
The non-return valve (N) must be opened during 35 litre expansion
system filling, and closed immediately after. vessels
Refer to the instructions provided with the water

return group for details on how to install it.
PUMP
The water return groups supplied with CS 25
300 and 400 systems are equipped with RNY 43-15
N IN OPEN POSITION N IN CLOSED POSITION
pumps. The groups supplied with CS 25 500
systems are equipped with RNY 63-15 pumps.
Pump RNY 43-15 WATER RETURN GROUP pressure drop

600
HEAD (mbar)
500
400
III 0,1
300
0,2
200 0,3
I II 0,4
100
0,6
0
0 0,5 1 1,5 2 2,5 3 0,8
PRESSURE DROP (kPa)
1
FLOW RATE (m3/h)
2
3
4
Pump RNY 63-15
800 6
8
700 10
600
HEAD (mbar)
20
III 30
500
40
400
60
300 II 80
200 100
I
10
20
0,01
0,02
0,03
0,04
0,06
0,08
0,1
1
0,2
0,3
2
0,4
3
0,6
4
0,8
6
8
100
0
0 0,5 1 1,5 2 2,5 3
FLOW RATE (m3/h)
FLOW RATE (m3/h)
INSTALLER 19
THERMOSTATIC MIXER VALVE
Domestic hot water from
the solar storage cylinder
A thermostatic mixer valve must be installed at the outlet
from the storage cylinder to keep the temperature of the
domestic hot water under 60°C (see pos. 17 in the figure DHW user
on page 24). points
Make sure that you fit the valve the right way
around.
The “+” mark identifies the inlet for hot water
from the solar storage cylinder.
The “-” mark identifies the inlet for domestic
cold water.
Cold water
SUN DIFFERENTIAL CONTROLLER (SD2)

(if included)
A1
The SUN differential controller (SD2) must be bracketed

prog
R
prog
to the storage cylinder in position (R) as shown in the

figure.
Heat is only transferred from the solar heating circuit to

the storage cylinder when the temperature of the solar
collector exceeds that in the storage cylinder. It is
therefore temperature differential rather than absolute
temperature that is important in controlling solar water
heating systems.
TO SAFETY DRAIN
Fit the probe with the temperature resistant (red)
silicone cable in the probe socket (P) in the outlet
from the leftmost collector in the collector series
(see page 12).
Fit the storage cylinder temperature probe in the

socket provided, taking care to expand the
securing spring (L) first.
Refer to Appendix 2 on page 55 for details on how to

set up the SUN differential controller (SD2).
Refer to the instructions provided with the controller

for details on how to install it.
For further information on water and electrical L

connections see the “Typical connection schemes”
section on page 24.
20 INSTALLATOR
PREPARING FOR INITIAL START-UP
FLUSHING THE SYSTEM
S
- Turn the knob of the return valve (R) fully anti-
clockwise.
- Open the non-return valve (N) at the outlet from the R
solar storage cylinder’s bottom coil.
- Close the flow regulator (V) (so that the screw slot is
horizontal)
- Open the cocks (A) and (B) on the return group. V A N
- Pump water in through the cock (A) and wait for it to IN OPEN
B
come out of the cock (B). POSITION
Leave water flow through the system until it has been
thoroughly flushed out.
- Close the cocks (A) and (B) and re-open the flow
regulator (V) (so that the screw slot is vertical).
If copper piping has been used and joints have

been hot brazed, flush out the system to remove
any brazing residues. Seal test the system after
you have flushed it out.
Fill the solar collector with glycol premix R

immediately after flushing it out, because flushing
water may remain trapped in the circuit (with a
consequent risk of freezing).
PREMIXING WATER + GLYCOL
Glycol anti-freeze is supplied separately and must be

premixed with water in a suitable container before being
used to fill the system. For example, a mix of 40% glycol
and 60% water provides anti-freeze protection down to A
a temperature of -21°C. V
Anti-freeze Temperature Density

B
50% -32°C 1,045 kg/dm3
40% -21°C 1,037 kg/dm3
30% -13°C 1,029 kg/dm3
The propylene glycol supplied is specially formulated Flow

regulator V
for solar collector applications and remains fully
efficient throughout the -32 to +180°C temperature
range.
It is also non-toxic, biodegradable and biocompatible.
CLOSED
position
Graduated
Do NOT part fill the circuit with pure glycol then scale in
add water later. l/min.
Do not use automatic or manual filling systems.

OPEN
position
If the water supply is highly chlorinated, use

distilled water to prepare the glycol/water mix.
INSTALLATOR 21
INITIAL START-UP
FILLING THE SYSTEM

S
Step 1
Turn the knob of the return valve (R) fully anti-clockwise. R
Close the flow regulator (V) (so that the screw slot is
horizontal).
Step 2 A
V N
Open the non-return valve (N) at the outlet from the solar
in open position
storage cylinder’s bottom coil. B
Step 3
Open the automatic vent valve (S) on the safety group
(and, if necessary, the manual bleed valve at the highest
point in the system) and keep it open throughout the
filling operation.
Step 4
S
Pump the heat transfer fluid around the circuit with an
external filling pump until all air bubbles have been
eliminated. Close the vent valve (S) (and, if it was
opened, the manual bleed valve at the highest point in
the system).
Step 5
Temporarily raise the pressure in the system to 4 bar.
Passo 6 R
Start up the system for about 20 minutes.
Step 7
Repeat the air bleed operation from step 3 on until all
residual air is eliminated from the circuit.
Step 8 Heat transfer fluid

Set the pressure in the system to 3 bar. filling pump
A
Step 9
Close the cocks (A) and (B) and re-open the flow V
regulator (V).
G
Step 10
Open the non-return valve (N) at the outlet from the solar
storage cylinder’s bottom coil (see the figure on page B
19).
Do not fill the system in bright, sunny conditions Anti-freeze mix

or if the collectors are hot.
Make sure that you have bled all the air out of the
system, using the vent valve (S) on the safety
group.
22 INSTALLATOR
ADJUSTING THE FLOW
Correct flow adjustment is essential to proper

functioning of the entire system.
To achieve the best possible flow and reduce wastage,
you need to find the right balance between the speed of
the filling pump (C) and the adjustment made on the
flow regulator (V).
Proceed as follows:
- Fully open the flow regulator (V) and adjust the pump
(C) to minimum speed (I).
- Read the flow rate from flow meter (G) and compare it
with the flow rate specified for the system (see the
table below for CS25 solar collector systems).
POSITION C
(I)
N° of collectors Required flow in l/min.
2 2÷3
3 3÷4
4 5÷6 V
5 6÷7
G
6 7÷8
Graduated
scale in
- If the required flow rate is below that currently l/min.
measured in the circuit, close the flow regulator (V)
gradually (turning it clockwise) until the correct value
is achieved.
- If the required flow rate is above that currently
measured in the circuit, increase the speed of the
pump (C), then read off the new measured flow rate
and repeat the previous step.
Checking the heat transfer liquid

