HOT TAP WATER EXCHANGER

with solar pump-group

ENSOL IT




200 300 500







INSTALLATION AND OPERATION
MANUAL
WARRANTY CARD






Version 1/13 ENSOL IT
2

Contents:

1. Structure and Intended Use ... 3
2. Safety devices and conditions for safe
use of exchangers .. 6
3. Installation .. 6
4. Operation and service .. 9
5. Warranty conditions . ... 10




Before you install and activate the exchanger, please read this "Installation and
Operation Manual" and Terms and Conditions of the Warranty


Attachments:
1. Operating instructions of the STDC controller
2. Operating instructions of the Solar 3 two-way solar station
3. Installation, start-up and operating manual of the expansion vessel along
with warranty conditions and warranty card


NOTE!
Correctly filled in, complete and not modified warranty cards
of the ENSOL IT exchanger and expansion vessel as well as
operating instructions of the STDC controller and the solar
station with entries of ZUG ELEKTROMET are the
prerequisite for granting the right to warranty repairs.













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1. Structure and Intended Use

ENSOL IT exchangers with solar pump group are pressure storage
water heaters that are designed to heat and store hot tap water, in systems
with solar collectors, for needs of flats, detached houses and multi-family
buildings, public utility buildings, industrial facilities and others.
ENSOL IT 200 i 300 exchangers have been adapted for installation in
rooms with doors that are up to 70 cm wide.
The exchangers (rys.1) are equipped with:
- two independent helical coils, allowing the connection of two power
sources with different heating media, such as solar collectors with a glycol-
based heating medium or e.g. low-temperature central heating water boiler,
- two-way pump group (2) integrated with the controller for the solar
systems (3),
- expansion vessel (4).
The two-way pump group includes:
- circulating pump in solar design,
- flow meter with control valve and two stubs: filling and drain,
- three-way cut-off check valve with thermometer (blue) and connecting
stub for safety group,
- 6 bar safety valve with manometer and connecting stub for expansion
vessel,
- cut-off check valve with thermometer (red),
- vent.
The controller used for solar systems is equipped, among others, with
smoothly controlled pump rotating speed, heat meter function, graphical
statistics, 7 language versions etc.
Two temperature sensors are connected to the junction box (5): S1-
collector and S2 - vessel.
Detailed data and information about the controller settings are given in
the attached Installation and operating manual.
Pressure tanks in these heat exchangers are made of steel sheet
covered inside with a layer of a special high-temperature vitreous enamel,
forming glass coating that protects them from corrosion and ensures clean
healthy water. Additional corrosion protection of the tanks is the
magnesium anode that owing to the difference of electrochemical potentials
of steel and magnesium in water, generates protective current for the tank.
Thermal insulation is made of PS expanded polystyrene permanently
joint to tank walls.
The outside coating of the exchangers is made of plastic.
ENSOL IT exchangers are designed for installation of an electric heating
element on the 1" plug, especially EJK type heating element produced by
ZUG ELEKTROMET with insulated heating units (Tab. 2), which do not
consume protective current generated by the magnesium anode for the
corrosion protection of the tank. This increases the durability of the tank
and the life of the magnesium anode.
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The structure and dimensions of exchangers are shown in Fig. 1, whereas
their connection dimensions and technical parameters in Tab. 1.
































1 tank with two coils
2 two-way solar pump group
3 - controller
4 expansion vessel
5 junction box with sensors
(S1 - collector; S2 - vessel)
- ~230V/50Hz




Fig. 1 Construction of the ENSOL IT exchanger









S1
S2
ENSOL IT 200
ENSOL IT 300
ENSOL IT 500

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Tab. 1 Dimensions and technical parameters of ENSOL IT













ENSOL IT
Type
200 300 500
Capacity

200 300 500
Height

H [mm] 1400 1900 2180
Max. height on the slope

H* [mm] 1545 2000 2330
Diameter

D [mm] 630 630 810

ZW

1
Cold water
A [mm]

360 250 350
CW

1
Hot water
I [mm]

1080 1570 1730
WEG

1 1 1
Heating water power upper coil
P [mm]

990 1320 1630
WYG

1 1 1
Heating water return upper coil
O [mm]

750 1000 1220
WES

1 1 1
Heating water power solar coil
E [mm]

805 1160 1383
WYS

1 1 1
Heating water return solar coil
B [mm]

735 1070 1290
RC


Circulation
F [mm]

690 1030 1080
MG

1 1 1
Socket heater
K [mm]

800 1030 1240
Magnesium anode x L [mm] 40 x 330 40 x 390 40 x 500
W 2 2 123/166/195
Wash out hole
M [mm]

325 325 425
Thermal isolation
60 mm Polyuretane foam
100 mm Polystyrene
foam
Mass [kg]

95 140 205
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* 80C, 70C, 60C - temperature of heating water in the coil supply
10C - temperature of cold tap water on sup ply
45C, 60C - temperature of hot tap water


