Technical Handbook 2011/2012

Solar Heating. Solar Electricity.
Components, Technology, Installation
Your Contact Persons

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PV Off-Grid Systems

Name / Email Telephone / Fax Function Languages

Inga.Paetsch Phone: +49 (0) 6421 8007-392 Sales PV Off-Grid Systems
@wagner-solar.com Fax: +49 (0) 6421 8007-492

Peter.Hoenen Phone: +49 (0) 6421 8007-336 Product Manager and
@wagner-solar.com Fax: +49 (0) 6421 8007-436 Technical Support
PV Off-Grid Systems
Preface

This 2nd edition of the Wagner & Co international technical handbook represents
a solid cross-section of our solar technology products and know how. The last
two years saw the introduction of the newly developed highly economical TRIC A
and F racking systems. The thought out and largely pre-assembled components
allow for flexible weather proof and efficient collector installation on any roof.
Another novelty is the new laser welded EURO L collector series, with the high
performance collector EURO L20 AR replacing its predecessor C20 AR. The EURO
L20 AR is the new Wagner & Co gold standard of flat-plate collector technology.
Over the last 2 years, many improvements of individual components as well
as fine tuned systems led Wagner & Co to three consecutive victories in major
comparative product tests in Germany. In addition we are proud to have been
nominated for the prestigious German Sustainability Award, so we feel confi-
dent that we are steering the right course, with visions also shared by our new
branches in Great Britain and the United States.
Remembering our roots in the environmental and civil rights movements of the
70s, for us solar energy is more than just another technology – it is an integral
part of a sustainable lifestyle. Wagner & Co is your one-stop total systems pro-
vider in the field of solar hot water and heating solutions and a major systems
integrator for solar power installations of any scale.
We hope you will find the information in this handbook to be useful. Not all
products and components on offer are described here. Please refer to the cur-
rent price list and feel free to inquire with us if you have questions and special
requirements.

How to use this handbook
The information in this handbook is divided into the main section “Solar Ther-
mal Energy“ and an additional section “Solar Electricity“. Besides that, there are
different categories of documents:
● Technical Information
● Installation Instructions
● Operation Instructions
● Planning Documents
● Certificates and Records

The table of contents will guide you through the handbook. We strive to keep
the information as complete and up-to-date as possible; however, innovation
often is faster than printed documentation. In order to always make the latest
documents available, we provide a download center in the partner area of our
website at www.wagner-solar.com. Follow the instructions on the website to
log in. There you will find the latest versions of the documents contained in this
handbook as well as numerous other documents as they become available. In
addition we equipped our distribution centre with a state of the art print-on-
demand (POD) system, thus assuring that always the latest version of technical
documentation will accompany your orders.
If you have any questions or suggestions regarding this handbook: don’t hes-
itate to contact the editorial team at editor_int@wagner-solar.com! We always
appreciate your feedback.

We wish you sunny times!

Your team at Wagner & Co, in Fall 2010
Overview

Content 4

Solar Thermal

Solar Collectors 9 1.1

Solar Storage Cylinders 133 1.2

Freshwater Units 201 1.3

Solar Circuit Components 247 1.4

Compact Solar Hot Water Systems 353 1.5

Planning, Start-up, Maintenance 415 1.6

Solar Electricity 469 2

General Business Conditions 517
Content Solar Thermal

1.1 Solar Collectors and Racking Systems
■ EURO Solar Collector L20 AR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

■ EURO Solar Collector Type C20/C22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

■ Flat Plate Solar Collector EURO L42 HTF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

■ LBM Solar Collector 6 AR / 10 AR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

■ EURO Solar Collector L20 MQ AR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

■ EURO TRIC A On-Roof Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

■ EURO TRIC F Free Standing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

■ EURO L20 MQ TRIC A and TRIC F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

■ EURO C20/L20 In-Roof Installation for Slate and Plain Tile Roofings . . . . . . . . 93

■ EURO C20/L20 In-Roof Installation for Pantile Roofing. . . . . . . . . . . . . . . . . . . 105

■ Roof Bracket Kits (Top) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

■ Roof Bracket Kit BS/SF (Top) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

■ Roof Bracket Kit K A2 Hv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

■ Roof Bracket Kit P (Top) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

■ Roof Bracket Kit PM A2 Hv (Top) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

1.2 Solar Storage Cylinders and Components
■ ECO Solar Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

■ ECOplus Solar Cylinder – Technical Information . . . . . . . . . . . . . . . . . . . . . . . . 147

■ ECOplus Solar Cylinder – Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . 155

■ TERMO Combi Cylinder – Technical Information . . . . . . . . . . . . . . . . . . . . . . . . 163

■ TERMO Combi Cylinder – Installation Instructions . . . . . . . . . . . . . . . . . . . . . . 169

■ RATIO Buffer Cylinder – Technical Information . . . . . . . . . . . . . . . . . . . . . . . . . . 177

■ RATIO Buffer Cylinder – Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . 185

■ Convection Brake CONVECTROL III. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

■ Thermostatic Mixing Valve BM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

■ Electrical Immersion Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

4
Content Solar Thermal

1.3 Freshwater Units
■ RATIOfresh 250/400 Freshwater Unit –
Technical Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

■ RATIOfresh 250/400 Freshwater Unit –
Installation and Operations Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

■ RATIOfresh 200 Fresh Water Station –
Technical Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
1.1
■ RATIOfresh 200 Freshwater Unit –
Installation and Operations Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

1.2
1.4 Solar Circuit Components and Accessories
■ CIRCO 6 Solar Circulation Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
1.3
■ CIRCO 25/80 Solar Circulation Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

■ SUNGOmini Solar Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

■ Solar Controller SUNGO S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
1.4
■ Solar Controller SUNGO SL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

■ Solar Controller SUNGO SXL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295

■ Expansion Vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335 1.5
■ Heat Meter WMZ for SUNGO SL / SXL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337

■ 2/3 Way Electronic Diverter Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339

■ Twinflex TVA Rapid Piping System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
1.6
■ Sensor Connection Box SP2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345

■ Solar Heat Transfer Liquid DC20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347

■ External Heat Exchangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351

1.5 Compact Solar Hot Water Systems 2
■ SECUSOL Solar Compact System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355

■ SECUterm 200 P / 300 P (Free Standing Setup) . . . . . . . . . . . . . . . . . . . . . . . . . 391

■ SECUterm 160 I / 200 I / 300 I (On-Roof Installation) . . . . . . . . . . . . . . . . . . . . 403

5
Content Solar Thermal

1.6 Planning, Start-up, Maintenance
■ Dimensioning List for Solar Thermal Installations . . . . . . . . . . . . . . . . . . . . . . . 417

■ Solar Thermal Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421

■ Dimensioning of a Solar Installation for Hot Water Preparation . . . . . . . . . . . 437

■ Sun Path Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439

■ Solar Installation for Hot Water Preparation
Single Storage Cylinder System
with ECOplus Solar Storage Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441

■ Solar Installation for Hot Water Preparation
ECOplus Solar Storage Cylinder Upstreamed
of Existing Hot Water Storage Cylinder
with Controlled Storage Cylinder Circulation . . . . . . . . . . . . . . . . . . . . . . . . . . . 443

■ Solar Installation for Hot Water Preparation
Downstreamed ECOplus Solar Storage Cylinder
and Existing Hot Water Storage Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445

■ Solar Installation for Hot Water Preparation
and Swimming Pool Heating System
with ECOplus Solar Storage Cylinder and Plate Heat Exchanger . . . . . . . . . . 447

■ Solar Installation for Hot Water Preparation and Heating Support
Single Storage Cylinder System with TERMO Combi Cylinder . . . . . . . . . . . . 449

■ Solar Installation for Hot Water Preparation and Heating Support
System with TERMO Combi Cylinder in Combination
with Pellet Boiler XILO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451

■ Solar Installation for Hot Water Preparation and Heating Support
Single Storage Cylinder System with Freshwater Unit RATIOfresh
and RATIO Buffer Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453

■ Solar Installation for Hot Water Preparation and Space Heating Support
Dual Cylinder System with ECOplus Solar Storage Cylinder
and RATIO Buffer Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455

■ Wagner-T*SOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457

■ Installation Protocol Solar Heating Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 461

■ Maintenance Protocol Solar Heating Installation . . . . . . . . . . . . . . . . . . . . . . . . 463

■ Cleaning of AR Solar Glass on EURO-Collectors . . . . . . . . . . . . . . . . . . . . . . . . 465

■ Solar Thermal Functional Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467

6
Content Solar Electricity

2. Solar Electricity
■ Off Grid Solar Power Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471

■ Dimensioning of Photovoltaic Off Grid Systems . . . . . . . . . . . . . . . . . . . . . . . . 475

■ Dimensioning a Grid Connected Solar Electricity Installation . . . . . . . . . . . . . 477

■ On Roof Module Mounting System TRIC A HDC . . . . . . . . . . . . . . . . . . . . . . . . 481

■ Free Standing Mounting System TRIC F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 489 1.1
■ Free Standing Mounting System TRIC F pro . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501

■ Commissioning Protocol for a PV-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 513

■ Measuring Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515 1.2

1.3

1.4

1.5

1.6

You can find up-to-date technical information about our solar modules and 2
grid-inverters at the following web addresses:

www.wagner-solar.com
www.bp.com
www.evergreensolar.com
www.recgroup.com
www.sanyo-component.com
www.schottsolar.com
www.sma.de
www.fronius.com

7
Solar Collectors and Racking Systems

Wagner & Co is one of the leading developers and manufacturers of solar coll-
ectors as well as collector racking systems for many different applications. The
following pages offer technical information and installation instructions for solar
collectors, solar collector racking kits and roof fixing materials. Racks and roof
brackets are the result of careful structural calculations following the latest EURO-
CODE EN 1992 for wind and snow loads, allowing safe installations on most roof
types and at almost any location. The Wagner & Co construction philosophy for
racking systems features ease of use with pre-assembled components and un-
compromised safety and durability. It includes the new “top” installation carried
out from above that now is implemented throughout the entire product portfolio 1.1
of the TRIC A on-roof and TRIC F free standing series of collector racking sys-
tems.

■ EURO Solar Collector L20 AR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

■ EURO Solar Collector Type C20/C22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

■ Flat Plate Solar Collector EURO L42 HTF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

■ LBM Solar Collector 6 AR / 10 AR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

■ EURO Solar Collector L20 MQ AR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

■ EURO TRIC A On-Roof Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

■ EURO TRIC F Free Standing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

■ EURO L20 MQ TRIC A and TRIC F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

■ EURO C20/L20 In-Roof Installation for Slate and Plain Tile Roofings . . . . . . . . 93

■ EURO C20/L20 In-Roof Installation for Pantile Roofing. . . . . . . . . . . . . . . . . . . 105

■ Roof Bracket Kits (Top) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

■ Roof Bracket Kit BS/SF (Top) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

■ Roof Bracket Kit K A2 Hv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

■ Roof Bracket Kit P (Top) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

■ Roof Bracket Kit PM A2 Hv (Top) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

9
TECHNICAL INFORMATION

EURO Solar Collector L20 AR

1.1

Solar Keymark
011-7S481 F
Figure 1 EURO L20 AR

Product Features sunarc®
anti reflection glass
EPDM rubber sealing

Anodized
Powerful Highly selective aluminium frame
● Collector cover with sandy sunarc® anti-reflection glass vacuum coating
for 96% light transmission Aluminium
● Laser fused aluminium absorber for optimized heat absorber
Side
transfer insulation
● 60 mm back-side insulation

Durable High Quality Materials
● Anodized aluminium frame in silver or black
● Solid aluminium back
● Full-surface aluminium absorber sheet with copper
pipe register
● Temperature resistant mineral wool with low binder
Insulation
content, heat conduction group 040

Aluminium back
Sophisticated Construction Details
● Seamless all-around side insulation Figure 2 Collector cross-section
● Long lasting and safe flat sealing connections
● UV resistant EPDM glass sealing with vulcanized corner
joints

Flexible Mounting Options
● Suitable for on-roof, roof-integrated and flat-roof (free
standing) mounting
● Serial connection of up to 5 collectors possible

Solar Thermal / Solar Collectors EN-XXX_EURO-L20-AR_TI-100119-11201R00 11
1. Technical Data
Table 1 Characteristic EURO L20 AR
Total area/aperture area (acc. to EN 12975) 2.61 / 2.39 m²
Dimensions (L x D x H) 2151 x 1215 x 110 mm
Collector efficiency (acc. to EN 12975) ηo = 84.8 %; k1 = 3.46 W/m²K; k2 = 0.0165 W/m²K²

Incident angle modifier (50°) kdir = 94.4 %, kdiff = 88 %
Annual collector yield (ITW 5 m²) 521 kWh/m²a
Silver or black anodized aluminium frame, aluminium back sheet,
Collector encasing
mineral wool insulation WLG 040 for back side and frame
Specific heat capacity 4.7 kJ/(m²K)
Glass cover and light transmission 4 mm solar safety glass with sunarc® anti reflection surface; τ = 96 %
Pipe register absorber:
Absorber
aluminium heat conductor sheet and 12 closely spaced copper pipes, laser fused
Absorber coating Highly selective vacuum coating, α = 95 %, ε = 5 %
Absorber content 1.5 litres
DC20 (propylene glycol with inhibitors),
Heat carrier
mixing ratio according to requirements (local climate)!
Operational pressure max. 10 bar
Stagnation temperature ( acc. to EN 12975) 209 °C
Solar sensor Receptacle, 6 mm internal diameter
Collector connections ½" M – threaded connection
Certificate/mark SolarKeymark; CE-mark; Blue Angel RAL – UZ 73
Allowable pressure/suction forces 3.4 kN/m²
Horizontal and vertical on-roof and free standing setup (10 – 85°);
Mounting options
roof integration with vertical orientation (20° – 85°)
Weight 48 kg

Pressure loss [mbar]
500 5 EURO L20
serial connection
450

4 EURO L20
400 serial connection

350
3 EURO L20
300 serial connection

250
2 EURO L20
serial connection
200

150 1 EURO L20

100

50

0
0 50 100 150 200 250 300 350 400 450 500
Volume flow [l/h]
Figure 3 Pressure loss curves for several collectors connected in series, depending on volume flow.
Heat carrier: 40 % Glycol / 60 % Water at 30 °C.

12 EN-XXX_EURO-L20-AR_TI-100119-11201R00
h [%]
90
E = 800 W/m²
80
70
60 EURO L20 AR

50
40
30
20
10
0
0 10 20 30 40 50 60 70 80 90 100 110
Tm - Tu [K]

Figure 4 Collector characteristics acc. to EN 12975 1.1

110
2.151

1.087

1.215
EURO L20 AR

Figure 5 Dimensions (mm)

2. Planning Notes Table 2
Dimensioning Examples for Snow/Wind Load Zones 1-2 1
2.1 Snow and Wind Loads Building Altitude On-roof Free standing, ballast
height (m) installation (kg/m² total collector area)
Comply with local regulations and norms related to snow (m) (no. of roof
and wind loads (within the EU to EN 1991-1-4 (Wind ac- brackets per Horizontal Vertical
collector) 2 setup setup
tions) and EN 1991-1-3 (snow loads). The standard in-roof
system originally was designed for the following condi- 10 400 4 140 195
tions: inland continental Europe up to 800 m ASL, unex-
10 800 6 140 195
posed location, maximum building height of 20 m, all wind
zones. Please contact our technical department for infor- 10-20 400 4 185 260
mation about other cases. 10-20 800 6 185 260
Structurally the EURO L20 AR can be treated identically to 1 45° inclination, installation in edge and corner areas of roofs not
the C20 AR. considered; wind speed vref ≤ 25 m/s, wind pressure at 10 m
above ground qref ≤ 0.39 (kN/m²)
2 Roof bracket P STv KF; ridge distance or distance to snow barrier
above < 1 m; roof bracket quantities are guide values – round
acc. to field size and individual situation.

EN-XXX_EURO-L20-AR_TI-100119-11201R00 13
2.2 Free Standing Setup and
Self-Shadowing
The following table applies to a shadowing angle β of 25°.
Depending on the geographical location the lower col-
lector areas may therefore be affected by self-shadowing
during winter months.
A
Table 3 Shadowing Distances
Distance Collector inclination α
in m
Horizontal setup Vertical setup
(s. fig. 6)
35° 45° 50° 37° 45° 50°
A 1.49 1.84 2.00 2.78 3.26 3.53 B
C
B 1.00 0.86 0.78 1.72 1.52 1.38
Figure 6 Shadowing distances of collectors mounted one behind the
C 3.49 3.56 3.56 6.21 6.30 6.30
other with collector inclination α and shadowing angle β

2.3 Connection Options

Solar sensor

Figure 7 Parallel connection of 2 x horizontal EURO L20 at v = 35 l/m²h.
Hereunto a special extension set for on-roof mounting (order no. 190 202
40) and a special connection set (order no. 190 202 30) are available. Solar sensor

Solar sensor Solar sensor

Figure 8 Serial connection of vertically mounted collectors at
v = 35 l/m2h (serial connection of max. 5 x EURO L20)

Solar sensor Solar sensor

Solar sensor
3.66 m

6.10 m

2.15 m

Figure 9 Serial connection of horizontally mounted collectors at Figure 10 Combination of serial and parallel connections of horizon-
v = 35 l/m2h (serial connection of max. 5 x EURO L20) tally mounted collectors at v = 35 l/m2h

2.4 Accessories
Table 4 Accessories Order No.
Marten protection for sensor cable 192 040 10 for silver and 192 040 09 for black frame
Collector carrying handles 188 005 02

Subject to modifications, errors excepted · © Wagner & Co, 2010 · www.wagner-solar.com
14 WAGNER & CO · Zimmermannstraße 12 · D-35091 Cölbe/Marburg · ☎
+49 (0) 64 21 80 07-0 · Fax 80 07-596
TECHNICAL INFORMATION

EURO Solar Collector Type C20/C22

Highly transparent EPDM rubber seal
safety glass or anti with vulcanised corner joints
reflection safety glass
Anodised
aluminium
casing
1.1

Selective coating
Side insulation
without heat bridges

Ultrasound fused
copper absorber

60mm insulation

TÜV - 0036

Aluminium back

Jur y
U mweltzeichen

Figure 1 The EURO C20/C22 – powerful, versatile and rapidly installed

Advantages
High Efficiency through Perfect Details Excellent Price/Performance Ratio
Thanks to its highly selective vaccuum coated flat plate Tested quality according to European norm EN 12975 and
absorber, a 60 mm back insulation and the seamless side the CE label. Repeated awards from the Independent In-
insulation, the EURO solar collector is characterized by stitute for Consumer’s Goods Testing “Stiftung Warentest”.
very low heat losses. In addition it is equipped with highly
transparent safety glass. The EURO C20 AR variation ad- Simple and Fast Installation
ditionally features sunarc® anti reflection glass increasing Tried and tested installation kits, photo-instructions and
the solar yield by an additional 6-10 % thanks to intelligent weldless connections to the solar circuit.
nano-technology based upon the moth-eye effect.
Variable Mountings and Arrangements
High-Quality Materials On-roof, roof integrated (in-roof) and free standing, verti-
Anodised aluminium profiles, aluminium back, high-trans- cally and horizontally.
parency safety glass cover, weather resistant EPDM rubber
seals with vulcanised corner joints and ultrasound-fused,
heat-resistant copper absorber ensure safe operation for
decades.

Solar Thermal / Solar Collectors EN-XXX_EURO-C20-C22_TI-0801xx-11201000 15
1. Technical Data
Feature EURO C20 AR EURO C20 HTF EURO C22 AR EURO C22 HTF
Total area / aperture area 2.61 / 2.39 m² 2.24 / 2.02 m²
Size W x H x D 2151 x 1215 x 110 mm 1930 x 1160 x 110 mm
ho = 85.4 % ho = 81.8 % ho = 85.4 % ho = 81.8 %
Efficiency (DIN 4757- 4) k1 = 3.37 W/m²K k1 = 3.47 W/m²K k1 = 3.37 W/m²K k1 = 3.47 W/m²K
k2 = 0.0104 W/m²K² k2 = 0.0101 W/m²K² k2 = 0.0104 W/m²K² k2 = 0.0101 W/m²K²
kdir = 97 % kdir = 94 % kdir = 97 % kdir = 94 %
Incident angle modifier 50°
kdiff = 94 % kdiff = 88 % kdiff = 94 % kdiff = 88 %
Annual collector yield
546 kWh/m²a 509 kWh/m²a 546 kWh/m²a 509 kWh/m²a
(ITW 5 m² *)
Collector housing 60 mm back insulated and frame insulated aluminium casing; specific heat capacity 4.7 kJ/(m²K)
4 mm solar safety 4 mm solar safety
4 mm solar 4 mm solar
Glass cover glass with sunarc®- glass with sunarc®-
safety glass safety glass
antireflex-coating antireflex-coating
Transmission τ = 96 % τ = 91 % τ = 96 % τ = 91 %
Absorber Heat conducting sheet and pipes made out of copper, max. pressure 10 bar
Absorber coating Highly selective vacuum coating, α = 95 %, ε = 5 %
Absorber capacity 1.3 litre 1.1 litre
Conductor fluid DC20 (Propylenglycol with inhibitors), mixing ratio according to requirements
Working pressure max. 10 bar
Idle temperature
232 °C 227 °C 232 °C 227 °C
(according to DIN 4757-3)
Sensor tube 6 mm internal diameter
Connections ½" male
CE lable TÜV certificate 0036, EC type test (Module B) in accordance with EU directive 97/23/EC
Max. allowed pressure/suction forces 3.4 kN/m² (take wind and snow loads into account! Consider static capacity of roof!)
Inclination range 10 - 85° for on-roof and free standing setup, 27 - 85° for roof integration
Weight 48 kg 43 kg

* Calculated for 4 person household at Würzburg/Germany with 300 l solar cylinder and 5 m² collector area.

Table 1 Technical Data EURO C20 / C22.

Pressure losses (mbar) Pressure losses (mbar)
200 200

180 180
4 EURO in series
160 160
2
0

C2
C2

140 140
O
O

UR
UR

4 EURO in series
xE
xE

120 120 2
C2
20

4
4

C

O
UR
O

100 100
R

E
EU

x
0 3
x

C2 C2
2
3

80 3 EURO in series 80
R O O
EU 3 EURO in series EUR
2x 2x
60 60

C20 C22
40 URO 40 URO
2 EURO in series 1xE 1xE
2 EURO in series
20 20

0 0
0 50 100 150 200 250 300 0 50 100 150 200 250 300
Flow rate (litre/h) Flow rate (litre/h)
Figure 2 Pressure loss EURO C20 in relation to the volume flow and Figure 3 Pressure loss EURO C22 in relation to the volume flow and
and the number of collectors connected in series and the number of collectors connected in series.
Volume flow v=30 l/m²h; heat transfer medium: 40 % glycol, 60 % water Volume flow v=30 l/m²h; heat transfer medium: 40 % glycol, 60 % water
at 30 °C; examples with v=30l/m²h; pressure losses do not account for at 30 °C; examples with v=30l/m²h; pressure losses do not account for
connections and connection pipes. connections and connection pipes.

16 EN-XXX_EURO-C20-C22_TI-0801xx-11201000
η [%]
2. Planning
90
E = 800 W/m²
80
2.1 Wind and Snow Loads
EURO C20-AR
70 Snow and wind loads are a significant factor for structural
60
planning. European norms were established, albeit with-
out specifically taking solar installations into account.
50 Wind and snow loads affect the collectors and the instal-
EURO C20/C22-HTF
40 lation system. Depending on the conditions and height of
the installation site as well as the collector inclination, the
30 mechanical loads on the system can vary considerably.
20 Also see guidelines for the planning of structural frame-
works and standards EUROCODE 1, (European guidelines
10
for structural planning). With combined snow and wind
0 loads the maximum strain for the EURO solar collector is
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 2,250 N/m². Note that wind suction spikes may occur on
∆T = Tm - Tu [K] roof edges! Please read the information in the applicable 1.1
Figure 4 Efficiency curves of EURO C20 / C22 HTF and EURO C20 AR guidelines for the planning of structural frameworks.
depending on Tm – TU (E = 800 W/m²) as measured at the ISFH Hameln It is mandatory to follow best practice rules for static plan-
according to DIN EN 12975.
ning, especially related to snow and wind loads. Different
codes and regulations apply in different countries and re-
gions. For more information refer to our installation manu-
als and the upcoming leaflet “Notes on Snow and Wind
safe Installation of Solar Collectors“.
In case of doubt and/or in absence of exact static calcula-
tions (not recommended!) always allow for additional fix-
tures, weight, anchors, and screws, especially in regions
with known weather extremes.
110

2151
1215
1086

EURO C20
110

1930
1035

1160

EURO C22

Figure 5 Dimensions EURO C20/EURO C22.

EN-XXX_EURO-C20-C22_TI-0801xx-11201000 17
2.2 Arrangements and
Installation Types
On-Roof Installation
The collectors can be installed above the roof surface with
rafter brackets and mounting rails, either horizontally or
vertically (horizontal preferred). Even during the installa-
tion, the roofing remains almost completely unharmed.
We offer roof-anchors and rafter brackets for almost every
roofing type. Up to 4 EURO collectors can be connected
in series. The connection hoses with pre-assembled insula-
tion also significantly simplify the on-roof pipeworks. Dis-
tribution pipes on the roof are not required.

In-Roof Installation
The attractive in-roof installation is possible for roofs with
a minimum pitch of 27° and any tile cover. In this case the
collectors are installed vertically, with the connections
pointing upwards. The aluminium and corrugated lead
flashing can be joined without requiring soldering work
in the roof.

Free Standing Installation
The free standing setup allows horizontal or vertical instal-
lation with adjustable inclination. Concrete slabs or gravel
covered aluminium trays can be used as foundation.

2.3 Horizontal Collector Arrangement
(On Roof)
Collector sensor Collector sensor Collector sensor Collector sensor Collector sensor

= position of roof brackets

Figure 6 Horizontal collector arrangement: Up to 4 EURO in serial connection. The mounting rails run vertically. Roof brackets must be evenly
distributed (the distances of brackets are approx. values). Combinations of serial and parallel connection are also possible (see right). A EURO
on-roof expansion kit is then required.

2.4 Vertical Collector Arrangement (On Roof and In Roof)
Collector sensor Collector sensor Collector sensor Collector sensor

Figure 7 Vertical collector arrangement: Up to 4 EURO in serial connection. The mounting rails run vertically. More than 4 EUROs are combined
from fields with serial and parallel connections.

Subject to modifications, errors excepted · © Wagner & Co, 2010 · www.wagner-solar.com
18 WAGNER & CO · Zimmermannstraße 12 · D-35091 Cölbe/Marburg · ☎ +49 (0) 64 21 80 07-0 · Fax 80 07-596
TECHNICAL INFORMATION

Flat Plate Solar Collector EURO L42 HTF

1.1

Figure 1 EURO L42 HTF

Features at a Glance
Solid and Powerful 3.2 mm solar EPDM rubber
sealing
● Collector cover with highly transparent solar-safety saftey glass
glass and 91 % light transmission Aluminum
● Single-plate aluminum absorber sheet Selektive frame
coating
● 30 mm back side insulation

Durable High Quality Materials Side
● Aluminum frame insulation
● Aluminum single plate absorber with copper pipe re-
gister (harp type), laser welded Aluminum
absorber
● Temperature resistant mineral wool with low binder
content, thermal conductivity class 040
Copper
pipes
Sophisticated Design Details
● Seamless all around side insulation Thermal
insulation
● Durable and safe flat sealing connections Aluminum back
● UV-resistant EPDM glass sealings with vulcanized cor-
ner joints Figure 2 Collector cross section

Flexible Racking Options
● Suitable for on-roof and free standing / flat roof setup;
roof integrated option is under preparation
● Vertical and horizontal collector orientation is possible
● Up to 5 collectors can be connected in series

Solar Thermal / Solar Collectors EN-XXX_EURO-L42-HTF_TI-101122-1WA10123 19
1. Technical Data
Table 1 Characteristic EURO L42 HTF
Gross area / aperture area
2.25 / 2.01 m²
(light collecting area acc. to EN 12975)
Dimensions (L x D x H) 1933 mm x 1163 mm x 80 mm
Collector efficiency ηo = 78.0 %; a1 = 3.95 W/m²K; a2 = 0.0139 W/m²K²
Incident angle modifier (50°) kθ (50°) = 88 %, kdiff = 82 %,
Annual collector yield (ITW 5 m²) Currently in test
Aluminum with seamless side insulation and 30 mm back side insulation,
Collector encasing
frame style: uncoated shiny or anodized black
Specific heat capacity 4.5 kJ/(m²K)
Glass cover and light transmissivity 3.2 mm solar safety glass; τ = 91 %
Single-plate aluminum absorber with 4 and 5 copper pipes (8 x 0.4),
Absorber
laser welded (double harp design)
Absorber coating Highly selective vacuum coating, α = 95 %, ε = 5 %
Absorber volume 1.2 liters
DC20 (propylene glykol with inhibitors),
Heat carrier
mixing ratio according to application and local conditions!
Operational pressure Max. 10 bar
Stagnation temperature (expected) 191 °C
Fixing of solar sensor Installation in receptacle, 6 mm internal diameter
Collector connection ½" external thread
Certificate / Mark Solar Keymark, eligible for state subsidies in Germany, SRCC OG 100 pending
Allowable pressure / suction forces 3.4 kN/m²
On-roof and free standing / flat roof setup with vertical or horizontal orientation (10 - 85°),
Racking options
roof integration system under preparation
Weight 33 kg

Pressure Drop [mbar]

700

650

600 5 EURO L42 HTF
in series
550

500 4 EURO L42 HTF
in series
450

400
3 EURO L42 HTF
350 in series

300

250 2 EURO L42 HTF
in series
200

150
1 EURO L42 HTF
100

50

0
0 50 100 150 200 250 300 350 400 450 500 Volume flow [l/h]

Figure 3 Pressure drop for several collectors in serial connection, depending on volume flow.
Heat transfer medium: 40 % glycol / 60 % water at 40 °C, pressure drop includes connection hoses and collector interconnections.

20 EN-XXX_EURO-L42-HTF_TI-101122-1WA10123 
[%]
90
G=800 W/m²
80
70
60
50
40
30
20
10
0
0 10 20 30 40 50 60 70 80 90 100
T = Tm-Ta [K]
Figure 4 Collector characteristic curve

1.1

80
1933

EURO L42 HTF

1163
1035

Figure 5 Dimensions [mm]

2. Planning Notes
2.1 Snow and Wind Loads
Comply with local regulations and norms related to snow Table 2 Dimensioning Examples for Snow/Wind Load Zones 1-2 1)
and wind loads (within the EU to EN 1991-1-4 (Wind Ac-
Building Altitude (m) On-roof Vertical setup
tions) and EN 1991-1-3 (Snow Loads). Please contact our
height (m) installation
technical department for information about other cases. (no. of roof
Structurally the EURO L42 AR can be treated identically brackets/
to the C22 or L22. collector ) 2)
10 400 2.8 194
10 800 5.1 194
10-20 400 2.9 257
10-20 800 5.2 257
1) 45° Inclination, installation in edge and corner sections of roofs
not considered. Wind speed vref ≤ 25 m/s, wind pressure at
10 m above ground qref ≤ 0.39 (kN/m²)
2) Roof bracket P STv KF; ridge distance or distance to snow
barrier above < 1 m; numbers of roof brackets are guide
values – round acc. to field size and individual situation.

EN-XXX_EURO-L42-HTF_TI-101122-1WA10123 21
2.2 Avoiding Mutual Shadowing of
Collectors on Free Standing Racks
The following table is valid for a location at 50° latitude
and a shadowing angle β of 25°. Occasional shadowing of
lower collector sections during winter is acceptable. A

Table 3 Min. Distance to Avoid Mutual Shadowing
Distances Collector inclination α
(m), see
Horizontal installation Vertical installation
figure 6
35° 45° 50° 37° 45° 50°
B
A 1.42 1.76 1.91 2.49 2.93 3.17 C
B 0.95 0.82 0.75 1.54 1.36 1.24
Figure 6 Shadowing distance A of collectors installed one behind
C 3.32 3.4 3.41 5.57 5.65 5.65 another, with collector inclination α and shadowing angle β

2.3 Collector Connection Examples
The shown layouts are based upon a volume flow of
v = 35 l/m²h (High-Flow)
Solar sensor

Solar sensor Solar sensor

Figure 7 Parallel connection of 2 x EURO L42 HTF, horizontally orien-
ted, at v = l/m²h. An extension set for on roof installation is available.
3.49 m

5.82 m
Solar sensor Solar sensor

1.93 m

Figure 8 Serial connection with vertical collector arrangement at Figure 9 Serial connection of horizontally oriented collectors
v = 35 l/m²h (max. 5 x EURO L42 HTF in series) at v = 35 l/m²h (max. 5 x EURO L42 HTF in series)

Solar sensor

Solar sensor

Figure 10 Combination of serial and parallel connection at horizontal orientation at v = 35 l/m²h

Subject to modifications, errors excepted · © Wagner & Co, 2010 · www.wagner-solar.com
22 WAGNER & CO · Zimmermannstraße 12 · D-35091 Cölbe/Marburg · ☎
+49 (0) 64 21 80 07-0 · Fax 80 07-596
TECHNICAL INFORMATION

LBM Solar Collector 6 AR / 10 AR

1.1

Figure 1 LBM – the large format Solar Keymark
011-7S643 F

Product Features
Ideal for Large Scale Solar Installations
● Collectors with a combined area of up to 50 m² can be Full surface absorber with
mounted next to each other with hydraulic parallel con- highly selective vacuum coating
nection – no additional pipeworks required thanks to Removable
aluminium Highly transparent sunarc®
internal manifolds (22 mm copper pipes). cover strips anti reflection solar glass
● Two sizes for optimized field layouts.
● Suitable for high-flow and low-flow applications. All-around
EPDM sealing
Powerful!
● Highly transparent sunarc®-anti reflection glass with
96 % transmissivity, thanks to the innovative nano sur-
face treatment utilizing the moth-eye effect! As a result
the heat yield increases by 6-10 %.
● Laser fused full-surface serpentine absorber made from
high-grade aluminium with highly selective vacuum
coating.
● 44 mm strong two-layer heat insulation.

Durable High-Grade Materials and Components
● Weather proof anodized aluminium frame with alumin-
ium back.
● UV-resistant EPDM glass sealing with vulcanized corner
joints. Aluminium frame
● All around seamless heat insulation without heat bridges 4 x 22 mm Cu pipe

Seamless Solid
Flexible Mounting Options side insulation aluminium
● Crane supported installation without additional trans- back
port crating. 23.5 mm PU foam
● Suitable for horizontal on-roof (roof parallel) and flat
roof / free-standing installation for practically every roof 20 mm mineral wool
type. Figure 2 Collector cross section

Solar Thermal / Solar Collectors EN-XXX_LBM-6-10-AR_TI-100127-11203500 23
1. Technical Specifications
Table 1 Characteristic LBM 6 AR LBM 10 AR
Total area / aperture area
6.75 / 6.1 m² 11.1 / 10.1 m²
(light collecting area acc. to EN 12975)
Dimensions (L x D x H, mm) 3468 x 1947 x 110 5762 x 1947 x 110
Collector efficiency (acc. to EN12975) η0 = 83.8 %; k1 = 3.77 W/m²K; k2 = 0.012 W/m²K²

Incident angle modifier (50°) kdir = 97 %, kdiff = 95 %, ktheta = 97 %
Annual collector yield 517 kWh/m²a
Aluminium frame and back side;
Collector encasing dual layer heat insulation made from 24 mm PU hard foam and 20 mm high-grade mineral
wool
Specific heat capacity 8,1 kJ/(m²K)
Glazing and glass transmissivity 4 mm solar safety glass with sunarc® nano anti reflection surfaces, τ =96 %
Absorber Serpentine absorber, aluminium absorber sheets and copper pipes, laser fused
Absorber coating Highly selective vacuum coating, α = 95 %, ε = 5 %
Absorber volume 4.9 l 8.1 l
Heat transfer medium DC20 (propylenglycol with inhibitor), mixing ratio depends on application!
Operational pressure (bar) max. 10 bar
Stagnation temperature (acc. to EN12975) 216.8 °C
Solar sensor Sensor sleeve with 7 mm Ø in 22 mm friction ring connection
Collector connection 4 x 22 mm Cu pipe
Certificate / mark SolarKeymark (DIN CERTCO), CE Mark, Blue Angel ECO Label RAL - UZ 73
Maximum pressure / suction loads 3.4 kN/m²
Mounting options Horizontal on-roof (roof-parallel) and freee standing setup (inclination 10 – 85°)
Total weight (with empty absorber) 130 kg 200 kg

[%]

90
E = 800 W/m²
80

70

60 LBM6 AR and LBM10 AR

50

40

30

20

10

0
0 10 20 30 40 50 60 70 80 90 100 110
Tm - Tu [K]

Figure 3 Characteristic curve acc. to EN 12975

24 EN-XXX_LBM-6-10-AR_TI-100127-11203500
3468

LBM 6 AR

1836
1947

110
1.1
5762

LBM 10 AR
1836
1947

110

Figure 4 Collector Dimensions (mm), a serpentine absorber between the two traversing manifolds

EN-XXX_LBM-6-10-AR_TI-100127-11203500 25
2. Planning Notes
2.1 Snow and Wind Loads 2.2 Self Shadowing when Free Standing
Comply with local regulations and norms related to snow The following table applies to shadowing angles β of
and wind loads (within the EU to EN 1991-1-4 (wind ac- 25°. Depending on the location the lower collector might
tions) and EN 1991-1-3 (snow loads). The standard in-roof therefore be shadowed during the winter months.
system originally was designed for the following condi-
tions: inland continental Europe up to 800 m ASL, unex- Table 3 Shadowing Distances
posed location, max. building height of 20 m, all wind Distances in m Collector inclination α
zones. Please contact our technical department for infor- (see figure 5)
30° 45°
mation about other cases. We offer comprehensive plan-
A 2.09 2.95
ning support on a project base. See table 2 for some LBM
related planning samples. B 1.69 1.38
C 5.46 5.71
Table 2 Dimensioning Samples for Snow / Wind Load Zones 1-21
Building Altitude On-roof installation Free standing
height above (No. of rafter brackets / setup, ballast
(m) sea collector) 2 requirements A
level (kg/m² coll. area)
(m)
LBM 6 AR LBM 10 AR LBM 6 AR / 10 AR
10 400 8 12 160
10 800 16 24 160
10-20 400 8 12 200
B
10-20 800 16 24 200 C
1 45° inclination, without taking installation in corner and edge
areas into account Figure 5 Shadowing of collectors standing one behind another, with
setup inclination α and shadowing angle β
2 Rafter bracket P STv KF; distance from roof ridge or from upper
snow stopper < 1 m

26 EN-XXX_LBM-6-10-AR_TI-100127-11203500
2.3 Connection Options
The pressure loss information applies under the following ● In order to avoid unnecessary pressure losses in large
conditions: collector fields beyond 25 m², we recommend plac-
● Heat carrier 40 % glycol, 60 % water at 40 °C. Individual ing the sensor in the unused connection, replacing the
resistances of required collector connectors are taken plug, opposite of the exit (see upper piping in figure 7).
into account.

T

Figure 6 Parallel setup with alternating connection

1.1
Table 4 Pressure Losses for Parallel Connections‚ (mbar)
Collector type LBM 6 AR LBM 10 AR
Specific volume flow (l/m²H) 15 25 35 15 25 35
1 collector * 27 50 73 29 52 77
2 collectors * 29 54 81 35 67 103
3 collectors * 34 64 96 50 101 163
4 collectors * 41 79 125 75 161 269
5 collectors * 51 104 169 112 252 436
6 collectors * 66 130 231 166 382 –
7 collectors * 85 184 314 237 – –
8 collectors * 109 243 421 – – –
9 collectors * 138 316 555 – – –
10 collectors * 174 404 – – – –
* Number of collectors installed next to each other with diagonal connection (manifold connected at top and bottom, see fig. 6)

T

T

Figure 7 Parallel setup with connection at one side

Table 5 Pressure Loss for Connection with Single Sided Connection (mbar)
Collector type LBM 6 AR LBM 10 AR
Specific volume flow (l/m²H) 15 25 35 15 25 35
1 collector * 30 55 80 (85) 32 57 85
2 collectors * 32 59 89 (113) 39 74 113
3 collectors * 37 70 106 (–) – – –
* Number of collectors with single side connection (manifold connected at top and bottom, see fig. 7)

EN-XXX_LBM-6-10-AR_TI-100127-11203500 27
Bleeder

T

Figure 8 Serial connection of two collectors

Bleeder

Figure 9 Two rows with 3 parallel connected collectors in each row

Table 6 Pressure Loss for 2 Rows with Parallel Connected Collectors in Each Row
Collector type LBM 6 AR LBM 10 AR
Specific volume flow (l/m²H) 15 25 15 25
1 collector * 124 216 128 230
2 collectors * 134 242 168 325
3 collectors * 160 304 262 –
4 collectors * 202 410 425 –
5 collectors * 270 – – –
6 collectors * 364 – – –
7 collectors * 490 – – –
* Number of collectors in parallel connection (diagonal pass through)

Please contact our support for additional connection op-
tions.

Subject to modifications, errors excepted · © Wagner & Co, 2010 · www.wagner-solar.com
28 WAGNER & CO · Zimmermannstraße 12 · D-35091 Cölbe/Marburg · ☎+49 (0) 64 21 80 07-0 · Fax 80 07-596
TECHNICAL INFORMATION

EURO Solar Collector L20 MQ AR

1.1

SolarKeymark
011-7S1404F

Figure 1 EURO L20 MQ AR – first choice for long collector strips

Product Features sunarc® anti
EPDM
rubber sealings
reflective glass
Collector with 4 pipe connectors for the simple setup of Anodized
long collector strips. Serial connection of up to 10 collec- Highly selective vac- aluminum
uum coating frame
tors possible. Collector fields of up to 50 m² can be easily
realized by combining groups in parallel and serial con- Side
insulation
nection.

Powerful
● Highly transparent low-iron solar glass
● Laser fused meander absorber with highly selective
Riser
vacuum coating pipe
● 60 mm backside insulation Aluminum
absorber
Durable High Quality Material
● Anodized aluminum frame in silver or black Back side
● Solid aluminum back sheet insulation
● Aluminum absorber sheet with copper pipe register Aluminum back sheet
● Temperature resistent mineral wool with low content of Figure 2 Collector cross-section
binders and heat conducting group 040

Sophisticated Design Details Heat expansion O-ring connection with
● Straight forward connection method with o-ring and compensator clamping ring
clamp
● All around seamless side insulation
● UV-resistant EPDM glass-sealing with vulcanized cor-
ner joints

Flexible Installation
● Suitable for on-roof and flat-roof (free standing) setup
● Horizontal orientation

Figure 3 Collector connection

Solar Thermal / Solar Collectors EN-XXX_EURO-L20-MQ-AR_TI-101007-1WA10055 29
1. Technische Daten
Table 1 Characteristic EURO L20 MQ AR
Gross area / aperture area
2.61 / 2.37 m²
(light collecting area acc. to EN 12975)
Dimensions (L x D x H) 2151 x 1215 x 110 mm
ηo = 84.2 %; k1 = 3.62 W/m²K;
Collector efficiency (expected)
k2 =0.016 W/m²K²
Incident angle modifier (50°) kdir = 92.8 %, kdiff = 87 %
Annual collector yield (ITW 5 m²) 502 kWh/m²a
Anodized aluminium frame, aluminium back, 60 mm back-side insulation,
Collector encasing
all-around seamless side insulation
Specific heat capacity 6.8 kJ/m²K
Glass cover and light transmissivity 4 mm anti reflective sunarc® solar safety glass; τ = 96 %
Meander absorber made from aluminium heat absorber sheet and copper pipes,
Absorber
LASER fused
Absorber coating Highly selective vacuum coating, α = 95 %, ε = 5 %
Absorber volume 2.3 liter
DC20 (Propylen glycol with inhibitors),
Heat carrier
mixing ratio depends on application and region (climate)
Operational pressure max. 10 bar
Stagnation temperature (expected) 207 °C
Solar sensor Receptacle, 6 mm internal diameter
Collector connection Clamp with o-ring and fitting 22 mm
Certificate / Mark CE-mark; SolarKeymark No. 011-7S1404F; Blue Angel RAL-UZ73 (application filed)
Max. allowable pressure / suction forces 3.4 kN/m²
Racking options On-roof and free standing (horizontally, 10 – 85°)
Weight 50 kg

Pressure drop [mbar]

550
497
500

450 10 EURO MQ parallel

400 389
.
350
302 .
300 .
250 231 1 EURO MQ .
200 224 .
164
178 .
150
103 131 .
100
87 .
50 .
0
15 22,5 30 35 37,5 45
Volume flow [l/m²h]

Figure 4 Pressure losses for one collector and ten collectors in paral- Figure 5 Efficiency characteristics acc. to EN 12975
lel connection, depending on the specific volume flow. Heat carrier:
40 % glycol and 60 % water at 40 °C.

30 EN-XXX_EURO-L20-MQ-AR_TI-101007-1WA10055
110
2151

1215
1056
EURO L20 MQ AR

1.1

2162

Figure 6 Dimensions (mm)

2. Planning Notes
2.1 Snow and Wind Loads 2.2 Mutual Shadowing of Free
Standing Collectors
Please make sure to conform to the Eurocode 1, Part 2-4:
Wind actions (ENV 1991-2-4: 1994) and the ISO Draft In- The following table is based upon a solar altitude of 25°,
ternational standard 4354, “Wind actions on structures” as therefore parts of the collector can be shadowed in win-
well as BS EN 1991-1-3 regarding snow loads (also part ter, depending on location.
of EUROCODE 1). Structurally the EURO L20 MQ can be
considered identical to the C20 AR and C20 HTF. Please
contact our technical support in case of doubt.

Table 2 Dimensioning Examples for Snow/Wind Load Zones 1-2 * Table 3 Shadowing Distances
Building Altitude On-roof mounting Free standing Distances (m) Collector inclination α
height above sea (no. of rafter- setup
35° 55°
(m) level (m) brackets / collector) (kg/m² collector
area) A 1.49 2.13
10 400 4 140 B 1.0 0.7
10 800 6 140 C 3.49 3.53
10-20 400 4 185
10-20 800 6 185
* 45° inclination, mounting in corner and edge areas of roofs not
considered

A

B
C

Figure 7 Shadowing distances of collectors set up behind one ano-
ther with inclination α and shadowing angle β

EN-XXX_EURO-L20-MQ-AR_TI-101007-1WA10055 31
2.3 Connection Options
The collector strips consist of max. 10 collectors in parallel connection.
Piping layout and pump dimension must be planned on a project-by-project base.

2151 66
1215

Figure 8 Field dimensions, without considering protruding connec-
tion parts on both outer sides

30

Figure 9 Leave approx. 30 mm space after the sixth collector to allow
for thermal expansion. Hereunto use the longer field compensator
(part no. 819 102 49); order separately.

Solar sensor Solar sensor

max. 10
collectors each

Figure 10 Collector strip diagonally connected at both ends, Figure 11 Connector strip with connections at one side
with V = 35 l/m²h at V = 35 l/m²hh

Solar sensor Solar sensor

max. 10 max. 10
collectors each collectors each

Figure 12 Parallel connection of collector strips at V = 35 l/m²h Figure 13 Serial connection of 2 collector strips,
only with Low-Flow, V = 15 l/m²h!

Solar sensor

max. 5
collectors each

Figure 14 Parallel connection of two collector strips connected at one and the same side (max 5 EURO L20 MQ each)

Subject to modifications, errors excepted · © Wagner & Co, 2010 · www.wagner-solar.com
32 WAGNER & CO · Zimmermannstraße 12 · D-35091 Cölbe/Marburg · ☎
+49 (0) 64 21 80 07-0 · Fax 80 07-596
INSTALLATION INSTRUCTIONS

EURO TRIC A On-Roof Installation

1.1

Figure 1 Vertical and horizontal on-roof installation

Content
1. General Safety Notes . . . . . . . . . . . . . 34
2. Horizontal Installation . . . . . . . . . . . . . 36
3. Vertical Installation . . . . . . . . . . . . . . 41
Installation instructions valid for these collectors:
4. Sensor Installation . . . . . . . . . . . . . . 46
5. Collector Connections . . . . . . . . . . . . . 47 EURO L20, EURO C20, EURO C30, EURO C22,
EURO L22, EURO C32
6. Accessories . . . . . . . . . . . . . . . . . 48

Solar Thermal / Solar Collectors EN-XXX_EURO-TRIC-A_MA-11216A00_MA-100119-11216A00 33
1. General Safety Notes 1.3 Qualification of the Installer
1.1 Symbols Setup, installation and proper commissioning of the solar
installation must be carried out by authorized profession-
The following symbols are used throughout these instruc- als. Non-compliance renders the warranty void.
tions and must be adhered to:

1.4 Intended Use and Application
DANGER of possibly serious personal injury Proper Outdoor Storage of Collectors
Remove protective film, and lay down collectors with glass
pane up. Avoid direct ground contact (e.g. underlay square
timber). Avoid scratches on glass panes by using spacers
WARNING against material damage. between collectors (e.g. wooden laths). When leaning col-
lectors against walls or similar, use a minimum inclination
of 15° and apply spacers. Do not use cardboard as under-
liner. If incorrectly stored, humidity can enter the collec-
NOTE as additional information tors through the air vents. Storing collectors in plastic film
package can damage the glass surface (see figure 2).

1.2 Norms and Regulations Scope and Limitations of Application
The collector is intended for the application in solar ther-
The standards and regulations applicable at the instal- mal installations for hot water preparation and space heat-
lation location must be adhered to. In absence of other ing support. As operating mediums water (attention – risk
regulations we recommend to follow the following norms: of freezing!) or an appropriate water-glycol mixture can
be used in a closed circuit. Operational conditions under-
Thermal Solar Systems and Components running the dew point within the collector for prolonged
● EN 12976 and EN V 12977 periods are not permitted! This can occur for example,
when collectors are integrated in the brine circuit of a heat
Electrical Work, Potential Equalization, Lightning pump.
Protection
● DIN EN 62305 Overheat Protection
● VDE 0185 part 305 For roof heating centrals and when 4 or more EURO col-
● DIN VDE 0100 part 540 lectors with anti reflective glass are installed vertically, the
● VDE 190 “Technical Information Solar Thermal Systems – Setup,
● DIN 18382 Commissioning and Maintenance” must be followed to
(Other regulations may apply, depending on your region, avoid damage to the solar circuit.
country or territory.)
Especially the pipes in the lower parts of the building Preventing frost Damage
must be connected electrically conductive, conforming to After pressure testing and flushing, collectors cannot be
standards. The collector installation must be profession- completely emptied. Make sure that no pure water re-
ally integrated with an existing or new lightning protection mains in collector during risk of frost!
system.
Empty Collector on Roof
Snow and Wind Loads After being installed on the roof, unfilled collectors should
Comply with local regulations and norms related to snow not be exposed to the sun for more than a few days. Other-
and wind loads, within the EU to EN 1991-1-4 (Wind Ac- wise thermal stress on gaskets can result in damage. Alter-
tions) and EN 1991-1-3 (Snow Loads). If you have ques- natively postpone the installation of gaskets to just before
tions related to structural conditions and planning, please filling the solar circuit.
contact our technical department for information. We offer
comprehensive planning support on a project base. Maintenance
For maintenance notes and additional information about
Work on Roofs setup and operation of the collector field, please refer to
Make sure to observe country and territory regulations re- the technical information “Solar Thermal Systems”.
lated to roof works and roof sealing standards as well as
professional codes for plumbing work.
The installation process must reflect the on-site condi-
tions as well as applicable rules, regulations and accident
prevention procedures. Installers must be qualified and -
where applicable - licensed to work on roofs.

34 EN-XXX_EURO-TRIC-A_MA-11216A00_MA-100119-11216A00
1.5 Pre Installation Notes
● Risk of burns at collector connections as soon as uncov-
ered collector is exposed to the sun (figure 3).
● Danger of open injuries when working with sharp
edged metal sheets and components!
● Remove protective plastic caps from connections be-
fore collector is exposed to the sun. Risk of melting and
damage to absorber!
● Remove glass protection PE-LD film before commenc-
ing installation work! (figure 4).

1.6 Recycling Note
At the end of the long operational lifetime, the valuable
Figure 2 Do not expose collector covered with protective film to rain. materials of the installation should be recycled in an en- 1.1
vironmentally sound manner. If recycling is not possible,
Wagner & Co will take the scrap material back.

Figure 3 Collector connections heat up during solar irradiation.

Figure 4 Remove glass protection film before installing collector!

EN-XXX_EURO-TRIC-A_MA-11216A00_MA-100119-11216A00 35
2. Horizontal Installation
2.1 Scope of Supply

2
1
6

7

9

5

4
3

8

Figure 5 Basic set for on-roof installation (collectors are not included in delivery)

Table 1 Figure no. Components: Basic Set for On-Roof Installation Quantity
1 Roof bracket 1 (6) 2
Collector supporting rail 1257 mm (EURO L20, C20, C30) or
2 2
1202 mm (EURO L22, C22, C32) incl. 2 collector clamps
Collector supporting rail 1223 mm (EURO L20, C20, C30) or
3 2
1168 mm (EURO L22, C22, C32) incl. 1 collector clamp
4 Collector supporting rail connector 2
5 Collector interconnection hose, 250 mm length 1
6 Collector connection hose for solar circuit, 900 mm length 2
7 Gasket ½" 6
8 Adapter fitting ½" – 18 mm 2
9 Wire strap 1
The included collector holders are not required for horizontal installation (4)
1 Not included in set; choose according to roofing type. 2 Required number depends on structural load calculation.

36 EN-XXX_EURO-TRIC-A_MA-11216A00_MA-100119-11216A00
3

1.1
4

5
2

1
Figure 6 Extension set for on-roof installation (collectors are not included in delivery)

Table 2 Figure no. Components: Extension Set for On-Roof Installation Quantity
1 Roof bracket1 (not included within the set) (2) 2
Collector supporting rail 1223 mm (EURO L20, C20, C30) or
2 2
1168 mm (EURO L22, C22, C32) incl. 1 collector clamp
3 Collector supporting rail connector 2
4 Collector interconnection hose, 250 mm length 1
5 Gasket ½" 2
The included collector holders are not required for horizontal installation (2)
1 Not included in set; choose according to roofing type. 2 Required quantity depends on structural load calculation.

2.2 Installation of Roof-Brackets
The roof brackets shown in this manual are given as ex-
amples only. The actual type varies and depends on the
roofing. For more information refer to the installation in-
structions included with the roof brackets.

Figure 6 Correct fixing of roof bracket type P Stv to rafter

EN-XXX_EURO-TRIC-A_MA-11216A00_MA-100119-11216A00 37
2.3 Supporting Rail Installation

C

B
A

B

Before commencing roof installation of the rails,
prepare rails on the ground by connecting them
with the included rail connector.

Figure 8 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.

Table 3 Section Distance (mm)
EURO L20, C20, C30 EURO L22, C22, C32
A min. 1600 min. 1500
B 1000 – 1300 900 – 1200
C 20 – 200 20 – 200

38 EN-XXX_EURO-TRIC-A_MA-11216A00_MA-100119-11216A00
2.4 Collector Installation

Mount uppermost collector first!

1.1

17 Nm

Loosen collector clamp slightly, then push tightly
against collector and tighten (17 Nm).
Badly positioned collectors can lead to insufficient
Figure 9 Installation of first (uppermost) collector fixation!

EN-XXX_EURO-TRIC-A_MA-11216A00_MA-100119-11216A00 39
X

Loosen collector clamp slightly, then push tightly
against collector and tighten screw (17 Nm).
Figure 10 Installation of the following collectors
Badly positioned collectors can lead to insufficient
fixation!

40 EN-XXX_EURO-TRIC-A_MA-11216A00_MA-100119-11216A00
3. Vertical Installation
3.1 Scope of Supply
8
3

4
5
1
9
2
7
6

1.1

10

Figure 11 Basic Set for on-roof installation (collectors are not included in delivery)

Table 4 Figure no. Components: Basic Set for On-Roof Installation Quantity
1 Roof brackets 1 (6) 2
Collector supporting rail 1257 mm (EURO L20, C20, C30) or
2 2
1202 mm (EURO L22, C22, C32) incl. 2 collector clamps
Collector supporting rail 1223 mm (EURO L20, C20, C30) or
3 2
1168 mm (EURO L22, C22, C32) incl. 1 collector rail
4 Collector supporting rail connector 2
5 Collector interconnection hose, 250 mm length 1
6 Collector connection hose for solar circuit, 900 mm length 2
7 Gasket ½" 6
8 Adapter fitting ½" – 18 mm 2
9 Wire strap 1
10 Collector holder 4
1 Not included in set; choose according to roofing type. 2 Required number depends on structural load calculation.

EN-XXX_EURO-TRIC-A_MA-11216A00_MA-100119-11216A00 41
1
2
5
4
3

6

Figure 12 Extension Set for on-roof installation (collector is not included in delivery)

Table 5 Figure no. Components: Extension Set for On-Roof Installation Amount
1 Roof brackets 1 (2) 2
Collector supporting rail 1223 mm (EURO L20, C20, C30) or
2 2
1168 mm (EURO L22, C22, C32) incl. 1 collector clamp
3 Collector interconnection rail connector 2
4 Collector connecting hose, 250 mm length 1
5 Gasket ½" 2
6 Collector holder 2
1 Not included in set; choose according to roofing type. 2 Required number depends on structural load calculation.

3.2 Installation of the Roof-Brackets
The roof brackets shown in this manual are given
as examples only. The actual type varies and de-
pends on the roofing. For more information refer
to the installation instructions included with the
roof brackets.

Figure 13 Correct fixing of roof bracket type P Stv to rafter

42 EN-XXX_EURO-TRIC-A_MA-11216A00_MA-100119-11216A00
3.3 Supporting Rail Installation

B

B

A
2

1
1.1

2

1
1 2

C

Before commencing roof installation of the rails,
prepare rails on the ground by connecting them
with the included rail connector.

30 Nm
17 Nm

Figure 14 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.

Table 6 Section Distance (mm)
EURO L20, C20, C30 EURO L22, C22, C32
A 1600 – 1900 min. 1500
B max. 1200 900 – 1200
C 20 – 200 20 – 200

EN-XXX_EURO-TRIC-A_MA-11216A00_MA-100119-11216A00 43
3.4 Collector Installation

1

X

2
X
17 Nm

Loosen collector clamp slightly, then push tightly
against collector and tighten (17 Nm).
Badly positioned collectors can lead to insufficient
Figure 15 Installation of first collector fixation!

44 EN-XXX_EURO-TRIC-A_MA-11216A00_MA-100119-11216A00
1.1

X

X

Place the second collectors frame ridge under the collector
clamps on the side of the first collector. Slightly loosen on
other side, push towards collector and fasten the collector
clamps (17 Nm).
Wrong or badly positioned collectors can lead to an
insufficient fixation!
Figure 16 Installation of following collectors

EN-XXX_EURO-TRIC-A_MA-11216A00_MA-100119-11216A00 45
4. Sensor Installation

Figure 17 Remove rubber plug from frame. If necessary use screw Figure 18 Pull sensor through rubber plug and insert sensor top into
driver to uncover sensor sleeve. sensor sleeve. Screw in rubber plug again.

46 EN-XXX_EURO-TRIC-A_MA-11216A00_MA-100119-11216A00
5. Collector Connections

1.1

Figure 19 Use counter force to support collector interconnection hose Figure 20 Use counter force to support collector interconnection hose
when tightening to protect connection and hose against damage. when tightening to protect connection and hose against damage.