Check the anti-freeze effect and the pH level of the heat
transfer liquid every 2 years.
- Use an instrument like a refractometer or densimeter

to check the effectiveness of the anti-freeze (which
must have a nominal protection value of approx. -
30°C). If protection falls below the threshold of -26°C,
replace the mix, or add anti-freeze as required.
- Use litmus paper to check the pH (nominal value
approx. 7.5). If the measured value is below 7, change
the mix.
INSTALLATOR 23
TYPICAL CONNECTION SCHEMES
SYSTEM 1: Water connection diagram for systems with IN - ISN, 23 G/R, heating only boilers
SE
19
40 60 80
20 100
0 120
4 0
3 1
2
ESATTO OMEGA
3
M 1 1 R
SCo
2
RI MI UAC
MC
RC
10 10
16 16 18 5 7
SZ 17
6
M
8
PI PB
SB1 10 10 9
PR
11 ϒC
10 10 16 PS
10 10
12
SC SB2
10 10 10
13
16 10 Valve group
14
10 10 15 10
7 EAF
9 8
1 - Solar collector UAC - Domestic hot water outlet

2 - Collector probe socket EAF - Domestic cold water inlet
3 - Manual bleed valve (accessory) MI - Heating flow
4 - Vent cock RI - Heating return
5 - Vent valve MC - Outlet from boiler
6 - Pressure gauge RC - Return to boiler
7 - Safety valve M - Collector outlet
8 - Drain R - Collector return
9 - Expansion vessel PB - Solar storage cylinder filling pump
10 - Disconnect valves PI - Heating system pump (if necessary, use
11 - Temperature gauge the Pump Replacement Sleeve Kit)
12 - Flow regulator PR - DHW recirculation pump
13 - Flow meter PS - Solar circuit pump
14 - Pressure reducer
15 - Softener filter SE - External probe
16 - Non SC - Boiler probe
17 - Thermostatic mixer valve SZ - Zone probe
18 Storage cylinder SB1 - Storage cylinder top probe
19 - Esatto OMEGA temperature SB2 - Storage cylinder bottom probe
control unit SCo - Collector probe
24 INSTALLATOR
1
2
3
PANEL
4 DB DB
5 N
6 MB MB
7 14 13 L
8 A6 A6
9 F4
BOILER CONTROL
10 MD MD
11 K4
12 1 MANUALE B9
F5 A7
9
2 B
K5 MD
CO1 CO6 3 M
10 E1
4 PI B3
F1 B9
5 B2 SE
11 K6 M
6 PB H1
Q3
NOTES:
B7 B3 SB1
7
12 F2
8 M B2 SC
Y1
B1 H1
Y2
B31/B41/H2
SYSTEM 1: Electrical wiring diagram for systems with
F6 M
B8/B6
Q2 B1 SZ
M
K7 B31 SB2
PROBE connections
B8
B4 SCo
M
IN - ISN,
ESATTO OMEGA temperature control unit
TEMPERATURE
1
2
3
1
2
3
4
1
2
3
4
5
B12
CONTROL
INTERFACE KIT
ESATTO OMEGA temperature control unit.

23 G/R,
3 1 2
Proceed as follows to connect up the
domestic hot water recirculation pump PR:
PE
PE
PE
- Disconnect the wire from terminal K6
PE
interface kit (code 4047694) for details on how to install it.

and fit an insulating cap.
- Refer to the instructions provided with the temperature control

- Connect the recirculation pump PR to
- Refer to Appendix 1 on page 48 for details on how to set up the

terminal K6 as shown in the figure.
PB PS PR
VMix-1
heating only boilers
Electrical connections to be made by the installer
INSTALLATOR
25
SYSTEM 2: Water connection diagram for systems with IN heating only boilers
SE
19
40 60 80
20 100
0 120
4 0
3 1
2
ESATTO OMEGA
3
M 1 1 R
SCo
2
RI MI UAC
MC
RC
10 10
16 16 18 5 7
SZ 17
6
M
8
PI PB
SB1 10 10 9
PR
11 ϒC
10 10 16 PS
10 10
12
SC SB2
10 10 10
13
16 10 Valve group
14
10 10 15 10
7 EAF
9 8

2 - Collector probe well EAF - Domestic cold water inlet
10 - Isolating valves PI - Heating system pump (if necessary, use
12 - Flow regulator PR - DHW recirculation pump
13 - Flow meter PS - Solar circuit pump
15 - Softener filter SE - External probe
16 - Non return valve SC - Boiler probe
17 - Thermostatic mixer valve SZ - Zone probe
18 Storage cylinder SB1 - Storage cylinder top probe
19 - Esatto OMEGA temperature SB2 - Storage cylinder bottom probe
control unit SCo - Collector probe
26 INSTALLATOR
SYSTEM 2: Electrical wiring diagram for systems with IN heating only boilers
PROBE connections
- Disconnect the wire from terminal K6
- Connect the recirculation pump PR to

Proceed as follows to connect up the
domestic hot water recirculation pump PR:
terminal K6 as shown in the figure.

SCo
SB1
SB2
SC
SE
SZ
and fit an insulating cap.

B31/B41/H2
B8/B6
MD
MB
DB
H1
A6
B9
B3
B2
B7
B1
B4
M
M
ESATTO OMEGA temperature control unit
Q3
Q2
K4
K5
E1
K6
Y1
Y2
K7
F4
F5
F1
F2
F6
N
L
PR
PE
CO23
Electrical connections to be made by the installer

5
4
PS
3 PE
2
1
PE
4
VMix-1
3
2
1
CO24
1 MANUALE
PB
PI
5
3
13
2 PE
PB
1
K1
CO22
14
10
11
12
TEMPERATURE
INTERFACE KIT
CONTROL
CO4 CO6
10
11
12
1
2
3
4
5
6
7
8
9
NOTES:
- Install the Pump Vessel kit code 4047488 in conjunction with the pump
BOILER CONTROL replacement sleeve kit before installing the temperature control interface
PANEL kit code 4047489. Refer to the instructions provided with the kit for details
on how to install it.
- Refer to Appendix 1 on page 48 for details on how to set up the
ESATTO OMEGA temperature control unit.
INSTALLATOR 27
SYSTEM 3: Water connection diagram for systems with IN - ISN, 23 G/R, heating only boilers
19
A1
prog
prog
RE 3
M 1 1 R
SCo
2
RI MI UAC
MC
RC
10 10
18 5 7
16 16 17
6
M
8
PI PB
SB1 10 9
11 ϒC
10 10 PS
10
12
10 10 10
13
16 10 Valve group
14
10 10 15 10
7 EAF
9 8

10 - Isolating valves PI - Heating system pump (if necessary,
11 - Temperature gauge use the Pump Replacement Sleeve Kit)
12 - Flow regulator PS - Solar circuit pump
13 - Flow meter
14 - Pressure reducer SB1 - Storage cylinder top probe
15 - Softener filter SB2 - Storage cylinder bottom probe
16 - Non return valve SCo - Collector probe
17 - Thermostatic mixer valve
18 Storage cylinder RE - Relay
19 - SUNdifferential controller (SD2)
28 INSTALLATOR
SYSTEM 3: Electrical wiring diagram for systems with IN - ISN, 23 G/R, heating only boilers
SCo - Collector probe

SB1 - Storage cylinder top probe N L SCo SB1 SB2
SB2 - Storage cylinder bottom probe
RE - Relay coil
CS - Switch contacts
PS - Solar circuit pump 11
L1'
10
A2
TL - Maximum temperature thermostat 12 9
13 8
PB - Solar storage cylinder filling pump 14 7
15 6
16 5
17 4
N2
NOTES: 18
N
3
- Refer to the instructions provided with the 19 2
L1
20 1
Storage Cylinder Electrical Interface Kit code
4047695 for details on how to install it. PE SUN
- See the diagram for SYSTEM 6 (and Appendix PE DIFFERENTIAL
PE
2 on page 55) for details on how to set up the CONTROLLER
SUN differential controller (SD2). (SD2)
PE
1 2
STORAGE CYLINDER
ELECTRICAL INTERFACE KIT PS
14
12
11
82Cϒ
TL
12
10
11
1
2
3
4
5
6
7
8
9
90Cϒ
9
1
2
3
4
5
6
7
8
24
22
21
CS
9
1
2
3
4
5
6
7
8
RE
NO NC C
12
10
11
1
2
3
4
5
6
7
8
9
1 N1
2 N
3 PE
4 TA
5 TA
6 CTB
7 1TB
8 2TB
9 LPI
10 PE
11 NPI
12 LPB
13 PE 1
14 NPB
PE
PB
2
BOILER CONTROL PANEL
INSTALLATOR 29
SYSTEM 4: Water connection diagram for systems with IN heating only boilers
19
A1
prog
prog
RE 3
M 1 1 R
SCo
2
RI MI UAC
MC
RC
10 10
18 5 7
16 16 17
6
M
8
PI PB
SB1 10 9
11 ϒC
10 10 PS
10
12
SB2 10
10 10
13
16 10 Valve group
14
10 10 15 10
7 EAF
9 8

10 - Isolating valves PI - Heating system pump (if necessary, use
12 - Flow regulator PS - Solar circuit pump
13 - Flow meter
14 - Pressure reducer SB1 - Storage cylinder top probe
15 - Softener filter SB2 - Storage cylinder bottom probe
18 Storage cylinder RE - Relay
19 - SUNdifferential controller (SD2)
30 INSTALLATOR
SYSTEM 4: Electrical wiring diagram for systems with IN heating only boilers
N L SCo SB1 SB2

SB1 - Storage cylinder top probe
L1'
SB2 - Storage cylinder bottom probe 11 10
12 A2 9
RE - Relay coil 13 8
CS - Switch contacts 14 7
15 6
PS - Solar circuit pump 16 5
17 4
N2
18 3
TL - Maximum temperature thermostat 19
N
2
L1
PB - Solar storage cylinder filling pump 20 1
DEI - Summer/Winter selector
M4 - 5 pin connector PE SUN
PE DIFFERENTIAL
PE
CONTROLLER
(SD2)
PE
1 2
ELECTRICAL CONNECTION KIT FOR
LATERAL STORAGE CYLINDER PS
14
12
11
82Cϒ
TL CS
10
11
12
1
2
3
4
5
6
7
8
9
RE
90Cϒ
1
2
3
4
5
6
7
8
9
24
22
21
NO NC C
1
2
3
4
5
6
7
8
9
M4
L1 5
L2 4
PE 3
N 2
L3 1 2
12
10
11
1
2
3
4
5
6
7
8
9
PE
PB
1
NOTES:
DEI - Install the Pump Vessel kit code 4047488 in
conjunction with the pump replacement sleeve
kit before installing the electrical connection kit
2
for lateral storage cylinder code 480031. Refer to

1
the instructions provided with the kit for details

4
on how to install it.

BOILER CONTROL PANEL - See the diagram for SYSTEM 6 (and Appendix 2
on page 55) for details on how to set up the SUN
differential controller (SD2).
INSTALLATOR 31
SYSTEM 5: Water connection diagram for systems with CONDEXA IS wall mounted boilers
19
A1
prog
prog
M 1 1 R
RI MI SCo
2
UAC
MC 16
RC
17
18 5 7
6 8
M
SBc
10 9
SB1
11 ϒC
PS
10
12
10
13
16 10 Valve group
14
10 10 15 10
7 EAF
9 8

10 - Disconnect valves PI - Heating pump
11 - Temperature gauge PS - Solar circuit pump
12 - Flow regulator
13 - Flow meter SB1 - Storage cylinder top probe
14 - Pressure reducer SB2 - Storage cylinder bottom probe
15 - Softener filter SBc - Boiler’s storage cylinder probe
18 Storage cylinder
19 - SUN differential controller (SD2)
32 INSTALLATOR
SYSTEM 5: Electrical wiring diagram for systems with CONDEXA IS wall mounted boilers
N L SCo SB1 SB2

CONDEXA IS
11 10
12 9
13 8
14 7
15 6
16 5
17 4
N2
18 3
N
19 2
L1
20 1
PE SUN DIFFERENTIAL
PE CONTROLLER (SD2)
PE
SBc
PE
1 2
PS
SBc - Boiler’s storage cylinder probe SCo - Collector probe

