GRANT GS222154HX Solar Pump Station Installation Guide Grant Solar Pump Station

June 1, 2024
GRANT

GS222154HX Solar Pump Station

Grant Solar Pump Station

Specifications

  • Product Code: GS222154HX

  • Manufacturer: Grant Engineering (UK) Limited

  • Address: Frankland Road, Blagrove Industrial Estate, Swindon,
    Wiltshire SN5 8YG

  • Contact: Tel: +44 (0)1380 736920, Fax: +44 (0)1380 736991,
    Email: info@grantuk.com

  • Website: www.grantuk.com

Introduction

The Grant Solar Pump Station is a vital component of the Grant
Sahara Solar Thermal System. These instructions provide detailed
information on installation and servicing to ensure optimal
performance and longevity of the system.

Technical Data

Grant Solar Pump Station

The technical data for the Grant Solar Pump Station includes
pump performance, dimensions, and components.

Pump Performance

The pump operates at a flow rate of 75 L/min and is designed for
efficient circulation within the solar thermal system.

Dimensions

The dimensions of the pump station ensure compatibility with
standard installation configurations.

Components

The pump station includes essential components such as a
circulating pump, expansion vessel, safety valve discharge, and
2-port valve.

Installation

General

Proper installation is crucial for system efficiency. Follow the
provided guidelines for a successful setup.

Regulations and Standards

Ensure compliance with all relevant regulations and standards to
guarantee safe and effective operation.

Location

Select an appropriate location for the pump station that allows
easy access for maintenance and servicing.

Commissioning

Commissioning the pump station is essential to ensure proper
functionality of the solar thermal system.

FAQ

Q: How often should the Grant Solar Pump Station be

inspected?

A: The pump station should be inspected at least every twelve
months to ensure optimal performance.

Grant
Solar Pump Station Installation & Servicing Instructions

45°

45°

OFF OFF

60 40

80 100
C° 120

20 0

140 160

60 40

80 100
C° 120

20 0

140 160

4

6

75

50

90

8

2

25

125

145

0

10

bar psi

GRANT

UK | DOC 0096 | Rev 1.1 | March 2024

IMPORTANT NOTE FOR INSTALLERS
Please read these instructions alongside the instructions supplied with the Grant Sahara Solar Thermal System (Grant UK DOC 0073).
After commissioning, please leave both the System Installation Instructions and these Pump Station Instructions with the user for future reference.
Important: All system pipe connections must use compression fittings with brass olives. Soft soldered joints must NOT be used on the solar primary circuit. Plastic pipe must not be used for any part of the solar primary circuit.
SPECIAL TEXT FORMATS
The following special text formats are used in these instructions for the purposes listed below:

CUSTOMER SUPPORT CENTRE
Grant UK provides an online support centre for Heating Professionals and Homeowners to access post-installation care, advice and maintenance support for Grant products. Follow the QR codes below to access your relevant Customer Support Centre.

! WARNING !

Homeowner`

Professional

Warning of possible human injury as a consequence of not following the instructions in the warning.

! CAUTION !
Caution concerning likely damage to equipment or tools as a consequence of not following the instructions in the caution.

! NOTE !
Used for emphasis or information not directly concerned with the surrounding text but of importance to the reader.

SERVICING
The Grant Solar Pump Station Supplied with your Grant Solar Thermal system should be inspected at least every twelve months.

PRODUCT CODES COVERED
These instructions cover the following product codes:

Grant Solar Pump Station

Product code GS222154HX

GRANT ENGINEERING (UK) LIMITED
Frankland Road, Blagrove Industrial Estate, Swindon, Wiltshire SN5 8YG Tel: +44 (0)1380 736920 Fax: +44 (0)1380 736991 Email: info@grantuk.com www.grantuk.com
This manual is accurate at the date of printing but will be superseded and should be disregarded if specifications and/or appearances are changed in the interests of continued product improvement. However, no responsibility of any kind for any injury, death, loss, damage or delay however caused resulting from the use of this manual can be accepted by Grant Engineering (UK) Limited, the author or others involved in its publication. All good sold are subject to our official Conditions of Sale, a copy of which may be obtained on application. © Grant Engineering (UK) Limited. No part of this manual may be reproduced by any means without prior written consent.

Contents

1

INTRODUCTION

4

1.1

General

4

2

TECHNICAL DATA

5

2.1

Grant Solar Pump station

5

Technical data

2.2

Pump performance

6

2.3

Dimensions

7

2.4

Components

8

3

INSTALLATION

9

3.1

General

9

3.2

Regulations and standards

9

3.3

Location

9

3.4

Safety

9

3.5

Fitting procedure

9

3.6

Flow and Return Connections 10

3.7

2-Port Valve

12

3.8

Expansion vessel

12

3.9

Safety valve discharge

12

3.10 Circulating Pump

13

4

COMMISSIONING

15

4.1

Expansion vessel

15

4.2

Filling valves

15

4.3

Gravity brakes

15

4.4

Solar Fluid

16

4.5

Filling the system

16

4.6

Filling procedure

17

4.7

Releasing trapped air

18

4.8

Setting the flow rate

18

5

FAULT FINDING

19

5.1

No system circulation

19

5.2

Pump not operating

19

5.3

Loss of system pressure (on

19

pressure gauge)

