PAW SolarBloC mega Owner's manual

Installation and Operation Instructions
Solar Station
SolarBloC® mega - DN 32
PAW GmbH & Co. KG
Böcklerstraße 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]........................................................................................ 10
4.1 Flushing and filling the solar circuit..........................................................................11
4.2 Preparations before flushing.....................................................................................13
4.3 Flushing and filling.....................................................................................................14
4.4 Adjustment of the solar installation......................................................................... 15
5 Maintenance [specialist]............................................................................................ 16
5.1 Replacement / adjustment of the pressure gauge...................................................16
5.2 Draining the solar system.......................................................................................... 17
5.3 Deinstallation..............................................................................................................18
6 Scope of delivery [specialist]..................................................................................... 19
7 Technical data............................................................................................................. 21
7.1 Dimensional drawing................................................................................................. 22
7.2 Pressure drop and pump characteristic curves SolarBloC® mega.......................... 22
8 Function of the check valves [Expert]....................................................................... 23
9 Disposal....................................................................................................................... 25
10 Commissioning report................................................................................................26
11 Notes............................................................................................................................27
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 solar
station SolarBloC® mega. For other components of the solar system, such as collectors, tanks,
expansion tanks and controllers, please observe the instructions of the corresponding manufacturer.
The chapters called [specialist] are intended for specialists only.
1.2 About this product
The SolarBloC® mega is a premounted group of fittings checked for leakage to be installed in the
primary or solar circuit. The station contains important valves, fittings and safety devices for the
operation of the installation:
●Ball valves with integrated thermometers in the solar circuit (flow and return)
●Check valves in the screw connections of the mounting plate, in the flow and return line
●Pressure relief valve to prevent inadmissible overpressure
●Pressure gauge to display the installation pressure in the solar circuit
●Connection for an expansion tank
●Pump group which can be completely isolated
The expansion tank required for operation is not a part of this station and must be ordered separately.
The cap-type valve (item no. 5301), which is also separately available, allows the expansion tank to be
easily mounted and separated from the solar thermal system.
1 General Information
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1.3 Designated use
The SolarBloC® mega may only be used between the solar and storage tank circuits in solar thermal
systems taking into consideration the technical limit values indicated in these instructions. Due to its
design, the station may only be installed and operated as described in these instructions!
Only use PAW accessories with the solar station. Improper usage excludes any liability claims.
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.
2 Safety instructions
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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.
NOTICE
Damage to property!
The installation site must be dry, stable, frost-proof and protected against ultraviolet radiation in
order to prevent material damage of the installation. Furthermore, access to the controller and
safety equipment must be guaranteed at all times during operation!
NOTICE
Damage to property!
The discharge line of the pressure relief valves must be conducted into heat-resistant collecting
containers of corresponding size. This prevents uncontrolled discharging into the environment and
enables the circuits to be refilled!
3 Mounting and installation [specialist]
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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.
3 Mounting and installation [specialist]
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1. Remove the station from the packaging.
2. Take off the thermometer handles and remove the
insulating front shell.
3. Copy the mounting holes of the wall bracket to the
mounting surface.
4. Drill the holes.
5. Fix the wall bracket to the wall using appropriate wall
plugs and screws.
6. Push the controller extension with the premounted
controller onto the solar station. Screw the mounting
plate and the wall bracket together.
7. Connect the station to the installation by using the
piping:
①Return to the collector field
②Safety group: expansion tank
③Return from the storage tank
④Flow to the storage tank
⑤Flow from the collector field
For continuous venting, we recommend to install a
microbubble resorber (for example item no. 52375) into
the flow of the solar circuit.
3 Mounting and installation [specialist]
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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
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
Check valve is operating,
flow only in flow direction.
Check valve not operating,
flow in both directions.
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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4.2 Preparations before flushing
1. Turn both check valves to the operating position
"Z" and open the ball valves in the flow and
return [1.2|5.2].
2. Close the shut-off valve [3.1]. This guarantees
that the dirt particles that may be still present
will be washed out of the system and will not
access the circuit again.
3. Connect the fill station to the solar station:
○pressure hose to the fill valve [3.2]
○flush hose to the drain valve [1.4]
4. Open the fill and drain valves [3.2|1.4].
4 Commissioning [specialist]
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4.3 Flushing and filling
1. Put the flush and fill station into operation.
2. Flush the collector system for at least 15 minutes.
3. In order to eliminate the air from the storage
tank, open the shut-off valve [3.1] and close the
ball valve in the flow [5.2].
4. Close the drain valve [1.4] while the filling pump
is running and increase the system pressure to
about 5 bars. The system pressure is displayed on
the pressure gauge.
5. Close the fill valve [3.2] and switch off the pump
of the flush and fill station.
