INSTALLATION AND INSTRUCTION MANUAL SOLAR STATION Installation and instruction manual SOLAR STATION SST 25-1E / SST25-2E EN April 2015 1
Table of contents Usage 3 Warranty 3 Safety instructions and symbol legend 3 Safety instructions 3 Symbol legend 4 Scope of delivery 4 Provisions 5 Statutory provisions 5 Manufacturer s specifi cations 5 Pumping medium 5 Technical data 5 Technical data SST25-2E 5 Technical data SST25-1E 6 Connection and performance data SST25-2E / SST25-1E 7 Installation 8 Installation on buffer tank 8 Connection of solar fl ow an return fl ow 9 Wall fastening SST25-2E 10 Wall fastening SST25-1E 11 Hydraulic installation 12 Electric connection 12 Standard operating mode 12 Functioning 13 Gravity brake 13 Operating position 13 Emptying/fi lling position 13 Closed position 13 Flow meter 14 Initiation 15 Filling 15 Rinsing 15 Bleeding 15 Service 16 Control rinsing 16 Control rinsing step 1 16 Control rinsing step 2 16 Appendix 17 Safety precautions for the operator 17 Pump 19 Pump Curve 20 Technical Data - Wilo Yonos Para 21 Notes 22 2
INSTALLATION AND INSTRUCTION MANUAL SOLAR STATION Usage The solar station SST25 is used to connect solar thermal collectors to a buffer or a hot water tank. It will be installed next to the buffer or hot water tank at the wall or directly onto the tank at special system solutions. Another use or installation is not intended. The manufacturer is not liable for damages due to inappropriate use and the operator bears the risk. The solar station is factory-equipped with a two-circuit controller. The controller measures the collector and tank temperatures with Pt1000 sensors and regulates based on that data the buffer or hot water tank temperature respectively. Warranty The Manufacturer issues a warranty of 2 years from the invoice date on the device and its constituent parts. Without proper installation and use of the device the warranty is void. Safety instructions and symbol legend Safety instructions The installation, initiation and maintenance must only be accomplished by qualifi ed technical professionals. The operation of this device is not allowed to persons (including children) with limited physical, sensory or intellectual abilities. Uninformed or unacquainted persons may operate the device only under the supervision or at a trained person s disposition. Replacements or repairing of electrical parts like the power cord must be conducted by a professional electrician. Follow the instructions in this manual closely to ensure proper functioning. Exclusively use the solar station in a solar thermal system. Fuses, wiring and earthing must be installed according to regional regulations. The electric connection needs to be realized with the provided power cord. The solar controller must be protected from overvoltage-induced damages. The solar controller must only be opened in case of a service. Make sure to disconnect the device from power supply prior to open the housing. Only install the device in dry and frost-free locations. Operate the device only at ambient temperatures between +2 C and +40 C. Interrupt the power supply of the system (230 V/AC) prior to installation. During operation the device can heat up and burns are possible. The device must be connected to an external circuit breaker to allow a shutdown at any time. Installation and operation must be performed according to regional laws, regulations and common practice. At the occurrence of malfunctions regardless of nature please contact your authorized technical professional. 3
Symbol legend Safety instructions are marked with a warning triangle as illustrated on the right. Safety instructions indicate important information for potentially dangerous situations for person and device. Additional buzzwords describe nature and severity of the danger. Advices are marked with an information sign as illustrated on the right. Advices highlight important information for situations without severe danger for person and device. Screw wrench indicates the maximum tightening torque [Nm] and the rotational direction. max. tightening torque [Nm] Scope of delivery Solar Station Mounting set SST25-2E Accessory kit sensor set SST25-1E SST25-1E SST25-2E Connenction set SST25-1E SST25-2E Sensor set SST25-1E SST25-2E 4
