wagner solar CIRCOtransfer 30 E User manual

2015/03 EN-XXX_CIRCOtransfer-30E-50E_TI-MA-BA-150401-3PAW0501 - 99609x7WAG0x-mub-en - V06 1
Installation and Operation Instructions
Transfer stations:
CIRCOtransfer 30 E
CIRCOtransfer 50 E
[Hydraulics]
CIRCOtransfer 30 E
CIRCOtransfer 50 E

1 General information
2 EN-XXX_CIRCOtransfer-30E-50E_TI-MA-BA-150401-3PAW0501 - 99609x7WAG0x-mub-en - V06 2015/03
EN-XXX_CIRCOtransfer-30E-50E_TI-MA-BA-150401-3PAW0501
Item no. 99609x7WAG0x-mub-en –Version V06 –Issued 2015/03
Translation of the original instructions
We reserve the right to make technical changes without notice!
Printed in Germany –Copyright by Wagner Solar GmbH
Wagner Solar GmbH
Industriestraße 10
D-35091 Cölbe, Germany

1 General information
2015/03 EN-XXX_CIRCOtransfer-30E-50E_TI-MA-BA-150401-3PAW0501 - 99609x7WAG0x-mub-en - V06 3
Contents
1General information ...........................................................................................................4
1.1 About these instructions ............................................................................................... 4
1.2 About this product ........................................................................................................ 5
1.3 Designated use ............................................................................................................ 6
2Safety instructions .............................................................................................................7
3Assembly and installation [specialist] ..................................................................................9
3.1 Controller connection ................................................................................................. 11
4Commissioning [specialist] ...............................................................................................12
4.1 Preparations before flushing and filling....................................................................... 13
4.2 Flushing and filling the storage tank circuit................................................................. 13
4.3 Flushing and filling the solar circuit............................................................................. 14
4.4 Maintenance [specialist] ............................................................................................. 19
4.5 Draining the solar installation ..................................................................................... 20
4.6 Deinstallation.............................................................................................................. 20
5Spare parts [specialist].....................................................................................................21
5.1Spare parts primary circuit CIRCOtransfer 30 E (15020220)...................................... 21
5.2 Spare parts secondary circuit CIRCOtransfer 30 E (15020220) ................................. 22
5.3 Spare parts primary circuit CIRCOtransfer 50 E (15020221)...................................... 23
5.4 Spare parts secondary circuit CIRCOtransfer 50 E (15020221) ................................. 24
6Technical data .................................................................................................................25
6.1 Dimensional drawing CIRCOtransfer 30 E ................................................................. 26
6.2 Dimensional drawing CIRCOtransfer 50 E ................................................................. 27
6.3 Pressure drop characteristics CIRCOtransfer 30 E .................................................... 28
6.4 Pressure drop characteristics CIRCOtransfer 50 E .................................................... 28
7Function of the check valves [specialist]............................................................................29
8Commissioning report ......................................................................................................31

1 General information
4 EN-XXX_CIRCOtransfer-30E-50E_TI-MA-BA-150401-3PAW0501 - 99609x7WAG0x-mub-en - V06 2015/03
1General information
Carefully read these instructions before installation and commissioning.
Save these instructions in the vicinity of the installation for future reference.
1.1 About these instructions
These instructions describe the function, installation, commissioning and operation of the
transfer stations CIRCOtransfer 30 E and CIRCOtransfer 50 E.
The chapters called [specialist] are intended for specialists only. For other components of the
installation, such as pumps, controllers or the distribution manifold, see the manufacturers'
instructions.
CIRCOtransfer 30 E –item number 150 202 20
Power [kW]
Collector surface [m²]
Low-flow [17 l/m²h]
30
50
High-flow [35 l/m²h]
16
26
CIRCOtransfer 50 E –item number 150 202 21
Power [kW]
Collector surface [m²]
Low-Flow [17 l/m²h]
54
90
High-Flow [35 l/m²h]
30
50

1 General information
2015/03 EN-XXX_CIRCOtransfer-30E-50E_TI-MA-BA-150401-3PAW0501 - 99609x7WAG0x-mub-en - V06 5
1.2 About this product
The station is a premounted group of fittings checked for leakage and used to transfer the heat
from the primary or solar circuit to the secondary or storage tank circuit.
It contains important fittings and safety devices for the operation of the installation:
Ball valves with integrated thermometers in the storage tank circuit
(flow and return)
Check valves to avoid involuntary gravity circulation in the flow and return of the primary
and the secondary circuit.
Pressure relief valves to prevent inadmissible overpressures
Pressure gauge to display the system pressure in the solar circuit
Vent valves to easily vent the solar circuit
Fill and drain valves to flush, fill and drain the solar circuit
Two flow meters and electronic temperature sensors for heat quantity balancing
(secondary) and speed control of the pumps depending on the performance
The expansion tank required for operation must be adapted to the size and the requirements of
the installation and must be ordered separately.
The cap-type valve, which is also separately available, allows the expansion tank to be easily
mounted and separated from the solar thermal system.
The wrapping materials are made of recyclable materials and can be disposed of with
recyclable materials.

