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Installation and servicing instructions
Solar pump station for solar thermal systems
AGS10-2, AGS10E-2, AGS20-2, AGS50-2
6 720 811 270 (2015/04) UK
2 | Table of contents
AGS10-2, AGS10E-2, AGS20-2, AGS50-26 720 811 270 (2015/04)
Table of contents
1 Key to symbols and safety instructions . . . . . . . . . . . . . . . . . . . 2
1.1 Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Information on the solar pump station . . . . . . . . . . . . . . . . . . . . 3
2.1 Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Determined use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Components and technical documentation . . . . . . . . . . . 5
2.4 EC Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . 6
2.5 Scope of Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.6 Other equipment required . . . . . . . . . . . . . . . . . . . . . . . . 6
2.7 Air vent valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 Installing pipework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.1 General information regarding pipework . . . . . . . . . . . . . 7
4.2 Laying pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 Installing the solar pump station . . . . . . . . . . . . . . . . . . . . . . . . 9
5.1 Layout of the installation space . . . . . . . . . . . . . . . . . . . . 9
5.2 Mounting the solar pump station . . . . . . . . . . . . . . . . . . . 9
5.3 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.4 Installing the safety assembly . . . . . . . . . . . . . . . . . . . . 10
5.5 Connecting the expansion vessel and pre-cooling
vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.6 Connecting pipework and pressure relief valve
discharge pipe to the solar pump station . . . . . . . . . . . 11
5.7 Installing temperature sensors . . . . . . . . . . . . . . . . . . . 12
6 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.1 Use of heat transfer fluid . . . . . . . . . . . . . . . . . . . . . . . . 12
6.2 Purging and filling with a hand pump (air vent on roof) 12
6.3 Setting the flow rate . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.4 Completion of work . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7 Environment / disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8 Commissioning, inspection and maintenance reports . . . . 18
9 Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1 Key to symbols and safety instructions
1.1 Key to symbols
Warnings
The following keywords are defined and can be used in this document:
NOTICE indicates a situation that could result in damage to property
or equipment.
CAUTION indicates a situation that could result in minor to medium
injury.
WARNING indicates a situation that could result in severe injury or
death.
DANGER indicates a situation that will result in severe injury or death.
Important information
Additional symbols
1.2 General safety instructions
Mounting
Installation and maintenance must only be carried out by an approved
contractor.
Please read these instructions carefully.
Never modify components.
Replace faulty parts immediately. Use only original spare parts.
To limit the temperature at the tap to a maximum of 60 °C, install a
DHW mixer.
Only use materials which are glycol resistant and which can withstand
temperatures of up to 150 °C.
Electrical work
Ensure that electrical work is only carried out by authorised
electricians.
Ensure that an isolator compliant with EN 60335-1 for disconnecting
all poles from the power supply is fitted.
If you wish to open the solar pump station:
Disconnect the solar pump station from the power supply.
Warnings in this document are identified by a warning
triangle printed against a grey background.
Keywords at the start of a warning indicate the type and
seriousness of the ensuing risk if measures to prevent
the risk are not taken.
This symbol indicates important information where
there is no risk to people or property.
Symbol Explanation
Step in an action sequence
Cross-reference to another part of the document
List entry
List entry (second level)
Table 1
Information on the solar pump station | 3
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Instructing the user
Instruct users as to how the appliance functions, as well as how to
operate the system as a whole.
Explain that conversions and maintenance must only be carried out by
an authorised contractor.
Point out the need for inspections and maintenance for safe and
environmentally friendly operation.
Hand these installation and maintenance instructions to the user.
Point out that these instructions must be kept and passed on to the
next owner/user.
2 Information on the solar pump station
2.1 Product description
If you wish to open the solar pump station:
Pull the cover (insulation part) forwards.
Fig. 1
Fig. 2 Single and twin-line solar pump stations without front insulation parts and without integral controllers and modules
[1] Ball valve with thermometer (red = flow
1)
, blue = return) and
integrated check valve
(position 0° = normal running, 45° = check valve bypassed)
[2] Compression fitting
[3] Pressure relief valve
[4] Pressure gauge
[5] Connection for expansion vessel
[6] Drain & fill valve (DFV)
[7] High-efficiency pump (with power cable and sensor cable)
[8] Flow limiter, type A
[9] Flow limiter, type B
[10] Air separator
1)
[11] Control/shut-off valve
[12] Holder for wall mounting
[13] Ventilation
1)
The illustrations in this manual show the twin-line solar
pump station with external solar controller.
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1) Not for single-line solar pump stations
4 | Information on the solar pump station
AGS10-2, AGS10E-2, AGS20-2, AGS50-26 720 811 270 (2015/04)
2.1.1 Specifications and variants
2.1.2 Energy efficiency
The following product data complies with the requirements of
EU Regulations 811/2013, 812/2013, 813/2013 and 814/2013 as
supplement to the Directive 2010/30/EU.
2.1.3 Solar system and additional heat sources
It is often possible to attach multiple heat sources to combi and buffer
cylinders. These heat sources can completely heat the contents of the
cylinder to over 80 °C.
AGS10-2 AGS10E-2
Maximum possible temperature °C Flow: 130 / return: 110 (pump)
Safety valve response pressure bar 66
Pressure relief valve DN 15, ¾ " connection DN 15, ¾ " connection
Mains voltage 230V AC, 50 - 60 Hz 230V AC, 50 - 60 Hz
Maximum current consumption per pump A 0,4 A / EEI 0,2 0,4 A / EEI 0,2
Measurements (height x width x depth) mm 353x284x248 355x185x180
Flow and return connections
(compression fittings)
mm 15 / 22 15 / 22
Table 2 Specifications of AGS10-2 and AGS10E-2
AGS20-2 AGS50-2
Maximum possible temperature °C Flow: 130 / return: 110 (pump)
Safety valve response pressure bar 66
Pressure relief valve DN 15, ¾ " connection DN 20, 1" connection
Mains voltage 230V AC, 50 - 60 Hz 230V AC, 50 - 60 Hz
Maximum current consumption per pump A 0,7 A / EEI 0,2 1,0 A / EEI 0,23
Measurements (height x width x depth) mm 353x284x248 403x284x248
Flow and return connections
(compression fittings)
mm 22 28
Table 3 Specifications of AGS20-2 and AGS50-2
AGS10-2 AGS10E-2 AGS20 AGS50
Power
consumption
standby (W)
solstandby
W 2.00 2.00 2.00 2.50
Power
consumption full
load (W)
solpump
1)
1) 50 % of nominal power input in operation at 72 mbar and 50 l/h.
W 15 15 22.5 50
Table 4
WARNING: Risk of injury from hot fluid leaks.
To avoid blocking the path to the safety equipment,
leave the ball valves of the solar pump station open
during operation.
