PAW SolarBloC midi Basic DN 20 User manual

Montage- und Bedienungsanleitung
Solarstationen
SolarBloC® midi Basic - DN 20
SolarBloC® maxi Basic - DN 25
optionally with controller SC2.3
PAW GmbH & Co. KG
Böcklerstraße 11, 31789 Hameln, Germany
Phone: [phone], Fax: [phone]
E-mail: [email protected], Web: www.paw.eu
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Table of Contents
1 General Information...................................................................................................4
1.1 About these instructions............................................................................................4
1.2 About this product......................................................................................................4
1.3 Designated use........................................................................................................... 5
2 Safety instructions......................................................................................................6
3 Mounting and installation [specialist]...................................................................... 8
4 Commissioning [specialist]........................................................................................ 12
4.1 Flushing and filling the solar circuit..........................................................................13
4.2 Preparations before flushing.....................................................................................16
4.3 Flushing and filling.....................................................................................................16
4.4 Setting the solar installation..................................................................................... 19
4.5 Commissioning and adjustment of the controller SC2.3........................................ 19
4.6 Heat quantity measurement......................................................................................21
5 Maintenance [specialist]............................................................................................ 22
5.1 Replacement / adjustment of the pressure gauge...................................................22
5.2 Draining the solar system.......................................................................................... 23
5.3 Deinstallation..............................................................................................................24
6 Scope of delivery [specialist]..................................................................................... 25
6.1 SolarBloC® midi Basic DN 20...................................................................................... 25
6.2 SolarBloC® maxi Basic DN 25..................................................................................... 27
6.3 SolarBloC® maxi Basic DN 25 for Grundfos Solar PML and Wilo Para MAXO.........29
7 Mounting of the insulation........................................................................................ 31
8 Technical data............................................................................................................. 32
8.1 Dimensional drawing SolarBloC® midi Basic DN 20.................................................33
8.2 Dimensional drawing SolarBloC® maxi Basic DN 25................................................ 33
8.3 Pressure drop and pump characteristic curves SolarBloC® midi Basic DN 20....... 34
8.4 Pressure drop and pump characteristic curves SolarBloC® maxi Basic DN 25.......34
9 Function of the check valves [Expert]....................................................................... 35
10 Disposal....................................................................................................................... 37
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11 Commissioning report................................................................................................38
12 Notes............................................................................................................................39
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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 installation, commissioning, function and operation of the solar
station SolarBloC®.
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 solar station is optionally equipped with a controller.
The station contains important valves, fittings and safety devices for the operation of the installation:
●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
●Pressure gauge to display the installation pressure
●Flowmeter to display the flow rate
●Ball valve to restrict 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 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.
*Controller optional
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
Sachschaden durch Mineralöle!
Mineralölprodukte beschädigen die EPDM-Dichtungselemente nachhaltig, wodurch die
Dichteigenschaften verloren gehen. Für Schäden, die durch derartig beschädigte Dichtungen
entstehen, übernehmen wir weder eine Haftung noch leisten wir Garantieersatz.
►Vermeiden Sie unbedingt, dass EPDM mit mineralölhaltigen Substanzen in Kontakt kommt.
►Verwenden Sie ein mineralölfreies Schmiermittel auf Silikon- oder Polyalkylenbasis, wie z. B.
Unisilikon L250L und Syntheso Glep 1 der Firma Klüber oder Silikonspray.
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.
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1. Remove the station from the packaging.
2. Remove the insulating front shell.
3. Only for version with Wilo 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 mounting holes next to the
thermometers of the solar station to the
mounting surface.
5. Drill the holes and mount the solar station to the
wall with appropriate wall plugs and screws.
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6. Connect the solar station to the installation by
using the pipes.
⑤Flow from the collector field
①Return to the collector field
④Flow to the storage tank
③Return from the storage tank
The expansion tank is not included in the
scope of delivery!
7. Connect the pipe for the expansion tank [1.5]
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.
3 Mounting and installation [specialist]
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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.
1. Push the controller extension with the premounted
controller (optional) onto the station.
2. Connect the mains connection cable according to type to
the pump.
L
PE
N
brown
yellow-green
blue
3. In addition, connect the PWM connection cable according
to type to the pump.
PWM
GND
brown
blue
4. Connect the sensors to the controller: collector sensor to
S1, storage tank sensor to S2.
The assembly of the station is now completed and the
station can be put into operation.
Source of image: Resol
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
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.
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!
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Airstop
The Airstop (vent valve with manual bleeder) 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
28 25 ~ 530 ~ 8.8
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.
The air separated from the solar fluid is collected in the upper part of the airstop and can be released
at the vent plug.
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 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. Please observe the instructions of the
manufacturer!
2. Turn the check valve in the flow ball valve [5.2]
into operating position (0°, see chapter 4.1).
3. Close the ball valve [1.2] in the return (90°C).
4. The ball valve [3.1] must be open.
5. 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 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 chapter 4.1.
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3. Slowly open the return ball valve [1.2] (0°, see
chapter 4.1) to vent the pump section.
4. Close the drain valve [3.2] while the filling pump
is running and increase the system pressure to
maximum 5 bars. The system pressure is
displayed on the pressure gauge. Close the fill
valve [1.4] by turning the valve in position
"closed" (see chapter 4.1) and switch off the
pump of the flush and fill station.
Consider the pressure relief valve (6 bars)!
5. Check the pressure gauge to see whether the
system pressure reduces and eliminate leaks
where necessary.
6. Reduce the pressure at the drain valve [3.2] to
the operating pressure.
7. 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).
8. Close the fill and drain valves [1.4|3.2]. For this,
turn the valve [1.4] into position "closed", see
chapter 4.1.
9. Turn the check valve in the return ball valve [1.2]
into operating position (0°, see chapter 4.1).
4 Commissioning [specialist]
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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.
optional
10. Connect the optional 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.
In the meantime, vent the solar system several
times at the vent plug of the airstop until the
solar fluid exits without forming bubbles, see
chapter 4.1.
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 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.
Reading edge =round edge of
the float
Example: 4 l/min
Scale DN 20:
3 – 22 l/min
Scale DN 25:
5 – 40 l/min
4.5 Commissioning and adjustment of the controller SC2.3
The controller is factory-wired depending on the pump plug:
Pump connection cable
PWM signal cable
Mains connection
to R1
to PWM A
to L, N, protective earth conductor
10 preset systems are available.
As a factory setting, the pump is connected to R1 (supply cable) and to PWM A (signal cable). After the
assembly and installation according to these instructions, the temperature sensors are connected
to S1 (collector), and S2 (storage tank). This corresponds to system 1 (solar thermal system with a
storage tank).
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Source of image: Resol
If another system is selected, it may be necessary to connect further sensors and switching elements.
Please observe the separate instructions of the controller!
The controller first runs through an initialisation phase, subsequently the commissioning starts in
which the most important settings are made according to the following schema:
Source of image: Resol
For for further settings or modifications related to the system, the options or the functions, please
observe the separate instructions of the controller.
4 Commissioning [specialist]
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