wagner solar ECOplus User manual

EN-XXX_ECOplus-Solar-Storage_MA-201026-1WA10603 1
Wagner Solar
INSTALLATION INSTRUCTIONS
ECOplus Solar Storage
Figure 1 ECOplus solar storage
Content
1 General Safety Notes . . . . . . . . . . . . . 2
1.1 Standards and Codes . . . . . . . . . . . . 2
1.2 Qualifications of the Installer . . . . . . . . . 2
1.3 Intended Use and Application . . . . . . . . . 2
2 Scope of supply . . . . . . . . . . . . . . . 2
3 Installation . . . . . . . . . . . . . . . . . 2
3.1 Preparation . . . . . . . . . . . . . . . . . 2
3.2 Setting up the Storage . . . . . . . . . . . . 2
3.3 Connecting the Domestic Water Circuit . . . . 4
3.4 Connecting the Solar- and Auxiliary Heating Circuit . . 5
3.5 Connecting Backup Heater . . . . . . . . . . 5
3.6 Installing Temperature Sensors . . . . . . . . 5
3.7 Install a Impressed Current Anode . . . . . . . 6
4 Startup of the System . . . . . . . . . . . . 6
4.1 Acceptance Protocol . . . . . . . . . . . . . 6
4.2 System Check . . . . . . . . . . . . . . . . 6
4.3 Flushing the Installation . . . . . . . . . . . 6
4.4 Settings at Boiler and Solar Controllers . . . . . 6
4.5 Filling, Venting, Pressure Check . . . . . . . . 6
5 Place the Insulation . . . . . . . . . . . . . 7
6 Troubleshooting . . . . . . . . . . . . . . . 8
7 Maintenance . . . . . . . . . . . . . . . . 8
8 Disassembly and Recycling . . . . . . . . . . 8

2EN-XXX_ECOplus-Solar-Storage_MA-201026-1WA10603
1 General Safety Notes
The following symbols can be found in the texts of the
instructions. Watch out for the symbols!
DANGER of personal injury
Live-threatening electrical shocks, burns, bruising and
other health hazards are possible during installation.
RISK of material damage
This symbol indicates that damage may be done to com-
ponents of the solar circuit or the function of the same
may be impaired seriously. Please make sure that you fol-
low the installation procedure step by step as instructed.
ADDITIONAL information
This symbol points to practical advice and tricks of the
trade which will make the installation and operation of the
solar circuit easier.
1.1 Standards and Codes
The standards and regulations applicable at the installati-
on location must be adhered to.
1.2 Qualifications of the Installer
Setting up, installation and commissioning of the solar
storage cylinder must be carried out by a qualified in-
staller.
1.3 Intended Use and Application
ECOplus is an enameled solar storage tank for DHW heat-
ing in closed circuit heating and solar installations. It must
be filled with domestic water only. The maximum tem-
perature in the storage must not exceed 95 °C. Observe
correct settings at boiler and solar controllers (e.g. max.
boiler temperature)! The storage tank shall be placed in
a frost-proof room. The foundation at the installation site
has to be dry and sufficiently stable to support the filled
tank.
Wagner Solar cannot be held liable for damages resulting
from improper use.
2 Scope of supply
The ECOplus solar cylinder is supplied standing upright
and screwed onto a pallet.
The serial no. is located on the type label.
Table 1 Scope of supply (fig. 2)
1 Storage
2Jacket insulation with hook ratchet closure (may be several
parts, depending on storage type)
3 Insulation plug with cap for access flange
4, Insulation plug with cap for imersion heater socket
5 Storage lid
6 Lid insulation
7 Outer ground insulation
8 Inner ground insulation
3 Installation
3.1 Preparation
The cylinder must be connected with short pipe lengths
to the taps.
In order to complete the installation the following materi-
als are required:
●Pipe connections to fit 1¼ “, 1“ and ¾“ male cylinder
connections.
●Thermostatic mixer (optional).
●Safety valve unit for the cold-water feed (optional).
All storage connection stubs are cylindrical and designed
for use with special heat resistant flat gaskets. The original
gaskets from our connection sets should be used or alter-
natively gaskets of identical quality.
To reduce heat losses we recommend to use the
CONVECTROL connection sets for all storage connection
stubs.
3.2 Setting up the Storage
Risk of injury during transport through heavy weight!
Wear safety shoes and protective gloves.
Knocks and banging can cause damage to the enamel
coating on the inside!
●Unscrew the storage from the palette, remove pack-
ing film and transport to the installation location.
The tank can be lifted at the foot ring and the hoisting
ring at the top.
●Positioning the storage tank for easy piping.
●Tilt the tank to place the round inner floor insulation
(fig. 3).

