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HOT TAP WATER EXCHANGERS
for solar systems
OEM SOLAR
200
250
400
300
350
500
INSTALLATION AND OPERATION
MANUAL
WARRANTY CARD
Before you install and activate the exchanger, please read this "Installation and
Operation Manual" and Terms and Conditions of the Warranty
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Version 02/12 OEM SOLAR ENSOL
1. Structure and Intended Use
SOLAR OEM exchangers are pressure storage water heaters that are
designed to heat and store hot tap water, in systems with solar collectors,
for needs of flats, detached houses and multi-family buildings, public utility
buildings, industrial facilities and others.
OEM SOLAR 200-350 exchangers have been adapted for installation in
rooms with doors that are up to 70 cm wide. They are equipped with two
independent helical coils, allowing the connection of two power sources
with different heating media, such as solar collectors with a glycol-based
heating medium or e.g. low-temperature central heating water boiler.
Pressure tanks in these heat exchangers are made of steel sheet covered
inside with a layer of a special high-temperature vitreous enamel, forming
glass coating that protects them from corrosion and ensures clean healthy
water. Additional corrosion protection of the tanks is the magnesium anode
that owing to the difference of electrochemical potentials of steel and
magnesium in water, generates protective current for the tank.
Thermal insulation is made of PS expanded polystyrene permanently
joint to tank walls.
The outer casing of exchangers is made of plastic or artificial leather like
fabric.
SOLAR OEM exchangers are designed for installation of an electric
heating element on the 1½" plug, especially EJK type heating element
produced by ZUG ELEKTROMET with insulated heating units (Tab. 3),
which do not consume protective current generated by the magnesium
anode for the corrosion protection of the tank. This increases the durability
of the tank and the life of the magnesium anode.
The structure and
dimensions of exchangers
are shown in Fig. 1,
whereas their connection
dimensions and technical
parameters – in Tab. 1 and
2.
Figure 1. Structure and
dimensions of OEM
SOLAR exchangers
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Version 02/12 OEM SOLAR ENSOL
Tab. 1 Dimensions of OEM SOLAR exchangers
Type
Capacity
Height
Max. height when tilted
Diameter
Diameter without the thermal
insulation
Cold tap water
Hot tap water
Heating water supply
upper coil
Heating water return
upper coil
Heating water supply
solar coil
Heating water return
solar coil
Circulation
Temperature sensor sleeve
Heater coupling
Thermometer coupling
Magnesium anode
Cleaning hatch
Outlet
OEM SOLAR
200
250
300
350
400
500
[dm³]
[mm]
215
1160
250
1280
290
1430
345
1680
415
1530
500
1780
H* [mm]
D [mm]
D* [mm]
1345
680
550
1450
680
550
1585
680
550
1815
680
550
1735
810
650
1960
810
650
90
1”
990
1”
900
1”
660
1”
570
1”
240
1”
610
¾”
370
790
½”
610
1½”
880
½”
40 x 330
2”
ø130
310
90
1”
90
1”
1110
1”
1010
1”
770
1”
680
1”
250
1”
590
¾”
470
890
½”
710
1½”
1000
½”
40 x 330
2”
ø130
310
90
1”
90
1”
1260
1”
1150
1”
820
1”
730
1”
250
1”
635
¾”
520
985
½”
760
1½”
1150
½”
40 x 390
2”
ø130
310
90
1”
90
1”
1400
1”
1250
1”
920
1”
730
1”
250
1”
825
¾”
520
1075
½”
795
1½”
1400
½”
40 x 390
2”
ø130
310
90
1”
100
1 ¼”
1320
1 ¼”
1215
1”
875
1”
770
1”
300
1”
680
¾”
490
1045
½”
