Askoll ES2 User manual

INSTALLATION AND OPERATION INSTRUCTIONS
EN
Askoll ENERGY SAVING
ES2
ES2 ADAPT
ES2 SOLAR
ES2 PURE

ENERGY SAVING
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Declaration of conformity
1 Declaration of conformity
We Askoll Sei S.r.l. declare under our sole responsibility that the family of products Askoll
ENERGY SAVING to which this declaration relates are in conformity with the Council Directives on
the approximations of the laws of the EC Member State relating to:
EMC Directive (2004/108/EC)
Standard used: EN 61000-3-2:2006, EN 61000-3-3:2013, EN 55014-1:2006, EN 55014-
2:1997 (including amendments)
LVD Directive (2006/95/EC)
Standard used: EN 62233:2008, EN 60335-1:2012, EN 60335-2-51:2003 (including
amendments)
ErP Directive (2009/125/EC)
Commission Regulations n. 641/2009 and n. 622/2012
Applies only to circulators marked with the energy efficiency index EEI. See the pump
nameplate.
Standard used: EN16297-1:2012 and EN16297-2:2012
RoHS II Directive (2011/65/EU)
Person authorized to compile technical file and empowered to sign the EC declaration of
Conformity.

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2 Contents
1Declaration of conformity .........................................................................................................2
2Contents..................................................................................................................................3
3Indication of instructions ..........................................................................................................5
4Important safety and installation instructions............................................................................6
5Field of application...................................................................................................................9
5.1 Types of system................................................................................................................9
5.2 Pumped liquids.................................................................................................................9
6Product information................................................................................................................10
6.1 Description of the product...............................................................................................10
6.2 Type key.........................................................................................................................10
6.3 Name plate .....................................................................................................................11
6.4 Components ...................................................................................................................11
6.5 Supply.............................................................................................................................11
6.6 Technical data ................................................................................................................12
7Installation at Site ..................................................................................................................14
7.1 Installation ......................................................................................................................14
7.2 Permissible installation positions.....................................................................................15
7.3 Motor housing regulation.................................................................................................15
7.4 Insulation of pump housing.............................................................................................16
8Electric connection.................................................................................................................17
9Commissioning ......................................................................................................................18
9.1 Start-up of the circulator..................................................................................................18
9.2 Operating elements.........................................................................................................18
9.3 Mode of operation...........................................................................................................19
9.4 Automatic detection of the presence of air - Vent system................................................20
10 Circulator setting ................................................................................................................21
11 Performance curves...........................................................................................................22
11.1 Performance curves - ES2 60.........................................................................................22
11.2 Performance curves - ES2 70.........................................................................................22
11.3 Performance curves - ES2 C 60......................................................................................23
11.4 Performance curves - ES2 C 70......................................................................................23
11.5 Performance curves - ES2 ADAPT 60............................................................................24
11.6 Performance curves - ES2 ADAPT 70............................................................................24
11.7 Performance curves - ES2 SOLAR 60............................................................................25
11.8 Performance curves - ES2 SOLAR 70............................................................................25
11.9 Performance curves - ES2 PURE C 40...........................................................................26

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Contents
12 Maintenance.......................................................................................................................27
13 Faults, causes and remedies..............................................................................................27
13.1 Fault finding table ...........................................................................................................27
13.2 Unlocking procedure.......................................................................................................28
14 Spare parts.........................................................................................................................28
15 Disposal.............................................................................................................................28

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These instructions include information necessary to assemble and use the product correctly.
Besides respecting the general safety regulations, it is necessary to observe all points specifically
and specially marked.
3 Indication of instructions
This manual contains information and prescriptions marked by the following symbols.
The inobservance of the safety provisions marked by the symbol “caution:
hazard” may endanger the safety of people.
The inobservance of the safety provisions marked by the symbol “caution:
electricity” may endanger the safety of people, as well as the integrity of things.
The inobservance of the safety provisions marked by the word “CAUTION”
may endanger the integrity and functionality of the equipment and of the
machines.
CAUTION
The Quick Guide contains following warning symbols.
The circulators are not to be used to transfer flammable liquids such as
gasoline, oils, gas oil or similar liquids.
The circulators are not to be used to transfer aggressive liquids, such as acids
and sea water.
CAUTION
The removal of the screws can cause the output of hot fluids under high
pressure from heating system. Drain the system or close the isolating valves.
CAUTION
High temperature surface. Pay utmost care to prevent people from getting in
contact with the hot surfaces of the circulator.

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Important safety and installation instructions
4 Important safety and installation instructions
Prior to installation, read these installation and operating instructions. The installation and
operation should also be in accordance with national regulations and accepted codes of good
practice.
This appliance can be used by children aged from 8 years and above and
persons with reduced physical, sensory or mental capabilities or lack of
experience and knowledge, only if they have been given supervision or
instruction concerning use of the appliance in a safe way and understand
the hazards involved. Children shall not play with the appliance. Cleaning
and user maintenance shall not be made by children without supervision.
To guard against injury, basic safety precautions should be observed,
including the following:
1. Read and follow all safety instructions and all the important notices on
the appliance before installing, using and maintaining the circulator. failure to
do so may cause personal injury or damage to the circulator or installation.
2. Always disconnect electrical supply before putting on or taking off parts
and whilst the equipment is being installed, maintained or handled. Never work
with bare feet and/or with wet hands.
3. To avoid possible electric shock, special care should be taken since
water is used with electrical equipment. Carefully examine the circulator
before and after installation. Do not operate the circulator if it has a damaged
supply cord or enclosure, or if it is malfunctioning or it is dropped or damaged
in any manner. Inspect the circulator periodically.
The circulator should not be electrically supplied if there is water on parts not
intended to be wet.
4. Risk of scalding.
To avoid injury before any servicing operation wait until the water has cooled
inside the circulator. Do not touch the fluid or the circulator when temperature
is higher than 60°C.

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5. Improper use
This is a circulator to be used in heating plants and for the circulation of clean
water without abrasive particles. This is not a submersible pump.
Do not use this circulator:
With liquids other than water (e.g. flammable liquids, etc.) (EN60335-2-
51);
For handling drinkable water or food related liquids;
For the circulation of domestic water;
In locations where special condition prevail, such as the presence of a
corrosive or explosive atmosphere (dust, vapor or gas) (EN60335-2-
51);
For other than intended use.
Never run the circulator dry. The circulator must be always fully filled with
water when operating.
6. Installation
The circulator must be mounted in a stable/fixed position in a dry, well
ventilated, frost-free, waterproof and protected place, with sufficient ventilation
around it. Make sure that the circulator is securely and correctly installed
before operating it and that there is enough room around it for maintenance
operations, dismantling, checking for free inspection.
The maximum ambient temperature at which the pump is to be used is 40°C
(EN60335-2-51).
To avoid circulator overheating, do not place any object on the circulator itself.
7. Electric connection
IMPORTANT: Connection to the power supply must be effected by means of a
fixed power cable which is fitted with a plug-type connection or an all-pole
isolating switch with a minimum contact opening of 3 mm.
Electrical connection must be carried out only by a qualified electrician and in
accordance with local regulations and both data on the name-plate and the
appropriate diagram inside the terminal box cover.
Follow all safety standards.
Do not connect to mains supply unless circulator is fully and correctly
assembled.
8. Supply cord must be selected following the requirements of EN60335-2-51
Chapter 25. Supply cord must be protected against any kind of mechanical
damage (cuts, abrasion, etc.). It must not touch the pipe or the pump. (EN
60335-2-51). If the insulation of the Supply cord can come in contact with parts
having a temperature exceeding 70°C the supply cord insulation must be
protected, for example, by insulating sleeving having an appropriate
temperature rating. (EN60335-2-51) .
9. Connect circulators only to a mains supply protected by a Residual Current
Device (RCD or Ground-Fault Circuit-Interrupter) with a rated residual
operating current not exceeding 30mA.
10. Any modification to the equipment must be prior agreed upon with and
authorized by the manufacturer. Original spare parts and accessories
authorized by the manufacturer are integral part contributing to the safety of the
equipment and of the machines. The use of not original components or

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Important safety and installation instructions
accessories may endanger the safety and causes the termination of the
warranty. A safe operation is assured only for the applications and conditions
described in → 5 Field of application of this manual.
Non-observance of the safety instructions results in the loss of any claims to
damages.
The indicated limit values are binding and cannot be exceeded for any reason
whatsoever.
KEEP THESE INSTRUCTIONS FOR FUTURE REFERENCE.

