Assembly and operating instructions
Contents
1. Fill rinse empty fig 7 mechanism For filling rinsing and emptying the solar plant use the BFE cocks 26 on the membrane expansion vessel connection 11 and on the flow meter 7 see Fig 7 Unscrew the caps from the closed boiler filling and boiler emptying cocks BFE cocks and attach the input pipes from the rinsing and filling Filling and emptying Fig 7 To fill and empty the solar plant the supply and return ball valve must be opened in the Gravity brake position 45 Turn the spindle of the flow meter to the flow position the slot in the spindle is vertical the flat area points downwards Open the BFE cocks The solar plant can now be emptied or filled Rinsing Fig 7a Fig 7a To rinse the solar plant turn the supply and return ball valve to the gravity brake open position 45 Turn the spindle on the flow meter to the S position The slot in the spindle is horizontal the flat points to the left Open the BFE cocks and begin the rinsing procedure Service Fig 7b Fig 7b 26a 26b When maintenance is being carried out e g a pump change the feed and return ball valve must be closed Turn the flow meter spindle to the E position The slot on the spindle is horizontal the flat points to the right With the BFE co2. in each case 20 mbar The gravity brakes are built into the feed ball valve handle and return ball valve They are operated by turning the SZ Gravity brakes closed Ball valves opened Fig 4a Operating position The valve discs should not be opened to prevent circulation under the force of gravity The slots in the handles are verical fig 4a The force of gravity brakes are in the operating position closed The ball valves are opened Fig 4b Emptying filling To fill and completly empty the solar plant open the gravity brakes by turning the handles to the right The slots in the handles are located at an angle of 45 to the vertical fig 4b The gravity brakes are opened Position Closed Turn the handles 90 to the right The ball valves are closed The slots in the handles are now horizontal fig 4c Flow meter rinsing and filling armature Adjusting the flow rate of the heat transfer fluid is achieved by selecting the r p m setting I Il Ill on the circulating pump and with the throttle C on the flow meter 7 The flow meter displays the flow rate The normal range is between 1 and 10 l min Flow rate adjustment range i Read off the flow rate from the upper edge of the float T a el he 2 2 c ALA 7 HH Fig 5 Fig 6
3. 1 Connection to membrane expansion vessel 1 12 Dial thermometer 2 13 Insulation insulating half jacket front 13a back 13b control console 13c 1 23 Mounting plate 1 16 Controller 1 24 Spring 2 26 BFE cocks 2 26a Grommets for BFE cocks 2 27 Wall assembly set wood screws 27a dowel 27b washers 27c 2 of each 1 Assembling the Ergo Pro Solar Station on the wall 306 7 72 5 80 330 Fig 3a Drilling dimensions Pull feed line A and return line B out of the mounting plate 23 Mark drilling points for the mounting plate 23 on the wall and drill two 8mm holes Fig 3a 27b 23 27c 27a Fig 3b Attaching the mounting plate Insert dowels 27b into the holes and bolt on the mounting plate using the screws 27a and washers 27c Adjust the mounting plate with a spirit level Fig 3c Wall assembly Check that the springs 24 sit in the slots of the mounting plate intake sockets 23 correctly Push the rear insulation jacket 13b over the intake sockets press the flow pipe A with the taps on the supply ball valve 1 and the return flow pipe B with the taps on the return ball valve 2 into the intake sockets until they engage Gravity brake function Gravity brake opening pressure
4. 263 Dortm Fig 5 WILO STAR ST 20 6 Operating instructions for the operator 1 General information Installation and start up may only be carried out by technical personnel 1 1 Intended purpose Type ST for thermal solar plants 1 2 Connection and performance data Minimum inlet pressure at the intake at a temperature f 50 C 0 05 bar at a temperature f 95 C 0 3 bar at a temperature of 110 C 1 0 bar Permissible temperature range 10 to 120 TC Maximum permitted ambient temperature 40 C These values apply at 300m above sea level adder for higher locations 0 01 bar 100m increase in altitude To avoid cavitation noise the minimum inlet pressure at the pump intake should be adhered to Fluids to be pumped Water and water glycol mixtures in ratios up to 1 1 When adding glycol the higher viscosity requires that the pumping data is corrected according to the mixing ratio Only use branded goods with corrosion inhibitors and observe manufacturer s data 2 Safety 2 1 Safety instructions for the operator Take note of current regulations for the prevention of accidents Eliminate all electrical risks Take note of regulations and those of local electricity supply companies 2 2 Safety instructions for inspection and assembly work The operator must ensure that all inspection and assembly work is ca
5. Assembly and operating instructions Ergo Pro Twinline Solar Station Complete with DeltaSol C Plus Controller Safety instructions Before using your equipment please read the following instructions for assembly and start up This will help you avoid any damage to your equipment that may arise from incorrect handling Use of the equipment in a manner that is contrary to its intended purpose together with changes during assembly or to the construction that are not permitted will invalidate any claims for liability Alongside country specific guidelines the following technical regulations must be given particular consideration DIN 4751 Central heating boilers DIN 4757 Solar heating and solar thermal systems DIN 18380 central heating systems and hot water supply systems DIN 18382 Electrical cable and wiring systems in buildings EN 12975 Thermal solar systems and components Table of contents Safety instructions Technical data Dimensions Structure scope of supply Assembly of the unit on a wall Gravity brake function Flow meter rinsing and filling armature Fill rinse empty Air jet Safety unit connection to membrane expansion vessel Controller electrical connections Extract from pump manual 00 SI Ni NI gt cn BJ wonne Technical data Dimensions Operating pressure max 6 bar Ope
