Assembly and operating instructions TPS- 5 Solar station EN
Contents
1. 4 Assembly and operating instructions TPS 25 Solar station 720 882 Z01 07 03 EN Contents 1 About THIS manuak essesi esa N EERENS ENA 3 L1 PROC ASG secara neire 3 Wee WSIS saute cecece cera eee eee ea ce ees 3 1 3 Description Of SYMDOIS sser naan NaN 3 2 BY A AA E PE E E AE A 4 2A PROD SN USAGES en A 4 22 iMproper Wage roine 5 2 3 Dangers during assembly and cOommMiISSIONING 0002eeeeee 6 ZA Detecting fauls ccrswintontniasaccoses nenedorevancidentosaneneatueunsareadaeavine 7 2 5 Exclusion of liability ccccccccccceseeeeeeeeeeeeeeeeeeeeeeeeeeeaeeeeeeeeas 7 3 Installation and operating INStruCtiONS eceeeeeeneeeeeeeeees 8 3 1 Work steps installation ccccccseeceesseeeeeeeeeeceeeseeseeeeeesaeeees 8 3 2 Uninstall the solar station ccccceceeeeeeeeeeeeeeeeeeeeeeaeeeeeeeeeas 9 4 Commission Geca EE 10 4 1 Filling flushing and commissioning the solar system 10 5 Draining the solar system ccccccseeeeeeeeceeeeeeeeeaeeeeeeeesaaaeeees 12 6 PS A CS E A A E A mdedace 13 7 Optional Flow display TPA F 25 cccsccccccsseeeeeeeeeeeeeeeeeeaees 14 8 Optional Air separator TPA A 25 ccccsccceccseeeeeseeeeeeseeeeesaees 15 9 Optional Cutting ring screw connection TPA SVS a an 16 Assembly Instruction cccccceceeeeceeeeeeeeeeeeneeeeeesaeeeeeeesaaaeees 16 10 Pressure drop and pump characteristics ccccccceeeeeeeeeeeeees2. 11 Individual parts Spare Parts ccccseeseeeeeeeeeeeeeeeeeseeeeeseeees e TOCHINICA Cal e E S These operating instructions are part of the product gt Read these operating instructions carefully before use gt Keep them over the entire lifetime of the product gt and pass them on to any future owner or user of this product l a a Ee EN 1 About this manual 1 1 Applicability This manual describes the installation commissioning func tion operation and dismantling of the solar station for solar thermal energy systems When installing the remaining com ponents e g the solar collectors the storage unit be sure to observe the appropriate installation instructions provided by each manufacturer 1 2 Users Installation commissioning operation and dismantling of the solar station may only be performed by trained professi onal personnel Before commissioning the solar station must be professionally assembled and installed by professional personnel in accordance with the applicable regional and transregional regulations as well as the safety instructions and general instructions within this installation and instruc tion manual The professional personnel must be familiar with this operation manual The solar station is maintenance free Use the solar station only after first thoroughly reading and understanding this instruction manual and the safety instructions Adhere to all safety instructions In
3. 27 l min scale Technical data Type TPA F 25 1 20 l min or 5 40 l min Materials Body Brass MS 58 Seal EPDM Sight glass Boronsilicateglass Technical data Nominal dimension DN 25 Indication range 5 40 I min Max pressure 10 bar Max temperature 120 C Measurements Connections 1 male thread flat sealing with compression fitting 1 male thread with counter nut Total height 135 mm 14 720 882 07 03 ee EN 8 Optional Air separator TPA A 25 The Air separator has been designed to permanently deaerate the heat transfer fluid of the solar system The separated air collects in the Airstop and can be released through an air bleed valve if necessary Operation The gases separated from the heat transfer fluid collect in the upper part of the Airstop see illustration From time to time directly after commissioning daily then depending on the quantity of air separated every week or month these gases must be released through the air bleed valve on the side In order to achieve optimal efficiency of the solar system the air should be released every six months Please note After the system has been deaerated the system pressure must be checked and increased to the operating pressure if necessa ry The collector circuit can only be deaerated properly if the flow speed in the flow is at least 0 3 m s The pipe dimensions must be adapted to the flow speed ee es EN ns 9
4. Cutting ring screw connection TPA SVS optional 18 720 882 07 03 EN 12 Technical data TPS 25 solar station Dimensions Heigth with insulation 550 mm Width w o controller 280 mm Depth 200 mm Distance axis wall 63 mm Axis Distance flow return 90 mm Pipe connections 1 male thread flat sealing compression fitting optional 18 or 22 mm Connection for expansion tank 3 4 male thread flat sealing Outlet safety valve 3 4 female thread Max pressure Max temperature 6 bar 120 C 160 C for a short time Solar safety valve Safety equipment 1 2 x 3 4 6 bar Solar manometer 0 6 bar to 130 C Circulation preventer TPS 25 valve 2 x 200 mm w c brass can be opened in flow and return ball valve Indication elements Solar dial thermometer 0 160 C TPS 25 optional 5 40 min Material Fittings Case brass Flat gaskets Klingersil max 200 C O rings VITON EPDM max 160 C TPS 25 valves brass max 180 C Insulation EPP A 0 041 W m k max 120 C 160 C for a short time 720 882 07 03 19 720882
