Weishaupt WHI sol/heat 20 1 User manual

Mounting and operating instructions
Separation station WHI sol/heat 20 #1 / 40 #1
Separation station WHI sol/aqua 20 #1 / 40 #1
83514202 ▪ 1/2014-
06

Installation and operation instructions
Separation station
WHI sol/heat 20 #1 / 40 #1; Separation station WHI sol/aqua 20 #1 / 40 #1
83514202
▪ 1/2014-06 ▪Ext. PAW 3-36
1
Information for the user ..................................................................................... 4
1.1
User guidance...............................................................................................4
1.1.1
Symbols........................................................................................................4
1.1.2
Target group .................................................................................................4
1.2
Warranty and liability.....................................................................................4
2
Safety ............................................................................................................... 5
2.1
Designated use.............................................................................................5
2.2
Safety instructions ........................................................................................5
2.3
Safety measures...........................................................................................6
2.4
Electrical connection.....................................................................................6
2.5
Structural modifications.................................................................................6
2.6
Disposal........................................................................................................6
3
Product description............................................................................................ 7
3.1
Function......................................................................................................10
3.2
Technical Data Separation stations ............................................................11
3.3
Technical Data Pumps................................................................................12
3.4
PWM input signal (solar profile) ..................................................................12
3.5
Hydraulilc performance data.......................................................................13
4
Installation ...................................................................................................... 14
4.1
Assembly ....................................................................................................14
4.2
Hydraulic connection...................................................................................16
4.3
Controller connection..................................................................................17
4.4
Electrical connection of the solar controller WRSol2.1................................17
5
Operation........................................................................................................ 18
5.1
Pressetting solar controller WRSol2.1 ........................................................18
6
Commissioning ............................................................................................... 18
6.1
Preparation for flushing and filling...............................................................19
6.2
Flushing and filling the storage tank circuit / potable water circuit
(lower connections).....................................................................................19
6.3
Flushing and filling the solar circuit (upper connections).............................20
7
Maintenance ................................................................................................... 24
7.1
Draining the solar system ...........................................................................24
8
Spare parts ..................................................................................................... 25
8.1
Spare parts separation station WHI sol/heat 20 #1 (40900015252) ...........25
8.2
Spare parts separation station WHI sol/aqua 20 #1 (40900015302) ..........27
8.3
Spare parts separation station WHI sol/heat 40 #1 (40900015262) ...........29
8.4
Spare parts separation station WHI sol/aqua 40 #1 (40900015312) ..........31
9
Accessories .................................................................................................... 33
10
Function of the check valves............................................................................ 33
11
Commissioning log.......................................................................................... 35

Installation and operation instructions
Separation station
WHI sol/heat 20 #1 / 40 #1; Separation station WHI sol/aqua 20 #1 / 40 #1
1 Information for the user
83514202
▪ 1/2014-06 ▪Ext. PAW
4-36
1
Information for the user
These installation and operation instructions form part of the device and must be stored
at the place of use.
Carefully read these instructions before installation and commissioning.
1.1
User guidance
1.1.1
Symbols
DANGER
Immediate danger of high risk.
Non-observance will result in serious injuries or death.
WARNING
Danger of medium risk.
Non-observance may result in environmental damage,
serious injuries or death.
CAUTION
Danger of low risk.
Non-
observance may result in material damage or light to medium
injuries.
NOTICE
Important information.
1.1.2
Target group
This installation
and operation manual is addressed to operators and qualified skilled
personnel. It must be observed by anyone working on the machine.
Work on the machine may only be performed by persons that have received the required
training or instruction.
Persons with
restricted physical, sensory or mental abilities may work on the machine if
supervised or instructed by an authorized person.
Children may not play with the machine.
1.2
Warranty and liability
Warranty and lilability claims for personal and material
damage are void if they are due
to one or several of the following causes:
Use of the machine contrary to its designated use,
Non
-observance of the installation and operation instructions,
Operation of the machine with non
-operational safety or protective devices,
Continued use despite the presence of a defect,
Improper assembly, commissioning, operation and maintenance of the machine,
Unauthorised modification of the machine,
Installation of additional components that were not tested together with the
machine,
Repairs carried out incorrectly,
Failure to use Weishaupt original parts
Defects in the supply lines,
Force majeure.

