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5 Assembly and installation

2016/05

996098460-mub-en – V02

13

5

Assembly 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.

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Содержание SolexMega-Kaskade HZ

Страница 1: ...1 D 31789 Hameln Germany Phone 49 5151 9856 0 Fax 49 5151 9856 98 E mail info paw eu Web www paw eu 2016 05 996098460 mub en V02 1 Installation and Commissioning Instructions Solar transfer station SolexMega Kaskade HZ Hydraulics ...

Страница 2: ...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 ...

Страница 3: ... 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 7 Maintenance specialist 33 7 1 Draining the solar installation 35 7 2 Deinstallation 35 8 Spare parts specialist 36 8 1 Spare parts control 36 8 2 Spare parts hydraulics prim...

Страница 4: ...nstructions 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 ...

Страница 5: ...ressure 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 an...

Страница 6: ...structions 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 ...

Страница 7: ...gulations 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 press...

Страница 8: ...lves 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 avo...

Страница 9: ...ons 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 ...

Страница 10: ...rimary 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 ...

Страница 11: ...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 ...

Страница 12: ...olexMega 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 ...

Страница 13: ... 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 in...

Страница 14: ...ensate 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 fro...

Страница 15: ... 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 th...

Страница 16: ...ad connection with a short A and a long pipe B Use the 1 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 piec...

Страница 17: ...n V02 17 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 ...

Страница 18: ... 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 th...

Страница 19: ...en V02 19 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 ...

Страница 20: ...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 Flow to the buffer tank warm Return from the buffer tank cold Solar flow from the collector warm Solar return to the co...

Страница 21: ...he expansion tank to the installation and connect the expansion tank Please observe the separate instructions of the expansion tank 5 Check all thread connections and tighten them if necessary 6 Mount the upper insulation of the transfer stations Make sure that the pipe insulation is flush with the insulation of the transfer station 5 4 Controller connection WARNING Risk to life and limb due to el...

Страница 22: ... the controller Collector sensor S1 Storage tank 1 bottom S2 In the piping set of the cascade S3 S9 Only one FlowRotor is connected bottom FlowRotor 2 Note The temperature sensors which are mounted in the stations are not connected to the controller 2 Tighten all union nuts and thread connections The installation of the transfer station is now completed and the station can be put into operation ...

Страница 23: ...possible to completely drain solar installations after flushing Thus there is a risk of frost damage when flushing with water Therefore flush and fill the solar installation 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 Flush and fill the installation in the following...

Страница 24: ...hing and filling Please observe the instructions of the manufacturer on this topic 6 2 Flushing and filling the storage tank circuit connections secondary The storage tank circuit is filled by means of the valves and fittings of the heating system To avoid that dirt particles are washed into the heat exchanger shut the ball valves of the module and wash out the present dirt particles scale residue...

Страница 25: ...k circuit via the corresponding valves and fittings with heating water 3 Vent the secondary circuit by actuating the pressure relief valve Make sure that the electrical components do not get wet 4 After filling the secondary circuit set the required operating pressure 5 If necessary vent the station at the pressure relief valve c1 c2 during commissioning to eliminate the air still present in the h...

Страница 26: ...alves must be open Turn the opening mechanism of the check valves into the position 180 The check valve is not operating For the operation of the installation all ball valves must be completely open and the check valves must be put into operating position position 0 Check valve normal flow direction in the figure downwards Position 0 Check valve is operating flow only in direction of flow Position...

Страница 27: ...from the solar fluid is collected in the upper part of the Airstop and can be released at the vent plug F WARNING Danger of scalding due to vapour escape The escaping fluid can heat up to more than 100 C and cause scalding Carefully open the vent plug and close it again as soon as medium escapes Venting the solar installation after commissioning At the beginning vent the solar installation daily a...

Страница 28: ... and drain valve L at the ball valve K1 f ex of the right module Note Connect the pressure hose and the flush hose to different modules in order to assure a correct flushing and filling 3 Open the flow and return ball valves B1 B2 and K1 K2 on both stations 4 Put the check valves J1 J2 out of operation on both stations position 180 see page 26 5 Open the fill and drain valves G L and put the flush...