Figure 21 Connect the collector interconnection hose to the solar cir- Figure 22 2 collectors installed on-roof, horizontal and next to each
cuit inside the roof via adapter fitting ½"-18 mm. other can be connected with a special connection set
(part no. 190 202 30).

EN-XXX_EURO-TRIC-A_MA-11216A00_MA-100119-11216A00 47
6. Accessories

Figure 23 Collector handles for an easy transport Figure 24 Protection of sensor cable against marten bites (part no.
(part no. 188 005 02). 192  040 09 for black collectors, part no. 192 040 10 for aluminium
coloured collectors).

Figure 25 Height adjustable roof brackets P Alu Hv Top for flat Figure 26 Roof brackets BS Stv KF Top for slate and plane tiles for
clay tiles for equalising uneven roofs (basic set includes 6 pieces, equalising uneven roofs (basic set incl. 6 items, part no. 192 030 25).
part no. 192 030 32).

Figure 27 EURO connection set, 2x horizontal (part no. 190 202 30) for
connecting two collectors next to each other, horizontal.

Subject to modifications, errors excepted · © Wagner & Co, 2010 · www.wagner-solar.com
48 WAGNER & CO · Zimmermannstraße 12 · D-35091 Cölbe/Marburg · ☎
+49 (0) 64 21 80 07-0 · Fax 80 07-596
INSTALLATION INSTRUCTIONS

EURO TRIC F Free Standing

1.1

Figure 1 Horizontal and vertical free standing setup

Content
1. General Safety Notes . . . . . . . . . . . . . 50
2. Scope of Supply . . . . . . . . . . . . . . . 53
3. Installation of Racking Triangles. . . . . . . . . 56
4. Horizontal Collector Installation . . . . . . . . 63
5. Vertical Collector Installation . . . . . . . . . . 64
Installation instructions valid for these collectors:
6. Sensor Installation . . . . . . . . . . . . . . 67
7. Collector Connections . . . . . . . . . . . . . 67 EURO L20, EURO C20, EURO C30, EURO C22,
EURO L22, EURO C32
8. Accessories . . . . . . . . . . . . . . . . . 68

Solar Thermal / Solar Collectors EN-XXX_EURO-TRIC-F_MA-100118-11216C00 49
1. General Safety Notes 1.3 Qualification of the Installer
1.1 Symbols Setup, installation and proper commissioning of the solar
installation must be carried out by authorized profession-
The following symbols are used throughout these instruc- als. Non-compliance renders the warranty void.
tions and must be adhered to:

1.4 Intended Use and Application
DANGER of possibly serious personal injury Proper Outdoor Storage of Collectors
Remove protective film and lay down collectors with glass
pane up. Avoid direct ground contact (e.g. underlay square
timber). Avoid scratches on glass panes by using spacers
WARNING against material damage. between collectors (e.g. wooden laths). When leaning col-
lectors against walls or similar, use a minimum inclination
of 15° and apply spacers. Do not use cardboard as under-
liner. If incorrectly stored, humidity can enter the collectors
NOTE as additional information through the air vents. Storing collectors in foil package can
damage the glass surface (see figure 2).

1.2 Norms and Regulations Scope and Limitations of Application
The collector is intended for the application in solar ther-
The standards and regulations applicable at the instal- mal installations for hot water preparation and space heat-
lation location must be adhered to. In absence of other ing support. As operating mediums water (attention – risk
regulations we recommend to follow the following norms: of freezing!) or an appropriate water-glycol mixture can
be used in a closed circuit. Operational conditions under-
Thermal Solar Systems and Components running the dew point within the collector for prolonged
● EN 12976 and EN V 12977 periods are not permitted! This can occur for example,
when collectors are integrated in the brine circuit of a heat
Electrical Work, Potential Equalization, Lightning pump.
Protection
● DIN EN 62305 Overheat Protection
● VDE 0185 part 305 For roof heating centrals and when 4 or more EURO col-
● DIN VDE 0100 part 540 lectors with anti reflective glass are installed vertically, the
● VDE 190 “Technical Information Solar Thermal Systems – Setup,
● DIN 18382 Commissioning and Maintenance” must be followed to
(Other regulations may apply, depending on your region, avoid damage to the solar circuit.
country or territory.)
Especially the pipes in the lower parts of the building Preventing frost Damage
must be connected electrically conductive, conforming to After pressure testing and flushing, collectors cannot be
standards. The collector installation must be profession- completely emptied. Make sure that no pure water re-
ally integrated with an existing or new lightning protection mains in collector during risk of frost!
system.
Empty Collector on Roof
Snow and Wind Loads After being installed on the roof, unfilled collectors should
Comply with local regulations and norms related to snow not be exposed to the sun for more than a few days. Other-
and wind loads, within the EU to EN 1991-1-4 (Wind Ac- wise thermal stress on gaskets can result in damage. Alter-
tions) and EN 1991-1-3 (Snow Loads). If you have ques- natively postpone the installation of gaskets to just before
tions related to structural conditions and planning, please filling the solar circuit.
contact our technical department for information. We offer
comprehensive planning support on a project base. Maintenance
For maintenance notes and additional information about
Work on Roofs setup and operation of the collector field, please refer to
Make sure to observe country and territory regulations re- the technical information “Solar Thermal Systems”.
lated to roof works and roof sealing standards as well as
professional codes for plumbing work.
The installation process must reflect the on-site conditions
as well as applicable rules, regulations and accident pre-
vention procedures. Basic accident prevention principles
are shown in figure 5. Installers must be qualified and –
where applicable – licensed to work on roofs.

50 EN-XXX_EURO-TRIC-F_MA-100118-11216C00
1.5 Pre Installation Notes
● Risk of burns at collector connections as soon as uncov-
ered collector is exposed to the sun (figure 3).
● Danger of open injuries when working with sharp
edged metal sheets and components!
● Remove protective plastic caps from connections be-
fore collector is exposed to the sun. Risk of melting and
damage to absorber!
● Remove glass protection PE-LD film before commenc-
ing installation work! (figure 4).

1.6 Recycling Note
At the end of the long operational lifetime, the valuable
Figure 2 Do not expose collector covered with protective film to rain. materials of the installation should be recycled in an en- 1.1
vironmentally sound manner. If recycling is not possible,
Wagner & Co will take the scrap material back.

You can find additional information in the “Partner Area” of
our website at http://www.wagner-solar.com

Figure 3 Collector connections heat up during solar irradiation.

Figure 4 Remove glass protection film before installing collector!

EN-XXX_EURO-TRIC-F_MA-100118-11216C00 51
fro
m
60
°
fro
m
45
°

from 3 m

Figure 5 Accident prevention guidelines for work on roofs.

52 EN-XXX_EURO-TRIC-F_MA-100118-11216C00
2. Scope of Supply
2.1 Horizontal

8 1.1
9

3
2

1
7
6
5
4

Figure 6 Basic Set, horizontal, free-standing installation (collector not included in delivery)

Table 1 Figure no. Components: Basic Set, Horizontal Quantity
1 Pre-assembled racking triangle 2
2 Hexagonal screw M8 x 40 2
3 Nut M8 interlocked 2
4 Collector clamp – lower side 4
5 Collector clamp – top 4
6 Washer Ø 8.4 4
7 Hexagonal screw M8 x 30 4
8 Gasket ½" 2
9 Interconnection (screw to solder) ½" – 18 mm 2

EN-XXX_EURO-TRIC-F_MA-100118-11216C00 53
2.2 Vertical

4

10
9

7
6
5

3
2

1

8
Figure 7 Basic Set, vertical, free-standing installation (collector not included in delivery)

Table 2 Figure no. Components: Basic Set, Vertical Quantity
1 Pre-assembled racking triangle 2
2 Hexagonal screw M8 x 40 2
3 Nut M8 interlocked 2
4 Collector rail 1257 mm (EURO L20, C20, C30) or 1202 mm (EURO L22, C22, C32) incl. 2 collector clamps 2
5 Clamping angle 4
6 Washer Ø 8,4 4
7 Hexagonal screw M8 x 30 4
8 Collector holder 2
9 Gasket ½" 2
10 Interconnection (screw to solder) ½" – 18 mm 2

54 EN-XXX_EURO-TRIC-F_MA-100118-11216C00
4
7
6
11 5
10

3
2

1
1.1

9 8
Figure 8 Extension Set, vertical, free-standing installation (collector not included in delivery)

Table 3 Figure no. Components: Extension Set, Vertical Quantity
1 Pre-assembled racking triangle 1
2 Hexagonal screw M8 x 40 1
3 Nut M8 interlocked 1
4 Collector rail 1223 mm (EURO L20, C20, C30) or 1168 mm (EURO L22, C22, C32) incl. 1 collector clamp 2
5 Clamping angle 2
6 Washer Ø 8.4 2
7 Hexagonal screw M8 x 30 2
8 Collector holder 2
9 Rail connector 2
10 Gasket ½" 2
11 Collector connection hose, 250 mm length 1

EN-XXX_EURO-TRIC-F_MA-100118-11216C00 55
3. Installation of the Racking Triangles
3.1 Possible Inclination Angles

12
57
0
-20
20
14
90
0
-20
20

Figure 9 EURO TRIC F horizontal for 35° – 50°
19
00

22
00

Figure 10 EURO TRIC F vertical for 37° – 50°

56 EN-XXX_EURO-TRIC-F_MA-100118-11216C00
3.2 Setting up the Racking Triangle

17 Nm

M8 x 40
17 Nm

1.1
3

2

1

Figure 11 Unfold racking triangle and fix

3.3 Determining the
Collector Inclination α
Table 4 Collector Type α [°] A [mm] B [mm]
35° 863 10
EURO TRIC F 40° 940 147
All EURO-
horizontal
collectors 45° 1009 311
35° – 50°
50° 1070 521
37° 1471 0
EURO L20, 40° 1553 153
EURO C20 and
EURO C30 45° 1679 458
A
EURO TRIC F 50° 1782 920
vertical
37° – 50° 37° 1338 0
EURO L22, 40° 1410 153
EURO C22 and
EURO C32 45° 1522 458 B

50° 1619 920 Figure 12 Collector inclination and setup dimensions

EN-XXX_EURO-TRIC-F_MA-100118-11216C00 57
3.4 Positions of the Ground Fixations

max. 200 max. 200

Figure 13 Max. distance from ground fixations (mm)

The number of clamping angles required for fixing the
racking triangles depends on the type of surface. If unsure,
please contact our technical support for more information.

3.5 Installation on Steel Beams

Ø
10
,5

Figure 14 Fixing the racking triangles on steel beams

58 EN-XXX_EURO-TRIC-F_MA-100118-11216C00
3.6 Installation on Concrete Slabs

Ø
12

1.1

Figure 15 Fixing the racking triangles on concrete slabs placed on protective underlay.

EN-XXX_EURO-TRIC-F_MA-100118-11216C00 59
3.7 Installation on Gravel Board Set

1

2

3

Figure 16 Gravel board basic set for vertical installation (prod. no. 192 020 75). At the supporting profile of the triangle use 4 clamping angles
to encompass the ground rail on both sides (magnifying glass 1). At the front (magnifying glass 2) use one angle on each side.

Provide protective underlay to avoid damage to roofing!

60 EN-XXX_EURO-TRIC-F_MA-100118-11216C00
1.1

Figure 17 Gravel board basic and extension sets for vertical installation (prod. no. 192 020 76)

Figure 18 Gravel board set for horizontal installation (prod. no. 192 020 74)

EN-XXX_EURO-TRIC-F_MA-100118-11216C00 61
1

2 Do not damage the
roofing when drilling!

max 30
Ø5 3

2/3

1/3

4
30
max 30

Ø5
max

5

Ø 5,2

Figure 19 Fixing the racking triangles on gravel boards.

62 EN-XXX_EURO-TRIC-F_MA-100118-11216C00
4. Horizontal Collector Installation

1.1

For lower fixation of EURO L20, C20 and C30
X use lowest rivet nut. Use rivet nut above lowest
for EURO L22, C22 and C32.

X

Loosely pre-install the collector clamps and then
place collector. Finally push collector clamps to
collector and tighten. Incorrectly positioned
collector clamps may result in insufficient stability!

Figure 20 Connecting collector and racking triangles

EN-XXX_EURO-TRIC-F_MA-100118-11216C00 63
5. Vertical Collector Installation
5.1 Installation of the Collector Supporting Rails
2 Table 5
Section Indications
17 Nm A 1700 mm (drilling hole distance)
Position the central supporting
triangle centred under the butt
B
joint of the collector supporting
1 rails.
C 20 – 200 mm

B

2
B

A
C
1

2

1

3 4

17 Nm

Figure 21 Overview supporting rail installation 1 rail with two collector clamps 2 rail with one collector clamp

64 EN-XXX_EURO-TRIC-F_MA-100118-11216C00
5.2 Collector Installation

1

1.1

X

2
X
17 Nm

Place collector, then push collector clamp tightly
against collector and tighten (17 Nm)
Incorrectly positioned collector clamps may result
Figure 22 Installation of the first collector. in insufficient stability!

EN-XXX_EURO-TRIC-F_MA-100118-11216C00 65
X
1

2
X

Position the frame ridge of the 2nd collector under the
fixed collector clamps at the side of the first collector.
On the other side loosen collector clamps slightly,
then push tightly against collector and tighten screw.
Incorrectly positioned collector clamps may result in
Figure 23 Installation of following collectors insufficient stability!

66 EN-XXX_EURO-TRIC-F_MA-100118-11216C00
6. Sensor Installation

1.1

Figure 24 Remove rubber plug from frame. Possibly use screwdriver Figure 25 Pull sensor through rubber plug and insert sensor tip into
to lay open sensor sleeve. sensor sleeve. Screw in rubber plug again.

7. Collector Connections

0
16 4
24

Figure 26 Counter collector connection hose (vertical, free standing Figure 27 Installation dimensions for connection set prod. no. 190 202
set-up) during tightening to protect collector connection and connec- 30; Cut to size for compression or solder connections.
tion hose against damages.

EN-XXX_EURO-TRIC-F_MA-100118-11216C00 67
8. Accessories

2x

Figure 28 Connection set prod. no 190 202 30 for 2 horizontal col- Figure 29 Collector handles for easier collector transport (prod. no.
lectors: 2 insulated T-connector pieces with 2 x ½" swivel nuts and 1 x 188 005 02)
¾" M thread.

Figure 30 Optional sensor protection against marten bites (part no.
192 040 09 for black collectors, part no. 192 040 10 for aluminum
colored collector frames).

Subject to modifications, errors excepted · © Wagner & Co, 2010 · www.wagner-solar.com
68 WAGNER & CO · Zimmermannstraße 12 · D-35091 Cölbe/Marburg · ☎
+49 (0) 64 21 80 07-0 · Fax 80 07-596
INSTALLATION INSTRUCTIONS

EURO L20 MQ TRIC A and TRIC F
Free Standing and On Roof Installation

1.1

Figure 1 EURO L20 MQ TRIC A

Content
Figure 2 EURO L20 MQ TRIC F
1. General Safety Notes . . . . . . . . . . . . . 70
2. TRIC A – On Roof Installation . . . . . . . . . . 73
3. TRIC F – Free Standing Installation . . . . . . . 80
4. Collector Connections . . . . . . . . . . . . . 90
5. Sensor Installation . . . . . . . . . . . . . . 91
6. Accessories . . . . . . . . . . . . . . . . . 92

Solar Thermal / Solar Collectors EN-XXX_EURO-L20-MQ-TRIC-A-TRIC-F_MA-100119-1WA10024 69
1. General Safety Notes 1.3 Qualification of the Installer
1.1 Symbols Setup, installation and proper commissioning of the solar
installation must be carried out by authorized profession-
The following symbols are used throughout these instruc- als. Non-compliance renders the warranty void.
tions and must be adhered to:

1.4 Intended Use and Application
DANGER of possibly serious personal injury Proper Outdoor Storage of Collectors
Remove protective film, and lay down collectors with glass
pane up. Avoid direct ground contact (e.g. underlay square
timber). Avoid scratches on glass panes by using spacers
WARNING against material damage. between collectors (e.g. wooden laths). When leaning col-
lectors against walls or similar, use a minimum inclination
of 15° and apply spacers. Do not use cardboard as under-
liner. If incorrectly stored, humidity can enter the collec-
NOTE as additional information tors through the air vents. Storing collectors in plastic film
package can damage the glass surface (see figure 3).

1.2 Norms and Regulations Scope and Limitations of Application
The collector is intended for the application in solar ther-
The standards and regulations applicable at the instal- mal installations for hot water preparation and space heat-
lation location must be adhered to. In absence of other ing support. As operating mediums water (attention – risk
regulations we recommend to follow the following norms: of freezing!) or an appropriate water-glycol mixture can
be used in a closed circuit. Operational conditions under-
Thermal Solar Systems and Components running the dew point within the collector for prolonged
● EN 12976 and EN V 12977 periods are not permitted! This can occur for example,
when collectors are integrated in the brine circuit of a heat
Electrical Work, Potential Equalization, Lightning pump.
Protection
● DIN EN 62305 Overheat Protection
● VDE 0185 part 305 For roof heating centrals and when 4 or more EURO col-
● DIN VDE 0100 part 540 lectors with anti reflective glass are installed vertically, the
● VDE 190 “Technical Information Solar Thermal Systems – Setup,
● DIN 18382 Commissioning and Maintenance” must be followed to
(Other regulations may apply, depending on your region, avoid damage to the solar circuit.
country or territory.)
Especially the pipes in the lower parts of the building Preventing frost Damage
must be connected electrically conductive, conforming to After pressure testing and flushing, collectors cannot be
standards. The collector installation must be profession- completely emptied. Make sure that no pure water re-
ally integrated with an existing or new lightning protection mains in collector during risk of frost!
system.
Empty Collector on Roof
Snow and Wind Loads After being installed on the roof, unfilled collectors should
Comply with local regulations and norms related to snow not be exposed to the sun for more than a few days. Other-
and wind loads, within the EU to EN 1991-1-4 (Wind Ac- wise thermal stress on gaskets can result in damage. Alter-
tions) and EN 1991-1-3 (Snow Loads). If you have ques- natively postpone the installation of gaskets to just before
tions related to structural conditions and planning, please filling the solar circuit.
contact our technical department for information. We offer
comprehensive planning support on a project base. Maintenance
For maintenance notes and additional information about
Work on Roofs setup and operation of the collector field, please refer to
Make sure to observe country and territory regulations re- the technical information “Solar Thermal Systems”.
lated to roof works and roof sealing standards as well as
professional codes for plumbing work.
The installation process must reflect the on-site condi-
tions as well as applicable rules, regulations and accident
prevention procedures. Installers must be qualified and -
where applicable - licensed to work on roofs.

70 EN-XXX_EURO-L20-MQ-TRIC-A-TRIC-F_MA-100119-1WA10024
1.5 Pre Installation Notes
● Risk of burns at collector connections as soon as uncov-
ered collector is exposed to the sun (figure 4).
● Danger of open injuries when working with sharp
edged metal sheets and components!
● Remove protective plastic caps from connections be-
fore collector is exposed to the sun. Risk of melting and
damage to absorber!
● Remove glass protection PE-LD film before commenc-
ing installation work! (figure 5).

1.6 Recycling Note
At the end of the long operational lifetime, the valuable
Figure 3 Do not expose collector covered with protective film to rain. materials of the installation should be recycled in an en- 1.1
vironmentally sound manner. If recycling is not possible,
Wagner & Co will take the scrap material back.

Figure 4 Collector connections heat up during solar irradiation.

Figure 5 Remove glass protection film before installing collector!

EN-XXX_EURO-L20-MQ-TRIC-A-TRIC-F_MA-100119-1WA10024 71
fro
m
60
°
fro
m
45
°

from 3 m

Figure 6 Accident prevention rules for working on roofs

72 EN-XXX_EURO-L20-MQ-TRIC-A-TRIC-F_MA-100119-1WA10024
2. TRIC A – On Roof Installation
2.1 Scope of Supply, Basic Set

4

2

1

1.1

6

3

4

5
Figure 7 Basic set for on roof installation
Table 1
Figure No. Part Quantity
Roof bracket or roof anchors (not included in delivery);
1 4-6
quantity according to structural requirements
2 EURO collector supporting rail, pre assembled, 2215 mm 2
3 EURO collector holder L34 2
4 EURO MQ connection set 1
5 Collector connection set, insulation 900 mm 2
6 Collector (not included in delivery)

The roof bracket is shown as an example – the ac-
tual type depends on the roofing. Please observe
the instructions accompanying the brackets.

Figure 8 Installation of roof bracket

EN-XXX_EURO-L20-MQ-TRIC-A-TRIC-F_MA-100119-1WA10024 73
2.2 TRIC A – Scope of Supply, Extension Set

2

1

6
5

4

3

Figure 9 Extension set for on roof installation

Table 2
Figure No. Part Quantity
Roof bracket or roof anchors (not included in delivery);
1 (4-6)
quantity according to structural requirements
2 EURO collector supporting rail, pre assembled, 2.215 mm 2
3 TRIC A rail connector set 2
4 EURO collector holder L34 2
5 EURO MQ connection set 2
6 Collector (not included in delivery)

74 EN-XXX_EURO-L20-MQ-TRIC-A-TRIC-F_MA-100119-1WA10024
2.3 TRIC A – Installation of Rails

A
B

1.1

C
1 2

30 Nm

Figure 10 Overview of supporting rail installation with indicated roof
bracket spacings for 4 roof brackets per collector (for structural limits
see table 4. In other cases our technical support provides assistance).
Table 4 Dimensioning Examples for Snow / Wind Load Zones 1-2 1
Building Altitude above On-roof installation (no. of roof
height (m) sea level (m) brackets per collector) 2
10 400 4
10 800 6
Table 3 Section Length [mm] 10-20 400 4

A ca. 1000 10-20 800 6

B 1815 - 2175
1 45° inclination, installation in edge and corner areas of roofs not
considered; wind speed vref ≤ 25 m/s, wind pressure at 10 m
C 20 - 200 above ground qref ≤ 0.39 (kN/m2)
2 Roof bracket P STv KF; ridge distance or distance to snow barrier
above < 1 m; roof bracket quantities are guide values – round
acc. to field size and individual situation.

EN-XXX_EURO-L20-MQ-TRIC-A-TRIC-F_MA-100119-1WA10024 75
2.4 TRIC A – Connecting Basic and Extension Sets

3

30 Nm

2

17 Nm

1

Figure 11 Connecting basic and extension set 30

Figure 12 After the 6th collector a spacing of approx. 30 mm is re-
quired to accommodate thermal expansion. For this please order the
additional longer field compensator (order no. 819 102 49). Take care
that the collector supporting rails are precisely aligned.

76 EN-XXX_EURO-L20-MQ-TRIC-A-TRIC-F_MA-100119-1WA10024
2.5 TRIC A – Placing of the First Collector

1.1

Figure 13 Warning labels of the first and last collector must be on inner side (absorber geometry!)

EN-XXX_EURO-L20-MQ-TRIC-A-TRIC-F_MA-100119-1WA10024 77
1 X

2

X
17 Nm

Slightly loosen collector clamp. Then push
towards collector and tighten (17 Nm)
Incorrectly positioned collector clamps may
Figure 14 Installation of the first collector result in insufficient stability!

78 EN-XXX_EURO-L20-MQ-TRIC-A-TRIC-F_MA-100119-1WA10024
2.6 TRIC A – Placing of the Next Collector

1

1.1

2 3 4

Figure 15 Installation of the next collector

EN-XXX_EURO-L20-MQ-TRIC-A-TRIC-F_MA-100119-1WA10024 79
3. TRIC F – Free Standing Installation
3.1 TRIC F – Scope of Delivery, Basic Set

4 5 6

2 3 9

10
1

9

7
8
Figure 16 Basic set free standing installation

Table 5
Figure No. Part Quantity Figure No. Part Quantity
1 EURO MQ racking triangle 2 6 Screw M8x40, A2 4
EURO collector supporting rail,
2 Screw M8x40, A2 2 7 2
pre-assembled, 2215 mm
3 Nut M8 with locking teeth, A2 2 8 EURO collector holder L34 2
4 Clamping bracket 4 9 EURO MQ connection set 1
5 Washer Ø 8.4 4 10 Collector (not included in delivery)

80 EN-XXX_EURO-L20-MQ-TRIC-A-TRIC-F_MA-100119-1WA10024
3.2 TRIC F – Scope of Delivery, Extension Set

2 3

7
1.1

1
10

4 5 6

11

9
8
10

Figure 17 Extension set for free standing installation

Table 6
Figure No. Part Quantity Figure No. Part Quantity
EURO collector supporting rail,
1 Racking triangle 1 7 2
pre-assembled, 2215 mm
2 Screw M8x40, A2 1 8 TRIC A rail connector set 2
3 Nut M8 with locking teeth, A2 1 9 EURO collector holder L34 2
4 Clamping bracket 2 10 EURO MQ connection set 1
5 Washer Ø 8.4 2 11 Collector (not included in delivery)
6 Screw M8x40, A2 2

EN-XXX_EURO-L20-MQ-TRIC-A-TRIC-F_MA-100119-1WA10024 81
3.3 TRIC F – Unfolding of Racking Triangles

M8 x 40

3

2

1

Figure 18 Unfolding and locking racking triangle

3.4 TRIC F – Possible Inclinations

A
10
50

C

Figure 20 Collector inclination and setup dimensions

11
90 Table 7 α [°] C [mm] A [mm]
35° 12 879
40° 110 952

Figure 19 Dimensions of racking triangle EURO L20 MQ 35° - 55° 45° 224 1018
50° 360 1077
55° 539 1127

82 EN-XXX_EURO-L20-MQ-TRIC-A-TRIC-F_MA-100119-1WA10024
3.5 TRIC F – Position of Ground Fixations

max. 200 max. 200
1.1

Figure 21 Projecting lengths

3.6 TRIC F – Installation on Steel Beams
The number of clamping brackets required to fix the tri-
angles depends on the ground conditions. For additional
information, please contact our technical support.
Ø
10
,5

Figure 22 Fixing racking triangles on steel beams

EN-XXX_EURO-L20-MQ-TRIC-A-TRIC-F_MA-100119-1WA10024 83
3.7 TRIC F – Installation on Concrete Slabs

Ø
12
Figure 23 Fixing racking triangles on concrete slabs

3.8 TRIC F – Installation on Gravel Boards

Figure 24 Overview TRIC F for 2 collectors

84 EN-XXX_EURO-L20-MQ-TRIC-A-TRIC-F_MA-100119-1WA10024
1

Do not damage the
roofing when drilling!

max 30
Ø5

2
3

Ø 5,2

1.1

2/3

1/3

3

4
3

Figure 25 Fixing of racking triangles
Enclose ground rail at the supporting leg of the triangle with 4 clamping brackets (magnifying glass 3). For the frontal part use 2 brackets (mag.
glass 4)

EN-XXX_EURO-L20-MQ-TRIC-A-TRIC-F_MA-100119-1WA10024 85
Table 8
4 Dimensioning Examples for Snow / Wind Load Zones 1-2 1
Building Altitude above Free standing ballast (kg/m²
height (m) sea level (m) collector area)
10 400 90
10 800 90
10-20 400 120
10-20 800 120
1 45° inclination, installation in edge and corner areas of roofs not
considered; wind speed vref ≤ 25 m/s, wind pressure at 10 m
above ground qref ≤ 0.39 (kN/m2)

3.9 TRIC F – Connecting Racking Triangles
and Collector Supporting Rails

B

C

Table 9 Section Length [mm]
B 1815 - 2175
C 20 - 200

1 2 3

17 Nm

Figure 26 Installation of the rails

86 EN-XXX_EURO-L20-MQ-TRIC-A-TRIC-F_MA-100119-1WA10024
3.10 TRIC F – Connecting Basic and Extension Sets

3

17 Nm

2

17 Nm
1.1

1

Position the central racking triangle
in the area of the rails’ butt joint.

Figure 27 Extension of basic set

EN-XXX_EURO-L20-MQ-TRIC-A-TRIC-F_MA-100119-1WA10024 87
3.11 TRIC F – Placing of the First Collector

X

1

2

X
17 Nm

Slightly loosen collector clamp. Then push
towards collector and tighten (17 Nm)
Incorrectly positioned collector clamps may
Figure 28 Connecting collector and racking triangles result in insufficient stability!

88 EN-XXX_EURO-L20-MQ-TRIC-A-TRIC-F_MA-100119-1WA10024
3.12 Placing of the Next Collector

1

1.1

2 3 4

Figure 29 Installing the next collector

EN-XXX_EURO-L20-MQ-TRIC-A-TRIC-F_MA-100119-1WA10024 89
4. Collector Connections
Push cylindrical end of the connection piece with O-ring
into the collector connection. Rotate the clamp into its
proper position on the parts that have to be connected,
and tighten with 4 mm Allen key, until the bracket arms
almost touch each other.

For connections in Figure 30 and 32 make sure that the
connector connection is not twisted when tightening the
friction ring connection.

Sample connection layouts you can find in the technical
information “EURO Solar Collector L20 MQ AR”.

2x
Figure 30 Fitting set for connection to the solar circuit (order no. Figure 31 Connection set (order no. 192 040 13)
192 040 12)

Figure 32 Air bleeder set (order no. 192 040 16) Figure 33 Plug set (order no. 192 040 11)

90 EN-XXX_EURO-L20-MQ-TRIC-A-TRIC-F_MA-100119-1WA10024
5. Sensor Installation

1.1

Figure 34 Remove rubber plug from frame. If necessary, use screw- Figure 35 Pull sensor through the rubber plug and insert sensor tip
driver to expose sensor sleeve. into the sensor sleeve. Then screw in rubber plug again.

Figure 36 Secure sensor cable at connection hose with a cable binder.

EN-XXX_EURO-L20-MQ-TRIC-A-TRIC-F_MA-100119-1WA10024 91
6. Accessories

Figure 37 Sensor protection kit against marten/animal bites optionally Figure 37 Collector handles for easier transport of collectors (order
available (order no. 19204010 – for silver coloured frame or order no. no. 188 005 02).
19204009 for black).

Subject to modifications, errors excepted · © Wagner & Co, 2010 · www.wagner-solar.com
92 WAGNER & CO · Zimmermannstraße 12 · D-35091 Cölbe/Marburg · ☎
+49 (0) 64 21 80 07-0 · Fax 80 07-596
INSTALLATION INSTRUCTIONS

EURO C20/L20 In-Roof Installation
for Slate and Plain Tile Roofings (straight and round cut)

1.1

Figure 1 EURO-roof integration in plain tile roof (round cut)

Content
● For roof pitch > 25° 1. General Safety Notes . . . . . . . . . . . . . 94
● Weather proof integration thanks to aluminum cladding 1.1 Symbols . . . . . . . . . . . . . . . . . . . 94
panels and aluminum skirting 1.2 Norms and Regulations . . . . . . . . . . . . 94
● Pipe connections protected under upper cladding 1.3 Qualification of the Installer . . . . . . . . . . 94
1.4 Intended Use and Application . . . . . . . . . 94
1.5 Pre Installation Notes . . . . . . . . . . . . . 95
The installation is shown for round cut plain tiles. The 1.6 Recycling Note . . . . . . . . . . . . . . . . 95
installation with slates is very similar, but the installer 2. Scope of Supply . . . . . . . . . . . . . . . 96
should have previous experience with slate roofing 2.1 Basic Set . . . . . . . . . . . . . . . . . . . 96
work. 2.2 Extension Set . . . . . . . . . . . . . . . . . 97
3. Installation Field Preparation . . . . . . . . . . 98
4. Installation . . . . . . . . . . . . . . . . . 100

Solar Thermal / Solar Collectors EN-XXX_EURO-C20-L20-In-Roof-Slate_MA-100902-1WA10143 93
1. General Safety Notes 1.3 Qualification of the Installer
1.1 Symbols Setup, installation and proper commissioning of the solar
installation must be carried out by authorized professio-
The following symbols are used throughout these instruc- nals. Non-compliance renders the warranty void.
tions and must be adhered to:

1.4 Intended Use and Application
DANGER of possibly serious personal injury Proper Outdoor Storage of Collectors
Remove protective film, and lay down collectors with glass
pane up. Avoid direct ground contact (e.g. underlay square
timber). Avoid scratches on glass panes by using spacers
WARNING against material damage between collectors (e.g. wooden laths). When leaning coll-
ectors against walls or similar, use a minimum inclination of
15° and apply spacers. Do not use cardboard as underli-
ner. If incorrectly stored, humidity can enter the collectors
NOTE as additional information through the air vents. Storing collectors in plastic film pa-
ckage can damage the glass surface (see figure 2).

1.2 Norms and Regulations Scope and Limitations of Application
The collector is intended for the application in solar ther-
The standards and regulations applicable at the installa- mal installations for hot water preparation and space hea-
tion location must be adhered to. In absence of other re- ting support. As operating mediums water (attention – risk
gulations we recommend to follow the following norms: of freezing!) or an appropriate water-glycol mixture can
be used in a closed circuit. Operational conditions under-
Thermal Solar Systems and Components running the dew point within the collector for prolonged
● EN 12976 and EN V 12977 periods are not permitted! This can occur for example,
when collectors are integrated in the brine circuit of a heat
Electrical Work, Potential Equalization, Lightning pump.
Protection
● DIN EN 62305 Overheat Protection
● VDE 0185 part 305 For roof heating centrals and when 4 or more EURO coll-
● DIN VDE 0100 part 540 ectors with anti reflective glass are installed vertically, the
● VDE 190 “Technical Information Solar Thermal Systems – Setup,
● DIN 18382 Commissioning and Maintenance” must be followed to
(Other regulations may apply, depending on your region, avoid damage to the solar circuit.
country or territory).
Especially the pipes in the lower parts of the building must Preventing Frost Damage
be connected electrically conductive, conforming to stan- After pressure testing and flushing, collectors cannot be
dards. The collector installation must be professionally completely emptied. Make sure that no pure water re-
integrated with an existing or new lightning protection mains in collector during risk of frost!
system.
Empty Collector on Roof
Snow and Wind Loads After being installed on the roof, unfilled collectors should
Comply with local regulations and norms related to snow not be exposed to the sun for more than a few days. Other-
and wind loads, within the EU to EN 1991-1-4 (Wind Ac- wise thermal stress on gaskets can result in damage. Alter-
tions) and EN 1991-1-3 (Snow Loads). If you have questi- natively postpone the installation of gaskets to just before
ons related to structural conditions and planning, please filling the solar circuit.
contact our technical department for information. We offer
comprehensive planning support on a project base. Maintenance
For maintenance notes and additional information about
Work on Roofs setup and operation of the collector field, please refer to
Make sure to observe country and territory regulations re- the technical information “Solar Thermal Systems”.
lated to roof works and roof sealing standards as well as
professional codes for plumbing work.
The installation process must reflect the on-site conditions
as well as applicable rules, regulations and accident pre-
vention procedures. Installers must be qualified and - whe-
re applicable - licensed to work on roofs.

94 EN-XXX_EURO-C20-L20-In-Roof-Slate_MA-100902-1WA10143
1.5 Pre Installation Notes
● Risk of burns at collector connections as soon as unco-
vered collector is exposed to the sun (figure 3).
● Danger of open injuries when working with sharp
edged metal sheets and components!
● Remove protective plastic caps from connections befo-
re collector is exposed to the sun. Risk of melting and
damage to absorber!
● Remove glass protection PE-LD film before commenci-
ng installation work! (figure 4).

1.6 Recycling Note
At the end of the long operational lifetime, the valuable
Figure 2 Do not expose collector covered with protective film to rain. materials of the installation should be recycled in an en- 1.1
vironmentally sound manner. If recycling is not possible,
Wagner & Co will take the scrap material back.

Figure 3 Risk of burns: Collector connections heat up during solar ir-
radiation.

Figure 4 Remove glass protection film before installing collector!

EN-XXX_EURO-C20-L20-In-Roof-Slate_MA-100902-1WA10143 95
2. Scope of Supply
2.1 Basic Set

2

6

5
1

3
4

7

8
10
9

12

16

14

15

13

Figure 5 Components of basic set 11

Table 1 Scope of Supply, Basic Set (Part. no. 192 010 70) Table 1, continued
Fig. no. Component Qty Part no. Flat gasket ½" (for no. 4 and 5) 6 190 201 52
1 Flashing sheet, upper left 1 819 721 62 Solder fitting ½"-18 mm
2 801 90
(for no. 4)
2 Flashing sheet, upper right 1 819 721 64
Felt nails (for no. 12) 35 188 53
3 Wooden support 2 819 920 46
Self tapping screw 4 x 35
4 Collector connection hose 2 130 26 26 819 501 86
(for no. 3 and 8)
5 Collector interconnection hose 1 130 000 10
Self tapping screw 5 x 120
4 819 501 88
6 Foam rubber sealing tape 3 819 450 20 (for no. 3)

7 Cellular rubber sealing tape 2 110 101 23 Sheet metal screw with washer,
4 819 501 87
5x25 (for no. 3)
8 Collector fixing clip 4 190 102 15
Silicone sealant 1 120 100 20
9 Side panels, plain tile / slate 28 819 720 99
9a Side panels, welsh sl. (not shown) 18 819 721 01
Sets for plain tiles and slates (except welsh slates) are
10 Silicone T-profile 1 819 721 50
delivered with the same number of side panels (no. 9).
Cladding corners, lower left 819 720 95 The actually required number depends on the roofing
11 1
(2-parts) 819 721 06
and slate size.
Cladding corners, lower right 819 720 98
12 1
(2-parts) 819 721 07
13 Cladding panel, lower left 1 819 720 96
14 Cladding panel, lower right 1 819 720 97
15 Collector holder, lower side 4 819 721 03
16 Retainer clip, lower side 4 819 721 02

96 EN-XXX_EURO-C20-L20-In-Roof-Slate_MA-100902-1WA10143
2.2 Extension Set

4

3

1

7
2

6
5

1.1

9

8

10

Figure 6 Components of extension set

Table 2 Scope of Supply, Extension Set (Part no. 192 010 72)
Fig. no. Component Qty Part no.
1 Flashing sheet, upper side 1 819 721 63
2 Wooden support 1 819 920 46
3 Collector interconnection hose 1 130 000 10
4 Foam rubber sealing tape 2 819 450 20
5 Cellular rubber sealing tape 1 110 101 23
6 Collector fixing clip 2 190 102 15
7 Silicone T-profile 1 819 450 10
8 Cladding panel, lower side 1 819 720 96
9 Collector holder, lower side 2 819 721 03
10 Retainer clip, lower side 1 819 721 02
Flat gaskets ½" (for no. 3) 2 190 201 52
Felt nails 10 188 53
Self tapping screws 4 x 35
12 819 501 86
(for no.‘s 2 and 6)
Self tapping screws 5 x 120 mm
2 819 501 88
(for no. 2)
Sheet metal screw with washer
2 819 501 87
4.5 x 25 (for no. 2)

EN-XXX_EURO-C20-L20-In-Roof-Slate_MA-100902-1WA10143 97
3. Installation Field Preparation
To warrant permanence of the installation, various prere- ● For best results properly utilize the flexible space below
quisites have to be fulfilled: the collector (distance to lower tile row between 60 and
● For plain tile (or similar) roofings on laths, a waterproof 100 mm).
and diffusion reducing film or sarking with at least 24 Leave the existing roof battens in place as supporting
mm counter-lathing must be present to assure proper construction, and affix the additional laths required for the
ventilation. If proper backside ventilation cannot be installation according to the dimensions given in figure 7
provided via ridge and eaves, a venting tile must be in- and 8. All laths that are part of the collector supporting
stalled, approx. 90 cm above and below the collector structure must be solidly screwed onto the rafters (min.
field (see also figure 8, lower part). screws 4x70).
● For roofings with slates on solid wood boards, an unda- The installation field between the cladding elements (figu-
maged diffusion proof sarking must be placed, and roof re 8 A) has to extend for at least 35 mm above the collector
vents should be integrated approx. every 90 cm. field. The collector field should be positioned so that the
● Keep a distance of at least 1m between collectors and side claddings can be comfortably cut to size.
roof components or extensions like vents, turrets, chim-
neys or roof windows that emit humid air. Otherwise Table 3 Installation Dimensions [mm]
additional humidity might enter the collector vents at No. of Coll. Width, collector field Width installation field A
the collector frame. 1 Collector 1215 1285
● There should be at least 2 to 3 rows of roof tiles above
2 Collectors 2435 2505
and below the collector field (dep. on tile size).
● The roof tile row above the collector should extend for 3 Collectors 3655 3725
at least 100 mm over the upper flashing sheets. If requi- 4 Collectors 4875 4945
red, the roof tiles have to be cut to size.

A

26
33
23
58
21
18

60
-1
00

35

Figure 7 Dimensions for installation field and position of installation laths. Choose lath strength according to the strength of existing laths.
Additionally required laths are highlighted in grey (5 pieces); Length of lath ≥ A (installation field width).

98 EN-XXX_EURO-C20-L20-In-Roof-Slate_MA-100902-1WA10143
1.1

1
2
3 6

4

5

Figure 8 In-roof installation longitudinal cut (upper image) and cross-ection (lower image).
1 Roof battens; 2 Counter battens; 3 Sarking; 4 Rafter; 5 Diffusion proof film; 6 Venting space

Solar sensor Solar sensor Solar sensor

Figure 9 Vertical orientation for two, three and max. four collectors in serial connection.
Connection of more than four units by combination of parallel and serial connection.

EN-XXX_EURO-C20-L20-In-Roof-Slate_MA-100902-1WA10143 99
4. Installation

Figure 10 Tools for installation: folding rule, drilling machine, Phillips- Figure 11 Pipe lead with sarking membrane: make a T-shape cut into
Bit PZ 2 and 3, open spanner sizes 16, 19, 24, hammer, cutter knife, the sarking, lead through the connection hose and close cuts with ap-
silicone gun (where required angle grinder with stone cutter). propriate tape.

1

2
00
x3
ma

00
x1
ma

Figure 12 Place two collector holders per collector on roof batten and Figure 13 Insert silicone T-profile between collectors. Alternately
fix each with 2 self tapping screws 4 x 35 (max. 100 mm dist. from coll- pushing and pulling eases work. Then push collectors towards each
ector edge, and max. 300 mm from rafter) (1). Then place the collectors other until flush.
with approx. 8 mm spacing (2).

Figure 14 Screw on upper collector fixing clip at both collector edges Figure 15 Apply thin layer of silicone seal between wings of T-profile
with 2 self tapping screws 4 x 35 each at max. 100 mm distance from and collector frame. Shorten projections of T-profile to approx 2 cm
collector corner and 200 mm from the next rafter. on each side.

100 EN-XXX_EURO-C20-L20-In-Roof-Slate_MA-100902-1WA10143
1.1
Figure 16 Connect collectors. Use 2nd wrench to secure connection Figure 17 Connect collectors to solar circuit. Later check for leak tight-
and avoid damage. ATTENTION: risk of burns at connections during ness! ATTENTION: risk of burns at connections during solar irradiation!
solar irradiation!

Figure 18 Slip rubber seal over cable, insert solar sensor into sensor Figure 19 Position wooden support along collector and fasten with
sleeve; close opening with rubber seal and lead cable through roof. 4 x 35 and 5 x 120 self tapping screws.

2

1

Figure 20 Cut tiles below collector to size, if required. Afix with self Figure 21 Afix retainer clips for lower cladding panel (1), then fold
tapping screws 4 x 35. onto tile (2) .

EN-XXX_EURO-C20-L20-In-Roof-Slate_MA-100902-1WA10143 101
2

3 1

Figure 22 Insert the two pieces of the corner wedge into deeper Figure 23 Insert side panel in lower groove of collector frame, place
groove at the collector (1 + 2) and slide together (3). seam between tile and collector and fold vertical sheet flat onto roofing
(see arrow).

1 2

Figure 24 Attach the corner piece and cut off above batten (1), then Figure 25 Alongside the side panels, the tiles may have to be narro-
fix with felt nails (2). wed. Drill holes into very narrow tiles and afix with screws.

Figure 26 Place following panels as in figures 22 and 23, adjust along Figure 27 Cover sheet fitting with a tile. Then alternately install panels
upper edge of the next batten and nail on. and tiles from bottom to top in the same way.

102 EN-XXX_EURO-C20-L20-In-Roof-Slate_MA-100902-1WA10143
1.1
Figure 28 Insert lower cladding panel. Figure 29 Fix lower cladding panel with retainer clips.

Figure 30 Glue cellular rubber tape to upper collector edge. Figure 31 Push upper left flashing sheet to collector. The flashing
sheet must lock into the upper groove of the frame (see details).

2

3

1

Figure 32 Additional flashing sheets are connected by sticking them Figure 33 Push upper flashing sheets to collector corners (1), nail onto
together. battens (2) and adjust standing up sheet section at the corners as de-
scribed before.

EN-XXX_EURO-C20-L20-In-Roof-Slate_MA-100902-1WA10143 103
Figure 34 Afix black foam rubber strip along the upper edge. Figure 35 Fix every flashing sheet with two sheet metal screws (with
washer).

Figure 36 Completed EURO in-roof installation on plain tile roof with rounded tiles.

Subject to modifications, errors excepted · © Wagner & Co, 2010 · www.wagner-solar.com
104 WAGNER & CO · Zimmermannstraße 12 · D-35091 Cölbe/Marburg · ☎
+49 (0) 64 21 80 07-0 · Fax 80 07-596
INSTALLATION INSTRUCTIONS

EURO C20/L20 In-Roof Installation
for Pantile Roofing (version 2010)

1.1

Figure 1 EURO roof integration on pantile roof

Content
1. General Safety Notes . . . . . . . . . . . . 106
1.1 Symbols . . . . . . . . . . . . . . . . . . 106
1.2 Norms and Regulations . . . . . . . . . . . 106
1.3 Qualification of the Installer . . . . . . . . . 106
1.4 Intended Use and Application . . . . . . . . 106
1.5 Pre Installation Note . . . . . . . . . . . . . 107
1.6 Recycling Note . . . . . . . . . . . . . . . 107
2. Scope of Supply . . . . . . . . . . . . . . 108
● For roof pitch > 20° 2.1 Basic Set . . . . . . . . . . . . . . . . . . 108
● Weather proof integration thanks to aluminum cladding 2.2 Extension Set . . . . . . . . . . . . . . . . 109
panels and aluminum skirting 3. Installation Field . . . . . . . . . . . . . . 110
● Pipe connections protected under upper cladding 4. Installation . . . . . . . . . . . . . . . . . 112

Solar Thermal / Solar Collectors EN-XXX_EURO-C20-L20-In-Roof-Pantile_MA-100503-1WA10141 105
1. General Safety Notes 1.3 Qualification of the Installer
1.1 Symbols Setup, installation and proper commissioning of the solar
installation must be carried out by authorized profession-
The following symbols are used throughout these instruc- als. Non-compliance renders the warranty void.
tions and must be adhered to:

1.4 Intended Use and Application
DANGER of possibly serious personal injury Proper Outdoor Storage of Collectors
Remove protective film, and lay down collectors with glass
pane up. Avoid direct ground contact (e.g. underlay square
timber). Avoid scratches on glass panes by using spacers
WARNING against material damage. between collectors (e.g. wooden laths). When leaning col-
lectors against walls or similar, use a minimum inclination
of 15° and apply spacers. Do not use cardboard as under-
liner. If incorrectly stored, humidity can enter the collec-
NOTE as additional information tors through the air vents. Storing collectors in plastic film
package can damage the glass surface (see figure 2).

1.2 Norms and Regulations Scope and Limitations of Application
The collector is intended for the application in solar ther-
The standards and regulations applicable at the instal- mal installations for hot water preparation and space heat-
lation location must be adhered to. In absence of other ing support. As operating mediums water (attention – risk
regulations we recommend to follow the following norms: of freezing!) or an appropriate water-glycol mixture can
be used in a closed circuit. Operational conditions under-
Thermal Solar Systems and Components running the dew point within the collector for prolonged
● EN 12976 and EN V 12977 periods are not permitted! This can occur for example,
when collectors are integrated in the brine circuit of a heat
Electrical Work, Potential Equalization, Lightning pump.
Protection
● DIN EN 62305 Overheat Protection
● VDE 0185 part 305 For roof heating centrals and when 4 or more EURO col-
● DIN VDE 0100 part 540 lectors with anti reflective glass are installed vertically, the
● VDE 190 “Technical Information Solar Thermal Systems – Setup,
● DIN 18382 Commissioning and Maintenance” must be followed to
(Other regulations may apply, depending on your region, avoid damage to the solar circuit.
country or territory.)
Especially the pipes in the lower parts of the building Preventing frost Damage
must be connected electrically conductive, conforming to After pressure testing and flushing, collectors cannot be
standards. The collector installation must be profession- completely emptied. Make sure that no pure water re-
ally integrated with an existing or new lightning protection mains in collector during risk of frost!
system.
Empty Collector on Roof
Snow and Wind Loads After being installed on the roof, unfilled collectors should
Comply with local regulations and norms related to snow not be exposed to the sun for more than a few days. Other-
and wind loads, within the EU to EN 1991-1-4 (Wind Ac- wise thermal stress on gaskets can result in damage. Alter-
tions) and EN 1991-1-3 (Snow Loads). If you have ques- natively postpone the installation of gaskets to just before
tions related to structural conditions and planning, please filling the solar circuit.
contact our technical department for information. We offer
comprehensive planning support on a project base. Maintenance
For maintenance notes and additional information about
Work on Roofs setup and operation of the collector field, please refer to
Make sure to observe country and territory regulations re- the technical information “Solar Thermal Systems”.
lated to roof works and roof sealing standards as well as
professional codes for plumbing work.
The installation process must reflect the on-site condi-
tions as well as applicable rules, regulations and accident
prevention procedures. Installers must be qualified and -
where applicable - licensed to work on roofs.

106 EN-XXX_EURO-C20-L20-In-Roof-Pantile_MA-100503-1WA10141
1.5 Pre Installation Notes
● Risk of burns at collector connections as soon as uncov-
ered collector is exposed to the sun (figure 3).
● Danger of open injuries when working with sharp
edged metal sheets and components!
● Remove protective plastic caps from connections be-
fore collector is exposed to the sun. Risk of melting and
damage to absorber!
● Remove glass protection PE-LD film before commenc-
ing installation work! (figure 4).

1.6 Recycling Note
At the end of the long operational lifetime, the valuable
Figure 2 Do not expose collector covered with protective film to rain. materials of the installation should be recycled in an en- 1.1
vironmentally sound manner. If recycling is not possible,
Wagner & Co will take the scrap material back.

Figure 3 Collector connections heat up during solar irradiation.

Figure 4 Remove glass protection film before installing collector!

EN-XXX_EURO-C20-L20-In-Roof-Pantile_MA-100503-1WA10141 107
2. Scope of Supply
2.1 Basic Set

2

17

5 10
1

3

4

7 11
8
12
18

6

9
14

15

13

Figure 5 Components of basic set

Table 1 Scope of Supply, Basic Set (Order No. 192 010 63) Table 1 continued
Fig. No. Component Qtty Order No. 15 Supporting lath 1205 mm 2 190 102 18
1 Flashing sheet, upper left 1 819 721 43 16 Supporting lath 200 mm 1 190 102 19
2 Flashing sheet, upper right 1 819 721 45 17 Roof tile supporting bar 2 819 721 57
3 Wooden support 2 819 920 53 Flat sealing gasket ½"
6 190 201 52
(for no. 4 and 5)
4 Collector connection hose 2 130 26
Solder fitting ½"-18 mm (for no. 4) 2 801 90
5 Collector interconnection hose 1 130 000 10
Felt nails (for no. 12) 12 188 53
6 Foam rubber sealing tape 7 819 450 20
Self tapping screws 4 x 35
7 Cellular rubber sealing tape 2 110 101 23 12 819 501 86
(for no. 3 and 8)
8 Collector fixing clip 4 190 102 15
Self tapping screw 4 x 70
10 819 500 55
9 Side panels, left 1 819 721 49 (for no. 15 and 16)

10 Side Panels, right 1 819 721 50 Self tapping screw 5 x 120 (for
4 819 501 88
no. 3)
11 Silicone T-profile 1 819 450 10
Sheet metal screw 4.5 x 25
12 Sheet fixing clips 10 181 060 00 4 819 501 87
(for no. 1 and 2)
13 Cladding panel, lower left 1 819 721 51 Drilling screw 4.3 x 13 with
4 819 501 85
14 Cladding panel, lower right 1 819 721 53 gasket (for no. 13 u. 14)

108 EN-XXX_EURO-C20-L20-In-Roof-Pantile_MA-100503-1WA10141
2.2 Extension Set

1.1

Figure 6 Components of extension set

Table 2 Scope of Supply, Extension Set (Order No. 192 010 60)
Fig. no. Component Qtty. Order no.
1 Flashing sheet, top 1 819 721 44
2 Wooden support 1 819 920 53
3 Collector interconnection hose 1 130 000 10
4 Foam ruber sealing tape 2 819 450 20
5 Cellular rubber sealing tape 1 110 101 23
6 Collector fixing clip, top 2 190 102 15
7 Silicone T-profile 1 819 450 10
8 Sheet fixing clip 2 181 060 00
9 Cladding panel, lower 1 819 721 52
10 Supporting lath 1205 mm 1 190 102 18
11 Roof tile supporting bar 1 819 721 57
Flat sealing gasket ½" (for no. 3) 2 190 201 50
Felt nails (for no. 8) 2 188 53
Self tapping screws 4 x 35 (for no. 2 u. 6) 8 819 501 86
Self tapping screws 4 x 70 (for no. 10) 5 819 500 55
Self tapping screws 5 x 120 (for no. 2) 2 819 501 88
Sheet metal screw 4.5 x 25 (for no. 1) 2 819 501 87
Drilling screw 4.3 x 13 with gasket (for no. 9) 2 819 501 85

EN-XXX_EURO-C20-L20-In-Roof-Pantile_MA-100503-1WA10141 109
3. Installation Field
To warrant permanence of the installation, various prereq- Leave the existing roof battens in place as supporting
uisites have to be fulfilled: construction, and affix the additional laths required for the
● A waterproof and diffusion reducing foil with at least 24 installation according to the dimensions given in figure 7
mm counter-lathing must be present to assure proper and 8.
ventilation. If proper backside ventilation cannot be Ideally determine the width of the collector field in such a
provided via ridge and eaves, a venting tile must be in- way that on one side the spacing between collectors and
stalled, approx. 90 cm above and below the collector roofing is approx 15 mm. On the other side cut tiles to fit.
field (see also figure 8, lower part).
● Keep a distance of at least 1m between collectors and Table 3 Dimensions for Installation [mm]
roof components or extensions like vents, turrets, chim- No. of collectors Width of collector Width of installation
neys or roof windows that emit humid air. Otherwise ad- field field (A)
ditional humidity might enter the collector vents at the 1 Collector 1215 1245
collector frame.
● There should be at least 2 rows of roof tiles above and 2 Collectors 2435 2465
below the collector field. 3 Collectors 3655 3685
● The roof tile row above the collector should extend for
4 Collectors 4875 4905
at least 100 mm over the upper flashing sheets. If re-
quired, the roof tiles have to be shortened.
● For best results properly utilize the flexible space below
the collector (distance to lower tile row between 60 and
130 mm).

A

26
45
24
52
21
11

60
-1
30

15

0
10

Figure 7 Dimensions for installation field and position of installation laths. Choose lath strength according to the strength of existing laths.
Additionally required laths are highlighted in grey (5 pieces); lath length = A (width of installation field);
Width of installation field =n x collector width + (n-1) x 5 mm (collector spacing) + 2 x 15 mm (distance from side).

110 EN-XXX_EURO-C20-L20-In-Roof-Pantile_MA-100503-1WA10141
26
20
-2
69
0

21
51

26
1.1
45 24
52
21
11

60
-13
0

1
2
3 6

4

5

Figure 8 In roof installation longitudinal section (upper drawing) and cross section (lower drawing).
1 Roof batten, 2 Counter lathing, 3 Sarking, 4 Rafters, 5 Low diffusion foil, 6 ventilation space

Solar sensor Solar sensor Solar sensor

Figure 9 Vertical orientation for two, three and max. four collectors in serial connection.
Connection of more than four units by combination of parallel and serial connection.

EN-XXX_EURO-C20-L20-In-Roof-Pantile_MA-100503-1WA10141 111
4. Installation

Figure 10 Tools for installation: folding rule, drilling machine, Phillips- Figure 11 Pipe lead with sarking membrane: make a T-shape cut into
Bit PZ 2 and 3, open spanner sizes 16, 19, 24, hammer, cutter knife, the sarking, lead through the connection hose and close cuts with ap-
silicone gun (where required angle grinder with stone cutter). propriate tape.

1
2

Figure 12 1. Affix supporting laths with self tapping screws 4x70, ends Figure 13 Insert silicone T-profile between collectors. Alternately
projecting approx. 100 mm 2. Place Collectors (approx. 8 mm dis- pushing and pulling eases work. Then push collectors at each other
tance between collectors). until flush.

Figure 14 Screw on upper collector fixing clip on both collector edges Figure 15 Apply thin layer of silicone seal between wings of T-profile
with 2 self tapping screws 4 x 35 each. and collector frame. Shorten projections of T-Profile to approx 2 cm
on each side.

112 EN-XXX_EURO-C20-L20-In-Roof-Pantile_MA-100503-1WA10141
1.1
Figure 16 Connect collectors. Use 2nd wrench to secure connection Figure 17 Connect collectors to solar circuit. Later check for leak tight-
and avoid damage. ATTENTION: risk of burns at connections during ness!
solar irradiation!

Figure 18 Slip rubber seal over cable, insert solar sensor into sensor Figure 19 Position wooden support along collector and fasten with
sleeve; close opening with rubber seal and lead cable through roof. 4 x 35 and 5 x 120 self tapping screws.

Figure 20 Insert lower aluminum panels into the deeper rear groove Figure 21 Affix the lower cladding panels with 2 self tapping screws
of the collector frame (see highlighted details). Proceed the same way 4.2 x 16 each (with washer gasket).
with the corner edges.

EN-XXX_EURO-C20-L20-In-Roof-Pantile_MA-100503-1WA10141 113
1

Figure 22 Insert the pushed together side panels into the rear groove Figure 23 Push lower panel section downwards, until it snaps into the
of the frame in such a way that the upper notch (1) snaps into the col- latch of the lower corner.
lector frame. The panel sheet must lay evenly on the battens.

Figure 24 Nail on side panels with 4 fixing clips. Figure 25 Affix cellular rubber tape to the upper collector edge.

Figure 26 Push upper left flashing sheet into left side panel. The upper Figure 27 Additional flashing sheets are connected by sticking them
locking bar of the flashing sheet must latch into the outer groove of the together.
collector frame (see highlighted details).

114 EN-XXX_EURO-C20-L20-In-Roof-Pantile_MA-100503-1WA10141
1.1
Figure 28 Fix upper flashing sheets on the batten using 2 fixing clips. Figure 29 Position the roof-tile supporting bar by vertically shifting it,
so that later the tile row will be aligned with the tiles on the sides. Then
affix with metal strips to roof battens.

Figure 30 Affix black foam rubber tape along the fold to the upper Figure 31 In storm prone regions secure every flashing sheet with 2
flashing sheet. additional sheet metal screws each.

Figure 32 Affix foam rubber tape along the folds of the side panels Figure 33 Roof tiles above the collectors may have to be cut to size.
as well. Drill holes into the pieces that have to be attached, and screw to bat-
tens.

EN-XXX_EURO-C20-L20-In-Roof-Pantile_MA-100503-1WA10141 115
Figure 34 Along the side panels, the retaining edge of the roofing tiles Figure 35 Remove adhesive protection foil from lower aluminum skirt-
may have to be removed; lateral size reduction may be required. Fixa- ing and press to surface of tiles.
tion if necessary via drilling (wire or screw).

Figure 36 Readily installed EURO in roof installation on pantile roof.

