En Ensol - Installation Manual Water Heater With Solar Pump-group

8/11/2019 En Ensol - Installation Manual Water Heater With Solar Pump-group

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HOT TAP WATER EXCHANGERwith solar pump-group

ENSOL IT

200 300 500

INSTALLATION AND OPERATIONMANUAL

WARRANTY CARD


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Version 1/13 ENSOL IT2

Contents:

1. Structure and Intended Use... 32. Safety devices and conditions for safe

use of exchangers.. 6

3. Installation .. 64. Operation and service.. 95. Warranty conditions. ... 10

Before you install and activate the exchanger, please read this "Installation andOperation Manual" and Terms and Conditions of the Warranty

Attachments:1. Operating instructions of the STDC controller2. Operating instructions of the Solar 3 two-way solar station3. Installation, start-up and operating manual of the expansion vessel alongwith warranty conditions and warranty card

NOTE!Correctly filled in, complete and not modified warranty cardsof the ENSOL IT exchanger and expansion vessel as well asoperating instructions of the STDC controller and the solarstation with entries of ZUG ELEKTROMET are theprerequisite for granting the right to warranty repairs.


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1. Structure and Intended Use

ENSOL IT exchangers with solar pump group are pressure storagewater heaters that are designed to heat and store hot tap water, in systemswith solar collectors, for needs of flats, detached houses and multi-familybuildings, 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 powersources with different heating media, such as solar collectors with a glycol-based heating medium or e.g. low-temperature central heating water boiler,- two-way pump group (2) integrated with the controller for the solarsystems (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 connectingstub for safety group,- 6 bar safety valve with manometer and connecting stub for expansionvessel,- cut-off check valve with thermometer (red),- vent.

The controller used for solar systems is equipped, among others, withsmoothly controlled pump rotating speed, heat meter function, graphicalstatistics, 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 inthe attached Installation and operating manual.

Pressure tanks in these heat exchangers are made of steel sheetcovered inside with a layer of a special high-temperature vitreous enamel,forming glass coating that protects them from corrosion and ensures cleanhealthy water. Additional corrosion protection of the tanks is the

magnesium anode that owing to the difference of electrochemical potentialsof steel and magnesium in water, generates protective current for the tank.

Thermal insulation is made of PS expanded polystyrene permanentlyjoint to tank walls.The outside coating of the exchangers is made of plastic.ENSOL IT exchangers are designed for installation of an electric heatingelement on the 1" plug, especially EJK type heating element produced byZUG ELEKTROMET with insulated heating units (Tab. 2), which do notconsume protective current generated by the magnesium anode for the

corrosion protection of the tank. This increases the durability of the tankand the life of the magnesium anode.


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The structure and dimensions of exchangers are shown in Fig. 1, whereastheir connection dimensions and technical parameters in Tab. 1.

1 tank with two coils2 two-way solar pump group3 - controller4 expansion vessel5 junction box with sensors

(S1 - collector; S2 - vessel)

- ~230V/50Hz

Fig. 1 Construction of the ENSOL IT exchanger

S1S2

ENSOL IT 200ENSOL IT 300

ENSOL IT 500


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Tab. 1 Dimensions and technical parameters of ENSOL IT

ENSOL ITType

200 300 500

Capacity200 300 500

HeightH [mm] 1400 1900 2180

Max. height on the slope H* [mm] 1545 2000 2330

DiameterD [mm] 630 630 810

ZW 1Cold water

A [mm]360 250 350

CW 1Hot water

I [mm]1080 1570 1730

WEG1 1 1

Heating water power upper coil

P [mm]990 1320 1630

WYG1 1 1

Heating water return upper coil

O [mm]750 1000 1220

WES1 1 1

Heating water power solar coil

E [mm]805 1160 1383

WYS1 1 1

Heating water return solar coil

B [mm]735 1070 1290

RC Circulation

F [mm]690 1030 1080

MG1 1 1Socket heater

K [mm]800 1030 1240

Magnesium anode x L [mm] 40 x 330 40 x 390 40 x 500

W 2 2 123/166/195Wash out hole

M [mm]325 325 425

Thermal isolation60 mm Polyuretane foam

100 mm Polystyrenefoam

Mass [kg] 95 140 205


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* 80C, 70C, 60C - temperature of heating water in the coil supply10C - temperature of cold tap water on sup ply45C, 60C - temperature of hot tap water

