Resol FlowCon S Owner's manual

F lo w C o n S
Manual
F lo w C o n S
Installation
Operation
Commissioning
Thank you for buying this product.
Read this manual carefully to get the best performance from this unit.
48001120
*48001120*

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Contents:
Imprint ................................................................................ 2
Safety advice ....................................................................... 2
Technical data and overview of functions ........................ 3
1. Installation ............................................................... 4
1.1 Mounting the pump station ...................................4
1.2 Mounting the pipes into a compression
ring connection .......................................................5
2. Filling and flushing the system .............................. 5
3. Emptying the system..............................................6
4. Non-return valves ................................................... 6
5. Safety assembly ....................................................... 6
Safety advice
Please pay attention to the following safety advice in order
to avoid danger and damage to people and property.
Appropriate usage
This product is to be used in solar thermal systems in com-
pliance with the technical data specified in these instructions
(see p. 3).
Improper use excludes all liability claims
Instructions:
Attention should be paid to
- valid local regulations
- the statutory provisions for prevention of industrial acci-
dents,
- the statutory provisions for environmental protection,
- the Health and Safety at Work Act 1974
- Part P of the Building Regulations 2005
- BS7671 Requirements for electrical installations and rele-
vant safety regulations of DIN, EN, DVGW, TRGI, TRF and
VDE.
These instructions are exclusively addressed to authorised
skilled personnel.
- Only qualified electricians should carry out installation and
maintenance work.
- Initial installation should be carried out by named qualified
personnel
Declaration of conformity
We, RESOL Elektronische Regelungen GmbH, D-45527 Hat-
tingen, declare under our sole responsibility that our pro-
duct F lo w C o n S 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
Subject to change without prior no tice. Errors excepted

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Solar pump station with integrated controller
• Integrated D e l t a S o l ® BS or
D e l t a S o l ® BS Plus controller
• Outstanding design
• Safety assembly with relief valve and pressure
gauge
• Flushing and filling unit
• Wall mounting with screws and dowels
• Insulated casing
Technical data:
Material:
fittings: bras
flat sealings: Klingerit, max. 200°C
O-ring-seal: VITON / EPDM,
max. 180 °C
Solar non-return valve: PPS,
max. 180 °C
Insulation: EPP, max. 120 °C con-
tinuous and up to180 °C intermittent
Admissible max. temp.:
0 ... 120 °C continuous and up to
180 °C intermittent
Size:
with insulation: 500 x 230 x 62 mm
distance axis / wall: 62 mm
Electrostatic discharge can
lead to damage of
electronic components!
Dangerous voltage
Mounting: wall mounting
Connections: 3/4" IG
Circulation pump: WILO Star
ST15/6 or ST 15/7 (extra cost)
Power supply:
220 ... 240 V~
Operation pressure: max. 8 bar
Spring pressure of non-return
valve: 200 mm head
Flowmeter: 0,5 ... 5 l/min,
1 ... 13 l/min (standard) or
8 ... 30 l/min

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1. Installation
1.1 Mounting the pump station
• Determine the mounting site.
• Take the station out of the packing.
• Take off the front part of the insulated casing.
Do not unscrew the pump station from the back
part of the insulated casing•
• Mark the bore holes through the holes in the insulated
casing, drill (8 mm) and insert the dowels (S 8).
• Fasten the pump station to the wall with the enclosed
screws (S6 x 60 mm). For this purpose, use a crosshead
screw driver.
• Connect the pipework between pump station and store
and collector respectively.
For connecting the pipes to the compression ring
connection, please pay attention to the following
instructions!
All connections are already tightened such that they have
not to be tightened again. However, during commissioning
of the system all connections have to be checked for leaks
(pressure test).
1 wall mounting
2 insulation - rear part
3 controller
4 insulation - front part
5 flowmeter
6 drain valve (fill/drain valve)
7 pump
8 ball valve with integrated non-
return valve
9 safety head piece with
fill valve (fill/drain valve)
10 solar pressure gauge 0 ... 6 bar
11 solar air vent
12 solar safety valve 6 bar
13 stainless steel corrugated pipe 3/4" IT
14 expansion vessel coupling
15 wall mounting for expansion vessel
1 2
4
13
9
12
10
8
7
56
3
11
14
15