Subject to modifications, errors excepted · © Wagner & Co, 2010 · www.wagner-solar.com
116 WAGNER & CO · Zimmermannstraße 12 · D-35091 Cölbe/Marburg · ☎
+49 (0) 64 21 80 07-0 · Fax 80 07-596
EN TECHNICAL INFORMATION

Roof Bracket Kits (Top)
ES DOCUMENTATIÓN TÉCNICA

Kit de anclajes (Top)
IT INFORMAZIONI TECHNICHE

Kit di fissaggio al tetto (Top)
1.1

P A2 Hv Top 200

86 - 126

41

102
162

140
P Alu Hv Top
60

81- 117
45 45

136 - 192

39-60

98
40 mm
182

Printed on 100 % recycled paper
Mounting systems XB-INT_Roof-bracket-kits-Top_TI-100804-11205Z00 117
P Stv KF Top 220

60

145

40

100
162 40
mm

220

60

145

40

100
162 40
mm

63
BS A2 Hv Top
50 40

78 - 105
120 - 140

11

229
358 mm

BS Stv KF Top

50

BS Stv IRL Top 98
11

229
358

mm

118 XB-INT_Roof-bracket-kits-Top_TI-100804-11205Z00
SF Stv Top

50

88

229
358
mm

PM A2 Hv Top 220 1.1

60

110-140
145-175

22
120

192
40 mm

M A2
40
55 - 95
85

372

232

mm

K A2 Hv

40

55 - 95 85

a

a b
K A2 Hv 180 180 25-45
b
K A2 Hv 200 200 45-65
12 K A2 Hv 300 300 50-150 mm

XB-INT_Roof-bracket-kits-Top_TI-100804-11205Z00 119
TR

25

t min 0,63
38 35

min 25
mm

KK 55

40
65 65

KS
150

40 55
57 - 72

mm

Subject to modifications, errors excepted · © Wagner & Co, 2010 · www.wagner-solar.com
120 WAGNER & CO · Zimmermannstraße 12 · D-35091 Cölbe/Marburg · ☎ +49 (0) 6421 80 07-0 · Fax 80 07-22
EN INSTALLATION INSTRUCTIONS

Roof Bracket Kit BS/SF (Top)
BS A2 Hv / BS Stv KF / BS Stv IRL / SF Stv
ES INSTRUCCIÓNES DE MONTAJE

Kit de anclajes BS/SF (Top)
BS A2 Hv / BS Stv KF / BS Stv IRL / SF Stv
IT ISTRUZIONI DI MONTAGGIO 1.1
Kit di fissaggio al tetto BS/SF (Top)
BS A2 Hv / BS Stv KF / BS Stv IRL / SF Stv

EN
DE Important Notes
● The dimensioning of the mounting system (number
of mounting triangels) should be specifically carried
out for each individual project, following the specified
structural engineering standards and regulations.
● Prerequisite for the proper application always is a solid
mounting base that can accommodate the occurring
forces (weight, wind and snow loads).

ES Observaciones importantes
● Hay que realizar el dimensionamiento del sistema de
montaje (número de anclajes de tejado etc.) orientado
al proyecto y conforme con las normas.
● Un subsuelo de fijación adecuado que puede absorber
las fuerzas surgiendas (fuerza de peso, carga eólica y
por nieve) es siempre condición de utilización

IT Informazioni importanti
● Il dimensionamento del sistema di montaggio (numero
delle staffe di ancoraggio, portata delle guide etc) deve
essere eseguito considerando le norme rispettive.
● Deve essere garantita un‘adeguata sottostruttura per il
montaggio cioè di una sottostuttura in grado di sosten-
ere le forze (peso proprio, carico di vento e di neve) che
si verranno a creare

Printed on 100 % recycled paper
Mounting systems XB-INT_Roof-bracket-kit-BS-SF-Top_MA-100804-1WA20080 121
63

50 40

78 - 105
120 - 140

11

229
358 mm

BS Stv KF Top

50

BS Stv IRL Top 98
11

229
358

mm

SF Stv Top

50

88

229
358
mm

122 XB-INT_Roof-bracket-kit-BS-SF-Top_MA-100804-1WA20080
BS

SF

1.1

BS BS

5

5

BS

5

SF SF

XB-INT_Roof-bracket-kit-BS-SF-Top_MA-100804-1WA20080 123
BS A2 Hv

b

a

Dimensions only for module installation
Medidas sólo para la montaje de módulos
Dimensioni per l‘installazione dei moduli
a min 900 mm
b max 450 mm

Subject to modifications, errors excepted · © Wagner & Co, 2010 · www.wagner-solar.com
124 WAGNER & CO · Zimmermannstraße 12 · D-35091 Cölbe/Marburg · ☎+49 (0) 6421 80 07-0 · Fax 80 07-22
EN INSTALLATION INSTRUCTIONS

Roof Bracket Kit K A2 Hv
ES INSTRUCCIÓNES DE MONTAJE

Kit de anclajes K A2 Hv
IT ISTRUZIONI DI MONTAGGIO

Kit di fissaggio al tetto K A2 Hv
1.1
EN
DE Important Notes
● The dimensioning of the mounting system (number
of mounting triangels) should be specifically carried
out for each individual project, following the specified
structural engineering standards and regulations.
● Prerequisite for the proper application always is a solid
mounting base that can accommodate the occurring
forces (weight, wind and snow loads).

ES
FR Observaciones importantes
● Hay que realizar el dimensionamiento del sistema de
montaje (número de anclajes de tejado etc.) orientado
al proyecto y conforme con las normas.
● Un subsuelo de fijación adecuado que puede absorber
las fuerzas surgiendas (fuerza de peso, carga eólica y
por nieve) es siempre condición de utilización

IT Informazioni importanti
● Il dimensionamento del sistema di montaggio (numero
delle staffe di ancoraggio, portata delle guide etc) deve
essere eseguito considerando le norme rispettive.
● Deve essere garantita un‘adeguata sottostruttura per il
montaggio cioè di una sottostuttura in grado di sosten-
ere le forze (peso proprio, carico di vento e di neve) che
si verranno a creare.

h
K A2 Hv 180 25-45 mm
K A2 Hv 200 45-65 mm
K A2 Hv 250 90-110 mm
h
K A2 Hv 300 100-150 mm

Printed on 100 % recycled paper
Mounting systems XB-INT_Roof-bracket-kit-K-A2-Hv_MA-100804-12211A00 125
∅ 15 mm

∅ 9 mm

m
35m
m in

S9 S15 S19 9 mm 15 mm

S19
45Nm

S9

80 mm

1

2

S15
30 Nm

Dimensions only for module installation
Medidas sólo para la montaje de módulos
b Dimensioni per l‘installazione dei moduli

a min 900 mm

b max 450 mm
a

Subject to modifications, errors excepted · © Wagner & Co, 2010 · www.wagner-solar.com
126 WAGNER & CO · Zimmermannstraße 12 · D-35091 Cölbe/Marburg · ☎+49 (0) 6421 80 07-0 · Fax 80 07-22
EN INSTALLATION INSTRUCTIONS

Roof Bracket Kit P (Top)
P Alu Hv / P A2 Hv / P A2 / P Stv KF / PS Stv
ES INSTRUCCIÓNES DE MONTAJE

Kit de anclajes P (Top)
P Alu Hv / P A2 Hv / P A2 / P Stv KF / PS Stv
IT ISTRUZIONI DI MONTAGGIO 1.1
Kit di fissaggio al tetto P (Top)
P Alu Hv / P A2 Hv / P A2 / P Stv KF / PS Stv

EN
DE Important Notes
● The dimensioning of the mounting system (number
of mounting triangels) should be specifically carried
out for each individual project, following the specified
structural engineering standards and regulations.
● Prerequisite for the proper application always is a solid
mounting base that can accommodate the occurring
forces (weight, wind and snow loads).

ES Observaciones importantes
● Hay que realizar el dimensionamiento del sistema de
montaje (número de anclajes de tejado etc.) orientado
al proyecto y conforme con las normas.
● Un subsuelo de fijación adecuado que puede absorber
las fuerzas surgiendas (fuerza de peso, carga eólica y
por nieve) es siempre condición de utilización

IT Informazioni importanti
● Il dimensionamento del sistema di montaggio (numero
delle staffe di ancoraggio, portata delle guide etc) deve
essere eseguito considerando le norme rispettive.
● Deve essere garantita un‘adeguata sottostruttura per il
montaggio cioè di una sottostuttura in grado di sosten-
ere le forze (peso proprio, carico di vento e di neve) che
si verranno a creare

Printed on 100 % recycled paper
Mounting systems XB-INT_Roof-bracket-kit-P-Top_MA-100804-1WA20079 127
P A2 Top
200

50

134

41
101
161
40
mm

P A2 Hv Top 200

50

86 - 126

145 - 185

41

102
40 mm
162

140
P Alu Hv Top
60

81 - 117
45 45

136 - 192

39 - 60

98
40 mm
182

220

60

145

40

100
162 40
mm

128 XB-INT_Roof-bracket-kit-P-Top_MA-100804-1WA20079
PS Stv Top 220

60

145

40

100
162 40

1.1

5m
m
5m
m

XB-INT_Roof-bracket-kit-P-Top_MA-100804-1WA20079 129
b
a

Dimensions only for module installation
Medidas sólo para la montaje de módulos
Dimensioni per l‘installazione dei moduli
a min 900 mm
b max 450 mm

Subject to modifications, errors excepted · © Wagner & Co, 2010 · www.wagner-solar.com
130 WAGNER & CO · Zimmermannstraße 12 · D-35091 Cölbe/Marburg · ☎ +49 (0) 6421 80 07-0 · Fax 80 07-22
EN INSTALLATION INSTRUCTIONS

Roof Bracket Kit PM A2 Hv (Top)
ES INSTRUCCIÓNES DE MONTAJE

Kit de anclajes PM A2 Hv (Top)
IT ISTRUZIONI DI MONTAGGIO

Kit di fissaggio al tetto PM A2 Hv (Top)
1.1
EN
DE Important Notes
● The dimensioning of the mounting system (number
of mounting triangels) should be specifically carried
out for each individual project, following the specified
structural engineering standards and regulations.
● Prerequisite for the proper application always is a solid
mounting base that can accommodate the occurring
forces (weight, wind and snow loads).

ES
FR Observaciones importantes
● Hay que realizar el dimensionamiento del sistema de
montaje (número de anclajes de tejado etc.) orientado
al proyecto y conforme con las normas.
● Un subsuelo de fijación adecuado que puede absorber
las fuerzas surgiendas (fuerza de peso, carga eólica y
por nieve) es siempre condición de utilización

IT Informazioni importanti
● Il dimensionamento del sistema di montaggio (numero
delle staffe di ancoraggio, portata delle guide etc) deve
essere eseguito considerando le norme rispettive. 110-140
● Deve essere garantita un'adeguata sottostruttura per il 145-175
montaggio cioè di una sottostuttura in grado di soste-
nere le forze (peso proprio, carico di vento e di neve)
che si verranno a creare.
22
120

192
mm

220

60

40 mm

Printed on 100 % recycled paper
Mounting systems XB-INT_Roof-bracket-kit-PM-A2-Hv-Top_MA-100804-1WA20083 131
Tx40

S15
30 Nm

5m
m
5m
m

Dimensions only for Module installation
Medidas sólo para la montaje de módulos
Dimensioni per l'installazione dei moduli
a min. 900 mm
b max. 450 mm

Subject to modifications, errors excepted · © Wagner & Co, 2010 · www.wagner-solar.com
132 WAGNER & CO · Zimmermannstraße 12 · D-35091 Cölbe/Marburg · ☎+49 (0) 6421 80 07-0 · Fax 80 07-22
Solar Storage Cylinders and Components

It is common sense knowledge that a system can only be as good as its indivi-
dual components. Although our collectors are among the world‘s most effective
Flat Plate Collectors, they would still be inefficient if the provided energy were
lost in other components of the solar energy system. Wagner & Co therefore
understood early that well designed hydronic components – especially effici-
ent solar storage cylinders – are a key element for an optimized solar yield. The
storage cylinders designed by Wagner & Co therefore are specifically developed
and dimensioned for various applications and system sizes, ranging from highly
effective small-scale single family home hot water systems to large scale resi-
dential installations with heating support and commercial applications (hotels,
campgrounds, car washes, livestock farms etc.). The programme includes fresh-
water cylinders, small single storage solutions, large buffer tanks and tank-in-tank
combi-cylinders, the latter combining the advantages of both worlds in one
compact unit. Special attention is paid to reducing energy loss for example with 1.2
the new high-quality polyester fiber fleece insulation introduced for some sto-
rage lines in 2010 or the new CONVECTROL III convection brake. Our series of
auxiliary electric immersion heaters and tank-installation kits for freshwater units
and solar circulation units complement the Wagner & Co storage line.

■ ECO Solar Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

■ ECOplus Solar Cylinder – Technical Information . . . . . . . . . . . . . . . . . . . . . . . . 147

■ ECOplus Solar Cylinder – Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . 155

■ TERMO Combi Cylinder – Technical Information . . . . . . . . . . . . . . . . . . . . . . . . 163

■ TERMO Combi Cylinder – Installation Instructions . . . . . . . . . . . . . . . . . . . . . . 169

■ RATIO Buffer Cylinder – Technical Information . . . . . . . . . . . . . . . . . . . . . . . . . . 177

■ RATIO Buffer Cylinder – Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . 185

■ Convection Brake CONVECTROL III. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

■ Thermostatic Mixing Valve BM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

■ Electrical Immersion Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

133
TECHNICAL INFORMATION / INSTALLATION INSTRUCTIONS

ECO Solar Cylinder

1.2

Figure 1 ECO solar cylinder

Content
1. Technical Information . . . . . . . . . . . . 136 4. Startup . . . . . . . . . . . . . . . . . . 146
2. General Safety Guidelines . . . . . . . . . . 141 5. Advice for the User . . . . . . . . . . . . . 146
3. Installation . . . . . . . . . . . . . . . . . 142 6. Problem-Solving . . . . . . . . . . . . . . 146
3.1 Preparations . . . . . . . . . . . . . . . . 142 7. Maintenance . . . . . . . . . . . . . . . . 146
3.2 Setting Up Cylinder . . . . . . . . . . . . . 142
3.3 Installing Domestic Water Unit . . . . . . . . 142
3.4 Connecting Solar Circuit . . . . . . . . . . . 144
3.5 Connecting Auxiliary Heating Unit . . . . . . 144
3.6 Connecting Temperature Sensor . . . . . . . 145

Solar Thermal / Solar Cylinder EN-XXX_ECObasic-Solar-Cylinder_TI-MA-0810xx-11204500 135
1. Technical Information
Contents of Kit
The ECO solar cylinder is supplied standing and screwed
down on a pallet. The insulation is glued on, fixed to the
cylinder and cannot be removed. It is surrounded by a pro-
tective PVC hull with additional soft PU insulation foam.
Before beginning the installation, please check that all
components presented in table 3 are present.

D

O

H G

N

F
M
E
J

C K

L
I
B
A

Figure 2 ECO solar cylinder / installation measurements (drawing not to scale)

136 EN-XXX_ECObasic-Solar-Cylinder_TI-MA-0810xx-11204500
Table 1 Technical Data ECO 200 ECO 300 ECO 400 ECO 500
Part no. 130 140 81 130 140 82 130 140 83 130 140 84
Volume domestic water (litre) 199 286 394 498
Auxiliary heating volume above connection D (litre) 64 99 127 168
Maximal allowed pressure (bar) 10
Maximal allowed temperature (°C) 95
Total height including insulation (mm) H 1232 1697 1660 1783
Tilting height including insulation (mm) 1396 1827 1816 1952
Diameter including insulation and PVC hull (mm) D 610 610 710 760
Total weight including insulation (kg) approx. 85 approx. 114 approx. 166 approx. 215
Cold and hot water connections 1" male 3 (mm) A/G 110 / 1257 110 / 1722 127 / 1685 128 / 1808
Circulation return ¾" male 3 (mm) 880 1045 1065 1125
Access flange, opening diameter = 110 mm (mm) l 272 272 278 285
Socket for electric heating coil 1 ½" female 3 (mm) K 705 770 770 870
Anode 1 ¼" female 3 O Size complies with DIN 4753
Analogue thermometer (mm) N 919 1384 1325 1441
Collector temperature sensor positioning (mm) L 330 380 420 445 1.2
Auxiliary heating temperature sensor pos. (mm) M 930 1146 1166 1225
Performance Data
Insulation material (glued-on PU foam; PVC wrapping with zipper Thickness of insulation, incl. PVC-hull: 55 mm
Heat losses according to DIN EN V 12977 -3 1 W/K < 2.3 < 2.8 < 3.2 < 3.6
Solar heat exchanger (High quality steel St 37-2; welded to the cylinder)
Solar flow / return connections ¾" male 3 (mm) B/C 180 / 630 180 / 580 205 / 635 205 / 685
Heat exchanger surface area (m²) 0.8 1.2 1.5 1.8
Maximum allowed pressure (bar) 16
Maximum allowed temperature (°C) 110
Volume of water contained in exchanger (litre) 5.7 7.5 9.4 11.3
Recommended collector area (m²) up to 5 m² up to 7 m² up to 9 m² up to 13 m²
Auxiliary heating heat exchanger (high quality steel St 37-2; welded to the cylinder)
Performance index NL / related boiler output2 -/kW 1.4 (10) 1.8 (14) 2.1 (17) 2.5 (21)
Continuous performance 2 litre/h 460 605 720 830
Aux. heat. flow / return conn. ¾" male 3 (mm) J/F 780 / 990 945 / 1215 965 / 1261 1020 / 1325
Heat exchanger surface area (m²) 0.6 0.8 1.0 1.2
Maximum allowed pressure (bar) 16
Maximum allowed temperature (°C) 110
Volume of water contained in exchanger (litre) 3.8 5.0 6.3 7.5
Remarks:
1 Calculations according to DIN EN V 12977 – T3: Temperature of entire cylinder = 60 °C, ambient temperature = 15 °C;
2 Calculations according to DIN 4708, relative to auxiliary heat exchanger, if temperature of the cylinder is set at 60 °C,
the supply temperature is 45 °C, the boiler flow and return temperatures are 80 °C and 60 °C;
3 Threads according to DIN ISO 228-1, flat tightening

EN-XXX_ECObasic-Solar-Cylinder_TI-MA-0810xx-11204500 137
Table 2 Accessories Part Numbers
ECO connection set “combi”, 4 x combi fitting ¾" x 18, 2 x combi fitting 1", cap and seals Part no. 139 000 66
Cylinder safety unit S22 including safety valve 10 bar, one-way valve,
– 22 mm soldericonnection fittings Part no. 130 100 56
– ¾" connection with screw thread Part no. 139 000 35
CORREX-UP anode, maintenance-free corrosion protection, 230V, consumption 2.5 kWh per year Part no. 130 101 26
Circulation pump BW 152, including ball valves and non-return valve, connection ½" M or solder to 15 Part no. 160 102 14
mm copper pipe
Electric immersion heater
1.5 kW / 230V / 260 mm; 1.5 kW: Part no. 139 001 45
3 kW / 230V / 400V / 360 mm; 3 kW: Part no. 139 001 42
6 kW / 400V / 550 mm; 6 kW: Part no. 139 001 43
9 kW / 400V / 600 mm. 9 kW: Part no. 139 001 44
Check cylinder diameter before ordering!
Thermostatic mixer, up to 55 °C
– 22 mm solder connection fittings Part no. 100 89
– ¾" connection with screw thread Part no. 150 300 75
Replacement sensor fixing clamp 139 00 118

Recommended System Solutions
Some system solutions including locations of connections
are shown in the following schematics.

P1 : Solar circuit pump Solar collector
P2 : Auxiliary heating pump for cylinder
P3 : Heating pump
BWM : Thermostatic mixing valve
Solar control
SUNGO

Central heating circuit

P1
CIRCO

P3
ECObasic

P2
Oil or gas
boiler

Domestic hot water BWM

Domestic water

Figure 3 Solar thermal system for domestic hot water preparation. Single storage system with ECO cylinder and auxiliary heating by gas or oil
boiler. The SUNGO controls the speed of the solar circuit pump depending on solar irradiation and cylinder temperature. This ensures continuous
operation, optimized yield and reduced electricity consumption.

138 EN-XXX_ECObasic-Solar-Cylinder_TI-MA-0810xx-11204500
Solar collector

Solar control

SUNGO
P1 : Solar circuit pump
V1 : 3-Way valve
(auxiliary domestic hot water
heating OR central heating)
BWM : Thermostatic mixing valve

Boiler

P1

CIRCO
Central heating circuit

ECObasic
V1

1.2
Domestic hot water BWM

Domestic water

Figure 4 Solar thermal system for domestic hot water preparation. Single storage system with ECO storage cylinder and a wall-mounted con-
densing gas boiler. Switching between central heating and auxiliary domestic hot water heating is by means of a 3-way valve in the flow pipe.
The central heating controller is in charge of the control. The SUNGO controller controls solar circuit pump speed depending on solar irradiation
and cylinder temperature. This ensures continuous operation, optimized yield and reduced electricity consumption.

Solar collector

Solar control
SUNGO

P1 : Solar circuit pump
BWM : Thermostatic mixing valve

ECObasic

P1
CIRCO

Electrical
immersion
heater

Domestic hot water BWM

Domestic water

Figure 5 Solar thermal system for domestic hot water preparation. Single storage system  with ECO cylinder and immersion heater. During
periods of insufficient solar radiation, the upper third of the cylinder can be heated with an electric immersion heater. The integrated thermostat
can be set to the required temperature. The SUNGO controller controls the solar circuit pump speed depending on solar irradiation and cylinder
temperature. This ensures continuous operation, optimized yield and reduced electricity consumption.

EN-XXX_ECObasic-Solar-Cylinder_TI-MA-0810xx-11204500 139
Solar collector
P1 : Solar circuit pump
P2 : Auxiliary heating pump for cylinder
P3 : Heating pump Solar control
V1 : 3-Way valve
(cylinder heating)

SUNGO
BWM : Thermostatic mixing valve

Central heating circuit

P1

CIRCO
P3
ECObasic

P2
Oil or gas
boiler

V1

Domestic hot water BWM

Domestic water

Figure 6 Solar thermal system for domestic hot water preparation. Serial connection of the ECObasic cylinder and a single-coil cylinder. The
solar energy is distributed optimally by the SUNGO control. Supply is taken from the priority-heated solar cylinder. Auxiliary heating of the solar
cylinder is done by oil, gas, etc. The single-coil cylinder serves as a buffer storage pre-heating the water. This type of pipe layout can be used in
connection with an existing cylinder.

140 EN-XXX_ECObasic-Solar-Cylinder_TI-MA-0810xx-11204500
2. General Safety Instructions
The following safety advice is deemed to protect against System Environment
dangers that can arise from improper handling of devices, Please ensure that
whether knowingly or unknowingly. ● you comply with local regulations about the connection
We distinguish between general advice which we refer to of the solar cylinder to the local water supply,
on this page and special advice which can be found in the ● you comply with rules and regulations about electrical
texts of the instructions. Watch out for the symbols! connections,
● you comply with installation requirements of the pro-
ducers of auxiliary heating equipment (oil boiler etc.),
● you comply with rules about lightning protection as
Danger of personal injury laid-out in EN 60335-1.
Live-threatening electrical shocks, burns, bruising and oth- We recommend connection of solar installations with aux-
er health hazards are possible during installation. iliary heating as shown in system solutions figure 3 to 6
(Chapter 1: Technical Information).

2.3 Standards and Codes
Risk of material damage Please comply with all standards and codes related to the
This symbol indicates that damage may be done to com- integration of the solar storage tank in drinking water and
ponents of the solar circuit or the function of the same may heating circuits as well as the electric connections of con-
be impaired seriously. Please make sure that you follow trollers. If you install auxiliary heating, please ensure com-
the installation procedure step by step as instructed. pliance with the installation requirements of the equip- 1.2
ment manufacturer.
● Declaration of compliance with EC rules: The ECO so-
lar cylinder has been designed and produced following
Additional information current EC regulations. The cylinder complies with all
This symbol points to practical advice and tricks of the conditions of DIN 4753-1. Corrosion protection accord-
trade which will make the installation and operation of the ing to DIN 4753-3 / 4753-6 is achieved through enamel-
solar circuit easier. ling and the use of anodes.
● Water supply to the cylinder must be done according
2.1 Qualification of the Installer to local regulations
Setting up, installation and commissioning of the ECO ● The safety valve must be checked regularly to be free of
solar storage cylinder must be carried out by a qualified obstructions and in functioning condition.
installer. ● If required, water filters must be installed in the supply
Please note that the guarantee is void, if the system has not to the cylinder.
been properly installed and commissioned, as certified by ● The solar storage cylinder ECO, if installed according
a qualified person in the commissioning protocol. to instructions, does fulfil the requirements of EN 806-1
and prEN 1717:1999.
2.2 Use and Application ● Electric connections must be carried out according to
Function local codes and standards.
The solar storage tank ECO is a suitable cylinder for the bi-
valent heating of domestic hot water. Water can be heated 2.4 Local Regulations
through the integrated solar heat exchanger. The auxiliary ● Please note that it is mandatory to observe local and
heating of the upper third of the cylinder can be accom- country regulations and legislation, which may divert
plished by an external heating device via the secondary from current European standards.
coil or an optional electric immersion heater.

Operational Limits
Please note that the ECO storage cylinder must not be
placed outside and must be operated within the limita-
tions specified in table 1. The installation location must
never be exposed to frost and connecting pipes must be
kept as short as possible. The cylinder is only suitable for
the storage of drinking water and must be secured against
pressures above 10 bar by installing a safety valve.

EN-XXX_ECObasic-Solar-Cylinder_TI-MA-0810xx-11204500 141
3. Installation 2

3.1 Preparations
The cylinder must be placed in a frost-safe location and
must be connected with short pipe lengths to the taps.
Please ensure that the placement area is dry and has suf-
ficient structural carrying capacity.

Required Materials
In order to complete the installation of the ECO solar cyl-
inder the following materials are required:
● Pipe connections to fit 1" and ¾" male cylinder connec- 8
tions (see table 1) 4
● Thermostatic mixer (optional)
● Safety valve unit for the cold-water feed (optional).

Required Tools
Tools for pipe connections, pipe wrench, adjustable span-
ner, Phillips screw driver
5
3.2 Setting up Cylinder
Please observe the following when setting up the cylinder:
● Start with the removal of the transport protection (4) and
(5) 7 1
● Remove lid (2), thermometer (8), 1 ½" plug (6) and the
flange cover (7) and sensor fixing clamps (9); put in a
safe place.
● Remove pallet fixing and carry cylinder to its final posi-
tion. There are circular indentations near the top and
bottom of the insulation which can serve as grips.
● Caution! Weight up to 120 kg (264 pounds)! Knocks
and banging can cause damage to the enamel coating 3
on the inside!
● Turn cylinder until connections face the wall to which 6
the pipes will be fixed. Allow enough space for comfort-
9
able working.
Figure 7 Removal of transport packaging
Table 3 Scope of Supply (see fig. 7) Quantity
Wooden pallet (3) 700 X 700 mm 1
ECO steel cylinder with foam insulation (1),
1
fixed with 3 bolts to pallet
PVC-Cover with zip (wrapped around cylinder) 1
Thermometer (8), supplied loose 1 3.3 Fitting of Domestic Water Unit
Polystyrene cover (7) for flange, in place 1 Hot and Cold Domestic Water
Polystyrene cover (2) for top of cylinder,
Cold and hot water connections must be carried out ac-
1 cording to the rules and regulations of your local water
in place, black
supplier. We recommend the connection as shown in fig-
Plug (6), male 1 ½" galvanized steel,
1 ure 8.
to close immersion heater inlet, fixed to pallet
● Connect the safety unit (2) to the cold water supply.
Transportation cover, bubble wrap (4) and plastic
1 each ● The hot water line should be shaped to create a siphon
cover (5)
in order to prevent convection movement inside the
Sensor fixing clamp 2 pipe work (length of legs at least 200 mm). If the water
pressure is sufficient, a non-return valve can be used
instead.
● Ensure that there is no shut-off valve between cylinder
and safety valve. The safety valve must be designed to
release pressure at the maximum operating pressure. If
supply pressure is likely to be above 10 bar, a pressure
reducer must be installed between water meter and cyl-
inder. When the cylinder is heating up, water may drip
from the safety valve which should be guided to a drain.
Alternatively an expansion vessel suitable for drinking
water can be installed.

142 EN-XXX_ECObasic-Solar-Cylinder_TI-MA-0810xx-11204500
● It is absolutely necessary to fit a thermostatic mixer, as Circulation
temperatures during the summer months can reach ● If circulation is required (21) then the return should be
up to 95 °C on the hot water outlet (5). There is seri- taken from close to the tapping point (22). The circu-
ous danger of scalding! The thermostatic mixer can be lation pump (23) should govern circulation according
connected via a T-connection (3) between safety unit to water temperature at a measuring point (24) at the
and cold-water inlet of the vessel (4). If no thermostatic furthest away tap and with a timer.
mixer is fitted, maximum vessel temperature must be
limited to 65 °C at the solar controller.
● Close the immersion heater inlet (8) with the 1½" plug
(7) using hemp and compound. Alternatively you may fit
a 1½" electrical immersion heater. Please read details in
the section about auxiliary heating.
● Retighten bolts around flange cover (9) to ensure leak-
age-free operation, and close off again with cover.

5

1.2

10

26
26

23 B
6

8

7

24

25
22
21 9
23

4

3

1
2

Figure 8 Drinking water connections at the ECO cylinder (1) Supply, (2) Safety unit including connectors, (3) T-junction, (4) Supply inlet includ-
ing connectors, (5) Hot water outlet including connectors, (6) Thermostatic mixer, (7) Plug, (8) 1½" inlet for electrical immersion heater, (9) Ac-
cess flange, (10) Siphoning of hot water connection, (21) Circulation line, (22) Hot water tap, (23) Circulation pump, (24) Temperature sen-
sor, (25) Copper T-junction, (26) Circulation connection of vessel.

EN-XXX_ECObasic-Solar-Cylinder_TI-MA-0810xx-11204500 143
● We recommend that the circulation, if required, is car-
ried out as shown in figure 8 and should be returned to
the T-junction (25) in the cold feed to the thermostatic
mixer valve. If, however, the circulation is done by a non-
regulated pump, then the return should be taken to the
circulation inlet (26) of the vessel.
● Please note, that circulation can cause significant loss
of heat.

Pressure Test of Drinking Water Circuit
Please carry out a pressure test after all drinking water
pipes and fittings are connected. Close taps after filling
cylinder with water, and check all connections and joints.
1
3.4 Connecting Solar Circuit 2
● Connect flow pipe of solar circuit to the top of the so- 3
lar (lower) coil (4) and the return pipe to the bottom of
same (5).
● Push 1" nut (3) over copper pipe, then solder on flange
fitting or fix screw thread fitting (2), then put washer into 4
place (1) and tighten connection.

Warning: On sunny days it is quite possible that storage
temperatures of up to 95 °C or higher can be reached in 5
the solar circuit. There is serious danger of scalding!

Figure 9 Connecting solar circuit

3.5 Auxiliary Heating
The auxiliary heating of drinking water can be done in vari-
ous ways. Figure 10 shows the connection options:
● If auxiliary heating with the help of an oil, gas, etc. boiler
is required, then this device should be connected to the
auxiliary heating coil in the top of the vessel (5). Against
common practice we recommend the following circuit-
ry: Connect the return pipe of the heating device (1)
with the fitting (2, 3, 4) to the top of the auxiliary heating
coil. Connect the flow pipe (7) in the same way to the
bottom of the auxiliary heating coil (8). Please observe 6 5
the instructions of the supplier of your heating device. 4
3
2
● As an option, an auxilliary electric heater (9) is avail- 1
able that can be installed in the 1½" socket on the side.
8
Please observe instructions supplied with the heating
device.
7
If no immersion heater is fitted, the inlet must be closed 10
with the supplied 1½" plug (11).
9
11

Figure 10 Connections for auxiliary heating devices.
(1) Flow pipe, (2, 3, 4) Fittings, (6) Auxiliary heating coil, top connec-
tion, (7) Return pipe, (8) Auxiliary heating coil, bottom connec-
tion, (9) Immersion heater, (10) 1½" inlet, (11) P lug.

144 EN-XXX_ECObasic-Solar-Cylinder_TI-MA-0810xx-11204500
3.6 Installing Temperature Sensors
● Please install the temperature sensor of the solar con-
troller (1), as illustrated in figure 11, by inserting it into
the sensor tube (2) at the bottom half of the cylinder. If
auxiliary heating is done by an oil, gas, etc. boiler, then
insert the sensor of the boiler-control device (3) into the
sensor tube (4) at the top half of the cylinder.
● Connect the sensor cable (1) of the lower cylinder sen-
sor to the solar controller. Connect the cable (3) of the 4
upper cylinder sensor to the auxiliary heating. Please
5
observe the instructions of the supplier. 3
● Temperature checking can be done for the top half of
the cylinder by reading the thermometer (5).

1 2 2

1

1.2

Figure 11 Connections of the temperature sensors:
(1) Solar control sensor, (2) Sensor tube, lower half, (3) Auxiliary heat-
ing sensor, (4) Sensor tube, upper half, (5) Thermometer.

EN-XXX_ECObasic-Solar-Cylinder_TI-MA-0810xx-11204500 145
4. Start Up 5. Advice for the User
Setting up, installation and startup must be carried out by Please note that the storage vessel should be inspected
a qualified installer. and maintained at least every two years by a qualified per-
son. We recommend a service contract.
4.1 Checking the System
After fitting all components, please carry out the following
checks: 6. Troubleshooting
● Are all components fitted correctly?
● Are all safety units installed? Is the 10 bar safety valve It is quite possible that problems occur despite careful
fitted? If necessary, is a pressure regulator fitted and can production methods and installation. Some possibilities
it be closed off from the vessel? are the following:
● Are all fittings and connections safe and tight?
● If present – were all electrical connections made to re- Leaks
quired standards? Leaks can be caused by insufficient pressure on wash-
● Are the temperature sensors in the correct positions? ers which are made out of best quality material but may
Do the controllers display reasonable values? change their density during the first few months of opera-
tion and may lead to dripping. It may be necessary to re-
4.2 Rinsing of the System tighten those fittings after a few weeks.
In spite of careful production methods, some residues of
the processes, including metal slack, may remain inside
the pipes, the vessel and the heat exchangers. These can 7. Maintenance and Care
cause problems during operation of the system and may
lead to damage. Therefore, the system must be rinsed be- The cleaning and maintenance of the solar vessel should
fore permanent operation starts. Also filtering/retaining be carried out every two years.
devices should be installed at convenient points in the sys- ● If a magnesium anode is fitted, this should be checked
tem, as even later some production residues may become and replaced if necessary.
dislodged and may need to be removed. ● Check for visible leakage of the vessel and fittings.
Check for lime-scale or moisture at the insulation. If nec-
4.3 Setting the Solar and Auxiliary Heating Controller essary retighten fittings.
The temperature limitation of 95 °C for the solar storage ● Release air from the vessel if necessary.
vessel must never be exceeded. Please ensure that the set- ● Remember to replace the washers if fittings were
tings are correct. opened. Flange washers may not seal properly if re-
used.
4.4 Filling, Air Release and Pressure Check ● Check safety valves, make sure they are not obstructed.
To avoid water damage, please make sure that before ● Cleaning of the vessel and checking of the system
filling and startup of the system, all openings are closed, should be carried out every 2 years.
connected or fitted with the proper fittings and mountings
(e.g. openings for emptying, venting, circulation, aux. heat- Periodical maintenance must be certified in the Mainte-
ing). nance Protocol by a qualified person in order to render
Carry out a pressure test after the system has been com- the warranty agreement valid.
pletely installed. Be aware that the test pressure must not
exceed 10 bar. In order to release air from the cylinder,
open one hot-water tap until water appears and reaches a
steady flow. While checking pressure is applied, check all
fittings and connections for leaks. If necessary retighten.
Heat the content of the storage cylinder, for example by
switching on the boiler, and keep checking the pressure.
Before reaching maximum allowed level, the safety valve
must come into operation to release pressure.

4.5 Final Check Protocol
The correct startup of the system must be certified by a
qualified person in the Final Check Protocol, in order ren-
der the warranty agreement valid.

Subject to modifications, errors excepted · © Wagner & Co, 2010 · www.wagner-solar.com
146 WAGNER & CO · Zimmermannstraße 12 · D-35091 Cölbe/Marburg · ☎ +49 (0) 64 21 80 07-0 · Fax 80 07-596
TECHNICAL INFORMATION

ECOplus Solar Cylinder

Minimized Heat Loss
due to convection brakes in the pipe connections, the
new close-fitting, 100-mm thick PU soft foam jacket insula-
tion, 150-mm thick and close fitting lid insulation and 50-
mm thick floor insulation; with robust polystyrene shell.

Connection option for CONVECTROL III – the Effective
Convection Brake
Technically optimized barriers separate the water cooled
in the pipes safely from the hot storage tank water. This
reduces heat losses at the pipe connections by up to 50 %. 1.2
Optional Mounting Kit for Solar Station
to minimize piping effort - time and space saving and neat
appearance.

Double Corrosion Protection
with durable high-quality enamel coating and magne-
sium protection anode.

Quick Installation
with flat-sealing screw connections, combi-fittings,
sensor terminal block, removable heat insulation with
hook closure; horizontal attachment of the connection
pipes made possible by CONVECTROL III.

Stable Thermal Stratification
due to slim column design with stabilized cold water inlet
and hot water outlet flows.

Lime-Scaling Resistant Heat Exchanger
made from plain pipe coils for solar and aux. heating cir-
cuit, energetically optimized design, generously sized.

High Quality
Only high-grade and environmentally friendly materials
are used. Manufactured and inspected in accordance with
DIN 4753. Options for circulation pipe and electrical im-
mersion heater. With cleaning flange.

Figure 1 The ECOplus solar cylinder with volumes of 300, 400, 500
and 750 liters.

Solar Thermal / Solar Cylinder EN-XXX_ECOplus-Solar-Cylinder_TI-100126-11204200 147
1. Technical Data
Table 1 Solar Cylinder
Feature 300 l 400 l 500 l 750 l
Part no. 130 140 01 130 140 11 130 140 21 130 140 31
Total volume 313 l 391 l 490 l 755 l
Auxiliary heating volume 135 l 165 l 220 l 310 l
Max. operational pressure 10 bar
Max. operational temperature 95 °C
Usable hot water volume with indicated aux.
138 l 162 l 215 l 260 l*2
heating temp. in liter at 50 °C *1
Coefficient of performance NL /
1.6 / 10 kW 2.4 / 12.5 kW 3.5 / 13.5 kW 5.7 / 17.5 kW
assoc. boiler output *1
Jacket insulation 100 mm PU soft foam with polystyrene shell,
Thermal insulation
lid 150 mm and floor 50 mm PU soft foam
Heat loss rate acc. to DIN ENV 12977-3 *3, *4 2.59 W/K 2.88 W/K 3.29 W/K 4.38 W/K
Anode, 1¼" F * 6 Protective magnesium anode CORREX-UP
Tilted dimension, without insulation 1600 mm 1680 mm 1800 mm 2050 mm
Weight, without insulation 130 kg 170 kg 230 kg 295 kg
Solar circuit heat exchanger * 5

Surface area / volume 1.4 m² / 8.5 l 1.7 m² / 10.0 l 1.9 m² / 12.0 l 2.6 m² / 15.0 l
Pressure loss at 40 °C / volume flow 2 mbar / 200 l/h 3 mbar /280 l/h 5 mbar / 360 l/h 7 mbar / 400 l/h
Max. operational pressure 16 bar
Max. recommended collector area 8 m² 10 m² 13 m² 18 m²
Aux. heating heat exchanger *5
Surface area m² / volume 1.0 / 6.0 l 1.2 / 7.0 l 1.3 / 8.0 l 1.7 / 10.0 l
Pressure drop at 60 °C / volume flow 4 mbar / 450 l/h 6 mbar / 550 l/h 11 mbar / 700 l/h 26 mbar / 1000 l/h
Max. permissable operational pressure 16 bar
Max. continuous power output *1 10 kW 13 kW 14 kW 18 kW

6 1
Table 2 Cylinder Connections (figures 3 to 6)

No.* Connection type
2 1 Cold water connection 1" M
2 Solar circuit return 1¼" M
5 3 Solar circuit flow 1¼" M
3
4 Flange for screw-in immersion heater 1½" IG
5 Auxiliary heating flow 1¼" M (recommended)
6 Circulation connection ¾" M
7 Aux. heating return 1¼" M (recommended)
8 Hot water connection 1¼" M
9 Bleeder ½" IG
4
10 Cleaning flange DN 100

Figure 2 Top view of ECOplus solar cylinder * Numbers for image details from figures 3 to 6.
1 Bleeder ½" M; 2  Protective anode 1¼" F; 3 Pipe connections
(compare table 2); 4 Sensor connection terminal; 5 Cleaning flange
DN 100; 6 Hoisting lug

148 EN-XXX_ECOplus-Solar-Cylinder_TI-100126-11204200
Ø 750

9

8

7

6

5

4

1695
Ø 550

1545
3

1370
1270
1050
930
1.2
803

10
675

2

1
280

205
110

Figure 3 ECOplus 300, vertical section with dimensions; pipe connections are on the right side G 1¼"; for legend see table 2.

Ø 800

9

8

7

6

5

Ø 600 4
1775
1625

3
1440
1340
1115
1000
845

10
690

2

1
296

220
120

Figure 4 ECOplus 400, vertical section with dimensions; pipe connections are on the right side G 1¼"; for legend see table 2.

EN-XXX_ECOplus-Solar-Cylinder_TI-100126-11204200 149
Ø 850

9

8

7

6

5

1885
Ø 650 4

1735
1541
3

1440
1120
1020
863

10
705

2

1
380

225
130

Figure 5 ECOplus 500, vertical section with dimensions; pipe connections are on the right side G 1¼"; for legend see table 2.

Ø 950

9

8
7

6

5

4
Ø 750
2132

3
1982
1763
1663
1373
1223
1092

10
960

2

1
380

280
157

Figure 6 ECOplus 750, vertical section with dimensions; pipe connections are on the right side G 1¼"; for legend see table 2.

150 EN-XXX_ECOplus-Solar-Cylinder_TI-100126-11204200
2. Accessories
Table 3 Accessories Prod. No.

ECOplus connection kit combi STANDARD
139 000 55
with combi fittings
ECOplus connection kit combi CONVECTROL III
139 002 07
with combi fittings
CIRCO 6 cylinder mounting kit 150 302 01
Cylinder height adjustment unit, (up to
139 000 16
500 l-cylinder 3 pcs., for 750 l 4 pcs. required)
Cylinder safety subassembly, S22 acc. to DIN 1988 130 100 56
CORREX-UP impressed current anode 130 101 26
Protective magnesium anode (for ECOplus 300) 130 101 27
Protective magnesium anode
130 101 65
(for ECOplus 400 u. 500)
Electrical screw-in immersion heater 1.5 kW (230 V) 139 001 45
Electrical screw-in immersion heater 3 kW
139 001 42
(230/400 V)
Electrical screw in immersion heater 6 kW (400 V) 139 001 43 1.2
EHK 9 kW (400 V) 139 001 44
DHW mixer with insulation shells 150 303 50
3 way actuator diverter valve (1" M) 160 101 44

Convection Brake CONVECTROL III
The patent protected design of the easy to install com-
ponent separates the water that cooled down in the Figure 8 Storage cylinder with attached cylinder mounting kit and
connection pipes from the hot storage content. The CIRCO 6 solar circulation unit.
CONVECTROL III reduces heat losses at storage connec-
tions by up to 50 %. This results in a reduction of total an-
nual storage heat losses by 10 to 20 %.

Figure 7 CONVECTROL III combined connection set.

EN-XXX_ECOplus-Solar-Cylinder_TI-100126-11204200 151
3. System Solutions - Examples

Figure 9 Solar installation for hot water preparation. Single storage system with solar hot water cylinder ECOplus and auxiliary heating with oil
or gas boiler. This way a continuous operation of the system can be assured, which reduces the electricity consumption of the pump (principle
representation, see figures 3 to 6 for real position of connections).

Figure 10 Solar installation for DHW preparation. Single storage system with solar hot water storage cylinder ECOplus and auxil-
iary heating by oil or gas boiler. The solar installation does not only take over the larger part of the hot water preparation, it also in-
creases the annual use efficiency of the boiler by avoiding the boiler‘s low summer time efficiency for hot water production.

152 EN-XXX_ECOplus-Solar-Cylinder_TI-100126-11204200
1.2

Figure 11 Solar installation for DHW preparation. Serial connection of ECOplus solar cylinder and monovalent hot water storage. The solar en-
ergy is distributed optimally to both cylinders by the SUNGO controller. The solar cylinder is integrated in the form of a draw-off cylinder and is
loaded with priority by the solar controller. The auxiliary heating with oil or gas boiler also is loaded to the solar cylinder. The monovalent cylinder
(only one heat exchanger) serves as preheating tank. This type of layout can be used with an existing hot water cylinder and is characterized by
reduced storage tank and system losses (principle representation, see figures 3 to 6 for real position of connections).

Figure 12 Solar installation for DHW preparation. Single storage system - solar DHW storage cylinder ECOplus and demand regulated auxiliary
heating with oil or gas boiler. The auxiliary domestic water heating is regulated by the boiler controller. The solar controller SUNGO operates the
solar circuit pump speed controlled, depending on solar irradiation and storage tank temperature. This way a continuous operation of the system
can be assured, which reduces the electricity consumption of the pump (principle representation, see figures 3 to 6 for real position of connections).

EN-XXX_ECOplus-Solar-Cylinder_TI-100126-11204200 153
Subject to modifications, errors excepted · © Wagner & Co, 2010 · www.wagner-solar.com
154 WAGNER & CO · Zimmermannstraße 12 · D-35091 Cölbe/Marburg · ☎ +49 (0) 64 21 80 07-0 · Fax 80 07-596
INSTALLATION INSTRUCTIONS

ECOplus Solar Cylinder

Piping Diagram

Hot water consumer

Optional
Backflow CORREX-UP
Optional preventer impressed
circulation current anode
pump
Protective Sensor
Safety valve, 10 bar magnesium connection
anode strip
Hot water connection, 1.2
OT 5/4"

Convection brake

Optional Optional
safety subassembly thermostatic Outlet
mixing valve
Cold water Odor cap
supply Auxiliary heating
Circulation connection, OT ¾" heat exchanger,
Drain pipe Cap OT 5/4"

Optional
immersion Inlet
heater,
IT 1½"

Inlet
Solar
heat exchanger,
OT 5/4"
Plug IT 1 ½"

Outlet

Optional
Cylinder
Optional Drain valve connection kit
Storage tank CONVECTROL III
connection kit with combi fittings

Cold water connection, OT 1"

Figure 1 ECOplus solar cylinder sample piping diagram. Components with grey background are optional.

Solar Thermal / Solar Cylinder EN-XXX_ECOplus-Solar-Cylinder_MA-100127-11214200 155
1. Assembly
1.1 Preparation
Please install the solar cylinder ECO plus as depicted in Insulation
the illustrations and take note of the following important The solar cylinder insulation consists of PU foam with a
information first: laminated polystyrene cover layer and hook closure.
The properties of plastics are subject to significant tem-
Convection Brake CONVECTROL perature fluctuations! The higher the ambient tempera-
The convection brakes are included in the CONVEC- ture, the more flexible the PU foam, and due to the shrink-
TROL III solar cylinder connection kit. Please consult the age behavior of the cover layer, these must be applied at
assembly instructions included with the kit. least at room temperature.
As an alternative to the convection brakes, it is also pos- In case of polystyrene, the breakage tendency drops with
sible to use threaded connections (5/4" – 1") or solder a rising temperature.
connections (e.g. 5/4" – 22 mm) with flat gasket seals.
Do not install insulation below 20 °C and allow insulation
Cold and Hot Water Line stored at cold temperatures to reach room temperature
Make sure there is no shutoff between the safety valve before installing.
and the solar cylinder.
The valve must be designed for a blow-off pressure that Solar Cylinder Connections
corresponds to the permissible working overpressure of All connections require flat seals. If raised seals are used,
the cylinder. In case of 10 bar and higher waterline pres- the potable water connections may be subject to corro-
sure, install a pressure reducer behind the water meter. sion.
Water drips from the safety valve when the cylinder is
heated. Collect this water with a siphon funnel and lead
away. Alternatively use a membrane expansion vessel cer-
tified for for use with drinking water.

Service Water Circulation Line
When a service water circulation line has been installed,
the circulation pump must be controlled with a timer and
a thermostat to reduce heat losses. The timer ensures
the pump is operated only during those times when hot
water is needed. The thermostat switches the pump off
whenever the temperature in the circulation line exceeds
30 °C, for example. The described functions are already
integrated in the SUNGO controller. The circulation pump
should have a rather low throughput (max. 600 l/h).
We recommend the circulation pump BW152 (Part no.
160 102 14) with integrated shutoff valve and backflow
preventer as well as the piping depicted in fig. 1.
The circulation return should be integrated between safe-
ty subassembly and cold water supply of the thermostatic
mixing valve to realize a circuit.
If the suggested circulation control with thermostat and
timer cannot be realized because of local circumstances,
apply the circulation line to the connection (¾" M) at the
flange of the drinking water solar cylinder.

156 EN-XXX_ECOplus-Solar-Cylinder_MA-100127-11214200
1.2 Hydraulic Installation

Figure 2 The following tools are required for installing the solar cyl- Figure 3 Open insulation at hook closure, set aside, unscrew solar
inder: Wrench sizes 10, 13, 24, 30, 37, and monkey wrench (or pipe cylinder from pallet, set up at installation location.
wrench).

1.2

Figure 4 Tilt solar cylinder and insert inner section of the floor insula- Figure 5 When installing the convection brakes, insert CONVEC-
tion. If circulation and electrical immersion heater connections are not TROL III in combined connection so that key and slot fit snugly.
utilized, close off with plug or cap.

S 46

S 24

Figure 6 Place gasket between cylinder connection and combined Figure 7 Connect flow and return legs of aux. heating circuit. The inlet
connection. Assure right position when screwing on (TOP marking for the auxiliary heating heat exchanger is at the bottom and the outlet
up!); secure with wrench S24 at the top (recommended).

EN-XXX_ECOplus-Solar-Cylinder_MA-100127-11214200 157
Figure 8 Option: If needed, now install the electrical auxiliary heating. Figure 9 Connect cold water line (with cold water filling and emptying
Please consult the information included with the immersion heater. tap) at the bottom of the solar cylinder.

Figure 10 Option: Install the safety group in the cold water line above Figure 11 Connect hot water line at top of solar cylinder.
the solar cylinder instead of the shutoff, check, and safety valves. No
shutoff between safety subassembly and solar cylinder!

Figure 12 Insert thermostatic mixing valve into hot water line to limit Figure 13 Option: If desired, install hot water circulation pump ac-
temperature. Refer to the markings on the unit for correct connections. cording to the piping diagram and install the pipe sensor as close to
Then insulate pipes. the last hot water tapping point as possible.

158 EN-XXX_ECOplus-Solar-Cylinder_MA-100127-11214200
Table 1 Height of sensor position from floor (mm)
Temperature
ECOplus ECOplus ECOplus ECOplus
sensor
300 400 500 750
Thermost. solar
cylinder bottom
230 245 250 305
sensor
(solar circuit)
Thermost. solar
cylinder top sensor 1100 1170 1255 1490
(aux. heat)

Figure 14 Screw on the temperature sensor for the solar controller
below the terminal bar at the solar cylinder. Observe the positions
given in Table 1.

1.2

Figure 15 Option: Screw CORREX® impressed current anode into Figure 16 Fasten one cable of the CORREX® electronics device to the
socket on lid of solar cylinder. Remove an existing magnesium anode grounding screw and plug the other one into the electrode.
first. No reduction needed with CORREX® 5/4" thread.

Figure 17 Option: Install wall socket and plug in CORREX® electron-
ics device. Green light signals correct operation. When the light flash-
es red consult the operating manual.

EN-XXX_ECOplus-Solar-Cylinder_MA-100127-11214200 159
1.3 Cylinder Insulation
After setting up the solar cylinder and before connecting Please do not use tools or tightening straps and do not
the potable water, circulation, and heating lines, the insu- close the hook closure by force. This could damage the
lation must be applied at the installation location. insulation and diminish its effectiveness.

During Installation:
● Place insulation loosely around solar cylinder and press
into place opposite the row of connections.
● Adjust the insulation by tapping with the flat of your
hand, i.e., tap or stroke from the rear in the direction
of the hook closure until the rows of the hook closure
are lined up properly and can be closed by applying
slight pressure.
● Make sure the heat insulation is tightly fitted to the wall
of the solar cylinder.
● Retighten the hook closure starting at the top until the
heat insulation fits tightly against the cylinder.

2

1

Figure 18 Now place the insulation ring around the bottom of the Figure 19 For cylinders from 500 l: use wire hook to lock left side of
solar cylinder. insulation in place for easier handling.

Figure 20 Close insulation with hook closure. First snap into weakest Figure 21 Insert upper circular insulation panel and attach lid.
position, then tighten alternately.

160 EN-XXX_ECOplus-Solar-Cylinder_MA-100127-11214200
2. Commissioning
● Please observe the instructions in the “Commissioning
the System” manual.
● Setup, installation, and proper commissioning as well
as maintenance of the solar cylinder must be carried
out by an accredited company.
● The cylinder must be installed in a frost-free room with
short lines to the consumer.
● When connecting to water lines, observe and comply
with the corresponding regional and national regula-
tions and guidelines as well as the specifications of
your water utility or provider.
● Observe regional and national regulations and guide-
lines as well as the specifications of your electric utility
company when performing electrical connections.
● A corresponding water filter meeting current technol-
ogy standards is to be installed into the cold water sup- Figure 22 For commissioning, fill solar cylinder with cold water using
ply line. the shutoff valve at the safety group in the cold water supply. Open
cock at the hot water side to allow air to escape.
● The max. temperature in the solar cylinder must not
exceed 90 °C. Make sure the correct settings are set at
the solar controller (max. solar cylinder temperature al- 1.2
ready preset with SUNGO S / SL / SXL) and at the boiler
controller (max. boiler temperature).
● Before filling and commissioning make sure, that all
openings (e.g. filling draining tap, vents, circulation
connections, sleeve for aux. electric heater) are tightly
closed!
● After the initial startup, check all screw connections and
flanges for leaks and retighten as needed.

The correct commissioning must be certified on the ac-
ceptance and inspection record by a technically trained
person to ensure that a warranty claim can be filed should
this become necessary.

Figure 23 Thoroughly flush and vent solar and heating circuit. Please
consult the solar installation’s operating manual – especially concern-
ing frost protection within the solar circuit!

Figure 24 After the initial startup, check all connections (including at Figure 25 Insulate pipes connected to the solar cylinder and press
convection brakes), flanges, and anode screw connection for leaks down insulating tubes firmly onto the insulation of the solar cylinder.
and retighten as needed.

EN-XXX_ECOplus-Solar-Cylinder_MA-100127-11214200 161
3. Maintenance
● The solar system and the solar cylinder must be ser-
viced every 2 years.
● The functionality of the safety valve must be checked
regularly (once or twice a month) by lifting up as out-
lined by DIN 4753 or relevant local regulations. The ex-
haust vent must never be closed or restricted.
● The solar cylinder must be cleaned and serviced at
least every 2 years.
● The protection anode made from magnesium must
be checked after two years and then at regular inter-
vals and replaced by a qualified service technician if
required.

The regular service and maintenance must be certified
on the acceptance and inspection record by a technically
trained person to ensure that a warranty claim can be filed
should this become necessary. Figure 26 Check the factory-installed magnesium protection anode
every two years. Unplug cable and measure current with multimeter.
Inspect and possibly replace if measurement yields less than 0.3 mil-
liampere.

Subject to modifications, errors excepted · © Wagner & Co, 2010 · www.wagner-solar.com
162 WAGNER & CO · Zimmermannstraße 12 · D-35091 Cölbe/Marburg · ☎+49 (0) 64 21 80 07-0 · Fax 80 07-596
TECHNICAL INFORMATION

TERMO Combi Cylinder

Tank-In-Tank System
using solar energy for hot water and heating support. For
integration into the heating circuit as return flow booster
or hydraulic compensator.
Available in two sizes 700 l (160 l domestic water storage)
and 1000 l (230 l domestic water storage).

Flow Flue
for effective potable water heating and to reinforce ther-
mal stratification in the buffer storage.
1.2
Minimal Heat Losses
thanks to tightly fitting, CFC-free 120-mm polyester fiber
fleece jacket insulation, tight 150-mm strong cover lid and
50-/30-mm floor insulation with scratch and impact resis-
tant polystyrene shell.

Optional Convection Brake CONVECTROL III
Technically and hydro dynamically optimized barriers
separate the water that cooled in the pipes safely from
the hot storage tank water.
Heat losses at pipe connections thus are reduced by up
to 50 %.

Optional Mounting Kit for Solar Station
Mounting kit for the solar circuit unit with minimized pipe
work. Time and space-saving, clear visual appearance.

Double Corrosion Protection
with high-quality and durable enamel and magnesium
protection anode (option: maintenance free impressed
current anode).

Quick Installation
with flat-sealing screw connections, sensor terminal strip,
heat insulation with hook ratchet closure; CONVECTROL III
and horizontal installation of the connection pipes.

Stable Thermal Stratification
due to stabilized cold water inlet and inflow brakes in the
buffer storage.

High Quality
thanks to high-grade and environmentally friendly mate-
rials. Produced and inspected in Germany according to Figure 1 The TERMO combi cylinder
DIN 4753 and DIN ENV 12977-3.
Options for circulation line, electrical immersion heater
and cleaning flange.

