WIKORA WPKR 750, WPKR 1000 Installation Manual Operating Instructions

WIKORA GmbH

Friedrichstr. 9

89568 Hermaringen

Phone: (07322) 9605-0

Fax: (07322) 9605-30

email: contact@wikora.de

Installation manual Operating instructions

Solar combi buffer tank tank-in-tank

WPKR 750 - 1000

Installation and commissioning must be undertaken by a specialist.

General terms and conditions of warranty state that all installations must be carried out by a suitably trained and qualified plumber who observes the local norms and regulations.

The installation and maintenance record must be entirely completed and the user has to be instructed accordingly.

Efficient operation can only be guaranteed if the instructions of this manual are followed. Warranty does not cover any damage caused due to non-observance of this manual and the technical rules in force. The system is to be checked annually by a specialized company. In addition, occurring defects must be repaired immediately.

This document should be handed over to the client on completion of the installation.

.

Index

1 General ............................................................................................................................................................................. 2

2 Transport and installation .................................................................................................................................................. 2

3 Dimensions and connections ............................................................................................................................................. 3

4 Technical data ................................................................................................................................................................... 4

5 Installation ......................................................................................................................................................................... 5

6 Commissioning .................................................................................................................................................................. 6

7 Maintenance and wear parts................................................................ .............................................................................. 6

8 Warranties and guarantee ................................................................................................................................................. 7

9 Installation record .............................................................................................................................................................. 9

1 General

Depending on the type and design, WIKORA tanks are suitable for heating and / or storing DHW and / or heating water. The heating is achieved indirectly via heat generators, if applicable, from different heat sources. The maximum working pressure and working temperature can be found in the technical data.

Set-up, installation and commissioning must be undertaken by a qualified specialist, who must observe these instructions.

The site of installation must be frost-protected according to DIN 4753 and should be in direct proximity to the heat generator.

When setting-up and installing the tank, the following regulations should be considered: In addition to the technical rules in force DIN 1988, DIN 18160, DIN 4753, DIN 4109, DIN 4708, DIN 4751 section 2-4 energy conservation law and VDE regulations are to be observed. Moreover, the relevant regulations of the suppliers as well as legal building regulations are to be considered.

DHW requirements:

 Minimum hardness:

- 2° dh (sum of alkaline earths 0,4 mmol/l)

 Conductivity

- if external current anode is used ≥ 100 µs/cm

- if Mg-anode is used 130 µs/cm – 1500 µs/cm

 pH-value according to Drinking Water Ordinance (6,5-9,5) Important: The exhaust pipe must be at least as big as the safety valve outlet in width. It may not have more than 2 bends and

should not be longer than 2 m. If for any compelling reasons 3 bends or a length up to 4 m are required, then the entire exhaust line must be designed one nominal size larger. More than 3 bends, or a length exceeding 4 m is prohibited. The exhaust pipe must be installed with downward gradient. The drain line behind the funnel must feature at least the double width of the valve entrance. A sign is to be attached close to the exhaust pipe of the safety valve or on the safety valve itself. „For safety reasons water may leak from the exhaust pipe during the heating process! Do not lock! "The operability of the safety valve is to be checked at regular intervals by means of de-ventilation.

2 Transport and installation

In order to prevent damage during transport, the packaging should only be removed at the site of installation. During shipment, it should be ensured that the tank does not come in contact with any spiky or sharp items, nor is damaged through dropping or knocks. During installation, the tank must be disconnected from any humidity carrying components. Moreover, sufficient space for maintenance and cleaning purposes should be kept free in front of, beside, above and behind the tank.

Please note that the insulation provided should be kept in a dry place at least 24 hours at a minimum temperature of 20°C before installation.

3 Dimensions and connections

Illustration1

Dimensions:

Type

 d

 D

H

K

L

(L)

M N R S T U V W X1

X2

X3

[mm]

mm

[mm]

mm

[mm]

mm

[mm]

WPKR 750

750

950

2000

1610

280

(1150)

865

280

620

1610

280

1370

930

1950

1550

1195

280

WPKR 1000

850

1050

1990

1590

280

(1150)

865

280

580

1590

280

1350

950

1950

1530

1195

280

Chart 1

W = Tilting dimension

Connections:

Type

WPKR

750

WPKR

1000

Cold water / hot water

1/2

Ga ¾ ¾

Circulation

3

Ga ¾ ¾

Aux boiler flow / return

4/5

Ga

5/4

Solar flow / return

6/7

Gi 1 1

Load flow / return

8/9

Ga

5/4

Heating flow / return

10/11

Ga

5/4

Plug for electric heater

12

Gi

6/4

Vent

13

Gi

1/8

Inspection flange

14

NW

142

Sensor socket

15

Gi ½ ½

Anode

19

Gi ¾ ¾

Chart 2

Ga = male thread

Gi = female thread

4 Technical data

Description

WPKR 750

WPKR 1000

Capacity heating buffer / DHW

[litre]

ca. 527 / 200

ca. 725 / 200

Max. working temperature buffer / DHW / heat exchanger

[°C]