6

SPARE PARTS

20

APPENDIX A – GRUNDFOS UPM3 21 SOLAR 25-75 130 CZA PUMP (HYBRID VARIANT)

A.1 Grundfos UPM3 Solar Pump

21

A.2 Fault indication

22

NOTES

23

Contents

Page 3

1 Introduction
1.1 GENERAL
The Grant Solar Pump Station is a two-line Solar Pump Station for the circulation of glycol mix solar fluid through Grant solar thermal systems. All components are housed within an insulated enclosure designed to be wall mounted. The Grant Solar Pump Station provides the following functions: · Filling and flushing connection points · Fluid flow rate regulation · System pressure and temperature readings · Check valves (Gravity Brakes) for anti- gravitation circulation · Safety pressure relief valve and discharge connection · System expansion vessel connection point · Isolation valves for upper and lower system levels and pump

45°

45°

60 40

80 100
C° 120

20 0

140 160

60 40

80 100
C° 120

20 0

140 160

4

6

75

50

90

8

2

25

125

145

0

10

bar psi

Return – to Collectors
OFF OFF

Flow – from Collectors

Page 4

L/min 12 10 8 6 4 0
Figure 1-1: Grant Solar Pump Station with front cover removed
Section 1: Introduction

2 Technical Data

2.1 GRANT SOLAR PUMP STATION TECHNICAL DATA

Table 2-1: Technical data Specifications for The Grant Solar Pump Station Dimensions Weight Pump mounting length Spacing between flow and return connections Body material Flow meter range System pipe connections Safety valve Safety valve discharge connection Expansion vessel connection Pressure gauge range Thermometer gauge range Maximum glycol (%) in solar fluid Circulating pump* Temperature range of pump operation
Pump connection Electrical supply Insulation material Flow and Return valves Min pressure to open check valve Check valve activation Solar controller
Pressure gauge assembly not included in unit width. **To see details refer to Appendix A.

480 x 275* x 180 (mm) 6 kg 130mm 125mm Brass 0-12 l/min. 3/4″ BSP Female. With safety valve 6 bar certified TUV according to SV 100 7.7 – Directive 97/23/CE. 3/4″ BSP Female. 3/4″ BSP Male. 0-10 bar. 0-160°C. 50 % Grundfos UPM3 Solar 25-75 130 CZA.(Hybrid variant). 11/2″ BSP Male. Maximum fluid temp of 110°C at 70°C ambient temperature. Maximum fluid temp of 130°C at 60°C ambient temperature. 1 ½” BSP Male. 230-240V 50 Hz. Black PPE (Density = 40 kg/m3). Plain. DN20. ¾” BSP Female connection, integral check valve. 2 kPa (200mm w.g./ 20mbar) Closure at 90° and opening at 45°. Available separately. Contact Grant UK for details.

Section 2: Technical Data

Page 5

2.2 2.2.1

PUMP PERFORMANCE GRUNDFOS UPM3 SOLAR 25-75 130 CZA (HYBRID VARIANT)

p [kPa] 80 70 60
50 40 30 20 10
0

H [m] 8 7 6 5 4 3 2 1 0
0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6 2.8 3.0 3.2 Q [m³/h]

P1 0.0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9 Q [l/s] [W]

50 40

30

20

10 0
0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6 2.8 3.0 3.2 Q [m³/h]

Figure 2-1: Grundfos UPM3 Solar Q(H) & energy consumption characteristics

Page 6

Section 2: Technical Data

2.3 DIMENSIONS
180

480

OFF

45°

125

100

45°

60 40

80 100
C° 120

20 0

140 160

OFF

60 40

80 100
C° 120

20 0

140 160

4

6

75

50

90

8

2

25

125

145

0

10

bar psi

GRANT

75

70

50 Figure 2-2: Side view

275 Figure 2-3: Front view
125

30

50

Section 2: Technical Data

Figure 2-4: Plan view
Page 7

2.4 COMPONENTS
19 18
17

45°

20

60 40

80 100
C° 120

20 0

140 160

OFF OFF

45°

60 40

80 100
C° 120

20 0

140 160

1 2

4

6

75

50

90

8

2

25

125

145

0

10

bar psi

3 4 5

16 14 15

6 7 8

13

L/min

9

12

10

8 6 4 0

10

12

11

Figure 2-5: Components of the Grant Solar Pump Station

Table 2-2: Components of the Grant Solar Pump Station

Key No.

Description

1

Return valve (right knob) – 3/4″ BSP Female connection.

2

Safety valve (6bar).

3

Safety valve discharge connection.

4

Pressure gauge (0-10bar).

5

Expansion vessel connection 3/4″ BSP Male – with flat gasket connection.

6*

Circulator – Grundfos UPM3 Solar 25-75 130 CZA. (Hybrid variant). 11/2″ BSP Male

7

Filling/shut-off valve.

8

Filling flow valve connection – 3/4″ BSP Male – with safety cap and rubber strip.

9

Flow meter – range 0-12 l/min.

10

Filling return valve connection – 3/4″ BSP Male – with safety cap and rubber strip.

11

System connection – 3/4″ Female.

12

System connection – 3/4″ Female.