Solar Thermal / Solar Cylinder EN-XXX_TERMO-Combi-Cylinder_TI-100126-11204400 163
1. Technical Data
Table 1 Technical Data
Ident. 1) Feature TERMO 700 TERMO 1000
Part No. 130 150 07 130 150 10
h/H Total height (with/without insulation)  1805 mm / 1905 mm 2105 mm / 2205 mm
Tilted dimension (without insulation) 1830 mm 2230 mm
d/D Diameter (without/with insulation) 750 mm / 990 mm 800 mm / 1040 mm
Total weight (with insulation) 230 kg 270 kg
Total capacity (without solar heat exchanger) 698 l 982 l
Coefficient of performance NL / assoc. boiler output 1.6 / 15 kW 3.2 / 20 kW
DHW internal cylinder made from high grade steel with high quality enamel acc. to DIN 4753 T3 (St 37-2)
Permissible working overpressure / perm. operating temperature 10 bar / 95 °C
Total capacity / in auxiliary heating area (above P2) 163 l / 108 l 229 l / 161 l
Usable hot water volume 118 l (49 °C) 200 liter (49 °C)
with indicated aux. heating temp. 2) 152 l (60 °C) 256 liter (60 °C)
Cold / hot water connections
A 1775 mm 2085 mm
(stainless steel and brass, OT 1¼" x 45), height 3) 8)
J Cleaning and inspection opening (inner diameter) Ø 115 mm
E Connection for circulation (OT ¾" x 45) 3) 8) Flange
K Brass protection anode acc. to DIN 4753 T6 4) Flange
U Immersion sleeve f. aux. heat. temp. sensor (inner Ø 15 mm, lenght) 550 mm 700 mm
Air vent / ½" IG x 33 for filling tap or manual bleeder
Buffer part made from high grade steel (St 37-2), primed on outside
Permissible working overpressure / perm. operating temperature 3 bar / 95 °C
Net volume (without DHW part and heat exchanger) 535 l 753 l
Auxiliary heating volume (above P2) net 170 l 238 l
Heating buffer volume net (between P2 and P4) net 105 l 162 l
Solar buffer volume (below P4) net 260 l 353 l
O/F Aux. heat flow (P1) / return (P2), (1¼" M x 45) , height
3) 5) 1525 mm / 1100 mm 1840 mm / 1260 mm
L/N Aux. heat flow (P3) / return (P5), (1¼" M x 45) 3) 5), height 1020 mm / 315 mm 1140 mm / 375 mm
M Heat return (P4), (1¼" M x 45) 3) 825 mm 890 mm
Sleeve for electr. immersion heater (1½" F x 40) 3) 6)
I 1100 mm 1260 mm
closed with plug, height
S/Q Emptying / bleeding (½" F x 33 for filling cock, height) 100 mm / 1680 mm 110 mm / 2010 mm
R Flow flue (diameter x height) 500 x 520 mm 540 x 520 mm
T Sensor terminal block, length ca. 1400 mm ca. 1700 mm
Polyester fiber fleece insulation jacket
Insulation jacket / outside cover (polystyrol) 120 mm / 1,3 mm
Cover lid (two parts) 100 + 60 mm
Bottom (two parts) 50 mm / 30 mm
Heat loss rate acc. to DIN EN V 12977-3 7) 9) 2.87 W/K 3.63 W/K
Solar heat exchanger, smooth pipe, made from high grade steel (St 37-2), welded into buffer cylinder
Heat transfer area 2.2 m² 2.4 m²
Permissible working overpressure in bar / max. operation temp. 10 bar / 110 °C
Pressure loss (with indicated volume flow) 7 mbar (400 l/h) 12 mbar (550 l/h)
C/B Solar flow / solar return (1¼" M x 45), height  745 mm / 133 mm 765 mm / 150 mm
Fluid volume of solar heat exchanger 12.9 l 14.1 l

164 EN-XXX_TERMO-Combi-Cylinder_TI-100126-11204400
Legend for Table 1
1) Dimension indications and identifications from figure 2
2) The volume of hot water that can be drawn from the storage at a temperature of 45 °C, when the aux. heating section of the storage was
heated to the indicated aux. heating temperature (at cold water temp. 10 °C), measurements based on DIN ENV 12977-3:2001
3) Pipe thread DIN ISO 228-1 (cyl.), flat-sealing
4) For union assembly (1" F), electr. insulated installation, removable ground wire
5) Connections P2, P4, and P5 equipped with convection brakes
6) Max. immersion length of immersion heater: 630 mm or 650 mm
7) Measurements acc. to test reports of the ITW Stuttgart based on DIN ENV 12977-3:2001
8) Cold water and circulation connection inside the cylinder are made from plastic approved for potable hot water (test acc. to KTW
recommendations)
9) Calculated acc. to DIN EN 12977-3:2001

D
d
J

1.2
E

P0

K
U
P1

T

P2

P3

Q

H
P4
h R
A
O
F
L
M
C I

P5

N B P6
S

Figure 2 Cross section of the TERMO combi cylinder with dimensions marked (see table 1)

EN-XXX_TERMO-Combi-Cylinder_TI-100126-11204400 165
10 1

9
2
8
7
3

Figure 3 Top view of the storage:
6 1 cold water connection; 2 hot water connection; 3 connections at
4 cylinder side (see table 1); 4 flange for immersion heater; 5 protec-
tive anode; 6 connection for circulation; 7 venting flange, external
tank; 8 venting flange, internal tank; 9 receptacle for temperature
5 sensor; 10 cleaning flange

2. Accessories
Table 2 Accessories Prod. No.
Combined connection set standard, CONVECTROL III 139 002 06
Combined connection set standard 139 000 63
Storage height adjustment units (4 pcs. req.) 139 000 16
Electric immersion heater 3 kW 139 001 42
Electric immersion heater 6 kW 139 001 43
Electric immersion heater 9 kW 139 001 44
Cylinder mounting kit CIRCO 6 /6E 150 302 01
CORREX-UP impressed current anode 130 101 18
Protective magnesium anode 130 101 25
Thermostatic water mixer (DHW) with insulation shells 150 303 50
3-way actuator switching valve (1" M) 150 470 13

Convection Brake CONVECTROL III
The patented and easily installed component separates
the water that cooled down in the connection pipes from
the hot water contained in the storage.
The CONVECTROL III can reduce heat losses at the stor-
age connections by up to 50 %. The total annual storage
losses thus can be reduced by 10 % to 20 %. Figure 5 Thermostatic mixer with insulation shell

Figure 4 CONVECTROL III combined connection set. Figure 6 3-way actuator valve

166 EN-XXX_TERMO-Combi-Cylinder_TI-100126-11204400
3. System Solutions – Examples

P1: Solar circuit pump
P2: Heating circuit pump
P3: Pump for domestic water aux. heating
V2: 3-way switching valve, return boost Solar controller Collector field
M1: Heating circuit mixer
BWM: Thermostatic mixing valve
(domestic water)

Hot Water

Cold Water

1.2
Oil- or gas boiler

Figure 7 Solar installation for hot water heating and heating support. Single storage system with combi cylinder TERMO and oil or gas boiler and
a mixed heating circuit (hydronic heating system with pipes and radiators). Potable water is heated in the corrosion-resistant inner container of
the combination cylinder. Solar energy for heating is fed to the return pipe of the heating circuit via the 3-way valve Vr.

P1: Solar circuit pump
V2: 3-way switching valve, return boost
V2: 3-way switching valve,
Solar controller Collector field
heating mode – aux heating
(domestic water)
BWM: Thermostatic mixing valve
(domestic water)

Hot water

Cold water

Gas boiler

Figure 8 Solar installation for hot water heating and heating support. A storage system with combination cylinder TERMO, a gas hot water heater
and hydronic heating circuit. The switching valve V2 for heating mode or hot water heating is located within the flow pipe of the heat source. Solar
energy for heating is fed to the return pipe of the heating circuit via the 3-way valve Vr.

EN-XXX_TERMO-Combi-Cylinder_TI-100126-11204400 167
P1: Solar circuit pump
P2: Boiler circuit pump
P3: Heating circuit pump Solar controller Collector field
M1: Heating circuit mixer
Vm: Thermostatic mixing valve
for keeping the min. return temperature
BWM: Thermostatic mixing valve (domestic water)
Hot water

Cold water

Figure 9 Solar installation for hot water heating and heating support. Single storage system with combination cylinder TERMO, a pellet boiler
and a hydronic mixed heating circuit. The combination cylinder is integrated into the heating system like a hydraulic bypass. The buffer volume
of the TERMO reduces partial load operation and irregular clocking of the pellet boiler.

P1: Solar circuit pump
P2: Heating circuit pump
P3: Pump for domestic water aux. heating
M1: Heating circuit mixer
V2: 3-way switching valve, return boost
V2: 3-way switching valve for oil/gas boiler bypass
Collector field
during solid fuel operation Solar controller
KAG: Boiler connection group
with return flow temperature increase
BWM: Thermostatic mixing valve (domestic water)

Hot water

Cold water

Relay

Solid fuel boiler Oil- or gas boiler

Figure 10 Solar installation for hot water heating and heating support. Single storage system with combi cylinder TERMO, an oil or gas boiler or
a solid fuel boiler. During solid fuel operation mode, the relay RL is used to switch valve Vr to position AB-A, and the entire combination cylinder
is loaded. The oil/gas boiler is then circumvented via valve V3. During oil/gas operation mode and sufficient solar energy, the heating return is
routed through the combi cylinder. To achieve this, the three-way switching valve Vr switches from position AB-B to AB-A. The oil/gas boiler then
has to supply much less heat – or none at all.

Subject to modifications, errors excepted · © Wagner & Co, 2010 · www.wagner-solar.com
168 WAGNER & CO · Zimmermannstraße 12 · D-35091 Cölbe/Marburg · ☎
+49 (0) 64 21 80 07-0 · Fax 80 07-596
INSTALLATION INSTRUCTIONS

TERMO Combi Cylinder

Circulation pump
Hot water Top view TERMO Combi Cylinder

Return-flow
Safety valve 10 bar check valve

HW
Cold water
filling-and-
draining tap
CW
1.2
Safety unit Domestic water mixer

Cold water
feed
Cold water
filling-and-draining tap
Drain pipe for venting

Air trap
Circulation,
HW, CW, ET 1¼"
external thread ¾"

Receptacle
Ø 15 mm
P1
Magnesium anode

Convection brakes

P2
P3
Caps,
Socket for
internal thread 1¼"
electrical heating element
P4

Thermostatic Threaded joints
mixing valve on 22 mm copper pipe

Solar
heat exchanger

P5

Cold water filling-and-draining tap

Figure 1 TERMO Combi Cylinder connection diagram for the system solution example “Return-flow temperature boost”.

Solar Thermal / Solar Cylinder EN-XXX_TERMO-Combi-Cylinder_MA-100127-11214400 169
1. Installation
1.1 Preparation
To install the cylinder, please follow the pictorial instruc- If it is not possible to set up the proposed circulation con-
tions. Prior to installation, it is essential to note the follow- trol with the thermostat and timer, affix the circulation pipe
ing important information: to the connection (¾" external thread) on the flange of the
drinking water storage tank.
In order to avoid damage to the inner tank, always trans-
port the TERMO cylinder in an upright position! Controller
The auxiliary heater for the back-up part of the TERMO
CONVECTROL III Convection Brake Combi Cylinder is regulated by the heating controller. For
The convection brakes are contained in the CONVEC- connecting the auxiliary-heating sensor, follow the installa-
TROL  III cylinder connection set. When installing them, tion instructions provided by the controller manufacturer.
please follow the instructions included with the connec- An in-tank tube is mounted in the flange of the domestic
tion set. water storage tank for this purpose.
As an alternative to the convection brakes, combi-fittings For regulating the solar-heating system and control of the
5/4" – 22mm, flat-sealing 5/4" – 1" threaded or soldered return-flow temperature boost or for acting as a hydraulic
connections, e.g. 5/4" – 22 mm can be used. switch, the SUNGO SL or SXL (not available everywhere)
can be used. Contact our technical office on tel. +49 6421
Hot and Cold Water Pipe 8007-0 to find out which is the ideal type of controller for
Make sure that there is no cutoff between the safety valve your applications.
and the cylinder.
The valve must be configured for a blow-off pressure General Safety Information
matching the permissible excess operating pressure of the ● Setting-up, installation and correct commissioning of
cylinder. Install a pressure reducer behind the flow meter the cylinder must be carried out by a certified specialist
where water-pipe pressure is 10 bar and above. company.
It is normal that water drips from the safety valve when the ● The system must be installed in a frost-proof room with
cylinder is heated and no expansion vessel for the domes- short pipe-work runs to the consumer.
tic water circuit is in place. Channel this water away using ● The heating circuits must be diffusion-proof.
a siphon funnel connected to the drain. ● For the water connection the relevant regional and
country regulations and recommendations and the
Safety Valve and Expansion Vessel regulations stipulated by your water supplier must be
Make sure that the safety valve in the heating circuit has a complied with.
maximum blow-off pressure of 3 bar. The expansion ves- ● For electrical connections, the relevant regional and
sel must be large enough to also accommodate the heat country regulations as well as the regulations stipulated
expansion of the cylinder’s buffer volume (see table 2). by your electricity provider must be adhered to.
During operation, there must be no cutoff between the ● The safety valve must be checked regularly for proper
expansion vessel and the cylinder. functioning by airing. The vent-valve opening must nev-
er be closed off or constricted.
Temperature Limitation ● Cleaning of the cylinder and a system check should be
The temperature in the cylinder must not exceed 95 °C. carried out every 2 years.
Check that the settings on the solar controller (max. cylin- ● The sacrificial magnesium anode must be checked and
der temperature in the SUNGO S/SL/SXL is set in the fac- renewed if necessary after 2 years and at regular inter-
tory) and the boiler controller (max. boiler temperature) vals after that.
are correct. ● An appropriate state-of-the-art water filter must be in-
stalled properly commissioned in the cold water feed
Domestic Water Circulation Pipe pipe.
If a domestic water circulation pipe has been installed, the
circulation pump must under all circumstances be con- Insulation
trolled via a timer and a thermostat, in order to reduce heat The cylinder insulation consists of the jacket (polyester
losses. The timer ensures that the pump only runs when fleece with polystyrene cover layer and a hook closure),
hot water is required. The thermostat always switches the the ground insulation (insulating ring and ground insula-
pump off when the temperature in the circulation pipe tion disk) and the cover insulation (2 cover insulation disks
exceeds, for example, 30 °C. The functions described are and 1 fleece strip).
already integrated into the SUNGO SXL controller. The cir-
culation pump should be operated with a flow as low as For polystyrene the tendency to break decreases with in-
possible. creasing temperature.
We recommend the BW152 circulation pump (Article No. Don’t install insulations at temperatures below 20 °C; insu-
160 102 14) with integrated shut-off valve and return-flow lations stored in cold must be warmed to room tempera-
check valve, connected as in figure1. ture.
The circulation should be integrated between the safety
unit and the domestic hot water mixer in order to achieve
a cycle.

170 EN-XXX_TERMO-Combi-Cylinder_MA-100127-11214400
1.2 Hydraulic Installation

Figure 2 You need the following tools to assemble the solar cylinder: Figure 3 Open insulation at ratchet closing strip, put aside, unscrew
open-ended spanner SW 13, 19, 24, 30, 37; valve wrench (or pipe cylinder from pallet and set up in required location.
wrench) and Phillips screwdriver.

1.2

Figure 4 Slightly tip cylinder and insert bottom insulation disk. Figure 5 Screw the cold water filling-and-draining tap into the bottom
connection.

S 46

S 24

Figure 6 When installing the convection brakes, insert CONVEC- Figure 7 Place gasket between cylinder connection and combined
TROL III in combined connection so that key and slot fit snugly. connection. Assure right position when screwing on (TOP marking up!);
secure with wrench S24.

EN-XXX_TERMO-Combi-Cylinder_MA-100127-11214400 171
Figure 8 Install elbow pieces flat sealing, and connect left (red mark- Figure 9 Optional: Install the safety unit in the cold water pipe above
ing) to hot and right (blue marking) to cold water. the cylinder instead of the stop, non-return and safety valves. No shut-
off between the safety unit and the cylinder!

H = hot C = cold
Flow direction

Mix = Mixing temperature

Figure 10 Option: Insert thermostatic mixing valve in the hot water Figure 11 Option: If desired, install drinking water circulation pump
pipe to limit the temperature. See attached notice for connection con- in accordance with the connection diagram and mount the clamp-on
figuration. Then insulate the pipe work. pipe temperature sensor as close to the last hot water tapping location
as possible.

Figure 12 Screw the cold water filling-and-draining venting tap onto Figure 13 Option: If necessary, install electric auxiliary heating. For
the cover at the top; slide on hose and secure with a pipe clamp. electric installation refer to the manual included with the heating ele-
ment.

172 EN-XXX_TERMO-Combi-Cylinder_MA-100127-11214400
Figure 14 Connect the solar circuit to the inlet and return pipes. The Figure 15 Option: With “Return-flow temperature boost” system solu-
inlet for the heat exchanger in the solar-heating circuit is at the top and tion install the switch-over valve as per connection diagram (Figure 1).
the outlet at the bottom.

1.2

Figure 16 Depending on which system you have, mount the other Figure 17 Screw the temperature sensor for the solar controller under
connections or screw on the caps. the cylinder clamp bar tight (see table 2 for positions). Insert the sensor
for the auxiliary heater into the in-tank tube on the flange. Make sure
that the contact is good.

Table 1 Position of Temperature Sensor on the Cylinder
Temp. sensor Height of sensor position from the floor in mm
TERMO 700 TERMO 1000
T (bottom) 220 240
T (centre) 900 980
T (top) 1200 1400
Auxiliary heater Receptacle in flange

Table 2 Additional Volume for Expansion Vessel in Heating Circuit
Blow-off pressure Admission TERMO
of heating-circuit pressure (Nominal volume in l)
safety valve (= filling pressure)
700 1000
2.5 bar 1.0 bar 65 l 95 l
2.5 bar 1.5 bar 130 l 185 l
3 bar 1.0 bar 50 l 70 l
Figure 18 Option: CORREX® anode. Attach one cable to grounding
screw and plug the other onto the electrode. 3 bar 1.5 bar 80 l 110 l
Observe manual of external anode.

EN-XXX_TERMO-Combi-Cylinder_MA-100127-11214400 173
Figure 19 Option: Install electrical socket and plug in the CORREX Figure 20 Please note that in order to accommodate the expansion of
electronic device. If the green light comes on after the cylinder has the contents of the storage tank, a suitably sized expansion vessel must
been filled, everything is OK. If a red light flashes, read the operating be installed in the heating circuit (see table 2).
instructions for further information.

Figure 21 For commissioning, first fill the drinking water storage tank. Figure 22 For commissioning the buffer storage tank, first connect the
To do this, first open the stopcock of the safety unit and then turn on cold water filling-and-draining tap at the bottom of the cylinder to a
the tap on the hot water side so that air can escape. hose and let the water flow in.

Figure 23 Open fill and drain valve on top to remove air. Figure 24 Thoroughly rinse, fill and vent the solar-heating circuit.
Please adhere to the operating instructions for commissioning the
system.

174 EN-XXX_TERMO-Combi-Cylinder_MA-100127-11214400
1.3 Storage Cylinder Insulation
After setting up the cylinder, the insulation has to be ● Make sure that insulation is fitted tightly to cylinder wall
mounted at the installation location before installing the ● Tighten hook closure from top to bottom until the insu-
drinking water, circulation and heating circuits. lation tightly fits the cylinder.

● Loosely place insulation jacket around the cylinder, and Please don’t use tools or tightening straps and don’t close
securely press against cylinder on opposite side of con- the closing strip violently, since this might result in damage
nections. and reduced effectiveness of the insulation.
● Adjust insulation jacket by thumping it with your flat
hand, thump or stroke from rear to front in the direction
of the hook closure, until the two sides of closing strip
are so close to each other that they can be closed with
slight pressure

1.2

Figure 25 Now position the insulating ring around the bottom of the Figure 26 Lock in the hook closure on the insulation jacket opposite
cylinder. the connections. If necessary, use the mounting accessory (Art. No. 130
00 239) or secure the hooked strip with screws.

2

1

Figure 27 Use included wire hook to lock left side of insulation in place Figure 28 Close the insulation with the front hook closure. First slot
for easier handling. into the loosest slot position and then gradually tighten.

EN-XXX_TERMO-Combi-Cylinder_MA-100127-11214400 175
Figure 29 Place fleece insulation into the space between cover lid and Figure 30 Insert both cover insulation discs and put on the cover. Insu-
insulation jacket, waterproof surface on outside. late all connected pipe work and press insulating hose firmly onto the
storage-tank insulation.

2. Start-Up
● First fill the domestic water storage tank If the desired hot water temperature is frequently not
In order to avoid damage caused by excess-pressure (wa- reached during operation, set the required temperature
ter hammer), it is essential to fill the domestic water stor- for the auxiliary heater at a higher level.
age tank first. Only after filling the drinking water storage ● Vent the cylinder again
tank you should fill the heating part. Check the hot- and Generally required to remove remaining air from circuit
cold water connections to the cylinder for air and water (s. fig. 23). Then replace the insulation lid.
tightness. ● Complete the acceptance report
● Fill the heating circuit Correct commissioning must be certified in the accep-
Open the vent tap on the storage tank (figure 23). If water tance report by an expert, so that in the case of any com-
flows out, close the tap. Depending on the water pressure plaint you can make a claim under the guarantee.
and the size of the storage tank, it can take between half
an hour and two hours to fill the tank.
● Commissioning the solar-heatig system 3. Maintenance
Please follow the instructions for commissioning the sys-
tem. Maintenance of the cylinder and the solar-heating system
● Check all cylinder screws for tightness! should be carried out at intervals of 2 years.
Check that all connections on the cylinder and flange are ● Venting the cylinder.
airtight and watertight and tighten where required. See “Commissioning“ for individual steps.
● Setting heater control ● Check the sacrificial magnesium anode
Mount the auxiliary-heating temperature sensor in the im- See figure 32 for individual steps.
mersion pocket on the flange of the domestic water stor- ● Complete the service report
age tank. Set the required auxiliary-heater temperature on Correct servicing must be certified in the servicing report
the heating controls in accordance with the manufacturer’s by an expert, so that in the case of any complaint you can
instructions. make a claim under the guarantee.

Figure 31 After commissioning the System check all connections (in- Figure 32 Check factory installed sacrificial magnesium anode every
cluding convection brakes), flanges, anode and screwings for tight- 2 years. Remove cable and measure the current with multimeter: Less
ness, and tighten if required. than 0.3 milliampere = check anode and renew if necessary.

Subject to modifications, errors excepted · © Wagner & Co, 2010 · www.wagner-solar.com
176 WAGNER & CO · Zimmermannstraße 12 · D-35091 Cölbe/Marburg · ☎
+49 (0) 64 21 80 07-0 · Fax 80 07-596
TECHNICAL INFORMATION

RATIO Buffer Cylinder

Versatile Applications
● Steel storage for space heating and solar thermal in-
stallations.
● Optionally with up to 2 plain-pipe heat exchanger coils
● Option for electrical immersion heater
● Hydronic versatility with many connections
● Prepared for installation of a freshwater unit (DHW
preparation by flow-through principle)

Energetically Optimized
● Close fitting environmentally compatible polyester fi- 1.2
ber fleece jacket insulation
● 100 or 120 mm thick insulation
● Exceptionally low connection losses with the
CONVECTROL III convection brakes (accessory)
● With vertical heat conductor sheet and deflector plate
to support stable stratification

Simple Installation
● Flat sealing 1¼" connections
● Storage connection kit with combined fittings for sol-
der or pressing connections available as accessory
● Flexible polyester fleece for easy fitting of insulation
● Sensor connection bar for variable sensor positions
● Ratchet hook closure
● Storage insulation can be removed

Robust and Durable
● Scratch and impact resistant polystyrene shell
● Made in Germany acc. to DIN 4753

Figure 1 RATIO buffer cylinder

Solar Thermal / Solar Cylinder EN-XXX_RATIO-Buffer-Cylinder_TI-100722-1WA10090 177
1. Technical Data
Table 1 300-G 1) 500-G 1) 700 / 1000 / 1500 /
Features 700-2G 2) 1000-2G 2) 1500-G 1)
130 102 80 / 130 102 84 / 130 102 86 /
Product no.: 130 102 85 130 102 81
130 102 82 130 102 83 130 102 87
Material High quality steel St 37-2 (inside untreated, outside primed)
1451 mm / 1765 mm / 1655 mm / 2147 mm / 2055 mm /
Total height, without / with Insulation jacket
1506 mm 1840 mm 1730 mm 2222 mm 2130 mm
550 mm / 650 mm / 790 mm / 800 mm / 1000 mm /
Diameter without / with insulation
750 mm 850 mm 1030 mm 1040 mm 1240 mm
Max. tilted height 1550 mm 1810 mm 1720 mm 2210 mm 2160 mm
Weight of tank (without insulation) 91 kg 125 kg 109 kg / 168 kg 153 kg / 237 kg 205 kg / 265 kg
Total net capacity 296 l 513 l 719 l / 690 l 980 l / 939 l 1443 l / 1413 l
Volume fraction, above layer A
138 l 136 l 299 l / 229 l 369 l / 307 l 488 l
(compare figures 3 - 7)
Max. operation pressure 3 bar
Max. operation temperature 90 °C
Heat insulation Lid and jacket 100 mm Lid and jacket 120 mm
(Polyester fiber fleece, polystyrene exterior) bottom 50 mm bottom 50 mm
Heat loss rate 3.1 W/K 3.2 W/K 3.3 W/K 3.7 W/K 4.4 W/K
Connection stubs, vertical row 7 - 11 pipe threads DIN ISO 228-1 (cylindrical, flat sealing), G 1¼"
RATIOfresh 200 /
RATIOfresh 200, RATIOfresh 200 RATIOfresh 200
Attachment of freshwater unit (optional) RATIOfresh 200 RATIOfresh 200
and 250/400 and 250/400 and 250/400
and 250/400
Optional Solar Coil Heat Exchanger 300-G 500-G 700-2G 1000-2G 1500-G
Material High quality steel St 37-2
Heat exchanger surface 1.38 m² 1.96 m² 2.16 m² 3.45 m² 3.45 m²
Liquid volume 8.67 l 12.31 l 13.76 l 21.67 l 21.67 l
1.4 mbar 3.5 mbar 8.2 mbar 17.3 mbar 24 mbar
Pressure drop at 40 °C with 40 % DC20
at 250 l/h at 350 l/h at 500 l/h at 600 l/h at 700 l/h
Max. operational pressure 10 bar
up to up to up to up to up to
Recommended total collector surface
approx. 8 m² approx. 11 m² approx. 12 m² approx. 20 m² approx. 20 m²
Option Aux. Coil Heat Exchanger 700-2G 1000-2G
Material High quality steel St 37-2
Heat exchanger surface 1.29 m² 1.51 m²
Liquid volume 8.23 l 9.49 l
Pressure drop at 60 °C and 800 l/h 13 mbar 15 mbar
Max. operation pressure 10 bar
Max. continuous thermal power output 14 kW 16 kW
1) G = Model with solar heat exchanger
2) 2G = Model with solar heat exchanger and aux. heat exchanger coil

3

4
2

1

5

Figure 2 RATIO buffer cylinder – view from top:
1 Connection stub (row, 7-11 pieces) 1 ¼" M; 2 Sensor connection
bar; 3 Connection stubs top 1 ¼" M; 4 Threaded socket for electri-
6 cal immersion heater; 5 Fixing bolts for storage add-ons; 6 Hoisting
loop

178 EN-XXX_RATIO-Buffer-Cylinder_TI-100722-1WA10090
750
G5/4”

550

A
G11/2”

1451
1321
1156
1.2
776
650
280
180
95

Figure 3 RATIO 300-G cross-section with dimensions;
A = reference plain in table 1 for aux. heating volume, connection row on right side 1¼" M.

850
G5/4”

A

650

G11/2”
1765
1618
1513
1260
1160
960
880
760
290
210
112

Figure 4 RATIO 500-G cross-section with dimensions;
A = reference plain in table 1 for aux. heating volume, connection row on right side 1¼" M.

EN-XXX_RATIO-Buffer-Cylinder_TI-100722-1WA10090 179
1030

G5/4”

A

1653
790

1480
G11/2”

1400
1315
1015
935
850
815
700
495
300
220
140

Figure 5 RATIO 700 and 700-2G cross-section with dimensions;
A = reference plain in table 1 for aux. heating volume, connection row on right side 1¼" M.

1040
G5/4”

A

800

G11/2”
2147
1971
1866
1780
1400
1301
1201
1041
801
331
251
141

Figure 6 RATIO 1000 and 1000-2G cross-section with dimensions;
A = reference plain in table 1 for aux. heating volume, connection row on right side 1¼" M.

180 EN-XXX_RATIO-Buffer-Cylinder_TI-100722-1WA10090
1240

G5/4”

A

G11/2”

1000

2055
1825
1720
1.2

1280
1180
900
780
385
305
195

Figure 7 RATIO 1500 and 1500-G cross-section with dimensions;
A = reference plain in table 1 for aux. heating volume, connection row on right side 1¼" M.

Figure 8 Lower storage section (cut) with internal flow guide deflec-
tor plate.

EN-XXX_RATIO-Buffer-Cylinder_TI-100722-1WA10090 181
2. Accessories
Table 2 Accessories Prod. No.
Combined connection set standard
139 002 06
with CONVECTROL III
Combined connection set standard 139 000 63
Storage height adjustment unit (for 300- and 500 l
139 000 16
version 3, for all others 4 are required)
Electrical immersion heater 3 kW 139 001 42
Electrical immersion heater 6 kW 139 001 46
Electrical immersion heater 9 kW 139 001 44
Tank mounting kit for RATIOfresh units 250/400 * 139 000 28
Tank mounting kit for RATIOfresh unit 200 139 002 42
Tank mounting kit for CIRCO 6 / 6E 150 302 01
3 way actuator valve (1" M) with insulation shells 150 303 51
* Cannot be used with RATIO 300-G, 700

Convection Brake CONVECTROL III
The patented and easily installed component separates
the water that cooled down in the connection pipes from
the hot water contained in the storage.
The CONVECTROL III can reduce heat losses at the stor-
age connections by up to 50 %. The total annual storage
losses thus can be reduced by 10 % to 20 %.

Figure 9 RATIO buffer cylinder with attached RATIOfresh 250

Figure 10 CONVECTROL III combined fittings.

182 EN-XXX_RATIO-Buffer-Cylinder_TI-100722-1WA10090
3. System Solutions Examples

P1: Pump, solar circuit
P2: Pump, heating circuit

Output

Inputs
P3: Pump, aux. heating DHW
P4: Pump, RATIOfresh primary circuit
P5: Pump: DHW recirculation
Collector field
M1: Mixer, heating circuit

Oil- or gas
boiler
1.2

Recirculation

Cold water

Hot water

Figure 11 Solar Installation for DHW preparation using the hygienic flow-through heating principle. System solution with RATIO buffer cylinder,
freshwater unit RATIOfresh 250/400 and an oil- or gas boiler. The controller of the freshwater unit assures constant hot-water tapping tempera-
tures and controls the recirculation pump. The performance control of the freshwater unit also assures low temperatures for the buffer storage
return, thus increasing the solar yield.

P1: Pump, solar circuit SUNGO SXL, system 1211
P2: Pump, heating circuit
Outputs

Inputs

P3: Pump, aux. heating DHW
P4: Pump, RATIOfresh primary circuit

M1: Mixer, heating circuit Collector field
V1: 3-way actuator valve, storage loading

HW: Hydronic switch

Recirculation

Cold water

Hot water

Figure 12 Solar installation for DHW preparation and space heating support: System solution with RATIO buffer cylinder and freshwater unit
RATIOfresh 250/400 and a gas boiler in a mixed heating circuit. DHW preparation uses the hygienic flow-through heating principle. Solar energy
is utilized for the heating circuit by means of return boost.

EN-XXX_RATIO-Buffer-Cylinder_TI-100722-1WA10090 183
P1: Pump, solar circuit SUNGO SXL, system 1221
P2: Pump, heating circuit

Outputs

Inputs
P3: Pump, aux. DHW heating via buffer

M1: Mixer, heating circuit Collector field
V1: 3-way actuator valve, storage loading
V2: 3-way actuator valve, return boost
V3: 2-way valve parallel to P3, closed when power off
V4: Thermostatic mixing valve

HW: Hydronic switch

Hot water

Cold water

Figure 13 Solar installation for DHW preparation and space heating support: 2-storage system with ECOplus solar DHW cylinder, RATIO buffer
cylinder, gas boiler and mixed heating circuit. The solar energy is optimally distributed to both storages by the solar controller. It is utilized for the
heating circuit by means of return boost. Additional solar heat from the buffer is available for DHW.

P1: Pump, solar circuit, primary SUNGO SXL, system 1212
P2: Pump, solar circuit, secondary
Outputs

Inputs

P3: Pump, solid fuel boiler circuit

P4: Pump, heating circuit
P5: Pump, RATIOfresh primary circuit Collector field
P6: Pump: DHW recirculation

M1: Mixer, heating circuit
V1: Thermostatic mixing valve
for keeping a minimum return temperature

PWT: Plate heat exchanger Recirculation

Cold water

Hot water

Solid fuel
boiler

PWT

Figure 14 System solution with RATIO buffer cylinder, freshwater unit RATIOfresh 250/400, solid fuel boiler, mixed heating circuit and larger
collector surface. DHW preparation by flow-through heating. Solar energy is loaded to the buffer cylinder via a powerful plate heat exchanger.
The solid fuel boiler utilizes the entire buffer volume. With a built in electrical immersion heater the heating operation can be assured during a
longer absence.

Subject to modifications, errors excepted · © Wagner & Co, 2010 · www.wagner-solar.com
184 WAGNER & CO · Zimmermannstraße 12 · D-35091 Cölbe/Marburg · ☎
+49 (0) 64 21 80 07-0 · Fax 80 07-596
INSTALLATION INSTRUCTIONS

RATIO Buffer Cylinder

1.2

Figure 1 Cross section of RATIO buffer cylinder

Content
1. General Safety Notes . . . . . . . . . . . . 186 4. Start-Up . . . . . . . . . . . . . . . . . . 190
1.1 Signs and Symbols . . . . . . . . . . . . . 186 4.1 Filling, Venting and Pressure Testing . . . . . 190
1.2 Standards and Codes . . . . . . . . . . . . 186 4.2 Flushing the System . . . . . . . . . . . . . 190
1.3 Qualification of the Installer . . . . . . . . . 186 4.3 Settings at Storage and Solar Controller . . . . 190
1.4 Intended Use and Application . . . . . . . . 186 4.4 Completing the Acceptance Protocol . . . . . 190
1.5 Recycling Note . . . . . . . . . . . . . . . 186 5. Fitting the Insulation . . . . . . . . . . . . 190
2. Scope of Supply . . . . . . . . . . . . . . 187 6. Troubleshooting . . . . . . . . . . . . . . 192
3. Installation . . . . . . . . . . . . . . . . . 188 7. Care and Maintenance . . . . . . . . . . . 192
3.1 Setting up the Storage. . . . . . . . . . . . 188
3.2 Connecting the Heating Circuit . . . . . . . . 188
3.3 Connecting the Solar Circuit . . . . . . . . . 189
3.4 Connecting Aux. DHW Heating Circuit. . . . . 189
3.5 Installing the Immersion Heater . . . . . . . . 189

Solar Thermal / Solar Cylinder EN-XXX_RATIO-Buffer-Cylinder_MA-100812-1WA10089 185
1. General Safety Notes 1.3 Qualification of the Installer
1.1 Signs and Symbols Setup, installation and startup of the storage must be car-
ried out by a registered professional installer.
The following symbols are used throughout this instruc- Note that in case of a warranty claim the warranty is only
tion manual. They relate to specific safety information and valid if the correct startup was certified in the acceptance
important additional information. Please observe their protocol by a professional and proof of regular mainte-
meaning nance can be presented.

1.4 Intended Use and Application
DANGER of possibly serious personal injury
The steel storage tank is designed for use in closed heat-
ing- and solar circuits. It is not suitable for DHW storage.
The storage must only be filled with water and it has to be
CAUTION against possible property damage secured with a 3-bar safety valve without shutoff mecha-
nism.
The heating circuit has to be equipped with a sufficiently
sized membrane expansion vessel (see table 1).
NOTE for additional information The storage must be set up in a frost-proof room. The
ground underneath the storage must be dry and have a
sufficient structural carrying capacity!
1.2 Standards and Codes Table 1 Additional Volume Required for Expansion Vessel in
Heating Circuit.
● EC Declaration of Conformity: this solar buffer cylinder
was designed and manufactured in accordance with Safety valve Prim. RATIO
existing laws and regulations of the EU countries. in heating pressure (Additional nominal volume of exp.
circuit vessel [l])
● Please take care, that the connection to the drinking
water supply is performed in compliance with local 300 500 700 1000 1500
regulations and recommendations and the specifica- 2.5 bar 1.0 bar 50 70 105 135 170
tions of your water utility or provider.
2.5 bar 1.5 bar 80 125 200 250 320
● Please also make sure that the electric connection is
in accordance to local regulations and specifications 3 bar 1.0 bar 40 55 85 105 135
of you electric utility company. The functionality of the 3 bar 1.5 bar 60 80 125 155 200
safety valve must be checked regularly by test-venting
as outlined for example in DIN 4753.The blowing-off The RATIO buffer cylinder offers the following possibili-
vent must never be closed or restricted. ties:
● Observe all relevant regulations when connecting the ● Installation of an electrical immersion heater
storage to the domestic water and heating circuits as ● Attachment of a RATIOfresh freshwater unit
well as all regulations pertinent to the electric connec- ● Connection of auxiliary DHW heating via a plain-pipe
tions of a controller. heat exchanger coil (storage types 2G)
● When installing an auxiliary heater, please comply with ● Connection to a solar thermal installation via plain pipe
the information of the device manufacturer. heat exchanger coil (storage types G and 2G)

Please make sure to note the relevant national and inter-
national standards, such as e.g.: 1.5 Recycling Note
● DIN 4753: Water heater and water heating systems for
potable and process water. At the end of an installation's operational lifetime the valu-
● DIN 1988: Technical rules for installing potable water able materials should be recycled in an environmentally
systems. sound manner. If no recycling option exists, Wagner & Co
● DVGW 551/552: Potable water heating and conduits: will take the scrap material back. Please contact us if you
Technical measure to reduce Legionella bacteria have questions.
growth.
● EN V 12977-3: Thermal solar installations and compo-
nents - Part 3: Efficiency tests of storage tanks for solar
heating systems.

186 EN-XXX_RATIO-Buffer-Cylinder_MA-100812-1WA10089
2. Scope of Supply

6

7

8

5

4

1.2
1

2

3

11

9

10

Figure 2 Components of the storage: see table 2 for legend of the position numbers.

Table 2 Scope of Supply Table 2, continued
No. Item Qty. 7 Lid insulation 1
1 Storage with 1¼"- connection stub row 1 8 Upper insulation filler 1
2 Jacket insulation 1-3 * 9 Outer floor insulation ring 1
3 Hook closure strip 1-3 * 10 inner floor insulation 1
4 Insulation plugs 4 Bottom finish strap (integrated in insulation jacket
11 1-3 *
with some storage types)
5 Insulation installation tools 2
* Different number, depending on storage type
6 Storage lid 1

EN-XXX_RATIO-Buffer-Cylinder_MA-100812-1WA10089 187
3. Installation
Technical information that might be relevant for the instal-
lation of the storage is published in the “Technical Infor-
mation Ratio Buffer Cylinder”, (file no. 1WA10090). These
include cutaways, technical data and sample schemes of
typical system solutions.
All storage connection stubs are cylindrical and designed
for use with special heat resistant flat gaskets. The original
gaskets from our connection sets should be used or alter-
natively gaskets of identical quality. 1
When using the buffer cylinder with a RATIOcompact
System refer to the separate RATIOcompact installation
instructions in place of the chapters 3.2 to 3.4.

3.1 Setting up the Storage
● Unscrew the storage from the palette, remove packing
film and transport to the installation location (weight
5
up to 256 kg!). For hoisting the tank can be lifted at the 4
foot ring and the hoisting ring at the top. 3
● Positioning the storage tank for easy piping. 2
● To lay in the bottom insulation tilt the tank

8

6

7

Figure 3 Tilt the storage to insert the inner floor insulation Figure 4 Connection example for a solar installation with space heat-
ing support via return boost: 1 Storage; 2 Swivel nut 1¼"; 3 Com-
bined connection 1¼"; 4 CONVECTROL III convection brake; 5 Flat
gasket 1¼"; 6 3-way diverter valve; 7 Filling and emptying
tap; 8 Cap 1¼".

3.2 Connecting the Heating Circuit
● Then make connections using the flat gaskets especial-
ly approved for this application. To reduce heat losses
we recommend to use the CONVECTROL III connec-
tion sets ) see figure 4, no.'s 2 to 5) as seen in figures
5 and 6.
● Close the unused connections with 1¼" caps (see fig-
ure 4, no. 8).
● Installation of a safety valve in the heating circuit with a
max. blowing-off pressure of 3 bar!
● Installation of a filling and emptying tap at the lowest
storage connection (see figure 4, no. 7).
● Installation of venting device (e.g. a tap) at the 1¼" con- Figure 5 When installing the convection brakes, make sure that key
nection of the upper rounded head of the storage - for and slot are aligned when inserting the CONVECTROL III into the com-
air release when filling the tank. bined connection.

188 EN-XXX_RATIO-Buffer-Cylinder_MA-100812-1WA10089
S 46

2

150

1

3

S 24

Figure 6 Place gasket between storage connection stub and com- Figure 8 Use the sensor connection bar to attach the temperature
bined connection. Assure correct position when tightening (TOP sensor at a storage with integrated solar heat exchanger, approx. 150
marking up!) and secure with open spanner S 24. mm above the solar return

3.4 Connecting the Aux. DHW Heating 1.2
Circuit
Connect the aux. DHW circuit to the storage versions G2
as follows:
● Connect aux. heating circuit to upper heat exchanger
coil with flat sealing gaskets.
● Attach a temperature sensor for the aux. heating con-
trol to the sensor connection bar in appropriate height
(fix in the same way as solar sensor in figure 8).

3.5 Connection of Immersion Heater
A series of electrical immersion heaters is optionally avail-
able.
Figure 7 Membrane expansion vessel (MEV) with upstream capped ● Screw the heater into the 1½" socket (see figure 9).
valve for easier checking of the primary pressure. Hereunto observe the additional information in the
heater's instruction.
● Laying the mains cable of the electrical heater: a heat
● Connection of a sufficiently sized membrane expan- resistant cable (min. up to 95 °C) must be used when
sion vessel (MEV) that can take up the thermal expan- laying the cable under the insulation jacket.
sion of the storage content (see table 1). For ease of
maintenance we recommend the downstream installa-
tion of a capped valve (see figure 7).

3.3 Connecting the Solar Circuit
Connect the solar circuit to the storage versions G and
G2 as follows:
● Connect the solar flow to the upper connection stub
of the solar heat exchanger coil and the return to the
lower. Temperatures of up to 95 °C are possible with
connected solar installation. Caution: Risk of scalding!
● Attach the temperature sensor 15 cm above the centre
of the solar return. To this end slightly loosen the sensor
connection bar, place sensor and snap in connection
bar again (see figure 8)

Figure 9 Screw in the immersion heater

EN-XXX_RATIO-Buffer-Cylinder_MA-100812-1WA10089 189
4. Start-Up 5. Fitting the Insulation
Before beginning with start-up procedures the correct Insulation jacket made of polyester fiber fleece with
installation according to safety regulations should be scratch and impact resistant polystyrene finish and a
checked again. hook closure strip. Depending on the type, it consists of
1 to 3 sections. The higher the ambient temperature, the
more flexible the polystyrene surface, with reduced risk
4.1 Flushing the System of breaking.
Do not therefore install the insulation jacket at temper-
● When the system is flushed, appropriate strainers have atures below 20 °C. Allow insulation jackets that were
to be inserted to remove remaining particles from the stored in a close place to warm up to room temperature!
piping. Do not use additional tools or tightening straps and do
● We recommend to install a dirt retainer at an appropri- not close the hook closure by force. This could damage
ate position within the heating circuit. the insulation and diminish its effectiveness.

If an immersion heater is used, the insulation jacket must
4.2 Filling, Venting and Pressure be prepared for placing the heater's controller case:
● Use a cardboard cutter to cut out and remove the poly-
Testing styrene finish along the pre-cut line (figure 10)
● Fill the storage with water at the lower filling tap. Max. ● Also remove the pre-cut insulation underneath (figure
pressure 3 bar (figure 4, no. 7). Release air using the 11)
vent at the upper rounded head.
● Afterwards close the vent and heat up the storage, ide-
ally to max. temperature while monitoring the opera-
tional pressure.
● Examine all connections and flanges for leak tightness,
retighten if required.
● Afterwards vent the storage once again, so that all air
trapped in the pipes is allowed to escape.

4.3 Settings at Boiler and Solar
Controller
For settings at the boiler and the solar controller (if ap-
plicable) the max. temperature for storage loading must
nut exceed 95 °C.
When a RATIOfresh freshwater unit is used for DHW prep-
aration, the aux. heating of the storage standby-section is
controlled by the boiler controller. For the installation of
the aux. heating sensor the instructions of the controller Figure 10 Remove the pre-cut immersion heater opening from the
manufacturer have to be observed. polystyrene finish of the insulation.

4.4 Completing the Acceptance
Protocol
Note: The correct installation and startup must be certi-
fied in the acceptance protocol by a licensed profession-
al. Non-compliance may render all warranties void.

Figure 11 Remove the pre-cut section of the insulation jacket

190 EN-XXX_RATIO-Buffer-Cylinder_MA-100812-1WA10089
2
1

1
2

Figure 12 First slide the cut-out opening of the insulation over the Figure 13 Wire hooks as installation support for the insulation jacket:
immersion heater, then lock hook closure. secure the left section of the insulation at the connection stubs and
then close slide the right insulation section into the hook closure.
1.2
Install the storage insulation as follows (parts depend on
storage type, see figure 2, no.'s 2 to 11):
● First, place outer floor insulating ring around the bot-
tom of the buffer cylinder.
● If an immersion heater is installed (EHK), the cut-out
section first has to be slid over the heater (see figure
12)
● In case of a one-part insulation jacket, lay insulation
around the cylinder and close hook closure.
● In case of insulation jackets consisting of several sec-
tions, connect sections at hook closure, close hooks at
connection row last.*
● Depending on the storage type, different installation
tools are supplied (see figures 13 and 14).
● Retighten the hook closure starting at the top, until the Figure 14 S-hook with rubber strap as installation tool for the insula-
heat insulation fits tightly against the cylinder. tion jacket: put the rubber strap over the respective S-hook and lock
right insulation section into the hook closure.
● Install insulation plugs
● Place upper insulation filler and upper lid insulation
● Place storage lid.
● Fasten the bottom finish with velcro strap (only re-
quired for some cylinder types)

* If a RATIOcompact unit is attached directly to the stor-
age, the hook closure at the connection row is closed first
in the last (strongest) hook position.

EN-XXX_RATIO-Buffer-Cylinder_MA-100812-1WA10089 191
6. Troubleshooting
Flat sealing gaskets tend to settle during the first months
of operation. Insufficiently tightened pipe connections
may result in slight leaking. The connections then must
be re-tightened.

7. Care and Maintenance
The storage should be cleaned and maintained at least
every 2 years, otherwise the warranty is void.
● Check for leak-tightness at storage and connections.
Watch out for signs of scaling or moist spots at the in-
sulation, Re-tighten connections, if required.
● Check the safety valve by test-venting.
● Vent the storage (for individual steps see chapter 4)
● Fill in and sign the maintenance protocol.

Renew flat sealing gaskets whenever a connection is
opened. Otherwise leak tightness cannot be guaranteed
anymore.

Subject to modifications, errors excepted · © Wagner & Co, 2010 · www.wagner-solar.com
192 WAGNER & CO · Zimmermannstraße 12 · D-35091 Cölbe/Marburg · ☎ +49 (0) 64 21 80 07-0 · Fax 80 07-596
TECHNICAL INFORMATION

Convection Brake CONVECTROL III

1.2

Figure 1 CONVECTROL III with combi fitting set

Benefits High heat loss

CONVECTROL III convection brakes reduce heat losses at
cylinder pipe connections by up to 50 %. The protected Without convection brake

barrier design separates water that cooled in the connec-
tion pipes from the hot cylinder content. Total annual cylin-
der heat losses are thus reduced by 10 to 20 %. 60 °C

Operational Principle
Without Convection Brake
When the solar cylinder is in stand-by mode, hot water
Storage 100 m Pipe
rises from the storage tank into the upper section of the cylinder soft foam insulation insulation
connection pipe and flows along the pipe wall. There the
water slowly cools to ambient temperature and sinks to Convection brake
the lower pipe section due to its increasing density. From
the lower pipe section, the cold water returns to the cylin- With convection brake

der (single-pipe convection). Energy is continuously with-
drawn from the cylinder.
60 °C
With Convection Brake
The offset in- and outlet nozzles create a barrier within the
connection pipes, effectively preventing convection and
the resulting heat losses. Additionally, losses through ther-
mal conduction at the pipe fittings are lowered by the flat Low heat loss
seals between the end faces. All in all heat loss at pipe Figure 2 Heat loss at cylinder connections – with and without CON-
connections is reduced by up to 50 %. VECTROL III convection brake

Solar Thermal / Solar Cylinder EN-XXX_CONVECTROL-III_TI-100121-11204800 193
Technical Data
Pressure loss ∆ p [mbar]
CONVECTROL III
35,0
Outer diameter Ø 30 mm/27 mm f. 5/4" male Solar fluid (40% DC20, 40 °C)
Length 30 mm 30,0

Material PPS; 40 % fibre glass re-enforced 25,0
Thermal stability
230 °C 20,0
acc. to ISO 75, Verf. A+B
Continuous operation 15,0
max. 95 °C
temperature
10,0
Temporary max. temperature max. 140 °C
5,0 Water (20 °C)
Tensile e-modulus ISO 527 14700 MPa
Creep modulus (1000 h) 6000 MPa 0,0
Coefficient 0 200 400 600 800 1000
0.26 x 10-4 K-1
of linear expansion Volume flow V [l/h]
Permits and certificates KTW Figure 3 Pressure loss of CONVECTROL III convection brake with wa-
ter and solar liquid

13010048
11/4"
13900197

81910178

81910178
28

22

Figure 4 Components of the CONVECTROL III convection brake with order numbers and dimensions

Subject to modifications, errors excepted · © Wagner & Co, 2010 · www.wagner-solar.com
194 WAGNER & CO · Zimmermannstraße 12 · D-35091 Cölbe/Marburg · ☎+49 (0) 64 21 80 07-0 · Fax 80 07-596
TECHNICAL INFORMATION

Thermostatic Mixing Valve BM

1.2

Figure 1 Thermostatic mixing valve BM with 2nd insulation shell re-
moved

Product Features Scope of Delivery
● Thermostatic mixer for the limitation of tapping tem- ● Thermostatic mixing valve
peratures in systems for hot water preparation. ● 2 insulation shells
● Hand wheel can be locked to avoid unauthorized ● Cold water brake to be placed in pipe connection
change of the set mixing temperature.
● Protection against scaling: the hot water flow is blocked
in case of failing cold water supply.
● Accurately fitting insulation shells avoid unnecessary
heat loss.
● Accessory: Temperature sensor in connection piece –
for the control of the mixing temperature.
● A dirt retainer is recommended for operation.

Solar Thermal / Solar Cylinder EN-XXX-Thermostatic-Mixing-Valve_TI-100120-1WA10082 195
Technical Data
Table 1BM Thermostatic Mixing Valve Hand Wheel Lock
Adjustable temperature 35 - 50 °C, stepless
Max. operating temperature 100 °C
Max. pressure difference
between hot and cold water 1 bar
connections
Pressure number PN 10
Max. volume flow 1500 l/h
Flow rate index Kv 1.4
Gun metal Rg5 valve housing;
teflon coated inside to avoid
Material scaling; valve taper and guide
components made of limescale
resistant high quality plastic.
Connection 1" M

Figure 4 Thermostatic mixing valve with removed hand wheel. The ad-
justing spindle can be locked with the thin nut. The setting of the mixer
then cannot be accidentally altered.

Table 2 Accessories for BM Thermostatic Mixing Valve
LT 22-1", swivel nut, seal and
Solder connection set solder connection 22 mm, 1 each,
order no. 100 85
Set of threaded connections
GT 1-"¾" swivel nut 1", seal and
(the included cold water
threaded connector ¾" M, 1 each,
stopper cannot be used;
order no. 139 100 11
provide on site)
Combi fitting 1"-22, swivel nut
Combined fitting set and copper nozzle,
order no. 819 100 87
Thermometer (63 mm Ø),
Temperature sensor measuring range 20 - 80 °C,
Figure 2 Dimensions in mm connection piece connection with swivel nut G1,
order no. 160 101 35
3
10 5
Pressure loss Δp [mbar]

Pressure loss Δp [Pascal]

10
9 9
8 8
7 7
6 6
5 5
4 4

3 3

2 2

2
10 10 4
9 9
8 8
7 7
6 6
5 5
4 4

3 3

2 2

10 10 3
2 3
5 6 7 8 910 2 3 4 5 6 7 8 910 2 3 4 5
Mass flow qm[kg/h]
Figure 3 Pressure loss curve

196 EN-XXX-Thermostatic-Mixing-Valve_TI-100120-1WA10082
Sample Installations

P1: Pump solar circuit
P2: Pump heating circuit
P3: Pump, aux heating drinking water Exit 230 V Low voltage section
M1: Mixer, heating circuit

RV: Back flow preventer Collector field
BWM: Thermostatic mixing valve
Mains

Oil- or gas
boiler 1.2

Hot water

Cold water

Figure 5 Sample installation 1: Thermostatic mixing valve in connection with solar storage without hot water circulation.

P1: Pump solar circuit
P2: Pump heating circuit
P3: Pump, aux heating drinking water Exit 230 V Low voltage section
P4: DHW circulation pump

M1: Mixer, heating circuit
Collector field
Mains
BWM: Thermostatic mixing valve

Oil- or gas
boiler

Hot water

Cold water

Circulation

Figure 6 Sample installation 2: Thermostatic mixing valve BM in connection with solar storage and hot water circulation. The piping makes sure
that the temperature set at the mixing valve in no case can be exceeded.

EN-XXX-Thermostatic-Mixing-Valve_TI-100120-1WA10082 197
P1: Pump solar circuit
P2: Pump heating circuit
P3: Pump, aux heating drinking water Exit 230 V Low voltage section
P4: DHW circulation pump

M1: Mixer, heating circuit
Collector field
Mains
BWM: Thermostatic mixing valve

Oil- or gas
boiler

Hot water

Cold water

Circulation

Figure 7 Sample installation 3: Thermostatic mixing valve in combination with hot water circulation. THe circulation return flow leads into the cold
water inlet of the storage, in order to support the temperature stratification.

Subject to modifications, errors excepted · © Wagner & Co, 2010 · www.wagner-solar.com
198 WAGNER & CO · Zimmermannstraße 12 · D-35091 Cölbe/Marburg · ☎
+49 (0) 64 21 80 07-0 · Fax 80 07-596
TECHNICAL INFORMATION / INSTALLATION INSTRUCTIONS

Electrical Immersion Heater

1.2
Figure 1 Electrical immersion heater

Technical Information
● For heating of domestic water (only insulated version) ● Temperature sensor of capillary tube controller is situ-
in enamelled or coated storage tanks with protective ated in protective tube between the heating elements.
anode. Not suitable for use in stainless steel containers! ● To prevent damage from corrosion, the heating ele-
● For heating of heating water in buffer tanks. ments are electrically insulated from the enamelled
● With control button for adjusting the target tempera- steel container and partially grounded via resistance
ture and with control LED indicating heating operation bridge. This increases the life of the protective mag-
(automatic switch-off, when max. temperature is ex- nesium anode as well as of the immersion heater itself
ceeded). (only insulated version).
● Integrated functions: Target temperature control (ad- ● Unheated section: 100 mm
justment range: 30-75 °C), excess temperature limita- ● Connection thread 1 ½"M
tion (94 °C +0K/-9K) and frost protection (8 °C ±6 K). ● Screw head protection class: IP64
● U-shaped heating elements, insulated and protected ● Product complies with EU regulations 73/23/EWG and
water pressure tight in a brass screw head in accord- 89/336/EWG (EC Conformity).
ance with DIN 44922 (only insulated version).

G 1½
PG M 20x1,25 DIN ISO 228-1
2
approx. 130
Ø 104

ECO

SW 60 1
16
approx. 145 Immersion depth L

Figure 2 Dimensions of immersion heater in mm, 1 button for adjusting target temperature, 2 Screw plug for unbolting

Table 1 Power (kW) / Current Immersion Depth Surface Load Tube Material Number of
Order no. Application (V) Lmax (mm) (W/cm²) Heating Tubes
139 001 46 6,0 / buffer (not insulated) 400 480 ~ 10 1.4571 3
139 001 45 1,5 / enamel and buffer 230 260 ~ 8,4 1.4876 (Incoloy 820) 2
139 001 42 3,0 / enamel and buffer 230/400 360 ~ 7,3 1.4876 (Incoloy 820) 3
139 001 43 6,0 / enamel and buffer 400 550 ~ 8,3 1.4876 (Incoloy 820) 3
139 001 44 9,0 / enamel and buffer 400 600 ~ 11,2 1.4876 (Incoloy 820) 3

Solar Thermal / Solar Cylinder EN-XXX_Electrical-Immersion-Heater_TI-MA-091109-11206300 199
3 ~ 400 V
General Safety Notes
● All local regulations and technical standards must be
complied with. Installation should only be carried out
by authorised expert personnel.
● The immersion heater must only be commissioned in a
horizontal position in water filled storage!
● The heater has an integrated safety temperature limita-
tion for overload protection and the power is switched
off when the water temperature reaches 94 °C +0/-9K).
L3 L2 L1 N

Figure 3 Connection to 400 V three phase current
Installation
1 ~ 230 V
Installation Notes
● Maximum ambient temperature for the screw head:
80 °C.
● When installing in enamelled storage with corrosion
protection anode, the screw head must have a conduc-
tive connection with the tank.
● The included copper gasket is only intended for single
use. Renew the gasket when the heater was unscrewed.
● If the total water hardness exceeds 12°dH / 9.58°e (ap-
L3 L2 L1 N
prox. 0.67 ppm CaCO3), we recommend to annually
descale the heating elements. Figure 4 Connection to 230 V AC
Please note that the risk of lime scale deposits increases
with higher target temperatures. Therefore please avoid
temperatures above 60 °C in regions with hard water.

Connecting of the Immersion Heater Operation
to 400 V Three-Phase Current
● Types 3 kW to 9 kW are suitable for operation in three ● Use the control button on the outside to adjust the tar-
phase current (400 V). get temperature (ca. 30-75 °C). The immersion heater is
● Connect the three phases of the cable to terminal L1, L2 switched off by the thermostat when the target temper-
and L3 on the control and safety thermostat (see figure ature is reached.
3). Please note: The switching temperature difference is 13
● Connect the blue neutral cable to terminal N. K± 6.5 K.
● The tank itself must be connected via min. 6 mm² cable ● We recommend setting the thermostat to the “ECO”
to the earthing terminal in the cellar. This can be done marking at approx. 50 °C. This reduces scaling, saves
by fixing a flange cable socket to one of the screws on energy and increases the solar yield.
the cylinder flange. ● At position “*” a minimum tank temperature of approx.
7 °C ± 6 K is kept for frost protection.
Connection of 1.5 and 3 kW Immersion Heater
to 230 V AC
● The 1.5 kW version must and the 3 kW can be operated Trouble Shooting
on a single phase 230 V connection. Connect the phase
of the connecting cable to terminal L1 on the control ● If the overheat protection was triggered, eliminate the
and safety thermostat (see figure 4). source of the fault and then manually re-set the tem-
● Connect the three phases of the 3 kW heater with the perature limiter by pressing the button next to the
enclosed bridges. Please note: Without bridging only thermostat button. Hereunto separate the immersion
one heating tube will heat up! heater from the grid and wait until the storage tank has
● Continue as outlined above. cooled. Then unscrew the plug and unbolt the limiter
with a tool, e.g. insert a screwdriver into the opening
The electrical connection of the heating elements must not and press against the steel contact inside.
be manipulated!
The temperature limitation may also be triggered when
the immersion heater is not in operation but the tempera-
ture exceeds 85 °C (e.g. in summer, when a solar energy
system is connected). To avoid this, set the max. storage
temperature to a value below 75 °C at the solar controller.

Subject to modifications, errors excepted · © Wagner & Co, 2010 · www.wagner-solar.com
200 WAGNER & CO · Zimmermannstraße 12 · D-35091 Cölbe/Marburg · ☎ +49 (0) 64 21 80 07-0 · Fax 80 07-596
Freshwater Units

The innovative RATIOfresh line of freshwater units for use with the RATIO buffer
cylinders is the modern and hygienic high-tech solution for domestic hot wa-
ter preparation. Hot water is produced by the hygienic flow-through principle
using an adaptive micro controller for optimal results. Only the water required is
heated on-demand and no drinking water storage is required. RATIOfresh units
are available in various sizes, ranging from single family home requirements to
scalable systems for large commercial and industrial applications.