6. Check the pressure gauge to see whether the system pressure reduces and eliminate leaks
where necessary.
7. Reduce the pressure on the drain valve to the operating pressure.
8. 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).
9. Open the ball valve [5.2] in the flow.
4 Commissioning [specialist]
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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 work, plug the mains plug into a socket. This avoids
an unintentional start of the motors.
10. Connect the optional controller to the mains and set
the solar circuit pump in manual mode to ON as
described in the controller manual. Allow the solar
circuit pump to run at the maximum rotation speed
level for at least 15 minutes.
11. 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.
4.4 Adjustment of the solar installation
1. Set the desired flow rate by adjusting the rotation speed of the solar circuit pump.
2. Mount the insulating front shell of the solar station.
3. Switch the controller to automatic mode (see controller instructions).
4 Commissioning [specialist]
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5 Maintenance [specialist]
5.1 Replacement / adjustment of the pressure gauge
1. Switch off the controller and secure it against
being switched on again.
2. Make sure that the valve [1.4] is closed with cap.
3. Turn the valve [1.4.] in position "maintenance" by
removing the stop screw, see chapter 4.1.
4. Replacement of the pressure gauge:
Dismount the pressure gauge [1.6]. It can happen
that a small amount of fluid leaks out (valve
content). After that, exchange the pressure
gauge.
Adjustment of the pressure gauge:
Loosen the counter nut and turn the pressure
gauge (from completely screwed in to max. 360°)
anti-clockwise. After that, secure it with the
counter nut.
5. Turn the valve [1.4.] again in position "closed" (see chapter 4.1.). During this, mount the stop
screw.
6. Check the pressure gauge for tightness. Also, check the system pressure [1.6] and increase it to
the prescribed operating pressure, if necessary.
7. Vent the installation. Repeat that weekly or monthly, depending on the vented air quantity.
5 Maintenance [specialist]
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5.2 Draining the solar system
Check valve is operating, flow only in flow
direction.
Check valve not operating, flow in both
directions
1. Switch off the controller and secure it against
being switched on again.
2. Turn the check valves to position "A" and open
the ball valves in the flow and return.
3. Connect a heat-resistant hose to the drain valve
[3.1]. Draining completely the solar
installation/the storage tank is only possible with
a drain valve at the lowest point of the
installation which must be ordered separately.
Make sure that the solar fluid is collected in a
heat-resistant container.
WARNING
Danger of scalding due to hot solar fluid!
The escaping solar fluid can be very hot!
►Position and secure the heat-resistant collecting container such that persons
nearby are not put at risk when the solar system is drained.
4. Open the drain valve [3.1] of the solar station.
5. Open the vent valve possibly present at the highest point of the solar installation.
6. Dispose of the solar fluid observing the local regulations.
5 Maintenance [specialist]
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5.3 Deinstallation
1. Drain the solar installation as described above.
2. Disconnect the pipe connections to the solar installation.
3. Loosen the screws of from the mounting plate in order to remove the solar station from the wall
bracket.
4. Remove the station by pulling it forward.
5 Maintenance [specialist]
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6 Scope of delivery [specialist]
NOTICE
Serial number
Complaints and requests/orders of spare parts will only be processed with information on the serial
number! The serial number is placed on the return pipe of the station.
►In case of a complaint, please send us the entirely completed commissioning report.
6 Scope of delivery [specialist]
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Position Spare part Item no.
1 Sealing kit, 30.0 x 21.0 x 2.0, ½", for thread connection 1", 10 pieces N00024
2 Thermometer ball valve return DN 32, F1¼" x 1¼" int. thread
Cross, 1" int. thread, self-sealing x ¾" int. thread x 1" ext. thread self-
sealing, with counter nut
5251
3 Pressure gauge 0-6 bars, G ¼" axial; d = 50 mm, 130 °C N00337
4 Thermometer handle for thermometer ball valve 1" and 1¼" N00248
5 Dial thermometer, blue scale, d = 50 mm, 0-160 °C N00194
6 Dial thermometer, red scale, d = 50 mm, 0-160 °C N00193
7 Union nut G 2" N00270
8 Sealing kit, 55.0 x 42.0 x 2.0, 1¼", for thread connection 2", 10 pieces N00047
9
Pump Grundfos Solar PML 32-145 N00361
Wilo-Stratos PARA 30/1-12 T2 N00366
10 Pump ball valve DN 32, 2" ext. thread x F 1¼", with nut and seal N00539
11 Thermo ball valve TK DN 32, F1¼" x 1¼" int. thread, ½"-sleeve left N00446
12 Thermo ball valve TK DN 32, F1¼" x 1¼" int. thread, ½"-sleeve right N00439
6 Scope of delivery [specialist]
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