If required, install an additional item of safety
equipment between the cylinder and the solar pump
station.
Information on the solar pump station | 5
6 720 811 270 (2015/04)AGS10-2, AGS10E-2, AGS20-2, AGS50-2
2.1.4 Application examples
Fig. 3 Different hydraulic applications
[1] Standard system with dual-circuit solar pump station
[2] Two collector arrays (e.g. east/west) with single and twin-line
solar pump stations
[3] 2-consumer system with single and twin-line solar pump station
[4] Standard system with 1-line solar pumping station and air vent on
roof
2.2 Determined use
Solar pump stations may only be used for the operation of solar
systems in conjunction with suitable controllers.
Solar pump stations may only be installed vertically ( Fig. 3) and
indoors.
The AGS solar pump stations must only be operated with propylene
glycol/water mixtures (heat transfer medium L or LS). The use of any
other heat transfer medium is not permitted.
2.3 Components and technical documentation
A solar thermal system is designed to heat domestic hot water (DHW)
and can also provide central heating backup where required. It is made
up of various components.
Fig. 4 Solar system components
[1] Collector with temperature sensor at the top
[2] Pipework (return)
[3] Solar pump station with expansion vessel, temperature and
safety equipment
[4] Solar cylinder
[5] Solar controller
[6] Pipework (flow)
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AGS10-2, AGS10E-2, AGS20-2, AGS50-26 720 811 270 (2015/04)
2.4 EC Declaration of Conformity
Design and operation of this product conform to European Directives
and the supplementary national requirements. Its conformity is
demonstrated by the CE marking. The Declaration of Conformity can be
requested from the manufacturer (see the back cover for the address).
2.5 Scope of Delivery
Check that the delivery is complete and undamaged.
Fig. 5 Solar pump station
[1] Solar pump station (single or twin-line solar pump station with or
without controller)
[2] Safety assembly (pressure relief valve, pressure gauge, fill and
drain valve)
[3] Bag with rawl plugs and screws
2.6 Other equipment required
In addition to the usual tools, a 13 mm socket with a 150 mm extension
is required for the installation work.
2.7 Air vent valve
Always provide an automatic air vent valve on each row of collectors for
the following systems connected in parallel:
1. System with more than two collector rows.
2. System with AGS50 solar pump station.
Solar-Lifestyle/Solar-Lito flat-plate collectors
The solar system is ventilated through one of the following processes:
1. Pressure filling with solar filling pump ( Chapter 6.2, page 12).
Install additional air vents if necessary, see point 1.– 2. above.
-or-
2. Automatic air vent valve [1] at the highest point of the system
( Chapter 6.2, page 12).
Fig. 6 Position of the automatic air vent valve
Solar-Lux vacuum tube collectors
Only pressure filling and heat transfer medium LS may be used for
ventilation ( Chapter 6.2, page 12). Install additional air vents if
necessary, see point 1.-2. above.
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3 Regulations
Practical work is subject to currently applicable technical rules.
Observe all standards, guidelines and requirements applicable to the
installation and operation of the system in your country and region.
Modified regulations or supplements are also valid at the time of
installation and must be observed.
Technical regulations applicable in the U.K. for the installation of
thermal solar heating systems
Electrical connection:
Current IEE wiring regulations
Connection of solar thermal systems:
EN 12976: Thermal solar systems and components (factory made
systems)
BS5918: Latest version: Solar heating systems for domestic hot
water.
Installation and fittings of hot water heaters:
BS5546:2006 Specification for installation of hot water supplies
for domestic purposes, using gasfired appliances of rated input not
exceeding 70kW.
BS6700:2006 Specifications for design, installation testing and
maintenance of services supplying water for domestic use within
buildings and their curtilages.
Installations should be made in accordance to the relevant MCS Solar
standards if the homeowner is applying for RHI
4 Installing pipework
4.1 General information regarding pipework
NOTICE: System damage through faulty parts.
Only use materials which are resistant to glycol,
pressure and heat (at least up to 150 °C).
Do not use plastic pipes (e.g. polyethylene pipes) or
galvanised pipework.
We recommend carrying out a pipe network analysis to
determine pipework sizing requirements. Basic design
estimates can be made using Tab. 5.
If there are many additional points of resistance
(bends, valves, etc.), you may need to select a pipe
with a larger diameter.
Straight pipe
length
Number of collectors
2 to 5 6 to 10 11 to 15 16 to 20
0 to 6 m Ø 15 mm
(DN12)
1)
1) For example, solar twin tube 15 (copper)
Ø 22mm
(DN20)
2)
2) Or solar twin tube DN20 (stainless steel)
Ø 22mm
(DN20)
Ø 22mm
(DN20)
7 to 10 m Ø 15 mm
(DN12)
1)
Ø 22mm
(DN20)
Ø 22mm
(DN20)
Ø 28mm
(DN25)
11 to 15 m Ø 15 mm
(DN12)
1)
Ø 22mm
(DN20)
Ø 28mm
(DN25)
Ø 28mm
(DN25)
16 to 20 m Ø 22 mm
(DN20)
2)
Ø 22mm
(DN20)
Ø 28mm
(DN25)
Ø 28mm
(DN25)
21 to 25 m Ø 22 mm
(DN20)
2)
Ø 28mm
(DN25)
Ø 28mm
(DN25)
Ø 35mm
(DN32)
Table 5 Pipework sizing
8 | Installing pipework
AGS10-2, AGS10E-2, AGS20-2, AGS50-26 720 811 270 (2015/04)
Install a device into the return at the lowest point in the solar system
for draining the solar system (tee with fill and drain valve [1]).
Fig. 7
4.2 Laying pipes
Evacuated tube collectors
The minimum pipe length from the solar pump station to the collector
array must be at least 10 m (single length).
The minimum height clearance for the connection of the expansion
vessel to the collector array is 2 m.
Fig. 8 Distance to the collector array (Solar-Lux)
Solar-Lifestyle/Solar-Lito flat-plate collectors
To prevent air pockets when using an automatic air vent valve on the
collector array:
Route the pipes from the pump station to the collector/air vent [1] on
a rising incline.
If a change of direction downwards is unavoidable, install additional
heat-resistant (150 °C) air vents.
Fig. 9 Position of the automatic air vent valve
In some cases, the solar pump station [1] cannot be installed
underneath the collectors (e.g. in the case of attic installations).
Form a "pipe trough" with the flow in order to prevent overheating in
such systems:
Firstly, route the flow to the height of collector return connection [2].
Then route it to the solar pump station.
Fig. 10
Connecting pipework
Copper pipes must only be soldered with brazing solder i.e. no low
temperature soldering.
-or-
Use glycol and heat-resistant (150 °C) compression fittings or push-
fit fittings.