6. be carried out by an authorised specialist Fuses wiring and earthing are to be made according to local regulations The connection to the mains must be made using the attached mains cable The solar controller must be protected against damage by excess voltage Opening the controller is only necessary for servicing Before opening the housing of the solar controller make sure the device is disconnected from the mains Pump cables and mains cables are attached to the solar controller Fig 10 at the factory Warning A x The terminals for the sensors can be accessed after loosening the Do not bend the cable sharply and Screw F on the solar controller s faceplate G do not lay it while energised Do 3 3 A not run the cable directly over Make the connection with the sensor according to the controller sharp edged components manual For a description of its function and operation see the controller manual Extract from the WILO pump installation and operation manual CE Declaration of Conformity We hereby declare that this unit meets the following regulations entspricht EEC machine guidelines 89 392 EWG in this version 91 368 EWG 93 44 EWG 93 68 EWG Electromagnetic compatibility 89 336 EWG ith D F 92 31 EWG 93 68 EWG Harmonized standards used in particular EN 809 EN 50 081 1 EN 50 082 1 EN 50 081 2 EN 50 082 2 J m WILO GmbH Nortkirchenst Quality Management 44
7. ck 26a on the membrane expansion vessel closed open the BFE cock 26b on the flow meter The heat transfer fluid in the pump can now be discharged Air jet The air that remains in the heat transfer fluid collects in the air jet 8 and can be discharged manually via the bleed nipple 9 To do this push the hose provided onto the bleed nipple sleeve and catch any fluid that comes out in al suitable container Bleeding may only be carried out by trained technical personnel Uncontrolled bleeding leads to a decrease in pressure and to malfunctions in the solar plant Warning Danger of scalding Both the air that escapes during bleeding and the heat transfer fluid can reach temperatures of over 100 C Finally retighten the nipple firmly When bleeding check the system pressure If necessary the solar plant sgould be refilled with the heat transfer fluid mixture Safety unit connection for membrane expansion vessel fig 8 The solar safety unit on the return ball valve is equipped with Solar relief valve response pressure 6 bar 4 Manometer measurement range 10 bar 3 Pipe union 11 for the membrane expansion vessel AG G flat sealing BFE cock 26a Warning Collect any heat transfer fluid from the relief valve in a basin using a suitable pipe Fig 8 Controller electrical connections Note Work on live parts may only
8. of current and voltage of the mains supply must correspond to the data given on the identification plate Carry out the connection to the mains according to fig 4 Earth the pump plant correctly 5 Start up Bleeding Bleeding the pump rotor area takes place automatically after a short period of operation Unlubricated operation for brief periods does not harm the pump If however it should be necessary to bleed the rotor area directly proceed as follows Switch off pump Close the line on the pressure side Carefully open the vent screw with a suitable screwdriver Fig 5 Depending upon the temperature of the delivery medium and the system pressure when opening the vent screw hot delivery medium in liquid or vapour form can leak or shoot out under high pressure There is a risk of scalding Carefully push back the pump shaft with a screwdriver several times protect electrical parts before allowing water to flow out Switch on pump after 15 30 s close the bleed screw again Open the shutoff valve again WARNING Where the screw plug is opened and depending on the operating pressure the pump may block Depending on the operating condition of the pump or the plant temperature of the delivery medium the entire pump can become very hot There is a risk of burning if the pump is touched 10
9. rating temperature of max 140 C feed line Operating temperature of max 120 C return line Medium Water with max 50 propylene glycol Nominal size DN 15 Screw connections flatsealing union nut 1 inch Collector connections Internal thread inch Tank connections Internal thread inch Materials Seals EPDM AFM 34 Housing CW 617 2 0402 Connecting CW 614 2 0401 components Insulation EPP foam Heat conductivity 0 038 W mK Weight approx 7 kg Operating voltage 230V 50Hz Pump capacity ST 20 63 min 34 W stage 1 max 82 W stage 3 Structure scope of supply Feed Return from to Collector Collector Rp ay D 26a SL to the RL of the 26a tank tank Fig 1 General layout drawing Item Designation PGS DN15 1 Feed line ball valve with integrated gravity brake 20 mbar 1 2 Return line ball valve with integrated gravity brake 20 mbar 1 3 Manometer 1 4 Solar relief valve 6 bar TUV tested 1 5 Circulation pump ST 20 6 3 1 6 Flow meter 1 10 l min with rinsing shut off function union nut G1 x IG Rp 1 8 Air jet union nut G1 x IG Rp with 1 9 Manual bleeding nipple 1
10. rried out by authorized qualified technical personnel who have studied the manual in sufficient detail Work on the pump plant may only be carried out when it is not in operation 2 3 Prohibited modes of operation The operational safety of the pump plant supplied is only guaranteed when used as intended according to section 1 of the manual The limit values indicated in the data sheet may under no circumstances be exceeded 3 Description of product and accessories The ST 20 25 pump is a solar thermal pump with special hydraulics coated pump housing for the use in thermal solar plants A motor contactor is not required Even the maximum overload current cannot damage the motor as it is that engine is block current proof Changing the r p m All pumps have a knob on the terminal box for manually changing the speed in r p m in 3 steps 1 min 2 3 max At the lowest step the number of revolutions is reduced to around 40 50 of the maximum The power input is reduced by approximately 50 4 Set up installation Assembly The directional marker on the pump housing shows the direction of flow Fig 2 pos 1 When bolting the pump onto the piping the pump can be secured to prevent rotation by using a combination wrench on the flats provided Fig 3 Electrical connections The connecting cable is to be laid in such a way that the piping the pump housing and motor housings are not affected The type
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