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
09/2023 9976x0210x-mub-en - V02 1

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
09/2023 9976x0210x-mub-en - V02 2

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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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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4.2 Preparations before flushing
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 valve [1.2] (90°, see
chapter 4.1).
3. The ball valve [3.1] at the flow meter must be
open.
4. Connect the fill station to the solar station:
- pressure hose to the fill valve [1.4]
- flush hose to the drain valve [3.2]
4.3 Flushing and filling
1. Open the fill and drain valves [1.4|3.2]. For this,
turn the valve [1.4] into position "open" (see
chapter 4.1).
2. Put the flush and fill station into operation and
flush the installation until the solar fluid exits
without bubbles.
3. During flushing, vent the solar installation several
times via the vent valves possibly present.
4. Slowly open the return ball valve [1.2] to vent the
pump section.
4 Commissioning [specialist]
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5. 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. Close the fill valve [1.4] by
turning it into position "closed" (see chapter 4.1)
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 at the drain valve [3.2] 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. Close the fill and drain valves [1.4|3.2]. For this, turn the valve [1.4] into position "closed"
(see chapter 4.1).
10. Turn the check valve in the return ball valve [1.2] into operating position (0°, see chapter 4.1).
11. Connect the additionally required controller to the mains and set the solar circuit pump to ON
in the manual mode (see the controller instructions).
12. 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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4.4 Setting the solar installation
1. Set the desired revolution speed of the solar pump depending on the required flow rate.
If necessary, the flow rate can be reduced by the ball valve [3.1] (only necessary if the pump is
not speed-controlled). Please observe the specifications of the collector manufacturer for the
correct adjustment of the flow rate.
2. Mount the insulating front shells of the solar station.
3. Switch the controller to automatic mode (see controller instructions).
The commissioning of the solar installation is now completed. Please fill in completely the
commissioning log.
Reading edge = round edge of
the float
Example: approx. 4 l/min
Scale DN 20:
3 – 22 l/min
Scale DN 25:
5 - 40 l/min
4 Commissioning [specialist]
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5 Maintenance [specialist]
WARNING
Risk of burning and scalding!
The valves and fittings and the solar fluid can have temperatures of more than 100 °C.
The solar fluid may escape as vapour and result in scalding.
►Perform maintenance work only when the collector temperatures are
below 50 °C.
►Wait until the solar fluid has cooled down to at least 50 °C.
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 [1.6] for tightness. Also, check the system pressure 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
1. Switch off the controller and secure it against
being switched on again.
2. Open the check valve in the return ball valve [1.2]
by turning the ball valve into position 45°
(see chapter 4.1).
Open the check valve possibly present in the
flow line.
3. Connect a heat-resistant hose to the lowest drain
valve of the solar installation (possibly drain valve
[3.2]). 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 at the lowest point of the solar installation.
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 in the previous
chapter.
2. Disconnect the pipe connections to the solar installation.
3. To remove the solar station from the mounting plate, pull
out the clip springs laterally with a screwdriver.
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 safety group.
►In case of a complaint, please send us the entirely completed commissioning report.
6.1 SolarBloC® midi Basic DN 20
6 Scope of delivery [specialist]
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Position Spare part Item number
1 Pressure relief valve ½" x ¾", 6 bars N00300
2 Pressure gauge 0-6 bars, G ¼" axial; d = 50 mm, 130 °C N00337
3
Alternative pumps:
Wilo Para ST 15/7 N00150
Wilo Para ST 15/13 N00299
Grundfos UMP3 Solar 15-75 N00025
Grundfos UMP3 Solar 15-145 N00215
4 Flowmeter ¾", 3-22 l/min, 1" M x ¾" int. thread x ½", with seal N00225
5 Sealing kit, 30.0 x 21.0 x 2.0, ½", for thread connection 1", 10 pieces N00024
6 Union nut G1", passage 28.1 mm, wrench size 37 N00302
7 Return ball valve DN 20, ¾" int. thread x F ¾" x ¾" ext. thread on the
right
N00290
8 Dial thermometer, blue scale, d = 50 mm, 0-160 °C N00194
6 Scope of delivery [specialist]
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