PAW SolarBloC midi 2S Owner's manual

Installation and Operation Instructions
Solar stations
SolarBloC® midi Basic 3-line - DN 20
PAW GmbH & Co. KG
Böcklerstr. 11, 31789 Hameln, Germany
Phone: [phone], Fax: [phone]
E-mail: [email protected], Web: www.paw.eu
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Table of Contents
1 General Information...................................................................................................3
1.1 About these instructions............................................................................................3
1.2 About this product......................................................................................................3
1.3 Designated use........................................................................................................... 4
2 Safety instructions......................................................................................................5
3 Mounting and installation [specialist]...................................................................... 7
4 Commissioning [specialist]........................................................................................ 11
4.1 Flushing and filling the solar circuit..........................................................................12
4.2 Preparations before flushing.....................................................................................15
4.3 Flushing and filling.....................................................................................................16
4.4 Setting the solar installation..................................................................................... 21
5 Maintenance [specialist]............................................................................................ 22
5.1 Replacement / adjustment of the pressure gauge...................................................22
5.2 Draining the solar system.......................................................................................... 23
5.3 Deinstallation..............................................................................................................24
6 Scope of delivery [specialist]..................................................................................... 25
6.1 2-line station............................................................................................................... 25
6.2 1-line station............................................................................................................... 27
7 Technical data............................................................................................................. 29
7.1 Dimensional drawing SolarBloC® midi Basic 3-line - two-tank solution................ 30
7.2 Dimensional drawing SolarBloC® midi Basic 3-line - two-roof solution.................31
7.3 Pressure drop and pump characteristic curve..........................................................32
8 Function of the check valves [Expert]....................................................................... 33
9 Disposal....................................................................................................................... 35
10 Commissioning report................................................................................................36
11 Notes............................................................................................................................37
Table of Contents
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1 General Information
Carefully read these instructions before installation and commissioning.
Save these instructions in the vicinity of the installation for future reference.
1.1 About these instructions
These instructions describe the installation, commissioning, function and operation of the 3-line solar
station SolarBloC® for installations with two tanks (2S) or two roof solutions / two collectors (2D).
The chapters called [specialist] are intended for specialists only.
For other components of the solar installation, such as pumps, collectors, storage tanks, expansion
tanks and controllers, please observe the instructions of the corresponding manufacturer.
1.2 About this product
The station is a premounted group of fittings checked for tightness and used to circulate the solar
fluid in the solar circuit. It is mounted on wall brackets and fixed with clips.
The station contains important components and safety devices for the operation of the installation:
●Three ball valves in the flow line and in the return lines
●Three check valves (integrated in the ball valves)
●Three thermometers in the flow line and in the return lines
●Pressure gauge to display the installation pressure
●Two flow meters to display the flow rate
●Two ball valves to reduce the flow rate
●Solar pressure relief valve
●Airstop for an easy venting
●Flush and fill valves
1 General Information
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1.3 Designated use
The solar station may only be used in solar thermal systems as a pump station in the solar circuit,
taking into consideration the technical limit values indicated in these instructions. Due to its design,
the station must only be mounted and operated as described in these instructions!
Only use PAW accessories with the solar station. Improper usage excludes any liability claims.
2S: two-tank solution 2D: two-roof solution
Under the influence of solar radiation, the collectors will heat up considerably.
The solar fluid in the solar circuit may heat up to more than 100 °C.
Only flush and fill the solar circuit when the collector temperatures are
below 70 °C.
1 General Information
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2 Safety instructions
The installation and commissioning as well as the connection of electrical components require
technical knowledge commensurate with a recognised vocational qualification as a fitter for
plumbing, heating and air conditioning technology, or a profession requiring a comparable level of
knowledge [specialist].
The following must be observed during installation and commissioning:
●relevant local and national regulations
●accident prevention regulations of the professional association
●instructions and safety instructions mentioned in these instructions
WARNING
Danger of scalding due to the escape of hot fluids!
With pressure relief valves, there is a risk of scalding due to the escape of vapour or
hot fluid.
Please ensure for each pressure relief valve that no personal injury or material
damage may occur due to possibly escaping medium.
