PAW SolexMega-Kaskade HZ 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 996098460-mub-en –V02 1
Installation and Commissioning Instructions
Solar transfer station
SolexMega-Kaskade HZ
[Hydraulics]

1 General Information
2 996098460-mub-en –V02 2016/05
Item no. 996098460-mub-en - Version V02 –Date 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 996098460-mub-en –V02 3
Contents
1General Information.........................................................................................................4
1.1 Scope of these instructions .......................................................................................... 4
1.2 About this product ........................................................................................................ 5
1.3 Designated use ............................................................................................................ 6
2Safety instructions ...........................................................................................................7
3Product description..........................................................................................................9
4Dimensioning and planning............................................................................................12
5Assembly and installation ..............................................................................................13
5.1 Secondary side .......................................................................................................... 16
5.2 Primary side ............................................................................................................... 18
5.3 Piping with the installation .......................................................................................... 20
5.4 Controller connection ................................................................................................. 21
6Commissioning [specialist].............................................................................................23
6.1 Preparations before flushing and filling....................................................................... 24
6.2 Flushing and filling the storage tank circuit (connections secondary).......................... 24
6.3 Flushing and filling the solar circuit (connections primary).......................................... 28
6.4 Parameters: SolexMega-Kaskade with controller SC5.14 .......................................... 32
7Maintenance [specialist].................................................................................................33
7.1 Draining the solar installation ..................................................................................... 35
7.2 Deinstallation.............................................................................................................. 35
8Spare parts [specialist] ..................................................................................................36
8.1 Spare parts control..................................................................................................... 36
8.2 Spare parts hydraulics primary circuit......................................................................... 37
8.3 Spare parts hydraulics secondary circuit .................................................................... 38
8.4 Spare parts installation set ......................................................................................... 39
9Technical data...............................................................................................................40
9.1 Pressure drop characteristic curve SolexMega HZ..................................................... 41
10 Functioning of the check valves .....................................................................................42
11 Commissioning report....................................................................................................43

1 General Information
4 996098460-mub-en –V02 2016/05
Carefully read these instructions before installation and commissioning.
Save these instructions in the vicinity of the installation for future reference.
1General Information
1.1 Scope of these instructions
These instructions describe the function, installation, commissioning and operation of the
solar transfer station SolexMega-Kaskade HZ. The chapters called [specialist] are intended
for specialists only.
For other components of the installation, such as storage tanks, controllers and pumps,
please observe the instructions of the corresponding manufacturer.
Item number
Controller SC5.14
Max. flow rate
Max. collector surface
6098460
8000 l/h
400 m²

1 General Information
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1.2 About this product
The SolexMega-Kaskade is a premounted group of fittings checked for tightness and used
to transfer the heat from the primary or solar circuit to the secondary or storage tank circuit.
The station consists of two parallel working cascade modules and contains a preset controller
as well as important fittings and safety devices for the operation of the installation:
Ball valves in the solar circuit and storage tank circuit (respectively in the flow and
the return)
Check valves to avoid undesirable gravity circulation in the flow and return of the
solar circuit and the storage tank circuit
Pressure relief valves to prevent inadmissible overpressures
Pressure gauge to display the system pressure in the solar circuit
Vent valves for an easy venting of the solar circuit and the storage tank circuit
Fill and drain valves with caps to flush, fill and drain the solar circuit
Temperature sensors in the primary and secondary circuit
Flow meters (FlowRotor) and temperature sensors for a revolution speed control
of the pumps depending on the performance and heat quantity balancing (secondary)
On the heating side, the installation must be equipped with a safety group that can be ordered
separately.
The expansion tank required for operation must be adapted to the size and the requirements
of the installation and must be ordered separately.
The separately available cap valve (item no. 5301) allows an easy installation and separation
of the expansion tank from the solar installation.
The wrapping materials are made of recyclable materials and can be disposed of
with recyclable materials.

1 General Information
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1.3 Designated use
The SolexMega-Kaskade may only be used as a transfer station between the solar circuit and
the heating circuit in solar thermal systems taking into consideration the technical limit values
indicated in these instructions. Due to its design, the station must only be mounted and
operated as described in these instructions!
Only use PAW accessories with the transfer 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.
Flush and fill the solar circuit only if the collector temperatures are
below 70 °C.
Schematic structure
SolexMega-Kaskade
Scope of
delivery

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 a 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 shell 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 causes high
pressures which can result in personal injury or damage to property!
Only close the ball valves for service and maintenance.
When closing the ball valves in case of servicing, also put the pumps
out of operation and close the piston valves of the secondary circuit.
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 Product description
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3Product description
Connections
1
Secondary side:
Return from the storage tank
(cold)
2
Secondary side:
Flow to the storage tank
(warm)
3
Primary side:
Solar flow from the collector
(warm)
4
Primary side:
Solar return to the collector
(cold)
For information on the equipment of the individual modules, see the following pages.

