Hamworthy Trigon ST1 Operation manual

Hamworthy Trigon
ST1 Dual Aspect / Field Solar Pump Station
Installation, Commissioning,
Operation & Service Instructions
IMPORTANT NOTE
THESE INSTRUCTIONS MUST BE READ
AND UNDERSTOOD BEFORE INSTALLING,
COMMISSIONING, OPERATING OR
SERVICING EQUIPMENT

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Heating range is available from our technical team in Poole and our accredited agents.
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we offer a higher quality of build and assurance of a boiler built and tested by the manufacturer.
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Commissioning of equipment by our own engineers, accredited agents or specialist sub-contractors will ensure the equipment is
operating safely and efciently.
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Regular routine servicing of equipment by Hamworthy service engineers inspects the safety and integrity of the plant, reducing the
risk of failure and improving performance and efciency. Service contracts enable you to plan and budget more efciently.
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options are available to suit you. Please refer to our website for more details.
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HAMWORTHY HEATING LTD Page
TRIGON SOLAR THERMAL 500001282/A
1
i
NOTE: THESE INSTRUCTIONS MUST BE READ AND UNDERSTOOD BEFORE
INSTALLING, COMMISSIONING, OPERATING OR SERVICING THIS EQUIPMENT.
THE TRIGON ST1 DUAL ASPECT / FIELD SOLAR PUMP STATION COMPLIES WITH ALL RELEVANT EUROPEAN DIRECTIVES.
PUBLICATION NO. 500001282
ISSUE ‘A’
JUNE 2013
Hamworthy Trigon
ST1 Dual Aspect / Field Solar Pump Station
Installation, Commissioning,
Operation & Service Instructions

0DNO0202 Installation-Operation Dual Pump Station With ST1 1/20
HAMWORTHY TRIGON
INSTALLATION AND
OPERATION MANUAL
DUAL PUMP STATION FOR USE WITH
SOLAR PUMP STATION ST1
Dual pump station for
installations with two collector fields
Customer Service Centre
Hamworthy Heating Limited
Fleets Corner, Poole,
Dorset BH17 0HH l

1 General information
2/20 Installation-Operation Extension Station ST1 TOP - Copyright by Hamworthy 0DNO0202
Contents
1General information ............................................................................................................. 3
1.1 About these instructions ................................................................................................. 3
1.2 About this product .......................................................................................................... 3
1.3 Designated use .............................................................................................................. 3
2Safety instructions ............................................................................................................... 4
3Assembly and installation [specialist] .................................................................................. 5
3.1 Assembly for installations with two collector fields ......................................................... 6
4Commissioning [specialist] .................................................................................................. 8
4.1 Flushing and filling the solar circuit ................................................................................ 9
4.2 Preparations before flushing ........................................................................................ 11
4.3 Flushing and filling ....................................................................................................... 11
Flushing and filling for installations with two collector fields ................................................... 12
4.4 Setting the solar system ............................................................................................... 14
5Maintenance [specialist] .................................................................................................... 15
5.1 Draining the solar system ............................................................................................ 15
6Technical data ................................................................................................................... 16
6.1 Pressure drop characteristics ...................................................................................... 16
6.2 Spare parts [specialist] ................................................................................................. 17

1 General information
0DNO0202 Installation-Operation Extension Station ST1 TOP - Copyright by Hamworthy 3/20
1General information
1.1 About these instructions
These instructions describe the installation, commissioning, function and operation of the
Solerio Transfert ST1 TOP.
The chapters called [specialist] are intended for specialists only. For other components of the
solar thermal system such as collectors, storage tanks, expansion tanks and controllers please
observe the instructions of the corresponding manufacturer.
1.2 About this product
The solar station is a premounted group of valves and fittings checked for leakage used to
circulate the solar fluid in the solar circuit. It may only be used in connection with a solar station
including safety devices. The station is mounted on a wall bracket and fixed with clips. It
contains important fittings and safety devices for the operation of the installation:
•Ball valve
•Check valve
•Thermometer
•Flowmeter to display the flow rate
•Ball valve to restrict the flow rate
•Flush and fill valve with hose connector
1.3 Designated use
The solar station may only be used as a pump station in the solar circuit taking into
consideration the technical limit values indicated in these instructions. Due to its design the
station must be mounted and operated as described in these instructions!
Improper usage excludes any liability claims.