SB1 - Storage cylinder top probe (optional)
PS - Solar circuit pump
With CONDEXA IS wall mounted boilers, the boiler’s storage cylinder probe (SBc) must be connected up
as shown. Parameter 35 must also be set to 02 (see the “Parameters” section in the boiler’s own
instruction manual).
See the diagram for SYSTEM 1 (and Appendix 2 on page 55) for details on how to set up the SUN
INSTALLATOR 33
SYSTEM 6: Water connection diagram for systems with FAMILY COND IS – IS wall mounted boilers
19
A1
prog
prog
M 1 1 R
RI MI SCo
2
UAC
MC 16
RC
17
18 5 7
6 8
M
SBc
10 9
SB1
11 ϒC
PS
10
12
10
13
16 10 Valve group
14
10 10 15 10
7 EAF
9 8

12 - Flow regulator
15 - Softener filter TB - Boiler’s storage cylinder thermostat
18 Storage cylinder
34 INSTALLATOR
SYSTEM 6: Electrical wiring diagram for systems with FAMILY COND IS wall mounted boilers
FAMILY COND IS N L SCo SB1 SB2
11 10
SBc 12 9
13 8
14 7
15 6
16 5
17 4
N2
18 3
N
19 2
L1
Terminal M4 20 1
PE SUN DIFFERENTIAL
PE
CONTROLLER (SD2)
PE
PE
1 2
PS
SBc - Boiler’s storage cylinder probe SCo - Collector probe

SB1 - Storage cylinder top probe (optional)
With FAMILY COND IS wall mounted boilers, the boiler’s storage cylinder probe (SBc) must be connected
up as shown. Parameter 10 must also be set to 4 (see the “Parameters” section in the boiler’s own
instruction manual).
See the diagram for SYSTEM 1 (and Appendix 2 on page 55) for details on how to set up the SUN
INSTALLATOR 35
SYSTEM 7: Water connection diagram for systems with RESIDENCE I - IS wall mounted boilers
19
A1
prog
prog
TB
3
M 1 1 R
RI MI SCo
2
UAC
MC 16
RC
17
18 5 7
6 8
M
10 9
11 ϒC
PS
10
12
SB2 10
13
16 10 Valve group
14
10 10 15 10
7 EAF
9 8

9 - Expansion vessel PB - Storage cylinder filling pump
12 - Flow regulator
15 - Softener filter TB - Boiler’s storage cylinder thermostat
18 - Three way valve with return spring
19 Storage cylinder
36 INSTALLATOR
SYSTEM 7: Electrical wiring diagram for systems with RESIDENCE I - IS wall mounted boilers
RESIDENCE IS
PE
L
N
SCo SB1 SB2

TB
N L

11 10
12 9 SB1 - Storage cylinder top probe
13 8 SB2 - Storage cylinder bottom probe
14 7
15 6 PS - Solar circuit pump
16 5
17 4
N2
18 3
N
19 2
L1
20 1
PE
PE
PE SUN DIFFERENTIAL
CONTROLLER (SD2)
PE
1 2
PS
RESIDENCE IS wall mounted boilers require a connection between the terminals of the boiler’s
storage cylinder thermostat (TB) and terminals 11 and 12 on the SUN controller, as shown in the
above diagram. (These terminals operate at 230 Vac.)
- See the diagram for SYSTEM 6 (and Appendix 2 on page 55) for details on how to set up the SUN
INSTALLATOR 37
SYSTEM 8: Water connection diagram for systems with PRONTACQUA combination boilers
20
A1
prog
prog
M 1 1 R
RI MI SCo
2
UAC
MC 16
RC
19 5 7
17
18 6
M 8
10 9
SB1
11 ϒC
PS
10
12
SB2 10
13
16 10 Valve group
14
10 10 15 10
7 EAF
9 8

9 - Expansion vessel PS - Solar circuit pump
10 - Disconnect valves
11 - Temperature gauge SB1 - Storage cylinder top probe
12 - Flow regulator SB2 - Storage cylinder bottom probe
13 - Flow meter SCo - Collector probe
15 - Softener filter
16 - Non return valve
19 Storage cylinder
38 INSTALLATOR
SYSTEM 8: Electrical wiring diagram for systems with PRONTACQUA wall mounted boilers
N L SCo SB1 SB2
L1' SCo - Collector probe

11 10
12
A2
9 SB1 - Storage cylinder top probe
14 7
15 6
16 5 18 - Three way valve with return spring
17 4
N2
18 3
N
19 2
L1
20 1
PE
PE
PE SUN DIFFERENTIAL
CONTROLLER (SD2)
PE PE
1 2 1 2
PS 18
- See the diagram for SYSTEM 6 (and Appendix 2 on page 55) for
details on how to set up the SUN differential controller (SD2).
INSTALLATOR 39
SYSTEM 9: Water connection diagram for systems with KV, KV, 29 combination boilers
20
A1
prog
prog
M 1 1 R
SCo
2
RI MI UAC
MC
RC
19 5 7
17
18 6
M
8
10 9
SB1
11 ϒC
PS
10
12
SB2 10
13
16 10 Valve group
14
10 10 15 10
7 EAF
9 8

9 - Expansion vessel PS - Solar circuit pump
10 - Disconnect valves
11 - Temperature gauge SB1 - Storage cylinder top probe
12 - Flow regulator SB2 - Storage cylinder bottom probe
13 - Flow meter SCo - Collector probe
15 - Softener filter
16 - Non return valve
19 - Storage cylinder
40 INSTALLATOR
SYSTEM 9: Electrical wiring diagram for systems with KV, KV, 29 combination boilers
N L SCo SB1 SB2
L1' SCo - Collector probe

11 10
12
A2
9 SB1 - Storage cylinder top probe
14 7
15 6
16 5 18 - Three way valve with return
17 4
18
N2
3
spring
N
19 2
L1
20 1
PE
PE
PE
SUN DIFFERENTIAL
CONTROLLER (SD2)
PE PE
1 2 1 2
PS 18
- See the diagram for SYSTEM 6 (and Appendix 2 on page 55) for
details on how to set up the SUN differential controller (SD2).
INSTALLATOR 41
CHECKS
On completion of the installation, perform the checks listed in the table below.
Description OK
HEATING UTILITY ROOM CHECKS
THERE ARE NO CONNECTIONS BETWEEN THE SOLAR HEATING CIRCUIT AND OTHER WATER
SUPPLIES.
External water supplies such as automatic filling systems can alter the strength of the water-glycol
mix and lead to serious frost damage.
The use of manual filling systems is likewise not recommended. Any drop in circuit pressure should
be restored using the proper water-glycol mix and not with water alone.
THE SAFETY VALVE OPERATES AT 6 BAR AND CANNOT BE SHUT OFF BY ANY COCKS.
The safety valve must be installed in such a way that the pipes between it and the solar collectors
cannot be shut off by any cocks.
THE DRAIN LINE FROM THE SAFETY VALVE IS PROPERLY CONNECTED

The solar circuit can reach very high temperatures, even up to 180°C, and pressures of 6 bar. It
can be extremely dangerous if the safety valve opens without being properly connected to a
suitable drain point. Make sure that the drain line is channelled to a suitable drain point.
THE EXPANSION VESSEL IS CORRECTLY LOCATED AND PRE-CHARGED TO 2.5 BAR.