►Install a discharge line.
►Observe the instructions regarding the pressure relief valve.
►The pressures for the expansion tank calculated by the plant designer and
the operating pressure of the installation must be set.
CAUTION
Risk of burns!
The valves and fittings and the pumps can become heated up to more than 100 °C
during operation.
►The insulating shell must remain closed during operation.
2 Safety instructions
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CAUTION
Personal injury and material damage due to overpressure!
Closing both ball valves in the primary circuit will separate the safety group from the
heat exchanger. A rise in temperature in the storage tank may result in high
pressures, which may lead to personal injury and material damage!
►Only close the ball valves for service and maintenance.
NOTICE
Material damage due to mineral oils!
Mineral oil products cause lasting damage to seals made of EPDM, whereby the sealant properties
are lost. We do not assume liability nor provide warranty for damage to property resulting from
sealants damaged in this way.
►It is imperative to prevent the EPDM sealing elements from making contact with substances
containing mineral oils.
►Use a silicone- or polyalkylene-based lubricant free of mineral oil such as Unisilikon L250L
and Syntheso Glep 1 from Klüber or a silicone spray.
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3 Mounting and installation [specialist]
NOTICE
Material damage due to high temperatures!
Since the solar fluid near the collector can be very hot, the group of fittings must be installed at a
sufficient distance from the collector field. It may be necessary to install an intermediate tank in
order to protect the expansion tank.
Not included in the scope of delivery!
Accessories: compression fitting
1. Push the union nut ②and the cutting ring ③onto
the copper pipe ①. The pipe must protrude at least 3
mm from the cutting ring in order to ensure the force
transmission and the sealing.
2. Insert the support sleeve ④into the copper pipe.
3. Insert the copper pipe with the plugged-on individual
parts (②, ③and ④) as far as possible into the body of
the compression fitting ⑤.
4. First, screw the union nut ②manually.
5. Tighten the union nut ②by rotating one full turn.
Secure the body of the compression fitting ⑤against
distort in order to avoid damaging the sealing ring.
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1. Remove the station from the packaging.
2. Remove the insulating front shell.
3. Loosen the clip spring for the fixation the pump
line of the 2-line station (see illustration).
4. Remove the line from the insulating shell.
5. In addition, mount the enclosed valve, hose connector and plug depending on the two-tank
solution (2S) or two-roof solution (2D):
2S: valve + hose connector [3.2] at 3 / plug [1.3] at 1
2D: valve + hose connector [3.2] at 1 / plug [1.3] at 3
6. Fix the clip spring in the groove provided at the ball valve and mount the line in the insulating
shell.
7. Screw the connecting piece [6] - depending on the application 2S / 2D) onto the return
connections of the 2-line station and the 1-line station, see chapter 1.3:
2S: [6.1] at [1.1] and [6.2] at [7.1]
2D: [6.1] at [3.4] and [6.2] at [9.4]
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8. Copy the mounting holes next to the
thermometers of the solar station to the
mounting surface.
9. Drill the holes and mount the solar station to the
wall with suitable wall plugs and screws.
10. Connect the solar station to the installation by
using the pipes as follows:
Two-tank solution:
①Common return to the collector field
⑨Return from storage tank 2
③Return from storage tank 1
④Flow to storage tank 1 and 2
⑤Flow from the collector field
Two-roof solution:
⑤Common flow from the collector field
①Return to collector field 1
⑦Return to collector field 2
③Return from the storage tank
④Flow to the storage tank
All thread connections have ¾" internal threads.
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Not included in the scope of delivery!
11. Connect the pipe for the expansion tank to [7.4]
and fix the bracket for the expansion tank.
12. Adapt the initial pressure of the expansion tank
to the system and connect the expansion tank.
Observe the separate instructions for the
expansion tank!
13. Check all thread connections and tighten them
if necessary.
WARNING
Risk to life and limb due to electric shock!
►Prior to commencing electrical work on the controller, pull the mains plug!
►Only after completing all installation work as well as the flushing and filling,
the mains plug of the controller can be plugged into a socket. This avoids an
unintentional start of the motors.
14. Connect the pumps and the sensors to the
controller.
