Wagner & Co SECUSOL, Technical Information Installation Instructions

Page 1: ...hing 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 fede...

Page 2: ...7 4 liters Solar controller Name SUNGO US plus Pump control Speed controlled Overheat protection 180 F temperature limitation for the tank Storage Nominal content 66 Gal 250l 92 2 Gal 350l Stand by heating volume approx 32 Gal 120l approx 42 Gal 160l 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 Perm...

Page 3: ...in 1163 mm EURO L42 HTF 3 15 in 80 mm 84 69 in 2151 mm 47 83 in 1215 mm EURO C20 AR M 42 79 in 1087 mm 4 33 in 110 mm 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 ...

Page 4: ...height If present 44 37in 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 Dimension...

Page 5: ...er without insulation 1 Flange with sacrificial anode 1 SECUSOL 350 1 2 3 4 5 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 in 300 mm 18 78 in 477 mm 32 17in 817 mm 46 69 in 1186 43 54 in 1106 mm 57 01 in 1448 mm 66 26 in 1683 mm 70 75 in 1797 mm 23 62 in 600 mm ...

Page 6: ... 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 4 EURO L42 76 1 in 1933 mm 76 1 in 1933 mm 160 in 4060 mm 91 5 7 in 23 26 m m 45 7 9 in 11 63 m m 45 7 9 in 11 63 m m 45 7 9 in 11 63 m m 45 7 9 in 11 63 m m 160 in 4060 mm ...

Page 7: ...cking 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 syste...

Page 8: ...tation 1 Solar liquid DC20 F 2 5l in 5l 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 Table 5 Scope of supply storage SECUSOL 250 SECUSOL 350 Position 1 Components Quantity 1 Jacket insulation 1 2 Cove...

Page 9: ...EN USA_SECUSOL_TI MA 111013 1121R800 9 Figure 8 Scope of supply of the SECUSOL storage cylinder shown for the 250l see table 5 for a position number legend s n k 7 2 4 5 p 6 8 9 10 3 1 13 f ...

Page 10: ...single collector Table 6 On roof racking set for single collector scope of supply Single collector Pos 1 Components Quantity Part no 1 Rafter bracket or roof anchor recommended 4 2 Collector rail 49 5 in 1257 mm EURO C20 AR M with two collector clamps 2 192 001 00 3 wire strip 1 4 Collector EURO C20 AR M 1 192 040 62 5 Compression olive connection 12mm 2 6 Gasket 2 1 Position no from Figure 10 2 N...

Page 11: ... 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 64 8 Compression olive connection 12 mm 2 9 Gasket 4 1 Position no from Figure 10 2 Not included in the set to be ordered separately Figure 10 Set for on roof installation of 2 collectors installed one above the other Note The roof brackets shown throughout this docum...

Page 12: ...03 3 Wire strap 1 4 Collector EURO C20 AR M or EURO L42 2 5 Compression olive connection 12 mm 4 150 303 93 6 Gasket 4 7 Compression T fitting 12mm 2 8 Copper tube 12mm 4 9 Foam insulation 4 1 Position no from Figure 11 2 Not included in the set to be ordered separately 1 3 2 9 8 4 5 6 7 Figure 11 Set for installation of 2 collectors next to each other Note The roof brackets shown throughout this ...

Page 13: ... 00 Position1 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 L422 1 2 1 Position numbers from Figure 12 2 Not included in the set Figure 12 Set for free standing setu...

Page 14: ... mm with integrated temperature sensor line 15m 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 2m 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 clamp...

Page 15: ... Description Part no 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 ...

Page 16: ...of 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 stat...

Page 17: ...tors 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 Scope and limitations of application The collector is intended for the application in solar ther mal installations for ho...

Page 18: ...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 i...

Page 19: ...ccessory 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 n...

Page 20: ... 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 Brackets The roof bra...

Page 21: ...he 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 t...

Page 22: ...upper collector first Installation of the Collectors RISK of falling objects and structural damage 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 ...

Page 23: ...ectors are installed with one above the other RISK of falling objects and structural damage 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 ...

Page 24: ...al for 35 50 Figure 20 Installation pitch and setup dimensions for ground or flat roof installation left or facade installation right Determining the pitch Table 13 Racking pitch a A C EURO TRIC F 35 50 35 33 98in 863mm 0 39in 10mm 40 37 01in 940mm 5 79in 147mm 45 39 72in 1009 mm 12 24in 311mm 50 42 13in 1070mm 20 51in 521mm 3 3 Free Standing Installation A C ...

Page 25: ...x 40 12 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 ...

Page 26: ...n steel beams Figure 22 Maximum rail projections Fixing of Racking Triangles Fixing 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 ...

Page 27: ...1R800 27 Ø 1 2 m m 0 4 7 2 i n 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 ...

Page 28: ... 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 RISK of falling objects and structural damage Improperly positioned collectors can lead to in sufficient fixation Loosen ...

Page 29: ... to the cold water inlet of the tank Within the United States the installation of an IAPMO compliant backflow pre venter is mandatory for all installations connected to the drinking water supply Risk of serious scalding for the end user 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 ...

Page 30: ...7 Protective anode 8 Re circulation return 9 Re circulator pump 10 DHW tap 11 Temperature sensor 12 Sensor clamp 13 Solar circuit pump 14 Safety valvel 15 Filling emptying cock 16 Solar circuit flow sub assembly 19 Backup heat exchanger 20 Solar heat exchanger Storage cylinder connections Solar circuit return Cold water feed Solar circuit flow Electric immersion heater Backup heating flow feed not...

Page 31: ...it 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 Circuit Observe 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...

Page 32: ...ying 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 ...

Page 33: ... 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 con...

Page 34: ...f 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 cabl...

Page 35: ...ins 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 ...

Page 36: ... monitor the system pressure Figure 38 Pressure Testing of the DHW System Cary 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 start...

Page 37: ...d 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 controller For 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 ...

Page 38: ...estic 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 Energ...

Page 39: ... 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 b...

Page 40: ...pe 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 e...