13

Filling hose connectors (x 2) ­ to fit filling/flushing valve – 15mm dia x ¾” swivel nut.

14

Connection pipe – copper d.18mm.

15

Air separator with integral manual vent .

16

Wall bracket.

17

Insulated housing.

18

Flow valve (left knob) – 3/4″ BSP Female connection.

19

Thermometer (0-160°C) – on flow valve (red).

20

Thermometer (0-160°C) – on return valve (blue).

*To see details refer to Appendix A.

Page 8

Section 2: Technical Data

3 Installation

3.1 GENERAL
Installation of this pump station must be carried out by a competent installer in compliance with all current local Building Regulations, Codes of practice, Health & Safety legislation and any relevant bylaws and regulations in force at the time.
All electrical installation work must be carried out by a qualified electrician. The electrical installation must comply with the requirements of the Electricity at Work Regulations 1989 and BS7671:2008 – IET Wiring Regulations 17th Edition British Standards Institutions (including all amendments).
3.2 REGULATIONS AND STANDARDS
The installation of the Grant Solar Pump Station must be in accordance with the following recommendations, as applicable:
· Building Regulations for England and Wales, and Building Standards for Scotland
· Local Bylaws (check with the Local Authority for the area)
· Water Supply (Water Fittings) Regulations 1999
The installation should also be in accordance with the latest edition of the following standards and Codes of Practice:
· BS7671 and amendments
· BS EN 12831
3.3 LOCATION
The Grant Solar Pump Station can be mounted on any suitable wall surface capable of carrying the weight of the Pump Station (refer to Table 2-1) where the required clearances can be achieved. Leave at least 200mm clearance around the Grant Solar Pump station’s housing.
The Solar Pump Station is designed for wall mounting in an upright position.
The Grant Solar Pump Station MUST only be installed inside a property, and not located externally, as it not designed to be weatherproof.
3.4 SAFETY
The Grant Solar Pump Station is intended only for a sealed solar installation. The Grant Solar Pump Station complies with the current technical standards and technical safety regulations.
Each device is checked for proper operation and safety prior to shipping.
The Grant Solar Pump Station MUST only be installed and operated by trained personnel. Untrained personnel can work only under the supervision of an experienced person, who is familiar with the way the unit works. Before installation, the installer must carefully read and understand these instructions.

3.5 FITTING PROCEDURE
1. Refer to Figure 3-1. Take the two coach screws (3), the two plugs (1) and the two metallic washers (2) from the wall bracket kit (Supplied).
2. Remove the front section of the insulated pump station housing.
3. Undo screw and remove retaining clip from wall bracket.
! WARNING !
Ensure that the electrical supply has been isolated before making any wiring connections.
4. Lift out both the flow valve/air separator assembly and the return valve/pump assembly.
5. Position the back section of the insulated housing in the required location. If necessary check the cover is level using a spirit level on the side and mark the top hole of the wall bracket.
6. Separate the wall bracket from the back section of the housing. Drill the wall with an 8 mm drill and securely fix the wall bracket to the wall using the fixings supplied.
7. Fit the back section of the insulated housing onto the wall bracket, taking care to insert it completely. Refer to Figure 3-2.
8. Re-fit the flow and return assemblies, inserting the body of the flow and return valves into the corresponding fork in the wall bracket. Refer to Figure 3-3.
9. Fit the retaining clip and secure using the screw provided. Refer to Figure 3-4.
10. Connect the flow and return pipes. Refer to Section 3.6.
! NOTE !
The Grant Solar Pump Station MUST only be installed vertically, as shown in Figure 1-1.

1

2x

! WARNING !
The temperature inside the Grant Solar Pump Station can reach dangerous levels that can cause serious burns.

2

2x

3

2x

Figure 3-1: Wall bracket kit items

Section 3: Installation

Page 9

45

45

60 40

80 100
C° 120

20
0 OFF

140 160

60 40

80 100
C° 120

20
0 OFF

140 160

4

6

75

50

90

8

2

25

125

145

0

10

bar psi

L/min 12
10
8 6 4 0

Figure 3-2: Fit back section of housing onto wall bracket
GRUNDFOS
HYBRID
Figure 3-3: Re-fitting flow and return assemblies to wall bracket

Figure 3-4: Fit retaining clip
! CAUTION !
The Grant Solar Pump Station should be installed with a minimum of 200mm clearance around the housing.
3.6 FLOW AND RETURN CONNECTIONS
The solar thermal system flow and return connections should be made to the four 3/4″ BSPF connections built into the pump station. Refer to items 1, 11, 12 and 18 in Figure 2-5.
These connections should be made using 3/4″ BSPM x 15mm compression connections with brass olives. (Not supplied).
The flow from the solar collectors to the DHW cylinder should be made on the left handside of the pump station, and the return from the DHW cylinder back to the collectors should be made on the right handside of the pump station (view from front). Refer to Figure 3-5.
The system flow and return connections should be made to the pump station as follows:
1. Insert 3/4″ BSPM end of the compression adaptor into the chosen 3/4″ BSPF connector in the pump station and tighten to form a waterproof seal.
2. Make the hydraulic pipe connection from the solar system to the chosen compression adapter using the 15mm compression end of the adapter.
If more than one solar collector is being connected to the Grant Solar Pump Station, pipework connections between the collectors should be made prior to making the final connections to the pump station. Refer to Installation Instructions for the Solar Thermal Collectors (DOC 0073) for further information.

