Grant GS222154E Release note

Grant Solar Pump Station
Installation & Servicing Instructions
Part No. DOC 96. Rev 02. October 2012

Important Note
2
Important Note
Important Note for Installers
The Pump Station supplied with your
Grant Solar Thermal system differs from
that shown in the Installation
Instructions supplied. This change is
part of our continued product
improvement process.
The information in these Solar Pump
Station Installation Instructions replaces
that given in Sections 13 and 14 of the
Grant Solar Thermal Systems
Installation Instructions (DOC 73.
Rev.02). Please read these Pump
Station instructions in conjunction with
the System Installation Instructions
supplied.
After commissioning, please leave
both the System Installation
Instructions and these Pump Station
Instructions with the user for future
reference.
GRANT ENGINEERING (UK) LIMITED
Hopton House, Hopton Industrial Estate, Devizes, Wiltshire SN10 2EU
Tel: [phone] Fax: [phone]
Email: [email protected] www.grantuk.com
This manual is accurate at the date of printing but will be superseded and should be disregarded if specifications and/or
appearances are changed in the interests of continued product improvement.
All good sold are subject to our official Conditions of Sale, a copy of which may be obtained on application.
© Grant Engineering (UK) Limited 2012. No part of this manual may be reproduced by any means without prior written consent.
Important:
All system pipe connections must
use compression fittings with
brass olives. Soft soldered joints
must NOT be used on the solar
primary circuit.
Plastic pipe must NOT be used for
any part of the solar primary circuit.

Contents
Contents
3
1Introduction 4
1.1 Description 4
2Technical Specifications 5
2.1 Specification 5
2.2 Pump Performance 5
2.3 Dimensions 6
2.4 Components 6
3Installation 7
3.1 General 7
3.2 Fitting Procedure 7
3.3 System Connections 8
3.4 Expansion Vessel 8
3.5 Safety Valve Discharge 9
3.6 Electrical Connection 9
4Commissioning 10
4.1 Expansion Vessel 10
4.2 Filling Valves 10
4.3 Gravity Brakes 11
4.4 Solar Fluid 11
4.5 Filling the System 12
4.6 Filling Procedure 12
4.7 Releasing Trapped Air 13
4.8 Setting the Flow Rate 13
5Fault Finding 14
5.1 No System Circulation 14
5.2 Pump not Operating 14
5.3 Loss of System Pressure 14
6Spare Parts 15

1Introduction
4
Introduction
1.1 Description
A two-line Solar Pump Station for the
circulation of glycol mix solar fluid
through Grant solar thermal systems.
All components are housed within an
insulated enclosure designed to be wall
mounted.
The pump station provides the following
functions:
• Filling and flushing connection
points
• Fluid flow rate regulation
• System pressure and temperature
readings
• Check valves (Gravity Brakes) for
anti-gravitation circulation
• Safety pressure relief valve and
discharge connection
• System expansion vessel
connection point
• Isolation valves for upper and lower
system levels and pump
bar
psi
MADE IN
ITALY
OFF
ON
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405421
OFF
ON
˚ C
Figure 1-1: Pump station with front cover removed
Flow - from Collectors
Return - to Collectors

2Technical Specifications
Technical
Specifications
5
2.1 Specification
Figure 2-1: Standard 6m head pump - performance curves
¾" BSP Female
6 bar - certified TUV to SV100 7.7 - Directive 97/23/CE
¾" BSP Female
0-10 bar
0-160° C
130°C
150°C
50%
WILO STAR ST 15-6 Eco. 3P connections, 1M-130mm
Class F, PN10, TF110, IP44, 2 µF, 230V 50Hz, VDE, CE
230-240V 50 Hz
Black PPE density 40kg/m³, plain
DN20. ¾" BSP Female connection, integral check valve
2 kPa (200mm w.g./ 20mbar)
Closure at 90° and opening at 45°
System pipe connections:
Safety valve:
Safety valve discharge connection:
Pressure gauge range:
Thermometer gauge range:
Maximum run temperatures:
Maximum peak temperatures:
Maximum glycol (%) in solar fluid:
Circulator:
Electrical supply:
Insulation:
Flow and Return valves:
Min pressure to open check valve:
Check valve activation:
0 0.5 1 1.5 2 2.5 3 3.5
6
5
4
3
2
1
0
Water flow (m3/h)
Head (m)
Figure 2-2: Optional 8m head pump - performance curves
0 0.5 1 1.5 2
8
7
6
5
4
3
2
1
0
Water flow (m3/h)
Head (m)
2.2 Pump Performance

