TECHNICAL INFORMATION / INSTALLATION INSTRUCTIONS CIRCO Solar Circulation Unit CIRCO Solar Circulation Unit in combination with the intelligent SUNGO controllers, it is the safe and reliable heart of a solar installation Fast Installation thanks to pre-assembled parts and compression fittings for the connection to the solar circuit Safe Deaeration by integrated air bleeder Operation Monitoring via flow-meter and integrated thermometer Controlled Heat Flow by two temperature resistant non-return ball valves Low Heat Loss made possible by all-around heat insulation made from close fitting hard foam shell Figure 1 CIRCO Solar Circulation Unit with integrated controller (not included in delivery). Solar Thermal / Solar Circuit EN-XXX_CIRCO-_MA-10011-111Y00 1
1. General Safety Guidelines Qualification of the Installer Setting up, installation and commissioning of the CIRCO solar circulation unit must be carried out by a qualified installer. Please note that in case of a fault report the guarantee benefits can only be claimed if the correct commissioning has been certified by a qualified person in the commissioning report. The warranty period for the station is years. Use and Application Function The CIRCO solar circulation unit is suitable for solar hot water systems and solar heating support systems in connection with antifreeze solar liquid as recommended. Limitations of Use Applications are limited to the hydraulic layout of the schematics supplied by Wagner and Co. Some solar installations for space heating and the application of vacuum tube collectors do require special provisions for overheating protection, like the installation of a heat dissipation vessel or alternative positioning of the safety components (See document Solar Thermal Systems - Setup, Startup and Maintenance ). The solar circulation unit can be wall-mounted or directly installed to the storage cylinder using the cylinder mounting kits for the ECO, TERMO and RATIO line solar cylinders The CIRCO solar circulation unit must not be installed outdoors. DANGER of personal injury Electrical installation of the device can lead to potentially fatal electric shocks, scalds, contusions as well as other health hazards. Therefore please ensure to observe all information in the guidelines marked with this symbol. CAUTION against property damage This symbol indicates dangers that can result in damage to the components or significantly degrade the functionality of the solar heating system. Please ensure to carry out the installation steps described in these guidelines in the correct order. NOTE for additional information This symbol indicates practical advice which will be useful for installing and operating the device. Norms and Directives EC conformity declaration The CIRCO solar circulation unit has been designed and constructed in accordance with EU regulations. Please regard national and EU regulations and guidelines for installation work. Especially observe EN 1 and ENV 1: Thermal solar systems and components. Standards and Codes The effective standards, codes and regulations at the installation location must be observed. In Germany especially: Electrical installations and device connections must be carried out according to VDE 0100 und DIN 11 Setting up potential equalization must follow VDE 010 DIN must be observed for installation, start up and maintenance of system for domestic hot water preparation and process water heating. DIN EN V 1: Thermal solar systems and components. EN-XXX_CIRCO-_MA-10011-111Y00
. Technical Information Scope of Delivery The CIRCO solar circulation unit is supplied pre-assembled. SUNGO control and CIRCO expansion kit are not part of the unit. Additional accessories are shown on the last page. Table 1 Maximum Number of Collectors to be Installed 1 Coll.-type EURO C0 HTF/AR, C HTF/AR Serial-/parallel connection Serial connection 1 Ø Ø Ø 1 Ø Ø Ø x x x EURO L0 AR x x x 1 Simple pipe length of solar circuit up to 0 m, heat transfer medium: antifreezes/water 0/0 Vol % = l/m². Connections and connection pipes of collectors are accounted for. No. of fields with collectors connected in series each Table Volume of Expansion Vessel 1 Sys.- Coll.- Volume (l) for system height (m) vol. (l) area. (m²).. 10 1. 1 1 1 1 1 1 1 1 0. 1 1 1 1 1 10 1. 1 0 0 0 0 1 These values only apply for collecor volumes of approx. 