TECHNICAL INFORMATION / INSTALLATION INSTRUCTIONS...

Solar thermal / Collectors EN-USA_SECUSOL_TI-MA-111013-1121R800 1

TECHNICAL INFORMATION / INSTALLATION INSTRUCTIONS

Compact Solar Drainback System SECUSOL

Figure 1 SECUSOL-System

Operational Safety and Low MaintenanceWhen the pump is not operating, there is no solar fluid present in the collectors. Therefore the solar fluid and any downstream system components are protected against detrimental effects from overheat. Unwanted gravitational forces as well as operational faults due to air pockets are eliminated. A service intensive membrane expansion ves-sel, air bleeds and check valves are not required. Operati-on with common anti-freeze solar fluid prevents potential frost damage.

High Yield Thanks To: ● High transparency anti reflection glass ● Single surface absorber with selective vacuum coating ● Solid insulation of individual components

Simplified Installation and Start-Up ● Pre-assembled unit of storage tank, solar controller and solar circulator, including all safety components.

● Flexible copper double-pipe with only 12mm cross section, for simple and time saving piping (supplied by Wagner & Co).

● No expansion vessel and hence no setting of pre-pres-sure required.

● Very simple flushing and filling ● No venting of solar circuit required

Installation, startup and maintenance of the SECUSOL solar thermal installation are intended to be carried out by trained professionals only, e.g. in line with SRCC Stan-dard OG-300 installation guidelines or NABCEP certifica-tion. They have to be licensed, must be familiar with the IAPMO Uniform Solar Energy Code and must conform to applicable federal, state and local regulations, codes, standards and meet all legal requirements related to the installation of solar hot water systems as well as plumbing, electrical wiring and roof works.

Content

1 TechnicalInformation 21.1 Technical Data 21.2 Scope of Supply 81.3 Accessories 142 GeneralSafetyNotes 162.1 Symbols 162.2 Standards and Codes 162.3 Qualification of the Installer 172.4 Intended Use and Application 172.5 Pre Installation Notes 182.6 Function of the SECUSOL system 18

3 Installation 193.1 Preparation 193.2 On-Roof Installation 203.3 Free Standing Installation 243.4 General Notes about Storage Installation 293.5 Setting up the Storage Tank 293.6 Connection to Domestic Water Supply 293.7 Laying the Solar Circuit 313.8 Installing the Controller 354 Startup 364.1 DHW System 364.2 Backup Heating Circuit 364.3 Solar Circuit 365 ConnectingthestorageInsulation 386 AdvicefortheUser 387 MaintenanceandCare 398 Troubleshooting 40

2 EN-USA_SECUSOL_TI-MA-111013-1121R800

1 Technical Information

1.1 Technical Data

Table1 TechnicalData

FeaturesSECUSOL

250-1SECUSOL

250-2SECUSOL

350-2

Solarcollectors

Type EURO C20 AR-M EURO L42 or EURO C20 AR-M

Gross area / aperture area sq ft (m²)EURO C20 AR-M

28.1 sq ft (2.61 m²) / 25.7 sq ft (2.39 m²)

EURO L42

24.2 sq ft (2.25 m²) / 21.6 sq ft (2.01 m²

Collector racking On roof or free standing

Orientation of collectorHorizontal installation only (pitch of 10° – 85°),

max. permitted diversion from horizontal orientation: 2°

No. of collectors 1 2 (cannot be extended)

Solarcircuit

Collector circuit material (on site) Cu 12 mm, order as needed from Wagner Solar, see material requirements in table 8

Insulation material (accessory) see material requirements in table 8

Length of solar circuit (sum of flow and return legs)1 Minimum 16.4 ft (5 m) / maximum 98.4 ft (30 m)

Maximum operating pressure 87 psi (6 bar)

Installation height 2) Minimum 3.3 ft (1 m), from the bottom of the tank to the bottom of the collector Maximum 28 ft (approx. 8.5 m), from the bottom of the tank to the top of the collector

Minimum temperature Frost resistant up to 1.4 °F (-17 °C), if correctly filled 2)

Heat transfer fluid in collector loop

Water/propylene glycol mix only with 33 % glycol 1) ,filling capacity: 1.9 to 1.95 Gal (7.2-7.4 liters)

Solarcontroller

Name SUNGO US plus

Pump control Speed controlled

Overheat protection 180 °F temperature limitation for the tank

Storage

Nominal content 66 Gal (250 l) 92.2 Gal (350 l)

Stand by heating volume approx. 32 Gal (120 l) approx. 42 Gal (160 l)

Total height (including insulation) 62.83 in (1596 mm) 72.64 in (1845 mm)

Diameter (including insulation) 29.53 in (750 mm)

Permissible operation pressure / Permissible operating temperature

145 psi / 203 °F (10 bar / 95 °C)

Corrosion protection of the storage cylinder

Enamel coating according to DIN 4753 T3

Cathodic corrosion protection Mg sacrificial anode acc. to DIN 4753 T6

Cold/hot water connections 1" NPT (M)

Sensor connection Clip in lower tank area

Solar heat exchanger approx. 12.39 sq ft (1.15 m²)

Backup heating coil none / approx. 6.0 sq ft (0.65 m²), depending on type approx. 8.61 sq ft (0.8) m²

Socket for electrical immersion heater, Position:

1" NPSM (F)

Heat insulation (PU foam, polystyrene jacket)

Cylinder and lid approx. 2.25 in (75 mm) Base 1.57 in (40 mm)

Weight 285.5 lb (129.5 kg) 307.5 lb (139.5 kg)

1) See Figure 28 page31.

2) Lower edge of storage cylinder to lower edge of collector (Figure 28 page31).

3) In order to achieve higher frost protection, the glycol content needs to be increased to over 33 %. However, this results in increased pressure drop and hence a reduced maximum installation height and length of solar circuit. Please also observe the technical information of the solar liquid. If required feel free to contact our technical support.

EN-USA_SECUSOL_TI-MA-111013-1121R800 3

Figure 2 Dimensions of solar collectors EURO L42 (upper image) and EURO C20 AR-M (lower image).

40

.78

in

/10

35

mm

76.10 in/1933 mm

45

.79

in

/11

63

mm

EURO L42 HTF

3.1

5 in

80

mm

84.69 in/2151 mm4

7.8

3 i

n/1

21

5 m

m

EURO C20 AR M

42

.79

in

/10

87

mm

4.3

3 i

n

11

0 m

m

Throughout this document and all other Wagner & Co do-cumentation the term „flow“ refers to the hot, outgoing pipe leg, while the term „return“ refers to the the colder, incoming leg of the heating or solar circuit (the one retur-ning to the heat generating device).


Table2 Storagedimensionsininch(mm)

Pos.1 Dimension SECUSOL250 SECUSOL350

Total height (without insulation) 55.91 in (1420 mm) 70.75 in (1797 mm)

4 Socket (1"NPSM(F)), height above ground 34.13 in (867 mm) 44.72 in (1136 mm)

7Hot water connection (stainless steel and brass, 1NPT(M)) 2), height above groand

51.3 in (1303 mm) 66.26 in (1683 mm)

2Cold water connection (stainless steel and brass, 1NPT(M)) 2), height above ground

18.78 in (477 mm)

3 Solar flow / hot side (G ¾) 2), height 32.17in (817 mm)

5 Backup heating flow / hot side2) (¾ NPTM(M)) 2), height

If present: 36.10 in (917 mm) 46.69 in (1186 mm)

6 Backup heating return (¾ NPTM(M)) 2) /colder side, height

If present: 44.37 in (1127 mm) 57.01 in (1448 mm)

Diameter (without insulation) 23.62 in (600 mm)

Base ring openings Ø 11.81 in (300 mm)

1 Solar return / colder side, pump flange height above ground

13.8 in (350) mm

Legend: 1) Dimension position numbers from figures 3 and 4

2) Pipe thread DIN ISO 228-1 (cyl.), flat sealing

Figure 3 Dimensions SECUSOL 250 solar storage tank; (1) Flange with sacrificial anode; Dimensions of cylinders are without insulation. SECUSOL 250 is available with and without backup heat exchanger (upper coil). The image shows the version with upper coil. The version without upper coil does not feature the connections 5 and 6.