2 Safety instructions
4/20 Installation-Operation Extension Station ST1 TOP - Copyright by Hamworthy 0DNO0202
2Safety instructions
The installation and commissioning as well as the connection of electrical components require
technical knowledge commensurate with a recognised vocational qualification as a fitter for
plumbing, heating and air conditioning technology, or a profession requiring a comparable level
of knowledge [specialist]. The following must be observed during installation and
commissioning:
•Relevant local and national regulations
•Accident prevention regulations of the professional association
•Instructions and safety instructions mentioned in this manual
Danger: danger of scalding due to vapour escape!
With pressure relief valves there is risk of scalding due to vapour escape.
During installation, check the local conditions and if a discharge line must
be connected to the safety group. Observe the instructions regarding the
pressure relief valve.
Attention: material damage due to high temperatures!
Install the solar station at a sufficient distance from the collector field,
since the solar fluid may be very hot near the collector. It may be
necessary to install an intermediate tank in order to protect the expansion
tank.
Notice: material damage due to mineral oils!
It is imperative to avoid that the EPDM sealing elements of the station get in
contact with substances containing mineral oils. Mineral oil products cause
lasting damage to the material, whereby its sealant properties are lost.
If necessary, ask the manufacturer whether the solar fluid, greases or
installation aids contain mineral oils.
We do not assume liability nor provide warranty for damage to property
resulting from sealants damaged in this way.

3 Assembly and installation [specialist]
0DNO0202 Installation-Operation Extension Station ST1 TOP - Copyright by Hamworthy 5/20
3Assembly and installation [specialist]
1. Take off the front shell of the solar station.
2. To remove the solar station from the mounting plate,
push the clips upwards using a screwdriver. The
station can then be pulled forwards (after
disconnecting the tubes!).
3. Screw off the safety group [5.2] of the ST1 TOP.
4. Mount this safety group to the ball valve [5.1] of the
extension station.

3 Assembly and installation [specialist]
6/20 Installation-Operation Extension Station ST1 TOP - Copyright by Hamworthy 0DNO0202
3.1 Assembly for installations with two collector fields
1. Screw the connecting piece [7] to the flowmeter
[6.2] of the extension station.
2. Unscrew the fill and drain valve of the flowmeter
[4.2] in the ST1 Top. Plug the outlet [4.3] with the
enclosed ½" plug.
3. Dismount the flowmeter of the 2-line station [4.2]
and screw it to the connecting piece.
4. Centre the Flowmeter [4.2I6.2] and tighten the
counter nuts.
5. Mount the insulating front shell of the extension
station. To do this, you must cut out the insulation
at the connecting piece.
6.Mount the reducer to the outlet of the return ball
valve [3.1] of the ST1 Top.
7. Screw the fill and drain valve dismounted before
into this reducer.
8. Centre the fill and drain valve and tighten the
counter nuts.
9. Mount the extension station with the flowmeter
[4.2] below the pump of the ST1 TOP and tighten
the screw connections manually.
10. Copy the mounting holes of the solar station (see
figure on the left) to the mounting surface.
11. Drill the holes and mount the solar station to the
wall with the enclosed wall plugs and screws.

3 Assembly and installation [specialist]
0DNO0202 Installation-Operation Extension Station ST1 TOP - Copyright by Hamworthy 7/20
12. Connect the solar station to the system:
① flow collector fields
② flow storage tank
③ return collector field 1
④ return storage tank
⑤ return collector field 2
All screw connections have ¾" internal threads. Use a
Teflon joint or use a sealing material resistant to high
temperatures.
13. Connect the pipe for the expansion tank below the
pressure gauge [5.4] and fix the bracket for the
expansion tank.
Optionally available!
14. Pressurise the expansion tank as specified by the
manufacturer and connect the expansion tank.
15. Mount the shut-off valve with integrated flush valve
so that you can check the pressure of the expansion
tank when servicing the system.
16. Check all screw connections and tighten them if
necessary.
The assembly of the solar station is completed and you
can put the station into operation.