The assembly of the solar station is now completed and the station can be put into operation.
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4 Commissioning [specialist]
Please observe the following safety instructions regarding the commissioning of the station:
WARNING
Risk of burning and scalding!
The valves and fittings may heat up to more than 100 °C. Therefore, do not clean or
fill the system when the collectors are hot (intense sunshine). Please note that hot
solar fluid leaks from the pressure relief valves in case of too high system pressure!
During venting the solar fluid may escape as vapour and result in scalding!
►Flush and fill the system only when the collector temperatures are
below 70 °C.
NOTICE
Risk of frost!
It often happens that solar systems cannot be completely drained after flushing. Thus, there is a risk
of frost damage later on when flushing with water. Therefore, only use the solar fluid used later on
for flushing and filling the solar installation.
►Use a water/propylene glycol mixture with max. 50% of propylene glycol as solar fluid.
NOTICE
Note regarding the commissioning sequence
During commissioning, fill the heating circuit first and the solar circuit afterwards. This guarantees
that the heat possibly absorbed by the collectors during commissioning can be dissipated.
NOTICE
Note regarding the expansion tank
The expansion tank must not be connected while flushing and filling in order to prevent dirt
particles from being flushed in. Please observe the instructions of the manufacturer.
4 Commissioning [specialist]
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4.1 Flushing and filling the solar circuit
The fill and drain valves necessary to flush and fill the installation are integrated in the solar station.
Make sure not to wash dirt particles that may be present in the solar installation into the expansion
tank. To do so, it may be necessary to disconnect the expansion tank during flushing and filling and to
use only flushing and filling stations that are equipped with suitable microfilters.
Ball valve with integrated flow check valve
(normal flow direction in the figure: downwards)
Position 0°
Check valve is operating,
flow only in flow direction.
Position 45°
Check valve not operating,
flow in both directions.
Position 90°
Ball valve closed, no flow.
4 Commissioning [specialist]
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Functions of the fill and drain valve within the safety group
Position Function
Position "closed" (station in operation):
Fill and flush circuit is closed. Pressure gauge indicates system pressure.
Position "open" (fill and flush processes):
Fill and flush circuit is open. Pressure gauge indicates pressure.
Position "maintenance" (maintenance work):
Fill and flush circuit is closed. Pressure gauge indicates, after removal of
cap, no pressure.
Attention: Remove stop bolt before changing the position!
4 Commissioning [specialist]
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Airstop
The Airstop (vent valve with manual bleeder) is used to vent the solar system.
To ensure a perfect venting of the solar circuit, the flow velocity must be at least
0.3 m/s in the flow line.
Pipe diameter [mm] Flow rate at 0.3 m/s
∅outside ∅inside l/h l/min
15 13 ~ 143 ~ 2.4
18 16 ~ 217 ~ 3.6
22 20 ~ 339 ~ 5.7
28 25 ~ 530 ~ 8.8
WARNING
Danger of scalding due to escaping vapour!
The escaping medium can have a temperature of more than 100 °C and cause
scalding.
►Carefully open the vent plug and close it again, as soon as medium escapes.
The air separated from the solar fluid is collected in the upper part of the airstop and can be released
at the vent plug.
Venting the solar installation after commissioning
At the beginning, vent the solar installation daily and then weekly or monthly, depending on the
vented air quantity. Thus, an optimum operation of the solar installation is ensured. Check the system
pressure after venting and increase it to the prescribed operating pressure, if necessary.
4 Commissioning [specialist]
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4.2 Preparations before flushing
2-tank solution 2-roof solution
The solar circuit is flushed in the direction of flow.
1. Disconnect the expansion tank from the solar system. Observe the separate instructions for the
expansion tank!
2. Close the return ball valves [1.2|7.1] (90°, see chapter 4.1).
3. The ball valve in the flow line [5.2] and the ball valves in the flow meters [3.1|9.1] must be open.
4. Connect the fill station to the solar station:
- pressure hose to the fill valve [7.3]
- flush hose to the drain valve [9.2]
4 Commissioning [specialist]
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4.3 Flushing and filling
2-tank solution
2-roof solution
1. Open the fill and drain valves [7.3|9.2]. For this,
turn the valve [7.3] into position "open", see
chapter 4.1.