If necessary, allow for the flow of a fill and drain valve as
well ( Chapter 6.2.1, page 13).
If the minimum pipe length or the minimum height
distance cannot be maintained:
Form a "pipe trough" at least 1.5 m high with the flow
and return lines on the collector array ( Fig. 8).
> 2 m
> 1,5 m
< 2 m
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NOTICE: Risk of damage to the collector through heat
created by brazing.
Do not solder close to evacuated tube collectors.
If threaded pipe connections are caulked with hemp:
Use a thread sealing compound resistant to
temperatures up to 150 °C (e.g. NeoFermit
universal).
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Earthing pipes
Arrange for work to be performed by a competent person.
One earthing clamp must be fitted to both the flow pipe and the return
pipe (at any position).
Connect the earthing clamps to the building's equipotential bonding
strip by means of a standard PVC-sheathed bonding cable (cable to be
sized in accordance with BS7671).
Insulating pipework
Thermally insulate the pipework in the entire solar circuit in
accordance with regulations and best practice.
Insulate outdoor piping with material which is both resistant to UV
light and high temperatures (up to 150 °C).
Insulate indoor piping with material which is resistant to high
temperatures (up to 150 °C).
Protect the insulation against damage from animals if required.
Fig. 11 Minimum requirements of the insulation
5 Installing the solar pump station
5.1 Layout of the installation space
To make it easier to connect the temperature sensors:
Install the solar pump station [2] as close as possible to the solar
cylinder [1].
Allow enough room for a solar expansion vessel [3] and holding
container [4].
Fig. 12 Recommended positioning (measurements in mm)
[1] Solar cylinder
[2] Solar station
[3] Expansion vessel
[4] Drip pan
5.2 Mounting the solar pump station
Use a socket (13 mm) with a 150 mm extension to screw in the screws.
With shorter extensions, the handles and temperature gauges [3] can be
pulled forwards and removed for easier access to the screws.
Single-line solar pump station
Drill hole and fix solar pump station using rawl plug and screw
supplied [1, 2].
Twin-line solar pump station
Drill holes spaced 60 mm apart and fix solar pump station using rawl
plugs and screws supplied [4, 2].
Fig. 13 Mounting the station
[1] Mounting for single-line solar pumping station
[2] Rawl plugs and screws supplied
[3] Thermometer
[4] Mounting for twin-line solar pump station
5.3 Electrical connection
UV
> 150 °C
> 150 °C
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Observe minimum clearances from the solar pump
station to the collector array of the vacuum tube
collectors ( Chapter 4.2, page 8)
DANGER: Danger to life through electric shock!
Before carrying out work on electrical components,
isolate them from the power supply (230 V AC) (fuse,
circuit breaker) and secure against unintentional
reconnection.
Electrical connections must only be completed by
appropriately qualified engineers subject to local and
national regulations.
NOTICE: Damage through pump running dry!
Do not run the pump until the pipework system has
been filled.
4
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150 mm
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AGS10-2, AGS10E-2, AGS20-2, AGS50-26 720 811 270 (2015/04)
5.3.1 Solar pump station with an external controller
You will find notes regarding the electrical connection in the controller
instructions.
5.4 Installing the safety assembly
Install the safety assembly on the solar pump station together with the
gasket supplied [1].
Fig. 14 Installing the safety assembly
[1] Gasket (21x30x2)
5.5 Connecting the expansion vessel and pre-cooling
vessel
5.5.1 Installing the pre-cooling vessel with evacuated tube
collectors (available as accessory)
With evacuated tube collectors, a pre-cooling vessel is required if:
The system is designed to support a central heating system.
The system is purely for DHW heating and the solar fraction is more
than 60 %.
The minimum pipe length or the minimum height distance cannot be
achieved ( Chapter 4.2, page 8).
The pre-cooling vessel protects the expansion vessel from excessively
high temperatures.
Connecting the pre-cooling vessel
If the pipeline to the expansion vessel needs to be laid on a rising incline,
an additional air vent must be installed.
Secure pipework to and from the pre-cooling vessel with pipe clips
[4]. Mount the pre-cooling vessel vertically.
Connect the expansion vessel [5] to the pre-cooling vessel by means
of a copper pipe.
Seal the connection on the pressure relief valve with a ¾ " cap [2] on
site.
Fig. 15 Installing the pre-cooling vessel
[1] Flexible stainless steel hose from the connection set for the
expansion vessel (available as accessory)
[2] Safety assembly (provided by installer)
[3] Pre-cooling vessel
[4] Pipe clip (on site)
[5] Expansion vessel
5.5.2 Installing the solar expansion vessel (available as an
accessory)
Install the expansion vessel with the mounting materials provided.
Never turn off the heating system when you are away on
holiday or in summer as this may disable the solar
system.
For a single-line solar pump station:
Install the safety assembly on the left.
Do not insulate the pre-cooling vessel (if fitted) and the
expansion vessel, nor the pipes connecting them to the
safety assembly.
6 litre 12 litre
Height 270 mm 270 mm
Diameter 160 mm 270 mm
Port 2 x R ¾ " 2 x R ¾ "
Maximum operating pressure 10 bar 10 bar
Table 6 Pre-cooling vessel specifications
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WARNING: Risk of injury If the pressure relief valve is
damaged, this may result in an explosion.
To protect the pressure relief valve from excessive
temperatures:
Connect the pre-cooling and expansion vessels with a
tee (¾ " outer thread with flat gasket) in the return 20
to 30 cm above the solar pump station.
WARNING: Risk of injury If the pressure relief valve is
damaged, this may result in an explosion.
To protect the pressure relief valve from excessive
temperatures:
Connect the pre-cooling and expansion vessels with a
tee (¾ " outer thread with flat gasket) in the return 20
to 30 cm above the solar heating station.
20-30 cm20-30 cm
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Connect the expansion vessel [3] in the return on the solar pump
station's safety assembly.
Fig. 16
[1] Pressure relief valve
[2] Flexible stainless steel hose from the connection set (available as
accessory)
[3] Expansion vessel
5.5.3 Adjusting the pre-charge pressure of the expansion vessel
To make use of the maximum possible volume:
Set the pre-charge pressure when the vessel is not subjected to load
(i.e. no fluid pressure).
If the calculated pre-charge pressure is higher or lower than the
factory-set pre-charge pressure (see table 7, page 11), correct the
pre-charge pressure accordingly.
5.6 Connecting pipework and pressure relief valve
discharge pipe to the solar pump station
Cut the pipes to length and push them as far as possible into the
compression fitting [1].
Route the discharge pipe [2] from the pressure relief valve so that any
discharge can be seen to empty out into the holding container [4] and
secure it in place with a pipe clip [3].
Maintain an air break.