4 Commissioning [specialist]
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4Commissioning [specialist]
Attention: risk of burns and scalding!
The valves and fittings can heat to temperatures of more than 100 °C due
to the solar fluid. Therefore, do not clean or fill the system with the
collectors heated (intense sunshine).
Please note that hot solar fluid can leak from the pressure relief valves in
case of too high system pressure!
Attention: risk of frost!
If you flush with water, make sure that the installation is completely
drained before filling with solar fluid.
Use the solar fluid Tyfocor L, a mixture of propylene glycol and water with
45% of propylene glycol.
Note regarding the commissioning sequence
When putting the system into operation, first fill the heating circuit and
then the solar circuit. This guarantees that heat that may possibly be
absorbed by the collectors during commissioning can be dissipated.
Note regarding the expansion tank
Close the shut-off valve of the expansion tank during flushing and filling to
prevent that dirt particles are washed from the solar installation into the
expansion tank.

4 Commissioning [specialist]
0DNO0202 Installation-Operation Extension Station ST1 TOP - Copyright by Hamworthy 9/20
4.1 Flushing and filling the solar circuit
The fill and drain valves required to flush and fill are integrated in the solar station.
To flush the dirt particles out of the installation only use flush and fill stations with fine filters.
Ball valve with check valve
(normal flow direction in the figure below: downwards)
0° 45° 90°
Ball valve open,
flow only in flow direction.
Ball valve half-closed,
flow in both directions.
Ball valve closed,
no flow.

4 Commissioning [specialist]
10/20 Installation-Operation Extension Station ST1 TOP - Copyright by Hamworthy 0DNO0202
Airstop
The Airstop with manual vent valve is used to vent the solar system.
To ensure perfect deaeration of the solar circuit, the flow velocity
must be at least 0.3 m/s in the flow line.
Pipe diameter [mm] Flow rate at 0.3 m/s
∅ outside ∅ inside l/h l/min
15 13 ~ 143 ~ 2.4
18 16 ~ 217 ~ 3.6
22 20 ~ 339 ~ 5.7
The air liberated from the solar fluid is collected in the upper part of the Airstop and can be
released at the vent plug.
Danger: danger of scalding due to vapour escape!
The escaping medium can have a temperature of more than 100 °C and
cause scalding.
Note: venting the solar system after commissioning
At the beginning, vent the solar system daily and then weekly or monthly,
depending on the vented air quantity. Thus, an optimum operation of the
solar installation is ensured. Check the system pressure after venting and
increase it to the specified operating pressure, if necessary.

4 Commissioning [specialist]
0DNO0202 Installation-Operation Extension Station ST1 TOP - Copyright by Hamworthy 11/20
4.2 Preparations before flushing
The solar circuit is flushed in the direction of
flow.
1. Disconnect the expansion tank from the
solar system. Close the return ball valve
[3.1I5.1] (90°, see page 9).
2. Connect the fill station to the solar station:
- Pressure hose to the fill valve [5.3]
- Flush hose to the drain valve [6.3]
4.3 Flushing and filling
1. Open the fill and drain valves [5.3|6.3].
2. Put the flush and fill station into operation
and flush the installation until the solar fluid
exits without bubbles.
3. Vent the solar system several times at the
vent plug of the Airstop [2.1] until clear
water exits without bubbles (see page 10).
4. Slowly open the return ball valve [3.1I5.1]
(0°, see page 9) to vent the pump section.

4 Commissioning [specialist]
12/20 Installation-Operation Extension Station ST1 TOP - Copyright by Hamworthy 0DNO0202
Flushing and filling for installations with two
collector fields
1. Connect the pressure hose to the fill
and drain valve of the second collector
field [3.2].
2. Repeat steps 1-4 under point
"4.3 Flushing and filling" and continue
with point 3.
Consider the pressure relief valve (6 bars)!
3. Close the drain valves [4.3I6.3] with the
filling pump running and increase the
system pressure to about 5 bars. The
system pressure can be read on the
pressure gauge. Close the fill valve
[3.2I5.3] and switch off the pump of the
flush and fill station.