SECUSOL 250

1

12

3

5

6

7 1" NPT(M)

1" NPT(M)

3/4" G1" NPSM (F)

3/4" NPT(M)

3/4" NPT(M)

3/4" NPT(F)

4

11.81 in300 mm

18.7

8 in

(477

mm

)

32.1

7in

(817

mm

)

36.1

0 in

(91

7 m

m)

44.3

7 in

(112

7 m

m)

51.3

in (1

303

mm

)

55.9

1 in

(142

0 m

m)

23.62 in (600 mm)


Figure 4 Dimensions of SECUSOL 350 solar cylinder (without insulation). (1) Flange with sacrificial anode

1

SECUSOL 350

1

2

3

45

6

7

3/4" G

1" NPT(M)

1" NPT(M)

1" NPSM (F)

3/4" NPT(M)

3/4" NPT(M)

3/4" NPT(F)

11.81 in300 mm

18.7

8 in

(477

mm

)

32.1

7in

(817

mm

)

46.6

9 in

(118

6)

43.5

4 in

/ 1

106

mm

57.0

1 in

(144

8 m

m)

66.2

6 in

(168

3 m

m)

70.7

5 in

(179

7 m

m)

23.62 in (600 mm)


Figure 5 Connection options for the EURO L42 for on-roof and free-standing installation, with sensor positions, dimensions of the collector field and racking system. The absorber connections can point to the left or to the right. (1) Solar sensor; (2) Rail; (3) Rafter bracket or roof anchor; (4) Racking triangle.

On roof

Free standing setup

EURO L42

1

2

3

4EURO L42

76.1 in / 1933 mm

76.1 in / 1933 mm

>160 in / 4060 mm

91

.57

in

23

26

mm

45

.79

in

11

63

mm

45

.79

in

11

63

mm

45

.79

in

11

63

mm

45

.79

in

11

63

mm

>160 in / 4060 mm


On roof

Free standing setup

EURO C20 AR-M

1

2

3

4EURO C20 AR-M

84.69 in / 2151 mm

84.69 in / 2151 mm

>177.17 in / 4500 mm

95

.79

in

24

33

mm

47

.83

in

12

15

mm

47

.83

in

12

15

mm

47

.83

in

12

15

mm

47

.83

in

12

15

mm

>177.17 in / 4500 mm

Figure 6 Connection options for the EURO C20 AR-M for on-roof and free-standing installation, with sensor positions, dimensions of the collector field and racking system. The absorber connections can point to the left or to the right. (1) Solar sensor; (2) Rail; (3) Rafter bracket or roof anchor; (4) Racking triangle

Figure 7 Design principle of the SECUSOL system. Left hand side: When in idle state, the collector loop and the collctor are filled with air (light-coloured lines). The solar fluid (darker lines) is located in the heat exchanger. Right hand side: When the system is in operation the air is pushed into the upper loops of the heat exchanger by the rising solar fluid.

System air

System air

Collector

Solar liquid

Solar liquid

System idle System in operation

Storage Storage

Heat exchanger

Pump


1.2 Scope of Supply

The complete system is delivered with the following com-ponents:

Table3 Components Qty.

Collector EURO L42 1 or 2

Collector EURO C20 AR-M 1 or 2

Solar storage, nominal content 250 l or 350 l, respectively (screwed onto pallet), incl. solar flow and return group with circulator and solar controller SUNGO US plus 1)

1

1 plug 1" NPSM (fixed to pallet), for closing the storage socket

1

1) For details see Table 5 and Figure 8

Table4 ScopeofSupply Systemwith

Boxedcomponents 1coll.

2coll.sidebyside

2coll.oneabovetheother

Customer information folder with instructions and system documentation

1

Solar liquid DC20 F 2.5 l in 5 l canisters

1

Collector adapter set 1

US Secusol serial connection set 1

US Secusol parallel connection set 1

Roof anchor / rafter bracket (only for on-roof installation)1) 4 8 8

1) Minimum no., actual no. depends on structural and geographical situation.

Table5 Scopeofsupply,storage SECUSOL250/SECUSOL350

Position 1) Components Quantity

1 Jacket insulation 1

2 Cover insulation 1

3 Ground insulation 1

4 Storage cylinder lid 1

5 Solar controller 1

6 Container 1

7 Socket cover with integrated protective anode 1

8 Solar return subassembly 1

9 Ventilation opening 1

10 Plug 1" NPSM 1

Compression olive fitting 12mm 2

13 Storage cylinder connection nozzle 5

f Collector sensor 1

k Collector sensor cable 1

n Mains cable 1

p Pump cable 1

s Storage cylinder temperature sensor 1

1) Position numbers from Figure 8.


Figure 8 Scope of supply of the SECUSOL storage cylinder shown for the 250 l- (see table 5 for a position number legend).

s

n

k

7

2

4

5

p

6

8

9

10

3

1

13

f


NoteThe roof brackets shown throughout this document are of the type A1 Pro+, specifically developed for common North-American asphalt shingle roofs. For installation details refer to the separate instructions coming with the roof brackets. Other roofing types require different roof anchors.

Set for single collector

Table6 Onroofracking,setforsinglecollector,scopeofsupply Singlecollector

Pos. 1) Components Quantity Partno.

1 Rafter bracket or roof anchor (recommended)²) (4)

2 Collector rail 49.5 in / 1257 mm (EURO C20 AR-M) with two collector clamps 2192 001 00

3 wire strip 1

4 Collector EURO C20 AR-M 1

192 040 625 Compression olive connection ½" - 12 mm 2

6 Gasket ½" 2

1) Position no. from Figure 10

2) Not included in the set, to be ordered separately

Figure 9 Single basic set for on-roof installation with collector EURO C20 AR-M

3

2

1

4

5

6

EN-USA_SECUSOL_TI-MA-111013-1121R800 11 11 EN-USA_SECUSOL_TI-MA-111013-1121R800

Table7 Onroofracking,setofcollectorsinstalledoneabovetheother,scopeofsupply Partno.

Pos. 1) Components Quantity forEUROC20 forEUROL42


2Collector rail 49.5 in / 1257 mm (EURO C20 AR-M) or 47.32 in / 1202 mm (EURO L42), respectively, with two collector clamps

2

192 000 98 192 001 023Collector rail 48.2 / 1223 mm (EURO C20 AR-M) or 45.98 in / 1168 mm (EURO L42) with one collector clamp

2

4 Rail connector 2

5 Wire strap 1

6 Collector EURO C20 AR-M or L42 2

7 Collector interconnection hose with insulation pieces and flat seals 1

192 040 648 Compression olive connection ½" - 12 mm 2

9 Gasket ½" 4



Figure 10 Set for on-roof installation of 2 collectors installed one above the other


1

2

4

3

5

8

9

6

7

Collector installation set for horizontal installation, one above the other


Collector installation set for horizontal installation, next to each other

Table8 Onroofracking,setofcollectorsinstallednexttoeachother,scopeofsupply Partno.

