Zuwa Solarcheck Mobilcenter UNISTAR 2000-A User manual

SOLARCHECK MOBILCENTER UNISTAR 2000-A
SOLARCHECK MOBILCENTER UNISTAR 2000-B
Operating Instructions
Solar Filling Unit
-Zumpe GmbH
Pumps and Sprayers

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Operating Instructions
Solarcheck Mobilcenter UNISTAR 2000-A
Solarcheck Mobilcenter UNISTAR 2000-B
Content
1. Declaration of conformity................................................................................ 3
2. Introduction .................................................................................................... 3
2.1 Legend ....................................................................................................... 3
2.2 General safety instructions ......................................................................... 4
3. Transportation and unpacking........................................................................ 5
4. Mounting and commissioning......................................................................... 6
5. End of operation............................................................................................. 8
6. Maintenance................................................................................................... 8
6.1 Connections................................................................................................ 8
6.2 Cleaning the filter........................................................................................ 8
6.3 Disassembling the pump ............................................................................ 9
6.4 Replacing components ............................................................................... 9
6.5 Assembling the pump ................................................................................. 9
7. Troubleshooting ........................................................................................... 10
8. Accessories.................................................................................................. 11
9. Parts lists ..................................................................................................... 12
9.1 Solarcheck Mobilcenter UNISTAR 2000-A ............................................... 12
9.2 Solarcheck Mobilcenter UNISTAR 2000-B ............................................... 14
10. Technical data.............................................................................................. 16

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1. Declaration of conformity
The product complies with the requirements of the applicable european
directives. The conformity was declared. The documents to which the
declaration relates and the original declaration of conformity are
available at the manufacturer.
2. Introduction
Intended use
The filling unit is designed for filling, flushing and venting thermal solar systems and
heat pump systems. Any other use or extended use is considered to be
improper. The manufacturer is not liable for any resulting damage.
Notes on the documentation
This manual provides important information for a safe and correct operation of the
solar filling unit Solarcheck Mobilcenter UNISTAR 2000-A and Solarcheck
Mobilcenter UNISTAR 2000-B.
The manual is designed for qualified personnel who are trained and specialised in
installing heating systems. Service and maintenance works must only be carried out
by approved specialists.
Subject to technical modifications
The continuous development and improvement of our products may cause minor
modifications of technical data and illustrations.
2.1 Legend
Danger: immediate danger of death and severe injury
Danger: danger of death from electric shock
Danger: danger of scald burn
Danger of environmental and material damage
Information, note

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2.2 General safety instructions
Store these instructions in such a way that they are accessible at all times for
operating personnel!
In addition to these operating instructions the following documents of related
components and of the pumping media should be applicated:
 technical specifications
 material safety data sheets
 operating instructions
The manufacturer shall not be held liable for damage resulting from non-
adherence to the operating instructions.
Danger
Danger of death due to electric shock
> Prior to work on the pump, always disconnect the drive from the
power supply.
Danger
Danger of death due to explosion
> Do not pump any liquids with a flash point of less than 55 ° C.
> Do not pump petrol or solvents.
Danger
Danger of scald burn due to high media temperature
> Fill the solar system only when cold – if necessary cover the solar
collectors.
Danger of burn due to hot motor casing
> Do not block neither suction nor pressure hose more than 1 minute
to avoid overheating of the motor.
Warning
Danger of injury due to splashing liquid
> Connect the hoses tightly to the pump.

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Caution
Material damage due to dry running
> Never allow the pump to run dry for more than 1 minute.
Material damage due to tilting of the cart on uneven ground
> Operate the filling unit only on even ground.
Danger of environmental damage due to hazardous pumped media
> Collect escaping pumped media and dispose of according to the
locally applicable regulations.
Material damage due to improper storage
> Prior to extended periods of pump down time clean pump to avoid
adhesions and damage to the impeller.
> Store pump under frost-protected conditions.
3. Transportation and unpacking
> After unpacking, immediately check the filling unit for completeness and damage.
> Immediately report any transit damage to the supplying company.
> Dispose of packaging material according to the respective local regulations.

