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Installation and operation instructions 

Separation station WHI sol/heat 20 #1 / 40 #1; Separation station WHI sol/aqua 20 #1 / 40 #1

 

 

 

 

 

  2 Safety 

 

83514202 

▪ 

1/2014-06 

▪

 Ext. PAW

 

5-36 

 

 

 

 

2

 

Safety 

 

 

2.1

 

Designated use 

 

  The station may only be used in solar thermal installations as separation station between 

the solar circuit and the heating circuit (in the case of WHI sol/heat) or the potable water 

circuit (in the case of WHI sol/aqua), taking into consideration the technical limit values 

indicated in this manual. Due to its design, the station may only be installed and  

operated as described in this manual! 
Use only original accessories in connection with the separation station. 
Using the station contrary to its designated use will invalidate all liability claims. 

 

 

2.2

 

Safety instructions 

 

  The following must be observed during installation and commissioning: 

•

 

Relevant local and national regulations 

•

 

Accident prevention regulations of the employers' liability insurance association  

•

 

Instructions and safety instructions mentioned in these instructions 

WARNING 

 

 

Danger of scalding due to escaping vapour! 
With safety valves there is a risk of scalding due to the escape of 

vapour.  

During installation, check the local conditions and check whether 

a discharge line must be connected to the safety group.  

 

Observe the instructions regarding the safety valve.  

 

The pressures for the expansion tank calculated by the 
plant designer and the operating pressure of the  
installation must be set.

 

WARNING 

Risk to life and limb due to electric shock! 

 

Prior to performing electrical work on the controller,  

de-energise the system. 
For more information, see enclosed installation and  

operation instructions of the station controller. 

 

Do not connect the controller to the mains until all  

installation work, flushing and filling have been  

completed.  

This avoids an unintentional start of the motors. 

 

The plug-in pump lines are permanently supplied with a 

mains voltage of 230 V and cannot be switched off via 

the controller. 

CAUTION 

 

Risk of burns! 
The valves and fittings and the pumps can become heated up to 

more than 100 °C during operation. 

 

The insulation shell must remain closed during  
operation.

 

 

 

Содержание WHI sol/aqua 20 1

Страница 1: ...Mounting and operating instructions Separation station WHI sol heat 20 1 40 1 Separation station WHI sol aqua 20 1 40 1 83514202 1 2014 06 ...

Страница 2: ......

Страница 3: ... 1 Assembly 14 4 2 Hydraulic connection 16 4 3 Controller connection 17 4 4 Electrical connection of the solar controller WRSol2 1 17 5 Operation 18 5 1 Pressetting solar controller WRSol2 1 18 6 Commissioning 18 6 1 Preparation for flushing and filling 19 6 2 Flushing and filling the storage tank circuit potable water circuit lower connections 19 6 3 Flushing and filling the solar circuit upper c...

Страница 4: ...ed personnel It must be observed by anyone working on the machine Work on the machine may only be performed by persons that have received the required training or instruction Persons with restricted physical sensory or mental abilities may work on the machine if supervised or instructed by an authorized person Children may not play with the machine 1 2 Warranty and liability Warranty and lilabilit...

Страница 5: ...nd safety instructions mentioned in these instructions WARNING Danger of scalding due to escaping vapour With safety valves there is a risk of scalding due to the escape of vapour During installation check the local conditions and check whether a discharge line must be connected to the safety group Observe the instructions regarding the safety valve The pressures for the expansion tank calculated ...

Страница 6: ...kon L250L and Syntheso Glep 1 from Klüber or a silicone spray In sunlight the collectors will heat up considerably The solar fluid in the solar circuit may heat up to more than 100 C Flush and fill the solar circuit only when the collector temperatures are below 70 C NOTICE Material damage due to high temperatures Since the solar fluid near the collector can be very hot the group of fittings must ...

Страница 7: ...s Piston valves in the potable water circuit supply and return of the WHI sol aqua modules Check valves in the supply and return of the primary circuit and in the supply of the secondary circuit to avoid involuntary gravity circulation Safety valves for avoiding inadmissible overpressure Pressure gauge to display the installation pressure in the solar circuit Vent valves for easy venting of the so...

