Grant Solar Pump Station Installation & Servicing Instructions

Grant Solar pump station Manual::18/10/12Assemble and fit the isolation valveunion as follows, referring to Figure 3-5: 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. Page 93.5 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.IMPORTANTPlastic pipe should NOT be used.Using the sealing washer supplied,fit the valve union to the expansionvessel connection.3.6 Electrical ConnectionTighten 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.The 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:Ensure that the bleed valve is fullyCLOSED before filling the system.Flexiblestainlesssteel pipe09:43Pipe unionnutInsert 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 3-6.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 3-6.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 operationof the pump.Cable glandIsolating valveBleed valveLive terminalVesselmountingbracketNeutral terminalEarth terminalUnion nutTerminal leverExpansionvesselFigure 3-5: Expansion vessel connectionFigure 3-6: Solar pump electricalconnectionsInstallationThin nut9Doc 96 Rev 03. February 2014.indd 913/03/2014 11:17

Grant Solar pump station Manual::29/10/1212:06Page 104 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.Height difference(height of the collectorfield minus heightof expansion vessel)Initial expansionvessel chargepressure (air chargesetting on valve)System charge pressure@20 C (0.2 – 0.5 bargreater than vesselcharge 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 barThe 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. 15mContact Grant Technical Department for guidanceTable 4-1: Expansion vessel pressuresThe 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.Filling/shut-offvalveFillingflowvalveFigure 4-2: Closing Filling/Shut off valveto prepare to fill systemFillingreturnvalveCommissioningFigure 4-1: Filling and flushing valves10Doc 96 Rev 03. February 2014.indd 1013/03/2014 11:17

Grant Solar pump station Manual::18/10/1209:43Page 114.3 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: C CFlow and Return valves OPEN – ‘ ’markers on valve handles inVERTICAL positionTo prevent ‘gravity’ circulation of solarfluid, gravity brakes must be in theoperating position (closed), i.e. with ‘ ’markers in vertical position. See Figure4-3.Figure 4-3: Flow and return valves openGravity Brakes OPEN – ‘ ’ markerson valve handles at 45 angleTo 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. C CFlow and Return valves CLOSED – ‘ ’markers on valve handles inHORIZONTAL positionThe flow and return valves are closed byturning the valve handles 90 to theright, i.e. until the ‘V’ markers arehorizontal. See Figure 4-5.Figure 4-4: Gravity breaks open4.4 Solar Fluid C CIn 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.Figure 4-5: Flow and return valves closedCommissioningIf required, a copy of the Material SafetyData Sheet for the Grant solar fluid isavailable on request from Grant UK.11Doc 96 Rev 03. February 2014.indd 1113/03/2014 11:17

Grant Solar pump station Manual::18/10/1209:44Page 124 Commissioning4.5 Filling the System4.6 Filling ProcedureGrant 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.IMPORTANTThe collectors must be cool beforefilling the system. They must becovered, to stop solar radiationreaching them, until the filling andcommissioning procedure iscompleted.!WARNINGIf 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.check if the pressure gauge showsany significant drop in pressure. If itdoes, this points to a leak in thesystem that must be traced andrectified. Before filling the system: Check allsystem connections and the expansionvessel charge pressure. Refer to Table4-1 (page 10).Phase 1Phase 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.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).Phase 4 Reset Flow and Return valves tofully open position. Refer toFigure 4-3 (page 11). Switch on the filling station to fill andthen flush the solar circuit forapprox.15 minutes. 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/Shutoff 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.Phase 2 Figure 4-6: Grant Solar Filling StationCommissioningCheck 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).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,12Doc 96 Rev 03. February 2014.indd 1213/03/2014 11:17

Grant Solar pump station Manual::18/10/1209:44Page 134.7 Releasing Trapped AirThe 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.Manual air ventMADE INITALYTo 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.!Air separator!CAUTIONDanger of scalding!CAUTIONVenting air from the system shouldonly be carried out only by acompetent installer. Frequent ventingleads to system pressure loss anddisruption to the system operation.The temperature of both theescaping air and the solar fluid canexceed 100 C.Figure 4-7: Air separator and air vent4.8 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.!NOTEFor larger installations, pleasecontact Grant Technical Departmentfor assistance.Read flow rate frombottom edge of bobbinNumber of solar panelsType of connectionFlow and return pipe diameterMinimum volume flow rateTable 4-2: System volume flow rates1 to 568912Up to 5 in series2 x 3 in parallel2 x 4 in parallel3 x 3 in parallel4 x 3 in parallel15mm22mm22mm22mm22mm2-3 l/ min4-5 l/ min4-5 l/ min6-8 l/ min6-8 l/ minCommissioningFigure 4-8: Flow rate indicator13Doc 96 Rev 03. February 2014.indd 1313/03/2014 11:17

Grant Solar pump station Manual::18/10/1209:44Page 145 Fault FindingIn the event of a problem occurringwith your Grant Solar Thermalsystem, follow the information givenbelow in order to identify and rectifythe matter:5.2 Pump not OperatingCheck for the following:5.3 Loss of System Pressure(on pressure gauge) No electrical supply to pump.Check for the following: Controller is not calling for pumpto operate (see below). Leaks on system – find and rectifyas necessary. Check power supply to controls(at fused spur). Expansion vessel pre-charge lost –check and re-charge vessel asnecessary. Pressure relief valve discharging fluid– check and rectify/replace valve.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. Check wiring to controller andpump is correct. Check for any loose connections. Controller is not calling for pump tooperate. Check controller settings andcorrect as necessary (seeInstructions supplied with theSolar Controller).Valves are closed – ensure thatFlow, Return and Filling/Shut offvalves are all fully open.Refer to Fig 4-3 on page 11. Collectors may be in stagnationmode – wait for system to cooldown. Collector temperature may be toolow (insufficient solar radiation). Cylinder temperature setting maybe satisfied.Pump is stuck - Turn off power,remove central screw on pumpmotor and rotate motor using ascrewdriver. Motor capacitor failed – replacecapacitor or pump motor.Fault Finding 14Doc 96 Rev 03. February 2014.indd 1413/03/2014 11:17

Grant Solar pump station Manual::18/10/1209:44Page 156 Spare Parts0203010405/060708DescriptionPart No.01Flow valve assembly (Red)GSE0102Return valve assembly (Blue)GSE0203Safety valve assembly (6 bar)GSE0304Pressure gaugeGSE0405Solar circulator (6 metre)GSE0506Solar circulator (8 metre)GSE0607Air separator assemblyGSE0708Fill/flush valve and flow regulator assemblyGSE08Spare PartsKey No.15Doc 96 Rev 03. February 2014.indd 1513/03/2014 11:17

Grant Solar pump station Manual::18/10/1209:44Page 16GRANT ENGINEERING (UK) LTDHopton House, Hopton Industrial Estate, Devizes, Wiltshire. SN10 2EUTelephone: 01380 736920 Fax: 01380 736991Email: info@grantuk.com Website: www.grantuk.comDoc 96 Rev 03. February 2014.indd 1613/03/2014 11:17

Grant Solar Thermal system differs from that shown in the Installation Instructions supplied. This change is part of our continued product improvement process. The information in these Solar Pump Station Installation Instructions replaces that given in Sections 13 and 14 of the Grant Solar Thermal Systems Installation Instructions (DOC 73. Rev.02).