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5 Field of application
5.1 Types of system
Models
Uses
ES2
ES C A
Circulation of water/liquids in hot water heating systems of all kind and in
similar systems:
One-pipe systems
Two-pipe systems
Systems with constant or variable flows
Underfloor heating systems
Boiler or primary circuit
Storage tank circuit
ES2 ADAPT
ES2 SOLAR
Circulation of water/liquids in hot water heating systems and in renewable
energy solar thermal systems:
Solar thermal systems
One-pipe systems
Two-pipe systems
Systems with constant or variable flows
Underfloor heating systems
Boiler or primary circuit
Storage tank circuit
ES2 PURE
Domestic hot water circulation, drinking water circulation systems and similar
domestic and industrial circulation systems. This circulator is suitable for
drinking water only.
5.2 Pumped liquids
Clean liquids, not aggressive and not explosive, not containing solid particles, fibers or mineral oils.
In heating systems:
Water for heating according to VDI 2035.
Mixtures of water and glycol with glycol percentages not greater than 30%.
In domestic hot water circulation systems, max. 38°d water hardness.
Any other use is regarded as incorrect use. For the use with other fluids, manufacturer’s
authorization is required.
The circulators are not to be used to transfer flammable liquids such as
gasoline, oils, gas oil or similar liquids.
The circulators must never be used in refrigeration systems, air
conditioning systems and similar installations.

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Product information
6 Product information
6.1 Description of the product
The Askoll ENERGY SAVING are a range of innovative wet rotor circulators with an integrated
frequency converter (INVERTER). Askoll ENERGY SAVING circulators combine an advanced
hydraulic system, a high efficiency motor, an intuitive electronic control and an operating software
that allow to perfectly adapt to the various operating conditions and the actual needs of the system.
The motor with electronic control module is mounted on the pump housing by four screws. The
criteria for differential pressure control depend on the set operating mode. In all operating modes,
the circulator adapts to the different loads of the system.
Askoll ENERGY SAVING provides excellent benefits:
1. Energy saving
2. Compact design
3. Ideal performance
4. Easy installation and adjustment
The Askoll ENERGY SAVING circulator range is available in the following versions:
ES2
Standard version with operating modes P, C and min-max.
Pump housing available in cast iron, plastic composite material (C) and
plastic composite material with air separator (C A)
ES2 ADAPT
Premium version with operating modes activeADAPT, P, C and min-max.
Pump housing available in cast iron.
ES2 SOLAR
Solar thermal systems version with operating modes P and min-max.
Pump housing available in cast iron.
ES2 PURE
Domestic hot water circulation systems with operating mode min-max.
Pump housing available in plastic composite material (C)
6.2 Type key

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6.3 Name plate
1
Type
2
Input power P1[W] / Input curren I1[A] / System
pressure [MPa]
3
Voltage, frequency
4
Temperature class / Protection class
5
Energy Efficiency Index (EEI)
6
CE mark / Appliance class / Quality mark
Fig. 6.1: Name plate (example)
6.4 Components
Fig. 6.2: Exploded view
A
Pump housing
E
Stator
B
Impeller and bearing plate
F
Electronics
C
Rotor
G
Motor housing
D
Can
H
Front cover
6.5 Supply
Complete circulator.
Two flat seals in EPDM.
Thermal insulation shells in EPP (supplied as standard only for mod. ES2 ADAPT)
Instructions for assembly, use and maintenance.

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Product information
6.6 Technical data
Power supply
1x230 V -10%/+6%, 50 Hz
Adjustment of the rotation speed
Manual by selector
Motor protection
Not required
Insulation class
H
Protection class
IP 44
Appliance class
II
Ambient temperature
from +2°C to +40°C
Allowed liquid temperature
ES2
ES2 C
ES2 C A
ES2 PURE C
from +2°C to +95°C
ES2 ADAPT
ES2 SOLAR
from +2°C to +110°C
Maximum relative humidity
≤ 95%
Maximum operating pressure
ES2
ES2 C
ES2 C A
0,6 MPa (6 bar)
ES2 ADAPT
ES2 SOLAR
ES2 PURE C
1,0 MPa (10 bar)
Minimum pressure on the intake opening1
Minimum pressure
Liquid temperature
0.03 MPa (0.3 bar)
50°C
0.10 MPa (1.0 bar)
95°C
0.15 MPa (1.5 bar)
110°C
Sound pressure level
< 43 dB(A)
EMC (electromagnetic compatibility)
EN 61000-3-2 / EN 61000-3-3
EN 55014-1 / EN55014-2
Specific EEI values 2
ES2 60
ES2 ADAPT 60
ES2 SOLAR 60
EEI ≤ 0,20 - Part 2
ES2 C 60
ES2 C 70
ES2 70
ES2 ADAPT 70
ES2 SOLAR 70
EEI ≤ 0,21 - Part 2
1
To avoid cavitation noise, minimum pressure values on the intake opening must be strictly respected.
2
The benchmark for most efficient circulators is EEI ≤ 0,20.

