Bosch Worcester AGS 5 User guide

INSTALLATION AND SERVICING INSTRUCTIONS

SOLAR PUMP STATIONS

AGS 5/5E, AGS 10/10E

FOR SEALED SOLAR HEATING SYSTEMS AND INDIRECT FED DOMESTIC HOT WATER

7747006489.00-1.SD

CONTENTS

6 720 643 603 (2011/11)

CONTENTS

1 Safety instructions and explanation

of symbols 3

1.1 General safety instructions 3

1.2 Symbols 3

2 Information about the product 4

2.1 EU Declaration of Conformity 4

2.2 Correct use 4

2.3 Included in delivery 4

2.4 Product description 4

2.5 Specifications and variants 5

2.6 Example applications 6

3Regulations 7

4 Installing pipework 8

4.1 General information regarding pipework 8

4.2 Installation of solar pipework 9

5 Installing the solar pump station 10

5.1 Layout of the installation space 10

5.2 Mounting the solar pump station 10

5.3 Electrical connection 10

5.4 Installing the safety assembly 11

5.5 Connecting the expansion vessel and

pre-cooling vessel 11

5.5.1 Installing the pre-cooling vessel

(available as accessory) 11

5.5.2 Installing the expansion vessel

(available as an accessory) 12

5.5.3 Adjusting the inlet pressure of the

expansion vessel 12

5.6 Connecting pipes and blow-off line to

the solar pump station 12

5.7 Installing the temperature sensors 13

5.7.1 Collector temperature sensor 13

5.7.2 Storage tank temperature sensor 13

6 Commissioning 14

6.1 Use of heat transfer fluid 14

6.2 Purging and filling with a hand pump

(air vent on roof) 14

6.2.1 Purging the pipes 14

6.2.2 Carrying out pressure test with water 15

6.2.3 Replacing water with heat transfer fluid 16

6.2.4 Verifying that the solar heating system is free of air 16

6.2.5 Determining the operating pressure 16

6.2.6 Determining the frost protection temperature 17

6.2.7 Correcting frost protection 17

6.3 Adjusting the flow rate 17

7 Commissioning, inspection and maintenance

report 19

8 Fault finding 21

SAFETY INSTRUCTIONS AND EXPLANATION OF SYMBOLS

6 720 643 603 (2011/11) 3

1 SAFETY INSTRUCTIONS AND EXPLANATION OF SYMBOLS

1.1 EXPLANATION OF SYMBOLS

WARNINGS

Keywords at the start of a warning indicate the type and

seriousness of the ensuing risk if measures to prevent

the risk are not taken.

•NOTICE indicates that material losses may occur.

•CAUTION indicates that minor to medium injury may

occur.

•WARNING indicates that severe injury may occur.

•DANGER indicates a risk to life.

IMPORTANT INFORMATION

ADDITIONAL SYMBOLS

1.2 GENERAL SAFETY INSTRUCTIONS

ABOUT THIS MANUAL

This manual contains important information for the safe

and correct installation and maintenance of the solar

pump station.

This manual is intended for qualified technicians.

The illustrations in this manual show the 2-line solar

pump station with external controller.

BGive the manual to the customer, and explain how the

device works and how to operate it.

PLEASE OBSERVE THESE INSTRUCTIONS

BPlease read these instructions carefully.

BTo prevent injury and property damage, always follow

the safety instructions.

BAny tasks that require the solar pump station to be

opened must be carried out by qualified electricians.

BThe electrical supply must be connected by a

qualified electrician.

BBefore opening the solar pump station, it must be

isolated from the power supply.

BInstall a blending valve to limit the temperature at the

tap to a maximum of 60°C.

BDo not make modifications to the device.

BUse only materials which can withstand possible

temperatures up to 150°C.

BPurge and fill the solar heating system only when the

sun is not shining on the collectors and (if purging

with water) no frost is expected.

Warnings in this document are framed and

identified by a warning triangle printed

against a grey background.

If there is a danger due to electricity, the

exclamation mark in the warning triangle is

replaced by a lightning symbol.

Important information where there is no risk

to people or property is indicated with the

adjacent symbol. It is bordered by lines

above and below the text.

Symbol Meaning

BAction step

ÆCross-reference to other parts of this

document or to other documents

•List/list entry

–List/list entry (second level)

Tab. 1

INFORMATION ABOUT THE PRODUCT

6 720 643 603 (2011/11)

2 INFORMATION ABOUT THE PRODUCT

2.1 EU DECLARATION OF CONFORMITY

The design and operation of this product conform to the

applicable European directives and supplementary national

requirements. The conformity has been confirmed.

2.2 CORRECT USE

AGS solar pump stations must only be used for the

operation of solar heating systems in conjunction with

suitable controllers from the same manufacturer.

AGS solar pump stations are solely designed for

operating solar heating systems filled with propylene

glycol/water mixtures (Tyfocor L or Tyfocor LS). Do not

use any other heat transfer medium.

2.3 INCLUDED IN DELIVERY

Fig. 1 Package contents - Solar pump station with

controller

1Solar pump station (1- or 2-line solar pump station with/

without controller)

2Safety assembly (safety valve, pressure gauge, fill & drain

valve)

And

Mounting materials (not shown)

2.4 PRODUCT DESCRIPTION

Fig. 2 Solar pump stations without front insulation

casing and without built-in controller

1Ball valve with thermometer (red=flow1), blue=return) and

integrated gravity brake:

- 0° = gravity brake ready for operation,

- 45° = gravity brake manually open

2Compression fitting

3Safety valve

4Pressure gauge

5Connection to diaphragm expansion vessel

6Fill & drain valve

7Solar pump

8Flow rate indicator

9Air eliminator1)

10 Control/shut-off valve

Benchmark places responsibilities on both

manufacturers and installers. The purpose is to ensure

that customers are provided with the correct

equipment for their needs, that it is installed,

commissioned and serviced in accordance with the

manufacturer’s instructions by competent persons and

that it meets the requirements of the appropriate

Building Regulations. The Benchmark Checklist can be

used to demonstrate compliance with Building

Regulations and should be provided to the customer for

future reference.

Installers are required to carry out installation,

commissioning and servicing work in accordance with

the Benchmark Code of Practice which is available from

the Heating and Hotwater Industry Council who manage

and promote the scheme. Visit

www.centralheating.co.uk for more information

7747006489.04-1.SD

1) Not for 1-line solar pump station

7747006489.01-1.SD

610

INFORMATION ABOUT THE PRODUCT

6 720 643 603 (2011/11) 5

2.5 SPECIFICATIONS AND VARIANTS

AGS 5 AGS 5E

Maximum possible temperature °C Flow: 130 / return: 110 (pump)

Safety valve response pressure bar 66

Safety valve –DN 15, ¾ " connection DN 15, ¾ " connection

Mains supply –230V AC, 50 - 60 Hz 230V AC, 50 - 60 Hz

Maximum current consumption per pump A0.25 0.25

Dimensions (HxWxD) mm 355x290x235 355x185x180

Flow and return connections

(compression fittings)

mm 15 15

Number of collectors –1 - 5 1 - 5

Tab. 2 Specifications for AGS 5 and AGS 5E

AGS 10 AGS 10E

Maximum possible temperature °C Flow: 130 / return: 110 (pump)

Safety valve response pressure bar 66

Safety valve –DN 15, ¾ " connection DN 15, ¾ " connection

Mains supply –230V AC, 50 - 60 Hz 230V AC, 50 - 60 Hz

Maximum current consumption per pump A0.54 0.54

Dimensions (HxWxD) mm 355x290x235 355x185x180

Flow and return connections

(compression fittings)

mm 22 22

Number of collectors –6 - 10 6 - 10

Tab. 3 Specifications for AGS 10 and AGS 10E

INFORMATION ABOUT THE PRODUCT

6 720 643 603 (2011/11)

2.6 EXAMPLE APPLICATIONS

Fig. 3 Different hydraulic applications

1Standard system with 2-line solar pump station

2Two collector arrays (east/west) with 1-line and 2-line solar

pump stations

3Dual-tank system with 1-line and 2-line solar pump stations

4Standard system with 1-line solar pump station and air vent

on roof

1 2

7747006489.03-2.SD

REGULATIONS

6 720 643 603 (2011/11) 7

3REGULATIONS

Observe all standards and guidelines applicable to the

installation and operation of the system in your country

and region.

TECHNICAL REGULATIONS APPLICABLE IN THE U.K.

FOR THE INSTALLATION OF THERMAL SOLAR

HEATING SYSTEMS

•Electrical connection:

–Current IEE wiring regulations

•Connection of thermal solar systems:

–EN 12976: Thermal solar systems and components

(factory made systems)

–ENV 12977: Thermal solar systems and

components (custom built systems)

–BS5918: Latest version: Solar heating systems for

domestic hot water.

•Installation and fittings of hot water heaters:

–BS5546:2006 Specification for installation of hot

water supplies for domestic purposes, using gas-

fired appliances of rated input not exceeding

70kW.

–BS6700:2006 Specifications for design, installation

testing and maintenance of services supplying

water for domestic use within buildings and their

curtilages.

INSTALLING PIPEWORK

6 720 643 603 (2011/11)

4 INSTALLING PIPEWORK

4.1 GENERAL INFORMATION

REGARDING PIPEWORK

The collectors, the solar pump station and the solar

storage tank are interconnected with copper pipes.

BTo prevent air locks: route the pipes from the tank to

the collector on a rising incline.

Fig. 4 The piping of the solar heating system

1Wire to the collector temperature sensor

2Collectors

3Solar pump station

4Solar storage tank

CONNECTING THE PIPES

BCopper pipes for solar heating systems should always

be brazed (i.e. no low-temperature soldering).

Compression fittings or pressfittings can be used

instead of brazing if they are glycol- and heat-resistant

(150 °C).

CAUTION: System damage from plastic

pipes (e.g. PE pipes)

BUse only materials which can withstand

the temperatures up to 150 °C which

occur in solar heating systems.

7747006489-05.1SD

CAUTION: System damage from heat

buildup when brazing

BDo not carry out brazing close to

evacuated tube collectors.

We recommend carrying out a pipe network

analysis to determine pipe requirements.

Basic design estimates can be made using

Tab. 4.

BIf there are many additional points of

resistance (bends, valves etc.), you may

need to select a pipe with a larger

diameter.

Straigh

t pipe

length

Number of collectors

Up to 5 Up to 10

Up to

6 m

Double pipe 15 Ø 15 mm

(DN12)

Ø 22 mm (DN15)

Up to

10 m

Double pipe 15 Ø 15 mm

(DN12)

Ø 22 mm (DN20)

Up to

15 m

Double pipe 15 Ø 15 mm

(DN12)

Ø 22 mm (DN20)

Up to

20 m

Ø 22 mm (DN15) Ø 22 mm (DN20)

Up to

25 m

Ø 22 mm (DN15) Ø 28 mm (DN25)

Tab. 4 Pipe sizing

If threaded pipe connections are caulked

with hemp:

BUse a thread sealing paste resistant

to temperatures up to 150 °C

(e.g. NeoFermit universal).

INSTALLING PIPEWORK

6 720 643 603 (2011/11) 9

4.2 INSTALLATION OF SOLAR PIPEWORK

EARTHING PIPES

Work must be carried out by an authorised electrician.

BOne earthing clamp must be fitted to both the flow

pipe and the return pipe (at any position).

BConnect the earthing clamps to the building's

equipotential bonding strip by means of a standard

PVC-sheathed bonding cable (NYM type, at least

6mm

2).

INSTALLING SOLAR PIPEWORK WITH AN AUTOMATIC

AIR VENT ON THE ROOF (AVAILABLE AS ACCESSORY)

BConnect pipes to the air vent on a rising incline.

For every downwards change of direction an

additional air vent unit is required (heat-resistant

to 150 °C).

Fig. 5 Position of the automatic air vent valve

1Automatic air vent

INSULATING PIPES

BInsulate outdoor pipework with material which is

class O rated, which is resistant to UV and to high

temperatures (150 °C).

BInsulate indoor piping with material which is resistant

to high temperatures (150 °C).

7747006489.06-1.SD

INSTALLING THE SOLAR PUMP STATION

6 720 643 603 (2011/11)

5 INSTALLING THE SOLAR PUMP STATION

5.1 LAYOUT OF THE INSTALLATION

SPACE

BTo make it easier to connect the temperature sensors:

install the solar pump station (2) as close as possible

to the solar storage tank (1).

BAllow enough room for an expansion vessel (3) and

storage vessel (4).

Fig. 6 Recommended positioning

(measurements in mm)

1Solar storage tank

2Solar pump station

3Expansion vessel

4Storage vessel

5.2 MOUNTING THE SOLAR PUMP

STATION

1-LINE SOLAR PUMP STATION

BDrill a hole (2) and mount the solar pump station

using the wall plug and screw supplied.

2-LINE SOLAR PUMP STATION

BDrill holes (1) 60 mm apart and mount the solar pump

station using the wall plugs and screws supplied.

Fig. 7 Mounting the station

1Mounting for 2-line solar pump station

2Mounting for 1-line solar pump station

5.3 ELECTRICAL CONNECTION

Electrical connections must be carried out by properly

authorised electricians and subject to locally applicable

regulations.

BConnect the cables for the pumps and temperature

sensors to the controller as directed by the

installation instructions for the controller.

CAUTION: Damage to the solar heating

station from pump buildup

BMake sure that the ventilation slots, at

the top and bottom of the thermal-

protective casing, are open.

7747006489.07.1.SD

CAUTION: Damage to pump

BDo not put the pump into operation until

the pipework has been filled. Otherwise

the pump can be damaged.

10 mm

8 mm

10 mm

7747006489.08-1.SD

60 mm

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