4 Commissioning [specialist]
0DNO0202 Installation-Operation Extension Station ST1 TOP - Copyright by Hamworthy 13/20
4. Check the pressure gauge to see
whether the system pressure reduces
and eliminate leaks where necessary.
5. Reduce the pressure on the drain valve
[4.3I6.3] to the operating pressure.
6. Connect the expansion tank to the solar
circuit and set the operating pressure of
the solar system by means of the flush
and fill station (see instructions
regarding the expansion tank).
7. Close the fill valve [3.2I5.3] and the
drain valve [4.3I6.3].
8. Turn the return ball valves [3.1I5.1] to
operating position (0°, see page 9).
9. Connect the required controller to the
mains and set the solar circuit pump to
ON in the manual mode according to
the controller instructions.
10. Remove the hoses of the flush and fill
station and screw the sealing caps onto
the fill and drain valves.
The sealing caps only serve to protect
the valves against dirt. They are not
designed to take up high system
pressures. The ball valves must be
closed.

4 Commissioning [specialist]
14/20 Installation-Operation Extension Station ST1 TOP - Copyright by Hamworthy 0DNO0202
4.4 Setting the solar system
1. Adjust the desired rotation speed of the solar circuit pumps depending on the required flow
rate. The equalizing valves mounted to each collector field allow for an exact adjustment of
the flow rate. The equalizing valve of the main collector allows you to adjust the overall flow
rate in the installation.
2. The flowmeter in the extension station for Solerio Transfert ST1 only serves to display the
flow rate.
3. For the correct adjustment, observe the adjustment values of the flow rate.
4. Fix the insulating front shells of the solar stations.
5. Switch the controller to automatic mode (see controller instructions).
Left scale:
1-13 /min
Right scale:
15-20 l/min
Reading edge =
Top edge of the turbine
Example:
about 10 l/min
Reading edge =
Bottom edge of the
turbine.

5 Maintenance [specialist]
0DNO0202 Installation-Operation Extension Station ST1 TOP - Copyright by Hamworthy 15/20
5Maintenance [specialist]
5.1 Draining the solar system
1. Open the check valves in the return ball
valves [3.1I5.1], by turning them to a 45°
position (see page 9).
2. Connect a heat-resistant hose to the lowest
drain valve of the solar system (or drain valve
[6.3I4.3]).
Make sure that the solar fluid is collected in a
heat-resistant container.
Danger: danger of scalding due to hot solar fluid!
The escaping medium may be very hot. Place the collecting
container so that people standing nearby are not endangered
when the solar system is being emptied.
3.Open the drain valve at the lowest point
of the solar thermal system.
4. Open a vent valve that may be present
at the highest point of the solar system.
5. Dispose of the solar fluid observing the
local regulations.

6 Technical data
16/20 Installation-Operation Dual Pump Station With ST1 0DNO0202
6Technical data
Dimensions
(without equipment):
Total height: 433 mm
Width (with 2-line station ST1): 547 mm
Depth (with insulation): 150 mm
Pipe connections: ¾" internal thread
Connection for expansion vessel: ¾" external thread, flat sealing
Outlet pressure relief valve: ¾" internal thread
Operating
Max. admissible pressure: PN 10
data:
Max. operating temperature: 120 °C
Max. short-time temperature: 160 °C, < 15 minutes
Max. propylene glycol concentration: 40 %
Equipment:
Pressure relief valve: 6 bars
Pressure gauge: 0-6 bars
Check valve: 200 mm wc, can be opened
Materials:
Valves and fittings: Brass
Seals: EPDM
Check valves: Brass
Insulation: EPP, l = 0.041 W/(m K)

6 Technical data
0DNO0202 Installation-Operation Dual Pump Station With ST1 17/20
6.1 Pressure drop characteristics Dual Pump Station
Pressure [m wc]
Pressure [kPa]
Flow rate [l/h]