Resol FlowSol XL User manual

*11201179* 11201179
Thank you for buying this RESOL product.
Please read this manual carefully to get the best performance from this unit.
Please keep this manual carefully.
FlowSol®XL
www.resol.com
Manual
en
Installation
Operation
Commissioning
Manual for the
specialised craftsman

2
Subject to technical change. Errors excepted.
© 20170215_11201179_FlowSol_XL.monen.indd
Safety advice
Please pay attention to the following safety advice in order to avoid danger and
damage to people and property.
Instructions
Attention must be paid to the valid local standards, regulations and directives!
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 specied in these instructions. Due to its design
the station must be mounted and operated as described in these instructions!
CE-Declaration of conformity
The product complies with the relevant directives and is therefore la-
belled with the CE mark. The Declaration of Conformity is available upon
request, please contact RESOL.
Target group
These instructions are exclusively addressed to authorised skilled personnel.
Only qualied electricians should carry out electrical works.
Initial installation must be effected by the system owner or qualied personnel
named by the system owner. Contents
1 Overview .............................................................................................. 3
2 Mounting the station........................................................................... 4
3 Flushingandlling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 Maintenance......................................................................................... 6
10 Safety devices....................................................................................... 6
11 Accessories .......................................................................................... 7
12 Information about the pump ............................................................. 7
13 List of spare parts................................................................................ 7
Description of symbols
WARNING! Warnings are indicated with a warning triangle!
ÎThey contain information on how to avoid the danger
described.
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 appliance can occur.
Note
Notes are indicated with an information symbol.
ÎArrows indicate instruction steps that should be carried out.
Disposal
• 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 environmen-
tally sound disposal of the devices.

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1 Overview
• Pre-assembled twin-line pump station
• Integrated DeltaSol®BX Plus controller (optional)
• Energy-savinghigh-efciencypump
• Safety assembly with connection for the expansion vessel, safety
valve and pressure gauge
• Ballvalvesinowandreturnwithnon-returnvalvesandthermom-
eter handles
• Flowmeter
• Air separator for manual venting of the solar thermal system
• Fill and drain valves
• Wall mounting bracket and mounting material
Technical data
Circulating pump: Wilo Stratos PARA 15/1-9 (
ErP power consumption of the
pump*: 45 W)
Safety valve: 6 bar
Pressure gauge: 0 … 10 bar
Flowmeter: 5 … 35 l/min
For low-ow systems (0.2 l/min/m²) with collector elds of up to 100 m²
For high-ow systems (0.5 l/min/m²) with collector elds of up to 50 m²
Take the pressure loss of the system into account!
Ballvalvesinowandreturnwithnon-returnvalvesandthermometer
handles: Non-return valve: Opening pressure 20 mbar, openable
Thermometer: 0 … 160 °C
Connection to expansion vessel: 1" ET, at sealing
Outlet safety valve: 1" IT
Connections to the solar pipes: 1" IT
Maximumtemperatureow/return: 120 °C / 95 °C
Maximum pressure: 6 bar
Medium: Water with max. 50 % glycol
Dimensions: approx. 470 x 380 x 220 mm (with insulation)
Distance centres: 125 mm
Distance centre/wall: 73 mm
Material: Fittings: brass
Seals:AFM 34
O-rings: FKM
Insulation: EPP foam
*50 % of the rated
power consumption
Pumpcharacteristic/pressurelosscharacteristic
335 212
90 125 82
Pressure loss [kPa]
Flowrate[m³/h]
Delivery height [m]
0
0
2
4
6
8
12 31,50,5 2,5
3,5
4044 / 15 PWM1 / 85 PWM2
3638 / 25 PWM1 / 75 PWM2
3231 / 35 PWM1 / 65 PWM2
2825 / 45 PWM1 / 55 PWM2
2419 / 55 PWM1 / 45 PWM2
2012 / 65 PWM1 / 35 PWM2
4450 / ≤5 PWM1 / ≥95 PWM2
Wilo Stratos PARA 1-9 min.
Wilo Stratos PARA 1-9 max.
FlowSol® XL
1606 / 75 PWM1 / 25 PWM2
1200 / 85 PWM1 / 15 PWM2

