Grant Solar Pump StationInstallation & Servicing Instructions

Part No. DOC 96. Rev 02. October 2012

Solar Thermal

Important Note

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Important Note for InstallersThe Pump Station supplied with yourGrant Solar Thermal system differs fromthat shown in the InstallationInstructions supplied. This change ispart of our continued productimprovement process.

The information in these Solar PumpStation Installation Instructions replacesthat given in Sections 13 and 14 of theGrant Solar Thermal SystemsInstallation Instructions (DOC 73.Rev.02). Please read these PumpStation instructions in conjunction withthe System Installation Instructionssupplied.

After commissioning, please leaveboth the System InstallationInstructions and these Pump StationInstructions with the user for futurereference.

GRANT ENGINEERING (UK) LIMITEDHopton House, Hopton Industrial Estate, Devizes, Wiltshire SN10 2EUTel: 01380 736920 Fax: 01380 736991Email: sales@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This manual is accurate at the date of printing but will be superseded and should be disregarded if specifications and/orappearances are changed in the interests of continued product improvement.All good sold are subject to our official Conditions of Sale, a copy of which may be obtained on application.© Grant Engineering (UK) Limited 2012. No part of this manual may be reproduced by any means without prior written consent.

Important:All system pipe connections mustuse compression fittings withbrass olives. Soft soldered jointsmust NOT be used on the solarprimary circuit.

Plastic pipe must NOT be used forany part of the solar primary circuit.

Contents

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1 Introduction 41.1 Description 4

2 Technical Specifications 52.1 Specification 5

2.2 Pump Performance 5

2.3 Dimensions 6

2.4 Components 6

3 Installation 73.1 General 7

3.2 Fitting Procedure 7

3.3 System Connections 8

3.4 Expansion Vessel 8

3.5 Safety Valve Discharge 9

3.6 Electrical Connection 9

4 Commissioning 104.1 Expansion Vessel 10

4.2 Filling Valves 10

4.3 Gravity Brakes 11

4.4 Solar Fluid 11

4.5 Filling the System 12

4.6 Filling Procedure 12

4.7 Releasing Trapped Air 13

4.8 Setting the Flow Rate 13

5 Fault Finding 145.1 No System Circulation 14

5.2 Pump not Operating 14

5.3 Loss of System Pressure 14

6 Spare Parts 15

1 Introduction

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1.1 DescriptionA two-line Solar Pump Station for thecirculation of glycol mix solar fluidthrough Grant solar thermal systems. All components are housed within aninsulated enclosure designed to be wallmounted.

The pump station provides the followingfunctions:

• Filling and flushing connectionpoints

• Fluid flow rate regulation

• System pressure and temperature readings

• Check valves (Gravity Brakes) foranti-gravitation circulation

• Safety pressure relief valve anddischarge connection

• System expansion vesselconnection point

• Isolation valves for upper and lowersystem levels and pump

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Figure 1-1: Pump station with front cover removed

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2 Technical Specifications

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2.1 Specification

Figure 2-1: Standard 6m head pump - performance curves

¾" BSP Female

6 bar - certified TUV to SV100 7.7 - Directive 97/23/CE

¾" BSP Female

0-10 bar

0-160° C

130°C

150°C

50%

WILO STAR ST 15-6 Eco. 3P connections, 1M-130mm Class F, PN10, TF110, IP44, 2 µF, 230V 50Hz, VDE, CE

230-240V 50 Hz

Black PPE density 40kg/m³, plain

DN20. ¾" BSP Female connection, integral check valve

2 kPa (200mm w.g./ 20mbar)

Closure at 90° and opening at 45°

System pipe connections:

Safety valve:

Safety valve discharge connection:

Pressure gauge range:

Thermometer gauge range:

Maximum run temperatures:

Maximum peak temperatures:

Maximum glycol (%) in solar fluid:

Circulator:

Electrical supply:

Insulation:

Flow and Return valves:

Min pressure to open check valve:

Check valve activation:

0 0.5 1 1.5 2 2.5 3 3.5

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Water flow (m3/h)

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Figure 2-2: Optional 8m head pump - performance curves