INSTALLATION AND INSTRUCTION MANUAL SOLAR STATION Provisions The device must be installed and operated according to the following norms and country specifi c directives and provisions. DIN 4751 DIN 4757 DIN 18380 DIN 18381 DIN 18382 DIN EN 12975 DIN EN 12828 VDE 0100 VDE 0185 VDE 0190 ÖNORM ENV 12977-1 ÖNORM M7701 ÖNORM M7731 Manufacturer s specifications Pumping medium Water and water-/glycol-mixes in mixing ratios up to 1:1. Due to admixing of glycol, the pump characteristic lines need to be adjusted according to the increased viscosity (depending on the mixing ratio). Only use dedicated pumping mediums with anticorrosive inhibitors Technical data SST25-2E 1 A 1 B 3 2 8 E 7 9 9 F 1 Ball valves with integrated gravity brake 2 Manometer 3 Solar safety valve (6 bar) 4 Charging pump 5 Flow meter 1-13 l/min with rinsing / shut-off function 6 Air-jet 4 6 7 Manual bleeding nipple 8 KFE-Valve 8 10 9 Dial thermometer 10 Controller 5 14 Hose nozzle for KFE Valve Connections: 14 A Collector feed C D B C Collector return Tank feed D Tank return E Membrane expansion vessel F Collecting vessel 5
Technical Data SST25/1 E 13 11 12 B 10 13 13 1 2 3 F 8 E 9 4 5 8 14 D 1 Ball valve with integrated gravity brake 2 Manometer 3 Solar safety valve (6 bar) 4 Charging pump 5 Flow meter 8 KFE-Valve 9 Dial thermometer 10 Controller 11 Safety spring 12 Mounting plate 13 Insulation 14 Hose nozzle for KFE-Valve Connections B Collector return D Tank return E Membrane expansion vessel F Collecting vessel 6
INSTALLATION AND INSTRUCTION MANUAL SOLAR STATION Solar Station SST25-1E SST25-2E Max. collector area [m 2 ] 25 m² 25 m² Controller STRG Omega 1 1-circuit-controller Charging pump [V/Hz] Wilo Yonos Para 15/7.0 PWR Power input [W] 3-45 STRG Omega 2-circuit-controller Temperatures[ C] Ambience 2-40 Buffer-/Boiler-water max. 95 Feed 140 Return 120 Max. operating pressure [bar] 6 Medium Water with max. 40% propylene-glycol Dimensions [mm] Width 285 330 Height 405 570 Depth 180 230 Connections Collector Rp¾" IG Rp¾" IG Tank G1" AG G1" AG Expansion vessel G¾" AG Nominal width DN 15 Insulation EPP Weight [kg] 6,8 8,5 Connection- and performance data Minimum feed-pressure at intake* at temperature + 50 C: at temperature + 95 C: at temperature +110 C: 0,05 bar 0,3 bar 1,0 bar Permitted temperature range: -10 C bis +140 C Maximum ambiance temperature: +40 C * These values are valid for regions up to 300 meters above sea level. Additional pressure for higher altitudes: 0,01 bar per 100 meters. To avoid cavitation noises, maintain the minimum feed-pressure at pump intake. 7
Installation Installation on buffer tank 1 3 Pre-assembly of cleats Installation of connection-set 2 4 Installation onto buffer tank Installation of piping 8
INSTALLATION AND INSTRUCTION MANUAL SOLAR STATION 5 6 Installation of sensors Final assembly max. 70Nm A 1.2 Connection of solar flow and return lines CAUTION! To tighten union nuts SW32 of the clamping ring connections: Rotate the handles of the ball valves to the closed position (slots stand horizontally) on the solar fl ow and return ball valve (1.1 + 1.2). Use an open-ended spanner SW36 (A) to fasten clamping ring connection above ball valves. Use an open-ended spanner SW36 (B) to exert counterpressure on the nuts beneath the ball valves. Finally rotate the ball valves to the open position. 1.1 B 9
359,5 800 445 570 Wall fastening SST25-2E 1 103 50 103 50 326 326 570 445 400 Pre-assembly of cleats Drilling plan 2 max. 10 Nm S12 12 mm Ø12 60 min. 80 80 Installation onto wall 10
370 25 124 INSTALLATION AND INSTRUCTION MANUAL SOLAR STATION Wall fastening SST25-1E 328 138 70 Pull return fl ow line out of mounting plate. Mark fastening point of mounting plate on the wall and drill two holes ø10 mm. (see picture) Set dowels and screw mounting plate tightly with screws and fl at washers. Adjust mounting plate horizontally. Slide back insulations cover on mounting plate. Check if molded springs are fi tted correctly in the mounting plates hulls. Slide the back cover over the hull, push return fl ow line on pin of ball valve until it latches 11
Hydraulic installation 3 Caution! The emergent pumping medium at the solar relief valve must be drained over a suitable pipe into a drain bottle. 2 Manometer (measurement range 10 bar) 3 Solar safety valve (6 bar) 8 KFE-Valve 8.1 Covering cap KFE-Valve E Pipe union for membrane expansion vessel F Connection drain bottle Electric connection Safety unit F 2 8.1 8 E Caution! Do not bend the cable sharply and do not lay it while energized! Do not run the cable directly over sharp-edged components. The installed cables must not touch the pipes and/or the pump. Connection schemes for sensors, pumps and actuators: see manual of controller. 10 10.1 10 Controller 10.1 Faceplate screw Controller Pump cables and mains cables are attached to the solar controller at the factory. The terminals for the sensors can be accessed after loosening the screw (10.1) on the controller s faceplate (10). Standard operating mode 1.1 1.2 8.1 Nr. Name Position Status 5.1 Spindle Flattening downwards Operation 1.1 Ball valve 0 Open incl. gravity brake 1.2 Ball valve 0 Open incl. gravity brake 8.1 KFE-Valve Vertical Closed 8.2 KFE-Valve Vertical Closed 4 8.2 Standard operating mode 5.1 12
