Resol FlowSol C Owner's manual
FlowSol®C
*48002501*
48002501
Installation
Operation
Commissioning
Manual for the
specialised craftsman
Thank you for buying this RESOL product.
Please read this manual carefully to get the best performance from this unit.
Please keep this manual carefully. www.resol.com
Manual
en
2
en
© 20110607_48002501_FlowSol_C.monen.indd
Subject to technical change. Errors excepted.
Safety advice
Please pay attention to the following safety advice
in order to avoid danger and damage to people and
property.
Instructions
Attention must be paid to the valid local standards,
regulations and directives!
Information about the product
Proper usage
The pump station may only be used in the solar cir-
cuit of solar thermal systems in compliance with the
technical data specified in these instructions. Due to
its design the station must be mounted and operated
as described in these instructions!
CE-Declaration of conformity
The product complies with the relevant di-
rectives and is therefore labelled with the
CE mark. The Declaration of Conformity
is available upon request, please contact
RESOL.
Target group
These instructions are exclusively addressed to au-
thorised skilled personnel.
Only qualified electricians should carry out electrical
works.
Initial installation must be effected by qualified per-
sonnel named by the manufacturer.
Description of symbols
WARNING! Warnings are indicated with a warn-
ing triangle!
ÎThey contain information
on how to avoid the danger
described.
Signal words describe the danger that may occur,
when it is not avoided.
• WARNING means that injury, possibly life-threat-
ening injury, can occur.
• ATTENTION means that damage to the appli-
ance can occur.
Note
Notes are indicated with an information
symbol.
ÎArrows indicate instruction steps that should be
carried out.
Disposal
• Dispose of the packaging in an environmentally
sound manner.
• Dispose of old appliances in an environmentally
sound manner. Upon request we will take back your
old appliances bought from us and guarantee an en-
vironmentally sound disposal of the devices.
Contents
1 Overview .................................................... 3
2 Mounting the station................................. 4
3 Commissioning.......................................... 4
3.1 Flushing and filling the solar thermal system .....4
3.2 Flushing the store for initial commissioning.......5
3.3 Flushing and filling the solar thermal system .....5
3.4 Emptying the solar thermal system......................6
4 Flowmeter.................................................. 6
5 Air separator ............................................. 6
6 Connection................................................. 6
7 Accessories for the station....................... 6
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FlowSol®C
Scope of delivery:
1 x pump station FlowSol®C
1 x flushing and filling unit (optional)
1 x wall mounting bracket
About this product
The pump station FlowSol®Cis a preinstalled and
leak-tested group of fittings for transferring heat from
the collector to the store. It contains important fit-
tings and safety devices for the operation of the solar
thermal system:
• Ball valves in flow and return in combination with
check valves to prevent gravity circulation
• Air separator for manual bleeding of the solar
thermal system
• Flowmeter for displaying the flow rate
• Manometer for displaying the system pressure
• Safety valve to prevent inadmissible overpressure
• Flushing and filling unit (optional) for flushing, filling
and emptying the solar thermal system
1 Overview
• Integrated controller DeltaSol®C
• Outstanding design
• Safety assembly with safety valve and
pressure gauge
• High-quality casing for reduced heat losses
• Flowmeter
Technical data
Dimensions (H x W x D):
approx. 417 x 374 x 179 mm (incl. insulation)
Distance centre: 1600 mm
Distance axis / wall: 55 mm
Pipe connections: ¾" IT
Connection to diaphragm-type expansion
vessel: ¾" ET, flat sealing
Outlet safety valve: ¾" IT
Safety valve: 6 bar
Pressure gauge: 0 ... 6 bar
Non-return valve: Opening pressure 20 mbar,
openable
Max. permitted pressure: 6 bar
Admissible max. temperature: +120 °C
Material:
Fittings: brass
Seals: EPDM
Insulation: EPP, l= 0,041 W/(m*K)
Flowmeter: 1 ... 20 l/min
160 mm 55 mm
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2 Mounting the station
thermometer
flow thermometer
return
flowmeter
controller
DeltaSol®C
pump
air separator
flushing and
filling unit
(optional)
safety
assembly
manometer
ÎDetermine the mouting site of the station.
ÎTake the station out of the packing. Remove the
front half of the insulation.
ÎHold the enclosed wall mounting bracket against
the wall and mark the fastening holes, drill holes
and insert dowels.
