CIRCO5SolarCirculationUnit

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TECHNICAL INFORMATION / INSTALLATION MANUAL CIRCO5SolarCirculationUnit Wagner& Co CIRCO 5 Solar Circulation Unit the reliable pump station for efficient circulation of the heating fluid in

1 TECHNICAL INFORMATION / INSTALLATION MANUAL CIRCO5SolarCirculationUnit Wagner& Co CIRCO 5 Solar Circulation Unit the reliable pump station for efficient circulation of the heating fluid in combination with SUNGO controls Fast Installation through pre-mounted parts and compression fittings for the connection to the solar circuit Safe deaeration by integrated air venting pipe Variable Installation wall mounting or fitted directly to the storage cylinder Function Control through flow meter and thermometers Controlled heat flow by two temperature resistant non return ball valves High Energy Efficiency All around insulation and speed controlled circulation pump (in combination with all SUNGO solar controllers) Figure 1 CIRCO 5 solar circulation unit (SUNGO is an optional extra) Solar Thermal / Solar Circuit EN-CIRCO-5-MA

2 1. General Safety Guidelines The following safety advice is deemed to protect against dangers that can arise from improper handling of the device, whether knowingly or unknowingly. We distinguish between general advice which is given on this page and special advice which can be found in the texts of the instructions. Watch for the symbols! Qualification of the installer Setting up, installation and commissioning of the CIRCO 5 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 protocol. Use and application Function The CIRCO 5 solar circulation unit is suitable for solar hot water systems and solar heating systems together with antifreeze solar as recommended. Limitations of use Use is limited to the hydraulic layout of the schematic drawings supplied by Wagner and Co. Some solar installations for space heating and the application of vacuum tube collectors do require special means of overheating protection, like the installation of an auxiliary vessel or alternative positioning of the safety components. The CIRCO 5 solar circulation unit can be mounted to a wall or directly to the storage cylinder. The CIRCO 5 solar circulation unit must not be mounted outside. Danger to Persons Live-threatening electrical shocks, burns, bruising and other health hazards are possible during installation. Please ensure that you pay attention to guidelines that are indicated with this symbol in the documentation. Caution Danger to Property This symbol indicates that damage may be done to components of the solar circuit or the function of the same may be impaired seriously. Please make sure that you follow the installation procedure step by step as instructed. Indicator for Additional Information This symbol points to practical advice, tricks of the trade which will make the installation and operation of the solar circuit easier. Norms and guidelines EC conformity declaration The CIRCO 5 solar circulation unit has been designed and constructed in accordance with EU regulations. Please regard national and EU regulations and guidelines for installation work. 2 EN-CIRCO-5-MA

3 2. Technical Information List of parts supplied The CIRCO 5 solar circulation unit is supplied pre-assembled. SUNGO control and CIRCO expansion kit are not part of the unit. You can find additional accessories on the last page. Maximum number of collectors to be installed Coll.- Type Serial-/Parallel connections * Serial connections 18 Ø 22 Ø 28 Ø 18 Ø 22 Ø 28 Ø EURO 2 x 3 3 x 3 x 3 Parallel connections LBM LBM * Number of fields each with 3 collectors connected in series Table 1 Maximum number of collectors that can be installed depending on the collector type, way of connection and size of piping. Single length of solar circuit up to 20m; heat carrier: frost protection/ water 0/ 60 % per. Volume, Volume flow = 35l/m²/hConnection and connection hoses at collectors are taken into account. Size of expansion vessel Fluid litre Coll. area m² Vessel volume in litres for system height in metres 2,5 5 7, , , CIRCO 5 solar circulation unit Order No Insulation Mounting plate Max. operating pressure EPP (λ = W/mK), in three parts with snap-lock Steel, galvanised 6 bar Max. operating temperature 120 C Circulation pump Wattage Max. pumping height Max. pumping volume Controller Non-return valves Temperature indicator Flow meter Safety unit Filler units Expansion vessel connection Security valve exhaust connection Solar circuit connections Centres distance of solar circuit connections ST 25/6 (230V, 50 Hz) 3 pump levels, /62/81 Watt 600 mbar 3.5 m³/h Suitable for SUNGO S/SL/SXL 2 x Heat-resistant metal 2 Integrated Thermometers Flow meter resistant to dirt clotting Safety valve 6 bar DN 15 in accordance with EN 12977, manometer 2 Filler and drain valves with caps ¾" male ¾" female Compression Fittings 18 and 22 mm 125 mm 2 12, Table 2 Size of expansion vessel depending on the fluid content of the entire system, collector area and height above vessel (distance vessel to upper edge of collectors). Dimensioning scenario: system exposed to full sun light but inactive. These values are only valid up to about 0.5 litres per m² collector volume. Installation options Dimensions (H xwxd) Weight Suitable for wall and cylinder installation (see accessories) 20x260x190mm 6.7 kg 7 v 0 0,5 1,0 1,5 2,0 [m/s] maximum H [m] economy ,0 2,0 3,0 [m /h] Figure 2 Pump characteristics curves Figure 3 Front and side view, measurements in mm 18 EN-CIRCO-5-MA

4 3. Installation compression fitting manometer safety valve ball valve with integrated thermometer and non-return valve compression fitting filler and drain valve air-release pipe circulation pump flow meter with filler and drain valve spring clips 15 D Figure The parts of the CIRCO 5 solar circulation unit (numbering fits to numbers in brackets at description of assembling steps), items with No. 7, 8, 9, 10, 12 and 1 are not part of the circulation unit. EN-CIRCO-5-MA

3.1 Installation Preparations The entire layout of flow and return pipes should be clear before mounting the CIRCO 5 solar circulation unit (125 mm centres)!

5 3.1 Installation Preparations The entire layout of flow and return pipes should be clear before mounting the CIRCO 5 solar circulation unit (125 mm centres)! In this context please also observe the operation instructions "Commissioning the System" If the solar system is installed for heating or if vacuum tubes are used you must pay attention to the technical documentation Heat Protection. These tools are required for the installation of the CIRCO 5 solar circulation unit: Power drill, masonry bits, pipe wrench, stilton etc. (figure 5). 3.2 Wall Mounting Use spirit level to place the wall mounting bracket (1), see figure, into the correct position, mark the three holes, drill and fix with plugs and screws supplied. Place the two pieces of assembly (2+6) into the correct holders of the wall mounting bracket and affix with the two spring clips (3). Place the two halves of the back insulation () with the recesses over the wall mounting bracket and push together. Connect the safety group (5) with the included ¾" gasket to the free exit of the return unit (6) using an open wrench SW30. Make sure of proper clamping during the tightening of the compression fittings to prevent damage or loosening of other parts of the assembly. Use the included wall anchors and screws to connect wall-mount (7) for the expansion vessel (8) to the right of the safety group. Observe length of the ¾" corrugated tube (9). There are special wall mounting kits for 35 litre and 50 litre vessels. Figure 5 Tools required for the installation of the CIRCO 5 solar circulation unit Rinse solar pump station and solar circuit and check for leaks. For this procedure a filler valve is fitted to the safety unit (5) and the flow meter below the pump. Install electrical wiring, switching and sensor circuits (12). Fix cables with cable ties to the prepared sections (notches and long holes) to the wall mounting bracket and ensure that there are no forces on the connectors of the control unit and that there is no contact with hot piping. If required feeding holes can be enlarged with a sharp knife. Always disconnect mains when working with electrical equipment! Remove frame (13) from the pump station in order to install the SUNGO control. Open SUNGO control (1) and affix with the four screws (15) supplied to the wall mounting bracket. You will find all required installation and operating instructions in the manuals for SUNGO S, SUNGO SL and SUNGO SXL. Put front insulation (16) into place. Connect the flexible hose with the expansion vessel and the pump station using supplied ¾ gaskets. It is recommended to fit in a special cap check valve between flexible hose and vessel. Connect exhaust pipe (10) to the safety unit and put empty container in place to collect any spills from the pipe. The connections to the solar circuit (11) (distance of pipes see figure 3) are made by compression fittings 18 or 22 mm (figure 6). Cut, burr pipes and push into fittings as far as possible, then tighten nuts. Using the 18 mm compression fitting a cracking sound will be heard, which is a sign of proper tightening. Continue until fully tight. Do not solder 18 mm compression fitting. Here too, special care must be taken to ensure proper clamping to prevent damage or loosening of other parts of the assembly. compression fitting for 22 mm snapping point compression fitting for 18 mm Figure 6 Compression fittings 18 and 22mm EN-CIRCO-5-MA

6 3.3 Mounting to Cylinder The adjustable mounting kits can be used with all Wagner solar cylinders with 1¼" flat tightening connections, if the vertical distance of these is between 00 and 60 mm. In order to prevent later obstructions of the pipe work in the area of the cylinder it is necessary to make proper layout plans before commencing. Connect pipes to cylinder using supplied gaskets. Adjust the height adjustment until both pipes are reaching the same level and have a distance of 125mm. Tighten adjustment nut. Trim off the insulation of the adjustable pipe and place pump station on top. Level the unit and affix to the cylinder. Connect remaining pipe work. 125 D=22mmfor compression fitting adjustable pipe fixing nut In order to prevent forces to the cylinder fixing because of pull from pipe work, pipe fixtures should be used at a near wall or at the ceiling. 50 mm The expansion vessel must not be hung from the pump station. Apply wall or floor mounting, depending on type of vessel. Always ensure proper clamping when tightening 32, 1 and 6 mm nuts in order to prevent loosening of other joints or damage to the unit. suitable for 50 mm to 69 mm 1¼ nut insulation filler and drain valve Figure 7 The adjustable cylinder mounting kit consisting of: Adjustable return pipe fitted with filler and drain valve, including insulation and fittings: 1¼" nut and 22 mm sleeve for compression joint. Flow pipe including insulation and fittings: 1¼" nut and 22 mm sleeve for compression joint. 6 EN-CIRCO-5-MA

7 +. Operating Advice The Flow Meter The flow meter indicates flow if the pump is switched on. The exact value can be read from the display. It is possible to adjust the flow by turning the adjustment screw with a mm Allen key during pump operation. If the screw is turned fully clockwise, flow will stop completely. Flow is cut off, when set screw is turned right to stop position. The Return-Flow Stoppers When the circulation pumps are turned of, unwanted heat distribution in the solar circuit is prevented by non-return ball valves. They only open into the flow direction and by pump pressure. The ball-valve handles can be used to turn them off. During operation litre/minute example 8 litre/minute mm + + Flow on Ball valve handle vertical Non-return valve in operation Flow off Ball valve handle vertical Non-return valve in operation Figure 9 Operational position Figure 8 Flow meter of the CIRCO 5 solar circulation unit with adjustment option Filling the system + Flow on Ball valve handle 5 Flow open, non-return valve off Flow off Ball valve handle horizontal Flow closed Figure 10 Filling the system Emptying the system + + Flow on Ball valve handle 5 flow open, non-return valve off Flow off Ball valve handle 5 Flow open, non-return valve off Figure 11 Emptying the System EN-CIRCO-5-MA

210 22 Automatic air release kit Consisting of 2 automatic air release valves and heat resistant ball valves (up to 200 C), connection 3/8" 190 210 11 Manual air release set Consisting of 2 Manual

8 5. Accessories Accessories Description Order No. Kit for solar circuit Air release kit (not normally required because of included air vent pipe) Accessories for the solar circuit pipe work: 2 filler and drain valves and 2 earth connector clips Automatic air release kit Consisting of 2 automatic air release valves and heat resistant ball valves (up to 200 C), connection 3/8" Manual air release set Consisting of 2 Manual Air Release Valves 3/8" and Key CIRCO expansion vessel kit Expansion vessel for the CIRCO 5 solar circulation unit, operating pressure max. 10 bar, stainless steel connection hose, connection ¾" female with gasket 12 l-volume, incl. wall mounting bracket, pre-pressurised: 1.5 bar 18 l-volume, incl. wall mounting bracket, pre-pressurised: 1.5 bar 2 l-volume, incl. wall mounting bracket, pre-pressurised: 1.5 bar 35 l-volume, with brackets for wall and floor fixing, pre-pressurised: 2.5 bar Cap check valve for expansion vessel Check valve 3/" with filler and drain valve and with cap against maloperation Cylinder mounting kit for CIRCO 5 Non-adjustable pipe work 1¼" male flat tightening, insulated, adjustable return pipe for cylinder connections with 00 to 60 mm vertical distance, with 22 mm sleeves to connect to compression fittings of CIRCO Subject to modifications, errors excepted. Wagner & Co, WAGNER & CO Zimmermannstraße 12 D Cölbe/Marburg Fax

Solar Controller SUNGO S

OPERATING INSTRUCTIONS, Issue SW1201/ 2.01/ HW2.4 Solar Controller SUNGO S Wagner& Co Figure 1 Solar Controller SUNGO S. The benefits at a glance Large display to indicate temperature, balance values and