Installation and operation instructions
Separation station
WHI sol/heat 20 #1 / 40 #1; Separation station WHI sol/aqua 20 #1 / 40 #1
2 Safety
83514202
▪ 1/2014-06 ▪Ext. PAW
5-36
2
Safety
2.1
Designated use
The station may only be used in solar thermal installations as
separation station
between
the
solar circuit
and the heating circuit (in the case of WHI sol/heat) or the potable water
ci
rcuit (in the case of WHI sol/aqua), taking into consideration the technical limit values
indicated in this manual. Due to its design, the station may only be installed and
operated as described in this manual!
Use only original accessories in connection with the
separation station.
Using the station contrary to its designated use will invalidate all liability claims.
2.2
Safety instructions
The following must be observed
during installation and commissioning:
•Relevant local and national regulations
•
Accident prevention regulations of the employers' liability insurance association
•Instructions and safety instructions mentioned in these instructions
WARNING
Danger of scalding due to escaping vapour!
With safety valves there is a risk of scalding due to the escape of
vapour.
During installation, check the local conditions and check whether
a discharge line must be connected to the safety group.
Observe the instructions regarding the safety valve.
The pressures for the expansion tank calculated by the
plant designer and the operating pressure of the
installation must be set.
WARNING
Risk to life and limb due to electric shock!
Prior to performing electrical work on the controller,
de-energise the system.
For more information, see enclosed installation and
operation instructions of the station controller.
Do not connect the controller to the mains until all
installation work, flushing and filling have been
completed.
This avoids an unintentional start of the motors.
The plug-in pump lines are permanently supplied with a
mains voltage of 230 V and cannot be switched off via
the controller.
CAUTION
Risk of burns!
The valves and fittings and the pumps can become heated up to
more than 100 °C during operation.
The insulation shell must remain closed during
operation.

Installation and operation instructions
Separation station
WHI sol/heat 20 #1 / 40 #1; Separation station WHI sol/aqua 20 #1 / 40 #1
2 Safety
83514202
▪ 1/2014-06 ▪Ext. PAW
6-36
CAUTION
Personal injuries and material damage due to overpressure!
Closing both ball valves in the primary circuit will separate the
safety group from the heat exchanger. Heating the storage tank
may result in high pressures, which may lead to personal injury
and material damage!
The ball valves may only be closed by skilled personnel
when service is required, after the system has been
switched off. When the system is recommissioned, all
locks must be opened again.
NOTICE
Material damage due to mineral oils!
Mineral oil products cause permanent damage in the material,
resulting in its sealing characteristics getting lost.
We cannot be held liable for damage caused by seals damaged in
this way, and nor will we give warranty replacement for such
parts.

It is imperative to prevent the EPDM from making contact
with substances containing mineral oils.
Use a silicone- or polyalkylene-based lubricant free of
mineral oil such as Unisilikon L250L and Syntheso
Glep 1 from Klüber or a silicone spray.
In sunlight the collectors will heat up considerably.
The solar fluid in the solar circuit may heat up to more than
100 °C.
Flush and fill the solar circuit
only when the collector temperatures
are below 70 °C.
NOTICE
Material damage due to high temperatures!
Since the solar fluid near the collector can be very hot, the group
of fittings must be installed at a sufficient clearance from the
collector field. It may be necessary to install an intermediate tank
in order to protect the expansion tank.
2.3
Safety measures
Immediately eliminate safety
-relevant defects and replace safety-relevant components
when they have reached the end of their service life due to their construction.
2.4
Electrical connection
When performing any work on live parts:
Observe the accident prevention regulations BGV A3 and local regulations,
Use tools according to EN 60900.
2.5
Structural modifications
Conversion measures are only allowed after prior approval in writing by the
Max Weishaupt GmbH.
Additional components
may only be installed if they were not tested together with the
machine.
Use only Weishaupt original parts.
2.6
Disposal
Dispose of the materials used properly and in an environmentally compatible manner.
In doing so, observe local regulations.