95 / 95 / 160

Max. working pressure buffer / DHW / heat exchanger

[bar]

3 / 10 / 10

Capacity of heat exchanger

[litre]

23

25

Heating area DHW tank

[m²]

2,0

Surface of heat exchanger

[m²]

2,7

3,0

Flow rate of heat exchanger

[m³/h]

5,0

Pressure drop of heat exchanger

[mbar]

340

380

Insulation

100 mm fleece insulation

Energy loss

[kWh/24h]

3,9

4,4

Nominal Load N

L

(according to DIN 4708)

ca. 2,9

Weight (empty)

[kg]

ca. 240

ca. 280

Chart 3

5 Installation

All pipes connecting to the tank should have removable connections (fitting/flange). Pipe thread seals with teflon are to be avoided.

All tank connecting pipes are to be planned, constructed and tested according to the technical rules in force, as well as to the corresponding norms and regulations in accordance with their application and supply medium.

Appropriate filters should be used to prevent dirt or particles from entering the tanks. Moreover, the tank should be ensured against pressure fluctuations and excess pressure through the installation of tested pressure reducing valves and safety valves. Sensors and thermostats necessary for temperature control must be securely and permanently positioned on the tank (immersion sleeve and sensor rail).

The tank’s venting and draining facilities must have the appropriate dimensions and be correctly installed. The installation company is responsible for the correct execution of work and for the safe and careful insulation of the pipes.

 When connecting to a solar plant, a temperature limiter is required and must be installed on site at the hot water outlet

in order to prevent scalding.

Safety valve

Drain pipe

Safety group according to DIN 1988

Stop valve

Manometer connection

Backflow preventer

Test valve

Pressure reducing valve

HW Circulation CW

Drain

Water plug

Connection Scheme

Hotwater-

mixer

Anode

Sensorsocket

Illustration 2 (Schematic diagram)

The size of the DHW safety valve is shown below:

Content of DHW space

Min. valve size

Max. heating performance

up to 200 l

NW 15 (1/2“)

75 kW

above 200 to 1000 l

NW 20 (3/4“)

150 kW

When installing a circulation pipe, the plug in the flange cover must be replaced by a circulation connection attachment (plastic immersion pipe with double nipple R ¾”, Wikora part number 096 090).

The thread diameter of the heating safety valve depends on the nominal capacity of the water space and the maximum heating capacity of the heat generator. It can be determined as follows:

Reaction pressure

Max. heating capacity of the heat generator

1,5 bar

36 kW

72 kW

144 kW

252 kW

433 kW

650 kW

2,0 bar

43 kW

86 kW

172 kW

302 kW

518 kW

778 kW

2,5 bar

50 kW

100 kW

200 kW

350 kW

600 kW

900 kW

3,0 bar

56 kW

112 kW

224 kW

395 kW

678 kW

1017 kW

Thread diameter (inch)

1/2 ¾ 1

5/4

6/4

2

Illustration 3 (Schematic drawing– example hydraulic system heating)

6 Commissioning

 Before putting into operation, the entire system should be flushed through. Particles in the system compromise the

operating reliability.

 When filling the system, fill the DHW tank first and put pressure on it. Open the cold water stop valve and all hot

water nozzles. The tank is full when water leaks out of all hot water nozzles. Then close all nozzles again.

 Fill the heating system slowly with water and vent all the air.  Start-up the heating system.  Set the DHW temperature and supervise the system while heating up.  While the System is heating up, water will leak out of the safety valve.  After the tank has heated up and cooled down for the first time, the flange screws must be retightened by

means of a set torque wrench and the flange connection should be checked for tightness. Torque chart

External diameter of flange/ Diameter of pitch circle

Torque Nm

170 / 145 mm

32 Nm

180 / 150 mm

32 Nm

210 / 180 mm

40 Nm

280 / 245 mm

70 Nm

 Before the handover of the system to the end user/owner, the plumbing contractor should ensure that the

system is tested to full load, controls are set and that pipe work and connections are without leaks. Afterwards,

the end user has to be instructed in the operation and handling of the tank, as well as the system. The instruction must to be documented in the installation and maintenance record.,

 Please note that the operation and lifetime of the system depend decisively on a regular maintenance.

7 Maintenance and wear parts

Regular maintenance increases the lifetime and operation reliability of the system. Decalcification at regular intervals may be necessary in highly calcareous water areas.

1 . Close the cold water stop valve and drain the tank to check the inner tank as well as the heat exchanger. Disconnect any

electrical devices from the appliance. Then, carefully remove the insulation of the flange cover and unscrew the flange cover. Limescale and rough residues can be crushed by a wooden bar. Only use an approved decalcifier. Screw the flange cover hermetically after the cleaning process by using a new flange seal. Fill the tank and check all connections for tightness. Finally, replace the insulation and, if necessary, remount the electrical devices accordingly.