Fig. 17 Connection to solar pump station
[1] Compression joints on all four outlets
[2] Discharge pipe (not supplied)
[3] Pipe clip (on site)
[4] Empty solar fluid container (holding container)
[5] Connection bracing points
The pre-charge pressure of the expansion vessel is
calculated based on the static system head
1)
plus an
allowance.
Calculate and set pre-charge pressure to at least
1.2 bar.
Flat plate Evacuated tube
Static height
1)
1) A one metre difference in height (between collector array and solar pump station)
equates to 0.1 bar
(10 m) 1.0 bar (10 m) 1.0 bar
+ allowance + 0.4 bar + 1.7 bar
= expansion vessel pre-
charge pressure
= 1.4 bar = 2.7 bar
Table 7 Example: collector-dependent pre-charge pressure
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WARNING: Injuries and system damage due to hot heat
transfer medium.
Make sure the discharge pipe size is at least that of the
pressure relief valve (maximum length = 2 m and
maximum of 2 bends).
To tighten the lower compression fittings, you can brace
against the points marked [5] using a 27 mm spanner or
pipe wrench.
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12 | Commissioning
AGS10-2, AGS10E-2, AGS20-2, AGS50-26 720 811 270 (2015/04)
5.7 Installing temperature sensors
The temperature sensors are not polarity sensitive. There are two
sensors, one identified for the Solar collector and one for the cylinder
storage; ensure that these be installed in the correct sensor pockets.
If the cable of the collector temperature sensor is joined to the sensor
lead going to the controller at a point which is exposed to moisture, a
waterproof junction box must be used [2].
If required, extend the sensor lead with a 2-wire cable [3] on site:
up to 50 m = 2 x 0.75 mm
2
up to 100 m = 2 x 1.5 mm
2
Fig. 18 Temperature sensor on solar pump station with integral
controller
[1] Collector temperature sensor
[2] Connection point
[3] 2-wire cable (on site)
[4] Fill & drain valve for emptying (not supplied)
[5] Cylinder temperature sensor, bottom
6 Commissioning
6.1 Use of heat transfer fluid
The heat transfer fluid is pre-mixed and ready to use. It guarantees safe
operation within the specified temperature range, protects the system
from frost damage and minimises risk of vaporisation.
The heat transfer medium is biodegradable. A safety data sheet with
further information can be requested from the manufacturer.
Only operate collectors with the following heat transfer medium
(available as an accessory):
6.2 Purging and filling with a hand pump (air vent on roof)
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NOTICE: Collector damage through evaporation in the
solar circuit or frozen water.
Flush and fill the solar system only when the sun is not
shining on the collectors and (if flushing with water)
no frost is expected.
When filling with heat transfer medium, take the
additional volume of the pre-cooling vessel into account
(if installed).
The pre-cooling vessel and the expansion vessel must be
adequately vented.
The pump in the solar pump station is self-venting. Do
not vent it by hand.
CAUTION: Risk of injury through contact with heat
transfer medium
When handling heat transfer fluid, always wear
protective gloves and goggles.
If heat transfer medium comes into contact with skin:
wash off with water and soap.
▶If heat transfer fluid comes into contact with eyes:
thoroughly rinse eyes with running water and if
required seek medical advice.
NOTICE: Using an unsuitable heat transfer medium may
damage the system and will invalidate the warranty.
▶Do not mix heat transfer medium with other heat
transfer media.
If the solar system is not in use for more than 4 weeks,
cover the collectors.
Collector version
Heat transfer
medium
Temperature range
Flat plate Type L – 28 ... +170 °C
Evacuated tube Type LS – 28 ... +170 °C
Table 8
NOTICE: Collector damage.
With vacuum tube collectors, always use pressure
filling ( Chapter 6.2) because water must not be
poured into the collectors.
Commissioning | 13
6 720 811 270 (2015/04)AGS10-2, AGS10E-2, AGS20-2, AGS50-2
6.2.1 Purging the pipework
Use a hose [1] to connect the DFV on the safety assembly to the mains
water supply.
To drain the water away, connect a hose [2] to the DFV on the flow
limiter.
Fig. 19 Solar pump station with ball valves and check valves in the
thermometers
[1] Hose for water supply
[2] Hose for water drainage
Open all shut-off devices.
Close the right-hand ball valve [2] on the solar pump station and the
ball valve on the air vent ( Fig. 21, [2]).
Purge the pipework, making sure that the maximum operating
pressure is not exceeded.
Shut off the water supply.
Close the fill and drain valves [3] in the solar pump station.
Fig. 20
[1] Left-hand ball valve completely open (0°)
[2] Right-hand ball valve closed (90°)
[3] Fill & drain valves in the solar pump station
6.2.2 Carrying out a tightness test with water
The solar thermal system is vented by opening the plug screw [2] on the
automatic air vent valve.
Open the ball valve [2].
▶Unscrew the plug screw [1] one turn.
Fig. 21 Opening the air vent valve
[1] Shut-off screw
[2] Ball valve
Set the ball valves [1] on the thermometers to 45° and open the flow
limiter [2] and other shut-off devices.
Carry out a tightness test, observing the permissible pressures for all
assemblies.
After the tightness test: drain the water and clean the automatic air
vent valve.
Fig. 22 Opened shut-off devices
[1] Ball valves and gravity brake open on the thermometers
(45° position)
[2] Flow limiter open
If a pre-cooling vessel is installed:
Disconnect the pre-cooling vessel from the solar
circuit while flushing so that the fluid remaining in the
pre-cooling vessel does not get mixed with the heat
transfer medium.
7747006489-21.2ST
2
1
7747006489.20-2.ST7747006489.20-2.ST
20
0
40
60
°C
80
100
120
20
0
40
60
°C
80
100
120
3
3
1
2
S E
6720801165.14-2.ST
2
1
2
6720801165.17-2.ST
1
20
0
40
60
°C
80
100
120
20
0
40
60
°C
80
100
120
S E
2
14 | Commissioning
AGS10-2, AGS10E-2, AGS20-2, AGS50-26 720 811 270 (2015/04)
6.2.3 Replacing water with heat transfer medium
You can use electric pumps, hand pumps or power drill attachments
capable of generating pressures of at least 2 bar for filling.
Using a pump, fill the solar system via one of the fill and drain valves
[1] in the solar pump station.
Fig. 23 Filling via DFV
Set the ball valves ( Fig. 22, [1]) on the thermometers to 45° and
open the flow limiter ( Fig. 22, [2]) and other shut-off devices.
Fill the solar system slowly so that air bubbles do not form.
Lastly, set the ball valves on the thermometers so that the gravity
brakes are ready for operation (0° position).
6.2.4 Verifying that the solar thermal system is free of air
Switch the solar pump(s) on and off manually.
While switching the pump on and off, observe the black pointer on the
pressure gauge [1] on the safety assembly.
