PAW SolarBloC midi Premium Owner's manual

PAW GmbH & Co. KG
Böcklerstr. 11, 31789 Hameln, Germany
Phone: [phone], Fax: [phone]
E-mail: [email protected], Web: www.paw.eu
2020/08 997xx3xx-mub-en – V01 1
Installation and Operation Instructions
Solar stations
SolarBloC midi Premium - DN 20
SolarBloC maxi Premium - DN 25
with SC3.5 controller
SolarBloC midi Premium
SolarBloC maxi Premium

1 General Information
2 997xx3xx-mub-en – V01 2020/08
Item no. 997xx3xx-mub-en – Version V01 – Issued 2020/08
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
2020/08 997xx3xx-mub-en – V01 3
Contents
1General Information.........................................................................................................4
1.1 About these instructions ...............................................................................................4
1.2 About this product ........................................................................................................4
1.3 Designated use ............................................................................................................5
2Safety instructions ...........................................................................................................6
3Assembly 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
5Maintenance [specialist].................................................................................................17
5.1 Replacing the temperature sensor at the Airstop........................................................ 17
5.2 Draining the solar installation ..................................................................................... 18
5.3 Deinstallation..............................................................................................................18
6Spare parts [specialist] ..................................................................................................19
6.1 SolarBloC midi Premium DN 20 ................................................................................. 19
6.2 SolarBloC maxi Premium DN 25 ................................................................................ 21
6.3 Connection of the PWM pumps.................................................................................. 23
7Assembly of the insulation .............................................................................................23
8Technical data...............................................................................................................24
8.1 Dimensional drawing SolarBloC midi Premium (DN 20) ............................................. 25
8.2 Dimensional drawing SolarBloC maxi Premium (DN 25) ............................................ 25
8.3 Pressure drop and pump characteristic curves SolarBloC midi Premium (DN 20) ...... 26
8.4 Pressure drop and pump characteristic curves SolarBloC maxi Premium (DN 25) ..... 26
9Disposal........................................................................................................................27
10 Function of the check valves [Expert] .............................................................................28
11 Commissioning report....................................................................................................30

1 General Information
4 997xx3xx-mub-en – V01 2020/08
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
solar stations SolarBloC midi (DN 20) and SolarBloC maxi (DN 25) with Premium equipment.
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 contains a preset controller as well as important fittings for
the operation of the system:
•Ball valves in the flow and return line with exchangeable spindle
•Check valves in the flow and return ball valves
•Thermometers in the flow and return
•FlowRotor (measuring device with Hall sensor)
•Temperature sensors in the flow and return
•Pressure gauge to display the system pressure in the solar circuit
•Airstop to easily vent the solar circuit
•Flush and fill valves with caps
•Solar pressure relief valve
•High-efficiency pump

1 General Information
2020/08 997xx3xx-mub-en – V01 5
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 be mounted and operated in a vertical position with
upward flow direction of the pump!
Only use PAW accessories with the solar station.
Improper usage excludes any liability claims.
Under the influence of solar radiation, the collectors can get very hot.
The solar fluid in the solar circuit can heat up to more than 100 °C.
Only flush and fill the solar circuit if the collector temperatures are
below 70 °C.

2 Safety instructions
6 997xx3xx-mub-en – V01 2020/08
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 of this manual
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, fittings and the pump may heat up to more than 100 °C
during operation.
The insulating shell must remain closed during operation.

2 Safety instructions
2020/08 997xx3xx-mub-en – V01 7
CAUTION
Personal injury and damage to property due to overpressure!
By closing the two ball valves in the primary circuit, the safety group is separated
from the heat exchanger. A rise in temperature in the storage tank will cause high
pressures which can result in personal injury or damage to property!
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 get lost. We do not assume liability nor provide warranty for damage to property
resulting from sealants damaged in this way.
It is imperative to avoid that EPDM gets in contact with substances containing
mineral oils.
Use a lubricant based on silicone or polyalkylene and free of mineral oils, such as
Unisilikon L250L and Syntheso Glep 1 of the Klüber company or a silicone spray.