The expansion vessel must be installed in such a way that the pipes between it and the solar
collectors cannot be shut off by any cocks.
The expansion vessel must be installed in the return line and connected to the fitting provided for
the purpose on the water return group.
The expansion vessel must be pre-charged to a pressure of 0.5 bar less than the normal cold
circuit pressure of 3 bar. The solar circuit can reach very high temperatures, even up to 180°C, and
pressures of 6 bar. It can be extremely dangerous if the safety valve opens without being properly
connected to a suitable drain point. Make sure that the drain line is channelled to a suitable drain point.
ITHE WATER RETURN GROUP IS INSTALLED IN THE RETURN LINE.

As the main heat source, the solar collectors are the reference point for the circuit. The return line
is therefore the section of piping taking cold water from the storage cylinder back to the solar
collectors. The outlet or delivery line is the section of piping taking hot water from the solar
collectors down to the heating utility room and the heat exchanger.
THE OUTLET OF THE SOLAR CIRCUIT IS CORRECTLY POSITIONED.

The bottom coil of the storage cylinder is dedicated to the solar water heating circuit. The solar
delivery line must be connected to the top of the coil and the return line to the bottom.
THE NON-RETURN VALVE FUNCTIONS AS A GRAVITY BRAKE AND IS CORRECTLY POSITIONED.

The spring loaded non-return valve opens at 40 mbar and prevents circulation starting under the
influence of gravity when the storage cylinder is hot and the collectors on the roof are cold.
42 TECHNICAL ASSISTANCE SERVICE

Description OK
SOLAR CIRCUIT CHECKS
THE PROPYLENE GLYCOL DELIVERED WITH THE COLLECTORS HAS BEEN USED TO MAKE
THE WATER-GLYCOL ANTI-FREEZE MIX.
It is essential to use the non-toxic, biodegradable and environmentally friendly propylene glycol
supplied with the collectors. The use of other types of anti-freeze mix can damage the solar
water heating system because other products form residues and deposits at high temperatures.
THE PERCENTAGE OF GLYCOL IN THE MIX IS BETWEEN 30% AND 50%.

The percentage of glycol in the anti-freeze mix must be adjusted to suit the minimum
temperature expected in the place of installation. 50% glycol provides anti-freeze protection
down to -32°C. Higher percentages can cause the mix to become too dense.
THE DENSITY OF THE HEAT TRANSFER LIQUID IS BETWEEN 1.029 AND 1.045 kg/dm3.
Use an instrument like a refractometer or densimeter to check the density of the anti-freeze.
Excessively dense mixes cause solid deposits to form at high temperatures and prevent
proper circulation. Insufficiently dense mixes expose the system to the risk of freezing.
THE pH OF THE HEAT TRANSFER LIQUID IS HIGHER THAN 7.

Use litmus paper to ensure that the pH of the mix is not too acid. This check is not necessary when
the system is started up for the first time, but becomes necessary after the system has been
operating for more than 2 years. If the mix becomes acidic, then the heat transfer liquid will
be corrosive.
THE PRESSURE IN THE SOLAR CIRCUIT IS 3 BAR.

Check that the pressure in the circuit, when cold, is 3 bar. Low pressure leads to lower
evaporation temperatures in the collectors during the stagnation phase. The evaporation point must
be kept high. With a cold pressure of 3 bar, and a heat transfer liquid density of 1.037, the
evaporation point is reached at 154°C and 5 bar.
THE FLOW RATE THROUGH THE CIRCUIT IS 0.5 l/min FOR EVERY m2 OF COLLECTOR.
Adjust the flow regulator to achieve a flow rate of 0.5 l/min for every m2 of collector.
For example, if you have a total of 5 m2 of collector area, flow rate must be 2.5 - 3 l/min.
THE DIFFERENCE IN TEMPERATURE BETWEEN THE COLLECTOR OUTLET AND RETURN IS

BETWEEN 10°C AND 25°C.
When the solar circuit is functioning, the difference in temperature between the collector outlet
and the return should be between 10°C and 25°C.
Connecting the collectors in series permits systems with low flow rates to achieve a higher
temperature differential between the outlet and the return.
TECHNICAL ASSISTANCE SERVICE 43

Description OK
TEMPERATURE CONTROLLER CHECKS
THE COLLECTOR TEMPERATURE PROBE IS CORRECTLY POSITIONED AT THE COLLECTOR

OUTLET.
The collector temperature probe must be installed at the outlet from the last collector in the series.
The socket for the temperature probe is located on the left hand side of the collectors supplied
with the system. Make sure that the cold water return leads to the right hand side of the collectors
and that the temperature probe is installed in the socket in the left of the leftmost collector
in the series.
THE STORAGE CYLINDER TEMPERATURE PROBE IS CORRECTLY POSITIONED IN THE

SOCKET AT THE BOTTOM OF THE STORAGE CYLINDER
The storage cylinder temperature probe must be installed to measure water temperature at the
bottom of the storage cylinder.
THE ‘PUMP ON’ ∆T BETWEEN THE COLLECTOR AND THE STORAGE CYLINDER
IS BETWEEN 6 AND 10 °C.
The temperature differential between the collectors and the storage cylinder that switches
on the circulation pump must be in the range between 6 and 10°C. If the differential is set too low,
the circulation pump will keep cycling on and off. If the temperature differential is set too high,
the efficiency of the system will be reduced.
THE ‘PUMP OFF’ ∆T BETWEEN THE COLLECTOR AND THE STORAGE CYLINDER
IS BETWEEN 2 AND 4 °C.
The temperature differential that switches the pump off serves to stop the circulation
pump cycling on and off.
MAXIMUM STORAGE CYLINDER TEMPERATURE IS BETWEEN 60 AND 80 °C.

The maximum temperature threshold must be set as high as the hardness of the water allows.
MINIMUM COLLECTOR TEMPERATURE IS BETWEEN 15 AND 20 °C.

Set the minimum collector temperature to suit minimum outdoor temperature and so that
the temperature controller receives the signal somewhere in the range between 15 and 20°C.