825
1½”
1210
½”
40 x 430
2”
ø130
365
100
1 ¼”
100
1 ¼”
1460
1 ¼”
1370
1”
1030
1”
830
1”
300
1”
920
¾”
610
1200
½”
895
1½”
1460
½”
40 x 500
2”
ø130
365
100
1 ¼”
H
S
[mm]
ZW
J [mm]
CW
I [mm]
WEG
F [mm]
WYG
E [mm]
WES
A [mm]
WYS
F [mm]
RC
B [mm]
G [mm]
CT
L [mm]
MG
M [mm]
RT
ø x L [mm]
AN
W
K [mm]
S [mm]
ZS
Tab. 2 Technical parameters of OEM SOLAR exchangers
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Version 02/12 OEM SOLAR ENSOL
OEM SOLAR
400 OEM SOLAR
500
Type
Type
200
Tank capacity
Exchanger surface
Coil capacity
Hot tap water capacity
0
80/10/45 C
0
70/10/45 C
0
60/10/45 C
Heating power
0
80/10/45 C
0
70/10/45 C
0
60/10/45 C
Hot tap water capacity
0
80/10/60 C
0
70/10/60 C
Heating power
0
80/10/60 C
0
70/10/60 C
Heating water flow in
the coil
Pressure loss
Initial performance
0
exchanger temp. 60 C
0
80/10/45 C
0
70/10/45 C
Daily readiness loss
Tank operation
parameters
Heating medium
parameters
Type of tank
Type of outer casing
Thermal insulation
Heater weight in the
casing
215
dm³
250
300
350
250
290
345
botto
m
top
botto
m
top
botto
m
top
botto
m
top
1.0
0.7
1.26
0.7
1.4
1.0
1.4
1.0
dm³
5.7
4.2
7.3
4.2
8.1
5.7
8.1
5.7
dm³/h
545
462
336
386
322
236
720
602
432
386
322
236
756
629
462
545
462
336
756
629
462
545
462
336
kW
22.2
18.8
13.7
15.7
13.1
9.6
29.3
24.5
17.6
15.7
13.1
9.6
30.8
25.6
18.8
22.2
18.8
13.7
30.8
25.6
18.8
22.2
18.8
13.7
dm³/h
327
241
230
198
375
275
230
198
451
330
327
241
451
330
327
241
kW
19
14
13.4
11.5
21.8
16
13.4
10
26.2
19.2
19
14
26.2
19.2
19
14
m³/h
1.7
1.2
2.0
1.2
2.2
1.7
2.2
1.7
mbar
35
25
50
25
70
35
70
35
m
2
dm³/10min
kWh/24h
169
169
223
158
158
210
3.0
3.2
3.4
Maximum pressure and operating temperature
pr = 1.0 MPa ot = 95°C
Maximum pressure and operating temperature
pr = 1.6 MPa ot = 100°C
steel tank coated inside with vitreous enamel
261
248
3.4
plate-like coating made of plastic or artificial leather
65 mm expanded polystyrene
kg
85
105
130
145
* 80°C, 70°C, 60°C - temperature of heating water in the coil supply
10°C - temperature of cold tap water on supply
45°C - temperature of hot tap water
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Version 02/12 OEM SOLAR ENSOL
Usable capacity of the
tank
dm³
Exchanger surface
m
Coil capacity
Hot tap water capacity
0
80/10/45 C
0
70/10/45 C
0
60/10/45 C
Heating power
0
80/10/45 C
0
70/10/45 C
0
60/10/45 C
Hot tap water capacity
0
80/10/60 C
0
70/10/60 C
Heating power
0
80/10/60 C
0
70/10/60 C
Heating water flow in
the coil
Pressure loss
Initial performance
0
exchanger temp. 60 C
0
80/10/45 C
0
70/10/45 C
Daily readiness loss
Tank operation
parameters
Heating medium
parameters
Type of tank
Type of outer casing
Thermal insulation
Heater weight in the
casing
415
500
bottom
top
bottom
top
1.8
1.3
2.0
1.3
dm³
10.5
6.8
11.5
6.8
dm³/h
1253
1081
762
934
786
540
1351
1155
811
934
786
540
kW
51
44
31
38
32
22
55
47
33
38
32
22
dm³/h
739
550
550
413
791
602
550
413
kW
43
32
32
24
46
35
32
24
m³/h
2.9
2.2
3.1
2.2
mbar
120
105
135
105
2
dm³/10min
348
388
323
363
kWh/24h
4.0
4.5
Maximum pressure and operating temperature
pr = 1.0 MPa ot = 95°C
Maximum pressure and operating temperature
pr = 1.6 MPa ot = 100°C
steel tank coated inside with vitreous enamel
plate-like coating made of plastic or artificial
leather
80 mm expanded polystyrene
kg
ca. 235
ca. 260
Accessories:
- safety valve with the opening pressure: 0.6 MPa
2. Safety devices and conditions for safe
use of exchangers.
