Resol FlowSol B Guide

en-US/CA
Manual
FlowSol
®
B
Manual for the
specialized craftsman
Installation
Operation
Commissioning
T hank you for buying t h is product.
Ple as e r ead this manual c areful ly to get t he best performan ce fr om this u nit.
Pleas e keep this manua l carefully.

2
WARNING! Warnings are indicated with a warn -
ing triangle!
   They contain information
on how to avoid the danger
described.
Please pay attention to the following s afet y
advi ce in order to avoid danger and damage to
people and property.
Instructions
Attention should be paid to
Valid national and local standards and
regulations
Re spe cti ve vali d stan dards and di re ctiv es
Equipment to be installed and used in
accordan ce with the rules of the National
Electrical Code ( NEC) or with Canadian
Electri cal Co de (CEC), Part I . These
instructions are exclusively addressed to au -
thorized skilled personnel.
Only qualified electricians should carry out
installation and maintenance work.
Initial installation should be carried out by
qualified personnel
Information about the product
Proper usage
The pump station may only be used in the solar
circuit of solar thermal systems in compliance
with the technical data specified in these
instructions. Due to its design, the station must
be mounted and operated as described in these
instructions!
These instructions are exclusively addressed to
authorized skilled personnel.
Only qualified electricians should carry out
electrical works.
Initial installation must be effected by qualified
personnel named by the manufacturer.
Description of symbols
Signal words describe the danger that may
occur, when it is not avoided.
WARNING means that injury, possibly life-
threatening injury, can occur.
ATTENTION means that damage to the appli-
ance can occur.
Note
Notes are indi cated with an information
symbol. Square Spots indicate instruction steps
that should be carried out.
Contents
1 Overview ............................................... 3
2 Mounting the station ............................. 4
3Flushing and filling the solar system................4
4 Ball valve positions................................................. 5
5 Draining the system .............................. 5
6 Non-return valves................................. 5
7 Flowmeter............................................. 6
8 Air separator .................................... 6
9 Maintenan ce .................................... 6
10 Safety devices ...........................................6
11 Accessories...............................................7
12 Information about the pump.................. 7
13 Lists of spare parts ...................................7
Disposal
Subject to technical change. Errors excepted.
© 201 30327_11202306_FlowSol_B.monusjndd
Dispose of the packaging in an
environmentally sound manner.
Dispose of old appliances in an
environmentally sound manner. Upon request
we will take back your old appliances bought
from us and guarantee an environmentally
sound disposal of the devices.

3
Pump characteristic / pressure loss characteristic
Flow rate [US gpm]
0 1 2 3 4 5
7,0
6,5
6,0
5,5
5,0
4,5
4,0
3,5
3,0
2,5
2,0
1,5
1,0
0,5
0,0
0 200 400 600 800 1000 1200
Flow rate [l/h]
Wilo Star S16
U15
Wilo Star S21
U15
FlowSol
®
B
21,0
9,0
0,0
18,0
15,0
12,0
6,0
3,0
FlowSol
®
B
1 Overview
Pre-assembled twin-line pump station
Integrated controller of choice from the
DeltaSol
®
BS series
Safety assembly with connection for the
diaphragm-type expansion vessel, safety valve
and pressure gauge
Fill and drain valves
Wall mounting bracket and mounting material
Design insulation
Stand ard pump
Ball valves in flow and return
Air separator
Technical data
Circulating pump: Wilo Star S21
U15
Safety valve: 60 psi/4 bar (or 87 psi/6 bar)
Pressure gauge: 0... 145psi/0... 10bar
Flowmeter: 0.25... 3.5gpm/1 ...13l/min
Non-return valves:
Opening pressure 0.3 psi /20 mbar, openable
Connection to diaphragm-type expansion vessel: 3/4''
IT NPT
Outlet safety valve: 3/4'' IT NPT
Connections to the solar pipes: 3/4" IT NPT
Maximum temperature flow/ return:
248 °F/203 °F 1 2 0 °C / 9 5 ° C
Maximum pressure: 60 psi/4bar
Medium: Water with max. 50 % glycol
Dimensions:
Approx. 18.94" ×1 2.6" × 7.48"/481 × 320 ×1
90mm (with insulation)
Distance centres: approx. 3.94"/1 00mm
Distance centre/wall: approx.
2.64"/67mm
Material:
Fittings: brass
Seals: AFM 34
Insulation: EPP
foam
Pressure [M WC]

