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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INSTALLING THE SOLAR PUMP STATION
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5.4 INSTALLING THE SAFETY ASSEMBLY
BInstall the safety assembly on the solar heating station
together with the gasket supplied (1).
Fig. 8 Installing the safety assembly of 2-line solar pump
station
1Gasket (21x30x2)
5.5 CONNECTING THE EXPANSION
VESSEL AND PRE-COOLING VESSEL
5.5.1 INSTALLING THE PRE-COOLING VESSEL
(AVAILABLE AS ACCESSORY)
A pre-cooling vessel is required:
•If the system is to be used to assist the central heating
system.
•If the system is purely for DHW heating: the solar
fraction is more than 60 %.
The pre-cooling vessel protects the expansion vessel
from excessively high temperatures.
CONNECTING THE PRE-COOLING VESSEL
If the pipeline to the expansion vessel needs to be laid
on a rising incline, an additional air vent must be
installed.
BTo protect the safety valve from excessive
temperatures: connect the pre-cooling and expansion
vessels with a tee (¾ " threaded outer with flange
gasket) in the return line 20 to 30 cm above the solar
heating station.
BSecure pipes to and from the pre-cooling vessel with
pipe clamps (4). Mount the pre-cooling vessel
vertically.
BConnect the expansion vessel (5) to the pre-cooling
vessel by means of a copper pipe.
BSeal the connection on the safety valve with a ¾ " cap
(2) (to be provided by the customer).
Fig. 9 Installing the pre-cooling vessel
1Flexible stainless steel tube from the connection set for the
expansion vessel (available as accessory)
2Plug on the safety assembly connection
(provided by customer)
3Pre-cooling vessel
4Pipe clamp (provided by customer)
5Expansion vessel
For 1-line solar pump station:
BInstall the safety assembly on the left.
For 2-line solar pump station:
BInstall the safety assembly on the right.
Do not insulate the pre-cooling vessel
(if fitted) and the expansion vessel, nor the
pipes connecting them to the safety
assembly.
5 litres 12 litres
Height 270 mm 270 mm
Diameter 160 mm 270 mm
Connection 2 x R ¾ " 2 x R ¾ "
Maximum operating pressure 10 bar 10 bar
Tab. 5 Pre-cooling vessel specifications
1
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20-30 cm
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INSTALLING THE SOLAR PUMP STATION
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5.5.2 INSTALLING THE EXPANSION VESSEL
(AVAILABLE AS AN ACCESSORY)
BInstall the expansion vessel with the relevant
mounting materials.
BConnect the expansion vessel (3) in the return line on
the solar heating station's safety assembly.
Fig. 10 Connecting the expansion vessel
1Safety valve
2Flexible stainless steel tube from connection set for the
expansion vessel (available as an accessory)
3Expansion vessel
5.5.3 ADJUSTING THE INLET PRESSURE OF THE
EXPANSION VESSEL
BTo make use of the maximum possible volume: set the
inlet pressure when the vessel is not under stress
(i.e. no fluid pressure).
BIf the calculated inlet pressure is higher or lower than
the factory-set inlet pressure, correct the inlet
pressure accordingly.
5.6 CONNECTING PIPES AND BLOW-OFF
LINE TO THE SOLAR PUMP STATION
BCut the pipes to a length which will allow them to be
pushed into the compression fitting (1) until they
bottom out.
BRoute the blow-off line (2) from the safety valve so
that it can be seen to empty out into the storage
vessel (4) and secure it in place with a pipe clamp (3).
Fig. 11 Connection to solar pump station
1Compression fitting
2Blow-off line
3Pipe clamp
4Empty solar fluid container (storage vessel)
INSTALLING THE FILL AND DRAIN VALVE
BInstall a fitting into the return pipe at the lowest point
in the solar heating system for draining the solar heat-
ing system (tee with fill & drain valve, ÆFig. 12, (4)).
The inlet pressure of the expansion vessel is
given by the static system height plus
0.5 bar (1 metre difference in height equals
0.1 bar).
BSet a minimum pressure of 1.5 bar.
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DANGER: Possible injuries and system
damage from incorrectly installed blow-off
line
BMake sure the blow-off line has the same
size as the cross-section of the safety
valve (maximum length = 2 m and
maximum of two bends).
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INSTALLING THE SOLAR PUMP STATION
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5.7 INSTALLING THE TEMPERATURE
SENSORS
Electrical connections must be carried out by authorised
electricians.
The temperature sensors are protected against polarity
reversal.
5.7.1 COLLECTOR TEMPERATURE SENSOR
If the collector sensor lead needs to be extended to
reach the controller, a waterproof junction must be used
at the connections where they are exposed to moisture.
BExtend the sensor lead with a two-core lead (3).
BIf necessary, protect the connection points (2) at top
and bottom with junction boxes.
Fig. 12 Collector and storage tank temperature sensors
to solar pump station with built-in controller
1Collector temperature sensor
2Connection point
3Two-core lead (2 x 0.75 mm2up to a maximum length
of 50 m
4Fill & drain valve for emptying (provided by customer)
5Cylinder temperature sensor
5.7.2 STORAGE TANK TEMPERATURE SENSOR
For installation instructions and data, see the
installation instruction manuals for the cylinder and
the controller.
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COMMISSIONING
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6 COMMISSIONING
6.1 USE OF HEAT TRANSFER FLUID
The heat transfer fluid is pre-mixed and ready to use.
It guarantees safe operation within the specified
temperature range, protects the system from frost
damage and minimises risk of vaporisation.
The fluid is biodegradable. A safety data sheet with
further information regarding the heat transfer fluid can
be requested from the manufacturer.
The collectors must only be operated with the following
heat transfer fluids:
6.2 PURGING AND FILLING WITH A HAND
PUMP (AIR VENT ON ROOF)
6.2.1 PURGING THE PIPES
BUse a hose (1) to connect the fill and drain valve on
the safety assembly to the mains water supply.
BTo drain the water away, connect a hose (2) to the fill
& drain valve on the flow limiter.
Fig. 13 Solar heating station with ball valves and gravity
brakes in the thermometers
1Hose for water supply
2Hose for water drainage
BOpen all shut-off fittings.
BClose the right-hand ball valve (2) on the solar heating
station and the ball valve on the air vent (ÆFig. 15,
(3)).
BPurge the pipework, making sure that the maximum
operating pressure is not exceeded.
BShut off the water supply.
At the time of commissioning, complete all
relevant sections of the Benchmark Checklist
located on the inside back pages of this
document.
After servicing, complete the relevant Service
Interval Record section of the Benchmark
Checklist located on the inside back pages of
this document.
CAUTION: System damage from frozen water
or vaporisation in the solar heating circuit
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.
When filling with heat transfer fluid, take the
additional volume of the pre-cooling vessel
into account (if installed).
The pre-cooling vessel and the expansion
vessel must be adequately drained.