Page 10

! NOTE !
If a thread sealant is to be used on any hydraulic connection in the solar thermal system, PTFE tape should be used in all cases due to its high temperature properties.
! CAUTION !
During assembly, do not overtighten the threads as some leakage could result over time.
Section 3: Installation

! NOTE !
This is a diagrammatic view showing the connections to the Grant Solar Pump Station. As such it does NOT include all valves and controls and is NOT intended as a complete system diagram.

! CAUTION !
All system pipe connections must use compression fittings with brass olives. Soft soldered joints must NOT be used on the solar primary circuit.
Plastic pipe must NOT be used for any part of the solar primary circuit.

Solar Collectors

45

45

Solar Hot Water Cylinder

60 40

80 100
C° 120

20
0 OFF

140 160

60 40

80 100
C° 120

20
0 OFF

140 160

4

6

75

50

90

8

2

25

125

145

0

10

bar psi

L/min 12
10
8 6 4 0

Section 3: Installation

Solar expansion vessel
Figure 3-5: System connections to solar pump station

Safety (presure relief) valve fluid recovery container
Page 11

3.7 2-PORT VALVE
For Grant Sahara solar thermal installations using a Grant QR Twin Coil cylinder, a high temperature rated motorised valve (contact Grant UK for details) may need to be fitted to the solar thermal system flow pipe to the cylinder.

Ensure that the expansion vessel isolation valve is OPEN – this is indicated when the two indicators (on the square end of the valve) are in line with the valve. Refer to figure 3-6.
Ensure that the bleed valve is fully CLOSED before filling the system.

! NOTE !
A high temperature rated motorised valve is only required on installations where the solar thermal collectors are installed below the level of the indirect solar coil contained in the DHW cylinder.

Flexible stainless steel pipe

Pipe union nut
Isolation valve Indicators

If the Grant Sahara solar collector is installed above the indirect solar coil, a high temperature motorised valve DOES NOT need to be fitted. Refer to Grant UK DOC 0179 (Grant QR Cylinder installation instructions) for system diagrams and wiring schematics.
3.8 EXPANSION VESSEL
The correct size of expansion vessel should be used based on the volume of the system – i.e. the number of collectors, the length and diameter of the system pipework, etc.
For systems using up to 4 Grant Solar Collectors, with no more than 50 metres of 15mm pipework (total length of flow and return combined), an 18 litre expansion vessel is supplied as standard. For 5 collectors a 24 litre expansion vessel is used. For larger system configurations, contact the Grant Technical department for guidance on the expansion vessel required.
The expansion vessel is connected to the Grant Solar Pump Station via the 3/4″ BSP Male connection on the safety valve manifold, using the 1250mm long flexible corrugated stainless steel pipe. This pipe is supplied with flanged ends, each fitted with a 3/4″ union nut, and two sealing washers (Grant Part No. GS222074).
! NOTE !
This flexible pipe cannot be cut and must be used as supplied.

Bleed valve
Union nut Thin nut

Isolation valve
Vessel mounting bracket

Expansion vessel

Figure 3-6: Expansion vessel connection
3.9 SAFETY VALVE DISCHARGE
A discharge pipe must be fitted to the outlet of the safety valve. It is recommended that the safety valve discharge should be connected to a suitable discharge recovery tank, such as the Grant safety valve liquid recovery container with drain valve (Grant Part No. GS550001). This discharge pipe should be 15mm copper.

The expansion vessel is fixed to the wall using the Vessel Mounting kit (Grant Part No. GS222073). This kit includes an isolation valve union and the vessel mounting bracket.
Fix the mounting bracket to the wall, using the screws and wall plugs provided, to position the vessel in the required location.

! NOTE !
Plastic pipe must NOT be used for the discharge pipe

! NOTE !
The expansion vessel must be located BELOW the connection on the Grant Solar Pump Station with the vessel connection pointing upwards. Refer to Figure 3-5.
Assemble and fit the expansion vessel isolation valve union as follows, referring to Figure 3-6:
· Fit the small black sealing washer onto the threaded connection of the bleed valve.
· Screw the bleed valve into the threaded port in the side of the valve union body and tighten.
· Remove the thin nut from the thread on the valve union.
· Fit the threaded connection on the expansion vessel up through the hole in the mounting bracket and secure using the thin nut.
· Using the sealing washer supplied, fit the valve union to the expansion vessel connection.
· Tighten the union nut to ensure the valve union in the required position.
Connect the flexible stainless steel pipe to the safety valve manifold and expansion vessel union valve, using the fibre sealing washers provided with the pipe.