Fig. 24 Checking the pressure gauge display
6.2.5 Determining the operating pressure
When putting the system into operation, the operating pressure must be
0.7 bar above the static pressure (1 metre difference in height equals
0.1 bar).
The system pressure must be at least 1.5 bar (when cold, 20 °C).
If there is not enough pressure, pump in more heat transfer medium.
Once ventilation is complete, close the ball valve [2] of the air vent
and the plug screw [1].
Fig. 25 Closing the air vent and ball valve
The pipes must be completely emptied of water,
otherwise the heat transfer medium can become diluted.
If the black pointer on the pressure gauge [1] indicates
pressure fluctuations when the solar pump is switched on
and off, there is still air in the solar thermal system which
must be removed.
7747006489.36-2.ST7747006489.36-2.ST
1
1
S E
7747006489.33-2.ST
1
Flat plate Evacuated tube
Static height
1)
1) A one metre difference in height (between collector array and solar pump station)
means 0.1 bar
(10 m) 1.0 bar (10 m) 1.0 bar
+ allowance + 0.7 bar + 2.0 bar
= operating pressure = 1.7 bar = 3.0 bar
Table 9 Example: collector-dependent operating pressure
When heat transfer medium evaporates in the collector,
pressure relief can only be achieved by the solar
expansion vessel if the air vent is closed.
6720801165.15-2.ST
2
1
Commissioning | 15
6 720 811 270 (2015/04)AGS10-2, AGS10E-2, AGS20-2, AGS50-2
6.2.6 Determining the frost threshold temperature
To determine the degree of frost protection, we recommend checking
the frost protection of the heat transfer fluid when first putting the
system into operation, by means of a frost protection gauge (a
refractometer). This check should be repeated at regular intervals (at
least every two years).
The commonly used instruments for testing motor vehicle engine
coolants are not suitable for this purpose. A suitable device can be
ordered separately.
For system operation with heat transfer medium LS
If the solar system is operated with heat transfer medium LS, the value
must be converted using Tab. 10.
6.2.7 Correcting frost protection
If the minimum frost protection level is not being maintained, more heat
transfer fluid must be added.
Use Tab. 11 to determine the volume of the system, so that you can
calculate the exact amount to be added (which is equal to the amount
which first needs to be drained out).
Use the formula on the right to determine the amount of concentrate
to be added (V
replace
).
Example of heat transfer medium L:
System volume (V
total
) = 22 l
Frost protection level (reading taken): – 14 °C
Equals concentration of ( Tab. 10, page 15): 29 % (C = 29)
•Result: V
replace
= 4.3 l
Drain the calculated amount to be added (V
replace
) and add
concentrate.
6.3 Setting the flow rate
The flow rate is set when the system is cold (30 - 40 °C).
When the solar pump is speed-controlled, the controller determines
the flow rate based on operating requirements.
If the controller is not equipped with speed control or if speed control
has been deactivated, the flow rate must be set to a fixed flow rate.
If you wish to set the flow rate:
1. Carry out the preparatory work ( Chapter 6.3.1)
2. Check the flow rate ( Chapter 6.3.2)
3. Set the flow rate ( Chapter 6.3.3)
6.3.1 Carrying out the preparatory work
Rotate ball valves [1] to 0° (check valves ready for operation).
Completely open the flow limiter [2].
On the controller, select mode “Manual ON” ( controller instruction
manual).
Fig. 26
[1] Gravity brake ready for operation
[2] Adjusting screw on the flow limiter, depending on the type
[3] Read-off edge for the flow rate, depending on the type
Value recorded for heat transfer
medium L (concentration)
Corresponds to frost protection
with heat transfer medium LS
– 23 °C (39 %) – 28 °C
– 20 °C (36 %) – 25 °C
– 18 °C (34 %) – 23 °C
– 16 °C (31 %) – 21 °C
– 14 °C (29 %) – 19 °C
– 11 °C (24 %) – 16 °C
– 10 °C (23 %) – 15 °C
– 8 °C (19 %) – 13 °C
– 6 °C (15 %) – 11 °C
– 5 °C (13 %) – 10 °C
– 3 °C (8 %) – 8 °C
Table 10
NOTICE: Frost damage
Every two years, check whether the required frost
protection level (to at least –25 °C) is being
maintained.
System part Fill volume
Collector: see collector instructions (technical data)
1 single-line solar pump station 0.20 l
1 twin-line solar pump station 0.50 l
1 coil in the solar cylinder (see technical guide)
1 m Cu pipe Ø 15 mm 0.13 l
1 m Cu pipe Ø 22 mm 0.31 l
1 m Cu pipe Ø 28 mm 0.53 l
1 m Cu pipe Ø 35 mm 0.86 l
1 m Cu pipe Ø 42 mm 1.26 l
1 m stainless steel corrugated pipe DN16 0.26 l
1 m stainless steel corrugated pipe DN20 0.41 l
1 m stainless steel corrugated pipe DN25 0.61 l
Table 11 Volume of the separate system parts
V
replace
= V
total
x
43 - C
concentration
100 - C
concentration
Table 12 Formula for calculating the amount of fluid to be replaced
0,5
7
6
5
4
3
2
1
L/min
7
6
5
4
1
0,5
3
2
6720801165.18-2.ST
1
20
0
40
60
°C
80
100
120
20
0
40
60
°C
80
100
120
S E
3
2
16 | Commissioning
AGS10-2, AGS10E-2, AGS20-2, AGS50-26 720 811 270 (2015/04)
6.3.2 Checking the flow rate
Refer to Tab. 13 for the required flow rate (at 30-40 °C in the return).
Check the flow rate in the sight glass of the flow limiter (
Fig.
27
[3]).
6.3.3 Setting the flow rate
It may be necessary to reduce the flow rate for solar systems with up to
4 flat plate collectors (or 3 evacuated tube collectors).
Set the speed to 100 % on the solar controller ( controller
instructions: "Function test").
If the maximum flow rate ( Tab. 14) is exceeded:
Reduce the flow rate at the flow limiter [2] until the flow rate drops
below the maximum.
After commissioning
The viscosity of the heat transfer fluid makes air bubbles substantially
more resilient than those in pure water.
After several hours of solar pump operation, vent the solar system via
the air separator in the solar pump station [4] and (if installed) the air
vent on the roof.
Fig. 27
[1] Gravity brake ready for operation
[2] Adjusting screw on the flow limiter, depending on the type
[3] Read-off edge for the flow rate, depending on the type
[4] Ventilation at the air separator
If the pre-set flow rate is not reached at the pump's
highest speed stage:
Check maximum permitted pipe lengths and sizing
( Chapter 4.1).
If necessary, install a more powerful solar pump.
