HOT TAP WATER EXCHANGER with solar pump-group ENSOL IT INSTALLATION AND OPERATION MANUAL WARRANTY CARD

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1 HOT TAP WATER EXCHANGER with solar pump-group ENSOL IT INSTALLATION AND OPERATION MANUAL WARRANTY CARD

2 Contents: 1. Structure and Intended Use Safety devices and conditions for safe use of exchangers Installation Operation and service Warranty conditions Before you install and activate the exchanger, please read this "Installation and Operation Manual" and Terms and Conditions of the Warranty Attachments: 1. Operating instructions of the STDC controller 2. Operating instructions of the Solar 3 two-way solar station 3. Installation, start-up and operating manual of the expansion vessel along with warranty conditions and warranty card NOTE! Correctly filled in, complete and not modified warranty cards of the ENSOL IT exchanger and expansion vessel as well as operating instructions of the STDC controller and the solar station with entries of ZUG ELEKTROMET are the prerequisite for granting the right to warranty repairs. 2

3 1. Structure and Intended Use ENSOL IT exchangers with solar pump group are pressure storage water heaters that are designed to heat and store hot tap water, in systems with solar collectors, for needs of flats, detached houses and multi-family buildings, public utility buildings, industrial facilities and others. ENSOL IT 200 i 300 exchangers have been adapted for installation in rooms with doors that are up to 70 cm wide. The exchangers (rys.1) are equipped with: - two independent helical coils, allowing the connection of two power sources with different heating media, such as solar collectors with a glycolbased heating medium or e.g. low-temperature central heating water boiler, - two-way pump group (2) integrated with the controller for the solar systems (3), - expansion vessel (4). The two-way pump group includes: - circulating pump in solar design, - flow meter with control valve and two stubs: filling and drain, - three-way cut-off check valve with thermometer (blue) and connecting stub for safety group, - 6 bar safety valve with manometer and connecting stub for expansion vessel, - cut-off check valve with thermometer (red), - vent. The controller used for solar systems is equipped, among others, with smoothly controlled pump rotating speed, heat meter function, graphical statistics, 7 language versions etc. Two temperature sensors are connected to the junction box (5): S1- collector and S2 - vessel. Detailed data and information about the controller settings are given in the attached Installation and operating manual. Pressure tanks in these heat exchangers are made of steel sheet covered inside with a layer of a special high-temperature vitreous enamel, forming glass coating that protects them from corrosion and ensures clean healthy water. Additional corrosion protection of the tanks is the magnesium anode that owing to the difference of electrochemical potentials of steel and magnesium in water, generates protective current for the tank. Thermal insulation is made of PS expanded polystyrene permanently joint to tank walls. The outside coating of the exchangers is made of plastic. ENSOL IT exchangers are designed for installation of an electric heating element on the 1½" plug, especially EJK type heating element produced by ZUG ELEKTROMET with insulated heating units (Tab. 2), which do not consume protective current generated by the magnesium anode for the corrosion protection of the tank. This increases the durability of the tank and the life of the magnesium anode. 3

4 The structure and dimensions of exchangers are shown in Fig. 1, whereas their connection dimensions and technical parameters in Tab. 1. S1 S2 ENSOL IT 200 ENSOL IT tank with two coils 2 two-way solar pump group 3 - controller 4 expansion vessel 5 junction box with sensors (S1 - collector; S2 - vessel) - ~230V/50Hz Fig. 1 Construction of the ENSOL IT exchanger ENSOL IT 500 4

5 Tab. 1 Dimensions and technical parameters of ENSOL IT Type Capacity Height Max. height on the slope Diameter ENSOL IT H H* D Cold water Hot water Heating water power upper coil Heating water return upper coil Heating water power solar coil Heating water return solar coil Circulation Socket heater I P O E B F K A ZW CW WEG WYG WES WYS RC MG ¾ ¾ 1¼ ¾ ¾ 1¼ ¾ ¾ ¾ ½ 1½ 1½ Magnesium anode ø x L 40 x x x 500 Wash out hole W /166/195 Thermal isolation Mass M [kg] mm Polyuretane foam 100 mm Polystyrene foam