4
2 Mounting the station
B
D
A
C
WARNING! Scald danger!
Pressure surge damage!
If the medium enters strongly
heated, empty collectors, pressure
surges caused by evaporation can
occur. In order to prevent the
solar fluid from vaporizing inside
the collectors, do not fill or flush
the system during times of strong
irradiation!
1
8
9
3
7
5
2
4
6
10
11
A) Wall mo unti ng b racket
B) Back half of the insulation
C) Front half of the insulation
D) Hinged controller panel
Controller and controller panel depend on the
version of the station
Dete rmi ne t he mount i ng site of the st ation . 
Mark the drill holes b y means of the
template enclosed, then drill and insert wall plugs
(see figure to the right).
Take the st ati on out of the packaging.
Remove the front half of the insulation.
Leave the pump station attached to the back half
of the insulation!
Fasten the p ump st ation to the wall with the
enclosed screws.
For this purpose, use a crosshead screw driver.
Fold the hinged controller panel to the left.
Connect the pipework from the t ank and the
collector respectively to the pump station.
Note
All connections are already tightened
such that they usually do not have to be
tightened again. However, during
commissioning of the system all
connections have to be checked for
leaks (pressure test).
3 Flushing and filling the solar
system
1. Safety Valve
2. Expansion Tank Port
3. Fill Valve
4. Pressure Gauge
5. Wilo S21 U15 Pump
6. Drain Valve
7. Flow Meter Spindle
8. Flow Meter
9. Air Vent Plug
10. Ball Valve with Thermometer
and check valve
11. Air Separator

5
Before flushing the system
Disconnect the expansion vessel from the sol ar
thermal system.
Connect the pressure hose of the filling and
flushing station to the fill valve (3) of the pump
station.
Connect the flushing hose of the filling and
flushing station to the drain valve ( 6) of the
pump station.
Cl ose the bal l valv e of the pu mp stat i on
(10).
Open t he fill val ve ( 3) and t he dr ain val ve
(6).
Switch on the filling pump of the filling and
flushing station.
Flush the solar t he rmal s yste m for at least 15
minutes by means of the filling and flushing sta-
tion until the discharged solar fluid is free of gas
bubbles and dirt particles.
Du ring flus hi ng, bl eed t he sol ar thermal
syste m several times until the discharged solar
fluid (e. g.Tyfocor
®
, see chap. 11) is free of air
bubbles.
Open the ball v alve of the pump stati on ( 10).

6
After flushing the system
Connect the e xp ansi on vessel t o the s ol ar
The rmal system
Cl ose t he dr ai n v al ve ( 6 ) o f t he p u mp
St ati on while the filling pump is running.
Increase syste m p ressure (approx. 5 1ps i /
3.5bar) . The system pressure can be read from
the pressure gauge.
Close the fil l v alve ( 3).
Switch off t he fi llin g pum p.
Ch eck th e pre ss ure gau ge t o see wh et he r the
system press ure red uces and eliminate leaks
where necessary.
Slowly discharge the heat transfer fluid by
Means of the drain valve (6) until the operating
pressure is set.
Remove the hoses of the fillin g and flushing
station and screw the caps onto the fill and
drai n valves. Manually start the solar thermal
pump at maximum speed (see controller manual)
and let the fluid circulate for at least 15 minutes.
Bleed the solar thermal system several times.
Check the system pressure at the pressure
gauge.
Check the antifreeze ration(not required if a
ready mix is used)
Connect the pressure hose of the filling and flushing station to the fill valve
Connect the flushing hose of the filling and flushing station to
the drain valve

7
4 Ball valve positions
Non-return valve in
operating position, fluid flow
in flow direction only
Ball valve open, fluid flow in
both directions possible
Ball valve closed, no fluid flow
5 Draining the system
Open t he bal l val ve ( 10).
Open the air vent at the hi ghest point of
the system (above the collectors).
Ope n t h e d r ai n v al v e .
6 Non-return valves
The non-return valves of the pump station are
integrated into the ball valves in flow and return
and have an opening pressure of 0.3 psi /20 mbar.
In order to co mpletely drain the system, the
non- return valves have to be opened.
For th is p urpose , t urn t he han dl es o f the
ball valves by 45°.
For normal system operation, open the ball valve
completely.