Quantity Flat plate l/min
1)
1) Nominal flow rate per collector: 50 l/h
Evacuated tube l/min
2)
2) Nominal flow rate per collector: 30 l/h
1 1 0.5-0.6
2 1.5-2 1-1.2
3 2.5-3 1.4-1.8
4 3-4 1.9-2.4
5 4-5 2.4-3.0
6 5-6 2.9-3.6
7 5.5-7 3.3-4.2
8 6.5-8 3.8-4.8
9 7.5-9 4.3-5.4
10 8-10 4.8-6.0
11 9-11 5.2-6.6
12 10-12 5.7-7.2
13 10.5-13 6.2-7.8
14 11.5-14 6.7-8.4
15 12.5-15 7.1-9.0
16 13-16 7.6-9.6
17 14-17 8.1-10.2
18 15-18 8.6-10.8
19 15.5-19 9.0-11.4
20 16.5-20 9.5-12.0
Table 13 Maximum flow rate at 30 - 40 °C in the return depending on
collector version and number of collectors
Low energy pumps do not require a step switch as they
are modulated using a control signal.
Quantity Flat plate l/min Evacuated tube l/min
1 2.5 --
2 5 5
3 7.5 7.5
4 10 10
Table 14 Flow rate (maximum flow rate) at 30 - 40 °C in the return
depending on collector version and number of collectors
0,5
7
6
5
4
3
2
1
L/min
7
6
5
4
1
0,5
3
2
6720801165.19-2.ST
1
20
0
40
60
°C
80
100
120
20
0
40
60
°C
80
100
120
S E
3
2
4
Environment / disposal | 17
6 720 811 270 (2015/04)AGS10-2, AGS10E-2, AGS20-2, AGS50-2
6.4 Completion of work
To close the solar pump station:
Push the cover onto the solar pump station.
Fig. 28
Fig. 29 Do not cover the ventilation slots
7 Environment / disposal
Environmental protection is a fundamental corporate strategy of the
Bosch Group.
The quality of our products, their efficiency and environmental safety
are all of equal importance to us and all environmental protection
legislation and regulations are strictly observed.
We use the best possible technology and materials for protecting the
environment taking into account of economic considerations.
Packaging
We participate in the recycling programmes of the countries in which our
products are sold to ensure optimum recycling.
All of our packaging materials are environmentally friendly and can be
recycled.
Old appliance
Old appliances contain materials that must be recycled.
The relevant assemblies are easy to separate, and all plastics are
identified. In this manner the individual components are easily sorted
and added into the recycling and disposal systems.
NOTICE: Damage to pump through overheating.
Ensure that the ventilation slots in the cover are freely
accessible from above and below.
6720801165.12-2.ST
6720801165.13-2.ST
18 | Commissioning, inspection and maintenance reports
AGS10-2, AGS10E-2, AGS20-2, AGS50-26 720 811 270 (2015/04)
8 Commissioning, inspection and
maintenance reports
We recommend conducting the first inspection or maintenance after
approx. 500 hours.
Test (inspect) solar systems at least once every 2 years. Immediately
remedy all faults (maintenance).
Perform activities and fill out log.
DANGER: Risk to life by falling from roof!
Whilst working on the roof, take all necessary
precautions against a possible fall.
If there are no general anti-fall safety devices
available, wear personal protective equipment.
DANGER: Danger to life through electric shock!
Before carrying out work on electrical components,
isolate them from the power supply (230 V AC) (fuse,
circuit breaker) and secure against unintentional
reconnection.
Commissioning, inspection and maintenance may only
be carried out by authorised contractors.
Follow the instructions for the components.
Commissioning, inspection and maintenance reports | 19
6 720 811 270 (2015/04)AGS10-2, AGS10E-2, AGS20-2, AGS50-2
This Commissioning Checklist is to be completed in full by the competent person who commissioned the Solar Thermal System and
associated equipment as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to
keep for future reference.
Failure to install and commission this equipment to the manufacturer’s instructions may invalidate the warranty but does not affect statutory rights.
SOLAR THERMAL COMMISSIONING CHECKLIST
Customer name: Telephone number:
Address:
Commissioned by (PRINT NAME): Telephone number:
Company name:
Company address:
Commissioning date:
7REHFRPSOHWHGE\WKHFXVWRPHURQUHFHLSWRID%XLOGLQJ5HJXODWLRQV&RPSOLDQFH&HUWL¿FDWH
%XLOGLQJ5HJXODWLRQV1RWL¿FDWLRQ1XPEHULIDSSOLFDEOH
&RQ¿UPDWLRQWKDWUHTXLUHGDUHDVRIWKHLQVWDOODWLRQKDYHEHHQQRWL¿HGWR/RFDO$XWKRULW\%XLOGLQJ&RQWURO/$%&
a). Initials of commissioning engineer
E&RPSHWHQW3HUVRQV6FKHPH&36GHWDLOVRUGHWDLOVRI/$%&GLUHFWQRWLL¿FDWLRQ
&RQ¿UPDWLRQWKDWSDQHOVKDYHEHHQLQVWDOOHGZLWKRXWOHVVHQLQJWKHVWUXFWXUHZHDWKHULQJDQG¿UHUHVLVWDQFHRIWKHURRILQDFFRUGDQFHZLWKWKHUHOHYDQW%XLOGLQJ
Regulations and standards. Initials of commissioning engineer
COLLECTOR DETAILS
Make of collector Model of collector
Serial number of each collector: (if more than 6 collectors please append additional sheet)
i. ii. iii.
iv. v. vi.
INSTALLATION DETAILS
Solar System Operating Pressure bar (cold) Expansion vessel air/nitrogen charge bar (cold)
Expansion or drain back vessel size litres
Operating correctly: Yes 7UHDWHGIRUOHDNVDQGÀXVKHG Yes Filled and purged for air: Yes
6\VWHPKHDWWUDQVIHUÀXLGGHWDLOV
:KDWW\SHPDNHRIKHDWWUDQVIHUÀXLGXVHG" System volume litres
:KDWLVWKHÀXLGPL[:DWHU % Glycol %
Frost protection provided to °C
,VWKHLQVWDOODWLRQLQDKDUGZDWHUDUHDDERYHSSP" Yes No
,I\HVKDVDZDWHUVFDOHUHGXFHUEHHQ¿WWHGRUKDV7PD[EHHQOLPLWHGWRÛ&" Yes No
:KDWW\SHRIVFDOHUHGXFHUKDVEHHQ¿WWHG"
Air purged from solar primary circuit: Yes 3ULPDU\FLUFXLWYDOYHVDQGDLUYHQWVVHWWR¿QDORSHUDWLQJSRVLWLRQV Yes
Pump speed setting recorded: Speed setting 0D[ÀRZUDWH litres/min
Solar primary circuit pressure relief valves tested for correct operation: Yes /RFDWLRQ
'HYLFHIRUOLPLWLQJKRWZDWHUWHPSHUDWXUHRXWOHWVKDVEHHQ¿WWHG Yes N o
Type /RFDWLRQ
All exposed pipework lagged in accordance with regulations using suitably temperature rated materials Yes
)RUXQYHQWHGKRWZDWHUVWRUDJHF\OLQGHUZLOOFRQWUROVVWRSVRODUÀXLGFLUFXODWLRQLQWKHHYHQWRIF\OLQGHURYHUKHDWLQJ" Yes
SOLAR SYSTEM CONTROLS
Make and model of DTC
Temperature sensors checked and operating correctly Yes
Differential Temperature Controller (DTC) settings:
T on °C T off °C
T max °C Other DTC Settings
Thermostat located in back-up heating zone of cylinder Yes No
+DYHRSWLPXPVHWWLQJVIRU+:FRQWUROVEHHQH[SODLQHGWRWKHFXVWRPHU" Yes No
'RHVWKLVLQFOXGH/HJLRQHOOD%DFWHULDSURWHFWLRQVHWWLQJVZLWKEDFNXSKHDWLQJV\VWHPWREULQJERLOHUYROXPHWR&IRUDQKRXURQFHDGD\" Yes No
Electrical installation is accordance with BS7671 Yes
/RFDWLRQRIHOHFWULFDOLVRODWLRQVZLWFKWRVRODUFRQWUROSXPSXQLW
ALL INSTALLATIONS
The heating and hot water system complies with the appropriate Building Regulations Yes
The system and associated products have been installed and commissioned in accordance with the manufacturer’s instructions Yes
7KHHI¿FLHQWRSHUDWLRQRIV\VWHPDQGLWVFRQWUROVKDYHEHHQGHPRQVWUDWHGWRDQGXQGHUVWRRGE\WKHFXVWRPHU Yes
7KHPDQXIDFWXUHU¶VOLWHUDWXUHLQFOXGLQJ%HQFKPDUN&KHFNOLVWDQG6HUYLFH5HFRUGKDVEHHQH[SODLQHGDQGOHIWZLWKWKHFXVWRPHU Yes
Commissioning Engineer’s Signature
Customer’s Signature
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$OOLQVWDOODWLRQVLQ(QJODQGDQG:DOHVPXVWEHQRWL¿HGWR/RFDO$XWKRULW\%XLOGLQJ&RQWURO/$%&HLWKHUGLUHFWO\RUWKURXJKD
&RPSHWHQW3HUVRQV6FKHPH$%XLOGLQJ5HJXODWLRQV&RPSOLDQFH&HUWL¿FDWHZLOOWKHQEHLVVXHGWRWKHFXVWRPHU
© Heating and Hotwater Industry Council (HHIC)
www.centralheating.co.uk
20 | Commissioning, inspection and maintenance reports
AGS10-2, AGS10E-2, AGS20-2, AGS50-26 720 811 270 (2015/04)
Commissioning, inspection and maintenance reports | 21
6 720 811 270 (2015/04)AGS10-2, AGS10E-2, AGS20-2, AGS50-2
General information on the solar system
User: System location:
Collector type: Number of collectors:
Collector array alignment (e.g. south): Collector array angle of inclination:
Collector installation (vertical, horizontal): Installation set (e.g. on roof):
Solar pump station type: Static height to collectors:
Expansion vessel size (l): Expansion vessel pre-charge pressure (unloaded):
Pressure relief valve type: Pressure relief valve excess pressure:
Controller type: Number of consumers (cylinder, swimming pool, etc.):
Cylinder 1 type and capacity: Cylinder 1 coil capacity:
Cylinder 2 type and capacity: Cylinder 2 coil capacity:
Miscellaneous:
Table 15
Commissioning, inspection and maintenance tasks Page
Commission-
ning
Inspection/maintenance
1. 2. 3. 4.
Date:
Solar thermal system
1. Pipework (flow and return) installed and earthed? 8
2. Pipework flushed and tightness test carried out? 13
3. Air vent closed? 14
4. Charge pressure of the expansion vessel checked? 11 ____ bar
5. Solar system verified to be free of air? 14
6. pH level of heat transfer fluid checked? Replace heat transfer fluid if value is
7 (heat transfer fluid coloured brown, strong odour).
1)
7. Frost protection to _______ °C checked and analysed? 15 ___ °C ___ °C ___ °C ___ °C ___ °C
Frost protection ensured until ________ (month/year)
(check frost protection at least every two years!)
8. Thermostatic DHW mixing valve functioning correctly (if installed)?
Solar station
1. Measure operating pressure when system is cold and enter the result here.
System temperature on return thermometer?
14 ____ bar
____ °C
___ bar
___ °C
___ bar
___ °C
___ bar
___ °C
___ bar
___ °C
2. Flow rate checked when the system is cold and result entered here? 15 ___ l/min __ l/min __ l/min __ l/min __ l/min
3. Gravity brakes ready to operate (closed)?
4. System adequately ventilated using air separator and air vent on roof (if
installed)?
Table 16
22 | Commissioning, inspection and maintenance reports
AGS10-2, AGS10E-2, AGS20-2, AGS50-26 720 811 270 (2015/04)
5. Pump functioning checked in the positions (On/Off/Auto)?
Collector groups
1. Visual inspection of collectors carried out (safe seating, visual impression)?
2)
3)
3)
3)
3)
2. Collector temperature sensor correctly positioned and pushed fully into the
sensor pocket?
3)
3)
3)
3)
3. Visual inspection of the installation system carried out?
3)
3)
3)
3)
4. Visual inspection for leaks carried out at points where mounting structure
meets roofing?
3)
3)
3)
3)
5. Visual inspection of pipework insulation carried out?
3)
3)
3)
3)
6. Visual inspection of glass panes. Cleaning if there is severe contamination?
3)
3)
3)
3)
3)
7. Backup heating is functioning properly?
Solar cylinder
1. Maintenance on solar storage cylinder carried out?
2)
Control system
1. Hours run for solar pump P1:
Period from _________ to _________ / _____ h
4)
2)
__ - __
_____ h
__ - __
_____ h
__ - __
_____ h
__ - __
_____ h
__ - __
_____ h
Hours run for solar pump P2:
Period from _________ to _________ / _____ h
4)
__ - ___
_____ h
__ - __
_____ h
__ - __
_____ h
__ - __
_____ h
__ - __
_____ h
3. Activation/deactivation temperature difference of solar pump ΔT pump 1
checked and entered here?
_ K/_ K _ K/_ K _ K/_ K _ K/_ K _ K/_ K
Activation/deactivation temperature difference of solar pump ΔT pump 2
checked and entered here?