2Technical Specifications
6
Technical
Specifications
bar
psi
312
430
130
38
75
50
100 102
25
50
160
Key No. Description
1 Flow valve (red knob) - ¾" BSP Female connection
2 Thermometer (0-160°C) – on flow valve
3 Wall bracket – with retaining clip and screw
4 Connection pipe - copper 18mm
5 Manual air vent – with hose connection
6 Air separator – with integral manual air vent
7 Filling hose connectors (x 2) – to fit filling/flushing
valve - 15mm dia x ¾" swivel nut
8 System connection - ¾" Female
9 System connection - ¾" Female
10 Filling return valve connection - ¾" BSP Male – with
safety cap and chain
11 Flow meter – range 2-12 l/min
12 Filling flow valve connection - ¾" BSP Male – with
safety cap and chain
13 Filling/shut-off valve
14 Circulator – Wilo STAR ST 15-6 – 6m head
15 Expansion vessel connection ¾" BSP Male – with
flat gasket connection
16 Pressure gauge (0-10bar)
17 Safety valve discharge connection
18 Safety valve (6 bar)
19 Return valve (blue knob) - ¾" BSP Female connection.
¾" BSP Male connection always open on right side
20 Thermometer (0-160°C) – on return valve
21 Insulated housing
1
21
2
3
4
5
6
7
8
18
17
16
15
14
13
12
11
10
9
20 19
2.3 Dimensions
2.4 Components
Plan view of pump station
Side view of pump station

Installation
7
3Installation
3.1 General
Installation of this pump station must be
carried out by a competent installer in
compliance with all current local
Building Regulations, codes of practice,
Health & Safety legislation and any
relevant bylaws and regulations in force
at the time.
All electrical installation work must be
carried out by a qualified electrician. All
wiring and bonding must comply with
current IEE wiring regulations (including
any amendments).
3.2 Fitting Procedure
1. Remove the front section of the
insulated pump station housing.
2. Undo screw and remove retaining
clip from wall bracket.
3. Lift out both the flow valve/air
separator assembly and the return
valve/pump assembly.
4. Position the back section of the
insulated housing in the required
location. If necessary check the
cover is level using a spirit level and
mark the two holes for the wall
bracket.
Note: The solar pump station MUST
only be installed vertically, as shown
in Figure 1-1.
5. Separate the wall bracket from the
back section of the housing. Drill the
wall with an 8mm drill and securely
fix the wall bracket to the wall using
the fixings supplied.
6. Fit the back section of the insulated
housing onto the wall bracket,
taking care to insert it completely.
Refer to Figure 3-1.
7. Re-fit the flow and return
assemblies, inserting the body of
the flow and return valves into the
corresponding fork in the wall
bracket. Refer to Figure 3-2.
8. Fit the retaining clip and secure
using the screw provided.
8. Connect the flow and return pipes.
Refer to figure 3-3.
Figure 3-1: Fit back section of housing onto wall bracket
Figure 3-2: Re-fitting flow and return assemblies to wall bracket
Wall bracket
Retaining clip
Insulated housing
back section

