ICM Controls S166 Owner's manual

ELECTRONIC CIRCULATOR FOR SOLAR THERMAL SYSTEMS - Art. S166
FI.S166.EN.C - 10/2022
Icma SpA - Via Garavaglia, 4 - 20012 Cuggiono (MI) ITALY Tel: [phone] - www.icmaspa.it - [email protected]
1
INSTALLATION AND OPERATION INSTRUCTIONS
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 specically and specially marked.

ELECTRONIC CIRCULATOR FOR SOLAR THERMAL SYSTEMS - Art. S166
FI.S166.EN.C - 10/2022
Icma SpA - Via Garavaglia, 4 - 20012 Cuggiono (MI) ITALY Tel: [phone] - www.icmaspa.it - [email protected]
2
INDEX
1. INDICATION OF INSTRUCTIONS........................................................................................................................................3
2. IMPORTANT SAFETY AND INSTALLATION INSTRUCTIONS........................................................................................4
3. FIELD OF APPLICATION...........................................................................................................................................................6
3.1Typesofsystem.........................................................................................................................................................................6
3.2 Pumped liquids.......................................................................................................................................................................6
4. INSTALLATION AT SITE............................................................................................................................................................8
4.1 Installation...............................................................................................................................................................................8
4.2 Permissible installation positions..................................................................................................................................9
4.3 Motor housing positions..........................................................................................................................................9
5. ELECTRIC CONNECTION.....................................................................................................................................................10
6. COMMISSIONING................................................................................................................................................................11
6.1 Start-up of the circulator.............................................................................................................................................11
6.2 Operating elements...........................................................................................................................................................12
6.3 Mode of operation.......................................................................................................................................................12
6.4 Automatic detection of the presence of air - Vent system...................................................................13
7. CIRCULATOR SETTING..........................................................................................................................................................14
8. PERFORMANCE CURVES.....................................................................................................................................................14
9. MAINTENANCE.......................................................................................................................................................................15
10. FAULTS, CAUSES AND REMEDIES.........................................................................................................................................15
10.1 Fault nding table......................................................................................................................................................15
10.2 Unlocking procedure......................................................................................................................................................16

ELECTRONIC CIRCULATOR FOR SOLAR THERMAL SYSTEMS - Art. S166
FI.S166.EN.C - 10/2022
Icma SpA - Via Garavaglia, 4 - 20012 Cuggiono (MI) ITALY Tel: [phone] - www.icmaspa.it - [email protected] Icma SpA - Via Garavaglia, 4 - 20012 Cuggiono (MI) ITALY Tel: [phone] - www.icmaspa.it - [email protected]
2 3
1. INDICATION OF INSTRUCTIONS
This manual contains information and prescriptions marked by the following symbols
This instruction sheet contains following warning symbols.
The circulators are not to be used to transfer ammable 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 uids 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 con-
tact with the hot surfaces of the circulator.
CAUTION

ELECTRONIC CIRCULATOR FOR SOLAR THERMAL SYSTEMS - Art. S166
FI.S166.EN.C - 10/2022
Icma SpA - Via Garavaglia, 4 - 20012 Cuggiono (MI) ITALY Tel: [phone] - www.icmaspa.it - [email protected]
4
2. 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 o 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 uid or the circulator when temperature is higher than 60°C.

ELECTRONIC CIRCULATOR FOR SOLAR THERMAL SYSTEMS - Art. S166
FI.S166.EN.C - 10/2022
Icma SpA - Via Garavaglia, 4 - 20012 Cuggiono (MI) ITALY Tel: [phone] - www.icmaspa.it - [email protected] Icma SpA - Via Garavaglia, 4 - 20012 Cuggiono (MI) ITALY Tel: [phone] - www.icmaspa.it - [email protected]
4 5
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 circula-
tor:
• With liquids other than water (e.g. ammable 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 lled with water
when operating.
6. Installation
The circulator must be mounted in a stable/xed position in a dry, well ventilated,
frost-free, waterproof and protected place, with sucient ventilation around it. As-
semble 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 disassem-
bly procedures. Foresee enough space for inspections and disassembling.
To avoid circulator overheating, do not place any object on the circulator itself.
7. Electric connection
IMPORTANT: Connection to the power supply must be eected by means of a xed
power cable which is tted 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 qualied 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.

ELECTRONIC CIRCULATOR FOR SOLAR THERMAL SYSTEMS - Art. S166
FI.S166.EN.C - 10/2022
Icma SpA - Via Garavaglia, 4 - 20012 Cuggiono (MI) ITALY Tel: [phone] - www.icmaspa.it - [email protected]
6
10. Any modication 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 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 →3 Field of application of
this manual. Non-observance of the safety instructions results in the loss of any
claims to damages.
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.
3. FIELD OF APPLICATION
3.2 Pumped liquids
3.1 Types of system
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 ows
• Underoor heating systems
• Boiler or primary circuit
• Storage tank circuit
Clean liquids, not aggressive and not explosive, not containing solid particles, bers 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 uids, manufacturer’s authorization is
required.
Keep these instructions for future reference.

ELECTRONIC CIRCULATOR FOR SOLAR THERMAL SYSTEMS - Art. S166
FI.S166.EN.C - 10/2022
Icma SpA - Via Garavaglia, 4 - 20012 Cuggiono (MI) ITALY Tel: [phone] - www.icmaspa.it - [email protected] Icma SpA - Via Garavaglia, 4 - 20012 Cuggiono (MI) ITALY Tel: [phone] - www.icmaspa.it - [email protected]
6 7
Ambient temperature Liquid temperature
[°C] Min. [°C] Max. [°C]
To avoid condensation in the motor and the electronics the temperature of the pumped liquid must always be
greater than the ambient temperature.

ELECTRONIC CIRCULATOR FOR SOLAR THERMAL SYSTEMS - Art. S166
FI.S166.EN.C - 10/2022
Icma SpA - Via Garavaglia, 4 - 20012 Cuggiono (MI) ITALY Tel: [phone] - www.icmaspa.it - [email protected]
8
Installation and service by qualied personnel only!
Avoid the installation in misaligned pipe work.
The circulator must be mounted in a stable/xed position in a dry, well ventilated, frost-free, waterproof and
protected place, with sucient 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.
4. INSTALLATION AT SITE
4.1 Installation
Fig. 4.1
Thread Pump housing material Tightening torque
G1 Ghisa EN-GJL-200 Max. 85 Nm

ELECTRONIC CIRCULATOR FOR SOLAR THERMAL SYSTEMS - Art. S166
FI.S166.EN.C - 10/2022
Icma SpA - Via Garavaglia, 4 - 20012 Cuggiono (MI) ITALY Tel: [phone] - www.icmaspa.it - [email protected] Icma SpA - Via Garavaglia, 4 - 20012 Cuggiono (MI) ITALY Tel: [phone] - www.icmaspa.it - [email protected]
8 9
Install the circulator with horizontal motor shaft axis (Fig. 4.2).
4.2 Permissible installation positions
4.3 Motor housing positions
Fig. 4.2
Fig. 4.3
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.
Procedure (Fig. 4.4):
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).
Pay attention not to damage the seal of the pump housing.
Fig. 4.4
CAUTION

ELECTRONIC CIRCULATOR FOR SOLAR THERMAL SYSTEMS - Art. S166
FI.S166.EN.C - 10/2022
Icma SpA - Via Garavaglia, 4 - 20012 Cuggiono (MI) ITALY Tel: [phone] - www.icmaspa.it - [email protected]
10
The electric connection has to be performed by a qualied 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 xed power cable which is tted 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 A1:G413 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 uids at a
temperature higher than 70 °C, use a connection cord resistant to high temperatures.
5. ELECTRIC CONNECTION
Fig. 5.1
1. Connect the power supply conductors to the terminals according to the diagram given in Fig. 5.1, from A to C.
When using three-pole cables, remove the end of the grounding cable.
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. 5.1.D).
3. Screw the two screws (Fig. 5.1.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. 5.1.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. 5.1.G).

ELECTRONIC CIRCULATOR FOR SOLAR THERMAL SYSTEMS - Art. S166
FI.S166.EN.C - 10/2022
Icma SpA - Via Garavaglia, 4 - 20012 Cuggiono (MI) ITALY Tel: [phone] - www.icmaspa.it - [email protected] Icma SpA - Via Garavaglia, 4 - 20012 Cuggiono (MI) ITALY Tel: [phone] - www.icmaspa.it - [email protected]
10 11
For cables with outer diameter of the sheath between 7 mm and 8.5 mm: remove the rubber retainer from the cable
gland. In this case, the circulator can only be installed with the cable gland down.
Activation frequency: activations/deactivations through the mains voltage ≤ 20/24 h
6. COMMISSIONING
6.1 Start-up of the circulator
Absolutely avoid dry operation. Start the circulator only after having
completely lled the plant.
Circulators with permanent magnets can not be driven in speed by means
of phase control of the supply voltage.
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
CAUTION
CAUTION

ELECTRONIC CIRCULATOR FOR SOLAR THERMAL SYSTEMS - Art. S166
FI.S166.EN.C - 10/2022
Icma SpA - Via Garavaglia, 4 - 20012 Cuggiono (MI) ITALY Tel: [phone] - www.icmaspa.it - [email protected]
12
SelectorLED light
6.2 Operating elements
6.3 Mode of operation
Fig. 6.1 Selector and LED light
LED COLOR DESCRIPTION
P mode (Δp-v) – Proportional dierential pressure
min-max mode – Fixed speed
Automatic detection of the presence of air - Vent system.
Proceed with the vent routine
Fault or malfunction
Faults, causes and remedies

