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SL-PS-I-O Rev B
Solar Pump Station
Installation and Operation
Manual
SPS0250, SPS0500 & SPS1000
This manual must only be used
WARNING:
by a qualified heating installer/
service technician. Read all
instructions, before installing.
Perform steps in the order given.
Failure to comply could result in
severe personal injury, death, or
substantial property damage.
Save this manual for future reference.
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Contents HAZARD DEFINITIONS .................................................... 2 6. VFS FLOW SENSOR .................................................. 9 1. GENERAL INFORMATION 7. TECHNICAL DATA FOR SOLAR STATION ........ 10-11 Included components ..................................................... 3-4 8. COMPONENT BREAKDOWN 2. INSTALLING THE SOLAR STATION SPS0250 ......................................................................... 12 Installing the solar station on a wall ......
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SL-PS Installation & Operation Manual 1 General Information Before starting work, the Installer must read, understand and note these installation and operating WARNING instructions. The solar pump station may only be installed and maintained by trained professionals. Trainees may WARNING only work on the product under the supervision of an experienced person. All instructions in this Installation & Operation manual should be observed when using the solar WARNING station. No other for
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SL-PS Installation & Operation Manual 1 General Information Included Components Figure 1-2 SPS1000 Solar Station: ■ Grundfos solar circulation pump ■ VFS sensor (flow sensor) ■ 145 psi relief valve, with pressure gauge ■ Multi-function instruments (Flow Check, Thermometer, Fill Valve) ■ EPP two-part bracket with mounting kit Installation kit: ■ Wall and tank bracket with mounting kit Solar Control unit: ■ LCD Plus solar control unit with integrated energy balance function. ■ 2
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SL-PS Installation & Operation Manual 2 Installing the solar station Installing the solar station on a wall Installation, wall bracket for expansion tank: (Lochinvar/TiSUN accessories) ■ Remove front insulation shell. ■ Fit the wall bracket for the expansion tank (if equipped) to ■ The solar pump station forms a single unit with the wall the right of the solar station. bracket and rear insulation shell. Secure both components as a complete unit at the intended location, wo
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SL-PS Installation & Operation Manual 3 Technology, installation and commissioning Clamp ring screw connections Figure 4-1 Forward flow multi-functioning instruments ■ Cut the copper pipe to length and deburr. ■ First, slide the clamp ring nut over the pipe, then slide the clamp ring. ■ Insert the prepared pipe into the screw connection until its stop is reached. SETTING FOR OPERATIONS, DRAINING SERVICE FILLING, FLUSHING, DRAINING FLOW CHECK OPEN ■ Tighten clamp ring nut by han
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SL-PS Installation & Operation Manual 4 Commissioning the solar system General ■ Before commissioning, all piping, connections and saftey ■ Fill the solar system via the filling and flushing pump and equipment should be checked to ensure that they are then flush the solar circuit for at least 15 min. to purge all of correctly installed. the air out of the circuit. ■ All pre-fitted solar station screw connections are firmly ■ Close the fill/flush valve (return) with the filli
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SL-PS Installation & Operation Manual 5 Pressure loss and residual delivery height Max. residual delivery height Solar group with Grundfos UPS 25-58U pump Figure 5-1 pressure drop of components (and GF sensor 0.5-3 GPM) residual delivery height SPS0250 25 20 15 10 5 0 0,0 0,5 1,0 1,5 2,0 2,5 3,0 3,5 4,0 Volumetric flow rate [GPM] Max. residual delivery height Figure 5-2 Solar group with Grundfos UPS 25-99U pump pressure drop of components SPS0500 (and GF-Sensor 0.5-10.5 GPM) residu