Page 12

Section 3: Installation

3.10 CIRCULATING PUMP
The Grant solar pump station will be supplied with the Grundfos UPM3 SOLAR 25-75 130 CZA (Hybrid) circulating pump. The “SOLAR” variation of the Grundfos UPM3 only features operating modes suitable for use with solar thermal systems. Refer to Appendix A at the back of these instructions for information on the operating modes available with the Grundfos UPM3 Solar pump.
! WARNING !
The electrical supply must be isolated before making the connections to the solar pump. After making the connections ensure cover is fitted to enclosure before reconnecting the electrical supply.
3.10.1 CONNECTING THE PUMP The UPM3 Solar circulating pump requires a 230V 50Hz power supply from the Grant GSX1 Solar Controller to operate. This connection is made via a 3-pin plug supplied with the pump. Refer to the installation instructions provided with the Solar Controller for further information on the electrical control system wiring. The pump can also be controlled using a PWM signal if a different Solar Controller that offers this feature is being used.
! NOTE !
If the Grant GSX1 Solar Controller is used to operate the circulating pump, It is not necessary to connect the PWM lead supplied. The circulating pump will run at a constant speed on the 230V supply from the GSX1 solar controller.
Before start-up Before you start-up the circulating pump: 1. Check the pump station is installed in the correct position. 2. Check that the unions are tightened. 3. Fill and vent the system (refer to Sections 4.6 and 4.7). The
solar thermal collectors must be cold when filling with solar fluid. 4. Check that the system is filled to the correct operating pressure. 5. When using the pump for the first time, check that the system has been vented. 6. Switch on the power supply to the solar pump (GSX1 Solar controller set to ‘manual’). 7. Refer to Appendix A for solar pump operating details.
! CAUTION !
Do not start the pump until the system has been filled and vented to avoid the possibility of damage.
! NOTE !
UPM3 pumps are self-venting and do not have to be vented before start-up. Air inside the pump is transported by the liquid into the system shortly after start-up.
Section 3: Installation

Page 13

Page intentionally left blank.

4 Commissioning

4.1 EXPANSION VESSEL

Ensure that the expansion vessel charge pressure is correct for the system pressure (when cold) and that this in turn corresponds to the height of the system. Refer to Table 4-1.

The height of the system should be measured from the expansion

vessel to the top of the highest collector.

! NOTE !
If the collectors are positioned below the level of the expansion vessel (e.g. if the collectors are mounted at ground level), then measure from the bottom of the collectors to the expansion vessel. This will be a `negative’

Filling/shut-off valve (shown closed)

Filling flow valve

(shown closed) L/min

12

10

Filling return valve

8

6

(shown closed)

4

0

height value, e.g. -5 metres. The vessel charge pressure

must be checked BEFORE filling the system.

FILLING

Filling station flow hose

Filling station return hose

Table 4-1: Expansion vessel pressures

Height difference (height of the
collector field minus height of expansion
vessel

Initial expansion vessel charge
pressure (air charge
setting on valve)

System charge pressure at 20°C (0.2 – 0.5 bar greater than vessel charge
pressure)

– 5m

~ 1.0 bar

~ 1.3 bar

< 0m

~ 1.0 bar

~ 1.3 bar

< 5m

~ 1.5 bar

~ 1.8 bar

< 10m

~ 2.0 bar

~ 2.3 bar

< 15m

~ 2.5 bar

~ 2.8 bar

15m

Contact Grant Technical Department for guidance

4.2 FILLING VALVES
The filling flow and return valves, and the Filling/Shut off valve, are used for filling and flushing the solar thermal installation. Refer to Figure 4-1.
To enable filling/flushing of the system, the Filling/Shut-off valve must be rotated fully 90°C clock-wise. Refer to Figure 4-2. This
will divert the flow from the filling station, entering the system via the Filling flow valve, through the pump, up to the collectors, through the coil of the cylinder and back to the filling station via the Filling return valve.

EMPTYING
Figure 4-2: Detail A – Closing filling/Shut off valve to prepare to fill the system
4.3 GRAVITY BRAKES
The gravity brakes (check valves) are incorporated into both the flow and return valve assemblies. These gravity brakes are activated at 20 mbar and are operated by turning the valve handle on the valves as follows:
4.3.1 FLOW AND RETURN VALVES OPEN – ‘ MARKERS ON VALVE HANDLES IN VERTICAL POSITION To prevent ‘gravity’ circulation of solar fluid, gravity brakes must be in the operation position (open), i.e. with ‘ markers in vertical position. Refer to Figure 4-3.
4.3.2 GRAVITY BRAKES OPEN – ‘ MARKERS OF THE VALVE HANDLES AT 45° ANGLE CLOCKWISE To fill or completely empty the solar thermal installation, the gravity brakes must be opened, i.e. by turning the valve handles clockwise to an angle of 45°. Refer to Figure 4-4. 4.3.3 FLOW AND RETURN VALVES CLOSED ‘ MARKERS ON VALVE HANDLES IN HORIZONTAL POSITION
The flow and return valves are closed by turning the valve handles clockwise to an angle of 90°, i.e. until the ‘ ‘ markers are horizontal. Refer to Figure 4-5.

Filling/shut-off valve (shown open)

Filling flow valve

(shown closed)

L/min 12

10

8 6 4 0

FLOW DIRECTION

Filling return valve
Figure 4-1: Filling and flushing valves
Section 4: Commissioning

Page 15

°C

°C

Figure 4-3: Flow and return valves open

°C

°C

Figure 4-4: Gravity breaks open

4.5 FILLING THE SYSTEM
Grant Solar Thermal systems should be flushed and filled using a purpose designed closed circuit solar thermal filling station, incorporating a high pressure pump, such as the Grant Solar Filling Station. Refer to Figure 4-6. The capacity of the filling station is 30 litres.
! WARNING !
If the Grant Solar Pump Station is located in the roof space, there must be a suitable flat surface on which to stand the filling station, e.g. floor, loft boarding or similar, capable of carrying the weight of the filling station with a full tank of solar fluid.

