Ergo-Pro Twinline Solar Station Assembly and Operating Instructions
Contents
1. 3 Pipe union 11 for the membrane expansion vessel AG G flat sealing BFE cock 26a assembled ee ISO 228 1 Warning Collect any heat transfer fluid from the relief valve in a basin using a suitable pipe Extract from the WILO installation and operation manual pump 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 AE WILO GmbH NortkirchenstraBe 100 S Quality Management 44263 Dortmund Germany WILO STAR ST 15 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 at a temperature of 110 C Permissible temperature range 10 C to 120 C Maximum permitted ambient temperature These values apply at 300m above sea level ad2. the E position The slot on the spindle is horizontal the flat section points to the right Lock the supply ball valve set the return ball valve to the operating position Open the BFE cocks and execute the control rinsing procedure as illustrated in fig 7d Then close the BFE cocks again switch the Draining hose supply ball valve to the operating position and turn the spindle of the flow meter to the flow position the slot in the spindle is vertical the flat section points downwards Filling hose 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 a 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 gould 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. the flow meter Pos 6 to the flow position The slot in the spindle is vertical the flat section points downwards see Il The air that is still trapped in the pump can rise to the top Reset the spindle of the flow meter Pos 6 to Pos I and rinse the solar plant until the residual air is removed from the plant lf a reverse rinsing procedure is necessary it is recommended to conduct a concluding control rinse See fig 7c and 7d control rinse 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 section points to the right Leave the BFE cock 26a on the membrane expansion vessel connection closed open the BFE cock 26b on the flow meter The heat transfer fluid in the pump can now be discharged gt 7c Control rinse lt Fill rinse empty service A concluding control rinse should be conducted in two steps See fig 7c and fig 7d Step 1 Turn the spindle on the flow meter to the S position The slot in the spindle is horizontal the flat section points to the left Set the supply ball valve to the operating position set the return ball valve to a 45 setting Open the BFE cocks and execute the control rinsing procedure as illustrated in fig 7c Close the BFE cocks again after the rinsing procedure Step 2 Turn the flow meter spindle to
4. SO LFEX energy systems Ergo Pro Twinline Solar Station Assembly and Operating Instructions Table of contents Fill rinse empty Control rinse Air jet Safety unit connection to membrane expansion vessel Extract from pump manual Technicaidta O O Dimesins Operating temperature of max 140 C feed line Operating temperature of max 120 C return line Collector connections External thread G 3 4 Tank connections External thread G 34 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 l Mass approx 7 kg ee eS Operating voltage 230V 50Hz Pump capacity ST 15 63 min 34 W stage 1 max 82 W stage 3 Structure scope of supply Feed from Return to Collector Collector 4 27b ye DE e a Vai N EN 10226 1 G 3ra 0 278 4 SL to the RL of the tank tank Fig 1 General layout drawing Designation Feed line ball valve with integrated gravity brake 20 mbar Return line ball valve with integrated gravity brake 20 mbar 3 Manometer 1 4 Solar relief valve 6 bar TUV tested 1 Circulation pump ST 15 6 3 Flow meter 1 10 l min with rinsing shut off function union nut G1 x AG 3 4 1 18 Airjet union nut G1 x IG Rp3 with 9 Manual bleeding nipple 11 Connection to membra
5. ating 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 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 Adjusting the flow rate of the heat transfer fluid is achieved by selecting the r p m setting I Il HI on the circulating pump and with the throttle C on the flow meter 6 The flow meter displays the flow rate The normal range is between 1 and 10 l min fot a ede Flow rate adjustment range Read off the flow rate from the upper edge of the float For filling rinsing and emptying the solar plant use the BFE cocks 26a 26b on the membrane expansion vessel connection 11 and on the flow meter 6 see Fig 7 Unscrew the caps from the Fill rinse empty fig 7 closed BFE cocks and connect the supply lines from the rinsing and filling mechanism filling hose to 26a draining hose to 26b Filling and emptying Filling To fill and empty the solar plant the supply an
6. 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 11 4 Setup 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 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 sys
7. d return ball valve must be opened in the Gravity brake position 45 Turn the spindle on the flow meter to the S position The slot in the spindle is horizontal the flat section points to the left see fig 7 1 a Connect the filling hose to the BFE cock 26a Connect the draining hose to the BFE cock 26b Open the BFE cocks The solar plant can now be emptied or filled b After filling the solar plant set the spindle of the flow meter Pos 6 to the flow position The slot in the spindle is vertical the flat section points downwards see II c If no flow rate is visible on the flow meter Pos 6 after the filling procedure gt conduct a control rinse lt see 7c and 7d d Emptying To 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 Pos IT The slot in the spindle is vertical the flat section points downwards Close the BFE cock 26b Remove the draining hose from the BFE cock 26b and connect it to an underlying designated BFE cock Rinsing 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 section points to the left Open the BFE cocks and begin the rinsing procedure Rinsing the pump Set the spindle of
8. der 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 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 VDE 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 carried 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 guarantted 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 15 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
9. ne expansion vessel ST 12 Dialthermometer gt gt gt S 2 O 13 Insulation insulating half jacket front 13a back 13b o SSS S 23 Mounting plate S 24 Spring o 2 O 26 BFEcocks S 2 26a Grommets for BFE cocks o S 2 O 27 Wall assembly set wood screws 27a dowel 27b washers 27c 2 ofeach O Z o Z o o OTi 28 _ Reducing nippel with external thread GP A O 29 Flatsedl oo O A Assembling the pump group on a wall Fig 3c Wall assembly 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 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 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 The gravity brakes are built into the feed and return ball valve They are operated by turning the ball valve handle Gravity brakes closed Ball valves opened in each case 20 mbar Oper
10. tem 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 oe oe
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