MAINTENANCE
CHECKS TO PERFORM DURING SYSTEM MAINTENANCE
- Use litmus paper to ensure that the pH of the heat transfer liquid is not below 7.5.
- Use an instrument like a refractometer or densimeter to check that the heat transfer liquid has not lost its anti-freeze
properties.
- Check all the controller settings.
- Check the position and functioning of the temperature probes.
- Check the pre-charge in the expansion vessel (2.5 bar).
- Check the functioning of the storage cylinder and protective anode.
REPLACING THE SOLAR HEATING CIRCUIT PUMP

ON
ON
Before starting work to replace the pump:
OFF
OFF
- Switch the electricity supply to the storage cylinder’s
valve group and to any associated boiler OFF at the
main switch and at the control panel.
- Close the flow regulator (V) (so that the screw slot is
horizontal)
- Turn the return valve knob 90° clockwise to close the

return valve (R).
R
H1
- Unscrew the ring nuts H1 and H2 and remove the

pump.
C
H2
Reverse the above steps to fit the new pump.

V

ANOMALIE E RIMEDI
PROBLEM CAUSE SOLUTION
Temperature in the
Air in the circuit. Bleed the circuit.
collectors is far higher
than in the storage
cylinder, and the pump is
working too, but heat The pump has not got enough Check the specifications of the
transfer is poor. head to push the water column pump and change the pump if
up to the collectors. necessary.
The flow rate through the circuit Adjust the flow rate through the
is too low. solar circuit to a value between
0.4 and 0.6 litres a minute per
square metre of collector area.
The collector probe is not Make sure that the temperature

reading the correct temperature. probe is in the right position and
that the connection cable has
not been laid near any power
cables.
The heat transfer liquid is too Check the density of the water-
dense. glycol anti-freeze mix.
If the mix is too dense, drain the
circuit and flush out any sludge
that might have formed in the
collectors.
The pump is working (and

Air in the circuit. Bleed the circuit.
is very hot), but there is
no transfer of heat from
the collectors to the
storage cylinder. The collector circuit is blocked Make sure that the temperature
by sludge or by an excessively differential between the collector
dense water-glycol mix. and the storage cylinder is
greater than 6 °C.
The pump cycles on and

The temperature differential set Make sure that the temperature
off, staying on for only a between the collectors and the differential between the collector
short time. storage cylinder is inadequate. and the storage cylinder is
greater than 6 °C.
The storage cylinder Make sure that the probe is

temperature probe has been correctly positioned.
installed in the return line. Make sure that the outlet from
the collectors is located at the
left of the series.
The pump gets switched The temperature differential set Make sure that the temperature
on very late and stops between the collectors and the differential between the collector
soon afterwards, giving storage cylinder is excessive. and the storage cylinder is less
no time for proper heat than 10 °C.
transfer.

PROBLEM CAUSE SOLUTION
The pump does not The storage cylinder has Make sure that the maximum
switch on even if the reached its maximum temperature threshold is set
temperature in the temperature threshold. between 60 and 80 °C.
collectors is significantly
higher than that in the
storage cylinder.
The collector has reached its Make sure that the maximum
maximum temperature threshold. temperature threshold is set
between 120 and 140 °C.
The pump is in manual mode. Make sure that all controller

settings are correct.
∆t ON between 6 and 10 °C
∆t OFF between 2 and 4 °C
min. coll. temp. between 15 and
20 °C
max. coll. temp. between 120
and 140 °C
max. stor. cyl. temp. between 60
and 80 °C
functioning mode: auto
The pump on signal is not being Make sure that the pump is not
received. seized or faulty.
The temperature controller has Check the fuse.

blown a fuse.
The storage cylinder The solar heating circuit pump is Make sure that all controller
loses a lot of heat continuing to work overnight. settings are correct (and that the
overnight. cooling function, if available, is
switched OFF).
Temperature in the collectors is Make sure that the non-return

higher than night-time outdoor valve is functioning as a gravity
temperature. brake and is correctly
positioned.
The domestic hot water Adjust the recirculation pump

recirculation pump is staying on. functioning times.
There is heat loss from the Make sure that there is no

domestic hot water circuit. natural circulation through the
domestic hot water circuit to
remove heat from the storage
cylinder.
Use a siphon on the hot water
outlet.

APPENDIX 1
SETTING THE PARAMETERS ON THE ESATTO OMEGA TEMPERATURE CONTROL UNIT

ACCESSING THE INSTALLATION MENU
Simultaneously press the two parameter selection keys

(1) for at least three seconds, until parameter 51 appears
on the left of the display.
Press the keys (1) to move to the parameter you want to 1 2

program, then press keys (2) to set the required value.
To quit programming mode, either wait for 8 minutes or

press one of the heating system function mode keys (3). 3
PARAMETER 95
Functioning mode of the pump connected to output K6
Parameter 95 determines how the pump connected to output terminal K6 functions.
NOTE! The setting of this parameter also affects automatic recognition of system type.
Range Unit of measure Default setting RECOMMENDED SETTING
0...11 – 0 5
The pump functions in one of the following modes:

0 Pump not used
1 Pump for central heating
2 Pump for central heating only (installed after the storage cylinder).
3 Pump for central heating and domestic hot water (installed before the storage cylinder).
4 Pump for central heating with external heat request
5 Pump for domestic hot water circulation
6 Pump for DHW electric immersion heater
7 Pump for solar heating circuit
8 Pump controlled by switch H1
9 Pump for boiler
10 Pump for boiler bypass
11 Alarm signal
Post-circulation is enabled in all settings except 5 and 7 (pump for solar heating circuit). Post-circulation normally
remains on for 1 minute, but if over-temperature protection cuts in, this time is extended by the value set in the ‘Pump
post-circulation’ parameter.