8
Installation
3.4 Expansion Vessel
The correct size of expansion vessel
should be used, based on the volume of
the system – i.e. the number of
collectors, the length and diameter of
the system pipework, etc.
For systems using up to 4 Grant solar
collectors, with no more than 50 metres
of 15mm pipework (total length of flow
and return combined), an 18 litre
expansion vessel is supplied as
standard. For 5 collectors a 24 litre
expansion vessel is used. For larger
system configurations, contact the
Grant Technical department for
guidance on the expansion vessel
required.
The expansion vessel is connected to
the pump station via the ¾” BSP
connection on the safety valve manifold,
using the 1250mm long flexible
corrugated stainless steel pipe. This
pipe is supplied with flanged ends, each
fitted with a ¾” union nut, and two
sealing washers (Grant Part No.
GS222074).
This flexible pipe cannot be cut and
must be used as supplied.
The expansion vessel is fixed to the wall
using the Vessel Mounting kit (Grant
Part No. GS222073). This kit includes
an isolation valve union and the vessel
mounting bracket.
Fix the mounting bracket to the wall,
using the screws and wall plugs
provided, to position the vessel in the
required location.
IMPORTANT
The expansion vessel must be
located BELOW the connection on
the pump station with the vessel
connection pointing upwards. See
Figure 3-3.
bar
psi
MADE IN
ITALY
OFF
ON
˚ C
405421
OFF
ON
˚ C
Figure 3-3: System connections to solar pump station
Solar expansion
vessel
Hot water cylinder
Solar
collectors
Safety (pressure relief)
valve fluid recovery
container
3.3 System Connections
3Installation
Note: This is a diagrammatic view
showing the connections to the
pump station. As such it does NOT
include all valves and controls and is
NOT intended as a complete system
diagram.
Important:
All system pipe connections must
use compression fittings with
brass olives. Soft soldered joints
must NOT be used on the solar
primary circuit.
Plastic pipe must NOT be used for
any part of the solar primary circuit.

Installation
9
3.5 Safety Valve Discharge
A discharge pipe must be fitted to the
outlet of the safety valve.
It is recommended that the safety valve
discharge should be connection to a
suitable discharge recovery tank, such
as the Grant safety valve liquid recovery
container with drain valve (Grant Part
No.GS550001).
This discharge pipe should be 15mm
copper.
IMPORTANT
Plastic pipe should NOT be used.
3.6 Electrical Connection
The pump requires a 230V 50Hz power
supply from the Solar Controller to
operate. Refer to the Installation
instructions provided with the Solar
Controller for further information on the
electrical control system wiring.
IMPORTANT
The electrical supply must be
isolated before making the
connections to the solar pump. After
making the connections ensure cover
is fitted to enclosure before
reconnecting the electrical supply.
The power supply should be connected
to the solar circulating pump (in the
pump station) as follows:
Insert the blade of a small flat
screwdriver into the retaining clip on the
side of the electrical enclosure on the
pump.
Carefully prise open the clip and pull the
cover upwards and remove from the
enclosure.
Slacken off the cable gland nut and feed
the electrical cable through the gland.
See Figure 3-5.
Prepare the cable – cut back the outer
sheath and strip the ends of the three
wires as required.
Fit the wires into the terminals by
pushing the black lever away from the
enclosure (to open the terminal). See
Figure 3-5.
Release the lever to secure the wire in
the terminal.
Fit the three wires into the terminals as
follows:
Live – terminal ‘L’
Neutral – terminal ‘N’
Earth – terminal ‘ ’
Tighten the cable gland to grip the cable
and re-fit the cover to the enclosure.
Reconnect the electrical supply to test the operation of the pump.
Assemble and fit the isolation valve
union as follows, referring to Figure 3-4:
• Fit the small black sealing washer
onto the threaded connection of the
bleed valve.
• Screw the bleed valve into the
threaded port in the side of the valve
union body and tighten.
• Remove the thin nut from the thread
on the valve union.
• Fit the threaded connection on the
expansion vessel up through the
hole in the mounting bracket and
secure using the thin nut.
• Using the sealing washer supplied,
fit the valve union to the expansion
vessel connection.
• Tighten the union nut to secure the
valve union in the required position.
Connect the flexible stainless steel pipe
to the safety valve manifold and
expansion vessel union valve, using the
sealing washers provided with the pipe.
Ensure that the expansion vessel
isolation valve is OPEN – this is
indicated when the two indicators (on
the square end of the valve) are in line
with the valve.
Ensure that the bleed valve is fully
CLOSED before filling the system.
Cable gland
Live terminal
Neutral terminal
Earth terminal
Terminal lever
Figure 3-5: Solar pump electrical
connections
Bleed valve
Flexible
stainless
steel pipe
Pipe union
nut
Isolating valve
Expansion
vessel
Union nut
Thin nut
Figure 3-4: Expansion vessel connection
Vessel
mounting
bracket