8
Read the flow rate from the upper edge of the
float
8 Air separator
WARNING! Scald danger!
During venting, the air
discharged can reach
temperatures of more than
212°F/100°C.
In order to avoid scalding, pay
attention to the system temperatures!
7 Flowmeter
The flowmeter measures and indicates the flow
rate with a range of 0.25 ... 3.5 gpm / 1 ... 13 l/min.
For the device to function faultlessly, the system
must be flushed and free of grit.
The air separator is used for venting the water /
glycol mixture in the solar circuit. The air
separated from the heat transfer fluid gathers in the
air scoop and can be discharged manually at the air
vent valve.
Open the air vent valve and collect the
discharged fluid in a suitable container.
Check the system pressure after bleeding and, if
necessary, increase it to the specified operating
pressure.
9 Maintenance
In the case of maintenance (such as a replacement
of the pump) proceed as follows:
Cl ose t he ball val ve ( 10).
Tu rn t h e s l ot of t he fl o wm et e r s p i ndl e b y
90 ° anti-clockwise (see figure below).
The heat transfer fluid can now be drained from
the pump.
Ope n t he drai n v al ve ( 6).
If necessary, open the union nut at the pressure
side.
N o w d i s m o u n t t h e p u m p .
10 Safety devices
The pump station is equipped with a diaphragm
safety valve which corresponds to the relevant
directives and regulations. For installation and
operation, please pay attention to the following
advice:
The safety valve has to be easily accessible. The
efficiency 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 6.6 ft / 2
m; more than 2 bends are inadmissible. When
these values are exceeded, you have to install a
discharge pipe with larger dimensions. Do not
use more than 3 bends and pipes longer than
13.1 ft/4m!
If the discharge pipe leads into a drain pipe with
a funnel, the diameter of the drain pipe has to
be at least twice as large as the valve inlet. The
opening of the discharge pipe must be inclined
downwards. It must be routed such that the
opening can be seen but does not present any
risk to a person standing or passing by.
We recommend placing a container below the
discharge pipe. If the safety valve opens, the
fluid will be collected and can be refilled into
the system when the pressure is too low.

9
7

10
1. 11200054—Safety Valve
1a. 11202311—Safety Valve Adaptor NPT
2. 11202319—Pressure Gauge
3. 11200058—drain Valve
4. 11202312—Ball Valve with Thermometer
and Integrated check valve
5. 11200058—Fill Valve
5a. 11202313—Fill/Drain Valve Adaptor GHT
6. 28001502—Wilo Pump S21-U15
7. 11202320—Flowmeter
8. 11202321—Ball Valve with Thermometer
and Integrated check valve
9. 11202322—Air Separator
10. 11200071—Wall Mounting Bracket
11. 70001512—Back Half of Insulation
12. Resol DeltaSol Controller
13. 70001612—Hinged Controller Panel

11
Distributed by:
Important note
The texts and drawings in this manual are correct to the best of our
knowledge. As faults can never be excluded, please note:
Your own calculations and plans, under consideration of the current standards
and directions should only be basis for your projects. We do not offer a
guarantee for the completeness of the drawings and texts of this manual -
they only represent some examples. They can only be used at your own risk.
No liability is assumed for incorrect, incomplete or false information and / or
the resulting damages.
Note
The design and the specifications can be changed without
notice. The illustrations may differ from the original
product.
Imprint
This manual including all parts is copyrighted. Another use outside the
copyright
requires the approval. This especially
applies for copies, translations, micro films and the storage into electronic
systems.