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2 Mounting the station
12
10
11
335
12090 125
440
317 123
10 Back half of the insulation
11 Front half of the insulation
12 Wall mounting bracket
Controller depending on the version of the station
ÎDetermine the mounting site of the station.
ÎTake the station out of the packaging.
ÎRemove the front half of the insulation and the controller panel.
ÎRemove the locking springs from the wall mounting bracket, lift and pull the
ow and return lines off the wall mounting bracket.
ÎRemove the back half of the insulation.
ÎMark the drill holes by means of the wall mounting bracket, then drill and
insert wall plugs.
ÎFasten the wall mounting bracket to the wall with the screws. For this purpose,
use a crosshead screw driver.
ÎPush the back half of the insulation onto the wall mounting bracket.
ÎInsert the ow and return lines into the wall mounting bracket and fasten
them by means of the locking springs.
ÎConnect the pipework between pump station and store and collector re-
spectively.
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llingthesolarsystem
WARNING! Scald danger!
Pressure surge damage!
If the medium enters strongly heated, empty collectors, pressure
surges caused by evaporation can occur.
ÎIn order to prevent the solar uid from vaporising
insidethecollectors,donotll or ush the system
during times of strong irradiation!
5
4
3
1
2
6
7
9
8
1 Safety valve
2 Pressure gauge
3 Drain valve
4 Return ball valve with non-return valve and thermometer handle
5 Fill valve
6 Pump
7 Flowmeter
8 Flow ball valve with non-return valve and thermometer handle
9 Air separator

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Beforeushingthesystem
ÎDisconnect the expansion vessel from the solar thermal system.
ÎConnect the pressure hose of the lling and ushing
station to the ll valve (5) of the pump station.
ÎConnect the ushing hose of the lling and ushing
station to the drain valve (3) of the pump station.
2.
ÎClose the ball valve of the pump station (4).
ÎOpen the ll valve (5) and the drain valve (3).
ÎSwitch on the lling pump of the lling and ushing
station.
ÎFlush the solar thermal system for at least 15 minutes by means of the lling
and ushing station until the discharged solar uid is free of gas bubbles and
dirt particles.
ÎDuring ushing, vent the solar thermal system several times until the dis-
charged solar uid (e. g. Tyfocor®, see chap. 11) is free of air bubbles.
ÎOpen the ball valve of the pump station (4).
Afterushingthesystem
ÎConnect the expansion vessel to the solar thermal system.
ÎClose the drain valve (3) of the pump station while the lling pump is running.
ÎIncrease the system pressure (approx. 3,5 - 4 bar).
The system pressure can be read from the pressure
gauge.
ÎClose the ll valve (5).
ÎSwitch off the lling pump.
BAR
ÎCheck the pressure gauge to see whether the system pressure reduces and
eliminate leaks where necessary.
ÎSlowly discharge the heat transfer uid by means of the drain valve (3) until
the operating pressure is set.
ÎRemove the hoses of the lling and ushing station and screw the caps onto
the ll and drain valves. Manually start the solar thermal pump at maximum
speed (see controller manual) and let the uid circulate for at least 15 minutes.
ÎVent the solar thermal system several times.
ÎCheck the system pressure at the pressure gauge.
ÎCheck the antifreeze ratio (not required if a ready-
mix is used).
11.
%
4 Ball valve positions
WARNING! Scald danger! Damage by overpressure!
When the ball valve is closed, too high pressure may occur in the
blocked-off line if it is heated.
ÎIn order to prevent scald danger and damage by
overpressure, make sure the blocked-off line is not
heated.
Ball valve in operating position, uid ow in ow direction
only
Ball valve open, uid ow in both directions possible
Ball valve closed, no uid ow
5 Draining the system
ÎOpen the ball valve (4).
ÎOpen the air vent at the highest point of the system (above the collectors).
ÎOpen the drain valve (5).
6 Non-return valves
The non-return valves of the pump station are integrated into the ball valves in
ow and return and have an opening pressure of 20 mbar.
In order to completely drain the system, the non-return valves have to be opened.
ÎFor this purpose, turn the handles of the ball valves by 45°.
ÎFor normal system operation, open the ball valves completely.