5. the event of any ambiguities regarding the operation and alteration of parameters or functions consult professional personnel 1 3 Description of symbols 1 3 1 The structure of the warning notices Z SIGNAL WORD Type source and consequences of the danger gt Measures for avoiding danger an a 1 3 2 Danger levels in warning notices Danger level Likelihood of Consequences occurrence resulting from non compliance Imminent Death serious A DANGER threat of danger bodily injury Possible Death serious A WARING threat of danger bodily injury Possible Minor A CAUNON threat of danger bodily injury CAUTION Possible Property damage threat of danger 1 3 3 Notes Note Notes on easier and safer working habits gt Measures for easier and safer working habits 1 3 4 Other symbols and markings Meaning J Condition for action gt Call to action gt Result of action List Emphasis on issue at hand Emphasis on issue at hand 2 Safety 2 1 Proper usage The usage of the solar station is limited to solar thermal systems within valid ambient conditions see chapter 12 e The distance between the fitting group and the collectors must be sufficient because of the possible high tempera tures near the collectors If the fitting group is installed in the attic it must be ensured that the fittings do not overheat e g by using a intermediate tank e For installin
6. Optional Cutting ring screw connection TPA SVS Assembly instruction gt Put the union nut 2 on the copper pipe 1 Then put the brass olive 3 on the copper pipe 1 In order to ensure a safe force transmission and sealing the pipe must stick out at least 3 mm 0 28 in out of the olive gt Insert the support sleeve 4 into the copper pipe 1 gt The copper pipe 1 and its components 2 3 and 4 must be inserted as far as possible into the connection nozzle gt Tighten the union nut by hand Then tighten the union nut it at least one full turn with an open end spanner gt S en EN 10 Pressure drop and pump cha racteristics li 7 10 3 8 P 7 E e i 2 1 Flow rate lh 17 an S EN 11 Individual parts spare parts D Description 1 Space for controller optional 2 Thermometer set red and blue 0 160 C 3 Insulation set 4 Wall holder steel 5 Air separator TPA A 25 optional 6 Flushing and filling unit 7 Flow display TPA F 25 optional 1 20 I min or 5 40 l min 8 Circulation pump optional 9 Safety cross 10 Flow ball valve 1 male thread female thread with check valve 11 Return ball valve 1 flange female thread with check valve 12 Union nut 112 male thread 13 Solar manometer 0 6 bar with valve 14 Solar safety valve 6 bar 15 Connection set for expansion tank optional 16
7. and technical connections controller pump sensor etc may only be made by qualified experts The relevant regulations VDE 0100 etc must be observed gt Fill and flush the solar system see 4 Commissioning gt Check the system for leaks and commission the system gt Attach the front insulation of the solar station after com missioning the system Then insert the thermometers red thermometer in the flow left blue thermometer in the return right All screws were tightened in the factory Therefore in ge neral it is not necessary to tighten them again However it is important to carry out a pressure test when commis sioning the system and to check it for leaks es en EN Screws 6 x 60 3 2 Uninstall the solar station In order to unscrew the solar station TPS 25 from the wall bracket remove the safety clips by means of a screwdriver a es 4 Commissioning 4 1 Filling flushing and commissioning the solar system gt Connect the pressure hose to the fill valve 3 of the filling and flushing unit and open this valve gt Connect the flush hose to the flush valve 5 of the filling and flushing unit and open this valve gt Close the ball valve in the middle of the filling and flushing unit 4 so that the handle is in a horizontal posi tion Open both TPS 25 valves in the ball valves above the pump and in the flow by turning the thermometers or use a combination
