GRANT GS222154HX Solar Pump Station Installation Guide Grant Solar Pump Station
- June 1, 2024
- GRANT
Table of Contents
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: [email protected] -
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: [email protected]
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: [email protected]
www.grantuk.com