Страница 8: ...Secondary side flow to buffer tank hot Equipment A Safety group with safety valve 6 bars pressure gauge and expansion tank connection B Return ball valve with check valve C Primary pump D Temperature sensor NTC 5K E Secondary pump F Return ball valve G Flow ball valve with check valve H Temperature sensor NTC 5K I Safety valve 6 bars Only for protection of the station Does not replace the safety v...

Страница 9: ...quipment A Safety group with safety valve 6 bars pressure gauge and expansion tank connection B Return ball valve with check valve C Primary pump D Temperature sensor NTC 5K E Secondary pump F Piston valve with drain valve return G Piston valve with drain valve supply H Temperature sensor NTC 5K I Safety valve 10 bars suitable for domestic water Only for protection of the station Does not replace ...

Страница 10: ... in the heat exchanger vary due to variations in radiation buffer temperatures and different system requirements For optimum operation of the overall system the flow rates in the heat exchanger must be adapted to the relevant control target and current situation To this end high efficiency pumps which have an extremely wide control range are used in the WHI sol modules This allows the controller t...

Страница 11: ...s sol aqua 10 bars Max operating temperature 120 C Max stagnation temperature 140 C Max propylene glycol content 50 Max power Qmax 30 kW at SUPprim 120 C RETprim 100 C 60 kW at SUPprim 120 C RETprim 100 C Flow rate at Qmax prim 1250 l h sec 1290 l h prim 2500 l h sec sol heat 2500 l h sol aqua 2600 l h Operating temperature sensors 25 C to 120 C Equipment Safety valve WHI sol heat prim 6 bars sec ...

Страница 12: ... IP 44 Max pressure 1 0 MPa 10 bars Max temperature 95 C TF 95 I 1 1 0 04 0 52 A 0 04 0 40 A 0 06 0 68 A 0 07 1 16 A 0 06 0 71 A 0 06 1 16 A P1 3 70 W 3 5 48 W 7 69 W 6 140 W 5 87 W 6 140 W Use in WHI sol heat 20 1 Sec Prim WHI sol aqua 20 1 Sec Prim WHI sol heat 40 1 Prim Sec WHI sol aqua 40 1 Prim Sec Prim primary side solar Sec secondary side heating potable water 3 4 PWM input signal solar pro...

Страница 13: ...014 06 Ext PAW 13 36 3 5 Hydraulilc performance data WHI sol heat 20 1 or WHI sol aqua 20 1 WHI sol heat 40 1 or WHI sol aqua 40 1 Heating PM2 15 65 Solar PM2 15 145 Potable water UPM2 15 75 CIL Flow rate l h Heating UPM GEO 25 85 Solar PML 25 145 Potable water UPML GEO 25 105 N Flow rate l h Residual delivery pressure mbars Residual delivery pressure mbars ...

Страница 14: ...ntrolled discharging into the environment and enables the circuits to be refilled Due to their construction the WHI sol aqua modules reduce the precipitation of scale in the heat exchanger For systems with a high total domestic water hardness and or high temperatures a water treatment is recommended in order to prevent scale formation NOTICE Material damage due to high temperatures Since the solar...

Страница 15: ...unting aid 2 Copy the dimension for the mounting holes to the mounting surface 3 Maintain a lateral clearance of 200 mm on the right and left of the station 4 Drill holes and insert the enclosed wall plugs into the drill holes Make sure that the ground has sufficient load carrying capacity 5 Screw in the screws allowing them to protrude about 40 mm from the wall 6 Remove the station from the packa...

Страница 16: ...ng WHI sol heat 40 1 1 female thread WHI sol aqua 40 1 1 male thread flat sealing 4 Secondary side supply to buffer tank hot Connection WHI sol heat 20 1 female thread WHI sol aqua 20 1 1 male thread flat sealing WHI sol heat 40 1 1 female thread WHI sol aqua 40 1 1 male thread flat sealing 2 Assemble the safety group consisting of safety valve c fill valve d and pressure gauge e on the connection...