CAUTION: Risk of injury through contact
with heat transfer fluid
BWhen handling heat transfer fluid, always
wear protective gloves and goggles.
BIf heat transfer fluid comes into contact
with skin: wash off the heat transfer fluid
with water and soap.
BIf heat transfer fluid comes into contact
with eyes: holding eyelids wide open,
thoroughly wash eyes with running water.
Heat transfer fluid Temperature range
Flat plate
collectors
Tyfocor L 45/55 – 29 ... +170 °C
Evacuated tube
collectors
Tyfocor LS – 28 ... +170 °C
Tab. 6 Tyfocor type in relation to collector type
If a pre-cooling vessel is installed:
BDisconnect the pre-cooling vessel from
the solar heating circuit while purging so
that the water remaining in the pre-
cooling vessel does not get mixed with
the heat transfer fluid.
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COMMISSIONING
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BClose the fill and drain valves (3) in the solar heating
station.
Fig. 14
1Left-hand ball valve completely open (0°)
2Right-hand ball valve closed (90°)
3Fill & drain valves in the solar heating station
6.2.2 CARRYING OUT PRESSURE TEST WITH WATER
The solar heating system is vented by the opening of the
plug screw (2) on the automatic air vent. To prevent
moisture entering the air vent during operation, the
weather protection cap (1) must always be over the plug
screw.
BOpen the ball valve (3).
BUnscrew the plug screw (2) one turn.
Fig. 15 Opening the air vent
1Weather protection cap
2Plug screw
3Ball valve
BSet the ball valves (1) on the thermometers to 45°
and open the flow limiter (2) and other shut-off
fittings.
Fig. 16 Opened shut-off fittings
1Ball valves and gravity brake open on the thermometers
(45° position)
2Flow limiter open
BCarry out a pressure test to check compliance with
the maximum permitted pressures of all components.
BAfter the pressure test, drain the water and clean the
automatic air vent.
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°C 80
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20
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°C 80
100
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COMMISSIONING
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6.2.3 REPLACING WATER WITH HEAT TRANSFER
FLUID
To add the heat transfer fluid, you can use electric
pumps, hand pumps or power drill attachments capable
of generating pressures of at least 2 bar.
BUsing a pump, fill the solar heating system with fluid
via one of the fill and drain valves (1) in the solar
heating station.
Fig. 17 Filling via fill & drain valve
1Fill & drain valves
BSet the ball valves (ÆFig. 16, (1)) on the
thermometers to 45° and open the flow limiter
(ÆFig. 16, (2)) and other shut-off fittings.
BFill the solar heating system slowly so that air bubbles
do not form.
BLastly, set the ball valves on the thermometers so that
the gravity brakes are ready for operation (0°
position).
6.2.4 VERIFYING THAT THE SOLAR HEATING
SYSTEM IS FREE OF AIR
BSwitch the solar pump(s) on and off manually.
BWhile switching the pump on and off, observe the
black pointer on the pressure gauge (1) on the safety
assembly.
Fig. 18 Checking the pressure gauge display
1Pressure gauge
6.2.5 DETERMINING THE OPERATING PRESSURE
When putting the system into operation, the operating
pressure must be 0.8 bar above the static pressure
(1 metre difference in height equals 0.1 bar).
The operating pressure must be at least 1.8 bar (when
cold, 20 °C).
Example: 10 m static height equals 1.0 bar plus 0.8 bar
= 1.8 bar operating pressure.
BIf there is not enough pressure, pump in more heat
transfer fluid.
BOnce the venting procedure is complete, close the
ball valve on the air vent.
When heat transfer fluid vaporises in the collectors,
pressure compensation can only be carried out by the
expansion vessel if the air vent is closed.
The pipes must be completely emptied of
water, otherwise the heat transfer fluid can
become diluted.
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If the black pointer on the pressure gauge
(1) indicates pressure fluctuations when the
solar pump is switched on and off, the solar
heating system still contains air.
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COMMISSIONING
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6.2.6 DETERMINING THE FROST PROTECTION
TEMPERATURE
To determine the degree of frost protection, we
recommend checking the frost protection of the heat
transfer fluid when first putting the system into
operation, by means of a frost protection gauge
(a “Glykomat” or a refractometer). This check should be
repeated at regular intervals (at least every two years).
The usual gauges used to test motor vehicle coolants are
not suitable for this purpose. A suitable device can be
ordered separately.
6.2.7 CORRECTING FROST PROTECTION
If the minimum frost protection level is not being
maintained, more heat transfer fluid concentrate must
be added.
BUse Tab. 7 to determine the volume of the system, so
that you can calculate the exact amount to be added
(which is equal to the amount which first needs to be
drained out).
BUse the following formula to determine the amount of
concentrate to be added (Vreplace) in the case of a pre-
mixed 45/55 heat transfer fluid mixture:
Fig. 19 Formula for calculating the amount of fluid to be
replaced for a heat transfer fluid with 45 % glycol
Example using Tyfocor L with 45 % glycol:
•System volume (Vtotal): 22 l
•Frost protection (recorded value): – 14 °C
•Equals concentration (ÆTab. 7): 29 % (C = 30)
•Result: Vreplace = 4.7 litres
BDrain the calculated amount to be added (Vreplace)
and add concentrate.
6.3 ADJUSTING THE FLOW RATE
The flow rate is set when the system is cold (30 - 40 °C).
•When the solar pump is speed-controlled, the
controller determines the flow rate based on
operating requirements.
BSet ball valves (1) to 0° (gravity brakes ready for
operation).
BUsing a size 4 Allen key, open the flow limiter (2)
completely.
BSelect the operating mode “Manual mode ON” on the
controller (Æinstruction manual for the controller).
Fig. 20
1Gravity brake ready for operation
2Adjusting screw on the flow limiter
3Indication point for the flow rate
4Pump switch on the solar pump
BFor the required flow rate, see Tab. 7.
CAUTION: Frost damage
BEvery two years, check whether the
required frost protection level (to at least
–25 °C) is being maintained.
System part Volume
1 Solar-Lito Mini collector 0.62 l
1 Solar-Lito collector 0.80 l
1 Solar-Lifestyle collector portrait 0.94 l
1 Solar-Lifestyle collector landscape 1.35 l
1 Solar-Lux 6 collector 0.97 l
1 Solar-Lux 12 collector 2.12 l
1 one-line solar heating station 0.20 l
1 two-line solar heating station 0.50 l
1 m Cu pipe Ø 15 mm 0.13 l
1 m Cu pipe Ø 22 mm 0.31 l
1 m Cu pipe Ø 28 mm 0.53 l
1 m Cu pipe Ø 35 mm 0.86 l
1 m Cu pipe Ø 42 mm 1.26 l
1 m steel pipe R ¾ 0.37 l
1 m steel pipe R 1 0.58 l
1 m steel pipe R 1¼ 1.01 l
1 m steel pipe R 1½ 1.37 l
Tab. 7 Volume of the separate system parts
Vreplace Vtotal
45 cconcentration –
100 cconcentration
–
-------------------------------------------------------------
×=
7747006489.37-1.SD
3
2
1
L/min
0,5
7
6
5
4
3
2
1
7 6
5
4
1
0,5
20
0
40
60
°C 80
100
120
20
0
40
60
°C 80
100
120
4