■ RATIOfresh 250/400 Freshwater Unit –
Technical Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

■ RATIOfresh 250/400 Freshwater Unit –
Installation and Operations Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

■ RATIOfresh 200 Fresh Water Station –
Technical Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

■ RATIOfresh 200 Freshwater Unit –
Installation and Operations Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
1.3

201
TECHNICAL INFORMATION

RATIOfresh 250/400 Freshwater Unit
Freshwater Unit for Higher Water Capacities

1.3

Figure 1 Freshwater Unit RATIOfresh 250/400

Product Characteristics Content
● Hygienic hot water preparation with continuous-flow 1. Technical Data . . . . . . . . . . . . . . . . 204
heater principle 2. Dimensions . . . . . . . . . . . . . . . . . 205
● High output with a tapping capacity of 25 and 40 l/min, 3. Functional Description . . . . . . . . . . . . 206
respectively 4. Hydraulic Characteristics . . . . . . . . . . . 207
● High solar yield thanks to very efficient stainless steel 5. Volume Flow and Temperature Specifications . . 208
plate heat exchanger and low return flow temperatures 6. Controller RATIOfresh 250/400 . . . . . . . . 208
achieved through precise demand adjustment 7. Mounting Options . . . . . . . . . . . . . . 209
● Incl. protection against legionella by thermal disinfec- 8. Accessories . . . . . . . . . . . . . . . . . 209
tion of the hot water and circulation pipe networks 9. Sample System Solutions . . . . . . . . . . . 210
● With integrated circulation function
● Suitable for mounting to wall or storage cylinder
● Can be combined with all common heat sources in
connection with a buffer storage

Solar Thermal / Freshwater Units EN-XXX_RATIOfresh-250/400_TI-100106-1WA10059 203
1. Technical Data
Table 1 Technical Data
Features RATIOfresh 250 RATIOfresh 400
Order no. 150 300 65 150 300 66
Nominal tapping capacity
10 °C ➝ 45 °C (sec.)
60 °C (prim.) ➝ RATIOfresh 250 25 l/min 40 l/min
65 °C (prim.) ➝ RATIOfresh 400
Transmission capacity
10 °C ➝ 45 °C (sec.) 61 kW 98 kW
10 °C ➝ 60 °C (sec.) 87 kW 139 kW
Performance coefficient acc. to DIN 4708 T3:
NL = 13 NL = 19,5
10 °C ➝ 45 °C (sec.), 82 °C (prim.)
Performance coefficient for other temperature
conditions:
NL = 11 NL = 17
10 °C ➝ 60 °C (sec.), 75 °C (prim.)
NL = 7 NL = 11
10 °C ➝ 60 °C (sec.), 82 °C (prim.)
Hot water temperature setting range 25 - 70 °C
Circulation return temperature 5 - 70 °C
Pressure loss secondary (Δ p) < 370 mbar for 25 l/min < 490 mbar for 40 l/min
Max. operating temperature Primary 95 °C, secondary 95 °C
Max. operating pressure Primary 6 bar, secondary10 bar
Heat exchanger Copper welded stainless steel plate heat exchanger
1.1 l (primary side) / 1.6 l (primary side) /
Water volume of heat exchanger
1.2 l (secondary side) 1.7 l (secondary side)
Primary circuit pump Wilo ST 25/6, 3-steps, 43/61/82W
Controller RATIOfresh domestic water heating controller integrated in unit
4 x KTY
Temperature sensor
Buffer storage sensor with 3.5 m cable length (prolongable)
Sensor for volume flow Volume flow meter Qn 2.5 in cold water flow
Voltage 230 V / 50 Hz
Protection class (controller) IP 44
Max. power input (power consumption of pumps) 2 x 400 W
Power consumption during stand-by modus 0.6 W
Casing material Powder coated steel
Top: light grey – RAL 7035
Colour
Bottom: black-grey – RAL 7021
Weight 26 kg 28 kg
Dimensions (H x W x D) 940 x 350 x 181 mm
Wall mounting, storage cylinder mounting in connection with the buffer storage
Mounting options
series RATIO (except RATIO 300 G and RATIO 700 without heat exchanger)

Special Variation
For the operation in connection with down streamed galvanised tubes, our special version “RATIOfresh Alfanova” is
available. It comes without copper-soldered connections in the stainless steel plate heat exchanger.

Table 2 Technical Data RATIOfresh Alfanova 250 and 400
Features RATIOfresh Alfanova 250 RATIOfresh Alfanova 400
Order no. 150 301 77 150 301 78
Heat exchanger Welded stainless steel plate heat exchanger
For further technical data please refer to RATIOfresh 250 or 400.

204 EN-XXX_RATIOfresh-250/400_TI-100106-1WA10059
2. Dimensions

350
80

160
A

57
100
85

80

340

57
B

160
570

940

85 160

Figure 2 External dimensions RATIOfresh 250/400 in mm 1.3

EN-XXX_RATIOfresh-250/400_TI-100106-1WA10059 205
3. Functional Description
Basic Principle 4
The RATIOfresh 250/400 Freshwater Unit heats up dome- 10
stic water via the flow-through principle. When hot wa-
16 7
ter is drawn, the primary circuit pump (3) pumps heating
water from the buffer storage through the stainless steel 11 12
plate heat exchanger (2).
On the other side of the plate heat exchanger (secondary
circuit), the domestic water is heated up to the set tempe- 6
rature (adjustable at controller (1), factory-setting 50 °C).
The now cooled heating water flows back to the lower
section of the buffer storage.

Output Regulation
9
With the assistance of temperature sensors in hot water
exit (12) and primary flow (16), the output of the primary
circuit pump is precisely matched to the tapping volume
2 8
flow.
The speed control of the primary circuit pump allows for
a constant tapping temperature and low primary return 13
flow temperatures. The latter helps to improve the tempe-
rature stratification within the buffer storage. 15

Protection against Legionella
The unit allows for thermal disinfection of the hot water
& Co

and circulation pipes with a programmable schedule. If
er

3
gn
Wa

required, aux. heating of the storage cylinder can be re-
quested via a potential-free relay, and then the pipe net-
work can be disinfected with hot water. 5
1

Operating in Stand-by Modus
The stand-by temperature keeping function allows for in-
stant hot water supply, also after long times without tap- 14
ping. This function can also be utilised as frost protection.
17

Switching, Primary Return Flow Figure 3 The most important components of the unit
For long circulation times (e. g. in apartment blocks) it may 1 RATIOfresh controller; 2 heat exchanger; 3 primary circuit
pump; 4 primary circuit flow with cut-off valve (1" male, flat seal-
be energetically reasonable, to lead the return flow of the
ing); 5 primary circuit return flow with ball valve and integrated grav-
primary circuit into two different levels of the buffer. This ity brake (ret. flow stopper, 1" male, flat sealing); 6 cold water inlet
can be easily realised in combination with a temperature- (1" male, flat sealing); 7 hot water outlet (1" male, flat sealing); 8 cir-
difference-controller and switching valves (see fig. 9). culation connection (½" female); 9 vol. flow meter; 10 encasing bot-
tom; 11 heat exchanger insulation made from EPP; 12 temperature
sensor hot water outlet; 13 temperature sensor cold water / return
flow; 14 temperature sensor prim. circuit storage cylinder flow (buffer
storage sensor); 15 switch for pump speed level; 16 temperature
sensor, primary circuit flow; 17 mains plug

206 EN-XXX_RATIOfresh-250/400_TI-100106-1WA10059
4. Hydraulic Characteristics

650

600

550
Max. pump speed level
500
Pressure loss / pump head in mbar

Medium pump speed level
450

400
Min. pump speed level
350

300
Pressure loss secondary side RF 250
250

200

150

100
Pressure loss primary side RF 250
50
1.3
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

Volume flow primary- / secondary side in l/min
Figure 4 Pressure loss curves and pump characteristics RATIOfresh 250

650

600
Max. pump speed level
550

500
Pressure loss / pump head in mbar

450

400
Medium pump speed level
350
Min. pump speed level
300

250

200

150 Pressure loss primary side RF 400
Pressure loss secondary side RF 400
100

50

0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40

Volume flow primary / secondary side in l/min
Figure 5 Pressure loss curves and pump characteristics RATIOfresh 400

EN-XXX_RATIOfresh-250/400_TI-100106-1WA10059 207
5. Volume Flow and Temperature Specifications
Table 3 Volume Flow- and Temperature Specifications of RATIOfresh 250 for Various Hot Water Temperatures
Hot water temperature Tapping volume flow Required temperature Required volume flow Return flow temperature
[°C] [l/min] primary side [°C] primary side [l/min] prim. circuit
50 13 23
45 10
60 8.1 16
50 21.9 26
45 15
60 12.8 18
60 23.4 22
45 25
70 17.3 18
65 14.5 30
60 10
75 9.4 21
65 24.9 34
60 15
75 15.1 24
75 28.2 29
60 25
80 24 26

Table 4 Volume Flow and Temperature Specifications of RATIOfresh 400 for Various Hot Water Temperatures
Hot water temperature Tapping volume flow Required temperature Required volume flow Return flow temperature
[°C] [l/min] primary side [°C] primary side [l/min] prim. circuit
50 19.1 22
45 15
60 12.1 16
55 26.2 21
45 25
65 18.4 17
65 31.5 20
45 40
75 24.7 17
65 21.2 29
60 15
75 14 20
65 30.4 28
60 25
75 25.2 24
85 33.7 24
60 40
90 30.4 22

6. Controller RATIOfresh 250/400
● Controller for domestic hot water preparation with pre-
cise output adjustment
● Protection against legionella
● Temperature keeping (standby function) for fast hot
water supply
● Integrated circulation control
● Illuminated display and intuitive menu navigation in 5
languages
● Serial interface RS 232 for data readout
● Frost protection
● For further information please see “Operating Manual
Controller RATIOfresh 250/400”

Figure 6 Fresh water controller RATIOfresh 250/400

208 EN-XXX_RATIOfresh-250/400_TI-100106-1WA10059
7. Mounting Options 8. Accessories
● Wall mounting Table 5 Accessories RATIOfresh 250/400
● Mounting to storage cylinder (see fig. 7) in connection
Item Order no.
with all types of RATIO buffer tanks, except RATIO 300
G and RATIO 700 (version without heat exchanger) Storage cylinder extension set 139 000 28
Combi fitting set 1"-22 mm
819 100 87
for tube connection
3-way-valve 1" for return flow switch 160 101 44

Figure 8 Storage cylinder mounting kit

1.3

Figure 7 Storage cylinder mounting of RATIOfresh 250/400 (with re-
moved top cover) in combination with RATIO buffer storage

Figure 9 Two and three way switching valves

Figure 10 Combi fitting 1"

EN-XXX_RATIOfresh-250/400_TI-100106-1WA10059 209
9. Sample System Solutions

P1: Solar circuit pump SUNGO SXL, system 1241
P2: Boiler circuit pump Collector area

Outputs

Inputs
P3: Heating circuit pump
P4: Pump RATIOfresh primary circuit
P5: Circulation pump, hot water

M1: Heating circuit mixer
WEZ: Heat generator request (if required via relay)

Vm: Thermal mixing valve for keeping
a min. return flow temperature

Circulation

Cold water

Hot water

Figure 11 System solution with RATIOfresh 250/400, RATIO buffer storage, pellet boiler, mixed heating circuit and solar installation. The pellet
boiler profits partially from the buffer volume for optimising its operating characteristics. During the summer half of the year, the solar installation
meets the hot water demand almost completely and additionally provides space heating support in spring and fall.

P1: Solar circuit pump SUNGO SXL, system 1211
P2: Boiler circuit pump Collector area
Outputs

Inputs

P3: Pump gas boiler
P4: Heating circuit pump
P5: Pump RATIOfresh primary circuit
P6: Circulation pump hot water

M1: Heating circuit mixer
V1: 3-way-switching valve, return flow boost
V2: Thermal mixing valve for keeping
a min. return flow temperature
V3: Unit internal switching valve, hot water preparation
HW: Hydraulic switch

Circulation

Cold water
Hot water

Figure 12 System solution with RATIOfresh 250/400, RATIO buffer storage, gas boiler, fire place with water pockets, mixed heating circuit and
solar installation. Both, open fire place and solar installation, can load the buffer storage. The buffer storage heat is supplied to the heating circuit
via return flow boost.

Subject to modifications, errors excepted · © Wagner & Co, 2010 · www.wagner-solar.com
210 WAGNER & CO · Zimmermannstraße 12 · D-35091 Cölbe/Marburg · ☎
+49 (0) 64 21 80 07-0 · Fax 80 07-596
INSTALLATION AND OPERATIONS MANUAL

RATIOfresh 250/400 Freshwater Unit
Freshwater Unit for Higher Water Demands

1.3

sh
fre
TIO
RA

Figure 1 Freshwater unit RATIOfresh 250/400

Content
1. Safety Instructions . . . . . . . . . . . . . 212 3. Commissioning . . . . . . . . . . . . . . . 219
2. Installation . . . . . . . . . . . . . . . . . 213 3.1 Pump Speed Selection . . . . . . . . . . . 219
2.1 Pre Installation Notes . . . . . . . . . . . . 213 3.2 Filling the System . . . . . . . . . . . . . . 220
2.2 Correct Handling . . . . . . . . . . . . . . 213 3.3 Adjusting Controller to Tapping Volume . . . . 222
2.3 Integration into the Hydraulic System . . . . . 214 4. Operation . . . . . . . . . . . . . . . . . 224
2.4 Wall Mounting . . . . . . . . . . . . . . . 215 5. Maintenance . . . . . . . . . . . . . . . . 224
2.5 Tank Mounting . . . . . . . . . . . . . . . 215 5.1 General Recommendations . . . . . . . . . 224
2.6 Primary Circuit Connections . . . . . . . . . 216 5.2 Decalcification . . . . . . . . . . . . . . . 224
2.7 Domestic Water Circuit Connections . . . . . 217 5.3 Removing the Heat Exchanger . . . . . . . . 225
2.8 Controller . . . . . . . . . . . . . . . . . 218 6. Troubleshooting . . . . . . . . . . . . . . 226
2.9 Connecting the Circulation Pump . . . . . . . 218

Solar Thermal / Freshwater Units EN-XXX_RATIOfresh-250-400_MA-BA-100225-1WA10060 211
1. Safety Instructions
1.1 Symbols

DANGER – possibility of personal injury

CAUTION – possibility of property damage

NOTE – important additional information

Figure 2 Install unit in dry and frost free location
1.2 Norms and Standards
Observe current national and regional codes and stand-
ards at installation location. In absence of such rules we Zn
WW
recommend to follow:
● IEC 364 or CENELEC HD 384, DIN VDE 0100 and IEC-
Report 664, DIN VDE 0110 and national accident pre-
vention rules and regulations, as well as VDE 0100,
VDE 0160 (EN 50178), VDE 0113 (EN 60204), and local KW
rules and specifications of your energy provider or util-
ity company.
● Potential equalisation according to VDE 0100-540 part
5-54 “Selection and construction – earthing, earthed
lead wires and potential equalisation” and VDE 0190.

RATIOfresh

1.3 User Qualification
Installation, commissioning, maintenance and reparation Figure 3 Do not use any galvanized pipes downstream, except in
must be realised from authorized specialists. combination with RATIOfresh Alfanova 250 and 400.

1.4 Intended Use
The purpose of the unit is to heat domestic water for pri- SV
vate and commercial applications in combination with KW
buffer storages. For buffer storage temperatures above
60 °C, the concentration of chloride within the domestic
water should be limited (see table 1).

Table 1 Maximimum Chloride in Domestic Water
Storage temperature Chloride SV
KW
< 60 °C No limit
up to 90 °C < 150 ppm

Figure 4 No cut-off valves between safety valve and unit

1.5 Recycling Notes
At the end of the long operational lifetime, the valuable
materials of the installation should be recycled in an en-
vironmentally sound manner. If recycling is not possible,
Wagner & Co will take the scrap material back.

212 EN-XXX_RATIOfresh-250-400_MA-BA-100225-1WA10060
2. Installation
2.1 Pre Installation Notes 2.2 Handling
● Installation of a safety group is required for the cold 20
water inlet (see fig. 13).
● For cold water pressure > 10 bar ➝ install pressure re-
ducer. 18
● Pipeworks in primary circuit (storage-unit) should be as
short as possible.
● For domestic water with hardness > 10 °dH (7.98 °e)
install rinsing valves. (see fig. 12).
● Unnecessarily high water temperatures increase the 10
energy consumption
● For apartments please observe protection against le-
gionella according to DVGW W551 or your local stand-
ards and codes!
● Make existing storage pressure-less and empty (see
fig. 5).

22

1.3
22

21

Figure 6 Correctly attach casing cover:
18 cover; 10 lower aprt of encasing; 20 connecting bar; 21 safety
plug; 22 safety sockets

Figure 5 Make existing storage pressure less and rain

EN-XXX_RATIOfresh-250-400_MA-BA-100225-1WA10060 213
2.3 Integration into the Hydraulic System

Figure 7 Overview hydraulic connection
WW hot water; KW cold water; P1 pump, primary circuit; P2 circulation pump (optional); E bleeder (if required by piping layout); SG safety
group; KFE rinsing valve; 1 RATIOfresh hot water sensor; 2 RATIOfresh cold water inlet sensor; 3 RATIOfresh storage sensor; 4 RATIOfresh
primary circuit flow sensor; 9 RATIOfresh volume flow sensor

214 EN-XXX_RATIOfresh-250-400_MA-BA-100225-1WA10060
2.4 Wall Mounting 2.5 Tank Mounting
● With special tank mounting kit for RATIO buffer storage
350 tanks (except RATIO 300 G and RATIO 700 without heat
80 exchanger).
● For some storage cylinder types the included corru-
gated tubes must be shortened.

100
340
26

570

940
27
31 30
28

85 160

Figure 8 Dimensions RATIOfresh 250 and 400 1.3

24

23
29

25
254
10

Figure 10 Storage mounting
26 RATIO buffer storage; 27 third connection from top (for RATIO
23 1000 G2 fifth connection from top); 28 mounting bracket; 29 flat
swivel nut ¼"; 30 Hexagonal bolts; 31 mounting plate

827

Figure 9 Wall mounting with screws
10 lower part of encasing; 23 fixing screw; 24 groove for fix-
ing; 25 dowel

EN-XXX_RATIOfresh-250-400_MA-BA-100225-1WA10060 215
2.6 Primary Circuit Connections

14

26

36

35
34 32
33

H=max

Figure 11 Connection to primary circuit
14 RATIOfresh storage sensor; 26 RATIO buffer storage; 32 sensor connection bar; 33 flat sealing; 34 combi connection 1"-22 mm; 35 swiv-
el nut 1"M 36 bleeder (if required by piping)

● The temperature sensor (14) should measure the flow
temperature of the unit as precisely as possible. It must
therefore be set to the highest position (32) of the sen-
sor connection strip. When using a storage from anoth-
er manufacturer use soft foam tape to attach the sensor
to the cylinder wall; assure good surface contact.
● Carry out connections flat sealing.
● Install bleeder (36) if required.
● The primary circuit must be hydraulically separated
from other pumps! Multiple configurations of flow and
return flow therefore are not possible.
● Keep pipe lengths in primary circuit short to avoid heat
loss and time lags. Besides that high pressure loss can
result in reduced performance.

216 EN-XXX_RATIOfresh-250-400_MA-BA-100225-1WA10060
2.7 Domestic Water Circuit Connections

44

39
38
35
34
33

KW

40

41

1.3
42

Wag
ne
r&
Co

43

Figure 12 Connection to domestic water circuit
33 flat gasket; 34 combi connection 1"-22; 35 swivel nut 1"; 38 rinsing valve (if rinsing of heat exchanger is intended); 39 cut off valve; 40 safety
group; 41 ½" plug for circulation connection; 42 optional circulation pump; 43 non-return valve (if circulation pump is used); 44 hot water tap

● Observe applicable codes, standards as well as the
regulations of the local water utility companies.
● Carry out connections flat sealing, except circulation
connection.
● Recommendation: install rinsing tabs, especially when
water hardness > 10 °dH (7.98 °e).
● Do not install shut off valves between safety group and
unit (see fig. 4)!

EN-XXX_RATIOfresh-250-400_MA-BA-100225-1WA10060 217
2.8 Controller
Only use the original pump as the primary circuit pump!
As circulation pump use a common speed controlled wet
runner. Don't use a pump with integrated motor protec-
tion or electronic on-off mechanism or controller! The cir-
culation pump must not have its own time or temperature
controller!
● For information about “thermal disinfection” and con-
trol of the auxiliary heating function of the boiler refer
to Mounting and Operating instructions “Freshwater
Controller RATIOfresh 250/400”.

2.9 Connecting the Circulation Pump
Cut mains connection!

2

1

Figure 13 Loosen Phillips screws and remove controller cover

Figure 14 Thread cables of the circulation pumps through a free lead
(open screw of lead) and attach to the connection bar (8 – see Mount-
ing and Operating Instructions “Freshwater Controller RATIOfresh
250/400”).

218 EN-XXX_RATIOfresh-250-400_MA-BA-100225-1WA10060
3. Commissioning
3.1 Pump Speed Selection
To arrive at optimal tapping characteristics and provide
sufficient tapping volume flows, the pump must be set to
the correct speed. It can be determined using the follow-
ing tables. You can find the hydraulic curves of the unit in
the “Technical Information RATIOfresh 250/400”

15

1.3

Figure 15 Speed selector 15 for the primary circuit pump

Table 2 Pump Settings RATIOfresh 250 for 45 °C or 60 °C Tapping Temperature against Tapping Volume Flow,
Primary Side Volume Flow and Primary Side Temperatures
Hot water temperature Tapping volume flow Required temperature prim. side Required volume flow prim. side Required
[°C] [l/min] [ °C] [l/min] pump speed
50 13 min
45 10
60 8.1 min
50 21.9 med
45 15
60 12.8 min
60 23.4 med
45 25
70 17.3 min
65 14.5 min
60 10
75 9.4 min
65 24.9 max
60 15
75 15.1 min
75 28.2 max
60 25
80 24 med

EN-XXX_RATIOfresh-250-400_MA-BA-100225-1WA10060 219
Table 3 Pump Settings RATIOfresh 400 for 45 °C or 60 °C against Tapping Volume Flow,
Primary Side Volume Flow and Primary Side Temperatures
Hot water temperature Tapping volume flow Required temperature prim. side Required volume flow prim. side Required
[ °C] [l/min] [ °C] [l/min] pump speed
50 19.1 min
45 15
60 12.1 min
55 26.2 max
45 25
65 18.4 min
65 31.5 max
45 40
75 24.7 med
65 21.2 med
60 15
75 14 min
65 30.4 max
60 25
75 25.2 med
85 33.7 max
60 40
90 30.4 max

3.2 Filling the System
First check all connections. Then follow the steps below:

Z Z
A A

Figure 17 Functional positions of the gravity brake (non return valve).
Observe black mark next to the screw slot.
Gravity brake operational = Z;
gravity brake open/not operational = A

37

5

Figure 16 Open ball valve 5 and gravity brake (non return valve) 37.

220 EN-XXX_RATIOfresh-250-400_MA-BA-100225-1WA10060
Figure 18 Filling and venting storage tank Figure 19 Possibly also vent the primary circuit

WW
WW

CW

CW

1.3

Figure 20 Vent Secondary or domestic water circuit, respectively Figure 21 Vent circulation pipe (if in place), hereunto open non return
valve.

Tprim

Figure 22 Vent primary circuit pump when in operation Figure 23 Heat storage tank to the temperature required on the pri-
mary side (see table 2 and 3)

EN-XXX_RATIOfresh-250-400_MA-BA-100225-1WA10060 221
Figure 24 Commence commissioning at the controller (see Mount-
ing and Operation Instructions “Freshwater Controller RATIOfresh
250/400”)

3.3 Adjusting the Controller to the
Tapping Volumes
Carry out a one-time adjustment of the controller to the
hydraulic conditions of the location. The maximum tapping WW Zirk. NH Des.
volume depends on the unit type and is divided into 11
tapping slots, where an adaptive value is assigned to every 1
tapping slot. The latter can either be entered manually
or they can be determined by the controller by means of Adapt. Value 0
controlled tapping. Here the number of the adaptive value 14°C 00 [07]
must always match with the number of the tapping slot. At
2 3 4
least for 3 tapping slots controlled tapping must be car-
ried out. Follow the steps below based upon the operation
instructions “Freshwater Controller RATIOfresh 250/400”

● Set hot water target temperature
● Adjust circulation settings
● Select Menu “Settings Service” Figure 25 Display values in Menue “Adaptive Values”:
● Enter service code 008 1 number of adaptive values; 2 hotwater exit values; 3 number of
tapping time slot; 4 determined or set adaptive value
● Select menu “Adaptive Values”

WW Zirk. NH Des. WW Zirk. NH Des.

Adapt. Value 0 Adapt. Value 1
14°C 00 [07] 14°C 00 [07]

Figure 26 When no tapping occurrs tapping slot 00 and adaptive Figure 27 The number of the adaptive values can be selected using
value no. 0 are displayed. the arrow keys.

222 EN-XXX_RATIOfresh-250-400_MA-BA-100225-1WA10060
WW Zirk. NH Des. WW Zirk. NH Des.

Adapt. Value 2 Adapt. Value 4
46°C 02 [x] 46°C 04 [x]

Figure 25 Choose no. 2 of the adaptive values. Open hot water tap Figure 29 Repeat action for tapping slot 04
until tapping time slot 2 and the target water temperature are reached
(to approx. plus-minus 1 °C). The controller then automatically deter-
mines an appropriate adaptive value (shown as “X”).

Adapt. Value 0
46°C 00 [07]
1.3
WW Zirk. NH Des.

Adapt. Value 1
Adapt. Value 6 46°C 01 [10]
46°C 06 [x]

Adapt. Value 2
46°C 02 [13]

Figure 30 Repeat action for tapping window 06 Figure 31 Enter adaptive values for tapping time slots 01, 03 and 05
manually (here shown for slot 01 as an example), or determine values
by additional controlled tappings.

WW

WW Zirk. NH Des. T = okay?

CW

Adapt. Value 7
46°C 07 [x]

Figure 32 Manually enter adaptive values for additional tapping slots. Figure 33 Carry out final functional test
They must follow an ascending order. The factory settings might pos-
sibly suffice.

EN-XXX_RATIOfresh-250-400_MA-BA-100225-1WA10060 223
4. Operation 5.2 Decalcification
The freshwater unit usually does not require any attention. Signs of Possible Scaling:
Please still observe the following points: ● Return temperature in primary circuit is too high
● Observe messages shown on the controller display ● Considerably reduced maximum tapping volume
(see controller instructions) ● Hot water target temperature cannot be reached any-
● The set hot water temperature can be changed in the more for high tapping columes
controller menu “settings” (see controller instructions).
● All values are saved in case of power failure. Procedure:
● Vacation or longer time of absence: to save electricity ● Cut off mains connection
simply cut off the unit from the mains connection. ● Make domestic water pipe (secondary side) pressure
● The unit should be regularly checked and maintained less and drain. Hereunto close cut off valve of safety
by a qualified technician. group (40) and cut off valve (39).
● In case of defects or malfunctions inform a qualified ● Connect decalcification unit or rinsing pump (45) to
technician. rinsing valves (38).
● Pump cleansing liquid through the circuit
● Observe instructions of cleaning liquid manufacturer
5. Maintenance ● If no rinsing valves are installed, the heat exchanger
should be taken out for cleaning
5.1 General Recommendations ● Only utilize cleaning liquids approved for use with
drinking water supply systems!
● Maintenance interval: annually ● Neutralise according to instruction
● Cut off mains before commencing
● Check unit for leaks (threaded and soldered connec-
tions) 39
● Check for scaling

40

38

2

44

Co
r&
ne
Wag

45

Figure 34 Connection of a decalcification unit
2 heat exchanger; 32 cold water rinsing valve; 39 cut off
valve; 40 safety group; 44 cleansing liquid; 45 rinsing pump

224 EN-XXX_RATIOfresh-250-400_MA-BA-100225-1WA10060
5.3 Removing the Heat Exchanger
If no rinsing valves are present the heat exchanger must
be removed.

Procedure: 48
● Cut off mains
● Make domestic water pipe (secondary side) pressure
46
less and drain.
● Cut off primary side and drain. Hereunto close cut off 2
valve (48) and ball valve (5). 47
● Loosen swivel nut (46) and drain heat exchanger (2).
● To dissassemble heat exchanger, loosen all 4 swivel
nuts (46 and 47)

1.3

10-10

47

5

Figure 35 Removing heat exchanger
2 heat exchanger; 5 ball valve; 46 swivel nut, primary side; 47 swiv-
el nut, secondary side; 48 cut off

EN-XXX_RATIOfresh-250-400_MA-BA-100225-1WA10060 225
6. Trouble Shooting
Table 4 Trouble Shooting
Problem Possible Cause Action
Cut off valve in cold water feed partly closed Open cut off valve in feed
Tapping volume (hot water)
Heat exchanger scaled Decalcify heat exchanger (see chap. 5.2)
too low
Sifter in cold water feed clogged Clean sifter
Cut off valves in cold water feed or hot water
No hot water output Open valves
pipe closed
Check power lines and fuses, check if controller
Power failure or RATIOfresh without power
display light is on
Buffer storage is cold Check auxiliary heating
Water is not heated Primary circuit pump P1 defunct Check pump in manual operation
Air in primary circuit Vent primary circuit, e.g. at the storage
Check operability, e.g. by acoustic checking of the
Single jet meter does not recognize tapping
impulse exit with a multimeter
Hot water target temperature set incorreclty Increase hot water target temperature
Air in primary circuit Vent primary circuit, e.g. at the storage
Hot water temperature Increase aux. heating temperature at aux. heating
Aux. heating temperature too low
too low device (boiler, electric heater etc.)
Wrong pump speed setting Check pump speed against values in tables 2 and 3.
Controler not yet adapted Carry out controlled tapping (see cap. 3.3)
Target temperature set incorrectly Adjust target temperature
Set pump mode to “Auto” (see Mounting and
Wrong oump mode set at primary circuit
operation instructions “Freshwater Controller
pump P1
RATIOfresh 250/400”)

Hot water temperature Set operation to “Auto” (see Mounting and operation
Wrong setting of disinfection operational
to high instructions “Freshwater Controller RATIOfresh
modet
250/400”)
Controller not yet adapted Carry out controlled tapping (see cap. 3.3)
Wrong pump speed setting Check pump speed against values in tables 2 and 3.
Vertical convection in primary circuit Check gravity brake (non return valve) and piping
Air in circulation circuit Vent circulation circuit
Circulation circuit Circulation pump does not open gravity Use gravity brake (non return valve) with lower
does not warm up brake (non return valve) opening pressure or use stronger circulation pump.
Circulation pump defunct Replace pump
Controller not yet adapted Carry out controlled tapping (see cap. 3.3)
Hot water temperature
Wrong pump speed setting Check pump speed against values in tables 2 and 3.
fluctuates
Defunct tap Replace tap
Air in circulation circuit Vent circulation circuit
Check circulation times (see Mounting and operation
Wrong setting of circulation instructions “Freshwater Controller RATIOfresh
Hot water temperature takes long 250/400”)
time to reach desired value Check aux. heating, increase aux. heating
No circulation and standby function because
temperature and therefore (indirectly) also the
primary circuit temperature too lown
primary circuit temperature
Circulation pump defunct Replace pump
Check disinfection temperature at the controller, start
disinfection manually. LED turns off when disinfection
Red LED is on Disinfection temperature not reached
was successfull, power is cut, or the disinfection
mode is set to “off”.

Error Display Controller ➝ see Mounting and operation instructions “Freshwater Controller RATIOfresh 250/400”

Subject to modifications, errors excepted · © Wagner & Co, 2010 · www.wagner-solar.com
226 WAGNER & CO · Zimmermannstraße 12 · D-35091 Cölbe/Marburg · ☎
+49 (0) 64 21 80 07-0 · Fax 80 07-596
TECHNICAL INFORMATION

RATIOfresh 200 Fresh Water Station
Fresh Water Station with Solar Controller

1.3

Figure 1 Fresh water station RATIOfresh 200

Product Characteristics Content
● Hygienic hot water preparation with a tapping output 1. Technical Data . . . . . . . . . . . . . . . . 228
of up to 20 l/min 2. Dimensions . . . . . . . . . . . . . . . . . 228
● Just one controller for domestic water heating and solar 3. Functional Description . . . . . . . . . . . . 229
installation 4. Hydraulic Characteristics . . . . . . . . . . . 229
● High solar yields due to a very efficient stainless steel 5. Controller RATIOfresh 200 . . . . . . . . . . 231
plate heat exchanger and low return flow temperatures 6. Accessories . . . . . . . . . . . . . . . . . 231
thanks to precise demand adjustment 7. System Solutions . . . . . . . . . . . . . . . 232
● Prepared for circulation operation
● Easy installation and maintenance
● Can be combined with all common heat sources in con-
nection with a buffer storage
● Low power consumption thanks to efficient circulation
pump

Solar Thermal / Freshwater Units EN-XXX_RATIOfresh-200_TI-091006-1WA10013 227
1. Technical Data
Table 1 Technical data
Features RATIOfresh 200
Part no. 150 303 39
Nominal tapping capacity
10 °C ➝ 45 °C (sec.) 55 °C (prim.) 20 l/min
10 °C ➝ 60 °C (sec.) with addition of 27 l/min
cold water up to 45 °C, 70 °C (prim.)
Transmission capacity
10 °C ➝ 45 °C (sec.) 49 kW
10 °C ➝ 60 °C (sec.) 70 kW
Performance number acc. to DIN 4708 T3
10 °C ➝ 60 °C (sec.) with the addition of NL = 4
cold water up to 45 °C, 82 °C (prim.)
10 °C ➝ 45 °C (sec.), 55 °C (prim.) NL = 2
Adjustable hot water temperature 20 - 60 °C
Circulation return Nominal temperature hot water – 5 K
Pressure loss secondary (Δ p) < 470 mbar for 20 l/min
Max. operating temperature Prim. 95 °C, sec. 70 °C
Max. operating pressure Prim. 6 bar, sec. 10 bar
Heat exchanger Copper soldered plate heat exchanger made from stainless steel
Water volume capacity 0.87 l (prim.) / 0.93 l (sec.)
Cover and rear insulation shell EPP (expande polypropylene)
Prim. circuit pump Wilo ST 15/6 ECO-1 / 1-step / max. 63 W
Integrated in station: RATIOfresh 200 controller for domestic water heating and
Controller
solar installation. Incl. circulation control and 6 choosable solar systems.
Temperature sensors 2 x Pt1000 installed, within flow; 1 x Pt 1000 for attachment on storage
Sensor for Combined sensor VFS within hot water outlet for
volume flow and temperature -measurements volume flow and temperature -measurements
Voltage 230 V / 50 Hz
Protection class IP 20
Power rating in standby 2.1 - 3.9 W
Weight 12 kg
Dimensions (W x H x D) 356 x 593 x 236 mm

2. Dimensions

Figure 2 Outside dimensions in mm

228 EN-XXX_RATIOfresh-200_TI-091006-1WA10013
3. Functional Description
The RATIOfresh 200 fresh water station heats up domes-
tic water via the flow-through principle. When hot water is 8
drawn, the primary circuit pump (3) pumps heating water 7
from the buffer storage through the stainless steel plate
heat exchanger (2).
9 1
On the other side of the plate heat exchanger (secondary
side) the domestic water is heated up to the set tempera- 5
ture (adjustable at controller (1), pre-setting: 45 °C). The 6
now cooled heating water flows back to the lower section
of the buffer storage.
The output of the primary circuit pump is precisely calcu-
lated to match the volume flow resulting from the drawn
quantity. This is achieved with the combined sensor for
flow and temperature (6), the temperature sensors in the
cold water feed (5) and in the primary flow (not in fig.!). 2
The precise speed control of the primary circuit pump al-
lows for a constant tapping temperature as well as very low
primary return flow temperatures. Therefore the tempera- 3
ture stratification within the buffer storage is preserved.
4

Figure 3 The main components of the station
1 RATIOfresh controller; 2 heat exchanger; 3 pump, primary cir-
cuit; 4 ball valve, primary circuit return flow ¾" male flat sealing incl.
gravity brake (ret. flow stopper); 5 temperature sensor cold water
1.3
feed; 6 combined sensor VFS (vol. flow and temperature) in hot water
leg; 7 hot water outlet ¾" male flat sealing; 8 flow primary circuit ¾"
male flat sealing; 9 cold water feed ¾" male flat sealing

4. Hydraulic Characteristics

600

Characteristics primary circuit pump
500
Pressure loss and pump head in mbar

400

Remaining pump head

300

Pressure loss secondary side
200

100
Pressure loss primary side

0
0 2 4 6 8 10 12 14 16 18 20 22 24

Volume flow, primary side in l/min
Figure 4 Pressure loss graph and pump characteristics RATIOfresh 200

EN-XXX_RATIOfresh-200_TI-091006-1WA10013 229
40 40
65°C
Primary return flow temperature in °C

Primary return flow temperature in °C
35 35

70°C
30 30
50°C
75°C
25 25
55°C
85°C
20 60°C 20
70°C 90°C
15 80°C 15
90°C
10 10

5 5

0 0
2 4 6 8 10 12 14 16 18 20 2 4 6 8 10 12 14 16 18 20
Tapping volume flow in l/min Tapping volume flow in l/min

Figure 5 Prim. return flow temperatures for domestic water heating Figure 6 Prim. return flow temperatures for domestic water heating
from 10 °C up to 45 °C and flow temperatures from 50 °C up to 90 °C from 10 °C up to 60 °C and flow temperatures from 65 °C up to 90 °C

30 30

50°C 65°C
Primary return flow temperature in °C

25
Req. prim. volume flow in l/min 25 70°C

55°C
20
75°C
20
60°C
15 15 85°C
70°C
90°C
80°C
10 10
90°C

5 5

0 0
2 4 6 8 10 12 14 16 18 20 2 4 6 8 10 12 14 16 18 20
Tapping volume flow in l/min Tapping volume flow in l/min

Figure 7 Required prim. volume flow for domestic water heating from Figure 8 Required prim. volume flow for domestic water heating from
10 °C up to 45 °C and flow temperatures from 50 °C up to 90 °C 10 °C up to 60 °C and flow temperatures from 65 °C up to 90 °C

230 EN-XXX_RATIOfresh-200_TI-091006-1WA10013
5. Controller RATIOfresh 200
● Combined controller for domestic hot water prepara-
tion and solar installations
● 9 temperature inputs, 1 pulse input, 1 voltage input
(combined sensor VFS), 6 switching outputs
● Integrated controller function for circulation operation
● Optional: Data-stick for saving and displaying meas-
ured data and for software updates
● Illuminated display with pictograms and plain text
● Operation with common 230 V wet running pumps or
high efficiency pumps (ECM-technology) of type Wilo
Stratos ECO possible
● For further information please refer to the installation
and instruction manual “Freshwater Controller RATIOf-
resh 200” Figure 9 Freshwater and solar controller RATIOfresh 200

6. Accessories
Table 2 Accessories RATIOfresh 200
Item Part no. 1.3
Temperature sensor Pt1000 150 400 39
Combined connection set ¾"-18 mm
819 100 89
for pipe connection
Data logging set
150 400 39
for data recording of the regulation
Sensor set, incl.:
Figure 10 Combi-fitting and temperature sensor Pt1000
4 x temperature sensors Pt1000, 150 400 56
6 mm plug-in sensor
with 2.5 m silicone cable (-50 °C ... +180 °C)
Heat meter set 0.6 m³/h
150 400 30
incl. immersion sleeve and sensor Pt1000
Heat meter set 1.5 m³/h
150 400 35
incl. immersion sleeve and sensor Pt1000
Heat meter set 2.5 m³/h
150 400 36
incl. immersion sleeve and sensor Pt1000

Figure 11 Data logging set

Figure 12 Heat meter set

EN-XXX_RATIOfresh-200_TI-091006-1WA10013 231
7. System Solutions – Examples

P1: Solar circuit pump RATIOfresh 200, system 1261
P2: Heating circuit pump

Outputs

Inputs
P3: Pump RATIOfresh primary circuit Collector area
P4: Circulation pump hot water

Vr: 3-way-switching-valve,
return flow increase
M1: Heating circuit mixer

VFS: Combined sensor VFS
HW: Hydraulic switch
RV: Backflow preventer

Hot water

Cold water

Circulation

Figure 13 System solution with RATIO buffer storage and RATIOfresh 200 freshwater station in connection with a gas boiler and a low tempera-
ture heating circuit. Solar energy for room-heating is implemented via return flow boost of the heating circuit.

P1: Solar circuit pump RATIOfresh 200, system 1264
P2: Pump boiler circuit, solid fuel furnace
Outputs

Inputs

P3: Heating circuit pump
P4: Pump RATIOfresh, primary circuit Collector area
P5: Circulation pump, hot water

Vu: 3-way-switching-valve, storage switching
M1: Heating circuit mixer

VFS: Combined sensor VFS

Hot water
Cold water

Circulation

Solid fuel
furnace

Figure 14 System solution as a heating-buffer-system incl. RATIOfresh 200 freshwater station and 2 RATIO buffer storages in connection with a
solid wood furnace and a low temperature heating circuit. Boiler as well as solar installation can load both storages.

232 EN-XXX_RATIOfresh-200_TI-091006-1WA10013
P1: Solar circuit pump, primary RATIOfresh 200, system 1263 Collector
P2: Solar circuit pump, secondary
Collector area 1 area 2
P3: Pump boiler circuit, solid fuel furnace

Outputs

Inputs
P4: Heating circuit pump
P5: Pump RATIOfresh primary circuit
P6: Circulation pump hot water

Vr: 3-way-switching-valve return flow increase
Vk1/2: 2-way-valve, collector area 1/2

M1: Heating circuit mixer
VFS: Combined sensor VFS
Tpo: Temperature sensor buffer top, heating
Tpu: Temperature sensor buffer bottom, heating

Hot water

Cold water

Circulation

Oil or gas
boiler

1.3

Figure 15 System solution with oil or gas central heating, fresh water station RATIOfresh 200, a low temperature heating circuit and 2 differently
oriented collector areas. Solar energy for space-heating implemented via return flow boost of the heating circuit.

P1: Solar circuit pump RATIOfresh 200, system 1262
P2: Heating circuit pump Collector area
Outputs

Inputs

P3: Pump aux. heating, domestic water
P4: Pump RATIOfresh primary circuit
P5: Circulation pump, hot water

Vr: 3-way-switching-valve, return flow increase
Vk1/2: 2-way-valve collector area 1/2
M1: Heating circuit mixer

VFS: Combined sensor VFS

Hot water
Cold water

Circulation

Solid fuel
furnace

Figure 16 System solution as a heating-buffer-system with fresh water station RATIOfresh 200 and a buffer storage RATIO in combination with
a solid wood furnace and a low temperature heating circuit. The buffer storage is loaded with solar energy via an external plate heat exchanger.

EN-XXX_RATIOfresh-200_TI-091006-1WA10013 233
Subject to modifications, errors excepted · © Wagner & Co, 2010 · www.wagner-solar.com
234 WAGNER & CO · Zimmermannstraße 12 · D-35091 Cölbe/Marburg · ☎ +49 (0) 64 21 80 07-0 · Fax 80 07-596
INSTALLATION AND OPERATIONS MANUAL

RATIOfresh 200 Freshwater Unit
Freshwater Unit with Solar Controller

1.3

Figure 1 Freshwater unit RATIOfresh 200

Content
1. Safety Instructions . . . . . . . . . . . . . 236
2. Installation . . . . . . . . . . . . . . . . . 237
2.1 Pre Installation Notes . . . . . . . . . . . . 237
2.2 Handling . . . . . . . . . . . . . . . . . 237
2.3 Integration into the Hydraulic System . . . . . 238
2.4 Mounting . . . . . . . . . . . . . . . . . 239
2.5 Primary Circuit Connections . . . . . . . . . 240
2.6 Domestic Water Circuit Connections . . . . . 241
2.7 Controller . . . . . . . . . . . . . . . . . 242
3. Commissioning. . . . . . . . . . . . . . . 242
4. Operation . . . . . . . . . . . . . . . . . 244
5. Maintenance . . . . . . . . . . . . . . . . 245
6. Troubleshooting . . . . . . . . . . . . . . 246

Solar Thermal / Freshwater Units EN-XXX_RATIOfresh-200_MA-BA-091006-11218M00 235
1. Safety Instructions
1.1 Symbols

DANGER – possibility of personal injury

CAUTION – possibility of property damage

NOTE – important additional information

1.2 Norms and Standards Figure 2 Mount unit in a dry and frost-protected room

Observe current national and regional standards and reg-
ulations at installation location. In absence of such rules we
recommend to follow:
● IEC 364 or CENELEC HD 384, DIN VDE 0100 and IEC- Zn
WW
Report 664, DIN VDE 0110 and national accident pre-
vention rules and regulations, as well as VDE 0160 (EN KW
50178), VDE 0113 (EN 60204), and local rules and spec-
ifications of your energy provider or utility company.
● Potential equalisation according to VDE 0100-540 part
5-54 “Selection and construction – earthing, earthed
lead wires and potential equalisation” and VDE 0190

1.3 User Qualification
Installation, commissioning, maintenance and reparation
must be realised from authorized specialists.

Figure 3 Do not use any galvanised pipes downstream
1.4 Recycling Notes
At the end of the long operational lifetime, the valuable
materials of the installation should be recycled in an en-
SV
vironmentally sound manner. If recycling is not possible,
Wagner & Co will take the scrap material back. KW

1.5 Intended Use
SV
The purpose of the unit is to heat domestic water for
private and commercial applications. For buffer storage KW
temperatures above 60 °C, the concentration of chloride
within the domestic water should be limited (see table 1).

Table 1 Max. Chloride Percentage, Domestic Water
Storage temperature Chloride percentage
< 60 °C No limit
Up to 90 °C < 150 ppm
Figure 4 No shutoff between safety valve and unit

236 EN-XXX_RATIOfresh-200_MA-BA-091006-11218M00
2. Installation
2.1 Pre Installation Notes
● Installation of a safety group is required for the cold wa-
ter inlet (see fig. 13).
● For cold water pressure > 10 bar ➝ install pressure re-
ducer.
● Pipeworks in primary circuit (storage-unit) should be as
short as possible.
● Pipe diameter, primary circuit:
18 mm for total length < 6 m
22 mm for total length < 10 m
Tapping output decreases for increasing pipe lengths.
● For domestic water with hardness > 10 °dH (7.98 °e)
install rinsing valves. (see fig. 13).
● For apartments please observe protection against le-
gionella according to DVGW W551!
● Make possibly existing storage pressure-less and empty
(see fig. 5). Figure 5 Make existing storage pressure less and then drain

2.2 Handling

1.3

Figure 6 Remove cover shell: reach into the grooves on the sides and Figure 7 Don’t hold and carry unit at cover shell. Use heat exchanger
detach from back. Then pull off forwards. as handle instead.

EN-XXX_RATIOfresh-200_MA-BA-091006-11218M00 237
2.3 Integration into the Hydraulic System

Figure 8 Overview hydraulic connection
WW hot water; KW cold water; P1 pump, primary circuit; P2 circulation pump (optional); E ventilation (if required by piping layout); SG safety
group; KFE rinsing valve; T3 RATIOfresh 200 storage sensor; T8 RATIOfresh 200 primary circuit flow sensor; T9 RATIOfresh 200 cold water
inlet sensor; VFS combined sensor VFS (temperature and volume flow)

238 EN-XXX_RATIOfresh-200_MA-BA-091006-11218M00
2.4 Wall Mounting

380
283

Figure 9 Installation at eye level Figure 10 Drilling distances and screw fastening

1.3
53

140 70

Figure 11 Pipe separation distances and distance of the pipes to the
wall

EN-XXX_RATIOfresh-200_MA-BA-091006-11218M00 239
2.5 Primary Circuit Connections

6

5

4

3

2

1

H

Figure 12 Integration into the primary circuit
1 flat gasket; 2 combi-fitting ¾"-18 mm; 3 swivel nut ¾"; 4 ventilation (if required by piping layout); 5 buffer storage; 6 RATIOfresh 200 stor-
age sensor T3

Table 2 Sensor Positioning (mm) for Various RATIO Buffer Storage Cylinders
Cylinder RATIO HP 500 Cylinder RATIO HP 800 RATIO HP 1000
T2* 375 401 401
T3 1590 1540 1925
*T2 is the sensor for solar loading

● Carry out connections flat sealing ● The primary circuit must be hydraulically separated
● If required install bleeder (4) from other pumps!
● Storage sensor (6) must measure the max. storage tem- ● If applicable mount further sensors at storage for solar
peratures. For RATIO buffer cylinders please install ac- controller. Therefore please carefully observe the in-
cording to table 2. stallation and operating manual “Freshwater Controller
RATIOfresh 200”

240 EN-XXX_RATIOfresh-200_MA-BA-091006-11218M00
2.6 Domestic Water Circuit Connections

8

10
11 3
12

2

1

7

9

1.3
KW

Figure 13 Connection within domestic water circuit
1 flat gasket; 2 combi-fitting ¾"-18 mm; 3 swivel nut ¾"; 7 rinsing valve (if rinsing of heat exchanger is intended); 8 cut-off valve; 9 safety
group; 10 optional circulation pump; 11 non-return valve (eventually integrated in circulation pump); 12 hot water tap

● Carry out connections flat sealing
● Integrate circulation return flow as close to the unit as
possible.
● Operate circulation pump with RATIOfresh 200 control-
ler (connection see installation and operating manual
“Freshwater Controller RATIOfresh 200”).

EN-XXX_RATIOfresh-200_MA-BA-091006-11218M00 241
2.7 Controller
In addition to the freshwater function, the RATIOfresh
200-controller can also control 5 different solar installation
variants and various special functions.
Number and positions of sensors and connection dia-
grams can be found in the installation and operating man-
ual “Freshwater Controller RATIOfresh 200”, as well as in
chapter 2.5 “Primary Circuit Connections”.

Figure 14 Wiring in cable ducts of the back side Figure 15 Leave groove in side of shell for wiring

3. Commissioning
First check all connections. Then carry out the following
steps:

Figure 16 Open all ball valves Figure 17 Fill storage and bleed

242 EN-XXX_RATIOfresh-200_MA-BA-091006-11218M00
Figure 18 Possibly bleed primary circuit piping separately Figure 19 Bleed primary circuit of unit

HW
HW

CW
1.3
CW

Figure 20 Bleed secondary / domestic water circuit Figure 21 Bleed circulation pipe leg (if existing). If required open non-
return valve.

60˚C

Figure 22 Heat storage up to 60 °C Figure 23 Carry out commissioning at controller. See operating man-
ual of controller RATIOfresh 200.

EN-XXX_RATIOfresh-200_MA-BA-091006-11218M00 243
HW

T=okay? CW

Figure 24 Vent primary circuit pump during operation. Figure 25 Make a final functional check

4. Operation
The freshwater unit usually does not require any attention.
Please still observe the following points:
● Observe messages shown on the controller display (see
controller instructions)
● The set hot water temperature can be changed in the
controller menu “set” (see controller instructions)
● Selecting lower hot water and/or aux. heating tempera-
tures for the buffer storage reduces the energy demand
and increases the solar yield.
● Please inform technical staff about damages and / or
failures
● The installation should be subjected to regular mainte-
nance intervals.

244 EN-XXX_RATIOfresh-200_MA-BA-091006-11218M00
5. Maintenance
5.1 General Advice
● Maintenance interval: annually
● Cut mains connection before commencing mainte-
nance
● Check installation for leaks
● Check unit for scaling (see chapter 5.2)

5.2 Decalcification
Indications of Possible Scaling: Procedure:
● Return flow temperature within primary circuit too high ● Cut mains connection
● Significantly reduced hot water tapping output ● Domestic water pipe must be without pressure
● Nominal hot water temperature is not reached for high ● Empty domestic water / secondary side of plate heat
tapping volumes exchanger
● For this, shut off safety group (9) and close cut-off valve
(8)
● Connect decalcification unit or rinsing pump (13) via
7
the rinsing valves (7)
● Pump cleansing liquid through the circuit
● Observe instructions of cleansing liquid manufacturer
8 ● If no rinsing valves are installed, the heat exchanger
should be taken out for cleaning
● Utilise only DVGW-approved cleansing liquids (ap- 1.3
proved for use with drinking water supply systems)
● Neutralise according to instruction

9

14

13

Figure 26 Installation of a decalcification unit
7 rinsing valve; 8 on-return valve; 9 safety group;
13 rinsing pump; 14 cleansing liquid

EN-XXX_RATIOfresh-200_MA-BA-091006-11218M00 245
6. Troubleshooting
Table 3 Troubleshooting
Failure Cause Troubleshooting
Shut-off valves in cold water supply partially
Shut-off valves must be opened
closed
Tap volume flow (hot water) too low
Heat exchanger scaled Decalcify heat exchanger (see chapter 5.2)
Filter in cold water supply blocked Clean filter
Closed shut-off valves within cold or hot
Hot water does not flow Open shut-off valves
water pipe
Mains failure or RATIOfresh 200 without Power supply lines and fuses; check if
power controller display lights up

No heating of cold water possible Cold buffer storage Check aux. heating
Defunct primary circuit pump P1 Check pump in manual operation
Air in primary circuit Bleed primary circuit, e.g. at storage
Hot water temperature set incorrectly Adjust hot water temperature setting
Air in primary circuit Bleed primary circuit, e.g. at storage tank
Hot water temperature too low
Increase aux. heating temperature at heat
Aux. heating temperature to low
source (boiler, furnace, electric heater)
Hot water temperature too high Hot water temperature set incorrectly Adjust hot water temperature setting

Hot water temperature reaches set value Circulation set incorrectly Check controller settings
only after a long tapping time Circulation pump damaged Replace circulation pump

Error displayed at controller ➝ see installation and operating manual “Freshwater Controller RATIOfresh 200”

Subject to modifications, errors excepted · © Wagner & Co, 2010 · www.wagner-solar.com
246 WAGNER & CO · Zimmermannstraße 12 · D-35091 Cölbe/Marburg · ☎
+49 (0) 64 21 80 07-0 · Fax 80 07-596
Solar Circuit Components and Accessories

If solar installations were living beings, our SUNGO series solar controllers could
be regarded as the brains, while the CIRCO solar circulation units are akin to their
hearts. Like all other components the CIRCO and SUNGO families look back onto
a long history of improvement, optimization and diversification. All in all Wagner
& Co currently offers 5 solar controllers to meet the requirements of every possi-
ble project (4 of which are presented in this handbook). Speed controlled pumps
significantly reduce the electricity consumption and the numerous additional
control and analysis functions of the SUNGO controllers allow optimal control of
a small scale single-collector single-tank solution as well as a multiple collector
multiple tank solution with multiple additional heat sources and extra functions,
e.g. pool heating (with SUNGO SXL). Other system components include expansi-
on vessels, electronic diverter valves, thermostatic mixing valves, heat meters and
more.

■ CIRCO 6 Solar Circulation Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

■ CIRCO 25/80 Solar Circulation Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

■ SUNGOmini Solar Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

■ Solar Controller SUNGO S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

■ Solar Controller SUNGO SL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

■ Solar Controller SUNGO SXL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295 1.4
■ Expansion Vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335

■ Heat Meter WMZ for SUNGO SL / SXL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337

■ 2/3 Way Electronic Diverter Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339

■ Twinflex TVA Rapid Piping System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341

■ Sensor Connection Box SP2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345

■ Solar Heat Transfer Liquid DC20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347

■ External Heat Exchangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351

247
TECHNICAL INFORMATION / INSTALLATION INSTRUCTIONS

CIRCO 6 Solar Circulation Unit

CIRCO 6 Solar Circulation Unit
in combination with the intelligent
SUNGO controllers, it is the safe
and reliable heart of a solar
installation

Fast Installation
thanks to pre-assembled parts
and compression fittings for the
connection to the solar circuit

Safe Deaeration
by integrated air bleeder

Operation Monitoring
via flow-meter and integrated
thermometer

Controlled Heat Flow
by two temperature resistant
non-return ball valves 1.4
Low Heat Loss
made possible by all-around heat
insulation made from close fitting
hard foam shell

Figure 1 CIRCO 6 Solar Circulation Unit
with integrated controller (not included in delivery).

Solar Thermal / Solar Circuit EN-XXX_CIRCO-6_MA-100119-1121Y800 249
1. General Safety Guidelines
Qualification of the Installer
Setting up, installation and commissioning of the CIRCO 6
solar circulation unit must be carried out by a qualified in- DANGER of personal injury
staller. Electrical installation of the device can lead to potentially
Please note that in case of a fault report the guarantee ben- fatal electric shocks, scalds, contusions as well as other
efits can only be claimed if the correct commissioning has health hazards. Therefore please ensure to observe all in-
been certified by a qualified person in the commissioning formation in the guidelines marked with this symbol.
report. The warranty period for the station is 2 years.

Use and Application
Function CAUTION against property damage
The CIRCO 6 solar circulation unit is suitable for solar hot This symbol indicates dangers that can result in damage
water systems and solar heating support systems in con- to the components or significantly degrade the functional-
nection with antifreeze solar liquid as recommended. ity of the solar heating system. Please ensure to carry out
the installation steps described in these guidelines in the
Limitations of Use correct order.
● Applications are limited to the hydraulic layout of the
schematics supplied by Wagner and Co.
Some solar installations for space heating and the appli-
cation of vacuum tube collectors do require special pro- NOTE for additional information
visions for overheating protection, like the installation of This symbol indicates practical advice which will be useful
a heat dissipation vessel or alternative positioning of the for installing and operating the device.
safety components (See document “Solar Thermal Sys-
tems - Setup, Startup and Maintenance”).
● The solar circulation unit can be wall-mounted or di-
rectly installed to the storage cylinder using the cylin-
der mounting kits for the ECO, TERMO and RATIO line
solar cylinders
● The CIRCO solar circulation unit must not be installed
outdoors.

Norms and Directives
EC conformity declaration
The CIRCO 6 solar circulation unit has been designed and
constructed in accordance with EU regulations. Please re-
gard national and EU regulations and guidelines for instal-
lation work. Especially observe EN 12976 and ENV 12977:
Thermal solar systems and components.

Standards and Codes
The effective standards, codes and regulations at the in-
stallation location must be observed. In Germany espe-
cially:
● Electrical installations and device connections must be
carried out according to VDE 0100 und DIN 18381
● Setting up potential equalization must follow VDE 0190
● DIN 4753 must be observed for installation, start up and
maintenance of system for domestic hot water prepara-
tion and process water heating.
● DIN EN V 12977: Thermal solar systems and compo-
nents.