10
Commissioning
4Commissioning
4.1 Expansion Vessel
Ensure that the expansion vessel charge
pressure is correct for the system
pressure (when cold) and that this, in
turn, corresponds to the height of the
system. Refer to Table 4-1.
The height of the system should be
measured from the expansion vessel to
the top of the highest collector.
NOTE: If the collectors are positioned
below the level of the expansion vessel
(e.g. if the collectors are mounted at
ground level), then measure from the
bottom of the collectors to the
expansion vessel. This will be a
‘negative’ height value, e.g. –5 metres.
The vessel charge pressure must be
checked before filling the system.
4.2 Filling Valves
The Filling flow and return valves, and
the Filling/Shut off valve, are used for
filling and flushing the solar thermal
installation. Refer to Figure 4-1.
To enable filling/flushing of the system,
the Filling/Shut-off valve must be rotated
fully 90° clockwise. Refer to Figure 4-2.
This will divert the flow from the filling
station, entering the system via the
Filling flow valve, through the pump, up
to the collectors, through the coil of the
cylinder and back to the filling station via
the Filling return valve.
Height difference Initial expansion System charge pressure
(height of the collector vessel charge @20°C (0.2 – 0.5 bar
field minus height pressure (air charge greater than vessel
of expansion vessel) setting on valve) charge pressure)
- 5m ~ 1.0 bar ~ 1.3 bar
< 0m ~ 1.0 bar ~ 1.3 bar
< 5m ~ 1.5 bar ~ 1.8 bar
< 10m ~ 2.0 bar ~ 2.3 bar
< 15m ~ 2.5 bar ~ 2.8 bar
> 15m Contact Grant Technical Department for guidance
Figure 4-1: Filling and flushing valves
Filling/
shut-off
valve
Filling
flow
valve
Filling
return
valve
Table 4-1: Expansion vessel pressures
Figure 4-2: Closing Filling/Shut off valve
to prepare to fill system

Commissioning
11
4.3 Gravity Brakes
The gravity brakes (check valves) are
incorporated into both the flow and
return valve assemblies. These gravity
breaks operate at 20 mbar and are
operated by turning the valve handle on
the valves as follows:
Flow and Return valves OPEN – ‘ ’
markers on valve handles in
VERTICAL position
To prevent ‘gravity’ circulation of solar
fluid, gravity brakes must be in the
operating position (closed), i.e. with ‘ ’
markers in vertical position. See Figure
4-3.
Gravity Brakes OPEN – ‘ ’ markers
on valve handles at 45° angle
To fill or completely empty the solar
thermal installation, the gravity brakes
must be opened, i.e. by turning the
valve handles to the right to an angle of
45°. See Figure 4-4.
Flow and Return valves CLOSED – ‘ ’
markers on valve handles in
HORIZONTAL position
The flow and return valves are closed by
turning the valve handles 90° to the
right, i.e. until the ‘V’ markers are
horizontal. See Figure 4-5.
4.4 Solar Fluid
In order to prevent frost and corrosion
damage to solar collectors and
pipework, the system must only be filled
with a high quality solar fluid. The Grant
solar fluid is a ready mixed 40% solution
of 1,2 propylene glycol/water providing
frost protection down to approx. -23°C.
To prevent damage to the system the
same specification solar fluid should be
used when replacing or topping up the
solar fluid in the system.
If required, a copy of the Material Safety
Data Sheet for the Grant solar fluid is
available on request from Grant UK.
˚ C ˚ C
Figure 4-3: Flow and return valves open
˚
C
˚
C
Figure 4-4: Gravity breaks open
˚
C
˚
C
Figure 4-5: Flow and return valves closed