0 0.5 1 1.5 2

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2.2 Pump Performance

2 Technical Specifications

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Key No. Description

1 Flow valve (red knob) - ¾" BSP Female connection

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

3 Wall bracket – with retaining clip and screw

4 Connection pipe - copper 18mm

5 Manual air vent – with hose connection

6 Air separator – with integral manual air vent

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

8 System connection - ¾" Female

9 System connection - ¾" Female

10 Filling return valve connection - ¾" BSP Male – with safety cap and chain

11 Flow meter – range 2-12 l/min

12 Filling flow valve connection - ¾" BSP Male – with safety cap and chain

13 Filling/shut-off valve

14 Circulator – Wilo STAR ST 15-6 – 6m head

15 Expansion vessel connection ¾" BSP Male – with flat gasket connection

16 Pressure gauge (0-10bar)

17 Safety valve discharge connection

18 Safety valve (6 bar)

19 Return valve (blue knob) - ¾" BSP Female connection.¾" BSP Male connection always open on right side

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

21 Insulated housing

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2.3 Dimensions

2.4 Components

Plan view of pump station

Side view of pump station

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3 Installation3.1 GeneralInstallation of this pump station must becarried out by a competent installer incompliance with all current localBuilding Regulations, codes of practice,Health & Safety legislation and anyrelevant bylaws and regulations in forceat the time.

All electrical installation work must becarried out by a qualified electrician. Allwiring and bonding must comply withcurrent IEE wiring regulations (includingany amendments).

3.2 Fitting Procedure1. Remove the front section of the

insulated pump station housing.

2. Undo screw and remove retainingclip from wall bracket.

3. Lift out both the flow valve/airseparator assembly and the returnvalve/pump assembly.

4. Position the back section of theinsulated housing in the requiredlocation. If necessary check thecover is level using a spirit level andmark the two holes for the wallbracket.

Note: The solar pump station MUSTonly be installed vertically, as shownin Figure 1-1.

5. Separate the wall bracket from theback section of the housing. Drill thewall with an 8mm drill and securelyfix the wall bracket to the wall usingthe fixings supplied.

6. Fit the back section of the insulatedhousing onto the wall bracket,taking care to insert it completely.Refer to Figure 3-1.

7. Re-fit the flow and returnassemblies, inserting the body ofthe flow and return valves into thecorresponding fork in the wallbracket. Refer to Figure 3-2.

8. Fit the retaining clip and secureusing the screw provided.

8. Connect the flow and return pipes.Refer to figure 3-3.

Figure 3-1: Fit back section of housing onto wall bracket

Figure 3-2: Re-fitting flow and return assemblies to wall bracket

Wall bracket

Retaining clip

Insulated housingback section

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3.4 Expansion VesselThe correct size of expansion vesselshould be used, based on the volume ofthe system – i.e. the number ofcollectors, the length and diameter ofthe system pipework, etc.

For systems using up to 4 Grant solarcollectors, with no more than 50 metresof 15mm pipework (total length of flowand return combined), an 18 litreexpansion vessel is supplied asstandard. For 5 collectors a 24 litreexpansion vessel is used. For largersystem configurations, contact theGrant Technical department for

guidance on the expansion vesselrequired.

The expansion vessel is connected tothe pump station via the ¾” BSPconnection on the safety valve manifold,using the 1250mm long flexiblecorrugated stainless steel pipe. Thispipe is supplied with flanged ends, eachfitted with a ¾” union nut, and twosealing washers (Grant Part No.GS222074).

This flexible pipe cannot be cut andmust be used as supplied.

The expansion vessel is fixed to the wallusing the Vessel Mounting kit (GrantPart No. GS222073). This kit includesan isolation valve union and the vesselmounting bracket.

Fix the mounting bracket to the wall,using the screws and wall plugsprovided, to position the vessel in therequired location.

IMPORTANTThe expansion vessel must belocated BELOW the connection onthe pump station with the vesselconnection pointing upwards. SeeFigure 3-3.

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Figure 3-3: System connections to solar pump station

Solar expansionvessel

Hot water cylinder

Solarcollectors

Safety (pressure relief)valve fluid recovery

container

3.3 System Connections

3 Installation

Note: This is a diagrammatic viewshowing the connections to thepump station. As such it does NOTinclude all valves and controls and isNOT intended as a complete systemdiagram.

Important:All system pipe connections mustuse compression fittings withbrass olives. Soft soldered jointsmust NOT be used on the solarprimary circuit.

Plastic pipe must NOT be used forany part of the solar primary circuit.

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3.5 Safety Valve DischargeA discharge pipe must be fitted to theoutlet of the safety valve.