2. Put the flush and fill station into operation and
flush the installation until clear solar fluid exits.
Vent the solar installation several times at the
vent plug of the Airstop [4.2] until the solar fluid
exits without bubbles (see chapter 4.1.)
To vent the pump section, carry out the following
steps for the two-tank solution:
3. Slowly open the ball valve [7.1] in the return (see
chapter 4.1).
4. Switch off the pump of the flush and fill station
and close the drain valve [9.2].
5. Connect the flush hose to the drain valve of the
second storage tank circuit [3.2].
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6. Open the fill and drain valves [7.3|3.2] by turning the valve [7.3] to position "open", see
chapter 4.1.
7. Put the flush and fill station into operation and flush the installation until clear solar fluid exits.
Vent the solar installation several times at the vent plug of the Airstop [4.2] until the solar fluid
exits without bubbles, see chapter 4.1.
8. To vent the pump section, slowly open the return ball valve [1.2], see chapter 4.1.
Consider the pressure relief valve (6 bars)!
9. Close the drain valve [3.2] while the filling pump
is running and increase the system pressure to
about 5 bars. The system pressure is displayed
on the pressure gauge.
10. Check the pressure gauge to see whether the
system pressure reduces and eliminate leaks
where necessary.
11. Reduce the pressure at the drain valve [3.2] to
the operating pressure of the installation.
12. Connect the expansion tank to the solar circuit
and set the operating pressure of the solar
installation by means of the flush and fill station
(for the required operating pressure, see
instructions of the expansion tank).
13. Close the fill and drain valves [7.3|9.2|3.2].
14. Turn the check valves in the ball valves [1.2|5.2|
7.1] into operating position (0°, see chapter 4.1).
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To vent the pump section, carry out the following
steps for the two-roof solution:
3. Slowly open the ball valve [7.1] in the return (see
chapter 4.1).
4. Switch off the pump of the flush and fill station
and close the fill and drain valves [7.3|9.2]. During
this, turn the valve [7.3] in position "closed".
5. Connect the pressure hose of the fill valve [7.3] to
the fill valve [3.2] of the second collector circuit.
6. Open the fill and drain valves [3.2|9.2].
7. Put the flush and fill station into operation and
flush the installation until clear solar fluid exits.
Vent the solar installation several times at the
vent plug of the Airstop [4.2] until the solar fluid
exits without bubbles, see chapter 4.1.
8. To vent the pump section, slowly open the return
ball valve [1.2], see chapter 4.1.
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9. Close the drain valve [9.2] while the filling pump
is running and increase the system pressure to
about 5 bars. The system pressure is displayed
on the pressure gauge.
10. Check the pressure gauge to see whether the
system pressure reduces and eliminate leaks
where necessary.
11. Reduce the pressure at the drain valve [9.2] to
the operating pressure of the installation.
12. Connect the expansion tank to the solar circuit
and set the operating pressure of the solar
installation by means of the flush and fill station
(for the required operating pressure, see
instructions of the expansion tank).
13. Close the fill and drain valves [3.2|7.3|9.2] by
turning the valve [7.3] into position "closed".
14. Turn the check valves in the ball valves [1.2|5.2|
7.1] into operating position (0°, see chapter 4.1).
WARNING
Risk to life and limb due to electric shock!
►Check whether the sensors and pumps have been connected to the
controller and the controller housing is closed. Only then, the mains plug of
the controller can be plugged into a socket.
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15. Connect the (optional) controller to the mains and set the solar circuit pump in the manual
mode to Max. according to the controller instructions. Let the solar circuit pump run at
maximum rotation speed for at least 15 minutes.
In the meantime, vent the solar system several times at the vent plug of the airstop until the
solar fluid exits without forming bubbles (see chapter 4.1).
If necessary, increase the system pressure to the operating pressure.
16. Remove the hoses of the flush and fill station
and screw the sealing caps on the fill and drain
valves.
The closure caps are only for protection against
contamination. They are not designed for high
system pressures. Their tightness is ensured by
the closed ball valves.
4 Commissioning [specialist]
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