PAW SolarBloC midi 2D Installation and operation manual

PAW GmbH & Co. KG
Böcklerstr. 11, 31789 Hameln, Germany
Phone: [phone], Fax: [phone]
E-Mail: [email protected], Web: www.paw.eu
2020/10 997655910x-mub-en – V09 1
Installation and Commissioning
Instructions
SolarBloC midi 2D – DN 20

1 General Information
2 997655910x-mub-en – V09 2020/10
Item no. 997655910x-mub-en – Version V09 – Issued 2020/10
Translation of the original instructions
We reserve the right to make technical changes without notice!
Printed in Germany – Copyright by PAW GmbH & Co. KG
PAW GmbH & Co. KG
Böcklerstraße 11
31789 Hameln, Germany

1 General Information
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Contents
1General Information.........................................................................................................4
1.1 About these instructions ...............................................................................................4
1.2 About this product ........................................................................................................4
1.3 Designated use ............................................................................................................5
2Safety instructions ...........................................................................................................6
3Mounting and installation [specialist]] ...............................................................................8
4Commissioning [specialist].............................................................................................11
4.1 Flushing and filling the solar circuit............................................................................. 12
4.2 Preparations before flushing....................................................................................... 14
4.3 Flushing and filling .....................................................................................................15
4.4 Setting the solar installation........................................................................................18
5Maintenance [specialist].................................................................................................19
5.1 Draining the solar system...........................................................................................19
5.2 Deinstallation.............................................................................................................. 19
6Spare parts [specialist] ..................................................................................................20
6.1 2-line station............................................................................................................... 20
6.2 1-line station............................................................................................................... 22
7Technical data and pressure drop curve .........................................................................24
8Function of the check valves [Expert] .............................................................................26
9Commissioning report....................................................................................................28
10 Disposal........................................................................................................................29

1 General Information
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1General 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 stations SolarBloC midi 2D (DN 20) for installations with 2 roofs.
The chapters called [specialist] are intended for specialists only. For other components of the
solar installation, such as 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 may only be installed and operated as described in this manual!
Improper usage excludes any liability claims.
Only use PAW accessories with the solar station.
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.

2 Safety instructions
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2Safety 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 calculated by the installation planner for the expansion tank
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 shells 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.
ATTENTION
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.

3 Mounting and installation [specialist]]
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3Mounting and installation [specialist]]
ATTENTION
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 ② and the cutting ring ③
onto 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 ④ into the copper
pipe.
3. Insert the copper pipe with the plugged-on
individual parts (②, ③ and ④) as far as
possible into the body of the compression
fitting ⑤.
4. First, screw the union nut ② manually.
5. Tighten the union nut ② by rotating one full
turn. Secure the body of the compression
fitting ⑤ against 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 insulating front shells.
3. Screw the connecting piece [6] onto the return
connections of the 2-line station and the 1-line
station (see figure).
4. Copy the mounting holes of the solar station
besides the thermometers to the mounting
surface.
5. Drill the holes and mount the solar station to
the wall with appropriate wall plugs and
screws.
6. Connect the solar station to the installation by
using the pipes
⑤Common flow of both collector fields
①Return to the collector field 1
⑦Return to the collector field 2
③Return from the storage tank
④Flow to the storage tank
All thread connections have ¾" internal
threads.

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Optionally available!
7. Connect the pipe for the expansion tank below
the pressure gauge [7.5] and fix the bracket
for the expansion tank.
8. Adapt the initial pressure of the expansion
tank to the system and connect the expansion
tank. Observe the separate instructions for the
expansion tank!
9. 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.
10. 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.

4 Commissioning [specialist]
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4Commissioning [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.
ATTENTION
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.
ATTENTION
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.
ATTENTION
Note regarding the expansion tank
To prevent any dirt particles contained in the solar installation from being flushed into the
expansion tank, some manufacturers recommend disconnecting the expansion tank from the
solar circuit during flushing and filling. 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.
To flush the dirt particles out of the installation, only use flush and fill stations with fine filters.
Ball valve with integrated flow check valve
(normal flow direction in the figure: downwards)
0°
45°
90°
Check valve is operating,
flow only in flow direction.
Check valve is not operating,
flow in both directions.
Ball valve closed,
no through-flow.
14

4 Commissioning [specialist]
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Airstop
The Airstop with manual vent valve 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
The air liberated from the solar fluid is collected in the upper part
of the Airstop and can be released at the vent plug [4.2].
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.
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.
4.2

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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 valves [1.2ￜ7.2] (90°, see page 12).
3. The ball valve in the flow line [5.2] and the ball valves in the flow meters [3.1ￜ9.1] must
be open.
4. Connect the fill station to the solar station:
- Pressure hose to the fill valve [7.4]
- Flush hose to the drain valve [9.2]

4 Commissioning [specialist]
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4.3 Flushing and filling
1. Open the fill and drain valves [7.4|9.2].
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 page 13).
3. Slowly open the return ball valve [7.2]
to vent the pump section (see page 12).
4. Switch off the pump of the flush and fill station
and close the fill and drain valves [7.4|9.2].
5. Connect the pressure hose of the fill valve [7.4]
to the fill valve [1.3]
of the second collector circuit.
6. Open the fill and drain valves [1.3|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 page 13).
8. Slowly open the return ball valve [1.2]
to vent the pump section (see page 12).
4.2

4 Commissioning [specialist]
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Consider the pressure relief valve
(6 bars)!
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 [1.3|7.4|9.2].
14. Turn the check valves in the ball valves
[1.2|5.2|7.2] into operating position
(0°, see page 12).

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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.
15. Connect the controller (not included in the scope
of delivery) to the mains and set the pump of the
solar circuit in the manual mode to Max.
according to the controller instructions. Let the
pump of the solar circuit run at maximum
revolution speed for at least 15 minutes.
16. Meanwhile, vent the solar installation several
times at the vent plug of the Airstop until the solar
fluid exits without bubbles (see page 13).
If necessary, increase the system pressure to the
operating pressure.
17. 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.

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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. Set the automatic mode on the controller (see controller manual).
The commissioning of the solar installation is now completed.
Please fill in completely the commissioning log on page 28.
Scale:
3 – 22 l/min
Reading edge =
round
edge
of the float
Example: about 4
l/min

5 Maintenance [specialist]
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5Maintenance [specialist]
5.1 Draining the solar system
1. Switch off the controller and secure it
against being switched on again.
2. Open the check valves in the return ball
valves [1.2I7.2], by turning them to
45°
position (45°, see page 12).
3. Connect a heat-resistant hose to the lowest
drain valve of the solar installation (possibly
drain valve [9.2]).
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. To accelerate draining of the solar circuit, you can open the air-bleed valve,
if present, at the highest point of the solar system.
6. Dispose of the solar fluid observing the local regulations.
5.2
Deinstallation
1. Drain the solar installation as described above.
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.

6 Spare parts [specialist]
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6Spare parts [specialist]
NOTICE
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 of the solar station.
In case of a complaint, please send us the entirely completed commissioning report
on page 28.
6.1 2-line station