PAW SolarBloC midi 2D Installation and operation manual

PAW GmbH & Co. KG
Böcklerstr. 11, D-31789 Hameln, Germany
Phone: [phone], Fax: [phone]
E-mail: [email protected], Web: www.paw.eu
2016/05 997655910x-mub-en –V07 1
Installation and Commissioning Instructions
SolarBloC midi 2D –DN 20

1 General Information
2 997655910x-mub-en –V07 2016/05
Item no. 997655910x-mub-en –Version V07 –Issued 2016/05
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
D-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
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
4.4 Adjustment of the solar installation............................................................................. 18
5Maintenance [specialist].................................................................................................19
5.1 Draining the solar installation ..................................................................................... 19
5.2 Deinstallation.............................................................................................................. 19
6Spare parts [specialist] ..................................................................................................20
7Technical data...............................................................................................................22
8Function of the check valves [Expert] .............................................................................24
9Commissioning report....................................................................................................26

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 system 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 must be mounted and operated as described in these instructions!
Improper usage excludes any liability claims.
Only use PAW accessories with the solar station.
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
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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 of this manual
WARNING
Danger of scalding due to vapour escape!
With pressure relief valves, there is risk of scalding due to vapour escape.
During installation, check if the local conditions require the connection of a
discharge line to the safety group.
For this purpose, please 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 shells must remain closed during operation.

2 Safety instructions
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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]
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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.

3 Assembly 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:
⑤ Common flow of both collector fields
① Return to the collector field 1
⑦ Return to the collector field 2
③ Return from the storage tank
④ Flow to the storage tank
All thread connections have ¾" internal
threads.

3 Assembly and installation [specialist]
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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 installation and connect the
expansion tank. Please observe the separate
instructions regarding 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.
An unintentional start of the motors is thus avoided.
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 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 leaks from the pressure relief valves
in case of too high system pressure! 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.
To flush dirt particles out of the installation, 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.
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 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
The air liberated from the solar fluid is collected 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]
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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 installation.
Please observe the separate instructions regarding 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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Observe 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 if the system
pressure decreases and eliminate leaks if
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
system by means of the flush and fill station
(for the required operating pressure, see the
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).

4 Commissioning [specialist]
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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.
15. Connect controller (not part of delivery) to the
mains and set the solar circuit pump 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. 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 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.

4 Commissioning [specialist]
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4.4 Adjustment of 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 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 26.
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 installation
1. Switch off the controller and make sure that
a restart is not possible.
2. Open the check valves in the return ball
valves [1.2I7.2], by turning them to position
45° (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 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.
5.2 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]
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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 26.