Heaters may only be used with a functional safety valve with the opening
pressure of 0.6 MPa (water pressure in the water supply network up to 0.6
MPa) or 1.0 MPa (water pressure in the water supply network up to 1.0
MPa) installed on the cold tap water inlet. This valve protects the
exchanger from excessive pressure in the water supply network or
excessive pressure increase as a result of heating the water in the tank.
Even in case of regular operation of the exchanger during heating, water
may leak from the safety valve for a short time, which shows that the valve
operates in a correct manner. Never obstruct the outlet hole in such cases.
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Version 02/12 OEM SOLAR ENSOL
All types of exchangers should be used with an installed thermometer of
the measuring range between 0 and 120°C, whereas on exchangers with
the capacity exceeding 250 l, also install pressure gauges with the
measuring range between 0 and 1 MPa.
ATTENTION!
1. A safety valve has to be installed on the cold water inlet to the
exchanger; the valve is supplied with the exchanger. Install it so that the
arrowhead on the valve body is in line with the direction of the water
flow.
2. Do not install any shut-off valves between the safety valve and the
exchanger.
3. It is not permitted to use the tank without a safety valve or with a
malfunctioning safety valve because
the situation may result in failure and poses a threat to human life and
health.
3. Installation
Installation and any repairs of the exchanger in terms of electricity
and water system should be entrusted only to skilled processionals
with relevant permissions.
3.1 Exchanger connection to the water supply network,
central heating system and solar collector.
Connect the exchanger vertically to the water supply network in which the
pressure does not exceed 0.6 MPa or 1.0 MPa and not lower than 0.1 MPa.
If the pressure in the network often exceeds 0.4 MPa, it is recommended to
install a pressure reducing valve or a diaphragm reservoir before the
exchanger in order to limit the inconvenient outflow of water from the safety
valve. When the pressure in the water supply network exceeds 0.6 MPa or
1.0 MPa, it is necessary to install the pressure reducing valve in order to
avoid the continuous outflow of water from the safety valve.
The exchanger is fed by the heating medium from the solar collector and
e.g. from a low-temperature water boiler that operates in an open system or
in a closed system, i.e. with a diaphragm vessel.
3.2 Installation of EJK type heating element
During the warranty period of the tank, only heating elements tanks
suitable for enamelled tanks may be used, i.e. those with insulated heating
units (insulated heating units do not "steal" protective current generated by
the magnesium anode). This is one of the warranty conditions for the
OEM SOLAR exchanger. EJK type heating
elements by ZUG ELEKTROMET comply with this condition.
Type
of heating
element
Type
Quantity of
heated
water
EJK1500
7 EJK2000
EJK3000
Version 02/12 OEM SOLAR ENSOL
EJK4500
EJK6000
OEM SOLAR 200
OEM SOLAR 250
OEM SOLAR 300
OEM SOLAR 350
OEM SOLAR 400
OEM SOLAR 500
dm³
h
h
h
h
h
97
100
120
160
180
250
4.8
4.8
5.8
7.8
8.8
12.5
3.6
3.6
4.4
5.8
6.5
9.2
2.4
2.4
2.9
4.0
4.5
6.0
1.6
1.6
1.9
2.6
3.0
4.0
1.2
1.2
1.5
2.0
2.5
3.0
Tab. 3 Selection of electric heating units and water heating time for Δt =
50°C
Among EJK heating elements manufactured by ZUG ELEKTROMET for
SOLAR OEM exchangers, you can install single phase 230 V 1.5 kW and
2.0 kW heating elements as well as three phase
400 V 3.0, 4.5 and 6.0 kW heating elements – see the summary in Tab. 3.
Install in accordance with the Installation and Operation Manual of the
heaters.
It is particularly important that the free end of the yellow-green protective
conductor drawn from the marked connection on the casing of the heating
element is connected using the M4 screw to the earth plate located on the
MG connector of the tank, see Fig. 2.
1 – tank casing
2 – electric EJK type heating
element
3 – earth wire
4 – MG 1 ½'' connector
5 – earth plate
6 – M4 screw
7 – spring washer
Fig. 2 Earth of the heating element
ATTENTION! Do not insert the plug of the connection into the
electrical socket without making sure that the tank is filled
with water.