°C °C

Figure 4-5: Flow and return valves closed
4.4 SOLAR FLUID
In order to prevent frost and corrosion damage to the Grant Solar Collectors and pipework, the system must only be filled with a high quality solar fluid. The Grant solar fluid is a ready mixed 40% solution of 1.2 propylene glycol/water providing frost protection down to approx. -21.5°C.
To prevent damage to the system, the same specification solar fluid should be used when replacing or topping up the solar fluid in the system.
If required, a copy of the Material Safety Data Sheet for the Grant solar fluid is available on request from Grant UK.

Figure 4-6: Grant Solar Filling Station

Page 16

Section 4: Commissioning

4.6 FILLING PROCEDURE
Important: The collectors must be cool before filling the system. They must be covered to stop solar radiation reaching them, until the filling and commissioning procedure is completed.
Before filling the system: Check all system connections and the expansion vessel charge pressure. Refer to Table 4-1. At the time of filling and venting of the solar installation, the expansion vessel should not be connected.

4.6.3 PHASE 3
1. Re-open the Filling/Shut-off valve by turning 90° anticlockwise.
2. Switch on the circulating pump (by setting the solar controller to “manual”) to the highest pumping speed and allow the solar fluid to circulate for at least 15 minutes.
3. Set the solar controller to “stand by” (pump = OFF).
4. Bleed the air separator using the manual air vent until the solar fluid begins to escape. Refer to section 4.7
5. Set the operating pressure (as in Table 4-1) by carefully opening the Filling Return valve and releasing the fluid back into the filling station tank.

4.6.4 PHASE 4
1. Reset Flow and Return valves to fully open position. Refer to Figure 4-3.
2. Switch on the circulating pump (solar controller set to “manual”).
3. Set the flow rate on the flow rate indicator (refer to section 4.8) by selecting the appropriate pump speed and by using the Filling/Shut-off valve.
4. Remove the filling station hoses from the filling connections and screw the caps on both valves. Release the Filling Return valve first and then the Filling Flow valve.
5. Switch the solar controller to automatic operation and remove covers from the collectors.

Figure 4-7: Rotating the filling/shut-off valve 90° clock-wise
4.6.1 PHASE 1 1. Connect the pressure hose from the Filling Station to the
Filling Flow valve connection and open the valve. Refer to Figure 4-2.
2. Connect the return hose from the filling station to the Filling Return valve connection and open the valve. Refer to Figure 4-2.
3. Using a small spanner to rotate the Filling/Shut-off valve 90° clock-wise to open it. Refer to Figure 4-7. This will divert the flow from the filling station through the pump, up to the collectors, through the coil of the cylinder and back to the filling station via the filling return valve.
4. Fill the filling station tank with sufficient solar fluid for the system.
5. Check that Flow and Return valves are set to ‘half open’ position (to open the gravity brakes) as shown in Figure 4-4.
6. Switch on the filling station to fill and flush the solar circuit for approx. 15 minutes.

! CAUTION !
Venting air from the system should only be carried out by a competent installer. Frequent venting leads to system pressure loss and disruption to the system operation.
Manual Air vent

4.6.2 PHASE 2
1. Whilst the filling pump is running, close the Filling Return valve and allow the system pressure to reach around 4 – 5 bar. If the pressure increases slowly, this indicates air is trapped in the solar thermal system. Rapidly open the filling return valve to lower the pressure. Repeat until the pressure increases to the maximum pressure (4 -5 bar) after closing the return valve.
2. When the pressure reaches 5 bar, close the Filling Flow valve and immediately switch off the filling pump.
3. Check that the system pipework and pump station are leakfree. After leaving the system at about 5 bar for a minimum of 15 minutes, check if the pressure gauge shows any significant drop in pressure. If it does, this points to a leak in the system that must be traced and rectified.
4. Check the operation of the pressure relief valve by slowly rotating the valve knob, lifting the valve, until fluid is discharged. This should be collected in a suitable container, e.g. a pressure relief valve fluid recovery container (Refer to Figure 3-5 in section 3.6).

Air separator
Figure 4-8: Air separator and air vent

Section 4: Commissioning

Page 17

4.7 RELEASING TRAPPED AIR
The residual air from the heat transfer fluid is collected in the air separator and manually released via the air vent. There is no need to use an automatic air vent elsewhere on the solar primary circuit, e.g. at high level.
To release any air collected in the air separator, push a plastic tube on the manual air vent outlet (Refer to Figure 4-8) and catch the fluid that is released in a suitable container. Open the manual air vent with a flat bladed screw driver turning the screw head anticlockwise until all air has been vented, i.e. a steady stream of solar fluid is flowing from air vent.

Detail B

! WARNING ! L/min

12

Danger of scalding!

10

8

The temperature of both the escaping air and the solar fluid

6

4

can exceed 100°C.