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SL-PS Installation & Operation Manual 6 VFS flow sensor ■ Vortex flow sensor for liquid media. Figure 6-4 VFS 2-40 temperature output signal ■ Measures flow rate and temperature for BTU metering (energy balance, etc.) VFS 2-40 output signal temperature ■ Zero wear (no moving parts). Assignment of measurement range: 32-212° F is equal to 0.5-3.5V Figure 6-1 VFS 1-12 flow ouput signal Temperature rate calculation: T =32° F + [(U-0.5)V/3 V]*180° F VFS 1-12 output signal flow Assignment of m
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SL-PS Installation & Operation Manual 7 Technical data for solar station Designation SPS0250 / SPS0500 SPS1000 SPS0250: Grundfos UPS 25 - 58 U SPS1000: Grundfos UP 25 - 120 U PUMP SPS0500: Grundfos UPS 25 - 99 U SOLAR AND TANK CONNECTIONS 3/4" compression 1" compression EXPANSION TANK CONNECTION 1/2" NPT INSTALLATION OPTIONS Wall mounting HOLDING PLATE FOR WALL With 2 slot holes 5" apart for M6 screws With 2 slot holes 5" apart for M6 screws MOUNTING Plastic 8x40 mm anchors MOUNTING MATERI
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SL-PS Installation & Operation Manual 7 Technical data for solar station (continued) Designation SPS0250 / SPS0500 SPS1000 Installation location: forward flow and return ball valves Material: Brass GRAVITY BRAKES Seal: O-ring 70 EPDM 291 Opening pressure: 2 x 200 mm WS (using metal spring) Can be positioned by moving thermometer handle to 45°F position Max temp 356°F Scale: 32 - 288°F in 3.6 F increments SOLAR DIAL INDICATOR THERMOMETER Diameter: 2" Size: 30 x 22 x 2 - 1" Size: 44.5 x 33 x
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SL-PS Installation & Operation Manual 8 Component breakdown SPS0250/ SPS0500 Item Name – SPS0250 - Pumpstation 250 sq-ft w/ flow sensor and CU – SPS0500 - Pumpstation 500 sq-ft w/ flow sensor and CU 1 Solar return ball valve USA 1 1/2" x M28 x 1.5 2 Solar forw. flow ball valve USA M28 x 1.5M28 3 Solar bleeder block M28 x 1.5 L=283mm 4 Nut M28 x 1.5mm 5 Clamp ring 22mm 6 Clamp ring 22.3 mm USA 7 Nut 1 1/2" x 16mm 8 Reducing socket 1 1/2" female x 1" male 9 Sealing kit 2x 1 1/2" ; 2x 1" ; 3x 3/
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SL-PS Installation & Operation Manual 8 Component breakdown (continued) SPS1000 Item Name – Pumpstation 1000 sq-ft w/ flow sensor and CU 1 Solar return ball valve 1 1/2" Fl. x M36 x 1.5 incl. CV 2 Solar forw. flow ball valve M28 x 1.5 x M36 x 1.5 incl. CV 3 Solar bleeder block M36 x 1.5 L=283mm 4 Nut M28 x 1.5mm 5 Clamp ring 22mm 6 Nut M36 x 1.5 x 28.3 7 Clamp ring 28mm 8 Nut 1 1/2" x 16mm 9 Nut M36 x 1.5 x 28.7 for KVSR 28.7 10 Clamp ring 28.7 mm 11 Reducing socket 1 1/2 female x 1" male 12
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SL-PS Installation & Operation Manual 9 Service De-energize and lock the solar control Draining the system WARNING and pump to prevent them from accidentally being switched back on ■ Fit corresponding drainage hoses on to the filling and again by mistake before any maintenance flushing connections and guide these into a collecting or repair work. vessel. Service is not permitted until components ■ Open the check valves by placing the red and blue and solar liquid have cooled. thermome
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SL-PS Installation & Operation Manual 10 Faults, causes and rectification Pump doesn’t run when power is switched on : ■ Check solar control unit for correct settings and tight wire connections. ■ Check fuses. ■ Check pump voltage, refer to the pump rating plate for requirements. Motor blocked: ■ Close shut-off instruments upstream and downstream of pump at high liquid temperatures and system pressures. Allow pump to cool first. ■ Fully unscrew bleed screw and check ease
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Revision Notes: Revision A (ECO C06520) initial release. Revision B (ECO C07610) reflects formatting adjustments. SL-PS-I-O Rev B 3/11