COMMISSIONING
6 720 643 603 (2011/11)
18
BCheck the flow rate in the inspection window of the
flow limiter (ÆFig. 20, (3)).
BTo pre-set the flow rate: adjust the solar pump's
speed level switch (ÆFig. 20, (4)) so that the
required flow rate is reached with as low a speed level
as possible.
SPEED-CONTROLLED SOLAR PUMP
BSelect the operating mode “Auto” on the controller.
The flow rate will be regulated by means of the solar
pump speed, based on current operating
requirements.
AFTER COMMISSIONING
The viscosity of the heat transfer fluid makes air bubbles
substantially more resilient than those in pure water.
BAfter several hours of solar pump operation, vent the
solar heating system via the de-airator in the solar
heating station and (if installed) the air vent on the
roof.
The values specified in Tab. 7 apply to
single-row collector arrays or multi-row
arrays connected in parallel. Collector
arrays connected in series must be set using
the total volumetric flow rate, which must
be calculated.
If the pre-set flow rate is not reached at the
pump's highest speed level:
BCheck maximum permitted pipe lengths
and sizing (Æsection 4.1).
BIf necessary, install a stronger pump.
Flow rate l/min (at 30 - 40 °C in return)
No. of collectors
(volumetric flow rate l/h) l/min
1 (50) 1
2 (100) 1.5 - 2
3 (150) 2.5 - 3
4 (200) 3 - 4
5 (250) 4 - 5
6 (300) 5 - 6
7 (350) 5.5 - 7
8 (400) 7 - 8
9 (450) 7.5 - 9
10 (500) 8 - 10
Tab. 8 Overview of flow rates