ÎFasten the wall mounting bracket to the wall with
the screws.
ÎPush the station against the wall mounting bra-
cket.The station catches and is then attached to
to the wall.
ÎConnect the station to the solar thermal system.
ÎCheck the inlet pressure of the expansion vessel
and, if necessary, adjust it to the local conditions
(P inlet[bar] = 1 bar + DTh [m]*1/10 (DTh = height
difference between collector and station).
ÎConnect the electrical components of the solar
station:Attach the store and collector sensor and
connect these to the controller. Plug the control-
ler into a socket.
ÎTighten all union nuts and screw connections.
ÎAttach the front half of the insulation to the sta-
tion.
3 Commissioning
3.1 Flushing and filling the solar thermal
system
Attention! Risk of scalding!
To prevent the solar fluid boiling in
the collectors, the system should not
be flushed or filled during periods of
strong sunshine!
Attention! Risk of frost!
Solar thermal systems cannot be
completely emptied after flushing.
There is a danger of frost damage if
water is used for flushing. Only use
solar fluid to flush and fill the solar
thermal system.
ÎUse a water-propylene glycol
mixture as a solar fluid (ma-
ximum 50% propylene glycol).
Instructions for initial commissioning
The optionally enclosed flushing and filling
unit can either be integrated into the stati-
on (below the Air separator, mounted by 30°
outwards,see fig.2) or installed horizontally at
the lowest point of the solar circuit (see fig.1).
fig.1 fig.2
In both cases a filter must be installed between the
store and the solar pump in order to prevent the
flushed-out scale from re-entering the solar circuit.
If the flushing and filling unit is integrated in the solar
station, we recommend an additional fill and drain ball
valve at the lowest point of the solar circuit, to flush
possible scale out.
This flushing process is described in “3.2 Flushing the
store for initial commissioning”.Then continue as de-
scribed in “3.3 Flushing and filling the solar thermal
system”.
5
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3.2 Flushing the store for initial
commissioning
• Connect the pressure hose of a flushing and filling
station to the fill ball valve.
• Connect the flushing hose of a flushing and filling
station to the fill and drain valve at the lowest
point of the solar thermal system.
• Close the ball valve.
• Open the fill ball valve (5) and the fill and drain val-
ve at the lowest point of the solar thermal system.
• Flush the solar thermal system by means of the
flushing and filling station until the discharged solar
fluid is free of dirt particles.
• Switch off the filling pump.
• Close the fill and drain valve at the lowest point of
the solar thermal system.
• Remove the flushing hose from the fill and drain
valve.
• Close the fill ball valve.
• Connect the flushing hose to the drain ball valve.
3.3 Flushing and filling the solar thermal
system
• Disconnect the expansion vessel from the solar
thermal system.
• Connect the pressure hose of a flushing and filling
station to the fill ball valve (5) of the flushing and
filling unit.
• Connect the flushing hose of a flushing and filling
station to the drain ball valve (3) of the flushing
and filling unit.
• Close the ball valve (4) in the centre of the flushing
and filling unit.
• Turn the ball valves in flow (1) and in return (2)
with an open-ended spanner (wrench width 14)
to a 45° position.The non-return valves in the ball
valves are now open.
• Open the fill and drain ball valves (3 and 5).
• Flush the solar thermal system using the flushing
and filling station for at least 15 minutes to remove
all air from the system.
• During flushing, bleed the solar thermal system
several times at the Air separator until the dischar-
ged solar fluid is free of air bubbles.
• Close the drain ball valve (3) of the flushing and fil-
ling unit with the filling pump running and increase
the system pressure to approx. 5 bar.The system
pressure can be read from the manometer.
• Close the fill ball valve (5) and switch off the pump
of the flushing and filling station.
• Check the manometer to see whether the system
pressure reduces and eliminate leaks where
necessary.
• Reconnect the expansion vessel to the other
components of the solar thermal system.
3
4
5
1 2
If it is necessary to set the pressure, observe
the following step:
• Set the operating pressure of the solar thermal
system by means of the flushing and filling station
(0.3-0.5 bar higher than the inlet pressure of the
expansion vessel).
• If you have put the flushing and filling station into
operation to set the operating pressure, switch off
the filling pump.
• Close the fill and drain ball valves and open the
ball valve.