250 EN-XXX_CIRCO-6_MA-100119-1121Y800
2. Technical Information Table 3 CIRCO 6 Solar Circulation Unit
Part no. 150 201 17
Scope of Delivery
The CIRCO solar circulation unit is supplied pre-assem- Insulation EPP two parts
bled. Max. operation pressure 6 bar
SUNGO control and CIRCO expansion kit are not part of
120 °C (during start-up phase
the unit. Additional accessories are shown on the last page. Max. operation temperature
temporarily up to 160 °C)

Table 1 Maximum Number of Collectors to be Installed 1 Circulation pump ST 25-6 (230 V, 50 Hz)

Coll.-type Serial-/parallel Serial connection Wattage 3-levels, 44/62/81 Watt
connection 2 Max. pump head 6m
18 Ø 22 Ø 28 Ø 18 Ø 22 Ø 28 Ø Max. flow rate 3.5 m³/h
EURO Return flow stoppers 2 x, can be disabled
C20 HTF/AR, 2x3 3x3 4x3 4 4 4
C22 HTF/AR Temperature display 2 dial thermometers

EURO L20 AR 2x3 3x3 4x3 4 5 5 Sockets for temperature In supply and return leg one each
sensors for sensors of max. 6 mm Ø
1 Simple pipe length of solar circuit up to 20 m, heat transfer
medium: antifreezes/water 40/60 Vol % = 35 l/m². Connections Flow meter 2-15 l/min
and connection pipes of collectors are accounted for.
Safety valve 6 bar ½",
2 No. of fields with 3 collectors connected in series each Safety group
pressure meter
Filling unit 2 filling valves with cap
Table 2 Volume of Expansion Vessel 1 Connection expansion vessel ¾" M

Sys.- Coll.- Volume (l) for system height (m) Connection bleeder pipe ¾" F
vol. (l) area. (m²) 2.5 5 7.5 10 12.5 15 Connection solar circuit 4 compression fittings, 22 mm
18 5 12 12 12 12 18 18 Axial pipe distance for solar
100 mm
circuit
20 7.5 18 18 18 18 18 24
Wall inst. / inst. at cylinder
23 10 24 24 24 24 24 24 Installation type
(with optional kit)
24 12.5 24 24 24 24 24 24
Dimensions (HxBxT), mm 375 x 270 x 195 mm
27 15 35 35 35 35 35 35
1.4
Weight, kg 7.2
≥ 32 20 35 35 35 50 50 50
Prepared for integration of
Slot for solar controller
1 These values only apply for collecor volumes of approx. 0.5 l/m² SUNGO S / SL / SXL

Pressure loss ∆p [mbar] Pressure loss ∆p [Pascal]
10³ 105
9 9
8 8
7 7
6 6
5 5
4 4
v 3 3
0 0,5 1,0 1,5 2,0 [m/s]
7 2 2

6
10² 104
5 9 9
8 8
7 7
III 6 6
4
5 5
H [m]

4 4
3
3 3

2 I 2 2

1
10 10³
0 5 6 7 8 910² 2 3 4 5 6 78910³ 2 3 4 5
0 1,0 2,0 3,0 [m3/h] Flow volume V [l/h]
Figure 2 Pump characteristics curves CIRCO 6 Figure 3 Pressure loss diagram CIRCO 6

EN-XXX_CIRCO-6_MA-100119-1121Y800 251
3. Installation
2

5 3
8

4

6

11
1

10
9
8
12

14
13
7

Figure 4 1 Pump; 2 Safety group; 3 Connection (¾") for expansion vessel-set (available as accessory); 4 Filling valve; 5 Rear insulation
shell; 6 Front insulation shell with opening for controller; 7 Cover (when controller not installed); 8 Wall brackets; 9 Bleeder; 10 Flow me-
ter; 11 Controller mounting block; 12 Dry wall anchors; 13 Controller SUNGO; 14 Fixing screw

250
G1 G1
Rp¾

130
375
262

G1 G1

100
Figure 5 Dimensions in mm

252 EN-XXX_CIRCO-6_MA-100119-1121Y800
3.1 Installation Preparations 3.2 Wall Installation
● The entire layout of flow and return pipes should be ● Remove front insulation shell (6).
clear before installing the CIRCO 6 solar circulation unit
(100 mm centres). ● Make two drilling holes with 262 mm vertical distance
● The location of the installation also must take into ac- for the two wall brackets (8) (figure 5). Screw on solar
count sufficient space for the expansion vessel! circulation unit.
● If the solar system is installed for heating or if vacuum
tubes are used you must pay attention to the technical ● Connect safety group (2) to the included ¾" – gasket to
documentation “Overheat Protection”. the return leg.
● For the required tools see figure 6 Secure nuts by applying counter force with 2nd wrench
while tightening the connections. Otherwise parts of
seals might come of or the connections could be dam-
aged.

● Affix wall bracket for expansion vessel next to the sta-
tion. Take length of the flexible connection tube into
account.

● Connect expansion vessel to safety group via the con-
nection tube. Don’t forget the seals/gaskets! Mainte-
nance can be made easier by installing an additional
capped valve between flexible tube and vessel.

● Connect venting pipe to safety valve and place an emp-
ty canister underneath to collect possible spills of solar
fluid.

Figure 6 Tools for CIRCO 6 installation ● The solar circuit pipes are connected via compression
fittings 18 mm or 22 mm.
Cut and burr pipes and push into fittings as far as pos-
sible, then tighten nuts. To avoid damage, secure nuts 1.4
by applying counter force with 2nd wrench while tight-
ening.

● Rinse solar pump station and solar circuit and check for
leaks. For this purpose filler valves are fitted to the safety
unit and to the flow meter.

● Install electrical wiring, switching and sensor lines. The
cables must not touch on hot pipe legs. Always discon-
nect mains when working with electrical equipment.

● The controllers SUNGO S, SL and SXL can be integrated
into the solar circulation unit. For this purpose screw the
4 included drywall anchors (12) into the drillings of the
controller installation slot. Then set on controller (13)
with lower side. Screw controller into the installation slot
with the 4 fixing screws (14 + 15). During wiring use wire
straps at appropriate place for pull relief of the control-
ler terminals.

● Re-attach front insulation shell (6).

EN-XXX_CIRCO-6_MA-100119-1121Y800 253
3.3 Installation at Cylinder
The adjustable installation kits can be used with all Wag-
ner solar cylinders with 1¼" flat sealing connections at the
heat exchanger, with a vertical distance between 470 and 1

0
2

4
3

850 mm. 40
60

To prevent later obstructions of the pipe work in the area 40
60
20

0
80

of the cylinder, it is recommended to make proper lay- out
20
80
0

plans before commencing installation.

● Connect pipes to cylinder using supplied gaskets, tight-
en hand-screwed.
D = 22 for
compression fitting
● Cut off longer return pipe until both pipes are reaching
the same level and have an axial distance of 100 mm.
Return pipe
Then screw tight adjustable pipe.
100
● Trim off the insulation of the cut-off return pipe and
place circulation unit on top of the two pipes.

450 mm
● Level the unit, affix to cylinder and tighten cylinder con-
nections.

● Continue with piping behind the solar circulation unit. 1¼“ union nut Insulation

In order to prevent forces to the cylinder fixing because Applicable for 470 to 850 mm
of weight load from the station, pipe fixtures should be
installed near the unit at the wall or at the ceiling.

The expansion vessel must not be freely suspended from
the pump station. Apply wall or floor installation, depend-
ing on type of vessel.

Filling valve

Figure 7 Cylinder installation kit (option) consisting of:
1 return pipe with integrated filling valve, incl. insulation; connec-
tions: 1¼" swivel nut – 22 mm pipe socket for compression fitting,
1 supply pipe incl. insulation; connections: 1¼" swivel nut – 22 mm
pipe socket for compression fitting.

254 EN-XXX_CIRCO-6_MA-100119-1121Y800
4. Operating Advice
The Flow Meter Return Flow Stoppers
The flow meter indicates flow in l/min during pump op- They are integrated into the ball valve components and
eration. The adjustment screw can be used to cut off the prevent unwanted heat distribution in the solar circuit
flow. For operation the adjustment screw must be turned when the pump is turned off. They only open in the flow
fully counterclockwise (max. flow). The adjustment of the direction under pump pressure. The stopper in the feed
volume flow should only be done via the pump settings. leg can be turned off with the ball valve handle, the one in
the return leg with a slotted screw (figure 9 and 10).

• Flow open
• Return flow stopper in operation
°C
• Operational position

L/MIN

• Flow open
15
• Return flow stopper off

°C
12
9 Index line
7
5
Flow metering
2

• Flow closed
°C • Return flow stopper without function

Figure 8 Flow meter of CIRCO 6

Setting Up the Pump Figure 9 Functions of ball valve and return flow stoppers in supply leg
Setting up the pump is carried out when the solar instal- (left pipe) 1.4
Return flow stopper adjustable via ball valve!
lation is filled and vented and the pump is operating. First
set pump to lowest level. Then switch on pump via control-
ler menu “manual operation”, so that speed control is dis-
abled. The recommended volume flow in the solar circuit
• Flow open
is 40 l/m² collector area and hour. Values between 30 and • Return flow stopper in operation (slot horizontal)
50 l/m² h are acceptable. • Operational position
Higher volumes result in increased power uptake of the °C

pump. Choose next higher pump level if the recommend-
ed volume flow is not reached. Example: Collector area
12 m² > recommended volume flow = 12 m² x 40 l/m²h =
480 l/h = 8 l/min.
After setting up the pump assure its automatic operation. • Flow open
• Return flow stopper off (slot vertical)
°C

• Flow closed
• Return flow stopper without function
°C

Figure 10 Functions of the ball valve and the return flow stopper in the
return leg (right pipe)
Return flow stopper adjustable via slotted screw!

EN-XXX_CIRCO-6_MA-100119-1121Y800 255
5. Accessoires
Table 4 Accessories Description Part no.
Compression fitting Acessory / spare part: for 18 mm copper pipe 150 301 84
for pipe connection for 22 mm copper pipe 150 301 85
Accessory set solar circuit Accessory parts for solar circuit piping: 190 210 22
2 filling valves and 2 grounding clamps for potential equalization
Air venting kit Automatic air venting kit consisting of 2 automatic air venting valves and 190 210 11
(not normally required heat resistant ball valves (up to 200 °C), connection 3/8"
because of included bleeder
Manual air release set consisting of 2 manual air release valves 3/8" and key 190 210 10
pipe)
CIRCO-expansion vessel set Expansion vessel for solar circulation unit, allowed positive operating pressure
10 bar, stainless steel corrugated tube for connecting with CIRCO solar
circulation unit, thread connection ¾" female flat sealing
12 l-volume, incl. wall bracket, pre-pressurized: 1.5 bar 150 450 10
18 l-volume, incl. wall bracket, pre-pressurized: 1.5 bar 150 450 11
24 l-volume, incl. wall bracket, pre-pressurized: 1.5 bar 150 450 13
35 l-volume, with brackets for wall and floor fixing, pre-pressurized: 2.5 bar 150 450 14
50 l-volume, with brackets for wall and floor fixing, pre-pressurized: 2.5 bar 150 450 15
Capped valve Check valve ¾" with filler and drain valve and with cap against operation
for expansion vessel mistakes. Suitable for maintenance purposes.

¾" - version 819 200 27
1" - version 819 200 36

Cylinder mounting kit Cylinder piping 1¼" M with flat seals, insulated; return pipe for cylinder 150 302 01
for CIRCO 6 und 6E connections with 470 to 850 mm vertical distance (can be cut to size),
with 22 mm sleeves to connect to compression fittings of CIRCO 6 and 6E.

Subject to modifications, errors excepted · © Wagner & Co, 2010 · www.wagner-solar.com
256 WAGNER & CO · Zimmermannstraße 12 · D-35091 Cölbe/Marburg · ☎
+49 (0) 64 21 80 07-0 · Fax 80 07-596
TECHNICAL INFORMATION / INSTALLATION INSTRUCTIONS

CIRCO 25/80 Solar Circulation Unit

CIRCO 25/80 Solar Circulation Unit
in combination with the intelligent
SUNGO controllers, it is the safe and
reliable control centre for larger solar
installations

Fast Installation
thanks to pre-assembled parts and
compression fittings for the connection
to the solar circuit

Safe Deaeration
by integrated air bleeder

Operation Monitoring
via flow-meter and integrated thermom-
eter

Controlled Heat Flow
by two temperature resistant non-return 1.4
ball valves

Low Heat Loss
due to wrap-around tightly fitting hard foam
encasing

Figure 1 CIRCO 25/80 solar circulation unit

Solar Thermal / Solar Circuit EN-XXX_CIRCO-25-80_MA-100123-11217800 257
1. General Safety Guidelines
Qualification of the Installer
Setting up, installation and commissioning of the CIRCO 6
solar circulation unit must be carried out by a qualified in- DANGER of personal injury
staller. Electrical installation of the device can lead to potentially
Please note that in case of a fault report the guarantee ben- fatal electric shocks, scalds, contusions as well as other
efits can only be claimed if the correct commissioning has health hazards. Therefore please ensure to observe all in-
been certified by a qualified person in the commissioning formation in the guidelines marked with this symbol.
report. The warranty period for the station is 2 years.

Use and Application
Function CAUTION against property damage
The CIRCO 6 solar circulation unit is suitable for solar hot This symbol indicates dangers that can result in damage
water systems and solar heating support systems in con- to the components or significantly degrade the functional-
nection with antifreeze solar liquid as recommended. ity of the solar heating system. Please ensure to carry out
the installation steps described in these guidelines in the
Limitations of Use correct order.
● Applications are limited to the hydraulic layout of the
schematics supplied by Wagner and Co.
● Some solar installations for space heating and the appli-
cation of vacuum tube collectors do require special pro- NOTE for additional information
visions for overheating protection, like the installation This symbol indicates practical advice, which will be useful
of a heat dissipation vessel or alternative positioning of for installing and operating the device.
the safety components (see “Solar Thermal Systems –
Setup, Commissioning and Maintenance”).
● The solar circulation unit can be wall-mounted or di-
rectly installed to the storage cylinder.
● The CIRCO solar circulation unit must not be installed
outdoors.

Norms and Directives
EC conformity declaration
The CIRCO 6 solar circulation unit has been designed and
constructed in accordance with EU regulations. Please re-
gard national and EU regulations and guidelines for instal-
lation work. Especially observe EN 12976 and ENV 12977:
Thermal solar systems and components.

258 EN-XXX_CIRCO-25-80_MA-100123-11217800
2. Technical Information Table 3 CIRCO 25/80 Solar Circulation Unit
Part no. 150 201 13
Scope of Delivery
The CIRCO solar circulation unit is supplied pre-assem- Insulation EPP three parts with latch
bled. Max. operational pressure 6 bar
SUNGO control and CIRCO expansion kit are not part of
120 °C (temporarily up to 160 °C
the unit. Max. operational temperature
during startup)
Additional accessories are shown on the last page.
Grundfos UPS 25-80 (230V, 50Hz)
Circulation pump
Table 1 Maximum Number of Collectors to be Installed Energy efficiency class C.

Coll.- Serial-/parallel connection Serial connection Power rating 3-levels, 110/155/165 Watt
type Max. pump head 8m
18 Ø 22 Ø 28 Ø 18 Ø 22 Ø 28 Ø
EURO 4 x 3* Max. pumping volume 7.5 m³/h
2 x 3* 6 x 3* 4 5 5
L20/C22 2 x 4* Return flow stoppers 2x
Parallel connection Temperature indication 2 dial thermometers
LBM 67 4 5 6 2 2 3 Flow meter 7 - 30 l/min
LBM 100 2 3 4 2 2 2 Safety group Safety valve 6 bar ½", manometer
* No. of collectors connected in series
Filling unit 2 filler valves with caps
Table 1 Max no. of collectors and pipe diameters for various connec- Connection expansion vessel ¾" M
tion layouts. Not valid for corrugated tubes! Assumptions: solar circuit
length up to 40 m / leg, 40 % glycol content, specific volume flow max. Connection bleeder pipe ¾" F
35 l/m²h. Connection solar circuit 4 compression fittings, 22 mm
Axial pipe distance
100 mm
for solar circuit
Table 2 Volume of Expansion Vessel
Mounting type Wall mounting
Sys.- Coll.- Volume (l) for system height (m)
vol. (l) area (m²) Dimensions (H x W x D), mm 425 x 250 x 195
2.5 5 7.5 10 12.5 15
Weight, kg 9
18 5 12 12 12 12 18 18
20 7.5 18 18 18 18 18 24
1.4
23 10 24 24 24 24 24 24
24 12.5 24 24 24 24 24 24
27 15 35 35 35 35 35 35
≥ 32 20 35 35 35 50 50 50

Table 2 Expansion vessel size depending on circuit volume, collector
area, system height. These figures are only valid for collector volumes
of approx. 0.5 l per m2.
Pressure loss ∆p [mbar] Pressure loss ∆p [Pascal]
10³ 105
9 9
8 8
7 7
6 6
5 5
4 4
3 3

2 2

10² 104
9 9
8 8
7 7
III 6 6
5 5
4 4
II
3 3

I 2 2

10 10³
5 6 7 8 910² 2 3 4 5 6 78910³ 2 3 4 5
Flow volume V [l/h]
Figure 2 Pump characteristics curves CIRCO 25/80 Figure 3 Pressure loss diagram CIRCO 25/80

EN-XXX_CIRCO-25-80_MA-100123-11217800 259
3. Installation

Figure 4 CIRCO 25/80 and its components: Figure 5 CIRCO 25/80 – dimensions in mm
1 Pump; 2 Safety group; 3 Front insulation shell; 4 Rear insulation
shell (left); 5 Rear insulation shell (right); 6 Wall mount; 7 Connec-
tion (¾", M) for expansion vessel set (optionally available)

3.1 Installation Preparations 3.2 Wall Mounting
● The entire layout of flow and return pipes should be well ● Take the solar circulation unit out of the insulation. To
planned before mounting the CIRCO 25/80 solar circu- this end remove front shell and pull apart rear insulation
lation unit (100 mm centers). shells (4+5).
Please also refer to the technical information “Solar
Thermal Systems – Setup, Commissioning and Mainte- ● Make two drilling holes with 262 mm distance for the
nance”. two wall mounts (6). Screw solar circulation unit onto
● If the solar system is installed for space heating or if wall mount.
vacuum tubes are used, you must also pay attention to
the technical documentation “Overheat Protection”. ● Push the two parts of the rear insulation shell (4+5)
● For the required tools see figure 6 tightly together.

● Connect safety group (2) to the included ¾" – gasket to
the return leg.
Secure nuts by applying counter force with 2nd wrench
while tightening the connections. Otherwise parts of
seals might come off or the connections could be dam-
aged.

● Affix wall mount for expansion vessel next to the right
side of the safety group, using the included dowels and
screws. Take length of the ¾" corrugated hose into ac-
count. The 35 l and 50 l expansion vessels are fixed with
a special wall clamp.

● Connect expansion vessel to safety group via the con-
nection tube. Don’t forget the seals/gaskets! Mainte-
nance can be made easier by installing an additional
Figure 6 Tools required for installation capped valve between flexible tube and vessel.

260 EN-XXX_CIRCO-25-80_MA-100123-11217800
● Connect venting pipe to safety valve and place an emp- Return flow stoppers
ty canister underneath to collect possible spills of solar They are integrated into the ball valve armatures and pre-
fluid. vent unwanted heat distribution in the solar circuit when
the pump is turned off. They only open in the flow direction
● The solar circuit pipes are connected via compression under pump pressure. The stopper in the feed leg can be
fittings. Cut and burr pipes and push into fittings as far turned off with the ball valve handle, the one in the return
as possible, then tighten nuts with wrenches. leg with a slotted screw.
To avoid damage, secure nuts by applying counter
force with 2nd wrench while tightening. ● In operation

● Rinse solar pump station and solar circuit and after-
wards check for leaks. For this purpose, filler valves are
fitted to the safety unit and to the flow meter. Tighten
connections of required.
°C °C
● Install electrical wiring, switching and sensor lines. The
cables must not touch on hot pipe legs. Always discon-
nect mains when working with electrical equipment.
Flow Return
● Re-attach front insulation shell (3). Ball valve handle 0°, Ball valve handle 0° Slit horizontal
return flow stopper Return flow stopper
in operation in operation

Figure 8 Operational setting

4. Operating Advice ● Filling the system
(see “Solar Thermal Systems – Setup, Commissioning
The Flow Meter and Maintenance”)
The flow meter indicates flow in l/min during pump opera-
tion. The exact volume flow can be read out at the level
indicator (Fig 7). The adjustment screw can be used to ad-
just the flow to a desired value during pump operation. 1.4
°C
The flow is cut off when the screw is turned clockwise to
°C

dead stop.

Flow Return
Ball valve handle 45°, Ball valve handle 90°,
passage open, passage closed
return flow stopper
off

Figure 9 Filling the system
Index line
Flow metering
● Draining the system
(see “Solar Thermal Systems – Setup, Commissioning
and Maintenance”)

Figure 7 Flow meter of CIRCO 25/80
°C

°C

Flow Return
Ball valve handle 45°, Ball valve handle 45°, Slit vertical
passage open, passage open Return flow stopper
return flow stopper off
off

Figure 10 Draining the system

EN-XXX_CIRCO-25-80_MA-100123-11217800 261
5. Accessories
Table 4 Accessories Description Part no.
Accessory parts for solar circuit piping:
Accessory set solar circuit 190 210 22
2 filling valves and 2 grounding clamps for potential equalization
Air venting kit Automatic air venting kit consisting of 2 automatic air venting valves and
190 210 11
(not normally required heat resistant ball valves (up to 200 °C), connection 3/8"
because of included
bleeder pipe) Manual air release set consisting of 2 manual air release valves 3/8" and key 190 210 10

CIRCO – Expansion vessel for solar circulation unit, allows positive operating pressure 10 bar,
expansion vessel set stainless steel corrugated tube for connection to CIRCO solar circulation unit, thread
connection ¾" female flat sealing
12 l-volume, incl. wall mounting bracket, pre-pressurized: 1.5 bar 150 450 10
18 l-volume, incl. wall mounting bracket, pre-pressurized: 1.5 bar 150 450 11
24 l-volume, incl. wall mounting bracket, pre-pressurized: 1.5 bar 150 450 13
35 l-volume, with brackets for wall and floor fixing, pre-pressurized: 2.5 bar 150 450 14
50 l-volume, with brackets for wall and floor fixing, pre-pressurized: 2.5 bar 150 450 15

Capped valve for Check valve ¾" with filler and drain valve and with cap against operation mistakes.
expansion vessel Suitable for maintenance purposes.

¾"-version 819 200 27
1"-version 819 200 36

Subject to modifications, errors excepted · © Wagner & Co, 2010 · www.wagner-solar.com
262 WAGNER & CO · Zimmermannstraße 12 · D-35091 Cölbe/Marburg · ☎
+49 (0) 64 21 80 07-0 · Fax 80 07-596
OPERATING INSTRUCTIONS, version V2.x

SUNGOmini Solar Controller

1.4
Figure 1 Solar controller SUNGOmini

The Benefits at a Glance Content
● Display showing temperature, balance values and sys- 1. Technical Description . . . . . . . . . . . . 264
tem status with clearly visible symbols for easy readabil- 2. General Safety Guidelines . . . . . . . . . . 265
ity. 2.1 Installer’s Qualifications . . . . . . . . . . . 265
● Simple and safe setting via push-button on the right 2.2 Operating Requirements . . . . . . . . . . 265
side 2.3 Installation and Operating Information . . . . 265
● Diagnostic system for monitoring system functions, e.g. 3. Installation . . . . . . . . . . . . . . . . . 266
sensor cut-off and monitoring of temperature differ- 3.1 Installation of the Controller Encasing . . . . . 266
ence “∆T too high” 3.2 Cable Connections . . . . . . . . . . . . . 266
● Integrated security functions and system protection 4. Operation . . . . . . . . . . . . . . . . . 267
● Solar charging of a 1 cylinder system 4.1 Display and Push-Button . . . . . . . . . . 267
● 2 temperature inputs PT1000 4.2 Menu “Information” . . . . . . . . . . . . . 267
● 1 speed controlled output for pump 4.3 Menu “Settings” . . . . . . . . . . . . . . 268
● Prepared for SECUSOL operation 4.4 Service – System Messages . . . . . . . . . 269
4.5 Service – Checking Sensors . . . . . . . . . 269
5. Application Examples . . . . . . . . . . . . 270
5.1 KEYline Standard Single Tank System . . . . . 270
5.2 SECUSOL System . . . . . . . . . . . . . 270

Solar Thermal / Solar Circuit EN-XXX_SUNGOmini_BA-091021-11221Q00 263
1. Technical Description
Table 1 Solar Controller SUNGOmini
Solar Charging
The solar circulation pump is switched on and off by a tem-
100 % recyclable ABS-housing
Material perature difference control. The sensors T1 (collector) and
for wall mounting
T2 (cylinder, bottom) are required as control elements. The
Dimensions (l x w x h, mm) 75 x 93 x 40 on/off conditions and the temperature limitation can be
Protection type IP41 according to VDE 0470 variably set in the settings menu. Note: The temperature
Rate of radio interference N according to VDE 0875
limitation always affects sensor T2 (cylinder, bottom).

230 Volt AC; 50 Hz;
Operating voltage Speed Control
-10 % to +15 %
The solar circuit pump can be operated via speed con-
Diameter of cable max. 2.5 mm² trol (in this case impulse packet control). This means that
for 230 V connections unifilar or finely stranded
individual sine half-waves in the alternate current are
Temperature sensor / Pt1000; 1000 Ω at 0 °C; switched on or off, depending on the temperature differ-
temperature range range: -30 °C up to +225 °C ence. Therefore the speed can be altered within a range
The cable of the sensor must be of 30-100 % which results in longer system run times. The
installed with no tension. The minimum speed can be custom set.
sensor must not be loaded
Sensor load
mechanically when the
System Messages
temperature of the collector is
more than 60 °C. The system messages “sensor cut-off” and “sensor short
circuit” are indicated with display symbols.
4kV 1min
Test voltage
according to VDE 0631
Triac
230V AC The Triac is an electronic switch for switching the 230-V
Switching voltage
1A / approx. 230 VA for
Output power of switches
cos ϕ = 0,7-1,0 for each output
outputs on and off, applicable for controllers SUNGOmini,
SUNGO S, SL and SXL.
Microfuse 5 x 20 mm;
Internal mains protection Operational principle: a Triac consists of 2 anti-parallel
2 A/T
switchable diodes (=anti-parallel thyristors). The thyristors
Operating temperature 0° up to +50 °C / switch the positive or negative sinus half-wave through, as
(internal) / storage temperature -10 °C up to +65 °C
long as a switching difference exists. The Triac switches off,
Weight approx. 150 g as soon as the difference falls below the turn-off value.

System Protection
If the collector temperature at sensor T1 rises above
the fixed value of 135 °C, the solar circulation pump is
switched off, despite operational temperature difference.
This way a destruction or damage of components of the
solar circuit is avoided.
The system protection is deactivated as soon as the tem-
perature at the collector falls below 100 °C.

SECUSOL Function
The solar heating system is operated on a drain back prin-
ciple. This means, if the solar circulation pump is not acti-
vated, there is no solar fluid in the collectors and risers. See
SECUSOL manual for further details.

264 EN-XXX_SUNGOmini_BA-091021-11221Q00
2. General Safety Guidelines 2.1 Installer’s Qualifications
The following safety advice is designed to protect you ● Setting up and commissioning of the SUNGO mini must
from dangers that can arise from improper handling of be carried out by a qualified installer.
devices, whether intentional or otherwise. A distinction is ● All national and local safety regulations need to be com-
made between general advice presented here and spe- plied with.
cific advice presented throughout the guidelines. ● Please note that in case of a complaint the guarantee is
only valid if correct commissioning has been certified in
a commissioning report.

DANGER for personal injury
Improper electrical installation of the device can lead to 2.2 Operating Requirements
potentially fatal electric shocks as well as other health haz-
ards. Application
● Controlling solar thermal systems through the selection
of applicable control patterns and additional functions
to adapt the control for the required operation of the
CAUTION for danger to property hydraulic system.
This symbol indicates dangers that can result in damage to ● The controller must only be operated in dry rooms.
the components or the function of the controller. ● The controller can be attached to the solar cylinder or
mounted on the wall.

Limitations of Use
NOTE for additional information ● When used in other than solar thermal applications, the
This symbol indicates practical advice and tricks of the functionality of the control has to be checked before
trade which will be useful for installing and operating the commissioning. If in doubt contact the controller ser-
controller. vice of Wagner & Co.
● If these operating requirements are not observed, any
claims under the warranty will not be accepted.

2.3 Installation and 1.4
Operating Information
● Any installation and wiring work has to be carried out
in an idle state as during operation the voltage on the
outside of the triac is 230 V.
● Mains power must be connected to the controller from
outside the solar station via an external ON/OFF switch.
● Operating temperatures above 50 °C are not permitted
for the controller.
● The base of the control is divided into a safe low volt-
age section and a 230 V section by a crosspiece. Make
sure that you do not confuse these sections during the
installation process!
● The standard operating mode is the automatic mode.
Manual operation is used only for functional testing of
the pump.
● Do not operate the system if the controller, the wiring
or the connected 230 V mains or consumer are visibly
damaged.
● The control is fitted with a mains microfuse.
● Collectors and hydraulic pipe work can get extremely
hot during solar irradiation. There is a risk of scalding
when fitting the collector temperature sensor.

EN-XXX_SUNGOmini_BA-091021-11221Q00 265
3. Installation
3.1 Installation of the Case 3.2 Connecting Wires
Opening the Case Layout of the SUNGO mini Connections
● To open the cover of the casing, use a small screw-driv- All electrical connections are made to the circuit board at
er to gently push from above into the small notch at the the bottom of the control. The sensor connections (safe
front of the cover. low voltage) are located on the right hand side and the
230 V mains connections and the switching output A1 on
Wall Mounting the left hand side.
● Mount the controller to the wall.
● Do not overtighten the screws to avoid damage to the General Connection Rules
lower part of the housing. ● If flexible wires are used and the controller is wall
mounted, a strain relief must be fixed within or outside
Mounting at SECUSOL Solar Cylinder the controller.
● Hook the SUNGOmini controller to the desired position ● In this case you must crimp the wire ends.
into the upper insulation of the storage cylinder.
● Finally connect to mains power. 230 V Mains Connection
● When the control is switched on, the voltage on the tri- ● Mains power is connected from outside the control via
acs housing is 230 V AC. an ON/OFF switch.
This switch is not required if mains power is with a pro-
tective plug to a socket.
● The controller is suitable for mains operation at approxi-
Mains voltage area Safe low voltage area mately 230V/50Hz.
● All earth wires are connected to the PE terminals.
Green
● The neutral terminals (N) are electrically connected!
● Switching output A1 is a 230 V normally open contact
which is activated via speed-control.
Fuse

Transformator Display Red

Connecting the Temperature Sensors
● The wires of the temperature sensors can be extended:
Triac
Control-IC An up to 15m length / 2x0.5mm² cable can be used, up to
Push-
Jumper on = Solar Button 50m a cable with 2x0.75mm² is necessary. Shielded ca-
Jumper off = SECUSOL bles should be used for long connections to the collector.
Do not connect the shielding at the sensor end, just trim
and isolate.
on off ● The polarity of the temperature sensors is irrelevant and
1 2 3 4 5 6 7 8 9 10
they can be connected either way.
Collector sensor, T1
Collector sensor, T1
Storage sensor, T2
Storage sensor, T2
Mains, phase
Solar circuit pump, phase
Mains, neutral
Solar circuit pump, neutral
Mains, potential earth
Solar circuit pump, potential earth

● The sensor wires must be installed separately from
230 V mains cables.

Lightning Protector Module
The SUNGOmini is fitted with spike protection on all sen-
sor terminals. Generally, further protection of the cylinder
sensor is not required.
Sensor T1 (collector) should be fitted with the sensor con-
nection box SP2 inclusive an overvoltage protection.

Figure 2 SUNGOmini circuit board components

266 EN-XXX_SUNGOmini_BA-091021-11221Q00
4. Operation
4.1 Display and Push Button
Tmax = temperature limitation
DT max = switching difference ON
DT min = switching difference OFF
Menu Tmin = min. temperature (solar only)
“Information” Dmax = max. pump speed (SECUSOL only)

LED green ON = mains ON
LED green flashing = solar circuit pump ON

dT min max

x

! I LED red on / flashing = error

Push-Button on side activates menu “Settings”

System Menu “Settings”
error
Number field
Pump ON temperature
Pump OFF
Measuring point
1 collector
2 storage
Figure 3 Display and functions 1.4

4.2 Menu “Information”
During standard operation the controller is in the menu
“information” where the values for the collector tempera-
ture (T1) and the lower storage temperature (T2) are shown
in 5-second-intervals.
When the switching difference is sufficient to switch on
the solar circulation pump, an additional pump symbol is
shown, and the green LED flashes.

Table 2 Menu “Information”
Symbol Description

Menu “Information”

I Sensor T1: Collector

2 Sensor T2: Storage, bottom

Solar circuit pump: ON

EN-XXX_SUNGOmini_BA-091021-11221Q00 267
4.3 Menu “Settings”
The controller is equipped with a micro push-button that In order to change the selected variables, the button must
can be reached with an appropriate tool via a small drilling be pushed for approx. 2 seconds until the shown value
on the left side of the casing. flashes. By further pushing, you can step through the val-
ues in ascending order to the end of the range, where it
Briefly pushing the button switches the controller from the jumps back to the lowest value to start over.
menu “Information” to the menu “Settings”, which is indi-
cated by two small arrow points at the right edge of the In order to save a value, you have to push the button for
display. Here the variables shown in tables 3 and 4 can another 2 seconds. The flashing mode is then turned off
be serially selected with single pushes on the button, de- and the new value is saved at the same time.
pending on the jumper position.
Additionally the maximum pump speed “dmax” can be
adjusted in the SECUSOL system variation.

Table 3 Menu “Settings” (Solar*)
Name Description Range Standard value
T max Temperature limitation storage, bottom 15 – 90 °C 85 °C
Switching difference (ON) between collector and storage /
T max 3 – 40 K 10 K
set temp. difference affected by the pump speed control.
dT min Switching difference (OFF) between collector and storage. 2 – 35 K 3K
T min Minimum temperature at which temp. difference is analyzed. 5 – 90 °C 10 °C
Minimum speed of solar circulation pump,
d min 30 – 100 % 30 %
adjustable step size in 5 %-steps
“off / on” Manual operation of output A1 off, on off
“res” Resetting to manufacturer values
“V2.x” Shows the current software version
* Solar = jumper setting “on”

Table 4 Menu “Settings” (SECUSOL = in jumper setting “off”)
Name Description Range Standard value
T max Temperature limitation storage, bottom 15 – 90 °C 85 °C
Switching difference (ON) between collector and storage /
dT max 3 – 40 K 15 K
set temp. difference affected by the pump speed control.
dT min Switching difference (OFF) between collector and storage. 2 – 35 K 3K
d max Max. speed of the solar circuit pump in system SECUSOL 45 – 100 % 100 %
Manual operation of output A1
“off / on” off, on off
(Remains in operation for 1 h when “on” and then returns to “automatic”.)
“res” Resetting to manufacturer values
“V2.x” Shows the current software version

Fixed Parameters that cannot be changed
Filling time, start For filling the system at 100 % pump speed
Min. pump speed In normal operation the pump speed of the system can be reduced to 45 %

268 EN-XXX_SUNGOmini_BA-091021-11221Q00
4.4 Service – System Messages
The operational state is indicated via two LEDs. Errors are
indicated by the red LED as well as by additional display
symbols. The error-codes are indicated by flashing inter-
vals within a few seconds.

Table 5 System messages in display
Display-/LED Description Action
LED green, ON Mains ON –
LED green, flashing Solar circuit pump ON –
LED red, 1 x flashing
Collector sensor cable interrupted

LED red, 2 x flashing
Short circuit in collector sensor cable
● Check and compare resistance of sensor.
LED red, 3 x flashing ● Check all contacts.
Storage sensor cable interrupted

LED red, 4 x flashing
Short circuit in storage sensor cable

● “dT too high” active
A value of 20K is added to the switching difference (ON)
between T1 and T2. The message occurs, when the total
difference is not reduced after 30 min. ● Check pump and wiring.
● “System protection” active ● Check system for air vent if necessary.
LED red, ON
If the collector temperature at sensor T1 rises above the set ● Check sensors / sensor cables, replace if
value of 135 °C the solar circuit pump is switched off, required.
despite operational temperature difference. The system
protection is deactivated as soon as the temperature at the
collector falls below 100 °C.

1.4
4.5 Service – Checking Sensors
Table 6 Temperature related resistance values for Pt1000-sensor
-20 °C -10 °C 0 °C 10 °C 20 °C 30 °C 40 °C 50 °C 60 °C 70 °C 80 °C 90 °C 100 °C 110 °C
922 Ω 961 Ω 1000 Ω 1039 Ω 1078 Ω 1117 Ω 1155 Ω 1194 Ω 1232 Ω 1271 Ω 1309 Ω 1347 Ω 1385 Ω 1423 Ω
Based upon this table the correct function of the temperature sensors can be checked with a multi-meter.

EN-XXX_SUNGOmini_BA-091021-11221Q00 269
5. Application Examples
5.1 KEYline-System

T1 : Sensor collector Collector field
T2 : Storage sensor, bottom
T1
P1 : Solar circulation pump
P2 : Heating circulation pump
P3 : Storage charging pump
M1 : Heating circuit mixer T2 T1
Ttw : Sensor hot water (boiler controller) A1
BWM : Thermostatic mixing valve

Ta
Heating circuit

Tvl

P1
P2

CIRCO
Ttw

M1

ECOplus

P3 T2
Oil or gas
boiler

Hot water BWM

Cold water

Figure 4 KEYline system for SUNGOmini

5.2 SECUSOL-System

T1 : Sensor collector Collector field (EURO C22)
T2 : Storage sensor, bottom

P1 : Solar circulation pump
P2 : Heating circulation pump
P3 : Storage charging pump T1
M1 : Heating circuit mixer T2 T1
Ttw : Sensor hot water (boiler controller) A1
BWM : Thermostatic mixing valve

Ta
Heating circuit

Tvl

SECUSOL

P2

M1 Ttw

T2
P3
Oil or gas
boiler

P1

Hot water BWM

Cold Water

Figure 5 SECUSOL-System for SUNGOmini

Subject to modifications, errors excepted · © Wagner & Co, 2010 · www.wagner-solar.com
270 WAGNER & CO · Zimmermannstraße 12 · D-35091 Cölbe/Marburg · ☎
+49 (0) 64 21 80 07-0 · Fax 80 07-596
OPERATING INSTRUCTIONS, Issue SW1201 / 3.0 / HW3.0

Solar Controller SUNGO S

1.4

Figure 1 Solar Controller SUNGO S

Product Features Contents
● Large illuminated display to indicate temperature, bal- 1. Technical Description . . . . . . . . . . . . 272
ance values and system status with clearly visible sym- 2. General Safety Guidelines . . . . . . . . . . 274
bols for easy readability. 2.1 Installer’s Qualifications . . . . . . . . . . . 274
● Easy and safe operation via four buttons for vertical and 2.2 Operating Requirements . . . . . . . . . . 274
horizontal scrolling through the menus. 2.3 Installation and Operating Information . . . . 274
● Extensive diagnostics for monitoring system functions, 3. Installation . . . . . . . . . . . . . . . . . 274
eg. sensor cutoff and monitoring of temperature differ- 3.1 Installation of the Case . . . . . . . . . . . 274
ence “∆T too high” 3.2 Connecting Wires . . . . . . . . . . . . . . 275
● Integrated security functions such as collector cooling, 4. Operation . . . . . . . . . . . . . . . . . 276
tank cooling, system protection and vacuum tube col- 4.1 Display and Buttons . . . . . . . . . . . . . 276
lector function. 4.2 Information Menu . . . . . . . . . . . . . . 278
● Solar charging of 1 tank systems 4.3 Settings Menu . . . . . . . . . . . . . . . 278
● Current/reset values 4.4 Manual Operation Menu . . . . . . . . . . . 279
● 3 temperature inputs Pt1000 4.5 Special Functions Menu . . . . . . . . . . . 279
● 1 output, speed-controlled 4.6 Service – System Messages. . . . . . . . . . 280
4.7 Service – Sensor Control . . . . . . . . . . . 280
5. Application Examples . . . . . . . . . . . . 281
5.1 Single-Tank System . . . . . . . . . . . . . 282
5.2 Single Tank System with PHE . . . . . . . . . 282

Solar Thermal / Solar Circuit EN-XXX_SUNGO-S_BA-100121-1122P200 271
1. Technical Description Manual Operation
Manual operation allows to manually switch input and
Solar Controller SUNGO S
output channels on or off. On exiting the manual opera-
tion menu, the software returns to automatic operation.
100 % recyclable ABS casing
Material The manual operation menu can be used for a maximum
for wall mounting
of 8 hours. After that the software automatically switches
Dimensions (L x H x W in mm) 173 x 138 x 51 back to automatic operation in the information menu.
Protection type IP40 according to VDE 0470
Rate of radio interference N according to VDE 0875
Manual Lag Function
In order to check the temperature values in the information
230 Volt AC; 50 Hz;
Mains supply menu, even when the output channels are set manually,
-10 % to +15 %
a time lag has to be selected in the manual lag function
Max. size of wiring of the manual operation menu. After exiting the manual
2,5 mm² stranded / single
for 230 V-connections
operation menu this time span passes once and then is set
Temperature sensor / Pt1000; 1000 Ω at 0 °C; back to zero. In this mode a blinking symbol for the manual
Temperature range Range: -30 °C to +225 °C operation is shown in the information menu.
Ensure that the cable does not
put strain on the sensor; Collector Cooling
Strain on sensor Do not put any mechanical The tank is loaded up to the preset temperature limitation
strain on the sensor if
which affects sensor T2 (tank, bottom). If the preset tem-
temperature is above 60 °C.
perature limitation is exceeded output A1 (solar circula-
4 kV for 1 min tion pump) switches off. If the temperature of T1 (collector)
Test voltage
according to VDE 0631
then rises above the selectable standard value of 110 °C
Switching voltage 230 Volt AC the solar circulation pump is switched on in order to cool
Output parameters of switches 1A / 230 VA for cos ϕ = 0,7-1,0 the collector. It switches off again when the temperature at
Low current fuse 5 x 20 mm; the collector sensor has decreased by 10 K.
Fuse, internal
2 A/T (2 Ampere, slow) This type of intermittent operation of the solar circulation
Operating temperature (inside), pump means, that the collector is never or only rarely in
0° to +50 °C / -10° to +65 °C
storage temp. an  idle state. If the preset tank temperature limitation is
Weight ca. 360 g exceeded by 5  K, the collector cooling function is sup-
pressed. The system shuts down completely.

Solar Charging Tank Cooling
The solar circulation pump is switched on and off by Tank cooling means that if necessary the tank temperature
means of a temperature difference control. The sensors can be reduced to a preset lowest switch-off value (e.g.
T1 (collector) und T2 (tank, bottom) are required as con- setting for vacations).
trol elements. The on/off conditions and the temperature When the collector cooling function is activated tank cool-
limitation can be variably set in the settings menu. Note: ing will also become active.
The temperature limitation always affects sensor T2 (tank, In order for tank cooling to become active the following 3
lower half). conditions must be met:
1. Temperature T2 (tank, lower half) must be higher than
Speed Control or equal to the preset tank temperature limitation plus 2 K.
The solar circulation pump can be controlled via speed 2. Temperature T2 (tank, lower half) must be higher than
control (in this case impulse packet control). This means the preset switch-off value for tank cooling.
that individual sine half-waves in the alternate current are 3. Temperature T1 (collector) must be lower than tempera-
switched on or off depending on the temperature differ- ture T2 (tank, lower half) minus 10 K.
ence. Therefore the speed can be altered within a range
of 30-100% which results in longer system run times. The In order for tank cooling to switch off one of the following
minimum speed can be custom set. 2 conditions must be met:
1. Temperature T2 (tank, lower half) is lower than the
Sensor T3 (tank, upper half) switch-off value for tank cooling.
SensorT3 (tank, upper half) is a measuring sensor which 2. Temperature T1 (collector) must be higher than tem-
indicates the temperature in the upper tank area. It has no perature T2 (tank, lower half) minus 2 K.
switch function and is not monitored by the diagnostics
system.

Balance Values
In addition to the actual values of the sensors T1 (collector)
and T2 (tank, lower half) the display also shows balance
values which represent the min. and max. temperature
values for each sensor. When reset the current actual tem-
perature value is displayed.

272 EN-XXX_SUNGO-S_BA-100121-1122P200
Vacuum Tube Collector Function
The vacuum tube collector function allows operation of
the solar heating system even if sensor T1 (collector) is in-
stalled in the connecting pipe of the collector. If the tem-
perature increase at sensor T1 exceeds the preset switch-
on value for the collector temperature increase (standard:
1 K) the solar circuit pump is switched on for the duration
of a preset lag time (standard: 15 s).
During this time the switch-on difference and the solar
charge between sensor T1 (collector) and sensor T 2 (tank,
lower half) has to be activated, otherwise the solar circula-
tion pump will switch off again.
The rise in temperature at sensor T1 (collector) is measured
again immediately after the last runtime of the pump.

System Messages
The system messages for interrupted or shorted-out sen-
sors are represented by symbols on the display. For better
readability of the system message the display illumination
switches on and off every second as long as the error pre-
vails and no key entry is made.

Triac
The Triac is an electronic on/off switch for the 230 V out-
puts of the SUNGO controllers.
Function: A triac switch consists of 2 diodes which can be
switched anti-parallel (= antiparallel thyristors). The thyris-
tors switch through the positive or negative sine half-wave
as long as a switch-on difference exists. The triac switch
switches off when the temperature falls below the switch-
off difference.
1.4
System Protection
In order to protect system components like solar circula-
tion pump, 2-/3 way valves etc. that are installed in the
solar circuit against excess temperatures, solar charging
is stopped entirely as soon as a set temperature limit is
exceeded at sensor T1 (collector), even when charging
would still be possible due to the temperature difference
between sensor T1 (collector) and sensor T2 (storage cyl-
inder).

The standard temperature value to activate the system
protection is set at 135 °C. However, it is possible to set a
variable value between 115 °C and 200 °C.

EN-XXX_SUNGO-S_BA-100121-1122P200 273
2. General Safety Guidelines 2.3 Guidelines for Installation and
The following safety advice is designed to protect you Operation
from dangers that can arise from improper handling of ● Because Triacs carry 230 V current at the case, the mains
devices, whether intentional or otherwise. A distinction is must be disconnected while any installation and wiring
made between general advice presented here and spe- work is carried out.
cific advice presented throughout the guidelines. Watch ● The mains must be connected to the control via an ex-
out for the symbols! ternal ON/OFF switch outside the solar circulation unit.
This is also necessary in order to be able to activate the
“Special Function” menu through ON and OFF switch-
ing.
DANGER for danger to the person ● Operating temperatures above 50 °C are not permis-
Improper electrical installation of the device can lead to sible for the control.
potentially fatal electric shocks as well as other health haz- ● LCD display panels are designed in such a way that a
ards. specific reading position is required. When installing
the solar circulation unit be careful to place the display
so that it is at eye level or slightly higher. This way you
can ensure optimal display contrast (for SUNGO S and
CAUTION for danger to property SL).
This symbol indicates dangers that can result in damage to ● The base of the control is divided into a low voltage
the components or the function of the control. section and a 230 V section by a crosspiece. Make sure
that you do not confuse these.
● Automatic mode is the default operation mode of the
control. Manual mode is only used for testing the dif-
NOTE for additional information ferent components like the pump and two/three-way
This symbol indicates practical advice and tricks of the valve.
trade which will be useful for installing and operating the ● The system must not be operated if damage to the con-
control. trol, the wiring or the mains is detected.
● The control is fitted with a low-current fuse.
● Collectors and pipe work become very hot during sun-
2.1 Installer’s Qualifications ny periods. There is a risk of scalding when fitting the
collector temperature sensor.
● Setting up, installation and commissioning of the
SUNGO S must be carried out by a qualified installer.
● Please ensure that you comply with national and local 3. Installation
regulations.
● Please note that if a complaint is made, the guarantee is 3.1 Installation of the Case
only valid if the correct commissioning has been certi-
fied by a qualified person in the commissioning report. Open the Casing
● You require no tools to open the control. The lid snaps
into the lower half. You can dislodge and lift up the lid
2.2 Use and Application by pulling gently on the side clips.
● The lid arrests automatically when fully opened to allow
Function for comfortable mounting and wiring.
● Controlling solar thermal systems through the selection
of applicable control patterns and additional functions Wall Mounting
to adapt the control for the required operation of the ● Using the supplied drilling template drill out the fixing
hydraulic system. holes for the control.
● The control is certified for use in dry rooms only. ● Mount the control to the wall.
● The control can either be integrated into the solar circu- ● Tighten screws only as far as necessary. Over-tightening
lation unit or it can be mounted on the wall. may damage the casing!

Limitations of Use
● The controls suitability should be checked before oper-
ation commences if it is used for any other purpose than
for controls suitability solar thermal systems. If you are
unsure you must check with the service of Wagner & Co.
● The use of the control for non-specified operation re-
sults in a lapse of the guarantee.

274 EN-XXX_SUNGO-S_BA-100121-1122P200
Installation in the Solar Circulation Unit 230 V Mains Connection
● Affix the SUNGO S with the appropriate screws to the ● Mains power is connected from outside the connector
wall mounting bracket of the solar circulation unit. via an ON/OFF switch.
● Open up the cable ducts next to the centre crosspiece If the unit is connected with a plug to a socket, the switch
in the bottom of the control. can be omitted.
● Remove outer insulation of the cables in such way that ● The unit is designed to work with 230 V AC/50Hz. Please
single isolated wires start as they enter the casing from check that your pump has compatible specifications.
the bottom. ● All earth wires are connected to the PE-connectors.
● Hold the connectors with one hand while tightening ● The neutral terminals (N) are connected electrically.
the screws in order to minimise pressure on the circuit ● Switch output A1 is a 230 V normally open contact
board and to avoid tearing the connectors off. which is activated via speed-control.
● Last connection should be to mains.
● If power is switched on now, 230 V AC will be present on Connecting the Temperature Sensors
the casing of the triacs. ● The wires for the temperature sensors can be extended:
Up to 15 m length = 2 x 0.5 mm² cable can be used ; up
to 50 m = 2 x 0.75 mm² cable is necessary.
3.2 Connecting Wires For long connections it is recommended to use shield-
ed cable.
Layout of the SUNGO S Connections Do not connect the shielding at the sensor
All connections are made to the circuit board at the bot- end, just trim and isolate!
tom of the control. On the right hand side you will find the ● Temperature sensors are without polarity and can be
connections for the sensors (low voltage area) while on the connected any way.
left hand side you will find the connections for mains and ● Sensor wires must be installed away from mains carry-
switching output A1. ing cables.

General Connection Rules Lightning Protector Module
● If flexible wires are used and the controller is fitted to The SUNGO S is fitted with spike protection on all sensor
the wall, wires must be tied externally in such way that terminals. Generally, further protection of the cylinder sen-
strain to the controller is avoided. sors is not required.
● In this case you must tin or crimp the wire ends. Sensor T1 (collector) requires installation of sensor con-
● If required PG9 screws can be fixed at the feed-throughs nection box SP2 with excess voltage protection.
if the control is mounted to the wall. 1.4

Mains microfuse 2A/T Mains voltage area Safety low voltage area Ribbon cable plug
for display circuit
Saf

Earth potential connector Sensors T1-T3 connectors
ety
fus
e

Mains connector

Switch output A1 connector
Transformer
for circuit voltage 12 V

Electronic triac switch Triac control IC

Figure 2 SUNGO S circuit board components

EN-XXX_SUNGO-S_BA-100121-1122P200 275
Mains voltage area Safety low voltage area

Saf
ety
Mains, PE T1, collector sensor

f
Solar circulation pump, PE

use
Mains, phase (L) T2, tank sensor, lower half
Mains, neutral (N)
Solar circulation pump, phase (L1) T3, tank sensor, upper half
Solar circulation pump, zero (N1)

Figure 3 Connections

4. Operation
4.1 Display and Buttons

Settings menu Manual operation menu

Information menu Special functions menu

Temperature difference

Balance or
start / stop values

dT min max start stop

88888
Number display for Units
temp. or sensor errors
°C %
Collector temperature
x h Tank temperature,
upper half
R
R
Reset symbol

!
Tank temperature, lower half
ok? Confirm /
save icon
Pump ON
Pump OFF
System error

Output A1

276 EN-XXX_SUNGO-S_BA-100121-1122P200
Horizontal operating level

Settings menu
as an example

T max

__°C Temperature limitation tank, bottom
dT max

__K Switch-on difference T1-T2, solar
Vertical dT min
operating level __K Switch-off difference T1-T2, solar
T min

__°C Minimum temperature source
dT 1.4
__K Set point temperature difference, speed control, solar
d min

__ Solar circulation pump
d max

__ Maximum speed solar circulation pump (SECUSOL)
T start

__ System filling time (SECUSOL)

Set values

➝ ➝ ➝ ➝

Activate Increase Decrease Activate Save
value value value save function value

EN-XXX_SUNGO-S_BA-100121-1122P200 277
4.2 Information Menu
Information menu
Menu item Description Display

Collector temperature; Current value °C
__°C

min
Collector temperature; Balance value; minimum,
°C
__°C resettable

max
Collector temperature; Balance value; maximum,
°C
__°C resettable

Tank temperature, lower half; Current value °C
__°C
min
Tank temperature, lower half; Balance value; minimum,
°C
__°C resettable

max
Tank temperature, lower half; Balance value; maximum,
°C
__°C resettable

Tank temperature, upper half 1; Current value °C
__°C

Operating hours, total; Current value h
__h

Reset operating hours, since last reset Balance value, display,
h
R __h resettable;

Pump symbol idle: Function display
Temperature difference between collector and tank —
is smaller than switch-on difference (solar circulation pump off).
Pump symbol active: Function display
Temperature difference between collector and tank —
is higher than switch-on difference (solar circulation pump on).
1 Sensor T3 (tank, upper half) is simply a measuring sensor, therefore it is not monitored by the sensor control.

4.3 Settings Menu
Settings menu
Menu item Description Range Base value
T max
Temperature limitation tank, lower half 15 - 90 °C 85 °C
__°C
dT max
Switch-on difference between collector and tank 3 - 40 K 10 K
__K

dT min
Switch-off difference between collector and tank 2 - 35 K 3K
__K
T min
Minimum temperature where analysis of switch-on difference starts 5 - 90 °C 10 °C
__°C

dT
Set point temperature difference the speed control adjusts to 2 - 50 K 10 K
__K

d min Minimum speed of the solar circulation pump
30 - 100% 30%
__ 10% increments

d max
Maximum speed of the solar circulation pump
30 - 100% 100%
__ SECUSOL only!

T start Charge time (s) of the solar heating system with speed 100%; in 10 s increments
20 - 360 s 60 s
__ SECUSOL only!

278 EN-XXX_SUNGO-S_BA-100121-1122P200
4.4 Manual Operation Menu
Manual operation menu
Menu item Description Range Base value

Off = 0 / On = 1
0-1 0
Manual on/off via output A1 (solar circulation pump)

T stop
Activation of manual operation lag time in automatic mode 0 - 600 min 0 min
__

4.5 Special Functions Menu

Within the first minute after switching on the controller, select the “Special Functions“ menu in order to activate it, so that
the individual parameters can be changed.
After leaving it, the menu remains active for one minute. Afterwards the parameters can only be viewed but not changed.
In order to change the functions again, it is necessary to disconnect the controller from the mains again.

Special functions menu
Menu Application Description Range Base value
item
0 - 1: Standard single-tank system
0 System choice 0 - 2: Cannot be selected! 1 or 3 1
0 - 3: SECUSOL system (see SECUSOL instructions for further info)
Off = 0 / On = 1
1 Activation of system protection. 0 or 1 1
System Protection Cannot be activated with SECUSOL!
2 System protection start temperature 115 - 200 °C 135 °C
Off = 0 / On = 1
3 Activation of collector cooling. 0 or 1 1
1.4
Collector Cooling Cannot be activated with SECUSOL!
4 Collector cooling start temperature 100 - 150 °C 110 °C
Off = 0 / On = 1
5 Activation of tank cooling. Only possible with collector cooling. 0 or 1 0
Tank Cooling Cannot be activated with SECUSOL!
6 Switch-off temperature 30 - 90 °C 60 °C
7 - 10 Menu items 7-10 are not available for the SUNGO S controller
Off = 0 / On = 1
11 0 or 1 0
Activation of vacuum tube collector function
Tube collector
12 function Run time of solar circulation pump from reaching the switch-on value 1 - 60 s 15 s
13 Switch-on value for temperature increase at sensor T1 (collector) 1.0 - 5.0 K 1.0 K

Only expert personnel
should edit the special functions menu.
Incorrect settings may adversely affect the solar heating
system.

EN-XXX_SUNGO-S_BA-100121-1122P200 279
4.6 Service – System Messages
Display of system information
Display Description Correction

!
System Messages
All system messages are displayed with a blinking caution symbol.
Blinking In case of sensor errors the sensor in question is also marked with short circuit or interruption symbols.

!
Interruption
°C Displayed sensor or line connection interrupted
Blinking / defunct. ● Check the resistance value of the sensor and compare
to the resistance table.
Short circuit
● Check all contact points up to the sensor.
°C !
Blinking
There is a short circuit of the sensor on the
display, the line or the sensor input on the
controller.
dT too high
A fixed value of 20 K is added to the ● Check pump/pump connections/wiring.

!
Blinking
temperature difference between collector (T1)
and tank sensor (T2). The message is displayed
● Check system for air, and vent if required.
● Check sensors/sensor lines and change sensor if
if after 30 minutes the total temperature required.
difference has not been reduced.

4.7 Service – Sensor Control
Resistance values for Pt1000-sensors in relation to the temperature
-10 °C 0 °C 10 °C 20 °C 30 °C 40 °C 50 °C 60 °C 70 °C 80 °C 90 °C 100 °C 110 °C
961 Ω 1000 Ω 1039 Ω 1078 Ω 1117 Ω 1155 Ω 1194 Ω 1232 Ω 1271 Ω 1309 Ω 1347 Ω 1385 Ω 1423 Ω
The working condition of the sensor can be checked with this table and an Ohm meter.

280 EN-XXX_SUNGO-S_BA-100121-1122P200
5. Application examples
5.1 Single-Tank System
P1: Pump, solar circuit
P2: Pump, heating circuit
P3: Pump, aux. heating DHW Exit 230 V Low voltage section

M1: Mixing valve, heating circuit
Collector field
BWM: Thermostatic mixing valve
Mains

Oil or gas
boiler

Hot water

Cold water 1.4
Figure 4 Single-tank system DHW preparation
Tvl = Temperature, flow; Ta = Temperature, outside; Ttw = Temperature, domestic hot water

EN-XXX_SUNGO-S_BA-100121-1122P200 281
5.2 Single Tank System with PHE

P1: Pump, solar circuit (primary)
P2: Pump, solar circuit (secondary/DHW)
P3: Pump, heating circuit Exit 230 V Low voltage section

M1: Mixing valve, heating cicuit

BWM: Thermostatic mixing valve Collector field
PWT: Plate heat exchanger Mains

Min. speed A1: 100%

Oil or gas
boiler

Hot water

Cold water

Figure 5 Single storage system with external plate heat exchanger (PWT) for DHW preparation
Tvl = Temperature, flow; Ta = Temperature, outside; Ttw = Temperature, domestic hot water

Subject to modifications, errors excepted · © Wagner & Co, 2010 · www.wagner-solar.com
282 WAGNER & CO · Zimmermannstraße 12 · D-35091 Cölbe/Marburg · ☎
+49 (0) 64 21 80 07-0 · Fax 80 07-596
OPERATING INSTRUCTIONS, Version SW1203/3.00/ HW3.0

Solar Controller SUNGO SL

1.4

Figure 1 Solar Controller SUNGO SL.