COMMISSIONING, INSPECTION AND MAINTENANCE REPORT
6 720 643 603 (2011/11) 19
7 COMMISSIONING, INSPECTION AND MAINTENANCE REPORT
We recommend conducting the first inspection and
maintenance after about 500 operating hours, and then
at intervals of 2 – 3 years.
BFill out the report and tick off the tasks performed.
Owner: Site location:
Tab. 9
Commissioning, inspection and maintenance tasks Page
Commis-
sioning
Inspection/maintenance
1. 2. 3.
Date:
General commissioning
1. Flow and return pipes connected and earthed? 9– – –
2. Pressure test carried out? 17, 15 – – –
3. Air vent closed? 16 – – –
4. Inlet pressure of the expansion vessel checked? 12 ______ bar – – –
5. Solar system verified to be free of air? 18 – – –
6. pH value of heat transfer fluid checked? Replace heat
transfer fluid if value is ≤7 (heat transfer fluid coloured
brown, strong odour). 1)
– 
7. Frost protection to _______ °C checked and analysed? 17 _____ °C _____ °C _____ °C _____ °C
Frost protection ensured until ________ (month/year)
(please check frost protection every two years!)
Solar heating circuit
1. Measure operating pressure when system is cold, and
enter the result here. System temperature on blue
thermometer?
17, 16 ______ bar
______ °C
______ bar
______ °C
______ bar
______ °C
______ bar
______ °C
2. Volumetric flow rate checked when the system is cold and
result entered here?
17 ___ l/min ___ l/min ___ l/min ___ l/min
Solar pump setting (1/2/3)?
3. Gravity brakes ready to operate (closed)? 17    
4. Thermostatic DHW blending valve functioning correctly
(if installed)?
   