It is recommended that the safety valvedischarge should be connection to asuitable discharge recovery tank, suchas the Grant safety valve liquid recoverycontainer with drain valve (Grant PartNo.GS550001).

This discharge pipe should be 15mmcopper.

IMPORTANT Plastic pipe should NOT be used.

3.6 Electrical ConnectionThe pump requires a 230V 50Hz powersupply from the Solar Controller tooperate. Refer to the Installationinstructions provided with the SolarController for further information on theelectrical control system wiring.

IMPORTANTThe electrical supply must beisolated before making theconnections to the solar pump. Aftermaking the connections ensure coveris fitted to enclosure beforereconnecting the electrical supply.

The power supply should be connectedto the solar circulating pump (in thepump station) as follows:

Insert the blade of a small flatscrewdriver into the retaining clip on theside of the electrical enclosure on thepump.

Carefully prise open the clip and pull thecover upwards and remove from theenclosure.

Slacken off the cable gland nut and feedthe electrical cable through the gland.See Figure 3-5.

Prepare the cable – cut back the outersheath and strip the ends of the threewires as required.

Fit the wires into the terminals bypushing the black lever away from theenclosure (to open the terminal). SeeFigure 3-5.

Release the lever to secure the wire inthe terminal.

Fit the three wires into the terminals asfollows:

Live – terminal ‘L’ Neutral – terminal ‘N’Earth – terminal ‘ ’

Tighten the cable gland to grip the cableand re-fit the cover to the enclosure.

Reconnect the electrical supply to test the operation of the pump.

Assemble and fit the isolation valveunion as follows, referring to Figure 3-4:

• Fit the small black sealing washeronto the threaded connection of thebleed valve.

• Screw the bleed valve into thethreaded port in the side of the valveunion body and tighten.

• Remove the thin nut from the threadon the valve union.

• Fit the threaded connection on theexpansion vessel up through thehole in the mounting bracket andsecure using the thin nut.

• Using the sealing washer supplied,fit the valve union to the expansionvessel connection.

• Tighten the union nut to secure thevalve union in the required position.

Connect the flexible stainless steel pipeto the safety valve manifold andexpansion vessel union valve, using thesealing washers provided with the pipe.

Ensure that the expansion vesselisolation valve is OPEN – this isindicated when the two indicators (onthe square end of the valve) are in linewith the valve.

Ensure that the bleed valve is fullyCLOSED before filling the system.

Cable gland

Live terminal

Neutral terminal

Earth terminal

Terminal lever

Figure 3-5: Solar pump electricalconnections

Bleed valve

Flexiblestainlesssteel pipe

Pipe unionnut

Isolating valve

Expansionvessel

Union nut

Thin nut

Figure 3-4: Expansion vessel connection

Vesselmounting

bracket

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4 Commissioning4.1 Expansion VesselEnsure that the expansion vessel chargepressure is correct for the systempressure (when cold) and that this, inturn, corresponds to the height of thesystem. Refer to Table 4-1.

The height of the system should bemeasured from the expansion vessel tothe top of the highest collector.

NOTE: If the collectors are positionedbelow the level of the expansion vessel(e.g. if the collectors are mounted atground level), then measure from thebottom of the collectors to theexpansion vessel. This will be a‘negative’ height value, e.g. –5 metres.

The vessel charge pressure must bechecked before filling the system.

4.2 Filling ValvesThe Filling flow and return valves, andthe Filling/Shut off valve, are used forfilling and flushing the solar thermalinstallation. Refer to Figure 4-1.

To enable filling/flushing of the system,the Filling/Shut-off valve must be rotatedfully 90° clockwise. Refer to Figure 4-2.This will divert the flow from the fillingstation, entering the system via theFilling flow valve, through the pump, upto the collectors, through the coil of thecylinder and back to the filling station viathe Filling return valve.

Height difference Initial expansion System charge pressure(height of the collector vessel charge @20°C (0.2 – 0.5 bar

field minus height pressure (air charge greater than vesselof expansion vessel) setting on valve) 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

Figure 4-1: Filling and flushing valves

Filling/shut-offvalve

Fillingflowvalve

Fillingreturnvalve

Table 4-1: Expansion vessel pressures

Figure 4-2: Closing Filling/Shut off valveto prepare to fill system

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4.3 Gravity BrakesThe gravity brakes (check valves) areincorporated into both the flow andreturn valve assemblies. These gravitybreaks operate at 20 mbar and areoperated by turning the valve handle onthe valves as follows:

Flow and Return valves OPEN – ‘ ’markers on valve handles inVERTICAL position

To prevent ‘gravity’ circulation of solarfluid, gravity brakes must be in theoperating position (closed), i.e. with ‘ ’markers in vertical position. See Figure4-3.

Gravity Brakes OPEN – ‘ ’ markerson valve handles at 45° angle

To fill or completely empty the solarthermal installation, the gravity brakesmust be opened, i.e. by turning thevalve handles to the right to an angle of45°. See Figure 4-4.

Flow and Return valves CLOSED – ‘ ’markers on valve handles inHORIZONTAL position

The flow and return valves are closed byturning the valve handles 90° to theright, i.e. until the ‘V’ markers arehorizontal. See Figure 4-5.

4.4 Solar FluidIn order to prevent frost and corrosiondamage to solar collectors andpipework, the system must only be filledwith a high quality solar fluid. The Grantsolar fluid is a ready mixed 40% solutionof 1,2 propylene glycol/water providingfrost protection down to approx. -23°C.

To prevent damage to the system thesame specification solar fluid should beused when replacing or topping up thesolar fluid in the system.

If required, a copy of the Material SafetyData Sheet for the Grant solar fluid isavailable on request from Grant UK.

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Figure 4-3: Flow and return valves open

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Figure 4-4: Gravity breaks open

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Figure 4-5: Flow and return valves closed

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4 Commissioning4.5 Filling the System Grant Solar Thermal systems should beflushed and filled using a purposedesigned closed circuit solar thermalfilling station, incorporating a highpressure pump, such as the Grant SolarFilling Station. See Figure 4-6.

4.6 Filling Procedure IMPORTANTThe collectors must be cool beforefilling the system. They must becovered, to stop solar radiationreaching them, until the filling andcommissioning procedure iscompleted.

Before filling the system: Check allsystem connections and the expansionvessel charge pressure. Refer to Table4-1 (page 10).

Phase 1

• Connect the pressure hose from thefilling station to the Filling Flow valveconnection and open the valve.Refer to Figure 4-1 (page 10).

• Connect the return hose from thefilling station to the Filling Returnvalve connection and open thevalve. Refer to Figure 4-1 (page 10).

• Using a small spanner, rotate theFilling/Shut-off valve 90° clockwise.Refer to Figure 4-2 (page 10).

This will divert the flow from thefilling station through the pump, upto the collectors, through the coil ofthe cylinder and back to the fillingstation via the filling return valve.

• Fill the filling station tank withsufficient solar fluid for the system.

• Check that Flow and Return valvesare set to 'half open' position (toopen the gravity brakes) as shownin Figure 4-4 (page11).

• Switch on the filling station to fill andthen flush the solar circuit forapprox.15 minutes.

Phase 2

• Whilst the filling pump is running,close the Filling Return valve andallow the system pressure to reacharound 4 - 5 bar.

• When the pressure reaches 5 bar,close the Filling Flow valve andimmediately switch off the fillingpump.

• Check that the system pipeworkand pump station are leak-free.After leaving the system at about 5bar for a minimum of 15 minutes,

check if the pressure gauge showsany significant drop in pressure. If itdoes, this points to a leak in thesystem that must be traced andrectified.

• Check the operation of pressurerelief valve by slowly rotating thevalve knob, lifting the valve, untilfluid is discharged. This should becollected in a suitable container, e.g.a pressure relief valve fluid recoverycontainer (as shown in Figure 3-3 onpage 8).

Phase 3

• Re-open the Filling/Shut-off valve byturning 90° anti-clockwise.

• Switch on the circulating pump (bysetting the solar controller to“manual”) to the highest pumpingspeed and allow the solar fluid tocirculate for at least 15 minutes.

• Set the solar controller to “stand by”(pump = OFF).

• Bleed the air separator using themanual air vent until the solar fluidbegins to escape. Refer to section4.7 (page 13).

• Set the operating pressure (as inTable 4-1) by carefully opening theFilling Return valve and releasing thefluid back into the filling station tank.

Phase 4

• Reset Flow and Return valves tofully open position. Refer to Figure 4-3 (page 11).

• Switch on the circulating pump(solar controller set to “manual”).