6 Type Capacity ENSOL IT COIL BOILER COIL SOLAR Exchange surface Capacity of coil Efficiency of hot water 80/10/45 C 70/10/45 C 60/10/45 C Heating power 80/10/45 C 70/10/45 C 60/10/45 C m² 0,8 1,0 1,4 dm³ 4,3 5,7 8,0 dm³/h kw Efficiency of hot water 80/10/60 C 70/10/60 C dm³/h Heating power 80/10/60 C 70/10/60 C kw 15,4 11, ,2 18,8 13,7 Exchange surface of coil m² 1,1 1,4 1,9 Capacity of coil Efficiency of hot water 80/10/45 C 70/10/45 C 60/10/45 C Heating power 80/10/45 C 70/10/45 C 60/10/45 C The maximum surface of the absorber connected solar Heating losses Parameters of the tank work Parameters of the upper coil work Parameters of the solar coil work Thermal isolation Magnesium anode Expansion vessel Mass ,2 18, ,5 19,6 dm³ 6,4 8,0 10,7 dm³/h kw ,7 15,8 11, ,6 20,5 15, ,3 27,7 20,6 m² 2, kwh/24h 2,1 2,5 4,5 Max. pressure and temperature pr = 0,6 MPa; tr = 80 C Max. pressure and temperature pr = 1,0 MPa; tr = 90 C Max. pressure and temperature pr = 1,0 MPa; tr = 110 C 60 mm Polyurethne foam 100 mm Polystyrene foam ø x L 40 x x x 500 dm³ kg * 80 C, 70 C, 60 C - temperature of heating water in the coil supply 10 C - temperature of cold tap water on sup ply 45 C, 60 C - temperature of hot tap water 2. Safety devices and conditions for safe use of exchangers. Heaters may only be used with a functional safety valve with the opening pressure of 0.6 MPa (water pressure in the water supply network up to 0.6 MPa) installed on the cold tap water inlet. This valve protects the 6

7 exchanger from excessive pressure in the water supply network or excessive pressure increase as a result of heating the water in the tank. Even in case of regular operation of the exchanger during heating, water may leak from the safety valve for a short time, which shows that the valve operates in a correct manner. Never obstruct the outlet hole in such cases. All types of exchangers should be used with an installed thermometer of the measuring range between 0 and 120 C, also inst all pressure gauges with the measuring range between 0 and 1 MPa. ATTENTION! 1. A safety valve has to be installed on the cold water inlet to the exchanger; the valve is supplied with the exchanger. Install it so that the arrowhead on the valve body is in line with the direction of the water flow. 2. Do not install any shut-off valves between the safety valve and the exchanger. 3. It is not permitted to use the tank without a safety valve or with a malfunctioning safety valve because the situation may result in failure and poses a threat to human life and health. 3. Installation Installation and any repairs of the exchanger in terms of electricity and water system should be entrusted only to skilled processionals with relevant permissions. 3.1 Exchanger connection to the water supply network, central heating system and solar collector. Connect the exchanger vertically to the water supply network in which the pressure does not exceed 0.6 MPa and not lower than 0.1 MPa. If the pressure in the network often exceeds 0.4 MPa, it is recommended to install a pressure reducing valve or a diaphragm reservoir before the exchanger in order to limit the inconvenient outflow of water from the safety valve. When the pressure in the water supply network exceeds 0.6 MPa, it is necessary to install the pressure reducing valve in order to avoid the continuous outflow of water from the safety valve. Perform the connection between the solar collector and exchanger according to the diagram (Fig. 2). Connect the collector output to the upper port (WES) and return to the lower port (WYS). After filling the solar system with heating medium, venting and filling the exchanger with water, connect the controller to the power supply system of 230V /50Hz (power cord extending from the junction box). 7

8 1 - ENSOL IT exchanger with: 6 central heating boiler 2 solar pump group 7 solar collector 3 controller 8 domestic hot water tap 4 expansion vessel 9 - circulation 5 junction box 10 water temperature sensor in the exchanger S1 - liquid temperature sensor in the ZW domestic cold water collector CW - domestic hot water S2 - water temperature sensor in the exchanger Fig. 2 Example installation diagram 3.2 Installation of EJK type heating element During the warranty period of the tank, only heating elements tanks suitable for enamelled tanks may be used, i.e. those with insulated heating units (insulated heating units do not "steal" protective current generated by the magnesium anode). This is one of the warranty conditions for the WGJ-SOL exchanger. EJK type heating elements by ZUG ELEKTROMET comply with this condition. Among EJK heating elements manufactured by ZUG ELEKTROMET for WGJ-SOL exchangers, you can install single phase 230 V 1.5 kw and 2.0 kw heating elements as well as three phase 400 V 3.0, 4.5 and 6.0 kw heating elements. 8

