CALEFFI. Solar pump stations 01166/14 NA. 278 and 279 series 01264/16 NA

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1 Solar pump stations 78 and 79 series 0/4 N CLEFFI 04/ N CCREDITED ISO 900 FM 4 ISO 900 No. 000 Function Solar pump stations are used on the primary circuit of solar thermal water heating systems to control the temperature of the hot water storage. The pump inside the unit is activated by the signal from a differential temperature controer. The unit contains the functional and safety devices for optimum circuit control. They are available with both supply and return connection or with return connection only. The isolar PLUS temperature differential controer, code 70 (optional), is suitable for management and control of 0 preconfigured solar thermal system arrangements instaed in an optional insulation jacket (code 7) that mounts to the top of the pump station for a nice clean assembly and simplified wiring. Product range Solar pump stations are pre-assembled and leak-tested. Components include three-speed pump with wide flow rate range, safety relief valve, ba valves with built-in flow checks in return (and supply/flow for dual-line models, not available in drainback model), temperature gauges in return (and supply/flow for dual-line models), pressure gauge, manual air vent (dual-line models only), expansion tank connection, connections for flushing and fiing, and foam insulation. 787 Single-line solar pump station with speed pump, return connection and flow meter scale to 8 gpm...connection /4 female 787 Single-line solar pump station without pump, return connection and flow meter scale to 8 gpm...connection /4 female 790 Dual-line solar pump station with speed pump, supply and return connections, flow meter scale to 8 gpm...connections /4 female 790 Dual-line solar pump station without pump, supply and return connections, flow meter scale to 8 gpm...connections /4 female 789 Single-line solar pump station for drainback with speed pump, return connection and flow meter scale to 8 gpm...connections /4 female Technical specifications Materials Shut-off valve body: Check valve: Temperature gauge: ir Separator Instrument holder fitting Sealing gaskets: O-Ring seal elements: Flow meter Transparent level gauge: Flow indicator: Hydraulic seals: steel/aluminum EPDM EPDM PS EPDM Insulation Material: PP verage thickness: /4 inch ( mm) Density:.8 lb/ft³ (4 kg/m ) Working temperature range: - 0 F (- C) Thermal conductivity: 0. BTU in/hr ft² F 0.07 W/(m K) at 0 F (0 C) Reaction to fire (UL94): class HBF Performance Suitable fluids: water, glycol solution Max. percentage of glycol: 0% Maximum working temperature: air separator side supply: F ( C) pump side return: 0 F (0 C) Max. working pressure: 4 psi (0 bar) Safety relief valve working temperature range: - to F (-0 C) Safety relief valve setting: 90 psi ( bar) Check valve min. opening pressure (Dp): /4 psi ( kpa) Shut-off and check valves working temperature range: - to F (-0 C) Flow meter working temperature range: to 0 F (-0 0 C) Flow rate adjustment range: to 8 gpm Flow rate indicator accuracy: ±0% Pressure gauge scale: 0 to 4 psi (0 0 bar) Temperature gauge scale: to F (0 C) Connections: /4 female straight thread Fitting adapters, purchase separately: ½", ¾", " male straight thread for SolarFlex and sweat connections Hose connection: /4 Fi/drain connections: with hose connection 9/" OD ( mm)

2 Pump Model Wilo Star S- Three-speed pump: Wilo Star SU--0 cast iron Electric supply: V 0 Hz Max. pressure: psi (0 bar) Max. liquid temperature: 0 F (0 C) Min. liquid temperature: 4 F (-0 C) Max. current: 0.97 Max. power consumption: 0 W Protection class: CS enclosure gency approval: culus Flow range: 0 to 8 gpm (0 to. l/s) Head range: 0 to ft (0 to.4 m) H [ft] [m /h] 7 4 H [m] H [ft] 9 9 Pump Model Grundfos Solar - Drainback Three-speed pump: Grundfos Solar -U 0 cast iron Electric supply: V 0 Hz Max. pressure: psi (0 bar) Max. liquid temperature: 0 F (0 C) Min. liquid temperature: 4 F (-0 C) Max. current: 0.9 Max. power consumption: 7 W gency approval: UL 778, CS./08 per Intertek Flow range: 0 to 8.4 gpm (0 to 0. l/s) Head range: 0 to ft (0 to.0 m) PPLICTION S NOTE: Pump data per Manufacturer technical specifications. Dimensions B B C D C F D Q [US gpm] [gpm] E E (no pump) ¾" B ¼" C " D ¾" E 8" 799 Weight 4 lb (.4 kg) 0 lb (4. kg) 4 lb (.4 kg) 790 ¾" B 4" C ¼" D " E 8" F ¾" 790 (no pump) Weight 7 lb (7.7 kg) lb (. kg)