Collector array
1. Visual inspection of collectors carried out? 2)  3) 3) 3)
2. Collector temperature sensor correctly positioned and
pushed into the sensor well until it bottoms out, and
secured with screw fitting?
 3) 3) 3)
3. Visual inspection of the mounting structure carried out?  3) 3) 3)
4. Visual inspection for leaks carried out at points where
mounting structure meets roofing?
 3) 3) 3)
5. Visual inspection of pipe insulation carried out?  3) 3) 3)
6. Flushing of collectors carried out (when needed) without
cleaning additives?
3) 3) 3) 3)
Solar storage tank
1. Maintenance on solar cylinder carried out? 2) – 
Tab. 10

COMMISSIONING, INSPECTION AND MAINTENANCE REPORT
6 720 643 603 (2011/11)
20
Control
1. Operating hours of solar pump P1: Period from _________
to _________ / _____ h
2) ___ - ___
______ h
___ - ___
______ h
___ - ___
______ h
___ - ___
______ h
Operating hours of solar pump P2: Period from _________
to _________ / _____ h (a system will run for about
1200-2500 hours each year) 4)
___ - ___
______ h
___ - ___
______ h
___ - ___
______ h
___ - ___
______ h
2. Pump functioning checked in the positions
(On/Off/Auto)?
   
3. Activation/deactivation temperature difference of solar
pump ΔT pump 1 checked and entered here?
__ K/__ K __ K/__ K __ K/__ K __ K/__ K
Activation/deactivation temperature difference of solar
pump ΔT pump 2 checked and entered here?
__ K/__ K __ K/__ K __ K/__ K __ K/__ K
4. Temperature indicated by all temperature sensors
(resistances checked)?
   
5. Temperature sensors correctly positioned, insulated and
connected?
   
6. Maximum tank temperature Tmax for solar cylinder 1
checked and entered here?
_____ °C _____ °C _____ °C _____ °C
Maximum tank temperature Tmax for solar cylinder 2
checked and entered here?
_____ °C _____ °C _____ °C _____ °C
7. Backup heating is functioning properly?    
8. Is the required set temperature (backup heating) being
maintained by the controller?
   
Comments
The solar heating system has been installed and put into operation,
or inspected and serviced, as instructed in this instruction manual.
   
Company stamp / date / signature
1) Litmus paper for testing pH available from chemists or in maintenance kit.
2) See instruction manual for the component.
3) When needed.
4) Depends on specific system data.
Commissioning, inspection and maintenance tasks Page
Commis-
sioning
Inspection/maintenance
1. 2. 3.
Tab. 10