Product Features Contents
● Large illuminated display to indicate temperature, bal- 1. Technical Description . . . . . . . . . . . . 284
ance values and system status with clearly visible sym- 2. General Safety Guidelines . . . . . . . . . . 286
bols for easy readability. 2.1 Installer’s Qualifications . . . . . . . . . . . 286
● Easy and safe operation via four buttons for vertical and 2.2 Operating Requirements . . . . . . . . . . 286
horizontal scrolling through the menus. 2.3 Installation and Operating Information . . . . 286
● Extensive diagnostics for monitoring system functions, 3. Installation . . . . . . . . . . . . . . . . . 286
eg. sensor cutoff and monitoring of temperature differ- 3.1 Installation of the Housing . . . . . . . . . . 286
ence “∆T too high” 3.2 Connecting Wires . . . . . . . . . . . . . . 287
● Integrated security functions such as collector cooling, 4. Operation . . . . . . . . . . . . . . . . . 288
storage tank cooling, system protection and vacuum 4.1 Display and Control Buttons . . . . . . . . . 288
tube collector function. 4.2 Information Menu . . . . . . . . . . . . . . 290
● Solar charging of 1 and 2 tank systems 4.3 Settings Menu . . . . . . . . . . . . . . . 291
● Choice of thermostat function or return temperature 4.4 Manual Operation Menu . . . . . . . . . . 292
increase 4.5 Special Functions Menu . . . . . . . . . . . 292
● Balance/reset values 4.6 Service – System Messages. . . . . . . . . . 293
● 5 temperature inputs PT1000 4.7 Service – Sensor Control . . . . . . . . . . . 293
● 1 output, speed-controlled 5. Application Examples . . . . . . . . . . . . 293
● The sensor T5 (solar return) and an external volume 5.1 Single Tank System with Return Boost . . . . . 293
measuring device provide energy measurement in kWh. 5.2 Dual Tank System . . . . . . . . . . . . . . 294

Solar Thermal / Solar Circuit EN-XXX_SUNGO-SL_BA-100127-1122P300 283
1. Technical Description Balance Values
In addition to the actual values of the sensors T1 (collector)
Solar Controller SUNGO SL and T2 (tank, bottom) the display also shows balance val-
ues which represent the smallest and biggest temperature
100 % recyclable ABS-housing
Material values for each sensor. After reset the actual temperature
for wall mounting
value is displayed.
Dimensions (L x H x W in mm) 173 x 138 x 51
Protection type IP20 according to VDE 0470 Manual Operation
Rate of radio interference N according to VDE 0875 Allows switching inputs and outputs on or off manually. On
230 Volt AC; 50 Hz;
exiting the manual operation menu, the software returns
Operating voltage to automatic operation. The manual operation menu can
-10 % to +15 %
be used for a maximum of 8 hours. After that the software
Diameter of cable max. 2.5 mm² unifilar or finely
for 230 V connections stranded automatically switches back to automatic operation and to
the information menu.
Temperature sensor / Pt1000; 1000 Ω at 0 °C;
Temperature range Range: -30 °C to +225 °C
Manual Lag Function
The cable of the sensor must be
In order to check the temperature values in the information
installed with no tension.
The sensor must not be loaded menu even when the outputs are set manually, a time lag
Sensor load has to be selected in the manual lag function in the manual
mechanically when the
temperature of the collector is operation menu. On exiting the manual operation menu,
more than 60 °C. this time span passes once and then is set back to zero. In
4 kV 1 min this mode a blinking symbol for the manual operation is
Test voltage
according to VDE 0631 shown in the information menu.
230 Volt AC
Switching voltage 1A / ca. 230 VA Collector Cooling
Output parameters of switches for cos ϕ = 0.7-1.0 The tank is loaded up to the preset temperature limita-
for each output tion which affects sensor T2 (tank, bottom). If the preset
Internal mains protection
Microfuse 5 x 20 mm; temperature limitation is exceeded output A1 (solar circuit
2 A/T pump) switches off. If the temperature of T1 (collector)
Operating temperature 0° to +50 °C / then rises above the selectable standard value of 110 °C
(internal) / storage temperature -10° to +65 °C the solar circuit pump is switched on in order to cool the
Weight ca. 360 g collector. It switches off again when the temperature at the
collector sensor has decreased by 10 K.
This type of intermittent operation of the solar circuit pump
Solar Charging means that the collector is never or only rarely in an idle
The solar circuit pump is switched on and off by means of a state. If the preset tank temperature limitation is exceeded
temperature difference control. The sensors T1 (collector) by 5  K the collector cooling function is suppressed. The
und T2 (tank, bottom) are required as control elements. system shuts down completely.
The on/off conditions and the temperature limitation can
be variably set in the settings menu. Note: The tempera- Storage Tank Cooling
ture limitation always affects sensor T2 (tank, bottom). Storage Tank Cooling means that if necessary the tank
temperature can be reduced down to a preset lowest
Speed Control switching off value (setting for vacations).
The solar circuit pump can be controlled via speed control When the collector cooling function is activated storage
(in this case by half wave control). This means that individ- tank cooling will also become active.
ual sine half-waves in the alternate current are switched on In order for storage tank cooling to become active the fol-
or off depending on the temperature difference. Therefore lowing 3 conditions must be met:
the speed can be altered within a range of 30-100 % which 1. Temperature T2 (tank, bottom) must be higher than or
results in longer system run times. The minimum speed equal to the preset tank temperature limitation plus 2 K.
can be custom set. 2. Temperature T2 (tank, bottom) must be higher than the
preset switching off value for storage tank cooling.
Sensor T3 (Tank, Top) 3. Temperature T1 (collector) must be lower than tempera-
Sensor T3 (tank, top) has different functions. By default it is ture T2 (tank, bottom) minus 10 K.
the measuring sensor for the top of the tank. In that case In order for storage tank cooling to switch off one of the
it has no switch function and is not monitored by the diag- following 2 conditions must be met:
nostics system. 1. Temperature T2 (tank, bottom) is lower than the switch-
With the return temperature increase function activated ing off value for storage tank cooling.
it functions as a hot sensor (source). With the thermostat 2. Temperature T1 (collector) must be higher than tem-
heating with additional sensor function activated it func- perature T2 (tank, bottom) minus 2 K.
tions as an additional sensor. In both cases this sensor is
used in the hot area of the tank and affects switching out-
put A2.
If used in this way the sensor function is monitored as nor-
mal by the diagnostics system.

284 EN-XXX_SUNGO-SL_BA-100127-1122P300
Vacuum Tube Collector Function Thermostat
The vacuum tube collector function allows operation The thermostat function for switching on can be set at a
of the solar heating system even if sensor T1 (collector) range between 0° to 130 °C with a variable difference be-
is installed in the connecting pipe of the collector. If the tween 1 to 40 K for switching off. Choose between the op-
temperature increase at sensor T1 exceeds the preset tions heating and cooling.
switching on value for the collector temperature increase With the heating option activated output A2 switches on if
(standard: 1 K) the solar circuit pump is switched on for the the current temperature T4 falls below the preset switch-
duration of a preset lag time (standard: 15 s). ing on level. Output A2 switches off if the current tempera-
During this time the switching on difference and the solar ture T4 is higher than the switch-on level plus the switch-off
charge between sensor T1 (collector) and sensor T 2 (tank, difference.
bottom) has to be activated, otherwise the solar circuit With the heating option an additional sensor T3 can be acti-
pump will switch off again. vated. If this is the case A2 is only switched on if temperature
The rise in temperature at sensor T1 (collector) is measured T3 is higher than the switching on level plus the switching
again immediately after the last runtime of the pump. off difference plus the additional difference for T3.
With the cooling option activated output A2 switches on
System Messages if the current temperature T4 falls below the preset switch
The system messages for interrupted or shorted-out sen- level. Output A2 switches off if the current temperature T4
sors are represented by symbols on the display. For better is lower than the switch level minus the switching off dif-
recognition of the system message the display illumina- ference.
tion switches on and off every second as long as the error There are 3 independent time windows available for the
prevails and no key entry is made. thermostat. If no time window is activated time window 1
has to be set to 0:00 and 23:59.
Triac
The Triac is an electronic on/off switch for the 230 V out- Return Flow Boost
puts of the SUNGO Controller. This is a freely adjustable temperature difference for sim-
Function: A triac switch consists of 2 diodes which can be ple heating support which leads the heating return-flow T4
switched anti-parallel (= antiparallel thyristors). The thyris- (drain) to the heating boiler, either directly or via the solar
tors switch through the positive or negative sine half-wave tank, depending on the preset temperature difference to
as long as a switching on difference exists. The triac switch the tank sensor T3 (source) , by switching the 3 way valve
switches off when the temperature falls below the switch- on output A2.
ing-off difference. Note: In addition to the switching phase (black) on out-
put A2, the switching head also requires a constant phase 1.4
System Protection (brown).
In order to protect the system components (solar circuit
pump, 2 or 3 way valves etc.) in the solar heating circuit SECUSOL Function
from extremely high temperatures the solar charge is The solar heating system is operated on a drain back prin-
stopped completely if a temperature limit at the collector ciple. This means if the solar circuit pump is not activated
sensor is exceeded, even if this was permitted on account there is no solar fluid in the collectors and risers. See SE-
of a temperature difference between sensor T1 (collector) CUSOL instructions for further details.
and sensor T2 (tank, bottom).
The standard temperature value for activating the system Measuring the Yield
protection function is 135 °C. However, this value can be For measurements of the solar yield in kWh. The heat yield
variably set within a range of 115° to 200 °C. is measured with a volume flow metre connected to input
T7, an additional sensor T5 (return) and the existing sensor
Dual Tank Operation T1 (collector).
The SUNGO SL is capable of controlling a dual tank system
by using output A2 for switching between tanks with the
help of a 3 way valve. Change the menu item 0 – 1 to 0 – 2
in order to control a dual tank system.
Note: If the dual tank option is selected menu item 10 can
no longer be activated.

Preference
The SUNGO SL always uses tank 1 as a preference for the
dual tank option. This cannot be changed.

EN-XXX_SUNGO-SL_BA-100127-1122P300 285
2. General Safety Guidelines 2.3 Installation and
The following safety advice is designed to protect you Operating Information
from dangers that can arise from improper handling of ● Any installation and wiring work has to be carried out
devices, whether intentional or otherwise. A distinction is in an idle state as during operation the voltage on the
made between general advice presented here and spe- outside of the triacs is 230 V.
cific advice presented throughout the guidelines. ● Mains power must be connected to the control from
outside the solar station via an external ON/OFF Switch.
This is also required to activate the special functions
menu through switching the mains power ON/OFF.
DANGER for danger to the person ● Operating temperatures above 50 °C are not permitted
Improper electrical installation of the device can lead to for the control.
potentially fatal electric shocks as well as other health haz- ● LCD display panels are designed in such a way that a
ards. specific reading position is required. When installing
the control, be careful to place the display so that it is
at eye level or slightly higher. This way you can ensure
optimal display contrast.
CAUTION for danger to property ● The base of the control is divided into a safety low volt-
This symbol indicates dangers that can result in damage to age section and a 230 V section by a crosspiece. Make
the components or the function of the control. sure that you do not confuse these sections during the
installation process.
● The default operating mode is the automatic mode.
Manual operation is used only for functional testing
NOTE for additional information of the different hydraulic components (pump, 2/3 way
This symbol indicates practical advice and tricks of the valve). In this operating mode maximum temperatures
trade which will be useful for installing and operating the or sensor functions are not monitored.
control. ● Do not operate the system if the control, the wiring or
the connected 230 V mains are visibly damaged.
● The control is fitted with a mains microfuse.
2.1 Installer’s Qualifications ● Collectors and hydraulic pipework can get extremely
hot during sunny periods. There is a risk of scalding
● Setting up and commissioning of the SUNGO SL must when fitting the collector temperature sensor.
be carried out by a qualified installer.
● All national and local safety regulations need to be com-
plied with. 3. Installation
● Please note that in case of a complaint the guarantee is
only valid if correct commissioning has been certified in 3.1 Installation of the Case
a commissioning report.
Opening the Case
● No tools are required to open the control case. The lid
2.2 Operating Requirements folds over on top of the lower half. You can dislodge and
lift up the lid by pulling gently on the side clips.
Application ● When fully opened the lid will not move so that you can
● Controlling solar thermal systems through the selection take care of mounting and wiring comfortably.
of applicable control patterns and additional functions
to adapt the control for the required operation of the Wall Mounting
hydraulic system. ● Use the supplied drilling template to drill the fixing
● The control must only be operated in dry rooms. holes for the controller.
● The control can be integrated into the solar circulation ● Mount the control to the wall.
unit or mounted on the wall. ● Do not overtighten the screws to avoid damage to the
lower part of the housing.
Limitations of Use
● If used in a non-solar thermal application the functionality
of the control has to be checked before commissioning.
If in doubt contact the control service of Wagner & Co.
● If these operating requirements are not observed any
claims under the warranty will not be accepted.

286 EN-XXX_SUNGO-SL_BA-100127-1122P300
Installation in the Solar Circulation Unit 230 V Mains Connection
● With the screws mount the SUNGO SL on the wall hold- ● Mains power is connected from out-
er of the solar circulation unit. side the control via an ON/OFF Switch.
● Break out the cable feeds which are located on the base This switch is not required if mains power is with a pro-
housing next to the crosspiece. tective plug to a socket.
● Strip the 230 V cables in a way that the insulated single ● The control is suitable for mains operation at approx.
cables start directly at the feed to the base housing. 230 V/50 Hz.
● Hold cable clamps steady when screwing tight in order ● All earth wires are connected to the PE terminals.
to minimise pressure on the circuit board. There is a ● The neutral terminals (N) are connected electrically.
danger of the terminals to be torn off! ● Switching output A1 is a 230 V normally open contact
● Finally connect to mains power. which is activated via speed-control. Switching output
● When the control is switched on the voltage on the tri- A2 is purely a normally open contact.
acs housing is 230 V AC.
Connecting the Temperature Sensors
● The wires of the temperature sensors can be extended:
3.2 Connecting Wires Up to 15 m length, 2 x 0.5 mm² cable can be used, be-
yond 15 m and up to 50 m 2 x 0.75 mm² is necessary.
Layout of the SUNGO SL Connections Shielded cables should be used for long connections
All electrical connections are made to the circuit board at to the collector.
the bottom of the control. The sensor connections (safety Do not connect the shielding at the sensor end, just
low voltage) are located on the right hand side and the trim and isolate.
230 V mains connections and the switching outputs A1 ● The polarity of the temperature sensors is irrelevant and
and A2 on the left hand side. they can be connected either way.
● The sensor wires must be installed separately from
General Connection Rules 230 V mains cables.
● If flexible wires are used and the control is wall mount-
ed, a strain relief must be fixed within or outside of the Lightning Protector Module
control. The SUNGO SL is fitted with spike protection on all sensor
● In this case you must crimp the wire ends. terminals. Generally, further protection of the tank sensors
● If required PG9 screws can be fixed at the feed-throughs is not required.
in case of wall mounting. Sensor T1 (collector) should be fitted with the sensor con-
nection box SP2 with an overvoltage protection. 1.4

ControllerIC Plug for Display

FUSE 5X20

Triac

T1 T2 T3 T4 T5 T7
Trafo
PE-PE A2 A1 L1 M M M M M M

PE-PE N N N

Potential Earth Collector sensor, T1

Switching output Tank sensor, bottom, T2

Solar circuit pump Tank sensor, top /
Additional thermostat sensor /
Mains L1 return flow boost (source)

Thermostat /
return flow boost (sink), T4

Heat meter (yield), return flow sensor, T5

“Volume flow meter” for yield measurement, T7

Figure 2 SUNGO SL circuit board components.

EN-XXX_SUNGO-SL_BA-100127-1122P300 287
4. Operation
4.1 Display and Buttons

Settings menu Manual operation menu

Information menu Special functions menu

Temperature difference

Balance or
start / stop values
Numerical display for temp. dT min max start stop

88888
or sensor errors Units

°C %
Collector temperature
x KWh Tank temp., top/
thermostat additional sensor
Temperature thermostat/

R
R return flow boost (sink)
Time slot thermostat
Symbol for reset value Tank temp., mid section/
return flow boost (source)

!
Tank temp., bottom
ok? Confirm and
Pump ON/ save symbol
Pump OFF
System error
Output A1
Output A2

288 EN-XXX_SUNGO-SL_BA-100127-1122P300
Horizontal operating level

Settings menu
as an example
Vertical
operating level

T max
R 2 dT min
Switching off diff. T3 - T4,
return temperature increase __K __°C Temperature limitation tank, bottom
R2 dT max dT max
Switching on diff. T3 - T4,
return temperature increase __K __K Switching on difference T1 - T2, solar
R2 T min dT min
Min temp. level,
return temperature increase __°C __K Switching off difference T1 - T2, solar
R2 T max T min
Temp. limitation,
return temperature increase __°C __°C Min. temp. source 1.4

3
stop dT

Stop time window 3, thermostat __:__ __K Design temp. diff. speed control, solar

3
start d min
1
Start time window 3, thermostat __:__ Min. speed, solar circuit pump
d max

2
stop
Stop time window 2, thermostat __:__ __ Max. speed solar circuit pump (SECUSOL)
T start

2
start
Start time window 2, xx thermostat __:__ __ Charge time solar heating system (SECUSOL)

I
stop
Stop time window 1, thermostat __:__ __:__ Current time

Start time window 1, thermostat __:__
start
I 4 __°C Switching on temperature, thermostat

4
dT

__K Switching off temperature, thermostat
dT

__K Difference additional sensor T3, thermostat

Set values

➝ ➝ ➝ ➝

Activate Increase Decrease Activate Save
value value value save function value

EN-XXX_SUNGO-SL_BA-100127-1122P300 289
4.2 Information Menu
Information menu
Menu item Description Display

Collector temperature; Current value °C
__°C

min
Collector temperature; Balance; minimum, resettable °C
__°C

max
Collector temperature; Balance; maximum, resettable °C
__°C

Tank temperature, bottom; Current value °C
__°C
min
Tank temperature, bottom; Balance; minimum, resettable °C
__°C
max
Tank temperature, bottom; Balance; maximum, resettable °C
__°C

Tank temperature, top; Current value °C
__°C

Operating hours, total; Balance h
__h

R operating hours since last reset; Balance, display, resettable h
R __h

1 Tank temperature 1 or 2, bottom;
2
°C
__°C (if 2 tank system is selected) Current value

min
1 Tank temperature 1 or 2, bottom;
°C
2
__°C (if 2 tank system is selected) Balance; minimum, resettable

max
1 Tank temperature 1 or 2, bottom;
2
°C
__°C (if 2 tank system is selected) Balance; maximum, resettable

1 Operating hours tank 1 or 2, total;
2
h
__h (if 2 tank system is selected) Balance

1 R operating hours tank 1 or 2
2 h
R __h since last reset; (if 2 tank system is selected) Balance; display, resettable

Thermostat or return temperature increase (drain); Current value °C
__°C

Heat meter return;
R °C
__°C (flow value corresponds to collector temperature) Current value

Heat meter total yield; Balance kWh
__kWh

R heat meter since last reset; Balance, display, resettable kWh
R __kWh

1
2
Heat meter, tank 1 or 2, total; Balance kWh
__kWh

1 R heat meter, tank 1 or 2
2 kWh
R __kWh since last reset; Balance, display, resettable

Pump symbol idle: Operating symbol
Temperature difference (collector, tank) is smaller than required —
to activate the solar circuit pump. The solar circuit pump is off.
Rotating pump symbol: Operating symbol
Temperature difference (collector, tank) is sufficient to activate —
the solar circuit pump. The solar circuit pump is running.

290 EN-XXX_SUNGO-SL_BA-100127-1122P300
4.3 Settings Menu
Settings menu
Menu item Description Range Default setting
T max
Temperature limitation tank, bottom 15 – 90 °C 85 °C
__°C

dT max
Switching on difference between collector and tank 3 – 40 K 5K
__K

dT min
Switching off difference between collector and tank 2 – 35 K 3K
__K
T min
Min. temp. above which the switching difference is analyzed 5 – 90 °C 10 °C
__°C

1 T max
Temperature limitation tank 1 or 2, bottom 15 – 90 °C 85 °C
2 __°C

1 dT max
Switching on difference between collector and tank 1 or 2 3 – 40 K 10 K
2 __K

1 dT min
Switching off difference between collector and tank 1 or 2 2 – 35 K 3K
2 __K

dT
Design temperature difference the speed control adjusts to 2 – 50 K 10 K
__K

d min Minimum speed of the solar circuit pump
30 – 100% 30%
1 __ 10 % increments

d max Maximum speed of the solar circuit pump
30 – 100% 100%
__ Only with SECUSOL!

T start
Charge time (s) of the solar heating system with speed 100 %; in 10 s increments
20 – 360 s 60 s
__ Only with SECUSOL! 1.4
__:__ Set current time (keep button pressed for faster run-through) 0:00-23:59 0:00

Switching on temperature thermostat 1 0° – 130 °C 30 °C
__°C

dT
Switching off difference thermostat 1 1 – 40 K 5K
__K

dT
Additional sensor difference for tank, top, can be selected in heating function. 1 3 – 20 K 10 K
__K
start
__:__ I Start time slot 1, thermostat 1 0:00-23:59 0:00
stop
__:__ I Stop time slot 1, thermostat 1 0:00-23:59 23:59
start
__:__ 2 Start time slot 2, thermostat 1 0:00-23:59 0:00
stop
__:__ 2 Stop time slot 2, thermostat 1 0:00-23:59 0:00

start
__:__ 3 Start time slot 3, thermostat 1 0:00-23:59 0:00

stop
__:__ 3 Stop time slot 3, thermostat 1 0:00-23:59 0:00

T max
R2
Temperature limitation return temperature increase 2 15° – 90 °C 85 °C
__°C

T min
R2
Minimum temperature from which the switching on difference is read 2 15° – 90 °C 20 °C
__°C

R 2 dT max Switching on difference return temperature increase between temperature
3 – 40 K 4K
__K measure location T3 and T4 2

R 2 dT min Switching off difference return temperature increase between temperature
2 – 35 K 2K
__K measure location T3 and T4 2
1 Only available if heating or cooling thermostat is used.
2 Only available if return temperature increase is used.

EN-XXX_SUNGO-SL_BA-100127-1122P300 291
4.4 Manual Operation Menu
Manual operation menu
Menu item Description Range Default setting

Off = 0 / On = 1
0–1 0
Switching the solar circuit pump on or off manually (A1)

Off = 0 / On = 1
0–1 0
Switching output A2 on or off manually (RLA or thermostat)

T stop
Activation of manual operation lag time in automatic mode 0 – 600 min 0 min
__

4.5 Special Functions Menu
During the first minute after switching on the control
activate the special functions menu by selecting it so that parameters can be altered. The menu stays active for 1 minute
after exiting it.
On exiting the menu the parameters can only be viewed but not changed again. Place the control in the idle position
once again if you need to alter any functions.

Special functions menu
Menu Application Description Range Default
item setting
0 – 1: Standard single tank system
0 System choice 0 – 2: Standard dual tank system 1–3 1
0 – 3: SECUSOL system (see SECUSOL instructions for further info)
Off = 0 / On = 1
1 System Activation of system protection. 0 or 1 1
Protection Cannot be activated with SECUSOL!
2 System protection start temperature 115 – 200 °C 135 °C
Off = 0 / On = 1
3 Activation of collector cooling. 0 or 1 1
Collector Cooling Cannot be activated with SECUSOL!
4 Collector cooling start temperature 100 – 150 °C 110 °C
Off = 0 / On = 1
5 Storage tank Activation of tank cooling. Only possible with collector cooling. 0 or 1 0
Cooling Cannot be activated with SECUSOL!
6 Switching off temperature 30 – 90 °C 60 °C
Off = 0 / On = 1
7 0 or 1 0
Activation of yield measurement
Frost protection type
8 8-1: DC20 for standard systems 1 or 2 1
Measuring
8-2: DC40 for vacuum tube collectors (ready mix)
the Yield
Glycol fraction in %.
0% = No Glycol (pure water)
9 0 – 100 % 40 %
100 % = Pure Glycol (no water)
Note: Glycol fraction for solar circuit can only be selected with DC20!
10 – 0: Additional functions off
10 – 1: Thermostat, heating
Function
10 10 – 2: Thermostat, heating with additional sensor T3 (tank, top) 0–4 0
selection
10 – 3: Thermostat, cooling
10 – 4: return temperature increase
Off = 0 / On = 1
11 0 or 1 0
Activation of vacuum tube collector function
Vacuum Tube
12 collector function Run time of solar circuit pump from reaching the switching on value 1 – 60 s 15 s
13 Switching on value for temperature increase at sensor T1 (collector) 1.0 – 5.0 K 1.0 K
The special functions menus should only be edited by expert personnel. Incorrect settings may adversely affect the solar heating system.

292 EN-XXX_SUNGO-SL_BA-100127-1122P300
4.6 Service – System Messages
System information with display
Display Description Remedy

!
System messages
All system messages are displayed with a blinking caution symbol. In case of sensor errors the sensor in
Blinking question is also marked with short circuit or interruption symbol.

!
Interruption
°C The sensor on the display or the pipe is
Blinking interrupted. ● Test the resistance value of the sensors and compare with
the tables.
● Check all connections to the sensor.
!
Short circuit
°C There is a short circuit on the sensor on the
Blinking display, the cable or the output on the control.

dT too high
● Check wiring to the pump

!
A value of 20 K is added to the switch-on
● Check system for air and vent if required
difference between T1 and T2. The message
● Check sensors and sensor wiring, replace sensors if
Blinking is displayed if after 30 minutes the total
required
difference has not been reduced.

4.7 Service – Sensor Control
Resistance values for Pt1000 sensors in relation to the temperature
-10 °C 0 °C 10 °C 20 °C 30 °C 40 °C 50 °C 60 °C 70 °C 80 °C 90 °C 100 °C 110 °C
961 Ω 1000 Ω 1039 Ω 1078 Ω 1117 Ω 1155 Ω 1194 Ω 1232 Ω 1271 Ω 1309 Ω 1347 Ω 1385 Ω 1423 Ω
The working condition of the sensor can be checked with this table and an Ohm meter.

5. Application examples 1.4
5.1 Single Tank System with Return Boost
P1: Solar circuit pump
P2: Heating circuit pump
P3: Tank charging pump
Vr: Switch-over valve for return temperature increase Collector field
T1: Collector sensor
T2: Tank sensor, bottom SUNGO SL
T3: Tank sensor, middle
T4: Sensor heating return-flow T3 T2 T4 T1 T1
T5:
T7:
Yield measurement, return flow sensor
Yield measurement, volume flow metre
A2 A1
Version 1 – TERMO Combi Cylinder

Hot water

Cold water

Heating circuit
TERMO

Ttw

T3 P3 P2

P1
CIRCO

T2 Vr
A B Oil or gas
boiler
AB

T4
Measuring the yield
Collector field

T1 T5
Solar
T7 return-flow

Figure 3 System solution for DHW preparation and space heating support. The SUNGO SL controller takes charge of storage loading and controls
the 3 way diverter valve for the return flow boost.

EN-XXX_SUNGO-SL_BA-100127-1122P300 293
5.2 Dual Tank System
P1: Solar circuit pump
P2: Heating circuit pump Collector field
P3: Tank charging pump
Vu: Switch-over valve, tank charging
SUNGO SL T1
T1: Collector sensor
T2:
T3:
Tank 1 sensor, bottom
Tank 1 sensor, top
T3 T2 T4 T1
T4: Tank 2 sensor, bottom A2 A1
T5: Yield measurement, return flow sensor
T7: Yield measurement, volume flow metre

Heating circuit

Ttw P1

CIRCO
T3

P2
ECOplus

P3
Oil or gas T2 T4
boiler
AB
A
M B
Vu
Measuring the yield
Collector field
Hot water

T1 T5
Solar
Cold water
T7 return-flow

Figure 4 System solution for DHW preparation. The SUNGO SL controller takes charge of loading a bivalent (2 heat exchangers) storage and the
monovalent (single heat exchanger) storage connected upstream to it.

Subject to modifications, errors excepted · © Wagner & Co, 2010 · www.wagner-solar.com
294 WAGNER & CO · Zimmermannstraße 12 · D-35091 Cölbe/Marburg · ☎ +49 (0) 64 21 80 07-0 · Fax 80 07-596
OPERATING INSTRUCTIONS

Solar Controller SUNGO SXL

Figure 1 Solar controller SUNGO SXL

● Large illuminated display to show temperature levels, ● System for large scale preheating buffers.
check values and system status. With clearly visible sym- ● Preselection of two thermostat functions, return flow 1.4
bols for easy readability. boost, and temperature difference control.
● Easy and safe handling via four buttons. Vertical and ● Data logging functionality.
horizontal scrolling through menus. ● Eight temperature inputs Pt1000, one pulse input, and
● Various preset hydraulic systems available one sensor for solar irradiation
● Extensive diagnostics to check system functions, e.g. ● Six outputs in total with one speed-controlled to adjust
sensor cutoff or temperature difference “dT too high”. flowrates.
● Built in safety functionality such as collector cooling, ● Possibilty to log the yield in kWh by using an external
storage tank cooling, system protection and vacuum flow meter and sensor T6 (solar return)
tube collector function. ● Optional DATAstick for updating firmware and logging
● Controlled solar heat storage and buffering with up to and transfering data for further investigation and sys-
3 cylinders using up to 2 independent collector fields. tem diagnostics.
● System with mixed heating circuit for efficient usage of ● The menues are provided in six languages.
solar and pellet heating.

Select language,
see page 320

Contents
1. Overview of Preset Hydraulic Systems . . . . . 296 5. Use . . . . . . . . . . . . . . . . . . . . 317
2. System Selection . . . . . . . . . . . . . . 298 5.1 Display and Buttons . . . . . . . . . . . . . 317
2.1 Explanation of System Depictions . . . . . . . 298 5.2 Initial Startup . . . . . . . . . . . . . . . . 320
2.2 Description of Special Functions . . . . . . . 300 5.3 Special Functions Menu . . . . . . . . . . . 321
2.3 Description of Additional Functions . . . . . . 303 5.4 Settings Menu . . . . . . . . . . . . . . . 325
2.4 System Details . . . . . . . . . . . . . . . 304 5.5 Information Menu . . . . . . . . . . . . . . 329
3. General Safety Information . . . . . . . . . . 314 5.6 Manual Mode Menu. . . . . . . . . . . . . 331
3.1 Operator/Installer Qualifications . . . . . . . 314 6. Technical Information . . . . . . . . . . . . 332
3.2 Intended Use . . . . . . . . . . . . . . . . 314 7. Accessories . . . . . . . . . . . . . . . . 333
3.3 Installation and Operating Information . . . . 314 8. Service . . . . . . . . . . . . . . . . . . 333
4. Installation . . . . . . . . . . . . . . . . . 315 8.1 Service – Message Log . . . . . . . . . . . 333
4.1 Attaching Case . . . . . . . . . . . . . . . 315 8.2 Service – System Messages. . . . . . . . . . 334
4.2 Connecting Cables . . . . . . . . . . . . . 315 8.3 Service – Sensor Check . . . . . . . . . . . 334

Solar Thermal / Solar Circuit EN-XXX_SUNGO-SXL_TI-MA-BA-0707xx-1122P400 295
1. System Components Overview

Meaning of the System Codes 12xx = “SUNGO SXL” software package
The SUNGO SXL system codes consist of 4 digits. The first xx1x = 1-tank systems
two digits “1 2” designate the “SUNGO SXL” software. The xx2x = 2-tank systems
third digit identifies the possible system types. The fourth xx3x = 3-tank systems
digit is for the numeric sequence of the associated systems xx4x = Heating systems with solar loading
per type. xx5x = Large scale solar installations

Function Systems
1211 (page 304) 1212 (page 305) 1213 (page 306)

1-tank system with one collector 1-tank system with bypass (valve or 1-tank system with two collector
field plate heat exchanger) and one fields
collector field
Return flow boost X X X
Thermostat A X X X
Thermostat B X X –
Degermination X X X
Def. control X – –
Yield measurement X X X
Pool protection X X –

Function Systems
1221 (page 307) 1222 (page 308) 1223 (page 309)

2-tank system with one collector 2-tank system with bypass (valve or 2-tank system (pool + drinking
field plate heat exchanger) and one water tank) with one collector field
collector field
Return flow boost X X X
Thermostat A – X X
Thermostat B X – X
Degermination X X –
Def. control X – –
Yield measurement X X X
Pool protection – – X

296 EN-XXX_SUNGO-SXL_TI-MA-BA-0707xx-1122P400
Function Systems
1224 (page 310) 1231 (page 311)

2-tank system with two collector fields 3-tank system with one collector field
Return flow boost X –
Thermostat A – X
Thermostat B – –
Degermination X X
Def. control – X
Yield measurement X X
Pool protection – –

Function Systems
1.4
1241 (page 312) 1251 (page 313)

Controlled mixed circuit with solar heating support 2-tank system with bypass and a preheating-buffertank-
(1 tank / 1 collector field) system
Return flow boost – –
Thermostat A – –
Thermostat B X –
Degermination – X
Def. control X X
Yield measurement X X
Pool protection – –

EN-XXX_SUNGO-SXL_TI-MA-BA-0707xx-1122P400 297
2. Select System
2.1 Explanation of the System Schematics

P1: Solar circuit pump
P2: Heating circuit pump E3 E7 E2 E8 E1
P3: Storage loading pump
Vr: Switching valve for return flow boost A6 A1
Collector field

2
T1: Collector sensor
T2: Tank sensor ↓
T3: Tank sensor ↑
T7:
T8:
Ttw:
Return flow boost sensor T7
Return flow boost sensor T8
Boosting sensor
3 T1

Variation 1 – TERMO combi tank

Hot water

Cold water

1 Heating circuit
TERMO

T3

Ttw

T7
P3 P2 P1

CIRCO
T2
Vr
A B Oil or gas
heating boiler
AB

4
T8

Standard System (Explained with Example 1211)
➀ Each system available in the controller is shown with the ➁ The key explains abbreviations in plain text.
most important hydraulic and electrical components,
making it possible to set up a functional system (de- ➂ Use the electrical connection lines to trace the inputs
tailed hydraulic wiring diagrams are available from the (E1 - E10) and the outputs (A1 - A6) to the actual sen-
technical customer service department). sors and sensor positions as well as the actual consumer
loads (pumps or valves).
IMPORTANT The systems shown on the following pages
are descriptive diagrams and may not include all com- ➃ The 10 systems use 2-/3-way valves 4012/4013 by Hon-
ponents, shut-off and safety devices needed for proper eywell. The electrical wiring is shown for these valves
assembly and installation. Always comply with all corre- (see also datasheet “2-/3-Way Valve”).
sponding and applicable standards and guidelines. Electrical connection: Brown = constant phase; black =
switching phase; blue = neutral wire.
Hydraulic connection: Power off, position is “AB” to “B”.
Power on Positon is “AB” to “A”.

Other hydraulic valves may cause functional problems or
increase hydraulic/electrical effort.

298 EN-XXX_SUNGO-SXL_TI-MA-BA-0707xx-1122P400
FUSE 5X20

3
1

1 2 3 4 5 6 7 8 9 10
A6 A5 A4 A3 A2 A1 L1
M M M M M M M M M M
PE-PE-PE N N N N N N N

Potential Ground 2
4

A6 A5 A4 A3 A2 A1 Mains E1 E2 E3 E4 E5 E6 E7 E8 E9 E10

230 V outputs Sensor inputs

Mains Sensor input /
irradiation sensor

Volume meter

Controller Connection
➀ Hardware position and actual designation of the 230 V ➃ In the respective system, inputs are shown with the des-
switching outputs A1 to A6. ignation E1 to E10 and not only with numbers 1 to 10 as
➁ The respective 230 V outputs are then also shown with it is done on the board.
the designation A1 to A6.
➂ Hardware position and actual designation of sensor, ir- The connection lines can be used to trace the input E1 to 1.4
radiation sensor, and volume meter inputs. sensor T1.
Input E1 usually corresponds with sensor T1, etc.

ECOplus RATIO with RATIOfresh

Storage Tank Options
The most common system option is shown in the drawn-in

RATIO-H PG
rectangular window in the “standard system” (for system T3
1211: here → TERMO tank). T3
Of course, the same basic system can also be applied to
alternative storage systems (here: RATIO storage tank,
T7
ECOplus drinking water storage tank). However, certain ECOplus

hydraulic functions are reduced in the basic system (1211,
RATIOfresh

e.g.: “return flow boost” function is hydraulically not pos- T2
sible with drinking water storage tank. The controller func-
T2
tion on the other hand is available for other applications as
free temperature difference).

Special Functions
Possible options concerning the system selected in “System Selection, Special Functions” are shown graphically under-
neath the standard system. The required inputs and outputs are labeled. The respective options are described in detail
starting on page 300. They have to be enabled in the “Special Functions” menu.
Yield
Return flow boost Thermostat A Thermostat B Degermination Control option (def. control) measurement Pool protection
Heating circuit

A4 T7** T1** T5
T3 T4 A5 A2
T8 Boiler Circulation T3** Boiler
Temp. difference Solar flow Solar Pool
T7 T8** or thermostat F
A3 E10 T6
Solar return
A6
Layout of system 1211 Tx** = a sensor (T1 to T8) can be selected here

EN-XXX_SUNGO-SXL_TI-MA-BA-0707xx-1122P400 299
2.2 Description of the Special Functions
Language
Selection of language for the controller menu and displays
(German, Dutch, Italian, French, Spanish, and English)
System selection
Selection from 10 possible systems
(1211, 1212, 1213, 1221, 1222, 1223, 1224, 1231, 1241, 1251)

Bypass Bypass
For systems with bypass, solar loading of buffers does not take place until the solar circuit
flow (T9) has reached a sufficient temperature. The bypass can be realized with a valve or a
plate heat exchanger (PHE) and a secondary circuit pump. With option “Valve” and “PHE”,
CIRCO

ECOplus
output A2 is switched on when the preset temp. difference T9 to either T2, T4 or T5 is
T9 reached. However, with option “PHE” the solar circuit pump is not speed-controlled but the
T2 secondary circuit pump instead. The speed of the solar circuit pump has to be set to 100%
A2 volume flow if desired (see special function “Primary circuit”).
Valve PHE

Tube collector
The tube collector function makes it possible to operate the solar system if the collector
sensor is mounted inside of the connection line of the connector. The “delta T” option is
automatically activated if an irradiation sensor is not connected.
In this case, the solar circuit pump is switched on acc. to a specific temperature increase
which is detected by sensor T1. The solar circuit pump remains switched on for the set
runtime and is switched off if the preset temp. difference between heat sink and solar circuit
is not reached.
It is also possible to select the “Irradiation” option if the irradiation sensor is connected. This
means the solar circuit pump is switched on for a short time when irradiation exceeds the
threshold value. The irradiation threshold value can be adjusted by the controller auto-
adaptively.

Return flow boost Return flow boost (temperature difference control)
Heating circuit Simple heating support that leads the return flow of the heating circuit (T8) directly to the
heating boiler or to the solar tank by switching the 3-way valve with output A6 in
dependence of the set temperature difference to the tank sensor (T7).
T8 Boiler

T7

A6

Thermostat A Thermostat A (adjustable switching threshold)
Thermostat A offers the options “Heating” and “Cooling” by preselecting.
With the option “Heating” output A3 switches on when the temperature T4 falls below the set
T3 T4 switch-on temperature. The output switches off when the temperature T4 is greater than the
Circulation switch-on temperature plus the switch-off difference.
A3 With the Variation “Cooling” output A3 switches on when the temperature T4 exceeds a
preset temperature to switch on. The output switches off when the temperature T4 is less
than the switch-on temperature minus the switch-off difference.
An additional sensor can be activated with the “Heating” Variation. The output is then only
switched on when the temperature T3 is greater than the switch-on temperature plus the
switch-off difference plus the additional sensor switching difference. E.g. that is useful if
circulation shouldn’t run in case there is not enough heat stored.
Independent time windows can be specified for thermostat A. The conditions listed above
are only interpreted within the respective time window.

Thermostat B Thermostat B (adjustable switching threshold)
Thermostat B offers the options “Heating” and “Cooling” by preselecting.
A4 The temperature sensor to be used for the thermostat function can be freely selected. With
the “Heating” Variation, output A4 (system 1241: A3) switches on when the temperature at
T3** Boiler
the sensor falls below the set switch-on temperature. The output switches off when the
temperature is greater than the switch-on temperature plus the switch-off difference.
With the Variation “Cooling”, output A4 switches on when the temperature exceeds the set
switch-on temperature. The output switches off when the temperature is less than the
switch-on temperature minus the switch-off difference.
Three independent time windows can be specified for thermostat B.

300 EN-XXX_SUNGO-SXL_TI-MA-BA-0707xx-1122P400
Degermination Degermination
To avoid or prevent the spread of legionella bacteria in drinking water, some system setups
(depending on local rules and regulations) require the use this function. Once activated, this
A5 function heats the entire drinking water tank to at least 60 °C once a day. The adjustable start
time, heating duration, and switch-off temperature are used to modify this function.
Output A5 is only activated if the set target temperature was not already reached during the
previous 20 hrs, e.g. by solar heating. The reference temperature is measured at the bottom
of the drinking water tank (T2, layout 1251: T8).
Note: The flow temperature of the boiler must be adjusted to the required heating
conditions.

Control option (def. control) Control option (def. control)
(adjustable switching threshold or temperature difference control)
With the “control option” function, it is possible to select either temperature difference
T7**
A2 control or thermostat function. The temperature sensor can be freely assigned in this case.
Temp. difference The temperature difference control offers a choice of the following options: On and off
T8** or thermostat F switching difference, max. temperature for sink (sensor 2), and min. temperature for source
(sensor 1).
Thermostat F corresponds with thermostat A. Three independent time windows can be
specified for thermostat F or the difference controller.

Yield measurement Yield measurement
Intended to determine the solar yield in kWh. A volume meter and a second measuring
sensor are used to calculate the generated amount of heat. The sensor that is used to
T1** measure the flow temperature can be freely selected (e.g. collector sensor).
Solar Note: Use the option “FV” instead of the usual “HQM” to measure the yield without a volume
flow
meter. This option works with a fixed volume flow entered into the controller and can
T6
therefore only be used as a function check. The exact determination of the amount of heat is
Solar not possible with the “DFM” option. The solar circuit pump should also be operated with a
E10 return
fixed speed when using this option.

System protection
The solar circuit pump is switched off when the set collector temperature has been
exceeded.
Collector cooling 1.4
The solar circuit pump is switched off when the tank has been heated up to the tank limit
temperature. If the collector temperature rises to the set start temperature, the solar circuit
pump is switched on again until the collector temperature has dropped by the switch-off
difference.
This additional interval loading of the tank ensures that the collector does not stagnate too
often. The system switches off entirely when the tank limit temperature has been exceeded
by 5 K.
Tank cooling
If the tank cooling function is active, the solar circuit pump is switched on if the collector
temperature drops below the tank temperature by 2 K. The excess energy in the tank is
dispersed via the collector until the value drops below the set switch-off temperature. The
tank cooling function can be activated only if the collector cooling function is switched on.

Pool protection Pool protection
The pool protection uses a measuring sensor to monitor the flow temperature of the
secondary circuit for the pool heating. If the temperature at the measuring sensor (T5, layout
T5
1223: T9) exceeds the set switch-off threshold, solar heating is interrupted. The interruption
is saved as a system message (see menu option “Special functions, Messages”).
Solar Pool

Primary circuit (only for systems with bypass and PHE option)
Setting the (fixed) speed of the solar circuit pump.

EN-XXX_SUNGO-SXL_TI-MA-BA-0707xx-1122P400 301
Details for system 1241 (page 312)
● System 1241 with a combinend solar / heating system with storage tank/combi tank as
hydraulic switch and with a heating circuit is able to cover all important control functions:
● Solar storage heating (single tank system)
● Boiler heating of the permanent buffer part in the tank with thermostat B
● Thermostat B is already active with system 1241 (default setting: Option “Heating”
switch-on temperature 50 °C). With system 1241, hot water heating has priority, which
means that the heating circuit pump (output A2) is switched off and the heating circuit
mixing valve will be closed completely if thermostat B switches on boiler demand (A3).
● Boiler demand for room heating acc. to heating curve
● The heating demand for heating the middle storage zone (T4) is based on the set values
for the heating curve and the desired excess temperature in the buffer storage.
● The tank loading pump (e.g. when using the LIGNOplus pellet boiler) can be controlled
with the help of the control option. Just select the temperature difference control option
and mount a sensor to measure the boiler temperature (T7). As soon as the boiler
temperature exceeds the switch-on difference in the middle of the tank,the tank loading
pump is switched on. The control option is not active in the default setting for system 1241.
● Mixing valve actuation for a heating circuit acc. to heating curve (see below).
● Speed control of the heating circulation pump (see below, correspond with the
CIRcontroller in the function).

Heating curve Heating curve (only for system 1241)
The weather-based control of a mixed heating circuit is carried out by determining the
heating curve here. The heating circuit mixing valve is controlled according to the heating
curve and the measured outdoor temperature. Lowering times as well as the modes “Auto”,
T5 T9 “Summer”, “Party” and “Emission (Chimneysweep)” can be activated to this purpose in the
menu settings.
The excess temperature in the storage tank (sensor T4) compared with the heating circuit
A4/5 flow can be specified here as well. If values drop below flow temperature plus excess
temperature in the storage tank, output A3 is used to trigger the boiler.

Flow temp. Heating limit: Ta average > Ta, max
Heating
curve
VL. Tmax = 70
Tmax limit flow
60
50 Offset
40 Tmin limit flow
VL. Tmin = 30
20
10 3K
Ambient
-24 -20 -16 -12 -8 -4 0 4 8 12 16 24 temperature
-15 = Ta, min 15 = Ta, max

Heating pump Heat pump (only for system 1241)
The speed of the heating circuit pump can be adjusted to save electricity when operating the
heat pump for low return temperatures. A setpoint for the temperature difference between
flow and return of the heating circuit is set as the default value.
T5 T8 A value below 100% (default setting) must then be selected for the min. speed of the pump.
A2 The bypass valve marked in the diagram between the heating flow and return should allow
for a low flow when the heating appliance valves are closed.
Only step-switchable circulation pumps without integrated electronic control can be
connected to the controller outputs with speed control!
Damage is possible when directly connecting electronically controlled pumps!

Mixed circuit Heating circuit mixing valve (only for system 1241)
The runtime of the mixing valve (datasheet) and the cycle time for actuating the heating
circuit mixing valve are set here.

T5 T9

A4/5

302 EN-XXX_SUNGO-SXL_TI-MA-BA-0707xx-1122P400
Control time
The control time is used for systems with bypass and multi-tank systems to affect the
switchover behavior of the controller. With systems with long lines or large line volumes, a
longer control time is selected and vice versa.
Factory configuration
All parameters (special functions + settings) are reset to the default settings but the reset
does not apply to the selected system.
Messages
The last 10 system messages together with date and time can be reviewed. Each message is
only listed once per day starting with the first incidence.
Controller info
This menu option is used to view information about the selected system, its version number,
as well as the number and version of the controller software.

2.3 Description of Additional Functions
Solar circuit operation
The solar circuit pump is switched on/off when the preset start or stop temp. difference has
been reached. It is also possible to specify a limit temperature for the tank. The solar circuit
pump is speed-controlled so that an adjustable temperature difference between collector
and tank can be maintained if possible. The min. speed can be specified (100%: no
speed-control).
2-tank operation
To ensure the selected priority tank is heated up when the collector produces sufficiently, the
controller checks the progression of the temperatures in the collector and priority tank and
possibly pauses the solar circuit pump for the duration of the control time. If the collector
temperature then reaches a sufficient value, the system switches to the priority tank.
Priority
The SUNGO SXL controller offers a choice of assigning priority to tank 1 or tank 2.
Tank 3 cannot be a priority tank.

Loading preheat tank Heating of the preheating tank (only system 1251, p. 313)
Serves to shift heat from a storage tank system to a drinking water tank (preheating tank)
1.4
T3 using a temperature difference control with two-point measurement function.
If the temperature in the storage tank top (T3) is larger than the temperature at the upper
Tank 1 Tank 3
measuring point in the preheating tank (T7) by the value of the switch-on difference,, the
A3 T7 loading pump is switched on via A3. If the difference between the temperature in the storage
tank top and the temperature at the lower measuring point in the preheating tank (T8) is
T8 lower than the switch-off difference, the loading pump is switched off.
Storing the preheating tank is stopped once the limit temperature has been reached (at T8).
Additionally, a min. temperature (T3) can be selected for the storage tank, below which a
storage shift is not initiated.
Triac
The triac is an electronic switch to switch the 230 V outputs of the SUNGO S, SL, and SXL
controller on or off.
How it works: A triac consists of 2 antiparallel switchable diodes (= antiparallel thyristors). The
thyristors switch through the positive or negative sine half-wave as long as a switching-on
difference exists. The triac switches off when the value drops below the switch-off difference.

EN-XXX_SUNGO-SXL_TI-MA-BA-0707xx-1122P400 303
P1: Solar circuit pump
P2: Heating circuit pump E3 E7 E2 E8 E1 Variation 2 – RATIO w. RATIOfresh

304
P3: Storage loading pump
Vr: Switching valve for return flow increase A6 A1
Collector field
T1: Collector sensor
T2: Tank sensor ↓
T3: Tank sensor ↑
T7: Return flow boost sensor T7 T1 T3
T8: Return flow boost sensor T8
Ttw: Aux. heating sensor
RATIO-H PG

Variation 1 – TERMO combination tank

Hot water
T7
2.4 Systems Details

Cold water
RATIOfresh

Heating circuit

T3 T2

TERMO
Ttw

Variation 3 – ECOplus
T7
P3 P2 P1

CIRCO
T2
Vr
A B Oil or gas T3
heating boiler
AB

ECOplus

T8
T2

Return flow boost
(already marked above) Thermostat A Thermostat B Degermination Control option (def. control) Yield measurement Pool protection
Heating circuit

A4 T7** T1** T5
T3 T4 A5 A2
Boiler Circulation Temp. difference
T8 T3** Boiler Solar
T7 flow Solar Pool
A3 T8** or thermostat F T6
Solar
E10 return
A6
Layout of system 1211 Tx** = a sensor (T1 to T8) can be selected freely here

EN-XXX_SUNGO-SXL_TI-MA-BA-0707xx-1122P400
System No. 1211
P1: Solar circuit pump
P2: Heating circuit pump
E3 E7 E2 E8 E9 E1 Variation 2 – RATIO w. RATIOfresh
P3: Storage loading pump
(P4: Secondary solar circuit pump)
A6 A2 A1
Vr: Switching valve for return flow boost Collector field
Vb: switching valve for bypass function
T1: Collector sensor
T2: Tank sensor ↓ T1
T3: Tank sensor ↑ T3
T7: Return flow boost sensor T7
T8: Return flow boost sensor T8
RATIO-H PG

T9: Solar return sensor
Ttw: Aux. heating sensor

Variation 1 – TERMO combination tank
T7
Hot water

Cold water
RATIOfresh

Heating circuit T2

EN-XXX_SUNGO-SXL_TI-MA-BA-0707xx-1122P400
T3

TERMO
Ttw
Variation 3 – ECOplus

T7
P3 P2 P1

CIRCO
T2 T3
Vr
A B Oil or gas
heating boiler
AB
ECOplus

T9 AB Vb alternative T2
T8 B
A P4

Return flow boost
(already marked above) Thermostat A Thermostat B Degermination Control option (def. control) Yield measurement Pool protection
Heating circuit

A4 T9** T5
T3 T4 A5
T8 Boiler Circulation Solar
T3** Boiler
T7 flow Solar Pool
A3 T6
Solar
E10 return
A6
Layout of system 1212 Tx** = a sensor (T1 to T9) can be selected freely here

305
System No. 1212

1.4
P1: Solar circuit pump
P2: Heating circuit pump
E3 E7 E2 E8 E9 E1 Variation 2 – RATIO w. RATIOfresh

306
P3: Storage loading pump
Vr: Switching valve for Return flow boost
A6 A1 A4 A2
Vk1: Collector field 1, 2-way motor valve Collector field Collector field
Vk2: Collector field 2, 2-way motor valve
T1: Collector 1 sensor
T2: Tank sensor ↓ T3
T3: Tank sensor ↑
T1 T9
T7: Return flow boost sensor T7
T8: Return flow boost sensor T8
RATIO-H PG

T9: Collector 2 sensor
Ttw: Aux. heating sensor Vc1 Vc2
Variation 1 – TERMO combination tank
T7
Hot water

Cold water
RATIOfresh

T2
Heating circuit

T3

TERMO
Ttw
Variation 3 – ECOplus

T7
Please note!
P3 P2 If Vk1 and Vk2 are in
return, the safety valve
P1
and expansion vessel
T2 must be aligned in the T3
Vr flow!
A B Oil or gas

CIRCO
heating boiler
AB
ECOplus

T8 T2

Return flow boost
(already marked above) Thermostat A Thermostat B Degermination Control option (def. control) Yield measurement Pool protection
Heating circuit

T3 T4 T5**
A5
Boiler Circulation
T8 Solar
T7 flow
A3 T6
Solar
E10 return
A6
Layout of system 1213 Tx** = a sensor (T1 to T8) can be selected freely here

EN-XXX_SUNGO-SXL_TI-MA-BA-0707xx-1122P400
System No. 1213
P1: Solar circuit pump
P2: Pump for secondary
E8 E5 E7 E3 E2 E1
P3: Heating circuit pump Collector field
A6 A2 A1
Vu: Solar flow switching valve
Vr: Switching valve for return flow boost
T1: Collector sensor T1
T2: Tank sensor 1 ↓
T3: Tank sensor ↑
T5: Tank sensor 2 ↓
T7: Return flow boost sensor T7
T8: Return flow boost sensor T8
Ttw: Aux. heating sensor

Heating circuit

EN-XXX_SUNGO-SXL_TI-MA-BA-0707xx-1122P400
T7
P1

RATIO-H PG
T3
P3 P2 Ttw
CIRCO

ECOplus

T2
T5 AB
T8 Oil or gas
heating boiler B A
AB
Vu
A B
Vr

Hot water

Cold water
Return flow boost
(already marked above) Thermostat A Thermostat B Degermination Control option (def. control) Yield measurement Pool protection
Heating circuit

A4 T7** T1**
A5 A3
Boiler Temp. difference
T8 T3** Boiler Solar
T7 flow
T8** or thermostat F T6
Solar
E10 return
A6
Layout of system 1221 Tx** = a sensor (T1 to T8) can be selected freely here

307
System No. 1221

1.4
P1: Solar circuit pump E8 E5 E7 E3 E2 E9 E1

308
P2: Pump for secondary circuit Collector field
P3: Heating pump A6 A4 A2 A1
Vu: Switching valve for Solar flow
Vr: Switching valve for Return flow boost T1
Vb: Switching valve for Bypass function; alternatively
plate heat exchanger with circulation pump P4

T1: Collector sensor
T2: Tank sensor 1 ↓
T3: Tank sensor ↑
T5: Tank sensor 2 ↓
T7: Return flow boost sensor T7
T8: Return flow boost sensor T8
T9: Solar flow sensor
Ttw: Aux. heating sensor

Heating circuit

T7
P1

RATIO-H PG
T3
P3 P2
Ttw
CIRCO

AB
ECOplus T9 B A alternativ

Vb P4
T2
T5
T8 Oil or gas AB
heating boiler B A
AB

A
Vu
B

Vr

Hot water

Cold water

Return flow boost
(already marked above) Thermostat A Thermostat B Degermination Control option (def. control) Yield measurement Pool protection
Heating circuit

T3 T4 T9**
A5
T8 Boiler Circulation Solar
T7 flow
A3 T6
Solar
E10 return
A6
Layout of system 1222 Tx** = a sensor (T1 to T9) can be selected freely here

EN-XXX_SUNGO-SXL_TI-MA-BA-0707xx-1122P400
System No. 1222
P1: Solar circuit pump
P2: Pool pump
E3 E2 E5 E9 E1 Variation 2 – RATIO w. RATIOfresh
Collector field
P3: Storage loading pump A5 A2 A1
P4: Heating pump
Vu: Switching valve for solar return
T1
T1 Collector sensor
T3

Relay
T2: Tank sensor 1 ↓
T3: Tank sensor
T5: Pool sensor
RATIO-H PG

T7: Return flow boost sensor T7
T8: Return flow boost sensor T8
T9: Pool protection T9 sensor

Ttw: Aux. heating sensor RATIOfresh T7

Variation 1 – ECOplus T2
Heating circuit

EN-XXX_SUNGO-SXL_TI-MA-BA-0707xx-1122P400
Variation 3 – TERMO combi tank
P1

P4 Ttw

CIRCO
T3

T3
ECOplus
TERMO

Pool
P3 T2
Oil or gas
heating boiler T7
T9
Vu AB
P2
B A T5

T2
Hot water

Cold water
Pool protection
Return flow boost Thermostat A Thermostat B Degermination Control option (def. control) Yield measurement (already marked ab.)
Heating circuit

A4 T1** T9
T3 T4
Boiler Circulation
T8 T3** Boiler Solar
T7 flow Solar Pool
A3 T6
Solar
E10 return
A6
Layout of system 1223 Tx** = a sensor (T1 to T8) can be selected freely here

309
System No. 1223

1.4
P1: Solar circuit pump
E8 E5 E7 E3 E2 E9 E1

310
P2: Storage loading pump Collector field Collector field
P3: Heating pump
Vk1: Collector field 1, 2-way motor valve
A6 A4 A1 A3 A2
Vk2: Collector field 2, 2-way motor valve
Vu: Switching valve for solar return T1 T9
Vr: Switching valve for return flow boost

T1: Collector sensor 1
T2: Tank sensor 1 ↓
T3: Tank sensor ↑
Vc1 Vc2
T5: Tank sensor 2 ↓
T7: Return flow boost sensor T7
T8: Return flow boost sensor T8
T9: Collector sensor 2

Ttw: Aux. heating sensor

Heating circuit
Please note!
If Vk1 and Vk2 are in return
flow, the safety valve and
T7 expansion vessel must be
P1
aligned in the flow!