12
Commissioning
4Commissioning
4.5 Filling the System
Grant Solar Thermal systems should be
flushed and filled using a purpose
designed closed circuit solar thermal
filling station, incorporating a high
pressure pump, such as the Grant Solar
Filling Station. See Figure 4-6.
4.6 Filling Procedure
IMPORTANT
The collectors must be cool before
filling the system. They must be
covered, to stop solar radiation
reaching them, until the filling and
commissioning procedure is
completed.
Before filling the system: Check all
system connections and the expansion
vessel charge pressure. Refer to Table
4-1 (page 10).
Phase 1
• Connect the pressure hose from the
filling station to the Filling Flow valve
connection and open the valve.
Refer to Figure 4-1 (page 10).
• Connect the return hose from the
filling station to the Filling Return
valve connection and open the
valve. Refer to Figure 4-1 (page 10).
• Using a small spanner, rotate the
Filling/Shut-off valve 90° clockwise.
Refer to Figure 4-2 (page 10).
This will divert the flow from the
filling station through the pump, up
to the collectors, through the coil of
the cylinder and back to the filling
station via the filling return valve.
• Fill the filling station tank with
sufficient solar fluid for the system.
• Check that Flow and Return valves
are set to 'half open' position (to
open the gravity brakes) as shown
in Figure 4-4 (page11).
• Switch on the filling station to fill and
then flush the solar circuit for
approx.15 minutes.
Phase 2
• Whilst the filling pump is running,
close the Filling Return valve and
allow the system pressure to reach
around 4 - 5 bar.
• When the pressure reaches 5 bar,
close the Filling Flow valve and
immediately switch off the filling
pump.
• Check that the system pipework
and pump station are leak-free.
After leaving the system at about 5
bar for a minimum of 15 minutes,
check if the pressure gauge shows
any significant drop in pressure. If it
does, this points to a leak in the
system that must be traced and
rectified.
• Check the operation of pressure
relief valve by slowly rotating the
valve knob, lifting the valve, until
fluid is discharged. This should be
collected in a suitable container, e.g.
a pressure relief valve fluid recovery
container (as shown in Figure 3-3 on
page 8).
Phase 3
• Re-open the Filling/Shut-off valve by
turning 90° anti-clockwise.
• Switch on the circulating pump (by
setting the solar controller to
“manual”) to the highest pumping
speed and allow the solar fluid to
circulate for at least 15 minutes.
• Set the solar controller to “stand by”
(pump = OFF).
• Bleed the air separator using the
manual air vent until the solar fluid
begins to escape. Refer to section
4.7 (page 13).
• Set the operating pressure (as in
Table 4-1) by carefully opening the
Filling Return valve and releasing the
fluid back into the filling station tank.
Phase 4
• Reset Flow and Return valves to
fully open position. Refer to
Figure 4-3 (page 11).
• Switch on the circulating pump
(solar controller set to “manual”).
• Set the flow rate on the flow rate
indicator (refer to section 4.8) by
selecting the appropriate pump
speed and by using the Filling/Shut-
off valve.
• Remove the filling station hoses
from the filling connections and
screw the caps on both valves.
Release the Filling Return valve first
and then the Filling Flow valve.
• Switch the solar controller to
automatic operation and remove
covers from the collectors.
Figure 4-6: Grant Solar Filling Station
If the pump station is located in the
roof space, there must be a suitable
flat surface on which to stand the
filling station, e.g. floor, loft boarding
or similar, capable of carrying the
weight of the filling station with a full
tank of solar fluid.
!WARNING

Commissioning
13
4.7 Releasing Trapped Air
The residual air from the heat transfer
fluid is collected in the air separator and
manually released via the air vent. There
is no need to use an automatic air vent
elsewhere on the solar primary circuit,
e.g. at high level.
To release any air collected in the air
separator, push a plastic tube on to the
manual air vent outlet and catch the
fluid that is released in a suitable
container. Open the manual air vent until
all air has been vented, i.e. a steady
stream of solar fluid is flowing from the
air vent.
4.8 Setting the Flow Rate
The setting of the solar fluid flow rate is
made via the speed setting of the
circulating pump and the Filling/Shut-off
valve. For required system flow rates
refer to Table 4-2.
The flow indicator displays the fluid flow
rate. The display range is between 1
and 13 litres per minute. See Figure 4-8.
Venting air from the system should
only be carried out only by a
competent installer. Frequent venting
leads to system pressure loss and
disruption to the system operation.
!CAUTION Danger of scalding!
The temperature of both the
escaping air and the solar fluid can
exceed 100°C.
!CAUTION
MADE IN
ITALY
Figure 4-7: Air separator and air vent
Figure 4-8: Flow rate indicator
Table 4-2: System volume flow rates
Manual air vent
Air separator
For larger installations, please
contact Grant Technical Department
for assistance.
!NOTE
Read flow rate from
bottom edge of bobbin
1 to 5 6 8 9 12
Up to 5 in series 2 x 3 in parallel 2 x 4 in parallel 3 x 3 in parallel 4 x 3 in parallel
15mm 22mm 22mm 22mm 22mm
2-3 l/ min 4-5 l/ min 4-5 l/ min 6-8 l/ min 6-8 l/ min
Number of solar panels
Type of connection
Flow and return pipe diameter
Minimum volume flow rate

5Fault Finding
14
Fault Finding
In the event of a problem occurring
with your Grant Solar Thermal
system, follow the information given
below in order to identify and rectify
the matter:
5.1 No System Circulation
Check for the following:
• Pump is not operating (see 5.2
below).
• If pump is noisy, there may be air in
the system.
• Pump may be air locked and needs
venting. Turn off power, remove
central screw on pump motor to
vent.
• Valves are closed – ensure that
Flow, Return and Filling/Shut off
valves are all fully open.
Refer to Fig 4-3 on page 11.
5.2 Pump not Operating
Check for the following:
• No electrical supply to pump.
•Controller is not calling for pump
to operate (see below).
•Check power supply to controls
(at fused spur).
•Check wiring to controller and
pump is correct.
•Check for any loose connections.
• Controller is not calling for pump to
operate.
•Check controller settings and
correct as necessary (see
Instructions supplied with the
Solar Controller).
•Collectors may be in stagnation
mode – wait for system to cool
down.
•Collector temperature may be too
low (insufficient solar radiation).
•Cylinder temperature setting may
be satisfied.
• Pump is stuck - Turn off power,
remove central screw on pump
motor and rotate motor using a
screwdriver.
• Motor capacitor failed – replace
capacitor or pump motor.
5.3 Loss of System Pressure
(on pressure gauge)
Check for the following:
• Leaks on system – find and rectify
as necessary.
• Expansion vessel pre-charge lost –
check and re-charge vessel as
necessary.
• Pressure relief valve discharging fluid
– check and rectify/replace valve.

6Spare Parts
Spare Parts
15
01
Key No. Description Part No.
01 Flow valve assembly (Red) GSE01
02 Return valve assembly (Blue) GSE02
03 Safety valve assembly (6 bar) GSE03
04 Pressure gauge GSE04
05 Solar circulator (6 metre) GSE05
06 Solar circulator (8 metre) GSE06
07 Air separator assembly GSE07
08 Fill/flush valve and flow regulator assembly GSE08
bar
psi
MADE IN
ITALY
OFF
ON
˚ C
405421
OFF
ON
˚ C
07
05/06
02
03
04
08

GRANT ENGINEERING (UK) LTD
Hopton House, Hopton Industrial Estate, Devizes, Wiltshire. SN10 2EU
Telephone: [phone] Fax: [phone]
Email: [email protected] Website: www.grantuk.com