Страница 17: ...uctor L to the bus bar in the controller housing To do so lift the lower lever and clamp the line pressing the lever down Next check whether the line is firmly clamped 3 The bus bar has already been connected to the screw terminal L of the controller and the pump lines for constant power supply Due to the high power consumption of the pumps the latter are not supplied with 230 V via relays but per...

Страница 18: ...e safety valve when the system pressure is too high During venting the solar fluid may escape as vapour and result in scalding Flush and fill the system only when the collector temperatures are below 70 C NOTICE Risk of frost It often happens that solar systems cannot be completely drained after flushing Thus there is a risk of frost damage later on when flushing with water Therefore only use the ...

Страница 19: ...g the heat exchanger shut the ball valves or piston valves of the station and flush dirt particles scale residues from the storage tank before commissioning Make sure to only use admissible medium see chapter 3 2 1 Open the ball valves C D of the WHI sol heat module or the piston valves of the WHI sol aqua module C D and disable the check valves 45 see next page 2 Vent the storage tank circuit or ...

Страница 20: ...into the expansion tank To do so it may be necessary to disconnect the expansion tank during flushing and filling and to use only flushing and filling stations that are equipped with suitable microfilters The solar circuit is flushed in the normal direction of flow This is why you should make sure that the solar circuit pump is not on Ball valve with integrated check valve Normal direction of flow...

Страница 21: ...8 26 860 14 3 35 32 6 1502 25 0 42 39 6 2437 40 6 54 51 4410 73 5 The air liberated from the solar fluid is collected in the upper area of the airstop and can be discharged via the vent plug j WARNING Danger of scalding due to escaping vapour The escaping medium can have a temperature of more than 100 C and cause scalding Carefully open the vent plug and close it again as soon as medium escapes Ve...

Страница 22: ...ess is finished flushing is started 7 To vent the pump stroke open and close the return ball valve b during flushing 8 Keep flushing the solar circuit until the solar fluid exits without forming bubbles see page 21 9 Flush the collector fields individually if possible 10 Close the drain valve g with the filling pump running and increase the system pressure to approx 5 bars The system pressure can ...

Страница 23: ...he maximum rotation speed level for at least 15 minutes In the meantime vent the solar system several times at the vent plug j of the airstop until the solar fluid exits without forming bubbles see page 21 20 If necessary increase the system pressure to the operating pressure 21 Remove the hoses of the flush and fill station and screw the sealing caps on the fill and drain valves The closure caps ...

Страница 24: ...tor temperatures are below 50 C Wait until the solar fluid has cooled down to at least 50 C 1 Close the station locks and drain the solar fluid Make sure that the solar fluid is collected in a heat resistant container 2 Replace the defective part with a new part 3 Fill the system as described under 6 Commissioning see page 18 7 1 Draining the solar system 1 Switch off the controller and secure it ...

Страница 25: ...on instructions Separation station WHI sol heat 20 1 40 1 Separation station WHI sol aqua 20 1 40 1 8 Spare parts 83514202 1 2014 06 Ext PAW 25 36 8 Spare parts 8 1 Spare parts separation station WHI sol heat 20 1 40900015252 ...

Страница 26: ...PM2 15 145 601876 11 Circulation pump Grundfos Solar PM2 15 65 601875 12 Seal 17 x 24 x 2 AFM34 48002002857 13 Seal 21 x 30 x 2 1 AFM34 48002002847 14 Solar controller WRSol 2 1 660327 15 Name plate WHI sol heat 20 1 40900015827 16 Thermo handle weishaupt 48002003132 17 Retaining clip insulation 40900015247 18 Cover screw G A 40900015257 19 Vent valve male thread with O ring 48002002537 20 Vent pl...

Страница 27: ...operation instructions Separation station WHI sol heat 20 1 40 1 Separation station WHI sol aqua 20 1 40 1 8 Spare parts 83514202 1 2014 06 Ext PAW 27 36 8 2 Spare parts separation station WHI sol aqua 20 1 40900015302 ...

