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
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CONTENTS
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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
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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
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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
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INFORMATION ABOUT THE PRODUCT
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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
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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
4
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REGULATIONS
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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
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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.
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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
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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).
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INSTALLING THE SOLAR PUMP STATION
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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.
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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
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