A chemical decalcification can be carried out by a specialist using an approved decalcifier and taking the appropriate precautions. Please note that the tank must be disconnected from the DHW installation (cold water / hot water / circulation).

2. For protection purposes, the tank is equipped with a magnesium protection anode. Its transmission depends on the local water properties. It should be examined for the first time after 2 years and afterwards annually in order to check its transmission. The diameter should be at least 1/3 of the original diameter, the surface should be homogenous and without any limescale crust. If necessary, it should be replaced by an original Wikora anode to protect the tank against corrosion.

2.a. Alternatively, the tanks can be equipped with an external current anode. Please note that a protection against corrosion is only guaranteed if the anode is energized and connected accordingly.

If the protection anode is neglected, this can cause damage through corrosion and lead to a loss of warranty.

3. The safety valve protects the tank against excess pressure. The functional capacity must be checked at regular intervals by venting. If an expansion vessel is used, the safety valve is not, or only rarely, required. Over a longer period of time therefore, it can become blocked and not function when needed.

4. If there is a danger of freezing, the DHW tank should be permanently heated or completely emptied.

5. A damp cloth is sufficient to clean the outer parts. Please avoid using any abrasive or solvent cleaning agents.

8 Warranties and guarantee

The warranty for our products is based on the legal provisions of the general Civil Code and the Consumer Protection Act. In addition, defective appliances are replaced within the framework of our full warranty within 1 year, as of the date of the

invoice, including the replacement, procurement and incidental costs. As far as our hot-water heaters and pressurized boilers are concerned, the warranty amounts for 6 months, as of the date of the invoice.

Subsequent to the full warranty, defective tanks are replaced within the framework of our guarantee. The guarantee of the different products and the conditions are shown in the table below.

All other claims are excluded. Repairs and costs which occur due to damage, inappropriate installation, chemical, electrochemical or electrical influences, incorrect operation or improper manipulation, are excluded. Furthermore, the warranty becomes invalid if th eappliance has been modified through the installation of externally supplied parts or through irregular professional maintenance.

Subject to our general terms and conditions.

Legal

warranty

2 years

Guarantee

years*

Conditions

WBO T/ToF ● 5 20 / 27 WBL ● 5 20 / 27 WBO Uno ● 5 20 / 27 WBO Duo ● 5 20 / 27 WP/Sol ● 5 20 / 27 WBO H ● 5 20 / 27 GS ● 5 20 / 27

Wikosol Twin ● 10 27 Wikosol ● 10 27 WPKR H Twin ● 5 20 / 27 WPKR Twin ● 5 20 / 27 WPKR ● 5 20 / 27 WPK ● 5 20 / 27 WPH-FW (tank) ● 5 27 WPR-FW (tank) ● 5 27

WPS ● 5 20 / 27 WPH ● 5 WPR ● 5 WPRR ● 5 WKS ● 5 -

Cu-finned tube heat exchanger ● - 27 Electric heating element ● - -

Conditions:

20

27

Coverage Germany: Compliance with the limits of the valid DHW regulations(TrinkwV 2001), especially the limits in accordance with Appendix 2, Part 1-2 and Appendix 3 Coverage EU : Compliance with the limits of the EG-Regulations 83/98

* Start of guarantee at date of invoice

Products

DHW storage tanks

Combi buffer tanks

Buffer tanks

Tank accessories

Under condition that the limits of the valid DHW regulations have been respected, the anode has been examined for the first time after 2 years and afterwards annually and that the anode has been replaced by an original Wikora anode (individual receipts needed) by a specialized company.

9 Installation record

The installation has been completed according to DIN and the technical rules in force. In addition, the customer has received instruction concerning the operation and maintenance.

Place……………………………………………….. Date…………………………………………………………

Customer Installer

……………………………………………………. ………………………………………………………………. Signature Signature

Place of installation: ………………………………………………………………………………………………………………………

Name: ……………………………………………………………………………………………………………………...

ZIP Code/Place: …………………………………………………..………………………………………………………………….

Street: ……………………………………………………………………...………………………………………………

Phone: ……………………………………………………………………………...……………………………………...

Tank model: ………………………………. Serial number …………….………………..………………

Date of invoice ………………………………………………………...…………………………………………………………..

Anode maintenance record

Date

Visual examination of

anode

Exchange of

anode

Signature + stamp of installer

In the case of reclamation, the receipts for maintenance must be provided as proof. Please complete the data sheet, including the reason for reclamation, and submit to Wikora.

Submitting the maintenance record does not ensure any promise of guarantee or claim.

WIKORA WPKR 750, WPKR 1000 Installation Manual Operating Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual