En Ensol - Installation Manual Water Heater 2 Heat Exchanger

HOT TAP WATER EXCHANGERS
ENSOL/2

200l 250l
300l 400l
500l 750l
1000l

INSTALLATION AND OPERATION
MANUAL
WARRANTY CARD

Version 01/13 ENSOL/2
2

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

3

1. Structure and Intended Use

ENSOL/2 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.
ENSOL/2 200-350 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.
The outer casing of exchangers is made of plastic or artificial leather like
fabric.
ENSOL/2 exchangers are designed for installation of an electric heating
element on the 1" plug, especially EJK type heating element produced by
ZUG ELEKTROMET with insulated heating units (Tab. 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, 2 and 3.

ENSOL/2 200 ENSOL/2 250 - 500

Fig. 1. Structure and dimensions of ENSOL/2 200- 500 exchangers

4
Tab. 1 Dimensions of ENSOL/2 200-500 exchangers

ENSOL/2 Type
200 250 300 400 500
Capacity [dm] 207 247 302 400 500
insulation PS - - - 1880 2180 Height
insulation PUR
H [mm]
1380 1580 1880 - -
insulation PS - - - 2050 2330 Max. height
when tilted insulation PUR
H* [mm]
1520 1700 1985 - -
insulation PS - - - 810 810 Diameter
insulation PUR
D [mm]
630 630 630 - -
Diameter without the thermal
insulation
D* [mm]
550 550 550 650 650
A [mm] 360 250 250 360 355 Cold tap water
ZW 1 1
Hot tap water I [mm] 1080 1270 1570 1500 1735
CW 1 1
P [mm] 990 1100 1320 1410 1635 Heating water supply
upper coil WEG 1 1 1 1 1
O [mm] 750 860 1000 1090 1225 Heating water return
upper coil WYG 1 1 1 1 1
E [mm] 640 720 810 910 1000 Heating water supply
bottom coil (solar) WED 1 1 1 1 1
B [mm] 270 350 350 450 460 Heating water return
bottom coil (solar) WYD 1 1 1 1 1
F [mm] 690 790 900 1000 1085 Circulation
RC
C [mm] 470 510 540 630 635
G [mm] 890 1000 1170 1280 1415
Temperature sensor sleeve

CT
K [mm] 800 895 1030 1140 1245 Heater coupling
MG 1 1 1 1 1
L [mm] 1020 1110 1340 1475 1705 Thermometer coupling
RT
N [mm] 325 325 325 455 455
K [mm] 800 895 1030 1140 1245
Temperature sensor sleeve -
closed
RK
x L [mm] 40 x 330 40 x 330 40 x 390 40 x 430 40 x 500 Magnesium anode
AN 2 2 2 2 2
W 2 2 2 130 130 Cleaning hatch
M [mm] 310 310 310 430 430
S [mm] 100 100 100 130 130 Drain
ZS
5
Tab. 2 Technical parameters of ENSOL/2 200-500 exchangers

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

ENSOL/2

Type

200 250 300
Tank capacity
dm
207 247 302
bottom upper bottom upper bottom upper
Exchanger surface

m
2
1.1 0.8 1.1 0.8 1.4 1.0
Coil capacity dm 6,4 4.3 6,4 4.3 8.0 5.7
Hot tap water capacity
80/10/45
0
C
70/10/45
0
C
60/10/45
0
C

dm/h

629
526
378

442
368
270

629
526
378

442
368
270

826
727
506

595
504
361
Heating power
80/10/45
0
C
70/10/45
0
C
60/10/45
0
C

kW

25,6
21,4
15,4

18
15
11

25,6
21,4
15,4

18
15
11

33,6
29,6
20,6

24,2
20,5
14,7
80/10/60
0
C
70/10/60
0
C

dm/h

354
227

264
198

354
227

264
198

450
279

326
206
Heating power
80/10/60
0
C
70/10/60
0
C

kW

20,6
13,2

15,4
11,5

20,6
13,2

15,4
11,5

26,2
16,2

19
12
Heating water flow in
the coil
m/h 1.8 1.4 1,8 1.4 2.2 1.7
Pressure loss mbar 40 25 40 25 70 35
Daily readiness loss kWh/24h 3.1 3.2 3.4
Tank operation
parameters
Maximum pressure and operating temperature
pr = 0,6 MPa ot = 80C
Heating medium
parameters
pr = 0.6 MPa ot = 100C
Type of tank steel tank coated inside with vitreous enamel
Type of outer casing
plate-like coating made of plastic or artificial leather
Thermal insulation 60 mm foam polyurethane
Heater weight in the
casing
kg 85 105 130
6


ENSOL/2

Type
400 500
Usable capacity of the
tank

dm
400 500
bottom upper bottom upper
Exchanger surface

m
2
1.6 1.1 1,9 1.4
Coil capacity dm 9.5 6.3 10,7 8,0
80/10/45
0
C
70/10/45
0
C
60/10/45
0
C

dm/h

948
826
600

629
526
378

1143
980
700

826
727
506
Heating power
80/10/45
0
C
70/10/45
0
C
60/10/45
0
C

kW

38,6
33,6
24,4

25,6
21,4
15,4

46,5
39,9
28,5

33,6
29,6
20,6
80/10/60
0
C
70/10/60
0
C

dm/h

523
330

354
227

621
392

450
279
Heating power
80/10/60
0
C
70/10/60
0
C

kW

30,4
19,2

20,6
13,2

36,1
22,8

26,2
16,2
Heating water flow in
the coil
m/h 2.9 2.2 3.1 2.2
Pressure loss mbar 110 40 130 70
Daily readiness loss kWh/24h 4.0 4.5
Tank operation
parameters
pr = 0,6 MPa ot = 80C
Heating medium
parameters
pr = 0.6 MPa ot = 100C
Type of outer casing plate-like coating made of plastic or artificial
leather
Thermal insulation 100 mm expanded polystyrene
casing
kg ca. 210 ca. 235
7

Structure of exchangers ENSOL/2 750 and ENSOL/2 1000

Fig. 2 Structure of exchangers 750 l.