Pos. 1) Components Quantity ForEUROC20 ForEUROL42


2Collector rail 49.5 in / 1257 mm (EURO C20 AR-M) or 47.32 in / 1202 mm (EURO L42), respectively, with two collector clamps

4192 000 99 192 001 03

3 Wire strap 1

4 Collector EURO C20 AR-M or EURO L42 2

5 Compression olive connection ½" - 12 mm 4

150 303 93

6 Gasket ½" 4

7 Compression T-fitting 12 mm 2

8 Copper tube 12 mm 4

9 Foam insulation 4



1

32

9

8

4

56

7

Figure 11 Set for installation of 2 collectors next to each other


EN-USA_SECUSOL_TI-MA-111013-1121R800 13 EN-USA_SECUSOL_TI-MA-111013-1121R800 13

45

76

32

1

8

Table9 Freestandingracks,scopeofsupply Singlecollector;orderno.19200100

2Collectorsnexttoeachother;order2xno.19200100

Position 1) Components Quantity

1 Pre-assembled racking triangle 2 4

2 Hexagonal head screw M8 x 40 2 4

3 Nut M8 with locking teeth 2 4

4 Collector clamp – lower part 4 8

5 Collector clamp – upper part 4 8

6 Washer Ø 8.4 mm 4 8

7 Hexagonal head screw M8 x 30 4 8

8 Collector EURO C20 AR-M or EURO L42 2) 1 2

1) Position numbers from Figure 12.

2) Not included in the set

Figure 12 Set for free standing setup

Set for free standing rackets


1.3 Accessories

Table10 Accessories Description Partno.

Euro collector carrying handles (2 pieces) 192 040 60

Thermostatic Mixing Valve ¾" 150 303 83

Twin Cu solar circuit pipe comprised of insulated double copper pipe 2 × 12 mm with integrated temperature sensor line, 15 m coil

150 300 67

Oval clamp set for for Twin-Cu 150 301 18

Solar circuit insulation: flexible foam insulation 13x12 for single pipes (Aeroflex), 6.56 ft / 2 m length,

170 000 38

Flange cover gasket 139 001 15

Magnesium sacrificial anode 130 101 28

Temperature sensor Pt 1000 150 102 49

Storage cylinder height adjustment (always order 3!) 139 000 16

Earthing clamps (order 2!) 120 100 12

US Sensor connection box SP10 150 400 60


Table10 Accessories Description Partno.

US Secusol parallel connection set 150 303 93

US Secusol serial connection set 192 040 64

Collector adapter set 1/2“-12mm 192 040 62

US_Secusol Cx-threaded elbow connection set 12mm 819 110 99

4 x straight compression fitting 12mm 819 111 00


2 General Safety Notes

2.1 Symbols

Thefollowingsymbolsareusedthroughoutthese inst-ructionsandmustbeadheredto.READALL INSTRUC-TIONSCAREFULLYBEFOREBEGINNINGINSTALLATIONWORK:

ImmediateDANGERofseriouspersonalinjury,includingriskofdeathandlifelongdisability.

WARNINGagainstsituationsleadingtopossiblysevereinjuriesanddeath.

CAUTIONagainstsituationsleadingtominorinjuryandmaterialdamage.

NOTICEofsituationswhichmayleadtopropertydama-geifnoprecautionistaken.

Noteswithadditionalimportantorusefulinformation.

2.2 Standards and Codes

Buildingandplumbingpermitsand/orinspectionsmayberequiredforinstallation.Complywithallcoderequire-mentsandapplicablestandardsandregulations.

Snowandwindloads-riskofinjuryfromfallingobjectsorcollapsingstructuresComply with federal, state, county and city regulations and standards related to snow and wind load as well as structural planning in general. Only install the installation set on roofs that can structurally support the additonal load. In case of doubt, always consult a structural engi-neer or a roofer. Follow the Solar Rating and Certification Organisation SRCC OG 300 guidelines for safe collector installation.

Workonroofs-riskoffallandfallingobjectsresultinginpotentiallyseriousinjuryanddeath

WestronglyrecommendtofollowtheNAHB-OSHAJob-siteSafetyHandbook,especially:

1. Inspect for and remove frost and other slipping hazards before getting onto roof surfaces.

2. Cover and secure all skylights and openings, or install guardrails to keep workers from falling through the openings.

3. When the roof pitch is over 4:12 and up to 6:12, install slide guards along the roof eave after the first 3 rows of roofing material.

4. When the pitch exceeds a 6:12 pitch, install slide gu-ards along the roof eave

5. Use a safety harness system with a solid anchor point on steep roofs with a pitch greater than 8:12 or if the ground-to-eave height exceeds 25 feet.

6. Stop all operations on roofs when storms, high winds or other adverse weather conditions create unsafe con-ditions.

7. Remove or properly guard any impalement hazards.8. Wear shoes with slip-resistant soles.

Make sure to observe all federal, state, county and city re-gulations related to roof works and roof sealing standards as well as professional codes for plumbing work.Installers must be qualified and - where applicable - li-censed to work on roofs.

Riskofinjuryandmaterialdamageresultingfromimpro-perhandlingofcollectorandstorage

Use soft crane straps for lifting collectors with crane (ob-serve secure overhead transport!). Alternatively loop rope around the frame and pull collector up a secured ladder. We also recommend the use of two ladders and our special collector handles. Never attach ropes to coll-ector connections and never use connection pipes as handles! Only use the crane hoisting lugs on top of the storage tank for crane transport. Observe good practice standards for construction sites. Object is heavy and can cause severe injuries and damage upon falling.

UniformSolarEnergyCodeThe installation has to be carried out by a licensed pro-fessional in accordance with all professional standards, in particular all safety, health and environmental standards, as given by the IAPMO Uniform Solar Energy Code. For detailed information and to obtain the full text of the code contact IAPMO:International Association of Plumbing and Mechanical Officials5001 E. Philadelphia StreetOntario, CA 91761-2816 USAwww.iapmo.org

SystemIntegrationDuring integration of the storage tank into the domestic water supply and connection of the solar controller, all national and local health and safety regulations must be complied with, including relevant lightning protection regulations. When installing a backup heating device please follow the manufacturer‘s guidelines. Follow the Uniform Solar Energy Code.


ConformityThe SECUSOL solar energy system and its components were designed and manufactured in accordance with cur-rent European Union and United States laws and regula-tions. The system and its components are in compliance with SRCC OG 100, IAPMO and NSF testing and/or certi-fication standards, where applicable.

EN 806-1andprEN 1717:1999Provided the system is installed correctly, the require-ments of EN 806-1 and prEN 1717:1999 are met.

EN 12976andEN 12977The entire system was designed and manufactured accor-ding to the regulations in EN 12976 and EN 12977.

2.3 Qualification of the Installer

RiskofinjuriesresultingfrominsufficientqualificationSetup, installation and commissioning of the SECUSOL compact solar heating system must be carried out by au-thorized professionals (e.g. NABCEP or Wagner Academy certified or equivalent combination of knowledge and ex-perience). The installation should be carried out following the guidelines established by the Solar Rating & Certifica-tion Corporation (SRCC). See SRCC OG 300: SOLAR WATER HEATING SYSTEM DE-SIGN AND INSTALLATION GUIDELINES, available on the SRCC website at www.solar-rating.org.Please note that in case of a warranty complaint the war-ranty is only valid if the correct start-up has been certified in a commissioning report. Contact us for further infor-mation.

2.4 Intended Use and Application

Collectorsshouldbestored inside inadryplace.Out-doorstoragecanresultindamage.For proper outdoor storage, remove PE film, and lay down collectors with glass pane up. Avoid direct ground con-tact (e.g. underlay square timber). Avoid scratches on glass panes by using spacers between collectors (e.g. wooden laths). When leaning collectors against walls or similar, use a minimum inclination of 15° and apply spa-cers. Do not use cardboard as underliner. If incorrectly stored, humidity can enter the collectors through the air vents. Storing collectors in foil package can damage the glass surface (Figure 13).