INSTALLATION AND INSTRUCTION MANUAL SOLAR STATION Functioning Gravity brake The gravity brakes are built into the feed and return ball valve. They are operated by turning the ball valve handle. Operating position Handle position: 0 The valve discs must not be opened, to prevent circulation under the force of gravity. The gravity brakes are closed and the ball valves are opened. Operating position Emptying/filling position Handle position: 45 The gravity brakes and ball valves are opened Emptying/fi lling position Closed position Handle position: 90 The ball valves are closed. Closed position 13
Flow meter Adjusting the fl ow rate of the pumping medium is achieved by selecting the RPM setting on the circulation pump (4) and with the throttle on the fl ow meter (5.1). The fl ow meter displays the fl ow rate. The range is between 1 and 13 l/min. Read the fl ow rate from the upper edge of the fl oat (5.2). 5.2 4 5 Flow meter 5.1 14
INSTALLATION AND INSTRUCTION MANUAL SOLAR STATION Initiation Prior to fi lling and rinsing the solar system, unscrew the caps from the closed KFE-Valves and connect the feed pipes to the fi lling and rinsing devices Adhere to sequence (SEQ)! In the following tables, the exact sequence is indicated in the column SEQ. 1.1 1.2 8.1 Filling SEQ Nr. Name Position Status 1 1.1 Ball valves incl. gravity brake 45 Open 1 1.2 Ball valves incl. gravity brake 45 Open 4 2 5.1 Spindle Flattening downwards Passage 3 8.1 KFE-Valve Horizontal Open 4 8.2 KFE-Valve Horizontal Open 8.2 Filling of solar station 5.1 Rinsing 1.1 1.2 8.1 If a rinsing process with opposite rinsing direction is necessary, it is advisable to conduct a fi nal control rinsing (see page 16 chapter control rinsing). SEQ Nr. Name Position Status 1 1.1 Ball valves incl. gravity brake 45 Open 4 1 1.2 Ball valves incl. gravity brake 45 Open 2 5.1 Spindle Flattening left (S) Rinsing 3 8.1 KFE-Valve Horizontal Open 4 8.2 KFE-Valve Horizontal Open Rinsing 8.2 5.1 Bleeding Caution danger of scalding! Bleeding may only be carried out by trained technical personnel. Depending on the temperature of the pumping medium and the system pressure, the hot medium can discharge fl uid or gaseous and with high pressure. Uncontrolled bleeding leads to a pressure loss and to malfunctions in the solar system. The Air-Jet (5) collects the remaining air in the pumping medium and that air can be discharged manually via the bleeding nipple (7). To discharge the air, push the provided hose onto the nozzle (7.1) on the nipple and catch any fl uid in a suitable container. Concluding, close bleeding nipple tightly and check system pressure. If necessary, refi ll the system with the needed amount of pumping fl uid Bleeding 7 7.1 5 15
Service Caution danger of burns! The pump may get very hot in various operational stages (e.g. due to the pumping medium). Adhere to sequence (SEQ)! Prior to opening the KFE-Valve (8.2), turn valves (1.1), (1.2), (8.1) and spindle (5.1)into the following positions. 1.1 1.2 8.1 SEQ Nr. Name Position Status 1 1.1 Ball valve 90 Closed incl. gravity brake 2 1.2 Ball valve incl. gravity brake 90 Closed 3 5.1 Spindle Flattening right (E) Service 4 8.1 KFE-Valve Vertical Closed 5 8.2 KFE-Valve Horizontal Open The pumping medium can be drained by out of the pump by opening the KFE-Valve (8.2). 4 8.2 5.1 Control rinsing 1.1 1.2 8.1 A fi nal control rinsing happens in two steps. Control rinsing, step 1 SEQ Nr. Name Position Status 1 5.1 Spindle Flattening left (S) Rinsing 2 1.1 Ball valve 0 Open incl. gravity brake 3 1.2 Ball valve 45 Open incl. gravity brake 4 8.1 KFE-Valve Horizontal Open 5 8.2 KFE-Valve Horizontal Open Close KFE-Valves (8.1) and (8.2) after rinsing. 4 8.2 5.1 Control rinsing, step 2 1.1 1.2 8.1 SEQ Nr. Name Position Status 1 5.1 Spindle Flattening right (E) Service 2 1.1 Ball valve 90 Closed incl. gravity brake 3 1.2 Ball valve 0 Open incl. gravity brake 4 8.1 KFE-Valve Horizontal Open 5 8.2 KFE-Valve Horizontal Open Close KFE-Valves (8.1) and (8.2) after rinsing. 4 8.2 16 5.1
