Installation Manual - UniMaxx-Plus Pump Station

8/6/2019 Installation Manual - UniMaxx-Plus Pump Station

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Manual

B

UniMaxx-Plus Pump Station

U

n i M a x x - P

l u s P u m

p S t a t i o n

Mounting

Installation

Operation

Commissioning

Thank you for buying this SunMaxx product. Please read this manual carefully to get the best

performance from this unit. 4 8 0 0 1

0 7 0

* 4 8 0 0 1 0 7 0 *


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Subject to technical changes. Errors excepted.

Safety advice

Please pay attention to the following safety advice in orderto avoid danger and damage to people and property.

This product is to be used in accordance with its intendeduse only (see page 3).

Please pay attention to the valid local regulations!

Instructions

Attention should be paid to

- the statutory provisions for prevention of industrial acci-

dents,

- the statutory provisions for environmental protection,

- the Health and Safety at Work Act 1974

- Part P of the Building Regulations 2005

- BS7671 Requirements for electrical installations and rele-vant safety regulations of DIN, EN, DVGW, TRGI, TRF andVDE.

These instructions are exclusively addressed to authorizedskilled personnel.

- Only qualied electricians should carry out electricalworks.

- Initial installation must be eected by qualified personnelnamed by the manufacturer

Declaration of conformity

We at SunMaxx Solar declare under our sole responsibility that ourproduct , UniMaxx-Plus Pump Station, complies with the following

EN 55 014-1

EN 60 730-1

According to the regulations of the above directives, the

product is labelled with :

89/336/EWG

73/ 23/EWG

Contents:

Safety advice ...................................................................... 2

Technical data and operation ........................................... 3

1. Installation .............................................................. 4

1.1 Wall mounting ....................................................... 41.2 Optional compression ring connection ............... 5

1.3 Mounting the expansion vessel (optional) .......... 5

1.4 Electrical connection ............................................. 6

1.5 Integration of the controller

IntelliMaxx-DHW Plus ....................................... 6

2. Commissioning ...................................................... 7

2.1 Filling and flushing the system ............................. 7

2.2 Emptying the system ............................................. 7

2.3 Non-return valves .................................................. 82.4 Safety assembly ...................................................... 8

2.5 Air-Stopp ................................................................ 9

3. Accessory ............................................................... 9

Imprint ............................................................................. 12


standards:


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315

5 2 0

•Prepared for integration of the

IntelliMaxx-DHW Plus controller

•Dial thermometer for flow and return

•Outstanding design

•Return line with ball valve and openable non-

return valve

•Integrated flowmeter

•Safety assembly with relief valve and pressure

gauge

•Fill/drain valve for filling and flushing the system

•Wall mounting bracket with screws and dowels

•Insulated casing

Technical dataHeight (with insulation): 520 mmWidth (with insulation): 315 mmDistance axis / wall: 63 mmPipe connections: ¾“ IT, with

cutting ring connections (optional)Connection for expansion vessel: ET pipe 3/4“, flat sealing Outlet safety valve: ET pipe 3/4“Max. admissible pressure: 8 barMax. admissible temperature: 120°C continuous and 160 °C intermittentSafety valve: 1/2“ x 3/4“ - 3 bar, 6 bar , 10 bar Pressure gauge: 0 - 6 bar, up to 130 °C

Non-return valve: 2 x 200 mm water column, openablein flow and return ball valve,PPS - max. 180 °C

Dial thermometer: 0 – 120 °C,Flowmeter (depending on the version): 0,5-5 l/min, 1-13 l/min, 8-30 l/min Flat sealings: Klingerit - max. 200 °CO-Ring sealings: VITON / EPDM - max. 180 °CInsulation: EPP, l = 0,041 W/(m*K)

max. 120 °C continuous and 180 °C intermittent




16

1

2

8

14

10

9

13

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315

4

6

11

5

1. Installation

12

1.1 Wall mounting

1. Determine where to mount the pump station; consider

the space for the (optional) expansion vessel!2. Take the complete station out of the packing.

3. Remove the front half of the insulation by pulling it. Thethermometers loosen from the ball valves.Do not unsrew the pump station from the back

part of the insulation!

4. Mark the fastening holes (centres 70 mm) and drill holes(diameter 8 mm); insert the enclosed dowels (S 8).

5. Fasten the complete pump station with the wallmounting bracket to the wall (depending on the pumpversion, upper or lower holes in the insulated casing)

and tighten the screws. For this purpose, use a positive

cross-recessed screwdriver!6. Connect the connection line between the pump

station and the store and the collectors repectively.

Optionally, compression ring connections can be usedfor mounting copper pipes.In order to connect the

pipes with the compression ring connections,

pay attention to the following instructions!

