Resol FlowCon C User manual

FlowConA
www.resol.de
Handbuch
RESOL FlowConC
Installation
Operation
Commissioning
Thank you for buying this RESOL product.
Please read this manual carefully to get the best performance from this unit.
FlowConC
www.resol.de
Manual
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48002500
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Safety advice
Please pay attention to the following
safety advice in order to avoid danger
and damage to people and property.
Instructions
Attention should be paid to
- the statutory provisions for preven-
tion of industrial accidents,
- the statutory provisions for envi-
ronmental protection,
- the Health and Safety at Work Act
1974
- Part P of the Building Regulations
2005
- BS7671 Requirements for electrical
installations and relevant safety re-
gulations of DIN, EN, DVGW,TRGI,
TRF and VDE.
These instructions are exclusively
addressed to authorised skilled per-
sonnel.
- Only qualified electricians should
carry out electrical works.
- Initial installation must be effected
by qualified personnel named by the
manufacturer
Appropriate usage
The solar station with the integra-
ted controller may only be used in
the collector circuit of solar ther-
mal systems in compliance with the
technical data specified in these
instructions.
Improper use excludes all liability
claims.
Suject to changes. Errors excepted.
Declaration of conformity
We, RESOL Elektronische Regelungen GmbH, D-45527 Hattingen, declare under
our sole responsibility that our product FlowCon C complies with the following
standards:
EN 55 014-1
EN 60 730-1
According to the regulations of the above directives, the product is labelled with
:
89/336/EWG
73/ 23/EWG
Hattingen, 04.Juli 2007
RESOL Elektronische Regelungen GmbH,
ppa. Gerald Neuse
Scope of delivery:
1 x pump station FlowConC with inte-
grated controller DeltaSol
®C/1
1 x flushing and filling unit (optional)
1 x collector sensor FKP6
2 x store sensor FRP6
1 x wall mounting bracket
1 x accessory bag
2 x screw and dowl
2 x strain reflief
Table of contents
Safety advice.............................................................................................2
1. Pump station with integrated controller......................................... 3
Technical data station ........................................................................ 4
2. Mounting the station.......................................................................... 4
3. Commissioning ................................................................................... 5
3.1 Flushing and filling the solar thermal system.......................................5
3.2 Flushing the store for initial commissioning ........................................5
3.3 Flushing and filling the solar thermal system.......................................6
3.4 Emptying the solar thermal system .......................................................7
4. FlowCheck...........................................................................................7
5. AirStopp .............................................................................................. 7
6. Connection..........................................................................................8
7. Accessories for the station................................................................ 8
8. Integrated controller DeltaSol
®C/3 ..............................................9
Technical data controller...................................................................9
9. Installation.........................................................................................10
10. Examples ........................................................................................... 10
11. Terminal allocation........................................................................... 10
11.1 Terminal Allocation Arrangement 1.....................................................10
11.2 Terminal Allocation Arrangement 2.....................................................11
12. Operation and function ...................................................................11
12.1 Buttons for adjustment...........................................................................11
12.2 System Monitoring Display....................................................................12
12.2.1 Channel display.........................................................................................12
12.2.2 Tool bar.....................................................................................................12
12.2.3 System Screen...........................................................................................12
12.3 Flashing codes...........................................................................................13
13. Initial Commissioning ...................................................................... 14
14. Control parameter and diaplay channels....................................... 15
14.1 Channel overview....................................................................................15
14.2 Functions and options.............................................................................16
15. Electrical connection........................................................................20
16. Troubleshooting................................................................................21
17. Accessories for the controller.........................................................24
Imprint ..............................................................................................24