3 Assembly and installation [specialist]
8 997xx3xx-mub-en – V01 2020/08
3Assembly and installation [specialist]
NOTICE
Material damage due to high temperatures!
As the solar fluid can be very hot near the collector, the group of fittings must be installed at a
sufficient distance from the collector field. It may be necessary to install an intermediate tank to
protect the expansion tank.
Not included in
the scope of delivery!
Accessories: cutting-ring 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
housing of the cutting-ring compression fitting ⑤.
4. First, screw the union nut ② manually.
5. Tighten the union nut ② by rotating one full turn.
Secure the housing of the compression fitting ⑤
against distort, in order to avoid damaging the
sealing ring.
1. Remove the station from the packaging.
2. Remove the insulating front shell.
Example: SolarBloC midi Premium

3 Assembly and installation [specialist]
2020/08 997xx3xx-mub-en – V01 9
3. Copy the mounting holes besides the thermometers
to the mounting surface.
4. Drill the holes and mount the solar station to the wall
with appropriate wall plugs and screws.
5. Connect the solar station to the installation
by using the pipes:
① Return to the collector field
③ Return from the storage tank
④ Flow to the storage tank
⑤ Flow from the collector field
Not included in the scope of delivery!
6. Connect the pipe for the expansion tank below the
pressure relief valve [1.5] and fix the bracket for the
expansion tank.
Adapt the initial pressure of the expansion tank to
the installation and connect the expansion tank.
Please observe the separate instructions regarding
the expansion tank!
7. Check all thread connections and tighten them
if necessary.

3 Assembly and installation [specialist]
10 997xx3xx-mub-en – V01 2020/08
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.
An unintentional start of the motors is thus avoided.
8. Slide the controller extension with the preassembled
controller onto the solar station.
9. Connect the supply line to the pump.
10. Connect the pump 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]
2020/08 997xx3xx-mub-en – V01 11
4Commissioning [specialist]
Please observe the following safety instructions regarding the commissioning of the station:
WARNING
Risk of burns and scalding!
The valves and fittings can heat up to more than 100 °C. It is therefore not
allowed to flush or fill the installation when the collectors are hot (intense solar
radiation). Please note that hot solar fluid can leak from the pressure relief valves
if the system pressure is too high! During venting, solar fluid may escape as
vapour and cause scalding!
Only flush and fill the installation if the collector temperatures are
below 70 °C.
NOTICE
Risk of frost!
It often happens that the solar system can not be completely drained after flushing. There is
thus a risk of late frost damage when flushing with water. Flush and fill the solar installation
therefore only with the solar fluid used later.
Use a water and propylene glycol mixture with maximum 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 heat that may possibly be absorbed by the collectors during
commissioning can be dissipated.
NOTICE
Note regarding the expansion tank
To prevent that dirt particles of the solar system are washed into the expansion tank, some
manufacturers recommend to disconnect the expansion tank from the solar circuit during
flushing and filling. Please observe the instructions of the manufacturer on this topic.

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. Disconnect the expansion tank from the solar circuit during flushing and filling,
if necessary, and only use flush and fill stations with fine filters.
Ball valve with integrated 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 flow.

4 Commissioning [specialist]
2020/08 997xx3xx-mub-en – V01 13
Airstop
The Airstop with manual vent valve is used to vent the solar
installation. To ensure a perfect venting of the solar circuit,
the flow velocity in the flow line must be at least 0.3 m/s.
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
The air separated from the solar fluid accumulates in the upper part of the Airstop and can be
released via the vent plug [4.2].
WARNING
Danger of scalding due to vapour escape!
The escaping fluid can reach temperatures of more than 100 °C and cause
scalding.
Carefully open the vent plug and close it again as soon as fluid escapes.
Venting the solar installation after commissioning
At the beginning, vent the solar system daily and then weekly or monthly, depending
on the vented air quantity. An optimum operation of the solar installation is thus
ensured. Check the system pressure after venting and increase it to the specified
operating pressure if necessary.
4.2

4 Commissioning [specialist]
14 997xx3xx-mub-en – V01 2020/08
4.2 Preparations before flushing
The solar circuit is flushed in the direction of flow.
1. Disconnect the expansion tank from the solar
installation. Please observe the separate
instructions regarding the expansion tank!
2. Turn the check valve in the flow ball valve [5.2]
into operating position (0°, see page 12).
3. Close the return ball valve [1.2]
(90°, see page 12).
4. The ball valve [3] in the FlowRotor must
be open.
5. The drain valve [3.2] must be closed.
6. Connect the fill station to the solar station:
- Pressure hose to the fill valve [1.4]
- Flush hose to the drain valve [3.2].
7. Open the fill valve [1.4] and the drain
valve [3.2].