2. Safety devices and conditions for safe
use of exchangers.

Heaters may only be used with a functional safety valve with the opening
pressure of 0.6 MPa (water pressure in the water supply network up to 0.6
MPa) installed on the cold tap water inlet. This valve protects the
ENSOL IT
Type
200 300 500
Capacity

200 300 500
Exchange surface

m 0,8 1,0 1,4
Capacity of coil

dm 4,3 5,7 8,0
Efficiency of hot water
80/10/45C
70/10/45C
60/10/45C
dm/h

442
368
270

545
462
336

737
620
460
Heating power
80/10/45C
70/10/45C
60/10/45C
kW

18
15
11

22,2
18,8
13,7

30
25,2
18,7
Efficiency of hot water 80/10/60C
70/10/60C dm/h

264
198

326
240

455
337
C
O
I
L


B
O
I
L
E
R


Heating power
80/10/60C
70/10/60C
kW

15,4
11,5

19
14

26,5
19,6
Exchange surface of coil m
1,1 1,4 1,9
Capacity of coil

dm 6,4 8,0 10,7
Efficiency of hot water
80/10/45C
70/10/45C
60/10/45C
dm/h

460
388
287

604
503
373

818
680
506
C
O
I
L


S
O
L
A
R

Heating power
80/10/45C
70/10/45C
60/10/45C

kW

18,7
15,8
11,7

24,6
20,5
15,2

33,3
27,7
20,6
The maximum surface of the
absorber connected solar
m 2,5 5 10
Heating losses

kWh/24h 2,1 2,5 4,5
Parameters of the tank work Max. pressure and temperature
pr = 0,6 MPa; tr = 80C
Parameters of the upper coil work Max. pressure and temperature
pr = 1,0 MPa; tr = 90C
Parameters of the solar coil work Max. pressure and temperature
pr = 1,0 MPa; tr = 110C
Thermal isolation
60 mm Polyurethne foam
100 mm Polystyrene
foam
Magnesium anode

x L [mm] 40 x 330 40 x 390 40 x 500
Expansion vessel

dm 18 18 25
Mass

kg 95 140 250
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exchanger from excessive pressure in the water supply network or
excessive pressure increase as a result of heating the water in the tank.
Even in case of regular operation of the exchanger during heating, water
may leak from the safety valve for a short time, which shows that the valve
operates in a correct manner. Never obstruct the outlet hole in such cases.
All types of exchangers should be used with an installed thermometer of
the measuring range between 0 and 120C, also inst all pressure gauges
with the measuring range between 0 and 1 MPa.


3. Installation

3.1 Exchanger connection to the water supply network,
central heating system and solar collector.

Connect the exchanger vertically to the water supply network in which the
pressure does not exceed 0.6 MPa and not lower than 0.1 MPa. If the
pressure in the network often exceeds 0.4 MPa, it is recommended to
install a pressure reducing valve or a diaphragm reservoir before the
exchanger in order to limit the inconvenient outflow of water from the safety
valve. When the pressure in the water supply network exceeds 0.6 MPa , it
is necessary to install the pressure reducing valve in order to avoid the
continuous outflow of water from the safety valve.
Perform the connection between the solar collector and exchanger
according to the diagram (Fig. 2). Connect the collector output to the upper
port (WES) and return to the lower port (WYS). After filling the solar system
with heating medium, venting and filling the exchanger with water, connect
the controller to the power supply system of 230V /50Hz (power cord
extending from the junction box).


ATTENTION!
1. A safety valve has to be installed on the cold water inlet to the
exchanger; the valve is supplied with the exchanger. Install it so that the
arrowhead on the valve body is in line with the direction of the water
flow.
2. Do not install any shut-off valves between the safety valve and the
exchanger.
3. It is not permitted to use the tank without a safety valve or with a
malfunctioning safety valve because
the situation may result in failure and poses a threat to human life and
health.
Installation and any repairs of the exchanger in terms of electricity
and water system should be entrusted only to skilled processionals
with relevant permissions.
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1 - ENSOL IT exchanger with: 6 central heating boiler
2 solar pump group 7 solar collector
3 controller 8 domestic hot water tap
4 expansion vessel 9 - circulation
5 junction box 10 water temperature sensor in the exchanger
S1 - liquid temperature sensor in the ZW domestic cold water
collector CW - domestic hot water
S2 - water temperature sensor
in the exchanger

Fig. 2 Example installation diagram

3.2 Installation of EJK type heating element
During the warranty period of the tank, only heating elements tanks
suitable for enamelled tanks may be used, i.e. those with insulated heating
units (insulated heating units do not "steal" protective current generated by
the magnesium anode). This is one of the warranty conditions for the
WGJ-SOL exchanger. EJK type heating elements by ZUG ELEKTROMET
comply with this condition.

Among EJK heating elements manufactured by ZUG ELEKTROMET for
WGJ-SOL exchangers, you can install single phase 230 V 1.5 kW and 2.0
kW heating elements as well as three phase 400 V 3.0, 4.5 and 6.0 kW
heating elements .
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Install in accordance with the Installation and Operation Manual of the
heaters.
It is particularly important that the free end of the yellow-green protective
conductor drawn from the marked connection on the casing of the heating
element is connected using the M4 screw to the earth plate located on the
MG connector of the tank, see Fig. 3.