0. l/m² Table CIRCO Solar Circulation Unit Part no. 10 01 1 Insulation EPP two parts Max. operation pressure bar Max. operation temperature 10 (during start-up phase temporarily up to 10 ) Circulation pump Wattage Max. pump head Max. flow rate Return flow stoppers Temperature display Sockets for temperature sensors Flow meter Safety group Filling unit Connection expansion vessel Connection bleeder pipe Connection solar circuit Axial pipe distance for solar circuit Installation type Dimensions (HxBxT), mm ST - (0 V, 0 Hz) -levels, //1 Watt m. m³/h x, can be disabled dial thermometers In supply and return leg one each for sensors of max. mm Ø -1 l/min Safety valve bar ½", pressure meter filling valves with cap ¾" M ¾" F Weight, kg. Slot for solar controller compression fittings, mm 100 mm Wall inst. / inst. at cylinder (with optional kit) x 0 x 1 mm Prepared for integration of SUNGO S / SL / SXL Pressure loss p [mbar] Pressure loss p [Pascal] 10³ 10 v 0 0, 1,0 1,,0 [m/s] H [m] III 10² 10 I 1 0 0 1,0,0,0 [m /h] Figure Pump characteristics curves CIRCO 10 10³ 10² 10³ Flow volume V [l/h] Figure Pressure loss diagram CIRCO EN-XXX_CIRCO-_MA-10011-111Y00
. Installation 11 1 10 1 1 1 Figure 1 Pump; Safety group; Connection (¾") for expansion vessel-set (available as accessory); Filling valve; Rear insulation shell; Front insulation shell with opening for controller; Cover (when controller not installed); Wall brackets; Bleeder; 10 Flow meter; 11 Controller mounting block; 1 Dry wall anchors; 1 Controller SUNGO; 1 Fixing screw 0 G1 G1 10 G¾ Rp¾ G1 G1 Figure Dimensions in mm 100 EN-XXX_CIRCO-_MA-10011-111Y00
.1 Installation Preparations The entire layout of flow and return pipes should be clear before installing the CIRCO solar circulation unit (100 mm centres). The location of the installation also must take into account sufficient space for the expansion vessel! If the solar system is installed for heating or if vacuum tubes are used you must pay attention to the technical documentation Overheat Protection. For the required tools see figure. Wall Installation Remove front insulation shell (). Make two drilling holes with mm vertical distance for the two wall brackets () (figure ). Screw on solar circulation unit. Connect safety group () to the included ¾" gasket to the return leg. Secure nuts by applying counter force with nd wrench while tightening the connections. Otherwise parts of seals might come of or the connections could be damaged. Affix wall bracket for expansion vessel next to the station. Take length of the flexible connection tube into account. Connect expansion vessel to safety group via the connection tube. Don t forget the seals/gaskets! Maintenance can be made easier by installing an additional capped valve between flexible tube and vessel. Connect venting pipe to safety valve and place an empty canister underneath to collect possible spills of solar fluid. Figure Tools for CIRCO installation The solar circuit pipes are connected via compression fittings 1 mm or mm. Cut and burr pipes and push into fittings as far as possible, then tighten nuts. To avoid damage, secure nuts by applying counter force with nd wrench while tightening. Rinse solar pump station and solar circuit and check for leaks. For this purpose filler valves are fitted to the safety unit and to the flow meter. Install electrical wiring, switching and sensor lines. The cables must not touch on hot pipe legs. Always disconnect mains when working with electrical equipment. The controllers SUNGO S, SL and SXL can be integrated into the solar circulation unit. For this purpose screw the included drywall anchors (1) into the drillings of the controller installation slot. Then set on controller (1) with lower side. Screw controller into the installation slot with the fixing screws (1 + 1). During wiring use wire straps at appropriate place for pull relief of the controller terminals. Re-attach front insulation shell (). EN-XXX_CIRCO-_MA-10011-111Y00
1 0. Installation at Cylinder The adjustable installation kits can be used with all Wagner solar cylinders with 1¼" flat sealing connections at the heat exchanger, with a vertical distance between 0 and 0 mm. To prevent later obstructions of the pipe work in the area of the cylinder, it is recommended to make proper lay- out plans before commencing installation. 0 0 0 0 0 0 0 0 0 0 Connect pipes to cylinder using supplied gaskets, tighten hand-screwed. Cut off longer return pipe until both pipes are reaching the same level and have an axial distance of 100 mm. Then screw tight adjustable pipe. Trim off the insulation of the cut-off return pipe and place circulation unit on top of the two pipes. 100 D = for compression fitting Return pipe Level the unit, affix to cylinder and tighten cylinder connections. 