4 Commissioning [specialist]
2020/08 997xx3xx-mub-en – V01 15
4.3 Flushing and filling
1. Put the flush and fill station into operation
and flush the solar installation for at least
15 minutes.
2. Vent the solar system several times at the vent
plug of the Airstop [4.2] until the solar fluid exits
without bubbles (see page 13).
3. To flush and to vent the pump line, slowly open
the check valve in the return ball valve [1.2]
(45°, see page 12) and then close the flow
ball valve [5.2] (90°, see page 12).
4. 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.
5. Check the pressure gauge to see if the system
pressure decreases and eliminate leaks
if necessary.
6. Connect the expansion tank to the solar circuit
and set the operating pressure of the solar
system by means of the flush and fill station
(for the required operating pressure, see the
instructions of the expansion tank).
7. Reduce the pressure at the drain valve [3.2]
to the operating pressure of the installation,
if necessary.
8. Close the fill and drain valves [1.4|3.2].
9. Turn the check valve in the return ball valve
[1.2] into operating position (0°, see page 12).
Observe the pressure relief valve
(6 bars)!

4 Commissioning [specialist]
16 997xx3xx-mub-en – V01 2020/08
WARNING
Risk to life and limb due to electric shock!
Check if the sensors and pumps are properly connected to the controller
and if the controller housing is closed.
Only then, the mains plug of the controller can be plugged into a socket.
10. Connect the 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.
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.
11. Remove the hoses of the flush and fill station
and screw the sealing caps onto the fill and drain
valves.
The sealing caps only serve to protect the valves
against dirt. They are not designed to take up
high system pressures. The ball valves must
be closed to guarantee tightness.
12. Mount the insulating front shell.
13. Set the controller to automatic mode
(see controller instructions).
The commissioning of the solar installation is
now completed. Please fill in completely the
commissioning report on page 30.

5 Maintenance [specialist]
2020/08 997xx3xx-mub-en – V01 17
5Maintenance [specialist]
WARNING
Risk of burns and scalding!
The valves, fittings and the solar fluid can heat up to more than 100 °C.
The solar fluid can escape as vapour and cause scalding.
Only carry out maintenance work if the collector temperatures
are below 50 °C.
Wait until the solar fluid has cooled down to maximum 50 °C.
5.1 Replacing the temperature sensor at the Airstop
1. Drain the solar circuit as described in
5.2
Draining the
solar installation
.
2. Pull out the fixation clip of the sensor.
3. Pull the sensor [4.1] to the front out of the Airstop.
4. Make sure that there is a sealing ring in the groove
of the new sensor. Make sure that the sealing ring
is correctly positioned when you insert the sensor.
5. After inserting the sensor, fix it by using the clip.
6. Connect the sensor cable.
7. Close the drain valve [3.2].
8. Fill the solar circuit as described in
4.2
Preparations
before flushing
and
4.3
Flushing and filling
.

5 Maintenance [specialist]
18 997xx3xx-mub-en – V01 2020/08
5.2 Draining the solar installation
1. Switch off the controller and make sure that a
restart is not possible.
2. Open the check valves in the flow and return
ball valve [5.2|1.2] by turning them into position
45° (see page 12).
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 may be very hot.
Place and secure the heat-resistant collecting container in such a way
that people standing nearby are not endangered during the draining of
the solar installation.
4. Open the lowest drain valve of the solar installation.
5. To accelerate the draining of the solar circuit, the vent valve possibly
present at the highest point of the solar installation can be opened.
6. Dispose of the solar fluid observing the local regulations.
5.3
Deinstallation
1. Drain the solar installation as described above.
2. Disconnect the pipe connections to the solar system.
3. To remove the solar station from the wall bracket, pull out
the clip springs laterally with a screwdriver.
4. Remove the station by pulling it forward.

6 Spare parts [specialist]
2020/08 997xx3xx-mub-en – V01 19
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 30.
6.1 SolarBloC midi Premium DN 20

6 Spare parts [specialist]
20 997xx3xx-mub-en – V01 2020/08
Position
Spare part
Item number
1 Return ball valve DN 20, ¾" int. thread x F ¾" x ¾" ext. thread
on the right, check valve for solar application 200 mm wc
N00290
2 Pressure relief valve ½" x ¾", 6 bars N00300
3 Pressure gauge 0-6 bars, with automatic isolation
⅜" ext. thread; d = 50 mm, 130 °C
N00301
4 Union nut G1", octagonal, wrench size 37 N00302
5 Sealing kit, 10 pieces, ½", for thread connection 1" N00024
6
Alternative pumps:
Wilo Para ST 15/7-50 iPWM2, 130 mm, 1" ext. thread N00150
Grundfos UPM3 Solar 15-75, 130 mm, 1" ext. thread N00025
7 Temperature sensor Pt1000-B, screw-in sensor 9 mm, G¼" N00230
8 Flow ball valve DN 20, ¾" int. thread x ¾" int. thread,
check valve for solar application 200 mm wc
N00291
9 Dial thermometer, red scale, d=50 mm, 0-160 °C N00193
10 Dial thermometer, blue scale, d=50 mm, 0-160 °C N00194