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1. Pump station with integrated controller
• IntegratedcontrollerDeltaSol
®C/3
• Outstandingdesign
• Safetyassemblywithsafetyvalveand
manometer
• High-qualitycasingforreducedheatlosses
• FlowCheck
About this product
The pump station FlowCon C is a preinstalled and leak-te-
sted group of fittings for transferring heat from the collector
to the store. It contains important fittings and safety devices
for the operation of the solar thermal system:
•Ballvalvesinowandreturnincombinationwithcheck
valves to prevent gravity circulation
•Airstoppformanualbleedingofthesolarthermalsystem
•FlowCheckfordisplayingtheowrate
•Manometerfordisplayingthesystempressure
•Safetyvalvetopreventinadmissibleoverpressure
•Flushingandllingunit(optional)forushing,llingand
emptying the solar thermal system
The installation and commissioning of the solar station as
well as the connection of electrical components requires
technical knowledge commensurate with a recognised
vocational qualification as a fitter for plumbing, heating and
air conditioning technology, or a profession requiring a com-
parable level of knowledge.The following must be observed
during installation and commissioning:
•therelevantregionalandnationalregulations
•theaccidentpreventionregulationsofthetradeassociation
•thetechnicalandsafetyinstructionsoftheseinstructions
Warning: Risk of scalding
There is a danger of steam emission with safety valves.
Therefore a discharge pipe must be connected to the ¾“
internal thread of the safety assembly. Please observe the
enclosed instructions regarding the safety valve when doing
this.
Attention: Damage to property
The group of fittings must be installed with sufficient spacing
to the collectors because temperatures in the vicinity of the
collectors can be very high.An intermediate vessel may be
necessary for installation in the attic.
Attention: Damage to property
It is imperative that you make sure the EPDM sealing ele-
ments of the solar station do not come into contact with
substances containing mineral oil. Mineral oil products
cause lasting damage to the material, whereby its sealant
properties are lost.
If necessary, ask the manufacturer whether the solar fluid,
fats 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.
Safety instructions
Scope of delivery:
1 x pump station FlowCon C with
integrated controller DeltaSol
®
C/1
1 x flushing and filling unit (optional)
1 x collector sensor FKP6
2 x store sensor FRP6
1 x wall mounting bracket
1 x accessory bag
2 x screw and dowl
2 x strain reflief

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Dimensions:
Height (with insulation): 417 mm
Width (with insulation): 374 mm
Depth (with insulation): 179 mm
Distance centre: 1600 mm
Distance axis/wall:55 mm
Pipe connections: ¾" IT
Connection for expansion vessel set:
3/4" ET, flat sealing
Outlet safety valve: 3/4" IT
Equipment:
Safety valve: 6 bar
Manometer: 0 - 6 bar
Non-return valves:
Opening pressure 200 mm water column,
openable
Material:
Fittings: brass
Seals: EPDM
Insulation: EPP, l= 0,041 W/(m*K)
Technical Data:
Max. permitted pressure: 6 bar
Max. operating temperature: 120°C
Flow rate: 1-20 l /min
160 mm
55 mm
thermometer
flow
thermometer
return
FlowCheck
controller
DeltaSol
®C/3
pump
Airstopp
flushing and
filling unit
(optional)
safety
assembly
manometer
2. Mounting the station
• Determinethemoutingsiteofthestation.
• Takethestationoutofthepacking.Removethefront
half of the insulation.
• Holdtheenclosedwallmountingbracketagainstthe
wall and mark the fastening holes, drill holes and insert
dowels
• Fastenthewallmountingbrackettothewallwiththe
screws.
• Pushthestationagainstthewallmountingbracket.The
station catches and is then attached to to the wall.
• Connectthestationtothesolarthermalsystem.
• Checktheinletpressureoftheexpansionvesseland,
if necessary, adjust it to the local conditions
(P inlet[bar] = 1 bar + DTh [m]*1/10 (DTh = height
difference between collector and station)
• Connect the electrical components of the solar
station: Attach the store and collector sensor and
connect these to the controller. Plug the controller
into a socket.
• Tighten all union nuts and screw connections.
• Attachthefronthalfoftheinsulationtothestation.

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fig.2
3.1 Flushing and filling the solar thermal
system
Attention: Risk of scalding!
To prevent the solar fluid boiling in the collectors, the
system should not be flushed or filled during periods of
strong sunshine.
Attention: Risk of frost!
Solar thermal systems cannot be completely emptied after
flushing.There is a danger of frost damage if water is used
for flushing. Only use solar fluid to flush and fill the solar
thermal system.
Use a water-propylene glycol mixture as a solar fluid (ma-
ximum 50% propylene glycol).
Instructions for initial commissioning:
The optionally enclosed flushing and filling unit can either
be integrated into the station (below theAirStopp,mounted
by 30° outwards, see fig.2) or installed horizontally at the
lowest point of the solar circuit (see fig.1).
In both cases a filter must be installed between the store
and the solar pump in order to prevent the flushed-out scale
from re-entering the solar circuit.
If the flushing and filling unit is integrated in the solar station,
we recommend an additional fill and drain ball valve at the lo-
west point of the solar circuit, to flush possible scale out.
This flushing process is described in “3.2 Flushing the store
for initial commissioning”.Then continue as described in“3.3
Flushing and filling the solar thermal system”.
3.2 Flushing the store for initial
commissioning
3. Commissioning
• Connectthepressurehoseofaushingandlling
station to the fill ball valve.
• Connecttheushinghoseofaushingandllingstation
to the fill and drain valve at the lowest point of the solar
thermal system.
• Closetheballvalve
• Openthellballvalve(5)andthellanddrainvalve
at the lowest point of the solar thermal system.
• Flushthesolarthermalsystembymeansoftheushing
and filling station until the discharged solar fluid is free
of dirt particles.
• Switchoffthellingpump
• Closethellanddrainvalveatthelowestpointofthe
solar thermal system.
• Removetheushinghosefromthellanddrainval-
ve.
• Closethellballvalve
• Connecttheushinghosetothedrainballvalve.
fig.1

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3.3 Flushing and filling the solar thermal
system
• Disconnecttheexpansionvesselfromthesolar
thermal system.
• Connectthepressurehoseofaushingandlling
station to the fill ball valve (5) of the flushing and filling
unit.
• Connecttheushinghoseofaushingandllingsta-
tion to the drain ball valve (3) of the flushing and filling
unit.
• Closetheballvalve(4)inthecentreoftheushingand
filling unit
• Turntheballvalvesinow(1)andinreturn(2)with
an open-ended spanner (wrench width 14) to a 45°
position. The non-return valves in the ball valves are
now open.
•Open the fill and drain ball valves (3 and 5).
• Flushthesolarthermalsystemusingtheushingand
filling station for at least 15 minutes to remove all air
from the system.
• Duringushing,bleedthesolarthermalsystemseveral
times at the Airstopp until the discharged solar fluid is
free of air bubbles.
• Closethedrainballvalve(3)oftheushingandlling
unit with the filling pump running and increase the
system pressure to approx. 5 bar.The system pressure
can be read from the manometer
• Closethellballvalve(5)andswitchoffthepumpof
the flushing and filling station.
• Checkthemanometertoseewhetherthesystem
pressure reduces and eliminate leaks where necessary.
• Reconnecttheexpansionvesseltotheothercompo-
nents of the solar thermal system.
If it is necessary to set the pressure, observe the
following step:
• Settheoperatingpressureofthesolarthermalsystem
by means of the flushing and filling station (0.3-0.5 bar
higher than the inlet pressure of the expansion ves-
sel).
• Ifyouhaveputtheflushingandfillingstationinto
operation to set the operating pressure, switch off the
filling pump.
• Closethellanddrainballvalvesandopentheball
valve.
• Removethehosesoftheushingandllingstationand
screw the caps onto the fill and drain ball valves.
• Putthenon-returnvalvesinowandreturninopera-
ting position by opening the ball valves with an open-
ball valve: 45°
non-return valve
not operating
flow-through in both
directions
ball valve: 90°
ball valve closed, no
flow-through
ball valve: 0°
non-return valve
in operation, flow-
through only in flow
direction
ended spanner (wrench width 14).
• Manuallyputthesolarthermalpumpinoperationat
the highest RPM level (see controller manual) and let
it circulate for at least 15 minutes
• Duringushing,bleedthesolarthermalsystemseveral
times at the Airstopp, until the discharged solar fluid is
free of air bubbles and increase, if required, the system
pressure to the operating pressure.
3
4
5
1 2

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• Openthenon-returnvalvesintheballvalvesinow
and return by turning the ball valves to a 45° position
with an open-ended spanner.
• Placeatemperature-resistantcollectioncontainer
under the drain ball valve at the lowest point of the
solar thermal system.
• Openthedrainballvalveatthelowestpointofthe
solar thermal system.
• Openthebleedingdevicesatthehighestpointofthe
solar thermal system, where available
• Disposeofthesolaruidinobservanceoflocalregu-
lations.
3.4 Emptying the solar thermal system
WARNING!
Risk of injury.The discharged fluid can have very high
temperatures. Place the collection container so that
people standing near by are not endangered when the
solar thermal system is being emptied.
4. FlowCheck The FlowCheck is for measurement and display of the
flow rate of 1-20 l/min. In order to guarantee the flawless
function of the measuring device the system must be flushed
and free from foreign substances.
The Airstopp (manual bled valve) is for bleeding the solar
fluid in the solar thermal system.The air precipitated from
the solar fluid gathers in the upper area of the manual bleed
valve (see diagram) and can, if required, be discharged at
the bleeding valve. To guarantee faultless bleeding of the
collector circuit the flow rate in the flow must be at least
0.3 m/s.
Check the system pressure after bleeding and if necessary
increase it to the specified operating pressure.
5. Airstopp
WARNUNG:
Risk of injury caused by very high temperatures. During
bleeding the escaping air and solar fluid can reach tempe-
ratures of over 100 °C.
Bleeding the solar thermal system directly after
commissioning
At first you should bleed the solar thermal system daily
and then weekly or monthly, depending on the volume of
discharged air., in order to achieve optimal efficiency.
Information for operators of solar thermal
systems
Bleed the solar thermal system half-yearly with the manual
bleed valve to achieve optimal efficiency..
Left scale:
Upper edge of
the propeller
Right scale:
Lower edge of
the propeller

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For further information on electrical connection, of
the controller, please see chapter 15.
6. Connection
The controller is already integrated in the station and ready
to plug in. In the case of maintenance or service work, the
controller is to be taken out from the station. Please pay
attention to the followong steps:
• switchoffthesystem,disconnectplugfromthemains
• removethefronthalfoftheinsulation
• unscrewthecross-recessedscrewoffthefrontcoverand
remove it by pulling it upwards
• unscrewthelowercross-recessedscrew,pushthecon-
troller upwards and remove it.
Mounting of the controller has to be carried out in reverse
order.
WARNING!
Always disconnect the controller
from power supply before ope-
ning the housing!
7. Accessories for the station
For installation screw connections are required, which are
not included in the scope of delivery. Self-sealing double
nipples, solder nipples or clamp-ring connections can be
used. For further information, please see product catalo-
gue.

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• System-Monitoring-Display
• upto4temperaturesensors
Pt1000
• heatquantitymeasurement
• functioncontrol
• user-friendlyoperation
through simple handling
• solaroperatinghourscounter
and thermostat function
• RESOLVBus®
• Realtimeclock
Technical data controller
Housing:
plastic, PC-ABS and PMMA
Protection type: IP 20 / DIN 40050
Ambient temp.: 0 ... 40 °C
Dimensions: 172 x 110 x 46 mm
Mounting: integrated in the pump
station FlowConC
Display: system monitor for system
visualisation,16-segment display, 7-seg-
ment display, pictograms
Operation: 3 push buttons at the
front of the housing
Functions: Differential temperature
controller with optional add-on system
functions. Function control according
to BAW-guidelines, operating hours
counter, tube collector function, ther-
mostat function and heat quantity
measurement
Inputs: for 4 temperature sensors
Pt1000
Outputs: 2 standard relays
Bus: RESOL VBus®
Power supply: 220 ... 240 V~
Total switching capacity:
4 (2) A (220 ... 240) V~
Mode of operation: Type 1.b
Switching capacity per relay:
Electromechanical relay:
2 (1) A (220 ... 240) V~
110
30
62
172
46
The controller DeltaSol
®C/3
is integrated into the pump station
FlowCon C standard solar thermal
systems and ready to plug in.
8. Integrated controller DeltaSol
®C/3
Electrostic discharge can cause da-
mage to electronic components.
High-voltage components.

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9. Installation
10. Examples DeltaSol
®C/3
standard solar system solar system
with afterheating
S1
S2
S4 / TRF
11.2. Terminal allocation Arr 1 Standard solar system with 1 store, 1 pump and 3 sen-
sors. The sensor S4 / TR can be optionally used for heat
quantity measurement.
R1
ARR1
S3 Symbol Specification
S1 collector sensor
S2 store base sensor
S3 store top sensor,
(optional)
S4 / TRF sensor for heat quantity
measurement (optional)
R1 solar pump
Note:
The controller is already integrated in the station and rea-
dy to plug in. In the case of maintenance work and repair,
pay attention to chapter 14 ‚Electrical connection‘!
11. Terminal allocation