0 mm Continue with piping behind the solar circulation unit. 1¼ union nut Insulation In order to prevent forces to the cylinder fixing because of weight load from the station, pipe fixtures should be installed near the unit at the wall or at the ceiling. The expansion vessel must not be freely suspended from the pump station. Apply wall or floor installation, depending on type of vessel. Applicable for 0 to 0 mm Filling valve Figure Cylinder installation kit (option) consisting of: 1 return pipe with integrated filling valve, incl. insulation; connections: 1¼" swivel nut mm pipe socket for compression fitting, 1 supply pipe incl. insulation; connections: 1¼" swivel nut mm pipe socket for compression fitting. EN-XXX_CIRCO-_MA-10011-111Y00
. Operating Advice The Flow Meter The flow meter indicates flow in l/min during pump operation. The adjustment screw can be used to cut off the flow. For operation the adjustment screw must be turned fully counterclockwise (max. flow). The adjustment of the volume flow should only be done via the pump settings. Return Flow Stoppers They are integrated into the ball valve components and prevent unwanted heat distribution in the solar circuit when the pump is turned off. They only open in the flow direction under pump pressure. The stopper in the feed leg can be turned off with the ball valve handle, the one in the return leg with a slotted screw (figure and 10). Flow open Return flow stopper in operation Operational position L/MIN 1 1 Index line Flow metering Flow open Return flow stopper off Flow closed Return flow stopper without function Figure Flow meter of CIRCO Setting Up the Pump Setting up the pump is carried out when the solar installation is filled and vented and the pump is operating. First set pump to lowest level. Then switch on pump via controller menu manual operation, so that speed control is disabled. The recommended volume flow in the solar circuit is 0 l/m² collector area and hour. Values between 0 and 0 l/m² h are acceptable. Higher volumes result in increased power uptake of the pump. Choose next higher pump level if the recommended volume flow is not reached. Example: Collector area 1 m² > recommended volume flow = 1 m² x 0 l/m²h = 0 l/h = l/min. After setting up the pump assure its automatic operation. Figure Functions of ball valve and return flow stoppers in supply leg (left pipe) Return flow stopper adjustable via ball valve! Flow open Return flow stopper in operation (slot horizontal) Operational position Flow open Return flow stopper off (slot vertical) Flow closed Return flow stopper without function Figure 10 Functions of the ball valve and the return flow stopper in the return leg (right pipe) Return flow stopper adjustable via slotted screw! EN-XXX_CIRCO-_MA-10011-111Y00
. Accessoires Table Accessories Description Part no. Compression fitting for pipe connection Accessory set solar circuit Air venting kit (not normally required because of included bleeder pipe) CIRCO-expansion vessel set Capped valve for expansion vessel Acessory / spare part: for 1 mm copper pipe for mm copper pipe Accessory parts for solar circuit piping: filling valves and grounding clamps for potential equalization Automatic air venting kit consisting of automatic air venting valves and heat resistant ball valves (up to 00 ), connection /" 10 01 10 01 10 10 10 10 11 Manual air release set consisting of manual air release valves /" and key 10 10 10 Expansion vessel for solar circulation unit, allowed positive operating pressure 10 bar, stainless steel corrugated tube for connecting with CIRCO solar circulation unit, thread connection ¾" female flat sealing 1 l-volume, incl. wall bracket, pre-pressurized: 1. bar 1 l-volume, incl. wall bracket, pre-pressurized: 1. bar l-volume, incl. wall bracket, pre-pressurized: 1. bar l-volume, with brackets for wall and floor fixing, pre-pressurized:. bar 0 l-volume, with brackets for wall and floor fixing, pre-pressurized:. bar Check valve ¾" with filler and drain valve and with cap against operation mistakes. Suitable for maintenance purposes. 10 0 10 10 0 11 10 0 1 10 0 1 10 0 1 ¾" - version 1" - version 1 00 1 00 Cylinder mounting kit for CIRCO und E Cylinder piping 1¼" M with flat seals, insulated; return pipe for cylinder connections with 0 to 0 mm vertical distance (can be cut to size), with mm sleeves to connect to compression fittings of CIRCO and E. 10 0 01 Subject to modifications, errors excepted Wagner & Co, 010 www.wagner-solar.com WAGNER & CO Zimmermannstraße 1 D-01 Cölbe/Marburg % + (0) 1 0 0-0 Fax 0 0-