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To avoid condensation in the motor and the electronics the temperature of the pumped
liquid must always be greater than the ambient temperature.
Ambient
temperature
Liquid temperature
[°C]
Min. [°C]
Max. [°C]
ES2
ES2 C
0
2
95
10
10
95
20
20
95
30
30
95
35
35
90
40
40
70
ES2 ADAPT
ES2 SOLAR
0
2
110
10
10
110
20
20
110
30
30
110
35
35
90
40
40
70

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Installation at Site
7 Installation at Site
Installation and service by qualified personnel only!
7.1 Installation
The circulator must be mounted in a stable/fixed position in a dry, well ventilated, frost-free,
waterproof and protected place, with sufficient ventilation around it.
Assemble the circulator only after having ended all welding and brazing works on the hosing.
Before installing the circulator, make sure that the internal part of the tubes is clean.
Install the circulator in an accessible place for future checks and disassembly procedures. Foresee
enough space for inspections and disassembling.
Foresee isolating valves at intake and output (before and after the circulator) to allow the
disassembly without emptying the plant. The assembly of the interception organs must be carried
out in such a way as to prevent possible water leaks from involving the terminal board.
Perform the assembly without mechanical stresses acting on the circulator.
Avoid the installation in misaligned pipe work.
Fig. 7.1:Mounting procedure.
The direction of the water flow is indicated by the arrow on the pump housing, as shown in Fig. 7.1.
1. Check that both isolating valves are closed
2. Install the circulator with the motor shaft in horizontal position. Connect the piping without
transmitting any stresses and strains.
3. Accurately insert the two gaskets supplied.
4. Establish a screwed connection between circulator and piping.
5. Tighten the screwed connection hand with an assembly tool (e.g. pipe wrench).

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Thread
Pump housing
material
Tightening torque
G1
Composite PA 66 GF
Max. 50 Nm
G1
Cast Iron EN-GJL-200
Max. 85 Nm
G1½
Cast Iron EN-GJL-200
Max. 125 Nm
G2
Cast Iron EN-GJL-200
Max. 165 Nm
7.2 Permissible installation positions
Install the circulator with horizontal motor shaft axis (Fig. 7.2).
Fig. 7.2:Permissible installation positions
7.3 Motor housing regulation
The motor body can be rotated in the positions shown in Fig. 7.3.
Pay utmost care to prevent people from getting in contact with the hot surfaces
of the circulator.
Drain the system or close the isolating valves on either side of the pump before
the screws are removed. The pumped liquid may be scalding hot and under
high pressure.
Pay attention not to damage the seal of the pump housing.
CAUTION
Fig. 7.3:Motor housing positions

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Installation at Site
Procedure (Fig. 7.4):
1. Slacken and remove the four screws M5 holding the motor.
2. Turn the motor to the desired position without extracting it from the pump housing.
3. Insert and tighten the pump housing screws (The tightening torque of the screws of the
pump housing must correspond to a value of 3.3 ± 0.5 Nm).
7.4 Insulation of pump housing
Fig. 7.5: Insulation of pump housing
The heat loss from the pump and pipework can be reduced by insulating the pump housing and the
pipe with the thermal insulation shells supplied with the circulator (supplied as standard only with
model ES2 ADAPT) →Fig. 7.5.
The thermal insulation shells can be ordered separately.
Do not insulate the control box or cover the control panel.
CAUTION
Fig. 7.4: Changing the motor body position

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8 Electric connection
The electric connection has to be performed by a qualified electrician in
compliance with the national regulations. Follow the safety regulations and
installation regulations of your country.
Connection to the power supply must be carried out in compliance with the
standards via a fixed power cable which is fitted with a plug-type connection or
an all-pole isolating switch with a minimum contact opening of 3 mm.
The circulator belongs to class II and therefore grounding is not necessary. The circulator does not
require any external protection of the motor. Compare the frequency and the voltage of the mains
with the rating data. All electric information concerning the circulator is on the signaling plate. The
connection cord must be laid in such a way as it cannot come in contact with the hosing or the
motor body. In case of use of the circulator with fluids at a temperature higher than 70 °C, use a
connection cord resistant to high temperatures.
Fig. 8.1:Electric connection
1. Connect the power supply conductors to the terminals according to the diagram given in
Fig. 8.1, from A to C.
2. Insert the terminal board in the proper seat, connecting the blue wire (neutral) with letter N
and the black/brown wire (phase) with letter L. (Fig. 8.1.D).
3. Screw the two screws (Fig. 8.1.E - The tightening torque of the screws must correspond to
a maximum value of 0,3 Nm).
4. Tighten the sealing nuts to the fairlead (Fig. 8.1.F - The tightening torque must correspond
to a maximum value of 2 Nm).
5. The LED light, if lighted, indicates that the power supply is present. (Fig. 8.1.G).