Installation and operation instructions
Separation station
WHI sol/heat 20 #1 / 40 #1; Separation station WHI sol/aqua 20 #1 / 40 #1
3 Product description
83514202
▪ 1/2014-06 ▪Ext. PAW
7-36
3
Product description
The station is a preassembled valves and fittings group checked for leakage and used to
transfer the heat from the primary circuit or
solar circuit to the secondary circuit or storage
tank/potable water circuit. It contains a preset controller and importan
t valves and fittings
and safety equipment to operate the unit:
•Ball valves in the solar circuit
and storage tank circuit (supply and return) of the
WHI sol/heat modules
•Piston valves in the potable water circuit (supply and return) of the
WHI sol/aqua modules
•
Check valves in the supply and return of the primary circuit and in the supply of
the secondary circuit to avoid involuntary gravity circulation
•Safety valves for avoiding inadmissible overpressure
•Pressure gauge to display the installation pressure in the solar circuit
•Vent valves for easy venting of the solar circuit
•Flushing and filling valves and fittings with sealing caps to flush, fill and drain
the solar circuit
•A flow meter (FlowRotor) and temperature sensors for power-dependent speed
control of the pumps and heat balance (primary)
The expansion tank necessary for operation must be adjusted to the size and requir
e-
ments of the installation and ordered separately. A connection for it is provided below the
pressure gauge.

Installation and operation instructions
Separation station
WHI sol/heat 20 #1 / 40 #1; Separation station WHI sol/aqua 20 #1 / 40 #1
3 Product description
83514202
▪ 1/2014-06 ▪Ext. PAW
8-36
Example: WHI sol/heat 20 #1
WHI sol/heat 20 #1 and 40 #1
Connections
1
Primary side: flow from collector
2
Primary side: return to collector
3
Secondary side: return from buffer tank (cold)
4
Secondary side: flow to buffer tank (hot)
Equipment
A
Safety group with safety valve 6 bars, pressure gauge
and expansion tank connection
B
Return ball valve with check valve
C
Primary pump
D
Temperature sensor NTC 5K
E
Secondary pump
F
Return ball valve
G
Flow ball valve with check valve
H
Temperature sensor NTC 5K
I
Safety valve 6 bars
(Only for protection of the station.
Does not replace the
safety valve that must be installed on-site.)
J
Heat exchanger
K
Airstop with manual vent valve
L
FlowRotor with Hall sensor and vent plug
M
Flow ball valve with check valve

Installation and operation instructions
Separation station
WHI sol/heat 20 #1 / 40 #1; Separation station WHI sol/aqua 20 #1 / 40 #1
3 Product description
83514202
▪ 1/2014-06 ▪Ext. PAW
9-36
Example: WHI sol/aqua 20 #1
WHI sol/aqua 20 #1 and 40 #1
Connections
1
Primary side: flow from collector
2
Primary side: return to collector
3
Secondary side: return from DHW storage tank (cold)
4
Secondary side: flow to DHW storage tank (hot)
Equipment
A
Safety group with safety valve 6 bars, pressure gauge
and expansion tank connection
B
Return ball valve with check valve
C
Primary pump
D
Temperature sensor NTC 5K
E
Secondary pump
F
Piston valve with drain valve, return
G
Piston valve with drain valve, supply
H
Temperature sensor NTC 5K
I
Safety valve 10 bars, suitable for domestic water
(Only for protection of the station. Does not replace the
safety valve that must be installed on-site.)
J
Heat exchanger
K
Non return valve with drain valve
L
Airstop with manual vent valve
M
FlowRotor with Hall sensor and vent valve
N
Flow ball valve with check valve