• Set the flow rate on the flow rateindicator (refer to section 4.8) byselecting the appropriate pumpspeed and by using the Filling/Shut-off valve.

• Remove the filling station hosesfrom the filling connections andscrew the caps on both valves.Release the Filling Return valve firstand then the Filling Flow valve.

• Switch the solar controller toautomatic operation and removecovers from the collectors.

Figure 4-6: Grant Solar Filling Station

If the pump station is located in theroof space, there must be a suitableflat surface on which to stand thefilling station, e.g. floor, loft boardingor similar, capable of carrying theweight of the filling station with a fulltank of solar fluid.

! WARNING

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4.7 Releasing Trapped Air The residual air from the heat transferfluid is collected in the air separator andmanually released via the air vent. Thereis no need to use an automatic air ventelsewhere on the solar primary circuit,e.g. at high level.

To release any air collected in the airseparator, push a plastic tube on to themanual air vent outlet and catch thefluid that is released in a suitablecontainer. Open the manual air vent untilall air has been vented, i.e. a steadystream of solar fluid is flowing from theair vent.

4.8 Setting the Flow RateThe setting of the solar fluid flow rate ismade via the speed setting of thecirculating pump and the Filling/Shut-offvalve. For required system flow ratesrefer to Table 4-2.

The flow indicator displays the fluid flowrate. The display range is between 1and 13 litres per minute. See Figure 4-8.

Venting air from the system shouldonly be carried out only by acompetent installer. Frequent ventingleads to system pressure loss anddisruption to the system operation.

! CAUTIONDanger of scalding! The temperature of both theescaping air and the solar fluid canexceed 100°C.

! CAUTION

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Figure 4-7: Air separator and air vent

Figure 4-8: Flow rate indicator

Table 4-2: System volume flow rates

Manual air vent

Air separator

For larger installations, pleasecontact Grant Technical Departmentfor assistance.

! NOTERead flow rate from

bottom edge of bobbin

1 to 5 6 8 9 12

Up to 5 in series 2 x 3 in parallel 2 x 4 in parallel 3 x 3 in parallel 4 x 3 in parallel

15mm 22mm 22mm 22mm 22mm

2-3 l/ min 4-5 l/ min 4-5 l/ min 6-8 l/ min 6-8 l/ min

Number of solar panels

Type of connection

Flow and return pipe diameter

Minimum volume flow rate

5 Fault Finding

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In the event of a problem occurringwith your Grant Solar Thermalsystem, follow the information givenbelow in order to identify and rectifythe matter:

5.1 No System CirculationCheck for the following:

• Pump is not operating (see 5.2below).

• If pump is noisy, there may be air inthe system.

• Pump may be air locked and needsventing. Turn off power, removecentral screw on pump motor tovent.

• Valves are closed – ensure thatFlow, Return and Filling/Shut offvalves are all fully open. Refer to Fig 4-3 on page 11.

5.2 Pump not OperatingCheck for the following:

• No electrical supply to pump.

• Controller is not calling for pump to operate (see below).

• 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 tooperate.

• Check controller settings and correct as necessary (see Instructions supplied with the Solar Controller).

• Collectors may be in stagnation mode – wait for system to cool down.

• Collector temperature may be toolow (insufficient solar radiation).

• Cylinder temperature setting may be satisfied.

• Pump is stuck - Turn off power,remove central screw on pumpmotor and rotate motor using ascrewdriver.

• Motor capacitor failed – replacecapacitor or pump motor.

5.3 Loss of System Pressure(on pressure gauge)Check for the following:

• Leaks on system – find and rectifyas necessary.

• Expansion vessel pre-charge lost –check and re-charge vessel asnecessary.

• Pressure relief valve discharging fluid– check and rectify/replace valve.

6 Spare Parts

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Key No. Description Part No.

01 Flow valve assembly (Red) GSE01

02 Return valve assembly (Blue) GSE02

03 Safety valve assembly (6 bar) GSE03

04 Pressure gauge GSE04

05 Solar circulator (6 metre) GSE05

06 Solar circulator (8 metre) GSE06

07 Air separator assembly GSE07

08 Fill/flush valve and flow regulator assembly GSE08

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GRANT ENGINEERING (UK) LTDHopton House, Hopton Industrial Estate, Devizes, Wiltshire. SN10 2EU

Telephone: 01380 736920 Fax: 01380 736991Email: info@grantuk.com Website: www.grantuk.com