8. g and mounting the solar station the standard DIN EN 12976 1 must be observed e The expansion tank must be checked regularly according to DIN 4807 e Solar stations must be earthed to protect them from lightning a a EN e Electrical and technical connections of the solar system may only be made by qualified experts The relevant re gulations VDE 0100 VDE 0185 VDE 0190 etc must be observed as must special local building regulations e The solar station is equipped with a solar diaphragm safe ty valve which complies with the relevant regulations e The safety valve must be easily accessible The function of the valve may not be affected or rendered ineffective by any obstruction e Strainers or other constrictions between the collector field and the safety valve are inadmissible e The diameter of the discharge line must be the same as the diameter of the valve outlet Its length may not exceed 2 metres More than 2 bends are inadmissible If these maximum values 2 metres line 2 bends are exceeded the line shall be increased in size However more than 4 metres line and 3 bends in total are inadmissible e If the discharge line is routed into a funnel with a drain line the size of the drain line must be at least double the cross section of the valve inlet The discharge line must be laid at a gradient The point of discharge must be clearly visible and terminate in a safe place so that there is no risk
9. n pump and select the highest speed see pump and controller operating instructions and allow it to circulate for at least 15 minutes 10 720 882 07 03 EN gt Then select the required speed of the circulation pump gt If necessary regulate the volume flow rate in accordance with the collector manufacturer s instructions by limi ting the flow rate with the ball valve in the middle of the flushing and filling unit 4 flow rate can be read on the TPA F 25 optional gt Remove the hoses of the filling and flushing station and screw the caps on the fill and flush valves gt Again check the system for leaks Then set all ralves to operating position gt Attach the front insulation of the solar station and insert the thermometers red thermometer in the flow left blue thermometer in the return right an a i 5 Draining the solar system gt Open the TPS 25 valves in the flow and return ball valves 1 and 2 by turning the thermometers to a 45 position see section 6 TPS 25 valves gt Open the deaerators at the highest point gt Open the drain valve at the lowest point of the installa tion if possible near the connection of the storage tank not included in delivery or open the flush valve 5 of the filling and flushing unit 3 5 below the pump a en ee EN 6 TPS 25 valves The TPS 25 valves are integrated in the thermometer ball val ves and have an opening p
10. ng Make sure that the permissible ambient conditions at the installation site are not exceeded see chapter 12 Be sure to comply with the specified degree of protection Factory labels and markings may not be altered removed or rendered unreadable Before connecting the device make sure that the power supply matches the specifications on the type plate Make sure that all devices which are connected to the controller conform to the technical specifications of the controller Secure the device against unintentional commissioning For all electronic installations please always disconnect from the mains Protect the controller against overloading and short circuiting es en an a EN 2 4 Detecting faults gt Check the solarstation gt In case of faults isolate the cause gt As soon as it becomes evident that safe operation is no longer possible e g visible damage remove the device from the mains supply immediately gt Have professional personnel remedy the fault 2 5 Exclusion of liability The manufacturer cannot monitor the compliance to this manual as well as the conditions and methods during the installation operation usage and maintenance of the solar station Improper installation of the system may result in damage to property and as a result in bodily injury Therefore we assume no responsibility and liability for loss damage or costs which result from or are in any way related t
11. o incorrect installation improper operation incorrect execu tion of installation work and incorrect usage and mainte nance Similarly we assume no responsibility for patent right or other right infringements of third parties caused by usage of this solar station The manufacturer reserves the right to make changes to the product technical data or assembly and operating instruc tions without prior notice EN 3 Installation and operating in structions 3 1 Work steps installation gt Determine the position of the solar station Consider the space for the expansion tank gt Pull the thermometers off Pull off the front insulation of the solar station Hold the solar station in position on the wall and mark the position of the wall holder gt Drill the holes put the dowels into the holes fix the solar station to the wall using the wall bracket Install a circulation pump if necessary if pump was not included in delivery gt Place assemble and connect the expansion tank gt Pipe the whole system and connect the solar station gt In order to prevent gravity circulation in the flow it should be pulled downwards to the lowest point siphon type gt Firmly tighten all union nuts and screws connections The manometer does not need to be sealed with hemp or other sealants before inserting it into the valve Hand tighten the manometer and loosen it until you can read the indication properly gt Electrical