INSTALLATION AND INSTRUCTION MANUAL SOLAR STATION Safety precautions for the operator General: Installation and service by qualifi ed personnel only Fields of application: Type: ST: for solar thermal systems Connection and output data: Minimum input pressure at the air intake* at temperatures +50 C: 0,05 bar at temperatures +95 C: 0,3 bar at temperatures +110 C: 1,0 bar Permissible temperature range: -10 C bis +140 C Max. permissible ambient temperature: +40 C * These values are valid up to 300 m above sea level. For higher elevations add: 0,01 bar / 100 m. The minimum inlet pressure must be maintained in order to avoid cavitation noise. Permissible fluids: Water and water/glycol mixtures up to a ratio of 1:1. Glycol mixtures require a reassessment of pump hydraulic data in line with the increased viscosity and depending on mixing ratios. Only approved marks of additives with corrosion inhibitors must be used instrict compliance with manufacturers instructions. Safety Rules Safety Rules For The Operator Local regulations for the prevention of accidents must be observed. Danger from electrical energy must be excluded (conforming to local or general regulations such as IEC, VDE, etc.) Safety Rules for Inspections and Installation Work It is the operator s responsibility to ensure that inspections and installation work are carried out by authorized and qualifi ed personnel only, having themselves made fully conversant with these instructions. Work must principally be carried out only with the plant switched off and at complete standstill. Abnormal Operating Conditions Operational safety of the plant is only ensured if used in accordance with these instructions. The limits stated there must not be exceeded under any circumstances. Description of Product and Accessories The pump YONOS PARA is a solar thermal pump with special hydraulic (pumphousing coated) for using in solar thermal systems. Motor overload protection is not required. The motor operates non-overloading. Sitting/Installation Installation Direction of fl uid fl ow must correspond with the arrow on the pump housing. When connecting the pump to the conduit of pipes, the pump can be secured against twisting using a spanner on the key surfaces which have been created for this purpose. 17
Electrical wiring: Cable leads to be routed in such a way to avoid any contact with pipe work and/or pump or stator housings. Check that the mains current and voltage comply with the data on the rating plate. Pump/installation must be earthed in compliance with regulations. Commissioning System filling and venting The pump is normally vented automatically after a short operational period. Danger of scalding exists! The pump can become extremely hot, depending on the operational state of the pump or the pipe system (fl uid temperature) Danger of scalding exists when touching the pump! 18
INSTALLATION AND INSTRUCTION MANUAL SOLAR STATION Charging pump Danger of scalding exists!! The pump can become extremely hot, depending on the operational state of the pump or the pipe system (fluid temperature). Function PWM The PWM-signal is used for RPM Controlling and therefore the power of the charging pump Declaration of conformity 14.2.2 Wilo Yonos Para 19
Performance curves Pressure loss: (bar) Pressure loss curve SST25-2E Volume: (m3/h) 20
INSTALLATION AND INSTRUCTION MANUAL SOLAR STATION Technical Data - Wilo Yonos Para Technical Data Yonos PARA 15 / 7.0 PWR Approved fluids (other fluids on request) Heating water (in accordance with VDI 2035) Water - Glycol - Mixtures (max. 1:1; above 20% admixture, the pumping data must be checked) Power Energy Effi ciency Index (EEI) ± 0,2 Max. delivery head (Hmax) 7.3 m Max. volume fl ow (Qmax) 3.3 m 3 /h Permitted field of application Temperature range at max. ambient temperature von 55 C = 0 bis 110 C von 62 C = 0 bis 90 C von 66 C = 0 bis 80 C von 71 C = 0 bis 70 C Maximaler operating pressure 10 bar Electrical connection Mains connection 1~230 V, 50/60 Hz Motor/Electronics Electromagnetic compatibilty EN 61800-3 Emitted interference EN 61000-6-3 EN 61000-6-4 Interference resistance EN 61000-6-2 EN 61000-6-1 Speed Control Frequency converter Protection class IP X4D Insulation class F Minimum suction head at suction port for avoiding cavitation at water pumping temperature minimum suction head at 50 / 95 / 110 C 0.5 / 4.5 / 11 m 21
Notes 22
INSTALLATION AND INSTRUCTION MANUAL SOLAR STATION Notes 23
Contact: 24