PAW SolarBloC midi Basic Owner's manual

Installation and Operation Instructions
return station
SolarBloC® midi Basic - DN 20
SolarBloC® maxi Basic - DN 25
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]........................................................................................ 10
4.1 Flushing and filling the solar circuit..........................................................................11
4.2 Preparations before flushing.....................................................................................13
4.3 Flushing and filling.....................................................................................................13
4.4 Setting 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
6.1 SolarBloC® midi Basic DN 20...................................................................................... 19
6.2 SolarBloC® maxi Basic DN 25..................................................................................... 21
6.3 SolarBloC® maxi Basic DN 25 for Grundfos Solar PML and Wilo Para MAXO.........23
7 Technical data............................................................................................................. 25
7.1 Dimensional drawing SolarBloC® midi Basic DN 20.................................................26
7.2 Dimensional drawing SolarBloC® maxi Basic DN 25................................................ 26
7.3 Pressure drop and pump characteristic curves SolarBloC® midi Basic DN 20....... 27
7.4 Pressure drop and pump characteristic curves SolarBloC® maxi Basic DN 25.......27
8 Function of the check valves [Expert]....................................................................... 28
9 Disposal....................................................................................................................... 30
10 Commissioning report................................................................................................31
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 function, installation, commissioning and operation of the return
stations SolarBloC® midi Basic and maxi Basic.
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 group of fittings checked for tightness and premounted (apart from the versions with
the Wilo Maxo pump and Grundfos Solar PML pump) used to circulate the solar fluid in the solar
circuit. It is mounted on a wall bracket and fixed with clips.
The station contains important valves, fittings and safety devices for the operation of the installation:
●Ball valve with exchangeable spindle
●Check valve
●Thermometer
●Pressure gauge to display the installation pressure
●Flowmeter to display the flow rate
●Ball valve to restrict the flow rate
●Solar pressure relief valve
●Connection for expansion vessel
●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 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.
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. Remove the insulating front shell.
3. Only for version with Wilo Para MAXO pump /
Grundfos Solar PML pump: Mount the enclosed
safety group for completion and prior to
commissioning. For this, screw the union nut (1)
of the safety bar onto the distance piece (3) by
using the corresponding gasket (2).
4. Copy the dimension of the mounting holes of the
solar station on the mounting surface.
5. Drill the holes and mount the solar station to the
wall with suitable wall plugs and screws.
3 Mounting and installation [specialist]]
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6. Connect the solar station to the installation by
using the pipes
①Return to the collector field
③Return from the storage tank
All thread connections have ¾" internal threads for
DN 20 and 1" internal threads for DN 25.
7. In order to prevent unwanted circulation, it is
mandatory to mount an additional check valve
④in the flow on site.
The expansion tank is not included in the
scope of delivery!
8. Connect the pipe for the expansion tank [1.5]
and fix the bracket for the expansion tank.
9. Adapt the initial pressure of the expansion tank
to the system and connect the expansion tank.
Observe the separate instructions for the
expansion tank!
10. Check all thread connections and tighten them
if necessary.
The assembly of the solar station is now completed and the station can be put into operation.
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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