9 Install in accordance with the Installation and Operation Manual of the heaters. It is particularly important that the free end of the yellow-green protective conductor drawn from the marked connection on the casing of the heating element is connected using the M4 screw to the earth plate located on the MG connector of the tank, see Fig tank casing 2 electric EJK type heating element 3 earth wire 4 MG 1 ½'' connector 5 earth plate 6 M4 screw 7 spring washer Fig. 3 Earth of the heating element ATTENTION! During the warranty period of the tank, use only heating elements with an insulated heating unit e.g. EJK manufactured by ZUG ELEKTROMET ATTENTION! Do not insert the plug of the connection into the electrical socket without making sure that the tank is filled with water. ATTENTION! The heating element and the metal tank have to be connected with an earth cable drawn from a marked connection on the heater casing. 4. Operation and service 1. Periodically, at least once a month and before every start-up, after putting out of service, check the correct operation of the safety valve (according to instructions of valve manufacturer). 2. A temporary small outflow of water from the safety valve during heating of water in the exchanger is normal and indicates the proper operation of the safety valve. ATTENTION! Continuous leaking of water from the safety valve outlet demonstrates a malfunction of the valve or overly high pressure in the water supply system. Never obstruct the outlet hole. 9

10 3. If the exchanger is put out of service in the winter and there is a concern that the water in the exchanger may freeze, drain the water by unscrewing the safety valve. 4. The magnesium anode wears down during operation, so its condition should be checked periodically, at least once a year. The anode should be replaced if it loses 2/3 of its volume, and always at the latest after 18 months. A relevant magnesium anode can be purchased at a point of sale or from the manufacturer of exchangers. The anode is located at the top end cap of the exchanger tank; to determine its condition or replace it with a new one: - cut off the cold water supply, open the hot tap water tap for a moment, then close the outlet of hot water from the exchanger, - remove the top cover of the exchanger casing, - remove the insulation element covering the cap with the affixed anode, - unscrew the cap with the anode, - install a new anode in the reverse order, paying particular attention to tightness of connections. ATTENTION! The magnesium anode plays an important role in the corrosion protection of the enamelled tank, and its regular checking and replacement with a new one is necessary to maintain the warranty of the tank. Replaced used anodes and certification of their exchange (anode purchase) should be kept in order to make them available for the manufacturer's service personnel in case of failure of the tank. 5. Periodically, depending on water hardness, remove the accumulated sediment and loose scale. 5. Warranty conditions 1. The warranty is granted for a period of 60 months for the enamelled tank 2. The warranty for other parts of the exchanger and for: - STDC controller, - 2-way-pump-group is 24 months 3. The warranty period starts on the date of sale of the product to the user, as entered in the warranty card and confirmed by a proof of purchase (bill) issued by the vendor. 4. The guarantor ensures the efficient operation of the exchanger provided that it is installed and used in accordance with its manual. 5. During the warranty period, the user is entitled to free repair of any damage occurring through the fault of the manufacturer of the exchanger. Any damage shall be removed in 14 days after the date of notification. 10

11 6. The user loses the right to warranty repairs in case of: - installation of the tank in a system without solar collectors, - improper use of the device, - repairs and modifications of the device by unauthorised persons, - improper installation and operation of the device that is not in conformity with this manual, - use of the exchanger without the safety valve or with malfunctioning safety valve, - lack of the magnesium anode and lack of documents confirming its replacement, - use of a heating element with non-insulated electrical units. 7. The guarantor may refuse to repair if: - it is not granted service access to the device, - it is necessary to dismantle other devices, partition walls, etc. in order to replace the tank, - the tank is connected to the water supply network permanently, by means of inseparable connections. 8. In case of damages, resulting from accidents caused by the user or force majeure ( lightning, natural disasters, etc.) the cost of repairing of the device must be covered by the enduser. 9. In case of unjustified calls for service, costs of arrival shall be borne by the customer. 10. In the event of the expansion vessel failure, please inform the technical support of the company: Reflex -POLSKA Sp. z o.o. ul. Mikołaja z Ryńska Wąbrzeźno, Poland tel / , fax / In case of irregularities in the operation of the exchanger, notify manufacturer's service, tel / from 6ºº to 14ºº, or by e- mail: sekretariat@ensol.pl or point of sale. DO NOT DISMANTLE THE DEVICE. 12. The manner of repair of the equipment is determined by the manufacturer. 13. The basis for repairs under the granted warranty is a correctly filled out, complete Warranty Card of the exchangers, 2 way-pump-group and expansion tank, that contains no amendments. 14. In all matters not regulated by these conditions, relevant regulations of the Civil Code apply. 15. We recommend that you keep the Warranty Card throughout the life of the exchanger. 11

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Energetyka Solarna Ensol Sp. z o.o. 47-400 Racibórz, ul.

16 Energetyka Solarna Ensol Sp. z o.o Racibórz, ul. Piaskowa 11 Tel/fax:

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