12. ressure of 200 mm water column each In order to fill flush and drain the solar station the TPS 25 valves must be open gt For this purpose turn the thermometers to a 45 position see illustration by turning the thermometers or use a combinationswrench SW 14 The ball inside the ball valve opens the TPS 25 valves gt During the operation the ball valves must be open com pletely left stop upright position of thermometer an a EN 7 Optional Flow display TPA F 25 TPA F 25 is a flowmeter Depending on the type the flowme ter indicates at 5 40 l min In order to limit the flow rate the ball valve in the flushing and filling unit 4 can be shut off partly higher pressure drop lower flow rate Another possibility to reduce the maximum flow rate is to reduce the pump speed using the speed switch It must be checked if the starting torque is sufficient with reduced pump rotation speed When regulating the flow rate the collector manufacturer s instructions must be considered In order to guarantee a smooth operation of the TPS 25 the system must be flushed and free from contaminants The upper end of the The lower end of the propeller is the reading propeller is the reading mark for flow rates up mark for values bet to 30 I min on the left ween 35 and 40 l min side of the scale on the right side of the scale Cc fe z O Example indicates approx
13. swrench SW 14 to a 45 position half open half closed gt Pour sufficient solar fluid into the container of a flushing and filling station not included in delivery and fill the system gt Flush the solar system for station at least 15 minutes by means of the filling and flushing unit In order to deaerate the solar system it is necessary to briefly open the ball val ve in the middle of the filling and flushing unit 4 when flushing the system The handle of the ball valve is in a vertical position if the ball valve is open s NOTE Never flush the solar station or carry out a pressure test ere water only As it is generally not possible to drain the system completely there is a risk of frost damage gt Close the flush valve 5 when the filling pump is running and increase the system pressure to approx 5 bar 87 psi You can read the pressure on the manometer gt Close the fill valve 3 and shut off the pump of the filling and flushing station Open the ball valve in the middle of the filling and flushing unit 4 so that the handle is in a vertical position gt Deaerate the system until the solar fluid exits without bubbles Again increase the system pressure to approx 5 bar 72 5 psi and check the system for leaks If the mano meter indicates a high pressure drop there are leaks in the system gt Set the operating pressure in accordance with the data of the system manufacturer gt Switch on the circulatio
14. to persons in the vicinity of the point of discharge e It is recommended to place a temperature resistant container under the discharge line If the safety valve is ac tivated the liquid is collected and can top up the system if the pressure drops too low 2 2 Improper usage The solar station must not be operated in the following environments e outdoors e in damp rooms e in rooms where highly flammable gas mixtures can occur e in rooms in which the operation of electrical and electron ic Components may cause dangers to arise an a EN 2 3 Dangers during assembly and commis sioning The following dangers exist during assembly commissioning of this solar station and during operation in case of assem bly errors Risk of death by electrocution Risk of fire due to short circuit Damage to any of the constructional fire safety measures present in the building due to incorrectly installed cables Damage to the solar station and connected devices due to improper ambient conditions inappropriate power supply and connecting prohibited devices or faulty devices and incorrect assembly or installation Therefore all safety regulations apply when working on the mains supply All electronic installations e g the connec tion of a controller or a pump only electricians may perform work gt When laying cables ensure that no damage occurs to any of the constructional fire safety measures present in the buildi
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