3 Characteristic components ) Circulation pump ) Safety relief valve ) Fi/drain valve with controever 4) Instrument holder fitting with pressure gauge ) Flow meter ) ir separator with air vent and shut-off valve with check valve 7) Supply (flow) temperature gauge 8) Return temperature gauge 9) Pre-formed she insulation 0) Shut-off ba valve with check valve and temperature gauge holder knob (Drainback station does not have a check valve) ) Connection kit for expansion tank (purchase separately) ) Hose connection ) Mounting bracket 4) Manual air vent release screw head ) 9 mm hex wrench for shut-off ba valve and flow meter valve Connection adapter fittings are purchased separately, see page Dual Single

4 Shut-off and check valves The shut-off valves are equipped with a built-in check valve, positioned inside the ba.. To aow the passage of the medium in both directions, the ba valves must be opened to 4 using a 9 mm hex wrench (supplied with unit). Temperature gauge can be removed if needed better view this operation. The check valve is opened by the ba, see figure (). Flow meter The flow meter is a flow rate measuring device, float equipped, with an adjustment ba valve. The meter has a range of to 8 gpm. The flow meter must always be instaed in a vertical position. Captive nut Flow rate adjustment. In normal system operation, the ba valves must be fuy open. 0 F /4 fitting C 0 Thermometric label Graduation /4 fitting thermometric label on the back of the flow meter signals if the maximum permitted temperature (0 F/0 C) has been exceeded: white = temperature not exceeded; dark = maximum temperature exceeded. Warranty wi be void if this label is removed. Correct position ir separator Incorrect position The solar pump stations with supply and return connections (79 series) are equipped with an air separator on the supply line. The gases separated from the heat transfer medium coect at the top of the air separator. The coected gases must be evacuated from time to time (every day after putting into operation and afterwards, depending on the quantity of air, once a week or once a month) by opening the manual air vent with a suitably sized screwdriver. To maintain optimal efficiency of the solar thermal system, afterwards, it is necessary to discharge air from the system every six months using the air separator. The reading is taken from the top edge of the float Correction for different density liquids Changes in flow rate readings remain within the indicated accuracy (±0%) for glycol percentages of up to 0%. Complete closing and opening of the valve The valve can be fuy closed or fuy open. slot on the valve adjusting stem indicates the status of the valve. 8 7 Fuy closed Important! Use only a 9mm hex wrench (supplied with unit) to adjust the flow meter. open closed Fuy open B

5 Pump station fittings Kits designed for connecting 78 and 79 pump stations to SolarFlex stainless steel piping with EPDM insulation to complete solar water heating system instaations. ½" SolarFlex connection directly to top or bottom ¾" female thread* connection. Kits designed for connecting 78 and 79 pump stations to copper piping with sweat connections to complete solar water heating system instaations. ½" sweat fittings to top or bottom ¾" female thread* connection. N ¾" male thread x ¾" male thread N49 ¾" male thread x ½" sweat fitting ½" SolarFlex connection directly to top and bottom ¾" female thread* connection. 4 each. ½" sweat fittings to top and bottom ¾" female thread* connection. 4 each. N7 ¾" male thread x ¾" male thread N749 ¾" male thread x ½" sweat fitting ¾" SolarFlex connection directly to top or bottom ¾" female thread* connection. ¾" sweat fittings to top or bottom ¾" female thread* connection. N0 ¾" male thread x " male thread ¾" SolarFlex connection directly to top and bottom ¾" female thread* connection. 4 each. N9 ¾" male thread x ¾" sweat fitting ¾" sweat fittings to top and bottom ¾" female thread* connection. 4 each. N70 ¾" male thread x " male thread " SolarFlex connection directly to top or bottom ¾" female thread* connection. N79 ¾" male thread x ¾" sweat fitting " sweat fittings to top or bottom ¾" female thread* connection. N0 ¾" male thread x ¼" male thread " SolarFlex connection directly to top and bottom ¾" female thread* connection. 4 each. N9 ¾" male thread x " sweat fitting " sweat fittings to top and bottom ¾" female thread* connection. 4 each. N70 ¾" male thread x ¼" male thread N79 ¾" male thread x " sweat fitting *a threads referenced on this page are straight (metric) threads.