Collectors:ScopeandlimitationsofapplicationThe collector is intended for the application in solar ther-mal installations for hot water preparation and space hea-ting support. ANY OTHER TYPE OF APPLICATION IS NOT PERMITTED unless explicitly permitted in writing by the manufacturer. Non compliance can lead to serious da-

Figure 13 Do not expose PE-film covered collector to rain

mage, health risks and renders all warranty void. As ope-rating mediums water (attention – risk of freezing!) or an appropriate water-glycol mixture can be used in a closed circuit. Prolonged operation of the collector at conditions below the dew point temperature within the collector is not permitted! This can occur, for example, when collec-tors are integrated in the brine circuit of a heat pump.

PreventingfrostdamageAfter pressure testing and flushing, collectors cannot always be completely emptied. Make sure that no pure water remains in collector during risk of frost!

UnfilledcollectoronroofAfter being installed on the roof, unfilled collectors should not be exposed to the sun for more than a few days. Otherwise thermal stress on gaskets can result in da-mage. Alternatively postpone the installation of gaskets to just before filling the solar circuit.

Maintenanceonlybytrainedprofessionals!Under normal operating conditions we recommend an-nual check and maintenance intervals. All testing, repair and maintenance work must be carried out by qualified and licensed professionals. For maintenance notes and additional information about setup and operation of the collector field, please refer to the technical information “Solar Thermal Systems - Setup, Commissioning and Maintenance”.


2.5 Pre Installation Notes

Riskofburnsatcollectorconnections!Collector connections can get very hot as soon as un-covered collector is exposed to the sun (figure 3). Wear gloves!

Dangerofopeninjuries!Always wear gloves to avoid severe cuts and lacerations when working with sharp edged metal sheets and com-ponents!

Riskofdamagetoabsorber!Remove protective plastic caps from connections before collector is exposed to the sun. Risk of molten plastic entering and damaging the absorber!

Riskofsuffocation!Remove glass protection PE-LD film before commencing installation work! (Figure 14) Keep plastic film out of reach of children!

2.6 Function of the SECUSOL system

FunctionThe SECUSOL solar thermal system is designed for dome-stic hot water (DHW) preparation.The solar fluid is pumped from the solar heat exchanger to the solar collector where it is heated. The thermal ener-gy carried by the solar fluid is then transferred to the do-mestic water in the storage tank. Backup heating of domestic water in the up-per part of the storage tank can be done via a suitable downstream continuous flow heater, an optional electrical immersion heater or via the integrated backup heating coil (not with SECUSOL 250 monovalent, i.e. only one heat exchanger), when connected to central heating. The included SUNGO US plus solar controller con-trols the circulation pump speed depending on the tem-perature difference between collector and storage. It also monitors the max. storage temperature. If the system is in stagnation, the entire solar flu-id is moved to the heat exchanger, while collector field and collector circuit are filled with system air (figure 7, left hand side). When the circulation pump is switched on, the collector and the collector circuit are filled with solar fluid and the system air is pushed into the upper coils of the heat exchanger (figure 7, right hand side). Once the storage tank is heated up to the maxi-mum temperature, the controller switches off the circu-lation pump. Normally the solar fluid automatically flows back to the heat exchanger. Otherwise if irradiation con-tinues, the solar fluid vaporizes in the collector field and the system is emptied this way. As the fluid retreats, the air within the system flows into the collectors which quickly reach their stagnation temperature. The heat transport to the tank stops and the solar fluid, which is temperature-sensitive, then is safely stored in the storage tank area.Using a solar fluid with 33 % glycol content ensures per-manent protection against frost damage, in addition to corrosion protection.By design heat loss from the storage tank due to over-night convective recirculation or thermosyphonic flows are impossible. Thus the installation of check valves is not required. The installation of venting equipment and a service-intensive membrane expansion vessel are un-necessary due to the special 2-phase operating system.

Operational LimitsNote that the storage tank and solar controller must not be installed outdoors and that the system may only be operated within the permitted operating conditions (Chapter 1: Technical Information).Due to the special system design a maximum of 2 collec-tors can be integrated. Retroactive extension of the coll-ector area is not possible.The maximum system height is 28 ft / 8.5 m, the maximum length of the solar circuit is 98 ft / 30 m (sum of flow and return legs, according to (Figure 28 page31).

Other Documents that have to be ObservedThe following documents must be observed during instal-lation and operation:

Figure 14 Remove glass protection film before installing collector!


● Operation instructions of the respective solar Control-ler SUNGO US plus.

● Technical information „Solar Liquid DC20 F “, the re-spective material safety data sheet and label on the canister.

● Technical information of the respective collectors

Material Specifications

Table11 Materialspecifications

Component Parameters Requirements

Solar circuit piping

Material Copper only

Dimension 0.47 in / 12 mm Cu

Pipe insulation

Outside UV-resistant

Inside No special requirements

Temperature resistance

Up to 347 °F /175 °C for a short time

Dimensionsandmeasurements

Dimensions usually are indicated in both: metric and US customary units. In case of doubt the metric dimensions must be considered more precise. The required screws are included in the package and conform to ISO metric standards. For some of the components included in the delivery no exact US pendants exist. In these cases only metric dimensions are indicated.

3 Installation

3.1 Preparation

Scope of SupplyBefore commencing the installation, please ensure that all components listed in table 3 and 4 are present.

Material Required on SiteIn order to complete the installation and commissioning of the SECUSOL solar energy system, the following is re-quired on site:

● Piping (copper pipe Cu12) for the collector loop pipes ● Insulation material for the collector loop pipes (for out-side use, UV-resistant), available as accessory

● Electric extension cable for the collector sensors (2 threads with cross section of 18/2 AWG.)

● Thermostatic DHW mixer, available as accessory ● Storage cylinder safety subassembly for cold water connection, available as an accessory,

For reasons of corrosion protection the collector loop must be made of materials meeting the requirements of table 8. Other materials are not permitted. Suitable con-necting methods are soldering, press fittings or clamp ring connectors.When installing the flat sealing connections please only use the original soft fiber sealants included in the deli-very. These sealants have been specially tested for this purpose.

Required ToolsThe following tools are required for the installation and fixing of the collector loop system:

● Combined wrench 13 mm / 1/2 inch (for hexagonal screw M8)

● Combined wrench 17 mm / 11/16 inch (for hexagonal screw M10)

● Pipe wrench ● 3/4" open-end ratcheting wrench (for collector con-nection)

● Electric power screw driver with star bit (e.g. TorxTM) set (for roof bracket fixation)

● 2 water hoses of 2 m / 6.56 ft length each, both with ½" hose connector on one side

● Water bucket with a minimum capacity of 2.64 gal / 10 li-ters

Safety NoteBefore installing the collectors, please read the informa-tion leaflet “Safety Precautions for the Installation of Coll-ectors”. Observe local statutory accident regulations as well as the technical installation rules described in these instructions. The SECUSOL system is suitable for on-roof and free stan-ding installation. The collectors have to be mounted ho-rizontally to allow them to empty in idle state and during stagnation.


Figure 15 Correct fixing of roof bracket type A1 Pro+ on rafter

3.2 On-Roof Installation

The on-roof racking system allows fast installation of the collectors on a pitched roof without having to open larger parts of the roof. This is achieved by positioning rafter bra-ckets on the roof. Rafter brackets of type A1pro+ for ex-ample are suitable for composition shingle roofs, as they are used in much of the north-eastern United States. The-re are also other bracket and roof anchor types available for a variety of roofings, including industrial metal sheet roofs. Two vertical mounting rails are fixed to the rafter brackets, and the collectors are installed horizontally on these brackets. All individual components are shown in figure 9 (see following page).

Fixing of the Roof-BracketsThe roof brackets of the type A1 Pro+ shown in this manu-al are given as examples only. The actual type and requi-red tools depend on the roofing.For more information refer to the installation instructions included with the roof brackets.

1

2

33


BA

B

12.5 lb-ft (17 Nm)

22.1 lb-ft (30 Nm)

C

C

Table12 Distanceininch/mm

Segment EUROC20AR-M EUROL42

A63 in - 74.8 in 1600 mm – 1 900 mm

59 in - 66.9 in 1500 mm – 1 700 mm

B max. 47.2 in / 1200 mm max. 47.2 in / 1200 mm

C max. 8 in / 200 mm max. 8 in / 200 mm

Already connect the rails while still on the ground

Figure 16 Overview of rail installation (upper image; collector clamps are pre-assembled). (1) supporting rail “1” fixed with two roof brackets and holding two collector clamps (2) supporting rail ”2“ fixed with rail connector to upper rail and one roof bracket; rail “2” holds one collector clamp.

For the side by side installation of two collectors the four supporting rails of type 1 (see figure 14) must be aligned at the given distance (see figures 5 and 6).

Installation of the Rails


12.0 lb-ft(17 Nm)

Figure 17 Installation of first collector

Install the upper collector first!

Installation of the Collectors

RISKoffallingobjectsandstructuraldamage

Improperly positioned collectors can lead to insufficient fixation! Loosen collector clamp slightly, then push tightly against collector and tighten screw (12.5 lb-ft / 17 Nm). After installation check for proper position.


X

Figure 18 Installation of the following collector when two collectors are installed, with one above the other


Improperly positioned collectors can lead to insufficient fixation! Loosen collector clamp slightly, then push tightly against collector and tighten screw (12.5 lb-ft / 17 Nm). After installation check for proper position.


49.49 inch (1257 mm)

58.66 inch (1490 mm) 20-200 mm

0.8-8 inch

20-200 mm

0.8-8 inch

Figure 19 EURO TRIC F horizontal for 35° - 50°

Figure 20 Installation pitch and setup dimensions for ground- or flat-roof installation (left) or facade installation (right)

Determining the pitch

Table13 Rackingpitch a[°] A C

EUROTRICF35°-50°

35°33.98 in 863 mm

0.39 in 10 mm

40°37.01 in 940 mm

5.79 in 147 mm

45°39.72 in 1009 mm

12.24 in 311 mm

50°42.13 in 1070 mm

20.51 in 521 mm

3.3 Free Standing Installation

A

C


33

2

1

M8 x 4012.5 lb-ft (17 Nm)

12.5 lb-ft (17 Nm)

Figure 21 Unfold racking triangle, set correct angle and lock in position

Installation of Racking Triangles

Use appropriate wrench, e.g. combined wrench 13 mm / 1/2 inch, such as Met-rinch MET-1113, or adjustable spanner.


max. 7.9 in (200 mm)

max. 7.9 in( 200 mm)

Ø 10.5 mm0.413 in (gauge Z)

Figure 23 Fixing the racking triangles on steel beams

Figure 22 Maximum rail projections

Fixing of Racking TrianglesFixing the racking triangles on different surfaces is depic-ted below. Local building standards and codes and struc-tural guidelines must be observed. Assure sufficient car-rying capacity of the installation surface. In case of doubt feel free to consult our technical department.


Ø 12 mm0.472 in

Figure 24 Fixing the racking triangles with concrete-slab installation kit (part no. 192 020 77)

Use appropriate wrench, e.g. combined wrench 17 mm / 11/16 inch, such as Met-rinch MET-1117. or adjustable spanner.


X

X

For the C20 AR-M use the lowest rivet nut and for L42 the one above the lowest.

Figure 25 Connecting collector and racking triangle

Installation of the Collectors on the Racking Triangles

Risk of injury from collapsing collector racks!

Make sure that the collector racks are properly set up and all screws are fastened before pla-cing the collectors. Improperly set up racking triangles could collapse and lead to injuries of limbs. Wear appropriate protective workwear!

Use appropriate wrench, e.g. combined wrench 17 mm / 11/16 inch, such as Met-rinch MET-1117. or adjustable spanner.


Improperly positioned collectors can lead to in-sufficient fixation! Loosen collector clamp slight-ly, then push tightly against collector and tighten screw (12.5 lb-ft / 17 Nm). After installation check for proper position.


3.4 General Notes about Storage Installation

The pre-assembled return flow sub-assembly has a 12 mm pipe nozzle on the solar circuit side (➊) --> Numbers in black circles refer to Figure 26.

3.5 Setting up the Storage Tank

Please observe the following when setting up the storage tank (Figure 8 page9):The tank insulation consists of 3 parts, the tank insulation (1), the cover insulation (2) and the pre-installed ground insulation (3).

● Remove the tank insulation, the storage cylinder lid (4) as well as the cover insulation and put safely aside.

● Unscrew cylinder (6) from the pallet and carry to its final position. Note that the enamel coating of the storage tank can be damaged if jolted.

● Remove 1“ NPSM plug (10) from the pallet and put aside.

● Place the storage cylinder so that the connections will face the wall.

● During transport a cable binder is used to secure the pre-wired controller at the cylinders hoisting lug. Cyl-inder temperature sensor and pump control cable also are pre-wired.

3.6 Connection to Domestic Water Supply

Hot and Cold Domestic WaterCold and hot water connections must be done according to the rules and regulations of your local water supplier. We recommend the connection as shown in Figure 26

● Connect a safety subassembly (2) with a safety valve and a non-return valve according to DIN 1988 to the cold water inlet of the tank (➋). Within the United States the installation of an IAPMO compliant backflow pre-venter is mandatory for all installations connected to the drinking water supply.

Riskofseriousscaldingfortheenduser!Water temperatures at hot water taps can reach up to 203 °F / 95 °C!A thermostatic mixing valve must be installed to avoid in-juries to end customers!

● It is absolutely necessary to install a thermostatic mix-ing valve (3) since temperatures during the summer months can reach up to 203 °F / 95 °C at the hot water outlet. ➐ Without thermostatic mixing valve there is a considerable risk of scalding. The thermostatic mixing valve can be connected between safety subassembly (2) and the cold water connection at the storage tank ➋ using a T-piece.

● Close the 1" NPSM socket ➍ with the plug and seal thoroughly. Alternatively an electrical immersion heat-er is available which can be installed in this socket, as outlined in the chapter “Backup Heating”.

● Re-tighten bolts around flange cover (6) to ensure leak-age-free operation.

Re-CirculationThe return leg (8) should be led away just before the tap-ping point (10). The circulation pump (9) should be cont-rolled according to the hot water temperature at the most distant tap (sensor 11). We recommend that the circula-tion should be returned to the cold water inlet (4) of the thermostatic mixer (3). A check valve should be installed in the circulation pipe. Please note that circulation can cause significant loss of heat. Hint: use a time, tempera-ture or tap-event controlled circulator.


Figure 26 Connection example for SECUSOL storage cylinder

1

2

3

5

6

7

10

8

4

1

2

3

9

5

6

7

11

1216

13

14

15

19

20

1 Cold water supply 2 Storage cylinder safety sub

assembly 3 Thermostatic mixer 4 Cold water return 5 DHW distribution pipe 6 Socket lid 7 Protective anode 8 Re-circulation return 9 Re-circulator pump10 DHW tap11 Temperature sensor

12 Sensor clamp13 Solar circuit pump14 Safety valvel15 Filling/emptying cock16 Solar circuit flow sub -assembly19 Backup heat exchanger20 Solar heat exchanger

Storagecylinderconnections:➊ Solar circuit return➋ Cold water feed➌ Solar circuit flow➍ Electric immersion heater➎ Backup heating flow/feed

(not with SECUSOL 250 mono)

➏ Backup heating return (not with SECUSOL 250 mono)

➐ Hot water connections

4


3.7 Laying the Solar Circuit

Connecting the Solar Sub AssembliesPlease note: when the pipes of the solar circuit are soldered, they must be flushed before connecting them to the storage cylinder (see chapter 4, Start-Up).