0

4.8 SETTING THE FLOW RATE
The setting of the solar fluid flow rate is made via the speed setting of the circulating pump and the Filling/Shut-off valve. For required system flow rates refer to Table 4-2 in this section.
To set the flow rate:
· Using a wrench, fully open the Filling/Shut-off valve by turning it anti- clockwise. Use the push button on the circulating pump operating panel (refer to Figure A-3) to set the pump to the lowest speed setting, CC1, (refer to Table A-3).
· At the solar controller, ensure that pump operation is set to “manual”; refer to the instructions supplied with the controller.
· Using a wrench, slowly turn the filling/shut-off valve until the required flow rate is achieved. A small adjustment of this screw can make a large difference to the flow rate set.
· If the required flow rate cannot be achieved, fully open the Filling/Shut- off valve, increase the pump speed and try again until the required flow rate is achieved.
The flow indicator displays the fluid flow rate. The display range is between 0 and 12 litres per minute. The lower edge of the float indicates the flow. Refer to Figure 4-9 and 4-10 in this section for details.

Figure 4-9: Flow rate indicator

Table 4-2: System volume flow rates

Number of solar panels

Type of connection

Flow and return pipe
diameter

1 to 5

Up to 5 in series 15mm

6

2 x 3 in parallel 22mm

8

2 x 4 in parallel 22mm

9

3 x 3 in parallel 22mm

12

4 x 3 in parallel 22mm

Minimum volume flow
rate
2-3 l/min
4-5 l/min
4-5 l/min
6-8 l/min
6-8 l/min

! NOTE !
For larger installations, please contact Grant Technical Department for assistance.

LL//mmiinn
12 12
1100
8
6 4 02

Read flow rate from bottom edge of bobbin Figure 4-10: Detail B – Flow rate indicator

Page 18

Section 4: Commissioning

5 Fault Finding
In the event of a problem occurring with your Grant Solar Thermal System, follow the information given below in order to identify and rectify the matter:
5.1 NO SYSTEM CIRCULATION
Check for the following: · Pump is not operating (Refer to section 5.2). · If pump is noisy, there may be air in the system. · Pump may be air locked and needs venting. Let the pump
run, the pump vents itself over time. · Valves are closed – ensure that Flow and Return valves are
fully open (see Figure 4-3). If filling or flushing the system (see section 4.6) ensure the Filling/Shut off valves are fully open.
5.2 PUMP NOT OPERATING
Check for the following: · No electrical supply to pump.
· Controller is not calling for pump to operate. · Check power supply to controls (at fused spur). · Check wiring to controller and pump is correct. · Check for any loose connections. · Controller is not calling for pump to operate. · Check controller settings and correct as necessary
(Refer to Instructions supplied with the Solar Controller) · Collectors may be in stagnation mode – wait for system
to cool down. · Collector temperature may be too low (insufficient solar
radiation). · Cylinder temperature setting may be satisfied. · Pump is stuck – Turn off power, locate de-blocking screw on pump motor (see Figure A-x) and rotate motor using a screwdriver. · Motor capacitor failed – replace capacitor or pump motor.
5.3 LOSS OF SYSTEM PRESSURE (ON PRESSURE GAUGE)
Check for the following: · Leaks on system – find and rectify as necessary. · Expansion vessel pre-charge lost – check and re-charge
vessel as necessary. · Pressure relief valve discharging fluid – check and rectify/
replace valve.

Section 5: Fault Finding

Page 19

6 Spare Parts

45°

45°

01 08

OFF OFF

60 40

80 100
C° 120

20 0

140 160

60 40

80 100
C° 120

20 0

140 160

4

6

75

50

90

8

2

25

125

145

0

10

bar psi

03

04

02 05

06

L/min

12

07

10

8 6 4 0

Figure 6-1: Spare Parts

Table 6-1: Key to Figure 6-1 Key No. Description

01

Flow valve assembly (Red)

02

Return valve assembly (Blue)

03

Safety valve assembly (6 bar)

04

Pressure gauge

05*

Grundfos UPM3 Solar 25-75 130 CZA. (Hybrid variant). 11/2″ BSP Male

06

Air separator assembly

07**

Fill/flush valve and flow regulator assembly

08

3/4″ BSPM to 15mm compression connections

*To see details refer to Appendix A. **11/2″ fittings

Page 20

Part No. GSE01AX GSE02X GSE03X GSE04X GS200032X GSE07AX GSE08BX Not supplied
Section 6: Spare Parts

Appendix A

GRUNDFOS UPM3 SOLAR 25-75 130 CZA PUMP (HYBRID VARIANT)

A.1 GRUNDFOS UPM3 SOLAR PUMP

Table A-1: Grundfos UPM3 Solar pump specifications

Feature

Specification

Nominal supply voltage

EU: 1 x 230V +10% / -15%, 50/60 Hz

Minimum supply voltage Motor protection Enclosure class Equipment class

160V AC (runs with reduced performance)
The motor is protected by the electronics in the control box and requires no external motor protection
IPX4D (standard without drain holes)
I (EN 60335-1)

Insulation class Temperature class High voltage protection

F (EN 60335-1)
TF110 – 110°C at 70°C ambient temperature
EN 60335-1 1000 VAC

Maximum ambient temperature

70°C at 110°C or 60°C at 130°C

Maximum media temperature Minimum media temperature Storage temperature

130°C for cast iron housings
2°C (IPX4D: above dew point of ambient air).
-40°C to +75°C