RATIO-H PG
T3
P3 P2
Ttw
CIRCO

ECOplus

T5
T8 Oil or gas
T2 AB
heating boiler B A
AB

A
Vu
B

Vr

Hot water

Cold water
Return flow boost
(already marked above) Thermostat A Thermostat B Degermination Control option (def. control) Yield measurement Pool protection
Heating circuit

T4**
A5
Boiler
T8 Solar
T7 flow
T6
Solar
E10 return
A6
Layout of system 1224 Tx** = a sensor (T1 to T8) can be selected freely here

EN-XXX_SUNGO-SXL_TI-MA-BA-0707xx-1122P400
System No. 1224
P1: Solar circuit pump
P2: Storage loading pump E8 E5 E7 E4 E3 E2 E1
P3: Heating pump Collector field
Vu1: Switching valve for solar return 1 A6 A3 A2 A1
Vu2: Switching valve for solar return 2
Vr: Switching valve for return flow boost T1
T1: Collector sensor
T2: Tank sensor 1 ↓
T3: Tank sensor ↑
T4: Tank sensor 3 ↓
T5: Tank sensor 2 ↓
T7: Return flow boost sensor T7
T8: Return flow boost sensor T8

Ttw: Aux. heating sensor

Heating circuit Tank 1

EN-XXX_SUNGO-SXL_TI-MA-BA-0707xx-1122P400
T7
P1

RATIO-H PG
RATIO-H PG
T3
P3 P2 Ttw
CIRCO

Tank 2 Tank 3

ECOplus

T2
T5 T4 AB
T8 Oil or gas
heating boiler B A
AB

A B
Vu1
Vr
A
AB
Vu2
B

Hot water

Cold water
Control option (def. control)
Return flow boost Thermostat A Thermostat B Degermination (already marked above) Yield measurement Pool protection

T7** T1**
T3 T9 A5 A6
Circulation Temp. difference Solar
flow
A4 T8** or thermostat F T6
If needed,
use additional Solar
control option E10 return

Layout of system 1231 Tx** = a sensor (T1 to T8) can be selected freely here

311
System No. 1231

1.4
P1: Solar circuit pump
P3: Storage loading pump E3 E4 E2 E7 E5 E8 E9 E1 Variation 2 – RATIO w. RATIOfresh

312
T1: Collector sensor
T2: Tank sensor ↓ A6 A3 A4 A5 A2 A1 Collector field
T3: Tank sensor ↑
= Thermost.B T3 sensor
T4: Tank sensor →

OPEN
= Diff. controller T4 sensor T1

CLOSED
T5: Temp. sensor flow T3
T7: Diff. controller T7 sensor
T8: Temp. sensor return
T9: Temp. sensor outdoor
RATIO-H PG

Variation 1 –
TERMO combination tank
T4
Hot water T9
Cold water Heating circuit
RATIOfresh

T2
Relay

T3

TERMO
P1

CIRCO
T4
T7
T5 T8
T2
P3 P2

M1

Thermostat B = water heating Control option (def. control;
in basic setting activated as diff. contr. for storage loading
Return flow boost Thermostat A (already marked above) Degermination pump already marked above) Yield measurement Pool protection

A3 T7** T1**
A6
T3** Kessel
Temp. difference Solar
flow
T4** or thermostat F T6
Solar
E10 return

Layout of system 1241 Tx** = a sensor (T1 to T8) can be selected freely here

EN-XXX_SUNGO-SXL_TI-MA-BA-0707xx-1122P400
System No. 1241
Collector field E1 E9 E5 E2 E3 E8 E7 T1: Collector sensor Vu: Solar flow/return switching valve
T2: Tank sensor 1 ↓ Vm: HW loading circuit limit valve
A1 A2 A4 A3 A5 T3: Tank sensor ↑ (Valve / aux. power)
T1 T5: Tank sensor 2 ↓ Vl: Legionella protection motor valve
T7: Tank sensor 3 →
T8: Tank sensor 3 ↓ P1: Pump for solar circuit
T9: Solar return sensor P2: Pump for secondary circuit
E10: Volume flow meter P3: Primary pump tank 3
P4: Secondary pump tank 3
P5: Legionella protection circulation pump
P6: Hot water circulation pump
P7: Pump for Hot water boiler

P6 Circulation

Hot water

EN-XXX_SUNGO-SXL_TI-MA-BA-0707xx-1122P400
T3
P1
Vu
A B
P5

CIRCO
AB
Tank 2 Tank 1 Tank 3
Vl Standby tank
(Preheating tank)
T9
T7
P7
P3 P4
T5 T2
Vm T8
A B

P2 AB Vu

Cold water

Degermination
(already marked
Return flow boost Thermostat A Thermostat B above) Control option (def. control) Yield measurement Pool protection

T4** T9**
A5 A6
Temp. difference Solar
flow
T2** or thermostat F T6
T8 Solar
E10 return

Layout of system 1251 Tx** = a sensor (T1 to T9) can be selected freely here

313
System No. 1251

1.4
3. General Safety Information 3.3 Installation and
The following safety information is intended to protect you Operating Information
from hazards and dangers that may suddenly occur when ● All installation and wiring work must be carried out
the device is handled incorrectly, either deliberately or un- while the system is powered off since the voltage on
knowingly. We differentiate between general safety infor- the outside of the triac is 230 V.
mation shown on this page and special safety information ● The mains power of the controller must be connected
explained over the course of this text. outside of the solar circuit station via an external ON/
OFF switch. This is also necessary to activate the “Spe-
cial Functions” menu by using the ON/OFF switch of the
mains power.
DANGER – Risk of personal injuries ● Operating temperatures > 50 °C are not permitted for
Improper electrical installation of the device can lead to controllers of the S-series (S, SL, SXL).
potentially fatal electric shocks as well as other health haz- ● Mount the solar circuit station in a way that allows an op-
ards. timal display contrast (looking straight at the controller).
● The bottom of the controller is divided into safe low
voltage inputs and 230 V outputs section by a cross-
piece. Make sure not to confuse these sections during
CAUTION – Risk of property damage the installation process.
This symbol indicates dangers that can result in damage to ● Automatic mode is the default operating mode of the
the components or malfunction of the controller. controller. Manual operation is used only for functional
testing of the different hydraulic components (pump,
2/3 way valves). In this operating mode, maximum tem-
peratures or sensor functions are not monitored.
NOTE – Additional information ● Do not operate the system if the controller, the wiring,
This symbol indicates practical advice and useful tricks, or the connected 230 V consumer loads are visibly dam-
which will make installing and operating of the controller aged.
more easy. ● The controller is equipped with a mains microfuse.
● Collectors and hydraulic supply pipes can get extreme-
ly hot during sunny periods. There is a risk of scalding
3.1 Operator/Installer Qualifications or burns when fitting the collector sensor.

● The connection and initial start-up of the SUNGO SXL
solar controller must always be carried out by trained
and authorized personnel.
● Compliance with applicable national and local safety
rules and regulations is mandatory.
● Please note that, in case of a claim, the warranty is only
valid if the correct initial startup is documented in the
release and approval log by a correspondingly trained
technician.

3.2 Intended Use
Function
● Controlling of solar thermal systems by selecting ap-
plicable control patterns and additional functions to
preset the controller for the required operations of the
hydraulic system.
● The controller is approved only for use in dry rooms.
● The controller can be integrated into the solar station
CIRCO 5/6 or mounted on the wall.

Application Limits
● If used in other than solar thermal applications, the
functionality of the controller has to be checked before
initial start-up. If in doubt, contact the controller service
of Wagner & Co.
● Usage that is not in compliance with the intended use
description always invalidates the warranty.

314 EN-XXX_SUNGO-SXL_TI-MA-BA-0707xx-1122P400
4. Installation
4.1 Attaching Case 4.2 Connecting Wires
Opening the Case Layout of the SUNGO SXL Connection Board
● Tools are not required to open the controller case. ● All electrical lines are connected at the bottom of the
The upper part of the case snaps into the bottom part. controller. The sensor connections (safety low voltage)
Slightly pull on the side clips of the upper section of the are located on the right-hand side and the 230 V mains
case to unlatch the case and flip it open. connections and switching outputs A1 to A6 on the left-
● The upper section now snaps into place automatical- hand side.
ly. It is now possible to install the controller easily and
quickly. General Connection Rules
● If flexible wires are used and the controller is wall
Wall mounting mounted, a strain relief must be fixed within or outside
● Use the supplied drilling template to drill the fixing of the controller.
holes for the controller. ● In this case, the wire ends must be crimped.
● Attach the controller to the wall. ● If required, PG9 screw connections can be mounted at
● Do not over tighten the screws to avoid damage to the the feed-throughs in case of wall mounting.
lower part of the case!
230 V Connection
Installation in the Solar Station ● The mains power is connected from outside the control-
● Use the screws to attach the SUNGO SXL controller to ler via an OFF/ON switch. This switch is not required
the wall holder of the solar station. if mains power is connected with a cable and safety
● Break out the cable feeds located on the base housing socket.
next to the crosspiece. ● The controller is designed for mains operation at ap-
● Strip the 230 V cables in a way that the insulated single prox. 230 V/50 Hz. Check to make sure the solar circuit
cables start directly at the opening to the bottom sec- pump is rated for this voltage.
tion. ● All grounding wires are connected to the PE terminals.
● Connect the mains power supply last. ● The neutral terminals (N) are connected electrically!
● When the controller is switched on, the voltage on the ● The switching output A1 (and A2 with systems featuring
triac case is 230 V AC. a bypass and option PHE as well as with system 1241)
is a 230 V, normally open contact actuated via speed- 1.4
control. Switching outputs A2 to A6 are pure NOCs (ex-
ception: A2, see above).

Connecting Temperature Sensors
● The wires of the temperature sensors can be extend-
ed as follows: Up to a length of 15 m = 2 x 0.5 mm²,
up to 50 m = 2 x 0.75 mm². In case of long connec-
tions to the collector, shielded cables should be used.
Do not connect the shielding at the sensor end, just trim
and isolate!
● The temperature sensors can be connected either way.
They do not have any polarity.
● The sensor wires must be installed separately from 230
V mains lines.

Lightning Protection Module
The SUNGO SXL is fitted with surge protection on all sen-
sor inputs. Generally, further protection of the sensors in
the basement is not required.
Sensor T1 (collector) must be be fitted with the sensor con-
nection box SP2 with integrated surge arrestor.

EN-XXX_SUNGO-SXL_TI-MA-BA-0707xx-1122P400 315
230 V side Low voltage side

Display board connection Data stick port

6

5 7

9
8
FUSE 5X20

3
1

1 2 3 4 5 6 7 8 9 10
A6 A5 A4 A3 A2 A1 L1
M M M M M M M M M M
PE-PE-PE N N N N N N N

Potential Ground 2
4

A6 A5 A4 A3 A2 A1 Mains E1 E2 E3 E4 E5 E6 E7 E8 E9 E10

230 V outputs Sensor inputs

Mains Sensor input /
irradiation sensor

Volume meter

Figure 2 Connection board of the solar controller SUNGO SXL

Connection Board
➀ Hardware position and actual designation of the 230 V ➄ Board cutouts for the fastening screws of the controller
switching outputs A1 to A6. case
➁ The corresponding 230 V outputs are also marked with ➅ Plug connector for connection cable to display board.
the designation A1 to A6 in the respective system de- ➆ Universal interface port for data stick and peripherals.
piction. ➇ Mains fuse as microfuse 4 AT.
➂ Hardware position and actual designation of the tem- ➈ The 230 V switching outputs are triacs.
perature sensor, irradiation sensor, and volume meter
inputs. IMPORTANT The 230 V AC is applied to the triac case dur-
➃ The corresponding inputs are not identified only with ing operation.
numbers from 1 to 10 in the respective system depiction
but they are also marked with the designation E1 to E10.
Input E1 usually corresponds with sensor T1, etc.

316 EN-XXX_SUNGO-SXL_TI-MA-BA-0707xx-1122P400
5. Use
5.1 Display and Buttons

Settings Special functions
menu menu
Manual
Information operation
menu

Main menu level
Selected menu

Alphanumeric display 1
Collector Measuring point, variable, selected add. option,
system info, and special functions

o Alphanumeric display 2

72,4 C Measuring value, variable number value,
special functions variation
Alphanumeric display 3
o
72 - C -➚ 126
➚ Selected add. functions, balance values, system
errors, add. info about selected special functions

A B
!
1234 ok? Status indicators
56

Pump OFF, System fault
pump ON 1.4
Confirmation /
Outputs A1 to A6 tank symbol

NOTE
● After switching on the controller, the “Special functions” < 60 s
menu can be activated within 60 seconds.

● If you remain in a selected menu without pressing ad-
ditional buttons, the menu “Information” is displayed
again automatically after 60 minutes.

● To make changes later in the “Special functions” menu,
briefly de-energize the controller and open the “Special
functions” menu within 60 seconds.

EN-XXX_SUNGO-SXL_TI-MA-BA-0707xx-1122P400 317
Information Information
Exit “Information” menu Activate “Reset balance values”
Cancel “Balance values” activation Save “Reset balance values”

Settings Settings
Exit “Settings” menu Select menu, e.g. “Tank”
Exit selected menu options, e.g. “Tank” Activate e.g. variable “Tank, max.”
Cancel activation, e.g. variable “Tank, max.” Save current value 85 °C, e.g. variable “Tank, max.”

Manual operation mode Manual operation mode
Exit “Manual mode” menu Activate, e.g. “Output 1”
Save current value ON, e.g. “Output 1”

Special functions Special functions
Exit “Special functions” menu Select menu, e.g. “Thermostat A”
Exit selected menu option, e.g. “Thermostat A” Activate, e.g. “Addit. sensor”
Cancel activation, e.g. variable “Heating” Save current value ON, e.g. “Addit. sensor”

Main menu: scroll left Main menu: scroll right

Information Information
Scroll down Scroll up

Settings Settings
Scroll down Scroll up
Reduce variable value, e.g. “85 °C” to “80 °C” Increasing variable value, e.g. ”85°C” to “90°C”

Manual operation mode Manual operation mode
Scroll down Scroll up

Special functions Special functions
Scroll down Scroll up
Reducing variable value, e.g. “17:00“ to “16:30” Increasing variable value, e.g. “17:00” to “05:30”
(Degermination) (Degermination)

Main menu: selecting the menu, e.g. “Settings” Main menu: this button is nonfunctional here

318 EN-XXX_SUNGO-SXL_TI-MA-BA-0707xx-1122P400
Language
[values]

Control info System selection
[values] [off]

Messages Bypass
[values] [values]

Factory configuration Tube collector
[off] [off]

Control time Return flow boost
[values] [off]
Special Functions E.g.
Heating circuit mixing Menu Thermostat A Activate thermostat A [off]
valve [values] [off]

Heating circuit pump Thermostat B 1. Press right button
[values] [off] Open function:
Remove brackets
Heating curve Degermination
[values] [off]
2. Press right button
Primary circuit Control option (def. control) Activate ON/OFF function
[values] [off]

Pool protection Yield measurement 3. Press upper button
[off] [off] Select function variation:
E.g. ON flashes
Tank cooling System protection
[off] [off]
4. Press right button 2x
Collector cooling
[off] Save selected Variation 1.4
E.g. ON

5. Press lower button
Select additional function variation:
E.g. “Heating/Cooling”

6. Press right button
Tank
[values] Activate “Heating/Cooling” function:
Preheating Tank 1 “Heating” flashes
[values] [values]

Pool protection 7. Press upper button
[values] Tank 2
[values] Select function variation:
Time E.g.: “Cooling” flashes
[values] Settings Tank 3
[values]
Cooling F Menu 8. Press right button 2x
[values] Save selected variation
Priority
[values] E.g. “Cooling”
Heating F
[values]
Speed
Heating [values] 9. Press left button
[values] Close function
Return flow boost Brackets are shown
Cooling B [values]
[values] Function set to ON
Heating B Heating A
[values] [values]
Cooling A
[values]

EN-XXX_SUNGO-SXL_TI-MA-BA-0707xx-1122P400 319
5.2 Initial Start-Up
1. Switch Controller On
After switching on the controller, change from the “Infor-
mation” menu
< 60 s
to the “Special Functions” menu within 60 seconds.

2. Select Language
Select the language from the “Special Functions” menu.
Additional information about this menu is listed on pages
321 - 324

1. Switching on
Use the ON/OFF switch to activate the mains power at the controller.
Collector
o
The controller automatically switches to the “Information” menu.
72,4 C
o
72 - C -➚ 126

2. Press left button 2x
The “Main menu” opens.
Wagner & Co
The “Special functions” symbol flashes.
12:00:00

Solar Technology

3. Press bottom button 1x
The “Special functions” menu opens with the “Language” option selected.
Language
4. Press right button 2x
[Values] GERMAN flashes.
5. Press bottom button 1x
Select from NEDERLANDS, ITALIANO, FRANCAIS, ESPANOL or ENGLISH.

6. Press right button 2x
The selected language is activated for the controller and saved.
LANGUAGE
The display switches to the selected language.
ENGLISH

3. Select System
Select the system from the “Special functions” menu (e.g.
1211).
Afterwards again, change from the “Information” menu to
the “Special Functions” menu within 60 seconds if addi-
tional options are required as well (e.g. return flow boost,
thermostat, etc.).
The time and date must be reprogrammed in the “Set-
tings” menu when selecting a different system.

4. Activate Additional Special Functions
Active and set values depending on requirements and se-
lected system.

5. Adjust Settings
Adjust preset values in the “Settings” menu as needed.
Additional information about this menu is listed on pages
325 - 327.

320 EN-XXX_SUNGO-SXL_TI-MA-BA-0707xx-1122P400
5.3 Special Functions Menu
Language [values]
Name Description Range Default value Your value
German, Dutch, Italian, French,
Language Select languages German
Spanish, English
System selection [off]
Name Description Range Default value Your value
System selection, start Activating system selection off, on Off
1211 – 1213,
System System selection 1221 – 1224, 1211
1231, 1241, 1251
Bypass [values]
Name
Activation of the plate heat
Bypass PHE, valve PHE
exchanger or valve variation
Tube collector [off]
Name Description Range Default value Your value
Activates the tube collector
Tube coll. off, on off
function
Tube coll., function Selection of the variations delta T, irradiation delta T
Runtime of solar circuit pump
Tube coll., runtime starting when reaching switchon 1 – 60 s 15 s
value.
1.0 K
Switch-on value temperature rise
Tube coll., delta T 1.0 – 5.0 K (only with
at T1
delta T)
Tube coll., irradiation
(only of irradiation sensor
Switch-on value of the irradiation
50 – 500 W
200 W
(only with
1.4
sensor
connected) irradiation)
Return flow boost [off]
Name Description Range Default value Your value
Boost return Activates the return flow boost off, on off
Thermostat A [off]
Name Description Range Default value Your value
Thermostat A Activates thermostat A off, on off
Thermostat A, function Selection of the variations Heating, cooling Heating
Thermostat A, additional sensor
Activating the additional sensor off, on off
(selectable only with “Heating”!)
Thermostat B [off]
Name Description Range Default value Your value
Thermostat B Activates thermostat B off, on off
Thermostat B, function Selection of the variations Heating, cooling Heating
Thermostat B, sensor Selection of the sensor T1 – T8 T3

EN-XXX_SUNGO-SXL_TI-MA-BA-0707xx-1122P400 321
Degermination [off]
Name Description Range Default value Your value
Activates
Degermination off, on off
degermination heating
Start time of
Degermination, time: start 0:00 – 23:59 17:00
degermination heating
Running time of the circulation
pump
Degermination, duration (lag time after reaching the 0:00 – 10:00 h 1:00 h
heating temperature internally is
5 minutes)
Heating temperature of the
Degermination, temperature 60 – 80 °C 60 °C
degermination
Control option (def. control) [off]
Name Description Range Default value Your value
Selection of the variations “def.
Control option (def. control) off, def. controller, thermos F off
control” or “Free thermostat”
Def. controller, sensor 1 Selecting the sensor assignment T1 - T8 T7
Selecting the sensor assignment
Def. controller, sensor 2 T1 - T8 T8
(sink)
Thermostat F, function Selection of the variations Heating, cooling Heating
Selecting the sensor assignment
Thermostat F, sensor T1 - T8 T7
(switching threshold)
Thermostat F, additional sensor
Activating the additional sensor off, on off
(selectable only with “Heating”!)
Selecting the sensor assignment
Thermostat F, additional sensor T1 - T8 T8
(additional sensor)
Yield measurement [off]
Name Description Range Default value Your value
Activating the yield
Yield measurement off, on off
measurement
Yield measurement, function Selection of the variations HQM, FV HQM 
1.0 l/pulse
Yield measurement, liter/pulse Pulse rate of the volume meter 0.5 - 25.0 liter/pulse (only with
HQM!)
Yield measurement, Defined volume flow of the 5.0 l/minute
0.1 - 75.0 liter/minute
liter/minute system (only with FV!)
Yield measurement , glycole 0 – 100%
Mixing ratio of glycole/water 40%
(only with DC20!) (in increments of 5%)
Selecting the sensor assignment
Yield measurement, T-flow T1 - T8 T1
(T-flow)
Yield measurement,
Selection of the variations DC 20, DC 40 DC 20
glycole type
System protection [off]
Name Description Range Default value Your value
Deactivating the system
System protection on, off ON
protection
Start temperature of the system
System protection, start 115 – 200 °C 1 135 °C
protection
1 The smallest possible setpoint depends on the “Start Temp., Collector Cooling” and is always minimally higher by 15 °C.

322 EN-XXX_SUNGO-SXL_TI-MA-BA-0707xx-1122P400
Collector cooling [off]
Name Description Range Default value Your value
Collector cool. Activating collector cooling off, on off
Start temperature of the
Collector cool., start 100 – 150 °C 2 110 °C
collector cooling
Switch-off difference of the
Collector cool., dT stop 3 – 20 K 5K
collector cooling
2 The largest possible setpoint range depends on the “Start Temperature, System Protection”
Tank cooling [off]3
Name Description Range Default value Your value
Tank cool. Activating the tank cooling off, on off
Tank cool., stop Stop temp. tank cooling 30 ° – 90 °C 60 °C
3 This function is only active if the collector cooling function is switched on.
Heating curve [values] (note – applies only to system number 1241, p. 312!)
Name Description Range Default value Your value
Lower value of outdoor temp. for
Heating curve, outdoor Tmin -20 ° to +30 °C -15 °C
heating curve
Desired flow temp. for outdoor
Heating curve, flow Tmax 0 ° to +80 °C 70 °C
Tmin
Upper value of outdoor temp.
Heating curve, outdoor Tmax -20 ° to +30 °C 15 °C
for heating curve, heating limit
Desired flow temp. for outdoor
Heating curve, flow Tmin 0 ° to +80 °C 30 °C
Tmax
Heating curve, offset Parallel shift of heating curve -15 K to +15 K 0K
Heating curve, flow Tmax limit Limit max. flow temp. 0 ° – 80 °C 70 °C
Heating curve,flow Tmin limit Limit min. flow temp. 0 ° – 80 °C 30 °C
Excess temperature storage
1.4
Heating curve, dT storage (center) to flow temperature for 1 – 20 K 5K
boiler request
Switch-off difference for boiler
Heating curve, dT stop 1 - 20 K 5K
request
Heating circuit pump [values] (note – applies only to system number 1241, p. 312!)
Name Description Range Default value Your value
Heating circuit pump, min. Heating circuit pump min. speed 30 – 100% 100%
Heating circuit pump, Setpoint temp. difference flow
1 - 50 K 15 K
dT setpoint and return heating circuit
Heating circuit mixing valve [values] (note – applies only to system number 1241, p. 312!)
Name Description Range Default value Your value
Time lag between control
Mixing valve, pulse period 10 s - 40 s 15 s
signals for the mixing valve
Gives the reaction value to the
Mixing valve, prop. coefficient control difference between set 0.1 s / K - 5.0 S / K 1.0 s / K s
and actual value.
Pool protection [off]
Name Description Range Default value Your value
Pool protection Activating the pool protection off, on off
Primary circuit [values] (note – applies only to systems with bypass and option “PHE”)
Name Description Range Default value Your value
Fixed % RPM for solar circuit
Primary circuit, speed 30 – 100% 100%
pump

EN-XXX_SUNGO-SXL_TI-MA-BA-0707xx-1122P400 323
Control time [values]
Name Description Range Default value Your value
Waiting time with bypass
Control time switching and 2-tank priority 30 – 480 s 90 s
control
Factory configuration [off]
Name Description Range Default value
Activating the factory
Factory config. off, on off
configuration

Message log [values] (note – corresponding table, see 8.1 Message Log, p. 333!)

Controller info [values]
Name Description Range Default value Your value
1211 - 1213,
Display of the selected
Controller info, system no. 1221 - 1224, 1211
system number
1231, 1241, 1251
Display of the selected Current
Controller info, system ver. V 1.00 - V X.xx
system version version: 1.00
Display of the selected
Controller info, software no. 1317SP1201 1317SP1201
software number
Display of the selected Current
Controller info, software ver. V 1.00 - V X.xx
software version version: 1.00

324 EN-XXX_SUNGO-SXL_TI-MA-BA-0707xx-1122P400
5.4 Settings Menu
Tank [values]
Name Description Range Default value Your value
Tank 1, 2 or 3, max. Tank limit temperature 15 – 90 °C 85 °C
Tank 1, 2 or 3, dT max. Switch-on difference: Tank – collector 3 – 40 K 10 K
Tank 1, 2 or 3, dT min. Switch-off difference: Tank – collector 2 – 35 K 3K
Priority [values]
Name Description Range Default value Your value
Priority, tank Tank 1 or 2 loading priority 1 or 2 1
Speed [values]
Name Description Range Default value Your value
Min. speed of the solar circuit pump; increment: in
increments of 5%
%RPM, min. 30 – 100% 30%
(systems with bypass and option “PHE”:
min. speed of P2)
%RPM, dT setpoint Setpoint temp. difference to which the speed is adjusting 2 – 50 K 10 K
Return boost [values]
Name Description Range Default value Your value
Boost return, max. Limit temperature, sink (T8) 15 – 90 °C 85 °C
Boost return, min. Min. temperature, source (T7) 15 – 90 °C 20 °C
Switch-on difference return flow boost
Boost return, dT max. 3 – 40 K 4K
between source and sink
Switch-off difference return flow boost
Boost return, dT min. 2 – 35 K 2K
between source and sink
Preheating [values]
Name Description Range Default value Your value 1.4
Preheating, max. Limit temperature, preheating tank (T8) 0 - 95 °C 85 °C
Preheating, min. Min. temperature top of storage tank (T3) 0 - 95 °C 20 °C
Switch-on difference storage tank top /
Preheating, dT max. 3 - 40 K 4K
preheating storage tank upper meas. point
Switch-off difference storage tank top /
Preheating, dT min. 2 - 35 K 2K
preheating storage tank lower meas. point
Heating A [values]
Name Description Range Default value Your value
Heating A, start Switch-on temperature, thermostat A 0 – 130 °C 30 °C
Heating A, dT stop Switch-off temperature, thermostat A 1 – 40 K 5K
Heating A,
Storage tank, check at top 3 – 20 K 10 K
additional sensor
Heating A, time 1: Start Time interval 1: start thermostat A 0:00 – 23:59 0:00
Heating A, time 1: Stop Time interval 1: stop thermostat A 0:00 – 23:59 23:59
Heating A, time 2/3: Start Time interval 2/3: start thermostat A 0:00 – 23:59 0:00
Heating A, time 2/3: Stop Time interval 2/3: stop thermostat A 0:00 – 23:59 0:00
Cooling A [values]
Name Description Range Default value Your value
Cooling A, start Switch-on temperature, thermostat A 0 – 130 °C 30 °C
Cooling A, dT stop Switch-off temperature, thermostat A 1 – 40 K 5K
Cooling A, time 1: Start Time interval 1: start thermostat A 0:00 – 23:59 0:00
Cooling A, time 1: Stop Time interval 1: stop thermostat A 0:00 – 23:59 23:59
Cooling A, time 2/3: Start Time interval 2/3: start thermostat A 0:00 – 23:59 0:00
Cooling A, time 2/3: Stop Time interval 2/3: stop thermostat A 0:00 – 23:59 0:00

EN-XXX_SUNGO-SXL_TI-MA-BA-0707xx-1122P400 325
Heating B [values]
Name Description Range Default value Your value
Heating B, start Switch-on temperature thermostat B 0 – 130 °C 30 °C
Heating B, dT stop Switch-off temperature, thermostat B 1 – 40 K 5K
Heating B, time 1: Start Time interval 1: start thermostat B 0:00 – 23:59 0:00
Heating B, time 1: Stop Time interval 1: stop thermostat B 0:00 – 23:59 23:59
Heating B, time 2/3: Start Time interval 2/3: start thermostat B 0:00 – 23:59 0:00
Heating B, time 2/3: Stop Time interval 2/3: stop thermostat B 0:00 – 23:59 0:00
Cooling B [values]
Name Description Range Default value Your value
Cooling B, start Switch-on temperature thermostat B 0 – 130 °C 30 °C
Cooling B, dT stop Switch-off temperature, thermostat B 1 – 40 K 5K
Cooling B, time 1: Start Time intervall 1: start thermostat B 0:00 – 23:59 0:00
Cooling B, time 1: Stop Time intervall 1: stop thermostat B 0:00 – 23:59 23:59
Cooling B, time 2/3: Start Time intervall 2/3: start thermostat B 0:00 – 23:59 0:00
Cooling B, time 2/3: Stop Time interval 2/3: stop thermostat B 0:00 – 23:59 0:00
Diff. controller [values]
Name Description Range Default value Your value
Differential C, max. Limit temperature, sink 0 – 120 °C 85 °C
Differential C, min. Min. temperature, source 0 – 120 °C 20 °C
Differential C, dTmax. Switch-on difference between source and sink 3 – 40 K 4K
Differential C, dTmin. Switch-off difference between source and sink 2 – 35 K 2K
Differential C, time 1: Start Time intervall 1: Differential controller start 0:00 – 23:59 0:00
Differential C,, time 1: Stop Time intervall 1: Differential controller stop 0:00 – 23:59 23:59
Differential C, time 2/3:
Time intervall 2/3: Differential controller start 0:00 – 23:59 0:00
Start
Differential C, time 2/3:
Time intervall 2/3: Differential controller stop 0:00 – 23:59 0:00
Stop
Heating F [values]
Name Description Range Default value Your value
Heating F, start Switch-on temperature thermostat F 0 – 130 °C 30 °C
Heating F, dT stop Switch-off temperature, thermostat F 1 – 40 K 5K
Heating F,
Check temperature 3 – 20 K 10 K
additional sensor
Heating F, time 1: Start Time intervall 1: thermostat F start 0:00 – 23:59 0:00
Heating F, time 1: Stop Time intervall 1: thermostat F stop 0:00 – 23:59 23:59
Heating F, time 2/3: Start Time intervall 2/3: thermostat F start 0:00 – 23:59 0:00
Heating F, time 2/3: Stop Time interval 2/3: thermostat F stop 0:00 – 23:59 0:00
Cooling F [values]
Name Description Range Default value Your value
Cooling F, start Switch-on temperature thermostat F 0 – 130 °C 30 °C
Cooling F, dT stop Switch-off temperature , thermostat F 1 – 40 K 5K
Heating F,
Check temperature 3 – 20 K 10 K
additional sensor
Cooling F, time 1: Start Time interval 1: thermostat F start 0:00 – 23:59 0:00
Cooling F, time 1: Stop Time interval 1: thermostat F stop 0:00 – 23:59 23:59
Cooling F, time 2/3: Start Time interval 2/3: thermostat F start 0:00 – 23:59 0:00
Cooling F, time 2/3: Stop Time interval 2/3: thermostat F stop 0:00 – 23:59 0:00

326 EN-XXX_SUNGO-SXL_TI-MA-BA-0707xx-1122P400
Heating [values]
Name Description Range Default value
Heating mode
Auto: Automatic mode with hot water priority Auto,
Summer: Only water heating, no heating operation (but Summer,
Heating, mode frost protection) Party, Auto
Party: Delay of the next lowering by 3 hrs Emission,
Emission: Boiler demand for 25 min. Off
Off: No heating operation, no water heating
Heating, weekly plan [values]
Master day [values] 4
Name Description Range Default value Your value
Time slot1 [values]
Master day time 1: Start Start time of lowering 1 0:00 - 23:59 23:00
Master day time 1: Stop Stop time of lowering 1 0:00 - 23:59 6:00
Master day lowering Adjustable value of lowering 1 0 - 30 K 0K
Time slot2 [values]
Master day time 2: Start Start time of lowering 2 0:00 - 23:59 0:00
Monday, time 2: Stop Stop time of lowering 2 0:00 - 23:59 0:00
Master day lowering Adjustable value of lowering 2 0 - 30 K 0K
Time slot3 [values]
Master day time 3: Start Start time of lowering 3 0:00 - 23:59 0:00
Master day time 3: Stop Stop time of lowering 3 0:00 - 23:59 0:00
Master day lowering Adjustable value of lowering 3 0 - 30 K 0K
Time slot4 [values]
Master day time 4: Start Start time of lowering 4 0:00 - 23:59 0:00
Master day time 4: Stop Stop time of lowering 4 0:00 - 23:59 0:00
1.4
Master day lowering Adjustable value of lowering 4 0 - 30 K 0K
4 All settings made for the master day are automatically applied to the remaining weekdays.
Data logging [value]
Name Description Range Default value Your value
1, 2, 5, 10,
Interval Scanning interval for data logging 15, 20, 30 1 min
min
Cyclical,
Record One-time or over-writing recording on data memory stick Cyclical
simple
Reset Resetting to first data set and display “0%” off, on off
The data logging menu option is only shown in the controller when a data stick is plugged in.

EN-XXX_SUNGO-SXL_TI-MA-BA-0707xx-1122P400 327
Individual Setting of Weekdays
Select the individual days of the week and change the
basic settings, to programme individual settings for the
weekdays that deviate from the “master” day.
Enter your changes into the table below.

Weekday Time 1 Time 2 Time 3 Time 4
Monday
Start
Stop
Lowering
Tuesday
Start
Stop
Lowering
Wednesday
Start
Stop
Lowering
Thursday
Start
Stop
Lowering
Friday
Start
Stop
Lowering
Saturday
Start
Stop
Lowering
Sunday
Start
Stop
Lowering

Pool protection [values]
Name Description Range Default value Your value
Pool protection, start Switch-on temperature of the pool protection 20 – 70 °C 40 °C
Time [values]
Name Description Range Default value
Time setup Setting the current time 0:00 - 23:59 12:00
Date setup Setting the current date 01.01 – 31.12. 1.01.
Day of week setup Monday to
Setting the current day of the week Thursday
(only system 1241) Sunday

328 EN-XXX_SUNGO-SXL_TI-MA-BA-0707xx-1122P400
5.5 Information Menu
Description of the displays and indicators
Temperature measured values

Collector Measuring point
o
72,4 C Current temperature (outdoor temperature display with system 1241:
o Sliding average value of last 60 minutes, after brief stop of controller: current value)

72 - C - 126

Min. value / max. value (reset by pressing right button 2x)

Sensor faults display

Storage Tank ↓ Measuring point

Grafical display of error (also 8.2 “System Messages”)

Line Interrupt Clear text error (“Short Circuit” or “Line Interrupt”)

Active controller functions display

Active solar circuit function
Storing T1…3, Pool Tank (or pool) being loaded
Bypass: Bypassing secondary circuit, only solar circuit is active
Tube Solar circuit runs temporarily (acc. to tube collector setting)
Pool protection Solar circuit pump switched off
S Protect System protection switches solar circuit off
C Cool Collector cooling function active
Function active T Cool Tank cooling function active

Storing T1
Waiting Waiting time before tank switching
1.4
Active additional function(s)
Return flow boost (Display changes if several functions are active at once)
A B Return flow incr. Return flow increase active
1234
5678 Heating A, B, F Heating with thermostat A, B, or F
Cooling A, B, F Cooling with thermostat A, B, or F
Diff. controller Temperature diff. controller switches on
Controlling mixing valve Mixing valve is opened or closed
Boiler req. Boiler request switches on for hot water or
to heat up the permanent buffer part of the tank
Mixing valve closed Mixing valve is closed completely
Degermination output Degermination switched on
Display of the active outputs

Balance values

Storage tank (h) Operating hours (separate for each tank or pool with multi-tank systems)

345 h Total running hours (tank loading)

R: 17 h Operating hours (reset by pressing right button 2x)

Yield (T1) Solar yield (separate for each tank or pool with multi-tank systems)

1450 kWh Absolute heat amount

R: 45 kWh • Heat amount (reset by pressing right button 2x, flashing point bottom right = count meter)

EN-XXX_SUNGO-SXL_TI-MA-BA-0707xx-1122P400 329
Additional displays

Solar circ.

100 % Current speed of solar circuit pump

Pump capacity

Solar circ.

12 l/min Current flow in solar circuit (only if yield meas. with heat meter option is activated)

Volume flow

Solar rad.

550 W Current irradiation in W/m²
(only if tube collector function with irradiation option is activated and sensor is connected)

0 - W - 930

Min. value / max. value

Pump heat c.

90 % Current speed of heating circuit pump
(only system 1241 if min. speed of heating pump <100%)
Pump capacity

Heating flow
o
38 C Setpoint for heating flow (if no heating operation: “-------------”, only system 1241)

Setpoint

Message

Message Only displayed if current fault is pending. Error history, see “Special functions” menu

Error If the display continues to depict “Message” and the error is eliminated, OK is displayed.

Pool protection Error explanation

DATA Logging Only displayed if data stick in port.

0% Remaining capacity of data stick memory in percent.

330 EN-XXX_SUNGO-SXL_TI-MA-BA-0707xx-1122P400
5.6 Manual Mode Menu
Outputs
Name Description Range Default value
1. T.: Output 1
Manually switching output 1 ON/OFF off, on off
2. T.: off
1. T.: Output 2
Manually switching output 2 ON/OFF off, on off
2. T.: off
1. T.: Output 3
Manually switching output 3 ON/OFF off, on off
2. T.: off
1. T.: Output 4
Manually switching output 4 ON/OFF off, on off
2. T.: off
1. T.: Output 5
Manually switching output 5 ON/OFF off, on off
2. T.: off
1. T.: Output 6
Manually switching output 6 ON/OFF off, on off
2. T.: off
Manual lag
Name Description Range Default value
Manual lag, duration Lag time of manual control in minutes 1 – 600 min 0 min
1. T.: Outputs The function of all outputs is tested and assigned a test
2. T.: off result when ON is activated. off, on off
3. T.: Total test The controller then switches automatically to OFF.

1.4

EN-XXX_SUNGO-SXL_TI-MA-BA-0707xx-1122P400 331
6. Technical Information
Solar Controller SUNGO SXL
General technical data
Material 100% recyclable ABS case for wall mounting
Dimensions (L x W x D in mm) 173 x 138 x 51
Protection class IP40 acc. to VDE 0470
Rate of radio interference N acc. to VDE 0875
Operating voltage 230 V AC; 50 Hz; -10% to +15%
Diameter of cable max. for 230 V connections 2.5 mm²; unifiliar/finely stranded
Temperature sensor / temperature range Pt1000; 1000 W at 0 °C; range: -25 °C to +200 °C
The cable of the sensor must be installed without tension. The
Sensor load sensor must not be loaded mechanically when the temperature of
the collector is more than 60 °C.
Test voltage 4 kV 1 min acc. to VDE 0631
Switching voltage 230 V AC
Output parameters of the switching outputs 1 A / approx. 230 VA for cosj = 0.7 to 1.0 per output
Internal mains protection Microfuse 5 x 20 mm; 4 A/T (4 ampere, slow)
Operating temperature (internal) / storage temperature 0 °C to +50 °C / -10 °C to +65 °C
Total capacity 920 VA
Weight Approx. 360 g

Hardware specifications
10
7 standard Pt1000 sensors
Inputs
3 selectable: 3 temperature sensors or
1 irradiation sensor, 1 volume meter and 1 temperature sensor
6 switching outputs 230 V/AC:
– Speed-control prepared for all outputs
Outputs
- Depends on selected layout
– Visual function check of the 230 V outputs
Illuminated, graphical symbols and plain text,
Display
5 lines (2 for graphic, 3 alphanumerical)
Use Scroll function using two key combinations (vertical, horizontal)

Software specifications
Sensor: Short-circuit, cancel, dT too high,
Complex diagnostic system
flow monitor HQM, additional control functions
Displayed text Multilanguage: 6 default languages
Data stick: Data logging, operating software update
Available soon:
Remote control via data stick port
Special functions
Modem-capable via data stick port
Interface for large displays
Error message relay

332 EN-XXX_SUNGO-SXL_TI-MA-BA-0707xx-1122P400
7. Accessories
Product Description Art. No.
Temperature sensor Pt1000, 6-mm plug-type sensor with 2.5 m silicone cable
Temperature sensor Pt1000 (-50 °C … +180 °C) 150 102 49
(4 Pt1000 sensors included in delivery scope SUNGO SXL)
Pt1000 sensor in plastic enclosure
Outdoor sensor TA1 Dimensions (H x W x D): 68 x 34 x 27 mm 150 400 37
terminal connectors, cable connection
Irradiation sensor, low ohm power output, UV-resistant design, connection cable
Irradiation sensor PSF3 150 400 29
approx. 1.5 m; including fastening brackets
Heat meter set
0.6 m³/h Volume meter 0.6/1.5/2.5 m³/h with immersion sleeve and Pt1000 sensor incl. brass 150 400 30
1.5 m³/h adapter, without screw connectors. 150 400 35
2.5 m³/h 150 400 36
Data stick
Multifunctional data memory stick for data logging and configuration. 8-pin plug-in
Data stick 150 400 34
enclosure, 1 MB integrated memory, L=35 mm, D=12 mm. Data security/reliability in
case of power failure
Consisting of data memory stick, PC adapter (USB), USB connection cable, and analysis
Data logging set 150 400 39
software

8. Service
8.1 Service – Message Log
Message log [values] (note – values are shown in the “Special Functions” menu under “Messages”!)
System message Description Range
Time / date T1 = temperature sensor 1 (E1)
T1 TF open = fault, sensor line open, T1 (E1) - T9 (E9) 1.4
TF open Cancellation of function
Time / date T2 = temperature sensor 2 (E2)
T2 TF short = fault, sensor line short-circuited, T1 (E1) - T9 (E9)
TF short Cancellation of function
Time / date
55.0 °C 55.0 °C = temperature reached during the switch-on duration of the circulation pump.
Error degermination Error degermination = switch-off value was not reached
Time / date In the background, 20 K are added to the default switch-on difference. If the total
difference reaches a value higher than 30 K for a duration of at least 30 minutes, the
dT too high error message “dT too high” is triggered.
Time / date
If the temperature exceeds the set switching threshold of the pool protection, solar
loading is completely stopped.
3. T.: P protection active
Time / date If heat metering is activated and the solar circuit pump is running, the cyclic pulse of
the volume meter is checked. An error message is displayed if pulses are not counted
HQM: No cyclic pulse within 15 minutes.
Time / date
If the corresponding output malfunctions or fails, the automatic test triggers an error
message. The corresponding function is switched off.
Output defective
Time / date To trigger the message “Nighttime Circulation”, 4 consecutive intervals of 30 minutes
each must be flawed. The individual error is set if the stop temperature at the end of
the interval is higher than the start temperature by 2 K.
Nighttime circulation The “Nighttime Circulation” check is active from 11:30 pm to 5:30 am.

EN-XXX_SUNGO-SXL_TI-MA-BA-0707xx-1122P400 333
8.2 Service – System Messages
System information with display
Display text Description Correction

!
System message
All of the triggered system messages are usually indicated with a flashing “Attention!“ symbol. In case of
Flashing sensor faults, the affected sensor is additionally identified with the “Short-Circuit/Disconnect” symbols.

Disconnect
The affected sensor is indicated in plain text
°C
and in the hardware position, if relevant
Cancel
(e.g.: Thermos. A T4). Sensor T4 has been
disconnected from controller input T4. ● Check resistance value of the sensor and compare with
Short-circuit resistance table.
The affected sensor is indicated in plain text ● Check all sensor contact points.
°C and in the hardware position, if relevant
Short-circuit (e.g.: Thermos. B T3). Sensor T3 or
controller input T3 is the cause of a
short-circuit.
dT too high
A fixed value of 20 K is added to the
temperature difference between collector ● Check pump/pump connection/wires for function
and tank sensor. The message is triggered if ● Check system for air, deaerate if needed
the total temp. difference has not been ● Check sensor/sensor line for function, replace sensor if
reduced within 30 min. necessary
Plain text display: dT too high in Information
menu under “Message”
Volume flow meter disconnected
● Check counts at volume meter using multimeter.
kWh The solar circuit pump is running but the
● Check system for air, deaerate if necessary.
volume meter does not register any counts.

System information without display
Description Possible Causes Correction
● Connect controller.
Mains power of 230 V not available. ● Switch controller on using the external ON/OFF switch.
● Check house fuse for the connection.
No display ● Check fuse and replace with new 2 A/T if necessary.
Internal fuse defective.
● Check solar pump for short-circuit.
● Call Wagner & Co Solartechnik at
Entire unit defective.
+ 49 (0) 6421/8007-0.
Manual mode of controller activated. ● Exit “Manual” menu.
Controller nonfunctional
Switch-on condition not met. ● Wait until the switch-on condition has been met.

Pump connection has been severed. ● Check cable to pump.
“Pump” symbol is rotating ● Unjam/unblock pump.
Pump jammed.
but pump is not working. ● Call Wagner & Co Solartechnik at
No voltage at switching output A1. + 49 (0) 6421/8007-0.
Sensor lines installed in proximity of ● Install sensor lines differently or shield lines.
Temperature display rapidly 230 V lines. ● Shield sensor lines.
fluctuating Long sensor lines extended without shield. ● Call Wagner & Co Solartechnik
Unit defective. at + 49 (0) 6421/8007-0.

8.3 Service – Sensor Check
Resistance values for Pt1000 sensors in dependence of temperature
-10 °C 0 °C 10 °C 20 °C 30 °C 40 °C 50 °C 60 °C 70 °C 80 °C 90 °C 100 °C 110 °C
961 W 1000 W 1039 W 1078 W 1117 W 1155 W 1194 W 1232 W 1271 W 1309 W 1347 W 1385 W 1423 W
The correct function of the temperature sensors can be checked with a multimeter and this table.

Subject to modifications, errors excepted · © Wagner & Co, 2010 · www.wagner-solar.com
334 WAGNER & CO · Zimmermannstraße 12 · D-35091 Cölbe/Marburg · ☎
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INSTALLATION INSTRUCTIONS

Expansion Vessel

Installation Steps
1. Mount attachment bracket on wall with dowels and
screws.
2. Slip expansion vessel into bracket opening.
3. Screw lock nut onto threaded connection and tighten.
4. Attach corrugated stainless steel tubes to Expansion
vessel with ¾" gasket.
5. Optionally install capped check valve between expan-
sion vessel and stainless steel tube.

Optional
capped check valve
Corrugated
stainless steel tube

1.4

¾" Gasket

Lock nut

Expansion vessel

Screws 6x60, hexagonal

Figure 1 Mount and connect expansion vessel.

Solar Thermal / Solar Circuit EN-XXX_Expansion-Vessel_MA-0403xx-1121L900 335
Subject to modifications, errors excepted · © Wagner & Co, 2010 · www.wagner-solar.com
336 WAGNER & CO · Zimmermannstraße 12 · D-35091 Cölbe/Marburg · ☎ +49 (0) 64 21 80 07-0 · Fax 80 07-596
TECHNICAL INFORMATION / INSTALLATION INSTRUCTIONS 1.00

Heat Meter
WMZ for SUNGO SL / SXL

Function
The heat meter for the solar controller SUNGO SL / SXL
consists of a volume flow meter and an additional sen-
sor for the return flow. It allows metering the heat energy
yielded by the system.

The heat quantity is analyzed via the volume flow, the tem-
perature difference and the properties of the heat carrying
medium. The flow temperature is equivalent to the tem-
perature T1 (collector), and the return flow is measured
with the additional sensor. The total yield of the system
in kw/h is then calculated using the heat quantity formula
Q = V x ρ  x cp  x ∆T stored in the controller.
Figure 1 Heat meter for SUNGO SL/SXL: Volume flow meter and
1 Pt1000 temperature sensor

1.4

Before installing the volume flow meter,
assure tight fitting of the thread exten-
sion from ¾" to 1"m with Allen key!

Technical Data
Heat meter for SUNGO SL / SXL
Part Characteristic Type WMZ 0.6 / WMZ 1.5 / WMZ 2.5
Rating Qn = 0.6 m³/h; 1.5 m³/h; 2.5 m³/h
Impulse value 1 Litre/Impulse
Impulse actuator Reed-switch
Wire length, Impulse actuator 1.5 m
Volume flow meter
Overall length, heat meter 130 mm
Connection thread G 1B
Pressure level PN16
Temp., max. 130 °C
Type Pt1000
Sensor Tolerance, max. ± 0.8 °C
Application range -50 °C up to +180 °C
Pipe connection Depending on application, include either solder or threaded connection set or combination fitting set in order.

Solar Thermal / Solar Circuit EN-XXX_WMZ-SUNGO-SL-SXL_TI-MA-0807xx-11218400 337
Installation Commissioning
Installation / Hydraulics Before commissioning the solar installation, thoroughly
Install the volume flow meter in the return flow of the so- rinse the solar circuit with water to flush out residues from
lar circuit. Pay attention to the correct flow direction. The cutting and burring.
return flow sensor is inserted into the immersion sleeve of Recommendation: during flushing install a distance piece
the volume flow meter. instead of the volume flow meter, in order to avoid soiling,
damaging or destruction of the propeller.
Installation / SUNGO SL After flushing, insert volume flow meter in the correct flow
On the SL board, the return flow sensor must be connect- direction and fill solar installation with water/glycol mix-
ed to the right terminal at input T5. The Volume meter must ture.
be connected to input T7. The connections are not poled.

Installation / SUNGO SXL System Messages
On the SXL board, the return flow sensor must be connect-
ed to the right terminal at input T6. The volume flow meter The return flow temperature sensor and the impulse exit
must be connected to E10. The connections are not poled. of the volume flow meter are monitored via the diagnos-
tic system of the SUNGO SL and SUNGO SXL controllers.
The respective system messages are described on the last
Operation pages of the controller manuals.

The activation is done in the menu “Special Functions”. To
enable programming, this menu must be selected within
the first minute after restarting the controller.
For the required steps for activating heat metering and
the necessary settings please refer to the manuals of the
SUNGO SL or SUNGO SXL controllers.

SL circuit board Plug connector, Display

Fuse
FUSE 5X20
Solar storage
Pi
n
as
sig
nm

T1 T2 T3 T4 T5 T7
en
tS

Transformer
UN

M M M M M M
G
O
SL

Flow
Yield measuring, return flow sensor T5

Volume flow meter, T7
B Return flow
L
SX

A sensor
SXL circuit board Plug connector, Display
O
NG

Volume Return flow
SU

meter
nt
me
gn
si
as

Fuse
Pin

FUSE 5X20

2 3 4 5 6 7 8 9 10
Transformer
M M M M M M M M M

Yield measuring, return flow sensor T6

Volume flow meter, E10

Figure 2 Hydraulic and electric connection of heat meter for SUNGO SL/SXL

Subject to modifications, errors excepted · © Wagner & Co, 2010 · www.wagner-solar.com
338 WAGNER & CO · Zimmermannstraße 12 · D-35091 Cölbe/Marburg · ☎
+49 (0) 64 21 80 07-0 · Fax 80 07-596
TECHNICAL INFORMATION / INSTALLATION INSTRUCTIONS

2/3 Way Electronic Diverter Valve

The 2/3 way valve VC 4012 consists of two parts, the
Actuator Actuator
230V actuator head and the hydraulik part (Fig. 1), that head head
is delivered with ¾" or 1" male threaded connection.
After pressing the locking button, the actuator head can
be disconnected from the hydraulic part by moving it ¼
(45°) turn counterclockwise. (Fig. 2)

The type VC4012 is wired via a plug. Electrically the actua-
tor head is connected via three cables (without ground): B A B A
brown is connected to L, parallel to the power supply of
the controller and is continuously under power. Black is Hydraulic part AB
2-way-valve
connected to the switching exit of the controller (see op-
eration instructions of controller), and is only under power
when switched. The blue neutral line connects to N.
3-way-valve

The plastic slider on the actuator head optically indicates Figure 1 2- and 3-way-valve consisting of actuator head and hydronic
the switching state of the valve. When the slider is in its valve.
uppermost position, the actuator head is without power.
The hydraulic path then is branching from AB to B (Fig. 3). Plastic slider
If the slider is in its lower position, the actuator head is on.
The hydraulic path is then branching from AB to A. (Fig. 3).
During power failure, the valve freezes in its momentary
position.
Connection
jack
1.4
For correct venting the plastic slider is set to position
“manual operation”. The manual operation is only pos-
sible, when the slider first is in its uppermost position. By Locking button Plug
strongly pressing the slider downwards and inwards, the
adjustment head is moved into its middle position.

The hydraulic paths A and B then are simultanously half Blue
B A Brown
opened. By momentarily removing the adjustment head Black
from the hydraulic part, the actuator head is re-set into the AB
standard position.

Figure 2 Press locking button, to remove hydronic valve (left).
VC4012 with separate plug connection (right).

Powerless
state (off)
Manual
Powered position
state (on)

B A B A B A

AB AB AB
Figure 3
Powerless state (off) = AB - B (left), powered state (on) = AB - A (centre), manual position = AB - ½A + ½ B

Solar Thermal / Solar Circuit EN-XXX_2-3-Way-Valve_TI-MA-0809xx-1121M700 339
Technical Data
Typ Honeywell 2/3 way valve
Actuator head VC4012 separate plug connection
Manipulation time max. 7 s
Operational Voltage 230 V (AC) ± 10 %, 50/60 Hz
Protection type of case IP 40
Power demand 4 VA (during valve movement)

Mains, L1
Plug connector,
Controller IC display

FUSE 5X20
black A2, phase
Triac Fuse
blue A2, null

A B
AB Transformer
PE-PE A2 A1 L1

PE-PE N N N

Potential Earth, PE Mains, L1

Solar circulation pump, A1

Figure 4 2/3 way valve for return flow boost with connection to SUNGO SL

Plug connector,
Mains, L1 Triacs display
Fuse
FUSE 5X20
black A6, phase
blue A6, null

A B A6 A5 A4 A3 A2 A1 L1 Transformer
AB
PE-PE-PE N6 N N N N N N
PE-PE-PE

Potential Earth, PE Mains, L1

A6, return flow boost Solar circulation pump, A1

Figure 5 2/3 way valve with connection to SUNGO SXL e.g. for return flow boost A6/N6

Subject to modifications, errors excepted · © Wagner & Co, 2010 · www.wagner-solar.com
340 WAGNER & CO · Zimmermannstraße 12 · D-35091 Cölbe/Marburg · ☎
+49 (0) 64 21 80 07-0 · Fax 80 07-596
TECHNICAL INFORMATION / INSTALLATION INSTRUCTIONS

Twinflex TVA
Rapid Piping System

Product Features
● Quickly installable double tube
● Flow and return pipe can be easily divided into 2 indi-
vidual tube legs for separate installation (e.g. for collec-
tor connection).
● Multiple seperations and reconnections of tube legs
possible.
● Robust and tear resistant outer skin
● UV- and temperature resistant
● Sensor line 2 x 0.50 mm²

Figure 1 Twinflex TVA rapid piping system incl. double tube and inte-
grated sensor cable
1.4
Pressure loss [mbar/m]
Table 1
Twinflex TVA 2-16 2-20 100
Highly flexible and insulated stainless steel 90
Tube double ripple tube with integrated 2-wire
sensor cable (2 x 0.75 mm²) 80

Separable insulating sleeve, λ = 0.038 W/mK, 70
Insulating sleeve short term temperature resistant up to
175 °C, robust and UV-resistant outer skin 60
DN 16
Part no. 150 301 33 150 301 34 50
DN 20
Ext. dimension, 40
double tube 122 x 60 134 x 66
(WxH, mm) 30

External diameter 20
60 x 60 66 x 66
single tube (mm)
10
PN (bar) at 250 °C 11.0 6.9
0
Length 15 m reel
0 200 400 600 800 1000 1200
Connection set Please order separately Volume flow [l/h]
(see Tab. 2) (4 items per TVA-reel)
Figure 2 Pressure loss of Twinflex 2-16/2-20 per m, depending on vol-
ume flow, heat carrier fluid DC20-water mix with 40/60 ratio, at operat-
ing pressure 4 bar and operating temperature 40 °C

Air-accumulation within the tube dents is possible.
Therefore make sure that tube is installed with continuous-
ly ascending slope, so that complete venting is possible.

Solar Thermal / Solar Circuit EN-XXX_Twinflex-TVA_TI-MA-100119-11217700 341
Table 2 Twinflex TVA connection sets and accessories
Part Connection Part no.

¾" ripple tube on 18 mm
DN 16 150 301 37
copper sleeve

Twinflex TVA 1" ripple tube on 22 mm
DN 20 150 301 38
solder connection set copper sleeve

1¼" ripple tube on 28 mm
DN 25 15030190
copper sleeve

¾" ripple tube on ½" ripple
DN 16 150 301 35
tube
1" ripple tube on a ½" male
DN 20 150 301 54
Twinflex TVA threaded connection
threaded connection set 1" ripple tube on a ¾"
DN 20 150 301 36
female threaded connection
1¼" ripple tube on a 1"
DN 25 150 301 89
male threaded connection
¾" ripple tube on 18 mm
female threaded connection
(like solder sleeve) and
DN 16 150 301 55
22 mm male
(e.g. directly connecting the
Twinflex TVA CIRCO solar circulation unit)
combi-fitting connection set
1" ripple tube on 18 mm
female (like capiliary socket)
DN 20 and 22 mm male 150 301 56
(e.g. directly connecting the
CIRCO solar circulation unit)

¾" ripple tube on a ½" IG
DN 16 (e.g. for connection to 150 301 68
EURO collectors)
Twinflex TVA
collector connection set
1" ripple tube on ½" female
DN 20 (e.g. for connection to 150 301 69
EURO collectors)

Extension
DN 16 150 301 39
¾" ripple tube

Twinflex TVA Extension
DN 20 150 301 40
coupling set 1" ripple tube

Extension
DN 25 15030191
1¼" ripple tube

DN 16 150 301 42

Txinflex TVA
oval clamp set DN 20 150 301 41
(4 items)

DN 25 15030191

342 EN-XXX_Twinflex-TVA_TI-MA-100119-11217700
Figure 3 Cut the corrugated stainless steel tube with a pipe cutter plain Figure 4 Slide swivel nut onto tube. Then place compression ring into
to the required length. Deburr to protect your hands and the seals. the first ripple and press together. If using pipe pliers, make sure to not
damage the tubes!

1.4

Figure 5 Now compress ripple at tube end to form a sealing surface. Figure 6 Tighten swivel nut with a spanner and screw in the connect-
For this, place an adequate washer into the swivel nut. ing piece. Then remove connecting piece and washer again.

Figure 7 When the connection is finalized, a gasket must be inserted! Figure 8 Make sure that upon completion of the installation the ripple
tube is insulated completely and insulation tape is applied at abutting
ends of insulation.

To allow complete draining and venting, install corrugated
tube at continuously ascending slope!

EN-XXX_Twinflex-TVA_TI-MA-100119-11217700 343
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TECHNICAL INFORMATION / INSTALLATION INSTRUCTIONS

Sensor Connection Box SP2
With Integrated Surge Arrester

Technical Data
Encasing: plastic, grey
Wall mounting ears (outside)
Protection class of encasing: IP 65
Dimensions: 80 x 80 x 50 mm Surge-arrester diode
Ambient temp.: -25 °C up to +70 °C (suppressor)

Function
The integrated surge arrester filters out a certain fraction
of the excess atmospheric voltage. This allows for a bet-
ter protection of sensor (type PT1000 or KTY) and down-
stream electronics. The connection box also functions as
E1 E2 A1 A2
an extension of the collector sensor cable.

Low voltage is impressed on the senor cables; therefore
Input Output
they must be laid separately from 230 V cables to avoid terminal terminal
interferences. 1.4
Figure 1 Sensor connection box SP2 / Schematics connection board.
Mechanical and Electric Installation
There are outside ears on the bottom of the box for easy
wall mounting.
The collector sensor is connected to the connection board
via the input terminals E1 and E2 (Fig. 1). The sensor ca-
ble extension from connection board to solar controller
SUNGO S/SL/SXL is led on via the output terminals A1 and
A2. The connection of the cables on in- and output is with-
out polarity.

Solar Thermal / Solar Circuit EN-XXX_Sensor-Connection-Box-SP2_TI-MA-0305xx-1121K700 345
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TECHNICAL INFORMATION

Solar Heat Transfer Liquid DC20

1.4

Figure 1 Solar liquid DC20 – reliable frost protection for solar thermal energy systems.

Properties
DC20 is an odourless antifreeze composed of non-haz- Reliable Corrosion Protection
ardous propylene glycol and corrosion inhibitors. Dilute Special inhibitors provide reliable corrosion protection for
DC20 with water, depending on the desired grade of frost solar energy systems with mixed installation (various dif-
protection. Use water of domestic water quality with a max. ferent metals). The outstanding corrosion protection was
chloride content of 100  mg/kg or demineralised water. proven in a special solar test by EMPA (Swiss Federal Labo-
The water content of the mixture must be between 25 % ratories for Materials Testing and Research).
and 70 %.
DC20 is suitable as a heat transfer liquid in solar energy Compatible with Plastics
systems as well as heating/cooling systems. DC20 has the Mixtures of DC20 and water are compatible with a large
following properties: number of commercial elastomeres. If in doubt carry out
a compatibility test.
Highly Efficient Heat Transfer
If DC20 is diluted with water it displays excellent heat ca- Non-Hazardous for Persons and the Environment
pacity and good flow capacity (viscosity) even at low tem- According to EU criteria, DC20 is not a hazardous prod-
peratures. This saves energy on pumping and allows for uct. It is easily biodegradable, non-irritant and only a weak
smaller pipe cross sections.