● Connect the inlet subassembly to the solar flow inlet of the storage tank (6) using the locking nut (5). Don‘t forget the flat seal (2). Align the filling tap horizontally or upwards (Figure 27).

Information: Here flow and return refer to the hot and cold sides at the solar collector. As a result the solar flow is the incoming leg at the solar storage heat exchanger.

● The return sub-assembly with solar circulation, safety sub-assembly and filling/emptying cock is pre-assem-bled. (Figure 26 pos. 13–15). If necessary, the screw fittings of the return and the inlet subassemblies should be re-tightened to ensure leak tightness.

Operational faults can lead to a discharge of fluids from the safety valve. To avoid soaking of the cylinder insulati-on we recommend discharging the fluid with a 1" Cu pipe or similar via the back ventilation opening at the bottom of the insulation (to be provided on site).

Figure 27 Solar circuit with flow sub-assembly 1 Copper-T-piece; 2 Flat sealing gaskets; 3 Filling/emptying cock; 4 Straight compression coupling, 12 mm; 5 Swivel nut; 6 Solar circuit pipe; 7 Storage cylinder connection nozzle of solar flow leg.

L 10

L 11

H

Figure 28 Solar circuit and definition of system length/height L11 = length of the flow pipe; L10 = length of the return pipe; H = system height (from the bottom of the tank to the top of the collector).

Connecting the Solar CircuitObserve the operational limits of the SECUSOL system in terms of system height and solar circuit length (Figure 28 and table 1) as well as the permitted connection schemes (Figure 5 and Figure 6). Only 12 mm copper pipes may be used for the solar circuit (included in the delivery).

● The collector loop pipes (figure 27) should be installed with down-grade slope from the collector connections to allow for fast emptying during times of inactivity. The collector loop can be installed without using el-bow pieces.

● The solar circuit can be layed without penetrating the roof see Figure 29.

● If pipes have to be led through the roofing, ventilation tiles or other safe roof penetrations complying with local building codes are required on site (Figure 30). Place the ventilation tile or pipe duct at the lower edge of the collector, below the collector connection. The upper rim of the elbow pipe under the roof must be installed lower than the collector connection (detail A). When installing a single collector or two collectors one above the other, the upper ventilation tile or duct has to be placed higher than the upper edge of the collec-tor (detail B).

● Use the included 12 mm coupling to connect the solar circuit return and flow legs (Figure 27 for the example of the solar flow sub-assembly) to the respective subas-sembly. Saw off the pipe ends, deburr the ridges and fully insert into the coupling. Then tighten nuts.3

1

2

34

5

6

7


Figure 29 Laying of solar circuit pipe along the outside wall.

1

12

h

1

12

h

B

A

Figure 30 Laying the solar circuit with penetration of the roof; detail A: Lower collector edge, detail B: Upper collector edge; 1 Collector connection; 12 Venting roof-tile.

1

12

h

1

12

h

B

A


Figure 31 Connecting two collectors placed next to each oth-er: 1 Collector connection; 2 Compression fitting ½" – 12 mm with flat sealing gasket; 3 Compression-fitting T-piece, 2 mm; 4 Con-necting pipes with insulation and 5 Solar circuit connections (copper pipe pieces, not part of the package).

Connecting the Collectors Depending on the type of connection, solar circuit and collectors are connected according to Figure 5 and Fi-gure 6).NOTE: When tightening the joints at the collector connec-tions there is a risk of damaging the absorber. The absor-ber should not be subjected to torque forces, therefore the connection at the collector side should be secured with an open spanner when tightening!

Connection variant with two collectors next to each other (Figure 31 below):

● Attach a compression fitting (2) to each of the levelled connections facing each other, and connect them with flat sealing gaskets to the collector connection noz-zle 1).

● Connect included short pieces of 12 mm copper pipe (4) to the compression fittings (2). Cut to length as needed.

● To avoid damage to the absorber, no pressure must be exerted onto the absorber pipe during the following insertion of the compression fitting T-piece (3). The col-lector therefore must be loosened for a moment at its four connection clamps and then pushed outwards.

● Insert compression fitting T-piece (3), return loosened collector to its previous position, and re-tighten the col-lector clamp screws.

● Tighten the lateral compression fitting nuts of the T-piece and the inserted pipes (4).

● Connect 12 mm copper pipe (5) of the solar circuit to the unconnected middle connection of the T-piece (3).

● Check all connections for tightness after completing all installation works.

Figure 32 Connection of two collectors, one above the other: 1 Collector connection; 6 Collector connection with flat sealing gaskets and 7 Insulation pieces.

Figure 33 Solar circuit connection of a single collector or of two collectors placed one above the other: 1 Collector connec-tion; 2 Compression fitting ½" – 12 mm with flat sealing gas-ket; 5 Solar circuit copper pipe (not part of the package).

1

5

2

5

3

12

24

4

Connection variant with two collectors one above the other (Figure 32):

● Slip insulation pieces (7) onto the adjacent collector connection nozzles.

● Then connect one connection of the collector connec-tion hose (6) to a collector connection nozzle (flat seal-ing).

● Bend connection hose and connect it in the same fash-ion to the connection nozzle of the adjacent collector.

● Pull the ends of the connection hose rubber bellow over both connection nozzle insulation pieces (7).

● The connections to the solar circuit are carried out in the same fashion (see below).

1

1

6

7

Variant with single collector (Figure 33): ● Connect compression fitting (2) to collector connection nozzle (1, flat sealing).

● Connect 12 mm copper pipe (5) to compression fit-ting (2); secure with open spanner during tightening to avoid damage to the absorber.

● Check all connections for tightness after completing the installation work.


Figure 34 Installing the collector sensor 5 Rubber grommet of sensor sleeve; 6 Collector sensor; 7 Sensor sleeve.

56

7

7

Installing the Collector SensorInsert the temperature sensor into the respective sensor sleeve, depending on collector positioning. (see Figure 5 and Figure 6) according to Figure 34.

● Pull rubber grommet (5) out of the sensor sleeve (7), remove from collector frame and slide onto the tem-perature sensor cable (6).

● Clear sensor sleeve from insulation material, if required (Figure 34 details), insert sensor into sensor sleeve and screw in the rubber grommet again.

● To avoid mechanical load on the sensor, use a wire strap to attach the sensor cable to the insulated collec-tor connection.

● Extend the sensor cable with a cable to the solar con-troller, if required (minimum cross section 18/2 AWG). Use the sensor connection box SP 10 for the extension on the collector side (accessory, see Table 10).


3.8 Installing the Controller

Install the controller to the storage cylinder as follows (fig-Figure 35):

● Only work on the controller when it is not connected to mains!

● Do not start-up the system if the controller, the cables or the connected 120 V consumers are visibly dam-aged!

● Before connecting the solar controller, place the tank insulation (1) around the cylinder without closing it, as shown in Figure 35.

● To affix the controller, break out one of the half-moon shaped perforated sections at the upper end of the in-sulation mantle; hook controller into the insulation

● Place the lid insulation (2) in the tank insulation (1) and loosely place the tank cover (3) on the cylinder.