Installation and operation instructions
Separation station
WHI sol/heat 20 #1 / 40 #1; Separation station WHI sol/aqua 20 #1 / 40 #1
3 Product description
83514202
▪ 1/2014-06 ▪Ext. PAW
10-36
3.1
Function
To protect the
solar circuit of a thermal solar system from frost, it is filled with a
propylene glycol/water mixture. The heat produced by solar energy is required in the
heating circuit or else in the potable water mains.
In small installati
ons, this function is performed in most cases by a plain tube heat
exchanger integrated into the storage tank. When the collector fields become larger,
the transfer capacity of these heat exchangers is no longer sufficient.
In large systems, the function
of separation stations is to transmit the heat energy
collected in the collector to the heating water circuit or to the potable water mains.
The centrepiece of these modules is a plate heat exchanger, whose cross
-
flow operating
mode allows excellent heat
transfer.
The operating conditions in the heat exchanger vary, due to variations in radiation, buffer
temperatures and different system requirements.
For optimum operation of the overall system, the flow rates in the heat exchanger must
be adapted to the
relevant control target and current situation.
To this end, high
-efficiency pumps, which have an extremely wide control range, are
used in the WHI sol modules. This allows the control
ler to adapt the pumps optimally to
the momentarily required flow rate w
ithin a very broad application range.
Moreover, the pumps used save far more than 50% of the electrical drive energy
compared with customary asynchronous pumps.
The control
ler is delivered preset, assembled and wired, thus ensuring easy adjustment
to the real system.
The use of flow rate sensors in the WHI sol modules moreover offers an integrated heat
quantity measurement
.
The WHI sol modules are equipped with safety, locking
and flushing valves and fittings,
allowing the solar system to be commissioned safely and quickly.
The WHI sol/hea
t modules are intended for operation in heating installations.
In contrast, the WHI sol/aqua modules are used for separating the
solar circuit from the
potable water mains.

Installation and operation instructions
Separation station
WHI sol/heat 20 #1 / 40 #1; Separation station WHI sol/aqua 20 #1 / 40 #1
3 Product description
83514202
▪ 1/2014-06 ▪Ext. PAW
11-36
3.2
Technical Data Separation stations
Separation station WHI sol/heat 20 #1
Separation station WHI sol/heat 40 #1
Dimensions
Separation station WHI sol/aqua 20 #1
Separation station WHI sol/aqua 40 #1
Total height
795 mm
829 mm
Total width
674 mm
676 mm
Total depth
298 mm
298 mm
Center distance, supply/return
120 mm
120 mm
Pipe connection prim
G ¾" female thread
G 1" female thread
Pipe connection sec: WHI sol/aqua
G ¾" female thread
G 1" female thread
Pipe connection sec: WHI sol/aqua G 1" male thread, flat sealing G 1¼" male thread, flat sealing
Connection for expansion tank
G ¾" male thread, flat sealing
Safety valve outlet:
G ¾" female thread
Operating data
Max. admissible pressure
prim.: 6 bars
sec. sol/heat: 6 bars; sol/aqua: 10 bars
Max. operating temperature
120 °C
Max. stagnation temperature
140 °C
Max. propylene glycol content
50 %
Max. power Qmax 30 kW at SUPprim. 120 °C / RETprim. 100 °C 60 kW at SUPprim. 120 °C / RETprim. 100 °C
Flow rate at Qmax prim.: 1250 l/h, sec.: 1290 l/h prim.: 2500 l/h,
sec. sol/heat: 2500 l/h; sol/aqua: 2600 l/h
Operating temperature sensors
-25 °C to +120 °C
Equipment
Safety valve WHI sol/heat
prim: 6 bars / sec: 6 bars
Safety valve WHI sol/aqua
prim: 6 bars / sec: 10 bars
Pressure gauge
prim: 0-6 bars
Heat exchanger
30 plates
60 plates
Flow meter FlowRotor, measuring range: 2-50 l/min, 55 pulses/litre
Sensors
3 NTC 5 K (built-in)
Check valves (in ball valves)
prim: 2 x 200 mm wc, can be opened
sec: 1 x 200 mm wc, can be opened
Material
Valves and fittings
Brass
Seals
EPDM
Check valves
Brass
Pipes
1.4404 (AISI 316 L)
Insulation
EPP,
λ
= 0.038 W/(m K), fire class B2
Heat exchanger
Plates + connecting pieces: 1.4401 (AISI 316) / Solder: 99.99% pure copper
Admissible medium
Prim.: Propylene glycol (max. 50%)
Sec. sol/heat: Heating water according to VDI 2035 / Austrian standard H 5195-1
Sec. sol/aqua: Chloride content <80 ppm