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Connections primary circuit
3
Solar flow from the collector (warm)
4
Solar return to the collector (cold)
Equipment primary circuit
A
Safety group with pressure relief
valve 6 bars, pressure gauge and
connection for expansion tank
B
Flow ball valve with fill and drain valve
C
Check valve
D
Vent plug (manual vent valve)
E
Heat exchanger
F
Airstop with manual vent valve
G
Drain valve
H
FlowRotor with Hall sensor
I
Primary pump
J
Check valve
K
Return ball valve with
fill and drain valve

3 Product description
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Connections secondary circuit
1
Return from the storage tank (cold)
2
Flow to the storage tank (hot)
Equipment secondary circuit
a
Flow ball valve with fill and drain valve
b
Check valve
c
Pressure relief valve 6 bars
Only for the protection of the module.
Does not replace the pressure relief
valve that has to be mounted on site!
d
Heat exchanger
e
Temperature sensor Pt1000
f
Drain valve
g
FlowRotor with Hall sensor
h
Secondary pump
i
Check valve
j
Return ball valve with
fill and drain valve

4 Dimensioning and planning
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4Dimensioning and planning
The SolexMega-Kaskade is a solar transfer station used to transfer the heat from
the primary or solar circuit to the secondary or storage tank circuit.
The cascade will only work flawlessly if the installation meets certain requirements.
Please take some time to plan the installation.
Mounting example

5 Assembly and installation
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5Assembly and installation
During operation, the access to the control and safety equipment must be guaranteed
at all time!
The discharge lines of the pressure relief valves must be conducted into heat-resistant
collecting containers of corresponding size. Thus, an uncontrolled discharging into the
environment is avoided and the refilling of the circuits is facilitated!
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.
NOTICE
Damage to property!
The location of installation must be dry, load-carrying, frost-proof and protected against
ultraviolet radiation, in order to prevent material damage of the installation.

5 Assembly and installation
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Top view
1. Determine the mounting location of the transfer station near the buffer tank.
In long pipes, the transmission performance may be reduced due to higher
pressure losses.
2. Remove the packaging.
3. Take the stations off the pallet.
4. Mount the enclosed stand feet to compensate the unevenness of the floor.
5. Position both modules side by side.
Note: The insulation between the frames remains mounted!
6. The station can be mounted with the rear panel against the wall. If you want to
remove the insulation, a free space of about 20 cm must be left to the wall (see figure).
7. For the operation of the hydraulics and a subsequent servicing, a free space of
at least 60 cm to the front (controller) and to both sides must be left (see figure).
8. Remove the upper elements of the insulation at the connections of the modules.

5 Assembly and installation
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9. In order to prevent damage at the
safety group, it is mounted in the
modules at the factory.
Commission the safety group
as follows:
a. Unscrew the pipe at the
connecting T-piece [1]
of the solar return.
b. Mount the pipe at the T-piece [1]
in such a way that the pressure
relief valve [2] is in a vertical
position.
c. Fix the pipe with the plastic
clamp at the frame (see figure).
10. Connect the transfer station to the installation by using the piping as shown in the figure
below. When the station is delivered, the ball valves are fitted with caps in order to protect
the module against dirt. Before connecting the pipes, make sure that the connections are
free from dirt.
1
2

5 Assembly and installation
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11. Mount the pipe set in the following order:
- Flow to the storage tank (2a and 2b)
- Return from the storage tank (1a and 1b)
- Solar flow from the collector (3a and 3b)
- Solar return to the collector (4a and 4b)
5.1 Secondary side
Connection flow piping to the storage tank:
1. Connect a T-piece [C] with transition thread
connection with a short [A] and a long pipe [B].
Use the 1½" gaskets for this purpose.
2. Mount the transition thread connections [M]
in the ball valves.
The o-ring provides a seal in the ball valve.
3. Mount the connection pipe onto the
connections (2a and 2b). Use the flange
gaskets for this purpose.
4. Adjust the pipe and firmly tighten the screw
connections.
5. Firmly tighten the screw connections at the
T-piece [C].
6. The continuing piping can be connected to
2" external thread or to flange DN 50. For this
purpose, an additional gasket must be added
to the flange DN 50 on site.

5 Assembly and installation
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Connection return piping from the storage tank:
7. Repeat the steps 1 - 5 for the connection of the
return to the storage tank (connections 1a and
1b). For this purpose, use the pipes [D] and [E]
as well as the T-piece [C] with transition thread
connections.

5 Assembly and installation
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5.2 Primary side
Connection flow piping from the collector:
1. Connect a T-piece [G] with a short [F] and
a long pipe [H]. Use the 2" gaskets for this
purpose.
2. Mount the transition thread connections [M]
in the ball valves.
3. Mount the connection pipe onto the
connections (3a and 3b). Use the flange
gaskets for this purpose.
4. Adjust the pipe and firmly tighten the screw
connections.
5. The continuing piping can be connected
to 2" external thread or to flange DN 50.
For this purpose, an additional gasket
must be added to the flange DN 50 on site.
6. Mount a vent valve that can be isolated
at the highest point of the pipeline on site.

5 Assembly and installation
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Connection return piping to the collector:
7. Repeat the steps 1 - 5 for the connection of
the solar return to the collector (connections
4a and 4b). For this purpose, use the pipes
[K] and [L] as well as the T-piece [G] with
transition thread connections.

5 Assembly and installation
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5.3 Piping with the installation
1. Connect the transfer station to the installation by using the piping as shown in the figure
below. Before connecting the pipes, make sure that the connections are free from dirt.
All thread connections of the cascade have 2" external threads. The continuing piping
can be connected to 2" external thread or to flange DN 50.
For this purpose, an additional gasket must be added to the flange DN 50 on site.
①Flow to the buffer tank (warm)
②Return from the buffer tank (cold)
③Solar flow from the collector (warm)
④Solar return to the collector (cold)