1 General information
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1.3 Designated use
The station may only be used as a transfer station between the solar and the heating circuit in
solar thermal systems taking into consideration the technical limit values indicated in these
instructions. Due to its design the station must be mounted and operated as described in these
instructions!
Only use original accessories with the transfer station.
Improper usage excludes any liability claims.
When the sun shines, the collectors can become very hot.
The solar fluid in the circuit can heat up to more than 100 °C.
Only flush and fill the solar circuit when the collector temperatures are
below 70 °C.
Schematic structure
CIRCOtransfer 30 E/50 E
Scope of
delivery

2 Safety instructions
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2Safety instructions
The installation and commissioning as well as the connection of electrical components require
technical knowledge commensurate with a recognised vocational qualification as a fitter for
plumbing, heating and air conditioning technology, or a profession requiring a comparable level
of knowledge [specialist].
The following must be observed during installation and commissioning:
relevant local and national regulations
accident prevention regulations of the professional association
instructions and safety instructions mentioned in this manual
WARNING
Danger of scalding due to vapour escape!
With pressure relief valves there is risk of scalding due to vapour escape.
During installation, check the local conditions and if a discharge line must be
connected to the safety group.
Observe the instructions regarding the pressure relief valve.
The pressures calculated by the installation planner for the expansion tank
and the operating pressure of the installation must be set.
CAUTION
Risk of burns!
The valves, fittings and the pump may heat up to more than 100 °C during
operation.
The shell must remain closed during operation.

2 Safety instructions
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CAUTION
Personal injury and damage to property due to overpressure!
By closing the two ball valves in the primary circuit you isolate the pressure relief
valve from the heat exchanger. A rise in temperature in the storage tank will
cause high pressures and could result in personal injury or damage to property!
Only close the ball valves for service and maintenance.
NOTICE
Material damage due to mineral oils!
Mineral oil products cause lasting damage to seals made of EPDM, whereby the sealant
properties get lost. We do not assume liability nor provide warranty for damage to property
resulting from sealants damaged in this way.
It is imperative to avoid that EPDM gets in contact with substances containing
mineral oils.
Use a lubricant based on silicone or polyalkylene and free of mineral oils, such as
Unisilikon L250L and Syntheso Glep 1 of the Klüber company or a silicone spray.

3 Assembly and installation [specialist]
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3Assembly and installation [specialist]
The location of installation must be dry, load-carrying, frost-proof and protected against
ultraviolet radiation. Furthermore, the access to the control and safety equipment must be
guaranteed at all time during operation!
The discharge line of the safety equipment should be guided into a heat-resistant container with
corresponding size. This allows you to avoid uncontrolled discharging into the environment and
to easily refill the circuits!
NOTICE
Material damage due to high temperatures!
Install the fitting group at a sufficient distance from the collector field, since the solar fluid may
be very hot near the collector.
It may be necessary to install an intermediate tank in order to protect the expansion tank.
1. You can use a drilling template in order to facilitate the
installation, which you can find on the station.
2. Copy the mounting hole measures to the mounting
surface.
3. Drill the holes and insert apropriate wall plugs into the
holes.
4. Screw in the screws and let them stick about 4 cm out
of the wall.
5. Remove the station from the packaging.
6. Remove the insulating front shell.
Hang the station onto the screws and tighten
the screws.

3 Assembly and installation [specialist]
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7. Connect the transfer station to the system:
①Solar flow from the collector
②Solar return to the collector
③Flow to the buffer tank
④Return from the buffer tank
All screw connections of the CIRCOtransfer 30 E have
¾" internal threads, all screw connections of the
CIRCOtransfer 50 E have 1" internal threads.
8. Mount the safety group, consisting of the pressure
relief valve [c], the fill valve [d] and the pressure
gauge [e], to the connection of the return ball valve [b].
9. Connect the expansion tank below the pressure
gauge [e]. During servicing at the expansion tank, we
recommend the installation of a cap valve on the
expansion tank.
NOTICE
Note regarding the expansion tank
The expansion tank must not be connected while flushing and filling in order to avoid that dirt
particles are washed in.
10. Pressurise the expansion tank as specified by the
manufacturer and connect the expansion tank.
Observe the separate instructions regarding the
expansion tank!
11. Check all screw connections and tighten them
if necessary.