• Remove the hoses of the flushing and filling station
and screw the caps onto the fill and drain ball
valves.
• Put the non-return valves in flow and return in
operating position by opening the ball valves with
an open-ended spanner (wrench width 14).
ball valve: 45°
non-return valve
not operating
flow-through in
both directions
ball valve: 90°
ball valve closed,
no flow-through
ball valve: 0°
non-return val-
ve in operation,
flow-through
only in flow
direction
• Manually put the solar thermal pump in operation
at the highest RPM level (see controller manual)
and let it circulate for at least 15 minutes
• During flushing, bleed the solar thermal system
several times at the Air separator, until the dischar-
ged solar fluid is free of air bubbles and increase,
if required, the system pressure to the operating
pressure.
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3.4 Emptying the solar thermal system
WARNING! Risk of injury.The discharged fluid
can have very high temperatures.
Place the collection container so
that people standing near by are
not endangered when the solar
thermal system is being emptied.
• Open the non-return valves in the ball valves in
flow and return by turning the ball valves to a 45°
position with an open-ended spanner.
• Place a temperature-resistant collection container
under the drain ball valve at the lowest point of
the solar thermal system.
• Open the drain ball valve at the lowest point of the
solar thermal system.
• Open the bleeding devices at the highest point of
the solar thermal system, where available.
• Dispose of the solar fluid in observance of local
regulations.
4 Flowmeter
The Flowmeter is for measurement and display of the
flow rate of 1-20 l/min. In order to guarantee the flaw-
less function of the measuring device the system must
be flushed and free from foreign substances.
Left scale:
Upper edge of
the propeller Right scale:
Lower edge of
the propeller
5 Air separator
The air separator (manual bled valve) is for bleeding
the solar fluid in the solar thermal system. The air
precipitated from the solar fluid gathers in the upper
area of the manual bleed valve (see diagram) and can,
if required, be discharged at the bleeding valve.To gu-
arantee faultless bleeding of the collector circuit the
flow rate in the flow must be at least 0.3 m/s.
Check the system pressure after bleeding and if ne-
cessary increase it to the specified operating pressure.
WARNING! Risk of injury caused by very high
temperatures. During bleeding the
escaping air and solar fluid can re-
ach temperatures of over 100 °C.
Bleeding the solar thermal system directly
after commissioning.
At first you should bleed the solar thermal system
daily and then weekly or monthly, depending on the
volume of discharged air, in order to achieve optimal
efficiency.
Note
Bleed the solar thermal system half-yearly
with the manual bleed valve to achieve op-
timal efficiency.
6 Connection
WARNING! Always disconnect the control-
ler from power supply before
opening the housing!
The controller is already integrated in the station and
ready to plug in. In the case of maintenance or service
work, the controller is to be taken out from the stati-
on. Please pay attention to the followong steps:
• switch off the system, disconnect plug from the
mains
• remove the front half of the insulation
• unscrew the cross-recessed screw off the front
cover and remove it by pulling it upwards
• unscrew the lower cross-recessed screw, push the
controller upwards and remove it
Mounting of the controller has to be carried out in
reverse order.
7 Accessories for the station
For installation screw connections are required, which
are not included in the scope of delivery. Self-sealing
double nipples, solder nipples or clamp-ring connec-
tions can be used. For further information, please see
product catalogue.
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Notes
Distributed by: RESOL - Elektronische Regelungen GmbH
Heiskampstraße 10
45527 Hattingen / Germany
Tel.: +49 (0) 23 24 / 96 48 - 0
Fax: +49 (0) 23 24 / 96 48 - 755
www.resol.com
Important note
The texts and drawings in this manual are correct to the best of our knowledge.
As faults can never be excluded, please note:
Your own calculations and plans, under consideration of the current standards and
directions should only be basis for your projects.We do not offer a guarantee for
the completeness of the drawings and texts of this manual - they only represent
some examples.They can only be used at your own risk. No liability is assumed for
incorrect, incomplete or false information and / or the resulting damages.
Note
The design and the specifications can be changed without notice.
The illustrations may differ from the original product.
Imprint
This mounting- and operation manual including all parts is copyrighted. Another
use outside the copyright requires the approval of RESOL – Elektronische Rege-
lungen GmbH. This especially applies for copies, translations, micro films and the
storage into electronic systems.
Editor: RESOL - Elektronische Regelungen GmbH
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