ELECTRONIC CIRCULATOR FOR SOLAR THERMAL SYSTEMS - Art. S166
FI.S166.EN.C - 10/2022
Icma SpA - Via Garavaglia, 4 - 20012 Cuggiono (MI) ITALY Tel: [phone] - www.icmaspa.it - [email protected] Icma SpA - Via Garavaglia, 4 - 20012 Cuggiono (MI) ITALY Tel: [phone] - www.icmaspa.it - [email protected]
12 13
6.4 Automatic detection of the presence of air - Vent system
1a 1b
23
10 min
Fig. 6.2 Filling and venting of heating systems
Par.7 Circulator setting
With solar thermal systems, ll the system with mixtures prepared for that application. The circulator cannot be used
to mix the uids in the system.
The plant cannot be drained by using the circulator.
Do not touch the uid or the circulator when the temperature is greater
than 60 °C. Hazard of scalding by simple contact.
CAUTION

ELECTRONIC CIRCULATOR FOR SOLAR THERMAL SYSTEMS - Art. S166
FI.S166.EN.C - 10/2022
Icma SpA - Via Garavaglia, 4 - 20012 Cuggiono (MI) ITALY Tel: [phone] - www.icmaspa.it - [email protected]
14
LED SELECTOR
* Factory setting
min-max
Proportional curve P
min
max
PP
0
1050 15 Q [US.gpm]
Q [m3/h]
Q [l/s]
0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.00.0
0.0 0.2
H [m]
Q [IMS.gpm]105
6
7
5
4
3
2
1
0
H [ft]
20
15
10
5
0
0.4 0.6 0.8 1.0
min - max
max
min
7. CIRCULATOR SETTING
8. PERFORMANCE CURVES

ELECTRONIC CIRCULATOR FOR SOLAR THERMAL SYSTEMS - Art. S166
FI.S166.EN.C - 10/2022
Icma SpA - Via Garavaglia, 4 - 20012 Cuggiono (MI) ITALY Tel: [phone] - www.icmaspa.it - [email protected] Icma SpA - Via Garavaglia, 4 - 20012 Cuggiono (MI) ITALY Tel: [phone] - www.icmaspa.it - [email protected]
14 15
The circulator does not require any special maintenance during operation.
Motor bearings are lubricated by the pumped liquid.
Before each maintenance intervention, disconnect power supply and
wait for the circulator to cool.
9. MAINTENANCE
10. FAULTS, CAUSES AND REMEDIES
10.1 Fault nding table
FAULTS CONTROL
PANEL CAUSES REMEDIES
The circulator is
noisy
Loud noises of
water circulation
→6.4 Automatic detection of
the presence of air - Vent system
→7 Circulator setting
Circulator is not
running although
the electrical
power supply is
switched on
Replace the pump
Let the pump cool down for some minutes. Then
try to re-start it. Verify that the water and ambient
temperature are within the indicated temperature
ranges.
Circulator is not
running although
the electrical
power supply is
switched on
Disassemble the motor and clean the impeller if
the Should you fail to eliminate the cause of the
malfunction, refer to the Distributor or nearest
Service Center. doesn’t succeed (→ 10.2)
Verify that the power supply matches the data on the
name plate.

ELECTRONIC CIRCULATOR FOR SOLAR THERMAL SYSTEMS - Art. S166
FI.S166.EN.C - 10/2022
Icma SpA - Via Garavaglia, 4 - 20012 Cuggiono (MI) ITALY Tel: [phone] - www.icmaspa.it - [email protected]
16
10.2 Unlocking procedure
A red light in the LED indicates a locking.
Turn the selector to the position max, disconnect and connect power supply to start the automatic release process.
The circulator operates 100 attempts to restart (process lasts approximately 15 minutes).
Every restart is signalled by a short ash of LED light. If the locking is not removed through the automatic release
process after 100 attempts to restart the circulator, it goes into standby and the LED remains red. In this case follow
the manual procedure described in the next steps:
1. Disconnect power supply - the warning light switches o.
2. Close both isolating valves and allow cooling. If there are no shut-o devices, drain the system so that the uid
level is beneath that of the circulator.
3. Carefully pull the rotor/impeller
4. Remove impurities and deposits with appropriate agents.
5. Reinsert the rotor/impeller
6. Set the selector on the wished position.
7. Connect power supply.
If the circulator doesn’t run →10 Faults, causes and remedies
With high uid temperatures and pressures there is the risk of burnings.
Hazard of scalding by simple contact.