1 tank casing
2 electric EJK type heating
element
3 earth wire
4 MG 1 '' connector
5 earth plate
6 M4 screw
7 spring washer




Fig. 3 Earth of the heating element


ATTENTION! During the warranty period of the tank, use only heating
elements with an insulated heating unit e.g. EJK
manufactured by ZUG ELEKTROMET

ATTENTION! The heating element and the metal tank have to be
connected with an earth cable drawn from a marked
connection on the heater casing.


4. Operation and service

1. Periodically, at least once a month and before every start-up, after
putting out of service, check the correct operation of the safety valve
(according to instructions of valve manufacturer).
2. A temporary small outflow of water from the safety valve during heating
of water in the exchanger is normal and indicates the proper operation of
the safety valve.

ATTENTION! Do not insert the plug of the connection into the
electrical socket without making sure that the tank is filled
with water.
ATTENTION! Continuous leaking of water from the safety valve outlet
demonstrates a malfunction of the valve or overly high pressure in
the water supply system. Never obstruct the outlet hole.
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3. If the exchanger is put out of service in the winter and there is a concern
that the water in the exchanger may freeze, drain the water by unscrewing
the safety valve.
4. The magnesium anode wears down during operation, so its condition
should be checked periodically, at least once a year. The anode should be
replaced if it loses 2/3 of its volume, and always at the latest after 18
months. A relevant magnesium anode can be purchased at a point of sale
or from the manufacturer of exchangers.
The anode is located at the top end cap of the exchanger tank; to
determine its condition or replace it with a new one:
- cut off the cold water supply, open the hot tap water tap for a moment,
then close the outlet of hot water from the exchanger,
- remove the top cover of the exchanger casing,
- remove the insulation element covering the cap with the affixed anode,
- unscrew the cap with the anode,
- install a new anode in the reverse order, paying particular attention to
tightness of connections.


5. Periodically, depending on water hardness, remove the accumulated
sediment and loose scale.

5. Warranty conditions

1. The warranty is granted for a period of 60 months for the enamelled tank
2. The warranty for other parts of the exchanger and for:
- STDC controller,
- 2-way-pump-group
is 24 months
3. The warranty period starts on the date of sale of the product to the user,
as entered in the warranty card and confirmed by a proof of purchase
(bill) issued by the vendor.
4. The guarantor ensures the efficient operation of the exchanger provided
that it is installed and used in accordance with its manual.
5. During the warranty period, the user is entitled to free repair of any
damage occurring through the fault of the manufacturer of the
exchanger. Any damage shall be removed in 14 days after the date of
notification.
ATTENTION!
The magnesium anode plays an important role in the corrosion
protection of the enamelled tank, and its regular checking and
replacement with a new one is necessary to maintain the warranty of the
tank.
Replaced used anodes and certification of their exchange (anode
purchase) should be kept in order to make them available for the
manufacturer's service personnel in case of failure of the tank.
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6. The user loses the right to warranty repairs in case of:
- installation of the tank in a system without solar collectors,
- improper use of the device,
- repairs and modifications of the device by unauthorised persons,
- improper installation and operation of the device that is not in conformity
with this manual,
- use of the exchanger without the safety valve or with malfunctioning
safety valve,
- lack of the magnesium anode and lack of documents confirming its
replacement,
- use of a heating element with non-insulated electrical units.
7. The guarantor may refuse to repair if:
- it is not granted service access to the device,
- it is necessary to dismantle other devices, partition walls, etc. in order
to replace the tank,
- the tank is connected to the water supply network permanently, by
means of inseparable connections.
8. In case of damages, resulting from accidents caused by the user or
force majeure ( lightning, natural disasters, etc.) the cost of repairing of
the device must be covered by the enduser.
9. In case of unjustified calls for service, costs of arrival shall be borne by
the customer.
10. In the event of the expansion vessel failure, please inform the technical
support of the company:
Reflex -POLSKA Sp. z o.o.
ul. Mikoaja z Ryska 36-40
87-200 Wbrzeno, Poland
tel. +48 56/688 44 18, 688 44 00
fax +48 56/688 44 68
11. In case of irregularities in the operation of the exchanger, notify
manufacturer's service, tel. +48 32/ 415 01 81 from 6 to 14, or by e-
mail: sekretariat@ensol.pl or point of sale. DO NOT DISMANTLE THE
DEVICE.
12. The manner of repair of the equipment is determined by the
manufacturer.
13. The basis for repairs under the granted warranty is a correctly filled out,
complete Warranty Card of the exchangers, 2 way-pump-group and
expansion tank, that contains no amendments.
14. In all matters not regulated by these conditions, relevant regulations of
the Civil Code apply.
15. We recommend that you keep the Warranty Card throughout the life of
the exchanger.





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Energetyka Solarna Ensol Sp. z o.o. 47-400 Racibrz, ul. Piaskowa 11 Tel/fax: 0048 32 415 96 65