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7 Flowmeter
The owmeter measures and indicates the ow rate with a range of 5 - 35 l/min.
For the device to function faultlessly, the system must be ushed and free of grit.
Read the ow rate from the upper edge of the oat.
8 Air separator
WARNING! Scald danger!
During venting, the air discharged can reach temperatures of
more than 100°C.
ÎIn order to avoid scalding, pay attention to the sys-
tem temperatures!
The air separator is used for venting the water/glycol mixture
in the solar circuit. The air separated from the heat transfer uid
gathers in the air scoop and can be discharged manually at the
air vent valve.
ÎOpen the air vent valve and collect the discharged uid in a
suitable container.
ÎCheck the system pressure after venting and, if necessary,
increase it to the specied operating pressure
9 Maintenance
In the case of maintenance (such as a replacement of the pump) proceed as follows:
ÎClose the ball valve (4).
ÎTurn the slot of the owmeter spindle by 90° anti-clockwise (see gure below).
The heat transfer uid can now be drained from the pump.
ÎOpen the drain valve (3).
If necessary, open the union nut at the pressure side.
ÎNow dismount the pump.
10 Safety devices
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 efciency of the valve must not
be inuenced or disabled by barriers!
• The strainer or other restriction devices must not be mounted between collec-
tor (-eld) 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
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 4 m!
• 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 uid will be collected and can be relled into the system when the
pressure is too low.

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13 List of spare parts
11
2
5
1
3
6
7
8
10 4
9
Pos. Art. no. Article
1 11201100 Safety valve 6 bar DN20
2 11200039 Pressure gauge
3 11200058 Fill / drain valve
4 11201103 Return ball valve with non-return valve and thermometer
handle DN 25
5 11200058 Fill / drain valve
6 64400075 Wilo Stratos PARA 15/1-9
7 11201105 Flowmeter 5 … 35 l/min
8 11201106 Flow ball valve with non-return valve and thermometer handle
DN 25
9 11201107 Air separator DN25
10 11201101 Back half of the insulation XL
11 11201102 Front half of the insulation XL
12 11201108 Wall mounting bracket XL (not shown)
13 11201117 Controller panel (not shown)
11 Accessories
SBS2000llingandushingstation
The SBS 2000 has been especially designed for profes-
sionally lling and ushing solar thermal and heating
systems. Its many thought-out details facilitate transport,
operation and cleaning, the attractive design makes it the
ideal companion for a professional performance.
Heattransferandcleaninguids
In our product portfolio, you will nd a range of heat
transfer uids for different applications, available as
readymix or concentrate, as well as cleaning uids.
Filling and injection pump
Filling and injection pump with non-return valve for pres-
sure increase and relling of heat transfer uids. ½" ET
self-sealing with O-ring, 15mm tube connection. Pump
output 2 l/min, 4,5 bar max.
See our full range of accessories on our website: www.
resol.com
12 Information about the pump
Depending on the version, the station is equipped with different pumps. Data con-
cerning the pump in your station are available at the pump manufacturer under
www.wilo.com or www.wilointec.com.
Upon request we will provide you with further information.

Distributed by: RESOL – Elektronische Regelungen GmbH
Heiskampstraße 10
45527 Hattingen / Germany
Tel.: [phone] / 96 48 - 0
Fax: [phone] / 96 48 - 755
www.resol.com
[email protected]
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 specications can be changed without notice.
The illustrations may differ from the original product.
Imprint
This mounting- and operation manual including all parts is copyrighted. Another
use outside the copyright requires the approval of RESOL– Elektronische Rege-
lungen GmbH. This especially applies for copies, translations, micro lms and the
storage into electronic systems.
© RESOL – Elektronische Regelungen GmbH