2. Safety devices and conditions for safeuse of exchangers.

Heaters may only be used with a functional safety valve with the openingpressure of 0.6 MPa (water pressure in the water supply network up to 0.6MPa) installed on the cold tap water inlet. This valve protects the

ENSOL ITType

200 300 500

Capacity200 300 500

Exchange surfacem 0,8 1,0 1,4

Capacity of coildm 4,3 5,7 8,0

Efficiency of hot water80/10/45C

70/10/45C60/10/45C

dm/h

442

368270

545

462336

737

620460

Heating power80/10/45C70/10/45C60/10/45C

kW181511

22,218,813,7

3025,218,7

Efficiency of hot water 80/10/60C70/10/60C dm/h 264

198326240

455337

COIL

BOILER

Heating power80/10/60C70/10/60C

kW 15,411,5

1914

26,519,6

Exchange surface of coil m 1,1 1,4 1,9

Capacity of coil dm 6,4 8,0 10,7

Efficiency of hot water80/10/45C70/10/45C60/10/45C

dm/h460388287

604503373

818680506

COIL

SOLAR

Heating power80/10/45C70/10/45C60/10/45C

kW18,715,811,7

24,620,515,2

33,327,720,6

The maximum surface of theabsorber connected solar

m 2,5 5 10

Heating losseskWh/24h 2,1 2,5 4,5

Parameters of the tank work Max. pressure and temperaturepr = 0,6 MPa; tr = 80C

Parameters of the upper coil work Max. pressure and temperaturepr = 1,0 MPa; tr = 90C

Parameters of the solar coil work Max. pressure and temperaturepr = 1,0 MPa; tr = 110C

Thermal isolation60 mm Polyurethne foam

100 mm Polystyrenefoam

Magnesium anode x L [mm] 40 x 330 40 x 390 40 x 500

Expansion vesseldm 18 18 25

Masskg 95 140 250


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exchanger from excessive pressure in the water supply network orexcessive pressure increase as a result of heating the water in the tank.Even in case of regular operation of the exchanger during heating, watermay leak from the safety valve for a short time, which shows that the valveoperates in a correct manner. Neverobstruct the outlet hole in such cases.All types of exchangers should be used with an installed thermometer ofthe measuring range between 0 and 120C, also inst all pressure gauges

with the measuring range between 0 and 1 MPa.

3. Installation

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 thepressure does not exceed 0.6 MPa and not lower than 0.1 MPa. If thepressure in the network often exceeds 0.4 MPa, it is recommended toinstall a pressure reducing valve or a diaphragm reservoir before theexchanger in order to limit the inconvenient outflow of water from the safetyvalve. When the pressure in the water supply network exceeds 0.6 MPa , itis necessary to install the pressure reducing valve in order to avoid thecontinuous outflow of water from the safety valve.Perform the connection between the solar collector and exchangeraccording to the diagram (Fig. 2). Connect the collector output to the upperport (WES) and return to the lower port (WYS). After filling the solar systemwith heating medium, venting and filling the exchanger with water, connectthe controller to the power supply system of 230V /50Hz (power cord

extending from the junction box).

ATTENTION!1. A safety valve has to be installed on the cold water inlet to theexchanger; the valve is supplied with the exchanger. Install it so that thearrowhead on the valve body is in line with the direction of the waterflow.2. Do not install any shut-off valves between the safety valve and theexchanger.

3. It is not permitted to use the tank without a safety valve or with amalfunctioning safety valve becausethe situation may result in failure and poses a threat to human life andhealth.

Installation and any repairs of the exchanger in terms of electricityand water system should be entrusted only to skilled processionals

with relevant permissions.