Страница 29: ...le the filling pump is running and increase the system pressure to about 5 bars The system pressure is displayed on the pressure gauge 12 Close the fill and drain valve G and switch off the pump of the flush and fill station 13 Check the pressure gauge to see if the system pressure decreases and eliminate leaks if necessary 14 Vent both stations respectively at the T piece D and at the Airstop F 1...

Страница 30: ...d 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 SC5 14 21 Connect the controller to the mains and set the solar circuit pumps in the manual mode to ON according to the controller instructions 22 Let the pump of the solar circuit run at maximum revolution speed for at least 15 minutes Me...

Страница 31: ...rve only 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 25 Mount all the elements of the insulation 26 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 43 ...

Страница 32: ...reset in the controller If you select and save another system the parameters are reset to the factory settings In this case the parameters must be modified in the menu Thus a proper functioning of the installation is ensured You will find a detailed description of the operation of the controller in the separate controller manual Preset system SolexMega Kaskade ...

Страница 33: ...he 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 Thus an unintentional start of the motors is avoided 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 vapor and cause scalding Only carry out maintenance wor...

Страница 34: ...he solar fluid at a fill and drain valve G1 G2 Make sure that the solar fluid is collected in a heat resistant container 2 Replace the faulty part by the new part Fill the station as described in the chapters 6 2 Flushing and filling the storage tank circuit connections secondary and 6 3 Flushing and filling the solar circuit connections primary ...

Страница 35: ...g 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 drain valves G1 G2 of the transfer stations 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 Dispos...

Страница 36: ...and requests orders of spare parts will only be processed with information on the serial number The serial number is placed in the upper right corner of the support sheet of the station In case of a complaint please send us the entirely completed commissioning report on page 43 8 1 Spare parts control ...

Страница 37: ...8 Spare parts specialist 2016 05 996098460 mub en V02 37 8 2 Spare parts hydraulics primary circuit ...

Страница 38: ...8 Spare parts specialist 38 996098460 mub en V02 2016 05 8 3 Spare parts hydraulics secondary circuit ...

Страница 39: ...8 Spare parts specialist 2016 05 996098460 mub en V02 39 8 4 Spare parts installation set ...

Страница 40: ... internal thread Operating data Max admissible pressure Prim 6 bars sec 6 bars Maximum operating temperature Prim 120 C sec 95 C Maximum stagnation temperature 130 C Maximum propylene glycol content 50 Operating temperature sensors 25 C to 120 C Equipment Pressure relief valve Prim 6 bars sec 6 bars Pressure gauge 0 6 bars Flow rate measurement device Prim 2 x FlowRotor 5 130 l min Sensors 4 x Pt1...

Страница 41: ...9 Technical data 2016 05 996098460 mub en V02 41 9 1 Pressure drop characteristic curve SolexMega HZ Pressure m wc Pressure kPa Flow rate m h ...

Страница 42: ...rculation Components such as syphons heat traps or additional check valves can be installed for this purpose Make sure that the collector field is not separated from the safety group by the additional valves Example Each cascade module is equipped with a check valve 200 mm wc in the return line You use a mixture of water and 40 of propylene glycol as solar fluid The installation height between the...

Страница 43: ...ion and collector field Pipes mm l m Venting collector field Manual vent valve Automatic vent valve No Vented Airstop station Vented Solar fluid type glycol Antifreeze tested up to C Serial numbers Flow rate l m Station Pump type Controller Pump speed level I II III System pressure mbars Software version Expansion tank type Initial pressure mbars Safety valve Checked Check valves Checked Plumbing ...

Страница 44: ...PAW GmbH Co KG Böcklerstraße 11 D 31789 Hameln Germany www paw eu Phone 49 0 5151 9856 0 Fax 49 0 5151 9856 98 996098460 mub en V02 2016 05 ...

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