Installation and operation instructions
Separation station
WHI sol/heat 20 #1 / 40 #1; Separation station WHI sol/aqua 20 #1 / 40 #1
3 Product description
83514202
▪ 1/2014-06 ▪Ext. PAW
12-36
3.3
Technical Data Pumps
UPM2
15-75 CIL
Solar PM2
15-65
Solar PM2
15-145
Solar PML
25-145
UPM GEO
25-85
UPML GEO
25-105 N
Length
130 mm
180 mm
Connections
1" male thread
1½" male thread
Protection class
IP 44
Max. pressure
1.0 MPa (= 10 bars)
Max. temperature
95 °C TF 95
I (1/1)
0.04-0.52 A
0.04-0.40 A
0.06-0.68 A
0.07-1.16 A
0.06-0.71 A
0.06-1.16 A
P1
3-70 W
3.5-48 W
7-69 W
6-140 W
5-87 W
6-140 W
Use in:
WHI sol/heat 20 #1
Sec
Prim
WHI sol/aqua 20 #1
Sec Prim
WHI sol/heat 40 #1
Prim
Sec
WHI sol/aqua 40 #1
Prim
Sec
Prim = primary side (solar) / Sec = secondary side (heating / potable water)
3.4
PWM input signal (solar profile)
PWM input signal
[%]
Pump status
< 6 Standby
6-8 Hysterese
9-15 Min. speed
16-90 Linear increase in
speed from rpm
min. to rpm max.
91-100 Max. speed
Speed
PWM input signal [%]
Min.
Stop
Max.

Installation and operation instructions
Separation station
WHI sol/heat 20 #1 / 40 #1; Separation station WHI sol/aqua 20 #1 / 40 #1
3 Product description
83514202
▪ 1/2014-06 ▪Ext. PAW
13-36
3.5
Hydraulilc performance data
WHI sol/heat 20 #1 or WHI sol/aqua 20 #1
WHI sol/heat 40 #1 or WHI sol/aqua 40 #1
Heating PM2 15-65
Solar PM2 15-145
Potable water UPM2 15-75 CIL
Flow rate [l/h]
Heating UPM GEO 25-85
Solar PML 25-145
Potable water UPML GEO 25-105 N
Flow rate [l/h]
Residual delivery pressure [mbars]
Residual delivery pressure [mbars]

Installation and operation instructions
Separation station
WHI sol/heat 20 #1 / 40 #1; Separation station WHI sol/aqua 20 #1 / 40 #1
4 Installation
83514202
▪ 1/2014-06 ▪Ext. PAW
14-36
4
Installation
4.1
Assembly
The installation site must be dry, stable and frostproof. Furthermore, access to the
control
ler and safety equipment must be guaranteed at all times during operation!
The
discharge line of the safety equipment should be guided into heat-resistant
collec
tion tanks of suitable size. This prevents uncontrolled discharging into the
environment and enables the circuits to be refilled!
Due
to their construction, the WHI sol/aqua modules reduce the precipitation of scale in
the heat exchanger. For systems with
a high total domestic water hardness and/or high
temperatures, a water treatment is recommended, in order to prevent scale formation.
NOTICE
Material damage due to high temperatures!
Since the solar fluid near the collector can be very hot, the group
of fittings must be installed at a sufficient clearance from the
collector field.
It may be necessary to install an intermediate tank in order to
protect the expansion tank.
Separation station WHI sol/heat 20 #1
Separation station WHI sol/heat 40 #1

Installation and operation instructions
Separation station
WHI sol/heat 20 #1 / 40 #1; Separation station WHI sol/aqua 20 #1 / 40 #1
4 Installation
83514202
▪ 1/2014-06 ▪Ext. PAW
15-36
Separation station WHI sol/aqua 20 #1
Separation station WHI sol/aqua 40 #1
1. For assembly, a drilling pattern can be used as mounting aid.
2. Copy the dimension for the mounting holes to the mounting surface.
3. Maintain a lateral clearance of 200 mm on the right and left of the station.
4. Drill holes and insert the enclosed wall plugs into the drill holes. Make sure that
the ground has sufficient load-carrying capacity.
5. Screw in the screws, allowing them to protrude about 40 mm from the wall.
6. Remove the station from the packaging.
7.
Pull off the front half the insulation. Hang the station into the wall and tighten the
screws.