ATTENTION! During the warranty period of the tank, use only heating
elements with an insulated heating unit e.g. EJK
manufactured by ZUG ELEKTROMET
ATTENTION! The heating element and the metal tank have to be
connected
with an earth cable drawn from a marked connection
on the heater casing.
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Version 02/12 OEM SOLAR ENSOL
4. Operation and service
1. Periodically, at least once a month and before every start-up, after
putting out of service, check the correct operation of the safety valve
(according to instructions of valve manufacturer).
2. A temporary small outflow of water from the safety valve during heating
of water in the exchanger is normal and indicates the proper operation of
the safety valve.
ATTENTION! Continuous leaking of water from the safety valve outlet
demonstrates a malfunction of the valve or overly high pressure in
the water supply system. Never obstruct the outlet hole.
3. If the exchanger is put out of service in the winter and there is a concern
that the water in the exchanger may freeze, drain the water by unscrewing
the safety valve.
4. The magnesium anode wears down during operation, so its condition
should be checked periodically, at least once a year. The anode should be
replaced if it loses 2/3 of its volume, and always at the latest after 18
months. A relevant magnesium anode can be purchased at a point of sale
or from the manufacturer of exchangers.
The anode is located at the top end cap of the exchanger tank; to
determine its condition or replace it with a new one:
- cut off the cold water supply, open the hot tap water tap for a moment,
then close the outlet of hot water from the exchanger,
- remove the top cover of the exchanger casing,
- remove the insulation element covering the cap with the affixed anode,
- unscrew the cap with the anode,
- install a new anode in the reverse order, paying particular attention to
tightness of connections.
5. Periodically, depending on water hardness, remove the accumulated
sediment and loose scale.
ATTENTION!
The magnesium anode plays an important role in the corrosion
protection of the enamelled tank, and its regular checking and
replacement with a new one is necessary to maintain the warranty of the
tank.
Replaced used anodes and certification of their exchange (anode
purchase) should be kept in order to make them available for the
manufacturer's service personnel in case of failure of the tank.
ATTENTION!
Installation of OEM SOLAR tank in the heating system with solar
collectors is the condition to obtain the warranty for the tank.
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Version 02/12 OEM SOLAR ENSOL
5. Warranty conditions
1. The warranty is granted for a period of 60 months for the enamelled tank.
2. The warranty for other parts of the exchanger is 24 months.
3. The warranty period starts on the date of sale of the product to the user,
as entered in the warranty card and confirmed by a proof of purchase
(bill) issued by the vendor.
4. The guarantor ensures the efficient operation of the exchanger provided
that it is installed and used in accordance with its manual.
5. During the warranty period, the user is entitled to free repair of any
damage occurring through the fault of the manufacturer of the
exchanger. Any damage shall be removed in 14 days after the date of
notification.
6. The user loses the right to warranty repairs in case of:
- installation of the tank in a system without solar collectors,
- improper use of the device,
- repairs and modifications of the device by unauthorised persons,
- improper installation and operation of the device that is not in conformity
with this manual,
- use of the exchanger without the safety valve or with malfunctioning
safety valve,
- lack of the magnesium anode and lack of documents confirming its
replacement,
- use of a heating element with non-insulated electrical units.
7. The guarantor may refuse to repair if:
- it is not granted service access to the device,
- it is necessary to dismantle other devices, partition walls, etc. in order
to replace the tank,
- the tank is connected to the water supply network permanently, by
means of inseparable connections.
8. In case of unjustified calls for service, costs of arrival shall be borne by
the customer.
9. In case of irregularities in the operation of the exchanger, notify
manufacturer's service, tel. 32/ 415 01 81 from 6ºº to 14ºº, or by e-mail:
[email protected] or point of sale. DO NOT DISMANTLE THE
DEVICE.
10. The manner of repair of the equipment is determined by the
manufacturer.
11. The basis for repairs under the granted warranty is a correctly filled out,
complete Warranty Card that contains no amendments.
12. In all matters not regulated by these conditions, relevant regulations of
the Civil Code apply.
13. We recommend that you keep the Warranty Card throughout the life of
the exchanger.
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Energetyka Solarna Ensol Sp. z o.o.
47-400 Racibórz, ul. Piaskowa 11
16
Tel./fax: 0048 32 415 96 65
Version 02/12 OEM SOLAR ENSOL