_ K/_ K _ K/_ K _ K/_ K _ K/_ K _ K/_ K
4. Temperature indicated by all temperature sensors (resistances checked)?
5. Temperature sensors correctly positioned, insulated and connected?
6. Maximum cylinder temperature Tmax for solar storage cylinder 1 checked
and entered here?
____ °C ____ °C ____ °C ___ °C ___ °C
Maximum cylinder temperature Tmax for solar storage cylinder 2 checked
and entered here?
____ °C ____ °C ____ °C ___ °C ___ °C
7. Is the required set temperature (backup heating) being maintained by the
controller?
Heat meter (if installed)
1. Period from __________ to __________ / ______ kWh
2)
__ - __
__ kWh
__ - __
__ kWh
__ - __
__ kWh
__ - __
__ kWh
__ - __
__ kWh
2. Temperature sensors correctly positioned, insulated and connected?
Notes
The solar system has been installed and put into operation, or inspected and serviced, in
accordance with all instructions.
The operator has been instructed in the functions and operation of the solar system.
Company stamp / date / signature
1) pH value = indicator of the acid content of a fluid; indicator strips available from chemists or service cases.
2) See instruction manual for the component.
3) Where required.
4) Not all controllers can display the number of hours run. A system runs for approx. 1200-2500 hours a year (depending on the system data).
Commissioning, inspection and maintenance tasks Page
Commission-
ning
Inspection/maintenance
1. 2. 3. 4.
Table 16
Faults | 23
6 720 811 270 (2015/04)AGS10-2, AGS10E-2, AGS20-2, AGS50-2
9 Faults
Information regarding faults can also be found in the installation instructions for the controllers.
Type of fault
Effect Possible causes Remedy
Pump not running although start conditions are met.
The solar cylinder is not being
heated by solar energy.
Pump is faulty. Check the pump and replace if necessary.
Pump sticking due to physical blockage.
Unscrew and remove the slotted screw on the pump head and use a
screwdriver to release the pump shaft. Do not strike the pump shaft
with the screwdriver.
Pump is not responding to the controller.
See controller instruction manual.
Pump continually switching on and off.
Solar yield too low. Difference between controller cut-in and cut-out temperatures
too small.
Check controller settings.
Volumetric flow rate too high.
Check and adjust the flow rate.
Temperature sensor position or contact is not correct.
Check temperature sensor position.
Pump does not switch off.
Heat is being transferred out of
the storage cylinder.
Temperature sensor faulty or in wrong position. Check temperature sensor position, installation and
characteristics.
Controller faulty.
Notice: speed-controlled pumps do not switch off immediately, but
only once the lowest speed is reached.
DHW too hot.
Risk of scalding Cylinder temperature limit and DHW mixer set too high. Set the cylinder temperature limit and DHW mixer to a lower setting.
DHW mixer faulty
Check the DHW mixer and replace if necessary.
DHW too cold (or inadequate volume).
DHW thermostat on the boiler, on the heating controller or on
the DHW mixer set too low.
Set the temperature as instructed in the applicable operating
instructions (maximum 60 °C).
Check that backup heating is functioning properly.
Temperature differences in solar circuit are too high / flow temperature is too high / high collector temperature reached too quickly
Solar yield too low or system
damage.
Faulty temperature sensor or controller malfunction. Check temperature sensor and settings of controller.
Air in the system.
Bleed or purge the system.
Volumetric flow rate too low.
Check/adjust the flow rate.
Blocked pipework.
Check/flush the pipework.
Collector arrays not hydraulically balanced.
Carry out hydraulic balancing.
Pressure drop in the system.
Solar yield too low. Loss of heat transfer fluid at joints. Braze any leaks. Replace seals. Retighten screw fittings.
Loss of heat transfer fluid through an open safety valve.
Check charge pressure and size of expansion vessel.
Vapour has escaped through open air vent (normal operating
function).
Close air vent after venting.
Frost damage.
Check frost protection.
No flow noticeable on flow rate indicator despite pump running.
Solar yield too low. The shut-off devices are closed. Open the shut-off devices.
Air in the system.
Bleed or purge the system.
Indicator element in the flow regulator is sticking.
Clean the flow regulator.
Noises in the collector array at high levels of solar exposure (vapour knocking).
Leakages in solar heating
circuit.
Even flow through the collector arrays is not possible. Check piping.
Expansion vessel too small or faulty.
Check design and charge pressure of the expansion vessel and
check operating pressure.
Pump power is too low.
Check pump, replace if necessary.
The collector with the collector temperature sensor is under
shade.
Remove shade.
Flow and return swapped over.
Check pipework, replace if necessary.
Air in the system.
Bleed or purge the system and check slope of pipes.
Table 17
24 | Faults
AGS10-2, AGS10E-2, AGS20-2, AGS50-26 720 811 270 (2015/04)
Solar storage cylinder is cooling rapidly.
High heat loss. Cylinder insulation is faulty or not correctly fitted. Check insulation. Insulate the cylinder connection points.
Controller setting for backup heating is not correct.
Check settings of boiler controller.
Single-pipe circulation (micro-circulation in the pipelines).
Install a "U" bend in the pipe to prevent heat convection.
Gravity circulation via collector array or DHW recirculation line
or backup heating.
Check gravity brakes.
Hot water recirculation running too frequently and/or at night.
Check programmed on/off times and cyclic mode.
When sun is shining on collectors, the collector glass is fogged for a long period of time.
Condensate in the
collector.
Insufficient ventilation of the collector (in the case of ventilated
collectors).
Clean ventilation openings.
System performance is falling.
Solar yield too low. Collectors are under shade. Remove shade.
Air in the system.
Bleed or purge the system.
Pump is running at decreased power.
Check the pump.
Heat exchanger dirty/calcified.
Wash/decalcify the heat exchanger.
Collector glazing is very dirty.
Clean the collector glazing with a glass-cleaning agent (no acetone).
Backup heating is running despite good solar exposure.
Solar yield too low. Storage cylinder temperature sensor for backup heating is
faulty or incorrectly positioned.
Check cylinder temperature sensor position, mounting and
characteristics.
DHW recirculation is incorrectly connected or switched on for
too long.
Check DHW circulation connection; if necessary, reduce switch-on
time for recirculation.
Backup heating temperature set too high. Check settings.
Air in the system.
Bleed or purge the system.
Controller faulty.
Check controller, replace if necessary.
Type of fault
Effect Possible causes Remedy
Table 17
| 25
6 720 811 270 (2015/04)AGS10-2, AGS10E-2, AGS20-2, AGS50-2
Notes
26 |
AGS10-2, AGS10E-2, AGS20-2, AGS50-26 720 811 270 (2015/04)
Notes
| 27
6 720 811 270 (2015/04)AGS10-2, AGS10E-2, AGS20-2, AGS50-2
Notes
13

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