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4. Mounting and commissioning
1. Connect filling hose to pump outlet. 2. Connect return hose to tank.
3. Connect filling hose (1) and return
hose (2) to the fill/vent valves and
open valves. Close stop valve (3).
4. Fi .
ll tank and open ball valve
5. Insert cable of pump motor into
socket.
6. Switch on pump.
2
1
3

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7. Open tank lid to ensure the circulation
of the air.
Caution: Monitor fluid level in the tank and, if
necessary, refill heat transfer fluid to prevent
air entering the solar circuit.
8. Flush the solar circuit with the fluid.
Check at the vision panel of the filter or
through the tank opening if there are
still air bubbles in the heat transfer fluid.
Continue flushing until there is no air
remaining in the fluid.

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tation.
> p valve (3) between fill and vent valve.
u
check Mobilcenter UNISTAR 2000-A:
n release the pressure that is
d let the
Afte filling hose easily from the fill valve.
ose from fill and vent valve.
piece in order to
5. End of operation
3
1
2
After filling and flushing the solar system:
> Switch off pump.
> Close fill and vent valve (1+2) at the solar s
Open sto
Ca tion: Collect escaping pumped media in a
container.
Only Solar
By opening the drain valve at the pump outlet you ca
generated between pump outlet and fill valve when flushing the pipe:
> Turn the green handwheel of the drain valve at the pump outlet an
remaining liquid run out.
r that you can unscrew the
Solarcheck Mobilcenter all types:
> Unscrew filling hose and return h
> Screw open hose ends together with the provided connecting
avoid dripping or escaping of fluid during transport.
6. Maintenance
Dange
Danger of death due to electric shock
connect the drive from the power
r > Prior to work on the pump, always dis
supply.
Caution
Danger of environmental damage due to hazardous pumped media
lly> Collect escaping pumped media and dispose of according to the loca
applicable regulations.
6.1 Connections
> Check regularly if hose couplings are tight.
suction side of the pump to filter out sold and
rainer and clean both with rinsing water
6.2 Cleaning the filter
There is a built-in fine filter on the
welder residues. Check the vision panel at the filter regularly and clean the filter
when you see dirt deposits on the strainer.
> Screw off the filter casing, remove the st
or compressed air.

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6.3 Disassembling the pump
1. Disconnect line connections
2. Unscrew bolts on the pump side
3. Remove cover and side disc
4. Pull housing with impeller and rear side disc off the shaft
6.4 Replacing components Outlet
Intake
Impeller
To change the impeller we recommend to use a
special tool. See chapter 8, Accessories.
> Push impeller out of the casing
> Insert a new impeller. Observe direction of
impeller wings (see adjacent illustration):
Impeller wings must be bent to the
opposite side of the rotating direction.
Lateral discs
> Turn around or replace
Seals
> Replace O-rings and push firmly into the recesses
Replacing shaft gasket:
1. Remove retaining ring with suitable pliers
2. Push out bearing and shaft gasket
3. Push in new shaft gasket and bearing
4. Insert retaining rings
6.5 Assembling the pump
Assembly of the pump is the reverse of disassembly – see exploded drawing.
1. Connect lateral disc with punched hole to the rear of the casing
2. Push casing with impeller and second lateral disc onto the shaft
3. Insert and tighten bolts
4. Attach lines
The lateral discs and O-rings must lie precisely in the recesses to ensure
that the O-rings are not pinched.

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7. Troubleshooting
Fault Possible cause Remedy
Intake line is not leaktight Seal connection or line
Impeller worn or damaged Replace impeller
Suction line or foot valve is
blocked
Clean suction line or foot
valve
Pressure line closed or
blocked
Open fittings on the pressure
side or clean pressure line
Pump does not take in
liquid
Ball valve at the tank outlet
closed or tank empty
Open ball valve or fill tank
Impeller or lateral discs are
worn
Replace impeller or lateral
discs
Filter clogged Clean filter (see chapter 6,
Maintenance)
Pump does not build up
pressure
Ball valve at the tank outlet
closed
Open ball valve
Liquid escapes from the
pump
Shaft gasket or O-ring is
missing or defective
Check whether part is in
place and insert or replace
defective component
Impeller blocked Fill pump with the medium to
be pumped
Impeller clogged up or
macerated
Use an impeller appropriate
to the medium
Pump does not start
Motor defective Have motor checked by
specialist personnel and have
repaired if necessary

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8. Accessories
 Multifunction valve with bypass for mixing the heat transfer medium on-site
 Kit for filling ground loops including two 150 litre tanks, hose extension, additional
stop valves and multifuncion valve to switch the suction line from external tanks
to internal tank
 Remote control with 10 metre cable
 Tool for changing the impeller
A useful tool to install the impeller easily into the casing. Suitable for all ZUWA
impellers. Order No.: 110 124 00
tool for changing the impeller