6 Replacement Pumps Replacement pumps fits current solar pump stations 78 & 79. speed V " male union thread. gency approval: culus. Replacement pump fits current drainback station, code 789. speed V " male union thread. gency approval: UL778, CS./08. N70 N8 Wilo Star S-, head / 8 gpm Wilo Star S-, head / 8 gpm N7 Grundfos Solar - Drainback, ' head / 8.4 gpm pplication diagrams Shut-off valve Pump Shut-off valve ir vent Pump Expansion tank ir vent Temperature gauge Expansion tank Safety valve Temperature gauge Safety valve utomatic fiing

7 Replacement temperature gauges Temperature gauges fit 78 & 79 solar stations. Scale: to F (0 to C). F979 F978 ½" red dial temperature gauge ½" blue dial temperature gauge SPECIFICTION SUMMRY 78 series Solar Pump Station: Single-line solar pump station for pressured closed-loop systems with or without pump. Connections ¾ inch female straight thread. Brass body. Steel and aluminum temperature gauges in return connection. EPDM seals, O-Rings and gaskets, asbestos free. PP insulating she, thermal conductivity 0. BTU in/hr ft² F 0.07 W/(m K) at 0 F (0 C). Ba valves with built-in flow checks in return line. Expansion tank connection ½ inch male straight thread. Fiilng/drain hose connections ¾ inch male hose thread. Suitable fluids: water or 0 percent maximum glycol solution. Maximum working temperature 0 degrees F (7 degrees C). Maximum working pressure 4 psi (0 bar). Safety relief valve temperature range minus to degrees F (minus 0 to degrees C). Safety relief valve factory set at 90 psi ( bar). Minimum opening shut-off and check valve differential pressure ¼ psi ( kpa). Flow meter scale to 8 gpm. Maximum return flow meter temperature degrees F (0 degrees C). Pressure gauge scale 0 to 4 psi (0 to 0 bar). Temperature gauge scale to degrees F (0 to degrees C). 787 station without pump. 787 includes Wilo Solar Star S- speed pump. Cast iron body. Power supply V - 0 Hz. Maximum pressure psi (0 bar). Maximum temperature 0 degrees F (0 degrees C). gency approval: culus. Provide with SolarFlex adapter or sweat fittings for top and bottom return connections, ½ inch, ¾ inch or inch. 79 series Solar Pump Station: Dual-line solar pump station for pressured closed-loop systems with or without pump. Connections ¾ inch female straight thread. Brass body. Steel and aluminum temperature gauges in return and flow (supply) connections. EPDM seals, O-Rings and gaskets, asbestos free. PP insulating she, thermal conductivity 0. BTU in/hr ft² F 0.07 W/(m K) at 0 F (0 C). Ba valves with built-in flow checks in return and flow (supply) lines. Expansion tank connection ½ inch male straight thread. Fiilng/ drain hose connections ¾ inch male hose thread. Suitable fluids: water or 0 percent maximum glycol solution. Maximum working temperature 0 degrees F (7 degrees C). Maximum working pressure 4 psi (0 bar). Safety relief valve temperature range minus to degrees F (minus 0 to degrees C). Safety relief valve factory set at 90 psi ( bar). Minimum opening shut-off and check valve differential pressure ¼ psi ( kpa). Flow meter scale to 8 gpm. Maximum return flow meter temperature degrees F (0 degrees C). Pressure gauge scale 0 to 4 psi (0 to 0 bar). Temperature gauge scale to degrees F (0 to degrees C). 790 station without pump includes Wilo Solar Star S- speed pump. Cast iron body. Power supply V - 0 Hz. Maximum pressure psi (0 bar). Maximum temperature 0 degrees F (0 degrees C). gency approval: culus. Provide with SolarFlex adapter or sweat fittings for top and bottom flow (supply) and return connections, ½ inch, ¾ inch or inch. 789 drainback pump station Solar Pump Station: Single-line solar pump station for drainback systems with pump. Connections ¾ inch female straight thread. Brass body. Steel and aluminum temperature gauges in return connection. EPDM seals, O-Rings and gaskets, asbestos free. PP insulating she, thermal conductivity 0. BTU in/hr ft² F 0.07 W/(m K) at 0 F (0 C). Ba valves with built-in flow checks in return line. Expansion tank connection ½ inch male straight thread. Fiilng/drain hose connections ¾ inch male hose thread. Suitable fluids: water or 0 percent maximum glycol solution. Maximum working temperature 0 degrees F (7 degrees C). Maximum working pressure 4 psi (0 bar). Safety relief valve temperature range minus to degrees F (minus 0 to degrees C). Safety relief valve factory set at 90 psi ( bar). Minimum opening shut-off and check valve differential pressure ¼ psi ( kpa). Flow meter scale to 8 gpm. Maximum return flow meter temperature degrees F (0 degrees C). Includes Grundfos Solar -U pump. Cast iron body. Power supply V - 0 Hz. Maximum pressure psi (0 bar). Maximum temperature 0 degrees F (0 degrees C). gency approval: UL standard 778 and CS standard C. No. 08 certified by Intertek. Provide with SolarFlex adapter fittings for top and bottom return connections, ½ inch, ¾ inch or inch.. We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice. Caleffi North merica, Inc. 88 W. Milwaukee Road Milwaukee, WI 8 Tel: Fax: sales@caleffi.com Copyright Caleffi North merica, Inc.