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
2016/05 997655910x-mub-en –V07 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
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
4 997655910x-mub-en –V07 2016/05
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
2016/05 997655910x-mub-en –V07 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 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
6 997655910x-mub-en –V07 2016/05
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
2016/05 997655910x-mub-en –V07 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 997655910x-mub-en –V07 2016/05
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]
2016/05 997655910x-mub-en –V07 9
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]
10 997655910x-mub-en –V07 2016/05
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.