Installation and operation instructions
Separation station
WHI sol/heat 20 #1 / 40 #1; Separation station WHI sol/aqua 20 #1 / 40 #1
4 Installation
83514202
▪ 1/2014-06 ▪Ext. PAW
16-36
4.2
Hydraulic connection
1. Pipe the separation station with the system according to the diagram below.
Pipe gap from the wall
(primary) = 95 mm
Pipe gap from the wall
(secondary) = 167 mm
1
Primary side: supply from collector
Connection:
WHI sol/heat and sol/aqua 20 #1: ¾" female thread
WHI sol/heat and sol/aqua 40 #1: 1" female thread
2
Primary side: return to collector
Connection:
WHI sol/heat and sol/aqua 20 #1: ¾" female thread
WHI sol/heat and sol/aqua 40 #1: 1" female thread
3
Secondary side: return from buffer tank (cold)
Connection:
WHI sol/heat 20 #1: ¾" female thread
WHI sol/aqua 20 #1: 1" male thread, flat sealing
WHI sol/heat 40 #1: 1" female thread
WHI sol/aqua 40 #1: 1¼" male thread, flat sealing
4
Secondary side: supply to buffer tank (hot)
Connection:
WHI sol/heat 20 #1: ¾" female thread
WHI sol/aqua 20 #1: 1" male thread, flat sealing
WHI sol/heat 40 #1: 1" female thread
WHI sol/aqua 40 #1: 1¼" male thread, flat sealing
2. Assemble the safety group consisting of safety valve [c], fill valve [d] and
pressure gauge [e] on the connection of the return ball valve [b].
3. Connect the expansion tank below the pressure gauge [e].
For service work on the expansion tank, we recommend assembling 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 prevent dirt particles from being flushed in.
4. Adapt the initial pressure of the expansion tank to the system and connect the
expansion tank. Observe the separate instructions for the expansion tank!
5. Check all screw connections and retighten them, if necessary.

Installation and operation instructions
Separation station
WHI sol/heat 20 #1 / 40 #1; Separation station WHI sol/aqua 20 #1 / 40 #1
4
3B
Installation
83514202
▪ 1/2014-06 ▪Ext. PAW
17-36
4.3
Controller connection
WARNING
Risk to life and limb due to electric shock!
Prior to performing electrical work on the controller,
de-energise the system.
For more information, see enclosed installation and
operation instructions of the station controller.
Do not connect the controller to the mains until all
installation work, filling and flushing have been
completed.
This avoids an unintentional start of the motors.
The plug-in pump lines are permanently supplied with a
mains voltage of 230 V and cannot be switched off via
the controller.
1.
Connect the neutral conductor (N) and the protective earth (PE) using the screw
terminals shown in the controller manual and in the figure opposite.
2. Connect the outer conductor (L) to the bus bar in the controller housing. To do
so, lift the lower lever and clamp the line pressing the lever down. Next check
whether the line is firmly clamped.
3. The bus bar has already been connected to the screw terminal (L) of the
controller and the pump lines for constant power supply. Due to the high power
consumption of the pumps, the latter are not supplied with 230 V via relays, but
permanently connected to the mains supply.
The speed control (0-100%) of the pumps is effected via the PWM control
signal.
4.4
Electrical connection of the solar controller WRSol2.1
Terminal
Acronym
Description
Execution
L/N
230V
Mains connection 230 V
on site
L/N
PS
Solar circuit pump
prewired
L/N
PWT
Secondary circuit pump
prewired
11/┴
TK1
Collector sensor
on site
12/┴
TWT
Secondary circuit outlet sensor
prewired
13/┴
TU1
Storage tank sensor, bottom
on site
17/┴
PWM2
PWM control signal for pump PWT
prewired
18/┴
PWM1
PWM control signal for pump PS
prewired
19/┴
TKR
Solar circuit return sensor
prewired
20/┴
TKV
Solar circuit supply sensor
prewired
21/25/┴
V1
Volume pulse input solar circuit
prewired