EN-XXX_ECOplus-Solar-Storage_MA-201026-1WA10603 3
Figure 2 Scope of supply.
Figure 3 Tilt the storage to insert the inner floor insulation
2
4
8
7
1
6
5
2
3

4EN-XXX_ECOplus-Solar-Storage_MA-201026-1WA10603
Figure 4 Drinking water connections (example): 9Air vent; 10 Magnesium protection anode with cable; 11Cold water; 12Hot water; 13Safety
unit; 14Circulation pump; 15Thermostatic mixer; 16Check valve; 17 Filling and emptying tap
3.3 Connecting the Domestic Water
Circuit
●(Fig. 4) Connect a safety unit (13) to the cold water sup-
ply and ideally position above the storage. This allows
for easy maintenance of the safety group without having
to empty the tank.
The storage tank might be damaged without safety
group or when the safety group is closed off!
The water expands when heated and thus high over-
pressure can build up in the system. Ensure that there
is no shut-off valve between cylinder and safety valve.
●Installation of a filling and emptying tap at the lowest
storage connection (17).
●Fit a thermostatic mixer (15). This assures that even
when the storage tank is heated to its maximum tem-
perature the DHW temperature set at the thermostatic
mixing valve will not be exceeded. If no thermostatic
mixer is fitted, maximum vessel temperature must
be limited to 65 °C at the solar controller.
Serious danger of scalding!
The solar installation may heat the storage water to tem-
peratures of up to 95 °C. .
The installation of a thermostatic mixing valve limits the
tap temperatures to a safe temperature level.
●Installation of a circulation pump if required (14). The
return should be taken from close to the tapping point.
The circulation pump should govern circulation ac-
cording to water temperature (temperature sensor)
and with a timer.
●The circulation control should be implemented in the
most energy saving fashion according to the state of
the art.
●Installation of an air vent (9). Part of the ECOplus con-
nection kit, part no. 13900207.
13
15
14
17
11
12
16
9
10
8 Cold water connection
3 Circulation connection
CONVECTROL
part of the ECOplus
connection kit,
part no. 13900207
1 Hot water connection
16
9
10
8 Cold water connection
3 Circulation connection
1 Hot water connection
11

EN-XXX_ECOplus-Solar-Storage_MA-201026-1WA10603 5
Figure 5 Connecting solar- and auxiliary heating circuit
Figure 6 Installation of the backup heater
Figure 7 Placing and fixing the temperature sensors
5 Inlet for electrical
immersion heater
3.4 Connecting the Solar- and Auxiliary
Heating Circuit
●Connect flow pipe of solar circuit to the top of the solar
coil (6) and the return pipe to the bottom (7) of same
(fig. 5).
●Connect the backup heating coil in the top of the
storage (fig 5). Flow pipe to connection (4), re-
turn pipe to connection (2).
Installation of a safety valve in the heating circuit with
a max. blow-off pressure of 3 bar!
●Close unused connection nozzles with 1¼“ caps.
3.5 Connecting Backup Heater
●As an option, an electric backup heater is available that
can be installed in the 1½“ socket on the side (fig. 6).
Please observe instructions supplied with the respec-
tive heating device.
●Laying the mains cable of the electrical heater: a heat
resistant cable (min. up to 95 °C) must be used when
laying the cable under the insulation jacket. .
The immersion heater must only be connected to
mains after the storage tank is filled!
●If no immersion heater is fitted, the inlet must be closed
with the supplied 1½“ plug.
7 Solar circuit return
6 Solar circuit flow
4 Auxiliary heating flow
2 Auxiliary heating return
3.6 Installing Temperature Sensors
●Placing and fixing a solar sensor and an auxilary heat-
ing sensor using the sensor terminal clamp (fig. 7). To
do this, slightly loosen the sensor connection terminal
(1), place sensor (2), and re-tighten terminal (3).
Table 2 Sensor position H (mm)
ECOplus 300 400 500
Solar sensor 230 245 250
Auxilary heating
sensor 1100 1170 1255
H
13
2
Sensor connection
terminal