Maximum system pressure Minimum inlet pressure Drinking water approvals De- blocking device
De-blocking software
Dry run ability – first start Dry run ability – during operation
Expected lifetime Minimum switching time power on/off Reaction time – power on Reaction time – standby Reaction time – speed change

1 MPa (10 bar)
0.05 MPa (0.50 bar) at 95°C liquid temperature.
ACS, WRAS, UBA, KTW, DVGW W270
Manual de-blocking device. Access from front side.
Continuously restarting with relay after 1.33 seconds, with NTC every 0.3 – 0.4 seconds with max. torque
3 x 20 seconds (5 minutes interval), all pumps are lubricated with glycerine
Rotor must be filled with water: fulfils EN 60335-2-51

100,000 h (with specified load profile). > 500,000 on/off cycles
With NTC: 1 minute. With relay: No specific requirements
With relay: < 2 seconds. With NTC: < 1 second
With relay: < 2 seconds. With NTC: < 1 second
< 1 second

Inrush current

With NTC: < 10 A. With relay: < 4 A

Maximum leakage current

3.5 mA (EN 60335-1)

Speed range Relative humidity Standby power consumption

563 to 5991rpm (depending on the variant)
Maximum 95%, non-condensing environment
With relay < 1 W. With NTC < 1 W

Sleep mode power consumption 0.4 W

Surge robustness

With relay/NTC > 3 kV (DM/CM)

RF emissions

-6 dB CE / EN 55014-1,-2

Acoustic sound pressure level (LP) 32 dB(A) on cast iron housings

Maximum altitude of installation 2000 m above sea level

A.1.1 CONTROL MODES AND CURVES
Two different control modes are available for Grundfos UPM3 Solar pumps. Constant Curve (3 different curves available) and PWM C profile (for use with solar controllers offering a PWM control feature).

Overview of operating panel control modes Grundfos UPM3 Solar pumps can be controlled with the button on the operating panel.
The LEDs on the operating panel show the control mode selected.

Table A-2: Setting Operating Status of the UPM3 pump

Control mode

LED1 Green

LED2 Green

LED3 Yellow

LED4 Yellow

LED5 Yellow

CC1

CC2

CC3

PWM C signal off

¹

PWM C signal on

²

¹ 1 Flash per second (No PWM signal connection) ² 12 Flashes per second (Correct PWM signal connection)

A.1.2 CONTROL MODE EXPLANATION Constant curve The pump runs on a constant curve, which means that it runs at a constant speed or power.
The duty point of the pump moves up or down on the selected constant curve, depending on the heat demand in the system.

Figure A-1: Constant curve

Table A-3: Control mode Constant Curve

Control mode

Head (m)

CC1

5

CC2

6

CC3 (max.)

7.5

PWM C profile (SOLAR) The pump runs on constant speed curves depending on the current PWM value.
Speed increases when the PWM value increases. If PWM equals 0, the pump stops.

Figure A-2: PWM C profile (solar)

Appendix A

Page 21

Table A-4: Control mode PWM C profile (solar) values

Control mode

Head (m)

C1

5

C2

6

C3 (max.)

7.5

Hint for installers · Heating systems must be flushed according to local
standards, such as BS EN 14336, before start-up. After filling the system for the first time, the pump must run for approx. 1 hour before a long-term stop.
· If filters are installed, they must be monitored and maintained thoroughly.
Operating panel The operating panel is designed with a single button, one red/ green LED and four yellow LEDs.
The operating panel shows:
· Control mode
· Alarm status

Table A-5: Key to Figure A-3

Item

Description

A

Push button

B

LED 1 (Red/Green)

C

LED 2 (Yellow)

D

LED 3 (Yellow)

E

LED 4 (Yellow)

F

LED 5 (Yellow)

Fault indication and alarm status on the operating panel If the pump has detected one or more alarms, LED 1 switches from green to red and one of the other LED lights yellow to indicate the alarm type. Refer to Table A-6.
If multiple alarms are active at the same time, the LEDs only show the error with the highest priority. The priority is defined by the sequence of the table as shown in the fault finding information given in Table A-6. When there is no active alarm anymore, the operating panel switches back to the operation mode.

A BCDE F

De-blocking screw

Figure A-3: Operating panel
A.2 FAULT INDICATION
When an alarm is active, the LEDs indicate the alarm type as defined in the Table A1-4.

Table A-6: Fault indication on the operating panel LED1 LED2 LED3 LED4 LED5 Indication

Operation panel Pump operation

Rotor is blocked

Trying to start again every 1.33 seconds

Counter action Wait or deblock the shaft

Supply voltage too
low

Only warning, pump runs

Electrical error

Pump is stopped because of low supply voltage or serious failure

Control the supply voltage Control the supply voltage. Replace the pump

Page 22

Appendix A

Notes

Notes

Page 23

GRANT ENGINEERING (UK) LIMITED
Frankland Road, Blagrove Industrial Estate, Swindon, Wiltshire, SN5 8YG Tel: +44 (0)1380 736920 Fax: +44 (0)1380 736991 Email: info@grantuk.com www.grantuk.com

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