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1.2 Mounting the pipes into a compression ring
connection
• First push the union nut (2) then the brass compression
ring (3) onto the copper pipe (1). To guarantee secure
load transmission and sealing, the pipe must extend at
least 3 mm out of the compression ring.
• Insert the support sleeve (4) into the copper pipe (1).
• Push the copper pipe (1) with the attached parts (2, 3
and 4) as far as possible into the body of the compres-
sion ring connection (5).
• First screw on the union nut by hand. Then tighten it
by at least one full rotation with a suitable open-ended
spanner.
2. Flushing and filling the system
• Connect the pressure hose to the fill and drain valve
below the manometer and open the valve.
• Connect the flushing hose to the fill and drain valve at
the flowmeter and open the valve.
• The slot of the adjustment screw at the flowmeter has
to be in a horizontal position. Thus the integrated ball
valve is closed (see flowmeter manual). Open the non-
return valve above the pump; for this purpose turn the
ball valve by means of an open-ended spanner (wrench
size 14) to a 45° position (half opened, half closed)
• Fill sufficient solar fluid into the tank of a flushing and
filling station (not supplied) and fill the solar thermal
system.
• Flush the solar thermal system using the flushing and
filling station for at least 15 minutes. To remove all air
from the system, open the adjustment screw at the
flowmeter several times.
• The system may be flushed with water before commis-
sioning but the final installation must contain antifreeze
to protect against frost damage.
• Close the drain valve while the filling pump is running
and increase the system pressure to approx. 6 bar. The
system pressure can be read at the pressure gauge
• Close the fill valve and switch-off the pump of the
flushing and filling station, open the adjustment screw
at the flowmeter (vertical position).
Please note:
In order to absorb the strain of the pipes, corresponding
fittings (expansion bushings) or more than two 90° bends
are necessary.
The distance between the bends has to be twice as large as
the diameter of the pipe in cm.
[Example: diameter of the pipe = 18 mm; distance between
the bends = more than 36 cm].
• Bleed the system above the collector until the solar
fluid is free of bubbles. Increase the pressure to approx.
6 bar and check the system for leaks. In the case of a
significant decrease in pressure, there may be leakage
in the system.
• Adjust the system to the manufacturer‘s recommended
pressure (possibly approx. 1,8 to 2,3 bar with a collector
height of approx. 5 to 10 m above the pressure gauge.
Please pay attention to the primary pressure of the
expansion vessel).
• Put the circulation pump into operation at maximum
speed (see pump manual) and let it circulate for at least
15 minutes.
• Afterwards, adjust the desired pump speed.
• Adjust the flow rate at the flowmeter according to the
specifications of the collector manufacturer.
• Remove the hoses of the flushing and filling station and
screw the caps onto the valves of the flushing and filling
valves.
• Check the system for leaks. Open the ball valve above
the pump.
• Attach the front insulation to the pump station.
5
43
2
1
> 3 mm

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3. Emptying the system
• Open the non-return valve in the ball valve (see follow-
ing advice).
• Open the air vent at the highest point of the system
(above the collector).
• Open the fill and drain valve at the lowest point of the
system, if possible close to the store connection (not
supplied) or at the drain valve and the pump.
4. Non-return valve
• The non-return valve of the pump station is integrated
into the ball valve above the circulation pump. It has an
opening pressure of 200 mm head.
• In order to empty the system completely, the nonreturn
valve has to be opened. For this purpose, the knob of
the ball valve has to be put in a 45° position. The ball
in the ball valve then opens the non-return valve.
• For normal system operation, the ball valve has to be
completely opened.
• In order to avoid false circulation ( “In-pipe-circulation“),
the flow line (from the collector to the store) has to
be equipped with a thermosiphon or an additional non-
return valve.
5. Safety assembly
• The pump station is equipped with a diaphragm safety
valve which corresponds to the relavant directives and
regulations. For installation and operation, please pay
attention to the following advice:
• The safety valve has to be easily accessible. The effici-
ency of the valve must not be influenced or disabled
by barriers!
• The strainer or other restriction devices must not be
mounted between collector (-field) and safety valve!
• The diameter of the discharge pipe must correspond to
the diameter of the valve outlet; the maximum length
must not exceed 2 m; more than 2 bends are inadmis-
sable. When these values are exceeded (2 bends, 2 m
pipe length), you have to install a discharge pipe with
larger dimensions. Do not use more than 3 bends and
pipes longer than 4 m!
• If the discharge pipe leads into a drain pipe with a hopper,
the diameter of the drain pipe has to be at least twice as
large as the valve inlet. The opening of the discharge
pipe should be inclined downwards. It should be routed
so that the opening can be seen but does not present
any risk to a person standing or passing by.
• It is useful to place a container under the discharge pipe.
If the safety valve opens, the fluid will be collected and
can be refilled in to the system when the pressure is
too low.
ball valve
open
ball valve
closed
ball valve
open closed
!

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Notes:

Distributed by:
Please note:
The design and specification may be changed without notice
and illustrations may differ from the original product.
RESOL - Elektronische Regelungen GmbH
Heiskampstraße 10
45527 Hattingen / Germany
Tel.: [phone] / 96 48 - 0
Fax: [phone] / 96 48 - 755
www.resol.de
[e-mail]
Reprinting / copying
This mounting- and operation manual including all parts is
copyrighted. Another use outside the copyright requires
the approval of RESOL - Elektronische Regelungen GmbH.
This especially applies for copies, translations, micro films
and the storage into electronic systems.
Editor: RESOL - Elektronische Regelungen GmbH
Important notice:
The texts and drawings in this manual are correct to the
best of our knowledge. As errors can never be entire-
ly excluded, please note: your own calculations and plans
designed to meet current local standards and directives
should be the basis of your project. We do not offer a guar-
an tee for the completeness of the drawings and texts of
this man ual - they only represent some examples. They can
only be used at your own risk. No liability is assumed for
in correct, incomplete or false information and / or the re-
sulting damages.