Страница 28: ...00015027 14 Circulation pump Grundfos Solar PM2 15 145 601876 15 Circulation pump Grundfos UPM2 15 75 CIL 601856 16 Seal 17 x 24 x 2 AFM34 48002002857 17 Seal 21 x 30 x 2 1 AFM34 48002002847 18 Seal 21 x 30 x 2 1 EPDM 90 40900015167 19 Solar controller WRSol 2 1 660327 20 Name plate WHI sol aqua 20 1 40900015807 21 Thermo handle weishaupt 48002003132 22 Retaining clip insulation 40900015247 23 Cov...

Страница 29: ...operation instructions Separation station WHI sol heat 20 1 40 1 Separation station WHI sol aqua 20 1 40 1 8 Spare parts 83514202 1 2014 06 Ext PAW 29 36 8 3 Spare parts separation station WHI sol heat 40 1 40900015262 ...

Страница 30: ...WM C 601798 11 Seal 17 x 24 x 2 AFM34 48002002857 12 Seal 21 x 30 x 2 1 AFM34 48002002847 13 Seal 27 x 38 x 2 1 AFM34 40900015127 14 Seal 32 x 44 x 2 1 AFM34 40900014097 15 Solar controller WRSol 2 1 660327 16 Name plate WHI sol heat 40 1 40900015837 17 Thermo handle weishaupt 48002003132 18 Retaining clip insulation 40900015247 19 Cover screw G A 40900015257 20 Vent valve male thread with O ring ...

Страница 31: ...operation instructions Separation station WHI sol heat 20 1 40 1 Separation station WHI sol aqua 20 1 40 1 8 Spare parts 83514202 1 2014 06 Ext PAW 31 36 8 4 Spare parts separation station WHI sol aqua 40 1 40900015312 ...

Страница 32: ... PML2 25 145 601877 14 Circulation Grundfos UPML 25 105 N 601872 15 Seal 17 x 24 x 2 AFM34 48002002857 16 Seal 21 x 30 x 2 1 AFM34 48002002847 17 Seal 27 x 38 x 2 1 AFM34 40900015127 18 Seal 32 x 44 x 2 1 AFM34 40900014097 19 Solar controller WRSol 2 1 660327 20 Name plate WHI sol aqua 40 1 40900015817 21 Thermo handle weishaupt 48002003132 22 Retaining clip insulation 40900015247 23 Cover screw G...

Страница 33: ...d used On the diagram shown below you can see whether the integrated check valves of the station are sufficient for your system If the check valves are not sufficient further structural measures must be taken to prevent gravity circulation You can install for example syphons heat traps 2 way valves zone valves or additional check valves Example The station is equipped with two check valves 2 x 200...

Страница 34: ...th large temperature differences the difference in densisty causes gravity circulation This circulation can result in the storage tank cooling down Calculation example Δp Δρ g h Collector temperature 5 C Solar fluid density ρ1 1042 kg m Storage tank temperature 67 C Solar fluid density ρ2 1002 5 kg m Δρ ρ1 ρ2 39 5 kg m g 9 81 m s System height h 10 m Δp 3875 Pa 395 mm wc At a system height of 10 m...

Страница 35: ...ollectors number type Collector surface area m System height m Height difference between station and collector field Pipeline mm l m Venting collector field Not available Vented Manual bleeder Automatic bleeder Airstop station Vented Solar fluid type of glycol Antifreeze checked up to C Serial numbers Flow rate l m Station Pump type Temperature sensor System pressure mbars Controller Expansion tan...

Страница 36: ...ual fuel burners operate reliably Solar systems The stylish flat plate collectors are the ideal complement for any Weishaupt heating system They are suitable for solar water heating and for combined heating support With versions for on roof in roof and flat roof installations solar energy can be utilised on almost any roof multiflam Burners up to 17 000 kW This innovative Weishaupt technology for ...

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