● The mains connection for the controller is pre-assembled. Since the cable is temperature resis-tant, it can be passed between the tank insulation and the cylinder and led out along the solar return. Mains power has to be connected from outside the controller via an ON/OFF switch. If a protective connec-tor plug is used for mains connection, the switch is not a must. If the cable needs to be extended, use a cable with a minimum cross section of 15/3 AWG.

● Local regulations must be complied with.

Figure 35 Connecting the sensors: (1) Insulation jacket; (2) Insulation lid; (3) Storage cover; (4) Ventilation opening; (s) Storage temperature sensor; (p) Pump connection cable; (k) Connection cable for collector sensor; (n) main cable

3

s

2

1

k

s2

n

p

4

Installing the Sensor (Figure 36) ● Pass the collector sensor connection cable (k) under the insulation to the solar flow and connect to sensor cable via luster terminal. If extending the sensor cable is required we recommend to use our sensor connec-tion box SP2 (see accessories tableTable 10 page14) as protection against current surges.

● Note that only the cables included in the delivery or cables temperature resistant up to 110 °C may be used! The temperature sensor cables must not be bent or placed under tension. The minimum bending radius is 50 mm.

● The SUNGO US plus controller features an additional mains terminal (e.g. for controlling an additional pump) as well as an additional temperature sensor (s2). It can be used to control a backup heating circulator pump or to measure the temperature of the cylinder’s standby-section (Figure 34).


4 Startup

System CheckAfter fitting all components please carry out the following checks:

● Are all components fitted correctly? ● Are all fittings and connections safe and tight and fitted with the original flat seals?

● Were the bolts on the flange cover re-tightened? ● Are all electrical connections installed correctly and ac-cording to regulations?

● Are the temperature sensors in the right position? Does the controller show plausible values?

4.1 DHW System

Rinsing the DHW Storage Cylinder ● Appropriate retainers are to be used when rising the storage cylinder in order to remove remaining particles from the piping.

● We also recommend to install a dirt retainer at an ap-propriate place of the heating circuit.

Filling and Venting the DHW System ● To fill the storage cylinder with domestic water, open the shutoff of the safety sub-assembly at the cold-water feed and the up-stream water tap. (Figure 37). Close all water taps after the pipework was successfully vented.

● Check for tightness of all connections and sockets, re-tighten, if required, and monitor the system pressure (Figure 38).

Pressure Testing of the DHW SystemCary out a pressure test of the system after successful in-stallation. :

● Connect the hot water taps and check all connections and welding points.

● Afterwards vent cylinder once again.

4.2 Backup Heating Circuit

If a heat generator is connected to the upper heat ex-changer coil, the bachup heating circuit has to be rinsed upon startup in order to remove production residues from the coil.

4.3 Solar Circuit

Rinsing the Solar CircuitTo avoid damage to the system or malfunctions, possi-ble residues from production or installation have to be flushed out of the system before startup (Figure 39):

● Connect a suitable hose (2) to the cold water filling tap of the solar return sub-assembly (3) and a domestic wa-ter tap (1).

● With a second hose (4) connect the cold water filling and emptying tap of the solar flow (feed) subassembly (5) to a waste water discharge or a container (6).

● Open filling and rinsing cocks (3 and 5). ● Open domestic water tap (1). Due to the higher pres-sure loss in the collector loop only the heat exchanger

Figure 36 Wiring scheme of the SUNGO US plus controller: (s) storage temperature sensor; (p) Pump connection cable; (k) Con-nection cable for collector sensor; (n) Mains connection cable with on/off switch.

s

k

p

n


Figure 37 Filling and venting of the storage cylinder

Figure 38 Check connections for tightness, re-tighten if required; monitor system pressure

bar

is rinsed. Continue the rinsing process until the flow-ing out liquid is clear, i.e. does not contain any visible residues.

● If the collector loop pipes were soldered, the collector loop also must be rinsed prior to connecting it to the storage tank. After rinsing, some unwanted domestic water residues may remain in the system. Therefore blow forcefully into the end of the hose mounted on the flow sub assembly to empty the collector loop pipe. To avoid corrosion, the system must be filled with frost resistant solar fluid immediately after rinsing.

Filling the Solar CircuitTo protect the system against frost damage, only use the solar fluid included in the delivery. Follow the steps men-tioned below to fill the system (Figure 40):

● Observe the included technical information and mate-rial safety advice “Solar Heat Transfer Liquid DC 20 F”.

● Remove canister with DC 20 F (7) from the box and empty the content (2.5 liters) into a container (6) with a minimum capacity of 10 liters. Add one full canister (5 li-ters) of water and stir. The solar liquid mix contains 33% Glycol guaranteeing frost protection to 1.4 °F / -17 °C.

● Connect hose (2) with a ½" swivel nut to the cold water filling and emptying tap at the bottom (3). Place the other end of the hose into the container (6). Place the container in a higher position than the solar inlet con-nection (5). A transparent hose is useful to monitor the filling level.

● Connect the second hose (4) to the flow connector and briefly suck on the hose end. Place the end in the empty canister (7) and place it on the floor. The solar liquid automatically siphons into the heat exchanger.

● After the heat exchanger is filled completely and solar fluid flows into the hose (4), the two filling taps on the solar return (3) and the solar flow (5) must be closed.

Setting up the controllerFor the operation of the SECUSOL system, special settings at the controller are required. Please observe the separate controller manual "SUNGO US plus“.

Switch on the SUNGO US plus controller. The default sys-tem is the system 1, but the systems 2, 3 and 8, which are also preset with the value of the Secusol drainback-system, can be selected as well.

2

The systems 4, 5, 6, 7, 9 and 10 should not be selected because they are not compatible with the Secusol-system.

Controller Operation:When the temperature difference between collector and storage tank bottom is continuously higher than the switch-on temperature (DT O) for 30 seconds or more, the controller output R1 switches the pump fully on for a defined filling time (tFLL). After the filling time the switch-off conditions will be ignored for a stabilization intervall of 1 minute (tSTB), in order to avoid a premature system shutdown, before the controller automatically switches to normal operating mode. The pump speed varies within the defined speed interval (nMN: 30% and nMX: 50%) ac-cording to the collector and tank temperature. The cont-roller output R1 switches off the solar pump if the tempe-rature difference between the collector and the storage tank falls below the specified switch-off temperature dif-ference (DT F) or if the maximum store temperature (S MX) is reached.

We recommend the specific SECUSOL settings for the so-lar circulation pump and the controller acc. to Table 14.

Table14 Controllersettings value

Switch-on temperature difference (DTO) 25.0 °Ra [12.5 K]

Switch-off temperature difference (DTF) 6.0 °Ra [3.0 K]

Nominal temperature difference (DTS) 30.0 °Ra [15.0 K]

Rise control (RIS) 10 °Ra [5 K]

Minimum speed pump (nMN) 30%

Maximum speed pump (nMX) 50%

Maximum tank temperature (SMX) 180 °F [82 °C]

Emergency temperature, collector (EM) 275 °F [135 °C]

Drainback option (ODB) On

ODB switch-on condition time period (tDTO)

30s

ODB filling time t(FLL) 2mn

ODB stabilization time (tSTB) 1mn


Starting the SystemIf the solar heat is sufficient, the controller switches to the start phase when the switch-on difference is reached. Keep an eye on the collector temperature. If the collector loop is filled successfully, the collector temperature chan-ges. Flow noises in the solar circuit inlet indicate that the filling process was successful. If after the startup time no flowing sounds can be heard in the collector loop/flow sub assembly, increase the start-up phase (time parame-ter “t1”) on the controller or set the pump speed to a high-er level.

5 Connecting the storage Insulation

● When installed or otherwise handled, the insulation jacket should not be colder than 60 °F / 15°C, in order to avoid material or optical damage.