1 Wall mounting bracket of the pump station2 Insulation - rear3 Controller4 Insulation - front cover5 Flowmeter

6 Drain valve7 pump8 ball valve in flow IT-IT, with integrated thermometer9 ball valve in return IT-IT, with integrated thermometer10 Safety head-piece, with fill valve11 Pressure gauge

12 Safety valve 6 bar13 Optional: expansion vessel set14 Optional: AirStopp15 Optional: Compression ring connection for

copper pipe




All connections are pre-assembled by the manufacturer buthave to be tightened by the installer. Check for leaks whencommissioning the station (pressure test).

Screws S6 x 60

- First push the union nut (2), then the brass compressionring (3) onto the copper pipe (1). In order to ensuresecure load transmission and sealing, the pipe mustextend at leat 3 mm out of the compression ring.

- Insert the support sleeve (4) into the copper pipe (1).- Push the copper pipe (1) with the attached parts

(2; 3; 4) as far as possible into the body of thecompression ring connection (2).

- First screw on the union nut by hand. Then tighten itby at least one full rotation with a suitable open-endedspanner.

Please note: In order to absorb the strain of the pipes, corresponding fittings (strain neutralizers) or expansion bends(consisting of at least two 90° - bends) are required. For expansion bends, the distance between the bends must belarger than twice the pipe diameter in cm.[Example: pipe diameter = 18 mm Þ distance between the bends more than 36 cm].

1.2 Optional compression ring connection

1.3 Mounting the expansion vessel (optional)

- Attach the wall mounting bracket of the expansionvessel in a suitable position to the wall. Pay attentionto the corrugated stainless steel hose (optionalaccessory).

- Connect the optional hose flatly sealing using theenclosed sealings (optional) to the quick connector(optional) of the expansion vessel and to the expansionvessel connection at the safety head piece of the pump

station.

5

32

1

> 3 mm

4




1.5 Integrating the IntelliMaxx-DHW Plus controller

1.4 Electrical connection

The unit must only be located in dry interior locations. Itis not suitable for installation in hazardous locations andshould not be placed close to any electromagnetic fields. Thecontroller must additionally be supplied from a double poleswitch with contact gap of at least 3 mm. Please pay atten-tion to separate routing of sensor cables and mains cables.

Push the cover in front of the controller downwards in orderto access the controller. Open the housing of the controller atthe front. Follow the steps described in the controller manual.

- Pull the cover at the front of the insulated casing down-wards and remove it.

- Put the controller into the provided space in the insula-tion and attacht it with the fastening screws 3 x 30 andlarge washers.

- Electrical connections (plug, sensor and relay connections)must be carried out according to the steps described inthe manual.

- The cables - especially those of the pump - must be longenough so that the front part of the insulation can beremoved without damaging the controller. Please ensurethat the cables do not come into contact with hot waterpipes!

- Attach the front part of the insulation to the pump station.Do not yet insert the thermometers (red in flow, on the

left / blue in return, on the right), because the insulationhas to be opened once again for commissioning.

For further information on the connection of the con -

troller, see IntelliMaxx-DHW Plus controller.

Front insluationfront view

Front insluationrear view




2.1 Filling, flushing and commissioning the pump station

2. Commissioning

· Connect the pressure hose to the fill valve at the safetyhead-piece below the pressure gauge (11) and open thefill and drain valve.

· Connect the flushing hose to the fill and drain valve atthe flowmeter and open the fill and drain valve.

· The slot of the adjustment screw at the flowmeter hasto be in a horizontal position. Thus the integrated ballvalve is closed (see flowmeter manual). Open the non-return valve above the pump; for this purpose turn theball valve by means of an open-ended spanner (wrenchsize 14) to a 45° position (half opened, half closed).

· Fill sufficient solar fluid into the tank of a flushing and

filling station (not supplied) and fill the solar thermalsystem.

· Flush the solar thermal system using the flushing andfilling station for at least 15 minutes. To remove all airfrom the system, open the adjustment screw at theflowmeter several times.

· The system may be flushed with water before

commissioning but the final installation must con -

tain antifreeze to protect against frost damage.

· Close the drain valve while the pump is running andincrease the system pressure to approx. 6 bar. Thesystem pressure is indicated at the pressure gauge.

· Close the fill valve and switch-o the pump of theflushing and filling station; open the adjustment screwat the flowmeter (vertical position).

· Bleed the system above the collector until the dis-charged fluid is free of bubbles. Increase the pressureto approx. 6 bar and check the system for leaks. In thecase of a significant decrease in pressure, there may beleakage in the system

Adjust the system to the manufacturer‘s recommendedpressure (to approx. 1,8 to 2,3bar with a collectorheight of approx. 5 to 10 m).