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1 - ENSOL IT exchanger with: 6 central heating boiler2 solar pump group 7 solar collector3 controller 8 domestic hot water tap4 expansion vessel 9 - circulation5 junction box 10 water temperature sensor in the exchanger

S1 - liquid temperature sensor in the ZW domestic cold watercollector CW - domestic hot water

S2 - water temperature sensorin the exchanger

Fig. 2 Example installation diagram

3.2Installation of EJK type heating elementDuring the warranty period of the tank, only heating elements tankssuitable for enamelled tanks may be used, i.e. those with insulated heatingunits (insulated heating units do not "steal" protective current generated bythe magnesium anode). This is one of the warranty conditions for theWGJ-SOL exchanger. EJK type heating elements by ZUG ELEKTROMETcomply with this condition.

Among EJK heating elements manufactured by ZUG ELEKTROMET forWGJ-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 kWheating elements .


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Install in accordance with the Installation and Operation Manual of theheaters.It is particularly important that the free end of the yellow-green protectiveconductor drawn from the marked connection on the casing of the heatingelement is connected using the M4 screw to the earth plate located on theMG connector of the tank, see Fig. 3.

1 tank casing2 electric EJK type heatingelement3 earth wire4 MG 1 '' connector5 earth plate6 M4 screw7 spring washer

Fig. 3 Earth of the heating element

ATTENTION!During the warranty period of the tank, use only heatingelements with an insulated heating unit e.g. EJKmanufactured by ZUG ELEKTROMET

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, afterputting 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 heatingof water in the exchanger is normal and indicates the proper operation ofthe safety valve.

ATTENTION!Do not insert the plug of the connection into the

electrical socket without making sure that the tank is filledwith water.

ATTENTION!Continuous leaking of water from the safety valve outlet

demonstrates a malfunction of the valve or overly high pressure inthe water supply system. Never obstruct the outlet hole.


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3. If the exchanger is put out of service in the winter and there is a concernthat the water in the exchanger may freeze, drain the water by unscrewingthe safety valve.4. The magnesium anode wears down during operation, so its conditionshould be checked periodically, at least once a year. The anode should bereplaced if it loses 2/3 of its volume, and always at the latest after 18months. 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; todetermine 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.

5. Periodically, depending on water hardness, remove the accumulatedsediment and loose scale.

5. Warranty conditions

1. The warranty is granted for a period of 60 months for the enamelled tank2. The warranty for other parts of the exchanger and for:

- STDC controller,- 2-way-pump-groupis 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 providedthat 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 theexchanger. Any damage shall be removed in 14 days after the date ofnotification.

ATTENTION!The magnesium anode plays an important role in the corrosionprotection of the enamelled tank, and its regular checking andreplacement with a new one is necessary to maintain the warranty of thetank.Replaced used anodes and certification of their exchange (anodepurchase) should be kept in order to make them available for the

manufacturer's service personnel in case of failure of the tank.


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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 orforce majeure ( lightning, natural disasters, etc.) the cost of repairing ofthe device must be covered by the enduser.

9. In case of unjustified calls for service, costs of arrival shall be borne bythe customer.

10. In the event of the expansion vessel failure, please inform the technicalsupport of the company:Reflex -POLSKA Sp. z o.o.ul. Mikoaja z Ryska 36-4087-200 Wbrzeno, Polandtel. +48 56/688 44 18, 688 44 00fax +48 56/688 44 68

11. In case of irregularities in the operation of the exchanger, notifymanufacturer's service, tel. +48 32/ 415 01 81 from 6 to 14,or by e-mail: [email protected] point of sale. DO NOT DISMANTLE THEDEVICE.

12. The manner of repair of the equipment is determined by themanufacturer.

13. The basis for repairs under the granted warranty is a correctly filled out,complete Warranty Card of the exchangers, 2 way-pump-group andexpansion tank, that contains no amendments.

14. In all matters not regulated by these conditions, relevant regulations ofthe Civil Code apply.

15. We recommend that you keep the Warranty Card throughout the life ofthe exchanger.


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Energetyka Solarna Ensol Sp. z o.o. 47-400 Racibrz, ul. Piaskowa 11 Tel/fax: 0048 32 415 96 65

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En Ensol - Installation Manual Water Heater With Solar Pump-group