● Close jacket insulation using the hook closure ( Figure 41). First hook into the looses position and then successively tighten. Apply extra pressure around the pipe connections. Completely insert cover lid in-sulation on top, and then attack lid on top and turn, so that the cutout is placed directly above the controller (fig.Figure 35 page35).

● The large round openings in the bottom area of the insulation are required to cool the circulation pump. The must not be closed or otherwise blocked during operation!

● Insulate the pipes and insert the insulation as deep as possible into the cutouts of the hook closure aound the pipe connections in order to minimize heat loss. ( Figure 42). The properties of the pipe insulation have to be as specified.

1

2

3

4

5

6

Figure 39 Rinsing the solar installation. 1 Domestic cold water connection; 2 and 4 Hose; 3 and 5 Cold water filling cock; 6 Con-tainer.

6 Advice for the User

During normal operation no further settings are required. Please note the following points:

● Set hot water temperature You can pre-set the desired hot water temperature on the backup heating device. If a thermostatic mixing valve is installed, it can be used to set the hot water temperature.

● Energy efficient operation Keep the pump level as well as the minimum speed dnMIN as low as possible. The backup heating tempera-ture of the electrical immersion heater, the installed continuous flow heater or the heating device should be set as low as possible. Normally 104 °F to 122 °F (40 °C to 50 °C) max. is sufficient.

● Troubleshooting Please contact expert personnel if the system displays faults or defects!

● Operation under frost conditions The special Drain-Back technology and the use of solar fluid guarantee protection against frost damage to at least up to 1.4 °F (-17°C). Therefore the solar energy system can also be operated in winter.

● Protection against overheating The solar energy system is absolutely safe during stag-nation. There is no risk of damage, even if the sun shines for longer periods without hot water being tapped. The system switches on automatically as soon as the solar cylinder is ready to take in more heat.

● Shutting down the system The system can be temporarily shut down by switching off the electric power supply to the solar controller.The system should be inspected (see following chapter 7).

6

2

3

5

4

7

DC 20

Water

0.66 Gal2.5 l

1.32 Gal

5 l

1.98 Gal

7.5 l

Figure 40 Filling the solar installation using the “siphoning principle”.1 Domestic cold water connection; 2 and 4 Hose;3 and 5 Cold water filling cock; 6 Container; 7 Canister for DC20 F.


7 Maintenance and Care

Some components of the SECUSOL system are subject to wear and have to be serviced regularly by expert per-sonnel and, if required, replaced timely. See table 12 for a list of wear components. For checking the sacrificial ano-de the flange cover has to be opened. The flange cover sealing and all flat sealing gaskets must be renewed after each opening. See also tab. 8 on page 12.

Annual service checks are required, otherwise the warran-ty is void:

● Check for leaks at the storage cylinder and all connec-tions. Look for signs of scaling or moist sections on the insulation. Re-tighten connections if required.

● Vent storage cylinder (follow steps as in chapter 4). Hereunto remove storage lid and lid insulation.

● To check the protective anode, the cold water supply must be shut off at the safety valve. A cock must be opened that is situated below the hot water connection nozzle ➐. Afterwards remove the protective anode: Open the flange cover for SECUSOL 250 and 350. The flange gasket has to be renewed after each opening (see Table 10 accessories, on page 12).

● Check the protective anode. If the substance of the anode is degraded, it has to be replaced. Otherwise re-install the anode and vent the pipe circuit. (Chapter 4).

● Check the solar liquid according to the technical in-formation “Solar Heat Transfer Liquid DC20 F” If the PH Value drops below 6.6 or frost protection does not reach -17 °C, the solar liquid should be replaced. If the liquid has a stingy smell or black coloration, it also has to be replaced.

● Fill in and sign the maintenance records.

Table12 Wearparts

Component Inspectioninterval

Sacrificial anode on tankBi-annual inspection – durability is dependent on domestic water quality, 2 - 10 years

Flange cover sealing Renew after each opening

Flat seals on pipe connectors

Renew after each opening

Solar fluid

Bi-annual inspection according to data sheet DC20 F: pH value > 6.6 and frost protection up to a minimum of 1.4 °F /-17 °C, otherwise replace

Figure 41 Attaching the jacket insulation by locking the hook closure.

Figure 42 Insulation of the pipe connections overlapping with the storage cylinder jacket insulation .

Subject to modifications, errors excepted · © Wagner Solar Inc., 2011 · 485 Massachusetts Ave, Suite300, Cmbridge, MA 02139 40 [email protected] · % TollFree: 877-97Wagner (877-979-2463)

8 Troubleshooting

Despite careful manufacture and installation defects may occur in your SECUSOL system. Some common faults and solutions for a professional installer are described below.

All maintenance and repair work (here in the columns „Solution“) must be carried out by a trained professional.

Table15 Fault Explanation Solution

DHWsection

1. DHW connections are leaking1.1 Settling of gaskets when

connections were not sufficiently tightened.

Re-tighten connections

Solarcircuit

1. Collectors are not filled.

1.1 Length of collector loop beyond limitations of use?

Table 1 shows the length limits for the collector loop. The maximum length may have been exceeded.

1.2 Incorrect filling capacity? Empty the system and refill as specified.

3. Cavitation noise 1

3.1 Incorrect filling capacity?Cavitation noises may occur if the filling quantity is too low. Empty the system and refill as specified.

3.2 Negative pressure in the system?

Negative pressure is possible if the system is opened for a short time during operation or if solar fluid is let off via the safety valve. Switch off system (controller), cool down solar circuit to < 68 °F / 20 °C. Open filling tap at the solar flow pipe to equalize the pressure and close filling tap again.

4. Safety valve in the solar circuit blows off.

4.1 Incorrect filling quantity?

The filling quantity of the solar fluid may have been incorrectly measured. Switch off system (controller, manual operation: pump OFF) until it has cooled down. If necessary draw off hot water until the tank sensor shows < 68 °F / 20 °C. Then open filling and emptying tap on the solar flow pipe and collect fluid in a container. Close filling and emptying tap.

4.2 Length of solar circuit outside min./max. limitations?

Table 1 shows the length limits for the solar circuit. The minimum length may have been undercut and solar fluid was blown off the safety valve. After equalizing the pressure (proceed as per 3.2) the system is operational again.

5. Pump is in idle state but collector loop does not empty.

5.1 Have the collector loop pipes not been installed at a steady down grade slope?

No further measures required. During strong solar radiation and idle pump, the collectors will empty by themselves as a result of momentary vapor formation.

6. The Storage cylinder insulation is moist at the bottom

6.1 Are all pipe connections and flange/socket properly tightened?

Flat sealing gaskets tend to settle during the first weeks of operation, therefore all connections should be re-tightened after a few weeks..

6.2 Safety valve blow off

Additional fault analysis acc. to 4.2 After the fault was removed, the insulation will dry off from the heat supplied by the heated storage cylinder. No further steps need to be taken.

1) For smooth operation the circulator pump used in the system requires a minimum liquid column on the suction side (i.e. towards the storage cylinder). If the column height drops below the required minimum cavitation can occur, which is spontaneous vaporization of small amounts of liquid that can cause mechanical damage to the pump impeller. Additionally underscoring the gas solubility limit air bubbles may form around the impeller, possibly diminishing the pump‘s capacity. Cavitations can be easily detected acoustically because of noticeable flow noise during operation and a significant drop in capacity. In order to avoid cavitation, the specified filling volume of the system has to be precisely adhered to. Furthermore the build-up of overpressure is neccessary when the solar liquid heats up, for which the system has to be airtight at all times.

TECHNICAL INFORMATION / INSTALLATION INSTRUCTIONS...

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