· Put the circulation pump into operation at maximumspeed (see pump manual) and let it circulate for at least15 minutes.

· Afterwards, adjust the desired pump speed.

· Adjust the flow rate at the flowmeter according to thespecifications of the collector manufacturer.

· Remove the hoses of the flushing and filling stationand screw the caps onto the valves of the flushing andfilling valves.

· Check the system for leaks. Open both ball valves

· Die vordere Isolierschale der Solarstation anbringen,die Thermometer einstecken.

2.2 Emptying the system

· Open the non-return valve in the ball valve (seefollowing advice).

· Open the air vent at the highest point of the system(above the collector).

· Open the fill and drain valve at the lowest point of thesystem, if possible close to the store connection (not

supplied) or at the drain valve and the pump.




2.3 Non-return valves

- The non-return valves of the pump station areintegrated into the ball valves above the circulationpump and into the flow and have an opening pressure

of 200 mm head each.- In order to empty the system completely, the

nonreturn valve has to be opened. For this purpose,the knob of the ball valve has to be put in a 45°position. The ball in the ball valve then opens thenon-return valve.

- For normal system operation, the ball valve has tobe completely opened.

2.4 Safety assembly

- The pump station is equipped with a diaphragm safetyvalve which corresponds to the relavant directives andregulations. For installation and operation, please payattention to the following advice:

- The safety valve has to be easily accessible. The efficien-cy of the valve must not be influenced or disabled bybarriers!

- The strainer or other restriction devices must not bemounted between collector (-field) and safety valve!

- The diameter of the discharge pipe must correspond tothe diameter of the valve outlet; the maximum lengthmust not exceed 2 m; more than 2 bends are inadmiss-able. When these values are exceeded (2 bends, 2 mpipe length), you have to install a discharge pipe withlarger dimensions. Do not use more than 3 bends andpipes longer than 4 m!

- If the discharge pipe leads into a drain pipe with a hop-per, the diameter of the drain pipe has to be at leasttwice as large as the valve inlet. The opening of thedischarge pipe should be inclined downwards. It shouldbe routed so that the opening can be seen but doesnot present any risk to a person standing or passingby

- It is useful to place a container under the discharge pipe. If the safety valve opens, the fluid will be collected and can berefilled in to the system when the pressure is too low.




2.5 AirStopp, manual bleed valve (optional)

Mounting

The AirStopp is for bleeding the solar fluid in the solar ther-mal system. The air precipitated from the solar fluid gathers in

the upper area of the manual bleed valve and can, if required,be discharged at the bleeding valve.

In order to make sure that the AirStopp operates fault-lessly, it is to be mounted vertically and with the bleed valve

upwards!

Operation

The air precipitated from the solar fluid gathers in the up-per area of the manual bleed valve (see figure). At first youshould bleed the solar thermal system daily and then weeklyor monthly, depending on the volume of discharged air. Bleedthe solar thermal system half-yearly with the manual bleedvalve to achieve optimal efficiency.

Plese note: Check the system pressure after bleeding and if necessary increase it to the specified operating pressure

3. Accessory

Overvoltage protection

In order to avoid overvoltage damage at collector sensors

(e.g. caused by local lightning storms), we recommend in-stalling the overvoltage protection RESOLSP1 .

Sensors

Our product range includes high temperature sensors, flat-screw sensors, outdoor temperature sensors, indoor tem-perature sensors, cylindrical clip-on sensors and irradiationsensors, also as complete sensors with immersion sleeves.

Flowmeter

If you wish to carry out a heat quantity measurement,you need a flowmeter for measuring the flow rate in yoursystem.




Notes




Notes




Distributed by:

SunMaxx Solar15 Catherwood RoadIthaca NY 14850877.786.6299 877.786.0329 Faxsunmaxxsolar.com

Important notice

We took a lot of care with the text and drawings of thismanualand to the best of our knowledge and consent. Asfaults can never be excluded, please note:

Your own calculations and plans, under consideration of thecurrent standards and directives should only be basis for yourprojects. We do not oer a guarantee for the completenessof the drawings and texts of this manual - they only representsome examples They can only be used at your own risk.No liability is assumed for incorrect, incomplete or falseinformation and / or the resulting damages.

Please note

The design and the specifications are to be changed without

i i

Imprint

This mounting- and operation manual including all parts iscopyrighted. Another use outside the copyright requires theapproval of SunMaxx Solar. This especially applies for copies,translations, micro films and the storage in electronic systems.


SunMaxx Solar56 Broome Corp. Pkwy Conklin NY 13748877.786.6299 877.786.0329 Fax

sunmaxxsolar.com

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Installation Manual - UniMaxx-Plus Pump Station