Fig. 3 Structure of exchangers 1000 l

1 tank
2 thermal insulation (10 cm foam
polyurethane)

3 outer casing
4 sling
5 cleaning hatch 130
6 magnesium anode 1 1/4
7 cold utility water - inlet 1 1/4
8 hot utility water - outlet 1 1/4
9 circulation 3/4
10 drain 1
11 heating element - sleeve
1 1/2
12 coil pipe 1
13 Temperature sensor sleeve -
closed 1/2 x 200
14 feeding with heating water
-inlet 1
15 return heating water -outlet 1
1 tank
2 thermal insulation (8 cm foam
polyurethane)
3 outer casing
4 sling
5 cleaning hatch 130
6 magnesium anode 1 1/4
7 cold utility water - inlet 1 1/4
8 hot utility water - outlet 1 1/4
9 circulation 1
10 drain 1
11 heating element - sleeve
1 1/2
12 coil pipe 1
open 1/2
closed 1/2 x 200
15 feeding with heating water
-inlet 1
16 return heating water -outlet 1
8
Dimensions of exchangers ENSOL/2 750 and 1000 l

Fig. 4 Dimensions of exchangers 750 l.

Fig. 5 Dimensions of exchangers 1000 l.

9
Tab. 3 Technical parameters of ENSOL/2 750 and 1000 exchangers


Accessories:
- safety valve with the opening pressure: 0.6 MPa

ENSOL/2

Type
750 1000
Usable capacity of the
tank

dm
750 1000
bottom upper bottom upper
Exchanger surface

m
2
2,5 1,6 2,8 1,8
Coil capacity dm 14,5 8,7 16,0 10,5
80/10/45
0
C
70/10/45
0
C
60/10/45
0
C

dm/h

1490
1285
860

948
826
600

1720
1400
983

1081
934
688
Heating power
80/10/45
0
C
70/10/45
0
C
60/10/45
0
C

kW

60,7
50,4
35

38,6
33,6
24,4

70,0
57,0
40,0

44,0
38,0
28,0
80/10/60
0
C
70/10/60
0
C

dm/h

882
646

523
330

911
585

585
378
Heating power
80/10/60
0
C
70/10/60
0
C

kW

51,3
37,6

30,4
19,2

53,0
34,0

34,0
22,0
Heating water flow in the
coil
m/h 3,5 2,7 5,0 3,0
Tank operation
parameters
pr = 0,6 MPa ot = 80C
Heating medium
parameters
pr = 0.6 MPa ot = 100C
Type of outer casing
plate-like coating made of plastic or artificial leather
Thermal insulation 100 mm foam polyurethane
80 mm foam
polyurethane
Diameter w/o thermal
insulation
mm 790 912
Height w/o thermal
insulation
mm ok. 1910 ok. 1980
Max. height at tilted
position
mm ok. 2220 ok. 2300
Magnesium anode ( 2 pc) mm 33 x 680 33 x 680
casing
kg ca. 330 ca. 460
10

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

Heaters may only be used with a functional safety valve with the opening
pressure of 0.6 MPa (water pressure in the water supply network up to 0.6
MPa) installed on the cold tap water inlet. This valve protects the
exchanger from excessive pressure in the water supply network or
excessive pressure increase as a result of heating the water in the tank.
Even in case of regular operation of the exchanger during heating, water
may leak from the safety valve for a short time, which shows that the valve
operates in a correct manner. Never obstruct the outlet hole in such cases.
All types of exchangers should be used with an installed thermometer of
the measuring range between 0 and 120C, whereas on exchangers with
the capacity exceeding 250 l, also install pressure gauges with the
measuring range between 0 and 1 MPa.

3. Installation

3.1 Exchanger connection to the water supply network,
central heating system and solar collector.
Connect the exchanger vertically to the water supply network in which the
pressure does not exceed 0.6 MPa and not lower than 0.1 MPa. If the
pressure in the network often exceeds 0.4 MPa, it is recommended to
install a pressure reducing valve or a diaphragm reservoir before the
exchanger in order to limit the inconvenient outflow of water from the safety
valve. When the pressure in the water supply network exceeds 0.6 MPa, it
is necessary to install the pressure reducing valve in order to avoid the
continuous outflow of water from the safety valve.
ATTENTION!
1. A safety valve has to be installed on the cold water inlet to the
exchanger; the valve is supplied with the exchanger. Install it so that the
arrowhead on the valve body is in line with the direction of the water
flow.
2. Do not install any shut-off valves between the safety valve and the
exchanger.
3. It is not permitted to use the tank without a safety valve or with a
malfunctioning safety valve because
the situation may result in failure and poses a threat to human life and
health.
Installation and any repairs of the exchanger in terms of electricity
and water system should be entrusted only to skilled processionals
with relevant permissions.
11
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
ENSOL/2 exchanger. EJK type heating elements by ZUG ELEKTROMET
comply with this condition.
Among EJK heating elements manufactured by ZUG ELEKTROMET for
ENSOL/2 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, 6.0 and 9.0 kW
heating elements.
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. 4.

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

Fig. 4 Earth of the heating element

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

ATTENTION! Do not insert the plug of the connection into the
electrical socket without making sure that the tank is filled
with water.
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.
12
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.

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! 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.
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.
13
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 6 to 14, or by e-mail:
sekretariat@ensol.pl 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.

14

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16

17

18

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

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