Installation and operation instructions
Separation station
WHI sol/heat 20 #1 / 40 #1; Separation station WHI sol/aqua 20 #1 / 40 #1
5 Operation
83514202
▪ 1/2014-06 ▪Ext. PAW
18-36
5
Operation
A detailed description of the operation of
the controller can be found in the enclosed
controller manual.
5.1
Pressetting solar controller WRSol2.1
Hydraulic version 2
Selected option: TKV, VIZ/TKR
Pulse rate 55 pulses/litre
Max. flow rate:
WHI sol/heat or sol/aqua 20 #1: 1250 l/h
WHI sol/heat or sol/aqua 40 #1: 2500 l/h
6
Commissioning
Observe the following safety instructions regarding the commissioning of the station:
WARNING
Risk of burns and scalding!
The valves and fittings may heat up to more than 100 °C. This is
why the installation may not be flushed or filled while the
collectors are hot. Please note that hot solar fluid will leak from
the safety valve when the system pressure is too high!
During venting the solar fluid may escape as vapour and result in
scalding!
Flush and fill the system only when the collector
temperatures are below 70 °C.
NOTICE
Risk of frost!
It often happens that solar systems cannot be completely drained
after flushing. Thus, there is a risk of frost damage later on when
flushing with water. Therefore, only use the solar fluid used later
on for flushing and filling the solar system.
Use a water/propylene glycol mixture with max. 50% of
propylene glycol as solar fluid.
NOTICE
Note regarding the commissioning sequence
Flush and fill in the following sequence:
1. Flush the storage tank (to remove scale residues).
2. Fill the storage tank circuit.
3. Vent the heat exchanger via the safety valve.
4. Flush and fill the solar circuit of the heat exchanger.
5. Flush and fill the collector field.
6. Flush and fill the solar circuit (total).
This guarantees that no dirt particles are flushed into the heat
exchanger and that any heat absorbed can be dissipated.

Installation and operation instructions
Separation station
WHI sol/heat 20 #1 / 40 #1; Separation station WHI sol/aqua 20 #1 / 40 #1
6 Commissioning
83514202
▪ 1/2014-06 ▪Ext. PAW
19-36
6.1
Preparation for flushing and filling
NOTICE
Note regarding the expansion tank
To prevent any dirt particles contained in the solar system from
being flushed into the expansion tank, some manufacturers
recommend disconnecting the expansion tank from the solar
circuit during flushing and filling. Please observe the
manufacturer's instructions.
6.2
Flushing and filling the storage tank circuit / potable water circuit
(lower connections)
The storage tank and potable water circuits are filled by means of the valves and fittings
of the heating system. To prevent dirt particles from entering the heat exchanger, shut
the ball valves or piston valves of the station and flush dirt particles/scal
e residues from
the storage tank before commissioning.
Make sure to only use admissible medium (see
chapter 3.2).
1. Open the ball valves [C|D] of the WHI sol/heat module or the piston valves of
the WHI sol/aqua module [C|D] and disable the check valves
(45°, see next page).
2. Vent the storage tank circuit or potable water circuit by actuating the fill and
drain valve [A].
3. Make sure that no water enters the electrical components.
4. Fill the storage tank circuit or potable water circuit.
5. After filling the storage tank circuit or potable water circuit is complete, set the
required operating pressure.
6. Vent the station during commissioning on the fill and drain valve [A], to remove
any air that may still be present in the heat exchanger.
It may be necessary to vent the pump (unscrew screw on pump head).
Separation station WHI sol/heat 20
Separation station WHI sol/aqua 20

Installation and operation instructions
Separation station
WHI sol/heat 20 #1 / 40 #1; Separation station WHI sol/aqua 20 #1 / 40 #1
6 Commissioning
83514202
▪ 1/2014-06 ▪Ext. PAW
20-36
6.3
Flushing and filling the solar circuit (upper connections)
The fill and drain valves required for flushing and filling have been integrated into the
separation station
. Make sure that dirt particles that may be present in the system are
not flushed into the heat exchanger and into the expansion tank. To do so, it may be
necessary to disconnect the expansion tank during flushing and filling and to use only
flushing and fil
ling stations that are equipped with suitable microfilters.
The
solar circuit is flushed in the normal direction of flow. This is why you should make
sure that the solar circuit pump is not on.
Ball valve with integrated check valve
(Normal direction of flow in the picture: downstream)
0°
45°
90°
Check valve in operation,
through-flow in flow direction
only.
Check valve not in operation,
through-flow in both
directions.
Ball valve closed,
no through-flow
.
To actuate the ball
valve, a handle is included in the delivery.