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Commissioning
9 Commissioning
9.1 Start-up of the circulator
Absolutely avoid dry operation. Start the circulator only after having completely
filled the plant.
CAUTION
Circulators with permanent magnets can not be driven in speed by means of
phase control of the supply voltage.
CAUTION
Circulators driven by an electronic frequency converter have a current peak at
each activation (inrush current) greater than traditional circulators
(asynchronous). The activation stage of the circulator has to be size taking into
account this current peak. For further details contact the manufacturer.
CAUTION
Activation frequency: activations/deactivations through the mains voltage ≤ 20/24 h.
9.2 Operating elements
Selector
All settings are made using the selector on the
housing front.
The selector can be adjusted in a continuous way
with a rotation angle of 270 °.
The arrow on the selector indicates the operating
mode chosen.
LED light
The LED light on the front advises the
commissioning/fault of the circulator.
Every operating mode is characterized by a fixed light
of different colour.
After a change of operating mode, the LED pulses 5
times. The pulse will be a change of brightness
intensity of the LED light.
Fig. 9.1: Selector and LED light

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9.3 Mode of operation
A LED provides information about the operation status of the circulator.
LED
COLOR
DESCRIPTION
Violet
activeADAPT mode
The activeADAPT mode enables the circulator to actively adapt
its performance to the demands of the system during short
control intervals inside a defined control area.
Improves the hydraulic balance of the system
Ensures optimum performance during partial load periods
Enables quick installation
Green
P mode (∆p-v) –Proportional differential pressure
The circulator head is proportionally reduced at falling water
demand and increased at rising water demand.
The circulator head is proportionally reduced with decreasing of
the heat demand from the heating system (flow rate decrease)
and is proportionally increased with increasing demand of the
heat demand from the heating system (flow rate increase).
Orange
C mode (∆p-c) - Constant differential pressure
The circulator maintains a constant pressure level (head)
irrespectively of the heat demand required from the heating
system (flow rate).
Blue
min-max mode–Fixed speed
The circulator maintains a fixed speed irrespectively of the heat
demand from the heating system (flow rate).
The speed regulation is done by positioning the selector in a
gradual manner at any point between the Min and Max positions.
Should this performance be insufficient, progressively increase
the set value. Should this performance be excessive or should
noise arise due to the speed of the pumped fluid, progressively
reduce the calibration.
Flashing
white
Automatic detection of the presence of air.
Proceed with the vent routine
Red
Fault or malfunction
→13 Faults, causes and remedies

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Commissioning
9.4 Automatic detection of the presence of air - Vent system.
Fig. 9.2: Filling and venting of heating systems
Fill and bleed the system correctly.
The circulator can be noisy at start due to the presence of air. Such noise should stop after few
minutes of operation. Usually the pump rotor chamber normally bleeds automatically after a short
time in operation.
The circulator is equipped with a special software system that detects the presence of excess of air
within the heating system. The LED shows the presence of air in the hydraulic circuit by flashing
and performing a rapid succession of WHITE colour.
Following the light signal, it’s possible to easily vent the heating system as follows:
1. Open the air vent valve in the hydraulic circuit above the circulator or open the cap of the
air separator in the pump housing, partially unscrewing it; when unscrewing the cap of the
air separator, beware of not losing the cap itself;
2. set the circulator to MAX position (maximum performance setting);
3. let the circulator run for a short period, according to the construction and the plant size;
4. once vented the system - the guide light (LED) stops blinking and the possible noise stops -
set the circulator as indicated in Par.10 Circulator setting
Repeat the procedure if necessary.
The plant cannot be drained by using the circulator.
CAUTION
With solar thermal systems, fill the system with mixtures prepared for that application. The
circulator cannot be used to mix the fluids in the system.
Do not touch the fluid or the circulator when the temperature is greater
than 60 °C. Hazard of scalding by simple contact.