PARAMETER 96
Functioning of the pump connected to output K7
Parameter 96 determines how the pump connected to output terminal K7 functions.
NOTE! The setting of this parameter also affects automatic recognition of system type.
0...7 – 0 4
The pump functions in one of the following modes:

0 Pump not used
1 Pump for central heating circuit 2
2 Pump for domestic hot water circulation
3 Pump for DHW electric immersion heater
4 Pump for solar heating circuit
5 Pump controlled by switch H2
6 Pump for boiler bypass
7 Alarm signal
Post-circulation is enabled in all settings except 5 and 7 (pump for solar heating circuit). Post-circulation normally
remains on for 1 minute, but if over-temperature protection cuts in, this time is extended by the value set in the ‘Pump
post-circulation’ parameter.
PARAMETER 98
Type of use of solar heating system
The heat generated by the solar collectors can be transmitted to a domestic hot water storage cylinder or to a central
heating water tank..
0...2 - 0 1
The setting in this parameter determines whether the solar collectors are used to heat a DHW storage cylinder or a
central heating water tank.
0 No solar collectors
1 Solar energy to DHW storage cylinder
2 Solar energy to central heating water tank
IMPORTANT!
To ensure proper functioning, the temperature probes for the central heating water tank must be positioned as follows:
Solar heating system for domestic hot water:

- B3 at top of storage heater
- B31 at bottom of storage heater
Solar heating system for central heating water tank:

- B4 at top of central heating water tank
- B41 at bottom of central heating water tank

PARAMETER 99
B6/B8 sensor input
This parameter determines whether the temperature sensor connected to input B6 / B8 is used to detect collector
temperature or flue gas temperature.
0...2 – 0 2
0 Pt 1000 flue gas sensor

1 Ni 1000 solar collector sensor
2 Pt 1000 solar collector sensor
PARAMETER 174
B31/H2/B41 input
This is a multi-purpose input and can be used for various functions.

IMPORTANT: The relay contacts are not suited to extra low voltage applications.
0...3 0 0
This parameter lets you change the function of terminals H2.
0 Second domestic hot water sensor

This setting configures the terminals for use with a second DHW temperature sensor. With this setting, a second
DHW sensor can be connected directly to the terminals. Storage cylinder temperature can be measured most
effectively by one sensor positioned at the bottom and a second at the top. In the case of storage cylinders heated
by solar energy, it is important to have sensor B3 at the top and sensor B31 at the bottom of the cylinder.
1 Minimum flow temperature setpoint (TVHw)
2 Boiler burner lockout
3 Second central heating water tank sensor
This setting configures the terminals for use with a second central heating water tank sensor. With this setting, a
second central heating water tank sensor can be connected directly to the terminals. Minimum central heating water
tank temperature is only of relevance if the tank is heated by a solar collector. Central heating water tank
temperature can be measured most effectively by one sensor positioned at the bottom and a second at the top. In
the case of central heating water tanks heated by solar energy, it is important to have sensor B4 at the top and
sensor B41 at the bottom of the tank.
PARAMETER 160
Temperature differential for switching the solar circuit pump on (TSdEin)
This parameter determines the threshold at which the solar circuit pump is switched on.
TSdAus...40 °C (K) 10 6
If the difference in temperature between the collector and the heating water tank exceeds this parameter (TsdEin), the
solar circuit pump is switched on.
50
PARAMETER 161
Temperature differential for switching the solar circuit pump off (TSdEin)
This parameter determines the threshold at which the solar circuit pump is switched off.
0...TSdEin °C (K) 8 da 2 a 4
If the difference in temperature between the collector and the heating water tank falls below the value set in this
parameter (TsdAus), the solar circuit pump is switched off.
PARAMETER 162
Solar heating strategy
This parameter determines the temperature at which the solar heating system starts to heat the central heating water tank.
- - - ; 20...130 °C (K) --- 20
Values:
--- Disabled:
Energy-related solar heating
20...130 Heating level::

Level-related solar heating..
Description of differential temperature control (∆T control)

If the solar collector produces sufficient heat, the collector circuit pump is switched on to heat the central heating water
tank or DHW storage cylinder. Depending on the strategy selected, heating can depend on either energy or level.
Energy-related strategy
With energy-related heating selected, the solar circuit pump is switched on and off exclusively on the basis of
temperature differential (TSdEin).
The solar collector pump is switched on as soon as the following conditions are reached:
- The difference in temperature between the collector and the storage cylinder exceeds the switch-on setting (TsdEin).
- The solar storage cylinder has not yet reached its maximum temperature threshold.
The solar collector pump is switched off as soon as the following conditions are reached:
- The difference in temperature between the collector and the storage cylinder drops below the switch-off setting
(TsdAus).
- The solar storage cylinder has reached its maximum temperature threshold at the top or bottom.
51
Level-related strategy
With level-related heating selected, the solar circuit pump is switched on and off on the basis of minimum temperature
as well as a temperature differential. With this setting, heat is only supplied to the storage cylinder starting from a
determined collector temperature (temperature level + TSdEin).
The solar collector pump is switched on as soon as the following conditions are reached:
- The difference in temperature between the collector and the storage cylinder exceeds the switch-on differential
(TsdEin) and the collector has reached its minimum temperature setting.
- The solar storage cylinder has not yet reached its maximum temperature threshold.
The solar collector pump is switched off as soon as the following conditions are reached:
- The difference in temperature between the collector and the storage cylinder drops below the switch-off setting
(TsdAus), or the temperature of the collector drops below its minimum temperature setting (solar heating temperature
level + TSdAus).
- The solar storage cylinder has reached its maximum temperature threshold at the top or bottom.
TKox Tx
°C
Maximum differential between
storage cylinder temperature
and the value set in parameter
TSdEin 162.
TSdAus TKox
Temperature of solar collector.
Tx
TSdEin
Pump ON differential (par. 160)
t
TSdAus
Pump OFF differential (par. 161)
K7
PARAMETER 163
Maximum temperature for solar heating of central heating water tank
The solar heating pump is switched off when the top or bottom of the central heating water tank reaches the value set
in this parameter.
if water hardness > 40°F, set 70

20...130 °C (K) 80
if water hardness < 40°F, set 80
If the difference in temperature between the collector and the central heating water tank drops below this value (TsdAus),
the solar circuit pump is switched off.
52
PARAMETER 164
Heat request with reduced DHW setpoint
When alternative energy sources are in use, it may be undesirable to have the burner ignite quickly when hot water is
drawn off outside the programmed time band. You can choose between 2 different strategies that switch the burner on
earlier or later.
0/1 – 1 0
This setting determines whether the burner is switched off or not to maintain the reduced DHW setpoint:
0 Applications with central heating water tank and alternative energy source
Outside the programmed time band, the system attempts to keep DHW temperature at the reduced setpoint by using
energy from the solar central heating water tank. This means that the domestic hot water heating pump is switched
on, but the burner request is suppressed.
The domestic hot water boiler is only switched on (heating the storage cylinder up to the nominal DHW setpoint)
when the temperature of the domestic hot water drops below the reduced setpoint by twice the value of the DHW
differential (par. 51OEM).
1 Standard procedure
Outside the programmed time band, DHW temperature is taken to the reduced setpoint. This is achieved by sending
a heat request signal to the heat source (individual or cascaded boiler).
CHECKING THE TEMPERATURE SENSOR READINGS
PARAMETER 59
Central heating water tank temperature 1 (top)
When alternative energy sources are in use, the Range Unit of measure
temperature of the central heating water tank is used as
the control criterion for switching additional heat sources 0...140 °C
off.
Central heating water tank temperature 1 is read by the