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9. Parts lists
9.1 Solarcheck Mobilcenter UNISTAR 2000-A
30
60
71-73
70
40
20
80
10
Pos.: Part / Designation Code Number
10 Chassis 13405110BT 1
20 Inflatable wheel 80120 2
30 30 litre tank 13405 1
40 Steam suction hose 13 x 6 30026 1
60 Steam hose 13 x 6 3 m 131123 2
70 T-piece brass 3 x ¾“ internal thread 80110 1
71 Reducer plug ¾"- ⅜" internal thread 132236 1
72 Drain valve ⅜" 132232 1
73 Threaded nipple brass ¾" x ¾" external thread 131215 1
80 Pressure pipe filter series 324-o ½" int. thread 53240T0235 1

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140180
200
260
220
210
230
110
120
150
130
250 190
170
240
160
140
Pos.: Part / Designation Code Number
110 Hexagon screw M5 x 55 70031 4
120 Front plate 11012002 1
130 Lateral disc – stainless steel 11012009 1
140 O-ring 56-2 NBR 80003 3
150 Perbunan impeller narrow with brass bush 11012907 1
160 Housing UNISTAR-A small 11012001 1
170 Lateral disc stainless steel with hole 11012709 1
180 Rotary shaft seal NBR 14 x 26 x 7 80537 1
190 Locking ring I 26 x 1,2 70284 1
200 Rear plate 12000502 1
210 Fitting key A 3 x 3 x 16 70315 1
220 Control box 80628 1
230 Handle for CEG motor 14000202 1
240 Motor base FUSS00071 1
250 Fan cover for CEG motor 80621 1
260 Motor 230 V; 0,37 kW; 2800 rpm 80607 1

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9.2 Solarcheck Mobilcenter UNISTAR 2000-B
80
60
30
90
Pos.: Part / Designation Code Number
10 Chassis 13405110BT 1
20 Inflatable wheel 80120 2
30 30 litre tank 80105 1
40 Steam suction hose 19 x 7 30028 1
60 Steam hose 19 x 7 3m 30087 2
70 Threaded nipple 1“ internal x ¾“ external thread 131062 1
80 Pressure pipe filter series 324-o ½" internal thread 53240T0235 1
90 Reducer plug 1" internal x ½" external thread 52452024 1
10
20
70
40

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180
260
210
110
120
130
150
160
140
170
230
220
190
250
240
200
Pos.: Part / Designation Code Number
110 Hexagon screw M5 x 75 70312 4
120 Front plate 11012009 1
130 Lateral disc – stainless steel 11012009 1
140 O-ring 56-2 NBR 80003 3
150 Perbunan impeller wide with brass bush 11012910 1
160 Housing UNISTAR-B 11013008 1
170 Lateral disc stainless steel with hole 11012709 1
180 Rotary shaft seal NBR 14 x 26x 7 80537 1
190 Locking ring I 26 x 1,2 70284 1
200 Rear plate 12000502 1
210 Fitting key A 3 x 3 x 36 70317 1
220 Switch box motor 80628 1
230 Handle for CEG motor 14000202 1
240 Motor base FUSS00071 1
250 Fan cover for CEG motor 80621 1
260 Motor 230 V; 0,55 kW; 2800 rpm 80606 1

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10.Technical data
Solarcheck Mobilcenter UNISTAR 2000-A UNISTAR 2000-B
Voltage 230 V 230 V
Frequency 50 Hz 50 Hz
Maximum power consumption 370 W 550 W
Maximum fluid temperature 80 °C 80 °C
Approved pumping media water, heat transfer medium
Maximum operating pressure 4 bar 4 bar
Maximum flow rate
with water / heat transfer medium 30 / 27 L/min 60 / 55 L/min
Diameter return hose / pressure hose Inch ½ / ½ Inch ¾ / ¾
Tank content 30 L 30 L
Motor protection class IP 55 IP 55
Dimensions (height/width/depth) 985/495/555 mm 985/495/555 mm
Weight without packaging
(empty tank) 21 kg 23 kg

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ZUWA-Zumpe GmbH
Franz-Fuchs-Straße 13 - 17 • D-83410 Laufen
Fon: [phone] • Fax: [phone]
e-Mail: [email protected] • Internet: www.zuwa.de
© 2008ZUWA