6EN-XXX_ECOplus-Solar-Storage_MA-201026-1WA10603
Figure 8 Installation of a CORREX® impressed current anode
3.7 Install a Impressed Current Anode
The installed sacrificial anode can be replaced with a
maintenance free impressed current anode (optional ac-
cessory, fig. 8).
●Remove cable and existing magnesium anode (1), (2).
●Screw impressed current anode and fasten the cable to
the electronics device (3) - (5).
●After filling the storage tank check function (see chap.
„Maintenance“).
4 Startup of the System
4.1 Acceptance Protocol
The correct startup of the system must be certified by a
qualified person in the Final Check Protocol in order ren-
der the warranty agreement valid.
4.2 System Check
After fitting all components, please carry out the following
checks:
●Are all components fitted correctly?
●Are all safety units installed? Is the 10 bar safety valve
fitted? If necessary, is a pressure regulator fitted and
can it be closed off from the vessel?
●Are all fittings and connections safe and tight?
●If present – were all electrical connections made to re-
quired standards?
●Are the temperature sensors in the correct positions?
Do all controllers display plausible values?
4.3 Flushing the Installation
Malfunction or damage when storage tank is not ade-
quately purged!
In spite of careful production methods, some residues of
the processes, including metal slack, may remain inside
the pipes, the vessel and the heat exchangers. These can
cause problems during operation of the system and may
lead to damage. Therefore, the system must be flushed
before permanent operation starts. Also filtering/retain-
ing devices should be installed at convenient points in
the system, as even later some production residues may
become dislodged and may have to be removed.
4.4 Settings at Boiler and Solar
Controllers
The temperature limitation of 95 °C for the solar storage
vessel must never be exceeded.
Observe correct settings at boiler and solar controllers
(e.g. max. boiler temperature).
4.5 Filling, Venting, Pressure Check
●Pease make sure that before filling and startup of the
system, all openings are closed.
●(Fig. 9) To fill the storage, open the cock of the safety
group in the cold water supply leg (17) and a water tap
of the connected supply. While doing so, allow air to
escape through the bleed (9).
●After venting the piping close all water taps. If water
escapes from the air bleed, close it as well.
●Carry out a pressure test after the system has been
completely installed (max. 10 bar). While test pressur-
izing, check all fittings and connections for leaks. If nec-
essary retighten.
1
2
3
4
5

EN-XXX_ECOplus-Solar-Storage_MA-201026-1WA10603 7
5 Place the Insulation
The solar cylinder insulation consists of PU foam with a
laminated polystyrene cover layer and hook closure (ei-
ther 1 or 2 parts, depending on storage type).
The higher the ambient temperature, the more flexible
the PU foam and due to the breakage tendency.
Do not install insulation below 20 °C and allow insulation
stored at cold temperatures to reach room temperature
before installing.
Please do not use tools or tightening straps and do not
close the hook closure by force. This could damage the
insulation and diminish its effectiveness.
●(Fig. 11) Place the insulation ring around the bottom of
the solar cylinder (1).
●Now set the insulation jacket to the connection side
around the connection openings and - if in place - the
immersion heater (2).
●First lock the ratchet closure into the loosest position
and then tighten from the top (alternating if the jacket
has more than one closure) until the jacket tightly fits
the storage tank (3).
●If no immersion heater is fitted insert insulation plug
with cap (4).
●Insert insulation plug with cap for access flange (5).
●Insert upper circular insulation panel and attach lid (6).
Figure 9 Filling and venting the storage
Figure 10 Monitor pipe connections for leak tightness and opera-
tional pressure
Figure 11 Place the insulation
bar
1
2
4
6
3
5
●Heat the content of the storage cylinder, for example
by switching on the boiler, and keep checking the pres-
sure. Before reaching maximum operational pressure,
the safety valve must come into operation.
17
9

Subject to modifications, errors excepted · ©Wagner Solar GmbH, 2017 · www.wagner-solar.com
8Wagner Solar GmbH · Sonnenallee 2 · D-35274 Kichhain [phone]
Figure 12 Insulation of the pipes
mA
●Insulate pipes: continue pipe insulation into the re-
spective openings in the ratchet closure to avoid heat
loss at the entering points (fig. 12).
6 Troubleshooting
The flat sealing gaskets may change their density during
the first few months of operation. This normal settling
behavior may occasionally lead to dripping. The connec-
tions should therefore re-tightened as required.
7 Maintenance
The cleaning and maintenance of the solar storage tank
should be carried out every two years together with the
maintenance of the solar installation. We recommend a
service contract.
●Defunct protective anode leads to corrosion of the
storage tank!
Over time the built-in protective sacrificial anode is con-
sumedduringoperation.Check the protectiveanode af-
ter two years, and afterwards annually.
- Remove the build in uninsulated sacrificial magne-
sium anode, examine remaining magnesium mass and,
if necessary, install new anode.
- For sacrificial anodes with insulated installation (MG an-
odes) test the protective current between storage and
anode (fig. 13). When the value is below 0.3mA, remove
and examine the anode and replace if required.
- If an impressed current anode is installed, observe the
related product documentation. A green light signals
correct function.
●Check for visible leakage of the fittings. If necessary
retighten fittings.
●The proper function of the safety valve regularly has to
be tested. The blow-off opening must never be closed
or obstructed.
●Required cleaning of the storage tank can be carried
out through the access/cleaning flange. Install new
gasket when closing!
Regular maintenance must be certified in the Mainte-
nance Protocol by a qualified person in order to render
the warranty agreement valid.
8 Disassembly and Recycling
At the end of the long operational lifetime, the valu-
able materials of the installation should be recycled in
an environmentally sound manner.
Figure 13 To check the factory-installed magnesium protection an-
ode unplug cable and measure current with multimeter