sensor connected to terminals B4. If no sensor is
connected to this terminal, the reading obtained through
terminals B31/H2/B41 is used instead (if available).
PARAMETER 60
Central heating water tank temperature 2 (bottom)
The temperature of the bottom of the central heating

water tank is used as the control criterion for starting Range Unit of measure
solar heating.
Input B31/H2/B41 must be properly configured before it 0...140 °C
can be used for the central heating water tank bottom
sensor. The central heating water tank bottom
temperature is read by the sensor connected to
terminals B31/H2/B41.
If no sensor is connected to this terminal, the reading
obtained through input B4 is used instead (if available).
53
PARAMETER 61
DHW storage cylinder temperature 1 (TBWx)
This is the temperature read by the solar storage Range Unit of measure
cylinder’s top sensor.
0...140 °C
If only one DHW storage cylinder temperature sensor is
connected, parameters 61 and 62 will give the same
value.
PARAMETER 62
DHW storage cylinder temperature 2
This is the temperature read by the solar storage Range Unit of measure
cylinder’s bottom sensor.
0...140 °C
If only one DHW storage cylinder temperature sensor is
connected, parameters 61 and 62 will give the same
value.
PARAMETER 64
Collector temperature (B6)
This is the solar collector temperature read by sensor B6. Range Unit of measure
This reading is used to control the solar heating of the
DHW storage cylinder or central heating water tank. 0...350 (Pt 1000) °C
0...230 (Ni 1000) °C
IMPORTANT!
Input B8/B6 must be properly configured before it can be
used for the collector temperature sensor.
54
APPENDIX 2
SETTING THE PARAMETERS ON THE SUN DIFFERENTIAL CONTROLLER (SD2)

ACCESSING PROGRAMMING MODE
To access programming mode, press the “+” and “-”

keys simultaneously.
A1
Press the “+” and “-” keys to select the number of the
prog
parameter you need to modify.
Press the “Prog” key. The LED alongside starts to flash.

Press the “+” and “-” keys to change the value of the
parameter.
A1
Press the “Prog” key to save your changes.
prog
To quit programming mode, press the “+” and “-” keys

simultaneously.
The following parameters determine system configuration. Parameters from 20 on are password protected. If these
parameters are incorrectly set, they can cause the system to malfunction or even damage the system.
The default password is “0000”. (You must press the “Prog” key to confirm each digit.)
PARAMETER 22
System type (see water connection diagram)
Default setting RECOMMENDED SETTING RECOMMENDED SETTING

System 1 System 6
1 1 6
PARAMETER 30
Switching threshold for diff. 1

System 1 System 6
2 3 °C 3 °C
PARAMETER 31
Dynamic differential

System 1 System 6
2 4 for short lines 4 for short lines

7 for long lines 7 for long lines
55
PARAMETER 33
Dynamic differential for diff. 2

System 1 System 6
3 not used 5
PARAMETER 40
Collector circuit pump ON temperature

System 1 System 6
35 15 15
PARAMETER 41
Maximum collector temperature

System 1 System 6
110 120 120
PARAMETER 42
Secondary heat source ON temperature

System 1 System 6
40 not used 50
PARAMETER 50
Maximum temperature for central heating water tank 1

System 1 System 6
if water hardness > 40°F, set 65 if water hardness > 40°F, set 65
60
if water hardness < 40°F, set 75 if water hardness < 40°F, set 75
PARAMETER 52
Solar equilibrium tolerance (system type 6 only)

System 1 System 6
10 not used 8
56
57
58
Code 068017(EN)
RIELLO S.p.A. - 37045 Legnago (VR)

Tel. 0442630111 - Fax 044222378 - www.riello.it
The manufacturer strives to continuously improve all products.

Appearance, dimensions, technical specifications, standard equipment and accessories
are therefore liable to modification without notice.

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SYSTEM

INSTALLATION AND MAINTENANCE MANUAL

THE RIGHT CLIMATE IN ALL WEATHER

CS25 water heating systems conform to EN 12976 standard

CS 25 300 COND 4383022.3

CS 25 200 RESIDENCE 4383025.4

CS 25 200 REG 4383025.1

TECHNICAL ASSISTANCE SERVICE:

The following symbols are used in this manual:

CAUTION = Indicates actions that require

STOP! = Identifies actions that you MUST NOT do.

This manual, Code 068017GB - Rev. 7 (04/06) is made

Serial number plate

The CS 25 solar water heating system

1 - Solar collector 10 - Flow regulator

The following accessories are available, to be ordered separately.

(*) Required if no automatic filling pump is available.

Contents of FIRST pallet:

The instruction manual is an integral part of the

Contents of SECOND pallet:

The parallel to roof or 45° collector fitting system

CS 25 systems with denominations ending

DESCRIPTION CS 25 400 CS 25 500

FITTING SYSTEM (accessory)

‘P’ TYPE FITTING SYSTEM

Ring nut (G)

Seal ring (H)

4 mm anti- Frame for glass

Top frame for glass 4 mm anti-reflection glass

Connection ring nut 1"

Wind and snow loads on collectors

Flow rate (kg/h)

Assembly Lightning protection

Risk of burns from hot fluid inside the collectors!

Only open the vent valve if the temperature of the

Braze the unions provided to the outlet and return pipes

When you have fitted the unions, hot braze the

MANUAL BLEED VALVE (accessory code 4383056)

The manual bleed valve is designed to bleed air quickly

Make sure that you close the manual bleed valve

Refer to the instructions provided with the bleed

The manual bleed valve is not necessary

Model 300/2 Models 200/2 - 400/2 - 500/2

The water return group is delivered together with the

All expansion vessels come pre-charged to a

Refer to the instructions provided with the water

Pump RNY 43-15 WATER RETURN GROUP pressure drop

SUN DIFFERENTIAL CONTROLLER (SD2)

The SUN differential controller (SD2) must be bracketed

to the storage cylinder in position (R) as shown in the

Heat is only transferred from the solar heating circuit to

Fit the storage cylinder temperature probe in the

Refer to Appendix 2 on page 55 for details on how to

Refer to the instructions provided with the controller

For further information on water and electrical L

FLUSHING THE SYSTEM

If copper piping has been used and joints have

Fill the solar collector with glycol premix R

Glycol anti-freeze is supplied separately and must be